Nissan Forklift Electric 1B1, 1B2 Series Service Repair Manual INSTANT

SECTION MA MAINTENANCE CONTENTS LUBRICATION CHART ..................................... MA-2 Lubrication Chart ............................................ MA-2 MAINTENANCE SCHEDULE ............................ MA-3 Maintenance Schedule ................................... MA-3 BATTERY ........................................................... MA-5 Battery ............................................................ MA-5 Battery Charger ..............................................MA-9 CONTROL SYSTEM ........................................ MA-10 Control System ............................................. MA-10 MOTORS .......................................................... MA-11 Motors .......................................................... MA-11 ELECTRICAL COMPONENTS ........................ MA-12 Electrical Components ................................. MA-12 DIFFERENTIAL CARRIER ...............................MA-13 Drive Unit (Reduction Gear) ......................... MA-13 FRONT AND REAR AXLES .............................MA-15 Front and Rear Axles ................................... MA-15 TIRES AND ROAD WHEELS ...........................MA-17 Tires and Road Wheels ................................ MA-17 BRAKE SYSTEM ..............................................MA-20 Brake System ............................................... MA-20 STEERING SYSTEM ........................................MA-24 Steering System ........................................... MA-24 HYDRAULIC SYSTEM .....................................MA-25 Hydraulic System ......................................... MA-25 LOADING MECHANISM ...................................MA-30 Loading Mechanism ..................................... MA-30

MA-2 LUBRICATION CHART LUBRICATION CHART Lubrication Chart (1) LUBRICATION SCHEDULE CHART (2) GREASE/OIL AND CAPACITY MAM0167 System/component Oil and grease Capacity Model 1B1 G1B1 1B2 G1B2 C1B1 C1B2 CG1B2 CG1B2 (3.0, 3.5 ton) Hydraulic oil tank (US gal, Imp gal) Hydraulic oil I.S.O. VG32 31 (8-1/4, 6-7/8) 44 (11-5/8, 9-5/8) 44 (11-5/8, 9-5/8) 52 (13-3/4, 11-1/2) 25.5 (6-3/4, 5-5/8) 34 (9, 7-1/2) 39.5 (10-1/2, 8-3/4) 39.5 (10-1/2, 8-3/4) Differential and reduction gear (US pt, Imp pt)/one side 80W-90 or API GL5 3.0 (6-3/8, 5-1/4) 2.5 (5-1/4, 4-3/8) Brake DOT 3 or DOT 4 — Greasing point The greasing points and grease type in use are listed in the above lubrication schedule chart.

MA-3 MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE Maintenance Schedule The following tables list the servicing required to keep your forklift operating in good mechanical condition. • Do not inspect any part of the system while the battery is being charged. • Before checking any part of the system, be sure to turn the key switch to off position and disconnect the battery plug. • When it is necessary to check with the battery connected, raise the drive wheels. Be extremely careful to prevent electric shocks. NOTE: The inspection/service timings shown below are based on the assumption that the forklift is operated for 200 hours in a month. When determining the inspection/service timing, take into account the actual working conditions of the forklift. (1) CONTROL SYSTEM MAINTENANCE Abbreviations: I = Inspect. Correct or replace if necessary. C = Clean MAINTENANCE OPERATION MAINTENANCE INTERVAL Page Periodic maintenance should be performed after specified intervals have elapsed in months or hours, whichever comes first. Months 1 2 3 4 5 6 7 8 9 10 11 12 Hundreds of hours 2 4 6 8 10 12 14 16 18 20 22 24 CONTROL SYSTEM MAINTENANCE 1. Dust from traction and pump motor C C MA-11 2. Rotor I I MA-11 3. Resistance between forklift body and negative/positive terminals I I I I MA-9 4. Operation of contactor points and plungers I MA-10 5. Resistance of contactor coils I MA-10 6. Controller surface C C C C C MA-10 7. Operation of low-voltage detecting circuit I I MA-10 8. Wiring, bolts and nuts I I I I I MA-10

MA-4 MAINTENANCE SCHEDULE Maintenance Schedule (Cont’d) (2) CHASSIS AND BODY MAINTENANCE NOTE: (1) Under dusty or other dirty operating conditions, more frequent maintenance should be necessary. Abbreviations: I = Inspect. Correct or replace if necessary. L = Lubricate C = Clean R = Replace MAINTENANCE OPERATION MAINTENANCE INTERVAL Page Periodic maintenance should be performed after specified intervals have elapsed in months or hours, whichever comes first. Months 1 2 3 4 5 6 7 8 9 10 11 12 Hundreds of hours 2 4 6 8 10 12 14 16 18 20 22 24 CHASSIS & BODY MAINTENANCE 1. Brake pedal free play I I I I I MA-21 2. Parking brake operation I I I I I MA-23 3. Lift chain tension I I I I I MA-31 4. Damage of carriage bracket rollers I I I I MA-31 5. Mast operation I I I I I MA-36 6. Damage of mast rollers I I MA-32 7. Lift & tilt cylinder fitting I I I I I I I I I I I I MA-36 8. Lift & tilt cylinder operation I I I I I MA-36 9. Hydraulic oil pump operation I I I I I MA-28 10. Hydraulic oil (1) R R MA-25 11. Hydraulic oil micron filter (1) R R MA-27 12. Differential gear oil I I I I R MA-13 13. Brake fluid R MA-20 14. Wheel bearing grease R MA-15 15. Lift chain (1) L L L L L L L L L L L L MA-36 16. Mast support bushing L L L L MA-37 17. All links of chassis L L L L MA-2 18. Liner L L L L L L L L L L L L MA-37 19. Thrust metals L L L L L L L L L L L L MA-37 20. Mast rail L L L L L L L L L L L L MA-37 21. Tilt cylinder pin L L L L MA-36

MA-5 BATTERY BATTERY Battery WARNING: • Do not smoke or place any fire near the battery being serviced or handled. • During battery maintenance, always wear safety goggles, rubber gloves and rubber boots. • Never let battery electrolyte containing dilute sulfuric acid stick to eyes, skins, clothes or the like. It may cause loss of eye sight and burns and holes on clothes. If stuck, wash it with a lot of water. If it enters eyes or you drink it by mistake, wash or drink a lot of water and consult with a doctor as soon as possible. • Be careful not to spill electrolyte on your body or clothes as this may cause injury or chemical burns. • If electrolyte flows out or leaks from the battery case, immediately dilute with a neutralizing detergent (such as sodium bicarbonate, calcium hydroxide, etc.) and then rinse with a large amount of running water. • Never place any metal objects (such as tools, etc.) on or across battery terminals. This may ignite and explode hydrogen gas emitted from the battery or cause damage to the battery and personal injury. • Static electricity may explode the battery. Do not attempt to wipe or clean the upper surface or terminals of the battery with a dry cloth or do not place a vinyl cover over the battery. Always wipe clean the battery case with a wet cloth. (1) INSPECTION OF ELECTROLYTE LEVEL CAUTION: Fill with distilled water when battery electrolyte level drops. NOTE: When battery electrolyte level drops, “BAT FLUID LEVEL DOWN” and “Wrench mark ( )” are displayed on LCD. 1. For inspection of battery electrolyte level, observe float condition from horizontal direction while keeping transparent case closed. If float tip is in between - in left figure, it is OK. CAUTION: Be careful because battery specifications may vary with each maker. BCM0017 BCT0010

Nissan Forklift Electric 1B1, 1B2 Series Service Repair Manual INSTANT

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