FB10-30P-DC70-Series SM

02W-2202
WORKSHOP MANUAL
FB-DC70 SERIES
10P, 15P, 18P
FB 20P, 25P, 30P
INTRODUCTION
sMost 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.
sIt 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.
Using this "WORKSHOP MANUAL"
This manual has information about the layout and names of main components, procedures for
disassembly, assembly, inspection, adjustment, maintenance, and pinpointing faults which are in effect
mainly for the model FB-DC70.
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 the "WORKSHOP MANUAL"
may not be identified.
Directions with and marks are very important, and must be followed.
Indicates a potentially hazardous situation which, if not avoided,

DANGER could result in death or serious injury.
You shall observe this instruction.
Indicates a potentially hazardous situation which, if not avoided,

WARNING could result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, may

CAUTION result in minor or moderate injury.
Indicates suggestions, tips and hints related to the safety of a

NOTE
operator and maintain of truck.
qPersonnel 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.
wConditions of a facility
The work conditions described in the "WORKSHOP MANUAL" are written on the assumption that the
work is performed at a shop where standard 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 where the facilities are
equivalent to these described in the "WORKSHOP MANUAL" or better, and the instructions described
should be strictly followed.
Copyright© 2002
NIPPON YUSOKI CO., LTD.
All Rights Reserved
CONTENTS
SAFETY WORK 1 4 .TYRE 43
1.Precautions for safe inspection and 4-1. Location, name and tyre size .......................43
maintenance work ..............................................1 4-1-1. Tyre - location and name ...........................43
2. Safety labels ......................................................5 4-1-2. Tyre size ....................................................43
3. Model name and serial numbers .......................9 4-2. Inspection and adjustment ...........................44
4. Cautions for maintenance ................................11 4-2-1. Hub nut - inspection ...................................44
5. Tightening torque for bolts ...............................14 4-2-2. Rim and rim bolt - inspection .....................44
4-2-3. Air pressure - inspection ............................45
4-2-4. Tyre - visual inspection and replacement ..45
1 .GENERAL 16 4-3. Troubleshooting............................................46
4-3-1. Tyre - troubleshooting ................................46
1-1. Appearance ..................................................16
1-2. Specifications ...............................................17
5. STEERING 47
2 .FRONT AXLE (DRIVE) 19 5-1. Location and name.......................................47

5-2. Disassembly and reassembly.......................48
2-1. Location and name.......................................19 5-2-1. Steering - removal and installation.............48
2-2. Disassembly and reassembly.......................20 5-2-2. Steering linkage - disassembly
2-2-1. Front axle - removal and installation ..........20 and reassembly..........................................50
2-2-2. Front axle - disassembly and reassembly..26 5-3. Inspection and adjustment ...........................52
2-3. Inspection and adjustment ...........................30 5-3-1. Joint - inspection and replacement ............52
2-3-1. Gears - Inspection and replacement..........30 5-3-2. Knob - inspection and replacement ...........52
2-3-2. Wheel hub and hub bolt - Inspection .........30 5-3-3. Steering wheel - inspection
2-4. Troubleshooting............................................31 and replacement ........................................52
2-4-1. Front axle - troubleshooting ...................31 5-3-4. Torque sensor neutral - check
and adjustment ..........................................53
5-3-5. Checking by voltage...................................55
3 .REAR AXLE (STEERING) 32 5-4. Troubleshooting............................................56
3-1. Location and name.......................................32 5-4-1. Steering linkage - troubleshooting .............56
3-2-1. Rear axle - removal and installation...........33
3-2-2. Rear axle - disassembly and reassembly ..35 6. BRAKE 57
3-2-3. Rear axle assembly - methods and
6-1. Location and name.......................................57
precautions ................................................37
6-1-1. Foot brake linkage - main part names .......57
3-3. Inspection and adjustment ...........................40
6-1-2. Parking brake linkage - main part names ..58
3-3-1. Bushing - inspection...................................40
3-3-2. Center arm - inspection..............................40
6-2-1. Wheel brake - removal and installation......59
3-3-3. Tie rod comp. - inspection..........................40
6-2-2. Wheel brake - disassembly
3-3-4. Knuckle - inspection...................................40
and reassembly..........................................61
3-3-5. King pin - inspection...................................41
6-3. Inspection and adjustment ...........................62
3-3-6. Hub and hub bolt - inspection ....................41
6-3-1. Brake drum - inspection, repair and
3-3-7. Rear axle comp. - inspection .....................41
replacement ...............................................62
3-4. Troubleshooting............................................42
6-3-2. Shoe & lining - inspection and replacement ..62
3-4-1. Rear axle - troubleshooting........................42
6-3-3. Adjustor ass'y - inspection
and replacement ........................................63
6-3-4. Wheel cylinder ass'y - inspection 7c. CONTROL VALVE 77
and replacement ........................................63
6-3-5. Master cylinder ass'y - inspection and 7c-1. Location and name .....................................77
replacement ...............................................64 7c-2. Disassembly and reassembly.....................79
6-3-6. Brake pedal - inspection ............................64 7c-2-1. Control valve - removal and installation.......79
6-3-7. Parking lever - inspection 7c-2-2. Inner kit of control valve - replacement........81
and adjustment ..........................................65 7c-3. Inspection and adjustment..........................82
6-3-8. Brake linkage - adjustment ........................65 7c-3-1. Relief pressure - measurement .............82
6-3-9. Discharge air from the brakes....................66 7c-3-2. Microswitch - adjustment.......................82
6-4. Troubleshooting............................................67 7c-4. Troubleshooting ..........................................83
6-4-1. Brake - troubleshooting..............................67 7c-4-1. Control valve - troubleshooting..............83
7. HYDRAULIC SYSTEM 68 7d. CYLINDER 84

7-1. Oil piping circuit ............................................68 7d-1. Location and name.....................................84
7d-1-1. Lift cylinder - main part names.................84
7d-1-2. Tilt cylinder - main part names.................85
7a. HYDRAULIC PUMP 69 7d-2. Disassembly and reassembly.....................86
7d-2-1. Lift cylinder (STD mast) - removal ...........86
7a-1. Location and name.....................................69
7d-2-2. Lift cylinder 2nd (M/PFL mast) - removal ........88
7a-2. Disassembly and reassembly.....................70
7d-2-3. Tilt cylinder - removal...............................90
7a-2-1. Hydraulic pump - removal
7d-2-4. Lift cylinder (STD mast) - installation .......91
and installation ...........................................70
7d-2-5. Lift cylinder 2nd (M/PFL mast)
7a-3. Inspection and adjustment .........................71 - installation...............................................91
7a-3-1. Coupling, pump - inspection ....................71
7d-2-6. Tilt cylinder - installation...........................92
7a-3-2. Hydraulic pump - inspection.....................71
7d-2-7. Lift cylinder - disassembly and reassembly ..92
7a-4. Troubleshooting..........................................72 7d-2-8. Tilt cylinder - disassembly and reassembly ..94
7a-4-1. Hydraulic pump - troubleshooting ............72 7d-3. Inspection and adjustment .........................95
7d-3-1. Cylinder comp - inspection.......................95
7d-3-2. Piston rod - inspection .............................95
7b. OIL TANK AND OIL PIPING 73 7d-3-3. Drift of lift lowering and tilt - inspection......95
7b-1. Location and name.....................................73 7d-4. Troubleshooting..........................................97
7b-1-1. lron oil tank - main part names.................73 7d-4-1. Cylinder - troubleshooting ........................97
7b-2. Disassembly and reassembly.....................74
7b-2-1. Oil tank - precautions ...............................74
7b-2-2. Oil piping replacement - precautions .......74
7b-3. Inspection and adjustment .........................75
7b-3-1. Oil - inspection .........................................75
7b-3-2. Recommended oil and oil quantity...........75
7b-3-3. Oil tank and filters - cleaning and check ..76
7b-4. Troubleshooting..........................................76
7b-4-1. Oil tank - troubleshooting .........................76
8. MAST 98 9-3-5. Oil seal and permanent magnet (EPS motor)
- inspection and replacement ......................125
8-1. Location and name.......................................98 9-4. Troubleshooting..........................................125
8-2. Disassembly and reassembly.....................100 9-4-1. Motor - troubleshooting ............................125
8-2-1. Lift bracket - removal ...............................100
8-2-2. Mast ass'y - removal ................................100
8-2-3. Mast - disassembly and reassembly........102 10. ELECTRIC PARTS 126
8-3. Inspection and adjustment .........................105
10-1. Location and name...................................126
8-3-1. Mast, lift bracket and roller shaft
- inspection...............................................105
8-3-2. Back shoe - inspection.............................106
8-3-3. Lift chain - inspection and replacement ......106 10a. CONTROL UNIT 127
8-3-4. Chain bolt - inspection .............................106 10a-1. Location and name.................................127
8-3-5. Chain wheel - inspection..........................107 10a-2. Disassembly and reassembly.................128
8-3-6. Hose pulley - inspection...........................107 10a-2-1. Control unit - removal and installation..128
8-3-7. Roller - inspection and replacement ........107 10a-2-2. Control unit - disassembly
8-3-8. Fork - inspection and replacement...........108 and reassembly....................................129
8-3-9. Lift chain - inspection and adjustment......109 10a-2-3. Contactor - removal and installation ....131
8-3-10. Mast inclination - inspection 10a-2-4. Contactor - disassembly
and adjustment ........................................109 and reassembly....................................132
8-4. Troubleshooting ..........................................110 10a-3. Check and replacement .........................134
8-4-1. Mast - troubleshooting .............................110 10a-3-1. Capacitor - discharging procedure.......134
10a-3-2. Diode - inspection ................................134
10a-3-3. FET - inspection...................................135
9. MOTOR 111 10a-3-4. Capacitor - check and replacement .....136
10a-3-5. MPU board - inspection .......................136
9-1. Location and name .....................................111
10a-3-6. EPS controller - specifications .............136
9-1-1. Traction motor - main part names............111
9-1-2. Hydraulic motor - main part names..........111
9-1-3. EPS motor - main part names..................112
9-1-4. Motors - specifications .............................112 10b. DISPLAY PANEL AND
9-2. Disassembly and reassembly .....................113 DIRECTIONAL SWITCH 137
9-2-1. Traction motor - removal and installation.113 10b-1. Disassembly and reassembly.................137
9-2-2. Hydraulic motor - removal 10b-1-1. Display panel - disassembly
and installation .........................................114 and reassembly....................................137
9-2-3. EPS motor - removal and installation.......116 10b-1-2. Directional switch - disassembly
9-2-4. Traction motor - disassembly and reassembly....................................138
and reassembly........................................117
9-2-5. Hydraulic motor - disassembly
and reassembly........................................118
10c. ACCELERATOR 140
9-2-6. EPS motor - disassembly and reassembly...118
9-3. Inspection and adjustment .........................119 10c-1. Disassembly and reassembly.................140
9-3-1. Armature comp. - inspection 10c-1-1. Accelerator linkage - removal
and replacement ......................................119 and installation .....................................140
9-3-2. Brush, brush holder and spring
- inspection and replacement...................121
9-3-3. Field coil - inspection ...............................123
9-3-4. Motor ass'y - inspection ...........................123
10d. CHARGER (BUILT-IN TYPE) 141 11. LASER POINTER (OPTIONAL) 157
10d-1. Disassembly and reassembly.................141 11-1. Adjustment................................................157
10d-1-1. Charger ass'y - disassembly 11-1-1. Fork level - adjustment...........................157
and reassembly....................................141 11-1-2. Laser optical axis - adjustment ..............157
10d-1-2. Transformer - disassembly
and reassembly....................................142
10d-1-3. Built-in charger - specifications ............142
12. SERVICE DATA 158
10d-2. Inspection and replacement ...................143
10d-2-1. Magnetic contactor - inspection ...........143 12-1. Annual Inspection Service Data ...............158
10d-2-2. Plug comp. and receptacle 12-2. Standard work hours ....................................158
- inspection and replacement...............143
10d-2-3. Link fuse and fuse base - inspection....143
10d-2-4. Transformer - inspection ......................144
10d-2-5. Diode - inspection ................................144
10d-3. Inspection After Assembly......................145
10d-3-1. Timer - inspection ................................145
10d-4. Charging procedure................................146
10d-4-1. Normal (Daily charge) ..........................146
10d-4-2. Balancing charge .................................149
10d-5. Voltage tap .................................................151
10d-5-1. Power voltage - check..........................151
10d-5-2. Voltage tap - selection .........................151
10d-5-3. Voltage tap - switching.........................152
10d-5-4. Link fuse (three-phase voltage)
- replacement .......................................152
10e. BATTERY 153

10e-1. Disassembly and reassembly.................153
10e-1-1. Battery - removal and installation.........153
10e-2. Inspection and adjustment .....................154
10e-2-1. Battery - inspection ..............................154
10e-2-2. Battery - Cleaning ................................155
10f. MPU BOARD 156

10f-1. Location and name..................................156
SAFETY WORK
1. Precautions for safe inspection and
maintenance work
Maintenance shops
CAUTION Facilities with adequate space and level

surfaces:
¡The floor area of the shop (location) where
inspection and maintenance are performed must
have adequate floor space, and have level sur-
faces without holes.
aIf these conditions are not met, unexpected acci-
dents, such as a roll-over of the forklift truck,
may result.
CAUTION WELL-VENTILATED AREA

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

GUISHING EQUIPMENT
¡Equipment such as first-aid boxes and fire extin-
guishers should be nearby when work is per-
formed.
CAUTION SAFE AND WELL-LIGHTED AREA

¡The 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.
aIf this is not observed, leaked oil may catch fire
when a light bulb pops.
CAUTION PROPER ARRANGEMENT

¡Arrange and clean always at a working place to
work safety.
¡Especially, arrange disassembled parts well.
1
Work clothing
CAUTION ¡The worker should wear a hat, work clothes, and

safety shoes that are suitable for safe work. The
work clothes should be close-fitting.
a If this is not observed, loose clothing may
become caught in a machine, resulting in seri-
ous injury.
Tools and gauges
CAUTION ¡Always use tools that are suitable for the work
being performed. Use proper size tools when
tightening and loosening the parts of the forklift
truck.
aFailure to observe the above could result in seri-
ous injury or damage to machines.
CAUTION Prepare tools and gauges before starting to work.
Safety work
WARNING ¡When hoisting a forklift truck or a heavy compo-

nent, use ropes or cable with correct capacity.
¡Do not use ropes or cables which are kinked.
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.
2
Parts
CAUTION When replacing any parts, be sure to use NICHIYU

genuine parts.
CAUTION When replenishing battery electrolyte, be sure to

use refined or distilled water.
Repair of electrical components
CAUTION Be sure to disconnect the battery plug when

replacing electrical component.
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

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

electrolyte . Keep clothing and skin away from
contact with battery fluid.
aIf this is not observed, the fluid may corrode
clothing or cause burns.
3
Hydraulics
CAUTION When removing the hydraulic pipes, cap them to

prevent dust from entering into the hydraulic com-
ponents and pipes.
CAUTION When disassembling and assembling the hydraulic

components, work at clean place and do not dam-
age the parts.
Tightening torque
CAUTION ¡Observe tightening torque specified in this man-

ual.
aIf not specified, refer to the table [Tightening
torque for bolts] on page 14.
4
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.
r
2210161
No. Parts No. Parts Name Q'ty Notes

q 0902-69814 Plate, Warning 2 No person on/under forks
w 0902-69774 Plate, Warning 2 Caution for fingers
e 24700-04830 Plate, Warning 1 Precaution for Safety Operation
0902-69944 Label, Tyre 2 Air pressure (bar) FB10P-18P
r 0902-69964 Label, Tyre 2 Air pressure (bar) FB20P/25P
0902-69914 Label, Tyre 2 Air pressure (bar) FB30P
t 24700-01850 Plate, Caution 1 Caution for Braking
y 0902-69794 Plate, Caution 1 No riding except Operator
u 0902-68384 Plate, Precaution 1 Precaution for Safety Operation
0902-69914 Label, Tyre 2 Air pressure (bar) FB10P-18P
i 0902-69964 Label, Tyre 2 Air pressure (bar) FB20P/25P
0902-69944 Label, Tyre 2 Air pressure (bar) FB30P
o 24700-01780 Plate, Caution 1 Operation of Gas spring lock
!0 24700-13490 Plate, Lubrication 1 Lubrication
* !1 38540-00520 Label, Caution 1 Caution for battery
* With Japanese battery only.
5
q w
6977F
2210158
6981F
e
Do Not Jump! Lean Forward FOR SAFETY NOTICE FOLLOWING WARNINGS exceeds the stability of the truck.
1. Lateral tipover can occur when unloaded if the combination of speed 4.Serious injury or death can occur to the operator if he/she is trapped
Fasten Hold between the truck and the ground.
and sharpness of turn products an overturning moment which exceeds
Seatbelt on the stability of the truck.
Tight Lean 2. Lateal tipover can occur if overloaded within capacity and the IN CASE OF TIPOVER
Truc can Away load is elevated and if turning and/ or braking when traveling rearward 1.The operator should say with the truck if lateral or longitudinal tipover
TIP OVER ! Brace From or if turning and/ or accelerating when traveling forward products an occurs. The operator should hold on firmiy and lean away from the point
Impact overturning moment which exceeds the stability of the truck. of impact.
Feet
Risk of serious Rearward tilt and/ or off-cecter positioning of the load and/ or uneven 2. The operator should stay with the truck if it falls off a loading dock
ground conditions will further aggravate the above conditions. or lamp. There are other situations where the enviroment of the landing
INJURY 3. Longitudinal tipover can occur if overloaded or when loaded within area presents a severe hazard. In those incidents. It may be prudent for
WARNING orDEATH IN CASE OF TIP OVER capacity and the load is elevated if foeward tilt, braking in forward travel.
or commencing rearward travel produces an overturnung moment which
the operator to leave the truck.
24700-0483
r (For CE)
(FB10P-18P) (FB20P/25P) (FB30P)
Apply parking brake before leav-

ing truck. Make adjustment to
provide adequate braking.
6
Name Plate (page 9)
2210160
i
2210159
PRECAUTIONS FOR SAFETY OPERATION

1. DO NOT OVERLOAD.
OBSERVE ALLOWABLE LOAD (BLUE ZONE).
2. PRIOR TO OPERATION, CHECK PERFORM-
ANCE OF BRAKE.
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. B E S U R E T O U S E T H E P R E S C R I B E D
FUSES.
i (For CE)
(FB10P-18P) (FB20P/25P) (FB30P)
7
!0
!1 (With Japanese battery only)
2210157
!0
!1 (With Japanese battery only)
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 well—ventilayed 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 White
line
and stop filling immediately if confirmed the white line of the
float as shown herein, for over—filling 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.
8
3. Model name and serial numbers
Model name
¡Name plate
(For Standard)
(For CE)
Capacity code .............................................................................. 10 : 1000kg

15 : 1500kg
18 : 1750kg
20 : 2000kg
25 : 2500kg
30 : 3000kg
Classification of tyre ................................................................. P : Pneumatic tyre

PN : No puncture tyre
PC : Cushion tyre
............................................... B : Large capacity battery equipped

C : Stationary charger
D : Dust resistant
Maximum lifting height [cm]
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 -35:
RP : Rust resistant
Z : Special type electrical component
Attachment etc.
9
Serial numbers
No. Serial numbers Stamped position
q Serial No. of a truck Stamped on the name plate
w Serial No. of a chassis Stamped on the right side of chassis
e Serial No. of a mast Stamped on the mast name plate
r Serial No. of a front axle Stamped on the left side of front axle
t Serial No. of a traction motor Stamped on the motor name plate
y Serial No. of a hyd. motor Stamped on the motor name plate
u Serial No. of a EPS motor Stamped on the motor name plate
i Serial No. of lift cylinders Stamped on lift cylinders
o Serial No. of tilt cylinders Stamped on tilt cylinders
¡Location of serial numbers
q
w
e y
o
r
2210162
10
4. Cautions for maintenance
General precautions
¡When replacing any parts, be sure to use genuine
NICHIYU parts.
¡ When parts are assembled, always replace old
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 C- Retainer for Retainer for
shape retainer in the direction the force is applied a groove a hole
when installed.
152E101
¡As shown in the illustration, face the slit side in the

direction the force is applied when driving in a spring
pin.
152E102
¡The split pin must be replaced with a new one and split
so it will not come out.
152E103
¡When using a thrust washer with oil grooves cut,

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

electrical harnesses, always disconnect the battery
plug.
11
Using liquid packing
¡ 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
¡ 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
¡ 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 BsBM2S-0 SUS304
(S55C)
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
MEMO
15
1. GENERAL
1- 1. Appearance
wFRONT AXLE
eREAR AXLE
rTYRE
uHydraulic system tSTEERING
yBRAKE
i
ua HYDRAULIC
y PUMP
t
uc ub OIL TANK AND
OIL PIPING
ua
uc CONTROL
o
VALVE
ud CYLINDER
ud
ub
iMAST
oMOTOR
r
!0 !0ELECTRIC PARTS
w
o
e !1LASER POINTER
r
!2SERVICE DATA
237W043
16
1 GENERAL
1- 2. Specifications
H
F
K A J
* This illustration shows FB15P.

234W001
17
GENERAL 1
Models FB10P FB15P FB18P FB20P FB25P FB30P

Capacity kg 1000 1500 1750 2000 2500 3000
Load center A mm 500
Lift height B mm 3000
Free lift C mm 145 150 155
Performance
Unloaded mm/s 540 470 410

Lift speed
Loaded mm/s 350 320 310 280 260 240
Forward D 6
Tilt angle
Backward E 12
Unloaded km/h 15.0 14.5
Travel speed
Loaded km/h 13.0 12.5 13.0 12.5
Min. turning radius F mm 1760 1775 1980 2035 2285
Max. gradeability(Loaded)(3min) % 17 14.5 12.5 10
Overall length G mm 3035 3080 3285 3345 3580
Overall width H mm 1090 1175 1180
Mast lifted I mm 4000
Overall
Dimensions
height Mast lowered J mm 1980 2215

Overhead guard K mm 2110 2225
Wheel base L mm 1250 1400 1600
Front wheel mm 900 955 955
Tread
Rear wheel mm 900 945 980
Road clearance mm 110 185
Service weight (w/o batt) kg 2075 2210 2385 2860 3305 3530
Aisle width with pallet 1100 x 1100 mm mm 3205 3225 3475 3530 3815
Single 21 x 8 - 9 - 14PR 23 x 9 - 10 - 16PR 28 x 9 - 15 - 12PR
Front No puncture 21 x 8-9 23 x 9 - 10 28 x 9 - 15
Tyre
Cushion 21 x 6 x 15 21 x 7 x 15 22 x 8 x 16 28 x 10 - 22
Single 5.00 - 8 - 8PR 18.00 x 7 - 8 -14PR 6.50 - 10 - 10PR
Rear No puncture 5.00 - 8 18 x 7 - 8 6.50 - 10
Cushion 18 x 5 x 12 22 x 6 - 16
Control system SICOS
For traction 7.8 8.3 10.0
Electric
For hydraulic kw 8.2 9.6 12.7
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/5H
Option 2 48V 485 48V 545 48V 565 - 72V 545
Option 3 48V 545 - 48V 600 - -
*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)
FRONT AXLE
2- 1. Location and name
¡Main parts of front axle
212E128
Support, drive
Case(3)comp., mission
Gear(4)
Sensor, magnetic
Case, differential
Case(1), mission
Gear(1)
Gear, pinion Gear, differential side
Gear, pinion
Gear(3)
Gear, differential side
Gear(2)
Case(2)comp., mission
Drum, brake Wheel brake ass'y
Hub, wheel
Shaft, drive
234W010
19
FRONT AXLE (DRIVE) 2
2- 2. Disassembly and reassembly
CAUTION ¡Lift or jack up the forklift truck and support it with safety blocks or rigid
stands.
¡Apply wheel chocks to rear tyres to prevent the truck from moving.
¡Record places of lead wire connections before disassembling.
¡When disconnecting hydraulic pipes, cap them to prevent dust from
entering into hydraulic components and pipes.
¡Be 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.
qDisconnect the high pressure hose from the control

valve and fix it in place.
wLoosen the hose clip on the control valve and
disconnect the low pressure hose (return hose).
¡Disconnecting the hydraulic hose

Control valve
Hose clip
Lift cylinder (2nd)
wLow pressure hose
qHigh pressure hose
Tank comp., oil
234W011
20
2 FRONT AXLE (DRIVE)
3. Disconnect harness connectors and lead wires as follows.
CAUTION Record places of lead wire connections before

disassembling.
qDisconnect harness connectors for magnetic sensors.

¡Loosening the terminal bolt
(for speed detection)
wDisconnect lead wires on the traction motor. Terminal bolt
NOTE Hold the terminal comp. by a wrench when

loosening the terminal bolt.
Terminal comp.
Wrench
234W020
¡Disconnecting the harness connector and the motor lead wire
Harness connector
Terminal comp.
Terminal bolt
Lead wire
Traction motor
234W012
21
4. Remove the parking linkage ass'y as follows.

qDisconnect the harness connector for the accelerator
and remove the floor plate.
¡Removing the floor plate

Mat, floor
Floor plate
Connector for accelerator
2210028
wRemove front covers as shown in the following illustration.

eRemove fitting bolts to remove the parking linkage ass'y.
¡Removing the parking linkage ass'y

Fitting bolt
Parking linkage ass'y

Cover(1), front
Cover(3), front
Cover(7), front
2210059
22
5. Remove front tyres as follows. ¡Removing the front tyre
qApply chocks to both rear tyres.

wLoosen hub nuts on the front tyres.
NOTE Do not remove nuts, just loosen.
eHoist the truck at the top of the mast to float the front
tyres from the ground.
rApply rigid stands or wood blocks (20-30 cm height)
under the frame.
tRemove hub nuts to remove front tyres.
Front axle
Hub bolt
234W013
Hub nut
Front tyre
¡Hub nut
Tightening torque (M16)

216-264 N m
[FB10P-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 ¡Removing the tilt pin
mast.
Outer mast
Tilt pin
Tilt cylinder
2210061
23
7. Disconnect brake pipes as follows. ¡Disconnecting the brake pipe

Master cylinder
qDrain the brake fluid from the brake oil tank.
wHoist the mast down and tilt it forward.
eDisconnect the brake pipes of the wheel brake ass'y.
Disconnect
Disconnect Brake pipes

2210062
8. Replace pivot caps with special ones as follows. ¡Replacing the pivot cap
qHoist the mast down and tilt it forward.

wRemove upper fitting bolts for both pivot caps.
Bushing
eHoist 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.
rRemove lower fitting bolts for both pivot caps.
Lower fitting bolt 2210131
¡Fitting bolt
Tightening torque
78-98 N m
{8-10 kgf m}
tReplace pivot caps with special caps. ¡Special cap details

yTighten all fitting bolts by hand.
2mm
uHoist the mast down and tilt it forward.
iUse a tool to tighten upper fitting bolts for both special
caps.
oHoist 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.
!0Use a tool to tighten lower fitting bolts for both special 2210132
caps.
24
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.
¡Removing the front axle and traction motor

¡Fitting bolts (M20x L65)
Tightening torque
65mm
450-550 N m
5 bolts {46-56 kgf m}
¡Fitting bolts (M20x L50)
1 Tightening torque
65mm 450-550 N m
Traction motor
{46-56 kgf m}
CAUTION
Pay attention to different bolt
lengths, when installing.
50mm
3 bolts
Spline MG
Apply molybdenum grease on a
part of spline.
Front axle Tightening torque

19.8-24.2 N m
: Tightening torque
{2.1-2.5 kgf m}
MG : Apply molybdenum grease
234W014
11. Remove the front axle from the mast as follows. ¡Removing the special cap
qApply wood blocks under the traction motor or front

axle.
wRemove fitting bolts for both special caps. Bushing
eMove the mast back and remove the front axle from the
mast. Special cap
NOTE Be careful to not lose the bushings. Fitting bolt
12. Remove the traction motor.

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

Transmission case and etc.
¡Disassembling and reassembling the front axle (1)
Support, drive
Case(3)Comp., mission
Tightening torque
98-127 N m
{10-13 kgf m}
Sensor, magnetic
Breather, air Oiling plug
Mission case B
Apply THREEBOND [#1215] on
Level plug the mating surfaces.
Case(1), mission
Drain plug
CAUTION
Before disassembling, remove the
Case(2)Comp., mission drain plug and drain oil.
Tightening torque
98-127 N m
: Tightening torque
{10-13 kgf m}
B : Apply THREEBOND
234W015
CAUTION In case that OIL SEALS, O RINGS, BEARINGS were removed, they should
be replaced to new ones.
26
Differential case and etc.
Tightening torque B
Apply THREEBOND[#1360K] and
tighten.
108-147 N m
{11-15 kgf m}
Case(3)Comp., mission
Case, differential
Case(1), mission
Shaft, drive
Shaft, drive
: Tightening torque
B : Apply THREEBOND
N : Not reusable
234W016
27
Gears and etc.
Gear(4)
Case, differential
Case(1), mission
Gear(1)
Tightening torque
176-216 N m
{18-22 kgf m}
A Bearing pre-load
Gear(3) 39-59 N m
{4-6 kgf m}
Gear(2)
: Tightening torque
N : Not reusable
234W017
28
Wheel hub , drive shaft and etc.

Oil seal B G
Apply grease on the lip of the oil seal,
and THREEBOND [#1104] around it.
¡Bearing nut
A Bearing pre-load
Measure at 392-686 N m
position A {40-70 kgf m}
O ring G
Apply grease.
Drum, brake
Tightening torque B
Hub, wheel Apply THREEBOND[#1360K] and
Hub bolt tighten.
98-127 N m
[FB10P-18P]
{10-13 kgf m}
157-206 N m
[FB20P-30P]
{16-21 kgf m}
Shaft, drive
Tightening torque B
Apply THREEBOND[#1360K] and
tighten.
176-235 N m
[FB10P-18P]
{18-24 kgf m}
157-206 N m
[FB20P-30P]
{16-21 kgf m}
Wheel brake ass’y
¡Hub nut

216-264 N m
[FB10P-18P]
{22-27 kgf m}
: Tightening torque Tightening torque (M18)
B : Apply THREEBOND
315-385 N m
G : Apply grease [FB20P-30P]
N : Not reusable {32-39 kgf m}
234W018
29
2- 3. Inspection and adjustment

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

qCheck wheel hubs for damage and crack.
wCheck hub bolts for loosening and damage.
¡Inspection of wheel hub and hub bolt

Wheel hub
Hub bolt
Drive shaft
Hub nut 234W019
30
2- 4. Troubleshooting
2-4-1. Front axle - troubleshooting
No. Symptom Problem Solution
Continuous noise while qPoor hypoid gear (differential gear) adjustment, Adjust or
travelling or teeth wear replace
wPoor hypoid gear (differential gear) bearing Adjust or

adjustment, or teeth wear replace
1
eLoose or bad wheel hub bearings Adjust or replace
rPoor ring gear and shaft (differential gear and

Adjust
beveled pinion) gearing or backlash
tNot enough gear oil Replenish
Abnormal noise while qBad hypoid gear (differential gear) bearings. Replace
travelling
wBad wheel hub bearings Replace
eBad backlash due to differential gear wear or

2 Replace
thrust washer wear
rForeign matter in the axle housing Inspect and clean
tLoose drive shaft or carrier ass'y bolts Retighten
Abnormal noise when qBad backlash due to differential gear wear or

Replace
turning corners thrust washer wear
3
wBroken teeth on the differential gear pinion, or
Replace
pinion shaft wear
Differential heat qBad gear backlash Adjust

4
wDamaged bearing due to excess bearing preload Replace
Oil leakage from the qOil surface too high (level plug is at regulated value) Drain
axle housing
wOil seal wear or damage Replace
5 ePoorly installed axle housing Retighten
rPoorly installed plug Retighten
tAir breather clogged Clean or replace
Oil leakage from the qOil seal wear or damage Replace

6 wheel hub
wOff-center rotation due to bearing wear or damage Replace
Oil leakage from the qOil seal wear or damage Replace

7
carrier
31
3. REAR AXLE (STEERING)
REAR AXLE
¡Main parts of rear axle
Axle comp., rear

Pin, center arm
Support, axle
Pin, king
Support, axle
Knuckle(R)
Rod(L) comp., tie
Hub
Arm comp., center

Rod(R) comp., tie
Knuckle(L)
Cap
2210013
32
3 REAR AXLE (STEERING)
CAUTION ¡Lift or jack up the forklift truck and support it with safety blocks or rigid stands.
¡Apply wheel chocks to front tyres to prevent the truck from moving.
3-2-1. Rear axle - removal and installation

1. Remove rear tyres before removing the rear axle.
¡Removing the rear tyre
Rear tyres
¡Hub nut
Tightening torque
88.2-108 N m
{9.00-11.0 kgf m}
: Tightening torque
2210014
33
REAR AXLE (STEERING) 3
2. Support the rear axle with a garage jack or another forklift.

3. Remove fitting bolts for the "support, axle".
4. Remove the rear axle.
¡Removing the rear axle
Support, axle
Support, axle
Rear axle
¡Fitting bolt
Tightening torque
87-107 N m
{8.9-10.9 kgf m}
: Tightening torque
2210015
* Install the rear axle in reverse order of removal.
34
3-2-2. Rear axle - disassembly and reassembly

Knuckle, hub and etc.
¡Disassembling and reassembling the rear axle (1)
Shim [0.5/1.0/2.3/3.2 mm]

Specific clearance : 0.1-0.7 mm
Oil seal MG
Apply molybdenum grease on the
lip of the oil seal.
Bearing G
Fill grease up between the bearings.
Hard lock nut

Tightening torque 21-31 N m
(Convex side) {2.1-3.1 kgf m}
Tightening torque 73-88 N m
(Concave side) {7.4-9 kgf m}
A Bearing pre-load
Measure at position 44-64 N m
: Tightening torque A (hub bolt) {4.5-6.5 kgf m}
G : Apply grease
N : Not reusable
2210016
35
Center arm, tie rod and etc.

¡Disassembling and reassembling the rear axle (2)
¡Nut, castle
1 Tightening torque [FB10P-18P]
93.1-112.7 N m
{9.5-11.5 kgf m}
Tightening torque [FB20P-30P]
147-171.5 N m
{15-17.5 kgf m}
¡Nut, jam
2 Tightening torque
156.8-176.4 N m
{16-18 kgf m}
: Tightening torque Bearing G

G : Apply grease Fill grease up between the bearings.
N : Not reusable
2210017
36
3-2-3. Rear axle assembly - methods and precautions

<FB10P/15P/18P>
qAdjust the length of the tie rod comps (L)/(R), and set parts to dimensions
indicated by marks. However, they are the designed dimension, so there may
*
be some differences depending on actual parts.
In such a case, adjust to actual dimensions of parts.
wAdjust the height of the stopper bolt, and then adjust the maximum rotation angle
for the part marked .
¡FB10P/15P/18P
Axle comp., rear
Stopper bolt
(15)
*434 *441
Tie rod comp.(L) Tie rod comp.(R)
Hard lock nut
Knuckle(L)
Arm comp., center
Knuckle(R)
(average effective radius)
220
King pin Castle nut

Hub
G.L.
760(King pin distance)
910.5(Tread)
234W021
37
<FB20P/25P>
*
¡FB20P/25P
Axle comp., rear
(16)
*426
*419
Tie rod comp.(L)
Stopper bolt Tie rod comp.(R)
Hub
Hard lock nut
Knuckle(L) Arm comp., center
Knuckle(R)
215.5
King pin
Castle nut
G.L.
941(Tread)
234W505
38
<FB30P>
*
¡FB30P
Axle comp., rear
Stopper bolt
(18)
*469
*476
Tie rod comp.(L) Tie rod comp.(R)

Hub
Knuckle(L)
Hard lock nut
Arm comp., center
Knuckle(R)
272.5
King pin
Castle nut
G.L.

983(Tread)
234W506
39

3-3-1. Bushing - inspection ¡Inspection of bushing
L (Length)
qCheck for wear and damage.
[mm]
D (Inner dia)
Specific dimension Wear limit Bushing
Bushing 50( D)X50(L) 50.2( D) Support, axle
2210019
3-3-2. Center arm - inspection ¡Inspection of center arm
qCheck for crack.
Center arm
2210020
3-3-3. Tie rod comp. - inspection ¡Inspection of tie rod comp.
qCheck for straightness.
Tie rod comp.
2210021
3-3-4. Knuckle - inspection ¡Inspection of knuckle

Fitting surface
qCheck for crack.
wCheck for wear on the fitting surfaces of the rear axle
Knuckle
comp and the tie rod comp.
Fitting surface 2210022
40
3-3-5. King pin - inspection ¡Inspection of king pin
qCheck for joggling or wear on the surface that King pin
contacts the bearing.
Bearing
Bearing
Bearing
2210023
3-3-6. Hub and hub bolt - inspection ¡Inspection of hub and hub bolt
qCheck hubs for damage and crack. Hub bolt

wCheck hub bolts for loosening and damage.
Hub
Hub nut
2210024
Tightening torque
88.2-108 N m
{9-11 kgf m}
3-3-7. Rear axle comp. - inspection ¡Inspection of rear axle comp.
Rear axle comp.

qCheck for deformation and damage.
2210025
41
3-4-1. Rear axle - troubleshooting
Steering is hard. qAdjustment of toe-in is not correct. Adjust
wBearing for king pin is damaged. Replace
eLow air pressure of wheels Adjust

1
rLack of lubrication for rear axle and steering linkage Lubricate
Repair or
tConnection of linkage is stuck.
replace
Return of steering qSteering linkage and each part of rear axle are Check and
wheel is bad. not adjusted correctly. adjust
2
Inspect and
wBad adjustment of wheel alignment
adjust
Steering wheel is qIncorrect air pressure of wheel Adjust

rotated un-expectedly
to one side. Inspect and
wDifference of diameter of wheels at L.H. and R.H. sides
replace
3
eBad adjustment of wheel alignment Inspect and
(toe-in, camber, king pin and etc.) adjust
Adjust or
rBad adjustment or wear of wheel bearing
replace
Steering wheel is qLarge gap between king pin and king pin bearing Replace
swung.
Adjust or
wBad adjustment or wear of wheel bearing
replace
eLoose hub nuts Tighten
rHeavy wear of ball joint of tie rod socket Replace

4
Inspect and
tBad mounting of rear axle
adjust
yIncorrect air pressure of wheel Adjust
Inspect and
uBad steering system
replace
42
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.
TYRE
4- 1. Location, name and tyre size
4-1-1. Tyre - location and name
Tyre
Rim
(One piece)
212E130
Front FB10P-30P
Rear FB20P/25P
Rim nut 212E126
Rim bolt Washer, lock
Rear FB10P/15P/18P, 30P

Rim (Two pieces)
4-1-2. Tyre size

<Pneumatic tyre>
Applicable model Size
FB10P/15P/18P 21X8-9-14PR
Front tyre FB20P/25P 23X9-10-16PR
FB30P 28X9-15-12PR
FB10P/15P/18P 5.00-8-8PR
Rear tyre FB20P/25P 18X7-8-14PR
FB30P 6.50-10-10PR
<No puncture tyre>

Applicable model Size
FB10P/15P/18P 21X8-9
Front tyre FB20P/25P 23X9-10
FB30P 28X9-15
FB10P/15P/18P 5.00-8
Rear tyre FB20P/25P 18X7-8
FB30P 6.50-10
43
TYRE 4

¡Inspection of hub nut
4-2-1. Hub nut - inspection
qCheck for damage.
wCheck for loosening.
aIf loose, retighten it.
Hub nut 212E034
sFront

216-264 N m
[FB10P-18P]
{22-27 kgf m}
315-385 N m
[FB20P-30P]
{32-39 kgf m}
sRear
Tightening torque
88.2-108 N m
{9-11 kgf m}
4-2-2. Rim and rim bolt - inspection ¡Inspection of rim and rim bolt
qCheck for damage.

wCheck for loosening.
aIf loose, retighten it.
NOTE There are no rim bolts for the following models:

Front : FB10P-30P
Rear : FB20P/25P
Rim
Rim bolt
212E035
sRear
Tightening torque
[FB10P-18P] 68.5-78.5 N m
[FB30P] {7-8 kgf m}
44
4 TYRE
4-2-3. Air pressure - inspection

<Pneumatic tyre> ¡Inspection of air pressure
¡Front tyre
Applicable model Type Air pressure
FB10P/15P/18P 21X8-9-14PR 900kPa(9.0kgf/cm2)
FB20P/25P 23X9-10-16PR 900kPa(9.0kgf/cm2)
FB30P 23X9-15-12PR 800kPa(8.0kgf/cm2)
¡Rear tyre
Applicable model Type Air pressure 212T001
FB10P/15P/18P 5.00-8-8PR 850kPa(8.5kgf/cm2)

FB20P/25P 18X7-8-14PR 900kPa(9.0kgf/cm2)
FB30P 6.50-10-10PR 700kPa(7.0kgf/cm2)
CAUTION Check for the air pressure when the tyres are cool.
4-2-4. Tyre - visual inspection and replacement

qCheck for cracks, damage, and wear.
aReplace the tyre if there are large cracks or damage to the inner
surface.
aReplace the tyre if there is wear down to the tyre grooves or the
bottom of the tread.
aReplace the tyre if there is wear down to the tip of the wearing limit
mark on the inner surface.
¡Cracks or damage ¡Tyre grooves ¡ wearing limit mark
45
TYRE 4
4-3-1. Tyre - troubleshooting
Abnormal wear of q Incorrect air pressure of wheel Adjust

wheels w Bad adjustment of wheel alignment Inspect and
1 (toe-in, camber, king pin and etc.) replace
e Incorrect preload of wheel bearing Adjust
r Different type of wheels at L.H. and R.H. sides Replace
46
5. STEERING
STEERING
¡Main 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
47
STEERING 5
CAUTION ¡Apply wheel chocks to tyres to prevent the truck from moving.
5-2-1. Steering - removal and installation

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

wRemove display panels and front covers as shown in
the following illustration.
¡Removing 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
48
5 STEERING
eDisconnect the harness connector for the accelerator,

and remove the floor plate.
¡Removing 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 50 for removal of the steering
linkage.
* Install the steering linkage in reverse order of removal.
49
STEERING 5
5-2-2. Steering linkage - disassembly and reassembly

Column ass'y, joint, steering box and etc.
¡Disassembling 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 53 for adjustment of the
potentiometer.
: Tightening torque Shim [t0.2/1.0 mm]

G : Apply grease To adjust the potentiometer.
N : Not reusable
2210029
50
5 STEERING
Drag link and actuator ass'y

¡Disassembling 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] 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
234W507
51
STEERING 5

5-3-1. Joint - inspection and replacement
qCheck for jolt of parts marked with arrows. ¡Inspection of joint
aIf jolted, replace it.
wCheck for crack of parts marked with stars.

aIf cracked, replace it.
212E044
5-3-2. Knob - inspection and replacement

qCheck for jolt and crack. ¡Inspection of knob
aIf jolted or cracked, replace it.
152T005
5-3-3. Steering wheel - inspection and replacement

qCheck for crack. ¡Inspection of steering wheel
aIf cracked, replace it.
wAfter turning off Key switch, measure Play of steering 50-100 mm
knob and check if it is within 50 -100 mm.
212E045
52
5 STEERING
5-3-4. Torque sensor neutral - check and adjustment

<Checking procedure>
q Turn the key switch off. ¡Neutral check of torque sensor
w Jack up rear wheels from the ground.
EPS
e Remove a rear cover. controller
(See "10a-2-1. control unit - removal and installation"
on page 128.)
r Put a clamp meter to a wire [yellow] or [green]
yellow
green
between EPS controller and EPS motor [DC range].
t 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. Clamp meter
y If any current is flown, adjust the potentiometer by the
following procedure.
EPS motor
461E133
<Adjusting procedure>
q Turn off the key switch off and disconnect the battery
plug.
w Disconnect the 3P water proof type type connector of
EPS sensor.
234W025
53
STEERING 5
e Check the resistance at sensor side (tab side) between,

<standard value>
¡ q pin (Orange) and e pin (Black/Red)=Approx. 5k ..................A
¡ q pin (Orange) and w pin (Green/Red)=Approx. 2.5k ..............B These should be
¡ w pin (Green/Red) and e pin (Black/Red)=Approx. 2.5k .........C even value.
q Orange q Blue 3
From EPS
sensor w Green/Red w Green/Blue 1 To EPS
Tab Rece
(potentiometer) e Black/Red e White controller
3P water proof type connector

234W026
r Adjust it by removing or inserting a shim to be the ¡Removing or inserting

even value between B and C above. the shims
NOTE The resistance value may depend on the type of

tester and each unit.
t Connect the battery plug and turn the key switch on.
Check and confirm that there is no EPS motor current
at the neutral steer by the above procedure, <Checking
procedure>.
Potentiometer
Shim
2210031
54
5 STEERING
5-3-5. Checking by voltage

<Checking by voltage>
Neutral adjustment of the potentiometer can be checked
by its output voltage.
q Turn the key switch off.
w 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.
e Check the voltage at w pin [Green/Red or Green/Blue

1] of the adapter.
r 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 0.8 V 0.3

Neutral 2.5 V 0.3
Left side end 4.2 V 0.3
From EPS q Orange q Blue 3

w Green/Red To EPS
sensor Tab w Green/Blue 1
Rece controller
(potentiometer) e Black/Red e White
3P water proof type connector
q pin
w pin
Rece Tab Adaptor
e pin
Tab
+ probe - probe
to w pin to e pin
(output) (negative)
461E134
55
STEERING 5
5-4-1. Steering linkage - troubleshooting
Symptom Problem
The main contractor is not qMain contactor

turned on. wEPS controller
With the key switch ON and the parking brake is released.
qEPS controller
The main contactor trips
wTorque sensor
immediately.
eEPS motor
The main contactor trips qEPS controller

when the steering wheel is wTorque sensor
turned. eEPS motor
The steering wheel The main contactor comes qEPS controller

does not turn! on, but there is no power wTorque sensor
steering. eEPS motor
qActuator
There is power steering, but wEPS controller
it is abnormally heavy. eEPS motor
rTorque sensor
qEPS motor
There is power steering, but wActuator
it feels like it is sticking. eEPS controller
rTorque sensor
qEPS controller
wTorque sensor
The steering wheel vibrates ePoor 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 qEPS controller

turns, but ... wheel operates by itself.) wTorque sensor
qEPS controller
The motor becomes wTorque sensor
Other
abnormally hot. eActuator
rEPS motor
56
6. BRAKE
FOOT BRAKE LINKAGE
6-1-1. Foot brake linkage - main part names
¡Main parts of foot brake linkage
212E132
Tank comp., oil
Pin
Pedal, brake
Cylinder ass'y, master
2210032
57
BRAKE 6
6-1-2. Parking brake linkage - main part names PARKING BRAKE LINKAGE
¡Main 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
58
6 BRAKE

6-2-1. Wheel brake - removal and installation

the wheel brake.
qRemove hub nuts to remove the front tyre.

wRemove fitting nuts (*1) for the drive shaft.
eRemove the drive shaft.
rRemove 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.
59
BRAKE 6
¡Removing the wheel brake ass'y

¡Inner diameter of brake drum
Model Inner dia. ( D)
FB10P/15P/18P 10-inch(254 mm)
FB20P/25P 11-inch(279.4 mm)
FB30P 310 mm ¡Bearing nut
A Bearing pre-load
Measure at 392-686 N m
position A {40-70 kgf m}
D
Wheel hub
Drum, brake
Hub bolt
Front tyre
Drive shaft
¡Fitting bolt (*2)
Tightening torque B
Apply THREEBOND [#1360K] and
tighten.
176-235 N m
[FB10P-18P]
{18-24 kgf m}
157-206 N m
[FB20P-30P]
{16-21 kgf m}
Wheel brake ass’y
¡Hub nut
216-264 N m
[FB10P-18P]
{22-27 kgf m}
315-385 N m
[FB20P-30P]
{32-39 kgf m}
: Tightening torque
B : Apply THREEBOND
N : Not reusable
234W027
60
6 BRAKE
6-2-2. Wheel brake - disassembly and reassembly

1. Disassemble the wheel brake ass'y as shown in the ¡Special 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
q Remove the return spring with special tool 221-4402.

w 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.
e Remove fitting bolts for the wheel cylinder ass'y.
r Remove inner parts.
212E041
¡Disassembling and reassembling the wheel brake ass'y

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

spring
Shoe and lining ass'y

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

61
BRAKE 6

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

qCheck the inner surface of the brake drum for streaks
(damage), wear, and cracks.
¡Inspection of brake drum
CAUTION If there are streaks or partial wear, perform repairs or
replacement within the limits shown below.
Inner dia.
¡Inner diameter of brake drum ( D)
Applicable model Specific dimension( D) Repair limit( D)
FB10P/15P/18P 10-inch(254 mm) 256 mm
FB20P/25P 11-inch(279.4 mm) 281.4 mm Brake drum

2210036
FB30P (310 mm) 312 mm
6-3-2. Shoe & lining - inspection and replacement

qMeasure the thickness of the lining. ¡Measuring thickness of lining
aIf the part is worn to 1.5 mm or less, replace it.
CAUTION Measure the area with the most wear.
wCheck for stains, burning, and deterioration.

aIf there are stains, burning, or deterioration, replace
the part.
eCheck for cracks and damage. 212E052
aIf there is a burn, repair it.

aIf cracked or damaged, replace it. ¡Inspection of shoe & lining
Lining
If the part is worn

to 1.5 mm or less,
replace it. 212E052
62
6 BRAKE
6-3-3. Adjustor ass'y - inspection and replacement

qCheck the teeth of the adjustor ass'y for wear and ¡Inspection 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 ¡Inspection of wheel cylinder ass'y
with a volatile cleaning grease, and then use
pressurized air to completely remove the grease.
Fitting surface of the
breather screw
qCheck the inside surface of the cylinder body and the
fitting surface of the breather screw for damage and rust.
wCheck for damage and deterioration on the inner parts. Piston
Piston
aIf there is damage or deterioration, replace the part.
eMeasure the distance between the piston and the Breather screw
cylinder body. Cylinder body
aIf the distance is 0.15 mm or greater, replace the wheel

cylinder ass'y.
2210056
CAUTION Replace the cylinder during disassembly or ¡Replacing the cylinder kit
once a year.
Cylinder kit
2210142
63
BRAKE 6
6-3-5. Master cylinder ass'y - inspection and replacement

CAUTION Before performing this inspection, clean the part ¡Inspection of master cylinder ass'y
with a volatile cleaning grease, and then use
pressurized air to completely remove the grease.
qCheck the inside surface of the cylinder body for

damage and rust.
wCheck for damage and deterioration on the inner parts.
aIf there is damage or deterioration, replace the part.
eMeasure the distance between the piston and the cylinder Piston
ass'y
body.
aIf the distance is 0.15 mm or greater, replace the master
cylinder ass'y.
Cylinder
body
212E055
CAUTION Replace the repair kit during disassembly or ¡Replacing the repair kit
once a year.
Repair kit
2210143
6-3-6. Brake pedal - inspection

qCheck the welded pointer for wear. ¡Inspection of brake pedal
wCheck the bushing for wear.
Pedal, brake Inner dia.
¡Inner diameter of bushing( d) ( d)
Bushing
Specific dimension Wear limit Bushing
20.0 mm 20.15 mm
eCheck the welded pointer for wear.
¡Outer diameter of pin( D)

Outer dia.( D)
Specific dimension Wear limit
20.0 mm 19.9 mm Pin 212E056
64
6 BRAKE
6-3-7. Parking lever - inspection and adjustment

1. Check for damage or deformation on the lever. ¡Inspection of parking lever
2. Check if the parking brake is applied when the lever is

pulled. Adjusting bolt Pull the lever.
aIf the brake is not applied, make the following
adjustments.
qLeave the lever in its pulled back position.

wLoosen the adjusting bolt. (Turn it clockwise.)
eReturn the lever to its lowered position.
rCheck if the forklift travels unobstructed while the
parking brake is not applied.
tIf there is an obstruction, perform the adjustment again.
2210125
6-3-8. Brake linkage - adjustment

qUse the adjusting bolt to adjust the height from the floor ¡Adjusting the brake pedal height
plate to the brake pedal to within the specific dimension
shown below.
Adjusting bolt
Specific dimension 100-120 mm
Brake pedal
Play should be
5 mm or less.
Floor plate
100-
120 mm
2210148
wUse the push rod of the master cylinder to adjust the ¡Adjusting 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
65
BRAKE 6
eUse the microswitch fitting nut to adjust the ON/OFF ¡Adjusting the microswitch position
position to within the specific dimension shown below.
Specific dimension 10-20 mm Microswitch
Fitting nut
The on and off positions

should be 10 mm to
20 mm apart.
2210183
6-3-9. Discharge air from the brakes

CAUTION After assembling the master cylinder, wheel
cylinder, or brake piping, be sure to discharge
the air.
<Air discharging procedure> ¡Air discharging procedure (1)

qRemove 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.
wDepress and hold the brake pedal several times.
Drain hose
Breather cap
152E115
eLoosen the breather screw to discharge the brake fluid ¡Air discharging procedure (2)
and air. Tighten the screw again before the flow stops.
rRepeat steps w and e 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
tAfter discharging the air, tighten the breather screw

securely. Drain hose
Breather screw
yMake sure no brake fluid has leaked out. Wheel cylinder 152E116
CAUTION Use the specified brake fluid. Do not mix different grades of fluid.
66
6 BRAKE
6-4-1. Brake - troubleshooting

qOil leakage from piston cup of master cylinder Replace
wAir is mixed into brake fluid due to shortage of fluid Refill and discharge air
Ineffective eOil leakage from cup of wheel cylinder Replace
1 braking rAir is mixed in brake pipings Discharge air
force tWear of linings or uneven contact with brake drum Inspect and replace
yAdhesion of oil on lining or brake drum Clean or replace
uBad adjustment of brake Adjust
qLining is grazed or adhesion of oil on lining Repair or replace
wBacking plate is transformed or fitting bolts are loose Inspect and retighten
eBrake shoe is transformed or badly mounted Repair or replace
Brake
2 rLining is badly worn Replace
squeals
tWheel bearing is loose Inspect and retighten
yAnchor pin of backing plate is worn or transformed Replace
uShoe ledge is worn Replace
qUnequal air pressure of tires at R.H and L.H sides Adjust to appropriate
pressure
wBad adjustment of brake Adjust
eLining is grazed or unequally contacted with brake drum Repair or replace
Braking rAdhesion of oil or water on lining Clean
3 only at one tLining is worn Replace
side yWheel cylinder is malfunctioned Replace
uBacking plate is transformed or badly mounted Replace or retighten
iBrake drum is eccentrically machined or mounted Repair or replace
oBrake piping is clogged Clean or replace
!0Wheel bearing is loose Inspect and adjust
qNo play of brake pedal Adjust

wWheel cylinder is malfunctioned Replace
eMaster cylinder is malfunctioned or hole for oil flow is clogged Repair or replace
Brake drags rReturn spring in brake ass'y is damaged Replace
4
truck tBad adjustment of brake or malfunction of brake shoe Adjust
yParking brake is not fully released or not adjusted correctly Adjust
uBrake piping is clogged Clean or replace
iWheel bearing is not mounted correctly Adjust
qBad adjustment of brake Adjust

Pedal
wAir is mixed in brake pipes Discharge air
5 stroke is
eOil leakage from brake pipings or shortage of brake fluid Discharge air
too large
rBad adjustment of brake pedal Adjust
qBad installation of parking cable Adjust

Ineffective
wWear of brake linings Replace
6 parking
eBad adjustment of brake Adjust
brake
rBad adjustment of brake lever Adjust
67
7. HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
7- 1. Oil piping circuit
2210174
Tilt cylinder
Control valve
A1 B1
Lift cylinder
Tilt
7a
Fuse valve 7b
A2
X
Flow control valve X
Lift
7c
Relief pressure
7d
Tilt cylinder
M
Applicable model Relief pressure
FB10P/15P 13.7MPa(140kgf/cm2)
Oil tank
2210141
s7a. Hydraulic pump ...................................................................................70
s7b. Oil tank and oil piping ..........................................................................74
s7c. Control valve........................................................................................78
s7d. Cylinder ...............................................................................................85
68
7a. HYDRAULIC PUMP
HYDRAULIC PUMP
7a- 1. Location and name
¡Main parts of hydraulic pump
Cushion
Bracket, cushion
Hydraulic motor 2210171
Hydraulic pump
Coupling, pump
Bracket, motor
Cushion
234W028
<Hydraulic pump type>

Applicable model Type Displacement (cm3)
DSG05-18 18.1
FB10P/15P
DGP4-18ATPF 17.8
DSG05-16 16.0
FB18P
DGP4-16ATPF 16.0
DSG05-18 18.1
FB20P/25P
DGP4-18ATPF 17.8
FB30P DSG1-19 19.0
* Choose one of two type pumps for model FB10P-25P.

69
HYDRAULIC PUMP 7a
7a- 2. Disassembly and reassembly

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 and pipes.
¡When disconnecting hydraulic pipes, cap them to prevent dust from entering
into hydraulic components and pipes.
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 the hydraulic pump. 7a
When damaged, replace the whole pump assembly.
¡Removing the hydraulic pump ¡Fitting bolt(*1)

Tightening torque
19.6-24.5 N m
High pressure {2.0-2.5 kgf m}
Hose clip
hose Elbow
Low pressure
hose Tightening torque
Connector comp.
39-49 N m
N Hydraulic motor {4-5 kgf m}
N
Hydraulic pump
Coupling, pump MG
serrations.
Cushion
Cover(R), side
Tightening torque
29.4-39.2 N m
{3-4 kgf m}
: Tightening torque
N : Not reusable
234W029
70
7a HYDRAULIC PUMP
* Install the hydraulic pump in reverse order of removal.

CAUTION Tighten the connector elbow until it touches to ¡Fitting elbow
the O ring and fix the fitting direction of
connector elbow and tighten the lock nut.
CAUTION In case that OIL SEALS, O RINGS, BEARINGS

were removed, they should be replaced to new
ones.
234W030
7a- 3. Inspection and adjustment
7a-3-1. Coupling, pump - inspection

qCheck the serration on the "coupling, pump" and the
hydraulic motor shaft for wear.
7a-3-2. Hydraulic pump - inspection

qInstall 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 350 540 340 520 310 470
FB15P 320 540 310 520 290 470
FB18P 310 540 300 520 270 470
FB20P 280 470 260 430 240 390
FB25P 260 470 240 430 220 390
FB30P 240 410 250 390 230 390
71
HYDRAULIC PUMP 7a
7a- 4. Troubleshooting
7a-4-1. Hydraulic pump - troubleshooting
No oil is pumped out. qShortage of hydraulic oil Replenish

1 Inspect and
wClogging of the suction hose or the suction filter
clean
Oil leakage qDamage of the oil seal Replace
wDamage of the gasket (O ring) Replace

2
eNo good tightening or damage of the cover and Retighten or
the body, or fitting surface is worn or damaged replace
Pressure is not raised. qWear of the bearing, gear and body Replace
wMixture of air
¡Shortage of hydraulic oil Replenish
3 ¡Air mixed from the suction hose connection. Retighten
¡Damage of the seal kit (oil seal, O ring) Replace
eNo good adjustment of the relief pressure of the

Adjust
control valve
Abnormal noise Correct or

qChoked in the suction hose
replace
wClogging of the suction filter Clean
eAir mixed from the suction hose connection Retighten
4 rAir mixed from the oil seal Replace
Withdraw air
tAir in the hydraulic oil
or replace
yShortage of the hydraulic oil Replenish
uHigh temperature or viscosity of hydraulic oil Replace
High oil temperature qContaminated oil Replace
wHigh viscosity of hydraulic oil Replace

5
Observe
eOverwork
specification
No rotation of qFailure or no good adjustment of the valve Replace or

6 hydraulic motor microswitch Adjust
wBlow out of the hydraulic fuse Replace
72
7b. OIL TANK AND OIL PIPING
7b- 1. Location and name
OIL TANK
7b-1-1. Iron oil tank - main part names
¡Main parts of oil tank
Cover, tank
Gauge, level
Gasket
Filter, suction
Filter, return 2210171
Tank comp., oil
Plug
2210166
73
OIL TANK AND OIL PIPING 7b
7b- 2. Disassembly and reassembly

7b-2-1. Oil tank - precautions
¡Pay attention to the following when disassembling and/or assembling the oil tank.
¡Retract the mast and lower forks to the ground when draining hydraulic oil.
¡When disconnecting hydraulic pipes, cap them to prevent dust from entering
into hydraulic components and pipes.
¡Wind seal tape on the thread of filters and the plug, and be sure to tighten them
when installing them.
7b-2-2. Oil piping replacement - precautions

¡Pay attention to the following on replacing and fitting when the hoses are abnormal.
NOTE Wrap sealant tape around the screws of the connector of hoses before connection.
7b
CAUTION ¡Use applicable hoses for the pressure.
Unexpected force may be applied.
152E125
¡Do not fit short hoses in the length.

Hose might be damaged due to sharp bending.
152E126
¡Do not fit a hose with twisting. Pay attention that hoses can twist by using even
if it was not twisted when connected.
Twisting can be known with the letters on the surface of hoses.
Letters Letters
152E127
74
7b OIL TANK AND OIL PIPING
7b- 3. Inspection and adjustment

7b-3-1. Oil - inspection
¡Put some hydraulic oil out in a test tube and compare
with new oil to check.
<Specific oil conditions>

Appearance Smell Conditions Countermeasure
Transparent, and color is

Good Good. Usable.
not different.
Transparent, but color is Check viscosity.

Good Different oil mixed.
light. If good, it is usable.
Color changed into milky Separate water. Then, it is

Good Air and/or water are mixed.
white. usable.
Color changed into dark

Bad Inferior with oxidizing. Exchange.
brown.
Transparent, but with

Good Foreign article mixed. Filter it. Then, it is usable.
small black spots.
7b-3-2. Recommended oil and oil quantity

<Recommended oil>
Specification Recommended Oil
Shell : Tellus Oils 32

Standard ESSO : Power lex 32
Mobile : Hydraulic oil 28
Shell : Tellus T15

CS
ESSO : Univis 43
75
OIL TANK AND OIL PIPING 7b
<Oil quantity> ¡Checking the oil level
CAUTION ¡Keep the oil level within 10 mm of the center

Oil
of level gauge. level gauge
¡Before checking oil level, up the tilt and lower
the fork on the flat ground.
H level
<Oil quantity in oil tank> [L] L level
Quantity [for reference]

Applicable model
H level L level
FB10P-18P 21 19
FB20P/25P 26 23
FB30P 29 26
NOTE Oil in pipings and cylinders ( 5-10L) is excluded

from the above quantity.
234W100
7b-3-3. Oil tank and filters - cleaning and check

qClean with compressed air and check the filter for
clogging and damage.
aIf the filter is clogged or damaged, replace it.
wRemove any dart or foreign material from the oil tank.
7b- 4. Troubleshooting
7b-4-1. Oil tank - troubleshooting
Bubbled Inspect and

1 qMixture of air retighten the
fitting hoses
Color of oil is qAir and water are mixed. Exchange

2 changed.
wInferior with oxidizing or foreign article mixed. Exchange
76
7c. CONTROL VALVE
CONTROL VALVE
7c- 1. Location and name
¡Main parts of the valve linkage and control valve (2 spools)
CS/FCS/DRP
Microswitch
Shaft, valve lever

2210172
Bracket, lever
Knob
Knob and lever B

Lever comp., valve
Apply THREEBOND[#1521], or an
equivalent product, to bond the
knob to the lever.
Link
¡Control valve (2 spools)
Relief valve
Wiper
O ring O ring
O ring
Wiper
Plate seal
Valve ass'y, control Seat, spring
Spring
Seat, spring
Cap
B : Apply THREEBOND
2210048
77
CONTROL VALVE 7c
¡Main parts of the valve linkage and control valve (3 spools)

CS/FCS/DRP
Microswitch
Bracket, lever
Shaft, valve lever Knob
Lever comp., valve
Knob and lever B

Apply THREEBOND[#1521], or an
Link equivalent product, to bond the
knob to the lever.
7c
¡Control valve (3 spools)
Relief valve
Wiper
O ring O ring
O ring
Wiper
Plate seal
Valve ass'y, control Seat, spring
Spring
Seat, spring
Cap
B : Apply THREEBOND
2210049
78
7c CONTROL VALVE
7c- 2. Disassembly and reassembly

¡Apply wheel chocks to tyres to prevent the truck from moving.
7c-2-1. Control valve - removal and installation

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

2210050
79
CONTROL VALVE 7c
wDisconnect hydraulic pipes and hoses as shown in the following illustration.
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.
¡Disconnecting the hydraulic pipe and hose

N Plug Connector comp.
N
Low pressure hose(oil tank)
Pipe(2)comp.,tilt
High pressure hose(mast piping) N (high pressure)
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
eRemove snap pins and valve pins to remove the control valve linkage.
2. Remove fitting bolts(*1) remove the control valve.

¡Removing 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.

80
7c CONTROL VALVE
7c-2-2. Inner kit of control valve - replacement

1. Replacing the inner kit of Control valve.
qRemove CAP, WIPER and RELIEF VALVE.
wPull out PLUNGER.
eReplace 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
212E069
2. Replacing the Relief valve and O RING.

qWhen replacing, tighten it with the following torque.
wAfter completing, measure the relief pressure.
¡Replacing the relief valve

Tightening torque
50 N m
{5 kgf m}
: Tightening torque
N : Not reusable
212E070
81
CONTROL VALVE 7c
7c- 3. Inspection and adjustment

7c-3-1. Relief pressure - measurement
CAUTION Use 20MPa {200kgf/cm2} pressure gauge with damper.
qTurn off the key switch. Push and pull each levers ¡Measurement of relief pressure
several times to lower pressure in the pipings.
Pressure gauge
wRemove the plug of Lift section, and install the
pressure gauge with the adapter.
eTurn on the key switch, and pull the Lift lever to the Damper
stroke end. Adjusting
screw
Then read the indication of pressure gauge.
<Specific relief pressure> [mm]

Applicable model Relief pressure
FB10P/15P 13.7 MPa(140 kgf/cm2)
FB18P/20P 15.7 MPa(160 kgf/cm2)
FB25P/30P 17.2 MPa(175 kgf/cm2)
Plug on lift section.
a If the relief pressure is deviated from the above

specification, adjust the pressure using the adjusting screw.
* This illustration shows the control valve
The adjusting screw needs only to be turned for 2 spools.
CAUTION 2210165
slightly to make an adjustment.
7c-3-2. Microswitch - adjustment

<Adjusting the microswitch> ¡Adjusting the microswitch
qAdjust the microswitch position to activate the switch 0.5-1.5 mm
when the lever is moved 15-25 mm away at the knob

Microswitch
from the neutral position.
Adjustment gap when in neutral 0.5-1.5 mm

2210126
<Adjusting the lift (fast) microswitch> ¡Adjusting the lift (fast) microswitch
qAdjust the microswitch position to activate the switch

when the spool moves 5 mm. Microswitch
Adjustment gap when in neutral 1.0-2.0 mm

1.0-2.0 mm
CAUTION After adjustment of the microswitch, apply

THREEBOND[#1401] or an equivalent product on
the both fixing nuts to lock the threads. 2210127
82
7c CONTROL VALVE
7c- 4. Troubleshooting
7c-4-1. Control valve - troubleshooting
Lifting or tilting can qFailure of the pump or the coupling Replace

not work.
wShortage of oil in the tank Replenish
1
eBreakage of Plunger spring Replace
rFailure of the hydraulic microswitch Replace
Load of rated qFailure of the relief valve Replace

2 capacity can not be
lifted.
wFailure of the pump Replace
Lifting or tilting can qOverdischarge of the battery Charge

not work.
wShort stroke of the plunger Inspect
eDamage of the packing in the cylinder Replace
rLow relief pressure Adjust

3 tDamage of the packings of the plunger Replace
yFailure of the pump Replace
Clean or
uClogging of the filter in the tank
replace
iNo good adjustment of hydraulic chopper Adjust
Too much drifting of qDamage of the packings of the plunger Replace

lifting or tilting
4 wDamage of the Cylinder or the Piston Replace
eDamage of the packing of Piston Replace
Too much shock qNo good adjustment of the Lift microswitch Adjust
5 when starting to lift.
wFailure of the relief valve Replace
Oil leakage qDamage of Ring, O or Wiper Replace

6
wLooseness of bolts of Valve block Retighten
83
7d. CYLINDER
CYLINDER
7d- 1. Location and name
7d-1-1. Lift cylinder - main part names
¡Main parts of lift cylinder for STD (simplex) mast,
and lift cylinder 2nd for M (triplex) mast
Bushing 2210173
Bearing, cushion
Spacer
Ring, snap
Rod ass'y, piston

Tube ass'y, cylinder
7d
2210063
¡Main parts of lift cylinder 1st for M (triplex) and PFL (duplex) masts
Valve, check
Plate
Bearing, cushion
Ring, snap

Rod ass'y, piston
Valve, down safety
Plug (FB10P-18P)
2210064
84
7d CYLINDER
¡Main parts of lift cylinder 2nd for PFL (duplex) mast
Ring, slide
Ring, slide Valve, check
Valve, check Ring, snap
Ring, snap Spool, Holder
Spool, cushion
Holder
cushion Spring
Spring

Tube ass'y,
cylinder
Rod (R),
Rod (L), piston
piston
Ring, wear
Ring, wear (MLH4300-5000)
(MLH4300-5000)
Spacer
Spacer Ring,
snap
Ring,
snap Piston
Piston
2210065
7d-1-2. Tilt cylinder - main part names

¡Main parts of tilt cylinder
Head kit, rod
Kit, cylinder head
STD/PFL mast
Bwd tilt 10
Spacer Spacer
Rod ass'y, piston
Spacer
2210066
85
CYLINDER 7d
7d- 2. Disassembly and reassembly

7d-2-1. Lift cylinder (STD mast) - removal

1. Operate the lift lever so that the inner mast rises about 50 mm.
2. Support the inner mast with a wire rope or wood block.
3. Remove fitting bolts for piston rod.
¡Removing the lift cylinder for STD mast 1 STD mast
Fitting bolt
Inner mast
Fitting bolt
Piston rod
Outer mast
2210067
86
7d CYLINDER
4. Disconnect hydraulic hoses.

Band
Low pressure hose

Band
Band
Low pressure hose
Band
Band
Band
High pressure hose
High pressure hose
Low pressure hose

2210069
5. Remove cylinder bands to remove the lift cylinders.

CAUTION Be sure to note the number and thickness of shims when removing them.
Shim
Lift cylinder
Cylinder band
2210072
87
CYLINDER 7d
7d-2-2. Lift cylinder 2nd (M/PFL mast) - removal

1. Operate the lift lever so that the inner mast rises about 50 mm.
2. Support the inner mast with a wire rope or wood block.
3. Remove set screws that fix the piston rod.
¡Removing the lift cylinder 2nd for M/PFL mast (1) M mast
Set screw
Set screw
Middle mast
Piston rod
Outer mast
PFL mast
Set screw
Inner mast
Piston rod
Outer mast
Set screw
2210068
88
7d CYLINDER
4. 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 release high
pressure in the hydraulic piping before disconnecting hydraulic hoses or pipes.
¡Removing the lift cylinder 2nd for M/PFL mast (2) M mast
Band
High pressure
hose High pressure hose
Low pressure
hose
Band
Band
High pressure
hose
High pressure Low pressure
hose hose
High pressure
hose
Pipe comp., lift
2210070
PFL mast
Pipe
High pressure hose
High pressure hose
High pressure hose

2210071
89
CYLINDER 7d
5. Remove cylinder bands to remove lift cylinders.

¡Removing the lift cylinder 2nd for M/PFL mast (3)
M mast PFL mast
Lift cylinder
Support, band
Cylinder band
Lift cylinder Cylinder band
2210149
7d-2-3. Tilt cylinder - removal

1. Operate the tilt lever to tilt the fork forward.
2. Place a rope on the "beam, upper" of the outer mast, and
use the hoist to support the mast.
3. Remove tilt pipes.

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.
4. Remove tilt pins to remove tilt cylinders.

¡Removing the tilt cylinder
Tilt pin
Tilt cylinder
Pipe(2)comp., tilt
Pipe(1)comp., tilt
Tilt pin
2210073
90
7d CYLINDER
7d-2-4. Lift cylinder (STD mast) - installation

1. Install the lift cylinder in reverse order of removal.
2. Operate the lift lever to raise the mast to the top.
Make sure if both right and left cylinder rods have no clearance at the top end.
If clearance is found, insert shims to support the top beam of the mast with both cylinders.
¡Installing the lift cylinder for STD mast STD mast
Bolt
Shim
2210074
7d-2-5. Lift cylinder 2nd (M/PFL mast) - installation

1. Install the lift cylinder in reverse order of removal.
2. Operate the lift lever to raise the mast to the top.
Make sure if both right and left cylinder rods have no clearance at the top end.
If clearance is found, loosen the set screw and turn the adjusting bolt to minimize
the clearance. After adjustment, tighten the set screw and install the "plate, lock" to
fix the adjusting bolt.
3. Tighten the set screw.

¡Installing the lift cylinder (2nd) for M/PFL mast M/PFL mast
Screw
Adjusting bolt
Plate, lock
Set screw
2210075
91
CYLINDER 7d
7d-2-6. Tilt cylinder - installation

1. Install the tilt cylinder in reverse order of removal. ¡Installing the tilt cylinder
Adjust the length

of the rod head
2. Operate the tilt lever, and check for unbalancing of length
of left and right cylinders at the stroke end.
If there are some unbalancing, loosen the rod head nut,
and adjust the rod length by turning the head.
Nut
212E080
7d-2-7. Lift cylinder - disassembly and reassembly

1. Vise the cylinder. ¡Removing the "head, cylinder"
CAUTION Do not vise "head, cylinder".
2. Remove the "head, cylinder" with a hook wrench.
Vise
Hook wrench
152T017
Lift cylinder 1st (M/PFL mast)

Head, cylinder B
Apply THREEBOND[#1901] on
threads when tightening.
FB20P-30P Tightening torque

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
FB30P
{46 10.6 kgf m}
Tightening torque
: Tightening torque 3.92 0.98 N m
B : Apply THREEBOND
N : Not reusable
{0.4 0.1 kgf m}
2210076
92
7d CYLINDER
Lift cylinder (STD mast) / lift cylinder 2nd (M mast)
Head, cylinder B
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}
: Tightening torque 275 61.8 N m
FB30P
B : Apply THREEBOND {28 6.3 kgf m}
N : Not reusable
2210077
Lift cylinder 2nd (PFL mast) Holder B

Tightening torque
206 39 N m
FB10P-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
the facing of parts. Face the slit
surface toward the spring.
[L.H.] [R.H.] 2 Tightening torque R

3.92 0.98 N m
{0.4 0.1 kgf m}
: Tightening torque
After tightening, use a 2
B : Apply THREEBOND L.H.
R : Apply LOCTITE
point punch or close.
N : Not reusable R.H. After tightening, apply LOCTITE.
2210078
CAUTION Replace packings after disassembling.
NOTE Apply grease on the packings and fitting parts when fitting them.
93
CYLINDER 7d
7d-2-8. Tilt cylinder - disassembly and reassembly

1. Vise the cylinder. ¡Removing the
"head KIT, cylinder"
CAUTION Do not vise "head KIT, cylinder".
2. Remove the "head, cylinder" with a hook wrench.
Vise
Hook wrench
152T017
¡Disassembling and reassembling the tilt cylinder
head, cylinder B
the threads when tightening.
Tightening torque
343 64 N m
FB10P-18P
{35 6.5 kgf m}
451 88.3 N m
FB20P-30P
{46 9.0 kgf m}
Set, screw B
Apply THREEBOND [#1324 (5M)]
1 Tightening torque
STD/PFL mast 206 25 N m
Bwd tilt 10
{21 2.5 kgf m}
Tightening torque
: Tightening torque 14.7 N m
B : Apply THREEBOND
N : Not reusable
{1.5 kgf m}
2210079
CAUTION Replace packings after disassembling.
NOTE Apply grease on the packings and fitting parts when fitting them.
94
7d CYLINDER
7d- 3. Inspection and adjustment

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

qCheck for rusting and damage. ¡Measuring deflection
aIf rusting or damaged, grind them with oil stone till they
Dial gauge
will not be felt by fingers.
wCheck for deflection.
Deflection limit 1.0 mm (1/2 of gauge indication)
Piston rod
CAUTION Use at least 3 points to measure deflection.

152T018
95
CYLINDER 7d
7d-3-3. Drift of lift lowering and tilt - inspection

¡After replacing packings or a cylinder, measure drift of lift lowering and tilt.
aIf it is over the specific drift of lift lowering or tilt, must be inspected again.
<Measuring drift of lift lowering>

qLoad the maximum weight, and then raise the fork ¡Measuring drift of lift lowering
about 70 cm from the ground. Outer mast Inner mast
wTilt the mast to level the fork.
(Use the tilt lever.)
eDraw a base line from the inner mast to the outer mast.
Draw a base line
rMeasure the drift of lift lowering 10 minutes later.
Drift of
lift lowering
<Specifications>
Drift of lift lowering [mm/10min.]
Applicable model
Inner mast
FB10P 25-40 Top surface

of the fork
FB15P/18P/20P 35-50
Drift of 70 cm
FB25P/30P 50-65 lift lowering
212E084
CAUTION If the drift of the lift lowering is measured at the

top surface of the fork, the specific values
should be double the values shown above.
<Measuring drift of tilt> ¡Measuring drift of tilt
qLoad the maximum weight, and then raise the fork

about 70 cm from the ground.
wTilt the mast to level the fork.
(Use the tilt lever.)
eMeasure the tilt drift of the piston rod 5 minutes later.
70 cm
<Specifications>
Drift of tilt [mm/5min.] Drift of tilt
Piston rod
Piston rod 5-10
Tilt cylinder
212E085
96
7d CYLINDER
7d- 4. Troubleshooting
7d-4-1. Cylinder - troubleshooting
Oil leakage from qDamage of the packing in the cylinder Replace

Cylinder head
1 wLooseness of Cylinder head Tighten
eDamage on the rod Repair, Replace
Oil leakage from

2 qDamage of the welded part Repair
Cylinder COMP
Too fast drifting qDamage of the packing in the cylinder Replace
3 wDamage of the bore wall Repair, Replace
eOil leakage in Control valve Replace
Cylinder vibrates qBend of the rod Replace
4 wShortage of hydraulic oil in the tank Replace
eAir from the fitting of the piping Tighten
Slow extended speed qOver-discharge of the battery Charge

of cylinder rod
wLack of displacement of the pump Replace
eShort stroke of the plunger of Control valve Inspect
5 rClogging of the filter in the tank Clean or replace
tLow relief pressure Adjust
yDamage of the packings of the piston Replace
uNo good adjustment of the hydraulic chopper Adjust
Abnormal lowering qStick of the spool in the flow control valve Replace
speed
wForeign article is caught in the flow control valve. Retighten
6 eThe spring in the flow control valve is damaged Replace

or weakened.
rReturn flow from the lift cylinder is choked in the Replace

hose.
Cylinder is not qFailure of the micro switch of the control valve Replace
extended / retracted.
wFailure of the wiring harness of the micro switch Inspect and
7 of the control valve repair
eNo good contact of the hydraulic contactor Inspect/repair
rBlow out of the hydraulic main fuse Replace
97
8. MAST
MAST
¡Main parts of STD (simplex) mast
Fork ass'y Inner mast

Bracket comp., lift
Lift cylinder
Outer mast
212E137
Lift cylinder
Tilt cylinder
¡Main parts of M (triplex) mast
Lift cylinder 1st Inner mast
Middle mast
Fork ass'y
Bracket comp., lift Lift cylinder 2nd
Outer mast
Lift cylinder 2nd
Tilt cylinder
2210080
98
8 MAST
¡Main parts of PFL (duplex) mast
Fork ass'y
Bracket comp., lift
Lift cylinder 1st
Inner mast
Lift cylinder 2nd

Outer mast
Lift cylinder 2nd
Tilt cylinder
2210081
99
MAST 8

8-2-1. Lift bracket - removal

1. Move the mast vertically and lower forks to the ground. ¡Removing the lift bracket
2. Remove cotter pins.

3. Slacken lift chains and remove nuts at the chain anchor Lift chain
bolt.
4. Remove lift chains to the front side (fork side).
CAUTION Nuts should be screwed on the chain anchor

bolt to prevent damage to the thread part.
5. Operate the lift lever to raise the inner mast to a height Lift bracket
where the lift bracket can be removed.

Nut
6. Move the truck backward, or move the lift bracket
Cotter pin
forward.
2210084
7. Lower the inner mast.
8-2-2. Mast ass'y - removal

1. Tilt the mast vertically. ¡Hoisting the mast ass'y
2. Hoist the mast ass'y until the wire ropes are just stretched.
212E087
100
8 MAST
3. Raise the inner mast until its lower end rises to the top of ¡Removing 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
2210082
7. Operate the tilt lever to retract the piston rod of the tilt
cylinder.
8. Disconnect hydraulic pipes and hoses.
9. Remove fitting bolts for the pivot caps to remove pivot ¡Removing the pivot cap
caps and bushings.
10. Hoist the mast ass'y.
Outer mast
Bushing
Pivot cap
Washer, lock
Fitting bolt 2210083
101
MAST 8
8-2-3. Mast - disassembly and reassembly
CAUTION ¡Be sure to note the number and thickness of shims when removing
them.
¡Disassembling and reassembling the STD mast
1 Sliding part G
Fork (See 8-3-8.) Apply grease on a part of sliding.
2 Shim
Chain wheel (See 8-3-5.) Note the number and thickness.
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
2210085
102
8 MAST
¡Disassembling and reassembling the M mast
1 Sliding part G
Apply grease on a part of sliding.
2 Shim
Note the number and thickness.
Hose pulley (See 8-3-6.)

Chain wheel
(See 8-3-5.)
Fork Lift chain
(See 8-3-8.) (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
2210086
103
MAST 8
¡Disassembling and reassembling the PFL mast
1 Sliding part G
Fork (See 8-3-8.)
Apply grease on a part of sliding.
Chain wheel (See 8-3-5.)
2 Shim
Note the number and thickness.
Back shoe (See 8-3-2.)
Lift chain (See 8-3-3, 8-3-4, 8-3-9)
Roller (See 8-3-7.)
Grease nipple G
Fill grease.
G : Apply grease
N : Not reusable
2210087
104
8 MAST

8-3-1. Mast , lift bracket and roller shaft - inspection
qCheck if welded parts are cracked with color check.
CAUTION Use welding rods of low hydrogen type when re-

welding on Mast channels and/or Roller shafts.
¡Inspection of mast, lift bracket and roller shaft STD/PFL mast
Roller shaft
Roller shaft
Mast channel
Roller shaft
Roller shaft
Mast channel 2210134
¡Inspection of mast, lift bracket and roller shaft M mast

Mast channel
Roller shaft Roller shaft
Mast channel
Roller shaft
Roller shaft
Roller shaft
Roller shaft
Mast channel 2210089
105
MAST 8
8-3-2. Back shoe - inspection

qCheck the back shoe for wear.
¡Inspection of back shoe
<Specifications> [mm]
Specific thickness [A] Wear limit
A
3 2.5
152T022
8-3-3. Lift chain - inspection and replacement

qCheck lift chains for stretch. ¡Inspection of lift chain
Measure the length per 20 links at the part which are
used frequently.
<Specifications>
¡FB10P-18P [mm]
Specific Elongation
Pich[P] Remarks
dimension limit
P
Leaf chain#50
317.5 324 15.875
(BL534)
¡FB20P-30P [mm]
Specific Elongation
Pich[P] Remarks
dimension limit
212E095
Leaf chain#60
381 389 19.05
(BL634)
wCheck lift chains for deformation and damage.

If it is jolted, replace it.
eCheck for lubrication.
Apply grease on chains.
8-3-4. Chain bolt - inspection

qCheck connecting part (S) for jolt. ¡Inspection of chain bolt
If it is jolted, replace it.
wCheck for damage of threads.
[S]
212E096
106
8 MAST
8-3-5. Chain wheel - inspection

qCheck the outer surface for deformation and the ¡Inspection of chain wheel
bearing for function.
152T025
8-3-6. Hose pulley - inspection

¡Check for wear. ¡Inspection of hose pulley
Item Specific diameter [d] Wear limit
Hose pulley 25.0 25.5
152T026
8-3-7. Roller - inspection and replacement

qMeasure the clearance between outer diameter of
rollers and inner width of mast channel.
aIf over the specific clearance, replace it.
Item Specific clearance
Mast roller, Lift roller 1.5
wCheck for function and jolt.
107
MAST 8
8-3-8. Fork - inspection and replacement

qCheck for transformation and leveling.
¡Leveling
Item Specific dimension
Leveling of fork tips 10
Opening of fork tips 15
461E123
¡Opening
461E124
wCheck for wear and cracks.

¡Bending
Applicable model Specific thickness Wear limit
FB10P/14P/15P 35 +2.00 32
+2.0
FB18P 36 0 33
+2.0
FB20P/25P 40 0 37
+2.0
FB28P/30P 47 0 44 461E125
¡Wearing
461E126
CAUTION ¡If cracked, replace them and never use them

after repairing.
¡Check for cracks by using color check.
108
8 MAST
8-3-9. Lift chain - inspection and adjustment

¡Measure the deflection of Lift chains, and if over ¡Adjusting the lift chain
specific one, adjust it.
<Adjustment>
qExtend the mast and lower forks on the flat floor.
Nut
wPush the chain at approx. 1000 mm height of Lift
0-20 mm
chains and measure it. Nut
Item Specific deflection 1000 mm
Lift chain 0-20

eIf over specific deflection, adjust it with nuts. 212E097
rIf the deflection of each chain (L.H./R.H.) is equal,

tighten nuts.
8-3-10. Mast inclination - inspection and adjustment

¡Check for the following in case the inner mast was ¡Mast facing
inclined when lifting forks to the stroke end.
qLift forks a little and check if the tension of each lift

chain is the same.
aRefer to "8-3-9. Lift chain - inspection and adjustment" .
wLift forks and check if the lift bracket touches the inner
mast.
aSTD mast : Remove or add shims(t0.2, 0.5, and/or
t1.0) to adjust it.
aM/PFL mast : Tighten or loosen the adjusting bolt to 152T033
adjust it.
¡Adjusting mast angle STD mast ¡Adjusting mast angle M/PFL mast
Adjusting bolt
Shim
2210120 212E098
eCheck if cylinder rods stop at the same time when lifting forks to the stroke end.
aRefer to "7d-2-4 or 7d-2-5. Lift cylinder - installation" on page 91.
rCheck for deflection in the chains when lowering forks.
109
MAST 8
8-4-1. Mast - troubleshooting
Inner mast lifts up

qImproper clearance of lift rollers and/or side
1 together with Lift Adjust
bracket rollers
Lifting and lowering qImproper clearance of lift rollers and/or side

Adjust
of Lift bracket is not rollers
smooth.
2 wNo good function of rollers Replace
eNo good sliding of chain wheel support and guide

Repai
shaft
Lift bracket is qToo big clearance of side rollers Adjust

3 inclined.
wUnequal tension of L.H. and R.H. chain Adjust
Lifting and lowering

qImproper clearance between rollers and mast Adjust
of Inner mast is not
4 smooth.
wNo good function of rollers Replace
Inner mast is inclined qL.H. and R.H. of Chain wheel support do not
at extended position. Adjust
raise Inner mast simultaneously
5
wExtending of Lift cylinder rod is not simultaneous Adjust
Extending / retracting qImproper clearance between Reach roller and

of mast is not Adjust
Reach channel
6 smooth.
wImproper clearance between rollers and Reach
Replace
liners
Lack of uniformity of Repair,

qBending of forks
Forks replace
Proper
7 wOne side load on forks
operation
Repair,
eBending of Tilt bar
replace
110
9. MOTOR
MOTOR
9-1-1. Traction motor - main part names
¡Main parts of traction motor
Core comp., field

Coil comp., field
212E138
Terminal comp.
Armature comp.
Fan
Seal, oil
Cover(D), end
Spring
Cap, rubber
Yoke
Cover(C), end
Holder sub comp., brush
Brush
Bolt, stud
Terminal comp. 234W031
9-1-2. Hydraulic motor - main part names

¡Main parts of hydraulic motor
Core comp., field
Coil comp., field
Armature comp.
Fan
Cover(C), end
Cover(D), end
Terminal comp.
Spring
Terminal comp.
Yoke
Holder sub comp., brush
Brush
234W032
111
MOTOR 9
9-1-3. EPS motor - main part names
¡Main parts of EPS motor

Spring
Brush
Brush holder
Yoke ass'y
Armature comp.
Cover(D) Cover(C), end
2210139
9-1-4. Motors - specifications

¡Traction motor
Applicable model Type Rating
FB10P/15P/18P DT-7.8BA-1550 7.8kW, 48V, 205A, 1650r/min, 1h
FB20P/25P DT-8.3B-1350 8.3kW, 48V, 225A, 1450r/min, 1h
FB30P DT-12BFA-1350 10kW, 72V, 170A, 1460r/min, 1h
¡Hydraulic motor
FB10P/15P/18P DTL-7.7HA-1580AS 8.2kW, 48V, 225A, 1700r/min, 1/12h
FB20P/25P DTL-9HA-1900AS 9.6kW, 48V, 245A, 2050r/min, 1/6h
FB30P DTL-13.5BA-2000AS 12.7kW, 72V, 210A, 1850r/min, 1/6h
¡EPS motor
FB10P/15P/18P 32911-03220 350W, 48V
FB20P/25P 32911-03280 550W, 48V
FB30P 32911-03290 550W, 72V
112
9 MOTOR

CAUTION ¡Lift or jack up the forklift truck and support it with safety blocks or rigid
stands.
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.
¡Removing the traction motor
Terminal comp.
Traction motor
Harness connector
Terminal bolt
Lead wire
Spline MG
Apply molybdenum grease on a
part of spline.
Tightening torque
Front axle 19.8-24.2 N m
{2.1-2.5 kgf m}
: Tightening torque
234W033
* Install the front axle and traction motor in reverse order of removal.
113
MOTOR 9
9-2-2. Hydraulic motor - removal and installation

CAUTION ¡Turn the key switch off and operate hydraulic levers a few times to
1. Remove the side cover(R). ¡Loosening the terminal bolt
2. Disconnect the high pressure hose and low pressure Terminal bolt
hose from the hydraulic pump.
3. Disconnect lead wires on the hydraulic motor.
NOTE Hold the terminal comp. by a wrench when

loosening the terminal bolt.
Terminal comp.
4. Remove fitting nuts(*1) for the motor bracket, and hoist

Wrench
the hydraulic motor with the motor bracket. 234W020
¡Removing the hydraulic motor (1)

Low pressure hose
High pressure hose Terminal bolt

Lead wire
Terminal comp.
¡Fitting nut (*1)
Motor bracket Hydraulic motor Tightening torque

29.4-39.2 N m
{3-4 kgf m}
Cushion
Side cover(R)
¡Fitting nut (*1)

Tightening torque
29.4-39.2 N m
: Tightening torque
{3-4 kgf m}
234W034
114
9 MOTOR
5. Remove fitting nuts(*2) to remove the hydraulic motor

with the hydraulic pump.
6. Remove fitting bolts(*3) to remove the hydraulic pump

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

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

¡Fitting bolt(*3)
Tightening torque
19.6-24.5 N m
{2.0-2.5 kgf m}
Coupling, pump MG
Cushion serrations.
Bracket, cushion
Hydraulic pump
Hydraulic motor
Motor bracket
¡Fitting nut(*2)
Tightening torque
8.8-10.8 N m
: Tightening torque {0.9-1.1 kgf m}
234W035
* Install the hydraulic motor in reverse order of removal.
115
MOTOR 9
9-2-3. EPS motor - removal and installation

1. Remove the floor plate and disconnect the harness connector for the accelerator.
Refer to "5-2-1. Steering - removal and installation" on page 48.
2. Remove the battery.

Refer to "10e-1-1. Battery - removal and installation" on page 153.
3. Disconnect harness connectors for the EPS motor.

4. Remove fitting bolts(*1), and remove the EPS motor from the actuator ass'y.
¡Removing the EPS motor
¡Fitting 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
: Tightening torque
Packing can not be reused.
G : Apply grease
Liquid packing can be used.
N : Not reusable
2210098
* Install the EPS motor in reverse order of removal.
116
9 MOTOR
9-2-4. Traction motor - disassembly and reassembly

CAUTION Mark the yoke, "cover(C), end" and "cover(D), end" before disassembling
to help reassembling.
¡Disassembling and reassembling the traction motor
Oil seal N B G
Apply grease on the lip of the oil seal,
N and THREEBOND[#1104] around it.
Cover(D), end
N
Marking
Marking
Cover(C), end
Yoke
Marking
Bolt, stud R
Apply LOCTITE [#648] to threads
B : Apply THREEBOND on the stud side.
R : Apply LOCTITE
G : Apply grease
N : Not reusable
234W036
117
MOTOR 9
9-2-5. Hydraulic motor - disassembly and reassembly

CAUTION Mark the yoke, "cover(C), end" and "cover(D), end" before disassembling
to help reassembling.
¡Disassembling and reassembling the hydraulic motor

N
Cover(C), end
Cover(D), end
Marking
Marking
Yoke Marking
N : Not reusable
234W037
9-2-6. EPS motor - disassembly and reassembly

CAUTION Mark the yoke and "cover(c), end" before disassembling to help
reassembling.
¡Disassembling and reassembling the EPS motor

Bolt
Cover(C), end
Marking
Yoke
2210101
118
9 MOTOR

9-3-1. Armature comp. - inspection and replacement
s1 Inspection of damage
¡Check the armature for damage, especially by burning.
\If it is damaged, replace it.
\ If the commutator surface is damaged, repair or
replace it.
<Repairing procedure>
q Machine turn the commutator. ¡Checking the commutator
surface
CAUTION Be sure to center the commutator when
machining.
Good Not Good
w Carry out the under cut.
e Finish the commutator surface with a sand paper
(#400).
152T035
<Repair limit>
¡Traction motor [mm]
¡Repair limit of commutator
Specific Repair limit
Applicable model Type dimension ( D) ( D)
FB10P/15P/18P DT-7.8BA-1550 104 99
FB20P/25P DT-8.3B-1350 104 99
FB30P DT-12BFA-1350 120 115
¡Hydraulic motor [mm]

Specific Repair limit
Applicable model Type dimension ( D) ( D)
FB10P/15P DTL-7.7HA-1580AS 90 85
FB18P/20P/25P DTL-9HA-1900AS 90 85
FB30P DTL-13.5BA-2000AS 104 99
152T036
¡Specific under cut [mm]

Applicable motor Specific under cut ¡Under cut of commutator
Traction motor 0.15 - 10

Hydraulic motor 0.15 - 10
EPS motor 0.5 - 0.8
152T037
119
MOTOR 9
s2 Inspection of insulation
¡Measure the insulation between the commutator and ¡Inspection of insulation

the armature shaft.
Clean up by compressed air before measuring. Positive

CAUTION
<Resistance>
Tool Specific resistance
Negative
Tester (Infinite at X1 k range)
Megger 0.5 M or greater (DC500V)
152T038
s3 Inspection of armature shaft and key
¡Check for wear of spline. ¡Inspection of armature

\If it is extremely worn, replace it. shaft and key
¡Check the key whether it fits securely in the groove of
Spline
the shaft.
\If jolted, replace it.
Groove of shaft
Key
152T039
s4 Inspection of ball bearing
¡Check fitting part in "COVER (C), END" and "COVER

(D), END".
\If loose, replace it.
120
9 MOTOR
9-3-2. Brush, brush holder and spring -

inspection and replacement
s1 Inspection of brush wear

¡If wear limit line is marked on the brush, wear limit is ¡Inspection of brush wear
up to this line.
¡If not marked, measure the height (A) of the brush and
compare with the following dimensions for wear limit.
<Wear limit> [mm]
Applicable motor Specific dimension Wear limit (A)
Traction motor 32 22 Wear limit line
Hydraulic motor 25 17 Warning line
EPS motor 25 15 Brush
Brush holder
Brush Spring
Commutator
461E048
s2 Inspection of clearance between

brush and brush holder
Applicable motor Specific clearance (B) ¡Inspection of clearance
Traction motor 0.4

Hydraulic motor 0.4
EPS motor 0.1 - 0.3 Brush
Brush holder
125E087
121
MOTOR 9
s3 Inspection of contacting surface of brush
¡If the contacting surface is not good, repair it as ¡Inspection of contacting

follows. surface of brush
Good Not Good Not Good
Brush
Commutator
152T042
<Repairing procedure> ¡Repairing surface of brush

q Insert a sand paper [#400] between the commutator Brush
and the brush.
Sand paper
(File surface toward the brush.)
w Grind the contacting surface by moving a sand paper
or rotating the commutator by hand.
e Clean up with compresses air after repairing.
Commutator
152T043
s4 Inspection of force of spring
¡Hook a spring scale to the spring and pull towards

arrow mark. Then make sure of equal force on 4
springs.
( 2 springs in EPS motor )
<Specific force of SPRING> ¡Inspection of force of spring

Applicable motor Specific force
Traction motor 6 - 12 N (0.6 - 1.2 kgf)

Hydraulic motor 7.5 - 15 N (0.75 - 1.5 kgf)
EPS motor 5N (0.5 kgf) Spring
CAUTION If the spring and/or the brush holder were

rusted, replace them.
152T044
122
9 MOTOR
9-3-3. Field coil - inspection

¡Measure the insulation between terminals and the coil. ¡Inspection of insulation
Negative
CAUTION Clean up by compressed air before measuring.
<Resistance>
Tester (Infinite at X1 k range)

Megger 0.5 M or greater (DC500V) Positive
152T045
9-3-4. Motor ass'y - inspection

¡Inspect the following after assembling.
s1 Abnormal noise and arc

¡Operate the motor. Then make sure that abnormal noise is not heard
and arc of brushes is not seen.
CAUTION When performing a motor test, be sure to securely fix the

motor to a work bench.
The motor will move suddenly when it is started.
q Be sure to secure the motor ass'y to a work bench.
w Apply the battery of 1/4 voltage to carry out testing.
e Connect wires as follows.
¡Traction motor
1) Connect (AA) terminal with (F) terminal.
2) Connect (A) terminal with positive (+) terminal of battery.
3) Connect (FF) terminal with negative (-) terminal of battery.
¡Hydraulic motor
1) Connect (A) terminal with positive (+) terminal of battery.
2) Connect (FF) terminal with negative (-) terminal of battery.
¡EPS motor
1) Connect (GREEN or WHITE) wire with positive (+) terminal of
battery.
2) Connect (YELLOW or BLACK) wire with negative (-) terminal of
battery.
123
MOTOR 9
(Traction and hydraulic motor)
¡Measure the insulation between terminals and the yoke ¡Inspection of insulation
with Megger. (Traction and hydraulic motor)
CAUTION Remove the diode from inside the hydraulic

motor before using the megger.
Failing to do so may cause damage to the diode.
<Resistance>
152T046
<Measuring procedure>
q Apply earth probe (negative [-]) of Megger to the bolt
of Yoke.
w Apply line probe (positive [+]) of Megger to each
terminal (A), (AA), (F), (FF).
s3 Inspection of insulation (EPS motor)
¡Measure the insulation between terminals and the yoke ¡Inspection of insulation
with Megger. (EPS motor)
<Resistance>
Tool Specific resistance Terminal
Yoke
q Apply earth probe (negative [-]) of Megger to the
yoke. 152T058
w Apply line probe (positive [+]) of Megger to each

terminal.
124
9 MOTOR
9-3-5. Oil seal and permanent magnet (EPS motor)

- inspection and replacement
s1 Oil seal
qCheck the oil seal for wear and damage.
aIf worn or damaged, replace it.
s2 Permanent magnet
qCheck permanent magnets of the yoke for damage and
sticking metallic dust.
aIf sticking metallic dust, remove it with compressed air.
aIf damaged, replace the assemble.
9-4-1. Motor - troubleshooting
1 Abnormal noise q Damage of bearing Replace
w Armature shaft is not centered Repair/replace
e Loose fan. Replace
r Loose field cores. Retighten
2 Arc q No good communication of brushes. Repair/replace
w Rough commutator. Repair
3 Remarkable q Rear short of Armature comp. Replace

temperature rise
w No good rotating Replace
4 Abnormal noise or q Wear of serration of Armature shaft or coupling Replace

temperature rise after
installing w No good adjustment or wear of gears or no good
Replace
bearings in Drive unit
e No good adjustment of Start current and Current

Adjust
limitation.
r Too heavy duty operation. Replace
125
10. ELECTRIC PARTS
¡Charger ¡Display panel ¡Directional switch ¡Battery
aSee page 141. aSee page 137. aSee page 138.

aSee page 153.
¡Accelerator
¡EPS controller
aSee page 140.
¡Transformer
aSee page 136.
aSee page 144.

¡Control unit ¡MPU board
(TRV/HYD board)
aSee page 127. aSee pages 128 and 156.

234W039
126
10a. CONTROL UNIT
10a-1. Location and name
¡Main parts of control unit
e !6 q w r t !5
!2
@0
!3 CU103-XX
o
!8
!7 !9
¡FB30P
!4 !0 u !1 i
(FB30P: o ) Battery
[-] line
y
* This illustration shows FB15P/18P

234W002
No. Part name Remarks FB10P FB15P/18P FB20P/25P FB30P

q Contactor Forward (M1)
MSW34-23 MSW44-23
w Contactor Backward (M2)
e Contactor Regenerative (M3)
r Contactor Bypass (M4) MS34-20 MS44-20
t Contactor Hydraulic (M6)
y Contactor Hydraulic bypass (M7) - MS44-20
u FET comp. Travel 14-parallel 20-parallel
i FET comp. Hydraulic 14-parallel 20-parallel
o Diode 45M20 3 pieces 4 pieces
!0 Diode SKR130 1 piece -
!1 Capacitor 100V/2200 F 2 pieces 4 pieces 6 pieces
!2 Sensor comp., current (1) Travel (field)
!3 Sensor comp., current (2) Travel (armature)
!4 Board comp., MPU PBC100-09
!5 Controller ass’y, EPS
!6 Resistor comp. 30W/2.2 x4 40W/2.2 x 2
!7 Board comp., printed PB83-62
!8 Fuse (DC96V / BN-275A) Hydraulic
!9 Fuse (DC96V / BN-275A) Travel
@0 Fuse (DC96V / BN-40A) EPS
127
CONTROL UNIT 10a
10a-2. Disassembly and reassembly

10a-2-1. Control unit - removal and installation

1. Remove fitting bolts (*1) to remove the rear cover.
2. Remove the control unit as follows.

qDisconnect wires on the control unit.
wRemove fitting bolts (*2) to remove the control unit.
3. Remove the MPU board as follows.

qDisconnect harness connectors from the MPU board.
wRemove fitting bolts for the MPU board.
eRemove the MPU board.
¡Removing the control unit
Weight
Control unit
Fitting bolt (*2)
Rear cover
(*1) Fitting bolt

with washers
MPU board
Fitting bolt
234W003
* Install the control unit in reverse order of removal.

128
10a CONTROL UNIT
10a-2-2. Control unit - disassembly and reassembly
¡Disassembling and reassembling the control unit (1)
1 Terminal R
Washer, lock
Sensor comp.,current (1) Apply LOCTITE [#242] or an equivalent
product on threads to prevent looseness.
Sensor comp.,current (2) Insert washers as shown in this

illustration.
Washer, plain
Washer, lock Washer, lock
Nut
Washer, plain
Washer, plain
Washer, lock
Nut
Washer, lock
Washer, plain
Washer, lock
Nut
For hydraulic
Washer,
lock 2 FET comp.
Apply conductive compound
[G-747](Shin-Ethu silicones) on
all mating surfaces.
Washer, plain
Washer, lock
Nut
For travel
R : Apply LOCTITE
234W004
129
CONTROL UNIT 10a
¡Disassembling and reassembling 1 Sink, heat

the control unit (2)
Apply conductive compound
[G-747](Shin-Ethu silicones) on
all mating surfaces.
¡Diode (45M20)
Tightening torque
FB10P
9.5-12.5 N m
{97-127 kgf cm}
Capacitor
Screw for terminal

Use a screw included with the
capacitor.
¡Diode (45M20)
Tightening torque
FB15P/18P FB20P-30P 9.5-12.5 N m
{97-127 kgf cm}
¡Diode (SKR130)
Tightening torque
9.0-11.0 N m
{92-112 kgf cm}
: Tightening torque
234W005
Resistor comp.
FB30P Controller ass’y, EPS
Fuse
(Hydraulic : 275A)
Fuse
Board comp., printed Fuse
(Travel : 275A)
(EPS : 40A)
Board comp., MPU

234W006
CAUTION ¡Be sure to install the fuse with the specific capacity one.
¡Be sure to tighten fuse fitting nuts after installing the fuse.
130
10a CONTROL UNIT
10a-2-3. Contactor - removal and installation

¡Removing contactors
FB10P
Hydraulic (M6)
[MS34-20]
Bypass (M4)
[MS34-20]
Backward (M2)
[MSW34-23]
Forward (M1)
[MSW34-23]
Screw for terminal
Regenerative (M3)
[MS34-20] Use a screw included with the
contactor.
FB15P-30P Hydraulic (M6)

[MS44-20]
Bypass (M4)
[MS44-20]
Backward (M2)
[MSW44-23]
Forward (M1)
[MSW44-23]
Regenerative (M3)
[MS44-20]
Hydraulic bypass (M7)
[MS44-20]
FB30P
234W007
131
CONTROL UNIT 10a
10a-2-4. Contactor - disassembly and reassembly

FB10P, [MS34-20] [MSW34-23]
¡Disassembling and reassembling the contactor (1)
Fitting bolt (*5)

1 Contact surface MG
Apply a little grease with
molybdenum disulfide.
t Contact
e Spring, return
r Contact comp.
q Holder
q Spring
q Holder
u Base
(*1) Pin, cotter
Fitting bolt (*4)
(*7)
Fitting screw y Yoke
(*6)
Fitting screw
Only for forward and backward contactors

[MSW34-23]
w Stopper
Frame,
magnet
Fitting bolt (*2)
u Solenoid
u Core

234W008
qRemove the "pin, cotter" (*1), holders and the spring.

wRemove fitting bolts (*2) to remove the stopper.
(Only for forward and backward contactors [MSW34-23])
eRemove the "spring, return".
rRemove the fitting bolt (*4) to remove the contact comp..
tRemove the fitting bolt (*5) to remove the contact.
yRemove the fitting screw (*6) to remove the yoke from the base.
uRemove fitting screws (*7) to remove the base, core and solenoid from the "frame,
magnet".
*Reassemble the contactor in the reverse order of disassembling.
132
10a CONTROL UNIT
FB15P-30P, [MS44-20] [MSW44-23]
¡Disassembling and reassembling the contactor (2)
1 Contact surface MG
(*2) Contact Apply a little grease with
w Fitting bolt molybdenum disulfide.
Fitting bolt (*2)
r Solenoid
r Core
e Spring, return q Holder

(*2) Fitting nut
q Spring
e Armature q Holder
t Surge absorber
(*1) Pin, cotter

q Contact comp.

234W009
qRemove the "pin, cotter" (*1), holders and the spring to remove the contact comp..
wRemove fitting bolts and nut (*2) to remove the contact.
eRemove the "spring, return" to remove the armature.
rRemove the core and solenoid.
tRemove the surge absorber.
CAUTION Be careful not to damage the coil terminals.
*Reassemble the contactor in the reverse order of disassembling.
133
CONTROL UNIT 10a
10a- 3. Check and replacement

¡Discharge capacitors on the control unit.
10a-3-1. Capacitor - discharging procedure

qPrepare a resistor (20W, 50 or 50W, 10 ). ¡Discharging the capacitor
wFit terminals of the resister to terminals of the capacitor.
152E118
10a-3-2. Diode - inspection

qMeasure the resistance value and check the diode. ¡45MA20
¡Specific resistance value Tester
Terminal
Resistance
[+] Positive [-] Negative
Anode Cathode
10 -100 k
Cathode Anode (Approx. 150k ) 461E110
Tightening torque
NOTE ¡The values indicated in ( ) are checked by a 9.5-12.5 N m
digital tester (KAISE SK 7711) as a reference. {97-127 kgf cm}
¡Each resistance value varies depending on the
type of tester.
¡SKR130 (FB10P-25P)
Tester
<Measuring procedure> A
qSet the tester knob to the resistance ( ) x 1 range.

wShort-circuit the tester rod to set the needle to 0.
A
ePlace the tester rod against the element to check it.
K
K
234W042
Tightening torque
9.0-11.0 N m
{92-112 kgf cm}
134
10a CONTROL UNIT
10a-3-3. FET comp. - inspection

¡Measure the resistance value and check the FET
comp.
¡Between drain (D) and source (S) ¡Between D and S

qSet the tester knob to the resistance ( ) x 1k range.
WH : White
wApply the (+) tester probe to the source (S) of the FET BL : Blue
comp. connector, and the (-) tester probe to the drain BK : Black
(D) of the FET comp. connector respectively.

WH Source
Connector
Resistance 1M or greater Drain
BL Gate
BK
NOTE Make sure that between the drain (D) and the
source (S) is not conducting. 234W511
¡Between gate (G) and source (S) ¡Between G and S

WH : White
wApply tester probes to the gate (G) and the source (S) BL : Blue
respectively. BK : Black
Resistance 100k or 10k WH Source
Connector
Drain
BL Gate
BK
234W512
¡Between gate (G) and drain (D) ¡Between G and D

WH : White
wApply the (+) tester probe to the drain (D) of the FET BL : Blue
BK : Black
comp. connector, and the (-) tester probe to the gate
(G) of the FET comp. connector respectively.
WH Source
Connector
Drain
Resistance 1k or greater BL
Gate
BK
234W513
NOTE ¡Make sure that between the drain (D) and the ¡FET element
gate (G) is not conducting.
¡They should be checked while the FET printed
board comp. is attached to a heat sink. Gate
¡Do not use a megger. Drain
Source
¡Resistance values vary depending on testers.
461E114
135
CONTROL UNIT 10a
10a-3-4. Capacitor - check and replacement

¡Visually check the outside. If no evidence of a leak is
observed, check the following.
CAUTION Use an analog tester to check the capacitor. ¡Checking the capacitor
qDischarge the energy stored in the capacitor with a Analog tester
resistor.
For the discharge procedure, see "10a-3-1. Capacitor -
discharging procedure" on page 134.
wSet the tester knob to resistance ( ) x 1k range.
eApply the (+) tester probe to the (+) pole of the
capacitor, and the (-) tester probe to the (-) pole.
rFirst, the tester reads a few k , then reads . 461E115
CAUTION The above checking procedure is only for a basic

performance of the capacitor.
If in case of doubt, replace all capacitors.
10a-3-5. MPU board - inspection

¡For details of MPU board, see "10f. MPU board" on
page 156.
10a-3-6. EPS controller - specifications
Applicable model Type Voltage Current limitation ¡EPS controller

FB10P-25P CU103-40 48V 38A
FB30P CU103-41 72V 30A
10P [Water-resistant]
Wire [GREEN] : to EPS motor

Wire [YELLOW] :to EPS motor
Wire [BLUE] :
NEGATIVE [-] to Control unit
Wire [RED] :
POSITIVE [+] to Control unit
22100180
136
10b. DISPLAY PANEL AND DIRECTIONAL SWITCH
10b-1. Disassembly and reassembly
10b-1-1. Display panel - disassembly and reassembly
¡Disassembling and reassembling the display panel
Seat, switch
Panel, display(1)
Cap(2)
Cap(1)
Board comp., printed

Harness,display panel
Harness comp.,panel
Bracket,display
CS/RP/DRP
Cover,display Switch comp.,
push button
Case
Switch, flasher
Switch comp.,
push button
Column ass’y
Switch comp., key
CS/RP/DRP
Panel, display(3)
Panel, display(2)
Switch comp., key

234W040
137
DISPLAY PANEL AND DIRECTIONAL SWITCH 10b
10b-1-2. Directional switch - disassembly and reassembly

Disassembling procedure and part names
¡Disassembling 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
Refer to "Wiring" on
Plate, switch
the following page Roller
for the location of
the microswitch on
the left lever.
Arm
Cover, case Cam(A)
Cam(B)
* This illustration shows the right lever (DS100-20).

2210112
138
10b DISPLAY PANEL AND DIRECTIONAL SWITCH
Wiring
<Type : DS100-20 (right lever)>
Case
DS1(Forward)
Red/Green4 Brown2
Forward
DS2(Backward)
Red/Green4 White/Red2
DS3(Neutral)
Red/Green4 Brown/Black1
Backward
Insulation tube (black)

Length: 100 DS1
DS2
DS3
Brown/Black1
White/Red2
Red/Green4
Brown2
Microswitch location
2 2 2 2
1 2 3 4 Forward Neutral Backward
4P DS1 Conducting Not conducting Not conducting
Cap DS2 Not conducting Not conducting Conducting
1 2
3 4 DS3 Not conducting Conducting Not conducting
234W509
<Type : DS100-21 (left lever)>
Case
DS2(Forward)
Red/Green4 Brown2
Forward
DS1(Backward)
Red/Green4 White/Red2
DS3(Neutral)
Red/Green4 Brown/Black1
Backward
Insulation tube (black)

Length: 100 DS2
DS1
DS3
Brown/Black1
White/Red2
Red/Green4
Brown2
Microswitch location
2 2 2 2 Forward Neutral Backward
1 2 3 4
DS2 Not conducting Not conducting Conducting
4P
Cap
DS1 Conducting Not conducting Not conducting
1 2
3 4 DS3 Not conducting Conducting Not conducting
234W510
139
10c. ACCELERATOR
10c-1. Disassembly and reassembly
10c-1-1. Accelerator linkage - removal and installation
¡Removing and installing the accelerator linkage
Rod
Pedal
Bracket(2), accelerator
Sensor, accel position
Bracket(1), accelerator
2210113
140
10d. CHARGER (BUILT-IN TYPE)
10d-1. Disassembly and reassembly
10d-1-1. Charger ass'y - disassembly and reassembly
CAUTION ¡Do not misconnect lead wires to each part.
¡Check for the misconnection of lead wires.
¡Securely tighten the connection of lead wires.
¡Insert insulation tubes for the terminals of lead wires in order to keep
them away from metal parts.
¡Disassembling and reassembling the charger ass'y (built-in type)

Charger ass'y
Cover
Earth Charger,
wire microcomputer
Magnetic
Bracket, panel contactor
Link fuse
Fuse ass'y
Receptacle
Relay
Plug comp.
To body harness
To "charger, microcomputer"
harness, BC Magnetic contactor(1)

2210114
141
CHARGER (BUILT-IN TYPE) 10d
10d-1-2. Transformer - disassembly and reassembly

¡Disassembling and reassembling the transformer (built-in type)
Terminal fuse
Terminal
SKR71/02
Diode
Primary coil
SKN71/02
Secondary coil
Diode
Bracket, transformer
2210223
10d-1-3. Built-in charger - specifications

Power Applicable Terminal
Battery capacity Capacity Transformer Link fuse
voltage model fuse
330Ah(Std) 5.2KVA T1224-2000 15A 100A
FB10P 480-485Ah(Opt) 6.4KVA T2224-2000 20A 150A
545Ah(Opt) 7.0KVA T3224-3000 20A 150A
400Ah(Std)/485Ah(Opt) 6.4KVA T2224-2000 20A 150A
FB15P/18P
3 200V 545Ah(Opt) 7.0KVA T3224-3000 20A 150A
T2224-2000(6.4KVA)
FB20P 450Ah(Std)/545-600Ah(Opt) 6.4/7.0KVA 20A 150A
T3224-3000(7.0KVA)
FB25P 565Ah(Std)/600Ah(Opt) 7.0KVA T3224-3000 20A 150A
FB30P 450Ah(Std)/485-600Ah(Opt) 12.0KVA T3324-1000 30A 200A
142
10d CHARGER (BUILT-IN TYPE)
10d- 2. Inspection and replacement

10d-2-1. Magnetic contactor - inspection
¡Inspection of magnetic
qCheck for burns and damage to the contacts. contactor
Magnetic contactor
2210224
10d-2-2. Plug comp. and receptacle - inspection and replacement

qCheck for burns and discoloration on the receptacle
¡Inspection of plug comp. and
terminal. receptacle
aIf there are any burns, discoloration, or rattling in the
Fitting nut
terminal, replace both the plug comp. and the receptacle.
wCheck the earth wire fitting nuts for loosening.
Earth wire
Receptacle
Plug comp.
2210225
10d-2-3. Link fuse and fuse base - inspection

qCheck link fuses for blow outs and discoloration.
¡Inspection of link fuse and
wCheck fuse fitting screws for loosening. fuse base
Fitting screw
Link fuse
2210222
143
10d-2-4. Transformer - inspection

qCheck for damage and dirt.
aIf there is a lot of dirt, clean it away with compressed air.
wMeasure the insulation resistance.
Specific parameter for insulation

resistance 5M or greater
<Measuring procedure> ¡Transformer insulation

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

terminals.
qRemove all diodes.

wUse a megger to measure the following locations and
check the insulation.
¡Between the primary and secondary coils
Megger
¡Between the primary coil and the chassis 2210227
¡Between the secondary coil and the chassis
10d-2-5. Diode - inspection

qMeasure the resistance value and check the diode. ¡Checking the diode
¡Specific resistance value Tester

Terminal Diode
Resistance
[+] Positive [-] Negative
Anode Cathode
10 -100 k
Cathode Anode (Approx. 150K )
K A
NOTE ¡The values indicated in ( ) are checked by a
digital tester (KAISE SK 7711) as a reference.
¡Each resistance value varies depending on the A K
type of tester. SKN71/02 SKR71/02
2210226
qSet the tester knob to the resistance ( ) x 1 range.
wShort-circuit the tester rod to set the needle to 0.
ePlace the tester rod against the element to check it.
144
10d- 3. Inspection After Assembly

CAUTION ¡Check for conduction in the plug socket earth wire and the chassis. (tester 1
range: 0 )
¡Perform the inspection in an area with good ventilation and no fires.
10d-3-1. Timer - inspection

<Total timer>
Magnetic Auto Equal Indicating LED of charging state
Checking procedure
contactor LED LED 1-2 3-4
1 Connect the battery plug. OFF
2 Connect the AC plug to wall outlet. OFF
Press and hold the Auto When pressed OFF

3 Button for at least 5
seconds. 5 seconds later ON
Once Auto LED begins to flash,

4 OFF
release the Auto Button.
The check will end approximately 1 minute and

5 OFF
36 seconds after Auto Button begins flashing.
:On
:Off
:May be on
:Flashing
Auto LED (green)
This LED is turned on when the
battery is fully charged.
Auto button
Completion
cycle LED
3
Equal LED (orange)
Indicating LED (green) of
charging state.
¡The LED lights indicate
2 the charge left in the
battery.
¡If the total timer is
operated, all 4 LEDs will
flash.
1
234W500
CAUTION ¡For a fully charged battery, check after performing approximately 2-3 minutes of
hydraulic operation.
¡If the charging state LEDs are flashed, they will not turn off until the battery
plug is unplugged.
145
10d- 4. Charging procedure
10d-4-1. Normal (Daily charge)

¡ This charge returns the battery to a full-charged
condition after operating the forklift truck.
<Built-in charger (Option)>

qMove the forklift truck to designated charging area.
wTurn off the key switch and remove the key.
2210200
<How to open the battery cover> Lock

¡In case of FB10P through 28P
Release the bonnet catch and open the battery cover.
Bonnet catch 2210228
¡In case of FB30P ¡How to open the battery cover of

(1) Release the bonnet catch and open the battery FB30P
cover until the left gas spring is locked.
Stopper
(2) Release both right and left stoppers under the
battery cover, and flap the top of the cover down. Flap
down Pull
The stopper can be released by pulling and sliding
Stopper Slide down
down the knob.
(3) Open the battery cover again until the locking pin
Locking pin
catches the hole. Locking
Open pin
NOTE Make sure that the locking pin is secured in the Secure
Gas spring into hole
hole.
Gas spring
Battery
cover
CAUTION Gas spring (assist damper with self locking) is 2210201
used at the battery cover.

Make sure the condition of locking.
146
eConnect the rectangular plug of the AC cable to the

receptacle on the charger panel.
rConnect the AC plug to wall outlet.
Receptacle
Rectangular plug
(to charger panel)
AC cable
AC plug (to wall outlet)
2210203
Then, all "AUTO" and "EQUAL" lamps are turned on.
NOTE If these lamps are not turned on, make sure the AC
cable is connected correctly.
234W501
tPush "AUTO" button. Automatic charge is started.

yThe "AUTO" lamp (green) is lit. The "EQUAL" lamp is
turned off.
234W502
uWhen charge is completed, the top green lamp of

charge status indicator is lit.
iDisconnect the rectangular plug and AC plug.

234W503
147
<How to close the battery cover of FB30P.>

¡For FB30P only ¡How to close the battery cover
(1) Pull the locking pin and close the battery cover until of FB30P.
the left gas spring is locked. Stopper
(2) Flap the top of the battery cover up, and fix it with
Flap Slide up
both right and left stoppers. The stopper can be up
locked by pulling and sliding up the knob. Stopper Pull
Locking pin
Pull
Close
Locking
pin
Gas spring
Gas spring
Battery
cover
2210207
oPush the yellow stopper at the center of the gas spring ¡Closing battery cover
and close the battery cover.
CAUTION Be careful not to pinch hands or fingers between

battery cover and case.
!0Apply the bonnet catch after closing the battery cover.
CAUTION ¡Do not disconnect the rectangular plug, AC 234W508
plug and battery plug while charging.

¡Do not operate any hydraulic valve levers or
accelerator pedal while charging.
¡Push the "STOP" button when discontinue to
charge.
CAUTION Do not touch any parts of charger and cable by

wet hand.
CAUTION The charger operates with high voltage. Touch

by wet hand may cause electrical shock.
148
10d-4-2. Balancing charge

¡Specific gravity of electrolyte in each cell becomes
unbalanced 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.
¡Every two weeks when the lift truck is operated every
day.
¡Not charged for a couple of days after discharged.
¡Over-discharged.
<Charging procedure> Start the balancing charge.
qPush the "EQUAL" button as the same way as with a

normal charge.
"EQUAL" lamp (orange) will turn on.
234W505
wMeasure specific gravity of all cells after completion of

charge.
Refer to "10e-2-1. Battery - inspection" on page 154 for
the procedure.
NOTE When the specific gravity is 1.26-1.28 at 20°C, the

battery is fully charged.
NOTE ¡If the battery plug is disconnected, the memorize

of time of charging is cleared in the controller 2210219
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 completion of charge, the supplement
charge function is activated automatically. Then,
the "AUTO" lamp is flashed.
149
NOTE All four lamps on the charging status indicator

may flash.
This means that the timer has completed and that
you should check the battery. If the battery plug is
unplugged, the flashing lights will go out.
234W506
All four (4) lamps of the charging

status indicator are flashed
150
10d- 5. Voltage tap

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

<Input voltage: 200V>
Power voltage (V) Voltage tap ¡Tap connection position
199 or lower 200V

200-209 210V
Primary coil
210-219 220V
<Input voltage: 400V>

Power voltage (V) Voltage tap
Secondary
379 or lower 380V coil
380-399 400V
400-419 420V Tap connection position
2210221
420-439 440V
Body side
3-core cable
(VCT) The body side and the
transformer side are
Vinyl caps are secured together using a
placed on for ring by terminal.
unused taps.
Washer
Nut
Mark band indicates the
tap voltage. Cartridge
Transformer side 461E116
151
10d-5-3. Voltage tap - switching

CAUTION ¡Turn off the key switch and disconnect the
power plug before proceeding with work.
¡ Securely tighten the screw for the ring
terminal so it will not be loosened.
qLoosen the screw and remove the ring terminal.

wReconnect it to the tap conforming to the power
210V
voltage and secure the ring terminal together with bolts
200V Factory
and nuts.
setting:
¡Factory setting: 220V 220V
461E117
10d-5-4. Link fuse (three-phase voltage) - replacement

CAUTION ¡Remove the AC plug of the power side.
¡ If the screws are not securely tightened,
Securely tighten the screw.
contact failure could result, causing
malfunctioning.
Link fuse
q Loosen the screw and replace the link fuse.
Applicable Power voltage

Battery capacity
model 3 200V
2210222
330Ah(Std) 15A
FB10P 480-485Ah(Opt) 20A
545Ah(Opt) 20A
400Ah(Std)/485Ah(Opt) 20A
FB15P/18P
545Ah(Opt) 20A
FB20P 450Ah(Std)/545-600Ah(Opt) 20A
FB25P 565Ah(Std)/600Ah(Opt) 20A
FB30P 450Ah(Std)/485-600Ah(Opt) 30A
152
10e. BATTERY
10e-1. Disassembly and reassembly
CAUTION ¡Turn off the key switch and disconnect the battery plug.
¡Be careful not to be wet with electrolyte to the body.
¡If the electrolyte would come into eye, wash eye with fine water, and go
to doctor.
¡ The inspecting battery should be done in a place which is well
ventilated and kept away from fire.
10e-1-1. Battery - removal and installation
¡Removing and installing the battery
Cover, battery
Gas spring
Catch, bonnet
Pin, battery
Battery
Case, battery
2210115
153
BATTERY 10e
10e-2. Inspection and adjustment

10e-2-1. Battery - inspection
s1 Inspection of quantity of electrolyte ¡Inspection of electrolyte level
and replenishment Appropriate level
<Checking electrolyte level>

qDisconnect the battery plug.
wOpen 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.
eCheck electrolyte level.
<Specification>
¡If the red float can seen, electrolyte level is correct.
If not, replenish with refined or distilled water.
Lowest level of electrolyte

d
Refined water
<Replenishing with refined water> ¡Replenishing procedure

qRemove the lid of the plastic tank, dip the hose with a Bottle Lidded hose
lid into the tank deeply and tighten it up.
wOpen the cap and put another end of the hose into the Hose
Pinch-cock
battery cell.
eOpen the pinch-cock and press the tank at the both Cap
sides several times.

rRefined water will flow into the cell by siphon action. Vent plug
tClose the pinch-cock to stop replenishing just before
the red-float touches the indicating plate of the cap.
Cap
Float
White line
Battery
Level of
electrolyte
154
10e BATTERY
s2 Measurement of specific gravity of electrolyte in each cell

<Reading hydrometer>
qTake reading at the contacting line of electrolyte and
the tube.
wDifference between max. and min. specific gravity shall ¡MEASUREMENT OF
SPECIFIC GRAVITY
be less than 0.05.
Thermo Hydrometer
Difference between max. meter
Less than 0.05
and min. specific gravity
<Recharging procedures>
qCarry out equalizing charging.
wCheck specific gravity at each cell after equalizing
charge and make sure the difference is within standard
value.
As specific gravity of electrolyte is based on the value
at 20:, convert measured specific gravity.
<How to convert to specific gravity at 20:>

qMeasure temperature of electrolyte.
¡CONVERSION
CAUTION ¡Use thermometer to measure
1.330
1.310
wMeasure specific gravity of electrolyte.
Specific gravity at 20:
Specific gravity at 20:

1.300 1.290
1.290
eMeasured specific gravity shall be converted to the 1.280 1.270
1.270
value at 20:. 1.260 1.250
1.250
1.240 1.230
1.230
1.220 1.210
[Conversion formula] 1.210
1.190
1.200
S20=St+0.0007(t-20) 1.190
1.180
1.170
1.170
S20 : Specific gravity converted at 20:. 1.160
1.150
1.150
St : Measured specific gravity. 50 40 30 20 10 0 -10 -20
t : Temperature of electrolyte. Temperature:
10e-2-2. Battery - Cleaning

s Cells, connectors and terminals
qKeep dry. When they get wet, clean with a dry cloth or
blow out with compressed air.
wIf they are rusted, clean with a wire brush or a sand
paper.
s Cleaning vent plug

qTurn the vent plug counter-clockwise to remove.
wClean it with a detergent so that the red-float is visible.
eSecurely fasten the vent plug that it will fit well with the
cell cover on installation.
NOTE If the swan screw part is damaged, replace the

plug comp. with new one.
155
10f. MPU BOARD
10f- 1. Location and name
<Type : PBC100-09>
MPU board has 3 (three) LEDs, 1 (one) potentiometer,
and 2 (two) rotary switches as the below illustration.
P12 (LED0) : Lights when the 12V power source is normal.

P5 (LED1) : Lights when the 5V power source is normal.
WD (LED2) : Lights when the microprocessor is normal.
CFL (VR0) : Brightness adjustment of back light of monitor.
[RS0] : Rotary switch for truck model selection
[RS1] : Rotary switch for monitor selection
Connector for personal computer
CN9 CN8 CN7
PBC100-XX
CN1 CN2 CN3 CN4 CN5 CN6
Controller harness Body harness

234W041
CAUTION Even when the key is turned off, voltage from the battery is still sent to the board. Remove
the battery plug before performing this work.
156
11. LASER POINTER (OPTIONAL)
11-1. Adjustment
11-1-1. Fork level - adjustment
qRaise forks to a height for easy work, and level them.
Sensor bracket
wAdjust the positions of the leveling sensor and the Sensor
Outer mast
magnet so that they are struck by the laser beam.
aWhen the laser beam strikes the targets, the fork
leveling indicator lamp will light.
Adjustment position Within 1.0 degree of the fork

leveling position
Magnet
<If the forks are not level> Magnet bracket
Either loosen the fixing bolts of the sensor bracket to

2210117
reposition it, or slightly adjust the magnet so that it is in

the center of the sensor sensing element when the
forks are level.
11-1-2. Laser optical axis - adjustment

qWith the forks positioned in level, adjust the height so
that the optical axis of the laser is aimed at the center Lift bracket
of the pallet insertion openings.
wSet the distance between the fork edge and the end
face of the pallet to the distance used for loading work
(30 mm or shorter), then park the forklift truck in line
with the pallet.
eIrradiate the pallet with the laser optical axis. Adjust
the body adjustment screw so that, if a line type is
used, the light is aimed at the center area of the pallet
beam, and if a point type is used, at the top of the deck
board.
¡Laser pointer unit
Loosen fixing bolts of the LASER POINTER UNIT,
adjust the height by moving the case body up and
Laser optical axis
down. Also adjust the horizontal direction of the optical
axis by loosening the lock screw and rotating the unit
(the wire portion) inside the body.
Case
After the adjustment is complete, securely tighten the
screw and fix it using a screw lock or equivalent item. Laser unit
rDrive the forklift truck forward and make sure that the
Lock screw
forks do not hit the pallet. Also, when the forks are
inserted, make sure that they do not hit the deck 461E050
board. If they do, adjust the optical axis again.

157
12. SERVICE DATA
12- 1. Annual Inspection Service Data
Overcurrent limiter Steering wheel Standard load Control valve
For travel For Right Left turn Drift of lift Drift of tilt Lift relief Tilt relief
Models (A) hydraulic turn radius lowering
Current (A) radius (mm/10min) (mm/5min)
limitation (Relief) (mm) (mm) Inner mast Tilt cylinder (MPa) (MPa)
FB10P 400-500 210-290 1760 25-40 5-10 13.7
FB15P 400-500 210-290 1760 35-50 5-10 13.7
FB18P 400-500 250-330 1775 35-50 5-10 15.7
FB20P 400-500 250-330 1980 35-50 5-10 15.7
FB25P 400-500 250-330 2035 50-65 5-10 17.2
FB30P 400-500 250-330 2285 50-65 5-10 17.2
12- 2. Standard work hours

qSimplified work name are used.
Some work incidental to a work should be construed to excluded in
the main work.
"For example, in case that Side covers should be removed at first, 0.1
hours should be added as incidental work."
wStandard work hours for maintenance represent inspection (lubricant,

charge) hours only."
eFor adjustment, replacement/removal/installation (R/R/I), etc, see the

respective group pages."
rUnit of work hours

"The work hours are based on decimal system and given down to one
decimal place,"
"(0.1 hour as minimum, and less than 0.1 hour shall be raise to unit
(0.1))"
"For example, 0.5=30 minutes, 1.0=1 hour"
tCombined jobs
For combined jobs select necessary job items and sum them up.
yCost of transportation and sub contractor work, and service car

charges are not included in the standard work hours."
"Those hours, if any, therefore, should be separately in estimating
service charges or claim."
158
12 SERVICE DATA
Rate (hour)
Group Work Job
10P-18P 20P/25P 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 gas 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
Battery 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 Seat damage and Looseness 0.02 0.02 0.02

inspection in mounting area
Overhead guard R/R/I Head guard (with Turn signal lamp 0.3 0.3 0.3
and Head lamp)
Turn signal lamp 0.2 0.2 0.2
Head lamp 0.2 0.2 0.2
159
SERVICE DATA 12
Rate (hour)
Group Work Job
10P-18P 20P/25P 30P
Overhead guard Monthly Looseness in mounting area 0.02 0.02 0.02
inspection Deformation, crack, and damage 0.02 0.02 0.02
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 Oil leakage from Drive gear case 0.02 0.02 0.02
inspection and unusual noise
Yearly Unusual noise, oil level, fouling, 0.1 0.1 0.1

inspection oil leakage, and fitting bolt looseness
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 brake R/R/I Wheel (1 piece) 0.1 0.1 0.1
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)
Brake drum (1 piece) 0.1 0.1 0.1

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

Grease (Wheel hub bearing) 0.1 0.1 0.1

(after removing Bearing)
Monthly inspection Retightening all wheel hub nuts 0.02 0.02 0.02
Drive shaft R/R/I Drive shaft (1 piece) 0.1 0.1 0.1

160
12 SERVICE DATA
Rate (hour)
Group Work Job
10P-18P 20P/25P 30P
Drive shaft R/R/I Stud bolt (1 piece) 0.1 0.1 0.1
Monthly Two pieces rim bolt and hub bolt/nut 0.02 0.02 0.02
inspection damage and looseness
Air pressure, crack, damage, wear, and 0.02 0.02 0.02

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 truck) 0.1 0.1 0.1

(after removing Rear axle)
Adjust Shim (Axle support) 0.1 0.1 0.1
Monthly inspection Rear axle jolt 0.02 0.02 0.02
Yearly Turn radius (Right mm) 0.02 0.02 0.02

inspection Turn radius (Left mm)
Stopper bolt looseness, if it is 0.02 0.02 0.02

not dropped off, and interference
with wheel
Knuckle R/R/I Hub (1 piece) (after removing Wheel) 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

(after removing King pin)
161
SERVICE DATA 12
Rate (hour)
Group Work Job
10P-18P 20P/25P 30P
Knuckle R/R/I Bolt (Knuckle stopper) (1 piece) 0.3 0.3 0.3
Yearly Wheel bearing and king pin jolt, 0.02 0.02 0.02
inspection unusual noise, crack and damage
Wheel hub R/R/I Hub (1 piece) (after removing Wheel) 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

(after removing King pin)
Hub bolt (1 piece) (after removing Hub) 0.1 0.1 0.1
Grease (Hub bearing) (one side) 0.1 0.1 0.1

(after removing Bearing)
Center arm R/R/I Center arm (after removing Rear axle) 0.4 0.4 0.4
Needle bearing(center arm) (2 pieces) 0.1 0.1 0.1

(after removing Center arm)
Yearly Crack, damage, deflection, jolt, 0.02 0.02 0.02

inspection fitting bolt looseness and dropped off
Tie rod R/R/I Tie rod (1 piece) (after removing Rear axle) 0.4 0.4 0.4
Rod end(Tie rod end) (1 piece) 0.1 0.1 0.1

(after removing Tie rod)
Yearly Crack, damage, deflection, jolt, 0.02 0.02 0.02

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 Measuring Potentiometer voltage 0.1 0.1 0.1

inspection
Steering handle play 0.02 0.02 0.02
Handle grip damage, looseness in 0.02 0.02 0.02

mounting area, and jolt
Yearly Gear box oil level, fouling, oil leakage, 0.1 0.1 0.1
162
12 SERVICE DATA
Rate (hour)
Group Work Job
10P-18P 20P/25P 30P
Steering linkage R/R/I Horn contact, Horn cup, 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) (after removing Drag link) 0.1 0.1 0.1
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)
Brake shoe ass'y (one side 2 pieces) 0.5 0.5 0.5

Shoe return spring (one side 2 pieces) 0.1 0.1 0.1

Adjustor ass'y (1 piece) 0.1 0.1 0.1

Adjustor cable 0.1 0.1 0.1

Parking brake cable (one side) 0.4 0.4 0.4

Brake ass'y (1 piece) 0.6 0.6 0.6

Adjust Brake (Discharging air) 0.5 0.5 0.5
Yearly Space in the shoe 0.5 0.5 0.5

inspection 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
Foot brake linkage R/R/I Pedal 0.3 0.3 0.3
Pedal bushing (after removing Pedal) 0.1 0.1 0.1
Pedal pad (after removing Pedal) 0.1 0.1 0.1
Return spring 0.2 0.2 0.2

163
SERVICE DATA 12
Rate (hour)
Group Work Job
10P-18P 20P/25P 30P
Foot brake linkage Adjust Brake pedal play 0.2 0.2 0.2
Monthly Height, level and clearance between pedal and floor 0.02 0.02 0.02
inspection
Microswitch timing 0.02 0.02 0.02
Yearly "Rod, link" damage, looseness and jolt 0.02 0.02 0.02
inspection "Pin, cotter" fracture
Master cylinder R/R/I Master cylinder 0.2 0.2 0.2
Repair kit (after removing Master cylinder) 0.2 0.2 0.2
Adjust Brake (discharging air) 0.5 0.5 0.5
Yearly Master cylinder and wheel cylinder 0.02 0.02 0.02

inspection 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 Entrained air, oil leakage, damage, 0.02 0.02 0.02

inspection aging, bolt looseness, if it is not
dropped off, 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 Lock condition 0.1 0.1 0.1

inspection 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 and fouling, if there is any moisture 0.3 0.3 0.3
Yearly Oil level and fouling, if there is any moisture 0.02 0.02 0.02
inspection
Filter fouling, clogging, and damage 0.02 0.02 0.02
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
164
12 SERVICE DATA
Rate (hour)
Group Work Job
10P-18P 20P/25P 30P
Hydraulic pump R/R/I Oil seal (after removing Pump) 0.1 0.1 0.1
Monthly Oil leakage, Unusual vibration, and 0.02 0.02 0.02

inspection unusual noise
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 Operation, oil leakage, and 0.02 0.02 0.02

inspection fitting bolt looseness
Lift cylinder R/R/I Lift cylinder (1 piece) 0.3 0.3 0.3

(STD 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 Operation, oil leakage, dent, crack, deflection, 0.02 0.02 0.02
inspection scratch, and fitting bolt looseness
Drift of lowering ( mm/10min) 0.2 0.2 0.2
1st lift cylinder R/R/I 1st lift cylinder ass'y 0.9 0.9 0.9
(PFL mast)
Seal kit (after removing Cylinder) 0.5 0.5 0.5
Yearly Operation, oil leakage, dent, 0.02 0.02 0.02

inspection crack, and deflection

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) (after removing Cylinder) 0.3 0.3 0.3
scratch, and fitting bolt looseness
165
SERVICE DATA 12
Rate (hour)
Group Work Job
10P-18P 20P/25P 30P
2nd lift cylinder Yearly Operation, oil leakage, dent, 0.02 0.02 0.02
(PFL mast) inspection crack, and deflection
1st lift cylinder R/R/I Lift cylinder ass'y 0.8 0.8 0.8
(M mast)
Seal kit (after removing Cylinder) 0.4 0.4 0.4
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
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)(after removing Cylinder) 0.3 0.3 0.3
Piping R/R/I Hose (1 piece) 0.2 0.2 0.2
Connector, elbow, nipple, etc (1 piece) 0.1 0.1 0.1
Flow control valve or fuse valve 0.2 0.2 0.2
Monthly Oil leakage, deformation, damage, 0.02 0.02 0.02

inspection jolt, and looseness
Yearly Crack, damage, aging, twisting, oil leakage, 0.02 0.02 0.02
inspection mounting condition, and bolt/nut looseness
166
12 SERVICE DATA
Rate (hour)
Group Work Job
10P-18P 20P/25P 30P
Valve lever linkage R/R/I Valve lever linkage ass'y 0.6 0.6 0.6
(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 truck) 0.6 0.6 0.6
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) (after removing Lift bracket) 0.8 0.8 0.8
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 0.7
Monthly inspection Lift bracket jolt, crack in welded area 0.02 0.02 0.02
Yearly Bracket deformation, crack, and damage 0.2 0.2 0.2

inspection Roller wear and jolt
167
SERVICE DATA 12
Rate (hour)
Group Work Job
10P-18P 20P/25P 30P
Lift bracket Yearly inspection Pin area crack 0.2 0.2 0.2
Chain wheel and lift Monthly Chain tension, extension, crack, 0.02 0.02 0.02
chain inspection deformation, damage, and wear,
Wheel deformation, damage, and jolt
Yearly Chain tension, extension, crack, 0.02 0.02 0.02
inspection deformation, damage, and wear,
Wheel deformation, damage, and jolt
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
R/R/I Fork (For 1 truck) 0.2 0.2 0.2
Monthly inspection Fork deformation, wear, and crack 0.03 0.03 0.03
Yearly Deformation, crack and wear in

locking pin area 0.1 0.1 0.1
inspection 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
1. Overhaul of drive motor ass'y 0.6 0.6 0.6
Incl.: (1) Cleaning
Incl.: (2) Testing
Excl.: (1) Removal/installation of motor ass'y
Excl.: (2) Grinding of commutator
2. Replacement of armature comp. 0.5 0.5 0.5
Incl.: (1) Replacement of bearings (both ends)
Incl.: (2) Cleaning
Incl.: (3) Testing
Excl.: Removal/installation of motor ass'y
3. Replacement of bearings (both ends) 0.5 0.5 0.5
Incl.: (1) Removal/installation of the armature ass'y
Incl.: (2) Cleaning

168
12 SERVICE DATA
Rate (hour)
Group Work Job
10P-18P 20P/25P 30P
Traction motor Incl.: (3) Testing
4. Replacement of fan 0.8 0.8 0.8
Incl.: (1) Removal/installation of armature comp.
Incl.: (2) Replacement of bearings
Incl.: (3) Cleaning
5. Grinding and under-cutting of commutator 1.2 1.2 1.2
Incl.: (2) Cleaning and testing
6. Removal/installation of replacement of
field coils or main pole cores (4pcs) 1.0 1.0 1.0
7. Replacement of carbon brushes (all of them) 0.3 0.3 0.3
8. Replacement of push spring (1pc) 0.1 0.1 0.1
9.Replacement of commutator cover 0.1 0.1 0.1
Excl.: Removal/installation of battery
10.Replacement of rocker with brushes 0.5 0.5 0.5
Monthly Unusual sound and unusual smell 0.02 0.02 0.02

inspection during motor rotation
Yearly Bolt looseness, fitting bolt 0.2 0.2 0.2

inspection looseness in main body
Motor rotation condition - 0.02 0.02 0.02

(low speed, inter mediate speed,
high speed, acceleration),
Yearly inspection unusual noise, unusual smell 0.02 0.02 0.02
Hydraulic motor 1.Removal/installation of motor ass'y with pump 0.4 0.4 0.4
Incl.: Removal/installation of hydraulic piping

169
SERVICE DATA 12
Rate (hour)
Group Work Job
10P-18P 20P/25P 30P
Hydraulic motor 2.Replacement of motor ass'y 0.6 0.6 0.6
Incl.: Removal/installation of;
Incl.: (1) Motor ass'y
Incl.: (2) Pump ass'y
Incl.: (3) Motor bracket
3.Overhaul of motor ass'y 0.5 0.5 0.5
Incl.: (1) Cleaning
Incl.: (2) Testing
Excl.: Removal/installation of;
Excl.: (1) Motor ass'y
Excl.: (2) Pump ass'y
Excl.: (3) Grinding of commutator
4.Replacement of armature comp. 0.5 0.5 0.5
Incl.: (1) Replacement of bearings
Incl.: (2) Cleaning
Incl.: (3) Testing
5.Replacement of bearings (both ends) 0.5 0.5 0.5
Incl.: (2) Cleaning
Incl.: (3) Testing
6.Replacement of fan 0.8 0.8 0.8
Incl.: (3) Cleaning
7.Grinding and under-cutting of commutator 1.2 1.2 1.2
8.Removal/installation of replacement of
field coils or main pole cores (4pcs) 1.0 1.0 1.0

170
12 SERVICE DATA
Rate (hour)
Group Work Job
10P-18P 20P/25P 30P
Hydraulic motor Excl.: Removal/installation of motor ass'y
9.Replacement of carbon brushes (all of them) 0.3 0.3 0.3
10.Replacement of push spring (1pc) 0.1 0.1 0.1

11.Replacement of commutator cover 0.1 0.1 0.1
Excl.: Removal/installation of hydraulic

contactor with bracket
12.Replacement of rocker with brush holders 0.5 0.5 0.5
Monthly inspection Hydraulic motor unusual noise, unusual smell 0.02 0.02 0.02
Yearly Bolt looseness, fitting bolt 0.2 0.2 0.2

inspection 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
EPS motor 1.Removal/installation or replacement of

EPS motor ass'y 0.4 0.4 0.4
2.Overhaul of EPS motor ass'y 0.5 0.5 0.5
Incl.: Cleaning and testing
3.Replacement of armature comp. 0.4 0.4 0.4
4.Replacement of bearings (2pcs) 0.4 0.4 0.4
5.Grinding and under-cutting of commutator 0.7 0.7 0.7

171
SERVICE DATA 12
Rate (hour)
Group Work Job
10P-18P 20P/25P 30P
EPS motor 6.Replacement of carbon brushes (all of them) 0.4 0.4 0.4
Monthly EPS motor unusual noise, unusual smell 0.02 0.02 0.02
inspection
EPS motor brush wear 0.03 0.03 0.03
Yearly inspection Brush wear, contact, commutator burnout 0.2 0.2 0.2
Control unit 1. Removal/installation or replacement of

control unit 1.5 1.5 1.5
2. Overhaul of control unit 2.0 2.0 2.0
Excl.: Removal/installation of control unit
3. Replacement of diode (1pc) 0.7 0.7 0.7
*Add 0.2 hour of additional replacement

work of diode
4. Replacement of FET comp. (1pc only) 0.6 0.6 0.6
*Add 0.3 hour when both (for travel and

hydraulic)FET comp. arereplaced
5. Replacement of resister (1pc) 0.8 0.8 0.8
*Add 0.3 hour for every additional

replacement work of one resister
6. Replacement of capacitor (1pc) 0.6 0.6 0.6
*Add 0.2 hour for additional replacement of

capacitor
7. Replacement of MPU board 0.4 0.4 0.4
Confirmation Travelling speed, lift speed, plugging distance, 0.5 0.5 0.5
idle running current, lock current
Monthly Looseness in terminal contact area, 0.03 0.03 0.03

inspection looseness in wiring mounting area
Resistor and capacitor terminal looseness 0.1 0.1 0.1

and burnout, fitting bolt looseness
Yearly [Overcurrent limiter] 0.1 0.1 0.1

inspection (for hydraulic A)
Motor lock current value
(for travel A)
[Safety device] Contactor operation 0.1 0.1 0.1

(pulling out arc or not)
Wiring looseness, damage, and clamp condition 0.2 0.2 0.2
172
12 SERVICE DATA
Rate (hour)
Group Work Job
10P-18P 20P/25P 30P
Accelerator R/R/I Accelerator 0.5 0.5 0.5
Monthly inspection Accelerator pedal operating condition 0.02 0.02 0.02
Indicator panel ass'y R/R/I Indicator panel ass'y 1.0 1.0 1.0
Directional switch Indicator panel cover 0.4 0.4 0.4
Cam comp. 0.2 0.2 0.2
Lever comp. 0.3 0.3 0.3
Microswitch 0.2 0.2 0.2

Add 0.1Hrs every time 1 piece is added
Monthly Each connected area jolt 0.02 0.02 0.02

inspection Lever movement condition
Microswitch timing and operating condition
Microswitch damage, looseness in mounting area
Yearly Adequacy of Microswitch timing, 0.2 0.2 0.2

inspection 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
Seat switch comp. 0.3 0.3 0.3
Monthly Turn signal lamp damage, operating 0.02 0.02 0.02

inspection condition, and mounting condition
Instruments operation
Contactor R/R/I Contactor comp. 0.4 0.4 0.4
Yearly Contact point looseness, damage, wear, 0.03 0.03 0.03

inspection operation, fouling, and fitting bolt looseness
Monthly Contactor timing and operating condition 0.02 0.02 0.02

inspection
Contactor contact point looseness, 0.02 0.02 0.02
damage, and wear
Contactor auxiliary contact point 0.02 0.02 0.02

wear, and damage
Contactor for hydraulic
1.Removal/installation or replacement of
contactor comp. 0.4 0.4 0.4
2.Overhaul of contactor comp. 0.4 0.4 0.4
Incl.: Adjustment
173
SERVICE DATA 12
Rate (hour)
Group Work Job
10P-18P 20P/25P 30P
Contactor Excl.: Removal/installation of contactor comp.
3.Replacemant of armature 0.4 0.4 0.4
4.Replacement of armature arm 0.2 0.2 0.2
5.Replacement of stopper 0.2 0.4 0.4
Excl.: Removal/installation of contactor comp.
6.Replacement of solenoid coil comp. 0.3 0.4 0.4
7.Replacement of ribbon wire 0.1 0.1 0.1
8.Replacement of contact (movable side) 0.2 0.2 0.2
9.Replacement of contact (fixed side) 0.2 0.2 0.2
10.Replacement of blow out comp. 0.2 0.2 0.2
Contactor for EPS
contactor comp. 0.4 0.4 0.4
Incl.: Adjustment
3.Replacemant of armature 0.3 0.3 0.3
4.Replacemant of contactor comp.

(Mono lith type of contact arm, contact and
ribbon wire) 0.3 0.3 0.3
6.Replacement of solenoid comp. 0.4 0.4 0.4
Contactor for traveling
contactor unit ass'y 0.4 0.4 0.4
contactor comp. (1set) 0.3 0.3 0.3
Note: Add 0.2 hours for an additional comp.
Incl.: Adjustment
174
12 SERVICE DATA
Rate (hour)
Group Work Job
10P-18P 20P/25P 30P
Contactor 4.Replacemant of armature 0.3 0.3 0.3
5.Replacemant of contactor comp.
(Mono lith type of contactor arm, contact
and ribbon wire) 0.3 0.3 0.3
7.Replacement of solenoid comp.
Excl.: Removal/installation of contact comp. 0.4 0.4 0.4
Others 1.Replacement of main fuse (1pc) 0.2 0.2 0.2

(electric parts)
2.Replacement of flasher switch ass'y 0.2 0.2 0.2
3.Replacement of horn 0.2 0.2 0.2
4.Replacement of battery plug

(for chassis side) 0.2 0.2 0.2
5.Replacement of back up buzzer 0.1 0.1 0.1
6.Replacement of head lamp (1pc) 0.2 0.2 0.2
7.Replacement of turn signal lamp (1pc) 0.2 0.2 0.2
8.Replacement of combination lamp 0.1 0.1 0.1
R/R/I Main fuse (1 piece) 0.2 0.2 0.2
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 Fuse fitting bolt looseness, capacity adequacy 0.1 0.1 0.1
inspection
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

175
SERVICE DATA 12
Rate (hour)
Group Work Job
10P-18P 20P/25P 30P
Others Monthly inspection Backup alarm operation 0.1 0.1 0.1

Charger (option) 1.Removal/installation or replacement of
transformer ass'y with diode and terminal 0.3 0.3 0.3
2.Replacement of diode 0.1 0.1 0.1
Note : Add 0.1 hour for an additional diode
panel ass'y with Mi-con charger and
connector 0.6 0.6 0.6
Incl.: Removal/installation of hood cover
4.Replacement of Mi-con charger 0.3 0.3 0.3
5.Replacement of connector 0.9 0.9 0.9
6.Replacement of magnet switch 0.8 0.8 0.8
7.Replacement of fuse 0.2 0.2 0.2
8.Replacement of charging cable and

connector 0.2 0.2 0.2
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 Timer operation 0.1 0.1 0.1

inspection
Magnet switch operating condition
AC cable damage and looseness
Receptacle contact condition
Yearly inspection Voltage detection relay operating voltage ( V) 0.1 0.1 0.1
176
12 SERVICE DATA
Rate (hour)
Group Work Job
10P-18P 20P/25P 30P
Battery 1.Removal/installation or replacement of battery 0.3 0.3 0.3
2.Inspection 0.5 0.5 0.5
Incl.: (1) Measurement of specific gravity
Incl.: (2) Replenishing refined water
Incl.: (3) Cleaning
3.Replacement of battery plug 0.4 0.4 0.4
R/R/I Battery 0.3 0.3 0.3
Battery plug 0.4 0.4 0.4
Adjust Replenishing water and clean up 0.2 0.2 0.2
Monthly Electrolyte level 0.1 0.1 0.1
inspection Terminal looseness, damage, and wear
Container damage and electrolyte leakage
Temperature and specific gravity after charging
(Max. , Min. )
LP plug and cord damage and looseness
Yearly Each electric battery voltage 0.1 0.1 0.1

inspection (Max. , Min. )
Electric power steering 1.Replacement of EPS controller ass'y 0.4 0.4 0.4
2.Replacement of EPS sensor ass'y 0.4 0.4 0.4
R/R/I EPS controller ass'y 0.4 0.4 0.4
EPS sensor ass'y 0.4 0.4 0.4
Monthly Looseness in gear box mounting area 0.02 0.02 0.02

inspection Interference with chassis
Right and left steering angle 0.02 0.02 0.02
177
Reproduction prohibited
First printing : April 2002
Issued by : Nippon Yusoki Co., Ltd

Edited by : Overseas division
Nippon Yusoki Co., Ltd.

FB10-30P-DC70-Series SM

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What are the main components and systems covered in the manual?

What are the main components and systems covered in the manual?

What safety precautions should be followed when performing maintenance and repairs?

What safety precautions should be followed when performing maintenance and repairs?

02W-2202

Performing maintenance and repair without adequate knowledge may

Indicates a potentially hazardous situation which, if not avoided,

Indicates a potentially hazardous situation which, if not avoided,

Indicates a potentially hazardous situation which, if not avoided, may

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

qPersonnel this "WORKSHOP MANUAL" is aimed at:

2 .FRONT AXLE (DRIVE) 19 5-1. Location and name.......................................47

7. HYDRAULIC SYSTEM 68 7d. CYLINDER 84

10e. BATTERY 153

10f. MPU BOARD 156

CAUTION Facilities with adequate space and level

CAUTION WELL-VENTILATED AREA

CAUTION LOCATION EQUIPPED WITH FIRE EXTIN-

CAUTION SAFE AND WELL-LIGHTED AREA

CAUTION PROPER ARRANGEMENT

CAUTION ¡The worker should wear a hat, work clothes, and

Tools and gauges

CAUTION Prepare tools and gauges before starting to work.

WARNING ¡When hoisting a forklift truck or a heavy compo-

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 replacing any parts, be sure to use NICHIYU

CAUTION When replenishing battery electrolyte, be sure to

Repair of electrical components

CAUTION Be sure to disconnect the battery plug when

CAUTION Be sure to jack up the drive wheel when trouble

NOTE Record the places of lead wire connection when

CAUTION CHARGING BATTERY

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

CAUTION When removing the hydraulic pipes, cap them to

CAUTION When disassembling and assembling the hydraulic

CAUTION ¡Observe tightening torque specified in this man-

No. Parts No. Parts Name Q'ty Notes

(FB10P-18P) (FB20P/25P) (FB30P)

Apply parking brake before leav-

PRECAUTIONS FOR SAFETY OPERATION

(FB10P-18P) (FB20P/25P) (FB30P)

!1 (With Japanese battery only)

!1 (With Japanese battery only)

GASES produced by this battery can be explosive.

Capacity code .............................................................................. 10 : 1000kg

Classification of tyre ................................................................. P : Pneumatic tyre

............................................... B : Large capacity battery equipped

q Serial No. of a truck Stamped on the name plate

w Serial No. of a chassis Stamped on the right side of chassis

e Serial No. of a mast Stamped on the mast name plate

t Serial No. of a traction motor Stamped on the motor name plate

y Serial No. of a hyd. motor Stamped on the motor name plate

u Serial No. of a EPS motor Stamped on the motor name plate

i Serial No. of lift cylinders Stamped on lift cylinders

o Serial No. of tilt cylinders Stamped on tilt cylinders

¡Location of serial numbers

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

¡When using a thrust washer with oil grooves cut,