Description
TCM FGE15-35E2 & FD20-35E2 Series Forklift Service Manual
This is the full service manual for TCM counter-balanced forklift trucks in the FGE15E2 through FGE35E2 LPG range and the FD20E2 through FD35E2 diesel range. It is the workshop reference that covers the truck as a whole system, from the GK21E/GK25E LPG and D04EG diesel engine mountings down to the final drive, mast rollers and brake shoes. If you are working on any of these chassis codes, this is the document that carries the procedures, clearances, tightening torques and wiring you will actually use on the shop floor.
File Details
- Manual type: Service Manual (Workshop Manual)
- Brand: TCM
- Manufacturer: Mitsubishi Logisnext Europe B.V. (MLE)
- Document number: STFEE-CH18E-202
- Publication date: August 2021 (originally issued 31 August 2021)
- Language: English
- File format: PDF
- Contents: 16 chapters, including full circuit diagrams
- Engines covered: GK21E / GK25E LPG, D04EG diesel
- Transmission type: Powershift (torque converter) and MC/FC hydraulic control variants
Trucks Covered by the TCM FGE15-35E2 & FD20-35E2 Forklift Service Manual
The manual identifies each truck by model name and serial number range, which is how TCM separates running changes across the FGE and FD lines. The LPG trucks are grouped by chassis prefix CH34A, CH17E and CH13G. The diesel trucks use CH18E and CH14G. Both MC (mechanical control) and FC (finger-tip control) truck types are covered, and the FC type is used on torque converter models only.
- FGE15E2 – CH34A-00001 to 19999, GK21E LPG
- FGE15E2F – CH34A-20001 to 39999, GK21E LPG
- FGE18E2 – CH34A-40001 to 49999, GK21E LPG
- FGE18E2F – CH34A-50001 to 59999, GK21E LPG
- FGE20CE2 – CH34A-60001 to 69999, GK21E LPG (compact, short wheelbase)
- FGE20CE2F – CH34A-70001 to 99999, GK21E LPG
- FGE20E2 – CH17E-00001 to 24999, GK21E LPG
- FGE20E2F – CH17E-25001 to 49999, GK21E LPG
- FGE25E2 – CH17E-50001 to 74999, GK21E LPG
- FGE25E2F – CH17E-75001 to 99999, GK21E LPG
- FGE30E2 – CH13G-00001 to 24999, GK25E LPG
- FGE30E2F – CH13G-25001 to 49999, GK25E LPG
- FGE35E2 – CH13G-50001 to 74999, GK25E LPG
- FGE35E2F – CH13G-75001 to 99999, GK25E LPG
- FD20E2 – CH18E-00001 to 24999, D04EG diesel
- FD20E2F – CH18E-25001 to 49999, D04EG diesel
- FD25E2 – CH18E-50001 to 74999, D04EG diesel
- FD25E2F – CH18E-75001 to 99999, D04EG diesel
- FD30E2 – CH14G-00001 to 24999, D04EG diesel
- FD30E2F – CH14G-25001 to 49999, D04EG diesel
- FD35E2 – CH14G-50001 to 74999, D04EG diesel
- FD35E2F – CH14G-75001 to 99999, D04EG diesel
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “TCM FGE15-35E2 & FD20-35E2 Series Forklift Service Manual – STFEE-CH18E-202 PDF” are as follows:
+CHAPTER 1 GENERAL INFORMATIONp. 25
+1.1 Model Viewp. 25
1.1.1 MC Modelp. 25
1.1.2 FC Modelp. 25
+1.2 Truck Models Coveredp. 26
1.2.1 Truck Nomenclature and Definitionsp. 26
1.3 Serial Number Locationsp. 27
1.4 Dimensionsp. 28
1.5 Technical Datap. 29
1.6 Performancep. 31
+CHAPTER 2 COOLING SYSTEMp. 33
+2.1 Specificationsp. 33
2.1.1 Specifications – Overviewp. 33
2.1.2 Structurep. 33
+2.2 Fan Beltp. 34
2.2.1 Fan Belt – Overviewp. 34
2.2.2 Fan Belt Removalp. 34
2.2.3 Fan Belt Installationp. 35
+2.3 Inspection and Adjustmentp. 35
2.3.1 Fan Belt Inspectionp. 35
2.3.2 Fan Belt Tensionp. 35
2.3.3 Connecting Hosesp. 36
2.3.4 Unit Layoutp. 37
2.3.5 Coolantp. 38
2.3.6 Radiator Capp. 38
+CHAPTER 3 ELECTRICAL SYSTEMp. 39
+3.1 Chassis Electrical Components and Wiring Outlinep. 39
3.1.1 D04EG Engine Modelp. 39
3.1.2 GK21/25E Engine Modelsp. 41
3.1.3 Electrical Components and Wiring Diagram of Each Systemp. 42
+3.2 Console Boxp. 53
3.2.1 Outline of Console Boxp. 53
3.2.2 Removing Meter Panelp. 53
+3.3 Main Electrical Componentsp. 57
3.3.1 Meter Panelp. 57
3.3.2 Key Switch (Anti-Restart Switch)p. 58
3.3.3 Combination Switchp. 60
3.3.4 Direction Switchp. 61
3.3.5 Hornp. 63
3.3.6 Tank Unitp. 64
3.3.7 Brake Fluid Sensorp. 65
3.3.8 Stop Light Switchp. 65
3.3.9 Thermoswitch for Engine Coolant Temperature (GK21 / 25E Engine Model and D04EG Engine Model)p. 66
3.3.10 Thermoswitch (T/C Oil)p. 67
3.3.11 Fuse Boxp. 68
3.3.12 Relay Boxp. 70
3.3.13 USB Port Socket (Option)p. 75
3.3.14 List of Lightsp. 75
+3.4 Battery Maintenancep. 76
3.4.1 Battery Specific Gravity Condition and Adjustmentp. 76
3.4.2 Relationship Between Electrolyte Specific Gravity and State of Chargep. 77
3.4.3 Precautions for Battery Chargingp. 77
+3.5 Meter Panelp. 78
3.5.1 Meter Panel Layoutp. 78
3.5.2 Screenp. 79
3.5.3 Basic Screen Displayp. 80
3.5.4 Basic Operationp. 84
3.5.5 Overspeed Warning Display (Standard: Diesel Model / Option: LPG Model)p. 90
3.5.6 Load Meter Display (Standard: Diesel Model / Option: LPG Model)p. 90
3.5.7 Load Meter Zero Set Switch (Standard: Diesel Model / Option: LPG Model)p. 91
3.5.8 Overload Warning Display (Standard: Diesel Model / Option: LPG Model)p. 91
3.5.9 Speed Restriction Switchp. 91
3.5.10 Start Acceleration Speed Selector Switchp. 92
3.5.11 When Diagnostic Code Is Shown on Screenp. 92
3.5.12 When Several Warnings Occur Simultaneouslyp. 95
3.5.13 Warning Iconsp. 98
3.5.14 Warning and Indicator Iconsp. 99
3.5.15 Engine Oil Warning Symbols (Diesel Model)p. 100
3.5.16 DPF (Diesel Particulate Filter) Warning Icon and Soot Accumulation Meter (Diesel Model)p. 101
3.5.17 HEST (High Exhaust System Temperature) Warning Icon (Diesel Model)p. 102
3.5.18 DPF (Diesel Particulate Filter) and Emission Control (Diesel Model)p. 102
3.5.19 DPF (Diesel Particulate Filter) Automatic Regeneration Disable Mode (Diesel Model)p. 109
3.5.20 Other Points to be Kept in Mind when Using DPF Units (Diesel Model)p. 109
3.5.21 Password Authentication (Option)p. 110
3.5.22 Service Interval Display (Option)p. 111
3.5.23 Hour Meterp. 111
3.5.24 Troubleshootingp. 112
+3.6 Wire Colorp. 114
3.6.1 Wire Color – Overviewp. 114
3.6.2 List of Wire Color Codesp. 114
+3.7 Troubleshootingp. 115
3.7.1 Engine Startup Problemp. 115
3.7.2 Gauge Related Problemp. 115
3.7.3 Light Related Problemsp. 116
3.7.4 Warning Device Problemp. 116
3.7.5 Battery Related Problemp. 117
+CHAPTER 4 CONTROLLERSp. 119
4.1 Outlinep. 119
+4.2 Main Functionsp. 121
4.2.1 Main Functions of Controllersp. 121
4.2.2 Meter Panelp. 123
4.2.3 VCM (Vehicle Control Module)p. 123
4.2.4 ECM (Engine Control Module) for Diesel Engine Modelp. 123
4.2.5 ECM (Engine Control Module) for LPG Engine Modelp. 123
4.2.6 Remote Input / Output Unitsp. 123
4.2.7 GSE Connectorp. 124
+4.3 Mast Interlock Systemp. 127
4.3.1 Functionp. 127
4.3.2 Checking Mast Interlock System of VCM Controllerp. 128
4.3.3 Active Test Inspection Procedurep. 130
+4.4 Driving Interlock Systemp. 131
4.4.1 Controller Functionp. 131
4.4.2 Driving Interlock System Functionsp. 132
4.4.3 Checking Driving Interlock Functionp. 133
4.4.4 Active Test Inspection Procedurep. 135
+4.5 Seat Belt Warning Iconp. 136
4.5.1 Functions of Seat Belt Warning Iconp. 136
4.5.2 Seat Belt Warning Functionsp. 136
4.5.3 Checking Seat Belt Warning Iconp. 137
+4.6 Parking Brake Warning Buzzer and Iconp. 138
4.6.1 Checking the Operation of Parking Brake Warning Buzzer / Iconp. 138
4.6.2 Parking Brake Warning Buzzerp. 140
4.6.3 Checking the Operation of Parking Brake Warning Buzzer / Icon with Key in OFF Positionp. 141
+4.7 Harness Codesp. 142
4.7.1 Harness Codes – Overviewp. 142
4.7.2 VCM (GK21 / 25E Engine Models)p. 144
4.7.3 VCM (D04EG Engine Model)p. 145
4.7.4 Connector of FC Armrest and Output Unit (FC Models)p. 149
4.7.5 ECM (D04EG Engine Model)p. 152
4.7.6 ECM (GK21/25E Engine Models)p. 156
4.7.7 Meter Panelp. 156
4.7.8 Seat Switchp. 158
4.7.9 Parking Brake Switchp. 158
4.7.10 Direction Lever Switchp. 159
4.7.11 Speed Sensorp. 159
4.7.12 T/M Solenoidp. 160
4.7.13 Unload Solenoidp. 160
4.7.14 Lift Lock Solenoidp. 161
4.7.15 Tilt Lock Solenoidp. 162
4.7.16 Warning Buzzerp. 163
4.7.17 Warning Buzzer Relayp. 163
4.7.18 Warning Buzzer Circuitp. 164
4.7.19 Meter Panelp. 165
+4.8 Truck Status Display and Troubleshootingp. 168
4.8.1 Truck Status Displayp. 168
4.8.2 Diagnosis Table (F Code)p. 170
4.8.3 LED Blink Patternp. 187
4.8.4 Diagnostic Codes and Troubleshootingp. 188
+CHAPTER 5 POWER TRAINp. 205
+5.1 Removal and Installation (MC Models)p. 205
5.1.1 Removal of Engine and Transmission Assembly (for LPG Engine Model)p. 205
5.1.2 Removal of Engine and Transmission Assembly (for Diesel Engine Model)p. 212
+5.2 Removal and Installation (FC Models)p. 219
5.2.1 Removal of Engine and Transmission Assemblyp. 219
+CHAPTER 6 POWERSHIFT TRANSMISSIONp. 221
+6.1 Structure and Functionsp. 221
6.1.1 Transmissionp. 221
6.1.2 Torque Converterp. 223
6.1.3 Control System for Powershift Transmissionp. 224
6.1.4 Hydraulic System Schematic of Powershift Transmissionp. 225
+6.2 Removal and Installationp. 227
6.2.1 Removalp. 227
6.2.2 Installationp. 227
+6.3 Outlinep. 228
6.3.1 Overall View of Powershift Transmissionp. 228
6.3.2 Overall View of Control Valvep. 230
+6.4 Powershift Transmission, Disassemblyp. 230
6.4.1 Preparationp. 230
6.4.2 Transmission External Parts, Removalp. 231
6.4.3 Oil Pump Assembly, Removalp. 233
6.4.4 Transmission Housing, Removalp. 233
6.4.5 Input Shaft, Idler Shaft, and Output Gear, Removalp. 235
6.4.6 Transmission Housing, Disassemblyp. 236
6.4.7 Torque Converter Housing, Disassemblyp. 237
6.4.8 Idler Shaft, Disassemblyp. 238
6.4.9 Output Gear, Disassemblyp. 238
6.4.10 Forward Input Shaft Gear Assembly, Disassemblyp. 238
6.4.11 Reverse Input Shaft Gear Assembly, Disassemblyp. 242
6.4.12 Oil Pump Body, Disassemblyp. 243
+6.5 Powershift Transmission, Assemblyp. 244
6.5.1 Transmission Housing, Assemblyp. 244
6.5.2 Torque Converter Housing, Assemblyp. 245
6.5.3 Idler Shaft Assembly, Assemblyp. 246
6.5.4 Output Gear Assembly, Assemblyp. 246
6.5.5 Input Shaft Gear Assembly, Inspectionp. 246
6.5.6 Forward Input Shaft Gear Assembly, Assemblyp. 248
6.5.7 Reverse Input Shaft Gear Assembly, Assemblyp. 253
6.5.8 Oil Pump Assembly, Assembly and Installationp. 253
6.5.9 Torque Converter Housing, Assemblyp. 257
6.5.10 Transmission Housing, Installationp. 259
6.5.11 Servo Case Assembly, Installationp. 260
6.5.12 Transmission External Parts, Installationp. 262
+6.6 Control Valve, Disassemblyp. 266
6.6.1 Control Valve External Parts, Removalp. 266
6.6.2 Valve Body Plate, Removalp. 266
6.6.3 Plugs, Removalp. 266
6.6.4 Strainer, Removalp. 267
6.6.5 Regulator Valve Section, Removalp. 267
6.6.6 Accumulator Valve Section, Removalp. 268
6.6.7 Inching Valve Section, Removalp. 269
6.6.8 Oil Seal and Plug, Removalp. 270
+6.7 Control Valve, Assemblyp. 272
6.7.1 Control Valvep. 272
6.7.2 Washing and Inspectionp. 273
6.7.3 Valve Plug and Oil Seal, Installationp. 273
6.7.4 Inching Valve Section, Assemblyp. 275
6.7.5 Accumulator Valve Section, Assemblyp. 276
6.7.6 Regulator Valve Section, Assemblyp. 276
6.7.7 Strainer, Installationp. 278
6.7.8 Plugs, Installationp. 278
6.7.9 Valve Body Plate, Breather Cover, Installationp. 279
6.7.10 Control Valve External Parts, Removalp. 280
+6.8 Inspection and Adjustmentp. 280
6.8.1 Oil Pressure Measurementp. 280
6.8.2 Brake (Inching) Pedal, Adjustmentp. 284
6.8.3 Inching Cable, Adjustment Orderp. 285
+6.9 Troubleshootingp. 287
6.9.1 Powershift Transmissionp. 287
6.10 Service Datap. 291
+CHAPTER 7 FRONT AXLE AND REDUCTION DIFFERENTIALp. 297
+7.1 Structurep. 297
7.1.1 1 ton classp. 297
7.1.2 2 ton classp. 298
7.1.3 3 ton classp. 299
+7.2 Removal and Installationp. 300
7.2.1 Front Wheelsp. 300
7.2.2 Front Axle and Reduction Differentialp. 302
+7.3 Disassembly and Assemblyp. 304
7.3.1 Front Axlep. 304
7.3.2 Reduction Differentialp. 310
7.4 Troubleshootingp. 322
7.5 Service Datap. 323
+CHAPTER 8 REAR AXLEp. 325
+8.1 Structure and Functionsp. 325
8.1.1 Rear Axle in Generalp. 325
8.1.2 Structure of Main Components of Rear Axlep. 327
8.1.3 Steering Cylinderp. 329
+8.2 Removal and Installationp. 330
8.2.1 Rear Wheel and Rear Axle Assemblyp. 330
+8.3 Disassembly and Assemblyp. 333
8.3.1 Wheel Hub, Disassembly, and Assembly Orderp. 333
8.3.2 Knuckle (King Pin), Disassembly and Assemblyp. 336
8.3.3 Steering Cylinder, Disassembly and Assemblyp. 339
8.3.4 Tie Rod, Disassembly and Assembly Orderp. 341
+CHAPTER 9 BRAKE SYSTEMp. 343
+9.1 Brake System Structurep. 343
+9.2 Disassembly and Assemblyp. 344
9.2.1 Master Cylinderp. 344
9.2.2 Wheel Brakesp. 346
9.2.3 Wheel Cylinderp. 354
+9.3 Inspection and Adjustmentp. 356
9.3.1 Automatic Adjuster Testp. 356
9.3.2 Manual Adjustmentp. 356
9.3.3 Parking Brake Cable Adjustmentp. 357
9.3.4 Brake Pedal Adjustmentp. 358
9.3.5 Brake Lines Bleedingp. 359
9.3.6 Braking Performance Testp. 361
9.3.7 Parking Brake Leverp. 361
9.4 Troubleshootingp. 362
9.5 Service Datap. 364
+CHAPTER 10 STEERING SYSTEMp. 367
+10.1 Structure and Functionsp. 367
10.1.1 Steering System Main Componentsp. 367
10.1.2 Steering Valvep. 368
10.1.3 Steering Column Main Componentsp. 370
+10.2 Disassembly and Assemblyp. 371
10.2.1 Hydraulic Component and Pipingp. 371
10.2.2 Steering Wheel and Steering Valve, Removal and Installationp. 373
10.2.3 Steering Wheelp. 374
10.2.4 Steering Valvep. 376
10.2.5 Tilt Lock Leverp. 376
+10.3 Steering Valvep. 378
10.3.1 Disassemblyp. 378
10.3.2 Assembly Orderp. 381
10.4 Troubleshootingp. 386
10.5 Service Datap. 388
+CHAPTER 11 HYDRAULIC SYSTEMp. 389
+11.1 Structure and Functionsp. 389
11.1.1 Hydraulic System Main Componentsp. 389
11.1.2 Hydraulic Circuit Diagram (MC Model)p. 391
11.1.3 Hydraulic Circuit Diagram (FC Model)p. 393
11.1.4 Hydraulic Tankp. 394
11.1.5 Hydraulic Pump (Gear Pump)p. 395
11.1.6 Control Valvep. 397
11.1.7 Flow Regulator Valve (FC Model)p. 399
11.1.8 Down Safety Valvep. 400
11.1.9 Lift Cylinderp. 401
11.1.10 Tilt Cylinderp. 409
+11.2 Disassembly and Reassemblyp. 410
11.2.1 Hydraulic Pumpp. 410
11.2.2 Lift Cylinderp. 414
11.2.3 Tilt Cylinderp. 430
11.2.4 Flow Regulator Valvep. 435
11.2.5 Pipingp. 436
11.2.6 Suction Strainer and Return Filterp. 438
+11.3 Inspection and Adjustmentp. 439
11.3.1 Hydraulic Tankp. 439
11.3.2 Control Valvep. 440
11.3.3 Descent Testp. 443
11.3.4 Forward Tilt Testp. 444
+11.4 Troubleshootingp. 445
11.4.2 Hydraulic System Cleaning After a Component Failurep. 449
11.5 Service Datap. 449
+11.6 MC Control Valvep. 453
11.6.1 Structure and Operationp. 453
11.6.2 Control Valve, Removal and Installationp. 464
11.6.3 Disassembly and Assemblyp. 465
+11.7 FC Control Valvep. 471
11.7.1 Structure and Operationp. 471
11.7.2 Actionp. 476
11.7.3 Pressure Control Valve Actionsp. 492
11.7.4 Specificationsp. 497
11.7.5 Precautionsp. 498
11.7.6 Disassembly of FC Control Valvep. 499
11.7.7 Assembling FC Control Valvep. 505
+CHAPTER 12 MAST AND FORKSp. 515
+12.1 Simplex Mastp. 515
12.1.1 Simplex Mast – Overviewp. 515
12.1.2 Mast Systemp. 515
12.1.3 Structure and Functionsp. 517
12.1.4 Removal Order of Mast and Lift Bracket Assemblyp. 519
12.1.5 Key Points for Removing Mast and Lift Bracket Assemblyp. 519
12.1.6 Key Points for Installing Mast and Lift Bracket Assemblyp. 522
12.1.7 Disassembly Order of Mast and Lift Bracketp. 524
12.1.8 Preparation for Disassembling Mast and Lift Bracketp. 525
12.1.9 Key Points for Disassembling Mast and Lift Bracketp. 525
12.1.10 Inspecting Mast and Lift Bracket (All Mast Models)p. 526
12.1.11 Assembly Order of Lift Bracket Roller (All Mast Models)p. 528
12.1.12 Lift Bracket Clearance Adjustment (All Mast Models)p. 529
12.1.13 Installing Mast Rollers (All Mast Models)p. 535
12.1.14 Installing Mast Strips (All Mast Models)p. 536
12.1.15 Installing Lift Cylinders (All Mast Models)p. 538
12.1.16 Connecting Chainsp. 540
12.1.17 Installing Hydraulic Linesp. 543
12.1.18 Removing and Installing Mast Rollers and Strips Without Removing Mast from Truckp. 545
12.1.19 Inspection and Adjustmentp. 547
12.1.20 Troubleshootingp. 564
12.1.21 Service Datap. 565
+12.2 Duplex Mastp. 567
12.2.1 Duplex Mast – Overviewp. 567
12.2.2 Mast Systemp. 567
12.2.3 Structure and Functionsp. 569
12.2.4 Removal Order of Mast and Lift Bracket Assemblyp. 571
12.2.5 Key Points for Removing Mast and Lift Bracket Assemblyp. 572
12.2.6 Key Points for Installing Mast and Lift Bracket Assemblyp. 574
12.2.7 Disassembly Order of Mast and Lift Bracketp. 576
12.2.8 Preparation for Disassembling Mast and Lift Bracketp. 577
12.2.9 Key Points for Disassembling Mast and Lift Bracketp. 577
12.2.10 Inspecting Mast and Lift Bracket (All Mast Models)p. 579
12.2.11 Assembly Order of Lift Bracket Roller (All Mast Models)p. 581
12.2.12 Lift Bracket Clearance Adjustment (All Mast Models)p. 582
12.2.13 Installing Mast Rollers (All Mast Models)p. 588
12.2.14 Installing Mast Strips (All Mast Models)p. 590
12.2.15 Installing Second Lift Cylinder (All Mast Models)p. 590
12.2.16 Installing First Lift Cylinderp. 592
12.2.17 Connecting Chainsp. 593
12.2.18 Installing Hydraulic Linesp. 596
12.2.19 Removing and Installing Mast Rollers and Strips Without Removing Mast from Truckp. 599
12.2.20 Inspection and Adjustmentp. 600
12.2.21 Troubleshootingp. 619
12.2.22 Service Datap. 620
+12.3 Triplex Mastp. 622
12.3.1 Triplex Mast – Overviewp. 622
12.3.2 Mast Systemp. 622
12.3.3 Structure and Functionsp. 624
12.3.4 Removal Order of Mast and Lift Bracket Assemblyp. 626
12.3.5 Key Points for Removing Mast and Lift Bracket Assemblyp. 627
12.3.6 Key Points for Installing Mast and Lift Bracket Assemblyp. 630
12.3.7 Disassembly Order of Mast and Lift Bracketp. 632
12.3.8 Preparation for Disassembling Mast and Lift Bracketp. 633
12.3.9 Key Points for Disassembling Mast and Lift Bracketp. 634
12.3.10 Inspecting Mast and Lift Bracket (All Mast Models)p. 636
12.3.11 Assembly Order of Lift Bracket Roller (All Mast Models)p. 638
12.3.12 Lift Bracket Clearance Adjustment (All Mast Models)p. 639
12.3.13 Installing Mast Rollers (All Mast Models)p. 645
12.3.14 Installing Mast Strips (All Mast Models)p. 647
12.3.15 Installing Second Lift Cylinder (All Mast Models)p. 647
12.3.16 Installing First Lift Cylinderp. 650
12.3.17 Connecting Chainsp. 651
12.3.18 Installing Hydraulic Linesp. 656
12.3.19 Removing and Installing Mast Rollers and Strips Without Removing Mast from Truckp. 659
12.3.20 Inspection and Adjustmentp. 662
12.3.21 Troubleshootingp. 682
12.3.22 Service Datap. 683
+CHAPTER 13 CABIN (OPTION)p. 685
+13.1 Cabin Model Exteriorp. 685
13.1.1 Cabin Model Exterior – Overviewp. 685
13.1.2 Door Opening / Closingp. 686
13.1.3 Removal and Installationp. 688
13.2 Cabin Model Labelsp. 695
+13.3 Cabin Model Switches and Controlsp. 696
13.3.1 Cabin Model Switches and Controls – Overviewp. 696
13.3.2 Cabin Model Switchp. 697
13.3.3 Heaterp. 699
13.3.4 AC 12 Volt Output Plugp. 700
13.3.5 Washer Tankp. 700
13.3.6 USB Port Socket (Option)p. 700
13.3.7 Removal and Installationp. 701
13.3.8 Cabin Maintenancep. 706
13.3.9 USB Port Plug (Option)p. 710
+CHAPTER 14 SERVICE DATAp. 713
14.1 Maintenance Schedulep. 713
+14.2 Maintenance Notep. 720
14.2.1 Brake Systemp. 720
14.2.2 Cooling Systemp. 723
14.2.3 Electrical Systemp. 725
14.2.4 Engine Systemp. 729
14.2.5 Frame and Chassisp. 735
14.2.6 Fuel Systemp. 736
14.2.7 Hydraulic Systemp. 739
14.2.8 Ignition Systemp. 742
14.2.9 Intake Systemp. 742
14.2.10 Front End Sectionp. 743
14.2.11 Steering and Axle Systemp. 746
14.2.12 T/M and Drive Systemp. 748
14.2.13 Wheels and Tiresp. 751
14.2.14 Generalp. 752
14.3 Tightening Torque for Standard Bolts and Nutsp. 753
14.4 Periodic Replacement Partsp. 757
+14.5 Lubrication Instructionsp. 759
14.5.1 Lubrication Chartp. 759
14.5.2 Fuel and Lubricant Specificationsp. 761
14.5.3 Adjustment Value and Oil Quantitiesp. 762
14.5.4 Refill Capacitiesp. 765
14.5.5 Capacities and Truck Weight (Standard Models)p. 767
+14.6 Dimensions and Performancep. 768
14.6.1 Dimensions and Performance – Overviewp. 768
14.6.2 1.5 Ton to 2.0 Ton Compact Model Dimension and Performancep. 769
14.6.3 2.0 Ton to 2.5 Ton Model Dimension and Performancep. 770
14.6.4 3.0 Ton to 3.5 Ton Model Dimension and Performancep. 771
14.7 Special Service Toolsp. 772
+CHAPTER 15 HOW TO READ CIRCUIT DIAGRAMSp. 779
+15.1 Description of Circuit Diagramsp. 779
15.1.1 Circuit Diagramsp. 779
15.1.2 Connector Diagramsp. 779
+15.2 How to Read Circuit Diagramsp. 780
15.2.1 How to Read Circuit Diagrams – Overviewp. 780
15.2.2 Symbolsp. 782
15.2.3 Sheet Symbolp. 784
15.2.4 Connecting Linesp. 785
15.2.5 Equipmentp. 787
15.2.6 Relay Contactor and Coilp. 788
15.2.7 Connectorsp. 789
15.2.8 Indication of Connecting Linep. 790
15.2.9 Indication of GND (Earth)p. 791
15.2.10 Indication of Another Specificationp. 792
15.3 How to Read Connector Diagramsp. 793
15.4 Abbreviationp. 796
+CHAPTER 16 CIRCUIT DIAGRAMp. 797
16.1 Circuit Diagram for D04EG Engine Modelp. 797
16.2 Circuit Diagram for GK21 / 25E Engine Modelp. 831
Chapters Covered in This TCM Forklift Service Manual
- Chapter 1 – General: Model view (MC and FC), truck nomenclature and definitions, serial number locations, dimensions, technical data, performance
- Chapter 2 – Cooling System: Specifications and structure, fan belt removal/installation, inspection and adjustment, fan belt tension, connecting hoses, unit layout, coolant, radiator cap
- Chapter 3 – Electrical System: Chassis electrical components and wiring outline, console box, main electrical components (meter panel, key switch, combination switch, direction switch, horn, tank unit, brake fluid sensor, stop light switch, thermoswitches, fuse box, relay box, USB port socket), battery maintenance, meter panel operation, wire colour codes, troubleshooting
- Chapter 4 – Controllers: Main functions of VCM, ECM, meter panel, remote I/O units, GSE connector, mast interlock system, driving interlock system, seat belt warning icon, parking brake warning buzzer and icon, harness codes, truck status display and troubleshooting, F-code diagnosis table, LED blink patterns
- Chapter 5 – Power Train: Removal and installation of engine and transmission assembly for MC models (LPG and diesel), removal and installation for FC models, DPF installation, diesel cooling circuit air bleeding
- Chapter 6 – Powershift Transmission: Structure and functions, torque converter, control system, hydraulic schematic, removal and installation, disassembly and assembly of transmission housing, input/idler/output shafts, forward and reverse input shaft gear assemblies, oil pump, control valve (regulator, accumulator, inching valve sections), oil pressure measurement, brake (inching) pedal adjustment, inching cable adjustment, troubleshooting, service data
- Chapter 7 – Front Axle and Reduction Differential: Structure for 1, 2 and 3 ton classes, removal and installation, front wheels, disassembly and assembly of front axle and reduction differential, adjustment of tooth contact, troubleshooting, service data
- Chapter 8 – Rear Axle: Structure and functions, steering cylinder, removal and installation of rear wheel and rear axle assembly, disassembly and assembly of wheel hub, knuckle (king pin), steering cylinder and tie rod
- Chapter 9 – Brake System: Brake system structure, disassembly and assembly of master cylinder, wheel brakes and wheel cylinder, inspection and adjustment (automatic adjuster test, manual adjustment, parking brake cable adjustment, brake pedal adjustment, brake lines bleeding, braking performance test, parking brake lever), troubleshooting, service data
- Chapter 10 – Steering System: Structure and functions, steering valve, steering column, disassembly and assembly of hydraulic components and piping, steering wheel and steering valve, tilt lock lever, steering valve disassembly and assembly order, troubleshooting, service data
- Chapter 11 – Hydraulic System: Structure and functions, hydraulic circuit diagrams (MC and FC), hydraulic tank, hydraulic pump, control valve, flow regulator valve, down safety valve, lift cylinder, tilt cylinder, disassembly and reassembly, inspection and adjustment, MC control valve and FC control valve, service data
- Chapter 12 – Mast and Forks: Simplex mast, duplex mast and triplex mast – overview, mast system, structure and functions, removal order, key points for removal/installation, disassembly order, inspection procedures, lift bracket roller assembly and clearance adjustment, mast roller installation, mast strip installation, lift cylinder installation, chain connection, hydraulic line installation, removal/installation of mast rollers without removing the mast, inspection and adjustment, troubleshooting, service data
- Chapter 13 – Cabin (Option): Cabin model exterior, door opening/closing, removal and installation (front window and wiper, rear window, rear wiper, sleeve tilt cylinder, side door, roof and floor), cabin model labels, switches and controls, heater, AC 12 volt output plug, washer tank, USB port socket, cabin maintenance, USB port plug
- Chapter 14 – Service Data: Maintenance schedule (prestart, weekly, 1st month, 500/1000/1500/2000/3000 hour intervals, 2-year items), maintenance notes for each system, tightening torque for standard bolts and nuts, periodic replacement parts, lubrication instructions and chart, fuel and lubricant specifications, adjustment values and oil quantities, refill capacities, truck weights, dimensions and performance, special service tools
- Chapter 15 – How to Read Circuit Diagrams: Description of circuit diagrams, symbols, sheet symbols, connecting lines, equipment numbering, relay contactor and coil, connectors, indication of GND, alternate specification, how to read connector diagrams, abbreviations
- Chapter 16 – Circuit Diagram: Full circuit diagrams for the D04EG engine model and the GK21/25E engine model (MC and FC), including VCM and ECM sheets
What This TCM FGE15-35E2 / FD20-35E2 Workshop Manual Gives You
A single source that covers the whole truck rather than just the engine or just the mast. The manual is organised by system, so you can jump straight to the section that matches the job in front of you, and each section carries its own specifications and tightening torques rather than pushing you into a separate spec book. The chapters on the controllers, the powershift transmission and the FC control valve are especially deep – these are the areas where generic forklift literature usually falls short and where the TCM truck rewards the technician who has the real data.
For the electrical side, the document goes beyond a simple wiring map. The controller chapter lists the F-code diagnostic table, LED blink patterns, harness codes with pin allocations for the VCM and ECM connectors, and the interlock logic for the mast and driving systems. That means a fault on the seat switch, the parking brake switch or a T/M solenoid can be traced methodically instead of by substitution.
On the mechanical side, the powershift transmission chapter takes you through the torque converter, the oil pump, the forward and reverse input shaft gear assemblies and the control valve down to individual springs, shims and snaprings, with the pressure values needed to confirm the rebuild afterwards. The mast chapter covers simplex, duplex and triplex masts as separate sections, including the roller clearance tables, the chain elongation limits, and the shim sizes used to bring each clearance back into specification.
The service data chapter is the one that will be open most often. It carries the maintenance schedule by hour interval, the refill capacities, the tightening torques for standard bolts and the periodic replacement parts table, so a scheduled service can be planned and priced without guesswork.
Practical Uses for This TCM FGE15E2 to FGE35E2 & FD20E2 to FD35E2 Service Manual
- Diagnose F-code and diagnostic-code faults on the VCM, ECM and meter panel
- Adjust mast and lift bracket roller clearances and shim stacks
- Set chain tension and measure chain elongation against the service limit
- Rebuild the powershift transmission control valve and set main, clutch, torque converter inlet and lubrication pressures
- Adjust the inching pedal and inching cable so the clutch disengages without slipping or burning
- Rebuild the reduction differential and reset the tooth contact pattern
- Service the master cylinder, wheel cylinders and wheel brakes, and adjust the automatic adjuster
- Rebuild the steering valve and set the steering system relief pressure
- Service the hydraulic pump, control valve, lift cylinders and tilt cylinders
- Plan scheduled maintenance using the hour-interval tables and refill capacities
- Trace circuits using the full D04EG and GK21/25E circuit diagrams
Having the correct clearances, torque figures and pressure values in front of you is what keeps a rebuild inside specification. Working from memory or from a generic guide on a truck with a controller-managed mast interlock and an electronically governed powershift transmission is how components get damaged. The TCM FGE15-35E2 and FD20-35E2 service manual removes that risk for every truck listed in the coverage table above.
The file is delivered as an instant PDF download after payment. There is nothing to ship and nothing to wait for. Open it on a workshop laptop, a tablet on the machine, or print the section you need for the job and take it under the truck with you.
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