FD50T9

Service Training
 Summary
For
TCM Forklift
Basic information
of
Electric

7
8
9
Electric Component
Mounting Diagram

10
Electric Component Mounting Diagram (front guard area)

11
Electric Component Mounting Diagram (right side of the frame of trucks)

Diesel engine Gasoline engine

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Electric Component Mounting Diagram (left side of the frame of trucks with diesel engine)

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Electric Component Mounting Diagram (left side of the frame of trucks with gasoline engine)

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 Wiring Diagram
for
Diesel trucks
Torque Converter Type

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Key OFF
Key ON
Key Start
Glow Relay
Neutral Relay
to Starter Relay
Direction switch
to Forward valve 16
to Reverse valve Diesel Torque Converter
Key OFF
OFF 24V

17
Diesel
 ON

Key OFF
Key ON ON→OFF 24V
Glow Relay

18
Diesel
 ON

Key ON 24V

19
Diesel
 ON

Key ON 24V

20
Diesel
Key ON 24V

21
Diesel
 ON

Key ON 24V

22
Diesel
 ON

ON

24V
Key Start

23
Diesel
 24V

Direction switch
to Forward valve 24
to Reverse valve Diesel
Wiring Diagram
for
Diesel trucks
Clutch Type

25
 ON

ON ON
ON

ON

Key OFF ON 24V

Key ON
Key Start
Glow Relay
Neutral Relay 26
to Starter Relay Diesel Clutch
Key OFF 24V

27
 24V
Key ON

28
 ON

ON
ON

24V
Key ON

29
 ON

ON ON ON

ON 24V
Key ON
Glow Relay
30
 ON
ON

ON

Key OFF ON 24V

Key ON
Key Start

Neutral Relay 31
to Starter Relay
Wiring Diagram
for
Gasoline trucks

32
 -
Key OFF
Key ON 12V
Key Start
Neutral Relay
to Starter Relay

33
Gasoline
 ON

-
Key OFF
12V

34
Gasoline
 ON

ON OFF ON

-
Key ON 12V

35
Gasoline
Key ON 12V

36
Gasoline
Key ON 12V

37
Gasoline
 ON

ON ON ON

ON

Key OFF
Key ON 12V
Key Start
Neutral Relay
to Starter Relay

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Gasoline
 Clutch type
Transmission

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Clutch System

GENERAL DESCRIPTION：
The clutch system consists of a clutch cover assembly, a clutch disk, a release cylinder, a clutch
booster, and clutch pedal assembly. It turns on and off the power from the engine to
the transmission.
CLUTCH HOUSING：
The clutch housing consists of a shift block, yoke, release bearing and shift arm assembly.
The clutch is splined to the shift arm shaft, with the Y-bend meshed with the pin on the outer
periphery of the shift block.
The shift block has the release bearing attached and its outer ring is in contact with the clutch
cover release lever.
The clutch disk is lubricated with oil which is picked up from the clutch housing and sprayed by
the nozzle. 40
Clutch Housing

41
CLUTCH COVER:
The clutch cover consists of a pressure plate,
a release lever, a cover and a pressure spring.
The pressure plate is forced against the flywheel
by the pressure spring. As the release lever is
pressed to the flywheel side, the pressure plate is
pulled to the cover side.

CLUTCH DISK:
The clutch disk consists of a spline hub, a
clutch plate, a retaining plate and torsion
springs.
The clutch plate has the drive plate, both sides
of which are covered with facing, mounted
with rivets. The drive plate is a little warped.

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CLUTCH PEDAL:
The clutch pedal, assembled on the same bracket as the brake pedal,
converts pedal effort to oil pressure, thus operating the release cylinder.
A brake booster, a clutch booster, a release cylinder and a pedal are mounted to
the bracket.

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Clutch booster:
The clutch booster consists of a control valve which converts pedal effort to oil pressure,
a master cylinder and a flow divider. It utilizes the oil pressure for the load handling system.

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RELEASE CYLINDER:
The release cylinder is installed on the left side of the transmission case.
This cylinder consists of a piston, a spring and a push rod, and the piston movement is
transmitted through the push rod to the shift arm.

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OIL CLUTCH HYDRAULIC CIRCUIT:
When the engine starts, the pump mounted to the engine gear case sends under pressure
the oil from the clutch housing to the oil cooler in the radiator.
After being cooled in the oil cooler, the oil enters the clutch housing, passing through the filter.
The clutch housing has a regulator valve in the oil inlet port.
The oil is pressure-regulated by this regulator valve and lubricates and cools the clutch plate and
then returns to the lower part of the clutch housing.

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CLUTCH TYPE DRIVE UNIT

GENERAL DESCRIPTION:
The clutch type drive unit consists of a synchromesh type transmission and a differential unit.
TRANSMISSION:
The transmission consists primarily of a main shaft, an output gear and an input shaft, each
shaft having gears of varying sizes.
The gears are shifted with the aid of the sliding sleeves installed on the main shaft by operation
of the shift arms.
The power from the output gear is transmitted through the differential to the drive axle.

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Clutch Type Transmission

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Clutch Type Transmission Gear train

In Forward 1st speed gear position:

In Forward 2nd speed gear position:
In Reverse 1st speed gear position:
In Reverse 2nd speed gear position:

① ⑨
⑥ ⑩

②
③ ④
⑬ ⑦⑮⑭⑧
⑤

⑪
49
Oil Pressure Check Port

50
Torque Converter type
Transmission

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The torque converter type drive unit consists of a torque converter, a power-shift transmission,
and a differential. The transmission has two forward speeds and one reverse speed.
The speed range is automatically switched over by the ATM controller. 52
53
Hydraulic circuit in Drive unit At neutral position

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Hydraulic circuit in Drive unit At forward 1st speed

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Hydraulic circuit in Drive unit At forward 2nd speed

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Hydraulic circuit in Drive unit At Reverse

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Drive unit Control valve

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Oil Pressure Check Port

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THE POWER TRANSMISSION COURSE ・・・ FORWARD 1st Speed

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THE POWER TRANSMISSION COURSE ・・・ FORWARD 2nd Speed

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THE POWER TRANSMISSION COURSE ・・・ REVERSE

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ATM Controller

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 Method for shifting 2nd speed

ＡＴＭ Controller

To control necessary
current for 2nd speed
shift solenoid valve

D: More than 7km/h shift into second, less than 6km/h shift down to first
Dopt: More than 9km/h shift into second, less than 7km/h shift down to first

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 ＡＴＭ Controller

1st-2nd Solenoid
→ No good
or relay
①Confirm coming 24V to Ｒ（B＋） and
Ｂ（B－）to the ground
wiring broken
VF

②Measure voltage for switch between L → 0V

( VF) and Ｂ（B－） wiring
broken
24V/12V

Ground front wheels off and start the engine

A Shift to forward and step on the accelerator

CONTROLLER 24V/12V Approx. 1.5V

Electrically in normal
Either solenoid or control valve defects

Check for ③, and it is in normal, either

Method for checking the sensor
In the state of A, disconnect the coupler to
measure voltage between G and WB setup to A.C
range by means of the circuit tester.
More than 0.5V → Normal
Zero 0V → Switch defects, maladjustment
or wiring broken
sensor or controller defects
③Disconnect the battery then and the coupler to
check for conductivity between WB and Y or
WB and YR
→ Non conductivity Either switch defects or
wiring broken 65
Front & Rear
Axle

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Front Axle

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Rear Axle

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Hydraulic System

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70
Hydraulic Piping Diagram (Torque Converter Model)

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Hydraulic Pump

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Control Valve

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Lift Cylinder

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Tilt Cylinder

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Oil Tank

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Oil

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Case studies

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Engine rotation speed does not pick up

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Broken the input plate

Break down bearing

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Broken the muffler

Break down front tube

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Wear Clutch Pack

Cause:
・Pushing work
・Stall tire
・Half clutch overload
・low clutch pressure
etc
84
Shock of the running start

Break down Accumulator spring

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Wear internal lift cylinder

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Thank you

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