01 - Om200 - Operation & Maintenance Manual BX50

OM200
OPERATION & MAINTENANCE MANUAL

AX50/BX50 SERIES FORKLIFT TRUCKS
AX50 Gasoline & LPG FG15/18/20(A)(S)HT-20 S/N 675001A~

EPA 2007 TIER 2 COMPLIANT
BX50 Gasoline & LPG FG20/25/28/30/32(S)(H)T-16 S/N 210001A~

FG35AHT-16 EPA 2007 TIER 2 COMPLIANT
BX50 Diesel FD20/25/28/30/32T-16 S/N 210001A~

FD35AT-16 EPA 2008 TIER 3 COMPLIANT
AX50
BX50
WARNING
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: JANUARY 2008

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 nameplate, which is located
on the top of the lift truck hood to
the right of the operator’s seat.
The Model Key describes the

code nomenclature.
Example Model Code: FG 30 HT US

Code Position: 1 2 3 4
In the example above, the FG30HTUS lift truck has a load capacity of
6,000 pounds, pneumatic tires, a high-performance gasoline engine,
TORQFLOW transmission, and anti-spark safety features.
Model Key
1 2 3 4
Load Capacity
Vehicle & Fuel Type Designations UL Safety Type
(Model = lbs)
FG = Gasoline forklift 15 = 3,000 S = Cushion Tire US = Anti-Spark Gas or
(includes LP) (no “S” = Pneumatic Tire) Diesel Special,
18 = 3,500 depending on Fuel Type
FD = Diesel forklift H = High Performance
(BX only) 20 = 4,000 LS = Anti-Spark Liquid
T = TORQFLOW-type power-shift Propane Special
25 = 5,000 transmission with torque converter
30 = 6,000
32 = 6,500
35 = 7,000
0-6
EMISSON CONTROL WARRANTY STATEMENT FOR DIESEL ENGINES
FEDERAL ENVIRONMENTAL PROTECTION AGENCY (EPA) EMISSION CONTROL

WARRANTY STATEMENT (DIESEL ENGINES)
The following statement is provided as required by regulations OWNER’S WARRANTY • Any application or installation KFI deems improper as
of the United States Environmental Protection Agency (EPA). explained in the Instruction Manual.
RESPONSIBILITIES • Attachments, accessory items or parts not authorized for
YOUR WARRANTY RIGHTS As the heavy-duty off-road engine owner, you are responsible use by KFI.
AND OBLIGATIONS for the performance of the required maintenance listed in • Improper off-road engine maintenance, repair or abuse.
owner's manual (Instruction Manual). KFI recommends that
The Federal EPA and Komatsu Forklift USA, Inc. (hereinafter you retain all receipts and records covering the maintenance • Owner's unreasonable delay in making the product
referred to as "KFI") are pleased to explain the emission con- on your engine, but KFI cannot deny warranty solely for the available after being notified of a potential product prob-
trol system warranty on your 2004 or later Diesel heavy duty lack of receipts and records or for your failure to ensure the lem.
off-road engine. All new, heavy-duty off-road engines must be performance of all scheduled maintenance. For your refer-
designed, built and equipped to meet the EPA’s stringent anti- ence, the following is an emission control maintenance sched-
smog standards. KFI must warrant the emission control sys- This warranty is in addition to the KFI standard warranty appli-
ule for certified Diesel engines. cable to the off-road engine product involved.
tem on your engine for the period of time listed below, pro-
vided there has been no abuse, damage, neglect or improper • Check oil level and coolant level – Everyday
maintenance of your engine. Remedies under this warranty are limited to the provision of
• Change of lubricating – Every 200 hours material and services as specified herein. KFI is not responsi-
• Change lubricating oil filter – Every 200 hours ble for incidental or consequential damages, such as down-
Your emission control system may include parts such as fuel • Initial adjustment of valve clearance – Every 200 hours
injection pump. Also included may be hoses, belts, connectors time or lost use of the forklift truck.
• Change fuel filter – Every 500 hours
and other emission-related assemblies. • Check turbocharger, rebuild or replace if necessary – CUSTOMER ASSISTANCE –
Every 2,000 hours
Where a warrantable condition exists, an authorized Komatsu • Adjust valve clearance – Every 2,000 hours
EMISSION CONTROL SYSTEMS
dealer will repair the heavy-duty off-road engine at no cost to
0-7
• Check fuel injection nozzles, replace if necessary – WARRANTY
the owner, including diagnosis, parts and labor. Every 2,000 hours Komatsu Forklift aims to ensure that the Emission Control
Now, KFI hereby certifies that diesel engines for lift trucks pro- Systems Warranty is properly administered. In the event that
Keep records to show proof of compliance with the required you do not receive the warranty service to which you believe
duced in 2004 model year and after shall be regulated by Fed- maintenance practices and intervals.
eral EPA exhaust gaseous regulations. The difference you are entitled under the Emission Control Systems War-
between current and EPA-certified engines is only the label ranty, call or write to your Komatsu Forklift Dealer.
• As the heavy-duty off-road engine owner you should,
attached on the engine. See available drawing and/or illustra- however, be aware that KFI may deny your warranty
tion of emission label and its location. Authorized dealers are recommended for major maintenance
coverage if your heavy-duty off-road engine or part has and repair work, as they are staffed with trained personnel,
MANUFACTURER’S WARRANTY failed due to abuse, damage, neglect, improper mainte- proper tools and are aware of the latest maintenance methods
nance or disapproved modifications. and procedures. Owners and others who desire to perform
COVERAGE • Your engine is designed to operate on commercial diesel their own work should purchase a service manual and obtain
Beginning January 1, 2004 heavy-duty off-road EPA engines fuel only. Use of any other fuel in our engine will result in current service information from their KFI engine dealer.
are warranted for a period of five (5) years, or three-thousand the engine operating in non-compliance with the Federal
(3,000) hours of operation, whichever occurs first. If any emis- EPA regulations. Follow the instructions in the Operations Manual concerning
sion-related part on your engine is defective, the part will be • You are responsible for initiating the warranty process. It any other maintenance programs not required for EPA compli-
repaired or replaced by at an authorized Komatsu Forklift is suggested that you present your heavy duty off-road ance.
dealer. engine to an authorized Komatsu dealer as soon as you
become aware that problem exists. The warranty repair For questions and additional information concerning EPA Die-
EMISSION RELATED PARTS should be completed by the dealer as expeditiously as sel Engine Exhaust Regulations, contact:
possible.
• Fuel Injection Pump If you have any questions regarding your warranty rights and
• Fuel Injection Nozzles Komatsu Forklift U.S.A., Inc.
responsibilities, you should contact the authorized KFI dealer. 14481 Lochridge Blvd., Building 2
• Turbocharger
Covington, Georgia 30014
LIMITATIONS Voice phone: (770) 385-4815
KFI is not responsible for resultant damages to an emission- Fax phone: (770) 385-4838
related part or component resulting from:
Class IV & V – U.S.A. Komatsu Forklift U.S.A., Inc. EPADSL rev 02/04
EMISSON CONTROL WARRANTY STATEMENT FOR DIESEL ENGINES
EMISSION CONTROL WARRANTY STATEMENT FOR GASOLINE/LPG ENGINES
FEDERAL ENVIRONMENTAL PROTECTION AGENCY (EPA) EMISSION CONTROL

WARRANTY STATEMENT (GASOLINE/LPG ENGINES)
The following statement is provided as required by KFI recommends that you retain receipts covering • Oxygen sensor
regulations of the United States Environmental Protec- maintenance on your off-road engine, but KFI cannot • PCV valve
tion Agency (EPA). deny warranty solely for the lack of receipts or for your • Water temperature sensor
failure to ensure the performance of all scheduled
YOUR WARRANTY RIGHTS maintenance. • Gasoline injector
AND OBLIGATIONS • LPG injector
All new off-road large spark-ignition (LSI) engines As the off-road large spark-ignition engine owner, you • LPG pressure sensor
must be designed, built and equipped to meet the Fed- should be aware, however, that KFI may deny you
• LPG solenoid
eral EPA’s stringent anti-smog standards. warranty coverage if your off-road large spark-ignition
engine, or a part thereof, has failed due to abuse, • Mass air flow sensor
Komatsu Forklift USA, Inc. ("KFI") must warrant the neglect, improper maintenance or unapproved modifi- • Throttle chamber
emission control system on your engine for the periods cations. • Ignition coil (K21/K25)
of time listed below provided there has been no abuse, • Crankshaft position sensor (K21/K25)
damage, neglect or improper maintenance of your Your engine is designed to operate on gasoline and/or
LPG fuel. Use of any other fuel may result in your • Camshaft position sensor (K21/K25)
engine.
engine no longer operating in compliance with the • Distributor (TB45)
Your emission control system may include parts such Federal EPA’s emissions requirements. • Spark plugs
as the carburetor, regulator or fuel-injection system, • Exhaust tube from manifold to catalytic converter
ignition system, engine computer unit (ECM), catalytic You are responsible for initiating the warranty process.
0-8
It is suggested that you present your off-road large • Gasoline fuel hose
converter and air induction system.
spark-ignition engine to an Authorized Komatsu • Gasoline fuel cap
Also included may be sensors, hoses, belts, connec- Dealer as soon as you become aware that a problem
tors and other emission-related assemblies. exists. The warranty repairs should be completed by
the dealer as expeditiously as possible. EMISSION CONTROL WARRANTY –
Where a warrantable condition exists, an Authorized 36 MONTHS OR 4,000 HOURS
Komatsu Forklift Dealer will repair your LSI engine at If you have any questions regarding your warranty FOR POWER TRAIN PARTS
no cost to you, including diagnosis, parts and labor. rights and responsibilities, you should contact
Komatsu's Product Support Dept. at 1-770-385-4815. • Intake manifold
MANUFACTURER’S WARRANTY • Exhaust manifold
COVERAGE In addition to the standard warranty periods, the com-
ponents listed below are covered by the following spe- • Exhaust connector (TB45)
The 2007 off-road large spark-ignition EPA engines cific warranty periods.
are warranted for the time periods listed below. If any
emission-related part on your engine is defective, the EMISSION CONTROL WARRANTY – EMISSION CONTROL WARRANTY –
part will be repaired or replaced by an Authorized 36 MONTHS OR 2,500 HOURS 60 MONTHS OR 3,500 HOURS
Komatsu Forklift Dealer. FOR THE FOLLOWING PARTS
FOR GENERAL PARTS
OWNER’S WARRANTY For the first 2,500 operating hours, or for a period of
RESPONSIBILITIES • ECM
thirty-six months from the date of the first use by the
original purchaser from an Authorized Komatsu Forklift • Catalytic converter
As the off-road LSI engine owner, you are responsible
for the performance of the required maintenance listed Dealer, whichever occurs first, KFI warrants the • Vaporizer
in your Operation and Maintenance Manual. following emission-related parts:
Class IV & V ICE – U.S.A. EPAGAS rev 12/06

EMISSION CONTROL WARRANTY STATEMENT FOR GASOLINE/LPG ENGINES
Komatsu Forklift U.S.A., Inc.

1. FOREWORD
1. FOREWORD
This manual provides rules and guidelines which will help you use this lift truck safely and effectively. Always be
sure to read and understand this manual thoroughly before operating and performing maintenance.
Some actions involved in operation and maintenance of the lift truck can cause a serious accident if they are not
done in the manner described in this manual.
• Improper operation and maintenance of this lift truck can be hazardous and could result in
serious injury or death.
• Operators and maintenance personnel should read this manual thoroughly before beginning
operation or maintenance.
• Keep this manual handy and have all personnel read it periodically.
• Do not use this lift truck unless you are sure that you understand the contents completely.
• If this manual has been lost or has become dirty or worn and cannot be read, request a
replacement manual from your Komatsu Forklift dealer.
• Komatsu Forklift delivers lift trucks that comply with (to the best of our knowledge at the time of
delivery) all applicable regulations and standards of the country to which they have been
shipped. If this lift truck has been purchased in another country or purchased from someone in
another country, it may lack certain safety devices and specifications that are necessary for use
in your country. If there is any question about whether your product complies with the applicable
standards and regulations of your country, consult your Komatsu Forklift dealer before operating
the lift truck.
• Continuing improvements in the design of this lift truck may not be reflected in this manual.
Consult Komatsu Forklift or your Komatsu Forklift dealer for the latest available information on
your lift truck or for questions regarding information in this manual.
• Information on safety is given in “SAFETY INFORMATION” on page 1-2 as well as in Chapter 2,
“SAFETY.”
DIRECTION OF TRUCK
This manual uses the directions left, right, front and rear as they are seen from the operator's seat.
RIGHT
FRONT REAR
LEFT
1-1
2. SAFETY INFORMATION
2. SAFETY INFORMATION
This Operation and Maintenance Manual contains information necessary for the operation of a basic fork lift truck.
Optional equipment is sometimes installed that can change some operating characteristics described in this
manual. Make sure the necessary instructions are available and understood before operating the lift truck.
Some of the components and systems described in this Operation and Maintenance Manual will NOT be installed
on your unit. If you have a question about any item described, contact your local dealer.
Additional information that describes the safe operation and use of lift trucks is available from the following
sources:
• Employment safety and health standards or regulations.
• Safety codes and standards, such as: American National Standard, ANSI B56.1, Safety Standard For Low Lift
and High Lift Trucks.
• Publications from government safety agencies, government insurers, private insurers and private organiza-
tions, such as: Accident Prevention Manual for Industrial Operations from the National Safety Council, and
NFPA 58: Liquefied Petroleum Gas Code.
NOTE: Forklift trucks are not intended for use on public roads.
Most accidents are caused by a failure to follow fundamental safety rules for the operation and maintenance of lift
trucks. To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the lift
truck before operating and performing maintenance. Do not operate or carry out maintenance of this lift truck
unless you are sure that you understand the explanations and procedures completely.
To identify safety messages in this manual and on lift truck labels, the following signal words are used.
These safety messages or labels describe precautions that must be taken to

avoid a hazard which carries a serious risk of serious injury or death.
These safety messages or labels usually describe precautions that must be taken
to avoid a hazard which may lead to serious injury or death.
This word is used on safety messages and safety labels for hazards which could
result in injury or damage to the lift truck or surrounding property if the hazard is
not avoided.
NOTICE This word is used for precautions that may not lead to damage or failure, but which must be taken
to avoid actions that could shorten the life of the lift truck.
Safety precautions are described in the SAFETY, OPERATION and MAINTENANCE sections of this manual.
Komatsu Forklift cannot predict every circumstance that might involve a potential hazard in operation and
maintenance. Therefore the safety messages in this manual and on the lift truck may not include all possible safety
precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your
responsibility to be sure that you and others can do such procedures and actions safely and without damaging the
lift truck. If you are unsure about the safety of some procedures, contact your Komatsu Forklift dealer.
The procedures and precautions given in this manual apply only to intended uses of the lift truck. If you use your lift
truck for any unintended use that is not specifically prohibited, you must be sure that it is safe for you and others. In
no event should you or others engage in prohibited uses or actions as described in this manual.
1-2
3. RUNNING IN A NEW LIFT TRUCK
3.1 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.
3.2 FIRST MONTH SERVICE OR INITIAL 200 HOURS SERVICE

For new lift trucks, carry out the following maintenance only after the first month or 200 hours of operation.
Unit Check items Remarks
Change oil
Replace oil filter element

Engine
Drain water from fuel filter Diesel engine lift truck only
Adjust valve clearance
Change oil
TORQFLOW transmission
Clean strainer and change filter
Differential Change oil
Change oil
Replace line filter

Hydraulic tank
Clean strainer
Clean inside tank
Particularly hub nuts, overhead guard

Other Tighten all bolts and nuts mounting bolts, load backrest mounting
bolts, and operator's seat mounting bolts
1-3
3.3 MODEL LINE-UP

MODELS COVERED IN THIS MANUAL
AX50/BX50 GASOLINE, LPG AND DUAL-FUEL ENGINE MODELS
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
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
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
FG25ST-16 5,000 lb. capacity, K21 gasoline engine, cushion tires
FG25STLS-16 5,000 lb. capacity, K21 LPG engine, cushion tires, LP special
FG25SHTLS-16 5,000 lb. capacity, K25 LPG engine, cushion tires, LP special
BX50 PNEUMATIC TIRE
FG20T-16 4,000 lb. capacity, K21 gasoline engine, pneumatic tires

FG20TUS-16 4,000 lb. capacity, K21 gasoline engine, pneumatic tires, gasoline special
1-4
MODELS COVERED IN THIS MANUAL (Continued)

FG20TLS-16 4,000 lb. capacity, K21 LPG engine, pneumatic tires, LP special
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
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 MODELS
FD20T-16 4,000 lb. capacity, 4D98E diesel engine, pneumatic tires
FD20TUS-16 4,000 lb. capacity, 4D98E diesel engine, pneumatic tires, diesel special
FD28TUS-16 5,500 lb. capacity, 4D98E diesel engine, pneumatic tires. diesel special
FD30TUS-16 6,000 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
4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK
4.1 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.
4.1.1 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):
1-6
4.1.2 WARRANTY
The following statement is required to be provided by regulations of the California Air Resources Board.
YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board is pleased to explain the emission control system warranty on your 2008
engine. In California, new off-road large spark-ignition (LSI) engines must be designed, built and equipped to meet
the state's stringent anti-smog standards.
Komatsu Forklift U.S.A. Inc. (“KFI”) 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 KFI Dealer will repair your LSI engine at no cost to you
including diagnosis, parts and labor.
MANUFACTURER'S WARRANTY COVERAGE

The 2008 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 KFI
Dealer.
OWNER'S WARRANTY RESPONSIBILITIES

As the off-road LSI engine owner, you are responsible for the performance of the required maintenance listed in
this 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 however be aware that KFI 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 California's emissions requirements.
You are responsible for initiating the warranty process. The ARB suggests that you present your off-road large
spark-ignition engine to an Authorized KFI 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 KFI's Product
Support Department at 1-770-385-4815.
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 KFI 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 • 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
1-7
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
NOTICE
Follow the instructions in this 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 USA, Inc.

14481 Lochridge Blvd., Bldg. #2
Covington, GA 30014-4908
Voice phone: (770) 385-4815

Fax phone: (770) 385-4838
1-8
4.2 FEDERAL EPA EMISSION CONTROL STATEMENT FOR

OFF-ROAD DIESEL ENGINES (4D94E 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 4D94E diesel engines in order to comply with current EPA regulations.
4.2.1 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:
1-9
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

The Federal EPA and KFI are pleased to explain the emission control system warranty on your 2007 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 2007 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, 2007 heavy-duty off-road EPA engines are warranted for a period of five (5) years, or three-
thousand (3,000) hours of operation, whichever occurs first. If any emission-related part on your engine is
defective, the part will be repaired or replaced by at an authorized Komatsu Forklift dealer.
EMISSION-RELATED PARTS
• Fuel injection pump
• Fuel injection nozzles
• Turbocharger
OWNER’S WARRANTY RESPONSIBILITIES

As the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance
listed in this manual. 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.
• 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 First 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 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.
1-10
LIMITATIONS
KFI is not responsible for resultant damages to an emission-related part or component resulting from:
• Any application or installation KFI deems improper as explained in this 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.
This warranty is in addition to the KFI 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. 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

KFI 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 KFI engine dealer.
NOTICE
Follow the instructions in this 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 USA, Inc.

14481 Lochridge Blvd., Bldg. #2
Covington, GA 30014-4908
Voice phone: (770) 385-4815

Fax phone: (770) 385-4838
1-11
4.3 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.
4.4 LIFT TRUCK SERIAL NUMBERS

Model Series EPA Compliance Applicable Lift Truck
FG15/18/20(A)(S)HT-20 AX50 2007 Tier 2 (Gas/LP) 675001A and up
FG20/25/28/30/32(S)(H)T-16 2004 Tier 1 (Gas/LP) 200001A - 209999A
FG35AHT-16 2007 Tier 2 (Gas/LP) 210001A and up
BX50
FD20/25/28/30/32T-16 2004 Tier 2 (Diesel) 200001A and up
FD35AT-16 2008 Tier 3 (Diesel) 210001A and up
4.5 SERIAL NO. PLATE POSITION

Located on the upper right side of the dashboard.
Remark
The serial number can also be found on the capacity data plate.
4.6 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.
1-12
4.7 EMBOSSED ENGINE SERIAL NO. LOCATION

The engine serial number is stamped in the position shown below.
• K21/K25 GASOLINE ENGINE
• 4D94E DIESEL ENGINE
4.8 LIFT TRUCK CAPACITY DATA PLATE

For insight on how to read the load capacity chart, see “LOAD
CENTER AND ACTUAL CAPACITY” on page 2-26.
4.9 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.
1-13
5. SAFETY MANAGEMENT
FOLLOW THE INSTRUCTIONS IN THE OPERATION AND MAINTENANCE MANUAL AS WELL AS

ON THE SAFETY LABELS
• Read the instructions in this manual and the safety labels attached to various parts of the lift truck, and make
sure that you understand and follow them. If you do not understand or do not follow the instructions, this will
lead to improper operation which may result in personal injury or damage.
• Be sure that you understand the proper method of using the lift truck and the procedure for carrying out an
inspection, and ensure that they are carried out safely.
• Read this manual and safety labels again from time to time. If the Operation and Maintenance Manual or
safety labels have been lost or have become dirty and cannot be read, obtain replacements from your
Komatsu Forklift dealer and attach the safety labels in the specified positions.
• See “SAFETY LABELS” on page 2-28.
MAKE SAFETY PLANS BEFOREHAND

• Before operation, establish an operating plan and hold a meeting to discuss operating safety.
• In confined areas, position a signal person and carry out operations in accordance with his/her instructions.
FOLLOW THE SAFETY RULES IN PLACE

• Do not operate the lift truck if you are fatigued, or when you have been drinking or have taken any medication
which can make you sleepy.
• When carrying out operation, inspection, or maintenance of the lift truck, always follow all work shop rules,
safety regulations and precautions.
• During operation, always pay attention to safety and be careful of pedestrians and other surrounding
conditions.
ENSURE SAFETY AT THE WORKING AREA

• Always work on level surfaces and wipe up all oil or grease from the ground.
• When working on quays, platforms, or docks, or other places where there is danger of falling, set up blocks to
prevent the lift truck from going over the edge.
• Put warning signs up in dangerous places to warn the operator not to approach.
• Mark the travel areas clearly and maintain the road surface in good condition.
• Put up signs to prevent unauthorized lift trucks from entering areas where lift trucks are being operated.
• Ensure that there is adequate lighting to enable safe operations to be performed.
WEAR SAFETY CLOTHES WHILE IN OPERATION

• Avoid loose clothing, jewelry, and loose long hair, which can
catch on controls or in moving parts and cause serious injury
or death.
• Always wear a hard hat and safety boots.
• Depending on the working conditions, wear other safety
equipment in addition to the hard hat and safety boots.
2-1
KEEP THE OPERATOR'S COMPARTMENT CLEAN AND CLEAR

• Keep the operator's compartment clean and tidy. Be sure to clean up all oil or mud. If the operator's hand or
foot slips it could lead to a serious accident.
• Do not leave tools or spare parts lying around in the operator's compartment; always keep them in the tool box
when not being used. They may damage or obstruct the control levers or pedals.
• Do not drive the lift truck if your hands are wet or covered with oil. Your hands will slip on the work equipment
control levers or directional lever and could cause a serious accident.
REDUCE LOAD FOR LIFT TRUCKS WITH ATTACHMENT

• The permissible load for lift trucks equipped with any attachment is lower than the permissible load for the
standard lift truck, the reasons being:
1. The overall permissible load is lowered by as much as the weight of an attachment itself.
2. The load center shifts toward the front due to the thickness of an attachment.
• Follow the load limit as indicated in the load capacity chart on the nameplate.
• On some detachable-type attachments and inserting-type attachments, there is an additional load capacity
chart or attachment weight label provided at a certain place. Follow the instructions in the chart or the label
when installing such an attachment.
UNAUTHORIZED MODIFICATION
• Do not install any additional equipment, parts or the like on the lift truck, or modify the lift truck without prior
written consent from Komatsu Forklift. An additional counterweight or unauthorized modification of the lift truck
can bring about a negative effect on the stability or strength of the lift truck, and can also impair its safety.
• Do not install any equipment or parts which obstruct or limit the operator's view.
DON'T REMOVE THE OVERHEAD GUARD AND LOAD BACKREST

• The overhead guard is installed to protect the operator from falling objects. It is designed to withstand the force
of light boxes or small packages. It is not designed to withstand every possible impact.
• Always be careful to prevent damage or injury from falling objects.
• Do not use a Komatsu lift truck when it is equipped with a non-genuine overhead guard or load backrest.
Note: Komatsu lift trucks are usually equipped with the optimum overhead guard and load backrest when they
are shipped out of Komatsu Forklift plants.
DON'T USE A DEFECTIVE LIFT TRUCK - USE LOCK-

OUT TAG-OUT PROCEDURES
• Remove the key from the faulty lift truck and hang signs in
the operator's compartment to prevent its use.
• If the lift truck has suffered a failure and the lift truck must be
parked without lowering the forks, put markers on the tips of
the forks and take steps to prevent pedestrians or other
vehicles from hitting the forks.
• Select a parking place where people or vehicles do not
pass, and stop the lift truck so that it is difficult for anyone to
go under the forks. The area under the forks is a danger
zone.
2-2
PRECAUTIONS WHEN REFUELING LPG TRUCKS

• Only trained and authorized personnel may change LPG cyclinders.
• LPG is heavier than air and will sink to the lowest area possible. Avoid parking near areas near floor drains,
lubrication pits, or other areas where escaped fuel may collect.
• After changing, ensure that the replacement cyclinder is securely mounted.
• If you smell LPG odor or there is frost on the fuel cyclinder:
- do not start the engine;
- close the fuel valve at the LPG cylinder;
- park and tag the truck and have qualified personnel inspect and repair the fuel system.
• For additional information, consult the National Fire Protection Association pamphlet 58 for the safe storage
and handling of liquified petroleum gases.
ENGINE EXHAUST GAS IS POISONOUS

Do not leave the engine running where there is poor ventilation.
The engine exhaust gas contains carbon monoxide, which can
cause gas poisoning and result in serious injury or death.
FIRE IS STRICTLY PROHIBITED DURING REFUELING

Fuel is extremely flammable and can cause fires and
explosions.
• Carry out refueling away from flames or sparks.
• Stop the engine when refueling.
• After refueling, tighten the gas cap securely and wipe up any
spilled fuel.
2-3
FIRE, FIRST AID AND GENERAL SAFETY

• When you feel something unusual occurring with the lift
truck, promptly stop working, move the lift truck to a safe
place for parking, stop the engine for safety. Then report to
the supervisor.
• Be sure that fire extinguishers have been provided and that
you read the labels to ensure that you know how to use
them.
• Know what to do in the event of a fire.
• Be sure that you know the phone numbers of persons you
should contact in case of an emergency.
• Provide a first aid kit at the storage point.
• If a fuel leak is discovered, do not operate the lift truck. Be sure to make repairs, stopping the leak before
starting the operation again, while reporting the trouble to the supervisor.
LPG FUEL SYSTEM SAFETY

• Testing of the LPG fuel system and repairs are to be performed by qualified personnel only.
• Accidents involving fuel systems are always dangerous and can cause fire and explosion, serious injury, death
and property damage. Keep the following points in mind when working with fuel systems.
- LPG is heavier than air and will sink to the lowest area possible. Avoid parking truck in areas near floor
drains or lubrication pits where escaped fuel may collect.
- Store all LPG cylinders OUTDOORS in a secured area and safe from any vehicle traffic.
- NEVER WELD ON AN LPG PRESSURE VESSEL, STORAGE TANK OR CYLINDER.
- Ensure that the fuel tank is properly mounted.
- Always use a UL-listed LPG tank.
• Before testing or repairing the LPG fuel system:
- Read, understand and remember relevant information in standard 58 of the NATIONAL FIRE
PROTECTION AGENCY (NFPA).
- Ensure you are wearing proper personal protective equipment.
- Ensure there are NO SOURCES OF IGNITION nearby.
- Ensure your work area is adequately ventilated.
- Keep in mind that LPG is stored under high pressure and ensure that the LPG fuel storage container valve
is turned OFF (closed), and pressure is released from the lines.
- Disconnect the battery and fuel hose coupling.
- Test for fuel leaks. DO NOT work on the system if the fuel storage container is filled with fuel past the 80%
liquid level. Before testing, make sure the system gas pressure is greater than 90 psi (621 kPa). Test all
connections, container, valves and fittings with soap and water or equivalent solution.
• When replacing LPG fuel system components, always use Komatsu genuine parts.
2-4
6. SAFE TRAVEL
6. SAFE TRAVEL
JUMPING ON AND OFF THE LIFT TRUCK IS

STRICTLY PROHIBITED
• When getting in or out of the lift truck, be sure to first stop the
truck and use the handrails (assist grip) as well as the step
to hold yourself securely.
• Do not hold on to or pull yourself up with the control levers or
steering wheel when getting on or off the lift truck.
• Keep the handrails (assist grip) clean all the time, and repair
any damage.
AJM00003
DON'T TRY TO OPERATE THE LIFT TRUCK FROM

OUTSIDE
• Always keep your body under the overhead guard.
• Do not put your hand or foot out of the overhead guard.
• You must be properly seated in the operator’s seat when
operating any function of the lift truck.
MAINTAIN PROPER POSTURE WHILE OPERATING

Travel Interlock (power transmission cutoff) and Lift/Tilt Interlock
(Option)
• If you operate the lift truck when you are not seated properly
or off the seat, an accident may happen unexpectedly. To
forestall such a possible accident, the truck is provided with
Travel Interlock and Lift/Tilt Interlock that make travel and
truck operation impossible if you are not seated properly
(Operator Presence System).
• If you operate the lift truck in such a posture that your weight
is not properly applied to the seat, like standing up or leaning
forward or sideways, the Travel Interlock begins to alarm in
approximately three seconds and cuts off the transmission of engine power. Then the truck will not move, even
if you depress the accelerator pedal or operate the forward-reverse lever.
• Additionally, Lift/Tilt Interlock locks lifting/lowering and tilting operations. Even if you operate the lift lever or tilt
lever, these functions will not work. (The lever for an attachment is not equipped with this function.)
• For details, see “TRAVEL INTERLOCK” on page 3-24 and “LIFT/TILT INTERLOCK” on page 3-28 in Chapter
3, “OPERATION”.
A SUDDEN SHIFT OF THE F-R LEVER IS DANGEROUS

To change the travel direction, stop the lift truck completely and then operate the F-R lever.
2-5
6. SAFE TRAVEL
DON'T ALLOW A PASSENGER ON THE TRUCK

• Never allow any other person to ride with you on the lift
truck.
• Do not use anyone for a makeshift human counterweight.
BE SURE TO WEAR THE SAFETY SEAT BELT

• Always fit your seat belt correctly when operating. If your
seat belt is fitted incorrectly, there is danger of serious
personal injury if the lift truck should tip over.
• Always check the seat belt mounts and check for any
damage to the seat belt. If any abnormality is found, repair
or replace the seat belt immediately.
CHECK THE SURROUNDINGS FOR SAFETY BEFORE

STARTING UP THE ENGINE
• Before stating the engine, check that the parking brake is
set, and that the directional and speed levers are in the
neutral position.
• Adjust the operator's seat and the steering wheel before
starting the engine. Always lock them in position after
adjusting. Adjusting the seat or steering wheel during
operation is dangerous as it may cause you to lose your
balance or operate the lift truck in an unsafe manner.
• Before starting the engine, first check that the surrounding
area is safe, and sit securely in the operator's seat.
• Sound the horn before starting the engine to warn people
around you.
• Do not attempt to start the engine by intentionally short-
circuiting the engine starting circuit.
• Do not attempt to jump start the lift truck.
CHECK AND ADJUST THE REAR VIEW MIRROR AND LAMPS

• When reversing, never depend on the rear view mirror. The operator must visually check behind him. Also,
adjust the rear view mirror so that the operator can check from the operator's seat that the area behind the lift
truck is safe. Always keep the surface of the mirror clean. If the mirror is broken, replace it with a new one.
• Check that all lamps light up correctly. Replace any broken bulbs (for lift trucks equipped with lamps).
2-6
6. SAFE TRAVEL
PERFORM A SAFETY CHECK BEFORE STARTING

THE LIFT TRUCK
• Before starting the lift truck, check that the surrounding area
is safe.
• Before moving the lift truck, raise the forks [approximately 15
to 20 cm (6 - 8 in) from the ground surface], and tilt the mast
back.
• When ready to move, release the parking brake.
BE SAFETY CONSCIOUS WHILE DRIVING

• Keep a clear view of the path of travel and watch for other
traffic, personnel, and safe clearances.
• When passing oncoming vehicles, reduce speed and keep a
safe distance from the other vehicle.
• In places where there are speed limits, observe the speed
limit and maintain a safe distance from other vehicles.
• When traveling, always pay careful attention to the area
around your lift truck, particularly in the direction of travel or
when turning.
• Do not attempt to pass another lift truck or vehicle on a
narrow path or on a spot of limited view like a crossing.
• When passing through an area of limited view, like a
crossing or when running into a narrow path, sound the horn
and check the surroundings for safety.
• Even if you sound the horn, not everyone in the surrounding area will necessarily hear it. Always pay careful
attention to the movements of people in the surrounding area.
• When crossing a passage or turning at a corner, stop the lift truck once to confirm the safety around.
• Always pay careful attention to the movements of people in the surrounding area, and take steps to prevent
people from entering the working area.
• When traveling on a slope or through a crowded spot, always give way (yield) to a loaded lift truck.
DO NOT DRIVE ON ROUGH GROUND OR SURFACE

• Avoid traveling in places which are flooded or where there
are holes.
• Do not try to drive the lift truck on soft ground.
• Avoid curbs, rails, ditches, or other obstacles, and do not
travel directly over them.
• Do not travel on slippery road surfaces.
• When entering buildings, check the weight limit of the floor
and be careful not to exceed the limit.
2-7
6. SAFE TRAVEL
DRIVING ON A ROAD SHOULDER IS STRICTLY

PROHIBITED
• There is a danger that soft road shoulders may collapse, so
do not go near them.
• Always maintain a safe distance from the edge of road
shoulders and platforms.
WHEN DRIVING INTO A RAILWAY CAR, TRUCK OR

CONTAINER, EXERCISE EXTRA CARE
• Do not travel on the edge of docks. There is a danger that
the lift truck may fall, which may result in serious injury or
death.
• Before starting operations, check the load limit for the
gangplanks, and do not use them if they do not have ample
strength to take the weight of the lift truck when loaded.
• Apply the brakes on the truck and block the wheels before
driving the forklift into the truck.
• When driving into trailers, use jacks and take steps to
prevent the trailer from sinking when the forklift truck travels
on it.
• When driving the forklift inside trucks, reduce speed when
backing out and be sure to check that the gangplanks are
safe.
• Be careful of pedestrians.
• Tell the truck driver not to move the truck until the operation
is completed.
• If there is some system to secure the truck to the dock,
always use this system. Secure the gangplanks so that they
do not slip and fall.
2-8
6. SAFE TRAVEL
BE AWARE OF THE LIFT TRUCK'S MAXIMUM HEIGHT

AND WIDTH
• Ensure that there is ample height and width for the lift truck
to pass.
• Do not extend your hands or legs outside the operator's
compartment or the area covered by the overhead guard
(safe area).
• Check that the surrounding area is safe.
• Be careful of electric wires and other obstacles inside and
outside the building.
WHEN DRIVING UP OR DOWN A SLOPE, EXERCISE

EXTRA CARE
• Do not turn, or travel across or at an angle on slopes. There
is danger that the lift truck will tip over.
• Before starting to drive up a slope, stop the lift truck and
adjust the clearance between the ground surface and the
bottom of the forks so that the bottom of the forks or pallet
do not contact the ground surface or the tip of the fork does
not stick into the ground when traveling.
• For safe travel on slopes:
When Travel forward up the slope, and in reverse
loaded: down the slope with the load upgrade.
When Travel in reverse up the slope and forward
unloaded: down the slope with the load-engaging
means downgrade.
• On a downslope, drive down slowly and use the foot brake.

• When starting on slopes, the lift truck may start to move
down the slope depending on the amount the pedals are
depressed.
Always leave ample room in front of and behind the lift truck
when starting on slopes.
• Be careful of the truck sliding downhill if Travel Interlock is
engaged while traveling uphill or on a slope. Stay securely in
the operator ’s seat! See “TRAVEL INTERLOCK” on
page 3-24 for more information.
2-9
6. SAFE TRAVEL
WHEN MAKING A TURN, BE CAREFUL OF THE

SWINGING COUNTERWEIGHT
• Remember that a fork lift truck steers with the rear wheels,
not the front wheels. It will not drive like an automobile.
• When turning while traveling forward, the counterweight will
swing far out. Keep an ample clearance from walls to ensure
safety.
• When turning, travel slowly and be careful that the front or
rear wheels do not come off the ground.
• When turning on soft road shoulders, there is danger that
the rear wheels may come off the road shoulder and cause
the lift truck to tip.
ANY OPERATION THAT MIGHT OVERTURN THE LIFT

TRUCK IS STRICTLY PROHIBITED
• If the load-engaging means or load is raised, the center of
gravity of the lift truck will also rise and increase the danger
of the lift truck tipping. Do not turn the lift truck when the
forks are raised high.
• Do not suddenly raise the forks or tilt the mast to the front or
rear when the forks are loaded. There is danger that the lift
truck will tip.
• Reduce speed before turning the lift truck.
• In particular, when traveling unloaded, the rear of the lift
truck is heavy. If the lift truck is turned at high speed, there is
a greater chance of tipping than when traveling with the
forks loaded.
WHEN BACKING UP THE LIFT TRUCK, VISUALLY

CHECK BEHIND THE TRUCK
• Before backing the lift truck, make sure that there is no one
behind the truck before starting to travel.
• The rear view mirror is simply an aid for checking the rear.
When driving in reverse, do not use the rear view mirror.
Turn to face the rear and check the area directly behind the
lift truck for safe unobstructed travel.
• Even if you sound the backup buzzer, the people behind the
truck may not necessarily hear it. Always check that there is
no one behind the truck before driving the truck. (For lift
trucks equipped with backup buzzer)
DON'T USE A LIFT TRUCK TO TOW ANOTHER BROKEN-DOWN LIFT TRUCK

If there is any problem with the brakes or steering system of your lift truck, do not use another lift truck to tow it as
there is danger that the lift truck may run out of control.
2-10
6. SAFE TRAVEL
WHEN CARRYING A HIGH LOAD, USE A SIGNAL

PERSON OR DRIVE BACKWARDS
• If the view to the front is obstructed by the load, turn to the
rear and drive the lift truck in reverse.
• When driving in reverse with a high load, use a signal
person to ensure the safety of the load and the safety in the
surrounding area.
APPLY THE BRAKES CORRECTLY WHILE RUNNING

• Do not stop the engine while the truck is in motion. When the
engine is not running, the operating efforts for power steering and power brakes (if present) increase. Thus it is
dangerous to stop the engine while running.
• If the inching pedal is depressed, the braking effect of the engine will be lost.
• Do not use the brakes unnecessarily or too frequently. If your lift truck is a TORQFLOW transmission type and
you rest your foot on the inching pedal during operations, the multiple clutch plates of the transmission will
overheat, deforming the clutch plates and causing them to malfunction, in the worst case.
PAY SPECIAL ATTENTION TO THE REAR VIEW WITH AN LPG CYLINDER-INSTALLED

(GASOLINE ENGINE) LIFT TRUCK
• The installed LP gas cylinder partially blocks the rear view and poses a danger of hitting people, piled
commodities, or contact with nearby objects. Therefore, install backup warning devices (backup alarm buzzer,
rotating warning lamp, etc.) or backup safety checking devices such as a rear view mirror in order to warn
people nearby and check for safe conditions in the area of the truck. See “OPTIONAL EQUIPMENT” on
page 2-34.
• When installing optional warning devices, call your Komatsu Forklift dealer for details.
REQUIRED BRAKING DISTANCE DIFFERS DEPENDING ON THE ROAD CONDITIONS

• When traveling downhill, it requires a longer distance for the lift truck to stop than when traveling on level
ground.
• When traveling downhill, reduce the speed and make sure that you have ample room at the bottom of the
slope to stop.
• Traveling on wet surfaces requires a longer distance to stop than when traveling on normal road surfaces.
Always leave ample room to stop.
2-11
6. SAFE TRAVEL
FOLLOW THESE STEPS FOR PARKING

1. Stop the lift truck on level ground.
2. Apply the parking brake securely to make sure that the
lift truck cannot move.
3. Set the directional lever and speed lever to neutral.
4. Tilt the mast forward and lower the fork to the floor.
5. Turn the starting switch to the OFF position.
6. Pull out the starting switch key and leave the lift truck.
7. LPG trucks: close fuel valve on fuel cylinder after park-
ing the lift truck.
PARK THE LIFT TRUCK IN A SAFE PLACE

• Park the lift truck in the specified place.
• Park the lift truck on a firm surface.
• Do not park near any emergency exit, stairway, fire extinguisher, or other safety equipment. Park the lift truck
in a place where it will not obstruct pedestrians or other vehicles.
• Never park the lift truck near heat, ignition sources, or any flammable object.
• If there is no way to avoid parking on a slope, immobilize the lift truck by putting blocks under the tires in
addition to normal parking procedures.
• LPG trucks: LPG is heavier than air and will sink to the lowest area possible. Avoid parking near areas near
floor drains or lubrication pits where escaped fuel may collect.
SHOULD THE LIFT TRUCK BECOME INOPERATIVE IN A DANGEROUS PLACE LIKE A

RAILROAD CROSSING, LET ALL PEOPLE AROUND KNOW IMMEDIATELY
• If engine trouble occurs on a railroad crossing and the lift truck does not move, it is impossible to use the
starting motor as can be done on a standard-shift automobile. (This is because a neutral safety switch is
installed.)
• In such an emergency, light a flare or smoke candle to warn approaching trains and people in the area that
there is a broken-down truck on the tracks.
DON'T USE THE DRAWBAR PIN FOR OTHER THAN

IT’S INTENDED PURPOSE
• Do not use the drawbar pin for any other towing purpose
than to bail out a stuck lift truck, or to be towed by another lift
truck or to be hoisted.
• The towing pin at the back of the counterweight is provided
to pull out the lift truck when it has gotten stuck in dirt or a
ditch as well as when it is being loaded on a truck.
2-12
7. LOADING OPERATIONS
PRECAUTIONS FOR LOADING AND UNLOADING

• If you operate the lift truck in such a posture that your weight
is not properly applied to the seat, like standing up or leaning
forward or sideways, Travel Interlock begins to alarm in
approximately three seconds and cuts off the transmission
of engine power. Then the truck does not move even if you
depress the accelerator pedal or operate the forward-
reverse lever.
The truck will slide downhill if Travel Interlock activates on
an uphill grade or a slope.
• Select flat and solid ground for loading and unloading. Avoid
a road shoulder or a place near a cliff.
• Use ramps of sufficient length, width and strength. Moreover, set them securely so that they will not shift or be
displaced.
• Always operate the mast and forks from the operator's compartment. Be careful not to operate the lever by
mistake. There is danger that the forks or work equipment may cause serious injury.
KEEP UNAUTHORIZED PEOPLE OUT OF WORKING AREA AND ENSURE A SIGNAL PERSON IS
ON DUTY
• Do not allow anyone in the working area except the signal person.
• Do not let any person or other lift truck come close during operation.
• When working with a signal person, always follow their instructions.
NEVER GO BENEATH RAISED FORKS

The space under a lifted fork is an area of danger, so never
allow anyone to go under the fork. There is a danger of
personal injury to any person who could be crushed under the
forks when they come down.
STANDING ON THE FORK(S) IS STRICTLY

PROHIBITED
• Do not let anyone place a load on the forks.
• Do not let anyone directly remove the load from the forks.
• Standing on the forks is dangerous because the forks are
slippery and the load may move.
• Do not use anyone to keep the load stable. The lift truck may
move unexpectedly, causing the load to fall and crush the
person.
2-13
BE CAREFUL NOT TO GET CAUGHT IN THE MAST

STRUCTURE
Never put your hands or feet into the mast structure. There is
danger that you will get caught in moving parts and be seriously
injured.
DON'T CLIMB ON THE MAST OR LOAD BACKREST

If you climb on the mast or load backrest, there is a danger that
you could get caught up in the moving parts or fall off.
USE A PALLET OR SKID OF SUFFICIENT STRENGTH

• Always be sure that the pallets and skids have ample strength. If broken or damaged pallets or skids are used,
there is a risk that the load may fall.
• Always check that the load is positioned securely and safely on the pallet before moving the truck.
HANDLE A LONG OR WIDE LOAD WITH EXTRA

CARE
• Be extremely careful when carrying long or wide loads.
Raise the load slowly and be careful not to touch anything in
the surrounding area.
• Keep the load as low as possible and be sure to maintain
the balance.
• When turning, operate slowly and be careful not to let the
load shift or move.
2-14
WATCH OUT OVERHEAD

• As the fork goes up, the mast height increases. Be mindful
of this fact during the operation.
• Take care so that the mast or the overhead guard will not hit
electric wiring, piping, sprinklers, beams in the ceiling, and
so on. If such contact occurs, there is the danger that the
load on the fork may fall off or the lift truck may tip over.
OVERLOADING IS STRICTLY PROHIBITED

• Do not load the lift truck over the maximum capacity shown
in the load capacity chart, otherwise there is the danger that
the rear wheels may come off the ground, the operator may
lose control of the lift truck; and the truck may tip over.
Moreover the load on the forks can collapse.
• Never exceed the max. load shown in the load capacity
chart on the nameplate. (See “LOAD CENTER AND
ACTUAL CAPACITY” on page 2-26.)
DON'T HANDLE A LOAD IN AN INSECURE MANNER

• Make sure that the center of gravity of the load is in line with
the center of the lift truck. Do not carry loads off-center.
There is danger that unbalanced loads may cause the lift
truck to tip.
• Place the load so that it contacts the load backrest.
• Do not handle unstable loads. If there is danger that the load
may fall off, secure it in position and take steps to prevent
the load from collapsing or falling.
DON'T HANDLE A LOAD EXCEEDING THE LOAD

BACKREST HEIGHT
Keep the height of the load within the height of the load
backrest. Do not carry any load that is higher than the load
backrest. If the load is higher than the load backrest, there
is danger that it will fall back on top of the operator,
resulting in serious injury or death.
2-15
BE CAREFUL OF THE FORK TIPS

• Do not allow the tips of the forks to get close to people. The
tips of the forks are pointed, so there is a risk that they may
cause injury.
• Do not attempt to hook something with the tips of the fork,
otherwise the hooked object can suddenly come off the tip,
and the reaction can cause danger to the lift truck as well as
to the hooked object.
DON'T USE THE FORK TO PUSH OR PULL A LOAD

There is a risk that the load will be damaged or fall.
DON'T TILT THE MAST FORWARD WITH A LOAD ON

THE FORK.
• Do not tilt the mast forward with the load raised. Do not raise
the load when the mast is tilted forward. There is danger of
the load falling or the truck tipping over.
• Do not travel with the mast tilted forward.
• Do not load and unload on slopes.
BE CAREFUL OF SLACK IN THE HOIST CHAINS

• If there is any slack in the chain, the mast rail or forks may
catch in the load or a shelf, and there is danger that the load
may fall and the lift truck tip.
• Always be careful that there is no slack in the chain when
pulling the forks out from pallet or shelf.
2-16
DON'T USE THE LIFT TRUCK IMPROPERLY

• Do not use the lift truck for any other purpose than was
originally intended (the loading work using the fork or
attachments).
• Do not use the forks to open or close the doors of railroad
cars or warehouses.
• Do not push any other vehicle.
• Do not hook ropes on the forks and use the forks to lift loads.
• Do not use the drawbar pin for towing operations.
2-17
8. SAFETY IN PERIODIC MAINTENANCE
PERIODIC MAINTENANCE WORK MUST BE CARRIED OUT BY QUALIFIED PERSONNEL

Only persons authorized by the owner or operator of the equipment and having proper certification (local or
national) may carry out inspection, maintenance and repairs of the lift truck. If inspection, maintenance, or repair
work is carried out incorrectly, it may create a hazardous condition.
DESIGNATE A LOCATION FOR PERIODIC MAINTENANCE WORK

• When carrying out inspection and maintenance, use a level, dry, dust-free area.
• If the work is carried out inside a building, make sure that there is ample ventilation.
PRECAUTIONS BEFORE PERIODIC MAINTENANCE WORK

• Read rules and regulations for safety control, safe driving, and loading and unloading operation carefully and
understand them fully.
• To be prepared for a fire, have a fire extinguisher nearby and make sure that you know how to use it.
• Before carrying out inspection, lower the forks to the ground and stop the machine.
• Before starting the inspection and maintenance work, turn the engine starting switch to the OFF position and
keep the engine at a standstill.
• Keep the engine starting switch in the OFF position except when otherwise required in order to keep the
engine at a standstill.
• Set the MAINTENANCE IN PROGRESS sign in a place in the operator's compartment or near the control
panel where it is easy to see.
• Set the forward-reverse lever, high/low speed lever, and work equipment lever each to the neutral position.
• Apply the parking brakes and put stoppers (chocks) both before and behind the tires.
PRECAUTIONS DURING PERIODIC MAINTENANCE WORK

• Wipe off any oil or grease. Immediately wipe up any oil that has leaked. If the lift truck is dirty, it becomes
difficult or impossible to find cracks or other problems.
• Always clean the lift truck before starting inspection.
• Do not smoke or allow any flame to exist under any circumstances.
• Do not use any cloth which is soaked in oil, or grease. There is danger that it may catch fire.
• Wear adequate working clothes and protective equipment (hard hat, safety shoes, goggles and gloves).
• When working on top of the lift truck, be careful not to fall.
• Do not put your feet under the forks.
• When opening or closing the floor plate or engine hood, be careful not to get your hands or body caught.
• When carrying out inspection with the forks raised, insert a stand under the inner mast to prevent the forks and
mast from dropping.
• Before starting the inspection and maintenance work, disconnect the cable from the battery negative (-)
terminal.
• When carrying out job with another worker, decide who is the leader and carry out the job in accordance with
instructions from that person.
• After finishing repair work, perform a test drive of the lift truck.
• During the trial run, start/operate the lift truck carefully because it is possible that the trouble has not been fully
corrected or that defective parts have not been removed.
2-18
PERIODIC INSPECTION OF CRITICAL REPLACEMENT PARTS

Replace critical safety parts with a new one periodically even if no defect is found. Parts tend to deteriorate as
time goes by, and can cause fire or failure in the work equipment system. However, if these parts show any
abnormality before the replacement interval has passed, they should be repaired or replaced immediately.
USE OF PROPER TOOLS AND EQUIPMENT

Always use tools that are suited for inspection and maintenance. It is extremely dangerous to use broken tools or
tools designed for another purpose.
SAFE HANDLING OF BRAKE OIL

It is dangerous if the brakes do not work because in this condition, the lift truck cannot be stopped. Always do the
following.
• Check the level of the brake fluid periodically.
• Always use the specified brake fluid.
• Check that the breather of the brake fluid reserve tank is not clogged.
• Be careful not to let dirt or dust get into the brake fluid reserve tank.
BE CAREFUL OF BOILING ENGINE COOLANT

• Immediately after using the lift truck, the engine coolant is at
high temperature and high pressure. Do not remove the
radiator cap under these conditions as hot water may spurt
out and cause burns.
• When removing the radiator cap, turn it slowly to release the
internal pressure.
• When checking the coolant level, stop the engine and wait
for the engine and radiator to cool down before checking.
2-19
BE CAREFUL OF HIGH PRESSURE AND HIGH

TEMPERATURE HYDRAULIC OIL
• Immediately after using the lift truck, the oil is at high
temperature. Do not drain the oil or replace the filter when
the oil is hot as hot oil may spurt out and cause burns.
• Wait for the truck temperature to go down before carrying
out the inspection and maintenance work.
• Do not forget that the work equipment circuits are always
under pressure. Do not add oil, drain oil, or carry out
maintenance or inspection before completely releasing the
internal pressure.
• If oil is leaking under high pressure from small holes, it is
dangerous if the jet of high-pressure oil hits your skin or
eyes. Always wear safety glasses and thick gloves, and use
a piece of cardboard or a sheet of plywood to check for oil
leakage.
• If you are hit by a jet of high-pressure oil, consult a doctor
immediately.
BE CAREFUL OF THE ROTATING COOLING FAN AND

BELT
• It is extremely dangerous if part of your body or a tool in your
hand gets caught up in the rotating fan or fan belt. Never
touch them when rotating.
• When inspecting rotating parts, do so only after the engine
comes to a stop.
• When inspecting the areas around rotating parts, do not
allow anything to come close which may get caught.
JUMP STARTING THE ENGINE IS PROHIBITED

Do not push the lift truck to start the engine. There is danger that the lift truck may suddenly start and operate
unexpectedly.
2-20
AVOID THE DANGER OF GETTING CAUGHT UP OR

FALLING OFF
• Never put your hands or feet into the mast structure. There
is danger that you will get caught in moving parts and be
seriously injured.
• Do not use the mast as a ladder.
If you slip, there is danger that you will fall.
INSPECTION AND INFLATION OF TIRES

• If the tire inflation pressure is low, it will affect truck stability.
However, do not inflate the tires before checking the rims for
damage. If a rim is damaged or cracked when a tire is
inflated, there is danger that the rim will break under the high
pressure of the tire, resulting in personal injury or death.
• For safety, when checking tire pressure, place your body in
front of the tread face of the tire. Do not check from the side
face of the tire.
• Always have tire inflation work carried out by properly
qualified personnel.
• The tire inflation pressure on a forklift truck is several times
higher than the pressure on an automobile, so exercise caution when handling tires.
• When the tires are being inflated, there is danger that dirt or dust may be thrown up by the compressed air and
enter your eyes, so always wear safety glasses.
HANDLING OF TIRES
• Disassembly and assembly of tires should be carried out by
a qualified tire dealer.
• The tire inflation pressure is extremely high, so caution is
needed when handling tires.
• When removing a tire, do so only after the internal air is
released. Loosen hub nut (1) to remove the tire from the
chassis. Never loosen rim nuts (2) if installed because it is
very dangerous to do so.
• After replacing the tires, make a trial run to make sure that
there are no loose hub nuts. If the tightening torque is not
sufficient, further tighten the hub nuts to the specified torque.
For the correct tightening torque, refer to “SERVICE DATA” on page 4-11.
2-21
JACKING-UP THE LIFT TRUCK FOR INSPECTION

AND REPLACEMENT OF TIRES
• Do not go under the forklift truck when it is jacked up.
• Check the following before jacking up the lift truck. (For
details, see “REPLACING TIRES” on page 4-38.)
1. Check that there is no one on the lift truck.
2. Check that there is no load on the forks.
• When jacking up, stop when the tires come off the ground
surface. Put blocks under both sides of the frame to prevent
the lift truck from coming down.
• Put a tire stopper behind the tires in contact with the floor so
that the lift truck will not move freely.
PRECAUTIONS WHEN USING BOOSTER (JUMPER) CABLES

• ALWAYS wear safety glasses or goggles when starting the lift truck with booster cables.
• When starting using the battery of another lift truck, do not allow the two lift trucks to touch.
• Stop the engine before connecting the cables.
• Be extremely careful not to let the cables get caught in the fan or fan belt.
• Ensure that the cables are hooked up correctly - positive-to-positive and negative-to-negative. Never let the
positive (+) and negative (-) terminals contact each other.
SAFE HANDLING OF WASTES FROM LIFT TRUCK

Obey appropriate laws and regulations when disposing of
harmful objects such as oil, filters, and batteries.
PRECAUTIONS FOR WASHING LIFT TRUCK WITH

WATER
• If water gets into the electrical system (controller, sensor,
connectors, etc.), there is the hazard that it will cause
malfunctions or operational failure. Do not wash the
electrical system with water or high-pressure steam.
• For more details on the washing method, see “LIFT TRUCK
WASHING PROCEDURE” on page 3-35.
2-22
SAFE HANDLING OF BATTERIES

• Battery electrolyte contains sulfuric acid, and can quickly
burn the skin and eat holes in clothing. If you spill battery
electrolyte on yourself, immediately shed the clothes, flush
the part with a large quantity of tap water and then consult a
doctor.
• Should battery electrolyte get into your eyes, flush them
immediately with fresh tap water for 10 to 15 minutes and
then consult a doctor at once.
• Should you drink battery electrolyte by accident, either drink
a large quantity of water or milk mixed with beaten egg white
or salad oil, and then consult a doctor at once.
• Be sure to wear goggles, safety gloves and rubber-soled shoes at the time of battery maintenance.
• Do not smoke or create any spark near the battery. Batteries generate hydrogen gas. Hydrogen gas is highly
EXPLOSIVE, and is easily ignited with a small spark or flame.
• When inspecting or handling the battery, do so only after turning the engine starting switch key to the OFF
position and stopping the engine.
• When disconnecting the battery cables, disconnect the cable of the negative (-) terminal first. Conversely,
when connecting them again, connect the cable of the positive (+) terminal first.
• Avoid short-circuiting the battery terminals through accidental contact with tools or other metal objects across
the terminals.
• Tighten the battery terminals securely. Loose terminals can generate sparks and lead to an explosion.
• When connecting the disconnected battery cables again, be sure which is the positive (+) terminal and which
is the negative (-) terminal in order to avoid improper connection.
• Tighten the battery caps securely.
• When cleaning the battery, leave the battery caps tightened.
• Do not put a metallic tool or plate on the battery terminals by accident. There is danger that such a metallic
object could cause short-circuiting leading to a fire.
PRECAUTIONS WHEN CHARGING BATTERIES

When the battery is charged, hydrogen gas is generated and the battery is heated by the chemical change. To
prevent the danger of gas explosion, always do as follows.
• Before charging the battery, check that the battery electrolyte level stays within the specified range. If the
electrolyte is found insufficient, add distilled or purified water without fail.
• Carry out the charging operation in a well-ventilated place.
• Do not smoke or allow any flame or ignition source.
• Start to charge the battery when the battery electrolyte temperature is below 35ºC (95ºF). If the electrolyte
temperature is above 50ºC (122ºF), wait until it goes below 35ºC (95ºF).
• When using a battery charger to charge the battery, take the battery caps off.
SAFE HANDLING OF ANTI-FREEZE

• Antifreeze can be a flammable. Keep away from flame when handling.
• Antifreeze is poisonous, so do not drink it. If you drink it by mistake, drink large amounts of water, vomit it out,
and get medical attention immediately. Follow safety precautions on container.
2-23
9. TOWING
9. TOWING
HOW TO MOVE A DISABLED LIFT TRUCK

Use extra care when towing a lift truck if there is a problem with any the following;
a. Brakes do not operate correctly.
b. Steering does not operate correctly.
c. Tires are damaged.
d. Traction conditions are poor.
a. The lift truck must be moved on a steep grade.
If the steering pump motor does not operate, steering control of the lift truck can be slow. This can make the
control of the lift truck difficult. If there is no power, there is no power steering.
DO NOT tow the lift truck if there is no power. Poor traction can cause the disabled lift truck or towing vehicle to
slide. Steep grades will require additional brake force to stop the lift truck.
Never carry a disabled lift truck unless the lift truck MUST be moved and cannot be towed. The lift truck used to
carry the disabled lift truck MUST have a rated capacity equal to or greater than the weight of the disabled lift
truck. The capacity must be for a load center equal to half the width of the disabled lift truck. See the nameplate of
the approximate total weight. The forks must extend the full width of the disabled lift truck. Center the weight of the
disabled lift truck on the forks and be careful not to the damage the under side of the lift truck.
HOW TO TOW THE LIFT TRUCK

1. The towed lift truck must have an operator.
2. Tow the lift truck slowly.
3. Raise the carriage and mast channels and secure from moving.
4. If another lift truck is used tow the disabled lift truck, that lift truck must have an equal or larger capacity
than the disabled lift truck. Install an approximate half-capacity load on the forks of the lift truck that is
being used to tow the disabled lift truck. This half-capacity load will increase the traction of the lift truck.
Keep the load as low as possible.
5. Use a towing link made of steel that attaches to the tow pins in the counterweights of both lift trucks.
HOISTING LIFT TRUCK

• Never lift the truck by the overhead guard. If the truck has to
be lifted frequently, it is necessary to install special lifting
equipment, so please contact your Komatsu Forklift dealer.
• Fit wire ropes to the specified lifting points.
• When lifting the lift truck, check that the wire ropes have
ample strength and are not damaged.
• Never go under the lifted truck.
• If the specified lifting point is the counterweight, check that
the counterweight mounting bolts are tightened to the
specified torque before carrying out the lifting operation.
Check also that there is no damage to the lifting portion on
the counterweight.
• When using the hooks on the counterweight to hoist the lift
truck, check beforehand that the counterweight mounting
bolts are tightened to the specified torque and that there is
no abnormality on the hooks.
2-24
10. STRUCTURE AND STABILITY OF THE LIFT TRUCK
To operate the lift truck safely, it is important to understand the structure and stability of the lift truck.
This section will educate the operator in methods to prevent tipping-over the lift truck.
STRUCTURE OF LIFT TRUCK

Forklift trucks basically consist of a lifting mechanism (fork and
mast) and a main body (vehicle). The front wheels act as a
fulcrum and the center of gravity of the lift truck and that of the
load are kept in balance. The relationship between the positions
of these two centers of gravity plays a very important role for the
safety of the lift truck.
CENTER OF GRAVITY OF LOAD

The loads carried by forklift trucks come in various shapes from
boxes to planks and long objects. To judge the stability of the lift
truck, it is important to distinguish the position of the center of
gravity for loads of various shapes.
CENTER OF GRAVITY AND STABILITY

The stability of the lift truck is determined by the position of a
combined center of gravity resulting from combining the centers
of gravity of the lift truck and the load. When the lift truck is
carrying no load, the center of gravity of the lift truck remains
unchanged. On the other hand, when it is carrying a load, the
center of gravity of the lift truck shifts to a combined center of
gravity from the centers of gravity of both the lift truck and the
load. The position of the center of gravity of a load changes as
the mast is tilted back or forth, or it is raised or lowered. The
position of the combined center of gravity also changes
depending on the following factors.
• Size, weight, shape of load
• Lifting height
• Tilting angle of mast
• Inflation pressure of tires
• Acceleration, deceleration, turning radius
• Condition of road surface, angle of road
• Type of attachments
2-25
STABLE RANGE OF CENTER OF GRAVITY

For the lift truck to remain stable, the combined center of gravity
of the lift truck must come within a stable range of the center of
gravity, i.e. a triangle formed by three points of the right and left
front wheels in contact with the floor and the center of the rear
axle.
When a position of the combined center of gravity shifts beyond
the front axle, the lift truck will tip over in the forward direction with
the front wheels acting as a fulcrum. On the other hand, when a
position of the combined center of gravity shifts outside of a
stable range of the center of gravity, the lift truck will overturn in
the direction of shifting.
ACTUAL CAPACITY
The horizontal distance from the position of the center of gravity
of a load on the fork to the upright load backrest of the fork is
called a load center.
Actual capacity means the maximum weight of a load that can be
loaded at a certain load center.
A load capacity chart is given in the name plate. The chart shows
the relationship between the actual capacity and a load center.
As a load center shifts toward the fork tips, so does the position of
the combined center of gravity, too. Therefore, the load has to be
decreased accordingly in the actual operation.
When the lift truck is equipped with an attachment, or when the mast is raised high, the actual capacity is reduced.
Take this fact into consideration in such a case.
LOAD CAPACITY CHART

In the load capacity chart, capacity is shown in relation to load center.
Capacity values are determined according to each model on the
condition of the specifications shown on the plate.
Before proceeding to loading a load, make sure that the load center
and the load are well within the confines of capacity.
When the load is in a complex shape, pull the load closer to the load
backrest so that the heaviest portion of the load comes to the fork
center.
Should a load be loaded beyond the confines of capacity, it would pose a serious danger to the lifting truck as the
rear wheels (for steering) are likely to lift off the ground, causing the operator to lose control of steering.
To make the things still worse, the lift truck will likely tip over while in operation. Therefore, always make sure that
the load is absolutely within the confines of capacity.
LOAD CENTER AND ACTUAL CAPACITY

A nameplate shown at right is just an example. In the actual
operation, follow the instructions on a nameplate of the actual lift
truck.
An example here shows a nameplate for a lift truck which has a
mast of max. fork height of 3.0 m and which is not equipped with any
attachment.
(1) When the load center is 500 mm (2) Capacity: 2,500 kg
(1) When the load center is 600 mm (2) Capacity: 2,250 kg
(1) When the load center is 1,000 mm (2) Capacity: 1,620 kg
Even when the load center is shorter than 500 mm, the actual capacity is 2,500 kg (2).
It is required to replace the present nameplate with a new one when the present nameplate is broken or has
become difficult to read. In that case, call your Komatsu Forklift dealer asking for a new replacement nameplate.
2-26
SPEED AND ACCELERATION

If a stationary object is not subjected to external force, it will remain stationary. In the same way, if a moving object
is not subjected to external force, it will continue to move at the same speed. This is called inertia.
Because of inertia, a force is applied towards the rear when the lift truck starts to move, and is applied towards the
front when the lift truck stops. If the brakes are applied suddenly, there is danger of a large force being applied
towards the front which may make the lift truck tip or the load to be expelled.
When the lift truck is turned, a centrifugal force is applied to the outside from the center of the turn.
This force pushes the lift truck to the outside and makes it tip. The range of stability to the left and right is
particularly small, so it is necessary to reduce speed when turning, in order to prevent the lift truck from tipping. If
the lift truck is traveling with a raised load, the position of the overall center of gravity is high, so the danger of
tipping to the front, left, or right becomes greater.
2-27
11. SAFETY LABELS
11. SAFETY LABELS
Keep safety and other labels clean. If a label comes off, stick it on again or replace with a new one.
Overhead guard
On dash to right On engine inside right
of steering column 8 Overhead guard
1 11 2 inside left
Right side 9
12 Inside rear
of bonnet
right stay
Outside both 5
outer masts
13
Rear outer 7
mast stay
15
3 Inside front
left stay
4 14
Outside both 10 Inside rear
front stays tire rims
6 Top of radiator shroud
Details and ordering information for labels are given in the following sections.
2-28
11. SAFETY LABELS
1. Jump start prohibited. Start the engine only after sitting down in the
operator's seat. Do not attempt to start the engine by short-circuit-
ing the engine starting circuit. Such an act may cause serious
bodily injury or fire.
2. Avoiding danger if lift truck overturns during operations.
Tip-over can occur even when unloaded. In case of

Don't risk injury or death. tip-over
Slow down before turning! Buckle seatbelt
Follow these
instructuions: Don't jump Hold on tight Brace feet Lean away WARNING
3EB-96-A5111
(a) (b) (c) (d) (e)

If the steering is operated suddenly during operations, there is danger that the lift truck may lose its balance and
tip over. To avoid this danger, always observe the following precautions strictly.
a. Always wear your seat belt during operations.
b. Never jump off the lift truck.
c. Hold on tight to avoid falling out and having the lift truck fall on top of you.
d. Brace yourself with both feet to support your body.
e. Lean in the opposite direction from the direction in which the lift truck is tipping.
Items (b) through (e) are instructions for when the lift truck tips over.
3. Using the parking brake.
WARNING
• Pull parking brake to locked position and shut off power before
leaving seat.
• When parked with the power on, place high-low and forward-reverse
lever in neutral.
• If force required to engage brake is low (less than 44 lbs.), chock
wheels when parking truck and contact forklift dealer for service.
See manual for details.
3EB-96-A5821
2-29
11. SAFETY LABELS
4. Seating capacity – One No passengers allowed.
5. Prohibit the operator from standing on the forks.

Never enter the area under the forks.
WARNING
3EB-96-A5920
6. Use caution to avoid getting hand caught in fan (not shown)

(P/N 3EB-96-A5931).
7. Use caution to avoid getting hand caught.
WARNING
3EB-96-A5940
2-30
11. SAFETY LABELS
8. Caution before operating machine.
9. Warning for operation.
WARNING
SERIOUS INJURY OR DEATH MAY RESULT IF YOU FAIL TO FOLLOW THESE PRECAUTIONS!
Before Operating
• Do not operate or repair truck unless trained and authorized. • Do not handle unstable loads or loosely stacked loads.
• Read and understand all warnings and instructions in manuals • Do not handle loads higher than load backrest.
and on truck before operating. • Space forks as far as load permits.
• Dealers have replacement manuals. • Be sure load is centered and forks are completely under load.
• Check truck before use. If truck is in need of repair, do not • Never tilt load with mast tilted forward.
operate until restored to safe condition. • Do not tilt forward when elevated except to pick
• Do not start truck if fuel is leaking or has leaked. up or deposit load.
• Use attachments for intended purpose only. • Travel load or lifting mechanism low and tilted back.
• Tipover can occur if operated improperly.
• Do not jump if truck begins to tipover.
While Operating Hold on firmly and lean away from point of impact.
• Operate truck only from operator's seat. Avoid being trapped between truck and ground.
• Sit firmly in the seat with good posture while driving.
Leaving the seat or sitting improperly for approximately 3 General Precautions
seconds may cause the drive system to disengage. • Allow no one to stand or pass under or near load or
Unintended truck movement like rolling on an incline may occur. lifting mechanism.
• Keep truck under control at all times. • Never place any part of body into mast structure, between
• Do not overload truck. Check capacity plate for load weight mast and truck or outside truck.
and load center. • Do not carry passengers on any part of truck.
• Avoid any sudden starts, stops, turn or change of direction. • Lift no one under any circumstances.
• Obey traffic safety rules. Yield right-of-way to pedestrians. • Do not operate without overhead guard and load backrest.
• Keep clear view of travel path. If load being carried blocks • Fill fuel or charge battery only in specified place.
forward view, travel with load trailing. • Stop engine when fueling and avoid open flame or sparks,
• Slow down and sound horn when vision is blocked. and provide adequate ventilation.
• Watch clearances, especially forks, mast, overhead guard and • Keep vent caps clear when charging battery.
tailswing area. • Disconnect battery during servicing.
• Slow down for turns and on uneven or slippery surfaces.
• Avoid running over loose objects.
• Never angle or turn on incline. After Operating
• Travel with load uphill when loaded. • Before getting off truck, shift F-R lever and high-low
• Travel with lifting mechanism downhill when empty. lever (clutch type) to neutral position, fully lower
• Secure dockboard or bridgeplate properly. lifting mechanism and pull parking lever securely.
• Do not exceed rated capacity. • Shut off power when leaving truck unattended.
• Use special care when operating on dockboard or bridgeplate. • Block wheels when parking on incline.
3EB-96-A6120
2-31
11. SAFETY LABELS
10. Warning for use of split rim (pneumatic tires only).
11. Replace overhead guard if damaged.
WARNING REPLACE IF DAMAGED!

This overhead guard offers reasonable protection to operator
from falling objects but cannot protect against every possible impact.
Impact test rating: 16000 foot pounds.
37B-1QT-A030
12. Method of hoisting the lift truck. Never use the overhead guard to
lift the truck. 3EB-96-25520
13. Warning for handling LPG/FLAMMABLE GAS (on LP tank

bracket).
2-32
11. SAFETY LABELS
14. Slide seat forward prior to opening bonnet.
15. Fuel type.

a b c
EPA REGULATION
GASOLINE FUEL
37B - 1Q A - 3010 3 7 B -1 QB -3 0 1 0
USE LOW SULFUR
FUEL OR ULTRA LOW
SULFUR FUEL ONLY
3EB-96-A7910
SAFETY LABEL ORDERING INFORMATION

Use the chart below to order the safety labels described above.
LABEL# ORDER PART NO.
1 09842-A0481
2 3EB-96-A5111
3 3EB-96-A5821
4 3EB-96-A5910
5 3EB-96-A5920
6 3EB-96-A5931
7 3EB-96-A5940
8 3EB-96-A5960
9 3EB-96-A6120
10 3EB-96-A5970
11 37B-1QT-A030
12 3EB-96-25520
13 3EB-96-A5951
14 3EB-96-A7560
a: 37B-1QA-3010
15 b: 37B-1QB-3010
c: 3EB-96-A7910 (DIESEL)
2-33
12. OPTIONAL EQUIPMENT
12. OPTIONAL EQUIPMENT
Various safety devices are available as options. If operating conditions demand it, please install these devices. The
devices listed below are only examples. Various other devices are also available. For details, please contact your
Komatsu Forklift dealer.
12.1 REAR LAMP

Install this when carrying out operations at night which require the rear area to be lighted.
(The law demands that sufficient lighting be provided to ensure safety.)
12.2 HIGH LOAD BACKREST

This improves the support for high loads and improves the stability of the load.
12.3 WIDE FORK CARRIAGE

This improves the support for wide load and improves the stability.
12.4 AUDIBLE SPEED ALARM

When the lift truck exceeds the preset speed, a buzzer sounds to warn the operator.
12.5 WARNING LAMPS

The following warning lamps may be added to the instrument panel.
• Battery electrolyte level warning lamp
• Air cleaner element clogging warning lamp
• Radiator cooling water level warning lamp
2-34
13. GENERAL VIEW
13.1 GENERAL VIEW OF LIFT TRUCK

13. GENERAL VIEW
1 2 3 4 5
17
8
16
15
14
10
11
12
13
1. Mast 10. Rear wheel

2. Lift cylinder 11. Engine hood
3. Head lamp 12. Tilt cylinder
4. Turn signal lamp 13. Front wheel
5. Overhead guard 14. Fork
6. Assist grip 15. Fork carriage
7. Operator's seat 16. Load backrest
8. Counterweight 17. Lift chain
9. Fuel filter
3-1
13. GENERAL VIEW
13.2 INSTRUMENTS AND CONTROLS

The numbered items in the illustration below are described in the "OPERATION" section starting on page 3-18.
1 2 3 4 5
7 8 9 10 11 12 13
1. Forward-Reverse lever 8. Parking brake lever

2. Horn button 9. Fuse box (under hood behind latch)
3. Combination switch (turn signal/lamp switch) 10. Inching pedal
4. Lift lever 11. Brake pedal
5. Tilt lever 12. Starting switch
6. Tiltable steering wheel lock lever 13. Accelerator pedal
7. Brake oil reservoir
3-2
13. GENERAL VIEW
13.3 METER PANEL COMPONENTS

The numbered items in the illustration below are described in the next section.
(on Diesel Engine truck)
5 6
1 2 3 4 7 8 9 10
Check
Engine
1. Fuel gauge 7. Lift/Tilt Interlock indicator lamp

2. Neutral/Travel Interlock indicator lamp (Operator Presence System)
(Operator Presence System) 8. Check engine lamp (gas engine truck)
3. Engine oil pressure warning lamp Sedimenter warning lamp (diesel engine truck)
4. Charge warning lamp 9. Failure indicator lamp (gas engine truck)
5. Operation indicator Glow indicator (diesel engine truck)
6. Hour meter 10. Water temperature gauge
NOTICE
CHECK WARNING LAMPS FOR BLOWN BULBS

• Check that each warning lamp lights up when the engine starting switch is turned ON.
• If there is any warning lamp that does not light up, check if the bulb is blown.
• Do not climb on top of the dashboard. There is the danger that your foot may slip and you fall off.
3-3
14. EXPLANATION OF INSTRUMENTS, CONTROLS AND COMPONENTS
The following is an explanation of the devices employed to operate the lift truck as illustrated on page 3-2.
To carry out suitable operations correctly and safely, it is important to understand fully the method of operating the
equipment and the meanings of the displays.
14.1 EXPLANATION OF INSTRUMENTS AND CONTROLS

FORWARD-REVERSE LEVER
This switch changes the direction of travel (forward or reverse).
Use light finger pressure to operate switch.
F: FORWARD
N: NEUTRAL
R: REVERSE
NOTICE
Always stop the lift truck completely before operating the

lever to change the travel direction.
Remark
The engine is equipped with a neutral safety switch and cannot be started if the lever is not in the N (neutral)
position.
HORN BUTTON
Press the button in the center of the steering wheel to sound the
horn.
COMBINATION LIGHT SWITCH AND TURN SIGNAL

This switch controls the lamps.
Light Switch
Position 1: “OFF” - Parking lamp (side clearance lamp) and
front lamps are OFF.
Position 2: Parking lamp (side clearance lamp) lights up.
Position 3: Parking lamp (side clearance lamp) stays lighted
up, and front lamp lights up.
3-4
Turn Signal Indicator Switch

This makes the turn signal indicator flash.
Left turn (L): Push lever forward

Push
Right turn (R): Pull lever back Forward for LEFT
Remark Pull
This lever is equipped with an auto-return mechanism, so the Back for RIGHT
lever will return automatically to the neutral position.
LIFT LEVER
This lever raises and lowers the forks.
Lower: Push the lever forward

Raise: Pull the lever back
Remark
The speed when raising the forks can be controlled by the
amount that the lever is operated and the amount that the
accelerator pedal is depressed. The lowering speed can be
controlled only by the amount that the lever is operated.
Before operating the lift lever, sit in the operator’s seat and check that the surrounding area is
safe.
TILT LEVER
This lever tilts the mast forward and back.
Tilt forward: Push the lever forward

Tilt back: Pull the lever back
Remark
The speed when tilting the mast forward or back can be con-
trolled by the amount that the lever is operated and the
amount that the accelerator pedal is depressed.
Before operating the tilt lever, sit in the operator’s seat and check that the surrounding area is
safe.
3-5
TILTABLE STEERING WHEEL LOCK LEVER

This lever adjusts the position of the steering wheel and locks it
into position after adjustment.
Position (1): Lock is released 1

Position (2): Lock is applied
2
Method of adjustment
1. Pull the lock lever (1) up
2. Move the steering wheel forward and backward to adjust to
the most suitable position.
3. Pull the lock lever (2) down to lock the steering wheel in posi-
tion.
BRAKE OIL RESERVOIR TANK

If the oil level in brake oil reservoir tank (1) is within the normal
range, then the amount of oil is adequate. If it is low, refill with
genuine Komatsu Forklift brake oil.
Always use Komatsu Forklift genuine brake fluid. Dashboard left
PARKING BRAKE LEVER

Position 1: Brake is applied.
When the lever is pulled back, the parking brake is applied and
the front wheels are locked.
Use this when temporarily stopping or parking the lift truck.
Position 2: Brake is released.

When the lever is pushed forward, the parking brake is released.
FUSE BOX
The fuses protect the electrical components and wiring from
burning out.
For details on replacing fuses, see “REPLACING FUSES” on
page 4-39.)
3-6
PEDALS
(1): Accelerator pedal
(2): Brake pedal
(3): Inching pedal
Use the inching pedal for fine control when driving the lift truck
slowly forward or in reverse for loading or unloading.
Remark
Do not put your foot on the inching pedal or accelerator pedal 1
3 2
unless necessary for operation. 9JL00220A
STARTING SWITCH
This switch starts and stops the engine.
TORQFLOW transmission lift truck: When starting the engine,

place the forward-reverse control lever in the neutral position, pull
the parking brake lever, depress the inching pedal fully, then turn
the key.
OFF: Engine stop position

The key can be inserted or removed. The lamps and horn are
activated at this position.
ON: Engine running position

Also activates glow plug preheating circuit in diesel engine BX lift trucks.
See “GLOW INDICATOR” on page 3-14.
START: Position for starting engine

After the engine starts, release the key. It will automatically return to the ON position.
Precautions for restarting the engine (applies to gasoline/LPG engine lift trucks only)
When the engine does not start, return the key from the START position to the OFF position.
With the anti-restart feature installed, the key cannot be turned to the START position again, if it is returned only to
the ON position. Return the key to the OFF position, then restart.
NOTICE
• When the engine is stopped, do not leave the key at the ON position. This will discharge the battery
and make it difficult to start the engine.
• Do not run the starting motor continuously for longer than the times given below.
Gasoline and LPG engine lift truck (AX and BX Models) Maximum 5 seconds
Diesel engine lift truck (BX models) Maximum 10 seconds
• Do not turn the key to the START position when the engine is running.
3-7
LPG LOW-FUEL ALARM LIGHT (OPTIONAL)

This optional alarm is located on the dashboard near the parking
brake lever. When this light comes on, the level of LPG is low.
OPTIONAL METER
When the following meters and gauges are installed in the lift
truck as an optional part, they are installed in the location
indicated by the arrow in the figure at right.
• Speedometer
• Ampere meter (ammeter)
• TORQFLOW transmission oil temperature gauge
• Engine cooling water temperature gauge (when the lift truck
is equipped with a digital type load meter)
A maximum of two optional meters and gauges can be installed.
3-8
The following is an explanation of the devices employed to operate the lift truck as illustrated on page 3-3.
14.2 EXPLANATION OF METER PANEL COMPONENTS

NEUTRAL /TRAVEL INTERLOCK INDICATOR LAMP
(OPERATOR PRESENCE SYSTEM)
This lift truck is equipped with KOPSplus (Komatsu Operator

Presence System Plus), which features neutral safety, Travel
Interlock safety, and Lift/Tilt Interlock safety. When the neutral
indicator blinks, it means that either the neutral safety or Travel
Interlock feature has been activated.
Neutral safety ensures that the operator starts the lift truck in
neutral, while Travel Interlock ensures that the operator sits with
good posture during operations.
When functioning normally, the neutral lamp:
• lights up briefly when the starting switch is turned ON.
• lights steady on when the forward-reverse lever is put into neutral.
When the lamp blinks, either neutral safety or Travel Interlock is indicated.
Neutral Indicator operation

Normal starting operation: When the operator turns the starter switch on with the forward-reverse lever in the
neutral position, the neutral indicator lamp turns on steady. After the engine starts and the operator puts the lift
truck into forward or reverse, the neutral lamp turns off.
Improper starting operation (neutral safety activation): When the operator attempts to start the lift truck in for-
ward or reverse, the neutral lamp starts blinking and the engine will not start.
To clear the indicator and resume travel:
1. Put the forward-reverse lever into neutral (neutral lamp steady on). The lift truck is now ready for travel.
2. Start the engine and put the lift truck into forward or reverse (neutral lamp off).
Travel Interlock Indicator operation

When the engine is running: During operations, when the operator sits improperly or leaves the operator’s seat
for three seconds or more, Travel Interlock disables the transmission of engine power, the lamp starts blinking,
and travel stops. The engine continues to run. To clear the indicator and resume travel:
• Sit in the operator’s seat using good posture.
• Return the forward-reverse lever to the neutral position (neutral lamp steady on).
• The lift truck is now ready for travel. Put the lift truck into forward or reverse (neutral lamp off). It is not
necessary to recycle the starter switch, as the engine will continue to run after Travel Interlock activates.
LOCATION OF OPERATOR PRESENCE SWITCH

This switch, built into the seat, activates the Operator
Presence System when it detects that the operator is not
properly seated in the operator’s seat. When the Operator
Presence System is engaged, normal travel and lift Operator Presence
operations are disabled by Travel Interlock and Lift/Tilt Switch
Interlock, respectively, and the corresponding indicators
blink on the meter panel.
For more information about the Operator Presence KOPS02

System, see:
• “OPERATOR PRESENCE SYSTEM” on page 3-10
• “TROUBLESHOOTING THE OPERATOR PRESENCE SYSTEM” on page 3-11
• “LIFT/TILT INTERLOCK INDICATOR LAMP” on page 3-12
3-9
OPERATOR PRESENCE SYSTEM
KOPSplus
Travel Interlock Indicator

When Travel Interlock indicator is blinking, power to
transmission is disabled and lift truck cannot travel.
Check
Engine
Lift/Tilt Interlock Indicator

When Lift/Tilt Interlock indicator is blinking, power to hydraulic
control valve is disabled and lift and tilt functions are disabled.
To clear blinking indicators and resume truck operations:

- Sit securely in the operator’s seat using good posture.
- Place the Forward/Reverse lever in neutral.
If either warning lamp continues to blink, call your local dealer.
WARNING
Lift/Tilt Interlock disables only the lift and tilt levers, and not the attachment
levers. Some attachments will still move when their lever is operated,
regardless of whether Lift/Tilt Interlock is engaged or not. Additionally, even
when the key switch is in the ON position, or when the engine is not
running, some attachments will move under their own weight or the load
weight when their lever is operated.
KOPS01
3-10
TROUBLESHOOTING THE OPERATOR PRESENCE SYSTEM

When travel is interrupted and indicators are blinking on your dashboard display, it could be due to activation of the
Operator Presence System. Consult this diagram to determine the correct course of action.
POSSIBLE PROBLEMS:
• Travel Interlock indicator is blinking
• Lift/Tilt Interlock indicator is blinking
• Truck won’t start
• Truck or mast stops operating
Are you properly

seated?
Is truck in neutral N
before starting?
NO • Sit fully in the operator seat

and fasten the seat belt.
• Put F/R lever in the neutral
position before starting truck.
YES
Stop truck operations, move the

truck to a safe area and shut down
the engine. Lock and tag the truck,
then call your dealer for service.
KOPS03
3-11
LIFT/TILT INTERLOCK INDICATOR LAMP

When you become improperly seated in the operator’s seat

during operations, Lift/Tilt Interlock is activated and the Lift/ Tilt
Interlock indicator lamp begins to flash, indicating that lifting and
tilting functions have been disabled.
When you seat yourself properly in the operator's seat, the
system will restore lifting and tilting functions and the lamp will
stop flashing.
Lift/Tilt Interlock disables only the lift and tilt levers, and not the attachment levers. Some
attachments will still move when their lever is operated, regardless of whether Lift/Tilt
Interlock is engaged or not. Additionally, even when the key switch is in the ON position, or
when the engine is not running, some attachments will move under their own weight or the
load weight when their lever is operated.
For more information about the Operator Presence System, see:

• “NEUTRAL /TRAVEL INTERLOCK INDICATOR LAMP” on page 3-9
FUEL GAUGE
Fuel gauge displays the remaining fuel level with a needle
indicator.
Check the fuel level with the engine starting switch turned ON.
Position (A): indicates that the fuel level is low.

Position (B): indicates that the fuel tank is full.
Do not use up all the fuel. Fill the fuel tank before the fuel runs
out.
ENGINE OIL PRESSURE WARNING LAMP

The engine oil pressure warning lamp indicates whether the
engine lubrication oil pressure is normal or not.
This lamp lights up when the engine starting switch is turned ON
and goes off after the engine startup. Then it is functioning
normally.
Should the lamp light up during operation, stop operations
immediately and check the engine lubrication system for any
abnormality.
CHARGE WARNING LAMP

The battery charging warning lamp indicates that the alternator is
generating power.
It is normal for the lamp to go on when the engine starting switch
is turned ON and to go off after the engine starts.
Should the lamp light up during operation, check the electrical
system for any abnormality.
3-12
OPERATION INDICATOR
The Operation indicator confirms that the hourmeter is
functioning.
While the engine starting switch is in the ON position, an
hourglass mark on the left side of the hourmeter keeps flashing.
HOURMETER
When the engine starting switch is turned ON, the hourmeter
begins to indicate the cumulative number of operating hours.
While the hourmeter is in operation, the operation indicator keeps
flashing.
The last digit advances by 1 (meaning 0.1 hour) when the engine
starting switch is kept in the ON position for 6 minutes, or when it
is turned to the START position.
CHECK ENGINE LAMP

(GASOLINE ENGINE TRUCK)
When the Check Engine lamp lights up, it is a warning that the
self-diagnostic system has detected a malfunction or failure.
When this occurs, contact your local authorized dealer for Check
service.
Engine
9JL00854
SEDIMENT WARNING/OPERATOR PRESENCE

ERROR LAMP
(DIESEL ENGINE TRUCK)
In diesel engine trucks, this lamp functions as the Sediment

warning lamp as well as the Failure Detection lamp.
• The Sediment warning function (steady light) indicates that
water has accumulated in the fuel filter.
When the lamp lights up steady during operations, you must
drain the water accumulation from the fuel filter. If water is left
in the fuel filter, the fuel injection pump and injection nozzle
function will likely be impaired. For the water draining
method, refer to “ENGINE MAINTENANCE” on page 4-30.
• The Failure Detection function (flashing light) indicates that an abnormality has occurred in the Operator Pres-
ence System.
When the lamp flashes on and off during operations, call your local dealer representative for service.
When functioning normally, this lamp lights up when the engine starting switch is turned ON and goes off after
engine startup.
3-13
FAILURE INDICATOR LAMP

(GASOLINE ENGINE TRUCK)
NOTICE
If the lamp begins to flash, stop operations promptly and

report the trouble to the administrator, or call your Komatsu
Forklift dealer for technical assistance.
The Failure Detection lamp begins to flash on and off when some
abnormality has occurred in the control system or the Operator
Presence System.
When this happens, call your local dealer representative for service.
GLOW INDICATOR
(DIESEL ENGINE TRUCK)
The Glow indicator indicates the preheating condition of the

engine.
The lamp lights up when the engine starting switch is turned ON
and goes off when engine preheating is finished. The lamp goes
off in approximately 8 seconds regardless of the ambient
temperature.
Lamp ON: the glow plug is heating the engine.

Lamp OFF: the glow plug has finished heating the engine.
WATER TEMPERATURE GAUGE

Engine cooling water temperature gauge (10) indicates the
engine coolant temperature with a needle.
White range: the coolant temperature is normal.

Red range: the coolant is overheated.
NOTICE
If the indicator enters the red range, stop operations immedi-

ately and park the truck in a safe place. (See “DON'T USE A
DEFECTIVE LIFT TRUCK - USE LOCK-OUT TAG-OUT PRO-
CEDURES” on page 2-2.) Then take corrective actions against engine overheating. (See “ACTIONS WHEN
ENGINE HAS OVERHEATED” on page 3-32.)
DIGITAL LOAD METER (OPTION)

The Digital Load Meter measures a load on the fork in a simple
way and displays the value.
When this meter is installed, the water temperature gauge, a
standard part, is moved to an optional meter location.
3-14
15. REMOVAL AND INSTALLATION OF ATTACHMENTS
15.1 SAFETY PRECAUTIONS

The attachment(s) and major components are heavy and can cause serious injury if
improperly handled.
1. When working underneath raised load-handling attachments, always secure them to prevent lowering. When
working with lifting equipment (forklifts) never walk or reach under suspended loads. Use only load-bearing
equipment that is in perfect condition (ropes, chains).
2. Secure the truck against accidental movement of truck or attachments when work is being carried out. When
working underneath raised load-handling attachments, always secure them to prevent lowering.
3. When repairing or renewing hydraulic and electrical components, all truck related setting values must be
observed. Under no circumstances may the working speeds be altered (e.g. lift speed, side shift speed).
4. Personnel may not remain in any Danger Zone in which they are at risk due to movement of the truck, attach-
ments or lift gear, or any Danger Zone into which descending or dislodged parts may fall.
5. Do not climb onto any part of the truck, which is in motion (e.g. mast, carriage).
6. No servicing should be carried out on the hydraulic system until the mast, carriage or relevant component has
been suitably supported or restrained.
15.2 FORKS
1. Lower the carriage until the forks are resting on the ground and the lift chains are still taut.
2. Release the fork stopper.
3. Move the forks toward center. Fit the lower hook into the notch and remove the fork.
4. Replacement is the reverse of the removal procedure. Smear the fork hooks with grease and adjust the fork
width to suit.
Chain
Anchor
Split Pins
Pin
Carriage Fork
3-15
15.3 CARRIAGE
1. Lower the carriage until the forks are resting on the ground.
NOTICE
If a side shift carriage is fitted, disconnect the hydraulic hoses at the carriage, draining the fluid into a suit-
able container. Plug and seal the opened connections to prevent ingress of foreign matter.
2. Disconnect the lift chains from the carriage and tie the ends of the chain to the outer mast upper cross member.
3. Raise the mast inner section under power until the bottom of the inner section clears the carriage top roller
assemblies.
Ensure that the lift chains do not foul during raising.
4. Reverse the truck away from the carriage.
5. Replacement of the carriage is the reverse of the removal procedure. If a side shift carriage is fitted, operate to
both extremes of travel several times to expel air from the system.
15.4 MAST
Prior to removal of the mast, detach the carriage and forks. Refer to paragraph “FORKS“ and “CARRIAGE“ above.
Remove the drive wheels (if required).
1. With the mast vertical, support the mast securely by attaching lifting tackle to the lifting eyes on the upper cross
brace indicated by the crane hook label. Remove tilt cylinder-to-mast pivot pins.
2. Disconnect hydraulic lines from lift cylinders; blank off all open ends to prevent the ingress of foreign matter.
Residual oil will be discharged during disconnection.
3. Inclining the mast forward a little from its vertical position, remove the differential mounting cap bolts.
4. Reassembly is the reverse of the removal sequence, noting the following:
a. Renew chain anchor spilled pins.
b. Tighten to the correct torque, the mast locking bolts - refer to service manual for torque figures.
c. Lubricate all pivot pins.
d. If any removal of components affecting tilt angles have been carried out, check and adjust tilt angles. Refer
to the service manual for further information.
Ensure that all locking devices are engaged upon assembly of attachment.
3-16
15.5 SIDE SHIFT, FORK POSITIONER AND CLAMP ATTACHMENTS

15.5.1 INSTALLATION/ASSEMBLY
The side shift, fork positioner and clamp attachments all have a common method of installation/assembly as
follows:
1. Before installing, inspect the truck carriage to make sure that the locating notches along the top of the truck
carriage are undamaged and that there are no obstructions on the faceplate itself.
2. Place the clamp into an upright position in preparation for mounting it on the truck.
3. Remove the lower mounting hooks from the back of the clamp frame.
4. Attach the two jumper hoses securely to the clamp's check valve before connecting them to the junction block
on the truck carriage.
5. The open line on the top of the valve is the “clamp open“ circuit. The line on the side of the valve is “clamp
close“ circuit.
6. If the hose junction block is located on the upper portion of the truck carriage, do not connect the jumper hoses
to it until the clamp is mounted on the truck. Lay the hoses over the top of the frame. However, if the junction
block is located on the lower portion or in the center opening of the carriage, and thus nearly inaccessible when
the clamp is mounted, attach the jumper hoses securely before installing the unit.
7. Install the clamp on the truck. It may be lifted onto the truck or simply positioned on the floor (and blocked up
under the frame and arms) or placed on a pallet so that the truck may be driven up and the truck carriage
moved under the upper mounting hooks on the frame. Line up the locating lug on the clamp with the center
notch on the truck carriage. (The carriage can be raised into the hooks at this point). Be careful not to pinch,
twist, or otherwise damage the jumper hoses in mounting. After the unit has been placed on the truck, bolt the
lower mounting hooks into position on the lower clamp frame, firmly securing it to the truck carriage.
8. Attach the hoses to the carriage junction block.
9. It is normal at this point to re-check the hoses from the truck valve to the clamp. Make sure that the hoses are
routed correctly, and that all connections are tight. For best results, there should be as few 90 degree bends,
and other similar flow restrictions, as possible in the hydraulic circuits. Check the mounting hooks to be certain
that the clamp is solidly mounted to the truck carriage.
10. Start the truck. Operate the clamping function several times to remove any air trapped in the system. Before
proceeding to the next step, check to make sure that the retaining nuts on the anchor and rod ends of each
clamp cylinder are tight.
11. Adjust the rate of arm travel. When the clamp is correctly adjusted both arms should close together from full
extension at the fastest possible speed and reach their minimum range at the same moment. The speed with
which the arms close is controlled by two restrictor fittings, one located on each cylinder at the rod end.
To equalize arm travel:

a. Open both restrictor fittings completely by loosening the lock nut and backing out the threaded shaft. The
restrictor is wide open when 1/2 inch of the shaft is exposed above the tightened lock nut. Opening the
valves completely before making the adjustment is important, because the speed of clamp operation is
directly affected by the degree of restriction in the lines. The fittings should be as wide open as possible
with both arms operating at the same speed.
b. Close the arms from their full extension, watching to see which one is closing most rapidly.
c. Close the restrictor fitting on the cylinder controlling the faster arm until both arms are travelling at the
same rate. The clamp will probably have to be opened and closed several times to make this adjustment
accurately.
4. To complete installation, insert a hydraulic pressure gauge into the truck system's test port and adjust the pres-
sure relief setting. Never exceed maximum operating pressure for this clamp.
15.5.2 REMOVAL
Removal is the reverse of the installation/assembly sequence noting all the safety precautions in paragraph 1.
Ensure that all locking devices are engaged upon assembly of attachment.
3-17
16. OPERATION
16.1 LPG FUEL CYLINDER REPLACEMENT PROCEDURE

16. OPERATION
• Only trained and authorized personnel may change LPG cyclinders.

• LPG is heavier than air and will sink to the lowest area possible. Avoid parking near areas near
floor drains, lubrication pits, or other areas where escaped fuel may collect.
• After changing, ensure that the cyclinder is securely mounted.
• If you smell LPG odor or there is frost on the fuel cyclinder: do not start the engine; close the fuel
valve at the LPG cylinder; park and tag the truck and have qualified personnel inspect and repair
the fuel system.
• For additional information, consult the National Fire Protection Association pamphlet 58 for the
safe storage and handling of liquified petroleum gases.
NOTICE
Use only HD-5 grade LPG fuel.
1. Park the lift truck on level ground with the parking brake applied, the transmission in NEUTRAL, the forks low-
ered and the engine at low idle.
2. Close the fuel valve at the LPG cylinder. Run the engine until it stops, then turn the key switch OFF.
3. Disconnect the fuel supply line.
4. Loosen the retaining clamps and remove the cylinder.
5. Inspect the replacement cylinder for damage such as dents, scrapes or gouges. Do not use a damaged
cyclinder. If you smell LPG odor or there is frost on the fuel cyclinder, or you suspect the fuel system is leaking:
a. Close the fuel valve at the LPG cylinder.
b. Park and tag the truck and have qualified personnel inspect and repair the fuel system.
3. Check for debris in the relief valve and damage to valves or the liquid level gauge. Inspect the couplings for
damage or missing flexible seals.
• Testing of the LPG fuel system and repairs should be performed by qualified personnel only.
• LPG fuel lines, fittings, valves and threaded connections should be tested for leaks using a soap
solution.
• Before testing for leaks, make sure the system gas pressure is greater than 90 psi (621 kPa).
4. Mount the fuel cylinder so that it does not extend outside the truck. Position the cylinder properly using the
locating pin through the positioning hole in the collar, or with the slot in the footring over the locating keyway.
Be sure to use the correct cylinder size and type according to the cylinder description plate.
5. Clamp the tank securely.
6. Connect the fuel supply line.
7. Turn the fuel valve on by slowly turning it counterclockwise. If the fuel valve is opened too quickly, a back pres-
sure check valve will shut off the fuel supply. If this happens, close the fuel valve completely, wait five seconds,
and then open the fuel valve very slowly.
3-18
16. OPERATION
16.2 MOUNTING/DISMOUNTING
When getting on and off the lift truck, face the left side of the lift
truck that is at a complete standstill and support yourself securely
with handrails (assist grips) (1) and step grip (2).
• Get on and off the lift truck only when it is at a complete

standstill.
• Never jump on or off the lift truck. It is extremely
dangerous.
• Do not hold to the control levers and steering wheel when getting on and off the lift truck.
• Keep the handrails (assist grips) and step clean all the time, and repair damage, if any. Do not use the
handrails (assist grips) for any other purpose than getting on and off.
16.3 SEAT POSITION ADJUSTMENT
• Adjust the seat position before getting on the lift truck, or at the time of operator change. Carry out
this adjustment only when the lift truck is at a complete standstill.
• Adjust the seat position so that you can sufficiently depress the brake pedal while reclining
yourself against the backrest. Carry out this adjustment only when the lift truck is at a complete
standstill.
• Be sure to wear the safety seat belt while operating the lift truck.
1. Set the parking brake. (See “TEMPORARY STOPPING AND

PARKING” on page 3-26.)
2. Take a seat and pull lever (1) to the left. (The operator's seat
can slide back and forth in this condition.)
3. Bring the operator's seat to the optimum position and release
lever (1). (It can be locked in this condition.)
4. After setting the seat, confirm that it is firmly locked by trying
to slide it forwards or backwards.
16.3.1 METHOD OF ADJUSTING RECLINING

ANGLE
(Suspension seat only)
1. Pull up lever (1). (The backrest angle can be adjusted in this

condition.)
2. Adjust the backrest angle and release lever (1).
After adjusting, try to move the seat back and forth slightly to
make sure that the seat is securely locked.
3-19
16. OPERATION
16.3.2 METHOD OF ADJUSTING SUSPENSION

(Suspension seat only)
Turn adjusting knob (1) located on the front right side of the
operator's seat to select suspension best suited to your weight.
Needle (2) indicating set weight swings to a heavier side if you

turn the knob to (B), and swings to a lighter side if you turn the
knob to (A).
(Weight adjustment range: 50 to 120 kg (110-265 lbs.))
16.3.3 METHOD OF ATTACHING AND RELEASING SEAT BELT

1. Pull tongue (1) out of the safety seat belt holder located on
the right side of the operator's seat and push it into buckle (2)
until it is clicked into place. (The safety seat belt is locked in
this condition.) The safety seat belt has a mechanism that
senses a shock and locks itself at the holder. For this charac-
teristic, it may be locked while the belt is tucked in the holder,
though quite rarely. If this happens, hold buckle (1) with both
hands firmly, give the belt a strong pull to loosen the belt and
then pull the belt out slowly.
2. To release the safety seat belt, hold tongue (1) with the left
hand and press red button (3) on buckle (2) with the right
hand.
3. Then the belt is tucked into the holder automatically. While
the belt is being tucked in, hold tongue (1) so that the belt is
tucked in slowly. Avoid twisting the belt.
3-20
16. OPERATION
16.4 ADJUSTING POSITION OF STEERING WHEEL
Always stop the lift truck completely before adjusting the position of the steering wheel. After
adjusting, try to move the steering wheel backward and forward to check that it is locked
securely in position.
1. Park the lift truck. (For details, see “TEMPORARY STOP-

PING AND PARKING” on page 3-26.)
2. Pull up lock lever (1). (In other words, move the lever to (A)
position.)
3. Move the steering wheel back and forth to select the optimum
position.
4. Pull down lock lever (1) (in other words, move the lever to (B)
position) and lock the steering wheel at the optimum position.
5. Try to move the steering wheel back and forth to be sure that
the it is firmly locked.
16.5 STARTING LIFT TRUCK OFF
• Do not attempt to start up the engine by intentionally short-circuiting the engine startup circuit.
Such a practice can cause serious personal injury and fire.
• Before startup, check the surroundings for safety and sound the horn.
• Do not allow personnel to come near the lift truck while it is operating.
• There is a blind spot at the rear of the truck. Use extra care when backing up.
• When starting up the engine, move the forward-reverse lever to the neutral position. Then apply
the parking brake and depress the inching pedal.
16.5.1 STARTING ENGINE
When turning the engine starting switch ON, be sure to seat yourself properly, move the
forward-reverse lever in the neutral position and do not step on the accelerator pedal.
1. Move the forward-reverse lever and high/low lever to the

neutral position. (The engine starting motor is not actuated
until after the forward-reverse lever is in the neutral position.)
3-21
16. OPERATION
2. Pull the parking brake lever to engage.
3. Depress the inching pedal.
4. Gasoline engine: with your foot off the accelerator pedal, turn the engine starting switch to the START posi-
tion. The engine will start up.
LPG engine: Slowly turn the tank fuel valve counterclockwise to ON. Turn the starting switch ON and release.
WARNING! If there is LPG odor or frost on the fuel tank, do not start the engine. Park and tag the truck
and have qualified personnel inspect and repair the fuel system.
Diesel engine: When the engine starting switch is turned ON, engine preheating begins and within 8 seconds
the glow indicator goes off, indicating that preheating is finished. When the engine starting switch is turned to
START while the accelerator pedal is depressed slightly (lightly), the engine will start up. If the engine is started
while still preheating, the preheating function is automatically released.
Time required for preheating can vary depending on the ambient temperature and engine coldness. Use the
following benchmark for preheating time.
12°C (53.6°F) Preheating not required
0°C (32°F) Several seconds
-20°C (-4°F) 8 seconds
5. When the engine has started up, release the engine starting switch key. (The key will automatically return to
the ON position.)
6. Carry out a warm-up run.
Gasoline engine type: The auto choke senses the rising engine cooling water temperature and automatically
stops the warm-up run.
Diesel engine type: Release the accelerator pedal and continue with warm-up for a while.
NOTICE
• Do not leave the engine starting switch in the ON position while the engine is not running. The bat-
tery charge will go down, making it difficult to start up the engine.
• Limit the use of the engine starting motor to 10 seconds at a time and do not let it run continuously
beyond 10 seconds. This will help prevent overheating the starter.
• Wait for another 20 seconds before using the engine starting motor again.
• Do not turn the engine starting switch to START while the engine is running.
3-22
16. OPERATION
16.5.2 STARTING OFF IN FORWARD OR

REVERSE
This lever acts to change the travel direction (forward or reverse)
of the lift truck.
F: Forward
N: Neutral
R: Reverse
The engine cannot be started if this lever is not at the N (neutral)

position (it is equipped with a neutral safety switch).
Release the parking brake and check that the direction of travel
and the area around the lift truck are safe and clear.
The lift truck will start up if you gently depress the accelerator
pedal with the right foot and release the inching pedal slowly.
Engage the clutchpack halfway with the inching pedal, and then
the truck will crawl along. Travel for a long time while the
clutchpack is half engaged can cause damage to the truck, so
limit such travel to the shortest time necessary (less than 10
seconds).
16.5.3 SHIFTING DIRECTION

Depress the inching pedal and move the forward-reverse lever to
the F or R position.
Move the forward-reverse control lever from F to R.
3-23
16. OPERATION
Or move the forward-reverse control lever from R to F.
NOTICE
• Do not rest your foot on the inching pedal and brake

pedal except when so required.
• Always stop the lift truck completely before operating
the lever to change the travel direction.
• Change the travel direction only after the lift truck comes
to a complete stop.
16.5.4 TRAVEL INTERLOCK

When you use bad sitting posture during lift truck operations and
your weight is not fully applied to the seat, such as when standing
up or leaning forward or sideways, Travel Interlock engages in
approximately three seconds and cuts off transmission of engine
power. The engine will continue to run, but the truck will not move
even if you depress the accelerator pedal or operate the forward-
reverse lever.
When Travel Interlock is engaged, the Travel Interlock indicator
lamp on the instrument panel blinks (see figure at right.) This
lamp doubles as the neutral lamp, which lights steady on when the forward-reverse lever is put in neutral while the
engine is on.
To return to travel condition after Travel Interlock has been activated:

Seat yourself properly and return the forward-reverse lever to the neutral position to enable the truck for travel
again. Take this step only after you check the surroundings for safety. Travel Interlock does not brake the truck
forcibly.

• “LIFT/TILT INTERLOCK INDICATOR LAMP” on page 3-12
3-24
16. OPERATION
16.6 STARTING AND INCHING ON

INCLINE
Never carry out inching by depressing the accelerator

pedal fully and then adjusting the amount the brake
pedal is depressed.
1. When trying to start up the lift truck on an upslope, pull back

parking brake lever (1) first.
2. While gradually depressing accelerator pedal (4), release
parking brake lever (1) slowly, allowing the lift truck to climb
up the slope.
3. When the lift truck has gained some speed, release parking
brake lever (1) completely. Climbing speed can be controlled
by the amount of depressed accelerator pedal (4).
4. When slowing down or bringing the lift truck to a complete
stop on an upslope, release accelerator pedal (4) gradually
and depress brake pedal (3) right before the lift truck stops.
(A) is the location of inching pedal in a torque converter type
lift truck.
5. After stopping the lift truck, always pull parking brake lever (1) fully to engage it.
16.7 TURNING
Take care to prevent the outside of the counterweight

hitting against objects when turning.
If equipped with a steering knob, operate it with the left hand.

When turning, keep to the inner side when advancing and outer
side when reversing, considering the properties of the rear
steering system.
NOTICE
If the lift truck is to be steered while stopped, a large steering

force is required.
In this case, depress the accelerator pedal slightly and oper-
ate the steering wheel while inching, to allow it to be rotated
smoothly.
3-25
16. OPERATION
16.8 TEMPORARY STOPPING AND

PARKING
Select a parking area well away from the driving area.
1. Release the accelerator pedal, then depress brake pedal.

2. After the lift truck comes to a stop, apply the parking brake by
pulling parking brake lever (3). After it stops completely, move
the forward-reverse lever to the neutral position.
3. Return forward-reverse control lever (4) to the neutral posi-
tion.
TORQFLOW
Clutch type
transmission
16.8.1 PARKING BRAKE LEVER

Locking position: The parking brake can be applied in this
position. When the parking brake lever is pulled back, the parking
brake is applied, locking the front wheels. Use this locking
function to temporarily stop or park the lift truck.
Free position: The parking brake is released in this position.
When releasing the parking brake, press a button on top of the
lever, releasing a hook, and return the lever to the free position.
16.8.2 WHEN LEAVING THE LIFT TRUCK

UNATTENDED
When leaving the lift truck, always perform the following
procedure.
1. Lower the forks to the ground.
2. Tilt the mast full forward.
3. Turn the starting key to the OFF position, then remove the
key.
(When it is in the OFF position, the engine starting switch key
can be inserted and pulled out and all the electric circuits are
switched off except for the horn and lamps.)
4. Check that the parking brake lever is pulled back.
3-26
16. OPERATION
16.9 FORK SPREAD ADJUSTMENT
Take extreme care not to get hands or fingers caught while

moving the forks.
1. Move the lift truck in front of the load, and stop.

2. Position the mast vertically and lift the forks 4 in. (10cm)
above the ground.
3. Tilt the mast forward.
4. Move up the fork stopper knob to the free position.
(The forks are movable to left and right at this position.)
5. Adjust the fork spread to the load size so that the load center
of gravity coincides with the center of the lift truck.
6. Set the mast vertically, lower the knob and insert the fork
stopper to lock the forks. (The forks are fixed.)
16.10 LOAD HANDLING OPERATION
Sit in the operator's seat and check that the surrounding area is safe before operating the lift
lever.
16.10.1 OPERATION OF CONTROL LEVERS

LIFT CONTROL LEVER
This is a lever that is used to raise or lower the forks.
RAISE: Push the lever forward

LOWER: Pull the lever back.
A raising and lowering speed of the fork can be adjusted with the
amount of lever travel.
TILT CONTROL LEVER

This lever tilts the mast back and forth.
Tilt forward: Push the lever forward.

Tilt back: Pull the lever back.
A speed of tilting the mast back and forth can be adjusted with
the amount of lever travel.
3-27
16. OPERATION
16.10.2 LIFT/TILT INTERLOCK

If you operate the lift truck in such a posture that your weight is
not fully applied to the seat, such as standing up or leaning
forward or sideways, Lift/Tilt Interlock activates in approximately
three seconds and disables all lifting and tilting functions.
While Lift/Tilt Interlock is in operation, the Lift/Tilt Interlock
indicator lamp on the instrument panel blinks.
To return to travel condition after Lift/Tilt Interlock activated:

Seat yourself properly and then the truck is ready for travel again.
Start the operation of the truck again only after you check the
surroundings for safety.
Lift/Tilt Interlock disables only the lift and tilt levers, and not the attachment levers. Some
attachments will still move when their lever is operated, regardless of whether Lift/Tilt
Interlock is engaged or not. Additionally, even when the key switch is in the ON position, or
when the engine is not running, some attachments will move under their own weight or the
load weight when their lever is operated.

• “NEUTRAL /TRAVEL INTERLOCK INDICATOR LAMP” on page 3-9
16.10.3 PICKING UP THE LOAD

1. Insert the fork up to the base.
2. If the fork cannot be inserted up to the base in one motion,
drive the lift truck forward until the fork is inserted into a pallet
by 2/3 to 3/4 of the fork length and lift the load by 5 - 10 cm (2
- 4 in) off the floor.
Then drive the lift truck backward by 4 - 8 in (10 - 20 cm),
lower the load on the floor once and then drive the lift truck
once again until the fork is inserted up to the base of the
forks.
3. Raise the load 2 - 4 in (5 - 10 cm) and reverse the lift truck to

a position where the load can be lowered.
3-28
16. OPERATION
4. Lower the load to the height of 6 - 8 in (15 - 20 cm) above the

ground and tilt the mast back.
16.10.4 STACKING THE LOAD

1. Stand the mast vertically and lift forks 2 - 4 in (5 - 10 cm) past
the stacking position. Advance the lift truck slowly.
2. Lower the load onto the desired location.
3. Pull the fork out of the pallet by as much as 4 - 8 in (10 -

20 cm) by backing up the lift truck. Then raise the load again
by as much as 2 - 4 in (5 - 10 cm), move it to a right stacking
spot, lower it on the floor and slowly back up the lift truck until
the fork is completely pulled out.
16.11 COMBINATION SWITCH OPERATION

16.11.1 LIGHTING SWITCH
This is a switch used to turn on the front lamps.
Position 1 (OFF): Parking lamp (side clearance lamp) and

front lamps are OFF
Position 2: Parking lamp (side clearance lamp) lights up
Position 3: Parking lamp (side clearance lamp) stays lighted
up, and front lamp lights up
3-29
16. OPERATION
16.11.2 TURN SIGNAL SWITCH

This is a switch used to flash the turning signal lamps.
Left turn (L): Push lever forward Push

Right turn (R): Pull lever backward Forward for LEFT
This lever has an auto-return mechanism, so it will return to the Pull
middle when the steering wheel is turned back. Back for RIGHT
3-30
17. COLD WEATHER OPERATION
17. COLD WEATHER OPERATION
Low temperatures may freeze the coolant or make it difficult to start the engine, so do the following to prevent this.
17.1 FUEL AND LUBRICANTS, HYDRAULIC OIL

Change fuel and lubrication oil for all the components to a lower viscosity type. For the designated viscosity, refer
to “LUBRICANT LIST” on page 4-2.
17.2 COOLANT
Coolant is flammable, so keep it away from open flame. Never smoke when handling coolant.
NOTICE
When the truck is shipped from the factory, it is filled with low-emission (non-amine) type glycol-based
coolant. It may be used in ambient temperatures as low as -4°F (-20°C), unless otherwise instructed. On
LPG lift trucks, coolant mixture should test safely down to -35°F (-37°C).
Precautions when handling coolant

• Coolants are commonly used after being diluted. When diluting coolants, use distilled water or tap water.
• Check that there is no leakage of water from the radiator, water pump, or water hoses.
• Drain all coolant and flush the inside of the system to remove any scale before adding new coolant.
• Do not mix the low-emission type coolant with other conventional coolants for use in the truck.
Dilution of glycol-based coolant

Use dilution commensurate with the lift truck’s operating environment. Note that the lowest allowable dilution is
30%. Be sure to use dilution percentages higher than 30%.
Proportions of water and antifreeze (or coolant)
Min. temperature °F (°C) 14 (-10) 5 (-15) -4 (-20) -13 (-25) -22 (-30) (-35) (-40) (-45) (-50)
Percentage (%) of Coolant 30 36 41 46 50 54 58 61 64
Table values allow for approximately 2% safety margin as against the standard values.
If coolant percentage exceeds 65%, freezing temperature rises conversely. DO NOT add too much coolant.
17.3 BATTERY
When the ambient temperature drops, the capacity of the battery will also drop. If the battery charge is low, the
battery electrolyte may freeze.
• Maintain the charging rate above 75%, and protect the battery from cold temperatures for an easy startup in
the morning.
• If distilled water is to be added, to prevent freezing, wait until before starting operations the next morning
before adding the distilled water.
17.4 PRECAUTIONS AFTER COMPLETING OPERATIONS

DRAIN WATER
Drain any water accumulated in the fuel tank to prevent the water from freezing during the night.
ADD FUEL
To prevent moisture from collecting inside the fuel tank, always fill the fuel tank after completing operations.
3-31
18. HANDLING IN HEAVY-DUTY CONDITIONS
18. HANDLING IN HEAVY-DUTY CONDITIONS
Take the following precautions when operating in heavy-duty conditions.
18.1 ACTIONS WHEN ENGINE HAS OVERHEATED
If your remove the radiator cap in an attempt to hurriedly cool the radiator, steam will spurt
out. Never try to remove the cap before the engine cools down sufficiently.
If the engine cooling water temperature gauge comes with the overheat range, move the lift truck to a safe place to
park and take the following actions.
1. Keep the engine running at low idling, open the engine hood for better airing of the engine room and wait for
the engine to cool down.
Should the radiator cooling fan be not turning, stop the engine immediately and let the engine cool down.
2. Stop the engine, after checking the coolant temperature gauge and being satisfied that the coolant temperature
has dropped sufficiently.
3. Check out the coolant level and water leakage from the radiator or radiator hose, only after the engine has suf-
ficiently cooled down.
4. If the cooling water is level is low, fill the radiator and sub-tank with additional water. Should water leakage be
found, stop the use of the lift truck and call your Komatsu Forklift dealer.
18.2 CLEAN INSIDE OF COOLING SYSTEM

If scales or rust are found in the cooling system, clean the radiator with appropriate cooling system cleaner to make
sure that clean water always circulates in the system.
18.3 CLEAN RADIATOR FINS
Dirt may fly and get into your eyes, so always wear
protective glasses or goggles.
If the radiator fins are clogged, it will cause overheating, so blow

out the radiator fins with compressed air, steam, or water.
When using air or steam, always point the nozzle at a right angle
to the radiator when cleaning. This helps to prevent damage to the fins.
Air pressure 0.98 MPa (10 kgf/cm2)

Steam pressure 0.39 MPa (4 kgf/cm2)
18.4 CHECK FAN BELT TENSION

If the fan belt is loose, adjust it to the specified tension.
3-32
19. LONG-TERM STORAGE
19.1 BEFORE STORAGE

19. LONG-TERM STORAGE
NOTICE
If the lift truck must be left outdoors, park the truck on flat ground and cover it with a tarpaulin.
If the lift truck is going to be out of service for a long period, store it in the following manner.
• Store it in an indoor dry parking area after washing and cleaning each part.
• Completely lubricate and change the oil.
• Apply a thin coating of grease to metal surfaces of hydraulic piston rods.
• Disconnect the negative (-) cable of the battery, and then either cover it or take down and store it indoors.
• If the temperature drops below 0 ºC, add anti-freeze to the cooling water.
19.2 DURING STORAGE
If it is necessary to carry out the rust prevention operation while the lift truck is indoors,
open the doors and windows to improve ventilation and prevent gas poisoning.
RUST PREVENTION OPERATION

Operate the engine and move the lift truck for a short distance once a month so that a new film of oil will coated
over lubricated surfaces. This prevents loss of the oil film over the long period of storage.
Before operating the work equipment, wipe off the coat of grease from the hydraulic cylinders.
CHARGING BATTERY
Batteries discharge naturally even though they are not used but left unattended. Charge the battery once a month.
19.3 AFTER STORAGE

• Remove the drain plugs from the oil pan and each case, and drain out the water.
• Wipe off the grease from the hydraulic cylinder rods.
• After starting the engine, carry out the warming-up operation until the engine oil pressure warning lamp goes
out in order to settle all the parts thoroughly.
3-33
20. TRANSPORTING THE LIFT TRUCK
20.1 DIMENSIONS / WEIGHTS

For truck dimensions and weights, see “TECHNICAL DATA” on page 5-1.
20.2 CENTER OF GRAVITY

The center of gravity of the Front lift is shown in the figure below. for For further information or regarding center of
gravity, contract the manufacturer or authorized manufacturer representative.
20.3 SECURING TRUCK
It is recommended that the transporting of the truck by road, rail or sea, may only be
undertaken by an authorized transport company.
All trucks being transported by road, rail, or sea have a common method of stowage, which reduces the possibility
of damage to the truck and paintwork.
The chassis will be secured to the deck of the truck, rail car or ship by means of chains from the chassis lifting eyes
to a convenient desk bolt. All four corners of the chassis must be secured, preferably with adjusting screws, to
ensure that the chains are under tension, as shown in the figure below.
The chassis will be secured with the mast tilted in the fully back position.
3-34
20.3.1 SECURING MAST

Where machines are being transported with the mast fitted onto the truck, no action is required. When it is
necessary to remove the mast during transportation the following procedure will be undertaken:
1. Remove forks from carriage and secure forks as shown below.

2. Remove mast and carriage assembly from truck.
3. Weld securing bar across bottom of mast and carriage, to prevent movement of mast and carriage assembly.
Where holes are available, fit bolt though masts and carriage, and retain with a nut as shown below.
Where possible, and in particular with high lift masts, the lift chain is to be lightly banded to the lift cylinder, at
not less than 1 meter intervals to ensure that the chain does not slap during transportation.
Install rubber padding (or equivalent) between the chain and the lift cylinder, and all around the cylinder where
banding is taking place, to protect the paintwork.
Where it is impracticable to retain the chain as above, the free end is to be wired to a suitable position, and
care taken to ensure paint work is not damaged during transportation.
NOTICE
Other than the welding specified Figure 3, no welding is to take place on the carriage and the mast
channels.
20.3.2 SECURING FORKS

Each pair of forks will be securely banded together using banding
material as shown in the figure at right.
3-35
20.3.3 SECURING FORKS - MAST ASSEMBLY IN TRUCK

The banded forks should be placed on the mast/carriage assembly and laid on the fork stowage brackets, which
should have been previously hooked onto the carriage. The assembly will then be securely banded to the carriage
as shown below.
20.3.4 SECURING FORK - MAST ASSEMBLY OUT OF TRUCK

The banded forks should be placed with the mast/carriage assembly.
Banding material is passed under the mast channels and over the forks, and securely connected (see Figure 6).
NOTICE
When welding to any part of the assembled truck, ensure that the batteries and alternator are
disconnected.
After welding has been completed, spray all bare metal with welding preservatives.
20.3.5 ELECTRICAL AND HYDRAULIC CONNECTIONS

All electrical and hydraulic connections which are lift disconnected are to be plugged and sealed.
3-36
20.4 SLINGING
Some of the suitable lifting points for the truck are indicated by the crane hook label shown in figure seven. These
lifting points are situated on the mast and counterweight
For further information or advice regarding suitable lifting for the truck, contact the manufacturer or their authorized
representative.
NOTICE
Ensure that all lifting tackle has a Safe Wiring Load (S.W.L) suitable for the truck unloaded weight.
Before any lifting attempt is made, check that the mast is in the vertical position.
20.4.1 LIFTING THE TRUCK

Attach suitable lifting tackle to the truck’s lifting points.
1. Place packing material to avoid damage to truck finish, where

lifting tackle is likely to contact track.
2. Take up the slack and stand clear of the truck.
3. Make a test lift, just clear of the ground, to ensure that the lift is
square and even, if not lower to ground and adjust lifting tackle
as required.
4. If the above items are correct, then proceed with the lift of the
truck to the required position, with slow and gentle movements.
5. Lower to the required position and remove lifting tackle.
3-37
21. OUTLINE OF SERVICE
21.1 GENERAL
21. OUTLINE OF SERVICE
• For replacement, use genuine spare parts from Komatsu Forklift.

• When changing or adding oil, do not use a different type of oil.
• Unless otherwise specified, the oil and coolant used at delivery from the factory is as listed below.
1. Tank, cases
Item Type of fluid

Differential case SAE80W or SAE90W
Hydraulic tank ISO # 32 Hyd. Oil
TORQFLOW transmission case DEXRON ATF
NOTICE
Use specified or higher grade oil
2. Cooling system: Fresh water + long life coolant

(This dilution is applicable to the ambient temperature as low as -20°C.)
21.2 SUITABLE OIL

21.2.1 OIL
• Since the oil is used for the work equipment under severe conditions (at high temperature and high pressure),
it will deteriorate as operation time passes. Always use an oil matching the grade and working temperatures
given in this manual. Always replace oil at the specified period even if not deteriorated.
• Oil is often likened to human blood. A lift truck should be maintained with the same care taken for the human
body so that impurities such as water, metal chips, and dust do not enter the lift truck system. Most lift truck
malfunctions are caused by entry of impurities. Take special care to avoid entry of impurities during storage
and lubrication.
• Never blend oils of different grades or brands.
• Add specified volume of oil. Both insufficient or excessive amounts of oil may cause problems.
• If the hydraulic oil in the work equipment has become murky, either air or water may have entered into the cir-
cuit. In this case, call your Komatsu Forklift dealer for advice.
• When replacing oil, replace the relevant filters at the same time.
21.2.2 GREASE
• Grease prevents the generation of squeaking or noise from joints.
• Nipples, which are not listed in this “MAINTENANCE“ section, do not have to be greased, as they are used for
overhauling. If a specific part develops stiffness after a long period of use, then grease it.
• After greasing, wipe off old grease forced out, especially on rotating parts that will be worn by adhering sand
and dirt.
21.2.3 OIL STORAGE AND PRESERVATION

• Store and preserve oil so as not to allow entry of any water or dust.
• When storing oil drums for long periods, place them side by side with the filler sides facing in the same direc-
tion. If necessary to store outdoors, cover them with waterproof sheets.
• To prevent deterioration during long-term storage, use drums on a “first in, first out“ basis.
21.3 FILTERS
• Filters are very important safety items which prevent problems caused by impurities contained in the oil or
hydraulic circuit which sends oil into important units. Periodically replace the filters referred to in this manual.
• When replacing oil filters, check for metal powder accumulated on the used filters.
• Do not unpack replacement filters until immediately before installation.
• Always use Komatsu Forklift genuine filters.
4-1
22. LUBRICANT LIST
22.1 OIL AND GREASING CHART

22. LUBRICANT LIST
OIL, GREASE LOCATIONS AND INSPECTION AND MAINTENANCE INTERVALS
(EPA gasoline engines: first month/200 hours,

then every 500 hours)
Symbol Type of fluid

Diesel engine oil
EO
Gasoline engine oil
MO Engine oil
GO Gear oil
HO Hydraulic oil
BF Brake fluid
G Grease
Indicates check and add fluid if necessary

Indicates change or add oil
Shows the number of places to add oil or grease
4-2
22. LUBRICANT LIST
22.2 AX50 – GASOLINE/LPG ENGINE

MODELS FG15/18/20(A)(S)HT-20
• Always use genuine Komatsu Forklift oil and grease.

• Oil and grease are available from your Komatsu Forklift
dealer.
• Never use fuel mixed with kerosene as it can damage the
fuel injection system.
• Never use the wrong type of brake fluid.
Ambient Temperature
Location Type of Fluid -4 14 32 50 68 86°F Capactities
-20 -10 0 10 20 30°C
Engine oil (including filter)
Engine oil pan
(SAE10W-30SJ) 4.02 quarts / 3.8 L
TORQFLOW DEXRON automatic

2.54 U.S. gal. / 9.6 L
transmission case transmission fluid
Gear oil (SAE80W)

Differential case 1.19 U.S. gal. / 4.5 L
Gear oil (SAE90W)
Pneumatic tire models:

10.6 U.S. gal. / 40 L
Hydraulic tank Hydraulic oil ISO #32
Cushion tire models:
5.28 U.S. gal. / 20 L
Gasoline: 87 octane Pneumatic tire models:

(recommended) 10.6 U.S. gal. / 40 L
Fuel tank Cushion tire models:
LPG: HD-5 grade
6.6 U.S. gal. / 25 L
propane
Brake fluid (DOT 3)

Brake reservoir 5.07 oz. / 0.15 L
(SAE7OR-3)
Lithium grease
Greasing points —
(NLGI No. 2)
Cooling system Glycol-based coolant 2.4 U.S. gal. / 9.1 L
4-3
22. LUBRICANT LIST
22.3 BX50 – GASOLINE/LPG ENGINE

MODELS FG20/25/28/30/32(S)(H)T-16 & FG35AHT-16

dealer.
• Never use fuel mixed with kerosene as it can damage the
fuel injection system.
• Never use the wrong type of brake fluid.
Ambient Temperature
Location Type of Fluid -22 -4 14 32 50 68 86 104°F Capactities
-30 -20 -10 0 10 20 30 40°C

Engine oil pan
(SAE10W-30SH) 1.0 U.S. gal. / 3.8 L

2.54 U.S. gal. / 9.6 L
1 - 1.75 ton:
Gear oil (SAE80W) 1.19 U.S. gal. / 4.5 L
Differential case 2 - 3.5 ton:
1.59 U.S. gal. / 6.0 L
Gear oil (SAE90W) 3 ton std:
1.53 U.S. gal. / 5.8 L
1 - 1.75 ton:
Hydraulic tank Hydraulic oil ISO #32 10.57 U.S. gal. / 40.0 L
2 - 3.5 ton:
14.53 U.S. gal. / 55.0 L
Gasoline: 87 octane 1 - 1.75 ton:

(recommended) 10.57 U.S. gal. / 40.0 L
Fuel tank 2 - 3.5 ton:
LPG: HD-5 grade 15.32 U.S. gal. / 58.0 L
propane
Brake fluid (DOT 3)

Brake Reservoir 5.07 oz. / 0.15 L
(SAE7OR-3)
Lithium grease
Greasing points —
(NLGI No. 2)
4-4
22. LUBRICANT LIST
22.4 BX50 – DIESEL ENGINE

MODELS FD20/25/28/30/32T-16 & FD35AT-16

dealer. EPA REGULATION
• Never use fuel mixed with kerosene as it can damage the USE LOW SULFUR
fuel injection system. FUEL OR ULTRA LOW
• Never use the wrong type of brake fluid. SULFUR FUEL ONLY
AE80369C
NOTICE
Use low sulfur or ultra- low sulfur diesel fuel only.
Ambient Temperature
Location Type of Fluid -22 -4 14 32 50 68 86 104°F Capactities
-30 -20 -10 0 10 20 30 40°C

Engine oil pan
SAE10W-30CH 1.98 U.S. gal. / 7.5 L
SAE30W-30CH

2.54 U.S. gal. / 9.6 L
Gear oil 1 - 1.75 ton:

1.19 U.S. gal. / 4.5 L
Differential case SAE80W 2 - 3.5 ton:
1.59 U.S. gal. / 6.0 L
SAE90W 3 ton std:
1.53 U.S. gal. / 5.8 L
1 - 1.75 ton:
Hydraulic tank Hydraulic oil ISO #32 10.57 U.S. gal. / 40.0 L
2 - 3.5 ton:
14.53 U.S. gal. / 55.0 L
Diesel
1 - 1.75 ton:
ASTM D975 No. 2 10.57 U.S. gal. / 40.0 L
Fuel tank S15, S500 2 - 3.5 ton:
ASTM D975 No. 1 15.32 U.S. gal. / 58.0 L
S15, S500
Brake fluid (DOT 3)
Brake Reservoir 5.07 oz. / 0.15 L
(SAE7OR-3)
Lithium grease
Greasing points —
(NLGI No. 2)
4-5
23. PERIODIC MAINTENANCE SCHEDULE CHART
For the first month/200 hours maintenance schedule, see “FIRST MONTH
SERVICE OR INITIAL 200 HOURS SERVICE” on page 1-3.
AT STARTUP
Engine Electrical System
Cooling system water leakage Battery terminal connections
Cooling system water level (subtank) Equipment

Fuel system fuel leakage Chain tension and stretch
Lubrication system oil leakage Fork and fork stopper deformation, cracking or damage
Lubrication system oil pan oil level General work equipment operating condition
Abnormal noise and vibration Hydraulic System

Acceleration, engine stop and knocking Hydraulic pump, abnormal noise
Exhaust gas color Hydraulic tank oil level
Startup condition Piping damage, oil leakage and deformation
Braking System Tires

Inching pedal operation Tire air pressure
Brake pedal play and depressed pedal height Tire cracking and damage
Brake pedal stroke and braking effect Tire tread depth, wear
Parking brake operating effort Wheel nut and bolt torque
Parking brake stroke Other

Parking brake warning buzzer operation Abnormality found previously - check completion of repairs
Reservoir tank oil level Alarm operating condition
Servo system air pressure build-up Directional signal lamps operating condition
Power Train Instrument reading
Differential gear oil leakage Light operating condition
Forward-reverse lever - neutral lamp light operates Overhead guard & load backrest deformation, cracking and damage
Inching pedal operating condition Seat belt assembly
Transmission oil leakage Rear view mirror checking adjustment, damage and cleanliness
Steering System Warning lamp and signal lamp
Power steering oil level and oil leakage
Steering wheel play
EVERY 2 WEEKS OR 100 HOURS

Equipment
Chain lubrication
EVERY MONTH OR 200 HOURS

Engine Braking System
Alternator belt adjustment Clearance between drum and lining
Cooling fan belt adjustment Brake pedal - brake link play and tightness
Cooling fan deformation, cracking or damage Brake pedal - play and depressed pedal height
Cooling fan installed condition Brake pedal stroke and braking effect
4-6
EVERY MONTH OR 200 HOURS (continued)

Engine (continued) Braking System (continued)
Radiator cap condition Hose & piping leakage, damage, installation, condition and wear
Radiator fin cleaning and damage check Parking brake braking effect
Radiator hose cracking and damage Reservoir tank oil level
Fuel filter clogging Rod and cable loosening, play, damage and wear
Fuel system fuel leakage Equipment

Governor motion (at max. Rpm) Chain anchor bolt condition, damage, rusting and lubrication
Fuel system link movement Chain / chain wheel deformation, damage, rusting and lubrication
Crankcase breather cleaning Chain lubrication
Oil leakage Chain wheel bearing play
Oil pan oil level Fork and fork stopper deformation, cracking or damage
Oil pan oil replacement (diesel engine) Fork tip alignment, positioning, bends or sagging
Abnormal noise and vibration General work equipment operating condition
Acceleration, engine stop and knocking Mast deformation, cracking, damage and wear
Air cleaner cleaning Mast roller play
Exhaust gas color Hydraulic System

Low idling Control lever operating condition
Startup condition Hydraulic cylinder operating condition
Hydraulic cylinder tightness, deformation, cracking, damage and

Power Train wear
Differential gear oil leakage Lift cylinder natural drift
Differential gear oil level check and refill Tilt cylinder natural forward tilting
Inching pedal operating condition Hydraulic tank oil level
Transmission oil leakage Piping clip and clamp tightening and condition
Transmission oil level Piping damage, oil leakage and deformation
Pedal height Electrical System

Gearbox mounting tightness Battery electrolyte level
Gearbox oil leakage Battery electrolyte specific gravity
Power steering mounting condition and tightness at connections Ignition timing
Power steering oil level and oil leakage Spark advance mechanism
Rod and arm ball joint dust boot cracking and damage Spark plug inspection
Steering wheel operation feel Ignition system wiring tightness and condition
Steering wheel play Starting motor pinion gear engagement
Tires Check wiring connections for tightness and condition
Front wheel bearing play Other

Rim deformation, cracking and damage All lubrication points
Tire air pressure Operator’s seat installation, condition or damage
Tire cracking and damage Overhead guard & load backrest deformation, cracking & damage
Tire tread depth, wear Seat belt assembly
4-7
EVERY 500 HOURS

Engine
Oil filter cartridge replacement (gasoline engine)
Oil pan oil replacement (gasoline engine)
EVERY 3 MONTHS OR 600 HOURS

Engine Power Train
Fuel injection pump governor lubrication and oil replacement Differential gear oil level check and refill
Oil filter cartridge replacement (diesel engine) Transmission oil level
EVERY 6 MONTHS OR 1200 HOURS

Engine Power Train
Cooling system flush and cleaning Differential gear oil leakage
Fan belt adjustment/damage Differential gear oil level check and refill
Water level (radiator) Differential gear oil replacement
Water level (subtank) Transmission filter cartridge replacement (line)
Fuel leakage Transmission oil leakage
Injection timing and volume Transmission oil level
Oil leakage Transmission oil replacement
Oil pan oil level Transmission strainer replacement
Air cleaner clogging Steering System

Air cleaner element replacement Knuckle play, deformation or damage at connection points
Compression pressure Wheel fluctuation in minimum turning radius
Exhaust gas color Electrical System

Valve clearance Battery electrolyte level
Braking System Battery terminal connections
Clearance between drum and lining Ignition system contact point deterioration and clearance
Brake pedal play and depressed pedal height Hydraulic System

Brake pedal stroke and braking effect Hydraulic tank line filter replacement
Hose & piping leakage, damage, installation, condition and wear Hydraulic tank oil replacement
Parking brake braking effect Hydraulic tank strainer cleaning
Parking brake stroke Hydraulic tank cleaning
Tires
Tire air pressure
Tires wheel nut and bolt torque
EVERY 2000 HOURS (DIESEL MODELS ONLY)

Engine
Check turbocharger, rebuild or replace if necessary
Adjust valve clearance
Check fuel injection nozzles, replace if necessary
4-8
EVERY YEAR OR 2400 HOURS

Engine Braking System
Radiator cap condition Backing plate installation condition, deformation and cracking
Cooling system water leakage Brake shoe operating condition
Fuel filter clogging Brake spring operating condition and deterioration
Injection nozzle, injection pressure and condition Drum operating condition, wear and damage
Injection timing and volume Shoe and lining wear
Fuel system link movement Brake pedal master cylinder cup and seals
Throttle valve and choke valve condition Brake pedal play and depressed pedal height
Acceleration, engine stop and knocking Brake pedal stroke and braking effect
Compression pressure Brake valve operating condition
Cylinder head bolt retightening Cylinder and disc caliper oil leakage
Low idling Cylinder and disc caliper operating condition, wear and damage
Startup condition Hose and piping air, water or oil line tightness
Valve clearance Parking brake braking effect
Steering System Parking brake lever and ratchet wear and damage
Gearbox mounting tightness Parking brake stroke
Knuckle play, deformation or damage at connection points Reservoir tank oil level
Power steering oil level and oil leakage Reservoir tank oil replacement
Rod and arm ball joint dust boot cracking and damage Rod and cable loosening, play, damage and wear
Rod and arm loosening, play and damage Servo system operating condition
Steering wheel operation feel Wheel cylinder cup and seal
Wheel left and right turning angles Electrical System

Wheel alignment Battery electrolyte specific gravity
Equipment Battery terminal connections
Chain & chain wheel deformation, damage, rusting & lubrication Ignition system contact point deterioration and clearance
Chain tension and stretch Spark advance mechanism
Cracking at fork base (by dye penetration method) Check wiring connections for tightness and condition
Fork and fork stopper deformation, cracking or damage Tires

Mast deformation, cracking, damage and wear Axle deformation, cracking and damage
Mast support area damage and wear Front wheel bearing play
Roller shaft cracking/damage Tire cracking and damage
Hydraulic System Tire tread depth, wear
Hydraulic cylinder operating condition Other

Hydraulic pump and hydraulic motor operating condition Alarm operating condition
Relief valve operating condition and relief valve set pressure Directional signal lamps operating condition
Tank air breather replacement Instrument operating condition
Exhaust muffler and pipe installation condition and damage

Frame and crossmember cracks and damage
Overhead guard & load backrest deformation, cracking & damage
Tightness and condition of each part
4-9
24. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
24. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
To ensure safety at all times when operating or driving the lift truck, the lift truck user must always carry out periodic
maintenance. In addition, to further improve safety, the user should also perform periodic replacement of parts
given in the table below. These parts in particular are closely related to safety and fire prevention.
The material of these parts may change over time, or may easily wear or deteriorate. However, as it is difficult to
judge the condition of the parts simply by periodic maintenance, they should always be replaced after a fixed time
has passed, regardless of their condition. This is necessary to ensure that their full function is always maintained.
However, if these parts show any abnormality before the replacement interval occurs, they should be repaired or
replaced immediately.
If the hose clamps show any sign of deterioration, such as deformation or cracking, replace them at the same time
as the hoses.
Note that the periodic replacement is not covered by warranty.
IMPORTANT PARTS LIST
Replacement
No. Part name
Period (Years)
1 Master cylinder, wheel cylinder cup and dust seal, etc. 1
2 Rubber parts for brake booster 1
3 Brake hose or tube 2
4 Reservoir tank, tube 2
5 Power steering hose 2
6 Stop lamp switch (hydraulic type) 2
7 Fuel hose 2
8 Rubber parts inside power steering system 2
9 Lift chain 3
10 Hydraulic hose (for travel, loading & unloading and torque converter) 2
4-10
25. SERVICE DATA
25.1 AX50 SERVICE DATA – ALL MODELS

25. SERVICE DATA
Component Inspection item Unit FG15/18/20(A)(S)HT-20

Engine model – NISSAN K21 (4-cyl)
Idling speed rpm 750
Engine Maximum speed rpm 2,700
Gasoline & Dual-fuel: 210/250
Compression psi/rpm
LPG: 228/250
Lubricating oil cooling Fan belt deflection in.(mm) 0.43 - 0.51 (11 - 13)
system finger pressure: 98 N (10 kgf)
Injection timing BTDC deg. ECU control
Injection order – 1-3-4-2
Engine
Fuel system Injection rail pressure psi 50

LPG maximum tank pressure psi 250
LPG dry gas pressure psi 4.6
Valve clearance Intake
Intake/exhaust system in.(mm) 0.015 (0.38) Warm
Exhaust
Electronic ignition air gap in. (mm) 0.0138 - 0.0177 (0.35 - 0.45)
Spark plug gap in.(mm) 0.031 - 0.035 (0.8 - 0.9)
Electric system Spark plug type – NGK: FR2A-D
Ignition timing (gasoline) Ignition timing (LPG) BTDC deg. Gasoline, LPG 0°/idle (ECM control)
Firing order – 1-3-4-2
Tire inflation pressure Front wheels
Tires psi (MPa) 100 (0.69) (7.0 kgf/cm2)*
Rear wheels
Travel system
Front wheels 116 - 181 (157 - 245) (16 - 25 kgfm)

Lug (hub) nuts Tightening torque
Rear wheels 61 - 108 (83 - 147) (8.5 - 15 kgfm)*
ft•lbs (Nm)
Front wheels 65 - 91 (88 - 123) (9.0 - 12.5 kgfm)*
Rim mating nuts Tightening torque
Rear wheels 44 - 55 (59 - 74) (6.0 - 7.5 kgfm)*
Steering wheel Play 1.2 - 2.4 (30 - 60)
Steering, braking system
Play in. (mm) 0 - 0.16 (0 - 4)

Inching pedal
Interconnected travel 1.38 - 1.61 (35 - 41)
Play 0 - 0.16 (0 - 4)
Brake pedal in. (mm) O/D : 2.99 - 3.78 (76 -96)
Pedal height when pedal is depressed
I/D : 3.78 - 4.57 (96 - 116)
Parking brake operating force lbs (N) 33 - 44 (147 - 196) (15 - 20 kgf)
Brake
Tightening torque for back plate mounting bolts ft•lbs (Nm) 130 - 145 (176 - 196) (18 - 20 kgfm)
1.5 ton truck: Min. 1.18 (30)
Loading equipment
Forks Fork thickness (at base of forks) 1.8 ton truck: Min. 1.30 (33)
in. (mm) 2.0 ton truck: Min. 1.28 (32.5)
1.5 - 1.8 ton: Max. 10.8 (275.5)
Chain Length over 17 links
2.0 ton: Max. 13.0 (330)
Hydraulic system Relief pressure psi (MPa) 2,525 (17.41) (175 kgf/cm2)
* Pneumatic tire lift trucks only
4-11
25. SERVICE DATA
25.2 BX50 GASOLINE ENGINE LIFT TRUCK – PNEUMATIC TIRE

Component Inspection item Unit FG20/25T-16 FG20/25HT-16
Engine model — K21 K25
Idling engine speed rpm 750 - 900
Engine
Max. engine speed rpm 2900 - 3100 2720 - 2920
Compression 2 177.8 (12.5) /250 185 (13.0) /250

PSI (kgf/cm )/rpm
Cooling system Fan belt deflection in. (mm) 0.43 - 0.51 (11 - 13)
[finger pressure: 98 N (10 kgf)]
Injection timing deg-BTDC — —
Fuel system Injection order — — —

Engine
Injection pressure PSI (kgf/cm2) — —
Valve Intake in. (mm) 0.015 (0.38) [Warm]

Intake, exhaust system clearance Exhaust in. (mm) 0.015 (0.38) [Warm]
Distributor point gap in. (mm) — —
Spark plug gap in. (mm) 0.031 - 0.035 (0.8 - 0.9)
Electric system Spark plug type — FR2A-D
Ignition timing deg-BTDC/rpm 2/850 0/850
Firing order — 1-3-4-2
Tire inflation Front wheels 100 (7.0)

Tires pressure PSI (kgf/cm2)
Rear wheels 100 (7.0)
Travel system
Tightening Front wheels 22 - 37 (30 - 50)

Hub (lug) nuts torque ft/lbs (kgfm)
Rear wheels 12 - 18 (16 - 25)

Rim mating nuts torque ft/lbs (kgfm)
Rear wheels 88 - 123 (9 - 12.5)
Steering wheel Play in. (mm) 0.4 - 1.2 (10 - 30)
Steering, Braking System
Play in. (mm) 0 - 0.16 (0 - 4)

Inching pedal
Interconnected travel in. (mm) 1.38 - 1.61 (35 - 41)
Play in. (mm) 0 - 0.16 (0 - 4)
Brake pedal Pedal height when pedal is in. (mm) 2.4 - 3.2 (62 - 82)
depressed
Parking brake operating force lbf (kgf) 33 - 44 (15 - 20)*

Brake
Tightening torque for back
ft/lbs. (kgfm) 13 - 14.8 (18 - 20)
plate mounting bolts
1.58-inch fork: Min. 1.42 (36)
Loading Equipment
Forks Fork thickness (at base) in. (mm)

1.75-inch fork: Min. 1.58 (40)
Chain Length over 17 links in. (mm) 2 - 2.5 ton lift truck: Max. 13.0 (330)
Hydraulic system Relief pressure PSI (kgf/cm2) 2,630 (185)
* When a lift truck is equipped with power brakes, this value is 55 - 66 lbf (25 - 30 kgf).
4-12
25. SERVICE DATA
BX50 GASOLINE ENGINE LIFT TRUCK – PNEUMATIC TIRE (CONT’D)

Component Inspection item Unit FG28HT-16 FG30HT-16
Engine Max. engine speed rpm 2720 - 2920
2
Compression PSI (kgf/cm )/ 185 (13.0)/250
rpm
0.43 - 0.51 (11 - 13)
Cooling system Fan belt deflection in. (mm) [finger pressure: 98 N (10 kgf)]
Engine
Intake, exhaust Intake in. (mm) 0.015 (0.38) [Warm]

Valve clearance
system Exhaust in. (mm) 0.015 (0.38) [Warm]
Ignition timing deg-BTDC/rpm 0/850
Tire inflation Front wheels 100 (7.0)

Tires
pressure PSI (kgf/cm2)
Rear wheels 100 (7.0)
Travel system

Hub (lug) nuts ft/lbs (kgfm)
torque Rear wheels 12 - 18 (16 - 25)
Tightening Front wheels 14.8 - 22(20 - 30) —

Rim mating nuts ft/lbs (kgfm)
torque Rear wheels 6.6 - 9.2(9 - 12.5) —
Play in. (mm) 0 - 0.16 (0 - 4)

Inching pedal
Play in. (mm) 0 - 0.16 (0 - 4)
Brake pedal Pedal height when pedal is
depressed in. (mm) 2.4 - 3.2 (62 - 82)

Brake
Tightening torque for back plate ft/lbs. (kgfm) 13 - 14.8 (18 - 20)
mounting bolts
1.58-inch fork: Min.
1.42 (36) 1.8-inch fork: Min.
Loading Equipment

1.75-inch fork: Min. 1.80 (45)
1.58 (40)
3 ton lift truck:
2 - 2.5 ton lift truck: Max. 21.7 (550)
Chain Length over 17 links in. (mm)
Max. 13.0 (330) 3.5 ton lift truck: Max.
17.3 (440)
4-13
25. SERVICE DATA
BX50 GASOLINE ENGINE LIFT TRUCK – PNEUMATIC TIRE (CONT’D)

Component Inspection item Unit FG32HT-16 FG35AHT-16
Engine model — NISSAN K25 NISSAN K25
Idling speed rpm 750 - 900
Engine
Max. speed rpm 2720 - 2920
Compression 2 185 (13.0)/250

PSI (kgf/cm )/rpm

Engine
Intake, exhaust Intake in. (mm) 0.015 (0.38) [Warm]

system Valve clearance
Exhaust in. (mm) 0.015 (0.38) [Warm]
Electric system Spark plug type — FR2A-D FR2A-D
Ignition timing deg-BTDC/rpm 0/850
Tire inflation
Front wheels PSI (kgf/cm2) 100 (7.0) 121 (8.5)
Tires
pressure
Rear wheels PSI (kgf/cm2) 100 (7.0) 128 (9.0)
Travel System
Tightening Front wheels ft/lbs. (kgfm) 217 - 362 (30 - 50)

Hub (lug) nuts torque Rear wheels ft/lbs. (kgfm) 116 - 181 (16 - 25)
Tightening Front wheels ft/lbs. (kgfm) — —

Rim mating nuts torque Rear wheels ft/lbs. (kgfm) — —
Play in. (mm) 0 - 0.16 (0 - 4)

Inching pedal
Interconnected travel in. (mm) 1.38 - 1.61 (35 - 41) 1.58 - 1.81 (40 - 46)
Play in. (mm) 0 - 0.16 (0 - 4)
depressed in. (mm) 2.4 - 3.2 (62 - 82)

Brake
Tightening torque for back plate ft/lbs. (kgfm) 13 - 14.8 (18 - 20) 18.4 - 22.1 (25 - 30)
mounting bolts
Forks Fork thickness (at base) in. (mm) 2-inch fork: Min. 1.80 (45)
Loading Equip.
3 ton lift truck: Max. 21.7 (550)

Chain Length over 17 links in. (mm) 3.5 ton lift truck: Max. 17.3 (440)
Hydraulic
system
Relief pressure PSI (kgf/cm2) 2,630 (185)
4-14
25. SERVICE DATA
25.3 BX50 GASOLINE ENGINE LIFT TRUCK – CUSHION TIRE

Component Inspection item Unit FG20/25ST-16 FG28SHT-16
Engine
Max. engine speed rpm 2900 - 3100 2720 - 2920
Compression 2 178 (12.5)/250 185 (13.0)/250

PSI (kgf/cm )/rpm

Engine
Valve Intake in. (mm) 0.015 (0.38) [Warm]

Intake, exhaust system clearance Exhaust in. (mm) 0.015 (0.38) [Warm]
Ignition timing deg-BTDC/rpm 2/850 0/850
Front wheels ft/lbs. (kgfm) 22 - 37 (30 - 50)
Wheels
Hub (lug) nuts Tightening

torque Rear wheels ft/lbs. (kgfm) N/A N/A

Play in. (mm) 0 - 0.16 (0 - 4)

Inching pedal
Play in. (mm) 0 - 0.16 (0 - 4)
depressed in. (mm) 2.4 - 3.2 (62 - 82)

Brake Tightening torque for back
ft/lbs. (kgfm) 13.2 - 14.8 (18 - 20)
plate mounting bolts
1.58-inch fork: Min. 36 (1.42)
Loading Equip.

1.75-inch fork: Min. 40 (1.58)
Chain Length over 17 links in. (mm) 2 - 2.5 ton lift truck: Max. 13.0 (330)
4-15
25. SERVICE DATA
BX50 GASOLINE ENGINE LIFT TRUCK – CUSHION TIRE (CONT’D)

Component Inspection item Unit FG30/32SHT-16
Engine model — K25
Engine
Max. engine speed rpm 2720 - 2920
Compression 2 185 (13.0)/250

PSI (kgf/cm )/rpm
Injection timing deg-BTDC —
Fuel system Injection order — —

Engine
Injection pressure PSI (kgf/cm2) —
Intake in. (mm) 0.015 (0.38) [Warm]

Intake, exhaust system Valve clearance
Exhaust in. (mm) 0.015 (0.38) [Warm]
Distributor point gap in. (mm) —
Ignition timing deg-BTDC /rpm 0/850
Front wheels 22 - 37 (30 - 50)
Travel System
Hub (lug) nuts Tightening ft/lbs. (kgfm)

torque Rear wheels N/A

Play in. (mm) 0 - 0.16 (0 - 4)

Inching pedal
Play in. (mm) 0 - 0.16 (0 - 4)
depressed in. (mm) 2.4 - 3.2 (62 - 82)

Brake Tightening torque for back plate
ft/lbs. (kgfm) 13.2 - 14.8 (18 - 20)
mounting bolts
Forks Fork thickness (at base) in. (mm) 2-inch fork: Min. 45 (1.80)
Loading Equip.
Chain Length over 17 links in. (mm) 3 ton lift truck: Max. 21.7 (550)
3.5 ton lift truck: Max. 17.3 (440)
4-16
25. SERVICE DATA
25.4 BX50 DIESEL ENGINE LIFT TRUCK

Component Inspection item Unit ALL MODELS
Engine model — KOMATSU 4D98E
Idling speed rpm 785 - 835
Engine proper
Max. speed rpm 2650 - 2750
Compression 2 426.7 (30)/250

PSI (kgf/cm )/rpm
Injection timing deg-BTDC ATDC6
Engine
Fuel system Injection order — 1-3-4-2
Injection pressure PSI (kgf/cm2)/rpm 1,706.8 (120)
Intake, exhaust Intake in. (mm) 0.0079 (0.2) [Cool]

system Valve clearance
Exhaust in. (mm) 0.0079 (0.2) [Cool]
Distributor point gap in. (mm) —
Spark plug gap in. (mm) —
Electric system
Ignition timing deg-BTDC/rpm —
Firing order — —
Tire inflation
Front wheels PSI (kgf/cm2) 100 (7.0)
Tires
pressure
Rear wheels PSI (kgf/cm2) 100 (7.0)
Travel System
Front wheels ft/lbs. (kgfm) 22.1 - 36.8 (30 - 50)

Hub nuts Tightening torque
Rear wheels ft/lbs. (kgfm) 11.8 - 18.4 (16 - 25)
Front wheels ft/lbs. (kgfm) 14.8 - 22.1(20 - 30)

Rim mating nuts Tightening torque [excluding 3-ton lift truck]
Rear wheels ft/lbs. (kgfm) 6.6 - 9.2 (9 - 12.5)
Play in. (mm) 0 - 0.16 (0 - 4)

Inching pedal
Play in. (mm) 0 - 0.16 (0 - 4)
Brake pedal
Pedal height when pedal is depressed in. (mm) 2.4 - 3.2 (62 - 82)
Parking brake operating force lbf (kgf) 33 - 44 (15 - 20)**
Brake Tightening torque for back plate
ft/lbs. (kgfm) 13.2 - 14.8 (18 - 20)
mounting bolts
1.58-inch fork: Min. 1.42 (36)
Loading Equipment
Forks Fork thickness (at base) in. (mm) 1.75-inch fork: Min. 1.58 (40)
2-inch fork: Min. 1.80 (45)
2 - 2.5 ton lift truck: Max. 13.0 (330)
Chain Length over 17 links in. (mm) 3 ton lift truck: Max. 21.7 (550)
3.5 ton lift truck: Min. 17.3 (440)
* In case of FD35AT, this value is 40 - 46 mm (1.6 - 1.8 in).
** In case of FD35AT or any other lift truck equipped with power brakes, this value is 55 - 66 lbf (25 -
30 kgf).
4-17
25. SERVICE DATA
25.5 TORQUE LIST

For unspecified bolts and nuts, use the torques specified in this
list.
Select a proper torque corresponding to the width across flats (b)
of bolts and nuts.
When replacing bolts and nuts, always use genuine Komatsu
Forklift parts the same size as the previous ones.
Thread diameter Width across Tightening torque

of bolt (mm) flat (mm)
(a) (b) Nm kgfm lbft
6 10 13.2 ± 1.4 1.35 ± 0.15 9.73 ± 1.03
8 13 31.4 ± 2.9 3.2 ± 0.3 23.2 ± 2.1
10 17 65.7 ± 6.8 6.7 ± 0.7 48.5 ± 5.0
12 19 112 ± 9.8 11.5 ± 1.0 82.6 ± 7.2
14 22 177 ± 19 18.0 ± 2.0 131 ± 14
16 24 279 ± 29 28.5 ± 3 206 ± 21
18 27 383 ± 39 39 ± 3 282 ± 29
20 30 549 ± 58 56 ± 6 405 ± 43
22 32 745 ± 78 76 ± 8 549 ± 58
24 36 927 ± 98 94.5 ± 10 684 ± 72
27 41 1320 ± 140 135 ± 15 973 ± 100
30 46 1720 ± 190 175 ± 20 1270 ± 140
33 50 2210 ± 240 225 ± 25 1630 ± 180
36 55 2750 ± 290 280 ± 30 2030 ± 210
39 60 3280 ± 340 335 ± 35 2420 ± 250
4-18
26. CHECK BEFORE OPERATION
Never operate the lift truck before the pre-operation check is completed.
If any abnormality is found during checking, immediately consult a Komatsu Forklift dealer
and do not operate the lift truck until repaired.
Oil leakage can cause a lift truck fire.
26.1 CHECK BEFORE OPERATION (WITH STARTING SWITCH OFF)

26.1.1 CHECK ABNORMALITIES FOUND ON PREVIOUS DAY
Re-check any repaired part which was found to be faulty during the previous day's checking and operation of the lift
truck.
26.1.2 CHECK FOR OIL LEAKAGE AND

BATTERY FLUID LEAKAGE
Check around the lift truck doing a visual inspection.
Look under the lift truck to check that there is no oil or water
leakage.
26.1.3 CHECK FOR CRACKS AND DAMAGE

Carry out a visual inspection for cracks and damage. Pay
attention to the following items in particular:
• Overhead guard
• Fork
• Load backrest
• Fork carriage
• Mast
• Fuel tank
• Hydraulic oil tank
26.1.4 CHECK TIRES AND RIMS

• Check that the tire inflation pressure is correct. For the cor-
rect tire pressure, refer to “SERVICE DATA” on page 4-11.
• Check the hub nuts for any loosening.
• Check the tires for excessive wear, damage, and adhesion of
foreign matter.
• Check the rims for deformation or damage.
NOTICE
Tighten the hub nuts to the specified torque. (For tightening

torque see “SERVICE DATA” on page 4-11.)
4-19
26.1.5 CHECK IN ENGINE COMPARTMENT
Be careful not to get your hand caught when opening or closing the hood.
26.1.6 METHOD OF OPENING ENGINE HOOD

1. Push up lever (1) on the front left side of the engine hood with
the left hand.
2. Push up the engine hood until engine hood stopper (2) is set.
26.1.7 METHOD OF CLOSING ENGINE HOOD

Push in the red stopper (stamped as “PRESS“), and then lower
the engine hood slowly with the right hand until it is securely
locked.
26.1.8 CHECK OIL LEVEL IN HYDRAULIC TANK

1. Lower the forks fully to the floor and stand the mast vertically
(perform on flat floor).
2. Open the engine hood and remove the dipstick (combined
with breather) on the right side of the lift truck.
3. Wipe off hydraulic oil with a clean cloth and insert dipstick into
the tank.
4. Pull out the oil level gauge again and check that the oil level
is within the normal range.
5. Refill with hydraulic oil if it is low. If any oil is spilled, wipe it
off.
NOTICE
Always use Komatsu Forklift genuine hydraulic oil.
4-20
26.1.9 CHECK OIL LEVEL IN ENGINE OIL PAN

Check with the oil level gauge that the engine oil level is within
the normal range. Refill if it is low.
• When the engine oil is considerably contaminated or has

been discolored, replace with new oil.
• For replacement engine oil, be sure to use genuine Komatsu
Forklift engine oil.
26.1.10 CHECK OIL LEVEL IN BRAKE

RESERVOIR TANK
If the oil level in brake oil reservoir tank (1) is within the normal
range, then the amount of oil is adequate. If it is low, refill with
genuine Komatsu Forklift brake oil.
Dashboard left
Always use Komatsu Forklift genuine brake fluid for the
brake fluid.
26.1.11 CHECK BATTERY ELECTROLYTE LEVEL

When the battery electrolyte level is not within the normal range,
refill with distilled water up to upper limit line (A).
Wipe out the battery cap breather and battery terminals.
• If the battery electrolyte has spilled and the level has gone
down, have your battery repair shop add dilute sulfuric acid of
the same density.
• Do not use a metal funnel when adding distilled water or
dilute sulfuric acid. Use only acid-resistant materials
designed for this purpose.
• If you have spilled battery electrolyte on your clothing or skin, immediately shed the
clothes and flush the part with a large quantity of tap water, and then consult a doctor. In
particular, should battery electrolyte get into your eyes, flush them immediately with fresh
tap water for 10 to 15 minutes and then consult a doctor at once.
• Do not cause short-circuiting or sparking in the electric circuit. In addition, never permit
fire or an ignition source near a battery. Never light a cigarette or smoke near a battery.
• Wear goggles, protective gloves and rubber-soled shoes during the inspection and
maintenance work of the battery.
4-21
26.1.12 CHECK COOLANT LEVEL
NOTICE
• Carry out a regular inspection of the coolant level through the sub-tank before beginning the day's
work when the engine is still cold.
• Even if the coolant level in the sub-tank seems normal, check the coolant level inside the radiator
every month or ever 200 hours of hour meter reading according to the maintenance schedule. A
radiator coolant level lower than specified may cause an engine overheating problem.
When the coolant temperature is still high, do not try to remove the radiator cap or sub-tank
cap. Steam or boiling water may spurt out, causing burns.
When removing the radiator cap after the coolant temperature has gone down, turn the cap
slowly to release the pressure before removing it.
1. Check the radiator and radiator hose for any water leakage.
2. If cooling water in the sub-tank is not within the normal range
when it is still cold, refill with fresh water up to “FULL“ level.
3. When the cooling water in the sub-tank runs low, refill the
radiator tank and sub-tank.
26.1.13 CHECK DEFLECTION OF V-BELT

• For the inspection of V-belt tension, depress the belt center
with force of 98 N (10 kgf).
• For the inspection of V-belt deflection, refer to “SERVICE
DATA” on page 4-11.
NOTICE
Replace the belt if the belt is stretched and there is no allow-

ance for adjustment, or if the belt is cut or cracked.
26.1.14 OPERATE FROM OPERATOR'S

COMPARTMENT
Inspection item of brake pedal
• Amount of play
• Height of pedal (H) when depressed
Inspection item of inching pedal

• Amount of play
• Interconnected stroke
For the standard value of each inspection item above, refer to

“SERVICE DATA” on page 4-11.
4-22
26.1.15 CHECK PARKING BRAKE
NOTICE
If the standard value of the parking brake lever operating

effort is not within the normal range, call your Komatsu Fork-
lift dealer.
Check that the operating effort of the parking brake lever is

normal. For the standard value of the parking brake lever
operating effort, see “SERVICE DATA” on page 4-11.
If the lift truck is equipped with a parking brake warning buzzer
(optional), check that the buzzer begins to sound when leaving the truck with the parking brake left in the released
condition.
26.1.16 CHECK HORN

Press the horn button and check that the horn sounds normally.
26.2 CHECK AFTER STARTING (WITH STARTING SWITCH ON)
NOTICE
Proceed to the following inspection after reading “MOUNTING/DISMOUNTING” on page 3-19, “SEAT POSI-
TION ADJUSTMENT” on page 3-19 and “STARTING LIFT TRUCK OFF” on page 3-21.
26.2.1 CHECK FOR ABNORMAL NOISE, ABNORMAL VIBRATION

Check in particular that there is no abnormal noise or abnormal vibration from the engine or hydraulic pump.
26.2.2 CHECK ENGINE EXHAUST GAS COLOR

Check that the engine exhaust gas color is normal.
Colorless Normal
Black Incomplete combustion
White Coolant or oil entering combustion chamber, defective head gasket, excessive fuel input
4-23
26.2.3 CHECK FUEL LEVEL IN FUEL TANK
Never use fuel mixed with kerosene, as such a practice

causes damage to the fuel injection system.
NOTICE
Before refilling fuel tank, remove dirt in and around the filler
port cap as precautions so that dirt will not get into the fuel tank.
1. When fuel level gauge needle points to (A), the fuel tank is full.
If the level is low, stop the engine and refill the fuel tank to the full level through the fuel filler port.
For the correct fuel, refer to “LUBRICANT LIST” on page 4-2.
When adding fuel, never let the fuel overflow. This may cause a fire. If you spill fuel,
thoroughly clean up any spillage.
2. After refilling, tighten the filler port cap securely and wipe off spilled fuel.
4-24
26.3 CHECKS USING GAUGES AND WARNING LAMPS

26.3.1 INDICATORS FOR OIL PRESSURE,
BATTERY CHARGE, LIFT/TILT Engine oil pressure Charge
INTERLOCK AND FAILURE DETECTION warning lamp warning lamp
These lamps light up when the engine starting switch key is
turned to the ON position and goes off after the engine startup.
After start up they function normally.
Lift/Tilt Interlock Failure Detection/

indicator Operator Presence
error indicator
9EL00841
26.3.2 NEUTRAL INDICATOR LAMP

The lamp is in normal condition if it lights steady when the
forward-reverse lever is in neutral and the engine starting switch
is turned to the ON position.
The neutral lamp is in a normal condition if it goes off when the
forward-reverse lever is moved to either the F or R positions.
When the lamp blinks, indicating either neutral safety or Travel
Interlock, travel is locked out. See “NEUTRAL /TRAVEL
INTERLOCK INDICATOR LAMP” on page 3-9.
26.3.3 WATER TEMPERATURE GAUGE

The indicator should be in the white range to indicate normal
operating temperature.
26.3.4 SEDIMENTER WARNING LAMP

(DIESEL ENGINE LIFT TRUCK)
The lamp is in a normal condition if it lights up when the starting

switch is turned ON and goes off after the engine startup.
If the lamp remains lighted even after engine startup, drain any
water from the sedimenter. (For draining water, refer to “DIESEL
ENGINE” on page 4-31.)
4-25
26.3.5 CHECK STEERING WHEEL

Check the following points.
• Play (the play should be 10 - 30 mm (0.4 - 1.2 in)).
• There must be no up-down play.
26.3.6 CHECK LAMPS

Check that the front lamps, parking lamps (clearance lamps), brake lamps and backup lamps work normally and
that none of them is dirty or damaged.
26.3.7 CHECK REARVIEW MIRROR

• The mirror is set at such an angle that it enables the operator
to see the rear easily.
• The mirror must be free of dirt or damage.
26.3.8 CHECK BACKUP BUZZER
Move the F-R lever to the neutral position, pull back the parking brake lever and depress
the inching pedal, and then carry out this inspection.
Check that the backup buzzer sounds when the forward-reverse control lever is set to the REVERSE position.
If the backup buzzer does not sound when the forward-reverse control lever is set to the REVERSE position, carry
out repairs or replacement immediately.
4-26
26.3.9 CHECK LIFT CHAIN TENSION
Move the forward-reverse lever to the neutral position, and then carry out this inspection.
Do not put your foot under the fork.
Make sure that the chain tension is the same on the left and right.
If the tension is not the same, the load will be unevenly balanced even if it is set in the center of
the lift truck, and there is danger that the chain may break or the lift truck may tip over.
1. Raise the fork from the ground.

Lift amount “A”: 10 - 15 cm (4 - 6 in)
2. Check the right and left deflections of the lift chain by
pressing it at the center.
The tension is normal when both deflections are
approximately equal.
3. If the deflections differ from each other, adjust with the lift-
chain stopper bolt nut.
26.3.10 CHECK ELONGATION OF THE LIFT CHAIN
Move the forward-reverse lever to the neutral position before carrying out this inspection.
Do not allow your feet to get under the forks.
Measure the length over 17 links and check that the length is
within the specified value. For the standard length over 17 links,
see “SERVICE DATA” on page 4-11.
If the measurement value exceeds this range, replace the chain.
4-27
26.3.11 CHECK THE LIFT CHAIN LUBRICANT

If the lift chains are poorly lubricated, coat them with engine oil.
When a lift chain gets rusted, it easily breaks. In order to prevent the chains from becoming rusted, coat them with
engine oil periodically.
Inspect the lift chains visually for damage and cracks. If any abnormality is been found, call your Komatsu Forklift
dealer for prompt replacement.
NOTICE
Use Komatsu Forklift genuine engine oil. See “LUBRICANT LIST” on page 4-2.
26.4 CHECK WHILE ADVANCING SLOWLY

26.4.1 CHECK STEERING WHEEL OPERATION
Check the following items while advancing slowly.
• No deviation of steering wheel.
• No unstable steering in straight drive.
• No feeling of abnormally-heavy steering when the steering wheel is turned.
26.4.2 CHECK BRAKE OPERATION

Check the following by depressing the brake pedal to apply the brakes while running the truck slowly.
• The brakes work satisfactorily.
• The brakes do not have an uneven action, pulsing, grabbing or pulling left or right.
26.4.3 CHECK OPERATION OF INCHING PEDAL

• Depress the pedal slightly (partially engage the clutchpack) and check that it is possible to carry out inching.
• Check that the lift truck stops when the pedal is completely depressed.
26.4.4 CHECK FOR ABNORMAL SOUND OR ODOR

Check that no abnormal sound or odor is generated while advancing slowly.
26.5 CHECK OF WORK EQUIPMENT

26.5.1 CHECK THE WORK EQUIPMENT OPERATION
Check that the forks lift and lower smoothly and the mast tilts forward and backward smoothly during operation of
the work equipment lever from the operator seat.
NOTICE
If there is any abnormality, please contact your Komatsu Forklift dealer immediately.
26.5.2 CHECK FOR ABNORMAL SOUND OR ODOR

Check that no abnormal sound or odor is produced while operating the work equipment from the operator seat.
4-28
27. CHECK AFTER OPERATION
CHECK AFTER OPERATION

27. CHECK AFTER OPERATION
After all the Check Before Operation inspections have been finished and each part of the lift truck is
cleaned, carry out the following inspections before it is stored.
1. Oil leakage or battery fluid leakage from the units.
2. Cracks or damage.
3. Check faults found during operation and report them to the person responsible for the lift truck.
4. Lubricate the units (if necessary).
4-29
28. MAINTENANCE PROCEDURES
NOTICE
For any maintenance item that you are not equipped to do, ask your Komatsu Forklift dealer.
28.1 ENGINE MAINTENANCE
Before starting engine maintenance, stop the engine and wait for it to cool down fully.
28.1.1 GASOLINE ENGINE

CHANGE ENGINE OIL
1. Complete one cycle of the adjustment mode with the mode
button. Remove the drain plug, drain the oil, then tighten the
plug again.
2. Remove the dipstick.
3. Add the specified amount of engine oil.
4. Check the oil level with the dipstick.
For the right amount of replacement engine oil, refer to the

“LUBRICANT LIST” on page 4-2.
REPLACE ENGINE OIL FILTER

1. Using a filter wrench, remove the cartridge.
2. Clean the filter holder, coat the thread and the seal of the new
cartridge with clean engine oil, then install.
NOTICE
After installing the cartridge, start the engine and check that
there is no leakage of oil from the filter mount surface.
28.1.2 REPLACE FUEL FILTER

1. Loosen the nut and remove the cover to take out the filter element.
2. Clean off any carbon stuck to the tip of the plug or the surrounding area. Drain the water and clean out the dirt
accumulated at the bottom.
3. Install the new filter.
• If any damage is found on the packing for the cover, replace it with a new one.
• After replacing defective packing, check that there is no fuel leakage from the hose mounting portion.
CHECK SPARK PLUG

1. Remove the plug using the plug wrench supplied with the lift
truck.
2. Clean off any carbon stuck to the tip of the plug or the
surrounding area.
3. Measure gap (A) with a plug gap gauge.
For the right type of plug in use, refer to “SERVICE DATA” on

page 4-11.
4-30
28.1.3 DIESEL ENGINE

CHANGE ENGINE OIL
1. Remove the drain plug, drain the oil, then tighten the plug
again.
2. Remove the dipstick.
3. Add the specified amount of engine oil.
4. Check the oil level with the dipstick.

REPLACE ENGINE OIL FILTER

2. Clean the filter holder, coat the thread and the seal of the new
cartridge with engine oil, then install.
NOTICE
After installing the cartridge, start the engine and check that
there is no leakage of oil from the filter mount surface.
DRAIN WATER FROM FUEL FILTER

Loosen the combination sensor plug and drain the water and
sediment accumulated at the bottom.
• Fuel will drain out at the same time, so prepare a con-

tainer to catch it.
• Always be sure to wipe up any spilled fuel.
REPLACE FUEL FILTER

1. Remove the combination sensor plug at the bottom of the
cartridge.
3. Install the combination sensor plug to the new cartridge.
4. Loosen plug (A) and move knob (B) up and down until no
more air bubbles come out.
5. Tighten Plug (A).
4-31
28.2 CHECK AIR CLEANER AND REPLACE FILTER WHEN DIRTY
Never clean or replace air cleaner while the engine is running.
• Do not replace an air filter on a diesel engine with a filter intended for a gasoline engine or
vice-versa: radial seal style filters are NOT interchangeable between diesel and gasoline
engines.
• Never clean the radial seal air filter or use compressed air on it; this will damage the filter.
Replace the air filter if dirty.
NOTICE
The engine warranty will be voided if improper or aftermarket elements are used.
REPLACE RADIAL SEAL AIR FILTER

1. Release latches to remove air cleaner housing cover.
2. Gently remove filter element, taking care not to dislodge dirt
and dust. Avoid knocking the filter against the housing. If your
air cleaner has a safety filter, replace it every third primary
filter change. Remove the safety filter as you would the
primary filter. Make sure you cover the air cleaner outlet tube
to avoid any unfiltered contaminant dropping into the engine.
3. Thoroughly clean air cleaner housing sealing surface and
outlet tube outer diameter. Then clean the inside of the outlet
tube using a clean cloth.
4. Inspect the old filter for leak clues. A streak of dust on the
clean side of the filter is a telltale sign. Remove any cause of
leaks before installing new filter.
5. Inspect the new filter for damage, paying careful attention to the inside of the open end, which is the sealing
area. Never install a damaged filter.
6. Insert new radial seal filter carefully with open end towards air
cleaner housing. Seat filter completely by hand, making certain
it is completely into the air cleaner housing before securing the
cover in place.
Each new element sealing surface is coated with a dry

lubricant to aid in sealing. DO NOT USE COVER TO
FORCE FILTER ELEMENT INTO PLACE. THIS WILL
DAMAGE THE FILTER AND THE HOUSING. When seating
element, apply hand pressure to outer edge of filter, not
in the flexible center.
7. Once element is seated and sealed, reinstall cover and secure the latches.
8. Check all clamps, bolts and connections for tightness.
4-32
28.3 CHECK BATTERY ELECTROLYTE SPECIFIC GRAVITY
Cautions when handling battery:

• If you have spilled battery electrolyte on your clothing or skin, immediately shed the
clothes and flush the part with a large quantity of tap water, and then consult a doctor. In
particular, should battery electrolyte get into your eyes, flush them immediately with fresh
tap water for 10 to 15 minutes and then consult a doctor immediately.
• Do not permit fire, spark or ignition source near any battery.
• Do not cause short-circuiting or sparking in the electric circuit.
• Do not smoke near any battery.
1. Charge the battery, and after charging, check that the battery electrolyte level is correct.
2. Using a specific gravity meter and thermometer, measure the specific gravity and temperature of the battery
electrolyte.
3. Insert the values measured in Steps 1 and 2 in the formula below, and calculate S20.
S20=St+0.0007(t-20)
S20: Specific gravity at 20°C

St: Specific gravity (measured value) at t° C
t: Temperature of battery electrolyte (measured value)
Normal value: S20=1.27 - 1.29
Specific gravity Condition of Necessity to

of electrolyte charge charge
1.280 Fully charged
No
1.240 1/4 discharged
1.210 1/2 discharged
Yes
1.130 Fully discharged
°
4. Charge the battery if necessary.
28.4 CLEAN RADIATOR FINS, CHECK FOR DAMAGE
Dirt may fly and get into your eyes when performing this procedure, so always wear protective
glasses or goggles.
1. Blow the radiator fins with compressed air, steam, or water.
Air pressure 0.98 MPa (10 kgf/cm2)

Steam pressure 0.39 MPa (4 kgf/cm2)
When using air or steam, always point the nozzle at a right
angle to the radiator when cleaning to minimize fin damage.
2. Check visually that there are no dents or damage to the fins.
4-33
28.5 CLEAN INSIDE OF COOLING SYSTEM
• Right after the engine has stopped, the cooling water is at a high temperature, so there is
always the danger of burns if the hot cooling water is drained immediately. Wait until the
hot cooling water cools down sufficiently and then carry out draining.
• Never attempt to crawl under a running lift truck under any circumstances.
• While the engine cooling water is still at a high temperature, do not try to unscrew the
radiator cap, as boiling water will likely spurt out. Unscrew the cap only after the
temperature goes down sufficiently and turn the cap slowly to release the internal
pressure.
• When engine cooling water is replaced, or when the radiator is replaced with a new one,
the engine sometimes overheats unless air is completely bled from the cooling system.
Therefore, make sure that air is completely bled from the system.
28.5.1 CLEAN RADIATOR

Stop the lift truck on level ground and allow to cool.
1. Open the drain valves at the bottom of the radiator and the
engine cylinder block to drain the water.
2. Close the drain valves, fill the radiator with fresh water (tap
water) and radiator flushing fluid through the water filler, then
run the engine at idling for approx. 15 minutes.
3. Stop the engine, open the drain valves to drain the water,
then add fresh water and run the engine at idling until clean
water comes out from the drain valves (5 - 10 minutes).
4. Stop the engine, drain all the water from the drain valves,
then close the drain valves and fill the radiator with fresh
water and long life coolant.
For the correct amount of cooling water, refer to the “LUBRICANT LIST” on page 4-2.
If air is not completely bled from the engine cooling system after cooling water is replaced, the engine may
overheat. Ensue that all air is bled from the cooling system.
28.5.2 Cautions when replacing engine cooling water

• If water is sprayed into the radiator from a hose, air bubbles will be contained in the water, so pour water in the
radiator tank gradually.
• In order to determine if enough water has been provided in the tank after the initial pouring, idle the engine for
about 5 to 10 minutes without the radiator cap being in place to release air inside the engine, and then stop the
engine to check the water level.
• Pour cooling water in the reservoir tank, too, up to the specified level.
Coolant is flammable, so keep it away from open flame.
• In cold areas, add long life coolant (Non-amine type). (For details, see “COLD WEATHER OPERATION” on
page 3-31.)
• When not using long life coolant, add rust prevention fluid to the radiator.
• Always use genuine Komatsu Forklift products for the flushing fluid, rust prevention fluid, and long life coolant.
4-34
28.6 CHANGE OIL IN DIFFERENTIAL CASE
Immediately after operations, the oil is at high temperature. Wait for the temperature to go
down before starting this operation.
28.6.1 CHECK OIL LEVEL

Remove the oil filler plug that doubles as an oil level check plug
and check the hydraulic oil level. When oil comes up as high as
the lower line in the plug hole, then the amount of the oil is
sufficient. If it does not, refill with additional oil.
28.6.2 CHANGE OIL

1. Remove the oil filler plug that doubles as an oil level check
plug and drain plug, and then drain the hydraulic oil.
2. After draining the oil, tighten the drain plug and add the
specified amount of oil through the oil filler.
3. After filling with oil, check the oil level.
NOTICE
For the gear oil, be sure to use genuine Komatsu gear oil.
Remark
On the TORQFLOW transmission lift truck, each case has its
own special oil, so it is necessary to check and change the oil
in the TORQFLOW transmission case in addition to checking
and changing the oil in the differential case.
4-35
28.7 CHANGE OIL IN TORQFLOW TRANSMISSION CASE AND CLEAN

STRAINER
28.7.1 CHECK OIL LEVEL
1. Open the inspection window in the floor plate and check with the dipstick.
2. If the oil level is low, remove the oil filler plug and add oil.
28.7.2 CHANGE OIL, CLEAN STRAINER

1. Remove the drain plug, drain the oil, then tighten the plug again.
2. Remove the mounting bolts, take out the strainer, and flush it with oil.
3. After washing, blow air from within the strainer to dry it off, and then install it again. If the strainer is clogged or
broken, replace it with a new one.
4. Add the specified amount of oil through the oil filler port.
5. After filling with oil, check the oil level. For the right amount of replacement engine oil, refer to the “LUBRICANT
LIST” on page 4-2.
TOP VIEW SIDE VIEW
NOTICE
For the engine oil, be sure to use genuine Komatsu engine oil.
4-36
28.8 CHANGE HYDRAULIC OIL
Immediately after operations, the oil is at high temperature.

Never change the oil immediately after stopping operations.
Wait for the oil temperature to go down before changing the oil.
1. Drain the oil from the drain plug at the bottom of the tank,
then remove the cover, take out the strainer, and flush it with
oil.
2. Clean the inside of the tank, then install the drain plug.
3. After washing the strainer, blow air from the inside of the
strainer to dry it completely, then install it again.
4. Replace the line filter and then install the cover.
5. Add the specified amount of hydraulic oil through the
insertion port of the breather (with dipstick), then check the oil
level with the dipstick.
6. Start the engine, then operate the cylinders (lift, tilt) to the end
of their travel 5 - 6 times to bleed the air.
NOTICE
Always use Komatsu Forklift genuine hydraulic oil.
28.9 CHECKING LPG FUEL SYSTEM FOR LEAKS

• See the "Safety" chapter for all safety precautions concerning LPG fuel systems.
• Before testing, make sure the system gas pressure is greater than 90 psi (621 kPa).
• Test all connections, container, valves and fttings with soap and water or equivalent solution. If there are any
leaks, have them repaired by qualified personnel.
• When replacing LPG fuel system components, use Komatsu genuine parts only.
4-37
29. REPLACEMENT PROCEDURES
29.1 REPLACING TIRES

GENERAL WARNINGS
• Check that rim nuts (2) are not loosened, and then loosen
hub nuts (1).
• Never loosen rim nuts (2), mistaking them for hub nuts (1).
• When lifting the lift truck with a jack, carry out the work, often
checking that the jack does not slip off, and never crawl
under the lifted truck.
• The tires are filled with highly pressurized air. For this reason,
a deformed or cracked rim poses a serious danger. Before
filling with air, check the rims and tires thoroughly for defor-
mation or crack, and do not use any defective tire.
• Set the air pressure of an air compressor for use at the spec-
ified value beforehand so that air of higher pressure than specified will not be sent to the tires.
• Leave the disassembly and reassembly work of the tires for professionals.
PROCEDURE
1. Stop the lift truck on flat ground in a safe area and apply the
parking brake.
2. Put blocks under the tire diagonally opposite to the tire which
is to be replaced.
3. Using a hub nut wrench, loosen hub nuts (1) to a point where
they can be turned by hand.
4. Set a jack to a jack-up point (see the illustration at right) and
jack up the truck until the wheels come off the ground.
(A) Front Tire Jack-up Point (the bottom of the outer mast)
(B) Rear Tire Jack-up Point (the underpart of the
counterweight)
5. Remove hub nuts (1), then remove the tire and replace it.
6. Install the replacement tire and partially tighten hub nuts (1).
7. Tighten hub nuts (1) in turn on opposite sides in a criss-cross
pattern until there is no play in the wheel.
8. Lower the jack to lower the lift truck to the ground, then
tighten hub nuts (1) to the specified tightening torque. (For
details of the tightening torque, see “SERVICE DATA” on
page 4-11.)
9. Adjust the inflation pressure of the tire to the specified
pressure. (For details of the inflation pressure, see
“SERVICE DATA” on page 4-11.)
4-38
29.2 REPLACING FUSES
When replacing the fuses, always turn off the electric power (turn the starting switch to the
OFF position) before starting.
Always replace the fuses with a fuse of the same capacity.
The fuses are used to protect the electrical components and wiring from burning out.
1. Turn the starting switch to the OFF position.

2. Open up the engine hood. (A fuse box and relay box are located close to the battery on the right side of the
chassis.)
3. Open the fuse box cover and replace the fuse inside. To open the fuse box cover, pull it back while pressing the
side of the box lightly with your fingers, then it can be taken off.
4. Check the relationship between the fuses and the electrical components when replacing.
29.2.1 FUSE BOX

Fuse capacity and related electrical component
Capacity F11 F1
No. Related electrical component
(Amp) F12 F2 F2
F2 10 Electronic throttle control motor relay F13 F13 F3 F3
F3 15 Ignition relay 1 F14 F14 F4 F4
F4 10 Ignition relay 2
F15 F15 F5 F5
F5 10 Head lamp
F16 F16 F6 F6
F6 10 Stop lamp
F17 F17 F7 F7
F7 10 Horn
F18 F18 F8
F9 10 Spare
F10 15 Spare F19 F9 F9
F13 15 Main relay F20 F20 F10 F10
F14 10 Control accessory
F15 10 Back lamp
F16 10 Gas injector solenoid
F17 10 Oxygen sensor
F18 10 Ignition accessory
F20 10 Main relay auxiliary
29.2.2 RELAY BOX

2
Fuse capacity and related electrical component
Related electrical
No. Capacity
component
1 60A Starting motor
2 40A Starting motor switch
100A (Gasoline engine truck)
3 Charger
120A (Diesel engine truck) 3 1
4-39
29.3 REPLACING LAMPS

1. Check that fuses are not blown and wires are not discon-
nected.
2. If disconnection is found, turn OFF the lamp switch and
replace the lamp.
Lamp capacity
Head lamp 55W (For 12V)
Turn signal lamp 23W (For 12V)
Clearance lamp 8W (For 12V)
Number plate lamp (option) 10W (For 12V)
Back lamp 8W (For 12V)
Stop lamp 23W (For 12V)
Warning lamp 1.4W (For 12V)
Meter lighting lamp 1.4W (For 12V)
4-40
30. LIFT TRUCK WASHING PROCEDURE
30.1 GENERAL PRECAUTIONS

When washing your lift truck, observe the following instructions to safeguard the truck.
Wet electrical equipment will result in the lift truck malfunctioning.
• Before washing, ensure that the controller and all other electrical equipment sensitive to water is protected
from water or removed prior to washing and blowing dry. NEVER wash or wet down the areas inside the dash-
board.
• Before washing, make sure that waterproof seals and covers are free from any deterioration and are fitted cor-
rectly in place.
• When using a water stream, use compressed air, an air blower and dry wiping to dry the truck and remove
water droplets before using the truck connectors and electrical components. (Water droplets may run along the
wiring and enter the controller chamber, dashboard or seep into the connectors.)
• If water does get into the controller chamber or dashboard, use a cloth or compressed air to remove the water
before using the truck.
• When removing dirt from electronic parts (such as printed circuit boards), use a commercially available, spray-
type electronic equipment cleaner.
30.2 WASHING INSTRUCTIONS
If water gets into the electrical system (controller, sensor, connectors, etc.) it will cause
malfunctions or operational failure. Do not wash the electrical system with water or high-
pressure steam.
1. Turn the starting switch key to the OFF position,

then remove the key.
2. Wash each part (1 to 4 parts in the figure at right),
following the instructions in the table on the
following page.
3. Dry off all wet areas with an air blower.
4. After checking that the washed parts have dried
out, insert the starting switch key and turn it to the
ON position, make sure that there is no abnormal-
ity, and then start operation.
4-41
No. Part to Wash Washing Method
1 Meter Panel • Wash from above by flushing with water from a hose.
• Use low water pressure from the hose as illustrated below
(parts 1 and 2 only).
• Dashboard Front
2 • Pedals
• Floor Plate
• Wash using high pressure steam or flush with water from a

• Front & Rear Tires
3 hose.
• Front & Rear Axles
• Do not steam or wash the tire angle sensor or electric wiring.
4 Exterior parts other than the above Wash with high pressure steam or flush with water from a hose.
• Never wash the inside of the dashboard.

• When using high pressure steam or water from a hose to
wash the engine room and power train parts under the floor
plate, cover the following parts and components with a tar-
Other Precautions paulin so that they do not get splashed with water:
- the engine and transmission, including the electric wiring
for them.
- electric system parts such as the connector and fuse
box.
4-42
31. TECHNICAL DATA
31. TECHNICAL DATA
See “DIMENSIONAL DIAGRAM” on page 5-17 for lift truck plan view.
31.1 AX50 - CUSHION TIRE LIFT TRUCKS (INDOOR)

Manufacturer’s Designation Unit FG15SHT-20 FG18SHT-20 FG20ASHT-20
• GENERAL
Power Type Gasoline Gasoline Gasoline
Operation Type Sit-Down Sit-Down Sit-Down
Capacity@24 in. (600 mm) load center * lbs. (kg) 3,000 (1360) 3,500 (1580) 4,000 (1810)
Load distance from center axle (2-stage) in. (mm) 15.0 (382) 15.0 (382) 15.0 (382)
Wheelbase in. (mm) 48.0 (1220) 48.0 (1220) 48.0 (1220)
• WEIGHT
Service weight (includes 2-stage std. mast & forks) lbs. (kg) 6,230 (2825) 6,700 (3040) 7,200 (3265)
Front lbs. (kg) 7,910 (3590) 8,640 (3920) 9,390 (4260)
Loaded
Rear lbs. (kg) 1,311 (595) 1,543 (700) 1,796 (815)
Axle Loading
Front lbs. (kg) 2,500 (1135) 2,360 (1070) 2,190 (995)
Unloaded
Rear lbs. (kg) 3,730 (1690) 4,340 (1970) 5,000 (2270)
• TIRE
Tire type Cushion Cushion Cushion
Tire size, front 18x6x12-1/8 18x6x12-1/8 18x6x12-1/8
Tire size, rear 14x4-1/2x8 14x4-1/2x8 14x4-1/2x8
Number of wheel, front / rear x= driven 2x/2 2x/2 2x/2
Front in. (mm) 32.1 (815) 32.1 (815) 32.1 (815)
Tread (center of tires)
Rear in. (mm) 32.1 (815) 32.1 (815) 32.1 (815)
• DIMENSIONS
Tilting angle, 2-stage (FV) masts, forward / backward deg. 6/8 6/8 6/8
Tilting angle, 3-stage (TFV) masts, forward / backward deg. 6/5 6/5 6/5
Mast height, lowered (2-stage std. mast) in. (mm) 83.5 (2120) 83.5 (2120) 83.5 (2120)
Mast height, extended (2-stage std. mast) † in. (mm) 176.0 (4470) 176.0 (4470) 176.0 (4470)
Maximum fork height (2-stage std. mast) ** in. (mm) 128.0 (3250) 128.0 (3250) 128.0 (3250)
Free lift height (2-stage std. mast) in. (mm) 5.5 (140) 5.5 (140) 5.5 (140)
Height overhead guard in. (mm) 80.3 (2040) 80.3 (2040) 80.3 (2040)
Length, with Standard Forks in. (mm) 121.9 (3095) 123.2 (3130) 124.6 (3165)
Length to fork face (2-stage mast) in. (mm) 79.7 (2025) 81.1 (2060) 87.6 (2095)
Overall width, at drive tires (single) in. (mm) 38.2 (970) 38.2 (970) 38.2 (970)
1.6x4.0x42.1 1.6x4.0x42.1 1.6x4.0x42.1
Forks, thickness x width x length in. (mm)
(40x100x1070) (40x100x1070) (40x100x1070)
Carriage width / ITA Class in. (mm) 37.0 (940)/II 37.0 (940)/II 37.0 (940)/II
Ground clearance, under mast in. (mm) 3.0 (76) 3.0 (76) 3.0 (76)
Ground clearance, center of wheelbase in. (mm) 4.0 (102) 4.0 (102) 4.0 (102)
Right angle stacking aisle (2-stage mast without load
in. (mm) 84.7 (2152) 85.9 (2642) 86.7 (2662)
length & clearance) ††
Turning radius, outside in. (mm) 69.7 (1770) 70.9 (1800) 71.7 (1820)
• PERFORMANCE
5-1
31. TECHNICAL DATA
Manufacturer’s Designation Unit FG15SHT-20 FG18SHT-20 FG20ASHT-20

10.6 (17.0)/10.6 10.6 (17.0)/10.6 10.6 (17.0)/10.6
Travel speed, forward, loaded / unloaded mph (km/h)
(17.0) (17.0) (17.0)
135 (685)/138 135 (685)/138 118 (600)/126
Lifting speed, loaded / unloaded (2-stage mast) fpm (mm/s)
(700) (700) (640)
Lowering speed, loaded / unloaded (2-stage mast) fpm (mm/s) 98 (500)/98 (500) 98 (500)/98 (500) 98 (500)/98 (500)
Maximum drawbar pull, loaded lbs. (kN) 4,300 (19.1) 4,300 (19.1) 4,300 (19.1)
Maximum gradeability % 41.0 37.0 36.0
Service brake, operation/control Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
Parking brake, operation/control Hand/Mechanic Hand/Mechanic Hand/Mechanic
Steering, type FHPS FHPS FHPS
• DRIVE
Engine Manufacturer / Engine model Nissan/K21 Nissan/K21 Nissan/K21
Rated output (SAE Net) HP (kW)@rpm 56 (41)@2700 56 (41)@2700 56 (41)@2700
Maximum torque (SAE Net) lb-ft (Nm)@rpm 116 (158)@1600 116 (158)@1600 116 (158)@1600
No. of cylinder / displacement cu. in. (cm3) 4/126 (2065) 4/126 (2065) 4/126 (2065)
Fuel tank capacity U.S. gal. (liters) 6.6 (25) 6.6 (25) 6.6 (25)
• OTHER
Relief pressure, maximum psi (bar) 2650 (181) 2650 (181) 2650 (181)
Transmission Powershift Powershift Powershift
Sound level, at operator ears dB 84 84 84
NOTE: Most values shown in this publication are rounded. Therefore, direct conversion between metric and English or Imperial may
be slightly different from those shown. The performance of machines is affected by the condition of the truck and how it is
equipped as well as the nature and condition of the operating area. If these specifications are critical or if your needs exceed the
specifications shown here, discuss the proposed application with your authorized dealer.
* Optional masts, attachments, longer load dimensions, and higher lifting heights may result in derating of the capacity. Contact your
authorized dealer.
** Other mast heights available. See MAST DATA chart for other standard mast heights. Contact your authorized dealer.
+ Includes 48-inch (1,220 mm) high load backrest. Contact your authorized dealer.
++ Add load distance and clearance. Contact your authorized dealer.
5-2
31. TECHNICAL DATA
31.2 AX50 - PNEUMATIC TIRE LIFT TRUCKS (OUTDOOR)

Manufacturer’s Designation Unit FG15HT-20 FG18HT-20 FG20AHT-20
• GENERAL
Operation Type Sit-Down Sit-Down Sit-Down
Capacity@24 in. (600 mm) load center * lbs. (kg) 3,000 (1360) 3,500 (1580) 4,000 (1810)
Load distance from center axle (2-stage) in. (mm) 15.4 (390) 15.4 (390) 15.4 (390)
Wheelbase in. (mm) 55.1 (1,400) 55.1 (1,400) 55.1 (1,400)
• WEIGHT
Service weight (includes 2-stage std. mast & forks) lbs. (kg) 5,940 (2695) 6,340 (2875) 6,850 (3105)
Front lbs. (kg) 7,770 (3525) 8,470 (3840) 9,340 (4235)
Loaded
Rear lbs. (kg) 1,170 (530) 1,355 (615) 1,499 (680)
Axle Loading
Front lbs. (kg) 2,620 (1190) 2,510 (1140) 2,490 (1130)
Unloaded
Rear lbs. (kg) 3,320 (1505) 3,820 (1735) 4,350 (1975)
• TIRE
Tire type Pneumatic Pneumatic Pneumatic
Tire size, front 6.50-10-10PR (I) 6.50-10-10PR (I) 6.50-10
Tire size, rear 5.00-8-8PR (I) 5.00-8-8PR (I) 5.00-8
Number of wheel, front / rear x= driven 2x/2 2x/2 2x/2
Front in. (mm) 35.0 (890) 35.0 (890) 35.0 (890)
Tread (center of tires)
Rear in. (mm) 35.2 (895) 35.2 (895) 35.2 (895)
• DIMENSIONS
Tilting angle, 2-stage (FV) masts, forward / backward deg. 6/8 6/8 6/8
Tilting angle, 3-stage (TFV) masts, forward / backward deg. 6/5 6/5 6/5
Mast height, lowered (2-stage std. mast) in. (mm) 85.5 (2170) 85.5 (2170) 85.5 (2170)
Mast height, extended (2-stage std. mast) † in. (mm) 176.0 (4470) 176.0 (4470) 176.0 (4470)
Maximum fork height (2-stage std. mast) ** in. (mm) 128.0 (3250) 128.0 (3250) 128.0 (3250)
Free lift height (2-stage std. mast) in. (mm) 5.5 (140) 5.5 (140) 5.5 (140)
Height overhead guard in. (mm) 81.5 (2070) 81.5 (2070) 81.5 (2070)
Length, with Standard Forks in. (mm) 129.7 (3295) 131.3 (3335) 132.7 (3370)
Length to fork face (2-stage mast) in. (mm) 87.6 (2225) 89.2 (2265) 90.6 (2300)
Overall width, at drive tires (single) in. (mm) 42.1 (1,070) 42.1 (1,070) 42.1 (1,070)
1.6x4.0x42.1 1.6x4.0x42.1 1.6x4.0x42.1
Forks, thickness x width x length in. (mm)
(40x100x1070) (40x100x1070) (40x100x1070)
Carriage width / ITA Class in. (mm) 41.0 (1040)/II 41.0 (1040)/II 41.0 (1040)/II
Ground clearance, under mast in. (mm) 4.7 (120) 4.7 (120) 4.7 (120)
Ground clearance, center of wheelbase in. (mm) 5.1 (130) 5.1 (130) 5.1 (130)
Right angle stacking aisle (2-stage mast without load length
in. (mm) 92.4 (2345) 93.7 (2380) 94.9 (2410)
& clearance) ††
Turning radius, outside in. (mm) 77.0 (1955) 78.3 (1990) 79.5 (2020)
• PERFORMANCE
11.8 (19.0)/ 11.8 (19.0)/ 11.8 (19.0)/
Travel speed, forward, loaded / unloaded mph (km/h)
12.4(20.0) 12.4 (20.0) 12.4 (20.0)
5-3
31. TECHNICAL DATA
Manufacturer’s Designation Unit FG15HT-20 FG18HT-20 FG20AHT-20

135 (685)/ 135 (685)/ 118 (600)/
Lifting speed, loaded / unloaded (2-stage mast) fpm (mm/s)
138 (700) 138 (700) 126 (640)
98 (500)/ 98 (500)/ 98 (500)/
Lowering speed, loaded / unloaded (2-stage mast) fpm (mm/s)
98 (500) 98 (500) 98 (500)
Maximum drawbar pull, loaded lbs. (kN) 3,700 (16.6) 3,700 (16.6) 3,700 (16.6)
Maximum gradeability % 39.0 35.0 34.0
Service brake, operation/control Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
Parking brake, operation/control Hand/Mechanic Hand/Mechanic Hand/Mechanic
Steering, type FHPS FHPS FHPS
• DRIVE
Engine Manufacturer / Engine model Nissan/K21 Nissan/K21 Nissan/K21
Rated output (SAE Net) HP (kW)@rpm 56 (41)@2700 56 (41)@2700 56 (41)@2700
Maximum torque (SAE Net) lb-ft (Nm)@rpm 116 (158)@1600 116 (158)@1600 116 (158)@1600
No. of cylinder / displacement cu. in. (cm3) 4/126 (2065) 4/126 (2065) 4/126 (2065)
Fuel tank capacity U.S. gal. (liters) 11 (40) 11 (40) 11 (40)
• OTHER
Relief pressure, maximum psi (bar) 2650 (181) 2650 (181) 2650 (181)
Transmission Powershift Powershift Powershift
Sound level, at operator ears dB 84 84 84
NOTE: Most values shown in this publication are rounded. Therefore, direct conversion between metric and English or Imperial
may be slightly different from those shown. The performance of machines is affected by the condition of the truck and how it is
equipped as well as the nature and condition of the operating area. If these specifications are critical or if your needs exceed the
specifications shown here, discuss the proposed application with your authorized dealer.
* Optional masts, attachments, longer load dimensions, and higher lifting heights may result in derating of the capacity. Contact
your authorized dealer.
** Other mast heights available. See MAST DATA chart for other standard mast heights. Contact your authorized dealer.
+ Includes 48-inch (1,220 mm) high load backrest. Contact your authorized dealer.
++ Add load distance and clearance. Contact your authorized dealer.
5-4
31. TECHNICAL DATA
31.3 BX50 - PNEUMATIC TIRE 2-TON LIFT TRUCKS (OUTDOOR)

Manufacturer’s Designation Unit FG20T-16 FD20T-16 FG20HT-16
• GENERAL
Power Type Gasoline Diesel Gasoline
Operation Type Sit Down Sit Down Sit Down
Capacity@24 in. (600 mm) Load Center* lbs. (kg) 4,000 (1,810) 4,000 (1,810) 4,000 (1,810)
Load Distance: Center Axle to Fork Face in. (mm) 17.9 (455) 17.9 (455) 17.9 (455)
Wheelbase in. (mm) 65.0 (1,650) 65.0 (1,650) 65.0 (1,650)
• WEIGHT
Service Weight (inc. 2-Stage STD Mast/Forks lbs. (kg) 7,180 (3,255) 7,290 (3,310) 7,180 (3,255)
Axle Loading - LOADED lbs. (kg) Fr 9,880 (4,480) Fr 9.980 (4,485) Fr 9,880 (4,480)
Axle Loading - LOADED lbs. (kg) Rr 1,300 (590) Rr 1,410 (640) Rr 1,300 (590)
Axle Loading - UNLOADED lbs. (kg) Fr 3,270 (1,485) Fr 3,280 (1,490) Fr 3,270 (1,485)
Axle Loading - UNLOADED lbs. (kg) Rr 3,900 (1,770) Rr 4,010 (1,820) Rr 3,900 (1,770)
• TIRES
Tire Type Pneumatic Pneumatic Pneumatic
Tire Size-Front 7.00-12-12PR (I) 7.00-12-12PR (I) 7.00-12-12PR (I)
Tire Size-Rear 6.00-09-10PR (I) 6.00-09-10PR (I) 6.00-09-10PR (I)
Number of Wheels-Front/Rear += Driven 2x/2 2x/2 2x/2
38.0 (966)/37.8 38.0 (966)/37.8 38.0 (966)/37.8
Tread (Center of Tires)-Front/Rear in. (mm)
(960) (960) (960)
• DIMENSIONS
Tilting Angle, Forward/Backward ° 6/12 6/12 6/12
Mast Height-Lowered-2-Stage Std. Mast ** in. (mm) 85.4 (2,170) 85.4 (2,170) 85.4 (2,170)
Mast Height-Extended-2-Stage Mast ** in. (mm) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470)
Height Overhead Guard in. (mm) 83.1 (2,110) 83.1 (2,110) 83.1 (2,110)
Length with Std. Forks in. (mm) 141.5 (3,595) 141.5 (3,595) 141.5 (3,595)
Length to Fork Face in. (mm) 99.4 (2,525) 99.4 (2,525) 99.4 (2,525)
Overall Width at Drive Tires (Single) in. (mm) 45.3 (1,150) 45.3 (1,150) 45.3 (1,150)
Forks-Thickness+Width+Length in. (mm) 1.6+3.9+42 (40+100+1,070)
Carriage Width/ITA Class in. (mm) 40.9 (1,040)/II 40.9 (1,040)/II 40.9 (1,040)/II
Ground Clearance under Mast in. (mm) 5.0 (127) 5.0 (127) 5.0 (127)
Ground Clearance-Center of Wheelbase in. (mm) 6.2 (158) 6.2 (158) 6.2 (158)
Right Angle Stacking Aisle (2-Stage Mast) in. (mm) 101.6 (2,580) 101.6 (2,580) 101.6 (2,580)
Turning Radius-Outside in. (mm) 86.2 (2,190) 86.2 (2,190) 86.2 (2,190)
• PERFORMANCE
Travel Speed, Forward-Loaded (1st/2nd) mph (k/hr.) 11.2 (18.0) 11.5 (18.5) 11.2 (18.0)
Travel Speed, Forward-Unloaded (1st/2nd) mph (k/hr.) 11.8 (19.0) 11.8 (19.0) 11.8 (19.0)
Lifting Speed-Loaded fpm (mm/s) 120.0 (610) 124.0 (630) 120.0 (610)
Lifting Speed-Unloaded (1st/2nd) fpm (mm/s) 124.0 (630) 130.0 (660) 124.0 (630)
Lowering Speed-Loaded fpm (mm/s) 98.0 (500) 98.0 (500) 98.0 (500)
Lowering Speed-Unloaded fpm (mm/s) 98.0 (500) 98.0 (500) 98.0 (500)
Maximum Drawbar Pull-Loaded lbs/f (kN) 3,960 (17.6) 4,072 (18.1) 4,720 (21.0)
5-5
31. TECHNICAL DATA
Manufacturer’s Designation Unit FG20T-16 FD20T-16 FG20HT-16

Maximum Gradeability-Loaded % 32 36 40
Service Brake-Operation/Control Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
Parking Brake-Operation/Control Hand/Mechanical Hand/Mechanical Hand/Mechanical
Steering Type FHPS FHPS FHPS
• DRIVE
Battery Voltage/Capacity (5 hour rating) V/Ah 12/33 12/64 12/33
Engine Model K21 4D98E K25
Rated Output (SAE Gross) HP (kW)@rpm 56.0 (41)@2,700 65.0 (48)@2,450 60.0 (44)@2,700
Maximum Torque (SAE Gross) lb.ft (Nm)@rpm 119 (160)@1,600 141 (191)@1,800 142 (193)@1,600
No. of Cylinders/Displacement 3 4/126 (2,065) 4/187 (3,062) 4/152 (2,488)

cu. in. (cm )
Fuel Tank Capacity U.S. gal. (liters) 15.3 (58) 15.3 (58) 15.3 (58)
• OTHER
Relief Pressure-Maximum psi (bar) 2,630 (181) 2,630 (181) 2,630 (181)
Hydraulic Tank Capacity U.S. gal. (liters) 8.98 (34) 8.98 (34) 8.98 (34)
Transmission PowerShift PowerShift PowerShift
may be slightly different than displayed in this table. The performance of the machines is affected by the condition of the vehicle
and how it is equipped as well as the nature and condition of the operating area. If these specifications are critical or if your
needs exceed the specifications shown here, discuss the proposed application with your authorized dealer.
* Optional masts, attachments, longer load dimensions and higher lifting heights may result in derating of the capacity. Contact your
authorized dealer.
** Other mast heights available. See MAST DATA CHART for other mast heights. Contact your authorized dealer.
5-6
31. TECHNICAL DATA
31.4 BX50 - PNEUMATIC TIRE 2.5/2.8-TON LIFT TRUCKS (OUTDOOR)

Manufacturer’s Designation Unit FG25T-16 FD25T-16 FG25HT-16 FG28HT-16
• GENERAL
Power Type Gasoline Diesel Gasoline Gasoline
Operation Type Sit Down Sit Down Sit Down Sit Down
Capacity@24 in. (600 mm) Load
lbs. (kg) 5,000 (2,267) 5,000 (2,267) 5,000 (2,267) 5,500 (2,495)
Center*
Load Distance: Center Axle to Front
in. (mm) 17.9 (455) 17.9 (455) 17.9 (455) 19.1 (485)
Face
Wheelbase in. (mm) 65.0 (1,650) 65.0 (1,650) 65.0 (1,650) 66.9 (1,700)
• WEIGHT
Service Weight (inc. 2-Stage STD Mast/
lbs. (kg) 7,941 (3,605) 8,060 (3,660) 7,941 (3,605) 8,888 (4,035)
Forks
Axle Loading - LOADED lbs. (kg) Fr 11,360 (5,155) Fr 11,440 (5,195) Fr 11,360 (5,155) 12,590 (5,710)
Axle Loading - LOADED lbs. (kg) Rr 1,590 (720) Rr 1,620 (735) Rr 1,590 (720) 1,810 (820)
Axle Loading - UNLOADED lbs. (kg) Fr 3,110 (1,410) Fr 3,190 (1,450) Fr 3,110 (1,410) 3,510 (1,590)
Axle Loading - UN LOADED lbs. (kg) Rr 4,840 (2,195) Rr 4,870 (2,210) Rr 4,840 (2,195) 5,390 (2,445)
• TIRES
Tire Type Pneumatic Pneumatic Pneumatic Pneumatic
Tire Size-Front 7.00-12-12PR (I) 7.00-12-12PR (I) 7.00-12-12PR (I) 28+9-15-12PR (I)
Tire Size-Rear 6.00-09-10PR (I) 6.00-09-10PR (I) 6.00-09-10PR (I) 6.50-10-10PR
Number of Wheels-Front/Rear += Driven 2x/2 2x/2 2x/2 2x/2
40.4 (1,025)/38.0
Tread (Center of Tires)-Front/Rear in. (mm) 38.0 (966)/37.8 (960)
(965)
• DIMENSIONS
Tilting Angle, 2-Stage Masts, Forward/
° 6/12 6/12 6/12 6/12
Backward
Mast Height-Lowered-2-Stage Std. Mast in. (mm) 85.4 (2,170) 85.4 (2,170) 85.4 (2,170) 85.0 (2,160)
† in. (mm) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470)
Mast Height-Extended-2-Stage Mast
Height Overhead Guard in. (mm) 83.1 (2,110) 83.1 (2,110) 83.1 (2,110) 83.9 (2,130)
Length to Fork Face in. (mm) 102.4 (2,600) 102.4 (2,600) 102.4 (2,600) 104.3 (2,650)
Overall Width at Drive Tires (Single) in. (mm) 45.3 (1,150) 45.3 (1,150) 45.3 (1,150) 48.6 (1,1235)
2+4.9+42
Forks-Thickness+Width+Length in. (mm) 1.6+3.9+42.0 (40+100+1,070)
(50+125+1,070)
Carriage Width/ITA Class in. (mm) 40.9 (1,040)/II 40.9 (1,040)/II 40.9 (1,040)/II 41.0 (1,041)/II
Ground Clearance under Mast in. (mm) 5.0 (127) 5.0 (127) 5.0 (127) 7.3 (186)
Ground Clearance-Center of Wheelbase in. (mm) 6.2 (158) 6.2 (158) 6.2 (158) 5.0 (127)
Right Angle Stacking Aisle (2-Stage
in. (mm) 106.5 (2,705) 106.5 (2,705) 106.5 (2,705) 110.1 (2,796)
Mast)
Turning Radius-Outside in. (mm) 88.2 (2,240) 88.2 (2,240) 88.2 (2,240) 90.9 (2,310)
• PERFORMANCE
Travel Speed, Forward-Loaded (1st/
mph (k/hr.) 11.2 (18.0) 11.5 (18.5) 11.2 (18.0) 11.5 (18.5)
2nd)
Travel Speed, Forward-Unloaded (1st/
mph (k/hr.) 11.8 (19.0) 11.8 (19.0) 12.1 (19.5) 12.1 (19.5)
2nd)
Lifting Speed-Loaded fpm (mm/s) 120.0 (610) 124.0 (630) 120.0 (610) 112 (570)
5-7
31. TECHNICAL DATA
Manufacturer’s Designation Unit FG25T-16 FD25T-16 FG25HT-16 FG28HT-16

Lifting Speed-Unloaded (1st/2nd) fpm (mm/s) 124.0 (630) 130.0 (660) 124.0 (630) 124 (630)
Lowering Speed-Loaded fpm (mm/s) 98.0 (500) 98.0 (500) 98.0 (500) 98 (500)
Lowering Speed-Unloaded fpm (mm/s) 98.0 (500) 98.0 (500) 98.0 (500) 98 (500)
Maximum Drawbar Pull-Loaded lbs/f (kN) 3,960 (17.6) 4,072 (18.1) 4,720 (21.0) 4,630 (20.6)
Maximum Gradeability-Loaded % 27 31 34 30
Service Brake-Operation/Control Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
Parking Brake-Operation/Control Hand/Mechanical Hand/Mechanical Hand/Mechanical Hand/Mechanical
Steering Type FHPS FHPS FHPS FHPS
• DRIVE
Battery Voltage/Capacity (20 hour
V/Ah 12/33 12/64 12/33 12/100
rating)
Engine Model K21 4D98E K25 K25
Rated Output (SAE Gross) HP (kW)@rpm 56.0 (41)@2,700 65.0 (48)@2,450 60.0 (44)@2,700 60.0 (44)@2,700
lb.ft
Maximum Torque (SAE Gross) 119 (160)@1,600 141 (191)@1,600 141 (191)@1,800 142 (193)@1600
(Nm)@rpm
No. of Cylinders/Displacement cu. in. (cm3) 4/126 (2,065) 4/187 (3,052) 4/152 (2,488) 4/152 (2,488)
Fuel Tank Capacity U.S. gal. (liters) 15.3 (58) 15.3 (58) 15.3 (58) 15.3 (58)
• OTHER
Relief Pressure-Maximum psi (bar) 2,650 (181) 2,650 (181) 2,650 (181) 2,650 (181)
Hydraulic Tank Capacity U.S. gal. (liters) 8.98 (34) 8.98 (34) 8.98 (34) 8.98 (34)
Transmission PowerShift PowerShift PowerShift PowerShift
authorized dealer.
5-8
31. TECHNICAL DATA
31.4.1 BX50 - PNEUMATIC TIRE 2.8/3-TON LIFT TRUCKS (OUTDOOR)

Manufacturer’s Designation FD28T-16 FG30HT-16 FD30T-16
• GENERAL
Power Type Gasoline Gasoline Diesel
Capacity@24 in. (600 mm) Load Center* lbs. (kg) 5,500 (2,495) 6,000 (2,722) 6,000 (2,722)
Load Distance from Center Axle (2-Stage) in. (mm) 19.1 (485) 19.1 (485) 19.1 (485)
Wheelbase in. (mm) 66.9 (1,700) 66.9 (1,700) 66.9 (1,700)
• WEIGHT
Axle Loading - LOADED lbs. (kg) Fr 12,640 (5,740) Fr 13,510 (6,130) Fr 13,590 (6,170)
Axle Loading - LOADED lbs. (kg) Rr 1,770 (805) Rr 1,910 (865) Rr 1,890 (8600)
Axle Loading - UN LOADED lbs. (kg) Rr 5,350 (2,430) Rr 5,810 (2,635) Rr 5,790 (2,630)
• TIRES
Tire Type Pneumatic Pneumatic Pneumatic
Tire Size-Front 28+9-15-12PR (I) 28+9-15-12PR (I) 28+9-15-12PR (I)
Tire Size-Rear 6.50-10-10PR 6.50-10-10PR 6.50-10-10PR
Tread (Center of Tires)-Front/Rear in. (mm) 40.4 (1,025)/38.0 (965)
• DIMENSIONS
Tilting Angle, 2-Stage (FV) Masts, Forward/Backward ° 6/12 6/12 6/12
Mast Height-Lowered-2-Stage Mast in. (mm) 85.5 (2,160) 85.5 (2,160) 85.5 (2,160)
Mast Height-Extended-2-Stage Mast in. (mm) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470)
Maximum Fork Height-2-Stage STD Mast** in. (mm) 128.0 (3,250) 128.0 (3,250) 128.0 (3,250)
Free Lift Height-2-Stage STD Mast in. (mm) 5.5 (140) 5.5 (140) 5.5 (140)
Length to Fork Face-2-Stage Mast in. (mm) 104.3 (2,705) 106.5 (2,705) 106.5 (2,705)
Overall Width at Drive Tires in. (mm) 48.6 (1,235) 48.6 (1,235) 48.6 (1,235)
Carriage Width/ITA Class in. (mm) 41.0 (1,040)/II 41.0 (1,040)/III 41.0 (1,040)/III
• PERFORMANCE
12.1 (19.5)/11.2 11.2 (18.0)/12.1 11.8 (19.0)/12.1
Travel Speed, Forward-Loaded/Unloaded mph (k/hr.)
(18.0) (19.0) (19.5)
104 (530)/124 104 (530)/128
Lifting Speed-Loaded/Unloaded (2-Stage) fpm (mm/s) 118 (600)/128 (650)
(630) (650)
Lowering Speed-Loaded/Unloaded (2-Stg) fpm (mm/s) 98 (500)/98 (500)
Maximum Gradeability-Loaded % 27 27 25
5-9
31. TECHNICAL DATA
Manufacturer’s Designation FD28T-16 FG30HT-16 FD30T-16

• DRIVE
Engine Model 4D98E K25 4D98E
Rated Output (SAE Gross) HP (kW)@rpm 65.0 (48)@2,450 60.0 (44)@2,700 65.0 (48)@2,450
No. of Cylinders/Displacement 3 4/187 (3,062) 4/152 (2,488) 4/187 (3,062)

cu. in. (cm )
Fuel Tank Capacity U.S. gal. (liters) 15.3 (58) 15.3 (58) 15.3 (58)
• OTHER
Transmission PowerShift Powershift
authorized dealer.
5-10
31. TECHNICAL DATA
31.4.2 BX50 - PNEUMATIC TIRE 3.2/3.5-TON LIFT TRUCKS (OUTDOOR)

Manufacturer’s Designation Unit FG32HT-16 FD32T-16 FG35AHT-16 FD35AT-16
• GENERAL
Power Type Gasoline Diesel Gasoline Diesel
Capacity@24 in. (600 mm) Load Center * lbs. (kg) 6,500 (2,948) 6,500 (2,948) 7,000 (3,175) 7,000 (3,175)
Load Distance from Center Axle (2-Stage) in. (mm) 19.1 (485) 19.1 (485) 19.9 (505) 19.9 (505)
Wheelbase in. (mm) 66.9 (1,700) 66.9 (1,700) 66.9 (1,700) 66.9 (1,700)
• WEIGHT
Service Weight (inc. 2-Stage STD Mast/Forks lbs. (kg) 9,791 (4,445) 9,930 (4,510) 10,793 (4,900) 10,970 (4,980)
Fr 14,200 Fr 14,380
Axle Loading - LOADED lbs. (kg) Fr 15,610 (7,080) Fr 15,700 (7,130)
(6,440) (6,530)
Axle Loading - LOADED lbs. (kg) Rr 2,110 (965) Rr 2,050 (930) Rr 2,200 (1,000) Rr 2,270 (1,030)
Axle Loading - UNLOADED lbs. (kg) Fr 3,480 (1,580) Fr 3,680 (1,670) Fr 3,970 (1,800) Fr 4,060 (1,845)
Axle Loading - UN LOADED lbs. (kg) Rr 6,320 (2,865) Rr 6,260 (2,840) Rr 6,830 (3,100) Rr 6,910 (3,135)
• TIRES
Tire Type Pneumatic Pneumatic Pneumatic Pneumatic
28+9-15- 28+9-15-
Tire Size-Front 250+15+16PR(I) 250+15+16PR(I)
12PR(I) 12PR(I)
Tire Size-Rear 650+10+10PR 650+10+10PR 650+10+12PR 650+10+12PR
Tread (Center of Tires)-Front/Rear in. (mm) 40.4 (1,025)/38.0 (965) 41.7 (1,060)/38.0 (965)
• DIMENSIONS
Tilting Angle, 2-Stage (FV) Masts, Forward/
° 6/12 6/12 6/12 6/12
Backward
Mast Height-Lowered-2-Stage Mast in. (mm) 88.6 (2,250) 88.6 (2,250) 89.2 (2,265) 89.2 (2,265)
Mast Height-Extended-2-Stage Mast in. (mm) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470)
Maximum Fork Height-2-Stage STD Mast ** in. (mm) 128.0 (3,250) 128.0 (3,250) 132.3 (3,360) 132.3 (3,360)
Free Lift Height-2-Stage STD Mast in. (mm) 5.5 (140) 5.5 (140) 5.5 (140) 5.5 (140)
Length to Fork Face-2-Stage Mast in. (mm) 108.5 (2,755) 108.5 (2,755) 110.0 (2,795) 110.0 (2,795)
Overall Width at Drive Tires in. (mm) 48.6 (1,235) 48.6 (1,235) 50.8 (1,290) 50.8 (1,290)
Carriage Width/ITA Class in. (mm) 42.1 (1,070)/III 42.1 (1,070)/III 41.7 (1,060)/III 41.7 (1,060)/III
Right Angle Stacking Aisle (2-Stage Mast) in. (mm) 114.4 (2,906) 114.4 (2,906) 117.6 (2,987) 117.6 (2,987)
• PERFORMANCE
10.9 (17.5)/11.5 11.2 (18.0)/11.8 10.9 (17.5)/11.5 11.2 (18.0)/11.5
Travel Speed, Forward-Loaded/Unloaded mph (k/hr.)
(18.5) (19.0) (18.5) (18.5)
104 (530)/114 98 (500)/112
Lifting Speed-Loaded/Unloaded (2-Stage) fpm (mm/s) 89 (450)/91 (460) 87 (440)/91(460)
(580) (570)
98 (500)/98 98 (500)/98
Lowering Speed-Loaded/Unloaded (2-Stg) fpm (mm/s) 79 (400)/79 (400) 79 (400)/79 (400)
(500) (500)
5-11
31. TECHNICAL DATA
Manufacturer’s Designation Unit FG32HT-16 FD32T-16 FG35AHT-16 FD35AT-16

Hand/ Hand/
Parking Brake-Operation/Control Hand/Mechanical
Mechanical Mechanical
• DRIVE
Engine Model K25 4D98E K25 4D98E
60.0 65.0
Rated Output (SAE Gross) HP (kW)@rpm 60. (45)@2,950 65.0 (48)@2,450
(44)@2,700 (48)@2,450
142 141
Maximum Torque (SAE Gross) lb.ft (Nm)@rpm 142 (193)@1,600 141 (191)@1,800
(193)@1,600 (191)@1,800
Fuel Tank Capacity U.S. gal. (liters) 15.3 (58) 15.3 (58) 15.3 (58) 15.3 (58)
• OTHER
Relief Pressure-Maximum psi (bar) 2,630 (181) 2,630 (181) 2,630 (181) 2,630 (181)
Hydraulic Tank Capacity U.S. gal. (liters) 8.98 (34) 8.98 (34) 8.98 (34) 8.98 (34)
Transmission Powershift
authorized dealer.
5-12
31. TECHNICAL DATA
31.5 BX50 - CUSHION TIRE 2/2.5-TON LIFT TRUCKS (INDOOR)

Manufacturer’s Designation Unit FG20ST-16 FG20SHT-16 FG25ST-16 FG25SHT-16
• GENERAL
Power Type Gasoline Gasoline Gasoline Gasoline
Capacity@24 in. (600 mm) Load Center * lbs. (kg) 4,000 (1,810) 4,000 (1,810) 5,000 (2,267) 5,000 (2,267)
Load Distance: Center Axle to Fork Face in. (mm) 16.9 (430) 16.9 (430) 16.9 (430) 16.9 (430)
Wheelbase in. (mm) 55.1 (1,400) 55.1 (1,400) 55.1 (1,400) 55.1 (1,400)
• WEIGHT
Service Weight (inc. 2-Stage STD Mast/
lbs. (kg) 7,300 (3,310) 7,300 (3,310) 8,180 (3,710) 8,180 (3,710)
Forks
Axle Loading - LOADED lbs. (kg) Fr 9,820 (4,455) Fr 9,820 (4,455) Fr 11,330 (5,140) Fr 11,330 (5,140)
Axle Loading - LOADED lbs. (kg) Rr 1,480 (670) Rr 1,480 (670) Rr 1,850 (840) Rr 1,850 (840)
Axle Loading - UNLOADED lbs. (kg) Fr 2,820 (1,280) Fr 2,820 (1,280) Fr 2,600 (1,180) Fr 2,600 (1,180)
Axle Loading - UNLOADED lbs. (kg) Rr 4,480 (2,030) Rr 4,480 (2,030) Rr 5,580 (2,530) Rr 5,580 (2,530)
• TIRES
Tire Type Cushion Cushion Cushion Cushion
Tire Size-Front 21+7+15 21+7+15 21+7+15 21+7+15
Tire Size-Rear 16.25+5+11.25 16.25+5+11.25 16.25+5+11.25 16.25+5+11.25
Number of Wheels-Front/Rear += Driven 2x/2 2x/2 2x/2 2x/2
34.6 (879)/35.4 34.6 (879)/35.4 34.6 (879)/35.4 34.6 (879)/35.4
(900) (900) (900) (900)
• DIMENSIONS
Tilting Angle, Forward/Backward ° 6/8 6/8 6/8 6/8
Mast Height-Lowered-2-Stage Std. Mast
in. (mm) 85.5 (2,170) 85.5 (2,170) 85.5 (2,170) 85.5 (2,170)
**
Mast Height-Extended-2-Stage Mast ** in. (mm) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470)
Length with Std. Forks in. (mm) 132.9 (3,595) 132.9 (3,595) 135.4 (3,440) 135.4 (3,440)
Length to Fork Face in. (mm) 90.8 (2,305) 90.8 (2,305) 93.3 (2,370) 93.3 (2,370)
Overall Width at Drive Tires (Single) in. (mm) 42.1 (1,070) 42.1 (1,070) 42.1 (1,070) 42.1 (1,070)
Forks-Thickness+Width+Length in. (mm) 1.6+3.9+42 (40+100+1,070) 1.6+4+42 (40+100+1,070)
Carriage Width/ITA Class in. (mm) 37.0 (940)/II 37.0 (940)/II 37.0 (940)/II 37.0 (940)/II
Right Angle Stacking Aisle (2-Stage Mast) in. (mm) 92.6 (2,355) 92.6 (2,355) 94.6 (2,405) 94.6 (2,405)
• PERFORMANCE
Travel Speed, Forward-Loaded (1st/2nd) mph (k/hr.) 10.6 (17.0) 10.6 (17.0) 10.6 (17.0) 10.6 (17.0)
Travel Speed, Forward-Unloaded (1st/
mph (k/hr.) 10.6 (17.0) 10.6 (17.0) 10.6 (17.0) 10.6 (17.0)
2nd)
Lifting Speed-Loaded fpm (mm/s) 120.0 (610) 124.0 (630) 120.0 (610) 120.0 (610)
Lifting Speed-Unloaded (1st/2nd) fpm (mm/s) 124.0 (630) 124.0 (630) 124.0 (630) 124.0 (630)
Lowering Speed-Loaded fpm (mm/s) 98.0 (500) 98.0 (500) 98.0 (500) 98.0 (500)
5-13
31. TECHNICAL DATA
Manufacturer’s Designation Unit FG20ST-16 FG20SHT-16 FG25ST-16 FG25SHT-16

Lowering Speed-Unloaded fpm (mm/s) 98.0 (500) 98.0 (500) 98.0 (500) 98.0 (500)
Service Brake-Operation/Control Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic Foot/Hydraulic
Hand/ Hand/
Parking Brake-Operation/Control Hand/Mechanical Hand/Mechanical
Mechanical Mechanical
• DRIVE
Engine Model K21 K25 K21 K25
56.0 56.0
Rated Output (SAE Gross) HP (kW)@rpm 60.0 (44)@2,700 60.0 (44)@2,700
(41)@2,700 (41)@2,700
119 119
Maximum Torque (SAE Gross) lb.ft (Nm)@rpm 142 (193)@1,600 142 (193)@1,600
(160)@1,600 (160)@1,600
Fuel Tank Capacity U.S. gal. (liters) 10.1 (38.4) 10.1 (38.4) 10.1 (38.4) 10.1 (38.4)
• OTHER
Transmission PowerShift PowerShift PowerShift PowerShift
authorized dealer.
5-14
31. TECHNICAL DATA
31.6 BX50 - CUSHION TIRE 2.8/3-TON LIFT TRUCKS (INDOOR)

Manufacturer’s Designation Unit FG28SHT-16 FG30SHT-16 FG32SHT-16
• GENERAL
Capacity@24 in. (600 mm) Load Center * lbs. (kg) 5,500 (2,495) 6,000 (2,722) 6,500 (2,948)
Load Distance: Center Axle to Fork Face in. (mm) 17.3 (440) 17.3 (440) 17.3 (440)
Wheelbase in. (mm) 57.1 (1,450) 57.1 (1,450) 57.1 (1,450)
• WEIGHT
Axle Loading - LOADED lbs. (kg) Fr 12,360 (6,015) Fr 13,260 (6,015) Fr 14,000 (6,350)
Axle Loading - LOADED lbs. (kg) Rr 2,000 (905) Rr 2,180 (990) Rr 2,430 (1,100)
Axle Loading - UNLOADED lbs. (kg) Rr 6,020 (2,730) Rr 6,570 (2,980) Rr 7,180 (3,255)
• TIRES
Tire Type Cushion Cushion Cushion
Tire Size-Front 21+8+15 21+8+15 21+8+15
Tire Size-Rear 16.25+6+11.25 16.25+6+11.25 16.25+6+11.25
35.2 (895)/34.7 35.2 (895)/34.7 35.2 (895)/34.7
(880) (880) (880)
• DIMENSIONS
Tilting Angle, Forward/Backward ° 6/8 6/8 6/8
Mast Height-Lowered-2-Stage Std. Mast ** in. (mm) 85.5 (2,170) 86.5 (2,197) 85.6 (2,250)
Mast Height-Extended-2-Stage Mast ** in. (mm) 176.0 (4,470) 176.0 (4,470) 176.0 (4,470)
Length with Std. Forks in. (mm) 136.6 (3,470) 137.8 (3,500) 139.2 (3,535)
Length to Fork Face in. (mm) 94.5 (2,400) 95.7 (2,430) 97.1 (2,465)
Overall Width at Drive Tires (Single) in. (mm) 43.3 (1,100) 43.3 (1,100) 43.3 (1,100)
1.6+4+42 2+4+42 2+4+42
Forks-Thickness+Width+Length in. (mm)
(40+100+1,070) (50+125+1,070) (50+125+1,070)
Carriage Width/ITA Class in. (mm) 37.0 (940)/II 37.0 (940)/III 37.0 (940)/III
• PERFORMANCE
Travel Speed, Forward-Loaded (1st/2nd) mph (k/hr.) 10.6 (17.0) 10.6 (17.0) 10.6 (17.0)
Travel Speed, Forward-Unloaded (1st/2nd) mph (k/hr.) 10.6 (17.0) 10.6 (17.0) 10.6 (17.0)
Lifting Speed-Loaded fpm (mm/s) 112.0 (570) 104.0 (530) 104.0 (530)
Lifting Speed-Unloaded (1st/2nd) fpm (mm/s) 124.0 (630) 124.0 (630) 108.0 (550)
Lowering Speed-Loaded fpm (mm/s) 98.0 (500) 98.0 (500) 98.0 (500)
Lowering Speed-Unloaded fpm (mm/s) 98.0 (500) 98.0 (500) 98.0 (500)
5-15
31. TECHNICAL DATA
Manufacturer’s Designation Unit FG28SHT-16 FG30SHT-16 FG32SHT-16

Maximum Gradeability-Loaded % 33 31 28.5
• DRIVE
Engine Model K25 K25 K25
Rated Output (SAE Gross) 60.0 (44)@2,700 60.0 (44)@2,700 60.0 (44)@2,700
No. of Cylinders/Displacement cu. in. (cm3) 4/152 (2,488) 4/152 (2,488) 4/152 (2,488)
Fuel Tank Capacity U.S. gal. (liters) 10.1 (38.4) 10.1 (38.4) 10.1 (38.4)
• OTHER
Transmission PowerShift PowerShift PowerShift
authorized dealer.
5-16
31. TECHNICAL DATA
31.7 DIMENSIONAL DIAGRAM
Overall Width
Tread, Rear
Turning Rad
ius, Outside
Mast Tilt
Fwd. / Bk.
Mast Height, Extended
Maximum Fork Height
Mast Height, Lowered
Height Overhead Guard

Free Lift
Load
Fork Length Distance Wheel Base
from
Center Length to Fork Face
Axle
Overall Length
5-17

01 - Om200 - Operation & Maintenance Manual BX50

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01 - Om200 - Operation & Maintenance Manual BX50

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OM200

OPERATION & MAINTENANCE MANUAL

AX50 Gasoline & LPG FG15/18/20(A)(S)HT-20 S/N 675001A~

BX50 Gasoline & LPG FG20/25/28/30/32(S)(H)T-16 S/N 210001A~

BX50 Diesel FD20/25/28/30/32T-16 S/N 210001A~

REVISED: JANUARY 2008

Komatsu Forklift Model Coding System for

Class IV (Cushion Tire) and V (Pneumatic Tire)

You can determine the lift truck

The Model Key describes the

Example Model Code: FG 30 HT US

FEDERAL ENVIRONMENTAL PROTECTION AGENCY (EPA) EMISSION CONTROL

FEDERAL ENVIRONMENTAL PROTECTION AGENCY (EPA) EMISSION CONTROL

Class IV & V ICE – U.S.A. EPAGAS rev 12/06

Komatsu Forklift U.S.A., Inc.

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

3.1 RUNNING IN A NEW LIFT TRUCK

3.2 FIRST MONTH SERVICE OR INITIAL 200 HOURS SERVICE

Unit Check items Remarks

Replace oil filter element

Adjust valve clearance

Differential Change oil

Replace line filter

Clean inside tank

Particularly hub nuts, overhead guard

3.3 MODEL LINE-UP

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

AX50 PNEUMATIC TIRE

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

BX50 CUSHION TIRE

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

BX50 PNEUMATIC TIRE

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

MODELS COVERED IN THIS MANUAL (Continued)

4.1 FEDERAL AND CALIFORNIA EMISSION CONTROL

STATEMENT FOR OFF-ROAD LSI (NON-DIESEL) ENGINES (K21/K25)

4.1.1 LABELS REQUIRED AND LABEL LOCATIONS

• Location on K21/K25 Series engines:

• Emission compliance label (sample):

YOUR WARRANTY RIGHTS AND OBLIGATIONS

MANUFACTURER'S WARRANTY COVERAGE

OWNER'S WARRANTY RESPONSIBILITIES

The warranty repairs should be completed by the Dealer as expeditiously as possible.

EMISSION CONTROL WARRANTY - 36 MONTHS or 2,500 HOURS FOR GENERAL PARTS

Komatsu Forklift USA, Inc.

Voice phone: (770) 385-4815

4.2 FEDERAL EPA EMISSION CONTROL STATEMENT FOR

4.2.1 LABELS REQUIRED AND LABEL LOCATIONS

Location on 4D94E Series diesel engines:

YOUR WARRANTY RIGHTS AND OBLIGATIONS

MANUFACTURER’S WARRANTY COVERAGE

OWNER’S WARRANTY RESPONSIBILITIES

• Check oil level and coolant level Every day

• Any application or installation KFI deems improper as explained in this manual.

CUSTOMER ASSISTANCE – EMISSION CONTROL SYSTEMS WARRANTY

Komatsu Forklift USA, Inc.

Voice phone: (770) 385-4815

4.3 KOMATSU FORKLIFT GENUINE

4.4 LIFT TRUCK SERIAL NUMBERS

4.5 SERIAL NO. PLATE POSITION

4.6 EMBOSSED SERIAL NO. LOCATION

Take care not to damage or remove the embossed serial

4.7 EMBOSSED ENGINE SERIAL NO. LOCATION