Download AX50 BX50 - Komatsu Forklift USA, Inc. v3.1

OM200
OPERATION & MAINTENANCE MANUAL
AX50/BX50 Series Forklift Trucks
AX50
FG15/18/20(A)(S)HT-20
675001A~/671578 - 672056
672057~
EPA Tier 2
CARB 2010
BX50
FG20/25/28/30/32(S)(H)T-16
FG35AHT-16
S/N 200001A~
S/N 210001A~
S/N 750875 - 751862
S/N A224001~
S/N 751863~
EPA Tier 1
EPA Tier 2
EPA Tier 2
EPA Tier 2/CARB 2010
CARB 2010
FD20/25/28/30/32T-16
FD35AT-16
S/N 200001A~/210001A~
S/N A223001~/750875~
EPA Tier 2
EPA Interim Tier 4
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:
Code Position:
FG
30
HT
LS
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
Vehicle & Fuel Type
Load Capacity
(Model = lbs)
Designations
UL Safety Type
FG = Gasoline
forklift (includes LP)
15 = 3,000
S = Cushion Tire
(no “S” = Pneumatic Tire)
18 = 3,500
FD = Diesel forklift
(BX only)
H = High Performance
20 = 4,000
25 = 5,000
T = TORQFLOW-type power-shift
transmission with torque converter
30 = 6,000
32 = 6,500
35 = 7,000
7
LS = Anti-Spark Liquid
Propane Special
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 organizations, 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
Other
4.
Particularly hub nuts, overhead guard
mounting bolts, load backrest mounting
bolts, and operator's seat mounting bolts
Tighten all bolts and nuts
MODELS AND SERIAL NUMBERS
Model
FG15/18/20(A)(S)HT-20
Series
AX50
FG20/25/28/30/32(S)(H)T-16
FG35AHT-16
BX50
FD20/25/28/30/32T-16
FD35AT-16
EPA Compliance
Serial Number Range
Tier 2 (Gas/LP)
675001A~ / 671578 - 672056
CARB 2010
672057~
Tier 1 (Gas/LP)
200001A~
Tier 2 (Gas/LP)
210001A~
Tier 2 (Diesel)
200001A~
Interim Tier 4 (Diesel)
210001A~
BX50 MODELS MANUFACTURED AFTER 2009
FG20/25/28/30/32(S)(H)T-16
FG35AHT-16
FD20/25/28/30/32T-16
FD35AT-16
BX50
Tier 2 (Gas/LP)
CARB 2010 (Gas/LP)
A224001~ / 750875 - 751862
A224001~ / 751863~
Interim Tier 4 (Diesel)
A223001~ / 750875~
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
1-4
FG20T-16
4,000 lb. capacity, K21 gasoline engine, pneumatic tires
FG20TUS-16
4,000 lb. capacity, K21 gasoline engine, pneumatic tires, gasoline special
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
5. WARRANTY AND SERVICE FOR NEW LIFT TRUCK
KFI OBLIGATION
KFI shall have the obligation to repair or replace,
at KFI's option, any defect in material or workmanship at no charge, by authorized KFI dealer,
during the specified warranty period.
LIMITATIONS AND EXCLUSIONS
4.
3.
2.
Batteries for battery-powered trucks.
Tires and tubes.
Normal replacement of any and all consumable parts such as, but not limited to light
bulbs, filter elements, hoses, lubricating and
hydraulic oil, and/or parts required to perform a regular maintenance service.
This warranty is not applicable to or inclusive of
any of the following:
1. Equipment which has been subjected to
alterations and/or modifications not
approved in writing from KFI, neglect, unauthorized repair, misuse, accidents, lack of
reasonable proper maintenance, normal
adjustments, improper repairs or replacements, use of parts which do not conform to
KFI's specifications.
5.
Attachments, components, parts or accessories of products or equipment not manufactured by KFI.
5.
4.
3.
2.
No modifications, alterations or changes of
this limited warranty is permitted or authorized by KFI-approved dealer.
KFI neither assumes nor authorizes any
other to assume for it any other liability in
connection with the sale or service of the
equipment.
In no event shall the dealer, its customers or
users be entailed to recover incidental or
consequential damages, including, but not
limited to, damages or inconvenience,
rental or replacement equipment, loss of
profits, or other commercial loss.
Gasoline/LPG engine
EPADSL2004-1
EPAGAS2010-1
EPAGAS2007-1
KPWCERT-STD-3
Diesel engine
Refer to the applicable Federal EPA warranty certificate for emission control warranty statements:
EPA PRODUCTS
Delivering Dealer
Delivery Date
City & State
Company
Serial Number
Truck Model
Some states prohibit exclusion or limitation
of implied warranty of merchantability or fitness for a particular purpose, and/or incidental or consequential damages, so you
may have additional rights.
PRODUCT WARRANTY – CLASS I, IV AND V
ICE & ELECTRIC SIT-DOWN TRUCKS
Komatsu Forklift U.S.A., LLC (hereinafter called
KFI) warrants new equipment to be free from
defects in materials and workmanship under the
conditions of the following provisions.
STANDARD WARRANTY
KFI Standard Warranty for new equipment shall
be (12) months or the first 2,000 operating hours
after delivery to the initial purchaser, rental or
lessee, whichever event shall occur first.
POWER TRAIN PROTECTION
WARRANTY
KFI warrants the following major components for
a period of 730 days or the first 4,000 operating
hours after delivery to the initial purchaser,
rental, or lessee, whichever shall occur first.
1. Internal combustion equipment
a. Engine (excluding all accessories and
consumable trade parts)
b. Torqflow and standard transmissions
(excluding dry clutch and components)
c. Torque converter assembly
d. Differential and drive axle (excluding
brake assembly)
2.
Used products or equipment.
LIMITED LIABILITY
6.
1.
Any and all other express, statutory, and
implied warranties applicable to the product, including, without limitation, all implied
warranties of merchantability and fitness for
use, are expressly disclaimed.
Komatsu Forklift U.S.A., LLC
Battery-powered equipment
a. Electric Motors (excluding sensors and
brushes)
b. AC Drive Control Panel (excluding
fuses)
c. Contactor Panel (excluding contact tips
& switches)
d. Differential and drive axle (excluding
brakes)
Class I, IV and V ICE & Electric Sit-down Trucks – U.S.A.
1-8
KOMATSU PRODUCT WARRANTY
5.6
5. WARRANTY AND SERVICE FOR NEW LIFT TRUCK
EMISSION CONTROL WARRANTY FOR GAS ENGINES
5.7
•
•
ECM
Catalytic converter
Vaporizer
Intake manifold
Exhaust manifold
EPAGAS2010-1 071310
LONG-TERM EMISSION CONTROL
WARRANTY – 60 MONTHS or 3,500
HOURS FOR GENERAL PARTS
•
•
•
EMISSION CONTROL WARRANTY 36 MONTHS or 4,000 HOURS FOR
POWER TRAIN 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
EMISSION CONTROL WARRANTY 36 MONTHS or 2,500 HOURS FOR
GENERAL PARTS
CALIFORNIA AND U.S. FEDERAL EMISSION CONTROL WARRANTY
STATEMENT (GASOLINE/LPG ENGINES)
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.
The following statement is required to be provided by
regulations of the California Air Resources Board and
U.S. Environmental Protection Agency.
YOUR WARRANTY RIGHTS AND
OBLIGATIONS
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.
Komatsu Forklift U.S.A., LLC
If you have any questions regarding your warranty
rights and responsibilities, you should contact
Komatsu Forklift’s Product Support Department at
1-847-437-5800.
The warranty repairs should be completed by the
Dealer as expeditiously as possible.
You are responsible for initiating the warranty process.
The ARB and U.S. EPA suggest that you present your
off-road large spark-ignition engine to all Authorized
Komatsu Forklift Dealer as soon as a problem exists.
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.
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.
The California Air Resources Board (CARB) and U.S.
Environmental Protection Agency (EPA) are pleased
to explain the emission control system warranty on
your 2010 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.
MANUFACTURER’S WARRANTY
COVERAGE:
The 2010 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.
Class IV & V – U.S.A.
1-9
5. WARRANTY AND SERVICE FOR NEW LIFT TRUCK
•
Fuel Injection Nozzles
Fuel Injection Pump
•
•
•
•
•
Adjust valve clearance – Every 1,000 hours
Initial adjustment of valve clearance – 200 hours
Change fuel filter – Every 500 hours
Change lubricating oil filter – AX/BX/EX: Every 500 hours
CX/DX: Every 200 hours
Change engine oil – AX/BX/EX: Every 500 hours
CX/DX: Every 200 hours
Check oil level and coolant level – Every day
•
•
•
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.
As the heavy-duty off-road engine owner you should, however, be aware that KFI 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.
Komatsu Forklift U.S.A., LLC
If you have any questions regarding your warranty rights and
responsibilities, you should contact the authorized KFI dealer.
You are responsible for initiating the warranty process. It is
suggested that you present your heavy duty off-road
engine to an authorized Komatsu dealer as soon as you
become aware that problem exists. The warranty repair
should be completed by the dealer as expeditiously as
possible.
Keep records to show proof of compliance with the required
maintenance practices and intervals.
•
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.
OWNER’S WARRANTY
RESPONSIBILITIES
•
•
•
•
Komatsu Forklift U.S.A., LLC
c/o Komatsu America Corp.
One Continental Towers
1701 W. Golf Rd.
Rolling Meadows, IL 60008
(847) 437-5800
EPADSL2004-1
For questions and additional information concerning EPA
Diesel Engine Exhaust Regulations, contact:
Follow the instructions in the Operations Manual concerning
any other maintenance programs not required for EPA
compliance.
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 KFI engine dealer.
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.
CUSTOMER ASSISTANCE –
EMISSION CONTROL SYSTEMS
WARRANTY
Remedies under this warranty are limited to the provision of
material and services as specified herein. KFI is not
responsible for incidental or consequential damages, such as
downtime or lost use of the forklift truck.
This warranty is in addition to the KFI standard warranty
applicable to the off-road engine product involved.
Any application or installation KFI deems improper as
explained in the Instruction Manual.
Attachments, accessory items or parts not authorized for
use by KFI.
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.
KFI is not responsible for resultant damages to an emissionrelated part or component resulting from:
LIMITATIONS
FEDERAL ENVIRONMENTAL PROTECTION AGENCY (EPA) EMISSION CONTROL
WARRANTY STATEMENT (DIESEL ENGINES)
The following statement is provided as required by regulations
of the United States Environmental Protection Agency (EPA).
YOUR WARRANTY RIGHTS
AND OBLIGATIONS
The Federal EPA and Komatsu Forklift U.S.A., LLC
(hereinafter referred to as "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
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 engine
emission-related components are warranted for a period of
(60) months or (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 an authorized Komatsu
Forklift dealer.
•
Turbocharger
EMISSION RELATED PARTS
•
Class IV & V – U.S.A.
1-10
EMISSION CONTROL WARRANTY FOR DIESEL ENGINES
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
1-12
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.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
6.2.5
•
•
6.2.6
•
•
•
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
EMISSION CONTROL WARRANTY – 36 MONTHS OR 4,000 HOURS FOR POWER
TRAIN PARTS
Intake manifold
Exhaust manifold
LONG-TERM EMISSION CONTROL WARRANTY – 60 MONTHS OR 3,500 HOURS
FOR GENERAL PARTS
ECM
Catalytic converter
Vaporizer
1-13
6. EMISSION CONTROL STATEMENTS
6.3
EPA CERTIFICATES OF CONFORMITY
K21 ENGINE - MODEL YEAR 2012
1-14
6. EMISSION CONTROL STATEMENTS
K25 ENGINE - MODEL YEAR 2012
1-15
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.
IES
SULFU Y. NONRO
WITH TRO
ENGINE
R
AD/OFFU. S.
L INF
ENGINE FAMILYFUEL
EPA
OR
ULTRA -ROAD AND
FUEL MODEL :
DIESELCALIFO ORM
LOW
REFERRATE
:
RNIA
ATIO
ENGINE
SULFU
ADJUS TO :
REGUL
OWNER MM 3
R
S.
TMENT
/STROK
DISPLAFUEL
ATIONS N
ONLY
S 'S MANUA E @
EMISSI CEMEN
L FOR
T
ON
kW
CONTR:
MAINTE/
RPM
OL
NANCE
SYSTELITERS
SPECIF
ICATION
M :
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
1-16
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 threethousand (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 offroad 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 authorized Komatsu Forklift dealer.
1-17
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.
1-18