Komatsu AX20 Series Manual

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

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.
WARNING: Breathing diesel engine exhaust exposes you to
chemicals known to the State of California to cause cancer and birth
defects or other reproductive harm.
• Always start and operate the engine in a well-ventilated area.
• If in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel
WARNING: This product can expose you to chemicals including
lead, which is known to the State of California to cause cancer and
birth defects or other reproductive harm.
For more information go to www.P65warnings.ca.gov

The information and specifications contained herein were accurate at the time of
publication, but may change without notice as required for product improvements.
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.
© Copyright 2011, Komatsu Forklift USA, LLC. All rights reserved. No part of this
document may be photocopied or reproduced in any way without prior written consent of
Komatsu Forklift USA, LLC.

CONTENTS
3
CONTENTS
FOREWORD
1. FOREWORD ................................................................................................................... 1-1
2. SAFETY INFORMATION ................................................................................................ 1-2
3. RUNNING IN A NEW LIFT TRUCK ................................................................................ 1-3
3.1 RUNNING IN A NEW LIFT TRUCK..............................................................................................1-3
3.2 FIRST MONTH OF SERVICE (OR INITIAL 200 HOURS OF SERVICE).....................................1-3
3.3 MODEL LINE UP ..........................................................................................................................1-4
4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK .................................................. 1-5
4.1 GENUINE KOMATSU FORKLIFT PARTS ...................................................................................1-5
4.2 FEDERAL EPA EMISSION CONTROL STATEMENT
FOR OFF-ROAD LSI (NON-DIESEL) ENGINES (K21 AND K25 ENGINES) ...........................1-6
4.3 FEDERAL EPA EMISSION CONTROL STATEMENT FOR
OFF-ROAD DIESEL ENGINES (4D94E ENGINES) .................................................................1-9
5. LOCATION OF PLATES AND SERIAL NUMBER ....................................................... 1-12
5.1 UL (UNDERWRITERS LABORATORIES) PLATE .....................................................................1-12
5.2 EMBOSSED VEHICLE SERIAL NUMBER.................................................................................1-12
5.3 CAPACITY DATA PLATE WITH VEHICLE SERIAL NUMBER..................................................1-12
5.4 ENGINE SERIAL NUMBER........................................................................................................1-12
6. CONTACTING KOMATSU FORKLIFT......................................................................... 1-13
7. MODEL CODING SYSTEM........................................................................................... 1-14
8. EPA EMISSION CONTROL WARRANTY STATEMENT (GASOLINE/LPG) .............. 1-15
9. EPA EMISSION CONTROL WARRANTY STATEMENT (DIESEL)............................. 1-16
SAFETY
10. SAFETY MANAGEMENT ............................................................................................... 2-1
11. SAFE TRAVEL................................................................................................................ 2-6
12. LOADING OPERATIONS ............................................................................................. 2-14
13. STOPPING AND PARKING.......................................................................................... 2-20
14. INSPECTION AND MAINTENANCE ............................................................................ 2-21
15. STRUCTURE AND STABILITY OF THE LIFT TRUCK................................................ 2-28
16. SAFETY LABELS ......................................................................................................... 2-31
OPERATION
17. OVERVIEW OF LIFT TRUCK ......................................................................................... 3-1

CONTENTS
4
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 FORKS .......................................................................................................................................3-13
19.3 CARRIAGE.................................................................................................................................3-14
19.4 MAST..........................................................................................................................................3-14
19.5 SIDE SHIFT, FORK POSITIONER AND CLAMP ATTACHMENTS...........................................3-15
20. OPERATOR’S COMPARTMENT ................................................................................. 3-16
20.1 ADJUSTING THE SEAT POSITION ..........................................................................................3-16
20.2 ADJUSTING THE RECLINING ANGLE .....................................................................................3-16
20.3 ADJUSTING THE SUSPENSION ..............................................................................................3-17
20.4 FITTING AND RELEASING THE SEAT BELT ...........................................................................3-17
21. ENGINE HOOD ............................................................................................................. 3-18
21.1 OPENING THE ENGINE HOOD ................................................................................................3-18
21.2 CLOSING THE ENGINE HOOD.................................................................................................3-19
21.3 FORK STOPPER .......................................................................................................................3-19
22. TRAVEL OPERATIONS ............................................................................................... 3-20
22.1 CHECK BEFORE OPERATION .................................................................................................3-20
22.2 MOUNTING/DISMOUNTING .....................................................................................................3-29
22.3 TRAVELING ...............................................................................................................................3-30
22.4 STARTING AND INCHING ON SLOPE .....................................................................................3-34
22.5 TURNING ...................................................................................................................................3-35
22.6 TEMPORARY STOPPING AND PARKING ...............................................................................3-36
22.7 FORK SPREAD ADJUSTMENT.................................................................................................3-37
22.8 LOAD HANDLING OPERATION ................................................................................................3-38
22.9 CHECK AFTER OPERATION ....................................................................................................3-42
23. COLD WEATHER OPERATION................................................................................... 3-43
23.1 PREPARATIONS FOR LOW TEMPERATURE .........................................................................3-43
23.2 PRECAUTIONS AFTER COMPLETING OPERATIONS ...........................................................3-44
24. HANDLING IN HEAVY-DUTY CONDITIONS ............................................................... 3-45
24.1 PRECAUTIONS WHEN USING IN HEAVY-DUTY CONDITIONS .............................................3-45
24.2 CLEAN INSIDE OF COOLING SYSTEM ...................................................................................3-45
24.3 CLEAN RADIATOR FINS ...........................................................................................................3-45
24.4 CHECK FAN BELT TENSION....................................................................................................3-45
24.5 ACTION WHEN ENGINE HAS OVERHEATED .........................................................................3-45
25. LONG-TERM STORAGE .............................................................................................. 3-46

CONTENTS
5
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 – GASOLINE/LPG ENGINE ...................................................................................................4-3
27.3 BX – DIESEL ENGINE .................................................................................................................4-4
27.4 OIL AND GREASING CHART ......................................................................................................4-5
28. SERVICE DATA .............................................................................................................. 4-6
28.1 AX SERVICE DATA – ALL MODELS ...........................................................................................4-6
28.2 BX SERVICE DATA – GASOLINE/LPG ENGINE ........................................................................4-7
28.3 BX SERVICE DATA – DIESEL ENGINE ......................................................................................4-8
28.4 TORQUE LIST..............................................................................................................................4-9
29. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..................................... 4-10
30. MAINTENANCE SCHEDULE CHART.......................................................................... 4-11
31. MAINTENANCE ............................................................................................................ 4-15
31.1 FIRST ONE MONTH OR INITIAL 200 HOURS SERVICE .........................................................4-15
31.2 EVERY 2 WEEKS OR EVERY 100 HOURS SERVICE .............................................................4-19
31.3 EVERY MONTH OR EVERY 200 HOURS SERVICE ................................................................4-19
31.4 EVERY 500 HOURS SERVICE..................................................................................................4-26
31.5 EVERY 3 MONTHS OR EVERY 600 HOURS SERVICE...........................................................4-27
31.6 EVERY 1,000 HOURS SERVICE (EPA AND DIESEL ENGINES).............................................4-27
31.7 EVERY 6 MONTHS OR EVERY 1,200 HOURS SERVICE........................................................4-27
31.8 EVERY 2,000 HOURS SERVICE...............................................................................................4-28
31.9 EVERY YEAR OR EVERY 2,400 HOURS SERVICE ................................................................4-28
31.10 EVERY 18 MONTHS OR EVERY 3,600 HOURS SERVICE......................................................4-29
32. REPLACEMENT PROCEDURES ................................................................................. 4-30
32.1 REPLACING FUSES AND RELAYS ..........................................................................................4-30
32.2 REPLACING TIRES ...................................................................................................................4-32
32.3 REPLACING LAMPS..................................................................................................................4-33
33. LIFT TRUCK WASHING PROCEDURE ....................................................................... 4-34
33.1 GENERAL PRECAUTIONS........................................................................................................4-34
33.2 WASHING INSTRUCTIONS.......................................................................................................4-34

CONTENTS
6
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

READ AND FOLLOW ALL SAFETY PRECAUTIONS.
FAILURE TO DO SO MAY RESULT IN SERIOUS
INJURY OR DEATH.
FOREWORD