SERVICE MANUAL - Komatsu Forklift USA, Inc. v3.1
Contents
1. 8 89 TROUBLESHOOTING o ea ode 8 90 SERVICE ricardo 8 91 D MQ SERIES 4 STAGE MAST 13 8 117 INTRODUCTIONS 2 camara apa a debe a ede a alan 8 118 INSTALLATION 2 Soe cian aia 8 119 PERIODIC MAINTENANCE 2 2 8 132 TROUBLESHOOTING 5000 tara rt a pod sth le sa a Bel aras 8 134 SERVICE ts asa ade a ah Att a das 8 135 D MS SERIES LIMITED FREE LIFT 2 STAGE 4 8 169 INTRODUCTION en dll il a ti de Le 8 170 INSTALLATION 8 1 124 8 171 a lr st ea de he a is 8 180 TROUBLESHOOTING o a ri ag wae 8 181 SERVICE soda ta ti y de a A a ge teak is 8 182 CONTENTS D MD SERIES FULL FREE LIFT 2 STAGE MAST R5 8 201 INTRODUC 2 545 a A a i 8 202 INSTALLATION INSTRUCTIONS ooo 8 203 PERIODIC 4 1 8 208 TROUBLESHOOTINO a a dt ad 8 209 SERVICE2. 5 4 INSPECT LPG VAPORIZER FOR TAR 5 4 INSPECT THE BLOW BY GAS RECIRCULATION SYSTEM 5 5 INSPECT COOLING SYSTEM AND 5 6 INSPECT CHARGING SYSTEM 5 6 INSPECT LPG VAPORIZER FOR TAR BUILDUP EVERY 5 6 INSPECT THE BLOW BY GAS RECIRCULATION SYSTEM 5 7 INSPECT COOLING SYSTEM AND 5 8 INSPECT CHARGING SYSTEM 5 8 INSPECT WHEEL TORQUE 5 8 INSPECT STEERING tics aaa cate ea a wal 5 8 INSPECT STEERING WHEEL coito Sa Ga cla ae ae 5 9 INSPECT THE POWER STEERING 5 5 9 INSPECT BRAKE SYSTEM RODS CABLES AND 5 9 INSPECT BRAKE PIPING AND CONNECTIONS 1 5 9 INSPECT BRAKE MASTER AND WHEEL 5 10 INSPECT BRAKE SHOES AND ASSOCIATED PARTS 5 10 INSPECT BRAKE 68 5 10 INSPECT BRAKE BACKING
3. 1 A 19 BX20 WIRING GASOLINE UL GS 2 A 21 BX20 WIRING GASOLINE UL GS 3 A 23 20 WIRING LP UL LPS SHEET 1 A 25 20 5 2 27 BX20 WIRING LP UL LPS SHEET 3 A 29 BX20 WIRING 4D94E A 31 20 TORQFLOW TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM A 33 ADJUSTING CLUTCH BRAKE PEDAL CLUTCH TYPE A 35 ADJUSTINGINCHING BRAKE PEDAL TORQFLOW A 37 TROUBLESHOOTING DIAGRAM SHEET 1 A 39 TROUBLESHOOTING DIAGRAM 2 A 41 FOREWORD FOREWORD This Service Manual has been developed as an information resource to help the reader learn about understand repair and maintain the BX20 Series forklift trucks and the various equip ment systems inspections sensors diagnostic procedures and diagnostic equipment utilized to maintain adjust and troubleshoot these systems Although reference is made to mainte n
4. 5 11 INSPECT LOAD FORKS 1 5 11 a A Ske Net da 5 12 INSPECT FORK CARRIAGE eek ta hea Sanaa a aca 5 12 INSPECT LIFT CHAINS Ad and 5 13 INSPECT CHAIN WHEELS 4 0 5 13 INSPECT 8 44 5 13 INSPECT HYDRAULIC 1 5 14 INSPECT CHASSIS AND ATTACHMENT PIPING 5 14 INSPECT HYDRAULIC PUMP 0 000000 eee 5 14 INSPECT LIFT CYEINDER ay fas sate a 5 14 INSPEGT TET CYEINDERS moras paa ate peda a a aa 5 14 INSPECT ATTACHMENT CYLINDERS IF 5 14 5 38 5 39 5 40 5 41 5 42 5 43 5 44 5 45 CONTENTS INSPECT LIFT TRUCK CHASSIS AND 5 14 INSPECT CAB IF EQUIPPED aa n a e a a a eee 5 14 INSPECT THE OPERATOR S 5 15 INSPECT EQUIPMENT USED FOR ACCESSING THE LIFT 5 19 INSPECT DISPLAY 1 5 19 INSPECT OVERHEAD GUARD 2 5
5. 7 9 DISASSEMBLE CLUTCH MANUAL TRANSMISSION 85 7 13 ASSEMBLE CLUTCH MANUAL TRANSMISSION TRUCKS 7 16 INSTALL TORQUE 4 24 7 17 INSTALL TRANSMISSION AND DRIVE 7 17 INSTALL PEDAL ASSEMBLY 8 7 17 BRAKE MASTER 7 18 CLUTCH MASTER CYLINDER MANUAL SHIFT TRUCKS 7 23 CLUTCH RELEASE CYLINDER 555 Sah ella hae aa 7 24 BLEED AIR FROM BRAKE SYSTEM LINES 7 28 STEERING AXLE a gd dial 7 29 STEERING AXLE LUBRICATION AND 7 34 POWER STEERING VALVE 7 38 POWER STEERING VALVE TROUBLESHOOTING 7 39 POWER STEERING CYLINDER 00 0 0 0 020 eee ee 7 60 deta edema da 7 61 CLUTCH TRANSMISSION 222 4 7 66 DRIVE AXLE dco ttn eye el adenine daha doa ase 7 75 DIFFERENTIAL DIRECT
6. FG30HTLS 14 6 000 Ib capacity K25 Engine Torqflow Spec LP Special Pneumatic Tire FG30SHT 14 6 000 Ib capacity K25 Engine Torqflow Spec Cushion Tire FG30SHTLS 14 6 000 Ib capacity K25 Engine Torqflow Spec LP Special Cushion Tire Diesel Models FD20T 14 4 000 Ib capacity 4D94E Engine Torqflow Trans Diesel Pneumatic Tire FD20TUS 14 4 000 Ib capacity 4D94E Engine Torqflow Trans Diesel Special Pneumatic Tire FD25T 14 5 000 Ib capacity 4D94E Engine Torqflow Trans Diesel Pneumatic Tire FD25TUS 14 5 000 Ib capacity 4D94E Engine Torqflow Trans Diesel Special Pneumatic Tire FD30T 14 6 000 Ib capacity 4D94E Engine Torqflow Trans Diesel Pneumatic Tire FD30TUS 14 6 000 Ib capacity 4D94E Engine Torqflow Trans Diesel Special Pneumatic Tire 11 FEDERAL EPA EMISSION CONTROL STATEMENTS FEDERAL EPA EMISSION CONTROL STATEMENTS 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 mainte nance of K21 and K25 engines in order to comply with the EPA off road large spark ignition LSI engine regulations 1 LABELS REQUIRED AND LABEL LOCATIONS All series engines will display the required identification label as follows Location on K21 K25 Series engines EPA LABEL LOCATION TOP VIEW OF ENGINE K21 K25 EPA
7. The following statement is hereby provided as required by regulations of the United States Envi ronmental Protection Agency EPA YOUR WARRANTY RIGHTS AND OBLIGATIONS 15 FEDERAL EPA EMISSION CONTROL STATEMENTS The Federal EPA and Komatsu Forklift U S A LLC hereinafter referred to as 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 con trol 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 draw ing and or illustration of emission label and its location MANUFACTURER S WARRANTY COVERAGE Beginning January
8. a ter RA neon hehe 1 7 1 3 EQADING OPERATIONS senera hit starts eae iad ath Sea E ona ete ee 1 15 1 4 SAFETY IN PERIODIC 2 1 20 1 5 TOWING do da Meta ale aia Hated a toe 1 26 1 6 STRUCTURE AND STABILITY OF THE LIFT 1 27 1 7 SAFETY LABELS die Da Gant bet dad Malate taney Sale dane Pt wa ath de 1 30 1 8 OPTIONAL 1 36 2 GENERAL INFORMATION 8 SPECIFICATIONS 2 1 SPECIFICATIONS MAST DATA 8 FEATURES INDOOR 8 OUTDOOR TRUCKS 2 2 2 2 SPECIFICATIONS MAST DATA 8 85 2 3 2 3 TRUCK DATA PNEUMATIC TIRE LIFT TRUCKS 2 4 2 4 TRUCK DATA CUSHION TIRE LIFT TRUCKS 2 10 2 5 PERIODIC REPLACEMENT OF CONSUMABLE 2 12 2 6 STANDARD TIGHTENING TORQUE FOR PIPE JOINTS 2 13 2 7 STANDARD TIGHTENING TORQUE FOR BOLTS 2 14 3 SERVICE DATA 3 1 SERVICE DATA GASOLINE ENGINE 3 2 3 2 SERVICE DATA GASOLINE ENGINE LIFT 5 3 4 3 3 SERVICE DA
9. DRIVE 7 79 ADJUST DIRECT DRIVE DIFFERENTIAL 7 81 DIFFERENTIAL TORQFLOW 7 85 ADJUST RING GEAR 7 93 TORQFLOW TRANSMISSION W TORQUE 7 97 DISASSEMBLE TORQFLOW TRANSMISSION 7 106 CONTENTS 7 28 TORQUE CONVERTER DISASSEMBLY ASSEMBLY 7 108 7 29 TORQFLOW TRANSMISSION DISASSEMBLY ASSEMBLY 7 109 7 30 TORQFLOW TRANSMISSION CONTROL 7 118 7 31 HYDRAULIC CONTROL VALVE 1 7 127 7 32 gt SHY DRAULIC PUMP Yk csr spin Joie tai ota ala AS ga 7 129 7 33 TIETOYEINDER tea aed oda Gah setae dew kee died oh Packers tale a 7 133 1 34 2 45 nek sa o Su a anal a eile anna bet eee dong ate 7 137 7 35 INSTALL MAS To ce dda et ge ee ede ed 7 138 730 CYBINDER 225 RAM a tcl tat a 7 138 7 37 CYLINDER SEAL SERVICE KITS 7 146 1 38 SIDESHIFTER daa neds of
10. Emission compliance label SAMPLE shown below 12 oF 1 N 4 375 inch 111 125 mm EMISSION CONTROL INFORMATION ENGINE FAMILY 4NSXB02 147C ENGINE DISPLACEMENT 2 1 LITER ENGINE MAXIMUM POWER 55 7 HP THIS ENGINE IS CERTIFIED TO OPERATE ON LPG ENGINE S USEFUL LIFE IS 5000 HOURS OF OPERATION OR SEVEN YEARS EXHAUST EMISSION CONTROL TYPE TBI TWC HO2S TEST MODE VARIABLE SPEED ONLY THIS ENGINE MEETS CALIFORNIA AND U S EPA REGULATIONS FOR 2004 LARGE NONROAD ENGINES NISSAN MOTOR CO LTD K21L FEDERAL EPA EMISSION CONTROL STATEMENTS 2 WARRANTY The following statement is hereby provided as required by regulations of the United States Envi ronmental 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 U S A 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 injec tion system ignition system engine computer module ECM catalytic converter and air induc tion system Also included may be sensors hoses belts connectors and other emission related assemblies Where a warrantable c
11. K25 Engine Torqflow Spec Pneumatic Tire FG20HTLS 14 4 000 Ib capacity K25 Engine Torqflow Spec LP Special Pneumatic Tire FG20SHT 14 4 000 Ib capacity K25 Engine Torqflow Spec Cushion Tire FG25C 14 5 000 Ib capacity K21 Engine Clutch Spec Pneumatic Tire FG25T 14 5 000 Ib capacity K21 Engine Torqflow Spec Pneumatic Tire FG25TUS 14 5 000 Ib capacity K21 Engine Torqflow Spec Gasoline Special Pneumatic Tire FG25TLS 14 5 000 Ib capacity K21 Engine Torqflow Spec LP Special Pneumatic Tire FG25ST 14 5 000 Ib capacity K21 Engine Torqflow Spec Pneumatic Tire FG25STUS 14 5 000 Ib capacity K21 Engine Torqflow Spec Gasoline Special Cushion Tire FG25STLS 14 5 000 Ib capacity K21 Engine Torqflow Spec LP Special Cushion Tire FG25HT 14 5 000 Ib capacity K25 Engine Torqflow Spec Pneumatic Tire FG25HTUS 14 5 000 Ib capacity K25 Engine Torqflow Spec Gasoline Special Pneumatic FG25HTLS 14 5 000 Ib capacity K25 Engine Torqflow Spec LP Special Pneumatic Tire FG25SHT 14 5 000 Ib capacity K25 Engine Torqflow Spec Cushion Tire FG25SHTLS 14 5 000 Ib capacity K25 Engine Torqflow Spec LP Special Cushion Tire FG30C 14 6 000 Ib capacity K21 Engine Clutch Spec Pneumatic Tire FG30HT 14 6 000 Ib capacity K25 Engine Torqflow Spec Pneumatic Tire FG30HTUS 14 6 000 Ib capacity K25 Engine Torqflow Spec Gasoline Special Pneumatic Tire
12. adie eed adden nea ad pas ddd waded f 7 150 8 MASTS E MS SERIES LIMITED FREE LIFT 2 STAGE MAST 3 8 1 INTRODUCTION ccoo cocoa ct dee gee 8 2 INSTALLATION INSTRUCTIONS ooo 8 3 PERIODIC MAINTENANCE 1 2 1 8 7 TROUBLESHOOTING pari e e y a 8 8 SERVICES ta OS 8 9 E MD SERIES FULL FREE LIFT 2 STAGE MAST 2 8 29 INTRODUCTIONS senate ony dl teed mabe ear 8 30 INSTALLATION INSTRUCTIONS 0 0 2 0 00 0022 eee eee 8 31 PERIODIC MAINTENANCE 8 44 TROUBLESHOOTING a A 8 45 SERVICE il hata hg aad Racal 8 46 E MT SERIES FULL FREE LIFT 3 STAGE MAST 9 8 71 INTRODUCTION a a ds Mande aera Re 8 72 6 8 73 PERIODIC
13. 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 e Fuel injection pump e Fuel injection nozzles e Turbocharger 16 FEDERAL EPA EMISSION CONTROL STATEMENTS 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 KFl 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 mainte nance schedule for certified Diesel engines e Check oil level and coolant level Everyday e Change of lubricating Every 200 hours e Change lubricating oil filter Every 200 hours e Initial adjustment of valve clearance Every 200 hours e Change fuel filter Every 500 hours e Check turbocharger rebuild or replace if necessary Every 2 000 hours e Adjust valve clearance Every 2 000 hours e Check fuel injection nozzles replace if necessary Every 2 000 hours Keep records to show proof of complia
14. 1 5 12 5 13 5 14 5 15 5 16 5 17 5 18 5 19 5 20 5 21 5 22 5 23 5 24 5 25 5 26 5 27 5 28 5 29 5 30 5 31 5 32 5 33 5 34 5 35 5 36 5 37 MEASURE BRAKE STOPPING DISTANCE BRAKING 4 15 ADJUST THE STOP LAMP 2 4 15 ADJUST THE INCHING BRAKE PEDAL TORQFLOW 4 16 CHECK TORQFLOW CLUTCH ACTUATION 0 4 18 CHECK TORQUE CONVERTER STALL SPEED 4 18 TEST SPECIFIC GRAVITY OF BATTERY ELECTROLYTE 4 19 CHECK TIRES AND ADJUST PNEUMATIC TIRE PRESSURE 4 20 MEASURE MINIMUM LEFT AND RIGHT TURNING 085 4 21 MEASURE HYDRAULIC CONTROL VALVE RELIEF 55 4 22 INSPECTION INSPECT ENGINE STARTING OPERATION 5 2 INSPECT ENGINE RUNNING 5 2 INSPECT AIR CLEANER 5 2 INSPECT FOR LOOSE CYLINDER HEAD MOUNTING BOLTS amp RE TORQUE 5 3 INSPECT ENGINE 8 5 40 5 3 INSPECT THE ENGINE LUBRICATING 5 5 3 INSPECT ENGINE FUEL SYSTEM
15. 19 INSPECT LIGHTS GAUGES AND WARNING DEVICES 5 19 INSPECT REAR VIEW MIRROR AND 85 5 19 MAINTENANCE OPERATIONS 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 LUBRICANT LIST 21 AND K25 6 2 LUBRICANT LIST 4D94E 6 3 OIL AND GREASING 6 4 CHANGE ENGINE OIL AND FILTER GASOLINE LP 6 5 DIFFERENTIAL 2 6 6 TORQFLOW TRANSMISSION 2 6 7 CHANGE OIL IN HYDRAULIC 6 7 REPLACE THE FUEL FILTERS a rt iaa 6 8 CLEAN AND OR REPLACE AIR CLEANER 6 9 REMOVAL DISASSEMBLY ASSEMBLY amp INSTALLATION 7 1 7 2 7 3 7 4 7 5 7 6 7 7 7 8 7 9 7 10 7 11 7 12 7 13 7 14 7 15 7 16 7 17 7 18 7 19 7 20 7 21 7 22 7 23 7 24 7 25 7 26 7 27 OVERALL DISASSEMBLY AND ASSEMBLY 7 2 WEIGHT TABLE COMPONENT ASSEMBLIES AND PARTS 7 4 ENGINE d id a 7 5 TRANSMISSION AND DRIVE
16. SM122 SERVICE MANUAL BX20 SERIES FORKLIFT TRUCKS Federal Environmental Protection Agency EPA Emission Control Compliant S N 580001A Gasoline amp LPG FG20 25 30 35S H T C LS US 14 FG20 25 30C 14 FG20 25T US LS 14 FG20 25 30HT US LS 14 Diesel FD20 25 30T US 14 AWARNING 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 KOMATSU REVISED SEPTEMBER 2014 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 U S A 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 2014 Komatsu Forklift U S A LLC No part of this document may be photocopied or reproduced in any way without prior written consent of Komatsu Forklift U S A CONTENTS CONTENTS woke A eae ees TA aed aw a 3 FOREWORD See A is ee ae y 9 ENGINE SERIAL NUMBER LOCATION 10 APPLICABLE BX20 EPA LIFT TRUCK MODELS 11 FEDERAL EPA EMISSION CONTROL STATEMENTS 12 1 SAFETY 1 1 SAFETY MANAGEMENT 1 2 1 2 SAFE TRAVEL
17. TA DIESEL ENGINE LIFT 3 6 4 TEST ADJUST AND MEASURE 4 1 0 2 4 2 4 2 ADJUST INJECTION TIMING MARK DIESEL 4 2 4 3 ADJUST NO LOAD ROTATING SPEED DIESEL 4 3 44 ADJUST SPARK PLUG GAP eve ee ake Gane a Reh eh we at 4 3 4 5 ADJUST VALVE 2 4 4 46 ADJUST FAN BELT TENSION 4 6 4 7 MEASURE ENGINE CYLINDER 2 4 6 48 ADJUST THE PARKING BRAKE 4 8 4 9 MEASURE HYDRAULIC DRIFT ON LIFT amp TILT CYLINDERS 4 9 4 10 ADJUST THE ACCELERATOR PEDAL 4 10 4 11 THROTTLE POSITION SENSOR SYSTEM 4 11 4 12 ACCELERATOR PEDAL POSITION 5 1 4 12 4 13 ADJUST THE CLUTCH BRAKE PEDAL MANUAL 5 4 14 4 14 CHECK BRAKE 4 15 CONTENTS 4 15 4 16 4 17 4 18 4 19 4 20 4 21 4 22 4 23 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 5 9 5 10 5 1
18. a sata guna tials adnate arab tole 8 210 D MT SERIES FULL FREE LIFT 3 STAGE MAST 3 8 233 INTRODUCTION MY Raa ia ta aa hh deat at al 8 234 5 2 1 8 236 PERIODIC 8 246 TROUBLESHOOTING vee coma ead peated ai 8 247 SERVICE fs fic irda lt big Saat dees Maa 8 248 APPENDIX BX20 WIRING GASOLINE SHEET 1 1 BX20 WIRING GASOLINE SHEET 2 A 3 BX20 WIRING GASOLINE SHEET 3 A 5 BX20 WIRING GASOLINE LP SHEET 1 2 142 A 7 BX20 WIRING GASOLINE 2 1 A 9 BX20 WIRING GASOLINE SHEET 3 A 11 BX20 WIRING GASOLINE DUAL FUEL SHEET 1 A 13 BX20 WIRING GASOLINE DUAL FUEL 2 1 A 15 BX20 WIRING GASOLINE DUAL FUEL SHEET A 17 BX20 WIRING GASOLINE 65
19. ance procedures necessary to perform servicing of this vehicle you should refer to the appli cable Operation and Maintenance Manual for these lift trucks for more complete maintenance information Komatsu is involved in a concentrated and highly technical program of designing and develop ing cleaner burning more efficient and more powerful engines for use in the industrial truck market As a result new computerized sensors systems and diagnostic monitors have been created to make the job of maintaining and repairing these systems simple and easy Read this manual carefully refer to it often and learn the repair testing and adjustment proce dures to the best of your ability Please note that some illustrations are generic and may not look exactly like your unit in every detail Ensure that when you are working on or around industrial trucks Safety is priority Number One Read understand and obey all WARNINGS and CAUTIONS Follow the instructions and procedures presented in this manual when working on these lift trucks and their systems Damage to the equipment and possible injury to yourself or others may result if these procedures are not adhered to carefully Keep this manual nearby and accessible for use when necessary If this book becomes dirty worn or illegible contact Komatsu for a replacement The procedures outlined in this manual will be updated periodically Be sure that you have the latest revision in order to learn the ne
20. d Komatsu Dealer as soon as you become aware that a problem exists The warranty repairs should be completed by the dealer as expedi tiously as possible If you have any questions regarding your warranty rights and responsibilities you should con tact the Komatsu Product Support Dept at 847 437 5800 In addition to the standard warranty periods the components listed below are covered by the following specific warranty periods 13 FEDERAL EPA EMISSION CONTROL STATEMENTS 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 KFl warrants the following emission related parts e Oxygen sensor e PCV valve e Water temperature sensor e Gasoline injector e LPG injector e LPG pressure sensor e LPG solenoid e LPG switching module e Mass air flow sensor e Throttle chamber e Ignition coil e Crankshaft position sensor e Camshaft position sensor e Distributor e Spark plugs 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 e ECM e Catalytic converter e Vaporizer NOTICE Follow the instructions in the Operations Manual concerning any other maintenance programs not required fo
21. nce with the required maintenance practices and inter vals e 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 e 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 dealer as soon as you become aware that problem exists The warranty repair should be completed by the dealer as expeditiously as possible e If you have any questions regarding your warranty rights and responsibilities you should contact the authorized KFI dealer LIMITATIONS KFI is not responsible for resultant damages to an emission related part or component resulting from e Any application or installation KFI deems improper as explained in the Instruction Man ual e Attachments accessory items or parts not authorized for use by KFI e Improper off road engine maintenance repair or abuse e Owner s unreasonable delay in making the product available after being notified of a potential product problem This warranty is in addition to the KFI standard warranty applicable to the off road engine
22. ondition 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 main tenance 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 perfor mance 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 5 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 Authorize
23. prod uct involved Remedies under this warranty are limited to the provision of material and services as specified 17 FEDERAL EPA EMISSION CONTROL STATEMENTS herein KFI 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 admin istered 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 KFI engine dealer 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 847 437 5800 18
24. r 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 847 437 5800 FEDERAL EPA EMISSION CONTROL STATEMENT FOR OFF ROAD DIESEL ENGINES 4D94E ENGINES Exhaust emissions produced by diesel engines are regulated by the United States Environmen tal Protection Agency EPA This section presents information concerning the correct labeling 14 FEDERAL EPA EMISSION CONTROL STATEMENTS warranty parts and maintenance of 4D94E diesel engines in order to comply with current EPA regulations LABELS REQUIRED AND LABEL LOCATIONS All certified 4D94E diesel engines will display the required identification label as follows e 4D94E diesel engines Labels will be affixed to all appropriate engines on KFI production trucks Location on 4D94E Series diesel engines EMISSION CONTROL LABEL a E A AA IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMS TO 2004 MODEL YEAR U S EPA REGULATIONS LARGE NONROAD AND COMPRESSION IGNITION ENGINES THIS ENGINE IS CERTIFIED TO OPERATE ON US2D FUEL ENGINE FAMILY 4YDXL2 78P4N DISPLACEMENT 2 776 LITERS ENGINE MODEL 4TNE94 1B__ EMISSION CONTROL SYSTEM REFER OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS YANMAR DIESEL ENGINE Co Ltd 010565 WARRANTY
25. w est information available Revision dates will be clearly displayed on the lower left hand corner of the cover page This will aid in maintaining your equipment in excellent condition and in ensuring that these lift trucks will operate safely at maximum efficiency ENGINE SERIAL NUMBER LOCATION ENGINE SERIAL NUMBER LOCATION The K21 K25 engine serial number is stamped on an angled and machined pad on the right side of the engine block in the center just beneath the valve cover The machined boss is split vertically by a groove The Engine Model number is on the left pad and the Engine Serial number is on the right pad ENGINE SERIAL NUMBER If 00 0001 10 APPLICABLE BX20 EPA LIFT TRUCK MODELS APPLICABLE BX20 EPA LIFT TRUCK MODELS Model Description Gasoline Models FG20C 14 4 000 Ib capacity K21 Engine Clutch Spec Pneumatic Tire FG20T 14 4 000 Ib capacity K21 Engine Torqflow Spec Pneumatic Tire FG20TUS 14 4 000 Ib capacity K21 Engine Torqflow Spec Gasoline Special Pneumatic Tire FG20TLS 14 4 000 Ib capacity K21 Engine Torqflow Spec LP Special Pneumatic Tire FG20ST 14 4 000 Ib capacity K21 Engine Torqflow Spec Cushion Tire FG20STUS 14 4 000 Ib capacity K21 Engine Torqflow Spec Gasoline Special Cushion Tire FG20STLS 14 4 000 Ib capacity K21 Engine Torqflow Spec LP Special Cushion Tire FG20HT 14 4 000 Ib capacity
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