Service Manual Chassis & Mast FD40N FD45N FD50CN FD50N FD55N
EF12B-00011-up
FG40N FG45N FG50CN FG50N FG55N
EF40-00011-up
MC/FC
EF19D-50001-up EF19D-80001-up EF28C-50001-up EF28C-80001-up
EF29D-50001-up EF29D-80001-up EF33C-50001-up EF33C-80001-up
For use with S6S and TB45 Engine Service Manuals.
99739-57100
CHAPTER INDEX CHAPTER INDEX
CHAPTER INDEX
Items
GENERAL INFORMATION
Truck Models Covered, Serial Number Locations, Dimensions, Technical Data
1
COOLING SYSTEM
Fan Belt Removal and Installation, Fan Belt Tension
2
ELECTRICAL SYSTEM
Console Box, Chassis Electrical Devices, Battery Maintenance, Electrical Schematic
3
CONTROLLERS
Main Functions of Controller, Input/Output Monitor, Error Codes and Troubleshooting
4
POWER TRAIN
Removal and Installation of Power Line
5
POWERSHIFT TRANSMISSION
Torque Converter, Singe Speed Powershift Transmission Control Valve, Automatic Two-Speed Transmission
6
FRONT AXLE AND REDUCTION DIFFERENTIAL
Front Tire, Front Axle, Reduction, Differential
7
REAR AXLE
Rear Axle, Rear Tire
8
BRAKE SYSTEM
Master Cylinder, Wheel Brake, Brake Booster
9
STEERING SYSTEM
Steering Gear, Power Cylinder, Flow Divider
10
HYDRAULIC SYSTEM
Tank, Pump, Control Valve, Lift and Tilt Cylinders, Flow Regulator Valve, Down Safety Valve
11
MAST AND FORKS
Simplex and Duplex Masts, Triplex Mast
12
SERVICE DATA
Maintenance Standard, Maintenance Schedule, Periodic Replacement Parts, Lubrication Instruction, Special Tool Needed
13
Chapter 1 GENERAL INFORMATION 1.
Model View............................................................................................... 1-1
2.
Lift Truck Models Covered ..................................................................... 1-2
3.
Serial Number Locations........................................................................ 1-3
4.
Dimensions.............................................................................................. 1-4
5.
Technical Data......................................................................................... 1-5
6.
Performance ............................................................................................ 1-6
1
GENERAL INFORMATION
1. Model View
Chapter 1 GENERAL INFORMATION
MC model
215315
FC model
215316
1-1
GENERAL INFORMATION
2. Lift Truck Models Covered This Service Manual provides service and maintenance information for the following lift trucks: Mounted engine
Gasoline model
Diesel model
Non-electronic control
-
MC / FC
Electronic control
MC / FC
-
Electronic Gasoline engine models
Non-electronic diesel engine models
Truck model
Serial number
Mounted engine
Truck model
Serial number
Mounted engine
FG40N
EF40-00011-up
TB45
FD40N
EF12B-00011-up
S6S
FG45N
EF29D-50001-up
TB45
FD45N
EF19D-50001-up
S6S
FG50CN
EF29D-80001-up
TB45
FD50CN
EF19D-80001-up
S6S
FG50N
EF33C-50001-up
TB45
FD50N
EF28C-50001-up
S6S
FG55N
EF33C-80001-up
TB45
FD55N
EF28C-80001-up
S6S
1-2
GENERAL INFORMATION
3. Serial Number Locations
Name plate
Gasoline engine model serial number
Diesel engine model serial number
Mast serial number
Chassis serial number
Transmission serial number
215340
1-3
GENERAL INFORMATION
4. Dimensions
K
G
L
C
O
E
J
A H
I
B
P
D
N
M F
215339
1-4
GENERAL INFORMATION
5. Technical Data Unit:mm (in.) class Truck model
4 ton class
5 ton class
Gasoline model
FG40N
FG45N
FG50CN
FG50N
FG55N
Diesel model
FD40N
FD45N
FD50CN
FD50N
FD55N
A Maximum lift B Free lift height
3350 (132)
3360 (132.5)
150 (5.9)
160 (6.3)
C Fork spread <min - max>
320 - 1184 (12.6 - 46.6)
D Fork length
1220 (48.0)
E Tilt angle <forward - backward>
Deg
F Overall length Overall width G <outside-to-outside of tires>
3000 (118) Single
3130 (123)
1415 (55.5)
Special double
1965 (77.5) 2320 (91.5)
Tread K <front wheel>
2400 (94.5)
4570 (180) 4230 (167)
4590 (181) 4190 (165)
Single
1175 (46.5)
Double
1310 (51.5)
Special double
1445 (57.0)
L Tread <rear wheel> M Wheelbase N Front overhang O Minimum turning radius P Under clearance <at frame>
3360 (132)
2280 (89.5)
With backrest Without backrest
3310 (130)
1460 (57.5) 1780 (70.0)
Height of the overhead guard
Overall height J <with mast extended>
3170 (125)
Double
H Overall height <with mast lowered> I
6 - 10
4330 (170)
1180 (46.5) 1850 (73.0)
2000 (78.5)
577 (22.7) 2580 (101)
2730 (107)
582 (22.9) 2760 (109)
2150 (84.5) 602 (23.7) 2890 (114)
2940 (116)
227 (8.9)
1-5
GENERAL INFORMATION
6. Performance Truck model
Class
Gasoline model
Truck model
4 ton class
kg (lb)
Capacity Load center
FG40N
FG45N
FG50CN
FG50N
FG55N
3500 (8000)
4000 (9000)
4500 (10000)
5000 (11000)
5500 (12000)
mm (in.) Loaded
570 (110)
490 (96)
2FF mast
530 (105)
430 (85)
530 (105)
450 (89)
600 (120)
520 (100)
2FF mast
560 (110)
460 (90)
3FF mast
560 (110)
480 (94)
2SP mast Unloaded
Loaded Forward Travel speed
mm/s (fpm)
1st speed
13.5 (8.5)
2nd speed
22.0 (14.0)
1st speed km/h 2nd speed (mph)
22.5 (14.0)
Loaded
1st speed
18.5 (11.5)
Unloaded
1st speed
Unloaded Reverse
600 (24)
2SP mast 3FF mast
Lift speed
Truck model
Class
Diesel model
Truck model
19.0 (12.0)
kg (lb)
Load center
FD45N
FD50CN
FD50N
FD55N
3500 (8000)
4000 (9000)
4500 (10000)
5000 (11000)
5500 (12000)
Loaded Forward Travel speed
Unloaded Reverse
600 (24) 550 (110)
470 (93)
2FF mast
510 (100)
420 (83)
520 (102)
440 (86)
610 (120)
530 (105)
2FF mast
570 (112)
470 (92)
3FF mast
570 (112)
490 (96)
2SP mast Unloaded
5 ton class
2SP mast 3FF mast
Lift speed
18.5 (11.5)
FD40N
mm (in.) Loaded
21.5 (13.5)
13.5 (8.5)
4 ton class
Capacity
1-6
5 ton class
mm/s (fpm)
13.5 (8.5)
1st speed 2nd speed 1st speed
km/h 2nd speed (mph)
Loaded
1st speed
Unloaded
1st speed
21.5 (13.5)
21.0 (13.0) 13.5 (8.5) 22.0 (13.5) 18.0 (11.0) 18.5 (11.5)
17.5 (11.0)
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Chapter 2 COOLING SYSTEM 1.
Specifications.......................................................................................... 2-1
2.
Structure .................................................................................................. 2-2
3.
Removal and Installation........................................................................ 2-3 3.1
4.
Inspection and Adjustment .................................................................... 2-5 4.1 4.2 4.3 4.4
5.
Fan Belt Removal .................................................................................................... 2-3 Fan Belt ................................................................................................................... 2-5 Radiator ................................................................................................................... 2-6 Upper Hose, Lower Hose ........................................................................................ 2-6 Coolant .................................................................................................................... 2-7
Troubleshooting...................................................................................... 2-8
2
COOLING SYSTEM Chapter 2 COOLING SYSTEM
1. Specifications Truck model Item Cooling method Cooling system
Radiator
FG40N
FG45N
FG50CN
FG50N
FG55N
FD40N
FD45N
FD50CN
FD50N
FD55N
Water-cooled, forced circulation Corrugated fin (pressure) type
Water pump
Centrifugal type
Thermostat
Wax pellet type
2-1
COOLING SYSTEM
2. Structure 3
4
3
4
2 2
7
7
1
1
5
5
6 Gasoline model
1 2 3 4
Engine Fan (coupled directly to the engine crankshaft) Shroud Radiator
2-2
6 Diesel model
5 Oil cooler for torque converter 6 Reserve tank 7 Radiator cap
215476
COOLING SYSTEM
3. Removal and Installation 3.1 Fan Belt Removal 1
1
2
3
3
Gasoline model
Diesel model 215477
1 Tension assembly (pulley lock bolt) 2 Alternator lock bolt
3 Fan belt
3.1.1 Start by Remove the radiator cover.
2-3