Komatsu operator manual OM010 puts the factory's own answers on record for 36 FG and FD forklift truck variants, gasoline FG20-8 through diesel FD45S-4, in 70 pages running break-in to storage. Service data tables cover fan belt deflection, spark plug gap, valve clearance, and tire air pressure, while the lubrication chart maps every grease point from lift chain to differential. Maintenance and replacement checks fill roughly the back half of the book, with intervals for engine oil, hydraulic tank, transmission, and air cleaner gathered in one table you can post by the workbench. Fill the hydraulic tank on a 20, 25, or 30 chassis to 38 liters; a 4D95L engine takes 7.0 liters of oil at a change. Hours disappear while a parked truck waits on an answer. The scan is bookmarked chapter by chapter, and the consumable parts section means your next order carries the right part number the first time.
What's Inside This Komatsu FG20-8 to FD40S-4 Series Operator Manual
| System | Pages | Key Topics |
|---|---|---|
| Breaking in Your New Machine, Before Operating and Consumable Parts | 6-9 | Master Cylinder, Brake Hose, Brake Reservoir Tank |
| General Locations | 10-11 | Mast, Lift Chain, Lift Cylinder, Forks, Overhead Guard, Counterweight |
| Instruments and Controls | 12-19 | Starting Switch, Fuel Gauge |
| Operating Your Machine | 20-25 | Starting Machine, Stopping and Parking, Loading and Unloading |
| Check Before Starting | 26-33 | Check Before Starting Engine, Check After Starting Engine, Brake System |
| Periodic Maintenance | 34 | Periodic Lubrication, Maintenance, Service Meter |
| Maintenance Table | 35-37 | Engine Oil, Hydraulic Tank, Transmission, Differential Gear Case, Air Cleaner, Radiator |
| Replacement and Check | 38-51 | Battery Maintenance, Engine Maintenance, Transmission Maintenance |
| Service Data | 52-54 | Fan Belt Deflection, Spark Plug Gap, Valve Clearance, Engine Compression, Tire Air Pressure, Relief Valve Pressure |
| Lubrication Chart | 55-56 | Lift Chain, Brake Fluid Tank, Clutch Shaft, Governor, Differential, Hydraulic Oil Tank |
| Handling Machine in Extremely Hot Places | 57 | Cooling System |
| Cold Weather Operation | 58-59 | Lubrication Oil, Diesel Fuel, Antifreeze, Cooling Water, Battery, Fuel System |
| Storage | 60-61 | Hydraulic Piston Rods, Battery, Cooling Water, Engine, Valves, Rocker Arms |
| Fuel and Lubricants | 62 | Engine Oil, Transmission Oil, Gear Oil |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Torqflow clutch pressure | 9.6 to 14 kg/cm² | p. 48 |
| Hydraulic oil capacity (FG(D)20/25/30, FG(D)20H/25H/30H) | 38 L | p. 45 |
| Hydraulic oil capacity (FG(D)20S/25S/30S) | 28 L | p. 45 |
| Relief Valve Pressure | 185 kg/cm2 | p. 54 |
| Brake Pedal Standard Play | 2 to 6 mm | p. 54 |
| FD20H/25H/30H | ||
| 4D95L Engine Oil Capacity | 7.0L | p. 43 |
| FD35Z/40Z, FD35/40/45, FD33S/35S/40S/45S | ||
| 6D95L Engine Oil Capacity | 11.0L | p. 43 |
| FG20/25/30 | ||
| Torque Converter Stall Speed | 1750 +/- 150 rpm | p. 52 |
Komatsu FG20-8 to FD40S-4 Series Common Problems This Manual Covers
Komatsu FG25-8 hydraulic oil overheating and slow lift after long shifts in warm weather
Check the hydraulic tank oil level with the dipstick before starting, following the procedure on page 26. Fill to the correct mark; FG25 tank capacity is 38 L per the chart on page 45. Clean dust from the radiator fins and check fan belt tension as covered on page 57 before hot weather work.
Manual Section: Check Before Starting p. 26Engine cranks slowly and won't start in cold weather after overnight parking
Check battery charge and terminal condition first; cold cranking drops fast on a weak battery. Follow the cold weather procedures on page 58 for fuel and antifreeze. Change to winter-grade engine oil per the chart on page 62; the 4D95L engine in FD20H, FD25H, and FD30H trucks holds 7.0 L, shown on page 43.
Manual Section: Cold Weather Operation p. 58Brake pedal feels soft and warning buzzer sounds when pedal is pressed
Check brake pedal play before operating; standard play is 2 to 6 mm, listed in the service data on page 54. Run the brake system checks in the check-before-starting section starting on page 26. If the buzzer keeps sounding or the pedal stays soft, park the truck and have the brake circuit bled of air.
Manual Section: Check Before Starting p. 26Mast jerks and squeals during lifting and forks drop unevenly under load
Grease the mast channels and oil the lift chain per the lubrication chart on page 55. Inspect the lift chain for stretch and damage; it is a periodic replacement item listed on page 8. If lifting stays weak with a full tank, have your dealer check relief valve pressure against the 185 kg/cm2 spec on page 54.
Manual Section: Lubrication Chart p. 55Transmission engages late or truck loses drive when shifting between forward and reverse
Check transmission oil level with the engine idling and warm, following the replacement and check procedures starting on page 38. Drain and refill at the interval in the maintenance table on page 35 and clean the strainer. If engagement stays delayed, have your dealer test TORQFLOW clutch pressure against the 9.6 to 14 kg/cm2 spec on page 48.
Manual Section: Replacement and Check p. 38Frequently Asked Questions
What is the engine oil capacity for the H20 engine in Komatsu FG20-8 and FD20-8 series forklifts?
The engine oil capacity for the H20 engine is 4.2 liters. This value is specified in the engine oil change section of the manual. p. 41
What is the standard valve clearance for the H20 engine in Komatsu FG20-8 series forklifts?
The standard valve clearance for the H20 engine is 0.38 mm for both intake and exhaust valves when the engine is warm. p. 52
What is the specified fan belt deflection for the H20 engine?
The fan belt deflection for the H20 engine should be between 10 to 15 mm when measured with 10 kg of pressure. p. 52
What is the hydraulic oil capacity for the Komatsu FG20-8, FG25-8 and FG30-8 forklift models?
The hydraulic oil capacity for the FG20/25/30 and FG20H/25H/30H models is 38 liters. p. 49
What is the specified torque converter stall speed for the Komatsu H30 engine?
The torque converter stall speed for the H30 engine is 1850 ± 150 rpm. p. 52
Do I get instant access to this Komatsu FG20-8 Operator Manual?
All 70 pages arrive as one scanned PDF at checkout. Read it at the desk, then take the phone out to the machine.
Am I free to print this Komatsu FG20-8 Operator Manual?
Yes, printing is unrestricted: a single page, a chapter, or the lot, on letter or A4.
Reviews
There are no reviews yet.