A torque converter that slips on a ramp or a mast that drifts under load won't get fixed from memory, which is why Komatsu published SM202, a 540-page service manual for its FG and FD -8 forklift trucks. Eighteen gasoline, LPG and diesel variants are covered, from the FG35ST-8 through the FD50AT2-8, in one service manual PDF. Wiring and piping diagrams trace circuits on both TB45E and S6D102E trucks, while the biggest share of the book walks you through tearing down and rebuilding the Torqflow transmission, torque converter, power steering valve and hydraulic pump. Troubleshooting charts sort engine, transmission and brake faults by symptom. Set diesel injection pressure to 19.6 to 20.4 MPa (2,843 to 2,959 psi) and front hub nuts to 294 to 490 Nm. A guessed lug torque can put a wheel on the floor under a full load. Bookmarks and a live text layer take you straight to the one section your repair calls for.
What's Inside This Komatsu CX20 FG35ST-8 to FD50AT2-8 Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 11 | CX20 Series Forklift Trucks, Sensors, Diagnostic Procedures |
| Engine Serial Number Location | 12 | TB45E Series Engine, S6D102E Series Engine |
| Forklift Trucks Covered in This Publication | 13 | Gasoline and LPG Trucks, Diesel Trucks |
| Federal EPA Emission Control Statements | 14-22 | Off-Road LSI Engines, TB45E Engines, Emission Control System Warranty, Off-Road Diesel Engines, S6D102E Engines |
| Safety | 23-58 | Safety Management, Safe Travel, Loading Operations, Safety in Periodic Maintenance, Towing, Structure and Stability of the Lift Truck, Safety Labels, Use of Proper Tools and Equipment |
| General Information & Specifications | 59-80 | Specifications - Mast Data & Features - Indoor Truck, Specifications - Mast Data & Features - Outdoor Trucks, Truck Data - Cushion Tire Lift Trucks |
| Service Data | 81-88 | Service Data Gasoline Engine Trucks, Service Data Diesel Engine Trucks |
| Testing, Adjusting and Measuring | 89-120 | Check Engine Oil, Adjust Engine Oil Level, Adjust Ignition Timing, Adjust Spark Plug Gap, Adjust Valve Clearance |
| Inspection | 121-146 | Inspect Engine Starting Operation, Inspect Engine Running Condition, Inspect Air Cleaner Assembly, Inspect the Filter Element, Inspect/Re-Torque Cylinder Head Mounting Bolts |
| Maintenance Operations | 147-168 | Lubricant List - Gasoline Engine Lift Trucks, Lubricant List - Diesel Engine Lift Trucks, Oil and Greasing Chart, Change Oil and Filter in Gasoline Engines |
| General Removal and Assembly Procedures | 169-180 | Unit Installation Positions, Disassembly Flow Chart, Component Weight Table, Mast Removal and Installation, Engine Removal and Installation |
| Torque Converter and Transmission (Pneumatic Trucks) | 181-228 | Torque Converter Assembly, Transmission Control Valve, Hydraulic Characteristics, Clutch Pack Disassembly, F1/R1 and F2/R1 Transmission Assembly |
| Torque Converter and Transmission (Cushion Trucks) | 229-252 | Transmission Control Valve, Torque Converter Parts, Hydraulic Circuit Diagram, Main Shaft Assembly, Output Shaft Assembly |
| Drive Axle, Differential, and Brake Systems | 253-280 | Drive Axle Parts, Differential Adjustment, Brake Booster, Master Cylinder, Wheel Brake Disassembly |
| Steering Axle and Hydraulic Pump Systems | 281-322 | Steering Axle Breakdown, Power Steering Cylinder, Power Steering Valve, Hydraulic Pump Disassembly, Hydraulic Pump Inspection |
| Hydraulic Control Valve, Tilt Cylinder, and Sideshifter | 323-334 | Hydraulic Pump Testing, Hydraulic Control Valve, Tilt Cylinder Disassembly, Sideshifter, Combination Switch |
| Troubleshooting and Mast Systems | 335-426 | Engine Troubleshooting, Transmission Troubleshooting, Brake System Troubleshooting, 2-Stage Mast Service, 3-Stage Mast Service |
| Conversion Tables and Service Diagrams | 427-540 | Measurement Conversion, Wiring Diagrams, Electrical Assembly Drawings, Piping Diagrams, Sideshifter Service |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Hub (Lug) Nut Tightening Torque - Front Wheels | 217 - 361.4 lb./ft (294 - 490 Nm) | p. 83 |
| Adjusting Bar Bolt Torque | 12.9 - 17.5 lbf/ft (17.5 - 23.7 Nm) | p. 96 |
| Alternator Bolts (2) Torque | 36.9 - 49.4 lbf/ft (50.0 - 67.0 Nm) | p. 96 |
| Hub (lug) nuts - Front Wheels | 217 - 361.6 lbs./ft (294 - 490 Nm) | p. 129 |
| Injection Pressure | 2,843 - 2,959 psi (19.6 - 20.4 MPa) | p. 126 |
| Nozzle Nut Torque | 22.1 lbf./ft (30 Nm) | p. 126 |
| Accumulator Piston to Body Clearance | .0007 - .0020 in (.020 - .051 mm) | p. 188 |
| Regulator Piston to Body Clearance | .0007 - .0024 in (.020 - .061 mm) | p. 188 |
| Hydraulic pump assembly bolt torque | 34 - 38 lbf./ft (46 - 51 Nm) | p. 304 |
| Hydraulic pump assembly nut torque | 34 - 38 lbf./ft (46 - 51 Nm) | p. 305 |
| Engine Oil Capacity (TB45E) | 8.0 qts. (7.6 L) | p. 82 |
| Engine Oil Capacity (S6D102E) | 12.15 qts. (11.5 L) | p. 85 |
Komatsu CX20 FG35ST-8 to FD50AT2-8 Common Problems This Manual Covers
Komatsu FG40T-8 Torqflow transmission reduced horsepower or no power transmission in forward and reverse
Check transmission oil pressure first. If pressure is good and the truck still won't pull, tear down the clutch pack. Measure F1/R1 drive plates against .098 - .106 in. (2.5 - 2.7 mm) and driven plates against .076 - .081 in. (1.93 - 2.07 mm) following page 201. Replace any plate below the range.
Manual Section: Torque Converter and Transmission (Pneumatic Trucks) p. 201Transmission control valve spool or piston wear with low transmission oil pressure
Remove the transmission control valve and measure each piston and spool bore. On pneumatic trucks, check regulator piston to body clearance against .0007 - .0024 in (.020 - .061 mm) and inching spool clearance against .0007 - .0020 in (.020 - .051 mm) following page 188. Cushion trucks use different limits on page 230.
Manual Section: Torque Converter and Transmission (Pneumatic Trucks) p. 188Gasoline or diesel engine showing low oil pressure, overheating, and abnormal water temperature
Check engine oil level before anything else and confirm the fill against capacity: 8.0 qts. (7.6 L) on the TB45E or 12.15 qts. (11.5 L) on the S6D102E diesel. For overheating, verify the radiator cap holds 12.8 psi (0.9 kgf/cm2). Then work the engine troubleshooting chart for the remaining causes.
Manual Section: Troubleshooting p. 336Diesel engine injection nozzles suspected on hard starting and heavy exhaust smoke
Remove the injection nozzles and test injection pressure against 2,843 - 2,959 psi (19.6 - 20.4 MPa) following page 126. Service or replace any nozzle outside that range. On reinstall, torque the nozzle nut to 22.1 lbf./ft (30 Nm) and the nozzle holder to 44.3 lbf./ft (60 Nm).
Manual Section: Inspection p. 126Charge lamp stays lit and the alternator makes abnormal noise while running
Inspect the alternator mounting for loose or shifted bolts before you condemn the unit. Following page 96, torque the adjusting bar bolt to 12.9 - 17.5 lbf/ft (17.5 - 23.7 Nm) and both alternator bolts to 36.9 - 49.4 lbf/ft (50.0 - 67.0 Nm). Then trace the charge circuit on the wiring diagram.
Manual Section: Testing, Adjusting and Measuring p. 96Hydraulic pump low discharge with slow lifting speed and noise from the pump
Verify hydraulic tank fill against capacity first: 14.53 gal (55 L) on pneumatic tire trucks or 14.27 gal (54 L) on cushion tire trucks, per page 160. Test pump discharge. If it is low, disassemble and inspect the pump. On reassembly, torque the rear section bolts and front section nuts to 34 - 38 lbf./ft (46 - 51 Nm) following page 304.
Manual Section: Steering Axle and Hydraulic Pump Systems p. 304Frequently Asked Questions
What are the transmission clutch replacement specifications for the Komatsu CX20 FG35ST-8 to FD50AT2-8?
The transmission clutch components, specifically the drive and driven plates, have specific thickness criteria. For F1/R1 transmissions, the drive plate thickness standard is 0.098 - 0.106 in. (2.5 - 2.7 mm) with a repair limit of 0.091 in. (2.3 mm). The driven plate thickness standard is 0.076 - 0.081 in. (1.93 - 2.07 mm) with a repair limit of 0.067 in. (1.7 mm). p. 201
What's the tightening torque for cylinder head mounting bolts on the TB45E in a Komatsu CX20 FG35ST-8 to FD50AT2-8?
The tightening torque for the cylinder head mounting bolts on the TB45E engine is 47 - 54 ft/lbs. (64 - 74 Nm) (6.5 - 7.5 kgfm). These bolts should be inspected and re-torqued every 12 months or 2,400 hours of operation, whichever occurs first. p. 123
What is the valve clearance specification for the S6D102E diesel engine in the Komatsu CX20 FG35ST-8 to FD50AT2-8?
For the S6D102E diesel engine, the intake valves should be adjusted to 0.010 in. (0.254 mm) and the exhaust valves should be adjusted to 0.020 in. (0.508 mm) while the engine is cold. p. 94
What is the hydraulic tank oil capacity for the pneumatic tire Komatsu CX20 FG35ST-8 to FD50AT2-8 forklift?
The hydraulic tank oil capacity for pneumatic tire trucks is 14.53 gallons (55 liters). p. 160
What is the procedure for bleeding air from the brake system?
To bleed the brake system, attach a vinyl hose to the bleeder tip and submerge the other end in a container 2/3 full of DOT 3 brake fluid. Have an assistant depress and hold the brake pedal while you loosen the bleeder plug 3/4 turn to drain fluid. Tighten the plug before the assistant releases the pedal, and repeat until no air bubbles appear. p. 167
How will I receive this Komatsu FG35ST-8 Service Manual?
You get a 540-page searchable PDF that downloads instantly after checkout. Open it on your laptop, tablet, or phone, and bring it right to the shop floor.
Am I free to print this Komatsu FG35ST-8 Service Manual?
Yes. The PDF is DRM-free, so printing works from any reader and any printer.
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