Original Illustrated Factory Workshop Service Manual for Mitsubishi Reach Truck RB-Series.

Original factory manuals for Mitsubishi Lift Trucks contains high quality images, circuit diagrams and instructions to help you to operate, maintenance and repair your truck. All Manuals Printable, without restrictions, contains Searchable Text and bookmarks

Covered models:
RB14N2HS
RB14N2S
RB16N2
RB16N2C
RB16N2H
RB16N2HC
RB16N2HS
RB16N2S
RB20N2H
RB20N2X
RB25N2X

Format: PDF, 432 Pages
Language: English
Contents:
1 Foreword
2 How to read this manual
2.1 Safety-related signs
2.2 Symbols and abbreviations
2.2.1 Safety symbols.
2.2.2 Other symbols and abbreviations
2.3 Units
3 Safety instructions
3.1 Service area safety
3.2 Personal safety
3.3 Work safety
4 General information .
4.1 Truck model covered by this manual
4.2 Identification plates on the truck
4.3 Overview of the truck
4.3.1 Operating devices
4.3.2 Control panel.
4.3.3 Steering wheel
4.3.4 Arm rest
4.3.5 Display panel
4.3.6 Truck operation modes.
4.3.7 Truck display
4.3.7.1 Display control buttons
4.3.7.2 Main view of the truck display.
4.3.7.3 Hierarchy of the truck display menus.
4.3.8 Pedals.
4.3.9 Operators seat
4.3.10 Operating position
4.3.11 Driving direction
4.3.12 Motor, hydraulic system and electrical system.
4.3.12.1 Instrument panel
4.3.12.2 Hydraulic system.
4.3.12.3 Motor compartment
4.3.13 Sensors.
4.3.14 Reach carriage.
4.3.15 Mast unit
4.3.16 Load support
5 Mechanical maintenance
5.1 Lifting points
5.1.1 Jack points
5.1.2 Hoist points
5.2 Transportation
5.3 Assembly and commissioning
5.3.1 Install the mast unit
5.4 Order spare parts
5.5 Truck covers
5.5.1 Remove the machinery cover
5.5.2 Remove the front bumper.
5.5.3 Remove the floor plate
5.5.4 Open the machinery top cover
5.5.5 Open the instrument panel
5.5.6 Remove the instrument panel cover
5.5.7 Remove the control panel
5.5.8 Remove the cup holder
5.5.9 Remove the reach carriage cover.
5.6 Steering wheel
5.6.1 Remove the steering wheel
5.7 Transmission gear
5.7.1 Remove the transmission gear
5.8 Slewing bearing
5.8.1 Lubricate the slewing bearing
5.9 Traction wheel
5.9.1 Disassemble the traction wheel
5.9.1.1 Replace the wheel shaft bolts.
5.9.2 Assemble the traction wheel.
5.10 Corner supports
5.10.1 Replace the corner supports
5.11 Load wheels
5.11.1 Remove the load wheels
5.12 Battery roller frame
5.12.1 Remove the battery roller frame
5.13 Reach carriage
5.13.1 Lubricate the rollers of the reach carriage
5.13.2 Adjust the guidance rollers of the reach carriage
5.13.3 Sensors of the reach carriage
5.13.4 Remove the reach carriage
5.13.5 Remove the reach cylinder.
5.13.6 Replace the reach carriage hoses
5.14 Mast unit
5.14.1 Detailed construction.
5.14.2 Mast unit maintenance
5.14.2.1 Daily maintenance.
5.14.2.2 Monthly maintenance
5.14.2.3 Annual maintenance (600 h)
5.14.3 Lubricant recommendations
5.14.3.1 Mast chains.
5.14.3.2 Mast channels.
5.14.4 Remove the lifting carriage.
5.14.5 Remove the mast unit
5.14.6 Disassemble the mast unit
5.14.7 Fork inspection.
5.14.8 Mast chains.
5.14.8.1 Inspect the mast chains.
5.14.8.2 Check the tension of the mast chains
5.14.8.3 Adjust the mast chains
5.14.8.4 Replace the mast chains
5.14.9 Guidance rollers
5.14.9.1 Adjust the guidance rollers
5.14.9.2 Replace the guidance rollers
5.14.10 Main rollers
5.14.10.1 Replace the main rollers.
5.14.11 Free lift cylinder.
5.14.11.1 Replace the free lift cylinder
5.14.11.2 Sealing housing of the free lift cylinder
5.14.11.3 Bleed out the air from the free lift cylinder
5.14.12 Side cylinders.
5.14.12.1 Replace the side cylinders
5.14.12.2 Sealing housing of the side cylinder
5.14.12.3 Bleed out the air from the side cylinders
5.14.13 Tilt cylinders
5.14.13.1 Remove the tilt cylinders
5.14.13.2 Sealing housing of the tilt cylinder
5.14.14 Sideshift cylinder
5.14.14.1 Remove the piston of the sideshift cylinder
5.14.14.2 Sealing housing of the sideshift cylinder
5.15 Load support
5.15.1 Remove the load support
5.16 Arm rest
5.16.1 Remove the arm rest.
5.16.2 Open the arm rest
5.16.3 Remove the arm rest levers
5.16.4 Remove the arm rest buttons
5.17 Operators seat
5.17.1 Replace the seat switch
6 Electrical operation
6.1 How to use the schematic diagram
6.2 Power source
6.3 Safety circuit (emergency stop button)
6.4 Key switch
6.5 Traction
7 Battery maintenance
7.1 Safety regulations concerning the handling of lead-acid batteries
7.2 Battery maintenance
7.2.1 Daily maintenance.
7.2.2 Weekly maintenance.
7.2.3 Monthly maintenance
7.2.4 Annual maintenance
7.3 Recharge the battery
7.4 Measure the specific gravity of the battery
7.5 Replace the battery
7.5.1 Guide the battery connector cables
7.6 Quick battery replacement
8 Electric system maintenance
8.1 Display panel
8.1.1 Emergency stop button
8.1.1.1 Emergency stop button functionality check
8.1.2 Key switch.
8.1.2.1 Key switch functionality check
8.2 Pedals
8.2.1 Operator presence pedal.
8.2.1.1 Operator presence pedal functionality check
8.2.1.2 Remove the operator presence pedal
8.2.2 Acceleration pedal.
8.2.2.1 Acceleration pedal functionality check
8.2.2.2 Remove the acceleration pedal
8.2.3 Brake pedal.
8.2.3.1 Brake pedal functionality check
8.2.3.2 Remove the brake pedal
8.3 Instrument panel
8.3.1 Discharge the controllers.
8.3.2 Vehicle controller.
8.3.3 Vehicle controller connectors
8.3.3.1 CNA external connector
8.3.3.2 CNB external connector
8.3.4 Traction controller
8.3.5 Traction controller connectors
8.3.5.1 CNA external connector
8.3.5.2 Description of the power connections
8.3.6 Pump controller
8.3.7 Pump controller connectors.
8.3.7.1 CNA external connector
8.3.7.2 Description of the power connections
8.3.8 Steering controller
8.3.9 Steering controller connectors
8.3.9.1 CNA external connector
8.3.9.1 Description of the power connections
8.3.10 Fuses
8.3.11 Remove the gas spring of the instrument panel.
8.4 Motor compartment
8.4.1 Traction motor
8.4.1.1 Remove the traction motor
8.4.1.2 Temperature sensor check.
8.4.1.3 HALL sensor
8.4.2 Steering motor
8.4.2.1 Remove the steering motor
8.4.2.2 Temperature sensor check.
8.4.2.3 HALL sensor
8.4.3 Magnetic brake
8.4.3.1 Coil resistance measurement
8.4.3.2 Install the magnetic brake
8.4.3.3 Adjust the air gap of the magnetic brake
8.4.4 Release the magnetic brake manually.
8.5 Pump motor
8.5.1 Pump motor (Standard model)
8.5.2 Pump motor (High performance model).
8.5.3 Replace the HALL sensor
8.6 Sensors
8.6.1 Steering wheel sensor.
8.6.1.1 Steering wheel sensor functionality check
8.6.1.2 Steering control safety circuit check
8.6.2 Steering reference sensor
8.6.2.1 Steering reference sensor functionality check
8.6.3 Reach end stop, retract limit, retract end stop and reach limit switch
8.6.3.1 Reach end stop, retract limit, retract end stop and reach limit switch functionality check
8.6.4 Battery lock sensor.
8.6.4.1 Battery lock sensor functionality check
8.6.5 Pressure sensor
8.6.5.1 Pressure sensor functionality check
8.6.6 Height reference sensor
8.6.6.1 Height reference sensor functionality check
9 Electric system adjustments and measurements
9.1 Calibrate the arm rest levers
9.2 Insulation resistance test
9.2.1 Test voltage
9.2.2 Checking the insulation tester
9.2.3 Measure the insulation resistance
9.2.3.1 Insulation resistance of the truck
9.2.3.2 Insulation resistance of the battery
10 Hydraulic operation
10.1 Hydraulic symbols
10.2 Hydraulic oil recommendations
10.3 Maintenance points of the hydraulic system
10.3.1 Replace the hydraulic oil return filter (sieve)
10.3.2 Clean the hydraulic oil suction filter
10.4 Hydraulic system
10.4.1 Disassemble the hydraulic system
10.5 Hydraulic valve unit
10.5.1 Valve M1
10.5.2 Valve M3, M4, M7 and M8
10.5.3 Valve M2, M5, M6, M9 and M10.
10.5.4 Emergency lowering valve
10.5.5 Set the lifting pressure.
10.5.6 Disassemble the valves.
11 TruckTool Diagnostics
12 Parameter descriptions
12.1 VCM
12.2 Traction controller
12.3 Pump controller
12.4 EPS controller
13 Alarm codes
13.1 VCM
13.1.1 VCM master
13.1.2 VCM slave
13.2 Traction controller
13.3 Pump controller
13.4 EPS
13.4.1 EPS master.
13.4.2 EPS slave
14 Service data
14.1 Special tightening torques
14.2 Tightening torque for standard bolts and nuts
14.3 Maintenance check list
14.4 Lubrication
14.4.1 Hydraulic oil
14.4.2 Transmission oil
14.5 Special tools
15 Options
15.1 Special color labels
15.2 Customer design labels
15.3 Display languages
15.4 Accessory rack
15.4.1 Install the accessory rack
15.4.2 Install the list bracket
15.4.3 Install the computer rack
15.4.4 Install the rear view mirror
15.5 Accessory rack under the truck floor
15.5.1 Install the accessory rack under the floor
15.6 Reading lamp
15.6.1 Install the reading lamp
15.7 Audio system
15.7.1 Install the audio system
15.8 Warning light
15.8.1 Install the warning light
15.9 Working lights
15.9.1 Install the working lights
15.10 Operator compartment fan
15.10.1 Install the operator compartment fan
15.11 Drive alarm (programmable)
15.11.1 Install the drive alarm
15.12 Steel safety net for overhead guard
15.12.1 Install the steel safety net to the overhead guard.
15.13 Plexiglass safety cover for the overhead guard
15.13.1 Install the plexiglass safety cover to the overhead guard
15.14 Left shoulder protection plate
15.14.1 Install the left shoulder protection plate
15.15 Fire extinguisher
15.15.1 Install the fire extinguisher
15.16 Cold storage modification
15.17 Hot storage modification
15.18 Current output
15.18.1 Install the DC-DC converter.
15.19 Quick battery changing device for 2 batteries
15.19.1 Remove an empty battery with the battery changing device for 2 batteries
15.19.2 Install a recharged battery with the battery changing device for 2 batteries
15.20 Battery connector + cables
15.20.1 Replace the battery connector.
15.21 Charger connector
15.21.1 Replace the charger connector
15.22 Extra valve with hosing to fork carriage
15.23 Fork positioner with sideshift
15.24 Fork carriage strengthening part
15.25 Fork camera with 7 LCD color display
15.26 Telescopic forks
15.27 Sideshift and tilt centering
15.27.1 Sideshift centering direction, sideshift centering midpoint and tilt centering sensor
15.27.1.1 Sideshift centering direction, sideshift centering midpoint and tilt centering sensor functionality check
15.28 Load weight indicator
15.29 Electric load wheel brakes
15.30 Lowering cut-off
15.31 Operators seat options and accessories
15.31.1 Arm rest
15.31.2 Backrest extension for MSG65/MSG75
15.31.2.1 Backrest extension adjustment.
15.31.3 Seat belt for MSG20 seat
15.31.3.1 Install the seat belt
15.32 PIN code access to the Start switch
15.33 Lifting height pre-selection
15.33.1 How to unstack with the lifting height pre-selection
15.33.2 How to stack with the lifting height pre-selection
16 Technical specification
16.1 RB14N2S, RB14N2HS, RB16N2S, RB16N2HS and RB16N2
16.2 RB16N2H, RB16N2C, RB16N2HC, RB20N2H, RB20N2X and RB25N2X
16.3 Mast heights
17 Index
APPENDIX A: Stickers.