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Read and observe all warnings on this unitbefore operating it.DO NOT operate this equipment unless allfactory-installed guards and shields are properlysecured in place.
WARNING
CX20
REVISED: MAY 2010
OPERATION & MAINTENANCE MANUALCX20 Forklift Truck
OM072R
Gasoline & LP FG35/45ST-8 FG40/45T(2)-8FG35/45BCS-8FG50AT2-8FG40ZT(2)-8
130001A~EPA 2004 TIER 1 COMPLIANT
135001A~EPA 2007 TIER 2 COMPLIANT
Diesel FD40/45T(2)-8FD50AT2-8FD40ZT(2)-8
130001A~135001A~EPA 2004 TIER 2 COMPLIANT
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The information and specifications contained herein were accurate at the time ofpublication, but may change without notice as required for product improvements.Neither Komatsu Forklift USA, LLC, nor its parent company nor any of its subsidiaries willbe held responsible for damages due to misuse or inappropriate use of its products.
© Copyright 2010, Komatsu Forklift USA, LLC. All rights reserved. No part of thisdocument may be photocopied or reproduced in any way without prior written consent ofKomatsu Forklift USA, LLC.
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CONTENTS
3
MODEL CODING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
PRODUCT WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
EPA EMISSION CONTROL WARRANTY STATEMENT (GASOLINE/LPG ENGINES) . . . . . . . . . . . . . . . . . . . . .8
EPA EMISSION CONTROL WARRANTY STATEMENT (DIESEL ENGINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
FOREWORD1. FOREWORD ................................................................................................................................................1-1
2. SAFETY INFORMATION .............................................................................................................................1-2
3. RUNNING IN A NEW LIFT TRUCK .............................................................................................................1-3
4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK ...............................................................................1-54.1 GENUINE KOMATSU FORKLIFT PARTS ...................................................................................1-54.2 2004 TIER 1 FEDERAL EPA EMISSION CONTROL STATEMENT FOR
OFF-ROAD LSI (NON-DIESEL) ENGINES (TB45)...................................................................1-64.3 2007 TIER 2 U.S. FEDERAL AND CALIFORNIA EMISSION CONTROL
WARRANTY STATEMENT FOR OFF-ROAD LSI (NON-DIESEL) ENGINES (TB45)..............1-94.4 2004 TIER 2 FEDERAL EPA EMISSION CONTROL STATEMENT
FOR OFF-ROAD DIESEL ENGINES (S6D102E) ...................................................................1-12
5. LOCATION OF PLATES AND SERIAL NUMBER ....................................................................................1-155.1 LIFT TRUCK SERIAL NUMBERS ..............................................................................................1-155.2 UL (UNDERWRITERS LABORATORIES) PLATE.....................................................................1-155.3 EMBOSSED VEHICLE SERIAL NUMBER.................................................................................1-155.4 NAMEPLATE WITH VEHICLE SERIAL NUMBER.....................................................................1-155.5 ENGINE SERIAL NUMBER........................................................................................................1-155.6 CONTACTING KOMATSU FORKLIFT.......................................................................................1-16
SAFETY6. SAFETY MANAGEMENT.............................................................................................................................2-1
7. SAFE TRAVEL.............................................................................................................................................2-5
8. LOADING OPERATIONS ..........................................................................................................................2-13
9. SAFETY IN PERIODIC MAINTENANCE ...................................................................................................2-18
10. TOWING .....................................................................................................................................................2-24
11. STRUCTURE AND STABILITY OF THE LIFT TRUCK.............................................................................2-25
12. SAFETY LABELS ......................................................................................................................................2-28
OPERATION13. OVERVIEW OF LIFT TRUCK ......................................................................................................................3-1
13.1 GENERAL VIEW OF LIFT TRUCK...............................................................................................3-113.2 INSTRUMENTS AND CONTROLS ..............................................................................................3-213.3 METER PANELCOMPONENTS...................................................................................................3-3
14. EXPLANATION OF INSTRUMENTS, CONTROLS AND COMPONENTS .................................................3-414.1 EXPLANATION OF INSTRUMENTS AND CONTROLS..............................................................3-414.2 EXPLANATION OF METER PANEL COMPONENTS .................................................................3-814.3 OPERATOR’S COMPARTMENT ...............................................................................................3-14
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CONTENTS
4
14.4 ENGINE HOOD ..........................................................................................................................3-16
15. OPERATION ..............................................................................................................................................3-1815.1 CHECK BEFORE OPERATION .................................................................................................3-1815.2 MOUNTING/DISMOUNTING.....................................................................................................3-2715.3 PLACING LIFT TRUCK IN MOTION ..........................................................................................3-2715.4 STARTING AND INCHING ON SLOPE .....................................................................................3-3115.5 TURNING ...................................................................................................................................3-3115.6 TEMPORARY STOPPING AND PARKING ...............................................................................3-3215.7 FORK SPREAD ADJUSTMENT.................................................................................................3-3315.8 LOAD HANDLING OPERATION ................................................................................................3-3415.9 CHECK AFTER OPERATION ....................................................................................................3-39
16. COLD WEATHER OPERATION ................................................................................................................3-4016.1 FUEL AND LUBRICANTS ..........................................................................................................3-4016.2 HYDRAULIC OIL ........................................................................................................................3-4016.3 COOLANT ..................................................................................................................................3-4016.4 BATTERY ...................................................................................................................................3-40
17. HANDLING IN HEAVY-DUTY CONDITIONS ............................................................................................3-4117.1 CLEAN INSIDE OF COOLING SYSTEM ...................................................................................3-4117.2 CLEAN RADIATOR FINS...........................................................................................................3-4117.3 CHECK FAN BELT TENSION....................................................................................................3-4117.4 ACTIONS WHEN ENGINE HAS OVERHEATED.......................................................................3-41
18. LONG-TERM STORAGE ...........................................................................................................................3-4218.1 BEFORE STORAGE ..................................................................................................................3-4218.2 DURING STORAGE...................................................................................................................3-4218.3 AFTER STORAGE .....................................................................................................................3-42
MAINTENANCE19. OUTLINE OF SERVICE ...............................................................................................................................4-1
19.1 OIL................................................................................................................................................4-119.2 GREASE.......................................................................................................................................4-119.3 OIL STORAGE AND PRESERVATION .......................................................................................4-119.4 FILTERS.......................................................................................................................................4-1
20. LUBRICANT LIST ........................................................................................................................................4-220.1 GASOLINE/LPG ENGINE LIFT TRUCKS ....................................................................................4-220.2 DIESEL ENGINE LIFT TRUCKS..................................................................................................4-320.3 OIL AND GREASING CHART......................................................................................................4-4
21. SERVICE DATA ...........................................................................................................................................4-521.1 SERVICE DATA – GASOLINE/LPG ENGINE LIFT TRUCKS......................................................4-521.2 SERVICE DATA – DIESEL ENGINE LIFT TRUCKS ...................................................................4-721.3 TORQUE LIST..............................................................................................................................4-8
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....................................................................4-9
23. MAINTENANCE SCHEDULE CHART.......................................................................................................4-10
24. MAINTENANCE .........................................................................................................................................4-1424.1 FIRST MONTH OR INITIAL 200 HOURS SERVICE..................................................................4-1424.2 CHECK BEFORE OPERATION .................................................................................................4-20
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24.3 EVERY 2 WEEKS OR EVERY 100 HOURS SERVICE .............................................................4-2024.4 EVERY MONTH OR EVERY 200 HOURS SERVICE................................................................4-2024.5 EVERY 500 HOURS SERVICE..................................................................................................4-2524.6 EVERY 3 MONTHS OR EVERY 600 HOURS SERVICE...........................................................4-2524.7 EVERY 6 MONTHS OR EVERY 1,200 HOURS SERVICE........................................................4-2524.8 EVERY 2,000 HOURS SERVICE...............................................................................................4-2624.9 EVERY YEAR OR 2,400 HOURS SERVICE..............................................................................4-2624.10 EVERY 18 MONTHS OR 3,600 HOURS SERVICE...................................................................4-28
25. REPLACEMENT PROCEDURES ..............................................................................................................4-2925.1 REPLACING FUSES..................................................................................................................4-2925.2 REPLACING TIRES ...................................................................................................................4-3125.3 REPLACING LAMPS..................................................................................................................4-32
26. LIFT TRUCK WASHING PROCEDURE ....................................................................................................4-33
27. CHECKING LPG FUEL SYSTEM FOR LEAKS ........................................................................................4-35
TECHNICAL DATA28. TECHNICAL DATA ......................................................................................................................................5-1
28.1 3.5 & 4.5-TON CUSHION TIRE & BOXCAR SPECIAL................................................................5-128.2 4-TON PNEUMATIC TIRE COMPACT CHASSIS........................................................................5-328.3 4-TON PNEUMATIC TIRE 1 & 2-SPEED.....................................................................................5-528.4 4.5-TON PNEUMATIC TIRE 1 & 2-SPEED..................................................................................5-728.5 5-TON PNEUMATIC TIRE............................................................................................................5-9
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6
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 truckmodel from the model code onthe nameplate, which is locatedon the top of the lift truck hood tothe right of the operator’s seat.
The key below describes thecode nomenclature.
In the example above, the FG40ZT2US lift truck has a gasoline engine,a load capacity of 9,000 pounds, a compact wheelbase, pneumatictires, 2-speed TORQFLOW transmission and anti-spark safetyfeatures.
Example Model Code: FG 40 ZT2 US
Position: 1 2 3 4
Model Key
1 2 3 4
Vehicle & Fuel Type Load Capacity(Model=lbs) Designations UL Safety Type
FG = Gasoline forklift (includes LP)
FD = Diesel forklift
35 = 8,000
40 = 9,000
45 = 10,000
50 = 11,000
S = Cushion Tire (no “S” designates Pneumatic Tire)
BCS = Box Car Special
Z = Compact Wheelbase
T = TORQFLOW 1-speed
T2 = TORQFLOW 2-speed
A = upsize capacity (CX chassis but with DX capacity rating)
US = Anti-Spark Gas or Diesel Special, depending on Fuel Type
LS = Anti-Spark Liquid Propane Special
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7
PRODUCT WARRANTY
Kom
atsu Forklift
U.S.A
., Inc.
(hereinaftercalled KFI) w
arrants new equipm
ent to be freefrom
defects
in m
aterials and
workm
anshipunder the conditions of the follow
ing provisions.
STAN
DA
RD
WA
RR
AN
TYK
FI Standard Warranty for new
equipment shall
be (12) months or the first 2,000 operating hours
after delivery to the initial purchaser, rental orlessee, w
hichever event shall occur first.
POW
ER TR
AIN
PR
OTEC
TION
WA
RR
AN
TYK
FI warrants the follow
ing major com
ponents fora period of 730 days or the first 4,000 operatinghours
after delivery
to the
initial purchaser,
rental, or lessee, whichever shall occur first.
1.Internal com
bustion equipment
a. Engine (excluding all accessories andconsum
able trade parts)b.
Torqflow
and standard
transmissions
(excluding dry clutch and components)
c. Torque converter assembly
d. D
ifferential and
drive axle
(excludingbrake assem
bly)2.
Battery-pow
ered equipment
a. Electric m
otors (excluding brushes)b. SC
R, Transistor & AC
Traction Control-
ler Panel (excluding fuses)
c. Contactor panels (excluding contact tips
and switches)
d. D
ifferential and
drive axle
(excludingbrake assem
bly)
KFI O
BLIG
ATION
KFI shall have the obligation to repair or replace,
at KFI's option, any defect in m
aterial or work-
manship at no charge, by authorized KFI
dealer, during the specified warranty period.
LIMITATIO
NS A
ND
EXCLU
SION
SThis w
arranty is not applicable to or inclusive ofany of the follow
ing:1.
Equipment w
hich has been subjected to alterations and/or m
odifications not approved in w
riting from KFI, neglect, unau-
thorized repair, misuse, accidents, lack of
reasonable proper maintenance, norm
al adjustm
ents, improper repairs or replace-
ments, use of parts w
hich do not conform to
KFI's specifications.
2.N
ormal replacem
ent of any and all consum-
able parts such as, but not limited to light
bulbs, filter elements, hoses, lubricating and
hydraulic oil, and/or parts required to per-form
a regular maintenance service.
3.Tires and tubes.
4.B
atteries for battery-powered trucks.
5.A
ttachments, com
ponents, parts or acces-sories of products or equipm
ent not manu-
factured by KFI.
6.U
sed products or equipment.
LIMITED
LIAB
ILITY1.
Any and all other express, statutory, and im
plied warranties applicable to the prod-
uct, including, without lim
itation, all implied
warranties of m
erchantability and fitness for use, are expressly disclaim
ed.2.
In no event shall the dealer, its customers or
users be entailed to recover incidental or consequential dam
ages, including, but not lim
ited to, damages or inconvenience,
rental or replacement equipm
ent, loss of profits, or other com
mercial loss.
3.KFI neither assum
es nor authorizes any other to assum
e for it any other liability in connection w
ith the sale or service of the equipm
ent.4.
No m
odifications, alterations or changes of this lim
ited warranty is perm
itted or autho-rized by KFI-approved dealer.
5.S
ome states prohibit exclusion or lim
itation of im
plied warranty of m
erchantability or fit-ness for a particular purpose, and/or inci-dental or consequential dam
ages, so you m
ay have additional rights.
Truck Model
Serial N
umber
Com
pany
City &
State
Delivery D
ate
Delivering D
ealer
Class I, IV &
V ICE &
Electric Sit-down Trucks – U
.S.A. K
omatsu Forklift U
.S.A., Inc. K
PWC
ERT-1 042706
PRO
DU
CT W
AR
RA
NTY – C
LASS I, C
LASS IV, C
LASS V IC
E & ELEC
TRIC
SIT-DO
WN
TRU
CK
S
EPA PR
OD
UC
TSR
efer to the applicable Federal EPA warranty certificate for em
ission control warranty statem
ents. G
asoline/LPG engine Federal EPA W
arranty Cert. P/N
EPAGAS-1 042706; D
iesel engine EPA Warranty C
ertificate P/N EPAD
SL-1 042706Prope
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8
EPA EMISSION CONTROL WARRANTY STATEMENT (GASOLINE/LPG ENGINES)
The following statem
ent is provided as required byregulations of the U
nited States Environm
ental Protec-
tion Agency (EPA
).
YOU
R W
AR
RA
NTY R
IGH
TSA
ND
OB
LIGATIO
NS
All new
off-road large spark-ignition (LSI) engines
must be designed, built and equipped to m
eet the Fed-eral E
PA’s stringent anti-smog standards.
Kom
atsu Forklift USA
, Inc. ("KFI") must w
arrant theem
ission control system on your engine for the periods
of time listed below
provided there has been no abuse,dam
age, neglect or improper m
aintenance of yourengine.
Your emission control system
may include parts such
as the carburetor, regulator or fuel-injection system,
ignition system, engine com
puter unit (EC
M), catalytic
converter and air induction system.
Also included m
ay be sensors, hoses, belts, connec-tors and other em
ission-related assemblies.
Where a w
arrantable condition exists, an Authorized
Kom
atsu Forklift Dealer w
ill repair your LSI engine atno cost to you, including diagnosis, parts and labor.
MA
NU
FAC
TUR
ER’S W
AR
RA
NTY
CO
VERA
GE
The 2007 off-road large spark-ignition EPA
enginesare w
arranted for the time periods listed below
. If anyem
ission-related part on your engine is defective, thepart w
ill be repaired or replaced by an Authorized
Kom
atsu Forklift Dealer.
OW
NER
’S WA
RR
AN
TYR
ESPON
SIBILITIES
As the off-road LS
I engine owner, you are responsible
for the performance of the required m
aintenance listedin your O
peration and Maintenance M
anual.
KFI recom
mends that you retain receipts covering
maintenance on your off-road engine, but K
FI cannotdeny w
arranty solely for the lack of receipts or for yourfailure to ensure the perform
ance of all scheduledm
aintenance.
As the off-road large spark-ignition engine ow
ner, youshould be aw
are, however, that K
FI may deny you
warranty coverage if your off-road large spark-ignition
engine, or a part thereof, has failed due to abuse,neglect, im
proper maintenance or unapproved m
odifi-cations.
Your engine is designed to operate on gasoline and/orLP
G fuel. U
se of any other fuel may result in your
engine no longer operating in compliance w
ith theFederal E
PA’s emissions requirem
ents.
You are responsible for initiating the warranty process.
It is suggested that you present your off-road largespark-ignition
engine to
an A
uthorized K
omatsu
Dealer as soon as you becom
e aware that a problem
exists. The warranty repairs should be com
pleted bythe dealer as expeditiously as possible.
If you have any questions regarding your warranty
rights and
responsibilities, you
should contact
Kom
atsu's Product S
upport Dept. at 1-770-385-4815.
In addition to the standard warranty periods, the com
-ponents listed below
are covered by the following spe-
cific warranty periods.
EMISSIO
N C
ON
TRO
L WA
RR
AN
TY –36 M
ON
THS O
R 2,500 H
OU
RS
FOR
GEN
ERA
L PAR
TSFor the first 2,500 operating hours, or for a period ofthirty-six m
onths from the date of the first use by the
original purchaser from an A
uthorized Kom
atsu ForkliftD
ealer, whichever occurs first, K
FI warrants the
following em
ission-related parts:
•O
xygen sensor•
PC
V valve
•W
ater temperature sensor
•G
asoline injector•
LPG
injector•
LPG
pressure sensor•
LPG
solenoid•
Mass air flow
sensor•
Throttle chamber
•Ignition coil (K
21/K25)
•C
rankshaft position sensor (K21/K
25)•
Cam
shaft position sensor (K21/K
25)•
Distributor (TB
45)•
Spark plugs•
Exhaust tube from
manifold to catalytic converter
•G
asoline fuel hose•
Gasoline fuel cap
EMISSIO
N C
ON
TRO
L WA
RR
AN
TY –36 M
ON
THS O
R 4,000 H
OU
RS
FOR
POW
ER TR
AIN
PAR
TS•
Intake manifold
•E
xhaust manifold
•E
xhaust connector (TB45)
EMISSIO
N C
ON
TRO
L WA
RR
AN
TY –60 M
ON
THS O
R 3,500 H
OU
RS
FOR
THE FO
LLOW
ING
PAR
TS•
EC
M•
Catalytic converter
•Vaporizer
Class IV &
V ICE – U
.S.A. K
omatsu Forklift U
.S.A., Inc. EPA
GA
S rev 12/06
FEDER
AL EN
VIRO
NM
ENTA
L PRO
TECTIO
N A
GEN
CY (EPA
) EMISSIO
N C
ON
TRO
L W
AR
RA
NTY STATEM
ENT (G
ASO
LINE/LPG
ENG
INES)
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9
EPA EMISSION CONTROL WARRANTY STATEMENT (DIESEL ENGINES)
FEDER
AL EN
VIRO
NM
ENTA
L PRO
TECTIO
N A
GEN
CY (EPA
) EMISSIO
N C
ON
TRO
L W
AR
RA
NTY STATEM
ENT (D
IESEL ENG
INES)
Class IV &
V – U
.S.A.K
omatsu Forklift U
.S.A., Inc.
EPAD
SL-3 032608
The following statem
ent is provided as required by regulationsof the U
nited States Environm
ental Protection A
gency (EPA).
YOU
R W
AR
RA
NTY R
IGH
TSA
ND
OB
LIGATIO
NS
The Federal
EPA
and Kom
atsu Forklift
U.S
.A.,
Inc.(hereinafter referred to as "K
FI") are pleased to explain theem
ission control system w
arranty on your 2004 or later Diesel
heavy duty
off-road engine.
All
new, heavy-duty
off-roadengines m
ust be designed, built and equipped to meet the
EPA’s stringent anti-sm
og standards. KFI m
ust warrant the
emission control system
on your engine for the period of time
listed below, provided there has been no abuse, dam
age,neglect or im
proper maintenance of your engine.
Your emission control system
may include parts such as fuel
injection pump. A
lso included may be hoses, belts, connectors
and other emission-related assem
blies.
Where a w
arrantable condition exists, an authorized Kom
atsudealer w
ill repair the heavy-duty off-road engine at no cost tothe ow
ner, including diagnosis, parts and labor.
Now, K
FI hereby certifies that diesel engines for lift trucksproduced in 2004 m
odel year and after shall be regulated byFederal EPA exhaust gaseous regulations. The differencebetw
een current and EPA-certified engines is only the labelattached
on the
engine. S
ee available
drawing
and/orillustration of em
ission label and its location.
MA
NU
FAC
TUR
ER’S W
AR
RA
NTY
CO
VERA
GE
Beginning January 1, 2004, heavy-duty off-road EPA engine
emission-related com
ponents are warranted for a period of
five (5) years, or three-thousand (3,000) hours of operation,w
hichever occurs first. If any emission-related part on your
engine is defective, the part will be repaired or replaced by an
authorized Kom
atsu Forklift dealer.
EMISSIO
N R
ELATED PA
RTS
•Fuel Injection P
ump
•Fuel Injection N
ozzles
•Turbocharger
OW
NER
’S WA
RR
AN
TYR
ESPON
SIBILITIES
As the heavy-duty off-road engine ow
ner, you are responsiblefor the perform
ance of the required maintenance listed in
owner's m
anual (Instruction Manual). K
FI recomm
ends thatyou retain all receipts and records covering the m
aintenanceon your engine, but KFI cannot deny w
arranty solely for thelack of receipts and records or for your failure to ensure theperform
ance of
all scheduled
maintenance.
For your
reference, the following is an em
ission control maintenance
schedule for certified Diesel engines.
•C
heck oil level and coolant level – Every day
•C
hange engine oil –A
X/BX/EX
: Every 500 hoursC
X/D
X: Every 200 hours
•C
hange lubricating oil filter –A
X/BX/EX
: Every 500 hoursC
X/D
X: Every 200 hours
•C
hange fuel filter – Every 500 hours
•Initial adjustm
ent of valve clearance – 200 hours
•A
djust valve clearance – Every 1,000 hours
Keep records to show
proof of compliance w
ith the requiredm
aintenance practices and intervals.
•A
s the heavy-duty off-road engine owner you should, how
-ever, be aw
are that KFI m
ay deny your warranty coverage
if your heavy-duty off-road engine or part has failed due toabuse, dam
age, neglect, improper m
aintenance or disap-proved m
odifications.
•Your engine is designed to operate on com
mercial diesel
fuel only. Use of any other fuel in our engine w
ill result inthe engine operating in non-com
pliance with the Federal
EPA regulations.
•You are responsible for initiating the w
arranty process. It issuggested
that you
present your
heavy duty
off-roadengine to an authorized K
omatsu dealer as soon as you
become aw
are that problem exists. The w
arranty repairshould be com
pleted by the dealer as expeditiously aspossible.
If you have any questions regarding your warranty rights and
responsibilities, you should contact the authorized KFI dealer.
LIMITATIO
NS
KFI is not responsible for resultant dam
ages to an emission-
related part or component resulting from
:•
Any application or installation K
FI deems im
proper asexplained in the Instruction M
anual.•
Attachm
ents, accessory items or parts not authorized for
use by KFI.•
Improper off-road engine m
aintenance, repair or abuse.•
Ow
ner'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 w
arrantyapplicable to the off-road engine product involved.R
emedies under this w
arranty are limited to the provision of
material
and services
as specified
herein. K
FI is
notresponsible for incidental or consequential dam
ages, such asdow
ntime or lost use of the forklift truck.
CU
STOM
ER A
SSISTAN
CE –
EMISSIO
N C
ON
TRO
L SYSTEMS
WA
RR
AN
TYK
omatsu Forklift aim
s to ensure that the Em
ission Control
System
s Warranty is properly adm
inistered. In the event thatyou do not receive the w
arranty service to which you believe
you are
entitled under
the Em
ission C
ontrol System
sW
arranty, call or write to your K
omatsu Forklift D
ealer.A
uthorized dealers are recomm
ended for major m
aintenanceand repair w
ork, as they are staffed with trained personnel,
proper tools and are aware of the latest m
aintenance methods
and procedures. Ow
ners and others who desire to perform
their own w
ork should purchase a service manual and obtain
current service information from
their KFI engine dealer.
Follow the instructions in the O
perations Manual concerning
any other
maintenance
programs
not required
for EPA
compliance.
For questions and additional inform
ation concerning
EPAD
iesel Engine E
xhaust Regulations, contact:
Kom
atsu Forklift U.S
.A., Inc.
14481 Lochridge Blvd., Building 2
Covington, G
eorgia 30014Voice phone: (770) 385-4815Fax phone: (770) 385-4838Pro
perty
of A
mer
ican
Airline
s
NOTES:
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READ AND FOLLOW ALL SAFETY PRECAUTIONS. FAILURE TO DO SO MAY RESULT IN SERIOUS
INJURY OR DEATH.
FOREWORD
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1. FOREWORD
1-1
1. FOREWORDThis 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 notdone in the manner described in this manual.
DIRECTION OF TRUCKThis manual uses the directions left, right, front and rear as they are seen from the operator's seat.
• Improper operation and maintenance of this lift truck can be hazardous and could result inserious injury or death.
• Operators and maintenance personnel should read this manual thoroughly before beginningoperation 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 beenshipped. If this lift truck has been purchased in another country or purchased from someonein another country, it may lack certain safety devices and specifications that are necessary foruse in your country. If there is any question about whether your product complies with theapplicable standards and regulations of your country, consult your Komatsu Forklift dealerbefore 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 informationon your lift truck or for questions regarding information in this manual.
• Information on safety is given in the SAFETY, OPERATION and MAINTENANCE sectionsthroughout this manual; please read it carefully and completely.
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2. SAFETY INFORMATION
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2. SAFETY INFORMATIONThis OPERATING MANUAL contains information necessary for the operation of a basic fork lift truck. Optionalequipment is sometimes installed that can change some operating characteristics described in this manual. Makesure the necessary instructions are available and understood before operating the lift truck.
Some of the components and systems described in this OPERATING MANUAL will NOT be installed on your unit.If you have a question about any item described, contact your local dealer.
Additional information that describes the safe operation and use of lift trucks is available from the followingsources:
• Employment safety and health standards or regulations• Safety codes and standards, such as: American National Standard, ANSI B56.1, Safety Standard For Low Lift
and High Lift Trucks.• Publications from government safety agencies, government insurers, private insurers and private organiza-
tions, such as: Accident Prevention Manual for Industrial Operations from the National Safety Council.
NOTE: Forklift trucks are not intended for use on public roads.
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 toavoid a hazard which carries a serious risk of serious injury or death.
These safety messages or labels usually describe precautions that must be takento avoid a hazard which may lead to serious injury or death.
This word is used on safety messages and safety labels for hazards which couldresult in injury or damage to the lift truck or surrounding property if the hazard isnot avoided.
Safety precautions are described in the SAFETY, OPERATION and MAINTENANCE sections of this manual.
Komatsu Forklift cannot predict every circumstance that might involve a potential hazard in operation andmaintenance. Therefore, the safety messages in this manual and on the lift truck may not include all possiblesafety precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is yourresponsibility to be sure that you and others can do such procedures and actions safely and without damaging thelift 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 lifttruck for any unintended use that is not specifically prohibited, you must be sure that it is safe for you and others. Inno event should you or others engage in prohibited uses or actions as described in this manual.
This word is used for precautions that may not lead to damage or failure, but which must be takento avoid actions that could shorten the life of the lift truck.
NOTICE
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3. RUNNING IN A NEW LIFT TRUCK
1-3
3. RUNNING IN A NEW LIFT TRUCKYour Komatsu lift truck has been thoroughly adjusted and tested before shipment.
However, operating the lift truck under severe conditions at the beginning can adversely affect performance andshorten the lift truck life. Be sure to take special care concerning the following items during this initial period ofoperation.
• 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.
3.1 FIRST MONTH OF SERVICE OR INITIAL 200 HOURS OF SERVICEFor new lift truck, carry out the following maintenance only after the first month or 200 hours.
Unit Check Items Remarks
Engine
Change oil in engine oil pan See page 4-15
Replace oil filter element See page 4-15
Check & adjust engine valve clear-ance See page 4-16
Tighten (retorque) engine cylinder head bolts
Check spark plugs for burning of electrode, burning of insulator See page 4-18
Check & clean air filter element See page 4-19
Check ignition timing
Check & adjust alternator belt (drive belt) tension See page 3-20
TORQFLOW transmission
Change transmission fluidSee page 4-17
Clean strainer
Differential Change oil See page 4-18
Hydraulic tank
Change oil
See page 4-14Replace line filter
Clean strainer
Clean inside tank
Misc. bolts & nuts TightenParticularly lug (hub) nuts, overhead guard mounting bolts, backrest mounting bolts, and operator's seat mounting bolts
Other Refer to “Check Before Operation” See page 3-18
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3. RUNNING IN A NEW LIFT TRUCK
1-4
3.2 MODEL LINE-UP
Model Description
FG35ST-8 8,000 lb. capacity, TB45E Engine, Torqflow, Cushion Tire
FG35STLS-8 8,000 lb. capacity, TB45E Engine, Torqflow, Cushion Tire, LP Special
FG35BCS-8 8,000 lb. capacity, TB45E Engine, Torqflow, Box Car Special, Cushion Tire
FG45ST-8 10,000 lb. capacity, TB45E Engine, Torqflow, Cushion Tire
FG45BCS-8 10,000 lb. capacity, TB45E Engine, Torqflow, Cushion Tire, Box Car Special
FG40ZT-8 8,000 lb. capacity, Compact Chassis, TB45E Engine, Torqflow, Pneumatic Tire
FG40ZTUS-8 8,000 lb. capacity, Compact Chassis, TB45E Engine, Torqflow, Pneumatic Tire, Gasoline Special
FG40ZTLS-8 8,000 lb. capacity, Compact Chassis, TB45E Engine, Torqflow, Pneumatic Tire, LP Special
FG40ZT2-8 8,000 lb. capacity, Compact Chassis, TB45E Engine, Torqflow, Pneumatic Tire, 2-speed
FG40ZT2US-8 8,000 lb. capacity, Compact Chassis, TB45E Engine, Torqflow, Pneumatic Tire, 2-speed, Gasoline Special
FG40ZT2LS-8 8,000 lb. capacity, Compact Chassis, TB45E Engine, Torqflow, Pneumatic Tire, 2-speed, LP Special
FD40ZT-8 8,000 lb. capacity, Compact Chassis, 6D102E Engine, Torqflow, Pneumatic Tire
FD40ZT2-8 8,000 lb. capacity, Compact Chassis, 6D102E Engine, Torqflow, Pneumatic Tire, 2-speed
FG40T-8 9,000 lb. capacity, TB45E Engine, Torqflow, Pneumatic Tire
FG40T2-8 9,000 lb. capacity, TB45E Engine, Torqflow, Pneumatic Tire, 2-speed
FD40T-8 9,000 lb. capacity, 6D102E Engine, Torqflow, Pneumatic Tire
FD40T2-8 9,000 lb. capacity, 6D102E Engine, Torqflow, Pneumatic Tire, 2-speed
FG45T-8 10,000 lb. capacity, TB45E Engine, Torqflow, Pneumatic Tire
FG45TLS-8 10,000 lb. capacity, TB45E Engine, Torqflow, Pneumatic Tire, LP Special
FG45T2-8 10,000 lb. capacity, TB45E Engine, Torqflow, 2-speed, Pneumatic Tire
FG45T2US-8 10,000 lb. capacity, TB45E Engine, Torqflow, 2-speed, Pneumatic Tire, Gasoline Special
FG45T2LS-8 10,000 lb. capacity, TB45E Engine, Torqflow, 2-speed, Pneumatic Tire, LP Special
FD45T-8 10,000 lb. capacity, 6D102E Engine, Torqflow, Pneumatic Tire
FD45T2-8 10,000 lb. capacity, 6D102E Engine, Torqflow, Pneumatic Tire, 2-speed
FD45T2US-8 10,000 lb. capacity, 6D102E Engine, Torqflow, Pneumatic Tire, 2-speed, Diesel Special
FG50AT2-8 11,000 lb. capacity, TB45E Engine, Torqflow, Pneumatic Tire, 2-speed
FD50AT2-8 11,000 lb. capacity, 6D102E Engine, Torqflow, Pneumatic Tire, 2-speed
FD50AT2US-8 11,000 lb. capacity, 6D102E Engine, Torqflow, Pneumatic Tire, 2-speed, Diesel Special
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4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK
1-5
4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK4.1 GENUINE KOMATSU FORKLIFT PARTSKomatsu Forklift genuine parts are manufactured from the samematerials, and by the same methods, as the parts built in the newlift truck.
In the event that the customer uses imitation parts, Komatsu Forkliftwill not be held accountable for any faults which result from the useof such imitation parts, and Komatsu Forklift warranty will not beapplicable.
Always use genuine Komatsu Forklift parts when replacing parts.
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4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK
1-6
4.2 2004 TIER 1 FEDERAL EPA EMISSION CONTROL STATEMENT FOROFF-ROAD LSI (NON-DIESEL) ENGINES (TB45)
This section presents information concerning the correct labeling, warranty, parts and maintenance of TB45engines in order to comply with the EPA off-road, large-spark-ignition (LSI) engine regulations.
4.2.1 LABELS REQUIRED AND LABEL LOCATIONSAll “TB45” series engines will display the required identification label as follows.
Location on TB45 engines (top view):
Emission compliance label (SAMPLE shown below)
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4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK
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4.2.2 WARRANTYThe following statement is hereby provided as required by regulations of the United States EnvironmentalProtection Agency (EPA).
YOUR WARRANTY RIGHTS AND OBLIGATIONSAll off-road large spark-ignition (LSI) engines must be designed, built and equipped to meet the Federal EPA’sstringent anti-smog standards.
Komatsu Forklift USA, LLC (“KFI”) must warrant the emission control system on your engine for the periods of timelisted below provided there has been no abuse, damage, neglect or improper maintenance of your engine.
Your emission control system may include parts such as the carburetor, regulator or fuel injection system, ignitionsystem, engine computer unit (ECM), catalytic converter and air induction system.
Also included may be sensors, hoses, belts, connectors and other emission-related assemblies.
Where a warrantable condition exists, an Authorized Komatsu Forklift Dealer will repair your LSI engine at no costto you, including diagnosis, parts and labor.
MANUFACTURER’S WARRANTY COVERAGEBeginning January 1, 2004 off-road large spark-ignition EPA engines are warranted for the time periods listedbelow. If any emission-related part on your engine is defective, the part will be repaired or replaced by anAuthorized Komatsu Forklift Dealer.
OWNER’S WARRANTY RESPONSIBILITIESAs the off-road LSI engine owner, you are responsible for the performance of the required maintenance listed inyour Operation and Maintenance Manual.
KFI recommends that you retain receipts covering maintenance on your off-road engine, but KFI cannot denywarranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
As the off-road large spark-ignition engine owner, you should be aware, however, that KFI may deny you warrantycoverage if your off-road large spark-ignition engine, or a part thereof, has failed due to abuse, damage, neglect,improper maintenance or unapproved modifications.
Your engine is designed to operate on gasoline and/or LPG fuel. Use of any other fuel may result in your engine nolonger operating in compliance with the Federal EPA’s emissions requirements.
You are responsible for initiating the warranty process. It is suggested that you present your off-road large spark-ignition engine to an Authorized Komatsu Forklift Dealer as soon as you become aware that a problem exists. Thewarranty 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 Komatsu ForkliftProduct Support Department.
In addition to the standard warranty periods, the components listed below are covered by the following specificwarranty periods.Pro
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EMISSION CONTROL WARRANTY – 36 MONTHS OR 2,500 HOURS FOR GENERAL PARTSFor the first 2,500 operating hours, or for a period of thirty-six months from the date of the first use by the originalpurchaser from an Authorized Komatsu Forklift Dealer, whichever occurs first, KFI warrants the following emission-related parts:
EMISSION CONTROL WARRANTY – 36 MONTHS OR 4,000 HOURS FOR POWER TRAIN PARTS• Intake manifold• Exhaust manifold
EMISSION CONTROL WARRANTY – 60 MONTHS OR 3,500 HOURS FOR GENERAL PARTS• ECM• Catalytic converter• Vaporizer
NOTICE
Follow the instructions in the Operations Manual concerning any other maintenance programs not required for EPA compliance.
• Oxygen sensor • PCV valve• Water temperature sensor • Gasoline injector• LPG injector • LPG pressure sensor• LPG solenoid • LPG switching module• Mass air flow sensor • Throttle chamber• Ignition coil • Crankshaft position sensor• Camshaft position sensor • Distributor• Spark plugs
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4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK
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4.3 2007 TIER 2 U.S. FEDERAL AND CALIFORNIA EMISSION CONTROLWARRANTY STATEMENT FOR OFF-ROAD LSI (NON-DIESEL) ENGINES (TB45)
This section presents information concerning the correct labeling, warranty, parts and maintenance of TB45engines in order to comply with the EPA and CARB off-road, large-spark-ignition (LSI) engine regulations.
4.3.1 LABELS REQUIRED AND LABEL LOCATIONSAll TB45 series engines will display the required identification label as follows.
Location of emission control label on TB45 engines (top view):
Sample of emission control label:
Rocker Cover
Emission Control Label
EMISSION CONTROL INFORMATION SEP
ENGINE FAMILY: 7NSXB04.546C, ENGINE DISPLACEMENT: 4.5 LITER OCTTHIS ENGINE IS CERTIFIED TO OPERATE ON GASOLINE AND LPG. NOV
CEDS2OH ,CWT ,IBT ,IPM :EPYT LORTNOC NOISSIME TSUAHXENAJYLNO SNOITACILPPA DEEPS-ELBAIRAV NI ESUBEFDEDEEN STNEMTSUJDA REHTO ONDEEPS ELDIRAM)TOH( mm 53.0HSAL EVLAVRPAC.D.T.B°01GNIMIT NOITINGIYAMmm 9.0PAG GULP KRAPS
JUNLUJ.DEDEEN STNEMTSUJDA REHTO ONGUArh-phb/g 3.8=OC ,0.1=xON+CH : SDRADNATS NOISSIME BRACPESrh-Wk/g 1.11=OC ,3.1=xON+CH : SDRADNATS NOISSIME 2reiT APE
THIS ENGINE COMPLIES WITH CALIFORNIA AND U.S. EPA REGULATIONS OCTVON.SENIGNE IS DAORNON EGRAL 7002 ROF
NISSAN MOTOR CO., LTD. TB45 D DEC
2006
2007
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4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK
1-10
4.3.2 WARRANTYThe following statement is required to be provided by regulations of the California Air Resources Board.
YOUR WARRANTY RIGHTS AND OBLIGATIONSThe California Air Resources Board is pleased to explain the emission control system warranty on your 2007engine. In California, new off-road large spark-ignition (LSI) engines must be designed, built and equipped to meetthe state's stringent anti-smog standards.
Komatsu Forklift U.S.A. LLC (“KFI”) must warrant the emission control system on your engine for the periods oftime 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, ignitionsystem, 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 youincluding diagnosis, parts and labor.
MANUFACTURER'S WARRANTY COVERAGE:The 2007 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 KFIDealer.
OWNER'S WARRANTY RESPONSIBILITIES:As the off-road LSI engine owner, you are responsible for the performance of the required maintenance listed inyour Operation and Maintenance Manual.
KFI recommends that you retain receipts covering maintenance on your off-road engine, but KFI cannot denywarranty 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 warrantycoverage if your off-road large spark-ignition engine or a part thereof has failed due to abuse, neglect, impropermaintenance or unapproved modifications.
Your engine is designed to operate on gasoline or LPG fuel. Use of any other fuel may result in your engine nolonger 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 largespark-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 ProductSupport Department at 1-770-385-4815.
EMISSION CONTROL WARRANTY - 36 MONTHS or 2,500 HOURS FOR GENERAL PARTSFor the first 2,500 operating hours or for a period of thirty-six months from the date of the first use by the originalpurchaser 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 • Distributor• Spark plugs • Exhaust tube from manifold to catalytic converter• Gasoline fuel tube • Gasoline fuel cap
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4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK
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EMISSION CONTROL WARRANTY - 36 MONTHS or 4,000 HOURS FOR POWER TRAIN PARTS• Intake manifold• Exhaust manifold• Exhaust connector
LONG-TERM EMISSION CONTROL WARRANTY - 60 MONTHS or 3,500 HOURS FOR GENERAL PARTS• ECM• Catalytic converter• Vaporizer
NOTICE
Follow the instructions in the Operations Manual concerning any other maintenance programs not required for regulatory compliance.
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4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK
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4.4 2004 TIER 2 FEDERAL EPA EMISSION CONTROL STATEMENTFOR OFF-ROAD DIESEL ENGINES (S6D102E)
Exhaust emissions produced by diesel engines are regulated by the United States Environmental ProtectionAgency (EPA). This section presents information concerning the correct labeling, warranty, parts and maintenanceof S6D102E diesel engines in order to comply with current EPA regulations.
4.4.1 LABELS REQUIRED AND LABEL LOCATIONSAll certified S6D102E diesel engines will display the required identification label as follows:
• S6D102E diesel engines: Labels will be affixed to all appropriate engines on KFI production trucks. Locationsare shown below.
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4. WARRANTY AND SERVICE FOR NEW LIFT TRUCK
1-13
4.4.2 WARRANTYThe following statement is hereby provided as required by regulations of the United States EnvironmentalProtection Agency (EPA).
YOUR WARRANTY RIGHTS AND OBLIGATIONSThe Federal EPA and KFI are pleased to explain the emission control system warranty on your 2004 or later Dieselheavy duty off-road engine. All new, heavy-duty off-road engines must be designed, built and equipped to meet theEPA’s stringent anti-smog standards. KFI must warrant the emission control system on your engine for the periodof 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-roadengine at no cost to the owner, including diagnosis, parts and labor.
Now, KFI hereby certifies that diesel engines for lift trucks produced in 2004 model year and after shall beregulated by Federal EPA exhaust gaseous regulations. The difference between current and EPA-certified enginesis only the label attached on the engine. See available drawing and/or illustration of emission label and its location.
MANUFACTURER’S WARRANTY COVERAGEBeginning January 1, 2004 heavy-duty off-road EPA engines are warranted for a period of five (5) years, or three-thousand (3,000) hours of operation, whichever occurs first. If any emission-related part on your engine isdefective, 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 RESPONSIBILITIESAs the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenancelisted in owner's manual (Instruction Manual). KFI recommends that you retain all receipts and records covering themaintenance on your engine, but KFI cannot deny warranty solely for the lack of receipts and records or for yourfailure to ensure the performance of all scheduled maintenance. For your reference, the following is an emissioncontrol maintenance schedule for certified Diesel engines.
• Check oil level and coolant level Every day• Change lubricating oil Every 200 hours• Change lubricating oil filter Every 200 hours• Initial adjustment of valve clearance Every 200 hours• Change fuel filter Every 500 hours• Check turbocharger, rebuild or replace if necessary Every 2,000 hours• Adjust valve clearance Every 2,000 hours• Check fuel injection nozzles, replace if necessary Every 2,000 hoursPro
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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 willresult in the engine operating in non-compliance with the Federal EPA regulations. You are responsible for ini-tiating the warranty process. It is suggested that you present your heavy duty off-road engine to an authorizedKomatsu Forklift dealer as soon as you become aware that problem exists. The warranty repair should be com-pleted 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.
LIMITATIONSKFI 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 the Instruction Manual.• Attachments, accessory items or parts not authorized for use by KFI.• Improper off-road engine maintenance, repair or abuse.• Owner's unreasonable delay in making the product available after being notified of a potential product problem.
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 notresponsible for incidental or consequential damages, such as downtime or lost use of the forklift truck.
CUSTOMER ASSISTANCE – EMISSION CONTROL SYSTEMS WARRANTYKFI aims to ensure that the Emission Control Systems Warranty is properly administered. In the event that you donot receive the warranty service to which you believe you are entitled under the Emission Control SystemsWarranty, call or write to your Komatsu Forklift Dealer.
Authorized dealers are recommended for major maintenance and repair work, as they are staffed with trainedpersonnel, proper tools and are aware of the latest maintenance methods and procedures. Owners and others whodesire to perform their own work should purchase a service manual and obtain current service information fromtheir Komatsu Forklift engine dealer.
NOTICE
Follow the instructions in the Operations Manual concerning any other maintenance programs not required for EPA compliance.
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5. LOCATION OF PLATES AND SERIAL NUMBER
1-15
5. LOCATION OF PLATES AND SERIAL NUMBER5.1 LIFT TRUCK SERIAL NUMBERS
5.2 UL (Underwriters Laboratories) plateLocated on the outside front left of the dashboard.
5.3 Embossed vehicle serial numberStamped on top of the left front fender.
5.4 Nameplate with vehicle serial numberLocated on the bonnet (hood) to the right of the operator’s seat.
5.5 Engine serial numberGas/LPG engine: stamped on left side of engine, near distributor.Diesel engine: sticker on left side of engine, near oil filter.
Model Series EPA Compliance Applicable Lift TruckFG35/45ST-8 FG40/45T(2)-8FG35/45BCS-8FG50AT2-8FG40ZT(2)-8 CX20
2004 Tier 1 (Gas/LP)2007 Tier 2 (Gas/LP)
130001A~135001A~
FD40/45T(2)-8FD50AT2-8FD40ZT(2)-8
2004 Tier 2 (Diesel) 130001A~135001A~
TB45 Gasoline/LPG engine S6D102E Diesel engine
(Right) near distributor
(Left) near oil filter
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5. LOCATION OF PLATES AND SERIAL NUMBER
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5.6 CONTACTING KOMATSU FORKLIFTWhen contacting a Komatsu Forklift dealer for parts ordering or problem consultation, always provide the lift truckserial number embossed on the lift truck.
NOTICE
Take care not to damage or remove the embossed serial number.
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READ AND FOLLOW ALL SAFETY PRECAUTIONS. FAILURE TO DO SO MAY RESULT IN SERIOUS
INJURY OR DEATH.
SAFETY
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6. SAFETY MANAGEMENT
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6. 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 willlead 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 aninspection, 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 orsafety labels have been lost or have become dirty and cannot be read, obtain replacements from yourKomatsu 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.
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.
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6. SAFETY MANAGEMENT
2-2
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 injuryor 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.
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 labelwhen 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 truckcan 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 theyare shipped out of Komatsu Forklift plants.
ENGINE EXHAUST GAS IS POISONOUSDo not leave the engine running where there is poor ventilation.The engine exhaust gas contains carbon monoxide, which cancause gas poisoning and result in serious injury or death.
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6. SAFETY MANAGEMENT
2-3
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 ofthe forks and take steps to prevent pedestrians or othervehicles from hitting the forks.
• Select a parking place where people or vehicles do notpass, and stop the lift truck so that it is difficult for anyone togo under the forks. The area under the forks is a dangerzone.
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 storageand handling of liquified petroleum gases.
FIRE IS STRICTLY PROHIBITED DURING REFUELINGFuel is extremely f lammable and can cause f ires andexplosions.• 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.
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6. SAFETY MANAGEMENT
2-4
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 safeplace for parking, stop the engine for safety. Then report tothe supervisor.
• Be sure that fire extinguishers have been provided and thatyou read the labels to ensure that you know how to usethem.
• 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 allconnections, container, valves and fittings with soap and water or equivalent solution.
• When replacing LPG fuel system components, always use Komatsu genuine parts.Prope
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7. SAFE TRAVEL
2-5
7. 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 stepto hold yourself securely.
• Do not hold on to or pull yourself up with the control levers orsteering wheel when getting on or off the lift truck.
• Keep the handrails (assist grip) clean all the time, and repairany damage.
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 OPERATINGTravel 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. Toforestall such a possible accident, the truck is provided withTravel Interlock and Lift/Tilt Interlock that make travel andtruck operation impossible if you are not seated properly(Operator Presence System).
• If you operate the lift truck in such a posture that your weightis not properly applied to the seat, like standing up or leaningforward or sideways, the Travel Interlock begins to alarm inapproximately three seconds and cuts off the transmission of engine power. Then the truck will not move, evenif 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 tiltlever, these functions will not work. (The lever for an attachment is not equipped with this function.)
• For details, see “TRAVEL INTERLOCK” on page 3-29 and “LIFT/TILT INTERLOCK” on page 3-34.
A SUDDEN SHIFT OF THE F-R LEVER IS DANGEROUSTo change the travel direction, stop the lift truck completely and then operate the F-R lever.
AJM00003
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7. SAFE TRAVEL
2-6
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 seriouspersonal injury if the lift truck should tip over.
• Always check the seat belt mounts and check for anydamage to the seat belt. If any abnormality is found, repairor 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 theneutral position.
• Adjust the operator's seat and the steering wheel beforestarting the engine. Always lock them in position afteradjusting. Adjusting the seat or steering wheel duringoperation is dangerous as it may cause you to lose yourbalance or operate the lift truck in an unsafe manner.
• Before starting the engine, first check that the surroundingarea is safe, and sit securely in the operator's seat.
• Sound the horn before starting the engine to warn peoplearound 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 lifttruck 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).
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7. SAFE TRAVEL
2-7
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 mastback.
• 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 orwhen turning.
• Do not attempt to pass another lift truck or vehicle on anarrow path or on a spot of limited view like a crossing.
• When passing through an area of limited view, like acrossing or when running into a narrow path, sound the hornand check the surroundings for safety.
• Even if you sound the horn, not everyone in the surrounding area will necessarily hear it. Always pay carefulattention 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.
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7. SAFE TRAVEL
2-8
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 ordeath.
• Before starting operations, check the load limit for thegangplanks, and do not use them if they do not have amplestrength to take the weight of the lift truck when loaded.
• Apply the brakes on the truck and block the wheels beforedriving the forklift into the truck.
• When driving into trailers, use jacks and take steps toprevent the trailer from sinking when the forklift truck travelson it.
• When driving the forklift inside trucks, reduce speed whenbacking out and be sure to check that the gangplanks aresafe.
• 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 theydo not slip and fall.
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7. SAFE TRAVEL
2-9
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 thebottom of the forks so that the bottom of the forks or palletdo not contact the ground surface or the tip of the fork doesnot stick into the ground when traveling.
• For safe travel on slopes:
• 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 aredepressed.Always leave ample room in front of and behind the lift truckwhen starting on slopes.
• Be careful of the truck sliding downhill if Travel Interlock isengaged while traveling uphill or on a slope. Stay securely inthe operator ’s seat! See “TRAVEL INTERLOCK” onpage 3-29 for more information.
Whenloaded:
Travel forward up the slope, and in reversedown the slope with the load upgrade.
Whenunloaded:
Travel in reverse up the slope and forwarddown the slope with the load-engagingmeans downgrade.
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7. SAFE TRAVEL
2-10
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 ensuresafety.
• When turning, travel slowly and be careful that the front orrear wheels do not come off the ground.
• When turning on soft road shoulders, there is danger thatthe rear wheels may come off the road shoulder and causethe 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 dangerof the lift truck tipping. Do not turn the lift truck when theforks are raised high.
• Do not suddenly raise the forks or tilt the mast to the front orrear when the forks are loaded. There is danger that the lifttruck 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 isa greater chance of tipping than when traveling with theforks 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 thelift truck for safe unobstructed travel.
• Even if you sound the backup buzzer, the people behind thetruck may not necessarily hear it. Always check that there isno one behind the truck before driving the truck. (For lifttrucks equipped with backup buzzer)
DON'T USE A LIFT TRUCK TO TOW ANOTHER BROKEN-DOWN LIFT TRUCKIf there is any problem with the brakes or steering system of your lift truck, do not use another lift truck to tow it asthere is danger that the lift truck may run out of control.
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7. SAFE TRAVEL
2-11
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 thesurrounding 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 isdangerous 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 willoverheat, 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 warnpeople nearby and check for safe conditions in the area of the truck.
• 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.
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FOLLOW THESE STEPS FOR PARKING1. 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 tank after parking
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 isinstalled.)
• In such an emergency, light a flare or smoke candle to warn approaching trains and people in the area thatthere 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 lifttruck or to be hoisted.
• The towing pin at the back of the counterweight is providedto pull out the lift truck when it has gotten stuck in dirt or aditch as well as when it is being loaded on a truck.
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8. LOADING OPERATIONS
2-13
8. 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 leaningforward or sideways, Travel Interlock begins to alarm inapproximately three seconds and cuts off the transmissionof engine power. Then the truck does not move even if youdepress the accelerator pedal or operate the forward-reverse lever.The truck will slide downhill if Travel Interlock activates onan uphill grade or a slope.
• Select flat and solid ground for loading and unloading. Avoida 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 bedisplaced.
• Always operate the mast and forks from the operator's compartment. Be careful not to operate the lever bymistake. 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 FORKSThe space under a lifted fork is an area of danger, so neverallow anyone to go under the fork. There is a danger ofpersonal injury to any person who could be crushed under theforks when they come down.
DON'T CLIMB ON THE MAST OR LOAD BACKRESTIf you climb on the mast or load backrest, there is a danger thatyou could get caught up in the moving parts or fall off.
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8. LOADING OPERATIONS
2-14
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 theperson.
BE CAREFUL NOT TO GET CAUGHT IN THE MAST STRUCTURENever put your hands or feet into the mast structure. There isdanger that you will get caught in moving parts and be seriouslyinjured.
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 inthe surrounding area.
• Keep the load as low as possible and be sure to maintainthe balance.
• When turning, operate slowly and be careful not to let theload shift or move.Pro
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8. LOADING OPERATIONS
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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, andso on. If such contact occurs, there is the danger that theload 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 thatthe rear wheels may come off the ground, the operator maylose 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 capacitychart on the nameplate. (See “LOAD CENTER ANDACTUAL 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 lifttruck 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 preventthe load from collapsing or falling.
DON'T HANDLE A LOAD EXCEEDING THE LOAD BACKREST HEIGHTKeep the height of the load within the height of the loadbackrest. Do not carry any load that is higher than the loadbackrest. If the load is higher than the load backrest, thereis danger that it will fall back on top of the operator,resulting in serious injury or death.
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8. LOADING OPERATIONS
2-16
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 maycause 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 asto the hooked object.
DON'T USE THE FORK TO PUSH OR PULL A LOADThere 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 ofthe 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 loadmay fall and the lift truck tip.
• Always be careful that there is no slack in the chain whenpulling the forks out from pallet or shelf.
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8. LOADING OPERATIONS
2-17
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 orattachments).
• Do not use the forks to open or close the doors of railroadcars 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.
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9. SAFETY IN PERIODIC MAINTENANCE
2-18
9. SAFETY IN PERIODIC MAINTENANCE
PERIODIC MAINTENANCE WORK MUST BE CARRIED OUT BY QUALIFIED PERSONNELOnly persons authorized by the owner or operator of the equipment and having proper certification (local ornational) may carry out inspection, maintenance and repairs of the lift truck. If inspection, maintenance, or repairwork 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.
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9. SAFETY IN PERIODIC MAINTENANCE
2-19
PERIODIC INSPECTION OF CRITICAL REPLACEMENT PARTSReplace critical safety parts with a new one periodically even if no defect is found. Parts tend to deteriorate astime goes by, and can cause fire or failure in the work equipment system. However, if these parts show anyabnormality before the replacement interval has passed, they should be repaired or replaced immediately.
USE OF PROPER TOOLS AND EQUIPMENTAlways use tools that are suited for inspection and maintenance. It is extremely dangerous to use broken tools ortools designed for another purpose.
SAFE HANDLING OF BRAKE OILIt is dangerous if the brakes do not work because in this condition, the lift truck cannot be stopped. Always do thefollowing.• 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 theradiator cap under these conditions as hot water may spurtout and cause burns.
• When removing the radiator cap, turn it slowly to release theinternal pressure.
• When checking the coolant level, stop the engine and waitfor the engine and radiator to cool down before checking.
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9. SAFETY IN PERIODIC MAINTENANCE
2-20
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 whenthe oil is hot as hot oil may spurt out and cause burns.
• Wait for the truck temperature to go down before carryingout the inspection and maintenance work.
• Do not forget that the work equipment circuits are alwaysunder pressure. Do not add oil, drain oil, or carry outmaintenance or inspection before completely releasing theinternal pressure.
• If oil is leaking under high pressure from small holes, it isdangerous if the jet of high-pressure oil hits your skin oreyes. Always wear safety glasses and thick gloves, and usea piece of cardboard or a sheet of plywood to check for oilleakage.
• If you are hit by a jet of high-pressure oil, consult a doctorimmediately.
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. Nevertouch them when rotating.
• When inspecting rotating parts, do so only after the enginecomes to a stop.
• When inspecting the areas around rotating parts, do notallow anything to come close which may get caught.
JUMP STARTING THE ENGINE IS PROHIBITEDDo not push the lift truck to start the engine. There is danger that the lift truck may suddenly start and operateunexpectedly.
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9. SAFETY IN PERIODIC MAINTENANCE
2-21
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 beseriously 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 fordamage. If a rim is damaged or cracked when a tire isinflated, there is danger that the rim will break under the highpressure of the tire, resulting in personal injury or death.
• For safety, when checking tire pressure, place your body infront of the tread face of the tire. Do not check from the sideface of the tire.
• Always have tire inflation work carried out by properlyqualified personnel.
• The tire inflation pressure on a forklift truck is several timeshigher 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 andenter 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 thechassis. Never loosen rim nuts (2) if installed because it isvery dangerous to do so.
• After replacing the tires, make a trial run to make sure thatthere are no loose hub nuts. If the tightening torque is notsufficient, further tighten the hub nuts to the specified torque.For the correct tightening torque, refer to “SERVICE DATA” on page 4-5.
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9. SAFETY IN PERIODIC MAINTENANCE
2-22
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 4-31.)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 groundsurface. Put blocks under both sides of the frame to preventthe lift truck from coming down.
• Put a tire stopper behind the tires in contact with the floor sothat 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 TRUCKObey appropriate laws and regulations when disposing ofharmful 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 causemalfunctions or operational failure. Do not wash theelectrical system with water or high-pressure steam.
• For more details on the washing method, see “LIFT TRUCKWASHING PROCEDURE” on page 3-35.
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9. SAFETY IN PERIODIC MAINTENANCE
2-23
SAFE HANDLING OF BATTERIES• Battery electrolyte contains sulfuric acid, and can quickly
burn the skin and eat holes in clothing. If you spill batteryelectrolyte on yourself, immediately shed the clothes, flushthe part with a large quantity of tap water and then consult adoctor.
• Should battery electrolyte get into your eyes, flush themimmediately with fresh tap water for 10 to 15 minutes andthen consult a doctor at once.
• Should you drink battery electrolyte by accident, either drinka large quantity of water or milk mixed with beaten egg whiteor 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 BATTERIESWhen the battery is charged, hydrogen gas is generated and the battery is heated by the chemical change. Toprevent 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.
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10. TOWING
2-24
10. TOWING
HOW TO MOVE A DISABLED LIFT TRUCKUse 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 thecontrol 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 toslide. 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 tocarry the disabled lift truck MUST have a rated capacity equal to or greater than the weight of the disabled lifttruck. The capacity must be for a load center equal to half the width of the disabled lift truck. See the nameplate ofthe approximate total weight. The forks must extend the full width of the disabled lift truck. Center the weight of thedisabled lift truck on the forks and be careful not to the damage the under side of the lift truck.
HOW TO TOW THE LIFT TRUCK1. 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 isbeing 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 liftingequipment, 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 thespecified torque before carrying out the lifting operation.Check also that there is no damage to the lifting portion onthe counterweight.
• When using the hooks on the counterweight to hoist the lifttruck, check beforehand that the counterweight mountingbolts are tightened to the specified torque and that there isno abnormality on the hooks.
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11. STRUCTURE AND STABILITY OF THE LIFT TRUCK
2-25
11. STRUCTURE AND STABILITY OF THE LIFT TRUCKTo 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 TRUCKForklift trucks basically consist of a lifting mechanism (fork andmast) and a main body (vehicle). The front wheels act as afulcrum and the center of gravity of the lift truck and that of theload are kept in balance. The relationship between the positionsof these two centers of gravity plays a very important role for thesafety of the lift truck.
CENTER OF GRAVITY OF LOADThe loads carried by forklift trucks come in various shapes fromboxes to planks and long objects. To judge the stability of the lifttruck, it is important to distinguish the position of the center ofgravity for loads of various shapes.
CENTER OF GRAVITY AND STABILITYThe stability of the lift truck is determined by the position of acombined center of gravity resulting from combining the centersof gravity of the lift truck and the load. When the lift truck iscarrying no load, the center of gravity of the lift truck remainsunchanged. On the other hand, when it is carrying a load, thecenter of gravity of the lift truck shifts to a combined center ofgravity from the centers of gravity of both the lift truck and theload. The position of the center of gravity of a load changes asthe mast is tilted back or forth, or it is raised or lowered. Theposition of the combined center of gravity also changesdepending 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
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11. STRUCTURE AND STABILITY OF THE LIFT TRUCK
2-26
STABLE RANGE OF CENTER OF GRAVITYFor the lift truck to remain stable, the combined center of gravityof the lift truck must come within a stable range of the center ofgravity, i.e. a triangle formed by three points of the right and leftfront wheels in contact with the floor and the center of the rearaxle.When a position of the combined center of gravity shifts beyondthe front axle, the lift truck will tip over in the forward direction withthe front wheels acting as a fulcrum. On the other hand, when aposition of the combined center of gravity shifts outside of astable range of the center of gravity, the lift truck will overturn inthe direction of shifting.
ACTUAL CAPACITY The horizontal distance from the position of the center of gravityof a load on the fork to the upright load backrest of the fork iscalled a load center.Actual capacity means the maximum weight of a load that can beloaded at a certain load center.A load capacity chart is given in the name plate. The chart showsthe relationship between the actual capacity and a load center.As a load center shifts toward the fork tips, so does the position ofthe combined center of gravity, too. Therefore, the load has to bedecreased 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 CHARTIn the load capacity chart, capacity is shown in relation to load center.Capacity values are determined according to each model on thecondition of the specifications shown on the plate.Before proceeding to loading a load, make sure that the load centerand the load are well within the confines of capacity.When the load is in a complex shape, pull the load closer to the loadbackrest so that the heaviest portion of the load comes to the forkcenter.Should a load be loaded beyond the confines of capacity, it would pose a serious danger to the lifting truck as therear 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 thatthe load is absolutely within the confines of capacity.
LOAD CENTER AND ACTUAL CAPACITYA nameplate shown at right is just an example. In the actualoperation, follow the instructions on a nameplate of the actual lifttruck.An example here shows a nameplate for a lift truck which has amast of max. fork height of 3.0 m and which is not equipped with anyattachment.
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 hasbecome difficult to read. In that case, call your Komatsu Forklift dealer asking for a new replacement nameplate.
(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
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11. STRUCTURE AND STABILITY OF THE LIFT TRUCK
2-27
SPEED AND ACCELERATIONIf a stationary object is not subjected to external force, it will remain stationary. In the same way, if a moving objectis 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 thefront when the lift truck stops. If the brakes are applied suddenly, there is danger of a large force being appliedtowards 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 isparticularly small, so it is necessary to reduce speed when turning, in order to prevent the lift truck from tipping. Ifthe lift truck is traveling with a raised load, the position of the overall center of gravity is high, so the danger oftipping to the front, left, or right becomes greater.
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12. SAFETY LABELS
2-28
12. SAFETY LABELSKeep these labels clean. If a label (decal) comes off, stick it on again in the same location or replace with a newone. Treat all labels (decals) in the same way, whether they are safety related or not.
The following items correspond to the above callouts.
1 2 3 4 5
8
6
10
SHROUD
7 14
9
11
12
13
AWB2296K
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12. SAFETY LABELS
2-29
1. FUEL LEVEL REQUIREMENTS - GASOLINE AND LPG(On dashboard over Fuel Gauge) (Dual-Fuel applications only)
2. Caution before operating machine. (Part No. 3EB-96-A5960)
3. Warning for operation (decal). (Part No. 3EB-96-A61203EB-96-A6120)
Dual-Fuel Truck LPG Fuel Truck
SERIOUS INJURY OR DEATH MAY RESULT IF YOU FAIL TO FOLLOW THESE PRECAUTIONS!B e f o r e O p e r a t i n g
W h i l e O p e r a t i n g
G e n e r a l P r e c a u t i o n s
A f t e r O p e r a t i n g
• Do not operate or repair truck unless trained and authorized.• Read and understand all warnings and instructions in manuals and on truck before operating.• Dealers have replacement manuals.• Check truck before use. If truck is in need of repair, do not operate until restored to safe condition.• Do not start truck if fuel is leaking or has leaked.• Use attachments for intended purpose only.
• Do not handle unstable loads or loosely stacked loads.• Do not handle loads higher than load backrest.• Space forks as far as load permits.• Be sure load is centered and forks are completely under load.• Never tilt load with mast tilted forward.• Do not tilt forward when elevated except to pick up or deposit load.• Travel load or lifting mechanism low and tilted back.• Tipover can occur if operated improperly.• Do not jump if truck begins to tipover. Hold on firmly and lean away from point of impact. Avoid being trapped between truck and ground.
• Allow no one to stand or pass under or near load or lifting mechanism.• Never place any part of body into mast structure, between mast and truck or outside truck.• Do not carry passengers on any part of truck.• Lift no one under any circumstances.• Do not operate without overhead guard and load backrest.• Fill fuel or charge battery only in specified place.• Stop engine when fueling and avoid open flame or sparks, and provide adequate ventilation.• Keep vent caps clear when charging battery.• Disconnect battery during servicing.
• Before getting off truck, shift F-R lever and high-low lever (clutch type) to neutral position, fully lower lifting mechanism and pull parking lever securely.• Shut off power when leaving truck unattended.• Block wheels when parking on incline.
• Operate truck only from operator's seat.• Sit firmly in the seat with good posture while driving. Leaving the seat or sitting improperly for approximately 3 seconds may cause the drive system to disengage. Unintended truck movement like rolling on an incline may occur.• Keep truck under control at all times.• Do not overload truck. Check capacity plate for load weight and load center.• Avoid any sudden starts, stops, turn or change of direction.• Obey traffic safety rules. Yield right-of-way to pedestrians.• Keep clear view of travel path. If load being carried blocks forward view, travel with load trailing.• Slow down and sound horn when vision is blocked.• Watch clearances, especially forks, mast, overhead guard and tailswing area.• Slow down for turns and on uneven or slippery surfaces.• Avoid running over loose objects.• Never angle or turn on incline.• Travel with load uphill when loaded.• Travel with lifting mechanism downhill when empty.• Secure dockboard or bridgeplate properly.• Do not exceed rated capacity.• Use special care when operating on dockboard or bridgeplate.
3EB-96-A6120
WARNING
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12. SAFETY LABELS
2-30
4. “NO JUMP START” decal located top center of starter solenoid. (Part No. 09842-A0481)
5. DUAL-FUEL SYSTEM FUEL CHANGE-OVER INSTRUCTIONS (On air cleaner housing)(Part No. 3EB-96-A5790)
6. Warning for handling LPG/FLAMMABLE GAS (decal). (Part No. 3EB-96-A5951)
7. Warning for use of split rim (pneumatic tires only) (decal). (Part No. 3EB-96-A5970)Prope
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12. SAFETY LABELS
2-31
8. Prevention of tip-over (decal). (Parts No. 3EB-96-A5111)
9. LPG LOW FUEL ALARM LIGHT (On dashboard to left of steering column) (OPTION)
10. Never touch fan when rotating. (Part No. 3EB-96-A5930)
11. No one is permitted to ride the lift truck together with the operator. (Part No. 3EB-96-A5910)
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12. SAFETY LABELS
2-32
12. Prohibit the operator from riding on the forks and lifting or lowering himself. Never enter the area under theforks. (Part No. 3EB-96-A5920)
13. Do not put your hand on the mast! (Warning to avoid getting hand caught) (Part No. 3EB-96-A5940)
14. Fuel type.37B-1QA-3010 37B-1QB-3010
GASOLINE FUEL37B-1QA-3010 37B-1QB-3010
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READ AND FOLLOW ALL SAFETY PRECAUTIONS. FAILURE TO DO SO MAY RESULT IN SERIOUS
INJURY OR DEATH.
OPERATION
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13. OVERVIEW OF LIFT TRUCK
3-1
13. OVERVIEW OF LIFT TRUCK13.1 GENERAL VIEW OF LIFT TRUCK
1. Mast 9. Turn signal lamp (option)2. Lift-chain 10. Head lamp (option)3. Lift cylinder 11. Operator’s seat4. Back rest 12. Engine hood5. Tilt cylinder 13. Counterweight6. Fork carriage 14. Rear wheel7. Fork 15. Front wheel 8. Head guard
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13. OVERVIEW OF LIFT TRUCK
3-2
13.2 INSTRUMENTS AND CONTROLS
See “EXPLANATION OF INSTRUMENTS AND CONTROLS” on page 3-4 for details.1. Meter panel (dashboard display) 9. Inching pedal2. Lift lever 10. Tiltable steering wheel lock lever3. Tilt lever 11. Fuse box4. Combination light/turn-signal lamp switch 12. Choke knob (gas engine)5. Starting switch 13. LPG low-fuel alarm light (optional)6. Horn button 14. Glow indicator (diesel only)7. Accelerator pedal 15. Parking brake lever8. Brake pedal 16. FORWARD/REVERSE switch
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13. OVERVIEW OF LIFT TRUCK
3-3
13.3 METER PANELCOMPONENTS
NOTICE
Method of checking for blown bulbs in warning lamps.1. Check that all warning lamps light up when the starting switch is turned ON.2. If any warning lamp does not light up, the bulb for that lamp is blown.
1. Engine water temperature gauge2. Fuel gauge3. Brake fluid level warning lamp4. Engine oil pressure warning lamp5. Charge warning lamp6. Hourmeter and Operation indicator lamp7. Lift/Tilt Interlock indicator lamp (Operator Presence System)8. Failure indicator lamp9. Sedimenter warning lamp (diesel models only)10. Glow indicator lamp (diesel models only)11. Neutral indicator/Travel Interlock indicator lamp (Operator Presence System)
1 2
11109876543
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14. EXPLANATION OF INSTRUMENTS, CONTROLS AND COMPONENTS
3-4
14. EXPLANATION OF INSTRUMENTS, CONTROLS AND COMPONENTS
The following is an explanation of the devices that operate the lift truck as illustrated on the previous pages.To carry out suitable operations correctly and safely, it is important to understand fully the meanings of the displaysand the method of operating the equipment.
14.1 EXPLANATION OF INSTRUMENTS AND CONTROLSMETER PANELSee “EXPLANATION OF METER PANEL COMPONENTS” on page 3-8.
LIFT LEVERThis lever is used to raise and lower the forks.
Lower forks: Push the lever forwardRaise forks: Pull the lever back
RemarkThe speed when raising the forks can be controlled by the amountthat the lever is operated and the amount that the accelerator pedalis depressed. The lowering speed can be controlled only by the amount that thelever is operated.
TILT LEVERThis lever is used to tilt the mast forward and back.
Tilt forward: Push the lever forwardTilt back: Pull the lever back
RemarkThe speed when tilting the mast forward or back can be controlledby the amount that the lever is operated and the amount that theaccelerator pedal is depressed.
Sit in the operator’s seat and check that the surrounding area is safe before operating the lift lever.
Sit in the operator’s seat and check that the surrounding area is safe before operating the tilt lever.
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14. EXPLANATION OF INSTRUMENTS, CONTROLS AND COMPONENTS
3-5
COMBINATION LIGHT SWITCHThis switch is used to control the lamps.
LIGHT SWITCHPosition 1: “OFF” - Parking lamp (side clearance lamp) and frontlamps 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.
TURN SIGNAL INDICATOR SWITCHThis controls the turn signal indicator.
Left turn (L): Push lever forwardRight turn (R): Pull lever back
RemarkThis lever is equipped with an auto-return mechanismthat thatreturns the lever automatically to the neutral position.
STARTING SWITCHThis switch starts and stops the engine.When starting the engine, place the forward/reverse control lever at theneutral position, pull the parking brake lever, and depress the inchingpedal fully, then turn the key.
OFF: Engine stop positionThe key can be inserted or removed. The lamps and horn areactivated at this position.
ON: Engine running positionFor diesel engine lift trucks, carry out preheating before starting theengine. See “GLOW INDICATOR” on page 3-10.
START: Position for starting engineAfter the engine starts, release the key. It will automatically return tothe ON position.
Precautions for restarting the engine (Gasoline/LPG trucks only)When the engine does not start, return the key from the STARTposition to the OFF position. With the anti-restart feature installed, the key cannot be turned tothe START position again when 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.• Do not run the starting motor continuously for longer than the times given below.
• Do not turn the key to the START position when the engine is running.
Gasoline and LPG engine lift truck Maximum 5 secondsDiesel engine lift truck Maximum 10 seconds
KFI03200102
AB816490B
LEFTPush Forward
RIGHTPull Back
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14. EXPLANATION OF INSTRUMENTS, CONTROLS AND COMPONENTS
3-6
HORN BUTTONPress the button in the center of the steering wheel to sound thehorn.
ACCELERATOR PEDALSee item 1 in the illustration at right.
RemarkDo not put your foot on the accelerator pedal unless neces-sary for operation.
BRAKE PEDALSee item 2 in the illustration at right.
INCHING PEDALSee item 3 in the illustration at right.The inching pedal is used for fine control when driving the lift truck slowly forward or in reverse for loading orunloading.
TILTABLE STEERING WHEEL LOCK LEVERThis lever is used to allow the position of the steering wheel to be adjusted and to lock it in position afteradjustment.
Position (1): Lock is releasedPosition (2): Lock is applied
Method of adjustment1. Pull the lock lever up (position (1))2. Move the steering wheel forward and backward to adjust to the most
suitable position.3. Pull the lock lever down (position (2) to lock the steering wheel in
position.
123
A
Always stop the lift truck completely before adjusting the position of the steering wheel. Afteradjusting, move the steering wheel backward and forward to check that it is locked securely inposition.
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14. EXPLANATION OF INSTRUMENTS, CONTROLS AND COMPONENTS
3-7
FUSE BOXThe fuses protect the electrical components and wiring from burning out. See “REPLACING FUSES” on page 4-29 for details of replacing thefuses.
CHOKE KNOB(GASOLINE ENGINE TRUCK)
Use this for starting the engine when it is cold and for carrying outwarming-up operations. Pull the choke knob out to make it easy to startthe engine. Press the knob in to its original position when the engine haswarmed up.
LPG LOW FUEL ALARM LIGHT(OPTION)
This optional alarm is located on the dashboard near the parking brakelever.When this light comes on, the level of LPG is low.
GLOW INDICATOR(DIESEL ENGINE TRUCK)
This lamp is located on the dashboard to the left of the parking brakelever and shows the preheating condition of the engine. It lights up whenthe starting switch is turned to the HEAT position, it goes off when thepreheating is completed.
Lamp ON: Glow plug heatingLamp OFF: Glow plug preheating completed
When the lamp goes out, start the engine.
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14. EXPLANATION OF INSTRUMENTS, CONTROLS AND COMPONENTS
3-8
PARKING BRAKE LEVERPosition 1: Brake is applied.
When the lever is pulled back, the parking brake is applied and thefront 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.
FORWARD/REVERSE SWITCHThis switch is used to change the direction of travel (forward/reverse).Use light finger pressure to operate switch.
1-speed TORQFLOW transmissionF: FORWARDN: NeutralR: REVERSE
2-speed TORQFLOW transmissionTo shift the lever to the F1 position, raise the lever and push itforward.
F1: FORWARD low speedF2: FORWARD high speedN: NeutralR: REVERSE
NOTICE
Always stop the lift truck completely before operating the lever to change the travel direction.
RemarkThe engine is equipped with a neutral safety switch and cannot be started if the lever is not at the N (neutral)position.
14.2 EXPLANATION OF METER PANEL COMPONENTSENGINE WATER TEMPERATURE GAUGEThis indicator shows the engine water cooling temperature.
White range: NormalRed range: Overheating
NOTICE
If the indicator enters the red range, stop operations immediately, and move the lift truck to a safe position.Then take corrective actions against engine overheating.(See “ACTIONS WHEN ENGINE HAS OVERHEATED” on page 3-41.)
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14. EXPLANATION OF INSTRUMENTS, CONTROLS AND COMPONENTS
3-9
FUEL GAUGEThis indicator shows the remaining fuel level.When the starting switch is turned on, a check is carried out.
(A): Empty(B): Full
If the lift truck is on a slope, the correct fuel level will not be shown, soalways check fuel level when the lift truck is on level ground.Do not use up all the fuel. Fill the fuel tank before the fuel runs out.Note that, on LPG or Dual-Fuel equipped trucks, the gauge is partially orcompletely covered by decals referencing the LPG tank gauge.(See “SAFETY LABELS” on page 2-28.)
BRAKE FLUID LEVEL WARNING LAMPIf this lamp lights up, check the brake fluid level and add fluid.
NOTICE
Always use genuine Komatsu Forklift brake fluid.
ENGINE OIL PRESSURE WARNING LAMPThis lamp indicates the engine lubricating oil pressure.When the starting switch is turned ON it lights up, and after the enginestarts it should go off.If this lamp lights up during operations, stop operations immediately andcheck the engine lubricating oil system.
CHARGE WARNING LAMPThis lamp indicates the generating condition of the alternator.When the starting switch is turned ON it lights up, and after the enginestarts, it should go off.If this lamp lights up during operations, check the electrical system.
HOURMETERWhen the starting switch is turned ON, the hourmeter starts moving anddisplays the total number of operating hours. (When the hour-meter is working, the operating indicator lamp flashes.)The last digit advances by 1 every 6 minutes when the starting switch isat the ON or START position.The operation indicator lamp (green) below the hourmeter lights whenthe starting switch is turned ON. It shows that the hourmeter is working.
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14. EXPLANATION OF INSTRUMENTS, CONTROLS AND COMPONENTS
3-10
LIFT/TILT INTERLOCK INDICATOR LAMP(OPERATOR PRESENCE SYSTEM)
When you become improperly seated in the operator’s seat duringoperations, Lift/Tilt Interlock is activated and the Lift/ Tilt Interlockindicator lamp begins to flash, indicating that lifting and tilting functionshave been disabled.When you seat yourself properly in the operator's seat, the system willrestore lifting and tilting functions and the lamp will stop flashing.For more details on the function of Lift/Tilt Interlock, see illustration onfacing page and “LIFT/TILT INTERLOCK” on page 3-34.
FAILURE INDICATOR LAMP(GAS / LPG TRUCKS)
If this lamp lights up, contact your Komatsu Forklift dealer for informationand corrective procedures.
SEDIMENTER WARNING LAMP(DIESEL ENGINE TRUCK)
This lamp indicates that there is water collected in the fuel filter.When the starting switch is turned ON, the check is carried out.
Lamp OFF: NormalLamp ON: Drain water from fuel filter.
See “(DIESEL ENGINE) DRAIN WATER FROM FUEL FILTER” onpage 4-23 for details of the method of draining the water.
GLOW INDICATOR(DIESEL ENGINE TRUCK)
Glow indicator indicates the preheating condition of the engine.The lamp lights up when the engine starting switch is turned ON andgoes off when engine preheating is finished. The lamp goes off inapproximately 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.
Lift/Tilt Interlock disables only the lift and tilt levers, and not the attachment levers. Some attachmentswill 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, someattachments will move under their own weight or the load weight when their lever is operated.
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14. EXPLANATION OF INSTRUMENTS, CONTROLS AND COMPONENTS
3-11
NEUTRAL /TRAVEL INTERLOCK INDICATOR LAMP(OPERATOR PRESENCE SYSTEM)
This lift truck is equipped with KOPSplus (Komatsu Operator PresenceSystem Plus), which features neutral safety, Travel Interlock safety, andLift/Tilt Interlock safety. When the neutral indicator blinks, it means thateither the neutral safety or Travel Interlock feature has been activated.For details on Lift/Tilt Interlock, see “LIFT/TILT INTERLOCK” onpage 3-34.Neutral safety ensures that the operator starts the lift truck in neutral,while Travel Interlock ensures that, during travel, the operator stays inthe operator’s seat and sits using good posture. When functioning normally, the neutral lamp:• lights up when the starting switch is turned ON and goes on after engine startup.• shines steady on when the Forward/Reverse lever is put into Neutral. When the lamp blinks, either neutral safety or Travel Interlock is indicated.
Neutral IndicatorNormal starting operation: When the operator turns the starter switch on with the forward/reverse lever in theneutral position, the neutral indicator lamp turns on steady. After the engine starts and the operator puts the lifttruck into forward or reverse, the neutral lamp turns off. Improper starting operation (neutral safety activation): When the operator attempts to start the lift truck inforward 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 IndicatorWhen the engine is running: During operations, when the operator sits improperly or leaves the operator’s seatfor three seconds or more, Travel Interlock disables the transmission of engine power, the lamp starts blinking,and travel stops. The engine continues to run. See “TRAVEL INTERLOCK” on page 3-29 for more details.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 even after Travel Interlock hasactivated.
LOCATION OF OPERATOR PRESENCE SWITCHThis switch, built into the seat, activates the OperatorPresence System when it detects that the operator is notproperly seated in the operator’s seat. When the OperatorPresence System is engaged, normal travel and liftoperations are disabled by Travel Interlock and Lift/TiltInterlock, respectively, and the corresponding indicatorsblink on the meter panel.
For more information about the Operator Presence System, see:• “LIFT/TILT INTERLOCK INDICATOR LAMP” on page 3-10• “METER PANEL INDICATORS FOR THE OPERATOR PRESENCE SYSTEM” on page 3-12• “TROUBLESHOOTING THE OPERATOR PRESENCE SYSTEM” on page 3-13
KOPS02
Operator PresenceSwitchPro
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14. EXPLANATION OF INSTRUMENTS, CONTROLS AND COMPONENTS
3-12
METER PANEL INDICATORS FOR THE OPERATOR PRESENCE SYSTEM
KOPS01
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.
WARNING
Travel Interlock IndicatorWhen Travel Interlock indicator is blinking, power to transmission is disabled and lift truck cannot travel.
Lift/Tilt Interlock IndicatorWhen Lift/Tilt Interlock indicator is blinking, power to hydraulic control valve is disabled and lift and tilt functions are disabled.
CheckEngine
- 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.
To clear blinking indicators and resume truck operations:
KOPSplus – Komatsu Operator Presence System plus
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14. EXPLANATION OF INSTRUMENTS, CONTROLS AND COMPONENTS
3-13
TROUBLESHOOTING THE OPERATOR PRESENCE SYSTEMWhen travel is interrupted and indicators are blinking on your dashboard display, it could be due to activation of theOperator Presence System. Consult this diagram to determine the correct course of action.
KOPS03
• Sit fully in the operator seat and fasten the seat belt.
• Put F/R lever in the neutral position before starting truck.
N
Are you properly seated?
Is truck in neutral before starting?
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.
YES
NO
POSSIBLE PROBLEMS:• Travel Interlock indicator is blinking• Lift/Tilt Interlock indicator is blinking• Truck won’t start• Truck or mast stops operating
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14. EXPLANATION OF INSTRUMENTS, CONTROLS AND COMPONENTS
3-14
14.3 OPERATOR’S COMPARTMENT14.3.1 ADJUSTING THE SEAT
It is possible to slide the seat forward or backward to set it to the optimumposition.
Method of adjusting seat position.1. Pull lever (1) left. (In this condition, the seat slides forward or back-
ward.)2. Set the seat to the optimum position, then release lever (1). (In this
condition, the seat is locked in position.)
NOTICE
Fore-and-aft adjustment is 5 in. (127 mm).
14.3.2 ADJUSTING THE RECLINING ANGLE(Optional suspension-style seat only)
With the suspension seat, it is possible to adjust the suspension to matchthe operator’s weight in addition to adjusting the fore-and-aft position andreclining angle.1. Pull up the lever. (When the lever is raised, the angle of the seat back
can be adjusted.)2. Adjust the angle of the seat back to a position where operation is easy,
then release the lever.After adjusting, move the seat lightly to the front and rear to check that it issecurely locked in position.
• Adjust the seat before starting operations or when changing operators at the beginning of ashift. (Always stop the lift truck before adjusting the seat.)
• Adjust the seat to a position where it is possible to depress the brake pedal fully with yourback against the backrest of the operator’s seat. (Always stop the lift truck before adjustingthe seat.)
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14. EXPLANATION OF INSTRUMENTS, CONTROLS AND COMPONENTS
3-15
14.3.3 ADJUSTING THE SUSPENSION(Optional suspension-style seat only)
1. Turn the adjustment knob on the right side of the operator’s seat toadjust the suspension to match your weight in kilograms.
2. Use the needle indicator and scale located on the front seat near theadjustment knob as a guide when setting the suspension.
Adjust as follows:To INCREASE the weight setting, turn to (B)To DECREASE the weight setting, turn to (A)
NOTICE
Weight adjustment range is 110 - 265 lbs. (50 - 120 kg).
14.3.4 FITTING AND RELEASING THE SEAT BELT(Standard and suspension-style seats; suspension-style seat shown here)
1. Pull the belt out of the holder at the right side of the seat, then insertthe tongue into the buckle until it clicks (once it clicks, the seat belt isin the locked position).The seat belt is designed to hold the operator stationary when theholder senses a hard pull.The seat belt may occasionally bind in its holder. If this happens, holdthe belt tongue with both hands, pull it up strongly, then pull the beltout slowly.
2. To unlatch the belt, hold the tongue portion of the belt with your righthand, then press the red button in the buckle with your left hand.
3. Continue to hold the belt and let it retract slowly into the holder.
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14. EXPLANATION OF INSTRUMENTS, CONTROLS AND COMPONENTS
3-16
14.4 ENGINE HOOD
14.4.1 OPENING THE ENGINE HOOD1. To prevent the hood from touching the steering wheel, lift the tilt steer-
ing wheel lock lever (1), and push the steering wheel to the most for-ward position (2), then return the lock lever to its original position (3).
2. Lift the lever (4) on the front left side of the engine hood with your lefthand, and release the hood from the frame. Lift the hood all the wayup (5) until the engine hood stopper fits into place.a. On trucks equipped with LPG capability, the seat back folds for-
ward to clear the tank bracket.b. On LPG trucks using the optional folding tank bracket, the bracket
folds away allowing more clearance when the hood is in the UPposition.
Be careful not to get your hand caught when opening or closing the hood.
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14. EXPLANATION OF INSTRUMENTS, CONTROLS AND COMPONENTS
3-17
14.4.2 CLOSING THE ENGINE HOOD1. Lift the engine hood up slightly with your right hand, push in the
stopper with your left hand, then lower the engine hood slowly andcheck that the lock is applied.
2. Lift the steering wheel lock lever, pull the steering column back to itsoriginal position, then return the lock lever to its original lockedposition.
14.4.3 FORK STOPPERLOCK position: The forks are secured to the fork carriage. Always usethis position during operations.
FREE Position: The forks can be moved to the left and right, so it ispossible to adjust the spread of the forks to match the size of the load.
NOTICE
For details of the method of adjustment, see “FORK SPREAD ADJUSTMENT” on page 3-33.
It is dangerous to operate the lift truck with the steering column pushed forward because the steeringwheel will not be fixed in position. Always be sure to return the steering column to its original positionand check that the lock is securely applied.
Lock
Free
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15. OPERATION
3-18
15. OPERATION15.1 CHECK BEFORE OPERATION
Check the lift truck thoroughly. If any abnormality is found, always repair it or consult your Komatsu Forklift dealer.
15.1.1 CHECK BEFORE OPERATION WITH KEY SWITCH OFF� OIL OR FUEL LEAKAGE AND BATTERY FLUID LEAKAGECheck for leakage by conducting a walk-around check.In particular, check the following items:• Tubing• Hydraulic unit• Cylinder• Control valve• Battery• LPG fuel system connections and fuel level
� CHECK FOR CRACKS AND DAMAGEVisually check for cracks and damage.In particular, check the following items:• Head guard• Fork• Load back-rest• Fork carriage• Mast • Fuel tank, LPG fuel tank and connections
� CHECK TIRES AND RIMSCheck the tires and rims for the following items.• Excessive wear, damage, and adhesion of foreign matter.• Deformation or damage.• No loose lug nuts or rim mating nuts. (See “TORQUE LIST” on
page 4-8 for torque.)• Tire pressure matches the specified pressure (pneumatic only).
Specified Pressure
Check Item PressureFront tires
100 PSI (0.69 MPa) (7.0 kgf/cm2)Rear tires
Tightening torque
Check Item CX Lug (Hub) Nut CX Rim Mating NutFront wheels 217 - 361 ft/lb (294 - 490 Nm)
(30 - 50 kgfm)—
Rear wheels 141 - 181 ft/lb (196 - 245 Nm) (20 - 25 kgfm)
• Never operate the lift truck before the check operation is completed.• If any abnormality is found during the checking, immediately consult a Komatsu Forklift
dealer and do not operate the lift truck until repaired.• Oil or fuel leakage can cause a lift truck fire. Check for any fluid or LPG leakage before
starting.
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15. OPERATION
3-19
� CHECK OIL LEVEL IN HYDRAULIC TANK1. 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.
(Diesel engine shown at right; gas/LPG engine similar).3. Wipe off hydraulic oil with a clean cloth and insert dipstick into the
tank.4. Take out the dipstick again and check to see if it indicates the proper
level.5. If the oil level is low, add genuine Komatsu Forklift oil through the
filler.
NOTICE
Always use genuine Komatsu Forklift hydraulic oil.
� CHECK OIL LEVEL IN BRAKE RESERVOIR TANK1. Remove the floor plate.2. Remove the connector of the brake fluid level sensor, then remove
the cap (1).3. The oil should be within the range shown in (A): 0.7 in. (18 mm).4. If the oil level is low, add genuine Komatsu Forklift brake fluid.
NOTICE
Always use genuine Komatsu Forklift brake fluid.
5. Install the cap6. Install the floorboard and close the engine hood.
� CHECK BATTERY ELECTROLYTE LEVEL
1. If the battery electrolyte is below the top of the electrode plates, adddistilled water to the top of the electrode plates.
2. Check the battery case for cracking and stain caused by electrolyteleakage.
3. Clean the battery cap breathers and terminals.
NOTICE
• 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 using distilled water or dilute sulfuric acid.
• Battery electrolyte is dangerous. If it gets in your eyes or on your skin or clothes, wash it offwith large amounts of water. In particular, if it gets in your eyes, consult a doctor quickly.
• To avoid gas explosions, do not smoke or cause short circuits or sparks near the battery.
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15. OPERATION
3-20
� CHECK PARKING BRAKEThe operating effort for the parking lever should be 55 ft/lb (245 N)(25 kgf). If it is less then 44 ft/lb (196 N) (20 kgf), please contact yourKomatsu Forklift dealer.
� CHECK HORNCheck that the horn sounds normally when the horn button is pressed.
� CHECK LAMPSCheck that the head lamps and turn signal lamps work properly. Checkalso for any dirt on, or damage to, the lamps.
� CHECK PEDALSDepress the pedal and check that there is no abnormal heaviness or catching.
BRAKE PEDAL
INCHING PEDAL
RemarkThe interconnected travel is the distance that the brake pedal and inching pedal move together.
� CHECK DEFLECTION OF V-BELTPush the belt at the mid-point between the pulleys with your finger andcheck that the deflection is the specified value.
NOTICE
Replace the belt if the belt is stretched and there no allowance for adjustment, or if the belt is cut or cracked.
� CHECK OIL LEVEL IN ENGINE OIL PANUse the dipstick to check that the oil is within the correct range. If the oillevel is low, add engine oil through the oil filler.
NOTICE
If the oil is markedly dirty or discolored, change the oil. Always use genuine Komatsu Forklift engine oil. (See “LUBRICANT LIST” on page 4-2.)
Play 0.51 - 0.67 in. (13 - 17 mm)Pedal height when depressed (h) 3.54 - 3.94 in. (90 - 100 mm)
Play 0.08 - 0.12 in. (2 - 3 mm)Interconnected travel 1.85 - 2.09 in. (47 - 53 mm)
Gas / LPG 0.59 - 0.67 in. (15 - 17 mm) (98 N fin-ger pressure) (10 kgf finger pressure)
Diesel Engine uses auto-tensioner for V-belt
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15. OPERATION
3-21
� CHECK COOLANT LEVEL
NOTICE
Even if the coolant level in sub-tank is normal, check radiator cool-ant level every month or 200 hours on hour meter. If the radiator coolant level is lower than specified, overheating may be likely.
1. Check radiator and hoses for any water leakage.2. Check that coolant in reservoir is cold and add coolant to MAX level.3. If reservoir is dry, add coolant to radiator and then to reservoir tank.4. Also check deflection of V-belt (See “CHECK DEFLECTION OF V-
BELT” on page 3-20.)
� CHECK ABNORMALITIES FOUND ON PREVIOUS DAYIf any abnormality was found during the checks or operation on the previous day, check that the repairs have beencarried out and that there is no abnormality.
NOTICE
On LPG trucks, open the fuel service valve, on the tank, by turning it gently counterclockwise.Turning the valve clockwise shuts off the LPG flow to the engine.
• Normally, do not open the radiator cap. Check the coolant when the engine is cold, and checkusing the reservoir tank.
• NEVER remove the radiator or sub-tank cap when the coolant is hot. Boiling water may spurtout.
• When removing the radiator cap after the coolant temperature has gone down, turn the capslowly to release the pressure before removing it.
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15. OPERATION
3-22
15.1.2 CHECK AFTER STARTING WITH KEY SWITCH ONBefore checking the following items, read:• “MOUNTING/DISMOUNTING” on page 3-27• “OPERATOR’S COMPARTMENT” on page 3-14• “PLACING LIFT TRUCK IN MOTION” on page 3-27
� CHECK FOR ABNORMAL NOISE, ABNORMAL VIBRATIONCheck in particular that there is no abnormal noise or abnormal vibration from the engine or hydraulic pump.
� CHECK ENGINE EXHAUST GAS COLORNo color, light blue: NormalBlack: Incomplete combustionWhite: Oil leaking into cylinder
� CHECK FUEL LEVEL IN FUEL TANK
NOTICE
Never use any fuel mixed with kerosene. (Diesel engine lift truck)
If the fuel gauge indicator is at the (A) position, the tank is full.If the fuel level is low, stop the engine and fill the tank through thefuel filler port. For details of the fuel to use, see “LUBRICANT LIST”on page 4-2.When adding fuel, remove all dirt from around the cap and becareful not to let any dirt get into the tank.After adding fuel, tighten the fuel filler cap securely and wipe up anyfuel that was spilled.
LPG ENGINE LIFT TRUCKSCheck the fuel gauge indicator on the LPG tank.
When adding fuel, never let the fuel overflow. This may cause a fire. If you spill fuel, clean up anyspillage.
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15. OPERATION
3-23
� CHECKS USING GAUGES AND WARNING LAMPSENGINE OIL PRESSURE WARNING LAMP, CHARGE WARNING LAMPThese lamps should NOT light up except briefly at start-up.
ENGINE WATER TEMPERATURE GAUGE, TORQUE CONVERTER OIL TEMPERATURE GAUGEThe indicator should be in the white range.
SEDIMENTER WARNING LAMP) (Diesel only)This lamp should not light up except briefly at start-up. If it does lightup, drain the water from the fuel filter. (See “(DIESEL ENGINE)DRAIN WATER FROM FUEL FILTER” on page 4-23.)
� CHECK STEERING WHEELCheck the following points.• Play (the play should be 1.2 - 2.4 in. (30 - 60 mm).• There must be no up-down play.
Engine oil pressure warning lamp
Travel Interlock warning lamp
Lift/Tilt Interlock warning lamp
Charge warning lamp
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15. OPERATION
3-24
� CHECK LAMPS AND BACK-UP BUZZER• Check that the lamps light up correctly. Replace any broken bulbs.• For trucks equipped with the back-up buzzer option, check that the
back-up buzzer sounds when the forward/reverse lever is placed inREVERSE. If the back-up buzzer does not sound when the forward/reverse lever is placed in REVERSE, carry out repairs or replacementimmediately.
� CHECK LIFT-CHAIN
Check lift-chain tension1. Lift the forks 4 - 6 in. (10 - 15 cm) from the ground.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 approxi-mately equal.
3. If the deflections differ from each other, adjust with the nut ofthe lift-chain stopper bolt.
Check elongation of the lift-chainMeasure the length over 17 links and check that the length iswithin the following specified value.
Replace the chain if the measurement value exceeds this range.
Length Over 17 Links3.5, 4-ton lift trucks
Max. 17.3 in. (440 mm)4.5 ton lift trucks
• Set the forward/reverse control lever to the neutral position and apply the parking brake. Thenperform checking.
• NEVER insert feet under the forks.
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15. OPERATION
3-25
The elongation of the lift-chain can be checked with the following“chain wear scale” also. Regular inspection and lubrication of thechains will increase their service life and reduce downtime.If the chains stretch beyond the recommended amount, theyshould be replaced in pairs. Chain stretch can be measured withchain wear scale part no. 661923. Measure the chains according to the instructions printed on thechain wear scale, without a load on the carriage.To check the hoist chains, raise the carriage 12.0 in. (30 cm) offthe ground to put tension on the chains.Check the lift-chain lubricant
NOTICE
Use genuine Komatsu Forklift engine oil. (See “LUBRICANT LIST” on page 4-2.)
15.1.3 CHECK WHILE ADVANCING SLOWLY� CHECK STEERING WHEEL OPERATIONCheck the following items while advancing slowly.• No deviation of steering wheel.• No unstable steering in straight travel.• No feeling of abnormally heavy steering when the steering wheel is turned.
� CHECK BRAKE OPERATIONCheck the following items by depressing the brake pedal to apply the brake while advancing slowly.• The brake is properly applied.• The brake is applied uniformly.
� CHECK OPERATION OF INCHING PEDAL (TORQFLOW TRANSMISSION LIFT TRUCK)• Depress the pedal slightly (partially engage the transmission) and check that it is possible to carry out inching.• Check that the lift truck stops when the pedal is completely depressed.
� CHECK FOR ABNORMAL NOISE, ABNORMAL SMELLCheck that there is no abnormal noise or abnormal smell when traveling at low speed. Check for odor of LPG, on LPG equipped lift trucks.
15.1.4 CHECKS WHILE OPERATING CONTROL LEVERS� CHECK OPERATION OF WORK EQUIPMENTOperate the work equipment control levers from the operator’s seat and check that the forks can be raised and lowered and that the mast can be tilted forward and back smoothly. If there is any abnormality, please contact your Komatsu Forklift dealer immediately.
� CHECK FOR ABNORMAL NOISE, ABNORMAL SMELLOperate the work equipment control levers from the operator’s compartment and check that there is no abnormalnoise or abnormal smell during travel.
• The lift-chain is liable to break if heavily rusted. • If lubrication is insufficient, apply engine oil to prevent rusting.• Visually check the lift-chain for damage or cracks. If any abnormality is found, consult your
Komatsu Forklift dealer.
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15. OPERATION
3-26
REMOVAL AND INSTALLATION OF LPG FUEL TANKS ON LIFT TRUCK
REMOVING LPG TANK FROM LIFT TRUCK1. Close fuel service (cylinder) valve (turn clockwise) with engine running.2. Let engine run out of fuel in lines before turning OFF ignition switch.3. Remove fuel hose connection at tank and release the tank clamp.4. Remove LPG tank from vehicle and place in designated area.
INSTALLING LPG FUEL TANK ON LIFT TRUCK1. Place correct size and type LPG fuel tank onto lift truck.
NOTICE
Use only HD-5 grade LPG fuel.
2. Securely mount the tank while positioning as follows:a. Locating pin must fit through positioning hole in collar.b. Slot in footring must fit over keyway.
3. Connect LPG fuel hose to tank securely and open fuel ser-vice valve SLOWLY to gently equalize pressure.
4. Check for leakage at connections. If leakage is suspected,check with soapy water and look for bubbles at connections.If leakage is confirmed, turn OFF fuel service valve, tag truck “OUT OF SERVICE” and have qualified per-sonnel make repairs.
• 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 andrepair the fuel system.
• For additional information, consult the National Fire Protection Association pamphlet 58 forthe safe storage and handling of liquified petroleum gases.
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15. OPERATION
3-27
15.2 MOUNTING/DISMOUNTING
Mount and dismount facing the lift truck, using the foot of the headguard as shown in the illustration.
15.3 PLACING LIFT TRUCK IN MOTION
15.3.1 STARTING ENGINE1. Set the forward/reverse control lever and high/low speed control
lever to the neutral position.
2. Pull the parking brake lever.3. Depress the inching pedal.
• Stop the lift truck completely BEFORE dismounting the lift truck.• Do not mount or dismount a moving lift truck.• NEVER jump on or off of the lift truck! This is very dangerous.
• Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an actmay cause serious bodily injury or fire.
• When placing lift truck in motion, check that the area around the lift truck is safe and soundthe horn before starting.
• Do not allow anyone to enter the area around the lift truck.• There is a blind-spot behind the lift truck, so be particularly careful when traveling in reverse.• When starting the engine, set the forward/reverse control lever and high/low speed control
lever (clutch-type lift truck) to the neutral position and pull the parking brake lever, thendepress the clutch pedal (inching pedal for lift trucks with torque converter) and start engine.
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15. OPERATION
3-28
4. Gasoline engine lift truck: Depress the accelerator pedal fully,then slowly release it. (If the engine is warmed up, there is no needto depress the accelerator pedal.) With the accelerator pedalreleased, turn the starting switch to the START position to start theengine.Diesel engine lift truck: Turn the starting switch to the HEATposition (left) and release it. When the glow plug lamp goes out, fullydepress the accelerator pedal and turn the key to the STARTposition (right). Allow the key to return to the ON position after theengine has started.
LPG engine lift truck: Open fuel service valve at tank. Turn ignitionswitch to START position without depressing the accelerator pedal.As the engine starts, depress accelerator pedal gently. Do notdepress pedal too far until warmed up.
5. When the engine starts, release the key. (The key will returnautomatically to the ON position.)
6. Carry out the warming-up operation (5 - 6 minutes).
Diesel engine lift truck: Release the accelerator pedal and carryout warming-up for a short time.
Gasoline engine lift truck: Warm up the engine for approx. 1minute, then depress the accelerator pedal slightly and release it. Ifthe ambient temperature is high, depress the accelerator pedallightly after starting, then release it. The engine speed will go down,and this will make it possible to carry out the warming-up operationmore quietly, and will also save fuel.
LPG engine lift truck: If engine does not start easily, do not “pump” the pedal or hold it open during starting toavoid damage to the regulator and the engine. Wait for about 2 minutes and retry.
NOTICE
• Do not run the starting motor continuously for longer than the times given below.
• If the engine does not start, wait for at least 20 seconds (LPG engine - wait 2 minutes) before trying to start again.
• Do not turn the key to the START position when the engine is running.
Gasoline/LPG engine lift truck Max. 5 secondsDiesel engine lift truck Max. 10 seconds
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15. OPERATION
3-29
15.3.2 PLACING LIFT TRUCK IN MOTION
NOTICE
Do not rest your feet on the inching pedal if you are not operating the pedal.
1. Depress the inching pedal and place the forward/reverse controllever at F1 or R position.
2. Release the parking brake and check that the direction of travel andthe area around the lift truck are safe.
3. Depress the accelerator pedal slowly with your right foot whilereleasing the inching pedal slowly with your left foot.
RemarkIt is possible to carry out inching with the inching pedal partiallyengaged.
15.3.3 TRAVEL INTERLOCK(OPERATOR PRESENCE SYSTEM)
When you use bad sitting posture during lift truck operations and yourweight is not fully applied to the seat, such as when standing up orleaning forward or sideways, Travel Interlock engages in approximatelythree seconds and cuts off transmission of engine power. The enginewill continue to run, but the truck will not move even if you depress theaccelerator pedal or operate the forward/reverse lever.When Travel Interlock is engaged, the Travel Interlock indicator lamp onthe instrument panel blinks (see figure at right.) This lamp doubles asthe 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 travelagain. Take this step only after you check the surroundings for safety. Travel Interlock does not brake the truckforcibly.
For more information about the Operator Presence System, see:• “LIFT/TILT INTERLOCK INDICATOR LAMP” on page 3-10• “NEUTRAL /TRAVEL INTERLOCK INDICATOR LAMP” on page 3-11• “METER PANEL INDICATORS FOR THE OPERATOR PRESENCE SYSTEM” on page 3-12• “TROUBLESHOOTING THE OPERATOR PRESENCE SYSTEM” on page 3-13
Always place the F/R lever in F1 or R when starting off the lift truck (2-speed transmission models).
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15. OPERATION
3-30
15.3.4 SHIFTING DIRECTIONAlways stop the lift truck completely before shifting between forward and reverse.
1. Stop the lift truck completely. (For details of the method of stoppingthe lift truck, see “TEMPORARY STOPPING AND PARKING” onpage 3-32.)
2. Move the forward/reverse control lever from F or F1 to R.Or move the forward/reverse control lever from R to F.
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15. OPERATION
3-31
15.4 STARTING AND INCHING ON SLOPE
1. When starting the lift truck on a slope, first pull parking brakelever (1) and check that the lift truck is held in position.
2. Depress accelerator pedal (4) a little at a time, then releaseparking brake lever (1) slowly so that the lift truck starts up theslope.
3. When the lift truck starts to move up the slope, release parkingbrake lever (1) fully. Adjust the uphill travel speed withaccelerator pedal (4).
4. When slowing down or stopping on slopes, gradually releaseaccelerator pedal (4), and depress brake pedal (3) just beforestopping.
5. After stopping the lift truck, always pull parking brake lever (1)fully.
15.5 TURNING• Operate the steering wheel 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 sys-tem.
NEVER carry out inching by depressing the accelerator pedal fully and then adjusting the amount thebrake pedal is depressed.
Use great care to prevent the outs ide o f thecounterweight hitting against objects when turning.
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15. OPERATION
3-32
15.6 TEMPORARY STOPPING AND PARKING
1. Release the accelerator pedal (1), then depress the brake pedal (2).
2. After the lift truck stops, pull parking brake lever (3) to apply theparking brake.
3. After the lift truck stops, return forward/reverse control lever (4) tothe NEUTRAL position.
15.6.1 WHEN LEAVING LIFT TRUCKWhen leaving the lift truck, always do as follows:1. Lower the forks to the ground.2. Tilt the mast until the fork tips touch the ground. Make sure there is
no gap between fork tips and ground, as this will create a hazardand possibly cause those passing the lift truck to trip and fall.
3. Turn the starting key to the OFF position, then remove the key.4. LPG engine trucks: When parking overnight, or for extended
periods, turn off fuel service valve on tank (clockwise) and wait untilengine stops before turning off ignition switch.
Do not park the lift truck on the route of travel for other vehicles or pedestrians.
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15. OPERATION
3-33
15.7 FORK SPREAD ADJUSTMENT
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 corresponding to the load size so that
the load center of gravity coincides with the center of the lifttruck.
6. Set the mast vertically, lower the knob and insert the forkstopper to lock the forks. (The forks are fixed in position.)
Take extreme care not to get hands or fingers caught while adjusting the fork spread.
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15. OPERATION
3-34
15.8 LOAD HANDLING OPERATION15.8.1 LIFT/TILT INTERLOCKIf you operate the lift truck in such a posture that your weight is notfully applied to the seat, like standing up or leaning forward orsideways, Lift/Tilt Interlock activates in approximately three secondsand disables all lifting and tilting functions.While Lift/Tilt Interlock is in operation, the Lift/Tilt Interlock indicatorlamp on the instrument panel blinks.
To return to travel condition after Lift/Tilt Interlock has been activated:Seat yourself properly and then the truck is ready for travel again. Start the operation of the truck again only afteryou check the surroundings for safety.
For more information about the Operator Presence System, see:• “LIFT/TILT INTERLOCK INDICATOR LAMP” on page 3-10• “NEUTRAL /TRAVEL INTERLOCK INDICATOR LAMP” on page 3-11• “METER PANEL INDICATORS FOR THE OPERATOR PRESENCE SYSTEM” on page 3-12• “TROUBLESHOOTING THE OPERATOR PRESENCE SYSTEM” on page 3-13
Lift/Tilt Interlock disables only the lift and tilt levers, and not the attachment levers. Some attachmentswill 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, someattachments will move under their own weight or the load weight when their lever is operated.
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15. OPERATION
3-35
15.8.2 LOADING
1. Stop slowly when reaching the stacking location.
2. Tilt the mast forward until it is vertical.
3. Raise the load to 2 - 4 in. (5 - 10 cm) above the stacking point.
4. Drive slowly forward.
• Check that there is no danger of collapse or breakage of the load at the loading point.• Check that the loading position is correct.• Never push the load with the fork tips.
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15. OPERATION
3-36
5. Lower the load temporarily to the stacking point.
6. Reverse and slowly withdraw the forks 1/4 to 1/3 of the way outfrom beneath the load.
7. Raise the load again 2 - 4 in. (5 - 10 cm).
8. Position the load correctly above the stacking point.
9. Lower the load to the correct stacking position.
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15. OPERATION
3-37
10. Reverse the lift truck slowly and withdraw the forks fully frombeneath the load.
11. Return the mast to the travelling position.
15.8.3 UNLOADING
1. Stop the lift truck squarely in front of the load.Then bring the mast to a vertical position.
2. Align the forks with the fork insertion point.
• Check that there is no danger of collapse of the load. • Check that the forks are positioned correctly for insertion under the load.• Check that the pallet is in a position where it can be lowered completely.
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15. OPERATION
3-38
3. Drive forward and insert the forks 2/3 to 3/4 of the way under theload, then raise the load 2 - 4 in. (5 - 10 cm).
4. Reverse slowly 6 - 8 in. (15 - 20 cm).
5. Lower the load slowly.
6. Drive forward slowly and insert the forks fully under the load.
7. Raise the load 2 - 4 in. (5 - 10 cm).
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15. OPERATION
3-39
8. Reverse the lift truck to a position where the load can be safelylowered.
9. Lower the load until it is 6 - 8 in. (15 - 20 cm) from the ground.
10. Tilt the mast fully back.
11. Carry the load to the desired location.
15.9 CHECK AFTER OPERATION� On completion of operation, wipe off any dirt and dust� Before storage, check for:
1. Oil leakage, battery fluid or fuel leakage from the units, LPG tank connections.2. Cracks or damage.3. Check for faults found during operation and report them to the person responsible for the lift truck.4. Lubricate the units (if necessary).
� Drain any water accumulated in the fuel system to prevent water from freezing during the night.� To prevent moisture from collecting inside the fuel tank, always fill tank after completing operations.
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16. COLD WEATHER OPERATION
3-40
16. COLD WEATHER OPERATIONIf the temperature drops to colder levels, it becomes difficult to start the engine and the coolant may freeze, soprepare for cold weather operation as follows.
16.1 FUEL AND LUBRICANTSChange to fuel and oil with low viscosity for all components. (See “LUBRICANT LIST” on page 4-2.)
16.2 HYDRAULIC OILAlways use genuine Komatsu Forklift oil. This gives better protection against rust than normal hydraulic oil.
16.3 COOLANT
NOTICE
When the truck is shipped from the factory, it is filled with low-emission type (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).
16.3.1 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.
16.3.2 Dilution of glycol-based coolantUse dilution commensurate with the lift truck’s operating environment. Note that the lowest allowable dilution is30%. Be sure to use dilution percentages higher than 30%.
• Table values allow for approx. 2% safety margin as against the standard values.• If coolant percentage exceeds 65%, freezing temperature rises conversely. DO NOT add too much coolant.
16.4 BATTERYWhen the ambient temperature drops, the capacity of the battery will also drop. If the battery charge is low, thebattery electrolyte may freeze.• Maintain the battery charge above 75%, and insulate the battery against cold temperature so that the lift truck
can be started easily in the morning.• To prevent freezing, wait until before starting operations the next morning to add distilled water.
Proportions of Water and Antifreeze (or Coolant)
Min. temperature °F (°C) Percentage (%) of Coolant14 (-10) 305 (-15) 36-4 (-20) 41-13 (-25) 46-22 (-30) 50-31 (-35) 54-40 (-40) 58-49 (-45) 61-58 (-50) 64
Coolant is flammable, so keep it away from open flame. Never smoke when handling coolant.
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17. HANDLING IN HEAVY-DUTY CONDITIONS
3-41
17. HANDLING IN HEAVY-DUTY CONDITIONSTake these precautions before operating in heavy-duty conditions.
17.1 CLEAN INSIDE OF COOLING SYSTEMScale and rust form easily inside the cooling system, so flush the system with genuine Komatsu Forklift radiatorrust prevention fluid, and take other steps to ensure that there is always clean water circulating in the system.
17.2 CLEAN RADIATOR FINS
If the radiator fins are clogged, it will cause overheating, so blow throughthe radiator fins with compressed air, steam or water.When using air or steam, always point the nozzle at a right angle to theradiator when cleaning.
17.3 CHECK FAN BELT TENSIONIf the fan belt is loose, adjust it to the specified tension. A loose fan belt can contribute to overheating.
17.4 ACTIONS WHEN ENGINE HAS OVERHEATED
If the coolant temperature gauge indicator enters the overheat (RED) range, immediately park the lift truckin a safe place and take the following actions:1. Keep engine running at low idle, open the engine hood (bonnet) for better airing of the engine compartment
and wait for the engine to cool down. Once cooled down, shut off the engine. If the engine fan is not turning,shut off the engine immediately and let it cool down naturally.
2. After the engine has cooled (and is OFF), check the coolant level. Also check for water leakage from radiatorand/or hoses.
3. If coolant level is low, refill the radiator (first), and sub-tank (second), with cooling water. If water leakage isdiscovered, place the lift truck OUT OF SERVICE and contact your Komatsu Forklift dealer for repairs.
Air pressure 142 psi (0.98 MPa) (10 kg/cm2)Steam pressure 57 psi (0.39 MPa) (4 kg/cm2)
Always wait for the engine to cool down before removing the radiator cap. If you attempt to cool theradiator too quickly and the radiator cap is removed too soon, hot steam may spurt out and may causeserious injury.
Dirt may fly and get into your eyes, so always wear protective glasses or goggles.
DO NOT REMOVE THE RADIATOR CAP FROM A HOT RADIATOR! ALWAYS WAIT FOR THE ENGINE TO COOL DOWN BEFORE REMOVING THE CAP. IF YOU TRY AND REMOVE THE CAP WHILE THE
COOLANT IS HOT, BOILING WATER AND HOT STEAM MAY SPURT OUT CAUSING INJURY.Prope
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18. LONG-TERM STORAGE
3-42
18. LONG-TERM STORAGE18.1 BEFORE STORAGEWhen putting the lift truck in storage for a long time, do as follows:• Wash, clean and dry every part, then house the lift truck in a dry building. Never leave it outdoors.
NOTICE
In case it must be left outdoors, park the lift truck on flat, dry ground, and cover it securely with a water-proof sheet.
• Completely fill the fuel tank, grease all parts, and change the oil before storage.• Apply a thin coat of grease to the exposed surface of the piston rods of the hydraulic cylinders.• Disconnect the negative terminal of the battery and cover the battery, or remove the battery from the lift truck
and store it separately.• If the temperature drops below 32° (0°C), add antifreeze to the cooling water.• LPG engine lift trucks: Turn off fuel service valve (clockwise) and let engine run out of fuel. Then turn ignition
switch of the OFF position. Remove the LPG tank from the truck and store properly in secured area.
18.2 DURING STORAGE
18.2.1 RUST PREVENTION OPERATIONOperate the engine and move the lift truck for a short distance once a month so that a new film of oil will be coatedover the 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.
18.2.2 CHARGE BATTERYEven if the battery is not used, it will naturally discharge if left for a long period. Always charge the battery once amonth.
18.3 AFTER STORAGE
NOTICE
If the lift truck has been stored for a long period without being covered or without carrying out the monthly rust prevention operation, do as follows before using it.
• 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.• Remove the cylinder head cover, add oil to the valves and rocker arms, and check the operation of the valves.• 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.
If it is necessary to carry out the rust prevention operation while the lift truck is indoors, open thedoors and windows to improve ventilation and prevent gas poisoning.
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READ AND FOLLOW ALL SAFETY PRECAUTIONS. FAILURE TO DO SO MAY RESULT IN SERIOUS
INJURY OR DEATH.
MAINTENANCE
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19. OUTLINE OF SERVICE
4-1
19. OUTLINE OF SERVICE• Use Komatsu Forklift specified parts and lubricants for replacement.• When changing or adding oil, use only the oil that is recommended. Do not use a different kind or grade of oil.• Unless otherwise specified, the oil and coolant used at delivery from the factory shall be as shown in the table
below.
19.1 OIL• Since the oil is used for the work equipment, etc., under severe conditions (at high temperature and high pres-
sure), it will deteriorate as operating time passes. Always use an oil matching the grade and working tempera-tures given in the Operation Manual.Always replace the oil at specified time intervals even if it is not deteriorated.
• Oil is often compared to human blood.A lift truck should be maintained with the same care taken for the human body so that impurities (water, metalchips, dust, etc.) do not enter the lift truck system.Most lift truck malfunctions are caused by the entry of impurities into the various systems.Take special care to avoid the entry of impurities during storage and lubrication, etc.
• Never blend oils of different grades or brands.• Add specified volume of oil.
Too little or too much oil may both cause problems in the fork lift truck.• If the oil in the work equipment becomes cloudy, it is likely that air or water have entered the circuit. Consult a
Komatsu Forklift dealer.• When replacing oil, replace the relevant filters at the same time.
19.2 GREASE• Grease prevents wear and tear and the generation of squeaking noise from the joints, etc.• Lift trucks are provided with grease nipples in various places. Some of these are not mentioned in this manual
since they are for overhauling purposes and do not require greasing.If friction is noticed in movable parts after operation, grease them.
• After greasing, wipe off any old grease that is forced out, especially on rotating parts that will be worn by adher-ing sand and dirt.
19.3 OIL STORAGE AND PRESERVATION• Store and preserve oil so as to prevent entry of dirt, dust, water or other contaminants.• When storing oil drums for long periods, place them side-by-side with filler sides facing in the same direction.
If necessary to store drums outdoors, cover them with waterproof sheeting. Ensure that the screw caps (bungplugs) are tight.
• To prevent oil deterioration during long periods of storage, use drums on a “first-in, first-out” basis.
19.4 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 referring to this manual.• When replacing oil filters, check for metal powder or shavings deposited on the used filters.• Do not unpack replacement filters until immediately before installation.• Always use specified filters.
Item Type of fluid
Engine oil SAE 10W30 (gas/LPG)SAE 30W (diesel)
Differential case SAE 90Hydraulic tank ISO # 32 Hydraulic FluidTORQFLOW transmission case Dexron Automatic Transmission FluidCooling system Fresh water and Glycol-based Coolant
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20. LUBRICANT LIST
4-2
20. LUBRICANT LIST20.1 GASOLINE/LPG ENGINE LIFT TRUCKSFG35S/45S-8, FG35BCS/45BCS-8, FG40/40Z/45/50-8
NOTICE
Always use specified oil and grease.
Never use the incorrect kind of brake fluid. Use genuine Komatsu Forklift DOT 3 brake fluid.
Engine oil pan Engine oil(SAE10W-30)
(including filter) 8.5 quarts8.0 L / 1.8 UK gal.
TORQFLOWtransmission case
DEXRON automatictransmission fluid
17 quarts16.1 L / 3.5 UK gal.
Differential caseTORQFLOW transmission:13.7 quarts13.0 L / 2.85 UK gal.
Hydraulic tank Hydraulic oil ISO #32
FG35S/45S, FG35BCS/45BCS,FG40Z:11.0 US gal.41.64 L / 9.16 UK gal.FG40/45/50:8.7 US gal.32.9 L / 7.25 UK gal.
FG35S/45S, FG35BCS/45BCS,FG40/45/50:26.5 US gal.100 L / 22.0 UK gal.FG40Z:21.0 US gal.80 L / 17.5 UK gal.
Fuel tank
Gasoline: 87 octane(recommended)
LPG: HD-5 gradepropane
Brake system Brake fluid (DOT 3) 0.04 US gal. / 0.15 L / 0.033 UK gal.
Greasing points Lithium grease(NLGI No. 2) —
Cooling systemGlycol-based coolantAdd antifreeze at ambient temp. 32°F/0°C or below
3.7 US gal., 14 L, 3.08 UK gal.
Gear oil (SAE80W)
Gear oil (SAE90W)
Ambient TemperatureLocation Type of Fluid Capactities-4
-2014-10
320
5010
6820
86°F30°C
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20. LUBRICANT LIST
4-3
20.2 DIESEL ENGINE LIFT TRUCKSFD40/45/50-8, FD40Z-8• Never use fuel mixed with kerosene.• Always use specified oil and grease.
Never use the incorrect kind of brake fluid. Use genuine Komatsu Forklift DOT 3 brake fluid.
Engine oil pan 4.03 US gal.15.2 L / 3.35 UK gal.
TORQFLOWtransmission case
DEXRON automatictransmission fluid
4.22 US gal.16 L / 3.52 UK gal.
Differential case TORQFLOW transmission:3.43 US gal.13 L / 2.86 UK gal.
Hydraulic tank Hydraulic oil ISO #32 14.53 US gal.55 L / 12.10 UK gal.
FD40/45/50:26.4 US gal.100 L / 22.0 UK gal.FD40Z:21.1 US gal. / 80 L / 17.6 UK gal.
Fuel tank
Brake system Brake fluid (DOT 3) 0.04 US gal. / 0.15 L / 0.033 UK gal.
Greasing points Lithium grease(NLGI No. 2) —
Cooling systemGlycol-based coolantAdd antifreeze at ambient temp. 32°F/0°C or below
3.7 US gal., 14 L, 3.08 UK gal.
Gear oil (SAE80W)
Gear oil (SAE90W)
Ambient Temperature-4
-2014-10
320
5010
6820
86°F30°C
Diesel fuel
ASTM D975 No. 1
ASTM D975 No. 2
Engine oil
(SAE 30W)
(SAE 10W)
Location Type of Fluid Capactities
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20. LUBRICANT LIST
4-4
20.3 OIL AND GREASING CHARTOIL, GREASE LOCATIONS AND INSPECTION AND MAINTENANCE INTERVALS
Check and add fluid if necessaryChange or add oilNumber of places to add oil or grease
Chart symbol Type of fluidAF Automatic transmission fluid
EODiesel engine oilGasoline engine oil
GO Gear oilHO Hydraulic oilBF Brake fluidG Grease
Daily inspectionEvery 2 weeks (100 hours)
Monthly (200 hours)Every 3 months (600 hours)Every 6 months (1200 hours)
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21. SERVICE DATA
4-5
21. SERVICE DATA21.1 SERVICE DATA – GASOLINE/LPG ENGINE LIFT TRUCKS
Component Inspection item Unit FG35/40/45/50-8, FG40Z-8
Eng
ine
Engine
Engine model – NISSAN TB45Idling speed rpm 675 ± 50Maximum speed (continuous load) rpm 3,000
Compression ratio – 8.5
Cooling system Fan belt deflection in. (mm) 0.59 - 0.67 (11 - 17)finger pressure: 22 ft/lb (98N) (10 kgf)
Fuel systemInjection timing BTDC deg. 10 ± 1Firing order – –Injection pressure MPa –
Intake / exhaust system
Valve clearance
Intake in. (mm) 0.014 (0.35) HotExhaust in. (mm) 0.014 (0.35) Hot
Electric system
Distributor point gap in. (mm) –Spark plug gap in. (mm) 0.028 - 0.031 (0.7 - 0.8)
Spark plug type – NGK: B-4ES or BPR-4ES (shielded) Hitachi L47W
Ignition timing (gasoline)Ignition timing (LPG)
BTDC deg./rpm 10 ± 1 / 700
Firing order – 1 - 5 - 3 - 6 - 2 - 4
Trav
el s
yste
m Tires Tire inflation pressure
Front wheelsPSI (MPa)
250-15-16PR: 120 (0.83)8.25-15-12PR: 98 (0.68)300-15-18PR: 113 (0.78)
Rear wheels 120 (0.83)
Lug nuts Tightening torque
Front wheels
ft/lb (Nm)217 - 361 (294 - 490)
Rear wheels
Rim mating nuts Tightening torque
Front wheels –Rear wheels 145 - 217 (196 - 294)
Stee
ring,
bra
king
sys
tem
Steering wheel Playin. (mm)
1.2 - 2.4 (30 - 60)
Inching pedalPlay 0.08 - 0.12 (2 - 3)Interconnected travel 1.38 - 1.41 (35 - 41)
Brake pedalPlay
in. (mm)0.12 - 0.28 (3 - 7)
Pedal height when pedal is depressed 3.54 - 3.94 (90 - 100)
BrakeParking brake operating force ft/lb (N) Min. 55 (196)Tightening torque for back plate mounting bolts ft/lb (Nm) 181 - 228 (245 - 309)
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21. SERVICE DATA
4-6
Load
ing
equi
pmen
t
Forks Fork thickness at base of forksin. (mm)
FG40Z: Min. 1.77 (45)FG40/45/50: Min. 1.97 (50)
Chain Length over 17 links Max. 17.3 (440)
Hydraulic system Relief pressure PSI (MPa) 2,610.7 (18)
Trav
el s
yste
m
Tires Tire inflation pressure
Front wheelsPSI (MPa)
250-15-16PR: 120 (0.83)8.25-15-12PR: 98 (0.68)300-15-18PR: 113 (0.78)
Rear wheels 120 (0.83)
Lug nuts Tightening torque
Front wheels
ft/lb (Nm)217 - 361 (294 - 490)
Rear wheels
Rim mating nuts Tightening torque
Front wheels –Rear wheels 145 - 217 (196 - 294)
Stee
ring,
bra
king
sys
tem
Steering wheel Playin. (mm)
1.2 - 2.4 (30 - 60)
Inching pedalPlay 0.08 - 0.12 (2 - 3)Interconnected travel 1.38 - 1.41 (35 - 41)
Brake pedalPlay
in. (mm)0.12 - 0.28 (3 - 7)
Pedal height when pedal is depressed 3.54 - 3.94 (90 - 100)
BrakeParking brake operating force ft/lb (N) Min. 55 (196)Tightening torque for back plate mounting bolts
ft/lb(Nm) 181 - 228 (245 - 309)
Load
ing
equi
pmen
t
Forks Fork thickness (at base of forks) in. (mm)
FG40Z: Min. 1.77 (45)FG40/45/50: Min. 1.97 (50)
Chain Length over 17 links Max. 17.3 (440)
Hydraulic system Relief pressure PSI (MPa) 2,610.7 (18)
(GASOLINE/LPG ENGINE LIFT TRUCKS SERVICE DATA – CONTINUED)
Component Inspection item Unit FG35/40/45/50-8, FG40Z-8
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21. SERVICE DATA
4-7
21.2 SERVICE DATA – DIESEL ENGINE LIFT TRUCKSComponent Inspection item Unit FD40/45/50, FD40Z
Eng
ine
Engine proper
Engine model – S6D102E (359 cu.in.) (95hp @ 2,150 rpm)Idling speed rpm 675 - 725Maximum speed rpm 3,000 - 2,400
Compression PSI (MPa)/rpm 486 (3.35) / 280 - 320
Cooling system Fan belt deflection in. (mm) 0.24 - 0.39 (6 - 10)finger pressure: 17.8 ft/lb (79N) (8 kgf)
Fuel systemInjection timing (at idle) BTDC deg. 1° ATDC (injection pump cam lift 1 mm)Injection order – 1 - 5 - 3 - 6 - 2 - 4Injection pressure PSI (MPa) 2,845 (19.6)
Intake / exhaust system
Valve clearance
Intake in. (mm) 0.0098 (0.25) CoolExhaust in. (mm) 0.020 (0.51) Cool
Trav
el s
yste
m Tires Tire inflation pressure
Front wheels PSI(MPa)
250-15-16PR: 120 (0.83)8.25-15-12PR: 98 (0.68)
300-15-18PR: 113 psi (0.78)Rear wheels 120 (0.83))
Lug nuts Tightening torque
Front wheels
ft/lb(Nm)
217 - 361 (294 - 490)Rear wheels
Rim mating nuts Tightening torque
Front wheels –Rear wheels 145 - 217 (196 - 294)
Stee
ring,
bra
king
sys
tem
Steering wheel Playin. (mm)
1.2 - 2.4 (30 - 60)
Inching pedalPlay 0.08 - 0.12 (2 - 3)Interconnected travel 1.38 - 1.41 (35 - 41)
Brake pedalPlay
in. (mm)0.12 - 0.28 (3 - 7)
Pedal height when pedal is depressed 3.54 - 3.94 (90 - 100)
Brake
Parking brake operating force ft/lb (N) Min. 55 (196)
Tightening torque for back plate mounting bolts ft/lb (Nm) 181 - 228 (245 - 309)
Load
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Forks Fork thickness at base of forks in. (mm)
FD40Z: Min.1.77 (45)FD40/45/50: Min. 1.97 (50)
Chain Length over 17 links Max. 17.3 (440)
Hydraulic system Relief pressure PSI (MPa) 2,610.7 (18)Prope
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21. SERVICE DATA
4-8
21.3 TORQUE LISTFor unspecified bolts and nuts, use the torque specifications in this list.
Select the proper torque corresponding to the width across flats (b) ofbolts and nuts.
When replacing bolts and nuts, always use genuine Komatsu Forkliftparts that match the previous installation in size.
Thread diameterof bolt (mm)
(a)
Width acrossflat (mm)
(b)
Tightening torque
ft/lb kgfm Nm
68
101214
1013171922
9.73 ± 1.0323.2 ± 2.148.5 ± 5.082.6 ± 7.2131 ± 14
1.35 ± 0.153.2 ± 0.36.7 ± 0.711.5 ± 1.018.0 ± 2.0
13.2 ± 1.431.4 ± 2.965.7 ± 6.8112 ± 9.8177 ± 19
1618202224
2427303236
206 ± 21282 ± 29405 ± 43549 ± 58684 ± 72
28.5 ± 339 ± 356 ± 676 ± 8
94.5 ± 10
279 ± 29383 ± 39549 ± 58745 ± 78927 ± 98
2730333639
4148505560
973 ± 1001,270 ± 1401,630 ± 1802,030 ± 2102,420 ± 250
135 ± 15175 ± 20225 ± 25280 ± 30335 ± 35
1,320 ± 1401,720 ± 1902,210 ± 2402,750 ± 2903,280 ± 340
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22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
4-9
22. 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 periodicmaintenance. In addition, to further improve safety, the user should also perform periodic replacement of partsgiven in the table below. These parts, in particular, are closely relate to safety and fire prevention.
The material of these parts may change over time, or they may easily wear or deteriorate. However, it is difficult tojudge the condition of these parts simply by periodic maintenance. The parts listed should always be replaced aftera fixed, specified time has passed, regardless of their condition. This is necessary to ensure that these partsmaintain their full function at all times.
Note that if these parts show any abnormality before the replacement interval has passed, they should be repairedor replaced immediately.
If the hose clamps show any signs of deterioration, such as deformation or cracking, replace them at the same timeas the hoses.
Note that this periodic replacement is not covered by warranty.
IMPORTANT PARTS LIST
No. Part name Period (Years)
1 Brake valve, wheel cylinder cup and dust seal, etc. 1
2 Brake hose or tube 1 - 2
3 Power steering hose 2
4 Stop lamp switch (hydraulic type) 2 - 4
5 Fuel hose 2
6 Rubber parts inside power steering system 2
7 Lift chain 2 - 4
8 Hydraulic hose for lifting mechanism 1 - 2
• Use only genuine fuel hose.• If a poor quality hose is used, plasticizer material or other harmful material from the hose may
contaminate the LPG and cause the injection valve to stick. This will prevent the engine from starting.Pro
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23. MAINTENANCE SCHEDULE CHART
4-10
23. MAINTENANCE SCHEDULE CHARTPerform maintenance at intervals of months or operation hours, whichever occurs first. Refer to servicemanual for procedures not detailed here.
Service Item Page
First month or initial 200 hours service (only after the first one month)
Change oil in hydraulic tank, replace line filter, clean strainer, clean inside of tank 4-14
(All) Change oil in engine oil pan and replace engine oil filter cartridge 4-15
(Gasoline engine) Inspect and clean fuel filter sock (not replaceable) 4-16
Check, adjust engine valve clearance 4-16
Tighten (retorque) engine cylinder head bolts 4-16
Change oil in TORQFLOW transmission case, clean TORQFLOW transmission strainer 4-17
Change oil in differential case 4-18
Check spark plugs for burning of electrode, burning of insulator 4-18
Check air cleaner and replace filter when dirty 4-19
Check ignition timing 4-19
Check, adjust alternator belt (drive belt) tension 4-19
Tighten bolts and nuts (especially lug nuts, overhead guard, load backrest, and operator’s seat mounting bolts and nuts) 4-19
Check before operation items 3-18
Every 2 weeks or every 100 hours service
Grease lift chain 4-20
Every month or every 200 hours service
Check wheel rims for deformation, cracking and damage 4-20
Check wheel bearings for play and abnormal noise 4-20
Check hydraulic cylinders for looseness, deformation, cracking, damage and wear 4-20
Check all piping/tubing/connectors for oil leakage, deformation or damage 4-20
Check operation of hydraulic cylinders 4-20
Check hydraulic drift of lift cylinder 4-20
Check hydraulic drift of tilt cylinders 4-20
Check movement of work equipment control lever(s) 4-20
Check forks and fork stopper for deformation, cracking, damage and wear 4-20
Check forks for unevenness and twisting 4-20
Check mast for deformation, cracking, damage and wear 4-20
Check mast roller for play 4-20
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23. MAINTENANCE SCHEDULE CHART
4-11
Check chain and chain wheel for deformation, damage, rust and poor lubrication 4-20
Every month or every 200 hours service (continued)
Check chain wheel bearing for play 4-20
Check chain anchor bolt for deformation and damage 4-20
Check gear box for oil leakage, looseness of mount 4-20
Check mounting condition of power steering, check for looseness at connections 4-20
Check brake link for play, looseness, damage and wear 4-20
Check brake piping/tubing for damage, leakage, looseness, contact, looseness of brake tubing clips and disconnection at fittings 4-21
Check clearance between brake drum and lining, check brake for grabbing, dragging or pulling 4-21
Check shift lever for play, meshing 4-21
Check for oil leakage from transmission and differential cases 4-21
Check oil level in TORQFLOW transmission, add oil as necessary (Do not overfill) 4-21
Check inching pedal height when pedal is depressed 4-21
Change oil in engine oil pan 4-15
Check starting of engine 4-21
(Gas & LPG engines) Check idling speed 4-21
Check, clean radiator fins, check for damage 4-21
Check for catching, stalling and knocking when accelerating 4-21
Check air cleaner and replace filter when dirty 4-19
Check operation of maximum rpm 4-21
Check piping/tubing and connections/fittings for fuel/gas leakage 4-21
(LPG) Check the vaporizer for tar, drain 4-22
Check radiator hoses for cracking, damage 4-22
Check operating condition of radiator cap, check installation 4-22
Check fan for deformation, cracking, and damage 4-22
Check fan for looseness and mounting 4-22
Check, adjust fan belt tension 4-22
Check, adjust alternator belt (drive belt) tension 4-19
Check clearance of distributor points, check contact surface for roughness 4-22
Check spark plugs for burning of electrode, burning of insulator 4-18
(Diesel Engine) Drain water from fuel filter 4-23
Service Item Page
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23. MAINTENANCE SCHEDULE CHART
4-12
Check operation of starting switch; check meshing of pinion gear 4-24
Every month or every 200 hours service (continued)
Check specific gravity of battery electrolyte 4-24
Check wiring connections for looseness 4-24
Check ignition timing 4-19
Check overhead guard, load backrest for deformation, cracking, damage and looseness 4-25
Check operator’s seat mount for looseness and damage, check LPG cylinder mounting bracket 4-25
Grease all lubrication points 4-25
Every 500 hours service
(Diesel Engine) Replace fuel filter 4-23
Every 3 months or every 600 hours service
(Diesel engine) Replace engine oil filter cartridge 4-15
Check oil level in transmission case, add oil as necessary 4-17
Check oil level in differential case, add oil as necessary 4-18
Every 6 months or every 1,200 hours service
Check steering link for bending, damage and wear 4-25
Check knuckle for play, deformation and damage 4-25
Check for marked variation in minimum turning radius 4-25
Change oil in TORQFLOW transmission case, clean strainer 4-17
Change oil in differential case 4-18
Replace torque converter oil filter 4-26
Change brake oil/fluid 4-26
Check, adjust valve clearance 4-26
Measure compression pressure 4-26
(Diesel Engine) Check, adjust fuel injection timing, check and inspect fuel injection nozzles 4-26
Check PCV blow-by gas reduction system for clogging, damage 4-26
Check distributor cap centerpiece for wear 4-26
(LPG engine) Replace LPG filter element 4-26
Replace air cleaner filter 4-19
Change oil in hydraulic tank, replace hydraulic line filter, clean hydraulic tank strainer, clean inside of hydraulic tank 4-14
Service Item Page
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23. MAINTENANCE SCHEDULE CHART
4-13
Every 2,000 hours of service
(LPG engine) Replace LPG mixer air valve diaphragm, under normal operating conditions. Replace more often in cold or severe service applications. Replace O-ring for LPG tank valve. 4-26
Every 12 months or every 2,400 hours service
Check operation of brake master cylinder, check for oil leakage, damage and wear 4-26
Check operation of wheel cylinders, check for oil leakage, damage and wear 4-26
Check operation of brake drum, check for damage and wear 4-26
Check brake linings for wear 4-26
Check operating condition of brake shoe 4-26
Check brake adjustment lever and ratchet for wear and damage 4-26
Check brake spring for deterioration 4-26
Check brake back plate for deformation and cracking; Check mounting condition 4-26
Check axle for deformation, cracking and damage 4-27
Check mounting condition of differential 4-27
Check root (base) of forks for cracking (use color check) 4-27
Check roller shaft of loading equipment for cracking and damage 4-27
Check mast support for damage and wear 4-27
Check operation of relief valve; check relief pressure 4-27
Replace air breather 4-27
Check distributor cap (gasoline), distributor inside (IC ignition system) for cracking or damage 4-27
Clean inside of fuel tank 4-27
Clean inside of cooling system, clean radiator, replace coolant (glycol-based) 4-27
Check fuel injection pressure, injection amount, injector condition 4-28
(Gasoline engine) Inspect and clean fuel filter sock (not replaceable) 4-16
Tighten (retorque) engine cylinder head bolts 4-16
Check frame and cross member for cracking and damage 4-28
Every 18 months or every 3,600 hours service
Replace spark plugs 4-28
Service Item Page
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24. MAINTENANCE
4-14
24. MAINTENANCE24.1 FIRST MONTH OR INITIAL 200 HOURS SERVICECarry out this maintenance, for new lift trucks only, after the first one month or initial 200 hours of operation,whichever comes sooner.
24.1.1 HYDRAULIC EQUIPMENT� CHANGE OIL IN HYDRAULIC TANK, REPLACE LINE FILTER, CLEAN STRAINER, CLEAN INSIDE OF
TANK
1. Remove the drain plug at the bottom of the tank. Then remove thecover, take out the strainer, and wash it in flushing 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 reinstall the strainer.4. Replace the line filter, then install the cover.5. Add the specified amount of ISO # 32 hydraulic oil through the
dipstick hole, then check the oil level with the dipstick.
6. Start the engine, then operate the cylinders (lift, tilt) to the end oftheir travel 5 or 6 times to bleed the air.
NOTICE
Always use specified hydraulic oil.
FG35/45S, FG35/45BCS, FG40Z 11.0 U.S. gal. (41.6 L, 9.16 UK gal.)
FG40/45/50 8.70 U.S. gal. (32.9 L, 7.25 UK gal.)
FD40/45/50, FD40Z 14.53 U.S. gal.(55 L, 12.10 UK gal.)
Watch out for HOT OIL. Immediately after operations, the oil will be very hot. Wait for the oiltemperature to go down before starting this maintenance operation.
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24. MAINTENANCE
4-15
24.1.2 ENGINE� CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
GASOLINE/LPG ENGINE (TB45)CHANGE ENGINE OIL (See illustration item 1 for filler location)1. Remove the drain plug, drain the oil, then reinstall and tighten
the drain plug.2. Add the correct amount of specified engine oil.3. Check the oil level with the dipstick.
NOTICE
Oil refill amount: 8.5 quarts (8.0 L, 1.80 UK gal.) including new oil filter.
REPLACE ENGINE OIL FILTER (See illustration item 2 for location)1. Use a filter wrench to remove the oil filter cartridge.2. Clean the filter holder on the engine.3. Coat the threads on the holder and the seal on the new filter with clean engine oil.4. Install the new filter.
NOTICE
After installing the new oil filter cartridge, start the engine and check for oil leakage around the oil filter seal and at the oil pan drain plug.
When carrying out engine maintenance, stop the engine and wait for it to fully cool down.
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24. MAINTENANCE
4-16
DIESEL ENGINE (S6D102E)CHANGE ENGINE OIL (See illustration item 1 for filler location)1. Remove the drain plug, drain the oil, then reinstall and
tighten the drain plug.2. Remove the dipstick.3. Add the specified amount of engine oil. Use care to pre-
vent oil overflow.4. Check the oil level with the dipstick.
NOTICE
Oil refill amount: 3.04 U.S. gal. (11.5 L, 2.53 UK gal.) (includ-ing new oil filter)
REPLACE ENGINE OIL FILTER (See illustration item 2 for location)1. Use a filter wrench to remove the oil filter cartridge.2. Clean the oil filter holder.3. Coat the threads of the holder and the new filter seal
with clean engine oil.4. Install the new oil filter cartridge.
NOTICE
After installing the new oil filter, start the engine and check for oil leakage at the filter seal and the oil pan drain plug.
� (GASOLINE ENGINE) INSPECT AND CLEAN FUEL FILTER SOCK� CHECK, ADJUST ENGINE VALVE CLEARANCE� TIGHTEN (RETORQUE) ENGINE CYLINDER HEAD BOLTS
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24. MAINTENANCE
4-17
24.1.3 POWER TRAIN� CHANGE OIL IN TORQFLOW TRANSMISSION CASE, CLEAN TORQFLOW TRANSMISSION STRAINER
1. Remove the floor plate and check oil with dipstick.2. If the oil level is low, remove the dipstick and add oil.3. Remove the drain plug, drain the oil, then reinstall and tighten
the drain plug.4. Remove the mounting bolts, take out the strainer, and wash it
off in flushing oil.5. After washing the strainer, blow air from the inside of the
strainer to dry it completely, then reinstall the strainer.6. Add the specified amount of oil through the oil filler port.7. After filling with oil, check the oil level.
NOTICE
Always use specified oil or DEXRON II Automatic Transmis-sion Fluid.
Specified Oil Refill AmountTORQFLOW transmission(including torque converter)
17 quarts / 4.25 gal. (16.1 L, 3.54 UK gal.)
Watch out for HOT OIL. Immediately after operations, the oil will be very hot. Wait for the oiltemperature to go down before starting this maintenance operation.
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24. MAINTENANCE
4-18
� CHANGE OIL IN DIFFERENTIAL CASE
CHECK OIL LEVELRemove the level plug and check that the oil is near the bottom edgeof the plug hole.If the oil level is low, remove the oil filler plug and add oil.
CHANGE OIL1. Remove the oil filler plug, then remove the drain plug and drain
the oil.2. After draining the oil, reinstall and tighten the drain plug and add
the correct amount of specified oil through the oil filler.3. Check the oil level after filling with new oil.
NOTICE
Always use specified gear oil (SAE 90). For details, see “LUBRICANT LIST” on page 4-2.
RemarkOn the TORQFLOW transmission lift truck, each case has its own special oil, so it is necessary to check andchange the oil in the TORQFLOW transmission case in addition to checking and changing the oil in the differ-ential case in two separate operations.
� CHECK SPARK PLUGS FOR BURNING OF ELECTRODE, BURNING OF INSULATOR1. Remove a spark plug using the plug wrench provided with
the lift truck.2. Clean off any carbon buildup on the tip of the plug or the
surrounding area. See illustration at right.3. Measure gap (A) with plug gap gauge.
Specified Oil Refill AmountTORQFLOW transmission lift truck
3.43 U.S. gal. (13 L, 2.86 UK gal.)
Specified Spark Plugs
NGK B-4ESBPR-4ES (Noise suppression type)
Hitachi L47W
Watch out for HOT OIL. Immediately after operations, the oil will be very hot. Wait for the oiltemperature to go down before starting this maintenance operation.
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24. MAINTENANCE
4-19
� CHECK AIR CLEANER AND REPLACE FILTER WHEN DIRTY
NOTICE
The engine warranty will be voided if improper or aftermarket elements are used.
REPLACE RADIAL SEAL AIR FILTER1. 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 yourair cleaner has a safety filter, replace it every third primaryfilter change. Remove the safety filter as you would theprimary filter. Make sure you cover the air cleaner outlet tubeto avoid any unfiltered contaminant dropping into the engine.
3. Thoroughly clean air cleaner housing sealing surface andoutlet tube outer diameter. Then clean the inside of the outlettube using a clean cloth.
4. Inspect the old filter for leak clues. A streak of dust on theclean side of the filter is a telltale sign. Remove any cause ofleaks before installing new filter.
5. Inspect the new filter for damage, paying careful attention to the inside of the open end, which is the sealingarea. 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 cleanerhousing before securing the cover in place. Each new element sealing surface iscoated with a dry lubricant to aid in sealing. DO NOT USE COVER TO FORCEFILTER ELEMENT INTO PLACE. THIS WILL DAMAGE THE FILTER AND THEHOUSING. When seating element, apply hand pressure to outer edge of filter, notin 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.
� CHECK IGNITION TIMING� CHECK, ADJUST ALTERNATOR BELT (DRIVE BELT) TENSION
24.1.4 GENERAL� TIGHTEN BOLTS AND NUTS, ESPECIALLY LUG NUTS, OVERHEAD GUARD, LOAD BACKREST AND
OPERATOR’S SEAT MOUNTING BOLTS AND NUTS
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 orvice-versa: radial seal style filters are NOT interchangeable between diesel and gasolineengines.
• Never clean the radial seal air filter or use compressed air on it; this will damage the filter.Replace the air filter if dirty.
• It is important that all air cleaner latches are present and in good working condition as theyretain the air filter element in place. DO NOT operate the lift truck unless all latches are presentand in good working condition.
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24. MAINTENANCE
4-20
24.2 CHECK BEFORE OPERATIONFor details, see “CHECK BEFORE OPERATION” on page 3-18.
24.3 EVERY 2 WEEKS OR EVERY 100 HOURS SERVICE24.3.1 LOADING EQUIPMENT� GREASE LIFT CHAIN
24.4 EVERY MONTH OR EVERY 200 HOURS SERVICE24.4.1 TRAVEL EQUIPMENT� CHECK WHEEL RIMS FOR DEFORMATION, CRACKING AND DAMAGE� CHECK WHEEL BEARINGS FOR PLAY AND ABNORMAL NOISE
24.4.2 HYDRAULIC EQUIPMENT� CHECK HYDRAULIC CYLINDERS FOR LOOSENESS, DEFORMATION, CRACKING, DAMAGE AND
WEAR� CHECK ALL PIPING/TUBING/CONNECTORS FOR OIL LEAKAGE, DEFORMATION OR DAMAGE� CHECK OPERATION OF HYDRAULIC CYLINDERS� CHECK HYDRAULIC DRIFT OF LIFT CYLINDER� CHECK HYDRAULIC DRIFT OF TILT CYLINDERS� CHECK MOVEMENT OF WORK EQUIPMENT CONTROL LEVER(S)
24.4.3 LOADING EQUIPMENT� CHECK FORKS AND FORK STOPPER FOR DEFORMATION, CRACKING, DAMAGE AND WEAR� CHECK FORKS FOR UNEVENNESS AND TWISTING� CHECK MAST FOR DEFORMATION, CRACKING, DAMAGE AND WEAR� CHECK MAST ROLLER FOR PLAY� CHECK CHAIN AND CHAIN WHEEL FOR DEFORMATION, DAMAGE, RUST AND POOR LUBRICATION� CHECK CHAIN WHEEL BEARING FOR PLAY� CHECK CHAIN ANCHOR BOLT FOR DEFORMATION AND DAMAGE
24.4.4 STEERING SYSTEM� CHECK GEAR BOX FOR OIL LEAKAGE, LOOSENESS OF MOUNT� CHECK MOUNTING CONDITION OF POWER STEERING, CHECK FOR LOOSENESS AT CONNECTIONS� CHECK BRAKE LINK FOR PLAY, LOOSENESS, DAMAGE
AND WEAR1. Check the play and the height of the brake pedal when it is
depressed to check that it matches the specified values.
2. Test the brake while gradually increasing your speed from a lowspeed. Check that the brakes do not pull, grab or drag. Ifnecessary, adjust the brakes until they apply smoothly.
Play 0.12 - 0.28 in. (3 - 7 mm)Pedal height when depressed 3.54 - 3.94 in. (90 - 100 mm)
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24. MAINTENANCE
4-21
� CHECK BRAKE PIPING/TUBING FOR DAMAGE, LEAKAGE, LOOSENESS, CONTACT, LOOSENESS OF BRAKE TUBING CLIPS AND DISCONNECTION AT FITTINGS
� CHECK CLEARANCE BETWEEN BRAKE DRUM AND LINING, CHECK BRAKE FOR GRABBING, DRAGGING OR PULLING
24.4.5 POWER TRAIN� CHECK SHIFT LEVER FOR PLAY, MESHING� CHECK FOR OIL LEAKAGE FROM TRANSMISSION AND DIFFERENTIAL CASES� CHECK OIL LEVEL IN TORQFLOW TRANSMISSION, ADD OIL AS NECESSARYSee “CHANGE OIL IN TORQFLOW TRANSMISSION CASE, CLEAN TORQFLOW TRANSMISSION STRAINER”on page 4-17 for details.
� CHECK INCHING PEDAL HEIGHT WHEN PEDAL IS DEPRESSED
24.4.6 ENGINE� CHANGE OIL IN ENGINE OIL PANSee “CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE” on page 4-15
� CHECK STARTING OF ENGINE� (GAS & LPG) CHECK IDLING SPEED� CHECK, CLEAN RADIATOR FINS, CHECK FOR DAMAGE
CleaningBlow the radiator fins with compressed air, steam or water.
TestingCheck visually to ensure there are no dents or damage to the fins.
� CHECK FOR CATCHING, STALLING AND KNOCKING WHEN ACCELERATING� CHECK AIR CLEANER AND REPLACE FILTER WHEN DIRTYSee “CHECK AIR CLEANER AND REPLACE FILTER WHEN DIRTY” on page 4-19 for details.
� CHECK OPERATION OF MAXIMUM RPM� CHECK PIPING/TUBING AND CONNECTIONS/FITTINGS FOR FUEL/GAS LEAKAGE
Air pressure 142 psi (0.98 MPa) (10 kgf/cm2)Steam pressure 56 psi (0.39 MPa) (4 kgf/cm2)
Inspect the lift truck in an area where it will not obstruct other vehicles or workers.
Dirt may fly and get into your eyes, so always wear protective glasses or goggles.
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24. MAINTENANCE
4-22
� (LPG) CHECK THE VAPORIZER FOR TAR; DRAINThe vaporizer is a device used during LPG operation to control and reduce fuel pressure within the LPG cylinderand regulate vaporization. Tar, a thick, sticky liquid, is produced during this process and accumulates in thevaporizer. Excess tar buildup in the vaporizer adversely affects idling speed.
NOTICE
Tar must be drained from the vaporizer at least once per month.
1. Run the engine until it is fully warmed up to operating tempera-ture.
2. As the engine continues to run, close the service valve on theline from the LP tank.
3. Turn the ignition switch to the OFF position when the enginestops.
4. Place a rag under the drain valve to catch the draining tar.5. Remove the drain plug from the bottom of the vaporizer.6. Reinstall the drain plug after draining the tar onto the rag.
� CHECK RADIATOR HOSES FOR CRACKING, DAMAGE� CHECK OPERATING CONDITION OF RADIATOR CAP, CHECK INSTALLATION� CHECK FAN FOR DEFORMATION, CRACKING AND DAMAGE� CHECK FAN FOR LOOSENESS AND MOUNTING� CHECK, ADJUST FAN BELT TENSION� CHECK, ADJUST ALTERNATOR BELT (DRIVE BELT) TENSION� CHECK CLEARANCE OF DISTRIBUTOR POINTS, CHECK CONTACT SURFACE FOR ROUGHNESS� CHECK SPARK PLUGS FOR BURNING OF ELECTRODE, BURNING OF INSULATORSee “CHECK SPARK PLUGS FOR BURNING OF ELECTRODE, BURNING OF INSULATOR” on page 4-18 fordetails.
• Ensure that the service valve on the fuel feed line is turned fully to the OFF position.Otherwise, pressure in the line may cause operator injury when the drain plug is removed.
• Always wear protective glasses or goggles.
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24. MAINTENANCE
4-23
� (DIESEL ENGINE) DRAIN WATER FROM FUEL FILTER1. Locate the fuel filter (item 1).
2. Loosen the combination sensor plug and drain any water andsediment accumulated at the bottom of the filter.
NOTICE
• Fuel will also drain out of the fuel filter, so prepare a suitable container to catch it.
• Always be sure to wipe up any spilled fuel.
24.4.7 (DIESEL ENGINE) REPLACE FUEL FILTER
(See the illustration above for location)
1. Remove the combination sensor plug at the bottom of the cartridge.2. Use a filter wrench to remove the cartridge.3. Install the combination sensor plug on the new cartridge.4. Fill the new cartridge with clean fuel, coat the packing surface with a
thin layer of clean engine oil, then install.5. Loosen plug (1), then hand-pump knob (2) up and down to bleed air
bubbles from fuel. Continue until no more bubbles come out with thefuel.
6. Tighten plug (1).
When carrying out engine maintenance, stop the engine and wait for it to fully cool down.
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24. MAINTENANCE
4-24
24.4.8 ELECTRICAL COMPONENTS� CHECK OPERATION OF STARTING SWITCH; CHECK MESHING OF PINION GEAR� CHECK SPECIFIC GRAVITY OF BATTERY ELECTROLYTE
1. Charge the battery, and after charging, check that the battery elec-trolyte level is correct. If the electrolyte level is below the top of theelectrode plates, add distilled water to the top of the plates. Checkand clean battery caps and terminals. Check the battery case forcracking and stains caused by leakage.
2. Using a specific gravity meter and thermometer, measure thespecific gravity and temperature of the battery electrolyte.Insert the values measured in steps 1 and 2 in the formula belowand calculate S20, which is the specific gravity at 68°F (20°C).
St: Specific gravity (measured value) at t°Ct: Temperature of battery electrolyte (measured value)
NOTICE
• Normal value: S20 = 1.27 - 1.29• If specific gravity is below 1.225, check terminals, cables, charging system and repair as
necessary.
3. Charge the battery if necessary.
� CHECK WIRING CONNECTIONS FOR LOOSENESS� CHECK IGNITION TIMING
Specific gravity of electrolyte Condition of charge Charge
needed?1.2801.240
Fully charged1/4 discharged No
1.2101.130
1/2 dischargedFully discharged Yes
• Precautions when handling battery:• Battery electrolyte is dangerous. If it gets into your eyes or on your skin or clothes, wash it
off with large amounts of water quickly. If it gets into your eyes, seek medical attention immediately.
• Keep away from sparks or flame.• To avoid gas explosions, do not smoke or cause short circuits or sparks near the battery.
S20 St 0.0007 t 20–( )+=
RELATION BETWEEN SPECIFIC GRAVITYAND TEMPERATURE OF ELECTROLYTE
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24. MAINTENANCE
4-25
24.4.9 GENERAL� CHECK OVERHEAD GUARD, LOAD BACKREST FOR DEFORMATION, CRACKING, DAMAGE AND
LOOSENESS� CHECK OPERATOR’S SEAT MOUNT FOR LOOSENESS AND DAMAGE, CHECK LPG CYLINDER
MOUNTING BRACKET� GREASE ALL LUBRICATION POINTS1. Mast support (left and right: 2 points)2. Fork stopper (left and right: 2 points)3. Front axle support (left and right: 2 points)4. Steering axle
a. Center pin (front and rear: 2 points)b. Power Steering cylinder rod (left and right:
2 points)c. Knuckle joint (left and right: 2 points)d. King pin (left and right: 4 points)
24.5 EVERY 500 HOURS SERVICE� (DIESEL ENGINE) REPLACE FUEL FILTERSee “(DIESEL ENGINE) REPLACE FUEL FILTER” on page 4-23 for details.
24.6 EVERY 3 MONTHS OR EVERY 600 HOURS SERVICE24.6.1 ENGINE� (DIESEL) REPLACE ENGINE OIL FILTER CARTRIDGESee “CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE” on page 4-15 for details.
24.6.2 POWER TRAIN� CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL AS NECESSARYSee “CHANGE OIL IN TORQFLOW TRANSMISSION CASE, CLEAN TORQFLOW TRANSMISSION STRAINER”on page 4-17 for details.
� CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL AS NECESSARY See “CHANGE OIL IN DIFFERENTIAL CASE” on page 4-18 for details.
24.7 EVERY 6 MONTHS OR EVERY 1,200 HOURS SERVICE24.7.1 STEERING SYSTEM� CHECK STEERING LINK FOR BENDING, DAMAGE AND WEAR� CHECK KNUCKLE FOR PLAY, DEFORMATION AND DAMAGE� CHECK FOR MARKED VARIATION IN MINIMUM TURNING RADIUS� CHANGE OIL IN TORQFLOW TRANSMISSION CASESee “CHANGE OIL IN TORQFLOW TRANSMISSION CASE, CLEAN TORQFLOW TRANSMISSION STRAINER”on page 4-17 for details.
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24. MAINTENANCE
4-26
� CHANGE OIL IN DIFFERENTIALSee “CHANGE OIL IN DIFFERENTIAL CASE” on page 4-18 for details.
� REPLACE TORQUE CONVERTER OIL FILTER
NOTICE
Replace with specified oil filter.
24.7.2 BRAKE SYSTEM� CHANGE BRAKE OIL/FLUID
24.7.3 ENGINE� CHECK AND ADJUST VALVE CLEARANCE� MEASURE COMPRESSION PRESSURE� (DIESEL ENGINE) CHECK AND ADJUST FUEL INJECTION TIMING; CHECK AND INSPECT FUEL
INJECTION NOZZLES� CHECK PCV BLOW-BY GAS REDUCTION SYSTEM FOR CLOGGING OR DAMAGE� CHECK DISTRIBUTOR CAP CENTERPIECE FOR WEAR� (LPG) REPLACE LPG FILTER ELEMENT� REPLACE AIR CLEANER ELEMENTSee “CHECK AIR CLEANER AND REPLACE FILTER WHEN DIRTY” on page 4-19 for details.
� CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC LINE FILTER, CLEAN HYDRAULIC TANK STRAINER, CLEAN INSIDE OF HYDRAULIC TANK
See “CHANGE OIL IN HYDRAULIC TANK, REPLACE LINE FILTER, CLEAN STRAINER, CLEAN INSIDE OFTANK” on page 4-14 for details.
24.8 EVERY 2,000 HOURS SERVICE� (LPG) REPLACE LPG MIXER AIR VALVE DIAPHRAGM (UNDER NORMAL OPERATING CONDITIONS;
REPLACE MORE OFTEN IN COLD OR SEVERE SERVICE APPLICATIONS) REPLACE O-RING FOR LPG TANK VALVE
24.9 EVERY YEAR OR 2,400 HOURS SERVICE� CHECK OPERATION OF BRAKE MASTER CYLINDER, CHECK FOR OIL LEAKAGE, DAMAGE AND
WEAR� CHECK OPERATION OF WHEEL CYLINDERS, CHECK FOR OIL LEAKAGE, DAMAGE & WEAR� CHECK OPERATION OF BRAKE DRUM, CHECK FOR DAMAGE AND WEAR� CHECK BRAKE LININGS FOR WEAR� CHECK OPERATING CONDITION OF BRAKE SHOE� CHECK BRAKE ADJUSTMENT LEVER AND RATCHET FOR WEAR AND DAMAGE� CHECK BRAKE SPRING FOR DETERIORATION� CHECK BRAKE BACK PLATE FOR DEFORMATION AND CRACKING, CHECK MOUNTING CONDITION
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24. MAINTENANCE
4-27
24.9.1 TRAVEL SYSTEM� CHECK AXLE FOR DEFORMATION, CRACKING AND DAMAGE� CHECK MOUNTING CONDITION OF DIFFERENTIAL� CHECK ROOT (BASE) OF FORKS FOR CRACKING (USE COLOR CHECK)� CHECK ROLLER SHAFT OF LOADING EQUIPMENT FOR CRACKING AND DAMAGE� CHECK MAST SUPPORT FOR DAMAGE AND WEAR
24.9.2 HYDRAULIC EQUIPMENT� CHECK OPERATION OF RELIEF VALVE, CHECK RELIEF PRESSURE� REPLACE AIR BREATHER
24.9.3 ENGINE� CHECK DISTRIBUTOR CAP (GASOLINE), DISTRIBUTOR INSIDE (IC IGNITION) FOR CRACKING OR
DAMAGE� (ALL) CLEAN INSIDE OF FUEL TANK� CLEAN INSIDE OF COOLING SYSTEM, CLEAN RADIATOR, REPLACE COOLANT (GLYCOL-BASED)
Stop the lift truck on level ground.
1. After the engine has cooled off, open the drain valves at thebottom of the radiator and the engine cylinder block to drainthe water/coolant mixture.
2. After draining, close the drain valves. Fill the radiator withfresh water (tap water) and radiator flushing fluid through thewater filler, then run the engine at idling for approximately 15minutes.
3. Stop the engine, open the drain valves to drain the water, thenadd fresh water and run the engine at idling until clean, clearwater comes out of the drain valves (5 - 10 minutes).
4. Stop the engine, drain all the water from the drain valves, thenclose the drain valves and fill the radiator with fresh water and glycol-based coolant.
Water and Coolant CapacitiesTB45 gas engine 4.5 U.S. gal. (17 L, 3.75 UK gal.)S6D102E diesel engine 4.75 U.S. gal. (18 L, 3.96 UK gal.)
• After the engine has been operated, the coolant is HOT. There is a danger of burns and injury ifthe cooling water is drained immediately. Always wait for the engine to cool down beforedraining the coolant.
• The cleaning operation is carried out with the engine running. The lift truck may movesuddenly and unexpectedly, so never go under the lift truck during this operation. Never gounder the lift truck when the engine is running.
• Do not remove the radiator cap when the engine and coolant is hot. Boiling water and steammay spurt out. Always wait for the temperature to go down, then turn the radiator cap slowlyto release pressure gradually before removing the cap completely.
• Coolant is flammable. Keep it away from open flame and sparks.
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24. MAINTENANCE
4-28
NOTICE
• In cold areas, add long-life coolant. (For details, see “COLD WEATHER OPERATION” on page 3-40.• When not using glycol-based coolant, add rust prevention fluid to the radiator.• Always use appropriate products for the flushing fluid, rust prevention fluid and glycol-based
coolant.
� CHECK FUEL INJECTION PRESSURE, INJECTION AMOUNT, INJECTOR CONDITION� (GASOLINE ENGINE) INSPECT AND CLEAN FUEL FILTER SOCK� TIGHTEN (RETORQUE) ENGINE CYLINDER HEAD BOLTS
24.9.4 GENERAL� CHECK FRAME AND CROSSMEMBER FOR CRACKING AND DAMAGE
24.10 EVERY 18 MONTHS OR 3,600 HOURS SERVICE� REPLACE SPARK PLUGS
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25. REPLACEMENT PROCEDURES
4-29
25. REPLACEMENT PROCEDURES25.1 REPLACING FUSESFuses protect the electrical components and wiring from burning out.
25.1.1 CHASSIS FUSES
NOTICE
• When replacing the fuses, always turn OFF the electric power (turn the starting switch to the OFF position) first.
• Always replace the fuses with a fuse of the same capacity.
1. Turn the starting switch to the OFF position.2. Open the cover of the fuse box and replace necessary
fuses inside.To remove the cover from the fuse box, push the side faceof the cover lightly with your fingers and pull it out.Check the relationship between the fuses and the electricalcomponents when replacing. Fuses are numbered from leftto right in the illustration.
No. Capacity (Amp) Related Electrical Component
Lift truck without Operator Presence System(1) 10 Meter(2) 10 Back-up lamp(6) 15 Gas (non-diesel trucks only)(7) 15 Stop lamp(8) 15 Lamps(9) 10 Horn
Lift truck with Operator Presence System(1) 10 Meter(2) 15 Main relay(3) 15 Engine controller(6) 10 Starter relay(7) 7.5 Mast relay(8) 10 Stop lamp(9) 15 Lamps(10) 10 Horn
10 15 15 10
7.5 10 15 107.5 10 15
LIFT TRUCK WITH OPERATOR PRESENCE SYSTEM
1015 15
10
10
10
10 10 15
LIFT TRUCK WITHOUT OPERATOR PRESENCE SYSTEM
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25. REPLACEMENT PROCEDURES
4-30
25.1.2 ENGINE FUSES AND RELAYS – TB45 ENGINE (GAS AND LP)
NOTICE
• When replacing the fuses, always turn OFF the electric power (turn the starting switch to the OFF position) first.
• Always replace the fuses with a fuse of the same capacity.
The ENGINE fuses and relays are located in separate boxes mounted at one corner of the engine under aprotective metal cover as viewed from the top.
1. Turn the starting switch to the OFF position.2. Open the engine bonnet and remove the protective metal cover.3. Remove the cover of the fuse box or relay box and replace the failed component.
To remove the cover from the fuse box or relay box, push the side face of the cover lightly with your fingers andpull it out.
Check the relationship between the fuses and the electrical components when replacing.
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25. REPLACEMENT PROCEDURES
4-31
25.2 REPLACING TIRES1. Stop the lift truck on a flat, safe area and apply the parking brake.2. Chock the wheel diagonally across from the wheel to be replaced.
3. Using a lug wrench, loosen the lug nuts until they can be turned by hand.
4. Place the jack on the jacking point and raise the lift truck up until thewheel to be replaced clears the ground.
5. Remove the lug nuts, then remove the wheel.
6. Install the replacement wheel on the hub and hand tighten the lugnuts to hold the wheel in place.
7. Tighten the lug nuts again with a lug wrench, using a diagonal “criss-cross” or star pattern, ensuring that the wheel is snugly in place, butnot fully tightened.
8. Let the jack down slowly to lower the lift truck. Tighten the lug nuts tothe specified torque. (For specified torque, see “TORQUE LIST” onpage 4-8.)
9. Adjust the tire inflation pressure to the set pressure (For details ofthe set inflation pressure, see “SERVICE DATA” on page 4-5.).
• After confirming that the rim mating bolts are tight, loosen the lug nuts.• NEVER loosen the rim mating bolts by mistake.
Jack up the fork lift truck after confirming that the jack will not slip. NEVER place any part of your bodyunder any part of the fork lift truck!
Ask a tire and wheel specialist to carry out disassembly andassembly of tires and wheels.
• Always ask a specialist to carry out disassembly of the tires, tubes and rims, and for inflationof the tires. The tires used on forklift trucks are at a high inflation pressure, so operations withtires are extremely dangerous.
• The tires are inflated to a high pressure, so deformed or cracked rims are extremelydangerous.
• Check carefully before inflating tires. NEVER use tires with deformed or cracked rims.• Before inflating the tires, adjust the pressure of the air compressor to the correct set pressure
so that the tires are not inflated above the set pressure.
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25. REPLACEMENT PROCEDURES
4-32
25.3 REPLACING LAMPSCheck for any blown fuses or disconnections in the wiring harnesses,and replace the lamps as necessary.
Lamp FunctionGas Engine
Trucks(12 Volt System)
Diesel Engine Trucks
(24 Volt System)Head lamp 55 W 70 WTurn signal lamp 23 W 25 WDriving (clearance) lamp 8 W 5 WStop lamp 27 WBack-up lamp 8 WWarning lamp 1.4 WMeter lighting lamp 3.4 W 3 W
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26. LIFT TRUCK WASHING PROCEDURE
4-33
26. LIFT TRUCK WASHING PROCEDURE26.1 GENERAL PRECAUTIONS
• Before washing, ensure that the controller and all other electrical equipment sensitive to water is protectedfrom 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 removewater droplets before using the truck connectors and electrical components. (Water droplets may run along thewiring 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 waterbefore using the truck.
• When removing dirt from electronic parts (such as printed circuit boards), use a commercially available, spray-type electronic equipment cleaner.
26.2 WASHING INSTRUCTIONS
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 thefollowing 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 theON position, make sure that there is no abnormal-ity, and then start operation.
When washing your lift truck, observe the following instructions to safeguard the truck. Wet electrical equipment will result in the lift truck malfunctioning.
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.
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26. LIFT TRUCK WASHING PROCEDURE
4-34
No. Spot 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).
2• Dashboard Front• Pedals• Floor Plate
3 • Front & Rear Tires• Front & Rear Axles
• Wash using high pressure steam or flush with water from ahose.
• 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.
Other Precautions
• 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 floorplate, cover the following parts and components with atarpaulin 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.
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27. CHECKING LPG FUEL SYSTEM FOR LEAKS
4-35
27. CHECKING LPG FUEL SYSTEM FOR LEAKS• See the "Safety" chapter for all safety precautions concerning LPG fuel systems.• Before testing, make sure the LPG 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.
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NOTES:
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READ AND FOLLOW ALL SAFETY PRECAUTIONS. FAILURE TO DO SO MAY RESULT IN SERIOUS
INJURY OR DEATH.
TECHNICAL DATA
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28. TECHNICAL DATA
5-1
28. TECHNICAL DATA
Most values shown in these tables are rounded. Therefore, direct conversion between metric and English or Imperialmay be slightly different from those shown. The performance of machines is affected by the condition of the vehicleand how it is equipped as well as the nature and condition of the operating area. If these specifications are critical orif your needs exceed the specifications shown here, discuss the proposed application with your authorized dealer.
28.1 3.5 & 4.5-TON CUSHION TIRE & BOXCAR SPECIALDESCRIPTION UNIT FG35ST-8 FG35BCS-8 FG45ST-8 FG45BCS-8
• GENERALPower Type Gasoline LPG Gasoline LPGOperation Type Sit-DownCapacity @ 24 in. (600 mm) load center lbs (kg) 8,000 (3,630) 10,000 (4,535)Load distance from center axle (2-stage mast) in. (mm) 17.9 (455)Load distance from center axle (3-stage mast) in. (mm) 20.2 (515)Wheelbase in. (mm) 63.0 (1,600)
• WEIGHTService weight (includes 2-stage std. mast & forks) lbs (kg) 12,960
(5,880)13,340 (6,050) 14,780 (6,705) 15,070 (6,835)
• TIRETire type CushionTire size, front 22x9x16 22x6x16 DualTire size, rear 18x7x12 1/8 18x6x12 1/8 18x7x12 1/8 18x7x12 1/8Number of wheel, front/rear x = driven 2x/2 4x/2Tread (center of tires), front/rear in. (mm) 38.8 (985)/39.8 (1,010) 41.9 (1,065)/39.8 (1,010)
• DIMENSIONSTilting angle, 2-stage (FV) masts, forward/backward deg. 6/6
Tilting angle, 3-stage (TFV) masts, forward/backward deg. 6/6
Mast height, lowered (2-stage std. mast) in. (mm) 91.0 (2,310) 95.0 (2,410)Mast height, extended (2-stage std. mast) in. (mm) 179.0 (4,545) 178.0 (4,520)Maximum fork height (2-stage std. mast) in. (mm) 131.0 (3,330) 130.0 (3,300)Free lift height (2-stage std. mast) in. (mm) 7.0 (180)Height overhead guard in. (mm) 83.7 (2,125)Length to fork face (2-stage mast) in. (mm) 104.1 (2,645) 95.9 (2,435) 108.3 (2,750) 99.6 (2,530)Length to fork face (3-stage mast) in. (mm) 106.4 (2,705) 98.2 (2,495) 110.6 (2,810) 102.3 (2,605)Overall width, at drive tires in. (mm) 48.0 (1,220) 53.9 (1,370)Forks, thickness x width x length in. (mm) 2.0x6.0x42.0 (50x150x1070)Carriage width/ITA Class in. (mm) 46.9 (1,190)/IIIGround clearance, under mast in. (mm) 4.0 (100)Ground clearance, center of wheelbase in. (mm) 4.9 (125)Right angle stacking aisle (2-stage mast) in. (mm) 107.9 (2,740) 100.4 (2,550) 111.6 (2,835) 105.7 (2,685)Right angle stacking aisle (3-stage mast) in. (mm) 110.2 (2,800) 102.7 (2,610) 113.9 (2,895) 108.0 (2,745)Turning radius, outside in. (mm) 90.0 (2,285) 82.5 (2,095) 93.7 (2,380) 87.8 (2,230)
• PERFORMANCETravel speed, forward, loaded/unloaded mph (km/h) 9.6 (15.5)/9.6 (15.5)Lifting speeds, loaded/unloaded (2-stage mast) fpm (mm/s) 112 (570)/114 (580) 93 (470)/95 (480)Lifting speeds, loaded/unloaded (3-stage mast) fpm (mm/s) 108 (550)/110 (560) 89 (450)/91 (460)Lowering speed, loaded/unloaded (2-stage mast) fpm (mm/s) 102 (520)/93 (470) 95 (480)/85 (430)Lowering speed, loaded/unloaded (3-stage mast) fpm (mm/s) 98 (500)/89 (450) 91 (460)/81 (410)Maximum drawbar pull, loaded lbs (kN) 7,730 (34.4) 7,500 (33.3)Maximum gradeability, loaded/unloaded at 1 mph % 40/18 36/18 32/16 29/16Service brake, operation/control Foot/HydraulicParking brake, operation/control Hand/MechanicalSteering, type Hydrostatic, Power
• DRIVEBattery voltage/capacity (20 hour rating) V/Ah 12/60Engine model TB45ERated output (SAE Gross) HP (kW) @ rpm 95 (71) @ 2400
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28. TECHNICAL DATA
5-2
Maximum torque (SAE Gross) lb-ft (Nm) @ rpm 203 (275) @ 1600No. of cylinder/displacement cu. in. (cm3) 6/273 (4,478)Cylinder bore x stroke in. (mm) 3.9 (99.5)x3.8 (96)Fuel tank capacity U.S. gallons (liters) 15.9 (60)
• OTHERRelief pressure, maximum psi (bar) 2,700 (186)Hydraulic tank capacity U.S. gallons (liters) 12.4 (47)Clutch Torque converterTransmission PowershiftAir cleaner type Cyclone
28.1 3.5 & 4.5-TON CUSHION TIRE & BOXCAR SPECIAL (Continued)DESCRIPTION UNIT FG35ST-8 FG35BCS-8 FG45ST-8 FG45BCS-8
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28. TECHNICAL DATA
5-3
28.2 4-TON PNEUMATIC TIRE COMPACT CHASSISDESCRIPTION UNIT FG40ZT-8 FG40ZT2-8 FD40ZT-8 FD40ZT2-8
• GENERALPower Type Gasoline DieselOperation Type Sit-DownCapacity @ 24 in. (600 mm) load center lbs (kg) 8,000 (3,630)Load distance from center axle (2-stage mast) in. (mm) 20.0 (510)Load distance from center axle (3-stage mast) in. (mm) 21.3 (540)Wheelbase in. (mm) 72.1 (1,830)
• WEIGHTService weight (includes 2-stage std. mast & forks) lbs (kg) 12,850 (5,830) 13,180 (5,980)
• TIRETire type PneumaticTire size, front 250-15-16PR (I)Tire size, rear 7.00-12-12PR (I)Number of wheel, front/rear x = driven 2x/2Tread (center of tires), front/rear in. (mm) 43.7 (1,110)/44.1 (1,120)
• DIMENSIONSTilting angle, 2-stage (FV) masts, forward/backward deg. 6/12Tilting angle, 3-stage (TFV) masts, forward/backward deg. 6/6Mast height, lowered (2-stage std. mast) in. (mm) 92.5 (2,350)Mast height, extended (2-stage std. mast) in. (mm) 179.0 (4,545)Maximum fork height (2-stage std. mast) in. (mm) 131.0 (3,330)Free lift height (2-stage std. mast) in. (mm) 7.0 (180)Height overhead guard in. (mm) 86.2 (2,190)Length to fork face (2-stage mast) in. (mm) 115.3 (2,930)Length to fork face (3-stage mast) in. (mm) 116.6 (2,960)Overall width, at drive tires in. (mm) 52.8 (1,340)Forks, thickness x width x length in. (mm) 2.0x6.0x42.0 (50x150 x1,070)Carriage width/ITA Class in. (mm) 46.9 (1,190)/IIIGround clearance, under mast in. (mm) 5.5 (140)Ground clearance, center of wheelbase in. (mm) 6.7 (170)Right angle stacking aisle (2-stage mast) in. (mm) 120.2 (3,055)Right angle stacking aisle (3-stage mast) in. (mm) 121.5 (3,085)Turning radius, outside in. (mm) 100.2 (2,545)
• PERFORMANCETravel speed, forward, loaded/unloaded mph (km/h) 11.8 (19.0)/
12.7 (20.5)13.4 (21.5)/14.3 (23.0)
11.2 (18.0)/12.1 (19.5)
12.4 (20.0)/13.7 (22.0)
Lifting speeds, loaded/unloaded (2-stage mast) fpm (mm/s) 114 (580)/116 (590) 110 (560)/116 (590)Lifting speeds, loaded/unloaded (3-stage mast) fpm (mm/s) 110 (560)/112 (570) 102 (520)/108 (550)Lowering speed, loaded/unloaded (2-stage mast) fpm (mm/s) 102 (520)/93 (470) 95 (480)/108 (550)Lowering speed, loaded/unloaded (3-stage mast) fpm (mm/s) 98 (500)/89 (450)Maximum drawbar pull, loaded lbs (kN) 6,830 (30.4) 8,815 (40.2) 7,230 (32.2) 9,760 (43.4)Maximum gradeability, loaded/unloaded at 1 mph % 32/21 47/21 35/21 52/21Service brake, operation/control Foot/HydraulicParking brake, operation/control Hand/MechanicalSteering, type Hydrostatic, Power
• DRIVEBattery voltage/capacity (20 hour rating) V/Ah 12/60 24/70Engine model TB45E S6D102ERated output (SAE Gross) HP (kW) @ rpm 95 (71) @ 2400Maximum torque (SAE Gross) lb-ft (Nm) @ rpm 203 (275) @ 1600 275 (372) @ 1000No. of cylinder/displacement cu. in. (cm3) 6/273 (4,478) 6/359 (5,880)Cylinder bore x stroke in. (mm) 3.9 (99.5)x3.8 (96) 4.0 (102)x4.7 (120)
Fuel tank capacity U.S. gallons (liters) 22.5 (85)
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28. TECHNICAL DATA
5-4
• OTHERRelief pressure, maximum psi (bar) 2,700 (186)
Hydraulic tank capacity U.S. gallons (liters) 14.5 (55)
Clutch Torque convertorTransmission PowershiftAir cleaner type Cyclone
28.2 4-TON PNEUMATIC TIRE COMPACT CHASSIS (Continued)DESCRIPTION UNIT FG40ZT-8 FG40ZT2-8 FD40ZT-8 FD40ZT2-8
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28. TECHNICAL DATA
5-5
28.3 4-TON PNEUMATIC TIRE 1 & 2-SPEEDDESCRIPTION UNIT FG40T-8 FG40T2-8 FD40T-8 FD40T2-8
• GENERALPower Type Gasoline DieselOperation Type Sit-DownCapacity @ 24 in. (600 mm) load center lbs (kg) 9,000 (4,080)Load distance from center axle (2-stage mast) in. (mm) 21.5 (545)Load distance from center axle (3-stage mast) in. (mm) 21.5 (545)Wheelbase in. (mm) 78.7 (2,000)
• WEIGHTService weight (includes 2-stage std. mast & forks) lbs (kg) 14,030
(6,365)14,030 (6,365)
14,420 (6,540)
14,420 (6,540)
• TIRETire type PneumaticTire size, front 300-15-18PR (I)Tire size, rear 7.00-12-12PR (I)Number of wheel, front/rear x = driven 2x/2Tread (center of tires), front/rear in. (mm) 45.3 (1,150)/44.1 (1,120)
• DIMENSIONSTilting angle, 2-stage (FV) masts, forward/backward deg. 6/12Tilting angle, 3-stage (TFV) masts, forward/backward deg. 6/6Mast height, lowered (2-stage std. mast) in. (mm) 95.0 (2,415)Mast height, extended (2-stage std. mast) in. (mm) 178.0 (4,520)Maximum fork height (2-stage std. mast) in. (mm) 130.0 (3,300)Free lift height (2-stage std. mast) in. (mm) 7.0 (180)Height overhead guard in. (mm) 88.8 (2,225)Length to fork face (2-stage mast) in. (mm) 122.2 (3,105)Length to fork face (3-stage mast) in. (mm) 122.2 (3,105)Overall width, at drive tires in. (mm) 57.1 (1,450)Forks, thickness x width x length in. (mm) 2.0x6.0x42.0 (50x150 x1,070)Carriage width/ITA Class in. (mm) 46.9 (1,190)/IIIGround clearance, under mast in. (mm) 5.5 (140)Ground clearance, center of wheelbase in. (mm) 8.7 (220)Right angle stacking aisle (2-stage mast) in. (mm) 129.8 (3,295)Right angle stacking aisle (3-stage mast) in. (mm) 129.8 (3,295)Turning radius, outside in. (mm) 108.3 (2,750)
• PERFORMANCETravel speed, forward, loaded/unloaded mph (km/h) 11.8 (19.0)/
12.7 (20.5)14.9 (24.0)/16.2 (26.0)
11.2 (18.0)/12.1 (19.5)
9.3 (15.0)/10.3 (16.5)
Lifting speeds, loaded/unloaded (2-stage mast) fpm (mm/s) 95 (480)/97 (490) 110 (560)/116 (590)Lifting speeds, loaded/unloaded (3-stage mast) fpm (mm/s) 91 (460)/93 (470) 85 (430)/91 (460)Lowering speed, loaded/unloaded (2-stage mast) fpm (mm/s) 95 (480)/85 (430) 95 (480)/108 (550)Lowering speed, loaded/unloaded (3-stage mast) fpm (mm/s) 91 (460)/81 (410)Maximum drawbar pull, loaded lbs (kN) 6,830 (30.4) 8,815 (36.3) 7,180 (31.9) 8,360 (37.2)Maximum gradeability, loaded/unloaded at 1 mph % 28/22 35/22 31/22 39/22Service brake, operation/control Foot/HydraulicParking brake, operation/control Hand/MechanicalSteering, type Hydrostatic, Power
• DRIVEBattery voltage/capacity (20 hour rating) V/Ah 12/60 24/70Engine model TB45E S6D102ERated output (SAE Gross) HP (kW) @ rpm 95 (71.0) @ 2400 95 (71.0) @ 2150Maximum torque (SAE Gross) lb-ft (Nm) @ rpm 203 (275) @ 1600 275 (372) @ 1000No. of cylinder/displacement cu. in. (cm3) 6/273 (4,478) 6/359 (5,880)Cylinder bore x stroke in. (mm) 3.9 (99.5)x3.8 (96) 4.0 (102)x4.7 (120)
Fuel tank capacity U.S. gallons (liters) 26.4 (100)
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28. TECHNICAL DATA
5-6
• OTHERRelief pressure, maximum psi (bar) 2,700 (186)
Hydraulic tank capacity U.S. gallons (liters) 14.5 (55)
Clutch Torque converterTransmission PowershiftAir cleaner type Cyclone
28.3 4-TON PNEUMATIC TIRE 1 & 2-SPEED (Continued)DESCRIPTION UNIT FG40T-8 FG40T2-8 FD40T-8 FD40T2-8
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28. TECHNICAL DATA
5-7
28.4 4.5-TON PNEUMATIC TIRE 1 & 2-SPEEDDESCRIPTION UNIT FG45T-8 FG45T2-8 FD45T-8 FD45T2-8
• GENERALPower Type Gasoline DieselOperation Type Sit-DownCapacity @ 24 in. (600 mm) load center lbs (kg) 10,000 (4,535)Load distance from center axle (2-stage mast) in. (mm) 21.5 (545)Load distance from center axle (3-stage mast) in. (mm) 21.5 (545)Wheelbase in. (mm) 78.7 (2,000)
• WEIGHTService weight (includes 2-stage std. mast & forks) lbs (kg) 14,730 (6,680) 15,110 (6,855)
• TIRETire type PneumaticTire size, front 300-15-18PR (I)Tire size, rear 7.00-12-12PR (I)Number of wheel, front/rear x = driven 2x/2Tread (center of tires), front/rear in. (mm) 45.3 (1,150)/44.1 (1,120)
• DIMENSIONSTilting angle, 2-stage (FV) masts, forward/backward deg. 6/12Tilting angle, 3-stage (TFV) masts, forward/backward deg. 6/6Mast height, lowered (2-stage std. mast) in. (mm) 95.0 (2,415)Mast height, extended (2-stage std. mast) in. (mm) 178.0 (4,520)
130.0 (3,300)Maximum fork height (2-stage std. mast) in. (mm)Free lift height (2-stage std. mast) in. (mm) 7.0 (180)Height overhead guard in. (mm) 88.8 (2,225)Length to fork face (2-stage mast) in. (mm) 124.0 (3,150)Length to fork face (3-stage mast) in. (mm) 124.0 (3,150)Overall width, at drive tires in. (mm) 57.1 (1,450)Forks, thickness x width x length in. (mm) 2.0x6.0x42.0 (50x150x1,070)Carriage width/ITA Class in. (mm) 46.9 (1,190)/IIIGround clearance, under mast in. (mm) 5.5 (140)Ground clearance, center of wheelbase in. (mm) 8.7 (220)Right angle stacking aisle (2-stage mast) in. (mm) 130.9 (3,325)Right angle stacking aisle (3-stage mast) in. (mm) 130.9 (3,325)Turning radius, outside in. (mm) 109.5 (2,780)
• PERFORMANCETravel speed, forward, loaded/unloaded mph (km/h) 11.2 (18.0)/
12.1 (19.5)14.6 (23.5)/16.2 (26.0)
10.9 (17.5)/11.8 (19.0)
13.7 (22.0)/15.2 (24.5)
Lifting speeds, loaded/unloaded (2-stage mast) fpm (mm/s) 95 (480)/97 (490) 91 (460)/95 (480)Lifting speeds, loaded/unloaded (3-stage mast) fpm (mm/s) 91 (460)/93 (470) 85 (430)/91 (460)Lowering speed, loaded/unloaded (2-stage mast) fpm (mm/s) 95 (480)/85 (430) 89 (450)/89 (450)Lowering speed, loaded/unloaded (3-stage mast) fpm (mm/s) 91 (460)/81 (410)Maximum drawbar pull, loaded lbs (kN) 6,610 (29.4) 8,165 (36.3) 6,890 (30.6) 8,440 (37.5)Maximum gradeability, loaded/unloaded at 1 mph % 26/21 32/31 29/21 35/21Service brake, operation/control Foot/HydraulicParking brake, operation/control Hand/MechanicalSteering, type Hydrostatic, Power
• DRIVEBattery voltage/capacity (20 hour rating) V/Ah 12/60 24/70Engine model TB45E S6D102ERated output (SAE Gross) HP (kW) @ rpm 95 (71) @ 2400 95 (71) @ 2150Maximum torque (SAE Gross) lb-ft (Nm) @ rpm 203 (275) @ 1600 275 (372) @ 1000No. of cylinder/displacement cu. in. (cm3) 6/273 (4,478) 6/359 (5,880)Cylinder bore x stroke in. (mm) 3.9 (99.5)x3.8 (96) 4.0 (102)x4.7 (120)
Fuel tank capacity U.S. gallons (liters) 26.4 (100)
• OTHER
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28. TECHNICAL DATA
5-8
Relief pressure, maximum psi (bar) 2,700 (186)
Hydraulic tank capacity U.S. gallons (liters) 14.5 (55)
Clutch Torque converterTransmission PowershiftAir cleaner type Cyclone
28.4 4.5-TON PNEUMATIC TIRE 1 & 2-SPEED (Continued)DESCRIPTION UNIT FG45T-8 FG45T2-8 FD45T-8 FD45T2-8
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28. TECHNICAL DATA
5-9
28.5 5-TON PNEUMATIC TIREDESCRIPTION UNIT FG50AT2-8 FD50AT2-8
• GENERALPower Type Gasoline DieselOperation Type Sit-DownCapacity @ 24 in. (600 mm) load center lbs (kg) 11,000 (5,000)Load distance from center axle (2-stage mast) in. (mm) 21.7 (550)Load distance from center axle (3-stage mast) in. (mm) 21.7 (550)Wheelbase in. (mm) 78.7 (2,000)
• WEIGHTService weight (includes 2-stage std. mast & forks) lbs (kg) 16,060 (7,285) 16,440 (7,455)
• TIRETire type PneumaticTire size, front 300-15-18PR (I)Tire size, rear 7.00x12x16PR (I)Number of wheel, front/rear x = driven 2x/2Tread (center of tires), front/rear in. (mm) 45.3 (1,150)/44.1 (1,120)
• DIMENSIONSTilting angle, 2-stage (FV) masts, forward/backward deg. 6/12Tilting angle, 3-stage (TFV) masts, forward/backward deg. 6/6Mast height, lowered (2-stage std. mast) in. (mm) 98.5 (2,500)Mast height, extended (2-stage std. mast) in. (mm) 178.0 (4,520)Maximum fork height (2-stage std. mast) in. (mm) 130.0 (3,300)Free lift height (2-stage std. mast) in. (mm) 7.0 (180)Height overhead guard in. (mm) 88.8 (2,255)Length to fork face (2-stage mast) in. (mm) 124.2 (3,155)Length to fork face (3-stage mast) in. (mm) 124.2 (3,155)Overall width, at drive tires in. (mm) 57.1 (1,450)Forks, thickness x width x length in. (mm) 2.2x6.0x42.0 (55x150x1,070)Carriage width/ITA Class in. (mm) 46.9 (1,190)/IVGround clearance, under mast in. (mm) 5.5 (140)Ground clearance, center of wheelbase in. (mm) 8.7 (220)Right angle stacking aisle (2-stage mast) in. (mm) 131.1 (3,330)Right angle stacking aisle (3-stage mast) in. (mm) 131.1 (3,330)Turning radius, outside in. (mm) 109.5 (2,780)
• PERFORMANCETravel speed, forward, loaded/unloaded mph (km/h) 13.1 (21.0)/14.9 (24.0)Lifting speeds, loaded/unloaded (2-stage mast) fpm (mm/s) 95 (480)/97 (490) 79 (400)/95 (480)Lifting speeds, loaded/unloaded (3-stage mast) fpm (mm/s) 91 (460)/93 (470) 79 (400)/89 (450)Lowering speed, loaded/unloaded (2-stage mast) fpm (mm/s) 89 (450)/89 (450)Lowering speed, loaded/unloaded (3-stage mast) fpm (mm/s) 95 (480)/83 (420)Maximum drawbar pull, loaded lbs (kN) 8,165 (36.3) 8,370 (37.2)Maximum gradeability, loaded/unloaded at 1 mph % 29.5/21.0 32.0/27.0Service brake, operation/control Foot/HydraulicParking brake, operation/control Hand/MechanicalSteering, type Hydrostatic, Power
• DRIVEBattery voltage/capacity (20 hour rating) V/Ah 12/60 24/70Engine model TB45E S6D102ERated output (SAE Gross) HP (kW) @ rpm 95 (71) @ 2400 95 (71) @ 2150Maximum torque (SAE Gross) lb-ft (Nm) @ rpm 203 (275) @ 1600 275 (372) @ 1000No. of cylinder/displacement cu. in. (cm3) 6/273 (4,478) 6/359 (5,880)Cylinder bore x stroke in. (mm) 3.9 (99.5)x3.8 (96) 4.0 (102)x4.7 (120)
Fuel tank capacity U.S. gallons (liters) 26.4 (100)
• OTHERRelief pressure, maximum psi (bar) 2,700 (186)
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28. TECHNICAL DATA
5-10
Hydraulic tank capacity U.S. gallons (liters) 14.5 (55)
Clutch Torque ConverterTransmission PowershiftAir cleaner type Cyclone
28.5 5-TON PNEUMATIC TIRE (Continued)DESCRIPTION UNIT FG50AT2-8 FD50AT2-8
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KOMATSU FORKLIFT USA, LLC
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