Mitsubishi Forklift PBPL12, PBPL15 Electric Pallet Trucks Parts Manual - PDF DOWNLOAD

Parts Manual PBPL12, PBPL15 Electric Pallet Trucks

PBPL12

2018-10001-19999 2019-10001-19999 2020-10001-19999 2021-10001-19999

PBPL15

2018-10001-19999 2019-10001-19999 2020-10001-19999 2021-10001-19999

SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

TRUCK LAYOUT

Tiller arm/ handle Key switch Power indicator

Lift motor Fork Oil cylinder

Wheel hub motor Fork wheel Balance wheel

Truck frame

Lithium battery

Puller

Guide plate

Connecting rod Rocker arm

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

1.1 Balance wheel adjusting

After correct adjustment, there should be a gap of 2mm between the balance wheels and the ground.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

1.2 Disassembly of covering parts 1.2.1 Disassembly of mud guard After disassembly

1) Remove two screws.

2) Remove mud guard.

1.2.2 Disassembly of trim cover After disassembly

1) Remove the two screws on either side of the cover.

2) Remove trim cover.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

1.2.3 Disassembly of motor housing After disassembly

1) Remove the two screws on either side of the cover.

2) Turn the steering gear 90 degrees, and lift the motor housing (2) to remove it.

1.2.4 Replacement of battery and checking of the fault indicating lamp Turn off the key switch.

With the battery removed, the fault indicator lamp can be checked.

If a fault is present, the battery can be connected externally, power turned back on and the fault indicator checked again.

Mounting the battery is the same procedure reversed.

5

Pull out the battery connector.

Lift up and tilt the battery 45° to remove it.

SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

1.3

Detail structure

Lifting motor Oil cylinder

Wheel hub motor

gear pump Motor/ brake wire connecting block

Contactor

Brake Brake disc

Controller

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

2 2.1

Maintenance of mechanical parts Disassembly of brake

Steer 90° to the left to allow access to the wiring block. Remove screw (1), lower the wiring block (2) and then pull out the brake wiring harness connector.

Disassemble the two hoops (3) of the brake wiring harness.

Remove both the brake and brake support at the same time.

Steer 90° to the right and turn screw (4) M5X35 in the accessory attachment on the brake and then release the brake. Unscrew (5).

Split brake (7) from support (6).

Finally, remove screws (8) & (9) and brake (7).

When assembling, apply adhesive to screws (8) & (9) and apply a small amount of lubricating grease to the connection to the support.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

2.2

Disassembly of brake friction disc When the brake suffers abrasion, the interval cannot be adjusted.

If you do not wish to replace the entire assembly, you may replace just the friction discs.

To disassemble the brake, remove screws (1) & (2) then take out the friction discs (3) & (4) and replace them.

When reassembling, apply adhesive when fastening screw (2).

2.3

Disassembly of wheel hub motor Before disassembling the wheel hub motor, first disassemble the brake.

Failure to do so will make reassembly of the wheel hub motor more difficult.

Steer to the left 90°, remove screw (1) and lower wiring block (2). Split the motor wiring harness inside the motor from the main wiring harness.

Remove screw (4) - there are four in total. Remove plate (3).

The wheel hub shown after disassembly.

Lift the truck frame and carefully remove the motor.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

2.4

Disassembly of brake disc

* 2 brake discs (on 1.5t only!) Equipped with double disc brake for secure stopping on slopes when lifting the max. load capacity of 1.5t.

After the wheel hub motor has been removed from the truck, remove the five screws (1) which will allow the brake disc* (2) to be separated from the wheel hub motor (3).

When reassembling, apply adhesive to the five screws (1) and take care to keep the brake disc clean.

2.5

Disassembly of pump motor If the motor housing has been removed and the electrical connections disconnected, the motor pump can be disassembled.

Lower the forks to their lowest position and detach the oil inlet pipe (1).

Be prepared to catch the oil that will drain from the tank - spilling oil onto the brake disc will adversely affect braking performance. Detach the oil outlet pipe (2).

Remove the motor pump assembly.

Remove the motor pump screws (3) - there is one either side of the assembly.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

2.6

Adjusting the connecting rod length

Detach the clamp spring (1) which connects the connecting rod to the rocker arm.

Remove pin (2) from the mounting hole.

After adjusting, check that the forks lift and lower smoothly and that the gap between the wheel carriage limit point (5) and the bottom surface of the fork (6) is greater than 1mm.

Loosen nut (3) then rotate the connecting head (4); turning clockwise will decrease the connecting rod length.

2.7

Disassembly of the fork wheel

2 1

Remove the two pins (1).

Remove the pin (2).

10

Remove wheel (3). Disassembly methods for single and double wheels are similar.

SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

2.8

Adjusting the system pressure

Locate the pressure adjusting valve and remove screw (1).

2.9

Using a flat-head screwdriver, adjust screw (2).

Turning clockwise increases the system pressure. Maximum pressure must not exceed 115% of the rated load. Tighten screw (1) after adjustment is complete.

Adding hydraulic oil

Locate the oil fill point and remove screw (1).

Add hydraulic oil via the oil fill point.

The system capacity is 250ml of oil.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3 3.1

Electrical system Electrical system drawing

Complete Harness 1.2t: LA113466 1.5t: LA113548

Tiller-Harness 1.2t: LA113533 1.5t: LA113534

No.

Part No.

Part name

1

LA113316

Lithium battery assembly

2

LA113315

Controller

3

LA113312

Wire seat

4

LA113468

Positive wire

5

LA113313

Hydraulic pump

6

LA113321

Microswitch

7

LA113318

Accelerator

8

LA113320

Buzzer 48V

9

LA113467

Key switch

10

LA113317

Power indicator lamp

11

LA113365

Terminal box

12

LA113314

Wheel hub motor

13

LA113319

Brake

14

LA113466

Wiring harness

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.2

Electrical schematic drawing

Brief introduction to the principle: 1) Travelling Plug in the battery connector, turn on the key switch, and 10# will be powered.

When the handle is positioned down, the tiller switch will be closed (TL=48V).

When the accelerator is rotated forward, FR=48V; meanwhile, FR accelerator output 0-5V analog voltage, the brake is opened, and the controller power module drives the motor to work in the forward direction. The motor speed and the accelerator output voltage are in direct proportion.

When reversing and the accelerator is rotated backward, BR=48V; meanwhile, FR accelerator outputs 0-5V analog voltage, the brake is opened, the motor rotates in reverse, and the speed and the accelerator output voltage are in reverse proportion.

2) Lifting: When the lifting switch is closed, LF wire is powered, contactor KM1 is powered, the touch point is through, motor M2 is powered on and the pump oil causes lifting action.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.3

Hydraulic schematic drawing

Cylinder Manual Valve

Check

Safety Speed Limit

Gear

Motor

Oil Filter

Oil

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.3 Electric device introduction 3.3.1 Controller

Loosen the controller housing screw and remove housing.

Lift up and tilt the battery 45° to remove it.

Controller

3.3.1.1 Specification (1) Controller type: permanent magnetic brushless control (BLDC) (2) Standby current: smaller than 0.5mA (3) 5V sensor power current: 40mA (4) Power voltage: 48V (5) Power current: 150mA (6) Working voltage: 48V (7) Standard accelerator input: 0-5V (8) Temperature range of full power working: -30°C to 90 °C, 100°C shutdown (temperature of the controller cover) (9) 1 minute phase line working current: 80A (10) Continuous phase line working current: 40A (11) Max. battery current: 120A

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.3.1 Controller 3.3.1.2 Connecting wire Power wire Red: Black: Yellow: Green: Blue:

B+, connects the battery positive pole B-, connects the battery negative pole A phase, connects motor A phase B phase, connects the motor B phase C phase, connects the motor C phase

Control wire (neg)

(neg)

1: 2: 3: 4: 5: 6: 7:

(neg)

(neg)

(neg)

(neg)

(neg)

Wire No. 15 is safety switch, valid for high electrical level Wire No. 25 is emergency direction switch, valid for high electrical level Wire No. 9 is electromagnetic brake negative pole drive opening Wire No. 3 is the accelerator signal wire Wire No. 14 is reverse switch, valid for high electrical level Wire No.12 is forward switch, valid for high electrical level 48V positive pole (neg)

(neg)

(neg)

(neg)

(neg)

motor hall butt connector

Computer debugging joint, can be connected to professional computer debugging software to make parameter settings.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.3.1 Controller 3.3.1.3 Controller LED fault code list Fault position

Red flashing light

Fault name

Analysis

ERR0

Identifying fault

The controller identifying angle fails; please identify again.

ERR1

Over voltage

1.The battery voltage is higher than max. working voltage of the controller; please check the battery voltage.

ERR2

Low voltage

1. Check the battery voltage.

2. Lower than the min. working voltage of the controller.

3. Charge the battery when necessary.

ERR3

Retain

ERR4

Locked-rotor

No rotate speed feedback after the controller outputs for 2 seconds; probably due to problems with angle sensor or phase line.

ERR5

Fault voltage

1. Check whether the battery voltage and the control voltage is correct or not; maybe the control voltage is too low.

2. Check the load of 5V voltage. Maybe the 5V voltage is overloaded. Incorrect connecting wire of the outer machines may make the load voltage too high.

3. Controller is damaged; please contact us.

ERR6

Over temperature fault

1. The temperature of the controller exceeds 100°C, and to protect the controller it stops output.

2. The controller needs to be closed till the temperature lowers. When the temperature of the controller is below 80°C, it will start working again.

ERR7

Pedal fault during start up

1. When open the controller and the pedal has valid area signal, this fault occurs (the default is valid between the range of 20%-80%. For example, 0-5V pedal is actually 1V equals to 1%, 4V equals to 100%).Through the configuration procedure, reset the valid range for pedal, or set the pedal safety switch.

2. If start up by treading on the pedal, the fault will disappear by re-start up, or releasing the pedal.

3. If it is “Hall” pedal, please mark the correct pedal type by the customer marking software.

ERR8

Retain

ERR9

A restoration inside the controller

1. Controller restoration after over-current, battery voltage too high or too low. Occasional occurences are not a cause for concern.

ERR10

Short circuit or open circuit of 1-4V Hall accelerator pedal when the controller starts up

1. Check the accelerator pedal is short/open circuited or not.

2. After the fault is removed, start the controller again and the fault warning will disappear.

ERR11

HALL sensor fault

1. Angle sensor type error. The customer needs to set the correct type by the marking software.

2. Fault connecting wire of the angle sensor.

3. Angle sensor damaged or occur occasionally.

ERR14

Over temperature of the motor

1. The motor temperature sensor exceeds the highest temperature, the output will stop till the motor temperature lowers to the recovery temperature, and then start again.

2. Change the over-temperature of the motor by the marking software.

ERR15

Current sensor fault

1. The current sensor inside the controller is damaged.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.3.1 Controller 3.3.1.4 Diagnostic software and connection cable A diagnostic connection cable can be found in the Parts Manual under Electrical System with part number LA113504.

(Cable, Controller – External Device).

The controller, as well the diagnostic connector, is located underneath the battery package.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.3.1 Controller 3.3.1.4 Diagnostic software and connection cable The software and the User Manual for this controller, manufactured by Kelly Controllers, can be downloaded using the following link: https://www.mitforkliftportal.com/ContentPage/126.

The software is an execute file which doesn’t need to be installed.

When you are running Windows 10, you probably have to run it in Compatibility Mode using your right mouse button.

Be aware that this program needs a truck connection to start up.

The next pages contain an overview of the parameter settings and the monitor window for all in-/outputs.

The setting descriptions can be found in the User Manual of the controller.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.3.1 Controller 3.3.1.4 Diagnostic software and connection cable Please read the User Manual before changing any of the settings.

After changing a parameter, the setting needs to be written to the controller by using the “Write” button. The setting will be set after switching off the controller’s supply by turning the key switch off/on. The “Read” button needs to be clicked to show the data on the reading device.

Please be aware that there isn’t a read and store to file function like ZAPI has.

It is recommended to take print screens of the basic settings before changing anything.

There are three pages with settings, of which most are configuration settings pre-adjusted by the manufacturer, and a Monitor window for all in-/outputs.

• Vehicle parameters • Control parameters • Motor parameters • Monitor window for all in-/outputs Vehicle

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.3.1 Controller 3.3.1.4 Diagnostic software and connection cable Control

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.3.1 Controller 3.3.1.4 Diagnostic software and connection cable Motor

NOTE! It is prohibited to do any software adjustments with a running motor!

Be aware that all parameters are free to adjust, but you need knowledge to adjust them.

You could harm the motor and cause unsafe driving or lifting behavior!

It’s strongly recommended not to do any adjustments of the motor settings.

They are pre-adjusted by the manufacturer!

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.3.1 Controller 3.3.1.4 Diagnostic software and connection cable Monitor window for all in-/outputs

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.3.2 Lithium battery

3.3.2.1 Normal performance Test item

Unit

Specification

Test method

Rated Capacity

Ah

20

4A charge and 10A discharge 4A charge and 10A discharge

Min. Capacity

Ah

19.0

Nominal voltage

V

48

Open circuit voltage

V

≥48

Within 1 hr after standard charge

Internal Resistance

mΩ

≤200

Rest 1-4h after standard charge, test the AC internal resistance of the battery

Weight (Approximately)

kg

5.7

Appearance

No distortion, no leakage, structure intact

Storage Performance

-10⁰C ~ 30⁰C

Inspection

3.3.2.2 Charge performance Test item

Unit

Charge Mode

Specification

Remarks

CC/CV

Standard

Charge Current

A

4-8

Standard

Charge Cut-off Voltage

V

54.6

Standard

Charge Cut-off Current

mA

400

Standard Standard

Charge Time

h

3-5

Ambient Temperature

⁰C

0~45

Due to the nature of lithium batteries, the battery capacity will have a certain attenuation when used in a low-temperature environment.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.3.2 Lithium battery 3.3.2.3 Lithium Battery Precautions

Please protect the battery from ingress of water or of any corrosive liquid.

Keep the battery away from open flames and heat as well as flammable and explosive objects.

Failure to do the above may cause the battery to leak, heat up excessively or smoke and increases the risk of fire or explosion.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.3.2 Lithium battery 3.3.2.3 Lithium Battery Precautions

0 40 °C -

°C

Charge the battery at an ambient temperature of between 0 and 40°C.

If a battery fault occurs, please contact your dealer to arrange an appointment for repair.

Never attempt to disassemble the battery.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.3.2 Lithium battery 3.3.2.4 BMS parameter No.

Item

Unit

Min.

Nominal

Max.

1

Charge Voltage

V

54.40

54.60

54.80

2

Charge Current

A

5

10

3

Discharge Current

A

15

20

4

Overcharge Protection Voltage

V

4.15

4.20

4.25

5

Overcharge Recover Voltage

V

4.05

4.10

4.15

6

Delay Time of Overcharge

s

0.96

1.20

1.44

7

Over Discharge Protection Voltage

V

2.70

2.80

2.88

8

Over Discharge Recover Voltage

V

2.85

2.90

2.95

115

144

172

65

80

9

Delay Time of Over Discharge

ms

10

Release Method of Short/ Over Discharge/ Over Current Protection

Remove the load

11

Release Method of Over Discharge Protection

Charge

12

Normal Current Mosfet Temperature Rise (max. load)

⁰C

13

Operating Temperature Range

⁰C

-20

+25

+45

14

Storage Temperature Range

⁰C

-20

+25

+60

3.3.2.5 Precautions 1. If the battery has not been used for a long time, please charge and discharge every 3months.

2. When using a new battery for the first time or after long-term storage please fully charge the

battery before use.

3. For charging methods, please refer to our technical manual.

4. Use the correct charger for Li-ion batteries.

5. Do not reverse charge batteries.

6. Do not short circuit batteries - permanent damage may occur.

7. Do not incinerate or damage batteries - this may cause them to burst or release toxic material.

8. Do not carry out welding jobs directly to cells or batteries.

9. Do not subject batteries to adverse conditions such as extreme temperature deep cycling and

excessive overcharge/over-discharge.

10. Store batteries in a cool and dry place.

11. Do not use our batteries together with other battery brands or batteries of a different

chemistry such as alkaline and zinc carbon.

12. Do not mix the use of new batteries with semi-used batteries, because over-discharge may occur.

13. When charging the battery with charger, ensure correct polarity.

14. If any noise, abnormal temperature or leakage occurs, please stop use.

15. When the battery is very hot, please do not touch it until it cools down.

16. Do not remove the outer sleeve from a cell (or battery pack).

17. When finding battery power descending during use, please switch off the device to avoid over-discharge.

18. When not in use, remove the battery from the lift truck.

19. When removing the battery, hold the connector rather than pulling the cord.

20. After use, if the battery is hot, please cool it down in a well-ventilated place before recharging it.

21. Never put a battery into water or seawater.

22. Do not attempt to take the battery apart, extrude or hit it, because heat may be generated and fire may occur.

23. Keep the battery away from children. If battery contents are swallowed, contact doctors immediately.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.3.3 Maintenance & Care Please replace the wheels and tyres with those specified by the manufacturer.

Non-conforming tyres can adversely affect the performance and stability of the forklift truck.

Do not clean the forklift truck with flammable liquids.

After the first 100 hours of operation, the forklift truck must be fully inspected and maintained. Thereafter conduct maintenance once every 250 hours.

If the forklift truck is to be parked for longer than one month, it must be stored in a dry and frost-free environment.

When the forklift truck is not in use, remove the battery.

If the parking time is less than one month, fully charge the battery first. If over one month, the battery must be charged once every three months.

Before maintenance, make sure that the power supply has been completely disconnected.

If the forklift truck is regularly used in dusty environments, fluctuating temperatures or for heavy duty tasks, please reduce the maintenance interval accordingly.

If the battery smells of overheating or deformation is noticed during charging, stop charging immediately and disconnect the charger power supply.

Contact your dealer for assistance.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.3.4 Maintenance Checklist Frame Structure

Check the condition of all supporting parts Check the bolts and screws are fully tightened

Drive System

Check the drive (motor) wheel for abnormal noise

Wheel

Check for wear and damage Check support and mountings Check wheel bolts for tightness. Retighten if necessary

Steering and Braking

Check the steering bearing clearance Check functions and settings Check the spring compression and for any damage

Lifting Device

Check functions and wear Check the load frame and moving parts for wear and damage

Hydraulic System

Check functions Check the sealing of hydraulic components and check for damage Check the oil level, oil type and capacity L-HV32 (GB/T7631.2 / 300 ml (0.3 kilograms)

Electrical System

Check functions Check the cables for damage and ensure the terminals are secure Check if the safety devices parameter values are correct Check if alarms and safety switches are functioning properly

Motor

Check the motor mountings

Lithium Battery

Check the battery cables and connectors for damage

To ensure long-term safe operation, the checks in the above list are to be performed every six months.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.3.5 Power indicator lamps

Red LED Yellow LED Green LED

No.

Description

1

Green light on, indicating the charge capacity is higher than 80%

2

Yellow light on, indicating the charge capacity is 50%

3

Red light on, indicating the charge capacity is 20%

4

Red light flashes, indicating the charge capacity is lower than 10%; please charge promptly

3.3.6 Charger When charging, red LED is on. Once charging is complete, the LED turns green.

Input voltage: AC110V/220V Input frequency: 60/50Hz Output voltage: DC54.6V Output current: 6A Charger for Lithium battery.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.3.6 Charger 3.3.6.1 Charging Battery If the charger is connected wrongly to the truck connector instead of to the battery connector, the charger will kick-out for approximately 10 to 15 minutes after being connected. After a faulty connection the LED won’t illuminate.

ACTIONS: Disconnect the 220 V supply, as well as the battery connector and let the charger rest for at least 15 minutes. Reconnect the 220 V supply (the LED will illuminate green) and the 48 V connector. If okay, the charger fan will start turning and the LED will illuminate red while charging and should turn green when the battery is fully loaded.

Please take all this into account before sending back any charger.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.3.6 Charger 3.3.6.1 Charging Battery

Wrong connection. The green LED is off. The charger is out of service for approximately 15 minutes.

The LED is off. Disconnect the charger and let it rest for approximately 15 minutes.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.3.6 Charger 3.3.6.1 Charging Battery

Reconnect the charger to the 220 V supply and observe if the green LED illuminates.

Connect the battery connector and the LED should go from illuminating green to red.

The charger fan should be running (normal operation).

NOTE! When the LED illuminates green, the battery is either not connected or has been fully charged.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

3.3.7 Wheel hub motor (drive motor) Sensor lead wire

Motor type: BLDC Rated power: 600w Rated speed: 106

Magnet

Rotor

Coil

Motor wire: HALL wire:

yellow - A phase, green - B phase, blue - C phase red - +5V, black - 0V, yellow - A phase, green - B phase, blue - C phase

3.3.8 Handle (tiller arm) Emergency reverse switch Acceleration rotary knob

Horn

Lifting button Lowering lever

4 Lubricants Location for adding oil

Oil specification

Quantity required

Hydraulic power unit oil tank

L-HV32

250ml

L-HV15 (low temperature)

250ml

34

Lead wire colour

Description

Red

Power supply +48V

Black

B- 0V

Blue

Forward

Green

Reverse

White

Accelerating signal 0-5V

Brown

Emergency reverse

SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

How to replace the driving wheel on PBPL12-15 electric hand pallet trucks.

To do this, a set of special tools (LA113516) has to be used. Regarding these tools, please take note of the following: 1. For trucks produced before August 2018 (serial numbers 201810001 to 201810642), it is not possible to replace the wheel only.

This is because the inside size of the wheel and motor has been changed in production for better performance.

So, for trucks with serial numbers 201810001 to 201810642, you will have to replace the complete wheel including the motor (LA113314).

2. For trucks produced after August 2018, you can replace the wheel only (LA113515). Do note that there are high risks during the disassembling and assembling: • Risk 1: If the inside of the wheel is not clean, the motor may not work properly.

• Risk 2: The magnetic force inside the wheel is very strong. Take caution and don't damage the magnetic pieces.

• Risk 3: Because of the strong magnetic force inside the wheel, you need to be careful to prevent injuries.

Your fingers can be clamped due to magnetic parts.

REF. NO.

DESCRIPTION

NEW

REMARKS

PART NO.

QTY

Wheel Tools

LA113516

1

If necessary

Wheel Only

LA113515

1

If necessary

Motor, incl. Wheel

LA113314

1

If necessary

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

How to disassemble and reassemble the Driving Wheel

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

1

Prepare tools: screwdriver, Allen wrench and brake release screws

2

Remove the two screws on the plastic box. There is one plastic box on each side of the wheel.

3

Remove three screws inside the box then unplug the wiring connectors.

5

Use two screws to release the wheel from the brake in the circled positions.

6

Remove the wheel with care.

7

Driving wheel is successfully removed from the truck.

Refit the driving wheel onto the truck by following the steps in reverse.

37

4

Overturn the truck, unscrew the two screws on each side of the wheel.

SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

How to Replace the Driving Wheel without changing the motor

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

1

Prepare tools: Allen wrench, socket wrench, brass or rubber hammer and two special tools as shown.

4

Install the self-made special tools on to the wheel.

5

Remove the nine screws on the wheel by socket wrench.

8

Hold on to one special tool while standing on the other, pull upward to disengage the motor.

9

The motor is successfully disassembled

39

2

Remove five screws on brake plate at each side of the wheel.

3

Brake plates are disassembled

6

Carefully use the hammer to loosen the metal rod.

7

Take off the cover, do not touch the copper coil.

SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

10 Do not touch the coil,

11 Prepare a new wheel: clean out

12 Attach the motor to

14 Hammer the cover with care.

15 Paste insulation glue

16 Mount the brake plates and five

cables or insulation parts.

any dust inside as dust will affect the performance of the motor.

(recommended Loctite 270) onto the screws before mounting.

the new wheel.

13 Paste insulation glue

(recommended Loctite 5145) onto the wheel then replace the cover, aligning the pin with the hole.

screws at both sides of the wheel.

TASK DURATION • Approximately 25-30 minutes to disassemble the motor and install to a new wheel.

• Approximately 20 minutes to disassemble and assemble the driving wheel with the truck.

Total 45-55 minutes to change the wheel without changing the driving motor.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes 1 Check if the chain is going through the hole in the shaft If not, pass the chain through the hole and check if the problem is solved.

2 Check if the pin is in the correct place as shown to the left If not, adjust the pin.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes 3 Loosen nut No.9.

Turn bolt No.8 two full turns anti-clockwise.

Then check if the problem is solved.

If the problem is not there, try to lift and lower the forks several times. This can help to clean the dust in the pump.

Then check if the problem is solved.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes 4 Dismantle the parts from No.11 to 16.

Place the No.11 ball back into the hole.

Use a stick and hammer to hit the ball to firmly locate it in the hole.

Then reassemble all parts.

Check if the problem is solved.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes 5 Take apart parts No.33 and 34.

Clean and reassemble.

Using a stick and hammer, gently tap No.35.

Check if the problem is solved.

6 If the problem remains, check the seals No.32 and 30.

Replace any damaged seals.

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SERVICE MANUAL PBPL12-15 ELECTRIC HAND PALLET TRUCK 1.2-1.5 tonnes 7 If the problem remains, check if the one-way valve in the picture to the left is damaged.

If air is able to pass through the valve in the direction of the arrow in the picture below, the valve is damaged and must be replaced.

8 If all previous steps have been done but the problem is not solved, the complete pump needs to be replaced.

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Mitsubishi Caterpillar Forklift Europe B.V. Hefbrugweg 77 1332 AM Almere, The Netherlands © 2019 MCFE. All registered trademarks are the property of their respective owners. Some products may be shown with optional equipment.

Printed in The Netherlands

06/19