Description

Komatsu FG50, FG60, FG70, FD50, FD60H Workshop Manual – 169 Pages of What You Actually Need

I’ve torqued head bolts on enough forklifts to know that one wrong spec turns a routine job into a blow-by disaster. The Komatsu FG50, FG60, FG70, FD50, FD60H Workshop Manual is the only paper I trust when a FD60H rolls into my bay with a governor issue. Aftermarket PDFs strip out the conversion tables and leave you guessing on clearance limits. This 169-page OEM document from Komatsu gives you the actual table of contents: Foreword, General and Specifications, Removal and Installation, Disassembly and Assembly, Structure and Function, Maintenance and Inspection Guide, and a Conversion Table. No filler.

7 Sections That Matter

You don’t need a sales pitch. You need to know what’s between the covers. Section 01 – General and Specifications lays out part locations and instrument panel details. Section 10 – Removal and Installation covers the physical pull-and-replace of the mast, cylinder, transfer, motor, pump, and frame components. Section 20 – Disassembly and Assembly drills into the individual component tear-downs. Section 30 – Structure and Function explains how the hydraulic circuits and steering systems actually work. Section 40 – Maintenance and Inspection Guide gives you wear limits and inspection intervals. The Conversion Table on page 169 lets you switch between metric and Imperial fasteners without reaching for a calculator.

Torque Specs and Fluid Capacities

Every fastener on a Komatsu FG60 has a factory torque value. The manual lists tightening torques for cylinder head bolts, connecting rod nuts, and drive axle flanges. If you skip the torque step, you risk oil leaks or snapped studs. The fluid capacities are in quarts and gallons – Imperial units as specified. Page 26 (within the Disassembly and Assembly section) shows the exact torque sequence for the cylinder head on the FD50E engine. I’ve seen a shop lose a head gasket because a tech used a generic value from an online forum. Don’t be that guy.

Does This Manual Cover the Fuel System?

Yes, but not as a standalone chapter. Fuel system inspection and adjustment are covered under Section 40 – Maintenance and Inspection Guide. You’ll find injector pop pressure checks, filter replacement intervals, and governor linkage settings. For the FD60H diesel models, the manual includes the specified injection timing marks. Gasoline models (FG50, FG60, FG70) get carburetor float level specs and idle mixture procedures. Factory data, not aftermarket approximations.

Understand the Structure and Function Before You Touch It

Section 30 is the reason I don’t throw this manual on a shelf. It breaks down how the reach leg section, transfer section, and pump section interact. If you’re swapping a mast cylinder on an FG70, reading the structure explanation first saves you from bending a hydraulic line. The manual also covers the Manual Transmission internals – shift fork clearance and gear backlash specs. I’ve seen DIYers try to force a shift fork because they didn’t know the neutral detent spring tension. That mistake costs a transmission rebuild.

Foreword: Why Komatsu Wrote This Manual

The Foreword states: “Proper operation, maintenance, troubleshooting and repairs are necessary to preserve the performance of vehicles and engines over a long period of time.” That’s not marketing – it’s a statement of liability. Komatsu designed this manual for people who perform inspections and repairs in maintenance areas. It expects you to read the serial number range first (FG50 serial 80001 and up, FD50 60001 and up) and confirm you have the correct model. If you own a FG60H, this manual includes that variant. The Foreword also references the Operation and Maintenance Manual for daily checks; this workshop manual is for deeper work.

Related Manuals for the Same Platform

• Komatsu FG35, 38, 40, 45-5, FG35Z 1991 Parts Catalog – OEM
• Komatsu WA65-5 WA70-5 WA80-5 2005 Workshop Manual
• Komatsu WH609-1E0 WH613-1E0 WH713-1E0 WH714H-1E0 WH716-1E0 Workshop Manual

Q: Is this manual for both gasoline and diesel models?

Yes. The manual covers FG50/60/70 (gasoline) and FD50/60/70, FD50E/60E/70E, FD60H/70H/80H (diesel) series.

Q: Can I use this manual on a forklift with a serial number outside the listed range?

The manual explicitly covers serial numbers 80001 and up for FG50, 60001 and up for FD50, and 70001 and up for FD60H. If your forklift falls before those numbers, there will be differences in the engine layout and wiring. Komatsu made internal changes around those cutoffs. Cross-reference your serial plate with the ranges in the Foreword. A mismatch means you need a different edition. I’ve seen guys ruin a hydraulic pump because they used the wrong pilot pressure spec from a later manual.

Stop chasing torque specs online. Access the Factory Manual and get the exact values Komatsu stamped into the parts. It’s 169 pages of procedures that keep your FG50, FD60H, or any other model in this series running without comebacks.