Mitsubishi PBP16N3, PBP18N3, PBP20N3, PBP20N3E, PBP20N3R Service Manual 660033 EN-A
Mitsubishi PBP16N3, PBP18N3, PBP20N3, PBP20N3E, PBP20N3R Service Manual 660033 EN-A - Image 2
Mitsubishi PBP16N3, PBP18N3, PBP20N3, PBP20N3E, PBP20N3R Service Manual 660033 EN-A - Image 3
Mitsubishi PBP16N3, PBP18N3, PBP20N3, PBP20N3E, PBP20N3R Service Manual 660033 EN-A - Image 4
Mitsubishi PBP16N3, PBP18N3, PBP20N3, PBP20N3E, PBP20N3R Service Manual 660033 EN-A - Image 5

Mitsubishi PBP16N3, PBP18N3, PBP20N3, PBP20N3E, PBP20N3R Service Manual 660033 EN-A

$50.00

  • Type Of Manual: Service Manual
  • Manual ID: 660033
  • Language: EN-A
  • Number of Pages: 289
  • Size: 10.7MB
  • Format: PDF
Category:

Product details

  • Model List:

    • PBP16N3, PBP18N3, PBP20N3, PBP20N3E, PBP20N3R
  • 1. Table of contents
  • 2. Foreword
  • 3. How to read this manual
  • 3.1. Safety-related signs
  • 3.2. Safety symbols
  • 3.3. Units
  • 3.4. Interactive links
  • 4. Safety instructions
  • 4.1. General safety instructions
  • 4.2. Safety requirements for industrial trucks
  • 4.3. Repairs and structural modifications
  • 4.4. Instructions for site supervision
  • 4.5. Service area safety
  • 4.6. Occupational safety
  • 4.7. Personal safety
  • 4.8. Work safety
  • 4.9. Operating temperature
  • 5. General information
  • 5.1. Truck models covered by this manual
  • 5.2. Transportation
  • 5.2.1. Lifting the truck
  • 5.2.1.1. Jack points
  • 5.2.1.2. Hoist points
  • 5.2.2. Towing the truck
  • 5.2.3. Brake release
  • 5.3. Operating position
  • 5.4. Operating direction
  • 5.5. Special tools
  • 5.6. Assembly and commissioning
  • 5.7. Order spare parts
  • 6. Main components
  • 6.1. Identification plates and stickers
  • 6.2. Operating devices
  • 6.3. Tiller arm
  • 6.3.1. Tiller arm controls
  • 6.3.2. Tiller arm positions
  • 6.4. Truck covers
  • 6.5. Battery compartment
  • 6.6. Control panel
  • 6.6.1. Emergency stop button
  • 6.6.2. Key switch
  • 6.6.3. Multi-functional display
  • 6.7. Foldable operator platform
  • 6.8. Load handling
  • 6.8.1. Hydraulic cylinders
  • 6.9. Electric system
  • 6.9.1. Electrical operation
  • 6.9.1.1. Overview
  • 6.9.1.2. How to use the schematic diagram
  • 6.9.1.3. Power source
  • 6.9.1.4. Safety circuit (emergency stop button)
  • 6.9.1.5. Key switch
  • 6.9.1.6. Traction
  • 6.9.1.7. AC motor operation
  • 6.9.2. Traction and pump controller
  • 6.9.2.1. Traction and pump controller connectors
  • 6.9.2.2. CNA external connector
  • 6.9.2.3. Description of the power connections
  • 6.9.3. Horn
  • 6.9.4. Sensors
  • 6.9.5. Fuses
  • 6.9.6. Relays and contactors
  • 6.9.7. Display connector
  • 6.10. Hydraulic operation
  • 6.10.1. Hydraulic aggregate
  • 6.10.1.1. Pump motor
  • 6.10.2. Hydraulic symbols
  • 6.10.3. Hydraulic operation overview
  • 6.10.4. Hydraulic operation lifting/lowering
  • 6.10.5. Additional hydraulic functions with lifting forks
  • 6.11. Drive unit
  • 6.11.1. Traction motor
  • 6.11.2. Magnetic brake
  • 6.11.2.1. Service brake
  • 6.11.2.2. Parking brake
  • 6.11.2.3. Emergency braking
  • 6.12. Wheels
  • 6.13. Truck suspension
  • 7. Maintenance
  • 7.1. Safety instructions for maintenance
  • 7.2. Maintenance intervals
  • 7.3. Opening the covers
  • 7.3.1. Remove the front cover
  • 7.3.2. Remove the control panel
  • 7.3.3. Remove the top cover
  • 7.3.4. Open the battery cover
  • 7.4. Drive unit
  • 7.4.1. Transmission gear
  • 7.4.1.1. Fastening of the transmission gear
  • 7.4.1.2. Leakage check of the transmission gear
  • 7.4.2. Slewing bearing
  • 7.4.3. Magnetic brake
  • 7.4.3.1. Measure the thickness of the brake disc
  • 7.4.3.2. Measure the coil resistance
  • 7.4.4. Drive unit suspension
  • 7.4.4.1. Inspect the drive unit suspension
  • 7.4.4.2. Lubricate the drive unit suspension
  • 7.5. Hydraulics
  • 7.5.1. Hydraulic system maintenance
  • 7.5.2. Hydraulic filters
  • 7.5.3. Solenoid valve functionality check
  • 7.5.4. Leakage check of the hydraulic system
  • 7.5.5. Hoses and cylinders
  • 7.5.6. Hydraulic oil tank
  • 7.5.6.1. Hydraulic oil change
  • 7.5.6.2. Oil level
  • 7.5.6.3. Clean the oil tank
  • 7.6. Lifting system
  • 7.6.1. Check the cylinders and piston rods
  • 7.6.2. Lifting test
  • 7.6.3. Fork inspection
  • 7.6.4. Examine the load backrest for cracks
  • 7.7. Lifting forks
  • 7.7.1. Examine the welding in lifting carriage for cracks
  • 7.7.2. Examine the rollers, pins and welds for cracking and damage
  • 7.7.3. Lifting chains
  • 7.7.3.1. Chain tension
  • 7.7.3.2. Chain lubrication
  • 7.7.3.3. Chain wear measurement
  • 7.7.3.4. Check the chain anchors and locking pins
  • 7.8. Wheels
  • 7.8.1. Before you replace the wheels
  • 7.8.2. Traction wheel
  • 7.8.2.1. Remove the traction wheel
  • 7.8.2.2. Replace the wheel shaft bolts
  • 7.8.2.3. Install the traction wheel
  • 7.8.3. Castor wheel
  • 7.8.3.1. Replace the castor wheel
  • 7.8.3.2. Adjust the castor wheel
  • 7.8.3.3. Inspect the castor wheel suspension
  • 7.8.4. Load wheels
  • 7.8.4.1. Replace the load wheels
  • 7.9. Electrics
  • 7.9.1. Electrical connections tightening torques
  • 7.9.2. Discharge the controllers
  • 7.9.3. Contactor functionality check
  • 7.9.4. Test the functionality of sensors
  • 7.9.4.1. Traction motor sensors
  • 7.9.4.2. Tiller arm sensor
  • 7.9.4.3. Operator platform sensors
  • 7.9.4.4. Battery cover sensor
  • 7.9.4.5. Lifting fork limit sensor
  • 7.9.4.6. Lifting forks down sensor
  • 7.9.5. Test the functionality of switches and buttons
  • 7.9.5.1. Emergency stop button
  • 7.9.5.2. Key switch functionality check
  • 7.9.5.3. Tiller arm control buttons
  • 7.9.6. Test the functionality of the horn
  • 7.9.6.1. Horn
  • 7.9.6.2. Horn diode
  • 7.9.7. Wiring harnesses and cables
  • 7.9.8. Examine and clear the alarm history
  • 7.9.9. Insulation resistance test
  • 7.9.9.1. Test voltage
  • 7.9.9.2. Check the insulation tester
  • 7.9.9.3. Measure the insulation resistance
  • 7.10. General
  • 7.10.1. How to clean the truck
  • 7.10.2. Lubrication
  • 7.10.3. Examine the welding in the truck frame for cracking
  • 7.10.4. Examine the truck frame and the lifting carriage
  • 7.10.5. Examine the gas springs
  • 7.10.6. Examine the condition and position of the identification plates
  • 7.10.7. Examine the covers
  • 7.10.8. Safety functions
  • 8. Battery maintenance
  • 8.1. Lead-acid batteries
  • 8.1.1. Safety with lead-acid batteries
  • 8.1.2. General information
  • 8.1.3. Requirements for battery charging areas
  • 8.1.4. Charge the battery with the external charger
  • 8.1.5. Charge the battery with the internal charger
  • 8.1.6. Battery maintenance
  • 8.1.6.1. General maintenance
  • 8.1.6.2. How to clean the battery
  • 8.1.6.3. Daily maintenance
  • 8.1.6.4. Weekly maintenance
  • 8.1.6.5. Monthly maintenance
  • 8.1.6.6. Annual maintenance
  • 8.1.7. Malfunctions
  • 8.1.8. Acquire a new battery
  • 8.1.9. Storage
  • 8.2. Lithium-ion batteries
  • 8.2.1. General information
  • 8.2.2. Safety signs
  • 8.2.3. Requirements for battery charging areas
  • 8.2.4. Charge the battery
  • 8.2.4.1. Recharging a lithium-ion battery
  • 8.2.4.2. Charge the battery with the external charger
  • 8.2.4.3. Charge the battery with the internal charger
  • 8.2.4.4. Opportunity charging
  • 8.2.4.5. Battery balancing
  • 8.2.5. Battery maintenance
  • 8.2.5.1. Examine the battery
  • 8.2.5.2. How to clean the battery
  • 8.2.5.3. Malfunctions
  • 8.2.5.4. Service and repair
  • 8.2.6. Acquire a new battery
  • 8.2.7. Storage
  • 8.3. Replace the battery
  • 8.3.1. General safety instructions
  • 8.3.2. Replace the battery with a lifting device
  • 8.3.3. Replace the battery with a battery change device
  • 8.4. Battery cover maintenance
  • 8.4.1. Remove the rubber absorbers of the battery cover
  • 8.4.2. Remove the battery cover lock
  • 9. Repair
  • 9.1. Repair drive unit
  • 9.1.1. Remove the drive unit
  • 9.1.2. Disassemble the drive unit
  • 9.1.3. Measuring the run-out of the connecting face of the motor
  • 9.1.4. Assemble the drive unit
  • 9.2. Repair foldable operator platform
  • 9.2.1. Remove the foldable operator platform
  • 9.2.2. Replace the rubber absorbers of the foldable operator platform
  • 9.2.3. Replace the gas springs of the platform
  • 9.2.4. Replace the slide bearing of the platform
  • 9.3. Repair tiller arm
  • 9.3.1. Remove the steering assembly
  • 9.3.2. Remove the tiller arm
  • 9.3.3. Replace the gas spring of the tiller arm
  • 9.3.4. Remove the tiller head
  • 9.3.4.1. Replace the acceleration controllers
  • 9.3.4.2. Replace the safety stop button
  • 9.3.4.3. Replace the low speed button
  • 9.3.4.4. Replace the tiller sensor box
  • 9.3.4.5. Replace the lifting/lowering buttons
  • 9.3.4.6. Replace the horn buttons
  • 9.4. Repair hydraulic system
  • 9.4.1. Disassemble the hydraulic aggregate
  • 9.4.2. Set the lifting pressure
  • 9.4.3. Disassemble the lifting fork valve
  • 9.5. Repair lifting system
  • 9.5.1. Disassemble the linkage mechanism
  • 9.5.2. Remove the hydraulic cylinder
  • 9.5.3. Replace the sealing housing of the hydraulic cylinder
  • 9.5.4. Replace the slide bearings of the hydraulic cylinder
  • 9.6. Repair lifting forks assembly
  • 9.6.1. Disassemble the lifting fork carriage
  • 9.6.2. Main rollers of the lifting fork carriage
  • 9.6.2.1. Adjust the main rollers of the lifting fork carriage
  • 9.6.2.2. Disassemble the main rollers of the lifting fork carriage
  • 9.6.3. Remove the lifting fork cylinder
  • 9.6.4. Replace the sealing housing of the lifting fork cylinder
  • 9.6.5. Adjust the lifting chains
  • 9.6.6. Replace the lifting chains
  • 9.7. Repair truck suspension
  • 9.7.1. Disassemble the castor wheel suspension
  • 9.7.2. Disassemble the drive unit suspension
  • 9.8. Repair electric system
  • 9.8.1. Replace the fuses
  • 9.8.2. Remove the electric panel
  • 9.8.3. Replace the contactor
  • 9.8.4. Replace the traction and pump controller
  • 9.8.5. Replace the truck connector
  • 9.8.6. Install the traction motor cables
  • 9.8.7. Replace the horn
  • 9.9. Repair sensors and switches
  • 9.9.1. Replace the rotation sensor
  • 9.9.2. Replace the tiller arm sensor
  • 9.9.3. Replace the operator platform sensors
  • 9.9.4. Replace the battery cover sensor
  • 9.9.5. Replace the lifting fork limit sensor
  • 9.9.6. Replace the lifting forks down sensor
  • 10. TruckTool Diagnostics
  • 10.1. Overview
  • 10.2. Location of the service socket
  • 10.3. Parameter descriptions
  • 11. Service data
  • 11.1. Special tightening torques
  • 11.2. Tightening torques for standard bolts and nuts
  • 11.3. Oils and lubricants
  • 11.3.1. Channels of the lifting structure
  • 11.3.2. Lifting chain
  • 11.4. Troubleshooting
  • 12. Options
  • 12.1. Options overview
  • 12.2. Load backrest
  • 12.2.1. Install the load backrest
  • 12.3. Pallet entry and exit rollers
  • 12.3.1. Remove the pallet entry and exit rollers
  • 12.4. Accessory rack
  • 12.4.1. Install the accessory rack
  • 12.4.2. Install the list bracket
  • 12.4.3. Install the computer holder
  • 12.4.4. Install the working light
  • 12.5. Battery connector and cable
  • 12.5.1. Replace battery connector and cable
  • 12.6. Battery change device
  • 12.7. Charger connector
  • 12.7.1. Replace the charger connector
  • 12.8. Internal charger and internal charger connector
  • 12.8.1. Install the internal charger and charger connector
  • 12.9. Voltage converter
  • 12.9.1. Install the voltage converter
  • 12.10. PIN code unit keyboard
  • 12.10.1. Install the PIN code unit
  • 12.10.2. Activate the truck with a PIN code
  • 13. Technical specifications
  • 13.1. Dimensions
  • 13.2. Technical data
  • 14. Declaration of Conformity
  • 15. Stickers
  • 16. Maintenance check list
  • 17. Notes
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