TCM FB10-7 Manual

Мо. ОВ-81ВАЕ
<ДМ-
-FB(10-
15-
il
|
OPERATION!
@,
-
MAINTENANCE
MANUAL
ELECTRIC FORKLIFT TRUCK
Counter-balanced type
FB10-7 ҒВ25-т.в
FB15.7 FB25.7v
FB20-7 FB30-7v
| FB25.7
|
|
FB30-7
• It is the responsibility of the Operator & Supervisor to read and understand this manual.
A е Protect the earth and be kind to your lift truck.
TCM CORPORATION

Thank you very much for your purchase of TCM’s product.
This Operation & Maintenance Manual was written to provide the owner/operator
with information about the safe operation and maintenance of the TCM forklift
truck. Read this manual thoroughly and become completely familiar with the lift
truck before using it. If you have any questions, see your dealer.
This manual was compiled based on the standard models. For trucks other than
the standard models, only the differences are explained.
Due to improvements in design, it is possible that the description contained herein
may not completely apply to the truck delivered to you.
Rona
ee
If
the
truck
is
to
be
leased,
loaned
or
sold
to
anyone,
this
manual
must
be
with
the
truck.
.
oe
D
CONTENTS
1. SAFETY
2. OPERATING
CONTROLS
3. OPERATION
4. MAIN-
TENANCE
5. SPECIFICA-
TIONS &
SERVICE DATA

1. SAFETY
CONTENTS
FOR SUPERVISORS .............. sesenta 1- 1
PROPER AND IMPROPER USES ............................. 1- 2
PLANNING AND WORKING AREA ........................... 1- 3
TRAVELING ON PUBLIC ВОАРЗ.............................. 1- 6
OPERATORS; sinite regen esie ei 1- 7
TYPES OF VEHICLES AND LOADS .... д 1- 9
INSPECTION... nei E RR RUN ERN 1-12
TRANSPORTING THE LIFT TRUCK ......................... 1-13
HOW THE LIFT TRUCK WORKS? ................................... 1-14
TRAVELING ................
LOAD HANDLING
РАНКЇМО:. у. tet er erras

This
manual
and
the
decals
affixed
to
the
truck
use
the
following
safety
alert
indications.
SIGNAL
WORD
CLASSIFICATION
Failure to follow the instructions in the message
A
DANGER
will
likely
cause
a
serious
accident
or
death.
Failure
to
follow
the
instructions
in
the
message
A
WARNING
might
cause
a
serious
accident
or
death.
Failure to follow the instructions in the message
A
CAUTION
|
may
cause
personal
injury
or
damage
to
the
truck
or
other
property.
The information will help to prolong the service
^en
NOTE
life
of
the
truck.
The
message
is
not
directly
related to accident prevention.
Forward €& » Backward
The
diagram
above
indicates
the
meanings
of
the
terms
"forward",
"backward",
"right"
and
"left"
used
in
this
manual.
FOR SUPERVISORS
Lift
truck
accidents
cause
dozens
or
hundreds
of
deaths
every
year,
and
even
greater
numbers
of
personal
injuries.
TCM
has
steadily
improved
the
design
and
fabrication
of
our
lift
trucks
so
they
may
be
used
more
safely
and
efficiently,
but
many
accidents
still
occur
due
to
improper
use.
Accidents
are
often
the
result
of
more
than
just
"bad
driving".
The
use
of
inappropriate
types
of
equipment,
the
selection
of
inappropriate
attachments
or
accessories,
inappropriate
operating
environments,
careless
designation
of
operators,
and
failure
to
properly
train
the
operator
are
other
common
causes
of
accidents.
This
chapter
covers
the
methods
of
accident
prevention
which
are
primarily
the
responsibility
of
supervisory
personnel.
•
Pages
1-
2
through
1-13
contain
instructions
which
should
be
enforced
by
the
personnel
supervising
the
operation
of
the
lift
truck.
Please
make
sure
the
operators
also
read
these
pages.
•
Page
1-14
and
the
following
pages
contain
specific
precautions
directly
related
to
the
operation
of
the
lift
truck.

FOR SUPERVISORS | PROPER AND IMPROPER USES
Ш PROPER USE OF THE LIFT TRUCK B IMPROPER USE
The proper use of a lift truck is to transport a load which is placed Transporting a person, elevating a person, and towing another
on the pallet and stacked within the prescribed height limit. vehicle are examples of the improper use of a lift truck. Uses which
With a proper attachment, a lift truck may be used to transport a this manual specifies as improper must never be requested or
load which is stacked elsewhere than on the pallet. permitted, under any circumstances.
(Examples of Improper Use)
е Transporting or elevating a person on the forks or pallet.
* Carrying a person on the pallet to control the load.
e Hanging а cable on the forks to suspend a load.
* Towing another vehicle.
e Pushing a load or another vehicle with the forks.
e Using the forks or truck body to close or open the door of a
freight vehicle.

КОН
SUPENVISUND
|
PLANNING
AND
WURKING
AHEA
|
i
MAKE
AN
OPERATING
PLAN
AND
DISCUSSIT
Ш
INSTALL
CURBS
OR
RAILINGS
Before
using
the
lift
truck,
plan
out
the
travel
routes
and
operating
If
the
truck
is
to
be
used
on
a
loading
dock,
shore
wall
or
other
procedures,
and
thoroughly
discuss
the
details
with
all
personnel
raised
surface,
install
curbs
or
railings.
involved
.
;
B
MARK
THE
TRAVEL
LANES
Ш
SET
SPEED
LIMITS
(Example)
Yard Speed
Limit
Designate
the
travel
lanes
for
the
lift
truck
and
mark
them
clearly,
Set
appropriate
speed
limits
on
your
company
grounds,
and
post
so
they
will
be
kept
free
of
obstruction.
signs that are clearly visible.
1-3

FOR SUPERVISORS | PLANNING AND WORKING AREA
Ш KEEP PEOPLE OUT OF THE OPERATING AREA
Closed to Pedestrians
No
Pedestrians
No other personnel should be allowed in areas where the lift truck
is used.
Where other people must be present, post a guide whose job is to
make sure people stay clear of moving vehicles.
Ш KEEP UNAUTHORIZED VEHICLES OUT
Unauthorized vehicles must be kept out of the load handling areas.
Post signs or give signals as required.
Ш KEEP THE GROUND LEVEL AND DRY
VESD
Ш
JENS
Be sure that all areas where the lift truck travels are level and regular.
Clear away pools of oil or water.
Ш PROVIDE ADEQUATE LIGHTING
Safe operation requires well-lit traveling routes, so pedestrians and
obstacles can be easily seen. Use headlights, taillights, helmet
lamps or other lights as appropriate.

FOR
SUPEHVISURD
|
PLANNING
AND
WORKING
AHEA
|
Ш
ASSIGN
TRAFFIC
GUIDES
TO
CONGESTED
Ш
PROVIDE
AND
MAINTAIN
EMERGENCY
AREAS
EQUIPMENT
(Example)
еф
H Jd
FIRE EXTINGUISHER
жа. ж. шу
fen
HOW TO OPERATE ORDINARY OIL ELECTRIC
peeti
PULL OUT SAFETY РИ
Fire
extinguishers
and
first
aid
kits
should
be
provided
and
maintained
for
use
in
case
of
a
fire
or
accident.
All
personnel
should
Post
a
traffic
guide
in
confined
or
congested
areas
where
other
understand
the
location
and
use
of
emergency
equipment.
people
or
vehicles
may
pass.
All
personnel
must
obey
the
guide.
Ш
KNOW
WHO
ТО
CALL
IN
AN
EMERGENCY
Ш
SAFETY
MEASURES
FOR
DANGER
SPOTS
Emergency Number
1. Fire
2. Earthquake
3. Ambulance
Post
warning
signs
or
take
other
appropriate
measures
to
ensure
Keep
information
on
hand
to
allow
immediate
calls
for
help
in
case
that
lift
truck
operators
keep
away
from
danger
spots
as
they
travel.
of a fire, accident or other emergency.
1-5

FOR SUPERVISORS | TRAVELING ON PUBLIC ROADS
Ш СОТ A LICENSE? m NO LOAD, NO TOWING
It is usually illegal to carry a load on a public road. It is also not
allowed to tow another vehicle on a public road (with the possible
exception of a disabled vehicle). Never tow another vehicle, even
on company property.
Ш OBEY TRAFFIC LAWS, AND TURN OFF
YOUR LIGHTS
Before traveling on a public road, be sure that the truck has
been licensed and inspected as required by local laws.
On a public road, the lift truck must obey the same laws as any
other vehicle. Do not use rear working light or tail lamp.

FUR
SUPENVISDUND
|UPEHAIUHS
Ш WEAR PROTECTIVE GEAR
•
Always
wear
proper
work
clothes
for
driving.
Work
clothes
should
be
designed
to
prevent
any
part
from
accidentally
catching
on
knobs
or
other
parts
of
the
truck
or
equipment.
For
example,
shirts
and
trousers
should
have
tight
cuffs.
e
Always
wear
a
hard
hat
and
safety
shoes.
•
Wear
other
protective
gear
as
appropriate
to
the
conditions
of
the
work
site,
i.e.,
goggles
or
gloves.

Ш TRAIN YOUR STAFF TO STACK SAFELY
“Stacking” means piling palleted load or materials directly on top
of each other, without using racks or shelves to separate them. ІР
the stacking work is not done properly, the loads may slip or fall,
endangering the operator as well as any other personnel in the
area.
Safety classes should be held to train all operators in the proper
methods of stacking and unstacking loads.
(Your TCM dealer can provide information about training for safe
stacking.)
FOR SUPERVISORS
B TIRED OR UNWELL? SEND THEM HOME!
Do not let people take chances. An operator who is overworked or
fatigued, an operator who is feeling unwell, or an operator who is
intoxicated must not be allowed in the driver's seat.

РОН
SUPERVIDUND
|
ТҮРЕ5
OF
VEHICLES
AND
LUAUS
|
Ш
USE
THE
RIGHT
TRUCK
FOR
THE
JOB
Ш
USE
THE
PROPER
ATTACHMENT
Be
sure
the
type
and
capacity
of
the
lift
truck
is
suitable
for
the
Popular
Attachment
Examples
work
environment.
г Choi
Check
Point
hoice
Roll
Clamp
(For paper roll or drum
handling)
Rotating Fork
(For dumping work or
charging work)
Capacity
Load
capacities
range
from
0.5
to
42
tons.
Pay
particular
attention
to
the
load
center.
(TCM Lift Truck Capacities: 0.5, 0.7, 0.9, 1, 1.35,
1.5, 2, 2.25, 2.5, 2.75, 3, 3.5, 4, 4.5, Б, 6, 7, 8, 10,
O9 ө 9
10.5,
11.5,
12,
13.5,
15, 18,
20,
22,
23,
24,
25,
30,
Hinged
Fork
37,
or
42
tons.)
(for
lumber
handling)
Side
Shift
(For precise stacking in
containers or other
narrow spaces)
Crane Arm
(For slinging work)
Power
Source
Gasoline,
natural
gas,
diesel,
and
battery-powered
models
are
available.
Fuel
costs
and
exhaust
composition
will
vary.
9
Balance
On
counterbalanced
models,
the
counterweight
at
the rear
makes
the
vehicle
longer
than
a reach
truck.
A
reach
truck
performs
loading
and
unloading
by
extending
the
front
part
of
the
mast
outward,
which
gives
it
the
advantage
of
compactness.
Tires
For
indoor
use,
there
are
models
with
solid
tires
?
\
(best
for
reach
trucks)
and
cushion
tires
(engine
ў
eS
ЖА.
|
ASN “i
type
or
battery
type).
Both
are
compact.
жок
For
outdoor
use,
pneumatic
tires
work
well.
Solid
pA
em.
А
cushion
tires,
with
the
same
dimensions
ав
55
5
pneumatic tires, may be the best choice in cases
where the load materials or surface conditions
could
puncture
pneumatic
tires.
A
WARNING
Flammable
Materials
|
For
handling
flammable
materials
such
as
Avoid
hoisting
a
load
with
wire
rope
hung
from
the
forks
petrochemicals,
a
combustion
engine
is
too
or
an
attachment,
or
avoid
lifting
a
freight
container
with
dangerous. An electric vehicle with explosion-
proof or safety-reinforced construction is required.
forks,
because
there
is
danger
of
the
truck
tipping.
If
(A
battery
power
source
always
offers
better
necessary,
have
a
qualified
operator
use
a
hook
or
crane
protection
against
fire
than
a
combustion
engine.)
arm
attachment.

FOR SUPERVISORS [TYPES OF VEHICLES AND LOADS
Ш NO OPERATION WITHOUT LIGHTS,
OVERHEAD GUARD, OR LOAD BACKREST
The lift truck cannot be used if the headlights, taillights, overhead
guard, load backrest, horn or turn signals have been removed. Any
parts that have been temporarily removed for some reason must
be reattached immediately.
Ш OBTAIN APPROVAL FOR ANY MODIFICATION
Do not add
counterweight
without approval.
Modifications or additions that affect the capacity, construction or
strength of the truck must not be performed by the user without the
manufacturer's prior permission. For example, don't add a
counterweight.
Ш KEEP DECALS LEGIBLE
пакптааккталяввиаут st сеа
| амапимиманантсаповастбкп
плеянспит,
The decals on the truck describe safety
precautions and operating instructions.
Replace any damaged or missing
decals. Check that the decals are
legible during regular inspections.
15 game: s эст.
Жзэздуп\-зоппиг.. й®Л,-»ашис
оп. вате. гэ%-йеезтсге\,
The overhead guard is а protective device that will moderate the
impact of an object falling from overhead, but it cannot withstand
every impact. If a heavy object seems likely to fall on the truck,
make every effort to prevent it from doing so.

ГОН
SUPENVISUND
|!YPES
ОР
VEHICLES
ANU
LUADS
|
Ш
USE
STURDY
PALLET
MATERIALS
Ш
KNOW
THE
LOAD
BEARING
CAPACITY
OF
Kd
|.
Pallets
and
skids
must
be
strong
enough
to
withstand
the
weight
of
The
lift
truck
is
heavier
than
it
appears.
For
example,
а
2-ton
truck
loads.
Remove
or
repair
any
damaged
pallets.
weighs
almost
3.5
tons
even
when
empty.
Furthermore,
when
loaded,
80
to
9096
of
the
total
weight
is
concentrated
on
the
front
Ш
STACK
LOADS
SECURELY
wheels.
Check
the
strength
of
your
floors
and
roadways,
and
if
necessary reinforce them.
When
stacking
loads,
place
them
in
a
stable
manner
that
they
will
not
easily
come
apart,
and
be
sure
the
weight
is
evenly
distributed.
Secure
the
top
layer
with
a
cord
wrapped
like
a
headband
or
in
a
similar
fashion.
1-11

B ALWAYS INSPECT BEFORE OPERATING
@@——@%—@———®®@®-®
The operator should always inspect the truck before each use to
verify that all essential safety features are working. Any abnormality
is to be reported to the supervisor, who is responsible for correcting
it.
B PERIODIC INSPECTIONS ARE MANDATORY
Monthly and annual inspections must be performed thoroughly, and
any abnormality promptly repaired. Only a certified expert who has
the advanced skills and equipment is required to conduct the
inspections. Preserve the inspection logs for at least three years.
FOR SUPERVISORS
Ш REPLACE SAFETY PARTS REGULARLY
Recommended replace-
Name of Safety Parts ment interval (years)
Cups and dust seals of master cylinder
and wheel cylinders 1
2 | Power steering hose 2
3 | Reserve tank tubing 2-4
4 | Steering actuator rubber boots 2
5 | Lift chain 2-4
6 | Load handling means hoses 1-2
Certain critical parts must be replaced at regular intervals. Since it
is difficult to detect wear on the above parts by visual inspection,
they must be replaced after a certain period of time. Failure to do
so would result in a falling load or runaway truck.
Ш NEVER USE AN UN-MAINTAINED TRUCK
A truck that has not passed an inspection must never be operated.
Hang a sign on the truck and remove the ignition switch, to make
sure no one uses it. Then report the problem to the supervisor and
wait for the repair to be completed.

FUR
SUPERVISUND
|
INSPECTION
IHANSPURIING
ІНЕ
LIFT
1FEUUR
|
m
DESIGNATE
A
REPAIR
AND
ASSEMBLY
SUPERVISOR
1. Preparation
2. Removal
3. Disassembly
Repairs
and
the
mounting
and
dismounting
of
attachments
must
be
performed
under
the
direction
of
a
designated
supervisor.
The
body
and
major
parts
of
the
lift
truck
are
quite
heavy
and
under
very
high
pressure.
Repair
or
assembly
work
undertaken
without
careful
and
thorough
preparation
can
lead
to
a
serious
injury.
1-13
Ш TRANSPORTING THE LIFT TRUCK
Use a level, hard road surface when loading the truck onto or
unloading from a trailer. Be certain that the loading ramps have
sufficient length and width as well as strength. Do not load or unload
the truck when it is raining, unless the ramps are fitted with an anti-
slipping surfaces.
It is safest to use a self-loading trailer truck equipped with a jack
and winch. For loading, tilt the pallet with the jack, attach the winch
to the towing pin of the lift truck, start the engine, and pull it up.
The
operator
must
not
ride
on
the
lift
truck
while
loading
or
unloading.

B KEEPING THE TRUCK BALANCED
Lift trucks are equipped with load handling means including a mast
and forks at their front. The front wheels of the truck work as a `
fulcrum to balance the center of gravity of the truck and the center
of gravity of the load. The relationship between the locations of
those two centers of gravity is vitally important for safety.
Ш KNOW THE CENTER OF GRAVITY OF YOUR
LOAD
Materials of various shapes such as boxes or flat or cylindrical
items may be loaded on the lift truck. In order to accurately judge
the stability of the truck, it is vitally important for the operator to
know the location of the center of gravity for each type of load.
HOW THE LIFT TRUCK WORKS?
Ш HOW THE CENTER OF GRAVITY SHIFTS
The stability of the lift truck is determined by the overall center of
gravity, which is the product of the centers of gravity of the truck
and the load. When the truck is empty, this point is the same as
the center of gravity for the truck, and when it is loaded it shifts
according to the center of gravity of the load. Since the center of
gravity of the load changes whenever the mast is tilted forward or
backward or the fork is raised or lowered, the overall center of
gravity also changes. The center of gravity is also governed by the
following factors:
e Size, weight and shape
of the load
e Unloading height
• Tilt angle of the fork
• Tire inflation
е Acceleration, deceleration
and turning
• Surface condition and
gradient of the road
• Type of attachment
The higher the
load, the higher
ihe truck's center
of gravity
ти)
Truck’s center of |
gravity with high
mast raised Н
Н
|
Truck’s center of
gravity with
standard mast
raise
LEE
-
Lift truck viewed from
front.

MWI IAC LIT! EMUR WYMNo:
Ш OUTSIDE THE TRIANGLE OF BALANCE, THE
TRUCK TIPS
For
a
lift
truck
to
remain
stable,
the
overall
center
of
gravity
must
be
inside
the
triangle
formed
by
the
contact
points
of
the
left
and
right
front
tires
and
the
center
point
between
the
steering
wheels.
The
triangle
defines
the
area
of
stability
for
the
center
of
gravity.
If the
overall
center
of
gravity
moves
further
forward
than
the
front
wheels,
the
truck
will
tip
forward
with
the
front
wheels
as
the
fulcrum.
if
the
overail
center
of
gravity
moves
outside
the
triangle
to
the
right or
the
left,
the
truck
will
fall
over
in
that
direction.
(2, 000k
a! oint ®
Axis of lateral
stability
If the center of gravity
W1 moves outward past
the axis of lateral
stability, the truck will
roll.
(As the center of gravity | `
comes closer to the rear
axle, the space between
the centerline of the
{ruck and the axis of
lateral stability narrows,
and the truck will roll
more easily.
Lift truck Viewed
from Above
1-15
m RATED LOAD (LOAD WEIGHT AND LOAD
CENTER)
The load center is the distance from the front face of the forks to
the center of gravity of the load. The rated load is the maximum
weight allowable with the nominal load center.
The Load Chart, showing the relationship between the load center
and the rated load, is attached to the truck as a decal. The rated
load decreases as the load center moves toward the tip of the forks,
and as the overall center of gravity moves forward.
HOW TO READ THE LOAD CHART
The higher the load is raised, and the further forward
from the front wheels the load is moved, the more the
weight of the load increases.
(Slightly heavier loads can be carried with dual tires)
(1,0208)
Point (C)
|

B ACCELERATING, DECELERATING AND
TURNING
The principle of inertia provides that a stationary object will remain
stationary as long as there is no external force acting on it, and
that a moving object will continue moving at a constant speed as
long as there is no external force acting on it.
Due to inertia, when the lift truck starts to move there is a momentary
backward force, and when it stops there is a momentary forward
force. As a result, if the brakes are applied suddenly, there is a
very strong hazard that the forward force will become strong enough
for the truck to tip forward.
Likewise, when the truck is turning there is a centrifugal force that
pulls it outward from the turning center. This force can cause the
truck to fall sideways. Since the zone of lateral stability is especially
narrow, it is necessary to slow down substantially when turning in
order to prevent the truck from tipping.
When the load is elevated the overall center of gravity is raised,
increasing the danger of the truck tipping over to the front or side.
HOW THE LIFT TRUCK WORKS?