Page 1 OM073R OPERATION & MAINTENANCE MANUAL AX20 and BX20 Forklift Trucks Federal Environmental Protection Agency (EPA) Emission-Control Compliant S/N 670001A~ and 580001A~ AX20 Gasoline & LPG FG15/18ST-17, FG15HC-17 FG15/18HT-17 BX20 Gasoline & LPG FG20/25/30/35S(H)(T/C)-14 FG20/25/30C-14, FG20/25T-14 FG20/25/30HT-14 BX20 Diesel FD20/25/30T-14 AX20...
Page 2 Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual, must be trained and authorized by the employer, before operating or maintaining this machine. This manual should be kept in or near the machine for reference and periodically reviewed by all personnel who come in contact with the machine.
Page 3 Neither Komatsu Forklift USA, LLC nor its parent company nor any of its subsidiaries will be held responsible for damages due to misuse or inappropriate use of its products.
Page 5: Table Of Contents
FIRST MONTH OF SERVICE (OR INITIAL 200 HOURS OF SERVICE)........1-3 MODEL LINE UP ..........................1-4 WARRANTY AND SERVICE FOR NEW LIFT TRUCK ..........1-5 GENUINE KOMATSU FORKLIFT PARTS ...................1-5 FEDERAL EPA EMISSION CONTROL STATEMENT FOR OFF-ROAD LSI (NON-DIESEL) ENGINES (K21 AND K25 ENGINES) ......1-6 FEDERAL EPA EMISSION CONTROL STATEMENT FOR OFF-ROAD DIESEL ENGINES (4D94E ENGINES) ..............1-9...
Page 6 CONTENTS 17.1 GENERAL VIEW OF LIFT TRUCK ....................3-1 17.2 INSTRUMENTS AND CONTROLS ....................3-2 17.3 METER PANEL COMPONENTS ....................3-3 18. EXPLANATION OF COMPONENTS ................3-4 18.1 EXPLANATION OF INSTRUMENTS AND CONTROLS ..............3-4 18.2 EXPLANATION OF METER PANEL COMPONENTS ..............3-9 19. REMOVAL AND INSTALLATION OF ATTACHMENTS ..........3-13 19.1 SAFETY PRECAUTIONS......................3-13 19.2...
Page 7 CONTENTS 25.1 BEFORE STORAGE ........................3-46 25.2 DURING STORAGE ........................3-46 25.3 AFTER STORAGE ........................3-46 MAINTENANCE 26. OUTLINE OF SERVICE ....................4-1 26.1 OIL ..............................4-1 26.2 GREASE............................4-1 26.3 OIL STORAGE AND PRESERVATION..................4-1 26.4 FILTERS ............................4-1 27. LUBRICANT LIST ......................4-2 27.1 AX – GASOLINE/LPG ENGINE ....................4-2 27.2 BX –...
Page 8 CONTENTS TECHNICAL DATA 34. TECHNICAL DATA - AX/BX MODEL LIFT TRUCKS ............ 5-1 34.1 AX (GASOLINE/LPG ENGINES)....................5-1 34.2 BX (DIESEL ENGINES) .......................5-3 34.3 BX (GASOLINE/LPG ENGINES)....................5-4...
Page 9: Foreword
FOREWORD READ AND FOLLOW ALL SAFETY PRECAUTIONS. FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR DEATH.
Page 11 Komatsu Forklift dealer. • Komatsu Forklift delivers lift trucks that comply with (to the best of our knowledge at the time of delivery) all applicable regulations and standards of the country to which they have been shipped.
Page 12: Safety Information
If you are unsure about the safety of some procedures, contact your Komatsu Forklift dealer. The procedures and precautions given in this manual apply only to intended uses of the lift truck. If you use your lift truck for any unintended use that is not specifically prohibited, you must be sure that it is safe for you and others.
Page 13: Running In A New Lift Truck
RUNNING IN A NEW LIFT TRUCK RUNNING IN A NEW LIFT TRUCK Your Komatsu lift truck has been thoroughly adjusted and tested before shipment. However, operating the lift truck under severe conditions at the beginning can adversely affect performance and shorten the lift truck life.
Page 14: Model Line Up
3. RUNNING IN A NEW LIFT TRUCK MODEL LINE UP APPLICABLE “EPA” LIFT TRUCK MODELS Model Description AX (K21 Gasoline Engine) FG15ST-17 3,000 lb. capacity, Cushion Tire, TORQFLOW FG15STLS-17 3,000 lb. capacity, Cushion Tire, TORQFLOW, Liquid Propane Special FG18ST-17 3,500 lb. capacity, Cushion Tire, TORQFLOW FG18STLS-17 3,500 lb.
Page 15: Warranty And Service For New Lift Truck
In the event that the customer uses imitation parts, Komatsu Forklift will not be held accountable for any faults which result from the use of such imitation parts, and Komatsu Forklift warranty will not be applicable.
Page 16: Federal Epa Emission Control Statement
4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK FEDERAL EPA EMISSION CONTROL STATEMENT FOR OFF-ROAD LSI (NON-DIESEL) ENGINES (K21 AND K25 ENGINES) This section presents information concerning the correct labeling, warranty, parts and maintenance of K21 and K25 engines in order to comply with the EPA off-road, large-spark-ignition (LSI) engine regulations. 4.2.1 LABELS REQUIRED AND LABEL LOCATIONS All “K”...
Page 17 All off-road large spark-ignition (LSI) engines must be designed, built and equipped to meet the Federal EPA’s stringent anti-smog standards. Komatsu Forklift USA, LLC (“KFI”) must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, damage, neglect or improper maintenance of your engine.
Page 18 Follow the instructions in the Operations Manual concerning any other maintenance programs not required for EPA compliance. For questions and additional information concerning EPA Diesel Engine Exhaust Regulations, contact: Komatsu Forklift U.S.A., LLC c/o Komatsu American Corp. One Continental Towers 1701 W.
Page 19: Federal Epa Emission Control Statement For Off-Road Diesel Engines (4D94E Engines)
4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK FEDERAL EPA EMISSION CONTROL STATEMENT FOR OFF-ROAD DIESEL ENGINES (4D94E ENGINES) Exhaust emissions produced by diesel engines are regulated by the United States Environmental Protection Agency (EPA). This section presents information concerning the correct labeling, warranty, parts and maintenance of 4D94E diesel engines in order to comply with current EPA regulations.
Page 20 You are responsible for initiating the warranty process. It is suggested that you present your heavy duty off- road engine to an authorized Komatsu Forklift dealer as soon as you become aware that problem exists. The warranty repair should be completed by the dealer as expeditiously as possible.
Page 21 Emission Control Systems Warranty, call or write to your Komatsu Forklift Dealer. Authorized dealers are recommended for major maintenance and repair work, as they are staffed with trained personnel, proper tools and are aware of the latest maintenance methods and procedures.
Page 22: Location Of Plates And Serial Number
5. LOCATION OF PLATES AND SERIAL NUMBER LOCATION OF PLATES AND SERIAL NUMBER UL (Underwriters Laboratories) Plate Located on the outside front left of the dashboard. Embossed Vehicle Serial Number Stamped on top of the left front fender. Capacity Data Plate With Vehicle Serial Number Located on the bonnet (hood) to the right of the operator’s seat.
Page 23: Contacting Komatsu Forklift
6. CONTACTING KOMATSU FORKLIFT CONTACTING KOMATSU FORKLIFT CONTACTING KOMATSU FORKLIFT When contacting a Komatsu Forklift dealer for parts ordering or problem consultation, always provide the lift truck serial number embossed on the lift truck. NOTICE Take care not to damage or remove the embossed serial number.
Page 24: Model Coding System
7. MODEL CODING SYSTEM MODEL CODING SYSTEM Komatsu Forklift Model Coding System for Internal Combustion Engine Trucks Class IV (Cushion Tire) and V (Pneumatic Tire) You can determine the lift truck model from the model code on the nameplate, which is located on the top of the lift truck hood to the right of the operator’s seat.
Page 25: Epa Emission Control Warranty Statement (Gasoline/Lpg)
8. EPA EMISSION CONTROL WARRANTY STATEMENT (GASOLINE/LPG) EPA EMISSION CONTROL WARRANTY STATEMENT (GASOLINE/LPG) 1-15...
Page 26: Epa Emission Control Warranty Statement (Diesel)
9. EPA EMISSION CONTROL WARRANTY STATEMENT (DIESEL) EPA EMISSION CONTROL WARRANTY STATEMENT (DIESEL) 1-16...
Page 27: Safety
SAFETY READ AND FOLLOW ALL SAFETY PRECAUTIONS. FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR DEATH.
Page 29: Safety Management
Any modification made without authorization from Komatsu Forklift can create hazards. • Before making any modification whatsoever, consult your Komatsu Forklift dealer. Komatsu Forklift will not be responsible for any damage, injury or death caused by any unauthorized modification. •...
Page 30 10. SAFETY MANAGEMENT EXHAUST GAS Do not leave the engine running where there is poor ventilation. The engine exhaust gas contains carbon monoxide. There is a danger that this will cause gas poisoning which may result in serious injury or death. FIRE EXTINGUISHER AND FIRST AID KIT •...
Page 31 10. SAFETY MANAGEMENT TRAVELING REGULATIONS ON PUBLIC ROADS • Do not travel on public roads unless you comply with local, state or other laws which regulate such activity. • Always observe all traffic regulations when operating the lift truck. • Do not drive on public roads with the lift truck loaded.
Page 32 10. SAFETY MANAGEMENT SAFE OPERATING PLAN • Before operation, establish an operating plan and hold a meeting to discuss operating safety. • In confined areas, position a signal person and carry out operations in accordance with his or her instructions. •...
Page 33 10. SAFETY MANAGEMENT FIRE PREVENTION FOR FUEL FUEL IS EXTREMELY FLAMMABLE AND CAN CAUSE FIRES AND EXPLOSIONS • Carry out refueling away from flames or sparks. • Stop the engine when refueling. • After refueling, tighten the gas cap securely and wipe up any spilled fuel. •...
Page 34: Safe Travel
11. SAFE TRAVEL SAFE TRAVEL PRECAUTIONS WHEN STARTING ENGINE • Before starting the engine, always check that the parking brake is applied and that the directional and speed levers are in neutral. Depress the clutch pedal (for clutch type trucks), or the brake pedal (for TORQFLOW transmission trucks), firmly, and then start the engine.
Page 35 11. SAFE TRAVEL TRAVEL ON SLOPES • Do not turn, or travel across or at an angle on slopes. There is danger that the lift truck will tip. • Before starting to drive up a slope, stop the lift truck and adjust the clearance between the ground surface and the bottom of the forks so that the bottom of the forks or pallet do not contact the ground surface or the tip of the fork does not stick into the ground when traveling.
Page 36 11. SAFE TRAVEL ROAD SHOULDER • There is danger that soft road shoulders may collapse, so do not go near them with the lift truck. • Always maintain a safe distance from the edge of road shoulders and platforms. LOADING HIGHWAY TRUCKS OR RAILROAD CARS •...
Page 37 11. SAFE TRAVEL NO RIDERS FORKLIFT TRUCKS ARE ONE-PERSON MACHINES • Do not allow any other person to ride on the truck under any circumstances. • Never allow anyone to act as an extra counterweight. DRIVING IN REVERSE When driving in REVERSE, turn to face the rear and check the area directly behind the lift truck.
Page 38 11. SAFE TRAVEL WHEN FRONT VIEW IS POOR • If the view to the front is obstructed by the load, turn to the rear and drive the forklift truck in reverse. • When driving in reverse with a high load, use a signal person to ensure the safety of the load and the safety in the surrounding area.
Page 39 11. SAFE TRAVEL ALWAYS SIT IN OPERATOR'S SEAT Always observe the following: • Never operate the lift truck from outside the operator's compartment. • Always keep your body under the overhead guard. • Do not extend your arms and legs outside the operator's compartment. SEAT BELT •...
Page 40 11. SAFE TRAVEL SAFETY DURING TRAVEL • Keep a clear view of the path of travel and observe for other traffic, personnel and safe clearances. • Yield the right of way to pedestrians. • When passing oncoming vehicles, reduce speed and keep a safe distance from the other vehicle.
Page 41 11. SAFE TRAVEL PRECAUTIONS WHEN TURNING • When turning while traveling forward, the counterweight will swing far out. Keep an ample clearance from walls and other objects to ensure safety. • When turning, travel slowly and be careful that the front or rear wheels do not come off the ground.
Page 42: Loading Operations
12. LOADING OPERATIONS LOADING OPERATIONS NO OVERLOADING • Do not load the lift truck over the capacity set forth in the load capacity chart. If the rear wheels come off the ground because of overloading, the lift truck cannot travel or turn. There is also danger that it may tip.
Page 43 12. LOADING OPERATIONS BE CAREFUL NOT TO GET CAUGHT OR FALL • Never put your hands or feet into the mast structure. There is danger that you will get caught in moving parts and be seriously injured. • Do not use the mast, load backrest or dashboard as a ladder or step. If you slip, there is danger that you will fall.
Page 44 12. LOADING OPERATIONS DO NOT TILT MAST FORWARD WHEN LOADED • Do not tilt the mast forward when the forks are loaded and raised. There is danger that the load may fall and that the lift truck may tip. • Do not travel with the mast tilted forward.
Page 45 12. LOADING OPERATIONS USING DRAWBAR PIN Do not use the drawbar pin for towing other lift trucks, for being towed by other lift trucks, or for lifting operations. The drawbar pin installed to the rear of the counterweight is used only to free the truck when the tires have become stuck in mud or in a ditch and the lift truck cannot move, or when loading the lift truck on to a trailer or truck.
Page 46 12. LOADING OPERATIONS BE CAREFUL OF FORK TIPS • Do not allow the tips of the forks to get close to people. The tips of the forks are pointed, so there is a risk that they may cause injury. • Do not hook the tips of the forks under objects.
Page 47 12. LOADING OPERATIONS OVERHEAD OBJECTS • Be careful not to let the mast, overhead guard or load contact electrical wiring, pipes, sprinklers or roof beams. If the truck hits such objects, there is a risk that the load will fall or the lift truck will tip. •...
Page 48: Stopping And Parking
13. STOPPING AND PARKING STOPPING AND PARKING PRECAUTIONS WHEN STOPPING OR PARKING Observe the following procedure when stopping or parking the lift truck: Stop the lift truck on level ground. Apply the parking brake securely to make sure that the lift truck cannot move.
Page 49: Inspection And Maintenance
14. INSPECTION AND MAINTENANCE INSPECTION AND MAINTENANCE USE QUALIFIED PERSONNEL FOR INSPECTION AND MAINTENANCE • Only persons authorized by the owner or operator of the equipment and having proper certification (local or national) may carry out inspection, maintenance and repairs of the lift truck. •...
Page 50 14. INSPECTION AND MAINTENANCE USE SUITABLE TOOLS Always use tools that are suited for inspection and maintenance. It is extremely dangerous to use broken tools or tools designed for another purpose. REPLACE SAFETY CRITICAL PARTS PERIODICALLY • Even if no abnormality is found, always replace safety critical parts periodically. As time passes, these parts deteriorate and may cause fire or failure in the work equipment system.
Page 51 14. INSPECTION AND MAINTENANCE PRECAUTIONS WITH HIGH PRESSURE, HIGH TEMPERATURE • Immediately after using the lift truck, the oil is at high temperature. Do INCORRECT not drain the oil or replace the filter when the oil is hot. Hot oil may spurt out and cause burns.
Page 52 14. INSPECTION AND MAINTENANCE CHECKING AND INFLATING TIRES • If the tire inflation pressure is low, it will affect truck stability. However, do not inflate the tires immediately. The inflation pressure may have gone down because of damage to the rim. If the rim is damaged or cracked and the tires are inflated, there is danger that the rim will break when the tire is under high pressure, and this may cause personal injury or death.
Page 53 14. INSPECTION AND MAINTENANCE LIFTING LIFT TRUCK (when checking tires) • Lift truck slinging work should be carried out by a qualified person who has completed a course in correct lifting methods. • Fit wire ropes to the specified lifting points. •...
Page 54 14. INSPECTION AND MAINTENANCE CHANGING LPG FUEL TANKS • Only trained and certified personnel may change LPG tanks. • Turn ignition switch to the OFF position. • Change LPG tanks in designated and well ventilated area approved for this operation. •...
Page 55 14. INSPECTION AND MAINTENANCE HANDLING BRAKE FLUID It is dangerous if the brakes do not work because, in this condition, the lift truck cannot be stopped. Always do the following: • Check the level of the brake fluid periodically. • Always use the specified brake fluid.
Page 56: Structure And Stability Of The Lift Truck
15. STRUCTURE AND STABILITY OF THE LIFT TRUCK STRUCTURE AND STABILITY OF THE LIFT TRUCK TO PREVENT LIFT TRUCK FROM TIPPING To operate the lift truck safely, it is important to understand the structure and stability of the lift truck. STRUCTURE OF LIFT TRUCK A forklift truck consists basically of the lifting mechanism (the forks and mast) at the front and the lift truck itself (with tires) at the rear.
Page 57 15. STRUCTURE AND STABILITY OF THE LIFT TRUCK STABLE RANGE OF CENTER OF GRAVITY For the lift truck to be stable, the position of the combined center of gravity must be inside the triangle (stable range of center of gravity) formed by the ground contact points of the left and right front tires and the center of the rear axle.
Page 58 15. STRUCTURE AND STABILITY OF THE LIFT TRUCK SPEED AND ACCELERATION If a stationary object is not subjected to external force, it will remain stationary. In the same way, if a moving object is not subjected to external force, it will continue to move at the same speed. This is called inertia. Because of inertia, a force is applied towards the rear when the lift truck starts to move, and is applied towards the front when the lift truck stops.
Page 59: Safety Labels
16. SAFETY LABELS SAFETY LABELS Keep these labels clean. If a label (decal) comes off, stick it on again in the same location or replace with a new one. Treat all labels in the same way, whether they are safety related or not. 3 4 5 6 SHROUD AWB2296K...
Page 60 16. SAFETY LABELS 1. FUEL LEVEL REQUIREMENTS - GASOLINE AND LPG (On dashboard over Fuel Gauge) (Dual-Fuel applications only) Dual-Fuel Truck LPG Fuel Truck 2. Caution before operating machine. (Part No. 3EB-96-A5960) 2-32...
Page 61 16. SAFETY LABELS 3. Warning for operation (decal). (Part No. 3EB-96-A6120) WARNING SERIOUS INJURY OR DEATH MAY RESULT IF YOU FAIL TO FOLLOW THESE PRECAUTIONS! B e f o r e O p e r a t i n g •...
Page 62 16. SAFETY LABELS 5. DUAL-FUEL SYSTEM FUEL CHANGE-OVER INSTRUCTIONS (On air cleaner housing) (Part No. 3EB-96-A5790) 6. LPG SAFETY MAINTENANCE DECAL (Right side of seat on hood upper surface) (Part No. 3EB-05-F5730) 2-34...
Page 63 16. SAFETY LABELS 7. Warning for handling LPG/FLAMMABLE GAS (decal). (Part No. 3EB-96-A5950) 8. LPG TANK CHANGE INSTRUCTIONS DECAL (On LPG Tank Bracket Base Plate) (Part No. 3EB-05-F5690) 9. Never touch fan when rotating. (Part No. 3EB-96-A5930) 10. Prevention of tip-over (decal). (Parts No. 3EB-96-A5111) 2-35...
Page 64 16. SAFETY LABELS 11. LPG LOW FUEL ALARM LIGHT (On dashboard to left of steering column) (OPTION) 12. Warning for use of split rim (pneumatic tires only) (decal). (Part No. 3EB-96-A5970) 13. No one is permitted to ride the lift truck together with the operator. (Part No. 3EB-96-A5910) 2-36...
Page 65 16. SAFETY LABELS 14. Prohibit the operator from riding on the forks and lifting or lowering himself. Never enter the area under the forks. (Part No. 3EB-96-A5920) 15. Do not put your hand on the mast! (Warning to avoid getting hand caught) (Part No. 3EB-96-A5940) 2-37...
Page 66 NOTES:...
Page 67: Operation
OPERATION READ AND FOLLOW ALL SAFETY PRECAUTIONS. FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR DEATH.
Page 69: Overview Of Lift Truck
17. OVERVIEW OF LIFT TRUCK OVERVIEW OF LIFT TRUCK 17.1 GENERAL VIEW OF LIFT TRUCK 1. Mast 9. Turn signal lamp (option) 2. Lift-chain 10. Head lamp (option) 3. Lift cylinder 11. Operator’s seat 4. Back rest 12. Engine hood 5.
Page 70: Instruments And Controls
17. OVERVIEW OF LIFT TRUCK 17.2 INSTRUMENTS AND CONTROLS See “EXPLANATION OF COMPONENTS” on page 3-4 for details. 1. Dashboard meter panel display (see following page for description) 2. Lift lever 3. Tilt lever 4. Combination light switch (turn-signal lamp and lamp ON/OFF switch) 5.
Page 71: Meter Panel Components
17. OVERVIEW OF LIFT TRUCK 17.3 METER PANEL COMPONENTS See “EXPLANATION OF COMPONENTS” on page 3-4 for details. 1. Engine water temperature gauge 2. Fuel gauge 3. Brake fluid level warning lamp 4. Engine oil pressure warning lamp 5. Charge warning lamp 6.
Page 72: Explanation Of Components
18. EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS The following is an explanation of the devices used to operate the lift truck shown on pages 3-2 and 3-3. To carry out suitable operations correctly and safely, it is important to understand fully the method of operating the equipment and the meanings of the displays.
Page 73 18. EXPLANATION OF COMPONENTS Turn Signal Indicator Switch This switch controls the turn signal indicator. LEFT Push Forward Left turn (L): Push lever forward Right turn (R): Pull lever back Remark This lever is equipped with an auto-return mechanism, so the lever RIGHT will return automatically to the neutral position.
Page 74 18. EXPLANATION OF COMPONENTS HORN BUTTON Press the button in the center of the steering wheel to sound the horn. PEDALS TORQFLOW transmission (1): Accelerator pedal (2): Brake pedal (3): Inching pedal The inching pedal is used for fine control when driving the lift truck slowly forward or in reverse for loading or unloading.
Page 75 18. EXPLANATION OF COMPONENTS FUSE BOX The fuses protect the electrical components and wiring from burning out. For details on replacing fuses, see “REPLACING FUSES AND RELAYS” on page 4-30.) LPG LOW-FUEL ALARM LIGHT (OPTIONAL) This optional alarm is located on the dashboard near the parking brake lever.
Page 76 18. EXPLANATION OF COMPONENTS HIGH/LOW SPEED LEVER (CLUTCH-TYPE LIFT TRUCK) When starting the engine, return this lever to the neutral position. Always depress the clutch pedal when operating the lever. This lever is used to change the travel speed range. (2): High speed (N): neutral (1): Low speed...
Page 77: Explanation Of Meter Panel Components
BRAKE FLUID LEVEL WARNING LAMP If this lamp lights up, check the brake fluid level and add fluid. NOTICE Always use genuine Komatsu brake fluid. AD803200 ENGINE OIL PRESSURE WARNING LAMP Engine oil pressure warning lamp indicates whether the engine lubrication oil pressure is normal or not.
Page 78 The Failure Indicator lamp begins to flash when some abnormality has occurred in the control system. If the lamp begins to flash, stop operations promptly and report the trouble to the administrator, or call your Komatsu Forklift dealer for technical assistance. 9JL00821...
Page 79 Lamp OFF: Glow plug preheating completed NEUTRAL/TRAVEL INTERLOCK INDICATOR (OPERATOR PRESENCE SYSTEM) The AX20/BX20 series trucks are equipped with KOPS (Komatsu Operator Presence System), which includes the neutral safety and Travel Interlock safety features. When the neutral lamp blinks, it means that a safety feature has been activated.
Page 80 18. EXPLANATION OF COMPONENTS TROUBLESHOOTING THE OPERATOR PRESENCE SYSTEM Travel Interlock Indicator When Travel Interlock indicator is blinking, power to transmission is disabled and forklift cannot travel. To clear the blinking Travel Interlock indicator and resume truck operations: - Sit securely in the operator’s seat using good posture. - Place the Forward/Reverse lever in neutral.
Page 81: Removal And Installation Of Attachments
19. REMOVAL AND INSTALLATION OF ATTACHMENTS REMOVAL AND INSTALLATION OF ATTACHMENTS 19.1 SAFETY PRECAUTIONS Attachments and major components are heavy and can cause serious injury if improperly handled. 1. When working underneath raised load-handling attachments, always secure them to prevent lowering. When working with lifting equipment (forklifts) never walk or reach under suspended loads.
Page 82: Carriage
19. REMOVAL AND INSTALLATION OF ATTACHMENTS 19.3 CARRIAGE 1. Lower the carriage until the forks are resting on the ground. 2. If a side shift carriage is fitted, disconnect the hydraulic hoses at the carriage, draining the fluid into a suitable container.
Page 83: Side Shift, Fork Positioner And Clamp Attachments
19. REMOVAL AND INSTALLATION OF ATTACHMENTS 19.5 SIDE SHIFT, FORK POSITIONER AND CLAMP ATTACHMENTS 19.5.1 INSTALLATION/ASSEMBLY The side shift, fork positioner and clamp attachments all have a common method of installation/assembly as follows: 1. Before installing, inspect the truck carriage to make sure that the locating notches along the top of the truck carriage are undamaged and that there are no obstructions on the faceplate itself.
Page 84: Operator's Compartment
20. OPERATOR’S COMPARTMENT OPERATOR’S COMPARTMENT 20.1 ADJUSTING THE SEAT POSITION • Adjust the seat before starting operations or when changing operators at the beginning of a shift. (Always stop the lift truck before adjusting the seat.) • Adjust the seat to a position where it is possible to depress the brake pedal fully with your back against the backrest of the operator’s seat.
Page 85: Adjusting The Suspension
20. OPERATOR’S COMPARTMENT 20.3 ADJUSTING THE SUSPENSION (OPTIONAL SUSPENSION SEAT) 1. Turn the adjustment knob on the right side of the operator’s seat to adjust the suspension to match your weight in kilograms. 2. Use the needle indicator and scale located on the front seat near the adjustment knob as a guide when setting the suspension.
Page 86: Engine Hood
21. ENGINE HOOD ENGINE HOOD 21.1 OPENING THE ENGINE HOOD Be careful not to get your hand caught when opening or closing the hood. 1. To prevent the hood from touching the steering wheel, lift the tilt steering wheel lock lever (1) and push the steering wheel to the most forward position (2), then return the lock lever to its original position (3).
Page 87: Closing The Engine Hood
21. ENGINE HOOD 21.2 CLOSING THE ENGINE HOOD Be careful not to get your hand caught when opening or closing the hood. 1. Lift the engine hood up slightly with your right hand, push in the stop- per with your left hand, then lower the engine hood slowly and check that the lock is applied.
Page 88: Travel Operations
Oil or fuel leakage can cause a lift truck fire. Check for any fluid or LPG leakage before starting. Check the lift truck thoroughly. If any abnormality is found, always repair it or consult your Komatsu Forklift dealer. 22.1.1 CHECK BEFORE OPERATION WITH STARTING SWITCH OFF n CHECK FOR OIL OR FUEL LEAKAGE, AND BATTERY FLUID LEAKAGE Check for leakage by conducting a walk-around check.
Page 89 4. Take out the dipstick again and check to see if it indicates the proper level. 5. If the oil level is low, add genuine Komatsu oil through the filler. NOTICE Always use genuine Komatsu hydraulic oil. n CHECK OIL LEVEL IN BRAKE RESERVOIR TANK 1.
Page 90 2. Remove the cap and the center cover, and check that the oil level is within the correct range of 0.39 in. (10 mm) from the cap as shown. 3. If the oil level is low, add genuine Komatsu brake fluid. NOTICE Always use genuine Komatsu brake fluid in the clutch reservoir tank.
Page 91 Use the dipstick to check that the oil is within the correct range. If the oil level is low, add engine oil through the oil filler. NOTICE • If the oil is markedly dirty or discolored, change the oil. • Always use genuine Komatsu engine oil. (See “LUBRICANT LIST” on page 4-2). 3-23...
Page 92 22. TRAVEL OPERATIONS n CHECK COOLANT LEVEL • Normally, do not open the radiator cap. Check the coolant when the engine is cold, and check using the reservoir tank. • NEVER remove the radiator or sub-tank cap when the coolant is hot. Boiling water may spurt out.
Page 93 22. TRAVEL OPERATIONS Warming up the engine Let the engine warm up for five or six minutes. On LPG trucks, do not depress the accelerator too far after starting or during warm-up. This may cause freezing of the regulator and/or damage to the engine. Precautions for restarting the engine (Applies to gasoline and LPG engine lift trucks only) When the engine does not start, return the key from the START position to the OFF position.
Page 94 22. TRAVEL OPERATIONS n REMOVAL AND INSTALLATION OF LPG FUEL TANKS ON LIFT TRUCK • Review “SAFETY” Section Warnings before changing tanks. • Use trained and qualified personnel only. • NO SMOKING during tank change operation. REMOVING LPG TANK FROM LIFT TRUCK 1.
Page 95 22. TRAVEL OPERATIONS SEDIMENTER WARNING LAMP (Diesel BX models) This lamp should not light up. If it lights up drain the water from the fuel filter. (See “(DIESEL ENGINE) DRAIN WATER FROM FUEL FILTER” on page 4-23.) n CHECK STEERING WHEEL Check the following points.
Page 96 Visually check the lift-chain for damage or cracks. If any abnormality is found, consult your Komatsu Forklift dealer. NOTICE Use genuine Komatsu engine oil. (See “LUBRICANT LIST” on page 4-2.) 22.1.3 CHECKS WHILE ADVANCING SLOWLY n CHECK STEERING WHEEL OPERATION Check the following items while advancing slowly.
Page 97: Mounting/Dismounting
Operate the work equipment control levers from the operator’s seat and check that the forks can be raised and lowered and that the mast can be tilted forward and back smoothly. If there is any abnormality, please contact your Komatsu Forklift dealer immediately. n CHECK FOR ABNORMAL NOISE, ABNORMAL SMELL Operate the work equipment control levers from the operator’s compartment and check that there is no...
Page 98: Traveling
22. TRAVEL OPERATIONS 22.3 TRAVELING 22.3.1 STARTING ENGINE • Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause serious bodily injury or fire. • When placing lift truck in motion, check that the area around the lift truck is safe and sound the horn before starting.
Page 99 22. TRAVEL OPERATIONS 4. Gasoline engine lift truck: Depress the accelerator pedal fully, then slowly release it. (If the engine is warmed up, there is no need to depress the accelerator pedal.) With the accelerator pedal released, turn the starting switch to the START position to start the engine.
Page 100 22. TRAVEL OPERATIONS 22.3.3 PLACING LIFT TRUCK IN MOTION Do not rest your feet on the clutch pedal or inching pedal if you are not operating the pedal. Clutch-type lift truck: Depress the clutch pedal, set the forward/reverse control lever to the F or R position, and set high/low speed control lever to position 1.
Page 101 22. TRAVEL OPERATIONS 22.3.5 SHIFTING DIRECTION (CLUTCH-TYPE LIFT TRUCK) Always stop the lift truck completely before shifting between forward and reverse. Stop the lift truck completely. (See “TEMPORARY STOPPING AND PARKING” on page 3-36 for details of the method of stopping the lift truck.) Move the forward/reverse control lever from F to R.
Page 102: Starting And Inching On Slope
22. TRAVEL OPERATIONS 22.4 STARTING AND INCHING ON SLOPE NEVER carry out inching by depressing the accelerator pedal fully and then adjusting the amount the brake pedal is depressed. 1. When starting the lift truck on a slope, first pull parking brake lever (1) and check that the lift truck is held in position.
Page 103: Turning
22. TRAVEL OPERATIONS 22.5 TURNING Use great care to prevent the outside of the counterweight hitting against objects when turning. Operate the steering wheel with the left hand. When turning, keep to the inner side when advancing and outer side when reversing, considering the properties of the rear steering system.
Page 104: Temporary Stopping And Parking
22. TRAVEL OPERATIONS 22.6 TEMPORARY STOPPING AND PARKING Do not park the lift truck on the route of travel for other vehicles or pedestrians. 1. Clutch-type lift truck: Release the accelerator pedal, depress brake pedal (1), then depress clutch pedal (2) immediately before the lift truck stops. TORQFLOW transmission lift truck: Release the accelerator pedal, then depress brake pedal (1) 2.
Page 105: Fork Spread Adjustment
22. TRAVEL OPERATIONS 22.7 FORK SPREAD ADJUSTMENT Take extreme care not to get hands or fingers caught while adjusting the fork spread. 1. Move the lift truck in front of the load, and stop. 2. Position the mast vertically and lift the forks 4 in. (10 cm) above the ground.
Page 106: Load Handling Operation
22. TRAVEL OPERATIONS 22.8 LOAD HANDLING OPERATION • Check that there is no danger of collapse or breakage of the load at the loading point. • Check that the loading position is correct. • Never push the load with the fork tips. 22.8.1 LOADING 1.
Page 107 22. TRAVEL OPERATIONS 5. Lower the load temporarily to the stacking point. 6. Reverse and slowly withdraw the forks 1/4 to 1/3 of the way out from beneath the load. 7. Raise the load again 2 - 4 in. (5 - 10 cm). 8.
Page 108 22. TRAVEL OPERATIONS 10. Reverse the lift truck slowly and withdraw the forks fully from beneath the load. 11. Return the mast to the travelling position. 22.8.2 UNLOADING • Check that there is no danger of collapse of the load. •...
Page 109 22. TRAVEL OPERATIONS 3. Drive forward and insert the forks 2/3 to 3/4 of the way under the load, then raise the load 2 - 4 in. (5 - 10 cm). 4. Reverse slowly 6 - 8 in. (15 - 20 cm). 5.
Page 110: Check After Operation
22. TRAVEL OPERATIONS 8. Reverse the lift truck to a position where the load can be safely lowered. 9. Lower the load until it is 6 - 8 in. (15 - 20 cm) from the ground. 10. Tilt the mast fully back. 11.
Page 111: Cold Weather Operation
See “LUBRICANT LIST” on page 4-2 for details. 23.1.2 HYDRAULIC OIL Always use genuine Komatsu oil. This gives better protection against rust than normal hydraulic oil. 23.1.3 COOLANT Coolant is flammable, so keep it away from open flame. Never smoke when handling coolant.
Page 112: Precautions After Completing Operations
23. COLD WEATHER OPERATION 23.2 PRECAUTIONS AFTER COMPLETING OPERATIONS 23.2.1 DRAIN WATER Drain any water accumulated in the fuel system to prevent water from freezing during the night. 23.2.2 ADD FUEL To prevent moisture from collecting inside the fuel tank, always fill tank after completing operations. 3-44...
Page 113: Handling In Heavy-Duty Conditions
CLEAN INSIDE OF COOLING SYSTEM Scale and rust form easily inside the cooling system, so flush the system with genuine Komatsu radiator rust prevention fluid, and take other steps to ensure that there is always clean water circulating in the system.
Page 114: Long-Term Storage
25. LONG-TERM STORAGE LONG-TERM STORAGE 25.1 BEFORE STORAGE When putting the lift truck in storage for a long time, do as follows: • Wash, clean and dry every part, then house the lift truck in a dry building. Never leave it outdoors. NOTICE In case it must be left outdoors, park the lift truck on flat, dry ground, and cover it securely with a water- proof sheet.
Page 115: Maintenance
MAINTENANCE READ AND FOLLOW ALL SAFETY PRECAUTIONS. FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR DEATH.
Page 117: Outline Of Service
26. OUTLINE OF SERVICE OUTLINE OF SERVICE • Use Komatsu Forklift genuine parts for replacement. • When changing or adding oil, use only the oil that is recommended. Do not use a different kind or grade of oil. • Unless otherwise specified, the oil and coolant used at delivery from the factory shall be as listed below.
Page 118: Lubricant List
AX – GASOLINE/LPG ENGINE MODELS FG15H(S)/18H(S)-17 NOTICE Always use genuine Komatsu Forklift oil and grease. Oil and grease are available from your Komatsu Forklift dealer. Never use the incorrect kind of brake fluid. Use genuine Komatsu Forklift DOT 3 brake fluid. Ambient Temperature...
Page 119: Bx - Gasoline/Lpg Engine
27.2 BX – GASOLINE/LPG ENGINE MODELS FG20/25/30-14, FG20H/25H/30H-14, FG20S/ 25S-14, FG20SH/25SH/30SH-14 NOTICE Always use genuine Komatsu Forklift oil and grease. Never use the incorrect kind of brake fluid. Use genuine Komatsu Forklift DOT 3 brake fluid. Ambient Temperature Location Type of Fluid Capactities 86°F...
Page 120: Bx - Diesel Engine
BX – DIESEL ENGINE MODELS FD20/25/30-14 NOTICE Never use fuel mixed with kerosene. Always use genuine Komatsu Forklift oil and grease. Never use the incorrect kind of brake fluid. Use genuine Komatsu Forklift DOT 3 brake fluid. Ambient Temperature Location...
Page 121: Oil And Greasing Chart
27. LUBRICANT LIST 27.4 OIL AND GREASING CHART OIL, GREASE LOCATIONS AND INSPECTION AND MAINTENANCE INTERVALS Check and add fluid if necessary Change or add oil Shows the number of places to add oil or grease Chart symbol Type of fluid Automatic transmission fluid Diesel engine oil Gasoline engine oil...
Page 122: Service Data
28. SERVICE DATA SERVICE DATA 28.1 AX SERVICE DATA – ALL MODELS FG15H(C)/18H-17 Component Inspection item Unit FG15S/18S-17 Engine model – NISSAN K21 (4-cyl) Idling speed Engine Maximum speed 2,950 Gasoline/Dual-fuel: 178/350 Compression psi/rpm LPG: 185/1,250 Lubricating oil 0.43 - 0.51 (11 - 13) Fan belt deflection in.(mm) cooling system...
Page 123: Bx Service Data - Gasoline/Lpg Engine
28. SERVICE DATA 28.2 BX SERVICE DATA – GASOLINE/LPG ENGINE FG20(C)/25(C)-14 FG20H/25H/30(C)(H)-14 Component Inspection item Unit FG20S/25S-14 FG20SH/25SH/30SH-14 NISSAN K21 Engine model – NISSAN K25 (4-cyl.) Idling speed Engine Maximum speed 2,950 2,900 Gasoline/Dual-fuel: 178/250 Compression psi/rpm LPG: 185/250 Lubricating oil 0.43 - 0.51 (11 - 13) Fan belt deflection in.
Page 124: Bx Service Data - Diesel Engine
28. SERVICE DATA 28.3 BX SERVICE DATA – DIESEL ENGINE Component Inspection item Unit FD20/25/30-14 Engine model – 4D94E Idling speed 675 - 725 Engine Maximum speed 2,650 - 2,750 psi/rpm 412 - 441 (min. 340)/250 Compression (MPa/rpm) (2.94/250) Lubricating oil 0.39 - 0.59 (10 - 15) Fan belt deflection in.(mm)
Page 125: Torque List
For unspecified bolts and nuts, use the torque specifications in this list. Select the proper torque corresponding to the width across flats (b) of bolts and nuts. When replacing bolts and nuts, always use genuine Komatsu Forklift parts that match the previous installation in size. Thread diameter...
Page 126: Periodic Replacement Of Safety Critical Parts
29. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS To ensure safety at all times when operating or driving the lift truck, the lift truck user must always carry out periodic maintenance. In addition, to further improve safety, the user should also perform periodic replacement of parts given in the table below.
Page 127: Maintenance Schedule Chart
30. MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART Perform maintenance at intervals of months or operation hours, whichever occurs first Service Item (gasoline/LPG/diesel engines) Page (#) Indicates Emissions-Related (EPA) Maintenance Service Items First month or initial 200 hours service (only after the first one month) Change oil in hydraulic tank, replace line filter, clean strainer, clean inside of tank 4-15 (#) Change oil in engine oil pan and replace engine oil filter cartridge (gasoline and diesel engines)
Page 128 30. MAINTENANCE SCHEDULE CHART Service Item (gasoline/LPG/diesel engines) Page (#) Indicates Emissions-Related (EPA) Maintenance Service Items Every month or every 200 hours service (continued) Check chain anchor bolt for deformation and damage 4-20 Check gear box for oil leakage, looseness of mount 4-20 Check mounting condition of power steering, check for looseness at connections 4-20...
Page 129 30. MAINTENANCE SCHEDULE CHART Service Item (gasoline/LPG/diesel engines) Page (#) Indicates Emissions-Related (EPA) Maintenance Service Items Every 500 hours service Change oil in engine oil pan and replace engine oil filter cartridge (gasoline engine) 4-16 (#) Drain water from fuel filter and replace fuel filter cartridge (diesel engine) 4-26 Every 3 months or every 600 hours service (#) Clean LPG filter...
Page 130 30. MAINTENANCE SCHEDULE CHART Service Item (gasoline/LPG/diesel engines) Page (#) Indicates Emissions-Related (EPA) Maintenance Service Items Every 2,000 hours service (#) Check and adjust fuel injection timing (diesel engine) 4-28 Replace LPG mixer air valve diaphragm, under normal operating conditions. Replace more often in cold 4-28 or severe service applications.
Page 131: Maintenance
10.6 U.S. gal. (40 L) (8.8 UK gal.) FG20SH/25SH/30SH-14 (BX) 6. Start the engine, then operate the cylinders (lift, tilt) to the end of their travel 5 or 6 times to bleed the air. NOTICE Always use genuine Komatsu Forklift hydraulic oil. 4-15...
Page 132 CHANGE ENGINE OIL (See illustration) 1. Remove the drain plug, drain the oil, then reinstall and tighten the drain plug. 2. Add the specified amount of genuine Komatsu Forklift engine oil. 3. Check the oil level with the dipstick. Oil refill amount: 1.0 US gal (3.8 L) (0.84 UK gal) REPLACE ENGINE OIL FILTER (See illustration) 1.
Page 133 31. MAINTENANCE n CHECK AIR CLEANER AND REPLACE FILTER IF DIRTY Never clean or replace air cleaner while the engine is running. • Do not replace an air filter on a diesel engine with a filter intended for a gasoline engine or vice-versa: radial seal style filters are NOT interchangeable between diesel and gasoline engines.
Page 134 1. Remove the oil filler plug, then remove the drain plug and drain the oil. 2. After draining the oil, reinstall and tighten the drain plug and add the specified amount of Komatsu Forklift oil through the oil filler. 3. After filling with new oil, check the oil level.
Page 135: Every 2 Weeks Or Every 100 Hours Service
31. MAINTENANCE Remark On clutch-type lift trucks, the oil is used for both the differential case and the transmission case. However, on the TORQFLOW transmission lift truck, each case has its own special oil, so it is necessary to check and change the oil in the TORQFLOW transmission case in addition to checking and changing the oil in the differ- ential case in two separate operations.
Page 136: Check Chain Anchor Bolt For Deformation And Damage
31. MAINTENANCE n CHECK CHAIN WHEEL BEARING FOR PLAY n CHECK CHAIN ANCHOR BOLT FOR DEFORMATION AND DAMAGE 31.3.4 STEERING SYSTEM n CHECK GEAR BOX FOR OIL LEAKAGE, LOOSENESS OF MOUNT n CHECK MOUNTING CONDITION OF POWER STEERING, CHECK FOR LOOSENESS AT CONNECTIONS n CHECK PEDALS FOR PLAY, LOOSENESS, DAMAGE AND WEAR 1.
Page 137: Check Oil Level In Torqflow Transmission, Add Oil As Necessary (Do Not Overfill)
3. After filling with oil, check the oil level. Do not overfill. TORQFLOW Trans Case Capacity TORQFLOW 12.5 qts (11.8 L) transmission (including (2.6 UK gal) torque converter) NOTICE Always use genuine Komatsu Forklift or DEXRON II Automatic Transmission Fluid. 4-21...
Page 138: Clean Inside Of Cooling System
• When not using glycol-based coolant, add rust prevention fluid to the radiator. • Always use genuine Komatsu Forklifts products for the flushing fluid, rust prevention fluid and gly- col-based coolant. n CHECK FOR CATCHING, STALLING AND KNOCKING WHEN ACCELERATING n CHECK AIR CLEANER AND REPLACE ELEMENT/FILTER IF DIRTY See “CHECK AIR CLEANER AND REPLACE FILTER IF DIRTY”...
Page 139: Check Radiator Hoses For Cracking, Damage
31. MAINTENANCE n (DIESEL ENGINE) DRAIN WATER FROM FUEL FILTER Loosen the combination sensor plug and drain any water and sediment accumulated at the bottom of the filter. NOTICE Fuel will also drain out of the fuel filter, so prepare a suitable con- tainer to catch it.
Page 140: Check Operation Of Starting Switch, Check Meshing Of Pinion Gear
31. MAINTENANCE 31.3.6 ELECTRICAL COMPONENTS n CHECK OPERATION OF STARTING SWITCH, CHECK MESHING OF PINION GEAR n CHECK SPECIFIC GRAVITY OF BATTERY ELECTROLYTE Precautions when handling battery: • Battery electrolyte is dangerous. If it gets into your eyes or on your skin or clothes, wash it off with large amounts of water quickly and seek medical attention immediately.
Page 141: Check Overhead Guard, Load Backrest For Deformation, Cracking, Damage And Looseness
31. MAINTENANCE 31.3.7 GENERAL n CHECK OVERHEAD GUARD, LOAD BACKREST FOR DEFORMATION, CRACKING, DAMAGE AND LOOSENESS n CHECK OPERATOR’S SEAT MOUNT FOR LOOSENESS AND DAMAGE, CHECK LPG CYLINDER MOUNTING BRACKET n GREASE ALL LUBRICATION POINTS 1. Mast support (left and right: 2 points) 2.
Page 142: Every 500 Hours Service
31. MAINTENANCE 31.4 EVERY 500 HOURS SERVICE n CHANGE OIL IN ENGINE OIL PAN AND REPLACE ENGINE OIL FILTER See procedure on page 4-16. n (DIESEL ENGINE) DRAIN WATER FROM THE FUEL FILTER AND REPLACE THE FUEL FILTER CARTRIDGE DRAIN FUEL FILTER (See illustration) Loosen the combination sensor plug and drain any water and sediment accumulated at the bottom of the filter.
Page 143: Every 3 Months Or Every 600 Hours Service
3. After filling with new oil, check the oil level. NOTICE Always use genuine Komatsu Forklift gear oil (SAE 90). See “LUBRICANT LIST” on page 4-2 for details. Remark On clutch-type lift trucks, the oil is used for both the differential case and the transmission case.
Page 144: Every 2,000 Hours Service
See procedure on page 4-18. n CLEAN TORQFLOW TRANSMISSION STRAINER See procedure on page 4-18. n REPLACE TORQUE CONVERTER OIL FILTER NOTICE Replace with genuine Komatsu Forklift oil filter. n CHANGE CLUTCH OIL 31.7.2 BRAKE SYSTEM n CHANGE BRAKE OIL/FLUID 31.7.3...
Page 145: Every 18 Months Or Every 3,600 Hours Service
31. MAINTENANCE n CHECK MOUNTING CONDITION OF DIFFERENTIAL n CHECK ROOT (BASE) OF FORKS FOR CRACKING (USE COLOR CHECK) n CHECK ROLLER SHAFT OF LOADING EQUIPMENT FOR CRACKING AND DAMAGE n CHECK MAST SUPPORT FOR DAMAGE AND WEAR 31.9.3 HYDRAULIC EQUIPMENT n CHECK OPERATION OF RELIEF VALVE, CHECK RELIEF PRESSURE n REPLACE AIR BREATHER 31.9.4...
Page 146: Replacement Procedures
32. REPLACEMENT PROCEDURES REPLACEMENT PROCEDURES 32.1 REPLACING FUSES AND RELAYS 32.1.1 CHASSIS FUSES (ALL TRUCKS) NOTICE • When replacing the fuses, always turn OFF the electric power first (turn the starting switch to the OFF position). • Always replace the fuses with a fuse of the same capacity. The CHASSIS fuses are used to protect the electrical components and wiring from burning out and are located in a fusebox located to the left of the steering column and below the dashboard panel of dials and gauges.
Page 147 32. REPLACEMENT PROCEDURES 32.1.2 ENGINE FUSES AND RELAYS K21 AND K25 ENGINES ONLY (BX GAS AND LP TRUCKS) NOTICE • When replacing the fuses, always turn OFF the electric power first (turn the starting switch to the OFF position). • Always replace the fuses with a fuse of the same capacity.
Page 148: Replacing Tires
32. REPLACEMENT PROCEDURES 32.2 REPLACING TIRES 1. Stop the lift truck on a flat, safe area and apply the parking brake. 2. Chock the wheel diagonally across from the wheel to be replaced. • After confirming that the rim mating bolts are tight, loosen the lug nuts (hub nuts). •...
Page 149: Replacing Lamps
32. REPLACEMENT PROCEDURES 32.3 REPLACING LAMPS Check for any blown fuses or disconnections in the wiring harnesses, and replace the lamps as necessary. Lamp capacity Head lamp 55 W (For 12 Volt) Turn signal lamp 23 W (For 12 Volt) Driving lamp 8 W (For 12 Volt) Tail lamp...
Page 150: Lift Truck Washing Procedure
33. LIFT TRUCK WASHING PROCEDURE LIFT TRUCK WASHING PROCEDURE 33.1 GENERAL PRECAUTIONS When washing your lift truck, observe the following instructions to safeguard the truck. Wet electrical equipment will result in the lift truck malfunctioning. • Before washing, ensure that the controller and all other electrical equipment sensitive to water is protected from water or removed prior to washing and blowing dry.
Page 151 33. LIFT TRUCK WASHING PROCEDURE Spot to Wash Washing Method Meter Panel • Wash from above by flushing with water from a hose. • Use low water pressure from the hose as illustrated below (parts 1 and 2 only). • Dashboard Front •...
Page 152 NOTES:...
Page 153: Technical Data
TECHNICAL DATA READ AND FOLLOW ALL SAFETY PRECAUTIONS. FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR DEATH.
Page 155: Technical Data - Ax/Bx Model Lift Trucks
34. TECHNICAL DATA - AX/BX MODEL LIFT TRUCKS TECHNICAL DATA - AX/BX MODEL LIFT TRUCKS 34.1 AX (GASOLINE/LPG ENGINES) Item Unit FG15H-17 FG18H-17 • PERFORMANCE Capacity lb (kg) 3,000 (1,361) 3,500 (1,588) Load center 24 (610) Max. lifting height in. (mm) 127.5 (3,239) Free lift 5.51 (140)
Page 156 34. TECHNICAL DATA - AX/BX MODEL LIFT TRUCKS AX (GASOLINE/LPG ENGINES) (Continued) Item Unit FG15H-17 FG18H-17 • PERFORMANCE Capacity lb (kg) 3,000 (1,361) 3,500 (1,588) Load center 24 (610) Max. lifting height in. (mm) 127.5 (3,239) Free lift 5.51 (140) Fork lifting speed (with load) in./s (mm/s) 27.0 (685)
Page 157: Bx (Diesel Engines)
34. TECHNICAL DATA - AX/BX MODEL LIFT TRUCKS 34.2 BX (DIESEL ENGINES) Item Unit FD20-14 FD25-14 FD30-14 • PERFORMANCE Capacity lb (kg) 4,000 (1,814) 5,000 (2,268) 6,000 (2,722) Load center 24 (610) Max. lifting height in. (mm) 127.5 (3,239) Free lift 5.7 (145) 6.0 (152) Fork lifting speed (with load)
Page 158: Bx (Gasoline/Lpg Engines)
34. TECHNICAL DATA - AX/BX MODEL LIFT TRUCKS 34.3 BX (GASOLINE/LPG ENGINES) Item Unit FG20-14 FG25-14 FG30-14 • PERFORMANCE Capacity lb (kg) 4,000 (1,814) 5,000 (2,268) 6,000 (2,722) Load center 24 (610) Max. lifting height in. (mm) 127.5 (3,239) Free lift 5.7 (145) 6.0 (152) Fork lifting speed (with load)
Page 159 34. TECHNICAL DATA - AX/BX MODEL LIFT TRUCKS BX (GASOLINE/LPG ENGINES) (Continued) Item Unit FG20H-14 FG25H-14 FG30H-14 • PERFORMANCE Capacity lb (kg) 4,000 (1,814) 5,000 (2,268) 6,000 (2,722) Load center 610 (24) Max. lifting height in. (mm) 127.5 (3,239) Free lift 5.7 (145) 6.0 (152) Fork lifting speed (with load)
Page 160 34. TECHNICAL DATA - AX/BX MODEL LIFT TRUCKS BX (GASOLINE/LPG ENGINES) (Continued) Item Unit FG20S-14 FG25S-14 • PERFORMANCE Capacity lb (kg) 4,000 (1,814) 5,000 (2,268) Load center 24 (610) Max. lifting height in. (mm) 127.5 (3,239) Free lift 5.7 (145) Fork lifting speed (with load) in./s (mm/s) 24.0 (610)
Page 161 34. TECHNICAL DATA - AX/BX MODEL LIFT TRUCKS BX (GASOLINE/LPG ENGINES) (Continued) Item Unit FG20SH-14 FG25SH-14 FG30SH-14 • PERFORMANCE Capacity lb (kg) 4,000 (1,814) 5,000 (2,268) 6,000 (2,722) Load center 24 (610) Max. lifting height in. (mm) 127.5 (3,239) Free lift 5.7 (145) 6.0 (152) Fork lifting speed (with load)
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