Komatsu BX50 Series Forklift Service Manual – Gas LPG Diesel FG20-FG35A FD20-FD35A Repair Guide

Description

Komatsu BX50 Series Forklift Service Manual – The Complete Workshop Reference

This is the Komatsu BX50 Series Forklift Service Manual, publication SM160, the full workshop guide used to test, adjust, remove, install, disassemble, assemble, inspect, and maintain the entire BX50 forklift truck family. It covers pneumatic and cushion tire models in the 2.0 to 3.5 ton range, running Nissan K21 and K25 gasoline or LPG engines as well as Komatsu 4D94LE and 4D98E diesel engines. If you own or service a BX50, this is the reference that lets you do the job with the manufacturer’s own procedures and specifications in front of you.

File Details

• Manual type: Service / Workshop Manual
• Brand: Komatsu
• Model series: BX50 Series Forklift Trucks
• Publication number: SM160
• Language: English
• Page count: Approximately 576 pages
• File format: PDF
• Copyright: 2016 Komatsu Forklift U.S.A., LLC

Chapters Covered

• 1. General Information – Outline views, specifications, load capacity charts, periodic replacement of consumable parts, basic safety, fire prevention, safety checks, safe travel, stopping and parking, loading operations, inspection and maintenance safety, hoisting and towing, structure and stability, safety labels, tightening torque standards
• 2. Testing and Adjusting – Service data for gas and diesel models, steering system troubleshooting, decompress hydraulic piping, gasoline and diesel engine service, air cleaner, ignition timing, compression pressure, valve clearance, cylinder head bolt torque, Torqflow transmission case, differential case, hydraulic tank, hydraulic drift measurement, inching and brake pedals, accelerator pedals, parking brake lever, wheel brake, bleeding air, lubricant list, lubricant and grease locations
• 3. Removal and Installation – General assembly diagram, weight tables, mast, lift cylinder, wheel brake, parking brake cable, steering axle, steering valve, power steering cylinder, hydraulic pump, engine, power train, drive axle and transfer
• 4. Disassembly and Assembly – Torque converter, Torqflow transmission, differential, wheel brake shoe clearance, brake master cylinder, combination switch, reservoir assembly, solenoid valve, steering valve, steering axle, power steering cylinder, lift cylinder, tilt cylinder, control valve, work equipment, flow divider, hydraulic pump, universal joint
• 5. Maintenance Standard – Torque converter, Torqflow transmission, transmission control valve, differential, wheel brake, brake master cylinder, brake booster, steering axle, power steering cylinder, lift cylinder, tilt cylinder, control valve, forks, universal joint, hydraulic pump
• 6. Structure and Function – Torque converter, gear pump and control valve, brake booster, flow divider, tilt cylinder, hydraulic control valve, ISO controller and KOPS operator presence system, hydraulic steering system, hydraulic circuit diagrams, wheel brake, steering valve, P-port pressure measuring port, fuse load list
• 7. Inspection and Maintenance – Engine, power train, traveling system, steering system, braking system, work equipment, hydraulic system, chassis and safety system, overall test
• 8. E-Series and Quad Masts – E-MS Series limited free lift 2-stage mast, E-MD Series full free lift 2-stage mast, E-MT Series full free lift 3-stage mast, 35D/45D/55D MQ Quad masts
• Electrical Diagrams – Diesel Tier 2 and Interim Tier 4, Gasoline Tier 1 and Tier 2, LPG Tier 1/Tier 2/CARB 2010, LPS Tier 1 and Tier 2, Dual Fuel Tier 1/Tier 2/CARB 2010, and CARB 2010 new KOPS wiring diagrams

What This Komatsu BX50 Series Forklift Service Manual Gives You

Rather than a slim maintenance booklet, this is a full technician’s workshop guide. It opens with specification tables for every BX50 variant, then moves through diagnostic and adjustment procedures before walking you into component-level teardown and rebuild. You get the tightening torques, service limits, clearances, and pressure values you need to make judgement calls on worn parts, plus exploded diagrams for the torque converter, differential, hydraulic pump, control valve, cylinders, and masts so nothing goes back together in the wrong order. The electrical section alone contains more than twenty complete wiring diagrams organised by engine family, emission tier, and serial number range.

The Komatsu BX50 Series Forklift Service Manual is arranged so the truck’s major systems are all covered in one place. The transmission and Torqflow chapter is detailed enough to work on clutch packs and control valves. The brake section runs from master cylinder internals through brake booster operation and shoe clearance adjustment. The hydraulic chapter covers the gear pump, flow divider, control valve spool assembly, cylinders, and the full circuit layout for both standard and power brake models. The mast section at the back covers the E-Series masts and the 35D/45D/55D MQ Quad masts with upright disassembly, chain adjustment, roller shimming, and skewing correction procedures.

Covered Models

• Gasoline / LPG (cushion): FG20ST-16, FG20STLS-16, FG20SHT-16, FG20SHTLS-16, FG25ST-16, FG25STLS-16, FG25SHT-16, FG25SHTLS-16, FG28SHT-16, FG28SHTLS-16, FG30SHT-16, FG30SHTLS-16, FG32SHT-16, FG32SHTLS-16
• Gasoline / LPG (pneumatic): FG20T-16, FG20TUS-16, FG20TLS-16, FG20HT-16, FG20HTUS-16, FG20HTLS-16, FG25T-16, FG25TUS-16, FG25TLS-16, FG25HT-16, FG25HTUS-16, FG25HTLS-16, FG28HT-16, FG28HTUS-16, FG28HTLS-16, FG30HT-16, FG30HTUS-16, FG30HTLS-16, FG32HT-16, FG32HTUS-16, FG32HTLS-16, FG35AHT-16, FG35AHTUS-16, FG35AHTLS-16
• Diesel (pneumatic): FD20T-16, FD20TUS-16, FD25T-16, FD25TUS-16, FD28T-16, FD28TUS-16, FD30T-16, FD30TUS-16, FD32T-16, FD32TUS-16, FD35AT-16, FD35ATUS-16

Engines Covered

• Nissan K21 (gasoline / LPG)
• Nissan K25 (gasoline / LPG)
• Komatsu 4D94LE (diesel)
• Komatsu 4D98E (diesel)

What You Can Do With This Manual

With this Komatsu BX50 Series Forklift Service Manual in hand, you can adjust valve clearance and measure compression on the K21, K25, 4D94LE, or 4D98E engines. You can torque cylinder heads to specification, set the ignition timing on export models, and run the transmission and differential through their proper oil change and strainer service routines. You can pull the torque converter, split the Torqflow transmission, tear down the differential, and rebuild clutch packs and pinion shaft assemblies with the correct shim thickness and backlash values. The brake section covers shoe clearance adjustment, master cylinder disassembly, booster service, and air bleeding. The hydraulic section gives you the relief pressure set points, drift limits for lift and tilt cylinders, and full control valve teardown instructions. The electrical chapter provides complete wiring diagrams matched to your truck’s serial number and emissions tier.

Every procedure is backed by the manufacturer’s own service data, so you aren’t guessing at clearances, torques, or assembly order. That’s the difference between a repair that lasts and a repair that comes back. Getting these values wrong on a forklift matters more than on most equipment, because stability, braking, and load handling are all directly affected by how the truck is set up.

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Instant PDF Delivery

This Komatsu BX50 Series Forklift Service Manual is delivered as a downloadable PDF immediately after checkout. No shipping, no waiting, no physical book to chase down. You can open it on a laptop or tablet in the shop, print the pages you need for the job at hand, and keep a copy on your phone for quick lookups in the yard. Whether you are servicing a single FG25T-16 or running a mixed fleet of gas, LPG, and diesel BX50 trucks, this manual gives you the full manufacturer reference in one file.