Service Manual MC/FC
Chassis, Mast & Options FB16N FB18N FB20CN
EFB15-20011-up EFB15-70001-up EFB17-20011-up
For use with FB16N-FB20CN Controller Service Manual.
99759-57110
GROUP INDEX GROUP INDEX
Items
GENERAL INFORMATION
Vehicle exterior, Models, Serial number locations, Chassis and mast model identification, Dimensions, Technical data
1
VEHICLE ELECTRICAL COMPONENT
Console box, Direction lever, Accelerator control, Key switch, Fuses, Lamp specification chart, Troubleshooting of lighting and horn systems, Joystick box
2
POWER TRAIN
Procedures and suggestions for removal and installation, Service data
3
TRANSFER UNIT
Specifications, Structure and functions, Procedures and suggestions for disassembly and reassembly, Service data
4
REAR AXLE
Structure, Procedures and suggestions for removal and installation, Procedures and suggestions for disassembly and reassembly, Adjustment, Troubleshooting, Service data
5
BRAKE SYSTEM
Specifications, Structure and functions, Procedures and suggestions for disassembly and reassembly, Inspection and adjustment, Troubleshooting, Service data
6
STEERING SYSTEM
Specifications, Structure and functions, Procedures and suggestions for removal and installation, Steering control valve, Hydraulic circuit diagram, Troubleshooting, Service data
7
HYDRAULIC SYSTEM
Specifications, Finger-tip control type (Description, Removal and installation, Disassembly and reassembly, Inspection and adjustment, Hydraulic circuit diagram), Mechanical control type (Control valve, Removal and installation, Hydraulic circuit diagram), Troubleshooting, Service data
8
MAST AND FORKS
Mast systems, Description, Removal and installation, Disassembly and reassembly, Inspection and adjustment, Troubleshooting, Service data
9
SERVICE DATA
Inspection standards, Periodic replacement of parts, Lubrication standards, Main component weights, Tightening torque for standard bolts and nuts, Special tool table
10
GENERAL INFORMATION Vehicle Exterior ........................................................................................ Models ....................................................................................................... Serial Number Locations ....................................................................... Chassis and Mast Model Identification ............................................... Dimensions ............................................................................................... Technical Data ..........................................................................................
1–1 1–1 1–2 1–3 1–4 1–5
1
GENERAL INFORMATION
Vehicle Exterior
Control lever (MC models)
Joystick box (FC models)
211146
Models This manual applies to FB16N, FB18N and FB20CN.
Truck Model
Serial Number
FB16N
EFB15-20011-up
FB18N
EFB15-70001-up
FB20CN
EFB17-20011-up
1-1
GENERAL INFORMATION
Serial Number Locations
Mast number
Chassis number
Nameplate
211270
1-2
GENERAL INFORMATION
Chassis and Mast Model Identification
[Chassis] FB
16
N
Generation designator
Maximum capacity 16: 1600 kg (3500 lb) 18: 1800 kg (4000 lb) 20: 2000 kg (4400 lb) Battery type
[Mast] 2
G
15
A
30
Maximum lifting height [“30” stands for 3000 mm (118 in.)] Order of the minor change (“A” for the original, “B” for the first change, “C” for the second change, and so on) Applicable truck model designation 15: 1 ton class 20: 2 ton class Kind of mast G: simplex mast H: duplex mast J: triplex mast Major change (“1” for the original, “2” for the first change, and so on up to “9”)
1-3
GENERAL INFORMATION
Dimensions
B
F
E
C
D A
213416
1-4
GENERAL INFORMATION
Technical Data Truck Models
FB16N
FB18N
FB20CN
Class
1.6 ton
1.8 ton
2.0 ton
15690 (1600)/500 [3530/20]
17650 (1800)/500 [3970/20]
19610 (2000)/500 [4410/20]
Load Capacity/Load Center
N (kgf)/mm [lbf/in.]
Truck size Length to Fork Face A
mm (in.)
2074 (81.7)
2074 (81.7)
2188 (86.1)
B
mm (in.)
1070 (42.1)
1070 (42.1)
1130 (44.5)
Height of Overhead C Guard
mm (in.)
2048 (80.6)
2048 (80.6)
2048 (80.6)
D
mm (in.)
1360 (53.5)
1360 (53.5)
1463 (57.6)
kg (lb)
3190 (7033)
3280 (7231)
3470 (7650)
mm (in.)
913/898 (35.9/35.4)
913/898 (35.9/35.4)
935/898 (36.8/35.4)
Tires Size Front
18 x 7-8
18 x 7-8
200/50-10
Rear
16 x 6-8
16 x 6-8
16 x 6-8
1810 (71.3)
1810 (71.3)
1910 (75.2)
17/17 (10.6/10.6)
17/17 (10.6/10.6)
17/17 (10.6/10.6)
35/27
35/25
35/24
Width
Wheelbase Truck weight, without load/ including battery Tread Front/Rear
E/F
Turning Radius Travel Speeds Unloaded/Loaded
mm (in.) km/h (mph)
Maximum Gradeability Unloaded/Loaded
%
Lift Speeds Unloaded/Loaded
m (in.)/sec
0.60/0.50 (23.6/19.7) 0.60/0.44 (23.6/17.3) 0.60/0.40 (23.6/15.7)
Lowering Speed Unloaded/Loaded
m (in.)/sec
0.5/0.52 (19.7/20.5)
0.5/0.52 (19.7/20.5)
0.5/0.52 (19.7/20.5)
V
48
48
48
Ah
600
600
720
Battery Voltage Battery Rated Capacity (5 hrs.) MAX Battery Compartment Size Battery Weight
mm (in.) kg (lb)
Tilt Angle (forwards-backwards)
1006 x 521 x 650 1006 x 521 x 650 1006 x 624 x 650 (39.6 x 20.5 x 25.6) (39.6 x 20.5 x 25.6) (39.6 x 24.6 x 25.6) 865 (1907)
865 (1907)
1000 (2205)
6°-7°
6°-7°
6°-7°
Traction Motor, 60 min rating
kW
2 x 5.0
2 x 5.0
2 x 5.0
Hydraulic Motor (15% duty)
kW
14
14
14
Traction Motor Control Method
MOSFET
MOSFET
MOSFET
Hydraulic Motor Control Method
MOSFET
MOSFET
MOSFET
1-5
VEHICLE ELECTRICAL COMPONENTS Console Box ............................................................................................. 2 – 1 Functions of Central Vehicle Monitor System ............................................ 2 – 1 Electrical Components in Console Box ..................................................... 2 – 5 Disassembly and Reassembly .................................................................. 2 – 6
Direction Lever ......................................................................................... Accelerator Control ................................................................................. Key Switch ................................................................................................ Lighting Switch ......................................................................................... Fuses ......................................................................................................... Lamp Specification Chart ....................................................................... Troubleshooting of Lighting and Horn Systems ................................ Joystick Box ..............................................................................................
2– 7 2– 8 2– 9 2– 9 2 – 10 2 – 10 2 – 11 2 – 12
2
VEHICLE ELECTRICAL COMPONENTS
Console Box 1 2 3 4 5 6
1 6
Central vehicle monitoring system (CVMS) Mode selector button Tilt steering column lock/unlock lever Key switch Lighting switch Mode check button
2
5 3 4
NOTE 103043
For setting the clock and selection of KPH or MPH, refer to “Selection of KPH or MPH” and “Setting the clock”.
Functions of Central Vehicle Monitor System (CVMS)
8
9
10
1
2
3
4
5
6
7
211131
Operations
No. 1
Monitor name
When OFF
When ON or flashing
Remarks
Service indicator
Starts flashing 20 hours before set time. Remains ON when set time is reached.
Seat belt warning light
Seat belt is fastened.
Seat belt is not fastened when operator sits on seat (seat switch is turned on).
2
2-1
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VEHICLE ELECTRICAL COMPONENTS
No.
Monitor name
When OFF
When ON or flashing
Controller/motor overheat indicator
Controller, traction motors and pump motor are normal temperature
Overheating
Remaining battery charge warning light
Normal battery condition
Flashing indicates battery needs to be recharged soon. ON indicates battery needs to be recharged and lifting function inoperable.
3
4
Remarks Overheating causes a significant output loss. When component temperature returns to normal levels, output power returns.
5
Brake fluid level indicator Normal fluid level
Low fluid level
6
Parking brake warning Parking brake disengaged light
Parking brake engaged
Fault detection indicator
Normal
Vehicle malfunction
Vehicle speed and error code display
Displays the vehicle speed during normal operation and displays an error code in the event of a malfunction.
Battery discharge indicator (BDI)
The battery charge status is indicated by the ten element indicator. When fully charged, all elements are lit through to the right side. As the battery discharges, the indicator elements decrease toward the left side. When only one element is on, the remaining battery charge warning light 4 in the LED section will flash. When the indicator completely goes off, the remaining battery charge warning light 4 will be continuously lit and the vehicle enters power reduction mode.
Hourmeter, time display
It normally displays the time. When the key switch is set to the I (ON) position, the traction motor, pump motor, and vehicle service hours are indicated sequentially.
7
8
9
10
2-2
Error codes appear on the error code display. The vehicle speed display can be switched between KPH and MPH. Follow the steps in “Selection of KPH or MPH” below.
The time of clock can be adjusted. Follow the steps in “Setting the clock” below.
VEHICLE ELECTRICAL COMPONENTS Selection of KPH or MPH
1. Apply the parking brake. 2. Place the direction lever in NEUTRAL. Button 1
3. Turn the key switch to the I (ON) position.
Button 2
4. Push and hold button 1 for one to two seconds. NOTICE: Display will show KPH and a 24-hour clock until it is changed. When MPH is selected, the clock will change to a 12-hour clock.
Setting the clock
103043
1. Apply the parking brake. 2. Place the direction lever in NEUTRAL. 3. Turn the key switch to the I (ON) position. 4. Push and hold button 1 until the minutes’ display flashes. 5. Release button 1. 6. Adjust the minutes with button 2. 7. Push button 1 and release when the hours’ display flashes. 8. Adjust the hour with button 2. 9. Push button 1 to lock in the time.
2-3
VEHICLE ELECTRICAL COMPONENTS Error code display
Indication (E)
Condition Indicator flashes if seat switch is turned off during driving operation. Then, indicator turns on when seat switch is turned on again. Indicator turns off when direction lever and accelerator pedal are returned.
E E 0
ON
Right traction motor overheated
E 1
ON
Left traction motor overheated
E 2
ON
Pump motor overheated
E 5
ON
Right traction inverter overheated
E 6
ON
Left traction inverter overheated
E 7
ON
Pump inverter overheated
H 1
ON
Faulty setting of lift lever
H 2
ON
Faulty setting of tilt lever
H 3
ON
Faulty setting of attachment 1 lever
H 4
ON
Faulty setting of attachment 2 lever
H 5
ON
Faulty setting of attachment 3 lever
(L)
Indicator flashes if seat switch is turned off during lifting operation. Then, H1 to H5 turn on when seat switch is turned on again. Indicator turns off when lifting operation is suspended.
(E) means flashing. NOTICE: For details of the error codes and their conditions, see Controller Service Manual.
2-4