TCM FD35T9-FD45T9 & FG35T2-FG45T2 Forklift Truck Service Manual – Diesel & Gas PDF

Description

TCM FD35T9-FD45T9 & FG35T2-FG45T2 Forklift Truck Service Manual

This is the complete service manual for TCM forklift trucks in the FD35T9, FD40T9, FD45T9 (diesel) and FG35T2, FG40T2, FG45T2 (gasoline) series. Published under document number SEF-43BBE in February 2010, this 116-page manual covers every major system on these trucks, from the engine and torque converter drive unit through to the electric wiring diagrams. Whether you are servicing a single machine or running a fleet, this manual gives you the procedures, specifications and diagrams needed to do the job correctly.

File Details

• Manual Type: Service Manual
• Brand: TCM
• Models Covered: FD35T9, FD40T9, FD45T9 (Diesel) / FG35T2, FG40T2, FG45T2 (Gasoline)
• Language: English
• Page Count: 116
• File Format: PDF
• Document Number: SEF-43BBE
• Date: February 2010

Chapters Covered

• 1. Engine
• 2. Torque Converter Type Drive Unit
• 3. Drive Axle
• 4. Brake System
• 5. Steering System (Orbitrol Type)
• 6. Hydraulic System
• 7. Load Handling System
• 8. Electric Wiring

1. Engine

Covers the S6S-31TFL diesel engine and TB45E gasoline engine in detail. Includes general description, fuel system (tank, level sender, fuel filter, fuel pump), cooling system (radiator, water pump, reserve tank), accelerator pedal, and air cleaner. The inspection and adjustment section provides procedures for the air cleaner, fuel filter, oil filter, and cooling system, along with valve clearance, injection timing, compression pressure, and fan belt tension specifications. Engine mounting diagrams, torque curves, and performance graphs are included for both engine types.

2. Torque Converter Type Drive Unit

Documents the torque converter, clutch packs, transmission control valve, oil circulation route, charging pump, and automatic transmission controller. Includes hydraulic circuit diagrams showing forward first gear, forward second gear, and reverse gear operation. Provides stall torque ratio, charging oil pressure, clutch oil pressure, and shift point specifications. The automatic transmission controller section covers speed shift points and adjustment.

3. Drive Axle

Covers the full-floating drive axle, wheel hub, tapered roller bearings, and differential. Includes exploded views with tightening torques for the 3.5- to 4.0-ton trucks and 4.5-ton trucks, along with differential reduction ratio and adjustment procedures. Bearing and oil seal replacement details are provided.

4. Brake System

Details the brake pedal, wheel brake, parking brake, automatic clearance adjuster, and brake booster. Provides wheel cylinder bore, brake drum inner diameter, lining dimensions, and hydraulic pressure specifications. Includes operating descriptions for forward and backward travel braking, plus parking brake lever adjustment and automatic clearance adjuster operation.

5. Steering System (Orbitrol Type)

Covers the steering axle, steering wheel assembly, orbitrol, and power cylinder. Includes steering angles, orbitrol discharge rate, cylinder bore and stroke, and detailed operation descriptions for neutral, counterclockwise, and clockwise steering positions, plus emergency steering with a defective pump. Steering axle tightening torques and knuckle bearing details are provided.

6. Hydraulic System

Documents the main pump, control valve (inlet, lift, and tilt sections), valve controls, lift cylinder, flow regulator valve, tilt cylinder, and oil tank. Includes pump discharge rates, relief valve pressure settings, cylinder dimensions, and a complete hydraulic piping diagram. Main relief valve operation is explained with detailed illustrations.

7. Load Handling System

Covers the outer and inner channels, carriage, and roller locations for the VM-43A and VM-43F masts. Includes exploded views of the mast assembly, carriage components, and roller adjustment procedures. Roller locations for both mast types are shown in cross-section.

8. Electric Wiring

Provides electric component mounting diagrams, fuse box layouts, wire harness routing, and complete wiring diagrams for both diesel and gasoline engine models. Includes color codes, connector symbols, and circuit diagrams for the engine, transmission controller, overhead guard, and ECM. Bulb replacement procedures for head lamps, work lights, and combination lamps are also covered.

Engines Covered

The manual covers two engines in full detail:

• S6S-31TFL Diesel: 4-cycle, water-cooled, overhead valve swirl chamber-type, 6 cylinders, 94 x 120 mm bore and stroke, 4996 cc displacement, 64.7 kW {88 PS} at 2300 rpm, 284 N-m {29 kgf-m} [210 lbf-ft] at 1600 rpm.
• TB45E Gasoline: 4-cycle, water-cooled, overhead valve, 6 cylinders, 99.5 x 96.0 mm bore and stroke, 4478 cc displacement, 72.8 kW {98 PS} at 2450 rpm, 287 N-m {29.2 kgf-m} [210.7 lbf-ft] at 1600 rpm.

Why This Manual Matters

These TCM forklift trucks are built for demanding industrial work, and keeping them running requires accurate specifications and correct procedures. This service manual gives you both. The engine chapter alone provides compression pressures, valve clearances, injection timing, and torque values that are essential for proper diagnosis and repair. The transmission and hydraulic sections include circuit diagrams and pressure specifications that let you trace faults methodically rather than guessing. The brake and steering chapters cover the safety-critical systems with the detail needed to service them correctly.

For anyone maintaining or repairing an FD35T9, FD40T9, FD45T9, FG35T2, FG40T2 or FG45T2, this manual is the reference that turns a difficult job into a straightforward one. The exploded views and tightening torques alone save hours of guesswork.

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This TCM forklift service manual is delivered as an instant PDF download. No shipping, no waiting. Use it on any device — laptop, tablet, or smartphone — and print the pages you need for the workshop. Whether you are servicing a single truck or managing a fleet, you have the complete manual at your fingertips immediately after purchase.