Komatsu shop manual SM094 pulls apart four M-3 electric forklift trucks, from the FB15 to the FB20, and rebuilds them over 150 pages of factory procedure. If you've been hunting a Komatsu FB15–FB20 series shop manual PDF that actually explains the AC drive, this is it: electronics and diagnostics fill more than a third of the book, tracing the Canion master controller circuit, CAN bus communications, and the full machine wiring diagram before working through the error handling table and flowcharts for codes 05 and 07. The hydraulic circuit, transfer, steering gear box, and mast sections carry teardown and inspection data for each assembly. Set brake master cylinder piston clearance at 0.02 to 0.105 mm, and shim the load rollers to 1.5 mm of side play at the tightest point. Swap a healthy contactor on a hunch and you pay twice: the part, then the same fault. Bookmarked and text-searchable, this PDF goes wherever your truck quits.
What's Inside This Komatsu FB15M-3, FB18M-3, FB18MG-3, FB20M-3 Manual
| System | Pages | Key Topics |
|---|---|---|
| General and Specifications | 6-13 | Overall Dimensions and Specifications (Mast Data, Fb15M-3, Fb18M-3, Fb18Mg-3, Fb20M-3), Truck Data |
| Removal and Installation | 14-28 | Weight Table, Frame, Power Train, Brake System, Hydraulic System (Pedal, Accelerator Pedal, Brake Pedal, Parking Brake) |
| Disassembly and Assembly | 29-61 | Transfer (Disassembly, Assembly, Precautions When Assembling), Rear Axle (Power Steering Cylinder, Brake System |
| Electronics and Diagnostics | 62-116 | Specification (Traction Control System, Main Specifications of Motors and Service Data) |
| Masts | 117-150 | Installation Instructions, Service |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Clearance between cylinder and piston | 0.02 - 0.105 mm | p. 41 |
| Load roller side to side clearance | 1/16 in. (1.5 mm) | p. 131 |
| Top side thrust roller capscrew torque | 70-80 ft.-lbs. (95-110 Nm) | p. 139 |
| 30D/35D/40D | ||
| Main Lift Cylinder Relief Pressure | 2000 psi | p. 121 |
| 50D/55D/60D | ||
| Main Lift Cylinder Relief Pressure | 2600 psi | p. 121 |
Komatsu FB15M-3, FB18M-3, FB18MG-3, FB20M-3 Common Problems This Manual Covers
Komatsu FB18M-3 loses travel power intermittently, meter panel shows ERR-3084 controller communication error
Check the CAN bus line and connectors between the travel controller, cargo handling controller, and meter panel; a chafed harness or loose pin drops communication intermittently. Discharge the capacitors before unplugging connectors. Trace circuits on the wiring diagram and match ERR-3084 against the error code reference, then work through the procedures.
Manual Section: Troubleshooting for Traction SystemBrake pedal feels spongy and slowly sinks, fluid weeping from master cylinder boot
Remove the master cylinder and disassemble it on the bench. Measure the clearance between cylinder and piston; if it falls outside 0.02 to 0.105 mm (0.0008 to 0.0041 in.), the spec on page 41, replace the cylinder rather than honing it. Bleed the system and confirm the pedal firms up before load testing.
Manual Section: Disassembly and Assembly p. 41Mast rattles under load and carriage shifts side to side during lifting
Shim each pair of load rollers on the uprights and carriage until total side-to-side clearance is no more than 1/16 in. (1.5 mm) at the tightest point through full travel, per page 131. Adjust the eccentric carriage side thrust rollers for unrestricted travel, then torque their capscrews to 70-80 ft.-lbs. (95-110 Nm), page 141.
Manual Section: Mast Troubleshooting p. 131Lift action feels jerky and forks bind partway up the mast travel
Inspect the top side thrust rollers on the carriage for flat spots and binding; replace worn rollers and torque the capscrews to 70-80 ft.-lbs. (95-110 Nm) as shown on page 139. Check that the hose reeving sheaves spin freely and tighten each sheave capscrew to 65 ft.lbs (88 Nm), page 145.
Manual Section: Masts p. 139Frequently Asked Questions
What are the replacement specifications for the brake master cylinder on Komatsu FB15M-3, FB18M-3, FB18MG-3, FB20M-3?
The brake system uses SAE 70R-3 or SAE 70R-1 brake fluid. The master cylinder reservoir capacity is 0.15 liters (0.049 gal US). p. 22
What are the brake pad replacement specifications for Komatsu FB15M-3, FB18M-3, FB18MG-3, FB20M-3 forklifts?
The standard thickness for a brake pad is 6 mm (0.24 in). The repair limit is 1 mm (0.04 in), at which point the pad should be replaced as an assembly. p. 41
What is the hydraulic system relief pressure specification for the Komatsu FB15M-3, FB18M-3, FB18MG-3, FB20M-3?
The relief pressure criteria for the hydraulic system is 170 - 185 kg/cm² (167 - 181 bar or 2480 - 2580 psi). p. 25
What is the torque spec for the steering gear box mounting bolts on Komatsu FB15M-3, FB18M-3, FB18MG-3, FB20M-3?
The mounting bolts for the steering gear box should be tightened to 250 - 300 kgcm (25 - 29 Nm or 18 - 22 ft lb). p. 42
How do I adjust the accelerator pedal output voltage?
With the pedal fully depressed to the stopper bolt, the output voltage should be 4.0 - 4.2 VDC. If it is outside this range, adjust the stopper bolt until the voltage is correct. p. 26
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Immediate download of the complete 150-page searchable Shop Manual. Access it on any device, from a laptop at your desk to a phone in the field.
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Zero restrictions. The PDF is DRM-free. Print whatever sections you need to take out to the shop. Standard letter or A4 paper works.
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