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TCM FG15C13 Operation & Maintenance Manual

Forklift truck
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Summary of Contents for TCM FG15C13

  • Page 2: Forklift Truck

    Gas. & LPG Powered Diesel powered It is the responsibility of the operator and supervisor to read and understand this manual. Protect the earth and be kind to your lift truck. TCM CORPORATION Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...
  • Page 3 Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...
  • Page 4 Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...

  • Page 5: Operating Controls

    1. SAFETY 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. 2. OPERATING...
  • Page 6 Rated load Truck model Engine model Rated load Truck model Engine model Rated load Truck model Engine model 1.5 tons FG15 2 tons FG20 3 tons FG30 FG20 FG15 FG30 FHG20 FHG15 FHG30 FHG20 FHG15 FHG30 FD20 TD27-II FD15 D1503 FD30 TD27-II FD15...

  • Page 7: Table Of Contents

    1. SAFETY CONTENTS FOR SUPERVISORS ............1 - 1 QUALIFIED OPERATORS ..........1 - 2 PLANNING AND WORKING AREA ......1 - 3 PROPER AND IMPROPER USES ......... 1 - 6 TYPES OF VEHICLES AND LOADS ......1 - 7 INSPECTION ...............

  • Page 8: Signal Word

    This manual and the decals affixed to the truck use the following TCM has steadily improved the design and fabrication of our lift safety alert indications. trucks so they may be used more safely and efficiently, but many accidents still occur due to improper use.

  • Page 9: For Supervisors

    • Always wear a hard hat and safety shoes. method of stacking and unstacking loads. • Wear other protective gear as appropriate to the conditions (Your TCM dealer can provide information about safety stacking of the work site, i.e., goggles or gloves. training.)

  • Page 10: Planning And Working Area

    FOR SUPERVISORS PLANNING AND WORKING AREA KNOW WHO TO CALL IN AN EMERGENCY MARK THE TRAVEL LANES Contacts in emergency ............................Designate the travel lanes for the lift truck and mark them clearly, Keep information on hand to allow immediate calls for help in so they will be kept free of obstruction.
  • Page 11 FOR SUPERVISORS PLANNING AND WORKING AREA KEEP PEOPLE OUT OF THE OPERATING AREA ASSIGN TRAFFIC GUIDES TO CONGESTED AREAS Closed to Pedestrians Pedestrians No other personnel should be allowed in areas where the lift truck is used. Post a traffic guide in confined or congested areas where other Where other people must be present, post a guide whose job people or vehicles may pass.
  • Page 12 FOR SUPERVISORS PLANNING AND WORKING AREA KEEP THE GROUND LEVEL AND DRY INSTALL CURBS OR RAILINGS If the truck is to be used on a loading dock, shore wall or other Be sure that all areas where the lift truck travels are level and raised surface, install curbs or railings.

  • Page 13: Proper And Improper Uses

    FOR SUPERVISORS PROPER AND IMPROPER USES PROPER USE OF THE LIFT TRUCK IMPROPER USE The proper use of a lift truck is to transport a load which is placed on the pallet and stacked within the prescribed height limit. With a proper attachment, a lift truck may be used to transport a load which is stacked elsewhere than on the pallet.

  • Page 14: Types Of Vehicles And Loads

    FOR SUPERVISORS TYPES OF VEHICLES AND LOADS READ MANUAL AND DECALS NO OPERATION WITHOUT LIGHTS, OVERHEAD GUARD, OR BACKREST Load Overhead Lamps backrest guard Read the Operation & Maintenance manual and caution plates on the truck, and become familiar with your truck and operating The lift truck cannot be used if the headlights, taillights, procedures.
  • Page 15 (TCM Lift Truck Capacities: 0.5, 0.7, 0.9, 1, 1.35, arm attachment. 1.5, 2, 2.25, 2.5, 2.75, 3, 3.5, 4, 4.5, 5, 6, 7, 8, 10, 10.5, 11.5, 12, 13.5, 15, 18, 20, 22, 23, 24, 25, 30,...
  • Page 16 FOR SUPERVISORS TYPES OF VEHICLES AND LOADS HAVE A GOOD VENTILATION STACK LOADS SECURELY Engine-powered trucks When stacking loads, place them in a stable manner that they When the engine is run indoors such as in an enclosed will not easily come apart, and be sure the weight is evenly warehouse, have a fresh-air ventilation.

  • Page 17: Inspection

    FOR SUPERVISORS INSPECTION ALWAYS INSPECT BEFORE OPERATING REPLACE SAFETY PARTS REGULARLY Recommended replace- Name of safety parts ment interval (year) Master cylinder and wheel cylinder cups and dust seals Power steering hose Reserve tank tubing 2 – 4 Fuel hose 2 –...

  • Page 18: Inspection/Transporting The Lift Truck

    FOR SUPERVISORS INSPECTION/TRANSPORTING THE LIFT TRUCK DESIGNATE A REPAIR AND ASSEMBLY TRANSPORTING THE LIFT TRUCK SUPERVISOR Use a level, hard road surface when loading the truck onto or Repairs and the mounting and dismounting of attachments must unloading from a trailer and when unloading it. Be certain that be performed under the direction of a designated supervisor.
  • Page 19 FOR SUPERVISORS INSPECTION/TRANSPORTING THE LIFT TRUCK USE OPTIONAL “LIFTING EYES” FOR LIFTING YOUR LIFT TRUCK WARNING Never hoist your lift truck at its overhead guard or counterweight; otherwise there is a danger of the truck falling. If hoisting the lift truck is necessary for any reason, use optional “Lifting Eyes.”...

  • Page 20: Traveling On Public Roads

    FOR SUPERVISORS TRAVELING ON PUBLIC ROADS GOT A LICENSE? NO LOAD, NO TOWING Before traveling on a public road, be sure that the truck has It is usually illegal to carry a load on a public road. It is also not been licensed and inspected as required by local laws.

  • Page 21: How The Lift Truck Works

    HOW THE LIFT TRUCK WORKS? KEEPING THE TRUCK BALANCED HOW THE CENTER OF GRAVITY SHIFTS The higher the load, the higher the truck’s center of gravity Truck’s center of gravity with truck tilted Truck’s center of gravity with high mast raised Lift trucks are equipped with load handling means including a Truck’s center of gravity with standard mast...
  • Page 22 HOW THE LIFT TRUCK WORKS? OUTSIDE THE TRIANGLE OF BALANCE, THE RATED LOAD (LOAD WEIGHT AND LOAD TRUCK TIPS CENTER) HOW TO READ THE LOAD CHART Rear The higher the load is raised, and the further forward wheels from the front wheels the load is moved, the more the Axis of lateral stability weight of the load increases.
  • Page 23 HOW THE LIFT TRUCK WORKS? 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.

  • Page 24: Traveling

    TRAVELING Do not operate the lift truck until preoperational Caution to be taken when starting the electric truck checks are finished Electric trucks If any defect is found during checking, report it to the supervisor Before trying to start the truck (before turning the key switch to and have it repaired.
  • Page 25 TRAVELING Sound horn when starting Never use man as an additional counterweight Before starting, make sure no one is near the truck. Let other workmen and bystanders know you are starting up by sounding Do not use man as an additional counterweight. Do not offer horn.
  • Page 26 TRAVELING Carry the load low Do not get into a soft ground area It is dangerous to travel with forks lifted higher than is appropriate, regardless of whether loaded or not. Keep the load as low as possible while traveling. Do not turn the truck with the load raised high.
  • Page 27 TRAVELING Safe traveling: When going into areas where there are limits in height and width, use the following cautions: • Always look in the direction of travel • Make sure there is enough height and width for the truck to Always look in the direction of travel;...
  • Page 28 TRAVELING Have a guide when handling bulky loads Back down and drive up: When handling bulky loads which restrict your vision, operate the truck in reverse and have a guide. • Do not make turns on a gradient. There is danger of the Reverse travel truck upsetting.
  • Page 29 TRAVELING Brake the truck in good time When driving over a dockboard: The truck takes a little longer to come to a stop on a slippery surface than on a usual surface. Brake the truck in good time. In addition, the stopping distance of the truck is longer on a downhill.
  • Page 30 TRAVELING Know the load bearing capacity of the floor Stay inside if the truck seems like it is about to turn over Before entering a building or going into an elevator, make sure the floor is strong enough to withstand the weights of the truck and the loads.

  • Page 31: Load Handling

    LOAD HANDLING Keep anyone but a guide away from the working area • Do not use the truck to open or close the doors of freight cars or warehouses. • Do not push other trucks. • Do not hoist loads, using ropes hung on the forks. •...
  • Page 32 LOAD HANDLING Make sure forks are securely locked Never lift a load over anyone After adjusting the fork spacing, lock the forks with fork stoppers. WARNING Unlocked forks will slide during traveling, causing the load to Never permit anyone to stand under raised forks. The fall off.
  • Page 33 LOAD HANDLING Do not pick up loads from other truck Use special caution when stacking or unstacking loads Do not pick up loads from raised forks of other truck. This When stacking or unstacking loads, stabilize them with ropes might cause an off-centered load or the load to fall off. or others, to prevent from falling off.
  • Page 34 LOAD HANDLING Never overload Do not tilt the mast with loads high WARNING Know the rated capacity of your lift truck and its attachment, if any, and never exceed it; otherwise the rear wheels will be raised, thus making it difficult to travel and turn.
  • Page 35 LOAD HANDLING Keep the chains tight A strong wind might cause loads to spill or the truck to tip over. A slack chain means a mast rail or carriage hang-up, which might cause the sudden fall of loads or carriage or the truck to Loads might spill or the truck could tip over due to a strong tip over.

  • Page 36: Parking

    PARKING Park at the specified area Do not park near flammables Park on a hard surface Park at an out-of-traffic area Park at an out-of-traffic area. Avoid parking near emergency exits, stairs, or fire hydrants. Block the wheels when parking on a slope When parking a faulty truck If unavoidable to park on a slope, apply the parking brake securely and block the wheels...
  • Page 37 PARKING Remove the key from a faulty truck and put up a sign When leaving the truck, observe the following conditions: Remove the starter key and attach a sign saying DO NOT 1) Park the truck on an out-of-traffic area and lower the forks OPERATE.

  • Page 38: Inspection And Service

    INSPECTION AND SERVICE Inspection and maintenance must be performed only Wipe any spilt oil or grease by qualified personnel Wipe any spilt oil or grease. If the truck is contaminated with WARNING oil or grease, it is difficult for you to find possible cracks or Inspection and maintenance of the truck should be other defects.
  • Page 39 INSPECTION AND SERVICE When working in a group, have a leader and follow Make sure the forks and other attachment (if any) his instructions are on the ground Before starting inspection, shut off the engine If unavoidable to work under raised forks or Engine-powered trucks attachment, use a stable support under the inner Make sure the engine is shut off before trying to start inspection...
  • Page 40 INSPECTION AND SERVICE Use caution not to get your fingers pinched in the Shut down the engine before working on rotating floor plates or hood parts Engine-powered trucks Be careful so as not to get your fingers caught when closing the battery cover or doors.
  • Page 41 Checking of accumulator and piping is hazardous temperature is high Engine-powered trucks Inspection of piping where an accumulator is installed is hazardous. When it needs to be inspected, ask your TCM dealer. When high pressure oil comes in contact with your body, immediately get medical attention Do not try to jump start the truck.
  • Page 42 “Chassis Lifting Eye”. truck might fall, getting you caught under it. For the Chassis Lifting Eye, consult your TCM dealer. • Lifting the truck must be performed only by qualified personnel (for crane or slinging work).
  • Page 43 INSPECTION AND SERVICE Cautions to be taken when handling batteries: • No fire Since explosive hydrogen gases are always being released • If electrolyte gets on your skin, flush it off with a copious from the battery, there is a danger of causing an explosion. amount of water Never smoke or use fire or naked flame near the battery.
  • Page 44 INSPECTION AND SERVICE • When charging the battery, follow the instructions in the • Static electricity is hazardous Instruction Manual of the charger Static electricity is generated when cleaning the top surface • No fire during charging or connections of the battery with a dry cloth, or covering the Batteries give off hydrogen gases during charging.
  • Page 45 INSPECTION AND SERVICE Obey regulations • Inflating tires to a high pressure requires special skill. Inflating tires requires special skill. Tires must be inflated only by a qualified person. • When using compressed air, wear safety glasses and mask. When inflating tires, wear safety glasses and mask because dust might get into your eyes or mouth.
  • Page 46 INSPECTION AND SERVICE If the bolts and nuts of the split rim assembly are removed, Make sure the lamps turn on and off properly. Burned-out bulbs the rims, bolts or nuts might blow off due to the internal must be replaced with new ones. pressure of the tire, to cause a serious personal injury.

  • Page 47: Carbon Monoxide Poisoning

    INSPECTION AND SERVICE gas, and diesel fuel. Internal combustion engines that use CARBON MONOXIDE POISONING these fuels are sources of exposure in the workplace. Engine-powered trucks • Control of carbon monoxide gas The following carbon monoxide control to avoid its Control of carbon monoxide levels in the workplace is poisoning is the user’s responsibility.

  • Page 48: Caution Plates

    CAUTION PLATES The caution plates attached to the lift truck explain cautions to be taken when using the truck, and procedures for operating the truck. Read messages on the caution plates as well as the description in this manual. Damaged or missing decals must be replaced with new ones.
  • Page 49 CAUTION PLATES A. Safe operation B. Warning decal for handling C. Warning decal for opening inflated tires and closing engine hood WARNING YOU MUST FOLLOW THESE RULES TO AVOID SEVERE INJURY OR DEATH TO YOURSELF AND OTHERS. Operate truck only if trained and authorized by your employer.

  • Page 50: Front Guard

    CAUTION PLATES E. Warning decal for seat belt F. Warning decal for front G. Warning decal for load (EXA) guard handling means WARNING WARNING WARNING AVOID SEVERE INJURY OR DEATH. DO NOT CLIMB ON FRONT GUARD. H. Warning decal for mast connecting member Warning decal for fan and other rotating parts...
  • Page 51 CAUTION PLATES Caution plate for handling batteries WARNING WARNING If the battery is used or charged when the electrolyte Hydrogen gas produced by a battery can explode. Keep level is below the LOWER LEVEL mark, the battery may all open flames and sparks away from the battery. To be damaged.
  • Page 52 MEMO Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...
  • Page 53 2. OPERATING CONTROLS The following symbols, found throughout this manual, alert you to potentially hazardous conditions to the owner and the operator. CONTENTS Become completely familiar with the truck before proceeding with operating, checking and servicing. PICTORIAL NOMENCLATURE ........2 - 1 INSTRUMENTS AND CONTROLS .........

  • Page 54: Pictorial Nomenclature

    PICTORIAL NOMENCLATURE 2 - 1 Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...
  • Page 55 PICTORIAL NOMENCLATURE 2 - 2 Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...

  • Page 56: Instruments And Controls

    INSTRUMENTS AND CONTROLS METER PANEL (DIESEL-POWERED TRUCKS) METER PANEL (GAS-POWERED TRUCKS) 2 - 3 Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...
  • Page 57 INSTRUMENTS AND CONTROLS C type 2 - 4 Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...

  • Page 58: Switches

    INSTRUMENTS AND CONTROLS SWITCHES STARTER SWITCH START 3. Do not keep the starter motor turning The engine starts. After the engine starts for more than 10 seconds at a time. up, remove your hand from the key. The STOP If the engine won’t start, wait about key switch will automatically return to the The position at which the key is inserted 20 seconds before trying again.

  • Page 59: Horn Button

    INSTRUMENTS AND CONTROLS COMBINATION LEVER (TURN SIGNAL) HORN BUTTON (LIGHTING SWITCH) Use the turn signals (front and rear) to Press the horn button at the center of the indicate the traveling direction of the truck. steering wheel to sound the horn. This lighting switch has two mode as follows: The horn sounds regardless of the starter Left-side lights turn on.

  • Page 60: Meters And Warning Lights

    INSTRUMENTS AND CONTROLS METERS AND WARNING LIGHTS (METERS) 1. Fuel gauge 2. Hour meter 3. Cooling water temperature gauge DIESEL-POWERED TRUCKS (WARNING LIGHTS, INDICATOR LIGHTS) 4. NEUTRAL LIGHT 5. TRAVELING AND LOAD HANDLING INTERLOCK SYSTEM WARNING LIGHT GLOW INDICATOR 7. SEAT BELT WARNING LIGHT 8.

  • Page 61: Hour Meter

    INSTRUMENTS AND CONTROLS HOUR METER FUEL GAUGE COOLING WATER TEMPERATURE GAUGE The hour meter operates while the engine The fuel gauge indicates the fuel level in This gauge indicates the temperature of is running, and records total operating the fuel tank. the engine cooling water.
  • Page 62 . St o p t h e o p e r a t i o n ( S ta n d a r d f o r E X E a n d E X N a n d immediately and ask your local TCM optional for other destinations) Fuel level at which dealer to check your truck.

  • Page 63: Charge Warning Light

    “UPPER LEVEL”. loose or broken fan belt or a defective power generating system. Stop the operation immediately and ask your local TCM dealer to check the truck. 2 - 10 Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com...

  • Page 64: Interlock System

    • If the operator’s seat is replaced with a new one, use a genuine the operator leaves his seat without applying the parking brake TCM operator’s seat equipped with a seat switch. when the starter switch is off. (Note that this function is also •...

  • Page 65: Levers And Pedals

    INSTRUMENTS AND CONTROLS LEVERS AND PEDALS LIFT LEVER TILT LEVER NOTE CAUTION CAUTION When the engine is not running, the Seat yourself in the operator’s seat Seat yourself in the operator’s seat mast won’t tilt even if the tilt lever is and make sure there is no one and make sure there is no one o p e r a t e d , b e c a u s e t h e t i l t - l o c k...
  • Page 66 INSTRUMENTS AND CONTROLS T type C type SHIFT LEVER T type DIRECTIONAL SHIFT LEVER C type NOTE SPEED RANGE SHIFT LEVER C type CAUTION The speed range shift lever C type The truck is equipped with two floor-shift Press the brake pedal to the floor and the shift lever T type have a control levers (forward/backward and before operating the shift lever.

  • Page 67: Parking Brake Lever

    INSTRUMENTS AND CONTROLS PARKING BRAKE LEVER STEERING WHEEL STEERING COLUMN TILT LEVER CAUTION CAUTION CAUTION Block the wheels when parking on P o w e r s t e e r i n g b e c o m e s •...

  • Page 68: Brake Pedal

    INSTRUMENTS AND CONTROLS CLUTCH PEDAL C type INCHING PEDAL T type BRAKE PEDAL The clutch allows the operator to couple Press the brake pedal to slow down or CAUTION the engine to, or uncouple the engine stop the truck. The brake lights come on Do not press the inching pedal for from, the transmission.

  • Page 69: Truck Body

    INSTRUMENTS AND CONTROLS TRUCK BODY RECEPTACLE SEAT CONNECTOR BELT Note: are optional on FG(D)15 - 18. SEAT BELT OPERATOR’S SEAT SEAT POSITION ADJUSTMENT LEVER R E C L I N I N G C O N T R O L L E V E R SEAT SUSPENSION ADJUSTMENT KNOB WARNING [Optional on FG(D)15 - 18]...

  • Page 70: Glove Box

    INSTRUMENTS AND CONTROLS DOCUMENT POCKET GLOVE BOX OVERHEAD GUARD MAGAZINE BOX The glove box is located under the WARNING dashboard diagonally to the left in front of The operator ’s seat has a document The overhead guard is an important the operator’s seat.

  • Page 71: Engine Hood

    INSTRUMENTS AND CONTROLS LOAD BACKREST ENGINE HOOD If the engine hood won’t open If the engine hood won’t be opened by CAUTION CAUTION pulling the hood opening lever, follow the Do not remove or modify the load When opening or closing the engine procedure given below: backrest.
  • Page 72 INSTRUMENTS AND CONTROLS LOCK FORK STOPPERS UNLOCK ENGINE HOOD STOPPER FORK STOPPER Secure the forks with the fork stoppers. Pull up the fork stoppers a little and turn CAUTION CAUTION 90° to unlock. Then adjust the fork spacing • • • • • After opening the engine hood, •...
  • Page 73 INSTRUMENTS AND CONTROLS FORK LOCK BOLT FORK LOCK BOLT DRAWBAR SAFETY STEP AND HAND GRIP CAUTION CAUTION CAUTION Do not remove the fork lock bolt Do not use the drawbar for towing Use the safety step and hand grip other than the following cases; another vehicle or for being towed when mounting or dismounting.

  • Page 74: Caution Plate

    INSTRUMENTS AND CONTROLS BRAKE AND CLUTCH FLUID RESERVOIR • (GLOVE BOX) FUSE BOX BATTERY BRAKE AND CLUTCH FLUID RESERVOIR The fuse box is located at the left area The battery is located on the left side of The brake fluid reservoir is located inside inside the engine hood.

  • Page 75: Fuel Tank Cap

    INSTRUMENTS AND CONTROLS FUEL TANK CAP • Never use naked flame (match or NOTE CAUTION lighter) for checking the fuel level. • Use gasoline for gas-powered trucks • When adding fuel, stop the truck, and light oil for diesel-powered trucks. The fuel tank cap is located at the left side shut down the engine, and apply •...

  • Page 76: Radiator Reservoir Tank

    INSTRUMENTS AND CONTROLS HYDRAULIC OIL TANK CAP HYDRAULIC OIL TANK CAP RADIATOR RADIATOR RESERVOIR TANK The hydraulic oil tank cap is located at the The radiator reservoir tank is located CAUTION right-side area inside the engine hood. behind the battery unit inside the engine Do not remove the radiator cap The cap is provided with an oil dipstick.

  • Page 77: Sideview Mirrors

    INSTRUMENTS AND CONTROLS TORQUE CONVERTER OIL LIGHTS AND LAMPS SIDEVIEW MIRRORS FILLER T type The torque converter oil filler is located CAUTION CAUTION near the accelerator pedal under the • When traveling in reverse, always Check that lights and lamps come floorboard.
  • Page 78 INSTRUMENTS AND CONTROLS Rear side The truck has combination lamps (stop and tail lamps , reflectors , turn signals , back-up lamps ) at its rear. 2 - 25 Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...

  • Page 79: Optional Equipment

    For more information about When the light switch is turned on, the dial optional equipment, consult your local TCM NOTE is illuminated by a built-in lamp. dealer. Some models may require tire chain...
  • Page 80 INSTRUMENTS AND CONTROLS SWITCHES The switches for the rear work light and others are located as shown above. Follow the instructions on the decal near each switch. 2 - 27 Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...

  • Page 81: Operation

    3. OPERATION The following symbols, found throughout this manual, alert you to potentially hazardous conditions to the owner and the CONTENTS operator. Become completely familiar with the truck before proceeding with operating, checking and servicing. PROPER OPERATION ............ 3 - 1 DURING BREAK-IN ............

  • Page 82: Proper Operation

    PROPER OPERATION RELATIONSHIP BETWEEN LOAD AND To operate the lift truck safely and get the most out of it, correct STABILITY OF TRUCK procedures are described on the following pages: The lift truck keeps a balance of weight between the truck and DURING BREAK-IN the load on the forks with the center of the front wheels as a We recommend to operate the truck under light load conditions...

  • Page 83: Basic Load Center And Rated Load

    PROPER OPERATION BASIC LOAD CENTER AND RATED LOAD CAUTION • When traveling with loads, keep the forks 15 to 20 cm (6 to 18 in.) above the ground surface and keep the mast tilted back fully. • The allowable load of a truck equipped with an attachment is reduced in comparison with that of the standard truck.

  • Page 84: Stability Of Lift Truck

    The stability of lift trucks is stipulated in JIS (Japanese Industrial The inching pedal works in the same manner as the clutch pedal Standards) or in other national industrial standards, and TCM of the C type truck. lift trucks are manufactured complying with these standards.

  • Page 85: Transporting Lift Truck

    PROPER OPERATION TRANSPORTING LIFT TRUCK OPERATING LIFT TRUCK MOUNTING AND DISMOUNTING CAUTION 1) Make sure there is no approaching vehicle or passerby. Make Transporting the lift truck on a trailer truck sure the truck is at a complete stop. • Securely lock the lift truck in place to prevent it from 2) Get on or off the truck from the left side of the truck, using moving on the trailer truck by fastening with wire the safety step and hand grip properly.

  • Page 86: Warming Up Engine

    PROPER OPERATION 2) Let other workmen and bystanders know you are starting up Gas-powered trucks by honking. CAUTION 3) Press the clutch pedal to the floor ( C type ) or brake pedal ( T type ) and turn the starter switch to “START” (do not keep Engine speed is high immediately after the engine has the starter switch at “START”...
  • Page 87 PROPER OPERATION WHEN ENGINE WON’T START 2) Pull back on the tilt lever to tilt back the mast fully. 3) Make sure there is no one around the truck and let other CAUTION workmen and bystanders know you are starting up by honking.

  • Page 88: Gear Shifting

    PROPER OPERATION T type C type • When reversing the direction of travel, from forward to reverse CAUTION or vice versa, be sure to bring the truck to a complete stop. Press the brake pedal to the floor before placing the •...
  • Page 89 PROPER OPERATION TURNING CAUTION CAUTION Safe parking • Park the truck on a level ground, preferably in a wide Note that the rear end (counterweight) of the truck area. swings when you turn the truck. If parking the truck without load on a slope is unavoidable, position the load handling means down-hill and block Unlike general passenger cars, the steer wheels are located at the wheels to prevent accidental roll.
  • Page 90 • When crossing a railroad, be sure to once stop, make using tire chains. sure to be safe and cross the railroad track at an angle For more information, consult your local TCM dealer. wherever possible. • Go around obstacles such as rocks and stumps, or pot holes.

  • Page 91: Measures Against Cold Or Hot Weather

    MEASURES AGAINST COLD OR HOT WEATHER IN COLD WEATHER When using the truck in a cold weather, special care should be taken more than when using it in a warm weather. Proper level Caution to be taken when adding fuel CAUTION When adding fuel, make sure to shut down the engine.
  • Page 92 MEASURES AGAINST COLD OR HOT WEATHER Battery care DANGER CAUTION Cautions to be taken when handling battery Never pour hot water over the battery case even if you Gases produced by the battery can be explosive. Do find it difficult to start the engine. The battery case might not smoke.

  • Page 93: In Hot Weather

    MEASURES AGAINST COLD OR HOT WEATHER IN HOT WEATHER Measures to be taken when the engine has overheated Cooling system CAUTION If the engine has overheated, do not open the radiator CAUTION cap. In addition, do not touch the radiator reservoir Make sure the engine is cold before opening or closing tank.

  • Page 94: Load Handling

    LOAD HANDLING PICK-UP STACKING 1) The fork spacing should be as wide as possible to maintain 1) When approaching the deposit area, slow down your truck. proper balance of the load. 2) Once stop the truck right in front of the area where your 2) Place the truck right in front of the load to be handled.

  • Page 95: Unstacking

    LOAD HANDLING UNSTACKING 1) When approaching the area where the load is to be retrieved, slow down the truck. 2) Once stop the truck right in front of the load so that the distance between the fork tips and the load is about 30 cm (12 in.).

  • Page 96: Storing

    STORING BEFORE STORING DAILY STORAGE • Park the truck at a specified place and block the wheels. CAUTION • Place the shift lever(s) in neutral “N” and pull the parking • • • • • If any time your lift truck is found to be in need of repair, brake lever fully.

  • Page 97: Long-Term Storage

    STORING LONG-TERM STORAGE OPERATING AFTER LONG-TERM STORAGE • Remove covers used to seal off moisture. Perform the following checks in addition to “BEFORE STORING” • Remove antirust from the exposed parts. and “DAILY STORAGE” services. • Taking the rainy season into consideration, park the truck at •...
  • Page 98 MEMO Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...
  • Page 99 4. MAINTENANCE The following symbols, found throughout this manual, alert you to potentially hazardous conditions to the owner and the CONTENTS operator. Become completely familiar with the truck before proceeding PREOPERATIONAL CHECKS .......... 4 - 1 with operating, checking and servicing. GENERAL RULES ON INSPECTION ......

  • Page 100: Preoperational Checks

    Before starting the lift truck, be sure to inspect the following items for safety’s sake and increased productivity. • Use TCM’s genuine parts only. • Use TCM’s genuine or recommended lubricants only. • Clean the oil fillers and grease fittings using a brush or CAUTION shop rag before adding oil or fuel or greasing.
  • Page 101 Check the inclination of the truck. If the truck is tilted to either side, it suggests that the tires or wheels are defective. Contact your local TCM dealer. Oil or water leaks Check for oil or water leaks under the truck. If there is a pool of oil or water on the ground or floor surface, contact your local TCM dealer.

  • Page 102: Items To Be Checked

    If you find reinstall the tire cap. any failure, contact your local TCM dealer. Check that each tire does not get damaged at the tread surface or side face or bending at the rim.
  • Page 103 PREOPERATIONAL CHECKS both the front tires or rear tires should be replaced as a set. Make sure new tires are the same size as those to be replaced. Hub nut check CAUTION A loose hub nut can be dangerous. In the worst case, the wheel comes off the truck, causing the truck to tip over.

  • Page 104: Battery Electrolyte Level

    PREOPERATIONAL CHECKS OVERHEAD GUARD Open the engine hood Check the overhead guard for loose mounting bolts or nuts, Remove the floor mat and pull up the engine hood opening cracks, deformation or damage. lever to open the hood. Make sure the hood damper stopper is securely locked before removing your hand.
  • Page 105 PREOPERATIONAL CHECKS 6 COOLING WATER LEVEL Checking cooling water level in radiator CAUTION • • • • • Do not try to remove the radiator cap when the engine is hot; otherwise you will get burnt. The cooling water level should be checked before starting the engine or when the engine is cold.

  • Page 106: Engine Oil Level

    PREOPERATIONAL CHECKS 7 ENGINE OIL LEVEL TD27-II, QD32 C240 CAUTION The exhaust system is hot for a while after the engine is shut down. Use caution not to get burnt. The engine oil level dipstick is located at the left side (K15, K21, K25, D1503, TD27-II, QD32, C240) or the right side (V3300) of the engine.
  • Page 107 PREOPERATIONAL CHECKS 8 FAN BELT C240 TD27-II, QD32 Push PULLEY CAUTION • Push Make sure the engine is shut down before checking the fan belt for tension. GENERATOR • PULLEY Check the belt tension (deflection) by pressing the middle part on each span (areas indicated by arrows).

  • Page 108: Rear Combination Lamp

    PREOPERATIONAL CHECKS 9 REAR COMBINATION LAMP Check the rear combination lamps (turn signals, tail lamps, brake lamp, back-up lamp, and rear reflector) for a damaged or contaminated lens. 10 HYDRAULIC OIL LEVEL Raise the right side-cover to remove. Check the hydraulic oil level in the tank using the oil level dipstick.

  • Page 109: Load Backrest

    PREOPERATIONAL CHECKS 12 TORQUE CONVERTER OIL LEVEL T TYPE 14 LOAD BACKREST Remove the floorboard. Check the load backrest for deformation, cracks or damage or Remove the oil dipstick of the filler cap. Clean the rod with a loose or missing mounting bolts. clean cloth and reinstall it.
  • Page 110 PREOPERATIONAL CHECKS 16 HEAD LIGHTS AND COMBINATION LAMPS 19 SHIFT LEVERS Check for dirty or damaged lens of the head lights. Check also Check the directional and speed range shift levers ( C type ) the front and rear combination lamps (side marker lights and and shift lever ( T type ) for looseness and smooth operation.

  • Page 111: Fuel Level

    If brake pedal or inching pedal fails to operate normally proper operation. or if they have improper height or play, ask your local TCM dealer for inspection and repair. 24 LIGHTS AND LAMPS Press each pedal to check if it operates smoothly. Release the Operate the lighting switch to check if the lights and lamps come pedal to check if it returns securely.

  • Page 112: Mast Operation

    TCM dealer for inspection and repair. NOTE Press each pedal to check if it operates smoothly. Release the WARMING UP CYLINDERS pedal to check if it returns securely.

  • Page 113: Steering Wheel

    PREOPERATIONAL CHECKS 30 LIFT CHAIN TENSION 31 STEERING WHEEL Raise the forks 50 mm (2 in.) off the ground or floor surface Turn the steering wheel counterclockwise and clockwise to and check that the right and left lift chains have the same check for play.
  • Page 114 PREOPERATIONAL CHECKS 32 EXHAUST GAS CONDITION Run the truck at a low speed (at an out-of-traffic area) 33 CLUTCH PEDAL OPERATION TEST C TYPE CAUTION • Exhaust fumes are very dangerous. When starting the Run the truck slowly and press the clutch pedal for proper lift truck in an enclosed space, make sure there is operation.

  • Page 115: Parking Brake Test

    PREOPERATIONAL CHECKS 35 BRAKE TEST 36 STEERING TEST Run the truck slowly and press the brake pedal to check if the Run the truck at a low speed and turn the steering wheel a little truck is braked properly without being pulled to one side. to the right and left to check if the truck is steered properly.

  • Page 116: Preventive Maintenance

    PREVENTIVE MAINTENANCE ENGINE ROOM K15, K21, K25 4 - 17 Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...
  • Page 117 PREVENTIVE MAINTENANCE D1503 4 - 18 Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...
  • Page 118 PREVENTIVE MAINTENANCE TD27-II, QD32 4 - 19 Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...
  • Page 119 PREVENTIVE MAINTENANCE C240 4 - 20 Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...
  • Page 120 PREVENTIVE MAINTENANCE V3300 4 - 21 Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...
  • Page 121 PREVENTIVE MAINTENANCE REMOVING WATER FROM SEDIMENTER TD27-II, QD32, C240 Diesel-powered trucks The sedimenter separates water from fuel. It is integral with the fuel filter. TD27-II, QD32 When the sedimenter warning light comes on, it indicates that more than the specified amount of water has accumulated in PRIMING PUMP the sedimenter.
  • Page 122 PREVENTIVE MAINTENANCE D1503, V3300 D1503, V3300 (SEDIMENTER) The sedimenter separates water from fuel. When the sedimenter warning light comes on, it indicates that more than the specified amount of water has accumulated in the sedimenter. Remove the water in the following matter: 1.
  • Page 123 PREVENTIVE MAINTENANCE AIR BLEEDING FUEL SYSTEM D1503 Diesel-powered trucks The D1503 engine has an automatic air bleeding system. Use it in the following manner: CAUTION 1. Turn the starter switch to the “ON” position. • Make sure there is not any fuel leak from the air bleeding 2.
  • Page 124 PREVENTIVE MAINTENANCE V3300 V3300 AIR BLEEDING 1. Open the air bleeding cock of the injection pump. COCK 2. Pump the priming pump on top of the fuel filter a few times or until fuel coming from the air bleeding cock of the injection pump is free from air bubbles.

  • Page 125: Replacing Fuses

    : They function when the key If replacement of the fusible link is switch is in “ON”. needed, the cause of blowout should be located and troubleshooted properly. Consult your local TCM dealer. 4 - 26 Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...

  • Page 126: Replacing Tires And Repairing Flat Tire

    PREVENTIVE MAINTENANCE REPLACING TIRES AND 1. Park the truck on a level, hard surface personnel. The lift truck uses tires REPAIRING FLAT TIRE and shut down the engine. which have an inflation pressure far 2. Apply the parking brake and block the h i g h e r t h a n t h o s e o f g e n e r a l wheel opposite the one you are going passenger cars.

  • Page 127: Replacing Lamp Bulbs

    PREVENTIVE MAINTENANCE REPLACING LAMP BULBS CAUTION When replacement of a bulb is needed, use a genuine part of the same capacity. Use of a bulb of a different capacity might cause a fire hazard. If any light bulb burns out, replace it with a new one of the same capacity, referring to the following table: Lamp capacity...

  • Page 128: Starting The Engine With Auxiliary Battery

    PREVENTIVE MAINTENANCE STARTING THE ENGINE CAUTION WITH AUXILIARY BATTERY • Keep the booster cable in place (WHEN YOU CANNOT START THE while the starter motor is turning; ENGINE BECAUSE THE BATTERY HAS BEEN EXHAUSTED) otherwise sparks occur to cause an accident. WARNING •...

  • Page 129: Adjusting Operating Force Of Parking Brake Lever

    PREVENTIVE MAINTENANCE ADJUSTING OPERATING ADJUSTMENT FORCE OF PARKING BRAKE 1. Engage the spring scale to the parking LEVER brake lever as shown in the left sketch and measure the force required to operate the lever. Standard operating force: 200 – 250 N (20 –...

  • Page 130: Periodic Inspection

    TCM dealer. If enough knowledge, special tools or have been reached, even if their appearances are good. equipment is not available, personal injury could occur during NOTE checking or servicing.
  • Page 131 PERIODIC INSPECTION MONTHLY (200 OPERATING HOURS) Items to be checked CHECKS • Air cleaner – Clean element. • Engine cylinder head bolt – Retighten (gas-powered trucks, Perform preoperational checks in addition to the following. for the first time only). • Engine oil – Change [1 week (50 operating hours) for the The adjustment and replacement of components and parts listed first time only].
  • Page 132 PERIODIC INSPECTION CHECKING AND CLEANING AIR CLEANER Items to be checked ELEMENT • Brake piping – Check for damage, leaks, interference or looseness. DUST CUP ELEMENT • Brake drum – Check for loose mounting. • Forks – Check for cracks or wear. •...

  • Page 133: Changing Engine Oil

    D1503 Do not drain waste oil into a waterway nor throw it away on the ground. Disposal of waste oil should be left to a specialist. TCM dealers will undertake oil change job, if required. CAUTION Do not try to change the engine oil immediately after the engine is shut down.

  • Page 134: Changing Engine Oil Filter

    PERIODIC INSPECTION 9. After oil is drained off completely, reinstall the drain plug. C240 10. Wipe areas around the drain plug clean. TD27-II, QD32 11. Wind cloth around the oil fill port neck to catch spilt oil. 12. Add oil up to the specified level, leaving a room of about one liter.
  • Page 135 PERIODIC INSPECTION LUBRICATING LIFT CHAIN 3. Wipe clean the cylinder block in the cartridge mounting area. 4. Apply a thin coat of engine oil on the “O”-ring of the new filter cartridge. 5. Hand tighten the new filter cartridge. After the “O”-ring touches the seal surface, use a filter wrench to tighten the cartridge.

  • Page 136: Greasing Points

    PERIODIC INSPECTION GREASING POINTS • Propeller shaft (2 points) ....• Clutch, inching and brake pedal shafts (1point) ........• Rear axle (8 points in all) ....(Axle support (2), king pin (3), knuckle (3) ) • Clutch release yoke shaft C type (1 point) ..........
  • Page 137 PERIODIC INSPECTION • • • • • Mast rear slipper Apply grease on the U-shape guides shown in the sketch (for masts with free lift mechanism) CAUTION Do not climb the mast. Do not pour your hand or foot on the connecting members or into the mast assembly. You might get injured if the mast moves accidentally.
  • Page 138 PERIODIC INSPECTION 3 MONTHS (600 OPERATING HOURS) Items to be checked CHECKS • Crankcase – Check the air breather for contamination and clean if necessary Perform the following checks in addition to preoperational • Engine oil filter – Change checks and one month (200 operating hours) checks. •...
  • Page 139 PERIODIC INSPECTION CLEANING FUEL FILTER Gas-powered trucks CHANGING FUEL FILTER Diesel-powered trucks COVER BOWL FILTER CASE SEDIMENTER ELEMENT SENSOR PACKING DRAIN PLUG (The sketch shows the fuel filter of the C240.) CAUTION Wipe away any spilt fuel around the fuel filter. There is CAUTION a danger of causing a fire hazard.
  • Page 140 PERIODIC INSPECTION 6 MONTHS (1200 OPERATING HOURS) Items to be checked CHECKS • Air cleaner element – Change. • Valve clearance – Check. Perform the following checks in addition to daily checks, one • Blow-by gas reducing device- Check metering valve and month (200 operating hours) checks, and 3 months (600 piping for clogging or damage.
  • Page 141 PERIODIC INSPECTION ANNUAL (2400 OPERATING HOURS) Items to be checked CHECKS • Engine cylinder head bolts – Retighten (C240 engine). • Engine cylinder – Measure compression pressure. Perform the following checks in addition to daily checks, one • Governor – Check proper operation (maximum rpm under month (200 operating hours) checks, and 3 months (600 unloaded condition).

  • Page 142: Preventive Maintenance Schedule

    PERIODIC INSPECTION PREVENTIVE MAINTENANCE SCHEDULE This maintenance schedule is worked out on the assumption that the lift truck will be used under typical working conditions. If the lift truck is used under severer working conditions, earlier preventive maintenance is required. (The black dots in the table mean “Change or addition”.) G : Gas-powered trucks, D : Diesel-powered trucks ENGINE...
  • Page 143 PERIODIC INSPECTION ENGINE Checking Monthly Trimonthly Semiannually Annually Service Required Tools Daily item (200 hrs) (600 hrs) (1200 hrs) (2400 hrs) Check for fuel leaks (piping, pump and tank). Visual Check for fuel filter for clogging G . Visual Clean fuel filter G . Operate Change fuel filter element D .
  • Page 144 PERIODIC INSPECTION POWER TRAINS Checking Monthly Trimonthly Semiannually Annually Service Required Tools Daily item (200 hrs) (600 hrs) (1200 hrs) (2400 hrs) Check clutch pedal for play and the clearance between Operate pedal and floorboard when disengaged. and scale Check for noise and proper disengagement. Operate Check for slipping and proper engagement.

  • Page 145: Steering System

    PERIODIC INSPECTION TIRE/WHEEL SYSTEM Checking Monthly Trimonthly Semiannually Annually Service Required Tools Daily item (200 hrs) (600 hrs) (1200 hrs) (2400 hrs) Check inflation pressure. Tire gauge Check for cracks or damage. Visual Tire Check tread depth. Depth gauge Check for undue wear. Visual Check for debris, stones or foreign matter in tread.

  • Page 146: Brake System

    PERIODIC INSPECTION STEERING SYSTEM Checking Monthly Trimonthly Semiannually Annually Service Required Tools Daily item (200 hrs) (600 hrs) (1200 hrs) (2400 hrs) Knuckle Check king pin for looseness or damage. Touch Check for bending, damage or wear. Visual Rear axle Check mounting condition.
  • Page 147 PERIODIC INSPECTION BRAKE SYSTEM Checking Monthly Trimonthly Semiannually Annually Service Required Tools Daily item (200 hrs) (600 hrs) (1200 hrs) (2400 hrs) Check for fluid leaks (oil leaks for trucks with power Visual brake). Check fluid level. Visual Wheel brake Check master cylinder and wheel cylinder for proper Operate operation.
  • Page 148 PERIODIC INSPECTION LOAD HANDLING SYSTEM Checking Monthly Trimonthly Semiannually Annually Service Required Tools Daily item (200 hrs) (600 hrs) (1200 hrs) (2400 hrs) Check for damage, deformation or wear. Visual Forks Check fork stopper pin for damage or wear. Visual Check for roots and teeth welded area for cracks or wear.

  • Page 149: Hydraulic System

    PERIODIC INSPECTION LOAD HANDLING SYSTEM Checking Monthly Trimonthly Semiannually Annually Service Required Tools Daily item (200 hrs) (600 hrs) (1200 hrs) (2400 hrs) Check piston rod, rod bolt, rod end for looseness, Visual/ deformation or damage. test hammer Check for proper operation. Operate Cylinder Check for oil leaks.

  • Page 150: Electrical System

    PERIODIC INSPECTION ELECTRICAL SYSTEM Checking Monthly Trimonthly Semiannually Annually Service Required Tools Daily item (200 hrs) (600 hrs) (1200 hrs) (2400 hrs) Check distributor cap for cracks. Visual Check spark plug for burn. Visual Adjust spark plug gap. Plug gap gauge Clean spark plug.
  • Page 151 PERIODIC INSPECTION SAFETY DEVICE AND OTHERS Checking Monthly Trimonthly Semiannually Annually Service Required Tools Daily item (200 hrs) (600 hrs) (1200 hrs) (2400 hrs) Overhead Check for loose mounting. Test hammer guard and load backrest Check for deformation, cracks or damage. Visual Check for operation and installation.
  • Page 152 MEMO Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...
  • Page 153 GENUINE TCM PARTS..........5 - 23 damage to the truck or other property. GENUINE TCM LUBRICANTS ........5 - 23 The information will help to prolong the TRUCK DATA .............. 5 - 24 NOTE service life of the truck.

  • Page 154: Specifications

    SPECIFICATIONS Specifications are subject to change without notice. 5 - 1 Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...
  • Page 155 SPECIFICATIONS Truck model FG15C13 FG15T13 FD15C13 FD15T13 Leading particulars Rated load kg (lbs) 1500 EXC 1350 (3000) Basic load center mm (in.) 500 EXC 600 (24) Max. height A mm (in.) 3000 (118.1) Free lift B mm (in.) 155 (6.1)
  • Page 156 SPECIFICATIONS Truck model FG18C13 FG18T13 FD18C13 FD18T13 Leading particulars Rated load kg (lbs) 1750 EXC 1580 (3500) Basic load center mm (in.) 500 EXC 600 (24) Max. height A mm (in.) 3000 (118.1) Free lift B mm (in.) 155 (6.1) Fork lifting speed mm/s (fpm) No load...
  • Page 157 SPECIFICATIONS Truck model FG20C3 FG20T3 FD20C3 FD20T3 FD20C3Z FD20T3Z Leading particulars Rated load kg (lbs) 2000 EXC 1810 (4000) Basic load center mm (in.) 500 EXC 600 (24) Max. height A mm (in.) 3000 (118.1) Free lift B mm (in.) 110 (4.3) Fork lifting speed mm/s (fpm)
  • Page 158 SPECIFICATIONS Truck model FG25C3 FG25T3 FD25C3 FD25T3 FD25C3Z FD25T3Z Leading particulars Rated load kg (lbs) 2500 EXC 2260 (5000) Basic load center mm (in.) 500 EXC 600 (24) Max. height A mm (in.) 3000 (118.1) Free lift B mm (in.) 110 (4.3) Fork lifting speed mm/s (fpm)
  • Page 159 SPECIFICATIONS Truck model FG30C3 FG30T3 FD30C3 FD30T3 FD30C3Z FD30T3Z Leading particulars Rated load kg (lbs) 3000 EXC 2720 (6000) Basic load center mm (in.) 500 EXC 600 (24) Max. height A mm (in.) 3000 (118.1) Free lift B mm (in.) 165 (6.5) Fork lifting speed mm/s (fpm)
  • Page 160 SPECIFICATIONS Truck model FG35T3S FD35T3S Leading particulars Rated load kg (lbs) 3500 EXC 3180 (7000) Basic load center mm (in.) 500 EXC 600 (24) Max. height A mm (in.) 3000 (118.1) Free lift B mm (in.) 170 (6.7) Fork lifting speed mm/s (fpm) No load 450 (88.6)
  • Page 161 SPECIFICATIONS Truck model FHG15C3 FHG15T3 FHD15C3 FHD15T3 FHD15C3Z FHD15T3Z Leading particulars Rated load kg (lbs) 1500 EXC 1350 (3000) Basic load center mm (in.) 500 EXC 600 (24) Max. height A mm (in.) 3000 (118.1) Free lift B mm (in.) 155 (6.1) Fork lifting speed mm/s (fpm)
  • Page 162 SPECIFICATIONS Truck model FHG18C3 FHG18T3 FHD18C3 FHD18T3 FHD18C3Z FHD18T3Z Leading particulars Rated load kg (lbs) 1750 EXC 1580 (3500) Basic load center mm (in.) 500 EXC 600 (24) Max. height A mm (in.) 3000 (118.1) Free lift B mm (in.) 155 (6.1) Fork lifting speed mm/s (fpm)
  • Page 163 SPECIFICATIONS Truck model FHG20C3 FHG20T3 FHD20C3 FHD20T3 FHD20C3A FHD20T3A Leading particulars Rated load kg (lbs) 2000 EXC 1810 (4000) Basic load center mm (in.) 500 EXC 600 (24) Max. height A mm (in.) 3000 (118.1) Free lift B mm (in.) 110 (4.3) Fork lifting speed mm/s (fpm)
  • Page 164 SPECIFICATIONS Truck model FHG25C3 FHG25T3 FHD25C3 FHD25T3 FHD25C3A FHD25T3A Leading particulars Rated load kg (lbs) 2500 EXC 2260 (5000) Basic load center mm (in.) 500 EXC 600 (24) Max. height A mm (in.) 3000 (118.1) Free lift B mm (in.) 110 (4.3) Fork lifting speed mm/s (fpm)
  • Page 165 SPECIFICATIONS Truck model FHG30C3 FHG30T3 FHD30C3 FHD30T3 FHD30C3A FHD30T3A Leading particulars Rated load kg (lbs) 3000 EXC 2720 (6000) Basic load center mm (in.) 500 EXC 600 (24) Max. height A mm (in.) 3000 (118.1) Free lift B mm (in.) 165 (6.5) Fork lifting speed mm/s (fpm)

  • Page 166: Equipment

    EQUIPMENT Standard equipment Full-transistor ignition system (G) Exhaust purification muffler Sedimenter (D) DPF muffler (D) View mast Hour meter Tertiary catalyst muffler (G) Forks (920 mm for 1.5- to 1.75-ton Engine water temp. gauge Upward-pointed tail pipe trucks, 1070 mm for 2- to 3.5-ton trucks) Fuel gauge Fire extinguisher J-lug tire...

  • Page 167: Load Chart

    LOAD CHART CAUTION The load charts given below refer to lift trucks of standard specifications and those with high mast whose lifting height is less than 5 m. Note that load charts for lift trucks with a high mast whose lifting height is more than 5 m or those with an attachment have different load charts. FG20, FD20, FHG20, FHD20 FG15, FD15, FHG15, FHD15 FG18, FD18, FHG18, FHD18...

  • Page 168: Service Data

    SERVICE DATA SERVICE DATA • • • • • Standard settings for the engines Gasoline engine Diesel engine V3300 D1503 TD27-II QD32 C240 Idle (rpm) No-load maximum 2650 3200 3100 3100 2700 2700 2700 2750 (rpm) – Ignition order 1-3-4-2 1-3-4-2 1-3-4-2 –...
  • Page 169 SERVICE DATA BOLT AND NUT TORQUE Engine mount bolts Transmission case mount bolts • K15, K21, K25, TD27-II, QD32 50 – 60 N-m (5 – 6 kgf-m) (36 – 43 ft-lbs) • D1503 M12: 100 – 120 N-m (10 – 12 kgf-m) (72 – 87 ft-lbs) M10: 50 –...
  • Page 170 SERVICE DATA Hub nuts (front wheel) Hub nuts (rear wheel) • • • • • Single tire • • • • • Double tires Inner nut Outer nut • 1.5- to 1.75-ton (For both inner and outer nuts) 150 – 175 N-m (15 – 17.5 kgf-m) •...

  • Page 171: Refill Capacity

    Consistency number: NLGI No. 0, 1, or 2 Notes: 1. Use gasoline for gas-powered trucks and light oil for diesel-powered trucks. See page 2 - 22. 2. For more information about lubricants to be used, contact your local TCM dealer. 5 - 18 Anhui Leading Forklift Parts Co., Ltd.
  • Page 172 Consistency number: NLGI No. 0, 1, or 2 Notes: 1. Use gasoline for gas-powered trucks and light oil for diesel-powered trucks. See page 2 - 22. 2. For more information about lubricants to be used, contact your local TCM dealer. 5 - 19 Anhui Leading Forklift Parts Co., Ltd.
  • Page 173 See NOTE. ESSO See NOTE. CALTEX Heavy Duty Brake Fluid NOTE: Brake fluids supplied by SHELL and ESSO have no particular names. Consult your TCM’s dealer or oil supplier. 5 - 20 Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...

  • Page 174: After-The-Sale Service

    AFTER-THE-SALE SERVICE TRUCK SERIAL NUMBER SERIAL NUMBERS OF NAME PLATE MAJOR COMPONENTS (EXB) SERIAL NUMBER (EXE) MODEL SERIAL NO. YEAR OF MANUFACTURE RATED CAPACITY APPROX. WEIGHT THE POWER The truck serial number is imprinted on In addition to the truck serial number, the The name plate is located on the front of the upper surface of the left fender of the serial numbers (unit numbers) of the major...

  • Page 175: Engine Serial Number

    AFTER-THE-SALE SERVICE ENGINE SERIAL NUMBER GASOLINE ENGINE DIESEL ENGINE D1503 K15, K21, K25 DIESEL ENGINE DIESEL ENGINE DIESEL ENGINE TD27-II, QD32 C240 V3300 5 - 22 Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...

  • Page 176: Genuine Tcm Parts

    U s e g e n u i n e T C M ’ s l u b r i c a n ts f o r deteriorates in performance with a long- lubrication. time use. To ensure the best performance of the lift truck, use genuine TCM’s parts which are used for new trucks. When ordering spare parts, be sure to designate TCM’s genuine parts.
  • Page 177 AFTER-THE-SALE SERVICE WRITE DOWN DATA OF YOUR TRUCK HERE: ENGINE TRUCK Manufacturer .............. Model ................Model ................Truck Serial No............Engine Serial No............Service Weight ..........kg (lbs) Max. Load ....mm (in.): ....kg (lbs) DATE OF PURCHASE ..............................DEALER’S NAME ..............
  • Page 178 MEMO Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...
  • Page 179 6. INDEX CONTENTS 0 - 9 ..................6-1 A - F ..................6-1 F - O ..................6-2 O - S ..................6-3 T - W ..................6-4 Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...

  • Page 180: 0 - 9 / A - F

    0 - 9 / A - F 0 - 9 CHARGE WARNING LIGHT ..........2-10 CHECKING AND CLEANING AIR CLEANER 3 MONTHS (600 OPERATING HOURS) CHECKS ..4-39 ELEMENT ................4-33 6 MONTHS (1200 OPERATING HOURS) CHECKS ..4-41 CLEANING FUEL FILTER ..........4-40 CLUTCH PEDAL ..............

  • Page 181: F - O

    FUSIBLE LINK (MAIN FUSE) ..........4-26 LOAD BACKREST .............. 2-18 LOAD CHART ..............5-14 LOAD HANDLING ............... 1-24 GENUINE TCM LUBRICANTS ........... 5-23 LOAD HANDLING ............... 3-13 GENUINE TCM PARTS ............5-23 LUBRICATING LIFT CHAIN ..........4-36 GLOVE BOX ................ 2-17 GLOW INDICATOR ...............

  • Page 182: O - S

    O - S OVERHEAD GUARD ............2-17 REPLACING FUSES ............4-26 OVERHEAD GUARD WITH WIRE NETTING ....2-26 REPLACING LAMP BULBS ..........4-28 REPLACING TIRES AND REPAIRING FLAT TIRE ..4-27 PARKING ................1-29 PARKING BRAKE LEVER ..........2-14 SAFETY STEP AND HAND GRIP ........2-20 PARKING BRAKE WARNING LIGHT ........

  • Page 183: T - W

    T - W TILT LEVER ................. 2-12 TIRE CHAIN (TC) ............... 2-26 TORQUE CONVERTER OIL FILLER ........ 2-24 TRANSPORTING LIFT TRUCK ........... 3-4 TRAVELING ................ 1-17 TRAVELING AND LOAD HANDLING INTERLOCK SYSTEM ................2-11 TRAVELING AND LOAD HANDLING INTERLOCK SYSTEM WARNING LIGHT ..........2-9 TRAVELING AND STARTING ON A SLOPE .......
  • Page 184 No. OF-2B0EE ISSUED: DEC., 2005 REVISED: MAY, 2006 REVISED: FEB., 2007 REVISED: OCT., 2007 REVISED: MAR., 2009 MARKETING GROUP: 1-15-5, Nishi-shimbashi, Minato-ku, Tokyo 105-0003, Japan FAX: Japan +81-3-35918154 All rights reserved JB-0903100(F) Printed in Japan Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...
  • Page 185 Anhui Leading Forklift Parts Co., Ltd. www.leadingforkliftparts.com www.youtube.com/@leadingforkliftparts...

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