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TCM FD35C9 - User Manual

TCM FD35C9
291 pages
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Summary

1. General Description of TCM Forklift Trucks

1.1 Safety Instructions for Forklift Operations

Provides essential safety guidelines for operating and servicing lift trucks, covering operator qualifications, work area organization, and protective gear.

1.2 Basic Servicing Knowledge and Techniques

Covers fundamental techniques for installing bearings, O-rings, oil seals, and using LOCTITE for effective and safe maintenance procedures.

1.3 List of Lubricants and Their Specifications

Details the recommended lubricants, their grades of viscosity, and prevailing ambient temperature ranges for various truck components.

1.4 Pre-Operation Inspection Checklist

Outlines critical checks for engine, radiator, fuel tank, clutch, brakes, tires, and steering before operating the truck.

1.5 Periodic Inspections and Maintenance Schedule

Emphasizes the importance of regular maintenance for performance, durability, and safety, including daily, monthly, and annual checks.

2. Forklift Truck Component Removal and Reinstallation

2.1 Electrical Parts Removal and Reinstallation

Covers the removal and reinstallation procedures for head lamps, front and rear combination lamps, and battery systems.

2.1.1 Head Lamp Removal and Reinstallation

Detailed steps for removing and reinstalling the head lamp assembly, including component disconnection and secure mounting.

2.1.2 Front Combination Lamp Removal and Reinstallation

Procedures for removing and reinstalling the front combination lamp, involving screw removal, disconnection, and secure attachment.

2.1.3 Rear Combination Lamp Removal and Reinstallation

Step-by-step guide for removing and reinstalling the rear combination lamp, including screw and connector handling.

2.1.4 Battery Removal and Reinstallation Procedures

Instructions for removing and reinstalling battery units for both diesel and gasoline truck models, emphasizing cable disconnection order.

2.2 Hood and Overhead Guard Removal and Reinstallation

Procedures for removing and reinstalling the engine hood and overhead guard, including disconnecting various components and hoses.

2.3 Engine Hood Removal and Reinstallation

Detailed steps for removing and reinstalling the engine hood, including gas spring detachment and bracket removal.

2.4 Counterweight Removal and Reinstallation

Guidance on safely removing and reinstalling the counterweight, including hoisting procedures and bolt specifications.

2.5 Muffler Removal and Reinstallation

Instructions for removing and reinstalling the muffler, involving counterweight removal and engine-side flange nut detachment.

2.6 Radiator Removal and Reinstallation

Covers the removal and reinstallation of the radiator, including draining coolant, hose disconnection, and fan shroud management.

2.7 Air Cleaner Removal and Reinstallation

Steps for removing and reinstalling the air cleaner assembly, emphasizing engine hood securing and hose disconnection.

2.8 Front Guard Removal and Reinstallation

Procedures for removing and reinstalling the front guard, involving various component disconnections and hoisting.

2.9 A Brake Pedal (Automatic Transmission Trucks) Procedures

Detailed instructions for removing and reinstalling the brake pedal assembly for automatic transmission trucks.

2.9 B Brake and Clutch Pedal Procedures (Manual Transmission Trucks)

Procedures for removing and reinstalling the brake and clutch pedal assemblies for manual transmission trucks.

2.10 Engine and Drive Unit Removal and Reinstallation

Comprehensive guide for removing and reinstalling the engine and drive unit, covering numerous components and wiring.

2.11 Drive Axle Removal and Reinstallation

Steps for removing and reinstalling the drive axle, including wheel removal, brake pipe disconnection, and axle shaft extraction.

2.12 Steering Axle Removal and Reinstallation

Procedures for removing and reinstalling the steering axle, involving counterweight removal, tie rod disconnection, and king pin management.

2.13 Steering Wheel Removal and Reinstallation

Detailed instructions for removing and reinstalling the steering wheel assembly, including cover removal and combination meter disconnection.

2.14 Tilt Cylinder Removal and Reinstallation

Steps for removing and reinstalling the tilt cylinder, covering hose disconnection, bolt removal, and connecting pin extraction.

2.15 Main Pump Removal and Reinstallation

Procedures for removing and reinstalling the main hydraulic pump, including oil draining and hose disconnection.

2.16 Control Valve Removal and Reinstallation

Guide for removing and reinstalling the control valve assembly, involving pin, hose, and bolt removal and secure reattachment.

2.17 Mast Assembly Removal and Reinstallation

Instructions for removing and reinstalling the mast assembly, including carriage and fork removal, and chain management.

3. Disassembly and Reassembly Procedures

3.1 Clutch Pedal and Brake Pedal Procedures

Covers the disassembly and reassembly of clutch and brake pedal mechanisms, including spring, linkage, and booster components.

3.2 Drive Unit Disassembly and Reassembly

Details the disassembly and reassembly procedures for the torque converter and synchromesh type transmissions.

3.3 Drive Axle Disassembly and Reassembly

Provides steps for disassembling and reassembling the drive axle, including hub, drum, and bearing components.

3.4 Wheel Brake Disassembly and Reassembly

Covers the disassembly and reassembly of wheel brake systems for 3.5-4.0 ton and 4.5-5.0 ton trucks, including shoe and cylinder procedures.

3.5 Steering Axle Disassembly and Reassembly

Instructions for disassembling and reassembling the steering axle, including hub, bearing, and tie rod components.

3.6 Steering Cylinder Disassembly and Reassembly

Detailed steps for disassembling and reassembling the steering cylinder, covering rod, piston, and seal components.

3.7 Steering Gear Box Disassembly and Reassembly

Procedures for disassembling and reassembling the steering gear box, including worm shaft, sector shaft, and ball nut mechanisms.

3.8 Tilt Cylinder Disassembly and Reassembly

Covers the disassembly and reassembly of the tilt cylinder, including piston, rod, and seal components.

3.9 Main Pump Disassembly and Reassembly

Step-by-step guide for disassembling and reassembling the main hydraulic pump, including gear and cover procedures.

3.10 Control Valve Disassembly and Reassembly

Detailed procedures for disassembling and reassembling control valve assemblies, including spool, poppet, and relief valve components.

3.11 Mast Disassembly and Reassembly

Covers the disassembly and reassembly of the VM and VFHM mast types, including roller and chain adjustments.

3.12 Lift Cylinder Disassembly and Reassembly

Instructions for disassembling and reassembling the lift cylinder, including piston, rod, and seal components.

4. Troubleshooting Guide for Forklift Trucks

4.1 Clutch Troubleshooting

Lists common clutch problems, their probable causes, and recommended remedies for slipping, dragging, and noisy operation.

4.2 Drive Unit (Synchromesh Type) Troubleshooting

Troubleshooting guide for synchromesh drive units, covering noisy transmission, hard shifting, gear disengagement, and differential issues.

4.3 Drive Unit (Torque Converter Type) Troubleshooting

Troubleshooting guide for torque converter drive units, addressing starting problems, poor acceleration, low oil pressure, and high oil temperature.

4.4 Reduction Gear and Differential Troubleshooting

Covers noisy differentials during driving or turning, and malfunctions related to starting or traveling.

4.5 Brake System Troubleshooting

Troubleshooting for brake issues like front wheel hub noise, poor braking effect, and brake drags, with probable causes and remedies.

4.6 Steering Wheel Troubleshooting

Addresses problems related to steering wheel operation, including hard steering, malfunctioning steering, excessive play, and truck wandering.

4.7 Steering Axle Troubleshooting

Troubleshooting guide for steering axle issues such as loose wheel hubs, noisy turns, hard steering, and oil leakage.

4.8 Main Pump Troubleshooting

Covers common problems with the main pump, including insufficient oil discharge, noise, and oil leakage, with their causes and remedies.

4.9 Control Valve Troubleshooting

Troubleshooting for control valve issues like plunger malfunction, oil leakage from oil seals, and no pressure buildup.

4.10 Lift Cylinder Troubleshooting

Addresses problems related to the lift cylinder, such as oil leakage, cylinder jolts, and natural drop of the piston.

4.11 Tilt Cylinder Troubleshooting

Troubleshooting guide for tilt cylinder issues including oil leakage, noisy operation, and natural piston drop.

4.12 Mast Troubleshooting

Covers troubleshooting for mast problems like noisy lifting/tilting, mast jolts, and issues with rollers or carriage.

TCM FD35C9 Specifications

General IconGeneral
ModelFD35C9
CategoryForklifts
Power SourceDiesel
Rated Load3500 kg
Standard Lift Height3000 mm
Load Centre500 mm
Load Capacity3500 kg
Lift Height3000 mm
Power TypeDiesel
Engine Power42 kW
Engine TypeDiesel

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