Ear) SERVICE MANUAL UR SSS) at MY ee WORKSHOP SERVICE DATA NICHIYU USA0. GENERAL 0-1 MODEL NAME AND NAME PLATE. - seston 3 1, MODEL CODING SYSTEM ~~ 2, NAME PLATE «ssssstsi snntnniinnnieiennnnenenienniiee 0-2 POSITION OF SERIAL NUMBER ON FRAME AND COMPONEMTS: nsmarninnitinannrinnnnennerennanicn 0-3 SPECIFICATIONS 1. SPECIFICATIONS FOR STANDARD TRUCKS « 2. SPECIFICATIONS FOR HIGH SPEED TRUCKS 0-4 STABILITY OF FORKLIFT TRUCK - 7 1. Load center and load chart s-vwssnneninnaiennnneyinnineniennnnnnnnenneeen J 0-5 BEFORE STARTING TO WORK ----0. GENERAL (0-1 MODEL NAME AND NAME PLATE 1, MODEL CODING SYSTEM Fa OO0eIO COOO0 Be 4s 739 1. Normal capacty i indicate at hundred KG, 2. Classification of tyre : Pneumatic yre type truck PC: Cushion tyre type truck PN: Sold tyre type tuck 8. Electric control system and et. U: High speed series 4. NICHIVU model chenge number 5. B: Large battery (©: Without batery D : Eleetical enclosure 6. Lifting height at contimeters 7. Mast type NO CODE : Two stage full visiitty mast IM: Three stage full vsibiity mast with ful free fit FL; Full foo ft mast (ull visibity) 28, Attacament ‘SF: Sige shiter RRC : Rotating rol camp ‘SO: Side camp ‘and so forth [9.68 Cold storage use for ~35°C FCS : Cold storage use for —50°C AP: Rust resistant2. NAME PLATE Fig. 0-1 Position of name plate 0-2 POSITION OF SERIAL NUMBER ON FRAME AND COMPONEMTS © Chasis serial No. (On name plate) @ Mast name plate @ Chasis serial No, (For cance plate) B Drive assy No. @ Un cylinder serial No, Fig. 0-2 Position of serial numbers) 0-3 SPECIFICATIONS {SPECIFICATIONS FOR STANDARD TRUCKS i : = SST Te port — __ Se , ie ee a (ore = SRS —— a —2. SPECIFICATIONS FOR HIGH SPEED TRUCKS er 8. MOTORS (DRIVE-HYDRAULIC-POWER:STEERING) 8-1 REMOVING ACAUTION ‘Disconnect the battery plug betore starting to work. ‘Before removing the drive motor, place the ‘wedged blocks to prevent the truck from moving. + Drive motor (1) Disconnect the lead wires from the drive moter terminal, GEE NOTE » When removing the fiting bots of the terminals, fix the terminals witha tool ang loosen the fiting bots. @Note the connection ofthe lead wires. (2) Remove the mast with the drive motor and the front av at fst, and then remove the dive ‘motor only Gam NOTE Refer to tom 1-1, 1 Removing front axle. 2. Hydraulle motor (1) Remove the side cover tL). {@) Disconnect the lead wires to the motor. {@) Disconnect the hoses to the hydraulic pump. (Takeoff he fing bots the motor Assy and” romove t (6) Remove the hydraulic pump. ‘3, Powar steering motor (1) Remove the floor plate. ma NOTE Disconnect connector of the accelerator (2) Disconnect the lead wires of the power steering motor. (@) Remove the fing bolts and the power ‘steering motor. » Fg. 0 Removig power steering moor = 109 —8-2 CONSTRUCTION AND. CONSTRUCTIVE PARTS. 1. Drive motor ® ® Fig. 8-4 Construction of drive motor 2. Hydraulle motor @ @ ® PHOD gOR It Fig. 85 Construction of hydraulle motor = 110 yore @ End cover (0) End eover () @Brush holder sub Ass'y © spring ®pnsh Field cot comp. @ Fd core comp. @ Armature comp. Fan @Commutator cover ermal comp. Cover (0) Sud bot ®Rubbor cap Oi soa Yoke End cover (0) @ End cover (C) @Brush holder sub Assy @Sprng @Brush @ Fake coil comp, @ Fela core comp. @ Armature comp, Fan ® Terminal comp, {Cover (0) Bearing8-3 DISASSEMBLING PROCEDURES AND CAUTIONS 1. Drive and hydraulle motor (1) Remove the cover. {2} Disconnect the lad wires of the brushes to the ‘brush holder. {8} Remove the brushes and the diode (a case of hydraulic motor). (4) Flemove the end cover (0) CAUTION. ‘Mark (38) on the end cover (C) and the yoke, ‘and the end cover (D) and the yoke to help reassembling. (6) Remove the brush holder sub Ass. CAUTION. Do not disassembling the brush holder Assy. {6} Remove the end cover (0) {7} Remove tho armture comp. {8) Disconnect connection tothe feld cols, ACAUTION ‘Note wiring. Do not damage the lead bars. (8) Remove the field coi, ® Screw, end cover (0), stud bot, bearing © Armature comp. @ Bok, spring washer ‘@a Field core comp, Feld col comp. ‘@b Inter core comp, inter coil comp. Fig. 6-6 Disassembling procedure of drive motor aina Brush (STD, FB10P-U) ® Bor, spring washor, end cover (0). bearing Db Brush (FB16-25P-U) armature com. (Bolt, spring washer, end cover (C) @ Bolt, spring washer Bot, spring washer, washer {® Field core comp, field col come. ® Bearing Fig. 8-7 Disassombiing procedure of hydraulic motor 2. Power steering motor (1) EPS motor Ass'y should be replaced when the ‘motor would be no good. ‘Only brushes and brush holders canbe replaced for maintenance. Poo RepscraePsnowney @ - 48-4 INSPECTION D 1-armature comp. (1) Check the commutator suface for damage, (Repairing) ‘DMachine turn the commutator. ACAUTION. machining. Be sure to center the commutator when @BCarry out under-cuting @Finish wth a sand paper [#400] after ‘carrying out undercutting, and clean by eS Fig. 88 Checking commutator ‘compressed ai » F810P or-7.86-1300 | 108 | 99 | DTL7.7e-1580A5 | 90 | 85 FauansP t t 1 t t t f2/?| reeoesp | or-esp-1350 | t 1 t 1 1 Eee [eran [aw [oe focaeemma oo 3] Feerses | oro seso 1 1 |prvse-ss00as | 90 | a5 3] retee-u t 1 + [pri-t08-200008 | t t | rezozse-u | orsops6s0 | t t t t t » depth of under-cuting Drive and hydraolic motors | 0.15-10. mm cut () Fig. 810 Repairing kit and under-cuting depth a(2) Measuring insulation Q.CAUTION Clean by compressed ale when measuring. (Measurement with V-ohm meter) Set the knob of V-ohm meter at K 2 range. Touch @ prod [x] on a prod (-] and adjust 0 Qlevel DFA the prod [1] to the commutator and the FRasistanca: Infinite at x 1K @ range, (Measurement with megger) Fit a line side [+] to the commutator and a eth side -]1o the armature shaft Dive and ycraulc | Moremanosm a motors (DCs00v) Power soerng nour | Moroman gs 2 (6) Armature shatt Check the spline or serraton of the armature shaft and the coupling for wear and transfor- mation Ifextremely worn or transformed, replace it 2. Carbon brush, brush holder and spring {1) Measure carbon brush wear If woaring lit line is marked on the brush, ‘wearing liitis up to ths line. 1 not marked, moasure the height of the brush and compare wit the following cimen- sions for wearing lit (2) Measure clearance between the carton brush and the brush holder. Fig. 8-11 Measuring insulation t4 Spectations num ea Sees] BS Ciearance | Wath 03-058 Carbon brush @Brsh holder Bughans ere Or ee oo | Sz nen wearing Ht ard Cones o Length foush 2pes) | 1.1.8 carbon brush aWearing limit of brush Units men I Deve motor I Hydrause motor gg By Mose! omal_ | Wesmg emal_ | Wesing Typ | eines | time Type | eersion| ist rete | orreetao0 | 92 | 22 |omrverseoas | 2 | 17 p| FBinse t 1 fot t 1 ft pS) rater t t 1 [ore77e-1se0as | t t 4 ao FazozsP | or-sab-1350 | t t t 1 B_[reor ormomse | + [1 [onsssezms) 7 | FeoPsspu|orssteso | 1 | t |oreeeteoas | t | t 3) Ferepu t ee EZ rezozs-u | orosseso | 1 | t 1 + [ft Fae Py Carron brash @Commutator Fig. 8-13 Checking surfaces of carbon brush (8) Check the contacting surfaces of carton brushes. itis baa, repair or replace (Repairing) : Cinsert a sand paper [#400] between the ‘commutator and the carbon brush. . (File surface toward the carbon brush) ®Ropair the contacting surtace by rotating the commutator. @ Clean by compressed al after repairing. (4) Measure the spring force pushing the carbon brush, (Measurement) Hook a spring scale tothe spring, pull towards ‘arrow mark, and confirm equal spring force on {our springs. CAUTION ‘ein case of the power steering motor, measure on two springs. ‘elf the spring and the brush holder has rusted, replace them. Fig. 8415 Measuring spring force = us—Wearing tint of brush Unt: mm Dive motor Hycraule motor 58) soso! r Type Spring force Tye Spring force Fair orrats00 | 0612 | omuz7eiseoas | 075-15 ‘FBI4I5P t t t t i FB18P t t DTL-7,78-1580AS t }5)?| Fesoase | or.anaso 1 1 1 | Faooe DT-128F-1380 1 DTL-19.58-200088 1 Fe10P-15P-u | 07-98-1650 1 OT1-96-1900A8 t FovePu 1 t OTL-108-200088 | 06.2 2) e205. | o7-108-1650 o7-45 + t 2. Fle cot (1) Measure iasiaton resistance. oO A.CAUTION When measuring Insulation, do not touch terminals, (Measurement) Rofer to Measuring insulation’ of the armature ) ‘comp. (Fig. 8-11} * Fig. 6-16 Measuring insulation . ‘Siloon adhesive 8-5 ASSEMBLING PROCEDURES 1.Mounting fleld coll and measuring Insu- - lation (1) Fitthefeld coll and the main pole core. ‘a)After cleaning up the core, apply the slicon ‘adhesive on the both sides ofthe core, (Fig. A) Gag NOTE ‘ADHESIVE : TOSHIBA SILICON TSE-982 ‘SHINETU SILICON KE-45 Fig. A )Set the center of the coll on the center of the Slicon achesive ‘1 Apply the sifcon adhesive on the both side betwaen the core and coll Ga NOTE Do not apply the silcon adhesive over the ‘0)Wait unt the sicon adhesive sets G@NOTE SETTING TIME: 24 hours Fig. 8-17 Fiting field coil — 16 —(2) Measure insulation, Db inote Insulation resistance: Mote than 0.5M {OC500V megger) (Measurement Fta [to the feta cot (8) Connect the terminal of th side [-] tothe yoke and a tne side the feld col with the lead wire, and make sure of clearance be- {wean the terminal bolt and the yoke. ‘Standard clearance More than 8.2mm 2. Mounting brush holder Da. ngnening termina! bor Whar comectng the ead wees to the motor termina igen ermine bas th star torque. When replacing only brush older, carry out ‘centering correctly on mounting, Tightening to 9411 Nimo: 4.4 kn} 4. Inspection of motor Ass'y (1) Check the motor for abnormal noise and the . D carbon brush for commutation (Wiring for motors) (Drive motor ‘© Connect the terminal (A) withthe battery [+] ‘© Connect he terminal (F) with the battery [-] © Con manai (FF) @Hydrausic mator the terminal (AA) with the tare ‘© Connect the terminal (A) withthe battery [+ Connect the terminal (FF) wit the battery [—) (Ga NOTE ‘The code is ited in {for miswiring. @Power stosring motor the motor. Be careful ‘© Connect the battery [4] with one of the motor lead wire. ‘© Connect the other motor lead wire wih the battory 1, ante Fig. 8-18 Measuring insulation AN ‘ opera @ Rocker Fig. 8-19 Mounting brush holderTesting! (Be sure to secure to workbench. Apply 112 voltage of the battery to carry out testing. Gea NOTE Reconfirm wring (polarity) on tensting hy- ‘raulic metor. ®Confirm that no abnormal noise is heard ‘and no arcing Is seen on the contacting surfaces ofthe carbon brushes. (2) Measure insulation of motor Assy, Ciinsviaton resistance Drive and hydraulic motors (Measurement) A.CAUTION ‘When measuring Insulation resistance, do ‘not touch terminal of lead wires. Ft a earth side [-] of a mogger to the ‘assembing batt and a line side [+] to the toad wre, A.CAUTION - Be sure to remove the diode Inthe hydraullo motor. ‘Or short ciroult anode (A) and cathode (K). Fig. 8-20 Measuring insuiaton of mator Ass'y8-6 TROUBLE SHOOTING ‘Symptom “Aanormaty and cause ‘Countermeasure 1. Abnormal noises | (1) Bad motor bearing Replace heard (@) Armature shat isnot centered Repair or repace (9) Loose motorfan Replace (4) Loose ttng bot of main pole core Retigtten 2.Acing (1) Ba commutation of carbon bush Repair or replace (2) Rough surtace of commutator Repair or replace 3. Heating (1) ncorect current lm oF plugging eurront 0 rare short of armature comp. Adjust or rplace (2) Bad rotating Replace 4. Abnormal nose | (1) Wear ofthe spline ofthe armature shat and temperature nce ater |" te coping Replace mounting on rack (2) Bac adjustment or wear of the crive oar, or bad bearing Repace {3) Incorrect current limit Adjust (6 Harsh operation Cautions on operation = 19—9, ELECTRIC SYSTEM 9-1 CONTROL UNIT 1. Main constructive parts 2. Removing ~~ 3 Rover pment cars 4. Inspection =r 5 Assembling procedures andenutons 6. Mounting se os 11 121 9-2 ACCELERATOR LINKAGE - 1. Constructive parts 7 2. Feature and construction of accelerator sensor ~ 8, Adjusting procedure 9-3 INDICATOR PANEL. 1. Constructive parts and dsplay of LED 2. Disassembling procedure 8. Assembiing and cautions sar 9-4 DIRECTIONAL SWITCH ~ 1. Removing ss 2 Deasvenbing procedure and snsucive pars 9-5 FUSE eect seen ee 15 1 Ronowg actos onepacoer senna oe 2. Capacity of fuse. ~ 9-6 BATTERY AND BATTERY PLUG - + napecton of betery 2. Cleaning == 5. Iepection of batoy plug 4, Trouble shooting 9-7 CHARGER (BUILT IN TYPE) - 186 1. Removing = + 158 2. pection en 189 8. Aasombing procedures ard Ko port 4. Inspection after assembling 5. Salting timer and charging procedures ~ 6. Selecing th erin of caring source otage 7. Trouble shooting = 120 =9. ELECTRIC SYSTEM 9-1 CONTROL UNIT 1. Main constructive parts (1) Modet : CU22-22 Applicable model: FBIOP (With regeneratve circu) FET comp. (Travel, 14 paratel) @ Battery sensor (840-06) (FET comp. (Hyarausc, 14 paral) +S MPU board comp. @ Current sensor Ass'y (CS10-72) ‘(Printed board (PB83-62) @Diode (4520) ‘© Contactor (For forward/backward, MSW34-23) @ Capacior (160V, 100014F, 4pcs) {© Contactor (For bypass, MS34-20) @ Resistor (15W, 680.2) {1 Contactor (For regeneration, MS34-20) Resistor (15W, 33.0) Contactor (For hydraulic, MS24-20) (@ Resistor (GOW. 222) Fig. 9-1 Constructive pars of control Ass'y, FBIOP (With regeneratve circuit) saa(2) Modal: 6u22.28, ‘aplcable mode: FB14-10P e (th regenerate cect) "y Se (FET comp, Travel 20 pra) © Bator sensor (64005) BrET comp. frau Sa paras) Bae Boat @ Current sensor Ass'y (CS19-72) (@)Printed board (PB83-62) @ Diode (45M20) Contactor (For forward/backward, MSW34-23) ®Capacitor (160V, 1000, 4pes) ‘Contactor (For bypass, MS34-20) Seon (sw 808) te Comacer or ohana, S420 e Dred ew, S68) (8 Contcer for rau eae20 ® Resistor (OW, 222) Fig. 8-2 Constructive parts of control Assy, FB14-18P (With rogeneraive circu) 12 =(@) Model: cu22-24 DN peplcable mode: FBRO/2SP (with regenerate crout) DFET comp. (Travel. 20 para) @ Batory sonsor (8740-06) @FET comp. (Hycraule, 20 paraleh {® MPU Board comp. ‘DGurent sensor Ass'y (C810-72) ‘© Printed board (883-62) @Diove (45620) _ SB Contactor (For forward/backward, MSW44-2) © Capacior (160, 10001, apes) ‘9 Contactor (For bypass, MS44-20) D ®rst (5w, 630.0) ‘ Gontactor (For regeneration, MS44-20) DResister (15W, 33.2) {8 Contactor (For hyoraube, MS44-20) @Resisior (OW, 220) Fig. 93 Constructive parts of control Assy, FB20/25P (With regeneratve crcut) — 128(4) Model: CU22.25 ‘Applicable model : FBS0P With regeneratve circu) ® @EET comp, (Travel, 20 paral) @ Battery sonsor (8Y0-05) FET comp. (Hydraulic, 20 paral) {0 MPU board coro, ® Current sensor Ass'y (810-72) 4) Prnted board (PB83-62) © Dove (45M20) © Contactor (For forwardIbackward, MSW44-25) ‘@ Capactor (160V, 1000uF, 698) {@ Contactor (For bypass, MS44-20) ‘© Resistor (15W. 680.0) { Contactor (For regeneration, MS44-20) ‘Resistor (15W, 332) {8 Contactor (For hydraulic, M&44-20) ‘© Resistor (GOW, 222) {8 Contactor (For hydraule bypass, MS44-20) Fig. 9-4 Constructive parts of contol Ass', FBSOP (With regeneratve crcut) — 126U (8) Model : CU22-26 ‘Applicable model: FB10-18P.U (With regeneratve circuit) (DFET comp. (Travel, 20 paralio) @FET comp. (Hysrautc, 20 pret) ‘@ourrnt sensor As (CS10-72) Drove (4520) © Capacior (160v, 10901F, pcs) Resistor (18H, 680.2) Resistor (150, 39.0) @ Resistor GOW, 222) ‘@ Contactor (For regeneration, MS44-20) {§ Contactor (For hydraulic, MS44-20) { Contactor (For over drive, MS44-25) Fig. 95 Constructive parts of contol Assy, FB10-18P-.U (With regeneratve crcut) = 125 —~(6) Model: CU22.27 e Applicable model: FB20/25P-U (With regeneratve crcut) @FET comp. (Travel, 20 paral) {BMPU board comp. @FET comp. (Hydraulic, 20 péraie) ‘60 Printed board (PB83-62) @ Current sensor Assy (CS10-72) {2 Contactor (Fr forward/backward, MSW44-23) @ Diode (4520) + {3.Gontactor (For bypass, MS44-20) @Cepactor (160V, 1000uF, 6pes) {1 Contactor (For regeneration, MS44-20) @ Resistor (15W, 680.2) { Contactor (For hydraulo, MS44-20), e @ Resistor (15W, 33 2) { Contactor (For hydrautc bypass, MS-44-20) @ Resistor (OW, 22.0) {Contactor (For overdrive, MS44-26) ‘Battery sensor (BY40-05) Fig. 9-6 Constructive parts of contol Assy, FB20/25P-U (With regeneratve crcul) = 126p 2 Removing 4 CAUTION ——_____ ‘Turn off the key switch and disconnect the battery plug. (1) Remove bolts and lock washers of the side ‘cover (LH). (@) Removing MPU board {2} Disconnect the connectors of the harness from the MPU boara, Remove the cover of MPU board, and discon- nact tho wiras of deplay. 1) Remove the MPU board (@) Removing control unit 'a} Disconneat te wires of contro uit. bb}Remove the fitting bots of control unit, and remove the control unit. Fig. ¢9 Removing contol unit — er3, Removing procedure of parts and cautions. (1) Removing bode (0) and heat sink. aa NOTE When removing the diode (0), remove the [MPU board fist thing, Refer to removing procedure. 28) Disconnect the diode of anode side, b)Release the fiting bot of heat sink and remove the heat sink ©) Remove the diode from the neat sink «d) Remove the mica sheet and the insulation cup. ACAUTION ‘9Be careful not to dent the fitting surtace of ‘the heat sink. ‘*Be careful not to damage the mica sheets ‘and the Insulation cup. (a) Diode (02) Diode (01), {) Adjust bott {2) Diode (03) (@ Diode (04) Fig. 9-10 Removing diode and heatsink 128Removing FET comp, GRR NOTE ‘When removing the FET comp., remove tie MPU board fist thing. (@) Adjust bott Insulate cap (@)Adust bon fC a) (0) FET comp. (lor travel) (©) FET comp, (for hydraulic) Do ar Asuetbort { Fig. 9-11 Removing FET comp, ‘a)Release the fiting bolts of terminal and bar, and disconnect, the lead wie. b)Remove the housing connector (4P red or 4P (green) of FET comp. ©}Romove the fiting bots of FET comp., and remove the FET comp. and the insulation cup. CAUTION ‘@Be careful not to damage the insulation ‘sheet and the insulation cup. ‘eThe parts on the PC board should not be roplaced, ft should be replaced as assem ‘bly when necessary. = i9-