Mitsubishi PBV20N2 User manual

SERVICE MANUALSERVICE MANUAL
PBV20N2
PBV20N2
615023615023
English 2013English 2013
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© Mitsubishi Forklift Trucks 2013. All
© Mitsubishi Forklift Trucks 2013. All rights reserved.rights reserved.Revision: BRevision: BDocument ID: 615023Document ID: 615023 2 (244)2 (244)
PBV20N2 PBV20N2 Service Service ManualManual
Only adequately trained service persons are allowed to carry out service operations. The terms of theOnly adequately trained service persons are allowed to carry out service operations. The terms of the
warranty prescribe appropriate maintenance of the truck. All spare parts must be original ones.warranty prescribe appropriate maintenance of the truck. All spare parts must be original ones.
It is recommended that you sign a maintenance agreement with the truck dealer, who can alsIt is recommended that you sign a maintenance agreement with the truck dealer, who can also supply spareo supply spare
parts. Only professional service ensures long-term, trouble-free truck operation. Service program monitoringparts. Only professional service ensures long-term, trouble-free truck operation. Service program monitoring
becomes easier if you enter the service dates in a service logbook. Contact our service organisation or yourbecomes easier if you enter the service dates in a service logbook. Contact our service organisation or your
truck dealer for qualified, authorized and efficient maintenance service.truck dealer for qualified, authorized and efficient 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 trademark of Mitsubishi Heavy Industries®, Inc. All brand or productMitsubishi Forklift Trucks® is a registered trademark of Mitsubishi Heavy Industries®, Inc. All brand or product
names are or may be trademarks of, and are used to identify products and services of, their respectivenames are or may be trademarks of, and are used to identify products and services of, their respective
owners.owners.
Unauthorized copying and lending are prohibited.Unauthorized copying and lending are prohibited.
Mitsubishi Caterpillar ForkliftMitsubishi Caterpillar Forklift
Asia Pte. Ltd.Asia Pte. Ltd.
RCB No.: 199203169HRCB No.: 199203169H
No. 1, Tuas West StreetNo. 1, Tuas West Street
Singapore 637444Singapore 637444
MCFA MCFA MCFE MCFE B.V.B.V.
2121 2121 W. W. Sam Sam Houston Houston Pkwy. Pkwy. N. N. Hefbrugweg Hefbrugweg 7777
Houston, Houston, TX TX 77043-2305 77043-2305 1332 1332 AM AM AlmereAlmere
USA USA The The NetherlandsNetherlands
Approvals and version historyApprovals and version history
ISSUE
ISSUE DATE DATE DESCRIPTION DESCRIPTION OF OF CHANGE CHANGE APPROVED APPROVED BYBY
AA 03.10.2012 03.10.2012 First First issueissue R&DR&D
BB 03.07.2013 03.07.2013 Second Second issueissue R&DR&D
Original instructions ___X___ / Translation of the Original instructions ___X___ / Translation of the original instructions _______original instructions _______
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Contents
Contents
Contents Contents ............................................................................................................................................................................................................................................... 3........... 3
11 Foreword Foreword .................................................................................................................................................................... 8................................................................ 8
22 How How to to read read this this manual manual ................................................................................................................................................ .................................. 99
2.12.1 Safety-related Safety-related signs signs ...................................................................................................................................... 9................................ 9
2.22.2 Symbols Symbols and and abbreviationabbreviations ..........................s ........................................................................ 9.............................................. 9
2.2.12.2.1 Safety Safety symbols .....................................................symbols .................................................................................................................................... 9................. 9
2.2.22.2.2 Other Other symbols symbols and and abbreviations..........................abbreviations...................................................................................................... .............. 1111
2.32.3 Units Units ............................................................................................................................................................. 11..................................................... 11
33 Safety Safety instructioinstructions ns ...................................................................................................................................................... 12.......................................... 12
3.13.1 Service Service area area safety .................................................................................. safety .................................................................................. 1212
3.23.2 Personal Personal safety safety ................................................................................................................................................ 1................................ 133
3.33.3 Work Work safety ....................................................................................safety .............................................................................................. 13.......... 13
44 General General informatioinformation n .................................................................................................................................................. 16.......................................... 16
4.14.1 Truck Truck model covered model covered by by this this manual manual ....................................................... ....................................................... 1616
4.24.2 Identification plates Identification plates on the on the truck .............................................................. truck .............................................................. 1616
4.34.3 Overview of Overview of the truck the truck ................................................................................................................................ .............................. 1717
4.3.14.3.1 Operating Operating devices devices ....................................................................................................................................................................................... 17..... 17
4.3.24.3.2 Tiller Tiller arm arm ........................................................................................................................................................................................................ 18................ 18
4.3.2.14.3.2.1 Tiller arm controlsTiller arm controls......................................................................................................................................................................................... ..... 1818
4.3.2.24.3.2.2 Tiller Tiller arm arm positions .....................................positions ............................................................................................................................ ......................... 1919
4.3.34.3.3 Control Control panel ..................................................panel ..................................................................................................................................... 20..................... 20
4.3.3.14.3.3.1 Emergency Emergency stop stop button ..............................................button .................................................................................................................... .......... 2020
4.3.3.24.3.3.2 Key Key switch switch .................................................................................................................................................................................................... 21................ 21
4.3.3.34.3.3.3 Multi-function displayMulti-function display...................................................................................................................................................... .............................. 2222
4.3.44.3.4 Driving Driving position ................................position ................................................................................................................................................................. 23..... 23
4.3.4.14.3.4.1 Pedestrian Pedestrian mode .......................................................mode ............................................................................................................................... 23.......... 23
4.3.4.24.3.4.2 Riding Riding mode mode ................................................................................................................................................................................................... 24........... 24
4.3.54.3.5 Driving Driving direction direction ............................................................................................................................................................................................. 25..... 25
4.3.64.3.6 Motor Motor and and electrical electrical system .......................................................system ............................................................................... ........................ 2626
4.3.6.14.3.6.1 Electric Electric panel .........................panel ................................................................................................................................................................... 27................ 27
4.3.6.24.3.6.2 Motor Motor compartment ........................................................compartment ........................................................................................................................... 28..... 28
4.3.6.34.3.6.3 Traction Traction motor motor .............................................................................................................................................................................................. 29.......... 29
4.3.74.3.7 Sensors Sensors ....................................................................................................................................................................................................... 30..................... 30
4.3.84.3.8 Truck Truck suspension ......................................................suspension .............................................................................................................................. 31.......... 31
55 MechanicMechanical al maintenanmaintenance ...................................................................................... 32ce ...................................................................................... 32
5.15.1 Lifting Lifting points ....................................................points ............................................................................................. 32......................................... 32
5.1.15.1.1 Jack Jack points points .................................................................................................................................................................................................. 32................ 32
5.1.25.1.2 Hoist Hoist points points ................................................................................................................................................................................................ 33................ 33
5.25.2 TransportatioTransportation n ........................................................................................................................................... 33......................................... 33
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5.35.3 Ordering Ordering spare spare parts ..........................................................parts ................................................................................ 3...................... 344
5.45.4 Opening Opening the the covers ............................covers .................................................................................. ...................................................... 3434
5.4.15.4.1 Front Front cover cover .................................................................................................................................................................................................. 35................ 35
5.4.25.4.2 Control Control panel ..................................................panel ..................................................................................................................................... 36..................... 36
5.4.35.4.3 Top Top cover cover ...................................................................................................................................................................................................... 37................ 37
5.4.45.4.4 Battery Battery cover cover ................................................................................................................................................................................................. 38........... 38
5.4.4.15.4.4.1 Removing Removing the the battery battery cover cover lock .......lock ..................................................................................................................................... .... 4040
5.4.4.25.4.4.2 Removing the Removing the battery cover’battery cover’s s rubber absorbers ..............................................rubber absorbers ................................................ .. 4141
5.55.5 Removing the Removing the side side guards ............................................guards ....................................................................... ........................... 4141
5.5.15.5.1 Replacing the Replacing the side side guard’s gas guard’s gas spring ........................spring .............................................................................................. ........ 4242
5.65.6 Removing Removing the the operator’s operator’s platform platform ............................................................................................................... 44......... 44
5.6.15.6.1 Replacing the Replacing the operator’s platform operator’s platform gas spring gas spring ................................................................................. ....................... 4848
5.6.25.6.2 Removing the Removing the operator’s platform operator’s platform slide slide bearing ..............................................bearing ................................................ .. 5050
5.75.7 Transmission Transmission gear.............................gear.................................................................................... 51....................................................... 51
5.85.8 Bogie Bogie bearing ..........................................bearing ........................................................................................... 52................................................. 52
5.95.9 Traction Traction wheel .................wheel .......................................................................................................................................................... 52......... 52
5.9.15.9.1 Disassembly Disassembly of of the the traction traction wheel.........................wheel..................................................................................................... .............. 5353
5.9.1.15.9.1.1 Replacing Replacing the the wheel wheel shaft shaft bolts .................................................bolts ......................................................................... ........................ 5454
5.9.25.9.2 Assembly of the traction wheel ....Assembly of the traction wheel ....................................................................................................................................... ......... 5555
5.105.10 Load Load wheels ............................................................wheels ............................................................................................. 56................................. 56
5.115.11 Lifting system Lifting system and and fork fork carriage carriage .................................................................................................................... .......... 5757
5.125.12 Castor Castor wheels .......................................................................................... wheels .......................................................................................... 5959
5.12.15.12.1 Disassembly Disassembly of of the the castor castor wheel......................wheel....................................................................................................... ................... 6060
5.12.25.12.2 Adjusting the castor wheels ...Adjusting the castor wheels ............................................................................................................................................. .............. 6060
5.12.35.12.3 Assembly of the castor wheel ......Assembly of the castor wheel ......................................................................................................................................... ......... 6161
5.135.13 Castor Castor wheel wheel suspension suspension .............................................................................................................................. 62.................... 62
5.145.14 Disassembly of Disassembly of the the drive drive unit unit suspension suspension ................................................ ................................................ 6464
5.155.15 Tiller Tiller arm ...............................................................................................arm .................................................................................................. 67... 67
5.165.16 Tiller Tiller arm arm joint joint ............................................................................................................................................. 6......................................... 699
66 Electrical Electrical operation .....................................................operation ............................................................................................... 72.......................................... 72
6.16.1 Using Using the the schematic schematic diagram diagram ........................................................................................................................... 72........... 72
6.26.2 Power Power source ..................................................................................source ........................................................................................... 75......... 75
6.36.3 Safety circuit Safety circuit (emergency stop (emergency stop button) .............................................button) .................................................... ....... 7575
6.46.4 Key Key switch .............................................................switch ................................................................................................ 75................................... 75
6.56.5 Traction Traction ..................................................................................................................................................... 76................................................... 76
6.66.6 AC motor operaAC motor operation tion ...................................................................................................................................... .............................. 7676
77 Battery Battery maintenancmaintenance e ................................................................................................................................................ 77.......................................... 77
7.17.1 Safety regulations concerning the Safety regulations concerning the handling of lead-acid handling of lead-acid batteries .......... batteries .......... 7878
7.27.2 Battery Battery maintenanmaintenance ................................................................................ 7ce ................................................................................ 799
7.2.17.2.1 Daily Daily maintenance ............................maintenance ........................................................................................................................................................... 79..... 79
7.2.27.2.2 Weekly Weekly maintenance .......................................maintenance ......................................................................................................................... 79.................... 79
7.2.37.2.3 Monthly Monthly maintenance ......................................................maintenance ....................................................................................................................... 79..... 79
7.2.47.2.4 Annual maintenance ...Annual maintenance ........................................................................................................................................................ ......................... 7979
7.37.3 Recharging Recharging the the battery battery ..................................................................................................................................... 80..................... 80
7.47.4 Measuring the Measuring the battery's specific battery's specific gravity .....gravity ................................................... .............................................. 8282
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7.57.5 Replacing Replacing the the battery .................................................battery ............................................................................... .............................. 8282
88 Electric Electric system system maintenanmaintenance .........................................................ce ............................................................................... 85...................... 85
8.18.1 Tiller Tiller arm ...............................................................................................arm .................................................................................................. 85... 85
8.1.18.1.1 Removing Removing the the tiller tiller head .................................................head ................................................................................................................... .... 8585
8.1.28.1.2 Removing Removing the the tiller tiller head shead switches...............................witches.................................................................................................... ......... 8787
8.1.38.1.3 Removing Removing the the safety safety button .................................................button ............................................................................... .............................. 8888
8.1.3.18.1.3.1 Installing Installing the the rubber rubber handles .......................handles ............................................................................................................. ........................ 9090
8.1.48.1.4 Removing Removing the the accelerator ...............................................accelerator ................................................................................................................. .... 9191
8.1.58.1.5 Installing Installing the the accelerator ............................................accelerator ................................................................................................................... ......... 9393
8.28.2 Electric Electric panel panel ............................................................................................................................................... 94......................................... 94
8.2.18.2.1 Removing Removing the the controller controller cover ...................................................cover ........................................................................... ........................ 9595
8.2.28.2.2 Zapi Zapi COMBIACX COMBIACX Power Power Controller ..................................Controller .................................................................................................. .... 9696
8.2.38.2.3 Zapi Zapi COMBIACX COMBIACX connectors .....................................................connectors ............................................................................. ........................ 9696
8.2.3.18.2.3.1 CNA CNA external external connector ...................................connector ................................................................................................................... .................... 9797
8.2.3.28.2.3.2 CNB CNB external external connector ...................................connector ................................................................................................................... .................... 9898
8.2.3.38.2.3.3 CNC CNC external external connector ...................connector .................................................................................................................................................. 99..... 99
8.2.3.48.2.3.4 CND CND external external connector ...................connector ................................................................................................................................................ 100... 100
8.2.3.58.2.3.5 Description Description of of the the power cpower connections .........................onnections ............................................................................................. ...... 101101
8.2.48.2.4 Contactors Contactors and and relays relays ................................................................................................................................................ ............................ 101101
8.2.58.2.5 Fuses Fuses ........................................................................................................................................................................................................... 103................... 103
8.2.68.2.6 Accessing the controller fan Accessing the controller fan ......................................................................................................................................... ................. 104104
8.38.3 Motor Motor compartmencompartment ................................................................................ 10t ................................................................................ 1066
8.3.18.3.1 Removing Removing the the drive drive unit ..................................................unit ................................................................................................................. ... 107107
8.3.28.3.2 Disassembly Disassembly of of the the drive drive unit ................................unit .......................................................................................................... ............ 108108
8.3.38.3.3 Installation Installation of of the the traction traction motor ..................motor ...................................................................................................... ...................... 109109
8.3.48.3.4 Assembly of the splined shaft-hub connection Assembly of the splined shaft-hub connection ............................................................................. ..................... 110110
8.3.58.3.5 Temperature Temperature sensor sensor check check ........................................................................................................................................... ................. 111111
8.3.68.3.6 HALL HALL sensor sensor ............................................................................................................................................................................................... 112......... 112
8.3.6.18.3.6.1 Replacing Replacing the the HALL HALL sensor .......................................................sensor ............................................................................. ...................... 113113
8.3.78.3.7 Magnetic Magnetic brake ......................................brake ............................................................................................................................... 114............................. 114
8.3.7.18.3.7.1 Coil Coil resistance resistance measurement .measurement ......................................................................................................................................... ............ 115115
8.48.4 Pump Pump motor ....motor .................................................................................................................................................... 115................................ 115
8.4.18.4.1 Solenoid Solenoid valve .................................................valve ................................................................................................................................ 116................... 116
8.58.5 Sensors Sensors ................................................................................................................................................... 117................................................. 117
8.5.18.5.1 Tiller, Tiller, side guard side guard and operator’s and operator’s platform sensors ......................platform sensors ........................................... ..................... 117117
8.68.6 Switches Switches and and buttons .........buttons ............................................................................................................................................. 120.... 120
8.6.18.6.1 Emergency Emergency stop stop button ..............................................button .................................................................................................................. ........ 120120
8.6.28.6.2 Key Key switch switch .................................................................................................................................................................................................. 121.............. 121
8.6.38.6.3 Tiller Tiller head head micro micro switch switch ................................................................................................................................................... ..................... 122122
8.78.7 Horn Horn ........................................................................................................................................................... 12................................................... 1233
8.7.18.7.1 Diode Diode test test with with a a multimeter ...multimeter ........................................................................................................................................... ............ 123123
8.88.8 Wiring Wiring harnesses harnesses and and cables cables ......................................................................................................................... 12......... 1244
8.8.18.8.1 Installing Installing the the traction traction motor motor cables..............................cables.................................................................................................. ...... 126126
99 Electric Electric system adjustments system adjustments and and measuremeasurements ments ............................................ ............................................ 128128
9.19.1 Calibrating Calibrating the the accelerator ...........................accelerator ..................................................................... .......................................... 128128
9.1.19.1.1 Acquiring the VACC with TruckTool Acquiring the VACC with TruckTool ............................................................................................................................ ...... 128128
9.1.29.1.2 Acquiring the VACC without Truck Tool Acquiring the VACC without Truck Tool ..................................................................................................................... . 129129
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9.29.2 Insulation resistance Insulation resistance test test ........................................................................................................................... ................... 129129
9.2.19.2.1 Test Test voltage .....................................voltage .................................................................................................................................................................... 129... 129
9.2.29.2.2 Checking Checking the the insulation insulation tester .....................tester ......................................................................................................... ...................... 130130
9.2.39.2.3 Measuring Measuring the the insulation insulation resistance .......resistance ................................................................................................ ........................... 130130
9.2.3.19.2.3.1 Insulation Insulation resistance resistance of of the the truck.................................truck.................................................................................................... ....... 131131
9.2.3.29.2.3.2 Insulation resiInsulation resistance of stance of the battery the battery .............................................................................................................................. ...... 132132
1010 Hydraulic Hydraulic operation .............operation ............................................................................................................................................................. 133................ 133
10.110.1 Hydraulic Hydraulic symbols .............................................symbols .................................................................................. 135..................................... 135
10.210.2 Hydraulic Hydraulic oil oil recommendrecommendations ......ations ..................................................................................................................... 137. 137
10.310.3 MaintenanMaintenance ce points of points of the the hydraulic system ...............hydraulic system .......................................... ........................... 137137
10.410.4 Hydraulic Hydraulic aggregate ...................aggregate ............................................................................... 13............................................................ 1388
10.4.110.4.1 Disassembly Disassembly of of the the hydraulic hydraulic aggregate ................aggregate ......................................................................................... ........... 138138
10.4.210.4.2 Disassembly Disassembly of the of the oil oil tank ........................................tank ............................................................................................................. ....... 139139
10.510.5 Replacing the Replacing the hydraulic chydraulic cylinder .............................ylinder ............................................................ ............................... 140140
10.5.110.5.1 Replacing the Replacing the hydraulic cylihydraulic cylinder’s slinder’s slide bearings ............................................ de bearings ............................................ 143143
1111 TruckTooTruckTool l Diagnostics .Diagnostics ................................................................................................................................................ 144............................... 144
1212 ParameteParameter r descriptiodescriptions ns .............................................................................................................................................. 145.............................. 145
12.112.1 Traction Traction controller .................................................................................. controller .................................................................................. 145145
1313 Alarm Alarm codes ..............................................codes ......................................................................................................... 1........................................................... 15454
13.113.1 Traction Traction controller .................................................................................. controller .................................................................................. 154154
1414 Service Service data data ............................................................................................................................................................... ................................................... 173173
14.114.1 Special Special tightening tightening torques torques .......................................................................................................................... 173.................. 173
14.214.2 Tightening torque for Tightening torque for standard bolts standard bolts and nuts ....................................... and nuts ....................................... 174174
14.314.3 MaintenanMaintenance ce check check list list ................................................................................................................................... 176................... 176
14.414.4 Lubrication .............................................................Lubrication .............................................................................................. ................................. 178178
14.4.114.4.1 Hydraulic Hydraulic oil .....................................oil .................................................................................................................................................................... 178... 178
14.4.214.4.2 Transmission Transmission oil oil ........................................................................................................................................................................................... 178... 178
14.514.5 Special Special tools ............................tools ........................................................................................... 17............................................................... 1788
1515 Options Options ..................................................................................................................................................................... 180............................................................. 180
15.115.1 Pallet Pallet entry entry / / exit exit rollers rollers ................................................................................................................................. ................... 181181
15.1.115.1.1 Disassembly Disassembly of the of the pallet entry pallet entry / exi/ exit rollers ............t rollers ................................................................................... ........... 181181
15.215.2 Load Load support .......................................................................................... support .......................................................................................... 182182
15.2.115.2.1 Installation Installation of of the lthe load oad support .........................support ........................................................................................................ ................. 183183
15.315.3 Accessory rack Accessory rack ....................................................................................................................................... ....................................... 183183
15.3.115.3.1 Installation Installation of of the acthe accessory cessory rack ................rack .................................................................................................... ...................... 184184
15.3.1.115.3.1.1 Installation Installation of of the the list list bracket bracket ....................................................................................................................................... ................. 185185
15.3.1.215.3.1.2 Installation Installation of of the cthe computer racomputer rack .................................k .................................................................................................... ....... 186186
15.3.1.315.3.1.3 Installation Installation of of the bottle the bottle rack ......................................................rack ............................................................................ ...................... 187187
15.3.1.415.3.1.4 Installation Installation of of the pen the pen rack ....................................rack .............................................................................................................. ............ 187187
15.3.1.515.3.1.5 Installation of Installation of the working the working lights .......................lights .......................................................................................................................188188
15.415.4 Lever Lever for for lifting and lifting and lowering lowering ................................................................................................................... ................. 190190
15.4.115.4.1 Removing the Removing the controller for controller for lifting lifting and lowering .....................................and lowering ............................................... .......... 191191
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15.4.215.4.2 Installing the Installing the controller for controller for lifting alifting a nd lowering .................................nd lowering ................................................. ................ 192192
15.4.315.4.3 Calibrating the Calibrating the controller for controller for lifting lifting and lowering ....................................and lowering .............................................. .......... 193193
15.4.3.115.4.3.1 Acquiring the VACC with TruckTool Acquiring the VACC with TruckTool ............................................................................................................................ ...... 193193
15.4.3.215.4.3.2 Acquiring the VACC without Truck Tool Acquiring the VACC without Truck Tool ..................................................................................................................... . 194194
15.515.5 Voltage Voltage converter ..............................................converter ................................................................................... 195..................................... 195
15.5.115.5.1 Installation of Installation of the voltage the voltage converter ......................................converter ................................................................. ........................... 195195
15.615.6 Pressure Pressure sensor .......................................................sensor ..................................................................................... 196.............................. 196
15.6.115.6.1 Installation Installation of of the pressthe pressure ure sensor ..............................sensor ................................................................................................. ....... 197197
15.6.215.6.2 Pressure Pressure sensor sensor functionality checfunctionality chec k k .......................................................................................................................... ...... 198198
15.715.7 Battery Battery lock lock sensor....................sensor................................................................................. ............................................................. 198198
15.7.115.7.1 Installation Installation of of the battery the battery lock lock sensor sensor ........................................................................................................................ ...... 199199
15.7.215.7.2 Battery locBattery lock k sensor functionalitsensor functionality cy check .......................heck ........................................................................................... ...... 200200
15.815.8 Battery Battery connector .............................connector ................................................................................... 20...................................................... 2000
15.915.9 Recharging Recharging plug .......................................................plug ..................................................................................... 200.............................. 200
15.9.115.9.1 Replacing Replacing the the recharging recharging plug ...................................................plug ......................................................................... ...................... 201201
15.1015.10 Quick Quick battery battery replacemenreplacement ..................................................................... t ..................................................................... 203203
15.10.115.10.1 Removing the rubber Removing the rubber absorbers with quick absorbers with quick battery replacement battery replacement ..........................................204204
15.1115.11 Electrical Electrical steering ..............steering ................................................................................................................................................... 205..... 205
15.11.115.11.1 Motor and Motor and electrical electrical system system with electricwith electrical steering ....................al steering ......................................... ..................... 206206
15.11.215.11.2 Zapi Zapi EPS EPS AC0 AC0 Power Power Controller .................................Controller .................................................................................................... ....... 208208
15.11.315.11.3 Zapi Zapi EPS EPS AC0 AC0 connectors ..............................................connectors .............................................................................................................. .. 208208
15.11.3.115.11.3.1 CNA CNA external external connector ...................................connector ................................................................................................................. .................. 209209
15.11.3.215.11.3.2 CNB CNB external external connector ...................................connector ................................................................................................................. .................. 210210
15.11.3.115.11.3.1 Description Description of of the the power cpower connections .........................onnections ............................................................................................. ...... 210210
15.11.3.215.11.3.2 Fuses Fuses with with electrical electrical steering ......................steering .......................................................................................................... ...................... 211211
15.11.415.11.4 Feedback sensorFeedback sensor......................................................................................................................................................................................... ... 211211
15.11.4.115.11.4.1 Functionality cFunctionality c heck heck of the of the feedback sensor ...............................................feedback sensor ..................................................... ...... 212212
15.11.515.11.5 Disassembly Disassembly of the of the electrical electrical steering motor steering motor unit unit ........................................................................... ............... 213213
15.11.615.11.6 Adjusting the motor belt ....Adjusting the motor belt ................................................................................................................................................ .................. 216216
15.11.715.11.7 Replacing Replacing the the motor motor belt ............................................belt ................................................................................................................. ....... 217217
15.11.815.11.8 Adjusting the electrically powered steering Adjusting the electrically powered steering .................................................................................. .......................... 217217
15.11.8.115.11.8.1 Adjusting the tiller and feedback sensors ..............Adjusting the tiller and feedback sensors ....................................................................................... ........... 217217
15.11.8.215.11.8.2 Feedback sensor teaching and steering angle Feedback sensor teaching and steering angle reduction ................................reduction ................................218218
15.11.8.315.11.8.3 Tiller Tiller sensor sensor teaching .................................teaching ...................................................................................................................... ....................... 219219
15.11.8.415.11.8.4 Steering Steering straight straight forward forward calibration...............................calibration................................................................................................ ... 220220
15.11.8.515.11.8.5 Final Final adjustment .........................................adjustment ............................................................................................................................. 221........................ 221
15.11.915.11.9 Steering Steering controller controller parameter descparameter descriptions ................................................riptions ...................................................... ...... 221221
15.11.1015.11.10 Steering Steering controller controller alarm alarm codes .................................................codes ....................................................................... ...................... 223223
1616 TechnicaTechnical l specificatspecification .................................................................................ion ....................................................................................... 230...... 230
1717 Index Index ............................................................................................................................................................................ 234.............................................................. 234
APPENDIX APPENDIX A: A: Stickers Stickers ..................................................................................................................................................... 2................................................. 23838
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1 Foreword1 Foreword
This service manual is a guide for servicing lift trucks.This service manual is a guide for servicing lift trucks.
The long productive life of your lift The long productive life of your lift truck depends on regular and proper servicing,truck depends on regular and proper servicing,
consistent with the instructions provided in this service manual.consistent with the instructions provided in this service manual.
Before starting to test, repair or rebuild a lift truck, read the respective sections of thisBefore starting to test, repair or rebuild a lift truck, read the respective sections 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 contained in this The descriptions, illustrations and specifications contained in this manual are for liftmanual are for lift
trucks with serial numbers in effect at the time of printing.trucks with serial numbers in effect at the time of printing.
The manufacturer reserves the right The manufacturer reserves the right to change specifications or designs without to change specifications or designs without noticenotice
and without incurring obligations. For your and without incurring obligations. For your convenienconvenience, the ce, the instructions are grouped byinstructions are grouped by
systems as an easy rsystems as an easy reference.eference.
Unauthorized copying and lending of this material is Unauthorized copying and lending of this material is strictly prohibited.strictly prohibited.
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2
2 How How to to read read this this manualmanual
2.12.1 Safety-related signsSafety-related signs
The following table explains the safety-related signs The following table explains the safety-related signs used in this used in this document.document.
DANGER
DANGER DANGERDANGERindicates a hazard with a high level of risk which, if notindicates a hazard with a high level of risk which, if not
avoided, will result in serious injury or avoided, will result in serious injury or death.death.
WARNINGWARNING
WARNINGWARNINGindicates a hazard with a indicates a hazard with a medium level of risk which, ifmedium level of risk which, if
not avoided, could result in serious injury not avoided, could result in serious injury or death, or damage toor death, or damage to
your machine.your machine.
CAUTIONCAUTION
CAUTIONCAUTIONindicates a hazard with a low level of risk which, if notindicates a hazard with a low level of risk which, if not
avoided, could result in minor or avoided, could result in minor or moderate injury, or damage to yourmoderate injury, or damage to your
machine.machine.
NOTE: Notes are used to indicate important information and useful tips.NOTE: Notes are used to indicate important information and useful tips.
2.22.2 Symbols and abbreviationsSymbols and abbreviations
2.2.1 2.2.1 Safety Safety symbolssymbols
Hazard symbolsHazard symbols
These symbols indicates a hazardous situation or action. Symbols are used to warn ofThese symbols indicates a hazardous situation or action. Symbols are used to warn of
situations, which may cause environmental damage and personal injury.situations, which may cause environmental damage and personal injury.
General hazard symbolGeneral hazard symbol
General warning signGeneral warning sign
Hazard symbolsHazard symbols
Explosion andExplosion and
fire hazardfire hazard Corrosive hazardCorrosive hazard
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Battery hazardBattery hazard Electrical hazardElectrical hazard
Prohibited action symbolsProhibited action symbols
These symbols are used in warnings and notifications to indicate an action that shouldThese symbols are used in warnings and notifications to indicate an action that should
not be taken. not be taken. The prohibited action symbols are presented below.The prohibited action symbols are presented below.
No smokingNo smoking
General symbol forGeneral symbol for
prohibited actionprohibited action
Mandatory action symbolsMandatory action symbols
These symbols are used in warnings and notifications to indicate an action that must These symbols are used in warnings and notifications to indicate an action that must bebe
taken. The mandatory action symbols are taken. The mandatory action symbols are presented below.presented below.
Wear eyeWear eye
protectionprotection
Read theRead the
manual ormanual or
instructionsinstructions
GeneralGeneral
symbol forsymbol for
mandatorymandatory
actionaction
Doctor symbolDoctor symbol
Batteries marked with this sign must Batteries marked with this sign must be recycled.be recycled.
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2.2.2 2.2.2 Other Other symbols symbols and and abbreviationsabbreviations
SYMBOL OR
SYMBOL OR
ABBREVIATIONABBREVIATION
DESCRIPTIONDESCRIPTION
OPOP OptionOption
COMCOM Common terminalCommon terminal
NCNC Normally closed terminalNormally closed terminal
NONO Normally open terminalNormally open terminal
R1/4R1/4 Taper pipe thread (external) 1/4 inch Taper pipe thread (external) 1/4 inch (formerly PT1/4)(formerly PT1/4)
RC1/8RC1/8 Taper pipe thread (external) 1/8 inch Taper pipe thread (external) 1/8 inch (formerly PT1/8)(formerly PT1/8)
G1/4AG1/4A Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)
Rp1/8Rp1/8 Straight pipe thread (internal) 1/8 Straight pipe thread (internal) 1/8 inch (formerly PS1/8)inch (formerly PS1/8)
2.32.3 UnitsUnits
SI units are SI units are used in this manual.used in this manual.
The following table shows the conversion of SI units The following table shows the conversion of SI units to customary units.to customary units.
ITEM
ITEM SI SI UNIT UNIT METRIC METRIC UNIT UNIT YARD-POUND YARD-POUND UNITUNIT
ForceForce 1 1 N N 0.102 0.102 kgf kgf 0.225 0.225 lbflbf
PressurePressure 1 1 MPa MPa 10.1972 10.1972 kgf/cm2 kgf/cm2 145.038 145.038 psipsi
TorqueTorque 1 1 N N m m 0.102 0.102 kgf kgf m m 0.7376 0.7376 lbf lbf ftft
LengthLength
1 mm1 mm
1 m1 m
--
--
0.039 inch0.039 inch
3.281 feet3.281 feet
WeightWeight 1 1 kg kg - - 2.205 2.205 lblb
TemperatureTemperature 1°C 1°C - - °F=1.8 °F=1.8 x x °C+32°C+32
VolumeVolume 1 1 L L - - 0.264 0.264 US.gal.US.gal.
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3
3 Safety Safety instructionsinstructions
WARNINGWARNING
The proper and safe lubrication and maintenance of these lift The proper and safe lubrication and maintenance of these lift trucks as recommendedtrucks as recommended
by the manufacturer is outlined in this document. Read by the manufacturer is outlined in this document. Read this manual before performingthis manual before performing
any lubrication or maintenance on these trucks. Improper performance of lubrication orany lubrication or maintenance on these trucks. Improper performance of lubrication or
maintenance procedures is dangerous and can result in injury or maintenance procedures is dangerous and can result in injury or death.death.
Do not make any alterations or Do not make any alterations or repairs that can weaken the truck’s structure orrepairs that can weaken the truck’s structure or
endanger safety.endanger safety.
Do not operate the truck unless you Do not operate the truck unless you have read and understood the instructions in thehave read and understood the instructions in the
operator manual. Improper truck operation is dangerous and can result in injury oroperator manual. Improper truck operation is dangerous and can result in injury or
death.death.
Knowledge of the system and/or its components is Knowledge of the system and/or its components is important before the removal orimportant before the removal or
disassembly of any components.disassembly of any components.
.
.
The following sections list The following sections list some basic precautions that should always some basic precautions that should always be observed.be observed.
3.13.1 Service area safetyService area safety
•
•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 all repairs with the truck parked on a the truck parked on a level, hard surface.level, hard surface.
•
•Before starting to work on Before starting to work on the truck, hang a "Do the truck, hang a "Do not Operate" sign in the operatornot Operate" sign in the operator
compartment.compartment.
••The truck must always be supported on jacks, The truck must always be supported on jacks, if working underneath it.if working underneath it.
•
•Do not work on any truck that is Do not work on any truck that is supported only by lift jacks or a hoist. Always usesupported only by lift jacks or a hoist. Always use
blocks or jack sblocks or jack stands to support the truck before performing any disassembly.tands to support the truck before performing any disassembly.
•
•Lower the forks or Lower the forks or other implementother implements to the s to the ground before performinground before performing any work ong any work on
the truck. If this cannot be done, make sure the forks or other implements arethe truck. If this cannot be done, make sure the forks or other implements are
blocked correctly to prevent blocked correctly to prevent them from falling unexpectedly.them from falling unexpectedly.
•
•Use steps and grab handles (if applicable) when mounting or dismounting a truck.Use steps and grab handles (if applicable) when mounting or dismounting a truck.
Clean any mud or debris from Clean any mud or debris from steps, walkways or work steps, walkways or work platforms before use.platforms before use.
Always face the trucAlways face the truck when using k when using steps, ladders asteps, ladders and walkways. Whnd walkways. When it is noten it is not
possible to use the designed access system, use ladders, scaffolds, or possible to use the designed access system, use ladders, scaffolds, or workwork
platforms to perform safe platforms to perform safe repair operations.repair operations.
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•
•To avoid back injury, use a To avoid back injury, use a hoist when lifting components weighinhoist when lifting components weighing 23 kg g 23 kg (51 lb) or(51 lb) or
more. Make sure all chains, hooks, slings, etc., more. Make sure all chains, hooks, slings, etc., are in good condition and of theare in good condition and of the
correct capacity. Make sure all hooks are correct capacity. Make sure all hooks are positioned correctly. Lifting eyes are notpositioned correctly. Lifting eyes are not
to be side-loaded during a lifting operation.to be side-loaded during a lifting operation.
••Make sure all Make sure all protective devices including guards and shields are protective devices including guards and shields are properly installedproperly installed
and functioning correctly before starting a repair. If a and functioning correctly before starting a repair. If a guard or shield must beguard or shield must be
removed to perform the repair work, use removed to perform the repair work, use extra caution.extra caution.
•
•Always suppoAlways support the mast and rt the mast and carriage to keep carriage to keep the carriage othe carriage or attachments rar attachments raisedised
when performing maintenance or repair work that requires the mast to be in thewhen performing maintenance or repair work that requires the mast to be in the
raised position.raised position.
3.23.2 Personal safetyPersonal safety
•
•Remove all rings, watches and other pieces of metal jewellery before you Remove all rings, watches and other pieces of metal jewellery before you startstart
working on the truck. If working on the truck. If a metal object gets into contact with a metal object gets into contact with an electricallyan electrically
conductive part, it may cause a short circuit or a serious burn.conductive part, it may cause a short circuit or a serious burn.
•
•Always wear proteAlways wear protective glasses active glasses and protective shnd protective shoes when wooes when working around rking around trucks.trucks.
In particular, wear protective glasses when using a hammer or In particular, wear protective glasses when using a hammer or sledge on any part ofsledge on any part of
the truck or the truck or its attachments. Use welder’s gloves, hood/gogglits attachments. Use welder’s gloves, hood/goggles, apron and otheres, apron and other
protective clothing appropriate to the welding job protective clothing appropriate to the welding job being performed. Do not wearbeing performed. Do not wear
loose fitting or torn clothing.loose fitting or torn clothing.
3.33.3 Work safetyWork safety
•
•UnauthorizeUnauthorized truck modification is not d truck modification is not permitted. No modifications or alterations to apermitted. No modifications or alterations to a
powered industrial truck, which could affect, for example, capacity, stability or safetypowered industrial truck, which could affect, for example, capacity, stability or safety
requiremenrequirements of the ts of the truck, shall be made without the truck, shall be made without the prior written approval of theprior written approval of the
original truck manufacturer, its authorized representative, or a original truck manufacturer, its authorized representative, or a successor thereof.successor thereof.
This includes changes affecting, for example, braking, steering, visibility This includes changes affecting, for example, braking, steering, visibility and theand the
addition of removable attachments. When the manufacturer or his addition of removable attachments. When the manufacturer or his successorsuccessor
approves a modification or alteration, the approves a modification or alteration, the manufacturemanufacturer or r or successor shall alsosuccessor shall also
make and approve appropriate changes to the capacity plate, decals, tags andmake and approve appropriate changes to the capacity plate, decals, tags and
operation and maintenance handbooks.operation and maintenance handbooks.
Only in the event that the Only in the event that the truck manufacturer is no longer in business and there istruck manufacturer is no longer in business and there is
no successor in the interest to no successor in the interest to the business, may the user arrange for a the business, may the user arrange for a modificatiomodificationn
or alteration to a powered industrial truck, provided, however, that the or alteration to a powered industrial truck, provided, however, that the user:user:
a. a. arranges arranges for for the the modification modification or or alteration alteration to to be be designed, designed, tested tested andand
implementeimplemented by an engineer(s) expert in industrial trucks d by an engineer(s) expert in industrial trucks and their safety,and their safety,
b. b. maintains maintains a a permanent permanent record record of of the the design, design, test(stest(s) ) and and implementation implementation of of thethe
modification or alteration,modification or alteration,
c. c. approves approves and and makes makes appropriate appropriate changes changes to to the the capacity capacity plate(s), plate(s), decals,decals,
tags and instruction handbook, andtags and instruction handbook, and
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d. d. affixes affixes a a permanent permanent and and readily readily visible visible label label to to the the truck truck stating stating the the manner manner inin
which the truck has which the truck has been modified or altered, together with the date of thebeen modified or altered, together with the date of the
modification or alteration and the name and address of the organization thatmodification or alteration and the name and address of the organization that
accomplished those tasks.accomplished those tasks.
•
•Switch off the truck's Switch off the truck's power before opening the cover of the motor compartment orpower before opening the cover of the motor compartment or
the electrical system.the electrical system.
•
•Relieve all pressure in the air, Relieve all pressure in the air, oil or water oil or water systems before disconnecting orsystems before disconnecting or
removing any lines, fittings or related items. Release the residual pressure whenremoving any lines, fittings or related items. Release the residual pressure when
removing a pressurized device.removing a pressurized device.
•
•With sit-on trucks, dismount the seat for With sit-on trucks, dismount the seat for the duration of the service work.the duration of the service work.
•
•Before operating, lubricating or repairing the product, Before operating, lubricating or repairing the product, read all warning plates read all warning plates andand
decals on the truck.decals on the truck.
•
•Do not use your hands to check for oil leaks.Do not use your hands to check for oil leaks.
•
•To avoid burns, pay attention to the To avoid burns, pay attention to the hot sections and hot fluids in hot sections and hot fluids in lines, tubes andlines, tubes and
compartments, even when the truck is idle or compartments, even when the truck is idle or off.off.
••Only use clean oil in Only use clean oil in the hydraulic system.the hydraulic system.
•
•Repairs requiring welding should be performed only with Repairs requiring welding should be performed only with the appropriate referencethe appropriate reference
information and by personnel adequately trained and knowledgeable in weldinginformation and by personnel adequately trained and knowledgeable in welding
procedures. Determine the type of metal and select the correct welding procedureprocedures. Determine 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 toprovide a weld metal strength equivalent at least to
that of the parent metal.that of the parent metal.
•
•When welding, always disconnect the battery When welding, always disconnect the battery and electronic devices. Remove alland electronic devices. Remove all
paint from a 10 paint from a 10 cm radius from the welding point to cm radius from the welding point to avoid creating toxic gasesavoid creating toxic gases
during welding.during welding.
•
•Use proper lifting Use proper lifting procedures when removing any components.procedures when removing any components.
•
•Be careful when removing cover plates. Gradually remove the last two bolts Be careful when removing cover plates. Gradually remove the last two bolts or nutsor nuts
located at opposite ends of the cover or located at opposite ends of the cover or device. Before removing the last two boltsdevice. Before removing the last two bolts
or nuts completely, pry the cover or nuts completely, pry the cover loose to relieve any springs or loose to relieve any springs or other pressures.other pressures.
•
•Be careful when removing filler caps, breathers and plugs on the Be careful when removing filler caps, breathers and plugs on the truck. Wrap a clothtruck. Wrap a cloth
around the cap or plug to prevent being sprayed or splashed by liquids underaround the cap or plug to prevent being sprayed or splashed by liquids under
pressure. Be aware that the danger of pressure. Be aware that the danger of being sprayed or splashed is always greaterbeing sprayed or splashed is always greater
immediately after stopping the truck, as the fluids are immediately after stopping the truck, as the fluids are very hot.very hot.
•
•Use only well-maintained tools. Also make sure that you use Use only well-maintained tools. Also make sure that you use the tools in a the tools in a properproper
way.way.
•
•Reinstall all fasteners with the same part Reinstall all fasteners with the same part number. If a replacement is needed, donumber. If a replacement is needed, do
not use a fastener of not use a fastener of lesser quality.lesser quality.
••Do not damage wiring during the removal process. Do not reuse any damagedDo not damage wiring during the removal process. Do not reuse any damaged
wiring. When reinstalling, make sure the wiring does not come into wiring. When reinstalling, make sure the wiring does not come into contact with anycontact with any
sharp corners or hot parts. Place all wiring away from the oil pipe.sharp corners or hot parts. Place all wiring away from the oil pipe.
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•
•Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can causeLoose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause
fires. Do not bend or fires. Do not bend or strike any high pressure lines or strike any high pressure lines or install ones that have beeninstall ones that have been
bent or damaged. Inspect all lines, tubes and hoses carefully. Pin hole (very bent or damaged. Inspect all lines, tubes and hoses carefully. Pin hole (very small)small)
leaks can result in a high velocity oil stream that will be invisible close to the hose.leaks can result in a high velocity oil stream that will be invisible close to the hose.
This oil can penetrate the skin and cause personal injury, so This oil can penetrate the skin and cause personal injury, so use cardboard oruse cardboard or
paper to locate pin hole leaks.paper to locate pin hole leaks.
•
•Tighten connectioTighten connections to the correct ns to the correct torque. Make sure that all heat shields, clampstorque. Make sure that all heat shields, clamps
and guards are installed correctly to avoid excessive heat, vibration or and guards are installed correctly to avoid excessive heat, vibration or rubbingrubbing
against other parts during operation. Protective shields against oil against other parts during operation. Protective shields against oil sprays onto hotsprays onto hot
exhaust componeexhaust components in the event of nts in the event of a line, tube or a line, tube or seal failure must be installedseal failure must be installed
correctly.correctly.
•
•Do not operate the truck, Do not operate the truck, if any rotating part is if any rotating part is damaged or comes into contact withdamaged or comes into contact with
any other part during operation. Every high speed rotating component that has beenany other part during operation. Every high speed rotating component that has been
damaged or altered should be checked for balance before reusing.damaged or altered should be checked for balance before reusing.
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4
4 General General informationinformation
4.14.1 Truck model covered by this manualTruck model covered by this manual
This service manual covers the service instructions of the This service manual covers the service instructions of the following truck model:following truck model:
•
•PBV20N2 - Pedestrian Power Pallet Truck - PBV20N2 - Pedestrian Power Pallet Truck - a five-wheel ride-on and pedestrian-a five-wheel ride-on and pedestrian-
operated electric pallet truck, equipped with a multifunctional tiller control for driving,operated electric pallet truck, equipped with a multifunctional tiller control for driving,
steering and load handling.steering and load handling.
NOTE: Throughout chaptersNOTE: Throughout chapters44 toto14,14,this this manual provides service instructions for themanual provides service instructions for the
basic truck model. All material related to optional features is available in Chapterbasic truck model. All material related to optional features is available in Chapter15.15.
4.24.2 Identification plates on the truckIdentification plates on the truck
NOTE: Check that all the plates and stickers on the truck are legible and securelyNOTE: Check that all the plates and stickers on the truck are legible and securely
attached!attached!
Figure 1Figure 1 below shows the truck’s plates and stickers below shows the truck’s plates and stickers and their locations. For moreand their locations. For more
details on the truck’s plates and stickers, details on the truck’s plates and stickers, see thesee theAPPENDIX A.APPENDIX A.
Figure 1. Truck’s plates and stickers overviewFigure 1. Truck’s plates and stickers overview
1.1. Operation warning stickerOperation warning sticker
2.2. Type plateType plate
3.3. Serial number stickerSerial number sticker
4.4. Battery maintenance warning stickerBattery maintenance warning sticker
5.5. Electric panel cleanup warning stickerElectric panel cleanup warning sticker
6.6. Battery type plateBattery type plate
7.7. Hoist point indication stickerHoist point indication sticker
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The truck's type plate states the The truck's type plate states the following:following:
•
•ManufacturerManufacturer
•
•Truck typeTruck type
•
•Serial numberSerial number
••Battery minimum weightBattery minimum weight
••Battery terminal voltageBattery terminal voltage
••Truck’s nominal lifting capacityTruck’s nominal lifting capacity
•
•Year of manufactureYear of manufacture
•
•CE markCE mark
4.34.3 Overview of the truckOverview of the truck
4.3.1 4.3.1 Operating Operating devicesdevices
Figure 2. Operating devicesFigure 2. Operating devices
1.1. Tiller armTiller arm
2.2. Control panelControl panel
3.3. Battery connector (under the batteryBattery connector (under the battery
cover)cover)
4.4. Side guardsSide guards
5.5. Operator’s platformOperator’s platform
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4.3.2 4.3.2 Tiller Tiller armarm
4.3.2.1 4.3.2.1 Tiller Tiller arm arm controlscontrols
Figure 3. Tiller arm controlsFigure 3. Tiller arm controls
1.1. Safety buttonSafety button
2.2. Push buttons for lifting and loweringPush buttons for lifting and lowering
3.3. HornHorn
4.4. SteeringSteering
5.5. AcceleratorAccelerator
6.6. Brake release / low speed buttonBrake release / low speed button
7.7. Lever for lifting and lowering (optional)Lever for lifting and lowering (optional)
Table 1. Control functionalitiesTable 1. Control functionalities
CONTROL
CONTROL FUNCTIONALITY FUNCTIONALITY DESCRIPTIONDESCRIPTION
Safety button (belly button)Safety button (belly button) The safety button prevents you from gettingThe safety button prevents you from getting
squeezed between the truck and an obstacle.squeezed between the truck and an obstacle.
When the safety button is pushed, the When the safety button is pushed, the trucktruck
reverses its travelling direction. When the button isreverses its travelling direction. When the button is
released, the truck stops.released, the truck stops.
Push buttons for lifting and loweringPush buttons for lifting and lowering Push the Up button to Push the Up button to lift the forks. Push the lift the forks. Push the DownDown
button to lower the forks.button to lower the forks.
HornHorn Press the button to give an audible warning signal.Press the button to give an audible warning signal.
SteeringSteering The tiller arm turns ± 100 The tiller arm turns ± 100 degrees.degrees.
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CONTROL
CONTROL FUNCTIONALITY FUNCTIONALITY DESCRIPTIONDESCRIPTION
AcceleratorAccelerator Use the accelerator with your right or left Use the accelerator with your right or left hand. Thehand. The
more you turn the accelerator, the higher more you turn the accelerator, the higher the speed.the speed.
The accelerator returns automatically to the centralThe accelerator returns automatically to the central
position, when it is released. Brake smoothly byposition, when it is released. Brake smoothly by
turning the accelerator to the opposite turning the accelerator to the opposite direction.direction.
Brake release / low speed buttonBrake release / low speed button The button has two functions:The button has two functions:
•
•Brake releaseBrake release
When the tiller arm is in the up position, hold theWhen the tiller arm is in the up position, hold the
button down to release the button down to release the parking brake andparking brake and
turn the accelerator to drive the turn the accelerator to drive the truck in the slowtruck in the slow
speed mode. Release the button to speed mode. Release the button to apply theapply the
parking brake.parking brake.
••Low speed modeLow speed mode
When the tiller arm is in the driving position,When the tiller arm is in the driving position,
activate the low speed mode by pressing theactivate the low speed mode by pressing the
button once. The Lo SPd button once. The Lo SPd symbol is shown in thesymbol is shown in the
multi-function display. Deactivate the low speedmulti-function display. Deactivate the low speed
mode by pressing the button again.mode by pressing the button again.
Lever for lifting and loweringLever for lifting and lowering
(optional)(optional)
Pull the lever up to lift the forks. Push the leverPull the lever up to lift the forks. Push the lever
down to lower the forks.down to lower the forks.
4.3.2.2 4.3.2.2 Tiller Tiller arm arm positionspositions
Figure 4. Tiller arm positionsFigure 4. Tiller arm positions
1.1. Driving positionDriving position 2.2. Emergency brakingEmergency braking
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© Mitsubishi Forklift Trucks 2013. All
© Mitsubishi Forklift Trucks 2013. All rights reserved.rights reserved.Revision: BRevision: BDocument ID: 615023Document ID: 615023 20 (244)20 (244)
PBV20N2 PBV20N2 Service Service ManualManual
4.3.3 4.3.3 Control Control panelpanel
Figure 5. Control panelFigure 5. Control panel
1.1. Emergency stop buttonEmergency stop button
2.2. Key switchKey switch
3.3. Multi-function displayMulti-function display
4.3.3.1 4.3.3.1 Emergency Emergency stop stop buttonbutton
Press the emergency stop button to disconnect the truck's power supply. Release thePress the emergency stop button to disconnect the truck's power supply. Release the
button by turning it clockwise.button by turning it clockwise.
Use the emergency stop button in the following cases:Use the emergency stop button in the following cases:
•
•In case of a In case of a short circuit or sshort circuit or some other electrical malfunction (for example, if theome other electrical malfunction (for example, if the
pump motor does not stop running).pump motor does not stop running).
••In case of an In case of an accident.accident.
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