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99759-55110-12 - Service Data

The document outlines service data for maintenance and inspection standards of a truck, including daily pre-start inspections and planned maintenance schedules. It details recommended lubricants, brake fluid specifications, and periodic replacement intervals for critical parts to ensure optimal performance and safety. Additionally, it provides a tightening torque table for standard bolts and nuts used in the truck's assembly.

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Jakub Cieślak
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0% found this document useful (0 votes)
0 views10 pages

99759-55110-12 - Service Data

The document outlines service data for maintenance and inspection standards of a truck, including daily pre-start inspections and planned maintenance schedules. It details recommended lubricants, brake fluid specifications, and periodic replacement intervals for critical parts to ensure optimal performance and safety. Additionally, it provides a tightening torque table for standard bolts and nuts used in the truck's assembly.

Uploaded by

Jakub Cieślak
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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SERVICE DATA

Inspection Standards ............................................................................12 – 1


Planned Replacement of Parts ...........................................................12 – 3
Recommended Lubricants and Brake Fluid ...................................12 – 4
Tightening Torque for Standard Bolts and Nuts ............................12 – 5
Special Tool Table ..................................................................................12 – 7

12
SERVICE DATA

Inspection Standards

Daily inspection and maintenance can be broadly divided into the following two categories:
(1) Daily pre-start inspection
This inspection is performed by the operator before start of day’s operation. The relevant Operation & Maintenance
Manual describes the procedure of this inspection in detail.
(2) Planned maintenance
This preventive maintenance of the truck includes checking of various components, change of hydraulic oil and
lubricant and other all kinds of service that are vital to maintain the performance of the truck at a level equivalent to
that having been available when it was new for the longest possible period. The planned maintenance should be
carried out regularly according to the schedule determined based on service hour intervals or calender day intervals.

1. Pre-start inspection

Maintenance problems found the day before


Oil or battery electrolyte leaks
Tires
Wheel nuts
Walk around Lights
inspection Backrest extension
Forks
Tilt cylinder socket bolts
Overhead guard
Brake fluid level
Battery electrolyte level
With seat tipped/
remove floor plate Fastener of battery cover
Hydraulic oil level
Seat adjustment and seat belt
Brake pedal
In seat check Parking brake lever
Horn
Lights
Vehicle monitoring system
Turn key to
I (ON) position Battery discharge indicator
Steering wheel
Lift chains
Operating check Mast
Driving check (drive motor, steering, service brakes)

12-1
SERVICE DATA

2. Planned maintenance

: Lubricate
: Check or clean
: Change or adjust
Periodic Maintenance
Interval

Every 100 hours or

Every 200 hours or


Every 50 hours or

Every 1200 hours

Every 2400 hours


Inspection/Maintenance Location and Item Remarks

or 2 years
2 months

or 1 year
2 weeks
weekly
Check – Worn brushes and Indicator comes on when brush has
Motor commutator worn down to limit.
Check – Looseness of connector
Battery Check – Specific gravity of battery

Contactors Check – Contact looseness, damage


and wear
Check – Gear box oil level Gear oil: GL-4 or GL-5
Should be changed 150 hours and 500
hours after start of use of new truck or
Change – Gear box oil
Rear axle after it has been overhauled.
No change is required thereafter.
Lubricate – Steering pivot bearing
Multi purpose type grease
Lubricate – Steering chain
Hydraulic Change – Oil filter
oil Change – Hydraulic oil Hydraulic oil (13.1 liter)
Brake fluid Change – Brake fluid Brake fluid (130 cc)
Mast supports Lubricate
Mast strips Lubricate
Roller Multi purpose type grease
surfaces Lubricate
Lift bracket
side rollers Lubricate
Lift chains Lubricate Engine oil
Tilt sockets Lubricate
Front axle
Lubricate Multi purpose type grease
supports
Tilt cylinders Lubricate

12-2
SERVICE DATA

Planned Replacement of Parts


The following parts should be periodically
Ref.
changed as noted below. Parts to be changed Interval
No.
These parts are made of materials which
will deteriorate with time. Further, it is Rubber parts of brake 2400 service hours or 2 years,
1
master cylinder whichever comes first
difficult to determine visually whether or
not they are still in good condition. Rubber parts of wheel 2400 service hours or 2 years,
2
Changing at proper intervals will reduce cylinders whichever comes first
the chance of injury to the operator and High-pressure hoses of 2400 to 4800 service hours or 2 to 4
3
damage to the truck. hydraulic system years, whichever comes first
NOTICE: Periodic change of these parts is 4800 service hours or 4 years,
4 Power steering hoses
not covered by Warranty. whichever comes first
4800 service hours or 4 years,
5 Lift chains
whichever comes first

103419A

12-3
SERVICE DATA

Recommended Lubricants and Brake Fluid

Recommendation for ambient temperature, °C (°F)

Lubricants/brake fluid Specification -30 -20 -10 0 10 20 30


(-22) (-4) (14) (32) (50) (68) (86)

Rear axle gear box oil API GL-4 or GL-5 Gear oil SAE 80W SAE 80 to 90

Hydraulic oil Hydraulic oil SAE 5W SAE 10W

Brake fluid F.M.V.S.S. No. 116 – DOT 3 or DOT 4 (SAE J1703)

Wheel bearings NLGI No. 2 grade multipurpose type (lithium base), consistency: 265 to 295
Grease
Chassis NLGI No. 1 grade multipurpose type (lithium base), consistency: 310 to 340

NOTICE: Avoid mixing lubricants. In some cases, different brands of lubricants are not compatible with each other
and deteriorate when mixed. It is best to stick with the same brand at successive service intervals.

Refill Capacities (standard models)

Rear axle gear box 4.2 liter

Normal level: 13.1 liter


Hydraulic tank
High level: 14.1 liter

Brake fluid reservoir 130 cm3

12-4
SERVICE DATA

Tightening Torque for Standard Bolts and Nuts


The bolts for the rear axle gear box should be tightened in accordance with the Standard Torque table for ZF products
given in the “Group 7 Rear Axle” of this manual.
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 97.6 192.2 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 29.1 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 1216.0 123.9 894.2 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.
12-5
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 0.08 147.14 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.

12-6
SERVICE DATA

Special Tool Table

Truck Models FB10 FB12 FB15


No. Part No. Name
Application KRT KRT KRT
1 91268-00701 Socket wrench Removal and installation of front wheel hub nut
(46 mm)
2 64309 - 15411 Spring remover Removal of wheel brake return spring
3 64309 - 15412 Hold down spring Removal and installation of brake shoe
retainer
4 65309 - 15413 Return spring Installation of wheel brake return spring
installer
5 Hook wrench (Disassembly and reassembly of lift cylinder)
05312 - 20580 φ 60 mm Duplex: second
05312 - 20520 φ 55 mm Simplex and triplex: second
6 97157 - 00100 Spring installer Installation of steering gear centering spring
Special tool (Disassembly and reassembly of rear axle
GK 25LD.)
A 97M68 - 00100 Assembly plate
B 97M68 - 00200 Bush
C 97M68 - 00300 Bush
D 97M68 - 00400 Measuring bush
F 97M68 - 00500 Clamping fixture
G 97M68 - 00600 Bush
H 97M68 - 00700 Sleeve See “Group 7 Rear Axle” for shape, application
M 97M68 - 00800 Puller and other information.

M’ 97M68 - 00900 Clamping pliers


N 97M68 - 01100 Pressure piece
S 97M68 - 01200 Assembly drift
T 97M68 - 01300 Assembly drift
U 97M68 - 01400 Assembly drift
V 97M68 - 01500 Assembly drift

12-7
SERVICE DATA

Unit: mm

➀ 200440 ➃ 203550

Hook wrench

➁ 203548 ➄ 203556A

Spring installer

➂ 203549 ➅ 206997

12-8

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