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Komatsu BX20 User Manual

Komatsu BX20
162 pages
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Read and observe all warnings on this unit
before operating it.
DO NOT operate this equipment unless all
factory-installed guards and shields are properly
secured in place.
WARNING
OPERATION & MAINTENANCE MANUAL
AX20 and BX20 Forklift Trucks
Federal Environmental Protection Agency (EPA) Emission-Control Compliant
S/N 670001A~ and 580001A~
REVISED: FEBRUARY 2007
AX20
BX20
OM073R
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

Table of Contents

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Komatsu BX20 Specifications

General IconGeneral
ModelBX20
Power SourceElectric
Rated Capacity2000 kg
Load Center500 mm
CategoryForklifts
Maximum Lift Height3000 mm
Lift Height3000 mm
TransmissionElectric
Tire TypeSolid

Summary

OPERATION & MAINTENANCE MANUAL

AX20 and BX20 Forklift Trucks

Manual for AX20 and BX20 forklift trucks, EPA compliant.

2. SAFETY INFORMATION

4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK

4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK (Continued)

EPA Emission Control Statement for LSI Engines

EPA emission control statement for LSI engines.

Warranty Rights and Obligations for LSI Engines

Details of warranty rights and obligations for off-road LSI engines.

EPA Emission Control Statement for Diesel Engines

EPA emission control statement for 4D94E diesel engines.

8. EPA EMISSION CONTROL WARRANTY STATEMENT (GASOLINE/LPG)

9. EPA EMISSION CONTROL WARRANTY STATEMENT (DIESEL)

Warranty Rights and Obligations

Details of warranty rights and obligations for diesel engines.

SAFETY

General Safety Warning

General safety warning to read and follow all precautions.

10. SAFETY MANAGEMENT

Operation Manual and Safety Labels

Importance of reading and understanding manuals and safety labels.

Unauthorized Modification

Hazards and responsibilities related to unauthorized modifications.

10. SAFETY MANAGEMENT (Continued)

Fire Prevention for Fuel

Safety precautions for fuel handling and fire prevention.

LPG Safety and Fuel System Safety

Safety precautions for LPG fuel systems.

Defective Lift Truck Procedures

Procedures for handling defective lift trucks.

11. SAFE TRAVEL

Precautions When Starting Engine

Safety steps before starting the engine.

Directional and Speed Lever Precautions

Safe operation of directional and speed levers.

Tipping Hazards and Precautions

Dangers and precautions related to lift truck tipping.

11. SAFE TRAVEL (Continued)

Travel on Slopes Safety

Safe travel procedures when operating on slopes.

Always Sit in Operator's Seat

Importance of remaining seated while operating.

Safety During Travel

General safety guidelines for traveling.

Tip-Over Escape Procedures

Safety instructions if the lift truck tips over.

Pre-Operation Checks

Pre-operation checks.

Seat Belt Usage and Checks

Importance of wearing and checking the seat belt.

Safety When Starting

Safety measures before starting and moving.

Braking While Traveling Precautions

Precautions for braking while traveling.

Maintain Proper Posture

Importance of proper posture and operator presence system.

12. LOADING OPERATIONS

No Overloading Warning

Warning against exceeding the load capacity.

Do Not Go Under Forks

Danger of going under raised forks or loads.

Do Not Lift People on Forks

Prohibition of lifting people on forks.

Operate From Operator's Compartment

Requirement to operate from the operator's compartment.

12. LOADING OPERATIONS (Continued)

Be Careful Not to Get Caught or Fall

Precautions to avoid getting caught or falling.

Do Not Tilt Mast Forward When Loaded

Danger of tilting mast forward with load.

No Unstable Loads

Warning against handling unstable loads.

Do Not Load Above Load Backrest Height

Safety limits for load height.

Use Only for Intended Purposes

Restriction to intended uses of the lift truck.

Loading/Unloading Precautions

General precautions for loading and unloading.

13. STOPPING AND PARKING

Stopping and Parking Precautions

Steps for safely stopping and parking the lift truck.

Parking After Failure Procedures

Procedures for parking a failed machine.

14. INSPECTION AND MAINTENANCE

Qualified Personnel for Maintenance

Requirement for certified personnel for maintenance.

Inspection and Maintenance Precautions

General safety precautions before starting inspection.

Maintenance Safety Precautions

Specific safety precautions during maintenance.

14. INSPECTION AND MAINTENANCE (Continued)

High Pressure, High Temperature Oil Safety

Safety when dealing with hot, high-pressure oil.

Tire Inflation Safety

Safety procedures for checking and inflating tires.

Changing LPG Fuel Tanks

Safe procedures for changing LPG fuel tanks.

Periodic Replacement of Critical Parts

Need for periodic replacement of critical safety parts.

Avoid Getting Caught or Falling

Avoiding getting caught or falling during maintenance.

Battery Hazard Prevention

Safety measures for handling batteries.

High Temperature Coolant Precautions

Safety when handling hot coolant.

Jacking Up Lift Truck Procedures

Safe procedures for jacking up the lift truck.

Starting with Booster Cables

Safe procedures for jump-starting.

Washing Lift Truck with Water Precautions

Safety measures when washing the truck with water.

15. STRUCTURE AND STABILITY OF THE LIFT TRUCK

Center of Gravity and Stability

Factors determining lift truck stability.

15. STRUCTURE AND STABILITY OF THE LIFT TRUCK (Continued)

Stable Range of Center of Gravity

Definition of the stable range for the center of gravity.

Speed and Acceleration Effects on Stability

Effects of speed and acceleration on stability.

Maximum Load and Load Center

Relationship between maximum load and load center.

Allowable Load Determination

How allowable load is determined by nameplate data.

16. SAFETY LABELS

16. SAFETY LABELS (Continued)

General Operation Warning Decal

General operation warnings and precautions.

LPG/Flammable Gas Handling Warning

Warning for handling LPG and flammable gas.

Fork Riding and Under-Fork Warning

Warnings against riding on forks or entering under them.

Mast Hand Catch Warning

Warning to avoid getting hands caught in the mast.

Tip-Over Prevention Decal

Decal showing tip-over prevention measures.

OPERATION

General Operation Safety Warning

General warning to follow safety precautions.

17. OVERVIEW OF LIFT TRUCK (Continued)

Instruments and Controls Diagram

Diagram of the lift truck's instruments and controls with labels.

Meter Panel Components

Detailed view of the meter panel components and indicators.

18. EXPLANATION OF COMPONENTS

Instruments and Controls Explanation

Detailed explanation of instruments and controls.

Lift Lever Operation

Explanation of the lift lever's function and operation.

Tilt Lever Operation

Explanation of the tilt lever's function and operation.

18. EXPLANATION OF COMPONENTS (Continued)

Operator Presence System Troubleshooting

Troubleshooting guide for the operator presence system.

Starting Switch Operation

Operation of the starting switch for engine start/stop.

Neutral/Travel Interlock Indicator

Indicates neutral safety and travel interlock status.

Operator Presence Switch

Function of the operator presence switch.

19. REMOVAL AND INSTALLATION OF ATTACHMENTS

Safety Precautions for Attachments

General safety precautions for handling attachments.

20. OPERATOR’S COMPARTMENT

Adjusting Seat Position

How to adjust the operator's seat position for comfort and safety.

20. OPERATOR’S COMPARTMENT (Continued)

Fitting and Releasing Seat Belt

Proper use of the seat belt.

22. TRAVEL OPERATIONS

Check Before Operation

Pre-operation checks for safe travel.

Pre-Start Checks

Checks to perform before starting the engine.

22. TRAVEL OPERATIONS (Continued)

Turning Precautions

Safety precautions when turning the lift truck.

Battery Electrolyte Level Check

Procedure to check battery electrolyte level.

Starting Engine Procedure

Step-by-step procedure for starting the engine.

Starting and Inching on Slope

Procedures for starting and inching on slopes.

Temporary Stopping and Parking

Procedures for temporarily stopping and parking.

Load Handling Operation

General information on load handling.

Unloading Procedure

Step-by-step guide for unloading operations.

Hydraulic Tank Oil Level Check

Procedure to check hydraulic oil level.

Loading Procedure

Step-by-step guide for loading operations.

Brake Reservoir Oil Level Check

Procedure to check brake fluid level.

Clutch Reservoir Oil Level Check

Procedure to check clutch fluid level.

23. COLD WEATHER OPERATION

23. COLD WEATHER OPERATION (Continued)

24. HANDLING IN HEAVY-DUTY CONDITIONS

Engine Overheating Actions

Steps to take when the engine overheats.

25. LONG-TERM STORAGE

MAINTENANCE

Maintenance Safety Warning

General safety warning for maintenance tasks.

27. LUBRICANT LIST

27. LUBRICANT LIST (Continued)

29. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

30. MAINTENANCE SCHEDULE CHART

First Month or Initial 200 Hours Service

Maintenance tasks for the first month or 200 hours.

30. MAINTENANCE SCHEDULE CHART (Continued)

31. MAINTENANCE

Initial 200 Hours Service

Initial maintenance for new lift trucks.

31. MAINTENANCE (Continued)

Engine Oil and Filter Replacement

Engine oil and filter replacement procedures.

Engine Oil and Filter Change

Procedure for changing engine oil and filter.

Diesel Fuel Filter Water Drain/Cartridge Replacement

Draining fuel filter and replacing cartridge.

32. REPLACEMENT PROCEDURES

32. REPLACEMENT PROCEDURES (Continued)

Replacing Tires Procedure

Step-by-step procedure for replacing tires.

TECHNICAL DATA

Technical Data Safety Warning

General safety warning for technical data.

34. TECHNICAL DATA - AX/BX MODEL LIFT TRUCKS

AX (Gasoline/LPG Engines) Specifications

Performance and dimension data for AX gasoline/LPG models.

34. TECHNICAL DATA - AX/BX MODEL LIFT TRUCKS (Continued)

AX (Gasoline/LPG Engines) Continued

Continued performance and dimension data for AX models.

BX (Diesel Engines) Specifications

Performance and dimension data for BX diesel models.

BX (Gasoline/LPG Engines) Specifications

Performance and dimension data for BX gasoline/LPG models.

BX (Gasoline/LPG Engines) Continued

Further performance and dimension data for BX gasoline/LPG models.

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