OM200

OPERATION & MAINTENANCE MANUAL

AX50/BX50 Series Forklift Trucks
AX50 FG15/18/20(A)(S)HT-20 675001A~/671578 - 672056 EPA Tier 2
672057~ CARB 2010

BX50 FG20/25/28/30/32(S)(H)T-16 S/N 200001A~ EPA Tier 1

S/N 210001A~ EPA Tier 2
FG35AHT-16 S/N 750875 - 751862 EPA Tier 2
S/N A224001~ EPA Tier 2/CARB 2010
S/N 751863~ CARB 2010

FD20/25/28/30/32T-16 S/N 200001A~/210001A~ EPA Tier 2

S/N A223001~/750875~ EPA Interim Tier 4
FD35AT-16

AX50
BX50

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.

REVISED: NOVEMBER 2012

 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 data plate, which is located
on the upper right side of the
dashboard.

The model code is described

by the Model Key below.

Data plate

Example Model Code: FG 30 HT LS

Code Position: 1 2 3 4

In the example above, the FG30HTLS lift truck has a load capacity of 6,000 pounds,
pneumatic tires, a high-performance gasoline/LPG engine, TORQFLOW transmission,
and anti-spark safety features.

Model Key

1 2 3 4

Load Capacity
Vehicle & Fuel Type Designations UL Safety Type
(Model = lbs)

FG = Gasoline 15 = 3,000 S = Cushion Tire LS = Anti-Spark Liquid

forklift (includes LP) (no “S” = Pneumatic Tire) Propane Special
18 = 3,500
FD = Diesel forklift H = High Performance
(BX only) 20 = 4,000
T = TORQFLOW-type power-shift
25 = 5,000 transmission with torque converter

30 = 6,000

32 = 6,500

35 = 7,000

7
 FOREWORD

READ AND FOLLOW ALL SAFETY PRECAUTIONS.

FAILURE TO DO SO MAY RESULT IN SERIOUS
INJURY OR DEATH.
 1. FOREWORD

1. FOREWORD
This manual provides rules and guidelines which will help you use this lift truck safely and effectively. Always be
sure to read and understand this manual thoroughly before operating and performing maintenance.
Some actions involved in operation and maintenance of the lift truck can cause a serious accident if they are not
done in the manner described in this manual.

• Improper operation and maintenance of this lift truck can be hazardous and could result in
serious injury or death.
• Operators and maintenance personnel should read this manual thoroughly before beginning
operation or maintenance.
• Keep this manual handy and have all personnel read it periodically.
• Do not use this lift truck unless you are sure that you understand the contents completely.
• If this manual has been lost or has become dirty or worn and cannot be read, request a
replacement manual from your 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. If this lift truck has been purchased in another country or purchased from someone in
another country, it may lack certain safety devices and specifications that are necessary for use
in your country. If there is any question about whether your product complies with the applicable
standards and regulations of your country, consult your Komatsu Forklift dealer before operating
the lift truck.
• Continuing improvements in the design of this lift truck may not be reflected in this manual.
Consult Komatsu Forklift or your Komatsu Forklift dealer for the latest available information on
your lift truck or for questions regarding information in this manual.
• Information on safety is given in “SAFETY INFORMATION” on page 1-2 as well as in Chapter 2,
“SAFETY.”

DIRECTION OF TRUCK
This manual uses the directions left, right, front and rear as they are seen from the operator's seat.

RIGHT

FRONT REAR

LEFT

1-1
2. SAFETY INFORMATION

2. SAFETY INFORMATION
This Operation and Maintenance Manual contains information necessary for the operation of a basic fork lift truck.
Optional equipment is sometimes installed that can change some operating characteristics described in this
manual. Make sure the necessary instructions are available and understood before operating the lift truck.

Some of the components and systems described in this Operation and Maintenance Manual will NOT be installed
on your unit. If you have a question about any item described, contact your local dealer.

Additional information that describes the safe operation and use of lift trucks is available from the following
sources:
• Employment safety and health standards or regulations.
• Safety codes and standards, such as: American National Standard, ANSI B56.1, Safety Standard For Low Lift
and High Lift Trucks.
• Publications from government safety agencies, government insurers, private insurers and private organiza-
tions, such as: Accident Prevention Manual for Industrial Operations from the National Safety Council, and
NFPA 58: Liquefied Petroleum Gas Code.

NOTE: Forklift trucks are not intended for use on public roads.

Most accidents are caused by a failure to follow fundamental safety rules for the operation and maintenance of lift
trucks. To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the lift
truck before operating and performing maintenance. Do not operate or carry out maintenance of this lift truck
unless you are sure that you understand the explanations and procedures completely.

To identify safety messages in this manual and on lift truck labels, the following signal words are used.

These safety messages or labels describe precautions that must be taken to

avoid a hazard which carries a serious risk of serious injury or death.

These safety messages or labels usually describe precautions that must be taken
to avoid a hazard which may lead to serious injury or death.

This word is used on safety messages and safety labels for hazards which could
result in injury or damage to the lift truck or surrounding property if the hazard is
not avoided.

NOTICE This word is used for precautions that may not lead to damage or failure, but which must be taken
to avoid actions that could shorten the life of the lift truck.

Safety precautions are described in the SAFETY, OPERATION and MAINTENANCE sections of this manual.

Komatsu Forklift cannot predict every circumstance that might involve a potential hazard in operation and
maintenance. Therefore the safety messages in this manual and on the lift truck may not include all possible safety
precautions.

If any procedures or actions not specifically recommended or allowed in this manual are used, it is your
responsibility to be sure that you and others can do such procedures and actions safely and without damaging the
lift truck. 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. In
no event should you or others engage in prohibited uses or actions as described in this manual.

1-2
 3. RUNNING IN A NEW LIFT TRUCK

3. RUNNING IN A NEW LIFT TRUCK

Your Komatsu forklift 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. Be sure to run in the lift truck, taking special care concerning the following items.
• Idle the engine for 5 minutes after starting it up.
• Avoid operation with heavy loads or at high speeds.
• Avoid sudden starting or acceleration, unnecessarily abrupt braking and sharp turning, except in the case of
emergency.

FIRST MONTH SERVICE OR INITIAL 200 HOURS SERVICE

For new lift trucks, carry out the following maintenance only after the first month or 200 hours of operation.

Unit Check items Remarks

Change oil

Replace oil filter element

Engine
Drain water from fuel filter Diesel engine lift truck only

Adjust valve clearance

Change oil
TORQFLOW transmission
Clean strainer and change filter

Differential Change oil

Change oil

Replace line filter

Hydraulic tank
Clean strainer

Clean inside tank

Particularly hub nuts, overhead guard

Other Tighten all bolts and nuts mounting bolts, load backrest mounting
bolts, and operator's seat mounting bolts

4. MODELS AND SERIAL NUMBERS

Model Series EPA Compliance Serial Number Range
Tier 2 (Gas/LP) 675001A~ / 671578 - 672056
FG15/18/20(A)(S)HT-20 AX50
CARB 2010 672057~
FG20/25/28/30/32(S)(H)T-16 Tier 1 (Gas/LP) 200001A~
FG35AHT-16 Tier 2 (Gas/LP) 210001A~
BX50
FD20/25/28/30/32T-16 Tier 2 (Diesel) 200001A~
FD35AT-16 Interim Tier 4 (Diesel) 210001A~
BX50 MODELS MANUFACTURED AFTER 2009
FG20/25/28/30/32(S)(H)T-16 Tier 2 (Gas/LP) A224001~ / 750875 - 751862
FG35AHT-16 CARB 2010 (Gas/LP) A224001~ / 751863~
BX50
FD20/25/28/30/32T-16
Interim Tier 4 (Diesel) A223001~ / 750875~
FD35AT-16

1-3
4. MODELS AND SERIAL NUMBERS

MODELS COVERED IN THIS MANUAL

MODELS COVERED IN THIS MANUAL

GASOLINE, LPG AND DUAL-FUEL ENGINE
AX50 CUSHION TIRE

FG15SHT-20 3,000 lb. capacity, K21 gasoline engine, cushion tires

FG15SHTLS-20 3,000 lb. capacity, K21 gasoline engine, cushion tires, LP special
FG18SHT-20 3,500 lb. capacity, K21 gasoline engine, cushion tires
FG18SHTLS-20 3,500 lb. capacity, K21 gasoline engine, cushion tires, LP special
FG20ASHT-20 4,000 lb. capacity, K21 gasoline engine, cushion tires
FG20ASHTLS-20 4,000 lb. capacity, K21 gasoline engine, cushion tires, LP special

AX50 PNEUMATIC TIRE

FG15HT-20 3,000 lb. capacity, K21 gasoline engine, pneumatic tires

FG15HTLS-20 3,000 lb. capacity, K21 gasoline engine, pneumatic tires, LP special
FG18HT-20 3,500 lb. capacity, K21 gasoline engine, pneumatic tires
FG18HTLS-20 3,500 lb. capacity, K21 gasoline engine, pneumatic tires, LP special
FG20AHT-20 4,000 lb. capacity, K21 gasoline engine, pneumatic tires
FG20AHTLS-20 4,000 lb. capacity, K21 gasoline engine, pneumatic tires, LP special

BX50 CUSHION TIRE

FG20ST-16 4,000 lb. capacity, K21 gasoline engine, cushion tires

FG20STLS-16 4,000 lb. capacity, K21 LPG engine, cushion tires, LP special
FG20SHT-16 4,000 lb. capacity, K25 gasoline engine, cushion tires
FG20SHTLS-16 4,000 lb. capacity, K25 gasoline engine, cushion tires, LP special
FG25ST-16 5,000 lb. capacity, K21 gasoline engine, cushion tires
FG25STLS-16 5,000 lb. capacity, K21 LPG engine, cushion tires, LP special
FG25SHT-16 5,000 lb. capacity, K25 gasoline engine, cushion tires
FG25SHTLS-16 5,000 lb. capacity, K25 LPG engine, cushion tires, LP special
FG28SHT-16 5,500 lb. capacity, K25 gasoline engine, cushion tires
FG28SHTLS-16 5,500 lb. capacity, K25 LPG engine, cushion tires, LP special
FG30SHT-16 6,000 lb. capacity, K25 gasoline engine, cushion tires
FG30SHTLS-16 6,000 lb. capacity, K25 LPG engine, cushion tires, LP special
FG32SHT-16 6,500 lb. capacity, K25 gasoline engine, cushion tires
FG32SHTLS-16 6,500 lb. capacity, K25 LPG engine, cushion tires, LP special

BX50 PNEUMATIC TIRE

FG20T-16 4,000 lb. capacity, K21 gasoline engine, pneumatic tires

FG20TUS-16 4,000 lb. capacity, K21 gasoline engine, pneumatic tires, gasoline special

1-4
 4. MODELS AND SERIAL NUMBERS

MODELS COVERED IN THIS MANUAL (Continued)

FG20TLS-16 4,000 lb. capacity, K21 LPG engine, pneumatic tires, LP special
FG20HT-16 4,000 lb. capacity, K25 gasoline engine, pneumatic tires
FG20HTUS-16 4,000 lb. capacity, K25 gasoline engine, pneumatic tires, gasoline special
FG20HTLS-16 4,000 lb. capacity, K25 LPG engine, pneumatic tires, LP special
FG25T-16 5,000 lb. capacity, K21 gasoline engine, pneumatic tires
FG25TUS-16 5,000 lb. capacity, K21 gasoline engine, pneumatic tires, gasoline special
FG25TLS-16 5,000 lb. capacity, K21 LPG engine, pneumatic tires, LP special
FG25HT-16 5,000 lb. capacity, K25 gasoline engine, pneumatic tires
FG25HTUS-16 5,000 lb. capacity, K25 gasoline engine, pneumatic tires, gasoline special
FG25HTLS-16 5,000 lb. capacity, K25 LPG engine, pneumatic tires, LP special
FG28HT-16 5,500 lb. capacity, K25 gasoline engine, pneumatic tires
FG28HTUS-16 5,500 lb. capacity, K25 gasoline engine, pneumatic tires, gasoline special
FG28HTLS-16 5,500 lb. capacity, K25 LPG engine, pneumatic tires, LP special
FG30HT-16 6,000 lb. capacity, K25 gasoline engine, pneumatic tires
FG30HTUS-16 6,000 lb. capacity, K25 gasoline engine, pneumatic tires, gasoline special
FG30HTLS-16 6,000 lb. capacity, K25 LPG engine, pneumatic tires, LP special
FG32HT-16 6,500 lb. capacity, K25 gasoline engine, pneumatic tires
FG32HTUS-16 6,500 lb. capacity, K25 gasoline engine, pneumatic tires, gasoline special
FG32HTLS-16 6,500 lb. capacity, K25 LPG engine, pneumatic tires, LP special
FG35AHT-16 7,000 lb. capacity, K25 gasoline engine, pneumatic tires
FG35AHTUS-16 7,000 lb. capacity, K25 gasoline engine, pneumatic tires, gasoline special
FG35AHTLS-16 7,000 lb. capacity, K25 LPG engine, pneumatic tires, LP special
BX50 DIESEL ENGINE
FD20T-16 4,000 lb. capacity, 4D98E diesel engine, pneumatic tires
FD20TUS-16 4,000 lb. capacity, 4D98E diesel engine, pneumatic tires, diesel special
FD25T-16 5,000 lb. capacity, 4D98E diesel engine, pneumatic tires
FD25TUS-16 5,000 lb. capacity, 4D98E diesel engine, pneumatic tires, diesel special
FD28T-16 5,500 lb. capacity, 4D98E diesel engine, pneumatic tires
FD28TUS-16 5,500 lb. capacity, 4D98E diesel engine, pneumatic tires. diesel special
FD30T-16 6,000 lb. capacity, 4D98E diesel engine, pneumatic tires
FD30TUS-16 6,000 lb. capacity, 4D98E diesel engine, pneumatic tires. diesel special
FD32T-16 6,500 lb. capacity, 4D98E diesel engine, pneumatic tires
FD32TUS-16 6,500 lb. capacity, 4D98E diesel engine, pneumatic tires, diesel special
FD35AT-16 7,000 lb. capacity, 4D98E diesel engine, pneumatic tires
FD35ATUS-16 7,000 lb. capacity, 4D98E diesel engine, pneumatic tires, diesel special

1-5
5. WARRANTY AND SERVICE FOR NEW LIFT TRUCK

5. WARRANTY AND SERVICE FOR NEW LIFT TRUCK

5.1 WHEN 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.

5.2 CAPACITY DATA PLATE LOCATION

Located on the upper right side of the dashboard.

Data plate

For insight on how to read the load capacity chart

on the data plate, see “LOAD CENTER AND
ACTUAL CAPACITY” on page 2-26.

5.3 EMBOSSED SERIAL NO. LOCATION

Stamped on top of the left front fender of the lift
truck.

NOTICE

Take care not to damage or remove the

embossed serial number.

Remark
The serial number can also be found on the
capacity data plate.

1-6
 5. WARRANTY AND SERVICE FOR NEW LIFT TRUCK

5.4 EMBOSSED ENGINE SERIAL NO. LOCATION

The engine serial number is stamped in the position shown below.

• K21/K25 GASOLINE ENGINE

• 4D98E DIESEL ENGINE

5.5 KOMATSU FORKLIFT GENUINE PARTS

Komatsu Forklift genuine parts are manufactured from the same
materials and by the same method as the parts built in the new lift
truck.
In the event that the customer uses imitation parts, Komatsu Forklift
will not be held accountable for any faults or failures which result
from the use of such imitation parts, and the Komatsu Forklift
warranty will not be applicable.
Always use Komatsu Forklift genuine parts when replacing parts.

1-7
 PRODUCT WARRANTY – CLASS I, IV AND V
ICE & ELECTRIC SIT-DOWN TRUCKS
Komatsu Forklift U.S.A., LLC (hereinafter called KFI OBLIGATION 2. In no event shall the dealer, its customers or
KFI) warrants new equipment to be free from users be entailed to recover incidental or
defects in materials and workmanship under the KFI shall have the obligation to repair or replace, consequential damages, including, but not
conditions of the following provisions. at KFI's option, any defect in material or work- limited to, damages or inconvenience,
manship at no charge, by authorized KFI dealer, rental or replacement equipment, loss of
STANDARD WARRANTY during the specified warranty period. profits, or other commercial loss.
KFI Standard Warranty for new equipment shall LIMITATIONS AND EXCLUSIONS 3. KFI neither assumes nor authorizes any
be (12) months or the first 2,000 operating hours other to assume for it any other liability in
after delivery to the initial purchaser, rental or This warranty is not applicable to or inclusive of connection with the sale or service of the
any of the following: equipment.
lessee, whichever event shall occur first.
5. WARRANTY AND SERVICE FOR NEW LIFT TRUCK

1. Equipment which has been subjected to 4. No modifications, alterations or changes of

POWER TRAIN PROTECTION alterations and/or modifications not this limited warranty is permitted or autho-
WARRANTY approved in writing from KFI, neglect, unau- rized by KFI-approved dealer.
thorized repair, misuse, accidents, lack of
KOMATSU PRODUCT WARRANTY

KFI warrants the following major components for reasonable proper maintenance, normal 5. Some states prohibit exclusion or limitation
a period of 730 days or the first 4,000 operating adjustments, improper repairs or replace- of implied warranty of merchantability or fit-
hours after delivery to the initial purchaser, ments, use of parts which do not conform to ness for a particular purpose, and/or inci-
rental, or lessee, whichever shall occur first. KFI's specifications. dental or consequential damages, so you
may have additional rights.
1. Internal combustion equipment 2. Normal replacement of any and all consum-
a. Engine (excluding all accessories and able parts such as, but not limited to light Truck Model
consumable trade parts) bulbs, filter elements, hoses, lubricating and
b. Torqflow and standard transmissions hydraulic oil, and/or parts required to per- Serial Number
form a regular maintenance service.
(excluding dry clutch and components) Company
c. Torque converter assembly 3. Tires and tubes.
City & State
d. Differential and drive axle (excluding 4. Batteries for battery-powered trucks.
brake assembly) Delivery Date
5. Attachments, components, parts or acces-
sories of products or equipment not manu- Delivering Dealer
2. Battery-powered equipment
factured by KFI.
a. Electric Motors (excluding sensors and
brushes) 6. Used products or equipment. EPA PRODUCTS
b. AC Drive Control Panel (excluding Refer to the applicable Federal EPA warranty cer-
LIMITED LIABILITY
fuses) tificate for emission control warranty statements:
1. Any and all other express, statutory, and
c. Contactor Panel (excluding contact tips implied warranties applicable to the prod- Gasoline/LPG engine EPAGAS2010-1
& switches) uct, including, without limitation, all implied EPAGAS2007-1
d. Differential and drive axle (excluding warranties of merchantability and fitness for
use, are expressly disclaimed. Diesel engine EPADSL2004-1
brakes)
Class I, IV and V ICE & Electric Sit-down Trucks – U.S.A. Komatsu Forklift U.S.A., LLC KPWCERT-STD-3

5.6

1-8
5. WARRANTY AND SERVICE FOR NEW LIFT TRUCK

1-9
CALIFORNIA AND U.S. FEDERAL EMISSION CONTROL WARRANTY
STATEMENT (GASOLINE/LPG ENGINES)
EMISSION CONTROL WARRANTY FOR GAS ENGINES

The following statement is required to be provided by OWNER’S WARRANTY EMISSION CONTROL WARRANTY -
regulations of the California Air Resources Board and RESPONSIBILITIES: 36 MONTHS or 2,500 HOURS FOR
U.S. Environmental Protection Agency. GENERAL PARTS
As the off-road LSI engine owner, you are responsible
YOUR WARRANTY RIGHTS AND for the performance of the required maintenance listed
For the first 2,500 operating hours or for a period of
OBLIGATIONS in your Operation and Maintenance Manual.
thirty-six months from the date of the first use by the
original purchaser from an Authorized Komatsu Forklift
The California Air Resources Board (CARB) and U.S. Dealer, whichever occurs first, Komatsu Forklift
Environmental Protection Agency (EPA) are pleased Komatsu Forklift recommends that you retain receipts warrants the following emission-related parts.
to explain the emission control system warranty on covering maintenance on your off-road engine, but • Oxygen sensor
your 2010 engine. New off-road large spark-ignition Komatsu Forklift cannot deny warranty solely for the • PCV valve
(LSI) engines must be designed, built and equipped to lack of receipts or for your failure to ensure the • Water temperature sensor
meet the nationwide stringent anti-smog standards. performance of all scheduled maintenance. • Gasoline injector
• LPG injector
Komatsu Forklift U.S.A., LLC must warrant the As the off-road large spark-ignition engine owner, you • LPG pressure sensor
emission control system on your engine for the periods should however be aware that Komatsu Forklift may • LPG solenoid
of time listed below provided there has been no abuse, deny you warranty coverage if your off-road large • Mass air flow sensor
neglect or improper maintenance of your engine. • Throttle chamber
spark-ignition engine or a part thereof has failed due to
abuse, neglect, improper maintenance or unapproved • Ignition coil
Your emission control system may include parts such
modifications. • Crankshaft position sensor
as the carburetor, regulator or fuel-injection system,
ignition system, engine computer unit (ECM), catalytic • Camshaft position sensor
converter and air induction system. Your engine is designed to operate on gasoline or LPG • Spark plugs
fuel. Use of any other fuel may result in your engine no • Exhaust tube from manifold to catalytic converter
Also included may be sensors, hoses, belts, longer operating in compliance with the emissions • Gasoline fuel hose
connectors and other emission-related assemblies. requirements. • Gasoline fuel cap
• Absolute pressure sensor
Where a warrantable condition exists, an Authorized You are responsible for initiating the warranty process.
Komatsu Forklift Dealer will repair your LSI engine at The ARB and U.S. EPA suggest that you present your
EMISSION CONTROL WARRANTY -
no cost to you including diagnosis, parts and labor. off-road large spark-ignition engine to all Authorized
36 MONTHS or 4,000 HOURS FOR
Komatsu Forklift Dealer as soon as a problem exists. POWER TRAIN PARTS
MANUFACTURER’S WARRANTY • Intake manifold
COVERAGE: The warranty repairs should be completed by the
• Exhaust manifold
The 2010 off-road large spark-ignition engines are
Dealer as expeditiously as possible. LONG-TERM EMISSION CONTROL
warranted for the time periods as listed below. WARRANTY – 60 MONTHS or 3,500
If you have any questions regarding your warranty HOURS FOR GENERAL PARTS
If any emission-related part on your engine is rights and responsibilities, you should contact • ECM
defective, the part will be repaired or replaced by an Komatsu Forklift’s Product Support Department at • Catalytic converter
Authorized Komatsu Forklift Dealer. 1-847-437-5800. • Vaporizer
Class IV & V – U.S.A. Komatsu Forklift U.S.A., LLC EPAGAS2010-1 071310
5.7
 FEDERAL ENVIRONMENTAL PROTECTION AGENCY (EPA) EMISSION CONTROL
WARRANTY STATEMENT (DIESEL ENGINES)
EMISSION CONTROL WARRANTY FOR DIESEL ENGINES

The following statement is provided as required by regulations OWNER’S WARRANTY LIMITATIONS

of the United States Environmental Protection Agency (EPA).
RESPONSIBILITIES KFI is not responsible for resultant damages to an emission-
related part or component resulting from:
YOUR WARRANTY RIGHTS As the heavy-duty off-road engine owner, you are responsible
AND OBLIGATIONS for the performance of the required maintenance listed in • Any application or installation KFI deems improper as
explained in the Instruction Manual.
owner's manual (Instruction Manual). KFI recommends that
The Federal EPA and Komatsu Forklift U.S.A., LLC you retain all receipts and records covering the maintenance • Attachments, accessory items or parts not authorized for
(hereinafter referred to as "KFI") are pleased to explain the on your engine, but KFI cannot deny warranty solely for the use by KFI.
emission control system warranty on your 2004 or later Diesel lack of receipts and records or for your failure to ensure the • Improper off-road engine maintenance, repair or abuse.
heavy duty off-road engine. All new, heavy-duty off-road performance of all scheduled maintenance. For your • Owner's unreasonable delay in making the product
engines must be designed, built and equipped to meet the reference, the following is an emission control maintenance available after being notified of a potential product
EPA’s stringent anti-smog standards. KFI must warrant the schedule for certified Diesel engines. problem.
emission control system on your engine for the period of time
listed below, provided there has been no abuse, damage, This warranty is in addition to the KFI standard warranty
• Check oil level and coolant level – Every day
5. WARRANTY AND SERVICE FOR NEW LIFT TRUCK

neglect or improper maintenance of your engine. applicable to the off-road engine product involved.
• Change engine oil – AX/BX/EX: Every 500 hours Remedies under this warranty are limited to the provision of
Your emission control system may include parts such as fuel CX/DX: Every 200 hours material and services as specified herein. KFI is not
injection pump. Also included may be hoses, belts, connectors responsible for incidental or consequential damages, such as
and other emission-related assemblies. • Change lubricating oil filter – AX/BX/EX: Every 500 hours
downtime or lost use of the forklift truck.
CX/DX: Every 200 hours
Where a warrantable condition exists, an authorized Komatsu
• Change fuel filter – Every 500 hours
CUSTOMER ASSISTANCE –
dealer will repair the heavy-duty off-road engine at no cost to
the owner, including diagnosis, parts and labor.
EMISSION CONTROL SYSTEMS
• Initial adjustment of valve clearance – 200 hours WARRANTY
Now, KFI hereby certifies that diesel engines for lift trucks • Adjust valve clearance – Every 1,000 hours Komatsu Forklift aims to ensure that the Emission Control
produced in 2004 model year and after shall be regulated by Systems Warranty is properly administered. In the event that
Federal EPA exhaust gaseous regulations. The difference Keep records to show proof of compliance with the required you do not receive the warranty service to which you believe
between current and EPA-certified engines is only the label maintenance practices and intervals. you are entitled under the Emission Control Systems
attached on the engine. See available drawing and/or Warranty, call or write to your Komatsu Forklift Dealer.
illustration of emission label and its location. • As the heavy-duty off-road engine owner you should, how-
ever, be aware that KFI may deny your warranty coverage Authorized dealers are recommended for major maintenance
MANUFACTURER’S WARRANTY if your heavy-duty off-road engine or part has failed due to and repair work, as they are staffed with trained personnel,
proper tools and are aware of the latest maintenance methods
COVERAGE abuse, damage, neglect, improper maintenance or disap-
proved modifications. and procedures. Owners and others who desire to perform
Beginning January 1, 2004, heavy-duty off-road EPA engine their own work should purchase a service manual and obtain
emission-related components are warranted for a period of • Your engine is designed to operate on commercial diesel current service information from their KFI engine dealer.
(60) months or (3,000) hours of operation, whichever occurs fuel only. Use of any other fuel in our engine will result in
Follow the instructions in the Operations Manual concerning
first. If any emission-related part on your engine is defective, the engine operating in non-compliance with the Federal
any other maintenance programs not required for EPA
the part will be repaired or replaced by an authorized Komatsu EPA regulations.
compliance.
Forklift dealer. • You are responsible for initiating the warranty process. It is For questions and additional information concerning EPA
suggested that you present your heavy duty off-road Diesel Engine Exhaust Regulations, contact:
EMISSION RELATED PARTS engine to an authorized Komatsu dealer as soon as you
become aware that problem exists. The warranty repair Komatsu Forklift U.S.A., LLC
• Fuel Injection Pump
should be completed by the dealer as expeditiously as c/o Komatsu America Corp.
• Fuel Injection Nozzles possible. One Continental Towers
1701 W. Golf Rd.
• Turbocharger
If you have any questions regarding your warranty rights and Rolling Meadows, IL 60008
responsibilities, you should contact the authorized KFI dealer. (847) 437-5800
Class IV & V – U.S.A. Komatsu Forklift U.S.A., LLC EPADSL2004-1

1-10
5.8
 6. EMISSION CONTROL STATEMENTS

6. EMISSION CONTROL STATEMENTS

6.1 FEDERAL AND CALIFORNIA EMISSION CONTROL
STATEMENT FOR OFF-ROAD LSI (NON-DIESEL) ENGINES (K21/K25)
This section presents information concerning the correct labeling, warranty, parts and maintenance of K21 and K25
engines in order to comply with the EPA and CARB off-road, large-spark-ignition (LSI) engine regulations.

6.1.1 LABELS REQUIRED AND LABEL LOCATIONS

All “K” series engines will display the required identification label as follows.

• Location on K21/K25 Series engines:

• Emission compliance label (sample):

1-11
6. EMISSION CONTROL STATEMENTS

6.2 CALIFORNIA AND U.S. FEDERAL EMISSION CONTROL WARRANTY

STATEMENT
The following statement is required to be provided by regulations of the California Air Resources Board and US
Environmental Agency.

6.2.1 YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board (“ARB”) and US Envrionmental Protection Agency (“EPA”) are pleased to
explain the emission control system warranty on your 2012 engine. New off-road large spark-ignition (LSI) engines
must be designed, built and equipped to meet the nationwide stringent anti-smog standards.

Komatsu Forklift U.S.A., LLC must warrant the emission control system on your engine for the periods of time listed
below provided there has been no abuse, neglect or improper maintenance of your engine.

Your emission control system may include parts such as the carburetor, regulator or fuel-injection system, ignition
system, engine computer unit (ECM), catalytic converter and air induction system. Also included may be sensors,
hoses, belts, connectors and other emission-related assemblies.

Where a warrantable condition exists, an Authorized Komatsu Forklift Dealer will repair your LSI engine at no cost
to you including diagnosis, parts and labor.

6.2.2 MANUFACTURER’S WARRANTY COVERAGE:

The 2012 off-road large spark-ignition engines are warranted for the time periods as listed below.
If any emission-related part on your engine is defective, the part will be repaired or replaced by an Authorized
Komatsu Forklift Dealer.

6.2.3 OWNER’S WARRANTY RESPONSIBILITIES:

As the off-road LSI engine owner, you are responsible for the performance of the required maintenance listed in
your Operation and Maintenance Manual.

Komatsu Forklift recommends that you retain receipts covering maintenance on your off-road engine, but Komatsu
Forklift cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all
scheduled maintenance.

As the off-road large spark-ignition engine owner, you should however be aware that Komatsu Forklift may deny
you warranty coverage if your off-road large spark-ignition engine or a part thereof has failed due to abuse, neglect,
improper maintenance or unapproved modifications.

Your engine is designed to operate on gasoline or LPG fuel. Use of any other fuel may result in your engine no
longer operating in compliance with the emissions requirements.

You are responsible for initiating the warranty process. The ARB and EPA suggest that you present your off-road
large spark-ignition engine to an Authorized Komatsu Forklift Dealer as soon as a problem exists. The warranty
repairs should be completed by the Dealer as expeditiously as possible.

If you have any questions regarding your warranty rights and responsibilities, you should contact KFl’s Product
Support Department at:

Komatsu Forklift U.S.A., LLC

c/o Komatsu American Corp.
1701 W. Golf Rd.
Rolling Meadows, IL 60008
(847) 437-5800

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 6. EMISSION CONTROL STATEMENTS

6.2.4 EMISSION CONTROL WARRANTY -36 MONTHS OR 2,500 HOURS FOR

GENERAL PARTS
For the first 2,500 operating hours or for a period of thirty-six months from the date of the first use by the original
purchaser from an Authorized Komatsu Forklift Dealer, whichever occurs first, Komatsu Forklift warrants the
following emission-related parts.

• Oxygen sensor
• PCV valve
• Water temperature sensor
• Gasoline injector
• LPG injector
• LPG pressure sensor
• LPG solenoid
• Mass air flow sensor
• Throttle chamber
• Ignition coil
• Crankshaft position sensor
• Camshaft position sensor
• Spark plugs
• Exhaust tube from manifold to catalytic converter
• Gasoline fuel hose
• Gasoline fuel cap
• Absolute pressure sensor

6.2.5 EMISSION CONTROL WARRANTY – 36 MONTHS OR 4,000 HOURS FOR POWER

TRAIN PARTS
• Intake manifold
• Exhaust manifold

6.2.6 LONG-TERM EMISSION CONTROL WARRANTY – 60 MONTHS OR 3,500 HOURS

FOR GENERAL PARTS
• ECM
• Catalytic converter
• Vaporizer

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6. EMISSION CONTROL STATEMENTS

6.3 EPA CERTIFICATES OF CONFORMITY

K21 ENGINE - MODEL YEAR 2012

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 6. EMISSION CONTROL STATEMENTS

K25 ENGINE - MODEL YEAR 2012

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6. EMISSION CONTROL STATEMENTS

6.4 FEDERAL EPA EMISSION CONTROL STATEMENT FOR

OFF-ROAD DIESEL ENGINES (4D98E ENGINE)
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 4D98E diesel engines in order to comply with current EPA regulations.

6.4.1 LABELS REQUIRED AND LABEL LOCATIONS

All certified 4D98E diesel engines will display the required identification label as follows:

• 4D98E diesel engines: Labels will be affixed to all appropriate engines on Komatsu Forklift production trucks.

Emission control label location on 4D98E series diesel engines:

EMI
THIS SSI
FOR ENGINE ON
COMPL CON
LOW M.
WITH TRO
SULFU Y. NONROIES
ENGINE
R
ENGINE FAMILYFUEL AD/OFFU. S.
EPA
L INF
OR
ULTRA -ROAD AND
DIESELCALIFO ORM
FUEL MODEL :
REFERRATE : LOW
ADJUS TO : SULFU ENGINERNIA ATIO
REGUL
OWNER MM 3 R
ATIONS N
TMENT /STROK DISPLAFUEL S.
S 'S MANUA E @ EMISSI CEMEN
ONLY
L FOR kW ON T
MAINTE/ CONTR:
RPM OL
NANCE SYSTELITERS
SPECIF M :
ICATION
S AND

Emission
control label

0001102B-01

Sample emission control label:

EMISSION CONTROL INFORMATION

THIS ENGINE COMPLIES WITH U. S. EPA AND CALIFORNIA REGULATIONS
FOR 2011 M.Y. NONROAD/OFF-ROAD DIESEL ENGINES.
ULTRA LOW SULFUR FUEL ONLY
ENGINE FAMILY : 8YDXL3.32R4N DISPLACEMENT : 3.319 LITERS
ENGINE MODEL : 3VNNA EMISSION CONTROL SYSTEM : EM
FUEL RATE : 48.7 MM3/STROKE @ 44.8 kW / 2450 RPM (37 ≤ Kw < 56)
REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND
ADJUSTMENTS

021752-002

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 6. EMISSION CONTROL STATEMENTS

6.4.2 WARRANTY
The following statement is hereby provided as required by regulations of the United States Environmental
Protection Agency (EPA).

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The Federal EPA and Komatsu Forklift are pleased to explain the emission control system warranty on your 2008
or later Diesel heavy duty off-road engine. All new, heavy-duty off-road engines must be designed, built and
equipped to meet the EPA’s stringent anti-smog standards.

Komatsu Forklift must warrant the emission control system on your engine for the period of time listed below,
provided there has been no abuse, damage, neglect or improper maintenance of your engine.

Your emission control system may include parts such as fuel injection pump. Also included may be hoses, belts,
connectors and other emission-related assemblies.

Where a warrantable condition exists, an authorized Komatsu Forklift dealer will repair the heavy-duty off-road
engine at no cost to the owner, including diagnosis, parts and labor.

Now, Komatsu Forklift hereby certifies that diesel engines for lift trucks produced in 2008 model year and after shall
be regulated by Federal EPA exhaust gaseous regulations. The difference between current and EPA-certified
engines is only the label attached on the engine. See available drawing and/or illustration of emission label and its
location.

MANUFACTURER’S WARRANTY COVERAGE

Beginning January 1, 2008 heavy-duty off-road EPA engines are warranted for a period of five (5) years, or three-
thousand (3,000) hours of operation, whichever occurs first. If any emission-related part on your engine is
defective, the part will be repaired or replaced by at an authorized Komatsu Forklift dealer.

EMISSION-RELATED PARTS
• Fuel injection pump
• Fuel injection nozzles
• Turbocharger

OWNER’S WARRANTY RESPONSIBILITIES

As the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance
listed in this manual. Komatsu Forklift recommends that you retain all receipts and records covering the
maintenance on your engine, but Komatsu Forklift cannot deny warranty solely for the lack of receipts and records
or for your failure to ensure the performance of all scheduled maintenance. For your reference, the following is an
emission control maintenance schedule for certified Diesel engines.
• Check oil level and coolant level Every day
• Change of lubricating oil Every 200 hours
• Change lubricating oil filter Every 200 hours
• Initial adjustment of valve clearance 200 hours
• Change fuel filter Every 500 hours
• Check turbocharger, rebuild or replace if necessary Every 2,000 hours
• Adjust valve clearance Every 2,000 hours
• Check fuel injection nozzles, replace if necessary Every 2,000 hours

Keep records to show proof of compliance with the required maintenance practices and intervals.
• As the heavy-duty off-road engine owner you should, however, be aware that Komatsu Forklift may deny your
warranty coverage if your heavy-duty off-road engine or part has failed due to abuse, damage, neglect,
improper maintenance or disapproved modifications.
• Your engine is designed to operate on commercial diesel fuel only. Use of any other fuel in our engine will
result in the engine operating in non-compliance with the Federal EPA regulations.
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.
• If you have any questions regarding your warranty rights and responsibilities, you should contact your autho-
rized Komatsu Forklift dealer.

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6. EMISSION CONTROL STATEMENTS

LIMITATIONS
Komatsu Forklift is not responsible for resultant damages to an emission-related part or component resulting from:

• Any application or installation Komatsu Forklift deems improper as explained in this manual.
• Attachments, accessory items or parts not authorized for use by Komatsu Forklift.
• Improper off-road engine maintenance, repair or abuse.
• Owner's unreasonable delay in making the product available after being notified of a potential product problem.

This warranty is in addition to the Komatsu Forklift standard warranty applicable to the off-road engine product
involved.

Remedies under this warranty are limited to the provision of material and services as specified herein. Komatsu
Forklift is not responsible for incidental or consequential damages, such as downtime or lost use of the forklift truck.

CUSTOMER ASSISTANCE – EMISSION CONTROL SYSTEMS WARRANTY

Komatsu Forklift aims to ensure that the Emission Control Systems Warranty is properly administered. In the event
that you do not receive the warranty service to which you believe you are entitled under the 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. Owners and others who
desire to perform their own work should purchase a service manual and obtain current service information from
their Komatsu Forklift engine dealer.

NOTICE

Follow the instructions in this manual concerning any other maintenance programs not required for EPA
compliance.

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