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

1. FOREWORD
1-1
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 the SAFETY, OPERATION and MAINTENANCE sections
throughout this manual; please read it carefully and completely.

2. SAFETY INFORMATION
1-2
2. SAFETY INFORMATION
This OPERATING 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 OPERATING 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.
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.
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.
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.
NOTICE

3. RUNNING IN A NEW LIFT TRUCK
1-3
3. RUNNING IN A NEW LIFT TRUCK
3.1 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. Be sure to take special care concerning the following items during this initial period of
operation.
•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.
3.2 FIRST MONTH OF SERVICE (OR INITIAL 200 HOURS OF SERVICE)
For new lift truck, carry out the following maintenance only after the first month or 200 hours.
Unit Check Items Remarks
Engine
Change oil in engine oil pan Page 4-16
Replace oil filter cartridge Page 4-16
Check & adjust engine valve clear-
ance
Tighten (retorque) engine cylinder
head bolts
Check spark plugs for burning of
electrode, burning of insulator Page 4-19
Check & clean air cleaner element Page 4-22
Check ignition timing
Check & adjust alternator belt (drive
belt) tension Page 3-23
TORQFLOW
transmission
Change transmission fluid
Page 4-18
Clean strainer
Differential Change oil Page 4-18
Hydraulic tank
Change oil
Page 4-15
Replace line filter
Clean strainer
Clean inside tank
Misc. bolts & nuts Tighten
Particularly lug (hub) nuts, overhead guard
mounting bolts, backrest mounting bolts,
and operator's seat mounting bolts
Other See “Check Before Operation” Page 3-20

3. RUNNING IN A NEW LIFT TRUCK
1-4
3.3 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. capacity, Cushion Tire, TORQFLOW, Liquid Propane Special
FG15HC-17 3,000 lb. capacity, Pneumatic Tire, High Performance, Clutch
FG15HT-17 3,000 lb. capacity, Pneumatic Tire, High Performance, TORQFLOW
FG15HTLS-17 3,000 lb. capacity, Pneumatic Tire, High Performance, TORQFLOW, Liquid Propane Special
FG18HT-17 3,500 lb. capacity, Pneumatic Tire, High Performance, TORQFLOW
FG18HTLS-17 3,500 lb. capacity, Pneumatic Tire, High Performance, TORQFLOW, Liquid Propane Special
BX (K21 and K25 Gasoline Engines)
FG20ST-14 4,000 lb. capacity, Cushion Tire, TORQFLOW
FG20STUS-14 4,000 lb. capacity, Cushion Tire, TORQFLOW, Gasoline Special
FG20STLS-14 4,000 lb. capacity, Cushion Tire, TORQFLOW, Liquid Propane Special
FG20SHT-14 4,000 lb. capacity, Cushion Tire, High Performance, TORQFLOW
FG25ST-14 5,000 lb. capacity, Cushion Tire, TORQFLOW,
FG25STUS-14 5,000 lb. capacity, Cushion Tire, TORQFLOW, Gasoline Special
FG25STLS-14 5,000 lb. capacity, Cushion Tire, TORQFLOW, Liquid Propane Special
FG25SHT-14 5,000 lb. capacity, Cushion Tire, High Performance, TORQFLOW
FG25SHTLS-14 5,000 lb. capacity, Cushion Tire, TORQFLOW, Liquid Propane Special
FG30SHT-14 6,000 lb. capacity, Cushion Tire, High Performance, TORQFLOW
FG30SHTLS-14 6,000 lb. capacity, Cushion Tire, High Performance, TORQFLOW, Liquid Propane Special
FG20C-14 4,000 lb. capacity, Pneumatic Tire, Clutch
FG20T-14 4,000 lb. capacity, Pneumatic Tire, TORQFLOW
FG20TUS-14 4,000 lb. capacity, Pneumatic Tire, TORQFLOW, Gasoline Special
FG20TLS-14 4,000 lb. capacity, Pneumatic Tire, TORQFLOW, Liquid Propane Special
FG20HT-14 4,000 lb. capacity, Pneumatic Tire, High Performance, TORQFLOW
FG20HTLS-14 4,000 lb. capacity, Pneumatic Tire, High Performance, TORQFLOW, Liquid Propane Special
FG25C-14 5,000 lb. capacity, Pneumatic Tire, Clutch
FG25T-14 5,000 lb. capacity, Pneumatic Tire, TORQFLOW
FG25TUS-14 5,000 lb. capacity, Pneumatic Tire, TORQFLOW, Gasoline Special
FG25TLS-14 5,000 lb. capacity, Pneumatic Tire, TORQFLOW, Liquid Propane Special
FG25HT-14 5,000 lb. capacity, Pneumatic Tire, High Performance, TORQFLOW
FG25HTLS-14 5,000 lb. capacity, Pneumatic Tire, High Performance, TORQFLOW, Liquid Propane Special
FG30C-14 6,000 lb. capacity, Pneumatic Tire, Clutch
FG30HT-14 6,000 lb. capacity, Pneumatic Tire, High Performance, TORQFLOW
FG30HTUS-14 6,000 lb. capacity, Pneumatic Tire, High Performance, TORQFLOW, Gasoline Special
FG30HTLS-14 6,000 lb. capacity, Pneumatic Tire, High Performance, TORQFLOW, Liquid Propane Special
BX (4D94E Diesel Engine)
FD20T-14 4,000 lb. capacity, Pneumatic Tire, TORQFLOW
FD20TUS-14 4,000 lb. capacity, Pneumatic Tire, TORQFLOW, Diesel Special
FD25T-14 5,000 lb. capacity, Pneumatic Tire, TORQFLOW
FD25TUS-14 5,000 lb. capacity, Pneumatic Tire, TORQFLOW, Diesel Special
FD30T-14 6,000 lb. capacity, Pneumatic Tire, TORQFLOW
FD30TUS-14 6,000 lb. capacity, Pneumatic Tire, TORQFLOW, Diesel Special

4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK
1-5
4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK
4.1 GENUINE KOMATSU FORKLIFT PARTS
Komatsu Forklift genuine parts are manufactured from the same
materials, and by the same methods, 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 which result from the use
of such imitation parts, and Komatsu Forklift warranty will not be
applicable.
Always use genuine Komatsu Forklift parts when replacing parts.

4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK
1-6
4.2 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” series engines will display the required identification label as follows.
Location on K21/K25 Series engines:
Emission compliance label (SAMPLE shown below)

4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK
1-7
4.2.2 WARRANTY
The following statement is hereby provided as required by regulations of the United States Environmental
Protection Agency (EPA).
YOUR WARRANTY RIGHTS AND OBLIGATIONS
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.
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.
MANUFACTURER’S WARRANTY COVERAGE
Beginning January 1, 2004 off-road large spark-ignition EPA engines are warranted for the time periods 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.
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.
KFI recommends that you retain receipts covering maintenance on your off-road engine, but KFI 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 be aware, however, that KFI may deny you warranty
coverage if your off-road large spark-ignition engine, or a part thereof, has failed due to abuse, damage, neglect,
improper maintenance or unapproved modifications.
Your engine is designed to operate on gasoline and/or LPG fuel. Use of any other fuel may result in your engine no
longer operating in compliance with the Federal EPA’s emissions requirements.
You are responsible for initiating the warranty process. It is suggested that you present your off-road large spark-
ignition engine to an Authorized Komatsu Forklift Dealer as soon as you become aware that 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 the Komatsu
Forklift Product Support Dept. at [phone].
In addition to the standard warranty periods, the components listed below are covered by the following specific
warranty periods.
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, KFI warrants the following emission-
related parts:
•Oxygen sensor •PCV valve
•Water temperature sensor •Gasoline injector
•LPG injector •LPG pressure sensor
•LPG solenoid •LPG switching module
•Mass air flow sensor •Throttle chamber
•Ignition coil •Crankshaft position sensor
•Camshaft position sensor •Distributor
•Spark plugs

4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK
1-8
EMISSION CONTROL WARRANTY – 36 MONTHS OR 4,000 HOURS FOR POWER TRAIN PARTS
•Intake manifold
•Exhaust manifold
EMISSION CONTROL WARRANTY – 60 MONTHS OR 3,500 HOURS FOR GENERAL PARTS
•ECM
•Catalytic converter
•Vaporizer
NOTICE
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. Golf Rd.
Rolling Meadows, IL 60008
[phone]

4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK
1-9
4.3 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.
4.3.1 LABELS REQUIRED AND LABEL LOCATIONS
All certified 4D94E diesel engines will display the required identification label as follows:
•4D94E diesel engines: Labels will be affixed to all appropriate engines on KFI production trucks.
Location on 4D94E Series diesel engines:

4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK
1-10
4.3.2 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 KFI are pleased to explain the emission control system warranty on your 2004 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. KFI 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, KFI hereby certifies that diesel engines for lift trucks produced in 2004 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, 2004 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 owner's manual (Instruction Manual). KFI recommends that you retain all receipts and records covering the
maintenance on your engine, but KFI 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.
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 KFI may deny your warranty cov-
erage if your heavy-duty off-road engine or part has failed due to abuse, damage, neglect, improper mainte-
nance 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 the autho-
rized Komatsu Forklift dealer.
•Check oil level and coolant level Every day
•Change of lubricating oil Every 200 hours
•Change lubricating oil filter Every 600 hours
•Initial adjustment of valve clearance Every 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