An engine oil pressure lamp glows halfway through a shift and the operator has no idea whether to park it or push on; this 96-page Komatsu FD and FG series forklift operator manual PDF (Komatsu OM025) settles questions like that across 34 diesel and gasoline models, FD10 through FG30H. Wiring diagrams close out the book, tracing the starting switch, alternator, fuse box, and lamp circuits so you can follow an electrical fault to its terminal. Daily check routines, a full maintenance table, and a lubrication chart lay out what gets inspected before starting and what gets replaced on schedule, down to brake hoses and lift chains. Draining a 4D95S diesel? Refill with 5.8 liters of engine oil; the 4FE1 takes 4.3. Two in the morning, one truck down, nobody awake to ask: the answer sits in here. Print the pages you work from and let them catch grease; bookmarks keep the on-screen copy in order.
What's Inside This Komatsu FD10-FG30 Series Operator Manual
| System | Pages | Key Topics |
|---|---|---|
| Machine Identification | 3-4 | Unit Xxa, Unit Xxb, Machine Serial Number, Registration Number |
| Breaking in and Before Operating | 6-8 | Engine, Torqflow Transmission, Differential |
| General Locations, Instruments and Controls | 9-24 | Mast, Lift Chain, Lift Cylinder, Starting Switch, Fuel Gauge, Battery Charge Warning Lamp, Engine Oil Pressure Warning Lamp, Water Temperature Gauge |
| Operating Your Machine | 25-30 | Engine Starting, Starting Machine, Speed Change, Forward-Reverse Change, Loading, Unloading |
| Check Before Starting | 31-38 | Water or Oil Leakage, Tire Air Pressure, Battery Electrolyte Level, Fan Belt Tension, Brake Fluid, Lift Chain Tension |
| Periodic Maintenance | 39 | Periodic Lubrication, Maintenance, Inspection Intervals |
| Periodic Replacement of Consumable Parts | 40 | Master Cylinder, Brake Hose, Power Steering Hose |
| Maintenance Table | 41-45 | Body Exterior, Engine Oil, Hydraulic Tank, Lift Chain, Air Cleaner, Fuel Filter |
| Replacement and Check | 46-64 | Battery, Air Cleaner, Engine Oil Filter, Fuel Filter Element, Transmission Oil, Cooling System |
| Service Data | 65-74 | Engine, Valve Clearance, Engine Compression, Idling Speed, Torque Converter Stall Speed, Tire Air Pressure |
| Lubrication Chart | 75-79 | Lift Chain, Torque Converter, Hydraulic Oil Tank, Engine Oil Pan, Differential, Tilt Cylinder Pin |
| Operating in Extreme Temperatures | 80-82 | Lubrication Oil, Diesel Fuel, Antifreeze, Cooling Water, Battery, Fuel System |
| Storage | 83-84 | Hydraulic Piston Rods, Batteries, Antifreeze, Engine, Oil Film |
| Fuel and Lubricants | 85-89 | Engine Oil, Gear Oil, Hydraulic Oil, Brake Fluid, Grease, Diesel Fuel |
| Wiring Diagrams | 90-96 | Starting Switch, Alternator, Fuse Box, Battery, Head Lamp, Turn Signal Lamp |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| FG10/14/15/18 | ||
| Engine Oil Capacity (4P Engine) | 3.5L | p. 50 |
| FD10/14, FD15/18 | ||
| Engine Oil Capacity (4FE1 Engine) | 4.3L | p. 53 |
| FD15H/18H | ||
| Engine Oil Capacity (C240 Engine) | 4.0L | p. 53 |
| FD20/25/30, FD20S/25S/30S | ||
| Engine Oil Capacity (4D95S Engine) | 5.8L | p. 52 |
| FD20H/25H/30H | ||
| Engine Oil Capacity (4D95L Engine) | 7.0L | p. 52 |
| Gasoline models | ||
| Spark Plug Gap | 0.7 to 0.8 mm | p. 50 |
| All Models | ||
| Parking Brake Operating Force | 20 kg | p. 35 |
| Front Tire Air Pressure | 7.0 kg/cm2 | p. 65 |
| Rear Tire Air Pressure | 7.0 kg/cm2 | p. 65 |
| FD18/18H | ||
| Rear Tire Air Pressure (FD18/18H) | 8.0 kg/cm2 | p. 66 |
Komatsu FD10-FG30 Series Common Problems This Manual Covers
Komatsu FG10 gasoline engine cranks but refuses to start or runs rough during daily operation.
Inspect the ignition system and verify the spark plug gap measures exactly 0.7 to 0.8 mm. Check the engine oil level on the dipstick. If changing the oil on the 4P engine, fill the crankcase with 3.5L of fresh oil as outlined on page 50.
Manual Section: Replacement and Check p. 50Parking brake fails to hold the truck on inclines or feels unusually loose when engaged.
Inspect the brake fluid level in the reservoir and look for obvious leaks. Adjust the lever mechanism until the parking brake operating force measures exactly 20 kg as detailed on page 35. Bleed the brake piping air if the pedal feels soft during operation.
Manual Section: Check Before Starting p. 35Forklift bounces excessively over flat concrete floors and steering feels sluggish under a heavy load.
Check the front and rear tire air pressure using a calibrated gauge. Inflate all standard model tires to 7.0 kg/cm2 as specified on page 65. If servicing an FD18 or FD18H model, inflate the rear tires to 8.0 kg/cm2 according to page 66.
Manual Section: Service Data p. 65Temperature gauge climbs into the red zone after only a few hours of heavy lifting.
Inspect the cooling water level and clean any debris blocking the radiator fins. Review page 80 for hot weather operating procedures. Check the fan belt tension. If running an FD20 with the 4D95S engine, confirm the crankcase has 5.8L of oil per page 52.
Manual Section: Handling Machine in Extremely Hot Places p. 80Frequently Asked Questions
What are the replacement specifications for the hydraulic line filter on a Komatsu FD10-FD30/FG10-FG30 forklift?
The hydraulic line filter should be replaced when changing the hydraulic oil. The procedure involves removing the strainer, cleaning it with flushing oil, and blowing it dry with compressed air before reinstallation. p. 60
What are the replacement specifications for the hydraulic tank strainer on Komatsu FD10 to FG30H series forklifts?
The hydraulic tank strainer must be removed and cleaned with flushing oil whenever the hydraulic oil is changed. After cleaning, it should be blown dry with compressed air from the inside out before being reinstalled. p. 60
What is the specified valve clearance for the Komatsu 4P forklift engine?
For the 4P engine, the intake valve clearance is 0.20 ± 0.01 mm and the exhaust valve clearance is 0.36 ± 0.01 mm. p. 65
What is the engine oil capacity for the H20 engine in a Komatsu forklift truck?
The engine oil capacity for the H20 engine is 4.0 liters (1.1 gallons US). p. 50
What is the tightening torque for the front hub nuts on Komatsu FD and FG series forklifts?
The tightening torque for the front hub nuts on the XXA models is 20 to 25 kgm. p. 66
What exactly do I receive with this Komatsu FD10 Operator Manual?
A 96-page Operator Manual in scanned PDF format, available the moment you complete checkout. View on computer, tablet, or phone, with no shipping wait.
Can I print specific sections of this Komatsu FD10 Operator Manual?
Yes. No DRM, nothing blocks printing, so run off the pages you need on whatever printer you have.
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