Nyk 75 Can-Bus PDF

INTRODUCTION
4Most accident happens due to the disregard of basic safety rules or

precautions. In order to prevent accidents from happening, the factors
responsible for accidents must be avoided beforehand.
For this reason, please read this manual and fully understand the
precautions for safety and the proper procedures and directions for
inspection and maintenance before starting operation.
Performing maintenance and repair without adequate knowledge may

cause inadvertent accidents.
4It is not possible to cover all the possible cases of accidents in this
"WORKSHOP MANUAL". Therefore, attention should be given to
precautions other than the ones mentioned in this "WORKSHOP
MANUAL". Especially, when repair and maintenance work which are not
covered in this "WORKSHOP MANUAL" are carried out, always work
under the direction of an instructor who understands the matter.
[Control System Transition]

Model IGBT Control FET Control CAN-BUS Control
FB10P~18P ~221AE1250 221AE1251~ 221AE3656~
FB20P~28P ~241AC4968 241AC4969~ 241AC6266~
FB30P ~251AC0880 - 251AC0881~
4Please note that the contents of the explanation in this manual are
different according to each control system.
Please refer to the applicable explanations.
Using this "WORKSHOP MANUAL"
This manual has information about the layout and names of main components, procedures for
disassembly, assembly, inspection, adjustment, maintenance, and hints for troubleshooting which are in
effect mainly for the model FB-75 series.
Since the parts used in this machine are subject to change for the sake of better quality, performance
enhancement and safety, some portions of the contents and illustrations of this "WORKSHOP MANUAL"
may not be identical.
Directions with and marks are very important, must be followed.
Indicates a potentially hazardous situation which, if not avoided,

DANGER could result in death or serious injury.
You must follow this instruction.
WARNING could result in death or serious injury.
CAUTION may result in minor or moderate injury.
Indicates suggestions, tips and hints related to the safety of a

NOTE
operator and maintain of truck.
1. Personnel this "WORKSHOP MANUAL" is aimed at:

This "WORKSHOP MANUAL" is directed at personnel who possess sufficient knowledge and technical
expertise. If you do not understand any of the contents of this "WORKSHOP MANUAL", perform
operation under the guidance of personnel who does.
2. Conditions of a facility
The work conditions described in the "WORKSHOP MANUAL" are written on the assumption that the
work is performed at standard work facilities and tools for the maintenance of NICHIYU electric lift trucks
are available.
For safe and reliable maintenance, the work should be performed at a shop which is equivalent to these
described in this "WORKSHOP MANUAL" with following all instructions strictly.
Copyright 2008
NIPPON YUSOKICO., LTD.
AllRights Reserved
CONTENTS
SAFETY WORK 1 4. TYRE 47
4-1. Location, name and tyre size...................... 47
1. Precautions for safe inspection and 4-1-1. Tyre - location and name 47
maintenance work. ....................................... 1 4-1-2. Tyre size 48
2. Safety labels................................................. 5 4-2. Inspection and adjustment.......................... 49
3. Model name and serial numbers.................. 9 4-2-1. Hub nut - inspection 49
4. Cautions for maintenance............................11 4-2-2. Rim and rim bolt - inspection 49
5. Tightening torque for bolts.......................... 14 4-2-3. Air pressure - inspection 50
4-2-4. Tyre - visual inspection and replacement 50
6. Data of LOCTITE and THREEBOND products........15
4-3. Troubleshooting.......................................... 51
4-3-1. Tyre - troubleshooting 51
1. GENERAL 16
1-1. Appearance................................................ 16
5. STEERING 52
1-2. Specifications. ............................................ 17
5-1. Location and name..................................... 52
5-2. Disassembly and reassembly..................... 53
5-2-1. Steering linkage - removal and installation 53
2. FRONT AXLE (DRIVE) 19 5-2-2. Steering linkage
2-1. Location and name..................................... 19 - disassembly and reassembly 55
2-2. Disassembly and reassembly..................... 20 5-3. Inspection and adjustment.......................... 57

2-2-1. Front axle - removal and installation 20 5-3-1. Joint - inspection and replacement 57
2-2-2. Front axle - disassembly and reassembly 26 5-3-2. Knob - inspection and replacement 57
2-3. Inspection and adjustment.......................... 34 5-3-3. Steering wheel - inspection and replacement 57
5-3-4. Torque sensor neutral - check and adjustment 58
2-3-1. Gears - Inspection and replacement 34
5-3-5. Checking by voltage 60
2-3-2. Wheel hub and hub bolt - Inspection 34
5-3-6. Actuator ass'y - inspection and adjustment 61
2-4-1. Front axle - troubleshooting 35
5-4-1. Steering linkage - troubleshooting 62
3. REAR AXLE (STEERING) 36

3-1. Location and name..................................... 36
3-2. Disassembly and reassembly..................... 37
3-2-1. Rear axle - removal and installation 37
3-2-2. Rear axle - disassembly and reassembly 39
3-2-3. Rear axle
- Reassembling method and attention 41
3-3. Inspection and adjustment.......................... 44
3-3-1. Bushing - inspection 44
3-3-2. Center arm - inspection 44
3-3-3. Tie rod Comp. - inspection 44
3-3-4. Knuckle - inspection 44
3-3-5. King pin - inspection 45
3-3-6. Hub and hub bolt - inspection 45
3-3-7. Rear axle Comp. - inspection 45
3-4-1. Rear axle - troubleshooting 46
6. BRAKE 63 7b-3. Inspection and adjustment....................... 84
7b-3-1. Oil - inspection 84
6-1. Location and name..................................... 63 7b-3-2. Recommended oil and quantity 84
6-1-1. Foot brake linkage - main part names 63 7b-3-3. Oil tank and filters - cleaning and check 85
6-1-2. Parking brake linkage - main part names 64 7b-4. Troubleshooting. ...................................... 85
6-2. Disassembly and reassembly..................... 65 7b-4-1. Oil tank - troubleshooting 85
6-2-1. Wheel brake - removal and installation 65
6-2-2. Wheel brake - disassembly and reassembly 68
6-3. Inspection and adjustment.......................... 69
6-3-1. Brake drum 7c. CONTROL VALVE 86
- inspection, repair and replacement 69 7c-1. Location and name................................... 86
6-3-2. Shoe & lining - inspection and replacement 69
7c-2. Disassembly and reassembly. ................. 88
6-3-3. Adjustor ass'y - inspection and replacement 70
7c-2-1. Control valve - removal and installation 88
6-3-4. Wheel cylinder ass'y
7c-2-2. Inner kit of control valve - replacement 91
- inspection and replacement 70
6-3-5. Master cylinder ass'y
7c-3. Inspection and adjustment....................... 92
7c-3-1. Relief pressure - measurement 92
7c-3-2. Microswitch - adjustment 93
6-3-6. Brake pedal - inspection 71
6-3-7. Parking lever - inspection and adjustment 72 7c-4. Troubleshooting........................................ 94
6-3-8. Brake linkage - adjustment 72 7c-4-1. Control valve - troubleshooting 94
6-3-9. Brake air bleeding 74
6-4-1. Brake - troubleshooting 76 7d. CYLINDER 95
7d-1. Location and name. ................................. 95
7d-1-1. Lift cylinder - main part names 95
7. HYDRAULIC SYSTEM 77 7d-1-2. Tilt cylinder - main part names 97
7-1. Oil pipimng circuit....................................... 77 7d-2. Disassembly and reassembly.................. 98

7d-2-1. Lift cylinder - removal
: P - mast (2 - stage simplex) 98
7d-2-2. Lift cylinder - removal : PFL-mast (2-stage
7a. HYDRAULIC PUMP 78 duplex), M-mast (3-stage triplex) 100
7d-2-3. Tilt cylinder - removal 103
7a-1. Location and name. ................................. 78
7d-2-4. Lift cylinder - installation and adjustment 104
7a-2. Disassembly and reassembly.................. 79 7d-2-5. Tilt cylinder - installation 105
7a-2-1. Hydraulic pump - removal and installation 79 7d-2-6. Lift cylinder - disassembly and reassembly 106
7a-3. Inspection and adjustment....................... 80 7d-2-7. Tilt cylinder - disassembly and reassembly 116
7a-3-1. Hydraulic pump - inspection 80 7d-3. Inspection and adjustment......................117
7a-4. Troubleshooting. ...................................... 81 7d-3-1. Cylinder comp. - inspection 117
7a-4-1. Hydraulic pump - troubleshooting 81 7d-3-2. Piston rod - inspection 117
7d-3-3. Drift for lift and tilt - inspection 118
7d-4. Variation of the tilt cylinder......................119
7d-4-1. Tilt angle by masts 119
7b. OIL TANK AND OIL PIPING 82
7d-5. Troubleshooting. .................................... 120
7b-1. Location and name. ................................. 82 7d-5-1. Cylinder - troubleshooting 120
7b-1-1. Plastic oil tank - main part names 82
7b-1-2. Iron oil tank - main part names 82
7b-2. Disassembly and reasembly.................... 83
7b-2-1. Oil tank - precautions 83
7b-2-2. Oil piping replacement - precautions 83
8. MAST 121 10. ELECTRIC PARTS 151
8-1. Location and name................................... 121 10-1. Location and name. ............................... 151
8-2. Disassembly and reassembly................... 123
8-2-1. Lift bracket - removal 123
8-2-2. Mast ass'y - removal 123
10a. CONTROL UNIT 152
8-2-3. Mast - disassembly and reassembly 125
8-3. Inspection and adjustment........................ 128 10a-1. Location and name. ............................. 152
8-3-1. Mast, lift bracket and roller shaft - inspection 128 10a-2. Disassembly and reassembly.............. 154
8-3-2. Back shoe - inspection 129 10a-2-1. Control unit - removal and installation 154
8-3-3. Lift chain - inspection and replacement 129 10a-2-2. Control unit - disassembly and reassembly 156
8-3-4. Chain bolt - inspection 130 10a-3. Check and replacement....................... 160
8-3-5. Chain wheel - inspection 130 10a-3-1. IGBT module - inspection and replacement 160
8-3-6. Hose pulley - inspection 131 10a-3-2. FET module comp.
8-3-7. Roller - inspection and replacement 131 - inspection and replacement 162
8-3-8. Fork - inspection and replacement 132 10a-3-3. Capacitor - inspection and replacement 163
8-3-9. Lift chain - inspection and adjustment 133 10a-3-4. EPS controller - specifications 164
8-3-10. Mast lean- adjustment 134
8-4. Troubleshooting........................................ 135
8-4-1. Mast Lift bracket Fork - troubleshooting 135
10b. DISPLAY PANEL AND DIRECTIONAL SWITCH 165
10b-1. Display panel
9. MOTOR 136 - Disassembly and reassembly............ 165
10b-1-1. Display panel - disassembly and reassembly 165
9-1. Location and name................................... 136 10b-2. Directional switch
9-1-1. Traction motor - main part names 136
- Disassembly and reassembly............ 167
9-1-2. Hydraulic motor - main part names 137
10b-2-1. Display panel - disassembly and name 167
9-1-3. EPS motor - main part names 137
10b-2-2. Wiring of directional switch 168
9-1-4. Motors - specifications 138
9-2. Disassembly and reassembly................... 139
9-2-1. Traction motor - removal and installation 139
9-2-2. Hydraulic motor - removal and installation 140 10c. ACCELERATOR 169
9-2-3. EPS motor - removal and installation 142
10c-1. Disassembly and reassembly. ............. 169
9-2-4. Traction motor - disassembly and reassembly 143
10c-1-1. Accelerator linkage - removal and installation 169
9-2-5. Hydraulic motor - disassembly and reassembly 144
9-2-6. EPS motor - disassembly and reassembly 144 10c-2. Inspection and adjustment................... 170
9-3. Inspection and adjustment........................ 145 10c-2-1. Potentiometer - adjustment 170
10c-2-2. Accelerator linkage - adjustment 171
9-3-1. Rotor comp. - inspection and replacement
(Traction and Hydraulic motor) 145
9-3-2. Armature comp.
9-3-3. Brush, Brush holder and Spring (EPS motor)
9-3-4. Motor ASS'Y (Traction/Hydraulic motor)
- inspection 148
9-3-5. Motor ASS'Y (EPS motor) - inspection 149
9-3-6. Oil seal and permanent magnet (EPS motor)
9-4. Troubleshooting........................................ 150
9-4-1. Motor - troubleshooting 150
10d. MAIN CONTACTOR AND FUSE 172 10g. MPU BOARD 204
10d-1. Disassembly and reassembly.............. 172 10g-1. Location and name. ............................. 204
10d-1-1. Control unit - removal and installation 172 10g-1-1. MPU board 204
10d-2. Inspection and replacement................. 174 10g-1-2. Display board 205
10d-2-1. Main contactor 10g-1-3. EPS controller board (EPS / DSP board) 205
10d-2-2. Fuse - replacement 174
11. LASER POINTER (OPTION) 206

11-1. Adjustment. ............................................ 206
10e. BUILT-IN CHARGER (OPTION) 175 11-1-1. Fork level - adjustment 206
10e-1. Disassembly and reassembly.............. 175 11-1-2. Laser optical axis - adjustment 206
10e-1-1. Charger ass'y
- disassembly and reassembly 175
10e-1-2. Transformer - disassembly and reassembly 177
10e-1-3. Built-in charger - specification 178 12. SERVICE DATA 207
10e-2. Inspection and replacement................. 180 12-1. Annual Inspection Service Data............. 207
10e-2-1. Magnetic contactor - inspection 180 12-2. Standard work hours.............................. 208
10e-2-2. Plug comp. and receptacle
10e-2-3. Fuse and fuse base - inspection 180
10e-2-4. Transformer - inspection 181
10e-2-5. Diode - inspection 181
10e-3. Inspection After Assembly.................... 182
10e-3-1. Timer - inspection 182
10e-3-2. Earth - inspection 183
10e-3-3. Reserve function - inspection 183
10e-4. Charging procedure............................. 184
10e-4-1. Automatic charge (Daily charge) 184
10e-4-2. Reserve charge 188
10e-4-3. Balancing charge 197
10e-5. Voltage tap........................................... 199
10e-5-1. Power supply voltage - check 199
10e-5-2. Voltage tap - selection 199
10e-5-3. Voltage tap - changing 200
10e-5-4. Fuse (three-phase voltage) - replacement 200
10f. BATTERY 201

10f-1. Disassembly and reassembly............... 201
10f-1-1. Battery - removal and installation 201
10f-2. Inspection and adjustment.................... 202
10f-2-1. Battery - inspection 202
10f-2-2. Battery - Cleaning 203
SAFETY WORK
1. Precautions for safe inspection and
maintenance work
Maintenance shops
CAUTION ADEQUATE SPACE WITH FLAT SURFACE:
l The floor area of the shop (location) where
inspection and maintenance are per formed
must have adequate floor space, and have level
surfaces without holes.
If these conditions are not met, unexpected
accidents, such as a roll-over of the forklift
truck, may result.
CAUTION WELL-VENTILATED AREA

lWork such as welding painted components or
sanding down coated parts should be carried
out in well-ventilated areas.
If this is not observed, harmful toxic gas or dust
may be inhaled.
CAUTION LOCATION EQUIPPED WITH FIRE

EXTINGUISHING EQUIPMENT
l Equipment such as first-aid boxes and fire
extinguishers should be nearby when work is
performed.
CAUTION SAFE AND WELL-LIGHTED AREA

lThe work area should be safe and well lighted.
When working inside the machine or underneath
of it, always use a safety lamp with a shielded
light bulb.
If this is not observed, leaked oil may catch fire
when a light bulb pops.
CAUTION PROPER ARRANGEMENT

lArrange and clean always at a working place to
work safety.
lEspecially, arrange disassembled parts well.

Work clothing
CAUTION l The worker should wear a safety hat, work
clothes, and safety shoes that are suitable for
safe work. The work clothes should be close-
fitting.
If this is not obser ved, loose clothing may
become caught in a machine, resulting in
serious injury.
Tools and gauges

CAUTION lAlways use tools that are suitable for the work
being performed. Use proper size tools when
tightening and loosening the parts of the forklift
truck.
Failure to observe the above could result in
serious injury or damage to machines.
CAUTION Prepare tools and gauges before starting to work.
Safety work
WARNING l W h en hoist ing a for kli f t t r uc k or a h eav y

component, use ropes or cable with correct
capacity.
lDo not use ropes or cables which are kinked.
WARNING l Do not lif t the forklif t truck by using other

f o r k l i f t . T h e b o t t o m o f t h e t r u c k m ay b e
damaged by hitting the forks.
WARNING After lifting or jacking up a forklift truck, support it

with safety blocks or rigid stands.
WARNING Apply wheel chocks to tyres to prevent the truck

from moving.
WARNING When working under a forklift truck, use a pit or

proper safety precautions.

Parts
CAUTION When replacing any parts, be sure to use NICHIYU
genuine parts.
CAUTION When replenishing battery electrolyte, be sure to

use refined water.
Repair of electrical components

CAUTION Be sure to disconnect the batter y plug when
replacing electrical component.
Do not pull the electric cable when disconnecting
the battery plug.
Hold the battery plug and disconnect it.
CAUTION Be sure to jack up the drive wheel when trouble

shooting electrical operations.
NOTE Record the places of lead wire connection when

disassembling.
CAUTION CHARGING BATTERY

l Batteries produce flammable gas during
charging. Do not allow batteries in the vicinity of
fire or flames.
Failure to observe the above could result in an
explosion.
CAUTION l Diluted sulfuric acid is used as the battery's

electrolyte . Keep clothing and skin away from
contact with battery fluid.
If this is not observed, the fluid may corrode
clothing or cause burns.

Hydraulics
CAUTION Before disconnecting hydraulic hoses, release internal oil pressure. To release
the pressure, follow next procedures.
1 Sit on the seat and turn on the key switch.
2 Push the lift lever forward to lower the fork on the ground.
3 Repeat pushing forward and releasing the lift lever a few times between
lowering and neutral positions to release the internal pressure.
4 Do not pull the lift lever nor operate any other hydraulic levers. (If the hydraulic
motor runs, high pressure is applied to all hydraulic circuits.)
5 You must sit on the seat and turn on the key switch to follow above steps 1, 2
and 3. Otherwise, the internal hydraulic pressure is not released because of the
OIS. (Operation Interlock System)
CAUTION When removing the hydraulic pipes, cap them

to prevent dust from entering into the hydraulic
components and pipes.
CAUTION When disassembling and assembling the

hydraulic components, work at clean place and do
not damage the parts.
Tightening torque
CAUTION l Obser ve tightening torque specified in this
manual.
If not specified, refer to the table [Tightening
torque for bolts] on page 14.
Marks and Symbols

: Tightening torque
B : Apply THREEBOND product or equivalent
L : Apply LOCTITE product or equivalent Refer to the page 15 for details.
G : Apply grease
MG : Apply molybdenum grease
S : Apply Silicone glue
C : Apply thermal conductive compound
N : Not reusable

2. Safety labels
The illustration below shows the location of safety labels for safe operation.
Always protect the safety labels from contamination and damage.
If they are damaged or lost, replace with new ones.
9 2 3 10 4 1
12
10
11
221W074E
No. Parts No. Parts Name Q'ty Notes

1 50004-65160 Plate, caution 1 Safety operation
2 50004-65170 Plate, caution 1 Parking brake
3 50004-65050 Plate, caution 2 No person on / under for
4 50004-65060 Plate, warning 1 Shearing point
5 50004-65180 Plate, caution 1 Battery cover lock
6 24700-13490 Plate, lubrication 1 Lubrication
38540-00630 w / battery, SHINKOBE
7 Label, caution 1
38540-00520 w / battery, G6E
8 50004-65220 Plate, caution 1 Caution for fingers
0902-69954 Air pressure (bar) FB10P-15P

9 Label, tyre 1
0902-69944 Air pressure (bar) FB30P
10 0902-69964 Label, tyre 1 Air pressure (bar) FB20P-28P
0902-69914 Air pressure (bar) FB30P
11 50004-65190 Label, hook 3 Hook position
12 24700-04830 Plate, warning 1 In case of tipover

1
Name plate
(page 9)
221W0001
1 3
PRECAUTIONS FOR SAFETY OPERATION
WARNING
1 Do not overload. observe allowable load (blue zone).
2 Prior to operation, check performance of brake
or turn quickly.
3 Do not make a sudden start and brake or turn
quickly.
4 Do not make a sudden valve lever operation at a
high lift.
5 Do not run sideways or handle on an incline.
6 When the red lamp of battery capacity indicator
turns on, charge battery.
7 Check electrolyte every week and replenish water.
8 Be sure to use the prescribed fuses.
50004-65050
2 4

Apply parking brake before WARNING
leaving truck. Make adjust
to provide adequate braking.

8
5
6
7
(with Japnese
battery only)
221W0002
6
5
Lock release method of gas spring
GASES produced by this battery can be explosive.

Cigarettes, flames or sparks could cause battery to explode.
Make sure batteries are stored and charged in a wellventilayed area.
Batteries contain SULFURIC ACID can cause severe burns.
Avoid contact with skin, eyes or clothing.
In event of accident flush with water and call a physician immediately.
Wear rubber gloves to prevent ELECTRIC SHOCK during checking.
and maintaining.
Keep out of reach of children.
IMPORTANT POINT FOR MAINTENANCE
1. Keep the electrolyte level at proper height. (EX.) VENT PLUG
(When electrolyte decreased, fill purified water Stopper
and stop filling immediately if confirmed the white line of the White line
float as shown herein, for overfilling causes overflow.)

2. Always give the battery an adequate charge and
FLOAT
do not use the battery at overdischarged condition.
3. Keep the surface of battery clean and dry.

9: for Front tyre (only for EEC)
FB10P / 14P FB15P ~ 28P FB30P
11
10: for Rear tyre (only for EEC)

FB10P ~18P FB20P ~ 28P FB30P 50004-65190
12
Do Not Jump ! Lean Forward
Fasten Hold
Seatbelt On
Tight Lean
Truck can Away
TIP OVER ! Brace From
Risk of serious Feet Impact
INJURY
WARNING or DEATH IN CASE OF TIPOVER
exceeds the stability of the truck.
FOR SAFETY NOTICE FOLLOWING WARNINGS 4. Serious injury or death can occur to the operator if he / she is trapped
1. Lateral tipover can occur when unloaded if the combination of speed between the truck and the ground.
and sharpness of turn produces an overturning moment which exceeds
the stability of the truck.
2. Lateral tipover can occur if overloaded or loaded within capacity and the
IN CASE OF TIPOVER
load is elevated and if turning and / or braking when traveling rearward 1. The operator should stay with the truck if lateral or longitudinal tipover
or if turning and / or accelerating when traveling forward produces an occurs. The operator should hold on firmiy and lean away from the point
overturning moment which exceeds the stability of the truck. of impact.
Rearward tilt and / or off-center positioning of the load and / or uneven 2. The operator should stay with the truck if it falles off a loading dock or
ground conditions will further aggravate the above conditions. ramp. There are other situations where the environment of the landing
3. Longitudinal tipover can occur if overloaded or when loaded within capacity area presents a severe hazard. In those incidents. it may be prudent for
and the load is elevated if forward tilt. braking in forward travel. or the operator to leave the truck.
commencing rearward travel produces an overturning moment which 24700-04830

3. Model name and serial numbers
Model name
lName plate (For Standard)
LOAD CHART
MODEL LIFT HEIGHT
mm
CAPACITY kg
MAXIMUM mm kg / mm
LOAD/LC
LIFT HEIGHT mm kg / mm
SERIAL NO. MFG. YEAR
SERVICE WEIGHT
W/O BATTERY kg VOLTAGE V LOAD CENTER mm
BATTERY WEIGHT MIN. kg MAX. kg 50006-95900
(For CE)
LOAD CHART
MODEL LIFT HEIGHT
mm
CAPACITY kg
MAXIMUM mm kg / mm
LOAD/LC
SERVICE WEIGHT
FB 75
Capacity code 10 : 1000kg
14 : 1350kg
15 : 1500kg
18 : 1750kg
20 : 2000kg
25 : 2500kg
28 : 2750kg
30 : 3000kg
Classification P : Pneumatic tyre

of tyre PN : No puncture tyre
PC : Cushion tyre
U : High speed type
B : Large capacity battery

equipped
C : Stationary charger
Maximum lifting height [cm] D : Dust resistant
Mast type NO CODE : Two stage full visibility (simplex) mast

M : Three stage full free lift (triplex) mast
(Full visibility mast)
PFL : Full free lift (duplex) mast
(Full visibility mast)
CS : Cold storage use for -35C

FCS : Cold storage use for -50C
RP : Rust resistant
Z : Special type
Attachment etc.

Serial numbers
No. Serial numbers Stamped position
1 Serial No. of a truck Stamped on the name plate
2 Serial No. of a chassis Stamped on the right chassis
3 Serial No. of a mast Stamped on the mast name plate
4 Serial No. of a front axle Stamped on the gear case
5 Serial No. of a traction motor Stamped on the motor name plate
6 Serial No. of a hydraulic motor Stamped on the motor name plate
7 Serial No. of a EPS motor Stamped on the motor name plate
8 Serial No. of lift cylinders Stamped on lift cylinders
9 Serial No. of tilt cylinders Stamped on tilt cylinders
lLocation of serial numbers
LOAD CHART
MODEL LIFT HEIGHT
2 mm
CAPACITY kg
MAXIMUM mm kg / mm
LOAD/LC
1
3
SERVICE WEIGHT
6
221W072E
10
4. Cautions for maintenance
General precautions
When replacing any parts, be sure to use genuine
l
NICHIYU parts.
When parts are assembled, always replace old
l
packing and O-rings with new ones. In addition, be
sure to apply a light coat of grease on the O-rings and
oil seals before installing them.
As shown in the illustration, face the flat side of the
l Retainer for a Retainer for a
groove hole
C-shape retainer in the direction the force is applied
when installed.
152E101
As shown in the illustration, face the slit side in the

l
direction the force is applied when driving in a spring
pin.
152E102
The split pin must be replaced with a new one and

l
split so it will not come out.
152E103
When using a thrust washer with oil grooves cut,

l Oil grooves
observe the direction of installation.
152E104
l When connecting and disconnecting couplers of

electrical harnesses, always disconnect the battery
plug.
11
Using liquid packing
l Scraping before application of seal
Remove the sealer adhered on the mating surface of the
casing by using a scraper or equivalent tool. Be careful
not to make scratches of 0.3 mm or deeper. If scratches
Scraper
are made, repair the area by using an oil stone.
152E105
l Applying liquid packing

1. Wipe off the mating surfaces using a cloth soaked in
gasoline to remove oil and contamination.
* Do not use kerosene, light oil, or crude oil.
Cut the nozzle at the

2. Cut the nozzle of the liquid packing tube at about the second section
second section so that the bead width will be 3 to 3.5
mm. 3 - 3.5 mm
Mating surface Liquid packing
152E106
3. Attach a key for rolling up the tube, and apply the liquid
packing to the mating surface while rolling up the tube.
* Do not smooth out the bead; doing so may cause
leakage. Not Good
* When applying the liquid packing to bolt holes, apply it 3 -3.5 mm

Key to evacuate
on the internal portion of the mating surface. liquid packing
Good 152E107
4. Close the mating surfaces within 15 minutes after the

Apply liquid packing
liquid packing is applied.
Within 15 minutes
5. When tightening the bolts, always tighten temporarily Assembly
first, and then tighten them gradually, moving from one to
the next in a diagonal pattern. Wait for 30 minutes or more
Filling oil/Operation
6. Wait for more than 30 minutes before adding oil or
operating the machine.
* Failure to do so may cause oil leakage.
12
l Deterioration of liquid packing
1. Once the tube has been opened, the liquid packing * If the oil has separated, the
packing has deteriorated.
anchoring the tip part of the nozzle might be cured and
deteriorated. Squeeze out that portion and discard it Squeeze out the
before reusing the packing. bead about 20
mm and check.
152E108
2. If oil (filler) was separated from the liquid packing and

the packing appears shiny when it is squeezed out, this
indicates that the liquid packing has deteriorated.
* Although the oil may have been separated from a
liquid packing opened before its expiration date, this is
not an indication of deterioration.
CAUTION If the state of the packing is normal, it will be

cured within approximately 2 hours. However, a
deteriorated packing will not.
13
5. Tightening torque for bolts
Classification of bolt 4T 8T Brass Stainless
SCM435
Material of bolt SS400
(S55C)
BsBM2S-0 SUS304
Nominal Pitch *1
of bolt Tightening torque *2 Unit : N m{kgf m}
(mm) (mm)
0.6 1.3 0.4 0.5
M3 0.5
{0.06} {0.14} {0.04} {0.05}
1.4 3.2 1.0 1.0
M4 0.7
{0.14} {0.33} {0.10} {0.11}
2.7 6.4 1.8 2.0
M5 0.8
{0.28} {0.66} {0.19} {0.21}
4.7 10 3.1 3.6
M6 1.0 {0.48} {1.1} {0.32} {0.37}
11 26 7.8 9.0
M8 1.25
{1.1} {2.7} {0.80} {0.92}
22 55 15 18
M 10 1.25
{2.3} {5.7} {1.6} {1.9}
39 98 29 33
M 12 1.25 {4.0} {10} {3.0} {3.4}
62 150 47 53
(M 14) 1.5
{6.3} {16} {4.8} {5.4}
97 240 73 81
M 16 1.5
{9.9} {25} {7.5} {8.3}
180 500 140 150
M 20 1.5
{19} {51} {15} {16}
250 670 200 220
(M 22) 1.5
{26} {69} {21} {23}
320 840 250 280
M 24 2.0
{33} {86} {26} {29}
640 1600 530 570
M 30 2.0
{66} {170} {54} {58}
*1. In the table above, the thread pitches of bolt diameters M3 to M8 are for coarse
screw threads and those of bolt diameters M10 or larger are for fine threads
according to our specifications.
*2. The tolerance range of tightening torque is to be +/- 10% of the reference values
given above. (The tolerance range is determined according to experience, related
standards, and records provided by other companies.)
14
6. Data of LOCTITE and THREEBOND products
LOCTITE product
Product number Content
#262 Thread-locking material
#542 Thread-sealing material
#648 Retaining compound
Visit: www.henkel.com for details.
THREEBOND product
Product number Content
#1212 (TB 1212) Liquid gasket
#1401 (TB 1401) Plastic thread locker
Molybdenum disulfide
#1901
lubricants
#1344 (1344N) Anaerobic sealant
Visit: www.threebond.co.jp/en/index.html for details.
15
1. GENERAL
1- 1. Appearance
2 FRONT AXLE
3 REAR AXLE
4 TYRE
7 Hydraulic system 5 STEERING
6 BRAKE
8
7a HYDRAULIC
PUMP
6
5 7b OIL TANK AND

7c OIL PIPING
7a 7c CONTROL
VALVE
9
7d CYLINDER
7d
7b 8 MAST
9 MOTOR
4 10 ELECTRIC
10 PARTS
2
9 11 LASER
3 POINTER
4
12 SERVICE
DATA
221W070E
16
1- 2. Specifications
Chassis number position
H
F
E D
I
B
A
K
J
C
* This illustration shows FB15P.
17
1) SPECIFICATIONS FOR STANDARD LIFT TRUCKS
MODELS FB10P FB14P FB15P FB18P FB20P FB25P FB28P FB30P
Capacity kg 1000 1350 1500 1750 2000 2500 2750 3000
Load center A mm 500
Lift height B mm 3000
Free lift C mm 145 150 155
Loaded 370 340 320 310 280 260 250 320
Performance
Lift speed mm/s

Unloaded 540 470 410 550
Forward D 6
Tilt angle
Backward E 12
Pneum. single 14.0 13.5 14.0 13.5 13.0 13.5
Loaded
Travel Pneum. cushion km/h 13.0 12.5 13.0 12.5 12.0 12.5
speed Pneum. single 16.0 15.5 16.0 15.5 15.0 15.5
Unloaded
Pneum. cushion 15.0 14.5 15.0 14.5 14.0 14.5
Min. turning radius F mm 1710 1725 1950 2005 2060 2240
Max. gradeability (Loaded) (5min) % 22 % 20 % 19 % 17 % 19 % 16 % 14 % 16 %
Overall length G mm 3035 3080 3285 3345 3410 3580
Overall width H mm 1050 1090 1175 1180
Mast lifted I 4000
Overall
Mast lowered J mm 1980 2215
Dimensions
height
Overhead guard K 2110 2225
Wheel base L mm 1250 1400 1600
Front wheel 890 900 955 955
Tread mm
Rear wheel 900 900 945 980
Road clearance mm 110 235
Service weight (w.o./Battery) kg 2065 2200 2210 2385 2860 3305 3520 3530
Aisle width with pallet 1100x1100 mm mm 3205 3225 3475 3530 3605 3815
Pneum. single 6.00-9-10PR 21 X 8-9-14PR 23 X 9-10-16PR 28X9-15-12PR
Front Pneum. cushion 6.00-9 Solid 21 X 8-9 Solid 23 X 9-10 Solid 28X9-15 Solid
Tyre
Pneum. double 4.50-12-8PR 6.50-10-10PR 6.00-15-10PR

Pneum. single 5.00-8-8PR 18 X 7-8-14PR 6.50-10-10PR
Rear
Pneum. cushion 5.00-8 Solid 18 X 7-8 Solid 6.50-10 Solid
Control system (Travel/Hydraulic) Inverter Control
Electric For traction 9.0 10.0
For hydraulic kw 9.5 12.0 15.0
motors For power steering 0.4 0.5
Std. 48V 330 48V 400 48V 450 48V 565 72V 450
Option (1) 48V 400 48V 485 48V 545 48V 600 72V 485
Battery Ah/5HR
Option (2) 48V 485 48V 545 48V 565 72V 545
Option (3) 48V 545 48V 600 72V 600
Charger (3 Phase 200/230V) Automatic Stationary Charger
*Subject to change without notice for improvement.
*Figures shown in the above specification table and unit with two stage full visibility mast.
2) SPECIFICATIONS FOR HIGH SPEED LIFT TRUCKS (U-Series)

MODELS FB10P-U FB14P-U FB15P-U FB18P-U FB20P-U FB25P-U
Capacity kg 1000 1350 1500 1750 2000 2500
Load center A mm 500
Lift height B mm 3000
Free lift C mm 145 150
Loaded 470 440 420 380 360 340
Performance
Lift speed mm/s

Unloaded 650 600
Forward D 6
Tilt angle
Backward E 12
Pneum. single 16.0 15.5 15.5 15.0
Travel Loaded
Pneum. cushion km/h 15.0 14.5 14.5 14.0
speed Pneum. single 18.0 17.5 17.5 17.0
Unloaded
Pneum. cushion 17.0 16.5 16.5 16.0
Min. turning radius F mm 1710 1725 1950 2005
Max. gradeability (Loaded) (5min) % 22 % 20 % 19 % 17 % 19 % 16 %
Overall length G mm 3035 3080 3285 3345
Overall width H mm 1050 1090 1175
Overall Mast lifted I 4000
Mast lowered J mm 1980
Dimensions
height
Overhead guard K 2110
Wheel base L mm 1250 1400
Front wheel 890 900 955
Tread mm
Rear wheel 900 900 945
Road clearance mm 110
Service weight (w.o./Battery) kg 2065 2200 2210 2385 2860 3305
Aisle width with pallet 1100x1100 mm mm 3205 3225 3475 3530
Pneum. single 6.00-9-10PR 21 X 8-9-14PR 23 X 9-10-16PR
Front Pneum. cushion 6.00-9 Solid 21 X 8-9 Solid 23 X 9-10 Solid
Tyre
Pneum. double 4.50-12-8PR 6.50-10-10PR

Pneum. single 5.00-8-8PR 18 X 7-8-14PR
Rear
Pneum. cushion 5.00-8 Solid 18 X 7-8 Solid
Control system (Travel/Hydraulic) Inverter Control
For traction 9.0 10.0
Electric
For hydraulic kw 12.0 13.5 14.0
motors For power steering 0.4 0.5
Std. 48V 330 48V 400 48V 450 48V 565
Option (1) 48V 400 48V 485 48V 545 48V 600
Battery Ah/5HR
Option (2) 48V 485 48V 545 48V 565
Option (3) 48V 545 48V 600
Charger (3 Phase 200/230V) Automatic Stationary Charger
*Subject to change without notice for improvement.
*Figures shown in the above specification table and unit with two stage full visibility mast.
18
2. FRONT AXLE (DRIVE)
2- 1. Location and name FRONT AXLE
lMain parts of front axle
Support, drive
Case (3) comp., mission 212E128
Gear(4)
Case, differential
Case (1), mission
Gear (1)
Gear, differential side
Gear, pinion
Gear, pinion
Shaft, pinion gear
Gear(3) Gear, differential side
Gear(2)
Case (2) comp., mission
Wheel brake ass'y

Drum, brake
Hub, wheel
Shaft, drive
2210005
19
FRONT AXLE (DRIVE) 2
2- 2. Disassembly and reassembly

CAUTION lLift or jack up the forklift truck and support it with safety blocks or rigid
stands.
lApply wheel chocks to tyres to prevent the truck from moving.
lRecord places of lead wire connections before disassembling.
lWhen disconnecting hydraulic pipes, cap them to prevent dust from
entering into hydraulic components and pipes.
lBe sure to disconnect the battery plug.
2-2-1. Front axle - removal and installation

1. Remove right and left forks.
2. Disconnect hydraulic hoses as follows.
CAUTION Turn the key switch off and operate hydraulic levers a few times to
release high pressure in the hydraulic piping before disconnecting
hydraulic hoses or pipes.
1. Disconnect the high pressure hose from the control valve and fix it in place.
2. Loosen the hose clip on the control valve and disconnect the low pressure hose
(return hose).
lDisconnecting the hydraulic hose

Lift cylinder (2nd) Low pressure hose
High pressure hose
Tank comp., oil
221W001E
3. Disconnect three lead wires on the traction motor and the lDisconnecting the motor lead wire
harness connector for the bearing sensor. Traction motor Lead wire
CAUTION Be careful not apply too much stress to the

l
cable of the accelerator potentiometer when
removing the floor plate.
Record places of lead wire connections
l Harness
before disassembling. connector
2210058
20
2 FRONT AXLE (DRIVE)
4. Remove the parking linkage ass'y as follows.

1. Disconnect the harness connector for the accelerator
and remove the floor plate.
lRemoving the floor plate

Mat, floor
Floor plate
Connector for accelerator
221W002E
2. Remove front covers as shown in the following illustration.

3. Remove fitting bolts to remove the parking linkage ass'y.
lRemoving the parking linkage ass'y

Fitting bolt
Parking linkage ass'y

Cover(1), front
Cover(3), front
Cover(7), front
2210059
21
5. Remove front tyres as follows. lRemoving the front tyre
1. Apply chocks to both rear tyres.

2. Loosen hub nuts on the front tyres.
NOTE Do not remove nuts, just loosen.
3. Hoist the truck at the top of the mast to float the front
tyres from the ground.
4. Apply rigid stands or wood blocks (20-30 cm height)
under the frame.
5. Remove hub nuts to remove front tyres. Front axle
Hub nut Hub bolt

2210060
Front tyre
lHub nut
Tightening torque (M12)

89-108 N m
[FB10P/14P]
{9-11 kgf m}
216-264 N m
[FB15P/18P]
{22-27 kgf m}
315-385 N m
[FB20P-30P]
{32-39 kgf m}
6. Remove right and left tilt pins that hold tilt cylinders and lRemoving the tilt pin
mast.
Outer mast
Tilt pin
Tilt cylinder
2210061
22
7. Disconnect brake pipes as follows. lDisconnecting the brake pipe

Master cylinder
1. Drain the brake fluid from the brake oil tank.
2. Hoist the mast down and tilt it forward.
3. Disconnect the brake pipes of the wheel brake ass'y.
Disconnect
Disconnect Brake pipes

2210062
8. Replace pivot caps with special ones as follows. lReplacing the pivot cap

2. Remove upper fitting bolts for both pivot caps.
Bushing
3. Hoist the mast to return it to the vertical position.
Pivot cap
CAUTION Keep the wire rope pulling backward on the Upper

fitting bolt
chassis to keep the mast vertical.
4. Remove lower fitting bolts for both pivot caps.
Lower fitting bolt 2210131
lFitting bolt
Tightening torque
78-98 N m
{8-10 kgf m}
5. Replace pivot caps with special caps. lSpecial cap details

6. Tighten all fitting bolts by hand.
2mm
8. Use a tool to tighten upper fitting bolts for both special
caps.
9. Hoist the mast to return it to the vertical position.
Shave off the standard cap
CAUTION Keep the wire rope pulling backward on the
chassis to keep the mast vertical.
10.Use a tool to tighten lower fitting bolts for both special 2210132
caps.
23
9. Remove fitting bolts and nuts for the front axle and frame.
CAUTION When removing bolts of one side, leave a bolt through the front axle and
frame to remove bolts on the other side easily.
10. Hoist the mast and remove the front axle and traction motor
from the frame.
NOTE Be careful not to catch or damage the brake pipes and parking brake
lever when removing the mast and front axle.
lRemoving the front axle and traction motor FB10P
lFitting bolts (M20x L65)

65mm
Tightening torque
s
4 bolts 450-550 N m
{46 - 56 kgf m}
3 bolts 1 Tightening torque

Traction motor 450-550 N m
{46 - 56 kgf m}
CAUTION
50mm
Pay attention to different bolt
Front axle lengths, when installing.
Spline MG
Apply molybdenum grease on a
part of spline.
Tightening torque
49.5-60.5 N m
: Tightening torque
{5.0 - 6.2 kgf m}
2210007
24
lRemoving the front axle and traction motor FB20P-30P
Tightening torque
65mm
450 - 550 N m
5 bolts
{46 - 56 kgf m}

65mm 1 Tightening torque
450 - 550 N m
Traction motor
{46 - 56 kgf m}
50mm
CAUTION
3 bolts
Pay attention to different bolt
Front axle lengths, when installing.
Spline MG
part of spline.
Tightening torque
49.5-60.5 N m
{5.0 - 6.2 kgf m}
: Tightening torque
2210154
11. Remove the front axle from the mast as follows. lRemoving the special cap
1. Apply wood blocks under the traction motor or front
axle.
2. Remove fitting bolts for both special caps.
Bushing
3. Move the mast back and remove the front axle from
the mast. Special cap
Fitting bolt
NOTE Be careful to not lose the bushings.
12. Remove the traction motor.

Fitting bolt
* Install the front axle in reverse order of removal. 2210131
25
2-2-2. Front axle - disassembly and reassembly

Transmission case and etc.
lDisassembling and reassembling the front axle (1)
FB10P-18P
Tightening torque
98 - 127 N m
{10 - 13 kgf m}
Support, drive
Breather, air
Case(2), mission
Oiling plug
Level plug
Mission case B
Apply THREEBOND [#1215] or
equivalent on the mating surfaces.
Case(1), mission
Drain plug
CAUTION
Before disassembling, remove the
drain plug and drain oil.
: Tightening torque
B : Apply THREEBOND
221W004E
CAUTION When OIL SEALS, O-RINGS and / or BEARINGS were removed, they
should be replaced to new ones.
26
FB20P-30P
Support, drive
Case(3)Comp., mission
Tightening torque
98 - 127 N m
{10 - 13 kgf m}
Breather, air
Mission case B
Oiling
plug Apply THREEBOND [#1215] or
equivalent on the mating surfaces.
Level plug
Case(1), mission
Drain plug
CAUTION
Before disassembling, remove the
drain plug and drain oil.
Tightening torque
98 - 127 N m
{10 - 13 kgf m}
: Tightening torque
B : Apply THREEBOND
2210008
27
Differential case and etc.

FB10P-18P 2 Tightening torque B

Apply THREEBOND [#1360K] or
equivalent and then tighten.
108-147 N m
{11-15 kgf m}
Tube(1), axle
Case(2), mission
Gear(5)
Case, gear
Case(1), mission
Shaft(1), drive
Tube(2), axle
Shaft(2), drive
: Tightening torque
B : Apply THREEBOND
N : Not reusable
221W005E
28
FB20P-30P
2 Tightening torque B
equivalent and then tighten.
108-147 N m
{11-15 kgf m}
Case, differential
Case(1), mission
Shaft, drive
Shaft, drive
: Tightening torque
B : Apply THREEBOND
N : Not reusable
2210163
29
Gears and etc.
FB10P-18P
Tightening torque
107-149 N m
{11-15 kgf m}
Case(2), mission
Gear(5)
Case, gear
Gear(4)
Case(1), mission
Tightening torque
49-69 N m
{5-7 kgf m}
Gear(3)
Gear(1)
Gear(2)
: Tightening torque
N : Not reusable
221W006E
30
FB20P-30P
Gear(4)
Case, differencial
Case(1), mission
Gear(1)
Tightening torque
176-216 N m
Gear(3)
{18-22 kgf m}
Bearing pre-load
39-59 N m
Gear(2)
{4-6 kgf m}
: Tightening torque
N : Not reusable
2210164
31
Wheel hub , drive shaft and etc.

lDisassembling and reassembling the front axle (4) FB10P/14P
Oil seal B G
Apply grease on the lip of the oil
seal, and THREEBOND [#1104]
or equivalent
lBearing nut
A Bearing pre-load
Measure at 392-686 N m
Drum, brake
position A {40-70 kgf m}
2 Tightening torque B
Hub bolt Apply THREEBOND[#1360K] or
Hub nut equivalent and tighten.
98-127 N m
[FB10P/14P]
Shaft, drive {10-13 kgf m}
Tightening torque
78-108 N m
[FB10P/14P]
{8-11 kgf m}
Tightening torque B
Apply THREEBOND[#1360K] or
equivalent and tighten.
176-235 N m
Wheel brake ass'y
[FB10P/14P]
{18-24 kgf m}
lHub nut
: Tightening torque Tightening torque (M12)

B : Apply THREEBOND 89-108 N m
G : Apply grease [FB10P/14P]
{9-11 kgf m}
N : Not reusable
221W007E
32
lDisassembling and reassembling the front axle (4) FB15-30P
Oil seal B G
Apply grease on the lip of the oil
seal, and THREEBOND [#1104] or
equivalent around it.
lBearing nut
A Bearing pre-load
O ring G
Apply grease.
Drum, brake Tightening torque B

Hub, wheel Apply THREEBOND[#1360K] or
98-127 N m
Shaft, drive [FB15P/18P]
{10-13 kgf m}
157-206 N m
[FB20P-30P]
{16-21 kgf m}
Hub bolt
Tightening torque B
Apply THREEBOND[#1360K] or
176-235 N m
[FB15P/18P]
{18-24 kgf m}
157-206 N m
[FB20P-30P]
Wheel brake ass'y {16-21 kgf m}
lHub nut

216-264 N m
[FB15P/18P]
{22-27 kgf m}
: Tightening torque Tightening torque (M18)
B : Apply THREEBOND 315-385 N m
G : Apply grease [FB20P-30P]
{32-39 kgf m}
N : Not reusable
2210155
33
2- 3. Inspection and adjustment

2-3-1. Gears - Inspection and replacement
Check point lInspection of gears
Gearing
Wear Drive shaft
Inspection of gears Scoring
Pitting
Damage of Splines
Gear(4)
Gear, differential
side
<Measures>
lIf beyond repair, replace as a set.
Gear(1) Gear, pinion
Gear(3)
Gear(2)
2210010
2-3-2. Wheel hub and hub bolt - Inspection

1. Check wheel hubs for damage and crack.
2. Check hub bolts for loosening and damage.
lInspection of wheel hub lInspection of hub bolt
Wheel hub
Hub bolt
Drive shaft
2210011 2210012
34
2- 4. Troubleshooting
2-4-1. Front axle - troubleshooting
No. Symptom Possible cause Solution
1. Poor hypoid gear (differential gear) adjustment, or
Adjust or replace
teeth wear
2. Poor hypoid gear (differential gear) bearing
Continuous Adjust or replace
adjustment, or teeth wear
1 noise while
3. Loose or out of wheel hub bearings Adjust or replace
travelling
4. Poor ring gear and shaft (differential gear and beveled
Adjust
pinion) gearing or backlash
5. Not enough gear oil Replenish
1. Out of hypoid gear (differential gear) bearings. Replace
2. Out of wheel hub bearings Replace
Abnormal
3. Out of backlash due to differential gear wear or thrust
2 noise while Replace
washer wear
travelling
4. Foreign matter in the axle housing Inspect and clean
5. Loose drive shaft or carrier ass'y bolts. Retighten
Abnormal 1. Out of backlash due to differential gear wear or thrust
Replace
noise when washer wear
3
turning 2. Broken teeth on the differential gear pinion, or pinion
corners Replace
shaft wear
Differential 1. Out of gear backlash Adjust
4
heat 2. Damaged bearing due to excess bearing preload Replace
1. Oil surface too high (level plug is at regulated value) Drain
Oil leakage 2. Oil seal wear or damage Replace
from
5 3. Poorly installed axle housing Retighten
the axle
housing 4. Poorly installed plug Retighten
5. Air breather clogged Clean or replace
Oil leakage 1. Oil seal wear or damage Replace
6 from the
wheel hub 2. Off-center rotation due to bearing wear or damage Replace
Oil leakage
7 from the 1. Oil seal wear or damage Replace
carrier
Recommended oil Model Qty of oil

FB10P - 18P 5.5
Hypoid Gear oil #90 GL-4 / GL-5
FB20P - 30P 5.0
35
3. REAR AXLE (STEERING)
3- 1. Location and name Rear axle
lMain parts of rear axle (Steering)
212E129
Pin, Rear axle Comp.,

center arm
Support, axle
Pin, king
Support, axle
Knuckle(R)
Rod Comp.(L),tie
Hun
Arm Comp.,center
Rod Comp.(R),tie
Knuckle(L)
Cap
2210013
36
3 REAR AXLE (STEERING)

stands.
lTurn the key switch off and operate hydraulic levers a few times to
3-2-1. Rear axle - removal and installation

1. Rear tyre should be removed before removing the rear
axle.
lRemoving the rear tyre
Rear tyre
lHub nut
Tightening torque
88.2 - 108 N m
{9 - 11 kgf m}
: Tightening torque 2210014
37
REAR AXLE (STEERING) 3
2. A rear axle should be supported from the lower side with

the lift etc.
3. Remove the fitting bolt of "support, axle".

4. Remove the rear axle.
lRemoving the rear axle
Support, axle
Support, axle
Rear axle
lFitting bolt
Tightening torque
87 - 107 N m
{8.9 - 10.9 kgf m}
: Tightening torque
2210015
* Installation the rear axle in reverse order of disassembly.
38
3-2-2. Rear axle - disassembly and reassembly

Knuckle hub, etc.
lDisassembling and reassembling the rear axle (1)
Shim [t0.5/1.0/2.3/3.2mm]
Clearance value : 0.1-0.7mm
Shim [t1.2/2.3/4.5mm]
Shim for adjustment the angle
(Refer to page 41.)
Oil seal MG
Apply molybdenum grease on rip.
Bearing G
Fill grease between bearing.
Nut Comp., hard lock

Tightening 21 ~ 31 N m
torque
[Convex side] {2.1 ~ 3.1 kgf m}
Tightening 73-88 N m
torque
[Concave side] {7.4-9 kgf m}
: Tightening torque
G : Apply grease A Bearing preload
Measure at A (hub 44-64 N m
N : Not reusable bolt installation
position). {4.5-6.5 kgf m}
221W009
39
Center arm tie rod, etc.

lDisassembling and reassembling the rear axle (2)
lNut, castle
Tightening torque
1 [FB10-18P]
93.1-1112.7 N m
{9.5-11.5 kgf m}
Tightening torque
[FB20-30P]
147-171.5 N m
{15-17.5 kgf m}
lNut, jam
2 Tightening torque
156.8-176.4 N m
{16-18 kgf m}
: Tightening torque Bearing G

G : Apply grease Apply grease between bearing.
N : Not reusable
2210017
40
3-2-3. Rear axle - Reassembling method and attention

<FB10P/14P/15P/18P>
1.Adjust the length of the tie rod comps (L)/(R), and set parts to dimensions
i n d i c a t e d b y * m a r k s . H o w e v e r, t h e y a r e t h e d e s i g n e d d i m e n s i o n ,
so there may be some differences depending on actual parts.
In such a case, adjust to actual dimensions of parts.
(2) Insert and adjust the shim to become the angle of sign to size of the
stopper bolt. (two places)
lReassembling the rear axle FB10P-18P
Insert shims to make the adjustment.
Shim
Axle comp., rear
*(441)
*(434)
Tie rod comp.(L) Tie rod comp.(R)

Stopper bolt
Hard lock nut
Knuckle(L) Arm comp., center
Knuckle(R)
(average effective radius)
220
Castle nut
122
Hub King pin

G.L.
760(King pin distance)
910.5(Tread)
221W010E
41
<FB20P/25P/28P>
2. Adjust the height of the stopper bolt, and then adjust the maximum rotation angle
for the part marked .
lReassembling the rear axle FB20P-28P
Axle comp., rear

0
-1

.5
78
18
.5)
(51
*476
*469
Tie rod comp.(L)
Stopper bolt Tie rod comp.(R)

Hub
Hard lock nut
Knuckle(L) Arm comp., center
Knuckle(R) 5
1
215.5
King pin
Castle nut
G.L.
941(Tread)
221W011E
42
<FB30P>
2. Adjust the height of the stopper bolt, and then adjust the maximum rotation angle
for the part marked .
lReassembling the rear axle FB30P
0 1
-
Axle comp., rear

76
Stopper bolt
18
.6)
(50
*469
*476
Tie rod comp.(L) Tie rod comp.(R)
Hub
Knuckle(L) Hard lock nut
Arm comp., center
Knuckle(R)
5
1

272.5
King pin
Castle nut
G.L.
983(Tread)
221W012E
43

3-3-1. Bushing - inspection
1.Check for wear and damage. lInspection of bushing
L(length)
[mm]
Item Standard value Wear limit
Bushing 50( D) 50(L) 50.2( D)
D(inner)
Bushing
Support, axle
2210019
3-3-2. Center arm - inspection

1.Check for crack.
lInspection of center arm
Arm Comp., center

2210020
3-3-3. Tie rod Comp. - inspection

1.Check for straightness. lInspection of tie rod Comp.
Tie rod Comp.
2210021
3-3-4. Knuckle - inspection

1.Check for crack. lInspection of knuckle
2. Check for wear on the fitting surfaces of the rear axle Clamp face
comp and the tie rod comp.

Knuckle
Clamp face 2210022
44
3-3-5. King pin - inspection

1.Check for joggling or wear on the surface that contacts lInspection of king pin
the bearing.
King pin
Bearing,
Bearing, neadle
thrust
Bearing,
neadle
2210023
3-3-6. Hub and hub bolt - inspection

1.Check hubs for damage and crack. lInspection of hub and hub bolt
2. Check hub bolts for loosening and damage.
Hub bolt
Hub
Hub nut
2210024
Tightening torque
88.2 - 108 N m
{9 - 11 kgf m}
3-3-7. Rear axle Comp. - inspection

1.Check for deformation and damage. lInspection of rear axle Comp.
Rear axle Comp.
2210025
45
3-4-1. Rear axle - troubleshooting
1. Adjustment of toe-in is not corrent. Adjust
2. Bearing for king pin is damaged. Replace
Steering is
1 3. Low air pressure of wheels Adjust
hard.
4. Lack of lubrication for rear axle and steering linkage Lubricate
5. Connection of linkage is stuck. Repair or replace
Return of 1. Steering linkage and each part of rear axle are not
Check and adjust
steering adjusted correctly.
2
wheel is
bad 2. Out of adjustment of wheel alignment Inspect and adjust
1. Incorrect air pressure of wheel Adjust
Steering 2. Difference of diameter of wheels at L.H. and R.H. Inspect and
wheel is sides replace
3 rotated un-
expectedly 3. Out of adjustment wheel alignment
Inspect and adjust
to one side. (toe-in, camber, king pin and etc.)
4. Out of adjustment or wear of wheel bearing Adjust or replace
1. Large gap between king pin and king pin bearing Replace
2. Out of adjustment or wear of wheel bearing Adjust or replace
3. Loose hub nuts Tighten
Steering
4. Heavy wear of ball joint of tie rod socket Replace
4 wheel is
swung. 5. Out of mounting of rear axel Inspect and adjust
6. Incorrect air pressure of wheel Adjust
Inspect and
7. Out of steering system
replace
46
4. TYRE
WARNING Air of the pneumatic tyre shall be discharged completely before
disassembling the rim. Failure to observe this instruction can cause
serious injury or death by explosion of wheel.
4- 1. Location, name and tyre size TYRE
4-1-1. Tyre - location and name

Tyre
Rim
(One piece)
212E130
Front FB15P-30P
Rear FB20P-28P
Rim bolt Rim nut

Washer, lock
Rim (Two pieces) Front FB10P/14P

Rear FB10P/14P/15P/18P/30P
2210133
47
TYRE 4
4-1-2. Tyre size

<Pneumatic tyre>
Applicable model Size
FB10P/14P 6.00-9-10PR
FB15P/18P 21X8-9-14PR
Front type
FB20P-28P 23X9-10-16PR
FB30P 28X9-15-12PR
FB10P-18P 5.00-8-8PR
Rear type FB20P-28P 18X7-8-14PR
FB30P 6.50-10-10PR
<No puncture tyre>

Applicable model Size
FB10P/14P 6.00-9
FB15P/18P 21X8-9
Front type
FB20P-28P 23X9-10
FB30P 28X9-15
FB10P-18P 5.00-8
Rear type FB20P-28P 18X7-8
FB30P 6.50-10
48
4 TYRE

4-2-1. Hub nut - inspection lInspection of hub nut
1. Check for damage.

2. Check for loosening.
If loose, re-tighten it.
Hub nut 212E034
4Front
89-108 N m
[FB10P/14P]
{9-11 kgf m}
216-264 N m
[FB15P/18P]
{22-27 kgf m}
315-385 N m
[FB20P-30P]
{32-39 kgf m}
4Rear
88.2-108 N m
{9-11 kgf m}
4-2-2. Rim and rim bolt - inspection lInspection of rim and rim bolt
1. Check for damage.

2. Check for loosening.
If loose, re-tighten it.
NOTE There are no rim bolts for the following models:

Front : FB15P-30P
Rear : FB20P-28P Rim
Rim bolt 212E035
4Front
68.5-78.5 N m
[FB10P/14P]
{7-8 kgf m}
4Rear
Tightening torque
[FB10P/14P/ 68.5-78.5 N m
15P/18P/30P] {7-8 kgf m}
49
TYRE 4
4-2-3. Air pressure - inspection

<Pneumatic tyre> lInspection of air pressure
lFront tyre
Air pressure: bar
Applicable model Type
(kgf/cm 2 )
FB10P/14P 6.00-9-10PR 850kPa(8.5kgf/cm 2 )
FB15P/18P 21X8-9-14PR 900kPa(9.0kgf/cm 2 )
FB20P-28P 23X9-10-16PR 900kPa(9.0kgf/cm 2 )
FB30P 23X9-15-12PR 800kPa(8.0kgf/cm 2 )
lRear tyre 212T001
Air pressure: bar

Applicable model Type
(kgf/cm 2 )
FB15P/18P 5.00-8-8PR 850kPa(8.5kgf/cm 2 )
FB20P-28P 18X7-8-14PR 900kPa(9.0kgf/cm 2 )
FB30P 6.50-10-10PR 700kPa(7.0kgf/cm 2 )
CAUTION Check for the air pressure when the tyres are cool.
4-2-4. Tyre - visual inspection and replacement

1. Check for cracks, damage, and wear.
Replace the tyre if there are large cracks or damages
on the side.
Replace the tyre if there is worn to the bottom of the
tread.
Replace the tyre if there is worn to the wear-limit mark.
lCracks or damages lTyre grooves l wearing limit mark
50
4 TYRE
4-3-1. Tyre - troubleshooting
1. Incorrect air pressure of tyre Adjust
2. Incorrect preload of wheel bearing Adjust
1 Abnormal wear of tyres
3. Different type of wheel or tyre at L.H. and . Use the same
R.H. sides ones.
51
5. STEERING
5- 1. Location and name STEERING
lMain parts of steering
Wheel ass'y, steering
212E131
Column ass'y
Joint
Box ass'y, steering Potentiometer
Arm, pitman
Actuator ass'y
Motor ass'y, EPS
Link ass'y, drag
2210026
52
5 STEERING

CAUTION Apply wheel chocks to tyres to prevent the truck from moving.
l
Record places of lead wire connections before disassembling.
l
Be sure to disconnect the battery plug.
l
When disconnecting hydraulic pipes, cap them to prevent dust from
l
5-2-1. Steering linkage - removal and installation

1. The following parts should be removed before removing
the steering linkage.
1. Remove the "Wheel ass'y, steering".

2. Remove display panels and front covers as shown in the
following illustration.
lRemoving the steering wheel ass'y, display panels and front covers
Panel, display(1)
Wheel ass'y, steering
Panel, display(3)
Panel, display(2)
Cover(3), front
Cover(4), front
Cover(1), front
Cover(2), front
Cover(7), front
2210027
53
STEERING 5
3. Disconnect the harness connector for the accelerator, and remove the
floor plate.
lRemoving the floor plate
Mat, floor
Floor plate
Harness connector for the accelerator
2210028
2. Refer to "5-2-2. Steering linkage - disassembly and reassembly" on page 55

for removal of the steering linkage.
* Install the steering linkage in reverse order of removal.
54
5 STEERING
5-2-2. Steering linkage - disassembly and reassembly

Column ass'y, joint, steering box and etc.
lDisassembling and reassembling the steering linkage (1)
Plunger & brush G

Apply grease on the plunger
contact surface and the brush
contact surface.
Knob
Bracket, pedal
Wheel, steering
Joint
Column ass'y
1 Tightening torque
90 - 110 N m
{9 - 11 kgf m}
Box ass'y, steering
CAUTION
Refer to "5-3-4. Torque sensor
neutral - check and adjustment"
on page 58 for adjustment of the
potentiometer.
: Tightening torque Shim [t0.2/1.0 mm]

G : Apply grease To adjust the potentiometer.
N : Not reusable
2210029
55
STEERING 5
Drag link and actuator ass'y

lDisassembling and reassembling the steering linkage (2)
Tightening torque
160 - 200 N m
{16 - 20 kgf m}
Tightening torque
130 - 160 N m
{13 - 16 kgf m}
Tightening torque
50 - 65 N m
{5 - 6.5 kgf m}
Disconnect the harness connectors

for EPS motor.
Tightening torque
19 - 30 N m
{1.9 - 3.1 kgf m}
Spline G
Apply grease on a part of spline.
Tightening torque
147 - 171.5 N m
{15 - 17.5 kgf m}
Tightening torque
200 N m
{20 kgf m}
Threads R
After cleaning with grease, apply
LOCTITE [#262] or equivalent on
threads.
Tightening torque
160 - 200 N m
{16 - 20 kgf m}
Tightening torque
: Tightening torque 220 - 260 N m
G : Apply grease
{22 - 26 kgf m}
R : Apply LOCTITE
2210030
56
5-3-1. Joint - inspection and replacement
1. Check for abnormal plays at marked parts with arrows. lInspection of joint
If abnormal, replace it.
2. Check for crack at marked parts with stars.
If cracked, replace it.
212E044
5-3-2. Knob - inspection and replacement

1. Check for abnormal play and/or crack. lInspection of knob
If plays abnormally or cracked, replace it.
152T005
5-3-3. Steering wheel - inspection and replacement

1. Check for crack lInspection of steering wheel
If cracked, replace it.
2 After turning off Key switch, measure playing at the 50-100 mm
steering knob and check if it is within 50 - 100 mm.
212E045
57
5-3-4. Torque sensor neutral - check and adjustment
<Checking procedure>
1. Turn the key switch off.
lNeutral check of torque sensor
2. Jack up rear wheels from the ground.
EPS
3. Remove a rear cover. controller
(See "10a-2-1. control unit - removal" on page 154.)
4. Put a clamp meter to a wire [yellow] or [green]
between EPS controller and EPS motor [DC range].
yellow
green
5. Turn the key switch on and measure the indication
at the clamp meter without steering operation. (= at
neutral steer) If the indication shows 0A, it is normal.
6. If any current is flown, adjust the potentiometer by the Clamp meter
following procedure.
black
red
EPS motor
461E133
<Adjusting procedure>
1. Turn the key switch off.
2. Remove the battery plug.
3. Remove the water proof connector.
3P water proof connector (Tab side)
Potentiometer
EPS sensor ASS'Y
221W088
58
5 STEERING
4. Check the resistance between the following pins (tab side).
[Standard value]
l Between (1) pin (orange) and (3) pin (black and red) = Approx. 5k ....... A
l Between (1) pin (orange) and (2) pin (green and red) = Approx. 2.5k .... B Make to the same
l Between (2) pin (green and red) and (3) pin (black and red) = Approx. 2.5k . ..... C value.
(1) Orange (1) Blue

From EP S
sensor (2) Green/Red Rece- (2) Green/Blue To EPS
Tab
(potentiometer) (3) Black/Red ptacle (3) White cont rolle r
3P water resistant connector

234W026E
5. Adjust for the resistance of above-mentioned B and C djustment of torque sensor neutral
lA
to reach the same value by Shim.
NOTE Resistance is somewhat different depending on

the kind of the tester.
6. Check the current of the EPS motor doesn't flow at a

neutral position of the steering according to <Checking
procedure> of last page.
Potentiometer
Shim
2210031
59
STEERING 5
5-3-5. Checking by voltage

<Checking by voltage>
Neutral adjustment of the potentiometer can be checked
by its output voltage.
1) Turn the key switch off.
2) Disconnect the connector of the torque sensor and put the
adapter for measuring voltage.
NOTE As the connector of the torque sensor is

waterproof type, it is impossible to put the tester
probe. Make an adapter by using the same type
adapter.
3) Check the voltage at [2] pin [Green/Red or Green/Blue 1]

of the adapter.
4) Turn the key switch on and operate the steering wheel
from right side end to left side end, then check the voltage.
The following values are the standard.
Right side end 0.6 1.8V

Neutral 2.4 2.6V
Left side end 3.2 4.4V
From EPS [1] Orange [1] Blue 3

[2] Green/Red To EPS
sensor Tab [2] Green/Blue 1
Rece controller
(potentiometer) [3] Black/Red [3] White
3P water proof type connector
[1] pin
Rece [2] pin Tab Adaptor
[3] pin
Tab
+ probe - probe
to [2] pin to [3] pin
(output) (negative)
461E134
60
5 STEERING
5-3-6. Actuator ass'y - inspection and adjustment

lInspection of actuator ass'y
Wire clamp
Socket
Actuator Bend the socket edge side along
the lock washer after tightening the
nut.
Threads L
After cleaning greases, apply
LOCTITE [#262] or equivalent on
threads.
L : Apply LOCTITE 221W0501
A B (Stroke)
B
427 C
D E F
40
25
A
40
H
G (Size when the
G most retracting)
Steering end Steering end
(Left) (Right)
Steering
center
Center axis
of motor
4- 11
80
45
View A 221W0502
A B C D E F G H
FB10P~18P 700 179 91 182 91 88 539 21
FB20P~28P 678 196 73.5 177.5 98 98 532 31.5
FB30P 683 193 76 180 96 97 534 31
CAUTION Set the position of the steering center properly when the actuator is replaced.
Otherwise the ball screw shaft might bend at the steering end position due to
excessive pressure.
61
STEERING 5
5-4-1. Steering linkage - troubleshooting
Symptom Problem
The main contractor is not 1 Main contactor

turned on. 2 EPS controller
With the key switch ON and the parking brake is released.
1 EPS controller
The main contactor trips
2 Torque sensor
immediately.
3 EPS motor
The main contactor trips 1 EPS controller

when the steering wheel is 2 Torque sensor
turned. 3 EPS motor
The steering wheel

The main contactor comes 1 EPS controller
does not turn! on, but there is no power 2 Torque sensor
steering. 3 EPS motor
1 Actuator
There is power steering, but 2 EPS controller
it is abnormally heavy. 3 EPS motor
4 Torque sensor
1 EPS motor
There is power steering, but 2 Actuator
it feels like it is sticking. 3 EPS controller
4 Torque sensor
1 EPS controller
2 Torque sensor
The steering wheel vibrates 3 Poor connector and/or
and can not be controlled. harness connection in EPS
controller, EPS motor, or
torque sensor
The steering wheel Self-steering (The steering 1 EPS controller

turns, but ... wheel operates by itself.) 2 Torque sensor
1 EPS controller
The motor becomes 2 Torque sensor
Other
abnormally hot. 3 Actuator
4 EPS motor
62
6. BRAKE
6- 1. Location and name
6-1-1. Foot brake linkage - main part names FOOT BRAKE LINKAGE
lMain parts of foot brake linkage
212E132
Tank comp., oil
Pin
Pedal, brake
Cylinder ass'y, master
2210032
63
BRAKE 6
6-1-2. Parking brake linkage - main part names PARKING BRAKE LINKAGE
lMain parts of parking brake linkage
2210182
Grip ass'y
Release rod ass'y
Bracket, ass'y parking brake
Lever, ass'y
Plate, lock
Rod ass'y, adjust
2210033
64
6 BRAKE

CAUTION lLift or jack up the forklift truck and support it
with safety blocks or rigid stands.
lApply wheel chocks to rear tyres to prevent
the truck from moving.
6-2-1. Wheel brake - removal and installation

the wheel brake.
1. Remove hub nuts to remove the front tyre.

2. Remove fitting nuts (*1) for the drive shaft.
3. Remove the drive shaft.
4. Remove bearing nuts to remove the wheel hub and
brake drum.
2. Remove fitting bolts(*2) to remove the wheel brake ass'y.
* Install the wheel brake in reverse order of removal.
65
BRAKE 6
lRemoving the wheel brake ass'y FB10P/14P

lInner diameter of brake drum
Model Inner dia ( D)
FB10P/14P 10-inch (254mm)
lBearing nut
A Bearing pre-load
Measure at a 392-686 N m
hub bolt A {40-70 kgf m}
Drum, brake
Hub bolt
Hub, wheel
Shaft, drive
lFitting nut (*1)

Tightening torque
78-108 N m
[FB10P/14P]
{8-11 kgf m}
lFitting bolt (*2)

Tightening torque B
176-235 N m
Wheel brake ass'y
[FB10P/14P]
{18-24 kgf m}
lHub nut
89-108 N m
[FB10P/14P]
{9-11 kgf m}
: Tightening torque
B : Apply THREEBOND
N : Not reusable
221W008E
66
6 BRAKE
lRemoving the wheel brake ass'y FB15P-30P

Model Inner dia. ( D)
FB15P/18P 10-inch (254mm)
FB20P-28P 11-inch (279.4mm)
FB30P 310mm
lBearing nut
A Bearing pre-load
D
Wheel hub
Drum, brake
Drive shaft
Front tyre
lFitting bolt (*2)

Tightening torque B
176-235 N m
[FB15P/18P]
{18-24 kgf m}
157-206 N m
[FB20P-30P]
{16-21 kgf m}
Wheel brake ass'y
lHub nut
216-264 N m
[FB15P/18P]
{22-27 kgf m}
315-385 N m
[FB20P-30P]
{32-39 kgf m}
: Tightening torque
B : Apply THREEBOND
N : Not reusable
2210156
67
BRAKE 6
6-2-2. Wheel brake - disassembly and reassembly

1. Disassemble the wheel brake ass'y as shown in the lSpecial tools
following illustration.
NOTE When disassembling and assembling the wheel (1)221-4001

brake, use the special tools for easy work.
For removing and installing the
(1) 221-4001
shoe hold down spring
(2) 221-4002 For removing the return spring (2)221-4002
(3) 221-4003 For installing the return spring
1. Remove the return spring with special tool 221-4402.

2. Remove the shoe hold down spring with special tool
221-4001.
(3)221-4003
* Use the procedure above to install and remove the
shoe and lining ass'y and other parts.
3. Remove fitting bolts for the wheel cylinder ass'y.
4. Remove inner parts.
212E041
lDisassembling and reassembling the wheel brake ass'y

Link
Boots Cylinder body
Piston
Piston cup
Breather screw
Spring Breather cap 3. Fitting bolt
Wheel cylinder ass'y
Shoe and lining ass'y
Shoe hold down

spring
2.
1.
Shoe and lining ass'y

Adjustor ass'y
Return spring
2210035
* Reassemble the wheel brake in reverse order of disassembly.

68
6 BRAKE

CAUTION The wheel brake is very important part for safety.
It shall be replaced if any damages are found.
6-3-1. Brake drum - inspection, repair and replacement

1. Check the inner surface of the brake drum for streaks
(damage), wear, and cracks.
lInspection of brake drum
CAUTION If there are streaks or partial wear, perform
repairs or replacement within the limits shown
below. Inner dia.
( D)
Applicable model Specific dimension( D) Repair limit( D)
FB10P-18P 10-inch(254 mm) 256 mm
FB20P-28P 11-inch(279.4 mm) 281.4 mm Brake drum
FB30P (310 mm) 312 mm 2210036
6-3-2. Shoe & lining - inspection and replacement

1. Measure the thickness of the lining. lMeasuring thickness of lining
If the part is worn to 1.5 mm or less, replace it.
CAUTION Measure the area with the most wear.
2. Check for stains, burning, and deterioration.

If there are stains, burning, or deterioration, replace
the part.
152T061
3. Check for cracks and damage.

If there is a burn, repair it. lInspection of shoe & lining
If cracked or damaged, replace it. Lining
If the part is worn

to 1.5 mm or less,
replace it. 212E052
69
BRAKE 6
6-3-3. Adjustor ass'y - inspection and replacement

1. Check the teeth of the adjustor ass'y for wear and lInspection of adjustor ass'y
deformation.
Teeth
CAUTION When the adjustor ass'y can not be turned

by hand or resistance is felt when turning it,
replace it with a new one.
212E053
6-3-4. Wheel cylinder ass'y - inspection and replacement
CAUTION Before performing this inspection, clean the part lInspection of wheel cylinder
with a volatile cleaning grease, and then use ass'y
pressurized air to completely remove the grease.
Fitting surface of the
breather screw
1. Check the inside of the "Cylinder body" and the fitting
surface of the breather screw for damage or rust.
2. Check for damage and deterioration on the inner parts. Piston
Piston
Breather screw
Cylinder body
2210056
CAUTION Replace the cylinder kit at every lReplacing the cylinder kit
disassembling or annually.
Cylinder kit
2210142
70
6 BRAKE
6-3-5. Master cylinder ass'y - inspection and replacement

CAUTION Before performing this inspection, clean the part lInspection of master cylinder ass'y
with a volatile cleaning grease, and then use
pressurized air to completely remove the grease.
1. Check the inside of the "Cylinder body" for damage or

rust.
2. Check for damage and deterioration on the inner parts.
Piston
ass'y
Cylinder
body
212E055
CAUTION Replace the repair kit at every disassembling or lReplacing the repair kit
annually.
Repair kit
2210143
6-3-6. Brake pedal - inspection

(1)Check any cracks or damages at welded parts. lInspection of brake pedal
(2)Check the bushing for wear.
Pedal, brake Inner dia.
<Wear limit of bushing> ( d)
Bushing
Specific dimension
Wear limit Bushing
(inner dia )
20.0 mm 20.15 mm
(3)Check the "Pin, brake" for abnormal wearing.
<Wear limit of pin>

Outer dia.( D)
Specific dimension
Wear limit
(outer dia )
20.0 mm 19.9 mm Pin 212E056
71
BRAKE 6
6-3-7. Parking lever - inspection and adjustment
1. Inspect for damage or deformation on the lever. lInspection of parking lever
2. Check if the brake is applied when the lever is pulled.

If the brake is not applied securely, make the following Adjusting bolt Pull the lever.
adjustments.
1. Leave the lever in its pulled back position.

2. Tighten the adjusting bolt. (Turn it clockwise.)
3. Push the lever forward to release the brake.
4. Check if the forklift travels without dragging the brake.
5. Perform adjustment again if the brake is not released
completely when the parking brake lever is released.
2210125
6-3-8. Brake linkage - adjustment

1. Use the adjusting bolt to adjust the height from the lAdjusting the brake pedal height
floor plate to the brake pedal to within the specific
dimension shown below.
Applicable model Specific dimension( D) Adjusting bolt

FB10P-28P 120-130 mm
Brake pedal
FB30P 130-140 mm
Play should be
5mm or less.
Floor plate A
221W014E
2. Use the push rod of the master cylinder to adjust the lAdjusting the brake pedal play
brake pedal play to the specific dimension shown
below, or less. Brake pedal
Specific dimension About 5 mm

Push rod
Adjust
2210147
72
6 BRAKE
3. Use the microswitch fitting nut to adjust the ON/OFF lAdjusting the microswitch
position to within the specific dimension shown below. position (1)
Specific dimension 10-20 mm

Microswitch
Fitting nut
The on and off positions

should be 10 mm to
20 mm apart.
2210183
4. When the brake pedal is pushed down all the way, lAdjusting the microswitch
adjust the switch roller so that it is pushed down by an position (2)
amount within the specific dimension shown below.
Specific dimension 3mm-7mm Switch roller

Adjust the switch
roller so that it is
pushed down
between 3 mm
and 7 mm.
Push down all

the way.
221W003E
73
BRAKE 6
6-3-9. Brake air bleeding

CAUTION After assembling the master cylinder, wheel
cylinder, or brake piping, be sure to bleed the
air.
Wheel cylinder air bleeding

<Air bleeding procedure> lAir bleeding procedure (1)
1. Remove the breather cap on the wheel cylinder and

connect a drain hose to the breather screw. The Container
opposite end of the drain hose should be connected to Breather screw
a container to receive the brake fluid.
2. Depress and hold the brake pedal several times.
Drain hose
Breather cap
152E115
3. Loosen the breather screw to bleed the brake fluid

lAir bleeding procedure (2)
and air. Tighten the screw again before the flow stops.
4. Repeat steps 2. and 3. until there are no longer any
Loosen
air bubbles in the discharged brake oil.
CAUTION Keep the brake fluid level in the tank by refilling. Tighten
5. After discharging the air, tighten the breather screw

securely. Drain hose
Breather screw
6. Make sure no brake fluid has leaked out. Wheel cylinder 152E116
CAUTION Use the specified brake fluid. Do not mix lBrake fluid reserve tank
different grades of fluid.
Brake fluid tank

Recommended brake fluid.
DOT 3 or DOT 4
221W0601
74
6 BRAKE
Master cylinder air bleeding

<Preparation for air bleeding>
1. Remove the original push rod from the master
cylinder.
2. Loosen the bolt to adjust the height of the pedal.
3. Remove the brake microswitch. lAir discharging procedure (1)
4. Insert a special rod into the master cylinder and hang Fit into the link hole
Brake pedal
it on the link hole of the brake pedal.
NOTE l If the piston of the master cylinder is not Special rod

pushed until at taching to the bot tom of
the cylinder, air in the cylinder cannot be
completely discharged.
It is not possible to push until attaching to
the bottom of the cylinder with a standard
push rod, use a special rod longer than the Dimensions of special rod
standard.
5
It is also possible to insert a long cross slot
6
l
20
80 20 (25)
screwdriver in the master cylinder instead of a
125
special rod and to move the piston.
H o w e v e r, i t i s n e c e s s a r y t o p u s h b y 244W041E
considerably strong power.
<Air discharging procedure> lAir discharging procedure (2)

While pushing down
1. Tighten the air discharging valve of the wheel cylinder. the master cylinder, the piston of
loosen the air vent valve.
2. Fill the brake oil in the tank.
CAUTION l The brake oil must be recommended oil.

Special rod
Do not mix it with the other articles.
l Do not feed the brake oil forcefully. Push
3. Loosen the discharging valve of master cylinder while Loosen

pushing the piston of the master cylinder.
4. Return the piston completely after tightening the air
Bleeding screw
discharging valve with pistons pushed into interiors most.
While pushing the piston to the bottom,
5. Air in the master cylinder comes off the air discharging tighten the screw and move the piston
valve completely and repeats the work of 3 and 4 until back to its original position.
only the brake oil comes to go out.

Special rod
CAUTION Do not make the brake oil in the lubricating oil
Push to
tank run short during discharging air. the bottom
6. Check there is no oil leak. Tighten
Bleeding screw
244W042E
75
BRAKE 6
6-4-1. Brake - troubleshooting
1. Oil leakage from piston cup of master cylinder Replace
2. Air is mixed into brake oil due to shortage of oil Refill oil and bleed air
Ineffective 3. Oil leakage from cup of wheel cylinder Replace

1 braking 4. Air is mixed in brake pipings Bleed air
force 5. Wear of linings or uneven contact with brake drum Inspect and replace
6. Adhesion of oil on lining or brake drum Clean or replace
7. Out of adjustment of brake Adjust
1. Lining is grazed or adhesion of oil on lining Repair or replace
2. Backing plate is transformed or fitting bolts are loose Inspect and retighten
Brake 3. Brake shoe is transformed or badly mounted Replair or replace
2
squeaks 4. Lining is badly worn Relpace
5. Wheel bearing is loosen. Inspect and retighten
6. Anchor pin of backing plate is worn or transformed Replace
Adjust to appropriate
1. Unequal air pressure of tires at R.H and L.H sides
pressure
3. Lining is grazed or unequally contacted with brake drum. Repair or replace
Braking 4. Lining is worn. Replace
3 only at one
5. Wheel cylinder is malfunctioned. Replace
side
6. Backing plate is transformed or badly mounted. Replace or retighten
7. Brake drum is eccentrically machined or mounted. Repair or replace
8. Brake piping is clogged. Clean or replace
9. Wheel bearing is loose. Inspect and adjust
1. No play of brake pedal Adjust
2. Wheel cylinder is malfunctioned. Replace
3. Master cylinder is malfunctioned or hole for oil flow is
Repair or replace
clogged.
Brake
4 4. Return spring in brake ass'y is damaged. Replace
drags
5. Parking brake is not fully released or not adjusted
Adjust
correctly
6. Brake piping is clogged. Clean or replace
7. Wheel bearing is not mounted correctly. Adjust
Pedal 2. Air is mixed in brake pipes. Bleed
5 stroke is 3. Oil leakage from brake pipings or shortage of brake Fill brake oil and
too large oil. bleed air
4. Bad adjustment of brake pedal Adjust
1. Bad installation of parking cable Adjust
Ineffective 2. Wear of brake linings Replace
6 parking
brake 3. Out of adjustment of brake Adjust
4. Out of adjustment of brake lever Adjust
76
7. HYDRAULIC SYSTEM
7- 1. Oil pipimng circuit HYDRAULIC SYSTEM
lIGBT and FET control

Tilt cylinder
Control valve
A1 B1
Lift cylinder
Tilt
2210174
Fuse valve
A2
X
Flow control valve X
Lift
Relief pressure
Tilt cylinder
M
Oil tank 2210141E
lCAN-BUS control
Control valve
A2
Lift cylinder
A1
B1
P T
Tilt cylinder M
Oil tank 221W0703E
Applicable model Relief pressure

FB10P/14P/15P 13.7MPa(140kgf/cm2)
FB18P/20P 15.7MPa(160kgf/cm2)
FB25P/28P/30P 17.2MPa(175kgf/cm2)
47a. Hydraulic pump.................................................................................. 78
47b. Oil tank and oil piping....................................................................... 82
47c. Control valve...................................................................................... 86
47d. Cylinder.............................................................................................. 95
77
7a. HYDRAULIC PUMP
7a- 1. Location and name HYDRAULIC PUMP
lMain parts of hydraulic pump
Hydraulic pump
Hydraulic motor
2210170
Cushion
7a
Bracket, motor
7b
7c
Tightening torque
7d
8.8 - 10.8 N m
{0.9 - 1.1 kgf m}
: Tightening torque
221W083E
<Hydraulic pump type>

Applicable model Type Displacement (cm 3 )
FB10P-18P TMG1-17 18.0
FB20P-18P
TMG1-23 24.5
FB10P-18P-U
FB30P
TMG1-27 28.8
FB20P-25P-U
78
7a- 2. Disassembly and reassembly
CAUTION Turn the key switch off and operate hydraulic levers a few times to release high
l
pressure in the hydraulic piping before disconnecting hydraulic hoses and pipes.
Before disconnecting hydraulic connections, release internal pressure to
l
prevent from splashing oil.Refer the CAUTION on the page 4 for the procedure.
When disconnecting hydraulic pipes, cap them to prevent dust from entering
l
into hydraulic components and pipes.
l
7a-2-1. Hydraulic pump - removal and installation

1. Remove the "cover(R), side".
2. Remove the high pressure hose and low pressure hose.
3. Remove fitting bolts(*1) to remove the hydraulic pump.
4. Remove the elbow and connector comp.
CAUTION Do not disassemble thehydraulic pump.
When damaged, replace the whole pump assembly.
lFitting bolt(*1)
Tightening torque
Elbow Hose clip
High pressure
19.6 - 24.5 N m
Connector comp.
hose Low pressure {2.0 - 2.5 kgf m}
hose
Spline MG
Hydraulic motor
part of spline.
Hydraulic pump
Tightening torque
29.4 - 39.2 N m
{3 - 4kgf m}
: Tightening torque
MG : Apply molybdenum grease Cover(R), side
N : Not reusable
2210044
* Install the hydraulic pump in reverse order of removal.

79
7a- 3. Inspection and adjustment
7a-3-1. Hydraulic pump - inspection
lInstall the hydraulic pump on a truck and check the
function by actual lift speed.
CAUTION Measure Lift speed after raising the temperature

of Hydraulic oil by operating.
<Specific lift speed> [mm/sec]

STD (simplex) mast M (triplex) mast PFL (duplex) mast
Model
Laden Unladen Laden Unladen Laden Unladen
FB10P 370 540 360 520 330 470
FB14P 340 540 330 520 300 470
FB15P 320 540 310 520 290 470
FB18P 310 540 300 520 270 470
FB20P 280 540 260 430 240 390
FB25P 260 470 240 430 220 390
FB28P 250 470 230 390 210 390
FB30P 320 410 330 520 300 520
FB10P-U 470 550 450 620 410 560
FB14P-U 440 650 420 620 380 560
FB15P-U 420 650 400 620 370 560
FB18P-U 380 650 360 620 330 560
FB20P-U 360 600 330 550 300 500
FB25P-U 340 600 310 550 280 500
80
7a- 4. Troubleshooting
7a-4-1. Hydraulic pump - troubleshooting

No oil is 1. Shortage of hydraulic oil Replenish
1 pumped
out. 2. Clogging of the suction hose or the suction filter Inspect and clean
1. Damage of the oil seal Replace
2. Damage of the gasket (O-ring) Replace
2 Oil leakage
3. No good tightening or damage of the cover and the Retighten or
body, or fitting surface is worn or damaged. replace
1. Wear of the bearing, gear and body Replace
2. Mixture of air
l Shortage of hydraulic oil Replenish
Pressure is
3 l Air mixed from the suction hose connection Retighten
not raised.
l Damage of the seal kit (oil seal, O-ring) Replace
3. No good adjustment of the relief pressure of the
Adjust
control valve
1. Choked in the suction hose Correct or replace
2. Clogging of the suction filter Clean
3. Air mixed from the suction hose connection Retighten
Abnormal 4. Air mixed from the oil seal Replace
4
noise Withdraw air or
5. Air in the hydraulic oil
replace
6. Shortage of the hydraulic oil Replenish
7. High temperature or viscosity of hydraulic oil Replace
1. Contaminated oil Replace
High oil 2. High viscosity of hydraulic oil Replace
5
temperature Observe
3. Overwork
specification
No rotation 1. Failure or no good adjustment of the valve
Replace or Adjust
6 of hydraulic microswitch
motor 2. Blow out of the hydraulic fuse Replace
81
7b. OIL TANK AND OIL PIPING
7b- 1. Location and name
7b-1-1. Plastic oil tank - main part names OIL TANK
lMain parts of oil tank Cap, oil tank FB10P-18P(STD)
Cover, tank
Gasket
2210171
Band comp., tank
Filter,
return
Hose, LP
7b
Bracket(1), tank
Plug Tank comp., oil
221W015E
7b-1-2. Iron oil tank - main part names

lMain parts of oil tank FB10P-18P(CS/FCS)
Cover, tank
Gauge, level FB20P-30P(STD/CS/FCS)
Gasket
Filter, suction
Filter, return
Tank comp., oil
Plug
2210046
82
7b OIL TANK AND OIL PIPING
7b- 2. Disassembly and reasembly

7b-2-1. Oil tank - precautions
lPay attention to the following when disassembling and/or assembling the oil tank.
l
Lower forks to the ground before draining hydraulic oil.
l
When disconnecting hydraulic pipes, cap them to prevent dust from entering
l
into hydraulic components and pipes.
Wrap the seal tape on the thread of oil filters and the plug. Make sure to tighten
l
them securely when installing.
Be sure to disconnect the battery plug before starting to disassemble.
l
7b-2-2. Oil piping replacement - precautions

lPay attention to the following on replacing and fitting when the hoses are abnormal.
NOTE Wrap the seal tape on the thread of the connector of hoses before connection.
CAUTION Use required rated hoses to keep enough strength.

l
Unexpected force may be applied by operating pressure.
152E125
lDo not fit short hoses in the length.

Hose might be damaged due to sharp bending.
152E126
Do not fit a hose with twisting. Make sure that the hose is not twisted by operation.
l
Twisting can be found by the line of letters marked on a hose.

Letters Letters
152E127
83
OIL TANK AND OIL PIPING 7b
7b- 3. Inspection and adjustment

7b-3-1. Oil - inspection
Pick some hydraulic oil from the hydraulic tank and
l
compare with new oil to check.
<Specific oil conditions>

Appearance Smell Conditions Countermeasure
Transparent. Color is almost
Normal Normal No need to change
same as new one.
Check viscosity.
Different oil may be
Transparent but color is thin. Normal If normal, it is
mixed.
usable.
Color is changed to milky Air and/or water are Separate water.
Normal
white. mixed. Then, it is usable.
Color is changed to dark
Bad Oxidized Exchange.
brown.
Transparent but with small Foreign article is Filter it. Then, it is
Good
black dusts. mixed. usable.
7b-3-2. Recommended oil and quantity

<Recommended oil>
Specification Recommended oil
Standard Shell : Tellus 32 (ISO VG 32)
CS/FCS Shell : Tellus T15 (ISO VG 15)
84
7b OIL TANK AND OIL PIPING
<Oil quantity> lChecking the oil level
CAUTION Keep the oil level within "H" and "L" marks on
l Cap, oil tank
the level gauge.

Before checking oil level, lower the fork on the
l
flat ground.
H livel
<Oil quantity in oil tank> [L] L livel
Quantity [Check the actual oil level by the

Applicable model gauge.] (Liter)
"H" level "L" level
FB-10P-18P 22.6 19.5
FB20P-28P 26 23
FB30P 29 26
NOTE Oils in pipings and cylinders (approx. 5-10L) is

not included in the quantity which are shown
above.
221W016E
7b-3-3. Oil tank and filters - cleaning and check

1. Clean with compressed air and check the filter for
clogging and damage.
If the filter is clogged or damaged, replace it.
2. Remove any dart or foreign material from the bottom

of the oil tank.
7b- 4. Troubleshooting
7b-4-1. Oil tank - troubleshooting
No. Symptom Problem Solution
Inspect any damages on
l
hoses.
1 Bubbled Air is mixed.
Re-tighten of the hose
l
clamp.
Air and/or water are mixed.
Color of oil is
2 Oxidized or contaminated with foreign Change oil
changed.
articles.
85
7c. CONTROL VALVE
7c- 1. Location and name CONTROL VALVE
lMain parts of the valve linkage and control valve

(2 spools)
CS/FCS/RP/DRP
Microswitch
Shaft, valve lever

2210172
Bracket, lever
Knob
Knob and lever B

Lever comp., valve
Apply THREEBOND[#1530] or
7c
equivalent to bond the knob to the
lever.
1 Boots switch B
Link Apply THREEBOND[#1521] or
equivalent to bond the switch to
the knob.
l IGBT and FET control

Control valve
Relief valve
Wiper
O ring O ring
O ring
Wiper
Plate seal
Seat, spring
CAN-BUS control
Valve ass'y, control Spring
Solenoid coil Seat, spring

(Lift lock coil for OIS)
Cap
B : Apply THREEBOND
221W0704E
86
7c CONTROLVALVE
lMain parts of the valve linkage and control valve

(3 spools)
CS/FCS/RP/DRP
1 Boots switch B
equivalent to bond the switch to
the knob.
Microswitch
Knob
Shaft, valve lever
Bracket, lever
Lever comp., valve
Spacer B
If the valve lever moves sideways,
add a spacer.
Link
Knob and lever B
equivalent to bond the knob to the
lever.

Control valve
Relief valve
Wiper
O ring O ring
O ring
CAN-BUS control
Valve ass'y, control Wiper
Plate seal
Solenoid coil
(Lift lock coil for OIS) Seat, spring
Spring
Seat, spring
Cap
B : Apply THREEBOND
221W0705E
87
CONTROLVALVE 7c
7c- 2. Disassembly and reassembly

stands.
7c-2-1. Control valve - removal and installation

the control valve.
1. Remove front covers as shown in the following illustration.
lRemoving the front cover
Cover(4), front
Cap, lever
Cover(1), front
Cover(7), front
* This illustration shows the control valve for 2 spools.

2210050
88
7c CONTROLVALVE
2. Disconnect hydraulic pipes and hoses as shown in the following illustration.
CAUTION Turn the key switch off and operate hydraulic levers a few times to

Disconnecting the hydraulic pipe and hose
Plug
N Connector comp.
N
Low pressure hose(oil tank)
High pressure hose Pipe(2)comp.,tilt

N (high pressure)
(mast piping) N
High pressure hose(hydraulic pump)

Pipe(2)comp.,tilt(high pressure)
N : Not reusable * This illustration shows the control valve for 2 spools.
2210051
l CAN-BUS control
Disconnecting the hydraulic pipe and hose
NOTE
Incase of solenoid coil trouble,
loosen the nut and bolt for
lowering the mast.
Connector comp.
N
Low pressure hose(oil tank)
Solenoid coil
(Lift lock coil for OIS) N
Pipe(2)comp.,tilt
N N (high pressure)
High pressure hose
(mast piping)
N
High pressure hose(hydraulic pump)

Transmitter,
pressure Pipe(2)comp.,tilt
(Load sensor) (high pressure)
* This illustration shows the control valve for 2 spools.

N : Not reusable 221W0706
3. Remove snap pins and valve pins to remove the control valve linkage.
NOTE Do not touch the terminals of the pressure transmitter (load sensor) by dry hand.
89
CONTROLVALVE 7c
2. Remove fitting bolts(*1) remove the control valve.

lRemoving the valve linkage
Shaft, valve lever
Lever comp., valve
Fitting bolt(*1)
Remove the
snap pin.
Link
Valve Snap pin [3-spools]

pin
1 Bushing G
Apply a spray or grease.
G : Apply grease
Control valve 2210052
* Install the control valve in reverse order of removal.
90
7c CONTROLVALVE
7c-2-2. Inner kit of control valve - replacement

1. Replacing the inner kit of Control valve.
1. Remove CAP, WIPER and RELIEF VALVE.
2. Pull out PLUNGER.
3. Replace the inner kit (WIPER and O RING).
Replacing the inner kit
Relief valve
Wiper
O ring
O ring [3 spools]
Plunger
O ring
Wiper
Plate seal
Seat, spring
Spring
Seat, spring
N : Not reusable Cap

221W091E
2. Replacing the Relief valve and O RING as follows.

1. When replacing, tighten it with the following torque.
2. After completing, measure the relief pressure.
(See the next page for measuring procedure.)
Replacing the relief valve
Tightening torque
39.2 - 44.1 N m
{4 - 5 kgf m}
: Tightening torque
N : Not reusable
221W092
91
CONTROLVALVE 7c
7c- 3. Inspection and adjustment

7c-3-1. Relief pressure - measurement
CAUTION
2
Use 20MPa {200kgf/cm } pressure gauge.
1. Turn off the key switch. l IGBT and FET control

Measurement of relief pressure
2. Release pressure in the pipings.
Pressure gauge
(Refer the CAUTION on the page 4.)
3 Remove the plug of the Lift section, and connect the
pressure gauge with the adapter.
4 Turn on the key switch, and pull the Lift lever to the top
end. Adjusting screw
Then read the indication of the pressure gauge with

pulling the Lift lever.
<Specific relief pressure>

Applicable model Relief pressure
FB10P/14P/15P 13.7 MPa(140 kgf/cm2)
Remove the plug
FB18P/20P 15.7 MPa(160 kgf/cm2) on the lift section.
FB25P/28P/30P 17.2 MPa(175 kgf/cm2)
221W112E
If the relief pressure is out of this specification, adjust the

pressure by the adjusting screw.
CAUTION Turn the adjusting screw gradually, because it is l CAN-BUS control

Measurement of relief pressure
very sensitive.
Pressure
Adjusting gauge
screw
If operator does not seat the correct position, all hydraulic
Dampner
operation including lift lowering can not work.
Remove Install the adapter

H.P. hose 221W0707E
92
lAdjusting the microswitch
7c-3-2. Microswitch - adjustment
0.5-1.5 mm
<Adjusting the microswitch>
(Except the lift 1st switch) Microswitch
1 Adjust the microswitch position to activate the switch

when the lever is moved 15 - 25 mm at the top of the
lever from the neutral position. 2210126
Specified gap when in neutral 0.5 - 1.5 mm lAdjusting the lift (fast) microswitch
<Adjusting the lift (1st) microswitch> Microswitch
1. Adjust the microswitch position to activate the switch

when the spool moves 5 mm.
1.0-2.0 mm
Specified gap when in neutral 1.0 - 2.0 mm
CAUTION
CAUTION After adjustment of the microswitch, apply
THREEBOND[#1401] or equivalent on both fixing 2210127
nuts of the switch.
93
CONTROLVALVE 7c
7c- 4. Troubleshooting
7c-4-1. Control valve - troubleshooting

1 Failure of the pump or the coupling Replace
Lifting or tilting 2 Shortage of oil in the tank Replenish
1
does not work 3 Breakage of Plunger spring Replace
4 Failure of the hydraulic microswitch Replace
Load with rated Replace or
1 Failure of the relief valve or out of adjustment
2 capacity can not adjust
be lifted 2 Failure of the pump Replace
1 Over-discharge of the battery Charge battery
Inspect valve
2 Short stroke of the plunger
linkage
3 Damage of the packing in the cylinder Replace
Lifting speed is 4 Rilief pressure is too low Adjust
3
too slow. 5 Damage of the packing of the plunger Replace
6 Failure of the pump Replace
7 Clogging of the oil filter Clean/Replace
8 Hydraulic speed setting in the control unit is not
Adjust
proper.
Too much 1 Damage of the packing of the plunger Replace

4 drifting for lifting 2 Damage of the Cylinider or the Piston Replace
or tilting 3 Damage of the packing of Piston Replace
Too much shock 1 Activation timing of lift microswitches is improper. Adjust
5 when starting to
lift. 2 Failure of the relief valve Replace
1 Damage of O-ring or wiper ring. Replace
6 Oil leakage
2 Looseness of tie bolts of the hydraulic valve Retighten
94
7d. CYLINDER
7d- 1. Location and name CYLINDER
7d-1-1. Lift cylinder - main part names

lMain parts of lift cylinder: P-mast (2-stage simplex)
M-mast (3-stage triplex)
Valve, check
Bushing Head, cylinder
2210173
Bearing, cushion
Ring, snap
Gasket Spacer
Plug
Rod ass'y, piston
Tube ass'y, cylinder
CS/FCS/RP/DRP
Head, cylinder
Bushing
Bearing, cushion
Ring, snap Spacer
Tube ass'y, cylinder Rod ass'y, piston
221W017E
95
CYLINDER 7d
l Main parts of lift cylinder 1st : PFL-mast (2-stage duplex) and

M-mast (3-stage triplex)
Valve, check
Plate
Head, cylinder
Bearing, cushion
Ring, snap
Plug
Gasket
Tube ass'y, cylinder

Rod ass'y, piston
Valve, down safety
Plug
221W018E
lMain parts of lift cylinder 2nd : PFL-mast (2-stage duplex)

7d
Ring, slide Ring, slide

Valve, check
Valve, check
Ring, snap
Ring, snap
Holder Spool, cushion Holder
Spool, cushion
Spring Spring
Tube ass'y Tube ass'y

cylinder cylinder
Rod(L), piston Rod(R), piston

Ring, wear Ring, wear
(MLH4300-5000) (MLH4300-5000)
Spacer Spacer
(MLH4300-5000) (MLH4300-5000)
Ring, snap Ring, snap
Piston Piston
121W071E
96
7d CYLINDER
7d-1-2. Tilt cylinder - main part names

lMain parts of tift cylinder
FB10P-18P
Head
Bushing
Washer
Ring, snap
Spacer
Rod ASS'Y,piston
Cylinder SUB ASS'Y
Piston
Nut
221W0701
FB20P-30P
Head
Bushing
Spacer
Rod ASS'Y,piston
Piston
Nut Tube ASS'Y,cylinder
251W013
97
CYLINDER 7d
7d- 2. Disassembly and reassembly

CAUTION l Lift or jack up the forklift truck and support it with safety blocks or
rigid stands.
l Apply wheel chocks to tyres to prevent the truck from moving.
l Before disconnecting hydraulic connections, release internal pressure
to prevent from splashing oil.
Refer the CAUTION on the page 4 for the procedure.
l When disconnecting hydraulic pipes, cap them to prevent dust from
l Be sure to disconnect the battery plug.
7d-2-1. Lift cylinder - removal : P - mast (2 - stage simplex)
1. Pull the lift lever backward to raise the inner mast about 50mm.(about 100 mm for forks)
2. Support the inner mast with a wire rope or wood block.
3. Remove fitting bolts for piston rod.
lRemoving the lift cylinder (1) P-mast
Fitting bolt
Inner mast
50 mm
Fitting bolt
Piston rod
Outer mast
221W020E
98
7d CYLINDER
4. Disconnect hydraulic hoses.

CAUTION Before disconnecting hydraulic connections, release internal pressure to
prevent from splashing oil.
High pressure hose
Valve, down safety
Tee
High pressure hose
221W021E
5. Remove cylinder bands to remove lift cylinders.

CAUTION Record note the number and thickness of shims when removing them.
Shim
lift cylinder
Band, cylinder
221W022E
99
CYLINDER 7d
7d-2-2. Lift cylinder - removal : PFL-mast (2-stage duplex), M-mast (3-stage triplex)
1. Pull the lift lever backward to raise the middle/inner mast about 50 mm.
2. Support the middle/inner mast with a wire rope or wood block.
3. Remove set screws that fix the piston rod.
lRemoving the lift cylinder (1)
M-mast
Middle mast
Set screw
Outer mast
Piston rod
Set screw
PFL-mast
Set screw
Inner mast
Piston rod
Outer mast
Set screw
221W023E
100
7d CYLINDER
4. Disconnect hydraulic pipes and hoses as shown in the following illustration.

M-mast
High pressure hose
Pipe comp., lift(2)
Pipe comp., lift
Elbow
Valve, down safety

Valve, flow control Tee
High pressure hose
Tee
PFL-mast
Pipe
High pressure hose
High pressure hose
High pressure hose

221W024E
101
CYLINDER 7d
5. Remove cylinder bands to remove outer (2nd) lift cylinders.

M mast PFL mast
Lift cylinder
Lift cylinder
Cylinder band
Cylinder band
221W025E
CAUTION Record note the number and thickness of shims when removing them.
Lift cylinder (1st)
Cylinder band
Shims
Spring pin
215S0728
102
7d CYLINDER
7d-2-3. Tilt cylinder - removal

1. Operate the tilt lever to tilt the fork forward.
2. Place a rope on the "top beam" of the outer mast and
support the mast by the hoist to prevent from falling
down.
3. Remove tilt pipes.

4. Remove tilt pins to remove tilt cylinders.

lRemoving the tilt cylinder
Tilt pin
Tilt cylinder
Pipe(2)comp., tilt
Pipe(1)comp., tilt
Tilt pin
2210073
103
CYLINDER 7d
7d-2-4. Lift cylinder - installation and adjustment

1. Install the lift cylinder in reverse order of removal.
2. After installation of all cylinders and hydraulic pipings, operate the lift lever to raise
the mast to the top end.
Make sure if both right and left cylinder rods are extended parallel and have no
clearance at the top end.
If clearance found, adjust in the following manner.
l P-mast : Insert proper thickness and number of shim (t0.2/t0.5/t1.0).
l M-mast : Turn the "Rod, head" at the top of the left cylinder to eliminate the
clearance at the top of the cylinder rod, and fix the "Rod, head" with the "Lock
nut."
Tighten the "Screw, set" to fix the cylinder rod.
l PFL-mast : Loosen the "Screw, set" and turn the "Adjust bolt" to eliminate the
clearance at the top of the cylinder rod.
Mount the "Plate, lock" to fix the "Adjust bolt".
Finally, tighten the "Screw, set" to fix the cylinder rod.
lAdjusting the lift cylinder
P-mast M-mast PFL-mast
Plate, lock
Adjust bolt
Bolt
Screw, set
Shim
Lock nut
221W026E
3. Make sure that oil is not leaked from anywhere.
104
7d CYLINDER
7d-2-5. Tilt cylinder - installation

1. Install the tilt cylinder in reverse order of removal. lInstalling the tilt cylinder
2. Operate the tilt lever and make sure if the mast is not Adjust the length
of the rod head
twisted at both forward and backward ends.
If the mast is twisted, adjust the length of the rod by
turning the head.
After adjustment, tighten the nut on the head.
3. Make sure that oil is not leaked from anywhere around

the tilt cylinder.
NOTE The tilt cylinder may be required to modify or

replace if the mast is exchanged for another one
Nut
with different lifting height.
Refer the section 7d-3 for details. 212E080
105
CYLINDER 7d
7d-2-6. Lift cylinder - disassembly and reassembly
Lift cylinder 1st (M/PFL-mast)
Head, cylinder B
Apply THREEBOND[#1901]
or equivalent on threads when
tightening.
Tightening torque
FB20P-30P 343 78.5 N m
FB10P-18P
{35 8.0 kgf m}
422 96.1 N m
FB20P/25P
{43 9.8 kgf m}
451 104 N m
FB28P/30P
{46 10.6 kgf m}
lPlug
Tightening torque
3.92 0.98 N m
{0.4 0.1 kgf m}
: Tightening torque
B : Apply THREEBOND
N : Not reusable
221W093
Lift cylinder (P-mast) / lift cylinder 2nd (M-mast)
Head, cylinder B
tightening.
Tightening torque
196 45.1 N m
FB10P-18P
{20 4.6 kgf m}
235 53.9 N m
FB20P/25P
{24 5.5 kgf m}
275 61.8 N m
FB28P/30P
{28 6.3 kgf m}
lPlug
Tightening torque
3.92 0.98 N m
{0.4 0.1 kgf m}
: Tightening torque
B : Apply THREEBOND
N : Not reusable
221W027
106
7d CYLINDER
Lift cylinder 2nd (PFL-mast)

Head, cylinder B
tightening.
Tightening torque
206 39 N m
FBT10P-18P
{24 4.0 kgf m}
235 54 N m
FB20P-30P
{24 5.5 kgf m}
1 Tightening torque
3.92 0.98 N m
{0.4 0.1 kgf m}
Tightening torque
196 35 N m
{20 3.6 kgf m}
3 Check valve
When assembling, be careful of
[L.H.] [R.H.] the facing of parts. Face the slit
surface toward the spring.
2 Tightening torque L
3.92 0.98 N m
{0.4 0.1 kgf m}
After tightening, use a
L.H.
2 point punch or close.
: Tightening torque After tightening, apply
R.H.
B : Apply THREEBOND LOCTITE.
L : Apply LOCTITE
N : Not reusable
2210078
CAUTION Replace packings when reassembling.
NOTE Apply grease on packings and seals when fitting them.
107
CYLINDER 7d
41 Preparation for disassembling

Make the preparations shown below before disassembling the cylinder.
lPreparation of the workbench

The workbench should be wide enough to put the parts on. It should be stable and solid
so that the parts will not fall off or move during the maintenance.
lPreparation of tools and materials
Prepare proper tools and materials.
42 General precautions for the maintenance

Before disassembling the cylinder, thoroughly clean any dirt or dust on the outer tube.
l
Since these are precision parts, handle them with care. Handle the parts carefully so as
l
not to hit them against each other or allow them to fall.
Don't tap or pry any parts by force. Such handling may cause burrs or damage parts.
l
As the result, parts may be impossible to reassemble properly and causes oil leaking or
degrades the performance.
If the parts are left halfway while maintenance, they may be rusted or damaged by dusts.
l
They must be covered or protected if the job is required to interrupt.
43 Maintenance standards
Replace the sliding parts and sealing parts according to the following instructions.
l Bushings : When more than 1/4 of circumference is worn out and shows a red copper
color.
l Seals : Whenever the cylinder is disassembled, replace them with new ones.
l Piston rod : If curved more than 0.5 mm / 1m.
108
7d CYLINDER
44 Disassembly procedure
1. Drain the oil.
2. Put the cylinder horizontal. Remove the plug and the

gasket.
CAUTION If the plug is not removed before disassembling,

piston, piston seal, bushing and /or ot her
internal parts may be damaged.
3. Loosen the cylinder head. Pipe Hook wrench

Loosen the cylinder head by using a hook wrench, and
then remove the cylinder head from the cylinder tube
ASS'Y.
Since the remaining oil may be spilled, put an oil pan to
receive. 221W095E
4. Pull out the cylinder head.

Pull the cylinder head straightly with care.
CAUTION When removing the cylinder head from the rod,

the end of the rod may hit and damage the head
if it is pulled out roughtly.
5. Pull out the piston rod ASS'Y.

Pull out the rod carefully with keeping horizontally.
Don't forget to remove the plug before pulling the rod out.
CAUTION Be careful not to damage the rod when pulling

out from the outer tube especially around the
thread part at the end of the tube or if the rod is
long.
Wear ring
Spacer
6. Pull out the spacer.

Pull the spacer out from the piston rod ASS'Y.
If the wear ring is fit on the spacer, that spacer cannot be
removed from the rod. Only the spacer without wear ring 221W111E
can be removed from the rod.

The wear ring itself can be removed by hand.
109
CYLINDER 7d
7. Disassembly of the piston U-ring Snap ring

Remove the piston seal, the bushing, the cushion Backup ring Bushing
bearing, the check valve, and the plate. Plate
(The plate is installed only in cylinders with an internal
diameter of 55 or greater.)
1. Draw out the U-ring and the backup ring by using a
spatula or a screwdriver. O-ring
2. Remove the bushing with expanding the joint with a Check valve
screwdriver.
Cushion bearing
221W096E
NOTE All removed seals must be replaced to new

ones.
3. Remove the snap ring, and pull out the cushion

bearing, the check valve and the plate. Pull the snap
ring out of the groove by using a sharp-pointed tool.
221W097
8. Disassembly of seals on the cylinder head. Wiper ring O-rings

Remove the X-ring, the wiper ring, and the O-ring. X-ring
1. Remove rings with extending by using a spatula or a

screwdriver.
2. The wiper ring is press-fitted. Stick the ring by a tool Bushing
like a screwdriver from the bushing side and tap to
push the wiper ring out.
3. Remove the O-ring and X-ring with the same manner
by using a spatula or a screwdriver.
221W098E
NOTE Replace all seals and rings to new ones when

reassembling.
110
7d CYLINDER
9. Disassembly of the bushing in the cylinder head (If

Press down using a press.
required).
Use a jig, as shown in the illustration on the right, and Jig
push the bushing out by using a press.
Cylinder
Or, pull out the bushing by the following procedure. head
1. Groove the inside face of the bushing by using a tool.
(Groove parallel about 10 mm away from the joint.) Bushing
2. Stick a flat head screwdriver into the joint of the

Jig
bushing, and twist along the groove to bend the edge
of the bushing.
221W099E
3. Grab the bent part of the bushing with a plier and pull it
out.
NOTE Replace the bushing to the new one when

reassembling.
10. Cleaning and storage

1. Clean all removed parts with kerosene.
After wipnig kerosene off, apply the hydraulic oil on
them before storage.
2. If removed parts are left without cleaning, they may be
rusted or damaged by moisture or dust.
111
CYLINDER 7d
45 Reassembly procedure
CAUTION Dust of paints may be peeled off from painted Press down using a press.
parts (such as the cylinder head) and come into
the cylinder which can cause oil leaking.
Jig
Pay attention not to come any dusts in the
cylinder when reassembling. Bushing
Cylinder
1. Reassembly of the cylinder head head
1. Fitting of the bushing

Press the bushing into the cylinder head by using a
press-fitting jig.
(Apply hydraulic oil to the inner surface of the cylinder 221W100E
head before pressing the bushing in. After press-fitting

the bushing, make sure for no gaps or unevenness.)
2. Fitting of the X-ring X-ring

Push the X-ring into the X-ring groove in the cylinder
head.
Do not damage the X-ring while installing.
After fitting the X-ring, make sure there are no
damages or transformations.
221W101E
3. Fitting of the wiper ring Press down by using a press.
Fit the wiper ring by using a jig.

Jig
Wiper ring
Cylinder head
221W102E
4. Fitting of the O-ring

O-rings
Because of using the thinner O-ring than the
conventional one, use Nichiyu Genuine part for
replacement.
Be careful not to damage the O-ring because it is
stretched when fitting.
221W103E
112
7d CYLINDER
2. Reassembly of the piston

1. Fitting of the U-ring
U-ring Jig
Insert the U-ring into the U-ring groove of the piston
with stretching.
Make sure if the direction of the U-ring is correct.
It might be easier to fit the U-ring if it is heated to
about 70 , or the hydraulic oil is applied on it.
If an insertion jig as shown in the illustration on the
right is used, the U-ring can be fitted easily and safely.
221W104E
2. Fitting of the backup ring

Backup ring
Insert the backup ring behind the U-ring.
(Refer the illustration on the right.)
221W105E
3. Fitting of the bushing

Bushing
Put the bushing on the bushing groove of the piston
with expanding at the joint.
(Refer the illustration on the right.)
221W106E
4. Fitting of the check valve, the plate and the cushion

Snap ring
bearing. Cushion bearing
Fit the check valve, the plate (only for cylinders with
an inner diameter of 55 or greater) and the cushion
bearing, the piston with this order.
Be careful about the direction of the cushion bearing.
Check valve
After fitting them, fit the snap ring into the groove in
the piston. Plate
221W108E
Cylinder inner diameter: Cylinder inner diameter:

50 or less 55 or greater
Direction to insert the cushion bearing 221W107E
113
CYLINDER 7d
3. Reassembling of the cylinder tube ASS'Y, the piston rod

ASS'Y and the cylinder head
1. Fixing of the cylinder tube ASS'Y

Fix the cylinder tube ASS'Y horizontally.
2. Inserting the spacer (Fitting of the wear ring)

Insert the spacer onto the piston rod ASS'Y. Insert the Wear ring
Spacer
spacer until it touches the piston.
If the wear ring was fitted on the spacer originally, fit
the new wear ring in the groove on the spacer.
221W111E
3. Inserting of the piston rod ASS'Y

Insert the piston rod ASS'Y into the cylinder tube
ASS'Y.
Push the piston rod ASS'Y all the way to the end of
the cylinder tube ASS'Y.
CAUTION Make sure that the plug is removed before

l
inserting the rod into the tube of the cylinder.
Keep the rod horizontally when inserting.
l
Pay attention not to hit the piston or the rod
l
to the thread of the cylinder tube. Otherwise,
par ts on the piston or the rod may be
damaged.
4. Lubrication
Fill the grease in the groove behind of the X-ring in the Apply grease all around the O-ring.
cylinder head.
X-ring Fill with grease.
221W109E
114
7d CYLINDER
5. Installation of the cylinder head

At first, put the ctlinder head through the piston rod
ASS'Y. (Insert the rod from the bottom of the head.)
Next, screw the head in the cylinder tube ASS'Y.
Hook wrench Pipe
Pay attention not to damage O-rings on the head
when screwing.
Then, tighten the head by a hook wrench with the
specified torque.
221W110E
6. Fitting of the plug and the gasket

Fit the plug and the gasket. Tighten them with the
specified torque.
4. Operating test
After finishing reassembling, fitting on the mast or
chassis, and re-connection of all hydraulic hoses, you
can start to test the function.
Move the hydraulic lever slowly to fill the hydraulic oil
through the circuit gradually.
Do not move the hydraulic lever quickly for the first 8
or 10 times to fill the oil to the end of the stroke of the
cylinder. Otherwise, the oil may be bubbled and the
hydraulic pump may be damaged.
115
CYLINDER 7d
7d-2-7. Tilt cylinder - disassembly and reassembly

1. Fix the cylinder on a vise. lRemoving the
"head KIT, cylinder"
CAUTION Do not vise around the head.
2. Remove the cylinder head by a hook wrench.
Vise
Hook wrench
152T017
lDisassembling and reassembling the tilt cylinder

FB10P-18P
Head, cylinder B
FB10P-18P equivalent on the threads when
tightening.
Tightening torque
Head
343 63.7 N m
FB10P-18P
{35 6.5 kgf m}
490 49 N m
FB20P-30P
{50 5 kgf m}
Tightening torque
343 49 N m
FB10P-18P
{35 5 kgf m}
735 74 N m
FB20P-30P
{75 7.5kgf m}
: Tightening torque
B : Apply THREEBOND
N : Not reusable Cylinder SUB ASS'Y
221W117E
CAUTION Replace all seals and packings when

reassembling.
NOTE Apply grease on all seals and packings when

fitting them.
116
7d CYLINDER
7d- 3. Inspection and adjustment

7d-3-1. Cylinder comp. - inspection
1. Check inside of the outer tube for rusting and/or
damage.
7d-3-2. Piston rod - inspection

1. Check for rusting and/or damage. lMeasuring deflection
If rusting or damaged, polish them with oil stone till
Dial gauge
they will not be felt by fingers.
2. Check for deflection.
Deflection limit 1.0 mm
Piston rod
CAUTION Measure at least 3 points to check for
deflection. 152T018
117
CYLINDER 7d
7d-3-3. Drift for lift and tilt - inspection

lAfter replacing packings or the cylinder ASS'Y, measure the drift of lift and tilt.
If it is out of the specification, it must be maintained again.
41 Measuring drift of lift

1. Load the maximum weight, and then raise the fork lMeasuring drift of lift lowering
about 70 cm from the ground. Outer mast Inner mast
2. Tilt the mast vertically to level the fork.
(Use the tilt lever.)
3. Draw a straight line over the inner mast and the outer Draw a straight line
mast.
Drift of lift
4. Measure the drift of lift 10 minutes later.
<Specifications>
Drift of lift [mm/10min.]
Applicable model
at the line on the Inner mast
FB10P
25-40
FB10P-18P-U
Drift of lift 70 cm
FB14P-20P 35-50
FB25P-30P
212E084
50-65
FB20P/25P-U
CAUTION If the drift of the lift is measured at the top

surface of the fork, the specific values should
be doubled of the values shown above.
42 Measuring drift of tilt lMeasuring drift of tilt

1. Load the maximum weight, and then raise the fork
about 70 cm from the ground.
2. Tilt the mast vertically to level the fork. (Use the tilt
lever.)
3. Measure the tilt drift of the piston rod of the tilt cylinder
5 minutes later.
70 cm
<Specifications>
Drift of tilt
Drift of tilt [mm/5min.] Piston rod
Piston rod 5-10
Tilt cylinder
212E085
118
7d CYLINDER
7d- 4. Variation of the tilt cylinder

The tilt angle is decided by the maximum lifting height.
If the mast is exchanged to another one but the different height, the tilt angle must be made
sure, and the replacement or modification of the tilt cylinder may be required.
7d-4-1. Tilt angle by masts

Tilt angle (Degrees)
Applicable Applicable Max. lifting Spacer Rod length Cylinder
model Mast model height (mm) Forward Backward P / No. (mm) I.D.
300P ~ 400P
3000 ~ 4000 6 12 - 336 L(R)G1
300PFL ~ 400PFL
200P ~ 430P 2000 ~ 2700
FB10 ~ 18P 4 6 31851-37500 380 L(R)G4
200PFL ~ 430PFL 4300
330M ~ 550M 3300 ~ 5500 4 6 31851-37500 380 L(R)G4
570M ~ 700M 5700 ~ 7000 1.5 6 31851-37580 380 L(R)G5
300P ~ 400P
3000 ~ 4000 6 12 - 363 L(R)O1
300PFL ~ 400PFL
200P ~ 430P 2000 ~ 2700
FB20P ~ 28P 200PFL ~ 430PFL 4 6 31851-37530 412 L(R)O4
4300
330M ~ 550M 3300 ~ 5500 4 6 31851-37530 412 L(R)O4
570M ~ 700M 5700 ~ 7000 1.5 6 31851-37610 412 L(R)O5
300P ~ 400P
3000 ~ 4000 6 12 - 397 L(R)R1
300PFL ~ 400PFL
200P ~ 430P 2000 ~ 2700
FB30P 4 6 31951-37450 452 L(R)R4
200PFL ~ 430PFL 4300
330M ~ 550M 3300 ~ 5500 4 6 31851-37450 452 L(R)R4
570M ~ 700M 5700 ~ 7000 1.5 6 31851-37540 452 L(R)R5
lRemoving the tift cylinder
Rod
Nut
Spacer
Piston
215S0729
119
CYLINDER 7d
7d- 5. Troubleshooting
7d-5-1. Cylinder - troubleshooting
Oil leakage 1. Damage of the packing in the cylinder Replace
1 from Cylinder 2. Looseness of Cylinder head Tighten
head 3. Damage on the rod Repair, Replace
Oil leakage
2 from Cylinder 1. Damage of the welded part Repair
Comp.
1. Damage of the packing in the cylinder Replace
Drift is too
3 2. Damage inside of the cylinder tube Repair, Replace
big
3. Oil leakage in the Control valve Replace
Cylinder 1. Bend of the rod Replace
vibrates 2. Shortage of hydraulic oil in the tank Replace
4
while
operation 3. Sucking air from the fitting of the piping Tighten
1. Over - discharging of the battery Charge
2. Lack of output of the pump Replace
Operating 3. Plunger of the control valve does not work properly. Inspect
speed of the 4. Clogging of the filter in the tank Clean or replace
5
cylinder is 5. Low relief pressure Adjust
slow.
6. Damage of the packings of the piston Replace
7. Hydraulic speed setting on the control system is not
Adjust
proper.
1. Stick of the spool in the flow control valve Replace
2. Foreign article is caught in the flow control valve. Clean
Lowering
6 speed is too 3. The spring in the flow control valve is damaged or
Replace
slow. weakened.
4. Hose of the return circuit from the lift cylinder is
Replace
choked or bent.
1. Failure of the micro switch of the control valve Replace
Cylinder 2. Failure of the wiring harness to the micro switch of
Inspect and repair
7 does not the control valve
work. 3. Failure of the hydraulic contactor or the contact tip. Inspect and repair
4. Blow out of the hydraulic main fuse. Replace
120
8 MAST
8. MAST
8- 1. Location and name MAST
lMain parts of P- mast (simplex)
Lift bracket Inner mast
Lift cylinder
212E137
Outer mast
Fork
Lift cylinder Lift

chain
Tilt cylinder
lMain parts of M- mast (triplex)

Inner mast
Middle mast
Lift cylinder 1st Lift chain
Lift chain Lift cylinder 2nd

Outer mast
Fork
Lift chain
Lift bracket
Tilt cylinder
221W028E
121
MAST 8
lMain parts of PFL-mast (duplex)
Inner mast
Lift cylinder 1st

Lift cylinder 2st
Outer mast
Lift chain
Tilt cylinder
Fork
Lift bracket
221W029E
122
8 MAST

CAUTION Lift or jack up the forklift truck and support it with safety blocks or
l
rigid stands.
Apply wheel chocks to tyres to prevent the truck from moving.
l
When disconnecting hydraulic pipes, cap them to prevent dust from
l
l
8-2-1. Lift bracket - removal

1. Tilt the mast vertically and lower forks to the ground. lRemoving the lift bracket
2. Remove cotter pins. P-mast Lift chain
3. Slacken lift chains and remove nuts at the chain anchor Cotter pin
bolt.
4. Remove lift chains from the front side (fork side).
CAUTION Put the nut on the anchor bolt after removing

the chain to prevent the thread from damages.
Lift bracket
5. Operate the lift lever to raise the inner mast to a height
where the lift bracket can be removed.
M/PFL-mast
6. Move the truck backward, or move the lift bracket Lift chain
forward.
7. Lower the inner mast.
Lift bracket
Nut
221W030
Cotter pin
8-2-2. Mast ass'y - removal

1. Tilt the mast vertically. lHoisting the mast ass'y
2. Hoist the mast ass'y until the wire ropes are just
stretched.
212E087
123
MAST 8
3. Raise the inner mast until its lower end rises to the top of lRemoving the tilt pin
the tilt pin.
View A
4. Remove the fitting bolt for the tilt pin.
5. Use a hammer to strike the tilt pin out from inside of the Hole
mast channel through the hole.
6. Lower the inner mast.

A
Tilt pin
Tilt cylinder
Washer, lock
Fitting bolt
221W031E
7. Operate the tilt lever to retract the piston rod of the tilt
cylinder.
8. Disconnect hydraulic pipes and hoses.
CAUTION Turn the key switch off and operate hydraulic

levers a few times to release high pressure
in the hydraulic piping before disconnecting
9. Remove fitting bolts for the pivot caps to remove pivot lRemoving the pivot cap
caps and bushings.
10. Hoist the mast ass'y.
Outer mast
Bushing
Pivot cap
Washer, lock
Fitting bolt 2210083
124
8 MAST
8-2-3. Mast - disassembly and reassembly
CAUTION Be sure to record the number and thickness of shims when removing them.
l
lDisassembling and reassembling the P-mast
1 Sliding part G
Apply grease on a sliding part.
2 Shim
Fork (See 8-3-8.) Record the number and thickness.
Chain wheel (See 8-3-5.)
Lift chain
(See 8-3-3, 8-3-4, 8-3-9.)
Back shoe
(See 8-3-2.)
Roller (See 8-3-7.)
Grease nipple G
Fill grease.
G : Apply grease
N : Not reusable
221W032E
125
MAST 8
lDisassembling and reassembling the M mast

1 Sliding part G
2 Shim
Record the number and thickness.
Chain wheel
(See 8-3-5.)
Hose pulley
(See 8-3-6.)
Fork
(See 8-3-8.)
Lift chain
(See 8-3-3, 8-3-4, 8-3-9.)
Back shoe
(See 8-3-2.)
Roller (See 8-3-7.)
Grease nipple G
Fill grease.
G : Apply grease
N : Not reusable
221W033E
126
8 MAST
lDisassembling and reassembling the PFL mast
1 Sliding part G
Chain wheel (See 8-3-5.)
2 Shim
Record the number and thickness.
Lift chain
(See 8-3-3, 8-3-4, 8-3-9.)
Back shoe
(See 8-3-2.)
Fork
(See 8-3-8.)
Roller (See 8-3-7.)
Grease nipple G
Fill grease.
G : Apply grease
N : Not reusable
221W034E
127
MAST 8

8-3-1. Mast, lift bracket and roller shaft - inspection
1. Check if welded parts are not cracked with color check.
CAUTION Use welding rods of low hydrogen type when re-welding on Mast
channels and/or Roller shafts.
lInspection of mast, lift bracket and roller shaft P/PFL-mast
Roller shaft (both sides)
Mast channel
Mast channel
221W035E
lInspection of mast, lift bracket and roller shaft M-mast

Mast channel
Mast channel

Mast channel

221W036E
128
8 MAST
8-3-2. Back shoe - inspection
1. Check the back shoe for wear. lInspection of back shoe

<Specifications> [mm]
Specific thickness [A] Wear limit
3 2.5
A
152T022
8-3-3. Lift chain - inspection and replacement

1. Check lift chains for stretch. lInspection of lift chain
Measure the length per 20 links at the part which are
used frequently.
<Specifications>
lFB10P-18P (per 20 links) [mm]
P
Specific Stretching
Pitch [P] Remarks
dimension limit
Leaf
317.5 324 15.875 chain#50
(BL534)
lFB20P-30P (per 20 links) [mm]

2210167
Specific Stretching
Pitch [P] Remarks
dimension limit
Leaf
381 389 19.5 chain#60
(BL634)
2. Check lift chains for deformation and damage.

If it is twisted, replace it.
3. Check for lubrication.
Apply grease on chains.
129
MAST 8
8-3-4. Chain bolt - inspection

1. Check connecting part ( ) for play. lInspection of chain bolt
If it is played, replace it. P-mast
Chain
2. Check for damage on the thread of the anchor bolt. Link
3. Check for damage on the link.
221W037
M/PFL-mast
Chain
Link
Anchor bolt
2210168
8-3-5. Chain wheel - inspection

1. Check the outer surface for deformation, and the lInspection of chain wheel
rotation of the bearing.
152T025
130
8 MAST
8-3-6. Hose pulley - inspection
1. Check for wear. lInspection of hose pulley
Item Specific diameter [d] Wear limit
Hose pulley 25.0 25.5
d
152T026
8-3-7. Roller - inspection and replacement

1. Measure the gap between the mast roller and the mast
channel.
If the gap is out of the range of the specification,
replace the roller.
Item Allowable gap

Mast roller, Lift roller 1.5
2. Check for play and rotation of the roller.
131
MAST 8
8-3-8. Fork - inspection and replacement

1. Check for transformation and height difference. lHeight difference
Item Allowance dimension

Height difference at the tip
10mm or less
of the fork.
Opening of fork tips 15mm or less
461E123
lOpening
461E124
2. Check for wear and cracks.

lBending
Applicable model Specific thickness Wear limit

FB10P/14P/15P/
35 +3
-0 32
18P
FB20P 36 +3
-0 33
FB25P 40 +3
-0 37 461E125
FB28P/30P 47 +3
-0 44
lWearing
CAUTION If any cracks are found on the fork, replace to

l
the new one immediately. Do not repair.
Check for cracks by using the color check.
l 461E126
132
8 MAST
8-3-9. Lift chain - inspection and adjustment

41 Adjustment of chain deflection
lAdjusting the lift chain
Measure the deflection of Lift chains, and adjust it if
l
out of the specification.
Nut
<Adjustment> 0-20 mm
1. Tilt the mast vertically. Nut
2. Lower forks on the flat floor.

3. Push the chain at approx. 1000 mm high from the floor 1000 mm
and measure the deflection.

212E097
Item Specification
Lift chain deflection Less than 20 mm
4. If the deflection is out of specification, adjust it with

nuts.
5. After making sure if the deflection of both chain (L.H./
R.H.) is equal, tighten nuts.
42 Adjustment of nut on chain anchor

1. After adjustment of the chain deflection, lAdjusting
tighten the nut (lower) securely with the lock nut. the nut on chain anchor
2. Tighten the nut (upper) on the anchor by hand, and
then tighten about 1/4 turn by using a tool.
Nut (upper)
NOTE This adjustment can reduce the noise at the
anchor.
Nut (lower)
Lock nut
215S0809
133
MAST 8
8-3-10. Mast lean- adjustment

l Check for the following if the inner mast is inclined lMast lean
when lifting forks to the top end.
1. Lift forks a little and check if the tension of both lift

chains are the same.
Refer to "8-3-9. Lift chain - inspection and adjustment".
2. Check if both cylinder rods are stopped at the same

time when lifting forks to the top end.
152T033
If defects are found, adjust by the following manner.

l P-mast :Change numbers or thickness
(t0.2/t0.5/t1.0) of shims.
l M-mast :Turn the "Rod, head" to adjust.
Then, tighten the lock nut securely.
l PFL-mast :Loosen "screw, set" and turn the adjust bolt.
lAdjusting the lift cylinder
P-mast M-mast PFL-mast
Plate, lock
Adjust bolt
Bolt
Screw, set
Shim
Lock nut
221W026E
3. Check for deflection in the chains when lowering forks.
134
8 MAST
8-4-1. Mast Lift bracket Fork - troubleshooting
NO. Symptom Problem Solution
Inner mast lifts up
1 together with Lift 1. Improper gap of lift rollers and/or side rollers Adjust
bracket.
Lifting and 1. Improper gap of lift rollers and/or side rollers Adjust
lowering of Lift
2 2. Defect of rollers Replace
bracket is not
smooth. 3. Chain roller does not rotate smoothly. Repair
Lift bracket is 1. Gap of side rollers is too big. Adjust

3
inclined 2. Unequal tension of L.H and R.H chains Adjust
Lifting and
1. Improper gap between rollers and mast channel Adjust
lowering of
4
inner mast is not
2. Defect of rollers Replace
smooth.
Inner mast Adjust

1. Adjustment at the top end of the lift cylinder is not
5 is inclined at
proper.
extended position Adjust
Repair,
1. Bending of forks
Replace
Tip of both forks
Proper
6 don't have the 2. One-sided load distribution on forks
operation
same height.
Repair,
3. Bending of the tilt bar
Replace
135
9. MOTOR
9-1-1. Traction motor - main part names MOTOR
lMain parts of traction motor
Terminal comp.
Bearing comp.,sensor
2210175
Cover,end
Cover (D),end Stator comp.
Rotor, sub ass'y
D : Dust resistant 221W050E
136
9 MOTOR
9-1-2. Hydraulic motor - main part names
lMain parts of hydraulic motor

Terminal comp.
Cover,end
Rotor sub ass'y
Cover (D),end Stator comp.
D : Dust resistant
221W051E
9-1-3. EPS motor - main part names
lMain parts of EPS motor Spring
Brush
Brush holder
Yoke ass'y
Armature comp.
Cover (D)
Cover (C),end
221W085E
137
MOTOR 9
9-1-4. Motors - specifications
lTraction motor
Applicable model Type Rating
FB10P/14P/15P/18P-75 AT90D2 9.0kW, 32V, 1650min-1, 60min
FB10P/14P/15P/18P-75 (Dust resistant) AT90D2A 9.0kW, 32V, 1650min-1, 30min
FB20P/25P/28P-75, FB20P/25P-U75 AT100E2 10.0kW, 32V, 1500min-1, 60min
FB20P/25P/28P-75, FB20P/25P-U75
AT100E2A 10.0kW, 32V, 1500min-1, 30min
(Dust resistant)
FB30P-75 AT100E3 10.0kW, 48V, 1500min-1, 60min
FB30P-75 (Dust resistant) AT100E3A 10.0kW, 48V, 1500min-1, 30min
lHydraulic motor
FB10P/14P/15P/18P-75 (With sensor) AH88B2C
FB10P/14P/15P/18P-75
AH88B2CA
(With sensor, dust resistant)
9.5kW, 30V, 5min (8.8kW, 10min)
FB10P/14P/15P/18P-75 (Without sensor) AH88B2CD
FB10P/14P/15P/18P-75
AH88B2CDA
(Without sensor, dust resistant)
FB10P/14P/15P/18P-U75 AH120C2D
12.0kW, 32V, 1710min-1, 10min
FB10P/14P/15P/18P-U75 (Dust resistant) AH120C2DA
FB20P-75 AH95C2D
9.5kW, 32V, 1950min-1, 10min
FB20P-75 (Dust resistant) AH95C2DA
FB25P/28P-75 AH120C2D
12.0kW, 32V, 1710min-1, 10min
FB25P/28P-75 (Dust resistant) AH120C2DA
FB20P-U75 AH135C2D
13.5kW, 32V, 1800min-1, 10min
FB20P-U75 (Dust resistant) AH135C2DA
FB25P-U75 AH140C2D
14.0kW, 32V, 1800min-1, 10min
FB25P-U75 (Dust resistant) AH140C2DA
FB30P-75 AH150C3D
15.0kW, 48V, 1800min-1, 10min
FB30P-75 (Dust resistant) AH150C3DA
lEPS motor
FB10P/14P/15P/18P-75 70000-15580 350W, 48V
FB20P/25P/28P-75 70000-15590 550W, 48V
FB30P-75 32911-03290 550W, 72V
138
9 MOTOR

CAUTION lLift or jack up the forklift truck and support it with safety blocks or rigid stands.
lApply wheel chocks to rear tyres to prevent the truck from moving.
9-2-1. Traction motor - removal and installation

1. Remove the traction motor.
Refer to "2-2-1. Front axle - removal and installation" on page 20.
NOTE The traction motor can be removed without removing the front axle.
However, when doing so, first remove any parts that could be damaged.
lRemoving the traction motor

Lead wire
Traction motor
Connector
Spline MG
part of spline.
Tightening torque
49.5-60.5 N m
: Tightening torque
{5.0-6.2 kgf m}
2210095
* Install the front axle and traction motor in reverse order of removal.
139
MOTOR 9
9-2-2. Hydraulic motor - removal and installation

CAUTION l Before disconnecting hydraulic connections, release internal pressure
to prevent from splashing oil.
1. Remove the cover ASS'Y, battery.

2. Remove the battery ASS'Y
3. Disconnect following hoses from the pump.
(1) High pressure hose [come from the Control valve]
(2) Low pressure hose [come from the Oil tank]
4. Disconnect lead wires on the hydraulic motor.

5. Remove fitting bolt for the motor bracket, and hoist the
hydraulic motor with the motor bracket.
lRemoving the hydraulic motor (1)

Low pressure hose
lFitting bolt(*1)
Hydraulic motor
High pressure hose
Tightening torque
29.4 - 39.2 N m
{3 - 4 kgf m}
Lead wire
Motor bracket
Side cover(R)
: Tightening torque
2210096
140
9 MOTOR
6. Remove fitting nuts(*2) to remove the hydraulic motor

from the bracket.
7. Remove fitting bolts(*3) to remove the hydraulic pump

from the hydraulic motor.
CAUTION Do not disassemblethe hydraulic pump.

When damaged, replace the whole pump assembly.
lRemoving the hydraulic motor (2)

lFitting bolt(*3)
Tightening torque
19.6 - 24.5 N m
{2.0 - 2.5 kgf m}
Spline MG
Apply molybdenum grease on the
spline.
Hydraulic pump Hydraulic motor
Cushion(1)
Motor bracket
lFitting nut(*2)
Tightening torque
8.8-10.8 N m
{0.9-1.1 kgf m}
: Tightening torque
2210097
* Install the hydraulic motor in reverse order of removal.
141
MOTOR 9
9-2-3. EPS motor - removal and installation

CAUTION lRecord places of lead wire connections before disassembling.
1. Remove the floor plate and disconnect the harness connector for the accelerator.
Refer to "5-2-1. Steering - removal and installation" on page 53.
2. Remove the battery.

Refer to "10f-1-1. Battery - removal and installation" on page 201.
3. Disconnect harness connectors for the EPS motor.

4. Remove fitting bolts(*1), and remove the EPS motor from the actuator ass'y.
lRemoving the EPS motor
lFitting bolt(*1)
Tightening torque
19-30 N m
{1.9-3.1 kgf m}
Harness connector
Spline part G
Apply grease on a part of spline.
Packing N
Apply grease oPacking can not be
: Tightening torque reused.
G : Apply grease Liquid packing can be used a part
N : Not reusable of spline.
2210098
* Install the EPS motor in reverse order of removal.
142
9 MOTOR
9-2-4. Traction motor - disassembly and reassembly

lDisassembling and reassembling the traction motor
Cap (Dust resistant) B

equivalent to bond the cap to the
"Cover, end".
Bolt, stud L
Apply LOCTITE [#648] or
equivalent to threads on the stud
side.
Oil seal N B G
B : Apply THREEBOND Apply grease on the lip of the oil
L : Apply LOCTITE seal, and apply the THREEBOND
G : Apply grease [#1104] or equivalent around the
N : Not reusable seal.
D : Dust resistant
221W052
143
MOTOR 9
9-2-5. Hydraulic motor - disassembly and reassembly

lDisassembling and reassembling the hydraulic motor
Tightening torque
13.5 N m 10%
Cap (Dust resistant) B

equivalent to bond the cap to the
"Cover, end".
Cover(D), end L
Apply THREEBOND[#648], [#262]
L : Apply LOCTITE or equivalent in M8 tapped holes,
N : Not reusable and tighten bolts.
D : Dust resistant
221W053
9-2-6. EPS motor - disassembly and reassembly

CAUTION Mark the yoke and "cover(C), end" before removing the bolts.
lDisassembling and reassembling the EPS motor

Bolt
Cover(C),end
Marking
Yoke
221W086E
144
9 MOTOR

9-3-1. Rotor comp. - inspection and replacement
(Traction and Hydraulic motor)
41 Inspection for damage lRotor comp. (Traction motor)
1. Check the rotor comp. for damage, especially by
burning.
If it is damaged, replace it.
42 Inspection of spline
1. Check for wear of spline. Rotor comp.
If it is extremely worn, replace it. Spline 2210102
lRotor comp. (Hydraulic motor)
43 Inspection of ball bearing Rotor comp.

Spline 2210121
1. Check fitting part of the bearing in the "cover, end" and

"cover(D), end".
If loose, replace them.
lInspection of fitting parts (Traction motor) lInspection of fitting parts (Hydraulic motor)
Bearing, radial ball Bearing, radial ball Bearing, radial ball Bearing, radial ball
Cover(D), end Cover, end Cover(D), end Cover, end

2210184 221W089E
CAUTION l When replacing the "bearing comp., sensor", lReplacing the "Bearing comp.,
be very careful not to damage the sensor. sensor"
If the sensor is damaged, the motor will not
operate correctly.
l Because the bearing sensor is very sensitive
for the static electricity, do not touch any Sensor
terminals in the connector directly.

2210144
145
MOTOR 9
9-3-2. Armature comp. - inspection and replacement

41 Inspection for damage lInspection of armature comp.
1. Check the armature for damage, especially for burning.
Armature comp.
If it is damaged, replace it.
If the surface of Commutator is damaged, repair or
Spline
replace it.
42 Inspection of spline
1. Check for wear of spline.
If it is extremely worn, replace it. 221W087
lInspection of fitting parts

43 Inspection of ball bearing
Bearing, radial ball Bearing, radial ball
1. Check fitting part of the bearing in the "cover(C), end"
and the cover(D).
If loose, replace it.
Cover(C), end
Cover(D)
2210169
9-3-3. Brush, Brush holder and Spring (EPS motor)

- inspection and replacement
41 Inspection of brush wearing lInspection of brush wear
Brush
1. Measure dimension (A).
If it is less than the wear limit, replace it.
Applicable Applicable Wearing limit

Specification
model motor (A)
FB10P-30P EPS motor 25mm 15mm Wear limit
Brush holder
Brush
Spring
Commutator
2210135
146
9 MOTOR
42 Inspection of contacting surface of brush
If the contacting surface is not good, repair it as

l lInspection of contacting
follows. surface of brush
Good Not Good Not Good
Brush
Commutator
152T042
<Repairing procedure> lRepairing surface of brush

1. Insert a sand paper [#400] between COMMUTATOR
Brush
and BRUSH.
(Face the file side to the brush.) Sand paper
2. Polish the contacting surface of the brush by moving a

sand paper or rotating COMMUTATOR by hand.
3. Blow the dust out with compressed air after repairing.
Commutator
152T059
43 Inspection of force of spring
lInspection of force of spring

l Hook a spring scale to the brush SPRING and check if
both springs have the same tension.
Then make sure of equal force on 2 springs.
<Specific force of SPRING> Spring scale Spring

Applicable motor Reference value
EPS motor
5N (0.5 kgf)
(NIKKO only)
CAUTION If the SPRING and/or the brush holder were

rusted, replace them. 152T060
147
MOTOR 9
9-3-4. Motor ASS'Y (Traction/Hydraulic motor) - inspection

Inspect the the motor with following procedures.
l
41 Abnormal noise check

Operate the motor. Make sure there is no abnormal
l
noise.
CAUTION If the motor is tested by itself, fix the motor on

a work bench securely. The motor may move
suddenly when starting.
Test the motor with the slow speed.
1. Be sure to secure the motor ASS'Y on a work bench.
2. Use the battery of the forklift truck to carry out testing.
3. Connect wires as follows.
lTraction motor
1) Connect the U1 cable from the chassis to the U1 terminal on the motor.
2) Connect the V1 cable from the chassis to the V1 terminal on the motor.
3) Connect the W1 cable from the chassis to the W1 terminal on the motor.
4) Connect the wire harness from the chassis
(water resistant type 4P) to the connector of the speed sensor in the motor
(water resistant type 4P).
lHydraulic motor
1) Connect the U2 cable from the chassis to the U2 terminal on the motor.
2) Connect the V2 cable from the chassis to the V2 terminal on the motor.
3) Connect the W2 cable from the chassis to the W2 terminal on the motor.
CAUTION If an extension cable is necessary, make them with the following parts:
1) Main cables for motor (3 cables)
2
1. Cable size : 38 mm
2. Terminal : 38-S8
2) Lead wires for speed sensor (4 wires)
2
1. Wire size : 0.5 mm
2. Receptacle : AMP171662-1
3. Tab : AMP173600-1
4. "Housing, cap 4P" : 37010-20940(AMP174259-2)
5. "Housing, plug 4P" : 37010-20890(AMP174257-2)
148
9 MOTOR
42 Inspection of insulation lInspection of insulation
Measure the insulation between terminals and stator

l Terminal
comp. with the Megger.
<Resistance>
Tool Specific resistance
Megger 0.5 M or greater (DC500V)
<Measuring procedure>
1. Apply the earth probe (negative [-]) of the Megger to
Stator comp.
the stator comp. 2210150
2. Apply the line probe (positive [+]) of the Megger to

each terminal. (U, V and W)
9-3-5. Motor ASS'Y (EPS motor) - inspection

lInspect with the following procedure after assembling.
41 Abnormal noise and spark

Operate the motor. Then make sure that abnormal
l
noise is not heard and sparks of brushes are not seen.
CAUTION If the motor is tested by itself, fix the motor on

a work bench securely. The motor may move
suddenly when starting.
Test the motor with the slow speed.
1. Be sure to secure EPS motor ass'y on a work bench.
2. Apply 1/4 voltage of the battery (about 12V) to carry out testing.
3. Connect wires as follows.
1) Connect (GREEN or WHITE) wire to the positive (+)
terminal of the battery.
2) Connect (YELLOW or BLACK) wire to the negative (-)
terminal of the battery.
2 Inspection of insulation
Measure the insulation between terminals in the
l
connector and the end cover with the Megger. lInspection of insulation
Connector
<Resistance>
Tool Specific resistance
Megger 0.1 M or greater (DC500V)
1. Apply the earth probe (negative [-]) of the Megger to
the yoke. End cover
Megger
2. Apply the line probe (positive [+]) of the Megger to
each terminal of connector plug. 152W225
149
MOTOR 9
9-3-6. Oil seal and permanent magnet(EPS motor)

- inspection and replacement
41 Oil seal
1. Check Oil seal for wear and damage.
If worn or damaged, replace it.
42 Permanent magnet
1. Check permanent magnets in the Yoke for damage
and sticking metallic dust.
If sticking metallic dust, remove it with compressed air.
If damaged, replace the whole motor.
9-4-1. Motor - troubleshooting
NO. symptom Problem Solution
1. Damage of bearing Replace
1 Abnormal noise Repair /

2. Armature shaft is not centered
replace
Abnormal
2 1. Improper rotating Replace
temperature rising.
Abnormal noise or 1. Wear of serration of Armature shaft or coupling Replace
3 temperature rise 2. Out of adjustment or wear of gears or faulty
Replace
after installing bearings in Drive unit
1. Damage of sensor bearing Replace
The motor does
4 2. Poor contact of wires or connectors of the speed
not rotate normally. Repair
sensor.
150
10. ELECTRIC PARTS
Display panel Directional switch Battery
See page 165 See page 167

See page 201
Charger (Option)
See page 175
Accelerator
See page 169
Transformer (Option)
EPS controller Control unit MPU board

See page 177
(TRV/HYD board)
Main contactor
See page 174 See page 164 See page 152 See page 204
221W049E
151
CONTROL UNIT 10a
10a. CONTROL UNIT

10a-1. Location and name
IGBT module
lMain parts of control unit
12
11
8 9
U1
U2
2
V1 9
6
V2
3
W1
7
W2
CU10X-XX
4
Battery [+] 10 Battery [-]

line line
221W054E
No. Part name Q'ty Remarks

1 Sink, heat 1
2 IGBT module 1 Travel U phase (U1)
3 IGBT module 1 Travel V phase (V1)
4 IGBT module 1 Travel W phase (W1)
5 IGBT module 1 Travel U phase (U2)
6 IGBT module 1 Travel V phase (V2)
7 IGBT module 1 Travel W phase (W2)
8 Sensor comp., heat 1
For the hydraulic U2, V2
9 Sensor comp., current 4
For the travel U1, V1
FB10P-28P=80V/5600 F x 9 pieces
10 Condenser comp. 1 FB30P=100V/4700 F x 9 pieces
11 Board comp., MPU 1 MPU board
12 Board comp., IGBT 1 Gate signal board
152
10a CONTROL UNIT
FET module
lMain parts of control unit
(1)
(7)
(5)
V1
(2)
(4)
W1
(6)
U1
V2
(4)
W2
(3)
U2
CU10X-XX
(8)
221W1002
No. Part name Q'ty Remarks

1 Sink, heat 1
2 Module, FET 1 Travel
3 Module, FET 1 Hydraulic
4 Sensoe Comp., current 4
FB10P-28P 80V/5600 F9
5 Condenser Comp. 1
FB30P 100V/4700 F9
6 Condenser Comp. 2 for EEC
7 Board Comp., MPU 1 MPU board
8 Board Comp., FET 1 Gate signal board
<IGBT module/ FET module Applicable serial No.>

Applicable model IGBT module FET module CAN-BUS control
FB10P-18P -221AE1250 221AE1251- 221AE3656-
FB20P-28P -241AC4968 241AC4969- 241AC6266-
FB30P -251AC0880 - 251AC0881-
153
CONTROL UNIT 10a
10a-2. Disassembly and reassembly

CAUTION Apply wheel chocks to tyres to prevent the
l
truck from moving.
l
Record places of lead wire connections before
l
disassembling.
10a-2-1. Control unit - removal and installation
1. Remove "fitting bolts" (*1) to remove the rear cover.
2. Remove "fitting bolts" (*2) to "bracket, cover".
3. Remove the control unit with following procedure.

1. Disconnect wires on the control unit.
NOTE Stamped mark on the ring terminal (at the end of

each cable) means followings.
Mark Connected to
+ Battery (+), Control unit (+)
- Battery (-), Control unit (-)
T+ Transformer (+)
T- Transformer (-)
Each phase for
U1,V1,W1
Travel control unit and motor
Each phase for
U2,V2,W2
Hydraulic control unit and motor
F Fuse
2. Remove "fitting nuts" (*3) for the control unit to remove

the control unit.
154
10a CONTROL UNIT
4. Remove the MPU board as follows.

1. Disconnect harness connectors from the MPU board.
2. Remove fitting bolts for the MPU board to remove the
MPU board.
lRemoving the control unit
Control unit
Bracket, cover
Rear cover
Cap
Fitting
nut (*2)
Fitting nut (*3)
MPU board
Fitting bolt Fitting bolt (*1)
221W055E
* Installation is in reverse order of removal.
155
CONTROL UNIT 10a
10a-2-2. Control unit - disassembly and reassembly

IGBT module
lDisassembling and reassembling the control unit (1)
Main terminal area (M6)
Tightening torque
3.5-4.5 Nm
{0.36-0.49 kgfm}
Use a bolt included with the "IGBT
module".
Sensor,current
1 Module comp., IGBT

Apply conductive compound
[G-747](Shin-Ethu silicones) on all
For travel
mating surfaces.
Sensor comp.,heat
Board comp.,IGBT
Module comp.,IGBT (travel)
For hydraulic
Installation area (M6)
Tightening torque
Sink,heat
3.5-4.5 Nm
{0.36-0.49 kgfm}
Module comp.,IGBT (hydraulic)
: Tightening torque
221W056E
156
10a CONTROL UNIT
MPU board
Main terminal area (M6)

Tightening torque
3.5-4.5 Nm
{0.36-0.49 kgfm}
Use a bolt included with the "IGBT
module".
Capacitor
Capacitor
2 Terminal L
Apply LOCTITE or equivalent on threads
to prevent looseness.
Insert washers as shown in this
L : Apply LOCTITE illustration.
: Tightening torque
221W057E
157
CONTROL UNIT 10a
FET module
Sink, heat
Impress or write unit cord No. on
position A with undamped ink.
Even the seal is possible.
Module, FET
1 Module, FET C
When installing, be sure to apply
condition compound [G-747] (Shin-
Etsu silicones) to the entire surface.
Travel
Hydraulic Module, FET
Condenser
Board Comp., FET
2 Terminal L Cushion
Apply LOCTITE [#242] or Put it on capacitor Comp side of
equivalent to the screws to prevent the position as shown the figure.
looseness.
Insert washers as shown in Figure A. Cushion Condenser Comp.
C : Apply compound
L : Apply LOCTITE
221W1003
158
10a CONTROL UNIT
Terminal Comp.
Sensor Comp.,
current
Bracket, board (2)
Bracket, board (1)
Board Comp., MPU
221W1004
159
CONTROL UNIT 10a
10a- 3. Check and replacement

l
Be sure to disconnect the battery plug first.
l
Discharge Capacitors on the Control Unit. (See next page)
l
l
lElectrical discharge of capacitor (control unit)

IGBT FET
W1
W2
W2
U2
CU105-XXX
Battery Battery Battery Battery

line [+] line [-] line [+] line [-]
221W1005 221W1006
10a-3-1. IGBT module - inspection and replacement

41 Type of IGBT module
lFor travel
Applicable model Type Element rating Qty
FB10P-30P
CM600DU-5F 600A(250V) 3
FB10P-25P-U
lFor hydraulic
Applicable model Type Element rating Qty
FB10P-30P CM400DU-5F 400A(250V) 3
FB20P-25P-U CM600DU-5F 600A(250V) 3
160
10a CONTROL UNIT
42 Checking IGBT module

1. Perform a continuity test at the test points 1 - 6 in the lInspection of
following table by using a digital tester. "IGBT module" (1)
E1
(Use the resistance range with beep function. If you E2
G2 G1
use the diode checking range, you may not able to get
the correct result.)
If continuity is shown at any test points, the tester will C1
beep. Then, replace the module (Travel or Hydraulic )
to the new one. E2
If any defects are found on the travel IGBT module,
both of two modules (for right and left) should be
C2, E1
replaced at the same time.
Replace the set of all nine capacitors at the same time
if the module is replaced.
* Apply the positive (+) prove * Apply the negative (-) prove
121W276
of the tester to; of the tester to;
1 G1 C1
2 G1 E2
3 G1 C2, E1
4 G2 C1
5 G2 E2
6 G2 C2, E1
* After inspection, swap the positive and negative prove and carry out
the same inspection again.
(Make sure that the beep function of a tester works fine before
starting the inspection.)
lInspection of
NOTE This is a simple check, and it is impossible to
"IGBT module" (2)
judge whether it is normal.
Main terminal area
2. When replacing the set of IGBT module, check for Installation area
burns on the "MPU board".

3. When installing the "IGBT module" to the "sink, heat",
be sure to apply conduction compound [G-747] (Shin-
Ethu silicones) to the entire contact surface.
4. Apply the tightening torque shown on the right to the
main terminal area (M6) and the installation area
(M6).
121W255E
lMain terminal area (M6)

CAUTION Do not touch each terminal of "IGBT module" lInstallation area (M6)
directly. Tightening torque

The element is damaged because of static 3.5 - 4.5 N m
electricity. {0.36 - 0.49 kgf m}
Remove the insulation cap which covers the : Tightening torque
terminal of "IGBT module" immediately before
connecting the connector.
161
CONTROL UNIT 10a
10a-3-2. FET module comp. - inspection and replacement

1. Perform a continuity test at the test points 1 - 6 in the
following table by using a digital tester.
(Use the resistance range with beep function. If you
use the diode checking range, you may not able to get
the correct result.) lInspection of "FET module (1)
If continuity is shown at any test points, the tester will

beep. Then, replace the module (Travel or Hydraulic ) D2-W
W
to the new one.
If any defects are found on the travel FET module, N V
D2-V
both of two modules (for right and left) should be

U D2-U
replaced at the same time. D1-U,V,W P
Replace the set of all nine capacitors at the same time
if the module is replaced.
NOTE Capacitors are replaced every year.

G2-W
G2-V
"Positive test" lead at "Negative test" lead at G2-U
1 P(Drain1) G1-(U) G1-W
G1-U G1-V
2 P(Drain1) G1-(V)
3 P(Drain1) G1-(W) 461S005
4 U(D2-U) G2-(U)
5 V(D2-V) G2-(V)
6 W(D2-W) G2-(W)
*Even both plus (+) and minus (-) are acceptable.
Do the continuity checking.
l[FET module] Circuit chart

P
D1 D1 D1
G1 G1
G1
U V W
D2 D2 D2
G2 G2
G2
N
461S006
162
10a CONTROL UNIT
2. If any continuities are shown, check

the Board comp. for any burning marks.
lInspection of "FET module" (2)
(Travel or Hydraulic : PBC107).
It is probably damaged also by electric surge Main terminal
Fitting part
3. When installing the "FET module" to the "sink, heat",
be sure to apply the thermal conductive compound
[G-747] (Shin-Ethu Silicones or equivalent) to the
entire contact surface.
4. Apply the tightening torque shown on the right to the
main terminal (M6) and the base plate (M6).
CAUTION Do not touch each terminal of "FET module" Main terminal 461S007E
directly. l Main terminal (M6)

l Fitting part (M6)
The element is damaged because of static
electricity. Tightening torque
Remove the insulation cap which covers the 3.5 - 4.5 N m
terminal of "FET module" immediately before {0.36 - 0.49 kgf m}
connecting the connector. : Tightening torque
10a-3-3. Capacitor - inspection and replacement

l Check the appearance visually.
If the appearance looks no problem, check with
following procedures. lChecking the capacitor
Analog tester
CAUTION Use an analog tester to check the capacitor.
1. Discharge the energy stored in the capacitor with a

resistor.
Refer the next clause "Procedure to discharge
capacitor".
2. Set the tester to the resistance range. (k range)
3. Apply the positive (+) prove to the (+) pole of the 252W1036
capacitor, and the negative (-) prove to the (-) pole.

4. First, the tester shows a few k , then increase the
resistance and shows " " finally if the capacitor is
normal.
CAUTION The above checking procedure is only for the

basic performance of the capacitor.
If you have any doubts, replace all capacitors.
CAUTION If it is found to break down IGBT module / FET

module, replace it.
163
CONTROL UNIT 10a
1. Prepare a resistor (20W, 50 or 50W, 20 ).
lDischarging the capacitor

2. Connect the resistor to the capacitor.
(See right)
3. Keep connection for 5 seconds. Then, the capacitor can
be discharged.
252W1037
10a-3-4. EPS controller - specifications

IGBT and FET control lEPS controller
Applicable
Type Voltage Current
model
STD CM103-44
FB10P-28P 48V 42A
EEC *CM103-49
FB30P STD CM103-45 72V 35A 10P

[water resistant]
*Only for FET control model
2P-Y : Fuse, GND

2P-X : to EPS motor
EPS sensor
Positive to control unit
221W059
CAN-BUS control lEPS controller (FET)
Applicable
Type Voltage Current
model
STD CU106-41B
FB10P-28P 48V 42A
CS CU108-40A
STD CU106-43B
FB30P 72V 35A
CS CU108-41A
Body harness
For power
supply
221W1007
164
10b. DISPLAY PANEL AND DIRECTIONAL SWITCH
10b-1. Display panel - Disassembly and reassembly
10b-1-1. Display panel - disassembly and reassembly
IGBT and FET control
lDisassembling and reassembling the display panel Mode select switch
Panel, display(2)
Cap(1) Cap(2)
Cover,display(1) A
Cover, printed
Display board
Support, display
CS/FCS/RP/DRP
Panel, display(3)
Display
Switch,flasher
Case
Switch comp., key
Cover,display(2)
CS/FCS/RP/DRP CS/FCS/RP/DRP
Panel, display(2)
Switch comp., key

221W060E
165
DISPLAY PANEL AND DIRECTIONAL SWITCH 10b
CAN-BUS control
lDisassembling and reassembling the display panel
Mode select switch Cap (2)
Panel, display (1)
Cap (1)
Support, display
Switch, flasher
Display
Directional switch
Panel, display (3)
Switch Comp., key

Panel, display (2)
CS/FCS,RP/DRP
Switch Comp., key

252W1011
166
10b DISPLAY PANEL AND DIRECTIONAL SWITCH
10b-2. Directional switch - Disassembly and reassembly

10b-2-1. Display panel - disassembly and name
lDisassembling and reassembling the directional switch
Lever
Boss, lever
Knob, lever
Panel, display (1)
Case
Microswitch
DS1(Forward)
Microswitch
DS2(Backward)
Column ASS'Y
Microswitch
DS3(Neutral)
Bushing
Spacer
Shaft
Spacer
Plate, SW
Refer to "Wiring" on next Roller
page for the layout of the
microswitch of a left lever.
Arm
Cover, case Cum (A)
Cum (B)
2210112
* This illustration shows right lever type. Some trucks may have the left lever type.
Refer to "Wiring" on next page for the layout of the microswitch of a left lever.
167
DISPLAY PANEL AND DIRECTIONAL SWITCH 10b
10b-2-2. Wiring of directional switch

<Type: DS100-20 (Right lever)>
Case
DS1(Forward)
Red Green/white
Forward
DS2(Backward)
Red Blue/yellow
DS3(Neutral)
Red White/black
Backward
Vinyl tube (Black) Forward Neutral Backward

(Length: 100) DS1
DS2 DS1 Close Open Open
DS3 DS2 Open Open Close
Green/white
Blue/yellow
White/black
DS3 Open Close Open

Red
Microswitch layout
2 2 2 2
1 2 3 4
4P
Waterproof
connector
1 2
3 4
2210186
<Type: DS100-21 (Left lever)>
Case
DS1(Forward)
Red Blue/yellow
Forward
DS2(Backward)
Red Green/white
DS3(Neutral)
Red White/black
Backward
Vinyl tube (Black)

(Length: 100) DS2
DS1
DS3
Green/white
Blue/yellow
White/black
Red
Microswitch layout
2 2 2 2
1 2 3 4 Forward Neutral Backward
4P DS1 Open Open Close
Waterproof
connector DS2 Close Open Open
1 2 DS3 Open Close Open
3 4
2210187
168
10c. ACCELERATOR
10c-1. Disassembly and reassembly
10c-1-1. Accelerator linkage - removal and installation
lRemoving and installing the accelerator linkage
1 Spring G
Apply Alvania Grease [RA] or
equivalent on the surface of
spring.
Rod
2 Spring G
Pedal equivalent on the hook of spring.
Plate
Lever Spring
Bushing
Shaft
Spacer
Spring
Potentiometer Shaft & shim G

equivalent and the shaft and the
Bracket shim.
Case
221W061E
169
ACCELERATOR 10c
10c- 2. Inspection and adjustment

10c-2-1. Potentiometer - adjustment
1. Adjust the fixing position of the potentiometer to get
lAdjusting the potentiometer
the following output voltage.
Lever
(1) Apply DC 5 0.5 volts between Red (+) and Black (-).
(2) Measure the voltage between White (output 1) and
Black (-), and make sure if the voltage is within the
range.
(3) Measure the voltage between Blue (output 2) and
Black (-), and make sure if the voltage is within the
range.
(4) If you cannot get the correct output voltage, remove 51.
5
Potentiometer Neutral
the potentiometer once and turn the shaft 180 . Then
install and test again. 221W1013
(5) If you cannot get the correct output voltage for both
output 1 (white) and output 2 (Blue), replace the
potentiometer to the new one.
Lever position Output voltage
Neutral 0.85 0.1 V
51.5 degree rotated 3.5 V - 4.5 V
NOTE This potentiometer is not a variable resistor.

So, the shaft does not have the mechanical
stopper (can turn 360 endless) and cannot
measure the resistance by a tester.
NOTE Apply Alvania Grease or equivalent between Spring

the shaft and the shim and also the surface of
spring.
A A
lSection A to A
Shim
Shaft
221W1015
170
10c ACCELERATOR
10c-2-2. Accelerator linkage - adjustment

<Adjustment procedure>
1. Adjust the rod length ( 2) to 178.5 mm.
The height of the accelerator pedal ( 1) should be
144 5 mm when the accelerator pedal is free.
2. Adjust the height of the stopper bolt ( 3) to 43.5 mm.
lAdjusting the accelator linkage
Original position
(when the pedal is released)
Pedal, accelerator

20
Ball link
1)
Adjusting bolt
5(
Rod
144
3)
43.5 (
2)
Spring G
5(
178.
Apply Alvania Grease {RA} or

51 Spring equivalent on the hook of spring.
.5
Accelerator ASS'Y
NOTE
Tighten the bolt together with
earth wire from potentiometer.
Earth wire
G : Apply grease 221W1014
171
10d. MAIN CONTACTOR AND FUSE
10d-1. Disassembly and reassembly
CAUTION Be sure to disconnect the battery plug.
l
Apply wheel chocks to tyres to prevent the truck from moving.
l
l
10d-1-1. Control unit - removal and installation
1. Remove caps, fitting bolts and the "Cover(L), side".
lRemoving the front cover
Fitting bolt
(with plain washer
and lock washer)
Cap
Main contactor
Cover(L),side Fuse
221W062E
172
10d MAIN CONTACTOR AND FUSE
2. Remove the main contactor and all fuses as follows.

1. Disconnect wiring connectors of the main contactor and lead wires.
2. Refer to the diagram below and remove the main contactor and all fuses.
lRemoving the main contactor and fuse
(L)
(R) Connector
10A,
Glass tube fuses
(F4, F6)
Harness, body
Main contactor
325A, travel,
Hydraulic fuse
(F1)
Bar (1), lead
40A,
EPS fuse
(F3)
160A, charger fuse
Bar (1), lead Main terminal area (M8)
Tightening torque(M8)
6.4-7.4 N m
{0.65-0.75 kgf m}
Use a bolt included with the main
contactor.
: Tightening torque
221W063E
* Install the main contactor and fuse in reverse order of removal.

173
MAIN CONTACTOR AND FUSE 10d
10d-2. Inspection and replacement

CAUTION Record places of lead wire connections before
l
disassembling.
l
10d-2-1. Main contactor - inspection and replacement

1. Remove screws, and check for burns or wear in the lInspection of main contactor
contact area.
If there is an abnormality in the contact, replace the
assembly.
CAUTION To be safe, the assembly should be replaced

every 2 years even if there are no abnormalities.
lMain contactor type

Applicable model Maker type Voltage
FB10P-30P HR-404394 48V
lMain terminal area (M8) M8
2. Use the tightening torque shown on the right for the Tightening torque (M8)
main terminal area (M8). 6.4-7.4 N m
{0.65-0.75 kgf m}
: Tightening torque
121W226
10d-2-2. Fuse - replacement

1. Be sure to replace Fuse with the specific capacity one. lFuse type
lFuse type
Application Capacity
MPU F1 325A 160A,
EPS F3 40A charger fuse
Transformer 160A
Control unit F4 10A
40A, EPS fuse (F3)
Accessory F6 10A
10A,
2. Be sure to tighten the nuts after replacing it. Glass tube fuses
(F4, F6)
325A,
travel/Hydraulic fuse
(F1)
221W064E
174
10e. BUILT-IN CHARGER (OPTION)
10e-1. Disassembly and reassembly
CAUTION lDo not misconnect the earth wire to the normal electric circuit.
lMake sure that all wires are connected correctly.
lSecurely tighten screws or bolts of lead wires.
lInsert insulation tubes for the terminals of the transformer in order to
keep them away each other and from metal parts.
10e-1-1. Charger ass'y - disassembly and reassembly

lDisassembling and reassembling the charger ass'y (built-in type)
Panel ASS'Y, charger
Cover
Charger,
Earth wire microcomputer
Magnetic contactor
Bracket, panel (Electromagnetic contactor)
Link fuse
Fuse ass'y
Receptacle
Relay
Plug comp.
Harness, BC
To Body harness To "charger,

microcomputer"
to Magnetic contactor
221W1010
175
CHARGER 10e
CAN-BUS control
lDisassembling and reassembling the charger ass'y (built-in type)
Panel ASS'Y, charger
Cover
Plate, name Charger, switch
Earth wire
Magnetic contactor
(Electromagnetic contactor)
Bracket, panel
Link fuse
Receptacle
Fuse ass'y
Relay
Harness, BC
Plug Comp.
To Body harness to Magnetic contactor to Switch board

221W1011
176
10e CHARGER
10e-1-2. Transformer - disassembly and reassembly
lDisassembling and reassembling the transformer (built-in type)
SKR
Diode
Primary coil
SKN Secondary coil
Diode
Bracket, transformer
221W066E
177
CHARGER 10e
10e-1-3. Built-in charger - specification

<3 200V>
Power
Applicable Transformer Fuse
supply Battery capacity Transformer model
model capacity capacity
voltage
T1224-2100,
330Ah (Std) 5.2kVA 15A
T1224-2101
T2224-2200,
FB10P/14P 480-485Ah (Opt) 6.4kVA T2224-2201, 20A
T2224-2202
T3224-3200,
545Ah (Opt) 7.0kVA 20A
T3224-3201
T2224-2200,
400Ah (Std)
6.4kVA T2224-2201, 20A
485Ah (Opt)
FB15P/18P T2224-2202
T3224-3200,
545Ah (Opt) 7.0kVA 20A
T3224-3201
T2224-2200,
200V 6.4kVA T2224-2201,
485Ah (Std) T2224-2202 20A
FB20P 545-600Ah (Opt)
T3224-3200,
7.0kVA
T3224-3201
650-730Ah (Opt) 10.0kVA T4224-0100 30A
T2224-2200,
6.4kVA T2224-2201,
565Ah (Std) T2224-2202 20A
FB25P/28P 600Ah (Opt)
T3224-3200,
7.0kVA
T3224-3201
650-730Ah (Opt) 10.0kVA T4224-0100 30A
485Ah (Std)
FB30P 12.0kVA T3324-1100 30A
545-600Ah (Opt)
178
10e CHARGER
<3 400V>
Power
Applicable Transformer
supply Battery capacity Transformer model
model capacity
voltage
330Ah 5.2kVA T1224-2100
FB10P/14P 480-485Ah 6.4kVA T2244-1100
545Ah 7.0kVA T3244-2100
480-485Ah 6.4kVA T2244-1100
FB15P/18P
545-600Ah 7.0kVA T3244-2100
400V 400-485Ah 6.4kVA T2244-1100
FB20P 545-600Ah 7.0kVA T3244-2100
650-730h 10.0kVA T4224-0100
565-600Ah 7.0kVA T3244-0100
FB25P/28P
650-730Ah 10.0kVA T4224-0100
FB30P 485-600Ah 12.0kVA T3344-1100
NOTE 400-volt type charger has the thermal relay

instead of the fuse.
179
CHARGER 10e
10e- 2. Inspection and replacement

10e-2-1. Magnetic contactor - inspection
1. Check for burnings and/or damages on the contacts. lInspection of magnetic contactor
Magnetic contactor
2210224
10e-2-2. Plug comp. and receptacle - inspection and replacement

1. Check for burnings and/or discoloration on the lInspection of plug comp. and
receptacle terminal. receptacle
If there are any burns, discoloration, or abnormal plays Fitting nut
on the terminal, replace both the plug comp. and the
receptacle.
2. Check the earth wire fitting nuts for loosening.
Earth wire
Receptacle
Plug comp.
2210225
10e-2-3. Fuse and fuse base - inspection

1. Check link fuses for blow outs or discoloration. l Inspection of link fuse and
2. Check fuse fitting screws for loosening. fuse base
Fitting screw
Fuse
2210222
180
10e CHARGER
10e-2-4. Transformer - inspection

1. Check for damage or dirt.
If there is dirty or dusty, clean it away with compressed air.
2. Measure the insulation resistance.
Specific value of insulation

5M or greater
resistance
<Measuring procedure> lTransformer insulation

measurement
CAUTION Be sure to disconnect the battery plug before
l
measuring. Transformer
If using a megger, do not touch the measuring

l
terminals.
1. Remove all diodes from the transformer.

2. Use a megger to measure the following locations and
check the insulation.
l Between the primary and secondary coils.
l Between the primary coil and the steel core of the coil. Megger
2210227
l Between the secondary coil and the steel core of the coil.
10e-2-5. Diode - inspection

1. Measure the resistance to check the diode. lChecking the diode
lSpecific resistance value Tester

Terminal Diode
Resistance
[+] Positive [-] Negative
Anode(A) Cathode(K)
10 -100 k
Cathode(K) Anode(A)
(Approx. 150K )
K A
NOTE Resistance may vary slightly by the circuit

l
tester.
A K
SKN71/02 SKR71/02
2210226
1. Set the tester to the resistance ( ) x 1 range.

2. Apply the positive (+) and negative (-) proves to
Anode(A) and Cathode(K) (or vice versa) to check the
resistance.
181
CHARGER 10e
10e- 3. Inspection After Assembly

CAUTION Check the continuity between the earth terminal in the receptacle and
l
the chasis. (It must be conducted without resistance.)
Carry out the inspection in well-ventilated area without fire.
l
10e-3-1. Timer - inspection

<Total timer>
Indicating LED
Magnetic Auto Reserve Equal of charging state
Checking procedure
contactor LED LED LED
1-2 3-4
1 Connect the battery plug. OFF
2 Connect the AC plug to wall outlet. OFF
When
Press and hold the Auto OFF
3 pressed
Button for at least 5 seconds.
5 seconds later ON
The check will end approximately 1 minute
4 OFF
and 36 seconds after flashing LED.
:On
Auto LED (green) :Off
This LED is turned on when
the battery is fully charged. :Flashing
Auto button
Reserve LED (green)

4
Completion
cycle LED
3
Equal LED (orange)
Indicating LED (green) of
charging state.
lThe LED lights indicate the
2 charge left in the battery.
lIf the total timer is
operated, all 4 LEDs will
flash.
1
2211089
CAUTION If the battery is just finished to charge, operate hydraulic function for 2 or 3
l
minutes to stabilize the battery voltage before starting to check the total timer.
If you interrupt to charge the batter y, push the "STOP" button before
l
disconnecting the battery plug to prevent from sparking.
For a fully charged battery, check after performing approximately 2-3 minutes
l
of hydraulic operation.
If the charging state LEDs are flashed, they will not turn off until the battery
l
plug is unplugged.
182
10e CHARGER
CAN-BUS control
<Checking of Total timer>
Magnetic Auto Reserve Equal
Checking procedure
contactor LED LED LED
1 Connect the battery plug. OFF
2 Connect the AC plug to wall outlet. OFF
Press and hold the Auto When
OFF
3 Button for at least 5 pressed
seconds. 5 seconds later ON
The check will end approximately 1 minute and
4 OFF
36 seconds after Auto Button begins flashing.
:On
Auto LED (green)
:Off
:Flashing
Auto button
Reserve LED (green)
Reserve button
Equal LED (orange)
Equal button
Stop button
252W1017
CAUTION If the battery is just finished to charge, operate hydraulic function for 2 or 3
l
minutes to stabilize the battery voltage before starting to check the total timer.
If you interrupt to charge the batter y, push the "STOP" button before
l
disconnecting the battery plug to prevent from sparking.
For a fully charged battery, check after performing approximately 2-3 minutes
l
of hydraulic operation.
If the charging state LEDs are flashed, they will not turn off until the battery
l
plug is unplugged.
10e-3-2. Earth - inspection

check the electric connection is done between the earth terminal and the body of the
receptacle of the charger panel. (0 by 1 range of the tester)
10e-3-3. Reserve function - inspection

From "
l "(month & date), set the timer for 1 to 14 minutes later from the
current time. Make sure that the battery charging starts correctly at the set time.
(Refer to "10e-4-2. Reserve charge" on page 188 for more information.)
183
CHARGER 10e
10e- 4. Charging procedure

WARNING Do not touch any parts of charger and cable by wet hand.
CAUTION lDo not disconnect the rectangular plug, AC plug and battery plug while charging.
lPush the "STOP" button when discontinue to charge.
l The charger operates with high voltage. Touch by wet hand may cause
electrical shock.
lDo not operate any hydraulic valve levers or accelerator pedal while charging.
10e-4-1. Automatic charge (Daily charge)

lThis charge returns the battery to a full-charged
condition after operating the forklift truck.
<How to open the battery cover>

1. Move the forklift truck to designated charging area.
2. Turn off the key switch and remove the key.
3. Release the bonnet catch and open the battery
cover. Make sure that the battery cover is supported by
the gas spring securely. 2210200
lThe battery cover of FB10P - 28P lThe battery cover of FB30P
Gas spring
Lock
Lock
Battery cover
Gas spring
Lock
Bonnet catch
221W079E 221W080E
CAUTION Gas spring (assist damper with self locking) is

used at the battery cover.
Make sure the condition of locking.
WARNING Do not remove the lock of the point part of the

battery cover when charging. (For FB30P. )
184
10e CHARGER
4. Connect the rectangular plug of the AC cable to the

receptacle on the charger panel.
5. Connect the AC plug to the wall outlet.
Receptacle (body side)
Charger plug
Charger cord
Power supply plug
2210203E
Then, all "AUTO", "RESERVE" and "EQUAL" lamps are

turned on.
NOTE If these lamps are not turned on, make sure the AC
cable is connected correctly. 2210204
5. Push "AUTO" button. Automatic charge is started.
The "AUTO" lamp (green) is lit. Both "RESERVE" and

"EQUAL" lamps are turned off.
2210231

6. When charge is completed, the top green lamp of
charge status indicator is lit.
2210232
185
CHARGER 10e
CAN-BUS control
7. When the charge is begun, the display power is turned
on and the charging passage is shown in the indicator.
lIndication of charging passage
221W1012
When the charge is completed, "CHARGE

COMPLETION" keeps being displayed.
NOTE When the charge is not completed even if 16

l
hours have passed since it began charging , the
end is displayed as a charge error.
If the charge plug is pulled out, the display is
l
turned off.
8. Disconnect the charger plug and AC plug.
9. Shut the battery cover while pushing a yellow part

(resin) in the middle of the gas spring. Closing battery cover
CAUTION Do not place the finger when pushing a yellow

part.
Do not place the finger when closing the battery
cover.
10. Fix the bonnet catch surely after shutting the battery
cover. 221W082E
DANGER Do not touch any parts of charger and cable by

wet hand.
186
10e CHARGER
CAUTION Do not disconnect the rectangular plug, AC plug and battery plug while
l
charging.
Push the "STOP" button when discontinue to charge.
l
The charger operates with high voltage. Touch by wet hand may cause
l
electrical shock.
Do not operate any hydraulic valve levers or accelerator pedal while charging.
l
CAN-BUS control
CAUTION l The display is turned off when blacking out while charging.
When the power returns within one hour after it blacks out and the power is
supplied , the charge is restarted and the charging passage is displayed.
The charge is not restarted when one hour or more has passed since it blacked
out and the charge passage is not displayed.
l 44 hours pass with the charge plug connected after the charge ends, and when
outside temperature is less than five degrees, re-charging is done only once.
In this case, the charging passage is displayed.
187
CHARGER 10e
10e-4-2. Reserve charge

lThis function is the timer to start charging of the
battery. If you want to start charging after a while, or
a few days later, for example, this is very convenient
function. This function can charge the battery as the
"AUTO" mode only.
<Setting of the starting time>
CAUTION l If any operation of traveling or hydraulics

are done while setting the timer, the setting
screen is returned to the normal screen
immediately.
Normal screen
lThis setting cannot be activated while traveling
and depressing the brake pedal.
1. Move the forklift truck to appropriate area and park.
2. Push the " " button of the mode select switch to get
Push R Push
the " " (reserve charge setting) screen. button button
(If pushing " " button, the screen returns to the

normal.)
The " " (reserve charge setting)
screen appears when the AC cable is connected to
the charger panel also.
Select by
pushing or .
3. Push " " or " " button to select " "

(month & date) or " " (daily).
NOTE When selecting " " (month & date)

The reserved time is revised automatically to the 121T319E
same time of seven (7) days later after expiring it.

It is convenient to charge the battery every weekend.
When selecting " " (daily)

The reserved time is revised automatically to the
same time of the next day after expiring.
It is convenient to charge the battery everyday.
CAUTION The displayed time is the star ting time of

charge. It is not the finishing time of charge.
188
10e CHARGER
<In case of setting of " " (month & date)>

lSelect " " (month & date) by pushing " " or
" ".
Screen displays the current setting. (or no date is dis-
played if not set before.)
Push " " button to move the cursor to the month.
Push " " button to get the normal screen.
NOTE When setting the mode of next 1 to 5, each button

works as below.
" " and " " buttons : M
ove the cursor to select
the value. 121T320E
" " button : Move the cursor to the next item.

" " button : Back the cursor to the previous item.
1. Set the month

Push " " or " " button to set the month.
After setting of the month, push " " button to select
the " " (date).
If pushing " " button, the cursor is returns to the
" " (month & date) or " " (daily) area.
121T321E
2. Set the date

Push " " or " " to select the date. The " " (day
of the week) is displayed automatically by setting the
date.
After setting the date, push " " button to move the
cursor to the time (AM or PM).
If pushing " " button, the cursor is returned to the
month area.
121T322E
3. Set the AM or PM
Push " " or " " to select "AM" or "PM".
After setting, push " " button to move the cursor to
the hour.
date area.
121T323E
189
CHARGER 10e
4. Set the hour

Push " " or " " to change the hour. Hour can be
selected from 1 through 12.
After setting the hour, push " " button to move the
cursor to the minute.
AM or PM area.
121T324E
5. Set the minute

Push " " or " " to set the minute. The minute can
be set to "00", "15", "30" or "45".
After setting, push " " button. Then, "COMPLETE"
sign is flashed three times and the display returns to
the normal screen.
hour area.
121T325E
CAUTION Make sure that the reserved date and time which
are displayed at the left lower corner of the
screen is correct.
CAUTION lThe past date and time cannot be set.

Example
Current time 2000 10 30 PM10:30
Input date and time 10 30 PM10:00
Reserved setting 2001 10 30 PM10:00

If input the past date and time, it is memorized as the
same date and time of the next year.
* If the reserved date and time is become past by
setting the current date and time, the same 121T326E
situation is occurred.
lThe reservation is invalid if all required data

are not entered.
Example : Input data 10 "blank" PM10:00 invalid

If any data is not entered (blanked) and move to the next step,
all data in that screen will be invalid and deleted.
190
10e CHARGER
<In case of setting of " " (daily)>

lPush " " or " " to select " " (daily). The screen
displays the current setting. If not set before, no data
are displayed.
Push " " button to move the cursor to the month.
Push " " button to get the normal screen.
NOTE When setting the mode of next 1 to 3, each button

works as below.
" " and " " buttons : M
ove the cursor to select
the value.
" " button : Move the cursor to the next item.
121T329E
" " button : Back the cursor to the previous item.
1. Set the AM or PM
Push " " or " " to select "AM" or PM".
After selecting, push " " button to move the cursor
to the hour.
If pushing " " button, the cursor is returned to the "
" (month & date) or " " (daily) area 121T330E
2. Set the hour

Push " " or " " set the hour. The hour can be set
from 1 through 12.
After setting, push " " button to move the cursor to
the minute. Push " " or " " button to set hour.

AM or PM area.
121T331E
3. Set the minute

Push " " or " " to set the minute. The minute can
be set to "00", "15", "30" or "45".
After setting the minute, push " " button. Then,
"COMPLETE" sign is flashed three times and the
display returns to the normal screen.
hour area.
121T332E
191
CHARGER 10e
After setting, push " " button. Then, "COMPLETE"

sign is flashed three times and the display returns to
the normal screen.
hour area.
CAUTION Make sure that the reserved date and time which
are displayed at the left lower corner of the
screen is correct.
121T333E
CAUTION lThe past time cannot be set.

Example
Current time 2000 10 30 PM10:30
Input date and time PM10:00
Reserved setting 2000 10 31 PM10:00

If input the past time, it is memorized as the same time
of the next day.
* If the reserved time is become past by setting the
current date and time, the same situation is
occurred.
lThe reservation is invalid if all required data

are not entered.
Example : Input data PM "blank" :00 invalid
If any data is not entered (blanked) and move to the next step,
all data in that screen will be invalid and deleted.
NOTE After the completion of the reserve setting, its data is

renewed automatically after the past of its time.
In case of " " (daily), it is renewed to the same
time of the next day.
In case of " " (month & date), it is renewed
to the same time of seven (7) days later.
192
10e CHARGER
<Reserve charge>
lThis mode starts to charge the battery by the preset
date and time.
1. Move the forklift truck to designated charging area.

2. Turn off the key switch and remove the key.
2210200
<How to open the battery cover>

Release the bonnet catch and open the battery cover.
lThe battery cover of FB10P - 28P lThe battery cover of FB30P
Gas spring
Lock
Lock
Battery cover
Gas spring
Lock
Bonnet catch
221W079E 221W080E
CAUTION Gas spring (assist damper with self locking) is

used at the battery cover.
Make sure the condition of locking.
WARNING Do not remove the lock of the point part of the

battery cover when charging. (For FB30P. )
193
CHARGER 10e
4. Connect the rectangular plug of the AC cable to the

receptacle on the charger panel.
5. Connect the AC plug to wall outlet.
Receptacle (body side)
Charger plug
Charger cord
Power supply plug
2210203E
Then, all "AUTO", "RESERVE" and "EQUAL" lamps are

turned on.
NOTE If these lamps are not turned on, make sure the AC
cable is connected correctly. 2210204
5. Push "AUTO" button. Automatic charge is started.
The "AUTO" lamp (green) is lit. Both "RESERVE" and

"EQUAL" lamps are turned off.
2210231

6. When charge is completed, the top green lamp of
charge status indicator is lit.
2210232
194
10e CHARGER
CAN-BUS control
7. When the charge is begun, the display power is turned
on and the charging passage is shown in the indicator.
lIndication of charging passage
221W1012
When the charge is completed, "CHARGE

COMPLETION" keeps being displayed.
NOTE When the charge is not completed even if 16

l
hours have passed since it began charging , the
end is displayed as a charge error.
If the charge plug is pulled out, the display is
l
turned off.
8. Disconnect the charger plug and AC plug.
9. Shut the battery cover while pushing a yellow part

(resin) in the middle of the gas spring. Closing battery cover
CAUTION Do not place the finger when pushing a yellow

part.
Do not place the finger when closing the battery
cover.
10. Fix the bonnet catch surely after shutting the battery
cover. 221W082E
DANGER Do not touch any parts of charger and cable by

wet hand.
195
CHARGER 10e
CAUTION Do not disconnect the rectangular plug, AC plug and battery plug while
l
charging.
Push the "STOP" button when discontinue to charge.
l
The charger operates with high voltage. Touch by wet hand may cause
l
electrical shock.
Do not operate any hydraulic valve levers or accelerator pedal while charging.
l
CAN-BUS control
CAUTION l The display is turned off when blacking out while charging.
When the power returns within one hour after it blacks out and the power is
supplied , the charge is restarted and the charging passage is displayed.
The charge is not restarted when one hour or more has passed since it blacked
out and the charge passage is not displayed.
l 44 hours pass with the charge plug connected after the charge ends, and when
outside temperature is less than five degrees, re-charging is done only once.
In this case, the charging passage is displayed.
196
10e CHARGER
10e-4-3. Balancing charge

l Specific gravity of electrolyte in each cell becomes
unbalance after a certain time of charge. In this case,
charge the battery for a little bit longer than a normal
charge in order to equalize all cells.
<Automatic balancing charge>

In the case of the built-in charger, the controller selects
the "EQUAL" mode automatically once of ten charges
even pushing the "AUTO" button.
<Manual balancing charge>

Balancing charge is required for the following cases.
lEvery two weeks when the lift truck is operated every
day.
lNot charged for a couple of days after discharged.
lOver-discharged.
<Charging procedure> To start the Balancing charge.
1. Push the "EQUAL" button as the same way as with a

normal charge.
"EQUAL" lamp (orange) will turn on.
2210242
2. Measure specific gravity of all cells after completion of

charge.
(See "Reading hydrometer" for specific gravity
measurement.)
NOTE When the specific gravity is 1.26-1.28 at 20C, the

battery is fully charged.
NOTE If the battery plug is disconnected, the memory

l
of time of charging is cleared in the controller 2210243
and the automatic balancing charge function is

not activated properly. In this case, the manual
balancing charge is recommended.
If the forklift truck is not used for a long time after
l
completion of charge, the supplement charge
function is activated automatically. Then, the
"AUTO" lamp is flashed.
197
CHARGER 10e
NOTE If all four (4) lamps of the charging status indicator

are flashed, the overtime error is detected.
Check if the volt-age tap selection of the transformer
is set to the correct voltage.
If any abnormalities are found, call your local
Nichiyu service dealer for inspection or repair.
The error status can be reset by disconnecting the
2210244
battery plug.
All four (4) lamps of the charging
status indicator are flashed
198
10e CHARGER
10e- 5. Voltage tap

10e-5-1. Power supply voltage - check
NOTE Measure the power supply voltage at the charging section without
l
running the charger.
Measure the voltage for 1 minute. The highest voltage obtained is the
l
power voltage.
If three-phase input power is used, the average of the highest voltages
l
of each phase (U-V, U-W, and V-W) is the power supply voltage.
CAUTION The measurement should be made when the peripheral facilities are
l
not used, such as during the lunch time or at night.
10e-5-2. Voltage tap - selection

lSelect a tap to match with the power supply voltage at
lLocation of the voltage tap
the charging place.
<Input voltage: 200V>

Primary coil
Power voltage (V) Voltage tap
199 or lower 200V
200 - 209 210V
210 - 219 220V Secondary
coil
<Input voltage: 400V>
Power voltage (V) Voltage tap
Voltage taps connection position
379 or lower 380V
380 - 399 400V
400 - 419 420V 2210221E
420 - 439 440V
Body side
3-core cable
(VCT)
Isolation tubes
are placed on for
These wires must be
unused taps.
connected securely with
bolt and nut.
Washer
Nut
Voltage and frequency

are marked on each wire. Isolation tube
Transformer side 461E116
199
CHARGER 10e
10e-5-3. Voltage tap - changing

CAUTION Turn off the key switch and disconnect the
l
power supply plug and the battery plug before
proceeding the work.
Securely tighten the screw for the ring
l
terminal to prevent from loosening.
210V
1. Loosen the screw and remove the ring terminal. 200V

Factory
setting:
2. Reconnect it to the tap fitting to the power supply 220V
voltage and secure the ring terminal together with
bolts and nuts.
3. Put the isolation tube over the connected part and fix it
with a wire tie.
lFactory default setting: 220 Volts 461E117
10e-5-4. Fuse (three-phase voltage) - replacement

CAUTION Disconnect the AC plug of the power supply
l
cable.
Securely tighten the screw.
Tighten all screws after replacement of fuses.
l
1. Loosen the screw to replace the link fuse. Link fuse
Power supply
Applicable model Battery capacity voltage
3 200V
2210222
330Ah(Std) 15A
FB10P/14P 480-485Ah(Opt) 20A
545Ah(Opt) 20A
400Ah(Std)/
20A
FB15P/18P 485Ah(Opt)
545Ah(Opt) 20A
485Ah(Std)/545-
20A
FB20P 600Ah(Opt)
650-730Ah(Opt) 20A
565Ah(Std)/
20A
FB25P/28P 600Ah(Std)
650-730Ah(Opt) 30A
450Ah(Std)/485-
FB30P 30A
600Ah(Opt)
200
10f. BATTERY
10f-1. Disassembly and reassembly
WARNING l Turn off the key switch and disconnect the battery plug.
l Apply wheel chocks to tyres to prevent the truck from moving.
l Be careful not to touch electrolyte to the body.
l If the electrolyte is splashed into eye, wash eye with clean water, and
consult a doctor immediately.
l The inspecting battery shall be done in a place where is well ventilated
and kept away from fire.
l Battery is very heavy.
Use proper slings or ropes to hang the battery with the hoist to remove
or install.and installing the battery
lRemoving
10f-1-1. Battery - removal and installation
Cover, battery
Gas spring
Catch, bonnet
Pin, battery
Battery
Case, battery
221W067E
201
BATTERY 10e
10f-2. Inspection and adjustment

10f-2-1. Battery - inspection
41 Inspection of quantity of electrolyte lInspection of electrolyte level
and replenishment Appropriate level
<Checking electrolyte level>

1. Disconnect the battery plug.
2. Open the battery cover and set the stopper.
CAUTION Since a gas spring (an assistant damper with

self-lock function) is used, the locking state Proper level of electrolyte
should be checked.
3. Check electrolyte level.
<Specification>
If the red float can seen, electrolyte level is normal.
l
If not, add refined or distilled water to the approproate
level. Lowest level of electrolyte
Add refined water to

CAUTION Do not add any sulfuric acid in the battery cell. the appropriate level.
The electroly te is the dilute sulfuric acid,

lAdding water
however, only distilled or refind water can be
used to add.
Cap
Float
<Adding refined water> White line
1. Open the cap of the battery cell.
Battery
2. Add the distilled or refined water until the top of the
red float is touched to the plate of the cap. Level of
electrolyte
NOTE The illustration shows the Japanese standard

battery and the actual battery on the truck may
have the different structure.
Refer the instruction from the battery supplier
for details.
202
10e BATTERY
42 Measurement of specific gravity of electrolyte in each cell

<How to use the hydrometer>
1. Open the cap of the battery cell.
2. Insert the tube of the hydrometer into the cell and suck lMEASUREMENT OF
the electrolyte. SPECIFIC GRAVITY
3. Read the scale at the surface of the sucked electrolyte.
Thermo Hydrometer
4. Read the specific gravity of all cells in turn. meter
The difference of the specific gravity of cells should be
less than 0.05.
5. If the difference is more than 0.05, carry out the
equalizing charge to the battery.
6. After finishing the equalizing charge, check and
compare the specific gravity of each cell.
If the difference is still more than 0.05, consult the
battery supplier for inspection.
<H ow to convert the specific gravity to the
standard value at 20 >
NOTE The specific gravity should be converted to the value

at 20 when judging the battery condition.
1. Measure temperature of electrolyte.
CAUTION lUse thermometer to measure lCONVERSION

1.330
Actual reading of hydrometer

2. Measure specific gravity of electrolyte. 1.310
1.290
Specific gravity at 20
3. Measured specific gravity shall be converted to the 1.300

1.290
1.280 1.270
1.270
value at 20 1.260 1.250
1.250
[Conversion formula] 1.240
1.230
1.230
1.210
S20=St+0.0007(t-20) 1.220
1.210
1.190
S20 : Specific gravity converted to 20 . 1.200
1.190 1.170
1.180
St : Measured specific gravity. 1.170
1.160
1.150
t : Temperature of electrolyte. 1.150
50 40 30 20 10 0 -10 -20
Temperature
10f-2-2. Battery - Cleaning

41 Cells, connectors and terminals
1. Keep dry. When they get wet, clean with a dry cloth or
blow out with compressed air.
2. If they are rusted, clean with a wire brush or a sand paper.
42 Cleaning vent plug

1. Turn the vent plug counter-clockwise to remove.
2. Clean it with a neutral detergent.
3. Securely fasten the vent plug on the cell after cleaning.
NOTE If the vent plug is damaged, replace the plug

comp. with new one.
203
10g. MPU BOARD
10g- 1. Location and name
10g-1-1. MPU board
lThis board controls the traction motor and the hydraulic motor.

Type : PB104-XX : IGBT control
PB108-XX : FET control
CPU (Flashes while the hydraulic CPU is normal.) P7 (Lights when the 7V power supply is normal.)
CPU (Flashes while the traction CPU is normal.) P15 (Lights when the 15V power supply is normal.)
RS1 (Rotary switch for truck model selection.)

CU harness (1)
Connector for PC (factory use only)
CN10 CN9
CN12 CN11 H CN7
HYD TRV
CN4
Equipped only for AOS / Fingertip (OPTION)
CN3
CPU Traction CPU
(T7xxxx) Body harness
CPU
CN2
Hydraulic CPU
(T8xxxx)
CN1
CN5 T
Current adjustment volume for the

proportional control valve
(Clockwise current reducing) CU harness (2)
221W119E
CAN-BUS control
Type : PB107-XX : STD
PB108-XX : CS Rotary switch for truck model selection
Traction CPU Hydraulic CPU
(T94xxx) (T95xxx) DIP switch (no use)
)
Current adjustment volume for the

%&'(
2
1

$

/,)7 proportional control valve

7,/7 (Clockwise current reducing)
&1
F2
5($&+
CPU CPU
$77 PV (Lights when the 12V power supply for
cooling fan is normal.)
&1
$77
39
3
P15 (Lights when the 15V power supply is normal.)
CU harness 3
+<' P6 (Lights when the 6V power supply is normal.)

759
HYD (Flashes when the hydraulic CPU is normal.)

&1
&1
+<'
TRV (Flashes when the traction CPU is normal.)

&1
&1
759
F1 F3

&1 &1 &1 &1 &1 &1
Body harness
Equipped only for AOS / Fingertip (OPTION)
Fuse (protection from short circuit)
F1 (FMC 1.0A for laser pointer)
F2 (FMC 3.0A for cooling fan)
F3 (FMC 1.0A for bearing sensor
and directional switch)
221T123E
204
10e MPU BOARD
10g-1-2. Display board

Type : PB106-XX : Stationary charger
PB103-XX : Built-in charger
This board controls both the data exchanged between the other boards and the display.
l
P7 (Lights when 7V power supply is normal)
CPU (flashes when the display CPU is normal.)
RS1 (Rotary switch for setting and adjustment)

Connector for
mode select switch Connector for display unit
F 0 12
B CDE
34 56
7 8 9A
CPU
CN2 CN1
Body harness Display CPU

Back up battery (L11xxx)
121T243E
10g-1-3. EPS controller board (EPS / DSP board)

EPS / DSP CPU
CAN-BUS control (E8xxxx)
Type : PB107-XX
RS1 (Rotary switch for setting and adjustment)
CPU ( Flashes when the EPS / DSP CPU is normal.)

F 0 12
B CDE
34 56
P7 (Lights when the 7V power supply is normal.) 7 8 9A
&38
3
CPU
ADJ (Volume for adjustment of starting
voltage of the charger timer) * no use $'-
F1 F2
Body harness
Fuse ( protection from short circuit)

F1 (FMC 2.0A for turn signal lamp-Left)
221T205E
F2 (FMC 2.0A for turn signal lamp-Right)
CAUTION Even when the key is turned off, voltage from the battery is still sent to the
display board or EPS controller (EPS / DSP board). Disconnect the battery plug
before performing this work.
205
11. LASER POINTER (OPTION)
11-1. Adjustment
11-1-1. Fork level - adjustment
1. Raise forks to a height for easy work, and level them.
2. Adjust the positions of the leveling sensor and the
magnet to light on the laser beam.
When the laser beam light on, the fork leveling indicator
is shown on the display. Magnet
Within 1.0 degree of

Adjustment position
the fork leveling position
Bracket,
<If the forks are not level> magnet
sensor
Either loosen the fixing bolts of the sensor bracket to
Bracket, sensor
reposition it, or slightly adjust the magnet so that it is
121W237E
in the center of the sensor sensing element when the

forks are level.
11-1-2. Laser optical axis - adjustment

1. Park the forklift truck face to the pallet.
Distance between the pallet and the tip of the fork
should be about 30 to 50 mm.
2. Level the fork horizontally.
3. Turn on the laser pointer.
Raise the fork to fit to the opening of the pallet.
4. Adjust the angle and height of the laser beam to show
the correct position on the side of the pallet.
If the "LINE" type is used, the laser line should hit the
center of the beam of the pallet.
If the "Dot" type is used, the laser point should hit the
upper board of the pallet..
5. Adjust the axis of the laser light by turning the "Screw,
set" on the side of the laser unit. Laser pointer unit
6. Make sure if the fork can be inserted into the pallet Laser optical axis
normally after indicating the position by the laser
pointer.
Case
Laser unit
Lock screw
121W238E
206
12. SERVICE DATA
12- 1. Annual Inspection Service Data
No.11 No.34 No.71 No.73
Overcurrent limiter Steering wheel (Standard load) Control valve
Drift of lift
Models For travel (A) For hydraulic lowering Drift of lift
Right turn Left turn Lift relief Tilt relief
Current (A) (mm/10min) (mm/5min)
radius (mm) radius (mm) (MPa) (MPa)
limitation Relief Top surface Tilt cylinder
of the fork
FB10P 400-500 210-290 1710 25-40 5-10 13.7
FB14P 400-500 210-290 1710 35-50 5-10 13.7
FB15P 400-500 210-290 1710 35-50 5-10 13.7
FB18P 400-500 250-330 1725 35-50 5-10 15.7
FB20P 400-500 250-330 1950 35-50 5-10 15.7
FB25P 400-500 250-330 2005 50-65 5-10 17.2
FB28P 400-500 250-330 2060 50-65 5-10 15.7
FB30P 400-500 250-330 2240 50-65 5-10 17.2
FB10P-U 400-500 250-330 1710 25-40 5-10 13.7
FB14P-U 400-500 250-330 1710 25-40 5-10 13.7
FB15P-U 400-500 250-330 1710 25-40 5-10 13.7
FB18P-U 400-500 310-390 1725 25-40 5-10 15.7
FB20P-U 400-500 310-390 2005 50-65 5-10 15.7
FB25P-U 400-500 310-390 2060 50-65 5-10 17.2
207
SERVICE DATA 12
12- 2. Standard work hours

<Confirmation procedure>
1. If some different works are required to carry out at the
same time, add all working time.
For example, if you need to remove the cover to
replace a part, add both hours for replacing the part
and removing the cover.
2. Standard work hour for maintenance represents the
inspection (lubricant, charge) job only.
3. For adjustment, replacement/removal/installation

(R/R/I), etc, see the respective group pages.
4. Unit of work hours

"The work hours are based on decimal system."
"For example, 0.5=30 minutes, 1.0=1 hour"
5. Combined jobs
For combined jobs, select necessary job items and
sum them up.
6. Cost of transportation, sub contractor work, and/or

service car charges are not included in the standard
work hours.
Those charge must be charged or claimed separately.
NOTE R/R/I : Replacement / Removal / Installation
208
12 SERVICE DATA
Rate (hour)
Group Work Job
10P-18P 20P-28P 30P
Maintenance Replace Drive axle gear oil 0.4 0.4 0.4
Hydraulic oil 0.4 0.4 0.4
R/R/I Lubrication 0.3 0.3 0.3
Battery electrolyte 0.3 0.3 0.3
Frame R/R/I Gas spring 0.3 0.3 0.3
Floor plate 0.1 0.1 0.1
Step (L) 0.1 0.1 0.1
Step (R) 0.1 0.1 0.1
Cover, battery (with spring) 0.4 0.4 0.4
Seat 0.2 0.2 0.2
Battery 0.3 0.3 0.3
Rear cover 0.1 0.1 0.1
Battery cover (L) 0.1 0.1 0.1
Battey cover (R) 0.1 0.1 0.1
Side cover (L) 0.1 0.1 0.1
Side cover (R) 0.1 0.1 0.1
Front hood R/R/I Front cover (1) 0.2 0.2 0.2
Front cover (2) 0.1 0.1 0.1
Front cover (3) 0.1 0.1 0.1
Front cover (4) 0.1 0.1 0.1
Front cover (5) 0.1 0.1 0.1
Front cover (6) - 0.1 0.1
Front cover (7) 0.1 0.1 0.1
Counter weight R/R/I Control unit 0.5 0.5 0.5
Counter weight (with Control unit) 0.5 0.5 0.5
Monthly inspection Retightening all fitting bolts 0.2 0.2 0.2
Seat R/R/I Seat ass'y 0.2 0.2 0.2
Monthly inspection Seat damage and Looseness in 0.1 0.1 0.1
mounting area
Overhead guard R/R/I Head guard (with Turn signal 0.3 0.3 0.3
lamp and Head lamp)
Turn signal lamp 0.2 0.2 0.2
Head lamp 0.2 0.2 0.2
Monthly inspection Looseness in mounting area 0.1 0.1 0.1
Deformation, crack, and damage 0.1 0.1 0.1
Front axle R/R/I Drive Ass'y (with Traction motor, 1.0 1.0 1.0
Brake, and Mast)
Wheel (1 piece) 0.1 0.1 0.1
Mast ass'y 0.6 0.6 0.6
Traction motor ass'y 0.7 0.7 0.7
Monthly inspection Oil leakage from Drive gear 0.1 0.1 0.1
case and unusual noise
Yearly inspection Unusual noise, oil level, fouling, 0.1 0.1 0.1
oil leakage, and fitting bolt
looseness
209
SERVICE DATA 12
Rate (hour)
Group Work Job
10P-18P 20P-28P 30P
Differential gear R/R/I Helical pinion and gear 1.2 1.5 1.5
(after removing Drive)
Differential gear 0.8 0.8 0.8
(after removing Drive)
Wheel hub and R/R/I Wheel (1 piece) 0.1 0.1 0.1
brake drum Drive shaft (1 piece) 0.1 0.1 0.1
(after removing Wheel)
Wheel hub (1 piece) 0.1 0.1 0.1
(after removing Drive shaft)
Wheel hub bearing (2 pieces) 0.1 0.1 0.1
(after removing Wheel hub)
Oil seal (Wheel hub) (1 piece) 0.1 0.1 0.1
(after removing Wheel hub)
Stud bolt (1 piece) 0.1 0.1 0.1
Fill grease (Wheel hub bearing) 0.1 0.1 0.1
(after removing Bearing)
Monthly inspection Retightening all wheel hub nuts 0.1 0.1 0.1
Drive shaft R/R/I Drive shaft (1 piece) 0.1 0.1 0.1
Stud bolt (1 piece) 0.1 0.1 0.1
Monthly inspection Two pieces rim bolt and hub 0.1 0.1 0.1
bolt/nut damage and looseness
Air pressure, crack, damage, 0.1 0.1 0.1
wear and metal chip caught in
between
Front wheel R/R/I Wheel (1 piece) 0.1 0.1 0.1
Pneumatic tyre (1 piece) 0.2 0.2 0.3
No puncture tyre (1 piece) 0.2 0.2 0.3
Rear wheel R/R/I Wheel (1 piece) 0.1 0.1 0.1
Pneumatic tyre (1 piece) 0.2 0.2 0.2
No puncture tyre (1 piece) 0.2 0.2 0.2
Steering axle R/R/I Wheel (1 piece) 0.1 0.1 0.1
(Rear axle) Steering axle (Rear axle) 1.0 1.0 1.0
Axle support bushing (For 1 0.1 0.1 0.1
truck) (after removing Rear axle)
Adjust Shim (Axle support) 0.1 0.1 0.1
Monthly inspection Rear axle joint 0.1 0.1 0.1
Yearly inspection Turn radius (Right mm) 0.1 0.1 0.1
(Left mm)
Stopper bolt looseness, if 0.1 0.1 0.1
it is not dropped off, and
interference with wheel
210
12 SERVICE DATA
Rate (hour)
Group Work Job
10P-18P 20P-28P 30P
Knuckle R/R/I Hub (1 piece) 0.2 0.2 0.2
King pin and Knuckle (1 piece) 0.1 0.1 0.1
(after removing Hub)
Taper roller bearing (one side) 0.2 0.2 0.2
Needle bearing (king pin) 0.3 0.3 0.3
(2 pieces)
(after removing King pin)
Oil seal (Wheel hub) (1 piece) 0.1 0.1 0.1
Bolt (Knuckle stopper) (1 piece) 0.3 0.3 0.3
Yearly inspection Wheel bearing and king pin jolt, 0.1 0.1 0.1
unusual noise, crack and damage
Wheel hub R/R/I Hub (1 piece) 0.2 0.2 0.2
Taper roller bearing (one side) 0.2 0.2 0.2
Oil seal (wheel hub) (1 piece) 0.1 0.1 0.1
Hub bolt (1 piece) 0.1 0.1 0.1
Fill grease (Hub bearing) (one 0.1 0.1 0.1
side) (after removing Bearing)
Center arm R/R/I Center arm 0.4 0.4 0.4
(after removing Rear axle)
Needle bearing (center arm) 0.1 0.1 0.1
(2 pieces) (after removing
Center arm)
Yearly inspection Crack, damage, deflection, 0.1 0.1 0.1
jolt, fitting bolt looseness and
dropped off
Tie rod R/R/I Tie rod (1 piece) 0.4 0.4 0.4
(after removing Rear axle)
Rod end(Tie rod end) (1 piece) 0.1 0.1 0.1
(after removing Tie rod)
Yearly inspection Crack, damage, deflection, 0.1 0.1 0.1
jolt, fitting bolt looseness and
dropped off
211
SERVICE DATA 12
Rate (hour)
Group Work Job
10P-18P 20P-28P 30P
Steering box R/R/I Steering gear box ass'y 0.4 0.4 0.4
(EPS) Pitman arm 0.3 0.3 0.3
Steering column 0.2 0.2 0.2
Joint (after removing Column) 0.1 0.1 0.1
Steering wheel 0.2 0.2 0.2
Horn contact, Horn cup, Spring 0.1 0.1 0.1
Potentiometer 0.5 0.5 0.5
Monthly inspection Measuring Potentiometer 0.1 0.1 0.1
voltage
Steering handle play 0.1 0.1 0.1
Handle grip damage, looseness 0.1 0.1 0.1
in mounting area, and jolt
Yearly inspection Gear box oil level, fouling, oil 0.1 0.1 0.1
leakage, fitting bolt looseness
and dropped off
Steering linkage R/R/I Horn contact, Horn cap, Spring 0.1 0.1 0.1
Pitman arm 0.3 0.3 0.3
Drag link 0.3 0.3 0.3
Rod end (1 piece) 0.1 0.1 0.1
(after removing Drag link)
Actuator 0.6 0.6 0.6
Adjust Turn radius 0.3 0.3 0.3
Wheel brake R/R/I Repair kit (1 set) 0.2 0.2 0.2
(after removing Brake drum)
Parking brake cable (one side) 0.4 0.4 0.4
Adjustment Brake (Discharging air) 0.5 0.5 0.5
Yearly inspection Space in the shoe 0.5 0.5 0.5
Lining peeling, damage and wear
Anchor pin corrosion
Spring permanent set
Drum crack, damage, wear, and
fitting bolt looseness
Back plate crack, damage,
deformation
and fitting bolt looseness
Monthly inspection Brake test (stopping distance, pull) 0.1 0.1 0.1
212
12 SERVICE DATA
Rate (hour)
Group Work Job
10P-18P 20P-28P 30P
Foot brake R/R/I Pedal 0.3 0.3 0.3
linkage Pedal bushing 0.1 0.1 0.1
(after removing Pedal)
Pedal pad 0.1 0.1 0.1
(after removing Pedal)
Return spring 0.2 0.2 0.2
Adjust Brake pedal play 0.2 0.2 0.2
Monthly inspection Height, level and clearance 0.1 0.1 0.1
between pedal and floor
Microswitch timing 0.1 0.1 0.1
Yearly inspection "Rod, link" damage, looseness 0.1 0.1 0.1
and jolt "Pin, cotter" fracture
Master cylinder R/R/I Master cylinder 0.2 0.2 0.2
Repair kit 0.2 0.2 0.2
(after removing Master cylinder)
Adjust Brake (discharging air) 0.5 0.5 0.5
Yearly inspection Master cylinder and wheel 0.1 0.1 0.1
cylinder operation, oil level,
fouling and oil leakage
Brake oil piping R/R/I Pipe (with tube nut) (1 piece) 0.1 0.1 0.1
Monthly inspection Entrained air, oil leakage, 0.1 0.1 0.1
damage, aging, bolt looseness,
and interference with wheel
Parking brake R/R/I Microswitch (parking brake) 0.3 0.3 0.3
Parking lever comp. 0.5 0.5 0.5
Parking brake cable (one side) 0.4 0.4 0.4
Monthly inspection Lock condition 0.1 0.1 0.1
Brake response time
Lever stroke and pulling force
Feeling, damage, and wear
Oil tank R/R/I Gasket 0.1 0.1 0.1
Suction filter 0.5 0.5 0.5
Return filter 0.5 0.5 0.5
LP hose 0.2 0.2 0.2
Clean Oil tank 0.5 0.5 0.5
Monthly inspection Oil level, any contaminations 0.3 0.3 0.3
Yearly inspection Oil level and fouling, if there is 0.1 0.1 0.1
any moisture
Filter, clogging, and damage 0.1 0.1 0.1
Hydraulic pump R/R/I Hydraulic pump 0.5 0.5 0.5
Connection elbow and nipple
Oil piping
Coupling (after removing Pump) 0.1 0.1 0.1
Oil seal (after removing Pump) 0.1 0.1 0.1
Monthly inspection Oil leakage, Unusual vibration, 0.1 0.1 0.1
and unusual noise
213
SERVICE DATA 12
Rate (hour)
Group Work Job
10P-18P 20P-28P 30P
Control valve R/R/I Control valve 0.5 0.5 0.5
Wiper and O-ring 0.1 0.1 0.1
(after removing Control valve)
Spring or spring seat 0.1 0.1 0.1
(after removing Control valve)
Relief valve 0.2 0.2 0.2
Linkage 0.6 0.6 0.6
Oil piping 0.9 0.9 0.9
Elbow and nipple 0.2 0.2 0.2
Adjust Relief valve pressure 0.3 0.3 0.3
Yearly inspection Operation, oil leakage, and 0.1 0.1 0.1
Lift cylinder R/R/I Lift cylinder (1 piece) 0.3 0.3 0.3
(P-mast) Chain support comp. 0.2 0.2 0.2
Lift bracket 0.4 0.4 0.4
Seal kit (1 set) 0.3 0.3 0.3
(after removing Cylinder)
Yearly inspection Operation, oil leakage, dent 0.1 0.1 0.1
crack, deflection, scratch, and
Drift of lowering 0.2 0.2 0.2
( mm/10min)
1st lift cylinder R/R/I 1st lift cylinder ass'y 0.9 0.9 0.9
(PFL-mast) Seal kit (after removing 0.5 0.5 0.5
Cylinder)
Yearly inspection Operation, oil leakage, dent, 0.1 0.1 0.1
crack, and deflection
( mm/10min)
Measuring drift of Inner mast
lowering
2nd lift cylinder R/R/I Lift cylinder ass'y (1 piece) 0.3 0.3 0.3
(PFL-mast) Seal kit (1 set) 0.3 0.3 0.3
scratch, and fitting bolt
looseness
crack, and deflection
( mm/10min)
214
12 SERVICE DATA
Rate (hour)
Group Work Job
10P-18P 20P-28P 30P
1st lift cylinder R/R/I Lift cylinder ass'y 0.8 0.8 0.8
(M-mast) Seal kit (after removing 0.4 0.4 0.4
Cylinder)
( mm/10min)
2nd lift cylinder R/R/I Lift cylinder ass'y (1 piece) 0.3 0.3 0.3
(M-mast) Seal kit (1 set) 0.3 0.3 0.3
Flow control valve 0.2 0.2 0.2
2nd lift cylinder Yearly inspection Operation, oil leakage, dent, 0.1 0.1 0.1
crack, deflection,scratch, and
( mm/10min)
Tilt cylinder R/R/I Tilt cylinder ass'y (1 piece) 0.3 0.3 0.3
Tilt cylinder rod end 0.1 0.1 0.1
Rod end bushing 0.2 0.2 0.2
Cylinder end cover bushing 0.1 0.1 0.1
Tilt pin 0.2 0.2 0.2
Seal kit (1 piece) 0.3 0.3 0.3
( mm/10min)
Piping R/R/I Hose (1 piece) 0.2 0.2 0.2
Connector, elbow, nipple, etc 0.1 0.1 0.1
(1 piece)
Flow control valve or fuse valve 0.2 0.2 0.2
Monthly inspection Oil leakage, deformation, 0.1 0.1 0.1
damage, jolt, and looseness
Yearly inspection Crack, damage, aging, twisting, 0.1 0.1 0.1
oil leakage, mounting condition,
and bolt/nut looseness
215
SERVICE DATA 12
Rate (hour)
Group Work Job
10P-18P 20P-28P 30P
Valve lever R/R/I Valve lever linkage ass'y 0.6 0.6 0.6
linkage (with control valve and
microswitch)
Valve lever (1 piece) 0.2 0.2 0.2
Link (1 piece) 0.2 0.2 0.2
Bushing (2 pieces on a lever) 0.2 0.2 0.2
(after removing Lever)
Lever knob (1 piece) 0.1 0.1 0.1
Microswitch (1 piece) 0.3 0.3 0.3
Mast R/R/I Mast ass'y 0.6 0.6 0.6
Mast support bushing (For 1 0.6 0.6 0.6
truck)
Mast roller (after removing Mast) 0.1 0.1 0.1
(Outer mast or Inner mast)
(1 piece)
Back shoe (after removing Mast) 0.3 0.3 0.3
Lift chain (1 piece) 0.3 0.3 0.3
Lift chain anchor bolt (1 piece) 0.5 0.5 0.5
Chain wheel (1 piece) 0.2 0.2 0.2
Chain support 0.5 0.5 0.5
Stopper cushion rubber 0.1 0.1 0.1
Stopper bracket 0.1 0.1 0.1
Adjust Mast roller adjustment 0.4 0.4 0.4
(Outer mast, inner mast)
Back shoe 0.1 0.1 0.1
Lift bracket R/R/I Lift bracket ass'y 0.4 0.4 0.4
Backrest 0.2 0.2 0.2
Roller (1 piece) 0.8 0.8 0.8
(after removing Lift bracket)
Side roller (1 piece) 0.8 0.8 0.8
(after removing Lift bracket)
Fork (For 1 truck) 0.2 0.2 0.2
Fork set pin, spring (1 piece) 0.1 0.1 0.1
Adjust Lift bracket adjustment 0.7 0.7 0.
Monthly inspection Lift bracket jolt, crack in welded area 0.1 0.1 0.1
Yearly inspection Bracket deformation, crack, and 0.2 0.2 0.2
damage Roller wear and jolt Pin
area crack
Chain wheel Monthly inspection Chain tension, extension, crack, 0.1 0.1 0.1
and lift chain deformation, damage, and wear,
Wheel deformation, damage,
and jolt
Yearly inspection Chain tension, extension, crack 0.1 0.1 0.1
deformation, damage, and wear,
Wheel deformation, damage,
and jolt
216
12 SERVICE DATA
Rate (hour)
Group Work Job
10P-18P 20P-28P 30P
Fork R/R/I Fork (For 1 truck) 0.2 0.2 0.2
Fork set pin, spring (1 piece) 0.1 0.1 0.1
Fork (For 1 truck) 0.2 0.2 0.2
Monthly inspection Fork deformation, wear, and 0.1 0.1 0.1
crack
Yearly inspection Deformation, crack and wear in 0.1 0.1 0.1
locking pin area
Fork tip opening and leveling
Bottom area, upper hock area
and under hock area crack and
wear
Traction motor R/R/I Drive ass'y 1.0 1.0 1.0
(with Traction motor, Brake,
Mast)
Wheel (1 piece) 0.1 0.1 0.1
Mast ass'y 0.6 0.6 0.6
Traction motor ass'y 0.7 0.7 0.7
Bearing, sensor 0.3 0.3 0.3
Cover, end 0.3 0.3 0.3
Rotor comp./bearing (2 pieces) 0.5 0.5 0.5
Seal, oil 0.2 0.2 0.2
Stator comp. 0.5 0.5 0.5
Cover 0.1 0.1 0.1
Clean/check Traction motor ass'y 0.6 0.6 0.6
Monthly inspection Unusual sound and unusual 0.1 0.1 0.1
smell during motor rotation
Yearly inspection Bolt looseness, fitting bolt 0.2 0.2 0.2
looseness in main body
Motor rotation condition - 0.1 0.1 0.1
(low speed, inter mediate speed,
high speed, acceleration),
unusual noise, unusual smell 0.1 0.1 0.1
Hydraulic motor R/R/I Hydraulic motor ass'y 0.3 0.3 0.3
(with pump)
Pump ass'y 0.4 0.4 0.4
Cover, end 0.3 0.3 0.3
Armature / bearing (2 pieces) 0.5 0.5 0.5
Stator comp. 0.5 0.5 0.5
Cover 0.1 0.1 0.1
Clean/check Motor ass'y 0.5 0.5 0.5
Monthly inspection Hydraulic motor unusual noise, 0.1 0.1 0.1
unusual smell
Yearly inspection Bolt looseness, fitting bolt 0.2 0.2 0.2
looseness in main body
Motor rotation condition -(low 0.1 0.1 0.1
speed, inter mediate speed,
high speed, acceleration),
Unusual noise, unusual smell
217
SERVICE DATA 12
Rate (hour)
Group Work Job
10P-18P 20P-28P 30P
EPS motor R/R/I EPS motor ass'y 0.4 0.4 0.4
Armature comp./ bearing (2 0.4 0.4 0.4
pieces)
Carbon brush (all) 0.4 0.4 0.4
Clean/check EPS motor ass'y 0.5 0.5 0.5
Repair Grinding commutator and under 0.5 0.5 0.5
cutting
Monthly inspection EPS motor unusual noise, 0.1 0.1 0.1
unusual smell
EPS motor brush wear 0.1 0.1 0.1
Yearly inspection Brush wear, contact, 0.2 0.2 0.2
commutator burnout
commutator burnout
218
12 SERVICE DATA
Rate (hour)
Group Work Job
10P-18P 20P-28P 30P
Control unit R/R/I Control unit ass'y removal / 1.5 1.5 1.5
installation
IGBT module (1 piece) 0.7 0.7 0.7
Add 0.2Hrs every time 1 piece is
added.
Sensor comp., current (1 piece) 0.6 0.6 0.6
added.
Capacitor (1 piece) 0.8 0.8 0.8
added.
Resister (1 piece) 0.8 0.8 0.8
added.
Sensor comp., heat (1 piece) 0.7 0.7 0.7
added.
Capacitor (1 piece) 0.6 0.6 0.6
added.
MPU board (travel/hydraulic) 0.4 0.4 0.4
Fan comp (1 piece) 0.5 0.5 0.5
added.
Confirmation Travelling speed, lift speed, 0.5 0.5 0.5
plugging distance.
Monthly inspection Looseness in terminal contact 0.1 0.1 0.1
area, looseness in wiring
mounting area
Resistor and capacitor terminal 0.1 0.1 0.1
looseness and burnout, fitting
bolt looseness
Yearly inspection [Overcurrent limiter] 0.1 0.1 0.1
(for hydraulic A)
Motor lock current value
(for travel A)
[Safety device] Contactor 0.1 0.1 0.1
operation
(pulling out arc or not)
Wiring looseness, damage, and 0.2 0.2 0.2
clamp condition
Accelerator R/R/I Accelerator 0.5 0.5 0.5
Monthly inspection Accelerator pedal operating 0.1 0.1 0.1
condition
Display panel R/R/I 1.0 1.0 1.0
Display panel ass'y
ass'y
219
SERVICE DATA 12
Rate (hour)
Group Work Job
10P-18P 20P-28P 30P
Directional R/R/I Indicator panel cover 0.4 0.4 0.4
switch Cam comp. 0.2 0.2 0.2
Lever comp. 0.3 0.3 0.3
Microswitch 0.2 0.2 0.2
added
Monthly inspection Each connected area jolt 0.1 0.1 0.1
Lever movement condition
Microswitch timing and
operating condition
Microswitch damage, looseness
in mounting area
Yearly inspection Adequacy of Microswitch 0.2 0.2 0.2
timing,damage, and fitting bolt
looseness
Indicator panel R/R/I Indicator panel cover 0.4 0.4 0.4
LCD display unit 0.3 0.3 0.3
Turn signal lamp switch 0.3 0.3 0.3
Sheet switch comp. 0.3 0.3 0.3
Display board 0.3 0.3 0.3
Monthly inspection Turn signal lamp damage, 0.1 0.1 0.1
operating condition, and
mounting condition
Instruments operation
Main contactor R/R/I Contactor comp. 0.4 0.4 0.4
Yearly inspection Contact point looseness, 0.1 0.1 0.1
damage, wear, operation,
fouling, and fitting bolt
looseness
Contactor Monthly inspection Contactor timing and operating 0.1 0.1 0.1
condition
Contactor contact point 0.1 0.1 0.1
looseness, damage, and wear
Contactor auxiliary contact point 0.1 0.1 0.1
wear, and damage
220
12 SERVICE DATA
Rate (hour)
Group Work Job
10P-18P 20P-28P 30P
Others R/R/I Main fuse (1 piece) 0.2 0.2 0.2
(electric parts) Turn signal lamp switch ass'y 0.2 0.2 0.2
Horn 0.2 0.2 0.2
Battery plug (chassis side) 0.2 0.2 0.2
Back buzzer 0.1 0.1 0.1
Head lamp (1 piece) 0.2 0.2 0.2
Turn signal lamp (1 piece) 0.2 0.2 0.2
Combination lamp 0.1 0.1 0.1
Monthly inspection Fuse fitting bolt looseness, 0.1 0.1 0.1
capacity adequacy
Warning device damage,
operating condition, and
mounting condition
Rear view mirror and reflecting
mirror fouling, damage, and
reflecting condition
Lightning system operation and
mounting condition
Direction indicator operation and
mounting condition
Display board and instruments
damage and mounting condition
Operation, water infiltration
Backup alarm operation 0.1 0.1 0.1
Charger (option) R/R/I Front panel (left side) 0.3 0.3 0.3
Transformer ass'y 0.3 0.3 0.3
Panel ass'y 0.6 0.6 0.6
Diode (1 piece) 0.1 0.1 0.1
Adjustment 0.3 0.3 0.3
Receptacle 0.6 0.6 0.6
Magnet switch 0.2 0.2 0.2
Fuse 0.2 0.2 0.2
AC cable and plug 0.2 0.2 0.2
Monthly inspection Timer operation 0.1 0.1 0.1
Magnet switch operating
condition
AC cable damage and
looseness
Receptacle contact condition
Yearly inspection Voltage detection relay operating 0.1 0.1 0.1
voltage ( V)
221
SERVICE DATA 12
Rate (hour)
Group Work Job
10P-18P 20P-28P 30P
Battery R/R/I Battery 0.3 0.3 0.3
Battery plug 0.4 0.4 0.4
Adjust Replenishing water and clean 0.2 0.2 0.2
up
Monthly inspection Electrolyte level 0.1 0.1 0.1
Terminal looseness, damage,
and wear
Cell damage and electrolyte
leakage
Temperature and specific gravity
after charging
(Max. , Min. )
Battery plug and cable damage
and looseness
Yearly inspection Each cell voltage 0.1 0.1 0.1
(Max. , Min. )
Electric power R/R/I EPS controller ass'y 0.4 0.4 0.4
steering EPS sensor ass'y 0.4 0.4 0.4
Monthly inspection Looseness in gear box mounting 0.1 0.1 0.1
area
Interference with chassis
Right and left steering angle 0.1 0.1 0.1
222
Reproduction prohibited
First printing : Dec 2003
Second edition : Sep 2008
Issued by : Nippon Yusoki Co., Ltd
Edited by : Overseas division
Nippon Yusoki Co., Ltd.

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What are the main components covered in the manual?

What are the main components covered in the manual?

What safety precautions are emphasized?

What safety precautions are emphasized?

INTRODUCTION

4Most accident happens due to the disregard of basic safety rules or

Performing maintenance and repair without adequate knowledge may

[Control System Transition]

Indicates a potentially hazardous situation which, if not avoided,

Indicates suggestions, tips and hints related to the safety of a

1. Personnel this "WORKSHOP MANUAL" is aimed at:

2-2. Disassembly and reassembly..................... 20 5-3. Inspection and adjustment.......................... 57

3. REAR AXLE (STEERING) 36

7-1. Oil pipimng circuit....................................... 77 7d-2. Disassembly and reassembly.................. 98

11. LASER POINTER (OPTION) 206

10f. BATTERY 201

CAUTION WELL-VENTILATED AREA

CAUTION LOCATION EQUIPPED WITH FIRE

CAUTION SAFE AND WELL-LIGHTED AREA

CAUTION PROPER ARRANGEMENT

Tools and gauges

CAUTION Prepare tools and gauges before starting to work.

WARNING l W h en hoist ing a for kli f t t r uc k or a h eav y

WARNING l Do not lif t the forklif t truck by using other

WARNING After lifting or jacking up a forklift truck, support it

WARNING Apply wheel chocks to tyres to prevent the truck

WARNING When working under a forklift truck, use a pit or

CAUTION When replenishing battery electrolyte, be sure to

Repair of electrical components

CAUTION Be sure to jack up the drive wheel when trouble

NOTE Record the places of lead wire connection when

CAUTION CHARGING BATTERY

CAUTION l Diluted sulfuric acid is used as the battery's

CAUTION When removing the hydraulic pipes, cap them

CAUTION When disassembling and assembling the

Marks and Symbols

No. Parts No. Parts Name Q'ty Notes

0902-69954 Air pressure (bar) FB10P-15P

GASES produced by this battery can be explosive.

float as shown herein, for overfilling causes overflow.)

10: for Rear tyre (only for EEC)

BATTERY WEIGHT MIN. kg MAX. kg 50006-95900

BATTERY WEIGHT MIN. kg MAX. kg 50006-91510

Classification P : Pneumatic tyre

U : High speed type

B : Large capacity battery

Mast type NO CODE : Two stage full visibility (simplex) mast

CS : Cold storage use for -35C

lLocation of serial numbers

BATTERY WEIGHT MIN. kg MAX. kg 50006-95900

As shown in the illustration, face the slit side in the

The split pin must be replaced with a new one and

When using a thrust washer with oil grooves cut,

l When connecting and disconnecting couplers of

l Applying liquid packing

Cut the nozzle at the

* When applying the liquid packing to bolt holes, apply it 3 -3.5 mm

4. Close the mating surfaces within 15 minutes after the

2. If oil (filler) was separated from the liquid packing and