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Komatsu FD20H-16, FD20N-16, FD25-16 Internal Combustion Forklift Shop Manual (SEN05692-08)

Format: PDF (Printable Document)

File Language: English

File Pages: 422

File Size: 27.72 MB (Speed Download Link)

Brand: Komatsu

Model: FD20H-16, FD20N-16, FD25-16 Internal Combustion Forklift

Book No: SEN05692-08

Type of Document: Shop Manual

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Komatsu FD20H-16, FD20N-16, FD25-16 Internal Combustion Forklift Shop Manual (SEN05692-08)

These Komatsu FD20H-16, FD20N-16, FD25-16 internal combustion forklifts are your day‑to‑day warehouse and yard machines: loading trucks, feeding production, stacking pallets. The Shop Manual is what the workshop reaches for when a truck is down or due for deeper scheduled work, not for basic daily checks. People usually buy this when they want to cut dealer call-outs, standardize repairs across the fleet, and plan parts and labor instead of firefighting.

What this manual helps you do

  • Trace hydraulic, brake, and mast issues step‑by‑step so you’re not guessing which component to replace.
  • Diagnose engine and transmission problems using the kind of tests most shops can perform with normal tools.
  • Follow teardown and reassembly sequences for major components so jobs are repeatable and don’t stall halfway.
  • Check adjustment points and settings after repairs so each forklift goes back into service safe and consistent.
  • Handle scheduled workshop services on FD20H-16, FD20N-16, and FD25-16 units in a way you can plan into your PM calendar.

Who this is for

This Komatsu FD20H-16, FD20N-16, FD25-16 Internal Combustion Forklift Shop Manual (SEN05692-08) is aimed at shop mechanics, field techs, and fleet managers who actually schedule and oversee repair work. It’s not the right buy if you’re just an operator or you only need daily/weekly checklists—then you’d want the Operation & Maintenance manual instead.

FAQ

Q: Is this a PDF I can search and print?

A: Yes, it’s a digital PDF you can search by keyword and print specific pages for the shop if needed.

Q: Is this deep enough for full overhauls, or just light service?

A: It’s a workshop‑level shop manual, so it’s meant to support diagnostics, major repairs, and component overhauls, not just basic maintenance.

Q: How do I know it matches my exact truck variant?

A: Check your forklift’s model designation and compare it to FD20H-16, FD20N-16, or FD25-16; if the model code matches, this SEN05692-08 manual is the right one.

Bottom line: if you’re planning and performing your own repairs on these specific Komatsu models, this is the manual you want; if you only do operator checks and call the dealer for everything else, you can skip it.

📘 Show Index

Table of Contents:

  • DESCRIPTION OF THE SYMBOLS
  • SECTION INDEX
  • 10. GENERAL AND SPECIFICATIONS
    • SPECIFICATIONS
    • PERIODIC REPLACEMENT OF CONSUMABLE PARTS
    • SAFETY ITEMS FOR MAINTENANCE
    • STANDARD TIGHTENING TORQUE FOR BOLTS
    • STANDARD TIGHTENING TORQUE FOR PIPE JOINTS
  • 20. TESTING AND ADJUSTING
    • SERVICE DATA
    • HOW TO DECOMPRESS THE HYDRAULIC PIPING
    • GASOLINE ENGINE
    • DIESEL ENGINE
    • AIR CLEANER
    • ADJUSTMENT OF IGNITION TIMING
    • ADJUSTMENT OF FUEL INJECTION TIMING
    • MEASUREMENT OF COMPRESSION
    • ADJUSTMENT OF VALVE CLEARANCE
    • TIGHTENING TORQUE OF CYLINDER HEAD MOUNTING BOLTS
    • REPLACEMENT OF CLUTCH DISC
    • TORQFLOW TRANSMISSION CASE
    • DIFFERENTIAL CASE
    • HYDRAULIC TANK
    • MEASUREMENT OF HYDRAULIC DRIFT OF LIFT AND TILT CYLINDERS
    • ADJUSTMENT OF CLUTCH AND BRAKE PEDAL
    • ADJUSTMENT OF INCHING AND BRAKE PEDAL
    • ADJUSTMENT OF ACCELERATOR PEDAL
    • ADJUSTMENT OF PARKING BRAKE LEVER
    • ADJUSTMENT OF CABLES OF THE FORWARD AND BACKWARD CONTROL LEVER AND THE HIGH AND LOW SPEED LEVER
    • WHEEL BRAKE
    • BLEEDING AIR
    • DESIGNATED FUEL AND LUBRICATING OIL
    • LIST OF LUBRICANT AND GREASE
  • 30. REMOVAL AND INSTALLATION
    • OVERALL DISASSEMBLY AND ASSEMBLY
    • WEIGHT TABLE
    • MAST
    • CHAIN (DOUBLE MAST)
    • CHAIN (TRIPLE MAST)
    • LIFT CYLINDER
    • POWER LINE
    • DRIVE AXLE AND TRANSFER
    • ALIGNMENT OF POWER LINE (1)
    • ALIGNMENT OF POWER LINE (2)
    • STEERING AXLE AND POWER STEERING
    • WHEEL BRAKE
  • 40. DISASSEMBLY AND ASSEMBLY
    • CLUTCH
    • CLUTCH MASTER CYLINDER
    • CLUTCH BOOSTER ASSEMBLY
    • CLUTCH TRANSMISSION
    • TORQUE CONVERTER
    • TORQFLOW TRANSMISSION
    • DIFFERENTIAL
    • DIFFERENTIAL ASSEMBLY DRAWING
    • WHEEL BRAKE
    • BRAKE MASTER CYLINDER
    • COMBINATION SWITCH
    • SOLENOID VALVE
    • STEERING VALVE
    • STEERING AXLE
    • POWER STEERING CYLINDER ASSEMBLY
    • LIFT CYLINDER
    • TILT CYLINDER
    • CONTROL VALVE
    • MAST
    • FORK CARRIAGE
    • FLOW DIVIDER
    • RESERVOIR ASSEMBLY
    • HYDRAULIC PUMP
    • UNIVERSAL JOINT
  • 50. MAINTENANCE STANDARD
    • CLUTCH RELIESE CYLINDER
    • CLUTCH
    • CLUTCH TRANSMISSION
    • TORQUE CONVERTER
    • TORQFLOW TRANSMISSION
    • TRANSMISSION CONTROL VALVE
    • DIFERENTIAL
    • WHEEL BRAKE
    • BRAKE MASTER CYLINDER
    • CLUTCH MASTER CYLINDER
    • BRAKE BOOSTER
    • CLUTCH BOOSTER
    • STEERING AXLE
    • POWER STEERING VALVE
    • POWER STEERING CYLINDER
    • LIFT CYLINDER
    • TILT CYLINDER
    • CONTROL VALVE
    • MAST, FORK CARRIAGE AND FORK
    • HYDRAULIC PUMP
    • UNIVERSAL JOINT
  • 60. STRUCTURE AND FUNCTION
    • TORQUE CONVERTER, GEAR PUMP AND CONTROL VALVE
    • BRAKE BOOSTER
    • FLOW DIVIDER
    • CLUTCH BOOSTER
    • TILT CYLINDER
    • WORK EQUIPMENT CONTROL VALVE
    • VEHICLE CONTROLLER
    • AS CONTROLLER (FORKLIFT TRUCK WITH SEAT BELT INTERLOCK)
    • HYDRAULIC STEERING SYSTEM
    • HYDRAULIC CIRCUIT DRAWING
    • P-PORT OIL PRESSURE MEASURING PORT
    • FUSE LOAD LIST
    • FUSE LOAD LIST (FORKLIFT TRUCK WITH SEAT BELT INTERLOCK)
    • ELECTRICAL CIRCUIT DRAWING
  • 80. CRITERIA FOR PERIODICAL INSPECTION AND JUDGMENT
    • ENGINE
    • POWER TRAIN
    • TRAVELING SYSTEM
    • STEERING SYSTEM
    • BRAKING SYSTEM
    • WORK EQUIPMENT
    • HYDRAULIC SYSTEM
    • CHASSIS AND SAFETY SYSTEM
    • OVERALL TEST
  • 90. CONVERSION TABLE
    • MILLIMETERS TO INCHES
    • INCHES TO MILLIMETERS
    • CUBIC METERS TO CUBIC YARDS
    • CUBIC YARDS TO CUBIC METERS
    • LITER TO U.S. GALLON
    • U.S. GALLON TO LITER
    • LITER TO U.K. GALLON
    • U.K. GALLON TO LITER
    • KILOGRAM TO POUND
    • POUND TO KILOGRAM
    • KG/CM2 TO IB/IN2
    • KGM TO FT IB
    • TEMPERATURE
  • APPENDIX

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