TCM Forklift Truck FD25T3 Workshop Service Manual Repair

No. SEF-0F7BE FORKLIFT TRUCK TCM CORPORATION FHG15T3 FHG18T3 FG20T3 FHG20T3 FG25T3 FHG25T3 FG30T3 FHG30T3 FG35T3S FHD15T3 FHD18T3 FD20T3 FHD20T3A FD25T3 FHD25T3A FD30T3 FHD30T3A FD35T3S SERVICE MANUAL SERVICE MANUAL FG20T3 – FG30T3, FHG15T3 – FHG30T3, FG35T3S FD20T3 – FD30T3, FHD15T3, FHD20T3A – FHD30T3A, FD35T3S No. SEF-0F7BE

No. SEF-0F7BE FOREWORD TCM’s new forklift trucks with capacities from 1.5 through 3.5 tons feature low operating noise and reduced vibration as well as improved controllability and higher safety, and come equipped with new high-performance engines. The gasoline engines used for this series are equipped with an electronically-controlled fuel supply unit to reduce emissions from the engine. The steering system can correct steering wheel knob deviation automatically to provide better driver control. The instrument panel accommodates optional OK monitors which allow the operator to check the water level, air cleaner plugging, and battery condition of charge with just a glance. The serviceability of these trucks has been greatly improved by these changes. This Service Manual describes all of the major components and their service procedures. We encourage you to make practical use of it while servicing the trucks. We also hope you will understand that, due to on-going improvements of the parts and components, the values and some of the descriptions in this manual are subject to change without notice. February 2010 The specifications and equipment covered in this manual will vary according to the intended destination. In our documents and manuals, these differences are coded according to the destination as follows. Export speciﬁcation code Destination EXA North America EXB All regions excluding North America, EU member countries, Oceania and South Africa EXC Oceania EXE EU member countries (excluding Scandinavia) EXK South Africa EXN Scandinavia

No. SEF-0F7BE

No. SEF-0F7BE SPECIFICATIONS (1) Truck model Item Performance Max. load kg[lbs] Basic load center mm[in.] Lift height mm[in.] Tilt angle (fwd-bwd) ° Free lift mm[in.] A Lift speed mm/s[fpm] (unloaded) (loaded) Traveling speed km/h[mph] fwd 1st 2nd rev 1st 2nd Max. drawbar pull kN{kgf}[lbf] (unload) (loaded) Gradeability (unload) (loaded) Min. turning radius mm[in.] B Min. 90° intersecting aisle mm[in.] C Dimensions mm[in.] Overall length D Overall width E Overall height (at overhead guard) F Overall height with extended mast G Wheelbase H Tread (front) J (rear) K Fork overhang L Rear overhang M Fork size (Length (N) x Width (P) x Thickness (Q)) Fork spacing R Under clearance (at frame) Weight Operating weight kg[lbs] FHG15T3 1360 [3000] 600 [24] 3000 [118.1] 6 - 12 155 [6.1] 680 [133.9] 650 [127.9] 19.5 [12.1] * 19.5 [12.1] * 6.9 {700} [1540] 15.7 {1600} [3530] 1/5.5 1/3.0 1980 [78] 1780 [70.1] 3165 [124.6] 1070 [42.1] 2070 [81.5] 4250 [167.3] 1425 [56.1] 890 [35] 920 [36.2] 395 [15.6] 425 [16.7] 920 x 100 x 35 [36.2 x 3.9 x 1.4] 200 - 920 [7.9 - 36.2] 105 [4.1] 2510 [5530] FHD15T3 660 [129.9] 620 [122.1] 18.6 {1900} [4190] 2620 [5780] FHG18T3 1580 [3500] 680 [133.9] 650 [127.9] 15.7 {1600} [3530] 1/5.8 1/3.2 2010 [79.1] 1800 [70.9] 3195 [125.8] 1100 [43.3] 920 [36.2] 455 [17.9] 2670 [5580] FHD18T3 660 [129.9] 620 [122.1] 18.6 {1900} [4190] 2780 [6120]

No. SEF-0F7BE SPECIFICATIONS (2) FG20T3 1810 [4000] 600 [24] 3000 [118.1] 6 - 12 160 [6.3] 590 [116.3] 580 [114.2] 19.0 [11.8] * 19.0 [11.8] * 8.3 {850} [1866] 16.7 {1700} [3754] 1/5.0 1/3.5 2170 [85.4] 1920 [75.6] 3555 [140] 1150 [45.3] 2070 [81.5] 4250 [167.3] 1600 [63.0] 970 [38.2] 970 [38.2] 450 [17.7] 435 [17.1] 1070 x 122 x 40 [42.1 x 4.8 x 1.6] 245 - 1020 [9.65 - 40.2] 110 [4.33] 3210 [7080] FHG20T3 640 [125.9] 620 [122.1] 22.1 {2250} [5000] 1/5.6 1/2.8 3220 [7110] FG25T3 2260 [5000] 590 [116.3] 580 [114.2] 16.7 {1700} [3754] 1/5 1/4.2 2240 [88.2] 2010 [79.1] 3625 [142.7] 450 [17.7] 505 [19.9] 1070 x 122 x 40 [42.1 x 4.8 x 1.6] 3570 [7870] FHG25T3 640 [125.9] 620 [122.1] 22.1 {2250} [5000] 1/5.6 1/3.0 3580 [7890] FG30T3 2720 [6000] 135 [5.3] 500 [98.4] 490 [96.4] 19.5 [12.1] 19.5 [12.1] 9.8 {1000} [2203] 14.2 {1450} [3192] 1/5 1/5.6 2400 [94.5] 2110 [83.1] 3775 [148.6] 1225 [48.2] 2090 [82.3] 4260 [168] 1700[66.9] 1000 [39.4] 480 [18.9] 525 [20.7] 1070 x 125 x 45 [42.1 x 4.9 x 1.8] 250 - 1090 [9.8 - 42.9] 140 [5.5] 4250 [9370] FHG30T3 540 [106.3] 520 [102.4] 19.6 {2000} [4400] 1/5.6 1/4.1 4260 [9390] Truck model Item Performance Max. load kg[lbs] Basic load center mm[in.] Lift height mm[in.] Tilt angle (fwd-bwd) ° Free lift mm[in.] A Lift speed mm/s[fpm] (unloaded) (loaded) Traveling speed km/h[mph] fwd 1st 2nd rev 1st 2nd Max. drawbar pull kN{kgf}[lbf] (unload) (loaded) Gradeability (unload) (loaded) Min. turning radius mm[in.] B Min. 90° intersecting aisle mm[in.] C Dimensions mm[in.] Overall length D Overall width E Overall height (at overhead guard) F Overall height with extended mast G Wheelbase H Tread (front) J (rear) K Fork overhang L Rear overhang M Fork size (Length (N) x Width (P) x Thickness (Q)) Fork spacing R Under clearance (at frame) Weight Operating weight kg[lbs]

No. SEF-0F7BE SPECIFICATIONS (3) Truck model Item Performance Max. load kg[lbs] Basic load center mm[in.] Lift height mm[in.] Tilt angle (fwd-bwd) ° Free lift mm[in.] A Lift speed mm/s[fpm] (unloaded) (loaded) Traveling speed km/h[mph] fwd 1st 2nd rev 1st 2nd Max. drawbar pull kN{kgf}[lbf] (unload) (loaded) Gradeability (unload) (loaded) Min. turning radius mm[in.] B Min. 90° intersecting aisle mm[in.] C Dimensions mm[in.] Overall length D Overall width E Overall height (at overhead guard) F Overall height with extended mast G Wheelbase H Tread (front) J (rear) K Fork overhang L Rear overhang M Fork size (Length (N) x Width (P) x Thickness (Q)) Fork spacing R Under clearance (at frame) Weight Operating weight kg[lbs] FD20T3 1810 [4000] 600 [24] 3000 [118.1] 6 - 12 160 [6.3] 670 [131.9] 630 [124.0] 18.5 [11.5] * 18.5 [11.5] * 8.3 {850} [1866] 19.1 {1950} [4300] 1/5.0 1/2.9 2170 [85.4] 1920 [75.6] 3555 [140] 1150 [45.3] 2070 [81.5] 4250 [167.3] 1600 [63.0] 970 [38.2] 970 [38.2] 450 [17.7] 435 [17.1] 1070 x 122 x 40 [42.1 x 4.8 x 1.6] 245 - 1020 [9.65 - 40.2] 110 [4.33] 3340 [7360] FHD20T3A 640 [126.0] 620 [122.1] 26.5 {2700} [6000] 1/2.9 FD25T3 2260 [5000] 670 [131.9] 630 [124.0] 19.1 {1950} [4300] 1/3.5 2240 [88.2] 2010 [99.1] 3625 [142.7] 450 [17.7] 505 [19.9] 1070 x 122 x 40 [42.1 x 4.8 x 1.6] 3700 [8160] FHD25T3A 640 [126.0] 620 [122.1] 26.5 {2700} [6000] 1/3.5 FD30T3 2720 [6000] 135 [5.3] 590 [116.1] 520 [102.4] 19.5 [12.1] 19.5 [12.1] 9.8 {1000} [2203] 17.2 {1750} [3850] 1/4.8 2400 [94.5] 2110 [83.1] 3775 [148.6] 1225 [48.2] 2090 [82.3] 4260 [168] 1700 [66.9] 1000 [39.4] 480 [18.9] 525 [20.7] 1070 x 125 x 45 [42.1 x 4.9 x 1.8] 250 - 1090 [9.8 - 42.9] 140 [5.5] 4390 [9680] FHD30T3A 540 [106.3] 520 [102.4] 23.5 {2400} [5300]

No. SEF-0F7BE SPECIFICATIONS (4) Truck model Item Performance Max. load kg[lbs] Basic load center mm[in.] Lift height mm[in.] Tilt angle (fwd-bwd) ° Free lift mm[in.] A Lift speed mm/s[fpm] (unloaded) (loaded) Traveling speed km/h[mph] fwd 1st 2nd rev 1st 2nd Max. drawbar pull kN{kgf}[lbf] (unload) (loaded) Gradeability (unload) (loaded) Min. turning radius mm[in.] B Min. 90° intersecting aisle mm[in.] C Dimensions mm[in.] Overall length D Overall width E Overall height (at overhead guard) F Overall height with extended mast G Wheelbase H Tread (front) J (rear) K Fork overhang L Rear overhang M Fork size (Length (N) x Width (P) x Thickness (Q)) Fork spacing R Under clearance (at mast) Weight Operating weight kg[lbs] FG35T3S 3500 [7000] 500 [24] 3000 [118.1] 6 - 12 170 [6.7] 450 [88.6] 440 [86.6] 19.5 [12.1] * 19.5 [12.1] * 10.8 {1100} [2420] 18.9 {1930} [4250] 1/6.4 1/6 2470 [97.2] 2280 [89.8] 3870 [152.4] 1290 [50.8] 2140 [84.3] 4255 [167.5] 1700 [66.9] 1060 [41.7] 970 [38.2] 495 [19.5] 605 [23.8] 1070 x 150 x 50 [42.1 x 5.9 x 2.0] 300 - 1090 [11.8 - 42.9] 145 [5.7] 4940 [10870] FD35T3S 490 [96.5] 460 [90.6] 18.1 {1850} [4070] 1/6 1/5.5 4820 [10605]

No. SEF-0F7BE Unit: mm [in.] Fig. 1 Truck Dimensions 3000 [118.1] Free lift

No. SEF-0F7BE

TCM Forklift Truck FD25T3 Workshop Service Manual Repair

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