TCM 1N1 A1N1 3-4 Wheel Forklift Service Manual – 2012 Draft
The TCM 1N1 A1N1 3-4 Wheel Forklift Service Manual – 2012 Draft is a comprehensive maintenance and repair reference for the TCM (A)1N1 series. Across 579 pages, it brings together service procedures, inspection and adjustment data, troubleshooting logic, electrical and hydraulic information, removal and installation steps, component disassembly and assembly, and detailed illustrations for major forklift systems. The manual addresses both 3-wheel and 4-wheel counterbalance configurations and identifies model classifications including FTB13-E1, FTB15-E1S, FTB15-E1, FTB18-E1, FTB16-E1, FTB20-E1, FB16-E1, FB18-E1 and FB20-E1.
File Details
- Manual type: Service Manual (Draft)
- Brand: TCM
- Series: 1N1 / A1N1, 3-4 wheel
- Language: English
- Pages: 579
- File format: PDF
- Date: 21-12-2012
Workshop Information Built Around Real Service Tasks
This TCM 1N1 / A1N1 forklift service manual is arranged around the work a technician performs on the truck. General-information pages explain identification, precautions, jacking, towing, lifting and standard bolt torque. Maintenance pages provide lubrication information, scheduled inspection intervals, battery checks, controller and motor inspection, drive-unit oil service, tire and wheel checks, brake maintenance, steering checks, hydraulic-fluid service and mast/loading-mechanism inspection.
For repair work, the manual goes well beyond routine maintenance. Major sections provide service data and specifications, tightening torques, trouble diagnoses and corrections, precautions, special-service-tool information where applicable, component construction, removal and installation sequences, disassembly, assembly, inspection and adjustment. Exploded views and technical drawings are used throughout to show component relationships, fastening points and service details.
Control System, Electrical Diagnosis and Wiring
A substantial portion of the TCM 1N1 A1N1 3-4 Wheel Forklift Service Manual – 2012 Draft is devoted to electronic control and diagnostics. The 1N1 and A1N1 control-system material covers system operation, AC motor control, meter-panel functions, LCD adjustment and diagnostic modes, controller construction, connector terminal layouts, controller-element inspection, sensor and switch checks, optional joystick control, steering-knob position control and troubleshooting flow charts.
The diagnostic material is particularly useful when the truck has a symptom rather than an obvious failed part. Flow-chart procedures cover controller-system faults, drive problems, loading-system faults for mechanical and joystick control types, power-steering faults and turn-signal problems. Error-code tables, voltage and resistance measurement procedures, controller reference data and terminal information help connect a displayed symptom or code to the relevant circuit and component checks.
The electrical-system section adds fuse and fusible-link information, electrical-unit locations, harness layouts, lamps, switches, relays, battery and motor cables, optional electrical parts and wiring diagrams. This gives the user a single reference for tracing electrical supply, switch signals, controller connections and associated circuits during diagnosis or repair.
Mechanical, Hydraulic and Loading-System Repair Coverage
The manual also provides extensive mechanical service information. Traction and pump motor chapters include specifications, troubleshooting, removal, installation, disassembly, assembly and inspection. The drive-unit section covers reduction-gear construction and service, including removal, disassembly, inspection, reassembly and installation. Tire and road-wheel information addresses general specifications, wheel-nut tightening, tire wear and related service checks.
Brake coverage includes system specifications, service-brake diagnosis, wet-disc brake service, brake pedal work, master cylinder, reservoir tank, brake piping, bleeding procedures and parking brake inspection and adjustment. Rear-axle and steering sections provide their own service data, trouble diagnosis, component construction and repair procedures. The hydraulic section includes piping, hydraulic circuit information, pump and control-valve service, control levers, lift and tilt cylinders, oil tank, pressure checks and adjustments. Loading-mechanism material covers forks, lift chains, carriage, mast assemblies, rollers, clearances, chain tension, cylinder inspection and lubrication points.
Chapters Covered
- General Information
- How to use the manual, identification information and service precautions
- Jacking, towing, lifting and standard bolt tightening torque
- Maintenance
- Lubrication chart and maintenance schedule
- Battery, control system, motors and electrical components
- Drive unit, tires, brakes, steering, hydraulics and loading mechanism
- Control System – 1N1
- Technical description, system layouts, meter panel and LCD monitor
- Adjustment and diagnostic modes, error codes and controller inspection
- Unit inspection, joystick option, knob-position option and troubleshooting
- Control System – A1N1
- Vehicle-control functions, meter panel, adjustment and manager modes
- Diagnostic mode, controller and unit inspection, options and error-code diagnosis
- Battery and Charger
- Battery specifications, diagnosis, removal, installation and inspection
- Off-forklift charging and battery mounting
- Electrical System
- Electrical-unit locations, harness layouts, fuses and lighting
- Switches, relays, buzzers, battery/motor cables, optional parts and wiring diagrams
- Motor Mechanism
- Traction and pump motor specifications and troubleshooting
- Removal, installation, disassembly, assembly and inspection
- Drive Unit
- Reduction gear specifications, diagnostics and precautions
- Removal, component parts, disassembly, assembly and inspection
- Front Tire & Rear Tire
- Tire and road-wheel specifications, inspection and service information
- Brake System
- Service data, diagnosis, construction and wet-disc service brake
- Brake pedal, master cylinder, reservoir, piping, bleeding and parking brake
- Rear Axle
- Service data, diagnosis, construction, removal, inspection, installation and adjustment
- Steering System
- Steering wheel and column, power-steering valve and cylinder
- Rear axle, steering piping, diagnosis and adjustment
- Hydraulic System
- Service data, hydraulic circuit, piping, pump and control valve
- Control lever, tilt cylinder, lift cylinder and oil tank service
- Loading Mechanism
- Fork, lift chain, carriage and mast service
- Roller clearances, adjustments, cylinders and lubrication points
- Body & Frame
- Instrument covers, floor board and mat, overhead guard and rearview mirror
- Seat, top panel, body panels and counterweight
- Option
- Cabin front/rear window and door assemblies
- Cabin electrical-component locations, outline and harness layout
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “TCM 1N1 A1N1 3-4 Wheel Forklift Service Manual – 2012 Draft” are as follows:
+GI_TCM.pdfp. 1
+HOW TO USE THIS MANUALp. 5
Outline of This Manualp. 5
Technical Term Definitionsp. 6
Manual Illustrationsp. 8
+IDENTIFICATION INFORMATIONp. 9
Vehicle Model Classification Numberp. 9
MODEL comparison for chassis serial numberp. 9
Vehicle Identification Numberp. 10
Identification Platep. 10
GENERAL PRECAUTIONSp. 10
+JACKING, TOWING AND LIFTINGp. 14
Jackingp. 14
Towing (Freeing a stuck forklift)p. 17
Liftingp. 17
TIGHTENING TORQUE OF STANDARD BOLTSp. 18
+MA.pdf
+LUBRICATION CHARTp. 21
+MAINTENANCE SCHEDULEp. 23
Maintenance Schedulep. 23
+BATTERYp. 25
+CONTROL SYSTEMp. 29
+MOTORSp. 30
+ELECTRICAL COMPONENTSp. 31
Electrical Componentsp. 31
+DRIVE UNIT (REDUCTION GEAR)p. 32
Drive Unit (Reduction Gear)p. 32
+TIRES AND ROAD WHEELSp. 33
Tires and Road Wheelsp. 33
+BRAKE SYSTEMp. 35
+STEERING SYSTEMp. 40
+HYDRAULIC SYSTEMp. 41
+LOADING MECHANISMp. 46
+CS 1N1.pdf
+TECHNICAL DESCRIPTIONp. 56
PRECAUTIONSp. 64
+LOCATION OF UNITS (LAYOUT)p. 65
Standard Equipment (3 – wheel)p. 65
Standard Equipment (4 – wheel)p. 66
Optional Equipmentp. 67
+METER PANELp. 68
Meters, Indicators and Lampsp. 68
Setting Adjustment Items (Normal Mode)p. 68
Meter Panel Explanationp. 69
+LCD MONITORp. 77
Adjustment Modep. 77
Diagnostic Modep. 85
Table of Error Codep. 96
+CONTROLLERp. 97
Constructionp. 97
Connector (Terminal layout)p. 99
Controller Element Inspectionp. 103
Removal and Installation (3 – wheel)p. 110
Removal and Installation (4 – wheel)p. 111
+UNIT INSPECTION AND ADJUSTMENTp. 112
Control Systemp. 112
Joystick Control System (Option)p. 124
Knob Position Control System (Option 3 – wheel only)p. 131
+TROUBLE DIAGNOSTIC PROCEDURESp. 132
Precautionsp. 132
How To Follow Flow Chartp. 133
Symbol Identificationp. 134
Voltage and Resistance Measurement Proceduresp. 135
TROUBLE DIAGNOSIS FOR CONTROLLER SYSTEMp. 136
TROUBLE DIAGNOSIS FOR DRIVING SYSTEMp. 144
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF MECHANICAL TYPEp. 151
TROUBLE DIAGNOSIS FOR LOADING SYSTEM OF JOYSTICK TYPEp. 156
TROUBLE DAIGNOSIS FOR POWER STEERING SYSTEMp. 162
TROUBLE DIAGNOSIS FOR TURN SIGNAL LAMP SYSTEMp. 163
+REFERENCE DATA OF CONTROL SYSTEMp. 164
Main Print Boardp. 164
Drive FET Board (for RH traction motor control)p. 168
Drive FET Board (for LH traction motor control)p. 168
Pump FET Boardp. 168
Traction Condenser Boardp. 169
Loading Condenser Boardp. 169
Joystick Controllerp. 170
+CS A1N1.pdf
+TECHNICAL DESCRIPTIONp. 173
PRECAUTIONSp. 182
+LOCATION OF UNITS (LAYOUT)p. 183
Standard Equipment (3 – wheel)p. 183
Standard Equipment (4 – wheel)p. 184
Optional Equipmentp. 185
+METER PANELp. 186
Meters, Indicators and Lampsp. 186
Setting Adjustment Items (Normal Mode)p. 186
Meter Panel Explanationp. 188
+LCD MONITORp. 198
Adjustment Modep. 198
Manager Modep. 206
Diagnostic Modep. 210
Table of Error Code (1)p. 221
+CONTROLLERp. 222
Constructionp. 222
Connector (Terminal layout)p. 223
Controller Element Inspectionp. 227
Removal and Installationp. 230
+UNIT INSPECTION AND ADJUSTMENTp. 231
Control Systemp. 231
Joystick Control System (Option)p. 243
Knob Position Control System (Option)p. 250
Tilt Leveling Device (Option)p. 251
+TROUBLE DIAGNOSTIC PROCEDURESp. 255
Precautionsp. 255
How To Follow Flow Chartp. 256
Symbol Identificationp. 257
Voltage and Resistance Measurement Proceduresp. 258
Table of Error Code (2)p. 259
+BC.pdf
+PRECAUTIONS AND PREPARATIONp. 267
+BATTERYp. 268
Specificationsp. 268
Trouble Diagnoses and Correctionsp. 269
Removalp. 270
Installationp. 271
Inspectionp. 271
+CHARGERp. 276
How to Charge the Battery (Off-Forklift Type)p. 276
BATTERY MOUNTINGp. 277
+EL 1N1.pdf
+PRECAUTIONSp. 279
+LOCATION OF ELECTRICAL UNITSp. 280
Electrical Component Parts (3 – wheel)p. 280
Electrical Component Parts (4 – wheel)p. 280
+HARNESS LAYOUTp. 282
Outlinep. 282
Body Harness for Mechanical Control Systemp. 283
Body Harness for Joystick Control Systemp. 286
Tail Harnessp. 289
Guard Harnessp. 289
Hydraulic Control Valve Switch Harness for Mechanical Control Systemp. 290
Sub-harness for Joystick Control System (Option)p. 290
+FUSESp. 291
Fuse and Fuse Boxp. 291
Fusible Linkp. 292
+LIGHTING SYSTEMp. 293
Lampsp. 293
Headlampp. 294
Back operation lamp (Option)p. 294
Patrol lamp (Option)p. 295
+SWITCHESp. 296
Key Switchp. 296
Battery Switchp. 296
Combination Switchp. 297
Back Operation Lamp Switch (Option)p. 298
Seat Switchp. 298
Seat Belt Switchp. 299
Parking Brake Switchp. 299
+MISCELLANEOUS ELECTRICAL PARTSp. 300
Horn Switchp. 300
Horn Relayp. 300
Tail Lamp, Auto Power Off, Battery Switch, Joystick Control System Relayp. 301
Hornp. 301
Warning Buzzerp. 302
Back Buzzerp. 302
+BATTERY CABLES AND MOTOR CABLESp. 303
Battery Cables and Moter Cablesp. 303
+LOCATION OF OPTIONAL PARTSp. 305
+EL A1N1.pdf
+PRECAUTIONSp. 307
+LOCATION OF ELECTRICAL UNITSp. 308
Electrical Component Parts (3 – wheel)p. 308
Electrical Component Parts (4 – wheel)p. 308
+HARNESS LAYOUTp. 310
+FUSESp. 311
Fuse and Fuse Boxp. 311
Fusible Linkp. 312
+LIGHTING SYSTEMp. 313
Lampsp. 313
Headlampp. 314
Back operation lamp (Option)p. 314
Patrol lamp (Option)p. 315
+SWITCHESp. 316
Key Switchp. 316
Battery Switchp. 316
Combination Switchp. 317
Back Operation Lamp Switch (Option)p. 318
Seat Switchp. 318
Seat Belt Switchp. 319
Parking Brake Switchp. 319
+MISCELLANEOUS ELECTRICAL PARTSp. 320
Horn Switchp. 320
Horn Relayp. 320
Tail Lamp, Auto Power Off, Battery Switch, Joystick Control System Relayp. 321
Hornp. 321
Warning Buzzerp. 322
Back Buzzerp. 322
+BATTERY CABLES AND MOTOR CABLESp. 323
Battery Cables and Motor Cablesp. 323
+LOCATION OF OPTIONAL PARTSp. 326
Earth Bandp. 326
DC/DC converter (Option)p. 327
+WIRING DIAGRAMp. 328
Power Supply for Controllerp. 328
+MM.pdf
+SERVICE DATA AND SPECIFICATIONSp. 339
General Specificationsp. 339
Tightening Torquep. 339
General Specificationsp. 340
Tightening Torquep. 340
TROUBLE DIAGNOSES AND CORRECTIONSp. 341
+PRECAUTIONS AND PREPARATIONp. 343
Precautionsp. 343
Special Service Toolp. 343
+TRACTION MOTORp. 344
Removalp. 344
Removalp. 345
Installation 1N1p. 346
Installation A1N1p. 347
+PUMP MOTORp. 348
Removalp. 348
Installation 1N1p. 349
Installation A1N1p. 349
+MOTOR DISASSEMBLY AND ASSEMBLYp. 350
Disassembly 1N1p. 350
Assemblyp. 351
Inspectionp. 352
Disassembly A1N1p. 353
Assemblyp. 354
Inspectionp. 354
+DU.pdf
+SERVICE DATA AND SPECIFICATIONSp. 357
General Specifications 1N1p. 357
Tightening Torque 1N1p. 357
General Specifications (J)A(G)1N1p. 357
Tightening Torque (J)A(G)1N1p. 357
+TROUBLE DIAGNOSES AND CORRECTIONSp. 358
+PRECAUTIONS AND PREPARATIONp. 359
Precautionsp. 359
Special Service Toolp. 359
+DRIVE UNITp. 360
Reduction Gear Assemblyp. 360
Removalp. 361
Installationp. 362
Component Partsp. 363
Disassemblyp. 365
Assemblyp. 367
Inspectionp. 370
+TR.pdf
+SERVICE DATA AND SPECIFICATIONSp. 373
General Specifications 1N1p. 373
Tightening Torquep. 373
+SERVICE DATA AND SPECIFICATIONSp. 374
General Specifications (J)A(G)1N1p. 374
Tightening Torquep. 374
+PRECAUTIONS AND PREPARATIONp. 375
TROUBLE DIAGNOSES AND CORRECTIONSp. 376
+TIRE AND ROAD WHEELp. 377
Tire and Road Wheel Assemblyp. 377
Replacing Tiresp. 380
Inspectionp. 380
+BR.pdf
+SERVICE DATA AND SPECIFICATIONSp. 383
General Specificationsp. 383
Tightening Torquep. 383
+TROUBLE DIAGNOSIS AND CORRECTIONSp. 384
Service Brakep. 384
Parking Brakep. 385
+PRECAUTIONS AND PREPARATIONp. 386
+CONSTRUCTIONp. 387
+SERVICE BRAKEp. 388
Removalp. 388
Installationp. 388
Disassemblyp. 390
Assemblyp. 391
Inspectionp. 391
+BRAKE PEDALp. 392
Removalp. 392
Installationp. 393
Disassembly and Assemblyp. 394
Inspectionp. 394
Adjustmentp. 395
+MASTER CYLINDERp. 396
Removalp. 397
Installationp. 397
Disassemblyp. 397
Assemblyp. 397
Inspectionp. 398
+RESERVOIR TANKp. 399
+BRAKE PIPINGp. 401
Brake Pipingp. 401
Brake Line Air Bleedingp. 402
+PARKING BRAKEp. 403
Removalp. 403
Installationp. 404
Disassembly and Assemblyp. 405
Inspectionp. 405
+RA.pdf
SPECIFICATIONp. 407
TROUBLE DIAGNOSES AND CORRECTIONSp. 408
+SERVICE DATA AND SPECIFICATIONSp. 409
Steering Axle Upper Surface (4 – wheel)p. 409
Steering Axle Front Surface (4 – wheel)p. 410
Steering Axle Front Surface (3 – wheel)p. 411
+Construction (4 – wheel)p. 412
Details of Rear Axle (4 – wheel)p. 412
precautionsp. 413
+Axle center (4 – wheel)p. 414
Removalp. 414
Installationp. 414
+COmponent parts (4 – wheel)p. 417
Disassembly and Assemblyp. 417
+Steering axle hub (4 – wheel)p. 418
Removalp. 418
Inspectionp. 418
Installationp. 418
Adjustmentp. 419
+KINGPIN (4 – wheel)p. 420
Detailsp. 420
Removalp. 421
Inspectionp. 421
Installationp. 422
Construction of Tire Angle Sensorp. 423
+axle centre (3 – wheel)p. 424
Details of Rear axle (3 – wheel)p. 424
+axle centre (3 – wheel)p. 425
Removalp. 425
Installationp. 425
Assemblyp. 427
+ST.pdf
+SERVICE DATA AND SPECIFICATIONSp. 431
General Specificationsp. 431
Tightening Torquep. 431
+precautions and preparationp. 432
Special Service Toolp. 432
+STEERING COLUMN ASSEMBLYp. 433
Installationp. 434
Inspection After Installationp. 434
+PS VALVEp. 435
Parts Constructionp. 435
Disassemblyp. 436
Inspectionp. 437
Assemblyp. 438
Trouble Diagnosis and Correctionsp. 441
+PS cylinder (4 – wheel)p. 443
Constructionp. 443
Specificationp. 443
Removalp. 444
Installationp. 444
Troubleshootingp. 445
Disassemblyp. 447
Assemblyp. 449
Periodical Inspection and Maintenancep. 453
+ps cylinder. (3 – wheel)p. 455
Constructionp. 455
Removalp. 458
Installationp. 458
PS PIPINGp. 462
+HD.pdf
+SERVICE DATA AND SPECIFICATIONSp. 467
General Specificationsp. 467
Inspection and Adjustmentp. 467
Adjusting Shimp. 468
Tightening Torquep. 468
TROUBLE DIAGNOSES AND CORRECTIONSp. 469
+PRECAUTIONS AND PREPARATIONp. 473
Precautionsp. 473
Special Service Toolp. 474
+HYDRAULIC SYSTEMp. 475
Hydraulic Circuit Diagramp. 475
Disassembly and Assemblyp. 477
Inspectionp. 490
+OIL PUMP (Gear pump)p. 491
Removalp. 491
Installationp. 491
Disassemblyp. 492
Inspectionp. 493
Assemblyp. 494
Test Proceduresp. 495
+HYDRAULIC CONTROL LEVERp. 497
Mechanical Control Systemp. 497
+CONTROL VALVEp. 498
Removalp. 498
Installationp. 499
Disassemblyp. 499
Inspectionp. 502
Assemblyp. 502
Hydraulic Testp. 502
+TILT CYLINDERp. 505
Constructionp. 505
Removalp. 505
Disassemblyp. 506
Inspectionp. 507
Assemblyp. 507
Installationp. 508
+LIFT CYLINDERp. 509
Constructionp. 509
Removalp. 513
Installation (2W, 2F, 3F, 3V)p. 517
Disassemblyp. 518
Inspectionp. 518
Assemblyp. 519
Adjustmentp. 519
+FULL-FREE CYLINDERp. 520
Constructionp. 520
Removalp. 523
Disassemblyp. 523
Inspectionp. 524
Assemblyp. 524
Installationp. 525
Adjustmentp. 525
+OIL TANK (3-wheel)p. 526
+OIL TANK (4-wheel)p. 527
+LM.pdf
+SERVICE DATA AND SPECIFICATIONSp. 529
Inspection and Adjustmentp. 529
Tightening Torquep. 530
TROUBLE DIAGNOSES AND CORRECTIONSp. 531
+PRECAUTIONS AND PREPARATIONp. 532
+FORKp. 533
Removalp. 533
Inspectionp. 533
Installationp. 533
+LIFT CHAINSp. 534
Removalp. 534
Installationp. 534
Adjustmentp. 534
Inspectionp. 535
+CARRIAGE ASSEMBLYp. 537
Removalp. 537
Inspectionp. 538
Adjustmentp. 538
Installationp. 540
+MASTp. 541
Mast Assemblyp. 541
Removalp. 545
Disassemblyp. 546
Inspectionp. 549
Assemblyp. 549
Installationp. 556
Adjustmentp. 557
Mast bushingp. 558
+BF.pdf
+SERVICE DATA AND SPECIFICATIONSp. 561
General Specificationsp. 561
Tightening Torquep. 562
+PRECAUTIONS AND PREPARATIONp. 563
+BODY AND FRAMEp. 564
Instrument Coversp. 564
Floor Board and Matp. 565
Overhead Guard and Rearview Mirrorp. 566
Seat and Top Panelp. 567
Panels and Counterweightp. 569
+OP.pdf
+OPTIONp. 573
Cabin Option Assembly of Front Window and Doorp. 573
Cabin Option Assembly of Rear Windowp. 574
Cabin Option Location of Electrical Component Parts (3 – wheel)p. 575
Location of Electrical Component Parts (4 – wheel)p. 575
Cabin Option Location of Electrical Component Partsp. 576
Cabin Option Outlinep. 577
Cabin Option Cabin Harness Layoutp. 578
Taken together, these chapters make the TCM 1N1 A1N1 forklift service manual useful for both scheduled servicing and deeper fault-finding. A technician can move from a maintenance requirement or symptom to the relevant specifications, inspection method, diagnostic sequence and component repair procedure without relying on a brief operator-level reference.
Model Identification and Service Context
The manual’s identification information distinguishes FB 4-wheel counterbalance trucks from FTB 3-wheel counterbalance trucks and explains the model-classification structure used across the series. The model comparison shown in the manual includes 1.25-ton through 2.0-ton classification codes and separates AS1N1, A1N1, AG1N1 and JAG1N1 groups. This is useful when checking that a procedure, specification or component illustration corresponds to the truck being serviced.
Service information is presented with SI values and, where shown, metric and foot-pound equivalents. Throughout the manual, specified tightening torques, adjustment values, service limits, inspection criteria and diagnostic measurements are integrated with the procedures rather than separated into a generic overview. That approach helps when carrying out repairs where the sequence and the final measured condition both matter.
Repair, Diagnose and Maintain with the Correct Reference
The TCM 1N1 A1N1 3-4 Wheel Forklift Service Manual – 2012 Draft supports a wide range of workshop jobs: scheduled maintenance, electrical fault tracing, controller and sensor checks, motor and drive-unit work, brake repairs and bleeding, steering service, hydraulic pressure diagnosis, hydraulic component repair, mast and carriage adjustment, loading-mechanism inspection and body/frame removal work. Using the procedures, specifications, tightening torques, diagrams and diagnostic charts in the same manual helps reduce guesswork and gives the technician the correct reference points for inspection, adjustment and reassembly.
Delivery is by instant PDF download after payment, with no physical shipping required. The manual can be opened on compatible phones, tablets and computers and pages can be printed when a paper workshop reference is preferred.
Reviews
There are no reviews yet.