Mitsubishi Reach Truck RB14N2, RB16N2, RB20N2, RB25N2 (H)(S)(C)(X) Workshop Service Manual

SERVICE MANUAL RB14-25N2(S)(C)(H)(X) 622075 English 2014

© Mitsubishi Forklift Trucks 2014. All rights reserved. Revision: A Document ID: 622075 2 (442) RB14-25N2(S)(C)(H)(X) Service Manual Only adequately trained service persons are allowed to carry out service operations. The terms of the warranty prescribe appropriate maintenance of the truck. All spare parts must be original ones. It is recommended that you sign a maintenance agreement with the truck dealer, who can also supply spare parts. Only professional service ensures long-term, trouble-free truck operation. Service program monitoring becomes easier if you enter the service dates in a service logbook. Contact our service organisation or your truck dealer for qualified, authorized and efficient maintenance service. Copyright © 2014 by Mitsubishi Forklift Trucks, bv. All rights reserved. Mitsubishi Forklift Trucks® is a registered trademark of Mitsubishi Heavy Industries®, Inc. All brand or product names are or may be trademarks of, and are used to identify products and services of, their respective owners. Unauthorized copying and lending are prohibited. Mitsubishi Caterpillar Forklift Asia Pte. Ltd. RCB No.: 199203169H No. 1, Tuas West Street Singapore 637444 MCFA MCFE B.V. 2121 W. Sam Houston Pkwy. N. Hefbrugweg 77 Houston, TX 77043-2305 1332 AM Almere USA The Netherlands Approvals and version history REVISION DATE DESCRIPTION OF CHANGE APPROVED BY A 4.11.2014 First issue R&D Original instructions ___X___ / Translation of the original instructions _______

© Mitsubishi Forklift Trucks 2014. All rights reserved. Revision: A Document ID: 622075 3 (442) RB14-25N2(S)(C)(H)(X) Service Manual Contents Contents ............................................................................................................................. 3 1 Foreword ................................................................................................................ 11 2 How to read this manual ....................................................................................... 12 2.1 Safety-related signs ................................................................................. 12 2.2 Symbols and abbreviations ...................................................................... 12 2.2.1 Safety symbols................................................................................................ 12 2.2.2 Other symbols and abbreviations .................................................................... 14 2.3 Units ......................................................................................................... 14 3 Safety instructions ................................................................................................ 15 3.1 Service area safety .................................................................................. 15 3.2 Personal safety ........................................................................................ 16 3.3 Work safety .............................................................................................. 16 4 General information .............................................................................................. 19 4.1 Truck model covered by this manual ....................................................... 19 4.2 Identification plates on the truck .............................................................. 19 4.3 Overview of the truck ............................................................................... 21 4.3.1 Operating devices ........................................................................................... 21 4.3.2 Control panel................................................................................................... 22 4.3.3 Steering wheel ................................................................................................ 23 4.3.4 Arm rest .......................................................................................................... 24 4.3.5 Display panel .................................................................................................. 25 4.3.6 Truck operation modes.................................................................................... 27 4.3.7 Truck display................................................................................................... 27 4.3.7.1 Display control buttons .................................................................................... 28 4.3.7.2 Main view of the truck display.......................................................................... 29 4.3.7.3 Hierarchy of the truck display menus............................................................... 38 4.3.8 Pedals............................................................................................................. 42 4.3.9 Operator’s seat ............................................................................................... 44 4.3.10 Operating position ........................................................................................... 45 4.3.11 Driving direction .............................................................................................. 46 4.3.12 Motor, hydraulic system and electrical system................................................. 47 4.3.12.1 Instrument panel ............................................................................................. 48 4.3.12.2 Hydraulic system............................................................................................. 49 4.3.12.3 Motor compartment ......................................................................................... 50 4.3.13 Sensors........................................................................................................... 50 4.3.14 Reach carriage................................................................................................ 52 4.3.15 Mast unit ......................................................................................................... 52 4.3.16 Load support ................................................................................................... 53 5 Mechanical maintenance ...................................................................................... 54 5.1 Lifting points ............................................................................................. 54 5.1.1 Jack points ...................................................................................................... 54

© Mitsubishi Forklift Trucks 2014. All rights reserved. Revision: A Document ID: 622075 4 (442) RB14-25N2(S)(C)(H)(X) Service Manual 5.1.2 Hoist points ..................................................................................................... 55 5.2 Transportation .......................................................................................... 55 5.3 Assembly and commissioning.................................................................. 58 5.3.1 Install the mast unit ......................................................................................... 58 5.4 Order spare parts ..................................................................................... 62 5.5 Truck covers............................................................................................. 62 5.5.1 Remove the machinery cover .......................................................................... 63 5.5.2 Remove the front bumper................................................................................ 64 5.5.3 Remove the floor plate .................................................................................... 64 5.5.4 Open the machinery top cover ........................................................................ 65 5.5.5 Open the instrument panel .............................................................................. 66 5.5.6 Remove the instrument panel cover ................................................................ 67 5.5.7 Remove the control panel ............................................................................... 68 5.5.8 Remove the cup holder ................................................................................... 68 5.5.9 Remove the reach carriage cover.................................................................... 68 5.6 Steering wheel ......................................................................................... 69 5.6.1 Remove the steering wheel ............................................................................. 69 5.7 Transmission gear.................................................................................... 70 5.7.1 Remove the transmission gear ........................................................................ 71 5.8 Slewing bearing........................................................................................ 72 5.8.1 Lubricate the slewing bearing.......................................................................... 72 5.9 Traction wheel .......................................................................................... 73 5.9.1 Disassemble the traction wheel ....................................................................... 74 5.9.1.1 Replace the wheel shaft bolts.......................................................................... 74 5.9.2 Assemble the traction wheel............................................................................ 76 5.10 Corner supports ....................................................................................... 76 5.10.1 Replace the corner supports ........................................................................... 77 5.11 Load wheels ............................................................................................. 77 5.11.1 Remove the load wheels ................................................................................. 78 5.12 Battery roller frame................................................................................... 79 5.12.1 Remove the battery roller frame ...................................................................... 79 5.13 Reach carriage ......................................................................................... 80 5.13.1 Lubricate the rollers of the reach carriage ....................................................... 80 5.13.2 Adjust the guidance rollers of the reach carriage ............................................. 81 5.13.3 Sensors of the reach carriage ......................................................................... 84 5.13.4 Remove the reach carriage ............................................................................. 84 5.13.5 Remove the reach cylinder.............................................................................. 86 5.13.6 Replace the reach carriage hoses ................................................................... 87 5.14 Mast unit ................................................................................................... 92 5.14.1 Detailed construction....................................................................................... 93 5.14.2 Mast unit maintenance .................................................................................... 94 5.14.2.1 Daily maintenance........................................................................................... 94 5.14.2.2 Monthly maintenance ...................................................................................... 94 5.14.2.3 Annual maintenance (600 h) ........................................................................... 94 5.14.3 Lubricant recommendations ............................................................................ 95 5.14.3.1 Mast chains..................................................................................................... 95 5.14.3.2 Mast channels ................................................................................................. 95 5.14.4 Remove the lifting carriage.............................................................................. 96 5.14.5 Remove the mast unit ..................................................................................... 99

© Mitsubishi Forklift Trucks 2014. All rights reserved. Revision: A Document ID: 622075 5 (442) RB14-25N2(S)(C)(H)(X) Service Manual 5.14.6 Disassemble the mast unit ............................................................................ 102 5.14.7 Fork inspection.............................................................................................. 108 5.14.8 Mast chains................................................................................................... 112 5.14.8.1 Inspect the mast chains................................................................................. 113 5.14.8.2 Check the tension of the mast chains ............................................................ 119 5.14.8.3 Adjust the mast chains .................................................................................. 120 5.14.8.4 Replace the mast chains ............................................................................... 120 5.14.9 Guidance rollers ............................................................................................ 123 5.14.9.1 Adjust the guidance rollers ............................................................................ 124 5.14.9.2 Replace the guidance rollers ......................................................................... 125 5.14.10 Main rollers ................................................................................................... 127 5.14.10.1 Replace the main rollers................................................................................ 127 5.14.11 Free lift cylinder............................................................................................. 129 5.14.11.1 Replace the free lift cylinder .......................................................................... 129 5.14.11.2 Sealing housing of the free lift cylinder .......................................................... 132 5.14.11.3 Bleed out the air from the free lift cylinder ..................................................... 133 5.14.12 Side cylinders................................................................................................ 135 5.14.12.1 Replace the side cylinders ............................................................................ 136 5.14.12.2 Sealing housing of the side cylinder .............................................................. 139 5.14.12.3 Bleed out the air from the side cylinders ........................................................ 141 5.14.13 Tilt cylinders .................................................................................................. 143 5.14.13.1 Remove the tilt cylinders ............................................................................... 143 5.14.13.2 Sealing housing of the tilt cylinder ................................................................. 145 5.14.14 Sideshift cylinder ........................................................................................... 146 5.14.14.1 Remove the piston of the sideshift cylinder ................................................... 147 5.14.14.2 Sealing housing of the sideshift cylinder ........................................................ 148 5.15 Load support .......................................................................................... 149 5.15.1 Remove the load support .............................................................................. 149 5.16 Arm rest.................................................................................................. 150 5.16.1 Remove the arm rest ..................................................................................... 150 5.16.2 Open the arm rest ......................................................................................... 151 5.16.3 Remove the arm rest levers .......................................................................... 151 5.16.4 Remove the arm rest buttons ........................................................................ 152 5.17 Operator’s seat....................................................................................... 153 5.17.1 Replace the seat switch ................................................................................ 153 6 Electrical operation ............................................................................................. 155 6.1 How to use the schematic diagram........................................................ 155 6.2 Power source ......................................................................................... 158 6.3 Safety circuit (emergency stop button) .................................................. 158 6.4 Key switch .............................................................................................. 158 6.5 Traction .................................................................................................. 159 7 Battery maintenance ........................................................................................... 160 7.1 Safety regulations concerning the handling of lead-acid batteries ........ 161 7.2 Battery maintenance .............................................................................. 162 7.2.1 Daily maintenance......................................................................................... 162

© Mitsubishi Forklift Trucks 2014. All rights reserved. Revision: A Document ID: 622075 6 (442) RB14-25N2(S)(C)(H)(X) Service Manual 7.2.2 Weekly maintenance ..................................................................................... 162 7.2.3 Monthly maintenance .................................................................................... 162 7.2.4 Annual maintenance ..................................................................................... 163 7.3 Recharge the battery.............................................................................. 163 7.4 Measure the specific gravity of the battery ............................................ 166 7.5 Replace the battery ................................................................................ 166 7.5.1 Guide the battery connector cables ............................................................... 170 7.6 Quick battery replacement ..................................................................... 171 8 Electric system maintenance ............................................................................. 172 8.1 Display panel .......................................................................................... 172 8.1.1 Emergency stop button ................................................................................. 173 8.1.1.1 Emergency stop button functionality check.................................................... 173 8.1.2 Key switch..................................................................................................... 174 8.1.2.1 Key switch functionality check ....................................................................... 174 8.2 Pedals .................................................................................................... 175 8.2.1 Operator presence pedal............................................................................... 175 8.2.1.1 Operator presence pedal functionality check ................................................. 176 8.2.1.2 Remove the operator presence pedal ........................................................... 176 8.2.2 Acceleration pedal......................................................................................... 177 8.2.2.1 Acceleration pedal functionality check ........................................................... 178 8.2.2.2 Remove the acceleration pedal ..................................................................... 178 8.2.3 Brake pedal ................................................................................................... 179 8.2.3.1 Brake pedal functionality check ..................................................................... 180 8.2.3.2 Remove the brake pedal ............................................................................... 180 8.3 Instrument panel .................................................................................... 181 8.3.1 Discharge the controllers............................................................................... 182 8.3.2 Vehicle controller........................................................................................... 183 8.3.3 Vehicle controller connectors ........................................................................ 183 8.3.3.1 CNA external connector ................................................................................ 184 8.3.3.2 CNB external connector ................................................................................ 186 8.3.4 Traction controller ......................................................................................... 187 8.3.5 Traction controller connectors ....................................................................... 188 8.3.5.1 CNA external connector ................................................................................ 189 8.3.5.2 Description of the power connections ............................................................ 190 8.3.6 Pump controller ............................................................................................. 190 8.3.7 Pump controller connectors........................................................................... 191 8.3.7.1 CNA external connector ................................................................................ 192 8.3.7.2 Description of the power connections ............................................................ 193 8.3.8 Steering controller ......................................................................................... 194 8.3.9 Steering controller connectors ....................................................................... 194 8.3.9.1 CNA external connector ................................................................................ 195 8.3.9.1 Description of the power connections ............................................................ 196 8.3.10 Fuses ............................................................................................................ 197 8.3.11 Remove the gas spring of the instrument panel ............................................. 199 8.4 Motor compartment ................................................................................ 200 8.4.1 Traction motor ............................................................................................... 201

© Mitsubishi Forklift Trucks 2014. All rights reserved. Revision: A Document ID: 622075 7 (442) RB14-25N2(S)(C)(H)(X) Service Manual 8.4.1.1 Remove the traction motor ............................................................................ 202 8.4.1.2 Temperature sensor check............................................................................ 203 8.4.1.3 HALL sensor ................................................................................................. 204 8.4.2 Steering motor .............................................................................................. 205 8.4.2.1 Remove the steering motor ........................................................................... 206 8.4.2.2 Temperature sensor check............................................................................ 207 8.4.2.3 HALL sensor ................................................................................................. 208 8.4.3 Magnetic brake ............................................................................................. 210 8.4.3.1 Coil resistance measurement ........................................................................ 210 8.4.3.2 Install the magnetic brake ............................................................................. 211 8.4.3.3 Adjust the air gap of the magnetic brake ....................................................... 212 8.4.4 Release the magnetic brake manually........................................................... 212 8.5 Pump motor............................................................................................ 213 8.5.1 Pump motor (Standard model) ...................................................................... 213 8.5.2 Pump motor (High performance model)......................................................... 214 8.5.3 Replace the HALL sensor ............................................................................. 215 8.6 Sensors .................................................................................................. 216 8.6.1 Steering wheel sensor................................................................................... 216 8.6.1.1 Steering wheel sensor functionality check ..................................................... 216 8.6.1.2 Steering control safety circuit check .............................................................. 217 8.6.2 Steering reference sensor ............................................................................. 219 8.6.2.1 Steering reference sensor functionality check ............................................... 219 8.6.3 Reach end stop, retract limit, retract end stop and reach limit switch ............. 220 8.6.3.1 Reach end stop, retract limit, retract end stop and reach limit switch functionality check......................................................................................... 220 8.6.4 Battery lock sensor........................................................................................ 221 8.6.4.1 Battery lock sensor functionality check .......................................................... 221 8.6.5 Pressure sensor ............................................................................................ 222 8.6.5.1 Pressure sensor functionality check .............................................................. 222 8.6.6 Height reference sensor ................................................................................ 223 8.6.6.1 Height reference sensor functionality check .................................................. 223 9 Electric system adjustments and measurements ............................................ 224 9.1 Calibrate the arm rest levers .................................................................. 224 9.2 Insulation resistance test ....................................................................... 224 9.2.1 Test voltage .................................................................................................. 224 9.2.2 Checking the insulation tester ....................................................................... 224 9.2.3 Measure the insulation resistance ................................................................. 225 9.2.3.1 Insulation resistance of the truck ................................................................... 225 9.2.3.2 Insulation resistance of the battery ................................................................ 226 10 Hydraulic operation ............................................................................................. 227 10.1 Hydraulic symbols .................................................................................. 232 10.2 Hydraulic oil recommendations .............................................................. 233 10.3 Maintenance points of the hydraulic system .......................................... 234 10.3.1 Replace the hydraulic oil return filter (sieve) .................................................. 235 10.3.2 Clean the hydraulic oil suction filter ............................................................... 236

© Mitsubishi Forklift Trucks 2014. All rights reserved. Revision: A Document ID: 622075 8 (442) RB14-25N2(S)(C)(H)(X) Service Manual 10.4 Hydraulic system.................................................................................... 237 10.4.1 Disassemble the hydraulic system ................................................................ 238 10.5 Hydraulic valve unit ................................................................................ 239 10.5.1 Valve M1 ....................................................................................................... 242 10.5.2 Valve M3, M4, M7 and M8 ............................................................................ 243 10.5.3 Valve M2, M5, M6, M9 and M10.................................................................... 243 10.5.4 Emergency lowering valve ............................................................................ 243 10.5.5 Set the lifting pressure................................................................................... 243 10.5.6 Disassemble the valves................................................................................. 245 11 TruckTool Diagnostics ........................................................................................ 246 12 Parameter descriptions ...................................................................................... 247 12.1 VCM ....................................................................................................... 247 12.2 Traction controller .................................................................................. 260 12.3 Pump controller ...................................................................................... 269 12.4 EPS controller ........................................................................................ 273 13 Alarm codes ......................................................................................................... 277 13.1 VCM ....................................................................................................... 277 13.1.1 VCM master .................................................................................................. 277 13.1.2 VCM slave .................................................................................................... 291 13.2 Traction controller .................................................................................. 306 13.3 Pump controller ...................................................................................... 321 13.4 EPS ........................................................................................................ 333 13.4.1 EPS master ................................................................................................... 333 13.4.2 EPS slave ..................................................................................................... 345 14 Service data ......................................................................................................... 359 14.1 Special tightening torques ...................................................................... 359 14.2 Tightening torque for standard bolts and nuts ....................................... 359 14.3 Maintenance check list ........................................................................... 361 14.4 Lubrication.............................................................................................. 365 14.4.1 Hydraulic oil .................................................................................................. 365 14.4.2 Transmission oil ............................................................................................ 365 14.5 Special tools ........................................................................................... 366 15 Options ................................................................................................................. 369 15.1 Special color labels ................................................................................ 371 15.2 Customer design labels ......................................................................... 371 15.3 Display languages .................................................................................. 372 15.4 Accessory rack ....................................................................................... 373 15.4.1 Install the accessory rack .............................................................................. 374 15.4.2 Install the list bracket..................................................................................... 374 15.4.3 Install the computer rack ............................................................................... 375 15.4.4 Install the rear view mirror ............................................................................. 375 15.5 Accessory rack under the truck floor...................................................... 376 15.5.1 Install the accessory rack under the floor ...................................................... 376

© Mitsubishi Forklift Trucks 2014. All rights reserved. Revision: A Document ID: 622075 9 (442) RB14-25N2(S)(C)(H)(X) Service Manual 15.6 Reading lamp ......................................................................................... 376 15.6.1 Install the reading lamp ................................................................................. 377 15.7 Audio system.......................................................................................... 378 15.7.1 Install the audio system................................................................................. 378 15.8 Warning light .......................................................................................... 380 15.8.1 Install the warning light .................................................................................. 380 15.9 Working lights......................................................................................... 382 15.9.1 Install the working lights ................................................................................ 382 15.10 Operator compartment fan ..................................................................... 384 15.10.1 Install the operator compartment fan ............................................................. 384 15.11 Drive alarm (programmable) .................................................................. 386 15.11.1 Install the drive alarm .................................................................................... 386 15.12 Steel safety net for overhead guard ....................................................... 387 15.12.1 Install the steel safety net to the overhead guard........................................... 387 15.13 Plexiglass safety cover for the overhead guard ..................................... 389 15.13.1 Install the plexiglass safety cover to the overhead guard ............................... 389 15.14 Left shoulder protection plate................................................................. 391 15.14.1 Install the left shoulder protection plate ......................................................... 391 15.15 Fire extinguisher..................................................................................... 392 15.15.1 Install the fire extinguisher............................................................................. 392 15.16 Cold storage modification ...................................................................... 394 15.17 Hot storage modification ........................................................................ 395 15.18 Current output ........................................................................................ 395 15.18.1 Install the DC-DC converter........................................................................... 395 15.19 Quick battery changing device for 2 batteries........................................ 397 15.19.1 Remove an empty battery with the battery changing device for 2 batteries ........................................................................................................ 398 15.19.2 Install a recharged battery with the battery changing device for 2 batteries ........................................................................................................ 400 15.20 Battery connector + cables .................................................................... 403 15.20.1 Replace the battery connector....................................................................... 403 15.21 Charger connector ................................................................................. 405 15.21.1 Replace the charger connector ..................................................................... 405 15.22 Extra valve with hosing to fork carriage ................................................. 406 15.23 Fork positioner with sideshift.................................................................. 407 15.24 Fork carriage strengthening part ............................................................ 407 15.25 Fork camera with 7” LCD color display .................................................. 408 15.26 Telescopic forks ..................................................................................... 409 15.27 Sideshift and tilt centering ...................................................................... 410 15.27.1 Sideshift centering direction, sideshift centering midpoint and tilt centering sensor ........................................................................................... 410 15.27.1.1 Sideshift centering direction, sideshift centering midpoint and tilt centering sensor functionality check .............................................................. 411 15.28 Load weight indicator ............................................................................. 412 15.29 Electric load wheel brakes ..................................................................... 413 15.30 Lowering cut-off...................................................................................... 414 15.31 Operator’s seat options and accessories ............................................... 415 15.31.1 Arm rest ........................................................................................................ 415

© Mitsubishi Forklift Trucks 2014. All rights reserved. Revision: A Document ID: 622075 10 (442) RB14-25N2(S)(C)(H)(X) Service Manual 15.31.2 Backrest extension for MSG65/MSG75 ......................................................... 416 15.31.2.1 Backrest extension adjustment...................................................................... 416 15.31.3 Seat belt for MSG20 seat .............................................................................. 417 15.31.3.1 Install the seat belt ........................................................................................ 417 15.32 PIN code access to the Start switch ...................................................... 418 15.33 Lifting height pre-selection ..................................................................... 419 15.33.1 How to unstack with the lifting height pre-selection........................................ 420 15.33.2 How to stack with the lifting height pre-selection ........................................... 421 16 Technical specification ....................................................................................... 422 16.1 RB14N2S, RB14N2HS, RB16N2S, RB16N2HS and RB16N2 .............. 423 16.2 RB16N2H, RB16N2C, RB16N2HC, RB20N2H, RB20N2X and RB25N2X ............................................................................................... 426 16.3 Mast heights ........................................................................................... 428 17 Index ..................................................................................................................... 430 APPENDIX A: Stickers................................................................................................... 433

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Mitsubishi Reach Truck RB14N2, RB16N2, RB20N2, RB25N2 (H)(S)(C)(X) Workshop Service Manual

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