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Komatsu FD30H-16, FD35A-16, FG10-21 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: FD30H-16, FD35A-16, FG10-21 Internal Combustion Forklift

Book No: SEN05692-08

Type of Document: Shop Manual

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Komatsu FD30H-16, FD35A-16, FG10-21 Internal Combustion Forklift Shop Manual (SEN05692-08)

These Komatsu FD30H-16, FD35A-16, FG10-21 internal combustion forklifts are the mid-size yard and warehouse trucks you see loading containers, trailers, and racks all day. The shop manual is what the techs grab when a truck won’t start, lifts slow, overheats, or needs a proper tear-down instead of another “quick fix.” People usually want this when they’re done guessing and need the right sequences, test points, and assembly order.

What this manual helps you do

  • Trace hard-start, no-start, or rough-running issues on the internal combustion engine using the proper diagnostic flow, not trial and error.
  • Check and adjust steering, brake, and mast systems so the truck tracks straight, stops correctly, and lifts without chattering or drifting.
  • Follow step‑by‑step disassembly and reassembly of major components like the mast, transmission, drive axle, and hydraulic cylinders with correct order and orientation.
  • Diagnose hydraulic problems—slow lift, weak tilt, or erratic functions—by following the usual pressure and flow test procedures for this forklift class.
  • Handle scheduled overhauls and major repairs using the same style of workshop guidance most dealer shops rely on.

Who this is for

If you’re a field tech, shop mechanic, or fleet maintenance manager working on these exact Komatsu FD30H-16, FD35A-16, FG10-21 models, this shop manual is what you want. Operators or new trainees looking for daily checks and safety basics should be hunting for the Operation & Maintenance manual instead.

FAQ

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

A: Yes, it’s a PDF you can search by keyword and print pages you want to take out to the truck.

Q: Does it go deep enough for full rebuilds?

A: This is a shop manual, so it’s aimed at full workshop-level repairs, not just light service or inspections.

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

A: Check your forklift’s model code against FD30H-16, FD35A-16, or FG10-21 and confirm the SEN05692-08 reference with your plate or dealer if you’re unsure.

Bottom line: if you’re the one actually turning wrenches on these specific Komatsu forklifts, this manual’s worth buying; if you just operate the truck, keep looking for the operator’s book instead.

📘 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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