Komatsu BX20 Series Forklift Parts Manual DIC 2005 – FG20/25/30-14 & FD20/25/30-14 PDF

Description

Komatsu BX20 Series Forklift Parts Manual (DIC 2005) – FG20/25/30-14 & FD20/25/30-14

This is the complete Komatsu BX20 Series Forklift Parts Manual published December 2005 under document number PM188. It covers gasoline, LP and diesel forklift trucks in the FG20/25/30-14 and FD20/25/30-14 model ranges with serial numbers from 580001A onward. Whether you are ordering replacement parts, identifying components after a breakdown, or rebuilding a system, this manual gives you the exploded illustrations and part numbers you need to get it right the first time.

File Details

• Manual Type: Parts Manual
• Brand: Komatsu
• Models Covered: FG20/25/30-14, FD20/25/30-14 (BX20 Series Forklift Trucks)
• Engines Covered: K21, K25 (Gasoline & LP), 4D94E (Diesel)
• Document Number: PM188
• Publication Date: December 2005 (DIC 2005)
• Language: English
• File Format: PDF
• Page Count: 712 pages
• Serial Number Range: 580001A and up

Chapters Covered

The manual is divided into numbered chapters, each covering a specific vehicle system or component group. Every chapter includes illustrated parts breakdowns with item numbers, part numbers, descriptions, quantities and serial number applicability.

• Chapter 00 – Recommended Stock List (FMSL, FRSL, EPASL)
• Chapter 01 – Engine and Related Parts (K21/K25/4D94E)
• Chapter 03 – Exhaust System
• Chapter 04 – Cooling System
• Chapter 05 – Fuel System – Gas
• Chapter 06 – Fuel System – LPG & Dual-Fuel
• Chapter 10 – Clutch
• Chapter 13 – Torque Converter
• Chapter 14 – Direct Drive Transmission
• Chapter 15 – Transmission – Torqflow Type
• Chapter 21 – Drive Axle
• Chapter 24 – Steer Axle
• Chapter 27 – Front Wheel / Tire, Drive
• Chapter 28 – Rear (Steering) Wheels
• Chapter 30 – Brakes, Service / Parking
• Chapter 33 – Steering, Handwheel Assembly
• Chapter 34 – Steering Column Assembly
• Chapter 35 – Transmission Shift Levers
• Chapter 36 – Pedals, Brake, Clutch & Inching & Master Cylinder
• Chapter 37 – Pedal, Accelerator
• Chapter 41 – Frame and Chassis
• Chapter 50 – Outer Panel, Overhead Guard, Operator Compartment
• Chapter 55 – Electrical System
• Chapter 60 – Hydraulic Pump
• Chapter 61 – Hydraulic Control Valve
• Chapter 64 – Tilt Cylinder
• Chapter 65 – Power Steering Cylinder
• Chapter 66 – Hydraulic Systems
• Chapter 72 – Masts (E50-MS, E50-MT, E60-MS, E60-MT)
• Chapter 83 – Options
• Chapter 93 – Forks
• Chapter 96 – Name Plates and Decals
• Chapter 97 – Service Kits
• Chapter 98 – Paint
• Chapter 99 – Appendix – Numerical Parts Index

This manual is organized for parts professionals and mechanics who need to identify, order and replace components on Komatsu BX20 Series forklifts. Every parts list page features an accompanying illustration with item numbers that correspond directly to the part numbers, descriptions and quantities in the adjacent table. The level of detail extends to sub-assemblies and individual components – washers, gaskets, o-rings, seals, bearings, bolts and nuts are all listed with their specific part numbers. Where serial number ranges affect part applicability, those ranges are clearly noted.

The engine chapter alone spans hundreds of pages covering the K21 and K25 gasoline/LP engines and the 4D94E diesel engine in exhaustive detail. You will find complete breakdowns for cylinder blocks, cylinder heads, rocker covers, crankshafts, pistons, flywheels, camshafts, valve mechanisms, front covers, manifolds, lubricating systems, water pumps, thermostats, ignition systems, alternators, starter motors, fuel injection pumps, fuel injection valves and more. Each engine variant has its own specific part numbers where components differ.

Transmission coverage includes both the direct drive (clutch) transmission and the Torqflow transmission. The direct drive section covers case assemblies, drive gears, differentials and hypoid gears. The Torqflow section covers torque converters, clutch drum assemblies, drive gears, filters, speed sensors, control valves, and carrier assemblies. Drive axles and steer axles are detailed for both pneumatic and cushion tire models, with different part numbers where the specifications diverge.

Hydraulic systems are thoroughly documented across multiple chapters. The hydraulic pump section covers pumps for both FG and FD models. The control valve chapters break down 2-spool, 3-spool and 4-spool configurations with mounting parts and inner components. Tilt cylinders, power steering cylinders and all hydraulic piping routes are illustrated with hose, pipe, clamp and fitting part numbers.

The mast chapter is exceptionally detailed, covering E50-MS 2-stage, E50-MT 3-stage, E60-MS 2-stage and E60-MT 3-stage masts. For each mast type you will find safety decals, main lift cylinders, free lift cylinders, outer uprights, intermediate uprights, inner uprights, carriages (4-roller and 6-roller), hoist chains, load backrests, mounting parts, hydraulic groups, lowering control valves and internal hose reeving configurations. The mast sections also include Recommended Stock Lists to help dealers and service operations maintain appropriate inventory.

Electrical system coverage includes engine wiring, chassis wiring, dashboard wiring, battery and holder, head lamps, rear combination lights, combination switches, fuel sending units, engine control units (ECU), speed signal converters and speed control modules. Wiring harnesses are listed with part numbers for gasoline, LP and dual-fuel configurations, with variations for Torqflow and clutch specifications.

Brake system chapters separate pneumatic tire and cushion tire models, covering backing plates, wheel cylinders, brake shoes, springs, adjusters, levers, cables, master cylinders and brake piping. The parking brake lever assembly is also documented. Steering system coverage includes the steering wheel assembly, steering column assembly and steering valve (OSPB).

The frame and chassis chapter covers frames for pneumatic and cushion tire models, including UL-S variants, with counterweights, tilt pins, bushings, shims and fittings. Outer panel and operator compartment coverage includes outer panels, sub-bonnets, bonnets, dashboard covers, floor plates, side steps, overhead guards, operator seats (standard and optional) and monitor panel components.

What This Manual Enables You To Do

With this Komatsu BX20 Series parts manual, you can accurately identify and order any serviceable component on your forklift. No more guessing whether a part fits your specific serial number range – the manual tells you exactly which part numbers apply. You can disassemble and reassemble systems with confidence, knowing every gasket, seal, bearing and fastener is documented. When a component fails, you can trace the entire assembly in the exploded illustrations and order not just the failed part but any related components that should be replaced at the same time.

The numerical parts index in Chapter 99 lets you look up any part number and find the exact page and figure where it appears. This is invaluable when you have a part number from a dealer or an old invoice and need to see the full assembly context. The Recommended Stock Lists in Chapter 00 help service operations and parts departments maintain appropriate inventory levels for fast-moving items, EPA-related components and common replacement parts.

This manual covers the K21 and K25 gasoline/LP engines in depth, including the emission control systems required for EPA compliance. The fuel system chapters cover gasoline, LPG and dual-fuel configurations, with specific part numbers for tanks, hoses, fittings, vaporizers, solenoids and injectors. The 4D94E diesel engine section includes fuel injection pump exploded views, fuel injection valves, fuel filters and the complete lubricating oil system.

For transmission and drivetrain work, the manual distinguishes between clutch-equipped and Torqflow-equipped trucks, and between pneumatic and cushion tire models. This matters because the same nominal model can have different internal components depending on these configurations. The drive axle and steer axle chapters provide the same level of detail, covering housings, hubs, shafts, bearings, seals, king pins, knuckles and linkage components.

Hydraulic system coverage is comprehensive enough to support complete system overhauls. The pump, control valve, cylinder and piping chapters work together to document every component in the hydraulic circuit. Whether you are resealing a tilt cylinder, replacing a control valve section, or tracing a hydraulic leak through the piping, the illustrations and part numbers give you the information you need.

Mast service is often the most demanding work on a forklift, and the mast chapters in this manual rise to the occasion. The level of detail provided for E50-MS, E50-MT, E60-MS and E60-MT masts means you can order the correct lift cylinder for your exact mast height, identify the right chain for your outer channel length, and get the correct carriage rollers, shims, sheaves and hose reeving components. The inclusion of Recommended Stock Lists for mast components shows this manual was designed for professionals who maintain fleets.

The electrical system chapter supports troubleshooting and repair of everything from a failed headlamp to a faulty ECU. Wiring harness part numbers vary by fuel type, transmission type and operator presence system configuration, and the manual clearly identifies these variations. The combination switch, ignition switch, fuel sending unit and sensor part numbers are all documented.

Options covered in Chapter 83 include back-up alarms, strobe lights, under carriage protectors, sideshifters and integral sideshifters. Forks are covered in Chapter 93 with Class II and Class III fork options in standard taper and full taper polished styles, in multiple lengths and capacities. Service kits in Chapter 97 consolidate commonly needed seal kits, gasket kits and cylinder kits for convenient ordering.

Why This Manual Matters

Komatsu forklifts are durable machines, but all equipment eventually needs parts. Using the wrong part – even a slightly different seal or bearing – can lead to premature failure, leaks, or damage to mating components. This parts manual removes the guesswork. Every part number in this manual is the one Komatsu specified for your exact model, serial number range, engine and configuration.

For businesses running Komatsu BX20 Series forklifts, having this manual on hand reduces downtime. When a machine breaks down, you can quickly identify the failed components, look up the part numbers, and get the right parts ordered on the first call. For service technicians, the exploded views serve as assembly guides, showing how components fit together and in what order. For parts departments, the Recommended Stock Lists help balance inventory investment against service responsiveness.

This manual covers a wide range of BX20 Series models – FG20C-14, FG20T-14, FG20TUS-14, FG20TLS-14, FG20ST-14, FG20STUS-14, FG20STLS-14, FG20HT-14, FG20HTLS-14, FG20SHT-14, FG25C-14, FG25T-14, FG25TUS-14, FG25TLS-14, FG25ST-14, FG25STUS-14, FG25STLS-14, FG25HT-14, FG25HTUS-14, FG25HTLS-14, FG25SHT-14, FG25SHTLS-14, FG30C-14, FG30HT-14, FG30HTUS-14, FG30HTLS-14, FG30SHT-14, FG30SHTLS-14 and the corresponding FD diesel models. Each model listing includes its specific engine, transmission type and tire configuration, so you can quickly confirm your exact model is covered.

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Instant PDF Delivery

This Komatsu BX20 Series forklift parts manual is delivered as a PDF download immediately after payment. There is no shipping, no waiting for a physical book, and no risk of a damaged or lost package. You can access the manual on any device – computer, tablet, or smartphone – and print any pages you need for use in the workshop. The PDF format makes it easy to store, search and share within your organization. Whether you need to look up a single part number or print an entire chapter for a major rebuild, this digital manual gives you instant access to the information.