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Service Manual: Chassis & Mast FBC15N, FBC18N, FBC18LN

This service manual provides information on servicing the chassis and mast components of various forklift truck models. The manual contains chapters covering the front axle and reduction differential, transfer assembly, rear axle, brake system, and specifications. Procedures for removal, disassembly, inspection, and reassembly are included for maintenance and repair of these components.

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0% found this document useful (0 votes)

1K views226 pages

Service Manual: Chassis & Mast FBC15N, FBC18N, FBC18LN

Uploaded by

roberto_robledo_6

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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Service Manual

Chassis & Mast

FBC15N, FBC18N, FBC18LN
A4BC1-10200-up
A4BC1-20200-up
A4BC1-30200-up
FBC20N, FBC25N
A4BC2-10200-up
A4BC2-20200-up
FBC25EN, FBC25LN, FBC30N
A4BC3-20200-up
A4BC3-30200-up
A4BC3-40200-up
FBC30LN
A4BC4-10200-up

99759-7B110
TABLE OF CONTENTS

Chapter 1: General Information

Scope ........................................................................................................................................... 1.1
Truck Models Covered ................................................................................................................. 1.1
Nameplate and Serial Number Locations .................................................................................... 1.2
Dimensions................................................................................................................................... 1.3
Dimensions Chart .................................................................................................................... 1.4
General Information (Standard Models)....................................................................................... 1.5

Chapter 2: Front Axle & Reduction Differential

Front Axle
Description ................................................................................................................................... 2.1
General Information ................................................................................................................. 2.1
Removal ....................................................................................................................................... 2.2
Front Wheels ............................................................................................................................ 2.2
Method 1.............................................................................................................................. 2.3
Method 2.............................................................................................................................. 2.3
Method 3.............................................................................................................................. 2.3
Installation .................................................................................................................................... 2.4
Disassembly ................................................................................................................................. 2.5
Removing Front Wheel Hub ..................................................................................................... 2.6
Inspection after Disassembly ....................................................................................................... 2.7
Reassembly.................................................................................................................................. 2.8
Axle Housing ............................................................................................................................ 2.8
Front Wheel Hub ...................................................................................................................... 2.8
Hub Bearing Preload................................................................................................................ 2.10
Installation and Setting Preload........................................................................................... 2.10
Reduction Differential
Description ................................................................................................................................... 2.11
Disassembly ................................................................................................................................. 2.12
Inspection after Disassembly ....................................................................................................... 2.13
Reduction Gear ........................................................................................................................ 2.13
Differential ................................................................................................................................ 2.13
Reassembly.................................................................................................................................. 2.14
Inspection and Adjustment........................................................................................................... 2.16
Side Bearing Preload ............................................................................................................... 2.16
Reduction Gear Backlash ........................................................................................................ 2.16
Reduction Gear Face Runout .................................................................................................. 2.17
Tooth Contact ........................................................................................................................... 2.17
Tooth Contact Adjustment ........................................................................................................ 2.18
Transfer Assembly.................................................................................................................... 2.21
Front Axle ................................................................................................................................. 2.23
99759-7B110
i
TABLE OF CONTENTS

Chapter 3: Transfer Assembly

Description ................................................................................................................................... 3.1
Disassembly ................................................................................................................................. 3.2
Disassembly Sequence................................................................................................................ 3.2
Inspection after Disassembly ....................................................................................................... 3.4
Reassembly.................................................................................................................................. 3.5

Chapter 4: Rear Axle

Description ................................................................................................................................... 4.1
Rear Wheels................................................................................................................................. 4.2
Removal ................................................................................................................................... 4.2
Steering Cylinder.......................................................................................................................... 4.3
Installation ................................................................................................................................ 4.4
Rear Axle ..................................................................................................................................... 4.7
Removal ................................................................................................................................... 4.7
Installation ................................................................................................................................ 4.8
Disassembly ............................................................................................................................. 4.9
Inspection after Disassembly ................................................................................................... 4.11
Reassembly.............................................................................................................................. 4.12
Inspection and Adjustment........................................................................................................... 4.17
Minimum Turning Radius Adjustment....................................................................................... 4.17

Chapter 5: Brake System

Description ................................................................................................................................... 5.1
Automatic Adjusting Device ..................................................................................................... 5.1
General Information ................................................................................................................. 5.1
Master Cylinder
Disassembly ............................................................................................................................. 5.2
Inspection after Disassembly ................................................................................................... 5.3
Reassembly.............................................................................................................................. 5.3
Service Brakes
Disassembly
(FBC15N - FBC18LN) ......................................................................................................... 5.4
(FBC20N - FBC30LN) ......................................................................................................... 5.5
Inspection after Disassembly ................................................................................................... 5.7
Reassembly
(FBC15N - FBC18LN) ......................................................................................................... 5.8
(FBC20N - FBC30LN) ......................................................................................................... 5.9
Wheel Cylinders
Disassembly ............................................................................................................................. 5.12
Inspection after Disassembly ................................................................................................... 5.13
Reassembly.............................................................................................................................. 5.13
Inspection and Adjustment....................................................................................................... 5.14

99759-7B110
ii
TABLE OF CONTENTS

Chapter 6: Steering System

Steering System
Description ................................................................................................................................... 6.1
Steering System ...................................................................................................................... 6.1
Oil Flow Sequence .............................................................................................................. 6.1
General Information............................................................................................................. 6.1
Steering Gear
Steering Wheel
Removal ................................................................................................................................... 6.2
Installation ................................................................................................................................ 6.2
Steering Gear............................................................................................................................... 6.3
Inspection after Removal ............................................................................................................. 6.4
Disassembly ................................................................................................................................. 6.5
Working Rules and Tips ........................................................................................................... 6.6
Suggestions ............................................................................................................................. 6.6
Inspection after Disassembly ................................................................................................... 6.6
Reassembly.................................................................................................................................. 6.7
Steer Pump
Removal ....................................................................................................................................... 6.8
Installation .................................................................................................................................... 6.9
Disassembly ................................................................................................................................. 6.10
Sequence ................................................................................................................................. 6.10
Working Rules and Tips ........................................................................................................... 6.11
Suggestions ............................................................................................................................. 6.11
Inspection after Disassembly ................................................................................................... 6.13
Reassembly.................................................................................................................................. 6.14
Sequence ................................................................................................................................. 6.14
Suggestions ............................................................................................................................. 6.15
Inspection after Reassembly.................................................................................................... 6.17

Chapter 7: Hydraulic System

99759-7B110
iii
TABLE OF CONTENTS

Hydraulic Pump
Removal ....................................................................................................................................... 7.12
Installation .................................................................................................................................... 7.13
Disassembly ................................................................................................................................. 7.14
Working Rules and Tips ........................................................................................................... 7.14
Suggestions ............................................................................................................................. 7.16
Inspection after Disassembly ....................................................................................................... 7.18
Body ......................................................................................................................................... 7.18
Mounting Flange Face ............................................................................................................. 7.18
Bushes and Balance Plate....................................................................................................... 7.18
Gears ....................................................................................................................................... 7.18
Reassembly.................................................................................................................................. 7.19
Inspection after Reassembly........................................................................................................ 7.23
Control Valve
Removal ....................................................................................................................................... 7.24
Installation .................................................................................................................................... 7.25
Disassembly ................................................................................................................................. 7.26
Suggestions ................................................................................................................................. 7.27
Reassembly.................................................................................................................................. 7.27
Lift and Tilt Cylinders
Removal
Lift Cylinders ............................................................................................................................ 7.28
Tilt Cylinders ............................................................................................................................ 7.31
Disassembly
Lift Cylinders ............................................................................................................................ 7.33
Tilt Cylinders ............................................................................................................................ 7.34
Inspection after Disassembly ................................................................................................... 7.35
Precautions for Reassembly ........................................................................................................ 7.35
Inspection and Adjustment
Hydraulic Tank.............................................................................................................................. 7.36
Control Valve ................................................................................................................................ 7.37
Lift and Tilt Cylinders.................................................................................................................... 7.40
Adjusting Method ..................................................................................................................... 7.41
Testing ...................................................................................................................................... 7.42

Chapter 8: Mast and Forks

99759-7B110
iv
TABLE OF CONTENTS

Disassembly ................................................................................................................................ 8.4

Inspection after Disassembly ....................................................................................................... 8.6
Reassembly.................................................................................................................................. 8.7
Inspection and Adjustment........................................................................................................... 8.8
Forks ........................................................................................................................................ 8.8
Chain Tension Adjustment ....................................................................................................... 8.9
Clearance Adjustment on Lift Bracket...................................................................................... 8.10
Mast Clearance Adjustment ..................................................................................................... 8.13
Main Roller Shim Replacement ............................................................................................... 8.15
Mast Strip Adjustment.............................................................................................................. 8.15
Tilt Angle Adjustment ............................................................................................................... 8.16
Lift Cylinder Stroke Adjustment................................................................................................ 8.17
Bleeding Lift Cylinders ............................................................................................................. 8.17
Service Data ................................................................................................................................ 8.18
Troubleshooting ............................................................................................................................ 8.20

Chapter 9: Troubleshooting
Front Axle and Reduction Differential .......................................................................................... 9.1
Brake System ............................................................................................................................... 9.2
Steering System........................................................................................................................... 9.4
Hydraulic System ......................................................................................................................... 9.6
Rear Axle ..................................................................................................................................... 9.8
Mast and Forks ............................................................................................................................ 9.9

Chapter 10: Maintenance Service Data

99759-7B110
v
TABLE OF CONTENTS

Tightening Torques for Taperlock Studs ....................................................................................... 10.19

Coarse Thread—Inches ........................................................................................................... 10.19
Maintenance Chart....................................................................................................................... 10.20
Planned Replacement Parts ........................................................................................................ 10.26
Lubrication Information................................................................................................................. 10.27
Chart ........................................................................................................................................ 10.27
Fuel and Lubricant Specifications ............................................................................................ 10.28
Recommended Brands of Lubricants....................................................................................... 10.28
Weight of Major Components (Approximate) ............................................................................... 10.29
Special Service Tools ................................................................................................................... 10.30
Special Tool Illustrations........................................................................................................... 10.31
Inspection Guide .......................................................................................................................... 10.34

99759-7B110
vi
TABLE OF CONTENTS

Chapter 1: General Information

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GENERAL INFORMATION

Scope
This service manual deals with all components or systems of the Mitsubishi forklift trucks, except for the
electrical system, which is covered in a separate manual.

8609141A

Truck Models Covered

This service manual furnishes service and maintenance information for the following trucks.

Truck Model Serial Number

FBC15N, FBC18N, FBC18LN A4BC1-10200-up
A4BC1-20200-up
A4BC1-30200-up
FBC20N, FBC25N A4BC2-10200-up
A4BC2-20200-up
FBC25EN, FBC25LN, FBC30N A4BC3-20200-up
A4BC3-30200-up
A4BC3-40200-up
FBC30LN A4BC4-10200-up

99759-7B110
1.1
GENERAL INFORMATION

Nameplate and Serial Number Locations

Mast
serial number

Chassis
serial number

Power steering
motor serial number

Traction motor
serial number
Hydraulic motor Nameplate
serial number
8609141

99759-7B110
1.2
GENERAL INFORMATION

Dimensions

8609142

8609143

99759-7B110
1.3
GENERAL INFORMATION

Dimensions Chart
Ref# Truck Model FBC15N, FBC18N FBC18LN FBC20N, FBC25N FBC25EN FBC25LN FBC30N FBC30LN

A Maximum Lift 3320 (130) 3320 (130) 3340 (131) 3340 (131) 3340 (131) 3310 (130) 3045 (119)

B Free Lift 115 (4.5) 115 (4.5) 130 (5.1) 130 (5.1) 130 (5.1) 135 (5.3) 135 (5.3)

Maximum Fork Spacing

C 818 (32.0) 818 (32.0) 818 (32.0) 818 (32.0) 818 (32.0) 818 (32.0) 818 (32.0)
(outside to outside)

D Fork Length 1070 (42) 1070 (42) 1070 (42) 1070 (42) 1070 (42) 1070 (42) 1070 (42)

Tilt Angle
E 5°/6° 5°/6° 5°/6° 5°/6° 5°/6° 5°/6° 5°/6°
(forward/backward)

F Overall Length 3050 (120) 3125 (123) 3155 (124) 3255 (128) 3255 (128) 3325 (131) 3325 (131)

Overall Width
G 945 (37) 970 (38) 1055 (41.5) 1055 (41.5) 1103 (43.5) 1103 (43.5) 1103 (43.5)
(outside of tires)

Overall Height (to top of

H 2105 (83) 2105 (83) 2110 (83.5) 2110 (83.5) 2110 (83.5) 2110 (83.5) 2110 (83.5)
mast, lowered)

Overall Height (to top of

I 2180 (86) 2180 (86) 2210 (87) 2210 (87) 2210 (87) 2210 (87) 2210 (87)
overhead guard)

Overall Height (to top of

J 4570 (180) 4570 (180) 4570 (180) 4570 (180) 4570 (180) 4550 (179) 4550 (179)
mast, extended)

K Tread (front) 793 (31) 818 (32) 875 (34.5) 875 (34.5) 900 (35.5) 900 (35.5) 900 (35.5)

L Tread (rear) 826 (32.5) 826 (32.5) 900 (35.5) 900 (35.5) 900 (35.5) 900 (35.5) 900 (35.5)

M Wheelbase 1170 (46) 1170 (46) 1280 (50.5) 1380 (54.5) 1380 (54.5) 1380 (54.5) 1380 (54.5)

N Front Overhang 376 (14.8) 376 (14.8) 394 (15.5) 394 (15.5) 394 (15.5) 406 (16) 406 (16)

O Rear Overhang 434 (17.2) 509 (20.2) 411 (16) 411 (16) 411 (16) 469 (18.5) 469 (18.5)

Underclearance
P 118 (4.6) 118 (4.6) 124 (4.9) 124 (4.9) 124 (4.9) 124 (4.9) 124 (4.9)
(at center of wheelbase)

Unit: mm (in.)

99759-7B110
1.4
GENERAL INFORMATION

General Information (Standard Models)

Truck Model

Units FBC15N FBC18N FBC18LN FBC20N FBC25N FBC25EN FBC25LN FBC30N FBC30LN

Standard Controller MHI SX Controller

Standard Simplex Mast Size meters 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3
Without 2095 2335 2595 2685 2870 2695 2865 3335 3530
Service Weight Battery (4620) (5140) (5720) (5920) (6330) (5940) (6320) (7353) (7770)
kg (lb)
(standard axle) With Max. 3295 3535 3795 4285 4420 4495 4665 5135 5330
Battery (7270) (7790) (8370) (9470) (9880) (9940) (10320) (11353) (11770)

Rated Capacity/ kg/mm 1350/600 1600/600 1800/600 1800/600 2275/600 2275/600 2500/600 2725/600 2950/600
Load Center (lb/in.) (3000/24) (3500/24) (4000/24) (4000/24) (5000/24) (5500/24) (5000/24) (6000/24) (6500/24)

Maximum Fork Height mm (in.) 33235 (131) 3340 (131) 3315 (131) 3345 (131)
Performance

36V .38 (75) .36 (71) .34 (67) .32 (63) .28 (55) .25 (49) .23 (45)
Work

Lift Speed m/sec.

(Rated Load) 48V (fph) .53 (104) .49 (96) .47 (93) .45 (89) .38 (75) .36 (71) .31 (61)

Lowering Speed (rated load) .50 (98)

Tilt Angle (forward/backward) degrees 5° / 6°

Free Lift mm (in.) 115 (4.5) 130 (5.1) 135 (5.3)

Performance

Travel Speed 36V km/h 18 (11.2) 17.3 (10.8) 17.4 (10.8) 17.0 (10.6) 17.1 (10.6)
Traveling

(Without Load) 48V (mph) 18.2 (11.3)

Minimum Turning mm 1790 1840 1990 2045

Radius (in.) (70.5) (72.5) (78.5) (80.5)

Traction Motor 36V 60min. 8.3 (6.2) 12.1 (9.0) 13.7 (10.2)
Output 48V HP(kW) 9.2 (6.8) 14.2 (10.6) 17.2 (12.8)

Transfer Type Spur

Power Train

Gear Ratio 3.538 3.067

Reduction Type Bevel

Gear Ratio 4.571 5.0

Axle Housing Banjo

Differential Gear Type/ Gears Straight Bevel/2

Number Pinions Straight Bevel/2

99759-7B110
1.5
GENERAL INFORMATION

Truck Model

Units FBC15N FBC18N FBC18LN FBC20N FBC25N FBC25EN FBC25LN FBC30N FBC30LN

Type Dynamic Load Sense

Power Steering System

Inside 83° 83°

Turning Angle Degrees
Outside 54° 56°

Steering Wheel Diameter mm (in.) 328 (13)

Cylinder Minimum kgf/cm2

107 (1522) [10,500] 163 (2320) [16,000]
Test Pressure (psi) [kPa]

Type Self-Adjusting Duo-Servo

Inside Drum +0 0.13(10.00 +0 0.0051)

mm (in.) 254
Diameter
Service Brake
Lining
mm (in.) 4.87 (0.19) 6 (0.24)
Thickness
Brake System

Master 22.22 (0.8748)

mm (in.)
Cylinder ID

Wheel 22.22 (0.8748) 28.58 (1.1252)

Cylinder ID

Type Mechanical, Mounted on Front Wheels

Park Brake Lever kgf 25 to 30

Operating (lbf) (55 to 66)
Effort [N] [245 to 295]

Front Wheels Fixed Type

Traveling System

Mounting
Rear Wheels Center Pivot Type

Wheel Oscillation 3°
Alignment Angle Degrees
Camber 1°

99759-7B110
1.6
GENERAL INFORMATION

Truck Model
Units FBC15N FBC18N FBC18LN FBC20N FBC25N FBC25EN FBC25LN FBC30N FBC30LN

Type Gear
Hydraulic Pump Make Casappa Parker Hydraulics, Inc.
Model KP20–24.5 25R029

Displacement cc (cu in.) 25 (1.526) 29 (1.77)

Make Husco International
Control Valve Model 9510 Sectional Valve
Hydraulic System

Relief kgf /cm2 AUX 158 (2250) [15513]

Interval Pressure (psi) [kPa] Lift Tilt 185 (2630) [18133}

Flow Regulator Type Variable
Valve Regulated liter
45 (2746) 60 (3661) 68 (4150)
Flow Rate (cu.in.) / min
Lift Cylinders
ID 45 (1.77) 50 (1.97) 55 (2.17)
mm (in.)
Tilt Cylinders ID 63 (2.48) 70 (2.75) 80 (3.15)

Hydraulic Tank Capacity liter 1 8 (4.8) 24 (6.3) 30 (7.9)

(Approx) (US gal.)
Mast Roller type CL
Mast 100 x 42 x 11 115 x 46 x 12
Outer
Dimensions (3.94 x 0.59 x 0.47) 4.53 x 0.79 x 0.51)
(Flange Inside mm (in.)
Width x THK x 100 x 60 x 10 115 x 45 x 11
Inner
WEB THK) (3.94 x 0.67 x 0.47) (4.53 x 0.83 x 0.51)
Mast and Forks

Main Rollers Type #6308 Ball Bearing #6309 Ball Bearing

Diameter x Width 100 x 27 (3.94 x 1.18) 115 x 30 (4.53 x 1.58) 115 x 30 (3.94 x 1.18)
Side Rollers Type Lubricating type needle roller bearing
Diameter x
mm (in.) 42 x 36 (1.65 x 1.42)
Width
Lift Chains BL534 BL634 BL834
Forks (Lgth x Wdth x Thk) 1070x100x35 1070 x100 x40 1070 x 125 x 45
(36x4x1.3) (42 x 3.9 x 1.6) (42 x 5 x 1.8)
mm (in.)
Fork Spacing 240 / 818 (9.4/32) 240 / 920 285 / 960
(out to out) min/max
Voltage 36/48 36/48 36/48 36/48 36/48 36/48
Amp Hours (6 hr. rate) 36V 900 1400
48V 700 1100
Compartment Height-Center 598 (23.6)
Battery

Dimensions Height-Edges 589 (23.2)

mm (in.)
Length 705 (27.8) 772 (30.4) 872 (34.3)
Width 903 (35.5) 1000 (39.4)
Weight (Min/Max) kg (lb) 750/1200 1000/1600 1315/1600 1400/1800
(1650/2650) (2200/3550) (2900/3550) (3100/4000)

99759-7B110
1.7
NOTES

Chapter 2: Front Axle & Reduction Differential

Front Axle
Description

6 8
5
7

4 3 1
2

203658

1. Front wheel hub 5. Reduction pinion

2. Frame support 6. Reduction gear
3. Axle shaft 7. Differential case
4. Axle housing 8. Differential carrier

General Information
The frame supports hold the front axle housing in
such a manner as to allow a limited amount of
rotary motion of the housing, the rotary sliding
surfaces being lubricated with grease.
The cushion tire is press-fitted to the outer ring of
the wheel hub.

99759-7B110
2.1
FRONT AXLE & REDUCTION DIFFERENTIAL

Removal
Front Wheels Suggestions
1. Park the truck on level floor with the parking
! WARNING brake applied, the direction lever in neutral,
Be sure to use the same size and brand the forks lowered, and the key switch off.
tire for replacement. 2. Prepare tools, jacks, and wheel blocks.
3. Block the rear wheels.
4. Loosen the wheel nuts about two turns.

Removal Sequence
2
Wheel nut

1
205952 100902B

1. Wheel Nuts
NOTE
2. Front Wheel
Loosen, but do not remove, the wheel
nuts.

5. Raise the front end of the truck. Use one of

the methods shown.

! WARNING

To prevent possible injury, do not replace

the tire when the truck is loaded.

Dismount the truck before raising the front

tire.

To prevent possible personal injury, raise

the truck only until the tire just clears the
ground.

Do not put any portion of your body under

the truck. Securely support the truck on
blocks after raising it.

2.2 99759-7B110
FRONT AXLE & REDUCTION DIFFERENTIAL

Method 1 Method 3
Position the jack under the frame and raise the Fasten a hoist to the mast and lift the front end of
truck until the tire clears the floor. the truck as shown.

100828 202778A

Jack Capacities 6. Remove the wheel nuts (loosened in Step 4.)

FBC15N - FBC18LN 3000 kgf (6700 lbf)

FBC20N - FBC30LN 5000 kgf (12,000 lbf) ! CAUTION
Be careful not to damage the bolt threads
when removing the wheel.
Method 2
Tilt the mast all the way back, place wood blocks
under the mast, and tilt the mast forward.
7. Remove the wheel.

! CAUTION
NOTE
After raising the front end, securely support
it by blocks. Service Limit For Cushion Tires
Replace the tire if the height of the solid
rubber portion is 25.4 mm (1 in. or less). For
tire replacement, consult your Mitsubishi
forklift dealer.

25.4 mm
200227 (1 inch)

100880

99759-7B110
2.3
FRONT AXLE & REDUCTION DIFFERENTIAL

Installation
To install, reverse the removal sequence and do 2. Lower the truck until the tire touches the
the following steps. floor. Then tighten the wheel nuts in numbered
sequence shown below, in two or three steps,
to the specified torque.
! CAUTION
1
Use the same size and brand of tire.
6
3
Make sure the clamping surfaces of the
wheel nuts and counterbores in the rim
are free of dirt.
4
5
1. Install the tire and tighten the wheel nuts.
2
Tighten each nut until its tapered portion is
in full-face contact with the counterbore in 205953

the rim.
Tightening Torque For Wheel Nuts
FBC15N - FBC18LN FBC20N - FBC30LN
Wheel Nut
16 kgf•m 38.5 kgf•m
Counterbore
(116 lbf•ft) (278 lbf•ft)
[157 N•m] [378 N•m]

100835A

99759-7B110
2.4
FRONT AXLE & REDUCTION DIFFERENTIAL

Disassembly
6 7

5 205954

Sequence
1. Axle shaft 4. Tapered roller bearing (outer bearing), oil seal,
2. Lock nut, lock washer, oil seal, and tapered and oil deflector
roller bearing (inner bearing) 5. Tapered roller bearing (inner bearing), and
3. Hub & drum assembly [Front wheel hub, brake seal retainer
drum, wheel bolts, drum nuts, and tapered 6. Brake assembly
roller bearing (outer bearing)] 7. Frame support and axle housing

Start By:
1. Remove the mast. (For replacement of the front 3. Support the front end of the truck at both sides
axle housing and disassembly of the differen- with blocks or stands to keep the truck in a
tial, refer to section, MAST AND FORKS.) horizontal position.
2. Jack up the truck. 4. Remove the front wheels.

NOTE

It is not necessary to remove the axle

housing or drain the oil for removal of the
shaft only.

99759-7B110
2.5
FRONT AXLE & REDUCTION DIFFERENTIAL

Suggestions Removing Front Wheel Hub

Removing the Lock Nut Use a wheel hub puller (Special Tool).
Use a lock nut wrench (Special Tool).
Tool FBC15N - FBC18LN FBC20N - FBC30LN

Tool FBC15N - FBC18LN FBC20N - FBC30LN

Wheel Hub Puller 64309-40100 MH061017
Lock Nut Wrench 91268-00800 03703-59001 (Puller seat) (64309-10601)

NOTE

It is not necessary to remove the oil seal

from the hub or to disassemble the oil
deflector unless the seal is defective.
Special Tool

Any wear or grooves in oil seal deflector would

require replacement.
It has been standard practice to replace the oil
seal every time the hub is removed to reduce the
200232 possibility of oil leaks.

Special Tool

200233

Removing Bearings
The inner race of the tapered roller bearing
remains in the axle housing when the hub is
drawn out. Remove this race together with the
seal retainer with a bearing puller.

203651

99759-7B110
2.6
FRONT AXLE & REDUCTION DIFFERENTIAL

Inspection after Disassembly

Axle Shafts
Looseness of Mating Splines Runout
Mount the differential bevel gear on the splined Set a dial indicator at the middle part of the axle
end of the shaft and set a dial indicator as shown shaft. Turn the shaft and read the indicator to find
below. Turn the bevel gear and read the indicator. runout.

Runout of shaft

Face runout of flange

200235 200236

0.07 to 0.17 FBC15N-FBC18LN FBC20N-

Free movement A
(0.0028 to 0.0067) FBC30LN
(looseness of
splines) B 0.5 (0.020) Runout of axle A 0.5 (0.020) 1.0 (0.039)
shaft (1/2 of dial maximum maximum
Unit: mm (in.) indicator reading B 1.0 (0.039) 2.0 (0.079)
A = Assembly Standard B = Repair or Service Limit
Unit: mm (in.)
Axle Housing A = Assembly Standard B = Repair or Service Limit
1. Check the surfaces of axle housing in contact
Set a dial indicator against the flange of the axle
with the mast bearing for damage.
shaft as shown. Turn the shaft and read the indi-
2. Check the entire axle housing for distortion, cator to find face runout.
dents, and other defects, paying particular
attention to the welds to see if any weld is A 0.05 (0.0020)
Face runout of axle
cracked. shaft flange B 0.5 (0.020)
Oil Seals and Retainers Unit: mm (in.)
1. Check the outer surface of the oil seal retainer A = Assembly Standard B = Repair or Service Limit
for wear or damage.
2. Check the outer and inner oil seals for wear
and damage.

99759-7B110
2.7
FRONT AXLE & REDUCTION DIFFERENTIAL

Reassembly Front Wheel Hub

1. Fill the front wheel hub, especially the roller
To reassemble, reverse the steps of the disassem-
holder and oil seal lip groove, with grease.
bly sequence and do the following steps.
Pack both bearings with grease.
Axle Housing
1. Install the O-ring in the outer groove (of the
two grooves in the bore of each frame sup-
port).
2. Apply grease to the surfaces A of the support
and axle housing.

Frame support
O-ring A

205954a

NOTE

Be careful not to apply grease to the brake

200237 drum.

Check for excessive movement between frame

support and axle housing.

200238

99759-7B110
2.8
FRONT AXLE & REDUCTION DIFFERENTIAL

2. Install the inner race and oil seal retainer of

the wheel hub bearing with an installer
(Special Tool).

Special tool

203569

FBC20N-
Tool FBC15N-FBC18LN
FBC30LN

Installer 64309-12300 91468-00300

3. Apply retaining compound to the flange sur-

faces of the axle shafts.

99759-7B110
2.9
FRONT AXLE & REDUCTION DIFFERENTIAL

Hub Bearing Preload Installation and Setting Preload

Tighten the inner nut to produce the required pre- 1. Fill the hub with the recommended grease as
load. Tighten the outer nut to the specified torque listed in the service manual.
and check the preload. Be sure that the preload 2. Pack the inner and outer bearing with the
noted after tightening the outer nut still meets the recommended grease.
specification. This step is for new bearings. Where
3. Install the inner bearing to the back side of the
the bearings removed in disassembly are reused,
hub.
try to produce the preload at the lower side of the
range. 4. Install the inner seal.
5. Clean the lining surface of the drum.
5 to 50 kgf•cm
Preload for hub bearing (0.4 to 3.6 lbf•ft) 6. Install the hub onto the axle.
[0.5 to 4.9 N•m] 7. Install the outer bearing, grease seal and pre-
Tightening torque 20 kgf•m load nut.
for (145 lbf•ft)
8. If the bearings are being reused, try to pro-
lock nuts [196 N•m]
duce the lower side of the applied force in tan-
gential direction.
9. For new bearings, tighten the preload nut to
14 kgf•m (101 lbf•ft) [137 N•m]. Slowly rotate
the hub slightly more than 3 turns, back the
nut off 80°, and set the applied force in tan-
gential direction.
10. For models with an outer lock nut, torque the
nut to 20 kgf•cm (145 lbf•ft) [196 N•m]. After
torquing the lock nut, check the force applied
in tangential direction again to insure the pre-
Inner nut Outer nut 200468 load did not change.

Bar

Spring
balancer

101653

99759-7B110
2.10
FRONT AXLE & REDUCTION DIFFERENTIAL

Reduction Differential
Description
3

4 5 2 1
200240

Sequence
1. Lock plates 4. Reduction gear and differential gear assembly
(spring pins, pinion shafts, differential pinions,
2. Side bearing nuts
differential bevel gear, washers, and differential
3. Differential carrier assembly (lock washers, case)
side bearing caps, and differential carrier)
5. Tapered roller bearings

Start By:
1. Remove the differential carrier from the trans-
mission case.
2. Check the pattern of gears at time of removal.
This step is important when assembly has
been completed and checking pattern of gears
to match.

99759-7B110
2.11
FRONT AXLE & REDUCTION DIFFERENTIAL

Disassembly
Suggestions Removing Bearing Inner Races
1. Before removing the differential carrier from Use a bearing puller to remove the inner races
the transmission case, measure the gear from the differential case.
backlash to aid in obtaining correct backlash
at the time of reassembly.

Backlash between reduction gear 0.15 to 0.25

and pinion (0.0059 to 0.0098)
Unit: mm (in.)

200242

200247

2. Put a mark across the bearing cap, adjusting

screw and carrier on each side.
The caps are not interchangeable.

200241

99759-7B110
2.12
FRONT AXLE & REDUCTION DIFFERENTIAL

Inspection after Disassembly

Reduction Gear Differential
Check the teeth for wear, pitting, flaking, or chip- 1. Check the differential cases for damage.
ping. Minor flaws on the tooth surface can be Check in particular the seat formed of each
repaired by grinding with an oil stone or a hand case for carrying the side bearing inner race
grinder. Check the teeth for contact. If the gear is to see whether the seat surface is galled or
badly damaged and requires replacement, replace not.
the pinion too. Reduction gear and pinion are a 2. Check the sliding surfaces of the thrust wash-
matched set and must be changed at the same ers and gears for wear or damage.
time.
3. Check the teeth of the differential pinions and
bevel gears for wear, pitting, chipping, or
galling.
4. Check the fit of each pinion on the spider.

A 0.02 to 0.07
Fit of differential (0.0008 to 0.0028)
pinions on spider
B 0.35 (0.0138)

Unit: mm (in.)
A = Assembly Standard B = Repair or service limit

99759-7B110
2.13
FRONT AXLE & REDUCTION DIFFERENTIAL

Reassembly

4 1

3 2
200243

Sequence
1. Tapered roller bearings 3. Spring pin

2. Differential gear assembly [differential case, 4. Reduction gear

thrust washers, bevel gears, pinions, and pin-
5. Differential carrier assembly [carrier, side bear-
ion shaft]
ing caps, side bearing nuts, and lock washers]

99759-7B110
2.14
FRONT AXLE & REDUCTION DIFFERENTIAL

Suggestions
Reassembling Differential Pinions Reassembling Differential Case
The thrust washers of the differential gears are to After putting the case assembly in place on the
be used for adjusting the backlash between the carrier, install the bearing caps tentatively by mak-
differential gears and pinions. Measure the backing the cap bolts snug tight. The caps are to be
lash and, if it exceeds the limit, replace the thrust secured tight after the bearing preload has been
washers. adjusted.

Installing Bearing Caps

Backlash between A 0.18 to 0.23
differential gears (0.0071 to 0.0091) Be sure to know which are the left and right caps
and pinions B 0.5 (0.020) and to put each cap in place correctly.

Unit: mm (in.)
12.8 kgf•m
A = Assembly Standard B = Repair or service limit Tightening torque for
(93 lbf•ft)
bearing cap bolts
[126 N•m]

200244
200241

Installing Reduction Gear

Apply LOCTITE No. 271 to the bolts for holding
the reduction gear to the case. Be sure to tighten
these bolts evenly so as not to strain the gear.
12.0 kgf•m
Tightening torque for
(87 lbf•ft)
reduction gear bolts
[118 N•m]

99759-7B110
2.15
FRONT AXLE & REDUCTION DIFFERENTIAL

Inspection and Adjustment

Side Bearing Preload Reduction Gear Backlash
Tie a wire on the reduction gear tooth and hook a Adjust the backlash between the reduction gear
spring scale to the wire. Tighten the side bearing and pinion after installing the differential carrier
nuts while reading the spring scale until the speci- assembly to the transmission case. To measure
fied preload is obtained. the backlash, set a dial indicator with its spindle
pointing squarely to the tooth face of the reduction
NOTE gear. With the pinion held, move the gear back
and forth to read the indicator. Adjust the backlash
Before measuring the preload, tap the using the left and right side bearing nuts and pin-
back of the reduction gear with a copper ion shims.
hammer while rotating the gear to center
between bearing. 0.15 to 0.25
Backlash between
(0.0059 to
reduction gear and pinion
0.0098)

15 to 30 kgf Unit: mm (in.)

Min. (1.1 to 2.2 lbf)
[1.5 to 2.9 N]

Preload for differential 1.32 to 2.5 kgf•cm

case side bearings Max. (2.9 to 5.5 lbf•ft)
[13 to 25 N•m]
As force applied to
reduction gear in
tangential direction.

200247

Backlash
Increase
Decrease

Decrease

Increase
200246
Increase

Backlash
Decrease
200248

99759-7B110
2.16
FRONT AXLE & REDUCTION DIFFERENTIAL

Reduction Gear Face Runout Tooth Contact

Using a dial indicator, check the reduction gear for Check the gear reduction tooth contact. To check,
face runout at the maximum radius position in apply a thin coat of bluing to several gear teeth on
back of the gear. If the runout exceeds the limit, both drive and coast sides. Press forward on the
check the reduction gear bolts for tightness; reduction pinion and rotate the reduction gear
retighten if necessary. Check the tapered roller back and forth until a contact pattern is noted on
bearings for condition. Readjust or replace them if both concave and convex faces of the gear teeth.
necessary. To adjust the tooth contact, refer to the chart.

Face runout of A 0.05 (0.0020) maximum

reduction gear B 0.05 (0.0020) maximum
Unit: mm (in.)
A = Assembly Standard B = Repair or Service Limit

200250

200249

99759-7B110
2.17
FRONT AXLE & REDUCTION DIFFERENTIAL

Tooth Contact Adjustment (FBC15N - FBC18LN)

Tooth Contact Adjustment

Extends from toe Correct tooth contact
to middle portion,
covering not less
1
than 50% of tooth
length.
203669-1

Short contact at 1. Move gear away from pinion.

toe of tooth. 2. Move pinion toward gear by increasing shim thick-
2 ness to secure correct backlash.

203669-2 203669-2A

Short contact at 1. Move gear toward pinion.

heel of tooth. 2. Move pinion away from gear by decreasing shim
3 thickness to secure correct backlash.

203669-3 203669-3A

Heavy contact on 1. Move pinion toward gear by increasing shim thick-

face or upper ness.
4 portion of tooth. 2. Move gear away from pinion to secure correct
backlash.

203669-4 203670-4A

Heavy contact on 1. Move pinion away from gear by decreasing shim

flank or lower thickness.
portion of tooth. 2. Move gear toward pinion to secure correct back-
5
lash.

203669-5 203670-5A

Repeat the above adjustment until the correct tooth contact is obtained.

99759-7B110
2.18
FRONT AXLE & REDUCTION DIFFERENTIAL

Tooth Contact Adjustment (FBC20N - FBC30LN)

Tooth Contact Adjustment

Extends from toe Correct tooth contact
to middle portion,
covering not less
1
than 50% of tooth
length.
203670-1

Short contact at 1. Move pinion toward gear by increasing shim

toe of tooth. thickness.
2 2. Move gear away from pinion to secure correct
backlash.

203670-2 203670-2A

Short contact at 1. Move pinion away from gear by decreasing shim

heel of tooth. thickness.
3 2. Move gear toward pinion to secure correct
backlash.

203670-3 203670-3A

Heavy contact on 1. Move pinion toward gear by increasing shim

face or upper thickness.
portion of tooth. 2. Move gear away from pinion to secure correct
4
backlash.

203670-4 203670-4A

Heavy contact on 1. Move pinion away from gear by decreasing shim

flank or lower thickness.
5 portion of tooth. 2. Move gear toward pinion to secure correct
backlash.

203670-5 203670-5A

Repeat the above adjustment until the correct tooth contact is obtained.

99759-7B110
2.19
NOTES

99759-7B110
2.20
TABLE OF CONTENTS

Chapter 3: Transfer Assembly

Description

Front axle center

1 8 2

6 Traction motor

5 9 4 6 209002

Main component
1 Transfer case 6 Taper roller bearing
2 Transfer cover 7 Lock nut
3 Input gear (13T) 8 Ball bearing
4 Output gear (48T) 9 Plug (standard) or pulse generator (option)
5 Bevel gear set

The transfer assemblies of all the 1 ton, 2 ton,

and 3 ton class trucks share completely identi-
cal components except the different bevel gear
sets as shown below.

No. of teeth on No. of teeth on

bevel pinion bevel gear
1 ton class trucks 7 32
2 and 3 ton class
7 35
trucks

99759-7B110
3.1
TRANSFER ASSEMBLY

Disassembly
Start by:
(1) Remove the drain plug on the front axle hous- (3) Remove the traction motor, reduction and dif-
ing to let the oil drain out. ferential assembly and transfer assembly as
(2) Disconnect the connectors of the traction one unit, from the front axle housing.
motor harnesses and pulse generator har- (4) Separate the three assemblies removed in
ness. step (3) from each other.

3 15 Liquid gasket
2

18 1

14
17
Plug (standard)
or 16
Pluse generator (option)

Staked
7

4
6

8 9

13 11 10 12
209002A

Disassembly sequence
1 Bolt 10 Output gear
2 Transfer cover 11 Spacer
3 Side cover with pulse generator, or plug 12 Bearing cup
4 Nut 13 Bearing cup
5 Shim 14 Snap ring
Remove parts 6 and 8 as a unit. Remove parts 15 to 17 as a unit.
6 Bevel pinion shaft 15 Input gear
7 Shim 16 Ball bearing
8 Bearing cone 17 Ball bearing
9 Bearing cone 18 Transfer case

99759-7B110
3.2
TRANSFER ASSEMBLY

Suggestions for Disassembly

1. Remove the bevel pinion shaft 6 as follows:

Shaft locking
(1) Using a chisel, cut the staked portion of 15 bar fixing bolt
the nut 4, taking care not to damage the Shaft locking
bevel pinion shaft. bar
18 Special
(2) Hold the input gear 15 with the special tool
tool to prevent the bevel pinion 6 from
rotating, then remove the nut 4 and 6
shims 5.
Special tool needed Staked

Transfer bearing tool 97E67 - 00100

4
5
(3) Using the bevel pinion puller (special
9
tool), pull the bevel pinion 6 out of the 12
8
bearing cone 9 (See the drawing on the 13 10
209003
right).
Special tool needed

Bevel pinion puller 91268 - 00300

(4) If the bearing cone 8 needs to be

removed, use a bearing puller and a
press to pull it from the bevel pinion 6.
(5) If the bearing cups 12 and 13 need to be
removed, use a bearing cup puller to pull
them out of the transfer case 18.
205829

NOTE

(1) The taper roller bearing cup and cone

are an exclusive pair. If either the cup
or cone of a pair is faulty, replace them
as a set.

(2) The removed shims should be kept

together until they are reinstalled.
(This only applies when the bevel
pinion and/or taper roller bearing are/is 205830
reused.)

(3) The bevel pinion and bevel gear are an

exclusive pair. If either of them is
defective, replace them as a set.

99759-7B110
3.3
TRANSFER ASSEMBLY

2. Remove the input gear as follows:

(1) Remove the snap ring 14.
M14 × 1.5
(2) Using a sliding hammer, pull the input 17 Thread 18
gear 15, complete with the ball bearings
out of the case 18.
14
(3) If the ball bearings 16 and 17 need to be
removed, use a puller to pull them out. 15
Do not attempt to tap them out. Rod of sliding
hammer

16
209004

Inspection after Disassembly

(1) Check the output gear 10 and the input gear
15 for damaged/worn teeth and worn splines.
(2) Check the bearings for wear or damage.
Make sure that they rotate freely without
making noise.
(3) Check the transfer case for cracks or other
damage.
(4) Check the bevel pinion and the bevel gear
for incorrect tooth contact, damage and
wear.

99759-7B110
3.4
TRANSFER ASSEMBLY

Reassembly
Follow the disassembly sequence in reverse.

2 4 5
1
17

3
18

16 19

13
10

8 Staked

6 11 12 7
209002B

Reassembly sequence
1 Transfer case 11 Spacer
Assemble the parts 2 to 4 first, then install the 12 Output gear
assembly into the case 1. 13 Bearing cone
2 Input gear 14 Shim
3 Ball bearing 15 Nut
4 Ball bearing 16 Side cover with pulse generator (option)
5 Snap ring 17 Liquid gasket
Press-fit the parts 6 and 7 into the case 1. 18 Transfer cover
6 Bearing cup 19 Bolt
7 Bearing cup
Assemble the parts 8, 9 and 10.
8 Bevel pinion shaft
9 Shim
10 Bearing cone

99759-7B110
3.5
TRANSFER ASSEMBLY

Suggestions for Reassembly

Mark “b” is indicated here.

! CAUTION

Axle center
Ball bearings and taper roller bearings can
be fitted onto shafts more easily when
they are warmed in hot oil. However, do
not increase the oil temperature above
120°C (250°F).

1. Install the input gear 2 as follows:

(1) Press-fit the ball bearings 3 and 4 into
the input gear 2. Force the assembly into
the transfer case 1. B
(2) Install the snap ring 5. A
2. Sub-assemble the bevel pinion shaft 8 as
follows:
Mark “a” is indicated here.
(1) Place shim stock 9 and bearing cone 10 209005
on the bevel pinion 8, then install these
into place using a press. The thickness C
of shims 9 can be calculated using the
following equation.
C = 1.8 + a/100 - b (unit: mm)
a: Machining error in the differential car-
rier dimension A
b: Machining error in the bevel pinion
dimension B
The machining error “a” is stamped on
the top surface of the differential carrier.
(No stamping is present if the error is
within ± 0.05 mm.)
The machining error “b” is marked on the
end surface of the bevel pinion using 1.0 mm (0.04 in.)
electric marking pen. No mark is present thick shim Standard shim
C stock thickness
if the error “b” is ± 0. 1.8 mm (0.071 in.)

209006

NOTE

When installing shim stock 9, be sure to

locate the 1.0 mm (0.04 in.) thick shim
closest to the bevel pinion.

99759-7B110
3.6
TRANSFER ASSEMBLY

(2) While inserting the bevel pinion shaft

2 Attach spring
sub-assembly into the case, install the scale hook here
spacer 11, output gear 12, bearing cone to measure the
tangential force.
13, and shim stock 14. Reuse the origi-
nally installed shim stock 14. Special
tool
Preload adjustment of taper roller bearing 8
(3) Hold the input gear 2 to prevent the
bevel pinion shaft 8 from rotating.
Special tool needed
14
Transfer bearing tool 97E67 - 00100

15
(4) Install a new nut 15 on the bevel pinion
shaft 8. Tighten and loosen the nut sev- 13
eral times, each time after rotating the 12
shaft a little, so that the bearing cups 11
209007
and cones settle completely on each
other. Finally, tighten the nut to the
torque shown below. Do not give the
bearings too much preload.

294 ± 20 N·m
Tightening torque of nut 15 (30.0 ± 2.0 kgf·m)
[217 ± 14.5 lbf·ft]

(5) With the special tool installed on the input

gear 2, measure the preload of the taper
roller bearing on the bevel pinion gear
shaft 8. The preload is measured in terms (1) Stake the nut completely against the
of the tangential force required to start the bottom of the groove on the bevel pinion.
(2) The staked portion should have a flat of
input gear 2 rotating. The measurement φ 4 mm (φ 0.16 in.) or more.
should meet the following specified value.

54 to 81 N
Tangential force required to
(5.5 to 8.3 kgf)
start input gear 2 rotating
[12.1 to 18.26 lbf]

(6) Adjust the preload as required by increas-

ing or decreasing the thickness of the
shim stock 14. The greater the shim stock Staking tool needed A screwdriver is not
thickness, the smaller the preload. The appropriate for staking.
smaller the shim stock thickness, the
greater the preload. Repeat the steps (4)
and (5) until the specified preload is
obtained.
(7) After the specified preload is obtained, R R
φ 4 to 6 mm
lock the nut 15 on the bevel pinion shaft (φ 0.16 to 0.24 in.) 209008
8 by staking to prevent it from loosening.
(See the drawing shown on the right.)
99759-7B110
3.7
TRANSFER ASSEMBLY

3. Bolts to be tightened to special torques

Supply liquid gasket onto

the face of flange.

4
2

209009

Tightening torque

N·m kgf·m lbf·ft

1 Cover-to-traction motor 33 ± 2 3.4 ± 0.2 24.6 ± 1.4
2 Side cover 39.2 ± 3.9 4.0 ± 0.4 29.0 ± 2.9
3 Plug or pulse generator 54.0 ± 4.9 5.5 ± 0.5 39.7 ± 3.6
4 Case-to-cover 39.2 ± 3.9 4.0 ± 0.4 29.0 ± 2.9
5 Lock nut 294 ± 20 30.0 ± 2.0 217 ± 14.5

99759-7B110
3.8
TABLE OF CONTENTS

Chapter 4: Rear Axle

Rear Axle
Description

3 2
1

7
3

6
B

8609001

1. Rear axle 5. Tie rods

2. Steering cylinder 6. Wheel rims
3. Steer knuckles 7. Shims
4. King pins

The truck is steered by the rear wheels. The rear

axle is connected to the frame by its center pivot
shaft. Because of the center pivoting feature, the
rear axle can oscillate up to 3° in each direction.

99759-7B110
4.1
REAR AXLE

Rear Wheels
Removal Suggestions
1. Park the truck on level floor with the parking
! CAUTION brake applied, the direction lever in neutral,
the forks lowered, and the key switch off.
Use the same size and brand of tire for
replacement. 2. Prepare the tools, parts, jack, and wheel
blocks.
Tools Needed: Spring scale, bearing installer,
and puller.
10 Parts Needed: Lock washer 3; oil seal 7;
cap 1 (when required); bearings 5, 8, 9, and
7 10 (when required); wheel assembly 6.
8 6 A
A
3. Cap 1 is press-fitted to the rim. Pry it off using
a chisel and hammer as shown. Discard the
954 3 2 1
removed cap. Use a new cap when installing a
replacement wheel.

207030

Removal Sequence
1. Cap
2. Outer nut
3. Lock washer
203614
4. Inner nut
5. Inner race bearing 4. Bend down lock washer 3.

6. Wheel assembly 5. Loosen nut 2.

7. Oil seal 6. Raise the wheels.

8. Outer race bearing Hoist Capacities

9. Outer race bearing 3000 kgf
FBC15N/FBC18LN
(6700 lbf)
10. Inner race bearing
FBC20N/FBC30LN 5000 kgf
(12,000 lbf)

99759-7B110
4.2
REAR AXLE

Steering Cylinder
*: Parts contained in seal kit
12
*
11
* 14 13
17 * * 6

▲ ▲
▲
▲ ▲ ▲

9
8
16
10 * 7
▲

▲
▲

▲
▲
•▲ •

▲ ▲ •
5

▲ ▲
2 * 1
15
3 4
207168

Double-action cylinder is used.

99759-7B110
4.3
REAR AXLE

Suggestions, continued Inspection

7. Block the front wheels. 1. Oil seal
Check the oil seal of the rim for excessive wear or
8. Fasten a hoist to the counterweight and lift damage.
the rear end of the truck. 2. Tires
9. Place the wood blocks under the side frames Check the height of the solid rubber portion and, if
to support the truck (with the left and right rear worn down to 25.4 mm (1 in.), replace the tire.
wheels slightly clearing the floor).
NOTE

Replace all tires if one tire is damaged. If

new and used tires are mixed, rapid tire
wear will result.

Installation
Blocks
To install, follow the reverse the removal sequence:
1. Using a puller, install bearings (outer) 8 and 9
100393B to the new wheel assembly 6.
2. Install oil seal 7 to the new wheel assembly 6.
10. Remove nut 2, lock washer 3 and nut 4.
11. Remove wheel assembly 6 from the rear
10
axle. Be careful not to cause damage to the
oil seal fitted to the rim. After removing the
7
assembly, raise the counterweight to a position 8 6 A
A
400 to 500 mm (16 to 20 in.) from the floor.
12. Using a puller, remove outer race bearings 8 954 3 2 1
and oil seal 7 from the wheel assembly.

NOTE
207030
Replace the cap and bearings (inner and
outer) if defective.

25.4 mm
(1 inch)

207029

99759-7B110
4.4
REAR AXLE

3. Fill the rim and oil seal with grease. Do not

overfill the oil seal to prevent leakage.
Oil seal
4. Tighten nut 4 to 137 N·m (14 kgf·m) [101 lbf·ft]
torque and back it off 80°, then put lock washer

▲
•
3. Install nut 2, tightening it to 157 N·m (16
Fill with
kgf·m) [116 lbf·ft] torque. Check the hub bearing
grease
preload, making sure it is 2.5 to 6.4 N·m (25 to
65 kgf·cm) [1.8 to 4.7 lbf·ft]. If the preload is cor-
rect, bend lock washer 3.

207024

5. Check to make sure the preload is correct.

Insert a 24mm round bar into the cast hole of Bar
the rim. Attach a spring balance to the round

▲
bar, and measure the tangential force.

FBC15N - FBC20N -
FBC18LN FBC30LN
Tangential 33.1 to 86 26.7 to 69.6
force (3.38 to 8.78) (2.73 to 7.10)
N (kgf) [lbf] [7.4 to 19.3] [6.0 to 15.6]

Tighten the inner nut to achieve the specified 207025

value.

Reference value
Bar
2.5 to 6.4 N·m
Preload for hub
(25 to 65 kgf·cm)
bearings
[1.8 to 4.7 lbf·ft]

Spring scale

207026

99759-7B110
4.5
REAR AXLE

6. After adjusting the preload, tighten a new lock

washer 3 and an outer nut 2 to the specified
torque.
Inside
nut
157N·m
Tightening torque for •• Outside
(16 kgf·m) nut
outer (lock) nut
[116 lbf·ft]

207024

7. Bend the lock washer to both sides (inward and

outward).

205436

8. Fill the cap with grease, and install the cap 1.

9. Raise the rear end of the truck and remove the
blocking from the side frames.
10 Lower the truck until the rear wheels just touch
the floor.

99759-7B110
4.6
REAR AXLE

Rear Axle
Removal

7
6

2 1

3
203613

Sequence
1. Cap 4. Rim and tire 7. Rear axle assembly
2. Nut and washer 5. Drag link
3. Bearing 6. Bearing support and bolts

Start By:
1. Apply the parking brake and block the front
wheels.
2. Raise the rear end of the truck with a jack and
place wood blocks under the side frames (with
the left and right rear wheels slightly clearing
the floor).
3. A hoist can be used instead of the jack to
raise the rear end (counterweight).

203622

99759-7B110
4.7
REAR AXLE

Suggestions Installation
Removing Rear Axle Assembly To install, reverse the removal sequence and do
the following steps.
! WARNING
Adjusting Bearing Support Clearance
Be sure the pressure in the hydraulic
system is released before any lines or Adjust the longitudinal clearance to 0.8 mm
hoses are disconnected. (0.031 in.) with the thrust washer and tighten the
bolts holding the bearing support to the specified
torque.
1. Put identification marks on the hoses, then
14.8 kgf•m
disconnect them. Tightening torque for
(107 lbf•ft)
2. Support the rear axle at its center with a bearing support bolts
[145 N•m]
garage jack.
3. Loosen and remove the axle mounting bolts.

Clearance:
0.8 mm
(0.031 in.)

200257
203615

Weight of Rear Axle

FBC15N-FBC18LN 60kg
[132 lb]

FBC20N-FBC30LN 85kg
[187 lb]

99759-7B110
4.8
REAR AXLE

Disassembly

REAR AXLE ASSEMBLY

17
16

15
14 2
15 4
17
19

13
11
2
10

9 3
8

6
18

10 1
5

207028

Disassembly
Disassembly sequence
1 Taper roller bearing (inner), Retainer 9 Taper roller bearing
2 Tie rod pin, Bolt, Spring washer, Plain 10 Oil seal
washer, Collar, Grease nipple 11 Cover, Retainer
3 Spherical bushing, Ring, Retainer, Dust seal 12 Boot
4 Tie rod 13 Cover
5 Kingpin plate, Shim 14 Clamp, Bolt, Spring washer
6 Kingpin, O-ring 15 Pipe (L.H., R.H.)
Remove parts 7 through 12 as an 16 Steering cylinder [Bolt, Spring washer, Nut]
assembly. 17 Elbow, O-ring
7 Knuckle 18 Stopper bolt, Lock nut
8 O-ring 19 Rear axle housing
99759-7B110
4.9
REAR AXLE

Suggestions
Removing Retainer and Bearing Mark Cylinder End Caps
Use a puller to remove the retainer and inner Mark the cylinder end caps for proper alignment
bearing from the knuckle. before they are disassembled from the cylinder.

Mark

Mark
203618 8609004

99759-7B110
4.10
REAR AXLE

Inspection after Disassembly

Tie Rods and Pins Seals and O-rings
1. Make sure that the pins are free of any sur- Examine all seals and O-rings for damage such
face flaws such as grooving or stepped wear. as cuts and tears. Replace seals which show
Examine the keeper plate weld for cracking. signs of aging.
2. Examine the bearings for wear or damage.
Hydraulic Pipes
3. Examine the tie rods for damage and align-
Inspect the hydraulic pipes for cracks, especially
ment. Inspect the welds for signs of cracks.
at the joints with the end fittings. Check for leaks.

Tires
NOTE
Check the height of the solid rubber portion and, if
If a pin must be replaced, replace its worn down to 25.4 mm (1 in.), replace the tire.
bearing as well.

Kingpins NOTE
Check the kingpins for any surface flaws such as
Replace all tires even if only one tire is
grooving or stepped wear. Inspect the pins for
damaged. If new and used tires are mixed,
cracks at the bearing shoulder.
rapid tire wear will result.
Kingpin Bearings
Examine the rollers and bearing races for groov-
ing, abrasive wear, pitting, bruising, or corrosion.
Replace both the cup and cone of damaged bear-
ings.

Knuckles 25.4 mm
(1 inch)
Inspect the inside of each knuckle for wear or
damage. Be sure to examine for casting cracks.
Check the tie rod pin hole. Examine the wheel nut
threads for damage. 100880

Cylinder Rod
Examine the rod for surface or plating damage.
Inspect the rod for straightness. Examine the pis-
ton for damage. Check the tie rod pin hole for
damage or wear.

99759-7B110
4.11
REAR AXLE

Reassembly

3
2

4
5 17
4 16
3
1

15
11
17
10

9 7
8

13
18

10 19
14

207028

Assembly sequence
1 Rear axle housing 11 Cover, retainer
2 Steering cylinder [bolt, spring washer, nut] 12 Boot
3 Elbow, O-ring 13 Kingpin, O-ring, bolt, spring washer
4 Pipe (L.H., R.H.) 14 Kingpin plate, shim, bolt, spring washer
5 Clamp, bolt, spring washer 15 Cover
6 Knuckle 16 Tie rod
7 Spherical bushing, ring, retainer, dust seal 17 Tie rod pin, bolt, spring washer, plain
8 O-ring washer, collar, grease nipple
9 Taper roller bearing 18 Stopper bolt, lock nut
10 Oil seal 19 Retainer, taper roller bearing

99759-7B110
4.12
REAR AXLE

Suggestions
Reassembling Steer Cylinder
1. Replace all seals and O-rings when reassem- 4. Pressure test cylinder reassembly for leaks.
bling the steer cylinder. Lubricate seals and O-
rings lightly with hydraulic fluid.
FBC15N-FBC18LN FBC20N-FBC30LN
2. Assemble wiper seal and U-seal as shown.
107 163
Minimum
(1522) (2320)
test pressure
[10,500] [16,000]
Unit: kgf/cm2 (psi) [kPa]

5. Use an alternating tightening pattern to tighten

the mounting bolts when attaching the cylinder
assembly to the axle beam.

Wiper seal U-Seal FBC15N-FBC18LN FBC20N-FBC30LN

8609006 17.9 kgf•m 26.7 kgf•m
Tightening torque
(130 lbf•ft) (193 lbf•ft)
for bolts
3. Align marks on the end caps to marks on the [176 N•m] [262 N•m]
cylinder body. Tighten nuts.

2.1 ± 0.2 kgf•m Reassembling Knuckles

Tightening torque for
(15.5 ± 1.5 lbf•ft)
cylinder nuts 1. Insert bearing cups into knuckles. Adequately
[21 ± 2 N•m]
fill bearing cages with “AUTOLEX A” grease.
Apply a coat of grease to the oil seal groove.
Mark Insert the bearing cages in the knuckles and
apply additional grease as required to meet
the recommended amount.

FBC15N-FBC18LN FBC20N-FBC30LN
Quantity of grease 40cc (2.44 in3) 80 cc (4.88 in3)

2. Reassemble remaining components (seals,

Mark O-rings, covers, and boots).
8609004
3. Assemble parts, knuckle 6 through Boot 12,
and insert this sub-assembly into the rear axle
housing.

99759-7B110
4.13
REAR AXLE

Reassembling Kingpins
1. Install the kingpins and measure the distances 3. Measure the tangential force at point “C”.
“A” on both the left and right kingpins. When the tangential force is larger than the
values shown in the table below, add shims.
When the tangential force is smaller than the
values shown in the table below, remove
shims. Repeat this procedure until the values
in the table are attained.

FBC15N-FBC18LN FBC20N-FBC30LN
1.6 to 2.6 kgf 2.5 to 4.5 kgf
Tangential force (3.5 to 5.7 lb.) (5.5 to 9.9 lb.)
15.7 to 25.5 N 24.5 to 44.1 N
A 8609007

2. Add shims to each side to within 0.1 mm

(0.004 in.) of the measured distance “A” and
C
tighten bolt “B”.

8609009

4. Tighten kingpin keeper plate bolts.

Kingpin Bolt Keeper Plate Bolts

1.7 kgf•m 3.4 kgf•m
Tightening torque
(12.3 lbf•ft) (24.6 lbf•ft)
for bolts
[16.7 N•m] [33.4 N•m]

Shims

Bolt B

8609008

99759-7B110
4.14
REAR AXLE

Reassembling Tie Rods 3. Reassemble rear axle hubs. The inner race of
Replace dust seals. Tighten tie rod pin bolts to the the inner bearing must be driven onto the shaft
specified torque. Grease the joints using the using a special tool as shown below.
grease zerks.

0.7 kgf•m
Tightening torque for bolts (5 lbf•ft)
[6.9 N•m]

Zerk

205022

Dust
seals Rod 4. There is space between the two tapered roller
pin
bearings inside the rear axle hub. Be sure to
bolt
fill this space with grease. Grease the oil seal
8609010 lip groove and roller retainers, too. Do not
overfill the oil seal lip groove as this can
cause leakage.
Reassembling Rear Axle Hub
1. Using Installation Tool #91268-01500 or
#64309-40400 install inner bearing races.
Oil
Using Tool #91268-01400 or 91268-00400 seal
install outer bearing races.

Fill
with
FBC15N-FBC18LN FBC20N-FBC30LN grease
Bearing installer 91268-01500 64309-40400

8609002A
2. Pack bearing cones.
5. Install wheel assembly carefully so as not to
damage the bearing or seal.
10

7
A 8 6 A

9 54 3 2 1

101744

99759-7B110
4.15
REAR AXLE

6. Install outer bearing and nut 4.

NOTE
7. Tighten nut 4 to
14 kgf•m (101 lbf•ft) [137 N•m] torque and Preload for bearing is given in tangential
back it off to 80°, then place lock washer 3. force measurement and must be measured
Install nut 2, tightening it to with a spring scale. Apply force to spring
16 kgf•m (116 lbf•ft) [157 N•m] torque. scale as shown in graphic #101653, read
scale. Adjust nut 4 to achieve correct
Check the hub bearing preload, making sure it is
preload.
25 to 65 kgf•cm (1.8 to 4.7 lbf•ft) [2.5 to 6.4 N•m].
If the preload is correct, bend lock washer 3.
8. Check to make sure the preload is correct.
25 to 65 kgf•cm
Preload for hub bearings (1.8 to 4.7 lbf•ft)
Inside [2.5 to 6.4 N•m]
nut
Outside
nut

Bar

8609002B

25 to 65 kgf•cm
Preload for hub bearings
(1.8 to 4.7 lbf•ft)
Tangential Force
[2.5 to 6.4 N•m]

8609002
16 kgf•m
Tightening torque for
(116 lbf•ft)
outer lock nut
[157 N•m]

Bar

Spring scale

101653

9. Install cap 1.
10. Raise the rear end of the truck and remove
the blocking from the side frames.
11. Lower the truck until the rear wheels are on
the floor.

99759-7B110
4.16
REAR AXLE

Inspection and Adjustment

Minimum Turning Radius Adjustment
1. Using a turning radius gauge, measure the 3. Drive the machine at low speeds in such a
angular swing of rear wheels. way as to make the sharpest possible turn to
either side. Measure the radius of the track left
2. Setting the turning angle of each rear wheel to
by the outer wheel.
the specification is not enough. The truck must
be driven to make the sharpest possible turn to 4. The minimum turning radius, R, is the distance
either side, and the radius of the track left from the turning center to the center of tire
behind by the outer wheel must be measured contact with the surface while the truck is exe-
for confirmation. The standard minimum turning cuting its sharpest turn, plus the rear over-
radius is indicated below. hang (distance from center of rear tire to the
outermost end of the counterweight).

FBC15N 1787 (70.4)

FBC15N-FBC18LN FBC20N-FBC30LN FBC18N 1787 (70.4)
Steering Angle FBC18LN 1841 (72.5)
Inside 83° 83° FBC20N 1890 (74.4)
Outside 54° 56° FBC25N 1890 (74.4)
Tightening torque 6.8 kgf•m FBC25EN 1991 (78.4)
for knuckle stopper (49 lbf•ft)
bolt lock nut [67 N•m] FBC25LN 1991 (78.4)
FBC30N 2045 (80.5)
FBC30LN 2045 (80.5)

202800

Turning radius [Unit: mm (in.)]

99759-7B110
4.17
REAR AXLE

STEERING CYLINDER
Disassembly

*: Parts contained in repair kit 10

11
9

A
11
3
*
4
5
2
* 1
6 *
7 7
A * 6
*
2
5
4

*
1 3

8
1
207036

Disassembly sequence
1 Nut, Spring washer, Tie rod 6 Wiper
Remove parts 7 through 12 as assembly. 7 U-seal
2 Cylinder head 8 Cylinder tube
3 O-ring 9 Piston rod
4 Snap ring 10 Guide ring, Piston seal
5 Bushing 11 Stopper ring

NOTE

(1) Do not remove bushing 5 from the

cylinder head 2 if acceptable.
(2) Do not remove bearing 11 from piston
rod 9 if acceptable.

99759-7B110
4.18
REAR AXLE

Suggestions
Mark Cylinder End Caps
Mark the cylinder end caps for proper alignment
before they are disassembled from the cylinder. Mark

Mark

207035

Inspection and Repair

1 Cylinder tube 8:
Check for wear, damage or rust inside the cylin-
der.
2 Piston rod 9:
Check for rust, damage, scratches or impact
marks on the rod surface.
3 Rings and gaskets:
Replace the entire seal kit.

A: Standard value
Unit: mm (in.) 205439
FBC15N-FBC18LN FBC20N-FBC30LN
Internal diameter of
A 63(2.480) 75(2.953)
cylinder tube 1
External diameter of
A 40(1.575) 50(1.968)
piston rod 2

2 1

207034

99759-7B110
4.19
REAR AXLE

Reassembly
5 5
13
1 2 4 14
16 12
• •
•

15 9
8
6
7 3
10 11 207034

Assembly sequence
1 Piston rod 7 Snap ring 13 Spring washer
2 Piston seal 8 U-seal 14 Nut
3 Guide ring 9 Wiper 15 Pivot joint
4 Cylinder tube 10 O-ring 16 Stopper ring
5 Cylinder head 11 O-ring
6 Bushing 12 Tie rod

Suggestions
1. Replace all seals and O-rings whenever reassem-
bling steer cylinder. Lubricate seals and O-rings
lightly with hydraulic fluid.
2. Assemble wiper seal and U-seal as shown.
3. Align marks on the end caps to marks on the
cylinder body. Tighten nuts.

Wiper U-seal
207042

Unit: N·m (kgf·m) [lbf·ft]

Tightening torque for 21±2
Mark
cylinder nuts (2.1±0.2)
N·m (kgf·m) [lbf·ft] [15.5±1.5]

4. Pressure test cylinder reassembly for leaks.

Unit: kPa (kgf/cm2) [psi]
FBC15N-FBC18LN FBC20N-FBC30LN
Mark
10500 16000
Minimum
(107) (163)
test pressure 207035
[1522] [2320]

99759-7B110
4.20
TABLE OF CONTENTS

Chapter 5: Brake System

Description
Automatic Adjusting Device

205955

General Information
This device adjusts the drum-to-lining clearance
automatically. As the clearance increases due to
lining wear, the lever mechanism of this device
turns the adjusting screw by one notch or tooth to
reposition the shoes closer to the drum. This cor-
responds to 1/24 of one rotation or 15°. In the
course of usage, the adjusting process repeats
itself at long intervals.

99759-7B110
5.1
BRAKE SYSTEM

Master Cylinder
Disassembly

9
8

4 7
10
6
5

*3
91484-37100 FBC15N - FBC18LN
91246-65300 FBC20N - FBC30LN
1

97146-10000A

1. Taper plug 6. Oil tank assembly

2. Master cylinder body 7. Push rod
3. Repair kit 8. Jam nut
4. Cap assembly 9. Clevis
5. Level sensor 10. Push rod assembly

NOTE

The parts* to be changed periodically are

included in the Repair Kit.

99759-7B110
5.2
BRAKE SYSTEM

Inspection after Disassembly

Brake Fluid Level Sensor Piston
1. Fill the reservoir with brake fluid. Connect the Replace the piston if it is damaged. Check the pis-
level sensor connector at the bottom of the ton clearance in the cylinder body. Replace the
fluid reservoir and turn the key to ON. cylinder body and piston if the clearance is in
excess of the service limit.

Clearance A 0.020 to 0.105

between piston (0.00079 to 0.00413)
and cylinder B 0.2 (0.008)
Unit: mm (in.)
A = Assembly Standard B = Repair or Service Limit

DOWN = ON UP = OFF Return Spring

Replace the return spring every year.
200270
Primary Cup, Secondary Cup, and Valve
2. The sensor is satisfactory if the brake fluid Check these rubber parts for swelling, tearing,
level warning lamp on the monitor flashes and deterioration from aging. Replace them every
when the reservoir filler is in the DOWN posi- year.
tion and goes off when it is in the UP position.

Cylinder Body Reassembly

1. Check the bore of the cylinder for rust, corro-
To reassemble, reverse the procedure for disas-
sion, and scoring.
sembly and do the following steps.
2. Check the inlet port and relief ports for cleanli-
1. Clean all metal parts with a volatile cleaning
ness. Also check the threads in the screw con-
solvent. Dry them with pressure air.
nection of each joint for damage. Make sure
the boot is free from defects. 2. Apply a thin coat of rubber grease (Metal
Rubber #20) or brake fluid to the piston cups
and the cylinder bore.

Master Cylinder Adjustment:

Adjust master cylinder only after pedal height
adjustment has been made (See pg. 5.18). With
master cylinder installed and push rod connected
to brake pedal, use the clevis pin to adjust the
master cylinder push rod so there is 0.5 to 2.8mm
of free play between the end of the push rod and
cylinder position contact. Tighten jam nut on push
rod clevis assembly.

99759-7B110
5.3
BRAKE SYSTEM

Service Brakes
Disassembly (FBC15N - FBC18LN)
1

2
16 23 3 24 13 9 9 21

7
22
6
26
4 10
27 17
15
11
14

18 25
8
12

97146-11800A

Components
1. Service Brake Assembly 15. Spring
2. Wheel cylinder assembly 16. Pin
3. Backing plate 17. Spring
4. Primary shoe and lining assembly 18. Strut
5. Secondary shoe and lining assembly 19. Spring washer
6. Parking Lever 20. Retainer
7. Adjusting screw 21. Bolt with washer
8. Adjusting lever 22. Snap ring
9. Spring 23. Cover
10. Cable guide 24. Parking cable assembly
11. Fitting cable 25. Spring
12. Spring 26. Spring washer
13. Shoe guide plate 27. Bolt
14. Cup
99759-7B110
5.4
BRAKE SYSTEM

Disassembly (FBC20N - FBC30LN)

2
16 23 10 3 24 13 27 28 29 21

26
9
20
19

7
22
6
31
30 4
14 17
15
14
18 11

12 8 25

97246-10900A

Components
1. Service Brake Assembly 10. Self-locking nut 21. Bolt with washer
2. Wheel cylinder assembly 11. Fitting cable 22. Snap ring
3. Backing plate 12. Spring 23. Cover
4. Primary shoe and lining 13. Shoe guide plate 24. Parking cable assembly
assembly 14. Cup 25. Spring
5. Secondary shoe and lining 15. Spring 26. Spring
assembly
16. Pin 27. Pin
6. Parking Lever
17. Spring 28. Sheave
7. Adjusting screw
18. Strut 29. Plain washer
8. Adjusting lever
19. Spring washer 30. Bolt
9. Spring
20. Retainer 31. Spring washer

99759-7B110
5.5
BRAKE SYSTEM

Start By:
1. Remove the front wheel. 4. Disconnect the brake pipe from the wheel
2. Remove the wheel hub and brake drum. brake assembly.
3. Separate the parking brake lever and cable
at the bottom of the wheel brake.

Suggestions
Removing Return Springs Removing Hold-Down Springs
Use a special tool to remove the return springs. Use a special tool to remove the hold-down springs.

Special Tool Part Number Special Tool Part Number

Spring remover 64309-15411 Spring remover 64309-15412

200271 200272

99759-7B110
5.6
BRAKE SYSTEM

Inspection after Disassembly

Backing Plate Brake Drums
1. Check the backing plate for cracks. Check the inside (friction) surface of the drum for
abnormal wear, grooving, and other defects. Minor
2. Tighten the backing plate mounting bolts to
grooving can be removed by grinding, provided
the specified torque.
that the service limit on the inside diameter is not
exceeded.
16 kgf•m
Tightening torque for backing
(116 lbf•ft)
plate mounting bolts
[157 N•m] FBC15N - FBC18LN FBC20N-FBC30LN
254 + 0.13 0 310 + 0.15 0
Inside
A 0.0051 0)
diameter of (10.0 + (12.2 + 0.0059 0)
Shoes and Linings brake drum
B 256 (10.08) 312 (12.28)
1. Check each shoe and lining for cracks.
Unit: mm (in.)
2. Replace the lining if it is dirty, greasy, burnt,
A = Assembly standard B = Repair or service limit
or glazed.
3. Check the thickness of the lining. Replace
the lining if it exceeds the service limit. Adjusting Screws
Check the wheel teeth for wear. Turn the screw by
hand to ensure its rotating parts turn freely.

203005

200274

FBC15N - FBC18LN FBC20N-FBC30LN

4.87 6 Parking Brake Cable
A
Lining (0.19) (0.24)
thickness Replace a cable if it is permanently stretched,
2.5 (0.10) 3 (0.12)
B rusted, or damaged.
maximum maximum
Unit: mm (in.) Other:
A = Assembly standard B = Repair or service limit
1. Check the return springs for cracks or fatigue.
2. Check the adjusting springs for cracks or
fatigue.
3. Check the fitting cables for stretching.

99759-7B110
5.7
BRAKE SYSTEM

Reassembly (FBC15N - FBC18LN)

6 10
A 3
12 1

8 12

13
5
8
4
7
1
11

9
9

14
16
2 Section A-A
15 A

205960

Sequence
1. Backing plate 9. Pin, hold-down spring, and cup
2. Parking brake cable 10. Shoe guide plate
3. Wheel cylinder 11. Fitting cable
4. Parking brake lever 12. Return spring
5. Shoe and primary lining 13. Cable guide
6. Retainer and washer 14. Adjusting lever and adjusting spring
7. Shoe and secondary lining 15. Adjusting screw
8. Strut and anti-rattle spring 16. Return spring

99759-7B110
5.8
BRAKE SYSTEM

Reassembly (FBC20N - FBC30LN)

A
3 11
6 9

13 1

7
4
8

10
10

16
14
Section A-A
15
2 A
205961

Sequence
1. Backing plate 9. Strut and anti-rattle spring
2. Parking brake cable 10. Pin, hold-down spring, and cup
3. Wheel cylinder 11. Shoe guide plate
4. Parking brake lever 12. Fitting cable
5. Shoe and primary lining 13. Return spring
6. Retainer and washer 14. Adjusting lever and adjusting spring
7. Pin, sheave, and washer 15. Adjusting screw
8. Shoe and secondary lining 16. Return spring

99759-7B110
5.9
BRAKE SYSTEM

Suggestions
Installing Wheel Cylinder Greasing
Apply 3 Bond to the mounting face of the wheel Apply a thin coat of the specified brake grease to
cylinder before positioning the cylinder in place. each of the following parts.
Secure it by tightening to the specified torque: 1. Shoe ledges (6 places):
The ledges are the portions of the backing
plate in contact with the shoe.
FBC15N - FBC18LN FBC20N-FBC30LN 2. Anchor pin surface in contact with the shoe
Tightening 0.8 to 1.2 1.8 to 2.7 ends.
torque for (6 to 9) (13 to 20)
wheel cylinder [8 to 12] [18 to 26] Installing Shoes
Unit: kgf•m (lbf•ft) [N•m] Make sure that each push rod of the wheel cylin-
der is snugly fitted to its shoe web.

Installing Return Springs

Use a special tool to install the return springs to
the backing plate pins

Special Tool Part Number

Spring installer 65309-15413

200275

200276

99759-7B110
5.10
BRAKE SYSTEM

Installing Automatic Adjusting Device

1. Clean the adjusting screw and associated
parts, then grease the screw threads and
screw socket. Be sure the screw turns freely
when rotated by hand. If the screw is hard to
turn, replace it.
2. The right and left adjusting screws are color-
coded.
• Right-hand adjusting screw and lever (left-
hand thread) is yellow.
• Left-hand adjusting screw and lever (right- 200277
hand thread) is white.

NOTE

After reassembly, bleed air out of the brake

fluid lines. (Refer to INSPECTION AND
ADJUSTMENT, p. 5.15).

99759-7B110
5.11
BRAKE SYSTEM

Wheel Cylinders
Disassembly

7
6 12

5 11

9
3
8

2
*

97246-10900B

Sequence
1. Connecting link 8. Spring
2. Boot 9. Cup
3. Piston 10. Piston
4. Piston cup 11. Boot
5. Body 12. Connecting Link
6. Bleeder screw
7. Cap

NOTE

The parts (*) to be changed annually are

included in the repair kit.

99759-7B110
5.12
BRAKE SYSTEM

Inspection after Disassembly

Cylinder Bodies Piston Cups
1. Check the bore for rusting, corrosion, and Check for swelling or other defects. Replace the
scoring. cups at the time of overhaul and every year.
2. Check the threads of the bleeder screw and oil
Boots
pipe for damage.
Replace the boots if they are hardened, damaged,
Pistons or otherwise deteriorated.
1. Check the sliding surface for rusting or
scratching. Cylinders with any rust, corrosion Reassembly
or scoring should be replaced.
To reassemble, reverse the procedure for disas-
2. Check the piston clearance in the cylinder sembly and do the following:
body. Replace the cylinder body and piston if
1. Coat the piston cups and the cylinder bore
the clearance exceeds the service limit.
with brake fluid.
2. Be careful not to damage the lips of the cups.

200280

FBC15N - FBC18LN FBC20N-FBC30LN

0.040 to 0.125 0.020 to 0.105
Clearance A (0.00157 to (0.00079 to
between 0.00492) 0.00413)
piston and
cylinder B 0.15 (0.0059)

Unit: mm (in.)
A = Assembly standard B = Repair or service limit

It is recommended that the brake cylinder kit be

replaced any time it is disassembled.

99759-7B110
5.13
BRAKE SYSTEM

Inspection and Adjustment

Automatic Adjusting Device
1. Have the service brake properly set with the 3. When the automatic adjusting device is sus-
drum-to-lining clearance adjusted to specifi- pected of malfunctioning during normal use of
cation. Pull the adjusting lever by giving a the machine, check for the following causes:
push to the cable, as shown, to see if the a. Adjusting spring is not correctly hooked to
lever turns the adjusting screw by one tooth the primary shoe.
and, as the push is released, returns to its
b. Any one of these parts is in bad condition
original position. If it does, the device is in
and needs replacing:
satisfactory condition.
1) fitting cable
2) adjusting lever
3) adjusting screw

Manual Adjustment
The drum-to-lining clearance can be adjusted by
rotating the adjusting screw with a screwdriver on
to the toothed wheel. The hole through which the
screwdriver tip can be inserted is in the backing
plate.

200281

2. If the lever fails or is sluggish to turn the

adjusting screw in the above test, the likely
cause is that the lever is not properly posi-
tioned relative to the toothed wheel. Be sure
that the lever is positioned so that its actuating
tip touches the toothed wheel at about 9 mm
(0.35 in.) under the center line of the screw, as
shown below. 200283

9 mm
(0.35 inch)

200282

99759-7B110
5.14
BRAKE SYSTEM

Brake Pedal Adjustment Bleeding Air Out of Brake Fluid Line

Set the dimensions A, B, and C to the specified Whenever any part of the brake fluid line is dis-
values. connected in servicing work, an air bleeding oper-
After the shoe linings have been replaced, turn ation must be performed to complete the job. Air
the adjusting screw as far as it will go (until the trapped in any part of the fluid line will cause the
clearance becomes zero) and back it off by the brake pedal to feel spongy.
amount of rotation shown below. Air Bleeding Operation Procedure:
FBC15N - FBC18LN: 19 clicks 1. Tie a flexible tube, such as a vinyl pipe, to the
FBC20N - FBC30LN: 16 clicks bleeder screw on the wheel cylinder. Insert the
free end of the tube into a vessel filled with
Height from floor to brake fluid.
120mm ± 3 mm
pedal (A) 2. Pump the brake pedal and depress it all the
Stroke (to a point where way. While keeping the pedal depressed,
3 to 10 (0.12 to 0.4)
brakes start to apply) (B) loosen the bleeder screw. When air bubbles
Clearance between piston cease to come out, tighten the screw. Repeat
0.5 to 2.7 (0.02 to 0.11)
and push rod (C) this process until nothing but brake fluid flows
Unit: mm (in.) into the vessel.
3. Repeat procedure at each wheel brake, and fill
up the brake fluid reservoir to level.
B

Push rod

200285

C Stop bolt NOTE

8609011 Be sure that the reservoir never becomes
empty of fluid at any time during the
procedure.

Use specified brake fluid. Avoid mixing

different brands of brake fluid before and
after filling up the reservoir.

Brake Test
After completion of necessary adjustments, test
the brake force by operating the truck at a slow
speed of 2.0 km/h (1.2 mph). Test brakes—then
increase speed up to 10 km/h (6.2 mph). Refer to
Manual Adjustment for necessary readjustment.
99759-7B110
5.15
NOTES

Chapter 6: Steering System

Steering System
Description
Steering System

6 4

1
8609044

Oil Flow Sequence

1. From hydraulic tank 4. Steering cylinder
2. Steering pump 5. Mast operating valve
3. Steer gear 6. To hydraulic tank

General Information
This steering system is an open-center type,
where the steering fluid is provided by a dedicated
steering pump. The oil is constantly available and
flows through the steer gear and back to the tank
via the mast operating valve.
In this type of steering system, only the small ded-
icated steer pump is pressurized, providing an
efficient, energy-conservation system.

99759-7B110
6.1
STEERING SYSTEM

Steering Gear
Removal
Steering Wheel

8609016

Sequence
1. Nut, washer
2. Wheel

Removal Installation
Use a special tool. To install, follow the reverse of the removal
sequence.
Special Tool Part Number
Wheel puller 91268-10600

Wheel puller

203466A

99759-7B110
6.2
STEERING SYSTEM

Steering Gear

Sequence
1. Column & Kick cover mounting hardware
! WARNING
2. Column & Kick covers
Hydraulic pressure can cause personal
3. Hoses, connectors and o-rings injury. Before any steering system hydraulic
4. Steer column mounting bolts lines or components are disconnected,
make sure all hydraulic pressure is released
5. Steer column in the steering system. Move the steer
6. Steer gear wheels to the left and right, then straight.

NOTE

For servicing the steer cylinder, see REAR

AXLE section.

99759-7B110
6.3
STEERING SYSTEM

Inspection after Removal

1. Inspect the grommets for cracks or tears in
the rubber or for signs of aging. Check the
O-rings for damage.

Installation
To install, follow the reverse order of the removal
sequence. Tighten bolts to the specified torque
2.9 ± 0.3 kgf•m
Tightening torque for bolts (20.9 ± 2.1 lbf•ft)
[28.4 ± 2.9 N•m]

99759-7B110
6.4
STEERING SYSTEM

Steering Gear
Disassembly

99759-7B110
6.5
STEERING SYSTEM

Steering Gear Disassembly

Working Rules and Tips
The steering gear is a precision-machined compo- 1. Remove the plug and inlet relief valve.
nent, so it must be handled with extreme care.
Cleanliness is Imperative: work in a clean place NOTE
and use clean tools.
1. Before disconnecting the hydraulic lines, clean The manual steering check is part of the
the port area of the steer gear unit. inlet relief valve. If inlet relief valve is not
2. Before disassembly, drain the oil and then plug present, the manual steering check is in
the ports and thoroughly clean the exterior of the housing.
the steer gear unit.
3. Clean the disassembled parts with a volatile sol-
2. Remove the four cap screws and the end cap
vent such as trichlene or chlorobenzene, and
and disassemble the the steer gear.
dry them with compressed air. This does not
3. Slide the spool and sleeve from the housing.
apply to rubber parts.
4. Remove the thrust bearing and bearing races.
4. Oil seals, O-rings, and the like are rubber
5. Remove the seal.
parts. Never clean them with solvents. Blow
6. Using a small blade screwdriver, carefully pry
dirt off rubber parts with compressed air and
the dust seal from the housing.
keep them immersed in a pool of hydraulic oil
7. Remove the pin that holds the spool and
until they are ready for reassembly. A rubber
sleeve together.
part showing even slight wear and tear must
8. Carefully slide the spool out of the sleeve. The
be replaced. Rubber parts are expendable
springs and retaining ring will stay with the
components that should be replaced once a
spool as it’s removed.
year.
9. Remove the retaining ring and springs.
5. Parts that need to be installed by pressing or
forcing need special treatment.
a. Oil Seals ! CAUTION
Oil seals, once removed, must not be The centering springs are under tension;
reused. After disassembly, examine the oil remove the retaining ring carefully.
seals in place. If they are in good condi-
tion, leave them in place. When installing a
replacement oil seal, be careful not to Inspection after Disassembly
score or scratch the lip area.
1. Check all mating surfaces. Replace any parts
Suggestions: that have scratches or burrs that could cause
leaks.
The steer gear is designed with very few servicea-
ble components. Only disassemble the steer gear 2. Clean all metal parts in clean solvent. Blow
if you plan to replace one of the following: dry with air. Do not wipe dry with cloth or
1. Dust Seal paper towels because lint or other matter can
2. Pressure Seal get into the hydraulic system and cause dam-
3. O-rings age. Do not use a coarse grit or try to file or
4. Thrust Race and/or Bearings grind these parts.
If replacing these parts does not improve per-
formance, you must replace the entire steer
gear assembly. Refer to your parts manual for
ordering information.
6.6 99759-7B110
STEERING SYSTEM

Steering Gear Reassembly

Suggestions
9. Apply a light coating of clean hydraulic fluid to
NOTE the spool and sleeve assembly and slide it into
the housing. Important: Do not damage the
DO NOT disassemble the steer gear
dust or quad seals.
further than required to replace
10. Clamp the housing in a vise. Use just enough
serviceable components. Doing do may
clamping force to hold the housing securely.
result in replacing entire gear.
11. Install manual steering check ball and pin into
housing, if no relief valve is present.
NOTE 12. Lubricate and install a new o-ring seal in the
groove in the housing.
Always use new seals when reassembling 13. Install the wear plate and align the timing groove
hydraulic steer gear units. on plate with the timing groove on the housing.
14. Install the drive, be sure the slot in the drive
NOTE engages the pin.

During reassembly lubricate the new seals NOTE

with petroleum jelly. Lubricate machined
surfaces and bearings with clean The holes in the wear plate are not
hydraulic fluid. symmetrical.

1. Install the quad seal

• Put one of the bearing races and sleeve into the 15. Lubricate and install a new o-ring and seal
housing. ring in the groove in the wear plate.
• Together, the housing and bearing race create a 16. Install the gerotor and align the timing groove
groove into which the quad seal will be installed. with the timing groove in the wear plate.
• Hold the bearing race tightly against the input 17. Lubricate and install a new o-ring seal in the
end of the housing by pushing on the gerotor groove in gerotor ring.
end of the sleeve. 18. Lubricate and install a new o-ring and seal
• Fit the quad seal into its seat through the input ring in the groove in the gerotor star.
end of the housing. Be sure the seal is not twisted.
19. Install the spacer.
• Remove the sleeve and the bearing race.
20. Install end cap and four cap screws. Align tim-
2. Lubricate and install the dust seal. ing groove on end cap with timing groove on
3. Install the centering springs in the spool. It is gerotor. Tighten cap screws in a criss cross
best to install the two flat pieces first. Next, pattern, to 16 – 18 Nm [250 lb-in].
install the curve pieces, three at a time. 21. Install the relief valve/check if present. Use a
4. Fit the retaining ring over the centering new o-ring and tighten the plug to 17 Nm [150
springs. lb-in].
5. Apply a light coating of clean hydraulic fluid to the 22. Remove the steering gear from the vise.
spool and slide it into the sleeve. Be sure the 23. Check the steering gear and confirm that all
centering springs fit into the notches in the sleeve. timing grooves are in line.
6. Install the pin.
7. Apply a light coat of petroleum jelly to the NOTE
inner edge of the dust and quad seals.
8. Put the thrust bearing and races into the hous- If timing grooves are not aligned properly,
ing. The thrust bearing goes between the two steering gear will not operate properly.
races.
99759-7B110
6.7
STEERING SYSTEM

Steer Pump
Removal

Sequence
1. Motor mounting bracket 3. Motor 5. Pump
2. Motor mounting hardware 4. Pump mounting hardware

Start By:
1. Remove the battery.
2. Remove the acid tray.
3. Disconnect the cables and wires from the
steer pump motor. Mark the wire leads and
cables so they can be correctly reconnected.
4. Disconnect the hydraulic lines from the pump.

99759-7B110
6.8
STEERING SYSTEM

Suggestions Installation
Removing the Motor and Pump Assembly 1. To install, reverse removal sequence.
After disconnecting the steer pump hoses, motor
cables, and harness leads, remove the pump and
motor assembly by removing the motor bracket
mounting hardware where the bracket is bolted to
the frame.

Removing the Pump

Remove the pump from the motor.

99759-7B110
6.9
STEERING SYSTEM

Disassembly

4
2

6 7

3
5
1

Sequence
1. Cover and mounting bolts 5. Rotor and vanes
2. O-ring 6. Retaining ring
3. Spring and Pressure plate 7. Shaft and bearing
4. Ring and locating pins 8. Body, O-ring, and seal

99759-7B110
6.10
STEERING SYSTEM

Working Rules and Tips Suggestions

The steer pump is a precision-machined compo- Removing the Motor and Pump Assembly
nent and must be handled with extreme care. Disconnect the steer pump hoses, motor cables,
Cleanliness is imperative: use clean tools and and harness leads. Remove the pump and motor
work in a clean place. assembly by removing the motor bracket mounting
1. Clean the disassembled parts with a volatile hardware where the bracket is bolted to the frame.
solvent such as trichlene or chlorobenzene
and dry them with compressed air. This does Removing the Pump
not apply to rubber parts. Remove the pump from the motor.
2. Oil seal, O-rings, and the like are rubber parts. Removing The Pump Cover
Never wash them with solvent. Blow dirt off
rubber parts with compressed air and keep Remove the four bolts holding the rear cover on
immersed in a pool of hydraulic oil until they the pump. Remove the cover. Remove the O-ring
are ready for reassembly. A rubber part show- located in the groove of the cover.
ing even slight wear and tear must be
replaced. Rubber parts are expendable com-
ponents and should be replaced yearly.
3. Parts to be installed by pressing or forcing
need special treatment.

Oil Seals
An oil seal, once removed, must not be reused.
After disassembly, examine the oil seal in place
(in the housing) and, if in sound condition, leave it 8609075
in place. When installing a replacement oil seal,
be careful not to score or scratch its lip portion.
Removing the Spring
Lift the spring off the pressure plate.

8609076

99759-7B110
6.11
STEERING SYSTEM

Removing the Pressure Plate Removing the Retaining Ring

Lift the pressure plate off of the ring and remove The shaft and bearing assembly is held in place
the two locating pins from the ring. by an internal retaining ring on the driven end of
the pump. Remove the retaining ring using a stan-
dard retaining ring tool.

8609077

Retaining
Removing the Rotor and Vanes
Ring
Remove the rotor and the vanes. Take care not to
lose any of the vanes.
8609080

8609078

Removing the Ring

Lift the ring off of the pump body.

8609079

99759-7B110
6.12
STEERING SYSTEM

Removing the Shaft and Bearing Removing the Seal and O-ring
1. Tap the end of the shaft very lightly to remove 1. Examine the shaft seal in place in the housing.
it from the pump body. Take extreme care not If it is in sound condition, do not attempt to
to damage the end of the shaft. remove it. Instead, use it as part of the rebuilt
2. Remove the external retaining ring from the unit. If there is any damage to the seal,
shaft to allow removal of the bearing. Tap the remove it and do not reuse it.
end of the shaft very lightly to separate the 2. Remove the O-ring from the slot in the body.
bearing from the shaft. Take extreme care not
to damage the end of the shaft.

8609082

8609081
Inspection after Disassembly
1. Check all mating surfaces. Replace any parts
that have scratches or burrs that could cause
leaks.
2. Clean all metal parts in clean solvent. Blow
dry with air. Do not wipe dry with cloth or
paper towels because lint or other matter can
get into the hydraulic system and cause dam-
age. Do not use a coarse grit or try to file or
grind these parts.

99759-7B110
6.13
STEERING SYSTEM

Reassembly

5
7
8

8609083

Sequence
1. Body and seal 5. Rotor and vanes
2. Shaft and bearing 6. Pressure plate
3. Retaining ring 7. Spring
4. Ring 8. Cover

99759-7B110
6.14
STEERING SYSTEM

Suggestions Reassembling the Shaft and Bearing

Press the bearing onto the shaft and secure it
with the external retaining ring.
NOTE

Replace all old seals with new seals.

Lubricate all seals with clean petroleum
jelly such as Vaseline.

Reassembling the Shaft Seal

1. Install the seal in the housing, orienting the
seal lip as shown. Take care not to damage
the seal during installation.
8609085
2. The seal must be bottomed against the shoul-
der when installed.
Reassembling the Shaft and Body
Install the shaft and bearing assembly into the
body, taking care not to damage the shaft seal
during installation. Secure the shaft by installing
the retainer ring.

8609084

Retaining
ring

8609086

99759-7B110
6.15
STEERING SYSTEM

Reassembling the Ring Reassembling the Pressure Plate

Press the O-ring into the groove in the body. Place Install the pressure plate by slipping it over the
the ring on the body, aligning the bolt holes and two pins
the pin holes. Install the two pins through the ring
and into the body.

8609089

8609087
Reassembling the Spring
Slip the spring over the spring seat of the pres-
Reassembling the Rotor and Vanes
sure plate.
Slip the rotor over the splined portion of the shaft.
Insert a vane in each of the slots in the rotor.

8609090

8609088

99759-7B110
6.16
STEERING SYSTEM

Reassembling the Cover Inspection after Reassembly

1. Press the O-ring into the groove in the cover.
Check the pump for smooth, free rotation. Check
Place the cover on the ring and align the four
for leaks after reinstallation in the truck.
bolt holes. Take care to properly orient the dis-
charge port to its original position prior to
assembly.
2. Install and tighten the cover bolts.

8609091

4.8 to 6.2 kgf•m

Tightening torque for cover bolts (35 to 45 lbf•ft)
[47 to 61 N•m]

99759-7B110
6.17
NOTES

Chapter 7: Hydraulic System

Hydraulic System
Description ................................................................................................................................... 7.1
Schematics .............................................................................................................................. 7.1
Hydraulic Tank.......................................................................................................................... 7.5
Hydraulic Pump ....................................................................................................................... 7.6
Control Valve ............................................................................................................................ 7.8
Lift and Tilt Cylinders................................................................................................................ 7.9
Down Safety Valve ................................................................................................................... 7.10
Removal and Installation Warning................................................................................................ 7.11
Hydraulic Pump
Removal ....................................................................................................................................... 7.12
Installation .................................................................................................................................... 7.13
Disassembly ................................................................................................................................. 7.14
Working Rules and Tips ........................................................................................................... 7.14
Suggestions ............................................................................................................................. 7.16
Inspection after Disassembly ....................................................................................................... 7.18
Body ......................................................................................................................................... 7.18
Mounting Flange Face ............................................................................................................. 7.18
Bushes and Balance Plate....................................................................................................... 7.18
Gears ....................................................................................................................................... 7.18
Reassembly.................................................................................................................................. 7.19
Inspection after Reassembly........................................................................................................ 7.23
Control Valve
Removal ....................................................................................................................................... 7.24
Installation .................................................................................................................................... 7.25
Disassembly ................................................................................................................................. 7.26
Suggestions ................................................................................................................................. 7.27
Reassembly.................................................................................................................................. 7.27
Lift and Tilt Cylinders
Removal
Lift Cylinders ............................................................................................................................ 7.28
Tilt Cylinders ............................................................................................................................ 7.31
Disassembly
Lift Cylinders ............................................................................................................................ 7.33
Tilt Cylinders ............................................................................................................................ 7.34
Inspection after Disassembly ....................................................................................................... 7.35
Precautions for Reassembly ........................................................................................................ 7.35
Inspection and Adjustment
Hydraulic Tank.............................................................................................................................. 7.36
TABLE OF CONTENTS

Control Valve ................................................................................................................................ 7.37

Lift and Tilt Cylinders.................................................................................................................... 7.40
Adjusting Method ..................................................................................................................... 7.41
Testing ...................................................................................................................................... 7.42
HYDRAULIC SYSTEM

Hydraulic System
Description
Schematic for Trucks

1. Hydraulic tank 4. Steer gear 7. Down safety valve 10. Steering cylinder
2. Hydraulic lift pump 5. Main control valve 8. Lift cylinder
3. Steer pump 6. Flow regulator valve 9. Tilt cylinder

General Information
The hydraulic pump draws oil from the oil tank
and delivers it to the main control valve, which dis-
penses it for lift and tilt functions.
The steer gear and steer pump are covered in the
STEERING SYSTEM section and the steering
cylinder is covered in the REAR AXLE section.

99759-7B110
7.1
HYDRAULIC SYSTEM

Hydraulic Tank
1

6 5

4
3 8609093

1. Cap 3. Drain plug 5. Suction line strainer

2. Oil level gauge 4. Return line filter 6. Lift cylinder pipe

General Information
The tank contains internal filtering means including
a strainer on the suction line and a filter on the
return line.
The lift cylinder return pipe allows the cylinders to
draw fluid when they retract, providing the bore
walls with oil which inhibits corrosion.

99759-7B110
7.5
HYDRAULIC SYSTEM

Hydraulic Pump

8609094A

General Information
This gear pump is capable of developing very high
pressure on its discharge side. A special arrange-
ment is incorporated in the pump construction for
the purpose of keeping the side clearances mini-
mized between bushings on the one side and
pump gears on the other. Note, in illustration
203585 (page 7.6), that discharge pressure is
applied to the back of each bushing through inter-
nal oilways.

99759-7B110
7.6
HYDRAULIC SYSTEM

Hydraulic Pump Operation Pressure Loading Principle

Essentially the pump consists of two gears—the This pump is a self-balanced type based on the
drive gear and the driven gear—closely fitted in principle of pressure loading, balancing for equal
the housing. The oil is carried around the periph- pressure on all sides of the revolving gear. This
ery of the revolving gears from the suction to the reduces bushing and gear wear. In operation, the
discharge side. The teeth meshing between the high-pressure oil on the discharge side is fed back
two gears prevents the return of oil from the dis- to the suction side. On the suction side, pressure
charge to the suction side. is exerted equally on both sides of the gears and
shafts, thereby cancelling out unequal pressure to
balance the pump.
Driven Gear
Clearance

Drive Gear
203585

Discharge side
200333

99759-7B110
7.7
HYDRAULIC SYSTEM

Control Valve
9 8 7
10

2 6

3 6

11
12 13

Sequence
1. Inlet / Unloader Spool 8. From Hydraulic Pump
2. Tilt Spool 9. To Tank
3. Auxiliary Spool 10. Main Relief Valve, Auxiliary Valve (back)
4. Auxiliary Attachment Spool 11. Auxiliary Relief Valve (front)
5. Outlet Spool 12. Tie bolt
6. Flow Control Screws 13. Nut
7. Lift Port 14. Switches

General Information
The control valve consists of three valve blocks, all
spool-type. The spools are finished by lapping for
their respective blocks and their combination
should not be changed. The lift valve assembly has
a built-in load check valve. The tilt valve spool has
a built-in tilt lock valve. The attachment valve
assembly has a built-in overload relief valve.

99759-7B110
7.8
HYDRAULIC SYSTEM

Lift and Tilt Cylinders

200345

205979

General Information
The left and right lift cylinders are single-acting
type.
The left and right tilt cylinders are double-acting
type. The piston rod carries a screw-on socket.
The socket is repositioned as necessary by turn-
ing when the cylinder is connected to the outer
mast. This feature allows the tilt cylinders to move
in unison.
The tilt angle is increased or decreased with the
spacer and shim of each cylinder.

99759-7B110
7.9
HYDRAULIC SYSTEM

Down Safety Valve

Burst

Normal When hose burst

204971

General Information
The down safety valve is built in the oil pipe joint at
the bottom end of the lift cylinder. This valve is
internally provided with an orifice to prevent shock
when the valve is closed. In the valve having no ori-
fice, the oil leaks around the valve to prevent
shock.

Valve Types
Down safety valves are available in six types differ- a
ing in terms of shutoff flow and identified by the
number punched on the flat (indicated as “a” on
illustration 201731A). The numbers are: 50, 70, 90,
100, 120, and 150. No. 90 and No. 120 valves each
come in two kinds differing in screw thread size. a

Truck Dual stage Dual-stage full Triple-stage full

panoramic free-lift panoramic free-lift panoramic
1st lift 2nd lift 1st lift 2nd lift
cylinder cylinder cylinder cylinder 201731A

FBC15N -
FBC18LN 70 90 70 90 70 Top View: • Dual-stage panoramic lift cylinder
FBC20N - • Dual-stage full free-lift panoramic,
FBC25EN 70 120 70 120 70
FBC25LN - 1st and 2nd cylinders
FBC30LN 90 90 120 120 90 • Triple-stage full free-lift panoramic,
2nd lift cylinder
Bottom View: • Triple-stage full free-lift panoramic
1st lift cylinder
99759-7B110
7.10
HYDRAULIC SYSTEM

Removal and Installation

Warning

! WARNING

Hydraulic oil under pressure can remain in

the hydraulic system after the truck and
pump have been stopped. To avoid
personal injury, this pressure must be
released before any work is done on the
hydraulic system.
To prevent possible injury, lower the lift
bracket to the ground, turn the truck off,
and move the control levers to make sure
all hydraulic pressure is released before
any fitting, plug, or hose is loosened,
tightened, removed, or adjusted.
Always move the forklift truck to a clean
and level location away from the path of
other machines.
Be sure that no personnel are near the
machine when the truck is running and
tests or adjustments are being made.

99759-7B110
7.11
HYDRAULIC SYSTEM

Hydraulic Pump
Removal

Sequence
1. Hardware
2. Pump

Start By:
1. Disconnect the battery from the truck. 5. Secure the motor from above with a crane,
hoist, or other adequate device, or support it
2. Disconnect the hoses attached to the pump
at its center with a garage jack.
fittings.
6. Remove the motor and pump assembly from
3. Disconnect the power cables and wire leads
the truck.
from the pump motor.
7. Remove the hydraulic fittings from the pump.
4. Raise the truck enough to allow the pump and
motor assembly to be removed from below the
truck. Make sure that the truck is stable and
secure in the raised position.

99759-7B110
7.12
HYDRAULIC SYSTEM

Installation
1. To install, follow the reverse sequence of the
disassembly procedure. Before installing
hydraulic fittings in the pump, inspect all
O-rings for damage or aging and replace
them as required.
2. Tighten hose to the following specifications.

Tightening Torque for Hose

FBC15N-FBC18LN FBC20N-FBC30LN

Supply hose from 6.5 ± 0.7 kgf•m 10.3 to 11.7 kgf•m

pump to mast (48 ± 5 lbf•ft) (74 to 85 lbf•ft)
operating valve [65 ± 7 N•m] [101 to 115 N•m]

3. Lube pump splines before installing into pump

motor. Use molybdenum disulfide grease.

HYDRAULIC PUMP APPLICATIONS

97E71-00030 97E71-00040 97271-00700
23cc 25cc 29cc
Pump Cast-Iron Gear Cast-Iron Gear Cast-Iron Gear
Market Models UL Motor Voltage w/ bronze wear pl. w/ bronze wear pl. split gear (quiet)
FBC15N-FBC18LN E & ES 8" DC & AC 36/48
No. Am.
FBC20N-FBC30LN E & ES 9" DC & AC 36/48
Europe FBC15N-FBC18LN N/A 8" AC 36/48
FBC20N-FBC30N N/A 9" AC 36/48
FBC15N-FBC18LN EE 8" DC & AC 36/48
FBC20N-FBC30LN EE 9" AC 36/48
No. Am. FBC20N, FBC25N, FBC25EN EE 9" DC 36/48
FBC25LN, FBC30N, FBC30LN EE 9" DC 36/48

99759-7B110
7.13
HYDRAULIC SYSTEM

Disassembly
Standard Pump (1 ton)

5
3

1
4

7
9
6

Sequence
1. End cover 4. Shaft seal and retainer ring 7. Drive shaft
2. O-ring, bush seal, and 5. O-ring, bush seal, and 8. Gear pack
back-up seal back-up seal 9. Body and rear bushes
3. Flange 6. Front bushes

Working Rules and Tips

The hydraulic pump is a precision-machined com- Oil Seal
ponent and as such must be handled with extreme An oil seal, once removed, must not be reused.
care. Cleanliness is imperative: use clean tools and After disassembly, examine the oil seal in place (in
work in a clean place. the pump flange) and, if in good condition, leave it
1. Clean the disassembled parts with a volatile in place. When installing a replacement oil seal,
solvent such as trichlene or chlorobenzene be careful not to score or scratch its lip portion.
and dry them with compressed air. This does
not apply to rubber parts.
2. Oil seals, O-rings, and the like are rubber
parts. Never clean them with solvent. Blow
dirt off rubber parts with compressed air, and
keep them immersed in hydraulic oil until they
are ready for reassembly. A rubber part show-
ing even slight wear and tear must be
replaced. Rubber parts are expendable items
that should be replaced once a year.
3. Parts that are installed by pressing or forcing
need special treatment.

99759-7B110
7.14
HYDRAULIC SYSTEM

Disassembly
Standard Pump (2/3.3 ton)

1 5

9
4
7
6

Start By:
Externally clean the pump to make sure that it is free
of all matter that may contaminate the pump parts
during disassembly, inspection, or reassembly.

99759-7B110
7.15
HYDRAULIC SYSTEM

Suggestions Removing the Flange

Removing the End Cover Turn the unit over and lightly tap the mounting
flange to disengage it from the locating dowels.
1. Lightly mark the end cover, pump body, and
Slide the flange squarely off the shaft.
mounting flange to ensure proper reassembly.
2. Remove the rear bolts, spring washers, and
the end cover.

Removing the Seals

Remove the O-ring from the pump body. Remove
the bush seal and the backup seal from the rear
bushings.

8609101

Removing the Shaft Seal

Remove the internal retaining clip in the front of
the flange. Push the shaft seal squarely out of the
mounting flange.

8609100

8609102

99759-7B110
7.16
HYDRAULIC SYSTEM

Removing the O-ring and Seals Separating the Gear Pack

Remove the O-ring from the groove in the body of 1. Separate the gears, key, and balance plate
the pump. Remove the bush seal and the backup from the drive shaft and driven idler shaft.
seal from the front bushings. 2. Note the position of the balance plate to
ensure proper location during reassembly.

Removing the Rear Bushes

Remove the remaining rear bushes from the body
bore.

8609103

Removing the Bushings

Before removing the internal components, mark
the bushings to denote the location in the body on
8609105
a plain area away from the seal location mark.
FD = Bush on flange end of the drive shaft
FI = Bush on flange end of idler shaft
CD = Bush on the cover of priority valve end
of the drive shaft
CI = Bush on the cover end of the idler shaft

Removing the Drive Shaft

With the unit lying on its side, hold the drive shaft
and pull it squarely out of the body, bringing with it
the bushings and the complete gear pack.

8609104

99759-7B110
7.17
HYDRAULIC SYSTEM

Inspection after Disassembly 3. The bush bearing liners are acceptable if they
are not scored or do not show other damage.
Body The general outside area of the bush should
not show any prominent signs of wear.
1. Inspect the body bore cut-in where gears wipe
into the body. Gears
2. The body can only be reused if the cut-in is
1. The gear side faces should be examined for
bright and polished in appearance and the
bushing or scoring. Often operation on con-
depth does not exceed .08 mm.
taminated fluid shows scoring between the
3. The body should be replaced if the surface is root of the gear and the journal, which leaves
scored, has a matte appearance, or shows a wear step. If a wear step can be felt, coinci-
signs that the tips of the gears have dug in dental with the root diameter, by drawing a
and torn away the surface material. sharp-pointed tool across the surface from the
4. The body should be inspected to ensure that journal outward towards the tip of the gear,
there is no superficial damage which may then the gear must be replaced.
adversely affect performance or sealing. Pay 2. The gear teeth should be carefully examined
particular attention to the port threads and to ensure that there are no signs of bruising or
body O-ring seal recesses. pitting.
3. The journal bearing surfaces should be com-
Mounting Flange Face
pletely free from scoring or bruising. The sur-
1. The inner surfaces should be inspected to face should be highly polished and smooth to
ensure that there is no unusual wear or scoring the touch.
in the regions where the body O-rings and bush
4. Examine the area where the shaft seal lips run
seals contact, which could result in external leakage.
on the drive shaft. This shows up as polished
2. Check the shaft seal recess for scoring or dam- ring or rings. If a noticeable groove can be felt,
age that could result in oil leakage around the or if there is scoring, the shaft should be
outer diameter of the shaft seal. A replacement replaced.
shaft seal can be refitted with Loctite hydraulic
5. Examine drive keyway in driveshaft journal
sealant to overcome slight damage in this area.
extension to ensure it is not damaged or
chipped.
Bushes and Balance Plate
6. If the driveshaft is not damaged from the drive
1. The side faces which abut the gears should be coupling and the gears have not been harmed
perfectly flat and show no signs of scoring. as described above, then the gears can be
Characteristically there are bright polished reused. If the gears are damaged, they must
areas on this surface caused by loading be replaced as a matched set.
against the gear side faces. This is often more
pronounced on the low-pressure side. These 7. As a matter of good practice, when pumps
should be replaced if there is any general have been dismantled, all the seals should be
scoring or fine scoring with a matte appearance replaced.
or tearing of the surface material.
2. Often, the tips of the opposing gears have
wiped an overlap in a half-moon shape. There
must be no noticeable wear step as it is criti-
cal that the bush side face and balance plate
are completely flat to the gear side face.

99759-7B110
7.18
HYDRAULIC SYSTEM

Reassembly
Trucks with Standard Hydraulic Pump

5
3

1
4

7
9
6

Start By:
Ensure that all parts are perfectly clean. Lubricate
the bushes and gears with clean hydraulic fluid.
Ensure that the O-ring recess and end faces of the
body remain dry. This will assist the assembly of
the components with the body bores.

99759-7B110
7.19
HYDRAULIC SYSTEM

Reassembling the Rear Bushes Fixturing with the End Cover

1. Install the rear bushes (marked CD and CI) Use the end cover to temporarily fixture the parts
into the undowelled end of the body. as they are reassembled. Place the end cover on
its back and set the undowelled end of the body
against it so that the dowels are pointing up.

Reassembling the Balance Plate

1. Hold the driveshaft and driven gear of the idler
shaft together and refit the balance plate in its
original position.
2. The two grooves in the plate must be to the
low-pressure side of the pump (the side where
the body bores meet in a point). With the drive
8609107 shaft nearest to you, these grooves will be on
the left-hand side as shown for the counter-
2. The C-shaped cutout in the bushes must be to clockwise rotation.
the side of the body with the cusp removal flat.
3. The diagram below shows the location of the
driveshaft and the front bushes and seals
installed.

Location Flange end

dowels

Cusp
Removal
Inlet 8609109

Position of
driveshaft

Counterclockwise Rotation
8609108

99759-7B110
7.20
HYDRAULIC SYSTEM

Reassembling the Gear Pack Reassembling the O-ring and Seals

1. Fit the key into the keyway in the driveshaft Fit a new O-ring, bush seal and backup seal,
and then carefully fit the gear over the key. Fit ensuring that the seals locate correctly in the seal
the second gear on the idler shaft. grooves.
2. Keeping the gear pack together, carefully feed
the assembly into the body bores with the
driveshaft positioned as previously shown.

8609112

Reassembling the Shaft Seal

8609110

Premium pump configuration 1. Fit a new shaft seal into the recess in the
mounting flange with the “garter” spring facing
into the pump.
2. If the seal recess was scored, then Loctite
hydraulic sealant must be applied to the outer
diameter of the seal.
3. Apply a coat of high-melting-point grease to
the shaft seal lips.
4. Reinstall the retaining ring. Ensure that it is
located in its groove.

Standard pump configuration

Reassembling the Front Bushes

Refit the front bushes (FD and FI) into their origi-
nal bores, remembering that the C-cutout must be
to the side of the body with the cusp removal flat.
They must match the rear end bushes.

8609102

8609111

99759-7B110
7.21
HYDRAULIC SYSTEM

Reassembling the Flange Reassembling the End Cover:

Slip the shaft seal and flange assembly over the Replace end cover and refit the bolts and wash-
driveshaft and carefully refit the mounting flange, ers. Tighten the bolts.
ensuring that it is positioned squarely onto the
dowels in the body.

End
cover

8609115A
8609113

Reassembling the Rear O-ring and Seals FBC15N - FBC18LN FBC20N - FBC30LN
1. Hold the whole unit together and carefully turn 4.7 to 5.2 kgf•m 9.0 to 10.4 kgf•m
it over. Ensure that it is supported on the Tightening torque (34 to 38 lbf•ft) (65 to 75 lbf•ft)
mounting flange, not the driveshaft. for bolts [46 to 51 N•m] [88 to 102 N•m]
2. Remove the end cover and install a new O-
ring, bush seal, and backup seal.

NOTE

Lube splines before installing in pump

motor. Use molybdenum disulfide grease.

8609114

99759-7B110
7.22
HYDRAULIC SYSTEM

Inspection after Reassembly

Pour a small amount of clean hydraulic fluid into a It is recommended that, initially, the unit is run in at
port and check that the shaft can be rotated with- 1500 rpm at zero pressure for one minute. The
out undue force using a smooth-jawed vise. pressure should then be increased in intervals of
35 bars a minute until maximum pressure is
Running In After Reassembly reached. Check the system temperature frequently,
A unit which has been reassembled with either new ensuring that it does not exceed the maximum per-
gears, bushes, or body, must be carefully run in missible temperature of 80°C. If the temperature
before it is subjected to full working conditions. exceeds the system or unit specification, the test
must be delayed and operated off-load until the
Ideally, this should be done on a test rig, where
temperature is lowered to an acceptable range.
pressure can be applied gradually and any wipings
Typical pump ratings are shown in the table below.
from the body cut-in can be arrested by filters.

Pressure
Test gauge
unit Micronic Variable
filter restrictor

Flow
Strainer Relief meter
Tank
valve

Typical pump test circuit

8609116

Typical performance applicable when using

ISOVG 32 at 40°C (104°F)
Pump Part Test Speed Max. Flow Rate
Number Continuous
Pressure
97L71-00030 1500 rpm [180 bar] 9.11 GPM
(2683 psi) 32.1 L/min
204 kg/cm2
97L71-00040 1500 rpm [180 bar] 9.91 GPM
(2683 psi) 34.2 L/min
209 kg/cm2
97271-00700 1500 rpm [185 bar] 11.49 GPM
(2683 psi) 43.5 L/min
204 kg/cm2

99759-7B110
7.23
HYDRAULIC SYSTEM

Control Valve Removal

Sequence Start By:

1. Auxiliary lines 1. Remove the floorplates and the front
2. Tilt lines, connectors, and O-rings dashboard cover.
3. Delivery hose, connector, and O-ring 2. Tilt the mast to vertical position, lower the forks
4. Return Hose
all the way, and relieve the pressure in the
5. Lift hose and connector
6. Steering return hose hydraulic lines.
7. Solenoid 3. Disconnect the battery.
8. Lower Switch 4. Disconnect the wire leads to the valve
9. Control Valve
switches.
10. Steering Return Connector
11. Switches 5. Disconnect the hydraulic lines per the listed
sequence solenoid, and lower switch.
6. Remove the 3 mounting bolts from the front of
the dash.
7. Remove the valve from the truck.

99759-7B110
7.24
HYDRAULIC SYSTEM

Control Valve Installation

1. To install, follow the reverse of the Tightening Torque for Hoses

disassembly sequence. Before installing
25 ± 0.5 N•m
hydraulic fittings, inspect all O-rings for A Tilt hoses 2.5 ± 0.5 kgf•m
damage or aging and replace them as 18 ± 3.6 lbf•ft
required. 65 ± 7 N•m
B Delivery hose 6.5 ± 0.7 kgf•m
2. Tighten hoses to the specifications shown in
47 ± 5 lbf•ft
the chart. 82 ± 8 N•m
C Lift Hose 6.5 ± 0.7 kgf•m
47 ± 5 lbf•ft
82 ± 8 N•m
D Aux Hoses 5.0 ± 0.5 kgf•m
36.2 ± 3.6 lbf•ft
Steer Gear 48 ± 5 N•m
E Return Connector 5 ± 0.5 kgf•m
36.2 ± 3.6 lbf•ft
98 ± 10 N•m
F Return Connector 10 ± 1.0 kgf•m
72 ± 7.2 lbf•ft

99759-7B110
7.25
HYDRAULIC SYSTEM

Disassembly

99759-7B110
7.26
HYDRAULIC SYSTEM

Suggestions Reassembly
Main Relief Valve Before Reassembly:
1. Wash all parts except for O-rings with solvent.
NOTE
2. Apply hydraulic oil to O-rings when installing
To remove main relief valve for cleaning or them.
inspection, loosen its plug. Loosening the 3. Make sure that each spool moves freely.
lock nut will disturb the pressure setting.

1. Lay out valve components on a clean, flat

Do not remove the main relief valve unless it is
working surface. The inlet assembly will
defective. This also applies to shut-off valve
include an o-ring, and the spool sections
assembly.
include an o-ring, a load check poppet and a
load check spring. Tools required for basic
Plug valve assembly include 1/2” and 9/16” open or
box end wrenches and a torque wrench with
thin wall sockets.
2. Assemble tie rod nuts to one end of each tie
rod with one or two threads showing. Insert
Lock nut rods through tie rod holes of inlet (larger tie
rod at top). Lay inlet on end with tie rods up,
place o-ring into position.
205025 3. Place first spool section (o-ring side up) on
inlet section, position o-ring and insert load
check poppet (nose down) and spring (behind
Auxiliary Relief Valve poppet) into load check cavity as shown.
Repeat this procedure for each spool section;
the load check springs are compressed by the
NOTE
following sections during assembly.
To remove auxiliary relief valve for 4. Position end section on last spool section and
cleaning or inspection, loosen its plug. hand tighten tie rod nuts. The end section is a
Loosening the lock nut will disturb the “turn around” section without ports. Universal
pressure setting. outlet / power beyond section and power
beyond and closed center sections are also
used as end sections. These end sections do
Do not remove the auxiliary relief valve unless it is
not have o-ring grooves.
defective. This also applies to shut-off valve
assembly. 5. Position valve assembly with the mounting
pads of the end sections on a flat surface. To
obtain proper alignment of end sections rela-
Plug tive to the spool sections apply downward
pressure to the end sections; snug tie rod nuts
to about 10 ft-lb.
Final torque the two 1.2” nuts to 14 ft-lb; final
torque the 9/16” nut to 33 ft-lb. check for prop-
Lock nut er spool movement.
6. Install auxiliary valves and plugs and torque to
proper specifications
205025
99759-7B110
7.27
HYDRAULIC SYSTEM

Lift and Tilt Cylinders

Removal
Lift Cylinders

5 4

1
207068

Sequence
1. Hose guard 4. Cylinder clamp (cushion, collar, and shims)
2. High-pressure hose 5. Lift cylinder and bracket
3. Set bolt and shims

99759-7B110
7.28
HYDRAULIC SYSTEM

Suggestions
1. Removing hose guard:
With the lift bracket raised to the maximum
height, remove each hose guard from the front
side of the mast.

! CAUTION
Be careful not to touch the lift control
lever.

2. Lowering lift bracket:

Lower the lift bracket by carefully operating the
lift control lever.
3. Disconnecting high-pressure hoses:
Disconnect the high-pressure hoses at the
joints indicated by arrows. Use a container to
catch oil flowing out of the hoses.

Right-hand cylinder
Left-hand cylinder

204933

99759-7B110
7.29
HYDRAULIC SYSTEM

Removing Set Bolts Removing Lift Cylinders

1. Remove the set bolt at the top of each lift cylin- Attach a lift sling to the lift cylinder from the rear
der. Lift the inner mast to separate the cylinder side of the mast and remove the cylinder. Attach
rod ends. To lift the inner mast, clove-hitch a the sling before removing the cylinder clamp.
sling to the mast with protective wad.

204935
204934

NOTE Installation
The rod end of either lift cylinder is shim-
Lift Cylinders
adjusted to eliminate the difference in To install, reverse the removal sequence and do
stroke between the cylinders. Before the following steps.
removing the stopper bolts, make a record 1. Extend and retract the lift cylinders several
of the number of shims and the cylinder to times under no-load conditions to expel air
which the shims are fitted. from the cylinder circuits and to make sure the
cylinders move smoothly.
2. Place wood blocks under the inner mast and 2. Check the oil level in the hydraulic tank with
detach the sling. Use blocks strong enough to the oil level gauge.
support the mast. 3. Check that the lift height is correct.
4. After the lift cylinders or piston rods have been
replaced, check for difference in stroke
between the two cylinders (refer to MAST
AND FORKS).

202983

99759-7B110
7.30
HYDRAULIC SYSTEM

Removal
Tilt Cylinders

3
1

206883

Sequence
1. Tilt socket pin (spacer) 3. Cylinder pin (spacer)
2. Rubber hose (O-ring) 4. Tilt cylinder

Start By:
1. Lower the forks all the way and tilt the mast
fully forward.
2. Hitch lifting slings to the top crossmember of
the outer mast by passing them through the
round holes. Take up the weight of the mast
with a hoist.

Suggestions
1. Retracting piston rod:
207085
Remove tilt cylinder pin (item 1), and retract
the piston rod all the way.
2. Disconnecting hoses:
Disconnect hoses (item 2) from the cylinder at
the connectors. Use a container to catch oil
from flowing out of the cylinder. Attach caps to
the connectors of the cylinder to protect the
threads of the connectors and to prevent oil
from flowing out of the cylinder when the cylin-
der is removed.
99759-7B110
7.31
HYDRAULIC SYSTEM

Suggestions
Removing Tilt Socket
Later Version

! WARNING

If both tilt cylinders are to be removed at

the same time, make sure that the mast is
held either by a hoist or is securely
supported and held in place by blocks.

1
4

2 3 206883

1. Rubber hose
2. Tilt socket pin, bolt, washer
3. Tilt cylinder pin, bolt, washer
4. Tilt cylinder

NOTE

When the tilt cylinders are to be replaced,

it is necessary to adjust the cylinder
stroke and tilt.

99759-7B110
7.32
HYDRAULIC SYSTEM

Disassembly
Lift Cylinders

5
4

204948

Sequence
1. Bracket assembly 4. Piston rod, snap ring, holder, U-ring, nylon
heel, and piston ring
2. Holder, wiper ring, U-ring and O-ring
5. Cylinder tube
3. Bushing and bearing

Suggestions
Removing Piston Rod
Draw the piston rod out gently, taking care not to
damage the sealing members fitted to the piston.

200349

99759-7B110
7.33
HYDRAULIC SYSTEM

Disassembly
Tilt Cylinders
✱ Parts contained in seal kit

3
✱

1 ✱
✱
✱

1
207050

Sequence
1. Tilt socket, bushing, bolt, washer, nut, and 3. Piston rod, piston seal, and nut
grease fitting
4. Cylinder tube and bushing
2. Bushing, O-ring, dust seal, packing and
buffer ring

NOTE

Do not remove the tilt socket and cylinder

tube bushing unless they are defective.

Suggestions
Removing Bushing
1. Wrap the cylinder with a wad of cloth and hold
it in a vise. Using a wrench, remove the bush-
ing from the cylinder.
2. When removing the bushing from the piston
rod, be careful not to rub the buffer ring, pack-
ing, etc., against the threads of the piston rod.
200351

99759-7B110
7.34
HYDRAULIC SYSTEM

Inspection after Disassembly Precautions for Reassembly

Lift and Tilt Cylinders 1. Wash all parts clean, making sure that each
part is clear of any gritty particles.
Cylinder Tube
2. Before inserting the piston rod complete with
1. Check the bore wall for wear, grooving, the piston, apply hydraulic oil to the bore wall
scratch marks, and rusting. of the cylinder tube and to the sealing parts:
2. Check the welds for cracks. O-rings, U-rings, wiper rings, nylon heels, pis-
ton seals, dust seals, and packings—so they
Piston Rod will slide smoothly into the bore.
1. Check for deflection in the manner shown. 3. When clamping the cylinder tube in the vise in
order to run the head into the cylinder tube, be
careful not to distort the tube #4 and #117.
Before fitting the piston seal to the tilt cylinder
piston, squeeze the seal by hand 5 or 6 times
to soften it. Hold the piston steady by clamping
the rod in a vise and apply a small amount of
hydraulic oil to the seal. Fit a portion of the
seal to the groove and push the rest of the
seal into place a little at a time until the seal is
in the groove.
200319 4. Be sure to torque the nut, not the bolt when
re-installing the tilt cylinder.
2. Check for surface flaws such as grooving, Torque to 108 to 118 N•m; 11 to 12 kgf•m.
scratch marks, rusting, and wear. The rod
must be replaced if its threads show signs of
stripping or any other damage.

Packings and Rings

1. Check the packings and the lips of dust seals
for damage, distortion, and deterioration due
to aging.
2. Check each ring for deterioration due to aging.

200352

200353

99759-7B110
7.35
HYDRAULIC SYSTEM

Inspection and Adjustment

Hydraulic Tank NOTE
Hydraulic Oil A general rule: in any machine, regardless
1. Check the hydraulic oil in the tank for cleanli- of the mast-and-attachment combination,
ness. Oil appearing dirty or whitish (showing the oil level should not be above the “H”
more or less emulsification) must be changed. mark on the level gauge when the mast is
2. Refill capacities in the amount of oil required. all the way down.

Suction Strainer
! WARNING
Check the suction strainer for clogging or damage.
Remove the hydraulic tank filler cap only
after the truck has been stopped and the Return Filter
fill cap is cool enough to remove with your
bare hand. Check the return filter for clogging or damage.

Hydraulic Tank Refill Capacities

FBC15N - FBC18LN FBC20N - FBC25N FBC25EN - FBC30LN

18 (4.8) 24 (6.3) 30 (7.9)

Unit: liter (U.S. gal)

99759-7B110
7.36
HYDRAULIC SYSTEM

Control Valve

External Leakage
1. Check for oil leaks from the joint between 2. Quickly disconnect the oil return hose and
adjacent valve housings sealed by O-ring. start collecting the oil coming out of the valve
2. Check for oil leaks from the scrapers sealed from the oil return port A.
by O-rings.
3. Check for oil leaks from the screw
connections.

Internal Leakage
It is not practical to check the control valve alone
for internal leakage. The correct way to check the
control valve in place under normal operating con-
ditions follows.
The internal leakage to be checked includes leak-
age occurring at the lift spool, tilt spool, tilt lock A
valve, and check valves.
[Test oil temperature: approx. 50°C (122°F)]
Amount of oil collected 500 cc (30.5 cu. in.)
1. Pick up a load equal to the rated capacity. Lift for 15 minutes maximum
it approximately 1 meter (3 ft) high. Tilt the
mast forward 3° - 4° and turn off key.
3. If the tilt cylinders or lift cylinders drift (the mast
tilts forward or the fork lowers) excessively even
3° - 4°
though the amount of oil collected in 15 min-
utes is less than 500 cc (30.5 cu. in.), measure
the internal leakage of each cylinder. (The
measurement is the assembly standard and not
the service limit.)
approx.
1 meter
(3 feet)

203521A

99759-7B110
7.37
HYDRAULIC SYSTEM

Main Relief Valve Adjustment Auxiliary Relief Valve Adjustment

1. Screw in special tool (6V3965) pressure port 1. Screw in special tool (6V3965) pressure port
with o-ring into gauge port on valve (B). with o-ring into delivery hose port on valve(B).
2. Attach a pressure gauge capable of measur- 2. Attach a pressure gauge capable of measur-
ing up to 250 kgf•cm2 (3555 psi) [25,000 kPa] ing up to 250 kgf•cm2 (3555 psi) [25,000 kPa]
to the pressure port. to the pressure port.
3. Start the truck and move the control lever to 3. Start the truck and move the Auxiliary 1 con-
the backward tilt position and hold. If the relief trol lever to the far right position and hold. If
pressure reading is the relief pressure reading is
197 ± 3 kgf/cm2 158 ± 5 kgf/cm2
(2630 ± 50 psi) (2250 ± 71 psi)
[19,650 ± 34 kPa] [15,513 ± 490 kPa]
when the tilt cylinders reach the end of their the auxiliary relief valve setting is correct.
stroke, the main relief valve setting is correct.

B
A
C

4. If the setting is incorrect, loosen the lock nut of

4. If the setting is incorrect, loosen the lock (C) the adjusting screw and, while observing the
nut of the adjusting screw and, while observ- pressure gauge reading, slowly turn the
ing the pressure gauge reading, slowly turn adjusting screw in either direction until the
the adjusting screw in either direction until the gauge indicates the prescribed set value.
gauge indicates the prescribed set value. 5. While holding the adjusting screw, tighten the
5. While holding the adjusting screw, tighten the lock nut to secure the adjusting screw.
lock nut to secure the adjusting screw. 6. After securing the adjusting screw, recheck the
6. After securing the adjusting screw, recheck the setting.
setting. 158 ± 5 kgf/cm2
197 ± 3 kgf/cm2 Auxiliary relief valve setting (2250 ± 71 psi)
Main relief valve setting (2630 ± 50 psi) [15,513 ± 490 kPa]
[19,650 ± 34 kPa]

99759-7B110
7.38
HYDRAULIC SYSTEM

Basic Hydraulic Switch Adjustments Install switch on Tilt spool or Auxiliary spool per
Install switch on Lift spool per Photo 1. Adjust and Photo 3 centered on spool lobe. Adjust and torque
torque bolts on switches to 7 ± 1 in-lbs [0.79 N•m bolts on switches to 7 ± 1 in-lbs [0.79 N•m ± 0.11
± 0.11 N•m] (0.08 kgf•m ± 0.01 kgf•m). N•m] (0.08 kgf•m ± 0.01 kgf•m).

Switch 1 Switch has Switch 3 Switch acti-

to activate
vates once
before
leaving
reaching
point C
point A (the
(the spool
top of the
Groove).
A cam).
C

Photo 1 Photo 3

Install switch 2 on Lift spool per Photo 2 centered

on identification groove. Adjust and torque bolts on
the switches to 7 ± 1 in-lbs [0.79 N•m ± 0.11 N•m]
(0.08 kgf•m ± 0.01 kgf•m).

Switch 2

Switch has
to activate
before
reaching
B
point B (the
top of the
cam).

Switch 2

Photo 2

99759-7B110
7.39
HYDRAULIC SYSTEM

Lift and Tilt Cylinders NOTE

Mast Tilt Angle Adjustment
It is not necessary to adjust the forward tilt
1. Place machine in a horizontal position. angle, provided that the backward tilt
2. Tilt the mast all the way backward, and stop angle is properly adjusted.
the truck.
3. Measure the tilt angle of the mast at both sides.
4. To adjust the tilt angle, loosen bolt A of the tilt
cylinder socket, and adjust the cylinder stroke Forward/backward tilt angle 5° – 6°
by turning the rod on either cylinder so that
there is no difference in stroke between the
cylinders.
Lift Cylinder Stroke Adjustment
1. Slowly raise the inner mast and check the
stopping manner of the left and right piston
rods at the moment the inner mast reaches its
maximum lift height.

207054

Tightening torque 127 to 152

for tilt cylinder (13 to 15.5)
socket bolt [94 to 112] 204698

2. If the top of the mast rocks at that moment, it

should be adjusted with shims. Abnormal con-
ditions will appear as a time lag in stopping
between right- and left-hand piston rods and
rocking of the rod with a longer cylinder
stroke.

99759-7B110
7.40
HYDRAULIC SYSTEM

Adjusting Method
1. Raise the inner mast, place blocks under the 3. Extend the piston rod and tighten the cylinder
right and left sides of the mast, and lower the stopper bolt. Remove the blocks from under
mast until it rests on the blocks. the inner mast.
4. Slowly lower the inner mast all the way to make
sure that the piston rods move smoothly.

202983

1. Remove the stopper bolt at the top of the lift

cylinder which stopped first, retract the piston
rod, and insert the shims at the top of the pis-
ton rod end.

Stopper bolt

Shims

200365

NOTE

To retract the piston rod, move the lift

control lever to the lowering position to let
the oil escape from the lift cylinder.

99759-7B110
7.41
HYDRAULIC SYSTEM

Testing
Lift Cylinder Drift Test Tilt Cylinder Drift Test
1. Pick up a load equal to the rated value, tilt the 1. Pick up a load equal to the rated value, tilt the
mast to the vertical position, raise the forks 1 mast to the vertical position, raise the forks
to 1.5 m (3.3 to 4.9 ft) and stop the truck. about 50 cm (20 in.) and stop the truck.
2. Scribe a line on the mast column and measure 2. Measure the drift extension of the tilt cylinder
the drift of the lift cylinder (drop for 15 minutes) for (extension) 15 minutes.

206891 207056

FBC15N - FBC25EN FBC25LN - FBC30LN FBC15N - FBC18LN FBC20N - FBC25EN FBC25LN - FBC30LN

Lift cylinder drift 50 (2.0) 40 (1.6) Tilt cylinder drift 22 (0.9) 20 (0.8) 15 (0.6)
(rated load) maximum (rated load) maximum
Unit: mm (in.)/15 min Unit: mm (in.)/15 min

Piping
1. Check each hydraulic circuit for leaks.
2. Check to make sure that each hose is free
from twisting or excessive loops.

99759-7B110
7.42
TABLE OF CONTENTS

Chapter 8: Mast and Forks

Description ................................................................................................................................... 8.1
Removal and Installation.............................................................................................................. 8.2
Disassembly ................................................................................................................................ 8.4
Inspection after Disassembly ....................................................................................................... 8.6
Reassembly.................................................................................................................................. 8.7
Inspection and Adjustment........................................................................................................... 8.8
Forks ........................................................................................................................................ 8.8
Chain Tension Adjustment ....................................................................................................... 8.9
Clearance Adjustment on Lift Bracket...................................................................................... 8.10
Mast Clearance Adjustment ..................................................................................................... 8.13
Main Roller Shim Replacement ............................................................................................... 8.15
Mast Strip Adjustment.............................................................................................................. 8.15
Tilt Angle Adjustment ............................................................................................................... 8.16
Lift Cylinder Stroke Adjustment................................................................................................ 8.17
Bleeding Lift Cylinders ............................................................................................................. 8.17
Service Data ................................................................................................................................ 8.18
Troubleshooting ............................................................................................................................ 8.20
NOTES

Mast and Forks

Description
G
1

3
Forward Forward

B Detail of A Detail of F

D
Forward Forward

C
Detail of B, C Detail of D
E

4
Forward
F

Detail of E Detail of G
5
207081 207082

Components
1. Inner mast A. Main roller E. Main roller
2. Outer mast B. Main roller F. Main roller
3. Lift chain C. Main roller G. Mast strip
4. Lift bracket D. Side roller
5. Mast support bearing cap
Diam. of
The simplex mast features two lift cylinders placed FBC15N - FBC18LN FBC20N - FBC30LN
main roller
behind the mast columns, right and left, to provide
maximum forward visibility. S 99 (3.90) 113.8 (4.48)
M 100 (3.94) 115 (4.53)
Mast strips are fitted to the top end parts of outer
mast. These strips are for backing up the inner L 101 (3.98) 116 (4.57)
mast when the mast is tilted backward. LL 102 (4.016) 117 (4.606)
Unit: mm (in.)

99759-7B110
8.1
MAST AND FORKS

Removal and Installation

Mast and Lift Bracket Assembly

6
1 207083

Sequence
1. Nut 4. Tilt socket pins
2. Forks and lift bracket 5. Tilt cylinders
3. High-pressure hose for lift cylinders 6. Mast-support bearing caps and bushing

Suggestions
Removing Lift Bracket
1. Tilt the mast forward, and lower the inner mast
all the way. Slacken the lift chains, and remove
the nuts from the anchor bolts.
2. Tilt the mast back to vertical position. Secure
the lift bracket to prevent it from falling over.
Raise the inner mast until the lift bracket
becomes free. Then, back the truck away,
leaving the lift bracket and fork assembly
standing on the floor.
207084

99759-7B110
8.2
MAST AND FORKS

Removing Lift Cylinder High-Pressure Removing Mast Support Bearing Caps

Hoses 1. Scribe marks on the bearing caps before
With the mast in the lowest position, disconnect removing them.
the hoses at the flow regulator valve.

Removing Tilt Cylinders

1. Attach a sling to the holes, left and right in the
top cross member of the mast, and lift the
mast with a hoist.

Marks

207087

2. Remove the cap bolts and lift off the mast

assembly, laying it down flat on a level floor.

207085
NOTE

NOTE Lay the mast assembly on a floor large

enough for disassembly.
Be sure to use a hoist having a capacity
enough to carry the weight of the mast
assembly.

Weight of Components
FBC15N - FBC20N - FBC30N
FBC18LN FBC25LN FBC30LN
Gross (Simplex 520 725 830
3.3 m mast) (1150) (1600) (1830)

Unit: kg (lb)

2. Remove the tilt socket pins, and separate the

masts from the tilt cylinders.

Tilt socket
pin

207086

99759-7B110
8.3
MAST AND FORKS

Disassembly
12 10
15
3

11
10

13
9
2
16 17

2
6

6
7

6 14
1
4
5 207088

Sequence
1. Nut 10. Cylinder clamp, seat, shims, cushion, collar
and bolts
2. Forks and lift bracket
11. Bolt and shims
3. Backrest
12. Mast strip and shims
4. Main roller and shims
13. Main roller and shims
5. Main roller and shims
14. Main roller and shims
6. Side roller, bracket, and shims
15. Inner mast
7. Hose guard
16. Lift cylinders
8. Lift hose (high pressure)
(Rubber hose, T-joint and down safety valve) 17. Outer mast
9. Snap ring and chain wheel

99759-7B110
8.4
MAST AND FORKS

Suggestions
Removing Mast Strips and Main Rollers
Remove bolts 10, 11 to free lift cylinder 16. Cross
the tops of the two lift cylinders. Slide inner mast
15 toward the bottom of outer mast 17, and
remove main rollers 13, 14 and mast strips 12.

Removing Inner Mast

After removing the main rollers, attach a sling to
the inner mast crossmember and slide the inner
mast toward the top of the outer mast until it gets
clear of the outer mast roller shafts. Sling the inner
mast again and remove it from the outer mast.

207089

99759-7B110
8.5
MAST AND FORKS

Inspection after Disassembly

Mast Lift Chains, Chain Wheels and Chain Wheel
Supports
1. Check each roller for wear, binding or other
1. Measure the length of each chain to be sure
defects.
that two chains are equal in length. Also check
2. Check each roller for flat spots on rolling sur- the chains for wear, evidence of breakage, link
face. binding and twist.
3. Check the mast member and the welds of 2. Check each chain anchor bolt for cracks or
crossmembers, shafts and supports for cracks. damaged thread.
4. Check the mast support bushings for wear or 3. Check each chain wheel support and chain
other damage. wheel for crack or wear. Check to be sure that
the wheels are capable of smooth rotation.
4. Measure sections of chain that travel over the
chain wheel.

Length of Chain (Per 20 Links)

FBC15N - FBC20N - FBC30N -
FBC18LN FBC25LN FBC30LN

A 318 (12.52) 381 (15.00) 508 (20.00)

B 327 (12.87) 392 (15.43) 523 (20.59)

Unit: mm (in.)
207090 A = Assembly standard B = Repair or service limit

Lift Bracket
Mast Strips
1. Check the main rollers and side rollers for
smoothness of rotation. Inspect each roller for Check the mast strips for damage, wear or
wear and cracks. distortion.
2. Check the welds of the bracket for cracks.
3. Check the finger bar for bend or distortion.

Finger bar

207091

Distortion of 5 mm (0.2 in.)

A
finger bar maximum

A = Assembly standard

99759-7B110
8.6
MAST AND FORKS

Reassembly
To reassemble, follow the reverse of disassembly Mast Supports
sequence and do the following steps: 1. Check mast support bushing for wear. Replace
if worn.
Adjusting Mast and Lift Bracket Clearance
2. Apply a grease to the inside surfaces and
Rollers for mast and lift bracket are available in grooves of the caps.
three sizes (diameters) for selective use. Select
3. Install mast support bushings and caps with
the size that will provide a longitudinal clearances
beveling toward the center of truck respective-
of 1 mm (0.04 in.) and less.
ly. Greasing will be facilitated if the mast is lift-
Clearance ed by placing wooden blocks under it.

Mast cap
Bushing
Clearance

Lower roller Upper/middle roller

Apply grease
207096
Side with wider cut
203712
Roller Sizes
Diameter of FBC15N - FBC18LN FBC20N - FBC30LN
main roller Precautions for Installing Chain Anchor Kit
Be careful not to install the center plate in the posi-
S 99 (3.90) 113.8 (4.48)
tion for link plate.
M 100 (3.94) 115 (4.53)
L 101 (3.98) 116 (4.57)
2
LL 102 (4.016) 117 (4.606) 3
Unit: mm (in.)

Cylinder Clamps
Install each lift cylinder in place (in vertical position)
by fitting to the support, and see if there is any
1
clearance between the outer mast and cylinder.
Reduce the clearance, if any, to zero by shimming. 4 Stamped mark
207094

1. Link plate (marked)

2. Center plate (not marked)
3. Link
4. Split pin
Shims

207093

99759-7B110
8.7
MAST AND FORKS

Inspection and Adjustment

Forks
1. Carefully inspect the forks for cracks. Special 3. Check the fork blade D. The fork should be
attention should be given to the heel section withdrawn from service if the thickness is
A, all weld areas and B mounting brackets. reduced to less than the tolerant thickness.

Forks with cracks should be removed from Check the heel of fork. Fork blade length may
service. also be reduced by wear, especially on
tapered forks and platens. Remove the forks
“Wet Test” magnetic particle inspection is gen-
from service when the blade length is no
erally preferred due to its sensitivity and the
longer adequate for the intended loads.
ease of interpreting the results.

D Toe
A

101628 Heel 101630

2. Check the difference in height of one fork tip

Tolerant Thickness Standard Limit
to the other when mounted on the fork carrier.
A difference in fork tip height can result in FBC15N 40 (1.6) 31 (1.2)
uneven support of the load and cause prob-
FBC18N - FBC18LN 40 (1.6) 33 (1.3)
lems when entering loads.
FBC20N 45 (1.8) 36 (1.4)
The maximum allowable difference in fork tip
FBC25N, FBC25EN, FBC25LN 45 (1.8) 39 (1.5)
elevation C is 5 mm (0.20 in.) for pallet forks.
FBC30N, FBC30LN 45 (1.8) 40 (1.57)
Replace one or both forks when the difference
Unit: mm (in.)
in fork tip height exceeds the maximum allow-
able difference.

101629

99759-7B110
8.8
MAST AND FORKS

Chain Tension Adjustment

Tightening Torque
! WARNING
FBC15N - FBC25LN FBC30N - FBC30LN
Personal injury can be caused by sudden 57 84
Nut 2
movement of the mast and lift bracket. (5.8) (8.6)
Nut 3
Blocks must be used to prevent the mast [42.0] [62.2]
and lift bracket from any movement while 98 147
the adjustments are made. Keep hands Nut 1 (10) (15.0)
and feet clear of any parts that can move. [72.3] [108.5]
Unit: N•m (kgf•m) [lbf•ft]

6. Adjust until tension is equal on both chains.

1. Have the truck standing on a level floor, with
the mast vertical and the forks lowered to the
floor. Check to be sure that the lift cylinders
are fully retracted.
2. Set the anchor bolts with nut 3.
3. Raise the forks slightly and push the chains
inward midway between the chain wheel and
anchor alternately to check the tension. When
adjusting the chains by means of the nut 3, tilt
the mast forward to slacken the chains to facil-
itate adjustment.
4. Turn nut 3 to adjust the chain tension. Then,
hold the anchor bolt in place with a wrench
and tighten nut 2 to the specified torque.
5. Hold nut 3 in place with a wrench, and tighten
nut 1 to the specified torque.

Anchor bolt

2 nut

3 nut
1 nut
102709

99759-7B110
8.9
MAST AND FORKS

Clearance Adjustment on Lift Bracket

Longitudinal Clearance Adjustment on Lift
Bracket Main Rollers
1. Raise the forks a little from the floor. Roller Sizes
2. Insert a bar between the upper part of lift Diameter of
FBC15N - FBC18LN FBC20N - FBC30LN
bracket and the inner mast, and push the main roller
inner mast to one side. Using a feeler gauge, S 99 (3.90) 113.8 (4.48)
measure the clearance F between the main
M 100 (3.94) 115 (4.53)
roller and inner mast on the opposite side.
L 101 (3.98) 116 (4.57)

F LL 102 (4.016) 117 (4.606)

Unit: mm (in.)

4. Lift bracket main rollers (upper and center

rollers).
The upper rollers should be the same in size
or 1-rank larger than the center rollers.

F
207095

0.1 to 1.0 mm
Clearance F
(0.004 to 0.039 in.)

3. If the clearance F is out of specification, use

oversize rollers.

Lower roller Upper/middle roller

207096

99759-7B110
8.10
MAST AND FORKS

Lateral Clearance Adjustment on

Lift Bracket Main Rollers and Side Rollers
1. Raise the mast all the way. For the lift bracket upper main roller or center
2. Set a dial indicator on the inner mast with its main roller, to extend 0.5 mm (0.02 in.), insert
contact point rested on the side of the lift a 0.5 mm (0.02 in.) shim (a) on the inside and
bracket. remove the 0.5 mm (0.02 in.) shim (b) from
the lower stopper, then tighten the bolts.
3. Go over to the opposite side of the mast, and
push the lift bracket to one side with a bar. Set Inner mast
the indicator to zero.
4. Insert a bar between the inner mast and lift
bracket on the indicator side, and push the lift Shims (b)
bracket to the opposite side.

Shims (a)

207156

203818

5. Read the indicator.

0.1 to 0.5 mm
Clearance G
(0.004 to 0.020 in.)

6. Adjust clearance G1 between the middle main

roller and weld plate 2 at the maximum lift
position by increasing or decreasing the thick-
ness of the shim.

1 1
G1

2 2

202276

99759-7B110
8.11
MAST AND FORKS

Lateral Clearance Adjustment on

Lift Bracket Main Rollers and Side Rollers,
continued
7. Lower the lift bracket slightly below its maxi- 8. With the lift bracket at the maximum lift posi-
mum lift position, then adjust clearance G2 tion, adjust clearance G3 with shims.
between the side roller and mast by increasing
or decreasing the thickness of the shim.

Side roller

Side Roller
G3
207158

202277

Adjust the side roller clearance by adding

shims under the roller bracket.

Shims

Shims
Roller 207157

Bracket
207098

99759-7B110
8.12
MAST AND FORKS

Mast Clearance Adjustment

Longitudinal Clearance Adjustment on Lateral Clearance Adjustment on
Mast Main Rollers Inner Mast Main Rollers
1. Tilt the mast all the way backward. 1. Raise the mast all the way.
2. Using a feeler gauge, measure the clearance 2. Set a dial indicator on the inside of the outer
H between the inner mast lower roller and the mast with its contact point rested on the inner
outer mast. mast.
3. Go over to the opposite side of the mast, and
0.1 to 1.0 mm
Clearance H push the inner mast against the outer mast.
(0.004 to 0.039 in.)
Set the indicator to zero.

3. If the clearance H is out of specification, use

oversize rollers.

Roller Sizes
Diameter of
FBC15N - FBC18LN FBC20N - FBC30LN
main roller

S 99 (3.90) 113.8 (4.48)

M 100 (3.94) 115 (4.53) J
204886
L 101 (3.98) 116 (4.57)
LL 102 (4.016) 117 (4.606)
4. Insert a bar between the outer and inner
Unit: mm (in.)
masts on the indicator side, and push the
inner mast to the opposite side.
5. Read the indicator.

H 0.1 to 0.5 mm
Clearance J
(0.004 to 0.020 in.)

207099

J
207101

99759-7B110
8.13
MAST AND FORKS

6. If the clearance J is out of specification, adjust K

it by using shims.

Shims
207103

6. If the clearance K is out of specification, adjust

207102
it by using shims.

NOTE

Refer to Main Roller Shim Replacement.

Lateral Clearance Adjustment on

Outer Mast Main Rollers Shims

1. Raise the mast all the way.

207104
2. Set a dial indicator on the outer mast with its
contact point rested on the inner mast.
3. Go over to the opposite side of the mast, and
push the outer mast against the inner mast NOTE
with a bar. Set the indicator to zero.
4. Insert a bar between the outer and inner masts, Refer to Main Roller Shim Replacement.
and push the inner mast to the opposite side.
5. Read the indicator.

0.1 to 0.5 mm
Clearance K
(0.004 to 0.020 in.)

204889

99759-7B110
8.14
MAST AND FORKS

Main Roller Shim Replacement Mast Strip Adjustment

1. Remove the lift bracket from the mast. 1. Check the clearance L with the clearance
between the outer mast rollers and inner mast
set to zero (0) in maximum lift position.
NOTE
L
Refer to REMOVAL AND INSTALLATION,
1. Lift Bracket Removal.

2. Lower the inner mast below the outer mast as

follows:
a. Raise the front end of the machine, and
block that end with a jack stand or the like.
b. Remove the upper set of bolts from the lift 200391
cylinders, and lift the inner mast with a
hoist. Remove the hose guard.
c. Remove the clamps from the lift cylinders. Clearance L
0.1 to 0.5 mm
Pull the bottom ends of the cylinders from (0.004 to 0.020 in.)
the outer mast, tilt the cylinders to the cen-
ter of the mast, and tie them to the cross-
member of outer mast with rope. 2. If the clearance L is out of specification, adjust
it by means of shims.
d. Slowly lower the inner mast until it comes in
contact with the lift cylinders.
e. Now the main rollers can be removed from
NOTE
the inner and outer masts. Remove the mast Refer to Main Roller Shim Replacement.
strips and shims in advance because they
are apt to come off under this condition.

3. After adjusting the all clearance, move the

mast and lift bracket slowly to make sure that
they move smoothly through their full stroke.

Shims

202961

200392

99759-7B110
8.15
MAST AND FORKS

Tilt Angle Adjustment

1. Adjust the tire pressure correctly and keep the 5. After adjusting the tilt angle, tighten the socket
truck level. bolts to the specified torque.
2. Tilt the mast all the way backward and stop
Tightening torque 127 to 152
the engine
for tilt cylinder (13 to 15.5)
3. Measure the backward tilt angle of the mast at socket bolt [94 to 112]
both sides. Unit: N•m (kgf•m) [lbf•ft]
3. To adjust the tilt angle, loosen the bolt of tilt
cylinder socket, and adjust the cylinder stroke
by turning the rod on either cylinder so that
there is no difference in stroke between the
cylinders, left and right.

Bolt

207105

NOTE

It is not necessary to adjust the forward tilt

angle if the backward tilt angle is properly
adjusted.

Forward/backward tilt angle 5° to 6° (standard)

99759-7B110
8.16
MAST AND FORKS

Lift Cylinder Stroke Adjustment

1. Slowly raise the inner mast, and check how 2. Remove the set bolt at the top of lift cylinder
the piston rods, left and right, stop at the which stopped first, retract the piston rod, and
moment the inner mast reaches its maximum insert shims at the top of piston rod end.
height. 3. Extend the piston rod, and tighten the cylinder
2. If the top of the inner mast rocks at that set bolt. Remove the blocks from under the
moment, make a shim adjustment. Abnormal inner mast.
condition can be told by a little time lag in
stopping between the piston rods, left and
right, and rocking of the rod with a longer Set bolt
cylinder stroke. Shims

200365

4. Slowly lower the inner mast all the way to

make sure that the piston rods move smoothly
204698 and that the left and right lift cylinders come to
the end of stroke simultaneously.
Adjusting Method
1. Raise the inner mast, place blocks under the Bleeding Lift Cylinders
left and right sides of the inner mast, and
When air and oil remaining inside the air chamber
lower the mast until it rests on the blocks.
of the rod and inside the rod chamber between the
tubes are compressed, they open the check valve
and flow out of the cylinder. Therefore, there is no
need to bleed the lift cylinders.

202983

99759-7B110
8.17
MAST AND FORKS

Service Data

Inner mast
F L

G2
B
F

Lift Bracket
A
C1
K

H E

J
C2

Outer mast D

207106

99759-7B110
8.18
MAST AND FORKS

Service Data
Item Truck Model FBC15N-FBC18LN FBC20N-FBC25LN FBC30N-FBC30LN
Difference in height between fork tips A 5 (0.20)
100 x 40 100 x 40 125 x 45
A
(3.9 x 1.6) (3.9 x 1.6) (4.92 x 1.8)
Forks Chains

B FBC15N FBC20N
Thickness of forks 100 x 31 100 x 38
(3.9 x 1.2) (3.9 x 1.5) 125 x 39
FBC18N FBC25N-FBC25EN (4.92 x 1.53)
100 x 33 100 x 40
(width x thickness) (3.9 x 1.3) (3.9 x 1.57)
A 318 (12.52) 381 (15.00) 508 (20.00)
Length of tilt chains (per 20 links)
B 327 (12.87) 392 (15.43) 523 (20.59)
S A 99 (3.90) 113.8 (4.48)
M A 101 (3.94) 115 (4.53)
Rollers

Diameter of main roller

L A 101 (3.98) 116 (4.57)
LL A 102 (4.016) 117 (4.606)
Diameter of side roller A 42 (1.65)
Distance between outer mast main rollers
A 523 (20.59) 575 (22.64)
(inside to inside) A

Distance between inner mast main rollers

A 581 (22.87) 639 (25.16)
(outside to outside) B

Distance between lift bracket main rollers

A 485 (19.09) 535 (21.06)
(outside to outside) C1

Distance between lift bracket main rollers

A 487 (19.17) 537 (21.14)
(outside to outside) C2

Distance between lift bracket main rollers

A 491 (19.33) 539 (21.22)
(outside to outside) D

Distance between lift bracket side rollers

Mast and Lift Bracket

A 496 (19.53) 546 (21.50)

(outside to outside) E

Longitudinal clearance of lift bracket middle rollers

A 0.1 to 1.0 (0.004 to 0.039)
(with forks slightly lifted) F

Lateral clearance of lift bracket middle main rollers

A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) G1

Lateral clearance of lift bracket side rollers

A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) G2

Lateral clearance of lift bracket lower main rollers

A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) G3

Longitudinal clearance of mast main rollers

A 0.1 to 1.0 (0.004 to 0.039)
(in the whole lift range) H

Lateral clearance of inner mast main rollers

A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) J

Lateral clearance of outer mast main rollers

A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) K

Mast strip clearance

A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) L

99759-7B110
8.19
MAST AND FORKS

Troubleshooting

Complaint Possible Cause

Lift bracket and inner mast will a) Main rollers and side rollers having no proper clearance
not move smoothly b) Rollers involved binding on their shafts
c) Rollers damaged
d) Improper mast-to-strip clearance
Lift bracket or inner mast cocks a) Too much clearance on side rollers, or side rollers damaged
b) Lift chains unequally tensioned
c) Shim adjustments unequally made on left and right lift cylinders
(at maximum height)
Mast makes noise Rollers not rotating smoothly on their shafts, or damaged
Load drops (drifts) a) Lift cylinder packing damaged
b) Lift cylinder bore grooved
c) Control valve defective
Mast shakes entirely Mast-support bushing worn
Mast is distorted Improper loading or overload
Fork tips differ in height a) Finger bar bent
b) Forks bent
c) Distortion of mast due to off-center loading

99759-7B110
8.20
TABLE OF CONTENTS

Troubleshooting
Front Axle and Reduction Differential
Complaint Possible Cause Remedy

Gear noise comes out Teeth worn excessively or tooth contact out Readjust or replace
continuously during of adjustment in spiral bevel drive
normal cruising run
Bearing preloads too much or too little, Readjust or replace
or bearings are worn excessively
Hub bearings broken Replace
Improper tooth contact between Readjust
reduction pinion (on output shaft) and
reduction gear
Irregular noise comes Bearings associated with spiral bevel Replace
out during normal travel drive or hub bearings broken
Differential side gears have broken teeth, Replace gears or washer
or thrust washers worn
Metal piece in axle housing Clean and replace oil
Bolts securing axle shaft or differential carrier Retighten
are loose
Abnormal noise comes Fit differential gears in differential case Replace worn parts
out when turning a are out of specification due to wear
corner
Broken teeth on differential pinions or Replace defective parts
side gears, or pinions seized on spiders
Differential overheats Bearings broken due to too large a Replace bearing and readjust
preload preload
Backlash between reduction pinion Replace bearings and readjust
(on output shaft) and reduction gear preload and backlash
too small

99759-7B110
9.1
TROUBLESHOOTING

Brake System
Complaint Possible Cause Remedy

Lack of Oil leaking past primary cup in master Replace piston cup if cylinder is worn.
braking force cylinder Replace cup and fluid if the cup is
distorted.
Oil leaking past cups in wheel cylinders Replace pipe and connector and
retighten
Oil leaking from oil pipe connection Retighten
Shoe linings excessively worn Replace
Linings dirty with oil or grease Clean or replace
Pedal stroke is Air trapped in brake oil line Bleed air at master cylinder and
too large wheel cylinder
Piston cup defective in master cylinder Replace
Not enough fluid in reservoir Refill
Push rod-to-piston clearance too large Readjust
in master cylinder
Service Brakes

Brake fluid leakage Replace piston cup if cylinder is worn.

Replace the cup and fluid if the cup is
distorted.
Automatic adjusting device out of order Check cable guide and adjusting
spring installation. If they are defective,
replace fitting cable, lever and
adjusting screw.
Uneven braking Lining or drum dirty with oil or grease in less Clean or replace
(machine pulls to effective brake
one side)
Wobbly or loose-mounted drum in less Replace drum. Readjust and retighten.
effective brake
Brake squeals Linings glazed Replace shoe & lining assembly
Linings badly worn Replace
Backing-plate securing bolts loose Retighten
Wheel bearings loose Readjust preload and retighten
Brake drum dirty Clean
Brake chatters Anchored ends of shoes rattling on anchor Repair or replace
or clatters
Shoe ledges badly worn Replace backing plate
Piston badly worn in wheel cylinder Replace

99759-7B110
9.2
TROUBLESHOOTING

Complaint Possible Cause Remedy

Lever stroke is Lining-to-drum clearance too small Readjust

too small
Squeals during Lining-to-drum clearance too small Readjust
traveling
Brake drum badly distorted Repair or replace
Parking Brake

Will not apply Parking brake cable longer than specified Check drum-to-lining clearance and,
if brake will not apply, turn adjusting
knob clockwise
Linings worn to service limit Replace shoe & lining assembly
Lining-to-drum clearance too small Readjust
Lack of brake lever operating effort Readjust to
25 to 30 kgf (55 to 66 lbf) [245 to 294 N]

Complaint Possible Cause Remedy

Hard steering a) Overloaded steer axle Reduce load

b) Damaged mechanical linkage Replace
c) Dry mechanical linkage joints Lubricate
d) Mechanical joints too tight Readjust
e) Kingpin bearings improperly preloaded Readjust
f) Low pump pressure Replace pump
Truck wanders a) Damaged or worn mechanical linkage Replace
Steering System

b) Loose cylinder piston Replace cylinder rod

Truck drifts a) Damaged or worn mechanical linkage Replace
b) Tire diameter differs between right and left Replace tire
Erratic steering Loose cylinder piston Replace cylinder rod
Excessive free play Damaged or worn linkage between cylinder Replace
at steered wheels and steered wheels
Axle shimmy a) Excessive clearance between the kingpin Repair or replace
and its bearings
b) Worn or damaged hub bearing Replace
Rear tires wear Tire on one side differs in kind or brand Replace tires
prematurely from that on the other side.
or unevenly

99759-7B110
9.3
TROUBLESHOOTING

Steering System
Complaint Possible Cause Remedy

Slow steering, Worn or malfunctioning pump Replace

hard steering or
loss of steering Malfunctioning relief valve Readjust or replace
Worn or malfunctioning steer gear Replace
Pipe or tube flattened, or restriction in an oil line Clean or replace
Truck wanders Air in system Low level of oil Fill as required
Leaking joint Tighten joint
Pinched pipe or hose Straighten or replace
Worn steer gear Replace
Steering slip Worn steer gear Replace
Leakage of cylinder seals or at lines between steer gear Repair
and cylinder
Temporary hang-up in Thermal shock—caused by actuation of hydraulic lift and Correct operating
steering tilt for long periods of time without actuation of steering procedure
system, creating more than a 28°C (50° F) temperature
differential between the oil in the tank and the oil in the
steer gear.
Erratic steering Air in system Low level of oil Fill as required
Leaking joint Tighten joint
Pinched pipe or hose Straighten or replace
Thermal shock damage to steer gear Replace
Motor not operating at correct speed Repair/replace
Spongy or soft steering Air in system Low level of oil Fill as required
Leaking joint Tighten joint
Pinched pipe or hose Straighten or replace
Air trapped in cylinder Bleed air

99759-7B110
9.4
TROUBLESHOOTING

Complaint Possible Cause Remedy

Steering wheel turns Problem with Column loose or damaged Repair or replace
with no axle response steering column
Column splines damaged or Repair or replace
disengaged from steer gear
Air in steer gear Starved at startup Temporary
Starved from long period of non-use Temporary
No flow to steer gear Low oil level Fill as required
Ruptured hose Replace
Thermal shock damage to steer gear Replace
Blown piston seal Replace
Steering instability or Air in lines Pump sucking air at inlet Check joints
oscillation
Components or lines contain air Bleed circuit
Improper relief setting Readjust
Steering wheel turns in Lines connected to wrong cylinder ports Correct connections
wrong direction
Excessive freeplay At steering wheel Loose steering wheel nut Tighten
Damaged or worn column shaft Replace
At steered wheels Leaky cylinder seals Replace
Binding or poor Binding or misalignment between column and steer gear Readjust steer gear
centering of steering mounting bracket or
wheel replace rubber mounting
grommets
High back pressure in tank return line Clear blockages
Contamination in steer gear unit Clean unit
Steer gear locks up Contamination in steer gear unit Clean unit
Insufficient hydraulic power Check pump and power
supply
Worn or damaged steer gear or steer gear pin Replace

99759-7B110
9.5
TROUBLESHOOTING

Hydraulic System
Complaint Possible Cause Remedy

Will not lift or tilt Not enough oil in hydraulic tank Refill
Relief valve out of order because of:
1) Seized main valve Replace
2) Broken valve spring Replace relief valve
Oil pump defective Replace
Control valve switch misaligned or defective Readjust or replace
Will not lift rated Relief valve out or order because of:
load 1) Too low a relief valve setting Readjust
2) Defective plunger and poppet seat Replace relief valve
3) Weakened spring Replace relief valve
4) Damaged O-ring in valve case Replace O-ring
Oil pump defective Replace
Piston seals worn or damaged Replace
Lift speed is too low Rpm too low Adjust
Control lever installed loose, resulting in not Repair or replace
enough spool stroke
Lift and Tilt Cylinders

Tank strainer clogged Clean or replace

Pump not delivering enough oil Repair or replace
Lowering speed Sleeve seized in flow regulator valve Repair
is too low
Dirt in flow regulator valve Clean, repair system and replace
defective hose
Abnormal resistance to flow due to flattened Replace hose
hose or local clogging
Cylinder vibrates Piston rod distorted Repair or replace
when actuated Control lever installed loose, resulting in not Repair or replace
enough spool stroke
Air in oil circuit Bleed air by operation cylinder
through full stroke
Not enough oil in hydraulic tank Refill
Load will not hold Control valve spool leaking internally Replace
Lift connector on bottom of control valve Torque to 33 ± 3.5 ft•lbs
not tight
Sliding (inside) surface of cylinder tube Repair or replace cylinder assembly
slightly grooved
Sliding (inside) surface of tube badly grooved Replace
Piston seals broken or distorted Replace seal kit
Oil leakage from piping Repair or replace
99759-7B110
9.6
TROUBLESHOOTING

Lift and Tilt Cylinders, continued Complaint Possible Cause Remedy

Mast tilts forward Control valve spool leaking internally Replace

(drifts)
Foreign particles lodged between packing Replace packing
and mating surface
Piston seal damaged Repair
Cylinder distorted Repair or replace
Bushing leaks Foreign particles lodged between sealing Replace
members such as oil seals and dust seals
Oil seals and dust seals defective Replace
O-rings damaged Replace
Cylinder distorted Repair or replace

Hydraulic tank heats Oil viscosity improper Change oil

excessively
Overload Check working conditions and, if
overloaded, urge the operator to
stay within the load limit
Local overheating of oil line due to a large Repair or replace
restriction flow
Hydraulic Tank

Relief valve adjustment improper Readjust pressure setting

Pressure drop due to weakened or broken Repair or replace and readjust
springs
Hydraulic pump worn Replace
Outlet pipe or tube flattened, or restriction Repair or replace
to flow
Cylinders move Shortage of oil due to a natural loss Refill
too slowly
Oil leakage due to damaged oil line seals Repair or replace
Oil viscosity too high Change oil
Cylinders move too Hydraulic pump defective Check pump and piping; repair or
slowly replace
Oil leakage from oil line Check oil for level and condition;
and/or change oil
Abnormal rise in oil temperature Check control valve spools for
Hydraulic Pump

misalignment: repair or replace

Hydraulic pump leaking internally Replace pump
Noisy Poor pumping Refill
Cavitation 1. Check suction pipe for any flat portion
or loose connection; retighten or
replace
2. Check shaft oil seal for airtightness;
replace pump
3. Check pump body for any outside
interference; repair
Forks will not lower Control Valve Solenoid Check positive and negative to solenoid.
Hyd. Cont.
Valve

Check wire #25 positive or wire #26 Repair wiring or replace solenoid.
negative to the solenoid.

99759-7B110
9.7
TROUBLESHOOTING

Rear Axle
Complaint Possible Cause Remedy

Hard steering Low pump pressure Check pressure, replace pump as needed
Damaged mechanical linkage Replace
Dry mechanical linkage joints Lubricate
Mechanical joints too tight Readjust
Kingpin bearings improperly preloaded Readjust
Truck wanders Damaged or worn mechanical linkage Replace
Loose cylinder piston Replace cylinder rod
Truck drifts Damaged or worn mechanical linkage Replace
Tire diameter differs between right and left Replace tire
Erratic steering Loose cylinder piston Replace cylinder rod
Excessive freeplay Damaged or worn linkage between cylinder Replace
at steered wheels and steered wheels
Axle shimmy Excessive clearance between the kingpin and Repair or replace
its bearings
Worn or damaged hub bearing Replace
Rear tires wear Tire on one side differs in kind or brand from Replace tires
prematurely or that on the other side
unevenly

99759-7B110
9.8
TROUBLESHOOTING

Mast and Forks

Complaint Possible Cause

Lift bracket and inner mast Main rollers and side rollers have proper clearance
do not move smoothly
Rollers involved are binding on their shafts
Rollers damaged
Improper mast-to-strip clearance
Lift bracket or inner mast Too much clearance on side rollers, or side rollers are damaged
cocks
Lift chains unequally tensioned
Shim adjustments unequally made on left and right lift cylinders
(at maximum height)
Mast makes noise Rollers not rotating smoothly on their shafts or are damaged
Load drops (drifts) Lift cylinder packing damaged
Lift cylinder bore grooved
Control valve defective
Entire mast shakes Mast-support bushing worn
Mast is distorted Improper loading or overload
Fork tips differ in height Finger bar bent
Forks bent
Distortion of mast due to off-center loading

99759-7B110
9.9
NOTES

Chapter 10: Maintenance Service Data

Maintenance Service Data........................................................................................................... 10.1
Front Axle and Reduction Differential ...................................................................................... 10.1
Transfer Case ........................................................................................................................... 10.3
Rear Axle ................................................................................................................................. 10.4
Brake System ........................................................................................................................... 10.6
Steering System,...................................................................................................................... 10.11
Hydraulic System ..................................................................................................................... 10.13
Mast and Forks (Simplex Mast) ............................................................................................... 10.16
Mast and Forks ........................................................................................................................ 10.17
Tightening Torques for Standard Bolts and Nuts ......................................................................... 10.18
Fine Thread—With Spring Washer .......................................................................................... 10.18
Fine Thread—Without Spring Washer ..................................................................................... 10.18
Coarse Thread—With Spring Washer...................................................................................... 10.18
Coarse Thread—With Spring Washer...................................................................................... 10.18
Tightening Torques for Standard Bolts and Nuts with Standard Threads .................................... 10.19
Coarse Thread—Inches ........................................................................................................... 10.19
Tightening Torques for Taperlock Studs ....................................................................................... 10.19
Coarse Thread—Inches ........................................................................................................... 10.19
Maintenance Chart....................................................................................................................... 10.20
Planned Replacement Parts ........................................................................................................ 10.26
Lubrication Information................................................................................................................. 10.27
Chart ........................................................................................................................................ 10.27
Fuel and Lubricant Specifications ............................................................................................ 10.28
Recommended Brands of Lubricants....................................................................................... 10.28
Weight of Major Components (Approximate) ............................................................................... 10.29
Special Service Tools ................................................................................................................... 10.30
Special Tool Illustrations........................................................................................................... 10.31
Inspection Guide .......................................................................................................................... 10.34
NOTES

Maintenance Service Data

Front Axle and Reduction Differential
Truck FBC15N - FBC18LN FBC20N - FBC30LN
Item
Model

A 0.05 (0.0020)
Face runout of axle shaft flange
B 0.5 (0.020)
Runout of axle shaft A 0.5 (0.020) max 1.0 (0.039) max
(1/2 of dial indicator reading)
B 1.0 (0.039) max 2.0 (0.079)
Preload for hub bearing 1,
A 5 to 50 (0.4 to 3.6) [0.5 to 4.9]
kgf•cm (lb•ft) [N•m]
Tightening Hub bearing lock nuts
A 20 (145) [196]
torque (outer) (2)
kgf•cm
Axle shaft bolts (3) A 8.8 (64) [86]
(lbf•ft)
[N•m] Backing plate bolts (4) A 6 (43) [59] 18.5 (134) [181]
Hubs and Wheels

Hub bolt lock nuts (5) A 6 (43) [59] 18.5 (134) [181]

Frame support bolts (6) A 22.9 (166) [225]

Wheel nuts (7) A 16 (116) [157] 38.5 (278) [378]

6 1

4 7

203665

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

99759-7B110
10.1
MAINTENANCE SERVICE DATA

Item Truck FBC15N - FBC30LN

Model

Gear backlash (1) A 0.18 to 0.23 (0.0071 to 0.0091)

B 0.5 (0.020)

A 0.02 to 0.07 (0.0008 to 0.0028)

Fit of bevel pinion on spider (2)
B 0.35 (0.0138)

15 to 30 (1.1 to 2.2) [1.5 to 2.9]

Preload for differential case side bearings (3) A
kgf•cm (lbf•ft) [N•m] 1.3 to 2.5 kgf (2.9 to 5.5 lbf) [13 to 25 N]
as force applied to reduction gear in tangential direction
Hubs and Wheels

Face runout of reduction gear (4) A 0.05 (0.0020) max

B 0.05 (0.0020)

Backlash between reduction gear

A 0.15 to 0.25 (0.0059 to 0.0098)
and pinion (5)

Free movement (looseness) of A 0.07 to 0.17 (0.0028 to 0.0067)

axle shaft splines (6)
B 0.5 (0.020)

Tightening Reduction gear bolts (7) A 12 (87) [118]

torque
kgf•cm Side bearing cap bolts (8) A 12.8 (93) [126]
(lbf•ft)
[N•m] Carrier bolts (9) A 6.1 (44) [60]

Differential carrier cover

A 3.4 (25) [33]
bolts (10)

6 5 4
7
10
9

3
8
2 1
203664

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

99759-7B110
10.2
MAINTENANCE SERVICE DATA

Transfer Case

N•m kgf•m lbf•ft

1 Cover-to-traction motor 33±2 3.4±0.2 24.6±1.4

2 Side cover 39.2±3.9 4.0±0.4 29.0±2.9
3 Plug or pulse generator 54.0±4.9 5.5±0.5 39.7±3.6
4 case-to-cover 39.2±3.9 4.0±0.4 29.0±2.9
5 Lock nut 292±20 30.0±2.0 217±14.5

Supply liquid gasket onto

the face of flange.
Transfer Case

4
2

5
209009

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

99759-7B110
10.3
MAINTENANCE SERVICE DATA

Rear Axle
Item Truck FBC15N - FBC18LN FBC20N - FBC30LN
Model

Oscillating angle A 3°

Toe-in A 0°

Caster A 0°

Camber A 1°

Total fore-aft play of axle at center pin (1) A 0.8 (0.031)

B 1.2 (0.047)

Turning Angle Inside (2) A 83° 83°

Outside (3) A 54° 56°

Tightening Support bolts (4) A 14.8 (107) [145]

torque, kgf•m
(lbf•ft) [N•m] Stopper bolt nuts (5) A 6.8 (49) [67]
Rear Axle

Cylinder minimum test pressure,

A 107 (1522) [10,500] 163 (2320) [16,000]
2
kgf•cm (psi) [kPa]

8609145

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

99759-7B110
10.4
MAINTENANCE SERVICE DATA

Rear Axle, continued

Item Truck FBC15N - FBC18LN FBC20N - FBC30LN
Model

Tightening torque Outer locknut (6) A 16 (116) [157]

kgf•m (lbf•ft) [N•m]
Cylinder nuts (7) A 1.9 to 2.3 (14 to 17) [19 to 23]

Cylinder bolts (8) A 17.9 (130) [176] 26.7 (193) [262]

Kingpin bolts (9) A 1.7 (12.3) [16.7] 3.4 (24.6) [33.4]

Tie rod bolts (10) A 0.7 (5) [6.9]

Preload for hub bearing (11)

A 25 to 65 (1.8 to 4.7) [2.5 to 6.4]
kgf•m (lbf•ft) [N•m]

8
Rear Axle

11
9

6
8609146

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

99759-7B110
10.5
MAINTENANCE SERVICE DATA

Brake System
Truck
Item FBC15N - FBC30LN
Model

Height of pedal (1) A 120 ± 3 (3.5 ± 0.12)

Stroke (to point where brakes start to apply) (2) A 3 to 10 (0.12 to 0.40)

Clearance between piston and push rod (3) A 0.5 to 2.7 (0.02 to 0.11)

A
Brake Pedal

Push rod

C Stop bolt

8609011

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

99759-7B110
10.6
MAINTENANCE SERVICE DATA

Brake System, continued

Truck FBC15N - FBC18LN FBC20N - FBC30LN
Item
Model

19.05 + 0 0.052 22.22 + 0 0.052

Inside diameter of cylinder body (1) A
(0.7500 + 0 0.00205) (0.8748 +0 0.00205)

19.05 -0.020 -0.053 22.22 -0.020 -0.053

Diameter of piston (2) A
(0.7500 -0.0079 -0.00209) (0.8748 -0.0079 -0.00209)

Clearance between cylinder and piston 0.020 to 0.105 0.020 to 0.105

A
(0.00079 to 0.00413) (0.00079 to 0.00413)
B 0.2 (0.008) 0.2 (0.008)

Diameter of primary cup (lip side) (3) 20 0 -0.3 23.2 ± 0.25

A
(0.79 0 -0.012) (0.913 ± 0.0098)

B replace every year replace every year

Diameter of secondary cup (lip side) (4) 20.2 ± 0.2 23.2 ± 0.25
A
(0.795 ± 0.008) (0.913 ± 0.0098)
B replace every year replace every year
Free length of return spring (5) A 46.8 (1.843) 85 (3.35)
Master Cylinder

B replace every year replace every year

Earlier Version

204936

Later Version 2
4

1 3 5
91246-07200

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

99759-7B110
10.7
MAINTENANCE SERVICE DATA

Brake System, continued

Truck FBC15N - FBC18LN FBC20N - FBC30LN
Item
Model

Inside diameter of cylinder body (1) A 22.22 + 0 0.052 28.58 + 0 0.052

(0.8748 - 0 0.00205) (1.1252 + 0 0.00205)

Diameter of piston (2) 22.22 - 0.040 - 0.073 28.58 - 0.020 - 0.058

A
(0.8748 - 0.00157 - 0.00287) (1.1252 - 0.00079- 0.00228)
Clearance between cylinder and piston 0.040 to 0.125 0.020 to 0.105
A
(0.00157 to 0.00492) (0.00079 to 0.00413)
B 0.15 (0.0059)
Diameter of piston cup (lip side) (3) 23.7 ± 0.2 30.5 ± 0.25
A
(0.933 ± 0.0079) (1.201 ± 0.0098)
B replace every year
Return Spring (4) Free length A 49.5 (1.95) 58 (2.28)
Length under test force A 20 (0.79) 23 (0.91)
1.2 ± 0.1 1.3 ± 0.1
Wheel Cylinder

A (2.6 ± 0.2) (2.9 ± 0.2)

Test force kgf (lbf) [N] [12 ± 1] [13 ± 1]
B replace every year
Tightening 0.8 to 1.2 1.8 to 2.7
torque, kgf•m Wheel cylinder bolts (5) A (6 to 9) (13 to 20)
(lbf•ft) [N•m] [8 to 12] [18 to 26]
Bleeder screw (6) A 0.6 to 0.9 (4 to 7) [6 to 9]

1 6 5

4 3 2

200426

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

99759-7B110
10.8
MAINTENANCE SERVICE DATA

Brake System, continued

Truck FBC15N - FBC18LN FBC20N - FBC30LN
Item
Model

Inside diameter of brake drum (1) 254 + 0 1.3 310 + 0 0.15

A
(10.00 + 0 0.0051) (12.20 + 0 0.0059)

B 256 (10.08) 312 (12.28)

Thickness of lining (2) A 4.87 (0.19) 6 (0.24)

B 2.5 (0.098) max 3 (0.118) max

Wheel Brakes

Clearance between drum and lining (3) A 0.2 to 0.5 0.2 to 0.6
(one side) (0.0079 to 0.0197) (0.0079 to 0.0236)

Return spring 102 (4.02) Primary:120 (4.72)

Free length A
(4) Secondary: 139.3 (5.48)

111 (4.37) Primary: 134 (5.28)

Length under test force A
Secondary: 145.4 (5.72)

16 ± 1.6 23 ± 2.3
Test force, kgf (lbf) [N] A (35 ± 3.5) (51 ± 5.1)
[157 ± 16] [226 ± 23]

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

99759-7B110
10.9
MAINTENANCE SERVICE DATA

Brake System, continued

Truck FBC15N - FBC18LN FBC20N - FBC30LN
Item
Model

Adjusting Free length A 79 (3.11) 104 (4.11)

spring (5)
Length under test force A 98.5 (3.88) 122 (4.80)
Test force, kgf (lbf) [N] A 14 ± 1.4 (31 ± 3) [137 ± 14] 8 ± 0.8 (18 ± 2) [78 ± 8]
Tightening torque for backing plate bolts (6) A 16 (116) [157]
kgf•m (lbf•ft) [N•m]
Service Brakes

1
4

2 6

3
Secondary spring 4

5
Free length
203588

Lever operating effort (F) 245–294N (20–30 kgf) [55–66 lbf]

Applied

F
Parking Brake

Released

209790

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

99759-7B110
10.10
MAINTENANCE SERVICE DATA

Steering System
Truck FBC15N - FBC18LN FBC20N - FBC30LN
Item
Model

Steering effort (at rim with truck on)

A 1.3 (2.9) [12.8]
kgf (lbf) [N]

Tightening Tank Plug (1) A 4.8 (35) [47.5]

torque kgf•cm,
(lbf•ft) [N•m] Body cap screws (2) A 2.3 (17) [23]
Steering Gear

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

99759-7B110
10.11
MAINTENANCE SERVICE DATA

Steering System

Truck FBC15N - FBC18LN FBC20N - FBC30LN

Item
Model

Inside diameter A 63 (2.48) 75 (2.95)

Diameter of piston rod A 40 (1.57) 50 (1.97)

Minimum test pressure for leaks, A 107 (1522) [10,500] 163 (2320) [16,000]
kgf•cm2 (psi) [kPa]

Tightening Cylinder nuts (1) A 2.1 ± 0.2 (15.5 ± 1.5) [21 ± 2]

Steering Cylinder

torque, kgf•cm,
(lbf•ft) [N•m] Mounting bolts (2) A 17.9 (130) [176] 26.7 (193) [262]

8609149

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

99759-7B110
10.12
MAINTENANCE SERVICE DATA

Hydraulic System
Item Truck FBC15N FBC18N FBC18LN FBC20N FBC25N FBC25EN FBC25LN FBC30N -
Model FBC30LN

48 volt lift speed (rated load) mm/sec (fpm) A .34 (67) .32 (64) .47 (93) .40 (78) .38 (74) .32 (64)

Lowering speed (rated load) mm/sec (fpm) A .58 (115) .57 (113) .59 (116) .52 (102)

Forward tilt angle A 5°

Simplex Mast

Backward tilt angle A 6°

Lift cylinder drift (rated load)

mm (in.) / 15 min. A 50 (2.0) max 40 (1.6)
[Oil temperature 45°C (113°F)]

Tilt cylinder drift (forward) rated load

mm(in.) / 15 min. A 22 (0.9) 20 (0.8) 15 (0.6)
[Oil temperature 45°C (113°F)]

Main relief valve setting, kgf•cm2, (psi) [kPa] A 197±kgf/cm2 (2630 ± 50 psi) [19650 ± 34 kPa]

Power steering relief valve setting 51 (725)[5000] 81.5 (1160) [8000]

A
kgf•cm2, (psi) [kPa]

Output, liter (cu. in.) / min Standard 55.2(3360) 60(3913) 60(3913)2400rpm

A
Hydraulic Pump

2400 rpm 2400 rpm 69.6 (4549)

2400 rpm 69.6 (4539)
Premium A 60(3913)2400rpm DNA 2400 rpm

Tightening torque for oil pump bolts

kgf•m (lbf•ft) [N•m] A 4.7 to 5.2 (34 to 38) [46 to 51]
Control Valve

Tightening Tie bolts (1/2 in.) A 1.9 (14) [19]

torque
kgf•m (lbf•ft)
[N•m] Tie bolts (9/16 in.) A 4.5 (33) [45]

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

99759-7B110
10.13
MAINTENANCE SERVICE DATA

Hydraulic System, continued

Truck FBC15N - FBC18LN FBC20N - FBC25EN FBC25LN - FBC30LN
Item
Model

45 +0.2 50 +0.2 55 +0.2

[Piston] 0 0 0
A
Inside diameter of cylinder tube (1) (1.77 +0.008) (1.97 +0.008) (2.17 +0.008)
0 0 0
Diameter of piston ring (2) A 35 (1.38) 40 (1.57) 45 (1.77)
Thread diameter (3) A M49 x 1.5 M54 x 1.5 M59 x 1.5
Tightening torque (4) 170 to 240 200 to 270 270 to 304
A (17.3 to 24.5) (20.4 to 27.5) (27.5 to 31.0)
Lift Cylinder

N•m (kgf•m) [lbf•ft] [125 to 175] [150 to 200] [200 to 225]

3 2 1

4
207073
Return

Tightening torque
Filter

A 49 ± 10 (5 ± 1) [36 ± 7.2]
N•m (kgf•m) [lbf•ft]

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

99759-7B110
10.14
MAINTENANCE SERVICE DATA

Hydraulic System, continued

Truck FBC15N - FBC18LN FBC20N - FBC25EN FBC25LN - FBC30LN
Item
Model

63 +0.1 70 +0.1 80 +0.1

0 0 0
A
Inside diameter of cylinder tube (1) (2.48 +0.004) (2.76 +0.004) (3.15 +0.004)
0 0 0

B 63.12 (2.485 0) 70.12 (2.760 6) 80.12 (3.154 3)

25 -0.02 30 -0.02 -0.025
35 -0.064
[Guide bushing] A -0.05 -0.05
(1.0 -0.000 8) (1.18 -0.000 8) (1.38 -0.000 98)
Diameter of piston rod (2) -0.002 0 -0.002 0 -0.002 52

Inside diameter of mast-side socket bushing 0

35 -0.012 0
(1.38-0.0005 )
A
(fitted) (3)
32 +0.085 +0.003)
A 0 (1.26 0
Inside diameter of frame-side head bushing
(fitted) (4) 32.6 (1.283)
B
[Guide bushing] thread diameter (5) A M68 x 2 M75 x 2 M85 x 2
Tightening torque 265 ± 29 314 ± 31 373 ± 37
A (27 ± 3) (32 ± 3.2) (38 ± 3.8)
N•m (kgf•m) [lbf•ft] [195 ± 22] [231 ± 23] [275 ± 27]
Tilt Cylinders

[Socket] thread diameter (6) A M24 x 1.5 M27 x 1.5 M30 x 1.5

Tightening Socket bolt (7) A 127 to 152 (13 to 15.5) [94 to 112]
torque, N•m
(kgf•m) [lbf•ft] 127 ± 9.8 235 ± 19.6 39.2 ± 25
Self-locking nut (8) A (13 ± 1.0) (24 ± 2.0) (40 ± 2.5)
[94 ± 7.2] [174 ± 14.5] [289 ± 18.1]

0.06 to 0.111 0.075 to 0.139

Clearance between rod and A
(0.002 4 to 0.004 4) (0.003 0 to 0.005 5)
guide bushing (9)
B 0.35 (0.013 8)
9
3
6 4

7 5 1 2 8 207033

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

99759-7B110
10.15
MAINTENANCE SERVICE DATA

Mast and Forks (Simplex Mast)

Truck FBC15N - FBC18LN FBC20N - FBC25EN FBC25LN - FBC30LN
Item
Model
Difference in height between fork tips A 5 (0.20)
Thickness of forks 100 x 40 100 x 45 125 x45
A (3.9 x 1.6) (3.9 x 1.8) (4.92 x 1.8)
Forks Chains

FBC15N FBC20N
100 x 31 100 x 38
B (3.9 x 1.2) (3.9 x 1.5) 125 X 39
FBC18N - FBC18LN FBC25N/FBC25EN/FBC25LN (4.92 x 1.53)
100 x 33 100 x 40
(width x thickness) (3.9 x 1.3) (3.9 X 1.57)
A 318 (12.52) 381 (15.00) 508 (20.00)
Length of tilt chains (per 20 links)
B 327 (12.87) 392 (15.43) 523 (20.59)
S A 99 (3.90) 113.8 (4.48)
Rollers

M A 100 (3.94) 115 (4.53)

Diameter of main roller
L A 101 (3.98) 116 (4.57)
LL A 102 (4.016) 117 (4.606)
Diameter of side roller A 42 (1.65)
Distance between outer mast main rollers
A 523 (20.59) 575 (22.64)
(inside to inside) A
Distance between inner mast main rollers
A 581 (22.87) 639 (25.16)
(outside to outside) B
Distance between lift bracket main rollers
A 485 (19.09) 535 (21.06)
(outside to outside) C1
Distance between lift bracket main rollers
A 487 (19.17) 537 (21.14)
(outside to outside) C2
Distance between lift bracket main rollers
A 491 (19.33) 539 (21.22)
(outside to outside) D
Mast and Lift Bracket

Distance between lift bracket side rollers

A 496 (19.53) 546 (21.50)
(outside to outside) E
Longitudinal clearance of lift bracket
A 0.1 to 1.0 (0.004 to 0.039)
middle rollers (with forks slightly lifted) F
Lateral clearance of lift bracket
A 0.1 to 0.5 (0.004 to 0.020)
middle main rollers (fully raised) G1
Lateral clearance of lift bracket side rollers
A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) G2
Lateral clearance of lift bracket lower main rollers
A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) G2
Longitudinal clearance of mast main rollers
A 0.1 to 1.0 (0.004 to 0.039)
(in the whole lift range) H
Lateral clearance of inner mast main rollers
A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) J
Lateral clearance of outer mast main rollers
A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) K
Mast strip clearance
A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) L

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)
99759-7B110
10.16
MAINTENANCE SERVICE DATA

Mast and Forks

Truck FBC15N FBC18N FBC20N FBC30N
Item Model FBC18LN FBC25N FBC30LN
FBC25EN
FBC25LN

F Inner mast
L

G2
Mast and Lift Bracket/Later Version

B
F

Lift Bracket
A C1
K

H
E
J
C2

D
Outer mast

207106

Tightening Mast support bolts A 7.5 (54) [74] 18.2 (132) [178]
torque, kgf•m
(lbf•ft) [N•m] Chain wheel support
A 9.9 (72) [97]
bolts

Distortion of finger bar A 5 (0.2)

A = Assembly Standard B = Repair or service limit

Unit: mm (in.)

99759-7B110
10.17
MAINTENANCE SERVICE DATA

Tightening Torques for Standard Bolts and Nuts

Fine Thread – With Spring Washer Fine Thread – Without Spring Washer
With Spring Washer Without Spring Washer

Nominal Size Pitch Nominal Size Pitch

mm in. mm in. kgf·m (lbf·ft) [N·m] mm in. mm in. kgf·m (lbf·ft) [N·m]
6 0.24 1 0.04 0.6 4.3 5.9 6 0.24 1 0.04 0.7 5.1 6.9
8 0.32 1.25 0.05 1.4 10.1 13.7 8 0.32 1.25 0.05 1.7 12.3 16.7

Metric Fine Thread

10 0.39 1.25 0.05 2.9 21.0 28.4 10 0.39 1.25 0.05 3.4 24.6 33.3
12 0.47 1.25 0.05 5.2 37.6 51.0 12 0.47 1.25 0.05 6.1 44.1 59.8
14 0.55 1.5 0.06 8.4 60.8 82.4 14 0.55 1.5 0.06 9.9 71.6 97.1
16 0.63 1.5 0.06 12.6 91.1 123.6 16 0.63 1.5 0.06 14.8 107.0 145.1
18 0.71 1.5 0.06 18.2 131.6 178.5 18 0.71 1.5 0.06 21.4 154.8 209.9
20 0.79 1.5 0.06 25.2 182.3 247.1 20 0.79 1.5 0.06 29.7 214.8 291.3
22 0.87 1.5 0.06 33.4 241.6 327.5 22 0.87 1.5 0.06 39.3 284.3 385.4
24 0.95 1.5 0.06 42.2 305.2 413.8 24 0.95 1.5 0.06 49.7 359.5 487.4

Note
1. These charts give the torques for standard bolts and nuts.
2. The tolerance for these torques is ± 10%.
3. Unless otherwise specified, use these torques.
4. These torques are for “dry” conditions.

Coarse Thread – With Spring Washer Coarse Thread – Without Spring Washer
With Spring Washer Without Spring Washer

Nominal Size Pitch Nominal Size Pitch

mm in. mm in. kgf·m (lbf·ft) [N·m] mm in. mm in. kgf·m (lbf·ft) [N·m]
10 0.39 1.5 0.06 2.8 20.3 27.5 10 0.39 1.5 0.06 3.3 23.9 32.4
Metric Coarse Thread

Metric Coarse Thread

12 0.47 1.75 0.07 4.9 35.4 48.1 12 0.47 1.75 0.07 5.8 42.0 56.9
14 0.55 2.0 0.08 8.1 58.6 79.4 14 0.55 2.0 0.08 9.5 68.7 93.2
16 0.63 2.0 0.08 12.1 87.5 118.7 16 0.63 2.0 0.08 14.2 102.7 139.3
18 0.71 2.5 0.10 16.8 121.5 164.8 18 0.71 2.5 0.10 19.8 143.2 194.2
20 0.79 2.5 0.10 23.5 170.0 230.5 20 0.79 2.5 0.10 27.7 200.4 271.6
22 0.87 2.5 0.10 31.5 227.8 308.9 22 0.87 2.5 0.10 37.0 267.6 362.8
24 0.95 3.0 0.12 40.5 292.9 397.2 24 0.95 3.0 0.12 47.7 345.0 467.8

99759-7B110
10.18
MAINTENANCE SERVICE DATA

Tightening Torques for Standard Bolts and Nuts with Standard Threads
Coarse Thread – Inches

Nominal Size Threads Standard Bolt &

per Nut Torque
inch

mm in. kgf·m (lbf·ft) [N·m]

6.35 1/4 20 1.2±0.4 9±3 12±4
7.94 5/16 28 2.5±0.7 18±5 25±7
9.52 3/8 16 4.6±0.7 33±5 45±7
11.11 7/16 14 7.0±1.5 50±11 70±15
Inch Coarse Thread

12.7 1/2 13 10.4±1.5 75±11 100±15

14.29 9/16 18 15.0±2.0 110±15 150±20
15.88 5/8 11 20±3 150±18 200±25
19.05 3/4 10 37±5 270±37 360±50
22.22 7/8 9 58±8 420±60 570±80
25.40 1 8 88±10 640±75 875±100
28.58 1 1/8 7 113±15 820±110 1100±150
31.75 1 1/4 7 138±18 1000±130 1350±175
34.92 1 3/8 6 163±20 1180±150 1600±200
38.10 1 1/2 6 205±28 1480±200 2000±275

Tightening Torques for Taperlock Studs

Coarse Thread – Inches

Nominal Size Threads Standard Bolt &

per Nut Torque
inch

mm in. kgf·m (lbf·ft) [N·m]

6.35 1/4 20 0.8±0.3 6±2 8±3
7.94 5/16 28 1.8±0.6 13±4 17±5
9.52 3/8 16 3.6±0.6 26±4 35±5
11.11 7/16 14 4.6±1.0 33±7 45±10
Inch Coarse Thread

12.7 1/2 13 6.6±1.0 48±7 65±10

14.29 9/16 18 9.0±1.5 65±11 90±15
15.88 5/8 11 11±1.5 80±11 110±15
19.05 3/4 10 17±2 125±15 170±20
22.22 7/8 9 26±3 190±22 260±30
25.40 1 8 41±4 300±30 400±40
28.58 1 1/8 7 51±4 370±30 500±40
31.75 1 1/4 7 66±5 480±37 650±50
34.92 1 3/8 6 76±5 550±37 750±50
38.10 1 1/2 6 88±5 640±37 870±50
99759-7B110
10.19
MAINTENANCE SERVICE DATA

Maintenance Chart
Use the service chart to determine servicing intervals. Calendar intervals shown (weekly, monthly, etc.)
may be used instead of service meter intervals if they provide more convenient servicing schedules and
approximate the indicated service meter reading. Recommended service should always be performed at
the interval that occurs first.
Perform service on items at multiples of the original requirement. For example, at every 1200 hours or 6
months, also service those items listed under every 200 hours or monthly, every 50 hours or weekly and
daily (pre-start).

● = Check or clean
★ = Change or adjust
R = Replace

Maintenance Intervals

Every 1200 hours

Every 2400 hours

Every 200 hours
Daily (pre-start)

Every 50 hours
Inspection Point How to Check Service Data

or 6 months
or monthly
or weekly

or 1 year
Motors Bearing lubrication, damage Visual ● ● Lubricate

Winding to case resistance Test ● ● Resistance to be > 1

Mega Ω
Armature to case resistance Test ● ●

Brush contact area Visual ● ● Change brush

Brush length Visual ● ● Change brush

Brush spring force Test ● ● Change spring

Commutator surface condition Visual ● ●

Commutator discoloration Visual ● ●

Interior, exterior cleanliness Visual ● ● ● Clean

Steering wheel Free-play, looseness, rattling Test ● ● ● ● ●

Operation Test ● ● ● ● ●

Steering gear Oil leaks Visual ● ● ● ● ●

Mounting bolts, tightness Wrench ● ● ●

Steering Beam structural damage Visual ●

linkage
Cylinder leaks Visual ● ● ● ● ●

Cylinder mounting bolts Wrench ●

Tie rod bearings and pins Visual ●

Kingpin looseness Test ●

Trunnion fore-aft looseness Test ● Nominal 0.8 mm

(0.031 in.) clearance
99759-7B110
10.20
MAINTENANCE SERVICE DATA

Maintenance Intervals

Every 2400 hours or

Every 1200 hours or
Every 200 hours or
Inspection Point How to Check Service Data

Every 50 hours or
Daily (pre-start)

6 months
monthly
weekly

1 year
89 ± 3 mm
Brake pedal Height of pedal above floor Scale ● ● ● ● ● (3.5 ± 0.12 in.)
Stroke to point where brakes Scale ● ● ● ● ● 3 to 10 mm
start applying (0.12 to 0.4 in.)
Parking brake Lever lock position:
Performance Test/spring 4° - 5°
balancer ● ● ● ● ●
Operating effort:
55–66 kgf
(25–30 lbf)
[245–294 N]
Brake hoses Fluid leaks, damage or Visual ● ● ● ● ●
and pipes installation
Brake fluid Level in reservoir Visual ● ● ● ● ★ 103cc (7.9 cu. in.)
Wheel brakes Master cylinder and wheel Overhaul/
cylinders—operation, wear and Replace ★
damage
Brake clutch/inching pedal rod Visual/wrench ●
Brake master cylinder hoses & R
rubber parts
Service brake fluid R
Brake wheel cylinder rubber parts R

Brakes drums FBC15N-FBC18LN

and shoes 0.2 to 0.5mm
Drum-to-lining clearance Feeler gauge ● ● ● (0.01 to 0.02)

FBC20N-FBC30LN
0.2 to 0.6mm
(0.01 to 0.02)

FBC15N-FBC18LN
Sliding surfaces of shoes and Disassemble/ ● 2.5mm (0.10 in.)
wear of lining calipers
FBC20N-FBC30LN
3.0mm (0.12 in.)

Service Limit:
FBC15N - FBC18LN
254 + 0 0.13 mm
Drum—wear or damage Visual scale ● (10.00 + 0 0.0051 in.)

FBC20N-FBC30LN
310 + 0 0.13 mm
(12.20 + 0 0.0051 in.)

Free length of return springs Scale ●

Operation of shoes Test ●

Anchor pins—seizure Visual ●

99759-7B110
10.21
MAINTENANCE SERVICE DATA

Maintenance Intervals

Every 1200 hours or

Every 2400 hours or

Every 200 hours or
Inspection Point How to Check Service Data

Every 50 hours or
Daily (pre-start)

6 months
monthly
weekly

1 year
Backing plates Distortion, cracks, or damage Dye check ●
Fitting cables– Visual/scale ●
damage and length
Ratchet–wear or damage Visual ●
Front axle Cracks, distortion, Dye check/ ●
or other defects visual
Front wheel bearings–preload Spring balancer ● Hub bearing preload
5 to 50 kgf
(0.4 to 3.6 lbf•ft)
[0.5 to 4.9 N•m]
Fore-aft play Test ●
Cracks, distortion, or Visual ●
other defects
Differential Oil level and oil leaks Visual ● ● ● FBC15N - FBC25EN
5.7 liters (1.5 U.S. gal)
FBC25LN - FBC30LN
6.1 liters (1.6 U.S. gal)

Mounting bolts Torque wrench ●

Rear axle Front wheel bearings–preload Spring balancer ● Hub bearing preload
Torque wrench 25 to 65 kgf
(1.8 to 4.7 lbf•ft)
[2.5 to 6.4 N•m]
Lock Nut (outside)
16 kgf•cm
(116 lbf•ft)
[157 N•m]
Wheels Tires–cuts or gouges Visual ● ● ● ● ●
Tires–wear Depth gauge ● ● ● ● ●
Tires–imbedded objects Visual ● ● ● ● ●
Wheel nuts–tightness Torque wrench ● ● ●
Front Wheel Nuts:
FBC15N - FBC18LN
16 kgf•cm (116 lbf•ft) [157 N•m]
FBC20N - FBC30LN
38.5 kgf•cm (278 lbf•ft) [378 N•m]
Rims–damage Visual ● ● ● ● ●

99759-7B110
10.22
MAINTENANCE SERVICE DATA

Maintenance Intervals

Every 2400 hours

Every 1200 hours
Every 200 hours
Daily (pre-start)
Every 50 hours
Inspection Point How to Check Service Data

or 6 months
or monthly
or weekly

or 1 year
Hydraulic tank Oil level and contamination Visual ● ● ● ● ★
Strainer—clogging Visual ★
Return filter—clogging Visual ★
Hydraulic pump Oil leaks or abnormal noise Visual / listen ● ● ●
Control valve Oil leaks Visual ● ● ● ● ●
185 kgf/cm2
Main relief valve setting Pressure gauge ● (2631 psi)
[18,142 kPa]
Auxiliary relief valve setting Pressure gauge ● 158±5 kgf/cm2
2250±71psi
15,513 ± 490 kpa
Overload relief setting (optional) Pressure gauge ●
Control levers and links—rattle Test ● ● ● ● ●
Lift cylinders Cracks, distortion, or Visual ● ● ● ● ●
other defects
● ● ● ● ● FBC15N - FBC25EN
Rod drift (rated load) Visual/watch/ 50 mm (2.0 in.)/15 min
scale FBC25LN - FBC30LN
40 mm (1.6 in.)/15 min
Attachment ● ● ● ● ●
Mounting bolts—tightness Wrench ● ● ●
Oil Leaks Visual ● ● ● ● ●

99759-7B110
10.23
MAINTENANCE SERVICE DATA

Maintenance Intervals

Every 1200 hours

Every 200 hours
Daily (pre-start)
Every 50 hours

hours or 1 year
Inspection Point How to Check Service Data

or 6 months
Every 2400
or monthly
or weekly
Tilt cylinders Cracks, distortion, Visual ● ● ● ● ●
or other defects
Oil leaks Visual ● ● ● ● ●
Forward rod drift (rated load) Watch/scale ● ● ● FBC15N - FBC18LN
22 mm (0.9 in.)/15 min
FBC20N - FBC25LN
20 mm (0.8 in.)/15 min
FBC30N - FBC30LN
15 mm (0.6 in.)/15 min
Mounts—rattle or damage Visual/free ● ● ● ● ●
Rod socket nut—tightness Torque wrench ● ● ● ● ● FBC15N - FBC18LN
15 kgf·m
(108 lbf•ft)
[147 N•m]
FBC20N - FBC30LN
40 kgf·m
(289 lbf·ft)
[392 N·m]
Piping Oil leaks Visual ● ● ● ● ●
Rubber hoses: damage Visual ● ● ●
Hose reels and swivel joint— Visual ● ● ●
distortion or other defects
Mast and Cracks, distortion, Visual/ ● ● ● ● ●
lift bracket or other defects dye check
Mast supports—rattle or ● ● ●
damage
Main rollers—clearance, Feeler gauge/ ● ● ● Each roller to
damage dial gauge mast clearance
(at max. height):
0.1 to 0.5 mm
(0.004 to 0.020 in.)

99759-7B110
10.24
MAINTENANCE SERVICE DATA

Maintenance Intervals

Every 1200 hours or

Every 200 hours or
Every 50 hours or

Every 2400 hours

Daily (pre-start)
Inspection Point How to Check Service Data

6 months

or 1 year
monthly
weekly
Lift chains and Length of lift chains (20 links) Scale ● FBC15N - FBC18LN
chain wheels 318 mm (12.5 in.)
FBC20N - FBC25LN
381 mm (15.0 in.)
FBC30N - FBC30LN
508 mm (20.0 in.)

Tension deflection of lift chains Scale ● ● ● ● ● Both chains to

equal in tension
Chains—damaged or rusting Visual ● ● ● ● ●
Chains wheels—wear, Visual ● ● ●
distortion, or other defects
Chain wheel bearings—rattle Feel ● ● ●
Chain anchor bolts—distortion Visual ● ● ●
or damage
Forks and Forks—wear and distortion Visual/scale ● ● ● ● ● Fork thickness—
backrest refer to Service Data
Forks stopper pins— Visual ● ● ● ● ●
damage or distortion
Backrest mounting bolts— Torque wrench ● ● ● ● ●
tightness
Backrest—distortion or damage Visual ● ● ● ● ●
Lights Operation Test/visual ● ● ● ● ●
Turn signals
Operation Test ● ● ● ● ●
(optional)
Rear view Rear vision Visual ● ● ● ● ●
mirrors (optional)
Overhead guard Installation and damage Visual/wrench ● ● ● ● ●
Chassis Loosen bolts or nuts Wrench ●
Operator’s seat— Visual ● ● ●
damage and installation
Lubricate mast supports
Lubrication points Lubricate ● ● ●
every 50 hours or weekly

Oil change Inspect ● ● ●

99759-7B110
10.25
MAINTENANCE SERVICE DATA

Periodic Replacement Parts

The parts listed below are important for the safe operation of the truck, and especially designed to be
replaced at specified periods. Each service shop is requested to adhere to the replacement schedule
given here on all trucks brought into its care.

Periodic Replacement Parts Service Period

1 month 1 month 6 months 1 year 2 years

after (200 hours) (1200 hours) (2400 hours) (4800 hours)
delivery

1 ★
Rubber parts for brake Replace ● ●
master cylinder
2 ★
Rubber parts for brake Replace ● ●
wheel cylinders
3 ★
Hydraulic hoses Replace ● ●
4 ★
Hoses for power steering Replace ●
5 ★
Rubber parts for Replace ●
steering cylinder
6 ★
Lift chains Replace ●
7 Hydraulic tank return filter Replace ● ● ● ●
8 Drum to lining clearance Check or replace ● ●
9 Motor brushes Check or replace ● ●

★
Indicates important safety-related parts

99759-7B110
10.26
99759-7B110
LUBRICATION AND MAINTENANCE CHART BE SURE TO PERFORM SERVICE ITEMS QUOTED BELOW

CHECK LUBRICATE
EVERY 50 HR. OR WEEKLY
Lubrication Chart

EVERY 10 HR. OR DAILY MULTIPURPOSE-TYPE GREASE

SPECIFIC GRAVITY OF BATTERY
ENGINE OIL
OIL LEAKS BOLTS, NUTS
EVERY 50 HR. OR WEEKLY
TIRES, WHEEL NUTS EVERY 500 HR. OR 3 MONTHS MAST SUPPORTS
DIFFERENTIAL OIL LEVEL EVERY 500 HR. OR 3 MONTHS
BRAKE FLUID LEVEL
MAST STRIPS, ROLLER
HYDRAULIC OIL LEVEL EVERY 500 HR. OR 3 MONTHS SURFACES (EACH SIDE)
CONTACTORS LIFT BRACKET SIDE
BATTERY ELECTROLYTE LEVEL MOTOR BRUSHES ROLLERS (EACH SIDE)

BATTERY RESTRAINT LIFT CHAIN (EACH SIDE)

MAST, FORKS, LIFT CHAINS TILT SOCKET (EACH SIDE)

CHANGE FRONT AXLE SUPPORT
SEAT BELT AND RAILS (EACH SIDE)
STEERING
OIL FLUID FILTER,
TILT CYLINDER (EACH SIDE)
SERVICE BRAKES EVERY 1200 HR. OR 6 MONTHS
TRANSFER AND DIFFERENTIAL OIL BRAKE PEDAL
PARKING BRAKE HYDRAULIC TANK OIL FILTER TIE ROD ENDS (4 FITTINGS) REAR
ACCELERATOR PEDAL AXLE CENTER PIN
(FRONT/REAR)
HORN EVERY 2400 HR. OR 1 YEAR
HYDRAULIC OIL
DASH MONITOR BRAKE FLUID

NOTE: REDUCE SERVICING INTERVALS IN DUSTY OR SEVERE CONDITIONS. REFER TO OPERATION MANUAL 97182-12900
MAINTENANCE SERVICE DATA

10.27
10.28
◆

Recommendation for ambient temperatures [°C (°F)]

Oil Recommendation (-22) (-4) (14) (32) (50) (68) (86)

-30 -20 -10 0 10 20 30
| | | | | | | | | | | | |
API service classification ISO Grade 32 ISO Grade 68
Gear oil multipurpose type GL-5 SAE 75W SAE 80W
(hypoid gear oil) AGMA-1EP AGMA-2EP
Hydraulic oil SAE 5W -30 to -10 SAE 10W

Brake fluid F.M.V.S.S. No. 116—DOT 3 or DOT4 (SAE J1703)

Wheel bearings NLGI No. 2 grade multipurpose type (lithium base), consistency: 265 - 295
Grease
MAINTENANCE SERVICE DATA

Chassis NLGI No. 1 grade multipurpose type (lithium base), consistency: 310 - 340

• Avoid mixing lubricants. In some cases, different brands of lubricants are not compatible with each other and deteriorate when mixed. It is best to stick
with the same brand at successive service intervals.
Fuel and Lubricant Specifications

EP 68 Gear oil with borate additives are not recommended.

Gear Oil Greases Hydraulic oils

Specifications
API service classification GL-5 NLGI No. 1 NLGI No. 2
Visc
osit
y SAE90W Consistency 310-340 Consistency 265-295 SAE5W SAE10W
Manufacturer
Mobil 90 Pegasus Gear Oil Mobil Grease JL 77 No. 1 Mobil Grease JL 77 No. 2 — Hydraulic oil 28 LP

Shell Shell Spirax EP90 Retinax A No. 1 Retinax A No. 2 Tellus oil 22 Tellus oil T-32

Exxon Gear Oil GX 80W90 ---- Ronex MP UNIVISN 22 Nuto H32

Castrol Castrol Hypoy Castrol LM Grease Castrol Spheerol API Castrol Hyspin Castrol Hyspin
AWS32 AWS68
■ Brands of oil are subject to change without notice.
■ When you buy oil, select recommended brands and check specifications.

99759-7B110
MAINTENANCE SERVICE DATA

Weight of Major Components (Approximate)

Component / Model FBC15N FBC18N FBC18LN FBC20N FBC25N FBC25EN FBC25LN FBC30N-
FBC30LN

Counterweight 470(1036) 625(1378) 910(2006) 540(1190) 730(1609) 540(1190) 730(1609) 1060(2337)

Power train 200 215

(Motor, transfer box, reduction (441) (474)
gear and differential)
Overhead guard 62.7 (138) 67.4 (149) 66.0 (146)
Rear axle 150 (331) 220 (485)
Mast (3.3 m simplex mast) 520 (1146) 725 (1598) 830 (1830)
Outer mast 140 (309) 190 (419) 205 (452)
Inner mast 135 (298) 180 (397) 190 (419)
Lift bracket (including backrest) 105 (231) 150 (331) 175 (386)
Forks (two) 80 (176) 130 (287) 165 (364)
Lift cylinder and related parts 60 (132) 75 (165) 95 (209)
Hydraulic motor 45 (99) 50 (110)
Traction motor 80 (176) 100 (220)
Unit: kg (lb)

99759-7B110
10.29
MAINTENANCE SERVICE DATA

Special Service Tools

Truck Models

Ref. Part No. Part Name Application FBC15N - FBC20N - FBC30N -

No. FBC18LN FBC25LN FBC30LN

1 91268-00700 Socket wrench Removal and installation of rear wheel nuts ● ● ●

2 91268-00300 Bevel pinion Removal of bevel pinion assembly ● ● ●

(or 91268-02100) puller

3 64309-17700 Gauge kit Measurement of hydraulic pressure ● ● ●

4 91268-00800 Socket wrench Removal/installation of front wheel hub nuts ● ● ●

(70 mm)

5 MH061108 Socket wrench Removal/installation of front wheel hub nuts ● — —

(90 mm)

6 91468-00300 Installer Installation of front axle wheel bearing inner — ● ●

races

7 64309-40400 Installer Installation of rear axle inner bearing inner — ● ●

races

8 64309-15411 Spring remover Removal of return spring ● ● ●

9 64309-15412 Spring remover Removal/installation of brake shoes ● ● ●

10 64309-15413 Spring hook Installation of return spring ● ● ●

11 91268-10600 Steering wheel Removal of steering wheel ● ● ●

puller

12 91268-01600 Installer Installation of tilt cylinder tube bushing ● ● ●

13 05312-20650 ● — —

05312-20750 Hook wrench Remove / install tilt cylinder guide bushing — ● —

05312-20850 — — ●

14 F4540-06300 Pipe connector Measurement of control valve main relief

pressure & overload relief pressure (to be ● ● ●
used with 64309-17701 gauge kit)

15 97157-00100 Spring installer Install centering spring in steer gear ● ● ●

16 64309-40100 Wheel puller Removal of drive wheel hub ● — —

17 MH061108 Wheel puller Removal of drive wheel hub — ● ●

18 K8000-02921 Nipple Assy Main Relief Valve Pressure Check ● ● ●

19 97E67-00100 Transfer Removal of Bevel Pinion Shaft ● ● ●

Bearing Tool

20 97E67-00200 Plug Assy Tool Torque or Steer Gear Tank ● ● ●

21 97E67-00500 Tool - STC Steer Gear Hose Removal (STC) ● ● ●

99759-7B110
10.30
MAINTENANCE SERVICE DATA

Special Tool Illustrations

1 2
M10 x 1.5
46
M14 x 1.5

164
95 17
250 10

22
155 91268-00300
91268-00701 91868-02100

3 4

64309-17701 91268-00800

5 6
90

03703-59001 91648-00300
7 8

64309-40400 64309-15411

99759-7B110
10.31
MAINTENANCE SERVICE DATA

9 10

64309-15412 64309-15413
11 12
M12 X 1.25

M8 X 1.25

ø32
ø35
45 30 45
55

91268-10600 91268-01600

13 14

Flame-hardened Hv >500,
depth 2mm (0.08 in.) 05312-20650
05312-20750
05312-20850 F4540-06300
15 16

97157-00100 64309-40100

99759-7B110
10.32
MAINTENANCE SERVICE DATA

17 18

MH061017 6V3965

19 20

97E67-00100 97E67-00200

Rubber Coated Handle

97E67-00500

99759-7B110
10.33
MAINTENANCE SERVICE DATA

Inspection Guide
Check For (item or defect) How

Antifriction bearings ITEMS Measure inside diameter with an indicator

hole gauge and shaft outside diameter with
a) Fit on shaft an indicating micrometer

b) Fit in housing Measure outside diameter with an indicat-

ing micrometer and housing inside
diameter with an indicator hole gauge

c) Preload (small initial load applied to As stated in service manual

absorb initial bearing deformation)

DEFECTS

a) High running temperature (caused by As shown

over lubrication)

b) Noise (humming), vibration, or rough

running

Radial bearing Thrust bearing

c) Creep (marks of circumferential slip 8609153

on inner ring’s surface in contact with Visually
shaft or on outer ring’s surface in
contact with housing due to loose fit
of bearing)

d) Corrosion Visually

8609151

e) True brineling (caused by careless

installation or removal)

8609152

99759-7B110
10.34
MAINTENANCE SERVICE DATA

Check For (item or defect) How

Antifriction bearings f) False brinelling (caused by a constant vibration Visually

or oscillation of non-rotating bearings through
small arc)

8609154

g) Cracked race (caused by forcing bearing or

oversize shaft or by cooking race when installing Visually
or removing)

8609155

h) Broken separator (caused by dirt, metal chips,

or lack of lubricant) Visually

8609156
i) Damaged seal (caused by
improper use of tools) Visually

8609157

j) Spalled race (caused by too loose a fit) Visually

8609158

99759-7B110
10.35
MAINTENANCE SERVICE DATA

Check For (item or defect) How

Antifriction bearings k) Bad discoloration (caused by overheating due to Visually

poor lubrication)

8609159

i) Craters (caused by passage of electric current) Visually

8609160

Bushings or sleeve ITEM

bearings Fit on shaft Determine by measuring inside
diameter of bushing and outside
diameter of shaft

DEFECTS
Nicks, burrs, or other flaws on bearing surface Hold bushing toward a light and look
through bore

Fasteners DEFECTS

a) Striped or otherwise damaged threads (bolts, Visually

nuts, screws, etc.)

b) Distortion or loss of tension (spring lock Examine by compressing

washers, snap rings, etc.)

Gears ITEMS

a) Fit on bearing, bushing, spline or key As stated in service manual

b) Backlash As stated in service manual

DEFECTS

a) Excessive wear on teeth, thrust faces, and end Visually

faces on hub

b) Scratching wear (caused by large particles other Visually

than associated with abrasive wear)

99759-7B110
10.36
MAINTENANCE SERVICE DATA

Check For (item or defect) How

Gears c) Abrasive wear (caused by fine particles carried Visually

in lubricant)

d) Overload wear Visually

e) Pitting Visually

f) Spalling Visually

g) Overload breakage Visually

h) Fatigue breakage Visually

i) Corrosive wear Visually

99759-7B110
10.37
MAINTENANCE SERVICE DATA

Check For (item or defect) How

Keys and keyways Wear on sides making parts not fit tightly Examine by placing

Oil seals Damage to lip Visually

Roller chains and a) Wear on pins, bushings, rollers, and plates in Visually
sprockets each link tending to increase in pitch.

b) Wear on sprocket teeth Visually

Chain load

Sprocket rotation

New Old
8609189

Rubber parts Hardening or softening, swelling, tackiness, Visually

tearing, and deterioration due to aging

Splines and serrations ITEM

Fit

DEFECTS

a) Nicks, burrs, chips, etc. Visually

b) Free movement (looseness) of mating splines Examine

c) Excessive wear polish on sides (sliding fit Visually

splines)

d) Ridge or edge left between worn and unworn Visually

areas (sliding fit spline)

8609170

99759-7B110
10.38
MAINTENANCE SERVICE DATA

Check For (item or defect) How

Springs ITEMS See specification

a) Type called for Use a square

b) Squareness

8609171

c) Free length test Examine

d) Test force

DEFECTS

a) Excessive clearance space between coils Visually

(compression springs) in free state

b) Any clearance space between coils (tension

springs) in free state

8609172

8609173

c) Condition or ends or hooks Visually

d) Cracks or breakage Visually

99759-7B110
10.39

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