Nichiyu Forklift 80 Series FBT9P-80 To FBT20PBN-80 Workshop Manual SM12-002-R6 2021

Description

Contents:
Safety Work
1. Precautions For Safe Inspection
Maintenance.
2. Safety Labels.
3. Model Name And Serial Numbers
4. Maintenance Cautions
5. Tightening Torque For Bolts.
6. Maintenance Tools And Inspection Devices
6-1. Maintenance Tools
6-2. Inspection Devices
7. Marks And Symbols.
1. General
1-1. Appearance.
1-2. Specifications
2. Front Axle (Drive)
2-1. Names Of Parts
2-2. Disassembly And Reassembly
2-2-1. Front Tire – Removal And Installation
2-2-2. Front Axle – Removal.
2-2-3. Front Axle – Installation.
2-2-4. Front Axle – Disassembly
2-2-5. Front Axle – Reassembly
2-3. Inspection And Adjustment
2-3-1. Gears – Inspection
2-3-2. Bearings – Inspection
2-3-3. Packing – Inspection And Replacement.
2-3-4. Overall – Inspection
2-3-5. Brake Plates – Inspection And Replacement
2-4. Troubleshooting.
2-4-1. Front Axle – Troubleshooting.
3. Rear Axle (Steering)
3-1. Names Of Parts
3-2. Disassembly And Reassembly
3-2-1. Rear Tire – Removal And Installation
3-2-2. Rear Axle – Removal
3-2-3. Rear Axle – Installation
3-2-4. Rear Axle – Disassembly
3-2-5. Rear Axle – Reassembly
3-3. Inspection And Adjustment
3-3-1. Steering Angle Potentiometer – Adjustment
3-3-2. Eps Torque Sensor – Adjustment
3-3-3. Minimum Turning Radius – Measurement
3-4. Troubleshooting.
3-4-1. Rear Axle – Troubleshooting
4. Tire
4-1. Front Tire
4-1-1. Names Of Parts
4-1-2. Front Tire – Specifications
4-1-3. Front Tire – Removal And Installation
4-2. Rear Tire
4-2-1. Names Of Parts
4-2-2. Rear Tire – Specifications
4-2-3. Rear Tire – Removal And Installation
4-3. Inspection And Adjustment
4-3-1. Hub Nut – Inspection.
4-3-2. Air Pressure – Inspection
4-3-3. Tire – Visual Inspection And Replacement
4-4. Troubleshooting.
4-4-1. Tire – Troubleshooting.
5. Steering Linkage
5-1. Names Of Parts
5-2. Disassembly And Reassembly
5-2-1. Steering Linkage – Removal
5-2-2. Steering Linkage – Installation
5-3. Inspection And Adjustment
5-3-1. Joint – Inspection And Replacement
5-3-2. Steering Wheel – Inspection And Replacement.
5-3-3. Roller Chain Comp. – Adjustment
6. Brake
6-1. Names Of Parts
6-1-1. Foot Brake Linkage – Names Of Parts
6-1-2. Parking Brake Linkage – Names Of Parts
6-2. Disassembly And Reassembly
6-2-1. Foot Brake Linkage – Disassembly
6-2-2. Foot Brake Linkage – Reassembly
6-2-3. Master Cylinder – Disassembly And Reassembly.
6-2-4. Wheel Brake – Disassembly And Reassembly
6-2-5. Parking Brake Linkage – Removal And Installation
6-3. Inspection And Adjustment
6-3-1. Wheel Brake – Inspection And Adjustment
6-3-2. Master Cylinder Ass’y – Inspection And Replacement
6-3-3. Brake Circuit – Air Bleeding
6-3-4. Brake Pedal – Inspection
6-3-5. Brake Pedal And Bracket – Adjustment Of Clearance.
6-3-6. Brake Pedal Height – Adjustment
6-3-7. Foot Brake Microswitch – Adjustment.
6-3-8. Parking Brake Lever – Inspection And Adjustment
6-4. Troubleshooting.
6-4-1. Wheel Brake – Troubleshooting.
6-4-2. Parking Brake – Troubleshooting.
7. Hydraulic System
7-1. Hydraulic Circuit.
7-1-1. Hydraulic Operating Circuit
7-2. Hydraulic Piping
7-2-1. Hydraulic Line
7-2-2. Hydraulic Piping – Precautions For Removing
7-2-3. Hydraulic Piping – Precautions For Installing
7a. Hydraulic Pump
7a-1. Names Of Parts
7a-2. Disassembly And Reassembly
7a-2-1. Hydraulic Pump – Removal And Installation
7a-3. Inspection And Adjustment
7a-3-1. Hydraulic Pump – Inspection
7a-4. Troubleshooting
7a-4-1. Hydraulic Pump – Troubleshooting
7b. Oil Tank
7b-1. Disassembly And Reassembly
7b-1-1. Oil Tank – Removal And Installation
7b-1-2. Oil Tank – Disassembly And Reassembly
7b-2. Inspection And Adjustment
7b-2-1. Oil – Inspection
7b-2-2. Recommended Oil And Oil Quantity
7b-2-3. Hydraulic Oil – Draining
7b-2-4. Oil Tank And Filters – Cleaning And Check
7b-3. Troubleshooting
7b-3-1. Oil Tank – Troubleshooting.
7c. Control Valve
7c-1. Control Valve Linkage.
7c-2. Disassembly And Reassembly
7c-2-1. Control Valve – Removal And Installation.
7c-2-2. Control Valve Relief Pressure – Identification
7c-3. Inspection And Adjustment
7c-3-1. Relief Pressure – Measuring And Adjustment
7c-3-2. Microswitch – Adjustment
7c-3-3. Manually Lowering Lift In Emergencies
7c-4. Troubleshooting
7c-4-1. Control Valve – Troubleshooting
7d. Cylinder
7d-1. Disassembly And Reassembly
7d-1-1. Lift Cylinder (P/M/Pfl-Mast) – Prepara
For Removing
7d-1-2. Lift Cylinder (P-Mast) – Removal.
7d-1-3. Lift Cylinder (M/Pfl-Mast) – Removal
7d-1-4. Tilt Cylinder – Removal
7d-1-5. Lift Cylinder – Installation
7d-1-6. Tilt Cylinder – Installation
7d-1-7. Lift Cylinder – Disassembly.
7d-1-8. Lift Cylinder – Reassembly
7d-1-9. Tilt Cylinder – Disassembly And Reassembly
7d-2. Inspection And Adjustment
7d-2-1. Cylinder Comp. – Inspection
7d-2-2. Piston Rod – Inspection
7d-2-3. Diagnosing Oil Leaks
7d-2-4. Vertical And Tilt Drift – Inspection
7d-3. Troubleshooting
7d-3-1. Cylinder – Troubleshooting.
8. Mast
8-1. Names Of Parts.
8-2. Disassembly And Reassembly
8-2-1. P-Mast – Removal
8-2-2. M/Pfl-Mast – Removal
8-2-3. Mast – Installation
8-2-4. Mast – Disassembly And Reassembly.
8-3. Inspection And Adjustment
8-3-1. Mast – Inspection.
8-3-2. Lift Bracket – Inspection.
8-3-3. Back Shoe – Inspection
8-3-4. Chain Wheel – Inspection.
8-3-5. Lift Chain – Inspection And Replacement
8-3-6. Fork – Inspection
8-3-7. Roller – Inspection And Adjustment
8-3-8. Clearance Between Back Shoe And Inner Mast – Inspection And Adjustment.
8-3-9. Lift Chain Tension – Inspection And Adjustment
8-3-10. Mast Leaning – Adjustment.
8-4. Troubleshooting
8-4-1. Mast · Lift Bracket · Fork – Troubleshooting.
9. Motor
9-1. Names Of Parts.
9-1-1. Traction Motor – Names Of Parts
9-1-2. Hydraulic Motor – Names Of Parts
9-1-3. Eps Motor – Names Of Parts
9-2. Disassembly And Reassembly
9-2-1. Traction Motor – Removal And Installation
9-2-2. Hydraulic Motor – Removal And Installation
9-2-3. Eps Motor – Removal And Installation
9-2-4. Traction Motor – Disassembly And Reassembly.
9-2-5. Hydraulic Motor – Disassembly And Reassembly
9-2-6. Eps Motor – Disassembly And Reassembly.
9-3. Inspection And Adjustment
9-3-1. Rotor Sub Ass’y (Traction And Hydraulic Motor) – Inspection And Replacement
9-3-2. Sensor Bearing Comp. (Traction Motor) – Inspection And Replacement
9-3-3. Stator Comp. (Traction And Hydraulic Motor) – Inspection And Replacement
9-3-4. Motor Ass’y (Traction And Hydraulic Motor) – Inspection
9-3-5. Armature Comp. (Eps Motor) – Inspection And Replacement
9-3-6. Brush, Brush Holder And Spring (Eps Motor) – Inspection And Replacement
9-4. Troubleshooting
9-4-1. Motor – Troubleshooting.
10. Electric Parts
10-1. Location And Name Of Parts
10a. Control Unit
10a-1. Names Of Parts
10a-2. Disassembly And Reassembly
10a-2-1. Control Unit · Capacitor – Discharge
10a-2-2. Control Unit – Removal And Installation
10a-2-3. Eps Controller – Removal And Installation
10a-2-4. Control Unit – Disassembly And Reassembly
10a-3. Inspection · Replacement · Specifications
10a-3-1. Main Contactor – Inspection And Replacement
10a-3-2-1.Fet Module – Inspection And Replacement (Mitsubishi).
10a-3-2-2.Fet Module – Inspection And Replacement (Shindengen).
10a-3-3. Capacitor – Inspection And Replacement
10a-3-4. Fan – Specifications.
10a-3-5. Eps Controller – Specifications
10a-3-6. Fuse
10b. Display Panel And Directional Switch
10b-1. Disassembly And Reassembly
10b-1-1. Display Panel – Removal And Installation
10b-1-2. Directional Switch – Removal And Installation.
10b-1-3. Directional Switch – Specifications
10c. Accelerator
10c-1. Disassembly And Reassembly
10c-1-1. Accelerator Linkage – Removal
10c-1-2. Accelerator Linkage – Installation
10c-1-3. Accelerator Potentiometer – Adjustment
10d. Charger (Built – In)
10d-1. Disassembly And Reassembly
10d-1-1. Charger Ass’y – Disassembly And Reassembly
10d-1-2. Transformer – Disassembly And Reassembly.
10d-1-3. Transformer – Specifications
10d-2. Inspection And Replacement
10d-2-1. Magnetic Contactor – Inspection
10d-2-2. Plug Comp. And Receptacle – Inspection And Replacement
10d-2-3. Transformer – Inspection.
10d-2-4. Diode – Inspection
10d-3. Inspection After Assembling
10d-3-1. Timer – Inspection
10d-3-2. Reserve Function – Inspection
10d-4. Charging Procedure
10d-4-1. Normal (Daily Charge).
10d-4-2. Reserve Charge (Charging At A Pre-Set Time)
10d-4-3. Equalizing Charge
10d-4-4. Supplementary Charging.
10d-4-5. Charging Ahead Of Long-Time Storage
10d-4-6. Check The Specific Gravity
10d-5. Voltage Tap
10d-5-1. Power Supply Voltage – Check
10d-5-2. Voltage Tap – Selection
10d-5-3. Voltage Tap – Change.
10e. Battery
10e-1. Disassembly And Assembly
10e-1-1. Battery – Removal And Installation
10e-2. Inspection And Adjustment
10e-2-1. Battery – Inspection And Adjustment
10e-2-2. Battery Cell – Inspection.
10e-2-3. Battery – Cleaning
10f. Control Board
10f-1. Name
10f-1-1. Trv/Hyd Board (Printed Board)
10f-1-2. Eps Controller.
11. Service Data
11-1. Annual Inspection Service Data
11-2. Standard Work Hours