This workshop service repair manual covers TCM forklifts designed for industrial material handling. The models included are 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, and FG35 T3S. These forklifts are equipped with internal combustion engines and utilize Petrol, Diesel, or LPG as fuel sources, paired with an automatic transmission system.
This manual provides comprehensive guidance for maintaining and repairing your TCM forklift. It details procedures for the engine, automatic transmission system, drive axle, brake system, steering system, hydraulic system, load handling mechanisms, and electrical wiring. With this resource, owners, mechanics, and technicians can effectively perform diagnostics, troubleshooting, and repairs, ensuring the continued optimal performance and longevity of the equipment.
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
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
