TCM FORKLIFT FD FHD FG FHG SERIES PETROL DIESEL LPG GASOLINE WORKSHOP SERVICE REPAIR MANUAL

(PDF version)



MODELS COVERED

FHD15 T3

FHD18 T3

FD20 T3

FHD20 T3A

FD25 T3

FHD25 T3A

FD30 T3

FHD30 T3A

FD35 T3S

FHG15 T3

FHG18 T3

FG20 T3

FHG20 T3

FG25 T3

FHG25 T3

FG30 T3

FHG30 T3

FG35 T3S


This is a comprehensive workshop service manual for TCM FORKLIFT. This manual has been written in a format that is designed to meet the needs of TCM technicians worldwide. You will never be dissapointed with the quality and content of this service manual.

TABLE OF CONTENTS
1. ENGINE ............................................................................................................................................ 1
1.1 GENERAL DESCRIPTION............................................................................................................. 3
1.1.1 FUEL SYSTEM (Gasoline and Diesel).................................................................................. 10
1.1.2 FUEL SYSTEM (LPG).......................................................................................................... 17
1.1.3 ENGINE CONTROL SYSTEM (Gasoline and LPG)........................................................... 19
1.1.4 COOLING SYSTEM............................................................................................................. 22
1.1.5 ACCELERATOR PEDAL...................................................................................................... 27
1.1.6 AIR CLEANER...................................................................................................................... 29
1.1.7 MUFFLER.............................................................................................................................. 35
2. AUTOMATIC TRANSMISSION SYSTEM ....................................................................... 37
2.1 GENERAL DESCRIPTION........................................................................................................... 37
2.1.1 TORQUE CONVERTER....................................................................................................... 40
2.1.2 CHARGING PUMP............................................................................................................... 41
2.1.3 TRANSMISSION.................................................................................................................. 42
2.1.4 TRANSMISSION CONTROL VALVE................................................................................. 46
3. DRIVE AXLE ................................................................................................................................ 51
3.1 GENERAL DESCRIPTION........................................................................................................... 51
3.1.1 REDUCTION GEAR AND DIFFERENTIAL....................................................................... 57
4. BRAKE SYSTEM ....................................................................................................................... 61
4.1 GENERAL DESCRIPTION........................................................................................................... 61
4.1.1 BRAKE PEDAL..................................................................................................................... 61
4.1.2 MASTER CYLINDER........................................................................................................... 66
4.1.3 WHEEL BRAKE.................................................................................................................... 67
4.1.4 PARKING BRAKE LEVER.................................................................................................. 69
4.1.5 WHEEL BRAKE TROUBLESHOOTING ........................................................................... 72
5. STEERING SYSTEM ................................................................................................................ 73
5.1 GENERAL DESCRIPTION........................................................................................................... 73
5.1.1 STEERING AXLE................................................................................................................. 74
5.1.2 STEERING WHEEL ASSEMBLY........................................................................................ 77
5.1.3 ORBITROL............................................................................................................................ 78
5.1.4 POWER CYLINDER............................................................................................................. 81
5.1.5 STEERING WHEEL DEVIATION CONTROL.................................................................... 82
6. HYDRAULIC SYSTEM ............................................................................................................ 85
6.1 GENERAL DESCRIPTION........................................................................................................... 86
6.1.1 MAIN PUMP.......................................................................................................................... 86
6.1.2 CONTROL VALVE................................................................................................................ 90
6.1.3 VALVE CONTROLS........................................................................................................... 103
6.1.4 LIFT CYLINDER................................................................................................................ 104
6.1.5 FLOW REGULATOR VALVE............................................................................................ 109
6.1.6 TILT CYLINDER................................................................................................................. 110
6.1.7 OIL TANK............................................................................................................................ 111
7. LOAD HANDLING ................................................................................................................... 115
7.1 GENERAL DESCRIPTION......................................................................................................... 116
7.1.1 OUTER AND INNER CHANNELS.................................................................................... 116
7.1.2 CARRIAGE.......................................................................................................................... 118
7.1.3 LOCATIONS OF ROLLERS .............................................................................................. 120
8. ELECTRIC WIRING ................................................................................................................ 123