Checking fan belt tension, topping up engine oil and running the pre-shift inspection on a Komatsu FG35ST-7 are the jobs this 146-page Operation and Maintenance Manual (OM049-1) is built for. It covers a dozen gasoline/LPG (FG) and diesel (FD) variants of the -7 series forklift truck. Safety and operation fill well over half the book: safe travel, loading operations, starting and inching on a slope, fork spread adjustment, and handling an overheated engine. Maintenance pages lay out lubricant lists for both fuel types, an oil and greasing chart, a torque list, and a schedule chart that starts with the initial 200 hours and continues through the 100 and 200 hour services. Fill the TB42 engine with 8.0 L (8.5 quarts) of oil, and set gasoline/LPG belt deflection at 15 to 17 mm. One missing figure can park your truck for a shift. The PDF is bookmarked and text-searchable, and it prints clean, so the schedule chart can live on your bench and take the grease.
What's Inside This Komatsu CX FG35-7 to FD50AT2-7 Operator Manual
| System | Pages | Key Topics |
|---|---|---|
| Operations and Maintenance Manual | 1-2 | Warning, CX Forklift Trucks, Information and Specifications, Requests for Information, Copyright |
| Safety Information | 9 | Signal Words, Safety Precautions, Komatsu Forklift Cannot Predict Every Circumstance |
| Running in New Lift Truck | 10 | Running in a New Lift Truck, First Month of Service, Oil Filter Element |
| Warranty and Service | 11 | Model Line Up, Komatsu Forklift Genuine Parts, Warranty Disclaimer |
| Location of Plates | 12 | Embossed Vehicle Serial Number, Nameplate with Vehicle Serial Number |
| Safety | 13-54 | Safety Management, Safe Travel, Loading Operations, Stopping and Parking, Structure and Stability of the Lift Truck |
| Operation | 55-102 | Mounting/Dismounting, Operator’s Seat Position Adjustment, Placing Lift Truck in Motion, Starting and Inching on Slope, Turning, Temporary Stopping and Parking |
| Maintenance | 103-138 | Outline of Service (Suitable Oil), Lubricant List (Gasoline/LPG Engine Lift Truck, Diesel Engine Lift Truck, Oil and Greasing Chart), Service Data (Torque List) |
| Technical Data | 139-146 | Specifications CX Model Forklift Trucks (General, Dimensions, Performance, Chassis and Wheels, Power Train) |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| V-belt deflection (Gas / LPG) | 0.59 - 0.67 in. (15 - 17 mm) | p. 78 |
| Spark plug gap | 0.028 - 0.031 in. (0.7 - 0.8 mm) | p. 109 |
| Fan belt deflection (Gasoline/LPG) | 0.59 - 0.67 in. (11 - 17 mm) | p. 109 |
| Cooling System Capacity | 3.7 U.S. gal. (14 L) | p. 106 |
| Front Tire Inflation Pressure | 100 PSI (0.69 MPa) | p. 75 |
| Rear Tire Inflation Pressure | 100 PSI (0.69 MPa) | p. 75 |
| Torque: Front Wheel Lug Nuts | 217 - 361 ft/lbs (294 - 490 Nm) | p. 75 |
| FG35S/45S-7, FG35BCS/45BCS-7, FG40/40Z/45-7 | ||
| Engine Oil Capacity (TB42) | 8.5 quarts (8.0 L) | p. 106 |
| FD40/45/50-7, FD40Z-7 | ||
| Engine Oil Capacity (6D102E) | 3.04 U.S. gal. (11.5 L) | p. 107 |
| Hydraulic Tank Capacity | 14.53 U.S. gal. (55 L) | p. 107 |
| FG35S/45S, FG35BCS/45BCS, FG40Z | ||
| Hydraulic Tank Capacity | 11.0 U.S. gal. (41.64 L) | p. 106 |
| FG40/45 | ||
| Hydraulic Tank Capacity | 8.7 gallons (32.9 L) | p. 106 |
Komatsu CX FG35-7 to FD50AT2-7 Common Problems This Manual Covers
Komatsu FG40T-7 LPG engine with clogged radiator fins and loose fan belt overheating on long shifts
Clean the radiator fins with the engine stopped and cooled down. Check fan belt deflection following page 78 and adjust it to 0.59 to 0.67 in. (15 to 17 mm). Refill coolant once the cap is safe to open; the cooling system holds 3.7 U.S. gal. (14 L) per page 106.
Manual Section: Engine Overheating p. 100Forks lifting slowly and hydraulic functions weak after long hours on the same oil and filter
Change the oil in the hydraulic tank and replace the line filter at the 6 month or 1,200 hour interval listed in the maintenance schedule on page 117. Use the oil grade from the lubricant list in the Maintenance section. If lift is still weak on fresh oil, have the relief valve checked against 2,610.7 PSI (18 MPa) on page 110.
Manual Section: Hydraulic System Maintenance p. 133TORQFLOW transmission slipping or slow to pick up drive in forward and reverse
Drain and change the oil in the TORQFLOW transmission case, then pull and clean the strainer and replace the filter. Check the maintenance schedule on page 117 for the change interval (every 6 months or 1,200 hours). On a new truck, do the running-in transmission fluid change listed on page 10 before blaming anything inside the case.
Manual Section: Transmission MaintenanceBrake pedal feels soft and stopping distance grows as the drum lining wears
Check the brake link for looseness or damage, then inspect the brake piping along its full run for leaks, dents, or chafed sections. Measure the clearance between drum and lining and adjust it as the maintenance procedure directs. Tag the truck out of service until it stops straight and firm.
Manual Section: Brake System MaintenanceSteering feels loose or truck needs more room than normal to turn
Check the steering link for looseness or damage and inspect each knuckle for play. Measure the turning radius both left and right on open floor; a difference between sides points back to the link or a knuckle. Correct any looseness you find before the truck goes back into rotation.
Manual Section: Steering System MaintenanceEngine won't crank at shift start with a dead or weak battery
Check the battery charge and recharge it in a ventilated area away from sparks and open flame. If the truck has to move now, start it with booster cables following the procedure in the Electrical section, keeping your face clear of the battery. The engine cannot be started if the forward/reverse lever is not at the N (neutral) position, so check that first (page 66). Wear eye protection any time you work near the cells.
Manual Section: Electrical System Troubleshooting p. 66Frequently Asked Questions
What are the recommended service intervals for the Komatsu CX FG35-FG50, FD40-FD50 -7 forklift truck?
The maintenance schedule is based on time or operation hours, whichever occurs first. Initial service is required after the first month or 200 hours. Subsequent intervals include every 2 weeks/100 hours, every month/200 hours, every 3 months/600 hours, every 6 months/1,200 hours, and every year/2,400 hours (the annual items are on page 118). p. 117
What are the fluid capacities for the Komatsu CX FG35–FG50, FD40–FD50 -7 gasoline/LPG lift truck?
For the FG35S/45S and FG35BCS/45BCS models, the engine oil pan capacity is 8.5 quarts (8.0 L). The TORQFLOW transmission case requires 17 quarts (16.1 L). The hydraulic tank capacity is 11.0 U.S. gallons (41.64 L) for the FG35S/45S, FG35BCS/45BCS, and FG40Z models. p. 106
What should I do if the engine does not start?
If the engine does not start, return the key from the START position to the OFF position (page 80). Then wait at least 20 seconds before trying to start again (2 minutes on LPG engines), as listed on page 87. Do not run the starting motor continuously for more than 5 seconds for gasoline/LPG engines or 10 seconds for diesel engines. p. 80
What are the intake and exhaust valve clearance specs for the diesel engine in the Komatsu CX FG35-FG50, FD40-FD50 -7?
For the diesel engine, the intake valve clearance is 0.0098 in. (0.25 mm) when cool, and the exhaust valve clearance is 0.020 in. (0.51 mm) when cool. p. 111
What is the tightening torque for a 10 mm thread diameter bolt on the Komatsu CX FG35–FG50, FD40–FD50 -7?
For a bolt with a thread diameter of 10 mm and a width across flats of 17 mm, the tightening torque is 48.5 + 5.0 ft/lbs (6.7 + 0.7 kgfm or 65.7 + 6.8 Nm). p. 113
What format is this Komatsu FG35ST-7 manual in?
This is a 146-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Is printing allowed for this Komatsu FG35ST-7 Operator Manual?
Yes. Print the pages you need for the job in your own shop, and bin them when they get greasy.
