This workshop service repair manual covers Komatsu FG/FD Series Forklift Trucks, including models FG10, FG15, FG18, FG20, FG25, FG30, FG35, FD10, FD15, FD18, FD20, FD25, FD30, and FD35. These internal combustion engine forklifts are renowned for their durability and performance in material handling environments. A global leader in industrial equipment, has a long-standing reputation for producing reliable machinery, and the FG/FD series exemplifies this commitment through its robust engineering and efficient operation. These forklifts are designed to handle a wide range of lifting capacities, from approximately 1,000 kg to 3,500 kg, making them versatile tools for various industrial and warehouse applications.
This comprehensive manual provides detailed, step-by-step instructions for all service and repair procedures across all models and variants. It covers every aspect of the forklift, including the engine mechanical systems, fuel, ignition, cooling, lubrication, and exhaust systems, as well as the hydraulic system, transmission, drivetrain, steering, braking, and electrical systems. Furthermore, it details maintenance for the chassis, bodywork, operator controls, mast system, and lifting mechanisms. Included are routine maintenance schedules, troubleshooting guides, diagnostic procedures, component removal and installation, adjustments, specifications, and overhaul procedures, empowering owners and technicians to effectively maintain and repair their Komatsu FG/FD Series Forklift Trucks.
Model:
FG/FD Series Forklift Truck
Model Variants:
FG10, FG15, FG18, FG20, FG25, FG30, FG35, FD10, FD15, FD18, FD20, FD25, FD30, FD35
Product Type:
Complete Workshop Service Repair Manual
Market Position:
Komatsu FG/FD series forklifts are workhorses in material handling, known for their durability and performance in industrial and warehouse environments. This manual supports owners and technicians in maintaining these reliable machines.
Key Features:
Empowers users to perform their own repairs, leading to significant cost savings. Provides clear, illustrated instructions for efficient servicing and troubleshooting.
Coverage Areas:
All service and repair procedures, all models/engines/trim/transmission types
Manual Type:
Workshop Service Repair Manual
Language:
English (Assumed)
Page Count:
Not Specified (Implied comprehensive)
Delivery Method:
Instant email delivery upon payment confirmation.
Usage Rights:
Purchased manual is for perpetual use by the buyer, allowing printing and device downloads.
Systems Covered:
Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system, hydraulic system, transmission (hydrostatic/torque converter), drivetrain, steering system, braking system, electrical system, chassis, bodywork, operator controls, mast system, lifting mechanisms, safety systems.
Procedures Included:
Routine maintenance, scheduled servicing, troubleshooting guides, diagnostic procedures, component removal and installation, assembly and disassembly, adjustments, specifications, repair techniques, wiring diagrams, schematic diagrams, overhaul procedures, replacement part identification.
Technical Depth:
Comprehensive A-Z coverage, detailed step-by-step instructions with accompanying pictures, suitable for both novice and experienced technicians.
Electrical System Coverage:
Comprehensive wiring diagrams, component identification, troubleshooting of lighting, starting, charging, and accessory circuits.
Hydraulic System Coverage:
Detailed diagrams of hydraulic circuits, pump, valve bank, cylinder repair, troubleshooting of pressure and flow issues.
Drivetrain Coverage:
Service and repair of drive axle, differential, wheel bearings, and associated components.
Chassis Body Coverage:
Frame inspection, steering linkage, suspension components, counterweight removal/installation, body panel repair and maintenance.
Mast Attachments Coverage:
Maintenance and repair of mast channels, rollers, lift chains, side shift mechanisms, fork assembly, and safety latches.
Print Quality:
High Quality, printable by chapter or full document
Searchable Text:
Implied by PDF format, allowing for text searches
Compatibility:
All PC & MAC Computers, tablets, mobile phones. Requires Adobe Reader.
Print Feature:
Printable by section or entire document, allowing users to create physical copies for workshop use.
Engine Type:
Internal Combustion (Likely LPG, Diesel, and Gasoline variants based on typical Komatsu offerings)
Displacement:
Not Specified (Varies by specific model and engine option)
Horsepower:
Not Specified (Varies by specific model and engine option)
Torque:
Not Specified (Varies by specific model and engine option)
Fuel Type:
LPG, Diesel, Gasoline (depending on specific model designation)
Fuel System Components:
Carburetor (LPG/Gasoline), Fuel Injection (Diesel), Fuel Pump, Fuel Filter, Fuel Lines.
Cooling System Components:
Radiator, fan, water pump, thermostat, hoses, coolant reservoir. Manual details flushing, leak testing, and component replacement.
Lubrication System Components:
Oil pump, oil filter, oil pan, oil passages. Manual covers oil pressure testing and component servicing.
Transmission Type:
Automatic Transmission (Likely Torque Converter type for many models, potentially hydrostatic for specific variants)
Transmission Controls:
Shift lever, potentially forward/reverse selector.
Transmission Fluid Type:
Not Specified (Requires consulting specific model sections within the manual)
Transmission Fluid Capacity:
Not Specified (Requires consulting specific model sections within the manual)
Lift Capacity Range:
Nominal capacities ranging from approximately 1,000 kg (FG/FD10) to 3,500 kg (FG/FD35), depending on specific model and configuration. Exact specifications require manual consultation.
Mast Height:
Variable depending on mast type (e.g., 2-stage, 3-stage) and free lift. Specifics detailed in manual.
Overhead Guard Height:
Standard dimension for operator protection, detailed in manual.
Operating Weight:
Varies significantly by model and configuration. Detailed specifications in manual.
Operator Protection:
Features overhead guard, seat belt (if equipped), and robust chassis design for operator safety. Manual details specific safety features and operational guidelines.
Braking System:
Hydraulic power-assisted brakes (e.g., drum or disc) for reliable stopping power. Manual covers brake system diagnostics and repair.
Load Capacity Warnings:
Forklifts are equipped with load charts and capacity indicators. Manual details proper loading procedures and safety limits.
Control Systems:
Mechanical and hydraulic controls for lift, tilt, steering, and drive. Manual covers adjustment and repair of these systems.
Operator Interface:
Dashboard indicators for fuel level, engine temperature, oil pressure, battery charge, and transmission status. Manual explains the function of each indicator.
Diagnostic Tools:
While primarily mechanical, some models may have basic electronic diagnostic ports. The manual will guide on any available diagnostic information or procedures.
Daily Checks:
Visual inspection of tires, forks, mast, hydraulic fluid, engine oil, coolant, brake fluid, horn, lights, and warning devices. Manual provides detailed checklist.
Hourly Service:
Engine oil and filter change, air filter inspection/cleaning, fuel filter inspection. Specific intervals (e.g., 250, 500, 1000 hours) are detailed in the manual based on operating conditions.
Periodic Service:
Transmission fluid and filter change, hydraulic fluid and filter change, cooling system service, brake system inspection, mast and lift mechanism lubrication, electrical system checks. Intervals specified in the manual.
Engine Oil Type:
Various viscosities (e.g., SAE 10W-30, 15W-40) depending on engine and ambient temperature. Specific recommendations in manual.
Hydraulic Fluid Type:
ISO VG 32 or VG 46 anti-wear hydraulic fluid typically recommended. Manual will specify precise type and grade.
Transmission Fluid Type:
Automatic Transmission Fluid (ATF) Type T-III or equivalent often used. Manual will specify exact type and capacity.
Coolant Type:
Ethylene glycol based antifreeze with corrosion inhibitors. Manual specifies mixture ratio and type.
Common Wear Items:
Tire wear, brake pad/shoe wear, hydraulic cylinder seal leaks, mast roller wear, engine tune-up requirements. Manual provides troubleshooting for these and more.
Typical Faults:
Difficulty starting, loss of hydraulic power, erratic transmission behavior, overheating. Manual's diagnostic sections are key.
Tire Pressure:
Not specified, requires consultation with specific tire manufacturer data and forklift load requirements. Manual may provide general guidance.
Bolt Torques:
Critical torque specifications for major components (e.g., wheel nuts, engine mounts, hydraulic fittings) are included in the manual.
Brand Heritage:
Komatsu is a globally recognized manufacturer of construction and industrial equipment, with a long history of producing reliable and high-performance machinery. Their forklift division is a significant part of their portfolio.
Series Development:
The FG/FD series represents Komatsu's commitment to versatile internal combustion engine forklifts, evolving over the years to incorporate improved ergonomics, efficiency, and emissions control. Specific generation details would be within the manual.
Manufacturing Locations:
Komatsu manufacturing facilities are located globally. Specific production origins for these models may vary and are not detailed in the product description.
