TCM FG15 thru FHG35-A1, FHD20-35-A1 & FCG15-36-A1 Forklift Service Manual Part 1 – PDF

Description

TCM FG15 thru FHG35-A1, FHD20-35-A1 and FCG15-36-A1 Forklift Service Manual – Part 1

This TCM forklift service manual covers the FCG15 thru FD35-A1 series of engine powered industrial trucks – cushion and pneumatic tire models running LPG, gasoline, dual fuel and diesel, in the 3,000 to 8,000 lb capacity range. It is Part 1 of the TCM service manual set, and it opens with the General Information section before working through Maintenance, Engine Removal, the automatic transmission variants and the Differential Carrier. Each procedure is written for the technician actually working on the truck: step-by-step removal, disassembly, inspection, assembly, installation and adjustment instructions, backed by illustrations, values, tightening torques and service data.

File Details

• Manual type: Service Manual (Part 1 of the set)
• Brand: TCM
• Models covered: FG15 thru FHG35-A1, FHD20-35-A1, FCG15-36-A1
• Engines: K21, K25, QD32 (separate tabs referenced for gasoline and diesel engine repair)
• Language: English
• Edition: November 2012
• Printing: November 2012 (01)
• Publication number: SEF-EAHAE
• Format: PDF

Chapters Covered

• GI – General Information: How to use this manual, description, technical term definitions, manual illustrations, identification information (serial number designation, vehicle model classification number), general precautions, jacking and lifting, tightening torque of standard bolts, specifications
• MA – Maintenance: Lubrication chart, grease and oil capacity, periodic maintenance and lubrication schedule for emission control system maintenance (K21/K25 and QD32), chassis and body maintenance schedule
• MA – Engine Maintenance: Cylinder head tightening, manifold tightening, valve clearance inspection and adjustment, compression pressure, fan belt adjustment, engine oil level and replacement, oil filter, coolant level and replacement, radiator and radiator cap, fuel filter, bleeding the fuel system, injection pressure and injection timing (QD32), tar draining from the vaporizer (LPG-gasoline dual fuel), maximum rpm under loaded and unloaded conditions, spark plug, air cleaner, battery
• MA – Chassis Systems: Tires and road wheels, wheel nut torque, brake system inspection and adjustment, brake burnishing, parking brake, steering free play and operation force, hydraulic pressure inspection, automatic transmission fluid level, A/T line pressure, stall speed, loading mechanism (fork, carriage height, lift chain tension, carriage roller, mast roller, mast roller clearance, mast operation, cylinders, greasing points), body electrical (fuses, bulbs), hydraulic shut-off valve test
• ER – Engine Removal: Joint removal of engine and transmission, head guard, cover, air cleaner and other parts, control system for torque converter models, piping and radiator, engine and transmission assembly removal, engine mounting, hoisting the engine
• AT – Automatic Transmission Pneumatic: Service data and specifications, construction, control valve, hydraulic circuit diagrams (neutral, forward, reverse), automatic transmission oil flow, disassembly and assembly of transmission, clutch drum assembly, control valve and oil pump, inspection of torque converter, oil pump, control valve and clutch drum, trouble diagnosis and corrections, adjustment values, hydraulic pressure values, tightening torques, oil pressure measurement, stall speed, brake pedal and inching pedal adjustment, inching valve adjustment
• ATC1 – Automatic Transmission, Cushion Single Speed: Specifications, construction, disassembly of the clutch drum, control valve and oil pump assembly, removing the reduction gears, inspection of construction parts, oil volume inspection, oil change, clamping torque
• ATC2 – Automatic Transmission, Cushion Two Speed: Torque converter and transmission operation, maintenance points, power train, gear pump, hydraulic pump, control valve, hydraulic circuit, cause of problems and countermeasures, disassembling and reassembling, maintenance standard, hydraulics, wear and fatigue, bolt and plug tightening torque
• DF – Differential Carrier (except 3.5T models): Disassembly, inspection and correction, assembly, adjustment, ring gear tooth contact
• DF – Differential Carrier for 3.5T Pneumatic Models: Trouble diagnosis and corrections, component parts location, removal and installation, disassembly, inspection, assembly, adjustment, final verification, special service tools

Together these sections cover the truck from the ground up. GI gives you the identification conventions and the torque standards that the rest of the book leans on; MA provides the full scheduled maintenance regime with lubrication points and intervals; ER walks the engine and transmission out of the chassis as an integrated unit; AT, ATC1 and ATC2 deal with the three automatic transmission configurations fitted across the model range; and DF handles the differential carrier, including the 3.5-ton pneumatic variant with its own dedicated procedures and special service tools. Along the way the manual supplies the measured values you need to judge whether a part is serviceable – valve clearances, compression pressures, oil and coolant capacities, tyre pressures, brake lining limits, fork wear limits, chain deflections, roller clearances, hydraulic pressures and stall speeds.

Service Bulletins Reproduced in This Manual

The document also reprints four TCM service bulletins that apply to these models, and they are worth reading before you start work:

• SB 2005-221 – Tilt cylinder pin lubrication. Two lubrication points per tilt cylinder are shown in the Maintenance section, and the body side pin sits behind the instrument panel covers on the left and right of the forklift. A rubber plug in each cover gives access to the grease fitting. Missing this pin can let it rotate, break the lock plate that secures it to the frame, and allow it to slide out of the tilt cylinder frame mounting bracket.
• SB 2005-220 – Cooling fan. TCMA does not recommend using the cooling fan to rotate the engine crankshaft, because unseen damage to the fan can later cause failure. The bulletin shows the opening in the flywheel housing used instead, with a screwdriver or pry bar turned against the starter ring gear teeth, ignition off and battery disconnected.
• SB 2006-260 – Pneumatic forklift transmission inching cable adjustment. Premature clutch plate wear can result from improper inching cable adjustment, so the bulletin sets out the inching lever travel, cable free play and pedal stopper clearance figures to work to.
• SB 2009-306 – Transmission troubleshooting and warranty repairs. Guidance on using the transmission diagnostic forms, confirming engine performance first, validating inching adjustment with a pressure gauge, and running the stall test and pressure test in the correct sequence.

Specification and Torque Data

Hard numbers are embedded throughout rather than gathered into one place, so they sit next to the job they belong to. Standard bolt tightening torque is tabulated in GI by grade (4T, 7T, 9T) and nominal diameter, with the bolt head markings that identify each grade. Cylinder head tightening for K21 and K25 is given as a staged sequence with an initial torque, a break-in torque, a return to zero and a re-tightening value, with the bolt order illustrated. Valve clearance for K21 and K25 is 0.38 mm; for QD32 it is 0.35 mm with separate intake and exhaust adjustment points. Compression pressure standards differ between the gasoline and diesel engines and the manual explains how to interpret a pressure rise after adding oil to the cylinder. Radiator cap holding pressure, engine oil and coolant capacities for each engine, tyre air pressures by tonnage, wheel nut torque by model and wheel type, brake shoe clearance, automatic transmission main, clutch and torque converter inlet pressures, and differential backlash figures are all present.

Safety and Lifting Procedures

The GI section sets out the general precautions that apply before any of the repair work in the rest of the manual begins, and it is explicit that these should be understood first. It also covers jacking and lifting in detail, with front, rear and complete forklift procedures, the dimensions of the square timbers to use, where they go, and the steps for raising the vehicle safely. Battery handling precautions, electrical system inspection precautions, and warnings about working around hot, rotating and sliding parts are included in the same section.

What This Manual Lets You Do

With this TCM service manual in hand you can carry out scheduled maintenance to the factory interval, diagnose and correct automatic transmission faults using the pressure and stall speed test procedures, strip and rebuild the torque converter, gear pump, control valve and clutch drum, remove and refit the engine and transmission as a unit, and set up a differential carrier including ring gear tooth contact adjustment. The maintenance schedule gives you the inspection and service timings, and the specification values let you decide whether a worn part is still within limits or has to be replaced. Model, engine, serial number and specification data are laid out clearly enough that you can confirm you are looking at the right procedure for the truck in front of you – which matters here, because the series spans four fuel types and six capacity bands.

IMAGES PREVIEW

Delivery is instant. The manual arrives as a downloadable PDF the moment payment clears, there is no shipping and nothing to wait for in the post. Open it on a laptop, tablet or phone in the workshop, or print the pages for the job you are on and take them to the truck with you. Because it is a PDF, you can zoom into the exploded views and the tightening sequence illustrations as far as you need to.