Related Manuals for TCM FB35-7S
Summarization of Contents
1. BATTERY AND CHARGER
1.1 GENERAL DESCRIPTION
General overview of battery and charger systems, including their types and functions.
1.1.1 BATTERY
Details on battery capacity, type, voltage, and maintenance requirements.
1.1.2 CHARGER
Description of the truck-mounted charger components, operation, and settings.
1.1.3 CHARGING PROCEDURES
Steps for normal, boosting, and equalizing battery charges, including safety precautions.
1.1.4 CHARGER OPERATION
Explanation of the charger's readiness, start sequence, and completion of operation.
2. MOTORS
2.1 GENERAL DESCRIPTION
Overview of the drive and pump motor locations and their control mechanisms.
2.1.1 DRIVE MOTOR
Details on the drive motor's structure, installation, and electronic control system.
2.1.2 PUMP MOTOR
Description of the pump motor's function, location, and operation.
2.2 MAINTENANCE
Procedures for maintaining motors, including checks and periodic inspections.
2.2.1 DRIVE MOTOR
Maintenance checks for drive motors while running and when stopped.
2.2.2 PUMP MOTOR
Maintenance procedures for pump motors, covering bearings, brushes, and commutator.
3. CONTROL SYSTEM
3.1 GENERAL DESCRIPTION
Overview of the control system, including inverter, chopper, and controller functions.
3.1.1 INVERTER
Explanation of the inverter's role in converting DC to AC and its schematic diagram.
3.1.2 ACCELERATOR PEDAL
Details on the accelerator pedal installation, function, and adjustment procedures.
3.1.3 INTERLOCK SYSTEM
Explanation of the safety interlock system and operating conditions to prevent false activation.
3.1.4 BACK-DOWN ALARM SYSTEM
Description of the back-down alarm system and how to release the alarm.
3.2 MAINTENANCE
Procedures for controller maintenance, including troubleshooting guides.
3.2.1 TROUBLESHOOTING GUIDE
Guide for identifying and resolving controller errors based on LED codes and charts.
4. DRIVE UNIT AND DRIVE AXLE
4.1 GENERAL DESCRIPTION
Overview of the drive unit and drive axle components and their assembly.
4.1.1 DRIVE UNIT
Description of the three-stage reduction drive unit, gears, and bearings.
4.1.2 DRIVE AXLE
Details on the drive axle assembly, including housing, wheel hub, and brake.
5. BRAKE SYSTEM
5.1 GENERAL DESCRIPTION
Overview of the hydraulic brake system, including pedal, master cylinder, and wheel brakes.
5.1.1 BRAKE PEDAL
Details on the installation and function of the brake pedal assembly.
5.1.2 MASTER CYLINDER
Description of the master cylinder, its internal components, and hydraulic pressure maintenance.
5.1.3 WHEEL BRAKE
Explanation of wheel brake operation, parking brake mechanism, and automatic adjuster.
5.1.4 PARKING BRAKE LEVER
Installation and adjustment of the parking brake lever and its alarm system.
5.2 MAINTENANCE
Procedures for brake system maintenance, disassembly, inspection, and reassembly.
5.2.1 DISASSEMBLING WHEEL BRAKE
Step-by-step instructions for disassembling the wheel brake assembly.
5.2.2 INSPECTION
Inspection procedures for wheel brake components like cylinder, lining, and drum.
5.2.3 REASSEMBLING WHEEL BRAKE
Step-by-step instructions for reassembling the wheel brake assembly.
5.2.4 OPERATION TEST OF AUTOMATIC CLEARANCE ADJUSTER
Procedure for testing the automatic clearance adjuster's operation after assembly.
5.2.5 ADJUSTING BRAKE PEDAL
Steps for adjusting the brake pedal height and the brake switch activation point.
5.2.6 TROUBLESHOOTING GUIDE
Guide for diagnosing and resolving common brake system problems.
6. STEERING SYSTEM
6.1 GENERAL DESCRIPTION
Overview of the steering system, including gear, actuator, controller, and axle.
6.1.1 OUTLINE OF STEERING SYSTEM
Description of the steering system's composition: gearbox, actuator, and controller.
6.1.2 STEERING GEARBOX
Details on the construction and components of the steering gearbox.
6.1.3 ACTUATOR
Description of the ball and nut screw type actuator and its installation.
6.1.4 REAR AXLE
Details on the rear axle unit, including construction, knuckles, and wheel hub.
6.1.5 ADJUSTING PRELOAD OF REAR WHEEL BEARING
Procedure for adjusting the preload of the rear wheel bearing.
6.1.6 ASSEMBLING WHEEL
Steps for assembling the tire, tube, flap, and rim correctly.
6.2 MAINTENANCE
Procedures for steering system maintenance, including actuator and gearbox service.
6.2.1 MAINTENANCE FOR ACTUATOR
Steps for replacing the motor, ball joint, and boot of the steering actuator.
6.2.2 MAINTENANCE OF STEERING GEARBOX
Procedures for disassembling and reassembling the steering gearbox.
7. HYDRAULIC SYSTEM
7.1 GENERAL DESCRIPTION
Overview of the hydraulic system, including pump, control valve, tank, and cylinders.
7.1.1 MAIN PUMP
Description of the gear type main pump, its components, and operation.
7.1.2 CONTROL VALVE
Explanation of the control valve, its plunger sections, and check valves.
7.1.3 HYDRAULIC OIL TANK
Location and function of the hydraulic oil tank, including filter replacement.
7.1.4 LIFT CYLINDER
Description of the single-acting lift cylinders and the cut-off valve safety device.
7.1.5 FLOW REGULATOR VALVE
Function and operation of the flow regulator valve controlling fork lowering speed.
7.1.6 TILT CYLINDER
Description of the double-acting tilt cylinder and its operation for mast tilting.
7.2 MAINTENANCE
Procedures for hydraulic system maintenance, including pump service and troubleshooting.
7.2.1 MAINTENANCE OF PUMP
Cautions, disassembly, and inspection steps for the hydraulic pump.
7.2.2 TRIAL RUN
Procedure for running in and testing the assembled hydraulic pump for performance.
7.2.3 TROUBLESHOOTING GUIDE
Guide for diagnosing and resolving common problems in the hydraulic system.
8. LOAD HANDLING SYSTEM
8.1 GENERAL DESCRIPTION
Overview of the load handling system, mast types, and chain specifications.
8.1.1 OUTER AND INNER CHANNELS
Description of the construction and support of outer and inner mast channels.
8.1.2 CARRIAGE
Description of the carriage assembly, including end and side rollers.
8.1.3 LOCATIONS OF ROLLERS
Diagram illustrating the positions of end and side rollers on the carriage.
8.2 MAINTENANCE
Procedures for load handling system maintenance, including adjustments and roller replacement.
8.2.1 ADJUST LIFT CYLINDER ROD WITH SHIMS
Procedure for adjusting the lift cylinder rod length using shims.
8.2.2 ADJUSTING HEIGHT OF CARRIAGE
Procedure for adjusting the carriage height via end rollers and chain anchor.
8.2.3 PROCEDURE FOR REPLACING ROLLERS AT CARRIAGE SIDE (excluding VM-77X)
Steps for replacing end and side rollers on the carriage.
8.2.4 PROCEDURE FOR REPLACING ROLLERS AT MAST SIDE (excluding VM-77X)
Steps for replacing end rollers on the mast side of the carriage.
8.2.5 PROCEDURE FOR ADDING OR SUBTRACING SHIMS (excluding VM-77X)
Procedure for adding or subtracting shims to adjust roller clearance.
9. ELECTRIC WIRING
■ FET UNIT
Description of the FET unit's function in controlling lights based on mechanical switches.
■ HEAD LIGHT
Structure and installation details of the head lights on the overhead guard.
■ Replacing light bulbs
Procedures for replacing bulbs in head lights and combination lights.
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