Torque values, relief pressure and the steering gear box rebuild order are settled in SM018, a 58-page Komatsu service manual for the FB10M-2 to FB18M-2 forklift truck series, four variants. Hydraulic circuit diagrams in this Komatsu FB15M-2 service manual PDF show the lift, tilt and power steering cylinder circuits, and a wiring diagram maps the electrical side. Exploded views break down the steering gear box, girotor, relief valve and control valve; mast work covers roller selection, shim adjustment and lift chain elongation. Transfer gear backlash is covered as well. Check hydraulic pump relief at a minimum of 140 kg/cm² (137 bar, 1990 psi), then torque the mast mounting bolts to 25 to 43.5 kgm (180 to 310 lbft). When your job is setting brake pad to disc clearance or bleeding air from the lift cylinder, the procedure is written out in full. Bookmarked by chapter and text-searchable, the pages print cleanly when you want a working copy beside the truck.
What's Inside This Komatsu FB10M-2, FB13M-2, FB15M-2, FB18M-2 Manual
| System | Pages | Key Topics |
|---|---|---|
| General Locations | 6 | |
| Removal and Installation | 7 | Steering Gear Box |
| Weight Table | 8 | Battery Assembly, Transfer, Brake Assembly, Steering Axle, Steering Gear Box, Mast |
| Mast | 9-10 | Lift Cylinder Air Bleeding |
| Power Train | 11-12 | Anti-Vibration Rubber, Hydraulic Pump, P.S Pump, Drain Plug, Oldham Coupling |
| Brake System | 13-14 | Procedure for Adjusting Clearance Between Brake Pad and Disc, Brake Pad |
| Hydraulic System Overview and Maintenance | 15-16 | Hydraulic System Diagram, Pressure Release Procedure, Hydraulic Pump Inspection, PS Cylinder Air Bleeding |
| Brake System Removal and Adjustment | 17-19 | Accelerator Pedal Adjustment, Brake Pedal Adjustment, Parking Brake Adjustment, Brake Switch |
| Transfer Disassembly and Assembly | 20-25 | Transfer Gear Specifications, Disassembly Procedure, Assembly Procedure, Gear Backlash |
| Rear Axle and Steering Cylinder | 26-29 | Steering Axle Assembly, Power Steering Cylinder, Steering Chain Tension, PS Pump Inspection |
| Brake System Disassembly and Inspection | 30-31 | Brake System Components, Brake Pad Replacement, Inspection Data, Clearance Specifications |
| Steering Gear Box Disassembly and Assembly | 32-44 | Steering Gear Box Components, Relief Valve Assembly, Girotor Assembly, Control Valve Assembly |
| Hydraulic Cylinder Maintenance | 45-53 | Hydraulic Circuit Diagram, Lift Cylinder, Tilt Cylinder, Power Steering Cylinder, Inspection Data |
| Mast Disassembly and Inspection | 54-58 | Mast Assembly, Roller Selection, Shim Adjustment, Lift Chain Elongation, Circuit Diagram |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Pneumatic tires rim connecting bolts torque | 16 - 25 kgm (120 - 180 lbft, 160 - 250 Nm) | p. 10 |
| Mast mounting bolt torque | 25 - 43.5 kgm (180 - 310 lbft, 250 - 430 Nm) | p. 10 |
| Drive motor bolt torque | 8 - 9 kgm (60 - 70 lbft, 80 - 90 Nm) | p. 14 |
| Hydraulic pump relief pressure | Min. 140 kg/cm² (137 bar, 1990 psi) | p. 16 |
| Delivery amount | 65 cc/rev. | p. 32 |
| Bolts (4) tightening torque | 25 - 29 Nm | p. 43 |
| Bolt (2) tightening torque | 49 - 59 Nm | p. 43 |
| Control valve assembly bolt torque | 46 Nm (34 lbft, 4.7 kgm) | p. 52 |
| Hydraulic system oil capacity | 18L | p. 11 |
| Hydraulic system tank only oil capacity | 15L | p. 11 |
| Brake system fluid capacity | 0.15L | p. 13 |
| Hydraulic system max pressure | 170 bar | p. 3 |
Komatsu FB10M-2, FB13M-2, FB15M-2, FB18M-2 Common Problems This Manual Covers
Komatsu FB10M-2 to FB18M-2 hydraulic pump relief pressure reading below minimum specification during pump inspection
Release hydraulic pressure using the procedure on page 15 before fitting a gauge. Never open the circuit right after running the truck: the manual warns boiling oil may spurt out. Test the hydraulic pump following the inspection on page 16 and compare the reading against a minimum of 140 kg/cm² (137 bar, 1990 psi).
Manual Section: Hydraulic System Overview and Maintenance p. 16Lift cylinder air trapped in hydraulic circuit after mast or cylinder removal and installation
Release hydraulic pressure per page 15 first, and let the truck sit before opening anything: the manual warns boiling oil may spurt out if you do it right after use. Bleed air from the lift cylinder following the procedure on page 9. If the mast came off, torque the mast mounting bolts to 25 to 43.5 kgm (250 to 430 Nm) per page 10.
Manual Section: Mast p. 9Brake pad to disc clearance out of adjustment on the wheel brake assembly
Adjust the clearance between brake pad and disc following the procedure on page 13. Inspect the pads against the inspection data and clearance specifications on page 30, and replace any pad that falls outside them. Check the brake fluid level while you are in there; page 13 lists total brake system capacity at only 0.15 L.
Manual Section: Brake System p. 13Parking brake and brake pedal out of adjustment after brake system removal and reinstallation
Inspect the parking brake installation against the removal and installation layout on page 7 before touching adjustments. Adjust the brake pedal and the parking brake following the procedures that start on page 17. Check brake switch operation once the pedal is set, since it is covered in the same section, then recheck the parking brake adjustment.
Manual Section: Brake System Removal and Adjustment p. 17Accelerator pedal height and pedal play measuring out of specification on the truck
Measure accelerator pedal height and adjust it to 100 to 115 mm following page 18. Check pedal play against 15 mm on the same page and readjust if it is off. Recheck both measurements after tightening, then confirm the brake pedal and brake switch adjustments covered in the same section starting on page 17 are still correct.
Manual Section: Brake System Removal and Adjustment p. 18Mast lift chain elongation beyond limit and mast rollers needing selection and shim adjustment
Measure lift chain elongation following the mast inspection starting on page 54, and replace chains that exceed the limit listed there. Inspect the mast rollers, select the correct rollers and set shim adjustment per the same section. When the mast goes back on, torque the mounting bolts to 25 to 43.5 kgm (180 to 310 lbft) per page 10.
Manual Section: Mast Disassembly and Inspection p. 54Frequently Asked Questions
What is the procedure for bleeding air from the lift cylinder?
To bleed air from the lift cylinder, raise or lower the mast, stopping approximately 100 mm before the highest or lowest positions. Repeat this procedure four or five times, then operate the mast to the highest and lowest positions and repeat the procedure again four or five times. p. 10
What is the required oil capacity for the transfer case on the Komatsu FB10M-2, FB13M-2, FB15M-2, FB18M-2?
The oil capacity for the transfer case is 2.4 liters (0.63 x 2 gal US) of SAE 90 oil. p. 20
What is the tightening torque for the brake assembly bolts on the Komatsu FB10M-2, FB13M-2, FB15M-2, FB18M-2?
The tightening torque for the brake assembly bolts is 8-9 kgm (60-70 lbft / 80-90 Nm). p. 13
What is the standard backlash for the transfer gears?
The standard backlash for the transfer gears is between 0.13 mm and 0.34 mm. p. 20
What is the hydraulic pump relief pressure criteria for the Komatsu FB10M-2, FB13M-2, FB15M-2, FB18M-2?
The relief pressure criteria for the hydraulic pump is 140 kg/cm² (137 bar / 1990 psi). p. 16
How is this Komatsu FB10M-2–FB18M-2 Series Service Manual delivered?
All 58 pages arrive as one searchable PDF at checkout. Read it at the desk, then take the phone out to the machine.
Am I free to print this Komatsu FB10M-2–FB18M-2 Series Service Manual?
Yes. Print a chapter or just the pages for the job at hand, for use in your own shop. Any home or office printer works.
