This manual provides comprehensive service and repair information for Forklift Lift Truck models, specifically the FH, FD, FHD, FG, and FHG series, encompassing load capacities from 15 through 35. Forklifts, known for their reliability and robust construction, are essential equipment in industries such as manufacturing, construction, agriculture, logistics, and warehousing. This extensive guide covers a wide range of vital systems, including gasoline, diesel, and LPG engines, automatic transmissions with torque converters, drive axles, brake systems, steering mechanisms, and hydraulic systems. It also details load handling components, electrical wiring, and specific service procedures for each, ensuring optimal performance and longevity for your material handling operations.
The purpose of this Service Workshop Repair Manual is to equip mechanics, technicians, and owners with the detailed knowledge required for the diagnosis, maintenance, and repair of forklifts. It contains in-depth technical information, step-by-step procedures for maintenance and overhaul, troubleshooting guides for common issues, and essential specifications. Key areas covered include engine diagnostics and repair, fuel system service for all fuel types, transmission system maintenance, brake and steering system adjustments, hydraulic component service, and load handling mechanism inspections. The manual also includes crucial electrical wiring diagrams and schematics, providing a complete resource for keeping your forklift in peak operational condition.
TCM Forklift truck service manual pdf download
FHD15
T3
FHD18
T3
FD20
T3
FHD20
T3A
FD25
T3
FHD25
T3A
FD30
T3
FHD30
T3A
FD35
T3
FHG15
T3
FHG18
T3
FG20
T3
FHG20
T3
FG25
T3
FHG25
T3
FG30
T3
FHG30
T3
FG35
T3S
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
No. SEF-0F7BE
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
....................................................................................................
TCM Forklift truck service manual pdf download
FHD15
T3
FHD18
T3
FD20
T3
FHD20
T3A
FD25
T3
FHD25
T3A
FD30
T3
FHD30
T3A
FD35
T3
FHG15
T3
FHG18
T3
FG20
T3
FHG20
T3
FG25
T3
FHG25
T3
FG30
T3
FHG30
T3
FG35
T3S
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
No. SEF-0F7BE
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
....................................................................................................
