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Service Manual Chassis, Mast & Options FB20K PAC FB25K PAC FB30K PAC FB35K PAC

EFB8C-00011-up EFB8C-50001-up EFB9C-00011-up EFB9C-50001-up

For use with FB20K PAC - FB35K PAC Controller Service Manual.

99759-5A110


GROUP INDEX GROUP INDEX

Items

Vehicle Exterior, Models, Serial Number Locations, GENERAL INFORMATION Chassis and Mast Model Identification, Dimensions, Technical Data

1

VEHICLE ELECTRICAL COMPONENTS

Electrical Component Locations, Console Box, Direction Lever, Accelerator Control, Key Switch, Lighting Switch, Fuses, Lamp Specification Chart, Auto-light System, Troubleshooting of Lighting and Horn Systems

2

POWER TRAIN

General Structure, Common Removal and installation Procedures, Power Train Assembly Removal, Power Train Assembly Installation

3

TRANSFER AND DIFFERENTIAL

Structure and Functions, Procedures and Suggestions for Disassembly and Reassembly, Service Data

4

FRONT AXLE

Structure and Functions, Disassembly and Reassembly of Front Axle Assembly, Service Data

5

REAR AXLE

Structure, Procedures and Suggestions for Removal and Installation, Procedures and Suggestions for Disassembly and Reassembly, Adjustment, Troubleshooting, Service Data

6

BRAKE SYSTEM

Specifications, Structure and Functions, Procedures and Suggestions for Disassembly, Inspection and Reassembly, Inspection and Adjustment, Troubleshooting, Service Data

7

STEERING SYSTEM

Specifications, Structure and Functions, Procedures and Suggestions for Removal and Installation, Steering Control Valve, Hydraulic Circuit Diagram, Troubleshooting, Service Data

8

HYDRAULIC SYSTEM

Specifications, Finger-tip Control Type, Mechanical Control Type, Troubleshooting, Service Data

9

MAST AND FORK

Structure and Functions, Removal and Installation, Disassembly and Reassembly, Inspection and Adjustment, Troubleshooting, Service Data

10

SERVICE DATA

Inspection Standards, Periodic Replacement of Parts, Lubrication Standards, Main Component Weights, Tightening Torque for Standard Bolts and Nuts, Special Tool Table

11

OPTIONS

Backup Buzzer Kit, Tire Kit (Non Mark), Foot Direction Control Kit

12


GENERAL INFORMATION 1 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


GENERAL INFORMATION

Vehicle Exterior

FC armrest (FC models)

Control lever (MC models)

213466

Models This manual applies to FB20K PAC, FB25K PAC, FB30K PAC and FB35K PAC.

Class

Truck Model

Serial Number

2 ton

FB20K PAC

EFB8C-00011-up

2.5 ton

FB25K PAC

EFB8C-50001-up

3 ton

FB30K PAC

EFB9C-00011-up

3.5 ton

FB35K PAC

EFB9C-50001-up

1-1


GENERAL INFORMATION

Serial Number Locations

Mast number

Chassis number

Nameplate

208204

1-2


GENERAL INFORMATION

Chassis and Mast Model Identification

[Chassis] FB

20

K

PAC AC motor Generation designator

Maximum capacity 20: 2000 kg (4400 lb) 25: 2500 kg (5500 lb) 30: 3000 kg (6600 lb) 35: 3500 kg (7700 lb) Battery type

[Mast] 4

R

35

C

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 35: 3.5 ton class

Kind of mast R: simplex mast S: duplex mast Y: triplex mast Major change (“2” for the original, “3” for the first change, and so on up to “9”)

1-3


GENERAL INFORMATION

Dimensions

B

E

F

C

D A

213443

1-4


GENERAL INFORMATION

Technical Data Truck model Class

FB20K PAC

FB25K PAC

2.0 ton

2.5 ton

Load capacity/load center

N (kgf)/mm [1bf/in.]

19600 (2000)/500 [4400/20]

24500 (2500)/500 [5500/20]

Truck size

Length to fork face

A mm (in.)

2249 (88.5)

2274 (89.5)

Width

B mm (in.)

1190 (46.9)

1190 (46.9)

Height of overhead guard C mm (in.)

2200 (86.6)

2200 (86.6)

D mm (in.)

1520 (59.8)

1520 (59.8)

kg (lb)

2775 (6118)

2995 (6603)

990/898 (39.0/35.4)

990/898 (39.0/35.4)

Front

23 x 9 – 10

23 x 9 – 10

Rear

18 x 7 – 8

18 x 7 – 8

1950 (76.8)

1970 (77.6)

Wheelbase Truck weight (w/o battery)

E/F mm (in.)

Tread Front/rear Tires size

Turning radius

mm (in.)

Travel speeds Unloaded/loaded

km/h (mph)

20.0/20.0 (12.4/12.4)

20.0/20.0 (12.4/12.4)

Lifting speeds Unloaded/loaded

m (in.)/sec

0.65/0.55 (25.6/21.7)

0.65/0.50 (25.6/19.7)

Lowering speeds Unloaded/loaded

m (in.)/sec

0.50/0.50 (19.7/19.7)

0.50/0.50 (19.7/19.7)

V

80

80

Ah

600

600

mm (in.)

1025 x 708 x 769 (40.4 x 27.9 x 30.3)

1025 x 708 x 769 (40.4 x 27.9 x 30.3)

1385 (3053)

1385 (3053)

6° – 8°

6° – 8°

Battery voltage Battery rated capacity (5 hrs.) MAX Battery compartment size Battery weight

kg (lb)

Tilt angle (forwards – backwards) Traction motor capacity

(60 min. short duty)

kW

14.5

14.5

Pump motor output

@ 15% duty factor

kW

20.0

20.0

Steering pump motor output (60 min. short duty) kW

1.2

1.2

Traction motor control method

MOS-FET

MOS-FET

Pump motor control method

MOS-FET

MOS-FET

1-5


GENERAL INFORMATION

Truck model Class

FB30K PAC

FB35K PAC

3.0 ton

3.5 ton

Load capacity/load center

N (kgf)/mm [1bf/in.]

29400 (3000)/500 [6600/20]

34300 (3500)/500 [7700/20]

Truck size

Length to fork face

A mm (in.)

2522 (99.3)

2577 (101.5)

Width

B mm (in.)

1230 (48.4)

1230 (48.4)

Height of overhead guard C mm (in.)

2250 (88.6)

2259 (88.9)

D mm (in.)

1690 (66.5)

1690 (66.5)

kg (lb)

3231 (7123)

3665 (8080)

990/898 (39.0/35.4)

990/898 (39.0/35.4)

Front

28 x 9 – 15

250 – 15

Rear

18 x 7 – 8

18 x 7 – 8

2180 (85.8)

2230 (87.8)

Wheelbase Truck weight (w/o battery)

E/F mm (in.)

Tread Front/rear Tires size

Turning radius

mm (in.)

Travel speeds Unloaded/loaded

km/h (mph)

20.0/20.0 (12.4/12.4)

18.0/16.5 (11.2/10.3)

Lifting speeds Unloaded/loaded

m (in.)/sec

0.60/0.45 (23.6/17.7)

0.55/0.40 (21.7/15.7)

Lowering speeds Unloaded/loaded

m (in.)/sec

0.50/0.50 (19.7/19.7)

0.50/0.50 (19.7/19.7)

V

80

80

Ah

750

750

mm (in.)

1025 x 852 x 769 (40.4 x 33.5 x 30.3)

1025 x 852 x 769 (40.4 x 33.5 x 30.3)

1872 (4127)

1872 (4127)

6° – 8°

6° – 8°

Battery voltage Battery rated capacity (5 hrs.) MAX Battery compartment size Battery weight

kg (lb)

Tilt angle (forwards – backwards) Traction motor capacity

(60 min. short duty)

kW

14.5

14.5

Pump motor output

@ 15% duty factor

kW

20.0

20.0

Steering pump motor output (60 min. short duty) kW

1.2

1.2

Traction motor control method

MOS-FET

MOS-FET

Pump motor control method

MOS-FET

MOS-FET

1-6


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VEHICLE ELECTRICAL COMPONENTS Electrical Component Locations .......................................................... 2 – 1 Console Box ............................................................................................. 2 – 5 Functions of Central Vehicle Monitor System (CVMS) ............................... 2 – 5 Electrical Components in Console Box ..................................................... 2 – 8 Disassembly and Reassembly .................................................................. 2 – 9

Direction Lever ......................................................................................... Accelerator Control ................................................................................. Key Switch ................................................................................................ Lighting Switch ......................................................................................... Fuses ......................................................................................................... Lamp Specification Chart ....................................................................... Auto-light System .................................................................................... Troubleshooting of Lighting and Horn Systems ................................ Electrical System of FC (Finger-tip Control System) .......................

2 – 10 2 – 11 2 – 12 2 – 12 2 – 13 2 – 13 2 – 14 2 – 15 2 – 16

Nomenclature ........................................................................................... 2 – 16 Precautions to be taken when handling FC system .................................. 2 – 17 Description ................................................................................................ 2 – 17 Operating Principles ................................................................................. 2 – 18 How to Set Controller (Setup Option Setting) ........................................... 2 – 20 Troubleshooting ........................................................................................ 2 – 21

2


VEHICLE ELECTRICAL COMPONENTS

Electrical Component Locations

Detail "A" 6

1

7

2

A

3 4

5

9

8

Detail "B"

13

10 B 12

11 213444

1 2 3 4 5 6 7

Central vehicle monitoring system (CVMS) Direction lever Lighting switch Key switch Auto-light switch Head lamp Auto-light sensor

8 9 10 11 12 13

2-1

Contactor Fuse holder DC/DC converter Horn Foot brake switch FC hydraulic control valve


VEHICLE ELECTRICAL COMPONENTS

14

15

211649

14 Parking brake switch

15 Brake fluid level sensor

2-2

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