DOWNLOAD PDF Mitsubishi Forklift Reach Truck ESR EDR ESS Service Manual P.NO WENBM8550-01 by www.heydownloads.com

SERVICE MANUAL Reach Trucks

Quality Makes the Difference

ESR

1ESR240501-up 1ESR360501-up

EDR

1EDR240501-up 1EDR360501-up

ESS

1ESS240501-up 1ESS360501-up

WENB8550-01

Mitsubishi® Reach Service Manual

Warning Pages

The proper and safe lubrication and maintenance for this machine, recommended by Mitsubishi, are outlined in the SERVICE MANUAL for this machine. Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or DEATH. Read and understand the SERVICE MANUAL before performing any lubrication or maintenance. The service person or mechanic may be unfamiliar with many systems on this machine. This makes it important to use caution when performing service work. A knowledge of the system and/or components is important before the removal or disassembly of any components. Because of the size of some of the machine components, the service person or mechanic should check the weights noted in this Manual. Use proper lifting procedures when removing any components. Following is a list of basic precautions that should always be observed: 1. Read and understand all Warning plates and decals on the machine before operating, lubricating, or repairing the product. 2. Always wear protective glasses and protective shoes when working around machines. In particular, wear protective glasses when pounding on any part of the machine or its attachments with a hammer or sledge. Use welder’s gloves, hood/goggles, apron, and other protective clothing appropriate to the job being performed. Do not wear loose-fitting or torn clothing. Remove all rings from fingers when working on machinery. 3. Do not work on any machine that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the machine before performing any disassembly. 4. Lower the forks or other implements to the ground before performing any work on the machine. If this cannot be done, make sure the forks or other implements are blocked correctly to prevent them from dropping unexpectedly. 5. Use steps and grab handles (if applicable) when mounting or dismounting a machine. Clean any mud or debris from steps, walkways, or work platforms before using. Always face the machine when using steps, ladders, or walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations. 6. To avoid back injury, use a hoist when lifting components, which weigh 23 kg (50 lb.) or more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation. 7. To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes, or components. 8. Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the covers or device and pry cover loose to relieve any spring or other pressure, before removing the last two bolts or nuts completely. 9. Be careful when removing filler caps, breathers, and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot.

PDMM-0058

Warning Pages

Mitsubishi® Reach Service Manual

10. Always use tools that are in good condition and be sure you understand how to use them before performing any service work. 11. Reinstall all fasteners with the same part number. Do not use a lesser quality fastener if replacements are necessary. Do not mix metric fasteners with standard nuts and bolts. 12. If possible, make all repairs with the machine parked on a hard, level surface. Block machine so that it does not roll while working on or under the machine. 13. Disconnect battery and discharge capacitors (electric trucks) before starting to work on the machine. Hang “Do Not Operate” tag in the Operator’s Compartment. 14. Repairs which require welding should be performed only with the benefit of the appropriate reference information, and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods, or wire to provide a weld strength equivalent at least to that of the parent metal. 15. Do not damage wiring during removal operations. Reinstall the wiring so that it is not damaged nor will it be damaged in operation by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid. 16. Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution. 17. Always support the mast and carriage to keep carriage or attachments raised when maintenance or repair work is being performed which requires the mast in the raised position. 18. Loose or damaged lubricant and hydraulic lines, tubes, and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes, and hoses carefully. Do not check for leaks with your hands. Pin hole (very small) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate pin hole leaks. 19. Tighten all connections to the correct torque. Make sure that all shields, clamps, and guards are installed correctly to avoid excessive heat, vibration, or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in the event of a line, tube, or seal failure must be installed correctly. 20. Relieve all pressure in air, oil, or water systems before any lines, fittings, or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure. 21. Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing. 22. On LP equipped lift trucks, be sure to close the valve on the LP tank before service work is performed. Always close the valve on the LP tank when the lift truck is being stored. Do not check for LP leaks with an open flame.

PDMM-0058

Mitsubishi® Reach Service Manual

Warning Pages

23. Caution should be used to avoid breathing dust that may be generated when handling components containing asbestos fibers. If this dust is inhaled, it can be hazardous to your health. Components in Mitsubishi products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated. If dust which may contain asbestos is present, there are several common sense guidelines that should be followed: 1. Never use compressed air for cleaning. 2. Avoid brushing or grinding of asbestos-containing materials. 3. For clean up, use wet methods or a vacuum equipped with a high efficiency particulate air (HEPA) filter. 4. Use exhaust ventilation on permanent machining jobs. 5. Wear an approved respirator if there is no other way to control the dust. 6. Comply with applicable rules and regulations for the workplace (for example, in the U.S.A., OSHA requirements as set forth in 29 CFR 1920.1001). 7. Follow environmental rules and regulations for disposal of asbestos. 8. Avoid areas where asbestos particles may be in the air.

PDMM-0058

iii

Warning Pages

Mitsubishi® Reach Service Manual

This page intentionally left blank.

PDMM-0058

Mitsubishi® Reach Service Manual

Overview of this Manual Using the Manual

Overview of this Manual

This manual is comprised of 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: • Warning Pages • Manual Overview • Truck Description • Installation • Operating Instructions • Theory of Operation • Maintenance • Troubleshooting • Charts and Schematics The following symbols are used throughout this manual to represent a condition or hazard of which the operator should be aware.

! WARNING Denotes a serious hazard that could cause injury or DEATH to the operator or other personnel from a particular action or condition.

! CAUTION Denotes a less serious hazard from an action or condition that could cause minor injury to the operator or maintenance personnel, or cause damage to the equipment itself. NOTE: Denotes a particular statement pertaining to a particular procedure or explanation.

Using the Manual This manual contains several elements necessary for effective use, which are: 1. Safety First and Last: Gives specific safety guidelines for truck operators, owners and maintenance personnel. This information is given at the beginning of the manual and at various areas throughout the manual. 2. Table of Contents: Guides the reader to major topics by page number reference. 3. List of Illustrations: Guides the reader to specific illustrations by page number reference. 4. Troubleshooting Charts: For quick logical tracking of troubles and suggested remedies; located in Chapter 6: "Troubleshooting". 5. Schematics: For ease of troubleshooting the truck electrical and hydraulic systems, see the “Electrical Schematic” on page A-13 and the “Hydraulic Schematic” on page A-18.

PDMM-0058

Overview of this Manual

Mitsubishi® Reach Service Manual

Using the Manual

This page intentionally left blank.

PDMM-0058

Mitsubishi® Reach Service Manual

Table of Contents

Warning Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i Overview of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Using the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi Truck Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 In this Chapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Truck Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Specification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Power Section Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Battery Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Battery Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Outriggers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Mast Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Mast Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Telescopic Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Mast Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Operator’s Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Compartment Floor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Overhead Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Operator’s Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Pivot Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Gear Reduction Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 PDMM-0058

vii

Table of Contents

Mitsubishi® Reach Service Manual

Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Lift Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Return Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Lift Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Lift/Lower Hydraulic Manifold Assembly . . . . . . . . . . . . . . . . . . . 1-15 Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 System Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 Operator’s Display Indicator (ODI). . . . . . . . . . . . . . . . . . . . . . . . 1-19 Maintenance Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 Interface Card Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 Travel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 EV100LX Solid-State Control System . . . . . . . . . . . . . . . . . . . . . 1-20 Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 Travel Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 P Contactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 Load Holding Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 Auxiliary Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 X Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 Deadman Pedal (Switch S2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 Emergency Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 Key Switch (S1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Warranty Coverage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 In this Chapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Inspecting the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 How the Truck is Shipped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Reasons for Doing a Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2-2 What to Look For . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Repairing Shipping Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Repairing Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Uprighting a Cradled Truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 viii

PDMM-0058

Mitsubishi® Reach Service Manual

Table of Contents

Items Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Option 1: Uprighting with Two Chain Hoists. . . . . . . . . . . . . . . . . . . . 2-6 Option 2: Uprighting with One Chain Hoist and a Lift Truck. . . . . . . . 2-7 Assembling the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Removing the Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Greasing the Mast Uprights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Installing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Doing a Functional Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Who Does the Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 What Needs to be Done . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Starting the Mitsubishi Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Reporting Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Using the Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Preparing the Truck for Cold Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Classes of Cold Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Types of Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Changing the Hydraulic System Oil . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Preparing the Truck for Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Storage Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 General Storage Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Mast Uprights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Electronics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 In this Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 EV100LX Operator System Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Display Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Battery Charge Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Informational Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Performance Limiting Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Operator’s Daily Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Forward/Reverse Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Braking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Plugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Entering an Aisle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 PDMM-0058

Table of Contents

Mitsubishi® Reach Service Manual

Operating the Truck on a Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Travel Speed and Lift Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 In this Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 EV100LX Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Silicon Controlled Rectifiers (SCR) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 #1 Rectifier (REC1) Chopper SCR . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 #2 Rectifier (REC2) Commutating SCR . . . . . . . . . . . . . . . . . . . . . 4-3 #5 Rectifier (REC5) Charging SCR . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Diode Rectifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 #3 Rectifier (REC3) Free Wheeling . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 #4 Rectifier (REC4) Plugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Reactor (Coil T3/T4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Capacitor 1-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Filters REC22, REC23, REC24, REC25 . . . . . . . . . . . . . . . . . . . . . 4-5 Thermal Protector (TP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Sensor (Sensor 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Creep Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Controlled Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Plugging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 1A Current Dropout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Speed Limit 1 (SL1) and Speed Limit 3 (SL3) . . . . . . . . . . . . . . . . . . . 4-7 Static Return to OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Accelerator Volts Hold-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Coil Driver Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Thermal Cutback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Pulse Monitor Trip (PMT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Internal Resistance Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Steer Pump Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Stored Fault Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Battery Discharge Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 On-board Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Basic SCR Controller Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Energizing the Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Gate Pulse to REC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Gate Pulse to REC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Firing REC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 OFF Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Oscillation Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Oscillator Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Wiring Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Operation of the Travel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 x

PDMM-0058

Mitsubishi® Reach Service Manual

Table of Contents

Sequence 1: Truck at Rest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Sequence 2: Connect the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Sequence 3: Closing the Key Switch and the Deadman Pedal . . . . . . 4-16 Sequence 4: PMT Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Sequence 5: Directional Contactor Closure. . . . . . . . . . . . . . . . . . . . 4-17 Sequence 6: REC1 Turn ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Sequence 7: REC5 Turn ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Sequence 8: Reverse Charging the 1C Capacitor. . . . . . . . . . . . . . . . 4-19 Sequence 9: REC2 Turn ON and REC1 Turn OFF. . . . . . . . . . . . . . . 4-19 Sequence 10: Free-Wheeling Current . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Sequence 11: 1A or Bypass Contactor Operation . . . . . . . . . . . . . . . 4-21 Sequence 12: Controlled Plugging . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Unique System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Braking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 General Maintenance Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 In this Chapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Jacking the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Welding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Electrostatic Discharge Damage . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Proper Handling of Static Sensitive Devices . . . . . . . . . . . . . . . . . . 5-5 Discharging the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Removing the Circuit Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Removing an Integrated Circuit (IC). . . . . . . . . . . . . . . . . . . . . . . . 5-8 Installing a New Integrated Circuit . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Removing a Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Troubleshooting with the Cable Connector Breakout Board. . . . . 5-10 Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Shunt Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Planned Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Time Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Planned Maintenance Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Grease Fitting Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 How Batteries Get Damaged. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Removing a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Installing a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Cleaning the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 PDMM-0058

Table of Contents

Mitsubishi® Reach Service Manual

Testing the Battery Electrical Leakage To Frame. . . . . . . . . . . . . . . . 5-22 Battery Discharge Indicator (BDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Internal Resistance Compensation . . . . . . . . . . . . . . . . . . . . . . . 5-23 Adjusting the Internal Compensation . . . . . . . . . . . . . . . . . . . . . 5-24 Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Using the Hydrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Checking the Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Voltage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 Adding Water to the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 Keeping a Battery History Record . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 Maintaining the Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Motor Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Brush Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Cleaning the Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 Measuring the Brush Spring Tension . . . . . . . . . . . . . . . . . . . . . 5-33 Replacing a Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 Preventing the Motor from Overheating . . . . . . . . . . . . . . . . . . . . . . 5-34 Checking the Torque on the Motor Stud Terminals . . . . . . . . . . . 5-34 Open Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 Testing for Open Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 Short Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 Testing for Short Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 Armature Shorts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37 Checking for Armature Shorts. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37 Grounded Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37 Testing for a Grounded Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37 Truck Grounds—General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38 Testing for Grounds on the Truck Frame . . . . . . . . . . . . . . . . . . 5-38 Hydraulic System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 Selecting the Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 Changing the Reservoir Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 Checking the Reservoir Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 Changing the Reservoir Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 Bleeding the Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41 Mechanical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42 Power Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42 Drive Unit Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42 Removing the Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 Installing the Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44 Preparing to Replace the Drive Axle Seal (36-Volt) . . . . . . . . . . . . 5-45 Replacing the Drive Axle Seal (36-Volt) . . . . . . . . . . . . . . . . . . . . 5-45 Preparing to Replace the Drive Axle Seal (24-Volt) . . . . . . . . . . . . 5-51 Disassembling the Drive Unit (24-Volt) . . . . . . . . . . . . . . . . . . . . 5-52 Assembling the Drive Unit (24-Volt). . . . . . . . . . . . . . . . . . . . . . . 5-53 Braking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57 Braking Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57 Adjusting Nut-Retained Style Brakes. . . . . . . . . . . . . . . . . . . . . . 5-59 xii

PDMM-0058

Mitsubishi® Reach Service Manual

Table of Contents

Inspecting the Brake Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61 Bleeding the Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61 Adjusting the Deadman Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62 Replacing the Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . 5-65 Replacing the Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65 Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67 Reassembling the Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68 Replacing the Brake O-Ring Seal. . . . . . . . . . . . . . . . . . . . . . . . . 5-69 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73 Steering Adjustment with Steerable Caster . . . . . . . . . . . . . . . . . 5-73 Initial Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73 Adjusting the Casters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74 Service Notes for Steering Components . . . . . . . . . . . . . . . . . . . . 5-77 Lift/Lower System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79 Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79 Removing and Inspecting the Chain . . . . . . . . . . . . . . . . . . . . . . 5-79 Lubricating the Lift Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81 Adjusting the Over the Mast Hose and Cable. . . . . . . . . . . . . . . . 5-82 Replacing the Over the Mast Hose . . . . . . . . . . . . . . . . . . . . . . . . 5-85 Replacing the Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87 Adjusting the Equalization Chain . . . . . . . . . . . . . . . . . . . . . . . . 5-89 Equalization Chain Removal and Installation . . . . . . . . . . . . . . . 5-91 Replacing the Equalization Chain Sheave . . . . . . . . . . . . . . . . . . 5-92 Applying Loctite® to the Reach Carriage Chain Anchors . . . . . . . 5-93 Adjusting the Mechanical Stop . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93 Reach Carriage Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . 5-94 Removing the Fork Carriage Tilt Pins . . . . . . . . . . . . . . . . . . . . . 5-94 Attaching the Mast to the Tractor . . . . . . . . . . . . . . . . . . . . . . . . 5-95 Adjusting the High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . 5-96

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 In this Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Verifying Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Locating the Problem Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Establishing a Logical Testing Sequence. . . . . . . . . . . . . . . . . . . . . . . 6-2 Identifying the Cause of the Problem . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Correcting the Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Checking the Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Shorts to the Truck Frame—Causes . . . . . . . . . . . . . . . . . . . . . . . 6-5 Shorts to the Truck Frame—Checking. . . . . . . . . . . . . . . . . . . . . . 6-5 Voltage To Frame—Causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Voltage To Frame—Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Voltage to Frame—Eliminating . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Board and Component Swapping Precautions . . . . . . . . . . . . . . . . . . 6-7 PDMM-0058

xiii

Table of Contents

Mitsubishi® Reach Service Manual

Troubleshooting Order for Component Failure . . . . . . . . . . . . . . . 6-7 Handling Printed Circuit Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Cleaning and Inspecting the Contactors . . . . . . . . . . . . . . . . . . . . 6-8 Contactors Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Testing Other Electrical Components . . . . . . . . . . . . . . . . . . . . . 6-10 EV100LX Component Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Checking for Hydraulic Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Maintenance Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Avoiding Hydraulic Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Lift/Lower Hydraulic System Troubleshooting. . . . . . . . . . . . . . . 6-16 Steps for Locating Problems in the Lift/Lower System . . . . . . . . . 6-17 Pump Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 EV100LX Codes and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Troubleshooting the EV100LX Solid-State Control System . . . . . . . . 6-20 Identifying a Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Replacing the Logic Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Wire Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Jacking the Truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Accessing the Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Visual Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Using the LX Handset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Operating the Handset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Function Set-Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Handset Programmable Functions . . . . . . . . . . . . . . . . . . . . . . . 6-25 System Voltage Drop vs. Function Setting . . . . . . . . . . . . . . . . . . 6-30 GE Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31 Status Code - Blank Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32 Status Code - 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 Status Code - 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Status Code - 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Status Code - 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 Status Code - 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42 Status Code - 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44 Status Code - 07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46 Status Code - 08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 Status Code - 09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50 Status Code - 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52 Status Code - 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53 Status Code - 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54 Status Code - 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55 Status Code - 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56 Status Code - 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57 Status Code - 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58 Status Code - 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59 Status Code - 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60 Status Code - 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61 Status Code - 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62 xiv

PDMM-0058

Mitsubishi® Reach Service Manual

Table of Contents

Status Code - 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63 Status Code - 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64 Status Code - 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65 Status Code - 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66 Status Code - 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67 Status Code - 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68 Status Code - 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69 Status Code - 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70 Status Code - 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-71 Status Code - 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72 Troubleshooting the Interface Card System . . . . . . . . . . . . . . . . . . . . . . 6-73 Running Learn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73 Setting up the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73 Interface Card Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75 Interface Card Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76 Interface Card Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77 Code 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78 Code 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78 Code 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79 Code 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79 Code 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-79 Code 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80 Code 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80 Code 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-81 Code 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82 Code C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82 Code E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83 Code F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-83 Code H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84 Code J . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84 Code L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85 Code U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85 Troubleshooting the Interface Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86 Display on Interface Card is Dark. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86 No Auxiliary Functions; Aux. Motor Runs; Other Functions OK . . . . 6-86 Auxiliary Motor Does not Run; Other Functions OK . . . . . . . . . . . . . 6-87 One Auxiliary Function Is Inoperative . . . . . . . . . . . . . . . . . . . . . . . 6-87 Auxiliary Functions Operate In Only One Direction: Steering OK . . . 6-88 No Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-88 No Lower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-88 No Travel, Other Functions OK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-88 No Speed Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91 No Lift Inhibit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92

Charts and Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Lubrication Equivalency Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 PDMM-0058

Table of Contents

Mitsubishi® Reach Service Manual

Torque Chart - Standard (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6 Torque Chart - Metric (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7 Torque Chart - Metric (Brass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7 Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8 Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-18 Decal Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-19 Pin-By-Pin Voltages - EV100LX Travel Control System . . . . . . . . . . . . . A-21 EV100 Interface Card Troubleshooting Relationships . . . . . . . . . . . . . . A-27 Brush Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-28

xvi

PDMM-0058

Mitsubishi® Reach Service Manual

List of Figures

Figure 1-1: Specification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Figure 1-2: Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Figure 1-3: Operator’s Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Figure 1-4: Hydraulic Steering Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Figure 1-5: Hydraulic System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Figure 1-6: Platform Components (Hydraulic) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Figure 1-7: Platform Components (Electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 Figure 1-8: EV100LX Silicon Controlled Rectifier (SCR) Controller . . . . . . . . . . . 1-21 Figure 2-1: Recommended Oil by Temperature . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Figure 3-1: Operator System Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Figure 4-1: System Identification (EV100LX Control Panel) . . . . . . . . . . . . . . . . . 4-2 Figure 4-2: Travel System Simplified Schematic (EV100LX) . . . . . . . . . . . . . . . . 4-14 Figure 4-3: Brake Schematic (Manual Steer Truck Shown) . . . . . . . . . . . . . . . . 4-25 Figure 5-1: Correct Jacking Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Figure 5-2: Proper/Improper Method of Holding Circuit Card . . . . . . . . . . . . . . . 5-5 Figure 5-3: Anti-Static Kit (P/N 1056022) with Wrist Strap and Mat . . . . . . . . . . 5-7 Figure 5-4: PROM Removal Tool, P/N NA010030 . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Figure 5-5: Removing an Integrated Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Figure 5-6: End View (Enlarged) of a Typical Molex Connector . . . . . . . . . . . . . . 5-9 Figure 5-7: Pin Extraction Tool Inserted into Molex Connector . . . . . . . . . . . . . . 5-9 Figure 5-8: Cable Connector Breakout Board . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Figure 5-9: Interface Card Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Figure 5-10: Lubrication/Inspection Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Figure 5-11: Battery Discharge Indicator Calibration Chart . . . . . . . . . . . . . . . . . 5-25 Figure 5-12: Example of Cleaning Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Figure 5-13: Measuring Brush Spring Tension . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 Figure 5-14: Drive Motor Armature Terminal - Proper Torque . . . . . . . . . . . . . . . 5-34 Figure 5-15: Motor Terminal Torque Specification for All Other Motors . . . . . . . . 5-35 Figure 5-16: Motor Terminals and Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 Figure 5-17: Drive Unit Replacement Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 Figure 5-18: Lower End of Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46 Figure 5-19: Ring Gear Before Being Pressed Toward Flange . . . . . . . . . . . . . . . . 5-47 Figure 5-20: Ring Gear After Being Pressed Toward Flange . . . . . . . . . . . . . . . . . 5-47 Figure 5-21: Removing Bearing Spacer Using Bearing Puller . . . . . . . . . . . . . . . . 5-48 Figure 5-22: Removing External Snap Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48 Figure 5-23: Removing Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49 Figure 5-24: Removal/Installation of Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . 5-49 Figure 5-25: Installing the Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50 Figure 5-26: Drive Unit Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51 Figure 5-27: Drive Unit Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51 Figure 5-28: Drive Unit Components - Lower End . . . . . . . . . . . . . . . . . . . . . . . . 5-52 Figure 5-29: Removing Axle Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53 Figure 5-30: Pressing Bearing Cone onto Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53 Figure 5-31: Assembly of Axle into Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54 Figure 5-32: Preparing Axle Seal for Assembly into Housing . . . . . . . . . . . . . . . . 5-54 PDMM-0058

xvii

List of Figures

Mitsubishi® Reach Service Manual

Figure 5-33: Install/Torque Clamp Nut on Axle . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55 Figure 5-34: Securing Clamp Nut by Tightening Retaining Screw . . . . . . . . . . . . 5-55 Figure 5-35: Installing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56 Figure 5-36: Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58 Figure 5-37: Brake Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58 Figure 5-38: Nut-Retained Style Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5-60 Figure 5-39: Brake Adjusting Bolt Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61 Figure 5-40: Deadman Brake Pedal Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . 5-63 Figure 5-41: Deadman Brake Pedal Installation (Sheet 2 of 2) . . . . . . . . . . . . . . . 5-64 Figure 5-42: High Side of Brake Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67 Figure 5-43: Hydraulic Brake - 24-Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71 Figure 5-44: Hydraulic Brake - 36-Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72 Figure 5-45: Steering Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73 Figure 5-46: Caster Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75 Figure 5-47: Stops Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76 Figure 5-48: Steering Maintenance Notes (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . 5-77 Figure 5-49: Steering Maintenance Notes (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . 5-78 Figure 5-50: Lubrication of Lift Chain Spherical Nut . . . . . . . . . . . . . . . . . . . . . . 5-81 Figure 5-51: Blocking Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82 Figure 5-52: Hose Clamping on Inner Telescopic . . . . . . . . . . . . . . . . . . . . . . . . . 5-83 Figure 5-53: Hose/Cable Tension Spring Adjustment . . . . . . . . . . . . . . . . . . . . . 5-84 Figure 5-54: Hose Routing Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86 Figure 5-55: Mast Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88 Figure 5-56: Rear Cylinder Piston/End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88 Figure 5-57: Adjusting the Equalization Chain . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90 Figure 5-58: Removing the Equalization Chain Sleeve . . . . . . . . . . . . . . . . . . . . . 5-92 Figure 5-59: Adjusting the Mechanical Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93 Figure 5-60: Reach Assembly Lubrication (Deep Reach Shown) . . . . . . . . . . . . . . 5-94 Figure 5-61: Removing Tilt Pivot Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94 Figure 5-62: Torque Specifications for Attaching the Mast to the Tractor . . . . . . . 5-95 Figure 6-1: EV100LX Silicon Controlled Rectifier (SCR) Control . . . . . . . . . . . . . 6-22 Figure 6-2: LX Handset (P/N NA010031) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Figure 6-3: Start-Up Display Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24 Figure 6-4: GE Status Code - Blank Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33 Figure 6-5: GE Status Code - 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Figure 6-6: GE Status Code - 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37 Figure 6-7: GE Status Code - 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Figure 6-8: GE Status Code - 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 Figure 6-9: GE Status Code - 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43 Figure 6-10: GE Status Code - 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 Figure 6-11: GE Status Code - 07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47 Figure 6-12: GE Status Code - 08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 Figure 6-13: GE Status Code - 09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51 Figure 6-14: Interface Card Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76 Figure A-1: Electrical Schematic (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . A-14 Figure A-2: Electrical Schematic (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . A-15 Figure A-3: Electrical Schematic (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . A-16 Figure A-4: Electrical Schematic (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . A-17 xviii

PDMM-0058

Mitsubishi® Reach Service Manual

Figure A-5: Figure A-6: Figure A-7:

PDMM-0058

List of Figures

Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-18 Decal Locations (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-19 Decal Locations (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-20

xix

List of Figures

Mitsubishi® Reach Service Manual

This page intentionally left blank.

PDMM-0058

Mitsubishi® Reach Service Manual

List of Tables

Table 1-1: Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Table 2-1: Visual Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Table 2-2: Functional Inpsection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Table 2-3: Classes of Cold Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Table 4-1: Pulse Monitor Trip (PMT) Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Table 4-2: Code Sleeve Identifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Table 4-3: Sequence 2 Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Table 4-4: PMT Test Conditions and Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Table 5-1: Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Table 5-2: Planned Maintenance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Table 5-3: Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Table 5-4: Grease Fitting Locations for Mitsubishi ESR and EDR Reach Trucks . . 5-19 Table 5-5: Battery Charge States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Table 5-6: Interpreting the Calibration Chart Reading . . . . . . . . . . . . . . . . . . . . 5-24 Table 5-7: Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Table 5-8: VOM Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 Table 5-9: What to Look for When Inspecting the Brushes . . . . . . . . . . . . . . . . . 5-32 Table 5-10: Nut-Retained Style Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 5-60 Table 5-11: Deadman Brake Pedal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64 Table 5-12: Defect-Cause Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80 Table 6-1: Contactor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Table 6-2: Component Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Table 6-3: Checking for Hydraulic Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Table 6-4: Handset Programmable Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26 Table 6-5: System Voltage Drop vs. Function Setting (Internal Resistance) . . . . . 6-30 Table 6-6: Interface Card Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75 Table 6-7: Interface Card Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77 Table A-1: Lubrication Equivalency Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Table A-2: Torque Chart - Standard (Ferrous) . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Table A-3: Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8 Table A-4: Standard/Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10 Table A-5: Pin-By-Pin Voltage - EV100LX Travel Control System . . . . . . . . . . . . A-21 Table A-6: EV100 Interface Card Troubleshooting Relationships . . . . . . . . . . . . A-27 Table A-7: Minimum Brush Lengths. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-28

PDMM-0058

xxi

Mitsubishi® Reach Service Manual

Chapter 1: Truck Description Overview

Chapter 1: Truck Description Overview This chapter describes the Mitsubishi Reach Truck, including detailed descriptions of major components that are supported by photographs and drawings.

In this Chapter

This chapter contains the following topics: Topic

PDMM-0058

See Page

Truck Overview

1-2

Mechanical

1-4

Hydraulic

1-11

Electrical

1-17

1-1

Mitsubishi® Reach Service Manual

Chapter 1: Truck Description Truck Overview

Truck Overview This section describes the general characteristics of the truck.

Use

The reach truck is designed for indoor narrow aisle warehouse use only.

Type

The truck is a stand up, rider type that is designed for narrow aisle installations where the operator must store and retrieve items up to two pallets deep from storage racks. The truck is manually operated.

Power

The battery is a 24- or 36-volt industrial battery.

Specification Plate

The specification plate on the truck lists maximum load information for safety reasons. The following figure shows the specification plate:

Mitsubishi model number Serial number assigned by the factory for this truck

Truck weight (with battery, without operator and load)

Nominal battery voltage Truck Weight (without battery)

Power rating of battery Battery weight (minimum and maximum)

Truck weight with Maximum Battery Maximum load capacity of truck (exceeding maximum might damage truck or affect stability) Figure 1-1:

1-2

Specification Plate

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 1: Truck Description Truck Overview

Mast

The mast is a two (simplex) and three (triplex) stage hydraulic lift with a variety of Overall Lowered Heights (OALH) and Elevated Heights (EH).

Controls

The operator controls consist of: • Lockable key switch • Emergency disconnect switch • Steering wheel • Hydraulic assisted steering • Travel, lift, and lower controller • Brake • Horn button Additional options, such as fans and working lights are available by customer request.

Indicators

Indicators include: • System display • Audible alarm that sounds to communicate with the operator of certain system conditions • Strobe light that gives the truck high visibility

PDMM-0058

1-3

Mitsubishi® Reach Service Manual

Chapter 1: Truck Description Mechanical

Mechanical This figure shows the mechanical components of the truck. The main components are the following: • Chassis • Mast assembly • Operator’s compartment • Steering system • Drive unit Overhead Guard

Mast

Main Cover

Battery Compartment

Outrigger

Forks Load Wheels

Figure 1-2:

1-4

Component Identification

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 1: Truck Description Mechanical

Chassis

The Chassis is constructed of the following parts: • Power section frame • Battery compartment • Battery connector • Outriggers • Covers

Power Section Frame

The power section frame is constructed of formed sheet and plate steel welded together to form a strong integral unit. The power section is bolted to the outriggers and mast.

Battery Compartment

The battery can be removed or installed from either side. Steel rollers support the battery and make it easy to remove and install.

Battery Connector

The battery connector is located on the right side of the truck and is mounted on the power section frame.

Outriggers

Each outrigger has one or two load wheels, depending on the truck configuration.

Covers

Two covers constructed of formed plastic enclose components on the power section. Screws allow both covers to be removed from the truck.

PDMM-0058

1-5

Chapter 1: Truck Description

Mitsubishi® Reach Service Manual

Mechanical

Mast Assembly

The mast assembly is constructed of the following parts: • Mast main frame • Telescopic frames • Mast bearings • Forks

Mast Main Frame

The mast main frame has a ladder type construction. The mast uprights are made of structural I-sections. The uprights are tied together using structural steel crossties. The mast uprights are welded to the outrigger frame forming a strong integral unit.

Telescopic Frame

The telescopic frame is also a ladder type construction. It is constructed of structural I-sections and crossties.

Mast Bearings

The mast bearings are roller type construction and lubricated for life.

Forks

The forks are constructed of 2 x 4 in. (50.8 x 101.6 mm) rectangular steel (fork length is optional). The forks are attached to the bottom of the fork carriage. The overall width of the forks is adjustable from 24 to 28 in. (609.6 to 711.2 mm).

1-6

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 1: Truck Description Mechanical

Operator’s Compartment

The Operator’s Compartment has been designed for safety, efficiency, and operator comfort. The operator’s compartment is constructed of the following parts: • Compartment floor • Overhead guard • Operator’s controls

Key Switch

Steering Wheel

Emergency Disconnect

Control Handle Figure 1-3:

PDMM-0058

Operator’s Display Indicator

Operator’s Compartment

1-7

Chapter 1: Truck Description

Mitsubishi® Reach Service Manual

Mechanical

Compartment Floor

The center section of the floor is plated steel. It is covered by a rubber cushion.

Overhead Guard

The overhead guard (shown in Figure 1-2) is constructed of steel tubing and bar stock. The overhead guard covers the floor area to protect the operator and complies with ANSI specification B56.1.

Operator’s Controls

The operator’s compartment provides the operator with complete control of the truck (see Figure 1-3 and Figure 1-4). The controls have been designed for operator safety, efficiency, and comfort.

Deadman Pedal

The deadman pedal is spring loaded. When the pedal is released, the travel circuit is disabled (turning the power off) and the brake is applied.

Operator Compartment Options

Additional options, such as fans and working lights, are available by customer request.

1-8

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 1: Truck Description Mechanical

Steering

The hydraulic steering system uses the auxiliary pump, which supplies hydraulic pressure. The steering orbitrol controls the rate and direction of the hydraulic fluid to the steer motor. The steer motor in turn rotates the drive unit.

Auxiliary Motor and Pump Orbitrol

Steer Motor

Deadman Pedal

Figure 1-4:

PDMM-0058

Hydraulic Steering Components

1-9

Chapter 1: Truck Description

Mitsubishi® Reach Service Manual

Mechanical

Drive Unit

The drive unit is a compact, self-contained assembly. It consists of: • Pivot bearing • Gear housing • Gear reduction assembly • Drive motor • Brake • Drive wheel

Pivot Bearing

The pivot bearing is the part of the drive unit assembly that provides support for the drive motor, wheel, and gear housing.

Gear Housing

The gear housing is a precision machined casting into which the gear reduction system is assembled.

Gear Reduction Assembly

The gear reduction assembly is comprised of: • Motor pinion • Drive gear • Drive pinion • Compound gear • Splined shaft The gears are continuously bathed in gear oil. The splined axle shaft turns on two ball bearings.

Drive Motor

The drive motor is a series wound motor and uses sealed bearings for long service life. The drive motor transmits power to the reduction unit by a motor pinion gear on the motor armature shaft.

Brake

The brake is hydraulically activated and mounted to the top of the drive motor. A brake drum is mounted on the end of the drive motor armature shaft.

Drive Wheel

The drive wheel consists of a polyurethane tire mounted on an inner hub. The design of the wheel permits replacement of the drive tire.

1-10

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 1: Truck Description Hydraulic

Hydraulic The hydraulic portion of the truck consists of the lift/lower system. The following figure shows the hydraulic system components.

PDMM-0058

1-11

Mitsubishi® Reach Service Manual

Chapter 1: Truck Description Hydraulic

Lift Pressure Relief Valve Reservoir Tank and Filter Lift Pump Auxiliary Motor

Manifold

DIRA, DIRB Solenoids Control Handle Steering Orbitrol

Load Holding Solenoid Steer Motor

Deadman Pedal

Figure 1-5:

1-12

Hydraulic System Components

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 1: Truck Description Hydraulic

Manifold

Auxiliary Pump Steer Motor

Brake Horn

Deadman Pedal (S2)

Drive Motor

Brake Reservoir (DOT 5 only) Dip Stick Filler Tube

Figure 1-6:

PDMM-0058

Platform Components (Hydraulic)

1-13

Chapter 1: Truck Description

Mitsubishi® Reach Service Manual

Hydraulic

Lift/Lower System

The lift/lower system consists of: • Lift pump • Lift motor • Lift cylinder assembly • Flow controls • Reservoir • Return line filter • Lift chain • Lift/lower hydraulic manifold assembly • Solenoids

Lift Pump

A splined, fixed displacement gear pump is used on both models. The pump is located under the operator’s console cover and to the right of the Operator’s Display Indicator (ODI).

Lift Motor

Power to drive the lift pump is a series wound, fan cooled, intermittent duty motor. The lift motor is located under the operator console cover and to the right of the ODI.

Lift Cylinder Assembly

The lift cylinder is composed of the following: • Cylinder housing • Piston • Flow controls

Cylinder Housing

The cylinder housing is constructed of welded steel tubing. The cylinder housing is attached to the mast main frame.

Piston

The piston is encased within the cylinder housing and lifts the telescopic section of the mast assembly. The piston is constructed from chrome plated tubing.

Flow Controls

The flow controls limit the rate that fluid leaves the cylinder if there is a broken hose.

1-14

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 1: Truck Description Hydraulic

Reservoir

The welded steel reservoir has a capacity of approximately 5.5 gal. (20.8 l). The reservoir is located in the upper left corner of the operator’s console and is vented to the atmosphere through the filler cap.

Return Line Filter

The return line filter consists of a 10-micron filter element and bypass valve set at 15 PSI (103.4 kPa) cracking pressure. The unit has a replaceable spin-on type canister. The filter is directly screwed onto the reservoir tank.

Lift Chain

The heavy duty lift chain is constructed of 3/4 in. pitch, 4x4 laced leaf chain. The lift chains comply with ANSI 829.8 requirements.

Lift/Lower Hydraulic Manifold Assembly

The lift/lower hydraulic manifold assembly controls hydraulic flow rate and direction in the lift/lower system. The manifold assembly is controlled electrically by the interface card. The assembly is located under the operator’s console cover and to the front and slightly left of the steering orbitrol. The lift/lower hydraulic manifold assembly consists of: • Manifold housing • Lift pump check valve (5 PSI [34 kPa)]) • High pressure relief valve • Output check valve

Manifold Housing

The manifold housing is machined from aluminum.

Lift Pump Check Valve

The check valve prevents hydraulic oil from flowing back through the lift pump. It should be at 5 PSI (34 kPa).

High Pressure Relief Valve

The high pressure relief valve is set to prevent lifting a load which exceeds the maximum load capacity of the truck.

Output Check Valve (100 PSI)

The check valve provides smooth stopping during lift. It should be at 100 PSI (689 kPa).

PDMM-0058

1-15

Mitsubishi® Reach Service Manual

Chapter 1: Truck Description Hydraulic

Solenoids

The following list describes the solenoids used in the Mitsubishi Reach Truck: Table 1-1: Solenoids

Solenoid

Description

Sol L/H

Load/holding prevents hydraulic fluid from leaving the lift cylinder when the carriage is elevated and the lift/lower control is in neutral.

Sol REACH

Enables the carriage to reach or retract; it works in conjunction with the DIRA and DIRB Solenoids.

Sol DIRB

Enables the carriage to extend or reach; it works in conjunction with the Reach Solenoid.

Sol DIRA

Enables the carriage to retract and move the forks back toward the mast; it works in conjunction with the Reach Solenoid.

Sol TILT

Enables the forks to tilt up or down. It works in conjunction with the DIRA and DIRB solenoids. The direction of tilt depends on the input received from the control handle in the operator’s compartment.

Sol SIDESHIFT Enables the fork carriage to move left or right. It works in conjunction with the DIRA and DIRB solenoids. The left or right movement of the carriage depends on the input received from the control handle in the operator’s compartment. Sol EQ

1-16

The Equalizing solenoid function is to stop or inhibit the return flow of hydraulic fluid during select operations. This ensures smooth controlled motion of the truck functions.

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 1: Truck Description Electrical

Electrical This section is primarily descriptive. For detailed operation, see Chapter 3: "Operating Instructions" and Chapter 4: "Theory of Operation". The descriptions for the 24- or 36-volt electrical system include: • System displays • Electronic control system • Travel system • Lift/lower system • Steering system

PDMM-0058

1-17

Mitsubishi® Reach Service Manual

Chapter 1: Truck Description Electrical

This figure shows the electrical components. Fuses: FU1

FU2

FU4 FU5

FU3

P Contactor

1A Contactor X Contactor Fwd

Handset Settings Decal

Rev

EV100LX Control System

Interface Card and Firmware Figure 1-7:

1-18

Platform Components (Electrical)

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 1: Truck Description Electrical

System Displays

There are two system displays: • Operator’s Display Indicator (ODI) • Maintenance Displays

Operator’s Display Indicator (ODI)

The Operator’s Display Indicator (ODI) is mounted on the operator’s console adjacent to the control handle and is visible to the operator. It displays information from the EV100 system. The Operator Display Indicator is used to: • Display battery charge level (as a percentage) • Hour meter (after key is turned OFF) • Display system messages and fault codes • Service required The (ODI) shows information on a four-segment Light Emitting Diode (LED), alphanumeric digital display. Information is displayed in a static format.

Maintenance Displays

An additional maintenance display is provided for Service Technician use. All trucks have a display mounted on the Interface Card Assembly (which is visible when the cover is removed). Trucks equipped with the EV100LX Solid-State Control System require the technician to use an LX Handset tool (P/N NA010131) to diagnose the system.

Electronic Control System

PDMM-0058

The Electronic Control System consists of an Interface Card Assembly.

1-19

Chapter 1: Truck Description

Mitsubishi® Reach Service Manual

Electrical

Interface Card Assembly

The Interface Card Assembly forms the core element for the truck’s electronic control system and functions as an interface between the Operator Control Handle Assembly and the EV100LX Solid-State Control System for travel system control. It is also used to control lift, lower, and auxiliary functions. It is equipped with DIP switches that allow different options to be turned on or off and for system configuration. The interface card is located behind the access panel on the right side wall of the operator’s compartment and directly below the EV100LX control panel. K1 Relay Coil: Supplies negative battery voltage to the horn, completing a circuit from B+ to B- across the horn assembly. K2 Relay Coil: Supplies positive battery voltage to the forward and reverse contactor coils when the S2 switch is closed, simulating the seat switch input to the EV100 system.

Travel System

The travel system consists of: • EV100LX Solid-State Control System • Drive motor • Travel contactors • Control handle

EV100LX SolidState Control System

1-20

The EV100LX Solid-State Control System controls the drive motor for truck direction and speed. It can perform status checks and provide error messages on the system display. It also calculates the battery state-of-charge. The control system is located behind the access panel on the right side wall of the operator’s compartment and just below the contactor panel.

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 1: Truck Description Electrical

The following figure shows the EV100LX Silicon Controlled Rectifier (SCR) Controller. Card Connection Terminals (TB1-TB6)

Oscillator Card

Charging SCR (REC5)

Thermal Protector

Filter (REC22)

Filter (REC23)

Commutating (Turn Off) SCR (REC5)

Commutating Capacitor

Filter (REC25) Filter (REC24)

Reactor/Choke

Motor Current Sensor

Main Chopper SCR (REC1)

Freewheeling (Flyback) Diode (REC3)

Plugging Diode (REC4)

Figure 1-8:

PDMM-0058

EV100LX Silicon Controlled Rectifier (SCR) Controller

1-21

Chapter 1: Truck Description

Mitsubishi® Reach Service Manual

Electrical

Drive Motor

The drive motor transmits power to the reduction unit through a pinion gear on the armature shaft. The drive motor is located inside on the left side of the operator’s compartment and behind the swing door.

Travel Contactors

The forward and reverse (F and R) contactors are included in a dual unit with two contacts actuated by each coil (forward and reverse). Each set of contactors is a single pole, double throw design. Drive motor direction of rotation is determined by which set of contacts is actuated. The 1A high speed (bypass) contactor is a single pole, single throw design with normally open tips. Activation of the 1A contactor bypasses the Chopper SCR (REC1) giving maximum speed. NOTE: Contactors used are magnetic type, designed for maximum interchangeability of parts. Contactor tips are silver alloy and are replaceable.

Lift/Lower System

The lift/lower system consists of: • Lift motor • P contactor • Load holding solenoid

Lift Motor

The lift motor is a series wound, fan cooled, intermittent duty motor. The lift motor is located under the operator’s console cover and to the right of the Operator’s Display Indicator (ODI).

P Contactor

The P Contactor is a single pole, single throw design with normally open tips. Activation of the P contactor energizes the lift motor circuit, which enables the lift function.

Load Holding Solenoid

The load holding (L/H) solenoid prevents hydraulic fluid from leaving the lift cylinder and prevents lifting and lowering until activated.

1-22

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 1: Truck Description Electrical

Steering System

The steering system consists of: • Auxiliary motor • X contactor • Control Handle • Deadman pedal (Switch S2) • Emergency disconnect • Key switch (S1)

Auxiliary Motor

Power to drive the auxiliary pump is a compound wound, intermittent duty motor. The auxiliary motor is located under the operator’s console cover and to the left of the operator’s control handle.

X Contactor

The X contactor is a single pole, single throw design with normally open tips. Activation of the X contactor energizes the auxiliary motor circuit, which enables: • Steering function • Reach • Tilt • Sideshift The travel contactors are located behind the access panel on the right sidewall of the operator’s compartment.

PDMM-0058

1-23

Mitsubishi® Reach Service Manual

Chapter 1: Truck Description Electrical

Control Handle

The control handle functions are: Function

Description

VR1

Throttle forward and reverse motion

Horn button

Reach button (high-speed retract)

Retract button (high-speed reach)

Tilt forks UP button

Tilt forks DOWN button

Carriage sideshift left

Carriage sideshift right

S20

Lift

S21

Lower

Deadman Pedal (Switch S2)

The deadman pedal is switch S2. Switch S2, which is normally open, is located on the brake assembly near the drive motor in the power section. When the deadman pedal is up, switch S2 is open, preventing travel.

Emergency Disconnect

The emergency disconnect is located on the operator’s control console, to the right of the control handle. The disconnect has two positions: • UP allows the truck to travel, lift, auxiliary, and steer • DOWN prevents travel and all other functions from operating

Key Switch (S1)

1-24

The lockable key switch is located to the left of the operator’s display. The key switch has two positions; OFF and ON.

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 2: Installation Overview

Chapter 2: Installation Overview This chapter describes how to install the truck.

Warranty Coverage

To assure full warranty coverage for your new Mitsubishi equipment, all installation procedures must be performed by a Mitsubishi Certified Dealer Technician. This is to ensure the customer receives a product that is in excellent operating condition and protected by the Mitsubishi warranty.

In this Chapter

This chapter contains the following topics: Topic

PDMM-0058

See Page:

Inspecting the Truck

2-2

Uprighting a Cradled Truck

2-5

Assembling the Truck

2-8

Doing a Functional Inspection

2-10

Preparing the Truck for Cold Storage

2-12

Preparing the Truck for Storage

2-14

2-1

Mitsubishi® Reach Service Manual

Chapter 2: Installation Inspecting the Truck

Inspecting the Truck Before installing the truck, inspect it for shipping damage and for Mitsubishi quality standards. This section explains how to do the inspection.

How the Truck is Shipped

Before doing the inspection, take note of how the truck was prepared for shipping from the factory: • The Mast/Tractor Assembly is laid down on a skid (this is known as cradling). Usually if the Overall Lowered Height (OALH) is 107 in. (2717.8 mm) or more, the truck will be secured to a cradle and shipped lying down (with its mast horizontal). Instructions for uncradling a truck are on page 2-5. • The carriage is strapped to the truck’s baselegs (for cradled trucks). • In the battery compartment: •

A glass mast guard is installed (if used).

•

Two battery doors are strapped in place.

•

Two battery gates are strapped in place.

• Solid gaskets are placed beneath the breather cap of the hydraulic reservoir and inside the cap of the brake reservoir to prevent leakage. (Instructions for removing the gasket are on page 2-8.)

Reasons for Doing a Visual Inspection

The reasons for visually inspecting a Mitsubishi truck are: • To look for shipping damage • To make sure the unit has been built to the sales order • To make sure the unit meets Mitsubishi’s high quality standards

What to Look For

Using the “Visual Inspection Checklist,” on page 2-4, look for anything that doesn’t meet Mitsubishi specifications or the sales order including: dents, cuts, missing components, leaks, cracks, and so on.

Repairing Shipping Damage

Any damage caused during shipping is the responsibility of the carrier and should be repaired at the carrier’s expense. Shipping damages are not covered under the Mitsubishi warranty policy.

2-2

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 2: Installation Inspecting the Truck

Repairing Defects

PDMM-0058

Report defects to Mitsubishi through your Dealer. Any items not meeting Mitsubishi high quality standards should be addressed and repaired by a Certified Mitsubishi Dealer Technician and reported to Mitsubishi using Mitsubishi policy guidelines.

2-3

Mitsubishi® Reach Service Manual

Chapter 2: Installation Inspecting the Truck

Table 2-1: Visual Inspection Checklist

Visual Inspection Checklist Responsibility of: Item

Description of Problem

Shipper

Mitsubishi

Attachment Options Auxiliary Control Handles Battery Battery Charger Battery Disconnect Directional/Speed Control Handle Electrical Power Cables Elevating Assembly Hoses and Cables Along Mast Hydraulic Hoses Hydraulic Lines Lift Chains Lift/Lower Control Handles Loose Hardware Mast Missing Decals Overhead Guard Paint Condition Tires Tractor Assembly Underside of Truck (if cradled) Welds

2-4

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 2: Installation Uprighting a Cradled Truck

Uprighting a Cradled Truck This section includes instructions for uprighting a cradled truck. Generally, when the OALH (Overall Lowered Height) of a truck is 107 in. (2717.8 mm) or higher, it will be secured to a cradle and shipped lying down (with the mast horizontal).

Warnings and Cautions

Be sure to follow these important warnings and cautions before uprighting a cradled truck:

! CAUTION Two technicians are required for erecting and assembling the unit.

! CAUTION Remove all jewelry from hands and wrists before doing the installation.

! WARNING Do not remove the banding that secures the carriage to the baselegs until after you have the truck standing upright. Use extreme caution when removing the metal banding which secures the forks to the cradle—bands might recoil when cut.

! WARNING To prevent possible injury or damage to the unit, use extreme caution when handling a cradled lift truck. Place the mast, truck, and pallets in an open area where it will be safe to work. The truck components are heavy, unstable, and difficult to handle. Use extreme care when lifting and assembling this truck. Proceed with extreme caution. • Anyone involved in setting up this unit should wear gloves, safety glasses, steel-toed boots, and a safety helmet. • There should be no distractions during setup of this truck. • Do not allow observers to stand nearby.

Items Needed

To upright the truck, you’ll need: • A hoist with a minimum working capacity of 5 tons (4536 kg). • An assembly area with a ceiling clearance in excess of the truck’s collapsed height. • A hoist sling for the mast.

PDMM-0058

2-5

Mitsubishi® Reach Service Manual

Chapter 2: Installation Uprighting a Cradled Truck

Option 1: Uprighting with Two Chain Hoists

Use this procedure when two chain hoists of suitable weight capacities are available. 1. Before lifting the truck into the upright position, remove the forks from the cradle. Use a lifting device to prevent personal injury because the forks weigh more than 50 lbs. (23 kg) each. 2. Position the cradled truck so it is lying directly beneath and parallel to the chain hoist rail. 3. Attach the first chain hoist to the upper cross piece of the cradled truck’s mast. 4. Attach the second chain hoist to the baselegs of the cradled truck. 5. Slowly raise each chain until all slack is gone.

! WARNING While performing the next step, be sure that the chain on the baselegs does not lift the cradle off the floor. Also, be sure not to let it become slack as this will allow the truck to lower too quickly. 6. Begin lifting the chain attached to the upper cross piece of the cradled truck’s mast. 7. Once the lifting chain reaches a certain point, the center of gravity will shift, causing the weight of the cradled truck to shift to the chain hoist attached to the baselegs. 8. Once the weight has shifted, continue to lower the truck with the baseleg chain hoist until it is standing on the floor in the upright position. 9. Remove the chains from the baselegs. 10. Remove the chain from the upper cross piece of the truck’s mast and attach it to the upper cross piece of the cradle. 11. Loosen and remove the nuts holding the wooden cradle cross piece to the mast; then remove the wooden cradle cross piece. 12. Remove the bolts from the bottom cradle cross piece that secures the cradle to the truck’s front bumper. 13. Lift the cradle up and away from the truck and slowly lower it to the floor. 14. Remove the strapping which secures the carriage to the baselegs. 15. Assemble the truck; see “Assembling the Truck” on page 2-8.

2-6

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 2: Installation Uprighting a Cradled Truck

Option 2: Uprighting with One Chain Hoist and a Lift Truck

Use this procedure when one chain hoist is available. This procedure uses a lift truck and a chain hoist, both of suitable weight capacity. 1. Before lifting the truck into the upright position, remove the forks from the cradle. Use a lifting device to prevent personal injury because the forks weigh more than 50 lbs. (23 kg) each. 2. Position the cradled truck so it is lying directly beneath and parallel to the chain hoist rail. 3. Position the forks of the lift truck you’re using to upright the truck under the upper cross piece of the cradle.

! WARNING Once the forks are positioned under the cradle, attach a safety chain between the fork carriage of the lifting truck and the upper cross piece of the cradle. This prevents the cradle from slipping off the forks during the uprighting procedure. 4. Attach the chain hoist to the baselegs of the cradled truck. 5. Slowly raise the chain hoist until all slack is gone.

! WARNING While performing the next step, be sure that the chain on the baselegs does not lift the cradle off the floor. Also, be sure not to let it become slack as this will allow the truck to lower too quickly. 6. Begin to raise the upper end of the cradle with the forks of the lifting truck. 7. Once the forks have lifted the cradle to a certain point, the center of gravity will shift. This causes the weight of the cradled truck to shift to the chain hoist. 8. Once the weight has shifted, continue to lower the truck with the chain hoist until the truck is standing on the floor in the upright position. 9. Remove the chain between the lifting truck carriage and the upper cross piece of the cradle. Back the lifting truck away. 10. Remove the chain from the baselegs and attach it to the upper cross piece of the cradle. 11. Loosen and remove the nuts holding the wooden cradle cross piece to the mast, then remove the wooden cross piece. 12. Remove the bolts from the bottom cradle cross piece that secure the cradle to the truck’s front bumper. 13. With the chain still attached to the cradle, lift the cradle up and away from the truck and slowly lower it to the floor. 14. Remove the strapping which secures the carriage to the baselegs. 15. Assemble the truck; see “Assembling the Truck” on page 2-8. PDMM-0058

2-7

Mitsubishi® Reach Service Manual

Chapter 2: Installation Assembling the Truck

Assembling the Truck This section describes how to assemble the truck.

Removing the Gaskets

Two solid gaskets need to be removed after the truck is upright and the cradle is removed, They are: • Beneath the breather cap on top of the hydraulic oil reservoir • Inside the cap of the brake reservoir After the gaskets are removed, check the fluid levels of each reservoir.

Greasing the Mast Uprights

Before placing the truck into service, clean the uprights, elevate the carriage so the telescopic section of the mast is accessible, then coat the main frame and telescopic uprights with Lube “E” using a 2 in. (50 mm) wide brush. See the “Lubrication Equivalency Chart” on page A-2.

2-8

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 2: Installation Assembling the Truck

Installing the Battery

To install the battery, do the following:

! CAUTION Under no circumstances should the truck be connected to the battery charger. The battery charger, when turned on, could instantly destroy the circuits within the interface card. It could also harm many electrical components, voiding any warranty claims on any of these components.

! CAUTION Improper battery procedures can shorten battery life!

! WARNING Take precautions not to jam or cut the battery cables during installation of the battery as this could result in a short, which could cause a fire or a battery explosion.

! WARNING When removing a battery, ALWAYS use a battery stand or equivalent material handling equipment. 1. Remove the battery doors (if included) and the glass mast guard (if included). 2. Be sure the battery is fully charged before putting the truck into operation. 3. Ensure that both gates are properly installed in the truck. 4. Remove one battery gate, usually the one on the side of the battery connector. 5. Ensure that the opposite battery gate is locked in place. 6. Slide the battery into the compartment from a battery stand, making sure the battery cable ends up in the correct position for connection to the truck connector. 7. Once the battery is in place, install the battery gate. Ensure both battery gates are securely locked into position. 8. Adjust the battery gate to prevent battery side-to-side movement during truck operation. 9. Install the doors (if included) and the glass mast guard (if included).

PDMM-0058

2-9

Mitsubishi® Reach Service Manual

Chapter 2: Installation Doing a Functional Inspection

Doing a Functional Inspection This section describes how to do a functional inspection.

Who Does the Inspection

A Certified Mitsubishi Dealer Technician must do the functional inspection.

What Needs to be Done

Before putting a truck into operation: • Do a functional inspection using the checklist shown on “Functional Inpsection Checklist,” on page 2-11. • Complete the “Mitsubishi Delivery Report” (MEEW0003-01), and forward it to Mitsubishi’s Warranty Division.

Starting the Mitsubishi Warranty

The Mitsubishi Delivery Report starts the Mitsubishi warranty on the truck. Failure to complete the delivery report can nullify the warranty on the truck.

Reporting Repairs

Any repairs that are needed because the sales order or Mitsubishi specifications were not met—not not repairs due to damage—should be addressed to the Mitsubishi Warranty Division by a Certified Mitsubishi Dealer.

Using the Checklist

Make a copy of the checklist before doing the inspection. When checking the truck, look for the following: • General operation of the truck • Meets Mitsubishi specifications • Built to satisfy the sales order Report any discrepancies or deficiencies in the truck immediately to the Mitsubishi Warranty Division.

2-10

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 2: Installation Doing a Functional Inspection

Table 2-2: Functional Inpsection Checklist

Functional Inspection Checklist Check

Item

Notes

Auxiliary Function Battery Battery Charger Battery Connectors Battery Gates Battery Stand Brake Covers/Doors Drive Unit Oil Level Fan (Optional) Grease at Fittings Horn Lift Lift Chains Lights Lubrication Points Mast Uprights Greased Master Cylinder Oil Level Operator’s Display Other Options Relief Valve Adjustment Reservoir Oil Level Steering Switches-Electrical Travel

PDMM-0058

2-11

Mitsubishi® Reach Service Manual

Chapter 2: Installation Preparing the Truck for Cold Storage

Preparing the Truck for Cold Storage If the truck will be used in a cold storage application, it will be equipped with Class I or Class II cold storage option components when delivered from the factory, except for the oil in the hydraulic reservoir and the drive unit, which has to be changed.

! CAUTION When the customer is ready to start using the truck in a cold storage environment, the oil in the hydraulic system and the drive unit must be changed as described in this section.

Classes of Cold Storage

All units are shipped from the factory with standard oil. Units that are to be used in cold storage applications must have the oil in the truck changed to the proper grade based on the class. See Figure 2-1. There are two classes of cold storage applications in Mitsubishi terminology. Those classes are listed in the following table: Table 2-3: Classes of Cold Storage

Class

Operating Environment • Continuously in an environment where temperatures fluctuate from +20oF to +70oF (-7oC to 21oC). • Application where the truck goes in and out of the freezer for short periods of time. • In and out of an environment where temperatures fluctuate from +40oF to -40oF (4oC to -40oC). • Continuously at -20oF (-29oC).

2-12

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 2: Installation Preparing the Truck for Cold Storage

Types of Oil

Figure 2-1 shows the recommended oil based on temperature. Use this figure to select the oil for the truck.

! CAUTION Using the incorrect oil for a particular application might cause chatter in the lift ram. No warranty will be paid on component damage resulting from using incorrect oil. Recommended Drive Unit Oils

30oF and Above (-1oC and Above) (P/N 1036912) 30oF and Below (-1oC and Below) (P/N 1056012)

Figure 2-1:

PDMM-0058

120

-1 -7

20 20

-29

Recommended Hydraulic Oils 50oF to 120oF (Standard) (10oC to 49oC) (P/N 8T9578) 20oF to 70oF (Class I) (-7oC to 21oC) (P/N 1056009) 20oF to 40oF (Class II) (-29oC to 4oC) (P/N 1056011)

Recommended Oil by Temperature

2-13

Mitsubishi® Reach Service Manual

Chapter 2: Installation Preparing the Truck for Storage

Changing the Hydraulic System Oil

To change the oil in the hydraulic system, do the following: 1. Be sure the truck is in a clean area, away from any possible contaminating elements that could enter the hydraulic system during the changing process. 2. Drain the hydraulic reservoir completely. Be sure to drain as much oil as possible from the hydraulic lines and cylinders. 3. Fill the hydraulic reservoir with the proper oil in accordance with Figure 2-1 and Figure 5-10, “Lubrication/Inspection Points,” on page 5-18. Also see the “Lubrication Equivalency Chart” on page A-2. 4. Operate all truck functions and check for possible hydraulic leaks. 5. Bleed the entire hydraulic system before placing the truck into service. 6. Check the reservoir oil level. The remainder of the original hydraulic oil left in the system, (approximately 5%) should not be detrimental to the operation of the truck.

Preparing the Truck for Storage This section describes how to prepare the truck for storage.

Storage Warranty

If the truck is going to be stored for any length of time, the following procedure should be used. A Certified Mitsubishi Dealer should contact the Mitsubishi Warranty Division for the proper warranty procedures.

General Storage Tips

Try to keep the truck in a dry and covered area. Cover the truck using plastic or canvas. Keeping the truck in a low moisture, temperature controlled environment will greatly reduce problems. If the truck is going to be stored for longer than 30 days, jack it up and block it off the floor.

2-14

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 2: Installation Preparing the Truck for Storage

! WARNING If the truck is going to be stored for longer than six months, spray the hydraulic components with a silicone protectant. Do not get spray on the circuit cards.

Hydraulic System

The hydraulic system will absorb moisture when left standing for a long time. Make sure the reservoir is full before storing. Before starting the truck up again, drain the reservoir and change the filters. Refill the reservoir with the proper grade of new hydraulic fluid. Operate the hydraulic systems slowly to allow internal components to get lubricated.

Hydraulic Cylinders

If possible, store the truck with the cylinder pistons in the retracted position. Coat all exposed chrome surfaces of the piston with hydraulic oil.

Lift Chains

Liberally coat all chains using oil to prevent rust and corrosion.

Mast Uprights

Grease the uprights by doing the following: 1. Before placing the truck into service, clean the mast uprights of any dust and dirt. 2. Elevate the mast until the telescopic uprights are accessible. 3. Swab telescopic and main frame uprights, using a 2” (50 mm) brush, with a light coating of Lube E. See the “Lubrication Equivalency Chart” on page A-2.

Electronics

No special precautions are necessary to store the electronics hardware except to ensure that all components stay dry.

Motors

Lift the brushes in each motor away from the commutator surface. Periodically, rotate the motor shafts; this coats the bearings with lubricant, which reduces oxidation and corrosion.

PDMM-0058

2-15

Mitsubishi® Reach Service Manual

Chapter 2: Installation Preparing the Truck for Storage

When preparing to put the truck back in use, the surface of the commutator should be inspected and polished, if required, using a rubber abrasive polish. Polishers are specifically made for polishing commutators. DO NOT use a stone.

Battery

Store the battery in a cool, dry area. High temperatures are not good for the battery; the higher the temperature, the quicker the opencircuit discharge rate. It is not recommended to store batteries in temperatures over 110oF (43oC) for extended periods of time. A fully charged battery can be stored three months without any service. DO NOT store a partially discharged battery; chemical reactions within the battery will ruin it. If wetness is observed on the top of the battery, neutralize the surface using one pound (0.45 kg) of baking soda to one gallon (3.78 l) of hot water. Rinse the battery with clear water and dry before storing. Check the condition of the batteries on a regular basis.

2-16

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 3: Operating Instructions In this Chapter

Chapter 3: Operating Instructions In this Chapter This chapter contains the following topics: Topic

See Page

EV100LX Operator System Display

3-1

Operator’s Daily Checklist

3-4

EV100LX Operator System Display Figure 3-1 provides visual information of specific conditions as they occur. The display shows: • Display test (one second) • Hour meter (after key is turned off) • Battery charge level (as a percentage) • Status codes • Service required

Figure 3-1:

PDMM-0058

Operator System Display

3-1

Chapter 3: Operating Instructions

Mitsubishi® Reach Service Manual

EV100LX Operator System Display

Display Test

When the key is turned ON, all segments of the display will light for approximately one second. This allows you to verify that the display is operating properly.

Hour Meter

The truck hour meter will automatically record traction control operating hours. The hour meter is a 4-digit display. Each time the key is turned to ON, the display will show 8888 briefly so that the LED’s can be checked for failures.

Battery Charge Level

The Battery Charge Level shows the energy level which remains in the battery, based on voltage readings. The value displayed is the percentage of useful energy remaining in the battery. Voltage fluctuations will occur during normal operation. The battery charge level is a 3-digit display. When the battery charge level reaches 20%, the LED above the battery icon on the display will begin to flash. This is a reminder to the operator that lift cutout is approaching. When the battery charge level reaches 10%, lift will be prevented. The battery must be recharged or replaced with a recharged battery before lift will function again.

Status Codes

Messages will appear on the System Display to inform you of certain operating conditions; the three types of messages are: • Information Messages • Performance Limiting Codes • Fault Codes

Informational Messages

An informational message will not restrict or limit truck performance. An example of an informational message is the battery charge level. The truck has only two informational messages. One is the battery charge level and the other is Code 01. Code 01 indicates that the deadman switch needs to be pressed.

3-2

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 3: Operating Instructions EV100LX Operator System Display

Performance Limiting Codes

Fault Codes

PDMM-0058

A performance limiting code will reduce the speed of the truck. The performance limiting code for this truck is: Code

Meaning

Effect

Traction system temperature is greater than 194oF (90oC).

Reduce travel performance until temforkperature of traction system is below 194oF (90oC).

If a fault occurs, the system disables travel and lift functions. Fault codes for the traction system will be shown on the system display.

3-3

Mitsubishi® Reach Service Manual

Chapter 3: Operating Instructions Operator’s Daily Checklist

Operator’s Daily Checklist For safe and efficient operation, complete the following checks at the beginning of each day or shift of operation. Report any malfunction to the Service Department.

! CAUTION Do not operate the truck until it is repaired. If you are not qualified to inspect the truck, or if you do not understand the proper inspection procedure, contact the authorized Mitsubishi Forklift dealer. The inspection procedure is in “Planned Maintenance” on page 5-12.

Visual Checks

Perform these visual checks: 1. Battery: •

Proper voltage

•

Fully charged

•

No leakage

•

Installed properly with secure fastening

•

Connector is in good condition and properly attached to mating connector

2. Guards and covers are properly installed. 3. The wearable surface of the drive and load wheels must not be damaged. They must have adequate material remaining. 4. Lift chains should be in place and properly lubricated. 5. Hydraulic hoses should be in good condition. 6. Warning and accessory lights should operate. 7. Safety decals should be in place and should be legible. 8. All controls should return to neutral when released. 9. General inspection (such as leaks, bent forks, abnormal sounds, cracked welds, loose hardware, and so on).

Operational Checks

Perform these operational checks: 1. Lift/lower—smooth and responsive to commands. 2. Auxiliary functions—operate when control is activated. 3. Brakes—travel slowly and check that brakes work. With a rated load at full speed, the truck should stop within 6 to 11 feet (1.83 to 3.35 meters).

3-4

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 3: Operating Instructions Operator’s Daily Checklist

4. Directional/speed control—truck motion should be smooth and should respond to commands throughout all speed ranges. 5. Steering—smooth without binding or excess play. 6. Horn—sound it. 7. Deadman pedal—should disable travel and apply the brake when released. 8. Battery disconnect button—should disable auxiliary, travel, and lift circuits when pressed.

Start-up Procedure

To start the truck, do the following: 1. Perform the Operator’s Daily Checklist. 2. Check that the battery is secure. 3. Connect the battery connection to the truck. Make sure that the Battery Disconnect separates the battery connector when you push it. 4. Step into the operator’s compartment. 5. Check the hour meter by turning the key to ON, then to OFF. 6. Turn the key switch to ON. 7. Use one foot to press and hold down the deadman pedal. 8. Use one hand to steer the truck and the other to control travel and auxiliary functions. The truck can be driven either forks first or tractor first.

! CAUTION If you are unsure what direction the truck will move, travel slowly until you know the truck path. 9. Check brake operation by releasing the deadman pedal moving. With a rated load, the brake should stop the truck within 6 to 11 feet (1.83 to 3.35 meters).

Forward/Reverse Travel

PDMM-0058

Move the directional/speed control toward the desired direction of travel. The amount of directional/speed control movement determines truck speed. To travel faster, move the directional/speed control further from neutral.

3-5

Mitsubishi® Reach Service Manual

Chapter 3: Operating Instructions Operator’s Daily Checklist

Braking

Brakes are the recommended method of stopping the truck, especially in an emergency. 1. Return directional/speed control to neutral. 2. Gradually let up on the deadman pedal to get the desired braking force. 3. In an emergency, release the deadman pedal quickly. This will disable the travel system and apply full braking effort to stop the truck in the shortest possible distance.

Plugging

Plugging is the recommended method of retarding travel speed and changing direction during operational maneuvers. Plugging can also be used to stop the truck. This method will not stop the truck as quickly as braking, but it will provide the operator with an alternate method to bring the truck to a smooth, controlled stop. 1. Move the directional/speed control through neutral to the direction opposite travel. 2. The truck will slow down, come to a stop, then start traveling in the opposite direction. The further past neutral you move the directional/speed control, the greater the plugging force. It is common practice to use the brakes while plugging to stop the truck. To do this, release the deadman pedal after plugging has slowed or stopped the truck. Releasing the pedal disables travel and applies the brake.

Parking

To park the truck, do the following: 1. Lower the forks all the way (in most cases, the forks will not touch the floor). 2. Turn the key OFF. Remove the key from the key switch.

! WARNING Never park this truck on a ramp or slope.

Entering an Aisle

To enter an aisle: 1. Center the load (from side to side) in the aisle you’re traveling. 2. Turn the steering wheel to pivot the truck on the load wheel nearest the corner being turned.

3-6

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 3: Operating Instructions Operator’s Daily Checklist

3. As the rear of the truck swings toward the center of the aisle, gradually begin returning the drive wheel to the straight-ahead position. 4. When the truck is aligned with the aisle entrance, proceed into the aisle.

Operating the Truck on a Ramp

To operate the truck on a ramp: 1. While carrying a load, the load should be upgrade when ascending or descending a ramp. 2. If the truck is empty (no load on forks), the forks should be downgrade when ascending or descending. 3. If the ramp is a movable dockboard, ensure it is of the proper width and capacity, and securely fastened before traveling on it. While on the ramp, operate the truck slowly and smoothly to prevent jarring the dockboard out of position.

! WARNING Never elevate a load with forks tilted down. Never travel with load elevated more than necessary to clear the wheels. Failure to obey proper methods of ramp operation results in a lack of truck stability which can be extremely dangerous. Ensure the truck is square with the ramp before ascending or descending. Never turn on a ramp.

Travel Speed and Lift Limits

The speed of the truck and its lift speed can be limited by the following: Cause

PDMM-0058

Effect

Power panel temperature too hot

Speed reduced

Power panel overheated

Traction system disabled

Forks are elevated above 204 in. (5182 mm)

Speed reduced

(Optional) Second stage of mast is engaged

Speed reduced

3-7

Mitsubishi® Reach Service Manual

Chapter 4: Theory of Operation In this Chapter

Chapter 4: Theory of Operation In this Chapter This chapter contains the following topics: Topic

See Page

EV100LX Control Panel

4-1

System Components

4-3

Control Features

4-6

Basic SCR Controller Circuit Operation

4-11

Wiring Conventions

4-13

Operation of the Travel System

4-14

Lift/Lower System

4-23

Braking

4-25

EV100LX Control Panel The Reach Truck has variable speed ranges in both forward and reverse directions. Infinite selection of speeds is obtained through the use of a main Silicon Controlled Rectifier (SCR). The SCR is turned ON and OFF to control the flow of electricity to the drive motor; the ON and OFF time varies from 1.8 to 20 milliseconds as shown in the following table: Creep Speed

Top Speed

1.8 milliseconds

20 milliseconds

OFF

20 milliseconds

1.8 milliseconds

Because of a small voltage drop across the SCR, maximum speed is obtained by bypassing the SCR and connecting the drive motor directly across the battery using the 1A contactor. See the following: • Figure 4-1, “System Identification (EV100LX Control Panel),” on page 4-2 • Figure 4-2, “Travel System Simplified Schematic (EV100LX),” on page 4-14

PDMM-0058

4-1

Mitsubishi® Reach Service Manual

Chapter 4: Theory of Operation EV100LX Control Panel

Card Connection Terminals (TB1-TB6)

Oscillator Card

Charging SCR (REC5)

Thermal Protector

Filter (REC22)

Filter (REC23)

Commutating (Turn OFF) SCR (REC5)

Commutating Capacitor

Filter (REC25) Filter (REC24)

Reactor/Choke

Motor Current Sensor

Main Chopper SCR (REC1)

Freewheeling (Flyback) Diode (REC3)

Plugging Diode (REC4)

Figure 4-1:

4-2

System Identification (EV100LX Control Panel)

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 4: Theory of Operation System Components

System Components The following system components are described: • Silicon Controlled Rectifiers (SCR) • Diode Rectifiers • Thermal Protector (TP)

Silicon Controlled Rectifiers (SCR)

The SCR is basically an electrically controlled ON/OFF switch. The SCR has a: • Positive side (anode) • Negative side (cathode) • Gate When the SCR is gated, current can pass through; when the SCR is turned OFF, no current can pass through. NOTE: In the schematic diagrams, current flows in the direction the arrow is pointing. The SCR is turned ON by applying the correct voltage to the rectifier control lead. It is turned OFF in two ways: 1. By placing on the negative side of the SCR, a positive charge that is greater than the battery positive. 2. By placing equal charges (both positive and negative) on both sides of the SCR. There are three SCR’s in the EV100LX Control; although each works in the same manner, each serves a different function.

#1 Rectifier (REC1) Chopper SCR

#2 Rectifier (REC2) Commutating SCR

PDMM-0058

The #1 rectifier (REC1) is the main rectifier in the power circuit and provides the switching effect for the current flowing through the drive motor. The power flows as shown in the following table: When the rectifier is...

Power...

Flows through the drive motor

OFF

Is OFF

The #2 rectifier (REC2) is a switching device used with the capacitor to turn OFF the #1 rectifier (REC1).

4-3

Chapter 4: Theory of Operation

Mitsubishi® Reach Service Manual

System Components

#5 Rectifier (REC5) Charging SCR

The #5 rectifier (REC5) is used as the 1-C capacitor charging switch.

Diode Rectifiers

Diode rectifiers are one-way electrical check valves similar to SCR’s except they have no gate. Current flow is in the direction of the arrow on the diagram. The #3 and #4 rectifiers (REC3 and REC4) in the power circuit are diode rectifiers.

#3 Rectifier (REC3) Free Wheeling

The #3 rectifier (REC3) is called the flyback diode because it is used in the flyback process. When the #1 rectifier (REC1) is turned OFF, the flyback diode directs current from the fields to the motor armature so that the armature will continue to rotate. The #3 rectifier (REC3) differs from the #1 rectifier (REC1) because it does not require gate voltage to be turned ON. It will conduct current any time the voltage polarity is correct across the stud and pigtail.

#4 Rectifier (REC4) Plugging

The #4 rectifier (REC4) is called the plugging diode because it functions during the plugging operation. It functions similarly to the #3 diode in that it is a simple diode and conducts current any time the voltage of the correct polarity is across the stud and pigtail. The #4 rectifier (REC4) acts as a sensing device for controlled plugging, which is a means of slowing the truck electrically using the motor instead of the brake.

Reactor (Coil T3/ T4)

The reactor has only one winding and builds voltage upon itself; it is used to shut OFF the #1 rectifier (REC1).

Capacitor 1-C

The 1-C capacitor acts as a storage cell for voltage; the stored charge is released by the #2 rectifier (REC2) to turn OFF the #1 rectifier (REC1).

Choke X1

The choke is a retarding device placed in the circuit to slow down current surges through the #2 rectifier (REC2). The choke controls and extends the discharge of the capacitor.

4-4

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 4: Theory of Operation System Components

Filters REC22, REC23, REC24, REC25

The filters protect the SCRs and diodes from voltage surges during turn ON and turn OFF cycles. The #1 rectifier (REC1) does not have a filter.

Thermal Protector (TP)

The thermal protector is a heat sensitive variable resistor used to protect the #1 rectifier (REC1) by slowing down the number of pulses to REC1 when it becomes overheated.

Sensor (Sensor 1)

The sensor is a monitoring device for the main card that tells the card how many amperes are crossing the armature. The lengths of the sensor wires are calibrated as well as the distances between their weld points. If these distances are changed, the truck might not operate properly. If these wires are damaged or broken, the entire unit must be replaced.

PDMM-0058

4-5

Chapter 4: Theory of Operation

Mitsubishi® Reach Service Manual

Control Features

Control Features The following briefly describes the features of the EV100LX SolidState Control System. Many of the system features are programmable. See “Troubleshooting” on page 6-1 for information and precautions.

Creep Speed

Creep speed is the rate at which the main SCR (REC1) is turned ON or OFF when the throttle is at its slowest speed position. It is adjustable to meet specific customer needs (Function 2, see Table 6-4 on page 626). Top speed is fixed by the controller.

Controlled Acceleration

Controlled acceleration is the pace at which the controller increases the percent of ON time of the main SCR (REC1). It controls the time required to go from creep speed to 96% applied battery voltage to the drive motor on hard acceleration. The 1A contactor will automatically close 0.2 seconds after the controlled acceleration stops and the speed voltage input is less than 0.5 volts. Controlled acceleration is adjustable from 0.1 to 22 seconds (Function 3, see Table 6-4, “Handset Programmable Functions,” on page 6-4).

Current Limit

The current limit monitors the current through the motor circuit. The motor current includes the flyback current and can exceed 2 to 3 times the battery current. When heavy motor loading takes place, this feature overrides the throttle command and limits the average current to the programmed value (Function 4, see Table 6-4 on page 6-26). The current limit setting is based on the maximum thermal rating of REC1 and the peak voltage of capacitor 1-C. When the main SCR (REC1) shuts OFF and stops conducting, the magnetic field in the drive motor collapses. Because the magnetic field collapses while moving across a set of windings, it induces a current of opposite polarity voltage. This voltage continues to drive the armature during the OFF time of the SCR. The average motor current is the sum of the flyback and the amount conducted by the SCR.

Plugging

4-6

Plugging lets the operator change the direction the truck is traveling without coming to a stop first. When the direction control is reversed, the truck comes to a smooth stop and gradually accelerates in the opposite direction. Easing back on the throttle during the plug

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 4: Theory of Operation Control Features

reduces the severity (increasing the stopping distance), and advancing the throttle increases the severity (reducing the stopping distance). The severity of the change is adjustable (see Function 5, in Table 6-4 on page 6-26). Plugging is based on the principle that the motor can also be used as a generator. When the controller senses that the operator has changed directional command during truck movement, it automatically puts the truck in plugging mode. During plugging mode the opposite direction contactor closes; the controller slowly pulses the motor fields so that a magnetic field is produced. The movement of the armature through this field generates an opposite polarity voltage which continues to drive the motor. The magnetic field, however, tends to slow the armature down as it tries to turn. The amount of "ON time" of the main SCR (REC1) during the slow pulsing controls the magnetic field strength, and thus the distance over which the truck continues to plug before starting to accelerate in the opposite direction.

1A Current Dropout

The 1A current dropout feature provides smooth transition from the main SCR to the 1A bypass. It also prevents arcing and burning of the 1A bypass contactor tips. It keeps the main SCR (REC1) pulsing during the pickup and dropout of the contactor. The dropout value is adjustable (see Function 6, in Table 6-4 on page 6-26). When the controller has dropped out of the 1A contactor due to excess current, the control handle must be returned to neutral to unlock the dropout circuit and allow the controller to pick up the 1A contactor again.

Speed Limit 1 (SL1) and Speed Limit 3 (SL3)

Speed Limit 1 (SL1) and Speed Limit 3 (SL3) can be adjusted (maximum battery volts to the motor) through Functions 11 and 13 (see Table 6-4 on page 6-26). The speed limit 2 function is not used. SL1 and SL3 speed limit switches are normally closed switches connected to battery negative; switch opening enables the respective speed limit. A function setting of 0 units disables speed limit functions and allows top speed.

Static Return to OFF

The Static Return to OFF built-in feature forces the operator to return the control handle to neutral anytime the operator leaves the truck. If the deadman switch or key switch is opened, the controller will shut OFF and cannot be restarted until the control handle is returned to neutral.

PDMM-0058

4-7

Chapter 4: Theory of Operation

Mitsubishi® Reach Service Manual

Control Features

Accelerator Volts Hold-Off

The Accelerator Volts Hold-Off checks the voltage level at the accelerator input (TB1) whenever the deadman switch is activated. If the voltage is less than 2.5 volts, the truck will not start. This assures that if there is an input-related failure, the truck will not start up at full speed. This feature is not adjustable.

Coil Driver Modules

The Coil Driver Modules are internal to the logic card. These are the power devices that operate the F, R, and 1A contactor coils. The drivers open or close the coils on command from the logic card. The contactor coils are 24-volt, which reduces current requirements. The card has internal spike protection, eliminating the need for external suppressors. All modules are equipped with reverse battery protection.

Thermal Cutback

4-8

The Thermal Cutback feature prevents the truck from learching. If the controller is excessively loaded for a long period of time, it will overheat. When this occurs, the controller will cut back current flow to the motor and reduce truck speed. If overheating is severe, this feature prevents the 1A contactor from closing, thereby avoiding truck lurching because of the lower control range speed and the transition to full bypass speed.

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 4: Theory of Operation Control Features

Pulse Monitor Trip (PMT)

The Pulse Monitor Trip (PMT) contains three subset features that prevent the controller from operating if fault conditions exist that would allow uncontrolled (runaway) speed of the truck. These features are: 1. Look Ahead 2. Look Again 3. Automatic Look Again and Reset

Table 4-1: Pulse Monitor Trip (PMT) Features

Feature Look Ahead

Description The PMT circuit will look ahead to see if certain faults exist prior to start-up and will not allow start-up if: • REC1 is shorted • 1A contactor tips are welded • Forward or reverse contactor coil drivers are shorted • REC3 is shorted

Look Again

The PMT circuit will shut down the control during operation (opening the forward or reverse contactor) if: • REC1 fails to turn OFF • 1A contactor tips remain closed when they should be open

Automatic Look Again and Reset

After opening the forward or reverse contactor, the PMT circuit will check for a fault and, if none is found, reclose the directional contactor. If the fault still exists, the directional contactor will open and remain open. If 1A closes before a second REC1 failure, the look again counter will automatically reset, eliminating the inconvenience of resetting the PMT with the key switch if the trip is caused by random noise. When the PMT circuit prevents the forward or reverse contactors from closing, the PMT circuit can be reset by cycling the key switch.

Internal Resistance Compensation

PDMM-0058

All batteries have a small amount of internal resistance and this value varies significantly. Additionally, internal resistance of individual trucks vary. This feature allows adjustment of the controller to compensate for these varying resistances (Function 14, see Table 6-4 on page 6-26). Adjustment of this function will also improve accuracy of the Battery Discharge Indicator.

4-9

Chapter 4: Theory of Operation

Mitsubishi® Reach Service Manual

Control Features

Steer Pump Time Delay

Actuation of the steer pump contactor is done through the controller; this allows the time delay for opening of the contactor to be adjusted (Function 18, Table 6-4 on page 6-26). The controller is set to open the steer pump contactor after the directional switch has been returned to neutral for 3.5 seconds. There is also an override function that drops the contactor out after the deadman switch has been opened for 1.5 seconds.

Stored Fault Code

This is a function register (Function 1, see Table 6-4 on page 6-26) that contains the last fault that shut down truck operation (PMT fault that is reset by cycling the key switch). This status code will be overwritten each time a new status code occurs and can be cleared from memory by adjusting the value to zero.

Battery Discharge Indicator

The Battery Discharge Indicator provides accurate battery state of charge information and supplies passive and active warning signals to the operator. Voltage range is adjustable for accuracy (Function 15, see Table 6-4 on page 6-26).

Hour Meter

The hour meter is built into the controller card and will automatically record hours on the deadman switch. Each time the key switch is turned ON, the display shows 8888 briefly to check the LEDs for failures. When the key switch is turned OFF, the hours will be displayed briefly.

On-board Diagnostics

The EV100LX logic card detects the system current operating status that can be displayed on either the dash display or the handset. There are approximately 30 status codes available; see “GE Status Codes” on page 6-31.

4-10

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 4: Theory of Operation Basic SCR Controller Circuit Operation

Basic SCR Controller Circuit Operation The following paragraphs provide a brief overview of the SCR controller operating cycle. Refer to the basic schematic drawing (Figure 4-2, “Travel System Simplified Schematic (EV100LX),” on page 4-14).

Energizing the Control Circuit

The control circuit is energized by closing the key switch, the deadman switch, and moving the control handle to forward or reverse command position. This applies power to the EV100LX Controller and turns on the PMT driver, which closes the selected directional contactor and completes the circuit to the drive motor.

Gate Pulse to REC2

The control circuit then supplies a gate pulse to REC2, turning it on to a conducting state, allowing current to flow from the battery through 1C, 1X, REC2, motor field, motor armature, sensor, and back to the battery. After 1C charges, REC2 shuts OFF through lack of holding a current. The control card checks that 1C is charged and unlocks the gate to REC1 and REC5.

Gate Pulse to REC1

The control card then supplies a gate pulse to REC1, turning it on to a conducting state, allowing current to flow from the battery through REC1, motor field, motor armature, sensor, and back to the battery. REC5 turns on and allows current to flow to T4-T3, 1C, REC1, REC5 to T4-T3. This current charges the bottom of 1C positive with respect to the battery positive bus. This charging cycle occurs in less than 1 millisecond (.001 second), and REC5 shuts OFF. The charge is stored on the capacitor until it is time to turn OFF REC1.

Firing REC2

Current continues to flow in REC1 until the control card fires REC2. When REC2 conducts, capacitor 1C discharges around the circuit composed of 1C, 1X, REC2, and REC1. This discharge current opposes the battery current through REC1 so that the resultant current is zero. With reverse voltage across REC1, REC1 is turned OFF. Current continues to flow in the REC2, 1C, motor, and battery loop until the capacitor (card terminal 14) is fully charged negative. This charge exceeds battery voltage by an amount which is a function of peak motor current, and REC2 turns OFF.

PDMM-0058

4-11

Chapter 4: Theory of Operation

Mitsubishi® Reach Service Manual

Basic SCR Controller Circuit Operation

OFF Time

During the OFF time, the energy stored in the motor (by virtue of the motor inductance) will cause current to circulate through the motor around the loop formed by REC3, thus providing "flyback" current. The motor current, therefore, is composed of both battery current and the inductive flyback current. It should be noted that the average motor current measured will be higher than the average battery current. The SCR control, in effect, converts battery current at battery volts into a higher motor current and lower motor volts.

Oscillation Frequency

The time for the next ON and OFF cycle to start is determined by the time that the control card takes to oscillate. The frequency of oscillation is controlled by the control handle, interface card, and automatic circuitry in the control card. Slow speed is obtained by having 2.5 volts or greater at TB1 (speed control input). As the voltage decreases, the speed of the motor increases. The SCR circuit is capable of delivering approximately 95% speed. For full speed operation, the 1A contactor is closed to apply full battery voltage across the motor.

Oscillator Features

The oscillator section of the control card has two adjustable features and one fixed feature. The creep speed can be adjusted by the handset unit. Top speed is fixed by the card and is obtained with the voltage at TB1 at zero. The percent ON time has a range of approximately 5 to 95%. The center operating condition of the oscillator is at 50% ON time with a nominal 1.8 milliseconds ON time and 1.8 milliseconds OFF time. This corresponds to a maximum operating frequency of about 300 hertz. At creep, the ON time will decrease to approximately 0.8 milliseconds while OFF time will be about 20 milliseconds. At full SCR operation, this condition is reversed (short OFF time, long ON time). The variation of ON and OFF time of the oscillator produces the optimum frequencies throughout the SCR range. The rate at which the oscillator might increase its percent ON time is limited by the "controlled acceleration" feature. The minimum time required to go from creep speed to 80-85% ON time is adjustable from 0.1 to 22.0 seconds.

4-12

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 4: Theory of Operation Wiring Conventions

Wiring Conventions The wiring cables and harnesses are identified to give an indication of what subsystem they are connected to. Below is a table of the code sleeve identifications that are used on the cables and the system they are related to: Table 4-2: Code Sleeve Identifications

Code Sleeve Identification JPS PA, PB, TB, PY, PZ

PDMM-0058

Attached to... Interface Card/Control Handle Connections on EV100LX Controller

JPN

Auxiliary Interface Card

Standard Wiring

4-13

Mitsubishi® Reach Service Manual

Chapter 4: Theory of Operation Operation of the Travel System

Operation of the Travel System Figure 4-2 is a simplified schematic of the travel system theory of operation. For a complete schematic of the truck system, see the electrical schematic on page A-14. Interface Card Key Switch and Deadman Relay

15A

350A

FU4

FU2 IC +

1 REC

1A CTR

1 5 6 9

EV100LX Card Plug "Z" 12 13

11 10

T5 X1

2 REC FWD CTR

REV CTR S1

BATTERY

FWD CTR

T4 REV CTR A1

5 REC

3 REC

D Motor A2

To Plug Z

4 REC

15A Horn Relay and Interface Card

Figure 4-2:

4-14

FU5 Travel System Simplified Schematic (EV100LX)

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 4: Theory of Operation Operation of the Travel System

Sequence 1: Truck at Rest

The schematic on page A-14 shows the truck in an "at rest" condition. This means all switches are open or no current is flowing through the system. This schematic should be used to follow the sequential theory provided in the following paragraphs. The travel system can be divided into three major areas: • Power Circuit - all the components and heavy power cables used to carry current to the drive motor. • Control Circuit - wiring and components used to control speed and direction of the truck. • Accessory Circuits - wiring and components that are peripheral to the drive control, such as the horn, operator’s display, and so on. These are described separately in this chapter.

Sequence 2: Connect the Battery

When the battery connector is plugged in, positive and negative voltage is connected to the following: Table 4-3: Sequence 2 Voltage Connections

The...

Makes a positive connection through...

Control card

The main power fuse FU2 by the Z plug connector pin 7

Key switch

Control fuse FU4 and to JPS9-15 on the interface card There is no flow at this time because the key switch is open.

Relay K2

Pin 4 of K2

Hydraulic pump and drive motor contactor tips

Power fuses FU3 and FU2, FU1

Horn

Control fuse FU4 This supplies a negative connection to the following: The...

PDMM-0058

Makes a negative connection through...

Control Card

Fuse FU5 and to Pin JPS4-7 and JPS4-8

EV100 Card

Plus Z-2

4-15

Mitsubishi® Reach Service Manual

Chapter 4: Theory of Operation Operation of the Travel System

Sequence 3: Closing the Key Switch and the Deadman Pedal

Closing the key switch and the deadman pedal (S2) provides battery positive to:

Sequence 4: PMT Test

Before the control will allow the directional contactors to close, it performs the look-ahead test previously mentioned. It checks for voltage on the blue wire at pin 9 of the Z plug. The control puts out a signal of half battery positive voltage on the blue wire that is connected to T2. It then uses a comparator circuit in the card to check this voltage.

1. Interface control card on JPS9 terminals 13 and 14 2. Terminal 16 through the K2 relay

The following table shows the conditions and actions: Table 4-4: PMT Test Conditions and Actions

Battery State

Effect

Higher battery positive potential

Knows there is a problem and won’t close the contactors

• Shorted REC1

Battery negative potential

Knows there is a problem

• Shorted REC3

Possible Causes

• Welded 1A contactor tips • Some other fault

• Directional contactor tips welded • Some other fault

4-16

Action

Directional Contactors Held Off if Battery Positive Potential is:

This condition must be corrected before the truck will run.

Higher than 80%

This condition must be corrected before the truck will run.

Less than 20%

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 4: Theory of Operation Operation of the Travel System

Sequence 5: Directional Contactor Closure

The interface card now finally closes the directional contactors by completing the path from battery negative to the coils through the drivers internal in the card. This still does not provide current to the drive motor because we have not turned on the REC1 by way of a gate lead signal. One more step must be taken: the control performs a capacitor precharge. This is done by sending a gate signal to the REC2 and turning it ON. When this happens, we have the following current path: 1. Battery positive through the FU2 fuse to one side of the capacitor. 2. Across the 1C capacitor and through the X1 choke. 3. Through the REC2 to the normally open (now closed) forward contactor tips. 4. Through the drive motor fields and then through the normally closed reverse contactor tips. This is important to keep in mind because technicians often overlook the fact that the reverse contactor can prevent the truck from running in forward and vice versa. This sometimes creates a lot of wasted troubleshooting time. 5. A path is then completed through the drive motor armature and Sensor 1 to battery negative. The current involved is too small to power the drive motor. This entire process takes less than .001 seconds (1 millisecond). 6. When the capacitor becomes fully saturated, current flow stops. At this point the capacitor is at battery volts. The voltage potential on both sides of REC2 are at battery negative and REC2 shuts OFF. This precharge is monitored by the control card by the voltage on the orange wire on pin 14 of the Z plug, in comparison to the white wire on pin 7 of the Z plug. If this precharge fails to take place, the control will not turn ON REC1 because it indicates a fault. Such a fault would mean the capacitor cannot be charged enough to turn OFF REC1. This could mean a bad capacitor, open REC2, or some other problem. This condition must be corrected before the truck will run.

PDMM-0058

4-17

Chapter 4: Theory of Operation

Mitsubishi® Reach Service Manual

Operation of the Travel System

Sequence 6: REC1 Turn ON

When inputs are all in place and the safety tests are complete, the control will send the gate signal to the REC1, turning it ON. The path to battery negative is now complete and while REC1 is ON, full battery voltage is available to turn the armature. The current flow path is as follows: 1. Battery positive through fuse FU2. 2. Through REC1 to the normally open forward contactor tips that are now closed. 3. Through the drive motor fields and the normally closed reverse contactor tips. 4. Through the drive motor armature and current sensor to battery negative.

Sequence 7: REC5 Turn ON

As soon as REC1 is turned ON, the control prepares to turn it OFF. Remember at creep speed, there is only 1.8 milliseconds to do this. The card sends a gate signal to REC5 to turn it ON. The capacitor is already charged to battery voltage. Now there is another path of current flow available while REC1 is conducting. That path is as follows: 1. Current flows from the previously charged positive side of the capacitor through REC1 then through REC5 to the T4 reactor winding connection. 2. Current then goes through the reactor winding to the previously charged negative side of the capacitor. 3. This process discharges the capacitor through the reactor windings and builds a magnetic field in the reactor windings. Note that this current flow through the reactor winding is from the capacitor and not from the battery. When the capacitor is discharged, flow through REC5 stops and REC5 turns OFF.

4-18

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 4: Theory of Operation Operation of the Travel System

Sequence 8: Reverse Charging the 1C Capacitor

When current stops flowing through the reactor, the magnetic field collapses. When this magnetic field collapses over the reactor windings, a voltage spike is generated. This voltage spike is higher than the battery and reverse from the polarity of the current, which was flowing through the reactor. The reactor then has acted as a power source. The amperage is lower than that which went through the reactor originally, but the voltage is higher, which is what is important. Because the two sides of the 1C capacitor are electrically isolated, the capacitor is being charged by the reverse polarity voltage generated when the reactor field collapses. This higher than battery voltage results in the battery positive side of the capacitor being negative in relation to the reactor side. For example, the battery side of the 1C is at 36-volts positive, but the reactor side might be at 100 volts positive. This reverse voltage spike generated in the reactor happens anytime a winding is used to create a magnetic field. This is why such components as contactor coils, horns, relays, back-up alarms, and so on, must be filtered to prevent stray spikes from getting into the control card. Such stray voltage spikes can cause damages or malfunctioning of the control system.

Sequence 9: REC2 Turn ON and REC1 Turn OFF

The control monitors the throttle position and decides it is time to turn OFF REC1. A signal is then sent to the REC2 gate to turn it ON. A path for current flow is then opened from: 1. The more positive side of the 1C capacitor through the X1 choke to the REC2. 2. The current tries to complete the circuit to the more negative side of the 1C capacitor. 3. When this occurs, the voltage potentials for REC1 are reversed and REC1 is shut OFF. Some of this voltage might also flow through the motor back to battery negative. This current is very small, but the voltage is high enough to turn OFF REC1. 4. The X1 choke is in the circuit to help protect REC2. It slows the voltage down from the 1C capacitor so the voltage surge is slower helping to prevent an REC2 failure. This also helps insure that REC1 sees this high voltage potential and has time to react and turn OFF. 5. The 1C capacitor then again becomes charged to battery potential as it was during initial precharge: battery positive on the battery positive side and battery negative on the REC2 side. When this occurs, REC2 stops conducting and shuts OFF.

PDMM-0058

4-19

Chapter 4: Theory of Operation

Mitsubishi® Reach Service Manual

Operation of the Travel System

Sequence 10: Free-Wheeling Current

The drive motor fields use a magnetic field generated by the current from REC1 to run the armature. When we turn OFF REC1, current stops flowing through the fields. The magnetic field collapses around the field windings. A reverse polarity voltage is induced across the field windings. This energy is harnessed and the current is used to continue to turn the drive motor by means of the Free-Wheeling Diode or REC3. REC3 is a simple diode and unlike REC1, REC2, and REC5, it does not have to have a gate signal to conduct. When the fields collapse and the induced current is evident, the current flow path is: 1. From the S2 field connection which is now positive through the normally closed reverse contactor tips. 2. Through the drive motor armature causing it to turn and go through the current sensor. 3. Through REC3 since this is now a positive potential, back through the normally open (now closed) forward contactor tips. Notice that although the field induced current is a reverse polarity voltage when compared to battery voltage, it goes through the fields in the same direction, thus maintaining the same direction of armature rotation. The free-wheeling current is in effect free, and by using it, we are able to run an SCR system more effectively. Otherwise we would have to find a way to absorb this voltage to prevent motor problems. Free wheeling also smoothes over the time between pulses so the truck runs without a jerking action. This entire series of events starts all over again with the entire sequence having consumed approximately 30 milliseconds.

4-20

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 4: Theory of Operation Operation of the Travel System

Sequence 11: 1A or Bypass Contactor Operation

All electrical devices have some resistance, and semi-conductors (like SCRs) have more resistance than simple power tips on a contactor. To get the maximum possible speed, the SCR type system uses a contactor to bypass the SCR system and connect the battery directly to the drive motor. This also allows the SCR system components an opportunity to cool down and helps prevent failures due to excessive heat. This is done by: 1. The control looks at the throttle voltage on pin 10 at TB1 to verify that full speed is being requested. When the throttle voltage falls below .5 volts, control will allow the bypass timer to start. 2. When controlled acceleration has achieved maximum REC1 ON time, the card will complete the connection to battery negative and energize the 1A contactor coil. The time it takes is determined by the preset programming in the card. 3. The REC1 continues to pulse until the 1A contactor has had time to close. This prevents arcing and burning of the power tips. The control also uses this full power transition when the operator lifts his foot up and the 1A contactor opens. 4. The current path is through the FU2 fuse, 1A contactor tips, normally open (now closed) forward contactor tips, the drive motor fields, the normally closed reverse contactor tips, the drive motor armature, and the sensor back to battery negative. 5. The control monitors the current going through the drive motor at all times by the voltage drop across the sensor. Because there is no control over the current when the truck is in 1A or bypass, there is a potential for abuse resulting in motor damage. If a truck being operated in 1A encounters a situation where current levels get to the point of possible motor damage, the control would drop out the 1A contactor and put the truck back in SCR mode. The motor then will be limited to the current levels programmed into the card. The point at which the control drops out the 1A contactor is preset by the programming in the card. When this 1A drop out occurs, there is not full power transition. The result is arcing and burning of the 1A tips. This is helpful so that when troubleshooting a truck, you will know if the 1A drop out has been occurring due to excessive current draws.

PDMM-0058

4-21

Chapter 4: Theory of Operation

Mitsubishi® Reach Service Manual

Operation of the Travel System

Sequence 12: Controlled Plugging

Silicon Controlled Rectifier (SCR) systems, including the EV100LX, use a method of electrically braking called "plugging." While driving, the operator can select the opposite direction and the truck will come to a controlled stop and then accelerate in the other direction. This is done by: 1. When traveling forward, the operator moves the directional control to reverse. The forward contactor drops out and the reverse contactor is closed. 2. The control sensing this directional control change, while the motor is turning, will not begin pulsing REC1 the way it did during normal acceleration. Instead, it will pulse at a very slow rate. This pulsing is just enough to generate a small magnetic field in the drive motor fields. The armature, moving by virtue of momentum through this magnetic field, becomes a generator. This current is in reverse polarity in comparison to the battery. 3. During the relatively long periods between pulses, the current being generated travels through the armature to keep the motor traveling in the same direction. The current flow for this current is from the A2 or normally negative side of the armature through the sensor and plugging diodes (REC4) back to the armature A1 connection. 4. The slight magnetic field which is created during REC1 pulsing, also works to gradually slow down the truck. The rate at which this takes place is determined in part by the programming in the card. The feature called "pedal position plugging" also helps control this. The further the directional control is advanced, the faster the truck slows down. In this way, the operator has some control over the rate at which the truck stops independent of the card’s preset programming.

4-22

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 4: Theory of Operation Lift/Lower System

Lift/Lower System The truck is equipped with the Variable Speed Lift/Lower lift system. The rate of lift/lower is controlled by a manual spool valve which is mechanically coupled to the control handle.

System Overview

All inputs and outputs related to the lift/lower system are controlled by the Interface Card. As the operator moves the control handle, it will activate either the lift (S20) or lower (S21) switch. The rate of lift/lower will be determined by the mechanical movement of the spool valve. The Interface Card determines what actions are required based on inputs from the operator and from system feedback. The Interface Card sends a current through Lift (S20) or Lower (S21), As either switch is activated by the operator, a voltage is sent back to the Interface Card. As the lift/lower controller is moved and Lift (S20) or Lower (S21) switch is activated, a voltage is sensed by the Interface Card.

Unique System Features

PDMM-0058

If the control is moved from lift to lower, the Interface Card will not allow the carriage to lower until the lift pump motor has stopped. The Interface Card monitors lift pump motor rotation (EMF) at JPS4-3. This allows smooth, controlled movement of the carriage without sudden "bumps." The length of the delay will depend on the oil viscosity, pump/motor tightness and temperature, and the load on the carriage.

4-23

Mitsubishi® Reach Service Manual

Chapter 4: Theory of Operation Lift/Lower System

Components

The lift/Lower components consist of: • 24-volt Lift Motor. • Lift Pump Contactor—Supplies battery potential to the lift motor when the contactor is energized (contacts closed). • Fixed Displacement Gear Pump—The pump is mated to the lift motor via a spline on the input shaft of the pump. • Lift/Lower Manifold—The lift/lower manifold contains: •

High Pressure Relief Valve—This limits the maximum hydraulic pressure which the lift system might encounter.

•

Check Valves—Provide proper control of hydraulic flow.

• Reservoir—The capacity of the reservoir is 6.36 gallons (24.0 liters), with a usable amount of 4.47 gallons (17.0 liters). Values are approximate. The reservoir has a return-line filter rated at 10 microns. The filter body contains a bypass valve having a cracking pressure of 15 psi (103 kPa). The filter element is a replaceable spin-on type. • Lift Cylinders—The lift cylinder transforms hydraulic pressure into mechanical motion. • Lift Chains—The heavy duty lift chain is constructed of 3/4 in. pitch, 4 x 4 laced leaf chain. The lift chains comply with ANSI 829.8 requirements. • Interface Card—Controls the load holding solenoid and lift contactor in response to commands sent to it.

Functionality

This section describes how to use the lift/lower system: 1. Moving the lift/lower control out of the neutral position to either the right Lift (S20) or left Lower (S21) activates a switch which causes a voltage. This voltage goes into the Interface Card at JPS1-15 (Lift) or JPS1-12 (Lower). The Interface Card determines whether a lift or lower operation is desired based on the switch that was activated by the operator’s input. 2. If a lift has been requested, the Interface Card will turn on the Pcoil driver which provides a ground for the P contactor at JPS4-2. As the P contactor is energized, voltage is applied to the lift motor MP and the carriage will lift. The lift motor/lift pump assembly supplies hydraulic pressure and flow to the lift system. NOTE: The EV100 will cause the lift function to be disabled if a low battery condition exists. When the battery is 90% discharged, the voltage at JPS3-4 will be 0 to 0.6 VDC. 3. If a lower has been requested, the Interface Card will activate SOL L/H, the load holding solenoid. When this solenoid is activated, hydraulic fluid will flow from the lift cylinders back to the reservoir.

4-24

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 4: Theory of Operation Braking

Braking The braking process works as follows (see Figure 4-3): 1. With the deadman pedal in its normal UP position, the master cylinder is deactivated; therefore, the slave cylinder is depressurized allowing the brake spring to keep the brake applied. 2. Stepping on the deadman pedal strokes the master cylinder, which increases the pressure in the slave cylinder, pushing against the brake spring and releasing the brake. 3. Just before the pressure releases the brake, the deadman switch S2 is actuated, supplying power to the hour meter and travel circuits.

Reservoir

Slave Cylinder

Master Cylinder

Deadman Pedal

Figure 4-3:

PDMM-0058

Brake Schematic (Manual Steer Truck Shown)

4-25

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance General Maintenance Instructions

Chapter 5: Maintenance General Maintenance Instructions Industrial reach trucks can be hazardous if general maintenance is neglected. Only trained technicians, using approved procedures in adequate maintenance facilities should work on this or any other lift truck.

In this Chapter

This chapter contains the following topics: Topic

PDMM-0058

See Page

General Maintenance Instructions

5-1

Maintenance Practices

5-2

Planned Maintenance

5-12

Battery Maintenance

5-20

Maintaining the Motor

5-30

Hydraulic System Maintenance

5-39

Mechanical Maintenance

5-42

5-1

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Maintenance Practices

Maintenance Practices Always do the following when performing maintenance on a truck: 1. Follow a scheduled lubrication, maintenance, and inspection schedule. 2. Only qualified, authorized technicians are permitted to inspect, maintain, adjust, and repair this truck.

! WARNING Remove rings, watches, and all jewelry before doing any work on the truck.

! WARNING When removing a battery, ALWAYS use a battery stand or equivalent material handling equipment. See “Removing a Battery” on page 5-21. 3. Before working on the truck: a. Lower the load handling mechanism completely to the floor. b. Put all controls in neutral. c. Release any trapped pressure in hydraulic system. d. Block the wheels to prevent movement of the truck. e. Disconnect battery connector. f. Elevate the drive tire off the floor.

5-2

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Maintenance Practices

5. Avoid fire hazards. Have adequate fire fighting equipment in the maintenance area. 6. DO NOT use open flame or sparking devices around the battery. The gasses given off by the battery are highly explosive. 7. Use extreme caution when using flammable cleaning solutions. 8. After working on the truck, test all controls and functions to assure proper operation. More information pertaining to operating and maintenance procedures can be obtained from: American Society of Mechanical Engineers (ASME) 22 Law Drive, Box 2900 Fairfield, New Jersey 07007-2900 Ask for the current version of ASME B56.1

Jacking the Truck

Any time the truck is jacked up for any reason, the service technician should take extra time and caution to ensure that the truck will not tip over or otherwise pose a hazard to himself or others. Figure 5-1 on page 5-4 illustrates the correct jacking points on the truck frame. Whenever the truck is jacked up: • There should not be any load on the forks. • The forks should be lowered all the way to the lowest possible point. • Disconnect the battery and remove the key. • Always use solid blocks to support the truck. • Never rely on jacks or chains to hold the truck. When the truck is jacked up at the tractor end of the truck, it should not be lifted more than 2 in. (50.8 mm) off the floor. When jacking on the side of the truck, the load wheels should not be lifted off the floor more than 1/2 in. (12.7 mm).

! WARNING Attach a chain to the top of the mast and an overhead hoist to stabilize the mast if jacking higher than described in this procedure.

! WARNING Before jacking the truck, check the A-frame bolt (shown in the lower left-hand corner of Figure 5-1). It should be securely in place. The hole in the truck frame that this bolt passes through should not be excessively worn. If the bolt is missing, or if the hole is excessively worn, the A-frame will not be held in place when the truck is jacked. The A-frame could pivot down and let the springs fall out. PDMM-0058

5-3

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Maintenance Practices

A-Frame

Only jack in this area, no more than 2 in. (50.8 mm) off the floor.

Make sure this bolt is securely in place before jacking the truck.

Figure 5-1:

Welding Procedures

Only jack in this area, no more than 1/2 in. (12.7 mm) off the floor.

Correct Jacking Locations

Before performing any electric resistance welding on the truck, do the following: 1. Turn the key switch off. 2. Remove the battery. 3. Disconnect all cables going to the Interface Card. 4. Disconnect all cables from the EV100LX Control Card.

Electrostatic Discharge Damage

Electronic circuit boards used in the system are sensitive and can be damaged by static discharge.

! CAUTION Before doing any welding on the truck, follow the procedures in “Welding Procedures” on page 5-4. Static discharges are created when non-conductive material (plastic bags opened, synthetic clothing, plastic-soled shoes) are moved or separated. The built-up static will discharge through nearby conductors such as the human skin. The static discharge could appear as a spark.

5-4

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Maintenance Practices

! CAUTION It is very important to note that potentially damaging static levels for electronic components are not always felt by a human or appear as a spark. This condition could happen when a person with a static charge potential touches a circuit board. If the circuit board is not being held properly, sensitive components on the circuit board will be damaged. When sensitive components are handled, protective measures must be taken to prevent damage which would result in the immediate failure or degradation of the component.

Proper Handling of Static Sensitive Devices

A moving lift truck or electric motor can build up a large charge that will discharge slowly after the truck or motor has stopped moving. It is important that proper precautions be taken to assure that electronic components are not damaged. Figure 5-2 shows the proper and improper methods for holding a circuit board.

! CAUTION To avoid creating a destructive static discharge, the technician should be grounded or discharged BEFORE touching a circuit card.

Proper Figure 5-2:

PDMM-0058

Improper Proper/Improper Method of Holding Circuit Card

5-5

Chapter 5: Maintenance

Mitsubishi® Reach Service Manual

Maintenance Practices

Discharging the Truck

Before removing a circuit card, disconnect the battery then discharge the truck. Discharge the truck by touching it with your hand or attaching a device to the frame of the truck which is connected to earth ground. The device should have a resistance of 500,000 to 2,000,000 ohms to eliminate any potential for shock hazard.

Removing the Circuit Card

After discharging the truck, the circuit card can be removed as follows: 1. Place the static control wrist strap around your wrist. It should fit snugly. 2. Connect the ground lead to the Electrostatic Discharge (ESD) receptacle on the truck and the loose end to the wrist strap. 3. Get into the correct position to remove the circuit card. DO NOT move your feet. 4. Remove the circuit card using the correct card handling method shown in Figure 5-2 on page 5-5. 5. When replacing a circuit card or an EPROM on a card, place the circuit card immediately in an anti-static bag. 6. If replacing an EPROM, take the card to a clean area and place the card on a surface which is conductive to antistatic. Use a wrist strap having a nominal resistance of 1,000,000 ohms (minimum 500,000 ohms) connected to common ground with the work surface.

! CAUTION EPROM pins are delicate, and if mishandled, can be easily bent or damaged. Before removing an EPROM, note the position of the beveled corner. The new EPROM must be installed in the same orientation. Incorrectly installed EPROMS could result in damage.

5-6

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Maintenance Practices

! CAUTION When working on sensitive electronics, always wear a static discharge wrist band and assure that it is properly grounded to the truck frame before touching any circuit card. The wrist band and associated accessories should be tested monthly to verify that everything is working properly. A defective static discharge wrist band will not alert you that it is bad. The static discharge components part numbers are: •

Wrist band (1056023); package of 25

•

Field service kit (1056022) includes static dissipating work surface, ground cord, and wrist band

•

Wrist strap tester (1056024)

Follow the instructions included with the field service kit. Wrist Strap

StaticDissipating Work

Ground Cord

Figure 5-3:

PDMM-0058

Anti-Static Kit (P/N 1056022) with Wrist Strap and Mat

5-7

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Maintenance Practices

Removing an Integrated Circuit (IC)

To remove the Integrated Circuit (IC), you’ll need special tools: • PROM Removal Tool - P/N NA010030 (see Figure 5-4) • Pin Extraction Tool - P/N NA010128

Figure 5-4:

PROM Removal Tool, P/N NA010030

To remove the integrated circuit: 1. Use a PROM Removal Tool as shown in Figure 5-4. 2. In Figure 5-5 on page 5-8, look at the socket for the IC in the board. Note that two holes in opposite corners of the socket. These holes are for the prongs of the removal tool. 3. Spread the jaws of the removal tool apart so that its prongs will fit into the two socket holes mentioned in the previous step. See CAUTION.

! CAUTION Failure to use the integrated circuit tool can damage or destroy the socket. 4. Gently squeeze the jaws of the tool together. The tool will grasp and then withdraw the IC from its socket.

Holes for removal tool prongs are located in the opposite corners of the socket.

Figure 5-5:

5-8

Removing an Integrated Circuit

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Maintenance Practices

Installing a New Integrated Circuit

To install a new IC into the socket: 1. Notice that one corner of this type of IC is beveled. Also notice that the corresponding corner of the socket is also beveled. 2. Align these two beveled corners and gently press the IC into the socket.

! CAUTION If forced, the EPROM can be installed incorrectly (so the beveled corners do not match). This will damage the EPROM and socket board.

Removing a Pin

To remove a pin from an over-the-mast cable Molex connector, you need a pin extraction tool, P/N NA010128. To remove a pin: 1. Insert the tool into the connector; this depresses small retaining ears on each side of the pin. 2. Notice the shape of the individual sockets. Each pin must be oriented correctly to mate with the connector. Connector Socket Retaining Ears

Figure 5-6:

End View (Enlarged) of a Typical Molex Connector Align extraction tool and push all the way in. This depresses the locking ears on the pin allowing it to be removed.

Top view of Molex Connector

Locking ears on pin. Extraction Tool

Side view of Molex Connector Figure 5-7:

PDMM-0058

Pin Extraction Tool Inserted into Molex Connector

5-9

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Maintenance Practices

Troubleshooting with the Cable Connector Breakout Board

Insert the cable connector breakout boards between the interface card and the corresponding cables to provide convenient troubleshooting test points.

Figure 5-8:

Fuses

Cable Connector Breakout Board

The following table lists the fuses used in the truck: Table 5-1: Fuses

Fuse

Protects

Amps

FU1

Power for Lift Motor

450

FU2

Power for Travel Motor

350

FU3

Power for Auxiliary Motor

150

FU4

B+ Fused

FU5

B- Fused

Figure 1-7, “Platform Components (Electrical),” on page 1-18 for location of all fuses.

5-10

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Maintenance Practices

Shunt Locations

Use Figure 5-9 to properly position jumper (E2) on the Interface Card Assembly for 24- and 36-volt trucks.

Shunt in 24-volt

Shunt in 36-volt

Figure 5-9:

PDMM-0058

Interface Card Assembly

5-11

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Planned Maintenance

Planned Maintenance A planned maintenance schedule ensures: • Maximized truck performance • Maximized truck life • Reduction of costly downtime • Avoidance of expensive repairs Planned maintenance includes: • Cleaning • Inspection • Lubrication • Creating a list of repairs required

Service Manual

Use this manual as required to perform the repair procedures listed in the “Inspection Schedule,” on page 5-16.

Planned Maintenance Schedule

Perform inspections and lubrication in accordance with the “Inspection Schedule,” on page 5-16. List any repairs required. See the “Lubrication Equivalency Chart” on page A-2. Please note the following: • Daily (8 hour) inspections should be performed by an authorized Owner-Employee. • All listed repairs should be scheduled for a convenient time between an authorized Customer Representative and the Qualified Service Technician. • All repairs should be carried out AFTER the planned maintenance tasks are completed. • Labor and parts for repairs should be calculated as part of the standard truck maintenance costs, separate from the planned maintenance charges.

Time Requirements

5-12

Doing the Planned Maintenance requires approximately 1.25 hours.

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Planned Maintenance

Planned Maintenance Checks

The following tables lists the planned maintenance checks for the truck.

Table 5-2: Planned Maintenance Checks

Item

What to Check

General Truck Operation

• Operate all functions of the truck and check for any abnormal operation. • Talk to the driver to see if he or she has noticed any problems. • Check to see if all the safety and operational decals are in place and legible (see “Decal Locations” on page A-19).

Gearbox Oil Level

• Check the dipstick level. • Check for leaks at the seals and the condition of the oil to see if it requires changing. • Check the drive unit gears for wear. Anything found here that can be fixed can save money on further repairs. • List any repairs required.

Reservoir Oil Level

• Check the oil level in the reservoir for the proper amount. If the reservoir is too low, the hydraulic pumps can be ruined by oil starvation. • Check the condition of the oil. • Check the time interval between the hydraulic filter replacements; does it need to be changed? • List any repairs required.

Truck Lubrication Points

See Figure 5-10. • Grease and lubricate all identified lubrication points. • Replace any broken grease fittings. • Look for any excessive wear in these areas. • List any repairs required.

Electrical Connections

• Check for loose connections. • Check for wires that are rubbing or ready to break off. • List any repairs required.

PDMM-0058

5-13

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Planned Maintenance

Table 5-2: Planned Maintenance Checks (Cont’d)

Item Electrical Grounds

What to Check • Using a voltmeter, check for any voltage leaks: •

Positive battery terminal to truck frame

•

Negative battery terminal to truck frame

• An open circuit should be indicated in both cases. If any voltage is read, clean the battery and check for leaks, cracks, and so on. • Using a voltmeter, check for any voltage leaks: •

PC-1 (+) to truck frame

•

TP4 (-) to truck frame

• An open circuit should be indicated in both cases. If any voltage is read, shorts or grounds exist in the truck wiring and must be located and eliminated. • Clean motors and other electrical components thoroughly. • List any repairs required. Wiring Harness Check Switches and Contactors

Check to make sure the harnesses are not oil soaked and that they are in good condition. • Make sure that the contactor tips are not burned or pitted. • Make sure that all switches are operating and providing their designated function. • List any repairs required.

Motor Brush Wear

• Check every brush in every motor for the proper length (see “Brush Replacement” on page A-28). • Check the spring tension on the brushes. • Check the commutator in the armature for wear. • List any repairs required.

Hydraulic Cylinder

• Check the lift cylinder for leaks, air in the hydraulic system, or damage to the chrome plating on the cylinder piston. • List any repairs required.

Hydraulic Lines

• Check to see if there are leaks or any improper wear of hoses. • Check that the hoses and lines are not crimped, or in danger of being damaged. • List any repairs required.

Brake and Linkage

• Check the brake for proper wear and adjustment. • Check the linkage to make sure it is not rubbing and that it is free and not sticking anywhere. • Lubricate as required. • List any repairs required.

5-14

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Planned Maintenance

Table 5-2: Planned Maintenance Checks (Cont’d)

Item Wheels

What to Check • Check to make sure there is enough material left on the wheels. • Check to make sure the bearings are still good and shimmed properly. • Check for all foreign matter in or between the wheels and housings. • List any repairs required.

Accessories

• Check these items for their proper functions. • List any repairs required.

Battery

• Check that the battery disconnect functions. • Check the battery leads for excessive wear and corrosion. • Check for corrosion on the battery case. • Check the crimp and soldered connections. • List any repairs required.

Chain Condition

• Check for excessive wear or stiff spots in the chain. • Check for proper adjustments and alignment. • List any repairs required.

Steering Assembly

• Check for proper operation. • Check for oil leaks. • List any repairs required.

PDMM-0058

5-15

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Planned Maintenance

Inspection Schedule

Use the following schedule for inspecting the truck:

Table 5-3: Inspection Schedule

Refer to Figure 5-10 for Item Number Locations

Item 1

1 Day

30 Days

180 Days

360 Days

8 Hrs

200 Hrs

1200 Hrs

2400 Hrs

Check the battery weight against the minimum and maximum allowable weights on the specification plate for the truck.

Cleanliness

Component Battery

Time Interval (Hours on Deadman Switch)

Check:

Battery Connector

No damage, solid electrical connections, battery disconnect works properly.

Battery Gates, Rollers

Gates properly installed, locked securely, horizontal motion of battery limited to 1/2" (13 mm). Check roller condition, lubrication.

Brake

Pedal moves freely without binding Lift truck stops in specified distance (8 to 10 ft. or 2.5 to 3.0 m) Deadman brake functions properly (travel circuits disabled)

Contactor Tips

Cable, Hoses, Hoses and cables in good condition. Tension Spring tension adjusted properly? Springs

No pitting, burning. Sufficient contact material remaining. X

Chassis and Mast

Grease as required. Guards and covers installed.

Deadman Switch Pedal

Smooth action, no binding, releases when foot is lifted off pedal.

Deadman Switch

Disables travel and lift functions and stops truck when pedal is released.

Drive Unit

• Check fluid level.

• Change fluid.

5-16

Forks

• Grease the ring gear.

• Grease the pivot bearing.

For damage, no modifications

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Planned Maintenance

Table 5-3: Inspection Schedule (Cont’d)

Refer to Figure 5-10 for Item Number Locations 12

Time Interval (Hours on Deadman Switch)

Function Controls

Travel and lift and lower should control their respective function. Steers smoothly from stop to stop.

Horn

Sounds when activated.

Hydraulic

Report any leaks, check all connections and hoses for leaks

Hydraulic Reservoir

• Check fluid level.

Lift Chains

• Change filter.

• Change fluid.

• Inspect for condition.

• Check adjustment and lubrication.

Lights

All lights should function.

Motor Brushes

Condition of brushes, springs, and holders. Does length exceed minimum length?

Switches

Control assigned function.

Wheels and Tires

No cracks, wearable surface in good condition. No flat spots and no bond failure.

Static Straps • Check all straps for wear. (beneath • Keep straps clean. truck) • Replace as necessary.

Overhead Guard

Inspect for cracks or damage.

Windscreen

Inspect for damage.

All Hardware Check for tightness or damage.

Decals, Warning Labels

In place and legible.

Fire • Check charge. Extinguisher • Replace if charge is low. (optional)

PDMM-0058

5-17

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Planned Maintenance

12,13

27 13 18 4,14

8,9

22 17 (optional)

23 6 16 2 12

1 3 11 20 20

21 Figure 5-10:

5-18

Lubrication/Inspection Points PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Planned Maintenance

Grease Fitting Locations

The following table lists the grease fitting locations for the Mitsubishi ESR and EDR Reach trucks:

Table 5-4: Grease Fitting Locations for Mitsubishi ESR and EDR Reach Trucks

Grease Fitting Location Drive Unit Area

Number of Fittings 3

Located in the drive unit area.

• One fitting that is accessible through a hole near the deadman pedal. • One fitting that is 180 degrees from the previous (up and over the drive motor appears to be the easiest way to access).

Radial Ring

Steer Shaft Self-aligning Bearing Caster Wheel Area A-frame Assembly

Steering Linkage (for vehicles with elevated height above 270 in.)

PDMM-0058

One fitting near the base of the steering shaft.

• One fitting on wheel hub • One fitting on the pivot area

Two fittings located on each side of the pivot area, accessible through the operator compartment floor.

• Six fittings located at pivot points of scissor assembly connections. • Two fittings located at side of main scissor bearing.

Located at the end of each axle.

Reach Carriage Area

Load Wheels

Location

• Four fittings located off of the steering linkage. • One fitting located at center pivot.

5-19

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Battery Maintenance

Battery Maintenance This section contains essential battery maintenance information. The battery is the energy source for the truck. Its condition should be of primary importance to the user to achieve maximum satisfactory service. Lack of proper battery maintenance will lead to short battery life and other component problems (for example, motors, contactors, and so on). The lead-acid batteries furnish all power requirements of the truck. Most industrial batteries can be expected to function properly for more than five years. Proper maintenance should extend battery life and increase truck efficiency.

! WARNING Wear eye protection.

How Batteries Get Damaged

Batteries in industrial trucks pick up various kinds of dirt and dust depending on their surroundings and the types of material handled. If cells are overfilled and electrolyte collects on the covers, the following process occurs: 1. The top of the battery becomes wet and stays wet, because the acid in the electrolyte does not evaporate. 2. This moist surface, in combination with certain kinds of dirt, becomes electrically conductive and permits stray currents to flow externally over the top of the battery. This affects battery performance and truck operation. 3. The acid also causes corrosion of cell posts, nuts, connectors, and the steel battery case.

5-20

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Battery Maintenance

! WARNING

Removing a Battery

When removing a battery, ALWAYS use a battery stand or equivalent material handling equipment. 1. Remove one battery gate, usually the one on the side of the battery connector. 2. Ensure that the opposite battery gate is locked in place. 3. Disconnect the battery connectors/cables from the battery. 4. Using a battery stand or equivalent material handling equipment, slide the battery out of the open end of the battery compartment. 5. Make sure the removed battery is properly stored.

! WARNING

Installing a Battery

Take precautions not to jam or cut the battery cables during installation of the battery as this could result in a short, which could cause a fire or a battery explosion.

! WARNING When installing a battery, always be sure that it is fully charged before placing the truck into operation. Ensure that both gates are properly installed on the truck. 1. Remove one battery gate, usually the one on the side of the battery connector. 2. Ensure that the opposite battery gate is locked in place. 3. Slide the battery into the compartment from a battery stand or equivalent material handling equipment, making sure the battery cable ends up in the correct position for connection to the truck connector. 4. Once the battery is in place, install battery gate. Ensure that both battery gates are securely locked into position. 5. Adjust both battery gates to prevent battery side-to-side movement during truck operation.

PDMM-0058

5-21

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Battery Maintenance

Cleaning the Battery

To clean the battery, do the following in an approved battery wash area: 1. Make a soda solution by mixing 1 lb. (0.45 Kg) baking soda and 1/2 gal. (1.89 l) of hot water. 2. Tighten the battery vent caps. 3. Use a brush with flexible bristles and apply the soda solution over the top of the battery. Leave the solution there until all “fizzing” stops, which indicates that the acid has been neutralized. 4. Rinse thoroughly with clean water. 5. Blow the battery case dry using compressed air (30 psi [206 kPa] max). NOTE: Wet covers can be an indication of overfilling, leaky seals at posts, or excessive gassing during charge. When observed, the cause should be determined and the adverse conditions corrected.

Testing the Battery Electrical Leakage To Frame

To test the battery electrical leakage: 1. Disconnect the battery from the truck. 2. Use a voltmeter set on the 50-volt scale. 3. Attach the meter leads: negative to truck frame, positive to battery positive. The voltmeter should show no voltage or at most a 2- to 3-volt reading. If there is more than a 2- to 3-volt reading, clean the battery and battery rollers. Have the battery checked for internal voltage leakage. 4. Attach the meter leads: negative to battery negative, positive to truck frame. The voltmeter should show no voltage or at most a 2to 3-volt reading. If there is more than a 2- to 3-volt reading, clean the battery and battery rollers. Have the battery checked for internal voltage leakage.

5-22

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Battery Maintenance

Battery Discharge Indicator (BDI)

The Battery Discharge Indicator (BDI) monitors and remembers the charge level of the battery connected to the truck and prevents excessive discharging of that battery. Operating a truck using a discharged battery can damage both the battery and the electrical components that make up the truck’s electrical system. This feature is adjustable, but should not be set so that it will allow over discharging of the battery. The BDI display is a 3-digit display. During the normal run mode, the EV100LX display indicates the battery state-of-charge. It has a range of 0 to 100% of charge state. When properly adjusted, the display reads as follows: Table 5-5: Battery Charge States

When the display reads... 100

It means... The battery is fully charged. The battery is low.

20 The display blinks as an early operator alert. The battery has no charge.

The battery has reached an 80% discharge rate. This is the recommended maximum amount of discharge before recharging. The control disables the pump contactor.

Internal Resistance Compensation

All batteries have a small amount of internal resistance and this value varies significantly. Likewise the internal resistance of individual trucks will vary depending on the size of the power cables, the length of the power cables, the routing of the cables, and so on. The Internal Resistance Compensation feature allows the control to be adjusted to compensate for these varying resistances. This makes the BDI feature much more accurate.

PDMM-0058

5-23

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Battery Maintenance

Adjusting the Internal Compensation

To adjust the internal compensation, do the following: 1. With the battery state-of-charge anywhere between 80 and 20, drive the truck for at least 2 minutes at top speed. This will give an accurate battery state-of-charge reading on the display. 2. Record this reading and reference it as the Display reading. 3. Let the truck sit for 5 minutes 4. Get the battery voltage by connecting a voltmeter to the points where the positive and negative battery cables attach to the control panel. 5. Divide this number (battery voltage) by the number of battery cells (18 for a 36-volt battery or 24 for a 48-volt battery): Battery Voltage / No. of Battery Cells = Open Circuit Volts per Cell (18 or 24) This gives the "Open Circuit Volts Per Cell" reading. Using the graph in Figure 5-11, find the intersection point for the display reading and the Open Circuit Volts Per Cell. This corresponds to the compensation achieved by the current IR Comp Function 14 setting (see Table 6-4 on page 6-26). The ideal setting should fall somewhere on the bold line going diagonally across the graph, and it is interpreted as follows:

Table 5-6: Interpreting the Calibration Chart Reading

If the intersection point is...

Then...

Readjust the function to a...

Above the bold line

The compensation is too low and the setting is too high.

Lower setting. Adjust the setting one or two points lower depending on how far above the line your point of intersection was on the graph.

Below the bold line

The compensation is too high and the setting is too low.

Higher setting. Adjust the setting one or two points higher depending on how far below the line your point of intersection was on the graph.

Repeat this procedure and continue readjusting the IR Comp Function 14 until the intersection point is as close to the ideal line as possible. It might be necessary to do this procedure two or three times to get the correct setting.

5-24

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Battery Maintenance

EV100 Internal Resistance Compensation Setting. Function #14 2.14 2.13 2.12 2.11

Compensation Too Low (IR Comp Function setting too high; decrease setting)

2.1 2.09 2.08 2.07

Open Circuit Volts Per Cell (Measure open circuit voltage at SCR "POS" and "NEG" terminals and divide by the number of battery cells)

2.06 2.05 2.04 2.03 2.02 2.01

Compensation Too High (IR Comp Function setting too low; increase setting)

2 1.99 1.98 1.97 1.96 1.95 1.94 100

Display Reading (After at least 2 min running)

Figure 5-11: PDMM-0058

Display at .009, 1.160 S.G. +\.005

Battery Discharge Indicator Calibration Chart

5-25

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Battery Maintenance

Charging the Battery

Consult your battery manual for specific charging procedures. When a battery is charged, direct current is passed through the battery cells in the direction opposite of discharge. Before charging a battery, become familiar with the following: • Charging rate, starting rate, and finish rate. • Time available for charge. • Variations in cell voltage. • Avoiding overheating, excessive gassing, or overcharging.

Precautions

Note the following precautions when charging the battery.

! WARNING When charging batteries, observe the following precautions: • Do not smoke, use open flame, or spark-producing devices near the batteries. • Charge in a well-ventilated area to avoid hydrogen gas concentration. • Keep batteries clean; corrosion causes grounds and possibly sparks. • Charge batteries at the rates shown on the battery. • Keep plugs, terminals, cables, and receptacles in good condition to avoid shorts and sparks. • Never lay tools on top of the batteries. • Wear protective clothing and eye protection when handling, checking, or filling batteries. NOTE: Get the maximum use out of each battery by recharging the batteries only when they are effectively discharged. DO NOT routinely recharge batteries when they are only partially discharged; this will decrease battery life. At maximum recommended discharge, the specific gravity should read 1.150 or less.

5-26

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Battery Maintenance

Using the Hydrometer

The hydrometer measures the specific gravity of the electrolyte. The specific gravity varies directly with the state-of-charge of a lead-acid battery as follows: Table 5-7: Specific Gravity

Charge

Specific Gravity

100%

1.280-1.300

75%

1.250-1.260

50%

1.200-1.210

25%

1.150-1.160

1.080

Note: Most industrial deep-cell discharge batteries are considered discharged when 20% of the charge remains (specific gravity of 1.140).

Checking the Specific Gravity

Note that no amount of charging will increase battery capacity or raise the specific gravity above its fully charged level (1.280 to 1.300). To check the specific gravity of the battery, do the following: 1. Insert the nozzle of the hydrometer into the battery cell, and draw enough electrolyte into the tube to permit the float to ride free. 2. Determine the specific gravity of the cell. See Table 5-7. 3. If there is insufficient electrolyte to obtain a hydrometer reading: •

Add just enough water to cover the battery plates. The electrolyte level will rise during charge. Adding too much water before charging the battery will cause electrolyte to spill from the top of the cell.

•

Now charge the battery and take additional readings.

4. The specific gravity reading for each cell should be taken and recorded on a battery chart. These charts can be obtained from the battery manufacturer. 5. Add water to the cell after completing the charging process. Consult your battery manual for further information.

PDMM-0058

5-27

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Battery Maintenance

Voltage Check

Take a voltage check on each cell after performing the hydrometer check (page 5-27). Connect the leads of a Simpson Volt/Ohmmeter (VOM) or equivalent to the positive and negative terminals of each cell. VOM readings will vary with the state-of-charge. Table 5-8: VOM Readings

Charge

Voltage Reading

100%

2.14

75%

2.07

50%

1.95

25%

1.80

1. Touch the voltmeter leads to the positive and negative terminals of each cell. There should be a reading of at least two volts for each fully charged cell and a variance of no more than 0.2 volts between cells. 2. Record the voltage reading for each cell on the battery maintenance chart.

Adding Water to the Battery

Water must be added to battery cells periodically. The frequency and quantity depend on the water level above the plates and the amount of gassing during charge. Note the following: • Use only approved or distilled water. • Add water after hydrometer and voltmeter readings are taken. • Add water after charging to minimize overfilling. • Always cover the plates entirely. • Keep the outside of the battery clean and dry.

5-28

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Battery Maintenance

Keeping a Battery History Record

A battery record system is essential because battery failure can cause production slowdowns and increased battery operating costs. A properly supervised record system can detect and call attention to such operating irregularities as: • Overcharging • Undercharging • Over discharging • Excessive water consumption • Excessive dirt and corrosion • Worn out batteries • Excessive current consumption of trucks Records should be kept for each battery. Your battery supplier should be able to provide maintenance record sheets. Each report should contain: • Battery number, type, serial number, and service data • Specific gravity and voltage readings for each cell • Temperature of the air and electrolyte • Electrolyte • Amperes • Condition of connectors, covers, sealing compound and tray • General cleanliness • Number of total cycles • Average specific gravity drop • Watering frequency • User comments and observations

PDMM-0058

5-29

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Maintaining the Motor

Maintaining the Motor All motors are designed to operate with a minimum of maintenance. Sealed bearings are used in all motors, thereby eliminating lubrication. Regular maintenance, along with periodic inspection, help to provide trouble-free motor performance. The following maintenance procedures are described: • Motor Cleaning • Brush Care • Replacing a Brush • Preventing the Motor from Overheating • Motor Stud Terminals • Testing for Open Circuits • Testing for Shorted Circuits • Checking for Armature Shorts • Testing for Grounded Motors

Motor Cleaning

Periodic motor cleaning is essential to prevent overheating and electrical grounds. See Figure 5-12. To clean the motor: 1. Wear safety glasses. 2. Use clean, dry, low pressure air (30 psi, (207 kPa)], to blow carbon dust and other foreign materials from: •

Motor housing

•

Brush holders

•

Commutator

•

Field and armature windings (if accessible)

! CAUTION Never use a chemical solvent to clean the motor because it will carry carbon dust to hard-to-clean areas and cause shorts within the motor. Washing with detergents requires complete disassembly and drying. This should only be attempted by an authorized motor repair shop.

5-30

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Maintaining the Motor

Direct airstream from nozzle into brush opening.

Motor

Figure 5-12:

Brush Care

Example of Cleaning Motor

Brushes should be inspected for: • Proper wear • Signs of overheating • Physical damage to brush holders • Proper spring pressure/alignment • Freedom of movement within brush holders

PDMM-0058

5-31

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Maintaining the Motor

Cleaning the Brushes

To clean the brushes: 1. Position the motors to provide easiest access to brushes. 2. Inspect the brushes in all motors for: Table 5-9: What to Look for When Inspecting the Brushes

Condition

Look for...

Proper Wear

The brush surface should be polished and show even wear.

Overheating

Overheating will be indicated if the brush shunts or brush springs are discolored.

Physical Damage

Inspect the brush holders for damage. Make sure the holders are not loose on the end head or brush holder plate.

Spring Pressure/ Alignment

Check spring pressure: • Insufficient spring pressure will cause excessive arcing and reduced motor performance. Excessive spring pressure will result in premature wear of the commutator. • A brush spring that does not apply even pressure on the center of the brush will cause the brush to wear unevenly.

Freedom of Movement Check for correct clearance and freedom of brush movement within the holder. Be sure connections are clean and tight and that brush wires do not ground the motor frame or armature.

5-32

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Maintaining the Motor

Measuring the Brush Spring Tension

Measure the brush spring tension as explained in Figure 5-13:

1. Place a paper strip between the brush face and commutator. 2. Hook the leather loop under the brush spring and attach it to the spring scale. Note: If the brush spring has a loop at the brush, hook the spring scale directly into the spring.

Spring Scale

Coil Spring

3. Pull the spring scale on a line directly opposite the line of force exerted by the spring while Leather applying a light pull on the paper Loop strip. When the paper strip begins to move freely, the spring scale will be indicating the brush spring tension. Paper

Rotation

Figure 5-13:

Replacing a Brush

4. A spring tension of 30-36 oz. (852-1022 g) for new brushes and springs is acceptable.

Measuring Brush Spring Tension

If any brushes must be replaced, the complete brush set should be replaced. Do not replace just one or two brushes. See “Pin-By-Pin Voltages - EV100LX Travel Control System” on page A-21 for the table listing the minimum brush lengths. When ordering replacements, refer to the motor serial number on the motor nameplate. Do not substitute brushes. The brushes are matched to the motor type and application to provide the best service. Substituting brushes of the wrong grade can cause commutator damage or excessive brush wear. Where accessible, new brushes should be seated to the commutator curvature. To do this, wrap a piece of #00 sandpaper around the commutator, seating the brush holder, and turning the armature. On smaller motors where space is limited, a brush seating stone can be used. DO NOT use emery cloth to seat brushes. After the brushes are seated, the dust should be blown out of the motor with dry compressed air (30 PSI [207 kPa]).

PDMM-0058

5-33

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Maintaining the Motor

Preventing the Motor from Overheating

Most motor overheating can be prevented by understanding the causes and preventions listed below:

! WARNING If an electrical failure or an extreme overload occurs, especially in a totally enclosed motor, personnel should not breathe the fumes which have been generated inside the machine. The heat of the failure arc or overload can generate noxious fumes by pyrolysis of the insulation materials. All power should be disconnected from the motor before any investigation of the failure is attempted. The area around the motor should be well ventilated. Personnel should not breathe the toxic fumes produced by the failure. If possible, allow time for the motor to cool and for the fumes to dilute with air.

Checking the Torque on the Motor Stud Terminals

To prevent premature motor failure, the nuts that secure the power leads to the motors should be checked for proper torque. The torque should be checked each time the motor brushes are inspected. The torque valves shown in Figure 5-14 are the same for all terminal sizes. Figure 5-14 shows the drive motor armature terminal.

Terminal Stud Stud Terminal Securing Nut Torque: 140 - 160 in lbs. (15.8 - 18.1 N•m) Motor Cable Securing Nut Torque: 100 - 120 in lbs. (11.2 - 13.6 N•m)

Cable Lug Terminal Flat Washer 1 or 2 Thread Gap

Fiber Washer Motor Housing

Figure 5-14:

5-34

Drive Motor Armature Terminal - Proper Torque

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Maintaining the Motor

Figure 5-15 shows the terminals for all other motors. Stud Terminal Securing Nut Torque: 140 - 160 in lbs. (15.8 - 18.1 N•m)

Motor Cable Securing Nut Torque: 100 - 120 in lbs. (11.2 - 13.6 N•m)

Flat Washer Motor Housing Fiber Washer

Figure 5-15:

Open Circuits

Motor Terminal Torque Specification for All Other Motors

An open circuit is one in which the electrical circuit within the motor has been broken. This can be caused by: • Bad brushes or brush springs • A broken wire in the field winding • A loose or bad connection

Testing for Open Circuits

To test for open circuits, use Figure 5-16, and do the following: 1. Disconnect the motor from the truck circuit. 2. Use a milliohmmeter (preferably) or analog ohmmeter (Simpson 250, and so on), to measure continuity in the armature and field circuits at room temperature. 3. Using a megohmmeter or analog ohmmeter, there should be NO continuity between the armature and the field terminals of the drive motor. The meter should register more than 100,000 ohms. 4. If the meter indicates an open circuit in the armature, check the condition of the brushes before rejecting the motor. NOTE: The lift and auxiliary motors have only two external connections because the armature and field windings are connected internally. The continuity check can be made between the two external terminals. If an open circuit is found, the motor must be returned to a motor rebuild facility to have the field and armature circuits checked for continuity.

PDMM-0058

5-35

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Maintaining the Motor

1(+) Drive Motor

Auxiliary Motor MD S2 1(+)

Lift Motor

A2 MD

MP 2(-)

Figure 5-16:

Short Circuits

MD S1

2(-)

Motor Terminals and Circuits

A short circuited motor is one in which the insulation on the field or armature windings has broken down at two or more points. The breakdown creates a low resistance current path, allowing current to flow from one turn of the coil to another adjacent coil turn, without actually flowing through the coil wire. The result is a decrease in total resistance of the motor winding and an increase in the current flow. Location of the short determines its severity. A shorted motor might be indicated by: • Slow or sluggish operation • Running faster than normal • Overheating • Blowing a power fuse

Testing for Short Circuits

Excessive motor current can be caused by abnormally high rolling resistance. Such resistance might be caused by brake dragging, defective wheel bearings, or transmission problems. The devices driven by the motor should be inspected before replacing the motor. To test for short circuits, do the following: 1. Refer to the inspection report showing the motor current when the motor was new. 2. Duplicate the same truck conditions (loaded and unloaded) and measure the present current. 3. If the present current reading is 25% more than the original current value, check the entire truck for possible causes, such as:

5-36

•

Bad wheel bearings

•

Dragging brake

•

A short circuit within the motor PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Maintaining the Motor

Armature Shorts

A short in the armature will cause heating, probably resulting in burning of the: • Armature coil • Banding wires • Commutator segments

Checking for Armature Shorts

Visual inspection should show this condition. Another method of checking for armature shorts is to: 1. Remove all the brushes. 2. Touch one lead from an ohmmeter to a bar on the commutator. 3. Work your way around the commutator, touching each bar, checking the resistance. 4. There should be only one commutator bar that shorts to the bar that has the ohmmeter attached to it. 5. The remainder of the commutator bars should have high resistance.

Grounded Motors

In a grounded motor, an electrical circuit exists between the currentcarrying conductors and the motor housing. This can be caused either by direct contact or through conductive foreign material. The ground might be caused by: • Insulation breakdown • Brush leads touching the motor housing • Build-up of carbon dust or other materials

Testing for a Grounded Motor

To test for a grounded motor, do the following: 1. Isolate the motor from the truck circuit. 2. Attach one lead of a megohmmeter (preferably), or an ohmmeter set to the highest resistance scale, to a motor terminal, and the other lead to the motor housing. Be sure paint does not interfere with connections. 3. If the megohmmeter indicates a resistance of less than 100,000 ohms, the motor is grounded. Clean, repair, or replace the motor as necessary.

PDMM-0058

5-37

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Maintaining the Motor

Truck Grounds— General

Another common cause of truck electrical problems is other grounding. Grounds can be caused by: • Accumulation of dirt • Breakdown of insulation • Bare Wires Grounds can occur at numerous locations including: • Batteries • Motors • Contactors • Terminal strips • Switches • Power panel insulators • Improper mounting of circuit cards

Testing for Grounds on the Truck Frame

To test for grounds on the frame of the truck, do the following: 1. Disconnect battery connector. 2. Measure the resistance to frame at B+, B-, and all fuses. A resistance reading of less than 1000 ohms indicates a serious short to frame. If this condition exists, the source of low resistance or short-to-frame must be located using the resistance method. DO NOT continue until this condition is corrected. 3. Remove the battery from the truck. 4. Connect the battery lead to the truck. 5. Use a volt/ohm/amp meter to measure the leakage current to frame at B+, B- at all fuses, and all motors. If the current is less than 0.001 amp (1 mA), the truck system passes. If the currents exceeds 1 mA, go to step 6. 6. To find the cause of the low resistance, you must disconnect the power cables from each motor or major sub-assembly to determine if that item is causing the low resistance.

5-38

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Hydraulic System Maintenance

Hydraulic System Maintenance This section explains how to maintain the hydraulic system.

Selecting the Oil

Before adding or changing hydraulic fluid, determine the environment and usage of the truck. See the “Lubrication Equivalency Chart,” on page A-2 to make the proper oil and lubricant selection.

Changing the Reservoir Fluid

To change the reservoir fluid, do the following: 1. Lower the forks all the way to the floor. Ensure that all hydraulic pressure is relieved. 2. Turn the key to OFF. Disconnect the battery. 3. Open the rear left hydraulic compartment door. 4. Place a 5-gallon (20 liter) container near the auxiliary inlet line. 5. Cover the drive motor. 6. Loosen the clamp securing the auxiliary inlet line. 7. Carefully remove the auxiliary inlet and allow the reservoir to drain into the 5-gallon container. 8. After all the oil is drained, attach and clamp the hose on the auxiliary inlet. 9. Change the filter (see “Changing the Reservoir Filter” on page 540). 10. Refill the reservoir with the proper grade of oil. See the “Lubrication Equivalency Chart,” on page A-2 and “Checking the Reservoir Fluid Level”. 11. Bleed the hydraulic system.

PDMM-0058

5-39

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Hydraulic System Maintenance

Checking the Reservoir Fluid Level

To check the reservoir fluid level, do the following: 1. With the oil at room temperature and the carriage lowered completely, fill the reservoir until the oil level is approximately 1 in. (25.4 mm) above the bottom of the strainer. 2. Elevate the carriage all the way to the stops. 3. If the lift pump cavitates (runs out of oil), add just enough oil to be able to lift to the maximum elevated height. Adding too much oil could result in the reservoir overflowing as the oil gets hot and expands. See CAUTION.

! CAUTION If the pump runs out of oil, do not continue to try to lift the carriage. The pump will be ruined if it is operated without oil.

Changing the Reservoir Filter

To change the reservoir filter, do the following: 1. Lower the forks all the way to the floor. Ensure that all the hydraulic pressure is relieved. 2. Turn the key to OFF. Disconnect the battery. 3. Remove the top console cover. 4. Place a suitable device under the oil filter to catch any oil that drains when the filter is removed. 5. Remove the filter. 6. Clean the sealing surface. 7. Apply a thin film of clean hydraulic oil on the gasket of the new filter. 8. Install the filter. Turn the filter 3/4 of a turn after the gasket makes contact with the seat. Use hand pressure only. 9. Start the system and check for leaks. 10. Check the reservoir level as described in “Checking the Reservoir Fluid Level”.

5-40

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Hydraulic System Maintenance

Bleeding the Hydraulic System

Bleed the hydraulic system if the system is opened for service or repair or if the load bounces. To bleed the hydraulic system: 1. Elevate the forks 2 to 3 in. (50.8 to 76.2 mm) off the floor. 2. Turn the key to OFF. Disconnect the battery. 3. Loosen (DO NOT remove) the bleed screw at the top of the back cylinder. 4. When oil starts flowing from the screw hole, tighten the screw. 5. Repeat steps 3 and 4 for the front cylinder. 6. Repeat steps 3 and 4 for the side cylinders (for trucks with free lift only). 7. Check the reservoir level as described in “Checking the Reservoir Fluid Level”.

PDMM-0058

5-41

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Mechanical Maintenance This section explains how to maintain the mechanical parts of the truck.

Power Section

The following procedures are recommended for repairing or replacing mechanical drive systems for both the 24- and 36-volt versions of the truck.

Drive Unit Service

Maintenance or replacement of components used in the drive transmission are limited to the following: • Steering gear • Pivot bearing and related components • Drive axle • Axle oil seal • Cover • Miscellaneous hardware NOTE: The Mitsubishi publication, Parts List, WEBN2754-01, lists specific part numbers for serviceable items. If the drive unit needs major rework or service, send the drive unit back to the factory.

5-42

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Removing the Drive Unit

To make it easier to remove the drive unit, build the tool shown in Figure 5-17.

35o Typ

0342-.351 Dia. 4 holes spaced as shown on a 10.50 in. bolt circle 5/16-18 UNC-2B equally spaced on a 10.50 in. bolt circle (used to separate tool from drive unit)

"Eye" welded onto plate

Figure 5-17:

Drive Unit Replacement Tool

Then do the following: 1. Drain the oil from the drive unit. 2. Loosen the drive tire lug nuts. 3. Remove the horn assembly. 4. Disconnect the power and sensor leads from the drive motor. 5. Disconnect and plug the brake hydraulic line. 6. Disconnect and plug the hydraulic lines to the hydraulic steer motor. 7. Remove the drive motor and brake assembly. If the tool has been built as described in Figure 5-17, attach it to the top of the drive unit using the screws that held the drive motor. 8. Remove the steer motor and the torque shaft. 9. Remove the dust shield between the ring gear and the tractor frame. 10. Jack the rear of the tractor off the floor approximately 6 in. (152.4 mm). See WARNING.

PDMM-0058

5-43

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

11. Remove the drive tire. 12. Disconnect the steer linkage from the drive unit; swing the linkage clear (if the truck has a steered idler). 13. Place a temporary support under the drive unit, or attach a hoist to the tool installed in Step 8. 14. Loosen, then remove the four mounting screws holding the drive unit to the tractor frame. The steering stop will also become unattached at this stage. 15. Lower the drive unit to the floor. Tip the drive unit over on its side and remove it.

Installing the Drive Unit

To install the drive unit, reverse the removal instructions noting the following: 1. Torque the drive unit to the tractor frame screws to 150 ft. lbs. (210 N•m). 2. Apply Loctite 242 to the bolt threads for the steer linkage. Torque to 150 ft. lbs. (210 N•m). 3. Use Loctite 242 when mounting the steer motor. 4. Clean the mounting surface of the drive motor. Coat the mating surfaces using 1008820. Torque the mounting screws to 13 ft. lbs. (18.2 N•m). 5. Torque the drive tire lug bolts to 130 ft. lbs. (182 N•m). 6. Bleed the brake system. Check the master cylinder reservoir level. 7. Bleed the hydraulic system. Check the reservoir level. 8. Refill the drive unit using the correct type fluid. 9. If you have trouble separating the tool from the drive unit, use the threaded holes in the tool. 10. Test the brake for proper operation.

5-44

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Preparing to Replace the Drive Axle Seal (36-Volt)

To replace the axle seal on the drive unit, first do the following: Parts required: • Axle seal - P/N 1049778 • Shim set - P/N 1049773 • Gasket material - Loctite #596 Red Tools required: • 13/16 in. socket to remove drive tire • 8 mm Allen socket to remove main cover • Bearing puller • Bearing press • Micrometer • Torque wrench, 150 ft lb. (210 N•m) capacity • Two tubes for pressing the bearings off:

Replacing the Drive Axle Seal (36-Volt)

•

First tube: 6.25 in. (159 mm) inside diameter x 6.00 in. (150 mm) long

•

Second tube: 3.5 in. (90 mm) inside diameter x 5.0 in. (130 mm) long

To replace the axle seal on the drive unit, see Figure 5-17, and do the following: 1. Turn the drive unit so the drive tire can be removed. 2. Using a 13/16 in. socket, loosen the lug bolts on the drive tire. 3. Jack the truck so the drive tire is approximately 1.00 in. (25.4 mm) off the floor. See WARNING.

PDMM-0058

5-45

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

8. Save the main cover shim set (5) so that the replacement can be matched for proper thickness.

Main Cover Shim (5)

Main Cover (11) Output Shaft (4) Spiral Ring Bevel Gear (3)

Ring Gear (3)

Main Cover Screws (2) Drain Plug (1)

Figure 5-18:

5-46

Lower End of Drive Unit

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

9. Place the main cover on the press as shown in Figure 5-19 and push the ring gear toward the flange of the output shaft enough to allow a bearing puller to be placed between the bearing spacer (6) and the ring gear (3). Figure 5-20 shows how the ring gear looks after being pressed toward the flange.

Press Ram

Bearing Spacer (6)

Tube Ring Gear (3)

Flange

Figure 5-19:

Ring Gear Before Being Pressed Toward Flange Bearing Spacer (6)

Space created after ring gear is pressed toward flange.

Tube

Figure 5-20:

PDMM-0058

Ring Gear After Being Pressed Toward Flange

5-47

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

10. Using a bearing puller as shown in Figure 5-21, remove the bearing spacer (6) along with the bearing (7) from the output shaft. Be careful not to damage the bearing cage.

Bearing (7) Bearing Puller

Bearing Spacer (6)

Ring Gear

Figure 5-21:

Removing Bearing Spacer Using Bearing Puller

11. Remove the external retaining ring (8). See Figure 5-22.

External Retaining Ring (8)

Figure 5-22:

5-48

Removing External Snap Ring

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

12. Support the main cover (11) with a large tube as shown in Figure 5-23. Press the output shaft (4) out.

Press Ram Main Cover (11)

Support Tube Output Shaft (4)

Figure 5-23:

Removing Output Shaft

13. Remove the output shaft seal (9). See Figure 5-24

Main Cover (11)

Output shaft seal (9); seal must be flush with outside of main cover Figure 5-24:

Removal/Installation of Shaft Seal

14. Apply Permatex sealer to the outside diameter of the new seal (9). Press the new seal into the main cover (11) bore flush with the outside.

PDMM-0058

5-49

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

15. Lubricate the seal lip using grease. Place the main cover (11) over the output shaft (4). See Figure 5-25.

Groove for retaining ring should be flushed with top of ring gear.

Press Ram

Support Tube Output Shaft (4)

Ring Gear (3)

Bearing Cone (10)

Figure 5-25:

Installing the Ring Gear

16. Install the bearing cone (10) and the ring gear (3) on the output shaft (4). Press the ring gear until the groove for the external retaining ring just becomes visible. 17. Reinstall the retaining ring (8, Figure 5-22). Do not substitute the correct retaining ring with a thinner one; doing so can cause the retaining ring to fail, allowing the axle to come out of the drive unit! 18. Press the spacer (6, Figure 5-21) onto the output shaft. 19. Press the bearing (7, Figure 5-21) onto the output shaft, being careful not to damage the bearing cage. 20. Using a micrometer, measure the thickness of the old cover shim set (5, Figure 5-18). Peel the layers off the new shim until the thickness is the same as the old one. 21. Clean the mating surface on the drive unit housing, then apply Permatex sealer. 22. Assemble the main cover subassembly onto the drive unit housing. 23. Lubricate, then install the main cover screws (2, Figure 5-18). Torque evenly to 35 ft. lbs. (49 N•m). 24. Install the drive tire. Torque the lug bolts to 130 ft. lbs. (182 N•m).

5-50

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

25. Refill the drive unit with the proper grade fluid. The drive unit capacity is 6.5 pints (3.1 liters).

Preparing to Replace the Drive Axle Seal (24-Volt)

If the axle is removed for replacement or for any other reason, replace the axle oil seal. Tools required to replace the axle and axle oil seal include: • 4 mm Allen wrench (for clamp nut) • Seal pressing ring (P/N 1008898); see Figure 5-26 • Clamp nut spanner (wrench P/N 1008856); see Figure 5-27 • Bearing puller • Torque wrench • 1/2 in. socket (for lowering the cover) • Hydraulic or arbor press

Seal Pressing Ring (P/N 1008898

Figure 5-26:

Clamp Nut Spanner Wrench (P/N 1008856)

Drive Unit Service Tools

If the drive unit has a shim located under this bearing, make sure that it is installed when the drive unit is reassembled.

Figure 5-27:

PDMM-0058

Drive Unit Cross Section

5-51

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Disassembling the Drive Unit (24Volt)

To disassemble the drive unit, see Figure 5-28, and do the following: 1. Remove the drive unit. 2. Remove the lower cover on the drive unit housing using a 1/2 in. socket.

Axle Seal

Clamp Nut

Lower Cover

Axle

Figure 5-28:

Drive Unit Components - Lower End

3. Use a 4 mm Allen wrench to loosen the screw in the clamp nut. 4. Use a spanner wrench to remove the clamp nut from the axle. 5. Press the axle out of the housing. 6. Use a bearing puller to carefully remove the bearing cone from the axle. See Figure 5-29. 7. Remove the old axle seal. 8. Clean and inspect all components.

5-52

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Bearing Puller

Figure 5-29:

Assembling the Drive Unit (24Volt)

Removing Axle Bearing

To assemble the drive unit, do the following: 1. After lubricating the lip of the new seal, place the new axle seal onto axle. This can be done by hand. 2. Carefully place the bearing cone onto the axle. Press it onto the axle. See Figure 5-30.

Bearing

Axle Seal

Figure 5-30: PDMM-0058

Pressing Bearing Cone onto Axle

5-53

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

3. Place the axle assembly into the housing. Mate the axle with the main drive gear. See Figure 5-31.

Axle Assembly

Main Drive Gear

Figure 5-31:

Assembly of Axle into Housing

4. Place the seal pressing tool between the seal and the tire mounting flange on the axle. See Figure 5-32.

Seal Pressing Tool

Figure 5-32:

5-54

Preparing Axle Seal for Assembly into Housing

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

5. Press the axle seal into the housing. The seal must be flush with the housing. 6. Push the axle out of the housing just enough so you can remove the pressing tool. 7. Push the axle back in until the bearing cone and bearing cup make contact. 8. Install the clamp nut on the axle. To set the bearing rollers, rotate the axle shaft, and torque the clamp nut to 150 in. lbs. (17 N•m). Loosen the clamp nut. While turning the axle shaft, torque the clamp nut to 40 in. lbs. (4.52 N•m). See Figure 5-33.

Clamp Nut

Figure 5-33:

Clamp Nut Spanner Wrench

Install/Torque Clamp Nut on Axle

9. Apply Loctite 242, then tighten the screw in the clamp nut to prevent the clamp nut from loosening. See Figure 5-34. 4mm Allen Wrench

Clamp Nut

Figure 5-34:

PDMM-0058

Securing Clamp Nut by Tightening Retaining Screw

5-55

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

10. Clean the cover plate and mating surface. Apply Permatex 6B to the sealing surface. See Figure 5-35. 11. Install the cover. Tighten all screws equally to 20 ft. lbs. (28 N•m). 12. Apply No.2 Permatex to the drain plug and install.

Cover

Figure 5-35:

5-56

Installing Cover

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Braking System

The braking system of the Mitsubishi Reach Truck meets all requirements of ANSI B56.1 and is the recommended system for stopping the truck, especially in an emergency. The brake assembly is mounted on top of the drive motor. The brake assembly consists of a rotor mounted on the drive motor armature shaft and stationary brake pads mounted within the brake housing. The brake is spring applied and hydraulically released. The brake unit is free-floating; that is, the assembly is not bolted to the drive motor. Instead, slip fit bushings inserted into the brake assembly are bolted to the motor end head. The following table shows the proper clearance after adjusting the brake:

Gap

Clearance Standard

Metric

Bottom Gap =

0.005 to 0.008 in.

(0.127 to 0.20 mm)

Top Gap =

0.020 to 0.030 in.

(0.508 to 0.76 mm)

Total for Both Gaps =

0.030 to 0.35 in.

(0.76 to 0.889 mm)

As the brake wears, the bottom gap increases and the top gap decreases. The brake must be readjusted when the top gap reaches 0.010 in. (0.254 mm). Refer to the appropriate procedures in this section. NOTE: Proper master cylinder operation will enable 0.030 to 0.035 in. (0.762 to 0.889 mm) of total brake rotor/pad gap. If not, recheck the pedal height and, if necessary, bleed the brake system.

Braking Process

The following describes how the braking process works: 1. With the deadman pedal in its normal up position, the master cylinder is deactivated. Therefore the slave cylinder is depressurized, which allows the brake spring to keep the brake applied. 2. Stepping on the deadman pedal strokes the master cylinder. This increases the pressure in the slave cylinder, which pushes against the brake spring and releases the brake. 3. As the deadman pedal is pressed, an arm on the mechanical linkage activates S2. The deadman switch (S2) is adjusted to activate the auxiliary system just before the brake is released.

PDMM-0058

5-57

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Bleeder Screw

Top Brake Show Assembly

Brake Rotor

Bottom Brake Show Assembly

Figure 5-36:

Brake Assembly

Reservoir Slave Cylinder

Master Cylinder S2

Deadman Pedal

Figure 5-37:

5-58

Brake Schematic

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Adjusting NutRetained Style Brakes

The nut-retained style brake can be identified by a long retaining nut with an integral encoder shaft. See Figure 5-38 on page 5-60 for a view of the nut-retained style brake.

Without Adjusting Bolts

To adjust the brakes without adjusting the bolts, use Figure 5-38 on page 5-60 and do the following: 1. Place the spacer (19) over the motor shaft. 2. Place the Woodruff key (10) on the motor shaft. 3. Place the brake assembly over the motor shaft. Slide it down all the way. Install the retaining nut (17) onto the upper end of the drive motor armature shaft. Use a torque wrench to properly torque the retaining nut to 90 ft-lbs (122 N•m). 4. Connect the brake line to the brake. Bleed the air from the brake lines. 5. Install the three M8 x 1.25 capscrews (7) and the three hardened washers (5) that hold the brake assembly to the top of the drive motor. Tighten the capscrews. 6. Press the deadman pedal. Measure the gap between the brake rotor and the bottom pad. It should be 0.005 to 0.008 in. (0.13 to 0.2 mm). Then measure the gap between the brake rotor and the top pad. This gap will vary, but it should not be less than 0.010 in. (0.25 mm). Proper master cylinder operation will enable 0.030 to 0.035 in. (0.762 to 0.889 mm) of total brake rotor and pad gap. If not, recheck the pedal height and, if necessary, bleed the brake system. 7. Loosen the three M8 X 1.25 capscrews (7) you installed in Step 5. Add shims (1 thru 4) between the hardened washer (5) and the top of the drive motor to get the 0.005 to 0.008 in. (0.13 to 0.2 mm) gap mentioned in the previous step. Make sure you add shims (1 thru 4) equally beneath each of the three spacers (6). Never install shims without a hardened washer beneath them. If the lower gap (mentioned in Step 6) is too small when there are no shims (20, 21) beneath the spacers (5), add shims beneath the spacer (19) on the drive motor armature shaft to increase the gap. 8. Clean the three M8 X 1.25 capscrews (7), apply Primer T (P/N 65V1541), and then red Loctite to the threads. Install the capscrews (7) and torque them to 16 ft-lbs (21.7 N•m).

PDMM-0058

5-59

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

17 12 18 11

8 7 0.01 inch (0.25 mm) minimum for upper gap

6 5

1 2

0.005-0.008 inch (0.130.2 mm) for lower gap

21 Figure 5-38:

Nut-Retained Style Brake Assembly

Table 5-10: Nut-Retained Style Brake Assembly

5-60

Item No.

Qty.

Item No.

Qty.

Shim 0.002

HHC screw

Shim 0.005

Bracket

Shim 0.010

Locknut 1/4-20 x 5/8

Shim 0.030

HHC Screw

Washer

Spacer

Ref

Spacer

M16 Nut

Ref

HHCS M8 x 1.25-6H .25mm lg.

Fitting 900 Elbow

Spacer

Brake Assembly

Shim

Woodruff Key

Shim

Bracket

Loctite

Description

Washer Harden Heavy

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

With Adjusting Bolts

A new style brake assembly is available with three threaded holes in the mounting plate for adjusting bolts. The bolts contact a support ring between the brake and rotor and allow the gap to be set by turning the bolts. See Figure 5-39. 1. Back off the three adjusting bolts and jam nuts until they do not contact the adjusting ring. 2. Check for the proper deadman pedal height. 3. Bleed the brake. See “Bleeding the Brake” on page 5-61. 4. Press the deadman pedal and place a 0.008 in. feeler gauge between the bottom brake pad and the rotor. 5. Tighten the adjusting bolts until the feeler gauge is just snug on all three bolts. 6. Tighten the jam nuts. 7. Check the clearance between the top brake pad and the rotor. The top gap should be not less than 0.010 in. (0.25 mm). 8. Test the brakes in a safe area. With a full load and traveling at full speed, the lift truck should stop within 8 to 10 feet (2.4 to 3.0 m), depending on the load, floor, and tire conditions. Adjusting Ring

Adjusting Bolt

Jam Nut

Figure 5-39:

Brake Adjusting Bolt Detail

Inspecting the Brake Pad

The thickness of the brake pad and the steel bracket they are attached to should not be less than 0.080 in. (2 mm). When new, the thickness of the brake pads and the steel bracket they are attached to should be 0.156 in. (3.96 mm)

Bleeding the Brake

To bleed the brake, do the following: 1. Attach a clear plastic bleeder hose to the bleed nipple on top of the brake assembly. Place the free end of the bleeder hose in a small container of clean brake fluid. 2. Loosen the bleeder nipple. 3. Press the deadman pedal. 4. Keeping the deadman pressed, tighten the bleeder.

PDMM-0058

5-61

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

5. Repeat steps 2 through 4 until a solid stream (no bubbles) flows from the slave cylinder. Refill the master cylinder fluid reservoir using DOT-5 brake fluid only.

Adjusting the Deadman Pedal

Correct brake operation also depends on proper functioning and adjustment of the deadman pedal. Thoroughly clean around and beneath the pedal to insure freedom of movement. This will also help ensure that the power steering functions until the truck is nearly stopped. See the following when adjusting the deadman pedal: • Figure 5-40 on page 5-63 • Table 5-11 on page 5-64 To adjust the deadman pedal, do the following: 1. Check the master cylinder mounting bolts for tightness. 2. Check the condition of the return spring. 3. Make sure all parts of the brake linkage are in place and in good condition. 4. Check the pedal mounting pivots and bearings for tightness and condition. 5. Adjust the yoke to obtain a minimum spring compressed length of 1.75 in. (44.5 mm). The maximum is 1.94 in. (49.27 mm). 6. Tighten the locknut. 7. Check the pedal height. If it is incorrect, check the condition of the pedal and linkage. For 24-volt models, it should be 3.75 to 4.0 in. (95 to 102 mm). For 36-volt models, it should be 4.75 to 5.0 in. (121 to 127 mm). NOTE: A fully pressed deadman pedal will enable 0.030 to 0.035 in. (0.762 to 0.889 mm) of total brake and rotor pad gap. If not, check for air in the brake system. 8. Check the brake release for proper operation. Adjust the deadman switch (S2) so that it engages when the deadman pedal is at 60% to 80% of full height.

5-62

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Figure 5-40:

PDMM-0058

Deadman Brake Pedal Installation (Sheet 1 of 2)

5-63

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Figure 5-41:

Deadman Brake Pedal Installation (Sheet 2 of 2)

Table 5-11: Deadman Brake Pedal Installation

Item No.

Qty.

Description

Item No.

Qty.

Brake Mounting Plate (< 271 E.H./MFH)

Brake Pedal Pad

Shaft Seal

Deadman Pedal Machine

Brake Cam

Master Cylinder

Actuator Switch

Round Head Screw #4-40 x 3/ 4

Round Head Screw #10-32 x 5/16

Brake Mounting Plate (< 270 E.H./MFH)

Hydraulic Connector

Hex Head Cap Screw 1/4-28 x 1-1/4

Bearing

Brake Stud

Shoulder Screw

Hex Nut 1/4-28

Bearing - Sleeve

Spacer

Sealed Switch (Cold Storage)

Compression Spring

Hex Head Cap Screw 5/16-18 x 1/2

5-64

Flat Washer #4 Hex Nut 5/16-24 Shoulder Screw Bearing

Switch (Standard)

Description Cotter Pin 3/32 x 3/4

Switch Bracket

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Table 5-11: Deadman Brake Pedal Installation

Item No.

Qty.

Item No.

Qty.

Hex Nut #4-40

Adhesive (Not illustrated)

Clevis Link

Brake Hose

Yoke Pin 5/16 x 1-1/16

Replacing the Brake Master Cylinder

Description

To replace the brake master cylinder, do the following: 1. The deadman pedal must be in the up position so the master cylinder is in the neutral position. 2. Remove and cap the hydraulic line. 3. Disconnect the linkage between the master cylinder and pivot. 4. Unbolt the master cylinder and remove it. 5. Remove any parts that will be needed on the new master cylinder and assemble. 6. Bolt in the new master cylinder. 7. Reattach the linkage. 8. Reattach the hydraulic lines. 9. Bleed the system. 10. Adjust the deadman pedal and switch according to “Adjusting the Deadman Pedal” on page 5-62. 11. Test the brake system.

Replacing the Brake Pads

If the brake pads need to be replaced, the top pad assembly, bottom pad assembly, and rotor must be replaced as a complete set. Tools required for disassembly: • 3/32-in. Allen wrench • 1/4-in. Allen wrench To replace the brake pads: 1. Remove the cable clamp. 2. Remove and cap the brake hydraulic line. 3. Remove the nut securing the brake rotor. Remove the shims (if any), noting the quantity. 4. Using the spanner wrench (P/N 1159870), turn the torque adjusting plate counterclockwise to remove pressure on the piston. See CAUTION.

PDMM-0058

5-65

Chapter 5: Maintenance

Mitsubishi® Reach Service Manual

Mechanical Maintenance

! CAUTION If the three Allen head screws holding the brake assembly together are removed before backing off the torque plate pressure, brake fluid might be forced out of the piston. If the brake assembly is left on the truck, brake fluid could drip on the drive motor. 5. Remove the bolts securing the brake to the drive motor. 6. Remove the brake assembly from the truck. See CAUTION:

! CAUTION Tool, P/N 1129907, must be used to separate the brake assembly from the drive motor. Using any other device will damage the bearing at the top of the drive motor. Any evidence of damage will void the warranty. 7. After backing off the torque ring, remove the three Allen head screws. 8. Remove the three springs and spacers. 9. Remove the lower brake pad assembly and rotor. See NOTE. NOTE: Observe the orientation of the rotor with respect to the brake assembly; the higher portion of the hub goes down toward the drive motor (see Figure 5-42 on page 5-67). 10. Remove the three Allen head screws holding the upper brake pad assembly to the piston. 11. Remove the upper brake pad assembly. 12. Using new brake pad assemblies and a new rotor assemble the brakes in the reverse of how you disassembled it. 13. For an approximate adjustment, turn the torque plate until the top is flush with the upper surface of the brake assembly. Make the final brake adjustment after it is installed on the truck. See “Brake Installation” on page 5-67.

5-66

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

High Side of Hub

Figure 5-42:

Brake Installation

High Side of Brake Hub Assembly

See the following figures: • Figure 5-38 on page 5-60 • Figure 5-43 on page 5-71 • Figure 5-44 on page 5-72 Reverse the procedure outlined “Replacing the Brake Pads” on page 565. If the O-ring seals leak: 1. Remove the brake assembly from the truck and separate the brake pads and rotor from the brake actuator. 2. Remove the torque adjustment plate from the top of the brake. 3. Carefully push the piston up and out of the housing. 4. Remove the two O-Rings. 5. Thoroughly clean and inspect individual components for damage or nicks which can cause leakage.

PDMM-0058

5-67

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

6. Now reassemble the brakes according to the following instructions,

Reassembling the Brake

After cleaning and inspecting the brake components, reassemble the brake as follows: 1. Use only new O-rings when reassembling the brake. It is critical that the individual components are clean. 2. Liberally coat the O-rings with new DOT-5 brake fluid only. 3. Install the new O-rings into the brake housing. 4. Coat the piston surface (which contacts the O-ring) with DOT-5 brake fluid. 5. Install the piston into the housing squarely. Push the piston completely into the housing until it bottoms out. 6. Start the torque ring into the housing by hand. Do not use the spanner wrench at this time. 7. Attach the inner brake pad assembly to the piston using three (3) Allen head screws. Tighten them securely using the 3/32 in. Allen head wrench. Note: It is important to properly align the holes in the inner brake pad assembly with the mating threaded holes in the brake housing. It might be necessary to rotate the brake pad assembly to achieve proper alignment. 8. Lay the brake rotor on the inner brake pad assembly. The rotor hubs are different heights on either side. The higher hub MUST face the drive motor (facing down when on the truck). See Figure 5-42 on page 5-67. 9. Install the three spacers and springs. 10. Lay the outer brake pad assembly on top of the rotor. 11. Install three Allen head screws through the springs and spacers. Tighten them equally. 12. Install the brake assembly on the truck. 13. Connect the brake hose. 14. As a rough setting, the torque ring should be flush with the surface of the brake housing. 15. Bleed air from brake hydraulic line. See “Bleeding the Brake” on page 5-61. Use DOT-5 brake fluid only. 16. Test and adjust the torque ring on the brake assembly to achieve proper braking.

5-68

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Replacing the Brake O-Ring Seal

It is not necessary to remove the entire brake assembly from the truck to replace the O-rings within the unit. Proceed as follows. 1. Disconnect the battery. 2. Remove the power cables from the drive motor. 3. Unplug the drive motor temperature sensor. 4. Remove the cable bracket assembly from the top of the drive motor along with the brake hydraulic line; position it up and out of the way. Cap the brake line. 5. Remove the brake retaining nut. 6. Back off the three 1/4-in. socket head screws just enough to relieve pressure on the brake pads. 7. Using the brake adjusting tool (P/N 1159870 [#442 - Martin, USA]), turn the top adjusting ring counterclockwise until all pressure is removed. A hammer or dead blow might be required to initially turn plate. 8. Remove the three brake assembly housing screws; be careful not to lose the spacers. 9. Lift the top part of the brake assembly off the drive motor. 10. On the bench, remove: •

the top adjusting plate

•

all the springs on top of the piston

•

the screws securing the upper disc plate assembly to the piston (use a 3/32 in. Allen head wrench). Note how the small holes in the piston align with the three mounting holes.

11. Push the piston from the bore, again noting the location of the screw holes that mount the upper disc plate assembly. 12. Remove the old O-rings. 13. Both new O-rings must have the following ID markings: •

1 large white dot

•

2 small yellow dots

14. Coat the new O-rings with new DOT-5 brake fluid and install them. 15. Install the piston into the bore. Be careful not to the damage seals. Before installing the piston, align the holes as noted in step 11. 16. Apply Loctite 242 (blue) to the Allen head screws removed in step 10, then mount the upper disc pad assembly to the piston. 17. Install the springs in the holes on the top of the piston. 18. Install the top adjusting plate. Just start the plate, do not tighten it at this point.

PDMM-0058

5-69

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

19. Install the upper assembly back on the drive motor. Secure it in place using the three spacers and long screws removed in step 6. Tighten the three housing screws equally to 35 40 ft lbs. (49 56 N•m). 20. Turn the top plate to the original position (a good starting point is to have the plate flush with the top of the assembly). 21. Install the power cables and temperature sensor; tie wrap in the original manner. 22. Connect the brake line. 23. Bleed the brake. 24. Check the deadman pedal adjustment. 25. With the deadman pedal pressed, check the clearance between the rotor and the brake pad assemblies. See “Adjusting NutRetained Style Brakes” on page 5-59. 26. Check the stopping distance of the truck as follows: When the truck is carrying its full rated load at full speed on a dry, level floor, the truck should stop within approximately 8 feet (2.44 meters). 27. Adjust the brake as required.

5-70

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Allen Head Screws (3)

Item No.

Qty.

Outer Body

O-Ring

Piston Body

Armature & Puck SubAssembly

Screw #10-24 x 1/2

Compression Spring

Description

Adjusting Plate

Friction Rotor

Adaptor & Puck SubAssembly

Spacer

Screw 5/16-18 x 2-3/4

Serrated Washer 5/16

Relief Fitting

Fitting Cap

Cap Plug (Not Illustrated)

Figure 5-43:

PDMM-0058

Hydraulic Brake - 24-Volt

5-71

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Allen Head Screws (3)

Item No.

Qty.

Piston Body

Compression Spring

O-Ring

Outer Body

Adjusting Plate

Friction Plate and Puck SubAssembly includes:

Pucks (4 pucks, 4 holes)

Rivets

Friction Plate

Friction Rotor (High Heat Dissipation)

Adaptor & Friction Puck Assembly includes:

Pucks

Rivets

Adaptor Plate

Spacer

Bleeder Screw

Pipe Plug

Screw #10-24 x 1/2

Description

1 2 6

3 13

4 11 14

Cap Plug

Shim

O-Ring (Not Illustrated) Figure 5-44:

5-72

Hydraulic Brake - 36-Volt PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Steering System

This section explains how to maintain the steering system.

Steering Adjustment with Steerable Caster

The drive and steerable caster wheel on the truck are designed to allow 101.5 degrees of rotation. Use the following procedure to adjust the steering mechanism and caster height.

Initial Adjustments

Caster height adjustment differs, depending on the type of mast on the truck. “Adjusting the Casters” on page 5-74 for caster height adjustment instructions.

Proper caster adjustment is critical for proper performance. A misadjusted caster can cause excessive braking distances or poor stability. Use Figure 5-45 as a reference to properly adjust the steering and caster.

Before doing any maintenance on the steering system, do initial adjustments as follows: 1. The drive and caster wheels should be parallel within 0.12 in. per 12.00 in. (0.3 cm per 30.5 cm). 2. If the wheels are not within tolerance, loosen the bolts (1). 3. Use adjusting bolts (2 and 3) to get the wheels parallel. 4. Apply Loctite to the adjusting bolts (2) and (3). Tighten all hardware when the adjustments are done.

1 (4 places) Torque to 70 ft lbs (98 N•m)

Figure 5-45: PDMM-0058

2 (Tighten locknuts after adjustment)

Steering Adjustments

5-73

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Adjusting the Casters

To adjust the casters, do the following: 1. Check the bolt (1) in Figure 5-46 on page 5-75. Make sure it is installed correctly. If the bolt is missing, the A-frame could drop and allow the springs to escape when the truck is jacked up. 2. Jack the truck until the caster is clear of the floor. See WARNING below.

Spring Length

Below 330 in. (8328 mm)

5.75 in. (146 mm)

6. Apply Blue Loctite and turn the screw (1) to adjust the gap between the bottom of the bolt head and the top of the flat washer.

Elevated Height

Truck Type

Gap

All elevated heights

36-Volt

0.12 in. (3.05 mm)

Below 270 in. (6858 mm)

24-Volt

0.0 in. (0.0 mm) *

* Don’t overtighten the bolt. The bolt head should apply slight pressure on the flat washer.

5-74

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

See chart in Step 5 for distance Grease Fittings 1 Flat Washer

See Step 6 for this gap 1.00 in. (25.4 mm) initial set-up gap (Step 3) Figure 5-46:

Caster Adjustment

7. Loosen the nut (4, Figure 5-47 on page 5-76) 8. Turn the stop bolt (5, Figure 5-47 on page 5-76) to adjust the gap between the bolt head and the top of the A-frame as follows: Elevated Height

Truck Type

Gap

Below 330 in. (8328 mm)

36-Volt

0.38 in. (9.65 mm)

Up to 250 in. (6350 mm)

24-Volt

0.38 in. (152 mm)

From 251 in. to 270 in. (6375 to 6858 mm)

24-Volt

0.25 in. (6.35 mm)

9. Apply Loctite to the stop bolt (5). Tighten the nut (4). 10. Test the truck for proper braking action.

PDMM-0058

5-75

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

View A-A

4 5

Figure 5-47:

5-76

See Step 8 for this gap.

Stops Adjustment

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Service Notes for Steering Components

Use Figure 5-48 as a reference when removing or replacing steering components. After replacing any components, make sure the steering is adjusted properly according to this section.

Apply Loctite to threads. Torque to 150 ft. lbs. (210 N•m).

Section D-D

Apply Loctite to threads. Torque to 150 ft. lbs. (210 N•m).

Section C-C

Apply Loctite to threads. Torque to 150 ft. lbs. (210 N•m).

Section B-B

Use 1050288 (A/R) to take up loose play in arms.

After steering adjustments are complete, tighten jam nut to lock bolt.

Apply Loctite to threads. Torque to 70 ft. lbs. (98 N•m) (4 Places). Figure 5-48:

PDMM-0058

Section A-A

Steering Maintenance Notes (Sheet 1 of 2)

5-77

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Apply

Loctite to threads. Torque to 150 ft. lbs. (210 N•m).

Note: This shows a truck with a steerable caster. Figure 5-49:

5-78

Steering Maintenance Notes (Sheet 2 of 2)

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Lift/Lower System

This section explains how to maintain the lift/lower system.

Lift Chains

Check the truck lift chains monthly because most unsatisfactory chain performance can be traced directly to inadequate chain maintenance. Remove the chain and inspect it for defects as explained in this section.

Removing and Inspecting the Chain

Both chains should be replaced when either is defective.

! CAUTION Do not steam clean or degrease new truck chains To remove and inspect the chain, do the following: 1. Using a jack or overhead hoist, raise the carriage enough to slacken the lift chains. 2. Secure the carriage with blocks to prevent the carriage from lowering. 3. Remove the chain and chain anchors by unscrewing the nuts on the carriage and the chain anchors on the main frame. 4. Thoroughly clean the chain in solvent. 5. Inspect the chain for defects listed in Table 5-12 on page 5-80. 6. Lubricate a used chain in good condition or a new chain before installing it on the truck. See “Lubricating the Lift Chain” on page 5-81. 7. Reinstall the chains on the truck. Be sure the chains are adjusted to share the load equally. Also, make sure they are not twisted so they will roll flat on the sheaves.

PDMM-0058

5-79

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Table 5-12: Defect-Cause Chart

Defect Chain Elongation

Cause Wear

Maintenance Procedure • Lay the chain on a flat surface and push it together. • Measure and mark a 12 in. length that has operated over the pulley sheave. • Stretch the chain; if more than 1/3 in. play is detected, replace the chain. (A wear scale can be obtained from Rex Chainbelt, Inc.)

Rust and corrosion

Cracked Plates

Steam cleaning or degreasing new truck chains

• Infrequent oiling

Frequent chain oiling. See Table 5-2, “Planned Maintenance Checks,” on page 513. Replace the chain.

• Rust • Corrosion • Chain fatigue Tight Joints

• Bent pins or plates

If the joints fail to loosen, replace the chain.

• Rusty joints or peened plate edges Chain side wear

5-80

Chain misalignment

Realign the chain on the pulleys.

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Lubricating the Lift Chain

To lubricate the lift chain, do the following: 1. Liberally apply oil (see Table 5-2, “Planned Maintenance Checks,” on page 5-13 for oil specifics) to the chain using a narrow paint brush. 2. Make sure the exterior surface is covered to prevent rust and to make sure that the oil penetrates the chain joints to reduce wear. 3. Lubricate the equalization chains, on 3 stage masts, at the same intervals and using the same lubricant as the lift chains. 4. Apply dry lube (NA012559) to spherical side of the chain anchor nut. See Figure 5-50. 5. See “Adjusting the Equalization Chain” on page 5-89.

Lift Chain

Chain Anchor

Spherical Nut Lubricate Here

Figure 5-50:

PDMM-0058

Lubrication of Lift Chain Spherical Nut

5-81

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Adjusting the Over the Mast Hose and Cable

If the mast hoses require adjustment, use the following procedure: 1. Remove the mast guard. 2. Elevate the inner telescopic enough to place the support block (as shown in Figure 5-51) under the inner and outer telescopics. Lower the mast onto the support. Clamp the support in place as shown.

Block and clamp reach mechanism.

Inner telescopic rests on 4x4

4x4

41 in. (104 cm)

2x4

20.5 in. (55 cm) Outer telescopic just clears 2x4

Nail 2x4 and 4x4 boards together as shown.

Figure 5-51:

5-82

Blocking Mast

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

3. Disconnect the battery. 4. Loosen the three retaining screws (1). See Figure 5-52.

Cable Grip Ref.

Adjust hoses and capture plate to apply 4.5-5.5 lbs. (2-2.5 Kg) tension on hoses/cables. 4.006 in. (10 cm)

Figure 5-52:

PDMM-0058

Hose Clamping on Inner Telescopic

5-83

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

5. Adjust the hoses that go over the mast by pulling any excess hose from the main carriage solenoid, over the free lift cylinders, around the hose guides on the bottom of the inner telescopic, and finally into the opening in the tractor frame. See Figure 5-51. 6. Adjust hose tensioners so the springs are extended as shown. See Figure 5-52.

3.75 in. (9.5 cm)

4.06 in. (10 cm) to 3.25 in. (8.25 cm) to 3.56 in. (9 cm)

Figure 5-53:

Hose/Cable Tension Spring Adjustment

7. Tighten the three retaining screws. 8. Reconnect the battery. Unclamp the support, and elevate the mast enough to remove the support. Lower the mast completely. Recheck the hose tension spring dimension. 9. Reinstall the mast guard after the adjustments are complete.

5-84

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Replacing the Over the Mast Hose

To replace the over the mast hose, do the following: 1. Remove the mast guard. 2. Elevate the inner telescopic enough to place the support block (as shown in Figure 5-51 on page 5-82) under the inner and outer telescopics. Lower the mast onto the support. Clamp the support in place as shown. 3. Extend the reach out and place a piece of 2 x 4 ft. (8.5 in. [21.6 cm]) board between the carriage frame and the scissor end as shown. Clamp in place. See Figure 5-51 on page 5-82. 4. Disconnect the battery. 5. Remove any hose clamps that are securing the hoses to the truck. 6. Remove the hose connections at the attachment and let the fluid drain into a container. 7. Disconnect the hose to be replaced in the power section. 8. Plug the open fittings to prevent contamination from entering the hydraulic system. Plug the open ends of the hose to prevent residual oil from draining out onto the truck and floor. 9. Remove the old hose. 10. Install the new hose by reversing steps 7 through 9. See Figure 554 on page 5-86 for hose routing. 11. Adjust the hose tension. 12. Remove the 2 x 4 board from the reach mechanism. 13. Plug the battery back in and operate the auxiliary functions. Check for leaks. 14. Unclamp the support, elevate the mast enough to remove the support. Lower the mast completely. Recheck the hose tension spring dimension. 15. Refill the reservoir as required. 16. Reinstall the mast guard.

PDMM-0058

5-85

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Hoses/ Cables

View E-E

View B-B

Figure 5-54:

5-86

Hose Routing Detail

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Replacing the Flow Control

The flow control in the three-stage mast is located internally at the base of the rear cylinder. The flow control can be replaced without removing the cylinder using the following procedure, (See Figure 5-55 and Figure 5-56.) 1. Elevate the forks enough to gain access to the base of the rear lift cylinder. 2. Use a chain hoist and blocks to support the telescopics; disconnect the battery. 3. Remove the locknut that secures the rear piston to the base of the mast main frame. 4. Disconnect and cap the hydraulic supply line to the cylinder and cylinder port. 5. Using the hoist, raise the inner telescopic. This causes the equalization chains to raise the outer telescopic enough to remove the end cap. 6. Using a fabric strap wrench to hold the piston, remove the lower end cap of the piston. 7. Remove the internal snap ring that holds the flow control in the cap. 8. Remove the flow control, noting the direction of the arrow on the flow control cartridge body. 9. Flush the cap using solvent to remove the dirt and oil. Thoroughly clean the cap threads. Blow dry using compressed air. 10. Install the new flow control ensuring the flow arrow points in the same direction as the flow control that was removed. Hydraulic flow should be restricted when the mast is lowered. 11. Install the snap ring. 12. Replace the O-ring. 13. Thoroughly clean the piston threads. 14. Apply Loctite 242 to the threads on the end cap. 15. Thread the end cap into the piston and tighten it. 16. Reverse steps 3 through 6 for reassembly.

PDMM-0058

5-87

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Piston End Cap

Flow Control

Snap Ring

5-88

Figure 5-55:

Mast Flow Control

Figure 5-56:

Rear Cylinder Piston/End Cap

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Adjusting the Equalization Chain

The equalization chains on the three-stage (TT) masts must be adjusted properly to prevent the possibility of stretched hoses and electrical cables. Depending on the mast configuration, the equalization chains will be located either between the outer telescopic and the main frame OR on the tractor-side of the mast uprights. Determine which mast configuration is used on the truck, then follow the appropriate procedure.

! CAUTION With both equalization chains slack, note the relationship between the top of the mast main frame and the telescopic frame sections. Under no circumstances should the equalization chains be adjusted so the inner telescopic is raised above the position noted before starting the adjustment procedure. 1. The equalization chains are properly adjusted if the inner telescopic contacts the mechanical stops on the outer telescopic, JUST BEFORE the outer telescopic contacts the mechanical stops on the main frame. 2. The adjusters are located near the top of the main frame, either between the mast main frame and the outer telescopic OR on the tractor-side of the mast. To adjust the equalization chains, turn the chain anchor locknut until the outer telescopic starts to move, then loosen the nut one-half turn. Repeat this step for the other side. 3. Check the adjustment by elevating the carriage (if required) so that 4-5 feet (1.2-1.5 m) of the equalization chains are visible. Using your fingers, apply pressure on each chain. Determine if the pressure is approximately the same on both sides. If there is a significant difference between the two sides, repeat this procedure on the chain that has the lower tension. See NOTE. NOTE: Make only minor adjustments to ensure that the chains are not overtightened. Make adjustments equally to both sides. Always recheck chain tension after any adjustments are made to either or both equalization chains.

PDMM-0058

5-89

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Note: Note This figure shows the location of the equalization chains on a mast with 8 in. thick uprights. These chains are located in back of the uprights on masts with a 9 in. thick upright.

Outer Telescopic Inner Telescopic Mast Main Frame

Chain Anchor Locknut

Hex Head Cap Screw

Chain Anchor Welded Block

Figure 5-57:

5-90

Adjusting the Equalization Chain

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Equalization Chain Removal and Installation

If the equalization chain requires removal or replacement, use the following procedure. See WARNING. See Figure 5-51 on page 5-82.

! WARNING With the mast attached to the tractor, never remove both equalization chains at the same time. When working on the mast, block in place as shown in Figure 5-51. To remove the chain: 1. Elevate the inner telescopic enough to place the support block (as shown in Figure 5-57 on page 5-90) under the inner and outer telescopics. Lower the mast onto the support. Clamp the support in place as shown. 2. Loosen the locknut on the equalization chain adjuster. 3. Remove the two hex head cap screws at the top of the mast main frame. 4. Using a screwdriver, push the chain anchor support towards the center of the mast. Once the anchor support clears the welded block on the inside of the mast main frame, the adjuster and chain will fall to the floor. 5. Disconnect the chain from the inner telescopic chain anchor. To install the chain: 1. Attach chain to the inner telescopic. 2. Attach an 8-10 ft. (2.4 - 3.0 m) length of wire to the chain anchor. 3. Pull the chain anchor (using the wire attached above) and chain up between the mast main frame and outer telescopic. 4. With the chain anchor in the proper position, start the two hex head cap screws; then tighten. 5. Ensure the chain is not twisted. 6. Remove the length of wire. After reassembling the equalization chain, adjust it according to the instructions in “Adjusting the Equalization Chain” on page 5-89.

PDMM-0058

5-91

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Replacing the Equalization Chain Sheave

This procedure is for Deep Mast Uprights of 7 or 8 in. (177.8 or 203.2 mm). If the equalization chain sheave needs to be removed or replaced, do the following. 1. Elevate the fork carriage to remove the access plate. Block the fork carriage. 2. Disconnect the battery from the truck. 3. Remove the sheave access plate at the base of the mast frame. See Figure 5-58. 4. Attach a length of wire to the equalization chain anchor at the top of the mast main frame. 5. Loosen the locknut on the equalization chain anchor. 6. Remove the two hex head cap screws holding the anchor in position. 7. Lower the chain enough to allow the sheave to be removed. 8. Repair or replace the sheave. 9. Reinstall the hex head cap screws removed in step 6. Make sure the chain is not twisted. 10. Reinstall the access plate on the bottom of the mast main frame. 11. Adjust the equalization chains.

Mast Upright

Telescopic

Lower Chain to allow removal of sheave

Equalization Chain Sheave

Figure 5-58:

5-92

Sheave Access Plate

Removing the Equalization Chain Sleeve

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Applying Loctite® to the Reach Carriage Chain Anchors

Reach carriage chain anchors on all triple telescopic masts are lubricated to prevent the anchors from backing out of the anchor mounting block. The anchor radial position is critical, and the anchors must be square with the carriage horizontal axis in order to prevent the lift chains from twisting. If the chain anchors are removed for any reason, Loctite should be reapplied to the anchor threads using the following procedure: 1. Ensure the threads of the chain anchor are clean. 2. Apply Loctite primer T to the male threads on the anchors and to the female threads of the anchor blocks. Allow to dry. 3. Apply Loctite 242 to the threads of the anchor and install. 4. Anchors must be square with the block on the carriage within +/- 2 degrees.

Adjusting the Mechanical Stop

If the mechanical stops require adjustment, install or remove the shims (P/N 1036790, item 1 in Figure 5-57) between the stop and the bumper. Use no more than three shims at each stop.

Figure 5-59:

PDMM-0058

1036790

Adjusting the Mechanical Stop

5-93

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Reach Carriage Lubrication Points

Lubricate both sides of the reach assembly as shown in Figure 5-60 using P/N 1036913 grease. Also, lubricate the hose assembly on the reach carriage in the area that it rubs on the frame.

Lubrication Points

Removing the Fork Carriage Tilt Pins

To remove the carriage tilt pins, you must remove the snap ring. See Figure 5-61.

Socket Head Screw

Washer Snap Ring

Pivot Pin being removed

Figure 5-61:

5-94

Removing Tilt Pivot Pin

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Attaching the Mast to the Tractor

Figure 5-62 shows the proper torque for fasteners attaching the mast to the tractor. Make sure that a hardened washer (1139696) is used in conjunction with the mounting bolts.

Before installing the bolts: • Clean the bolts and mating holes with Loctite 755 solvent • Prime the bolts with Loctite Primer N • Apply Loctite 242 to the bolt threads. • Torque the 5/811 mast mount bolts to 160-170 ft. lbs. (224-238 N•m).

The gates should be installed so that the oval holes are closer to the top of the gate. Figure 5-62:

PDMM-0058

Torque Specifications for Attaching the Mast to the Tractor

5-95

Mitsubishi® Reach Service Manual

Chapter 5: Maintenance Mechanical Maintenance

Adjusting the High Pressure Relief Valve

To adjust the high pressure relief valve, do the following: 1. Install a calibrated pressure gauge (3000 psi/20,682 kPa) in a test port. 2. Back-out the high pressure relief valve. 3. Place a rated load on the forks. 4. Start the lift system and turn the pressure relief screw clockwise until the carriage starts to lift. Note the pressure required when the carriage elevates above the free lift stage (carriage and telescopics elevated). 5. Adjust the pressure relief valve to a pressure 100 - 300 psi (689.4 - 2068 kPa) greater than the values observed in step 4. This can be done by chaining the mast sections together or by adding more weight to the forks. 6. After the adjustment is complete, tighten the relief valve lock nut. 7. Check the lift system for proper operation.

5-96

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting In this Chapter

Chapter 6: Troubleshooting In this Chapter This chapter contains the following topics: Topic

See Page

Troubleshooting Procedure

6-1

Electrical

6-4

Hydraulics

6-12

EV100LX Codes and Tests

6-20

Troubleshooting the Interface Card System

6-73

Troubleshooting the Interface Card

6-86

Troubleshooting Procedure When troubleshooting truck problems, it is important to: • Use a logical, common sense approach. • Begin with the simplest solution and work towards the most complex. The following procedure can aid in developing a logical and systematic troubleshooting procedure:

Verifying Problems

Verify problems by: • Obtaining as much information as you can about the problem. • Determining, if possible, what the truck’s performance was before the problem began. • Seeing any records which might have been kept about the truck’s performance. • Operating the truck yourself to verify the problem.

PDMM-0058

6-1

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting Procedure

Locating the Problem Area

Locate the truck’s problem area by: • Opening the various truck compartment doors and visually inspecting the systems, then consult the hydraulic, electrical, and mechanical maintenance sections in 1 for general information that can save you time. • Determining if the problem is in the control circuit or the power circuit if there is no obvious physical problem.

Establishing a Logical Testing Sequence

Establish a logical testing sequence by: • Using the electrical schematic on page A-13. Begin at the battery and establish a sequence of testing points to locate the problem. • Establishing test points which indicate that all components between any new test point and the battery are good. • Avoiding haphazard checking which provides inconclusive results.

Identifying the Cause of the Problem

6-2

Identify the cause of the problem by: • Checking for improper truck usage. • Bringing the problem to the service manager’s attention to avoid repetition of the cause.

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting Procedure

Correcting the Problem

Correct the problem by: • Repairing or replacing defective components. • Complying with appropriate safety procedures.

! CAUTION Disconnect the battery when checking electrical circuits with an ohmmeter. Battery current can damage the ohmmeter. • Use the electrical schematic and the hydraulic schematic when troubleshooting. • Check all truck fail-safe and overload circuits:

PDMM-0058

•

Before attempting any troubleshooting procedure

•

After making any repairs or adjustments before returning the truck to operation

6-3

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Electrical

Electrical This section explains how to troubleshoot the electrical system.

Checking the Wiring

Save time and trouble; look for simple causes first. 1. Visually inspect all wiring in all components for: •

Broken wiring and shorted conditions (especially close to metal edges or surfaces).

•

Loose connections

•

Loose or broken terminals

•

Damaged terminal blocks or strips

2. Use an ohmmeter to check wiring continuity. 3. Repair or replace the wiring wherever a problem exists.

Troubleshooting Procedure

If a truck problem cannot be located in the wiring or a short-to-frame test, troubleshoot using the following procedure:

! CAUTION Disconnect the battery when checking electrical circuits with an ohmmeter. The battery current can damage the meter. 1. Determine exactly what operations the truck is failing to perform. 2. To accomplish this, it is often advisable to jack up and block the truck so the drive wheel is off the floor. Be sure the mast is supported by a suitable hoist so the truck does not tip over.

6-4

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Electrical

Shorts to the Truck Frame—Causes

A common cause of truck electrical problems is shorting to the truck frame that can be caused by: • Accumulation of dirt • Breakdown in insulation • Bare wires Shorts to the frame can occur at many locations including: • Battery • Motors • Cables • Buss bars • Heat sinks • Solenoids

Shorts to the Truck Frame—Checking

Check for shorts to frame using the following procedure:

! CAUTION Unplug the battery; battery current can damage the meter. 1. Use an ohmmeter set to Rx10,000 scale. 2. Connect one lead to the truck frame and the other to different points in the electrical system, for example, terminal strips, contactors, wire connections, and so on. 3. If the ohmmeter registers less than two megohm, the short within the particular circuit must be located. 4. Reverse the leads and repeat steps 3 through 5. 5. Remove the control fuses (FU4 and FU5). 6. For each fuse, make a connection between the battery side terminal and the truck frame with the ohmmeter. 7. Any reading below 200K ohms in the power system (motors) indicates unacceptable shorts somewhere in the system. 8. For each fuse, make a connection between the control side terminal and the truck frame with the ohmmeter. 9. A reading registering below 2 megohms on the meter indicates unacceptable shorts in the control system.

PDMM-0058

6-5

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Electrical

Voltage To Frame—Causes

Voltage grounds are the most common causes for system intermittent “overloads.” Voltage to frame leakage is a result of dirt accumulation and can occur at: • Motors • Heatsinks • Battery • Switches • Contactor panel • Cables and wiring

Voltage To Frame—Checking

Check for voltage to frame using the following procedure: 1. Use a voltmeter set to a voltage above that of the truck system. 2. Connect the voltmeter leads as follows:

Voltage to Frame— Eliminating

•

Positive lead to TP5; negative lead to truck frame.

•

Positive lead to truck frame; negative lead to TP4.

Voltage readings of 2 to 3 volts in either test should be eliminated. Eliminate the voltage to frame by isolating a particular area of the truck’s electrical system. Use the following procedure: 1. Connect the voltmeter leads as described in Step 2 above. 2. Remove the battery from the truck. Reconnect the battery to the receptacle. If the voltage drops, the battery needs cleaning or resealing. 3. If the battery checks good, reinstall it in the truck and:

6-6

•

Remove the fuses (one at a time). If the voltage drops when the fuse is removed, the defective circuit is isolated.

•

Disconnect the motor leads (one at a time). If the voltage drops, the motor needs cleaning or repair.

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Electrical

Board and Component Swapping Precautions

Troubleshooting by following the instructions given in this manual is usually more productive than swapping components until the problem is corrected. Bear in mind that the Interface Card Setup Procedure (see “Running Learn” on page 6-73) must be run after swapping, replacing, or adjusting any of the following components: • Throttle potentiometer (pot) • Interface card Every time a new Interface Card is placed into a truck, it must be Learned. Be particularly aware of this when swapping cards between trucks to isolate a problem. When swapping the Interface Card between a working and non-working truck, both must be re-Learned after finishing troubleshooting. Additionally, verify all DIP switch settings (see Figure 6-14 on page 6-76). When in doubt, run Learn after servicing a truck.

Troubleshooting Order for Component Failure

When troubleshooting a problem, some components should be suspected before others. This “suspect order” is based on either: • The probability of a particular component failing • The ease of replacing a particular component All troubleshooting is based on the following “suspect order:” 1. Wiring and terminal connections before circuit cards. 2. Hydraulic fluid contamination. 3. Component mis adjustment before component failure (throttle potentiometer). 4. Mast switches before other components. 5. Circuit cards are usually the last item to suspect.

Handling Printed Circuit Cards

PDMM-0058

For information on handling circuit cards, see “Proper Handling of Static Sensitive Devices” on page 5-5.

6-7

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Electrical

Cleaning and Inspecting the Contactors

Clean and inspect the contactors regularly to help ensure their proper operation. See “Planned Maintenance” on page 5-12 for the suggested service interval.

Inspecting

Visually inspect all parts for: • Nicks • Broken or damaged leads • Broken terminals or springs • Burned contact tips • Cracked or deteriorating bushings, insulation, or contact guards • Stripped threads • Other obvious damage

Inspection Guidelines

When inspecting the contactors, remember: • Darkening of points does not indicate burning. • Burning means loss of contact point material or droplets of molted contact material being displaced. • The contact can be used until the material is almost completely gone. • Replace the contact points if, in the opinion of the Maintenance Department, there is not enough contact point material to last until the next regular inspection. • The silver alloy part of the point is usable contact material; the copper backing is not. • Do not file the contact points to remove discoloration or minor irregularities. This is wasteful and produces a surface more susceptible to sticking. • If a cone and crater appear, remove the cone only with a file; do not use sandpaper or emery cloth.

Cleaning

To clean the contactors: • Wear safety glasses. • Remove dust, dirt, and other foreign materials from contactors with dry, filtered, compressed air (maximum 30 PSI [207 kPa]). • Use a cleaning solution on a clean cloth to remove stubborn dirt if necessary.

Replacing

6-8

The only replaceable components of the contactor assembly are the contactor tips. If any other segment of the contactor is found to be defective, the entire contactor assembly must be replaced.

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Electrical

Contactors Specifications

The contactors used in the Reach Truck are all General Electric brand contactors. The following table lists the specific contactors: If you suspect a defective contactor coil, before you replace the contactor, test the coil with an ohmmeter.

Contactor

Purpose

F&R

Forward Reverse

Type

Part Number

Gap Adjustment

NA010015

None

NA010034

None

NA010034

None

NA010016

None

24/36VDC 300 amp DPDT 24/36VDC

Lift Pump 300 amp SPNO 24/36VDC

High Speed 300A SPNO 24/36VDC

Auxiliary Pump 100A SPNO

Legend: Legend DT-Double Throw DP-Double Pole NC-Normally Closed

NO-Normally Open SP-Single Pole ST-Single Throw

Table 6-1: Contactor Specifications

PDMM-0058

6-9

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Electrical

Testing Other Electrical Components

Table 6-2 gives the recommended test procedures for electrical components not previously covered. Use an ohmmeter (Fluke 8060A or equivalent) to make the checks. The readings do not mean components checked will function properly in the system under different current and voltage conditions. The ohmmeter, however, will indicate most shorted or open circuited conditions.

! CAUTION Disconnect the component from the truck for testing.

Component

Meter Setting

Relay Coil

Rx1

Horn, Contactors, and Solenoids

Rx1

Connections

Readings

Between coil terminals

30-60 ohms. Ohmmeter should give a 10-15 ohm reading, depending on the component tested. • If the meter reads 0, the coil is shorted. • If the meter reading is over 100 ohms, the coil is open.

R x 10,000

Between each coil terminal and truck frame.

Ohmmeter shall not read less than 1 meg. Replace the coils that fail the check.

Table 6-2: Component Test Procedures

EV100LX Component Tests

This section explains how to test the rectifiers and capacitor.

Testing the REC1, REC2, and REC5 Rectifiers

To test the REC1, REC2, and REC5 rectifiers, do the following: 1. Connect a continuity test light with the positive lead on the Cathode and the negative lead on the Anode. The light should not come on, if it does, replace the rectifier. 2. Reverse the leads and the light should still not come on. 3. Using a jumper wire connected to the positive lead, touch the gate terminal. The light should now come on and should stay on even when you disconnect the gate lead. 4. After the flow has been stopped, the rectifier should have shut off and the light will not come on until positive is applied to the gate again.

Testing the REC3 and REC4 Rectifiers

6-10

Since these are simple diodes, the REC3 and REC4 rectifiers can be checked with any of three test instruments. PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Electrical

1. With the continuity light, connect the negative lead to the base or Anode and the positive lead to the pigtail or Cathode of the rectifier. The light should not come on. If it does, the diode is shorted and must be replaced. 2. Reverse the leads and the light should come on. If it fails to light, the rectifier is open and should be replaced. To check with a VOM: 1. Connect the negative lead to the base and the positive lead to the pigtail. You should read at least 50K ohms. 2. If reading is below this, the diode is shorted or possibly weak and leaking and should be replaced. 3. Reverse the leads. You should read about 7 to 12 ohms. If it is higher, the rectifier should be replaced. Minor differences in tolerances, test instrument batteries, and leads or connections can make the readings vary. Testing the 1C Capacitor

The 1C Capacitor cannot be checked with a continuity tester. It can be checked with a VOM, however, a visual inspection of the capacitor is nearly as good as this test because most capacitor failures will result in the can swelling. To check with a VOM: 1. Disconnect it from the truck wiring and hook the meter leads to the terminals. Since the 1C Capacitor in the EV100 system is not polarity sensitive, it doesn’t make any difference which lead is on which terminal. 2. Turn the meter to the 22K resistance scale. You should see a gradual rise in ohms until the meter reads OL (overload). 3. Reverse the leads and you should see the capacitor discharge through the meter as the ohms gradually go down to zero and then recharge back up to OL.

PDMM-0058

6-11

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Hydraulics

Hydraulics It is important to keep accurate records of all hydraulic inspections and work performed on the trucks. Such records are helpful in determining: • Repair and maintenance costs • Reliability of components • Durability of hydraulic fluid • Scheduling of maintenance

Checking for Hydraulic Leaks

Hydraulic leaks can cause: • Load drop • Load drift • Bouncing carriage • Noisy pumps To check for hydraulic leaks, wipe all connections clean when checking for leaks. Remember. leaking fluid is likely to run down the underside of pipes and drip at low spots. Many situations cause hydraulic leakage. Any leakage inspection should include operating the units as well as connections.

! WARNING Use extreme caution while looking for high pressure hydraulic leaks. Personal injury can result if struck by a high pressure stream of hydraulic fluid.

6-12

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Hydraulics

The following table is a list of items to check for hydraulic leaks: Table 6-3: Checking for Hydraulic Leaks

Item

What to Check

Faulty Flexible Connectors

When installing a flexible connector, avoid twisting it which creates a strain on the joint.

Fitting

Do not spring a tube into place before tightening a fitting. The resultant stress can cause a leak.

Cracked or Bad Tubing Flare

Inspect all tubing before installation. Make sure when making the flare that it is the right size.

Foreign Material in the Flare

Make sure the flare is clean before installation.

Defective Threads

Check for leakage around the threads when installing new tubing.

Dirt Around the O-Rings

Thoroughly clean and lubricate any O-rings before installation.

Wrinkled or Flattened Tube

Use a known-to-be-good tube bender and carefully bend the tube.

Worn Packings

Examine packings for wear and leakage around the cylinder pistons. If the packing is too tight, abnormal friction and wear will occur. See that cylinders are securely anchored and that pistons are in alignment. Misalignment is a cause of heavy wear of both pistons and packings. Worn packings should be replaced because they can cause internal leakage. If the truck is slugglish, check the packing inside the cylinder.

Bad Connections

When checking connections to pumps, cylinders, manifold valves, and so on, be sure to watch both pressure and suction sides. Pressure side leaks can be found by wiping the connections and checking the accumulations of oil after a brief truck operation. Brushing soap solution on the joints can be helpful. Air leaks on the suction side of the various components can cause considerable trouble; listen for these leaks because they can lead to air bubbles in hydraulic oil. Suction leaks are always difficult to find, but they are important.

Drive Coupling Alignment

Check the alignment of the drive coupling between the motor and the pump. Also, check the motor as suggested in “Maintaining the Motor” on page 5-30. Be sure hydraulic fluid from a leak is not seeping onto the field windings and armature.

System Contamination

System contamination can cause erratic or slugglish operation of the lift or auxiliary functions, load drift, load drop, clogging, leaking, and damage to the valve and pump parts.

PDMM-0058

6-13

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Hydraulics

Table 6-3: Checking for Hydraulic Leaks (Cont’d)

Item

What to Check

Packing Disintegration

Examine the rod surfaces that contact the packing. If these are nicked or scratched, they should be resurfaced or replaced.

Cylinder and Piston Packing Wear

If a hydraulic cylinder is disassembled, inspect the inside of the cylinder housing. If the inside cylinder surface is scored, packing grit is probably in the hydraulic fluid.

Hydraulic System Oxidation

Oxidation can cause internal rusting and sludge. Use a top grade oil with additives. See the “Lubrication Equivalency Chart” on page A-2.

Opening the Hydraulic System

Whenever a hydraulic system is opened, all hoses should be capped or plugged to keep out dirt and moisture-laden air. Examine pipe fittings and hoses to be certain there are no seal particles, nicks, burrs, or dirt present when reassembling the parts. Wipe all fittings before reconnecting them.

Clogged Filter

If the filter becomes clogged in less than the recommended change interval, the bypass valve will allow contaminants into the system. Inspect, clean and replace the element whenever contamination is evident. If severe contamination occurs, drain the system, flush all components, and replace the oil and filter.

6-14

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Hydraulics

Maintenance Tips

The following table provides some maintenance tips:

! CAUTION Never use pipe joint compound on hydraulic fittings. Joint compounds can dissolve, contaminating the oil.

Task

Procedure

Cleaning Hydraulic Components

• Dip in clean kerosene or equivalent light solvent. • Wash them off. • Blow them dry using dry, compressed air.

Replacing or Reinstalling Hydraulic Cartridge Valves

• Dip the cartridge in hydraulic oil. Ensure the O-ring is well lubricated. Screw them in by hand until the outer O-ring touches the manifold. • Use a wrench to tighten them. Tighten the cartridge 1/2 turn then back off 1/4 turn. Continue this process until the cartridge is tight. Tightening the O-ring components in this manner will prevent damage to the O-ring seal.

Replacing or Reinstalling Hydraulic Seals

• Immerse the compounds with spring chambers in hydraulic oil. • Activate the spring to remove any air.

After locating and repairing any leak or other problem, fill the reservoir and bleed the system.

! CAUTION When clamping the lift/lower manifold in a vise, ensure the valve body is not damaged because this might void the warranty.

PDMM-0058

6-15

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Hydraulics

Avoiding Hydraulic Problems

Follow these procedures to avoid hydraulic problems. Item

Action

Hydraulic Oil

Check regularly for the correct level and for the presence of contaminants or bubbles.

Reservoir Oil

Change semi-annually.

Reservoir Strainer

Clean semi-annually.

New Oil

Use only clean containers. Pass all oil added to the reservoir thru a 25 micron rated filter.

Filling cap Air Vent

Check for possible clogging.

Return Filter

Replace semi-annually.

! CAUTION Do not use brake fluid in the hydraulic system.

Lift/Lower Hydraulic System Troubleshooting If... The load drifts excessively (more than 3 inches in 10 minutes with a 3000# load).

The forks begin to drop while LIFT is actuated.

The following table is designed to refer service personnel to diagnostics and procedures that should aid in pinpointing and eliminating problems in the lift/lower hydraulic system.

Then...

Perform Steps...

The lift relief valve might be faulty or maladjusted.

4,1,2,3,5

Load holding check valve might be faulty.

1,2,3,5

L/L SOL might be faulty.

1,2,3,5

Lift relief valve might be faulty. 4,1,2,3,5

Note: The steps shown are found below; do them in the order listed in this table.

6-16

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Hydraulics

Steps for Locating Problems in the Lift/Lower System

These checks and procedures are designed to aid in locating the cause of trouble in the lift/lower system. 1. Check the operation of the indicated component: •

Solenoids: Remove, energize, watch for spool or poppet motion, listen for click of plunger.

•

Relief valves: Check the poppet for sticking; back off adjustment (counterclockwise) if necessary.

2. Check the indicated component for contamination: •

Visually inspect for metal chips, grit, teflon tape bits.

•

Remove foreign material.

•

Inspect the sealing surfaces for damage.

3. Check the O-rings and the backup rings; Replace the seals if any doubt exists or if they are: •

Nicked

•

Extruded

•

Deformed

4. Readjust the relief valves to factory specifications. 5. Replace the indicated component. If any doubt exists about the operation or condition of a component, the factory recommends replacing it.

PDMM-0058

6-17

Chapter 6: Troubleshooting

Mitsubishi® Reach Service Manual

Hydraulics

Pump Problems Trouble Pump Not Delivering Fluid

Use this list to troubleshoot pump problems in the hydraulic system.

Probable Cause

Remedy

Fluid intake pipe in reservoir restricted.

Check all strainers and filters for dirt and sludge. Clean if necessary.

Air leaks at the intake. Pump not priming.

Check the inlet connections to determine where air is being drawn in. Tighten any loose connections. See that the fluid in the reservoir is at the proper level.

Fluid viscosity incorrect.

Completely drain the system. Add new filtered fluid of the proper viscosity.

Coupling or shaft sheared or disengaged.

Repair/replace pump.

Insufficient Pressure Build-Up

System relief valve set too low.

Use a pressure gauge to correctly adjust the relief valve.

Complete loss of flow from pump.

Broken relief inlet or pressure line.

Replace/repair as required.

Noisy pump caused by cavitiation.

Oil supply low.

Fill reservoir.

Oil too heavy.

Change to proper viscosity.

Oil filter plugged.

Clean filters.

Suction line plugged or too small.

Clean line and check for size.

Oil supply low.

Fill reservoir.

Contaminated oil.

Drain reservoir and refill with clean oil.

Setting of relief valve too high or too low.

Set to correct pressure.

Oil viscosity incorrect.

Drain reservoir and refill with proper viscosity oil.

Worn shaft seal. Broken diaphragm seal or backup gasket. Bearings out of position. Excessive internal wear.

Replace shaft seal. If replacing shaft seal does not stop leakage, the pump should be disassembled and checked or replaced.

Air leaking into suction line.

Tighten fittings.

Wrong kind of oil.

Drain and fill reservoir with non-foaming oil.

Oil overheating

Shaft seal leakage.

6-18

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Hydraulics

Trouble Pump making Noise

PDMM-0058

Probable Cause

Remedy

Pump intake partially blocked.

Check the fluid condition and if necessary, drain and flush the system. Refill with clean fluid of the correct viscosity.

Air leaks at the intake or shaft seal. (Oil in reservoir would probably be foamy).

Check the inlet connections and seal to determine where air is being drawn in. Tighten any loose connections and replace the seal if necessary. See that the fluid in the reservoir is at the proper level.

Coupling misalignment.

Check if the shaft seal bearing or other parts have been damaged. Replace any damaged parts. Realign the coupled shafts.

6-19

Chapter 6: Troubleshooting

Mitsubishi® Reach Service Manual

EV100LX Codes and Tests

EV100LX Codes and Tests Separate codes and tests are required to troubleshoot the EV100LX Solid-State Control System and the Interface Card System. Each series of codes and tests are in this chapter. The EV100LX codes and tests are displayed on the Operator Display; the Interface Card has a display built into the card. The Interface Card displays are not usually visible to the operator. Any codes associated with the traction and lift systems will be displayed on the Operator’s Display. Any codes associated with lift/lower systems and general truck status will be displayed on the Interface Card.

Troubleshooting the EV100LX Solid-State Control System

Follow the instructions outlined in the status code instruction sheets (starting on page 6-31) to troubleshoot the EV100LX Solid-State Control System (Figure 6-1 on page 6-22).

Identifying a Malfunction

If the truck malfunctions, a status code is displayed on the Operator’s Display. If the truck is not equipped with a display, plug in a handset into the logic card’s plug Y location and read the status code. With the status code number, follow the procedures outlined in the status code instruction sheets (starting on page 6-31) to determine the problem.

Replacing the Logic Card

Due to the interaction of the logic card with all truck functions, almost any status code or control fault could be caused by the logic card. After all other status code procedures have been followed and no problem is found, the logic card should then be replaced as the last option to correct the problem.

Wire Numbers

The wire labels on your truck should correspond to the labeling on the electrical schematic on page A-13.

Jacking the Truck

Before troubleshooting, jack up the wheels, disconnect the battery, and discharge the capacitor 1C. Reconnect the battery as needed for the specific check.

6-20

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Accessing the Terminals

If capacitor 1C terminals are not accessible, discharge the capacitor by connecting from the Silicon Controlled Rectifier (SCR) POS terminal to REC 2 anode. Check the resistance on an Rx1000 scale from frame to the SCR power and control terminals. A resistance of less than 20,000 ohms can cause misleading symptoms. Resistance less than 1000 ohms should be corrected first.

Visual Check

Before proceeding, visually check for loose wiring and signs of overheating of components.

PDMM-0058

6-21

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Z Plug Y Plug Terminals 1-6

Control Card Mounting Screws

Control Card

A and B Plugs

Mounting Screw

Figure 6-1:

6-22

EV100LX Silicon Controlled Rectifier (SCR) Control

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Using the LX Handset

Use the LX Handset (shown in Figure 6-2) to set up the EV100LX Controller Logic Card and to program changes (see Table 6-1 on page 6-9); it also prevents tampering by unauthorized personnel. The LX Handset is a multi-functional tool that consists of a lightemitting diode display, a keyboard, and an adjusting knob. The handset displays a status code to identify the latest fault that occurred in the truck, even if the fault condition does not currently exist. The LX Handset is available from the parts ordering system (P/N NA010031). HANDSET

CONT STORE

9 10 11 12 13 14 15

Figure 6-2:

LX Handset (P/N NA010031)

! WARNING Operating the Handset

Before connecting or disconnecting the handset, jack up the drive wheels, turn OFF the key switch, unplug the battery, and discharge the capacitors. The truck can be operated with the handset connected, however the adjustment knob must be set fully clockwise to ensure the control operates at full speed. To operate the handset, do the following: 1. At the SCR controller card, unplug the “Y” plug and plug in the handset at location “Y” on the card. 2. Connect the battery and turn ON the key switch; the following start-up display sequence (Figure 6-3) occurs:

PDMM-0058

6-23

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

START-UP DISPLAY SEQUENCE

Key Switch ON

Verify Display Segments for one second 8888

BDI Display or

Diagnosis override

Blank Display

with fault

(No BDI used) Run Mode

Diagnosis override

BDI Display or Blank Display

with fault

(No BDI used) Key Switch OFF Display traction hourmeter for four seconds

Display pump hourmeter for four seconds or Blank (If no Pump SCR used)

Figure 6-3:

6-24

Start-Up Display Sequence

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

! WARNING Function Set-Up Procedures

Before making any adjustments to the control, you must read and comprehend the operating and maintenance instructions (Chapter 3 and Chapter 5) in this manual. Failure to follow proper set-up procedures could result in malfunctions and damage to the truck. With the handset connected, hold down the CONT key and turn ON the key switch. This places you in the set-up mode, ready to monitor or adjust control function settings as outlined in the following chart: Action

Display Shows

Hold down CONT, turn ON key

8888

Push function number After one second time delay

Selected function number is displayed

085

Stored value for the function is displayed

(((085)))

Change value with adjustment knob

(((125)))

Push ESC

Segment check displayed

U005

Push CONT

Push STORE

Remarks

Displayed value will blink Value changes while blinking

125

New Value stored and blinking stops

8888

Segment check displayed

Note: “Push” means to depress the key for approximately one second. At this point, another function can be monitored or changed by pushing another function number, or the truck can be placed in the run mode by holding the ESC key down for one second or longer. The display will return to either the diagnostics mode, the Battery Discharged Indicator (BDI) display, or a blank display (if the BDI is not used and there are no fault codes). The truck can now be operated with the handset connected or the handset can be disconnected before operation. You can return to the segment check mode at any time by holding down the ESC key until 8888 appears on the display.

Handset Programmable Functions

PDMM-0058

The following table lists the programming functions for the LX handset.

6-25

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Table 6-4: Handset Programmable Functions

Function

Message

Description

Function 1 See Note 1

Stored Fault Code

WARNING: These settings must be made by authorized personnel only, following instructions supplied by the manufacturer. Card type selection (Function 17) must be made within the capabilities of the SCR control panel used and the supporting electromechanical device. Failure to comply with proper application standards could result in malfunctions and damage to the control and the motors. This function register contains the last fault that shut down truck operation (PMT type fault that is reset by cycling the key switch). This fault will be overwritten each time a new fault occurs and can be cleared from memory by adjusting the value to zero. Factory Set: 24V:0

Function 2

Creep Speed

Allows for the adjustment of the creep speed of the truck. A constant creep speed frequency will be maintained when an accelerator input voltage between 3.5 and 3.7 volts or an accelerator ohmic input between 4.7K ohms and 6K ohms is provided. It can be set from 5% to 15% of REC1 on time. Each unit on the handset is equal to .03% on time. For example, if 0=5%, a setting of 20 = 5.6%. Factory Set: 24V:153

Function 3

Controlled Acceleration and 1A Time

36V:0

36V:153

Allows for the adjustment of the rate of time it take for the control to accelerate to 96% applied battery voltage to the motor on hard acceleration. The 1A contactor will automatically close 0.2 seconds after the controlled acceleration stops and the throttle input is less than 0.5 volts or less than 50 ohms. It can be set from 0.1 to 22 seconds. Each unit on the handset is equal to 0.084 seconds. For example, a setting of 20 = 1.76 seconds. Factory Set: 24V:010 36V:010 Note: 000 is the lowest possible setting on the handset.

Function 4

Current Limit

Allows for the adjustment of the current limit of the control. This function is determined by the match of the control components with the motor installed in the truck. It must be set at Factory Specification or the truck will either underperform or the Controller might be damaged. Factory Set: 24V:061 36V:061 Note: 000 is the lowest possible setting on the handset.

6-26

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Table 6-4: Handset Programmable Functions (Cont’d)

Function

Message

Description

Function 5

Plugging Distance (Current)

Allows for the adjustment of the plugging distance of the truck (the distance a truck will travel before coming to a stop and accelerating in the other direction). The larger the current setting, the shorter the stopping distance. It can be set between 200 and 1000 amps. Each unit on the handset is equal to 3.14 amps. For example, a setting of 20 would be 200+20 x 3.14 = 263 amps. Factory Set: 24V: 095

36V:150

WARNING: Plug settings must be in accordance with Factory Setting. An excessively high setting could damage the controller or the drive motor. Function 6

1A Drop Out Current

Allows for the adjustment of the 1A contactor drop out current. The 1A contactor will be dropped out and the truck motor torque will be limited to SCR current limit when the set dropout current is reached. The setting is adjustable from 450 amps (unit 0) to 1260 amps (unit 250). Settings above 250 will disable this function and 1A dropout will not occur. Each unit is equal to 3.24 amps. For example, a setting of 20 = 515 amps. Factory Set: 24V:255

Function 7

Not Used

Function 8

Not Used

Function 9

Not Used

Function 10

Not Used

Function 11

Speed Limit 1

36V:255

Allows for the adjustment of the speed limit (maximum battery volts to the motor) when the SL1 limit switch input signal is received by the control card. SL1 limit switch is a normally closed switch connected to battery negative; the switch opening enables speed limit. The setting is adjustable from 0 to 180 (96% to 0% battery volts). Setting of 0 units will disable speed limit functions and allow top speed with no limit switch connected. Factory Set: 24V:106 36V:125 Note 2: Function 11 on the handset must be set to 125 to allow 3.5 mph speed limit.

PDMM-0058

6-27

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Table 6-4: Handset Programmable Functions (Cont’d)

Function

Message

Function 12

Speed Limit 2 See Note 3

Description Same as Function 11, except using limit switch for input. Factory Set: 24V:129 36V:145 Note 3: For trucks equipped with two switches on the mast, Function 12 on the handset must also be set at 145 to allow 2.0 mph speed limit.

Function 13

Speed Limit 3

Same as Function 11, except using SL3 limit switch for input. Factory Set: 150

Function 14

Internal Resistance Function

This function is used when the Battery Discharge Indicator is ON. Adjustment of this function will improve the accuracy of the BDI. In order to make this setting, the voltage drop of the battery under load must be determined, as follows: 1. Load the drive motor to 100 amps in 1A and record the voltage (Vo) at the SCR positive and negative power terminals. 2. Load the drive motor to 200 amps in 1A and record the voltage (Vl) at the SCR positive and negative power terminals. 3. Calculate voltage drop (Vd) as follows: Vd = Vo - Vl. 4. Use Table 6-5, “System Voltage Drop vs. Function Setting (Internal Resistance),” on page 6-30 to determine the setting, using the calculated Vd as a reference. Note: An alternate method of adjusting this function is provided in “Battery Discharge Indicator (BDI)” on page 523. Factory Set: 24V:025 36V:025

Function 15

Battery Volts

Allows adjustment of voltage range for trucks equipped with the Battery Discharge Indicator. In order for the BDI to function properly at 24 volts, the setting must be between 0 and 31 units. Factory Set: 24V:024

36V:036

Note: The following functions have function numbers larger than the numbers on the handset keyboard. To access these functions, push the CONT key and the number given in the following instructions at the same time.

6-28

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Table 6-4: Handset Programmable Functions (Cont’d)

Function

Message

Function 16 (push CONT and 1)

Pedal Position Plug

Description Allows adjustment of the stopping distance during plug range. Throttle position will reduce the plugging current to the current value set by this function as the control is returned to the creep speed position. The setting is adjustable from 100 amperes (unit 0) to 930 amps (unit 255). Each handset unit is equal to 3.2 amps. For example, a setting of 20 = 164 amperes. Factory Set: 24V:040

36V:040

To disable the throttle position plug function, adjust the current value to the same current value as the plug distance current. Example: If plug distance current (Function 5) is set at 500 amps, then set throttle plug current at 500 amps. With this setting, throttle position will have no effect on plugging distance. Function 17 (push CONT and 2)

Card Type Selection

Allows selection of the controller card type used with the customer application. The EV100LX controls offer a variety of options within each control type; the card must be programmed to “know” what options are on the truck control system. Each card contains a two-letter designation number. Replacement cards must match the current installed card number. Factory Set: 24V:022

Function 18 (push CONT and 3)

Steer Pump Time Delay

Allows for the selection of steer pump contactor pickup input, either deadman switch or directional switch closing and adjustment of the time delay for the contactor dropout. Settings from 0 to 128 control deadman switch operation and 199 to 255 control directional switch operation. Directional switch closure with dropout will occur 3.5 seconds after lever is returned to neutral; the contactor will also drop out 1.5 seconds after the deadman switch opens. This function can be adjusted from 1.5 seconds (unit 0) to 65 seconds (unit 128). In both situations each unit of the handset equals 0.5 seconds. For example, a setting of 149 = 10.5 seconds. Factory Set: 24V:002

PDMM-0058

36V:022

36V:002

6-29

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

System Voltage Drop vs. Function Setting

The following table lists the system voltage drop vs. the function setting: Table 6-5: System Voltage Drop vs. Function Setting (Internal Resistance)

Function Setting

6-30

Voltage Drop

Function Setting

Voltage Drop

11.44

01.04

0.780

00.99

05.72

00.95

04.57

00.91

03.81

00.88

03.27

00.85

02.86

00.82

02.54

00.79

02.28

00.76

02.08

00.74

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

GE Status Codes

PDMM-0058

This section lists the GE Status Codes.

6-31

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code Blank Display

Traditional EV100LX code descriptions have been modified to apply to this truck. Code schematics are for theory only; refer to the electrical schematic on page A-13 for troubleshooting. Status Code - Blank Display

No display on dash display or handset.

Memory Recall

Circuit

Display - see Figure 6-4.

Symptom

Display screen on dash display or handset is blank.

Possible Causes

• Blown Fuse (FU4). • Positive or negative control volts missing. Ensure that, with key switch on, voltage is present between PZ7(+) and PZ3 (neg.) and voltage is present between TB4(+) and PZ3 (neg.) • Open circuit between logic card Y plug and dash display or handset. Check for open circuit or loose connections between each wire going between logic card Y plug and dash display/ handset. • Defective dash display/handset; replace dash display/handset.

Status Indication Criteria

6-32

A blank display indicates a lack of input voltage to the logic card and/or display unit.

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Figure 6-4:

PDMM-0058

GE Status Code - Blank Display

6-33

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 01 Status Code - 01

No deadman switch input.

Memory Recall

Circuit

Traction - see Figure 6-5.

Symptom

Forward or reverse contactor will not pick up.

Possible Causes

Misadjusted or defective deadman switch. • Brakes not being released. •

Check switch to ensure proper closure.

•

Open circuit between battery positive and TB3.

•

Check for loose connections or broken wire between switch and TB3, between key switch and positive side of the deadman switch and between deadman switch and switch to TB4.

•

Check for loose connections or broken wire from TB4 and to TB3.

• Other symptoms not allowing brake release.

Status Indication Criteria

6-34

•

Check for error codes on the Interface Card.

•

If truck is equipped with electronic power steering, check for error code.

•

Check status of emergency disconnect switch.

Status Code 01 indicates that TB3 is less than 50% battery voltage.

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Figure 6-5:

PDMM-0058

GE Status Code - 01

6-35

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 02 Status Code - 02

Forward directional request on initial power up.

Memory Recall

Circuit

Traction - see Figure 6-6.

Symptom

Forward contactor will not pick up static return to off (SRO) lock out.

Possible Causes

Forward directional request on initial power-up (closure of battery plug, key switch, or deadman switch). • Return directional controller to neutral and select a direction. •

Directional potentiometer (variable resistor) is defective.

•

Over the mast cable.

•

Interface Card is malfunctioning.

Short circuit between TB2 and TB5 • Disconnect wire from TB5 and check for short circuit between TB2 and wire. Defective Card. • Disconnect wire at TB5. Measure voltage at TB5; should be less than 60% of battery volts. Status Indication Criteria

6-36

Status Code 02 indicates that TB5 is greater than 60% battery volts at initial power-up.

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Figure 6-6:

PDMM-0058

GE Status Code - 02

6-37

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 03 Status Code - 03

Reverse directional request on initial power up.

Memory Recall

Circuit

Traction - see Figure 6-7.

Symptom

Reverse contactor will not pick up static return to off (SRO) lock out.

Possible Causes

Reverse directional request on initial power up (closure of battery plug, key switch, or deadman switch). • Return directional switch lever to neutral and select a direction. •

Mast cable

•

Directional pot (variable resistor)

•

Over the mast cable

Short circuit between TB2 and TB6 • Disconnect wire from TB6 and check for short circuit between TB2 and wire. Defective Card. • Disconnect wire at TB6. Measure voltage at TB5; should be less than 60% of battery volts. Status Indication Criteria

6-38

Status Code 03 indicates that TB6 is greater than 60% battery volts at initial power-up.

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Figure 6-7:

PDMM-0058

GE Status Code - 03

6-39

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 04 Status Code - 04

Start switch input low after initial start up.

Memory Recall

Yes

Circuit

Traction - see Figure 6-8.

Symptom

Forward or reverse contactor will not pick up.

Possible Causes

Forward or reverse directional request on initial start-up. • Advance throttle to initiate start. Status code will change to 03 if reverse is requested or to 02 if forward is requested. If either code appears, return directional controller to neutral then select desired direction. • Relay K2 defective. • Open wire. • EV100 Control Card defective. Excessive leakage from TB2 to battery negative. • Check voltage at TB2 with key switch and deadman switche closed and directional switch in neutral. Voltage should be greater then 60%, remove wire and measure ohmic value from wire to SCR negative. Value should be less than 22k ohms. • Check for code on Interface Card.

Status Indication Criteria

6-40

Status Code 04 indicates that TB2 voltage is less than 60% of battery volts at initial start-up (seat switch closure).

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Figure 6-8:

PDMM-0058

GE Status Code - 04

6-41

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 05 Status Code - 05

Start switch or brake switch fails to close.

Memory Recall

Circuit

Traction - see Figure 6-9.

Symptom

Forward or reverse contactor will not pick up.

Possible Causes

Defective deadman switch circuit. • Check brake switch to ensure closure with brake pedal activated. • Check for open circuit or loose connections in wiring from Interface Card to TB3. Defective accelerator circuit. • Check start switch to ensure closure when throttle is advanced. EV100 Control Card defective. • Check for code on Interface Card. • Check for open circuit or loose connections in wiring from brake switch to start switch and from TB2 to start switch.

Status Indication Criteria

6-42

Status Code 05 indicates that TB1 is less than 2.5 volts and TB2 is less than 60% volts.

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Figure 6-9:

PDMM-0058

GE Status Code - 05

6-43

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 06 Status Code - 06

Throttle advanced with no direction selected.

Memory Recall

Circuit

Traction - see Figure 6-10.

Symptom

Forward or reverse contactor will not pick up.

Possible Causes

Throttle is advanced before closing forward or reverse directional switch. Status code will disappear when directional switch is closed or when throttle is released. Defective directional switch. Check forward or reverse switch to ensure closure when direction is selected. Open circuit between directional switch(es) and battery positive or between directional switch(es) and TB5 or TB6. Check all control wires and connections shown in illustration. EV100 Control Card defective. Check for code on Interface Card.

Status Indication Criteria

6-44

Status Code 06 indicates that TB5 and TB6 are less than 60% of battery volts, and TB1 is less than 2.5 volts.

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Figure 6-10:

PDMM-0058

GE Status Code - 06

6-45

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 07 Status Code - 07

Speed control input voltage too high.

Memory Recall

Circuit

Traction - see Figure 6-11.

Symptom

Forward or reverse contactor picks up, but control will not operate when throttle is advanced or Status Code 07 appears then disappears when the truck starts to accelerate.

Possible Causes

Accelerator input misadjusted or defective. • Input voltage at TB1 should be less than 3.7 volts. Adjust or replace accelerator unit to ensure that the voltage at TB1 will vary from 3.5 volts to less then 0.5 volts when the pedal is pressed. Open circuit between battery negative and TB1 in accelerator input circuit. • Check for broken wires, loose connections or open potentiometer/voltage supply in the circuit shown in the illustration. Short circuit from battery positive to wiring in accelerator input circuit. • Disconnect wire from TB1 and measure voltage at wire to negative. Voltage should be zero for potentiometer type and less than 3.7 volts for solid-state type accelerator input. Defective EV100 Control Card. • Check for code on Interface Card.

Status Indication Criteria

6-46

Status Code 07 indicates that accelerator input voltage at TB1 is higher than 3.7 volts, and a directional contactor is picked up.

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Figure 6-11:

PDMM-0058

GE Status Code - 07

6-47

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 08 Status Code - 08

Speed control input voltage too low on power-up after initial key switch closure.

Memory Recall

Circuit

Traction - see Figure 6-12.

Symptom

Forward or reverse contactor will not pick up.

Possible Causes

Speed control input misadjusted or defective. • Input voltage at TB1 should be more than 3.0 volts. Adjust or replace accelerator unit to ensure that the voltage at TB1 is more than 3.0 volts before advancing throttle. Short circuit between battery negative and TB1 in accelerator input circuit. • Disconnect wire from TB1. Check for short circuit from wire to battery negative. Resistance should be greater than 4.7K ohms. Defective card. • Disconnect wire from TB1. Measure voltage from TB1 to negative. Voltage should be greater than 4.5 volts. If not, replace card. Defective EV100 Control Card. • Check for code on Interface Card.

Status Indication Criteria

6-48

Status Code 08 indicates that speed control input voltage at TB1 is less than 3.0 volts, and any of the following connections are opened and closed: battery plug, deadman switch or key switch.

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Figure 6-12:

PDMM-0058

GE Status Code - 08

6-49

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 09 Status Code - 09

Both forward and reverse directional switches are closed at the same time.

Memory Recall

Circuit

Traction - see Figure 6-13.

Symptom

Forward or reverse contactor will not pick up.

Possible Causes

Forward or reverse directional switch is welded closed or mis-adjusted to be held close. • Replace or adjust directional switches to ensure that they open when directional switch is returned to neutral. Short circuit between battery positive and TB5 or TB6. • Disconnect wires from TB5 and TB6. Check for short circuit to positive side of directional switch. Defective card. • Disconnect wires and measure voltage at TB5 and TB6. Voltage should be less than 60% of battery volts. Defective EV100 Control Card. • Check for code on Interface Card.

Status Indication Criteria

6-50

Status Code 09 indicates that TB5 and TB6 are greater than 60% of battery voltage at the same time.

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Figure 6-13:

PDMM-0058

GE Status Code - 09

6-51

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 15 Status Code - 15

Battery volts too low.

Memory Recall

Circuit

Traction

Symptom

Forward or reverse contactor will not pick up.

Possible Causes

Discharged battery. • Check battery for proper open circuit voltage as outlined in illustration and charge battery if required. Defective battery. • Check each battery cell for battery being used. See handset instruction sheet for details. Adjust to proper settings. Incorrect control card adjustment. • Check function 15 for proper adjustment for battery being used. See handset instruction sheet for details. Adjust to proper settings.

Status Indication Criteria

Status Code 15 indicates that battery volts are less than 1.95 volts per cell at initial startup (see Table A below). Battery Connection Table A

Battery

Battery Connection

6-52

Nominal Battery Volts

Minimum Limit Volts @ 1.95

23.4

35.1

46.8

70.2

81.9

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 16 Status Code - 16

Battery volts too low.

Memory Recall

Circuit

Traction

Symptom

Forward or reverse contactor will not pick up.

Possible Causes

Incorrect control card adjustment. • Check function 15 for proper adjustment for battery being used. See handset instruction sheet for details. Adjust to proper settings. Open circuit in regen sensor-circuit. • Check yellow wire from sensor #2 to PA4 for broken wire, loose connections or broken weld at sensor. Check PA4 for loose plug or pin connection. Battery overcharged or incorrect battery used. • Check battery for proper open circuit voltage per Table A. If voltage is excessive, check battery charger for proper output voltage.

Status Indication Criteria

Status Code 16 indicates that battery volts are greater than 2.40 volts per cell at initial start-up (see Table A below).

Sensor #2 P

Yellow

Battery Connector

REC7 7 REC PA4

Table A Battery

Battery Connector

PDMM-0058

Nominal Battery Volts 24 36 48 72 84

Minimum Limit Volts @ 1.95 23.4 35.1 46.8 70.2 81.9

6-53

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 17

6-54

Status Code - 17

Invalid card type selection.

Memory Recall

Circuit

Traction

Symptom

Forward or reverse contactor will not close.

Possible Causes

Invalid card type selection.

Status Indication Criteria

Status Code 17 indicates that card type selection value is set to an invalid number.

• Review function 17 in the handset instruction sheets. Adjust and set card type value as instructed by the service manual.

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 23 Status Code - 23

Forward or reverse contactor coil current low.

Memory Recall

Circuit

Traction

Symptom

Forward or reverse contactor will not pick up. Status code can alternate between code 23 and 24. Complete check for code 23. If the problem is not found, perform check for code 24.

Possible Causes

Defective F and R contactor coil circuit. • Check for open circuit or loose connection between PB4 and positive side of F contactor coil and between PB5 and positive side of R contactor coil. • Remove plug B. Check ohmic value from PB4 to positive side of F coil. Value should be 10-14 ohms. Make same check for R coil. Defective 1A contactor coil. • Remove plug B. Check ohmic value from positive side of each coil to its respective plug connection. Value should be 10-14 ohms.

Status Indication Criteria

Status Code 23 indicates that the current draw in the forward or reverse contactor coil is less than 100 ma.

F PB4 PB5 PB6 PB2 PB3

R 1A RB PS FW

PB1

PDMM-0058

6-55

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 24 Status Code - 24

T2 Voltage too high. (Greater than 12% of battery voltage).

Memory Recall

Circuit

Traction

Symptom

SCR control does not operate. Status code can alternate between 23 and 24. Complete check for 24. If problem is not found, perform check for 23.

Possible Causes

Defective F and R contactor. • F or R power tips fail to close because: a. Welded normally closed power tips. b. Binding contactor tip assembly. c. Defective F or R contactor coil (Status Code 23). • Open motor circuit. a. Check for open circuit or loose connection in motor circuit from A1 connection to A2 connection on SCR control panel. b. Defective 1A contactor. c. Perform checks as outlined in Status Code 23.

Status Indication Criteria

Status Code 24 indicates that T2 volts are greater than 12% of battery voltage, and the F and R driver is energized.

T2 F

A1 A2 A2

6-56

S1 S2 Field

R A1 Armature

PB4 PB4 PB4 PB4 PB4 PB4

R 1A RB PS FW

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 25 Status Code - 25

1A contactor does not drop out or drops out slowly.

Memory Recall

Yes

Circuit

Traction

Symptom

Short trip life on F and R or 1A contactor. Status Code 46 displayed and no fault was found.

Possible Causes

This status code can be found only by using the handset and looking at function 1. This status code is furnished as a troubleshooting aid for status code Status Code 46. Defective 1A contactor. • Check 1A contactor for binding or slow operation when dropping out.

Status Indication Criteria

Status Code 25 indicates that 1A contactor dropout time exceeds 0.060 seconds.

PDMM-0058

6-57

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 41 Status Code - 41

Open thermal protector or control over temperature.

Memory Recall

Circuit

Traction

Symptom

Reduced power or no power to traction motor in SCR range.

Possible Causes

Open thermal protector circuit. • Check for loose connection or broken wire between: Black wire - thermal protector and PZ1. Gray wire - thermal protector and PZ5. Defective thermal protector. • Disconnect wires from PZ1 and PZ5. At room temperature (25oC/75oF), measure resistance between black and gray wire. • Replace TP if ohmic value is greater than 300 ohms. SCR is in thermal cut-back • Allow control to cool; status code should disappear.

Status Indication Criteria

Status Code 41 indicates that voltage between PZ1 and PZ5 is greater than 1.8 volts.

Black

Thermal Protector

6-58

Gray

PZ1

PZ5

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 42 Status Code - 42

SCR motor current sensor input missing.

Memory Recall

Circuit

Traction

Symptom

No power to traction motor in SCR range.

Possible Causes

Open sensor wire circuit to PZ4.

Status Indication Criteria

Status Code 42 indicates that voltage between PY7 and negative is greater than 1.6 volts with no current flowing in the motor circuit.

• Check for loose connection or broken wire (green wire) from current sensor to PZ4 on the logic card.

SCR Current Sensor

Green

PZ4

Negative

PDMM-0058

6-59

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 43 Status Code - 43

SCR motor current sensor input missing.

Memory Recall

Circuit

Traction

Symptom

Stall currents in SCR range are higher than normal and uncontrollable with C/L adjustment.

Possible Causes

Open sensor wire circuit to PZ3.

Status Indication Criteria

Status Code 43 indicates that voltage between PY7 and negative is less than 0.84 volts with no current flowing in the motor circuit.

• Check for loose connection or broken wire (yellow wire) from current sensor to PZ3 on the logic card.

SCR Current Sensor

Yellow

PZ3

Negative

6-60

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 44 Status Code - 44

REC 1 did not turn off properly.

Memory Recall

Yes

Circuit

Traction

Symptom

Forward or reverse contactor opens, closes, and then opens again and can only be closed by opening and closing the key switch.

Possible Causes

Defective REC 5 circuit. • Check for shorted REC 5. • Check for shorted REC 5 snubber (REC 25). Defective REC 2 circuit. • Check for shorted REC 2. • Check for shorted REC 2 snubber (REC 22). Open choke (1X). • Check for open circuit between T5 and T3. • Ohmmeter should read zero ohms. REC 1 is defective. • Turn off time for REC 1 out of specification. No field test is possible. Replace REC 1 after above checks show no problem found.

Status Indication Criteria

Status Code 44 indicates that REC 1 fails to turn off during SCR operation.

P 1 REC

2 REC

T5 Choke X1

22 REC 5 REC

25 REC

PDMM-0058

6-61

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 45 Status Code - 45

REC 1 did not turn on properly.

Memory Recall

Yes

Circuit

Traction

Symptom

Forward or reverse contactor opens, closes, and then opens again and can only be closed by opening and closing the key switch.

Possible Causes

Defective REC 2 circuit. • Check for shorted REC 2. • Check for shorted REC 2 snubber (REC 22). Defective REC 1 circuit. • Check for open circuit or loose connections between REC 1 and PZ8 (white/blue wire). • Check for open circuit or loose connection between REC 1 (REC 3 snubber) and PZ9 (blue wire). Defective REC 1. • Intermittent or open REC 1 gate. Field test might or might not show defect. Replace REC 1 after above checks show no problem found.

Status Indication Criteria

Status Code 45 is displayed when REC 1 fails to gate on.

1 REC

White/ Blue Blue

PZ8 PZ9 2 REC

22 REC

6-62

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 46 Status Code - 46

Look ahead test for T2 volts (greater than 85% of battery voltage).

Memory Recall

Circuit

Traction

Symptom

Forward or reverse contactor will not pick up.

Possible Causes

Defective REC1. • Check for shorted REC1. • Check for defective REC 1 insulator (co-therm) that can short REC 1 heatsink to base plate. Defective 1A contactor. • Check for welded 1A contactor power tips.

Status Indication Criteria

Status Code 46 indicates that voltage at T2 is greater than 85% of battery volts.

P 1 REC 1A

PDMM-0058

6-63

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 47 Status Code - 47

REC 2 does not turn on properly.

Memory Recall

Yes

Circuit

Traction

Symptom

Forward or reverse contactor opens, closes, and then opens again and can only be closed by opening and closing the key switch.

Possible Causes

Defective REC 2 circuit. • Check that REC 2 will gate on. • Check for open circuit or loose connections between REC 2 and PZ10 (white/red wire). • Check for open circuit or loose connection between REC 1 and 1C through the REC 2 circuit. F or R contactor or power tips bouncing open. • Check that power tips on F and R contactors do not bounce open during operation (i.e., travel over speed bumps or dock plates).

Status Indication Criteria

Spider

Status Code 47 is displayed when REC 2 fails to turn on.

Bus A

5 REC Bus B

2 REC

Red Wire

White/Red Wire PZ10 White/Red Wire

2 REC

6-64

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 48 Status Code - 48

Look ahead test for T2 volts (less than 12% of battery voltage).

Memory Recall

Circuit

Traction

Symptom

Forward or reverse contactor will not pick up.

Possible Causes

Defective forward or reverse contactor power tips. • Check for welded forward or reverse contactor power tips. • Check for sluggish operation of forward or reverse contactor. Defective REC 3 circuit. • Check for shorted REC 3 snubber (REC 23).

Status Indication Criteria

Status Code 48 is displayed when the voltage at T2 is less than 12% of battery volts.

T2 F F

S2 Field

R R

A1 A2

23 FR.

3 REC

A2 SCR Current Sensor Negative

PDMM-0058

6-65

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 49 Status Code - 49

REC 5 does not turn on properly.

Memory Recall

Yes

Circuit

Traction

Symptom

Forward or reverse contactor opens, closes, and then opens again and can only be closed by opening and closing the key switch.

Possible Causes

Defective REC 5 circuit. • Check for shorted REC 5. • Check for shorted REC 5 snubber (REC 25). • Check that REC 5 will gate on. • Check for open circuit or loose connection between REC 5 gate and PZ12 (white/violet wire). Shorted REC 2 circuit. • Check REC 2 and REC 2 snubber (REC 22) for short circuit. Defective capacitor circuit. • Check for open capacitor. • Check for loose connections at capacitor terminals.

Status Indication Criteria

White/ Violet

Status Code 49 is displayed when the REC 5 circuit fails to turn on.

PZ12

PZ14

Orange White/ Violet

X1 2 REC T5 Choke 2 REC

5 REC T4 25 REC

6-66

T3 Orange Wire

Reactor

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 50 Status Code - 50

Look ahead test for T2 volts (Greater than 12% of battery voltage)

Memory Recall

Circuit

Traction

Symptom

Forward or reverse contactor picks up. Control does not operate.

Possible Causes

Defective REC 2 circuit. • Open circuit or loose connection between spider assembly and REC 5 (BUSA). • Open circuit or loose connection between REC 5 and REC 2. • Open circuit or loose connection between REC 5 and PZ11 (red wire) and between REC 2 gate and PZ10 (white/red wire). • Check REC 2 to ensure that it will gate on.

Status Indication Criteria

Spider

Status Code 50 is displayed when REC 2 circuit fails to turn on at initial start up.

Bus A

5 REC Bus B

2 REC

Red Wire

White/Red Wire PZ10 White/Red Wire

2 REC

PDMM-0058

6-67

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 51 Status Code - 51

Excessive capacitor voltage when motor current is high.

Memory Recall

Yes

Circuit

Traction

Symptom

Forward or reverse contactor opens, closes, and then opens again and can only be closed by opening and closing the key switch.

Possible Causes

Excessive source inductance. • Tag lines without filters are being used. • Battery cables are too long. High peak current in motor. Shorted REC2 circuit. • Check for shorted field winding. • Check for shorted armature winding.

Status Indication Criteria

Status Code 51 is displayed when capacitor volts exceed 225 volts and motor current is greater than 300 amps.

T2 F F A1 Armature A2

S1 S2 Field

R R A1

A2 SCR Current Sensor Negative

6-68

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 52 Status Code - 52

Excessive capacitor voltage when motor current is low.

Memory Recall

Yes

Circuit

Traction

Symptom

Forward or reverse contactor opens, closes, and then opens again and can only be closed by opening and closing the key switch.

Possible Causes

Excessive source inductance. • Tag lines without filters are being used. • Battery cables are too long. Defective REC 4 circuit. • Check for shorted REC 4. • Check for open circuit or loose connection in REC 4 circuit. Defective REC 4 circuit. • Check for open circuit or loose connection in REC 3 circuit.

Status Indication Criteria

Status Code 52 is displayed when capacitor volts exceed 225 volts and motor current is less than 200 amps.

T2 F F

S1 S2 Field

R R

A1 Armature A2 A2 SCR Current Sensor

3 REC

4 REC

Negative

PDMM-0058

6-69

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 53 Status Code - 53

REC 1 fails to turn off during plugging cycle.

Memory Recall

Yes

Circuit

Traction

Symptom

Forward or reverse contactor opens, closes, and then opens again and can only be closed by opening and closing the key switch.

Possible Causes

REC 1 turn-off failure not related to plugging. • Stall truck in both directions and note any status codes displayed that more closely define the failure mode. Troubleshoot per new status code. REC 1 turn-off related to plugging. • check REC 4 circuit for open REC 4, loose or open cable/bus connections. • Check current sensor for loose or open connection in power circuit. Check yellow and green wire from sensor to logic card for open and loose connection. Defective motor circuit. • Check motor circuit for open or loose connections. • Check motor brushes for proper seating. F or R contactor power bouncing open. • Ensure that F and R contactor does not bounce open during truck operation (i.e., traveling over speed bumps and dock plates).

Status Indication Criteria

Status Code 53 is displayed when capacitor volts exceed 225 volts and motor current is greater than 300 amps.

T2 F

4 REC

A2 SCR Current Sensor

Green PZ4 PZ3 Yellow

Negative

6-70

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 54

PDMM-0058

Status Code - 54

Shorted F, R, or 1A contactor coil driver.

Memory Recall

Yes

Circuit

Traction

Symptom

Control will not operate.

Possible Causes

Defective logic card.

Status Indication Criteria

Status Code 54 is displayed when either the forward, reverse, or 1A contactor coil is shorted internal to the logic card.

• Replace logic card.

6-71

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting EV100LX Codes and Tests

Status Code - 57 Status Code - 57

Current sensor output voltage polarity check.

Memory Recall

Yes

Circuit

Traction

Symptom

Forward or reverse contactor opens, closes, and then opens again and can only be closed by opening and closing the key switch.

Possible Causes

Reversed yellow and green sensor wires. • Ensure that green wire connects to PZ4 with no open circuits, and yellow wire connects to PZ3 with no open circuits or loose connections. Reversed power cable connection. • Ensure that battery negative cable connects to SCR negative and motor A2 cable connects to SCR A2.

Status Indication Criteria

Status Code 57 is displayed when voltage input to PZ4 and PZ3 is the wrong polarity.

A2 A2 SCR Current Sensor

Green Yellow

PZ4 PZ3

Negative

6-72

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting the Interface Card System

Troubleshooting the Interface Card System The Interface Card (Figure 6-14 on page 6-76) incorporates a number of features to help facilitate debugging. These features fall into two groups: • Status codes • Diagnostic procedures Troubleshooting usually begins with a status code, which leads into one or more diagnostic procedures. See Table 6-7, “Interface Card Codes,” on page 6-77 for a listing of the codes. Based on the status, the service technician should read the corresponding status code explanation. The status code pages explain how the code is caused and what troubleshooting is necessary to isolate the problem. Often you are directed to run one or two more tests. If a particular test fails, then appropriate troubleshooting listed in that test’s section should also be performed. Generally, as long as the Interface Card is functioning enough to display a status code, then it can also run the setup procedure (Learn).

Running Learn

Some status or fault code conditions can be corrected by running Learn.. For example, the Throttle Potentiometer might stop at a different neutral setting than previously Learned. The troubleshooting section for the particular code will indicate if Learn should be run. Test mode does not depend on any of the Learned constants. Therefore, running Learn will never affect the results of any test. It is generally unproductive to indiscriminately run in the Learn mode as a response to every problem. However, as long as the Learn procedure is performed properly, there is no harm in running in the Learn mode, even when it was not required.

! WARNING

Setting up the Truck

Remove rings, watches, and all jewelry before doing any work on the truck. 1. Before working on the truck: a. Lower the load handling mechanism completely to the floor. b. All controls must be in neutral. c. Release any trapped pressure in the hydraulic system. d. Block the wheels to prevent movement of the truck. e. Disconnect the battery connector. f. Elevate the drive tire off the floor.

PDMM-0058

6-73

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting the Interface Card System

! WARNING Use extreme care whenever the truck is jacked up for any reason. Never block the truck between the telescopic and the floor. Use a suitable hoist to stabilize the mast. Keep hands and feet clear from beneath the truck while jacking. Use jack stands or solid blocks to support the truck; do not rely on jacks. See “Jacking the Truck” on page 5-3. 2. For 36-volt trucks, move Dip Switch S1-1 to the OFF or open position. Make sure that jumper E2 is in the 36V position (Figure 6-14 on page 6-76). 3. For 24-volt trucks, move Dip Switch to the ON or closed position. Make sure that jumper E2 is in the 24V position (Figure 6-14 on page 6-76). 4. Verify the throttle potentiometer neutral setting: a. Connect the voltmeter leads to TP2 (positive) and TP3 (negative) on the Interface Card next to the Dip Switches (Figure 6-14 on page 6-76). b. Connect the battery and turn the key switch ON. c. Adjust VR1 until the voltage at the test points indicate 2.50 volts. There is no tolerance for this setting. When complete, turn the key switch OFF and remove the meter leads. 5. Learn the throttle potentiometer: a. Move the Dip Switch S1-7 to the ON or closed position. b. Turn the key switch to ON. An "L" appears on the Interface Card Display. c. Return S1-7 to the OFF or open position. The horn sounds a single beep and a "J" appears on the display. Move the throttle control to full speed in the forks first direction. The horn will beep twice. Release the throttle control. A single beep from the horn indicates neutral. Now do the opposite direction and see a "0" on the display. d. Check that the Interface Card displays "0". The truck is now ready to operate. e. Fully engage the brake.

! CAUTION Do not release the brake while performing the following Step f. f. Verify speed control to the GE EV100 Control by measuring voltage at TB1 (positive) and TP4 (negative) on the Interface Card while applying full throttle in either direction. Voltage should be less than or equal to 0.5 volts.

6-74

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting the Interface Card System

g. Set Dip Switch S1 for truck options as follows: • One/Two-Speed Reach/Retract Option: For one speed, S12 should be OFF. For two-speed, S1-2 should be ON. • Lift Inhibit Option: With no lift inhibit, set S1-8 to ON. With lift inhibit, set S1-8 to OFF. • Second Mast Switch Option: With no mast switch, set S1-4 to ON. With mast switch, set S1-4 to OFF. Settings S1-3, S1-5, and S1-6 are not used on all trucks. h. Verify Interface Card is set correctly by measuring 22-25 volts across the lift contactors coil. If not, re-check switch S1-1 setting.

Interface Card Switch Settings

Table 6-6 provides a listing of switch positions and related functions. When individual switch tabs or Dip Switch S1 is in the lower position (near the indentation), it indicates that the switch is ON. Number and Position

Option Selected

S1-1 OFF

36-Volt Truck

S1-1 ON

24-Volt Truck

S1-2 ON

Two-speed Reach

S1-2 OFF

Single (High) Speed Reach

S1-3

Enables Tilt - see Note

S1-4 ON

Second Mast Switch Not installed on truck.

S1-4 OFF

Second Mast Switch installed on truck

S1-5

Enables Sideshift - see Note

S1-6

Enables Reach - see Note

S1-7 ON

Learn mode in process

S1-7 OFF

Normal run position

S1-8 ON

Without lift inhibit option

S1-8 OFF

With lift inhibit option

Table 6-6: Interface Card Settings

PDMM-0058

6-75

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting the Interface Card System

Interface Card Assembly

The following figure shows the Interface Card Assembly:

Figure 6-14:

6-76

Interface Card Assembly

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting the Interface Card System

Interface Card Codes

The following table lists the status codes that help troubleshoot the Interface Card. The codes are detailed on the following pages.

Code

Meaning

Performance Limit

No Error

None

Internal Error Detected

Truck Shutdown

Forward Contactor

Forward Direction Requested

Reverse Contactor

Reverse Direction Requested

Lift

Lift Requested

Lower

Lower Requested

Not Used

Throttle Potentiometer Out Of Range

Traction Shutdown

Lowering Error

Lower System Shutdown

Lifting Error

Lift System Shutdown

Not Used

Internal Error Detected

Truck Shutdown

Internal Error Detected

Truck Shutdown

Internal Error Detected

Truck Shutdown

Throttle Potentiometer must be Learned Via Learn Mode

Traction Shutdown

Move Throttle to Upper Limit during Learn Mode

Learning Throttle

Throttle Learn Mode

Traction Shutdown

Not Used

Unable to Program EEPROM

Traction Shutdown

Table 6-7: Interface Card Codes

PDMM-0058

6-77

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting the Interface Card System

Code 0 Code Title

No Error

Reason

The system is operating properly

System Response

1. Interface Card Display: 0 2. System Response: The heartbeat LED in the lower right corner of the display will blink at a rate of approximately 60 times per minute.

How to Clear

None

Corrective Actions and Checks

None

Code Title

Internal Error Detected

Reason

This is an internal problem with the Firmware on the Interface Card.

System Response

1. Interface Card Display:1

Code 1

2. System Response: Complete Shutdown How to Clear

Cycle the key switch OFF/ON.

Corrective Actions and Checks

If turning the key switch OFF/ON does not correct the problem, then replace the firmware first. If that doesn’t correct the problem, replace the Interface Card. Remember, if the firmware is replaced Learn must be run.

6-78

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting the Interface Card System

Code 2 Code Title

Throttle Request - Forward

Reason

The system has detected a throttle forward command.

System Response

1. Interface Card Display:2 2. System Response: Traction system drives in the forks-first direction.

How to Clear

None

Corrective Actions and Checks

None

Code Title

Throttle Request - Reverse

Reason

The system has detected a throttle reverse command.

System Response

1. Interface Card Display:3

Code 3

2. System Response: Traction system drives in the tractor-first direction. How to Clear

None

Corrective Actions and Checks

None

Code Title

Lift Request

Reason

The system has detected a lift command.

System Response

1. Interface Card Display:4

Code 4

2. System Response: Lift pump contactor coil is energized.

PDMM-0058

How to Clear

None

Corrective Actions and Checks

None

6-79

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting the Interface Card System

Code 5 Code Title

Lower Request

Reason

The system has detected a Lower command.

System Response

1. Interface Card Display:5 2. System Response: Load Holding Solenoid is activated.

How to Clear

None

Corrective Actions and Checks

None

Code Title

Throttle Potentiometer Out Of Range

Reason

The system has detected that the voltage from potentiometer VR1 is greater than 4.9 volts or less than 0.1 volts.

System Response

1. Interface Card Display: 7

Code 7

2. System Response: Throttle is disabled. Truck coasts to a stop. How to Clear

Turn key switch OFF/ON.

Corrective Actions and Checks

1. Try moving the throttle to a different position to see if the code clears. If the problem occurs repeatedly, have a technician check the output of VR1 through the entire range of handle movement. If the voltage is erratic, replace VR1. 2. Check for continuity, loose connections or shorted wires between VR1 and JPS1 on the Interface Card. 3. Check for +5 volts at JPS1-9 on the Interface Card with respect to TP4 on the contactor panel. If the voltage is not approximately +5 volts, replace the Interface Card. Remember to run Learn if VR1, firmware or the Interface Card is replaced.

6-80

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting the Interface Card System

Code 8 Code Title

Lowering Error

Reason

The reason will vary depending on the voltage of the truck. On a 24-volt truck, this code will be displayed: If lower is not requested and the voltage at the Load Holding Solenoid is less than 1 volt for at least 1/2 second. Or If lower is requested and the Load Holding Solenoid voltage is greater than 1 volt for 1/2 second. On a 36-volt truck, this code will be displayed: If lower is not requested and the voltage at the Load Holding Solenoid is less than 2 volts for at least 1/2 second. Or If lower is requested and the Load Holding Solenoid is greater than 2 volts for 1/2 second.

System Response

1. Interface Card Display: 8 2. System Response: Lower function is disabled.

How to Clear

Turn key switch OFF/ON.

Corrective Actions and Checks

1. Check the wiring between the Load Holding Solenoid and the Interface Card (JPS9-3/ JPS9-4). Check for both continuity and positive connections. •

With the key switch ON, there should always be B+ on pin 2 of the Load Holding Solenoid.

2. Connect a volt meter between JPS5-1 and TP4 on the contactor panel. Turn the key switch ON. If the voltage is less than 1 volt without a code on the Interface Card, replace the Interface Card. 3. Check the Load Holding Solenoid for proper resistance. Remember to run Learn if the firmware or Interface Card is replaced.

PDMM-0058

6-81

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting the Interface Card System

Code 9 Code Title

Lifting Error

Reason

This code will appear for either of the following: 1. If the voltage sensed at the lift contactor tip (JPS4-8 with respect to TP4 on the contactor panel) is greater than 6 volts for at least 1/2 second when lift is not requested. 2. If the voltage sensed at the lift contactor tip (JPS4-8) is less then 1.6 volts for at least 1/2 second when lift is requested.

System Response

1. Interface Card Display: 9 2. System Response: Lift function is disabled.

How to Clear

Turn key switch OFF/ON.

Corrective Actions and Checks

1. Check the wiring between the P contactor and JPS4 on the Interface Card for continuity and positive connections. 2. Connect a volt meter between the P contactor and JPS-4 and TP4 on the contactor panel. Turn the key switch ON. If battery voltage is measured, replace the Interface Card. 3. Replace the Load Holding Solenoid. Remember to run Learn if the Interface Card is replaced.

Code C Code Title

Internal System Error

Reason

This is an internal problem with the Firmware on the Interface Card.

System Response

1. Interface Card Display: C 2. System Response: Truck Shutdown

How to Clear

Turn key switch OFF/ON.

Corrective Actions and Checks

If turning the key switch OFF/ON does not correct the problem, then replace the firmware first. If that doesn’t correct the problem, replace the Interface Card. Remember to run Learn if the firmware or Interface Card is replaced.

6-82

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting the Interface Card System

Code E Code Title

EEPROM Checksum Error

Reason

This is an internal problem with the Firmware on the Interface Card.

System Response

1. Interface Card Display: E 2. System Response: Truck Shutdown

How to Clear

Turn the key switch OFF/ON.

Corrective Actions and Checks

Code F Code Title

Internal Error

Reason

This is an internal problem with the Firmware on the Interface Card.

System Response

1. Interface Card Display: F 2. System Response: Truck Shutdown

How to Clear

Turn the key switch OFF/ON.

Corrective Actions and Checks

PDMM-0058

6-83

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting the Interface Card System

Code H Code Title

Throttle Potentiometer (VR1) must be Learned.

Reason

A new firmware chip or new Interface Card has been installed.

System Response

1. Interface Card Display: H 2. System Response: Traction Shutdown

How to Clear

Run Learn.

Corrective Actions and Checks

Learn is required before the truck can operate.

Code Title

Move Throttle to Limits

Reason

System Learning Throttle.

System Response

1. Interface Card Display: J

Code J

2. System Response: Traction Shutdown How to Clear

Complete Learn.

Corrective Actions and Checks

When a J is displayed, the system is ready to have the travel potentiometer Learned (the horn will make a single beep). Move the travel control all the way towards the forks and hold. When the horn beeps twice, let the travel control return to neutral. When the travel control passes through neutral, the horn will beep once. Move the travel control all the way towards the tractor and hold. The horn will beep twice. When Learn is complete, the display will show a zero (0). The voltage from the travel potentiometer (VR1) to the GE EV100 system can be verified by measuring TB1 on the EV100 with respect to pin N on the GE EV100 controller. With the throttle against the stops in either direction, the voltage read should be a maximum of 0.5 volts.

6-84

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting the Interface Card System

Code L Code Title

Throttle Learn Mode

Reason

Learn has been started.

System Response

1. Interface Card Display: L 2. System Response: Truck Shutdown

How to Clear

Complete Learn.

Corrective Actions and Checks

A code L indicates that the system is being prepared to run Learn. When the truck is actually in Learn Mode, a Code J is displayed. See “Troubleshooting the Interface Card System” on page 6-73 for more information.

Code Title

Unable to Program EEPROM

Reason

Values obtained during Learn cannot be saved.

System Response

1. Interface Card Display: U

Code U

2. System Response: Traction Shutdown

PDMM-0058

How to Clear

Turn the key switch OFF/ON.

Corrective Actions and Checks

6-85

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting the Interface Card

Troubleshooting the Interface Card This section is for troubleshooting the truck when a system code is not displayed on the Interface Card or other troubleshooting has not resolved the problem.

Display on Interface Card is Dark

Symptom: Key switch ON, Display on Interface Card is completely dark: 1. Check FU4. FU4 protects the B+ supply to the Interface Card. 2. Check FU5. FU5 protects the B- (PGND/DGND) of the Interface Card. 3. Check key switch S1. 4. Check the continuity and connections of the wires between: •

B+ to TP5

•

TP5 to FU4-1

•

FU4-2 to S1-1.

•

S1-2 to JPS9-13 (B+ Key).

•

JPS4-7(PGND) and -8 (DGND) to FU5-2

•

FU5-1 to TP4 (or terminal N on the EV100 Panel)

•

TP4 to B-

5. Replace the Interface Card and Firmware. Remember to run Learn if the Interface Card is replaced.

No Auxiliary Functions; Aux. Motor Runs; Other Functions OK

Symptom: No auxiliary functions operate, truck travels normally, lift/ lower is OK. The auxiliary pump runs when the deadman pedal is pressed and steering is functional. 1. With the battery connected, check for B+ at: •

JPS9-15 (B+ Fused). If no B+, trace the wiring back to FU4-2.

•

JPS9-1 (B+ Fused). If no B+ is found, replace the Interface Card.

2. With the battery connected and the key switch turned ON, check for B+ at: •

JPS5-5 (B+ Key). If no B+ is found, replace the Interface Card.

•

Pin 2 of the reach, sideshift, and tilt solenoid coils. If no B+ is found, check the wiring between pin 2 of each auxiliary function to JPS5-5 (B+ Key) on the Interface Card.

3. Check for continuity between terminal 1 of each function to the respective connection at the Interface Card. 4. Replace the Interface Card and Firmware.

6-86

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting the Interface Card

Remember to run Learn if the Interface Card is replaced.

Auxiliary Motor Does not Run; Other Functions OK

Symptom: No auxiliary functions operate, truck travels normally. Lift/ lower is OK. The auxiliary pump does not run when the deadman pedal is pressed. 1. With the key switch turned ON, check for B+ at JPS4-5. If no B+ is found, replace the Interface Card. Remember to run Learn if the Interface Card is replaced. 2. Check for B+ at PB3 and TB4 on the GE EV100 controller. If no B+ is found, troubleshoot the circuit back to the Interface Card. This would include checking the wiring and auxiliary contactor coil for continuity. 3. If B+ is found at PB3 and TB4, check for B+ at TB3. If B+ is not at TB3, check for B+ (approx.) at JPS3-7. If not found, replace the Interface Card. If B+ is at JPS3-7 then troubleshoot the wiring between JPS3-7 and TB3. 4. If B+ is found at TB3, PB3 and TB4, the GE EV100 controller is defective.

One Auxiliary Function Is Inoperative

Symptom: One auxiliary function is inoperative; all other functions work properly. 1. The easiest way to isolate the problem is to remove the wires from the auxiliary coil that does not work and connect the wires to it from an auxiliary function that is OK. An example follows: a. Assume that reach does not work. The other functions are OK. Remove the wires from terminal 1 and 2 at the reach solenoid coil. b. Temporarily remove the wires from either sideshift or tilt and connect them to the reach solenoid coil. Make sure that you connect the wires to the correct terminals. c. Activate sideshift (or tilt). • If reach works then it is either defective wiring between terminal TS21-3 or the reach solenoid , and the Interface Card at JPS5-3. The Interface Card could be defective. • If reach does not work either the coil is not getting B+ from JPS5-5 on the Interface Card or the reach solenoid coil is defective. • If you know the coil is working properly and getting power, there might be a mechanical reason that the solenoid is not working. Chips or other contaminants in the hydraulic oil might have caused the solenoid to seize.

PDMM-0058

6-87

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting the Interface Card

2. When finished, ensure that all wiring is returned to the respective solenoid coils.

Auxiliary Functions Operate In Only One Direction: Steering OK

Symptom: Auxiliary functions work in only one direction, i.e., reach no retract; tilt down - no tilt up; sideshift right - no sideshift left. 1. Check SFC switches and wiring. 2. Check for B+ and the coils of DIRA/DIRB solenoids on the hydraulic manifold. NOTE: If both DIRA and DIRB solenoids can be activated, the problem might be a defective valve. 3. Check the valve by: a. Temporarily remove the solenoid retaining nut. b. Remove one solenoid from the stem; activate the remaining solenoid. c. Slide the activated solenoid up and down the stem; check that the related valve-controlled function (physical movement) follows the manual movements of the coil. d. Replace valve if movement does not occur.

No Lift

Troubleshoot EV100 lift interrupt, wiring, Interface Card B+, lift switch, relief valve, and manual valve.

No Lower

Check lower switch and load holding (L/H) solenoid.

No Travel, Other Functions OK

Symptom: The truck will not travel, all other functions OK.

6-88

Jack the truck up so that the drive tire is off the floor. 1. Press the deadman pedal, move the throttle and look at the display on the Interface Card. •

If you see 2 or 3 on the display it means that the throttle potentiometer is working correctly and that the processor on the Interface Card is OK. The problem could be caused by bad wiring, defective contactor coil, the GE EV100 controller, or the Interface Card.

•

If a 2 or 3 is not on the display, it means that the problem could be caused by K2, wiring, throttle potentiometer, or the Interface Card.

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting the Interface Card

Code 2 or 3 is NOT displayed when throttle is moved. 1. Check that the deadman switch (S2) operates properly. 2. With the pedal pressed, check for continuity between S1-2 and JPS9-14 (deadman coil Gnd). If continuity is not found, it might be caused by an open in the: a. wiring between S1-2 and S2-1. b. wiring between S2-2 and K2-1. c. coil of the K2 relay. If the coil, replace K2. NOTE: If K2 has failed, make sure that DIP switch S1-1 and jumper E2 are positioned properly on the Interface Card. See the table below: Truck Voltage

DIP Switch S1-1

Jumper E2 Position

OFF

d. wiring between K2-5 and JPS9-14 (deadman coil Gnd). 3. Check for the following values measured between JPS9-14 (deadman coil Gnd) and JPS4-8: Truck Voltage

Jumper E2 Position

Meter Reading

Continuity

Approx. 470 ohms

4. Check that the K2 relay is operating properly. With K2 energized (key switch ON, deadman down), B+ should be at terminal 3 on relay as well as JPS9-16 (deadman) on the Interface Card. If B+ is not found, replace the K2 relay. 5. Replace the Interface Card. Remember to run Learn if the firmware or Interface Card is replaced. Code 2 or 3 IS displayed when throttle is moved. 1. With the key switch ON and the deadman pedal pressed, check for B+ at TB2, PB4, and PB5 on the GE EV100 controller (all with respect to TP4). a. If B+ is not found, check the wiring between the GE EV100 and JPS4-4 (deadman) on the Interface Card. b. If the wiring in step (a) checks good, check for B+ at JPS4-4 (key switch ON, deadman pressed). If B+ is not found, replace the Interface Card. Remember to run Learn if the firmware or Interface Card is replaced.

PDMM-0058

6-89

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting the Interface Card

2. Check the contactor coils for opens or shorts. 3. Check the wiring between the GE EV100 controller and the Interface Card for continuity. 4. Check the voltage at TB1 on the GE EV100 controller. With the handle full forward or reverse, voltage should be 0.5 volts (the voltage in the neutral position should be 3.5-3.65 and changes in steps as a faster speed is requested). If voltage is not as specified: a. Check the voltage at TB5 and TB6; B+ should be present on one location. If not check the wiring. b. Disconnect wire from TB1 on the GE controller. Connect the meter to the end of the disconnected wire. If the voltage readings are still not correct, check the throttle potentiometer and wiring. c. If the throttle potentiometer and wiring check OK, replace the Interface Card. d. If the problem is still not corrected, replace the GE EV100 controller. Remember to run Learn if the firmware or Interface Card is replaced.

6-90

PDMM-0058

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting the Interface Card

No Speed Limit

Symptom: The truck will not limit the speed regardless of the position of the forks. Remember to turn the truck OFF each time you make or break an electrical connection. 1. Check to make sure that the GE EV100 is configured correctly for the speed limit option. a. If the truck has the first mast switch option (Mast SW1), Function 11 on the GE handset must be set to 125 to enable a speed limit of approximately 3.5 mph. 2. If the truck has the second mast switch option (Mast SW2), DIP switch S1-4 on the Interface Card should be set as follows: •

S1-4 OFF = speed limit enabled. Also, Function 12 on the GE handset must be set to 145 to enable a speed limit of approximately 2.0 mph.

•

S1-4 ON = speed limit disabled.

3. Turn the truck OFF. 4. Disconnect the mast switch (JPN7/JPN8) from the circuit. 5. Turn the truck ON. 6. If the truck is speed limited, the switch is defective. 7. Turn the truck OFF. 8. Disconnect JPN1 from the Interface Card. 9. Turn the truck ON. 10. If the truck is still not speed limited with JPN1 disconnected from the Auxiliary Interface Card, the cable is probably bad. This can be verified by checking the continuity of the cable. 11. If the truck is not speed limited and the cable checks good, replace the Interface Card. Remember to run Learn if the firmware or Interface Card is replaced.

PDMM-0058

6-91

Mitsubishi® Reach Service Manual

Chapter 6: Troubleshooting Troubleshooting the Interface Card

No Lift Inhibit

Symptom: The mast fails to stop elevating at the lift inhibit switch. Remember to turn the truck OFF each time you make or break an electrical connection. 1. Check that DIP S1-8 on the Interface Card is set properly. •

S1-8 OFF = lift inhibit option enabled.

•

S1-8 ON - lift inhibit option disabled

2. Turn the truck OFF. 3. Disconnect the lift mast switch (JPN12) and lift inhibit bypass switch (JPN13) from the Auxiliary Interface Card. If the forks will not elevate above the lift inhibit height, either the mast switch or bypass switch is defective. a. Turn the truck OFF. b. Connect the mast switch (JPN12) to the Auxiliary Interface Card. Leave JPN13 disconnected. c. Turn the truck ON. d. If the forks will not elevate above the lift inhibit height, the lift inhibit bypass switch is bad. If the forks elevate above the limit, replace the lift inhibit switch. 4. Disconnect JPN1 from the Interface Card. If the forks elevate, the Auxiliary Interface Card is defective. 5. If the forks do not elevate with JPN1 disconnected from the Auxiliary Interface Card, the cable is probably bad. This can be verified by checking the continuity of the cable. 6. If the forks elevate and the cable checks good, replace the Interface Card. Remember to run Learn if the firmware or Interface Card is replaced.

6-92

PDMM-0058

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics

Appendix A: Charts and Schematics This appendix contains the following:

Topic

PDMM-0058

See Page

Lubrication Equivalency Chart

A-2

Torque Chart - Standard (Ferrous)

A-5

Torque Chart - Standard (Brass)

A-6

Torque Chart - Metric (Ferrous)

A-7

Torque Chart - Metric (Brass)

A-7

Decimal Equivalent Chart

A-8

Standard/Metric Conversions

A-10

Electrical Schematic

A-13

Hydraulic Schematic

A-18

Decal Locations

A-19

Pin-By-Pin Voltages - EV100LX Travel Control System

A-21

EV100 Interface Card Troubleshooting Relationships

A-27

Brush Replacement

A-28

A-1

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Lubrication Equivalency Chart

Lubrication Equivalency Chart Table A-1: Lubrication Equivalency Chart

Approved Mitsubishi Lubricants Where Used

Type

Drive Unit Gear Case (above 30° F/-1° C)

Gear Lubricant

Drive Unit Gear Case (below 30° F) (below -1° C) Lift Chains

Oil

Approved Manufacturer Forsythe Ltd.

Mitsubishi Part Number 219440 (1 quart/0.9 liter)

Shell Spirax HD Chevron Delco 400 15W-40 API Service SE

219405 (1 quart/0.9 liter)

Citgo C-6 10W-30 Motor Oil MIL-H46152 Exxon Extra Motor Oil 10W-30 API Service SE Gulflube Motor Oil X.H.D. 10W-30 Mobil Delvac Special 10W-30 API Service SE Phillips Trop-Arctic All Season Motor Oil 10W-40 MIL-L-46152 Shell Rotella T 15W-40 API Service SE, CC and CD Sohio Multron 10W-30 MIL-L-46152 API Service SE Texaco URSATEX 10W-30 2166

A-2

PDMM-0058

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Lubrication Equivalency Chart

Table A-1: Lubrication Equivalency Chart (Cont’d)

Approved Mitsubishi Lubricants Where Used Hydraulic Reservoir (non-cold storage trucks)

Type Hydraulic Fluid

Approved Manufacturer Chevron AW ISO 46

Mitsubishi Part Number 219440 (1 quart/0.9 liter)

Citgo 46 Exxon Nuto H 46

1008835 (5 gal./18.9 liters)

Forsythe AWTH215 ISO46 Mobil DTE-1B NOCO NOCOLUBE AW46 Texaco Cygnus 46 or HD 46 Ultramar Ultra Hydraulik AW46 Hydraulic Reservoir (cold storage trucks) (+40° F to -20° F) (4° C to -29° C)

Hydraulic Fluid

Hydraulic Reservoir (cold storage trucks) (20° F to 70° F) (-6° C to 21° C)

Hydraulic Fluid

Hydraulic Reservoir (for extreme heating conditions)

Hydraulic Fluid

PDMM-0058

Exxon Univis J13 (similiar to MIL-H5606A)

1056011 (1 gal./3.785 liters)

Mobil Aero HFA Texaco Aircraft Hydraulic Fluid 15 NOCO NOC 1866

Check availability with Dealer

Shell Tellus T Oil 32 Texaco HD AZ 32 1627 Rando or Cygnus 32 Chevron AW-MV

1008915 (1 gal./3.785 liters)

Mobil 423 or 424 NOCO Torque TDH

A-3

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Lubrication Equivalency Chart

Table A-1: Lubrication Equivalency Chart (Cont’d)

Approved Mitsubishi Lubricants Where Used Bearings, etc.

Type Grease

Approved Manufacturer Chevron Avi-Motive Grease Citgo HEP2 (above 30° F only)

Mitsubishi Part Number 1036913 (10 cartridges per case)

Exxon RONEX MP or UNIREX N2 Gulf Gulfcrown Grease No. 2 Mobil Grease 77 Phillips Philube 1B and RB Grease Shell Alvania Grease EP2 Sohio Bearing Guard “LT” Texaco Regal AFB 2 Grease MIL-G18709A

A-4

PDMM-0058

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Torque Chart - Standard (Ferrous)

Torque Chart - Standard (Ferrous) Table A-2: Torque Chart - Standard (Ferrous)

Grade Identification Marking

Size

None SAE Grade 2 Bolts Tightening Torque

SAE Grade 5 Bolts Tightening Torque

SAE Grade 8 Bolts Tightening Torque

Dry

Oiled*

Dry

Oiled*

Dry

Oiled*

in. lbs. 5 6 10 19 20 27 31 66 76

in. lbs. 4 5 8 14 15 21 23 49 56

in. lbs. 8 9 16 30 31 43 49 96 120

in. lbs. 6 7 12 22 23 32 38 75 86

in. lbs. 12 13 23 41 43 60 68 144 168

in. lbs. 9 10 17 31 32 45 51 108 120

ft. lbs. ft. lbs. ft. lbs. ft. lbs. 5/16-18 11 8 17 13 5/16-24 12 9 19 14 3/8-16 20 15 30 23 3/8-24 23 17 35 25 7/16-14 30 24 50 35 7/16-20 35 25 55 40 1/2-13 50 35 75 55 1/2-20 55 40 90 65 9/16-12 70 55 110 80 9/16-18 80 60 120 90 5/8-11 100 75 150 110 5/8-18 110 85 170 130 3/4-10 175 130 260 200 3/4-16 195 145 300 220 7/8-9 165 125 430 320 7/8-14 185 140 470 350 1-8 250 190 640 480 1-12 270 200 700 530 1 1/8-7 350 270 800 600 1 1/8-12 400 300 880 660 1 1/4-7 500 380 1120 840 1 1/4-12 550 420 1240 920 1 3/8-6 660 490 1460 1100 1 3/8-12 740 560 1680 1260 1 1/2-6 870 650 1940 1460 1 1/2-12 980 730 2200 1640 *Note Note: Use “oiled” values for bolts with thread-locking compound. Note

ft. lbs. 25 25 45 50 70 80 110 120 150 170 220 240 380 420 600 660 900 1000 1280 1440 1820 2000 2380 2720 3160 3560

ft. lbs. 18 20 35 35 55 60 80 90 110 130 170 180 280 320 460 500 680 740 960 1080 1360 1500 1780 2040 2360 2660

4-40 4-48 6-32 8-32 8-36 10-24 10-32 1/4-20 1/4-28

PDMM-0058

A-5

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Torque Chart - Standard (Brass)

Torque Chart - Standard (Brass) Brass MS63 Standard Bolts, Coarse Thread Size

Torque (with bolts oiled*) Newton-meters

Inch-pounds

4-40

0.37

3.3

4-48

0.40

3.6

6-32

0.69

6.1

6-40

0.77

6.8

8-32

1.24

8-36

1.24

10-24

1.58

10-32

1.92

1/4-20

3.96

1/4-28

4.52

5/16-18

8.25

5/16-24

9.15

3/8-16

14.69

130

3/8-24

16.61

147

*Note: Use “oiled” values for bolts with thread-locking compound.

A-6

PDMM-0058

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Torque Chart - Metric (Ferrous)

Torque Chart - Metric (Ferrous) Ferrous Metric Bolts (The grade rating is stamped on the head of the bolt.) Diameter (in millimeters)

Grade 8.8

Grade 10.9

Torque (with bolts oiled*)

Newton-meters

Foot-pounds

Newton-meters

Foot-pounds

8.6

101

174

130

245

181

340

255

475

350

580

435

820

605

*Note Note: Note Use “oiled” values for bolts with thread-locking compound.

Torque Chart - Metric (Brass) Brass MS63 Metric Bolts, Coarse Thread Torque (with bolts oiled*)

Diameter (in millimeters)

Newton-meters

Inch-pounds

0.5

4.4

3.5

0.79

1.2

2.2

3.9

150

*Note Note: Note Use “oiled” values for bolts with thread-locking compound

PDMM-0058

A-7

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Decimal Equivalent Chart

Decimal Equivalent Chart Table A-3: Decimal Equivalent Chart

4ths

8ths

16ths

32nds

64ths

To 3 Places

To 2 Places

MM Equivalent

1/64

.016

.02

.397

.031

.03

.794

.047

.05

1.191

.062

.06

1.587

.078

.08

1.984

.094

.09

2.381

.109

.11

2.778

.125

.12

3.175

.141

.14

3.572

.156

.16

3.969

.172

.17

4.366

.188

.19

4.762

.203

.20

5.159

.219

.22

5.556

.234

.23

5.593

.250

.25

6.350

.266

.27

6.747

.281

.28

7.144

.297

.30

7.540

.312

.31

7.937

.328

.33

8.334

.344

.34

8.731

.359

.36

9.128

.375

.38

9.525

.391

.39

9.922

.406

.41

10.319

.422

.42

10.716

.438

.44

11.112

.453

.45

11.509

.469

.47

11.906

.484

.48

12.303

.500

.50

12.700

1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2

A-8

PDMM-0058

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Decimal Equivalent Chart

Table A-3: Decimal Equivalent Chart (Cont’d)

4ths

8ths

16ths

32nds

64ths

To 3 Places

To 2 Places

MM Equivalent

33/64

.516

.52

13.097

.531

.53

13.494

.547

.55

13.891

.562

.56

14.288

.578

.58

14.684

.594

.59

15.081

.609

.61

15.478

.625

.62

15.875

.641

.64

16.272

.665

.66

16.669

.672

.67

17.065

.688

.69

17.462

.703

.70

17.859

.719

.72

18.256

.734

.73

18.653

.750

.75

19.050

.766

.77

19.447

.781

.78

19.844

.797

.80

20.241

.812

.81

20.637

.828

.83

21.034

.844

.84

21.431

.859

.86

21.828

.875

.88

22.225

.891

.89

22.622

.906

.91

23.019

.922

.92

23.416

.938

.94

23.812

.953

.95

24.209

.969

.97

24.606

.984

.98

25.003

1.000

1.00

25.400

17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8 57/64 29/32 59/64 15/16 61/64 31/32 63/64

PDMM-0058

A-9

Appendix A: Charts and Schematics

Mitsubishi® Reach Service Manual

Standard/Metric Conversions

Standard/Metric Conversions Table A-4: Standard/Metric Conversions

To Convert...

Multiply...

Inches to Millimeters

Inches x 25.4

Millimeters to Inches

Millimeters x 0.039

Inches to Centimeters

Inches x 2.54

Centimeters to Inches

Centimeters x 0.394

Feet to Meters

Feet x 0.305

Meters to Feet

Meters x 3.281

Yards to Meters

Yards x 0.914

Meters to Yards

Meters x 1.094

Miles to Kilometers

Miles x 1.609

Kilometers to Miles

Kilometers x 0.621

Square Inches to Square Centimeters

Square Inches x 6.452

Square Centimeters to Square Inches

Square Centimeters x 0.155

Square Feet to Square Meters

Square Feet x 0.093

Square Meters to Square Feet

Square Meters x 10.753

Square Yards to Square Meters

Square Yards x 0.836

Square Meters to Square Yards

Square Meters x 1.196

Pints to Liters

Pints x 0.473

Liters to Pints

Liters x 2.113

Quarts to Liters

Quarts x 0.946

Liters to Quarts

Liters x 1.057

Gallons to Liters

Gallons x 3.785

Liters to Gallons

Liters x 0.26

Ounces to Grams

Ounces x 28.35

Grams to Ounces

Ounces x 0.035

A-10

PDMM-0058

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Standard/Metric Conversions

Table A-4: Standard/Metric Conversions (Cont’d)

To Convert...

Multiply...

Ounces to Kilograms

Ounces x 0.028

Kilograms to Ounces

Kilograms x 35.27

Pounds to Kilograms

Pounds x 0.454

Kilograms to Pounds

Kilograms x 2.2

Pounds per Square Inch to Kilopascals

Pounds per Square Inch x 6.894

Kilopascals to Pounds per Square Inch

Kilopascals x 0.145

Inch Pounds (in. lbs.) to Newton Meters (N•m)

Inch Pounds x 0.113

Newton Meters (N•m) to Inch Pounds (in. lbs.)

Newton Meters x 8.85

Foot Pounds (ft. lbs.) to Newton Meters (N•m)

Foot Pounds x 1.3568

Newton Meters (N•m) to Foot Pounds (ft. lbs.)

Newton Meters x 0.737

Miles per hour to Kilometers per hour

Miles per hour x 0.6214

Kilometers per hour to Miles per hour

Kilometers per hour x 1.609

Fahrenheit to Celsius

(°F - 32) x 0.555

Celsius to Fahrenheit

(°C x 1.8) + 32

PDMM-0058

A-11

Appendix A: Charts and Schematics

Mitsubishi® Reach Service Manual

Standard/Metric Conversions

This page intentionally left blank

A-12

PDMM-0058

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Electrical Schematic

Electrical Schematic The following schematic shows the electrical system.

PDMM-0058

A-13

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Electrical Schematic

B 1

FU4 15A

2 TP1

TP5

FU2 350A 1

FU3 150A

P 2

TP REC1

WHT

BLK

FU1 450A W/BLU

1 8

GRY

BLU

1A 2

PLUG "Z" EV100 CARD 14

11 10 RED

ORN W/RED

W/VIO

VIO

REC2

PB6

REC22

PB3 T4

REC5

1A X

X X

T3 TB4

REC25

TB2 Y

PB5 T2

PB4

X X

B+

2 MD-S1 MD-S2

4 B-

EV100

DISPLAY

A1 MX 2

MP 2

MD A1 A2

TB3

PT1 PT2 PT3

PY-3 PY-4 PY-2

PT4 PT5

PY-1 PY-5

PA3 TB5 TB6 PA2

REC4

REC3 TB1

FIL24

FIL23 PA6 PA4

6 SENSOR

GRN YEL BRN

TP4

4 3 2

PLUG "Z"

N EV100 CARD

FU5 15A

B Figure A-1:

A-14

Electrical Schematic (Sheet 1 of 4)

PDMM-0058

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Electrical Schematic

1 S1

2 1

2 S2

1 5 4

DEADMAN

B+ KEY

DM COIL GND

B+ FUSED

P SENSE

JPS4 -5

-13 -14 -16

LOAD HOLDING B+ KEY

B+ KEY B+ FIL HORN ENABLE

-4

B+ FUSED

-2

JPS6 -1

-2 -3 -4

DIRA SOL

+5V

+12V

THROTTLE DGND

SIGNAL NC

LIFT

DGND

HORN DEADMAN M

REACH RETRACT

-3 -4

FOR.

TILT UP TILT DOWN

REV.

SSHIFT LEFT LOW BATT CUTOUT SSHIFT RIGHT

-10 -5 -9 TS21

TS19 -6

-5

-3

REACH

JPS5 -6 -5 -3

DGND SHIELD

SPEED CONTROL

TILT

-2 -2

-1 JPS4 -8

-12

-11

DIRB

2 1

DIRA

-2 JPS1 -9 -14 -11

JPC1- 9 -14 -11

-15

-1

-12

-13

-2

-8

-7

-6

-5

-4

-3

-10 -1

-10

VR1

S20

S21

S3 S4

S5 S6 S7 S8 S9 CONTROL HANDLE

JPS9 +12V

AUXILIARY INTERFACE CARD

+12V

-17

JPN1 -1

-10

-2

PGND

-9

-4

+12V

-18

-5

MAST SW1

-19

-6

PGND

-20

-3

+12V

MAST SW2

PGND

B+ KEY

MAST SW 1

REACH SOL

SSHIFT SOL

LIFT INHIBIT L.I. BYPASS

TILT SOL

PGND PGND DGND

PGND

E Figure A-2:

JPN8 -2 -1

G F Electrical Schematic (Sheet 2 of 4)

MAST SW 2

-3 JPN7 -2 -1

MAST SW 1

-3 JPN12 -2 -1

LIFT INHIBIT

INTERFACE CARD

PDMM-0058

POS NEG

-1

L.I. BYPASS -7

H2 H1

-7

PGND

-2 -1

-1

-6

MAST SW 1 OUT MAST SW 2 OUT

MAST SW 2 SIDE SHIFT

-3

DGND

-2

P CNTR

LOWER

JPS3 -7

L/H

5 B+ KEY

EQ SOL

DEADMAN D DIRB SOL

-1

JPS9 -4

JPS9 -15

JPS4 -3

LIFT INHIBIT

-3 JPN13 -1 -2

LIFT INHIBIT BYPASS

A-15

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Electrical Schematic

STANDARD MAST SPEED LIMIT SWITCH

WORKING LIGHTS & FAN

JPN71 AUX. INTERFACE CARD

MASTSW1

S10 COM

SINGLE LIGHT

+12V

PGND

B+KEY

TS195

*MAST IN FULLY LOWERED POSITION

OTHER THAN STANDARD MAST SPEED LIMIT SWITCH JPN8-

AUX. INTERFACE CARD

MASTSW2

LIGHT

JP32

PGND

DUAL LIGHTS LIGHT

S11 COM

+12V

LIGHT 1

PGND

JP3-

TS19FAN 5

*MAST IN FULLY LOWERED POSITION

B+KEY

4 6 PGND

STROBE OR WARNING LIGHT TS195 B+KEY

PGND

WL +

JP21

TRAVEL ALARM AND OR LIGHT R PB4

DA26

F PB5

5 TS19-5 B+KEY

LIFT INHIBIT WITH BYPASS

4 S12

JPN13-

1 INHBTBYP

1 +12V PGND

TS19-4

SPL-1

JP1-1

JPN12LIFT INHBT

PGND AUX. INTERFACE CARD

S13 COM

2 3

TZ1

ALARM

LIGHT

CONNECT DA2-6 TO R-Y FOR REVERSE TRAVEL. CONNECT DA2-5 TO F-Y FOR FORWARD TRAVEL. CONNECT DA2-6 AND DA2-5 FOR ALL TRAVEL.

*REMOVE S12 TO ELIMINATE BYPASS CAPABILITY TS19-6 PGND

A-16

B Figure A-3:

C Electrical Schematic (Sheet 3 of 4)

JP1-2

PDMM-0058

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Electrical Schematic

LEGEND IDENT SHEET DESCRIPTION H

HORN

JP1

CONNECTOR TO TRAVEL LIGHT

JPB+ JPBJPC1

1 1 1

CONNECTOR TO BATTERY POS. CONNECTOR TO BATTERY NEG. CONNECTOR ON CONTROL HANDLE

JPN1 JPN7 JPN8 JPN12 JPN13

1 2 2 2 2

CONNECTOR ON AUX. INTERFACE CARD CONNECTOR ON AUX. INTERFACE CARD FOR STANDARD MAST SWITCH CONNECTOR ON AUX. INTERFACE CARD FOR OTHER THAN STANDARD MAST SWITCH CONNECTOR ON AUX. INTERFACE CARD FOR LIFT INHIBIT SWITCH CONNECTOR ON AUX. INTERFACE CARD FOR LIFT INHIBIT BYPASS

JPS1 JPS3 JPS4 JPS5 JPS6 JPS9

1 1 1 1 1 1

INTERFACE CARD CONNECTOR FOR CONTROL HANDLE INTERFACE CARD CONNECTOR FOR GE CONTROLLER INTERFACE CARD CONNECTOR FOR CONTACTOR PANEL INTERFACE CARD CONNECTOR FOR MAST MOUNTED HYDRAULIC SOLENOIDS INTERFACE CARD CONNECTOR FOR OPTIONAL LIFT MOTOR THERMISTOR INTERFACE CARD CONNECTOR FOR TRACTOR HYDRAULIC SOLENOIDS, KEYSWITCH, DEADMAN, AUX INTERFACE CARD AND RELAY INPUT

JPZ

CONNECTOR ON LIFT MOTOR TEMPERATURE SENSOR (OPTIONAL)

K1 K2 K3

1 1 2

RELAY FOR HORN RELAY FOR DEADMAN RELAY FOR BACKUP ALARM OPTION

L/H

SOLENOID FOR LOAD HOLDING

MD MP MX

1 1 1

DRIVE MOTOR LIFT PUMP MOTOR AUX PUMP MOTOR

P PT

1 1

LIFT PUMP CONTACTOR CONNECTOR ON OPERATOR DISPLAY

G.E. CONTROLLER CONNECTOR FOR OPERATOR DISPLAY

R1 REC1 REC2 REC3 REC4 REC5

2 1 1 1 1 1

RESISTOR FOR TRAVEL ALARM (OPTION) CHOPPER SCR COMMUTATING SCR FREE WHEELING RECTIFIER PLUGGING RECTIFIER CHARGING SCR

S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13 S20 S21

1 1 1 1 1 1 1 1 1 2 2 2 2 1 1

KEY SWITCH DEADMAN SWITCH HORN SWITCH REACH SWITCH RETRACT SWITCH TILT UP SWITCH TILT DOWN SWITCH SIDE SHIFT LEFT SWITCH SIDE SHIFT RIGHT SWITCH SPEED LIMIT SWITCH SPEED LIMIT SWITCH LIFT INHIBIT BYPASS SWITCH LIFT INHIBIT SWITCH LIFT SWITCH LOWER SWITCH

SPL-1

SPLICE TO TRAVEL LIGHT

SOLENOID FOR REACH SOLENOID FOR TILT SOLENOID FOR SIDE SHIFT

REACH, SOL 6 TILT, SOL 7 SIDESHIFT, SOL 8 TP TP1 TP4 TP5 TS19 TS21

1 1 1 1 2 1

HEATSINK TEMPERATURE SENSOR TIE POINT FOR AUX FUSE TIE POINT FOR BTIE POINT FOR B+ TERMINAL STRIP FOR MAST CABLE AND POWER FOR OPTIONS TERMINAL STRIP FOR MAST CABLE ON CARRIAGE

TZ1

TRANSZORB ACROSS ALARM

TIE POINT ON GE CONTROLLER FOR B-

VR1

VARIABLE RESISTOR FOR THROTTLE

WARNING LIGHT

AUX PUMP CONTACTOR

CONNECTOR ON EV100

JP1 JP2 JP3 A 1A

2 2 1 1

CONNECTOR FOR BACKUP LIGHT CONNECTOR FOR STROBE OR WARNING LIGHT CONNECTOR FOR FAN AND/OR WORKING LIGHTS CONNECTOR ON EV100 MAXIMUM SPEED CONTACTOR (BYPASS)

CONNECTOR ON EV100

DA2

DIODE ASSEMBLY FOR BACKUP ALARM

DIRA DIRB

1 1

SOLENOID FOR AUXILLARY SYSTEM OIL DIRECTION CONTROL SOLENOID FOR AUXILLARY SYSTEM OIL DIRECTION CONTROL

SOLENOID FOR AUX PRESSURE EQUALIZING CONTROL

FU1 FU2 FU3 FU4 FU5

1 1 1 1 1

POWER FUSE FOR LIFT, 450A POWER FUSE FOR TRAVEL, 350A POWER FUSE FOR AUX MOTOR, 150A CONTROL FUSE FOR B+, 15A CONTROL FUSE FOR B-, 15A

E Figure A-4:

PDMM-0058

7 2. FOR SYSTEM ELEC SEE 828-004-960/. 1. SCHEMATIC SHOWS TRUCK SWITCHED OFF, DEADMAN SWITCH OFF AND CARRIAGE FULLY LOWERED.

G F Electrical Schematic (Sheet 4 of 4)

A-17

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Hydraulic Schematic

Hydraulic Schematic The following schematic shows the hydraulic system.

Low Performance Remote Lift / Lower

2nd Sol.

Pump

Man.

Spool Val.

NOT ON ALL MODELS

L/H Sol.

Cyl.

R L/L

P P1

B P1

CV 1

Cyl.

Remote Lower

Tank

Lift Rel.

CV 2

Sol 1 D

2nd Sol.

Sol 1 Option D

Reach Sol.

Dir A Sol. Dir B Sol. Aux. Press.

S/S Sol.

EQ Sol.

A2 Steer Ret.

Tilt Sol.

Tank

LEGEND Pressure Lines Return Lines Suction Lines

Figure A-5:

A-18

Hydraulic Schematic

PDMM-0058

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Decal Locations

Decal Locations

Operator Display Handle Instructions

Mitsubishi Logo (right and left sides)

Battery Warning (right and left sides)

Figure A-6:

PDMM-0058

Decal Locations (Sheet 1 of 2)

A-19

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Decal Locations

General Warning

Battery Warning

Cold Storage Lubrication and Standard Lubrication

Battery Warning

Specification Plate

Control Setting

Auxiliary

Figure A-7:

A-20

General Warning

Decal Locations (Sheet 2 of 2)

PDMM-0058

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Pin-By-Pin Voltages - EV100LX Travel Control

Pin-By-Pin Voltages - EV100LX Travel Control System Table A-5 shows the pin-by-pin voltage referenced to the basic truck schematic. The voltages listed are with the truck fully lowered, battery connected, and key switch turned on, unless stated otherwise. TP4 on the power panel is the connection for negative, unless otherwise specified. Table A-5: Pin-By-Pin Voltage - EV100LX Travel Control System

Connector

JPS1

Name

Description

Condition

DGND

Digital Ground

Used for Switch 20 input

B-

HORN

Horn Request S3

Switch not activated

10.5-12

Switch activated JPS1

SSHIFTRIGHT

Sideshift right request

Switch not activated Switch activated

JPS1

SSHIFTLEFT

Sideshift Left request

Switch not activated Switch activated

JPS1

TILTDOWN

Tilt Down requested

Switch not activated Switch activated

JPS1

TILTUP

Tilt Up requested

Switch not activated Switch activated

JPS1

RETRACT

Retract forks requested

Switch not activated Switch activated

JPS1

Volts

REACH

Reach forks requested

Switch not activated Switch activated

B10.5-12 B10.5-12 B10.5-12 B10.5-12 B10.5-12 B10.5-12 B-

+5V

5-volt supply to VR1

DGND

Digital Ground

Used for S3-S9 input

B-

JPS1

DGND

Digital Ground

Used for VR1 ref.

B-

JPS1

LOWER

Carriage Lower Request

Switch open

JPS1

LOWER

Carriage Lower Request

Switch closed

JPS1

PDMM-0058

10.5 to 12 volts B-

A-21

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Pin-By-Pin Voltages - EV100LX Travel Control System

Table A-5: Pin-By-Pin Voltage - EV100LX Travel Control System (Cont’d)

Connector

Name

Description

Condition

JPS1

DGND

Digital Ground

Switch closed

B-

JPS1

THROTTLE

Travel Pot Signal

Switch closed

Variable

JPS1

LIFT

Carriage Lift Request

Switch open

10.5 to 12 volts

JPS1

LIFT

Carriage Lift Request

Switch closed

JPS3

FOR

Forward request to EV100

Handle moved forward Handle in neutral

JPS3

REV

LOW BATT CUTOUT

MAST SW1 OUT

DEADMAN M JPS3

JPS3

MAST SW2 OUT

SPEED CONTROL

Reverse request to EV100

Signal from EV100 to disable lift due to battery

Mast Switch 1 status to EV100

Signal to EV100 to request X Contactor coil activation

Mast Switch 2 status to EV100

Signal to EV100 For Speed request

Handle moved reverse

A-22

B+KEY

Battery Positive KEYED

BB+ 0-.6 B+

Handle in neutral

0-.6

Battery OK <90% Discharged

Battery >90% Discharged in lift cutout

0-.6

Vehicle below mast switch

B-

Vehicle above mast switch

4.6-5

Auxiliary function requested

B+

No function requested

0-.6

Vehicle below mast switch

B-

Vehicle above mast switch

4.6-5

Creep Speed 3-4 Top Speed

JPS4

Volts

Key OFF

.5-0 0 PDMM-0058

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Pin-By-Pin Voltages - EV100LX Travel Control

Table A-5: Pin-By-Pin Voltage - EV100LX Travel Control System (Cont’d)

Connector

JPS4

Name

P CNTR

Description

Condition

Volts

Supply for P Coil

Key Switch Activated

B+

Lift contactor control

Lift Coil Activated Lift Coil Not Activated

JPS4

JPS5

Lift Motor Sense Line

Used to sense lift motor status for control

DEADMAN D

Positive Supply for F&R and TB2

K2 coil activated

B+KEY

Battery Positive KEYED

Key OFF

Supply for 1A & X Coil

Key Switch Activated

DGND

Digital Ground

Used for neg ref.

B-

PGND

Power Ground

Power Ground for interface Card

B-

TILT SOL

Tilt Solenoid control

Tilt Coil Activated

SSHIFT SOL

Sideshift Solenoid control

Sideshift Coil Activated Sideshift Coil Not Activated

JPS5

REACH SOL

Reach Solenoid control

Reach Coil Activated Reach Coil Not Activated

JPS5

JPS9

PDMM-0058

B+

P SENSE

Tilt Coil Not Activated JPS5

0-.5

B+KEY

Battery Positive KEYED

Key OFF

Supply for Reach, Tilt, Sideshift Coil

Key Switch Activated

PGND

Power Ground

Power Ground for Options

B+FUSED

B+ After control fuse, Supply for DirA,DirB,EQ

With battery plugged in

B+ 0 B+

0-.5 B+ 0-.5 B+ 0-.5 B+ 0

B+

B-

B+

A-23

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Pin-By-Pin Voltages - EV100LX Travel Control System

Table A-5: Pin-By-Pin Voltage - EV100LX Travel Control System (Cont’d)

Connector

JPS9

Name EQ SOL

Description Equalizing Solenoid Control

Condition EQ Coil Activated EQ Coil Not Activated

B+KEY

JPS9

LOAD HOLDING

B+FIL JPS9

HORN ENABLE

MAST SW1 9

Supply for Load Holding Coil

Key Switch Activated

Load Holding Solenoid Control

Load Holding Coil Activated

0-.5

Load Holding Coil Not Activated

B+

B+ Filtered Supply to Horn Relay Coil

Horn Relay Coil Control

Mast Switch 1 Input to Interface Card

JPS9

DIRA SOL

K1 Coil Activated

DIRB SOL 12

Directional Solenoid B Control

+12V

A-24

12 Volt supply to Auxiliary Interface Card

0-.5 B+ 10.5-12 B-

B-

DirA Coil Activated 0-.5 B+

DirB Coil Activated 0-.5 DirB Coil Not Activated

JPS9

B+

Switch Not Activated

DirA Coil Not Activated JPS9

B+

Power Ground Used to Determine Switch Status Directional Solenoid A Control

Key OFF

Switch Activated PGND

B+

Key OFF

K1 Coil Not Activated JPS9

0-.5

Battery Positive KEYED

Key Switch Activated JPS9

Volts

B+

Key OFF 0

PDMM-0058

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Pin-By-Pin Voltages - EV100LX Travel Control

Table A-5: Pin-By-Pin Voltage - EV100LX Travel Control System (Cont’d)

Connector

Name

MAST SW2 JPS9

Description

Mast Switch 2 Input to Interface Card

Condition

Volts

Key Switch Activated

10.5-12

Switch Not Activated 10.5-12 Switch Activated

LIFT INHIBIT JPS9

Lift Inhibit Switch Input to Interface Card

Switch Not Activated 10.5-12 Switch Activated

L.I.BYPASS JPS9

Lift Inhibit Bypass Switch Input to Interface Card

MAST SW1

PGND JPN7

JPN8

MAST SW2

PGND JPN8

LIFT INHIBIT

10.5-12

JPN12

Mast Switch 1 input to

Switch Not Activated

Auxiliary Interface Card

Switch Activated

Power Ground used to determine status of SW1 Switch Not Activated

Auxiliary Interface Card

Switch Activated

Power Ground used to determine status of SW2

10.5-12 B-

B-

Switch Not Activated 10.5-12

Switch Activated

PDMM-0058

B-

Mast Switch 2 input

Lift Inhibit Switch Input to Auxiliary Interface Card

B-

Switch Not Activated

Switch Activated JPN7

B-

A-25

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Pin-By-Pin Voltages - EV100LX Travel Control System

Table A-5: Pin-By-Pin Voltage - EV100LX Travel Control System (Cont’d)

Connector

Name PGND

JPN12

L.I.BYPASS JPN13

Description

Condition

Power Ground Used to Determine Status of Lift Inhibit Switch Lift Inhibit Bypass Switch Input to Auxiliary Interface Card

B-

Switch Not Activated 10.5-12

Switch Activated PGND JPN13

Power Ground Used to Determine Status of Lift Inhibt Bypass Switch

Volts

B-

Notes: Notes • Testing Travel Potentiometer (VR1) • Travel pot is 2K ohms + or - 10% (1900-2100 ohms). • Full travel in either direction should change reading from neutral to approximately 200220 ohms in a smooth progressive manner. If the reading jumps out of sequence, it indicates a defective potentiometer.

A-26

PDMM-0058

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics EV100 Interface Card Troubleshooting

EV100 Interface Card Troubleshooting Relationships Table A-6: EV100 Interface Card Troubleshooting Relationships

PDMM-0058

Code

Description

No B+ input at B+

B+ input at PB5 on initial start

B+ input at PB6 on initial start

Indicates TB2 is less than 60% of battery volts at initial start up

Indicates that TB1 is less than 2.5 volts and TB2 is less than 60% volts

Indicates that TB5 and TB6 are less than 60% of battery volts and TB1 is less than 2.5 volts

Indicates that Accelerator input voltage at TB1 is higher than 3.9 volts, and a directional contactor is picked up

Indicates that Accelerator input at TB1 is less than 3.0 volts, and any of the following connections are opened and closed: Battery plug, seat switch or key switch.

Indicates that both TB5 and TB6 are greater than 60% of battery voltage at the same time.

A-27

Mitsubishi® Reach Service Manual

Appendix A: Charts and Schematics Brush Replacement

Brush Replacement If any of the brushes require replacement, the complete brush set should be replaced. Do not replace just one or two brushes. See the following table for minimum brush lengths. Do not substitute brushes. The brushes are matched to the motor type and application to provide the best service. Substituting brushes of the wrong grade can cause commutator damage or excessive brush wear. Where accessible, new brushes should be seated to the commutator curvature. This can be accomplished by wrapping a piece of 00 sandpaper around the commutator, seating the brush in the brush holder, and turning the armature. On smaller motors where space is limited, a brush seating stone may be used. DO NOT use emery cloth to seat brushes. After the brushes are seated, the dust should be blown out of the motor with dry compressed air (30 PSI [207 kPa]). Table A-7: Minimum Brush Lengths

Motor

Drive Lift

Auxiliary

Manufacturer

Part Number

Minimum Commutator Diameter

General Electric General Electric

24-volt Trucks NA57002 2.625 in. NA057002 (66.67mm) NA57003 2.625 in. NA057003 (66.67mm)

0.75 in. (19.05mm) 0.75 in. (19.05mm)

General Electric

NA57036 NA057036

0.57 in. (14.47mm)

2.875 in. (73.02mm)

36-volt Trucks NA57001 3.11 in. NA057001 (78.99 mm) Lift NA57004 2.625 in. NA057004 (66.67mm) Auxiliary 1011418 2.75 in. (69.85 mm) * Measurement of brush length refers to the "short" side dimension. Drive

Minimum Length*

General Electric General Electric Advanced

0.60 in. (15.24 mm) 0.75 in. (19.05mm) 0.62 in. (15.8mm)

When ordering replacements, refer to the motor part number on the motor nameplate.

A-28

PDMM-0058