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Komatsu FG15-21, FG15H-21, FG18-21 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: FG15-21, FG15H-21, FG18-21 Internal Combustion Forklift

Book No: SEN05692-08

Type of Document: Shop Manual

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Komatsu FG15-21, FG15H-21, FG18-21 Internal Combustion Forklift Shop Manual (SEN05692-08)

These Komatsu FG15-21, FG15H-21, FG18-21 internal combustion forklifts are the small yard and warehouse trucks you see loading trailers, feeding production lines, and shuttling pallets all day. The Shop Manual (SEN05692-08) is what the dealer tech or serious in‑house mechanic reaches for when a truck is down and a basic operator or maintenance book just won’t cut it. People usually want this when they’re tearing into the engine, transmission, mast, or hydraulics and need the right sequence and checks so they don’t create more downtime.

What this manual helps you do

  • Trace fuel, ignition, and engine-control issues step by step to confirm whether you’ve got a sensor, wiring, or mechanical problem.
  • Check hydraulic and mast functions using the standard test points and procedures these manuals usually spell out for workshop diagnosis.
  • Follow teardown and reassembly sequences for engine, transmission, steer axle, and mast so parts come off and go back on in the right order.
  • Diagnose brake, steering, and drive complaints using the kind of flowcharts and symptom tables most Komatsu shop manuals provide.
  • Verify adjustments after repairs so the truck runs safely and you’re not sending it back out only to have it bounce right back to the shop.

Who this is for

This is aimed at field techs, shop mechanics, and fleet maintenance leads who are actually doing repair work on Komatsu FG15-21, FG15H-21, and FG18-21 forklifts. If you just operate the truck or only need daily checks and safety info, you’d be better off with the operator or operation & maintenance manual instead.

FAQ

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

A: Yes, it’s a digital PDF you can download, search by keyword, and print specific pages for use at the jobsite or in the shop.

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

A: The Komatsu FG15-21, FG15H-21, FG18-21 Internal Combustion Forklift Shop Manual is meant for workshop-level repairs, from diagnostics through major component disassembly and reassembly.

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

A: Check your model code against FG15-21, FG15H-21, or FG18-21 and make sure your truck aligns with the SEN05692-08 reference; if your ID plate shows a different series, you’ll want the matching shop manual for that series instead.

Bottom line: if you’re repairing or rebuilding these specific Komatsu forklift models, this is the right manual; if you only need basic operation or routine service intervals, keep looking for an operator or O&M book.

📘 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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