Komatsu FD-FG-14-Serie Forklift Service Repair Workshop Manual (FG20/25/30-14 FG20H/25H/30H-14 FD20/25/30-14 FD20H/25H/30H-14 FD20J/25J/30J-14)

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Typ: Forklift

Anbieter:

Art.-Nr: 158069

Stichworte: FD20-14 FD20H-14 FD20J-14 FD25-14 FD25H-14 FD25J-14 FD30-14 FD30H-14 FD30J-14 Featured FG Series FG20-14 FG20H-14 FG25-14 FG25H-14 FG30-14 FG30H-14 Forklift Forklifts Komatsu Material Handling

Produktvarianten

Beschreibung

The Komatsu FD/FG-14 Series Forklift Truck represents a robust line of industrial material handling equipment, encompassing models such as the FG20-14, FG25-14, FG30-14, and their 'H' and 'J' variants, as well as the FD series equivalents. These forklifts are engineered for demanding applications in warehouses, manufacturing facilities, and logistics operations, offering reliable performance and efficient material movement. Built with Komatsu's heritage in heavy machinery, the FD/FG-14 series is designed for durability and operational longevity, providing essential lifting capabilities typically ranging from 2000 kg to 3000 kg, powered by versatile engine options including propane, diesel, and gasoline. This comprehensive Service Repair Workshop Manual provides complete factory-level documentation for the Komatsu FD-FG-14 Series Forklift Truck. It covers all essential aspects required for maintenance, diagnosis, and repair, including general information, specifications, testing and adjusting procedures, component removal and installation, disassembly and assembly, maintenance standards, structure and function explanations, and detailed troubleshooting guides. The manual is designed to assist both experienced technicians and less experienced users in effectively maintaining and repairing these forklifts, ensuring reduced downtime and optimal operational performance through clear, step-by-step instructions, detailed diagrams, and illustrative examples.

🏷️ Basic Information

Identification

Make:

Komatsu

Model:

FD/FG-14 Series Forklift Truck

Model Variants:

FG20-14, FG25-14, FG30-14, FG20H-14, FG25H-14, FG30H-14, FD20-14, FD25-14, FD30-14, FD20H-14, FD25H-14, FD30H-14, FD20J-14, FD25J-14, FD30J-14

Codes

Manual Product Name:

Komatsu FD-FG-14-Serie Forklift Truck Service Repair Workshop Manual

👋 Introduction

Market Position

Application Segment:

Industrial forklift trucks for material handling in warehouses, manufacturing, and logistics

Competitive Analysis

Competitors:

Toyota, Hyster, Yale, Caterpillar, Mitsubishi Forklift Trucks

Key Features

Manual Value Proposition:

Provides comprehensive, factory-level repair information to reduce downtime and maintenance costs for Komatsu FD/FG-14 series forklifts.

User Benefits:

Empowers both experienced technicians and DIY users with detailed instructions, diagrams, and troubleshooting for efficient repairs.

Format Advantages:

Digital PDF format allows for easy searching, selective printing of specific pages, and space-saving storage.

📋 Manual Details

Coverage Areas

Documentation Scope:

Complete factory service, repair, and workshop procedures

Specific Sections Covered:

General and Specifications, Testing and Adjusting, Removal and Installation, Disassembly and Assembly, Maintenance Standard, Structure and Function, Troubleshooting, Conversion Tables

Page Count

Estimated Pages:

N/A (Digital PDF, content varies based on specific model and engine)

Manual Type

Type:

Service Repair Workshop Manual

Language

Primary Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (all variants), Transmission (automatic/hydrostatic), Driveline, Differentials

Chassis And Steering:

Frame, Mast Assembly, Steering System, Axles, Brakes (hydraulic/drum/disc), Suspension

Hydraulics:

Hydraulic System (lift, tilt, steer), Pumps, Valves, Cylinders, Hoses, Filters

Electrical And Controls:

Wiring Diagrams, Control Systems, Instrumentation, Lighting, Batteries, Starters, Alternators

Operator Compartment:

Seat, Controls, Safety Guards, Operator Station

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, lubrication

Diagnostics And Troubleshooting:

Systematic troubleshooting guides, fault code identification, common problem solutions

Repair And Overhaul:

Component removal, disassembly, inspection, assembly, and installation for all major systems

Testing And Adjustment:

Performance testing, calibration, adjustment procedures for various systems

Specifications And Standards:

Maintenance standards, clearance specifications, torque values, wear limits

Technical Depth

Level Of Detail:

Comprehensive factory-level detail, suitable for both DIY and professional mechanics

Instruction Style:

Step-by-step instructions with detailed exploded diagrams, illustrations, and real photo examples

Special Features:

Includes notes, cautions, and warnings to pinpoint critical information

📊 Manual Specifications

File Format

Compatibility:

Requires PDF Reader (e.g., Adobe Acrobat Reader)

Print Quality

Visual Clarity:

High-quality diagrams, illustrations, and photo examples

Searchability:

Searchable text content within the PDF file

Binding Type

Format:

Digital Download (PDF)

Paper Type

Not applicable for digital format

⚙️ Engine Specifications

Primary Engine

Engine Manufacturer And Type:

Varied, likely internal Komatsu or licensed industrial engines (e.g., based on LP gas, diesel, or gasoline models as indicated by H/J variants)

Performance

Lift Capacity:

Ranges typically from 2000 kg to 3000 kg (4,500 lbs to 6,500 lbs) depending on the specific model (FG20/25/30, FD20/25/30)

Fuel System

Fuel Types:

Propane (LP Gas - indicated by 'H'), Diesel ('D'), Gasoline (implied for non-'H'/'J' variants, or potentially 'J' indicates a specific engine family)

Cooling System

Type:

Liquid-cooled

Lubrication System

Oil Type:

Specific SAE viscosity grade and API service classification required (detailed in manual)

🔧 Transmission

Standard

Type:

Likely hydrostatic transmission (HST) or torque converter automatic transmission, common for industrial forklifts of this era.

Optional

Not specified, typically one primary transmission type per series.

Features

Transmission Fluid:

Specific ATF or hydraulic fluid type and specification required (detailed in manual)

📐 Dimensions

Exterior

Mast Configurations:

Various mast heights and types (e.g., 2-stage, 3-stage, full free lift) would be specified in the manual.

Weights

Operating Weight:

Varies significantly based on model and configuration (e.g., 3500 kg - 4500 kg+)

🛡️ Safety Features

Ratings

No specific safety ratings (like NHTSA or Euro NCAP) are applicable to industrial forklifts in the same way as passenger vehicles.

Active Features

Operator Safety Systems:

Operator presence system (operator seat switch), parking brake, safety interlocks.

Passive Features

Operator Protection:

Overhead guard (Forks Protection Device - FPD), operator restraints (seat belt), secure operator station.

💡 Technology Features

Infotainment

Industrial forklifts of this era do not typically feature infotainment systems.

Driver Assistance

Driver assistance technologies as found in passenger vehicles are not present. Focus is on operational safety and efficiency.

Connectivity

No advanced connectivity features.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Typically every 250-500 operating hours, depending on operating conditions and specific engine model.

Hydraulic Fluid Change:

Usually every 1000-2000 operating hours or as per manual recommendation.

Filter Replacements:

Fuel filters, oil filters, hydraulic filters, and air filters typically replaced at scheduled maintenance intervals coinciding with fluid changes.

Fluid Specifications

Engine Oil Grade:

Specific SAE viscosity (e.g., SAE 30, 10W-30, 15W-40) and API classification (e.g., CD, CE, CF) detailed in manual.

Transmission Fluid Type:

May require specific ATF fluid or a dedicated hydraulic transmission fluid, specified in manual.

Hydraulic Fluid Type:

Typically ISO VG 32, 46, or 68 hydraulic oil, depending on operating temperature and pump requirements, as specified in manual.

Coolant Type:

Ethylene glycol based coolant with appropriate corrosion inhibitors, usually a 50/50 mix with distilled water.

Known Issues

Common Wear Items:

Mast rollers, forks, hydraulic hoses, seals, brake components, tires, engine mounts.

Electrical Component Wear:

Contactors, limit switches, wiring harness integrity can degrade over time, especially in dusty or wet environments.

Hydraulic System Performance:

Slow lift or tilt functions can indicate pump wear, internal leaks, or blockages in the hydraulic circuit.

Preventative Measures

Cleanliness:

Maintaining overall cleanliness of the forklift, especially engine bays and hydraulic components, is crucial for longevity.

📚 Vehicle History

Brand Heritage

Komatsu Forklift Division:

Komatsu Ltd. is a renowned manufacturer of construction machinery, with a significant division dedicated to industrial vehicles like forklifts.

Model Evolution

Fg Fd Series:

The FG/FD series represents Komatsu's established line of internal combustion engine forklifts, evolving through various generations (indicated by series numbers like -14).

Production

Series Production Period:

The '-14' designation typically refers to models produced in the late 1990s to early 2000s, but precise years would require cross-referencing Komatsu's production data.

🏆 Awards & Recognition

Recognitions

No specific industry awards are typically cited for individual forklift models in this manner.

Ratings

Certifications

Safety Standards:

Adherence to relevant industrial safety standards (e.g., ANSI/ITSDF B56.1 in the US, EN 16307 in Europe) would be expected, though not explicitly detailed in the manual product description.