PDF Service Manual Mitsubishi PBV & SBV Series Trucks - 3 MB
This service manual provides comprehensive information for Mitsubishi PBV and SBV series forklift trucks.
It is an indispensable tool for maintenance and repair, covering all major systems from the engine to the hydraulics.
Follow the manufacturer's recommended procedures to ensure safety and reliability.
This guide will help you diagnose problems and perform repairs like a professional.
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Service manual
PBVSBV
Pub no.: SM19GBPBV,SBVA4
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1 General information and technical data 7
Modell
1 Model
2 Serie nr.
Serial no.
r.
3 Tillverkningsår
Year of manufacturing
4 Vikt utan batteri
Weight without battery
Batterivikt min.
5 Battery weight min.
Batterivikt max.
6 Battery weight max.
7 Batterispänning
Battery voltage
Referensnummer
8 Reference number
12
D=
H(mm)
Q2 (kg) Q2
9 13
10 14
16
Q1 (kg)
11 15
Fig. 3. Example of type plate, PBV
1 Model designation 9 Lift height for truck, H
2 Type Series no./Version (S = Special version) 10 Maximum lifting height for fork carriage with load
on straddle legs
3 Year of manufacture 11 Lift height for straddle leg
4 Weight without battery 12 Distance to centre of gravity, D
5 Minimum battery weight 13 Load limit for fork carriage without load on
straddle leg
6 Maximum battery weight 14 Load limit for fork carriage with load on straddle
leg, Q2
7 Battery voltage 15 Load limit for straddle leg, Q1
8 Reference number (year and month of 16 Straddle legs must always be lowered when
manufacture) stacking
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1 General information and technical data 17
Table 18. Weight, SBV 16P (cont'd.)
Weight
No. Description Unit SBV 16P, SBV 16 P, SBV 16 P,
Duplex Duplex Triplex
with free with free
lift lift
2.3 Max. wheel load, without rated kg 860/320 900/350 970/405
load, front axle/rear axle
- Max. wheel load, without/with MPa 4.5/4.8 4.5/4.9 5.5/5.1
rated load
Table 19. Wheel and tyre, SBV 16P
Wheel and tyre
No. Description Unit SBV 16P, SBV 16 P, SBV 16 P,
Duplex Duplex Triplex
with free with free
lift lift
3.1 Wheel type, operator's side/ Vulcollan Vulcollan Vulcollan
load side
3.2 Wheel size, operator's side (m- ø 230x70 ø 230x70 ø 230x70
m)
3.3 Wheel size, load side (m- ø 85x70 ø 85x70 ø 85x70
m)
3.4 Castor wheel (m- ø140x60 ø140x60 ø140x60
m)
3.5 Number of wheels, front/rear 2/4 2/4 2/4
(x = drive wheel)
3.6 Wheel track, operator's side b10 (m- 501 501 501
m)
3.7 Wheel track, load side b11 (m- 390 390 390
m)
Table 20. Truck dimensions, SBV 16P
Truck dimensions
No. Description Unit SBV 16P, SBV 16 P, SBV 16 P,
Duplex Duplex Triplex
with free with free
lift lift
4.2 Mast height in lowered position h1 (m- (h13+h3)/2 (h13+h3)/ (h13+h3)/
m) +555 2+550 2+550
4.3 Full free lift h2 (m- 120 h3/2-40 h3/2-40
m)
4.4 Lifting height h3 (m- 1580-4110 1580- 3510-
m) 4110 5310
- Lifting height h13+h3 H (m- 1670-4200 1670- 3600-
m) 4200 5400
4.5 Mast height in raised position h4 (m- h13+h3 h13+h3 h13+h3
m) +500 +500 +512
4.6 Straddle lift h5 (m- - - -
m)
4.7 Height over protective roof h6 (m- 2288 2288 2288
m)
4.8 Standing height h7 (m- 165 165 165
m)
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1 General information and technical data 27
Table 31. Second letter
Code Designation Designation (Eng)
B Brake Brake
C Control system Control system
E Emergency function Emergency function
F Forward Forward
H Hour Hour
K Key Key
L Lower Lower
M Manoeuvre Manoeuvre
P Pump Pump
R Reverse Reverse
S Speed Speed
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3 Service 37
3.2.4 Lubrication schedule (SBV)
A
G
B
H
C
I
D
E J
K
F
200h
500h
1000h
L M
Fig. 7. Lubrication schedule SBV
3.2.5 Components to lubricate (SBV)
Location Explanation
A Thrust rollers
B Mast profile roller surfaces and slide surfaces
C Bogie wheel
D Gates, bearing surfaces
E Fork carriage
F Hydraulic oil
G Spring for speed controller
H Lift chains
I Steering chain
J Gearbox bearing, grease nipple
K Gearbox oil
L Castor wheel, sliding bearings, 2 grease nipples
M Platform, 2 grease nipples
3.2.6 Symbol key, lubrication chart
Table 40. Symbols in the lubrication chart
Symbol Explanation Symbol Explanation
Hydraulic oil Hydraulic oil and oil filter,
air filter, change
Gearbox oil Gearbox oil, change
Grease Chain spray
Chain spray/oil Only cold store version
Applicable in general for the symbols:
• Unfilled symbol: Check/lubricate
• Filled symbol: Replacement
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4 Chassis 47
4.2.4.2 Adjusting the “friction force” tension
1 Check the spring lengths by measurement. Compare the lengths of the springs with the
values in 41. Adjusting the “friction force” spring tension page 47.
NOTE
When checking the measurement the truck must be standing unloaded on the
floor with the forks lowered.
Table 41. Adjusting the “friction force” spring tension
Spring Value
Red spring 221 mm
Yellow spring 167 mm
2 Note the differences between the measured results and the values in the table.
3 Lift up the truck to remove the pre-tensioning of the springs.
4 Adjust the tensions by tightening the nuts (pos. B and E) to eliminate the differences.
5 Lower the truck down to the floor.
6 Check measurement. Repeat steps 3 - 5 until the correct value is obtained.
7 Lock the adjustment by tightening the nuts (pos. A and F).
4.2.4.3 Adjusting the position of the drive unit housing (PBV)
To achieve a more stable traction the sideways movement of the drive unit housing can be
adjusted.
B
A
1 Loosen the two locking screws (pos. B) located on either side of the drive unit housing.
2 Tighten the two adjusting screws (pos. A).
3 Tighten the locking nuts.
4.2.5 Battery
4.2.5.1 Battery replacement
Work in an area where the old battery can be removed without risk to the environment from
battery acid. Wear acid resistant gloves and clothes, plus safety glasses, to protect from burns.
WARNING
Take care not to splash acid or oxide from the battery.
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6 Mast system 57
6.2.5.1.9 Worn fork hook...........................................................85
6.2.5.1.10Fork labelling.............................................................86
6.2.6 Wheels ..................................................................................................86
6.2.6.1 Dismounting and installation of the load wheel, (Single)...............86
6.2.6.2 Dismounting and installation of the load wheel (Bogie) ................87
6.2.6.3 Dismounting and installation of the front climbing wheel ..............87
6.2.6.4 Dismounting and installation of the rear climbing wheel ...............88
6.3 Diagnostics and troubleshooting.................................................................. 88
6.3.1 Troubleshooting chart .............................................................................88
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6 Mast system 67
6.2.2.5 Removal and installation of TV mast (SBV 12P)
4
4
3
5
1
6
5
2
2
1 Dismantling the fork carriage (see 6.2.4.1 Removal and installation of the fork carriage
page 78).
2 Lower the mast to its bottom position.
3 Remove the SGA fuses (pos 3) from the side cylinders (pos 5).
4 Lift the inner mast (pos 1) straight up until the inner mast's lower support roller (pos 2) and
the outer mast's (pos 6) upper support roller (pos 4) meet. Then pull the inner mast
forward to release it from the outer mast.
5 Install in the reverse order.
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6 Mast system 77
2
6
3
4
2
1 5
Remove the stop screws (pos 1) so that the adjusting screws (pos 2) are accessible.
3 Adjust the slide bearings (pos 3) laterally with the adjusting screws, by hand, until they are
flush. Make sure that they are equally adjusted on the right and left sides. Then loosen the
screws by 90°.
4 Insert the stop screws.
5 Lubricate the bearings, see 6.2.3.5 Straddle leg lift, Lubrication of bearings in roller (SBV
16P) page 78.
6 Check the function.
6.2.3.4 Adjusting of slide bearing (SBV 12P)
1 Raise the forks to the top so that you reach the outer mast.
2
5
3
5
4
1 2
Remove the nuts (pos 1) so that the adjusting screws (pos 2) are accessible.
3 Adjust the slide bearings (pos 3) laterally with the adjusting screws, by hand, until they are
flush. Make sure that they are equally adjusted on the right and left sides. Then loosen the
screws by 90°.
4 Install the nuts.
5 Lubricate the bearings, see 6.2.3.6 Straddle leg lift, Lubrication of bearings in roller (PBV,
SBV 12P) page 78.
6 Check the function.
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6 Mast system 87
6.2.6.2 Dismounting and installation of the load wheel (Bogie)
3 5
4
5
1
1
2
2
Fig. 42. Load wheel (Bogie)
1 Lift up the truck, and secure it with blocks.
2 Remove the screws (pos. 1) from the wheel ends (pos. 2).
3 Lift off the wheels (pos. 3) with their axles (pos. 4) and washers (pos. 5).
4 Inspect, and replace all damaged parts.
5 Install in the reverse order.
6.2.6.3 Dismounting and installation of the front climbing wheel
4
2 3
1
2
5
3
6
4
5
6
1 Remove the countersunk bolts on the straddle legs (item 6).
2 Remove the holder (item 1) with the climbing wheel and secure the assembly in a vice.
3 Remove the bolts (item 4) securing the spacers (item 3).
4 Remove the climbing wheel (item 2).
5 Inspect, and replace all damaged parts.
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7 Steering 97
NOTE
Ensure that accelerator springs are working properly after installation. To achieve
this, the wing must be installed at the correct angle relative to the bearing.
7.2.2.4 Installation of the main cabling
Securing the tiller arm main cabling
The cabling is secured by cable clamps to the tiller arm head. The cabling is secured inside
the truck by cable ties to the cable strip.
CAUTION
The cabling must have enough slack so that the arm can be lowered to its lowest
position without straining the cable. It must also be possible to open the upper part
of the tiller head with being restricted by the cabling.
CAUTION
The cabling must not be so long that the programming cable takes the load when
the upper part is hanging on the cabling.
Cable routing, standard version
Fig. 48. Cable routing, standard version
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8 Hydraulic system 107
8.1 Design and function
8.1.1 General
8.1.1.1 Lift
The operator activates a lift control which starts the lift motor by Combination controller. The
electric motor drives the hydraulic pump, which pumps hydraulic oil to the lift cylinders. The
hydraulic motor is controlled by speed, so the lifting rate is determined by the motor's rotation
speed.
In the hydraulic system there is a pressure limiting valve which limits the maximum hydraulic
oil pressure. The pressure of the hydraulic oil increases when the cylinder goes to its end
position. The relief valve opens if the maximum system pressure is reached and leads the oil
from the pump back to the tank. The opening pressure of the relief valve is set at the factory,
so that the machine will be able to handle the load it is designed for.
WARNING
The relief valve must only be adjusted by authorised and trained personnel, since it
is a safety part. All work with the hydraulic system must be carried out in a
pressureless state, and in a clean environment.
8.1.1.2 Lower
The operator activates the lowering movement by a lowering control.
Between the hydraulic pump and the cylinder there is a proportional valve which regulates the
lowering speed in proportion to the control. The maximum lowering speed is determined by a
lowering brake valve.
When lowering commences, oil is led from the cylinder through the proportional valve back to
the tank and the cylinder is compressed by the weight of the fork carriage.
On certain cylinders there is also a hose rupture valve, which provides protection from
accidents during uncontrolled oil discharge.
If the forks or straddle legs are stuck in their raised position, they may need to be lowered by
emergency measures, see 8.2.4.4 Lowering the forks/straddle legs (PBV) page 120.
8.1.2 Hydraulic unit valves
8.1.2.1 Overview
3
2
1
6
4
6
5
8
8
7
Fig. 56. PBV
1 Valve housing 5 Proportional valve
2 Lowering brake valve 6 Directional valve
3 Pressure relief valve 7 Solenoid valve
4 Check valve 8 Solenoid valve
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8 Hydraulic system 117
6 PBV: Detach the rear end by removing the two bolts (item 5, 62. Replacing the brushes,
PBV page 116).
SBV: Detach the rear end by removing the four bolts (pos 7, 63. Replacing the brushes,
SBV 16P page 116).
Make sure that the terminals remain in their positions.
7
A
B
6
C
7
Fig. 64. Replacing the brushes
Disconnect all four carbon brushes by releasing the screws (item 6, 64. Replacing the
brushes page 117) - A. Then press each brush towards the commutator. - B. Remove the
brush set from the brush rigging – C. The old brush set is replaced with a new set by the
reverse procedure. It is recommended to replace each brush separately to avoid
confusion. Make sure that each brush set is replaced with the correct part, i. e. one that
has the cable on the correct side. (The service kits consist of two matching pairs of brush
sets!)
8
TORQUE
Tighten the screw (pos. 6, 64. Replacing the brushes page 117), to approx. 1.3-
1.8 Nm.
9
TORQUE
Secure the bolts to the rear end. Tighten the bolts to approx. 4.8-6.8 Nm.
10
TORQUE
Fit and secure the perforated metal ring. Tighten the nuts to approx. 3-4 Nm.
11
TORQUE
Refit the electric motor into the truck. Tighten the four bolts at the motor end to
approx. 16 Nm.
12 Replace the cables to the motor terminals.
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9 Hydraulic cylinders 127
Fig. 73. Lift cylinders, mast (SBV)
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10 Electrical system 137
Table 56. Sensors (cont'd.)
Designa- Designation Detects
tions
S33 Top switch, straddle legs Straddle legs in top position Straddle lift is then
switched off. This is so that the "friction force"
will not receive overpressure which could lead to
the drive wheel lifting the truck.
S34 1,8 m switch Forks and gates positions. When the forks reach
a height of 1.8 m, the side protection gates must
be lowered before the forks can be raised any
further, if the truck is not equipped with an
overhead guard.
Safety functions and logic
For safety reasons, the maximum speed is determined by the positions of the gates, platform
and the switch for the forks/straddle legs, see 57. Safety functions and logic page 137.
Table 57. Safety functions and logic
Safety function Conditions
Driving speed is limited by The operator is not standing on the platform
(PBV and SBV 16P).
The side gates are folded down (PBV and
SBV 16P).
The forks are higher than 1.65 m (PBV).
The forks are higher than 1.8 m (PBV and
SBV 16P).
The truck cannot be driven The platform is lowered but the operator is
not standing on it.
The platform is raised but the side protection
gates are raised.
The platform is lowered, the side gates are
raised but the operator is not standing on the
platform.
The straddle legs cannot be raised The straddle legs are already in their
uppermost position.
The forks cannot be raised higher than The side protection gates are raised and the
1.8 m (PBV, SBV) truck does not have an overhead guard.
For safety reasons the side protection gates
must be lowered so that the operator will
have three escape routes if the load tips
over.
The truck cannot be driven at 12.5 km/h The forks are not lowered.
(option "Extended drive speed PBV")
The straddle legs are not lowered.
The sensors generate different values depending on the positions of the gates, platform and
the forks/straddle legs switch. Different combinations of values from the sensors limit, for
example, the maximum speed and other safety-related functions, see 58. Sensor
combinations, safety functions and logic, PBV page 138 59. Sensor combinations, safety
functions and logic, SBV 12P page 138 and 60. Sensor combinations, safety functions and
logic, SBV 16P page 139.
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10 Electrical system 147
EPS signal connection
Table 64. Connector X26, 8-pole minifit pins, PBV
Position Cable colour Description
X26.1 Brown FB sensor, negative supply
X26.2 Green FB sensor, positive supply
X26.3 Red/Black Input for motor temperature switch
X26.4 Red Motor encoder, positive supply
X26.5 Red/Blue SP sensor, positive supply
X26.6 Yellow Signal from the FB sensor
X26.7 White Motor encoder, channel B
X26.8 Blue Motor encoder, channel A
Table 65. Connector X26, 8-pole minifit pins, SBV
Position Cable colour Description
X26.1 - FB sensor, negative supply
X26.2 - FB sensor, positive supply
X26.3 Orange Input for motor temperature switch
X26.4 Yellow Motor encoder, positive supply
X26.5 Blue, Red/Blue SP sensor, positive supply
X26.6 Orange Signal from the FB sensor
X26.7 Green Motor encoder, channel B
X26.8 White Motor encoder, channel A
Table 66. Connector X27, 14-pole minifit pins, PBV
Position Cable colour Description
X27.1 Red/White Drive signal input (+24 V) via X27.5
X27.2 - -
X27.3 - -
X27.4 Red/White Safety relay. Opens in the case of an
EPS controller error
X27.5 Red/White Safety relay
X27.6 Yellow/White CAN low
X27.7 Red/White Positive supply in (+24 V) via X27.5
X27.8 Yellow Signal 1 from the SP sensor
X27.9 Orange Signal 2 from the SP sensor
X27.10 Green/Brown SP sensor, negative supply
X27.11 Black Motor encoder negative supply
X27.12 - -
X27.13 Blue/White Motor temperature switch negative
supply
X27.14 Brown/White CAN high
Table 67. Connector X27, 14-pole minifit pins, SBV
Position Cable colour Description
X27.1 Red/White Drive signal input (+24 V) via X27.5
X27.2 - -
X27.3 - -
X27.4 Pink/Black Safety relay. Opens in the case of an
EPS controller error
X27.5 Violet, Red/White Safety relay
X27.6 Yellow/White CAN low
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10 Electrical system 157
1 Step to the option that is to be set and press Enter.
Lift stop: no
0: 1:yes
2 Press the 0 key to turn off the option or 1 to turn it on.
Lift stop: yes
New value saved!
10.2.7.7 Calibrating the speed controller
Under calibration you can calibrate the speed controller. Do this in the following way:
1 Navigate to Service menu:→Calibrate→Speed controller. Then press Enter. The
following screen appears:
Speed controller to 0
press ENT
2 Leave the speed controller in neutral, and press enter. The following screen appears:
Give max. signals
press ENT
3 Give maximum speed in both directions, without pressing hard to the end position, and then
press enter.