TCM FB30-7 - Page 57

- 45 -
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oororgroundtopreventthe
truck from moving accidentally when the motor suddenly starts rotating for any reason.
In addition, use caution to prevent your body from touching the tires.
1. Checking electrical components of controller
(1) Tools and measuring equipment
(2) Tightening torque
No. Name Spec. & remarks Use
   Phillipsandat-bladedscrewdrivers(large,medium, Tightenandremovescrews.
 1 Screwdriverset andsmall,oneforeach),at-bladedscrewdriverfor Setadjustmentcontrol.
small screws
2 Wrench set
7 mm, 13 mm, 17 mm Tighten and remove bolts and nuts
(socket wrenches)
 3 Torquewrench Powermodulettingscrews:M4,M5 Measuretighteningtorqueofpowermodules
4 Tweezers and pliers Install and remove small parts
 5 Ammeter DC500Aor1000A Measureelectriccurrent
 6 Digitaltester upto12V,30V,120V Measurevoltage
Analog tester
range: x 1 Ω, x 100 Ω, x 1000 Ω Measureresistance(digitaltestercannotbeusedforthispurpose.)
7 Oscilloscope Check transistor circuit
8 Stabilized power
0 - 50 V, variable, 3A conductable Check operation of each component.
supply for control
Where to tighten
Symbol Truck Model
Screw Torque
Remarks
Part name Item size (N-m)
Printedcircuit Fixed  1t N61F30851=3 M4.5 1.0
board (CPU) 2 t N61F30851=4
3 t, 3.5 t N61F30851=5
Printedcircuitboard Fixed  Common N61F30841=7 M4.5 1.0
(power supply)
Powermodule Fixed TMDU 1t N51F45956=222 M5 2.5±0.5 Heat-dissipation,insulation
  TMDV/W  N51F45481=222   sheetisplacedonthebase.
  TMP  N51F45956=216   Forshape,see*1.
  TMDU 2t N51F46529=224
  TMDV/W  N51F46528=224
  TMP  N51F45956=216
  TMDU 3t N51F46529=124
  TMDV/W 3.5t N51F46528=124
  TMP  N51F45956=114
Powermodule Fixed  Common N55F42549 M5 2.5±0.5
Alminumblockterminal Terminal    M8 9.8±1
Capacitorboard Fixed&terminal CBD 1t N61F30830=221 M5 2.5±0.5 M4screwisusedfortwo
  CBP  N61F30831=215 M4 1.5±0.2 studsofCBP.
CBD 2 t N61F30813=230
CBP N61F30831=215
CBD 3 t N61F30813=150
CBP 3.5 t N61F30831=114
Contactor Fixed MD 1t,3t, MA25M46V M5 2.5±0.5
 Terminal MP 3.5t MA25M46V M8 9.8±1
 Fixed MD 2t MA27M46V M5 2.5±0.5
 Terminal MP  MA25M46V M8 9.8±1
Contactor Fixed MPS Common CM2-ADC48V M4 1.5±0.2
 Terminal    M4 1.3±0.2
Currentsensor Fixed CSDU/W,CSP Common S3CM7-800/4MD M4 1.5±0.2
IGBT Fixed TMPS1/2 Common 2MBI100N-60 M5 2.5±0.5
 Terminal    M5 2.5±0.5
CapacitorCP5 Fixed CPS Common N71F41314 M4 1.5±0.2 HFC-MPP63Y155K
+0.5
0
+0.5
0