Mitsubishi PBV20N2 Service Manual Download

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Revision: B

Document ID: 615023

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PBV20N2

Service

Service Manual

Manual

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Summary of Contents for PBV20N2

Page 1: ...SERVICE MANUAL SERVICE MANUAL PBV20N2 PBV20N2 615023 615023 English 2013 English 2013 https www forkliftpdfmanuals com...

Page 2: ...t maintenance service Copyright 2013 by Mitsubishi Forklift Trucks bv All rights reserved Copyright 2013 by Mitsubishi Forklift Trucks bv All rights reserved Mitsubishi Forklift Trucks is a registered...

Page 3: ...e truck the truck 17 17 4 3 1 4 3 1 Operating Operating devices devices 17 17 4 3 2 4 3 2 Tiller Tiller arm arm 18 18 4 3 2 1 4 3 2 1 Tiller arm controls Tiller arm controls 18 18 4 3 2 2 4 3 2 2 Till...

Page 4: ...of the traction wheel 55 55 5 10 5 10 Load Load wheels wheels 56 56 5 11 5 11 Lifting system Lifting system and and fork fork carriage carriage 57 57 5 12 5 12 Castor Castor wheels wheels 59 59 5 12...

Page 5: ...8 3 Motor Motor compartmen compartment 10 t 106 6 8 3 1 8 3 1 Removing Removing the the drive drive unit unit 107 107 8 3 2 8 3 2 Disassembly Disassembly of of the the drive drive unit unit 108 108 8...

Page 6: ...on controller controller 145 145 13 13 Alarm Alarm codes codes 1 154 54 13 1 13 1 Traction Traction controller controller 154 154 14 14 Service Service data data 173 173 14 1 14 1 Special Special tigh...

Page 7: ...Motor and electrical electrical system system with electric with electrical steering al steering 206 206 15 11 2 15 11 2 Zapi Zapi EPS EPS AC0 AC0 Power Power Controller Controller 208 208 15 11 3 15...

Page 8: ...of this manual carefully and familiarize yourself with manual carefully and familiarize yourself with all of all of the components the components The descriptions illustrations and specifications con...

Page 9: ...ge to or death or damage to your machine your machine CAUTION CAUTION CAUTION CAUTION indicates a hazard with a low level of risk which if not indicates a hazard with a low level of risk which if not...

Page 10: ...ed action symbols are presented below No smoking No smoking General symbol for General symbol for prohibited action prohibited action Mandatory action symbols Mandatory action symbols These symbols ar...

Page 11: ...ernal 1 4 inch formerly PF1 4 A Straight pipe thread external 1 4 inch formerly PF1 4 A Rp1 8 Rp1 8 Straight pipe thread internal 1 8 Straight pipe thread internal 1 8 inch formerly PS1 8 inch formerl...

Page 12: ...ty Keep the service area clean Oil grease and water Keep the service area clean Oil grease and water make the floor slippery make the floor slippery If possible make all repairs with If possible make...

Page 13: ...b protective clothing appropriate to the welding job being performed Do not wear being performed Do not wear loose fitting or torn clothing loose fitting or torn clothing 3 3 3 3 Work safety Work safe...

Page 14: ...termine the type of metal and select the correct welding procedure and electrodes rods or wire to and electrodes rods or wire to provide a weld metal strength equivalent at least to provide a weld met...

Page 15: ...d or paper to locate pin hole leaks paper to locate pin hole leaks Tighten connectio Tighten connections to the correct ns to the correct torque Make sure that all heat shields clamps torque Make sure...

Page 16: ...or the basic truck model All material related to optional features is available in Chapter basic truck model All material related to optional features is available in Chapter 15 15 4 2 4 2 Identificat...

Page 17: ...eight Battery minimum weight Battery terminal voltage Battery terminal voltage Truck s nominal lifting capacity Truck s nominal lifting capacity Year of manufacture Year of manufacture CE mark CE mark...

Page 18: ...UNCTIONALITY FUNCTIONALITY DESCRIPTION DESCRIPTION Safety button belly button Safety button belly button The safety button prevents you from getting The safety button prevents you from getting squeeze...

Page 19: ...p position hold the button down to release the button down to release the parking brake and parking brake and turn the accelerator to drive the turn the accelerator to drive the truck in the slow truc...

Page 20: ...stop stop button button Press the emergency stop button to disconnect the truck s power supply Release the Press the emergency stop button to disconnect the truck s power supply Release the button by...

Page 21: ...ay be still however that power may be still connected to certain electronic devices connected to certain electronic devices When the key switch is turned once to the right the truck s electrical syste...

Page 22: ...3 3 LED indicator LED indicator The multi function display shows the following information The multi function display shows the following information Level of battery charge Level of battery charge I...

Page 23: ...gas spring to lift slightly and allowing the gas spring to lift it up completely and then fold the it up completely and then fold the side guards side guards in in To drive the truck in the direction...

Page 24: ...ing balance To drive the truck in the riding mode step on the platform and keep both hands on the To drive the truck in the riding mode step on the platform and keep both hands on the tiller arm When...

Page 25: ...o forward drive the truck in the direction of the forks To To go forward drive the truck in the direction of the forks To go backward drive the go backward drive the truck in the truck in the opposite...

Page 26: ...2 Service Service Manual Manual 4 3 6 4 3 6 Motor Motor and and electrical electrical system system Figure 11 Overview of the motor and electrical system Figure 11 Overview of the motor and electrical...

Page 27: ...tric panel overview Figure 12 Electric panel overview 1 1 Fuse box Fuse box 2 2 Traction and pump controller COMBIACX Traction and pump controller COMBIACX A1 with the drive pump motor fuse A1 with th...

Page 28: ...ID 615023 28 244 28 244 PBV20N2 PBV20N2 Service Service Manual Manual 4 3 6 2 4 3 6 2 Motor Motor compartment compartment Figure 13 Motor compartment overview Figure 13 Motor compartment overview 1 1...

Page 29: ...Service Manual Manual 4 3 6 3 4 3 6 3 Traction Traction motor motor Type Type 3 phase AC 3 phase AC Voltage Voltage 16 V 16 V Output power Output power 2 3 kW 2 3 kW Figure 14 Traction motor Figure 14...

Page 30: ...ance of the loop changes loop changes according to the material inside it and since according to the material inside it and since metals are much more effective inductors metals are much more effectiv...

Page 31: ...n suspension Together these suspension systems improve the truck s Together these suspension systems improve the truck s driving experience driving experience The purpose of the suspension systems is...

Page 32: ...ck up the truck and support it with safety blocks or truck and support it with safety blocks or rigid stands rigid stands Apply wheel chocks to the Apply wheel chocks to the load wheels to prevent the...

Page 33: ...oist points 5 2 5 2 Transportation Transportation When transporting the truck it is important that you secure it safely to prevent it from When transporting the truck it is important that you secure i...

Page 34: ...parts To ensure that you r spare parts To ensure that you receive the correct parts include the following eceive the correct parts include the following information in your order information in your...

Page 35: ...k covers overview 1 1 Front cover Front cover 2 2 Control panel Control panel 3 3 Top cover Top cover 4 4 Battery cover Battery cover 5 4 1 5 4 1 Front Front cover cover 1 1 Remove the two screws at t...

Page 36: ...Control panel panel Figure 21 Control panel overview Figure 21 Control panel overview 1 1 Control panel Control panel 2 2 Key switch connector Key switch connector 3 3 Emergency switch connector Emer...

Page 37: ...onnect the emergency switch key switch and key switch and multi function display multi function display connectors connectors 3 3 Remove the control panel Remove the control panel 5 4 3 5 4 3 Top Top...

Page 38: ...Service Service Manual Manual 1 1 Remove the four screws holding the Remove the four screws holding the top cover in place top cover in place 2 2 Remove the top cover Remove the top cover 5 4 4 5 4 4...

Page 39: ...Manual 1 1 Push the locking button down and Push the locking button down and leave it open leave it open 2 2 Open the battery cover Open the battery cover NOTE When closing the battery cover make sur...

Page 40: ...N2 PBV20N2 Service Service Manual Manual 5 4 4 1 5 4 4 1 Removing Removing the the battery battery cover cover lock lock Figure 24 Battery cover lock overview Figure 24 Battery cover lock overview 1 1...

Page 41: ...s rubber rubber absorbers absorbers Figure 25 Battery cover s rubber absorbers Figure 25 Battery cover s rubber absorbers Remove the battery cover s rubber absorbers by simply screwing them out Remov...

Page 42: ...ace 2 2 Remove the plastic cover Remove the plastic cover 3 3 Remove the screws at the base Remove the screws at the base of of the side guard the side guard 4 4 Release the side guard s gas spring Fo...

Page 43: ...emove the gas spring Note the location of the wiring location of the wiring 4 4 Check the condition of the ball joints Check the condition of the ball joints holding the gas spring in place holding th...

Page 44: ...Operator s platform overview 1 1 Operator s platform Operator s platform 2 2 Rubber absorbers Rubber absorbers Before you can remove the operator s platform remove the two rubber absorbers at Before...

Page 45: ...en removed you can ved you can remove the o remove the operator s perator s platform platform 1 1 Remove the two screws under the Remove the two screws under the operator s platform operator s platfor...

Page 46: ...s reserved Revision B Revision B Document ID 615023 Document ID 615023 46 244 46 244 PBV20N2 PBV20N2 Service Service Manual Manual Figure 29 Supporting the operator s platform during installation Figu...

Page 47: ...l Manual Figure 30 Operator s platform detailed construction Figure 30 Operator s platform detailed construction 1 1 Rubber mat Rubber mat 2 2 Locking screw Locking screw 3 3 Shaft Shaft 4 4 Mounting...

Page 48: ...tely from the truck frame Instructions for frame Instructions for replacing the operator s platform gas spring are provided below but the same replacing the operator s platform gas spring are provide...

Page 49: ...d is making sure that the spring s head is positioned correctly into the slot positioned correctly into the slot inside the operator s platform inside the operator s platform 7 7 Carefully lift the op...

Page 50: ...om the truck frame For Remove the operator s platform from the truck frame For instructions see the instructions see the section section 5 6 5 6 2 2 Remove the support at the base of Remove the suppor...

Page 51: ...smission gear lubricant during the truck s lifetime change the transmission gear lubricant during the truck s lifetime During maintenance check the transmission gear for During maintenance check the t...

Page 52: ...ounting bolts are tightened properly mounting bolts are tightened properly 5 9 5 9 Traction wheel Traction wheel CAUTION CAUTION Before installing the traction wheel make sure that Before installing t...

Page 53: ...diameter reaches 214 When the traction wheel s diameter reaches 214 mm replace the traction mm replace the traction wheel wheel and adjust the castor wheels as instructed in and adjust the castor whee...

Page 54: ...lts bolts Figure 35 Wheel shaft bolts overview Figure 35 Wheel shaft bolts overview If the wheel shaft If the wheel shaft bolts of the traction wheel are bolts of the traction wheel are defective you...

Page 55: ...Tighten the new wheel shaft bolt The correct tightening torque is The correct tightening torque is 27 Nm 27 Nm 5 9 2 5 9 2 Assembly Assembly of of the the traction traction wheel wheel 1 1 Align the...

Page 56: ...truck so that the load so that the load wheels are off the floor see the wheels are off the floor see the correct lifting points in the section correct lifting points in the section 5 1 5 1 of this m...

Page 57: ...arriage overview Figure 37 Lifting system and fork carriage overview 1 1 Fork carriage shaft Fork carriage shaft 2 2 Link Link 3 3 Chassis shaft Chassis shaft 4 4 Slide bearing Slide bearing 5 5 Tub p...

Page 58: ...anism s fork carriage side open the screw from carriage side open the screw from the fork carriage shaft the fork carriage shaft 4 4 Screw a bolt size M8 onto the Screw a bolt size M8 onto the threads...

Page 59: ...11 11 Remove the shaft Remove the shaft 12 12 Remove the slide bearings from the Remove the slide bearings from the link link 5 12 5 12 Castor wheels Castor wheels Figure 38 Castor wheel overview Fig...

Page 60: ...heel from the Remove the castor wheel from the bracket bracket 4 4 Remove the sleeves from the Remove the sleeves from the bearing and save them bearing and save them 5 12 2 5 12 2 Adjusting Adjusting...

Page 61: ...wheel wheel 1 1 Install the sleeves into the new castor Install the sleeves into the new castor wheel wheel 2 2 Place the castor wheel into the bracket Place the castor wheel into the bracket 3 3 Pus...

Page 62: ...l have a considerable effect on the truck s driving uck s driving capability capability When the castor wheel suspension mechanism need When the castor wheel suspension mechanism needs to be s to be s...

Page 63: ...Check that there is not too much play in the too much play in the bearing of the castor wheel unit bearing of the castor wheel unit 4 4 Check that the castor wheel rotates properly Check that the cas...

Page 64: ...h the electrical steering option you need to disassemble the electrical steering motor unit first before you can perform the steps disassemble the electrical steering motor unit first before you can p...

Page 65: ...15 5 15 3 3 Remove the drive unit For instructions see section Remove the drive unit For instructions see section 8 3 1 8 3 1 4 4 Remove the hydraulic cylinder For Remove the hydraulic cylinder For in...

Page 66: ...r bed to the top part of the motor bed to the motor bed frame motor bed frame 11 11 Remove the slide bearings Remove the slide bearings 12 12 Tilt the motor bed forward Tilt the motor bed forward appr...

Page 67: ...42 Tiller arm overview Figure 42 Tiller arm overview 1 1 Tiller arm Tiller arm 2 2 Tiller arm fastener Tiller arm fastener 3 3 Tiller connector Tiller connector Removing the tiller arm Removing the t...

Page 68: ...netic brake arm fastener to the magnetic brake 5 5 Remove the tiller arm fastener and Remove the tiller arm fastener and the tiller arm the tiller arm During the installation of the tiller arm tighten...

Page 69: ...Tiller arm joint overview 1 1 Aisle pipe Aisle pipe 2 2 Gas spring Gas spring 3 3 Spring lock Spring lock 4 4 Bearing Bearing 5 5 Shaft Shaft Disassembly of the tiller arm joint Disassembly of the ti...

Page 70: ...ocking spring from the Remove the locking spring from the gas spring s head gas spring s head 5 5 At the base o At the base of the gas spring f the gas spring push push the spring lock off its place a...

Page 71: ...eserved Revision B Revision B Document ID 615023 Document ID 615023 71 244 71 244 PBV20N2 PBV20N2 Service Service Manual Manual 7 7 Remove the locking screw Remove the locking screw 8 8 Remove the sha...

Page 72: ...iate page To troubleshoot a particular component locate the component on the appropriate page of the schematic diagram and check the of the schematic diagram and check the circuitry associated with it...

Page 73: ...f the numbers are given without the slash numbers are given without the slash the connection is on the same page of the connection is on the same page of the the schematics schematics Table 2 Table 2...

Page 74: ...nnected together at this Splice Multiple wires are connected together at this point point Figure 45 Figure 45 shows the reference to which shows the reference to which Figure 44 Figure 44 referred ref...

Page 75: ...s B from the main When the button is pressed the connection opens and removes B from the main contactor coil K1 contactor coil K1 6 4 6 4 Key switch Key switch The main key switch S1 The main key swit...

Page 76: ...d through the rotor is changing rotating The changing rotating The rotor has windings in the form rotor has windings in the form of closed wire loops The rotating magnetic flux induces of closed wire...

Page 77: ...charged and store it in a dry frost free room The storage time should be taken dry frost free room The storage time should be taken into into account when considering the lifetime of the battery acco...

Page 78: ...mbers or sparks as it may cause the battery to explode battery to explode Acid splashes in the ey Acid splashes in the eyes or on the skin mu es or on the skin must be washed immediately w st be washe...

Page 79: ...lugs and to the battery s components Pay special attention to the battery charging plugs and cables In special cases when charging with an IU cables In special cases when charging with an IU character...

Page 80: ...e air pipes but for some reason the defect signal of for some reason the defect signal of the air mixing system on the charger or on the battery on the DC air pump or r the air mixing system on the ch...

Page 81: ...do not pull the cables not pull the cables 3 3 Check the battery according to Check the battery according to the battery manufacturer s maintenance the battery manufacturer s maintenance instructions...

Page 82: ...r dimensions and weight to maintain the ith similar dimensions and weight to maintain the stability and the braking properties of the truck The stability and the braking properties of the truck The ba...

Page 83: ...battery overview 1 1 Battery connector Battery connector 2 2 Battery holder Battery holder 3 3 Battery Battery 1 1 Open the battery cover For instructions see the Open the battery cover For instructio...

Page 84: ...the battery 6 6 Insert a new battery verify Insert a new battery verify the battery type and voltage the battery type and voltage 7 7 Attach the latch Attach the latch and close th and close the batte...

Page 85: ...Before opening the tiller head turn the Before opening the tiller head turn the key switch to the OFF position and key switch to the OFF position and disconnect disconnect the battery plug connector R...

Page 86: ...ogo plate Logo plate 1 1 Remove the logo plate Remove the logo plate 2 2 Remove the tiller head fixing screw Remove the tiller head fixing screw 3 3 Lift the tiller head carefully upwards Lift the til...

Page 87: ...m the Remove the tiller head from the pipe pipe 8 1 2 8 1 2 Removing Removing the the tiller tiller head head switches switches CAUTION CAUTION When removing the switches be careful not When removing...

Page 88: ...switches 8 1 3 8 1 3 Removing Removing the the safety safety button button NOTE Before you can remove the accelerator knobs you have to remove the rubber NOTE Before you can remove the accelerator kno...

Page 89: ...emove the right hand side rubber Remove the right hand side rubber handle handle 2 2 Remove the right hand side Remove the right hand side accelerator knob s fixing screw accelerator knob s fixing scr...

Page 90: ...e rubber rubber handles handles 1 1 Clean the surface of the tiller arm Clean the surface of the tiller arm handle carefully handle carefully 2 2 Spread two lines of Loctite 435 glue Spread two lines...

Page 91: ...elerator connector because the new accelerator is delivered without a connector connector Figure 53 Accelerator overview Figure 53 Accelerator overview 1 1 Rubber handle Rubber handle 2 2 Accelerator...

Page 92: ...e microswitch bracket 4 4 Remove the accelerator connector Remove the accelerator connector from the mounting bracket from the mounting bracket 5 5 Open the fixing screws and remove Open the fixing sc...

Page 93: ...r to the mounting bracket Fit the accelerator connector to the mounting bracket 5 5 Install the microswitch bracket Install the microswitch bracket 6 6 Install the safety button For instructions see I...

Page 94: ...ry plug connector Never drive the truck without the electrical Never drive the truck without the electrical panel cover in place panel cover in place CAUTION CAUTION Before inspecting and replacing fu...

Page 95: ...l 8 2 1 8 2 1 Removing Removing the the controller controller cover cover 1 1 Remove the screw holding the Remove the screw holding the controller cover in controller cover in place place 2 2 Pull the...

Page 96: ...asynchrono asynchronous 3 phase motors plus a chopper for us 3 phase motors plus a chopper for DC series DC series pump motors pump motors Regenerative braking functions Regenerative braking function...

Page 97: ...0 8 mm2 for CNA CNB CNC and CND connectors Spare part Contact 0 2 0 8 mm2 for CNA CNB CNC and CND connectors Spare part RL450666 RL450666 8 2 3 1 8 2 3 1 CNA CNA external external connector connector...

Page 98: ...e default function is the controller LOWER enable input controller LOWER enable input A12 DI8 XA1 A 12 A12 DI8 XA1 A 12 economy mode S1 economy mode S1 Input of the switch DI8 The Input of the switch...

Page 99: ...e to B1 to Batt A built in freewheeling diode to B1 B6 NLC XA1 B 6 B6 NLC XA1 B 6 K1 K1 Main contactor coil driver output PWM controlled 3 Main contactor coil driver output PWM controlled 3 A maximum...

Page 100: ...figured to the output 12 V or 5 V to be configured to the output 12 V or 5 V C9 CPOTL C9 CPOTL pressure sensor output B42 pressure sensor output B42 Lift lower potentiometer wiper input Lift lower pot...

Page 101: ...torque for the COMBIACX Power terminal bolts is The correct tightening torque for the COMBIACX Power terminal bolts is 7 Nm 1 4 Nm 7 Nm 1 4 Nm 8 2 4 8 2 4 Contactors Contactors and and relays relays T...

Page 102: ...check 1 1 Measure the Measure the ohms ohms between the between the coil A1 coil A1 A2 A2 terminals terminals The ohms value should be 55 The ohms value should be 55 If the ohms value is 0 If the ohms...

Page 103: ...Fuses 1 1 Line connector fuse Line connector fuse 2 2 Control circuit fuse Control circuit fuse 3 3 Optional Optional 4 4 Working lights fuse optional Working lights fuse optional 5 5 Drive pump moto...

Page 104: ...oller fan Controller fan 2 2 Controller fan fixing screws Controller fan fixing screws 3 3 Controller fan connector Controller fan connector 4 4 Fan plate Fan plate The controller fan is located behin...

Page 105: ...the Remove the cable tie attaching the wires of the electric panel to the wires of the electric panel to the truck frame Record the places of truck frame Record the places of the connectors and wires...

Page 106: ...s and terminate marked cable ends to the correct terminals terminate marked cable ends to the correct terminals marked on the motor Cables terminated at the w marked on the motor Cables terminated at...

Page 107: ...gnetic brake 5 5 Tiller arm fastener Tiller arm fastener 8 3 1 8 3 1 Removing Removing the the drive drive unit unit NOTE If the truck NOTE If the truck has the electric steering option in use see sec...

Page 108: ...y to prevent it from falling See the correct lifting points in the section lifting points in the section 5 1 5 1 of this manual of this manual 7 7 While supporting the motor from the While supporting...

Page 109: ...t be perfectly clean perfectly clean and undamag and undamaged Using a dial indicator or ed Using a dial indicator or similar tool check the face r similar tool check the face run out of the un out of...

Page 110: ...r pinion carefully The taper connection must be free from any connection must be free from any grease or oil grease or oil 2 2 For versions with a curved washer For versions with a curved washer inser...

Page 111: ...bination 1 1 During key o During key on move n move the tiller arm the tiller arm to the d to the driving position riving position and press and press the brake the brake release low speed and safety...

Page 112: ...ce variation according to temperature Figure 62 Resistance variation according to temperature 8 3 6 8 3 6 HALL HALL sensor sensor Type Type HALL sensor HALL sensor V Vs s 5 24Vdc 5 24Vdc Output signal...

Page 113: ...screw Remove the socket screw 2 2 Disconnect the sensor Disconnect the sensor connector connector 3 3 Disassemble the wires from the Disassemble the wires from the sensor connector Note the pin sensor...

Page 114: ...g to the magnet body The decelerating rotor is released and the magnet body The decelerating rotor is released and the brake torque is neutralized the brake torque is neutralized The electro magnetic...

Page 115: ...e should be 21 measured between the brake wires The value should be 21 8 4 8 4 Pump motor Pump motor Figure 65 Pump motor overview Figure 65 Pump motor overview The pump motor is an The pump motor is...

Page 116: ...ve The solenoid converts electrical energy into mechanical mechanical energy which in turn opens or energy which in turn opens or closes the valve mechanically This basic ON OFF closes the valve mecha...

Page 117: ...5 11 and its subsections and its subsections 8 5 1 8 5 1 Tiller Tiller side side guard guard and and operator s operator s platform platform sensors sensors Type Type Inductive proximity sensor Induct...

Page 118: ...S17 OFF S17 OFF Not operational Not operational S10 ON S10 ON S11 OFF S11 OFF S12 ON S12 ON S13 OFF S13 OFF S15 ON S15 ON S16 ON S16 ON S17 OFF S17 OFF Pedestrian mode with the side Pedestrian mode wi...

Page 119: ...maximum speed limited to 9 km h maximum speed limited to 9 km h Sensor functionality check Sensor functionality check 1 1 Connect Connect the sup the supply voltag ply voltage betwee e between the n t...

Page 120: ...Emergency stop button Figure 68 Emergency stop button Emergency stop button functionality check Emergency stop button functionality check Measure at the ohms area that the Measure at the ohms area th...

Page 121: ...he key switch are contacts inside the key switch are not stuck together not stuck together When the key switch is in the 0 position the ohms value is 0 When the key switch is in the 0 position the ohm...

Page 122: ...Spare part RL109007 RL109007 Figure 70 Tiller head micro switch Figure 70 Tiller head micro switch Micro switch functionality check Micro switch functionality check Measure at the ohms area between th...

Page 123: ...ltage peaks that may cause problems to other electrical electrical devices To prevent these voltage peaks a diode V8 in devices To prevent these voltage peaks a diode V8 in the circuit diagram is inst...

Page 124: ...nesses To prevent disconnection of the switches the protective spiral shield of the To prevent disconnection of the switches the protective spiral shield of the motor motor cables must not touch the k...

Page 125: ...ect to prevent vent insulation damage see insulation damage see Figure 73 Figure 73 If If you have to disassemble the factory installed cable you have to disassemble the factory installed cable set re...

Page 126: ...3 3 Cable holder Cable holder 4 4 Mounting plate Mounting plate 5 5 Support Support 6 6 Bolt Bolt 1 1 Install the cables inside the yellow Install the cables inside the yellow protective spiral protec...

Page 127: ...te to the support mounting plate to the support approximately 10 mm from the cable approximately 10 mm from the cable tie tie 6 6 Insert Loctite 248 glue to the bolts Insert Loctite 248 glue to the bo...

Page 128: ...erator must be calibrated Also if the must be calibrated Also if the truck does not drive smoothly it truck does not drive smoothly it is recommended that you is recommended that you always first perf...

Page 129: ...mode The truck enters the accelerator teach in mode 2 2 Release Release all all the the buttons buttons 3 3 Teach th Teach the accele e accelerator by rator by turning turning it first fully it first...

Page 130: ...n insulation resistance resistance The test is The test is performed with the battery disconnected from the truck All the performed with the battery disconnected from the truck All the electrical elec...

Page 131: ...istance between the live parts of all the The insulation resistance between the live parts of all the electric components and the electric components and the frame of the industrial truck with the exc...

Page 132: ...ounted on the truck is at least 50 mounted on the truck is at least 50 multiplied by the nominal voltage of the truck multiplied by the nominal voltage of the truck system between the live parts and t...

Page 133: ...aintenance Contact your supplier or technical support for information on obtaining up to date documentation for your truck model information on obtaining up to date documentation for your truck model...

Page 134: ...id tank The opening tank The opening pressure of the relief valve pressure of the relief valve is indicated in the hydraulic schematics is indicated in the hydraulic schematics 4 4 The pressu The pres...

Page 135: ...lowering Figure 81 Hydraulic fluid flow during lowering NOTE Different truck models can NOTE Different truck models can have different hydraulic system configuration have different hydraulic system co...

Page 136: ...0N2 PBV20N2 Service Service Manual Manual SYMBOL DESCRIPTION SYMBOL DESCRIPTION Solenoid valve Solenoid valve Pump motor and hydraulic pump Pump motor and hydraulic pump Adjustable pressure re Adjusta...

Page 137: ...SO VG 32 ISO VG 32 Cold storage Cold storage ISO VG 15 ISO VG 15 Hot temperatures Hot temperatures ISO VG 46 ISO VG 46 Fill the hydraulic oil tank up to of the full volume The filling hole for hydraul...

Page 138: ...the oil tank the suction filter the pressure relief valve the suction filter the pressure relief valve the solenoid valve hydraulic the solenoid valve hydraulic hoses and connections for various hoses...

Page 139: ...ssure relief valve or To adjust the pressure relief valve or to clean the hydraulic oil suction filter to clean the hydraulic oil suction filter you must you must disassemble the oil tank disassemble...

Page 140: ...shown in the figure 10 5 10 5 Replacing the hydraulic cylinder Replacing the hydraulic cylinder CAUTION CAUTION Attach caps to the cylinder connectors to protect the Attach caps to the cylinder conne...

Page 141: ...uppermost position before cylinder removal 1 1 Remove the bolts attaching the Remove the bolts attaching the shaft shaft to the frame to the frame 2 2 Remove the guide bracket Remove the guide bracket...

Page 142: ...Service Service Manual Manual 7 7 Bend the machine slightly backward Bend the machine slightly backward 8 8 Remove the spacers Remove the spacers 9 9 Lift the cylinder out off the slot Lift the cylind...

Page 143: ...linder s slide slide bearings bearings 1 1 Remove the hydraulic cylinder as instructed in section Remove the hydraulic cylinder as instructed in section 10 5 10 5 above above 2 2 Remove the slide bear...

Page 144: ...ruckTool can be used to receive display and modify settings update flash controller TruckTool can be used to receive display and modify settings update flash controller firmware reset settings to hard...

Page 145: ...n rate of the traction motor in the the traction motor in the standard drive mode standard drive mode Value range Value range 0 1 Fastest 0 1 Fastest 10 Slowest 10 Slowest Acceleration ramp end s Acce...

Page 146: ...s parameter controls the deceleration rate when the speed is reduced but not the speed is reduced but not stopped while moving stopped while moving in the economy drive mode in the economy drive mode...

Page 147: ...ive mode economy drive mode Value range Value range 0 1 Fastest 0 1 Fastest 10 Slowest 10 Slowest Inversion braking ramp Inversion braking ramp INVERS BRAKING INVERS BRAKING This parameter controls th...

Page 148: ...d speed cutback Maximum load speed cutback MAX SPEED LOAD MAX SPEED LOAD This parameter controls the maximum speed This parameter controls the maximum speed forward with maximum load in percentage of...

Page 149: ...or is released in the the accelerator is released in the standard drive standard drive mode mode Value range Value range 0 1 Fastest 0 1 Fastest 10 Slowest 10 Slowest Speed limit braking ramp Speed li...

Page 150: ...e voltmeter between Batt and key input Connect the voltmeter between Batt and key input K1 1 Use a high quality voltmeter to check the K1 1 Use a high quality voltmeter to check the battery voltage an...

Page 151: ...his parameter controls the temperature limit for fans If any of the fans If any of the measured temperatures exceed measured temperatures exceeds s this value the fans are started this value the fans...

Page 152: ...with the battery lock sensor option BATTERY CHECK BATTERY CHECK Option Battery check Option Battery check This parameter controls the specification of low This parameter controls the specification of...

Page 153: ...l 1 digital Option PIN code lock Option PIN code lock PIN CODE LOCK PIN CODE LOCK PIN code lock function PIN code lock function Value range Value range 0 OFF 0 OFF 1 ON 1 ON Option Pin code timeout Op...

Page 154: ...ault diagnostic system of the traction controller is The fault diagnostic system of the traction controller is divided into two main groups divided into two main groups Alarms Alarms These are faults...

Page 155: ...d Stored This warning is caused by a hardware or This warning is caused by a hardware or software defect of the non volatile embedded memory software defect of the non volatile embedded memory support...

Page 156: ...he line contactor tips and the a case check the line contactor tips and the battery power cable connections battery power cable connections In some cases this error can also happen during In some case...

Page 157: ...y one and expects the phase voltage to and expects the phase voltage to increase toward the rail increase toward the rail capacitor value If the phase voltage does capacitor value If the phase voltage...

Page 158: ...faults are If no faults are found the problem is in found the problem is in the COMBIACX controller the COMBIACX controller 37 37 Contactor is stuck closed Contactor is stuck closed CONTACTOR CLOSED...

Page 159: ...a logic failure oc A power failure or a logic failure occurred in the controller In this c curred in the controller In this case replace the ase replace the COMBIACX controller COMBIACX controller 62...

Page 160: ...tor XA1 C pin 6 and Batt If there is a short circuit between the connector XA1 C pin 6 and Batt Condition of the wiring of Condition of the wiring of the main contactor related harness the main contac...

Page 161: ...functioning and its wirings connections Also check the encoder s mechanical installation if the functioning and its wirings connections Also check the encoder s mechanical installation if the encoder...

Page 162: ...ng This is only a notification This is only a notification To limit further heat generation To limit further heat generation the parameter cutback starts when the parameter cutback starts when the con...

Page 163: ...his alarm occurs if the motor resistance is different than This alarm occurs if the motor resistance is different than the value of the the value of the parameter MOTOR parameter MOTOR RESIST RESIST I...

Page 164: ...the tester menu the tester menu Operation of the tiller and the lift buttons is correct Operation of the tiller and the lift buttons is correct There are no short circuits in the lift button wirings T...

Page 165: ...are OK the problem is in the COMBIACX controller problem is in the COMBIACX controller 208 208 Controller memory error EEPROM Controller memory error EEPROM EEPROM KO EEPROM KO Alarm Stored Alarm Sto...

Page 166: ...microcontroller detects a mismatch between the valve set point and the voltage measured on the and the voltage measured on the solenoid valve output This can be caused by t solenoid valve output This...

Page 167: ...he built in smart driver is open and not smart driver is open and not able to provide the able to provide the magnetic magnetic brake positive brake positive In such a case check the harness to see In...

Page 168: ...he brake release switch are brake release switch are open open In such a case check the wiring to In such a case check the wiring to see that there is no see that there is no extra positive supply con...

Page 169: ...alve EVXX XX 01 02 solenoid valve EVXX XX 01 02 or 03 driver is shorted or 03 driver is shorted Check if there is a short or low impedance between the negative of one of the coils and Batt Check if th...

Page 170: ...edance Solenoid valve coil impedance Wiring Wiring If the solenoid valve driver circuit is If the solenoid valve driver circuit is damaged replace the controller damaged replace the controller 241 241...

Page 171: ...aged so the controller has to be replaced to be replaced 247 247 Acquisition of gain values Acquisition of gain values DATA ACQUISITION DATA ACQUISITION Warning Warning This warning indicates acquisit...

Page 172: ...If the button terminal If the battery voltage is measured anywhere else it will cause invalid battery voltage is measured anywhere else it will cause invalid operation operation of the battery dischar...

Page 173: ...14 Service Service data data 14 1 14 1 Special tightening torques Special tightening torques Traction wheel Traction wheel 80 Nm 80 Nm COMBIACX Power controller terminal COMBIACX Power controller ter...

Page 174: ...eserved rights reserved Revision B Revision B Document ID 615023 Document ID 615023 173 244 173 244 PBV20N2 PBV20N2 Service Service Manual Manual 14 2 14 2 Tightening torque for standard bolts and nut...

Page 175: ...13 All Mitsubishi Forklift Trucks 2013 All rights reserved rights reserved Revision B Revision B Document ID 615023 Document ID 615023 174 244 174 244 PBV20N2 PBV20N2 Service Service Manual Manual htt...

Page 176: ...astening of the gearbox C C C C Hydraulics Hydraulics Leakage checking Leakage checking C C C C C C Cleaning the oil filter Cleaning the oil filter R R Hydraulic oil change Hydraulic oil change R R Oi...

Page 177: ...air gap and disc thickness C C C C Controller power cable torque Controller power cable torque C C C C Motor s cable torque Motor s cable torque C C C C EMS Emergency switch EMS Emergency switch C C...

Page 178: ...hts C C C C C C C C Accessory Accessory bracket bracket C C C C C C C C Quick battery change mechanism Quick battery change mechanism C C C C C C C C 14 4 14 4 Lubrication Lubrication 14 4 1 14 4 1 Hy...

Page 179: ...for traction pump controller signal line connectors pump controller signal line connectors RL362138 RL362138 Extraction tool for main connector series Extraction tool for main connector series RL3600...

Page 180: ...purchase after purchase Figure 87 Figure 87 below illustrates the available options below illustrates the available options NOTE Electrical steering is not presented in the figure below NOTE Electric...

Page 181: ...re 88 Pallet entry exit rollers overview The pallet entry exit The pallet entry exit rollers make it possible to rollers make it possible to handle the truck s load pallets sideways handle the truck s...

Page 182: ...rollers Disassembly of the front rollers 1 1 Remove the lock ring Remove the lock ring 2 2 Remove the washer Remove the washer 3 3 Remove the roller Remove the roller 15 2 15 2 Load support Load suppo...

Page 183: ...Install the load support to the Install the load support to the front of front of the truck s battery the truck s battery compartmen compartment and t and screw it in place screw it in place 15 3 15...

Page 184: ...mputer The computer rack is suited for rack is suited for computer computers with a s with a maximum width of 345 mm maximum width of 345 mm Bottle rack Bottle rack The bottle rack provides a holder f...

Page 185: ...ing bracket to the accessory rack to the accessory rack 3 3 Slide the T slot fasteners into the Slide the T slot fasteners into the operator side groove of the operator side groove of the mounting bra...

Page 186: ...e screws and Install and tighten the screws and nuts attaching the mounting bracket nuts attaching the mounting bracket to the accessory rack to the accessory rack 3 3 Slide the T slot fasteners into...

Page 187: ...rack 2 2 Tighten the bottle rack with the Tighten the bottle rack with the M5x30 screw and M5 nut provided M5x30 screw and M5 nut provided 15 3 1 4 Installation of the pen 15 3 1 4 Installation of th...

Page 188: ...ng lights CAUTION CAUTION Always use the correct schematic diagram for the Always use the correct schematic diagram for the specific model you are servicing The specific model you are servicing The la...

Page 189: ...and draw them via the hoist point hole into the point hole into the battery compartment See battery compartment See Figure 91 Figure 91 below below 6 6 Draw the working light wires Draw the working l...

Page 190: ...stalled to the truck during truck during manufacturing so this option needs to be selected prior to purchasing the truck manufacturing so this option needs to be selected prior to purchasing the truck...

Page 191: ...the controller for lifting and lowering Figure 93 Removing the controller for lifting and lowering overview overview 1 1 Screw Screw 2 2 Controller for lifting and lowering Controller for lifting and...

Page 192: ...marked on the connector with lines and help you in determining the rest of the pin marked on the connector with lines and help you in determining the rest of the pin locations Details of the controlle...

Page 193: ...lowering must be calibrated Also if changed the controller for lifting and lowering must be calibrated Also if the truck does the truck does not drive smoothly it is not drive smoothly it is recommend...

Page 194: ...Acquiring the VACC without Truck Tool 15 4 3 2 Acquiring the VACC without Truck Tool 1 1 During key o During key on lower the n lower the forks and forks and turn the a turn the accelerator fo cceler...

Page 195: ...the the voltage voltage converter converter CAUTION CAUTION Always use the correct schematic diagram for the Always use the correct schematic diagram for the specific model you are servicing The spec...

Page 196: ...sor the system With this sensor the traction controller can adjust the driving speed according traction controller can adjust the driving speed according to the lifted load The to the lifted load The...

Page 197: ...ic model you are servicing The latest schematic diagrams are available from the manufacturer s Web site latest schematic diagrams are available from the manufacturer s Web site 1 1 Disconnect the hydr...

Page 198: ...bar The output signal level rises relatively to the hydraulic oil pressure and with the The output signal level rises relatively to the hydraulic oil pressure and with the maximum load 2000 kg the val...

Page 199: ...or s mounting plate into the truck frame mounting plate into the truck frame next to the battery lock next to the battery lock 2 2 Screw the battery lock sensor onto Screw the battery lock sensor onto...

Page 200: ...ange the value is the same as When a metallic object is moved within the sensing range the value is the same as the supply voltage i e the supply voltage i e 24Vdc 24Vdc 4 4 If the If the values d val...

Page 201: ...tructions for removing the Instructions for removing the recharging plug are provided below Install recharging plug are provided below Install the recharging the recharging plug by repeating the steps...

Page 202: ...cument ID 615023 201 244 201 244 PBV20N2 PBV20N2 Service Service Manual Manual 3 3 Remove the bolts of the battery Remove the bolts of the battery connector connector 4 4 Disconnect the battery connec...

Page 203: ...use of a lifting device lifting device 1 1 Open the battery cover For instructions see the Open the battery cover For instructions see the section section 5 4 4 5 4 4 2 2 Disconnect the battery connec...

Page 204: ...rs with quick battery replacement ent Figure 101 Rubber absorbers with the quick battery replacement option Figure 101 Rubber absorbers with the quick battery replacement option 1 1 Battery lock hing...

Page 205: ...ing slowly stopped or moving slowly The power steering system has no direct mechanical connection to the steering The The power steering system has no direct mechanical connection to the steering The...

Page 206: ...re 102 Motor and electrical system with electrical Figure 102 Motor and electrical system with electrical steering overview steering overview 1 1 Electric panel covered with a Electric panel covered w...

Page 207: ...Sensor mounting bracket Sensor mounting bracket 3 3 Motor belt Motor belt 4 4 Motor belt s tightening screw Motor belt s tightening screw 5 5 Belt roller Belt roller 6 6 Motor rack Motor rack 7 7 Belt...

Page 208: ...elay inside Double safety relay inside 15 11 3 15 11 3 Zapi EPS A Zapi EPS AC0 connec C0 connectors tors CAUTION CAUTION Before any inspection or repair work turn the Before any inspection or repair w...

Page 209: ...50937 connector spare part RL450937 Contact 0 2 0 8 mm2 for CNA CNB CNC and CND connectors spare part Contact 0 2 0 8 mm2 for CNA CNB CNC and CND connectors spare part RL450666 RL450666 15 11 3 1 15 1...

Page 210: ...XA2 B 3 temperature sensor positive temperature sensor positive Motor temperature sensor KTY84 130 input Motor temperature sensor KTY84 130 input B4 5VDC XA2 B 4 B4 5VDC XA2 B 4 5V 5V Encoder positive...

Page 211: ...dback sensor sensor The feedback sensor is used for monitoring the steering wheel position With this The feedback sensor is used for monitoring the steering wheel position With this sensor the steerin...

Page 212: ...The value should be 5 Vdc 3 3 Measure b Measure between th etween the negativ e negative XP2 3 an e XP2 3 and output d output XP2 2 wires o XP2 2 wires on the vo n the voltage ltage area area When a s...

Page 213: ...section Remove the motor belt For instructions see section 15 11 7 15 11 7 2 2 Remove the screws of the sensor Remove the screws of the sensor mounting bracket mounting bracket 3 3 Remove the sensor...

Page 214: ...ng bracket bracket 10 10 Remove the hydraulic aggregate Remove the hydraulic aggregate and its mounting bracket and its mounting bracket 11 11 Remove the screws of the motor Remove the screws of the m...

Page 215: ...ering controller mounting bracket 17 17 Remove the steering controller Remove the steering controller mounting bracket mounting bracket 18 18 Remove the three screws of the Remove the three screws of...

Page 216: ...6 N When the motor belt is in place and tightened it should give in approximately When the motor belt is in place and tightened it should give in approximately 1 8 mm If the belt gives in more or less...

Page 217: ...eplacing t Replacing the motor he motor belt belt 1 1 Loosen the motor belt fastener Loosen the motor belt fastener 2 2 Loosen the motor belt s tightening Loosen the motor belt s tightening screw scre...

Page 218: ...system installed to the truck system 4 4 It is very im It is very important to a portant to assemble the ssemble the sensor axis sensor axis in the co in the correct position rrect position When the...

Page 219: ...11 With the Zapi hand console go to the ADJUSTMENTS menu and to the SET MIN 11 With the Zapi hand console go to the ADJUSTMENTS menu and to the SET MIN FB POT parameter Then press OUT and ENTER FB PO...

Page 220: ...t and by increasing this value the steering mechanism turns to the left and by decreasing decreasing this value the steering mechanism turns to the r this value the steering mechanism turns to the rig...

Page 221: ...e difference between the tiller and the steered wheel on which between the tiller and the steered wheel on which dynamic numbness is applied dynamic numbness is applied Value range Value range 0 No nu...

Page 222: ...ng angle cutback start speed Steering angle cutback start speed AUX FUNCTION AUX FUNCTION 2 2 This parameter defines the steering angle reduction This parameter defines the steering angle reduction ra...

Page 223: ...10 15 11 10 Steering Steering controller controller alarm alarm codes codes NOTE Before you start to troubleshoot the truck make sure that NOTE Before you start to troubleshoot the truck make sure th...

Page 224: ...EEPROM operation Switch the truck s warning try to execute a CLEAR EEPROM operation Switch the truck s power off and on and check the result power off and on and check the result If the alarm occurs...

Page 225: ...voltage error VMN NOT OK VMN NOT OK Alarm Alarm Stored Stored This alarm occurs in the initial This alarm occurs in the initial rest state after startup if the rest state after startup if the outputs...

Page 226: ...is positive supply to the controller There is positive supply to the controller Continuity of the phase cable from the Continuity of the phase cable from the controller to the motor controller to the...

Page 227: ...larm occurs if the feedback sensor or potentiometer does not This alarm occurs if the feedback sensor or potentiometer does not change the value or change the value or changes the value to the o chang...

Page 228: ...mation from the trac ntroller needs information from the traction controller to close the tion controller to close the internal safety contacts and to switch to the internal safety contacts and to swi...

Page 229: ...re in order connectors and cables are in order and measure that the feedback sensor signal voltage is and measure that the feedback sensor signal voltage is within tolerance within tolerance 250 250 I...

Page 230: ...Trucks 2013 All rights reserved rights reserved Revision B Revision B Document ID 615023 Document ID 615023 229 244 229 244 PBV20N2 PBV20N2 Service Service Manual Manual 16 16 Technical Technical spec...

Page 231: ...battery battery weight drive load side weight drive load side kg kg 950 950 1 710 1 710 2 3 2 3 Shaft loadings without load Shaft loadings without load with battery drive with battery drive load side...

Page 232: ...t 800x1 200 load lengthwise lengthwise Ast mm Ast mm 2 120 2 600 2 120 2 600 4 35 4 35 Turning Turning radius radius Wa Wa mm mm 1 680 1 680 2 160 2 160 5 PERFORMANCE 5 PERFORMANCE 5 1 5 1 Travel Trav...

Page 233: ...rding to EN 13 059 2002 A1 2008 059 2002 A1 2008 m m s s 0 0 8 8 PBV20N2 PBV20N2 Service Service Manual Manual Hand arm vibration according to EN 13 Hand arm vibration according to EN 13 059 2002 A1 2...

Page 234: ...connector connector 200 200 Battery cover Battery cover Opening the Opening the battery cover battery cover 38 38 Removing the Removing the battery cover battery cover lock lock 40 40 Removing the ba...

Page 235: ...a multimeter multimeter 123 123 Hydraulic aggregate Hydraulic aggregate Disassembly of the hydraulic Disassembly of the hydraulic aggregate aggregate 138 138 Disassembl Disassembly of y of the oil ta...

Page 236: ...50 Replacing the operator s platform Replacing the operator s platform gas gas spring spring 48 48 P P Pallet entry exit rollers Pallet entry exit rollers Disassembl Disassembly of the pallet entry y...

Page 237: ...See See Tiller arm Tiller arm Tiller head micro switch Tiller head micro switch 122 122 Top cover Top cover Opening the Opening the top cover top cover 37 37 Traction controller Traction controller A...

Page 238: ...rights reserved rights reserved Revision B Revision B Document ID 615023 Document ID 615023 237 244 237 244 PBV20N2 PBV20N2 Service Service Manual Manual APPENDIX A Stickers APPENDIX A Stickers Figur...

Page 239: ...1 Operation warning sticker PBV20N2 PBV20N2 Service Service Manual Manual Figure 112 Serial number sticker Figure 112 Serial number sticker Figure 113 Battery maintenance warning sticker Figure 113 Ba...

Page 240: ...rights reserved rights reserved Revision B Revision B Document ID 615023 Document ID 615023 239 244 239 244 PBV20N2 PBV20N2 Service Service Manual Manual Figure 116 Hoist point indication sticker Fig...

Page 241: ...13 All Mitsubishi Forklift Trucks 2013 All rights reserved rights reserved Revision B Revision B Document ID 615023 Document ID 615023 240 244 240 244 PBV20N2 PBV20N2 Service Service Manual Manual htt...

Page 242: ...13 All Mitsubishi Forklift Trucks 2013 All rights reserved rights reserved Revision B Revision B Document ID 615023 Document ID 615023 241 244 241 244 PBV20N2 PBV20N2 Service Service Manual Manual htt...

Page 243: ...ishi Forklift Trucks 2013 All Mitsubishi Forklift Trucks 2013 All rights reserved rights reserved Revision B Revision B Document ID 615023 Document ID 615023 242 244 242 244 https www forkliftpdfmanua...

Page 244: ...h o o r r i i z z e e d d c c o o p p y y i i n n g g a a n n d d l l e e n n d d i i n n g g a a r r e e p p r r o o h h i i b b i i t t e e d d MCFE B V MCFE B V Hefbrugweg 77 Hefbrugweg 77 1332 AM...

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