Mitsubishi Forklift PBP PBP16N2 18N2 20N2 20N2E Service Manual – PDF DOWNLOAD

Description

Mitsubishi Forklift PBP PBP16N2 18N2 20N2 20N2E Service Manual – PDF DOWNLOAD

FILE DETAILS:

Mitsubishi Forklift PBP PBP16N2 18N2 20N2 20N2E Service Manual – PDF DOWNLOAD

MITSUBISHI FORKLIFT PBP PBP16N2 18N2 20N2 20N2E SERVICE MANUAL – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Mitsubishi Forklift PBP PBP16N2 18N2 20N2 20N2E Service Manual – PDF DOWNLOAD

FOREWORD:

This service manual is a guide for servicing lift trucks. The long productive life of your lift truck depends on regular and proper servicing, consistent with the instructions provided in this service manual. Before starting to test, repair or rebuild a lift truck, read the respective sections of this manual carefully and familiarize yourself with all of the components. The descriptions, illustrations and specifications contained in this manual are for lift trucks with serial numbers in effect at the time of printing. The manufacturer reserves the right to change specifications or designs without notice and without incurring obligations. For your convenience, the instructions are grouped by systems as an easy reference. Unauthorized copying and lending of this material is strictly prohibited.

Work safety:

• Unauthorized truck modification is not permitted. No modifications or alterations to a powered industrial truck, which could affect, for example, capacity, stability or safety requirements of the truck, shall be made without the prior written approval of the original truck manufacturer, its authorized representative, or a successor thereof.
• This includes changes affecting, for example, braking, steering, visibility and the addition of removable attachments. When the manufacturer or his successor approves a modification or alteration, the manufacturer or successor shall also make and approve appropriate changes to the capacity plate, decals, tags and operation and maintenance handbooks.
• Only in the event that the truck manufacturer is no longer in business and there is no successor in the interest to the business, may the user arrange for a modification or alteration to a powered industrial truck, provided, however, that the user:

a. arranges for the modification or alteration to be designed, tested and implemented by an engineer(s) expert in industrial trucks and their safety,
b. maintains a permanent record of the design, test(s) and implementation of the modification or alteration,
c. approves and makes appropriate changes to the capacity plate(s), decals, tags and instruction handbook, and © Mitsubishi Forklift Trucks 2013. All rights reserved. Revision: A Document ID: 618022 13 (210) PBP Service Manual
d. affixes a permanent and readily visible label to the truck stating the manner in which the truck has been modified or altered, together with the date of the modification or alteration and the name and address of the organization that accomplished those tasks.

• Switch off the truck’s power before opening the cover of the motor compartment or the electrical system.
• Relieve all pressure in the air, oil or water systems before disconnecting or removing any lines, fittings or related items. Release the residual pressure when removing a pressurized device.
• With sit-on trucks, dismount the seat for the duration of the service work.
• Before operating, lubricating or repairing the product, read all warning plates and decals on the truck.
• Do not use your hands to check for oil leaks.
• To avoid burns, pay attention to the hot sections and hot fluids in lines, tubes and compartments, even when the truck is idle or off.
• Only use clean oil in the hydraulic system.
• Repairs requiring welding should be performed only with the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine the type of metal and select the correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of the parent metal.
• When welding, always disconnect the battery and electronic devices. Remove all paint from a 10 cm radius from the welding point to avoid creating toxic gases during welding.
• Use proper lifting procedures when removing any components.
• Be careful when removing cover plates. Gradually remove the last two bolts or nuts located at opposite ends of the cover or device. Before removing the last two bolts or nuts completely, pry the cover loose to relieve any springs or other pressures.
• Be careful when removing filler caps, breathers and plugs on the truck. Wrap a cloth around the cap or plug to prevent being sprayed or splashed by liquids under pressure. Be aware that the danger of being sprayed or splashed is always greater immediately after stopping the truck, as the fluids are very hot.
• Use only well-maintained tools. Also make sure that you use the tools in a proper way.
• Reinstall all fasteners with the same part number. If a replacement is needed, do not use a fastener of lesser quality.

TABLE OF CONTENTS:

Mitsubishi Forklift PBP PBP16N2 18N2 20N2 20N2E Service Manual – PDF DOWNLOAD

Contents 3
1 Foreword 7
2 How to read this manual 8
2 1 Safety-related signs 8
2 2 Symbols and abbreviations 8
2 2 1 Safety symbols 8
2 2 2 Other symbols and abbreviations 10
2 3 Units 10
3 Safety instructions 11
3 1 Service area safety 11
3 2 Personal safety 12
3 3 Work safety 12
4 General information 15
4 1 Truck model covered by this manual 15
4 2 Identification plates on the truck 15
4 3 Overview of the truck 16
4 3 1 Operating devices 16
4 3 2 Tiller arm 17
4 3 3 Control panel 19
4 3 4 Driving position 24
4 3 5 Driving direction 24
4 3 6 Motor and electrical system 25
4 3 7 Sensors 28
4 3 8 Truck suspension 29
4 3 9 Ergo lift 30
5 Mechanical maintenance 31
5 1 Lifting points 31
5 1 1 Jack points 31
5 1 2 Hoist points 31
5 2 Transportation 32
5 3 Ordering spare parts 33
5 4 Opening the covers 33
5 4 1 Front cover 34
5 4 2 Control panel 34
5 4 3 Battery cover 36
5 5 Transmission gear 38
5 6 Bogie bearing 39
5 7 Traction wheel 39
5 7 1 Disassembly of the traction wheel 40
5 7 2 Assembly of the traction wheel 42
5 8 Load wheels 43
© Mitsubishi Forklift Trucks 2013 All rights reserved Revision: A Document ID: 618022 4 (210)
PBP Service Manual
5 9 Lifting system and fork carriage 44
5 10 Castor wheels 46
5 10 1 Disassembly of the castor wheel 47
5 10 2 Assembly of the castor wheel 47
5 11 Castor wheel suspension 48
5 12 Tiller arm 50
5 13 Tiller arm joint 52
5 14 Ergo lift 56
5 14 1 Disassembly of the ergo lifting carriage 56
5 14 2 Inspecting the chains 58
5 14 3 Main rollers 64
6 Electrical operation 66
6 1 Using the schematic diagram 66
6 2 Power source 69
6 3 Safety circuit (emergency stop button) 69
6 4 Key switch 69
6 5 Traction 70
6 6 AC motor operation 70
6 7 Sensorless operation 71
7 Battery maintenance 72
7 1 Safety regulations concerning the handling of lead-acid batteries 73
7 2 Battery maintenance 74
7 2 1 Daily maintenance 74
7 2 2 Weekly maintenance 74
7 2 3 Monthly maintenance 74
7 2 4 Annual maintenance 75
7 3 Recharging the battery 75
7 4 Measuring the battery’s specific gravity 78
7 5 Replacing the battery 78
8 Electric system maintenance 81
8 1 Tiller arm 81
8 1 1 Removing the tiller head 81
8 1 2 Removing the tiller head switches 83
8 1 3 Removing the safety button 84
8 1 4 Removing the accelerator 86
8 1 5 Installing the accelerator 88
8 2 Electric panel 90
8 2 1 Removing the controller cover 91
8 2 2 Traction controller 92
8 2 3 Traction controller connectors 92
8 2 4 Contactors and relays 97
8 2 5 Removing the electric panel 99
8 2 6 Fuses 100
8 3 Truck connector 101
8 3 1 Replacing the truck connector 102
© Mitsubishi Forklift Trucks 2013 All rights reserved Revision: A Document ID: 618022 5 (210)
PBP Service Manual
8 4 Motor compartment 102
8 4 1 Removing the drive unit 103
8 4 2 Disassembly of the drive unit 104
8 4 3 Installation of the traction motor 105
8 4 4 Assembly of the splined shaft-hub connection 105
8 4 5 Temperature sensor check 107
8 4 6 Magnetic brake 108
8 5 Pump motor 109
8 5 1 Solenoid valve 110
8 6 Sensors 111
8 6 1 Tiller sensor 111
8 6 2 Ergo cutback sensor 113
8 7 Switches and buttons 114
8 7 1 Emergency stop button 114
8 7 2 Key switch 115
8 7 3 Tiller head microswitch 116
8 8 Horn 117
8 8 1 Diode test with a multimeter 117
8 9 Wiring harnesses and cables 118
8 9 1 Installing the traction motor cables 120
9 Electric system adjustments and measurements 122
9 1 Calibrating the accelerator 122
9 1 1 Acquiring the VACC with TruckTool 122
9 1 2 Acquiring the VACC without TruckTool 123
9 2 Calibrating the motor resistance 123
9 2 1 Acquiring the motor resistance with TruckTool 123
9 2 2 Acquiring the motor resistance without TruckTool 123
9 3 Insulation resistance test 124
9 3 1 Test voltage 124
9 3 2 Checking the insulation tester 124
9 3 3 Measuring the insulation resistance 124
10 Hydraulic operation 127
10 1 Hydraulic symbols 129
10 2 Hydraulic oil recommendations 131
10 3 Maintenance points of the hydraulic system 131
10 4 Hydraulic aggregate 132
10 4 1 Disassembly of the hydraulic aggregate 133
10 4 2 Disassembly of the oil tank 133
10 5 Replacing the hydraulic cylinder 135
10 5 1 Replacing the hydraulic cylinder’s slide bearings 137
10 6 Hydraulic system with the ergo lift 138
10 6 1 Disassembly of the valves 138
10 6 2 Removing the ergo lift hydraulic cylinder 139
11 TruckTool Diagnostics 140
12 Parameter descriptions 141
© Mitsubishi Forklift Trucks 2013 All rights reserved Revision: A Document ID: 618022 6 (210)
PBP Service Manual
12 1 Traction controller 141
13 Alarm codes 148
13 1 Traction controller 148
14 Service data 164
14 1 Special tightening torques 164
14 2 Tightening torque for standard bolts and nuts 165
14 3 Maintenance check list 167
14 4 Lubrication 169
14 4 1 Hydraulic oil 169
14 4 2 Transmission oil 169
14 5 Special tools 170
15 Options 171
15 1 Pallet entry / exit rollers 172
15 1 1 Disassembly of the pallet entry / exit rollers 172
15 2 Load support 173
15 2 1 Installation of the load support 174
15 3 Accessory rack 174
15 3 1 Installation of the accessory rack 175
15 4 Lever for lifting and lowering 181
15 4 1 Removing the controller for lifting and lowering 182
15 4 2 Installing the controller for lifting and lowering 183
15 5 Voltage converter 184
15 5 1 Installation of the voltage converter 184
15 6 Battery lock sensor 185
15 6 1 Installation of the battery lock sensor 186
15 6 2 Battery lock sensor functionality check 187
15 7 Battery connector 188
15 7 1 Replacing the battery connector 188
15 8 Charger connector 189
15 8 1 Replacing the charger connector 189
15 9 Quick battery replacement 190
15 9 1 Removing a discharged battery with the battery changing device 190
15 9 2 Installing a recharged battery with the battery changing device 191
15 9 3 Removing the rubber absorbers 192
15 10 Internal charger 193
15 10 1 Changing the type setting of the internal charger 195
15 11 Equipment for hot conditions 196
16 Technical specification 197
17 Index 201
18 APPENDIX A: Stickers 205

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]