INTRODUCTION

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

precautions. In order to prevent accidents from happening, the factors
responsible for accidents must be avoided beforehand.
For this reason, please read this manual and fully understand the
precautions for safety and the proper procedures and directions for
inspection and maintenance before starting operation.

Performing maintenance and repair without adequate knowledge may

cause inadvertent accidents.

It is not possible to cover all the possible cases of accidents in this
"WORKSHOP MANUAL". Therefore, attention should be given to
precautions other than the ones mentioned in this "WORKSHOP
MANUAL". Especially, when repair and maintenance work which are not
covered in this "WORKSHOP MANUAL" are carried out, always work
under the direction of an instructor who understands the matter.
 Using this "WORKSHOP MANUAL"
This manual has information about the layout and names of main components, procedures for
disassembly, assembly, inspection, adjustment, maintenance, and hints for troubleshooting which are in
effect mainly for the model FBT-13P~20PN-75 .
Since the parts used in this machine are subject to change for the sake of better quality, performance
enhancement and safety, some portions of the contents and illustrations of this "WORKSHOP MANUAL"
may not be identical.
Directions with and marks are very important, and shall be followed.

Indicates a potentially hazardous situation which, if not avoided,

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

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

NOTE
operator and maintain of truck.

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

This "WORKSHOP MANUAL" is directed at personnel who possess sufficient knowledge and technical
expertise. If you do not understand any of the contents of this "WORKSHOP MANUAL", perform
operation under the guidance of personnel who does.

2. Conditions of a facility
The work conditions described in the "WORKSHOP MANUAL" are written on the assumption that the
work is performed at standard work facilities and tools for the maintenance of NICHIYU ELECTRIC LIFT
TRUCKS are available.
For safe and reliable maintenance, the work should be performed at a shop which is equivalent to these
described in this "WORKSHOP MANUAL" with following all instructions strictly.

Copyright© 2007
NIPPON YUSOKI CO., LTD.
All Rights Reserved
 CONTENTS - WORKSHOP
SAFETY WORK 1 4. TYRE 49
4-1. Front tyre .................................................... 49
1. Precautions for safe inspection and 4-1-1. Front tyre - disassembly and reassembly 49
maintenance work ........................................ 1 4-1-2. Tyre size (front) 49
2. Safety labels................................................. 5 4-2. Rear tyre .................................................... 50
3. Model name and serial numbers.................. 8 4-2-1. Rear tyre - disassembly and reassembly 50
4. Cautions for maintenance .......................... 10 4-2-2. Tyre size (rear) 50
5. Tightening torque for bolts ......................... 13 4-3. Inspection and adjustment ......................... 51
6. Maintenance tools and inspection devices ....... 14 4-3-1. Bolt nut - inspection 51
4-3-2. Air pressure - inspection 51
7. Data of LOCTITE and THREEBOND products ...... 15
4-3-3. Tyre - visual inspection and replacement 52
4-4. Troubleshooting .......................................... 52
4-4-1. Tyre - troubleshooting 52
1. GENERAL 16
1-1. Appearance ................................................ 16
1-2. Specifications ............................................. 17 5. STEERING LINKAGE 53
5-1. Disassembly and reassembly .................... 53
5-1-1. Steering linkage- disassembly and reassembly 53
2. FRONT AXLE (DRIVE) 19 5-2. Inspection and adjustment ......................... 56
2-1. Disassembly and reassembly .................... 19
5-2-1. Joint - inspection and replacement 56
5-2-2. Knob - inspection and replacement 56
2-1-1. Front axle - removal 19
5-2-3. Steering wheel - inspection and replacement 56
2-1-2. Disassembly transfer ASS'Y 21
5-2-4. Chain comp., roller - adjustment 57
2-1-3. Reassembly the transfer ASS'Y 28

3. REAR AXLE (STEERING) 42 6. BRAKE 58

6-1. Foot brake .................................................. 58
3-1. Disassembly and reassembly .................... 42
6-1-1. Foot brake - disassembly and reassembly 58
3-1-1. Rear axle - removal and installation 42
3-1-2. Rear axle - disassembly and reassembly 43 6-2. Parking brake ............................................. 59
3-2. Inspection and adjustment ......................... 45 6-2-1. Parking brake - disassembly and reassembly 59
3-2-1. Angle sensor comp. - adjustment 45 6-3. Inspection and adjustment ......................... 60
3-2-2. EPS torque sensor - adjustment 45 6-3-1. Brake pedal - adjustment 60
3-3. Troubleshooting .......................................... 48 6-3-2. Brake pedal - inspection 61
6-3-3. Microswitch of parking brake lever - adjustment 62
3-3-1. Rear axle - troubleshooting 48
6-3-4. Parking lever - inspection and adjustment 62
6-3-5. Master cylinder ASS'Y- inspection and replacement 63
6-3-6. Master cylinder air bleeding 64
6-4. Troubleshooting .......................................... 66
6-4-1. Brake - troubleshooting 66
7. HYDRAULIC SYSTEM 68 7d. CYLINDER 82
7-1. Oil piping circuit .......................................... 68 7d-1. Disassembly and reassembly .................. 82
7d-1-1. Lift cylinder - removal : P - mast (2 - stage simplex) 82
7d-1-2. Lift cylinder - removal : PFL-mast
(2-stage duplex), M-mast (3-stage triplex) 85
7a CONROL VALVE AND VALVE LINKAGE 69 7d-1-3. Tilt cylinder - removal 88
7a-1. Disassembly and reassembly .................. 69 7d-1-4. Lift cylinder - installation and adjustment 89
7a-1-1. Valve linkage - disassembly and reassembly 69 7d-1-5. Tilt cylinder - installation 90
7a-1-2. Control valve 71 7d-1-6. Lift cylinder - disassembly and reassembly 90
7a-2. Inspection and adjustment ...................... 72 7d-1-7. Tilt cylinder - disassembly and reassembly 101
7a-2-1. Relief pressure - adjustment 72 7d-2. Inspection and adjustment .................... 102
7a-2-2. Microswitch - adjustment 73 7d-2-1. Cylinder comp. - inspection 102
7a-3. Trouble shooting ...................................... 74 7d-2-2. Piston rod - inspection 102
7d-2-3. Drift for lift and tilt - inspection 103
7a-3-1. Control valve - troubleshooting 74
7d-3. Variation of the tilt cylinder ..................... 104
7d-3-1. Tilt angle by masts 104
7d-4. Troubleshooting ..................................... 105
7b. OIL TANK AND OIL PIPING 75 7d-4-1. Cylinder - troubleshooting 105
7b-1. Disassembly and reassembly .................. 75
7b-1-1. Oil tank - disassembly and reassembly 75
7b-1-2. Oil piping replacement - precautions 78
8. MAST 106
7b-2. Inspection and adjustment ...................... 79
7b-2-1. Oil - inspection 79 8-1. Disassembly and reassembly .................. 106
7b-2-2. Recommended oil and quantity for hydraulic circuit 8-1-1. Lift bracket ASS'Y- removal 106
(except brake and gear oil) 79 8-1-2. Mast ASS'Y - removal 107
7b-2-3. Oil tank and filters - cleaning and check 80 8-1-3. Mast - disassembly and reassembly 109
7b-3. Troubleshooting ....................................... 80 8-2. Inspection and adjustment ....................... 112
7b-3-1. Oil tank - troubleshooting 80 8-2-1. Mast, lift bracket and roller shaft - inspection 112
8-2-2. Back shoe - inspection 113
8-2-3. Lift chain - inspection and replacement 113
8-2-4. Chain bolt - inspection 114
7c. HYDRAULIC PUMP 81 8-2-5. Chain wheel - inspection 114
8-2-6. Roller - inspection and replacement 115
7c-1. Removal and installation .......................... 81 8-2-7. Fork - inspection and replacement 115
7c-1-1. Hydraulic pump - removal and installation 81 8-2-8. Lift chain - inspection and adjustment 116
8-2-9. Mast lean- adjustment 117
8-3. Troubleshooting ........................................ 118
8-3-1. Mast Lift bracket Fork - troubleshooting 118
9. MOTOR 119 10. ELECTRIC PARTS 134
9-1. Disassembly and reassembly .................. 119 10-1. Location and name ................................ 134
9-1-1. Traction motor - removal and installation 119
9-1-2. Hydraulic motor - removal and installation 119
9-1-3. EPS motor - removal and installation 121
9-1-4. Traction motor - disassembly and reassembly 122 10a. CONTROL UNIT 135
9-1-5. Hydraulic motor - disassembly and reassembly 123 10a-1. Location and name .............................. 135
9-1-6. EPS motor - disassembly and reassembly 124 10a-2. Disassembly and reassembly .............. 136
9-2. Inspection and adjustment ....................... 125 10a-2-1. Control unit - removal and installation 136
9-2-1. Rotor comp. (Traction/hydraulic motor) 10a-2-2. EPS controller - removal and installation 138
- inspection and replacement 125 10a-2-3. Control unit - disassembly and reassembly 139
9-2-2. Armature comp. (EPS motor) 10a-3. Check and replacement....................... 142

rs
- inspection and replacement 126
10a-3-1. Main connector - inspection and replacement 142
9-2-3. Brush, brush holder and spring (EPS motor)

te ale
10a-3-2. Module, FET - inspection and replacement 143
- inspection and replacement 128
10a-3-3. Capacitor - check and replacement 145
9-2-4. Motor ASS'Y (Traction/Hydraulic motor)
- inspection bu e 130
tri d D
9-2-5. Motor ASS'Y (EPS motor) - inspection 131
9-2-6. Oil seal and permanent magnet (EPS motor) 10b. ACCELERATOR 146
D ize

inspection and replacement 132

10b-1. Disassembly and reassembly .............. 146
9-2-7. Motor - specification 132
ot or

10b-1-1. Accelerator linkage - removal and installation 146

9-3. Troubleshooting ........................................ 133
10b-2. Inspection and adjustment .................. 147
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9-3-1. Motor - troubleshooting 133

10b-2-1. Potentiometer - adjustment 147
10b-2-2. Accelerator linkage - adjustment 148
D rA
fo

10c. DISPLAY PANEL AND DIRECTIONAL SWITCH 149

o
y

10c-1. Disassembly and reassembly .............. 149

nl
O

10c-1-1. Display panel

- disassembly and reassembly 149
10c-1-2. Directional switch
- disassembly and reassembly 150

10d. BATTERY 152

10d-1. Removal and installation ..................... 152
10d-1-1. Battery - removal and installation 152
10d-2. Inspection and adjustment .................. 153
10d-2-1. Battery - inspection and adjustment 153
10d-2-2. Battery - Cleaning 155
10e. CHARGER (BUILT - IN) 156
10e-1. Disassembly and reassembly .............. 156
10e-1-1. Charger ASS'Y - disassembly and reassembly 156
10e-1-2. Transformer - disassembly and reassembly 157
10e-1-3. Built-in charger - specification 158
10e-2. Inspection and replacement ................ 159
10e-2-1. Magnetic contactor - inspection 159
10e-2-2. Plug comp. and receptacle
- inspection and replacement 159
10e-2-3. Fuse and fuse base - inspection 159
10e-2-4. Transformer - inspection 160
10e-2-5. Diode - inspection 160
10e-3. Inspection After Assembly ................... 161
10e-3-1. Timer - inspection 161
10e-4. Charging procedure ............................. 161
10e-4-1. Automatic charge (Daily charge) 161
10e-4-2. Balancing charge 164
10e-4-3. Inspection after charging 165
10e-5. Voltage tap ........................................... 166
10e-5-1. Power supply voltage - check 166
10e-5-2. Voltage tap - selection 166
10e-5-3. Voltage tap - changing 167
10e-5-4. Fuse (three-phase voltage) - replacement 167

11. LASER POINTER (OPTION) 168

11-1. Adjustment............................................. 168
11-1-1. Fork level - adjustment 168
11-1-2. Laser optical axis - adjustment 168

12. SERVICE DATA 169

12-1. Standard work hours ............................. 169
MEMO
 SAFETY WORK
1. Precautions for safe inspection and
maintenance work
Maintenance shops
CAUTION
ADEQUATE SPACE WITH FLAT SURFACE:
 The floor area of the shop (location) where
inspection and maintenance are performed
must have adequate floor space, and have level
surfaces without holes.
If these conditions are not met, unexpected
accidents, such as a roll-over of the forklift
truck, may result.

CAUTION WELL-VENTILATED AREA

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

CAUTION LOCATION EQUIPPED WITH FIRE

EXTINGUISHING EQUIPMENT
 Equipment such as first-aid boxes and fire
extinguishers should be nearby when work is
performed.

CAUTION SAFE AND WELL-LIGHTED AREA

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

CAUTION PROPER ARRANGEMENT

Arrange and clean always at a working place to
work safety.
Especially, arrange disassembled parts well.

1
 Work clothing
CAUTION The worker should wear a hat, work clothes, and
safety shoes that are suitable for safe work. The
work clothes should be close-fitting.
If this is not observed, loose clothing may
become caught in a machine, resulting in
serious injury.

Tools and gauges

CAUTION Always use tools that are suitable for the work
being performed. Use proper size tools when
tightening and loosening the parts of the forklift
truck.
Failure to observe the above could result in
serious injury or damage to machines.

CAUTION Prepare tools and gauges before starting to work.

Safety work

WARNING  Wh e n hoist ing a fork li f t t ruck or a h e av y

component, use ropes or cable with correct
capacity.
Do not use ropes or cables which are kinked.

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

with safety blocks or rigid stands.

WARNING Apply wheel chocks to tyres to prevent the truck

from moving.

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

proper safety precautions.

2
 Parts
CAUTION When replacing any parts, be sure to use NICHIYU
genuine parts.

CAUTION When replenishing battery electrolyte, be sure to

use refined or distilled water.

Repair of electrical components

CAUTION Be sure to disconnect the battery plug when
replacing electrical component.

CAUTION Be sure to jack up the drive wheel when trouble

shooting electrical operations.

NOTE Record the places of lead wire connection when

disassembling.

CAUTION CHARGING BATTERY

 Batteries produce flammable gas during
charging. Do not allow batteries in the vicinity of
fire or flames.
Failure to observe the above could result in an
explosion.

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

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

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

CAUTION When removing the hydraulic pipes, cap them

to prevent dust from entering into the hydraulic
components and pipes.

CAUTION When disassembling and assembling the

hydraulic components, work at clean place and do
not damage the parts.

Tightening torque
CAUTION  Observe tightening torque specified in this
manual.
If not specified, refer to the table [Tightening
torque for bolts] on page 13.

Marks and Symbols

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

4
 2. Safety labels
The illustration below shows the location of safety labels for safe operation.
Always protect the safety labels from contamination and damage.
If they are damaged or lost, replace with new ones.

9
5

2 10

8
7
12
4 11

215S0001E

No. Parts No. Parts Name Q'ty Notes

1 50004-65060 Plate, Warning 1 Shearing point
2 50004-65050 Plate, Caution 2 Caution for fingers
3 50004-65220 Plate, Caution 1 Caution for fingers
38540-00520 Label, Caution 1 Caution for battery
4
38540-00630 Label, Caution 1 Caution for battery
5 50004-65170 Plate, Caution 1 Parking brake
6 50005-95230 Plate, Lubrication 1 Lubrication
0902-69964 Label, Tyre 1 Air pressure (8.8 bar) FBT 13P/15P
7
24700-09410 Label, Tyre 1 Air pressure (9.8 bar) FBT 18P
8 50004-65110 Plate, Lubrication 1 In case of tip over
9 50006-14760 Plate, Caution 1 Caution for brake fluid
10 50004-65160 Plate, Precaution 1 No riding except Operator
11 50004-65180 Plate, Caution 1 Operation of Gas spring lock
24700-09410 Label, Tyre 1 Air pressure (9.8bar) FBT 13P/15P
12
0902-69954 Label, Tyre 1 Air pressure (8.3bar) FBT 20P

5
 1 2 5
WARNING

WARNING Apply parking brake before

leaving truck. Make adjust
to provide adequate braking.

50004-65050

4 (with Japanese bettery only)

GASES produced by this battery can be explosive.

Cigarettes, flames or sparks could cause battery to explode.
Make sure batteries are stored and charged in a wellÐventilayed area.
Batteries contain SULFURIC ACID can cause severe burns.
Avoid contact with skin, eyes or clothing.
In event of accident flush with water and call a physician immediately.
Wear rubber gloves to prevent ELECTRIC SHOCK during checking.
and maintaining.
Keep out of reach of children.
IMPORTANT POINT FOR MAINTENANCE
1. Keep the electrolyte level at proper height. (EX.) VENT PLUG
(When electrolyte decreased, fill purified water Stopper
White line
and stop filling immediately if confirmed the white line of the
float as shown herein, for overÐfilling causes overflow.)
2. Always give the battery an adequate charge and
FLOAT
do not use the battery at overdischarged condition.
3. Keep the surface of battery clean and dry.

6 7
(For CE)
LUBRICATION 1200 HOURS [FBT13P/15P]
600 HOURS
200 HOURS

LIFT BAR TILT CYLINDER ROD END

G G 8.8
DRIVE AXLE MAST SUPPORT
AF G

BRAKE MASTER CYLINDER LIFT CHAIN

M0 M0 G

STEERING SHAFT HYDRAULIC OIL TANK

[FBT18P]
RG HO HO

STEERING CHAIN PIVOT HOUSING

G G

STEERING GEAR BOX WHEEL SHAFT 9.8

GO G

: LUBRICATION G : CHASSIS GREASE (For pneumatic tyre only)

: REPLACE GO : GEAR OIL

: CHECK AND ADJUSTMENT HO : HYDRAULIC OIL

MO : MINERAL OIL

RG : RUBBER GREASE

AF : AUTOMATIC TRANSMISSION FLUID

50005-95230-0

6
 8
Do Not Jump ! Lean Forward
Fasten Hold
Seatbelt On
Tight Lean
Truck can Away
TIP OVER ! Brace From
Risk of serious Feet Impact
INJURY
WARNING or DEATH IN CASE OF TIPOVER
exceeds the stability of the truck.
FOR SAFETY NOTICE FOLLOWING WARNINGS 4. Serious injury or death can occur to the operator if he / she is trapped
1. Lateral tipover can occur when unloaded if the combination of speed between the truck and the ground.
and sharpness of turn produces an overturning moment which exceeds
the stability of the truck.
2. Lateral tipover can occur if overloaded or loaded within capacity and the
IN CASE OF TIPOVER
load is elevated and if turning and / or braking when traveling rearward 1. The operator should stay with the truck if lateral or longitudinal tipover
or if turning and / or accelerating when traveling forward produces an occurs. The operator should hold on firmiy and lean away from the point
overturning moment which exceeds the stability of the truck. of impact.
Rearward tilt and / or off-center positioning of the load and / or uneven 2. The operator should stay with the truck if it falles off a loading dock or
ground conditions will further aggravate the above conditions. ramp. There are other situations where the environment of the landing
3. Longitudinal tipover can occur if overloaded or when loaded within capacity area presents a severe hazard. In those incidents. it may be prudent for
and the load is elevated if forward tilt. braking in forward travel. or the operator to leave the truck.
commencing rearward travel produces an overturning moment which 24700-04830

9 10
The brake oil MUST be “Tellus T15 (Shell)”. PRECAUTIONS FOR SAFETY OPERATION
DO NOT USE “DOT3” or
any other type of oils or fluids. 1 Do not overload. observe allowable load (blue zone).
50006-14760
2 Prior to operation, check performance of brake
or turn quickly.
3 Do not make a sudden start and brake or turn
11 quickly.
4 Do not make a sudden valve lever operation at a
Lock release method of gas spring
high lift.
5 Do not run sideways or handle on an incline.
6 When the red lamp of battery capacity indicator
turns on, charge battery.
7 Check electrolyte every week and replenish water.
8 Be sure to use the prescribed fuses.

12
[FBT20PN]

(For pneumatic tyre only)

7
3. Model name and serial numbers
Model name
Name plate

FB 75

T T : Three-wheeler
Capacity code 13 : 1250kg
15 : 1500kg
18 : 1750kg
20 : 2000kg

Classification P : Pneumatic tyre

of tyre PN : No puncture tyre
PC : Cushion tyre

B : Large capacity battery

equipped
C : Stationary charger
D : Dust resistant
Maximum lifting height [cm]
Mast type NO CODE : Two stage full visibility (simplex) mast
M : Three stage full free lift (triplex) mast
(Full visibility mast)
PFL : Full free lift (duplex) mast
(Full visibility mast)

CS : Cold storage use for -35:

FCS : Cold storage use for -50:
RP : Rust resistant
: Attachment
SF : Side shifter
WB : Wide lift carriage
RP : Rust resistant
Z : Special type

8
 Serial numbers

No. Serial numbers Stamped position

1 Serial No. of a truck Stamped on the name plate
2 Serial No. of chassis Stamped on the upper rear frame
3 Serial No. of a mast Stamped on the mast name plate
4 Serial No. of a front axle Stamped on the gear case
5 Serial No. of a traction motor Stamped on motor name plate
6 Serial No. of a hydraulic Stamped on motor name plate
7 Serial No. of EPS motor Stamped on motor name plate
8 Serial No. of lift cylinders Stamped on lilt cylinders

Location of serial numbers

8
3

4
6

215S0002

9
4. Cautions for maintenance
General precautions
 When replacing any parts, be sure to use genuine
NICHIYU parts.
 When par ts are assembled, always replace old
packing and O-rings with new ones. In addition, be
sure to apply a light coat of grease on the O-rings and
oil seals before installing them.
 As shown in the illustration, face the flat side of the Retainer for a Retainer for a
groove hole
C-shape retainer in the direction the force is applied
when installed.

152E101

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

direction the force is applied when driving in a spring
pin.

152E102

 The split pin must be replaced with a new one and split
so it will not come out.

152E103

 When using a thrust washer with oil grooves cut, Oil grooves
observe the direction of installation.

152E104

 When connecting and disconnecting couplers of

electrical harnesses, always disconnect the battery
plug.

10
 Using liquid packing
 Scraping before application of seal
Remove the sealer adhered on the mating surface of the
casing by using a scraper or equivalent tool. Be careful
not to make scratches of 0.3 mm or deeper. If scratches
Scraper
are made, repair the area by using an oil stone.

152E105

 Applying liquid packing

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

Cut the nozzle at the

2. Cut the nozzle of the liquid packing tube at about the second section
second section so that the bead width will be 3 to 3.5
mm. 3 - 3.5 mm
Mating surface Liquid packing
152E106

3. Attach a key for rolling up the tube, and apply the liquid
packing to the mating surface while rolling up the tube.
* Do not smooth out the bead; doing so may cause
leakage. Not Good

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

Key to evacuate
on the internal portion of the mating surface. liquid packing

Good 152E107

4. Close the mating surfaces within 15 minutes after the

Apply liquid packing
liquid packing is applied.
Within 15 minutes
5. When tightening the bolts, always tighten temporarily Assembly
first, and then tighten them gradually, moving from one to
the next in a diagonal pattern. Wait for 30 minutes or more

Filling oil/Operation
6. Wait for more than 30 minutes before adding oil or
operating the machine.
* Failure to do so may cause oil leakage.

11
  Deterioration of liquid packing

1. Once the tube has been opened, the liquid packing * If the oil has separated, the
packing has deteriorated.
anchoring the tip part of the nozzle might be cured and
deteriorated. Squeeze out that portion and discard it Squeeze out the
before reusing the packing. bead about 20
mm and check.

152E108

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

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

CAUTION If the state of the packing is normal, it will be

cured within approximately 2 hours. However, a
deteriorated packing will not.

12
 5. Tightening torque for bolts
Classification of bolt 4T 8T Brass Stainless

SCM435
Material of bolt SS400
(S55C)
BsBM2S-0 SUS304

Nominal Pitch *1
of bolt Tightening torque *2 Unit : N m{kgf m}
(mm) (mm)
0.6 1.3 0.4 0.5
M3 0.5 {0.06} {0.14} {0.04} {0.05}
1.4 3.2 1.0 1.0
M4 0.7 {0.14} {0.33} {0.10} {0.11}
2.7 6.4 1.8 2.0
M5 0.8 {0.28} {0.66} {0.19} {0.21}

rs
4.7 10 3.1 3.6
M6 1.0 {0.48} {1.1} {0.32} {0.37}

te ale
11 26 7.8 9.0
M8 1.25
bu e
{1.1} {2.7} {0.80} {0.92}
tri d D
22 55 15 18
M 10 1.25 {2.3} {5.7} {1.6} {1.9}
D ize

39 98 29 33
M 12 1.25 {4.0} {10} {3.0} {3.4}
ot or

62 150 47 53
is
N uth

(M 14) 1.5 {6.3} {16} {4.8} {5.4}

D rA

97 240 73 81
M 16 1.5 {9.9} {25} {7.5} {8.3}
fo

180 500 140 150

M 20 1.5
o

{19} {51} {15} {16}

y
nl

250 670 200 220

(M 22) 1.5
O

{26} {69} {21} {23}

320 840 250 280
M 24 2.0 {33} {86} {26} {29}
640 1600 530 570
M 30 2.0 {66} {170} {54} {58}

*1. In the table above, the thread pitches of bolt diameters M3 to M8 are for coarse
screw threads and those of bolt diameters M10 or larger are for fine threads
according to our specifications.
*2. The tolerance range of tightening torque is to be +/- 10% of the reference values
given above. (The tolerance range is determined according to experience, related
standards, and records provided by other companies.)

13
6. Maintenance tools and inspection devices
The table shows tools/devices required for inspection and maintenance.
Type No. Tool/Device name Detail
1 Doubleended spanner 6x7, 8x10, 11x13, 12x14, 17x19, 22x24
2 Single-ended spanner 24, 27, 30, 32
3 Offset wrench 10x12, 14x17, 22x24, 23x26
4 Extension bar 12.7x150mm
5 Box socket 12.7x10, 12, 13, 14, 17, 19, 21, 22, 23, 24, 26, 27, 30, 32
6 Adjust wrench 300mm
7 Hexangular wrench
8 Screwdriver (+)100, 150, 200, (-)100, 150, 200
9 Hammer 1P
10 Shockless hammer
11 Needle nose pliers 150mm
Maintenance
tools 12 Cutting pliers 150mm
13 Pliers 150mm
14 Wire Cutter 150mm
15 Water pliers 250mm
16 Pressure pliers
17 Snap ring pliers
18 Gear puller For outward form 30～150mm
19 Pipe wrench 200, 350, 900
20 Scraper
21 Adjustable wrench
22 Chisel
23 File
24 Thickness gauge 0.03～3mm
25 Measure 300mm、1000mm
26 Tape measure 10m
Resistor
27 (For discharging procedure) 20Wx50 or 50Wx10 or 10Wx15
28 Digital tester
29 Clamp tester
30 Analog clamp ammeter Hioki 3109-01
31 Digital clamp ammeter Hioki 3209AC/DC high tester/Yokogawa CL-612(for measuring solenoid valve current)
Megger
Inspection 32 (For inspection of insulation)
devices 33 Oil pressure gauge 25MPa
34 Thermometer Alcohol thermometer
35 Hydrometer Suction type
36 Color tester Color check
37 Stopwatch
38 Torque wrench 0.5～1.5, 3～15, 40～200, 150～800Nm（preset type）
39 Dial gauge
40 Spring scale
41 Angle gauge
14
 7. Data of LOCTITE and THREEBOND products
LOCTITE product
Product number Content
#262 Thread-locking material
#542 Thread-sealing material
#648 Retaining compound

Visit: www.henkel.com for details.

THREEBOND product
Product number Content
#1212 (TB 1212) Liquid gasket
#1401 (TB 1401) Plastic thread locker
#1901 Molybdenum disulfide
lubricants
#1344 (1344N) Anaerobic sealant

Visit: www.threebond.co.jp/en/index.html for details.

15
 1. GENERAL
1- 1. Appearance
2 FRONT AXLE

3 REAR AXLE

4 TYRE

5 STEERING
LINKAGE
8
7 Hydraulic system
6 BRAKE

7a CONTROL VALVE
7d AND VALVE LINKAGE

7b OIL TANK AND

OIL PIPING
7c HYDRAULIC
PUMP
7a
6 7d CYLINDER
7b

8 MAST
7c

9 MOTOR
8
4
10 ELECTRIC
2 PARTS (*)
5 11 LASER
4
POINTER
9
12 SERVICE
DATA

*See page 134. for the arrangement of the electric parts.

215S0101

16
1 GENERAL

1- 2. Specifications

E° D°

I
B
K

A
C (Free lift)

17
 GENERAL 1

MODELS FBT13P-300 FBT15P-300 FBT18P-300 FBT20PN-300

Capacity kg 1250 1500 1750 2000

Load center A mm 500
Lift height B mm 3000
Free lift C mm 145
Laden mm/s 400 380 360 300
Lift speed
Unladen mm/s 610 500
Forward D deg 5
Tilt angle
Backward E deg 6
Laden km/h 15.0 14.5 14.0
Travel speed
Unladen km.h 16.5 16.5 16.0 15.5
Min. turning radius F mm 1400 1500 1545 1695
Max.gradeability (3min. rating,
% 20 18 15 14
1.5km/h and over)
Overall length G mm 2830 2930 2975 3155
Overall width H mm 1070
Mast lifted I mm 4000
Overall
Mast lowered J mm 1980
height
Overhead guard K mm 1985
Wheel base L mm 1200 1300 1420
Tread (Front / Rear) mm 895/250 895/230
Service weight (w.o battery) kg 2155 2185 2380 2655
18x7-8-
Pneumatic 18 x 7 - 8 - 14PR
16PR
Front
Tyres
Solid 18 x 7 - 8

Cushion 18x6x12 (1/8)

16x6-8-
Pneumatic 15 x 4 (1/2) - 8 - 12PR
Rear Rear 10PR

Solid 5 x 4 (1/2) - 8 16x6-8

Control system (Travel / Hydraulic) Inverter Control

Traction 4.5 (2 pcs.)
Motor Hydraulic kw 9.5
EPS 0.3 0.45

Battery (48V) Ah/5HR 320 350 390

*This specification shows when a single tyre is installed, and a standard battery is loaded.
Specifications may vary by the mast, tyres and/or the battery.

*Subject to change without notice for improvement.

18
 2. FRONT AXLE (DRIVE)
2- 1. Disassembly and reassembly
CAUTION Lift or jack up the forklift truck and support it with safety blocks or rigid
stands.
Apply wheel chocks to tyres to prevent the truck from moving.
Record places of lead wire connections before disassembling.
 Turn the key switch off and operate hydraulic levers a few times to
release high pressure in the hydraulic piping before disconnecting
hydraulic hoses or pipes.
 When disconnecting hydraulic pipes, cap them to prevent dust from
entering into hydraulic components and pipes.
Be sure to disconnect the battery plug.

2-1-1. Front axle - removal

1. Remove the mast ASS'Y.
Refer to [8-1-2. Mast ASS'Y - removel]
Disconnecting the motor lead wire
2. Remove the floor plate.
3. Disconnect three lead wires on the traction motor and the
Traction
harness connector for the bearing sensor. motor

CAUTION Be careful not apply too much stress to the Lead wire
cable of the accelerator potentiometer when
removing the floor plate. Connector

 Record places of lead wire connections

before disassembling. 215S0266

19
4. Remove the front tyre.
5. Remove the front axle.
Disconnecting the front and rear tyres Fitting bolt (M14xL95)
Tightening torque
150 N m
{16.0 kgf m}
Traction motor
5 parts
55mm Fitting bolt (M8xL55)
Tightening torque
26 N m
95mm
{2.7 kgf m}

Fitting bolt (M8 xL75)

Tightening torque
26 N m
Front axle {2.7 kgf m}
75mm
2 parts Fitting bolt (M14 xL65)
Hub nut Tightening torque
Front tyre 150 N m
65mm {16 kgf m}
2 parts

215S0201
: Tightening torque

20
 2 FRONT AXLE (DRIVE)

2-1-2. Disassembly transfer ASS'Y

CAUTION Replace all when removing the oil seal, piston seal, O-ring, friction plate and
bearing.

1. Remove the hab cap and lock nut. 4. Remove the inner ring of the taper
roller bearing.

1
2
1

(1)Hub cap, (2)Lock nut

(1)The inner ring of the taper roller bearing
Don't be damaged the top of
NOTE
the lock nut. Don't remove if it is not
NOTE replaced.
2. Remove the hub wheel after the lock
plate and O-ring. 5. Remove hex socket screws(6 pieces).

1 1

(1)Lock plate,(2) O-ring,(3)Hub wheel (1)Hex socket screw

3. Remove the dust cover from the hub 6. Put the transfer cover in the bottom.
wheel. Remove hex socket screws
(2 pieces) and the transfer case.
1
2

(1)Dust cover 1
(1)Transfer cover,(2)Transfer case

21
 FRONT AXLE (DRIVE) 2

Disassembly the transfer cover

1. Remove the carrier ASS'Y 4. Remove the inner ring of the taper
roller bearing from the carrier ASS'Y.
1

2
2
(1)Carrier ASS'Y,(2)Planet gear
(1)Carrier ASS'Y
Carrier ASS'Y has combined
NOTE with the planet gear.
(2)The inner ring of the taper roller bearing

Don't remove if it is not

NOTE replaced.
2. Remove the snap ring, the thrust
washer (t=1), the thrust washer (t=2),
the planet gear (25 of teeth), the needle 5. Remove the sun gear ASS'Y.
bearing from the carrier ASS'Y.
6 1
5

4 1
3 (1)Sun gear ASS'Y
2
(1)Carrier ASS'Y, (2)Snap ring, (3)Thrust
washer (t=1), (4)Thrust washer (t=2),
(5)Planet gear, (6)Needle bearing
6. Remove the snap ring from the sun
gear ASS'Y.

3. Remove the thrust needle bearing,

thrust washer (t=2.5).
2
1

2
1

(1)Sun gear ASS'Y(2)Snap ring

(1)Thrust needle bearing, (2)Thrust washer

(T=2.5)

22
 2 FRONT AXLE (DRIVE)

7. Remove the driven gear (86 teeth) 9. Remove return springs (4 pieces),
friction plate (3 sheets), mating plate (3
1
sheets) and pressure plate.

2
3
4
(1)Return spring, (2)Friction plate,
2 (3)Mating plate, (4)Pressure plate

1
10. Apply the compressed air from the
brake fluid port on the back to remove
the brake piston.
Remove hex socket screws (M5 0.8)
(6 pieces) and the piston inner sleeve.
(1)Driven gear, (2)Ball bearing 1
When ball bearings are
3
NOTE replaced, knock it from 2 holes
of a driven gear, to take out.

8. Remove bearing retainers (4 pieces)

2
after hex socket screws (M6 1.0)(8 (1)Brake piston, (2)Hex socket screw
pieces). (3)Piston inner sleeve

1 CAUTION When applying the compressed

air, the brake piston may be
jumped off.
So, put the face down of the
gear case on the working desk
2
3 or floor to prevent from jumping
off.
(1)Hex socket screw(2)Bearing retainer
(3)Return spring

Pay attention not to loss return

NOTE springs (4 pieces) when
removing the bearing retainer.

23
 FRONT AXLE (DRIVE) 2

11. Remove the O-ring and the piston 14. Remove the snap ring, spacer and ball
inner seal (X ring) from the piston inner bearing from the drive gear.
sleeve.
1
2 3

4 2

(1)Ball bearing, (2)Snap ring

3 (3)Spacer, (4)Drive gear
(1)Piston inner sleeve(2)O-ring
(3)Piston inner seal
15. Remove the air breather (R1/8)
12. Remove the piston outer seal (X ring)
1
1

(1)Air breather
(1)Piston outer seal

16. Remove stop rings (2 pieces) and the

13. Remove the ball bearing with the snap brake pin to remove the brake lever.
ring, the spacer and the drive gear (18
teeth). 3

1
3 2
4
2
1

(1)Stop ring, (2)Brake pin (3)Brake lever

(1)Ball bearing, (2)Snap ring,

(3)Spacer, (4)Drive gear

24
 2 FRONT AXLE (DRIVE)

17. Remove the O-ring after removing the

brake rod.

(1)Brake rod, (2)O ring

18. Remove the sleeve from the brake

lever.

(1)Brake lever(2)Sleeve

Don't remove if it is not

NOTE replaced.

19. Remove the bushing from the transfer

cover.

(1)Transfer cover, (2)Bushing

Don't remove if it is not

NOTE replaced.

25
 FRONT AXLE (DRIVE) 2

Disassembly the transfer case

1. Remove the retaining ring 3. Remove the oil seal

from the transfer case.

1
2

1 (1)Oil seal
(1)Transfer case, (2)Retaining ring
Don't remove if it is not
NOTE replaced.
2. Remove keys (6 pieces) after removing
the ring gear (64 teeth) from the
transfer case. 4. Remove the outer ring of the taper
roller bearing.

1
2

(1)Ring gear, (2)Key

(1)Outer ring of the taper roller bearing

Don't remove if it is not

When the ring gear doesn't NOTE replaced.
come off easily, it may be
tapped from the opposite side Pay attention not to damage on
NOTE (shown below) with a long bar NOTE the rolling surface of the outer
such as a screw driver. ring.
Be careful not damage the oil
seal or the gear.

26
 2 FRONT AXLE (DRIVE)

5. Remove the outer ring of the taper

roller bearing.

(1)Outer ring of the taper roller bearing

Don't remove if it is not

NOTE replaced.

Pay attention not to damage on

rs
NOTE the rolling surface of the outer

te ale
ring.

bu e
tri d D
6. Remove the needle bearing.
D ize
ot or
is
N uth

1
D rA
fo
o
y

(1)Needle bearing
nl

Don't remove if it is not

NOTE
O

replaced.

7. Remove the O-ring after removing the

seal plug (G1/4)

(1)O-ring seal plug, (2)O-ring

27
 FRONT AXLE (DRIVE) 2

2-1-3. Reassembly the transfer ASS'Y

CAUTION Replace all when removing the oil seal, piston seal, O-ring, friction plate and
bearing.

1. Install the bushing after upturning the 3. Install the O-ring in the piston inner
inside of the transfer cover. sleeve.

1 1

(1)Transfer cover, (2)Bushing (1)Piston inner sleeve, (2)O-ring

Pay attention that the O-ring is

2. Install the outer piston seal (X ring) in NOTE not twisted when installing.
the transfer cover.
1 Apply grease or the brake oil (*)
NOTE when installing.
2

1
4. Install the piston inner seal in the piston
inner sleeve.

(1)Transfer cover, (2)Outer piston seal

2
Pay attention that the outer
NOTE piston seal is not twisted when
fitting.
1
Apply grease or the brake oil (*)
NOTE when installing.
(1)Piston inner sleeve
(2)Piston inner seal

Pay attention that the piston

NOTE inner seal is not twisted when
installing.

Apply grease or the brake oil (*)

NOTE when installing.

CAUTION Do not use the conventional brake fluid (such as DOT3) for (*) part.
Use SHELL Tellus T-15 only.

28
 2 FRONT AXLE (DRIVE)

7. Install the brake piston.

Groove
1

5. Install the piston inner sleeve in the

transfer cover.

(1)Transfer cover
(2)Piston inner sleeve
(1)Brake piston

6. Tighten the piston inner sleeve Pay attention to the direction of

temporarily after apply LOCTITE # 262 NOTE the groove of the brake piston
or equivalent to the hex socket screw when installing.
(M5 0.8) (6 pieces).
Confirm the complete
NOTE insertion.
LOCTITE
L Glue [#262] or
equivalent 8. Tighten hex socket screws (6 pieces).
2
Tightening
5.5 ~ 8 Nm
1 torque
LOCTITE
L Glue [#262] or
equivalent

(1)Piston inner sleeve

(2)Hex socket screw

1
(1)Hex socket screw

29
 FRONT AXLE (DRIVE) 2

9. Assemble the drive gear (18 teeth) , 11. Insert the clutch pin (4 pieces) and the
the ball bearing with the stop circle, the parallel pin (2 pieces) to the transfer
spacer and the snap ring. cover.
3

1 4 1

2 2

(1)Transfer cover, (2)Clutch pin

(3)Parallel pin
2 3
1
4 12. Put the pressure plate through the
hole for the clutch pin.

Stop circle must be faced

to the gear side.
(1)Drive gear, (2)Ball bearing with stop circle
(3)Spacer (4)Snap ring

Pay attention to the direction of 1

NOTE the ball bearing with stop circle
(1)Pressure plate
when installing.

10. Install the combined ball bearing on the

transfer cover.

2
(1)Transfer cover, (2)Ball bearing

30
 2 FRONT AXLE (DRIVE)

13. Put the mating plate through the hole 17. Put and set the bearing retainer to the
for the clutch pin. position of the clutch pin and the return
spring.

Cut part Projected

1 part

(1)Mating plate

14. Put the friction plate.

(1)Bearing retainer
(1)Friction plate
Pay attention to the direction of a
projected side of the bearing
NOTE
retainer and the position of a
notch when installing.
15. Repeat the step 13 and 14 for all mating
plates (three pieces) and friction plates
18. Tighten in order of arrangement
(three pieces) which are installed in the diagonal after tighten hex
alternately. socket screws (M6 1.0) (8 pieces)
temporarily.
Make sure that the friction plate
NOTE is the top after installing.
Tightening
11 ~ 15 Nm
torque
LOCTITE
L Glue [#262] or
equivalent
16. Put return spring (4 pieces).

(1)Return spring (1)Hex socket screw

31
 FRONT AXLE (DRIVE) 2

Tighten with confirmation that 21. Install the snap ring on the sun gear
NOTE the spring donesn't shift while ASS'Y.
tightening.

2
19. Install the ball bearing in the driven
gear (86 teeth).
1

2 1

(1)Sun gear ASS'Y, (2)Snap ring

22. Insert the sun gear with engaging the

(1)Driven gear, (2)Ball bearing teeth to the spline of friction plates.

20. Install the driven gear with engaging

the drive gear. 1

2
2
3
(1)Sun gear ASS'Y, (2)Snap ring
(3)Driven gear

Pay attention not to damage

(1)Driven gear, (2)Drive gear NOTE the spline of the friction plate
when inserting the sun gear.

Make sure the snap ring is

NOTE completely fitted in the groove
on the driven gear.

32
 2 FRONT AXLE (DRIVE)

23. Install the inner ring of the taper roller 25. Install the thrust washer (t=2), the
bearing on the carrier ASS'Y. planet gear (25 teeth), the needle
bearing, the thrust washer (t=1) and the
1 snap ring.

2
5
6
2 1
2
(1)Carrier ASS'Y, (2)Taper roller bearing 4

2 3
2

24. Install the thrust needle bearing and

thrust washer (t=2.5) in the carrier
ASS'Y.

2 (1)Carrier ASS'Y, (2)Thrust washer [t=2]

(3)Planet gear, (4)Needle bearing
3 (5)Thrust washer [t=1],(6)Snap ring

Pay attention that parts

1 NOTE installed in the step 24 do not
come off when installing.

(1)Carrier ASS'Y, (2)Thrust needle bearing

(3)Thrust washer

Pay attention that the needle

side of the thrust needle
NOTE bearing must be faced to the
thrust washer.

33
 FRONT AXLE (DRIVE) 2

Reassembly the transfer case

1. Install the outer ring of the taper roller Pay attention not to damage on
bearing inside of the transfer case. NOTE the lip of the oil seal.

2
3. Install the taper roller bearing in the
opposite side of the transfer case.

1
2

1 2
(1)Transfer case, (2)Taper roller bearing

Pay attention to the direction

NOTE of the taper roller bearing when
installing.

Pay attention not to damage

NOTE on the rolling surface of the (1)Transfer case, (2)Oil seal

bearnig. Pay attention to the direction

NOTE of the taper roller bearing when
2. Install the oil seal in the transfer case. installing.
THREEBOMD
Liquid Pay attention not to damage
B packing
#1212 or
NOTE on the rolling surface of the
equivalent
bearing.
1

(1)Transfer case, (2)Oil seal

Pay attention to the direction of

NOTE the oil seal.
34
 2 FRONT AXLE (DRIVE)

4. Insert the ring gear in the transfer case 6. Install the retaining ring in the transfer
with matching the position of notches. case.
1
1
2

(1)Retaining ring

2 7. Install the needle bearing in the transfer

Chamfering Recessed part case.

(1)Transfer case, (2)Ring gear

Pay attention to the direction of

NOTE the ring gear when installing.

1
5. Insert keys in notches of the transfer Stamped side
case and the drive gear.

1 (1)Needle bearing

Pay attention that the stamped

(1)Key
NOTE side of the outer ring must be
outside when installing.

When installing the bearing,

NOTE don't hit with hammer directly
and seriously.

35
 FRONT AXLE (DRIVE) 2

8. Install the O-ring seal plug in transfer 10. Install the carrier ASS'Y with engaging
case after installing the O-ring on it. the planet gear on the sun gear.

2
11. Apply liquid packing to the shaded part
of the transfer cover.

THREEBOMD
Liquid
B packing
#1104 or
equivalent

(1)O-ring, (2)O-ring seal plug

9. Input the the parallel pin (2 pieces) to the

transfer case.

Applying part

(1)Parallel pin

Applying part

36
 2 FRONT AXLE (DRIVE)

12. Put the transfer case on the transfer 14. Press hub bolts (6 pieces) into the
cover. wheel hub.
Be careful not to touch the oil seal 1
when putting on.
2
Apply the glue on the thread of the hex
socket screws (M6 1.0)
(2 pieces), insert from the cover side
and tighten.

Tightening
11 ~ 15 Nm Side "A"
torque
LOCTITE
Cut part
L Glue [#262] or
equivalent

(1)Wheel hub, (2)Hub bolt

2
Pay attention that the cut part
of the head of the hub bolt
NOTE
(1)Transfer case, (2)Transfer cover
must be faced to the center of
13. Turn the transfer ASS'Y sideways. the wheel hub.
Apply the glue on hex socket screws
Pay attention not to damage on
(M6 1.0) (6 pieces), insert and
NOTE the oil seal sliding area (Side
tighten.
"A") when installing.

Tightening
11 15 Nm
torque 15. Install the inner ring of the taper roller
LOCTITE bearing on the wheel hub after fitting
L Glue
[#262] equivalent the hub bolt.

1 1

(1)Transfer ASS'Y, (2)Hex socket screw (1)Whell hub, (2)Taper roller bearing

37
 FRONT AXLE (DRIVE) 2

16. Install the dust cover on the wheel hub. 19. Install the O-ring in the groove.

1
1

2
Cut part

(1)Whell hub, (2)Dust cover (1)O-ring

Fit the cut part of the dust Pay attention that the O-ring
cover to the position of the is completely inserted, and
wheel hub and install it so
NOTE it doesn't come off from the
NOTE that the projected part on the groove when installing.
dust cover fits in the notch of
the wheel hub when installing. 20. Install the lock plate.

1
17. Fill grease between lips of the oil seal.

(1)Lock plate

The direction of the plate is not

(1)Oil seal NOTE a matter.

18. Install the wheel hub.

(1)Wheel hub

Pay attention not to damage

NOTE the lip of the oil seal when
installing.

38
 2 FRONT AXLE (DRIVE)

21. Tighten the nut (M30 1.5) 22. Tap the flange of the lock nut to caulk.
completely.
Then loosen a bit and check the
preload by the spring scale.

Caulking
(1)Lock nut

Caulk to the groove bottom

NOTE surely.

2 23. Install the hub cap.

(1)Hub cap

F
(1)Lock nut, (2)Spring scale

Adjust tightening to get the

NOTE preload with 60 ~ 80N.

39
 FRONT AXLE (DRIVE) 2

24. Install the brake rod on the transfer Pay attention that the direction
cover with the O-ring.
NOTE of installation is different for L
and R. (Refer the figure below)

1 Y48190L (for L)

(1)Brake rod, (2)O ring

Pay attention to
the position with
Pay attention to the direction the tap hole.
so that the small diameter side
NOTE of the brake rod must be faced
Y48190R (for R)

to outside when installing.

25. Install the sleeve in the brake lever.

(1)Brake lever, (2)Sleeve

26. Install the brake lever on the transfer

cover with the brake pin and the stop
ring (2 pieces).

(1)Brake lever, (2)Brake pin

(3)Stop ring

Install the brake lever so that

NOTE the oval hole must become
inside when installing.

40
 2 FRONT AXLE (DRIVE)

27. Install the air breather (R1/8).

Wrap the seal tape or apply LOCTITE
on the thread of the air breather.
LOCTITE
L Seal [#542] or
equivalent

(1)Air breather

Pay attention that the fitting

NOTE position is different for L and
R. (Refer the figure below)

Y48190L (for L) Y48190R (for R)

Air breather Oil filling port Air breather

Pay attention to
the position with
the tap hole.

Drain port Drain port

28. Data of the gear oil

Type : ATF DEXRON
Quantity : 0.35 (per axle)

41
 3. REAR AXLE (STEERING)
3- 1. Disassembly and reassembly
CAUTION Lift or jack up the forklift truck and support it with safety blocks or rigid stands.
Apply wheel chocks to front tyres to prevent the truck from moving.
Record places of lead wire connections before disassembling.
Turn the key switch off and operate hydraulic levers a few times to
release high pressure in the hydraulic piping before disconnecting
hydraulic hoses or pipes.
When disconnecting hydraulic pipes, cap them to prevent dust from
entering into hydraulic components and pipes.
Be sure to disconnect the battery plug.

3-1-1. Rear axle - removal and installation

1. Open the cover ASS'Y, battery.

2. Remove the chain roller of the steering linkage.
Refer to "5-1-1. STEERING LINKAGE-Disassembly and reassembly".

3. Disconnect lead wires to the EPS motor and the sensor

ASS'Y, EPS.

4. Remove the axle ASS'Y, rear.

Removing and installing the rear axle

Tightening torque
88.2 - 108 N m
{9 - 11 kgf m}

Axle ASS'Y, rear

Lead wire

: Tightening torque
215S0301

* Install the rear axle in reverse order of removal.

42
3 REAR AXLE (STEERING)

3-1-2. Rear axle - disassembly and reassembly

Disassembling and reassembling the rear axle(1)
Torque sensor
(Potentiometer)
Tightening torque
9.9 - 12.1 N m
{1.0 - 1.2 kgf m}

Sensor ASS'Y, EPS Spline shaft G

Apply grease on the spline shaft.

Oil seal B G
EPS motor
Apply grease on the lip.

rs
Apply THREEBOND #1104 (or
Cover, EPS equivalent) around the seal.

te ale
1 Plug, breather
bu e
tri d D
Apply seal tape on the thread.
D ize

Spacer B
Cover, EPS and EPS motor
ot or

Gear (1) O
Gear (2)
Apply THREEBOND #1212
is
N uth

(or equivalent) on the contact

surface.
D rA

Fill the gear oil (HE#80 or

equivalent) with 0.5 liter.
fo
o
y
nl
O

Support, rear axle

Pinion, steering

: Tightening torque Spline shaft G

B : Apply THREEBOND Apply grease on the spline shaft.
G : Apply grease
N : Not reusable
252S0302

CAUTION When OIL SEALS, O-RINGS and / or BEARINGS

were removed, they should be replaced to new
ones.

43
 REAR AXLE (STEERING) 3

Disassembling and reassembling the rear axle(2)

Sensor Comp.,
angle
Support,
Coupling L
potentiometer Apply LOCTITE[#262] or an
Lever, equivalent product.
potentiometer
Screw, set L
Apply LOCTITE[#262] or an
equivalent product at 2 places.

Tightening torque(Lower)
39-59 N m
Washer
{4-6 kgf m}
Plate, cam X Pre-load
Measure at 9.5-13.5 N m
position X. {1.0-1.4 kgf m}
Support, rear axle

Support, rear axle G

Fill grease up between bearings.

Plate

Axle ass'y, rear Gear (2), steering

Tightening torque
88.2-108 N m
{9-11 kgf m}

Stopper, rubber

Rear wheel Bracket comp., wheel

Hub, wheel G
Fill grease up between bearings.

A Bearing pre-load
44-64 N
FBT10 - 18P
Tightening torque
{4.5-6.5 kgf}
See "REAR TYRE". 34.3-53.9 N
FBT20PN
{3.5-5.5 kgf}
: Tightening torque
G : Apply grease
L : Apply LOCTITE
N : Not reusable
461S002

CAUTION When OIL SEALS, O-RINGS and / or BEARINGS

were removed, they should be replaced to new
ones.
44
3 REAR AXLE (STEERING)

3- 2. Inspection and adjustment

3-2-1. Angle sensor comp. - adjustment
Adjustment of "angle sensor comp."
1 Adjustment of fitting position
Adjust the dimension "L" between the surface Sensor comp., angle
of "bracket Comp., wheel" and "support,
Support,
potentiometer" to 24 to 26mm. potentiometer
Apply LOCTITE [#262] or an equivalent

L
product on "screw set" before tightening.

(Approx. 103)
2 Adjustment of output voltage

75
Turn the shaft of the sensor comp. to adjust
the output voltage within the following range
when the rear axle is in the straight position.
Bracket comp.,
<Reference value> wheel

461E201
Rear axle position Output voltage range
Straight 2.47 - 2.53 V
* It is the measured value of the voltage of lead
wires of the "Sensor comp., angle" between
"Black" and "Brown" when 5 volts D.C. is
applied between lead wires "Red" and "Black".

3-2-2. EPS torque sensor - adjustment

1 Check of neutral position Check neutral position of torque sensor

1. Turn off the key switch. EPS
EPS
2. Jack up rear wheels from the ground. コントローラ
controller

3. Put a clamp meter on the wire [yellow] or

[green] between EPS controller and EPS
�� �
yellow

motor.
�

green

4. Turn on the key switch and measure the

current flow without steering operation(=at
neutral position). If the indication shows
把握電流計
Clamp meter
0A (zero Amps.), it is normal.
��

(Use DC range)
��
black
red

5. If it is not 0A (zero Amps.), adjust the neutral

position of the torque sensor.
EPSモータ
EPS motor
(Refer 3-2-2. 3: Adjustment procedure) 212E006

NOTE Make sure the tension of the steering chain at

the same time.
Refer to "5-2-4. Chain comp., roller - adjustment"

45
 REAR AXLE (STEERING) 3

2 Checking by voltage
1. Turn off the key switch. water-proof type
2. Disconnect the connector of the torque sensor and 3P （防水） コネクタ
Connector
タブ
Tab
insert the adapter for measuring voltage. 1 2 3

NOTE As the connector of the torque sensor is water proof 2

type, it is impossible to apply the test probe. 3

Use the special tool "Adapter", or you may make by 1 2 3

3P
3P
yourself. リセ
Receptacle
アダプタ
Special Tool
3. Turn on the key switch.
"Adapter"
4. Check the voltage between "green / blue" and " white" 2210140[W]

with operating the steering wheel from right end to left

end. Checking of voltage

EPS
EPS
Position of steering handle Appropriate voltage controller
コントローラ
torque
トルクセンサsensor
Right side end 0.6 - 1.8V
アオ
blue
ミドリアオ
green/blue
Neutral 2.4 - 2.6V TS
white
シロ

Left side end 3.2 - 4.4V

テスター棒（－）
negative(-) prove
of tester
If the voltage values are not appropriate, refer the
next page to adjust the resistance value of the torque
sensor.

テスター棒
positive
（＋）
(+) prove
of tester

461S003

46
3 REAR AXLE (STEERING)

3 Adjustment procedure
1. Turn off the key switch and disconnect the battery plug.
2. Disconnect the connector of the torque sensor.

Adjustment of EPS torque sensor

3P water proof type

Torque sensor connector(tab side)
(potentiometer)

kΩ

Sensor ass'y., EPS

461S004

3. Check the resistance value at the connector.

<standard value>
 Between (1) pin [Orange] and (3) pin [Black/Red] = approx. 5k ......... (A)
 Between (1) pin [Orange] and (2) pin [Green/Red] = approx. 2.5k ..... (B)
 Between (2) pin [Green/Red] and (3) pin [Black/Red] = approx. 2.5k (C)
 (B) and (C) should be the half value of (A)
 (B) and (C) should be the same value.
(1) Orange (1) Blue
From EP S
sensor (2) Green/Red Rece- (2) Green/Blue To EPS
Tab
(potentiometer) (3) Black/Red ptacle (3) White controller

3P water proof type connector

461S043

4. Adjust (B) and (C) to be at even value by removing or Adjustment of neutral position
inserting shims. Potentiometer

NOTE Resistance value may be slightly different by the type

of tester
Shim
5.Connect the battery plug and check the voltage again.
6.Turn the key switch ON and confirm that the EPS
motor current does not flow when the steering wheel is
released.
7.If the EPS motor current is not nil even if the resistance
of (B) and (C) are the same by above test, check the
tension of the steering chain. (Refer to "5 STEERING 461S008

LINKAGE")

47
 REAR AXLE (STEERING) 3

3- 3. Troubleshooting
3-3-1. Rear axle - troubleshooting

No. Symptom Problem Solution

1. Bearing of the rear axle support is damaged. Replace
2. Air pressure of tyres are too low. Adjust
3. Lack of lubrication for rear axle and steering linkage Lubricate
1 Hard to steer.
Repair or
4. Connection of linkage is stuck.
replace
5. Tension of the steering chain is too much. Adjust
Steering wheel 1. Steering linkage and each part of rear axle are not Check and
2 does not turn adjusted correctly. adjust
smoothly. 2. Air pressure of the rear tyres is too low. Adjust
1. Air pressure of each tyre is not the same. Adjust
Steering wheel 2. Difference of diameter of tyres at L.H. and R.H. Inspect and
is turned sides replace
3 un-expectedly to
one side while Adjust or
3. Out of adjustment or wear of wheel bearing
travelling. replace
4. EPS torque sensor is out of adjustment. Adjust
Adjust or
1. Out of adjustment or wear of wheel bearing
replace
2. Loose hub nuts Tighten
Steering wheel is Inspect and
4 3. Improper mounting of rear axle
swung. adjust
4. Incorrect air pressure of wheel Adjust
Inspect and
5. Steering linkage is out of adjustment.
adjust

48
 4. TYRE
4- 1. Front tyre
4-1-1. Front tyre - disassembly and reassembly

Tyre

Rim, wheel
(*See NOTE)

Hub bolt and Nut

Tightening torque
216 - 264 N m
{22.0 - 26.9 kgf m}

: Tightening torque
215S0401

4-1-2. Tyre size (front)

Applicable model Size

18 x 7-8-14PR (Std)
FBT13P/15P
18 x 7-8 Solid (Opt)
18 x 7-8-16PR (Std)
FBT18P
18 x 7-8 Solid (Opt)
FBT20PN 18 x 7-8 Solid

NOTE The offset of the rim is different between FBT13 /

15 / 18P and FBT20PN.
(Not interchangeable)

49
 Tyre 4

4- 2. Rear tyre
4-2-1. Rear tyre - disassembly and reassembly
FBT13P-18P

Tightening torque
68.5 - 78.5 N m
Rim bolt and Nut
{7 - 8 kgf m}

Tightening torque
88.2 - 108 N m
Hub bolt and Nut
{9 - 11 kgf m}
461E036

FBT20PN

Tightening torque
Rim bolt and Nut 88.2 - 108 N m
{9 - 11 kgf m}

Tightening torque
216 - 264 N m
Hub bolt and Nut {22 - 26.9 kgf m}
: Tightening torque
461E032

4-2-2. Tyre size (rear)

Model Size
15 x 4 1/2-8-12PR(Std)
FBT13P-15P
15 x 4 1/2-8 SOLID(Opt)
FBT18P 15 x 4 1/2-8 SOLID(Std)
16 x 6-8-10PR(Std)
FBT20PN
16 x 6-8 SOLID(Opt)

50
4 Tyre

4- 3. Inspection and adjustment

4-3-1. Bolt and nut - inspection
1. Check for damage.
2. Check for loosening.
If loose, re-tighten it.
Refer to "4-1. Front tyre, 4-2. Rear tyre"

4-3-2. Air pressure - inspection

CAUTION Check for the air pressure when the tyres are cool. Inspection of air pressure

<Air pressure>
Front tyre
Applicable model Air pressure: bar kgf/
FBT13P/15P 8.8 (9.0)
FBT18P 9.8 (10.0)
212T001

FBT20PN -

Rear tyre
Applicable model Air pressure: bar kgf/
FBT13P/15P 9.8 (10.0)
FBT18P -
FBT20PN 8.3 (8.5)

51
 Tyre 4

4-3-3. Tyre - visual inspection and replacement

1. Check for cracks, damage, and wear.
Replace the tyre if there are large cracks or damages
on the side.
Replace the tyre if there is worn to the bottom of the
tread.
Replace the tyre if there is worn to the wear-limit mark.

Cracks or damages Tyre grooves  wearing limit mark

4- 4. Troubleshooting
4-4-1. Tyre - troubleshooting
No. Symptom Possible cause Solution
1. Incorrect air pressure of tyre Adjust
2. Incorrect preload of wheel bearing Adjust
1 Abnormal wear of tyres
3. Different type of wheel or tyre at L.H. and . Use the same
R.H. sides ones.

52
 5. STEERING LINKAGE
5- 1. Disassembly and reassembly
CAUTION Apply wheel chocks to front tyres to prevent the truck from moving.
Record places of lead wire connections before disassembling.
Be sure to disconnect the battery plug.

5-1-1. Steering linkage - disassembly and reassembly

Disassembling and reassembling the steering linkage (1)

Wheel ass'y, steering

Bracket
Column ass'y, steering 29.4N(3kgf) Deflection
4±2mm

29.4N(3kgf) Deflection
7±2mm

Chain, roller

Chain, roller
sensor ASS'Y, EPS

Tube comp. Shaft

comp.,
joint

Chain, roller
Knob

29.4N(3kgf)
Rear axle ASS'Y
Deflection
FBT13P 10 2mm
FBT15P/18P 12 2mm
FBT20PN 15 2mm
 Inspection point
[Specification of steering force]
Adjust the chain tension so the steering
force becomes less than 14.7N (15kgf)
at the steering wheel knob.
Column ass'y G
Apply grease on the contact
Column ass'y
surface and the brush contact
(inside of the steering wheel).

G : Apply grease
215S0501

53
 STEERING LINKAGE 5

Disassembling and reassembling the steering linkage (2)

Bracket, pedal

Column ass'y
Screw, set

1 Spline shaft G
Apply grease on the spline shaft.

Joint
Handle Bolt, handle

Bracket comp.,
housing

Sprocket (1)

Sprocket (2)

Chain, roller
Collar
Chain
adjusting bolt

Tube comp.

Sprocket (3)

Chain, roller
Sprocket (4)
G : Apply grease
215S0502

54
5 STEERING LINKAGE

Disassembling and reassembling the steering linkage (3)

Chain, roller

Sprocket (5)
Sensor ASS'Y EPS

Chain adjusting bolt

Bracket comp.,
housing

Chain adjusting bolt

1 Spline shaft G
Apply grease on the spline shaft.

Shaft comp., joint

Case comp.,
sprocket
Sprocket (4)

G : Apply grease
215S0503

55
 STEERING LINKAGE 5

5- 2. Inspection and adjustment

5-2-1. Joint - inspection and replacement
1. Check for abnormal plays at marked parts with arrows. Inspection of joint
If abnormal, replace it.
2. Check for crack at marked parts with stars.
If cracked, replace it.

212E044

5-2-2. Knob - inspection and replacement

1. Check for abnormal play and/or crack. Inspection of knob
If plays abnormally or cracked, replace it.

152T005

5-2-3. Steering wheel - inspection and replacement

1. Check for crack Inspection of steering wheel

If cracked, replace it.
2 After turning off Key switch, measure playing at the 50-100mm
steering knob and check if it is within 50 - 100 mm.

244W073

56
5 STEERING LINKAGE

5-2-4. Chain comp., roller - adjustment

1. Adjust tensions of A, B and C of the chain comp., roller
(1), (2) and (3) to meet the following table,
when the center of these chains are pressed with
about 3kgf.

<Chain deflection>
[mm]
Apllicable model FBT13P FBT15P/18P FBT20PN
Deflection
A [Chain comp., roller (1)] 7 2
B [Chain comp., roller (2)] 10 2 12 2 15 2
C [Chain comp., roller (3)] 4 2

Adjusting the chain comp., roller

Knob Wheel ASS'Y, steering

Column ASS'Y, steering 3kgf

3kgf

A
Chain comp.,
roller (3)
Chain comp.,
roller (1)
Sensor ASS'Y, EPS
Tube comp,
Shaft
comp.,
joint

Chain comp.,
roller (2)
3kgf

Rear axle ASS'Y

215S0504

2. Adjust the chain tension so that the steering operating

force is 14.5N m (15kgf) or less at the knob.

57
 6. BRAKE
6- 1. Foot brake
6-1-1. Foot brake - disassembly and reassembly
Disassembling and reassemblig the foot brake

rs
te ale
Frame

bu e
tri d D
D ize

Tank ASS'Y,
ot or

reservoir Bracket, pedal

is
N uth

Pedal height Microswitch

adjusting bolt
D rA

Bushing
fo
o
y
nl
O

Bushing

Pedal,
brake

1 Shim
If the gap between the "Bracket,
pedal" and the "Pedal, brake" is
more than 1mm, insert shim.

Master
cylinder
Pin G
Apply grease

G : Apply grease
215S0601

58
6 BRAKE

6- 2. Parking brake
6-2-1. Parking brake - disassembly and reassembly
Disassembling and reassemblig the parking brake

Lever ASS'Y, brake

Frame

Microswitch

Wire, brake

Front axle (LH)

Front axle (RH)

251S0602

59
 BRAKE 6

6- 3. Inspection and adjustment

6-3-1. Brake pedal - adjustment
1 Adjustment of pedal gap
 If the gap between the brake pedal and the pedal Pedal, Shim
bracket is 1mm or larger at right end or left end, insert If 1mm or lager brake

shims to minimize a gap.

Pedal, brake

Bracket, pedal

215S0603

2 Adjustment of rod length

Lock nut
Push the rod to touch to the piston lightly. Then, adjust

1.5
Rod
the length of the rod (A) to 90.5 1.5 mm and fix with

.5
the lock nut.

A=90
215S0604

3 Adjustment of pedal height

Microswitch
(1) Release the brake pedal.
(2) Adjust the bolt to get the play of the pedal about 5 or
7 mm.
Adjust
Then the dimension of "B" should be about 17 mm. bolt
(3) Make sure if the height of the pedal "C" is 87 5 mm
from the floor plate.
(4) If the pedal height is not within the specification,
adjust the dimension "B". Pedal, brake
You may be required to adjust the length of the push
rod of the master cylinder to get the proper height of
Floor plate
the pedal.
461E101

60
6 BRAKE

4 Adjustment of microswitch
Microswitch
(1)Adjust dimension "D" (specification : 24 mm) so
that the micro switch activates when the pedal is
depressed 10 - 20mm.

(2)Be sure to tighten each adjusting (fitting) bolts and

nuts after adjusting the brake linkage.

Pedal, brake

461E102

6-3-2. Brake pedal - inspection

(1)Check any cracks or damages at welded parts. Inspection of brake pedal
(2)Check the bushing for wear.

<Wear limit of bushing> Bushing

Specific dimension (inner dia ) Wear limit
Pedal, brake
20.0 20.15

(3)Check the "Pin, brake" for abnormal wearing.

<Wear limit of pin>

Specific dimension (outer dia ) Wear limit Inner dia.( d)
20.0 19.9 Pin, brake
Outer dia.( D)
252W0602

61
 BRAKE 6

6-3-3. Microswitch of parking brake lever - adjustment

Adjust the microswitch so that it activates in the range of Adjustment the microswitch
20 - 25 degrees from the position which the brake lever is 58
released.

Brake
lever

461E204

6-3-4. Parking lever - inspection and adjustment

1. Inspect for damage or deformation on the lever. Inspection of parking lever

2. Check if the brake is applied when the lever is pulled.

If the brake is not applied securely, make the following. Adjusting bolt Pull the lever.
adjustments.

1. Leave the lever in its pulled back position.

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

215S0606

62
6 BRAKE

6-3-5. Master cylinder ASS'Y - inspection and replacement

CAUTION  Before performing this inspection, check the function of the master cylinder.
If the brake pedal keeps lowering while depressing, the master cylinder may be
leaked internally.
Then, replace the master cylinder ASS'Y.
 Before performing this inspection, clean the part with a wash oil, and then
blow oils away by compressed air.
 Bleed air after finishing the maintenance of brake parts.

1. Check the inside of the "Cylinder, body" for damage or

rust.
2. Check for damage or deterioration on inner parts.
Replace parts if any damage or deterioration are
found.

Inspection of master cylinder ASS'Y

Push rod ASS'Y

Cylinder

clamp
Piston Tightening torque
ASS'Y
Cylinder, body 1.96 - 2.94 N m
{20 - 30 kgf m}

: Tightening torque 215S0605

63
 BRAKE 6

Replace the piston ASS'Y

CAUTION Replace the piston ASS'Y at every
disassembling or annually.

4. When assembling parts, apply mineral oil on the

Piston ASS'Y
surface of each parts.

WARNING Do not use any conventional brake fluid such as

DOT3 for automobile. Piston

Use only specified oil (SHELL TELLUS T-15).

Cylinder
244W062

6-3-6. Master cylinder air bleeding

CAUTION  Use the specified oil [SHELL Tellus T15] as the
brake oil.
 Do not use or mix with any conventional brake
fluid for automobile.
 Be sure to bleed air after reassembling the
brake system.

<Preparation>
1. Remove the original push rod from the master
Air bleedng Preparation
cylinder.
2. Loosen the pedal height adjustment bolt. Fit into the link hole
Brake pedal
3. Remove the brake micro switch.
4. Insert the special rod into the master cylinder, and fit
the end into the link hole. Special rod

NOTE  To bleed air completely, the piston of the

master cylinder must be pressed down to the
bottom several times. The standard push
Dimensions of special rod
rod is not long enough for this purpose.
5

Therefore, use a special rod (longer one)

6

20

instead. 20 (25)
80
 You may use a phillips screwdriver with an 125
appropriate length instead of a special rod,
244W041E

however, it may be tough to push the piston to

the bottom.

64
6 BRAKE

<Procedure>
1. Master cylinder side Procedure of air bleeding
(1) Make sure if the bleeding screw is tightened.
(2) Fill the brake oil to the reservoir tank. Do not apply
pressure.
Container
(3) Remove the rubber cap on the bleeding screw. Bleeding screw
(4) Connect a drain hose to the bleeding screw.
Another end of a hose should be kept in a container.
(5) Depress the piston several times and hold
depressing.
(6) Loosen the bleeder screw to discharge the brake fluid
with air. Drain hose
Cap
Tighten the screw again before stopping to discharge
completely. 152E115

CAUTION  Keep the brake oil level in the reservoir tank

by refilling. While pushing down
the master cylinder, the piston of
loosen the air vent valve.

(7) Repeat the step (1) to (6) several times until the air
bubble is not shown in discharged oil. Special rod

(8) Disconnect a hose and put the rubber cap on the

Push
bleeder screw.

Loosen
2. Drive axle side
(1) Follow the same procedure as the master cylinder. Bleeding screw
(2) Both right and left drive axles must be bled the air. While pushing the piston to the bottom,
tighten the screw and move the piston
back to its original position.

Special rod

Push to
the bottom

Tighten

Bleeding screw 244W042E

Bleeding screw
1 Tightening torque
6.9 - 8.8 N m
{70 - 90 kgf m}

: Tightening torque

65
 BRAKE 6

6- 4. Troubleshooting
6-4-1. Brake - troubleshooting
No. Symptom Possible cause Solution
1. Oil leakage from piston cup of master cylinder Replace
Refill oil and
2. Air is mixed into brake oil due to shortage of oil.
Ineffective bleed air
1 braking 3. Air is mixed in brake pipings. Bleed air
force 4. Wear of mating plate or uneven contact with friction Inspect and
plate replace
5. Out of adjustment of brake Adjust
1. Friction plate is hardened or oil is contaminated. Repair or replace
2. Pressure plate is transformed or fitting bolts are Inspect and
loosen. retighten
Brake 3. Mating plate is transformed or mounted incorrectly. Repair or replace
2
squeaks 4. Mating plate is worn seriously. Replace
Inspect and
5. Wheel bearing is loosen.
retighten
6. Anchor pin of Mating plate is worn or transformed. Replace
Adjust to
1. Unequal air pressure of tyres at R.H and L.H sides. appropriate
pressure
2. Out of adjustment of brake. Adjust
3. Friction plate is hardened or unequally contacted with
Repair or replace
Mating plate.
Braking
3 only at 4. Mating plate is worn. Replace
one side 5. Mating plate or friction plate is malfunctioned. Replace
Replace or fit
6. Pressure plate is transformed or mounted incorrectly.
properly
7. Brake piping is clogged. Clean or replace
Inspecet and
8. Wheel bearing is not tightened with correct torque.
adjust
1. No play of brake pedal Adjust
2. Brake piston is malfunctioned. Replace
3. Brake rod is malfunctioned. Replace
4. Master cylinder is malfunctioned or hole for oil flow is
Repair or replace
Brake clogged.
4
drags 5. Return spring in brake ASS'Y is damaged. Replace
6. Parking brake is not fully released or not adjusted
Adjust
correctly.
7. Brake piping is clogged. Clean or replace
8. Wheel bearing is not tightened with correct torque. Adjust

66
6 BRAKE

1. Out of adjustment of brake. Adjust

Pedal 2. Air is mixed in brake pipes. Bleed air
5 stroke is Fill brake oil and
too large 3. Oil leakage from brake pipings or shortage of brake oil.
bleed air.
4. Out of adjustment of Brake pedal Adjust
1 Bad installation of parking brake cable Adjust
Ineffective 2 Wear of friction plate Replace
6 parking
brake 3 Out of adjustment of brake Adjust
4 Out of adjustment of brake lever Adjust

67
 7. HYDRAULIC SYSTEM
7- 1. Oil piping circuit
Applicable model Relief pressure
FBT13P/15P 13.7 MPa (140 kgf / )
FBT18P/20P 15.7 MPa (160 kgf / )

コントロールバルブ
Control valve
リフトシリンダ
Lift cylinder

A2

リフト
Lift

A1

B1
Tilt
ティルト
Tilt

Power steering valve

M
ティルトシリンダ
Tilt cylinder

オイルタンク
Oil tank
215S0701

7a. Conotrol valve and valve linkage ..................................................................... 69

7b. Oil tank and oil piping ............................................................................... 75

7c. Hydraulic pump ....................................................................................... 81

7d. Cylinder .................................................................................................. 82

68
 7a. CONTROL VALVE AND VALVE LINKAGE
7a- 1. Disassembly and reassembly
CAUTION  Before disconnecting hydraulic connections, release internal pressure to
prevent from splashing oil.
Refer the CAUTION on the page 4 for the procedure.
 Record places of lead wire and hydraulic hose connections before
disassembling.
 When disconnecting hydraulic pipes, cap them to prevent dust from
entering into hydraulic components and pipes.
 Be sure to disconnect the battery plug.

7a-1-1. Valve linkage - disassembly and reassembly

Disassembling and reassembling the 2-way hydraulic valve linkage

Lever (R) comp., valve

Lever (L) comp., valve

Cover
Boots, valve
Piece, touch

Panel (R), front

Holder,
switch

Bracket, lever

Control valve
215S0702

69
 CONTROL VALVE 7a

Disassembling and reassembling the 3-way hydraulic valve linkage

Lever comp., valve

Lever (R) comp., valve

Lever (L) comp., valve

Cover
Boots, valve

Piece, touch

Panel (R), front

Holder,
switch

Bracket, lever

Control valve

215S0703

70
7a CONTROL VALVE

7a-1-2. Control valve

2-way valve

Control valve

Solenoid valve
(for lowering interlock of OIS)

215S0704

3-way valve

Control valve

Solenoid valve
(for lowering interlock of OIS)

215S0705

71
 CONTROL VALVE 7a

7a-2. Inspection and adjustment

7a-2-1. Relief pressure - adjustment
CAUTION
2
Use 20MPa {200kgf/cm } pressure gauge.

1. Turn off the key switch. Measurement of relief pressure

2. Release pressure in the pipings.
Pressure gauge
(Refer the CAUTION on the page 4.) Adjusting
3 Remove the plug of the Lift section, and connect the screw

pressure gauge with the adapter.

4 Turn on the key switch, and pull the Lift lever to the top
end.
Then read the indication of the pressure gauge with
pulling the Lift lever.

<Specific relief pressure>

Applicable model Relief pressure Remove the plug
on the lift section.
FBT13P/15P 13.7 MPa (140 kgf/ )
FBT18P/20P 15.7 MPa (160 kgf/ )

If the relief pressure is out of this specification, adjust the

pressure by the adjusting screw. 244W075

CAUTION Turn the adjusting screw gradually,

because it is very sensitive.

72
7a CONTROL VALVE

7a-2-2. Microswitch - adjustment

<Adjusting the microswitch> Microswitch
(Except the lift 1st switch)
1 Adjust the microswitch position to activate the switch
when the lever is moved 15 - 30 mm at the top of the
lever from the neutral position.

Specified gap when in neutral 0.1 - 0.7 mm

41E044

<Adjusting the lift (1st) microswitch>

rs
Piece, touch

te ale
1 Adjust the microswitch position to activate the switch
when the lever is moved 70 - 80 mm at the top of the
bu e
lever from the neutral position.
tri d D
(Then, the spool moves 5 mm - 5.5 mm from the
neutral position.)
D ize

Specified gap when in neutral

ot or

Height from
is
N uth

the top face of 24.0mm

the "Holder, switch" Holder switch
D rA

Gap with Microswitch

0.7 - 1.0mm
the "Piece, touch" 461E045
fo
o
y

CAUTION
nl

After adjustment of the microswitch, apply

O

THREEBOND[#1401] or an equivalent product on

both fixing nuts of the switch.

73
 CONTROL VALVE 7a

7a- 3. Troubleshooting
7a-3-1. Control valve - troubleshooting
No. Symptom Possible cause Solution
1 Failure of the pump or the coupling Replace
2 Shortage of oil in the tank Replenish
3 Breakage of Plunger spring Replace
Lifting or tilting 4 Failure of the hydraulic microswitch Replace
1
does not work
5 Lift interrupt function is activated.
Check battery
(Battery is discharged too much.)
6 OIS (Operation Interlock System) is activated or
Check OIS
failed.
Load with rated Replace or
1 Failure of the relief valve or out of adjustment
2 capacity can not adjust
be lifted 2 Failure of the pump Replace
1 Over-discharge of the battery Charge battery
Inspect valve
2 Short stroke of the plunger
linkage
3 Damage of the packing in the cylinder Replace
Lifting speed is 4 Rilief pressure is too low Adjust
3
too slow. 5 Damage of the packing of the plunger Replace
6 Failure of the pump Replace
7 Clogging of the oil filter Clean/Replace
8 Hydraulic speed setting in the control unit is not
Adjust
proper.
1 Damage of the packing of the plunger Replace

Too much 2 Damage of the Cylinider or the Piston Replace

4 drifting for lifting 3 Damage of the packing of Piston Replace
or tilting 4 Failure of the valve Clean/Replace
5 Contamination of hydraulic oil Replace
Too much shock 1 Activation timing of lift microswitches is improper. Adjust
5 when starting to
lift. 2 Failure of the relief valve Replace
1 Damage of O-ring or wiper ring. Replace
6 Oil leakage
2 Looseness of tie bolts of the hydraulic valve Retighten

74
 7b. OIL TANK AND OIL PIPING
7b- 1. Disassembly and reassembly
CAUTION  Apply wheel chocks to tyres to prevent the truck from moving.
 Lower forks to the ground before draining hydraulic oil.
 Before disconnecting hydraulic connections, release internal pressure to
prevent from splashing oil.
Refer the CAUTION on the page 4 for the procedure.
 When disconnecting hydraulic pipes, cap them to prevent dust from
entering into hydraulic components and pipes.
 Wrap the seal tape on the thread of oil filters and the plug. Make sure
to tighten them securely when installing.
 Be sure to disconnect the battery plug before starting to disassemble.

7b-1-1. Oil tank - disassembling and reassembling

Variation of the hydraulic tank and applicable model
Maximum lifting
Model Specification Mast Type of tank
height
P M PFL up to 5000 mm Plastic tank
Standard
M more than 5300 mm
FBT13P ~ 18P Steel tank
CS FCS (with oil circulation circuit)
All masts All heights
RP
P M up to 4000 mm
Plastic tank
PFL up to 3500 mm
from 4300 mm
P
to 5000 mm Steel tank
Standard
from 4300 mm (with oil circulation circuit)
M to 5500 mm
FBT20PN more than 5700 mm Large capacity Steel tank
PFL more than 3700 mm (with oil circulation circuit)
P M up to 5500 mm Steel tank
CS FCS PFL up to 3500 mm (with oil circulation circuit)
RP M more than 5700 mm Large capacity Steel tank
PFL more than 3700 mm (with oil circulation circuit)

NOTE  If the mast is exchanged with the different

one, please make sure if the oil tank is
suitable for the new mast.
 In case of the large capacity tank, the floor
plate is different from the standard one.

75
 OIL TANK AND OIL PIPING 7

Plastic oil tank

Gauge comp., level Bracket, tank

Cover, tank

Gasket

Filter, oil

Tank comp., oil

Plug

215S0706

76
7 OIL TANK AND OIL PIPING

Steel oil tank

Cover, tank

Gauge comp., level

Gasket

Filter, suction

Filter, oil Bracket, tank

Tank comp., oil

Plug

215S0707

Steel oil tank (Large capacity)

Structure is similar to above steel tank but taller.

77
 OIL TANK AND OIL PIPING 7

7b-1-2. Oil piping replacement - precautions

CAUTION  Before disconnecting hydraulic connections, release internal pressure to

prevent from splashing oil.
Refer the CAUTION on the page 4 for the procedure.
 When disconnecting hydraulic pipes, cap them to prevent dust from
entering into hydraulic components and pipes.
 Be sure to disconnect the battery plug.

 Pay attention to following cautions when replacing

hydraulic hoses.

NOTE Wrap the seal tape on the thread of the

connector of hoses before connection.

CAUTION  Use required rated hoses to keep enough strength.

Unexpected force may be applied by operating pressure.

152E125

 Use correct hoses with proper length.

Hose might be damaged due to sharp bending.

152E126

 Do not fit a hose with twisting. Make sure that the hose is not twisted by
operation.
Twisting can be found by the line of letters marked on a hose.
Letters
文字列 Letters
文字列

152E127

78
7 OIL TANK AND OIL PIPING

7b- 2. Inspection and adjustment

7b-2-1. Oil - inspection
 Pick some hydraulic oil from the hydraulic tank and
compare with new oil to check.

<Specific oil conditions>

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

7b-2-2. Recommended oil and quantity for hydraulic circuit (except brake and gear oil)
1 Recommended oil
Specification Recommended oil
Standard Shell : Tellus 32
CS/FCS Shell : Tellus T15

2 Oil quantity
CAUTION  Keep the oil level within "H" and "L" marks on
the level gauge.
 Before checking oil level, lower the fork on the
flat ground.

<Oil quantity in oil tank>

Quantity [Check the actual oil level by the gauge.] (Liter)
Type
"H" level "L" level
Plastic tank 10 9
Steel tank 10.5 9.5
Large (FBT20 with high lifting
13.5 12.5
mast only)

NOTE Oils in pipings and cylinders (approx. 5-10L) is

not included in the quantity which are shown
above.

79
 OIL TANK AND OIL PIPING 7

7b-2-3. Oil tank and filters - cleaning and check

1. Clean with compressed air and check the filter for

clogging and damage.
If the filter is clogged or damaged, replace it.
2. Remove any dart or foreign material from the bottom
of the oil tank.

7b- 3. Troubleshooting
7b-3-1. Oil tank - troubleshooting

No. Symptom Problem Solution

 Inspect any damages
on hoses.
1 Bubbled Air is mixed.
 Re-tighten of the hose
clamp.
Air and/or water are mixed.
Color of oil is
2 Oxidized or contaminated with Change oil
changed.
foreign articles.

80
 7c. HYDRAULIC PUMP
7c- 1. Removal and installation
CAUTION  Apply wheel chocks to tyres to prevent the truck from moving.
 Before disconnecting hydraulic connections, release internal pressure to
prevent from splashing oil.
Refer the CAUTION on the page 4 for the procedure.
 When disconnecting hydraulic pipes, cap them to prevent dust from
entering into hydraulic components and pipes.
 Be sure to disconnect the battery plug.

7c-1-1. Hydraulic pump - removal and installation

Hydraulic motor Pump

1 Tightening torque
19.6 - 24.5 N m
{2.0 - 2.5 kgf m}
Cushion (1)

Bracket, motor

Tightening torque
8.8 - 10.8 N m
{0.9 - 1.1 kgf m}

Tightening torque
35.1 - 42.9 N m
{3.6 - 4.4 kgf m}

: Tightening torque
215S0708

<Hydraulic pump type>

Applicable model Type

FBT13P-20PN TMG 1-18

81
7d. CYLINDER
7d- 1. Disassembly and reassembly
CAUTION  Lift or jack up the forklift truck and support it with safety blocks or
rigid stands.
 Apply wheel chocks to tyres to prevent the truck from moving.
 Before disconnecting hydraulic connections, release internal pressure to
prevent from splashing oil.
Refer the CAUTION on the page 4 for the procedure.
 When disconnecting hydraulic pipes, cap them to prevent dust from
entering into hydraulic components and pipes.
 Be sure to disconnect the battery plug.

7d-1-1. Lift cylinder - removal : P - mast (2 - stage simplex)

1. Pull the lift lever backward to raise the inner mast about 50mm.(about 100 mm for forks)
2. Support the inner mast with a wire rope or wood block.
3. Remove fitting bolts for piston rod.
Removing the lift cylinder (1) P-mast

Bolt

Bolt

Inner mast
50 mm

Piston rod

Outer mast

215S0710

82
7 CYLINDER

4. Disconnect hydraulic hoses.

CAUTION Before disconnecting hydraulic connections, release internal pressure to
prevent from splashing oil.
Refer the CAUTION on the page 4 for the procedure.

Removing the lift cylinder (2) P-mast

Control valve

Lift cylinder

Valve, down safety

High pressure hose

High pressure hose

Valve, flow control

Joint
215S0711

83
 CYLINDER 7

5. Remove cylinder bands to remove lift cylinders.

CAUTION Record the number and thickness of shims when removing them.

Removing the lift cylinder (3) P-mast

Shims

Lift cylinder

Cylinder band

215S0713

84
7 CYLINDER

7d-1-2. Lift cylinder - removal : PFL-mast (2-stage duplex), M-mast (3-stage triplex)

1. Pull the lift lever backward to raise the middle/inner mast about 50 mm.
2. Support the middle/inner mast with a wire rope or wood block.
3. Remove set screws that fix the piston rod.

Removing the lift cylinder (1) M-mast

Middle mast

Outer mast Set screw

Set screw

Piston rod

215S0714

PFL-mast

Set screw

Set screw

Piston rod

Inner mast

Outer mast

215S0715

85
 CYLINDER 7

4. Disconnect hydraulic pipes and hoses as shown in the following illustration.

CAUTION Before disconnecting hydraulic connections, release internal pressure to
prevent from splashing oil.
Refer the CAUTION on the page 4 for the procedure.

Removing the lift cylinder (2) M-mast

High pressure hose

Pipe comp., lift

Bracket, pipe
Control valve
Pipe comp., lift
Valve, down
Elbow safety

Tee High pressure hose

High pressure
hose

Valve, flow control

Joint
215S0716

PFL-mast
Nipple
O-ring

Pipe

Control valve
U bolt

High pressure hose

Elbow
Joint
High pressure hose
Valve, down safety
High pressure
hose

Valve, flow control

Joint 215S0718

86
7 CYLINDER

5. Remove cylinder bands to remove outer (2nd) lift cylinders.

CAUTION Record the number and thickness of shims when removing them.

Removing the lift cylinder (3)

M-mast PFL-mast

Lift cylinder
Lift cylinder

Cylinder band

Cylinder band

215S0719

6. Slacken the lift chain and remove the chain wheel with
the lift chain from the top of the center (1st) cylinder.

7. Remove spring pin and cylinder clamp, then remove the

center (1st) cylinder.

CAUTION Record the number and thickness of shims when removing them.

Removing the lift cylinder (1)

Lift cylinder (1st)

Cylinder band

Shims

Spring pin

215S0728

87
 CYLINDER 7

7d-1-3. Tilt cylinder - removal

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

3. Remove the pipe comp., tilt.

CAUTION Before disconnecting hydraulic connections, release internal pressure to

prevent from splashing oil.
Refer the CAUTION on the page 4 for the procedure.

4. Remove tilt pins to remove tilt cylinders.

rs
te ale
Removing the tilt cylinder

bu e
tri d D
Tilt pin
D ize
ot or

Pipe comp., tilt (A)

is
N uth
D rA
fo
o
y
nl

Pipe comp.,
Tilt cylinder tilt (B)
O

215S0720

Tilt pin

NOTE The tilt cylinder may be required to modify or replace if the mast is
exchanged for another one with different lifting height.
Refer the section 7d-3 for details.

88
7 CYLINDER

7d-1-4. Lift cylinder - installation and adjustment

1. Install the lift cylinder in reverse order of removal.
2. After installation of all cylinders and hydraulic pipings, operate the lift lever to raise
the mast to the top end.
Make sure if both right and left cylinder rods are extended parallel and have no
clearance at the top end.
If clearance found, adjust in the following manner.
 P-mast : Insert proper thickness and number of shim (t0.2/t0.5/t1.0).
 M-mast : Turn the "Rod, head" at the top of the left cylinder to eliminate the
clearance at the top of the cylinder rod, and fix the "Rod, head" with the "Lock
nut."
Tighten the "Screw, set" to fix the cylinder rod.
 PFL-mast : Loosen the "Screw, set" and turn the "Adjust bolt" to eliminate the
clearance at the top of the cylinder rod.
Mount the "Plate, lock" to fix the "Adjust bolt".
Finally, tighten the "Screw, set" to fix the cylinder rod.

Adjusting the lift cylinder

P-mast M-mast PFL-mast

Plate, lock

Adjust bolt

Shim Lock nut

Rod, head
Screw, set Screw, set

215S0810

3. Make sure that oil is not leaked from anywhere.

89
 CYLINDER 7

7d-1-5. Tilt cylinder - installation

1. Install the tilt cylinder in reverse order of removal. Installing the tilt cylinder

2. Operate the tilt lever and make sure if the mast is not Adjust the length
of the rod head
twisted at both forward and backward ends.
If the mast is twisted, adjust the length of the rod by
turning the head.
After adjustment, tighten the nut on the head.

3. Make sure that oil is not leaked from anywhere around

the tilt cylinder.

NOTE The tilt cylinder may be required to modify or

replace if the mast is exchanged for another one
Nut
with different lifting height.
Refer the section 7d-3 for details. 212E080

7d-1-6. Lift cylinder - disassembly and reassembly

CAUTION Replace packings when reassembling.

NOTE Apply grease on packing and seals when fitting

them.

Lift cylinder (P-mast)

Head, cylinder B
Apply THREEBOND[#1901] on
threads when tightening.
Tightening torque
196 45.1 N m
FBT13P-18P
{20 4.6 kgf m}
235 53.9 N m
FBT20PN
{24 5.5 kgf m}

Plug
Tightening torque
Disassemble cylinder after
removing the plug.
3.92 0.98 N m
: Tightening torque {0.4 0.1 kgf m}
B : Apply THREEBOND
N : Not reusable 221W027

90
7 CYLINDER

Lift cylinder 1st (M / PFL-mast)

Head, cylinder B
Apply THREEBOND[#1901] on
threads when tightening.
Tightening torque
FBT20PN
343 78.5 N m
FBT13P-18P
{35 8 kgf m}
422 96.1 N m
FBT20PN
{43 9.8 kgf m}

Plug
Tightening torque
3.92 0.98 N m
{0.4 0.1 kgf m}

: Tightening torque
B : Apply THREEBOND
N : Not reusable
215S0722

Lift cylinder 2nd (M-mast)

Head, cylinder B
Apply THREEBOND[#1901] on
threads when tightening.
Tightening torque
196 45.1 N m
FBT13P-18P
{20 4.6 kgf m}
235 53.9 N m
FBT20PN
{24 5.5 kgf m}

Plug
Tightening torque
Disassemble cylinder after
removing the plug.
3.92 0.98 N m
{0.4 0.1 kgf m}
: Tightening torque
B : Apply THREEBOND
N : Not reusable 221W027

91
 CYLINDER 7

Lift cylinder 2nd (PFL-mast)

Holder B
Apply THREEBOND[#1901] on
threads when tightening.
Tightening torque
196 45.1 N m
FBT13P-18P
{20 4.6 kgf m}
235 53.9 N m
FBT20PN
{24 5.5 kgf m}

1 Tightening torque
3.92 0.98 N m
{0.4 0.1 kgf m}

Tightening torque
196 35 N m
{20 3.6 kgf m}

2 Tightening torque
3.92 0.98 N m
{0.4 0.1 kgf m}
After tightening, fix the screw with
punching at two (2) points.

3 Check valve
When assembling, make sure that
the slit side of the check valve
must face to the bottom of the
cylinder.
: Tightening torque (Do not fit upside down.)
B : Apply THREEBOND
N : Not reusable 2210078

92
7 CYLINDER

1 Preparation for disassembling

Make the preparations shown below before disassembling the cylinder.

Preparation of the workbench

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

2 General precautions for the maintenance

 Before disassembling the cylinder, thoroughly clean any dirt or dust on the outer tube.
 Since these are precision parts, handle them with care. Handle the parts carefully so as
not to hit them against each other or allow them to fall.
 Don't tap or pry any parts by force. Such handling may cause burrs or damage parts.
As the result, parts may be impossible to reassemble properly and causes oil leaking or
degrades the performance.
 If the parts are left halfway while maintenance, they may be rusted or damaged by dusts.
They must be covered or protected if the job is required to interrupt.

3 Maintenance standards
Replace the sliding parts and sealing parts according to the following instructions.
 Bushings : When more than 1/4 of circumference is worn out and shows a red copper
color.
 Seals : Whenever the cylinder is disassembled, replace them with new ones.
 Piston rod : If curved more than 0.5 mm / 1m.

93
 CYLINDER 7

4 Disassembly procedure
1. Drain the oil.

2. Put the cylinder horizontal. Remove the plug and the

gasket.

CAUTION If the plug is not removed before disassembling,

piston, piston seal, bushing and/or other internal
parts may be damaged.

3. Loosen the cylinder head. Pipe Hook wrench

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

4. Pull out the cylinder head.

Pull the cylinder head straightly with care.

CAUTION When removing the cylinder head from the rod,

the end of the rod may hit and damage the head
if it is pulled out roughtly.

5. Pull out the piston rod ASS'Y.

Pull out the rod carefully with keeping horizontally.
Don't forget to remove the plug before pulling the rod out.

CAUTION Be careful not to damage the rod when pulling

out from the outer tube especially around the
thread part at the end of the tube or if the rod is
long.
Wear ring
Spacer
6. Pull out the spacer.
Pull the spacer out from the piston rod ASS'Y.
If the wear ring is fit on the spacer, that spacer cannot be
removed from the rod. Only the spacer without wear ring 221W111E

can be removed from the rod.

The wear ring itself can be removed by hand.

94
7 CYLINDER

7. Disassembly of the piston U-ring Snap ring

Remove the piston seal, the bushing, the cushion Backup ring Bushing
bearing, the check valve, and the plate. Plate
(The plate is installed only in cylinders with an internal
diameter of 55 or greater.)
1. Draw out the U-ring and the backup ring by using a
spatula or a screwdriver. O-ring

2. Remove the bushing with expanding the joint with a Check valve
screwdriver.
Cushion bearing
221W096E

NOTE All removed seals must be replaced to new ones.

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

bearing, the check valve and the plate. Pull the snap
ring out of the groove by using a sharp-pointed tool.

221W097

8. Disassembly of seals on the cylinder head. Wiper ring O-rings

Remove the X-ring, the wiper ring, and the O-ring. X-ring

1. Remove rings with extending by using a spatula or a

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

NOTE Replace all seals and rings to new ones when

reassembling.

95
 CYLINDER 7

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

2. Stick a flat head screwdriver into the joint of the

bushing, and twist along the groove to bend the edge Jig

of the bushing.
221W099E

3. Grab the bent part of the bushing with a plier and pull it
out.

NOTE Replace the bushing to the new one when

reassembling.

10. Cleaning and storage

1. Clean all removed parts with kerosene.
After wipnig kerosene off, apply the hydraulic oil on
them before storage.
2. If removed parts are left without cleaning, they may be
rusted or damaged by moisture or dust.

96
7 CYLINDER

5 Reassembly procedure
CAUTION Dust of paints may be peeled off from painted Press down using a press.
parts (such as the cylinder head) and come into
the cylinder which can cause oil leaking.
Jig
Pay attention not to come any dusts in the
cylinder when reassembling. Bushing
Cylinder
1. Reassembly of the cylinder head head

1. Fitting of the bushing

Press the bushing into the cylinder head by using a
press-fitting jig.
221W100E
(Apply hydraulic oil to the inner surface of the cylinder
head before pressing the bushing in. After press-fitting
the bushing, make sure for no gaps or unevenness.)

2. Fitting of the X-ring

X-ring
Push the X-ring into the X-ring groove in the cylinder
head.
Do not damage the X-ring while installing.
After fitting the X-ring, make sure there are no
damages or transformations.

221W101E

3. Fitting of the wiper ring Press down by using a press.

Fit the wiper ring by using a jig.

Jig

Wiper ring

Cylinder head

221W102E

4. Fitting of the O-ring

O-rings
Because of using the thinner O-ring than the
conventional one, use Nichiyu Genuine part for
replacement.
Be careful not to damage the O-ring because it is
stretched when fitting.

221W103E

97
 CYLINDER 7

2. Reassembly of the piston

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

2. Fitting of the backup ring

Backup ring
Insert the backup ring behind the U-ring.
(Refer the illustration on the right.)

221W105E

3. Fitting of the bushing

Bushing
Put the bushing on the bushing groove of the piston
with expanding at the joint.
(Refer the illustration on the right.)

221W106E

4. Fitting of the check valve, the plate and the cushion

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

221W108E

Cylinder inner diameter: Cylinder inner diameter:

50 or less 55 or greater
Direction to insert the cushion bearing 221W107E

98
7 CYLINDER

3. Reassembling of the cylinder tube ASS'Y, the piston rod

ASS'Y and the cylinder head

1. Fixing of the cylinder tube ASS'Y

Fix the cylinder tube ASS'Y horizontally.

2. Inserting the spacer (Fitting of the wear ring)

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

221W111E

3. Inserting of the piston rod ASS'Y

Insert the piston rod ASS'Y into the cylinder tube
ASS'Y.
Push the piston rod ASS'Y all the way to the end of
the cylinder tube ASS'Y.

CAUTION  Make sure that the plug is removed before

inserting the rod into the tube of the cylinder.
 Keep the rod horizontally when inserting.
 Pay attention not to hit the piston or the rod to
the thread of the cylinder tube. Otherwise,
parts on the piston or the rod may be
damaged.

4. Lubrication
Fill the grease in the groove behind of the X-ring in the Apply grease all around the O-ring.

cylinder head.

X-ring Fill with grease.

221W109E

99
 CYLINDER 7

5. Installation of the cylinder head

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

221W110E

6. Fitting of the plug and the gasket

Fit the plug and the gasket. Tighten them with the
specified torque.

4. Operating test
After finishing reassembling, fitting on the mast or
chassis, and re-connection of all hydraulic hoses, you
can start to test the function.
Move the hydraulic lever slowly to fill the hydraulic oil
through the circuit gradually.
Do not move the hydraulic lever quickly for the first 8
or 10 times to fill the oil to the end of the stroke of the
cylinder. Otherwise, the oil may be bubbled and the
hydraulic pump may be damaged.

100
7 CYLINDER

7d-1-7. Tilt cylinder - disassembly and reassembly

1. Fix the cylinder on a vise. Removing the "head KIT, cylinder"

CAUTION Do not vise around the head.

2. Remove the cylinder head by a hook wrench.

Vise

Hook wrench
152T017

Disassembling and reassembling the tilt cylinder

Head, cylinder B
Apply THREEBOND [#1344] on
threads when tightening.
Tightening 343 63.7 N m
torque {35 6.5 kgf m}

Tightening torque
98 9.8 N m
{10 1 kgf m}

Tightening torque
343 - 441 N m
{35 - 45 kgf m}

: Tightening torque
B : Apply THREEBOND
Cylinder SUB ASS'Y
N : Not reusable 215S0726

CAUTION Replace all seals and packings when

reassembling.

NOTE Apply grease on all seals and packings when

fitting them.

101
 CYLINDER 7

7d- 2. Inspection and adjustment

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

7d-2-2. Piston rod - inspection

1. Check for rusting and/or damage. Measuring deflection
If rusting or damaged, polish them with oil stone till
Dial gauge
they will not be felt by fingers.

2. Check for deflection.

Deflection limit 1.0 mm

CAUTION Measure at least 3 points to check for deflection.

Piston rod

152T018

102
7 CYLINDER

7d-2-3. Drift for lift and tilt - inspection

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

1 Measuring drift of lift

1. Load the maximum weight, and then raise the fork Measuring drift of lift lowering
about 70 cm from the ground. Outer mast Inner mast
2. Tilt the mast vertically to level the fork.
(Use the tilt lever.)
3. Draw a straight line over the inner mast and the outer Draw a straight line
mast.
Drift of lift
4. Measure the drift of lift 10 minutes later.

<Specifications>

rs
Drift of lift [mm/10min.]

te ale
Applicable model at the line on the Inner mast Drift of lift

FBT13P - 20PN bu e less than 50

tri d D
70 cm
D ize

215S0727
ot or

CAUTION
is
N uth

If the drift of the lift is measured at the top

surface of the fork, the specific values should be
D rA

doubled of the values shown above.

fo

2 Measuring drift of tilt Measuring drift of tilt

o
y
nl

1. Load the maximum weight, and then raise the fork

O

about 70 cm from the ground.

2. Tilt the mast vertically to level the fork. (Use the tilt
lever.)
3. Measure the tilt drift of the piston rod of the tilt cylinder
5 minutes later.
70 cm

<Specifications>
Drift of tilt [mm/5min.]

Piston rod less than 10 Drift of tilt

Piston rod

Tilt cylinder

212E085

103
 CYLINDER 7

7d- 3. Variation of the tilt cylinder

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

7d-3-1. Tilt angle by masts

Tilt angle (Degrees) Spacer
Applicable Max. lifting Rod length
thickness Cylinder I.D.
Mast model height (mm) Forward Backward (mm)
(mm)
200P ~ 250P
2000 ~ 2500 5 3 22 285 LX4
200 PFL ~ 250 PFL
270P ~ 400P 0
2700 ~ 4000 5 6 263 LX1
270PFL ~ 400PFL (No spacer)
430P ~ 500P
4300 ~ 5000 3 6 14 263 LX2
430 PFL ~ 500PFL
330M ~ 350M 3300 ~ 3500 5 3 22 285 LX4
0
370M ~ 400M 3700 ~ 4000 5 6 263 LX1
(No spacer)
430M ~ 500M 4300 ~ 5000 3 6 14 263 LX2
530M ~ 700M 5300 ~ 7000 1.5 6 25 263 LX3

NOTE LX1, LX2 and LX3 are interchangeable if the internal spacer is exchanged
with the specified one.
For example, LX1 can be used as LX2 if the spacer (t=14mm) is inserted.

Removing the tift cylinder

Rod
Nut

Spacer

Piston

215S0729

104
7 CYLINDER

7d- 4. Troubleshooting
7d-4-1. Cylinder - troubleshooting
No. Symptom Possible cause Solution
Oil leakage 1. Damage of the packing in the cylinder Replace
1 from Cylinder 2. Looseness of Cylinder head Tighten
head 3. Damage on the rod Repair, Replace
Oil leakage
2 from Cylinder 1. Damage of the welded part Repair
Comp.
1. Damage of the packing in the cylinder Replace
Drift is too
3 2. Damage inside of the cylinder tube Repair, Replace
big
3. Oil leakage in the Control valve Replace
Cylinder 1. Bend of the rod Replace
vibrates 2. Shortage of hydraulic oil in the tank Replace
4
while
operation 3. Sucking air from the fitting of the piping Tighten
1. Over - discharging of the battery Charge
2. Lack of output of the pump Replace

Operating 3. Plunger of the control valve does not work properly. Inspect
speed of the 4. Clogging of the filter in the tank Clean or replace
5
cylinder is 5. Low relief pressure Adjust
slow.
6. Damage of the packings of the piston Replace
7. Hydraulic speed setting on the control system is not
Adjust
proper.
1. Stick of the spool in the flow control valve Replace
2. Foreign article is caught in the flow control valve. Clean
Lowering
6 speed is too 3. The spring in the flow control valve is damaged or
Replace
slow. weakened.
4. Hose of the return circuit from the lift cylinder is
Replace
choked or bent.
1. Failure of the micro switch of the control valve Replace
Cylinder 2. Failure of the wiring harness to the micro switch of
Inspect and repair
7 does not the control valve
work. 3. Failure of the hydraulic contactor or the contact tip. Inspect and repair
4. Blow out of the hydraulic main fuse. Replace

105
 8. MAST
8- 1. Disassembly and reassembly
CAUTION  Lift or jack up the forklift truck and support it with safety blocks or
rigid stands.
 Apply wheel chocks to tyres to prevent the truck from moving.
 When disconnecting hydraulic pipes, cap them to prevent dust from
entering into hydraulic components and pipes.
 Be sure to disconnect the battery plug.

8-1-1. Lift bracket ASS'Y- removal

1. Tilt the mast vertically and lower forks to the ground. Removing the lift bracket

2. Remove cotter pins. P mast Lift chain

リフトチェン

3. Slacken lift chains and remove nuts at the chain anchor 割ピンpin
Cotter
bolt.

4. Remove lift chains from the front side (fork side).

CAUTION Put the nut on the anchor bolt after removing

the chain to prevent the thread from damages.

Lift bracket
リフトブラケット

5. Operate the lift lever to raise the inner mast to a height

M/PFL mast
where the lift bracket can be removed.

6. Move the truck backward, or move the lift bracket Lift chain
リフトチェン
forward.

7. Lower the inner mast.

Lift bracket
リフトブラケット
ナット
Nut
Cotter
割ピンpin
221W030

106
8 MAST

8-1-2. Mast ASS'Y - removal

1. Tilt the mast vertically. Hoisting the mast ass'y

2. Hoist the mast ass'y until the wire ropes are just
stretched.

215S0801

3. Remove the fitting bolt for the tilt pin on the side of the Removing the tilt pin
mast.
View "A"
4. Remove the tilt pin to disconnect the tilt cylinder from the
mast. Through
hole

A
Tilt pin

Tilt cylinder

Washer lock
Ftting bolt

5. Operate the tilt lever to retract the piston rod of the tilt
cylinder. 215S0802

6. Disconnect hydraulic pipes and hoses from the mast.

CAUTION Before disconnecting hydraulic connections,

release internal pressure to prevent from
splashing oil.
Refer the CAUTION on the page 4 for the
procedure.

107
 MAST 8

7. Remove the "Screws, cap" to remove the "Pin comp.,  Removing the pin comp.,
mast support". mast support

CAUTION Be sure to record the number and thickness of

shims

8. Hoist the mast ASS'Y.

NOTE Number of the ring shim

Shim,
 The number of the shim (ring type) on the mast
shaft of the "Pin comp." should be arranged
to keep proper clearance against the chassis,
Outer mast
however, the basic number is as follows.
(See NOTE)
[P-mast, PFL-mast] Pin comp., mast support
4 mm each : 1 mm thick shim 4 pieces
on both right and left. 1 Screw, cap L
[M-mast] 207-253 N m
Tightening
7 mm each : 1 mm thick shim 7 pieces {21.1-25.9 kgf
torque
on both right and left. m}
Apply LOCTITE [#262] or an
equivalent.
: Tightening torque
L : Apply LOCTITE 215S0803

108
8 MAST

8-1-3. Mast - disassembly and reassembly

CAUTION  Be sure to record the number and thickness of shims when removing
them.
 When disconnecting hydraulic pipes, cap them to prevent dust from
entering into hydraulic components and pipes.

Disassembling and reassembling the P-mast

1 Sliding part G
Apply grease on a sliding part.
Fork
(Refer to 8-3-7) 2 Shim
Record the number and thickness.

Chain wheel
(Refer to 8-3-5)
Lift chain
(Refer to 8-3-3)

Back shoe
(Refer to 8-3-2)

Roller
(Refer to 8-3-6)

Grease nipple G
Fill grease.

3 Screw, cap L
207-253 N m
: Tightening torque Tightening torque
G : Apply grease {21.1-25.9 kgf m}
L : Apply LOCTITE Apply LOCTITE [#262] or an
N : Not reusable equivalent.
252S0811

CAUTION In case that OIL SEALS, O-RINGS and/or BEARINGS were removed, they
should be replaced to new ones.

109
 MAST 8

Disassembling and reassembling the M-mast

1 Screw, button head L
Apply LOCTITE [#242] or an
equivalent.

2 Shaft, pulley MG
Chain bolt Apply the molybdenum lube spray
(Refer to 8-2-4) before fitting the plastic hose pulley.

Chain wheel
(Refer to 8-2-5)

Fork
(Refer to 8-2-7)

Lift chain
(Refer to 8-2-3)

Back shoe
(Refer to 8-2-2)

Roller
(Refer to 8-2-6)

3 Sliding part G
Apply grease on sliding parts.

4 Grease nipple G
Fill grease.

5 Screw, cap L
207-253 N m
Tightening torque
{21.1-25.9 kgf m}
Apply LOCTITE [#262] or an
equivalent.

: Tightening torque
G : Apply grease
6 Shim
L : Apply LOCTITE Record the number and thickness.
MG : Apply molybdenum grease
N : Not reusable 215S0804

CAUTION In case that OIL SEALS, O-RINGS and/or BEARINGS were removed, they
should be replaced to new ones.

110
8 MAST

Disassembling and reassembling the PFL-mast

1 Sliding part G
Chain wheel Apply grease on a part of sliding.
(Refer to 8-2-5)
2 Shim
Record the number and thickness.
Chain bolt
(Refer to 8-2-4) 3 Screw, button head
Lift chain Apply LOCTITE [#242] or an
(Refer to 8-2-3) equivalent.

Fork
(Refer to 8-2-7)
Back shoe
(Refer to 8-2-2)

Roller
(Refer to 8-2-6)

4 Grease nipple G
Fill grease.

5 Screw, cap L
: Tightening torque 230 N m
Tightening torque
G : Apply grease {23.5 kgf m}
215S0805

L : Apply LOCTITE Apply LOCTITE [#262] or an

N : Not reusable equivalent.
215S0805

CAUTION In case that OIL SEALS, O-RINGS and/or BEARINGS were removed, they
should be replaced to new ones.

111
 MAST 8

8- 2. Inspection and adjustment

8-2-1. Mast, lift bracket and roller shaft - inspection
1. Check if welded parts are not cracked with color check.

CAUTION Use welding rods of low hydrogen type when re-welding on Mast
channels and/or Roller shafts.

Inspection of mast, lift bracket and roller shaft P/PFL-mast

Roller shaft (both sides)

Mast channel
Roller shaft (both sides)

Roller shaft (both sides)

Mast channel

215S0806

Inspection of mast, lift bracket and roller shaft M-mast

Roller shaft (both sides)

Mast channel Roller shaft (both sides)

Mast
channel
Roller shaft (both sides)
Roller shaft (both sides) Mast channel
Roller shaft (both sides)

215S0807

112
8 MAST

8-2-2. Back shoe - inspection

1. Check the back shoe for wear. Inspection of back shoe

<Specifications> [mm]

Specific thickness [A] Wear limit

3 2.5 A

152T022

8-2-3. Lift chain - inspection and replacement

1. Check lift chains for stretch. Inspection of lift chain
Measure the length per 20 links at the part which are
used frequently.

<Specifications>
FBT13P-18P (per 20 links) [mm]
P
Specific Stretching
Pitch [P] Remarks
dimension limit
Leaf
317.5 324 15.875 chain#50
(BL534)

FBT20PN (per 20 links) [mm]

2210167

Specific Stretching
Pitch [P] Remarks
dimension limit
Leaf
381 389 19.5 chain#60
(BL634)

2. Check lift chains for deformation and damage.

If it is twisted, replace it.
3. Check for lubrication.
Apply grease on chains.

113
 MAST 8

8-2-4. Chain bolt - inspection

1. Check connecting part ( ) for play. Inspection of chain bolt
If it is played, replace it. P-mast

Chain

2. Check for damage on the thread of the anchor bolt. Link

3. Check for damage on the link.

221W037

M/PFL-mast

Chain

Link

Anchor bolt
2210168

8-2-5. Chain wheel - inspection

1. Check the outer surface for deformation, and the Inspection of chain wheel
rotation of the bearing.

152T025

114
8 MAST

8-2-6. Roller - inspection and replacement

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

<Specifications> [mm]
Item Allowable gap
Mast roller, Lift roller 1.5

2. Check for play and rotation of the roller.

8-2-7. Fork - inspection and replacement

1. Check for transformation and height difference. Height difference

<Specifications> [mm]

Item Allowance dimension

Height difference at the tip
10mm or less
of the fork.
Opening of fork tips 15mm or less
461E123

Opening

461E124

2. Check for wear and cracks.

Bending

<Specifications> [mm]

Applicable model Specific thickness Wear limit

+3
FBT13P/15P/18P 35 -0 32
+3
FBT20PN 40 -0 37

461E125

Wearing

CAUTION  If any cracks are found on the fork, replace to

the new one immediately. Do not repair.
 Check for cracks by using the color check.
461E126

115
 MAST 8

8-2-8. Lift chain - inspection and adjustment

1 Adjustment of chain deflection
Adjusting the lift chain
 Measure the deflection of Lift chains, and adjust it if
out of the specification.

Nut
<Adjustment> 0-20 mm
1. Tilt the mast vertically. Nut

2. Lower forks on the flat floor.

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

and measure the deflection.

212E097

<Specifications> [mm]

Item Specification
Lift chain deflection Less than 20 mm

4. If the deflection is out of specification, adjust it with

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

2 Adjustment of nut on chain anchor

1. After adjustment of the chain deflection, Adjusting
tighten the nut (lower) securely with the lock nut. the nut on chain anchor
2. Tighten the nut (upper) on the anchor by hand, and
then tighten about 1/4 turn by using a tool.

Nut (upper)
NOTE This adjustment can reduce the noise at the
anchor.

Nut (lower)

Lock nut

215S0809

116
8 MAST

8-2-9. Mast lean- adjustment

Check for the following if the inner mast is inclined Mast lean
when lifting forks to the top end.

1. Lift forks a little and check if the tension of both lift

chains are the same.
Refer to "8-3-8. Lift chain - inspection and adjustment".

2. Check if both cylinder rods are stopped at the same

time when lifting forks to the top end.

152T033

If defects are found, adjust by the following manner.

 P-mast :Change numbers or thickness
(t0.2/t0.5/t1.0) of shims.
 M-mast :Turn the "Rod, head" to adjust.
Then, tighten the lock nut securely.
 PFL-mast :Loosen "screw, set" and turn the adjust bolt.

Adjusting the lift cylinder

P-mast M-mast PFL-mast

Plate lock
Adjust bolt

Shim Lock nut

Rod, head
Screw, set

215S0810

3. Check for deflection in the chains when lowering forks.

117
 MAST 8

8- 3. Troubleshooting
8-3-1. Mast  Lift bracket  Fork - troubleshooting
NO. Symptom Problem Solution
Inner mast lifts up
1 together with Lift 1. Improper gap of lift rollers and/or side rollers Adjust
bracket.

Lifting and 1. Improper gap of lift rollers and/or side rollers Adjust

lowering of Lift
2 2. Defect of rollers Replace
bracket is not
smooth. 3. Chain roller does not rotate smoothly. Repair

Lift bracket is 1. Gap of side rollers is too big. Adjust

rs
3
inclined 2. Unequal tension of L.H and R.H chains Adjust

te ale
Lifting and
1. Improper gap between rollers and mast channel Adjust
lowering of
bu e
tri d D
4
inner mast is not
2. Defect of rollers Replace
smooth.
D ize

Inner mast Adjust

1. Adjustment at the top end of the lift cylinder is not
ot or

5 is inclined at
proper.
Adjust
is
N uth

extended position

Repair,
D rA

1. Bending of forks
Replace
Tip of both forks
Proper
fo

6 don't have the 2. One-sided load distribution on forks

operation
o
y

same height.
Repair,
nl

3. Bending of the tilt bar

Replace
O

118
 9. MOTOR
9- 1. Disassembly and reassembly
9-1-1. Traction motor - removal and installation
Refer to "2-1-1. Front axle - removal".

9-1-2. Hydraulic motor - removal and installation

CAUTION  Before disconnecting hydraulic connections, release internal pressure
to prevent from splashing oil.
Refer the CAUTION on the page 4 for the procedure.
 Record places of lead wire connections before disassembling.
 When disconnecting hydraulic pipes, cap them to prevent dust from
entering into hydraulic components and pipes.
 Be sure to disconnect the battery plug.

1. Remove the cover ASS'Y, battery.

2. Remove the battery ASS'Y

3. Disconnect following hoses from the pump.

(1) High pressure hose [come from the Control valve]
(2) Low pressure hose [come from the Oil tank]

4. Disconnect lead wires on the hydraulic motor.

5. Remove fitting bolt for the motor bracket, and hoist the
hydraulic motor with the motor bracket.

Removing the hydraulic motor (1)

(1)High pressure hose

Hydraulic motor
(2)Low pressure hose

Lead wire

Bracket, motor

Fitting bolt
Tightening torque
29.4 - 39.2 N m
{3.0 - 4.0 kgf m}

: Tightening torque 215S0901

119
 MOTOR 9

6. Remove fitting nut to remove the hydraulic motor from

the bracket.

7. Remove fitting bolt to remove the hydraulic pump from

the hydraulic motor.

CAUTION Do not disassemble the hydraulic pump.

When damaged, replace the whole pump ASS'Y.

Removing the hydraulic motor (2)

Fitting bolt
Tightening torque
19.6 - 24.5 N m
{2.0 - 2.5 kgf m}

Hydraulic motor
Hydraulic pump

Spline MG
Apply molybdenum grease on the
spline.

Cushion (1)
Cushion
Install the longer screw side of the
Bracket, motor cushion into the bracket.

Fitting nut
Tightening torque
8.8 - 10.8 N m
{0.9 - 1.1 kgf m}

: Tightening torque
MG : Apply molybdenum grease
215S0902

* Install the hydraulic motor in reverse order of removal.

120
9 MOTOR

9-1-3. EPS motor - removal and installation

CAUTION Record places of lead wire connections before disconnecting.
Be sure to disconnect the battery plug.

1. Remove the cover ASS'Y, battery.

2. Disconnect lead wires on the EPS motor.

3. Remove fitting bolt for the EPS motor, and remove the
EPS motor.

Removing the EPS motor (1)

Fitting bolt
Cover, EPS and EPS motor B
Apply THREEBOND [#1212] on
the mating surfaces.

Lead wire
Connector

B : Apply THREEBOND
215S0903

* Install the EPS motor in reverse order of removal.

121
 MOTOR 9

9-1-4. Traction motor - disassembly and reassembly

Disassembling and reassembling the traction motor

Tightening torque
13.5 N m 10%

Cover, end

Bearing comp.,
sensor

Terminal
comp.

Stator comp.

Sub-rotor ASS'Y

Oil seal N B G
Apply grease on the lip of the oil
seal, and apply the THREEBOND
[#1104] around the seal.

Cover, end D L
: Tightening torque Apply LOCTITE [#648], [#262] or
B : Apply THREEBOND an equivalent product in M8 thread
holes.
G : Apply grease
L : Apply LOCTITE
N : Not reusable 215S0904

CAUTION In case that OIL SEALS, O-RINGS and/or BEARINGS were removed, they
should be replaced to new ones.

122
9 MOTOR

9-1-5. Hydraulic motor - disassembly and reassembly

Disassembling and reassembling the hydraulic motor

Tightening torque
13.5 N m 10%
Terminal
comp.

Housing
sensor

Stator comp.

Sub-rotor ASS'Y

Cover(D), end L
Apply LOCTITE [#648], [#262] or
an equivalent product in M8 thread
holes.
: Tightening torque
B : Apply THREEBOND
L : Apply LOCTITE
N : Not reusable 215S0906

CAUTION In case that OIL SEALS, O-RINGS and/or BEARINGS were removed, they
should be replaced to new ones.

123
 MOTOR 9

9-1-6. EPS motor - disassembly and reassembly

Disassembling and reassembling the EPS motor

Holder comp., brush

Brush comp. Cover, brush

Yoke ASS'Y
Bolt
Bearing
Armature comp. Wire
comp.,
lead
Bearing

Oil seal
Marking
Cover, D

N : Not reusable 461E0901

CAUTION In case that OIL SEALS, O-RINGS and/or BEARINGS were removed, they
should be replaced to new ones.

124
9 MOTOR

9- 2. Inspection and adjustment

9-2-1. Rotor comp. (Traction/Hydraulic motor) - inspection and replacement

1 Inspection for damage Rotor comp. (Traction motor)

1. Check the rotor comp. for damage, especially for
burning.
If it is damaged, replace it.

2 Inspection of spline
1. Check for wear of spline. Rotor comp.
If it is extremely worn, replace it. Spline 2210102

Rotor comp. (Hydraulic motor)

3 Inspection of ball bearing Rotor comp.

Spline 2210121

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

the "cover(D), end".
If loose, replace them.

Inspection of fitting parts (Traction motor) Inspection of fitting parts (Hydraulic motor)
Bearing, radial ball Bearing, radial ball Bearing, radial ball Bearing, radial ball

Cover(D), end Cover, end

2210191 Cover(D), end Cover, end 221W089E

CAUTION  When replacing the "bearing comp., sensor", Replacing the "Bearing comp.,
be very careful not to damage the sensor. sensor"
If the sensor is damaged, the motor will not
operate correctly.
 Because the bearing sensor is very sensitive Sensor

for the static electricity, do not touch any Connecter

terminals in the connector directly.
121W164

125
 MOTOR 9

9-2-2. Armature comp. (EPS motor) - inspection and replacement

1 Inspection for damage Inspection of armature comp.
1. Check the armature for damage, especially for
burning. Armature comp.

If it is damaged, replace it.

Spline
If the surface of Commutator is damaged, repair or
replace it.

2 Inspection of spline
1. Check for wear of spline.
If it is extremely worn, replace it. 221W087E

Inspection of fitting parts

3 Inspection of ball bearing
Bearing, radial ball Bearing, radial ball
1. Check fitting part of the bearing in the "cover(C), end"
and the cover(D).
If loose, replace it.

Cover(C), end
Cover(D)

2210169

126
9 MOTOR

Inspection of commutator Check the surface of

4
commutator
 Check the armature for damage especially by high
temperature.
If it is damaged, replace it.
Good Not Good
If the surface of Commutator is damaged, repair or
replace it.

<How to repair> 152T035

1. Grind or polish the Commutator.

Wear limit
CAUTION If grinding, use the lathe.

2. Undercut the commutator after grinding.

3. Finish the surface of Commutator with a sand paper
(#400).

<Wear limitation>
 Wear limitation of Commutator [mm]
Motor Specification Wear limit ( D)
( D)
EPS motor 49 47 152T036

 Specific under cut [mm] Under cut of commutator

Motor Specific under cut

EPS motor 0.8-0.85

152T037

5 Inspection of insulation
Inspection of insulation
 Check the insulation between Commutator and
Armature shaft.
Positive

CAUTION Clean up the armature by compressed air before

checking.

<Resistance> Negative
TOOL SPECIFIC RESISTANCE
152T038

Tester Infinite at x1k range

Megger 0.5 M or greater (DC500V)

127
 MOTOR 9

9-2-3. Brush, Brush holder and Spring (EPS motor)

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

Applicable Applicable Wearing limit

Specification
model motor (A)
FBT13P-18P 14.5mm 8mm Wearing limit
EPS motor
Brush holder Brush
FBT20PN 25mm 15mm
Spring

Commutator
2210135

2 Inspection of contacting surface of brush

 If the contacting surface is not good, repair it as Inspection of contacting

follows. surface of brush

Good Not Good Not Good

Brush

Commutator
152T042

<Repairing procedure> Repairing surface of brush

1. Insert a sand paper [#400] between COMMUTATOR
Brush
and BRUSH.
(Face the file side to the brush.) Sand paper

2. Polish the contacting surface of the brush by moving a

sand paper or rotating COMMUTATOR by hand.
3. Blow the dust out with compressed air after repairing.

Commutator
152T059

128
9 MOTOR

3 Inspection of force of spring

Inspection of force of spring

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

<Specific force of SPRING> Spring scale Spring

Applicable motor Reference value
EPS motor
5N (0.5 kgf)
(NIKKO only)

CAUTION If the SPRING and/or the brush holder were

rusted, replace them. 152T060

129
 MOTOR 9

9-2-4. Motor ASS'Y (Traction/Hydraulic motor) - inspection

 Inspect the the motor with following procedures.

1 Abnormal noise check

 Operate the motor. Make sure there is no abnormal
noise.

CAUTION If the motor is tested by itself, fix the motor on

a work bench securely. The motor may move
suddenly when starting.
Test the motor with the slow speed.

<Checking procedure>
1. Be sure to secure the motor ASS'Y on a work bench.
2. Use the battery of the forklift truck to carry out testing.
3. Connect wires as follows.

Traction motor
1) Connect the U1 cable from the chassis to the U1 terminal on the motor.
2) Connect the V1 cable from the chassis to the V1 terminal on the motor.
3) Connect the W1 cable from the chassis to the W1 terminal on the motor.
4) Connect the wire harness from the chassis
(water resistant type 4P) to the connector of the speed sensor in the motor
(water resistant type 4P).
Hydraulic motor
1) Connect the U2 cable from the chassis to the U2 terminal on the motor.
2) Connect the V2 cable from the chassis to the V2 terminal on the motor.
3) Connect the W2 cable from the chassis to the W2 terminal on the motor.

CAUTION If an extension cable is necessary, make them with the following parts:
1) Main cables for motor (3 cables)
2
1. Cable size : 38 mm
2. Terminal : 38-S8
2) Lead wires for speed sensor (4 wires)
2
1. Wire size : 0.5 mm
2. Receptacle : AMP171662-1
3. Tab : AMP173600-1
4. "Housing, cap 4P" : 37010-20940(AMP174259-2)
5. "Housing, plug 4P" : 37010-20890(AMP174257-2)

130
9 MOTOR

2 Inspection of insulation Inspection of insulation

 Measure the insulation between terminals and stator Terminal

comp. with the Megger.

<Resistance>

Tool Specific resistance

Megger 0.5 M or greater (DC500V)

<Measuring procedure>
1. Apply the earth probe (negative [-]) of the Megger to Stator comp.
2210150
the stator comp.
2. Apply the line probe (positive [+]) of the Megger to
each terminal. (U, V and W)

9-2-5. Motor ASS'Y (EPS motor) - inspection

Inspect with the following procedure after assembling.

1 Abnormal noise and spark

 Operate the motor. Then make sure that abnormal
noise is not heard and sparks of brushes are not seen.

CAUTION If the motor is tested by itself, fix the motor on a

work bench securely. The motor may move
suddenly when starting.
Test the motor with the slow speed.

<Checking procedure>
1. Be sure to secure EPS motor ass'y on a work bench.
2. Apply 1/4 voltage of the battery (about 12V) to carry out testing.
3. Connect wires as follows.
1) Connect (GREEN or WHITE) wire to the positive (+)
terminal of the battery.
2) Connect (YELLOW or BLACK) wire to the negative (-)
terminal of the battery.

2 Inspection of insulation
 Measure the insulation between terminals in the
Inspection of insulation
connector and the end cover with the Megger.
Connector
<Resistance>
Tool Specific resistance
Megger 0.1M or greater (DC500V)
<Measuring procedure>
1. Apply the earth probe (negative [-]) of the Megger to
the yoke. End cover
Megger
2. Apply the line probe (positive [+]) of the Megger to
each terminal of connector plug. 152W225

131
 MOTOR 9

9-2-6. Oil seal and permanent magnet (EPS motor)

inspection and replacement
1 Oil seal
Check Oil seal for wear and damage. If worn or
damaged, replace it.

2 Permanent magnet
Check permanent magnets in the Yoke for damage or
sticking metallic dust.
If sticking metallic dust, remove it with compressed air.
If damaged, replace the whole motor.

9-2-7. Motor - specification

Traction motor
Applicable model Type Rating
AT43A2T/L For left 4.5kW, 30V, 60min
FBT13P-20PN
AT43A2T/R For right 4.5kW, 30V, 60min

Hydraulic motor
Applicable model Type Rating
FBT13P-20PN AH95C2D/1 9.5kW, 32V, 10min

EPS motor
Applicable model Parts number Rating
FBT13P-18P 37410-01470 300W, 48V, 60min
FBT20PN 37410-01270 450W, 48V, 60min

132
9 MOTOR

9- 3. Troubleshooting
9-3-1. Motor - troubleshooting
NO. symptom Problem Solution
1. Damage of bearing Replace

1 Abnormal noise Repair /

2. Armature shaft is not centered
replace

Abnormal
2 1. Improper rotating Replace
temperature rising.
Abnormal noise or 1. Wear of serration of Armature shaft or coupling Replace
3 temperature rise 2. Out of adjustment or wear of gears or faulty
Replace
after installing bearings in Drive unit
1. Damage of sensor bearing Replace
The motor does
4 2. Poor contact of wires or connectors of the speed
not rotate normally. Repair
sensor.

133
10. ELECTRIC PARTS
10- 1. Location and name
�Display panel �Directional switch �Battery

Refer to p. 149
*** Refer to p. 150
***

Refer to p. 152
***

rs
te ale
bu e
tri d D
�Charger
D ize
ot or
is
N uth
D rA

Refer to p. 156
***
fo
o
y
nl
O

�Accelerator �Control unit �EPS controller �Transformer

p.157
Refer to p. 146
*** Refer to p. 135
*** Refer to p. 138
*** Refer to p. ***
p.160
215S1001E

134
10a. CONTROL UNIT
10a-1. Location and name
Main parts of control unit Top
1. Shink, heat

9. Fuse (100A)
2. Contactor
10. Fuse (40A)

11. Fuse (325A)

3. Module, FET

4. Sensor, current
W
6. Board comp. Hydraulic V
N
P

U
W

Board comp.
MPU 7. Board comp. Travel (L)
V
N
P

U
W

8. Board comp. Travel (R)

V
N
P

5. Capacitor comp.
12. Cooling fan
215S1002

No. Part name Qty Remarks

1 Shink, heat 1
2 Contactor 1
3 Module, FET 3
4 Sensor, current 6
5 Capacitor comp. 1 Travel/Hydraulic 80V/5600 F x 9
6 Board comp. Hydraulic 1 Hydraulic
7 Board comp. Travel (L) 1 Travel (Left)
8 Board comp. Travel (R) 1 Travel (Right)
9 Fuse 1 BNE-100A (with the built-in charger only.)
10 Fuse 1 BN-40A
11 Fuse 1 BN-325A
EEC truck has another fan at the top of the
12 Cooling fan 1 control unit.

135
 CONTROL UNIT 10a

10a-2. Disassembly and reassembly

CAUTION  Apply wheel chocks to tyres to prevent the
truck from moving.
 Be sure to disconnect the battery plug.
 Record places of lead wire connections
before disassembling.

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

1. Open the "cover, battery"

2. Remove the "cover, side (L1)" and the "cover, side (L2)".

3. Remove the "cover, unit (2)".

4. Remove the control unit with following procedure.

1. Disconnect wires on the control unit.

NOTE Stamped mark on the ring terminal (at the end of

each cable) means followings.
Mark Connected to
+ Battery (+), Control unit (+)
- Battery (-), Control unit (-)
T+ Transformer (+)
T- Transformer (-)
Each phase for
U1,V1,W1
Travel control unit and motor
Each phase for
U2,V2,W2
Hydraulic control unit and motor
F Fuse

2. Remove the fitting bolt for the "cover, unit (1)" and
remove the control unit.

136
10a CONTROL UNIT

Removing the control unit

Cover, battery

Cover, side (L1)

Knob

Cover, unit (1)

Control unit

Cover, side (L2) Cover, unit (2)

215S1003

* Install the Control unit in reverse order of removal.

137
 CONTROL UNIT 10a

10a-2-2. EPS controller - removal and installation

CAUTION  Apply wheel chocks to tyres to prevent the
truck from moving.
 Be sure to disconnect the battery plug.
 Record places of lead wire connections
before disassembling.

1. Open the "cover, battery".

2. Remove the transformer.(Only for the built-in charger)
Refer to "10e-1-2. Transformer - disassembly and reassembly".

3. Remove the EPS controller.

1. Disconnect the lead wires for the EPS controller.
2. Remove the EPS controller.

Removing and installing the EPS controller

EPS controller

215S100

138
10a CONTROL UNIT

10a-2-3. Control unit - disassembly and reassembly

Disassembling and reassembling the control unit (1)

Wire, guard

Sensor, current

Bracket, board (2)

Board comp., MPU

Bracket, board (1)

Bracket, board (3)

Fan
(See note.)

215S1004

NOTE EEC specified truck has another cooling fan at

the top of the control unit.

139
 CONTROL UNIT 10a

Disassembling and reassembling the control unit (2)

Terminal L
Apply LOCTITE[#262] or an
equivalent product on threads to
prevent from looseness.

Tightening torque
Contactor
3.5 - 4.5 N m
{0.36 - 0.49 kgf m}

Bar, lead (2)

Plate, fuse

Fuse (100A)
(for the optional built-in charger)

Bar, lead (1)

Fuse
(40A) (for EPS)

Fuse (325A)
(for Travel & Hyd.) Bar, lead (2)

Bar, lead (1)

•Main terminal of the contactor (M8)

Tightening torque
12.7 - 14.7 N m
{1.3 - 1.5 kgf m}
L : Apply LOCTITE
: Tightening torque
215S1005

140
10a CONTROL UNIT

Disassembling and reassembling the control unit (3)

for EEC specification only
Sink, heat Hydraulic

Travel (L)
A

(This side only)

D
Travel (R)
B Capacitor comp., (2) S
Fix it with silicon glue on the FET
module.

E Slicon glue
C

Capacitor comp., (2)

0.47 F

E
B

(This side only) C

2 Module, FET C
Be sure to apply thermal
conductive compound [G-747]
(Shin-Etsu Slicones) on the entire
contact surface.

•Main terminal area (M6)

3 Tightening torque
3.5 - 4.5 N m
{0.36 - 0.49 kgf m}

4 Terminal L
: Tightening torque Apply LOCTITE[#262] or an
S : Apply silicon glue equivalent product on threads to
C : Apply compound
prevent from looseness.
L : Apply LOCTITE
215S1006E

141
 CONTROL UNIT 10a

10a- 3. Check and replacement

CAUTION Discharge capacitor
 Apply wheel chocks to tyres to prevent the (control unit)
truck from moving. Resistor (20w 50 or
50w 20 )
 Be sure to disconnect the battery plug first. Top
 Discharge Capacitors on the Control Unit. Battery line [-]
(See right)
 Record places of lead wire connections
before disassembling.

Battery line [+]

215S1010

10a-3-1. Main connector - inspection and replacement

CAUTION  Be sure to disconnect the battery plug.

 Record places of lead wire connections
before disassembling

Inspection of main contactor

1. Remove screws, and check for burning or wearing of
the contact.
If there is an abnormality on the contact, replace as
the whole contactor ASS'Y.

 The contactor is recommended to replace at

CAUTION Main
every two years even if no problem is
terminal
occurred for safety sake. (M8)

Main contactor type

Applicable model Model Voltage
Main
• terminal (M8)
FBT13P~20PN CP23NR-A44 48V
Tightening torque 121W226

2. Use the tightening torque shown on the right for the 12.7 - 14.7 N m
main terminal. (M8) {1.3-1.5 kgf m}
: Tightening torque
215S1011

142
10a CONTROL UNIT

10a-3-2. Module, FET - inspection and replacement

1. Perform a continuity test at the test points 1 - 6 in the
Inspection of "Module, FET" (1)
following table by using a digital tester.
(Use the resistance range with beep function. If you
D2-W
use the diode checking range, you may not able to get W
the correct result.)
N D2-V
V
If continuity is shown at any test points, the tester will
beep. Then, replace the module (Travel or Hydraulic ) U D2-U
D1-U,V,W P
to the new one.
If any defects are found on the travel FET module,
both of two modules (for right and left) should be
replaced at the same time.
Replace the set of all nine capacitors at the same time
G2-W
if the module is replaced.
G2-V
G2-U
G1-W
NOTE Replace the Capacitor annually or every 1000 G1-U G1-V
461S005

operating hours.

* Apply the positive (+) prove * Apply the negative (-) prove
of the tester to; of the tester to;
1 P(D1-U) G1-U
2 P(D1-V) G1-V
3 P(D1-W) G1-W
4 U(D2-U) G2-U
5 V(D2-V) G2-V
6 W(D2-W) G2-W
* After inspection, swap the positive and negative prove and carry out
the same inspection again.
(Make sure that the beep function of a tester works fine before
starting the inspection.)

Internal circuit of "Module, FET"

D1 D1 D1

G1 G1
G1

U V W

D2 D2 D2

G2 G2
G2

N 461S006

143
 CONTROL UNIT 10a

2. If any continuities are shown, check Inspection of

the Board comp. for any burning marks. "module, FET" (2)
(Travel or Hydraulic : PBC107). Main terminal
It is probably damaged also by electric surge Base plate
3. When installing the "module, FET" to the "sink, heat",
be sure to apply the thermal conductive compound
[G-747] (Shin-Ethu Silicones or equivalent) to the
entire contact surface.
4. Apply the tightening torque shown on the right to the
main terminal (M6) and the base plate (M6).
Main terminal
461S007

Main terminal (M6)

CAUTION  Do not touch any terminals (especially
Base plate (M6)
Tightening torque
terminals in the connector) by hand.
3.5 - 4.5 N m
The FET module is very sensitive for the static
{0.36-0.490 kgf m}
electricity and may be destroyed by touching
terminals.
 The insulation cap on the terminal of the new : Tightening torque

FET module should be removed just before

connecting cables or the connector.

NOTE In case of the EEC specified truck, a small condenser is bonded on the
FET module to meet with the CE regulation.
If the FET module with a condenser is used for the non-EEC truck, the
condenser must be removed from the FET module. If you will mix FET
modules with and without condenser on the same truck, the control
circuit may be damaged.

144
10a CONTROL UNIT

10a-3-3. Capacitor - check and replacement

 Check the appearance visually. Checking the capacitor
If the appearance looks no problem, check with
following procedures. Analog tester

CAUTION Use an analog tester to check the capacitor.

1. Discharge the energy stored in the capacitor with a

resistor.
Refer the next clause "Procedure to discharge
capacitor". 252W1036

2. Set the tester to the resistance range. (k range)

3. Apply the positive (+) prove to the (+) pole of the
capacitor, and the negative (-) prove to the (-) pole.
4. First, the tester shows a few k , then increase the
resistance and shows " " finally if the capacitor is
normal.

CAUTION The above checking procedure is only for the

basic performance of the capacitor.
If you have any doubts, replace all capacitors.

<Procedure to discharge capacitor> Discharging the capacitor

1. Prepare a resistor (20W, 50 or 50W, 20 ).

2. Connect the resistor to the capacitor.

(See right)
3. Keep connection for 5 seconds. Then, the capacitor can
be discharged.

252W1037

145
10b. ACCELERATOR
10b-1. Disassembly and reassembly
10b-1-1. Accelerator linkage - removal and installation
Removing and installing the accelerator linkage

Ball link

Pedal

Rod

1 Spring G
Apply grease on surface.

Plate floor (1)

Lever
Ball link

Plate
Bushing

Spacer

Spring
Spring
Potentiometer

Shaft & shim G

Apply grease between shaft and
Bracket shim.
Case
2 Spring G
Apply grease on hooks.

G : Apply grease 461S021

146
10b ACCELERATOR

10b- 2. Inspection and adjustment

10b-2-1. Potentiometer - adjustment
1. Adjust the fixing position of the potentiometer to get
Adjusting the potentiometer
the following output voltage.
Lever Neutral
(1) Apply DC 5 volts between Red (+) and Black (-).
(2) Measure the voltage between White (output 1) and
Black (-), and make sure if the voltage is within the

53
.5
range.

°
(3) Measure the voltage between Blue (output 2) and
Black (-), and make sure if the voltage is within the
range.
(4) If you cannot get the correct output voltage, remove Potentiometer
the potentiometer once and turn the shaft 180 . Then
461S022
install and test again.
(5) If you cannot get the correct output voltage for both
output 1 (white) and output 2 (Blue), replace the
potentiometer to the new one.

Lever position Output voltage

Neutral 0.8 ± 0.1 V

53.5 degree rotated 4.0 V - 4.5 V

NOTE This potentiometer is not a variable resistor.

So, the shaft does not have the mechanical
stopper (can turn 360 endless) and cannot
measure the resistance by a tester.

147
 DISPLAY PANEL AND DIRECTIONAL SWITCH 10c

10b-2-2. Accelerator linkage - adjustment

<Adjustment procedure>
1. Adjust the dimension *2 to get the dimension *1 as
130.5 5 mm when the accelerator pedal is released.
(The dimension *2 should be about 119.5 mm if the
adjustment is fine.)
2. Adjust the height of the stopper bolt (*3) as 46 mm.

Adjusting the accelator linkage

Original position
(when the pedal is released)
12

Pedal, accelerator
1)

2)
9.5 ox.
130.5 5(

pr
(
Ap

Adjusting bolt
11

Ball link
Plate,
floor
46( 3)

Rod

.5
53

Spring

Accelerator ASS'Y
461S023

148
10c. DISPLAY PANEL AND DIRECTIONAL SWITCH
10c-1. Disassembly and reassembly
10c-1-1. Display panel - disassembly and reassembly
Disassembling and reassembling the display panel
Seat, switch Cap (2)

Panel, display (1)

rs
B

te ale
bu e
tri d D
Cap (1)

Support, display
D ize

Switch, flasher
Display
ot or
is
N uth

Directional switch
D rA

B
fo
o
y
nl
O

Panel, display (3)

Switch comp., key

Panel, display (2)

CS/FCS,RP/DRP

Switch comp., key

252W1011

149
 DISPLAY PANEL AND DIRECTIONAL SWITCH 10c

10c-1-2. Directional switch - disassembly and reassembly

Disassembly procedure and parts name

Disassembling and reassembling the directional switch

Lever

Boss, lever
Knob, lever
Panel display(1)

Case

Column ASS'Y
Microswitch Bushing
DS1(Forward)

Microswitch
DS2(Backward) Shaft
Spacer
Microswitch
DS3(Neutral)
Roller
Plate, SW

Arm
Cover, case
Cam (A)

215S1014

The illustration shows the right lever type. Some trucks may have the left lever
type.
Refer to the next page "Wiring" for the location of the left lever microswitch.

150
10c DISPLAY PANEL AND DIRECTIONAL SWITCH

Wiring of the directional switch

<Type : DS100-20 (Right lever)>

DS1(Forward) Case
Red Green/White
Forward
DS2(Backward)
Red Blue/Yellow

DS3(Neutral)
Red White/Black

Backward

Vinyl tube (Black) Forward Neutral Backward

(length: 100) DS1
DS2 DS1 Close Open Open
White/Black

DS3
Green/White

DS2 Open Open Close

Blue/Yellow

DS3 Open Close Open

Micro Switch location
Red

2 2 2 2
1 2 3 4

4P
Waterproof
connector
1 2
3 4

2210186

<Type : DS100-21 (Left lever)>

DS1(Forward) Case
Red Blue/Yellow
Forward
DS2(Backward)
Red Green/White

DS3(Neutral)
Red White/Black

Backward

Vinyl tube (Black)

(length: 100) DS2
DS1
White/Black
Green/White

DS3
Blue/Yellow

Micro Switch location

Red

2 2 2 2 Forward Neutral Backward

1 2 3 4
DS1 Close Open Open
4P Waterproof
connector DS2 Open Open Close
1 2 DS3 Open Close Open
3 4

2210187

151
10d. BATTERY
10d-1. Removal and installation
WARNING  Turn off the key switch and disconnect the battery plug.
 Apply wheel chocks to tyres to prevent the truck from moving.
 Be careful not to touch electrolyte to the body.
 If the electrolyte is splashed into eye, wash eye with clean water, and
consult a doctor immediately.
 The inspecting battery shall be done in a place where is well ventilated
and kept away from fire.
 Battery is very heavy.
Use proper slings or ropes to hang the battery with the hoist to remove
or install.

10d-1-1. Battery - removal and installation

Removing and installing the battery

Battery

215S1015

152
10d BATTERY

10d-2. Inspection and adjustment

10d-2-1. Battery - inspection and adjustment
1 Inspection of quantity of electrolyte Inspection of electrolyte level
and replenishment Appropriate level

<Checking electrolyte level>

1. Disconnect the battery plug.
2. Open the battery cover and set the stopper.
3. Check electrolyte level.

Proper level of electrolyte

<Specification>
If the red float can seen, electrolyte level is normal.
If not, add refined or distilled water to the approproate
level.

CAUTION Do not add any sulfuric acid in the battery cell.

The electrolyte is the dilute sulfuric acid,
Lowest level of electrolyte
however, only distilled or refind water can be
used to add. Add refined water to
the appropriate level.

<Adding refined water> Adding water

1. Open the cap of the battery cell.
2. Add the distilled or refined water until the top of the Cap
red float is touched to the plate of the cap.
Float
White line

NOTE The illustration shows the Japanese standard Battery

battery and the actual battery on the truck may
Level of
have the different structure. electrolyte
Refer the instruction from the battery supplier
for details.

153
 BATTERY 10d

2 Measurement of specific gravity of electrolyte in each cell

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

NOTE The specific gravity should be converted to

the value at 20 when judging the battery
condition.

1. Measure temperature of electrolyte.

CAUTION Use thermometer to measure CONVERSION

1.330

Actual reading of hydrometer

2. Measure specific gravity of electrolyte. 1.310
1.290
Specific gravity at 20

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

154
10d BATTERY

10d-2-2. Battery - Cleaning

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

2 Cleaning vent plug

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

NOTE If the vent plug is damaged, replace the plug

comp. with new one.

155
10e. CHARGER (BUILT - IN)
10e- 1 Disassembly and reassembly
CAUTION Do not misconnect the earth wire to the normal electric circuit.
Make sure that all wires are connected correctly.
Securely tighten screws or bolts of lead wires.
Insert insulation tubes for the terminals of the transformer in order to
keep them away each other and from metal parts.

10e-1-1. Charger ASS'Y - disassembly and reassembly

Disassembling and reassembling
the charger ASS'Y (only built-in type)

Cover, panel

Panel, charger
Board comp.,
printed

Magnetic
contactor

Earth Fuse comp.

wire

Receptacle
Relay
215S1016

156
10e CHARGER (BUILT - IN)

10e-1-2. Transformer - disassembly and reassembly

Disassembling and reassembling the transformer (only built-in type)

“SKR”
type
Diode

Primary coil

Secondary coil “SKN”

type
Diode

Bracket, transformer

215S1017

157
 CHARGER (BUILT - IN) 10e

10e-1-3. Built-in charger - specification

<3 200V>
Power Transformer Transformer
Applicable
supply Battery capacity Fuse capacity
model Capacity Model
voltage
320Ah T1224-2100
FBT13P 5.2kVA 15A
370Ah T1224-2101
FBT15P 350Ah
390Ah
T2224-2200
476Ah 6.4kVA 20A
FBT15P-20PN T2224-2202
530Ah
565Ah

<3 400V>
Power Transformer Transformer
Applicable
supply Battery capacity
model Capacity Model
voltage
320Ah T1244-2100
FBT13P 5.2kVA
370Ah T1244-2101
FBT15P 350Ah
390Ah
T2244-1100
476Ah 6.4kVA
FBT15P-20PN T2244-1101
530Ah
565Ah

NOTE 400-volt type charger has the thermal relay

instead of the fuse.

158
10e CHARGER (BUILT - IN)

10e- 2. Inspection and replacement

10e-2-1. Magnetic contactor - inspection
1. Check for burnings and/or damages on the contacts. Inspection of magnetic contactor

Magnetic contactor

2210224

10e-2-2. Plug comp. and receptacle - inspection and replacement

1. Check for burnings and/or discoloration on the Inspection of plug comp. and
receptacle terminal. receptacle
If there are any burns, discoloration, or abnormal plays Fitting nut
on the terminal, replace both the plug comp. and the
receptacle.
2. Check the earth wire fitting nuts for loosening.

Earth wire

Receptacle

Plug comp.
2210225

10e-2-3. Fuse and fuse base - inspection

1. Check fuses for blow outs or discoloration.  Inspection of link fuse and
2. Check fitting screws for loosening. fuse base

Fitting screw

Fuse

2210222

159
 CHARGER (BUILT - IN) 10e

10e-2-4. Transformer - inspection

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

Specific value of insulation

5M or greater
resistance

<Measuring procedure> Transformer insulation

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

1. Remove all diodes from the transformer.

2. Use a megger to measure the following locations and
check the insulation.
 Between the primary and secondary coils.
Megger
 Between the primary coil and the steel core of the coil. 2210227

 Between the secondary coil and the steel core of the coil.

10e-2-5. Diode - inspection

1. Measure the resistance to check the diode. Checking the diode

Specific resistance value Tester

Diode
Terminal
Resistance
[+] Positive [-] Negative
Anode(A) Cathode(K)
Cathode(K) Anode(A) 10 -100 k

K A
NOTE  Resistance may vary slightly by the circuit
tester.
244W063E

A K
<Measuring procedure> SKN130/04 SKR130/04

1. Set the tester to the resistance ( ) x 1 range.

2. Apply the positive (+) and negative (-) proves to
Anode(A) and Cathode(K) (or vice versa) to check the
resistance.

160
10e CHARGER (BUILT - IN)

10e- 3. Inspection After Assembly

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

10e-3-1. Timer - inspection

Refer to Troubleshooting "1-3-27. Buit-in charger working check"

10e- 4. Charging procedure

10e-4-1. Automatic charge (Daily charge)
 This charge returns the battery to a full-charged
condition after operating the forklift truck.

1. Move the forklift truck to designated charging area.

2. Turn off the key switch.
3. Release the bonnet catch and open the batter y
cover. Make sure that the battery cover is supported by 2210200

the gas spring securely.

CAUTION  Open the battery cover anytime when Battery cover

charging the battery to release Hydrogen gas
which is created while charging.

Bonnet catch

215S1018

161
 CHARGER (BUILT - IN) 10e

4. Connect the charging plug to the receptacle on the

charger panel.
5. Connect the AC plug to the wall outlet.
Charger

Receptacle

Charging plug

AC plug

215S1019

Then, all "AUTO" and "EQUAL" lamps are turned on.

NOTE If these lamps are not turned on, make sure the AC
cable is connected correctly.

215S1020

6. Push the "AUTO" button. Auto charge is started automatically

The "AUTO" lamp (green) is lit. The "EQUAL" lamp is
turned off.

215S1021

7. When charge is completed, the "AUTO" lamp (green)

is blinking.

8. Push the "STOP" button to turn off the lamp.

162
10e CHARGER (BUILT - IN)

9. Disconnect the charging plug and AC plug.

CAUTION  Do not disconnect the charging plug, AC plug

and battery plug while charging.
 Do not operate any hydraulic valve levers or
accelerator pedal while charging.
 Push the "STOP" button when interrupt to
charge.

CAUTION Do not touch any parts of charger and cable by

wet hand.

WARNING

rs
The charger operates with high voltage. Touch

te ale
by wet hand may cause electrical shock.

bu e
tri d D
10. Apply the bonnet catch after closing the battery cover.
D ize

CAUTION Be careful not to pinch hands or fingers

ot or

between battery cover and the battery box.

is
N uth
D rA

NOTE If the forklift truck is not used for a few days

fo

after completion of the normal charge, the

o
y

supplement charge function may be activated

nl

automatically. Then, the "AUTO" lamp is flashed.

O

In this case, push the "STOP" button before

disconnecting the charging plug and AC plug.

163
 CHARGER (BUILT - IN) 10e

10e-4-2. Balancing charge

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

<Automatic balancing charge>

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

<Manual balancing charge>

Balancing charge is required for the following cases.
Every two weeks when the lift truck is operated every
day.
Not charged for a couple of days after discharged.
If over-discharged

<Charging procedure> To start the Balancing charge.

1. Push the "EQUAL" button as the same way as

the normal charge.
"EQUAL" lamp (green) will turn on.

215S1022

2. Measure specific gravity of all cells after completion of

charge.
Refer to "10d-2-1. Battery - inspection and adjustment"
for the procedure.

NOTE When the specific gravity is 1.26-1.28 at 20°C,

the battery is fully charged.

NOTE  If the battery plug is disconnected, the memory of

time of charging is cleared in the controller and 2210219

the automatic balancing charge function is not

activated properly. In this case, the manual
balancing charge is recommended.

164
10e CHARGER (BUILT - IN)

10e-4-3. Inspection after charging

The water in Battery electrolyte decreases after charging.
Check the liquid level and replenish the water to the
appropriate level.

CAUTION Use distilled water or purified water when you

replenish the water.

165
 CHARGER (BUILT - IN) 10e

10e- 5. Voltage tap

10e-5-1. Power supply voltage - check
NOTE  Measure the power supply voltage at the charging section without
running the charger.
 Measure the voltage for 1 minute. The highest voltage obtained is the
power voltage.
 If three-phase input power is used, the average of the highest voltages
of each phase (U-V, U-W, and V-W) is the power supply voltage.

CAUTION  The measurement should be made when the peripheral facilities are
not used, such as during the lunch time or at night.

10e-5-2. Voltage tap - selection

Select a tap to match with the power supply voltage at
the charging place.
<Input voltage: 200V>
Power voltage (V) Voltage tap Location of the voltage top
199 or lower 200V
200-209 210V
Primary coil
210-219 220V

<Input voltage: 400V>

Power voltage (V) Voltage tap Secondary
coil
379 or lower 380V
380-399 400V
400-419 420V Voltage taps
252W1030

420-439 440V

Body side

3-core cable
(VCT)
Isolation tubes are placed
on unused taps. These wires must be
connected securely with
bolt and nut.

Bolt

Washer
Nut

*Voltage is marked on each wire.

Isolation tube
Transformer side 215S1030

166
10e CHARGER (BUILT - IN)

10e-5-3. Voltage tap - changing

 Turn off the key switch and disconnect the
CAUTION
power supply plug and the battery plug before
proceeding the work.
 Securely tighten the screw for the ring
terminal to prevent from loosening.
1. Loosen the screw and remove the ring terminal.
2. Reconnect it to the tap fitting to the power supply at 210V

voltage and secure the ring terminal together with at 200V

220V
bolts and nuts. (Factory
setting)
3. Put the isolation tube over the connected part and fix it
with a wire tie.
Factory default setting: 220 Volts

461E117

10e-5-4. Fuse (three-phase voltage) - replacement

CAUTION  Disconnect the AC plug of the power supply

cable. Securely tighten the screw.
 Tighten all screws after replacement of fuses.

Fuse
1. Loosen the screw to replace the link fuse.

<Applicable fuse>
Power supply
Applicable model Battery capacity voltage 2210222

3 200V
FBT13P 320 - 370 Ah 15A
FBT15P 350 - 565 Ah
FBT18P 390 - 565 Ah 20A
FBT20PN 390 - 565 Ah

167
11. LASER POINTER (OPTION)
11- 1. Adjustment
11-1-1. Fork level - adjustment
1. Raise forks to a height for easy work, and level them.
2. Adjust the positions of the leveling sensor and the
Bracket, sensor
magnet to light on the laser beam.
Sensor
When the laser beam light on, the fork leveling
indicator is shown on the display. Magnet
Within 1.25 degree of the
Adjustment position
fork leveling position Bracket, magnet

215S1023

11-1-2. Laser optical axis - adjustment

1. Park the forklift truck face to the pallet.
Distance between the pallet and the tip of the fork Lift bracket
should be about 30 to 50 mm.
2. Level the fork horizontally.
3. Turn on the laser pointer.
Raise the fork to fit to the opening of the pallet.
4. Adjust the angle and height of the laser beam to show
the correct position on the side of the pallet.
If the "LINE" type is used, the laser line should hit the
center of the beam of the pallet.
If the "Dot" type is used, the laser point should hit the
upper board of the pallet..
5. Adjust the axis of the laser light by turning the "Screw,
set" on the side of the laser unit. Laser pointer unit
6. Make sure if the fork can be inserted into the pallet Laser Screw,
set
normally after indicating the position by the laser
pointer.

Support,
laser

Laser pointer

461E215

168
12. SERVICE DATA
12- 1. Standard work hours
<Confirmation procedure>
1. If some different works are required to carry out at the
same time, add all working time.
For example, if you need to remove the cover to
replace a part, add both hours for replacing the part
and removing the cover.
2. Standard work hour for maintenance represents the
inspection (lubricant, charge) job only.

3. For adjustment, replacement/removal/installation

(R/R/I), etc, see the respective group pages.

4. Unit of work hours

"The work hours are based on decimal system."
"For example, 0.5=30 minutes, 1.0=1 hour"

5. Combined jobs
For combined jobs, select necessary job items and
sum them up.

6. Cost of transportation, sub contractor work, and/or

service car charges are not included in the standard
work hours.
Those charge must be charged or claimed
separately.

NOTE R/R/I : Replacement / Removal / Installation

169
 SERVICE DATA 12

Rate (hour)
Group Work Job
FBT13P FBT15P/18P FBT20PN
Drive gear oil 0.4 0.4 0.4
Replace
Hydraulic oil 0.4 0.4 0.4
Maintenance Monthly/
Lubricant 0.3 0.3 0.3
Yearly
Battery electrolyte 0.3 0.3 0.3
check
Gas spring 0.3 0.3 0.3
Floor plate (1) 0.1 0.1 0.1
Floor plate (2) 0.1 0.1 0.1
Floor plate (L) 0.1 0.1 0.1
Floor plate (R) 0.1 0.1 0.1
Cover, battery(with gas spring) 0.4 0.4 0.4
Seat 0.2 0.2 0.2
Battery 0.3 0.3 0.3
Frame R/R/I
Rear cover 0.1 0.1 0.1
Battery cover comp. 0.1 0.1 0.1
Side cover (L-1) 0.1 0.1 0.1
Side cover (R-1) 0.1 0.1 0.1
Side cover (L-2) 0.1 0.1 0.1
Side cover (R-2) 0.1 0.1 0.1
Front plate 0.1 0.1 0.1
Control unit 0.5 0.5 0.5
Front cover(L) 0.2 0.2 0.2
Front hood R/R/I Front cover(R) 0.1 0.1 0.1
Lever panel 0.1 0.1 0.1
R/R/I Counter weight 0.5 0.5 0.5
Monthly/
Counter weight
Yearly Retightening all fitting bolts 0.1 0.1 0.1
check
R/R/I Seat ASS'Y 0.2 0.2 0.2
Monthly/
Seat Seat damage and
Yearly 0.1 0.1 0.1
Looseness in mounting area
check
Head guard (with Turn signal lamp and 0.3 0.3 0.3
Head lamp)
R/R/I
Turn signal lamp 0.2 0.2 0.2
Overhead guard Head lamp 0.2 0.2 0.2
Monthly/
Looseness in mounting area 0.1 0.1 0.1
Yearly
Deformation, crack, and damage 0.1 0.1 0.1
check
Drive ASS'Y (with Traction motor, Brake) 1.0 1.0 1.0
R/R/I Wheel (1 piece) 0.1 0.1 0.1
Mast ASS'Y 0.6 0.6 0.6
Front axle (1) Traction motor ASS'Y 0.7 0.7 0.7
Monthly Oil leakage from Drive gear case and
0.1 0.1 0.1
check anusual noise
Yearly Unusual noise, oil level, fouling,
0.1 0.1 0.1
check oil leakage, and fitting bolt looseness

170
12 SERVICE DATA

Rate (hour)
Group Work Job
FBT13P FBT15P/18P FBT20PN
Disassembly and reassembly of the front 1.0 1.0 1.0
axle

Front axle (2) R/R/I Replace internal traction parts (gears, 1.0 1.0 1.0
bearing, etc.)
Replace internal brake parts (friction 1.0 1.0 1.0
plates, springs, etc.)
Wheel (1 piece) 0.1 0.1 0.1
Wheel hub (1 piece) 0.2 0.2 0.2
(after removing Wheel shaft)
Wheel hub bearing 0.2 0.2 0.2
R/R/I (after removing Wheel hub)
Wheel hub Oil seal (wheel hub) (1 piece) 0.1 0.1 0.1
Stud bolt (1 piece) 0.1 0.1 0.1
(after removing Wheel hub)

Fill grease (Wheel hub bearing) 0.1 0.1 0.1

Monthly/
Retightening all wheel hub nuts 0.1 0.1 0.1
Yearly check
Two pieces rim bolt and hub bolt/nut 0.1 0.1 0.1
Monthly/
damage and looseness
Wheel rim Yearly
Air pressure, crack, damage, wear, and 0.1 0.1 0.1
check
metal chip caught in between
Wheel (1 piece) 0.1 0.1 0.1
Front wheel R/R/I Pneumatic tyre exchange (1 piece) 0.2 0.2 0.3
No puncture tyre exchange (1 piece) 0.2 0.2 0.3
Wheel (1 piece) 0.1 0.1 0.1
Rear wheel R/R/I Pneumatic tyre exchange (1 piece) 0.2 0.2 0.2
No puncture tyre exchange (1 piece) 0.2 0.2 0.2
Angle sensor comp. R/R/I Steering angle sensor 0.5 0.5 0.5
Potentiometer R/R/I EPS torque sensor 0.5 0.5 0.5
Rear axle ASS'Y (with EPS motor) 1.0 1.0 1.0
R/R/I Wheel (1 piece) 0.1 0.1 0.1
(after removing Rear axle ASS'Y)
Monthly
Rear axle ASS'Y Rear axle jolt 0.1 0.1 0.1
check
(Rear axle)
Turning radius 0.1 0.1 0.1
Yearly
Stopper bolt looseness, if it is not 0.1 0.1 0.1
check
dropped off, and interference with wheel

171
 SERVICE DATA 12

Rate (hour)
Group Work Job
FBT13P FBT15P/18P FBT20PN
Hub (1 piece) 0.2 0.2 0.2
(after removing Wheel)
Taper roller bearing (one side) 0.2 0.2 0.2
(after removing Hub)
Rear wheel hub R/R/I OIl seal (wheel hub) (1 piece) 0.1 0.1 0.1
Hub bolt (1 piece) 0.1 0.1 0.1
(after removing Hub)
Fill grease (Hub bearing) (one side) 0.1 0.1 0.1
(after removing Bearing)
Rear axle ASS'Y 1.0 1.0 1.0
R/R/I Steering gear 1.3 1.3 1.3
Bearing, oil seal 0.7 0.7 0.7
Monthly/ ** ** **
Steering gear
Yearly ** ** **
check ** ** **
Yearly
0.1 0.1 0.1
check
Horn contact, horn cap, spring 0.1 0.1 0.1
Column ASS'Y ** ** **
Steering linkage R/R/I Chain roller 0.3 0.3 0.3
Sprocket ** ** **
Bearing ** ** **
Adjustment Brake (Discharging air) 0.5 0.5 0.5

Wheel brake Monthly/

Yearly Brake test (stopping distance, pull) 0.1 0.1 0.1
check
Pedal 0.3 0.3 0.3
Pedal bushing (after removing Pedal) 0.1 0.1 0.1
R/R/I
Pedal pad (after removing Pedal) 0.1 0.1 0.1
Return spring 0.2 0.2 0.2
Adjustment Brake pedal play 0.2 0.2 0.2
Foot brake linkage
Monthly/ Height, level and clearance between 0.1 0.1 0.1
Yearly pedal and floor
check Microswitch timing 0.1 0.1 0.1
Yearly "Rod, link" damage, looseness and jolt 0.1 0.1 0.1
check "Pin, cotter" fracture 0.1 0.1 0.1
Master cylinder 0.2 0.2 0.2
R/R/I Repair kit 0.2 0.2 0.2
(after removing Master cylinder)
Master cylinder Adjustment Brake (discharging air) 0.5 0.5 0.5
Master cylinder and Wheel cylinder
Yearly
operation, oil level, fouling 0.1 0.1 0.1
check
and oil leakage
R/R/I Pipe (with tube nut) (1 piece) 0.1 0.1 0.1
Monthly/ Entrained air, oil leakage, damage, agin
Brake oil piping
Yearly g, bolt looseness and interference with 0.1 0.1 0.1
check wheel

172
12 SERVICE DATA

Rate (hour)
Group Work Job
FBT13P FBT15P/18P FBT20PN
Microswitch (parking brake) 0.3 0.3 0.3
R/R/I Parking lever comp. 0.5 0.5 0.5
Parking brake cable (one side) 0.4 0.4 0.4
Parking brake Lock condition
Monthly/
Brake response time
Yearly 0.2 0.2 0.2
Lever stroke and pulling force
check
Feeling, damage, and wear
Gasket 0.1 0.1 0.1
Suction filter 0.5 0.5 0.5
R/R/I
Return filter 0.5 0.5 0.5
LP hose 0.2 0.2 0.2
Oil tank Clean Oil tank 0.5 0.5 0.5
Monthly
Oil level, any contaminations 0.3 0.3 0.3
check
Yearly Oil level , any contaminations 0.1 0.1 0.1
check Filter, clogging, and damage 0.1 0.1 0.1
Hydraulic pump 0.4 0.4 0.4
Connection elbow and nipple 0.1 0.1 0.1
R/R/I Oil piping 0.1 0.1 0.1
Coupling (after removing Pump) 0.1 0.1 0.1
Hydraulic pump
Oil seal (after removing Pump) 0.1 0.1 0.1
Monthly/
Oil leakage, unusual vibration, and
Yearly 0.1 0.1 0.1
unusual noise
check
R/R/I Control valve 0.5 0.5 0.5
Adjustment Relief valve pressure 0.3 0.3 0.3
Control valve
Yearly Operation, oil leakage, and fitting bolt
0.1 0.1 0.1
check looseness
Lift cylinder (1 piece) 0.3 0.3 0.3
Chain support comp. 0.2 0.2 0.2
Oil piping 0.9 0.9 0.9
R/R/I
Lift bracket 0.4 0.4 0.4
Lift cylinder Seal kit (1 set) 0.3 0.3 0.3
(P-mast) (after removing Cylinder)
Operation, oil leakage, dent, crack, 0.1 0.1 0.1
Yearly deflection, scratch, and fitting bolt
check looseness
Drift of lowering 0.2 0.2 0.2

1st lift clylinder ASS'Y (1 piece) 0.9 0.9 0.9

R/R/I
Seal kit (after removing Cylinder) 0.5 0.5 0.5
1st lift clylinder
(PFL-mast) Operation, oil leakage, dent, crack, and 0.1 0.1 0.1
Yearly deflection
check Drift of lowering 0.2 0.2 0.2
Measuring drift of Inner mast lowering

173
 SERVICE DATA 12

Rate (hour)
Group Work Job
FBT13P FBT15P/18P FBT20PN
Lift clylinder ASS'Y (1 piece) 0.3 0.3 0.3
R/R/I Seal kit (after removing Cylinder) 0.3 0.3 0.3
2nd lift clylinder Scratch, fitting bolt looseness
(PFL-mast) Operation, oil leakage, dent, crack, and 0.1 0.1 0.1
Yearly
deflection
check
Drift of lowering 0.2 0.2 0.2
Lift clylinder ASS'Y (1 piece) 0.9 0.9 0.9
R/R/I
Seal kit (after removing Cylinder) 0.5 0.5 0.5
1st lift clylinder Operation, oil leakage, dent, 0.1 0.1 0.1
(M-mast) Yearly crack,deflection, scratch, and itting bolt
check looseness
Drift of lowering 0.2 0.2 0.2
Lift clylinder ASS'Y (1 piece) 0.3 0.3 0.3
R/R/I Seal kit (1 set) (after removing Cylinder) 0.3 0.3 0.3
Flow control valve 0.2 0.2 0.2
2nd lift clylinder
Operation, oil leakage, dent, crack, 0.1 0.1 0.1
(M-mast)
Yearly deflection, scratch, and fitting bolt
check looseness
Drift of lowering 0.2 0.2 0.2
Tilt cylinder ASS'Y (1 piece) 0.3 0.3 0.3
Tilt cylinder rod end 0.1 0.1 0.1
(after removing cylinder)
Rod end bushing 0.2 0.2 0.2
(after removing cylinder)
R/R/I
Cylinder end cover bushing 0.1 0.1 0.1
(after removing cylinder)
Tilt cylinder
Tilt pin 0.2 0.2 0.2
Seak kit (1 piece) 0.3 0.3 0.3
(after removing cylinder)
Operation, oil leakage, dent, crack, 0.1 0.1 0.1
Yearly deflection, scratch, and fitting bolt
check looseness
Drift of lowering 0.2 0.2 0.2
Hose (1 piece) 0.2 0.2 0.2
R/R/I Connector, elbow, nipple, etc (1piece) 0.1 0.1 0.1
Flow control valve or fuse valve 0.2 0.2 0.2
Piping Monthly Oil leakage, deformation, damage, jolt, and
0.1 0.1 0.1
check looseness
Yearly Crack, damage, aging, twisting, oil leakage,
0.1 0.1 0.1
check mounting condition, and bolt/nut looseness
Valve lever linkage ASS'Y 0.6 0.6 0.6
(with control valve and microswitch)
Valve lever (1 piece) 0.2 0.2 0.2
Link (1piece) 0.2 0.2 0.2
Valve lever linkage R/R/I
Bushing (2 pieces on a lever) 0.2 0.2 0.2
(after removing Lever)
Lever knob (1 piece) 0.1 0.1 0.1
Oil piping 0.3 0.3 0.3

174
12 SERVICE DATA

Rate (hour)
Group Work Job
FBT13P FBT15P/18P FBT20PN
Mast ASS'Y 0.6 0.6 0.6
Mast roller (after removing Mast) 0.1 0.1 0.1
(Outer mast or Inner mast) (1 piece)
Back shoe (after removing Mast) 0.3 0.3 0.3
R/R/I
Lift chain (1 piece) 0.3 0.3 0.3
Mast Lift chain anchor bolt (1 piece) 0.5 0.5 0.5
Chain wheel (1 piece) 0.2 0.2 0.2
Chain support 0.5 0.5 0.5
Mast roller adjustment 0.4 0.4 0.4
Adjustment (Outer mast, Inner mast)
Back shoe 0.1 0.1 0.1
Lift bracket ASS'Y 0.4 0.4 0.4
Backrest 0.2 0.2 0.2
Roller (1 piece) 0.8 0.8 0.8
(after removimg Lift bracket)
R/R/I
Side roller (1 piece) 0.8 0.8 0.8
(after removimg Lift bracket)
Fork (for 1 truck) 0.2 0.2 0.2
Lift bracket
Fork set pin, spring (1 piece) 0.1 0.1 0.1
Adjustment Lift bracket adjustment 0.7 0.7 0.7
Monthly
Lift bracket jolt, crack in welded area 0.1 0.1 0.1
check
Bracket deformation, crack, and damage
Yearly
Roller wear and jolt 0.2 0.2 0.2
check
Pin area crack
Chain tension, extension, crack,
Monthly
deformation, damage, and wear 0.2 0.2 0.2
check
Chain wheel and lift Wheel deformation, damage, and jolt
chain Chain tension, extension, crack,
Yearly
deformation, damage, and wear 0.2 0.2 0.2
check
Wheel deformation, damage, and jolt
Fork (for 1 truck) 0.2 0.2 0.2
R/R/I
Fork set pin, spring (1 piece) 0.1 0.1 0.1
Monthly
Fork deformation, wear, and crack 0.1 0.1 0.1
check
Fork Deformation crack, and wear in locking
pin area
Yearly
Fork tip openin and leveling 0.1 0.1 0.1
check
Bottom area, upper hock area and under
hock area crack and wear

175
 SERVICE DATA 12

Rate (hour)
Group Work Job
FBT13P FBT15P/18P FBT20PN
Drive ASS'Y 1.0 1.0 1.0
(with Traction motor, Brake, and Mast)
Wheel (1 piece) 0.1 0.1 0.1
Mast ASS'Y 0.6 0.6 0.6
Traction motor ASS'Y 0.7 0.7 0.7
R/R/I Bearing, sensor 0.3 0.3 0.3
Cover, end 0.3 0.3 0.3
Rotor comp./bearing (2 pieces) 0.5 0.5 0.5
Seal, oil 0.2 0.2 0.2
Stator comp. 0.5 0.5 0.5
Traction motor
Cover 0.1 0.1 0.1
Clean\Test Traction motor ASS'Y (1pc.) 0.5 0.5 0.5
Monthly Unusual noise and unusual smell during
0.1 0.1 0.1
check motor rotaion
Bolt looseness, fitting bolt looseness in 0.2 0.2 0.2
main body
Yearly Motor rotation condition-(low speed, 0.1 0.1 0.1
check inter mediate speed, high speed,
acceleration), unusual noise, unusual
smell
Hydraulic motor ASS'Y (with pump) 0.3 0.3 0.3
Pump ASS'Y 0.4 0.4 0.4
Cover, end 0.3 0.3 0.3
R/R/I
Rotor comp./bearing (2 pieces) 0.5 0.5 0.5
Stator comp. 0.5 0.5 0.5
Cover 0.1 0.1 0.1
Clean\Test Motor ASS'Y 0.5 0.5 0.5
Hydraulic motor Monthly Unusual noise and unusual smell during
0.1 0.1 0.1
check motor rotaion
Bolt looseness, fitting bolt looseness in 0.2 0.2 0.2
main body
Yearly Motor rotation condition-(low speed, 0.1 0.1 0.1
check inter mediate speed, high speed,
acceleration), unusual noise, unusual
smell
Motor ASS'Y 0.4 0.4 0.4
Cover, end 0.3 0.3 0.3
R/R/I
Armature/bearing (2 pieces) 0.3 0.3 0.3
Cover 0.1 0.1 0.1
Clean\Test Motor ASS'Y 0.5 0.5 0.5
Monthly Unusual noise and unusual smell during
Electric Power steering 0.1 0.1 0.1
check motor rotaion
motor
Bolt looseness, fitting bolt looseness in 0.2 0.2 0.2
main body
Yearly Motor rotation condition-(low speed, 0.1 0.1 0.1
check inter mediate speed, high speed,
acceleration), unusual noise, unusual
smell

176
12 SERVICE DATA

Rate (hour)
Group Work Job
FBT13P FBT15P/18P FBT20PN
Control unit ASS'Y removal/installation 1.0 1.0 1.0
FET module (1 piece) 0.2 0.2 0.2
Add 0.2Hrs every time 1piece is added.
Current sensor (1 piece) 0.5 0.5 0.5
R/R/I Add 0.3Hrs every time 1piece is added.
Capacitor (for total 9 pcs.) 0.5 0.5 0.5
MPU board (travel/hydraulic) 0.4 0.4 0.4
Fan 0.2 0.2 0.2
Travelling speed, lift speed, plugging
Control unit Confirmation 0.2 0.2 0.2
distance
Monthly/Yearly Loseness in terminal contact area,
0.1 0.1 0.1
check looseness in wiring mounting area
Looseness and burnout of resistor and
Monthly
capacitor terminal, 0.1 0.1 0.1
check
fiting bolt looseness
[Safety device] Contactor operation 0.1 0.1 0.1
Yearly (pulling out arc or not)
check Wiring looseness, damage, and clamp 0.2 0.2 0.2
condition
R/R/I Accelerator 0.5 0.5 0.5
Accelerator Monthly/Yearly
Accelerator pedal operating condition 0.1 0.1 0.1
check
Display panel ASS'Y 0.2 0.2 0.2
Display panel cover 0.2 0.2 0.2
R/R/I Cam comp. 0.2 0.2 0.2
Lever comp. 0.3 0.3 0.3
Microswitch (for all 3 pieces) 0.2 0.2 0.2
Each connected area jolt
Directional switch Lever movement condition
Monthly Microswitch timing and operating
0.2 0.2 0.2
check condition
Microswitch damage,
looseness in mounting area
Yearly Adequacy of Microswitch timing,
0.2 0.2 0.2
check damage, and fitting bolt looseness
Display panel cover 0.2 0.2 0.2
Display unit 0.3 0.3 0.3
R/R/I
Turn signal lamp switch 0.2 0.2 0.2
Display panel Sheet switch comp. 0.2 0.2 0.2
Turn signal lamp damage, operating
Monthly
condition, and mounting condition 0.1 0.1 0.1
check
Instruments operation

177
 SERVICE DATA 12

Rate (hour)
Group Work Job
FBT13P FBT15P/18P FBT20PN
R/R/I Contactor 0.3 0.3 0.3
Contactor (main) timing and operating 0.1 0.1 0.1
Monthly
Contactor (main) contact point 0.1 0.1 0.1
check
Main contactor looseness,damage and wear
Contact point looseness, damage,
Yearly
wear, operation, fouling, and fitting bolt 0.1 0.1 0.1
check
looseness
Main fuse (1 piece) 0.2 0.2 0.2
Turn signal lamp switch ASS'Y 0.2 0.2 0.2
Horn 0.2 0.2 0.2
Battery plug (chassis side) 0.2 0.2 0.2
R/R/I
Back buzzer 0.2 0.2 0.2
Head lamp (1 piece) 0.2 0.2 0.2
Turn signal lamp (1 piece) 0.2 0.2 0.2

rs
Combination lamp 0.2 0.2 0.2
Fuse fitting bolt looseness,

te ale
capacity adequency
Others Warning device damage, operating
bu e
condition, and mounting condition
tri d D
(electric parts)
Rear view mirror and reflecting mirror
fouling, damage, and rflecting condition
D ize

Monthly/
Lighting system operation and mounting
Yearly 0.1 0.1 0.1
condition
ot or

check
Direction indicator operation and
is
N uth

mounting condition
Display board and instruments damage,
D rA

mounting condition, operation and water

infiltration
fo

Back buzzer operation

o

Front panel (left side) 0.3 0.3 0.3

y
nl

Transformer ASS'Y 0.3 0.3 0.3

O

Panel ASS'Y 0.6 0.6 0.6

Diode (1 piece) 0.1 0.1 0.1
R/R/I Adjustment 0.3 0.3 0.3
Receptacle 0.6 0.6 0.6
Magnet switch 0.2 0.2 0.2
Charger(option) Fuse 0.2 0.2 0.2
AC cable and plug 0.2 0.2 0.2
Timer operation
Monthly/
Magnet switch operating condition
Yearly 0.1 0.1 0.1
AC cable damageand looseness
check
Receptacle contact condition
Yearly Operating voltage of Voltage detection
0.1 0.1 0.1
check relay

178
12 SERVICE DATA

Rate (hour)
Group Work Job
FBT13P FBT15P/18P FBT20PN
Batterry 0.3 0.3 0.3
R/R/I
Batterry plug 0.4 0.4 0.4
Adjustment Replenishing water and clean up 0.2 0.2 0.2
Electrolyte level
Terminal looseness, damage and wear
Monthly/ Cell damage and electrolyte leakege
Batterry
Yearly Temperature and specific gravity after 0.1 0.1 0.1
check charging
Battery plug and cable damage and
looseness
Yearly
Each cell voltage 0.1 0.1 0.1
check

179
 Reproduction prohibited
First printing : November 2007

Issued by : Nippon Yusoki Co., Ltd

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