Komatsu FG50/60/70-7 FD50/60/70/80-8 Forklift Shop Manual – PDF Download

Description

Komatsu FG50/60/70-7 and FD50/60/70/80-8 Forklift Shop Manual

This Komatsu FG50/60/70-7 FD50/60/70/80-8 Forklift Shop Manual is the complete workshop reference for the 5 to 8 tonne DX-Series forklift range. It covers both the gasoline-powered FG models and the diesel-powered FD models in a single document, with section-level detail that runs from engine tuning and torque converter stall checks through to axle overhaul, brake adjustment, mast roller shimming, and hydraulic circuit diagnostics. Whether you are servicing a single truck or running a fleet, this Komatsu forklift shop manual gives you the specifications, procedures, and system explanations needed to carry out the work correctly.

File Details

• Manual type: Shop Manual (workshop / service manual)
• Brand: Komatsu
• Model range: FG50/60/70-7 and FD50/60/70/80-8
• Document number: BED08E1-01
• Language: English
• Page count: 336 pages
• File format: PDF
• Serial number ranges: FG50/60/70-7 — 40001 and up; FD50/60/70/80-8 — 46001 and up

Chapters Covered

This Komatsu FG50/60/70-7 FD50/60/70/80-8 shop manual is organised into nine numbered sections, each of which is broken down into sub-sections that a technician can navigate directly.

• 00. Foreword — how to use the manual, safety symbols and their meaning
• 10. General and Specifications — specification tables for FG50-7/FD50-8, FG60-7/FD60-8, FG70-7/FD70-8, FD80-8, periodic replacement of consumable parts, safety items for maintenance, standard tightening torque, how to use Loctite, conversion tables
• 20. Testing and Adjusting — service data, fuel filter replacement, engine oil change, oil filter replacement, spark plug checking, governor oil change, air cleaner element service, injection timing adjustment, compression measurement, valve clearance adjustment, cylinder head bolt tightening, accelerator pedal adjustment, brake and inching pedal adjustment, wheel brake adjustment, parking brake adjustment, accumulator inspection, TORQFLOW transmission oil check, differential oil check, hydraulic tank service, cylinder hydraulic drift measurement, mast shim adjustment, roller and shim selection, finger bar adjustment, cooling system cleaning, brake air bleeding
• 30. Removal and Installation — unit assembly positions, weight tables, removal and installation flowchart, overall disassembly and assembly drawing, lift cylinder, mast, engine, torque converter and transmission, drive axle, steering axle and power steering, wheel brake, standard tightening torque, Loctite use
• 40. Disassembly and Assembly — torque converter, TORQFLOW transmission, transmission control valve, propeller shaft, differential, final drive, steering axle, master back and master cylinder, brake valve, wheel brake, parking brake, hydraulic pump, control valve, hydraulic cylinders, mast, special tool list
• 50. Maintenance Standard — wear limits, clearances, torque values and service criteria for torque converter, transmission, transmission control valve, propeller shaft, differential, final drive, steering axle, master back and master cylinder, brake valve, wheel brake, parking brake, hydraulic pump (single and tandem type), power steering cylinder, lift cylinder, tilt cylinder, mast, control valve
• 60. Structure and Function — power train, torque converter and transmission control valve, work equipment control valve, hydraulic circuit diagram, brake system, master back and master cylinder, brake valve, assembly drawings for accelerator pedal, brake and inching pedal, parking brake, torque converter, TORQFLOW transmission, differential, front axle, steering axle, brake piping, work equipment hydraulic piping, mast, electrical system, electrical circuit diagrams, speedometer (option), hinged fork, side shift, clamp base
• 70. Troubleshooting — engine, electrical system, TORQFLOW system, steering system, brake system, hydraulic system
• 80. Check Items for Each Equipment — engine, power train, travel system, steering system, braking system, load system, hydraulic system, body safety system, overall test

Across these sections, the manual documents the complete machine. The specification tables alone cover rated capacity, load centre, wheelbase, service weight, axle loading, tyre size and pressure, travel and lifting speeds, drawbar pull, gradeability, engine output and torque, transmission type, and tank capacities for all seven models. The testing and adjusting section provides the day-to-day service values a technician needs — idling speeds, compression pressures, valve clearances, injection timing, pedal heights, pedal strokes, brake shoe clearances, and hydraulic drift limits. The disassembly and assembly section goes into component-level detail with exploded views and tightening torques for the torque converter, transmission clutch packs, differential pinion shaft shimming, final drive, steering axle, wheel brakes, hydraulic pumps, control valves, and all three hydraulic cylinder families. The structure and function section explains how the systems actually work — the hydraulic circuit of the TORQFLOW transmission, the load sensing valve in the work equipment control valve, the operation of the master back and fast fill valve, and the principle of the brake valve on the 8-tonne model. The troubleshooting section rounds it out with symptom-to-cause-to-remedy tables covering the engine, electrical system, TORQFLOW system, steering, brakes, and hydraulics.

What This Komatsu Forklift Shop Manual Covers in Practice

The value of this manual is in the level of detail. On the engine side, it covers the Nissan TB42 gasoline engine used in the FG50/60/70-7 trucks and the Komatsu S6D102E and SA6D102E diesel engines used in the FD50/60/70-8 and FD80-8 trucks. You get idling speed, maximum speed, compression, ignition timing, injection timing, valve clearance, and torque converter stall speed for each engine variant. The fuel system service procedures include fuel filter replacement with air bleeding, water draining from the fuel filter, and governor oil change on the gasoline engine.

The power train coverage is equally thorough. The TORQFLOW transmission section includes oil level checking, oil changing, strainer cleaning, and the hydraulic circuit diagram. The disassembly and assembly section shows the clutch pack assembly procedure for the F1/F2 and R1/R2 input shafts, with plate and disc quantities per clutch pack and the special tool required for compressing the return spring. The differential section explains the pinion shaft adjusting procedure step by step, including the shim thickness calculation formula and the tooth contact check using red lead.

For the braking system, the manual covers the vacuum hydraulic brake system on the 5 to 7 tonne models and the fully hydraulic brake system with accumulator on the 8-tonne model. It includes wheel brake adjustment with the auto adjuster, parking brake clearance and lever effort adjustment, brake air bleeding, and the accumulator gas charging procedure for the FD80. The hydraulic system section covers the single hydraulic pump on the FG models and the tandem pump on the FD models, with relief pressures, delivery rates, and inspection criteria.

The mast section covers shim adjustment for the outer main roller, inner roller, and strip, plus finger bar roller and shim adjustment, chain length adjustment, and roller engagement checks. The lift cylinder and tilt cylinder sections include hydraulic drift measurement procedures and limits, and the disassembly and assembly procedures for cylinder head and piston rod assemblies.

Who This Manual Is For

This Komatsu FG50/60/70-7 FD50/60/70/80-8 forklift shop manual is written for the repair shop environment. It assumes the reader has a working knowledge of forklift systems and provides the specifications, procedures, and service limits needed to carry out preventive maintenance, troubleshooting, removal and installation, disassembly and assembly, and periodic inspection and adjustment. It is not an operator’s manual — it does not cover daily checks or safe operating procedures for the driver beyond the maintenance safety items listed in section 10.

Get the Komatsu FG50/60/70-7 FD50/60/70/80-8 Shop Manual

With this Komatsu forklift shop manual you can diagnose engine faults, adjust injection timing, service the torque converter and TORQFLOW transmission, overhaul the differential and final drive, adjust the wheel brake and parking brake, repair the hydraulic pump and control valve, rebuild the lift, tilt, and power steering cylinders, and set the mast rollers and chains to specification. Having the correct procedures and torque values matters — an incorrectly shimmed differential, a wrongly adjusted brake shoe, or a mast roller set with the wrong clearance can lead to premature failure, poor load handling, or unsafe operation. This manual gives you the numbers Komatsu specified.

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Delivery is instant. After payment you receive a PDF download link — no shipping, no waiting for a physical book. The file works on any device: desktop, laptop, tablet, or smartphone. You can print individual pages or the whole manual for use in the workshop. Keep a copy on your phone for quick reference during a job and a printed copy in the shop for the reference desk.