Komatsu BX20 Series Forklift Service Manual – FG20 FG25 FG30 FD20 FD25 FD30 – PDF

Description

The Komatsu BX20 Series Forklift Service Manual (SM122) is the complete workshop reference for the BX20 family of forklift trucks, covering gasoline, LPG and diesel variants built to Federal EPA emission-control standards from serial number 580001A onward. Published by Komatsu Forklift USA, Inc. and revised in January 2008, this Komatsu BX20 Series Forklift Service Manual gives technicians, fleet maintenance departments and independent repair shops the full range of factory procedures needed to inspect, test, adjust, disassemble, repair and reassemble these trucks — from engine and transmission overhauls through to mast, hydraulic, brake and steering service.

File Details

• Manual Type: Service Manual
• Brand: Komatsu Forklift USA, Inc.
• Document Number: SM122
• Revision Date: January 2008
• Page Count: Approximately 452 pages
• File Format: PDF
• Language: English
• Gasoline & LPG Models Covered: 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
• Diesel Models Covered: FD20T-14, FD20TUS-14, FD25T-14, FD25TUS-14, FD30T-14, FD30TUS-14
• Engines Covered: K21, K25 (gasoline/LPG), 4D94E (diesel)
• Serial Number Range: S/N 580001A and up

Chapters Covered

• 1. Safety — Safety Management, Safe Travel, Loading Operations, Safety in Periodic Maintenance, Towing, Structure and Stability of the Lift Truck, Safety Labels, Optional Equipment
• 2. General Information & Specifications — Mast Data & Features for Indoor and Outdoor Trucks, Truck Data for Pneumatic Tire and Cushion Tire Lift Trucks, Periodic Replacement of Consumable Parts, Standard Tightening Torque for Pipe Joints and Bolts
• 3. Service Data — Gasoline Engine Trucks (Pneumatic and Cushion), Diesel Engine Lift Trucks
• 4. Test, Adjust and Measure — Ignition Timing, Injection Timing Mark, No-Load Rotating Speed, Spark Plug Gap, Valve Clearance, Fan Belt Tension, Engine Cylinder Compression, Parking Brake Lever, Hydraulic Drift on Lift and Tilt Cylinders, Accelerator Pedal, Throttle Position Sensor System, Accelerator Pedal Position Sensor, Clutch and Brake Pedal, Brake Fluid, Brake Stopping Distance, Stop Lamp Switch, Inching and Brake Pedal, Torqflow Clutch Actuation Pressure, Torque Converter Stall Speed, Battery Electrolyte Specific Gravity, Tires and Pneumatic Tire Pressure, Turning Radius, Hydraulic Control Valve Relief Pressure
• 5. Inspection — Engine Starting and Running, Air Cleaner, Cylinder Head Mounting Bolts, Engine Mounts, Lubricating System, Fuel System, LPG Vaporizer Tar Build-Up, Blow-By Gas Recirculation System, Cooling System and Radiator, Charging System Wiring, Steering and Power Steering, Brake System (Rods, Cables, Piping, Master and Wheel Cylinders, Shoes, Drums, Backing Plates), Load Forks, Mast, Fork Carriage, Lift Chains, Chain Wheels, Attachments, Hydraulic Tank, Chassis and Attachment Piping, Hydraulic Pump, Lift Cylinder, Tilt Cylinders, Attachment Cylinders, Chassis and Frame, Cab, Operator’s Seat and Komatsu Operator Present System (KOPS), Display Panel, Overhead Guard, Lights and Warning Devices, Rear View Mirror and Reflectors, Speed and Forward/Reverse Levers
• 6. Maintenance Operations — Lubricant Lists (K21/K25 and 4D94E), Oil and Greasing Chart, Engine Oil and Filter Change, Differential Case, Torqflow Transmission Case, Hydraulic Tank Oil, Fuel Filter, Air Cleaner Element
• 7. Removal, Disassembly, Assembly & Installation — Overall Disassembly and Assembly Drawing, Engine, Transmission and Drive Axle, Clutch, Torque Converter, Brake Master Cylinder, Clutch Master and Release Cylinders, Steering Axle, Power Steering Valve (OSPC), Power Steering Cylinder, Wheel Brake, Clutch Transmission, Drive Axle, Differential (Direct Drive and Torqflow), Torqflow Transmission with Torque Converter, Torqflow Transmission Control Valve, Hydraulic Control Valve, Hydraulic Pump, Tilt Cylinder, Mast Removal and Installation, Lift Cylinder, Cylinder Seal Service Kits, Sideshifter
• 8. 50D/55D/60D-MS Limited Free Lift 2-Stage Masts — Introduction, Installation, Periodic Maintenance, Troubleshooting, Service
• 9. 50D/55D/55ND/60D-MD Full Free Lift 2-Stage Mast — Introduction, Installation, Periodic Maintenance, Troubleshooting, Service
• 10. 50D/55D/60D-MT Full Free Lift 3-Stage Mast — Installation, Periodic Maintenance, Troubleshooting, Service
• 11. 45D/55D MQ Quad Mast — Introduction, Installation, Periodic Maintenance, Troubleshooting, Service
• Appendices — Schematics, Hydraulic Circuit Diagram, Pedal Adjustment Diagram, Troubleshooting Diagram, K21/K25 Engine Manual Pre EPA 2007, TB94(L)E Engine Manual

Across these chapters the Komatsu BX20 Series Forklift Service Manual builds a complete picture of the truck. The general information and specification chapters give mast data, truck data and consumable replacement schedules for both pneumatic and cushion tire trucks. Service data chapters split gasoline, LPG and diesel engine trucks so the technician can find the correct values for the machine on the bench. Test, adjust and measure covers everything from ignition and injection timing through to hydraulic drift measurement, brake stopping distance and hydraulic control valve relief pressure. Inspection chapters walk through each major assembly — engine, cooling, fuel, steering, brakes, load handling, hydraulic tank and operator safety systems including KOPS — so nothing is overlooked during scheduled servicing. Maintenance operations give the lubricant lists, oil and greasing chart and step-by-step fluid and filter change procedures, and the removal, disassembly, assembly and installation chapter is the heavy-lifting portion of the book, taking the engine, clutch, transmission, torque converter, drive axle, differential, brakes, steering axle, power steering valve (OSPC), hydraulic pump, cylinders and mast apart and back together with torque values throughout.

Coverage Depth for the BX20 Series

The BX20 forklift family is split across gasoline, LPG and diesel power, and this Komatsu BX20 Series Forklift Service Manual reflects that. K21 and K25 gasoline/LPG trucks get their own service data, valve clearance procedures, ignition timing notes and LPG vaporizer tar build-up inspection. The 4D94E diesel trucks get injection timing mark adjustment, no-load rotating speed adjustment, diesel-specific valve clearance and compression measurement. Pneumatic and cushion tire trucks are separated in the truck data, so mast heights, tilting angles, turning radius, wheelbase and service weights are all findable per configuration. The applicable BX20 EPA model table on the model listing page confirms exactly which trucks the manual was written against, and the serial range from 580001A onward keeps you working on the correct generation of BX20 machine.

What You Can Do With This Manual

With the Komatsu BX20 Series Forklift Service Manual on hand you can diagnose and repair the full range of BX20 systems, not just the routine service items. Engine removal and installation, cylinder head re-torquing, valve clearance adjustment, compression testing, fuel filter and air cleaner service, cooling system and radiator inspection are all covered. Transmission-side work is covered for both the clutch transmission and the Torqflow transmission with torque converter, including clutch actuation pressure checks, torque converter stall speed, differential disassembly and ring gear backlash adjustment. Steering axle removal and installation, hub bearing preload, toe-in and turning angle adjustment are spelled out, along with the OSPC power steering valve disassembly and assembly sequence. Wheel brake disassembly and assembly, brake master cylinder, brake bleeding and parking brake lever adjustment are all in the book. For the load handling side, the manual covers mast removal and installation, lift and tilt cylinder disassembly and assembly, cylinder seal service kits, sideshifter service and lift chain inspection limits.

Document Quality and Usability

This is the SM122 edition, revised January 2008 and issued by Komatsu Forklift USA, Inc. for the BX20 Series. It contains the full safety chapter up front, standard tightening torque tables for pipe joints and bolts, consumable part replacement intervals, an oil and greasing chart, and appendices covering schematics, hydraulic circuit diagrams, pedal adjustment diagrams, troubleshooting diagrams, the pre-EPA 2007 K21/K25 engine manual and the TB94(L)E engine manual. Illustrations include exploded assembly views, cross-sections and wiring schematics that support the procedures in the text. It is a PDF file that can be kept on a laptop, tablet or phone in the workshop and printed for the bench when a page needs to sit next to the machine.

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Whether you run a fleet of BX20 trucks, maintain a single FG25 or FD30 in a warehouse, or repair forklifts for customers, having the correct Komatsu BX20 Series Forklift Service Manual on hand shortens every job. Correct torque values, correct clearances, correct sequence of operations and correct inspection limits mean fewer returns, fewer damaged parts and safer trucks. The Komatsu BX20 Series Forklift Service Manual is delivered as an instant PDF download after payment — no waiting for shipping, no physical book to keep track of, and you can print only the pages you need for the job in front of you. Get the SM122 service manual and keep your BX20 forklift service work running to the book.