Komatsu FG35ST-8 User Manual

Read and observe all warnings on this unit
before operating it.
DO NOT operate this equipment unless all
factory-installed guards and shields are properly
secured in place.
WARNING
SERVICE MANUAL
CX Forklift Truck
Federal Environmental Protection Agency (EPA) Emission-Control Compliant
S/N 130001A~
CX20
ISSUED: APRIL 2008
SM202
Gasoline & LP FG35/45ST-8
FG40/45T(2)-8
FG35/45BCS-8
FG50AT2-8
FG40ZT(2)-8
Diesel FD40/45T(2)-8
FD50AT2-8
FD40ZT(2)-8
Komatsu Forklift USA, Inc.

Komatsu FG35ST-8 Specifications

General

Brand	Komatsu
Model	FG35ST-8
Category	Forklifts
Language	English

Summary

1. Safety

1.1. Safety Management

Management procedures and guidelines for ensuring operational safety.

1.2. Safe Travel

Safe driving practices and precautions for operating lift trucks.

1.3. Loading Operations

Procedures and safety measures for loading and unloading operations.

1.4. Safety in Periodic Maintenance

Safety precautions to be followed during inspection and maintenance work.

1.5. Towing

Guidelines and safety measures for towing disabled lift trucks.

1.6. Structure and Stability of the Lift Truck

Understanding lift truck structure and factors affecting stability to prevent tipping.

1.7. Safety Labels

2. General Information & Specifications

4. Testing, Adjusting and Measuring

4.1. Check Engine Oil (TB45E)

4.2. Adjust Engine Oil Level

4.3. Adjust Ignition Timing (TB45E)

4.4. Adjust Spark Plug Gap (TB45E)

4.5. Adjust Valve Clearance (TB45E)

4.6. Adjust Valve Clearance (S6D102E)

4.7. Adjustment of Engine Drive Belts (TB45E)

4.8. Measure Engine Cylinder Compression (TB45E)

4.9. Measure Hydraulic Drift on Lift & Tilt Cylinders

5. Inspection

5.5. Inspect/Re-torque Cylinder Head Mounting Bolts (TB45E)

5.6. Inspect / Re-torque Cylinder Head Bolts (S6D102E)

5.10. Inspect Diesel Fuel Injection Nozzles

5.11. Inspect LPG Vaporizer for Tar Buildup (TB45E)

5.12. Inspect Blow-by Gas Recirculation System (TB45E)

6. Maintenance Operations

6.4. Change Oil and Filter in Gasoline Engines

6.5. Change Oil and Filter in Diesel Engines

6.6. Change Gear Oil in Differential Case

6.7. Change Transmission Fluid in Torqflow Transmission Case

6.8. Change Oil in Hydraulic Tank

6.9. Replace Fuel Filter - Gasoline Engines

6.10. Replace Fuel Filter - Diesel Engines

6.14. Bleed Air from Brake System

7. Removal, Disassembly, Assembly, Installation

7.1. Mast

Procedures for mast removal and installation.

7.2. Engine

Steps for engine removal, disassembly, assembly, and installation.

7.3. Transmission and Drive Axle

Procedures for transmission and drive axle removal, installation, and related components.

7.4. Torque Converter/Transmission Control Valve - Pneumatic Trucks

Details on torque converter and transmission control valve for pneumatic trucks.

7.5. Torqflow Transmission w/ Torque Converter - Cushion Trucks

Procedures for Torqflow transmission with torque converter for cushion trucks.

7.6. Drive Axle

Information on drive axle breakdown, torque charts, and related components.

7.7. Differential

Details on differential breakdown, specifications, and adjustment.

7.8. Brake Booster and Master Cylinder

Procedures for brake booster and master cylinder disassembly, assembly, and testing.

7.9. Wheel Brake

7.10. Steering Axle

7.11. Power Steering Cylinder

7.12. Power Steering Valve (Orbital)

7.13. Hydraulic Pump - Gasoline Engines

7.14. Hydraulic Pump - Diesel Engines

7.15. Test Hydraulic Pump

7.16. Hydraulic Control Valve

7.17. Tilt Cylinder

8. Troubleshooting

8.1. Engine Troubleshooting Chart

Chart for troubleshooting engine-related issues.

8.2. Torqflow Troubleshooting Chart

Chart for troubleshooting Torqflow transmission issues.

8.3. Torque Converter Troubleshooting Chart - Cushion Trucks

Chart for troubleshooting torque converter issues on cushion trucks.

8.4. Torque Converter Troubleshooting Chart - Pneumatic Trucks

Chart for troubleshooting torque converter issues on pneumatic trucks.

8.5. Torqflow Control Valve Troubleshooting Chart - Cushion

Chart for troubleshooting Torqflow control valve on cushion trucks.

8.6. Torqflow Control Valve Troubleshooting Chart - Pneumatic

Chart for troubleshooting Torqflow control valve on pneumatic trucks.

8.7. Electrical System Troubleshooting Chart

Chart for troubleshooting electrical system issues.

8.8. Steering System Troubleshooting Chart

Chart for troubleshooting steering system issues.

8.9. Power Steering Valve Troubleshooting Chart

Chart for troubleshooting power steering valve issues.

8.10. Brake System Troubleshooting Chart

Chart for troubleshooting brake system issues.

8.11. Hydraulic System Troubleshooting Chart

Chart for troubleshooting hydraulic system issues.

8.12. Hydraulic Pump Troubleshooting Chart

Chart for troubleshooting hydraulic pump issues.

Forklift Trucks Covered in This Publication

Federal EPA Emission Control Statement

2. Warranty

Federal EPA Emission Control Statement for Off-Road Diesel Engines (S6D102E Engines)