TCM FD60-2 FD70-2 FD80-2 FD100-2 Forklift Service Manual – SEF-30RAE PDF Download

Description

TCM FD60-2 FD70-2 FD80-2 FD100-2 Forklift Service Manual (SEF-30RAE)

This is the workshop service manual released by TCM for the FD60-2, FD70-2, FD80-2 and FD100-2 forklift trucks, issued under document number SEF-30RAE and dated January 2008. It is the single reference a technician needs to service, adjust, diagnose and repair these four diesel forklift models, from the 6,000 kg capacity FD60-2 up to the 10,000 kg capacity FD100-2.

The trucks share the 4HK1-TC common-rail diesel engine, a full-power-shift transmission with an automatic two-speed ATM controller, a full-hydraulic brake system with accumulator, a centre-pin steering axle with an orbitrol, and a roller-type two-stage mast. The manual walks through every one of those systems with cutaway views, hydraulic schematics and exploded assemblies so you can see the part before you touch it.

File Details

• Manual type: Service Manual
• Brand: TCM
• Models covered: FD60-2, FD70-2, FD80-2, FD100-2
• Document number: SEF-30RAE
• Date: January 2008
• Language: English
• Page count: 114 pages
• File format: PDF

Chapters Covered

• 1. Engine – General Description; Fuel System; Cooling System; Accelerator Pedal; Air Cleaner; Muffler; Inspection and Adjustment (Air Cleaner, Fuel Filter, Oil Filter, Cooling System)
• 2. Drive Unit – General Description; Torque Converter; Charging Pump; Transmission; ATM Controller
• 3. Drive Axle – General Description; Differential; Final Reduction Gear
• 4. Brake System – General Description; Brake Pedal; Brake Valve; Accumulator; Wheel Brake; Parking Brake
• 5. Steering System – General Description; Steering Axle; Steering Wheel Assembly; Orbitrol; Steering Cylinder
• 6. Hydraulic System – General Description; Front Pump; Rear Pump (FD80-2, FD100-2 only); Control Valve; Valve Controls; Lift Cylinder; Flow Regulator Valve; Tilt Cylinder; Oil Tank
• 7. Load Handling System – General Description; Outer & Inner Channel; Carriage; Locations of Rollers
• 8. Electric Wiring – Wire harnesses, combination meter, fuse box, lamp assemblies and component location diagrams

Taken as a whole, this TCM service manual gives a working technician the full picture of how the FD60-2 through FD100-2 trucks are put together and how each subsystem is meant to behave. The engine chapter alone goes deep into the 4HK1-TC fuel system, cooling circuit, air cleaner and filter service. The drive unit chapter breaks down the torque converter, charging pump, clutch packs and the transmission control valve, including the accumulator and inching spool circuit, and explains the ATM controller shift points. The brake chapter covers the full-hydraulic system end to end: brake valve open/closed operation, accumulator charging, wheel brake duo-servo and two-leading layouts, auto adjuster behaviour and parking brake lever adjustment. Steering, hydraulics and the load handling system are documented with exploded views of the orbitrol, steering cylinder, lift and tilt cylinders, flow regulator valve, control valve plunger sections and mast roller positions.

What You Can Do With It

With this manual on hand you can tear down and rebuild the 4HK1-TC engine ancillaries, bleed the fuel system correctly, service the charging pump and transmission control valve, set clutch pressures to the specified figures, overhaul the wheel brakes and accumulator, adjust the parking brake lever pull force, rebuild the orbitrol and steering cylinder, reseal the lift and tilt cylinders, and diagnose electrical faults against the colour-coded wiring diagrams and fuse box chart. Torque figures and tightening sequences appear at the point of use throughout the illustrations, so you are not left guessing.

Having the correct procedures and specification values matters most when a wrong clearance, a mis-set clutch pressure or an incorrectly bled circuit turns a routine service into a repeat repair. This manual gives you the numbers TCM published for these exact models rather than generic guidance.

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The TCM FD60-2 FD70-2 FD80-2 FD100-2 service manual is delivered as an instant PDF download after checkout – no shipping, no waiting. Open it on a laptop in the workshop, a tablet beside the machine, or print only the pages you need for the job at hand.