AEE08E1-03

AEE08E1-03

F D 1 0 0 / 1 6 0 E - 8

Operation & Maintenance Manual FORKLIFT TRUCK

FD100 / 115 -8 FD135 / 150E 150E-8 FD160E -8

WARNING

2-4-1 Shiba-koen, Minato-ku, Tokyo105-0011, Tokyo105-0011, Japan

PRINTED IN JAPAN 12-07(01)0150101)10001

3

Unsafe use of this lift truck may cause serious injury or death. Operators and maintenance personnel must read this manual and be sure that they understand its contents before operating, inspecting, or carrying out maintenance on this lift truck. This manual should be kept near the lift truck for reference and periodically reviewed by all operators and maintenance personnel who will come into contact with it.

INTRODUCTION

1

11

1-1

INTRODUCTION

1.1 ABOUT THIS MANUAL

1. INTRODUCTION

1

1.1 ABOUT THIS MANUAL

1

This manual describes procedures for proper operation, inspection, and maintenance of this lift truck, and rules you must follow for your safety. Some actions involved in operation and maintenance of the lift truck can cause a serious accident if they are not done in the manner described in this manual.

WARNING This manual describes fundamental prohibitions and precautions for operations, inspections, and maintenance of this lift truck. Failure to follow these instructions will result in a serious bodily injury or damage. Operators and service staffs must follow the followings before conducting operations, inspections, and maintenance of this lift truck. Operators must understand this manual for conducting safety control of this li ft truck.

• Read this manual carefully and understand it fully. fully. • Make sure you fully understand the instructions and safety indicators of this manual. Be sure to store this manual in the designated location for the Operation and Maintenance Manual as shown below, so that it will be avail for the concerned persons repeatedly as needed. If this manual has been lost or has become dirty or worn and cannot be read, request a replacement manual from your KOMATSU KOMATSU FORKLIFT distributor. When you transfer this lift truck to others, make sure to attach this manual together. together. Continuing improvements in the design of this lift truck may not be reflected in this manual. Consult Komatsu Utility Co., Ltd. FORKLIFT COMPANY or your KOMATSU FORKLIFT distributor for the latest available information on your lift truck or for questions regarding information in this manual.

Storage location for Operation and Maintenance Manual ・Storage compartment (1) under the operator's seat

1-2

INTRODUCTION

1.2 ENGINE MOUNTED ON THIS LIFT TRUCK

1.2 ENGINE MOUNTED ON THIS LIFT TRUCK

1

1.2.1 EXHAUST GAS CONTROL

1

The engine mounted on this lift truck is approved by the following diesel engine exhaust gas control standards. (1) STAGE3 provided in Directive 2004/26/EC (For EU) (2) TIER3 provided in 40CFR1039/EPA (For USA and Canada)

1.2.2 CERTIFICATION LABEL AFFIXED POSITION

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1-3

INTRODUCTION

1.3 FOR YOUR SAFETY

1.3 FOR YOUR SAFETY

1

For your safety, the information of possible hazards and how to avoid them are provided on this manual and with the safety indicators attached to this lift truck.

1.3.1 SIGNAL WORDS

1

The following signal words indicate the possible hazard which leads bodily injury. For this lift truck and this manual, the following signal words are used depending on the de gree of possible hazard. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Example of safety message using signal word

CAUTION Do not open the radiator cap immediately after the engine stops, since the coolant temperature is very high. Steam or boiling water may spurt out, causing burns. After the coolant temperature has gone down, turn the cap slowly to release the pressure before removing it.

Other signal words Besides the above signal words, the followings indicate prec autions you must take for the lift truck as well as useful information.

NOTICE - - - - - - - The lift truck can get damaged or shortens its service life when handled incorrectly. REMARKS - - - - - Useful information.

1-4

INTRODUCTION

1.3 FOR YOUR SAFETY

1.3.2 SAFETY INDICATORS

1

Safety indicators are used in the various locatio ns of the lift truck to indicate the possible hazards to the co ncerned persons during operations, inspections, and maintenances. This lift truck employs [verbal safety indicator] and [pictorial safety indicator] for safety indicators. EXAMPLE OF VERBAL SAFETY INDICATOR

There are safety indicators which consist of drawing and words in addition to verbal-only safety indicators.

EXAMPLE OF PICTORIAL SAFETY INDICATOR

The pictorial safety indicators indicate the hazard equivalent to the signal words. Illustrations are used for these safety indicators to tell the operators and service staffs clearly of the existence and content of a hazard. In addition, there are pictorial indicators which simply indicate the prohibition content as well as indicators which comply with the international standards.

Komatsu Utility Co., Ltd. FORKLIFT COMPANY cannot predict every circumstance that the customers will experience. Therefore the precautions in this manual and on the lift truck may not include all possible safety precautions. When carrying out any procedures or actions which are not specifically recommended or allowed in this manual, it is your responsibility to carry out such procedures and actions safely. The explanations, numeric vales, and illustrations of this manual are based on the information at the time of publication. Continuing improvements in the design of this lift truck may not be reflected in this manual. Consult KOMATSU FORKLIFT distributor for the latest available information or for questions regarding this manual.

1-5

INTRODUCTION

1.4 APPLICABLE MODEL AND SERIAL No.

1.4 APPLICABLE MODEL AND SERIAL No.

1

This Operation and Maintenance Manual applies to the following lift trucks. Model type

Serial No.

FD100/115-8

M246-7001 and up

FD135/150E/160E-8

M247-7001 and up

1.5 GENERAL VIEW OF LIFT TRUCK

1

1.5.1 APPLICATION OF LIFT TRUCK

1

This lift truck is intended to use mainly for the following work. • Load handling with the forks of the lift truck.

1.5.2 DIRECTION OF LIFT TRUCK

1

This manual determines the left and right directions and fore and aft directions as seen from the operator's seat.

Right

Front

Rear

Left

1.6 UNITS OF MEASURE This manual uses the international system of units (SI) for units of measure. Also the gravitational system of units, conventionally used, are provided as { } for reference.

1-6

1

INTRODUCTION

1.7 QUALIFICATION FOR OPERATION

1.7 QUALIFICATION FOR OPERATION

1

WARNING Only the trained and qualified persons are allowed to operate this lift truck. Operatio n by unqualified persons may result in serious injury or death.

1.8 RUNNING IN NEW LIFT TRUCK 1.8.1 RUNNING IN NEW LIFT TRUCK

1

1

Your KOMATSU FORKLIFT truck has been thoroughly adjusted and tested before shipment. However, operate moderately during the first one month (or initial 200 hours) until each part of the lift truck comes into stable. Operating the lift truck under severe conditions at the beginning can adversely affect performance and shorten the lift truck life. Be sure to run in the lift truck, taking special care concerning the followings. • Idle the engine for 5 minutes after starting it up. • Do not operate with heavy loads or at high speeds. • Avoid sudden starting, acceleration, braking, and sharp turning.

1.8.2 MAINTENANCE FOR NEW LIFT TRUCK

1

For new lift truck, carry out the followings after the first month or 200 hours: Replacement of oil and cleaning of filters, retightening of bolts and nuts. Have your lift truck serviced by KOMATSU FORKLIFT distributor.

1.9 WARRANTY AND SERVICE 1.9.1 PERIODICAL EXCHANGE PARTS

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1

Other than those specified by the law, KOMATSU FORKLIFT designates " periodical exchange parts. " Deterioration of such parts is unavoidable over time but is critical for safety and therefore must be replaced periodically. Replace those parts at the designated periods regardless of their appearance. For the periodic replacement of safety critical parts, see the Section "4.15 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS (PAGE 4-54)".

1.9.2 USE OF GENUINE PARTS AND OILS

1

Any problem caused by the use of other than Genuine Parts (including oils) warranted by KOMATSU FORKLIFT is not covered by the warranty.

1-7

1.10 NECESSARY INFORMATION OF LIFT TRUCK


INTRODUCTION

1

When you need maintenance of the lift truck or order parts, please provide KOMATSU FORKLIFT distributor with necessary information of the lift truck such as model type, serial No. engine serial No. attachment, option, etc.

1.10.1 MEMORANDUM (To be filled by KOMATSU FORKLIFT distributor)

1

Model type Serial No. Engine serial No. Attachment/option Distributor Address Telephone, fax No. Service person in charge Sales representative in charge

1.10.2 MODEL AND SERIAL NO. LOCATION LIFT TRUCK SERIAL NO. PLATE LOCATION Located in the right top of the dashboard.

LIFT TRUCK EMBOSSED SERIAL NO. LOCATION Besides the serial No. plate, serial No. is also embossed on the top of the left-side front wheel fender. Example of embossed mark: M *** - #### Serial No. is shown as # after the hyphen.

1-8

1

INTRODUCTION


1.10.3 ENGINE SERIAL NO. PLATE OR EMBOSSED LOCATION

1

A serial No. plate and embossed mark are provided in the following places: • Mounted engine : Diesel engine (SAA6D107E-1-A) (1) Serial No. plate : On top of engine

(2) Embossed : Left side of engine

1.10.4 HOUR METER LOCATION

1

Located in the meter panel under the steering wheel.

1-9

CONTENTS

CONTENTS

INTRODUCTION

1

1. INTRODUCTION ------------------------------------------------------------ ---------------------------------------------------------- 1-1 1.1 ABOUT THIS MANUAL ----------------------------------------------------------------- ------------------------------------- 1-2 1.2 ENGINE MOUNTED ON THIS LIFT TRUCK ----------------------------------------------------------- --------------- 1-3 1.2.1 EXHAUST GAS CONTROL ----------------------------------------------------------- ----------------------------- 1-3 1.2.2 CERTIFICATION LABEL AFFIXED POSITION--------------------------------------------------------------- 1-3 1.3 FOR YOUR SAFETY ---------------------------------------------------------------------- ----------------------------------- 1-4 1.3.1 SIGNAL WORDS--------------------------------------------------------------------------------------- --------------- 1-4 1.3.2 SAFETY INDICATORS------------------------------------------------------------------------------- --------------- 1-5 1.4 APPLICABLE MODEL AND SERIAL No. --------------------------------------------------------------- ---------------- 1-6 1.5 GENERAL VIEW OF LIFT TRUCK ------------------------------------------------------------------------ --------------- 1-6 1.5.1 APPLICATION OF LIFT TRUCK-------------------------- -------------------------------------------------------- 1-6 1.5.2 DIRECTION OF LIFT TRUCK --------------------------------------------------------------- ---------------------- 1-6 1.6 UNITS OF MEASURE------------------------------------ ------------------------------------------------------------------- - 1-6 1.7 QUALIFICATION FOR OPERATION ------------------------------------------------------------------------------------ 1-7 1.8 RUNNING IN NEW LIFT TRUCK --------------------------------------------------------------------------------- -------- 1-7 1.8.1 RUNNING IN NEW LIFT TRUCK ---------------------------------------------------------- ----------------------- 1-7 1.8.2 MAINTENANCE FOR NEW LIFT TRUCK---------------------------------------------------------------------- 1-7 1.9 WARRANTY AND SERVICE ---------------------------------------------------------- ------------------------------------- 1-7 1.9.1 PERIODICAL EXCHANGE PARTS ----------------------------------------------------------------- ------------- 1-7 1.9.2 USE OF GENUINE PARTS AND OILS ------------------------------------------------------------------------- 1-7 1.10 NECESSARY INFORMATION OF LIFT TRUCK------------------------------- ------------------------------------- 1-8 1.10.1 MEMORANDUM (To be filled by KOMATSU FORKLIFT distributor)---------------------------------- 1-8 1.10.2 MODEL AND SERIAL NO. LOCATION ----------------------------------------------------------------------- 1-8 1.10.3 ENGINE SERIAL NO. PLATE OR EMBOSSED LOCATION -------------------------------------------- 1-9 1.10.4 HOUR METER LOCATION------------------------------------------------------------------------ --------------- 1-9 2. SAFETY ----------------------------------------------------------------------- ---------------------------------------------------------- 2-1 2.1 SAFETY LABEL------------------------------------------------------------------ ---------------------------------------------- 2-2 2.1.1 SAFETY LABEL LOCATION CHART -------------------------------------------------------------------------- - 2-2 2.1.2 SAFETY LABELS ------------------------------------------------------------------ ----------------------------------- 2-4 2.2 BASIC PRECAUTIONS-------------------------------------------------------------------------------- ---------------------- 2-8 2.2.1 FOLLOW RULES ---------------------------------------------------------------- ------------------------------------- 2-8 2.2.2 NEVER OPERATE THE BROKEN-DOWN LIFT TRUCK ----------------------------------------------- --- 2-8 2.2.3 WEAR ADEQUATE CLOTHES AND SAFETY EQUIPMENT FOR OPERATION------------------- 2-9 2.2.4 FIRE EXTINGUISHER AND FIRST AID KIT ------------------------------------------------------------------ 2-9 2.2.5 CAUTIONS FOR SAFETY-RELATED EQUIPMENT-------------------------------------------------- ------ 2-9 2.2.6 PRACTICE SUFFICIENTLY BEFORE OPERATION ------------------------------------------------------- 2-9 2.2.7 JUMPING ON AND OFF FROM THE LIFT TRUCK IS STRICTLY PROHIBITED --- ------------- 2-10 2.2.8 KEEP THE OPERATOR'S COMPARTMENT AND PLATFORM CLEAN AND TIDY------------- 2-10 2.2.9 PRECAUTION WHEN WASHING LIFT TRUCK------------------------------------------------------------ 2-10 2.2.10 TO AVOID BURN INJURY-------------------------------------------------------------------------------------- 2-11 2.2.11 FIRE PREVENTION ----------------------------------------------------------- ----------------------------------- 2-11 2.2.12 IF A FIRE BREAKS OUT---------------------------------------------------------------------------------------- 2-12 2.2.13 DO NOT MODIFY THE LIFT TRUCK------------------------------------------------------------------------ 2-12 2.2.14 DO NOT REMOVE THE OVERHEAD GUARD AND LOAD BACKREST-------------------------- 2-13 2.2.15 SECURE SAFETY AT THE WORKING AREA------------------------------------------------------------ 2-13 2.2.16 ENGINE EXHAUST GAS IS POISONOUS----------------------------------------------------------------- 2-14 2.2.17 ASBESTOS CAUTION------------------------------------------------------------------------------------------- 2-14 2.2.18 WINDOW WASHER CAUTION-------------------------------------------------------------------------------- 2-14 2.3 BEFORE STARTING OPERATION ------------------------------------------------------------------------------------ 2-15 2.3.1 START-UP INSPECTION----------------------------------------------------------------------------------------- 2-15 2.3.2 INSPECTION AND ADJUSTMENT BEFORE STARTING ENGINE ---------------------------- ------ 2-15 2.3.3 START-UP INSPECTION----------------------------------------------------------------------------------------- 2-16 2.4 TRAVELING THE LIFT TRUCK ----------------------------------------------------------------------------------------- 2-17 2.4.1 PREPARATION BEFORE TRAVELING THE LIFT TRUCK--------------------------------------------- 2-17 2.4.2 WHILE TRAVELING THE LIFT TRUCK ---------------------------------------------------------------------- 2-18 2.4.3 STOPPING AND PARKING-------------------------------------------------------------------------------------- 2-24 2.4.4 TOWING--------------------------------------------------------------------------------------------------------------- 2-25

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INTRODUCTION

CONTENTS

2.5 LOAD HANDLING OPERATION --------------------------------------------------------------------------------- --------2-26 2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE------------------------------------------------------2-31 2.6.1 ALWAYS PERFORM THE START-UP INSPECTION ----------------------------------------------------- 2-31 2.6.2 PUT UP A WARNING SIGN DURING INSPECTION AND MAINTENANCE ------------------------2-31 2.6.3 KEEP THE WORKING AREA CLEAN AND TIDY ----------------------------------------------------------2-31 2.6.4 CAUTIONS BEFORE INSPECTION AND MAINTENANCE ---------------------------------------------2-32 2.6.5 KEEP UNAUTHORIZED PEOPLE OFF------------------------------------------------------------ -----------2-32 2.6.6 USE OF RIGHT TOOLS AND EQUIPMENT ----------------------------------------------- ------------------2-32 2.6.7 CAUTIONS WHEN WORKING UNDER WORK EQUIPMENT------------------------------------------2-32 2.6.8 AVOID GETTING CAUGHT UP BY THE MAST OR FALLING OFF-----------------------------------2-33 2.6.9 BE CAREFUL OF BOILING COOLANT ----------------------------------------------------- ------------------2-33 2.6.10 BE CAREFUL OF HIGH PRESSURE OIL ------------------------------------------------------------------2-34 2.6.11 BEWARE OF ROTATING COOLING FAN AND BELT ---------------------------------------------- ----2-34 2.6.12 CAUTION WHEN REPAIRING THE ELECTRICAL SYSTEM -----------------------------------------2-34 2.6.13 CAUTIONS FOR USING COMPRESSED AIR FOR CLEANING -------------------------------------2-3 4 2.6.14 CAUTIONS WHEN REPLACING THE SEAT --------------------------------------------------------------2-34 2.6.15 CAUTION WHEN HANDLING BATTERY -------------------------------------------------------- -----------2-35 2.6.16 STRICTLY FOLLOW THE INSTRUCTIONS SHOWN BELOW TO AVOID GENERATION OF SPARKS ------------------------------------------------------------------------------ --------------------------------2-35 2.6.17 CAUTION WHEN CHARGING A BATTERY----------------------------------------------------------------2-35 2.6.18 CAUTION WHEN HANDLING TYRES----------------------------------------------------- ------------------2-36 2.6.20 CAUTION AFTER INSPECTION AND REPAIR ----------------------------------------------------------- 2-36 2.6.21 PERIODIC INSPECTION OF SAFETY CRITICAL PARTS---------------------------------------------2-37 2.7 HOISTING AND TRANSPORTING THE LIFT TRUCK ------------------------------------------------------------2-38 2.7.1 CAUTION WHEN HOISTING THE LIFT TRUCK -----------------------------------------------------------2-38 2.7.2 PRECAUTIONS FOR LOADING AND UNLOADING THE LIFT TRUCK-----------------------------2-3 8 2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING) ------------------------------------------------------------------------ -----------------------------------------------2-39 2.8.1 LONGITUDINAL STABILITY -------------------------------------------------------------------------------------2-39 2.8.2 CENTER OF GRAVITY OF A LOAD --------------------------------------------------------- ------------------2-39 2.8.3 COMBINED CENTER OF GRAVITY AND STABILITY ON THE LOADED LIFT TRUCK-------- 2-40 2.8.4 ACTUAL CAPACITY------------------------------------------------------------------------------------------------2-40 2.8.5 SERIAL NO. AND LOAD TABLE ------------------------------------------------------- -------------------------2-41 2.8.6 INTRODUCTION OF OPTIONAL SAFETY DEVICE-------------------------------------------------------2-43 3. OPERATION --------------------------------------------------------------------------------------------------------------------------- 3-1 3.1 GENERAL VIEW -------------------------------------------------------------------------------------------------------------- 3-2 3.1.1 GENERAL VIEW OF LIFT TRUCK ------------------------------------------------------------------------------ 3-2 3.1.2 INSTRUMENTS AND CONTROLS ---------------------------------------------------- -------------------------- 3-3 3.2 EXPLANATION OF COMPONENTS------------------------------------------------------------------------------------- 3-5 3.2.1 METER PANEL ------------------------------------------------------------------------------------------------------- 3-5 3.2.2 OPERATING DEVICES--------------------------------------------------------------------------------------------3-10 3.3 OPERATION ------------------------------------------------------------------------------------------------------------------3-23 3.3.1 START-UP INSPECTION -----------------------------------------------------------------------------------------3-23 3.3.2 MOUNTING / DISMOUNTING AND OPERATING POSTURE ADJUSTMENT---------------------3-23 3.3.3 STARTING, GEAR SHIFTING, AND TRAVELING ---------------------------------------------------------3-27 3.3.4 STARTING AND STOPPING ON SLOPE --------------------------------------------------------------------3-32 3.3.5 INCHING TRAVEL --------------------------------------------------------------------------------------------------3-32 3.3.6 TURNING ---------------------------------------------------------------------- ----------------------------------------3-33 3.3.7 OPERATION ON SNOWY AND FROZEN ROADS -------------------------------------------------------- 3-33 3.3.8 TEMPORARY STOPPING, PARKING AND STOPPING ------------------------------------------------- 3-34 3.3.9 LOAD HANDLING OPERATION --------------------------------------------------------------------------------3-36 3.3.10 CHECKING AFTER OPERATION-----------------------------------------------------------------------------3-40 4. INSPECTION AND MAINTENANCE -------------------------------------------------------------------------------------------- 4-1 4.1 ABOUT INSPECTION AND MAINTENANCE ------------------------------------------------------------------------- 4-2 4.2 START-UP INSPECTION--------------------------------------------------------------------------------------------------- 4-2 4.2.1 CHECKING ABNORMALITIES DETECTED ON THE PREVIOUS DAY ------------------------------ 4-4 4.2.2 WALK AROUND A LIFT TRUCK -------------------------------------------------------------- ------------------- 4-4 4.2.3 INSPECTION CONDUCTED BY OPENING COVER AND HOOD-------------------------------------- 4-6

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CONTENTS

INTRODUCTION

4.2.4 CHECKING FROM THE OPERATOR SEAT---------------------------------------------------------------- 4-11 4.2.5 CHECK BY SETTING THE STARTING SWITCH TO [ | ] (ON) POSITION ------------------------- 4-13 4.2.6 CHECKING WITH THE ENGINE STARTED ---------------------------------------------------------------- 4-16 4.2.7 CHECKING WHILE TRAVELING SLOWLY ----------------------------------------------------------------- 4-17 4.2.8 CHECKING BY OPERATING THE WORK EQUIPMENT LEVER------------------------------------- 4-17 4.2.9 CHECKING OF SAFETY FUNCTION ----------------------------------------------------- -------------------- 4-19 4.3 CHECKING AND REPORTING AFTER OPERATION ----------------------------------------------- ------------- 4-20 4.4 SIMPLE MAINTENANCE-------------------------------------------------------------------------------------------------- 4-21 4.4.1 GREASES AND FUEL--------------------------------------------------------------------------------------------- 4-21 4.4.1.1 BASIC PRECAUTIONS----------------------------------------------------------------------------------- 4-21 4.4.1.2 LUBRICANT LIST --------------------------------------------------------------- --------------------------- 4-24 4.4.2 AIR CLEANER ELEMENT CLEANING ----------------------------------------------------------------------- 4-27 4.4.3 FUEL PRE-FILTER AIR BLEEDING--------------------------------------------------------------------------- 4-29 4.4.4 REPLACING TYRES----------------------------------------------------------------------------------------------- 4-30 4.4.5 ADJUSTING PARKING BRAKE LEVER OPERATING EFFORT -------------------------------------- 4-32 4.4.6 REPLACING FUSES----------------------------------------------------------------------------------------------- 4-32 4.4.7 REPLACING BULBS----------------------------------------------------------------------------------------------- 4-34 4.4.8 CHECKING BRAKE ACCUMULATOR------------------------------------------------------------------------ 4-35 4.4.9 CHECKING FOR LOOSE ENGINE HIGH-PRESSURE PIPING CLAMPS, HARDENING OF RUBBER ------------------------------------------------------------------------ ------------------------------------- 4-36 4.4.10 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAPS, HARDENING OF RUBBER ------------------------------------------------------------------------ ------------------------------------- 4-36 4.5 PROCEDURE FOR A DOWN BATTERY--------------------------------------------------------------------------- -- 4-37 4.6 RUNNING IN COLD WEATHER ---------------------------------------------------------------------------------------- 4-39 4.7 ACTION IN ENGINE OVERHEATING -------------------------------------------------------------------- ------------- 4-41 4.8 OPERATING LIFT TRUCKS IN SPECIAL ENVIRONMENT OR IN FORCIBLE WAY-------------------- 4-43 4.9 ACTION TO TAKE IF THE FORK FAILS TO LOWER ----------- ------------------------------------------------- 4-44 4.10 WASHING LIFT TRUCK ------------------------------------------------------- ------------------------------------------ 4-45 4.11 LONG-TERM STORAGE --------------------------------------------------------- --------------------------------------- 4-46 4.12 HOISTING LIFT TRUCK----------------------------------------------------------------------------- -------------------- 4-47 4.13 LOADING AND UNLOADING OF LIFT TRUCK------------------------------------------------------------------- 4-48 4.14 INSPECTION AND MAINTENANCE SCHEDULE CHART----------------------------------------------------- 4-49 4.15 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ------------------------------------------ ------ 4-54 4.16 SERVICE DATA------------------------------------------------------------------------------------------------------------ 4-55 5. TECHNICAL DATA --------------------------------------------------------------------- ---------------------------------------------- 5-1 6. EMISSION CONTROL WARRANTY STATEMENT ------------------------------------------------------------------------ - 6-1 7. INDEX -------------------------------------------------------------------------- ---------------------------------------------------------- 7-1

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SAFETY

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22

WARNING Please be sure that you fully understand this manual and the precautions related to safety for the lift truck. When operating, inspecting, or servicing the lift truck, always follow these precautions strictly. strictly.

2-1

2.1 SAFETY LABEL

2. SAFETY 2.1 SAFETY LABEL

SAFETY

2

2

Followings are the safety labels used for this lift truck. • Make sure that you understand the exact locations of the safety labels, the contents of the danger, and how to avoid them. • Keep the safety safety labels clean so that that it can be easily seen at all times. times. Do not use organic solvent solvent or gasoline gasoline for cleaning. Or the safety label may come unstuck. • If the safety label is damaged, damaged, lost, or become unreadable, unreadable, replace replace it with a new one. Before placing an order to KOMATSU FORKLIFT distributor, check the part No. of safety label referring to this manual or the replacing label itself. • Concerning Concerning labels other than the safety safety labels, use these in the same way. way.

2.1.1 SAFETY LABEL LOCATION CHART

2-2

2

SAFETY

No .

2.1 SAFETY LABEL

Safety labels name

Position

1

Caution to avoid getting hand caught

Near the upper center of the tilt stay

2

Seating capacity

Top of the left and right front fenders

3

Caution when hoisting the lift truck

Outside of left and right outer masts

4

Prohibit the operators from riding on the forks and lifting/lowering themselves

Outside of left and right outer masts

5

Jump start prohibited

Starting motor (Inside of engine hood)

6

Caution when parking (the lift truck)

Right on the dashboard

7

Avoiding danger if lift truck tips over during operations

Inside in front of the head guard gu ard (on the wiper motor cover for the steel cab specification)

8

Take ake a rig right ht post postur ure e whi while le oper opera ating ting lift lift truc truck k

Insi Inside de in fron frontt of of the the head head guard uard

9

Caution before operation

On the rear panel of the floor

10

Hois Ho istt the the lift lift truc truck k by desi design gnat ated ed posi positi tion ons s

On the top of the mast and on the counter balance-weight portion

11

Caution to avoid getting caught

Inside of engine hood (shroud)

KOMATSU FORKLIFT reserves the right to change or add to these safety label requirements and label contents.

2-3

SAFETY

2.1 SAFETY LABEL

2.1.2 SAFETY LABELS

2

(1) Caution to avoid getting hand caught (3EB-96-25850) (3EB-96-25121) • Do not place your hands. (General)

(2) Seating capacity (3EB-96-54110)

(3) Caution when hoisting the lift truck (3EB-96-31710) • Never lift the truck by the overhead guard.

2-4

(USA)

SAFETY

(4) Prohibit the operators from riding on the forks and lifting/ (General) lowering themselves (3EB-96-25131) (3EB-96-25840) • Never enter the area under the forks.

2.1 SAFETY LABEL

(USA)

(5) Jump start prohibited (09842-A0481) • Start the engine only after sitting down in the operator's seat. • Do not attempt to start the engine by intentionally shortcircuiting the engine starting circuit. Such a malpractice can cause a serious bodily injury and fire.

(6) Caution when parking (the lift truck) (3EB-96-21211)

2-5

SAFETY

2.1 SAFETY LABEL

(7) Avoiding danger if lift truck tips over during operations (3EB-96-32610) (3EB-96-25730) (General)

(USA)

BEFORE OPERATION:

IF THE LIFT TRUCK SEEMS TO TIP OVER ANY MOMENT DURING OPERATION:

1. Always use your seat belt when operating.

3. Do not jump off the lift truck.

2. Read and understand the Operation and Maintenance Manual.

4. Lean yourself in the opposite direction to the tipping of the lift truck. 5. Grip the steering wheel tightly. 6. Brace yourself with both feet to support your body.

(8) Take a right posture while operating lift truck (3EB-96-59231) (option) • If you operate the lift truck in such a posture that your weight is not properly applied to the seat, like standing up or leaning forward/backward or sideways, the power will be cut off in approx. three seconds, making travel and lift truck operation impossible. Take a right posture while operating. It is especially dangerous when you operate like this on an uphill. Due to the power is cut off, the lift truck will slither down even if you depress the accelerator pedal, which can lead an accident such as crash or falling off.

2-6

SAFETY

2.1 SAFETY LABEL

(9) Caution before operation (3EB-96-25721) (3FD-96-29310) (General)

(USA)

(10) Hoist the lift truck by designated positions (3BA-96-59140)

(11) Caution to avoid getting caught (37C-1KB-3100) • Keep hand off the rotating fan.

(12) Caution when handling battery(3FE-96-32320) (Shape and layout may vary depending on the battery supplier.)

2-7

SAFETY

2.2 BASIC PRECAUTIONS


2

2.2.1 FOLLOW RULES

2

• Only the trained and qualified persons are allowed to operate this lift truck. • Fully understand and follow this operation and maintenance manual. • Do not operate the lift truck when you are ill conditioned, taking medicine that causes drowsiness, under the influence of alcohol, or mentally unstable.

• Plan safety work beforehand. Before operation, make up an operating plan that fits the workplace conditions, type and capacity of the lift truck, and the load conditions. In confined areas or when loading/unloading large items, position a signal person and carry out operations in accordance with their instructions. • During operation, safety must be your primary responsibility ensuring the safety of those you are working around, the lift truck, yourself, and other property in the work area.

2.2.2 NEVER OPERATE THE BROKEN-DOWN LIFT TRUCK • If any abnormality is detected during the start-up inspection or during the operation (noise, vibration, odor, maladjusted gauge, smoke, oil leak, or erroneous indication of warning device or monitor), report the administrator immediately and take adequate corrective actions. • Do not operate the lift truck until the abnormality is corrected. • Remove the key from the faulty lift truck and put up signs in the operator's compartment to prevent its use. • If the lift truck has a failure and must be parked without lowering the forks, put markers on the tips of the forks and take steps to prevent pedestrians or other vehicles from hitting the forks. • Select a parking place where people or vehicles do not pass. Take measures to prevent anyone to go under the forks. (Space under lifted forks is dangerous zone.)

2-8

2

u N s e e v e r D a n g e r

SAFETY


2.2.3 WEAR ADEQUATE CLOTHES AND SAFETY EQUIPMENT FOR OPERATION

2

• Avoid loose clothing and accessories. It is dangerous when they catch on control levers and projections. • Long, loose hair can be caught in a rotating part. Long hair must be tied back. • Always wear a safety helmet and safety shoes. Wear other safety equipment appropriate for the working conditions or as may be required by your administrator. • Check that the safety equipment works properly before use.

2.2.4 FIRE EXTINGUISHER AND FIRST AID KIT

2

• In preparation for a fire or bodily injury, check the locations of fire extinguisher and first aid kit, and be familiar with the usage.

2.2.5 CAUTIONS FOR SAFETY-RELATED EQUIPMENT

2

• Confirm that all protective guards, covers, and mirrors are properly mounted. Repair them immediately when broken. • Be sure that you fully understand the usage of safety-related equipment. • Never remove the safety-related equipment. Keep them fully functional at any time. • Do not operate this lift truck if the overhead guard or load backrest has been or appears to have been damaged or loosened until repairs have been made by your authorized KOMATSU FORKLIFT distributor.

2.2.6 PRACTICE SUFFICIENTLY BEFORE OPERATION

2

• Take sufficient time for practice until you become familiar with the operation of each component before starting the actual operation. • Even after you become familiar with it, operate with caution and avoid harsh operation. Or it can cause a bodily injury or dama ge. • Each lift truck is more or less peculiar in the performance of brake, accelerator, and load handling device even though it is the same model type. When you changeover the lift trucks, understand the peculiarity of each lift truck before stating operation. Be especially careful with brake, since its performance varies by individual lift truck.

2-9


2.2.7 JUMPING ON AND OFF FROM THE LIFT TRUCK IS STRICTLY PROHIBITED

SAFETY

2

• Never jump on or off the lift truck. It is extremely dangerous. • Even if the lift truck accidentally starts to move without operator onboard, never attempt to jump on the lift truck to stop. • Always mount and dismount the lift truck from the left side. • During mounting or dismounting the lift truck, place the left foot on the step hold the assist grip with the left hand, hold the head guard leg with the right hand to support the body securely always at three places with the hands and feet. • Do not hold on the control levers or steering wheel when mounting or dismounting the lift truck.

2.2.8 KEEP THE OPERATOR'S COMPARTMENT AND PLATFORM CLEAN AND TIDY

2

• Always keep the operator's compartment and platform (assist grip, step, floor) clean and tidy. Oil, mud or dust attached, or spare parts or tools left lying around in the operator's compartment may cause the operator's hand or foot slips or the clothes get caught, which will lead a falling accident or erroneous operation.

2.2.9 PRECAUTION WHEN WASHING LIFT TRUCK • If water gets into the electrical system (controller, sensor, connector, etc.), there is a hazard that it will cause malfunctions or miss-movement. Do not use flushing water or high- pressure steam to wash the electrical system. For washing the lift trucks, see the Section "4.10 WASHING LIFT TRUCK (PAGE 4-45)".

2 - 10

2

SAFETY

2.2.10 TO AVOID BURN INJURY


2

HIGH TEMPERATURE COOLANT

• Immediately after the operation, the cooling water is at a high temperature, so there is always the danger of burns if you open the radiator cap as steam or boiling water may spurt out. Turn the radiator cap slowly, after the coolant temperature has gone down sufficiently.

HIGH TEMPERATURE PARTS AND OIL

• To prevent burns with the high temperature parts or by the spurt of oil, wait for the lift truck temperature to go down enough before the inspection and maintenance work.

2.2.11 FIRE PREVENTION

2

FIRE WITH FUEL AND OIL

Fuel, oil, coolant and window washer fluid are flammable, s o keep them away from open flame. Strictly follow the instructions shown below. • Do not smoke or allow any flame near fuel, oil, coolant or window washer fluid, or clothes soaked in them. • Stop the engine before refilling fuel. • Do not leave the area while refilling fuel or oil. • Tighten the fuel cap and oil cap securely. • Do not spill fuel on the overheated surface or electrical system components. • Store fuel and oil in a well-ventilated dark cold place. • Store fuel and oil in a designated place away from unauthorized people. • Wipe off the spilled fuel, oil, and grease after refilling. • Put clothes soaked in oil and other flammable objects in a secure container and store them in a safe place. • Also, be cautious and take measures for fires ignited with a spark or flame, when inspecting or servicing the lift truck using devices and equipment. Failure to comply with these safety policies may result in serious injury or death.

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SAFETY


FIRE CAUSED BY DEPOSITS AND FOULING OF FLAMMABLE OBJECTS

• Deposits or fouling of flammable objects in the engine exhaust manifold, muffler, exhaust pipe, near the battery, and inside the under cover may cause a fire. Remove the depo sits and fouling from the above locations.

FIRE FROM ELECTRICAL WIRING

Short-circuiting of the electrical wiring may cause a fire. • Clean all the electrical wiring connections, and fix them firmly. • Check daily for looseness, wear and damage of the wiring. Retighten the loose connector and wiring clamp. Damaged wiring must be repaired or replaced by KOMATSU FORKLIFT distributor.

FIRE FROM PIPING

• Make sure that the clamp, guard and cushion of the hose and tube are fixed securely. Loose hose or tube may get damaged by vibration during operation or by rubbing against other parts, and cause the high pressure fluid to spurt out which may lead a fire or bodily injury.

2.2.12 IF A FIRE BREAKS OUT

2

• If a fire breaks out, turn the starting switch to the [Q] (OFF) position to stop the engine. • Do not jump off the lift truck in a rush. Support yourself securely with handrails and steps to evacuate.

2.2.13 DO NOT MODIFY THE LIFT TRUCK • Contact KOMATSU FORKLIFT distributor in advance for any modification (installation, removal and modification) of the lift truck, attachment or option. It may cause safety hazard and may violate the law. • KOMATSU FORKLIFT will not be responsible for any bodily injury, damage or failure which results from the modification made without prior consent of KOMATSU FORKLIFT in writing.

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2

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SAFETY


2.2.14 DO NOT REMOVE THE OVERHEAD GUARD AND LOAD BACKREST

2

• Do not remove the overhead guard or load backrest, which are installed to protect the operator from falling objects. • Do not operate this lift truck unless it is equipped with the overhead guard and load backrest shipped with the lift truck from the factory by KOMATSU FORKLIFT. • The overhead guard is built in compliance with the safety standards. However, it is not designed to withstand every possible impact. Always be careful to prevent damage or injury from falling objects.

2.2.15 SECURE SAFETY AT THE WORKING AREA

2

• Working on a rough surface can result in bodily injuries such as backache. Always keep the passages and work areas flat and smooth without bump. • Wipe up all spill oil or grease from the ground to prevent tip over or collision due to slipping. • When working on platforms, docks, quays, 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 traffic areas clearly, and establish a clear traffic rule such as temporary stop line, speed limit, no-entry area for other vehicles and pedestrians. • Provide adequate lighting for safety operations.

2 - 13


2.2.16 ENGINE EXHAUST GAS IS POISONOUS

SAFETY

2

• Do not leave the engine running where there is poor ventilation. The engine exhaust gas contains carbon monoxide. There is danger that this will cause gas poisoning. Open the windows and doors for ventilation.

2.2.17 ASBESTOS CAUTION

2

• Non-Genuine Parts (unspecified parts of KOMATSU FORKLIFT) such as clutch disc, brake lining, gasket and packing may contain asbestos. Use Genuine Parts. • All the parts used in this lift truck are asbestos-free.

2.2.18 WINDOW WASHER CAUTION • Use the window washer which contains ethyl alcohol. • Never use the window washer containing methanol which is harmful to eyes.

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SAFETY

2.3 BEFORE STARTING OPERATION


2

2.3.1 START-UP INSPECTION

2

ALWAYS CONDUCT A START-UP INSPECTION IN THE BEGINNING OF THE DAY FOR YOUR SAFETY OPERATION OF THE LIFT TRUCK

• For details of the inspection, see the Section "4.1 ABOUT INSPECTION AND MAINTENANCE (PAGE 4-2)" .

2.3.2 INSPECTION AND ADJUSTMENT BEFORE STARTING ENGINE

2

CHECK THE FOLLOWINGS BEFORE STARTING THE ENGINE

• Check for coolant level, fuel level and oil level in the engine oil pan, and clogging in the air cleaner. • Adjust the seat (seat position, backrest angle, etc), steering wheel position and rear view mirror, and make sure the locks are secured.

CAUTION WHEN STARTING THE ENGINE

• Before starting the engine, check that the parking brakes are set, and that the forward/reverse lever and high/low speed levers are in the neutral position. • When starting the engine, first check that the surrounding area is safe, and sit in the operator's seat. • Sound the horn before starting the engine to warn people around.

• Do not start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire. • Do not start the engine by pushing the lift truck.

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SAFETY

CAUTION IN COLD WEATHER

• Allow sufficient time for warming-up the engine in cold weather. If the engine is insufficiently warmed-up, the lift truck may move slow or change its motion suddenly which will result in an accident. • For operation and maintenance, see the Section "3.3.3 STARTING, GEAR SHIFTING, AND TRAVELING (PAGE 3-27)" and Section "4.6 RUNNING IN COLD WEATHER (PAGE 4-39)".

2.3.3 START-UP INSPECTION CHECK THE FOLLOWING BEFORE STARTING THE OPERATION

• Check the operating conditions of the lamps and warning lights on the instrument panel. • Make sure that the traveling and load handling interlock function properly. • This lift truck is provided with TRAVEL INTERLOCK (OPTION) and LIFT INTERLOCK (OPTION) that make travel and truck operation impossible when you are not seated properly. see "TRAVEL INTERLOCK (ENGINE POWER CUTOFF) (OPTION) (PAGE 3-30)" and "LIFT INTERLOCK (OPTION) (PAGE 3-38)". • If any fault is found (noise, vibration, heat, odor, maladjusted gauge, oil leak, or fuel leak), be sure to repair the fault before starting the operation.

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2

SAFETY

2.4 TRAVELING THE LIFT TRUCK


2

2.4.1 PREPARATION BEFORE TRAVELING THE LIFT TRUCK

2

USE THE SEAT BELT

• Always fit the seat belt properly before operation. • Not using the seat belt properly may result in serious bodily injuries if the lift truck tips over. • Make sure the seat belt is free from damage and flaw.

TAKE A RIGHT POSTURE ON THE SEAT

• If you operate the lift truck when you are not seated properly or off the seat, an accident may happen unexpectedly. To forestall such a possible accident, this lift truck is provided with TRAVEL INTERLOCK (OPTION) and LIFT INTERLOCK (OPTION) that make traveling and lift truck operation disabled if you are not seated properly. For details, see "TRAVEL INTERLOCK (ENGINE POWER CUTOFF) (OPTION) (PAGE 3-30)" and "LIFT INTERLOCK (OPTION) (PAGE 3-38)".

TAKE A RIGHT POSTURE WHILE OPERATING

• Do not stick the hand or foot outside the machine body. • Always keep your body under the overhead guard.

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SAFETY

BEFORE TRAVELING THE LIFT TRUCK, CHECK THE SAFETY OF SURROUNDING AREA • Before starting to travel the lift truck, check that the surrounding area is clear of obstructions such as pedestrians, other trucks and loads. • Raise the forks approx. 15 - 20 cm (6 - 8 in) from the ground and tilt the mast back. • Sound the horn areas as may be needed. 15 - 20 cm (6 - 8 in)

2.4.2 WHILE TRAVELING THE LIFT TRUCK AVOID SUDDEN STARTING OR SUDDEN FORWARD/REVERSE DIRECTIONAL CHANGE • Stop the lift truck before changing the forward/reverse travel direction.

BE ALWAYS CONSCIOUS OF SAFETY WHILE TRAVELING • Avoid sudden starting, braking, or making sharp turns. • Keep a clear view of the path of travel. • When passing oncoming vehicles, reduce speed and keep a safe distance from the other vehicle. • In places where there are speed limits, observe the speed limit and maintain a safe distance from other vehicles. • When traveling, always pay careful attention to the area around your lift truck, particularly in the direction of travel or when turning. • Do not attempt to pass another lift truck or vehicle on a narrow path or on a spot of limited view like a crossing. • When passing through a crossing or turning a corner, or when traveling into a narrow path, stop the lift truck once to check the safety. Sound the horn to warn people around if necessary. • Even if you sound the horn, not everyone in the surrounding area will necessarily hear it. Always pay careful attention to the movements of people in the surrounding area. • Do not allow people to enter the working area. • When traveling on a slope or through a crowded spot, always give way to a loaded lift truck.

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2

SAFETY


DO NOT ALLOW ANY PASSENGER

• Never allow any other person to ride with you on the lift truck for whatever reasons. • Do not use anyone for a counterbalance-weight.

NEVER TURN OFF THE STARTING SWITCH WHILE TRAVELING

• When the starting switch is turned to [Q] (OFF) while traveling, the operating efforts for power steering and power brakes (if present) may increase, which is dangerous.

DO NOT HOLD YOUR FOOT RESTED ON THE INCHING PEDAL WHILE TRAVELING

• Keep your foot off the inching pedal in the normal traveling. Otherwise the brake will overheat and the braking effect may be lost. • Depressing the pedal engages the clutch halfway, which makes the engine brake ineffective. • This can cause the transmission to overheat, leading the overheat of transmission fluid, and wear or seizure of the multiple clutch plates.

OPERATING BRAKE PEDAL

• Allow plenty of time for brake operation depending on the situation, as the road surface and weight of the load affect the stopping distance. Longer distance is required to stop on a downhill, wet or slippery surfaces, and with heavy load.

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WHEN BACKING UP THE LIFT TRUCK, CHECK REVERSE DIRECTION VISUALLY • When backing up the lift truck, always look back and make a direct visual check on the rear of the lift truck. The rear view mirror is simply an auxiliary aid for checking the rear. When reversing, do not depend on the rear view mirror alone for checking safety. • Even if you sound the backup buzzer, the people behind the lift truck do not necessarily hear it. Always visually check directly with your own eyes that there is no one behind the truck while traveling.

WHEN CARRYING A HIGH LOAD, USE A SIGNAL PERSON OR TRAVEL BACKWARD • If the view to the front is obstructed by the load, operate the lift truck in reverse while minding safety in the area the truck is heading to, or have a signal person to guide the travel.

DO NOT TRAVEL THE LIFT TRUCK WHEN THE FORKS ARE RAISED HIGH • If loaded or unloaded, raising the forks also raises the center of gravity of the lift truck increasing a risk of tipping over. Do not travel the lift truck with the up-raised forks. (During a travel, keep the forks approx. 15 - 20 cm (6 - 8 in) above the ground with the mast tilted backward.)

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SAFETY

SAFETY


NEVER JUMP OFF THE LIFT TRUCK WHEN THE LIFT TRUCK SEEMS TIPPING OVER (1) Always use your seat belt during operations for your safety if lift truck should tip over. (2) To avoid tipping over and other accidents, carry on proper operation, inspection and maintenance work, read and understand the Operation and Maintenance Manual. (3) Do not jump off the lift truck if the lift truck seems tipping over. Or you may be crushed by the lift truck resulting a serious bodily injury. (4) Lean yourself in the opposite direction to the direction the lift truck is tipping. (5) Grip the steering wheel tightly. (6) Brace yourself with both feet to support your body. • Practice this series of actions from time to time to master how to act in emergency situations. (General)

(USA)

WHEN MAKING A TURN, BE CAREFUL OF THE SWINGING TAIL • The lift truck has rear steering wheels. Be careful as if behaves differently from passenger cars. • When turning while traveling forward, the counterbalanceweight will swing far out. Keep an ample clear ance from walls to ensure safety.

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PAY CAREFUL ATTENTION TO THE LIFT TRUCK'S MAX. HEIGHT AND WIDTH

• Ensure that there is ample height and width for the lift truck to pass. • Keep clearance from the doors, ceiling, wirings and pipes. • Be careful with the height of the mast and load backrest when the forks go up.

DO NOT TRAVEL ON ROUGH OR SLIPPERY ROAD

• Do not try to travel on bumpy or soft ground. It can lead to a serious accident when you lose steering control or the tyres stuck in the mud. • Avoid traveling on the slippery road covered with water and oil. You will lose brake or steering control.

OBSERVE THE WEIGHT LIMIT

• Do not allow overweight on the floors and roads where weight limit is specified.

DO NOT TRAVEL DIRECTLY OVER OBSTACLES ON THE ROAD

• Avoid clutter, curbs, rails, ditches, or other obstacles, and do not travel directly over them. Also, the impact applied when traveling over obstacles can result in bodily injuries such as backache.

TRAVELING ON A ROAD SHOULDER IS STRICTLY PROHIBITED

• There is danger that soft road shoulders may collapse. Do not approach them. • Always maintain a safe distance from the edge of road shoulders and platforms to prevent the lift truck from falling off.

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SAFETY

SAFETY


EMERGENCY ACTION AT A RAILWAY CROSSING

• If the lift truck becomes immovable due to an engine trouble at a railway crossing, etc., the truck cannot be moved with the cell motor as on a passenger vehicle. (because of the activation of the neutral safety switch). • In such an emergency, burn a safety flare or take a similar action to inform the neighboring object like an approaching train of the failure of the lift truck.

CAUTION WHEN TRAVELING ON SLOPES

• Do not turn, or traverse or be careful for the approach/departure angle on slopes. The lift truck may tip over. • Before traveling uphill, stop the lift truck and adjust the fork clearance between the ground. Keep the bottom of the forks or pallet off the ground or prevent the tips of the forks from sticking into the ground when traveling.

• For safe travel on slopes. When loaded : Travel forward uphill and in reverse downhill. When unloaded: Travel in reverse uphill and forward downhill. • On a down slope, travel down slowly using the engine as a brake. • If you are not properly seated, the travel interlock (option) activates to cut off the engine power, resulting the lift truck may slither down on a slope. Take a right posture while operating. For more details on the function of travel interlocking, see "TRAVEL INTERLOCK WARNING LAMP (OPTION) (PAGE 3-6)" .

When

When unloaded

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SAFETY


EXERCISE CARE WHEN TRAVELING INTO A RAILWAY WAGON OR CONTAINER

• Check that brake and block are applied to the wagons, trailers, and containers to stop them. • Tell the carrier drivers not to move their vehicles until the load handling operation is completed. • Ramps used for approaching the wagon and/or trailers must stand the travels of loaded lift trucks. • Engage the ramps securely to wagons and trainers. • Do not travel at the edge of the platforms or loading docks, or there is a danger of the lift truck falling down.

2.4.3 STOPPING AND PARKING

2

FOLLOW THE STEPS FOR STOPPING AND PARKING

1. Stop the lift truck on level ground. 2. Apply the parking brake lever to prevent the lift truck from moving. 3. Set the forward/reverse lever to neutral.

4. Tilt the mast forward and lower the forks to the floor. 5. Turn the starting switch key to the [Q] (OFF) position. 6. Pull out the starting key and leave the lift truck.

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Free

Lock

SAFETY


PARK THE LIFT TRUCK IN A SAFE PLACE

• Park the lift truck on a firm level ground. • Do not stop or park near any emergency exit or other safety equipment. Stop or park the lift truck in a place where it will not obstruct pedestrians or other vehicles. • Do not park the lift truck on a slope. If parking on a slope is unavailable, apply blocks to the tyres.

2.4.4 TOWING

2

BE CAREFUL WHEN USING THE DRAWBAR PIN

• The drawbar pin is provided for being towed by the wrecking car when the tyres are stuck in a ditch or mud. • Do not use it for towing or hoisting. • The drawbar pin can be used for an anchor point of this lift truck when being transported by a truck.

DO NOT TOW A DISABLED LIFT TRUCK

• If there is any problem with the brakes or steering system of your lift truck, do not use tow with another lift truck. There is a danger that disabled the lift truck may move accidentally.

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2.5 LOAD HANDLING OPERATION

2.5 LOAD HANDLING OPERATION SIT ON THE SEAT CORRECTLY FOR LOAD HANDLING OPERATION

• To avoid accidents, Load Handling Interlock activates to disable the load handling operation when you are not seated properly or off the seat. For more details on the function of load handling interlocking, see "LIFT INTERLOCK (OPTION) (PAGE 3-38)".

DO NOT ALLOW ANYONE IN THE WORKING AREA EXCEPT THE SIGNAL PERSON

• To avoid accidents, keep unauthorized people and other vehicle off the working area except a signal person during the load handling operation. • Use a signal person when it is necessary to ensure visibility or for other safety reasons. • When working with a signal person, always follow his/her instructions.

DO NOT GO UNDER THE LIFTED FORKS

• The lifted forks may accidentally fall down to cause serious injuries to person below, of any. Keep everyone away from under the lifted forks.

WORKING ON THE FORKS IS STRICTLY PROHIBITED

• Do not directly place a load manually on the forks. • Do not directly remove a load manually from the forks. • Don not step on the forks to handle a load. The load may slip down the forks. • Do not hold the load on the forks by hands. Sudden lift truck movement may cause the load to fall on the person below.

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SAFETY

2

SAFETY


BE CAREFUL NOT TO GET CAUGHT IN THE MA ST STRUCTURE

• Never put your hands, feet, or other body parts into the mast structure. There is a danger that you may get caught in moving parts and be seriously injured. • Do not stand between mast and operator's compartment as you may be crushed and be seriously injured or killed. • Always operate the mast and forks from the operator's compartment.

DO NOT CLIMB ON THE MAST OR LOAD BACKREST

• If you climb on the mast or load backrest, there is a danger of being caught in the moving parts or fall off.

USE A PALLET OR SKID OF AMPLE STRENGTH

• Always use the pallets and skids of robust construction. Do not use broken or damaged pallets or skids. • Before traveling, always check that the load is positioned securely and safely on the pallet.

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HANDLE A LONG OR WIDE LOAD WITH EXTRA CARE

• Be extremely careful when carrying long or wide loads. Lift the load slowly without hitting anything in the surrounding area. • When switching direction, keep the load as low as possible and maintain the balance.

BE CAREFUL WITH THE MAST HEIGHT

• As the forks go up, the mast height increases. Be mindful of this face during the operation. • Take care not to hit with the mast electric wirings, piping, sprinklers, beams in the ceiling, etc. If such hitting occurs, there is a danger that the load on the forks drops o ff or the lift truck tips over.

OVERLOADING IS STRICTLY PROHIBITED

• Overloading may cause the rear wheels come off the ground, and the lift truck loses the balance and tips over. Do not load the lift truck over the max. capacity shown in the load table. For details, see "2.8.4 ACTUAL CAPACITY (PAGE 2-40)" and "2.8.5 SERIAL NO. AND LOAD TABLE (PAGE 2-41)".

DO NOT TILT THE MAST FORWARD WITH A LOAD ON THE FORKS

• Do not tilt the mast forward with the load raised. Do not raise the load with the mast tilted forward. Or the load may fall or the lift truck may tip over. • Do not travel with the mast tilted forward.

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SAFETY

SAFETY


DO NOT 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. • Secure the load in position to prevent collapsing or falling. Do not handle unstable loads. • Place the load so that it makes contact with the load backrest.

DO NOT LOAD AND UNLOAD ON SLOPES

• Loading or unloading on the slopes may cause the lift truck to lose its balance and tip over.

DO NOT LOWER THE LOADED FORKS HASTILY

• Do not operate the forks roughly or make a sudden stop. Sudden lowering may cause the collapsing or falling of the load, and the lift truck may go off balance and tip over.

DO NOT HANDLE A LOAD EXCEEDING THE LOAD BACKREST HEIGHT

• If the load is higher than the load backrest, there is danger that it may fall back on the operator. Do not handle a load exceeding the load backrest height.

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DO NOT PRY SOMETHING WITH THE TIPS OF THE FORK

• Or the hooked object may suddenly come off the tip and be damaged. The reaction may result in an unexpected motion of the lift truck or load and the risk to the safety.

DO NOT USE THE FORKS TO PUSH OR PULL A LOAD

• There is a risk that the load will be damaged or fall.

DO NOT USE THE LIFT TRUCK FOR ANY OTHER PURPOSE

• Do not use the lift truck for any other purpose than load handling using forks or attachments. • Do not open or close the doors of railroad cars or warehouses with the forks. • Do not push or pull any other vehicle. • Do not lift loads suspended from the fork with ropes. The rope may slip, come off, break, or even cause cracks on the forks. Also the lift truck may lose its balance and tip over as the load swings.

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SAFETY

SAFETY

2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE


2

2.6.1 ALWAYS PERFORM THE START-UP INSPECTION

2

• This Operation and Maintenance Manual provides only the simple inspection and maintenance information that operators can perform relatively easily. For inspection and maintenance that requires a trained, skilled and qualified personnel, contact your KOMATSU FORKLIFT distributor. • Do not operate the lift trucks before completing start-up inspection. • Report abnormality, if any, immediately to the administrator. Do not operate faulty lift truck until the repair is completed. • Incorrect inspection, maintenance and repair services may cause critical accident or shorten machine service life. For your safety operation, contact KOMATSU FORKLIFT distributor for inspection, maintenance and repair services.

2.6.2 PUT UP A WARNING SIGN DURING INSPECTION AND MAINTENANCE • Put up a warning sign on the steering wheel or load handling lever during inspection and maintenance work. Put up the sign around the lift truck, if necessary. • Do not let any other person than the inspector or maintenance staff start lift truck or touch the load handling lever during inspection and maintenance. Or serious injuries may result. When jointly making inspection or maintenance with other personnel, name the leader and follow his/her instructions.

2.6.3 KEEP THE WORKING AREA CLEAN AND TIDY

2

Do not operate

2

• Keep the working area clean and tidy. Get obstacles out of the way. Wipe off any grease or oil. • Perform the work on level surface with ample space. • If the work is carried out inside a building, keep it well-ventilated.

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2.6 PRECAUTIONS FOR INSPECTION AND MAINT ENANCE

2.6.4 CAUTIONS BEFORE INSPECTION AND MAINTENANCE

SAFETY

2

• Arrange for a fire extinguisher. Know the location and how to use it. • Do not allow anyone with loose clothing or long loose hair near the mast while operation. • Wear adequate working clothes and protective items (safety helmet, safety shoes, goggles and gloves). • Lower the forks to the ground, pull the parking brake lever in the direction to the rear of the lift truck, set all the lever to the neutr al positions, then turn the starting switch to [Q] (OFF) to stop the engine. • Block the front and rear tyres.

2.6.5 KEEP UNAUTHORIZED PEOPLE OFF

2

• No unauthorized person is allowed near the lift truck under maintenance service.

2.6.6 USE OF RIGHT TOOLS AND EQUIPMENT

2

• Use a suitable tool correctly. Do not use broken or deformed tools, or wrong tools designed for another purpose, or a serious accident may result.

2.6.7 CAUTIONS WHEN WORKING UNDER WORK EQUIPMENT • Block the forks and mast to prevent falling before working under the raised forks. Otherwise a serious accident may result.

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SAFETY


2.6.8 AVOID GETTING CAUGHT UP BY THE MAST OR FALLING OFF

2

• Do not put your hands, feet, or other body parts into the mast structure. Or you may be caught by the mast parts. • Do not stand between mast and operator's compartment as you may be crushed and be seriously injured or killed. • Always operate the mast and forks from the operator's compartment.

• Do not climb on the mast load backrest or on top of the dashboard. You may slip and fall or get caught in the moving parts. Use a stepladder for inspection and maintenance at elevated level.

2.6.9 BE CAREFUL OF BOILING COOLANT

2

• Immediately after using the lift truck, the engine cooling water is at high temperature and high pressure. Do not remove the radiator cap under these conditions or it may cause burns. • When removing the radiator cap, turn it slowly to release the internal pressure after the coolant temperature has gone down sufficiently.

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2.6.10 BE CAREFUL OF HIGH PRESSURE OIL

SAFETY

2

Remember that the hydraulic system is constantly under pressure. Check the hydraulic system for no pressure before checking or replacing piping or hose, or a serious accident may result. Follow the instructions below: • When checking hydraulic piping or hose for leakage, don't touch it directly by hand. The pipe or hose may be pressurized. • If your skin and/or eye are injured by high-pressure oil, wash it with fresh water and immediately see a physician.

2.6.11 BEWARE OF ROTATING COOLING FAN AND BELT

2

• Keep hand off the rotating fan or fan belt. • Always stop the engine before opening the engine hood. Only the authorized people are allowed to open the engine hood.

2.6.12 CAUTION WHEN REPAIRING THE ELECTRICAL SYSTEM

2

• When repairing the electrical system, disconnect the cable of the negative ( - ) terminal to stop power supply.

2.6.13 CAUTIONS FOR USING COMPRESSED AIR FOR CLEANING

2

• The dust particles may cause a serious bodily injury if compressed air is used for cleaning. • Always wear protective gears such as goggles, dust mask, and gloves.

2.6.14 CAUTIONS WHEN REPLACING THE SEAT Seat is equipped with important safety functions: • Seat belt and support to operator’s body • Travel and lift interlock (option) function switches • Storage case for instruction manual Always use Genuine Seat for replacement.

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2

SAFETY


2.6.15 CAUTION WHEN HANDLING BATTERY

2

Batteries generate flammable hydrogen gas and may explode. Battery electrolyte also contains dilute sulfuric acid. If you make a mistake in handling, it may cause personal injuries, explosions and fires. Strictly follow the instructions shown below. • Do not use or charge the battery if the battery electrolyte level is below the lower level. This may cause battery expl osion. Check the electrolyte level regularly to maintain it between the lower level and upper level. If the level is low, refill distilled water. • When handling the battery, always wear safety glasses and rubber gloves. • Do not smoke or allow any flame near the battery. • If you spill battery electrolyte on yourself, immediately flush the part with a large quantity of tap water. • If battery electrolyte gets into your eyes, flush them immediately with fresh tap water and see a physician. • When inspecting or handling the battery, the starting switch must be turned to the [Q] (OFF) position.

2.6.16 STRICTLY FOLLOW THE INSTRUCTIONS SHOWN BELOW TO AVOID GENERATION OF SPARKS

2

• Do not place tools or other metal objects on the battery. They may accidentally contact the positive ( + ) and negative ( - ) terminals of the battery. • When disconnecting the battery cables, always disconnect the cable of the negative ( - ) terminal first. Conversely, when connecting them again, connect the cable of the positive ( + ) terminal first.

2.6.17 CAUTION WHEN CHARGING A BATTERY

2

• When the battery is charged, flammable hydrogen gas is generated. • Remove the battery from the lift truck, and open the battery cap in a well-ventilated place before charging. • Tighten the battery cap securely. • Fix the battery in place securely.

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SAFETY

2.6.18 CAUTION WHEN HANDLING TYRES

2

The lift truck tyres are very highly pressurized with the air. Do not mishandle, or the tyres may burst, be damaged or the rim may break into pieces causing a serious injury. For your safety, follow the instructions shown below. • Do not disassemble/assemble tyre, tube or rim, nor inflate removed tyres with the air. • For safety, when filling a tyre with air or replacing it, place your body in front of the tread face of the tyre (see the figure a t right). Do not work from the side of the tyre. • Always use the specified tyre of KOMATSU FORKLIFT, and observe the specified tyre inflation pressure. For the right tyre inflation pressure, see "4.16 SERVICE DATA (PAGE 4-55)". • When filling up the tyres, make sure no one is around and use a clip-on air chuck that can be fixed to the air valve. Fill up the tyre while checking with an air gauge to avoid over inflation. • The rim will not " fit " the tyre if either the tyre or rim is defective, or if it is not properly assembled. To fit, the rim must contact with the tyre evenly around the circumference. Contact your KOMATSU FORKLIFT distributor.

2.6.19 CAUTION IN WASTE DISPOSAL Take full cautions for waste disposal to prevent e nvironment pollution. • Always drain waste fluid such as oil, fuel, coolant and battery electrolyte into containers like cans and tanks. ( Do not drain the battery electrolyte into metallic containers. Always use plastic containers.) Do not pour on the ground or into rivers, drains, seas or lakes. • Comply strictly with applicable laws and regulations when disposing of harmful objects such as oil, fuel, coolant, solvent, filters, batteries and refrigerant (CFCs).

2.6.20 CAUTION AFTER INSPECTION AND REPAIR • Wipe off the spilt oil and grease immediately. If the lift truck is dirty, it becomes difficult or impossible to find cracks or other problems. • Test the lift truck upon completion of the repair to check if there is no abnormality.

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SAFETY


2.6.21 PERIODIC INSPECTION OF SAFETY CRITICAL PARTS

2

• To ensure the safety and long service life of the lift truck, be sure to perform lubrication, inspection and maintenance regularly. Especially the safety critical parts, must be replaced regularly. • Quality of these parts may change over time or deteriorate, wear or fatigue as they are repeatedly used, leading serious bodily injuries and damages. Furthermore, the remain ing service life of such parts is usually hard to determine for operators or during visual inspection. • For details of safety critical parts, see "4.15 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS (PAGE 454)". • Replace the safety critical parts with a new one periodically even if no anomaly is found. • Replace the safety critical parts immediately when any abnormality is found, even if the replacement interval is not up yet. REMARK

• This Operation and Maintenance Manual does not describe the details on how to inspect or replace the safety critical parts. • Inspection and replacement of the safety critical parts, and refilling of greases must be done by KOMATSU FORKLIFT distributor.

2 - 37

SAFETY

2.7 HOISTING AND TRANSPORTING THE LIFT TRUCK

2.7 HOISTING AND TRANSPORTING THE LIFT TRUCK

2

2.7.1 CAUTION WHEN HOISTING THE LIFT TRUCK

2

• Never lift up by the overhead guard. • Before lifting-up, Check that the mounting bolts of mast and counterbalance-weight are tightened to the specified torque. Tightening torque for the counterbalance-weight mount bolts : 980 - 1,373Nm {100 - 140kgfm} Tightening torque for the mast lower mount bolts : 824 - 1,030Nm {84 - 105kgfm} • To hoist the lift truck, hook on the holes on the top of the outer mast for the front, and the hole on the top of the counterbalanceweight for the rear. • Do not go under the lifted truck. • Use undamaged wire having sufficient strength. For the hoisting of lift truck, see "4.12 HOISTING LIFT TRUCK (PAGE 4-47)".

2.7.2 PRECAUTIONS FOR LOADING AND UNLOADING THE LIFT TRUCK Loading and unloading a lift truck to and from a trailer always involve a hazard of the lift truck tipping over or falling off by handling error. Follow the instructions below: • Stop the trailer on level, flat road. Always apply parking brake. Apply blocks to the tyres. • Use ramps or dock plate of appropriate length, width and strength. Secure it tightly to prevent it from being dislocated or disengaged. • Take a right posture on the seat while operating. • If you operate the lift truck in such a posture that your weight is not properly applied to the seat, like standing up or leaning forward or sideways, travel interlock activates to cut off the transmission of engine power. Then the lift truck may slither down even if the accelerator pedal is stepped on or an uphill. Operate the lift truck assisted by a signal person if necessary so that you don't have to stand up or lean forward or sideways to watch. For more details on the function of travel interlocking, see "TRAVEL INTERLOCK (ENGINE POWER CUTOFF) (OPTION) (PAGE 3-30)". • When using the ramps, set them in gentle gradient, align the center of both the trailer and the lift truck and lock securely to prevent misalignment. • Do not change the course of the lift truck while on the ramps. If course change is needed, move off the ramps once and make another uphill travel on them in right direction.

2 - 38

2

Ramp

Blocks

SAFETY

2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING)


2

To operate the lift truck safely, it is important to understand the structure and stability of the lift truck.

2.8.1 LONGITUDINAL STABILITY

2

• The front wheels of the lift truck act as a fulcrum, and the load weight and the weight on the rear wheels are kept in balance to prevent the lift truck from falling forward. • When an overbalanced load weight is applied, the rear wheels will be raised off the ground. It is very dangerous and poses a high risk of serious accident like tipping over.

Load

Load weight Fulcrum

2.8.2 CENTER OF GRAVITY OF A LOAD

Weight on the rear wheels

2

• The shapes of loads carried by lift trucks vary from boxes to planks and long objects. • To judge the stability of the lift truck, it is important to determine the position of the center of gravity for loads of various shapes.

Center of gravity

Center of gravity

2 - 39


SAFETY

2.8.3 COMBINED CENTER OF GRAVITY AND STABILITY ON THE LOADED LIFT TRUCK

2

COMBINED CENTER OF GRAVITY The center of gravity of the loaded lift truck shifts to a combined center of gravity of both the lift truck and the load. When the load is raised, its center of gravity will rise, hence the combined center of gravity will also rise.

Combined center of gravity at high lifting height

Center of gravity of load

Combined center of gravity at low lifting height Center of gravity of lift truck

COMBINED CENTER OF GRAVITY AND STABILITY The higher the position of the center of gravity, the worse the longitudinal and lateral stabilities become. In addition, swaying or shock encountered during traveling or load handling will have a larger impact on the stability of the lift truck. Stability of the lift truck also changes depending on the following factors. • Size, weight, shape of load (position of center of gravity etc.) • Lifting height • Tilting angle of mast • Inflation pressure of tyres • Acceleration, deceleration and turning speed when traveling and load handling • Road condition and gradient • Type of attachments Do not travel with the forks (load) raised. Do not make sharp turns or apply sudden brakes. Do not raise or tilt the forks ab ruptly. There are dangerous and poses a high risk of serious accident like tipping over.

2.8.4 ACTUAL CAPACITY • The horizontal distance from the position of the center of gravity of a load on the forks to the upright load backrest of the fork is called a load center. Actual capacity means the maximum weight of a load that can be loaded at a certain load center. • The load table is given in the name plate accessible from the operator's seat. The table shows the relationship between the actual capacity and load center. • When the load center shifts toward the fork tips, the load weight (mass) has to be decreased in the actual operation to maintain the balance.

2 - 40

2

Load center: Small Load : Large

Load center: Large Load : Small

SAFETY


2.8.5 SERIAL NO. AND LOAD TABLE

2

A serial No. plate for lift trucks of the US specifications differs from the one shown above in the shape. Since actual conditions will vary, be sure to check your capacity rating being adequate fo r the particular job before beginning. If you are unsure at the capacity, please contact your employer for assistance.

EXPLANATION OF LOAD TABLE • In the load table of the serial No. plate, actual capacity and maximum load (2) are shown in relation to load center (1). • Actual capacity and maximum load are determined according to each model on the condition of the specifications shown in area (3). • Before loading, make sure that the load center and the load are well within the range of capacity. • When the load is in a complex shape, pull the load so that the heaviest portion of the load comes to closer to the load backrest and the lateral center comes to the two forks center. • Should a load be loaded beyond the range of capacity, it would pose a big danger to the lift truck as the rear wheels (for steering) may lift off the ground, letting the operator lose control of steering, or the lift truck may tip over. Always keep the load within the range of capacity. • Work within the specification ranges given in the serial No. plate attached to the lift truck. Replace the broken or unreadable serial No. plate. Call your KOMATSU FORKLIFT distributor for a new serial No. plate.

EXAMPLE OF LOAD CENTER AND ACTUAL CAPACITY • The areas (1) and (2) in the example provide the following information: When the load center is 600 mm - - - Maximum capacity: 10,000 kg (*1) When the load center is 800mm - - - - - -Capacity: 8,700 kg When the load center is 1,200mm - - - - Capacity: 6,800 kg *1: Even when the load center is smaller than 600 mm, the maximum capacity is 10,000 kg. • The area (3) shows the main specifications of the model. Max. lifting height :3m Attachment : Not equipped Front wheel tread : 1,700 mm Mast rear tilting angle : 12 degrees Front wheel size, inflation pressure: 9.00-20-14PR ( I ), 735 kPa Rear wheel size, inflation pressure : 9.00-20-14PR ( I ), 735 kPa

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SAFETY


• The following symbols indicate the types of attachment if any. Symbol

Attachment Side shifter Fork positioner Tyre handler

F F C

Type S M T

* * *

* * *

Capacity * * *

* * *

* marks in the chart will be replaced with alphabets and numbers which stand for types and capacities of the attachment. Numbers are not necessarily in 6 digits.

LOAD CAPACITY WHEN EQUIPPED WITH ATTACHMENT AND / OR HIGH MAST • Please note that the lift truck equipped with attachments and/or high mast has a smaller maximum capacity an d actual capacity than the standard truck. • Follow the load limit as indicated in the load table of the serial No. plate.

LOAD TABLE AND LOAD CAPACITY FOR DETACHABLE AND INSERT-TYPE ATTACHMENTS • For some detachable attachments, additional load table is provided at a certain place of the lift truck. In this case, follow the instructions in the table when installing such an attachment. • For insert-type bucket and fork extension sleeve, calculate the capacity as follows: Subtract the weight of insert-type bucket or fork extension sleeve from the capacity on the chart. • To check if weight of the insert-type bucket or fork extension sleeve must be considered, see the label attached on the right side of the operator's seat.

OTHER INFORMATION ON THE SERIAL NO. PLATE • The area (4) shows other basic information of the lift truck. Model Serial No. Date of manufacture Unladen mass • [ - ] means that no information is required. • Logo and the company name are shown on the top and bottom of the serial No. plate.

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SAFETY


2.8.6 INTRODUCTION OF OPTIONAL SAFETY DEVICE

2

Various safety devices are available as options. The devices listed below are o nly examples. Contact your KOMATSU FORKLIFT distributor for more information. Note that the devices and equipment may not be effective depending on the usage and working conditions. Follow the instruction of the safety control personnel for installation. • Working lamp : Top and rear • Warning for traveling (forward/reverse) or approach Revolving warning lamp and flash light • Handling of high/wide item: High or wide load backrest, and finger board (fork carriage) • Speed warning : Speedometer and alarm buzzer • Load indicator/warning : Load sensor • Better visibility : Rear view mirror, under mirror • Fire extinguisher etc.

2 - 43

OPERATION

3

33

WARNING Please be sure that you fully understand this manual and the precautions related to safety for the lift truck. When operating the lift truck, always strictly follow these precautions. Failing to heed this warning may result in serious injuries.

3-1

3.1 GENERAL VIEW

OPERATION

3. OPERATION

3

3.1 GENERAL VIEW

3

3.1.1 GENERAL VIEW OF LIFT TRUCK

3

(1) (2) (3) (4) (5) (6)

Lift chain Mast Lift cylinder Head lamp Rear view mirror (option) Turn signal lamp and clearance lamp (parking lamp) (7) Rear wheel (8) Fuel filler (9) Assist grip (10) Tilt cylinder

3-2

(11) Load backrest (12) Fork carriage (13) Front wheel (14) Fork (15) Overhead guard (16) Operator’s seat (17) Engine hood (18) Counterbalance-weight (19) Back-up lamp (20) Under mirror (option) (21) Rear combination lamps (turn signal lamp, brake lamp and tail lamp)

OPERATION

3.1 GENERAL VIEW

3.1.2 INSTRUMENTS AND CONTROLS

3

• OPERATOR’S COMPARTMENT

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Gearshift lever AUTO/MANUAL selector switch (option) Parking brake lever Forward/reverse lever Steering wheel knob Horn switch Steering wheel Starting switch Combination switch (Turn signal switch and lighting switch) (10) Attachment control lever (option)

(11) (12) (13) (14) (15) (16) (17) (18)

Tilt control lever Lift control lever Accelerator pedal Brake pedal Tiltable steering wheel lock lever Inching pedal Gearshift adjustment dial (option) Auto transmission controller (option) (The controller main body is normally protected with the cover.)

3-3

OPERATION

3.1 GENERAL VIEW

• Meter panel

(1) (2) (3) (4) (5)

Engine coolant temperature gauge Hour meter Torque converter oil temperature gauge Fuel gauge Neutral indicator lamp / Travel interlock warning lamp (option) (6) Parking brake warning lamp (7) Charge warning lamp

3-4

(8) Operation indicator (9) Lift Interlock warning lamp (option) (10) Engine warning lamp (11) Failure indicator (12) Air cleaner element warning lamp (13) Radiator coolant level warning lamp (14) Glow indicator (15) Speedometer (option)

OPERATION

3.2 EXPLANATION OF COMPONENTS


3

The followings are explanation of the devices employed to op erate the lift truck. To carry out suitable operations correctly and safely, it is important to fully understand the method of operating the equipment and the meanings of the displays.

3.2.1 METER PANEL

3

METER LAMPS Each meter is provided with lamp for easy view at night. The lamps turn on with the lighting switch on, regardless the starting switch position. NOTICE How to check a blown bulb of each warning light 1. With the engine stopped, check that the warning lights light up when the starting switch is turned to the [ | ] (ON). 2. If there is any warning light that does not light up, check if the bulb is blown. When the warning light lights up during operation, it indicates an abnormality. You should take corrective actions. Contact your KOMATSU FORKLIFT distributor immediately.

FUEL GAUGE Fuel gauge displays the approximate remaining amount of fuel. Check the fuel amount on a level surface. Check the remaining fuel level with the engine starting switch in the [ | ] (ON) position. Position (A): it indicates that there is little fuel left. Position (B): it indicates that the fuel tank is full now. Do not use up all the fuel. Fill the fuel tank before the fuel runs out.

NEUTRAL INDICATOR LAMP Neutral indicator lamp indicates that the forward/reverse lever is in the neutral position. With the starting switch key in the [ | ] (ON) position, this lamp lights up when the forward/reverse lever is in the neutral position, and goes off when it is either in the forward or reverse position. Before starting up the engine, be sure to turn the starting switch is in the [ | ] (ON) position and check that this lamp is on.

3-5


TRAVEL INTERLOCK WARNING LAMP (OPTION) This warning lamp doubles as the neutral indicator lamp. It begins to flash when travel interlock activates, cutting off the transmission of engine power. When you seat yourself properly and return the forward/reverse lever to the neutral position, the flashing lamp goes off and the lift truck is now ready for travel again. For more details on the function of travel interlocking, see "TRAVEL INTERLOCK (ENGINE POWER CUTOFF) (OPTION) (PAGE 3-30)".

ENGINE WARNING LAMP This warning lamp lights up or flashes if any abnormality occurs to the engine. NOTICE If the lamp lights up or flashes during operation, stop operation immediately and report to the administrator or call your KOMATSU FORKLIFT distributor for checkup.

CHARGE WARNING LAMP This warning lamp indicates abnormality of the alternato r charging system while the engine is running. This lamp lights up when the starting switch is turned to the [ | ] (ON) position, and goes off after the engine startup. Should the lamp light up during the work, check the V-belt for cutting and the electrical system for any abnormality.

OPERATION INDICATOR The indicator (green) flashes when the starting switch is turned ON.

3-6

OPERATION

OPERATION


HOUR METER Hour meter begins to work when the starting switch is turned to the [ | ] (ON) position, and indicates the cumulative value of operating hours. (While the hour meter is in operation, the operation indicator keeps flashing.) Use this meter for checking the periodic inspection intervals and operation hours. The last digit advances by 1 (meaning 0.1 hour) when the starting switch is kept in the [ | ] (ON) position for 6 minutes.

LIFT INTERLOCK WARNING LAMP (OPTION) It begins to flash when Load Handling Interlock activates, stopping the operation of forks and mast. When you seat yourself properly on the operator's seat, the lamp stops flashing and the lift truck is now ready for load handling operation again. For more details on load handling interlocking, see "LIFT INTERLOCK (OPTION) (PAGE 3-38)".

FAILURE INDICATOR This indicator lights up or flashes if any abnormality occurs to the control system. NOTICE If the lamp lights up or flashes during operation, stop operation immediately and report to the administrator or call your KOMATSU FORKLIFT distributor for checkup.

GLOW INDICATOR This indicator acts to indicate that the engine is being preheated. This indicator automatically lights up according to the ambient temperature or engine temperature at the start. It turns out when preheating is completed.

3-7


ENGINE COOLANT TEMPERATURE GAGE The engine coolant temperature gauge indicates the engine cooling water temperature with a needle. White range : Normal Red range : Overheat REMARK If the pointer of the water temperature gauge approaches the red range as the result of excessive rising of the engine coolant temperature, automatic function is activated to prevent the engine overheating. For the engine overheating prevention system, see "4.7 ACTION IN ENGINE OVERHEATING (PAGE 4-41)". NOTICE If the indicator enters the red range, stop the work immediately and park the lift truck in a safe place. Then take corrective actions against engine overheating. For the engine overheating, see "4.7 ACTION IN ENGINE OVERHEATING (PAGE 4-41)".

RADIATOR COOLANT LEVEL WARNING LAMP This warning lamp lights up to indicate when the water level of reservoir tank is LOW. If the warning lamp lights up, check the level of the coolant. For the checking, see "CHECKING OF COOLANT LEVEL (PAGE 47)".

PARKING BRAKE WARNING LAMP This warning lamp indicates that the parking brake is being applied. When applied : ON When released : OFF

3-8

OPERATION

OPERATION


AIR CLEANER ELEMENT WARNING LAMP This warning lamp lights up to indicate that the clogging of the air cleaner is near the limit. If the warning lamp lights up, clean the elements. For the cleaning, see "4.4.2 AIR CLEANER ELEMENT CLEANING (PAGE 4-27)".

TORQUE CONVERTER OIL TEMPERATURE GAUGE The indicator shows the torque converter oil temperature. White range : Normal Red range : Abnormal NOTICE Action to take if indicator enters red range. 1. Stop operations, stop the lift truck, run the engine at idling, and wait for the temperature to go down. 2. Stop the engine and check the oil level in the TORQFLOW transmission. 3. If the oil level is correct and the indicator enters the red range, please contact your KOMATSU FORKLIFT distributor.

SPEEDOMETER (OPTION) This indicates the travel speed of the lift truck.

3-9


3.2.2 OPERATING DEVICES STARTING SWITCH This switch turns on and off the engine. (1) [Q] position : You can insert and pull out the starting switch key at the OFF position. (2) [ | ] position : The electric circuits are switched on at the ON position. (3) [ | ] position : The starter begins to rotate to start-up the engine at the START position. When the engine has started up, release the engine starting switch key. The key automatically returns to the (2) position. REMARK • When the starting switch is ON (in position No.2), the glow indicator on the meter panel lights up and preheating starts automatically according to the ambient temperature and the engine temperature at engine start. • The necessary preheating time varies depending on the ambient temperature and engine temperature. • When the glow indicator is ON, wait until it turns out before turning the starting switch to START (position No. 3). NOTICE Do not leave the starting switch key in the [ | ] (ON) position while the engine is not running. The battery capacity goes down, making it difficult to start up the engine.

HORN SWITCH Press the switch in the middle of the steering wheel to sound the horn.

3 - 10

OPERATION

3

OPERATION


FORWARD/REVERSE LEVER This lever acts to change the travel direction (forward/reverse) of the lift truck. q : F (Forward) q : N (Neutral) q : R (Reverse)

Forward

Neutral

The engine cannot be started if this lever is not at the [ q ] N (Neutral) position. Reverse

GEARSHIFT LEVER MANUAL GEARSHIFT MODE This lever is used to select the transmission speed position when traveling. This lift truck has a 3-FORWARD, 3-REVERSE speed transmission. Place the gearshift lever in the desired speed range. Lever position

Gearshift mode

1

1st gear fixed

2

2nd gear fixed

3

3rd gear fixed

NOTICE When loaded, always start in 1st gear.

AUTOMATIC GEARSHIFT MODE (OPTION) The following number of speed ranges can be selected depending on the position of the gearshift lever. Lever position

Gearshift mode

1

1st gear fixed

2

Automatic 1st and 2nd gear

3

Automatic 1st, 2nd and 3rd gear

3 - 11


AUTO AUTO TRANSMISSION CONTROLLER (OPTION) • This controller controller (1) (1) is the central unit unit of the system system that decides the shift gear and the gear shift timing a ccording to the shift lever position and travel speed signals on the automatic gear sift mode. (The controller main body is normally protected with the cover.)

• The controller controller (1) (1) has a red (2) (2) and a green (3) (3) LED error error indicator lamps. These lamps inform the content of a failure by the pattern of flashing.

LED ERROR INDICATOR INDICATOR LAMP If this lamp starts flashing, stop the engine once. Set the forward/ reverse lever to N (neutral) position, and start the engine again. The controller resets the abnormality and starts operation. REMARK If the LED error indicator persists to flash after resetting the error, it may be caused by the failure of the automatic transmission controller. Contact your KOMATSU KOMATSU FORKLIFT distributor for servicing. NOTICE • Shift the forward/reverse travel only after the lift truck stops completely. • During high speed travel on AUTO (automatic gear shift) mode, do not change the shift lever to the 1st speed position. (For safety operation, shift down to the 1st speed is disabled when the travel speed is 9 km/h or higher. • Do not use water or high-pressure (steam) for cleaning of the controller, gear shift control dial and other electrical parts.

3 - 12

OPERATION

OPERATION


GEARSHIFT ADJUSTMENT DIAL (OPTION) This dial adjusts running speed when gearshift takes place. The running speed can be adjusted within the range shown below, when gearshift takes place like F1 o F2 o F3 (or R1 o R2 o R3). An optimum speed can be set according to the type of work. For a higher speed, turn the dial to the right and for a lower speed to the left. Gearshift pattern

Speed range

1st gear o 2n 2nd gear

2.5 - 7.5 km/h

2nd gear o 3r 3rd gear

8 - 16 km/h

REMARK The gearshift patterns are factory-set to the following speed.

Gearshift pattern

Speed

1st gear o 2n 2nd gear

5.5 km/h

2nd gear o 3r 3 rd gear

12 km/h

AUTO / MANUAL SELECTOR SWITCH (OPTION) Set the forward/reverse lever to N (neutral) position. Make sure that the parking lever is pulled toward the rear of the lift truck. Then proceed to shifting the transmission. • Manua Manuall gears gearshif hiftt mode mode : set the the shift shifting ing swi switc tch h to MANUA MANUAL L (upper) position. • Automatic Automatic gearshift gearshift mode: set the shifting shifting switch to AUTO AUTO (lower) position. NOTICE Shift the transmission only after the lift truck stops completely.

3 - 13

OPERATION


COMBINATION COMBINATION SWITCH (LIGHTING SWITCH/TURN SIGNAL SWITCH) This lever incorporates the lighting switch and the turn signal switch.

LIGHTING SWITCH When turning the switch to the arrow marks, the lamps light up and go off as follows.

4

No .

Head lamp

Meter lamp, clearance lamp, and tail lamp

1

OFF

OFF

2

OFF

ON

3

ON

ON

Lo

ON (Low beam)

ON

Hi

ON (High beam)

ON

TURN SIGNAL SWITCH Left Left turn turn (L) (L) : Pus Push h lev lever er forw forwar ard d Right turn (R) (R) : Pull Pull lever lever backward backward

Forward

This lever will automatically return to the neutral position when the steering wheel is turned back.

Backward

PARKING BRAKE LEVER This lever is used to operate the parking brake. • Pulling Pulling back the parking parking lever fully fully (Lock position) position) will will set the parking brake. • To release the parking parking brake, press and hold the button button on top of the lever, and return the lever to the free position. REMARK A reminder buzzer sounds when the parking brake is not applied. (Option)

3 - 14

Free

Lock

OPERATION


ACCELERATOR PEDAL

This pedal adjusts the engine speed. The engine speed increases in response to the amount of the pedal depressed.

BRAKE PEDAL

This pedal is used to stop or decelerate traveling the lift truck.

INCHING PEDAL

This pedal adjusts the travel speed during a very low speed travel such as for load handling operation. Depressing this pedal slightly engages the clutch ha lfway, and the lift truck will crawl along. Further depressing this pedal applies the brake by working with the brake pedal. Depressing this pedal to the full disengages the clutch completely.

3 - 15

OPERATION


LIFT CONTROL LEVER

This is a lever to raise or lower the forks with.

Lower

Raise : Pull the lever backward. Lower : Push the lever forward.

Raise

TILT CONTROL LEVER

This lever tilts the mast back and forth.

Tilt forward

Tilt forward : Push the lever forward. Tilt backward : Pull the lever backward.

Tilt backward

STEERING WHEEL AND STEERING WHEEL KNOB

• The steering wheel changes the direction of the lift truck to the right and left. • Hold the knob on the steering wheel with your left hand for operation.

TILTABLE STEERING WHEEL LOCK LEVER

• This lever adjusts the tilt angle (up / down) of the steering wheel. • Pulling this lever up adjusts the steering wheel tilt angle. Pushing the lever down locks the steering wheel. Free

Lock

3 - 16

OPERATION


HANDLING OF AIR CONDITIONER (OPTION)

CAUTION • Use the air conditioner only while the engine is running in order to prevent overloading the engine and air compressor. • If the working environment of the lift truck involves much dust or bad odor, select indoor air circulation. • If the lift truck is not operated regularly, operate the air conditioner a few times a month (for several minutes) to prevent refrigerant leakage from the air conditioner cooling circuit. If the air conditioner is left unused for a long time with the refrigerant in leaking state, the air conditioner will be rusted internally to cause a failure. • Do not overcool inside the cab nor allow the cold air to blow directly onto the operatorÊs body to prevent any health trouble. Also ventilate the indoor air from time to time. • If the temperature in the cabin rises high, open the door and window to replace the hot air with the fresh outdoor air before starting operation.

NAMES OF PARTS ON AIR CONDITIONER OPERATION PANEL

(1) (2) (3) (4)

Main power switch Airflow control switch Air conditioner switch Temperature control switch

(5) (6) (7) (8)

Room/fresh air select switch Mode select switch Defrost mode switch Display monitor

3 - 17

OPERATION


MAIN POWER SWITCH (1) Use this switch (1) to turn the fan and main power ON or OFF. When the main power is turned ON, the display monitor displays each setting status.

Display monitor

AIRFLOW CONTROL SWITCH (2) This switch adjusts the fan airflow rate. Press the HI switch (A) to increase the flow rate, and the LO switch (B) to decrease the flow rate. The flow rate can be adjusted in four levels.

Display monitor Flow rate: Increase

Flow rate: Decrease

AIR CONDITIONER SWITCH (3) Use this switch (3) to run or stop the air conditioner (cooling or dehumidification and heating). Press this switch when the main power is ON to start the air conditioner (compressor), and (A) appears on the display monitor . Press it again to stop the air conditioner, and (A) on the display monitor disappears.

Display monitor

TEMPERATURE CONTROL SWITCH (4) Use this switch to set the temperature in the cabin. When the main power is ON, the display monitor indicates the temperatu re setting level. • Press the C switch (A) to lower the outlet temperature. • Press the H switch (B) to raise the outlet temperature.

3 - 18

Display monitor

OPERATION


ROOM/FRESH AIR SELECT SWITCH (5) Use this switch (5) to select room air circulation or fresh outdoor air intake. Press the switch (5) to select room air circulation, and (A) appears on the display monitor.Press the switch again to select fresh air intake, and (B) appears on the display monitor. Display monitor

Room air circulation : The air in the cabin is circulated with the fresh air inlet shut off. Outdoor air intake : Fresh outdoor air is taken into the cabin. Use this mode to take clean, fresh outdoor air into the cabin or to defrost the cab windows.

MODE SELECT SWITCH (6) Use this switch (6) to select the air outlet. The air outlet is changed in the follows order each time switch (6) is pressed, and the selected mode appears on the display panel. Vent outlet mode 

Vent outlet mode / foot outlet mode 

Foot outlet mode

Display monitor

Vent outlet mode

Vent outlet mode / foot outlet mode

Foot outlet mode

DEFROST MODE SWITCH (7) Use this switch (7) to shift the air outlet to the defrost m ode and (A) appears on the display monitor. To select the vent outlet mode or the foot outlet mode, press the mode select switch (6).

Display monitor

3 - 19


DISPLAY MONITOR (8) This monitor (8) displays each setting status when the main power is ON.

OPERATION METHODS COOLING OPERATION 1. Press main power switch (1). 2. Press the HI airflow control switch (2) and set the airflow level. 3. Press the C temperature control switch (3) to set the display monitor to the COOL side (A). 4. Press the air conditioner switch (4). (B) appears on the display monitor and the air conditioner is operated. 5. Press room/fresh air select switch (6) to select room air circulation. (C) appears on the display monitor. 6. Press the mode select switch (8) to select the vent outlet mode. (D) appears on the display monitor. 7. When the temperature in the cab drops, adjust to the desired temperature and flow, outlet mode rate.

HEATING OPERATION 1. Press main power switch (1). 2. Press the HI airflow control switch (2) and set the airflow level. 3. Press the H temperature control switch (3) to set the HOT side (A) on the display monitor. 4. Press the room/fresh air select switch (4) and select fresh air intake. (B) appears on the display monitor. 5. Press the mode select switch (6), and select the foot outlet mode. (C) appears on the display monitor. 6. When the temperature in the cab rises, adjust to the desired temperature and flow rate. REMARK Engine coolant is used as the heating source. Start heating after the coolant temperature rises sufficiently.

3 - 20

OPERATION

OPERATION


DEHUMIDIFYING AND HEATING / DEMISTING OPERATION

1. Press main power switch (1). 2. Press airflow control switch (2) and set to the desired flow rate level. 3. Press the temperature control switch (3) to set the desired temperature. 4. Press the room/fresh air select switch (4) and select fresh air intake. (A) appears on the display monitor. 5. Press the mode select switch (5) to select the desired mode. 6. Press the air conditioner switch (6) to operate the air conditioner. (B) appears on the display monitor. REMARK

When the ambient temperature is below 0 C, the air conditioner (compressor) may fail to operate. °

3 - 21

OPERATION


WIPER SWITCHES (OPTION) Use these switches to start and stop respective wipers. (1) Rear wiper switch (2) Roof wiper switch (3) Front wiper switch

OPERATION METHODS Each switch selects wiper ON or OFF as follows: Pull the switch (ON)

:

Starts and operates continuously. Return the switch (OFF) : Stops the wiper.

the

wiper

REMARK • The front washer fluid is discharged when the front wiper switch is turned clockwise (switch ON). • The rear washer fluid is discharged when the rear wiper switch is pressed.

ROOM LAMP SWITCH (OPTION) Use this switch to select room lamp ON or OFF. ON : The room lamp lights up. OFF : The room lamp turns out.

3 - 22

OPERATION

3.3 OPERATION

3.3 OPERATION

3

3.3.1 START-UP INSPECTION

3

CAUTION • Do not operate the lift truck before completing start-up inspection. • Report abnormality, if any, immediately to the administrator. Never operate the lift truck in question until the repair is completed. For your safe operation, always make the start-up inspection. For details about the start-up inspection and daily maintenance, see "4.2 START-UP INSPECTION (PAGE 4-2)" .

3.3.2 MOUNTING / DISMOUNTING AND OPERATING POSTURE ADJUSTMENT

3

MOUNTING / DISMOUNTING

CAUTION • Mount or dismount the lift truck only after the lift truck comes to a complete stop. • Never jump on or off the lift truck. It is extremely dangerous. • Do not hold on the control levers or steering wheel when mounting or dismounting the lift truck. • Keep the handrails (assist grips) and step clean all the time, and repair the damage, if any. • Do not use the handrails (assist grips) for any other purpose than mounting or dismounting the lift truck. • Always mount and dismount the lift truck from the left side. • During mounting or dismounting the lift truck, place the left foot on the step (2) hold the assist grip (3) with the left hand, hold the head guard leg (1) with the right hand to support the body securely always at three places with the hands and feet.

3 - 23

OPERATION

3.3 OPERATION

SEAT POSITION ADJUSTMENT

CAUTION • Adjust the seat position before getting on the lift truck, or at the time of operator change. (Adjust only when the lift truck is at a complete standstill.) • Adjust the seat position so that you can fully depress the brake pedal while reclining yourself against the backrest. 1. Park the lift truck. For details on parking, see "3.3.8 TEMPORARY STOPPING, PARKING AND STOPPING (PAGE 3-34)". 2. Take a seat and pull the lever (1) to the left. (The operator's seat can slide back and forth in this condition.) 3. Bring the operator's seat to the optimum position and release the lever (1). The seat is locked in this condition. 4. After adjusting the seat, check that it is firmly locked by pulling it forwards/backwards.

BACKREST ANGLE ADJUSTMENT 1. Pull up the lever (2). The backrest angle can be adjusted in this condition. 2. Adjust the backrest angle and release the lever (2). After adjusting the backrest, check that it is firmly locked by pushing and pulling it.

SUSPENSION ADJUSTMENT Turn the seat cushioning adjustment dial (3) located on the front right side of the operator's seat to select the scale to your weight (4) for suspension adjustment. Turn the dial to the (A) side for lighter weight and to the (B) side for heavier weight. Weight adjustable range: 50 to 120kg

3 - 24

OPERATION

3.3 OPERATION

FASTENING AND UNFASTENING THE SEAT BELT

CAUTION Always wear your seat belt during operations.

1. Pull the tongue (1) out of the belt holder located on the left side of the operator's seat and push it into the buck le (2) on the right until it clicks into place.The safety seat belt is locked in this condition.

2. To unfasten, hold the belt with your left hand, and push down the red button of the buckle (2) with your right hand. 3. The belt is tucked into the holder automatically. While the belt is being tucked in, hold tongue (1) so that the belt is tucked in slowly.

OPERATION AND MAINTENANCE MANUAL STORAGE

CAUTION • Store the Operation and Maintenance Manual in the storage compartment under the operatorÊs seat readily available for reference. • If this manual has been lost or has become dirty or worn and cannot be read, request for a replacement from your KOMATSU FORKLIFT distributor. 1. Unlock the lock (1) of the storage compartment under the operator's seat. 2. Open the cover (2) of the storage compartment to take out or store the Operation and Maintenance Manual.

3 - 25

OPERATION

3.3 OPERATION

ADJUSTING STEERING WHEEL POSITION

CAUTION • Always stop the lift truck completely before adjusting the position of the steering wheel. • After adjusting, move the steering wheel backward and forward to check that it is locked securely in position. 1. Park the lift truck. For details on parking, see "3.3.8 TEMPORARY STOPPING, PARKING AND STOPPING (PAGE 3-34)". 2. Pull up the tiltable steering wheel lock lever (1) to the position (A). 3. Move the steering wheel back and forth to select the optimum position. 4. Push down the tiltable steering wheel lock lever (1) to the position (B) to lock the steering wheel. 5. After adjusting the steering wheel, check that it is firmly locked by pushing and pulling it.

3 - 26

Free

Lock

OPERATION

3.3 OPERATION

3.3.3 STARTING, GEAR SHIFTING, AND TRAVELING

3

STARTING ENGINE

3

WARNING Do not attempt to start the engine by short-circuiting the engine starting circuit. Such a malpractice can cause a serious bodily injury and fire.

CAUTION • Start the engine only after sitting down in the operator's seat. • Before starting the engine, move the forward/reverse lever to the neutral positions, and pull the parking brake lever in the direction to the rear of the lift truck. • Exhaust gas is toxic. When starting engine indoor or in a poorly-ventilated site, take extreme care for ventilation. • If you lean forward or sideways, or if you are not seated properly while operating the lift truck on an uphill, the system will cut off power to the engine and the lift truck may slither down, which can result in an accident or a crash. Maintain the correct right posture while traveling uphill. 1. Move the forward/reverse lever to the N (neutral) positions. REMARK The engine does not start unless the forward/reverse lever is set in the N (neutral) position.

Forward

Neutral

Reverse

2. Apply parking brake by pulling the lever to the rear direction of the lift truck. (Parking brake being applied) Free

Lock

3. Depress the inching pedal.

3 - 27

OPERATION

3.3 OPERATION

4. Turn the starting switch key ON (to position [ | ] (2) and release the key. The glow indicator lamp on the meter panel lights up to start automatic preheating. wPreheating time The necessary preheating time varies depending on the

ambient temperature and engine temperature. Use the followings as rough guide. If the engine is started while preheating, the preheating is terminated automatically. -4 C or over : Preheating not required -4 to -15 C : 5 to 30 sec -15 C : 30 sec 5. When the indicator lamp turns out, the preheating is completed. Turn the starting switch key to the [ | ] (START) position (3) to start the engine. 6. When the engine has started up, release the key immediately. The key will automatically return to the [ | ] (ON) position (2). Make sure the key is kept in this position while the engine is rotating. °

°

°

REMARK To improve durability by improving the engine lubrication performance at cold start, no fuel is fed to the engine for 3 seconds immediately after turning the starting switch key to the [ | ] (START) position. Therefore, the engine does not start during this period. Hold the starting switch key in the [ | ] (START) position to keep the starter turning until the engine starts. NOTICE • The starting switch key must be at the [Q] (OFF) position (1) while the engine is not running. Do not leave the starting switch key in the [ | ] (ON) position (2). The battery capacity goes down, making it difficult to start up the engine. • Limit the use of the starting motor within 10 seconds and do not let it run continuously beyond 10 seconds. • Wait for another 20 seconds before using the star ting motor again. • Do not turn the starting switch key to the [ | ] (START) position (3) while the engine is running.

3 - 28

OPERATION

3.3 OPERATION

AUTOMATIC WARMING-UP RUN

3

Starting the engine with the engine coolant temperature being at 20 C or lower sets the engine automatically to warming-up run (engine speed : 1,000 rpm). The automatic warming-up run is cancelled when the engine coolant temperature reaches 30 C or higher. (Engine speed : 725 rpm) °

°

REMARK The engine speed does not change even if the accelerator pedal is pressed during automatic warming-up operation.

d e e p s e n i g n E

725

Engine coolant temperature

STARTING LIFT TRUCK OFF

3

1. Depress the inching pedal and move the forward/reverse lever to either the forward [ I ] (F) or reverse [ O ] (R) position. Forward

Neutral

Reverse

2. Return the parking brake lever in the direction of the front of the lift truck to the free position. (Parking brake being released) Free

Lock

NOTICE • If you travel the lift truck with the parking brake lever pulled in the direction to the rear of the lift truck, the brake will overheat and the braking effect may be lost. Also it accelerates wear on the brakes. • If you had traveled long distance with this condition, have your lift truck inspected by KOMATSU FORKLIFT distributor.

3. Check that the direction of travel and the area around the lift truck are safe. 4. Slowly return the inching pedal (4) while depressing the accelerator pedal (3) gently to start the lift truck. Release the inching pedal (4) when the lift truck starts. NOTICE Do not rest the foot on the clutch pedal, inching pedal, or brake pedal except when so required.

3 - 29

3.3 OPERATION

TRAVEL INTERLOCK (ENGINE POWER CUTOFF) (OPTION) This safety device disables operation of the lift truck if you are seated in such a posture that your weight is not fully applied to the seat, like standing up or leaning forward or sideways. If you take such posture, the travel interlock activates in approx. three seconds and cuts off the transmission of engine power. Then the lift truck does not move any more even if you depress the accelerator pedal or operate the forward/reverse lever.

• While travel interlock is activated, the travel interlock warning lamp on the instrument panel flashes. (The lamp doubles as the neutral indicator lamp.) • Return to travel condition: Seat yourself properly and return the forward/reverse lever to the N (neutral) position. Then the lift truck is ready for travel again. Take this step only after you check the surroundings for safety. This Traveling Interlock does not brake the lift truck forcibly.

3 - 30

OPERATION

3

OPERATION

3.3 OPERATION

GEAR SHIFTING

3

MANUAL GEARSHIFT MODE While depressing the accelerator pedal, set the gearshift lever from the first speed (1) to the second speed (2) and the third speed (3). Lever position

Gearshift mode

1

1st gear fixed

2

2nd gear fixed

3

3rd gear fixed

NOTICE When loaded, always start in 1st gear.

AUTOMATIC GEARSHIFT MODE Select the gearshift lever position after setting to the automatic gearshift mode. Lever position

Gearshift mode

1

1st gear fixed

2

Automatic 1st and 2nd gear

3

Automatic 1st, 2nd and 3rd gear

SHIFTING DIRECTION 1. Release accelerator pedal (1), and fully depress brake pedal (2).

2. After the lift truck stops completely, move the forward/reverse lever from the forward [ I ] (F) to reverse [ O ] (R) position or vise versa. NOTICE Shift the direction only after the lift truck stops completely.

Forward

Neutral

Reverse

3 - 31

OPERATION

3.3 OPERATION

3.3.4 STARTING AND STOPPING ON SLOPE 1. When starting off the lift truck on an upslope, pull the parking brake lever in the direction to the rear of the truck. (Parking brake activated) 2. While gradually depressing accelerator pedal (1) return the parking brake lever to the forward direction of the truck slowly, allowing the lift truck to climb up the slope. (Parking brake being released)

3

Free

Lock

3. When the lift truck has gained some speed, release the parking brake lever comp letely. Climbing speed can be controlled by the amount of accelerator pedal (1) depressed. 4. When slowing down or stopping the lift truck on an upslope, release the accelerator pedal (1) gradually and depress the brake pedal (2) immediately before the lift truck stops. 5. After the lift truck stops completely, pull the parking brake lever to the rear direction of the lift truck. (Parking brake activated.)

3.3.5 INCHING TRAVEL

CAUTION Never carry out inching by depressing the accelerator pedal (1) and adjusting the amount the brake pedal (2) depressed.

Engaging the clutch halfway with the inching pedal (3) enables the lift truck to crawl along. NOTICE • Traveling a long distance while the clutch is half engaged can cause damage to the lift truck, so limit such travel to the shortest time necessary (less than 10 seconds). • Do not hold your foot rested on the inching pedal (3) while traveling. You may unintentionally engage the clutch half way, which can cause damage to the lift truck.

3 - 32

3

OPERATION

3.3 OPERATION

3.3.6 TURNING

3

CAUTION Take care to avoid the outside of the counterbalance-weight hitting against people and objects around when turning.

The forklift has rear steering wheels. When turning, keep to the inner side when advancing and outer side when reversing. REMARK • Turning the steering wheel with the lift truck stand still (stationary steering) will accelerate wear of the tyres. • Turning the steering wheel as traveling low speed will help to reduce this problem.

3.3.7 OPERATION ON SNOWY AND FROZEN ROADS

3

CAUTION • Be aware that even tyre chains or snow tyres cannot prevent skidding completely. • Tyre chains or snow tyres may not fit on some model. • Put on tyre chains or snow tyres when traveling on snowy or frozen roads. • Avoid sudden braking, acceleration, or steering on snowy or frozen roads. Operate the accelerator carefully or skidding may result.

3 - 33

OPERATION

3.3 OPERATION

3.3.8 TEMPORARY STOPPING, PARKING AND STOPPING

3

CAUTION Select a parking area well away from the traffic areas.

TEMPORARY STOPPING 1. Release the accelerator pedal (1), then depress brake pedal (2).

2. After the lift truck comes to a stop, apply the parking brake by pulling the parking brake lever in the direction to the rear of the lift truck. (Parking brake activated) After it stops completely, move the forward/reverse lever to the N (neutral) positions. REMARK When the parking brake lever is in the Free position, an d if you take a posture that your weight is not fully applied to the seat, e.g. leaving the operator's seat or leaning forward or sideways, the parking brake alarm buzzer (option) begins to sound. When it does, take the following actions.

When leaving the lift truck: Pull the parking brake lever in the rear direction of the lift truck to the Lock position. When continuing to operate the lift truck : Seat yourself properly.

3 - 34

Free

Lock

OPERATION

3.3 OPERATION

PARKING 1. Stop the lift truck on level ground. 2. Pull the parking brake lever to the rear direction of the lift truck. (Parking brake activated) 3. Set the forward/reverse lever to N (neutral).

Free

Lock

4. Tilt the mast forward and lower the forks to the floor. 5. Turn the starting switch key to the [Q] (OFF) position. 6. Pull out the starting switch key and leave the lift truck. REMARK If you leave the lift truck without pulling the parking brake lever in the direction to the rear of the lift truck, an alarm buzzer (option) will sound.

STOPPING 1. Run the engine at low idle for about 5 minutes to cool the engine down gradually. 2. Turn the starting switch to [Q] (OFF) position (1) to stop the engine. 3. Extract the starting switch key. NOTICE • Since sudden stopping before engine cooling shortens the engine parts service life, avoid sudden stopping unless in an emergency. • If the engine is overheated, do not stop the engine suddenly but stop it after gradual cooling at a medium speed.

3 - 35

OPERATION

3.3 OPERATION

3.3.9 LOAD HANDLING OPERATION FORK SPREAD ADJUSTMENT Before carrying out load handling, always adjust the space between the forks to fit the size of the pallets and loads.

CAUTION Take extreme care not to get hands or fingers caught while fork spread adjustment.

1. Move the lift truck in front of the load, and stop. 2. Position the mast vertically and lift the forks 10cm (4 in) above the ground. 3. Tilt the mast forward.

4. Remove stopper pin (1) at the rear of the fork. (In this condition, the forks can be moved to the left or right.)

3 - 36

3

3

OPERATION

3.3 OPERATION

5. Adjust the fork spread corresponding to the load size so that the center of gravity of the load coincides with the center of the lift truck. 6. Hold the mast in vertical position, insert the stopper pin to the end to lock the mast. (In this condition, the forks are locked in position.) 7. After fork spread adjustment, check that the forks are secured with the fork stopper. If forks are not secured, there is the danger that the forks freely move sideways to let the load fall, while the lift truck is traveling.

OPERATION OF CONTROL LEVERS

3

CAUTION Sit in the operator's seat properly and check that the surrounding area is safe before operating the lift control lever. Operating the lift truck when you are not seated properly or oper ating it from outside the operator's compartment can result in erroneous operation, and may result in serious injuries.

LIFT CONTROL LEVER Raise : Pull the lever backward. Lower: Push the lever forward.

Lower

REMARK A rising and lowering speed of the forks can be adjusted with the extent of lever tilting. Rising speed can also be adjusted by the degree of accelerator pedal depressed. Raise

TILT CONTROL LEVER Tilt forward : Push the lever forward. Tilt backward : Pull the lever backward.

Tilt forward

REMARK The forward and backward tilting speed of the forks can be adjusted with the extent of lever tilting and the degree of accelerator pedal depressed. Tilt backward

3 - 37

3.3 OPERATION

LIFT INTERLOCK (OPTION) • If you operate the lift truck in such a posture that your weight is not fully applied to the seat, like standing up or leaning forward or sideways, the Load Handling Interlock activates in approx. three seconds. Then each motion of the fork and mast is locked and none of them moves any more even if you operate the lift control lever or the tilt control lever.

• While lift Interlock is in operation, the lift interlock warning lamp on the instrument panel flashes. (See the figure at right.) • Return to operation condition : When you seat yourself properly on the operator's seat, the lift truck is ready for load handling operation again. Start the load handling operation again only after you check the surroundings for safety.

3 - 38

OPERATION

OPERATION

3.3 OPERATION

PICKING UP

3

1. Insert the fork up to the bottom. 2. If the fork cannot be inserted up to the bottom at one go, drive the lift truck forward until the fork is inserted into a pallet by 2/3 to 3/4 of the fork length and lift the load by 5 - 10 cm (2 - 4 in). Then drive the lift truck backward by 10 - 20 cm (4 - 8 in), lower the load once and then drive the lift truck once again until the fork is inserted up to the bottom. 3. Raise the load 5 - 10 cm (2 - 4 in) and reverse the lift truck to a position where the load can be lowered.

5 - 10 cm (2 - 4 in)

4. Lower the load to the height of 15 - 20 cm (6 - 8 in) above the ground and tilt the mast back.

15 - 20 cm (6 - 8 in)

STACKING

3

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

3 - 39

3.3 OPERATION

3.3.10 CHECKING AFTER OPERATION After all the above procedures have been finished and each part of the lift truck is cleaned, and before it is stored, carry out the following inspections. 1. Leakage of fuel, water, and battery electrolyte. 2. Cracks or damage. 3. Check faults found during operation and report them to the administrator. Be sure to place a sign or other notice identifying " Do Not Use ". (if necessary) 4. Lubricate the units (if necessary) For the procedure during cold weather, procedure with overheated engine, long-term storage, and loading and unloading of lift truck, see the followings: • For the procedure during cold weather, see "4.6 RUNNING IN COLD WEATHER (PAGE 4-39)". • For the procedure with overheated engine, see "4.7 ACTION IN ENGINE OVERHEATING (PAGE 4-41)". • For the long-term storage, see "4.11 LONG-TERM STORAGE (PAGE 4-46)". • For the loading and unloading of lift truck, see "4.13 LOADING AND UNLOADING OF LIFT TRUCK (PAGE 4-48)" .

3 - 40

OPERATION

3

INSPECTION AND MAINTENANCE 4

44

WARNING Please be sure that you fully understand this manual and the precautions related to safety for the lift truck. When inspecting or servicing the lift truck, always strictly follow these precautions. Failing to heed this warning may result in serious injuries.

4-1

INSPECTION AND MAINTENANCE

4.1 ABOUT INSPECTION AND MAINTENANCE

4. INSPECTION AND MAINTENANCE 4.1 ABOUT INSPECTION AND MAINTENANCE

4

4

This inspection and maintenance manual describes start-up inspection mandatory for the operators and replenishment of oil, cleaning of air filters and other related simple maintenance work. For other inspection and maintenance items not described here, contact KOMATSU FORKLIFT distributor. For your safe inspection and maintenance work, peruse "2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE (PAGE 2-31)". Carry on inspection and maintenance service with care. Incorrect maintenance and repair service may cause critical accident or shorten machine service life. Contact KOMATSU FORKLIFT distributor for maintenance and repair services.

4.2 START-UP INSPECTION

4

CAUTION • Do not operate the lift trucks before completing start-up inspection. • Report abnormality, if any, immediately to the administrator. Never operate the lift truck in question until the repair is completed.

OBLIGATION TO CONDUCT START-UP INSPECTION • For your safe operation, always conduct a start-up inspection of the lift truck before starting operation for the day. • Record and store the results of start-up inspection in the inspection record.

4-2



LIST OF START-UP CHECK POINTS

Item -

Check points Checking of repaired abnormalities detected on previous day Leakage of oil, fuel, coolant and battery electrolyte Cracks, damages and the state of mounting (of overhead gu ard, fork, load backrest, etc.) Loose tilt cylinder rod lock nuts

Walk around a lift truck

Contamination and/or damages of lamp, lens, etc. Contamination and/or damages of reflector Loose hub nuts Deformed or damaged tyres and rims Inflation pressure of tyres Engine oil level and contamination Coolant level Fuel pre-filter water draining

Open the covers and food

Checking of the brake cooling o il level (Wet disk brake type) Checking of water separator Hydraulic oil level Battery electrolyte level TORQFLOW transmission case oil level Damages and performance of seat belt Seat and steering wheel adjustment Brake pedal play and height

Sit on the operator seat

Inching pedal play and height Parking brake lever operating effort Horn performance Rear view mirror (option) contamination, damages and angle Performance of warning lamps on the instrument panel (Check by turning the starting switch ON and OFF)

Turn the starting switch to ON position

Operation of lamps Fuel level Backup buzzer performance Start-up condition and abnormal sound

Start the engine

Abnormal noise and vibration Exhaust gas color, exhaust sound Play of steering wheel Operating state of steering wheel (runout and unstable driving)

Travel slowly

Brake operating condition (response) Inching pedal operating condition (letting out the clutch, slip, inching travel) Low speed travel and accelerating state

Operating load handling

Mast operating condition Tension, damages and rusted condition of lift chain Travel interlock function (option)

Checking of safety function

Lift interlock function (option) Neutral safety function Overlooking application of parking brake, warning buzzer function (option)

4-3



4.2.1 CHECKING ABNORMALITIES DETECTED ON THE PREVIOUS DAY

4

Check again the abnormal points detected during the operation and closing inspection on the preceding day. Double check that no abnormality persists to exist.

4.2.2 WALK AROUND A LIFT TRUCK CHECKING FOR LEAKAGE OF FUEL, WATER, OR BATTERY ELECTROLYTE • Walk around the lift truck to check for leakage of oil, fuel, coolant and battery electrolyte. • Look under the lift truck to check for oil or water leakage.

CHECKING OF CRACKS, DAMAGES AND THE STATE OF MOUNTING Visually check for any damages, cracks, loose mounting and/or play. Give priority in checking the following points particularly. • Overhead guard • Fork • Fork carriage • Mast • Fuel tank • Hydraulic oil tank

CHECKING OF LOOSE TILT CYLINDER ROD AND LOCK NUTS Visually check if the tilt cylinder rod and the rod head are rotating in loose condition or if the lock nut (1) is loosened.

4-4

4



CONTAMINATION AND/OR DAMAGES OF LAMP, LENS, ETC Visually check lamp, lens, etc. for any contamination and/or damages.

CHECKING OF CONTAMINATION AND/OR DAMAGES OF REFLECTOR Visually check the reflector for any contamination and/or da mages.

CHECKING OF LOOSE HUB NUTS Check for loose hub nuts by tightening them with a wrench. NOTICE Tighten the hub nuts to the specified torque. For the right tightening torque, see "4.16 SERVICE DATA (PAGE 4-55)".

CHECKING OF TYRES AND RIMS • Visually check for any excessive wear, damages, spikes and other foreign matters stuck to the tyres, deformation and damages of the rims. • Replace a tyre if the slip sign (wear limit mark) should appear.

CHECKING OF INFLATION PRESSURE OF TYRES

CAUTION Tyres have high pressure air inside. When checking the infl ation pressure, position yourself to face the tyre tread surface (see the figure at right) while holding the tyre air gauge firmly.

Check the tyre inflation pressure with the tyre air gauge and adjust it to specified pressure. For the right tyre inflation pressure, see "4.16 SERVICE DATA (PAGE 4-55)".

4-5



4.2.3 INSPECTION CONDUCTED BY OPENING COVER AND HOOD

CAUTION • Before opening the engine hood, always stop the engine. • Be careful not to have hand caught when opening/closing the engine hood. • Only the authorized people are allowed to open the engine hood.

HOW TO OPEN THE ENGINE HOOD 1. Stand on the right side of the lift truck, and lift engine hood lock lever (1) with the left hand. The hood is unlocked. 2. Grip the engine hood handle (2) with the right hand, and pull it upward.

3. Lift the engine hood up until the red stopper (3) of the support stay is applied.

HOW TO CLOSE THE ENGINE HOOD 1. Manually release the red stopper of the support stay (arrow portion punched PRESS) by pushing it in the direction of the arrow (forward). 2. Grip the engine hood handle with the right hand and close the hood slowly. 3. Check that the engine hood is closed completely and locked.

4-6

4



CHECKING THE ENGINE OIL LEVEL IN THE OIL PAN 1. Check if the engine oil is within the normal range. 2. Withdraw the oil gauge. Wipe hydraulic oil off the oil gauge with a clean cloth and insert the gauge back into the tank. 3. Pull out the oil level gauge again and check that the stuck oil is within the normal range. 4. When hydraulic oil is low, replenish it. If the oil is spilt, wipe it off completely.

Correct range

NOTICE • When the engine oil is considerably contaminated or has been discolored, replace with new oil. • Always use Genuine Engine oil.

CHECKING OF COOLANT LEVEL

CAUTION Do not open the radiator cap immediately after the engine stops, since the coolant temperature is very high. Steam or boiling water may spurt out, causing burns. After the coolant temperature has gone down, turn the cap slowly to release the pressure before removing it.

• Check whether the coolant level is within the normal range, i.e. between FULL and LOW when the coolant in the radiator reservoir tank in the engine hood is in a cooled state. • If not in normal range, refill coolant to FULL position. • Check the radiator and radiator hose for any water leakage. Correct range

• When the cooling water in the reservoir tank is all gone, open radiator cap (1) to refill the radiator tank and reservoir tank with coolant.

4-7



FUEL PRE-FILTER WATER DRAINING

CAUTION • Beware the engine is high-temperature immediately after stopping. Drain water and/or bleed air after the engine temperature has lowered sufficiently. • When draining water, fuel is also drained. Receive them in a oil pan. Always wipe spilt fuel off and keep it away from open flame. 1. Remove the cover on the left side of the lift truck. 2. Loosen the drain plug (1) on the bottom of the fuel filter and drain water and sediments deposited. 3. After draining, tighten the drain plug (1) securely.

CHECKING OF THE BRAKE COOLING OIL LEVEL (WET DISC BRAKE TYPE) 1. Remove the cover on the left side of the lift truck. 2. Check the oil level with the gauge (1) on the side of the brake cooling oil tank. The level must be higher than the middle point. 3. If the oil is low, remove the cap (2) and refill the brake cooling oil to higher than the middle point of the gauge (1). NOTICE • When replenishing brake cooling oil, be careful not to allow sands and dirt to enter the oil tank. • Shortage in the brake cooling oil may cause overheating of the brake. • For the brake cooling oil, see "4.4.1.2 LUBRICANT LIST (PAGE 4-24)".

4-8



CHECKING OF WATER SEPARATOR (* REF)

CAUTION • Beware the engine is high-temperature immediately after stopping. Drain water and/or bleed air after the engine temperature has lowered sufficiently. • When draining water, fuel is also drained. Receive them in a oil pan. Always wipe spilt fuel off and keep it away from open flame. The water separator is used to separate water from fuel. Drain water according to the following steps when the float (2) exceeds the red line (1).

Fuel pre-filter

Water separator

DRAIN WATER 1. Remove the cover on the left side of the lift truck. 2. Loosen the drain plug (3) and drain the trapped water until the float (2) reaches bottom. 3. After draining, tighten the drain plug (3) securely. REMARK If air leaks into the fuel circuit during draining water, bleed air, referring to "4.4.3 FUEL PRE-FILTER AIR BLEEDING (PAGE 429)".

* REF (Reliable-Extra-Filtration) : This specification provides an additional main filter and a filter with the water separation function for the inferior fuel.

CHECKING OF OIL LEVEL IN HYDRAULIC TANK Sight gauge (1) and hydraulic oil tank filler port (2) are provided on the right side of the lift truck. With the sight gauge (1), the oil contamination and approximate level of the oil can be checked.

1. Wipe hydraulic oil off the oil gauge (integrated with the breather) (3) with a clean cloth and insert the gauge (3) into the tank. 2. Pull out the oil level gauge (3) again and check that the stuck oil is within the normal range. 3. When hydraulic oil is low, replenish it. If the oil is spilt, wipe it off completely.

Correct range

NOTICE Always use Genuine Hydraulic oil.

4-9



CHECKING OF BATTERY ELECTROLYTE LEVEL

CAUTION Batteries generate flammable hydrogen gas and may explode. Battery electrolyte also contains dilute sulfuric acid. Handling error may cause personal injuries, explosions and fires. Strictly follow the "2.6.15 CAUTION WHEN HANDLING BATTERY (PAGE 2-35)".

• Check whether the battery electrolyte level is within the normal range between the upper limit line (A) and lower limit line (B). If the level is low, refill it with distilled water until the level re aches the upper limit line (A). • Always keep the breather and terminal of the battery cap on the top of the battery clean with no dust attachment.

Correct range

NOTICE • If the battery electrolyte has spilled and the level has gone down, have your battery repair shop add dil ute sulphuric acid of the same density. • Do not use a metal funnel when adding distilled water or dilute sulphuric acid.

CHECKING OF OIL LEVEL IN TORQFLOW TRANSMISSION CASE

CAUTION Immediately after operations, the oil is at high temperature. Wait for the temperature to go down before starting this operation.

1. Open the inspection window in the floor plate and check with the dipstick (1). 2. If the oil level is low, remove the oil filler plug (2) and add oil. Correct range

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4.2.4 CHECKING FROM THE OPERATOR SEAT


4

CHECKING OF SEAT BELT

Upon sitting on the operator seat, first check the seat belt. • Any damages to the belt and/or fittings? • Does the belt come out and retract smoothly? Does the fitting lock and unlock without abnormality? • Does the belt lock when pull suddenly?

CHECKING THE SEAT AND STEERING WHEEL POSITION

Upon sitting on the operator seat, check if the pedals, levers and switches can be operated smoothly. For the position of the seat and steering wheel, see the section for "SEAT POSITION ADJUSTMENT (PAGE 3-24)" and "ADJUSTING STEERING WHEEL POSITION (PAGE 3-26)".

CHECKING THE BRAKE PEDAL

Check the brake pedal for correct application effort, play and for correct dimensions of the pedal height. For the standard values of the play (S1) and pedal height dimensions during braking effort (H), see the "4.16 SERVICE DATA (PAGE 4-55)".

CHECKING THE INCHING PEDAL

Check the brake pedal for correct application effort, play and for correct interlocked stroke with the brake pedal. For the standard values of the play (S2) and the interlocked stroke dimension (S3), see the "4.16 SERVICE DATA (PAGE 4-55)".

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CHECKING THE PARKING BRAKE LEVER Check if the parking brake lever can be pull back fully toward the rear of machine. Also check if the parking brake lever returns fully and smoothly when released toward the front of the machine. For the standard value of the lever operating effort, see "4.4.5 ADJUSTING PARKING BRAKE LEVER OPERATING EFFORT (PAGE 4-32)". NOTICE If the value of the lever operating effort is not within the standard range, contact your KOMATSU FORKLIFT distributor for repair.

CHECKING THE HORN Check if the horn sounds normally when switched ON.

CHECKING THE REARVIEW MIRROR (OPTION) Check if the mirror is set at an easy angle for the operator to see the rear. Also check for any contamination or damages.

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Free

Lock



4.2.5 CHECK BY SETTING THE STARTING SWITCH TO [ | ] (ON) POSITION

4

CHECKING PERFORMANCE OF WARNING LAMPS ON THE INSTRUMENT PANEL Check that the following lamps are ON when the starting switch is set to the [ | ] (ON) position: engine oil pressure warning, charge warning, lift interlock warning lamp (option), radiator coolant level warning lamp and the air cleaner element warning lamp. REMARK • Lift interlock warning lamp will flash if the operator fails to sit on the seat correctly. For more details on the function of load handling interlocking, see "LIFT INTERLOCK (OPTION) (PAGE 3-38)". • Engine abnormality warning lamp turns out approx. 2 seconds after lighting.

Engine warning lamp

Charge warning lamp

Lift interlock warning lamp

Failure indicator

Radiator coolant level warning lamp

Air cleaner element warning lamp

NEUTRAL INDICATOR LAMP (OPTION) The neutral indicator lamp is functioning normally when it lights up as the starting switch is set to the [ | ] (ON) position, and goes off when forward/reverse lever is set to forward (F) or rear (R).

ENGINE COOLANT TEMPERATURE GAUGE The pointer points to the left when the engine is cold, and po ints at the white range when warmed up.

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PARKING BRAKE WARNING LAMP

The parking brake warning lamp is normal if it lights up when the parking brake lever is moved toward the rear of the lift truck (lock position) with the starting switch in the [ | ] (ON) position and if it turns out when the parking brake lever is returned toward the front of the lift truck (free position).

CHECKING OPERATION OF LAMPS

Check if the head lamps, clearance lamps, turn signal lamps, brake lamps and backup lamp work normally.

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CHECKING OF FUEL TANK LEVEL AND REPLENISHMENT

CAUTION • Before refilling fuel, always stop the engine and keep fire away. • When refilling fuel, never let the fuel overflow. This may cause a fire. If the fuel is spilt, wipe it off completely. Check the fuel gauge to see if the fuel tank contains enough fuel for the day's work. • When fuel level gauge needle points to (A), the fuel tank is full. • If the fuel level is low, stop the engine and refill fuel from the fuel filler port while watching the oil gauge (1). • When refilling, remove dirt in and around the filler port cap (2) to prevent the dirt from entering the fuel tank.

• After refilling, tighten the filler port cap (2) securely and wipe off spilt fuel without fail. NOTICE Always use diesel oil for the fuel. To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted on this machine uses an electronically controlled high-pressure fuel injection device. This device requires high precision parts and lubrication, so if low viscosity fuel with low lubricating ability is used, the durability may drop markedly. REMARK The following indicate approximate fuel capacity when the fuel gauge needle points at the center of the scale.

Model 10.0 - 11.5 ton

13.5 - 16.0 ton

Center

Full

110 l (29.06 US gal) [24.2 UK gal] 130 l (34.35 US gal) [28.6 UK gal]

260 l (68.69 US gal) [57.2 UK gal] 280 l (73.98 US gal) [61.6 UK gal]

Fill up position

CHECKING BACKUP BUZZER PERFORMANCE

CAUTION Check the backup buzzer performance under the following conditions. • Pull the parking brake lever in the direction to the r ear of the machine and step on the inching pedal.

Check that the backup buzzer sounds when the forward/reverse lever is set to the REVERSE position.

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4.2.6 CHECKING WITH THE ENGINE STARTED

4

CAUTION Exhaust gas is toxic. When starting engine indoors or in a poorly-ventilated site, take extreme care for ventilation.

CHECKING OF ENGINE START-UP CONDITION AND ABNORMAL SOUND • When starting the engine, check for abnormal noise and start-up condition. • Check that no abnormal sound is emitted during idling and slightly higher revolution. • When engine starts with abnormal sound, it may be damaged if that condition is allowed to persist. Contact your KOMATSU FORKLIFT distributor for checking at an early data.

CHECKING THE GOING OFF OF WARNING LAMPS ON THE INSTRUMENT PANEL • Check that the warning lamps on the instrument panel go off immediately upon starting the engine. • Engine pressure warning lamp may goes off with slight time lag, which does not mean a failure.

CHECKING ABNORMAL NOISE AND VIBRATION Check in particular that there is no abnormal noise or abnormal vibration from the engine or hydraulic pump .

CHECKING ENGINE EXHAUST GAS COLOR AND SOUND • Check if the color of exhaust gas is not in black or white. • Check the exhaust sound for any abnormality. REMARK • For diesel engines, some black or white exhaust gas may be emitted immediately after the engine start, which is n ot abnormal. • Black or white exhaust may be caused by the following: Black: Incomplete combustion White: Engine oil scraped up or scraped down

CHECK THE STEERING WHEEL FOR PLAY • Check the play of steering handle by operating it in the direction of a turn. Play should be normal if within 30 - 60 mm (1.2 - 2.4 in). • Check if it is free of looseness by shaking it in the vertical and longitudinal directions.

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30 - 60 mm (1.2 - 2.4 in)



4.2.7 CHECKING WHILE TRAVELING SLOWLY

4

CHECKING OF THE STEERING WHEEL FUNCTION Check the following points by operating the wheel while traveling slowly. Make sure that: • The steering wheel does not have any 'play'. • The steering wheel is stable (i.e. : does not move left or right) when the vehicle traveling in a straight line. • The steering wheel does not have any abnormal swing or does not seem heavy when it is turned.

CHECKING OF BRAKE FUNCTION Check the brake response by stepping on the brake pedal while traveling slowly. Make sure that: • The brakes are operating effectively. • Both brakes are responding, (not just one side).

CHECKING THE INCHING PEDAL FUNCTION Check the inching function by stepping on the inching pedal while traveling slowly. • Can the travel speed be adjusted according to the stepping effort of the inching pedal? • Does the lift truck stop when the inching pedal is fully stepped on?

CHECKING OF ENGINE DURING LOW SPEED TRAVEL AND ACCELERATION Check the engine revolution for any irregularity or stall upon stopping the truck after normal traveling. Check that the truck accelerates smoothly when the accelerator pedal is depressed. • Conduct the checking in a safe place by paying attention to the surrounding area. • When the truck has seriously adverse conditions in the low speed travel and acceleration, it may damage the engine, confuse the operator's driving sense, degrade braking effect and lead to other unexpected accidents if such engine conditions are allowed to persist.

CHECKING OF ABNORMAL NOISE AND ODOR Check that no abnormal sound or odor is emitted while traveling slowly.

4.2.8 CHECKING BY OPERATING THE WORK EQUIPMENT LEVER

4

CHECKING OF MAST FUNCTION AND ABNORMAL NOISE AND ODOR • Check that the forks lift and lower smoothly and the mast tilts forward and backward smoothly during operation of the work equipment lever from the operator seat. Always make full stroke operation of cylinder piston two to three times everyday before starting work. • Check that no abnormal sound or odor is emitted while operating the work equipment lever.

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CHECKING OF TENSION OF LIFT CHAIN

CAUTION • If the chain tension is asymmetrical to the left and right, load would concentrate on the chain of one side to cause it to break, leading to the falling of material and the tipping over of lift truck. • To prevent the lift truck from traveling uncontrolled or the checking personnel from being caught by the truck, set the forward/reverse lever to the neutral position, pull the parking brake lever in the direction of the truck, stop the engine, and alight from the truck before starting check. • Never step the foot under the fork as it may get caught. 1. Raise the fork 40 - 50 cm (15.8 - 19.7 in) from the ground. (A) 2. Press the center of lift chain with a finger and check if the tension is equal to the right and left.

CHECKING OF LIFT CHAIN

CAUTION • If the lift chain break, the load may fall down or the lift truck may tip over. When lift chain is found abnormal with damages and cracks, please contact your KOMATSU FORKLIFT distributor for replacement of the lift chain. • Rust on the lift chain is a cause of damages and cracks. Take rust preventive measures at an early date to keep rust off. 1. Visually check lift chain for any damages, cracks and rust. 2. Check the state of lubrication of lift chain. If it is in poor state or rust has generated on the lift chain, apply engine oil, etc. on it.

CHECKING OF ATTACHMENT FUNCTION AND ABNORMAL NOISE AND ODOR (FOR MACHINES WITH ATTACHMENTS) Check the attachment according to the relevant operating manual.

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4.2.9 CHECKING OF SAFETY FUNCTION

4

CAUTION • Check this function by placing the lift truck on a level, hard flat road surface. • Secure enough traveling space without human beings and other obstacles around the lift truck.

CHECKING OF TRAVEL INTERLOCK FUNCTION (OPTION) Check the safety function to disable the lift truck to travel when the operator is away from the seat.

CHECKING PROCEDURE 1. 2. 3. 4. 5.

Park the lift truck in a level, flat and hard surface and apply the parking brake. (Parking brake activated) Set the forward/reverse lever to the N (neutral) position, and raise the forks 15 cm (6 in) above the ground. Step the foot off the brake pedal, inching pedal and accelerator pedal. Set the forward/reverse lever to F (forward) or R (reverse) and lift the hip from the seat. Check that the travel interlock warning lamp (with N mark) on the instrument panel starts flashing about 3 seconds later. 6. In this condition, release the parking brake. (Parking brake being released) 7. Depress the accelerator pedal with your hip lifted from the seat, and check that the lift truck does not travel. 8. Releasing travel interlock function. Sit on the seat correctly and set the forward/reverse lever to N (Neutral) position. Flashing travel interlock warning lamp turn out and the lift truck returns to normal operating conditions.

CHECKING OF LIFT INTERLOCK FUNCTION (OPTION) Check the safety function to disable the lift operation when the operator is away from the seat.

CHECKING PROCEDURE 1. Park the lift truck in a level, flat and hard surface and apply the parking brake. (Parking brake activated) 2. Set the forward/reverse lever to the neutral position, and raise the fork to a position about 1 meter from the ground which is visible to the operator. 3. Step foot from every pedal and lift the hip from the seat. 4. Check that the lift interlock warning lamp on the instrument panel starts flashing about 3 seconds later. 5. Check the following in this state: • The forks do not rise or lower if the lift lever is operated. • The mast does not tilt forward or backward if the tilt lever is operated. 6. Releasing lift interlock function. Take a right posture in the operator's seat. Flashing lift interlock warning lamp turn out and the lift truck returns to normal operating conditions.

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4.3 CHECKING AND REPORTING AFTER OPERATION


CHECKING OF NEUTRAL SAFETY FUNCTION (OPTION) Check the neutral safety function to prevent the risk of the lift truck suddenly traveling when the engine is started with the forward/reverse lever set in either forward (F) or reverse (R) position.

CHECKING PROCEDURE 1. Park the lift truck in a level, flat and hard surface and apply the parking brake. (Parking brake activated) 2. Set the forward/reverse lever to N (neutral) and stop the engine. 3. Check that the starter motor does not run and the engine does not start if the starting switch is set to [ | ] (START) position and the forward/reverse lever set to either forward (F) or reverse (R) position. 4. Releasing neutral safety function. After checking the neutral safety function, set the forward/reverse lever to the neutral position. The neutral safety function is released and the engine returns to normal state. The engine starts when the starting switch is set to [ | ] (START) position.

CHECKING OF WARNING BUZZER AGAINST OVERLOOKING APPLICATION OF PARKING BRAKE LEVER (OPTION) Check the warning function that activates a buzzer if the operator leaves the seat without pulling the parking brake lever to the rear direction of the lift truck.

CHECKING PROCEDURE 1. Park the lift truck in a level, flat and hard surface and apply the parking brake. (Parking brake activated) 2. Set the forward/reverse lever to the neutral position, and lower the forks to the ground. Tilt the mast forward until the fork is in contact with the ground. 3. Stop the engine. Pull out the starting switch. Return the parking brake lever to the forward direction of the lift truck (release) and leave the seat. 4. Check that the warning buzzer sounds about 3 seconds later. 5. Stopping the sound of warning buzzer Pull the parking brake lever to the rear direction of the lift truck. The buzzer stops sounding and the system returns to normal state.

4.3 CHECKING AND REPORTING AFTER OPERATION

4

Checking and reporting after the day's operation are important job for getting the lift truck ready for operation on the following day. Before washing and storing the lift truck after the day's operation, take the following check procedure and always report to the administrator on the finding. 1. 2. 3. 4.

Checking of leakage of oil, fuel, coolant and battery electrolyte. Checking of cracks, damages and loosened parts, etc. Grease up and lubricate the parts if necessary. Checking of abnormal points detected during the operation.

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4.4 SIMPLE MAINTENANCE 4.4.1 GREASES AND FUEL 4.4.1.1 BASIC PRECAUTIONS

4.4 SIMPLE MAINTENANCE

4

4

4

When refilling greases according to " Start-up inspection " and/or " Checking after operation ", do so by understanding the following basic cautions for required greases.

OIL

CAUTION • When checking leakage from hydraulic piping or hose, do not touch it directly by hand. The pipe or hose may be pressurized and can be dangerous. • If your skin and/or eye are injured by high-pressure oil, wash the skin/eye with fresh water and immediately see a physician. • For other than leakage that can be checked visually by the appearance, call your KOMATSU FORKLIFT distributor for inspection and repair service. • Since engine oil, hydraulic oil, TORQFLOW transmission oil, gear oil, etc. are used under severe conditions (at high temperature and high pressure), they deteriorate as the operation time passes. Therefore oil must be changed periodically. For the standard oil change intervals, see "OIL AND GREASING CHART (PAGE 4-24)" and "LUBRICANT LIST (PAGE 4-25)". • Always replace oil at the specified period even if not deteriorated. • Always use Genuine Engine oil. At shipment from a plant, the lift truck is applied with those listed in the "LUBRICANT LIST (PAGE 4-25)". • Never mix oils of different grade (class) or brand. • A lift truck should be maintained so that contaminants (water, metal chips, dust, etc.) do not enter the lift truck system. Most lift truck malfunctions are caused by entry of impurities such as dirt, dust, water, etc. Take special care to avoid entry of impurities during storage and lubrication, etc. • Add specified volume of oil. Insufficient or excessive amounts of oil may both cause problems. • If the hydraulic oil has become murky, there is a possibility that either air or water entered into the circuit. If no corrective measures were taken, it may damage the lift truck. In such a case, call your KOMATSU FORKLIFT distributor for their service. • When replacing oil, replace the relevant filters at the same time. For oil and filter changes, contact your KOMATSU FORKLIFT distributor for service.

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FUEL

CAUTION Always use diesel oil for the fuel. To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted on this machine uses an electronically controlled high-pressure fuel injection device. This device requires high precision parts and lubrication, so if low viscosity fuel with low lubricating ability is used, the durability may drop markedly.

• At the end of the day's work, fill the fuel tank to full. Reducing the air inside the fuel tank helps reduce mixture in the fuel of condensed moisture from the air. • Since the fuel pump is a precision machine, it may fail to operate if fuel containing moisture and/or impurities is used. Take special care to avoid entry of moisture and impurities during storage and lubrication. • Always use fuel of appropriate grade from among those listed in the "LUBRICANT LIST (PAGE 4-25)". • When a diesel engine runs out of fuel or has its filters replaced, the fuel circuit has to be purged.

COOLING WATER (COOLANT AND DILUTED WATER)

CAUTION • After the engine stops, the coolant temperature is very high, and high pressure is accumulated inside the radiator. Do not remove the radiator cap under these conditions or it may cause burns. After the coolant temperature has gone down, turn the cap slowly to release the pressure before removing it. • Undiluted Supercoolant is flammable. So keep i t away from open flame. • Dilute the coolant according to the ambient temperature before applying to the radiator. Use distilled or soft water for dilution. Hard water contains high mineral contents (calcium and magnesium). These contents are deposited inside the radiator as water stain and scale, causing an overheat of engine. They are difficult to remove. For the radiator, it is recommended to use diluted water having total hardness of 100 ppm (mg/ l) or under. • This lift truck is filled with Genuine Supercoolant (FAF-NAC). This Supercoolant has other important function as the corrosion inhibitor of the cooling system than antifreeze function. Continue to use this Supercoolant in an area where antifreeze is not required. Using other brand of coolant may cause critical failure to the cooling system including the engine. • Genuine Supercoolant is good for continual use for two years or 4,000 service hours. • Apply different mixing ratio for the Supercoolant according to the outside temperature. For the right mixing ratio, see "4.6 RUNNING IN COLD WEATHER (PAGE 4-39)". • Shortage of coolant causes engine overheating and corrosive defect of cooling circuit due to the mixing of the air.

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GREASE • Grease prevents the joints from seizure, rusting and noise emission. • Always use recommended grease and strictly follow the greasing intervals. For the type of grease, see the "LUBRICANT LIST (PAGE 4-25)". • Wipe clean old grease extracted after greasing. Wipe grease off with particular care from sections where attached sands and dirt promote the wear of the rotating units.

FILTERS • Filters are very important items which prevent impurities contained in the oil, fuel and hydraulic circuits from entering important machine components to cause failure. They require periodical replacement. Call your KOMATSU FORKLIFT distributor for service. • Never have your lift truck parts changed by other than. Never reuse filters (cartridge type) after washing. • Always use Genuine Filters. NOTICE • Special filter of high-efficiency filtration property is adopted for the Genuine Fuel filter cartridges. Always use Genuine Parts for replacement. • The common rail fuel injection system adopted for the machine is configured with components of higher accuracy compared with conventional injection pumps and nozzles. Using other fuel filter cartridges than Genuine Parts may cause mixing of foreign matters, leading to a failure of injection system. Never use substitute parts. • For inspection and maintenance of the fuel system, more care should be given for the mixing of foreign matters than before. Attached dirt, if any, must be fully washed off using fuel. • Some of commercial filters are inferior to the genuine product in performance. Using such fil ters may affect performance and durability of the fork truck. If genuine Komatsu Utility products are not used, quality assurance may not apply.

4 - 23



4.4.1.2 LUBRICANT LIST

4

OIL AND GREASING CHART (OIL, GREASE LOCATIONS AND INSPECTION AND MAINTENANCE INTERVALS)

Fork slide shaft

4

Differential case

Lift chain

Tilt cylinder pin TORQFLOW transmission

Mast support

Pedal pin

Engine oil pan

Brake cooling oil tank (option)

Hydraulic tank Power steering cylinder pin

Center pin, King pin

Daily inspection Once every 2 week (100 hours) Monthly (200 hours) Every 2 months (400 hours) Every 3 months (600 hours) Every 6 months (1200 hours)

E: Q T

Check and add fluid if necessary : Total oil change or greasing and application Symbol Type of fluid : Figure inside the box shows the number of places to apply oil EO Diesel engine oil or grease to. MO Engine oil GO

Gear oil

HO

Hydraulic oi oil

G

4 - 24

Lithium grease



LUBRICANT LIST

4

Ambient temperature Lubrication point

Type of fluid

-22

-4

14

32

50

68

86

140 F

-30

-20

-10

0

10

20

30

40 C

°

°

SAE J300 0W30 (*1) SAE J300 5W40 (*1) Engine oil pan

Diesel engine oil

SAE J300 10W30 (*1) SAE J300 15W40 (*1) SAE J300 30 (*1)

TORQFLOW transmission case

Differential case

Engine oil

SAE 10W (*2)

SAE 80 Gear oil SAE 90

SAE 5W (*2) Hydraulic system

Hydraulic oil SAE 10W (*2)

ASTM Grade No.1-D S15 ASTM Grade No.1-D S500

Fuel tank

Diesel fuel ASTM Grade No.2-D S15 ASTM Grade No.2-D S500

Brake cooling oil (option)

Engine oil

SAE 10W (*2)

Greasing points

Lithium grease

G2-LI

Cooling system

Super coolant

*1 Use API CF-4 or higher grade oil. *2 Use API CD or higher grade oil.

FAF-NAC SAE : Society of Automotive Engineers ASTM: American Society of Testing and Material API : American Petroleum Institute

4 - 25



Capacity

Engine oil pan Model

10.0 ton 11.5 ton 13.5 ton 15.0 ton 16.0 ton

20.3 l (5.36 US gal) 4.47 UK gal

TORQFLOW transmission Diffe ifferrenti ential al cas case e Hydr ydrauli aulic c tank tank case

40 l (10.57 US gal) 8.80 UK gal

20 l (5.28 US gal) 4.40 UK gal

Fuel Fuel ta tank

170 l 260 l (44.91 US gal) (68.69 US gal) 37.4 UK gal 57.2 UK gal 200 l (52.8 US gal) 44.0 UK gal

280 l (74.0 US gal) 61.6 UK gal

Brake cooling Cooling system oil tank (option)

14.5 l (3.83 US gal) 3.19 UK gal

28 l (7.40 US gal) 6.16 UK gal

NOTICE • Always use diesel oil for the fuel. To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted on this machine uses an electronically controlled high-pressure fuel injection device. This device requires high precision parts and lubrication, so if low viscosity fuel with low lubricating ability is used, the durability may drop markedly. • Always use Genuine Parts for greases.

CAUTION Using wrong type brake fluid may cause critical failure to the brake s ystem. Check the type of brake fluid without fail before using.

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4.4.2 AIR CLEANER ELEMENT CLEANING

4

CAUTION • Physical injuries may be caused by being caught by the fan or in the belt while the engine is running. Always stop the engine before removing or cleaning the air cleaner element. • While cleaning the element, dust may fly out to enter the eye or be inhaled. Always wear safety goggles, dust mask and other protective gears. Clean the element in a place where no other persons are endangered by it.

CLEANING NOTICE • Checking, cleaning or maintaining the air element while the engine is running may allow the dirt to enter the engine, damaging it. Carry on maintenance work always after stopping the engine. • Do not knock the element, or hit it against something hard or let it fall. • When the working environment or conditions are less than normal, clean the element at a shorter interval. • When the element is wet, clean it only after it dries off. (Cleaning with air blow)

1. Release the latch (1) (at four locations) and take off the service cover (2). 2. Turn the element (3) with both hands to take it off. If it is too hard to turn, shake it lightly to the left and right as well as up and down. 3. Clean the interior of the air cleaner body (4) and the service cover (2).

O-ring

4. There are two ways to clean the element (3). They are; • Cleaning with compressed air (effective with dried dust) Blow dry compressed air from within the element (3) along folds, moving the nozzle tip up and down.The compressed air pressure then should be lower than 0.69 MPa (7 kgf/cm2, 99.4 PSI), and keep an adequate distance (approx. 50 cm (19.7 in) between the nozzle tip and the filter. • Cleaning with water (effective with oil and smut) Immerse the element in water of neutral detergent for about 30 minutes. Take care so that no dust enters inside the element at that time. Then rinse the element in clean water and let it dry off naturally.

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REMARK Hot water and hot air may also be used for cleaning and drying. In that case, keep the temperature of water and air lower than the level indicated below.

Hot water cleaning: Lower than 50 C (122 F) Hot air drying : Lower than 60 C (140 F) °

°

°

°

5. After cleaning, shine the interior of the element with a light bulb for inspection. If a small hole or thinned portion is found, replace the element with a new one. NOTICE • Do not use an element with a damaged fold or seal. • If a mark like a stripe appears on the element seal, it is a sign of dust leakage. So do not use an element having such a mark any longer.

6. Set the cleaned element, install the service cover and fasten the element with the latch. 7. If the air cleaner element clogging warning lamp lights on immediately after the cleaning, replace it with a new one. REMARK • Always use Genuine Parts for the elements. • Contact your KOMATAU FORKLIFT distributor replacement of elements.

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for

the

O-ring


4.4.3 FUEL PRE-FILTER AIR BLEEDING


4

1. Fill up the fuel tank to full (to the maximum rising position of the float). 2. Loosen and pull out the knob (2) of the feed pump. Operate it forward and backward. • The plug on the side of the fuel pre-filter head need not be removed. • Keep operating the pump until the knob (2) starts meeting resistance. 3. When bleeding of the air is completed, push back and tighten the feed pump knob (2). REMARK

• The fuel filter main body need not be removed. • If the lift truck runs out of fuel, operate the feed pump same way to bleed the air. • Contact your KOMATSU FORKLIFT distributor for the replacement of the fuel filter.

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4.4.4 REPLACING TYRES

WARNING • Beware of danger of being caught by the jack if it came away. When lifting the lift truck with a jack, check that the jack is firmly in place. Do not crawl under the lifted truck body. • Forklift truck tyre air pressure is high and dangerous. • Do not disassemble/assemble tyre, tube and rim or fill removed tyres from the lift truck with the air. 1. Unload the lift truck. Stop it on level, flat and hard road surface. (Apply parking brake) 2. Put blocks under the tyre diagonally opposite to the tyre which is to be replaced. 3. Always jack a lift truck up by the specified jack up point. • For replacing a front tyre - - - Under the outer mast. • For replacing a rear tyre - - -Under the counterbalanceweight. 4. Jack the lift truck up to a level where the tyre is still slightly in contact with the ground. Place a block under the lift truck frame for preventing the falling. Place the block in front when replacing a front wheel, and in the rear when replacing a rear tyre.

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4



5. Removing tyres.

WARNING • For safety, when filling a tyre with air or replacing it, place your body in front of the tread face of the tyre. Do not work from the side of the tyre. • When adjusting the air pressure with an air compressor, adjust the compressor pressure in advance to prevent pressurizing the tyre beyond the specified level. • Deformed or cracked rim poses a great danger. Before installing a replacement tyre, check it thoroughly. Do not use a tyre with deformed or cracked rim.

(1) Using a hub nut wrench or other tool, loosen the hub nuts(1) until they can be turned manually. (2) Jack the lift truck up until the tyre slightly clear the ground. Remove the hub nuts (1) and remove the tyre.

6. Install a replacement tyre to the hub. Tighten the hub nuts(1) temporarily. Tighten the nuts diagonally until the tyre does not rattle. 7. Remove the block from under the frame. Lower the jack and tighten the hub nuts (1) with the specified torque. For the right tightening torque, see "4.16 SERVICE DATA (PAGE 4-55)". 8. Adjust the tyre inflation pressure to specified pressure. For the right tyre inflation pressure, see "4.16 SERVICE DATA (PAGE 4-55)". 9. After replacing the tyre, have a trial run to check the hub nuts (1) for looseness. Tighten if necessary.

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4.4.5 ADJUSTING PARKING BRAKE LEVER OPERATING EFFORT

4

CAUTION Block the front and rear tyres before starting adjustment.

1. Press push button (1) and set parking brake lever (2) to the front direction (free position) of the lift truck.

Free

Lock

2. Turn the visible adjust bolt (3) with a driver and adjust the parking brake lever operating effort to reach the specified value. Turn the bolt clockwise : Operating force increases Turn the bolt counterclockwise : Operating force decreases For the standard value of the parking brake lever operating effort, see "4.16 SERVICE DATA (PAGE 4-55)".

4.4.6 REPLACING FUSES If the lamps and indicator lamps fail to light up or the control system fails to operate, there is a possibility that fuses may be blown. Check fuses that protect each equipment and system for blowing.

CAUTION • When replacing the fuses, always turn off the electric power (turn the starting switch to [ ] (OFF) position before replacing. • Always use fuse of same capacity for replacement. • If replaced fuse is blown again, abnormal electric system may be causing the problem. Contact KOMATSU FORKLIFT distributor for checking. 1. Turn the starting switch to the [Q] (OFF) position. 2. Remove the cover on the right side of the lift truck. 3. Remove the fuse box cover (1). Remove the puller attached to the inside of the fuse box.

4 - 32

4



4. Hold the fuse with the puller to remove. Visually check if it is blown. 5. If a fuse is blown, replace it with spare fuse of same capacity.

RESPECTIVE FUSES AND THE DEVICES THEY PROTECT

• FUSE BOX Fuse capacity and related electrical component. No.

Capacity

Color

Related electrical component

1

15A

Green

2

10A

Red

Starting relay

3

10A

Blue

Clearance lamp, brake lamp

4

10A

Red

Buzzer

5

15A

Red

Horn

6

10A

Red

Turn signal lamp

7

10A

Blue

Head lamp

8

10A

Red

Meter panel

9

10A

Red

Accessory

10

10A

Red

Main

11

5A

12

10A

Engine controller

Orange Key signal Red

Option

The unmarked fuses (10A x 2, 15A x 1, 30A x 1) are spares.

• RELAY BOX Fuse related electrical component. No.

Related electrical component

13

Transmission valve (Forward)

14

Transmission valve (Reverse)

15

Buzzer

16

Main

17

Mast lock

18

Parking

4 - 33



4.4.7 REPLACING BULBS

4

If a lamp fails to light up, it may be caused by burnt bulb beside blown fuse. Replace the bulb after checking if the fuse is blown.

CAUTION • Always use bulb of same capacity for replacement. • If replaced bulb still fails to light up, abnormal electrical system may be causing the problem. Contact your KOMATSU FORKLIFT distributor for checking immediately. 1. Turn the starting switch to the [Q] (OFF) position, and the lamp switch to the OFF position. 2. Remove the lamp lens and replace the bulb.

Lamp name

capacity

Head lamp

60W (For 24V)

Turn signal lamp

25W (For 24V)

Clearance lamp

5W (For 24V)

Backup lamp

10W (For 24V)

Stop lamp

25W (For 24V)

Warning lamp

3W (For 24V)

Tail lamp

4 - 34

10W (For 24V)



4.4.8 CHECKING BRAKE ACCUMULATOR

4

CAUTION • Brake failure may lead to a serious accident. • If the alarm buzzer does not sound, or if the alarm buzzer sounds early, or if the alarm buzzer does not stop, do not move the lift truck under any circumstances.Please contact your Komatsu Forklift distributor immediately. Check the remaining pressure in the accumulator with the alarm buzzer. 1. Stop the lift truck at a safe horizontal place, then apply the parking brake. Free

2. Set the forward/reverse lever to neutral, depress the accelerator pedal, and run the engine at full throttle for approx. 1 minute to charge the accumulator.

Lock

Forward

Neutral

Reverse

3. Stop the engine, turn the starting switch to ON, depress the brake pedal, and check that the alarm buzzer sounds. Number of times of stepping down the brake pedal until the alarm buzzer starts sounding. Number of times of stepping down the pedal

Judgment

Min.10 times

Normal

Max.10 times

Abnormal

REMARK • When the remaining pressure in the brake accumulator is smaller than a certain value, the alarm buzzer sounds. • Each time you step down the brake pedal once, the remaining pressure in the accumulator will reduce. • It is normal that, when the accumulator is filled with oil pressure after being fully rotated for a minute, the alarm buzzer does not sound until the brake pedal is stepped down10 times. This means that it could b e fully filled with oil pressure because the accumulator is normal. On the other hand, when the alarm buzzer sounds before the brake pedal is stepped down 10 times, the accumulator could not be fully filled with oil pressure, and the accumulator is judged to be abnormal.

4 - 35



4.4.9 CHECKING FOR LOOSE ENGINE HIGH-PRESSURE PIPING CLAMPS, HARDENING OF RUBBER

4

Check visually and touch by hand to check that there is no loose bolts of the mounting clamps (2 places) for the high-pressure piping between the supply pump and the common rail and no hardening of the rubber. If there are any problems, the parts must be replaced. Contact for inspection and repair.

4.4.10 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAPS, HARDENING OF RUBBER

4

The fuel spray prevention caps (*14 places) on the fuel injection piping and both ends of the high-pressure piping act to prevent the fuel from coming into contact with high-temperature pa rts of the engine and causing a fire if the fuel should leak or spray out. Check visually and tou ch by hand to check that there are no missing caps, loose bolts or hardening of the rubber. If there are any problems, th e parts must be replaced. Contact for inspection and repair.

*

*

*

4 - 36

*

*


4.5 PROCEDURE FOR A DOWN BATTERY


4

If a battery is down, the lift truck can be started by using the battery of other lift truck via booster cables.

CAUTIONS ON CONNECTING / DISCONNECTING BOOSTER CABLES

CAUTION • When connecting the booster cables, never connect its positive ( + ) and negative ( - ) terminals. • When starting the engine using the booster cables, always wear protective goggles and rubber gloves. • When using other lift truck for starting engine, be careful not to allow the normal lift truck to make contact with faulty lift truck. Batteries generate hydrogen gas. Hydrogen gas is highly explosive, and is easily ignited with a small spark emitted near the battery. • Turn the starting switch to the [ ] (OFF) position on both the normal and faulty lift trucks when the booster cables are connected. Or the lift trucks may make a sudden movement when the power supply is connected. • Do not make mistake about the right connection of the booster cables. Start with the positive ( + ) terminal for connection. Conversely, start with the negative ( - ) terminal (grounding side) for disconnection. When making connection, the final length of cable is connected to the engine block of the faulty lift truck emitting the sparks. Make connection to a spot as separated from the battery as possible on the engine block. • When disconnecting the booster cables, never allow the clip to contact with other clip or the lift truck. • The mating battery for booster connection must have same voltage as one on the faulty lift truck.

BOOSTER CABLE CONNECTION Turn the starting switch to the [Q ] (OFF) position on both the normal and faulty lift trucks. Then set the forward/reverse lever to neutral. Check if the parking brake lever is ON and connect the cable according to the numbers in the figure in that order. 1. Connect the clip of booster cable (A) to the positive ( + ) terminal of the faulty lift truck. 2. Connect the other clip of booster cable (A) to the positive ( + ) terminal of the normal lift truck. 3. Connect the clip of booster cable (B) to the negative ( - ) terminal of the normal lift truck. 4. Connect the other clip of booster cable (B) to the engine block of the faulty lift truck.

Battery of normal lift truck

Battery of faulty lift truck

Engine block of faulty lift truck

NOTICE • Use appropriate size of booster cables and clips for the size of battery. • For the normal lift truck, use battery of same capacity as that on the faulty lift truck. • Check that the cables and clips are free from damages and corrosion • Connect the clip securely to the mating terminal or block.

4 - 37



STARTING ENGINE

CAUTION Check if both normal and faulty lift trucks for their forward/reverse lever being set to the neutral position and the parking brakes to ON.

1. Check that clips clips are securely securely connecte connected d to the the battery battery terminals. 2. Start the engine engine on the normal normal lift lift truck truck and raise raise the speed speed to full (maximum revolution). 3. Turn Turn the starting starting switch switch on the faulty faulty lift truck truck to [ | ] (START) (START) to to start engine. If the engine fails to start, try again after two minutes or over.

REMOVING REMOVING THE BOOSTER CABLES When the engine has started, remove the booster cables in reverse order to the connection. 1. Disconnect Disconnect the the clip of booster booster cable (B) from from the engine engine block block of the faulty lift truck. 2. Disconnect Disconnect the clip of of booster booster cable (B) (B) from the negative negative ( - ) terminal of the normal lift truck. 3. Disconnect Disconnect the other clip clip of booster booster cable cable (A) from from the positive positive ( + ) terminal of the normal lift truck. 4. Disconnect Disconnect the other clip clip of booster booster cable cable (A) from from the positive positive ( + ) terminal of the faulty lift truck.

Battery of normal lift truck

Battery of faulty lift truck

Engine block of faulty lift truck

4 - 38


4.6 RUNNING IN COLD WEATHER


4

PREPARATIONS FOR LOW TEMPERATURE When the temperature becomes becom es low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows.

FUEL, LUBRICANT AND HYDRAULIC OIL Use fuel, lubricant and oil of low viscosity. For specified viscosity, see the "4.4.1.2 LUBRICANT LIST (PAGE 4-24)". 4-24)" .

COOLANT

CAUTION • Supercoolant is toxic. Protect your skin and/or from it. If exposed to it, wash the skin/eye with fresh water and immediately see a physician. • For disposing Supercoolant-added waste coolant drained during the replacement of coolant and the repair of radiator, contact a disposal specialist or your KOMATSU KOMATSU FORKLIFT distributor. Supercoolant is toxic, so be sure not drain it to the drainage ditch or the ground. • Undiluted Supercoolant is flammable. Keep it away from fire. Don't smoke while handling it. NOTICE Use Genuine Supercoolant (FAF-NAC). (FAF-NAC). Other brands than Genuine Supercoolant are not recommended as principle.

When the lift truck is shipped out from the factory, it is filled with Supercoolant of concentration applicable to the outside temperature of -20 C. When the ambient temperature should fall below -20 C, raise the concentration of the coolant according to the following table. °

°

Diluted concentration for Supercoolant (FAF-NAC) Minimum temperature ( C) Concentration (%) °

- 10 30

- 15 35

-20 40

-2 5 45

- 30 50

- 35 55

Cautions when refilling or replacing coolant. • Dilute the coolant with distilled water or supply water (soft water) to an appropriate concentration for use. • Check the radiator radiator,, water pump and hoses for for any water leakage. leakage. • Drain all coolant coolant and flush flush the inside of the system system before adding adding new coolant.

4 - 39



BATTERY

CAUTION • Batteries generate flammable gas. Keep it away from open flame. • Battery electrolyte is hazardous substance. Protect your skin and/or from it. If exposed to it, wash the skin/eye with large amount of fresh water and immediately see a physician. • Battery electrolyte is hazardous substance, substance, so be sure not drain it to the drainage ditch or the ground. • Battery electrolyte dissolves the coating. If attached to the lift truck, wash it down with water immediately. immediately. • If battery is frozen, do not charge it or start the engine using other power supply. Or the battery may explode. • When the temperature drops, the battery performance is deteriorated, making engine start difficult. Insufficiently Insufficiently charged battery electrolyte may freeze. Get ready for the start in the following morning by charging the battery close to 100% at the day's end. • Since battery performance remarkably drops as the temperature drops, remove it from the lift truck, place it in a warmer place overnight and install it the following morning. (Particularly when the temperature is low or the lift truck is not to be used for some period) • If the battery electrolyte level is low, low, refill distilled water before starting operation the next morning. To To prevent freezing during the night, do not refill electrolyte after the end of operation. REMARK For finding the battery charge level, measure the specific gravity of battery electrolyte and convert it according to the following table.

Electrolyte temperature ( C) °

20

0

- 10

-20

1 00

1 .2 8

1 .2 9

1 .3 0

1 .3 1

90

1 .2 6

1 .2 7

1 .2 8

1 .2 9

80

1 .2 4

1 .2 5

1 .2 6

1 .2 7

75

1 .2 3

1 .2 4

1 .2 5

1 .2 6

Battery charge level (%)

PRECAUTIONS AFTER COMPLETION OF OPERATIONS OPERATIONS Drain water to prevent water deposited in the fuel pipe from freezing. For water draining, see "FUEL PRE-FILTER WATER DRAINING (PAGE 4-8)"

WHEN COLD SEASON IS OVER When the weather becomes milder with the change of season, do as follows. • Change oil of respective respective devices devices and fuel to those of specified viscosity viscosity according according to the "LUBRICANT LIST (PAGE (PAGE 4-25)" 4-25 )"..

4 - 40


4.7 ACTION IN ENGINE OVERHEATING


4

ACTION WHEN ENGINE HAS OVERHEATED

CAUTION When overheated, opening the radiator reservoir tank or radiator cap immediately after stopping engine let steam spurt out to cause burns. Do not open the cap until the engine cools down.

ENGINE OVERHEATING PREVENTION SYSTEM If the pointer of the engine coolant temperature gauge approaches the red range as the result of excessive rising of the eng ine coolant temperature, automatic function is activated to prevent the engine overheating. The abnormality warning lamp either lights up or flashes, engine speed being controlled and held at a specific level if the accelerator pedal is pressed on. Do not apply undue load to the truck. Wait till the engine coolant temperature gauge pointer starts lowering.

When the engine has overheated and the coolant temperature gauge points the red range, do not panic and take the following actions: 1. Park the lift truck in a safe place. 2. Keep the engine running at low idling, open the engine hood for better ventilation of the engine room. If the cooling fan is not running, stop the engine immediately. 3. When the water temperature gauge enters the white range, stop the engine. 4. Check the followings after the engine has fully cooled down. • Is the coolant level right? • Is the fan belt not sheared or loosened? • Is the engine oil level right? • Isn't the radiator clogged? 5. If coolant or engine oil level is low, refill to appropriate level. In the case of other failure or the cause of overheat is unknown, contact the administrator, stop using the lift truck and call your KOMATSU FORKLIFT distributor.

4 - 41


CLEANING INSIDE THE COOLING SYSTEM If water stain and/or rust is generated inside the cooling system, cooling efficiency is deteriorated, causing overheat. As the cooling system requires periodical inspection and washing using radiator detergent liquid, please call KOMATSU FORKLIFT distributor for maintenance service.

CLEANING OF RADIATOR FINS

CAUTION • To prevent flying objects from getting into your eyes, always wear protective glasses or goggles when cleaning. • Never direct compressed air, steam or water at yourself or any personnel as injury and/or burns may occur. Clogged radiator fins can cause engine overheat. Clean them by blowing the air, steam or water. Set the pressure for the air or steam for blowing as described below. Direct the nozzle at right angles. Air pressure : 0.98MPa ({10kgf/cm2}, 142PSI) or under Steam pressure : 0.39MPa ({4kgf/cm2}, 56.8PSI) or under

4 - 42



4.8 OPERATING LIFT TRUCKS IN SPECIAL ENVIRONMENT OR IN FORCIBLE WAY

4.8 OPERATING LIFT TRUCKS IN SPECIAL ENVIRONMENT OR IN FORCIBLE WAY

4

This lift truck is designed and tested to cover most customers' uses under general application or environment. Under some special working environment or condition that requires mode of operation quite punishing to the lift truck, abnormality and degradation occur to it including early failures, shorter service life, persisting failure to certain parts and failure of usually fault-free parts and components. When the lift truck is used under special environment or in forcible way, it requires to receive maintenance and various other measures appropriate to a lift truck subjected to such har d and trying operating conditions. For more details, call your KOMATSU FORKLIFT distributor.

EXAMPLES OF SPECIAL ENVIRONMENT OR FORCIBLE USE OF LIFT TRUCK • Operating environment where the lift truck has to travel on the roads covered with salt water, chemicals (acid and/or alkaline), solvents, etc. or it is indirectly poured or attached with them via operator's hands and feet. • Environment surrounded by corrosive gases that corrode metal and/or resin. • Environment near the sea shore blown by salty wind from the sea. • Environment where dew condensation occurs to the lift truck as it travels indoor and outdoor by getting sharp temperature difference or environment where it is constantly soaked with water. • Environment filled with excessive sludge and those filled with dust, fine dust, and aggressive dust from polishing. • Using lift truck for other application than original designed. • Operation by which a lift truck is used for a specific work for extended span of time or used continuously in concentration for a particular work. • Application inhibited by this operating manual. • Others. NOTICE Operating the lift trucks in a special environment or in forcible way excludes them from the object of warranty provided by KOMATSU FORKLIFT. • There are conditions technologies cannot cover. • This lift truck cannot be used under a condition to which a risk of explosion accompanies.

4 - 43

4.9 ACTION TO TAKE IF THE FORK FAILS TO LOWER


4.9 ACTION TO TAKE IF THE FORK FAILS TO LOWER

4

CAUTION • If the fork stops lowering during operation, stop the work immediately. Never use this lift truck until repaired. • Put up " No Entry " and " Never use " signs to keep other persons from entering under or in front of the raised fork. • The lift truck may suddenly start moving leading to a critical a ccident. Do not touch the mast, fork, chain and other load handling devices. (Do not shake, touch or pry with a stick or tool.) • Immediately contact with the administrator or your KOMATSU FORKLIFT distributor for repair service. 1. If the fork stops lowering during operation, stop the work immediately. 2. Move the lift truck in question to a flat place and park it by avoiding emergency exit or fire fighting equipment. For details on parking, see "2.4.3 STOPPING AND PARKING (PAGE 224)" and "3.3.8 TEMPORARY STOPPING, PARKING AND STOPPING (PAGE 3-34)". 3. If the loaded fork should stop operating in raised condition, secure wide " No Entry " area around the lift truck or park the lift truck directly facing a stout wall surface in checking a risk of falling load to the ground.

4 - 44

u N s e e v e r

D a n g e r


4.10 WASHING LIFT TRUCK

4.10 WASHING LIFT TRUCK

4

CAUTION If water gets into the electrical system (controller, sensor, connector, etc.), there is a hazard that it will cause malfunctions or miss-movement. Do not use flushing water or high-pressure steam to wash the electrical system.

STEP FOR WASHING 1. Turn the starting switch key to the [Q] (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 below.cm 2 3. Dry off the washed parts. 4. After checking that the washed parts have dried out, insert the starting switch key and turn it to the [ | ] (ON) position then make sure that there is no abnormality, and then start operation. No.

Spot to Wash

1

Meter Panel

2

Dashboard Front Pedals Floor Plate

3 4

Front & Rear Tyres Front & Rear Axles Exterior parts other than the above

Other Precautions

Washing Method Wash by spraying water with a hose from above. (Note) In washing, reduce the flow of water to lower water pressure as illustrated below (only for (1) and (2) parts).

Wash with high pressure steam or flushing water from a hose. (Note) Do not use high pressure steam or flushing water for the electric wirings. Wash with high pressure steam or flushing water from a hose. 1. Never wash the inside of the dashboard. 2. When using high pressure steam or flushing water from a hose to wash the engine room and underpart of the floor plate (power train parts), cover the engine and transmission including electric wirings for them, and the electric system parts like the connector, fuse box, etc. with a tarpaulin so that tho se parts and components do not get splashed with water.

4 - 45


4.11 LONG-TERM STORAGE

4.11 LONG-TERM STORAGE

4

Store lift trucks as follows when storing them for a long period. (over one month)

BEFORE STORAGE After washing and cleaning respective parts, implement the following maintenance service before storing the lift trucks indoor: If it must unavoidably be left outdoors, park the lift truck on flat ground and cover it with a tarpaulin. • Fill up the fuel tank to full. This helps prevent water deposit. • Apply grease and change oil without fail. • Fully apply grease to the exposed portions of hydraulic cylinder piston rod. • Disconnect the negative ( - ) terminal of the battery and cover it or remove it from the lift truck and store indoors. • To prevent freezing, add Genuine Supercoolant (FAF-NAC) (concentration 30% or upward) to the engine coolant.

DURING STORAGE

CAUTION If it is necessary to carry out the rust prevention operation indoors, open the doors and windows to improve ventilation and prevent gas poisoning.

• During storage, always operate and move the lift truck once a month to retain the lubricated sections fully covered under oil film. • When operating work equipment, wipe the applied grease off the hydraulic cylinder piston rod. • As the battery discharges naturally, charge it once a month.

AFTER STORAGE When using lift trucks after some long period of storage, implement the following service before proceeding to operation: • Wipe the applied grease off the hydraulic cylinder piston rod. • Apply grease and oil to necessary sections without fail. • When a lift truck has been in storage for a long period, moisture in the air is mixed in oil. Check oil of respective sections before and after starting engine. If water is mixed in oil, change oil completely. NOTICE When using lift trucks that were not operated once a month to prevent rusting, consult your KOMATSU FORKLIFT distributor before operation.

4 - 46


4.12 HOISTING LIFT TRUCK

4.12 HOISTING LIFT TRUCK

4

CAUTION • Hook the sling to the designated holes on the top of the mast and the counterbalance-weight. • Overhead guard and the cab mount (for a cab specification lift truck) have no strength to hoist the lift truck. Never use them for hoisting lift truck, or there is a danger of falling. • Hook the sling to the mast and counterbalance-weight after checking that they are securely installed. • Never allow other persons to go under or near the lifted truck. 1. The sling hooking positions are the holes on the top of the outer mast and the counterbalance-weight. 2. Check that the mast and counterbalance-weight are securely installed. Tightening torque for the counterbalance-weight mount bolts. : 980 - 1,373Nm {100 - 140kgfm} Tightening torque for the mast lower mount bolts. : 824 - 1,030Nm {84 - 105kgfm} 3. Use undamaged sling and wire, having sufficient strength. 4. When hoisting a lift truck, do not allow the overhead guard and/or cab to make contact with wire, etc. Adjust the wire length to prevent the lift truck from being tilted. Do not give impact to it while hoisting.

4 - 47

4.13 LOADING AND UNLOADING OF LIFT TRUCK


4.13 LOADING AND UNLOADING OF LIFT TRUCK

4

CAUTION The work of loading and unloading a lift truck on a trailer always involves a hazard that the lift truck tips over or falls off if you make a mistake in handling. Strictly follow the instructions shown below. • Stop the trailer on level, flat road surface. Apply parking brake without fail and apply blocks to the tyres. • Use ramps or dock plate of sufficient length, width and sufficient strength. Secure it tightly to prevent it from being dislocated or disengaged. • Take a right posture on the seat while operating. • If you operate the lift truck in a posture that your weight is not properly applied to the seat, like standing up or leaning forward or sideways, travel interlock functions to cut off the transmission of engine power. Then the lift truck may slither down if the accelerator pedal is stepped on an uphill or a slope. Operate the lift truck assisted by a signal person if necessary so that you don't have to stand up or lean forward or sideways to watch. For more details on the function of travel interlocking, see "TRAVEL INTERLOCK (ENGINE POWER CUTOFF) (OPTION) (PAGE 330)". • When using the ramp, make the gradient gentle, align the center of both the trailer and the lift truck and lock the ramp securely to prevent misalignment. • Never correct the course of the lift truck while on the ramps. If course change is required, move off the ramps once and correct the course direction.

1. Arrange for a trailer having adequate loading capacity for the weight and size of a lift truck to transport. 2. Stop the trailer on level, flat road surface. Apply parking brake without fail and apply blocks to the tyres. 3. Install the ramp, dock plate, etc. between the loading platform of the trailer and the road surface and fix it securely so that it would not be disengaged. 4. Instruct the trailer operator not to move the trailer until loading/ unloading of lift truck is completed. 5. When loading/unloading a lift truck to or from the trailer, drive the lift truck at slow speed by sitting on the seat with right posture. 6. To prevent a loaded lift truck from moving during transportation, apply blocks to the tyres and secu re it with wire rope and/or chain before starting the trailer.

4 - 48

Ramp

Blocks


4.14 INSPECTION AND MAINTENANCE SCHEDULE CHART


4

• For other inspection and maintenance items not described in this manual, contact KOMATSU FORKLIFT distributor. • Incorrect inspection, maintenance and repair services may cause critical accident or shorten machine service life. For your safety operation, contact KOMATSU FORKLIFT distributor for inspection, maintenance and repair services. INSPECTION AND MAINTENANCE SCHEDULE CHART

[ Q] indicates the intervals and time of inspection and maintenance by operating hours recommended by KOMATSU FORKLIFT. Inspection & Maintenance Intervals (hours)

Inspection & Maintenance Item

p u t r a t s t A

s k e e ) w h 0 2 0 1 y r ( e v E

h t n o ) h m 1 0 0 y ( r 2 e v E

s h t n o ) h m 0 3 0 y 6 ( r e v E

s h t n ) o h 0 m 6 0 2 y 1 ( r e v E

r a e ) y h 1 0 0 y r 4 e 2 ( v E

r a e ) y h 2 0 0 y r 8 e 4 ( v E

) r e u c i o v r h ( e g s n y i b d l a a e r v r r e e t t n e I m

) h t t n n e o m m e ( c l s a a l p v e r e R t n I

Engine proper Startup condition

Q

Q

Q

Q

Q

Abnormal noise & vibration

Q

Q

Q

Q

Q

Exhaust gas color, Exhaust sound

Q

Q

Q

Q

Q

Low idling

Q

Q

Q

Q

Q

Acceleration, engine stop and knocking

Q

Q

Q

Q

Q Q

Checking of vibration damper Valve clearance

Q

Q

Air cleaner element clogging

Q

Q

Q

Q

Q

Q

Q

Air cleaner element cleaning Air cleaner element replacement

200 2400 1200 200 200 4000 2000 1200 200 1200

6

1200 400 400

2 2

Lubrication system Oil pan oil level

Q

Q

Q

Q

Q

Oil leakage

Q

Q

Q

Q

Q

Oil pan oil replacement e Oil filter cartridge n i g n Fuel system E

replacement

Fuel leakage

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

200 2400 200

Q

Fuel filter clogging Q

Fuel filter crack and damage Fuel pre-filter water drain

Q

Water separator water drain

Q

400 800

Fuel pre-filter cartridge replacement *1 Fuel main filter cartridge replacement *2 *3 Fuel tank crack and damage

Q

Fuel tank fuel level

Q

Fuel tank cleaning Checking for loose engine high-pressure piping clamps, hardening of rubber High-pressure piping clamps replacement Checking for missing fuel spray prevention cap, hardening of rubber Fuel spray prevention caps replacement

2 4

2400

Q Q

4000 8000

24

8000

24

Q

*1 Make initial replacement 200 hours after using the fuel pre-filter cartridge on a new lift truck. *2 Make initial replacement 400 hours after using the fuel main filter cartridge on a new lift truck. *3 Two fuel main filter cartridges are equipped.

4 - 49



Inspection & Maintenance Intervals (hours)


p u t r a t s t A

s k e e ) w h 2 0 0 y ( r 1 e v E

h t n o ) m h 1 0 0 y ( r 2 e v E

s h t n ) o m h 0 3 0 6 y r ( e v E

s h t n ) o h m 0 6 0 2 y ( r 1 e v E

r a e ) y h 1 0 0 y r 4 e 2 v ( E

r a e ) y h 2 0 0 y r 8 e 4 v ( E

) ) e r t t h c u n n o i o e v h r ( m m ( e g e s n s c l y i a a l b d a p v l e e r a r e v r R t r n e I e t t e n I m

Cooling system Water level (reservoir tank)

Q

Water level (radiator) Fan belt slackening and damage Water leakage

Q Q

Radiator cap condition Radiator hose crack and damage

e n i g n E

Cooling fan installed condition Cooling fan belt tension Cooling fan deformation, crack and damage Radiator fin cleaning and checking for damage

Q Q Q Q Q Q Q Q Q Q

Q Q Q Q Q Q Q Q Q Q

Cooling system interior cleaning

Q Q Q Q Q Q Q Q Q Q Q

Q Q Q Q Q Q Q Q Q Q Q

200 200 1000 200 200 200 200 200 200 1200

Accessory

Q 4000 Q 4000 1000

Checking of starter Checking of water pump Looseness of engine intake piping clamps Transmission Oil leakage

Q

Oil level Inching pedal operating condition Pedal height

Q Q

Q Q Q Q

Q Q Q Q

Oil replacement Strainer replacement n i Line filter cartridge replacement a r t r Differential gear e w o Oil leakage P Oil level checking and refilling

Q

Q

Q Q

Oil replacement

Q Q Q Q Q Q Q

Q Q Q Q Q Q Q

Q 200 1200 1200 1200

6 6 6

Q Q Q

Q Q Q

200 200 1200

6

200 200

Gearshift lever Play and engagement condition

Q

Q

Q Q

Q Q

200 1200

Q Q

Q Q

Q Q

Q Q

200

Q Q

Q Q

Q Q

Q Q

200 200

Q

2400

Q

Q

1200

Q

Q Q Q

2400 2400 1200

Q Q

Q Q

200 200

Installation condition Forward/reverse lever Lighting of neutral lamp

Q

Steering wheel Operation feel Amount of play

Q Q

Gearbox Loose mounting Oil leakage mCylinder e t s Loosening, play and damage y s g Knuckle n i r e Play, deformation and damage at joint e t S Wheel Wheel alignment

Left & right turning angle Fluctuation in min. turning radius Power steering Oil leakage and oil level Mounting condition and loosening at connection

4 - 50

Q

Q Q

Q Q





p u t r a t s t A

s k e e ) w h 2 0 0 y ( r 1 e v E

h t n o ) m h 1 0 0 y ( r 2 e v E

s h t n o ) m h 0 3 0 6 y r ( e v E

s h t n ) o h m 0 6 0 2 y ( r 1 e v E

r a e ) y h 1 0 0 y r 4 e 2 v ( E

r a e ) y h 2 0 0 y r 8 e 4 v ( E

) ) h e r t t u c o n n i e o v ( h r m m ( e g e s n c s i y a l l a b d a p v l e a r e r e v r r R t n e I e t t n e I m

Brake pedal Stroke and braking effect Play and pedal height when depressed Inching pedal operation

Q Q Q

Brake link play and loosening

Q Q

Q Q

Q Q

Q Q

200 200

Q

Q

Q

Q

200

Q Q

Q Q

Q Q

Q Q

200 200

Parking Brake Stroke

Q

Braking effect Operating effort

Q Q

Lever and ratchet wear and damage Warning buzzer operation

Q

Cable m Loosening, play, damage and wear e t s Hose and Piping y s g Leakage, damage, installation condition and wear n i k Air tightness of piping a r BBrake cooling oil tank (option)

Oil level

Q

Q

Q

Q

Q

200

Q

Q

Q

Q Q

200 200

Q

Q

Q Q

Q Q

200

Oil replacement Cylinder and Disc Caliper

Q 2400 Q 2400

Operating condition, wear and damage Oil leakage Brake Valve Operating condition, wear and damage

Q

Operating condition

Q 2400 2400

Accumulator for the brake Checking of accumulator

Q

Checking of sealed gas pressure and filling Wheel Cylinder Cup and Seal

Q Q

2400

General Work equipment operating condition

Q

Q

Q

Q

Q

200

Q

Q

Q

Q

Q Q

Q Q

Q Q

Q Q Q Q

200 2400 200

Q Q

Q Q

Q Q

Q Q Q Q

200 200 2400 2400 100

Fork Fork and fork stopper deformation, crac k and damage t n e Crack at fork bottom (by dye penetration check) m p Fork disarray and sagging i u q Greasing of mast roller, roller support e g n Mast i d a Mast deformation, crack, damage and wear o L Mast roller play Mast support portion damage and wear Roller shaft crack and damage

Q Q

Runout, play of propeller shaft and loose mount bolts

4 - 51





p u t r a t s t A

s k e e ) w h 2 0 0 y ( r 1 e v E

h t n o ) m h 1 0 0 y ( r 2 e v E

s h t n o ) m h 0 3 0 6 y r ( e v E

s h t n ) o h m 0 6 0 2 y ( r 1 e v E

r a e ) y h 1 0 0 y r 4 e 2 v ( E

r a e ) y h 2 0 0 y r 8 e 4 v ( E


Chain t n e m p i u q e g n i d a o L

Chain lubrication Chain and chain wheel deformation, damage, rusting and lubrication Chain wheel bearing play Chain anchor bolt deformation, damage, rusting and lubrication Chain tension and elongation

Q

Q

Load backrest damage and cracks

100

Q

Q

Q

Q

200

Q

Q

Q

Q

200

Q

Q

Q

Q

200

Q

Q

Q Q

Q Q

200 1200

Q

Q

Q

Q

200

Q Q Q Q

Q Q Q Q

Q Q Q Q

Q Q Q Q Q Q

200 200 200 200 2400 2400

6

Q Q

Q Q Q Q Q Q

1200

Q

Q Q Q

1200 2400 1200 1200

12 6

Q

Chain elongation

Q

Q

Hydraulic Equipment Loose tilt cylinder rod lock nuts Hydraulic cylinder loosening, deformation, crack, damage and wear Hydraulic cylinder operating condition

Q

Lift cylinder natural drift Tilt cylinder natural forward tilting Control lever operating condition Relief valve operating condition and relief set pressure m e Hydraulic pump and hydraulic motor operating condition t s y Hydraulic pump abnormal noise s c i l u Hydraulic oil a r d Hydraulic oil tank damage and cracks y H Oil replacement Oil level

Q Q Q

Q

Tank cleaning Air breather replacement Line filter replacement Strainer cleaning Piping Piping damage, oil leakage and deformation

Q

Piping clip loosening and slipping off

Q Q

Q Q

Q Q

Q Q

200

Q

Q

Q

Q

200

Q

Q

Q

Q

Q

Q

Q Q Q

200 2400 200

Q

Q

Q

Q

200

Starting motor Engagement of switch and pinion gear m e Battery t s y Electrolyte level s c i r Terminal connection loosening t c e Electrolyte specific gravity l E Wiring Loosening at connection and damages

4 - 52

Q





p u t r a t s t A

s k e e ) w h 2 0 0 y ( r 1 e v E

h t n o ) m h 1 0 0 y ( r 2 e v E

s h t n o ) m h 0 3 0 6 y r ( e v E

s h t n ) o h m 0 6 0 2 y ( r 1 e v E

Q Q Q Q Q

Q Q Q Q Q

Q Q Q Q Q

r a e ) y h 1 0 0 y r 4 e 2 v ( E

r a e ) y h 2 0 0 y r 8 e 4 v ( E


Wheel Tyre inflation pressure t n e m p i u q e g n i l e v a r T

Tyre crack and damage Tyre tread depth and abnormal wear

Q Q Q

Wheel bearing play Disk, wheel deformation, crack and damage Wheel nut and bolt damage Loose wheel nut and bolt Disk, wheel installation condition Loose hub nuts

Q Q Q

Q Q

Axle deformation, crack and damage Main Body Overhead guard and load backrest deformation, crack and damage Each part loosening and damage Exhaust muffler and pipe installation condition and damage Operator's seat installation condition and damage

Q Q Q Q Q Q

Q

Q

Q

Q

200 200 200 200 200 1200

Q Q

2400

Q

200

Q

2400

Q

2400

Q

Q

Q

Q Q Q

200 2400 2400

Runout, play of propeller shaft and loose mount bolts Frame and cross member crack and damage Directional Signal Lamp Operating condition

Q

Q

Q

Q

Q

Q

200

Q

Q

Q

Q

Q

Q

200

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q Q

Q Q Q

Q Q Q

Q Q Q

Q Q Q

Alarm Operating condition s r Operating condition of each lamp (head lamp, clearance e h t lamp, brake lamp and backup lamp) OInstrument Operating condition Checking reading

Q

2400

Abnormality Found on Preceding Day Checking completion of repairs

Q

Rear view Mirror (Option) Checking setting, smudge and damage Lubrication Each lubrication point properly lubricated Warning Lamp and Indicator Lamp Backup buzzer sounding performance

Q

200 200

Safety Device Performance (Travel interlock, Lift interlock and Neutral safety) (Option) t sConduct traveling and lifting tests and verify functions e t e Operation of various devices v i s Abnormal vibration, noise, odor and heating n e h e r p m o C

Q Q Q

200 Q Q

Q Q

Q Q

Q Q

200 200

4 - 53

4.15 PERIODIC RE PLACEMENT OF SAFETY CRITICAL PARTS


4.15 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

4

For your safety use of lift trucks, you are requested to always implement period ic replacement of parts listed in the Periodic Replacement of Safety Critical Parts below related particularly to the safety and fires. The material of these parts may change over time, or may easily wear or deteriorate. However, as it is difficult to judge the condition of the parts simply by periodic maintenance, they should always be replaced after a fixed time has passed, regardless of their condition. This is necessary to ensure that their full function is always maintained. However, if these parts show any abnormality before the replacement interval has passe d, they should be repaired or replaced immediately. If the hose clamps show any sign of deterioration such as deformation or cracking, replace them with the hoses at the same time. Note that the periodic replacement is not covered by warranty. IMPORTANT PARTS LIST

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

4 - 54

Part name Fuel hose (fuel tank - fuel pre-filter) Fuel hose (fuel pre-filter - supply pump) Fuel hose (supply pump - fuel main filter) Fuel hose (fuel main filter - supply pump) Fuel hose (supply pump - common rail overflow) Fuel hose (engine - fuel tank) Brake hose or tube Brake tank and tube Power steering hose Stop lamp switch (hydraulic type) Rubber parts inside power steering system Lift chain Hydraulic hose (for travel, loading & unloading and torque converter) Engine high-pressure piping clamp Fuel spray prevention cap

Years elapsed 2 2 2 2 2 2 2 2 2 2 2 2-4 2 Every 8000 hours


4.16 SERVICE DATA

4.16 SERVICE DATA

4

SERVICE DATA Component

e n i g n E

Engine proper

Compression Fuel system Intake, exhaust system

m e t s Tyres y S l e v a r T Hub nut

Steering wheel Inching pedal m e t s y Brake s g n i k a r b , g n Brake i r e e t S

t n e m p i u q e g n i d a o L

Inspection item Engine model Idling speed Max. speed

pedal

Injection order Intake Valve Clearance Exhaust Tyre inflation pressure Tightening torque

Front wheels Rear wheels Front wheels Rear wheels

Play Play Interconnected stroke Play Pedal height when pedal is depressed Parking brake operating force Tightening torque for back plate mounting bolts

Unit – rpm rpm MPa (PSI) {kgf/cm2}/ rpm – mm (in) mm (in) kPa (PSI) {kgf/cm2} kPa (PSI) {kgf/cm2} Nm {kgfm} Nm {kgfm} mm (in) mm (in) mm (in) mm (in)

FD100-8

FD115-8 FD135-8 FD150E-8 FD160E-8 KOMATSU SAA6D107E-1-A 700 - 750 2375 - 2475 Min.24 (3490) {246} / 250-280 1-5-3-6-2-4 0.25 (0.01) 0.51 (0.02)

735 (107) 690 (99.4) 660 (95.8) 760 (110) 690 (99.4) {7.5} {7.0} {6.75} {7.75} {7.0} 735 (107) 690 (99.4) 660 (95.8) 760 (110) 690 (99.4) {7.5} {7.0} {6.75} {7.75} {7.0} 441 - 539 {45 - 55} 441 - 539 {45 - 55} 30 - 60 (1.2 - 2.4) 2 - 3 (0.08 - 0.12) 28.5 - 33.5 (1.1 - 1.3) 2 - 6 (0.08 - 0.24)

mm (in)

65 (2.6)

N {kgf}

Min.196 {20}

Nm {kgfm}

147 - 245 {15 - 25}

147 - 196 {15 - 20}

Gas pressure of brake accumulator

MPa (PSI) {kgf/ cm2}

4.9 (710) {50}

(Wet disc brake type)

Gas pressure of brake accumulator


3.4 (497) {35}

Fork

Fork thickness (at base)

mm (in)

Chain

Length over 17 links

mm (in)

Hydraulic system Relief pressure


Min. 70 (2.8) Max.60 (26.0)

Min. 75 (3.0)

Min. 80 (3.2)

Max. 770 (30.3) 21.6 (3120) {220}

4 - 55


4.16 SERVICE DATA

BOLT TIGHTENING TORQUE • For unspecified metric bolts and nuts, use the torques specified in this list. • Select a proper torque corresponding to the width across flats (b) of bolts and nuts. • When replacing bolts and nuts, always use Genuine Parts of the same size as the previous ones.

Thread outside Width across diameter (a) mm flat (b) mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39

4 - 56

10 13 17 19 22 24 27 30 32 36 41 46 50 55 60

Tightening torque Nm {kgfm} Within target allowable range 13 {1.35} 12 - 15 {1.2 - 1.5} 31 {3.2} 27 - 34 {2.8 - 3.5} 66 {6.7} 59 - 74 {6.0 - 7.5} 113 {11.5} 98 - 123 {10.0 - 12.5} 177 {18.0} 157 - 196 {16.0 - 20.0} 279 {28.5} 245 - 309 {25.0 - 31.5} 382 {39.0} 343 - 427 {35.0 - 43.5} 549 {56.0} 490 - 608 {50.0 - 62.0} 745 {76.0} 662 - 829 {67.5 - 84.5} 927 {94.5} 824 - 1030 {84.0 - 105.0} 1324 {135.0} 1177 - 1471 {120.0 - 150.0} 1716 {175.0} 1520 - 1912 {155.0 - 195.0} 2206 {225.0} 1961 - 2452 {200.0 - 250.0} 2746 {280.0} 2452 - 3040 {250.0 - 310.0} 3285 {335.0} 2893 - 3628 {295.0 - 370.0}

TECHNICAL DATA

5

55

5-1

TECHNICAL DATA

TECHNICAL DATA

5-2

TECHNICAL DATA

5

TECHNICAL DATA

1.2 s 1.3 c i t s 1.4 i r e 1.5 t c a r 1.6 a h C 1.8 1.9 2.1 t 2.2 h g 2.2.1 i e W2.3 2.3.1 3.1 3.2 s 3.3 e r y T 3.5 3.6 3.7 4.1 4.2 4.3 4.4 4.5 4.7 s 4.19 n 4.20 o i s n 4.21 e m i D 4.22

Model Power Type Operation Type Rated Capacity Load Center Load Distance Wheelbase Service Weight

TECHNICAL DATA

Manufacturer's Designation Electric, Diesel, Gasoline, LPG, Cable Q c x y

Front Axle Center to Fork Face

Loaded Axle Loading Unloaded

Front Rear Front Rear

24/80

24/80

24/80

KW(HP) min-1 Nm@min-1

KOMATSU SAA6D107E-1 122(164) 2200 575(424)@1600

KOMATSU SAA6D107E-1 122(164) 2200 575(424)@1600

KOMATSU SAA6D107E-1 122(164) 2200 575(424)@1600

cm3(cu.in)

6/6690(408)

6/6690(408)

6/6690(408)

Ltr(US Gal)

260(69)

260(69)

280(74.0)

bar(psi)

215(3,100)

215(3,100)

215(3,100)

Ltr(US Gal)

170(45) Torque Converter TORQFLOW



mm(in) mm(in) degree mm(in) mm(in) mm(in) mm(in) mm(in) mm(in) mm(in) mm(in)

Forks

s/e/l Thickness x Width x Length

mm(in)

b2 m1 Under Mast m2 at Center of Wheelbase Ast plus load length Wa

mm(in) mm(in) mm(in) mm(in) mm(in)

Travel Speed (FWD)

Ground Clearance Right Angle Stacking Aisle Turning Radius

Loaded,1st/2nd/3rd

km/h(mph)

Unloaded,1st/2nd/3rd

km/h(mph) mm/s(fpm) mm/s(fpm) KN(ib) %

e 5.2 c n 5.3 a m r 5.6 o f r 5.8 e P 5.10

Lifting Speed Lowering Speed Max. Drawbar Pull Max. Gradeability

Loaded/Unloaded Loaded/Unloaded Loaded, 1.5km/h, 3min rating Loaded, 1.5km/h, 3min rating

Service Brake

Operation/Control

5.11

Parking Brake

Operation/Control

5.12

Steering

Type

6.4

Battery

Voltage/ Capacity at 5-hour rating

7.1

Maker Model

8.7

V/Ah

kg(lb) mm(in) mm(in) mm(in) kg(lb) kg(lb) kg(lb) kg(lb) kg(lb)

Number of Wheels Tread, Front Tread, Rear Tilting Angle Mast Height, Lowered Std. Free Lift Std. Lift Height Mast Height, Extended Height, Overhead Guard Length, with Std. Forks Length, to Fork Face Width, at Tyre

5.1

8.2 s r e 8.2.1 h t O 8.6

FD135-8 Diesel Sitting 13500(30,000) 600(24) 740(29.1) 3100(122.0) 15480(34,130) 26450(58,310) 2530(5,580) 7110(15,670) 8370(18,450) Pneumatic 11.00-20-14PR(I) 11.00-20-14PR(I) 4x/2 1770(69.7) 1890(74.4) 6/12 3170(124.8) 0(0.0) 3000(118) 4680(184.3) 2810(110.6) 5860(230.7) 4640(182.7) 2410(94.9) 80x185x1220 (3.1x7.3x48.0) Pin Mount 2210(87.0) 260(10.2) 350(13.8) 5090(200.4) 4350(171.3) 9/19.5/27.5 (5.6/12.1/17.1) 9.5/21/32 (5.9/13.0/20.2) 350/375(69/74) 400/500(79/98) 85(19,150) 28 Foot/Hydraulic, Powered Hand/Mechanical Hydraulic Power Steering

Front Rear Front/Rear (x=driven) b10 b11 α/β Forward/Backward h1 2-stage Std. Mast h2 2-stage Std. Mast, from Ground h3 2-stage Std. Mast, from Ground h4 2-stage Std. Mast h6 L1 L2 b1 Single

Tyre Size

Fork Carriage Class Width, Fork Carriage

7.6

FD115-8 Diesel Sitting 11500(25,000) 600(24) 715(28.1) 2800(110.2) 14360(31,660) 23490(51,790) 2370(5,220) 6590(14,530) 7770(17,130) Pneumatic 10.00-20-14PR(I) 10.00-20-14PR(I) 4x/2 1700(66.9) 1890(74.4) 6/12 3160(124.4) 0(0.0) 3000(118) 4670(183.9) 2800(110.2) 5505(216.7) 4285(168.7) 2310(90.9) 75x185x1220 (3.0x7.3x48.0) Pin Mount 2140(84.3) 250(9.8) 345(13.6) 4725(186.0) 4010(157.9) 8.5/19/28 (5.3/11.8/17.4) 9/21/32 (5.6/13.0/19.9) 430/450(85/89) 400/500(79/98) 87(19,610) 34 Foot/Hydraulic, Powered Hand/Mechanical Hydraulic Power Steering

Tyre Type

4.23 4.24 4.31 4.32 4.33 4.35

e 7.2 n i g 7.3 n E 7.3.1 C . I 7.4

FD100-8 Diesel Sitting 10000(22,000) 600(24) 695(27.4) 2800(110.2) 12980(28,620) 20860(45,990) 2120(4,670) 6230(13,730) 6750(14,880) Pneumatic 9.00-20-14PR(I) 9.00-20-14PR(I) 4x/2 1700(66.9) 1900(74.8) 6/12 2890(113.8) 0(0.0) 3000(118) 4400(173.2) 2780(109.4) 5465(215.2) 4245(167.1) 2280(89.8) 75x170x1220 (3.0x6.7x48.0) Pin Mount 2140(84.3) 250(9.8) 325(12.8) 4695(184.8) 4000(157.5) 8.5/18/28 (5.3/11.2/17.4) 9/20/32 (5.6/12.4/19.9) 470/500(93/98) 400/500(79/98) 89(20,010) 40 Foot/Hydraulic, Powered Hand/Mechanical Hydraulic Power Steering

Rated Output, SAE net Rated RPM Max. Torque, SAE net No. of Cylinder/ Displacement Fuel Tank Capacity Relief Pressure for Attachment Hydraulic Tank Capacity Clutch Transmission

5-3

TECHNICAL DATA

TECHNICAL DATA

1.2 s 1.3 c i t s 1.4 i r e 1.5 t c a r 1.6 a h C 1.8 1.9 2.1 t 2.2 h g 2.2.1 i e W2.3 2.3.1 3.1 3.2 s 3.3 e r y T 3.5 3.6 3.7 4.1 4.2 4.3 4.4 4.5 4.7 s 4.19 n o 4.20 i s n 4.21 e m i D 4.22

Model Power Type Operation Type Rated Capacity Load Center Load Distance Wheelbase Service Weight

Manufacturer's Designation Electric, Diesel, Gasoline, LPG, Cable Q c x y

Front Axle Center to Fork Face

Loaded Axle Loading Unloaded

Front Rear Front Rear

KW(HP) min-1 Nm@min-1

KOMATSU SAA6D107E-1 122(164) 2200 575(424)@1600

KOMATSU SAA6D107E-1 122(164) 2200 575(424)@1600

cm3(cu.in)

6/6690(408)

6/6690(408)

Ltr(US Gal)

280(74.0)

280(74)

bar(psi)

215(3,100)

215(3,100)

Ltr(US Gal)



Forks

s/e/l Thickness x Width x Length

mm(in)

b2 m1 Under Mast m2 at Center of Wheelbase Ast plus load length Wa

mm(in) mm(in) mm(in) mm(in) mm(in)

Ground Clearance Right Angle Stacking Aisle Turning Radius

Loaded,1st/2nd/3rd

km/h(mph)

Unloaded,1st/2nd/3rd

km/h(mph) mm/s(fpm) mm/s(fpm) KN(ib) %

e 5.2 c n 5.3 a m r 5.6 o f r 5.8 e P 5.10

Lifting Speed Lowering Speed Max. Drawbar Pull Max. Gradeability

Loaded/Unloaded Loaded/Unloaded Loaded, 1.5km/h, 3min rating Loaded, 1.5km/h, 3min rating

Service Brake

Operation/Control

5.11

Parking Brake

Operation/Control

5.12

Steering

Type

6.4

Battery

Voltage/ Capacity at 5-hour rating

7.1

Maker Model

5-4

24/80

mm(in) mm(in) degree mm(in) mm(in) mm(in) mm(in) mm(in) mm(in) mm(in) mm(in)

Travel Speed (FWD)

8.7

24/80

Number of Wheels Tread, Front Tread, Rear Tilting Angle Mast Height, Lowered Std. Free Lift Std. Lift Height Mast Height, Extended Height, Overhead Guard Length, with Std. Forks Length, to Fork Face Width, at Tyre

5.1

8.2 s r e 8.2.1 h t O 8.6

V/Ah

kg(lb) mm(in) mm(in) mm(in) kg(lb) kg(lb) kg(lb) kg(lb) kg(lb)

Front Rear Front/Rear (x=driven) b10 b11 α/β Forward/Backward h1 2-stage Mast h2 2-stage Std. Mast, from Ground h3 2-stage Std. Mast, from Ground h4 2-stage Std. Mast h6 L1 L2 b1 Single

Tyre Size

Fork Carriage Class Width, Fork Carriage

7.6

FD160E-8 Diesel Sitting 16000(35,000) 600(24) 750(29.5) 3100(122.0) 17200(37,920) 30140(66,450) 3060(6,750) 7170(15,810) 10030(22,110) Pneumatic 12.00-20-16PR(I) 12.00-20-16PR(I) 4x/2 1770(69.7) 1870(73.6) 6/12 3290(129.5) 0(0.0) 3000(118) 4800(189.0) 2830(111.4) 6020(237.0) 4800(189.0) 2480(97.6) 85x210x1220 (3.3x8.3x48.0) Pin Mount 2210(87.0) 270(10.6) 370(14.6) 5250(206.6) 4500(177.2) 9.5/20/28 (5.9/12.4/17.4) 10/21.5/32 (6.2/13.4/20.5) 320/345(63/68) 400/400(79/79) 80(18,030) 23 Foot/Hydraulic, Powered Hand/Mechanical Hydraulic Power Steering

Tyre Type

4.23 4.24 4.31 4.32 4.33 4.35

e 7.2 n i g 7.3 n E 7.3.1 C . I 7.4

FD150E-8 Diesel Sitting 15000(33,000) 600(24) 750(29.5) 3100(122.0) 16570(36,530) 28740(63,360) 2830(6,240) 7210(15,900) 9360(20,640) Pneumatic 11.00-20-16PR(I) 11.00-20-16PR(I) 4x/2 1770(69.7) 1890(74.4) 6/12 3270(128.7) 0(0.0) 3000(118) 4780(188.2) 2810(110.6) 5920(233.1) 4700(185.0) 2410(94.9) 85x190x1220 (3.3x7.5x48.0) Pin Mount 2210(87.0) 250(9.8) 350(13.8) 5150(202.8) 4400(173.2) 9/19.5/27.5 (5.6/12.1/17.1) 9.5/21/32 (5.9/13.0/20.2) 325/350(64/69) 400/400(79/79) 80(18,160) 25 Foot/Hydraulic, Powered Hand/Mechanical Hydraulic Power Steering

Rated Output, SAE net Rated RPM Max. Torque, SAE net No. of Cylinder/ Displacement Fuel Tank Capacity Relief Pressure for Attachment Hydraulic Tank Capacity Clutch Transmission

EMISSION CONTROL WARRANTY STATEMENT 6

61

6-1

EMISSION CONTROL WARRANTY


6

A. FEDERAL EMISSION CONTROL WARRANTY STATEMENT (APPLICABLE IN ALL STATES) 1. Products Warranted Komatsu Forklift USA Inc. (collectively " KFi ") produce and/or market products under brand names of Komatsu and TUSK. This emissions warranty applies to new engines bearing the Komatsu name installed in these products and used in the United States in machines designed for industrial off- highway use. This warranty applies to these engines produced after the following dates: 175 to 750 HP - January 1, 1996; 100 to 174 HP - January 1, 1997; 99 HP and less - January 1, 1998; and 751 HP and higher - January 1, 2000. 2. Coverage KFi warrants to the ultimate purchaser and each sub sequent purchaser that the engine is designed, built and equipped so as to conform, at the time of sale by KFi, with all U.S. Federal emission regulations applicable at the time of manufacture and that it is free from defects in workmanship or material which would cause it not to meet these regulations within five years or 3,000 hours of operation, whichever occurs first, as measured from the date of delivery of the engine to the ultimate purchaser. If the machine in which the engine is installed is first placed in service in the state of California, a separate California Emission Warranty also applies. 3. Limitations Failures, other than those resulting from defects in materials or workmanship, are not covered by this warranty. KFi is not responsible for failures or damage resulting from what KFi determines to be abuse or neglect, including, but not limited to: operation without adequate coolant or lubricants~ over fueling; over speeding; lack of maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up, run-in or shutdown practices; unauthorized mod ifications of the engine. KFi is also not responsible for failures caused by incorrect fuel or by water, dirt or other contaminants in the fuel. kFi is not respon sible for non-engine repairs, " downtime " expense, related damage, fines, all business costs or other losses resulting from a warrantable failure. KFi IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES

B. CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT 1. Products Warranted This Emission Control System Warranty applies to heavy-duty off-road diesel engines certified with the California Air Resources Board, marketed by Komatsu Forklift USA Inc. (collectively KFi) in their Komatsu or TUSK products and first placed in service in California for use in industrial off-highway applications. This warranty applies to engines bearing the Komatsu name produced after the following dates: 175 to 750 HPJanuary 1, 1996; 100 to 174 HP-January 1, 1997; 99 HP and less - January 1, 1998; and 751 HP and higherJanuary 1, 2000.

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2. Your Warranty Rights and Obligations The California Air Resources Board and KFi are pleased to explain the emission control system warranty on your emissionized engine. In California, new heavy-duty off-road diesel engines must be designed, built and equipped to meet the State's stringent anti-smog standards. KFi must warrant the Emission. Your emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your engine. Your emission control system may include parts such as the fuel injection system and air induction system. Also included may be hoses, belts, connectors and other emissionrelated assemblies. Where a warrantable cond ition exists, Komatsu will repair your heavy-duty off-road diesel engine at no cost to you including diagnosis, parts and labor. 3. Manufacturer's Warranty Coverage The heavy-duty off-road diesel engines are warranted for 5 years or 3,000 hours of engine operation, whichever occurs first, from the date of delivery of the engine to the first user. If any emission-related part o n your engine is defective, the part will be repaired or replaced by KFi. 4. Owner's Warranty Responsibilities As a heavy-duty off-road diesel engine owner, you are responsible for the performance of the required maintenance listed in your Komatsu, or TUSK, Operation and Maintenance Manual. Komatsu recommends that you retain all receipts covering maintenance on your heavy-duty off-road diesel engine, but Komatsu cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. You are responsible for presenting your heavy-duty off-road diesel engine to an authorized KFi or TUSK as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible. As the heavy-duty off-road diesel engine owner, you should also be aware that Komatsu may deny you warranty coverage if your heavy-duty off-road diesel engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with California's emissions requirements. If you have an y questions regarding your warranty rights and responsibilities, you should contact:

Komatsu Forklift U.S.A., Inc. 14481 Lochridge Boulevard Covington, GA 30014 PHONE: 770-787-5100

OR

California Air Resources Board Manager, 9528 Telstar Avenue El Monte, CA 91731

Prior to the expiration of the applicable warranty, owner must give notice of any warranted emission control failure to an authorized KFi or TUSK Dealer and deliver the engine to such facility for repair. Owner is responsible for incidental costs such as: communication expenses, meals, lodging incurred by owner or employees of owner as a result of a warrantable failure.

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KFi IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH INCLUDE, BUT ARE NOT LIMITED TO, BUSINESS LOSSES AND COSTS, " DOWNTIME " EXPENSES, FINES, PENALTIES, THEFT, VANDALISM OR COLLISION DAMAGE. 5. Coverage: This emission control system warranty applies to the following emission control parts, if equipped:

Fuel Pump

Turbocharger

Injectors

Intake Manifold

APC Spring

Compressor Wheel

Calibration

Charge Air Cooler

APC Setting

Turbine Wheel

Needle

Aftercooler

Static Timing

Turbine Oil Seal

Nozzle

Positive Crankcase Ventilation

Delivery Valve

Wastegate Valve

Spring

Fuel Lines Control Module

Other Emission Parts Exhaust Manifold

Hoses Connectors

6. Replacement Parts KFi recommends that any service parts used for maintenance, repair or replacement of emission control systems be new, genuine Komatsu parts and assemblies, and that the engine be serviced by an authorized Dealer. The owner m ay elect to have maintenance, replacement or repair of the emission control parts performed by a facility other than an authorized Dealer and may elect to use parts other than new genuine Komatsu parts and assemblies for such maintenance, replacement or repair, however, the cost of such service or parts will not be covered under this emission control system warranty. 7. KFi Responsibilities Repairs and service will be performed by any authorized Dealer using new, genuine Komatsu parts and assemblies. KFi will repair any of the emission control parts found by KFi to be defective without charge for parts or labor (including diagnosis which results in determination that there has been a failure of a warranted emission control part). 8. Warranty and Limitations The manufacturer warrants to the ultimate purchaser, and each subsequent purchaser, that the engine is designed, built, and equipped so as to conform with a applicable regulations adopted by the Air Resources Board, and that it is free from defects in material and workmanship which cause the failure of a warranted part for the time periods stated herein. Any warranted part which is not scheduled for replacement as required maintenance, or which is scheduled only for regular inspection to the effect of " re pair or replace as necessary " is warranted for the warranty period. Any warranted part which is scheduled for replacement as required maintenance is warranted for the period of time prior to the first scheduled replacement point for that part. The owner will not be charged for diagnostic labor which leads to the determination that a warranted part is defective, if the diagnostic work is performed at an a uthorized Dealer. The manufacturer is liable for damages to other engine components caused by the failure under warranty of any warranted part. KFi is not responsible for failures resulting from improper repair or the u se of parts which are not genuine Komatsu parts. KFi is not responsible for failures resulting from owner or operator abuse or neglect, such as: operation without adequate coolant, fuel or lubricants; over fueling; over speeding, lack of maintenance of lubricating, cooling or air intake systems; improper storage, starting, warm-up, run-in or shutdown practices.

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C. GENERAL EXCLUSIONS

1. The foregoing engine emission control warranties do not apply to engines in our products, which bear trademarks or names other than Komatsu (i.e. Cummins). The emission control warranty res ponsibility of such engines shall rest with the respective engine manufacturer. For information on such warranties, please refer to the operator's manual for the engine in question or contact the applicable dealer organization. In the case of Cummins trademarked engines, you may also contact your Komatsu distributor who has been certified by Cummins, under it’s Certified Distributor Program. 2. These warranties, together with the express commercial warranties, are the sole warranties of Komatsu. THERE ARE NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

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INDEX

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INDEX

ABOUT INSPECTION AND MAINTENANCE ----------- 4-2 ABOUT THIS MANUAL ------------------------------------ 1-2 ACTION IN ENGINE OVERHEATING ------------------4-41 ACTION TO TAKE IF THE FORK FAILS TO LOWER --------------------------------------------------4-44 ACTUAL CAPACITY---------------------------------------2-40 ALWAY PERFORM THE START-UP INSPECTION --2-31 APPLICABLE MODEL AND SERIAL No. ---------------- 1-6 ASBESTOS CAUTION ------------------------------------2-14 AVOID GETTING CAUGHT UP BY THE MAST OR FALLING OFF ------------------------------------------2-33

BASIC PRECAUTIONS ------------------------------------ 2-8 BE CAREFUL OF BOILING COOLANT ----------------2-33 BE CAREFUL OF HIGH PRESSURE OIL --------------2-34 BEFORE STARTING OPERATION ---------------------2-15 BEWARE OF ROTATING COOLING FAN AND BELT -----------------------------------------------------2-34

CAUTION AFTER INSPECTION AND REPAI ---------2-36 CAUTION WHEN CHARGING A BATTERY -----------2-35 CAUTION WHEN HANDLING BATTERY --------------2-35 CAUTION WHEN HANDLING TYRES ------------------2-36 CAUTION WHEN REPAIRING THE ELECTRICAL SYSTEM -------------------------------------------------2-34 CAUTIONS BEFORE INSPECTION AND MAINTENANCE ----------------------------------------2-32 CAUTIONS FOR SAFETY-RELATED EQUIPMENT -- 2-9 CAUTIONS FOR USING COMPRESSED AIR FOR CLEANING ----------------------------------------------2-34 CAUTIONS WHEN REPLACING THE SEAT ----------2-34 CAUTIONS WHEN WORKING UNDER WORK EQUIPMENT --------------------------------------------2-32 CENTER OF GRAVITY OF A LOAD --------------------2-39 CHECKING AND REPORTING AFTER OPERATION --------------------------------------------4-20 COMBINED CENTER OF GRAVITY AND STABILITY ON THE LOADED LIFT TRUCK ---------------------2-40

DO NOT MODIFY THE LIFT TRUCK -------------------2-12 DO NOT REMOVE THE OVERHEAD GUARD AND LOAD BACKREST -------------------------------------2-13

EMISSION CONTROL WARRANTY --------------------- 6-2 ENGINE EXHAUST GAS IS POISONOUS -------------2-14 ENGINE MOUNTED ON THIS LIFT TRUCK EXHAUST GAS CONTROL ----------------------------- 1-3 EXPLANATION OF COMPONENTS --------------------- 3-5 METER PANEL -------------------------------------------- 3-5 OPERATING DEVICES ---------------------------------3-10

FIRE EXTINGUISHER AND FIRST AID KIT ------------ 2-9

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FIRE PREVENTION ---------------------------------------2-11 FOLLOW RULES ------------------------------------------- 2-8 FOR YOUR SAFETY --------------------------------------- 1-4 SAFETY INDICATORS ---------------------------------- 1-5 SIGNAL WORDS ----------------------------------------- 1-4

GENERAL VIEW -------------------------------------------- 3-2 INSTRUMENTS AND CONTROLS --------------------- 3-3 GENERAL VIEW OF LIFT TRUCK --------------------- 3-2 GENERAL VIEW OF LIFT TRUCK ----------------------- 1-6 APPLICATION OF LIFT TRUCK ------------------------ 1-6 DIRECTION OF LIFT TRUCK --------------------------- 1-6 ENGINE MOUNTED ON THIS LIFT TRUCK CERTIFICATION LABEL AFFIXED POSITION ------ 1-3

HOISTING AND TRANSPORTING THE LIFT TRUCK --------------------------------------------------2-38 HOISTING LIFT TRUCK ----------------------------------4-47

IF A FIRE BREAKS OUT ---------------------------------2-12 INSPECTION AND ADJUSTMENT BEFORE STARTING ENGINE -----------------------------------2-15 INSPECTION AND MAINTENANCE SCHEDULE CHART --------------------------------------------------4-49 INTRODICTION OF OPTIONAL SAFETY DEVICE --2-43

JUMPING ON AND OFF FROM THE LIFT TRUCK IS STRICTLY PROHIBITED --------------------------2-10

KEEP THE OPERATOR’S COMPARTMENT AND PLATFORM CLEAN AND TIDY ----------------------2-10 KEEP THE WORKING AREA CLEAN AND TIDY ----2-31 KEEP UNAUTHORIZED PEOPLE OFF ----------------2-32

LIFT INTERLOCK -----------------------------------------3-38 LOAD HANDLING OPERATION ------------------------2-26 LOADING AND UNLOADING OF LIFT TRUCK -------4-48 LONGITUDINAL STABILITY -----------------------------2-39 LONG-TERM STORAGE ---------------------------------4-46

NECESSARY INFORMATION OF LIFT TRUCK ------- 1-8 ENGINE SERIAL NO. PLATE OR EMBOSSED LOCATION ----------------------------------------------- 1-9 HOUR METER LOCATION ------------------------------ 1-9 MEMORANDUM (To be filled by KOMATSU FORKLIFT distributor) ---------------------------------- 1-8 MODEL AND SERIAL NO. LOCATION ---------------- 1-8 NEVER OPERATE THE BROKEN-DOWN LIFT TRUCK --------------------------------------------------- 2-8

INDEX

OPERATING LIFT TRUCKS IN SPECIAL ENVIRONMENT OR IN FORCIBLE WAY ----------4-43 OPERATION -----------------------------------------------3-23 CHECKING AFTER OPERATION ---------------------3-40 FORK SPREAD ADJUSTMENT -----------------------3-36 INCHING TRAVEL --------------------------------------- 3-32 LOAD HANDLING OPERATION -----------------------3-36 MOUNTING/DISMOUNTING AND OPERATING POSTURE ADJUSTMENT ---------------------------3-23 STARTING AND STOPPING ON SLOPE ------------3-32 STARTING, GEAR SHIFTING, AND TRAVELING --3-27 START-UP INSPECTION -------------------------------3-23 TEMPORARY STOPPING, PARKING AND STOPPING----------------------------------------------3-34 TURNING -------------------------------------------------3-33 OPERATION ON SNOWY AND FROZEN ROADS ---3-33 OPERATION OF CONTROL LEVERS -----------------3-37

PERIODIC INSPECTION OF SAFETY CRITICAL PARTS ---------------------------------------------------2-37 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ---------------------------------------------------4-54 PICKING UP ------------------------------------------------ 3-39 PRACTICE SUFFICIENTLY BEFORE OPERATION ---2-9 PRECAUTION WHEN WASHING LIFT TRUCK ------2-10 PRECAUTIONS FOR INSPECTION AND MAINTENANCE ----------------------------------------2-31 PREPARATION BEFORE TRAVELING THE LIFT TRUCK --------------------------------------------------2-17 PROCEDURE FOR A DOWN BATTERY --------------4-37 PUT UP A WARNING SIGN DURING INSPECTION AND MAINTENANCE ---------------------------------2-31

QUALIFICATION FOR OPERATION ---------------------1-7

RUNNING IN COLD WEATHER ------------------------- 4-39 RUNNING IN NEW LIFT TRUCK --------------------------1-7 MAINTENANCE FOR NEW LIFT TRUCK --------------1-7 RUNNING IN NEW LIFT TRUCK ------------------------1-7

REPLACING FUSES ------------------------------------ 4-32 REPLACING TYRES ------------------------------------ 4-30 STACKING ------------------------------------------------- 3-39 STARTING ENGINE -------------------------------------- 3-27 STARTING LIFT TRUCK OFF --------------------------- 3-29 START-UP INSPECTION -------------------- 2-15 2-16 4-2 CHECK BY SETTING THE STARTING SWITCH TO [ | ] (ON) POSITION ------------------------------- 4-13 CHECKING ABNORMALITIES DETECTED ON THE PREVIOUS DAY -----------------------------------4-4 CHECKING BY OPERATING THE WORK EQUIPMENT LEVER ---------------------------------- 4-17 CHECKING FROM THE OPERATOR SEAT -------- 4-11 CHECKING OF SAFETY FUNCTION ---------------- 4-19 CHECKING WHILE TRAVELING SLOWLY --------- 4-17 CHECKING WITH THE ENGINE STARTED -------- 4-16 INSPECTION CONDUCTED BY OPENING COVER AND HOOD -----------------------------------------------4-6 WALK AROUND A LIFT TRUCK ------------------------4-4 STOPPING AND PARKING ------------------------------ 2-24 STRICTLY FOLLOW THE INSTRUCTIONS SHOWN BELOW TO AVOID GENERATION OF SPARKS - 2-35 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING) --- 2-39

TECHNICAL DATA ------------------------------------------5-2 TOWING ---------------------------------------------------- 2-25 TRAVEL INTERLOCK (ENGINE POWER CUTOFF) 3-30 TRAVELING THE LIFT TRUCK ------------------------- 2-17

UNITS OF MEASURE --------------------------------------1-6 USE OF RIGHT TOOLS AND EQUIPMENT ---------- 2-32

WARRANTY AND SERVICE ------------------------------1-7 PERIODICAL EXCHANGE PARTS ---------------------1-7 USE OF GENUINE PARTS AND OILS -----------------1-7 WASHING LIFT TRUCK ---------------------------------- 4-45 WEAR ADEQUATE CLOTHES AND SAFETY EQUIPMENT FOR OPERATION ----------------------2-9 WHILE TRAVELING THE LIFT TRUCK ---------------- 2-18 WINDOW WASHER CAUTION ------------------------- 2-14

SAFETY -------------------------------------------------------2-2 SAFETY LABEL----------------------------------------------2-2 SAFETY LABEL LOCATION CHART -------------------2-2 SECURE SAFETY AT THE WORKING AREA --------2-13 SERIAL NO. AND LOAD TABLE ------------------------2-41 SERVICE DATA -------------------------------------------4-55 SHIFTING GEAR ------------------------------------------3-31 SIMPLE MAINTENANCE ---------------------------------4-21 ADJUSTING PARKING BRAKE LEVER OPERATING EFFORT -------------------------------- 4-32 AIR CLEANER ELEMENT CLEANING ---------------4-27 FUEL PRE-FILTER AIR BLEEDING ------------------ 4-29 GREASES AND FUEL ---------------------------------- 4-21 BASIC PRECAUTIONS -------------------------------4-21 LUBRICANT LIST --------------------------------------4-24 REPLACING BULBS ------------------------------------4-34

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