TCM FB10-7 Service Manual
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TCM FB10-7 Service Manual

Forklift truck
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FORKLIFT TRUCK
TCM CORPORATION
No. SEB-81BBE
Counter Balanced
FB10
FB15
FB18
FB20
FB25
FB30
FB25
FB25
FB30
FB35
-7
-7
-7
-7
-7
-7
-7LB
-7V
-7V
-7S

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Summary of Contents for TCM FB10-7

  • Page 1 No. SEB-81BBE FORKLIFT TRUCK Counter Balanced FB10 FB15 FB18 FB20 FB25 FB30 FB25 -7LB FB25 FB30 FB35 TCM CORPORATION...
  • Page 3 No. SEB-81BBE FOREWORD The new TCM’s FB-7 Series battery-powered forklift trucks are provided with a newly designed speed control system and an AC traction motor to assure high performance. The trucks of this series are provided with a self-diagnosis function which keeps watching the operating statuses of the main systems of the truck.
  • Page 4 No. SEB-81BBE...
  • Page 5 No. SEB-81BBE SPECIFICATIONS (1) Model FB10-7 FB15-7 FB18-7 Item Performance Max. load kg [lbf] 1000 [2000] 1500 [3000] 1750 [3500] Load center mm [in.] 500 [24] ← ← Max. lifting height mm [in.] 3000 [118.1] ← ← Tilting angle °...
  • Page 6 No. SEB-81BBE SPECIFICATIONS (2) Model FB25-7LB FB20-7 FB25-7 Item FB25-7V Performance ← Max. load kg [lbf] 2000 [4000] 2500 [5000] ← ← Load center mm [in.] 500 [24] ← ← Max. lifting height mm [in.] 3000 [118.1] Tilting angle ← ←...
  • Page 7 No. SEB-81BBE SPECIFICATIONS (3) FB30-7 Model FB35-7S Item FB30-7V Performance Max. load kg [lbf] 3000 [6000] 3500 [7000] Load center mm [in.] 500 [24] ← Max. lifting height mm [in.] 3000 [118.1] ← Tilting angle ° ← ° Free lift A mm [in.] 165 [6.5] 150 [5.9]...
  • Page 8 No. SEB-81BBE...
  • Page 9 No. SEB-81BBE Unit: mm [in.] Fig. 1 Overall Dimensions...
  • Page 10 No. SEB-81BBE...

  • Page 11: Table Of Contents

    No. SEB-81BBE CONTENTS 1. BATTERY AND CHARGER ....................1.1 GENERAL DESCRIPTION ....................... 1.1.1 BATTERY ..........................1.1.2 CHARGER ........................... 1.1.3 CHARGING PROCEDURES ....................13 1.1.4 CHARGER OPERATION ....................15 2. MOTORS ............................ 17 2.1 GENERAL DESCRIPTION ....................... 17 2.1.1 DRIVE MOTOR ........................17 2.1.2 PUMP MOTOR ........................
  • Page 12 No. SEB-81BBE 5.2.5 ADJUSTING BRAKE PEDAL .................... 77 5.2.6 TROUBLESHOOTING GUIDE ..................78 6. STEERING SYSTEM ......................79 6.1 GENERAL DESCRIPTION ....................... 79 6.1.1 OUTLINE OF STEERING SYSTEM ................... 80 6.1.2 STEERING GEARBOX ......................81 6.1.3 ACTUATOR .......................... 84 6.1.4 REAR AXLE ......................... 84 6.1.5 ADJUSTING PRELOAD OF REAR WHEEL BEARING ...........

  • Page 13: Battery And Charger

    The description in this section applies to our optional batteries and chargers. For other types of batteries and chargers, refer to their respective instruction manuals. The description of the VTM unit applies to all the trucks because the VTM unit is standard equipment. Truck model FB15-7 FB10-7 FB20-7 FB25-7 Item FB18-7...

  • Page 14: General Description

    1. BATTERY AND CHARGER 1.1 GENERAL DESCRIPTION 1.1.1 BATTERY The battery unit consists of twenty-four 2-volt battery cells connected in series. Figure 1.1 shows its construction. LOCK PIN ELECTROLYTE LEVEL INDICATOR BATTERY CELL WITH ELECTROLYTE LEVEL SENSOR Note: The sketch shows a 48-volt battery unit. The 72-volt battery unit has 36 battery cells. Fig.
  • Page 15 1. BATTERY AND CHARGER Specific gravity (at 20°C) Voltage (V) Voltage Alert ! Specific gravity (Discharge duration) (Discharge rate) Fig. 1.3 An Example of Specific Gravity Drop (2) Charging the battery When discharged, the battery should be recharged as soon as possible. Leaving the battery discharged for a long time may cause sulfation, which will result in a drop of the battery performance.

  • Page 16: Charger

    1. BATTERY AND CHARGER 1.1.2 CHARGER The charger mounted on the truck is a computer-controlled, semiconstant-voltage type consisting of a transformer, diodes, an operation panel, and a VTM unit. Thermal relay current settings BAND INSULATION TUBE Transformer model Setting (A) INSULATION TUBE M80B M80C...
  • Page 17 1. BATTERY AND CHARGER (1) Transformer The transformer is located at the right side frame and converts input voltage to a voltage of the level necessary for charging the battery. There are three taps provided with a 10-volt difference from one to another. Make a selection among them at the input side according to the input voltage level.
  • Page 18 1. BATTERY AND CHARGER (2) Diode The diode, installed on the speed controller, is a 3-phase, full-wave rectification type which converts AC to DC. The current rectified by the diode flows through the fuse F6 to charge the battery. fUSE (130A) (fB25-7LB, fB25-7V: 200A) POSITIVE TERMINAL...
  • Page 19 1. BATTERY AND CHARGER (3) Operation panel The operation panel is located on the left side of the cabinet and equipped with a charger control switches, lamps and service power outlet. Fig. 1.7 Operation Panel (4) VTM unit The VTM unit is installed inside the right side frame. It sets the charging time for the battery assembly by the signal from the operation panel.
  • Page 20 1. BATTERY AND CHARGER The VTM unit has two timers: One is called first timer and the other second timer. It is the first timer on which the microprocessor sets the charging time (4 hours maximum). The time to be set on the second timer is 15 hours for normal charging. If a single charging continues longer than that duration, charging is treated as an abnormal termination.
  • Page 21 1. BATTERY AND CHARGER COMMUNICATION 4-DIGIT ROTARY SWITCH SWITCHES (MODE, HIGH, LOW) SETTING MODE SYMBOL ROTARY SWITCH CALLING UP 4-DIGIT LED Fig. 1.9 VTM Unit (for trucks manufactured on and after February 1, 2004) - 9 -...
  • Page 22 Observe the following conditions when changing those settings. Note 1. When changing those settings on the VTM unit, inform your local TCM dealer of the model name, chassis serial number of the truck you are going to change those settings, and the user name of the said truck.
  • Page 23 1. BATTERY AND CHARGER [Procedure for changing VTM settings] (for trucks manufactured earlier than January 31, 2004) ① Park the truck on a level surface and turn the key switch off. ② Disconnect the battery connectors. ③ Remove the left side cover of the truck. ④...
  • Page 24 1. BATTERY AND CHARGER [Procedure for changing VTM settings] (for trucks manufactured on and after February 1, 2004) ① Preparations Park the truck on a level surface, turn the key switch off, and then disconnect the battery connectors. Remove the right side cover of the truck and then remove the VTM unit cover. Connect the battery connectors.

  • Page 25: Charging Procedures

    1. BATTERY AND CHARGER 1.1.3 CHARGING PROCEDURES (1) Normal charge ① Turn off the key switch and apply the parking brake. ② Make sure that the power supply at the facility side is off and insert the plug into the receptacle at the truck side.
  • Page 26 However, for the truck-mounted type charger, the second timer is operated after charging the battery for 15 to 17 hours, so that the charging is forcibly terminated and the CHARGING lamp blinks. In such a case, inspect the cause and contact your TCM dealer. Note: Have a helper for this procedure.

  • Page 27: Charger Operation

    1. BATTERY AND CHARGER 1.1.4 CHARGER OPERATION (1) When the power switch is turned on, the charger is made ready for operation by the photocoupler in the VTM unit. (2) When the START button (PB1) is pressed, a circuit formed through the magnet switch CM, thermal relay TH, and the terminal V-25 of the VTM unit, and at the same time the battery voltage is applied for the terminal M-10 of the meter panel.
  • Page 28 1. BATTERY AND CHARGER NOTE - 16 -...

  • Page 29: Motors

    2. MOTORS 2. MOTORS Truck model FB30-7 FB10-7 FB15-7 FB20-7 FB25-7 FB30-7V FB18-7 FB25-7LB FB25-7V Item FB35-7S Drive motor Name HO-NR Type Self-ventilated, 3-phase induction motor Rated output 11.5 kW (3-min rate) 13.1 kW (3-min rate) 17.3 kW (3-min rate) Rated voltage 24.5 V...
  • Page 30 2. MOTORS DRIVE AXLE DRIVE MOTOR DRIVE UNIT Fig. 2.1 Drive Motor Installation - 18 -...
  • Page 31 2. MOTORS THERMO-SENSOR CONNECTOR REAR BRACKET FRONT BRACKET SLITTED DISC W PHASE SPEED SENSOR A V PHASE SPEED SENSOR B SLITTED DISC U PHASE Detail of Sensor Two slitted discs are joined by aligning their respective teeth. WAVE WASHER SNAP RING View looking from A Detail of Slitted Discs Fig.
  • Page 32 2. MOTORS ■ Operating principle of 3-phase induction motor As shown in Fig. 2.3, when the magnetic poles N and S are rotated outside the rectangular oil, the coil side cuts the magnetic flux to induce electromotive force in the direction indicated in the figure, thus (Rotating flowing circulating current inside the coil.

  • Page 33: Pump Motor

    2. MOTORS 2.1.2 PUMP MOTOR The pump motor is located on the left side frame and is used to drive the main pump. Its rotation is controlled by the load handling chopper built in the speed controller only when the lift lever is operated.
  • Page 34 2. MOTORS BRUSH WEAR INDICATOR THERMAL SWITCH CLAMP BRUSH FIELD COIL YOKE AMATURE BRUSH HOLDER BRUSH COVER Fig. 2.7 Pump Motor - 22 -...

  • Page 35: Maintenance

    2. MOTORS 2.2 MAINTENANCE 2.2.1 DRIVE MOTOR (1) Check the following points with the motor running Check item Location Criteria Remedy Dust Motor frame No remarkable deposit of dust allowed If too much deposit of compared with usual operation. dust is found, stop the Usual temperature rise.
  • Page 36 2. MOTORS (3) Periodic inspection ■ Inspection criteria Check the motor at periodic intervals, referring to the following troubleshooting chart. If the motor is used under a severe working condition, earlier or more frequent preventive maintenance is required. Operation time more than 12 hours/day 8 –...
  • Page 37 2. MOTORS ■ Inspection procedure Inspect the motors observing the following conditions: ① Select a place which is not dusty or humid. ② Parts which have been disassembled should be kept in order and the order of disassembly recorded to ensure correct reassembly. Screws and wave washers removed should be put in order in boxes.
  • Page 38 2. MOTORS (4) Maintenance of bearings The service life of bearings varies with the magnitude of loads and operating conditions. Replace the bearings with new ones when the temperature rises excessively or produces noise. Sealed bearings sealing in lithium soap-based grease ensure effective lubrication and prevent the entrance of dust.

  • Page 39: Pump Motor

    2. MOTORS 2.2.2 PUMP MOTOR (1) Ball bearing In case when the ball bearing gives out abnormal noise or seizes up, remove it from the armature shaft. For removing the ball bearing, apply a force to the outer race of the bearing by using a small-sized puller.
  • Page 40 2. MOTORS (4) Checking the commutator The commutator is the most important part of the motor. If operated with oil or dust sticking to it, the brush will be abnormally worn and commutator operation will be disabled. Keep it always clean by removing such foreign matters by air blow or by wiping with dry, clean cloth.

  • Page 41: Control System

    3. CONTROL SYSTEM 3. CONTROL SYSTEM 3.1 GENERAL DESCRIPTION The control system consists primarily of an inverter assembly which controls the drive motor, a DC chopper which controls the pump motor, and a PS controller which controls the PS motor. 3.1.1 INVERTER The inverter converts direct current into 3-phase alternating current.
  • Page 42 3. CONTROL SYSTEM Fig. 3.2 Inverter Assembly (1.0- to 2.5-ton Trucks) - 30 -...
  • Page 43 3. CONTROL SYSTEM Fig. 3.3 Inverter Assembly (3.0- to 3.5-ton Trucks) - 31 -...
  • Page 44 3. CONTROL SYSTEM Fig. 3.4 Controller Wiring (1.0- to 2.5-ton Trucks) - 32 -...
  • Page 45 3. CONTROL SYSTEM Fig. 3.5 Controller Wiring (3.0- to 3.5-ton Trucks) - 33 -...

  • Page 46: Accelerator Pedal

    3. CONTROL SYSTEM 3.1.2 ACCELERATOR PEDAL The accelerator pedal is installed as shown in Fig.3.6, and the amount of accelerator pedal effort is transmitted to the potentiometer. The potentiometer converts pedal effort into voltage change and sends it to the controller. Connection diagram View looking from B LEVER...

  • Page 47: Interlock System

    • Don’t rest anything heavy on the operator’s seat; otherwise the driving interlock may fail to operate as it should. • If the operator’s seat is replaced with a new one, use a genuine TCM operator’s seat equipped with a seat switch.

  • Page 48: Back-Down Alarm System

    3. CONTROL SYSTEM ■ The interlock system is activated if any of the following conditions occurs. Operation of the truck Power Traction Pump steering ○ The key switch is turned to ON when the operator is not in the operator’s seat. ×...

  • Page 49: Maintenance

    3. CONTROL SYSTEM 3.2 MAINTENANCE 3.2.1 TROUBLESHOOTING GUIDE The CPU board of the controller has an LED (green) which shows the content of errors occurring in the truck, using their corresponding code numbers that are distinguished by different blinking intervals. Each error code is displayed by a 2-digit decimal number, with both the second and first digits blinking at an interval of 0.5 seconds while a pause of 1 second OFF is inserted between the second digit and the first digit. Once an error code is displayed, an OFF period of 4 seconds is inserted before the...
  • Page 50 3. CONTROL SYSTEM ■ Checking procedure by error code (1) Traveling system Remedy Problem Error Reset Remarks Proceed with remedy in numerical order of encircled numbers. Traveling power module The truck won’t move. Turn off the If any power module is ① Check traveling power modules (TMDU, shorted (MD contactor does not...
  • Page 51 3. CONTROL SYSTEM Remedy Problem Error Reset Remarks Proceed with remedy in numerical order of encircled numbers. Traveling accelerator The truck won’t move. Restore to Accelerator power supply ① Check harness between CN2-8, 9, 20 (CPU [301] output defective board) and traveling accelerator, and repair or normal.
  • Page 52 3. CONTROL SYSTEM Remedy Problem Error Reset Remarks Proceed with remedy in numerical order of encircled numbers. Traveling motor temp. The truck can move. Thermo sensor (THD) ① Cool down traveling motor. [502] rises abnormally (This error is detected ② Check the resistance/voltage of traveling motor traveling voltage under normal when the traveling...
  • Page 53 3. CONTROL SYSTEM Remedy Problem Error Reset Remarks Proceed with remedy in numerical order of encircled numbers. Load dump error Neither traveling or load Restore to Power module bridge ① Check battery connectors and connection [501] handling system does harness, and repair if needed. normal.
  • Page 54 3. CONTROL SYSTEM (2) Load handling system Remedy Problem Error Reset Remarks Proceed with remedy in numerical order of encircled numbers. Load handling power The load handling Turn key If the power module is ① Check load handling power module (TMP) and [403] module shorted system does not work. change if needed.
  • Page 55 3. CONTROL SYSTEM Remedy Problem Error Reset Remarks Proceed with remedy in numerical order of encircled numbers. Load handling contactor Load handling system Turn off ① Check load handling contactor (MP), and repair [405] (MP) shorted does not work. or change if needed. key switch. Detection circuit harness (seized contact points or mechanical hitch) defective ②...
  • Page 56 3. CONTROL SYSTEM (3) PS system Remedy Problem Error Reset Remarks Proceed with remedy in numerical order of encircled numbers. PS main Tr. shorted Hard steering wheel (PS ① Check main Tr. (TMPS1, 2) and change if needed. Turn off [403] does not work) (When changing either of the TMPS1 or 2, key switch. (MPS contactor does not change the other one, too, along with EPS board.) close.) ②...
  • Page 57 3. CONTROL SYSTEM ■ Inspecting controller components Do not touch any electrical component with the truck in conduction. When it is necessary to touch an electrical component for any reason, such as inspection or maintenance, disconnect the battery connectors and wait for more than 2 minutes before starting the operation. If avoidable to inspect an energized truck, raise the drive wheels off the floor or ground to prevent the truck from moving accidentally when the motor suddenly starts rotating for any reason.
  • Page 58 3. CONTROL SYSTEM Where to tighten Screw Torque Symbol Truck Model Remarks Part name Item size (N-m) Shunt R Fixed Common MBP20A10MJN 1.5 ± 0.2 Terminal 1.3 ± 0.2 Terminal Fixed +, DU, DV, DW Common 1P-M8X40-M 12 ± 1 Terminal PA, CH, F terminal 9.8 ± 1 Terminal Fixed Common 1P-M8X36X8 12± 1 Terminal 9.8 ± 1 Hex. stud Fixed +, PB...
  • Page 59 3. CONTROL SYSTEM 2. CPU board and power supply board The CPU board controls the controller and the power supply board supplies electric power to the CPU board, FET power module drive circuit and sensors. Visually check the CPU board and power supply board for scores, scratches, or undue discoloration, and connectors for corrosion, observing the following conditions: •...
  • Page 60 3. CONTROL SYSTEM 3. Checking traveling/load handling power modules (TMDU, TMDV, TMDW, TMP) (1) Composition of FET power module Multiple FETs connected in parallel are connected in series vertically to form a half bridge. Each FET lets electric current flow from the drain (D) to source (S) when a voltage is applied between the gate (G) and source (S). Fig.
  • Page 61 3. CONTROL SYSTEM (3) Checking embedded temperature sensor The U-phase power module (TMDU) and load handling power module (TMP) have temperature sensors embedded to monitor the temperature of the power module. When the temperature sensor detects an abnormal temperature of the module, the output current is restricted.
  • Page 62 3. CONTROL SYSTEM 4. Checking fuses If an overcurrent flows through the main circuit, the fuses will blow to prevent damage to the controller and the possibility of catching fire. When checking the fuses on the truck, measure the battery voltage in advance. F3 UPPER TERMINAL F2 UPPER TERMINAL F2 LOWER TERMINAL F1 UPPER TERMINAL F3 LOWER TERMINAL F1 LOWER TERMINAL Fig.
  • Page 63 3. CONTROL SYSTEM (3) Checking PS fuse (F3) ① Set the tester to the voltage measurement range and attach the negative pole of the tester to the negative cable connection terminal of the controller. ② Attach the positive pole of the tester to the upper terminal of the F3 fuse and then to the lower terminal to measure the voltage at each terminal.
  • Page 64 3. CONTROL SYSTEM 6. Checking PS transistors (TMPS1, TMPS2) The PS drive transistors are two IGBT modules which form an H bridge. ① Visually check the transistors for scores, scratches, damage, or excessive discoloration. ② Remove all the cables from the module you are going to check, and measure the resistance between terminals using the tester according to the table given below.
  • Page 65 3. CONTROL SYSTEM (2) Checking contactor coils ① Remove the coil wiring connector. ② Set the tester to a resistance range of 100 Ω and MPS CONTACTOR MOVABLE measure the resistance between terminals using CONTACT the tester. ③ Judge whether the coil is good or not using the measured values. CONTACT Judgment Contactor...
  • Page 66 3. CONTROL SYSTEM 10. Checking motor thermo sensor The traveling motor has a thermo sensor embedded to monitor the motor temperature at all times. If the temperature monitored by the sensor exceeds a certain level, the output current is restricted. ①...

  • Page 67: Drive Unit And Drive Axle

    4. DRIVE UNIT AND DRIVE AXLE 4. DRIVE UNIT AND DRIVE AXLE Truck model FB30-7 FB10-7 FB15-7 FB20-7 FB25-7 FB30-7V FB18-7 FB25-7LB FB25-7V Item FB35-7S Drive unit Type Three-stage reduction ← ← Model 81E-25 81N-25 81U-25 Reduction ratio 25.1 30.144 ←...
  • Page 68 4. DRIVE UNIT AND DRIVE AXLE RING GEAR PINION SHAFT Tightening torque: 95 to 142 N-m WASHER {970 to 1450 kgf-cm} [840.8 to 1257 lbf-in.] PINION GEAR WASHER Tightening torque: 44 to 54 N-m SIDE GEAR {450 to 550 kgf-cm} [389.4 to 477.9 lbf-in.] COUNTER GEAR TAPER PIN...
  • Page 69 4. DRIVE UNIT AND DRIVE AXLE RING GEAR SPIDER Tightening torque: 95 to 142 N-m {970 to 1450 kgf-cm} WASHER [840.8 to 1257 lbf-in.] PINION GEAR WASHER SIDE GEAR Tightening torque: 44 to 54 N-m {450 to 550 kgf-cm} [389.4 to 477.9 lbf-in.] COUNTER GEAR Tightening torque: 34.3 to 44 N-m...
  • Page 70 4. DRIVE UNIT AND DRIVE AXLE Tightening torque: 137 to 177 N-m {1400 to 1800 kgf-cm} RING GEAR [1212.6 to 1566.6 lbf-in.] SPIDER Tightening torque: SIDE GEAR 95 to 142 N-m WASHER {970 to 1450 kgf-cm} [840.8 to 1257 lbf-in.] PINION GEAR WASHER COUNTER GEAR...

  • Page 71: Drive Axle

    4. DRIVE UNIT AND DRIVE AXLE 4.1.2 DRIVE AXLE The drive axle is composed of an axle housing, wheel hub, and wheels. It is mounted at the front side of the frame. At each end of the axle housing are a wheel hub and a wheel brake. The wheel hub is supported on the spindle by two taper roller bearings, and is driven by the axle shaft.
  • Page 72 4. DRIVE UNIT AND DRIVE AXLE Fig. 4.5 Drive Axle (2- to 2.5-ton Trucks) - 60 -...
  • Page 73 4. DRIVE UNIT AND DRIVE AXLE Fig. 4.6 Drive Axle (3.0- to 3.5-ton Trucks) - 61 -...
  • Page 74 4. DRIVE UNIT AND DRIVE AXLE ■ Procedure for installing the wheel hub (1) Put the specified amount of grease into the space of the wheel hub and install it onto the spindle. (2) Tighten the adjustment nut to approx. 98 N-m {1 kgf-m} [7.23 lbf-ft] torque and loosen it by 1/2 turn.

  • Page 75: Brake System

    5. BRAKE SYSTEM 5. BRAKE SYSTEM Model FB30-7 FB10-7 FB15-7 FB20-7 FB25-7 FB30-7V FB18-7 FB25-7LB FB25-7V Item FB35-7S Type Front two wheel braking, internal expansion, hydraulic type Pedal ratio ← ← Master cylinder bore 19.05 mm [0.75 in.] ← ←...
  • Page 76 5. BRAKE SYSTEM Fig. 5.2 Brake Pedal - 64 -...

  • Page 77: Master Cylinder

    5. BRAKE SYSTEM 5.1.2 MASTER CYLINDER The master cylinder is installed on the bracket of the brake pedal unit as shown in Fig. 5.3. Built in the master cylinder are a check valve, spring and piston. They are kept in position by a snap ring.

  • Page 78: Wheel Brake

    5. BRAKE SYSTEM 5.1.3 WHEEL BRAKE The wheel brake is duo-servo type, and is mounted on each of the both ends of the drive axle. ANCHOR PIN The wheel brake is composed of two pairs of brake shoes, a wheel cylinder and adjuster. One end of the brake shoe is contacted with the Working force anchor pin and another end is contacted with the...
  • Page 79 5. BRAKE SYSTEM (3) Automatic clearance adjuster The automatic clearance adjuster automatically keeps the lining-todrum clearance properly. The CABLE components are as shown in Fig. 5.7. It is put in GUIDE action when the brakes are applied while traveling backward. SPRING LEVER ADJUSTER...

  • Page 80: Parking Brake Lever

    5. BRAKE SYSTEM 5.1.4 PARKING BRAKE LEVER The parking brake lever is a toggle type and it is installed as shown in Fig. 5.9. An adjuster adjusting the braking force is located on the top of the lever. RELEASE PARKING BUTTON BRAKE LEVER View looking from C...
  • Page 81 5. BRAKE SYSTEM Sectional view D - D Sectional view C - C Sectional view E - E Shoe expanding direction Sectional view A - A Sectional view of wheel cyl. Sectional view B - B 1. BRAKE LEVER 8. SHOE HOLD-DOWN PIN 15.
  • Page 82 5. BRAKE SYSTEM Sectional view C - C Sectional view E - E Sectional view D - D Shoe expanding direction Sectional view A - A Sectional view B - B Sectional view of wheel cyl. 1. BRAKE LEVER 8. SHOE HOLD-DOWN PIN 15.

  • Page 83: Maintenance

    5. BRAKE SYSTEM 5.2 MAINTENANCE This section describes the procedure for disassembling, reassembling and adjusting the wheel brake and the procedure for adjusting the brake pedal, with the wheel brake and hub removed. 5.2.1 DISASSEMBLING WHEEL BRAKE (1) Remove the shoe hold-down pin, adjuster lever, adjuster and spring from the secondary shoe.
  • Page 84 5. BRAKE SYSTEM (4) Remove the primary and secondary shoes. Also remove the adjuster and adjuster spring at the same time. Fig. 5.16 (5) Remove the brake pipe from the wheel cylinder. Remove the bolts securing the wheel cylinder. Remove the wheel cylinder from the backing plate.

  • Page 85: Inspection

    5. BRAKE SYSTEM 5.2.2 INSPECTION Check each part and repair or replace any defective one. (1) Check the wheel cylinder inner surface and piston outer periphery for rust. Measure the clearance between the piston and cylinder. Standard: 0.03 to 0.10 mm [0.0012 to 0.0039 in.] Limit: 0.15 mm [0.0059 in.]...

  • Page 86: Reassembling Wheel Brake

    5. BRAKE SYSTEM 5.2.3 REASSEMBLING WHEEL BRAKE (1) Apply brake fluid to the cup and piston of the wheel cylinder. Install the spring, piston cup, piston and boot in this order. (2) Install the wheel cylinder on the backing plate. Tightening torque: 17.7 to 26.5 N-m {180 to 270 kgf-cm} [156.7 to 234.5 lbf-in.] (3) Install the backing plate on the drive axle. Tightening torque: 117.7 to 137.3 N-m {1200 to 1400 kgf-cm} [1042 to 1215 lbf-in.] (4) Apply high-temperature grease to the points shown in Fig.
  • Page 87 5. BRAKE SYSTEM (8) Install the shoe guide pin in the anchor pin, and install the shoe return spring. In this step, install the spring at first on the primary side and then on the secondary side. Fig. 5.25 (9) Install the spring, adjuster, adjuster spring and adjuster lever, paying attention to the following items: ①...

  • Page 88: Operation Test Of Automatic Clearance Adjuster

    5. BRAKE SYSTEM 5.2.4 OPERATION TEST OF AUTOMATIC CLEARANCE ADJUSTER (1) Set the outer diameter of the brake shoe to nearly the normal mounting dimension. Push up the adjuster lever and adjust the diameter, turning the teeth of the adjuster. When your finger is released, the teeth of the adjuster do not turn and the adjuster lever returns to the original position.

  • Page 89: Adjusting Brake Pedal

    5. BRAKE SYSTEM 5.2.5 ADJUSTING BRAKE PEDAL (1) Shorten the push rod length of the master cylinder. (2) Using the stopper bolt, adjust the pedal upheight to the value shown in Fig. 5.29. (3) Keeping the pedal pressed down by the pedal play, extend the push rod so that its tip contacts the piston of the master cylinder.

  • Page 90: Troubleshooting Guide

    5. BRAKE SYSTEM 5.2.6 TROUBLESHOOTING GUIDE Trouble Probable Cause Remedy 1. Brake fluid leaks from the brake system Repair. 2. Maladjustment of brake shoe clearance Check and adjust the adjuster. Poor braking 3. Overheating brake Check for dragging. force 4. Poor contact between brake drum and lining Adjust contact.

  • Page 91: Steering System

    6. STEERING SYSTEM 6. STEERING SYSTEM Model FB30-7 FB10-7 FB15-7 FB20-7 FB25-7 FB30-7V FB18-7 FB25-7LB FB25-7V Item FB35-7S Steering system Type Rear wheel steering, electric power steering Steering gear Type Ball nut type Name PU41 Reduction ratio 18.9 Operating angle 92°...

  • Page 92: Outline Of Steering System

    6. STEERING SYSTEM 6.1.1 OUTLINE OF STEERING SYSTEM As shown in Fig. 6.1, the steering system is composed of a steering gearbox, actuator, and controller. The steering gearbox is provided with a potentiometer which detects the steering handwheel operating force and sends to the controller a signal which corresponds to the strength and direction of the force.

  • Page 93: Steering Gearbox

    6. STEERING SYSTEM 6.1.2 STEERING GEARBOX The steering gearbox is constructed as shown in Fig. 6.2. Rotation of the steering handwheel is transmitted to the sector shaft by way of the ball nut screw. At the lower part of the steering gearbox unit is located the potentiometer which converts slight up-and-down movement of the steering shaft into a voltage and sends the voltage to the controller.
  • Page 94 6. STEERING SYSTEM STEERING HANDWHEEL STEERING WHEEL LOCK LEVER JOINT STEERING GEARBOX View looking from A DRAG LINK EPS ACTUATOR Fig. 6.3 Steering Linkage - 82 -...
  • Page 95 6. STEERING SYSTEM F/R LEVER LIGHTING SWITCH STEERING HANDWHEEL ASSEMBLY COMBINATION Front of SWITCH ASSEMBLY the truck STEERING SHAFT Front of the truck ASSEMBLY Assembly drawing View looking from C Front of the truck View looking from A View looking from B Adjusting the position of the combination switch angle sensor 1.

  • Page 96: Actuator

    6. STEERING SYSTEM 6.1.3 ACTUATOR The actuator is a ball and nut screw type. The screw lengthens and shortens according to motor operation. Motor operation is transmitted to the ball and nut unit after its speed is reduced by two gears. The ball and nut unit is supported by two taper roller bearings on the gearbox.
  • Page 97 6. STEERING SYSTEM NEEDLE BEARING OIL SEAL KNUCKLE (RIGHT) TIE ROD (RIGHT) Sectional view A - A CENTER ARM TIE ROD (LEFT) KNUCKLE (LEFT) OIL SEAL OIL SEAL TAPERED ROLLER BEARING NEEDLE BEARING THRUST ADJUSTMENT NUT BEARING COTTER PIN WASHER KING PIN TAPER PIN Detail of knuckle...
  • Page 98 6. STEERING SYSTEM KNUCKLE (RIGHT) TIE ROD (RIGHT) TIE ROD (LEFT) KNUCKLE (LEFT) CENTER ARM OIL SEAL OIL SEAL NEEDLE TAPERED ROLLER BEARING BEARING THRUST BEARING ADJUSTMENT NUT COTTER PIN WASHER KING PIN TAPER PIN Detail of knuckle Fig. 6.7 Rear Axle (2- to 3.5-ton Trucks) - 86 -...
  • Page 99 6. STEERING SYSTEM (1) Knuckle and king pin The king pin supporting the knuckle is secured to the knuckle side with the lock pin. Its upper and lower ends are each installed on the axle boss through each needle bearing. The thrust bearing is installed between the axle upper boss and the knuckle so that the knuckle rotates smoothly around the king pin with its load.

  • Page 100: Adjusting Preload Of Rear Wheel Bearing

    6. STEERING SYSTEM 6.1.5 ADJUSTING PRELOAD OF REAR WHEEL BEARING (1) As shown in Fig. 6.9, apply grease to the hub, inner bearing, outer bearing, and cap. Also apply grease to the oil seal lips. (2) Set the bearings on the hub, then installed the hub on the knuckle spindle. (3) Place a washer, then tighten the adjustment nut with a torque of 206 to 235 N-m {21 to 24 kgf-m} [1823 to 2080 lbf-in.].

  • Page 101: Assembling Wheel

    6. STEERING SYSTEM 6.1.6 ASSEMBLING WHEEL Put the tube and flap into the tire and assemble the rim paying attention to the following: Notes: 1. Align the air valve with the notch of the rim, directing the valve to the outside of the truck. 2.

  • Page 102: Maintenance

    6. STEERING SYSTEM 6.2 MAINTENANCE 6.2.1 MAINTENANCE FOR ACTUATOR (1) Replacing the motor ① As shown in Fig. 6.11, securely hold the actuator assembly by a vise. Note: Be sure to hold it in a lying position. Fig. 6.11 ② Remove the motor securing bolts, then remove the motor.
  • Page 103 6. STEERING SYSTEM (2) Replacing the ball joint ① Securely fix the ball joint with its connector held BOOT BALL JOINT in a vise. • Hold this section by vise Fig. 6.15 ② Loosen the lock nut of the ball joint, then remove the ball joint.
  • Page 104 6. STEERING SYSTEM ② Remove the clamp of the boot connector side. CLAMP LOCK NUT Shift the position of the boot. Then loosen the BOOT CLAMP connector lock nut, and remove the connector. • Note: Fix the ball joint to prevent it from turning. •...

  • Page 105: Maintenance Of Steering Bearbox

    6. STEERING SYSTEM 6.2.2 MAINTENANCE OF STEERING GEARBOX (1) Disassembling the steering gearbox ① Hold the pitman arm in a vise, and remove the fixing nut. Fig. 6.24 ② Move the pitman arm till the slit mark on the end surface of the sector shaft faces down, then hold the steering gear in a vise.
  • Page 106 6. STEERING SYSTEM ⑤ Install a set plate jig (See Fig. 6.61) on the front cover installing position. Tightening torque: 44 N-m {4.5 kgf-m} [32.5 lbf-ft] Fig. 6.28 ⑥ Extend outward the caulked part of the lock nut. Fig. 6.29 ⑦...
  • Page 107 6. STEERING SYSTEM ⑨ Remove the set plate. Pull out the sensor housing assembly, taking caution not to lose the spring. Then remove the thrust washer, needle bearing, and thrust washer. Fig. 6.32 ⑩ Remove the bolt securing the side cover. Remove the side cover and sector shaft as one unit.
  • Page 108 6. STEERING SYSTEM (2) Reassembling the steering gearbox ① Holding the gearbox by a vise, install the ball screw with its gear facing the sector shaft. Note: Be sure to apply grease to the oil seal lips and bearing. Fig. 6.35 ②...
  • Page 109 6. STEERING SYSTEM ⑤ Till the center of the ball nut gear is aligned with the center of the hole, turn the shaft. Fig. 6.39 ⑥ Align the center of the sector shaft gear with the center of the hole, then install the side cover with a packing.
  • Page 110 6. STEERING SYSTEM ⑨ Apply grease to the inside of the slide ring, then install it with spring. Fig. 6.43 ⑩ Install the set plate jig. Tightening torque: 44 N-m {4.5 kgf-m} [32.5 lbf-ft] Fig. 6.44 ⑪ Install the washer with an outer diameter of 40 mm [1.6 in.], needle bearing, and washer with an outer diameter of 31 mm [1.22 in.].
  • Page 111 6. STEERING SYSTEM ⑬ Leave your hand from the worm shaft. Caulk the nut at two positions by the caulking jig (See Fig. 6.61). Fig. 6.47 ⑭ Make sure that the nut does not show looseness when the worm shaft is turned clockwise. If still loose, caulk the nut again.
  • Page 112 6. STEERING SYSTEM (3) Adjustment ① Install the pitman arm on the sector shaft. While pushing and pulling the pitman arm with a force of about 19.6 N {2 kgf} [4.4 lbf], measure the backlash. Backlash: Below 0.35 mm [0.0138 in.] If not satisfied, take step that follows.
  • Page 113 6. STEERING SYSTEM ⑥ Apply grease to the roller of the potentiometer, put the roller in the arm, and then install the potentiometer by lightly tightening the fixing screw. Fig. 6.55 ⑦ Connect a tester, power supply unit, and VOLTMETER resistances to the connector of the potentiometer, (Sub) (Main)
  • Page 114 6. STEERING SYSTEM ⑩ Install the potentiometer cover. When installing, fix the wire harness with a clip. Fig. 6.59 ⑪ Hold the pitman arm by a vise, fix it with the nut. Tightening torque: 176.5 to 215.8 N-m {18 to 22 kgf-m} [130 to 159 lbf-ft] Fig.

  • Page 115: Hydraulic System

    7. HYDRAULIC SYSTEM 7. HYDRAULIC SYSTEM Truck model FB30-7 FB10-7 FB15-7 FB20-7 FB25-7 FB30-7V FB18-7 FB25-7LB FB25-7V Item FB35-7S Main pump ← ← Type Gear type Name TMG1A18 TMG1A20 TMG1A23 Discharge 18.9 c.c./rev 21 c.c./rev 24.5 c.c./rev ← ← Drive...

  • Page 116: Main Pump

    7. HYDRAULIC SYSTEM 7.1.1 MAIN PUMP The main pump is a gear type as shown in Fig. 7.1. The main pump consists of a pump body, a pair of gears, bushings and packings. To minimize the gap between the gears’ side-faces, pressure-balanced type bearings and lubrication method are used. The pressure-balanced type directs part of the oil discharged from the main pump into between the pressure plate and pump body, to press the pressure plate toward the gear side.
  • Page 117 7. HYDRAULIC SYSTEM LIFT SPOOL TILT SPOOL PORT G PORT B2 PORT T PORT A2 PORT A1 PORT P RELIEF VALVE SOLENOID VALVE POTENTIOMETER Fig. 7.2 Control Valve - 105 -...
  • Page 118 7. HYDRAULIC SYSTEM (1) Valve control The control valve plungers are operated with the levers shown in Figure 7.3, with each of the levers installed on a single shaft. The bracket supporting each shaft is attached to the front guard. The movement of each lever is transmitted through the rod to the corresponding plunger.
  • Page 119 7. HYDRAULIC SYSTEM (2) Oil pressure adjustment ① Remove the plug of the check port (G) located in the inlet section of the control valve, then set there a 20 MPa {200 kgf/cm } [2901 psi] capacity oil pressure gauge. ②...

  • Page 120: Hydraulic Oil Tank

    7. HYDRAULIC SYSTEM 7.1.3 HYDRAULIC OIL TANK The hydraulic oil tank is located at the center of the frame. In the tank, a suction filter and a return filter are provided for the purpose of ensuring clean oil supply. FB10 - 18: 18L FB20 - 35: 25L OIL FILL CAP RETURN FILTER...

  • Page 121: Lift Cylinder

    7. HYDRAULIC SYSTEM 7.1.4 LIFT CYLINDER The two lift cylinders of single-acting type are located on the outer mast frame. Each lift cylinder, consists of cylinder body, rod, piston, and cylinder cap. The piston fastened to the rod with a snap ring is provided with a wear ring and packing on its circumference.
  • Page 122 7. HYDRAULIC SYSTEM Cylinder support 1. PISTON HEAD 2. SHIM 3. WIPER SEAL 4. ROD PACKING 5. CYLINDER CAP 6. “O”-RING 7. BUSHING 8. ROD 9. CYLINDER 10. WEAR RING 11. LOCK RING 12. PACKING 13. PISTON 14. SNAP RING 15.
  • Page 123 7. HYDRAULIC SYSTEM Cylinder support 1. PISTON HEAD 2. SHIM 3. WIPER SEAL 4. ROD PACKING 5. CYLINDER CAP 6. “O”-RING 7. BUSHING 8. ROD 9. CYLINDER 10. LOCK RING 11. WEAR RING 12. PACKING 13. PISTON 14. SNAP RING 15.
  • Page 124 7. HYDRAULIC SYSTEM Cylinder support 1. PISTON HEAD 2. SHIM 3. WIPER SEAL 4. ROD PACKING 5. CYLINDER CAP 6. “O”-RING 7. BUSHING 8. ROD 9. CYLINDER 10. LOCK RING 11. WEAR RING 12. PACKING 13. PISTON 14. SNAP RING 15.
  • Page 125 7. HYDRAULIC SYSTEM Cylinder support 1. PISTON HEAD 2. SHIM 3. WIPER SEAL 4. ROD PACKING 5. CYLINDER CAP 6. BUSHING 7. “O”-RING 8. ROD 9. CYLINDER 10. LOCK RING 11. WEAR RING 12. PACKING 13. PISTON 14. CUT-OFF VALVE 15.

  • Page 126: Flow Regulator Valve

    7. HYDRAULIC SYSTEM 7.1.5 FLOW REGULRATOR VALVE The fl ow regulator valve is located at the position as shown in Fig. 7.12. It not only controls the fork LIFT CYLINDER lowering speed but works as a safety device in case (RIGHT) of a rupture of the high-pressure hose.
  • Page 127 7. HYDRAULIC SYSTEM Free flow Regulated flow Lift cylinder side Control valve side 1. SPRING 5. PISTON 9. “O”-RING 2. CASE 6. SLEEVE 10. NIPPLE 3. SPRING 7. ORIFICE 4. BALL 8. SPRING Fig. 7.14 Flow Regulator Valve (3.5-ton Trucks) ■...

  • Page 128: Tilt Cylinder

    7. HYDRAULIC SYSTEM 7.1.6 TILT CYLINDER The tilt cylinder is a double-acting type. The piston rod end is supported by the mast, and the cylinder tail by a pin on the frame. Two tilt cylinders are mounted on both sides of the truck, one at each.
  • Page 129 7. HYDRAULIC SYSTEM Fig. 7.16 Hydraulic Oil Piping - 117 -...

  • Page 130: Maintenance

    7. HYDRAULIC SYSTEM 7.2 MAINTENANCE 7.2.1 MAINTENANCE OF PUMP ■ Cautions 1. Before disassembling the pump, check for oil leaks from the oil seal, the mating section of the pump body and cover, and other areas. 2. Remove rust, dust and dirt at the shaft end and the pump body. Failure to do so might damage the parts or allow them to enter the inside of the pump during disassembly, thus misleading your diagnosis about the pump.
  • Page 131 7. HYDRAULIC SYSTEM ③ Remove the four fitting bolts. Fig. 7.19 ④ Remove the rear cover by tapping the side face of the pump body with a plastic mallet. If the gaskets remain inside the pump body, move them toward the rear cover side. Fig.
  • Page 132 7. HYDRAULIC SYSTEM ⑦ Put the mark “R” on the driven gear shaft end and remove the drive gear. Fig. 7.23 ⑧ Holding the front side plate, remove the drive gear. Fig. 7.24 ⑨ Put the mark “FV” on the front side plate at the drive gear side, and remove the side plate.
  • Page 133 7. HYDRAULIC SYSTEM ⑪ Remove the oil seal from the front cover. Fig. 7.27 - 121 -...
  • Page 134 7. HYDRAULIC SYSTEM (2) Inspection CAUTION 1. Inspections are carried out to locate the cause of troubles and to determine whether parts are reusable or not. Inspections must be carried out only by personnel with a certain amount of knowledge and experience in hydraulic equipment. 2.
  • Page 135 7. HYDRAULIC SYSTEM Name of component Items to be checked Remarks (cause and others) (c) Check for discoloration, undue wear, or Contaminants in oil, too high oil temperature (continued from the roughness on the gears. (120℃ [248° F] or higher), too frequently idle preceding page) operations Useful limit...
  • Page 136 7. HYDRAULIC SYSTEM (3) Pump reassembly ① As shown in Fig. 7.28, hold the front cover in a vice. Fig. 7.28 ② Install a new gasket in the groove in the front cover. Fig. 7.29 ③ Install a new “E” gasket in the groove in the front cover, referring to Fig.
  • Page 137 7. HYDRAULIC SYSTEM ④ Install the pump body on the front cover, referring to Fig. 7.33. Fig. 7.32 Counterclockwise rotation: Drive side Front side Counterclockwise Clockwise rotation: rotation: Rear side Suction port Rear side (larger radius) Clockwise rotation: Discharge port Front side (smaller radius) Projection (to be always...
  • Page 138 7. HYDRAULIC SYSTEM ⑥ Install the drive gear in the pump body, with its splines pointed downward. Fig. 7.36 ⑦ Install the drive gear in the pump body, as shown in Fig. 7.38. Fig. 7.37 CAUTION The sketch shows the engagement of the left-rotation pump. Since the tooth profi les of the two gears are asymmetric, install them with their larger pressure angle sides pointed to each other.
  • Page 139 7. HYDRAULIC SYSTEM ⑧ Install the rear side plate in the pump body, as shown in Fig. 7.35. Fig. 7.39 ⑨ Apply grease on a new gasket in some points and install the gasket in the rear cover groove. Fig. 7.40 Gasket groove ”E”...
  • Page 140 7. HYDRAULIC SYSTEM ⑪ Install the rear cover in the pump body with its gasket pointed downward. Fig. 7.43 ⑫ Install the four bolts and tighten them to the specified torque: Tightening torque: 88 - 98 N-m {9 - 10 kgf-m} [65.1 - 72.3 ft-lbs] Fig.
  • Page 141 7. HYDRAULIC SYSTEM ⑭ Secure the oil seal with a snap ring and remove the oil seal guide. Cross section of “C” lock ring (Front cover) Side at which corner is chamfered. Oil seal Fig. 7.48 Fig. 7.49 ø4 [0.16] ø17 ø4 [0.67]...

  • Page 142: Trial Run

    7. HYDRAULIC SYSTEM 7.2.2 TRIAL RUN Trial runs should be performed to run in an assembled pump and to ensure that it delivers the specified performance. Trial runs are preferably carried on a special test stand, but may be carried out with the pump on the machine using the following manner: (If the pump were disassembled because of a seized pump or an abnormally worn internal component, be sure to change the hydraulic oil and replace the filters with new ones before trying to make a trial...

  • Page 143: Troubleshooting Guide

    7. HYDRAULIC SYSTEM 7.2.3 TROUBLESHOOTING GUIDE If any problem occurs in the hydraulic system, locate the cause of the problem and take necessary measures, referring to the tables given below. (1) Control valve Problem Cause Remedy PF circuit pressure does not Spool is stuck.
  • Page 144 7. HYDRAULIC SYSTEM (2) Main pump Problem Cause Remedy No oil discharged from gear Low oil level in oil tank Add oil to specified level. pump Clogged suction tube or strainer Clean or change oil if necessary. • Worn pressure plate •...

  • Page 145: Load Handling System

    8. LOAD HANDLING SYSTEM 8. LOAD HANDLING SYSTEM Model FB10-7 FB15-7 FB20-7 FB25-7 FB30-7 FB35-7S Item FB18-7 FB25-7LB FB25-7V FB30-7V Name VM-81E VM-81N VM-39F FM-77X Type Roller type 2-step telescopic mast with free lift Max. standard lifting height 3000 mm [118.1 in.]...

  • Page 146: General Description

    8. LOAD HANDLING SYSTEM 8.1 GENERAL DESCRIPTION The load handling system is of roller type having a two-staged telescopic mast. It consists of an outer channel, inner channel, and carriage. 8.1.1 OUTER AND INNER CHANNELS Outer and inner channels are of welded construction. The lower part of the outer channel is provided with a support to be used for installing the mast assembly on the drive axle.
  • Page 147 8. LOAD HANDLING SYSTEM 1. INNER CHANNEL 2. OUTER CHANNEL 3. END ROLLER 4. SHIM 5. SNAP RING 6. END ROLLER 7. SHIM 8. SLIPPER 9. SHIM 10. PIN 11. CAP 12. BUSHING Fig. 8.2 Outer and Inner Channels (VM-81N, VM-81R, VM-39F) - 135 -...

  • Page 148: Carriage

    8. LOAD HANDLING SYSTEM 1. OUTER CHANNEL 2. INNER CHANNEL 3. END ROLLER 4. SNAP RING 5. SLIPPER 6. NUT 7. PLUG 8. SLIPPER 9. SHIM 10. SIDE ROLLER 11. SHIM 12. SPACER 13. PIN 14. STOPPER 15. CAP 16. BUSHING Fig.
  • Page 149 8. LOAD HANDLING SYSTEM 1. FORK 2. CARRIAGE 3. END ROLLER 4. SHIM 5. SNAP RING 6. SIDE ROLLER 7. SHIM 8. SPACER Fig. 8.4 Carriage - 137 -...
  • Page 150 8. LOAD HANDLING SYSTEM 1. FORK 2. CARRIAGE 3. END ROLLER 4. SNAP RING 5. SIDE ROLLER 6. SNAP RING 7. SHAFT 8. SHIM 9. RETAINING ROLLER 10. SNAP RING Fig. 8.5 Carriage (VM-77X) - 138 -...

  • Page 151: Locations Of Rollers

    8. LOAD HANDLING SYSTEM 8.1.3 LOCATIONS OF ROLLERS The end and side rollers are installed on the carriage. The end rollers support longitudinal load and the side rollers support lateral load so that the inner channel and carriage are raised and lowered smoothly. Fig.
  • Page 152 8. LOAD HANDLING SYSTEM Fig. 8.7 Locations of Rollers (2- to 3.0-ton Trucks) - 140 -...
  • Page 153 8. LOAD HANDLING SYSTEM Fig. 8.8 Locations of Rollers (3.5-ton Trucks) - 141 -...

  • Page 154: Maintenance

    8. LOAD HANDLING SYSTEM 8.2 MAINTENANCE 8.2.1 ADJUST LIFT CYLINDER ROD WITH SHIMS After the lift cylinder, inner channel, and outer channel are replaced, the lift cylinder rod length needs to be adjusted. (1) Install a piston head on the rod of each left cylinder without using shims.
  • Page 155 8. LOAD HANDLING SYSTEM (3) Make sure that the clearance between the carriage and the inner channel stoppers is 0 mm INNER CHANNEL STOPPER when the fork is raised to the maximum lifting height Note 1: When the mast lifting height is over 4000 mm [157.5 in.], the dimension is +50 mm [1.97 in.].

  • Page 156: Procedure For Replacing Rollers At Carriage Side

    8. LOAD HANDLING SYSTEM 8.2.3 PROCEDURE FOR REPLACING ROLLERS AT CARRIAGE SIDE (excluding VM-77X) (1) Attach the pallet to the fork and stop the truck on a level surface. (2) Lower the fork with the pallet to the ground. (3) Remove the joint link of the mast side anchor pin and remove the chain from the sheave.
  • Page 157 8. LOAD HANDLING SYSTEM (8) Extend the lift cylinder rod so that the inner channel bottom projects the upper section of the carriage. (9) Bring the truck close to the carriage side so that Groove for balls each roller enters inside of the outer channel. (10) Contract the lift cylinder rod to lower the inner channels gradually.

  • Page 158: Procedure For Replacing Rollers At Mast Side

    8. LOAD HANDLING SYSTEM 8.2.4 PROCEDURE FOR REPLACING ROLLERS AT MAST SIDE (excluding VM-77X) (1) Remove the carriage from the inner channel in the same procedure as described in “8.2.2 PROCEDURE FOR REPLACING ROLLERS AT CARRIAGE SIDE.” (2) Move the truck to a level surface and put the both rear wheels on the bench of 250 –...

  • Page 159: Procedure For Adding Or Subtracting Shims

    8. LOAD HANDLING SYSTEM 8.2.5 PROCEDURE FOR ADDING OR SUBTRACING SHIMS (excluding VM-77X) Move the inner channel and carriage to one side of the outer channel. Measure the clearance between the end roller at the opposite side and each channel. Clearance between roller and channel: 0 to 0.5 mm [0 to 0.197 in.] 0 to 0.5 mm at upper side Make contact...
  • Page 160 8. LOAD HANDLING SYSTEM NOTE - 148 -...

  • Page 161: Electric Wiring

    9. ELECTRIC WIRING 9. ELECTRIC WIRING The electric components of the truck are wired using several types of wire harnesses and color coded by circuit (wire number). The wire harnesses are connected with connectors (2 types) or screws. Table 9.1 Color symbols and examples Wire L 110 Wire...
  • Page 162 9. ELECTRIC WIRING ■ FET UNIT The FET unit consists of semiconductor switches in which FETs are used as switching elements, and turns on and off the lights in response to the input from the mechanical switches. View A Fig. 9.1 - 150 -...
  • Page 163 9. ELECTRIC WIRING PR 51W TURN SIGNAL LIGHT (RIGHT) RL 51W TURN SIGNAL LIGHT (LEFT) RM 80W HEAD LIGHT RT 44W TAIL LIGHT BRAKE SIGNAL BB 20W BACK-UP LIGHT BEACON LIGHT OPTIONAL EQUIPMENT CHIME: 0.15A BEACON LIGHT OPTIONAL EQUIPMENT BEACON LIGHT Fig.
  • Page 164 9. ELECTRIC WIRING HEAD LIGHT REAR COMBINATION LIGHT FRONT COMBINATION LIGHT FB10－FB18 FB20－FB35 View A Fig. 9.3 Light Installation Position - 152 -...
  • Page 165 9. ELECTRIC WIRING ■ HEAD LIGHT The head light has a structure as shown in Figure 9.4. Two head lights are installed on the front poles of the overhead guard, one for each. ① ② 1. LENSE ⑤ 2. RIM 3.
  • Page 166 9. ELECTRIC WIRING ■ Replacing light bulbs If you want to remove a bulb, push it into the SCREW reflector and then turn to the left. If you want to install a new bulb, push it into the REFLECTOR reflector and then turn to the right. 40W‑48V GASKET (1) Head light and work light...
  • Page 167 9. ELECTRIC WIRING to HORN SWITCH to LIGHTING SWITCH to F/R SWITCH to METER PANEL to KEY SWITCH to RWL SWITCH to FLASHER UNIT OPTION WIRE HARNESS, to WIRE HARNESS, to BRAKE SWITCH OVERHEAD GUARD (RIGHT) OVERHEAD GUARD (LEFT) CAPACITOR to HORN to WIRE HARNESS, FRAME Fig.
  • Page 168 9. ELECTRIC WIRING to HORN SWITCH to LIGHTING SWITCH to F/R SWITCH to METER PANEL to KEY SWITCH to FLASHER UNIT to RWL SWITCH OPTION OVERHEAD GUARD (RIGHT) to BRAKE SWITCH to WIRE HARNESS, OVERHEAD GUARD (LEFT) CAPACITOR to HORN to WIRE HARNESS, FRAME Fig.
  • Page 175 No. SEB-81BBE Issued: February, 2008 INTERNATIONAL MARKETING DIVISION: 1-15-5, Nishi-shimbashi, Minato-ku, Tokyo 105-0003, Japan FAX: JApAN +81-3-35918152, 3-35918153 All rights reserved JB-0802030(HO) Printed in Japan...

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