Komatsu FG20-8, FG25-8, FG30-8, FD20-8, FD25-8, FD30-8, FD20-10, FD25-10, FD30-10, FG20S-4, FG25S-4, FG30S-4, FD20S Shop Manual

Description

• Model List:
  • FG20-8 Forklift Truck
  • FG25-8 Forklift Truck
  • FG30-8 Forklift Truck
  • FD20-8 Forklift Truck
  • FD25-8 Forklift Truck
  • FD30-8 Forklift Truck
  • FD20-10 Forklift Truck
  • FD25-10 Forklift Truck
  • FD30-10 Forklift Truck
  • FG20S-4 Forklift Truck
  • FG25S-4 Forklift Truck
  • FG30S-4 Forklift Truck
  • FD20S-4 Forklift Truck
  • FD25S-4 Forklift Truck
  • FD30S-4 Forklift Truck
  • FD20S-5 Forklift Truck
  • FD25S-5 Forklift Truck
  • FD30S-5 Forklift Truck
  • FG20H-8 Forklift Truck
  • FG25H-8 Forklift Truck
  • FG30H-8 Forklift Truck

• 1. ASFORE
• 1.1. FOREWORD
• 1.2. DISASSEMBLY AND ASSEMBLY DIAGRAM
• 1.3. DESCRIPTION OF THE SYMBOLS
• 2. ASGEN
• 2.1. GENERAL AND SPECIFICATIONS
• 2.1.1. General locations
• 2.1.2. Machine serial number
• 2.1.3. Engine serial number
• 2.1.4. Weight of main components
• 2.1.5. Specifications
• 2.1.6. Overall dimensions
• 2.1.7. Standard tightening torque
• 2.1.8. Periodic replacement
• 2.1.9. Precautions for maintenance
• 3. AGDIS
• 3.1. DISASSEMBLY AND ASSEMBLY
• 3.1.1. SERIES
• 3.1.1.1. General disassembly
• 3.1.1.2. General assembly
• 3.1.1.3. Tighteneing torque
• 3.1.2. SERIES
• 3.1.2.1. General disassembly
• 3.1.2.2. General assembly
• 3.1.2.3. Tightenening torque
• 3.2. MAINTENANCE STANDARD
• 3.3. Turbocharger
• 3.4. Cylinder head
• 3.5. Valve and valve guide
• 3.6. Rocker arm shaft, push rod and tappet
• 3.7. Cylinder block
• 3.8. Crankshaft
• 3.9. Camshaft
• 3.10. Timing gear
• 3.11. Piston, piston ring and piston pin
• 3.12. Connecting rod
• 3.13. Flywheel and flywheel housing
• 3.14. Oil pump
• 3.15. Regulator valve
• 3.16. Water pump and thermostst
• 4. AGSERV
• 4.1. SERVICE INFORMATION
• 4.2. Procedure for selection and installation of pistons on 4D95S (L) and 6D95L engine
• 5. AGSTRUC
• 5.1. STRUCTURE AND FUNCTION
• 5.2. GENERAL STRUCTURE
• 5.3. INTAKE AND EXHAUST SYSTEM
• 5.3.1. Intake and exhaust system
• 5.3.2. Main circulation system
• 5.3.3. Timing gear
• 5.3.4. Valve system
• 5.3.5. Flywheel and flywheel housing
• 5.4. LUBRICATION SYSTEM
• 5.4.1. Lubrication system chart
• 5.4.2. Oil pump
• 5.4.3. Oil filter
• 5.5. FUEL SYSTEM
• 5.5.1. Fuel system chart
• 5.5.2. Fuel injection pump
• 5.5.3. Fuel injection nozzle
• 5.5.4. Fuel filter
• 5.6. COOLING SYSTEM
• 5.6.1. Cooling system chart
• 5.6.2. Water pump
• 5.6.3. Oil cooler (option)
• 5.6.4. Thermostat and fan drive
• 5.7. ELECTRICAL SYSTEM
• 5.7.1. Starting and charging circuit
• 5.7.2. Alternator
• 5.7.3. Starting motor
• 5.7.4. Electrical intake air heater
• 5.7.5. Fuel solenoid
• 6. AGTEST
• 6.1. TESTING AND ADJUSTING
• 6.2. INTAKE AND EXHAUST SYSTEM
• 6.2.1. Adjusting valve clearance
• 6.2.2. Measuring exhaust gas color
• 6.3. ENGINE BODY
• 6.3.1. Measuring compression pressure
• 6.3.2. Measuring blowby pressure
• 6.4. FUEL SYSTEM
• 6.4.1. Checking and adjusting fuel injection timing
• 6.4.2. Adjustment of fuel injection pressure
• 6.4.3. Adjustment of fuel injection volume
• 6.4.4. Adjustment of governor
• 6.5. LUBRICATION SYSTEM
• 6.5.1. Measuring oil pressure
• 6.5.2. Measuring oil temperature
• 6.6. COOLING SYSTEM
• 6.6.1. Measuring water temperature
• 6.6.2. Testing and adjusting fan belt tension
• 6.7. PERFORMANCE TEST
• 6.7.1. Runin standard
• 6.7.2. Performance test criteria
• 6.7.3. Testing and adjusting tool list
• 6.7.4. Testing and adjusting data
• 6.8. TROUBLESHOOTING
• 6.8.1. Method of reading troubleshooting table
• 6.8.2. Troubleshooting table
• 7. ASAPPEN
• 7.1. APPENDIX
• 7.1.1. Change in structure of radiator mount
• 7.1.2. Change of TORQFLOW transmission control valve
• 7.1.3. Improved tilt valve
• 7.1.4. Quick on start system
• 7.1.5. Auto stop system
• 7.1.6. Local modification for full transisterized ignition system
• 8. ASDIS
• 8.1. DISASSEMBLY AND ASSEMBLY OF COMPONENTS
• 8.1.1. POWER TRAIN
• 8.1.1.1. General
• 8.1.1.2. Clutch
• 8.1.1.3. Transmission
• 8.1.1.4. Torque converter
• 8.1.1.5. TORQFLOW transmission
• 8.1.1.6. Front axle
• 8.1.1.7. Differential
• 8.1.1.8. Front wheel, Rear wheel
• 8.1.2. STEERING SYSTEM
• 8.1.2.1. General
• 8.1.2.2. Power steering pump
• 8.1.2.3. Steering gear box
• 8.1.2.4. Power steering cylinder
• 8.1.2.5. Rear axle
• 8.1.3. BRAKE SYSTEM
• 8.1.3.1. General
• 8.1.3.2. Master cylinder
• 8.1.3.3. Wheel brake
• 8.1.4. HYDRAULIC SYSTEM
• 8.1.5. MAST AND RELATED PARTS
• 8.2. REMOVAL AND INSTALLATION OF UNIT
• 8.2.1. STRUCTURE
• 8.2.2. FLOW CHART
• 8.2.3. REMOVAL AND INSTALLATION OF UNIT
• 8.2.3.1. Mast
• 8.2.3.2. Lift cylinder
• 8.2.3.3. Torque converter (or clutch) Transmission Front axle
• 8.2.3.4. Engine
• 8.2.3.5. Muffler
• 8.2.3.6. Wheel brake
• 8.2.3.7. Rear axle
• 8.2.3.8. Power steering cylinder
• 8.2.3.9. Tightening torque
• 9. ASTEST
• 9.1. TESTING AND ADJUSTING
• 9.1.1. Engine
• 9.1.2. Drive system
• 9.1.3. Travel system
• 9.1.4. Steering system
• 9.1.5. Brake system
• 9.1.6. Work system
• 9.1.7. Hydraulic system
• 10. ASTROUB
• 10.1. TROUBLESHOOTING
• 10.1.1. Engine
• 10.1.2. Electrical system
• 10.1.3. Clutch and clutch transmission
• 10.1.4. TORQFLOW system
• 10.1.5. Steering system
• 10.1.6. Brake system
• 10.1.7. Hydraulic system
• 11. AWELEC
• 11.1. ENGINE ELECTRICAL SYSTEM
• 11.2. ENGINE LUBRICATION SYSTEM
• 11.3. OIL PUMP
• 12. AWMECH
• 12.1. ENGINE MECHANICAL
• 12.1.1. DISASSEMBLY
• 12.1.2. INSPECTION AND CORRECTION
• 12.1.3. ASSEMBLY
• 12.1.4. TIGHTENING TORQUE