Komatsu BX-12 Series Forklift Chassis & Masts Parts Manual – FG20/25/30-12 & FD20/25/30-12 PDF

Description

Komatsu BX-12 Series Forklift Chassis & Masts Parts Manual

This is the Komatsu BX-12 Series Forklift Trucks Parts Manual covering Chassis & Masts, published under document number PM086-MC-1. It is the illustrated parts book used to identify and order service parts for the FG20-12, FG25-12, FG30-12, FD20-12, FD25-12 and FD30-12 forklift trucks, including the H and S variants, in gasoline, LP and diesel configurations.

Every figure in this Komatsu BX-12 forklift parts manual pairs an exploded illustration with a matching parts list, so you can locate a component visually and then read off the exact part number, description, quantity and serial-number range that applies to your truck. The manual is split by system and by serial range, which matters because Komatsu changed a number of assemblies between the earlier S/N 10001A- trucks and the later S/N 550001A(E)- machines.

File Details

• Manual type: Illustrated Parts Manual (Parts Book)
• Brand: Komatsu
• Series: BX-12 Series Forklift Trucks
• Document number: PM086-MC-1
• Coverage: Chassis & Masts
• Language: English
• Page count: 775 pages
• File format: PDF
• Serial number ranges: BX Series S/N 10001A~; BX Gasoline & LP S/N 500001A~; BX Diesel S/N 550001A(E)~

Chapters Covered

The Komatsu BX-12 Series forklift chassis and masts parts book is organised into the following chapters, with each chapter further divided by figure number, model and serial range:

• Chapter 00 – Recommended Stock List (RSL) for S/N 10001A-549999A and S/N 550001A(E)-
• Chapter 01 – Engine and Related Parts: engine unit and power train, engine mounting parts and attachments, air intake connections (FG and FD)
• Chapter 03 – Exhaust System: muffler and exhaust connections for FG pneumatic, FG cushion and FD models
• Chapter 04 – Cooling System: radiator (clutch spec, torqflow spec, FD), radiator piping, torque converter cooler piping, reservoir tank, radiator cover
• Chapter 05 – Fuel System Gas/Diesel: gasoline (FG) and diesel (FD) fuel systems
• Chapter 06 – Fuel System LPG & Dual-Fuel: LP C.A.R.B. system, LPG carburetor, dual-fuel conversion kit major components and details
• Chapter 10 – Clutch: dry clutch, pneumatic, early and late serial ranges
• Chapter 13 – Torque Converter (cross-referenced to Chapter 15)
• Chapter 14 – Direct Drive Transmission: case assembly, drive gears, differential and hypoid gears, clutch release cylinder
• Chapter 15 – Transmission Torqflow Type: torque converter and pump assembly, clutch drum assembly, drive gears, filters, control valve mounting, differential assembly mounting, control valve assembly, carrier assembly
• Chapter 21 – Drive Axle: pneumatic and cushion tire versions
• Chapter 24 – Steer Axle: pneumatic and cushion tire versions
• Chapter 27 – Front Wheel/Tire, Drive: drive wheels by model and tire type, lug (hub) nuts, front fenders
• Chapter 28 – Rear (Steering) Wheels: cushion and pneumatic rear wheels
• Chapter 30 – Brakes, Service/Parking: brake system by tire type, parking brake lever, brake piping
• Chapter 33 – Steering, Handwheel Assembly: early and late serial ranges
• Chapter 34 – Steering Column Assembly: column assembly, steering valve (early and OSPB)
• Chapter 35 – Transmission Shift Levers: clutch spec and torqflow spec
• Chapter 36 – Pedals, Brake, Clutch & Inching & Master Cylinder: brake and clutch pedals, brake and inching pedals, brake master cylinder variants
• Chapter 37 – Pedal, Accelerator: FG models and FD models
• Chapter 41 – Frame and Chassis: pneumatic and cushion frames, counterweight, counterweight cap, fuel cap
• Chapter 50 – Operator’s Seat, Dashboard, Step and Side Covers, Floor Mat, Floor Plate, Bonnet, Sub-Bonnet, Insulators, Overhead Guard, Lamp Guard, Monitor Panel
• Chapter 55 – Dashboard Wiring, Head Lamps, Rear Combination Lights, Battery, Back-Up Buzzer, Combination Switch, Engine Wiring, Fuel Sending Unit
• Chapter 60 – Hydraulic Pump and Mounting Parts, and hydraulic pump inner parts
• Chapter 61 – Hydraulic Control Valve: 2-spool, 3-spool and 4-spool mounting parts, inner parts and control valve levers
• Chapter 64 – Tilt Cylinder: 6″/12″, 6″/10″, 6″/5″, 3″/3″, 10″/5″ bottler’s tilt, and late serial range
• Chapter 65 – Power Steering Cylinder
• Chapter 66 – Hydraulic Systems: hydraulic tank cover, pump-to-control valve piping, tilt cylinder lines, power steering lines, return line, lift cylinder line, P/S return line, control valve suction tube, side-shifter hoses
• Chapter 72 – Masts: E50-MS 2-stage, E50-MT 3-stage, E60-MS 2-stage, E60-MT 3-stage, 50D-MS 2-stage limited free lift, 50D-MT 3-stage, 50D-MD dual mast, plus safety decals, main lift cylinders, free lift cylinders, outer/intermediate/inner uprights, carriages, hoist chains, load backrests, mounting parts, hydraulic groups, lowering control valves and internal hose reeving
• Chapter 83 – Options: back-up alarm and strobe light
• Chapter 93 – Forks: Class II and Class III forks, fork pin kits
• Chapter 96 – Name Plates and Decals for FG pneumatic, FG cushion and FD models
• Chapter 97 – Service Kits: service kit list and kit parts breakdown
• Chapter 99 – Appendix: Numerical Parts Index

Read as a whole, this Komatsu BX-12 forklift parts book gives a technician or parts counter the complete chassis-side and mast-side parts breakdown for the truck. Engine, transmission, axle, brake, steering, hydraulic and mast assemblies are all broken down to component level, with the recommended stock list in Chapter 00 telling a service operation which fast-moving parts to keep on the shelf for a fleet of roughly twenty trucks. Because the manual is split by serial range throughout, you can order the correct variant of a superseded assembly rather than a part that fits only the other build.

How the Parts Listings Are Organised

Each figure in this BX-12 parts manual uses a five-column layout: an item number that keys back to the illustration, the part number, the description, the quantity required, and the serial number range the part applies to. Sub-components of an assembly are indented with a leading dot beneath the parent item, so you can see at a glance whether a seal, bearing or bolt is available separately or only as part of a larger assembly. Where a part is not sold separately, the listing marks it accordingly.

The manual also explains Komatsu’s standard ordering information requirements: the complete part number including any prefix or suffix letters, the part name, the quantity, the complete machine model number, the machine serial number, the engine serial number, and where relevant the serial numbers of the transmission, torque converter and axles. That is why the serial ranges printed throughout this manual matter so much when you are placing an order.

Models Covered in Detail

The publication covers the following Komatsu BX-12 forklift trucks:

• FG20-12 – 4,000 lb. capacity, pneumatic tire, H20-11 engine
• FG25-12 – 5,000 lb. capacity, pneumatic tire, H25 engine
• FG20H-12 – 4,000 lb. capacity, pneumatic tire, H20-11 engine
• FG25H-12 – 5,000 lb. capacity, pneumatic tire, H25 engine
• FG30H-12 – 6,000 lb. capacity, pneumatic tire, H20-11 engine
• FG20S-12 – 4,000 lb. capacity, cushion tire, H25 engine
• FG25S-12 – 5,000 lb. capacity, cushion tire, H25 engine
• FG20SH-12 – 4,000 lb. capacity, cushion tire, H25 engine
• FG25SH-12 – 5,000 lb. capacity, cushion tire, H25 engine
• FG30SH-12 – 6,000 lb. capacity, cushion tire, H25 engine
• FD20-12 – 4,000 lb. capacity, pneumatic tire, 4D94E diesel engine
• FD25-12 – 5,000 lb. capacity, pneumatic tire, 4D94E diesel engine
• FD30-12 – 6,000 lb. capacity, pneumatic tire, 4D94E diesel engine

What This Komatsu BX-12 Parts Manual Lets You Do

With this manual on hand you can identify and order the correct service part for a BX-12 forklift without guessing. Need to rebuild a Torqflow transmission? Chapter 15 breaks out the torque converter, clutch drum, drive gears, filters, control valve and carrier assembly by serial range. Replacing steer axle king pins or knuckles? Chapter 24 gives you the part numbers for both pneumatic and cushion versions. Chasing a hydraulic fault on a 3-spool or 4-spool control valve? Chapter 61 lists the inner parts down to individual springs, spools, wipers and O-rings. Rebuilding a mast lift cylinder? Chapter 72 covers every mast family Komatsu fitted to this series, from the E50-MS two-stage through the 50D-MD dual mast, including seal kits, check valve kits, chain anchors, load rollers and internal hose reeving.

Getting the right part number the first time is the difference between a truck back on the floor and a truck sitting in the shop waiting on a return. Because Komatsu revised several assemblies between the earlier and later serial ranges, ordering from a generic listing or an aftermarket cross-reference can send you the wrong seal, the wrong gear or the wrong master cylinder. This Komatsu BX-12 Series forklift chassis and masts parts book removes that risk by tying every part number to the exact figure and serial range it belongs to.

You get instant access to the PDF after checkout – no shipping, no waiting for a disc or a paper book to arrive. The file opens on any phone, tablet, laptop or desktop, and every page can be printed for the workshop if you prefer a paper copy on the bench. Keep the numerical parts index in Chapter 99 handy and you can search a part number straight to the figure it appears on.

Why Buy This Parts Manual

This is a 775-page illustrated parts book covering the complete chassis and mast side of the Komatsu BX-12 forklift series, including the recommended stock list, every major assembly broken down to serviceable components, the full numerical parts index, and the service kit list with kit parts breakdown. For anyone maintaining FG20/25/30-12 or FD20/25/30-12 forklifts, whether a single truck or a working fleet, it is the reference that makes ordering parts accurate instead of approximate.

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