02W-2202
WORKSHOP MANUAL
FB
10P, 15P, 18P
20P, 25P, 30P
FB-DC70 SERIES
INTRODUCTION
sMost accident happens due to the disregard of basic safety rules or
precautions. In order to prevent accidents from happening, the factors
responsible for accidents must be avoided beforehand.
For this reason, please read this manual and fully understand the
precautions for safety and the proper procedures and directions for
inspection and maintenance before starting operation.
Performing maintenance and repair without adequate knowledge may
cause inadvertent accidents.
sIt is not possible to cover all the possible cases of accidents in this
"WORKSHOP MANUAL". Therefore, attention should be given to
precautions other than the ones mentioned in this "WORKSHOP
MANUAL". Especially, when repair and maintenance work which are not
covered in this "WORKSHOP MANUAL" are carried out, always work
under the direction of an instructor who understands the matter.
Using this "WORKSHOP MANUAL"
This manual has information about the layout and names of main components, procedures for
disassembly, assembly, inspection, adjustment, maintenance, and pinpointing faults which are in effect
mainly for the model FB-DC70.
Since the parts used in this machine are subject to change for the sake of better quality, performance
enhancement, and safety, some portions of the contents and illustrations of the "WORKSHOP MANUAL"
may not be identified.
Directions with and marks are very important, and must be followed.
qPersonnel this "WORKSHOP MANUAL" is aimed at:
This "WORKSHOP MANUAL" is directed at personnel who possess sufficient knowledge and technical
expertise. If you do not understand any of the contents of this "WORKSHOP MANUAL", perform
operation under the guidance of personnel who does.
wConditions of a facility
The work conditions described in the "WORKSHOP MANUAL" are written on the assumption that the
work is performed at a shop where standard facilities and tools for the maintenance of NICHIYU
ELECTRIC LIFT TRUCKS are available.
For safe and reliable maintenance, the work should be performed at a shop where the facilities are
equivalent to these described in the "WORKSHOP MANUAL" or better, and the instructions described
should be strictly followed.
Copyright
©
2002
NIPPON YUSOKI CO., LTD.
All Rights Reserved
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
You shall observe this instruction.
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
You shall observe this instruction.
Indicates a potentially hazardous situation which, if not avoided, may
result in minor or moderate injury.
You shall observe this instruction.
Indicates suggestions, tips and hints related to the safety of a
operator and maintain of truck.
DANGER
WARNING
CAUTION
NOTE
CONTENTS
SAFETY WORK 1
1.Precautions for safe inspection and
maintenance work ..............................................1
2. Safety labels ......................................................5
3. Model name and serial numbers .......................9
4. Cautions for maintenance ................................11
5. Tightening torque for bolts ...............................14
1 .GENERAL 16
1-1. Appearance ..................................................16
1-2. Specifications ...............................................17
4 .TYRE 43
4-1. Location, name and tyre size .......................43
4-1-1. Tyre - location and name ...........................43
4-1-2. Tyre size ....................................................43
4-2. Inspection and adjustment ...........................44
4-2-1. Hub nut - inspection ...................................44
4-2-2. Rim and rim bolt - inspection .....................44
4-2-3. Air pressure - inspection ............................45
4-2-4. Tyre - visual inspection and replacement ..45
4-3. Troubleshooting ............................................46
4-3-1. Tyre - troubleshooting ................................46
6. BRAKE 57
6-1. Location and name .......................................57
6-1-1. Foot brake linkage - main part names .......57
6-1-2. Parking brake linkage - main part names ..58
6-2. Disassembly and reassembly.......................59
6-2-1. Wheel brake - removal and installation ......59
6-2-2. Wheel brake - disassembly
and reassembly..........................................61
6-3. Inspection and adjustment ...........................62
6-3-1. Brake drum - inspection, repair and
replacement ...............................................62
6-3-2. Shoe & lining - inspection and replacement ..62
6-3-3. Adjustor ass'y - inspection
and replacement ........................................63
5. STEERING 47
5-1. Location and name .......................................47
5-2. Disassembly and reassembly.......................48
5-2-1. Steering - removal and installation.............48
5-2-2. Steering linkage - disassembly
and reassembly..........................................50
5-3. Inspection and adjustment ...........................52
5-3-1. Joint - inspection and replacement ............52
5-3-2. Knob - inspection and replacement ...........52
5-3-3. Steering wheel - inspection
and replacement ........................................52
5-3-4. Torque sensor neutral - check
and adjustment ..........................................53
5-3-5. Checking by voltage...................................55
5-4. Troubleshooting ............................................56
5-4-1. Steering linkage - troubleshooting .............56
2 .FRONT AXLE (DRIVE) 19
2-1. Location and name .......................................19
2-2. Disassembly and reassembly.......................20
2-2-1. Front axle - removal and installation ..........20
2-2-2. Front axle - disassembly and reassembly..26
2-3. Inspection and adjustment ...........................30
2-3-1. Gears - Inspection and replacement ..........30
2-3-2. Wheel hub and hub bolt - Inspection .........30
2-4. Troubleshooting ............................................31
2-4-1. Front axle - troubleshooting ...................31
3 .REAR AXLE (STEERING) 32
3-1. Location and name .......................................32
3-2. Disassembly and reassembly.......................33
3-2-1. Rear axle - removal and installation...........33
3-2-2. Rear axle - disassembly and reassembly ..35
3-2-3. Rear axle assembly - methods and
precautions ................................................37
3-3. Inspection and adjustment ...........................40
3-3-1. Bushing - inspection...................................40
3-3-2. Center arm - inspection..............................40
3-3-3. Tie rod comp. - inspection..........................40
3-3-4. Knuckle - inspection ...................................40
3-3-5. King pin - inspection...................................41
3-3-6. Hub and hub bolt - inspection ....................41
3-3-7. Rear axle comp. - inspection .....................41
3-4. Troubleshooting ............................................42
3-4-1. Rear axle - troubleshooting ........................42
7. HYDRAULIC SYSTEM 68
7-1. Oil piping circuit ............................................68
7c. CONTROL VALVE 77
7c-1. Location and name .....................................77
7c-2. Disassembly and reassembly .....................79
7c-2-1. Control valve - removal and installation.......79
7c-2-2. Inner kit of control valve - replacement........81
7c-3. Inspection and adjustment ..........................82
7c-3-1. Relief pressure - measurement .............82
7c-3-2. Microswitch - adjustment .......................82
7c-4. Troubleshooting ..........................................83
7c-4-1. Control valve - troubleshooting..............83
7d. CYLINDER 84
7d-1. Location and name .....................................84
7d-1-1. Lift cylinder - main part names .................84
7d-1-2. Tilt cylinder - main part names .................85
7d-2. Disassembly and reassembly.....................86
7d-2-1. Lift cylinder (STD mast) - removal ...........86
7d-2-2. Lift cylinder 2nd (M/PFL mast) - removal ........88
7d-2-3. Tilt cylinder - removal ...............................90
7d-2-4. Lift cylinder (STD mast) - installation .......91
7d-2-5. Lift cylinder 2nd (M/PFL mast)
- installation ...............................................91
7d-2-6. Tilt cylinder - installation...........................92
7d-2-7. Lift cylinder - disassembly and reassembly ..92
7d-2-8. Tilt cylinder - disassembly and reassembly ..94
7d-3. Inspection and adjustment .........................95
7d-3-1. Cylinder comp - inspection.......................95
7d-3-2. Piston rod - inspection .............................95
7d-3-3. Drift of lift lowering and tilt - inspection......95
7d-4. Troubleshooting ..........................................97
7d-4-1. Cylinder - troubleshooting ........................97
7a. HYDRAULIC PUMP 69
7a-1. Location and name .....................................69
7a-2. Disassembly and reassembly.....................70
7a-2-1. Hydraulic pump - removal
and installation ...........................................70
7a-3. Inspection and adjustment .........................71
7a-3-1. Coupling, pump - inspection ....................71
7a-3-2. Hydraulic pump - inspection.....................71
7a-4. Troubleshooting ..........................................72
7a-4-1. Hydraulic pump - troubleshooting ............72
7b. OIL TANK AND OIL PIPING 73
7b-1. Location and name .....................................73
7b-1-1. lron oil tank - main part names.................73
7b-2. Disassembly and reassembly.....................74
7b-2-1. Oil tank - precautions ...............................74
7b-2-2. Oil piping replacement - precautions .......74
7b-3. Inspection and adjustment .........................75
7b-3-1. Oil - inspection .........................................75
7b-3-2. Recommended oil and oil quantity ...........75
7b-3-3. Oil tank and filters - cleaning and check ..76
7b-4. Troubleshooting ..........................................76
7b-4-1. Oil tank - troubleshooting .........................76
6-3-4. Wheel cylinder ass'y - inspection
and replacement ........................................63
6-3-5. Master cylinder ass'y - inspection and
replacement ...............................................64
6-3-6. Brake pedal - inspection ............................64
6-3-7. Parking lever - inspection
and adjustment ..........................................65
6-3-8. Brake linkage - adjustment ........................65
6-3-9. Discharge air from the brakes ....................66
6-4. Troubleshooting ............................................67
6-4-1. Brake - troubleshooting ..............................67
8. MAST 98
8-1. Location and name .......................................98
8-2. Disassembly and reassembly.....................100
8-2-1. Lift bracket - removal ...............................100
8-2-2. Mast ass'y - removal ................................100
8-2-3. Mast - disassembly and reassembly ........102
8-3. Inspection and adjustment .........................105
8-3-1. Mast, lift bracket and roller shaft
- inspection...............................................105
8-3-2. Back shoe - inspection .............................106
8-3-3. Lift chain - inspection and replacement ......106
8-3-4. Chain bolt - inspection .............................106
8-3-5. Chain wheel - inspection ..........................107
8-3-6. Hose pulley - inspection ...........................107
8-3-7. Roller - inspection and replacement ........107
8-3-8. Fork - inspection and replacement...........108
8-3-9. Lift chain - inspection and adjustment......109
8-3-10. Mast inclination - inspection
and adjustment ........................................109
8-4. Troubleshooting ..........................................110
8-4-1. Mast - troubleshooting .............................110
9. MOTOR 111
9-1. Location and name .....................................111
9-1-1. Traction motor - main part names ............111
9-1-2. Hydraulic motor - main part names ..........111
9-1-3. EPS motor - main part names..................112
9-1-4. Motors - specifications .............................112
9-2. Disassembly and reassembly .....................113
9-2-1. Traction motor - removal and installation.113
9-2-2. Hydraulic motor - removal
and installation .........................................114
9-2-3. EPS motor - removal and installation.......116
9-2-4. Traction motor - disassembly
and reassembly........................................117
9-2-5. Hydraulic motor - disassembly
and reassembly........................................118
9-2-6. EPS motor - disassembly and reassembly ...118
9-3. Inspection and adjustment .........................119
9-3-1. Armature comp. - inspection
and replacement ......................................119
9-3-2. Brush, brush holder and spring
- inspection and replacement ...................121
9-3-3. Field coil - inspection ...............................123
9-3-4. Motor ass'y - inspection ...........................123
10. ELECTRIC PARTS 126
10-1. Location and name ...................................126
10c. ACCELERATOR 140
10c-1. Disassembly and reassembly .................140
10c-1-1. Accelerator linkage - removal
and installation .....................................140
10b. DISPLAY PANEL AND
DIRECTIONAL SWITCH 137
10b-1. Disassembly and reassembly.................137
10b-1-1. Display panel - disassembly
and reassembly....................................137
10b-1-2. Directional switch - disassembly
and reassembly....................................138
10a. CONTROL UNIT 127
10a-1. Location and name .................................127
10a-2. Disassembly and reassembly.................128
10a-2-1. Control unit - removal and installation..128
10a-2-2. Control unit - disassembly
and reassembly....................................129
10a-2-3. Contactor - removal and installation ....131
10a-2-4. Contactor - disassembly
and reassembly....................................132
10a-3. Check and replacement .........................134
10a-3-1. Capacitor - discharging procedure .......134
10a-3-2. Diode - inspection ................................134
10a-3-3. FET - inspection ...................................135
10a-3-4. Capacitor - check and replacement .....136
10a-3-5. MPU board - inspection .......................136
10a-3-6. EPS controller - specifications .............136
9-3-5. Oil seal and permanent magnet (EPS motor)
- inspection and replacement ......................125
9-4. Troubleshooting ..........................................125
9-4-1. Motor - troubleshooting ............................125
10e. BATTERY 153
10e-1. Disassembly and reassembly.................153
10e-1-1. Battery - removal and installation.........153
10e-2. Inspection and adjustment .....................154
10e-2-1. Battery - inspection ..............................154
10e-2-2. Battery - Cleaning ................................155
10f. MPU BOARD 156
10f-1. Location and name ..................................156
11. LASER POINTER (OPTIONAL) 157
11-1. Adjustment ................................................157
11-1-1. Fork level - adjustment...........................157
11-1-2. Laser optical axis - adjustment ..............157
12. SERVICE DATA 158
12-1. Annual Inspection Service Data ...............158
12-2. Standard work hours ....................................158
10d. CHARGER (BUILT-IN TYPE) 141
10d-1. Disassembly and reassembly.................141
10d-1-1. Charger ass'y - disassembly
and reassembly....................................141
10d-1-2. Transformer - disassembly
and reassembly....................................142
10d-1-3. Built-in charger - specifications ............142
10d-2. Inspection and replacement ...................143
10d-2-1. Magnetic contactor - inspection ...........143
10d-2-2. Plug comp. and receptacle
- inspection and replacement ...............143
10d-2-3. Link fuse and fuse base - inspection....143
10d-2-4. Transformer - inspection ......................144
10d-2-5. Diode - inspection ................................144
10d-3. Inspection After Assembly ......................145
10d-3-1. Timer - inspection ................................145
10d-4. Charging procedure................................146
10d-4-1. Normal (Daily charge) ..........................146
10d-4-2. Balancing charge .................................149
10d-5. Voltage tap .................................................151
10d-5-1. Power voltage - check..........................151
10d-5-2. Voltage tap - selection .........................151
10d-5-3. Voltage tap - switching .........................152
10d-5-4. Link fuse (three-phase voltage)
- replacement .......................................152
1
SAFETY WORK
Precautions for safe inspection and
maintenance work
1.
Maintenance shops
CAUTION
Facilities with adequate space and level
surfaces:
¡ The floor area of the shop (location) where
inspection and maintenance are performed must
have adequate floor space, and have level sur-
faces without holes.
aIf these conditions are not met, unexpected acci-
dents, such as a roll-over of the forklift truck,
may result.
CAUTION
WELL-VENTILATED AREA
¡Work such as welding painted components or
sanding down coated parts should be carried
out in well-ventilated areas.
aIf this is not observed, harmful toxic gas or dust
may be inhaled.
CAUTION
LOCATION EQUIPPED WITH FIRE EXTIN-
GUISHING EQUIPMENT
¡Equipment such as first-aid boxes and fire extin-
guishers should be nearby when work is per-
formed.
CAUTION
SAFE AND WELL-LIGHTED AREA
¡The work area should be safe and well lighted.
When working inside the machine or underneath
of it, always use a safety lamp with a shielded
light bulb.
aIf this is not observed, leaked oil may catch fire
when a light bulb pops.
CAUTION
PROPER ARRANGEMENT
¡Arrange and clean always at a working place to
work safety.
¡Especially, arrange disassembled parts well.
2
Work clothing
Tools and gauges
CAUTION
¡The worker should wear a hat, work clothes, and
safety shoes that are suitable for safe work. The
work clothes should be close-fitting.
a If this is not observed, loose clothing may
become caught in a machine, resulting in seri-
ous injury.
CAUTION
Prepare tools and gauges before starting to work.
CAUTION
¡Always use tools that are suitable for the work
being performed. Use proper size tools when
tightening and loosening the parts of the forklift
truck.
aFailure to observe the above could result in seri-
ous injury or damage to machines.
Safety work
WARNING
¡When hoisting a forklift truck or a heavy compo-
nent, use ropes or cable with correct capacity.
¡Do not use ropes or cables which are kinked.
WARNING
After lifting or jacking up a forklift truck, support it
with safety blocks or rigid stands.
WARNING
Apply wheel chocks to tyres to prevent the truck
from moving.
WARNING
When working under a forklift truck, use a pit or
proper safety precautions.
3
Parts
Repair of electrical components
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.
CAUTION
CHARGING BATTERY
¡Batteries produce flammable gas during charg-
ing. Do not allow batteries in the vicinity of fire
or flames.
aFailure to observe the above could result in an
explosion.
CAUTION
¡Diluted sulfuric acid is used as the battery's
electrolyte . Keep clothing and skin away from
contact with battery fluid.
aIf this is not observed, the fluid may corrode
clothing or cause burns.
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.
Record the places of lead wire connection when
disassembling.
NOTE
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Nichiyu FB-70 Series FB 10P, FB 14P, FB 15P, FB 18P, FB 20P, FB 25P, FB 28P, FB 30P Forklift Full Service & Repair Manual
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The Nichiyu FB-70 Series FB 10P, FB 14P, FB 15P, FB 18P, FB 20P, FB 25P, FB 28P, FB 30P Forklift Full Service & Repair Manual is a comprehensive resource for all your repair needs. Whether you are a professional mechanic or a DIY enthusiast, this manual provides detailed instructions for servicing, repairing, and troubleshooting the forklift.
Containing hundreds of pages with detailed photos and diagrams, this professional manual is the same type used by professional mechanics and technicians. It includes step-by-step instructions and highly detailed exploded diagrams and pictures to guide you through each job accurately.
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