Nippon FB10P Manual de instrucciones

INTRODUCTION

4Most 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.

4It 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.

[Control System Transition]

Model IGBT Control FET Control CAN-BUS Control

FB10P~18P ~221AE1250 221AE1251~ 221AE3656~

FB20P~28P ~241AC4968 241AC4969~ 241AC6266~

FB30P ~251AC0880 - 251AC0881~

4Please note that the contents of the explanation in this manual are

different according to each control system.

Please refer to the applicable explanations.

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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 FB-75 series.

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, must be followed.

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.

NIPPON YUSOKI CO., LTD.

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

could result in death or serious injury.

You must follow this instruction.

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

could result in death or serious injury.

You must follow this instruction.

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

may result in minor or moderate injury.

You must follow this instruction.

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

operator and maintain of truck.

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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

Data of LOCTITE and THREEBOND products.......

1. GENERAL 16

1-1.Appearance................................................ 16

1-2.Specifications............................................. 17

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......................... 34

2-3-1. Gears - Inspection and replacement 34

2-3-2. Wheel hub and hub bolt - Inspection 34

2-4.Troubleshooting ......................................... 35

2-4-1. Front axle - troubleshooting 35

3. REAR AXLE (STEERING) 36

3-1.Location and name .................................... 36

3-2.Disassembly and reassembly.................... 37

3-2-1.

Rear axle - removal and installation 37

3-2-2. Rear axle - disassembly and reassembly 39

3-2-3. Rear axle

- Reassembling method and attention 41

3-3.Inspection and adjustment......................... 44

3-3-1. Bushing - inspection 44

3-3-2. Center arm - inspection 44

3-3-3. Tie rod Comp. - inspection 44

3-3-4. Knuckle - inspection 44

3-3-5. King pin - inspection 45

3-3-6. Hub and hub bolt - inspection 45

3-3-7. Rear axle Comp. - inspection 45

3-4.Troubleshooting ......................................... 46

3-4-1. Rear axle - troubleshooting 46

4. TYRE 47

4-1.Location, name and tyre size..................... 47

4-1-1. Tyre - location and name 47

4-1-2. Tyre size 48

4-2.Inspection and adjustment......................... 49

4-2-1. Hub nut - inspection 49

4-2-2. Rim and rim bolt - inspection 49

4-2-3. Air pressure - inspection 50

4-2-4. Tyre - visual inspection and replacement 50

4-3.Troubleshooting ......................................... 51

4-3-1. Tyre - troubleshooting 51

5. STEERING 52

5-1.Location and name .................................... 52

5-2.Disassembly and reassembly.................... 53

5-2-1. Steering linkage - removal and installation 53

5-2-2. Steering linkage

- disassembly and reassembly 55

5-3.Inspection and adjustment......................... 57

5-3-1. Joint - inspection and replacement 57

5-3-2. Knob - inspection and replacement 57

5-3-3. Steering wheel - inspection and replacement 57

5-3-4. Torque sensor neutral - check and adjustment58

5-3-5. Checking by voltage 60

5-3-6. Actuator ass'y - inspection and adjustment 61

5-4.Troubleshooting ......................................... 62

5-4-1. Steering linkage - troubleshooting 62

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6. BRAKE 63

6-1.Location and name .................................... 63

6-1-1. Foot brake linkage - main part names 63

6-1-2. Parking brake linkage - main part names 64

6-2.Disassembly and reassembly.................... 65

6-2-1.

Wheel brake - removal and installation 65

6-2-2. Wheel brake - disassembly and reassembly 68

6-3.Inspection and adjustment......................... 69

6-3-1. Brake drum

- inspection, repair and replacement 69

6-3-2. Shoe & lining - inspection and replacement 69

6-3-3. Adjustor ass'y - inspection and replacement 70

6-3-4. Wheel cylinder ass'y

- inspection and replacement 70

6-3-5. Master cylinder ass'y

- inspection and replacement 71

6-3-6. Brake pedal - inspection 71

6-3-7. Parking lever - inspection and adjustment 72

6-3-8. Brake linkage - adjustment 72

6-3-9. Brake air bleeding 74

6-4.Troubleshooting ......................................... 76

6-4-1. Brake - troubleshooting 76

7. HYDRAULIC SYSTEM 77

7-1.Oil pipimng circuit....................................... 77

7a. HYDRAULIC PUMP 78

7a-1. Location and name.................................. 78

7a-2. Disassembly and reassembly.................. 79

7a-2-1.

Hydraulic pump - removal and installation 79

7a-3. Inspection and adjustment ...................... 80

7a-3-1.

Hydraulic pump - inspection 80

7a-4. Troubleshooting....................................... 81

7a-4-1.

Hydraulic pump - troubleshooting 81

7b. OIL TANK AND OIL PIPING 82

7b-1. Location and name.................................. 82

7b-1-1.

Plastic oil tank - main part names 82

7b-1-2.

Iron oil tank - main part names 82

7b-2. Disassembly and reasembly ................... 83

7b-2-1.

Oil tank - precautions 83

7b-2-2.

Oil piping replacement - precautions 83

7b-3. Inspection and adjustment ...................... 84

7b-3-1.

Oil - inspection 84

7b-3-2.

Recommended oil and quantity 84

7b-3-3.

Oil tank and filters - cleaning and check 85

7b-4. Troubleshooting....................................... 85

7b-4-1.

Oil tank - troubleshooting 85

7c. CONTROL VALVE 86

7c-1. Location and name.................................. 86

7c-2. Disassembly and reassembly.................. 88

7c-2-1.

Control valve - removal and installation 88

7c-2-2.

Inner kit of control valve - replacement 91

7c-3. Inspection and adjustment....................... 92

7c-3-1.

Relief pressure - measurement 92

7c-3-2.

Microswitch - adjustment 93

7c-4. Troubleshooting....................................... 94

7c-4-1.

Control valve - troubleshooting 94

7d. CYLINDER 95

7d-1. Location and name.................................. 95

7d-1-1.

Lift cylinder - main part names 95

7d-1-2.

Tilt cylinder - main part names 97

7d-2. Disassembly and reassembly.................. 98

7d-2-1.

Lift cylinder - removal

: P - mast (2 - stage simplex) 98

7d-2-2.

Lift cylinder - removal : PFL-mast (2-stage

duplex), M-mast (3-stage triplex) 100

7d-2-3.

Tilt cylinder - removal 103

7d-2-4.

Lift cylinder - installation and adjustment 104

7d-2-5.

Tilt cylinder - installation 105

7d-2-6.

Lift cylinder - disassembly and reassembly 106

7d-2-7.

Tilt cylinder - disassembly and reassembly 116

7d-3. Inspection and adjustment .....................117

7d-3-1.

Cylinder comp. - inspection 117

7d-3-2.

Piston rod - inspection 117

7d-3-3.

Drift for lift and tilt - inspection 118

7d-4. Variation of the tilt cylinder .....................119

7d-4-1.

Tilt angle by masts 119

7d-5. Troubleshooting..................................... 120

7d-5-1.

Cylinder - troubleshooting 120

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8. MAST 121

8-1.Location and name .................................. 121

8-2.Disassembly and reassembly.................. 123

8-2-1. Lift bracket - removal 123

8-2-2. Mast ass'y - removal 123

8-2-3. Mast - disassembly and reassembly 125

8-3.Inspection and adjustment....................... 128

8-3-1.

Mast, lift bracket and roller shaft - inspection

128

8-3-2. Back shoe - inspection 129

8-3-3.

Lift chain - inspection and replacement 129

8-3-4. Chain bolt - inspection 130

8-3-5. Chain wheel - inspection 130

8-3-6. Hose pulley - inspection 131

8-3-7. Roller - inspection and replacement 131

8-3-8. Fork - inspection and replacement 132

8-3-9. Lift chain - inspection and adjustment 133

8-3-10.

Mast lean- adjustment 134

8-4.Troubleshooting ....................................... 135

8-4-1. Mast · Lift bracket · Fork - troubleshooting 135

9. MOTOR 136

9-1.Location and name .................................. 136

9-1-1. Traction motor - main part names 136

9-1-2. Hydraulic motor - main part names 137

9-1-3. EPS motor - main part names 137

9-1-4. Motors - specifications 138

9-2.Disassembly and reassembly.................. 139

9-2-1. Traction motor - removal and installation 139

9-2-2. Hydraulic motor - removal and installation 140

9-2-3. EPS motor - removal and installation 142

9-2-4. Traction motor -

disassembly and reassembly

143

9-2-5. Hydraulic motor -

disassembly and reassembly

144

9-2-6. EPS motor - disassembly and reassembly 144

9-3.Inspection and adjustment....................... 145

9-3-1. Rotor comp. - inspection and replacement

(Traction and Hydraulic motor) 145

9-3-2. Armature comp.

- inspection and replacement 146

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

- inspection and replacement 146

9-3-4.

Motor ASS'Y (Traction/Hydraulic motor)

- inspection 148

9-3-5.

Motor ASS'Y (EPS motor) - inspection 149

9-3-6.

Oil seal and permanent magnet (EPS motor)

- inspection and replacement 150

9-4.Troubleshooting ....................................... 150

9-4-1. Motor - troubleshooting 150

10. ELECTRIC PARTS 151

10-1. Location and name................................ 151

10a. CONTROL UNIT 152

10a-1. Location and name.............................. 152

10a-2. Disassembly and reassembly.............. 154

10a-2-1.

Control unit - removal and installation 154

10a-2-2.

Control unit - disassembly and reassembly 156

10a-3. Check and replacement ...................... 160

10a-3-1.

IGBT module - inspection and replacement 160

10a-3-2.

FET module comp.

- inspection and replacement 162

10a-3-3.

Capacitor - inspection and replacement 163

10a-3-4.

EPS controller - specifications 164

10b.

DISPLAY PANEL AND DIRECTIONAL SWITCH

165

10b-1. Display panel

- Disassembly and reassembly........... 165

10b-1-1.

Display panel - disassembly and reassembly165

10b-2. Directional switch

- Disassembly and reassembly........... 167

10b-2-1.

Display panel - disassembly and name 167

10b-2-2.

Wiring of directional switch 168

10c. ACCELERATOR 169

10c-1. Disassembly and reassembly.............. 169

10c-1-1.

Accelerator linkage - removal and installation169

10c-2. Inspection and adjustment................... 170

10c-2-1.

Potentiometer - adjustment 170

10c-2-2.

Accelerator linkage - adjustment 171

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10d. MAIN CONTACTOR AND FUSE 172

10d-1. Disassembly and reassembly.............. 172

10d-1-1.

Control unit - removal and installation 172

10d-2. Inspection and replacement................ 174

10d-2-1.

Main contactor

- inspection and replacement 174

10d-2-2.

Fuse - replacement 174

10e. BUILT-IN CHARGER (OPTION) 175

10e-1. Disassembly and reassembly.............. 175

10e-1-1.

Charger ass'y

- disassembly and reassembly 175

10e-1-2.

Transformer - disassembly and reassembly 177

10e-1-3.

Built-in charger - specification 178

10e-2. Inspection and replacement................ 180

10e-2-1.

Magnetic contactor - inspection 180

10e-2-2.

Plug comp. and receptacle

- inspection and replacement 180

10e-2-3.

Fuse and fuse base - inspection 180

10e-2-4.

Transformer - inspection 181

10e-2-5.

Diode - inspection 181

10e-3. Inspection After Assembly................... 182

10e-3-1.

Timer - inspection 182

10e-3-2.

Earth - inspection 183

10e-3-3.

Reserve function - inspection 183

10e-4. Charging procedure............................. 184

10e-4-1.

Automatic charge (Daily charge) 184

10e-4-2.

Reserve charge 188

10e-4-3.

Balancing charge 197

10e-5. Voltage tap .......................................... 199

10e-5-1.

Power supply voltage - check 199

10e-5-2.

Voltage tap - selection 199

10e-5-3.

Voltage tap - changing 200

10e-5-4.

Fuse (three-phase voltage) - replacement 200

10f. BATTERY 201

10f-1. Disassembly and reassembly............... 201

10f-1-1.

Battery - removal and installation 201

10f-2. Inspection and adjustment ................... 202

10f-2-1.

Battery - inspection 202

10f-2-2.

Battery - Cleaning 203

10g. MPU BOARD 204

10g-1. Location and name.............................. 204

10g-1-1.

MPU board 204

10g-1-2.

Display board 205

10g-1-3.

EPS controller board (EPS / DSP board) 205

11. LASER POINTER (OPTION) 206

11-1. Adjustment............................................. 206

11-1-1.

Fork level - adjustment 206

11-1-2.

Laser optical axis - adjustment 206

12. SERVICE DATA 207

12-1. Annual Inspection Service Data ............ 207

12-2. Standard work hours............................. 208

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CAUTION

WELL-VENTILATED AREA

lWork 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

lEquipment such as first-aid boxes and fire

extinguishers should be nearby when work is

performed.

CAUTION

PROPER ARRANGEMENT

lArrange and clean always at a working place to

work safety.

lEspecially, arrange disassembled parts well.

CAUTION

ADEQUATE SPACE WITH FLAT SURFACE:

lThe 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

SAFE AND WELL-LIGHTED AREA

lThe 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.

SAFETY WORK

Precautions for safe inspection and

maintenance work

Maintenance shops

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Work clothing

Tools and gauges

CAUTION

lThe worker should wear a safety 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.

WARNING

When working under a forklift truck, use a pit or

proper safety precautions.

WARNING

Apply wheel chocks to tyres to prevent the truck

from moving.

WARNING

After lifting or jacking up a forklift truck, support it

with safety blocks or rigid stands.

WARNING

lWhen hoisting a forklift truck or a heavy

component, use ropes or cable with correct

capacity.

lDo not use ropes or cables which are kinked.

CAUTION

lAlways 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

lDo not lift the forklift truck by using other

forklift. The bottom of the truck may be

damaged by hitting the forks.

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Parts

Repair of electrical components

CAUTION

lDiluted 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.

NOTE

Record the places of lead wire connection when

disassembling.

CAUTION

Be sure to jack up the drive wheel when trouble

shooting electrical operations.

CAUTION

CHARGING BATTERY

lBatteries 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

When replenishing battery electrolyte, be sure to

use refined water.

CAUTION

When replacing any parts, be sure to use NICHIYU

genuine parts.

CAUTION

Be sure to disconnect the battery plug when

replacing electrical component.

Do not pull the electric cable when disconnecting

the battery plug.

Hold the battery plug and disconnect it.

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