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 2

mitsubishi pbp16n3 pbp18n3 pbp20n3 pbp20n3e pbp20n3r service manual 660033 en a 3

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: Mitsubishi Service Manual PDF

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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