Nichiyu FB 75 Series CAN-BUS Forklift Workshop Manual – FB10P to FB30P Service & Repair Guide

Description

The Nichiyu FB 75 Series CAN-BUS Forklift Workshop Manual is the comprehensive service and repair guide for the FB10P through FB30P electric counterbalance forklift range. Whether your truck runs IGBT control, FET control, or the CAN-BUS control system, this manual provides the manufacturer’s own procedures for disassembly, reassembly, inspection, adjustment, maintenance, and troubleshooting. It covers the front drive axle, rear steering axle, tyres, steering linkage and EPS system, wheel and parking brakes, the complete hydraulic circuit from pump to cylinders, mast assemblies, traction and hydraulic motors, the EPS motor, and the full electric parts system including control unit, display panel, accelerator, contactors, charger, and battery.

File Details

• Manual type: Workshop Manual (service, repair, maintenance)
• Brand: Nichiyu (Nippon Yusoki Co., Ltd.)
• Series: FB 75 series electric counterbalance forklifts
• Models covered: FB10P, FB14P, FB15P, FB18P, FB20P, FB25P, FB28P, FB30P, plus -U high speed variants and CS/FCS/RP/DRP configurations
• Control systems: IGBT control, FET control, and CAN-BUS control
• Language: English
• Page count: 230 pages
• File format: PDF
• Edition: Second edition, September 2008 (first printing December 2003)

Chapters Covered

• 1. General — appearance, specifications
• 2. Front Axle (Drive) — location and name, removal and installation, disassembly and reassembly, gear inspection and replacement, wheel hub and hub bolt inspection, troubleshooting
• 3. Rear Axle (Steering) — location and name, removal and installation, disassembly and reassembly, reassembling method and attention, bushing/center arm/tie rod/knuckle/king pin/hub inspection, troubleshooting
• 4. Tyre — location, name and tyre size, hub nut inspection, rim and rim bolt inspection, air pressure inspection, visual inspection and replacement, troubleshooting
• 5. Steering — location and name, steering linkage removal and installation, disassembly and reassembly, joint/knob/steering wheel inspection, torque sensor neutral check and adjustment, voltage checking, actuator assembly inspection and adjustment, troubleshooting
• 6. Brake — foot brake linkage and parking brake linkage main part names, wheel brake removal and installation, wheel brake disassembly and reassembly, brake drum inspection, shoe and lining inspection, adjustor assembly inspection, wheel cylinder and master cylinder inspection, brake pedal inspection, parking lever adjustment, brake linkage adjustment, brake air bleeding, troubleshooting
• 7. Hydraulic System — oil piping circuit; hydraulic pump location, removal and installation, inspection, troubleshooting; oil tank and oil piping; control valve removal, inner kit replacement, relief pressure measurement, microswitch adjustment, troubleshooting; lift and tilt cylinder removal, installation, disassembly, reassembly, inspection, drift measurement, tilt cylinder variations, troubleshooting
• 8. Mast — location and name (P-mast simplex, M-mast triplex, PFL-mast duplex), lift bracket removal, mast assembly removal, mast disassembly and reassembly, mast/lift bracket/roller shaft inspection, back shoe inspection, lift chain inspection and replacement, chain bolt inspection, chain wheel inspection, hose pulley inspection, roller inspection and replacement, fork inspection and replacement, lift chain adjustment, mast lean adjustment, troubleshooting
• 9. Motor — traction motor, hydraulic motor, EPS motor main part names and specifications; removal and installation; disassembly and reassembly; rotor, armature, brush, brush holder and spring inspection and replacement; motor assembly inspection; oil seal and permanent magnet inspection; troubleshooting
• 10. Electric Parts — control unit (IGBT module, FET module, capacitor, EPS controller), display panel and directional switch, accelerator and potentiometer adjustment, main contactor and fuse, built-in charger (transformer, charging procedures, voltage tap), battery removal and inspection, MPU board, display board, EPS controller board
• 11. Laser Pointer (Option) — fork level adjustment, laser optical axis adjustment
• 12. Service Data — annual inspection service data, standard work hours

What This Manual Gives You

This Nichiyu FB 75 series CAN-BUS workshop manual is a complete technical reference for the FB10P, FB14P, FB15P, FB18P, FB20P, FB25P, FB28P, and FB30P electric forklifts. It begins with general specifications and appearance views, then moves through every major system in the order a technician would approach a repair. The front axle section explains how to remove the drive axle and traction motor, disassemble the transmission case and differential, inspect gears and bearings, and reassemble with correct preload and torque values. The rear axle section covers the steering axle, knuckle, king pin, tie rod, and center arm, with the reassembly geometry dimensions and stopper bolt adjustments needed to restore correct steering angle. Brake coverage includes both the foot brake linkage and parking brake, with drum and lining wear limits, cylinder kit replacement, air bleeding procedures, and pedal height and play adjustment.

The hydraulic system is treated in full detail: hydraulic pump removal and installation, oil tank and piping replacement precautions, control valve removal and inner kit replacement, relief pressure measurement with model-specific values, microswitch adjustment, and complete lift and tilt cylinder disassembly and reassembly with seal replacement and drift measurement. The mast chapter covers P-mast (2-stage simplex), M-mast (3-stage triplex), and PFL-mast (2-stage duplex) configurations, with lift chain inspection, chain wheel and hose pulley checks, roller replacement, fork inspection, chain deflection adjustment, and mast lean adjustment. Motor coverage includes traction, hydraulic, and EPS motors, with rotor and armature inspection, brush wear limits, insulation testing, and bearing sensor replacement precautions.

Electric parts coverage is extensive, reflecting the CAN-BUS control system. It includes control unit removal and disassembly for both IGBT and FET control variants, IGBT and FET module testing with continuity test points, capacitor inspection and discharging procedures, EPS controller specifications, display panel and directional switch disassembly, accelerator potentiometer adjustment with output voltage values, main contactor and fuse replacement, built-in charger operation and charging procedures, battery inspection and electrolyte maintenance, and MPU board layout. The service data chapter provides annual inspection values and standard work hours for every major job, giving a workshop the information needed to quote and schedule repairs accurately.

Why This Manual Matters

Electric forklifts like the Nichiyu FB series use high-voltage systems, precise hydraulic pressures, and electronic control units that demand correct procedures and specifications. Guessing at torque values, relief pressures, or electrical test points can lead to component damage, unsafe operation, or costly repeat repairs. This workshop manual provides the manufacturer’s own figures: tightening torques for bolts from M3 through M30, relief pressure settings by model, brake drum wear limits, lining thickness limits, chain stretch limits, roller clearance specifications, and electrical resistance and voltage values. It also includes the safety precautions that apply to battery-powered equipment, hydraulic pressure release, and capacitor discharge.

Who This Manual Is For

This Nichiyu FB 75 series workshop manual is written for professional forklift technicians, fleet maintenance departments, and experienced mechanics who already have a working knowledge of electric lift trucks and hydraulic systems. It assumes access to standard workshop facilities and tools. The procedures are detailed enough for a competent technician to carry out major repairs, but they are not a substitute for training or experience with high-voltage electric systems. Anyone working on these trucks should follow the safety warnings and use the specified tools and materials.

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The Nichiyu FB 75 Series CAN-BUS Forklift Workshop Manual is delivered as an instant PDF download. There is no shipping, no waiting, and no physical book to store. You can view it on any device, search through the sections, and print the pages you need for the job at hand. Whether you are servicing a single FB20P or maintaining a mixed fleet of FB10P through FB30P trucks, this manual puts the complete factory service information at your fingertips. Order now and have the full workshop manual ready for your next repair.