SERVICE DATA

Inspection Standards ............................................................................10 – 1

Periodic Replacement of Parts ..........................................................10 – 7
Critical Safety Parts ..................................................................................10 – 7
Lubricating Standards ..........................................................................10 – 8
Lubrication Chart ......................................................................................10 – 8
Lubricant Quantities ..................................................................................10 – 9
Recommended Lubricant ..........................................................................10 – 9
Main Component Weights ...................................................................10 – 9
Tightening Torques for Standard Bolts and Nuts .......................... 10 – 10
Special Tool Table .................................................................................. 10 – 12

10
 SERVICE DATA

Inspection Standards

Inspect and conduct maintenance according to the specified hourmeter indication or the number of calendar days,
whichever comes first.

: Inspect or clean
: Replace or adjust
Periodic Inspection

Pre-operation Inspection
Interval

Every 12 Months or
Every 3 Months or

Every 6 Months or
Remarks
Inspection/Maintenance Location and Item

1000 Hours

2000 Hours
Service Standard

500 Hours
Electrical system
Abnormal noise during rotation
Commutator contamination,
streaks and wear irregularities
Motors Looseness of connections
Grease replacement in motors,
shafts and couplings
Insulation resistance
Electrolyte levels Inspection: Every week or 50 hours
Specific gravity of electrolyte after Inspection: Every week or 50 hours
charging Specific gravity: 1.28
Voltage of each cell 48 V

Batteries Terminal corrosion, damage,

contamination and looseness
Case damage and contamination,
and fluid leaks
Insulation resistance
Charge level

Contactors Contact looseness, damage and

wear

10-1
SERVICE DATA

Periodic Inspection

Pre-operation Inspection
Interval

Every 12 Months or
Every 3 Months or

Every 6 Months or
Remarks
Inspection/Maintenance Location and Item

1000 Hours

2000 Hours
Service Standard

500 Hours
Control valve microswitch
operating condition
Damage and mounting looseness
Foot brake switch operating
Micro condition
switches
Damage, mounting looseness
Hand brake switch operating
condition
Damage and mounting looseness
Controller operating condition
(1) Seat switch
(2) Forward/reverse selector switch
(3) Control valve switch
(4) Brake switch

Main (5) Accelerator switch

controller (6) Line contactors
(7) Forward
(8) Reverse
(9) Regeneration bypass
Internal contamination and damage
Over-current limit value
Fuse mounting looseness
Fuses
Fuse capacity
Wire harness damage and
clamp looseness

Wiring Terminal connection looseness and

taping condition
Battery connector contacts and
bolt looseness
Power transmitting system
Transfer oil level and L.H.: 1.09 liter (0.29 U.S. gal)
contamination R.H.: 1.86 liter (0.49 U.S. gal)
Transfers
Oil leaks
Bolt looseness

10-2
 SERVICE DATA

Periodic Inspection

Pre-operation Inspection
Interval

Every 12 Months or
Every 3 Months or

Every 6 Months or
Remarks
Inspection/Maintenance Location and Item

1000 Hours

2000 Hours
Service Standard

500 Hours
Drive system
Tire cracking and damage
Tire tread depth
Tires Abnormal tire wear
Metal pieces, rocks, other foreign
materials on tires
Hub bolts Damage and looseness
Rims and
wheel discs Damage
Wheel bearing rattle
Wheel
bearings Abnormal noise in wheel bearings
Grease replacement
Steering system
Play, looseness, rattling and
Steering Play: 15 to 30 mm (0.6 to 1.2 in.)
operating condition
wheel
Gear box mounting looseness
Deformation, cracking and damage
Rear axle Oil leaks
Bolt looseness
Braking system
Free play 3 to 9 mm (0.12 to 0.35 in.)
Distance between depressed brake
pedal and floor board
Air trapped in fluid
Brakes
Braking performance
Uneven braking performance
between right and left
Reservoir tank level and oil leaks 99 cc (6.04 cu. in.)
Parking Lock condition
brake Braking performance 3rd or 4th notch engagement
Rods and Operating condition
cables Looseness of links and clamps

10-3
SERVICE DATA

Periodic Inspection

Pre-operation Inspection
Interval

Every 12 Months or
Every 3 Months or

Every 6 Months or
Remarks
Inspection/Maintenance Location and Item

1000 Hours

2000 Hours
Service Standard

500 Hours
Damage, leaks and contact with
Hoses and other parts
pipes
Looseness of links and clamps
Clearance between brake disc and
0.4 to 1.1 mm (0.016 to 0.043 in.)
pad
Brake disc mounting looseness

Brake discs Brake pad wear Service limit : 1 mm (0.039 in.)

and pads Brake pad operating condition
Rusting of pins
Return spring fatigue and damage
Brake disc wear and damage Service limit : 9 mm (0.354 in.)
Lift system
Fork and stopper pin damage
Allowed fork thickness wear limit:
Forks Forks—wear and distortion
33 mm (1.3 in.)
Cracking and wear in fork base
and tooth weld
Cracking in cross-member welds
of outer and inner masts
Cracking in welds of tilt cylinders
and masts
Cracking in welds of outer masts
and cylinder support
Masts and Cracking in lift bracket welds
lift bracket Roller bearing rattle

Wear and damage of mast support

metal
Cracking and damage in rollers,
roller pins and welds
Mast operating condition and
mounting looseness

10-4
 SERVICE DATA

Periodic Inspection

Pre-operation Inspection
Interval

Every 12 Months or
Every 3 Months or

Every 6 Months or
Remarks
Inspection/Maintenance Location and Item

1000 Hours

2000 Hours
Service Standard

500 Hours
Allowed lift chain stretch:
Length of lift chains (20 links) 1 ton class: 327 mm (12.87 in.)
2 ton class: 392 mm (15.43 in.)
Chain deformation, damage,
Chains and lubrication and rusting
chain wheels Chain bushing coupling, bolt
deformation and damage
Chain wheel deformation and
damage
Chain wheel bearing rattle

Attachments Attachment abnormality and

mounting conditions
Hydraulic system
Looseness, deformation and
damage of rods, rod bolts and
rod ends
Cylinder operating condition
Drift lowering distance:
Cylinders Drift lowering and forward 50 mm (1.97 in.)/15 min
tilting distances Drift forward tilting distance:
22 mm (0.87 in.)/15 min
Cylinder oil leaks and damage
Wear and damage of piston and
cylinder shaft bearings

Oil pump Oil leaks, abnormal noise, wear in

drive unit, and mounting looseness
N level: 14.7 liter (3.88 U.S. gal)
Hydraulic Oil level and contamination
H level: 16.8 liter (4.44 U.S. gal)
tank
Filter clogging
Operation Linkage looseness
levers Lever functions
Oil leaks

Control Safety valves

valves 18142 + 0490 kPa
Release pressure measurement (185 + 05 kgf/cm2)
[2631 + 071 psi]

10-5
SERVICE DATA

Periodic Inspection

Pre-operation Inspection
Interval

Every 12 Months or
Every 3 Months or

Every 6 Months or
Remarks
Inspection/Maintenance Location and Item

1000 Hours

2000 Hours
Service Standard

500 Hours
Safety devices and others
Head guard Mounting looseness
and backrest Deformation, cracking and damage

Turn signal operation and

mounting condition
Alarm device operation and
mounting condition
Lamp operation and mounting
condition
Safety Backup warning device operation
devices and mounting condition
Rear-view mirror dirtiness and
damage
Rear-view mirror image and
condition
Proper function of seat belt and
hip restraint
Instruments Instrument operations
Seat Looseness and damage
Vehicle Damage and cracking in frame and
body cross-members
Inspection of chassis lubricating
Oil and conditions after cleaning
grease
replacement Confirmation of oil replacement
intervals

10-6
 SERVICE DATA

Periodic Replacement of Parts

Replace the following critical safety-related parts and elements according to the specified intervals.

Replacement Interval
Parts for Periodic Replacement Method After 1
Every Every Every Every
Month of
Month 6 Months Year 2 Years
Initial Use
1 * Rubber parts in brake master cylinder Replace
2 * Rubber parts in brake caliper cylinders Replace
3 * High-pressure hoses for lift and tilt Replace
systems
4 * Lift chains Replace
Hydraulic tank return oil filter Replace
Note: “ * ” mark indicates critical safety parts.

Critical Safety Parts

3
1
206929

10-7
SERVICE DATA

Lubricating Standards

Lubrication Chart

Lift chain HO

MPG Tilt socket

Roller surface
MPG
Mast strip

MPG Mast support

Lift bracket MPG
side roller

Brake BF
fluid

Transfer HO HO

Hydraulic HO
oil

Every 3 months or 500 hours

Every 6 months or 1000 hours

Every 12 months or 2000 hours

: Inspection, replenishment MPG: Multipurpose grease

: Replacement BF: Brake fluid
❋: Parts located on both sides of vehicle HO: Hydraulic oil 211155

10-8
 SERVICE DATA

Lubricant Quantities
Truck Models
1 ton class 2 ton class
Items

L.H.: 1.09 (0.29)

Transfer oil capacity liter (U.S. gal)
R.H.: 1.86 (0.49)

N level: 14.7 (3.88)

Hydraulic system oil capacity liter (U.S. gal)
H level: 16.8 (4.44)

Brake fluid capacity cc (cu. in.) 99 (6.04)

Recommended Lubricant
Grease: NLGI No. 1, NLGI No. 2
Brake fluids: SAE J1703f
Hydraulic, transfer and rear axle oils: SAE 5W, SAE 10W

Main Component Weights

Unit: kg (lb)

Truck Models
EP16NT EP18NT EP20NT
Item

740 805 955

Counterweight
(1631) (1775) (2105)

Power line

72.4 72.4 72.4

Transfer
(159.6) (159.6) (159.6)

40 40 40
Traction motor
(88.2) (88.2) (88.2)

70 70 70
Head guard
(154.3) (154.3) (154.3)

33 33 33
Rear axle
(72.8) (72.8) (72.8)

Mast [3.3 m (130 in.), Simplex]

Outer mast 164.84 (363.4) 164.84 (363.4) 164.84 (363.4)

Inner mast 136.73 (301.4) 136.73 (301.4) 136.73 (301.4)

Lift bracket (including backrest) 93.34 (205.8) 93.34 (205.8) 108.22 (238.6)

Forks (set of two) 78.4 (172.8) 78.4 (172.8) 78.4 (172.8)

Lift cylinders, etc. 78.47 (173) 78.47 (173) 78.47 (173)

Mast [3.3 m (130 in.), Duplex] 566 (1248) 566 (1248) 577 (1272)

Mast [4.8 m (189 in.), Triplex] 691 (1523) 691 (1523) 702 (1548)

10-9
SERVICE DATA

Tightening Torque for Standard Bolts and Nuts

With Spring Washer 101656

Nominal Size Pitch

mm in. mm in. N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
6 0.24 1 0.04 7.4 0.75 5.4 9.6 0.98 7.1 12.7 1.3 9.4
8 0.32 1.25 0.05 16.7 1.7 12.3 22.6 2.3 16.6 30.4 3.1 22.4
10 0.39 1.25 0.05 34.3 3.5 25.3 45.1 4.6 33.3 69.6 7.1 51.4
12 0.47 1.25 0.05 63.7 6.5 47.0 82.4 8.4 60.8 122.6 12.5 90.4
14 0.55 1.5 0.06 102.0 10.4 75.2 132.4 13.5 97.6 191.2 19.5 141.8
16 0.63 1.5 0.06 154.9 15.8 114.3 202.0 20.6 149.0 287.3 29.3 211.9
18 0.71 1.5 0.06 224.6 22.9 165.6 292.2 29.8 215.5 413.8 42.2 305.2
20 0.79 1.5 0.06 310.9 31.7 229.3 404.0 41.2 298.0 573.7 58.5 423.1
22 0.87 1.5 0.06 413.8 42.2 305.2 537.4 54.8 396.4 763.0 77.8 562.7
24 0.95 1.5 0.06 547.2 55.8 403.6 711.0 72.5 524.4 1006.2 102.6 742.1
27 1.06 1.5 0.06 794.3 81.0 585.9 1032.6 105.3 761.6 1451.1 148.0 1070.5
30 1.18 1.5 0.06 1100.3 112.2 811.5 1430.8 145.9 1055.3 2012.3 205.2 1484.2
33 1.30 1.5 0.06 1467.1 149.6 1082.1 1907.4 194.5 1406.8 2680.2 273.3 1976.8
36 1.42 1.5 0.06 1918.2 195.6 1414.8 2493.8 254.3 1839.4 3497.1 356.6 2579.3
39 1.54 1.5 0.06 2461.5 251.0 1815.5 3198.8 326.2 2359.4 4469.9 455.8 3296.8
Metric Without Spring Washer 101656
fine
thread Nominal Size Pitch

6 0.24 1 0.04 8.6 0.88 6.4 10.8 1.1 8.0 14.7 1.5 10.8
8 0.32 1.25 0.05 19.6 2.0 14.5 26.5 2.7 19.5 36.6 3.7 26.8
10 0.39 1.25 0.05 41.2 4.2 30.4 53.0 5.4 39.1 81.4 8.3 60.0
12 0.47 1.25 0.05 74.5 7.6 55.0 97.1 9.9 71.6 144.2 14.7 106.3
14 0.55 1.5 0.06 119.6 12.2 88.2 155.9 15.9 115.0 226.5 23.1 167.1
16 0.63 1.5 0.06 182.4 18.6 134.5 237.3 24.2 175.0 338.3 34.5 249.5
18 0.71 1.5 0.06 263.8 26.9 194.6 343.2 35.0 253.2 487.4 49.7 359.5
20 0.79 1.5 0.06 365.8 37.3 269.8 475.6 48.5 350.8 674.7 68.8 497.6
22 0.87 1.5 0.06 486.4 49.6 358.8 632.5 64.5 466.5 897.3 91.5 661.8
24 0.95 1.5 0.06 643.3 65.6 474.5 836.5 85.3 617.0 1183.7 120.7 873.0
27 1.06 1.5 0.06 934.6 95.3 689.3 1215.0 123.9 896.2 1707.3 174.1 1259.3
30 1.18 1.5 0.06 1294.5 132.0 954.8 1682.8 171.6 1241.2 2367.3 241.4 1746.0
33 1.30 1.5 0.06 1726.0 176.0 1273.0 2243.8 228.8 1654.9 3153.8 321.6 2326.1
36 1.42 1.5 0.06 2256.5 230.1 1664.3 2934.1 299.2 2164.1 4114.0 419.6 3035.0
39 1.54 1.5 0.06 2896.0 295.3 2135.9 3763.8 383.8 2776.0 5258.3 536.2 3878.3

Remarks : 1. The tolerance on these torques is ±10%.

2. These torques are for “dry” condition.

10-10
 SERVICE DATA

With Spring Washer 101656

Nominal Size Pitch

mm in. mm in. N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
10 0.39 1.5 0.06 33.3 3.4 24.6 43.1 4.4 31.8 67.7 6.9 49.9
12 0.47 1.75 0.07 58.8 6.0 43.4 76.5 7.8 56.4 115.7 11.8 85.3
14 0.55 2 0.08 96.4 9.8 70.9 124.5 12.7 91.9 182.4 18.6 134.5
16 0.63 2 0.08 147.1 15.0 108.5 191.2 19.5 141.0 274.6 28.0 202.5
18 0.71 2.5 0.10 203.0 20.7 149.7 264.8 27.0 195.3 383.4 39.1 282.8
20 0.79 2.5 0.10 286.4 29.2 211.2 371.7 37.9 274.1 536.4 54.7 395.6
22 0.87 2.5 0.10 383.4 39.1 282.8 499.2 50.9 368.2 715.9 73.0 528.0
24 0.95 3 0.12 492.3 50.2 363.1 640.4 65.3 472.3 924.8 94.3 682.1
27 1.06 3 0.12 724.7 73.9 534.5 942.2 96.1 695.1 1350.4 137.7 996.0
30 1.18 3.5 0.14 969.9 98.9 715.3 1259.2 128.4 928.7 1843.7 188.0 1359.8
33 1.30 3.5 0.14 1328.8 135.5 980.1 1727.0 176.1 1273.7 2477.2 252.6 1827.1
36 1.42 4 0.16 1676.0 170.9 1236.1 2180.0 222.3 1607.9 3199.9 326.3 2360.1
39 1.54 4 0.16 2219.2 226.3 1636.8 2884.1 294.1 2127.2 4118.8 420.0 3037.9
42 1.65 4.5 0.18 2754.7 280.9 2031.8 3581.4 365.2 2641.5 5137.7 523.9 3789.4
Metric Without Spring Washer 101656
coarse
thread Nominal Size Pitch

10 0.39 1.5 0.06 39.2 4.0 28.9 51.0 5.2 37.6 79.4 8.1 58.6
12 0.47 1.75 0.07 69.6 7.1 51.4 90.2 9.2 66.5 135.3 13.8 99.8
14 0.55 2 0.08 112.8 11.5 83.2 146.1 14.9 107.8 215.7 22.0 159.1
16 0.63 2 0.08 172.6 17.6 127.3 224.6 22.9 165.6 323.6 33.0 238.7
18 0.71 2.5 0.10 239.3 24.4 176.5 311.9 31.8 230.0 451.1 46.0 332.7
20 0.79 2.5 0.10 336.4 34.3 248.1 437.4 44.6 322.6 630.6 64.3 465.1
22 0.87 2.5 0.10 392.3 40.0 289.3 587.4 59.9 433.3 842.4 85.9 621.3
24 0.95 3 0.12 578.6 59.0 426.7 753.2 76.8 555.5 1088.5 111.0 802.9
27 1.06 3 0.12 852.2 86.9 628.5 1108.2 113.0 817.3 1588.7 162.0 1171.7
30 1.18 3.5 0.14 1140.5 116.3 841.2 1481.8 151.1 1092.9 2168.3 221.1 1599.2
33 1.30 3.5 0.14 1563.2 159.4 1153.0 2031.9 207.2 1498.7 2915.5 297.3 2150.4
36 1.42 4 0.16 1972.1 201.1 1454.6 2564.4 261.5 1891.4 3765.8 384.0 2777.5
39 1.54 4 0.16 2610.5 266.2 1925.4 3393.1 346.0 2502.6 4845.5 494.1 3573.8
42 1.65 4.5 0.18 3241.1 330.5 2390.5 4212.9 429.6 3107.3 6044.8 616.4 4458.4

Remarks : 1. The tolerance on these torques is ±10%.

2. These torques are for “dry” condition.

10-11
SERVICE DATA

Special Tool Table

Reference Truck Models 1 ton 2 ton

Part No. Name
No. Application class class

1 64309-17701 Gauge kit Measurement of hydraulic pressure

2 91268-01500 Installer Installation of rear axle inner bearing and inner race

3 91268-01400 Installer Installation of rear axle outer bearing and inner race

Steering wheel
4 91268-10600 Removal of steering wheel
puller

5 91268-03200 Puller Removal of steering column and needle roller bearing

6 91268-01600 Installer Installation of tilt cylinder tube bushing

7 09305-00680 Hook wrench Removal and installation of tilt cylinder guide bushing

09305-00520 Hook wrench Removal and installation of lift cylinder guide bushing

Removal and installation of first lift cylinder guide

09305-00750 Hook wrench
bushing

8 97157-00100 Spring installer Installation of centering spring in steering gear

10-12
 SERVICE DATA

Gauge kit Puller

➀ 203544 ➄ 203552

Installer Unit: mm (in.) Installer Unit: mm (in.)

➁ 200447 ➅ 200448

Installer Unit: mm (in.) Hook wrench

➂ 200446 ➆ 203556

Steering wheel puller Unit: mm (in.) Spring installer

➃ 203551 ➇ 206997

10-13