TCM FD35C9 Instruction manual
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No. MEF‑43AAE
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塁WORKSHOPMANUAL
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IMPORTANT
For detailed procedures about operating the lift truck, see the lift truck “OPERATION
AND MAINTENANCE MANUAL.” Improper operation of the lift truck might cause serious
bodily injury or death to you or fellow workers.
The decals on your lift truck indicate the level of hazard, such as “ CAUTION,”
“WARNING,” and “ DANGER.” They are intended to alert the operator and service
personnel to potentially dangerous conditions in the operation and servicing of the lift truck.
Failure to follow the instructions in the message can lead to serious personal injury or death,
or damage to the lift truck or other property.
The “1. GENERAL DESCRIPTION” in this Workshop Manual describes basic safety
instructions for servicing the lift truck. Before starting, study the safety instructions carefully
and become completely familiar with the procedures for servicing the lift truck as well as
the various points to be kept in mind. Improper techniques can lead to injury to oneself or
others.
Service personnel must be completely familiar with the systems and components of
the lift truck, and the tools to be used, as well as the correct service procedures.
Read this Workshop Manual and the lift truck Service Manual thoroughly, and become
completely familiar with the lift truck.
The following safety symbol is used in this manual and on the decals found on the
truck. If you see this safety symbol, pay special attention to the instructions and messages.
Otherwise there is a likelihood of personal injury or death and of damaging the lift truck.
(Empty page)
1. GENERAL
DESCRIPTION
2. REMOVING/
REINSTALLING
3. DISASSEMBLY/
REASSEMBLY
4.
TROUBLESHOOTING
GUIDE
INDEX
INTRODUCTION
TCM offers a wide variety of lift trucks which have
been enthusiastically welcomed by users all over the
world. The lift trucks covered in this Workshop Manual
have also been developed through years of research and
experience, and they feature high quality designs and
parts.
However, to get the most out of their performance, it
is necessary to service, inspect and adjust them at regular
intervals, as well as to operate them properly.
The purpose of this workshop manual is to serve as
a guide to proper service, inspection and adjustment
techniques for the major components of your TCM lift
truck. Study this manual carefully before servicing or
inspecting the major components of your lift truck. For
details about the construction and operating principles
of the components, see the lift truck Service Manual.
We hope this manual will serve as a useful guide to your
service and inspection work.
Please note that the descriptions and specications in
this manual are subject to change without prior notice.
July 2009
(Empty page)
1. GENERAL DESCRIPTION
1.1 SAFETY INSTRUCTIONS ............................................................................. 1-1
1.2 BASIC SERVICING KNOWLEDGE ........................................................... 1-17
1.3 LIST OF LUBRICANTS ............................................................................... 1-26
1.4 PRE-OPERATION INSPECTION ................................................................ 1-27
1.5 PERIODIC INSPECTIONS........................................................................... 1-29
1-1
1.1 SAFETY INSTRUCTIONS
1.1.1 Introduction
■Lift trucks should only be operated by qualied
operators
(1) A qualified operator must have training and possess any required
licenses to operate this truck.
(2) The operation of a crane or performing any welding must be only
attempted by qualied personnel.
■Make a good plan
(1) Perform all service and inspections as planned.
(2) Any worker who is fatigued, feeling unwell, or intoxicated must not
be allowed to do this work.
(3) Locate the correct cause of any problem.
■Keep the work area clean and orderly
(1) Make sure the work area is organized before starting to service the lift
truck.
Arrange the tools and replacement parts so they can be reached easily.
(2) Avoid working in a hazardous or cluttered area.
(3)
Wipe up any oil, grease, or water in the work area. Do not work on an
incline.
(4) Before starting to service the lift truck, make sure there is no one
around the truck except a guide or helper.
1.1.2 Protective gear
(1) Wear all the protective clothing and personal safety gear devices
called for by the job conditions, such as a hard hat, gloves, safety
shoes, safety glasses/goggles, and other.
(2) Shirts and pants should have tight cuffs.
(3) Wear a rubber apron and gloves when handling corrosive material.
(4) Do not touch electric devices or power tools with wet hands.
(5) Keep sparks and open flames away from the work area. This is
especially important if your clothing is contaminated with a lubricant.
(6) Do not put a knife or any other sharp object in your pocket.
(7) Do not wear any jewelry, such as rings, pendants or bracelets, that
can become easily entangled in the machinery. Entanglement causes
serious personal injury. Do not wear a necktie or a watch.
(8) Do not wear gloves when checking rotating parts.
(9) Wear a safety belt when working in an elevated location.
(10) Keep your shoes clean, free of grease, oil, and mud.
1.1.3 Organize the work area
(1) Select a at work area that is wide enough for the job.
(2) Organize the work area before starting to service the truck.
(3) Clean up any water, oil or grease on the floor. Take all necessary
measures to prevent accidents from slipping, such as by sprinkling
sand on the oor surface.
Hard
Hat
Work
Clothes
Safety
Shoes
1-2
(4) Clear away any obstructions or hazards from the work area.
(5) Do not stack unstable objects. Take any necessary measures to prevent
any stacks of objects from collapsing.
(6) Keep the areas around the switchboard, re extinguisher, stairs, and
emergency exits clear of obstacles.
(7) Hazardous objects must only be stored in specied areas, surrounded
by a white line.
(8) Remove any waste or unnecessary objects from the work area
immediately.
(9) Do not bring any personal objects into the work area.
(10) Arrange the tools and replacement parts so they can be reached easily.
1.1.4 Maintenance precautions (before starting to work)
(1) Service personnel should keep safety in mind at all times, and work in
an orderly manner.
(2) Make sure you have read the Operation and Maintenance Manual and
any other relevant technical documents concerning the truck you are
going to service, and get familiar with the construction and operation
of the truck.
(3) Always attach a sign in the control area stating DO NOT OPERATE
when the truck is being repaired.
(4) In principle, you should not run the engine while servicing the truck.
Remove the ignition key when leaving the truck unattended.
(5) Keep yourself in good shape before and during work.
(6) If you are overworked, fatigued or feeling unwell, do not operate or
service the truck.
Report to the specied supervisor.
(7) Make sure there is good ventilation when working in an enclosed area.
(8) Before starting the service, make a work plan and make sure you
understand the work procedures well.
(9) Make certain you have all the necessary replacement parts, materials
and tools at hand.
(10) When working in a group, discuss the details with all personnel
involved and make sure everyone understands the meaning of any
hand signals and the communication methods that will be used.
(11) Check the equipment and tools you are going to use in advance. In
particular, wipe off any oil or grease. Check the power tools, such as
drills, for electrical cable problems.
(12) Take the necessary measures to prevent the directional and load
handling control levers from moving unexpectedly.
(13) Read the caution decals carefully and obey the instructions written on
them.
Block the
wheels
“Do not
operate”
1-3
1.1.5 Maintenance precautions (while working)
(1) Follow the specied work procedure.
(2) Do not remove any covers or components other than those necessary
to do the job.
(3) Do not allow people other than service personnel to enter the work
area.
Do not speak to service personnel while they are working.
(4) When working in a group, pay attention to the safety of your fellow
worker(s) as well as to your own safety. Do not try to perform tasks
other than the ones specied in advance.
(5) Sound an alarm immediately if you notice a danger.
(6) Do not toss tools or parts to a fellow worker. Hand them over with
care.
(7) When leaving the equipment unattended during maintenance, turn it
off.
If the power fails, turn off the power switch on the equipment. For
example,
• Lower any raised load to the ground
• Turn off the switch to any power tools, such as drills, grinders or
welders.
(8) Do not use unstable objects, such as a box or a component, as a step-
ladder.
(9) Do not spill oil or grease on the floor. Wipe up any spilled oil or
grease on the oor right away.
(10) Clean the oil ll ports and grease ttings before adding oil or grease.
(11) Lubrication and oil level checks should always be performed with the
truck parked on a level surface.
(12) Do not stand or walk under raised forks, buckets or hoists.
When using a jack or hoist, do not exceed its rated capacity.
Always keep safety in mind when servicing the machine.
Work procedure
Do not speak!
1-4
1.1.6 Maintenance precautions (after servicing)
(1) Clean the equipment and tools.
(2) After servicing, return the work bench, truck carriage, tools and pallets
to their designated positions.
(3) Wipe up any contaminants, spilled oil or grease in the work area.
(4) Discard waste such as waste oil, used waste cloth, and glass at the
specied place.
You should always have in mind that the environment must be
protected.
(5) Neutralize any spilt battery electrolyte with sodium bicarbonate or
wash it away with a large amount of water.
(6) Make certain all the switches on the electrical equipment you used
have been turned off.
(7) Use only TCM approved replacement parts and lubricants.
(8) After servicing, make sure the truck operates properly.
1.1.7 Modications to the truck might void your warranty
Do not try to modify your truck. Modifications to your truck which
affect the performance, safety or strength of the truck might cause an
accident and will void your warranty as well.
1.1.8 When working in an elevated place
If you need to work in an elevated place, refer to the “Safety Instructions
for Working in Elevated Locations.”
1.1.9 When working in a group
(1) Pick a group leader.
(2) Make sure everyone understands the meaning of any hand signals and
the communication methods that will be used.
(3) Work in an orderly manner that is specied in advance.
(4) Lift heavy loads as a group of two or more or using mechanical aids.
Put a support on the ground before lowering the load to prevent your
hands from getting pinched.
(5) Before moving a load handling lever, sit down properly in the
operator’s seat and make sure all your fellow workers know you are
going to move the loading system.
No!
Weight
Support
Good
1-5
1.1.10 Safety rules for maintenance
<Before starting maintenance>
Before starting maintenance service, make sure:
(1) The travel and load handling control levers are in neutral.
(2) The parking brake is securely applied.
(3) The wheels are blocked.
(4) Put a sign stating “Do not operate” on the truck or mark the off-limits
area around the truck with trafc cones or chains to keep people away
from the work area.
(5) Lower the forks or bucket to the ground. If you need to work with
the forks or bucket raised, use supports to prevent the forks or bucket
from lowering unexpectedly.
(6) Clean the oor surface and the truck steps, oorboard, engine hood
and tires of the truck before starting, to prevent an accident caused by
slipping.
(7) Do not try to repair the truck while it is on a trailer.
(8) Do not try to work while sitting on a tire. Use a suitable step stool or
an elevating work platform.
(9) If you must go under the truck, use goggles or safety glasses to
prevent dust from getting into your eyes.
(10) Remove any caked-on mud from the truck and forks with a hammer
before cleaning the truck with water.
<Jacking up or hoisting the truck>
(1) When jacking up or hoisting the truck, make sure there is no one near
the truck.
(2) Place the jack directly under the part of the truck that it should contact
when it is raised.
Jack up the truck slowly and only high enough to service the truck.
Before you begin to work, wiggle the truck a little to make sure that it
is resting securely on the jack.
(3) Jacks are used only to get a truck off the ground. They should never
be used to hold a truck in place. You must use jack stands when you
work underneath a truck.
Do not
operate
Being serviced
Work platform
Danger!
1-6
(4) Use jack stands, supporting blocks or a bench suitable for supporting
the truck:
·Do not use square timbers as supporting blocks.
· Use only specied jack stands, supporting blocks or platform.
·Use jack stands, supporting blocks and a bench that have enough
strength for the purpose.
·Test the jack stands, supporting blocks or bench before using them
and make sure you understand their weight limit.
·Use hard timbers such as apitong or pine as supporting blocks.
Check them for cracks, deformation, or corrosion at regular
intervals, and replace them if necessary.
(5) When inserting jack stands or supporting blocks under the truck, use
caution not to get your hands or ngers pinched.
<Crane>
(1) Operation of cranes with a lifting capacity of 5 tons or more or mobile
cranes (excluding a floor type crane) must be only performed by a
qualied operator.
(2) Setting up a sling for a load of 1 ton or more must be performed by a
person qualied to do so.
(3) Basic rules of sling work:
·Do not exceed the rated capacity of the crane. As a rough guide,
assume the capacity of the crane is 20 percent less than the rated
capacity.
·Lift the truck from two points or more, never from a single point.
The lifting angle of the chains or cable must be less than 60 degrees
and the position of the center of gravity of the load must be low as
possible.
· Do not exceed the specied capacity for the wire ropes.
·Position the hook directly over the load you are going to lift.
·Attach pads to any sharp areas on the load where the wires might
come in contact with the load.
·Do not hook the lifting cables on a slippery area or any area from
which the hook can be easily disengaged.
·Do not lift at an angle and do not pull horizontally.
·Stop lifting the load when it is about 10 cm above its resting
position and check for stability and the center of gravity of the load.
·Have a guide at a position clearly visible by the worker, and let him
give instructions for the work.
·Make sure everyone understands the meaning of any hand signals
and the communication methods that will be used.
·Do not ride on a load being lifted. Do not allow anyone to stand or
walk under a raised load.
·Use a guide rope when lifting a long load.
·Before lifting the load off the ground, reposition the main hook just
above the load’s center of gravity, to prevent the load from rolling.
Rectangular
cross section
No projecting
bolts allowed
Pads
1-7
(4) Chain blocks
·Do not toss or drag a chain block. If a block becomes wet, wipe
away the moisture and lubricate it properly. An elongated or
deformed hook should not be used.
·Make sure that the hook and other lifting equipment is working
properly before use.
·Do not use a chain block with any cracks or deformation in the
welds or shoulders.
<Installing and removing forks>
(1) With the forks raised a little off the ground, place blocks under the
root of the forks. Bring both fork prongs to the center by alternately
pushing on the top and bottom (heel) of the fork face. Do not use
your hands. Otherwise you might get your hands or ngers pinched.
(2) Put blocks under the root of the forks. Lower the forks to disengage
the forks from the carriage.
(3) Lift the tip of each fork prong to remove it from the carriage.
Do not
toss!
Do not
drag!
Welded
part
Shoulder
Check visually for deformation and
replace as necessary.
No good No good No good
1-8
<Removing and reinstalling tires and rims>
(1) Deate the tire before loosening the bolts connecting the rims (for the
split rim type) or before removing the side ring or lock ring (for the
side ring type).
(2) It is particularly dangerous if you try to remove an inated tire from
the truck with the split-rim having a loose or missing rim connecting
bolt. When connecting the rims, tighten them to the specied torque
with the tire deated.
(3) Use a safety cage for inating the tire. If one is not available, place the
tire on the ground or oor with the lock ring or side ring facing down.
(4) Do not weld or cut the rim while the tire is on the truck.
(5) Deate the tire before trying to remove any nail or other foreign object
from the tire.
(6) Do not use a damaged tire or rim. Do not use a mismatched tire and
rim assembly.
(7) Inate the tires to the specied pressure by using an air compressor.
Wow!
Blown off!
Underinated
Good
Overinated
1-9
<Precautions to take when overhauling cylinders>
(1) Do not try to overhaul cylinders while they are mounted on the truck.
Remove the cylinder assembly and overhaul it in a workshop.
(2) When removing a cylinder from the truck, secure it to a mast
connecting member with rope, to prevent it from falling. Do not try to
hold it in your hands.
(3) Do not try to lift a cylinder by hand. Your hands might get crushed
under the cylinder if you can’t hold it or if you lose your balance.
(4) Put the cylinder you are going to overhaul on a work bench and hold
in a vise. The work bench should be equipped with a V groove to
prevent the piston rod from rolling off the bench.
(5) Remove the piston rod from the cylinder. If the piston rod is hard
to remove by hand, apply compressed air from the tail side of the
cylinder to push the piston rod out.
(6) When using compressed air, t a cylinder cap over the piston rod, to
prevent the piston rod from popping out. Be very careful not to be
injured by the piston rod extending unexpectedly.
(7) When removing the piston rod with a crane, the cylinder cap might
drop onto the piston. Use caution not to get your hands pinched. Hold
the side of the piston or hold the piston with a rope.
(8) For cylinders used in lift trucks with a capacity over 8 tons, secure the
cylinder tail to a pole in the room and remove the piston rod using a
sling hook and a lift truck.
(9) When replacing the piston seal with a new one, use a special spatula to
remove the old seal. (Do not use a prick punch. You might get injured
and you may damage the piston.)
Boom and bucket cylinders
Lift cylinder
1-10
<Mast inspection>
(1) Use a helper to inspect the mast operation: one person in the operator’s
seat operating the load handling levers and the other standing by the
side of the mast checking the mast operation. Do not climb between
the mast and the operator’s compartment.
(2) Use a mobile or fixed elevating work platform when working on
components at an elevated position. Do not climb between the mast
and the operator’s compartment.
(3) If you need to inspect the truck with the forks raised, install the load
handling lever stoppers and/or the inner mast stopper.
(4) Do not put your hands or feet on or near the mast rails or connecting
members of the mast.
(5) Never try to operate the hydraulic control levers in the operator’s
compartment from the mast side. In particular, do not try to operate
them from in between the truck body and the mast.
(6) When working alone, use a crane to remove or reinstall the load
backrest.
(7) When working with the mast raised, take the necessary steps to
prevent the mast from falling unexpectedly, or install control lever
stoppers.
(8) Apply genuine TCM Chain Coat chain lubricant to the lift chains from
the front of the mast with the forks lowered to the ground. (You can
use engine oil for this purpose. Do not use grease.)
<Opening the radiator cap>
(1) If the radiator cap is equipped with a pressure reducing valve, reduce
the pressure by lifting the lever before opening the radiator cap.
(2) If there is no pressure reducing valve, cool the engine by running it at
idle speed for a while before opening the radiator cap. (If the engine is
overheating, splash cold water on the engine.)
(3) If you need to open the radiator cap when the engine is hot:
·Wear leather welding gloves. Do not use cotton work gloves.
·Cover the radiator cap with a water-resistant material such as a
piece of inner tube, to prevent hot water from splashing on your
hands.
·Loosen the radiator cap slowly to allow the steam to escape.
·It is good practice to use a special tool for opening the radiator cap.
CAP
INNER
CHANNEL
CONNECTING
MEMBER
STOPPER
OUTER
CHANNEL
PLATE
SLOT
Insert into
dashboard.
WING NUT
LEVER
1-11
<Electrical system>
(1) Precautions when recharging batteries
·Make sure the power cable is securely connected before turning on
the battery charger. Do not disconnect or reconnect the power cable
while the battery charger is on.
·Loosen the cap on each cell in the battery.
·Do not remove the battery receptacle during recharging; otherwise
there is danger of causing sparks.
·Do not try to check the battery voltage by shorting the poles of the
battery.
·The battery must only be recharged in a well-ventilated space, with
no ammable materials in the area.
·Charge batteries on an acid-resistant floor surface that is well
drained, because the battery electrolyte might spill on the floor
during recharging.
·Make sure that the charging equipment is equipped with a ground
fault interrupter. (it must be grounded).
(2) Take the following precautions to prevent accidents such as electric
shocks or shorts when repairing the electrical system on the truck:
·Make sure the power switch is turned off before starting any repairs
or inspections.
(Remove the grounding cable from the battery if the truck does not
have a battery relay.)
·Make sure the cables are not wet or frayed. Avoid using any electric
tool in a wet atmosphere.
·Be careful not to drop a wire, tools or parts inside the truck. If you
drop something, make sure to remove it.
(3) Do not touch any switch which has a warning sign attached to it. Use
special caution if you do need to touch it.
(4) Keep clear of broken wires.
(5) Always attach a sign to the battery charging unit stating “Do not
operate” when the electric system is being repaired.
(6) Write the name, rated voltage, and current of the power supply unit
and the name of the person in charge of the battery charging unit near
the power supply switch.
(7) Only use approved fuses for the power supply switch.
(8) If the battery charging unit fails to operate normally, turn off the
power switch immediately and report to the supervisor.
(9) Do not smoke near the battery. Do not use an open ame to check the
battery electrolyte level. Explosive gases are always being released
from the battery and there is a danger of causing an explosion.
(10) Keep the top surface of the battery case clean. If it is contaminated
with dust or water, there is a danger that an explosion may occur due
to an interfacial discharge occurring between the battery terminal and
the truck frame.
Electric
shock!
Danger!
Electric
shock!
1-12
<Welding>
(1) Observe the following conditions when welding:
·When welding near a tire, note that there is a danger of the tire
exploding if it is heated excessively.
·Do not try to weld or gas cut any container or pipe containing fuel
or oil. Remove the fuel or oil. It is good practice to put water in the
object before welding it.
(2) Wear a welding mask to protect your eyes.
(3) Using a welding mask will obstruct your sight. Organize the work
area properly before starting to weld or cut. In particular, move away
anything that can fall easily or be tripped over.
(4) Wear safety gloves.
(5) Hold the welder above the work whenever possible. If the welder must
be used below the work, wear a welder’s hat.
(6) When using gas to cut the cutting edge of the bucket, keep distance
between the cutting edge and the oor surface to less than 10 cm, to
prevent your legs from getting crushed by the cutting edge if it falls.
(7) When welding a new cutting edge to the bucket, weld a piece of angle
iron inside the bucket rst, to prevent the bucket from being deformed.
Do not use a jack instead of welding in a piece of angle iron. Using a
jack creates the danger of the jack coming loose and popping out to
cause serious personal injury.
(8) Keep any ammables away from the welding area.
(9) Observe the following precautions when arc welding:
· Arc welding should only be performed by a qualied person.
·Use a safety holder.
·Use a welding machine equipped with a voltage reducing device if
welding is performed in a place where the welder might come into
contact with a conductor.
·Use caution to keep the safety holder from coming in contact with
the ground side. Do not place the safety holder on wet ground or a
wet oor.
·When chipping off slag after welding, wear safety glasses to protect
your eyes from ying slag.
<Press work>
(1) Make sure the hydraulic press workrest does not have any cracks.
(2) Do not bring your face or hand close to the press during operation.
(3) Place the platform in a stable position and keep it in place during
operation.
(4) Extend the ram as far as possible. Avoid using an intermediate jig.
Blowout!
Person in
charge:
Mr. ______
This manual suits for next models
8
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