Mitsubishi Reach EDR24, ESR24, ESS24, EDR36, ESR36, ESS36 Workshop Service Manual

Reach Trucks ESR 1ESR240501-up 1ESR360501-up EDR 1EDR240501-up 1EDR360501-up ESS 1ESS240501-up 1ESS360501-up SERVICE MANUAL Quality Makes the Difference WENB8550-01

Mitsubishi ® Reach Service Manual Warning Pages PDMM-0058 i Warning Pages 1: 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.

Warning Pages Mitsubishi ® Reach Service Manual ii PDMM-0058 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.

Mitsubishi ® Reach Service Manual Warning Pages PDMM-0058 iii 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.

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Mitsubishi ® Reach Service Manual Overview of this Manual Using the Manual PDMM-0058 v Overview of this Manual 2: 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 Denotes a serious hazard that could cause injury or DEATH to the operator or other personnel Denotes a serious hazard that could cause injury or DEATH to the operator or other personnel Denotes a serious hazard that could cause injury or DEATH to the operator or other personnel from a particular action or condition. from a particular action or condition. from a particular action or condition. from a particular action or condition. CAUTION ! Denotes a less serious hazard from an action or condition that could cause minor injury to the Denotes a less serious hazard from an action or condition that could cause minor injury to the Denotes a less serious hazard from an action or condition that could cause minor injury to the 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. operator or maintenance personnel, or cause damage to the equipment itself. operator or maintenance personnel, or cause damage to the equipment itself. 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.

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Mitsubishi ® Reach Service Manual Table of Contents PDMM-0058 vii Table of Contents 3: 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

Table of Contents Mitsubishi ® Reach Service Manual viii PDMM-0058 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

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Mitsubishi Reach EDR24, ESR24, ESS24, EDR36, ESR36, ESS36 Workshop Service Manual

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