Mitsubishi EDR36 Forklift Service Manual

Mitsubishi EDR36 Forklift Service Manual - Image 2

Mitsubishi EDR36 Forklift Service Manual - Image 3

Mitsubishi EDR36 Forklift Service Manual - Image 4

Mitsubishi EDR36 Forklift Service Manual - Image 5

mitsubishi edr36 forklift service manual 2

mitsubishi edr36 forklift service manual 3

Mitsubishi EDR36 Forklift Service Manual

$50.00

Type Of Manual: Service Manual
Number of Pages: 296
Size: 4.7MB
Format: PDF

Category: Mitsubishi Service Manual PDF

Model List:
- EDR36 Forklift

1. CHARTS AND SCHEMATICS
1.1. APPENDIX A CHARTS AND SCHEMATICS
1.1.1. Lubrication Equivalency Chart
1.1.2. Torque Chart – Standard (Ferrous)
1.1.3. Torque Chart – Standard (Brass)
1.1.4. Torque Chart – Metric (Ferrous)
1.1.5. Torque Chart – Metric (Brass)
1.1.6. Decimal Equivalent Chart
1.1.7. Standard/Metric Conversions
1.1.8. Electrical Schematic
1.1.9. Hydraulic Schematic
1.1.10. Decal Locations
1.1.11. Pin-By-Pin Voltages – EV100LX Travel Control System
1.1.12. EV100 Interface Card Troubleshooting Relationships
1.1.13. Brush Replacement
2. GENERAL INFORMATION
2.1. GENERAL INFORMATION
2.1.1. Warning Pages
2.1.2. Overview of this Manual
2.1.3. List of Figures
2.1.4. List of Tables
3. INSTALLATION
3.1. INSTALLATION
3.1.1. Overview
3.1.1.1. Warranty Coverage
3.1.1.2. In this Chapter
3.1.2. Inspecting the Truck
3.1.2.1. How the Truck is Shipped
3.1.2.2. Reasons for Doing a Visual Inspection
3.1.2.3. What to Look For
3.1.2.4. Repairing Shipping Damage
3.1.2.5. Repairing Defects
3.1.3. Uprighting a Cradled Truck
3.1.3.1. Warnings and Cautions
3.1.3.2. Items Needed
3.1.3.3. Option 1 Uprighting with Two Chain Hoists
3.1.3.4. Option 2 Uprighting with One Chain Hoist and a Lift Truck
3.1.4. Assembling the Truck
3.1.4.1. Removing the Gaskets
3.1.4.2. Greasing the Mast Uprights
3.1.4.3. Installing the Battery
3.1.5. Doing a Functional Inspection
3.1.5.1. Who Does the Inspection
3.1.5.2. What Needs to be Done
3.1.5.3. Starting the Mitsubishi Warranty
3.1.5.4. Reporting Repairs
3.1.5.5. Using the Checklist
3.1.6. Preparing the Truck for Cold Storage
3.1.6.1. Classes of Cold Storage
3.1.6.2. Types of Oil
3.1.6.3. Changing the Hydraulic System Oil
3.1.7. Preparing the Truck for Storage
3.1.7.1. Storage Warranty
3.1.7.2. General Storage Tips
3.1.7.3. Hydraulic System
3.1.7.4. Hydraulic Cylinders
3.1.7.5. Lift Chains
3.1.7.6. Mast Uprights
3.1.7.7. Electronics
3.1.7.8. Battery
4. MAINTENANCE
4.1. MAINTENANCE
4.1.1. General Maintenance Instructions
4.1.1.1. In this Chapter
4.1.2. Maintenance Practices
4.1.2.1. Jacking the Truck
4.1.2.2. Welding Procedures
4.1.2.2.1. Electrostatic Discharge Damage
4.1.2.2.2. Proper Handling of Static Sensitive Devices
4.1.2.2.3. Discharging the Truck
4.1.2.2.4. Removing the Circuit Card
4.1.2.2.5. Removing an Integrated Circuit (IC)
4.1.2.2.6. Installing a New Integrated Circuit
4.1.2.2.7. Removing a Pin
4.1.2.2.8. Troubleshooting with the Cable Connector Breakout Board
4.1.2.3. Shunt Locations
4.1.3. Planned Maintenance
4.1.3.1. Service Manual
4.1.3.2. Planned Maintenance Schedule
4.1.3.3. Time Requirements
4.1.3.4. Planned Maintenance Checks
4.1.3.4.1. Inspection Schedule
4.1.3.5. Grease Fitting Locations
4.1.4. Battery Maintenance
4.1.4.1. How Batteries Get Damaged
4.1.4.2. Removing a Battery
4.1.4.3. Installing a Battery
4.1.4.4. Cleaning the Battery
4.1.4.5. Testing the Battery Electrical Leakage To Frame
4.1.4.6. Battery Discharge Indicator (BDI)
4.1.4.6.1. Internal Resistance Compensation
4.1.4.6.2. Adjusting the Internal Compensation
4.1.4.7. Changing the Battery
4.1.4.7.1. Precautions
4.1.4.7.2. Using the Hydrometer
4.1.4.7.3. Checking the Specific Gravity
4.1.4.8. Voltage Check
4.1.4.9. Adding Water to the Battery
4.1.4.10. Keeping a Battery History Record
4.1.5. Maintaining the Motor
4.1.5.1. Motor Cleaning
4.1.5.2. Brush Care
4.1.5.2.1. Cleaning the Brushes
4.1.5.2.2. Measuring the Brush Spring Tension
4.1.5.2.3. Replacing a Brush
4.1.5.3. Preventing the Motor from Overheating
4.1.5.3.1. Checking the Torque on the Motor Stud Terminals
4.1.5.4. Open Circuits
4.1.5.4.1. Testing for Open Circuits
4.1.5.5. Short Circuits
4.1.5.5.1. Testing for Short Circuits
4.1.5.6. Armature Shorts
4.1.5.6.1. Checking for Armature Shorts
4.1.5.7. Grounded Motors
4.1.5.7.1. Testing for a Grounded Motor
4.1.5.8. Truck Grounds – General
4.1.5.8.1. Testing for Grounds on the Truck Frame
4.1.6. Hydraulic System Maintenance
4.1.6.1. Selecting the Oil
4.1.6.2. Changing the Reservoir Fluid
4.1.6.3. Checking the Reservoir Fluid Level
4.1.6.4. Changing the Reservoir Filter
4.1.6.5. Bleeding the Hydraulic System
4.1.7. Mechanical Maintenance
4.1.7.1. Power Section
4.1.7.1.1. Drive Unit Service
4.1.7.1.2. Removing the Drive Unit
4.1.7.1.3. Installing the Drive Unit
4.1.7.1.4. Preparing to Replace the Drive Axle Seal (36-Volt)
4.1.7.1.5. Replacing the Drive Axle Seal (36-Volt)
4.1.7.1.6. Preparing to Replace the Drive Axle Seal (24-Volt)
4.1.7.1.7. Disassembling the Drive Unit (24-Volt)
4.1.7.1.8. Assembling the Drive Unit (24-Volt)
4.1.7.2. Braking System
4.1.7.2.1. Braking Process
4.1.7.2.2. Adjusting Nut-Retained Style Brakes
4.1.7.2.3. Inspecting the Brake Pad
4.1.7.2.4. Bleeding the Brake
4.1.7.2.5. Adjusting the Deadman Pedal
4.1.7.2.6. Replacing the Brake Master Cylinder
4.1.7.2.7. Replacing the Brake Pads
4.1.7.2.8. Brake Installation
4.1.7.2.9. Reassembling the Brake
4.1.7.2.10. Replacing the Brake O-Ring Seal
4.1.7.3. Steering System
4.1.7.3.1. Steering Adjustment with Steerable Caster
4.1.7.3.2. Initial Adjustments
4.1.7.3.3. Adjusting the Casters
4.1.7.3.4. Service Notes for Steering Components
4.1.7.4. Lift/Lower System
4.1.7.4.1. Lift Chains
4.1.7.4.2. Removing and Inspecting the Chain
4.1.7.4.3. Lubricating the Lift Chain
4.1.7.4.4. Adjusting the Over the Mast Hose and Cable
4.1.7.4.5. Replacing the Over the Mast Hose
4.1.7.4.6. Replacing the Flow Control
4.1.7.4.7. Adjusting the Equalization Chain
4.1.7.4.8. Equalization Chain Removal and Installation
4.1.7.4.9. Replacing the Equalization Chain Sheave
4.1.7.4.10. Applying Loctite to the Reach Carriage Chain Anchors
4.1.7.4.11. Adjusting the Mechanical Stop
4.1.7.4.12. Reach Carriage Lubrication Points
4.1.7.4.13. Removing the Fork Carriage Tilt Pins
4.1.7.4.14. Attaching the Mast to the Tractor
4.1.7.4.15. Adjusting the High Pressure Relief Valve
5. OPERATING INSTRUCTIONS
5.1. OPERATING INSTRUCTIONS
5.1.1. In this Chapter
5.1.2. EV100LX Operator System Display
5.1.2.1. Display Test
5.1.2.2. Hour Meter
5.1.2.3. Battery Charge Level
5.1.2.4. Status Codes
5.1.2.4.1. Informational Messages
5.1.2.4.2. Performance Limiting Codes
5.1.2.4.3. Fault Codes
5.1.3. Operators Daily Checklist
5.1.3.1. Visual Checks
5.1.3.2. Operational Checks
5.1.3.2.1. Start-up Procedure
5.1.3.2.2. Forward/Reverse Travel
5.1.3.2.3. Braking
5.1.3.2.4. Plugging
5.1.3.2.5. Parking
5.1.3.2.6. Entering an Aisle
5.1.3.2.7. Operating the Truck on a Ramp
5.1.3.2.8. Travel Speed and Lift Limits
6. THEORY OF OPERATION
6.1. THEORY OF OPERATION
6.1.1. In this Chapter
6.1.2. EV100LX Control Panel
6.1.3. System Components
6.1.3.1. Silicon Controlled Rectifiers (SCR)
6.1.3.1.1. 1 Rectifier (REC1) Chopper SCR
6.1.3.1.2. 2 Rectifier (REC2) Commutating SCR
6.1.3.1.3. 5 Rectifier (REC5) Charging SCR
6.1.3.2. Diode Rectifiers
6.1.3.2.1. 3 Rectifier (REC3) Free Wheeling
6.1.3.2.2. 4 Rectifier (REC4) Plugging
6.1.3.2.3. Reactor (Coil T3/T4)
6.1.3.2.4. Capacitor 1-C
6.1.3.2.5. Filters REC22, REC23, REC24, REC25
6.1.3.3. Thermal Protector (TP)
6.1.3.4. Sensor (Sensor 1)
6.1.4. Control Features
6.1.4.1. Creep Speed
6.1.4.2. Controlled Acceleration
6.1.4.3. Current Limit
6.1.4.4. Plugging
6.1.4.5. Current Dropout
6.1.4.6. Speed Limit 1 (SL1) and Speed Limit 3 (SL3)
6.1.4.7. Static Return to OFF
6.1.4.8. Accelerator Volts Hold-Off
6.1.4.9. Coil Driver Modules
6.1.4.10. Thermal Cutback
6.1.4.11. Pulse Monitor Trip (PMT)
6.1.4.12. Internal Resistance Compensation
6.1.4.13. Steer Pump Time Delay
6.1.4.14. Stored Fault Code
6.1.4.15. Battery Discharge Indicator
6.1.4.16. Hour Meter
6.1.4.17. On-board Diagnostics
6.1.5. Basic SCR Controller Circuit Operation
6.1.5.1. Energizing the Control Circuit
6.1.5.2. Gate Pulse to REC2
6.1.5.3. Gate Pulse to REC1
6.1.5.4. Firing REC2
6.1.5.5. OFF Time
6.1.5.6. Oscillation Frequency
6.1.5.7. Oscillator Features
6.1.6. Wiring Conventions
6.1.7. Operation of the Travel System
6.1.7.1. Sequence 1 Truck at Rest
6.1.7.2. Sequence 2 Connect the Battery
6.1.7.3. Sequence 3 Closing the Key Switch and the Deadman Pedal
6.1.7.4. Sequence 4 PMT Test
6.1.7.5. Sequence 5 Directional Contactor Closure
6.1.7.6. Sequence 6 REC1 Turn ON
6.1.7.7. Sequence 7 REC5 Turn ON
6.1.7.8. Sequence 8 Reverse Charging the 1C Capacitor
6.1.7.9. Sequence 9 REC2 Turn ON and REC1 Turn OFF
6.1.7.10. Sequence 10 Free-Wheeling Current
6.1.7.11. Sequence 11 1A or Bypass Contactor Operation
6.1.7.12. Sequence 12 Controlled Plugging
6.1.8. Lift/Lower System
6.1.8.1. System Overview
6.1.8.2. Unique System Features
6.1.8.3. Components
6.1.8.4. Functionality
6.1.9. Braking
7. TROUBLESHOOTING
7.1. TROUBLESHOOTING
7.1.1. In this Chapter
7.1.2. Troubleshooting Procedure
7.1.2.1. Verifying Problems
7.1.2.2. Locating the Problem Area
7.1.2.3. Establishing a Logical Testing Sequence
7.1.2.4. Identifying the Cause of the Problem
7.1.2.5. Correcting the Problem
7.1.3. Electrical
7.1.3.1. Checking the Wiring
7.1.3.1.1. Troubleshooting Procedure
7.1.3.1.2. Shorts to the Truck Frame – Causes
7.1.3.1.3. Shorts to the Truck Frame – Checking
7.1.3.1.4. Voltage To Frame – Causes
7.1.3.1.5. Voltage To Frame – Checking
7.1.3.1.6. Voltage To Frame – Eliminating
7.1.3.2. Board and Component Swapping Precautions
7.1.3.2.1. Troubleshooting Order for Component Failure
7.1.3.2.2. Handling Printed Circuit Cards
7.1.3.2.3. Cleaning and Inspecting the Contactors
7.1.3.2.4. Contactors Specifications
7.1.3.2.5. Testing Other Electrical Components
7.1.3.2.6. EV100LX Component Tests
7.1.4. Hydraulics
7.1.4.1. Checking for Hydraulic Leaks
7.1.4.2. Maintenance Tips
7.1.4.2.1. Avoiding Hydraulic Problems
7.1.4.2.2. Lift/Lower Hydraulic System Troubleshooting
7.1.4.2.3. Steps for Locating Problems in the Lift/Lower System
7.1.4.2.4. Pump Problems
7.1.5. EV100LX Codes and Tests
7.1.5.1. Troubleshooting the EV100LX Solid-State Control System
7.1.5.1.1. Identifying a Malfunction
7.1.5.1.2. Replacing the Logic Card
7.1.5.1.3. Wire Numbers
7.1.5.1.4. Jacking the Truck
7.1.5.1.5. Accessing the Terminals
7.1.5.1.6. Visual Check
7.1.5.2. Using the LX Handset
7.1.5.2.1. Operating the Handset
7.1.5.2.2. Function Set-Up Procedures
7.1.5.2.3. Handset Programmable Functions
7.1.5.2.4. System Voltage Drop vs. Function Setting
7.1.5.3. GE Status Codes
7.1.5.3.1. Status Code – Blank display
7.1.5.3.2. Status Code – 01
7.1.5.3.3. Status Code – 02
7.1.5.3.4. Status Code – 03
7.1.5.3.5. Status Code – 04
7.1.5.3.6. Status Code – 05
7.1.5.3.7. Status Code – 06
7.1.5.3.8. Status Code – 07
7.1.5.3.9. Status Code – 08
7.1.5.3.10. Status Code – 09
7.1.5.3.11. Status Code – 15
7.1.5.3.12. Status Code – 16
7.1.5.3.13. Status Code – 17
7.1.5.3.14. Status Code – 23
7.1.5.3.15. Status Code – 24
7.1.5.3.16. Status Code – 25
7.1.5.3.17. Status Code – 41
7.1.5.3.18. Status Code – 42
7.1.5.3.19. Status Code – 43
7.1.5.3.20. Status Code – 44
7.1.5.3.21. Status Code – 45
7.1.5.3.22. Status Code – 46
7.1.5.3.23. Status Code – 47
7.1.5.3.24. Status Code – 48
7.1.5.3.25. Status Code – 49
7.1.5.3.26. Status Code – 50
7.1.5.3.27. Status Code – 51
7.1.5.3.28. Status Code – 52
7.1.5.3.29. Status Code – 53
7.1.5.3.30. Status Code – 54
7.1.5.3.31. Status Code – 57
7.1.6. Troubleshooting the Interface Card System
7.1.6.1. Running Learn
7.1.6.2. Setting up the Truck
7.1.6.3. Interface Card Switch Settings
7.1.6.4. Interface Card Assembly
7.1.6.5. Interface Card Codes
7.1.7. Troubleshooting the Interface Card
7.1.7.1. Display on Interface Card is Dark
7.1.7.2. No Auxiliary Functions Aux. Motor Runs Other Functions OK
7.1.7.3. Auxiliary Motor Does not Run Other functions OK
7.1.7.4. One Auxiliary Function Is Inoperative
7.1.7.5. Auxiliary Functions Operate In Only One Direction Steering OK
7.1.7.5.1. No Lift
7.1.7.5.2. No Lower
7.1.7.6. No Travel, Other Functions OK
7.1.7.7. No Speed Limit
7.1.7.8. No Lift Inhibit
8. TRUCK DESCRIPTION
8.1. TRUCK DESCRIPTION
8.1.1. Overview
8.1.1.1. In this Chapter
8.1.2. Truck Overview

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