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AEE08E1-03

FD100/160E-8
Operation & Maintenance Manual

FORKLIFT TRUCK

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

WARNING
Unsafe use of this lift truck may
cause serious injury or death.
Operators and maintenance per-
sonnel must read this manual and
be sure that they understand its
2-4-1 Shiba-koen, Minato-ku, Tokyo105-0011, Japan contents before operating, in-
specting, or carrying out mainte-
nance on this lift truck. This
manual should be kept near the
lift truck for reference and peri-
odically reviewed by all opera-
tors and maintenance personnel
who will come into contact with

PRINTED IN JAPAN
3 it.

12-07(01)0150101)10001
INTRODUCTION 1

11

1-1
1.1 ABOUT THIS MANUAL INTRODUCTION

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 lift truck.

• Read this manual carefully and understand it 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
FORKLIFT distributor.
When you transfer this lift truck to others, make sure to attach this manual 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 1

1-3
1.3 FOR YOUR SAFETY INTRODUCTION

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 degree 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 precautions 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 locations of the lift truck to indicate the possible hazards to the concerned
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
1.4 APPLICABLE MODEL AND SERIAL No. INTRODUCTION

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 1

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
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. Operation by unqualified persons may result in serious
injury or death.

1.8 RUNNING IN NEW LIFT TRUCK 1

1.8.1 RUNNING IN NEW LIFT TRUCK 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

1.9.1 PERIODICAL EXCHANGE PARTS 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

1.10 NECESSARY INFORMATION OF LIFT TRUCK 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 1

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
INTRODUCTION 1.10 NECESSARY INFORMATION OF LIFT TRUCK

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 INTRODUCTION

CONTENTS 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

1 - 10
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 -------------------------------------2-34
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 -----------------------------2-38
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

1 - 11
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

1 - 12
SAFETY 2

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.

2-1
2.1 SAFETY LABEL SAFETY

2. SAFETY 2

2.1 SAFETY LABEL 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 labels clean so that it can be easily seen at all times. Do not use organic solvent or gasoline for
cleaning. Or the safety label may come unstuck.
• If the safety label is damaged, lost, or become unreadable, 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 labels other than the safety labels, use these in the same way.

2.1.1 SAFETY LABEL LOCATION CHART 2

2-2
SAFETY 2.1 SAFETY LABEL

No. 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

Prohibit the operators from riding on the forks


4 Outside of left and right outer masts
and lifting/lowering themselves

5 Jump start prohibited Starting motor (Inside of engine hood)

6 Caution when parking (the lift truck) Right on the dashboard

Avoiding danger if lift truck tips over during Inside in front of the head guard (on the wiper motor
7
operations cover for the steel cab specification)

8 Take a right posture while operating lift truck Inside in front of the head guard

9 Caution before operation On the rear panel of the floor

On the top of the mast and on the counter


10 Hoist the lift truck by designated positions
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
2.1 SAFETY LABEL SAFETY

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) (USA)

(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
SAFETY 2.1 SAFETY LABEL

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

(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 short-
circuiting 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
2.1 SAFETY LABEL SAFETY

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

(General)

(USA)

IF THE LIFT TRUCK SEEMS TO TIP OVER ANY


BEFORE OPERATION:
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 4. Lean yourself in the opposite direction to the tipping of
Maintenance Manual. 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
2.2 BASIC PRECAUTIONS 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 2

• 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
use
Never

monitor), report the administrator immediately and take


adequate corrective actions.
Danger

• 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
SAFETY 2.2 BASIC PRECAUTIONS

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 damage.
• 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 BASIC PRECAUTIONS SAFETY

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

• 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
SAFETY 2.2 BASIC PRECAUTIONS

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, so 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.

2 - 11
2.2 BASIC PRECAUTIONS 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 deposits 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. Re-
tighten 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 2

• 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 modify

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.

2 - 12
SAFETY 2.2 BASIC PRECAUTIONS

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 BASIC PRECAUTIONS SAFETY

2.2.16 ENGINE EXHAUST GAS IS POISONOUS 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 2

• Use the window washer which contains ethyl alcohol.


• Never use the window washer containing methanol which is
harmful to eyes.

2 - 14
SAFETY 2.3 BEFORE STARTING OPERATION

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.

2 - 15
2.3 BEFORE STARTING OPERATION 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 2

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.

2 - 16
SAFETY 2.4 TRAVELING THE LIFT TRUCK

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.

2 - 17
2.4 TRAVELING THE LIFT TRUCK 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 2

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.

2 - 18
SAFETY 2.4 TRAVELING THE LIFT TRUCK

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.

2 - 19
2.4 TRAVELING THE LIFT TRUCK SAFETY

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.)

2 - 20
SAFETY 2.4 TRAVELING THE LIFT TRUCK

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 counterbalance-
weight will swing far out. Keep an ample clearance from walls to
ensure safety.

2 - 21
2.4 TRAVELING THE LIFT TRUCK SAFETY

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.

2 - 22
SAFETY 2.4 TRAVELING THE LIFT TRUCK

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
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 unloaded

2 - 23
2.4 TRAVELING THE LIFT TRUCK 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. Free Lock
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.

2 - 24
SAFETY 2.4 TRAVELING THE LIFT TRUCK

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.

2 - 25
2.5 LOAD HANDLING OPERATION SAFETY

2.5 LOAD HANDLING OPERATION 2

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.

2 - 26
SAFETY 2.5 LOAD HANDLING OPERATION

BE CAREFUL NOT TO GET CAUGHT IN THE MAST 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.

2 - 27
2.5 LOAD HANDLING OPERATION SAFETY

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 off 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.

2 - 28
SAFETY 2.5 LOAD HANDLING OPERATION

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.

2 - 29
2.5 LOAD HANDLING OPERATION SAFETY

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.

2 - 30
SAFETY 2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE

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 2

• 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 Do not operate
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

• 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.

2 - 31
2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE SAFETY

2.6.4 CAUTIONS BEFORE INSPECTION AND MAINTENANCE 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 neutral
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 2

• Block the forks and mast to prevent falling before working under
the raised forks. Otherwise a serious accident may result.

2 - 32
SAFETY 2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE

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.

2 - 33
2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE SAFETY

2.6.10 BE CAREFUL OF HIGH PRESSURE OIL 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 2

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.

2 - 34
SAFETY 2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE

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 explosion. 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.

2 - 35
2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 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 at 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 environment
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 2

• 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.

2 - 36
SAFETY 2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE

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 remaining 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 4-
54)".
• 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
2.7 HOISTING AND TRANSPORTING THE LIFT TRUCK SAFETY

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 counterbalance-
weight 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 2

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. Ramp
• 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. Blocks
• 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
SAFETY 2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING)

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 Load
will be raised off the ground. It is very dangerous and poses a
high risk of serious accident like tipping over.

Weight on
Load weight Fulcrum the rear wheels

2.8.2 CENTER OF GRAVITY OF A LOAD 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
2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING) 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 Combined center of gravity at
high lifting height Center of gravity
center of gravity of both the lift truck and the load. When the load of load
is raised, its center of gravity will rise, hence the combined center
Combined center of
of gravity will also rise. 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 abruptly. There
are dangerous and poses a high risk of serious accident like
tipping over.

2.8.4 ACTUAL CAPACITY 2

• 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. Load center: Small Load center: Large
Load : Large Load : Small

2 - 40
SAFETY 2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING)

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 for 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

2 - 41
2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING) SAFETY

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

Symbol
Attachment
Type Capacity
Side shifter F S * * * *
Fork positioner F M * * * *
Tyre handler C T * * * *
* 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 and 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.

2 - 42
SAFETY 2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING)

2.8.6 INTRODUCTION OF OPTIONAL SAFETY DEVICE 2

Various safety devices are available as options. The devices listed


below are only 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) Lift chain (11) Load backrest


(2) Mast (12) Fork carriage
(3) Lift cylinder (13) Front wheel
(4) Head lamp (14) Fork
(5) Rear view mirror (option) (15) Overhead guard
(6) Turn signal lamp and clearance lamp (parking (16) Operator’s seat
lamp) (17) Engine hood
(7) Rear wheel (18) Counterbalance-weight
(8) Fuel filler (19) Back-up lamp
(9) Assist grip (20) Under mirror (option)
(10) Tilt cylinder (21) Rear combination lamps (turn signal lamp,
brake lamp and tail lamp)

3-2
OPERATION 3.1 GENERAL VIEW

3.1.2 INSTRUMENTS AND CONTROLS 3

• OPERATOR’S COMPARTMENT

(1) Gearshift lever (11) Tilt control lever


(2) AUTO/MANUAL selector switch (option) (12) Lift control lever
(3) Parking brake lever (13) Accelerator pedal
(4) Forward/reverse lever (14) Brake pedal
(5) Steering wheel knob (15) Tiltable steering wheel lock lever
(6) Horn switch (16) Inching pedal
(7) Steering wheel (17) Gearshift adjustment dial (option)
(8) Starting switch (18) Auto transmission controller (option)
(9) Combination switch (The controller main body is normally protected
(Turn signal switch and lighting switch) with the cover.)
(10) Attachment control lever (option)

3-3
3.1 GENERAL VIEW OPERATION

• Meter panel

(1) Engine coolant temperature gauge (8) Operation indicator


(2) Hour meter (9) Lift Interlock warning lamp (option)
(3) Torque converter oil temperature gauge (10) Engine warning lamp
(4) Fuel gauge (11) Failure indicator
(5) Neutral indicator lamp / Travel interlock warning (12) Air cleaner element warning lamp
lamp (option) (13) Radiator coolant level warning lamp
(6) Parking brake warning lamp (14) Glow indicator
(7) Charge warning lamp (15) Speedometer (option)

3-4
OPERATION 3.2 EXPLANATION OF COMPONENTS

3.2 EXPLANATION OF COMPONENTS 3

The followings are explanation of the devices employed to operate


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
3.2 EXPLANATION OF COMPONENTS OPERATION

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 alternator 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 3.2 EXPLANATION OF COMPONENTS

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
3.2 EXPLANATION OF COMPONENTS OPERATION

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 4-
7)".

PARKING BRAKE WARNING LAMP


This warning lamp indicates that the parking brake is being
applied.

When applied : ON
When released : OFF

3-8
OPERATION 3.2 EXPLANATION OF COMPONENTS

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.


Fo r th e cle an ing , see "4.4 .2 A IR CL EA NE R EL E ME NT
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 EXPLANATION OF COMPONENTS OPERATION

3.2.2 OPERATING DEVICES 3

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 3.2 EXPLANATION OF COMPONENTS

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

AUTO TRANSMISSION CONTROLLER (OPTION)


• This controller (1) is the central unit of the system that decides
the shift gear and the gear shift timing according 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 (1) has a red (2) and a green (3) LED error
indicator lamps. These lamps inform the content of a failure by
the pattern of flashing.

LED ERROR 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 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 3.2 EXPLANATION OF COMPONENTS

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 2nd gear 2.5 - 7.5 km/h
2nd gear o 3rd gear 8 - 16 km/h

REMARK
The gearshift patterns are factory-set to the following speed.
Gearshift pattern Speed
1st gear o 2nd gear 5.5 km/h
2nd gear o 3rd 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.
• Manual gearshift mode : set the shifting switch to MANUAL
(upper) position.
• Automatic gearshift mode: set the shifting switch to AUTO
(lower) position.

NOTICE
Shift the transmission only after the lift truck stops completely.

3 - 13
3.2 EXPLANATION OF COMPONENTS OPERATION

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.
Meter lamp, clearance lamp,
No. Head lamp
and tail lamp
1 OFF OFF
2 OFF ON
3 ON ON
Lo ON (Low beam) ON
4
Hi ON (High beam) ON

TURN SIGNAL SWITCH


Left turn (L) : Push lever forward Forward
Right turn (R) : Pull lever backward

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 back the parking lever fully (Lock position) will set the
parking brake. Free
Lock
• To release the parking brake, press and hold the 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
OPERATION 3.2 EXPLANATION OF COMPONENTS

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 halfway, 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
3.2 EXPLANATION OF COMPONENTS 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 3.2 EXPLANATION OF COMPONENTS

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) Main power switch (5) Room/fresh air select switch


(2) Airflow control switch (6) Mode select switch
(3) Air conditioner switch (7) Defrost mode switch
(4) Temperature control switch (8) Display monitor

3 - 17
3.2 EXPLANATION OF COMPONENTS 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.
Display monitor
Press the HI switch (A) to increase the flow rate, and the LO switch
Flow rate: Increase
(B) to decrease the flow rate. The flow rate can be adjusted in four
levels.

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 temperature setting
level.

• Press the C switch (A) to lower the outlet temperature.


Display monitor
• Press the H switch (B) to raise the outlet temperature.

3 - 18
OPERATION 3.2 EXPLANATION OF COMPONENTS

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

Display monitor
Foot outlet mode
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 mode 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
3.2 EXPLANATION OF COMPONENTS OPERATION

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 3.2 EXPLANATION OF COMPONENTS

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
3.2 EXPLANATION OF COMPONENTS 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 the wiper


continuously.
Return the switch (OFF) : Stops 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
3.3 OPERATION 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 buckle (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
3.3 OPERATION 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
Free
(A).
3. Move the steering wheel back and forth to select the optimum
position. Lock
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
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 Forward
The engine does not start unless the forward/reverse lever is set in
the N (neutral) position.
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
3.3 OPERATION 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 starting 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

Engine speed
cancelled when the engine coolant temperature reaches 30°C or
higher. (Engine speed : 725 rpm) 725

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

TRAVEL INTERLOCK (ENGINE POWER CUTOFF) (OPTION) 3

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
fo r wa r d /r e v e rs e le v e r to th e 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 3.3 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. Forward

NOTICE
Shift the direction only after the lift truck stops completely. Neutral

Reverse

3 - 31
3.3 OPERATION OPERATION

3.3.4 STARTING AND STOPPING ON SLOPE 3

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
Free
brake activated) Lock
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. When the lift truck has gained some speed, release the
parking brake lever completely. 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 3

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
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
3.3 OPERATION 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) Free
Lock
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, and 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
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) Free
Lock
3. Set the forward/reverse lever to N (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 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
3.3 OPERATION OPERATION

3.3.9 LOAD HANDLING OPERATION 3

FORK SPREAD ADJUSTMENT 3

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
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 operating 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
Lower : Push the lever forward.

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 forward
Tilt backward : Pull the lever backward.

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 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 surround-
ings for safety.

3 - 38
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 OPERATION

3.3.10 CHECKING AFTER OPERATION 3

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
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
4.1 ABOUT INSPECTION AND MAINTENANCE INSPECTION AND MAINTENANCE

4. INSPECTION AND MAINTENANCE 4

4.1 ABOUT INSPECTION AND MAINTENANCE 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
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION

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 guard, fork, load backrest, etc.)
Loose tilt cylinder rod lock nuts
Contamination and/or damages of lamp, lens, etc.
Walk around a lift truck
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
Checking of the brake cooling oil level (Wet disk brake type)
Open the covers and food
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 Operation of lamps
ON position
Fuel level
Backup buzzer performance
Start-up condition and abnormal sound
Abnormal noise and vibration
Start the engine
Exhaust gas color, exhaust sound
Play of steering wheel
Operating state of steering wheel (runout and unstable driving)
Brake operating condition (response)
Travel slowly
Inching pedal operating condition (letting out the clutch, slip, inching travel)
Low speed travel and accelerating state
Mast operating condition
Operating load handling
Tension, damages and rusted condition of lift chain
Travel interlock function (option)
Checking of safety Lift interlock function (option)
function Neutral safety function
Overlooking application of parking brake, warning buzzer function (option)

4-3
4.2 START-UP INSPECTION INSPECTION AND MAINTENANCE

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 4

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
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION

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 damages.

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 inflation 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 START-UP INSPECTION INSPECTION AND MAINTENANCE

4.2.3 INSPECTION CONDUCTED BY OPENING COVER AND HOOD 4

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
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION

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.
Correct
3. Pull out the oil level gauge again and check that the stuck oil range
is within the normal range.
4. When hydraulic oil is low, replenish it. If the oil is spilt, wipe it
off completely.

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
4.2 START-UP INSPECTION INSPECTION AND MAINTENANCE

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
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION

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 Water separator
Fuel pre-filter
the red line (1).

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 4-
29)".

* 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. Correct range
3. When hydraulic oil is low, replenish it. If the oil is spilt, wipe it
off completely.

NOTICE
Always use Genuine Hydraulic oil.

4-9
4.2 START-UP INSPECTION INSPECTION AND MAINTENANCE

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 reaches
the upper limit line (A).
• Always keep the breather and terminal of the battery cap on the
Correct
top of the battery clean with no dust attachment. range

NOTICE
• If the battery electrolyte has spilled and the level has gone down, have
your battery repair shop add dilute 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

4 - 10
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION

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)".

4 - 11
4.2 START-UP INSPECTION INSPECTION AND MAINTENANCE

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 Free
Lock
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.

4 - 12
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION

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
Engine warning lamp Charge warning lamp
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 Lift interlock warning lamp Failure indicator
handling interlocking, see "LIFT INTERLOCK (OPTION) (PAGE
3-38)".
• Engine abnormality warning lamp turns out approx. 2 seconds
after lighting.

Radiator coolant level Air cleaner element


warning lamp 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 points at
the white range when warmed up.

4 - 13
4.2 START-UP INSPECTION INSPECTION AND MAINTENANCE

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.

4 - 14
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION

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 Center Full
Fill up position
110 l 260 l
10.0 - 11.5 ton (29.06 US gal) (68.69 US gal)
[24.2 UK gal] [57.2 UK gal]
130 l 280 l
13.5 - 16.0 ton (34.35 US gal) (73.98 US gal)
[28.6 UK gal] [61.6 UK gal]

CHECKING BACKUP BUZZER PERFORMANCE

CAUTION
Check the backup buzzer performance under the following conditions.
• Pull the parking brake lever in the direction to the rear 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.

4 - 15
4.2 START-UP INSPECTION INSPECTION AND MAINTENANCE

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 not
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 30 - 60 mm
of a turn. Play should be normal if within 30 - 60 mm (1.2 - 2.4 in). (1.2 - 2.4 in)
• Check if it is free of looseness by shaking it in the vertical and
longitudinal directions.

4 - 16
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION

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.

4 - 17
4.2 START-UP INSPECTION INSPECTION AND MAINTENANCE

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.

4 - 18
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION

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. 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 N (neutral) position, and raise the forks 15 cm (6 in) above the ground.
3. Step the foot off the brake pedal, inching pedal and accelerator pedal.
4. Set the forward/reverse lever to F (forward) or R (reverse) and lift the hip from the seat.
5. 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.

4 - 19
4.3 CHECKING AND REPORTING AFTER OPERATION INSPECTION AND MAINTENANCE

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. Checking of leakage of oil, fuel, coolant and battery electrolyte.


2. Checking of cracks, damages and loosened parts, etc.
3. Grease up and lubricate the parts if necessary.
4. Checking of abnormal points detected during the operation.

4 - 20
INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE

4.4 SIMPLE MAINTENANCE 4

4.4.1 GREASES AND FUEL 4

4.4.1.1 BASIC PRECAUTIONS 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.

4 - 21
4.4 SIMPLE MAINTENANCE INSPECTION AND MAINTENANCE

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 it 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.

4 - 22
INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE

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 filters 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 SIMPLE MAINTENANCE INSPECTION AND MAINTENANCE

4.4.1.2 LUBRICANT LIST 4

OIL AND GREASING CHART 4

(OIL, GREASE LOCATIONS AND INSPECTION AND MAINTENANCE INTERVALS)

Fork slide shaft Differential case

Lift chain Tilt cylinder pin

Mast support TORQFLOW


transmission

Pedal pin Engine oil pan

Brake cooling oil


Hydraulic tank
tank (option)

Power steering
Center pin, King pin
cylinder 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: Check and add fluid if necessary


Q : Total oil change or greasing and application Symbol Type of fluid
T : 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 oil
G Lithium grease

4 - 24
INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE

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)

Diesel
Engine oil pan engine oil SAE J300 10W30 (*1)

SAE J300 15W40 (*1)

SAE J300 30 (*1)

TORQFLOW
transmission Engine oil SAE 10W (*2)
case

SAE 80
Differential
Gear oil
case
SAE 90

SAE 5W (*2)
Hydraulic Hydraulic oil
system
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 Lithium
points grease G2-LI

Cooling system Super


coolant FAF-NAC

*1 Use API CF-4 or higher grade oil. SAE : Society of Automotive Engineers
*2 Use API CD or higher grade oil. ASTM: American Society of Testing and Material
API : American Petroleum Institute

4 - 25
4.4 SIMPLE MAINTENANCE INSPECTION AND MAINTENANCE

Capacity
TORQFLOW Brake cooling
Engine oil pan transmission Differential case Hydraulic tank Fuel tank oil tank (option) Cooling system
Model case
170 l 260 l
10.0 ton
(44.91 US gal) (68.69 US gal)
11.5 ton 20.3 l 40 l 20 l 14.5 l 28 l
[37.4 UK gal] [57.2 UK gal]
(5.36 US gal) (10.57 US gal) (5.28 US gal) (3.83 US gal) (7.40 US gal)
13.5 ton [4.47 UK gal] [8.80 UK gal] [4.40 UK gal] 200 l 280 l [3.19 UK gal] [6.16 UK gal]
15.0 ton (52.8 US gal) (74.0 US gal)
16.0 ton [44.0 UK gal] [61.6 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 system. Check the type of brake fluid without fail before using.

4 - 26
INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE

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 O-ring
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).

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.

4 - 27
4.4 SIMPLE MAINTENANCE INSPECTION AND MAINTENANCE

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. O-ring

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 for the
replacement of elements.

4 - 28
INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE

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.

4 - 29
4.4 SIMPLE MAINTENANCE INSPECTION AND MAINTENANCE

4.4.4 REPLACING TYRES 4

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 counterbalance-
weight.

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.

4 - 30
INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE

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.

4 - 31
4.4 SIMPLE MAINTENANCE INSPECTION AND MAINTENANCE

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 4

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 [Q] (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
INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE

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 Engine controller
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 Orange Key signal
12 10A 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 SIMPLE MAINTENANCE INSPECTION AND MAINTENANCE

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 10W (For 24V)

4 - 34
INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE

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 Lock

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. 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
Judgment
stepping down the pedal
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 be 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 SIMPLE MAINTENANCE INSPECTION AND MAINTENANCE

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 parts of the engine and causing a fire if the
fuel should leak or spray out. Check visually and touch by hand to check that there are no missing caps, loose bolts
or hardening of the rubber. If there are any problems, the parts must be replaced. Contact for inspection and repair.

* * *

4 - 36
INSPECTION AND MAINTENANCE 4.5 PROCEDURE FOR A DOWN BATTERY

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 [Q] (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.
Battery of Battery of
2. Connect the other clip of booster cable (A) to the positive ( + ) normal lift truck faulty lift truck
terminal of the normal lift truck.
3. Connect the clip of booster cable (B) to the negative ( - ) Engine block of faulty lift truck
terminal of the normal lift truck.
4. Connect the other clip of booster cable (B) to the engine block
of the 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
4.5 PROCEDURE FOR A DOWN BATTERY INSPECTION AND MAINTENANCE

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 are securely connected to the battery


terminals.
2. Start the engine on the normal lift truck and raise the speed to
full (maximum revolution).
3. Turn the starting switch on the faulty lift truck to [ | ] (START) to
start engine.
If the engine fails to start, try again after two minutes or over.

REMOVING THE BOOSTER CABLES


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

4 - 38
INSPECTION AND MAINTENANCE 4.6 RUNNING IN COLD WEATHER

4.6 RUNNING IN COLD WEATHER 4

PREPARATIONS FOR LOW TEMPERATURE


When the temperature becomes 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)".

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 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). 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) -10 -15 -20 -25 -30 -35
Concentration (%) 30 35 40 45 50 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, water pump and hoses for any water leakage.
• Drain all coolant and flush the inside of the system before adding new coolant.

4 - 39
4.6 RUNNING IN COLD WEATHER INSPECTION AND MAINTENANCE

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, 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.
• 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
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, refill distilled water before starting operation the next morning. 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
Battery charge
level (%)
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26

PRECAUTIONS AFTER COMPLETION OF 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 devices and fuel to those of specified viscosity according to the "LUBRICANT LIST
(PAGE 4-25)".

4 - 40
INSPECTION AND MAINTENANCE 4.7 ACTION IN ENGINE OVERHEATING

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 engine 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
4.7 ACTION IN ENGINE OVERHEATING INSPECTION AND MAINTENANCE

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
INSPECTION AND MAINTENANCE 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 hard 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 INSPECTION AND MAINTENANCE

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 accident. 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

use
Never
avoiding emergency exit or fire fighting equipment. For details
on parking, see "2.4.3 STOPPING AND PARKING (PAGE 2-

Danger
24)" 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
INSPECTION AND MAINTENANCE 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.cm2
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 Washing Method


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

Dashboard Front
2 Pedals
Floor Plate

Front & Rear Tyres Wash with high pressure steam or flushing water from a hose.
3
Front & Rear Axles (Note) Do not use high pressure steam or flushing water for the electric wirings.
Exterior parts other than
4 Wash with high pressure steam or flushing water from a hose.
the above
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
Other Precautions
transmission including electric wirings for them, and the electric system parts like
the connector, fuse box, etc. with a tarpaulin so that those parts and components
do not get splashed with water.

4 - 45
4.11 LONG-TERM STORAGE INSPECTION AND MAINTENANCE

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
INSPECTION AND MAINTENANCE 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 INSPECTION AND MAINTENANCE

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 3-
30)".
• 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 Ramp
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. Blocks
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 secure it with wire
rope and/or chain before starting the trailer.

4 - 48
INSPECTION AND MAINTENANCE 4.14 INSPECTION AND MAINTENANCE SCHEDULE CHART

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)

Intervals (month)
meter reading (hour)
Interval by service

Replacement
Every 3 months

Every 6 months
Every 2 weeks

Every 1 month

Every 1 year

Every 2 year
At start-up

(1200h)

(2400h)

(4800h)
(100h)

(200h)

(600h)
Inspection & Maintenance Item

Engine proper
Startup condition Q Q Q Q Q 200
Abnormal noise & vibration Q Q Q Q Q 2400
Exhaust gas color, Exhaust sound Q Q Q Q Q 1200
Low idling Q Q Q Q Q 200
Acceleration, engine stop and knocking Q Q Q Q Q 200
Checking of vibration damper Q 4000
Valve clearance Q Q 2000
Air cleaner element clogging Q Q 1200
Air cleaner element cleaning Q Q Q 200
Air cleaner element replacement Q Q 1200 6
Lubrication system
Oil pan oil level Q Q Q Q Q
Oil leakage Q Q Q Q Q 1200
Oil pan oil replacement 400 2
400 2
Engine

Oil filter cartridge replacement


Fuel system
Fuel leakage Q Q Q Q 200
Fuel filter clogging Q 2400
Fuel filter crack and damage Q Q Q Q 200
Fuel pre-filter water drain Q Q Q Q
Water separator water drain Q
Fuel pre-filter cartridge replacement *1 400 2
Fuel main filter cartridge replacement *2 *3 800 4
Fuel tank crack and damage Q
Fuel tank fuel level Q
Fuel tank cleaning Q 2400
Checking for loose engine high-pressure piping clamps,
hardening of rubber
Q 4000
High-pressure piping clamps replacement 8000 24
Checking for missing fuel spray prevention cap, hardening
of rubber
Q
Fuel spray prevention caps replacement 8000 24

*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
4.14 INSPECTION AND MAINTENANCE SCHEDULE CHART INSPECTION AND MAINTENANCE

Inspection & Maintenance Intervals (hours)

Intervals (month)
meter reading (hour)
Interval by service

Replacement
Every 3 months

Every 6 months
Every 2 weeks

Every 1 month

Every 1 year

Every 2 year
At start-up

(1200h)

(2400h)

(4800h)
(100h)

(200h)

(600h)
Inspection & Maintenance Item

Cooling system
Water level (reservoir tank) Q Q Q Q Q 200
Water level (radiator) Q Q Q Q 200
Fan belt slackening and damage Q Q Q Q Q 1000
Water leakage Q Q Q Q Q 200
Radiator cap condition Q Q Q Q 200
Radiator hose crack and damage Q Q Q Q 200
Q Q Q Q
Engine

Cooling fan installed condition 200


Cooling fan belt tension Q Q Q Q
Cooling fan deformation, crack and damage Q Q Q Q 200
Radiator fin cleaning and checking for damage Q Q Q Q 200
Cooling system interior cleaning Q Q 1200
Accessory
Checking of starter Q 4000
Checking of water pump Q 4000
Looseness of engine intake piping clamps 1000
Transmission
Oil leakage Q Q Q Q Q 200
Oil level Q Q Q Q 200
Inching pedal operating condition Q Q Q Q Q
Pedal height Q Q Q Q Q Q 200
Oil replacement Q Q 1200 6
Strainer replacement Q Q 1200 6
Power train

Line filter cartridge replacement Q Q 1200 6


Differential gear
Oil leakage Q Q Q Q Q 200
Oil level checking and refilling Q Q Q 200
Oil replacement Q Q 1200 6
Gearshift lever
Play and engagement condition Q Q Q Q 200
Installation condition Q Q 1200
Forward/reverse lever
Lighting of neutral lamp Q
Steering wheel
Operation feel Q Q Q Q Q 200
Amount of play Q Q Q Q Q
Gearbox
Loose mounting Q Q Q Q 200
Oil leakage Q Q Q Q 200
Steering system

Cylinder
Loosening, play and damage Q 2400
Knuckle
Play, deformation and damage at joint Q Q 1200
Wheel
Wheel alignment Q 2400
Left & right turning angle Q 2400
Fluctuation in min. turning radius Q Q 1200
Power steering
Oil leakage and oil level Q Q Q Q Q 200
Mounting condition and loosening at connection Q Q Q Q 200

4 - 50
INSPECTION AND MAINTENANCE 4.14 INSPECTION AND MAINTENANCE SCHEDULE CHART

Inspection & Maintenance Intervals (hours)

Intervals (month)
meter reading (hour)
Interval by service

Replacement
Every 3 months

Every 6 months
Every 2 weeks

Every 1 month

Every 1 year

Every 2 year
At start-up

(1200h)

(2400h)

(4800h)
(100h)

(200h)

(600h)
Inspection & Maintenance Item

Brake pedal
Stroke and braking effect Q Q Q Q Q 200
Play and pedal height when depressed Q Q Q Q Q 200
Inching pedal operation Q
Brake link play and loosening Q Q Q Q 200
Parking Brake
Stroke Q Q Q Q Q 200
Braking effect Q Q Q Q 200
Operating effort Q
Lever and ratchet wear and damage Q
Warning buzzer operation Q
Cable
Loosening, play, damage and wear Q Q Q Q 200
Braking system

Hose and Piping


Leakage, damage, installation condition and wear Q Q Q Q 200
Air tightness of piping Q 200
Brake cooling oil tank (option)
Oil level Q Q Q Q Q 200
Oil replacement Q Q
Cylinder and Disc Caliper
Operating condition, wear and damage Q 2400
Oil leakage Q 2400
Brake Valve
Operating condition, wear and damage Q 2400
Operating condition Q 2400
Accumulator for the brake
Checking of accumulator Q
Checking of sealed gas pressure and filling Q 2400
Wheel Cylinder Cup and Seal Q
General
Work equipment operating condition Q Q Q Q Q 200
Fork
Fork and fork stopper deformation, crack and damage Q Q Q Q Q 200
Loading equipment

Crack at fork bottom (by dye penetration check) Q 2400


Fork disarray and sagging Q Q Q Q 200
Greasing of mast roller, roller support Q Q Q Q Q
Mast 200
Mast deformation, crack, damage and wear Q Q Q Q Q 200
Mast roller play Q Q Q Q 2400
Mast support portion damage and wear Q 2400
Roller shaft crack and damage Q 100
Runout, play of propeller shaft and loose mount bolts

4 - 51
4.14 INSPECTION AND MAINTENANCE SCHEDULE CHART INSPECTION AND MAINTENANCE

Inspection & Maintenance Intervals (hours)

Intervals (month)
meter reading (hour)
Interval by service

Replacement
Every 3 months

Every 6 months
Every 2 weeks

Every 1 month

Every 1 year

Every 2 year
At start-up

(1200h)

(2400h)

(4800h)
(100h)

(200h)

(600h)
Inspection & Maintenance Item

Chain
Chain lubrication Q Q 100
Loading equipment

Chain and chain wheel deformation, damage, rusting and


lubrication
Q Q Q Q 200
Chain wheel bearing play Q Q Q Q 200
Chain anchor bolt deformation, damage, rusting and
lubrication
Q Q Q Q 200
Chain tension and elongation Q Q Q Q Q 200
Chain elongation Q Q Q 1200
Load backrest damage and cracks Q
Hydraulic Equipment
Loose tilt cylinder rod lock nuts Q
Hydraulic cylinder loosening, deformation, crack, damage
and wear
Q Q Q Q 200
Hydraulic cylinder operating condition Q Q Q Q 200
Lift cylinder natural drift Q Q Q Q 200
Tilt cylinder natural forward tilting Q Q Q Q 200
Control lever operating condition Q Q Q Q 200
Relief valve operating condition and relief set pressure Q 2400
Hydraulic system

Hydraulic pump and hydraulic motor operating condition Q 2400


Hydraulic pump abnormal noise Q
Hydraulic oil
Hydraulic oil tank damage and cracks Q
Oil replacement Q Q 1200 6
Oil level Q Q Q Q Q
Tank cleaning Q Q 1200
Air breather replacement Q 2400 12
Line filter replacement Q Q 1200 6
Strainer cleaning Q Q 1200
Piping
Piping damage, oil leakage and deformation Q Q Q Q Q 200
Piping clip loosening and slipping off Q Q Q Q
Starting motor
Engagement of switch and pinion gear Q Q Q Q 200
Electric system

Battery
Electrolyte level Q Q Q Q Q 200
Terminal connection loosening Q 2400
Electrolyte specific gravity Q Q Q Q 200
Wiring
Loosening at connection and damages Q Q Q Q 200

4 - 52
INSPECTION AND MAINTENANCE 4.14 INSPECTION AND MAINTENANCE SCHEDULE CHART

Inspection & Maintenance Intervals (hours)

Intervals (month)
meter reading (hour)
Interval by service

Replacement
Every 3 months

Every 6 months
Every 2 weeks

Every 1 month

Every 1 year

Every 2 year
At start-up

(1200h)

(2400h)

(4800h)
(100h)

(200h)

(600h)
Inspection & Maintenance Item

Wheel
Tyre inflation pressure Q Q Q Q Q 200
Tyre crack and damage Q Q Q Q Q 200
Traveling equipment

Tyre tread depth and abnormal wear Q Q Q Q Q 200


Wheel bearing play Q Q Q Q 200
Disk, wheel deformation, crack and damage Q Q Q Q 200
Wheel nut and bolt damage Q
Loose wheel nut and bolt Q Q 1200
Disk, wheel installation condition Q
Loose hub nuts Q Q Q
Axle deformation, crack and damage Q 2400
Main Body
Overhead guard and load backrest deformation, crack and
damage
Q Q Q Q Q 200
Each part loosening and damage Q 2400
Exhaust muffler and pipe installation condition and
damage
Q 2400
Operator's seat installation condition and damage Q Q Q Q 200
Runout, play of propeller shaft and loose mount bolts Q 2400
Frame and cross member crack and damage Q 2400
Directional Signal Lamp
Operating condition Q Q Q Q Q Q 200
Alarm
Operating condition Q Q Q Q Q Q 200
Operating condition of each lamp (head lamp, clearance
Others

lamp, brake lamp and backup lamp)


Q Q Q Q Q Q
Instrument
Operating condition Q Q Q Q 2400
Checking reading Q
Abnormality Found on Preceding Day
Checking completion of repairs Q
Rear view Mirror (Option)
Checking setting, smudge and damage Q Q Q Q Q
Lubrication
Each lubrication point properly lubricated Q Q Q Q 200
Warning Lamp and Indicator Lamp Q Q Q Q Q Q
Backup buzzer sounding performance Q Q Q Q Q 200
Safety Device Performance
(Travel interlock, Lift interlock and Neutral safety) (Option) Q 200
Comprehensive test

Conduct traveling and lifting tests and verify functions


Operation of various devices Q Q Q Q Q 200
Abnormal vibration, noise, odor and heating Q Q Q Q Q 200

4 - 53
4.15 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS INSPECTION AND MAINTENANCE

4.15 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4

For your safety use of lift trucks, you are requested to always implement periodic 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 passed, 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. Part name Years elapsed
1 Fuel hose (fuel tank - fuel pre-filter) 2
2 Fuel hose (fuel pre-filter - supply pump) 2
3 Fuel hose (supply pump - fuel main filter) 2
4 Fuel hose (fuel main filter - supply pump) 2
5 Fuel hose (supply pump - common rail overflow) 2
6 Fuel hose (engine - fuel tank) 2
7 Brake hose or tube 2
8 Brake tank and tube 2
9 Power steering hose 2
10 Stop lamp switch (hydraulic type) 2
11 Rubber parts inside power steering system 2
12 Lift chain 2-4
13 Hydraulic hose (for travel, loading & unloading and torque converter) 2
14 Engine high-pressure piping clamp
Every 8000 hours
15 Fuel spray prevention cap

4 - 54
INSPECTION AND MAINTENANCE 4.16 SERVICE DATA

4.16 SERVICE DATA 4

SERVICE DATA
Component Inspection item Unit FD100-8 FD115-8 FD135-8 FD150E-8 FD160E-8
Engine model – KOMATSU SAA6D107E-1-A
Idling speed rpm 700 - 750
Max. speed rpm 2375 - 2475
Engine proper
MPa (PSI)
Engine

Compression {kgf/cm2}/ Min.24 (3490) {246} / 250-280


rpm
Fuel system Injection order – 1-5-3-6-2-4
Intake, exhaust Valve Intake mm (in) 0.25 (0.01)
system Clearance Exhaust mm (in) 0.51 (0.02)
kPa (PSI) 735 (107) 690 (99.4) 660 (95.8) 760 (110) 690 (99.4)
Front wheels
Travel System

Tyre inflation {kgf/cm2} {7.5} {7.0} {6.75} {7.75} {7.0}


Tyres
pressure kPa (PSI) 735 (107) 690 (99.4) 660 (95.8) 760 (110) 690 (99.4)
Rear wheels
{kgf/cm2} {7.5} {7.0} {6.75} {7.75} {7.0}
Tightening Front wheels Nm {kgfm} 441 - 539 {45 - 55}
Hub nut
torque Rear wheels Nm {kgfm} 441 - 539 {45 - 55}
Steering wheel Play mm (in) 30 - 60 (1.2 - 2.4)
Play mm (in) 2 - 3 (0.08 - 0.12)
Inching pedal
Interconnected stroke mm (in) 28.5 - 33.5 (1.1 - 1.3)
Steering, braking system

Play mm (in) 2 - 6 (0.08 - 0.24)


Brake pedal Pedal height when pedal is
mm (in) 65 (2.6)
depressed
Parking brake operating
N {kgf} Min.196 {20}
force
Tightening torque for back
Brake Nm {kgfm} 147 - 245 {15 - 25} 147 - 196 {15 - 20}
plate mounting bolts
Gas pressure of brake MPa (PSI)
4.9 (710) {50}
accumulator {kgf/cm2}
(Wet disc brake Gas pressure of brake MPa (PSI)
3.4 (497) {35}
type) accumulator {kgf/cm2}
Loading equipment

Min. 75
Fork Fork thickness (at base) mm (in) Min. 70 (2.8) Min. 80 (3.2)
(3.0)
Max.60
Chain Length over 17 links mm (in) Max. 770 (30.3)
(26.0)
MPa (PSI)
Hydraulic system Relief pressure 21.6 (3120) {220}
{kgf/cm2}

4 - 55
4.16 SERVICE DATA INSPECTION AND MAINTENANCE

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 Tightening torque Nm {kgfm}


diameter (a) mm flat (b) mm Within target allowable range
6 10 13 {1.35} 12 - 15 {1.2 - 1.5}
8 13 31 {3.2} 27 - 34 {2.8 - 3.5}
10 17 66 {6.7} 59 - 74 {6.0 - 7.5}
12 19 113 {11.5} 98 - 123 {10.0 - 12.5}
14 22 177 {18.0} 157 - 196 {16.0 - 20.0}
16 24 279 {28.5} 245 - 309 {25.0 - 31.5}
18 27 382 {39.0} 343 - 427 {35.0 - 43.5}
20 30 549 {56.0} 490 - 608 {50.0 - 62.0}
22 32 745 {76.0} 662 - 829 {67.5 - 84.5}
24 36 927 {94.5} 824 - 1030 {84.0 - 105.0}
27 41 1324 {135.0} 1177 - 1471 {120.0 - 150.0}
30 46 1716 {175.0} 1520 - 1912 {155.0 - 195.0}
33 50 2206 {225.0} 1961 - 2452 {200.0 - 250.0}
36 55 2746 {280.0} 2452 - 3040 {250.0 - 310.0}
39 60 3285 {335.0} 2893 - 3628 {295.0 - 370.0}

4 - 56
TECHNICAL DATA 5

55

5-1
TECHNICAL DATA TECHNICAL DATA

TECHNICAL DATA 5

5-2
TECHNICAL DATA TECHNICAL DATA

1.2 Model Manufacturer's Designation FD100-8 FD115-8 FD135-8


1.3 Power Type Electric, Diesel, Gasoline, LPG, Cable Diesel Diesel Diesel
Characteristics

1.4 Operation Type Sitting Sitting Sitting


1.5 Rated Capacity Q kg(lb) 10000(22,000) 11500(25,000) 13500(30,000)
1.6 Load Center c mm(in) 600(24) 600(24) 600(24)
1.8 Load Distance x Front Axle Center to Fork Face mm(in) 695(27.4) 715(28.1) 740(29.1)
1.9 Wheelbase y mm(in) 2800(110.2) 2800(110.2) 3100(122.0)
2.1 Service Weight kg(lb) 12980(28,620) 14360(31,660) 15480(34,130)
2.2 Front kg(lb) 20860(45,990) 23490(51,790) 26450(58,310)
Weight

Loaded
2.2.1 Rear kg(lb) 2120(4,670) 2370(5,220) 2530(5,580)
Axle Loading
2.3 Front kg(lb) 6230(13,730) 6590(14,530) 7110(15,670)
Unloaded
2.3.1 Rear kg(lb) 6750(14,880) 7770(17,130) 8370(18,450)
3.1 Tyre Type Pneumatic Pneumatic Pneumatic
3.2 Front 9.00-20-14PR(I) 10.00-20-14PR(I) 11.00-20-14PR(I)
Tyre Size
3.3 Rear 9.00-20-14PR(I) 10.00-20-14PR(I) 11.00-20-14PR(I)
Tyres

3.5 Number of Wheels Front/Rear (x=driven) 4x/2 4x/2 4x/2


3.6 Tread, Front b10 mm(in) 1700(66.9) 1700(66.9) 1770(69.7)
3.7 Tread, Rear b11 mm(in) 1900(74.8) 1890(74.4) 1890(74.4)
4.1 Tilting Angle α/β Forward/Backward degree 6/12 6/12 6/12
4.2 Mast Height, Lowered h1 2-stage Std. Mast mm(in) 2890(113.8) 3160(124.4) 3170(124.8)
4.3 Std. Free Lift h2 2-stage Std. Mast, from Ground mm(in) 0(0.0) 0(0.0) 0(0.0)
4.4 Std. Lift Height h3 2-stage Std. Mast, from Ground mm(in) 3000(118) 3000(118) 3000(118)
4.5 Mast Height, Extended h4 2-stage Std. Mast mm(in) 4400(173.2) 4670(183.9) 4680(184.3)
4.7 Height, Overhead Guard h6 mm(in) 2780(109.4) 2800(110.2) 2810(110.6)
4.19 Length, with Std. Forks L1 mm(in) 5465(215.2) 5505(216.7) 5860(230.7)
Dimensions

4.20 Length, to Fork Face L2 mm(in) 4245(167.1) 4285(168.7) 4640(182.7)


4.21 Width, at Tyre b1 Single mm(in) 2280(89.8) 2310(90.9) 2410(94.9)
75x170x1220 75x185x1220 80x185x1220
4.22 Forks s/e/l Thickness x Width x Length mm(in)
(3.0x6.7x48.0) (3.0x7.3x48.0) (3.1x7.3x48.0)
4.23 Fork Carriage Class Pin Mount Pin Mount Pin Mount
4.24 Width, Fork Carriage b2 mm(in) 2140(84.3) 2140(84.3) 2210(87.0)
4.31 m1 Under Mast mm(in) 250(9.8) 250(9.8) 260(10.2)
Ground Clearance
4.32 m2 at Center of Wheelbase mm(in) 325(12.8) 345(13.6) 350(13.8)
4.33 Right Angle Stacking Aisle Ast plus load length mm(in) 4695(184.8) 4725(186.0) 5090(200.4)
4.35 Turning Radius Wa mm(in) 4000(157.5) 4010(157.9) 4350(171.3)
8.5/18/28 8.5/19/28 9/19.5/27.5
Loaded,1st/2nd/3rd km/h(mph)
(5.3/11.2/17.4) (5.3/11.8/17.4) (5.6/12.1/17.1)
5.1 Travel Speed (FWD)
9/20/32 9/21/32 9.5/21/32
Unloaded,1st/2nd/3rd km/h(mph)
(5.6/12.4/19.9) (5.6/13.0/19.9) (5.9/13.0/20.2)
5.2 Lifting Speed Loaded/Unloaded mm/s(fpm) 470/500(93/98) 430/450(85/89) 350/375(69/74)
Performance

5.3 Lowering Speed Loaded/Unloaded mm/s(fpm) 400/500(79/98) 400/500(79/98) 400/500(79/98)


5.6 Max. Drawbar Pull Loaded, 1.5km/h, 3min rating KN(ib) 89(20,010) 87(19,610) 85(19,150)
5.8 Max. Gradeability Loaded, 1.5km/h, 3min rating % 40 34 28
Foot/Hydraulic, Foot/Hydraulic, Foot/Hydraulic,
5.10 Service Brake Operation/Control
Powered Powered Powered
5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical Hand/Mechanical
Hydraulic Power Hydraulic Power Hydraulic Power
5.12 Steering Type
Steering Steering Steering
6.4 Battery Voltage/ Capacity at 5-hour rating V/Ah 24/80 24/80 24/80
KOMATSU KOMATSU KOMATSU
7.1 Maker Model
SAA6D107E-1 SAA6D107E-1 SAA6D107E-1
7.2 Rated Output, SAE net KW(HP) 122(164) 122(164) 122(164)
I.C Engine

7.3 Rated RPM min-1 2200 2200 2200


7.3.1 Max. Torque, SAE net Nm@min-1 575(424)@1600 575(424)@1600 575(424)@1600
No. of Cylinder/
7.4 cm3(cu.in) 6/6690(408) 6/6690(408) 6/6690(408)
Displacement
7.6 Fuel Tank Capacity Ltr(US Gal) 260(69) 260(69) 280(74.0)
Relief Pressure for
8.2 bar(psi) 215(3,100) 215(3,100) 215(3,100)
Attachment
Others

8.2.1 Hydraulic Tank Capacity Ltr(US Gal) 170(45) 170(45) 200(53)


8.6 Clutch Torque Converter Torque Converter Torque Converter
8.7 Transmission TORQFLOW TORQFLOW TORQFLOW

5-3
TECHNICAL DATA TECHNICAL DATA

1.2 Model Manufacturer's Designation FD150E-8 FD160E-8


1.3 Power Type Electric, Diesel, Gasoline, LPG, Cable Diesel Diesel
Characteristics

1.4 Operation Type Sitting Sitting


1.5 Rated Capacity Q kg(lb) 15000(33,000) 16000(35,000)
1.6 Load Center c mm(in) 600(24) 600(24)
1.8 Load Distance x Front Axle Center to Fork Face mm(in) 750(29.5) 750(29.5)
1.9 Wheelbase y mm(in) 3100(122.0) 3100(122.0)
2.1 Service Weight kg(lb) 16570(36,530) 17200(37,920)
2.2 Front kg(lb) 28740(63,360) 30140(66,450)
Weight

Loaded
2.2.1 Rear kg(lb) 2830(6,240) 3060(6,750)
Axle Loading
2.3 Front kg(lb) 7210(15,900) 7170(15,810)
Unloaded
2.3.1 Rear kg(lb) 9360(20,640) 10030(22,110)
3.1 Tyre Type Pneumatic Pneumatic
3.2 Front 11.00-20-16PR(I) 12.00-20-16PR(I)
Tyre Size
3.3 Rear 11.00-20-16PR(I) 12.00-20-16PR(I)
Tyres

3.5 Number of Wheels Front/Rear (x=driven) 4x/2 4x/2


3.6 Tread, Front b10 mm(in) 1770(69.7) 1770(69.7)
3.7 Tread, Rear b11 mm(in) 1890(74.4) 1870(73.6)
4.1 Tilting Angle α/β Forward/Backward degree 6/12 6/12
4.2 Mast Height, Lowered h1 2-stage Mast mm(in) 3270(128.7) 3290(129.5)
4.3 Std. Free Lift h2 2-stage Std. Mast, from Ground mm(in) 0(0.0) 0(0.0)
4.4 Std. Lift Height h3 2-stage Std. Mast, from Ground mm(in) 3000(118) 3000(118)
4.5 Mast Height, Extended h4 2-stage Std. Mast mm(in) 4780(188.2) 4800(189.0)
4.7 Height, Overhead Guard h6 mm(in) 2810(110.6) 2830(111.4)
4.19 Length, with Std. Forks L1 mm(in) 5920(233.1) 6020(237.0)
Dimensions

4.20 Length, to Fork Face L2 mm(in) 4700(185.0) 4800(189.0)


4.21 Width, at Tyre b1 Single mm(in) 2410(94.9) 2480(97.6)
85x190x1220 85x210x1220
4.22 Forks s/e/l Thickness x Width x Length mm(in)
(3.3x7.5x48.0) (3.3x8.3x48.0)
4.23 Fork Carriage Class Pin Mount Pin Mount
4.24 Width, Fork Carriage b2 mm(in) 2210(87.0) 2210(87.0)
4.31 m1 Under Mast mm(in) 250(9.8) 270(10.6)
Ground Clearance
4.32 m2 at Center of Wheelbase mm(in) 350(13.8) 370(14.6)
4.33 Right Angle Stacking Aisle Ast plus load length mm(in) 5150(202.8) 5250(206.6)
4.35 Turning Radius Wa mm(in) 4400(173.2) 4500(177.2)
9/19.5/27.5 9.5/20/28
Loaded,1st/2nd/3rd km/h(mph)
(5.6/12.1/17.1) (5.9/12.4/17.4)
5.1 Travel Speed (FWD)
9.5/21/32 10/21.5/32
Unloaded,1st/2nd/3rd km/h(mph)
(5.9/13.0/20.2) (6.2/13.4/20.5)
5.2 Lifting Speed Loaded/Unloaded mm/s(fpm) 325/350(64/69) 320/345(63/68)
Performance

5.3 Lowering Speed Loaded/Unloaded mm/s(fpm) 400/400(79/79) 400/400(79/79)


5.6 Max. Drawbar Pull Loaded, 1.5km/h, 3min rating KN(ib) 80(18,160) 80(18,030)
5.8 Max. Gradeability Loaded, 1.5km/h, 3min rating % 25 23
Foot/Hydraulic, Foot/Hydraulic,
5.10 Service Brake Operation/Control
Powered Powered
5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical
Hydraulic Power Hydraulic Power
5.12 Steering Type
Steering Steering
6.4 Battery Voltage/ Capacity at 5-hour rating V/Ah 24/80 24/80
KOMATSU KOMATSU
7.1 Maker Model
SAA6D107E-1 SAA6D107E-1
7.2 Rated Output, SAE net KW(HP) 122(164) 122(164)
I.C Engine

7.3 Rated RPM min-1 2200 2200


7.3.1 Max. Torque, SAE net Nm@min-1 575(424)@1600 575(424)@1600
No. of Cylinder/
7.4 cm3(cu.in) 6/6690(408) 6/6690(408)
Displacement
7.6 Fuel Tank Capacity Ltr(US Gal) 280(74.0) 280(74)
Relief Pressure for
8.2 bar(psi) 215(3,100) 215(3,100)
Attachment
Others

8.2.1 Hydraulic Tank Capacity Ltr(US Gal) 200(53) 200(53)


8.6 Clutch Torque Converter Torque Converter
8.7 Transmission TORQFLOW TORQFLOW

5-4
EMISSION CONTROL
WARRANTY STATEMENT
6

61

6-1
EMISSION CONTROL WARRANTY

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 subsequent 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 modifications 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 responsible 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 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.

6-2
EMISSION CONTROL WARRANTY

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 emission-
related assemblies. Where a warrantable condition 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 on
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 any questions regarding
your warranty rights and responsibilities, you should contact:

Komatsu Forklift U.S.A., Inc. OR California Air Resources Board Manager,


14481 Lochridge Boulevard 9528 Telstar Avenue
Covington, GA 30014 El Monte, CA 91731
PHONE: 770-787-5100

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.

6-3
EMISSION CONTROL WARRANTY

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 Other Emission Parts
Control Module 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 may 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 " repair 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 authorized 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 use 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.

6-4
EMISSION CONTROL WARRANTY

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 responsibility 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.

6-5
INDEX 7

76

7-1
INDEX

INDEX
<A> FIRE PREVENTION --------------------------------------- 2-11
ABOUT INSPECTION AND MAINTENANCE ----------- 4-2 FOLLOW RULES ------------------------------------------- 2-8
ABOUT THIS MANUAL ------------------------------------ 1-2 FOR YOUR SAFETY --------------------------------------- 1-4
ACTION IN ENGINE OVERHEATING ------------------4-41 SAFETY INDICATORS ---------------------------------- 1-5
ACTION TO TAKE IF THE FORK FAILS TO SIGNAL WORDS ----------------------------------------- 1-4
LOWER --------------------------------------------------4-44
ACTUAL CAPACITY---------------------------------------2-40 <G>
ALWAY PERFORM THE START-UP INSPECTION --2-31 GENERAL VIEW -------------------------------------------- 3-2
APPLICABLE MODEL AND SERIAL No. ---------------- 1-6 INSTRUMENTS AND CONTROLS--------------------- 3-3
ASBESTOS CAUTION ------------------------------------2-14 GENERAL VIEW OF LIFT TRUCK --------------------- 3-2
AVOID GETTING CAUGHT UP BY THE MAST OR GENERAL VIEW OF LIFT TRUCK ----------------------- 1-6
FALLING OFF ------------------------------------------2-33 APPLICATION OF LIFT TRUCK------------------------ 1-6
DIRECTION OF LIFT TRUCK --------------------------- 1-6
<B> ENGINE MOUNTED ON THIS LIFT TRUCK
BASIC PRECAUTIONS ------------------------------------ 2-8 CERTIFICATION LABEL AFFIXED POSITION ------ 1-3
BE CAREFUL OF BOILING COOLANT ----------------2-33
BE CAREFUL OF HIGH PRESSURE OIL--------------2-34 <H>
BEFORE STARTING OPERATION ---------------------2-15 HOISTING AND TRANSPORTING THE LIFT
BEWARE OF ROTATING COOLING FAN AND TRUCK -------------------------------------------------- 2-38
BELT -----------------------------------------------------2-34 HOISTING LIFT TRUCK ---------------------------------- 4-47

<C> <I>
CAUTION AFTER INSPECTION AND REPAI ---------2-36 IF A FIRE BREAKS OUT --------------------------------- 2-12
CAUTION WHEN CHARGING A BATTERY -----------2-35 INSPECTION AND ADJUSTMENT BEFORE
CAUTION WHEN HANDLING BATTERY --------------2-35 STARTING ENGINE ----------------------------------- 2-15
CAUTION WHEN HANDLING TYRES ------------------2-36 INSPECTION AND MAINTENANCE SCHEDULE
CAUTION WHEN REPAIRING THE ELECTRICAL CHART -------------------------------------------------- 4-49
SYSTEM -------------------------------------------------2-34 INTRODICTION OF OPTIONAL SAFETY DEVICE -- 2-43
CAUTIONS BEFORE INSPECTION AND
MAINTENANCE ----------------------------------------2-32
CAUTIONS FOR SAFETY-RELATED EQUIPMENT -- 2-9 <J>
CAUTIONS FOR USING COMPRESSED AIR FOR JUMPING ON AND OFF FROM THE LIFT TRUCK
CLEANING ----------------------------------------------2-34 IS STRICTLY PROHIBITED -------------------------- 2-10
CAUTIONS WHEN REPLACING THE SEAT ----------2-34
CAUTIONS WHEN WORKING UNDER WORK <K>
EQUIPMENT --------------------------------------------2-32 KEEP THE OPERATOR’S COMPARTMENT AND
CENTER OF GRAVITY OF A LOAD --------------------2-39 PLATFORM CLEAN AND TIDY ---------------------- 2-10
CHECKING AND REPORTING AFTER KEEP THE WORKING AREA CLEAN AND TIDY ---- 2-31
OPERATION --------------------------------------------4-20 KEEP UNAUTHORIZED PEOPLE OFF ---------------- 2-32
COMBINED CENTER OF GRAVITY AND STABILITY
ON THE LOADED LIFT TRUCK ---------------------2-40
<L>
LIFT INTERLOCK ----------------------------------------- 3-38
<D> LOAD HANDLING OPERATION ------------------------ 2-26
DO NOT MODIFY THE LIFT TRUCK -------------------2-12 LOADING AND UNLOADING OF LIFT TRUCK ------- 4-48
DO NOT REMOVE THE OVERHEAD GUARD AND LONGITUDINAL STABILITY ----------------------------- 2-39
LOAD BACKREST -------------------------------------2-13 LONG-TERM STORAGE --------------------------------- 4-46

<E> <N>
EMISSION CONTROL WARRANTY --------------------- 6-2 NECESSARY INFORMATION OF LIFT TRUCK ------- 1-8
ENGINE EXHAUST GAS IS POISONOUS-------------2-14 ENGINE SERIAL NO. PLATE OR EMBOSSED
ENGINE MOUNTED ON THIS LIFT TRUCK LOCATION ----------------------------------------------- 1-9
EXHAUST GAS CONTROL ----------------------------- 1-3 HOUR METER LOCATION ------------------------------ 1-9
EXPLANATION OF COMPONENTS --------------------- 3-5 MEMORANDUM (To be filled by KOMATSU
METER PANEL -------------------------------------------- 3-5 FORKLIFT distributor) ---------------------------------- 1-8
OPERATING DEVICES ---------------------------------3-10 MODEL AND SERIAL NO. LOCATION ---------------- 1-8
NEVER OPERATE THE BROKEN-DOWN LIFT
<F> TRUCK --------------------------------------------------- 2-8
FIRE EXTINGUISHER AND FIRST AID KIT ------------ 2-9

7-2
INDEX

<O> REPLACING FUSES ------------------------------------ 4-32


OPERATING LIFT TRUCKS IN SPECIAL REPLACING TYRES ------------------------------------ 4-30
ENVIRONMENT OR IN FORCIBLE WAY ---------- 4-43 STACKING ------------------------------------------------- 3-39
OPERATION ----------------------------------------------- 3-23 STARTING ENGINE -------------------------------------- 3-27
CHECKING AFTER OPERATION --------------------- 3-40 STARTING LIFT TRUCK OFF --------------------------- 3-29
FORK SPREAD ADJUSTMENT ----------------------- 3-36 START-UP INSPECTION -------------------- 2-15,2-16,4-2
INCHING TRAVEL --------------------------------------- 3-32 CHECK BY SETTING THE STARTING SWITCH
LOAD HANDLING OPERATION----------------------- 3-36 TO [ | ] (ON) POSITION ------------------------------- 4-13
MOUNTING/DISMOUNTING AND OPERATING CHECKING ABNORMALITIES DETECTED ON
POSTURE ADJUSTMENT --------------------------- 3-23 THE PREVIOUS DAY ----------------------------------- 4-4
STARTING AND STOPPING ON SLOPE ------------ 3-32 CHECKING BY OPERATING THE WORK
STARTING, GEAR SHIFTING, AND TRAVELING -- 3-27 EQUIPMENT LEVER---------------------------------- 4-17
START-UP INSPECTION------------------------------- 3-23 CHECKING FROM THE OPERATOR SEAT -------- 4-11
TEMPORARY STOPPING, PARKING AND CHECKING OF SAFETY FUNCTION ---------------- 4-19
STOPPING ---------------------------------------------- 3-34 CHECKING WHILE TRAVELING SLOWLY --------- 4-17
TURNING ------------------------------------------------- 3-33 CHECKING WITH THE ENGINE STARTED -------- 4-16
OPERATION ON SNOWY AND FROZEN ROADS--- 3-33 INSPECTION CONDUCTED BY OPENING COVER
OPERATION OF CONTROL LEVERS ----------------- 3-37 AND HOOD ----------------------------------------------- 4-6
WALK AROUND A LIFT TRUCK ------------------------ 4-4
STOPPING AND PARKING------------------------------ 2-24
<P> STRICTLY FOLLOW THE INSTRUCTIONS SHOWN
PERIODIC INSPECTION OF SAFETY CRITICAL BELOW TO AVOID GENERATION OF SPARKS - 2-35
PARTS --------------------------------------------------- 2-37 STRUCTURE AND STABILITY OF THE LIFT TRUCK
PERIODIC REPLACEMENT OF SAFETY CRITICAL (TO PREVENT LIFT TRUCK FROM TIPPING) --- 2-39
PARTS --------------------------------------------------- 4-54
PICKING UP ------------------------------------------------ 3-39
PRACTICE SUFFICIENTLY BEFORE OPERATION ---2-9 <T>
PRECAUTION WHEN WASHING LIFT TRUCK ------ 2-10 TECHNICAL DATA ------------------------------------------ 5-2
PRECAUTIONS FOR INSPECTION AND TOWING ---------------------------------------------------- 2-25
MAINTENANCE ---------------------------------------- 2-31 TRAVEL INTERLOCK (ENGINE POWER CUTOFF) 3-30
PREPARATION BEFORE TRAVELING THE LIFT TRAVELING THE LIFT TRUCK ------------------------- 2-17
TRUCK -------------------------------------------------- 2-17
PROCEDURE FOR A DOWN BATTERY -------------- 4-37 <U>
PUT UP A WARNING SIGN DURING INSPECTION UNITS OF MEASURE -------------------------------------- 1-6
AND MAINTENANCE --------------------------------- 2-31 USE OF RIGHT TOOLS AND EQUIPMENT ---------- 2-32

<Q> <W>
QUALIFICATION FOR OPERATION ---------------------1-7 WARRANTY AND SERVICE ------------------------------ 1-7
PERIODICAL EXCHANGE PARTS --------------------- 1-7
<R> USE OF GENUINE PARTS AND OILS ----------------- 1-7
RUNNING IN COLD WEATHER------------------------- 4-39 WASHING LIFT TRUCK ---------------------------------- 4-45
RUNNING IN NEW LIFT TRUCK --------------------------1-7 WEAR ADEQUATE CLOTHES AND SAFETY
MAINTENANCE FOR NEW LIFT TRUCK --------------1-7 EQUIPMENT FOR OPERATION ---------------------- 2-9
RUNNING IN NEW LIFT TRUCK ------------------------1-7 WHILE TRAVELING THE LIFT TRUCK ---------------- 2-18
WINDOW WASHER CAUTION ------------------------- 2-14

<S>
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

7-3
FD100/160E-08 FORKLIFT TRUCK

Form No. AEE08E1-03

PRINTED IN JAPAN