Documentos de Académico
Documentos de Profesional
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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
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.
• 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.
1-2
INTRODUCTION 1.2 ENGINE MOUNTED ON THIS LIFT TRUCK
The engine mounted on this lift truck is approved by the following diesel engine exhaust gas control standards.
1-3
1.3 FOR YOUR SAFETY INTRODUCTION
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.
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.
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.
NOTICE- - - - - - - The lift truck can get damaged or shortens its service life when handled incorrectly.
1-4
INTRODUCTION 1.3 FOR YOUR SAFETY
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.
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
This Operation and Maintenance Manual applies to the following lift trucks.
This lift truck is intended to use mainly for the following work.
• Load handling with the forks of the lift truck.
This manual determines the left and right directions and fore and aft directions as seen from the operator's seat.
Right
Front Rear
Left
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
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.
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.
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.
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)".
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
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.
Model type
Serial No.
Engine serial No.
Attachment/option
Distributor
Address
Telephone, fax No.
Service person in charge
Sales representative in charge
1-8
INTRODUCTION 1.10 NECESSARY INFORMATION OF LIFT TRUCK
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
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
1 - 11
CONTENTS INTRODUCTION
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
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.
2-2
SAFETY 2.1 SAFETY LABEL
1 Caution to avoid getting hand caught Near the upper center of the tilt stay
3 Caution when hoisting the lift truck Outside of left and right outer masts
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
KOMATSU FORKLIFT reserves the right to change or add to these safety label requirements and label contents.
2-3
2.1 SAFETY LABEL SAFETY
2-4
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.
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)
(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
(General) (USA)
2-7
2.2 BASIC PRECAUTIONS SAFETY
2-8
SAFETY 2.2 BASIC PRECAUTIONS
• 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
2.2.8 KEEP THE OPERATOR'S COMPARTMENT AND PLATFORM CLEAN AND TIDY 2
2 - 10
SAFETY 2.2 BASIC PRECAUTIONS
2 - 11
2.2 BASIC PRECAUTIONS SAFETY
• 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 - 12
SAFETY 2.2 BASIC PRECAUTIONS
• 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 - 14
SAFETY 2.3 BEFORE STARTING OPERATION
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 - 15
2.3 BEFORE STARTING OPERATION SAFETY
2 - 16
SAFETY 2.4 TRAVELING THE LIFT TRUCK
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 - 18
SAFETY 2.4 TRAVELING THE LIFT TRUCK
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.
2 - 19
2.4 TRAVELING THE LIFT TRUCK SAFETY
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.
(General)
(USA)
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.
2 - 22
SAFETY 2.4 TRAVELING THE LIFT TRUCK
2 - 23
2.4 TRAVELING THE LIFT TRUCK SAFETY
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
2.4.4 TOWING 2
2 - 25
2.5 LOAD HANDLING OPERATION SAFETY
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.
2 - 26
SAFETY 2.5 LOAD HANDLING OPERATION
2 - 27
2.5 LOAD HANDLING OPERATION SAFETY
2 - 28
SAFETY 2.5 LOAD HANDLING OPERATION
2 - 29
2.5 LOAD HANDLING OPERATION SAFETY
2 - 30
SAFETY 2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE
• 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
• 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.
• 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
• 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.
• 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 - 34
SAFETY 2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE
2 - 35
2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE SAFETY
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.
• 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
• 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 - 38
SAFETY 2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING)
To operate the lift truck safely, it is important to understand the structure and stability of the lift truck.
• 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
• 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.
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
Center of gravity of
lift truck
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 - 40
SAFETY 2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING)
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.
2 - 41
2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING) SAFETY
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 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.
2 - 42
SAFETY 2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING)
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
3-2
OPERATION 3.1 GENERAL VIEW
• OPERATOR’S COMPARTMENT
3-3
3.1 GENERAL VIEW OPERATION
• Meter panel
3-4
OPERATION 3.2 EXPLANATION OF COMPONENTS
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.
3-5
3.2 EXPLANATION OF COMPONENTS OPERATION
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.
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.
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
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)".
If the warning lamp lights up, check the level of the coolant. For
the checking, see "CHECKING OF COOLANT LEVEL (PAGE 4-
7)".
When applied : ON
When released : OFF
3-8
OPERATION 3.2 EXPLANATION OF COMPONENTS
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
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.
NOTICE
When loaded, always start in 1st gear.
3 - 11
3.2 EXPLANATION OF COMPONENTS OPERATION
• 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.
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
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
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
This lever will automatically return to the neutral position when the
steering wheel is turned back.
Backward
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
Raise
Tilt backward
Free
Lock
3 - 16
OPERATION 3.2 EXPLANATION OF COMPONENTS
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.
3 - 17
3.2 EXPLANATION OF COMPONENTS OPERATION
Display monitor
3 - 18
OPERATION 3.2 EXPLANATION OF COMPONENTS
Display monitor
Foot outlet mode
Vent outlet mode
Display monitor
3 - 19
3.2 EXPLANATION OF COMPONENTS OPERATION
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
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
OPERATION METHODS
Each switch selects wiper ON or OFF as follows:
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.
3 - 22
OPERATION 3.3 OPERATION
3.3 OPERATION 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.
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
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.
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.
3 - 24
OPERATION 3.3 OPERATION
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.
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.
3 - 25
3.3 OPERATION OPERATION
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.
3 - 26
OPERATION 3.3 OPERATION
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.
REMARK Forward
The engine does not start unless the forward/reverse lever is set in
the N (neutral) position.
Neutral
Reverse
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
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
Neutral
Reverse
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
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.
This Traveling Interlock does not brake the lift truck forcibly.
3 - 30
OPERATION 3.3 OPERATION
GEAR SHIFTING 3
NOTICE
When loaded, always start in 1st gear.
SHIFTING DIRECTION
1. Release accelerator pedal (1), and fully depress brake pedal
(2).
NOTICE
Shift the direction only after the lift truck stops completely. Neutral
Reverse
3 - 31
3.3 OPERATION OPERATION
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.)
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.
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.
3 - 33
3.3 OPERATION OPERATION
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
CAUTION
Take extreme care not to get hands or fingers caught while fork spread
adjustment.
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
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.
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
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
3 - 38
OPERATION 3.3 OPERATION
PICKING UP 3
5 - 10 cm
(2 - 4 in)
15 - 20 cm (6 - 8 in)
STACKING 3
3 - 39
3.3 OPERATION OPERATION
After all the above procedures have been finished and each part of
the lift truck is cleaned, and before it is stored, carry out the
following inspections.
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
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.
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.
4-2
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION
4-3
4.2 START-UP INSPECTION INSPECTION AND MAINTENANCE
4-4
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION
NOTICE
Tighten the hub nuts to the specified torque.
For the right tightening torque, see "4.16 SERVICE DATA (PAGE 4-55)".
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
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.
3. Lift the engine hood up until the red stopper (3) of the support
stay is applied.
4-6
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION
NOTICE
• When the engine oil is considerably contaminated or has been
discolored, replace with new oil.
• Always use Genuine Engine oil.
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
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.
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
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.
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.
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
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)".
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.
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 - 11
4.2 START-UP INSPECTION INSPECTION AND MAINTENANCE
NOTICE
If the value of the lever operating effort is not within the standard range,
contact your KOMATSU FORKLIFT distributor for repair.
4 - 12
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION
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.
4 - 13
4.2 START-UP INSPECTION INSPECTION AND MAINTENANCE
4 - 14
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION
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]
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
CAUTION
Exhaust gas is toxic. When starting engine indoors or in a poorly-ventilated site, take extreme care for ventilation.
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
4 - 16
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION
4 - 17
4.2 START-UP INSPECTION INSPECTION AND MAINTENANCE
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.
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.
4 - 18
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION
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 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 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 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 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.
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.
4 - 20
INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE
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.
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.
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
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)
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
Diesel
Engine oil pan engine oil SAE J300 10W30 (*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)
Brake cooling
oil (option) Engine oil SAE 10W (*2)
Greasing Lithium
points grease G2-LI
*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
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.
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
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
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.
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.
4 - 31
4.4 SIMPLE MAINTENANCE INSPECTION AND MAINTENANCE
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.
For the standard value of the parking brake lever operating effort,
see "4.16 SERVICE DATA (PAGE 4-55)".
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.
4 - 32
INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE
• 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
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.
4 - 34
INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE
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.
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
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.
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
If a battery is down, the lift truck can be started by using the battery
of other lift truck via 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.
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.
4 - 38
INSPECTION AND MAINTENANCE 4.6 RUNNING IN COLD WEATHER
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.
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
4 - 40
INSPECTION AND MAINTENANCE 4.7 ACTION IN ENGINE OVERHEATING
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.
4 - 41
4.7 ACTION IN ENGINE OVERHEATING INSPECTION AND MAINTENANCE
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.
4 - 42
INSPECTION AND MAINTENANCE 4.8 OPERATING LIFT TRUCKS IN SPECIAL ENVIRONMENT OR IN FORCIBLE WAY
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.
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
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.
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
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.
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
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
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
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.
4 - 48
INSPECTION AND MAINTENANCE 4.14 INSPECTION AND MAINTENANCE SCHEDULE CHART
• 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.
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
*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
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
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
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
4 - 51
4.14 INSPECTION AND MAINTENANCE SCHEDULE CHART INSPECTION AND MAINTENANCE
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
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
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
4 - 53
4.15 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS INSPECTION AND MAINTENANCE
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.
4 - 54
INSPECTION AND MAINTENANCE 4.16 SERVICE DATA
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
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
4 - 56
TECHNICAL DATA 5
55
5-1
TECHNICAL DATA TECHNICAL DATA
TECHNICAL DATA 5
5-2
TECHNICAL DATA TECHNICAL DATA
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
5-3
TECHNICAL DATA TECHNICAL DATA
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
5-4
EMISSION CONTROL
WARRANTY STATEMENT
6
61
6-1
EMISSION CONTROL WARRANTY
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.
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
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.
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.
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:
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:
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).
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
<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
PRINTED IN JAPAN