Komatsu FB25-12 FB30-12 ForkLift Truck Operation & Maintenance Manual TEN00722-04 - PDF DOWNLOAD

TEN00722-04

FORKLIFT TRUCK

FB25 -12 FB30 -12 SERIAL NUMBERS

WARNING Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintaining this machine.

This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with it.

FB25-101700 FB30-101700

and up

INTRODUCTION 1

11

1-1

INTRODUCTION

ABOUT THIS MANUAL

1

INTRODUCTION ABOUT THIS MANUAL

This manual describes procedures for proper operation, inspection, and maintenance of this lift truck, and rules you must follow for your safety. Most accidents are caused by a failure to follow fundamental safety precautions for the operation, inspection, and maintenance of lift trucks. Also, knowing the possible hazards in advance will help to avoid accidents.

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 personal injury or death or damage.

Operators and service staffs must follow the followings before conducting operations, inspections, and maintenance of this lift truck.

Administrators must understand this manual for conducting safety control of this lift truck. ･ Read this manual carefully and understand it fully. ･ Make sure you fully understand the instructions and safety labels 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 available 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 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 Ltd. FORKLIFT COMPANY or your Komatsu distributor for the latest available information your lift truck or for questions regarding information in this manual.

Storage location for Operation and Maintenance Manual ･ Seat back pocket (1) behind the operator's seat

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INTRODUCTION

FOR YOUR SAFETY

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

1

SIGNAL WORDS

The following signal words indicate the possible hazard which leads personal injury or death.

For this lift truck and this manual, the following signal words are used depending on the degree of possible hazard.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Example of safety message using signal word

CAUTION Entering of water into the electrical parts (controllers, sensors, connectors) may cause a malfunction, which is dangerous.

OTHER SIGNAL WORDS Besides the above signal words, the followings indicate precautions you must take for the lift truck as well as useful information.

IMPORTANT•••••••The lift truck can get damaged or shortens its service life when handled incorrectly.

REMARK•••••Useful information.

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FOR YOUR SAFETY

INTRODUCTION

SAFETY INDICATORS

1

Safety indicators are used in the various locations of the lift truck to indicate the possible hazards to the concerned persons during operations, inspections, and maintenances. This lift truck employs [verbal safety indicator] and [pictorial safety indicator] for safety indicators.

EXAMPLE OF VERBAL SAFETY INDICATOR There are safety indicators which consist of drawing and words in addition to verbal-only safety indicators.

EXAMPLE OF PICTORIAL SAFETY INDICATOR The pictorial safety indicators indicate the hazard equivalent to the signal words.Drawings are used for these safety indicators to tell the operators and service staffs clearly of the existence and content of a hazard.

The safety indicators used in this lift truck comply with the standard pictorial safety indicator established by Japan Industrial Vehicles Association.

In addition, there are pictorial indicators which simply indicate the prohibition content as well as indicators which comply with the international standards.

Komatsu Ltd. 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 distributor for the latest available information or for questions regarding this manual.

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INTRODUCTION

GENERAL VIEW OF LIFT TRUCK

GENERAL VIEW OF LIFT TRUCK 1

APPLICATION OF LIFT TRUCK This lift truck is intended to use mainly for the following work. ･ Load handling with the forks of the lift truck

1

DIRECTION OF LIFT TRUCK

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

Right

Rear

Front

Left

UNITS OF MEASURE This manual uses the international system of units (SI) for units of measure.

Also the gravitational system of units, conventionally used, are providedas { } for reference.

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INTRODUCTION

QUALIFICATIONS FOR OPERATION

QUALIFICATIONS 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.

RUNNING IN NEW LIFT TRUCK RUNNING IN NEW LIFT TRUCK

1

Your Komatsu Forklift truck has been thoroughly adjusted and tested before shipment. However, operate moderately during the first one month (or initial 200 hours) until each part of the lift truck comes into stable.

Operating the lift truck under severe conditions at the beginning can adversely affect performance and shorten the lift truck life.

Be sure to run in the lift truck, taking special care concerning the followings. ･ Do not operate with heavy loads or at high speeds. ･ Avoid sudden starting, acceleration, braking, and sharp turning.

MAINTENANCE FOR NEW LIFT TRUCK

1

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

WARRANTY AND SERVICE PERIODICAL EXCHANGE PARTS

1

Other than those specified by the law, Komatsu Forklift designates "periodical exchange parts." Deterioration of such parts is unavoidable over time but is critical for safety and therefore must be replaced periodically.Replace those parts at the designated periods regardless of their appearance.For the periodic replacement of safety critical parts, see "INSPECTION AND MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS (4-73 page)".

USE OF GENUINE KOMATSU PARTS AND OILS

1

Any problem caused by the use of other than genuine Komatsu parts (including oils) warranted by Komatsu is not covered by the warranty.

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INTRODUCTION

NECESSARY INFORMATION OF LIFT TRUCK

NECESSARY INFORMATION OF LIFT TRUCK When you need maintenance of the lift truck or order parts, please provide Komatsu distributor with necessary information of the lift trucksuch as model type, serial number, attachment,option, etc.

MEMORANDUM (TO BE FILLED BY KOMATSU DISTRIBUTOR)

1

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

MODEL AND SERIAL NUMBER PLATE LOCATION

1

SERIAL NUMBER PLATE LOCATION Serial number plate is located in the right top of the dashboard.

SERIAL NUMBER STAMPING LOCATION Besides the plate, serial number is also stamped on the top of the left-side front wheel fender.

Example of stamping mark: ****-##### The manufacturing number is shown as # after the hyphen.

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INTRODUCTION

Table of contents

Table of contents INTRODUCTION ------------------------------------------------------------------------------------------------------------------------ 1-1 ABOUT THIS MANUAL ---------------------------------------------------------------------------------------------------------- 1-2 FOR YOUR SAFETY ------------------------------------------------------------------------------------------------------------- 1-3 SIGNAL WORDS ------------------------------------------------------------------------------------------------------------ 1-3 SAFETY INDICATORS----------------------------------------------------------------------------------------------------- 1-4 GENERAL VIEW OF LIFT TRUCK ------------------------------------------------------------------------------------------- 1-5 APPLICATION OF LIFT TRUCK ---------------------------------------------------------------------------------------- 1-5 DIRECTION OF LIFT TRUCK -------------------------------------------------------------------------------------------- 1-5 UNITS OF MEASURE------------------------------------------------------------------------------------------------------------ 1-5 QUALIFICATIONS FOR OPERATION--------------------------------------------------------------------------------------- 1-6 RUNNING IN NEW LIFT TRUCK---------------------------------------------------------------------------------------------- 1-6 RUNNING IN NEW LIFT TRUCK---------------------------------------------------------------------------------------- 1-6 MAINTENANCE FOR NEW LIFT TRUCK ---------------------------------------------------------------------------- 1-6 WARRANTY AND SERVICE --------------------------------------------------------------------------------------------------- 1-6 PERIODICAL EXCHANGE PARTS ------------------------------------------------------------------------------------- 1-6 USE OF GENUINE KOMATSU PARTS AND OILS ---------------------------------------------------------------- 1-6 NECESSARY INFORMATION OF LIFT TRUCK -------------------------------------------------------------------------- 1-7 MEMORANDUM (TO BE FILLED BY KOMATSU DISTRIBUTOR) -------------------------------------------- 1-7 MODEL AND SERIAL NUMBER PLATE LOCATION-------------------------------------------------------------- 1-7 SAFETY------------------------------------------------------------------------------------------------------------------------------------ 2-1 SAFETY LABELS------------------------------------------------------------------------------------------------------------------ 2-2 SAFETY LABEL LOCATION CHART ---------------------------------------------------------------------------------- 2-2 SAFETY LABELS------------------------------------------------------------------------------------------------------------ 2-4 FIRE PREVENTION -------------------------------------------------------------------------------------------------------------- 2-9 BATTERY FIRE PREVENTION------------------------------------------------------------------------------------------ 2-9 FIRE PREVENTION DURING CHARGING--------------------------------------------------------------------------2-10 FIRE PREVENTION CAUSED BY OIL AND GREASE -----------------------------------------------------------2-13 FIRE PREVENTION CAUSED BY OIL LEAKAGE-----------------------------------------------------------------2-13 FIRE PREVENTION CAUSED BY DEPOSITED OR ADHERED FLAMMABLE SUBSTANCES ------2-13 FIRE PREVENTION FROM ELECTRICAL WIRING --------------------------------------------------------------2-13 FIRE PREVENTION COMING FROM PIPING ---------------------------------------------------------------------2-14 CLEAN-------------------------------------------------------------------------------------------------------------------------2-14 ACTION IF FIRE OCCURS ----------------------------------------------------------------------------------------------2-14 BASIC PRECAUTIONS ---------------------------------------------------------------------------------------------------------2-15 FOLLOW RULES -----------------------------------------------------------------------------------------------------------2-15 NEVER OPERATE THE BROKEN-DOWN LIFT TRUCK --------------------------------------------------------2-16 WEAR ADEQUATE CLOTHES AND SAFETY EQUIPMENT FOR OPERATION -------------------------2-16 FIRE EXTINGUISHER AND FIRST AID KIT ------------------------------------------------------------------------2-16 CAUTIONS FOR SAFETY-RELATED EQUIPMENT--------------------------------------------------------------2-17 PRACTICE SUFFICIENTLY BEFORE OPERATION -------------------------------------------------------------2-17 JUMPING ON AND OFF FROM THE LIFT TRUCK IS STRICTLY PROHIBITED-------------------------2-17 KEEP THE OPERATOR'S COMPARTMENT AND PLATFORM CLEAN AND TIDY ---------------------2-17 CAUTION WHEN WASHING LIFT TRUCK--------------------------------------------------------------------------2-18 TO AVOID BURN INJURY -----------------------------------------------------------------------------------------------2-18 FIRE PREVENTION -------------------------------------------------------------------------------------------------------2-19 IF A FIRE BREAKS OUT -------------------------------------------------------------------------------------------------2-20 DO NOT MODIFY THE LIFT TRUCK ---------------------------------------------------------------------------------2-20 DO NOT REMOVE THE OVERHEAD GUARD AND LOAD BACKREST------------------------------------2-20 SECURE SAFETY AT THE WORKING AREA ---------------------------------------------------------------------2-21 PRECAUTIONS RELATED TO SPECIAL ENVIRONMENT-----------------------------------------------------2-21 ASBESTOS CAUTION ----------------------------------------------------------------------------------------------------2-21 WINDOW WASHER CAUTION -----------------------------------------------------------------------------------------2-21 START-UP INSPECTION ------------------------------------------------------------------------------------------------------2-22 TRAVELING -----------------------------------------------------------------------------------------------------------------------2-23 PREPARATION BEFORE TRAVELING THE LIFT TRUCK -----------------------------------------------------2-23 WHILE TRAVELING THE LIFT TRUCK ------------------------------------------------------------------------------2-25

1-9

Table of contents

INTRODUCTION

STOPPING AND PARKING--------------------------------------------------------------------------------------------- 2-31 TOWING --------------------------------------------------------------------------------------------------------------------- 2-32 LOAD HANDLING OPERATION--------------------------------------------------------------------------------------------- 2-33 PRECAUTIONS FOR INSPECTION AND MAINTENANCE ---------------------------------------------------------- 2-38 ALWAYS PERFORM THE CHECKS BEFORE STARTING ---------------------------------------------------- 2-38 PUT UP A WARNING SIGN DURING INSPECTION AND MAINTENANCE------------------------------- 2-38 KEEP THE WORKING AREA CLEAN AND TIDY----------------------------------------------------------------- 2-38 PRECAUTIONS BEFORE INSPECTION AND MAINTENANCE ---------------------------------------------- 2-39 KEEP UNAUTHORIZED PEOPLE OFF ----------------------------------------------------------------------------- 2-40 USE OF RIGHT TOOLS AND EQUIPMENT------------------------------------------------------------------------ 2-40 CAUTIONS WHEN WORKING UNDER WORK EQUIPMENT ------------------------------------------------ 2-40 AVOID GETTING CAUGHT UP BY THE MAST OR FALLING OFF ----------------------------------------- 2-41 BE CAREFUL OF HIGH PRESSURE OIL--------------------------------------------------------------------------- 2-41 BEWARE OF ROTATING COOLING FAN -------------------------------------------------------------------------- 2-42 PRECAUTIONS WHEN INSTALLING RADIO CONTROL SYSTEM----------------------------------------- 2-42 CAUTIONS FOR USING COMPRESSED AIR FOR CLEANING --------------------------------------------- 2-42 CAUTIONS WHEN REPLACING THE SEAT----------------------------------------------------------------------- 2-42 REMOVE BATTERY PLUG --------------------------------------------------------------------------------------------- 2-43 CAUTION WHEN HANDLING BATTERY --------------------------------------------------------------------------- 2-43 CAUTION WHEN HANDLING TIRES -------------------------------------------------------------------------------- 2-45 CAUTION IN WASTE DISPOSAL ------------------------------------------------------------------------------------- 2-46 CAUTION AFTER INSPECTION AND REPAIR ------------------------------------------------------------------- 2-46 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ------------------------------------------------- 2-46 HOISTING AND TRANSPORTING THE LIFT TRUCK ---------------------------------------------------------------- 2-47 CAUTION WHEN HOISTING THE LIFT TRUCK ------------------------------------------------------------------ 2-47 CAUTIONS FOR LOADING AND UNLOADING THE LIFT TRUCK ------------------------------------------ 2-47 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING) -------------------------------------------------------------------------- 2-48 LONGITUDINAL STABILITY-------------------------------------------------------------------------------------------- 2-48 CENTER OF GRAVITY OF A LOAD---------------------------------------------------------------------------------- 2-48 COMBINED CENTER OF GRAVITY AND STABILITY ON THE LOADED LIFT TRUCK --------------- 2-49 ALLOWABLE LOAD------------------------------------------------------------------------------------------------------- 2-49 SERIAL NO. PLATE AND LOAD TABLE ---------------------------------------------------------------------------- 2-50 INTRODUCTION OF OPTIONAL SAFETY AUXILIARY DEVICE--------------------------------------------- 2-52 OPERATION ------------------------------------------------------------------------------------------------------------------------------ 3-1 GENERAL VIEW ------------------------------------------------------------------------------------------------------------------- 3-2 GENERAL VIEW OF LIFT TRUCK-------------------------------------------------------------------------------------- 3-2 INSTRUMENTS AND CONTROLS ------------------------------------------------------------------------------------- 3-3 EXPLANATION OF COMPONENTS ----------------------------------------------------------------------------------------- 3-4 EXPLANATION OF OPERATING DEVICES ------------------------------------------------------------------------- 3-4 HOW TO READ MONITOR PANEL------------------------------------------------------------------------------------------- 3-9 GENERAL VIEW OF MONITOR PANEL ------------------------------------------------------------------------------ 3-9 HOUR METER (SMR) INTEGRATION STATE -------------------------------------------------------------------- 3-10 PARKING BRAKE INDICATION --------------------------------------------------------------------------------------- 3-10 TRAVEL INTERLOCK/LOAD HANDLING INTERLOCK INDICATION--------------------------------------- 3-10 SEATBELT CAUTION LAMP ------------------------------------------------------------------------------------------- 3-11 CLOCK/HOUR METER (SMR)/TRAVEL DISTANCE (ODOMETER)/CAUTION SYMBOL------------- 3-12 TRAVEL POWER MODE ------------------------------------------------------------------------------------------------ 3-16 LOAD HANDLING POWER MODE ----------------------------------------------------------------------------------- 3-16 CURRENT TRAVEL SPEED-------------------------------------------------------------------------------------------- 3-17 BATTERY DISCHARGE INDICATOR (BDI) ------------------------------------------------------------------------ 3-17 AVERAGE POWER CONSUMPTION/INSTANTANEOUS POWER CONSUMPTION (ECO GAUGE) ---------------------------------------------------------------------------------------------------------------------------------- 3-18 DIRECTIONAL LEVER POSITION/ACTION LEVEL DISPLAY ------------------------------------------------ 3-18 OPERATION OF MONITOR PANEL --------------------------------------------------------------------------------------- 3-20 OPERATION MODE ------------------------------------------------------------------------------------------------------ 3-20 CLOCK/HOUR METER (SMR)/TRAVEL DISTANCE (ODOMETER) SELECTION ---------------------- 3-22 USER MENU---------------------------------------------------------------------------------------------------------------- 3-22

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INTRODUCTION

Table of contents

Working Record -------------------------------------------------------------------------------------------------------------3-30 Maintenance -----------------------------------------------------------------------------------------------------------------3-35 Monitor Setting --------------------------------------------------------------------------------------------------------------3-36 CHARGING MODE---------------------------------------------------------------------------------------------------------3-41 ID KEY FUNCTION (ONLY LIFT TRUCKS EQUIPPED WITH ID KEY)--------------------------------------3-42 OPERATION -----------------------------------------------------------------------------------------------------------------------3-46 START-UP INSPECTION ------------------------------------------------------------------------------------------------3-46 MOUNTING/DISMOUNTING AND OPERATING POSTURE ADJUSTMENT ------------------------------3-46 TRAVEL LIMIT SPEED AT HIGH LIFT FUNCTION ---------------------------------------------------------------3-51 SEAT HEATER--------------------------------------------------------------------------------------------------------------3-54 STARTING AND TRAVEL------------------------------------------------------------------------------------------------3-55 STARTING AND STOPPING ON SLOPE----------------------------------------------------------------------------3-58 INCHING TRAVEL ---------------------------------------------------------------------------------------------------------3-59 PLUGGING (ELECTRIC BRAKE) --------------------------------------------------------------------------------------3-59 TURNING ---------------------------------------------------------------------------------------------------------------------3-60 OPERATION ON SNOWY AND FROZEN ROADS ---------------------------------------------------------------3-60 TEMPORARY STOPPING, PARKING AND STOPPING --------------------------------------------------------3-61 TRAVEL INTERLOCK FUNCTION ------------------------------------------------------------------------------------3-63 LOAD HANDLING OPERATION ---------------------------------------------------------------------------------------3-64 CHECKING AFTER OPERATION -------------------------------------------------------------------------------------3-70 KOMTRAX--------------------------------------------------------------------------------------------------------------------3-71 INSPECTION AND MAINTENANCE ----------------------------------------------------------------------------------------------- 4-1 INSPECTION AND MAINTENANCE ----------------------------------------------------------------------------------------- 4-2 START-UP INSPECTION ------------------------------------------------------------------------------------------------------- 4-2 CHECKING ABNORMALITIES DETECTED ON THE PREVIOUS DAY -------------------------------------- 4-4 WALK AROUND A FORKLIFT ------------------------------------------------------------------------------------------- 4-4 CHECKS CONDUCTED BY OPENING COVER AND HOOD --------------------------------------------------- 4-7 CHECKING FROM THE OPERATOR'S SEAT ---------------------------------------------------------------------4-13 CHECKING BY SETTING THE STARTING SWITCH TO [ | ] (ON) POSITION ----------------------------4-15 CHECKING WHILE TRAVELING SLOWLY -------------------------------------------------------------------------4-17 CHECKING BY OPERATING THE WORK EQUIPMENT CONTROL LEVER -----------------------------4-18 CHECKING OF SAFETY FUNCTION ---------------------------------------------------------------------------------4-20 CHECKING OF SAFETY AUXILIARY FUNCTION ----------------------------------------------------------------4-23 CHECKING OF LIFT TRUCK WITH FRONT GLASS SPECIFICATION (ONLY LIFT TRUCK WITH FRONT GLASS SPECIFICATION)------------------------------------------------4-25 CHECKING AND REPORTING AFTER OPERATION------------------------------------------------------------------4-26 PERIODICAL INSPECTION ---------------------------------------------------------------------------------------------------4-27 INSPECTION FOR EVERY 50 HOURS (1 WEEK) ----------------------------------------------------------------4-27 INSPECTION FOR EVERY 100 HOURS (2 WEEKS) ------------------------------------------------------------4-28 SIMPLE MAINTENANCE-------------------------------------------------------------------------------------------------------4-29 GREASES --------------------------------------------------------------------------------------------------------------------4-29 REPLACING TIRES--------------------------------------------------------------------------------------------------------4-33 ADJUSTING PARKING BRAKE LEVER OPERATING EFFORT ----------------------------------------------4-35 REPLACING FUSE --------------------------------------------------------------------------------------------------------4-36 STATIONARY CHARGER------------------------------------------------------------------------------------------------4-40 REPLACING BULBS-------------------------------------------------------------------------------------------------------4-41 HANDLING OF BATTERY -----------------------------------------------------------------------------------------------------4-42 CHARGING ------------------------------------------------------------------------------------------------------------------------4-46 CHARGING WITH STATIONARY CHARGER ----------------------------------------------------------------------4-48 BATTERY REPLACEMENT ---------------------------------------------------------------------------------------------------4-52 RUNNING IN COLD WEATHER----------------------------------------------------------------------------------------------4-55 LONG-TERM STORAGE -------------------------------------------------------------------------------------------------------4-55 BEFORE STORAGE-------------------------------------------------------------------------------------------------------4-55 DURING STORAGE -------------------------------------------------------------------------------------------------------4-55 AFTER STORAGE ---------------------------------------------------------------------------------------------------------4-55 OPERATING LIFT TRUCKS IN SPECIAL ENVIRONMENT OR IN FORCIBLE WAY--------------------------4-56 ACTION TO TAKE IF THE FORK FAILS TO LOWER ------------------------------------------------------------------4-57 HOW TO TOW THE LIFT TRUCK OR BE TOWED ---------------------------------------------------------------------4-58

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Table of contents

INTRODUCTION

ELECTRONIC CONTROL SYSTEM---------------------------------------------------------------------------------------- 4-60 TELEPHONE NUMBER FOR THE POINT OF CONTACT IF AN ERROR OCCURS ------------------------- 4-60 ACTION LEVEL DISPLAY----------------------------------------------------------------------------------------------------- 4-61 WASHING LIFT TRUCK ------------------------------------------------------------------------------------------------------- 4-62 HOISTING LIFT TRUCK ------------------------------------------------------------------------------------------------------- 4-64 LOADING AND UNLOADING OF LIFT TRUCK ------------------------------------------------------------------------- 4-65 INSPECTION AND MAINTENANCE SCHEDULE CHART ----------------------------------------------------------- 4-67 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ------------------------------------------------------- 4-73 CONSUMABLE PARTS -------------------------------------------------------------------------------------------------------- 4-74 SERVICE DATA------------------------------------------------------------------------------------------------------------------ 4-75 TECHNICAL DATA ---------------------------------------------------------------------------------------------------------------------- 5-1 INDEX--------------------------------------------------------------------------------------------------------------------------------------- 6-1

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SAFETY

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 strictly follow these precautions. Failing to heed this warning may result in serious personal injury or death.

2-1

SAFETY LABELS

SAFETY

SAFETY

2

SAFETY LABELS 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 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.

SAFETY LABEL LOCATION CHART

2-2

2

SAFETY

SAFETY LABELS

No.

Safety label name

Safety label location

1

Caution to avoid getting caught

Rear side of tilt stay and head stay

2

Prohibition of standing under forks and riding on forks/pallet

Outside of right and left outer masts

3

Caution for disconnecting battery plug

Right side of step

4

Caution to avoid getting caught

Right and left sides of frame (under the cover)

5

Fix battery hood

Top surface of battery hood (right and left sides of operator's seat)

6

Caution when closing the battery hood

Top surface of battery hood (right side of operator's seat)

7

Caution when washing lift truck

Top surface of the battery hood (rear side of operator's seat) and right and left sides of frame (under the cover)

8

Caution when hoisting the lift truck

Left rear inside of overhead guard

9

Take a right posture on the seat while operating lift truck.

Right rear inside of overhead guard

10

Avoiding danger if lift truck tips over during operations

Right front inside of overhead guard

11

Caution for safety operation

Rear left inside of head guard

12

Caution for blasting site (lift truck with KOMTRAX)

Left inside of overhead guard

13

Do not step on the counterweight cover

Top surface of counterweight cover

14

Battery

Rear of the battery case

15

Prohibit 2 operators on the lift truck

Rear left inside bottom of the head guard

16

Caution when handling battery

Inside surface of battery hood

2-3

SAFETY LABELS

SAFETY LABELS (1) Caution to avoid getting hand caught (3EB-96-25121) ･ Do not place your hands.

(2) Prohibited to enter the area under the forks, prohibited to ride on the forks/pallet (3EB-96-25131) ･ Upper line ---- Never enter the area under the forks. ･ Lower line ---- Never allow any person to ride on the forks and lifting/lowering himself/herself.

(3) Caution for disconnecting battery plug (3BB-96-61440)

2-4

SAFETY

2

SAFETY

SAFETY LABELS

(4) Caution to avoid getting caught (37B-1QL-5030) ･ Be careful of cooling fan rotating.

(5) Fix battery hood (3BA-96-36230) ･ When operating the lift truck, always fix the battery hood.

(6) Caution when closing the battery hood (3BB-96-61430) ･ Be careful not to get your hand caught in the hood.

(7) Caution when washing lift truck (37B-1QC-5030) ･ When washing the lift truck, see "INSPECTION AND MAINTENANCE WASHING LIFT TRUCK (4-62 page)".

2-5

SAFETY

SAFETY LABELS

(8) Caution when hoisting the lift truck (3BA-96-72640) ･ Never lift the truck by the overhead guard.

(9) Take a right posture on the seat while operating lift truck. (3EB-96-59231) ･ If you operate the forklift truck in such a posture like half rising or standing up or leaning forward/backward or sideways, the power will be cut off in approximately 3 seconds and the travel interlock and lift interlock operate.

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 resulting in serious personal injury or death such as crash or falling off.

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

BEFORE OPERATION: 1. Always use your seat belt when operating.

2. Read and understand the Operation and Maintenance Manual.

2-6

IF THE LIFT TRUCK SEEMS TO TIP OVER ANY MOMENT DURING OPERATION: 3. Do not jump off the lift truck.

4. Lean yourself in the opposite direction to the tipping of the lift truck.

5. Grip the steering wheel tightly.

6. Brace yourself with both feet to support your body.

SAFETY

SAFETY LABELS

(11) Caution for safety operation (3EB-96-54120) ･ Be sure to read the Operation and Maintenance Manual thoroughly before operating, servicing, disassembling, assembling or transporting.

(12) Caution for blast site (only for the lift truck equipped with KOMTRAX) (09845-00480) The radio transmitter in operation can cause an accidental explosion at a blasting site.Keep the lift truck at a safe distance from the blasting side and the detonator.

(13) Do not step on the counterweight cover (3BB-96-61420)

(14) Battery (09664-70001)

(15)Prohibit 2 operators on the lift truck (3EB-96-54110) ･ Never allow any other person to ride with you on the lift truck for whatever reasons. ･ Do not use anyone for a counterbalance-weight.

2-7

SAFETY LABELS

(16) Caution when handling battery (3BB-96-36840) ･ For handling battery, see "SAFETY FIRE PREVENTION (2-9 page)", "SAFETY FIRE PREVENTION (2-19 page)", "SAFETY CAUTION WHEN HANDLING BATTERY (2-43 page)", "INSPECTION AND MAINTENANCE HANDLING OF BATTERY (4-42 page)".

2-8

SAFETY

SAFETY

FIRE PREVENTION

FIRE PREVENTION BATTERY FIRE PREVENTION Caution for handling battery

2 2

･ Handling error of the battery may cause explosions, fire, and serious injuries.

Handle batteries after fully understanding how to handle and their hazards. ･ Batteries generate flammable hydrogen gas and may explode in contact with open flame.

Leave the battery hood open while charging. ･ Never smoke cigarette or use open flame near the battery. ･ Sparks may ignite and explode the gas. Do not place tools, parts or other metal objects on the battery. ･ To clean the top surface of battery, wipe with wet cloth before recharging. Using dry cloth for wiping, dusting or covering battery with vinyl sheeting generates statistics that may cause explosion. ･ Depending on the weather, environmental, clothing material and other conditions, human bodies may deposit and spark statistics. Therefore, before touching lift truck in charging or after charging, discharge statistic deposit in the human bodies by grounding. ･ Charge batteries always in a well-ventilated place with the battery hood open. ･ Flammable substances or water that is deposited on or that has adhered to the motor or battery may cause a fire. Remove the deposits and attached material from the above locations. ･ When repairing the electrical system, disconnect the battery plug to stop power supply.

ACTION FOR ABNORMALITIES

2

Do not drain battery electrolyte, disassemble or repair batteries or battery plugs, which may cause explosion and/ or electric shock.

If the following abnormalities are detected, call your Komatsu distributor for service: ･ Battery plug and charging plug mating become loosened or play is generated. (Plug becomes hot abnormally) ･ Battery electrolyte temperature is high. ･ Battery electrolyte decreases sharply. ･ Battery emits unusual smell. ･ Battery electrolyte is turbid. ･ Looseness and play of the battery terminals ･ Leakage from or corrosion on the top surface of the battery ･ Corrosion in periphery of battery ･ Damage to battery cap (vent plug) ･ Charging requires too long time. (Charging is not completed although the battery was not used till late hours on the preceding day.)

2-9

FIRE PREVENTION

FIRE PREVENTION DURING CHARGING CAUTIONS BEFORE CHARGING ･ Change the battery in a well-ventilated place sheltered from rainfall. Do not charge the battery near open flame or hazardous substances, in a high humidity place, or in a place splashed with water, which may cause a fire. ･ Before starting charging, turn the starting switch to "Q" (OFF) position first. ･ Open and secure the battery hood to prevent accumulation of hydrogen gas by hooking the fixing bar on the back side of the hood to the hole on the right side of the battery. ･ Be careful not to allow electrolyte to drop below the minimum level. Otherwise, battery may become overheated to cause fire. ･ Wipe the top surface of battery before charging to prevent statistic accidents that can occur during cleaning. ･ Check of plug, cable and receptacle (monthly check item) Check the charging plug, battery plug (1), and cables for damage. Also check the fitted portions of the power receptacle and charging plug on the lift truck for looseness and play. If any abnormality is detected, do not use the lift truck until the abnormal part is repaired.

In particular, ensure that battery plug (1) is securely fitted, and check the fitting portions of battery plug (1) and the plug on the lift truck for looseness and play. ･ When connecting or disconnecting a plug, be sure to release the lock by holding the plug body. Pulling cable may cause short circuit of the cable and plug, leading to fires. ･ It is prohibited to remove or modify the lock of the charging plug. ･ Use the charging cable specified by Komatsu and attached to the lift truck. Do not use cable from other manufacturers or that are different in shape.

2 - 10

SAFETY

2 2

SAFETY

PRECAUTIONS FOR CHARGING OPERATION

FIRE PREVENTION

2

･ Always charge the battery in a well-ventilated place. Open and secure battery hood (1) by hooking fixing bar (2) on the back side of the hood to the hole on the right side of the battery.

･ Connection of charging cable Stationary charger: Securely insert charging plug (3) of the charging cable and battery plug (4).

Use the charging cable specified by Komatsu and attached to the lift truck. Do not use cable from other manufacturers or that are different in shape.

(A): Stationary charger

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FIRE PREVENTION

CAUTIONS DURING CHARGING

SAFETY

2

･ While charging and immediately after the battery is charged, surrounding area may be filled with flammable hydrogen gas.

Never smoke cigarette or use open flame near the battery. ･ Sparks and/or statistics can ignite the gas, as well. Do not handle tools and other metals carelessly in the surrounding area of the lift truck. Before touching the lift truck or charger, discharge static electricity from your body by grounding. ･ To interrupt charging, hold down "STOP" button of the charger, and then disconnect the charging plug.

Disconnecting the plug without pressing the STOP button may generate sparks, potentially leading to burns or fire.

Be sure to release the lock before connecting/disconnecting the plug. The plug may be damaged if you try to forcibly connect/disconnect it without releasing the lock. ･ Charge battery when the ambient temperature is 0 °C to 40 °C. ･ The battery and charger are so combined that they can charge the battery properly. To avoid fire, do not charge batteries having capacity larger than the rated capacity of charger or batteries of different types. ･ Do not disconnect the battery plug during charging.

CHECK AND MAINTENANCE

2

The following are to be inspected monthly. They must all be checked. ･ Fitting condition and damage of the charging plug and the battery plug. ･ Fitting condition and damage of the battery plug and the plug on the lift truck. ･ Do not place the charging plug directly on the ground, or store it in a location where it may be exposed to dripping water or be damaged. ･ Komatsu distributor will adjust the transformer tap of the charger. The customers should not change it, since doing so can overheat the charger and cause a fire. ･ Work on the power supply equipment should be made under the instructions of chief electric engineer or by an electric contractor designated by a power company. ･ Connect the ground cable to the electrical outlet on the plant side to prevent electrical shock accident. ･ Do not use supply voltage and power receptacles other than those specified. ･ Use the circuit breaker with ground fault circuit interrupter. ･ Variation of supply voltage must be between 190 V and 219 V (50 Hz/60 Hz). ･ Do not disassemble or modify the charger. ･ The charger is designed and manufactured according to the service life of the lift truck. When discarding a lift truck, discard its charger, as well. Do not reuse the charger to prevent an accident.

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SAFETY

FIRE PREVENTION CAUSED BY OIL AND GREASE

FIRE PREVENTION

2

Oil, window washer fluid, etc. are flammable, so keep them away from open flame.

Always observe the following. ･ Do not smoke or allow any open flame near oil or window washer fluid or clothes soaked with them. ･ Do not leave the area while refilling oil. ･ Tighten caps securely. ･ Do not spill oil and greases on the overheated surface or electrical system components. ･ Store oil and grease in a designated well-ventilated place.

Keep unauthorized people off the storage. ･ After supplying oil or grease, wipe off the spilled oil or grease. ･ Put clothes soaked in oil and other flammable objects in a secure container and store them in a safe place. ･ Also, be cautious and take measures for fires that may be ignited with a spark or flame when handling equipment and devices for inspection and/or maintenance.

FIRE PREVENTION CAUSED BY OIL LEAKAGE

2

Oil leakage may cause the fire. Contact your Komatsu distributor when the oil leakage is found from following place. ･ Hydraulic tank ･ Hydraulic piping ･ Pump ･ Control valve ･ Cylinder

FIRE PREVENTION CAUSED BY DEPOSITED OR ADHERED FLAMMABLE 2 SUBSTANCES ･ If flammables are deposited or attached to around the motor or in the batteries, they may cause fire. Remove the deposits and attached material from the above locations.

FIRE PREVENTION FROM ELECTRICAL WIRING

2

Short-circuiting of the electrical wiring may cause a fire. ･ Keep all electric wiring connections clean and securely tightened.

2 - 13

FIRE PREVENTION

SAFETY

･ Check daily for looseness, interference and damage of the wiring. Retighten the loose connector and wiring clamp.

Damaged wiring must be repaired or replaced by Komatsu distributor.

FIRE PREVENTION COMING FROM PIPING

2

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

CLEAN

2

After the operation, use an air blower or similar device to clean off any dirt or dust that has entered into the battery hood or that has deposited on the traveling motor.

(In particular, any dirt or dust that has accumulated in the following locations must be removed. In addition, other locations will also need to be cleaned as necessary.) ･ Periphery of the battery

･ Periphery of the travel motor

ACTION IF FIRE OCCURS ･ If a fire breaks out, stop the lift truck and remove the battery plug to cut off the electrical circuit. ･ Do not jump off the lift truck in a rush. Support yourself securely with handrails and steps to evacuate.

2 - 14

2

SAFETY

BASIC PRECAUTIONS

BASIC PRECAUTIONS FOLLOW RULES

2

･ Only the trained and qualified persons are allowed to operate this lift truck. ･ Fully understand and follow this operation and maintenance manual.

･ Do not operate the lift truck when you are ill conditioned, taking medicine that causes drowsiness, under the influence of alcohol, or mentally unstable. ･ Plan safety work beforehand.

Before operation, make up an operating plan that fits the workplace conditions, type and capacity of the lift truck, and the load conditions.

In confined areas or when loading/unloading large items, po sition a signal person and carry out operations in accordance with their instructions.

2 - 15

SAFETY

BASIC PRECAUTIONS

2

NEVER OPERATE THE BROKEN-DOWN LIFT TRUCK

Never use Danger

･ If any abnormality is detected during the start-up inspection or during the operation (noise, vibration, odor, maladjusted gauge, smoke, oil leak, or erroneous indication of warning device or monitor), report the administrator immediately and take adequate corrective actions. ･ Do not operate the lift truck until the abnormality is corrected. ･ Remove the key from the faulty lift truck and put up signs in the operator's compartment to prevent its use. ･ If the lift truck has suffered a failure and the lift truck must be parked without lowering the forks, put markers on the tips of the forks and take steps to prevent pedestrians or other vehicles from hitting the forks. ･ Select a parking place where people or vehicles do not pass.

Take measures to prevent anyone to go under the forks.(Space under lifted forks is dangerous zone.)

WEAR ADEQUATE CLOTHES AND SAFETY EQUIPMENT FOR OPERATION2 ･ Avoid loose clothing and accessories. It is dangerous when they catch on control levers and projections. ･ Long, loose hair can be caught in a rotating part. Long hair must be tied back. ･ Always wear a hard hat and safety shoes. Wear protective eyeglasses, mask, gloves, ear plugs, and personal fall-arrest equipment as appropriate for the work function. ･ Check that the safety equipment works properly before use.

FIRE EXTINGUISHER AND FIRST AID KIT ･ In preparation for a fire or personal injury or death, check the locations of fire extinguisher and first aid kit, and be familiar with the usage.

2 - 16

2

SAFETY

CAUTIONS FOR SAFETY-RELATED EQUIPMENT

BASIC PRECAUTIONS

2

･ Confirm that all protective guards, covers, and mirrors are properly mounted. Repair them immediately when broken. ･ Be sure that you fully understand the usage of safety-related equipment. ･ Never remove the safety-related equipment. Keep them fully functional at any time.

PRACTICE SUFFICIENTLY BEFORE OPERATION

2

･ Take sufficient time for practice until you become familiar with the operation of each component before starting the actual operation. ･ Even after you become familiar with it, operate with caution and avoid harsh operation. Or it can cause a serious personal injury or death 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.

JUMPING ON AND OFF FROM THE LIFT TRUCK IS STRICTLY PROHIBITED2 ･ Never jump on or off the lift truck. It is extremely dangerous. ･ Even if the lift truck accidentally starts to move without operator onboard, never attempt to jump on the lift truck to stop. ･ Always mount and dismount the lift truck from the left side. ･ While mounting and dismounting the lift truck, always support yourself securely with your hands and feet at more than 3 locations. Put your left foot on the step, grab the assist grip (handrail) with your left hand, and grab the backrest or assist grip of the seat with your right hand. ･ Do not hold on the control levers or steering wheel when mounting or dismounting the lift truck.

KEEP THE OPERATOR'S COMPARTMENT AND PLATFORM CLEAN AND TIDY2 ･ Always keep the operator's compartment and platform (assist grip, step, floor) clean and tidy. Oil, mud or dust attached, or spare parts or tools left lying around in the operator's compartment may cause the operator's hand or foot slips or the clothes get caught, which will lead a falling accident or erroneous operation.

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BASIC PRECAUTIONS

CAUTION WHEN WASHING LIFT TRUCK

SAFETY

2

･ Entering of water into the electrical parts (controllers, sensors, connectors) may cause a malfunction, which is dangerous. Do not wash the electrical parts or use a high-pressure washer (steam cleaner) on them.

For washing the lift trucks, see "INSPECTION AND MAINTENANCE WASHING LIFT TRUCK (4-62 page)".

TO AVOID BURN INJURY HIGH TEMPERATURE PARTS AND OIL ･ To prevent burns with the high temperature parts or by the spurt of oil, carry out inspection and maintenance work after these parts cool down and can be touched safely with bare hands.

2 - 18

2

SAFETY

FIRE PREVENTION

BASIC PRECAUTIONS

2

FIRE PREVENTION CAUSED BY HYDROGEN GAS EMITTED FROM BATTERIES ･ Batteries generate flammable hydrogen gas. ･ Never smoke cigarette or use open flame near the battery. ･ Sparks may ignite and explode the gas. Do not place tools, parts or other metal objects on the battery. ･ Charge batteries always in a well-ventilated place with the battery hood open. ･ Flammable substances or water that is deposited on or that has adhered to the motor or battery may cause a fire. Remove the deposits and attached material from the above locations.

FIRE PREVENTION CAUSED BY OIL AND GREASE Oil, window washer fluid, etc. are flammable, so keep them away from open flame.

Always observe the following. ･ Do not smoke or allow any open flame near oil or window washer fluid or clothes soaked with them. ･ Do not leave the area while refilling oil. ･ Tighten caps securely. ･ Do not spill oil and greases on the overheated surface or electrical system components. ･ Store oil and grease in a designated well-ventilated place.

Keep unauthorized people off the storage. ･ After supplying oil or grease, wipe off the spilled oil or grease. ･ Put clothes soaked in oil and other flammable objects in a secure container and store them in a safe place. ･ Also, be cautious and take measures for fires that may be ignited with a spark or flame when handling equipment and devices for inspection and/or maintenance.

FIRE PREVENTION CAUSED BY DEPOSITED OR ADHERED FLAMMABLE SUBSTANCES ･ If flammables are deposited or attached to around the motor or in the batteries, they may cause fire. Remove the deposits and attached material from the above locations.

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SAFETY

BASIC PRECAUTIONS

FIRE PREVENTION FROM ELECTRICAL WIRING Short-circuiting of the electrical wiring may cause a fire. ･ Clean all the electrical wiring connections, and fix them firmly. ･ Check daily for looseness, wear and damage of the wiring.

Retighten the loose connector and wiring clamp. Damaged wiring must be repaired or replaced by Komatsu distributor.

FIRE PREVENTION COMING FROM PIPING ･ Make sure that the clamp, guard and cushion of the hose and tube are fixed securely. Loose hose or tube may get damaged by vibration during operation or by rubbing against other parts, and cause the high pressure fluid to spurt out which may lead a fire or serious personal injury or death.

2

IF A FIRE BREAKS OUT ･ If a fire breaks out, stop the lift truck and remove the battery plug to cut off the electrical circuit. ･ Do not jump off the lift truck in a rush. Support yourself securely with handrails and steps to evacuate.

2

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

Modification

DO NOT REMOVE THE OVERHEAD GUARD AND LOAD BACKREST ･ Do not remove the overhead guard or load backrest, which are installed to protect the operator from falling objects. ･ Do not use a lift truck not equipped with overhead guard or load backrest. ･ The overhead guard is built in compliance with the safety standards. However, it is not designed to withstand every possible impact. Always be careful to prevent damage or injury from falling objects.

2 - 20

2

SAFETY

SECURE SAFETY AT THE WORKING AREA

BASIC PRECAUTIONS

2

･ Working on a rough surface can result in bodily injuries such as backache.

Always keep the passages and work areas flat and smooth without bump. ･ Wipe up all spill oil or grease from the ground to prevent tip over or collision due to slipping. ･ When working on platforms, docks, quays, or other places where there is danger of falling, set up blocks to prevent the lift truck from going over the edge. ･ Put warning signs up in dangerous places to warn the operator not to approach. ･ Mark the traffic areas clearly, and establish a clear traffic rule such as temporary stop line, speed limit, no-entry area for other vehicles and pedestrians. ･ Provide adequate lighting for safety operations.

PRECAUTIONS RELATED TO SPECIAL ENVIRONMENT

2

If the forklift truck is used in the special environment as follows, this may lead to serious personal injury or death. So do not use the forklift truck in such environment. ･ Environment which has a risk of explosion caused by explosive gas or dust ･ Environment where toxic gas may harm human body

ASBESTOS CAUTION

2

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

WINDOW WASHER CAUTION

2

･ Use the window washer which contains ethyl alcohol. ･ Never use the window washer containing methanol which is harmful to eyes.

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START-UP INSPECTION

SAFETY

START-UP INSPECTION 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 "INSPECTION AND MAINTENANCE INSPECTION AND MAINTENANCE (4-2 page)". ･ 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.

CAUTIONS FOR OPERATING STARTING SWITCH, STARTING THE LIFT TRUCK AND OPERATING WORK EQUIPMENT ･ When operating the starting switch key, always seat yourself properly on the operator's seat and pull the parking brake lever toward the rear of the lift truck. ･ Before starting the lift truck or operating the work equipment (mast, fork, etc.), check the safety in the surrounding areas and sit in the operator's seat. ･ Before moving the lift truck or operating the work equipment, sound the horn to warn people around.

CAUTION WHEN CHECKING SAFETY FUNCTION ･ When you check the safety function, secure sufficient space around in considering unexpected movement of the vehicle and perform after confirming no people and obstacles. (Apply travel interlock, load handling interlock, seatbelt interlock (forklift truck with seat belt interlock), neutral start, and parking brake warning)

CAUTION IN COLD AREAS ･ Immediately upon starting operation for the day in cold weather, travel and lifting speed may be slow or steering effort may be heavier or steering movement may change suddenly, leading to accident. Operate the lift truck carefully until oil and lift truck components warm up properly. ･ For the method of maintenance, see "OPERATION SIMPLE MAINTENANCE (4-29 page)" and "INSPECTION AND MAINTENANCE RUNNING IN COLD WEATHER (4-55 page)".

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SAFETY

TRAVELING

TRAVELING PREPARATION BEFORE TRAVELING THE LIFT TRUCK

2

FASTEN THE SEAT BELT ･ Always fasten the seat belt properly before operation. ･ Not fastening the seat belt properly may result in serious personal injury or death if the lift truck tips over.

The lift truck with seat belt interlock is provided with a safety auxiliary function ("seat belt interlock") that operates the travel interlock and lift interlock if the seat belt is not correctly fastened. ･ Make sure the seat belt is free from damage and flaw.

TAKE A RIGHT POSTURE ON THE SEAT ･ If you operate the lift truck when you are not seated properly or off the seat, an accident may happen unexpectedly. To forestall such a possible accident, this lift truck is provided with a safety function that operates the travel interlock and lift interlock if the operator is not seated properly.

For travel interlock, see "OPERATION TRAVEL INTERLOCK FUNCTION (3-63 page)". For load handling interlock, see "OPERATIONLOAD HANDLING INTERLOCK (3-67 page)".

TAKE A RIGHT POSTURE WHILE OPERATING ･ Do not stick the hand or foot outside the lift truck body. ･ Always keep your body under the overhead guard.

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TRAVELING

SAFETY

BEFORE MOVING OFF, 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 to 8 cm (6 to 8 in) from the ground and tilt the mast back. ･ Sound the horn areas as may be needed.

15 to 20 cm (6 to 8 in)

OPERATE LIFT TRUCK EQUIPPED WITH SOLID TIRES FOR USE ON PNEUMATIC TIRE RIMS (NONPUNCTURE) ACCORDING TO THE FOLLOWING ･ Solid Tires For Use On Pneumatic Tire Rims (non-puncture) has more remarkable increase of internal heat generation in the traveling than pneumatic type tire (pneumatic filling). Never travel continuously for a long time in the work with load on the tire such as overload, high-speed travel, and repeated operation of steering.

If the degree of heat generation of the tire is high, it easily causes premature wear, rim displacement, etc. by rubber deterioration.

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SAFETY

WHILE TRAVELING THE LIFT TRUCK

TRAVELING

2

NEVER SWITCH OVER FORWARD AND REVERSE AT HIGH SPEED ･ In case of switchover between forward and reverse, perform this after sufficient speed reducing by brake pedaling.

BE ALWAYS CONSCIOUS OF SAFETY WHILE TRAVELING ･ Avoid sudden starting, braking, or making sharp turns. ･ Keep a clear view of the path of travel. ･ When passing oncoming vehicles, reduce speed and keep a safe distance from the other vehicle. ･ In places where there are speed limits, observe the speed limit and maintain a safe distance from other vehicles. ･ When traveling, always pay careful attention to the area around your lift truck, particularly in the direction of travel or when turning. ･ Do not attempt to pass another lift truck or vehicle on a narrow path or on a spot of limited view like a crossing. ･ When passing through a crossing or turning a corner, or when traveling into a narrow path, stop the lift truck once to check the safety. Sound the horn to warn people around if necessary. ･ People around do not always realize even if horn is sounded.

Always pay attention to the movement of people around. ･ Do not allow people to enter the working area. ･ When traveling on a slope or through a crowded spot, always give way to a loaded lift truck.

DO NOT ALLOW ANY PASSENGER ･ Never allow any other person to ride with you on the lift truck for whatever reasons. ･ Do not use anyone for a counterbalance-weight.

NEVER TURN OFF THE STARTING SWITCH WHILE TRAVELING ･ If the starting switch is turned to "Q" (OFF) while traveling, the power steering effort becomes heavier, which is dangerous.

2 - 25

TRAVELING

DO NOT KEEP YOUR FOOT ON THE BRAKE PEDAL WHILE TRAVELING ･ If you travel the lift truck with your foot on the brake pedal, brakes may not work satisfactorily or wear out earlier. If this situation continues, overheat protection function may work to deteriorate the accelerating performance. Keep your foot off the brake pedal during normal traveling.

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

WHEN TRAVELING THE LIFT TRUCK IN REVERSE, CHECK REVERSE DIRECTION VISUALLY ･ When traveling the lift truck in reverse, always look back and make a direct visual check on the rear of the lift truck. The rearview mirror is simply an auxiliary aid for checking the rear.

When traveling in reverse, do not depend on the rearview mirror alone for checking safety. ･ Even if you sound the backup buzzer, the people behind the lift truck do not necessarily hear it. Always visually check directly with your own eyes that there is no one behind the lift truck while traveling.

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

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SAFETY

SAFETY

TRAVELING

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 to 20 cm (6 to 8 in) above the ground with the mast tilted backward.)

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TRAVELING

SAFETY

NEVER JUMP OFF THE LIFT TRUCK WHEN THE LIFT TRUCK SEEMS TIPPING OVER (1) Always fasten 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) Never jump off the lift truck when the lift truck seems tipping over. Or you may be crushed by the lift truck resulting a serious personal injury or death.

(4) Lean yourself in the opposite direction to the direction the lift truck is tipping.

(5) Grip the steering wheel tightly.

(6) Brace yourself with both feet to support your body. ･ Practice this series of actions from time to time to master how to act in emergency situations.

WHEN MAKING TURN, BE CAREFUL OF THE SWINGING TAIL ･ The lift truck has rear steering wheels. Be careful as it behaves differently from passenger vehicle. ･ When turning while traveling forward, the counterbalanceweight will swing far out. Keep an ample clearance from walls to ensure safety. ･ Never making rapid turn because it might be the risk of causing vehicle to tip over.

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 - 28

SAFETY

TRAVELING

DO NOT TRAVEL ON ROUGH OR SLIPPERY ROAD ･ Do not try to travel on bumpy or soft ground. It can lead a serious accident when you lose steering control or the tires stuck in the mud. ･ Avoid traveling on the slippery road covered with water and oil.

You will lose brake or steering control. ･ Do not travel into a flooded place. If water enters above the bottom surface of the frame of lift truck, serious personal injury or death can result.If you touch an electric part or wiring carelessly, you may get an electric shock. Always ask your Komatsu distributor for inspection and repair.

OBSERVE THE WEIGHT LIMIT ･ Do not allow overweight on the floors and roads where weight limit is specified.

DO NOT TRAVEL DIRECTLY OVER OBSTACLES ON THE ROAD ･ Avoid clutter, curbs, rails, ditches, or other obstacles, and do not travel directly over them. Also, the impact applied when traveling over obstacles can result in bodily injuries such as backache.

TRAVELING ON A ROAD SHOULDER IS STRICTLY PROHIBITED ･ There is a danger that soft road shoulders may collapse. Do not approach them. ･ Always maintain a safe distance from the edge of road shoulders and platforms to prevent the lift truck from falling off.

2 - 29

SAFETY

TRAVELING

CAUTION WHEN TRAVELING ON SLOPES ･ Never drive the lift truck of turning, crossing and angle-driving on a slope. There might be the risk of lift truck tipping over. ･ Before starting to travel up a slope, stop the lift truck and adjust the clearance between the ground surface and the bottom of the forks so that the bottom or the tip of the forks, or pallet do not contact the ground when traveling.

･ For safe travel on slopes When loaded: Travel forward uphill and in reverse downhill.

When unloaded: Travel in reverse uphill and forward downhill. ･ On a down slope, travel down slowly by using brake pedal. ･ If you half rise from the seat, the travel interlock activates to cut off the engine power, resulting the truck may slither down on a slope. Take a right posture on the seat while operating. For the travel interlock, see "OPERATION TRAVEL INTERLOCK FUNCTION (3-63 page)".

EXERCISE CARE WHEN TRAVELING INTO A RAILWAY WAGON OR CONTAINER ･ Check that brake and chocks are applied to the wagons, trailers, and containers to stop them. ･ Tell the carrier drivers not to move their vehicles until the load handling operation is completed. ･ Ramps used for approaching the wagon and/or trailers must stand the travels of loaded lift trucks. ･ Engage the ramps securely to wagons and trailers. ･ Do not travel at the edge of the platforms or loading docks, or there is a danger of the lift truck falling down.

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When loaded

When unloaded

SAFETY

TRAVELING

2

STOPPING AND PARKING FOLLOW THE STEPS FOR STOPPING AND PARKING 1. Park the forklift truck on a firm level place.

2. In order to prevent the forklift truck from moving, apply the parking brake by pulling the parking brake lever toward the rear direction of the forklift truck.

3. Set the directional lever to neutral position.

Free

Lock

4. Tilt the mast forward and lower the work equipment to the ground.

5. Turn the starting switch to "Q" (OFF) position.

6. Pull out the starting switch key and get off the forklift truck.

PARK THE LIFT TRUCK IN A SAFE PLACE ･ Park the forklift truck on a firm level place. ･ Do not stop or park near any emergency exit or other safety equipment. Stop or park the lift truck in a place where it will not obstruct pedestrians or other vehicles. ･ Never park the vehicle on a slope. If parking on a slope is unavoidable, chock the tires.

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TRAVELING

TOWING

SAFETY

2

BE CAREFUL WHEN USING THE DRAWBAR PIN ･ The drawbar pin is provided for being towed by the wrecking car when the tires are stuck in a ditch or mud. ･ Do not use it for towing or hoisting. ･ The drawbar pin can be used for an anchor point of this lift truck when being transported by a truck.

DO NOT TOW A DISABLED LIFT TRUCK ･ If there is any problem with the brakes or steering system of your lift truck, do not tow it with another lift truck.

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SAFETY

LOAD HANDLING OPERATION

LOAD HANDLING OPERATION SIT ON THE SEAT CORRECTLY FOR LOAD HANDLING OPERATION ･ To avoid accidents, load handling interlock activates to disable the load handling operation when you are not seated properly or off the seat. For the load handling interlock, see "OPERATIONLOAD HANDLING INTERLOCK (3-67 page)".

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 their instructions.

DO NOT GO UNDER THE LIFTED FORKS ･ There is a danger of serious bodily injury under lifted forks that a person can be crushed under the forks or loads when they come down. Keep everyone away from under the lifted forks.

WORKING ON THE FORKS IS STRICTLY PROHIBITED ･ Do not directly place a load manually on the forks. ･ Do not directly remove a load manually from the forks. ･ Do not step on the forks to handle a load. The load may slip down the forks. ･ Do not hold the load on the forks by hands. Sudden lift truck movement may cause the load to fall on the person below.

2 - 33

LOAD HANDLING OPERATION

BE CAREFUL NOT TO GET CAUGHT IN THE MAST STRUCTURE ･ Never put your hands, feet, or other body parts into the mast structure. There is a danger that you may get caught in moving parts and be seriously injured.

DO NOT CLIMB ON THE MAST OR LOAD BACKREST ･ If you climb on the mast or load backrest, there is a danger of being caught in the moving parts or fall off.

USE A PALLET OR SKID OF AMPLE STRENGTH ･ Always use the pallets and skids of robust construction. Do not use broken or damaged pallets or skids. ･ Before traveling, always check that the load is positioned securely and safely on the pallet.

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SAFETY

SAFETY

LOAD HANDLING OPERATION

HANDLE A LONG OR WIDE LOAD WITH EXTRA CARE ･ Be extremely careful when carrying long or wide loads. Lift the load slowly without hitting anything in the surrounding area. ･ When switching direction, keep the load as low as possible and maintain the balance.

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

OVERLOADING IS STRICTLY PROHIBITED ･ Overloading may cause the rear wheels come off the ground, and the lift truck loses the balance and tips over. Do not load the lift truck over the max. capacity shown in the load table. For the capacity, see "SAFETY ALLOWABLE LOAD (2-49 page)".

For the load table, see "SAFETY SERIAL NO. PLATE AND LOAD TABLE (2-50 page)".

DO NOT TILT THE MAST FORWARD WITH A LOAD ON THE FORKS ･ Do not tilt the mast forward with the load raised. Do not raise the load with the mast tilted forward. Or the load may fall or the lift truck may tip over. ･ Do not travel with the mast tilted forward.

2 - 35

LOAD HANDLING OPERATION

DO NOT HANDLE A LOAD IN AN INSECURE MANNER ･ Make sure that the center of gravity of the load is in line with the center of the lift truck. Do not carry loads off-center. ･ Secure the load in position to prevent collapsing or falling. Do not handle unstable loads. ･ Place the load so that it makes contact the load backrest.

DO NOT LOAD AND UNLOAD ON SLOPES ･ Loading or unloading on the slopes may cause the lift truck to lose its balance and tip over.

DO NOT LOWER THE LOADED FORKS HASTILY ･ Do not operate the forks roughly or make sudden stop. Sudden lowering may cause the collapsing and falling of the load, and the lift truck may go off balance and tip over.

DO NOT HANDLE A LOAD EXCEEDING THE LOAD BACKREST HEIGHT ･ If the load is higher than the load backrest, there is danger that it may fall back on the operator. Do not handle a load exceeding the load backrest height.

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SAFETY

SAFETY

LOAD HANDLING OPERATION

DO NOT PRY LOAD WITH THE TIPS OF THE FORK ･ If you pry load with the tip of the fork, the load may be damaged or hooked load can suddenly come off the tip, and the reaction causes big danger to the lift truck as well as to the hooked load.

DO NOT USE THE FORKS TO PUSH OR PULL A LOAD ･ There is a risk that the load will be damaged or fall.

DO NOT USE THE LIFT TRUCK FOR ANY OTHER PURPOSE ･ Do not use the lift truck for any other purpose than load handling using forks or attachments. ･ Do not open or close the doors or railroad cars or warehouses with the forks. ･ Do not push or pull any other vehicle. ･ Do not lift loads suspended from the fork with ropes. The rope may slip, come off, break, or even cause cracks on the forks.

Also the lift truck may lose its balance and tip over as the load swings.

Caution at strong wind ･ There might be the risk of being wind-fanned and tipping over so be careful of work with sufficient attention.

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PRECAUTIONS FOR INSPECTION AND MAINTENANCE

SAFETY

PRECAUTIONS FOR INSPECTION AND MAINTENANCE ALWAYS PERFORM THE CHECKS BEFORE STARTING

2

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

PUT UP A WARNING SIGN DURING INSPECTION AND MAINTENANCE

2

･ Put up a warning sign on the steering wheel or the work equipment control lever during inspection and maintenance work. Put up the sign around the lift truck, if necessary. ･ Do not let any other person than the inspector or maintenance staff start the lift truck or touch the work equipment control lever during inspection and maintenance. Otherwise serious personal injury or death may result.

When jointly making inspection or maintenance with other personnel, name the leader and follow their instructions.

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

2 - 38

2

SAFETY

PRECAUTIONS FOR INSPECTION AND MAINTENANCE

2

PRECAUTIONS BEFORE INSPECTION AND MAINTENANCE ･ Arrange for a fire extinguisher. Know the location and how to use it. ･ Wear adequate working clothes and protective items (hard hat, safety shoes, goggles and gloves). ･ In order to prevent the forklift truck from moving, apply the parking brake by pulling the parking brake lever toward the rear direction of the forklift truck.

Free

Lock

･ Set the directional lever to neutral position (N).

･ Tilt the mast forward and lower the work equipment to the ground.

･ Turn the starting switch to "Q" (OFF) position to stop the electric power.

･ Chock the front and rear wheels.

2 - 39

PRECAUTIONS FOR INSPECTION AND MAINTENANCE

KEEP UNAUTHORIZED PEOPLE OFF

SAFETY

2

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

USE OF RIGHT TOOLS AND EQUIPMENT

2

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

CAUTIONS WHEN WORKING UNDER WORK EQUIPMENT ･ When performing the inspection and maintenance work while forks are raised, block the forks and mast to prevent falling.

Otherwise, a serious accident may result.

2 - 40

2

SAFETY

PRECAUTIONS FOR INSPECTION AND MAINTENANCE

AVOID GETTING CAUGHT UP BY THE MAST OR FALLING OFF

2

･ Never put your hands, feet, or other body parts into the mast structure. There is a danger that you may get caught in moving parts and be seriously injured.

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

BE CAREFUL OF HIGH PRESSURE OIL

2

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

2 - 41

PRECAUTIONS FOR INSPECTION AND MAINTENANCE

BEWARE OF ROTATING COOLING FAN

SAFETY

2

･ If your hands or a tool touch on a fan in rotation, they may be caught and it is very dangerous.

PRECAUTIONS WHEN INSTALLING RADIO CONTROL SYSTEM

2

When installing the radio control device to the forklift truck, consult your Komatsu distributor for the installing location since it affects the electronic control system depending on its location. ･ Install the antenna to a place as far apart from the control unit as possible. ･ Install the antenna feeder cable at least 20 cm or more apart from the control unit.

There is a danger that the radio transmitter and RFID reader may affect behavior of a pacemaker. It is your responsibility to install the devices and follow the instructions of manufacturer of each device when installing.

CAUTIONS FOR USING COMPRESSED AIR FOR CLEANING

2

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

CAUTIONS WHEN REPLACING THE SEAT Seat is equipped with important safety functions: ･ Seat belt and support to operator's body ･ Travel, lift and seat belt interlock (forklift truck with seat belt interlock) function switches ･ Storage case for instruction manual Always use Genuine Seat for replacement.

2 - 42

2

SAFETY

PRECAUTIONS FOR INSPECTION AND MAINTENANCE

REMOVE BATTERY PLUG

2

･ When repairing the electrical system, disconnect the battery plug to stop power supply. ･ When disconnecting the plug, check that the system operating lamp is OFF.

CAUTION WHEN HANDLING BATTERY

2

Handling error of the battery may cause explosions, fire, and serious injuries. Handle batteries after fully understanding how to handle and their hazards. ･ Batteries generate flammable hydrogen gas and may explode in contact with open flame. Leave the battery hood open while charging. ･ Do not use a dry wipe to clean the battery. A wet wipe will prevent fire or explosion from static electricity. ･ Never smoke cigarette or use fire near the battery. ･ Sparks may ignite and explode the gas. Do not place tools, parts or other metal objects on the battery. ･ Depending on the weather, environmental, clothing material and other conditions, human bodies may deposit and spark statistics. Therefore, before touching lift truck in charging or after charging, discharge statistic deposit in the human bodies by grounding. ･ Batteries for battery-driven trucks store large energy in highvoltage. Beware of an electric shock and a burn. Never allow h u m a n b o d y t o t o u c h a c u r r e n t - c a r r y i n g pa r t d u r i n g maintenance, inspection, removal and installation.

･ Battery electrolyte contains dilute sulphuric acid, which can attack skins and clothes. Always wear protective eyeglasses, rubber gloves and rubber sole shoes when servicing or inspecting the batteries.

2 - 43

PRECAUTIONS FOR INSPECTION AND MAINTENANCE

･ If battery electrolyte gets into your eyes, flush them immediately with fresh tap water for 10 to 15 minutes continually and consult a doctor. ･ If you spill battery electrolyte on yourself, immediately take off clothes and flush the contact portion of the skin with a large quantity of tap water and consult a doctor. ･ If you drink battery electrolyte by accident, either drink a large quantity of water or milk mixed with beaten egg white or salad oil, and then consult a doctor at once. ･ If you spill battery electrolyte around, immediately neutralize battery electrolyte with an acid neutralizing agent (baking soda, calcium hydroxide or sodium carbonate, etc.) and wash it down with large amount of water. The floor and loads are attacked by the electrolyte. ･ Do not drain battery electrolyte or disassemble or repair the battery, since it is dangerous. ･ If the following abnormalities are detected, call your Komatsu distributor: ･ Fitting portion of battery plug and charging plug is loosened or has play. (Plug becomes hot abnormally) ･ Battery electrolyte temperature is high or battery electrolyte decreases sharply. ･ Charging requires too long time. (Charging is not completed although the battery was not used till late hours on the preceding day.)

2 - 44

SAFETY

SAFETY

PRECAUTIONS FOR INSPECTION AND MAINTENANCE

CAUTION WHEN HANDLING TIRES

2

The lift truck tires are very highly pressurized with the air. Do not mishandle, or the tires may burst, be damaged or the rim may break into pieces causing a serious personal injury or death. For your safety, follow the instructions shown below. ･ Do not disassemble/assemble tire, tube or rim, nor inflate removed tires with the air. ･ For safety, when filling a tire with air or replacing it, place your body in front of the tread face of the tire (see the figure at right).

Do not work from the side of the tire.

･ When you remove a tire with divided rim from a lift truck, always loosen hub nuts (1) after depressurizing the tire completely. Never loosen the rim bolts (irregular shape) (2) of the divided rim. For the tire replacement, see "INSPECTION AND MAINTENANCE REPLACING TIRES (4-33 page)".

･ Always use the specified tire of KOMATSU, and observe the specified tire inflation pressure. ･ For the right tire inflation pressure, see "INSPECTION AND MAINTENANCE SERVICE DATA (4-75 page)". ･ When filling up the tires, make sure no one is around and use a clip-on air chuck that can be fixed to the air valve.

Fill up the tire while checking with an air gauge to avoid over inflation. ･ The rim will not "fit" the tire if either the tire or rim is defective, or if it is not properly assembled. To fit, the rim must contact with the tire evenly around the circumference. Always contact your Komatsu distributor.

2 - 45

PRECAUTIONS FOR INSPECTION AND MAINTENANCE

CAUTION IN WASTE DISPOSAL

SAFETY

2

To prevent environment pollution, pay full attention to the way to dispose of waste materials. ･ Always drain waste fluid such as oil and battery electrolyte into containers like cans and tanks.

(Do not drain the battery electrolyte into metallic containers.

Always use plastic containers.) Do not pour on the ground or into rivers, drains, seas or lakes. ･ Comply strictly with appropriate laws and regulations when disposing of harmful objects such as oil, solvent, filters, batteries and refrigerant (CFCs).

CAUTION AFTER INSPECTION AND REPAIR

2

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

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ･ 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, causing serious bodily injuries and damages. Further more, 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 "INSPECTION AND MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS (4-73 page)". ･ 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 due time has not passed 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 distributor.

2 - 46

2

HOISTING AND TRANSPORTING THE LIFT TRUCK

SAFETY

HOISTING AND TRANSPORTING THE LIFT TRUCK 2

CAUTION WHEN HOISTING THE LIFT TRUCK ･ Never lift up by the overhead guard. ･ Before lifting-up, check that the mast is tightened with torque as specified. ･ To hoist the lift truck, hook on the holes on the top of the outer mast for the front. For the rear, use the counterbalance-weight and rear axle. ･ Do not go under the lifted truck. ･ Use undamaged sling and wire having sufficient strength. For hoisting the lift truck, see "INSPECTION AND MAINTENANCE HOISTING LIFT TRUCK (4-64 page)".

2

CAUTIONS FOR LOADING AND UNLOADING THE LIFT TRUCK Loading and unloading a lift truck to and from a trailer always involve a hazard of the lift truck tipping over or falling off by handling error. Always observe the following. ･ Stop the trailer on level, flat road. Always apply parking brake.

Apply blocks to the tires. ･ Use ramps or dock plate of appropriate length, width and strength. Secure it tightly to prevent it from being dislocated or disengaged. ･ Take a right posture on the seat while operating.

If you operate the lift truck in such a posture that your weight is not properly applied to the seat, like standing up or half rising from the seat, travel Interlock activates to cut off the power.

Then the lift truck may slither down even if the accelerator pedal is stepped on during uphill travel. Operate the lift truck assisted by a signal person if necessary so that you do not have to stand up or half rise from the seat to watch. For the travel interlock, see "OPERATION TRAVEL INTERLOCK FUNCTION (3-63 page)". ･ When using the ramps, set them in gradient gentle, align the center of both the trailer and the lift truck and lock 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. For the loading and unloading of lift truck, see "INSPECTION AND MAINTENANCE LOADING AND UNLOADING OF LIFT TRUCK (4-65 page)".

Ramp

Blocks

2 - 47

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

SAFETY

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.

2

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

Load

Load weight Fulcrum

Weight on the rear wheels

2

CENTER OF GRAVITY OF A LOAD

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

Center of gravity

2 - 48

Center of gravity

SAFETY

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

COMBINED CENTER OF GRAVITY AND STABILITY ON THE LOADED LIFT 2 TRUCK COMBINED CENTER OF GRAVITY ･ The center of gravity of the loaded lift truck shifts to a combined center of gravity of both the lift truck and the load. When the load is raised, its center of gravity will raise, hence the combined center of gravity will also raise.

Combined center of gravity at high lifting height

Center of gravity of load

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

COMBINED CENTER OF GRAVITY AND STABILITY The higher the position of the center of gravity, the worse the longitudinal and lateral stabilities become. In addition, swaying or shock encountered during traveling or load handling will have a larger impact on the stability of the lift truck.

Stability of the lift truck also changes depending on the following factors. ･ Size, weight, shape of load (position of center of gravity etc.) ･ Lifting height ･ Tilting angle of mast ･ Inflation pressure of tires ･ Acceleration, deceleration and turning speed when traveling and load handling ･ Road condition and gradient ･ Type of attachments Do not travel with the forks (load) raised. Do not make sharp turns or apply sudden brakes. Do not raise or tilt the forks abruptly. These operations are very dangerous since they can pose a serious accident like tipping over. Accordingly, never do these operations.

ALLOWABLE LOAD ･ Allowable load means the maximum weight of a load that can be loaded at a certain load center. The horizontal distance from the position of the center of gravity of a load on the forks to the upright load backrest of the fork is called a load center. ･ The load table is given in the serial No. plate accessible from the operator's seat. The table shows the relationship between the allowable load and load center. ･ When the load center shifts toward the fork tips, the load weight (mass) has to be decreased in the actual operation to maintain the balance.

Load center:Small Load :Large

Load center:Large Load :Small

2 - 49

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

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

EXAMPLE OF LOAD CENTER AND ALLOWABLE LOAD ･ The areas (1) and (2) in the example provide the following information: When the load center is 500 mm ··· Maximum load capacity: 2,500 kg (*) When the load center is 600 mm··· Allowable load: 2,250 kg When the load center is 1,000mm··· Allowable load: 1,630 kg *1: Even when the load center is smaller than 500 mm, the maximum load capacity is 2,500 kg. ･ The area (3) shows the main specifications of the model.

Max. lifting height: 3 m Attachment: None Front wheel tread: 975 mm Mast rear tilting angle: 11 deg.

Front wheel size, inflation pressure: 23x9-10-16PR, 900 kPa Rear wheel size, inflation pressure: 18x7-8-16PR, 1000 kPa

2 - 50

SAFETY

SAFETY STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIP･ The following symbols indicate the types of attachment if any.

Attachment Side shifter Fork positioner Load stabilizer HINGED FORK Push pull Pusher

Symbol Type F S F M F T H F P P P A

     

Capacity            

Attachment      

Clamp Rotating clamp Rotating fork Ram Hook

Symbol Type C  R S R F L  K 

    

Capacity          

    

At the position marked with * in the symbol field in the table, letters or figures showing detailed model or capacity for the attachment are listed.

Numbers are not necessarily in 6 digits.

LOAD CAPACITY WHEN EQUIPPED WITH ATTACHMENT AND/OR HIGH MAST ･ Please not that the lift truck equipped with attachment and/or high mast has a fewer maximum capacity and actual capacity that the standard lift truck. ･ Follow the load limit as indicated in the load table of the serial No. plate.

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

OTHER INFORMATION ON THE SERIAL NO. PLATE ･ The area (4) shows other basic information of the lift truck.

Model Serial No. Year of manufacture Unladen mass Lift truck weight without battery Battery mass max/min Battery voltage ･ [-] means that no information is required. ･ Logo and the company name are shown on the top and bottom of the serial No. plate.

2 - 51

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

INTRODUCTION OF OPTIONAL SAFETY AUXILIARY DEVICE Various safety auxiliary device are available as options. The devices listed below are only examples. Contact your Komatsu distributor for more information.

Note that the devices and equipment may not be effective depending on the usage and working conditions. Follow the instruction of the safety control personnel for installation. ･ Working lamp: Top and rear ･ Warning for traveling (forward/reverse) or approach: Seatbelt interlock, Chime revolving warning lamp and flash light ･ Handling of high/wide item : High or wide load backrest and finger board (fork carriage) ･ Load indicator/warning: Load sensor ･ Visibility Improvement: Rearview mirror ･ Fire extinguisher etc.

2 - 52

2

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

GENERAL VIEW

OPERATION

OPERATION

3

GENERAL VIEW GENERAL VIEW OF LIFT TRUCK

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

Fork Fork carriage Tilt cylinder Load backrest Lift chain Mast Lift cylinder Rearview mirror Turn signal lamp and clearance lamp (parking lamp) (10) Overhead guard

3-2

3

(11) Rear combination lamp (turn signal lamp, backup lamp, brake lamp, tai lamp) (12) Headlamp (13) Assist grip (14) Operator's seat (15) Battery hood (16) Counterweight (17) Rear wheel (18) Front wheel (19) Charging cable (4 m)

OPERATION

GENERAL VIEW

3

INSTRUMENTS AND CONTROLS

(1) Parking brake lever (2) Directional lever (3) Steering wheel (4) Horn button (5) Brake pedal (6) Combination switch

(7) Monitor panel (8) Accelerator pedal (9) Lift lever (10)Tilt lever (11)Attachment lever (if equipped) (12)Steering tilt lock lever

3-3

OPERATION

EXPLANATION OF COMPONENTS

EXPLANATION OF COMPONENTS The following is explanation of the components necessary for operation.

To perform suitable operations correctly and safely, it is important to fully understand methods of operating the equipment, and the meanings of the displays.

EXPLANATION OF OPERATING DEVICES

3

STARTING SWITCH

CAUTION When turning the starting switch to " l " (ON) position, be sure to set the directional lever to neutral position and release the accelerator pedal.

This switch is used to prepare the operation of lift truck.

OFF: You can insert and pull out the key at this position.

ON : If you turn the switch clockwise by 1 click from "Q" (OFF) position to " | " (ON) position, the lift truck is ready to operate.

COMBINATION SWITCH (HEADLAMP SWITCH/ TURN SIGNAL SWITCH) Headlamp switch This switch is used to turn each lamp ON. Position 1: Both parking lamp (clearance lamp) and headlamp are OFF Position 2: Parking lamp (clearance lamp) is ON Position 3: Parking lamp (clearance lamp) is kept ON and headlamp is ON

3-4

OPERATION

EXPLANATION OF COMPONENTS

Turn signal switch This switch is used to flash the turn signal lamps.

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

REMARK The lever returns automatically to neutral (N) position.

PARKING BRAKE LEVER This lever is used to operate the parking brake. ･ Pulling back the parking brake lever (Lock position) will set the parking brake. ･ To release the parking brake, press and hold button (1) on tip of the lever, and return the lever to Free position.

Free

Lock

REMARK A reminder buzzer sounds when the parking brake is not applied in the following cases. ･ The parking brake lever is returned to Free position while the starting switch is in "○" (OFF) position. ･ The operator leaves seat while the starting switch is in "|" (ON) position and the parking brake lever is in Free position.

HORN BUTTON When the button in the center of the steering wheel is pressed, the horn sounds.

3-5

OPERATION

EXPLANATION OF COMPONENTS

DIRECTIONAL LEVER

CAUTION When turning the starting switch to " | " (ON) position, be sure to set the directional lever and work equipment control lever to neutral position and release the accelerator pedal.

This lever is used to change the travel direction (forward/reverse) of the lift truck.

F: Forward N: Neutral R: Reverse

IMPORTANT ･ Plugging operation enables smooth braking for stopping or reverse travel. For details, see "OPERATION PLUGGING (ELECTRIC BRAKE) (3-59 page)". ･ When stopping the lift truck, set the directional lever to neutral position (N). ･ When setting the starting switch to " | " (ON) position, set the directional lever to neutral position (N).

3-6

OPERATION

EXPLANATION OF COMPONENTS

ACCELERATOR PEDAL

CAUTION Do not put your foot on the brake pedal while depressing the accelerator pedal.

This pedal is used to control the travel speed.

The travel speed changes in response to the depressing amount of pedal.

When pedal is depressed, electrical braking force varies. For details, see "OPERATION TEMPORARY STOPPING, PARKING AND STOPPING (3-61 page)".

Depressing amount of pedal

Travel speed

Electric brake braking force

Greater

Faster

Greater

Smaller

Slower

Smaller

IMPORTANT ･ When turning the starting switch to " | " (ON) position, release the accelerator pedal. ･ The load handling (lifting, tilting) speed is not related to the depressing amount of pedal. ･ Unless starting switch is set to " | " (ON) position under the following conditions, the lift truck does not travel even if accelerator pedal is depressed.

Directional lever: Neutral position Accelerator pedal: Released As for the neutral start function, see "INSPECTION AND MAINTENANCE CHECKING OF NEUTRAL START FUNCTION (4-21 page)".

BRAKE PEDAL

CAUTION When depressing the brake pedal, always release the accelerator pedal.

This pedal is used to decelerate and stop the lift truck.

IMPORTANT With the accelerator pedal depressed lightly, electric brake is activated. Deeper depressing the pedal activates mechanical brake (wheel brake) to produce strong braking force.

3-7

OPERATION

EXPLANATION OF COMPONENTS

LIFT LEVER This lever is used to raise or lower the forks.

Lower

RAISE: Pull the lever backward LOWER: Push the lever forward

Raise

TILT LEVER This lever is used to tilt the mast forward and backward.

Tilt forward

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

Tilt backward

STEERING WHEEL ･ The steering wheel changes the direction of the lift truck to the right and left. ･ Hold the knob on the steering wheel with your left hand for operation. ･ When turned clockwise (1), the lift truck turns to the right. ･ When turned counterclockwise (2), the lift truck turns to the left.

STEERING TILT LOCK LEVER ･ This lever is used to adjust the tilt angle (up/down) of the steering wheel. ･ Pulling this lever up can adjust the steering wheel tilt angle.

Pushing the lever down locks the steering wheel.

Free

3-8

Lock

OPERATION

HOW TO READ MONITOR PANEL

HOW TO READ MONITOR PANEL 3

GENERAL VIEW OF MONITOR PANEL

AA: When abnormality or warning occurs (1) Travel power mode (2) Message display (3) Travel interlock indication (4) Load handling interlock indication (5) Parking brake indication (6) Hour meter (SMR) integration state (7) Load handling power mode (8) Clock (8) Hour meter (SMR) indication (8) Travel distance (Odometer) indication

(9) Travel speed (10) Battery discharge indicator (BDI) (11) Average power consumption/Instantaneous power consumption (12) Function button (13) Directional lever position/ Action level display (14) Guidance icon (15) Seatbelt caution lamp (forklift truck with seat belt interlock) (16) Caution symbol

FUNCTION BUTTON Function button is used to operate the monitor panel.

GUIDANCE ICON It indicates the functions currently allotted to function buttons F1 to F8.

3-9

OPERATION

HOW TO READ MONITOR PANEL

HOUR METER (SMR) INTEGRATION STATE 3 This monitor indicates the integration state of the hour meter.

The green portions are displayed from 1 to 5 parts at intervals of 1 second during integration.

PARKING BRAKE INDICATION

3

This monitor is displayed while the parking brake is applied.

IMPORTANT If the lift truck travels with the parking brake applied, the brake is worn or broken. To prevent this, the alarm sounds.

TRAVEL INTERLOCK/LOAD HANDLING INTERLOCK INDICATION

3

This monitor is displayed while the travel interlock or load handling interlock is in operation.

For the operations of the travel interlock and load handling interlock, see "OPERATION TRAVEL INTERLOCK FUNCTION (3-63 page)" and "OPERATION LOAD HANDLING INTERLOCK (3-67 page)".

3 - 10

OPERATION

SEATBELT CAUTION LAMP

HOW TO READ MONITOR PANEL

3

(forklift truck with seat belt interlock) Always fasten the seat belt while traveling and handling loads because there may be a possible danger.

When lighting If the seat belt is not fastened, the seat belt caution lamp lights up.

The travel interlock display and lift interlock display light up at the same time.

Seat yourself properly on the seat, wear the seat belt, and return the directional lever to NEUTRAL position. The displays of travel interlock and lift interlock go out and the forklift truck is now ready for traveling and load handling operations again.

When flashing If the seat belt fastened state is detected while no one sits on the seat, the seatbelt caution lamp flashes. At the same time, the alarm buzzer sounds intermittently, and the travel interlock display and lift interlock display light up.

Unfasten the seat belt first, seat yourself properly on the seat, wear the seat belt, and return the directional lever to NEUTRAL position.

The displays of travel interlock and lift interlock go out and the forklift truck is now ready for traveling and load handling operations again.

3 - 11

HOW TO READ MONITOR PANEL

OPERATION

CLOCK/HOUR METER (SMR)/TRAVEL DISTANCE (ODOMETER)/CAUTION SYMBOL The hour meter, integrated travel distance, or clock is displayed.

In addition, if abnormality or warning occurs, the caution symbol is displayed.

Each time "F2" on the standard screen is pressed, the display changes to hour meter, integrated travel distance, clock, and hour meter in order.

HOUR METER (SMR) INDICATION The hour meter reading is displayed by the unit of 0.1 h.

INTEGRATED TRAVEL DISTANCE (ODOMETER) INDICATION The integrated travel distance is displayed by the unit of 0.1 km.

The integrated distance is an estimated value.

This value varies with the wear of the tire.

CLOCK The clock is displayed. The indication can be set to the 24-hour system or the 12-hour system.

For the setting method, see "OPERATION Clock Adjustment (337 page)".

3 - 12

3

OPERATION

HOW TO READ MONITOR PANEL

CAUTION SYMBOL The displayed symbol varies with the contents of abnormality and warning.

DETAILS OF CAUTION SYMBOL TRAVEL SYSTEM CAUTION LAMP Travel system caution lamp notifies that the travel system has an abnormality.

When a light trouble occurs (Work with care), the lamp lights up in yellow. When a serious trouble occurs (Stop working and turn the starting switch to "Q" (OFF) position),

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HOW TO READ MONITOR PANEL

PUMP SYSTEM CAUTION LAMP Pump system caution lamp notifies that the load handling system has an abnormality.

When a light trouble occurs (Work with care), the lamp lights up in yellow. When a serious trouble occurs (Stop working and turn the starting switch to "Q" (OFF) position), the lamp lights up in red.

SYSTEM CAUTION LAMP The system caution lamp notifies that the system has an abnormality.

When a light trouble occurs (Work with care), the lamp lights up in yellow. When a serious trouble occurs (Stop working and turn the starting switch to "Q" (OFF) position), the lamp lights up in red.

TRAVEL SYSTEM TEMPERATURE CAUTION LAMP The travel system temperature caution lamp indicates a temperature abnormality in the travel inverter or travel motor.

The lamp lights up in yellow for temperature warning and in red for temperature abnormality.

LOAD HANDLING SYSTEM TEMPERATURE CAUTION LAMP Load handling system temperature caution lamp indicates temperature abnormality in the load handling pump inverter or load handling pump motor.

The lamp lights up in yellow for temperature warning and in red for temperature abnormality.

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OPERATION

OPERATION

HOW TO READ MONITOR PANEL

MAINTENANCE TIME CAUTION LAMP Maintenance time caution lamp notifies that the maintenance time is approaching or it has been passed.

Lighted in yellow: The maintenance due time is within 30 hours.This indicates the maintenance time is approaching. Contact your Komatsu distributor for the change of the time to start lighting.

Lighted in red: The maintenance due time has already passed.

STEERING SYSTEM CAUTION LAMP Steering system caution lamp notifies that the steering system has an abnormality.

When a light trouble occurs (Work with care), the lamp lights up in yellow. When a serious trouble occurs (Stop working and turn the starting switch to "Q" (OFF) position), the red lamp lights up.

BATTERY CAUTION LAMP The battery caution lamp indicates an abnormality in the battery.

The battery voltage is too high or too low. After finishing the work, call your Komatsu distributor.

BATTERY ELECTROLYTE LEVEL CAUTION LAMP The battery level caution lamp indicates that the battery fluid is insufficient.

The electrolyte level is low. Add specified distilled water or purified water.

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OPERATION

HOW TO READ MONITOR PANEL

SEATING CAUTION LAMP Seating caution lamp warns that the seating condition of the operator is not correct.

The seating posture of the operator may not be recognized correctly. Sit in the correct position.

TRAVEL POWER MODE

3

Setting of lift truck travel performance is indicated in 3 stages.

L: Low power M: Middle power H: High power REMARK For details of each level, see "OPERATION Travel Power Mode Set (3-23 page)".

LOAD HANDLING POWER MODE

3

Setting of lift truck load handling performance is indicated in 3 stages.

L: Low power M: Middle power H: High power REMARK For details of each level, see "OPERATION Load Handling Power Mode Set (3-24 page)".

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OPERATION

CURRENT TRAVEL SPEED

HOW TO READ MONITOR PANEL

3

This monitor indicates the current travel speed.

IMPORTANT If other tires than the standard or optional tires are used, there may be error in the displayed travel speed.

BATTERY DISCHARGE INDICATOR (BDI)

3

Indicates electric power stored in the battery in 10 levels.

As the battery discharges power, the indication turns out sequentially from the top.

When fully charged, the meter indicates all 10 levels.

WARNING ON BATTERY OVER DISCHARGE 1) When the battery charge level decreases below 30%, the monitor indicates that the battery needs to be recharged. ･ The lowest 3 levels become yellow.

2) When the battery charge level decreases below 20%, the battery is over-discharged. In this case, recharge the battery immediately. ･ The lowest 2 levels become red. ･ Alarm buzzer sounds for 5 seconds to warn over-discharge. It sounds repeatedly every 1 minutes.

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OPERATION

HOW TO READ MONITOR PANEL

AVERAGE POWER CONSUMPTION/ INSTANTANEOUS POWER CONSUMPTION 3 (ECO GAUGE) POWER CONSUMPTION INDICATION This monitor indicates the average power consumption of each day.

INSTANTANEOUS POWER CONSUMPTION This monitor indicates the power consumption in the immediate last 3 seconds.

DIRECTIONAL LEVER POSITION/ACTION LEVEL DISPLAY

3

DIRECTIONAL LEVER POSITION DISPLAY This monitor indicates forward ( I F), reverse ( O R), and neutral (N).

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OPERATION

HOW TO READ MONITOR PANEL

ACTION LEVEL DISPLAY This monitor is displayed when abnormality occurs.

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OPERATION OF MONITOR PANEL

OPERATION OF MONITOR PANEL OPERATION MODE 3 Various settings can be done by operating the function button.

OPERATION INFORMATION When function button F1 is pressed on the standard screen, the screen changes to the Working Information screen. On this screen, you can check the following information.

On this screen, you can check the following information.

Use button F1 to move the selection to the upper item and F2 to move the selection to the lower item.

If button F3 is pressed or no operation is performed for 30 seconds, the screen returns to the standard screen.

Items in the Working Information menu ･ SMR ･ Traveling Hours ･ Load Handling Hours ･ Actual Working Hours ･ Actual Working Hours Ratio ･ Electric Power Last Charging ･ Electric Power Accumulated ･ CO2 Emission Accumulated ･ Resetting Accumelated Value ･ SMR The integrated operation hours is displayed. This is the same as the one displayed on the standard screen. ･ Traveling Hours The integrated hours in which the lift truck traveled at speed higher than 1 km/h is displayed. ･ Load Handling Hours The integrated hours in which the work equipment control lever was operated is displayed. ･ Actual Working Hours The integrated hours in which the lift truck traveled at speed higher than 1 km/h or the work equipment control lever was operated is displayed. ･ Actual Working Hours Ratio The ratio of the actual working hours to the integrated working hours is indicated by %.

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OPERATION

OPERATION

OPERATION OF MONITOR PANEL

･ Electric Power Last Charging The electric power (kWh) used for the previous charging operation is displayed.

The electric power is an estimated value. Use it for reference. ･ Electric Power Accumulated The integrated electric power (kWh) used for charging operation up to now is displayed.

The electric power is an estimated value. Use it for reference. ･ CO2 Emission Accumulated This is the quantity of CO2 discharged during charging up to now. (Unit: kgCO2) The discharge is an estimated value. Use it for reference. ･ Resetting Accumulated Value The integrated charge value can be reset to "0".

While this portion is selected, if button F4 is pressed, the confirmation message for resetting is displayed. To reset, press button F4 (YES) again.

To cancel, press button F3 (NO).

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OPERATION

OPERATION OF MONITOR PANEL

CLOCK/HOUR METER (SMR)/TRAVEL DISTANCE (ODOMETER) SELECTION Each time button F2 is pressed on the standard screen, the displayed item changes.

CAUTION CHECK If a trouble has occurred and "!" is lit in the guidance icon, press the button F3, and the screen changes to "Error List" screen. ･ Error List screen The failures occurring at present are displayed in order from the most serious one.

When 4 or more failures are occurring, press button F6, and the following failures appear.

USER MENU

3

In the user menu, you can set the following items and check their states.

Press button F4 on the standard screen to display the menu.

Press buttons F6 of F7 to change the menu.

Power Mode Setting ･ Travel Power Mode Set ･ Load Handling Power Mode Set Machine Setting ･ ES Volume Adjustment ･ Travel Speed (Tortoise) Set ･ Max Speed Limit Set ･ Overspeed Alarm Set ･ Lift Speed Adjustment ･ Tilt Speed Adjustment ･ Overload Alarm Set (only for the lift truck equipped with load checker) ･ Overload Alarm Value (only for the lift truck equipped with load checker) ･ O. Alarm Cancel Load Diff (only for the lift truck equipped with load checker)

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3

OPERATION

OPERATION OF MONITOR PANEL

Working Record ･ Consumed Elec. Power Record ･ Operat. Record by Operator ･ Operating Record ･ Display Setting Maintenance ･ Hydraulic Oil ･ Brake Oil ･ Transfer Case Oil ･ Hyd. Oil Line Filter ･ Hyd. Oil Tank Breather Monitor Setting ･ Screen Adjustment ･ Clock Adjustment ･ Language ･ Unit for Speed/Distance ･ Unit ･ CO2 Emission Ratio KOMTRAX Message

Power Mode Setting You can set the power performance of travel and load handling.

To set, select the Power Mode Setting menu with buttons F6 and F7.

To return to the standard screen, press button F3.

Travel Power Mode Set You can set the travel performance of the lift truck to 3 levels of H, M and L. 1. Select the Travel Power Mode Set on the Power Mode Setting menu with buttons F1 and F2 and press button F4, and the display changes to the Setting screen.

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OPERATION

OPERATION OF MONITOR PANEL

2. Change the set value with buttons F1 and F2 on the setting screen and enter it with button F4.

Power mode

Content

L

Low power

Enables smooth travel with good energysaving.

M

Middle power

Provides travel performance adequate for normal operation.

H

High power

Increases speed and provides powerful travel.Battery power consumption increases.

To return to the Power Mode Setting menu, press button F3.

Load Handling Power Mode Set You can set the load handling performance of the lift truck to 3 levels of H, M and L. 1. Select the Load Handling Power Mode Set on the Power Mode Setting menu with buttons F1 and F2 and press button F4, and the display changes to the Setting screen.

2. Change the set value with buttons F1 and F2 on the setting screen and enter it with button F4.

Power mode

Content

L

Low power

Smooth and energy saving load handling is available.

M

Middle power

Provides load handling performance adequate for normal operation.

H

High power

Increases speed and provides powerful load handling. Battery power consumption increases.

To return to the Power Mode Setting menu, press button F3.

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OPERATION

OPERATION OF MONITOR PANEL

Machine Setting You can set the characteristics related to the speed of the following items.

CHASSIS SETTING menu items ･ ES Volume Adjustment ･ Travel Speed (Tortoise) Set ･ Max Speed Limit Set ･ Overspeed Limit Set ･ Lift Speed Adjustment ･ Tilt Speed Adjustment ･ Overload Alarm Set (only for the lift truck equipped with load checker) ･ Overload Alarm Value (only for the lift truck equipped with load checker) ･ O. Alarm Cancel Load Diff (only for the lift truck equipped with load checker) To perform setting, change the display to the Machine Setting menu with buttons F6 and F7.

To return to the standard screen, press button F3.

ES Volume Adjustment You can set the acceleration performance of the lift truck to 8 levels of 1 to 8.

(The larger the number is, the higher the acceleration performance is.)

1. Select the ES Volume Adjustment on the Machine Setting menu with buttons F1 and F2 and press button F4, and the display changes to the Setting screen.

2. Change the set value with buttons F1 and F2 on the setting screen and enter it with button F4.

To return to the Machine Setting menu, press button F3.

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OPERATION

OPERATION OF MONITOR PANEL

Travel Speed (Tortoise) Set You can set the speed limit in the speed limit (tortoise) mode.

For km/h display You can set the speed limit in the range from 2 to 20 km/h (2 to 12 mph).

1. Select the Travel Speed (Tortoise) Set on the Machine Setting menu with buttons F1 and F2 and press button F4, and the display changes to the Setting screen.

2. Change the digit place with buttons F6 and F7 on the setting screen and change the value with buttons F1 and F2.

For mph display To return to the Machine Setting menu, press button F3.

Max Speed Limit Set You can set the speed limit of the maximum travel speed.

You can set the speed limit in the range from 2 to 20 km/h.

1. Select the Max Speed Limit Set on the Machine Setting menu with buttons F1 and F2 and press button F4, and the display changes to the Setting screen.

2. Change the digit place with buttons F6 and F7 on the setting screen and change the value with buttons F1 and F2.

To return to the Machine Setting menu, press button F3.

Overspeed Alarm Set You can set the speed to warn overspeed.

You can set the warning speed in the range from 2 to 20 km/h.

1. Select the Overspeed Alarm Set on the Machine Setting menu with buttons F1 and F2 and press button F4, and the display changes to the Setting screen.

2. Change the digit place with buttons F6 and F7 on the setting screen and change the value with buttons F1 and F2.

To return to the Machine Setting menu, press button F3.

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OPERATION

OPERATION OF MONITOR PANEL

Lift Speed Adjustment You can set the maximum lifting speed. You can set the maximum speed in the range of 10 levels.

1. Select the Lift Speed Adjustment on the Machine Setting menu with buttons F1 and F2 and press button F4, and the display changes to the Setting screen.

2. Change the value with buttons F1 and F2.

To return to the Machine Setting menu, press button F3.

Tilt Speed Adjustment You can set the maximum tilting speed.

You can set the maximum speed in the range of 10 levels.

1. Select the Tilt Speed Adjustment on the Machine Setting menu with buttons F1 and F2 and press button F4, and the display changes to the Setting screen.

2. Change the value with buttons F1 and F2. Enter with button F4.

To return to the Machine Setting menu, press button F3.

Overload Alarm Set This function is available on only lift trucks equipped with the load checker.

You can set or cancel the warning display when the lifting truck is overloaded.

1. Select the Overload Alarm Set on the Machine Setting menu with buttons F1 and F2 and press button F4, and the display changes to the Setting screen.

2. Change the value with buttons F1 and F2. Enter with button F4.

To return to the Machine Setting menu, press button F3.

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OPERATION OF MONITOR PANEL

Overload Alarm Value This function is available on only lift trucks equipped with the load checker.

You can set the load to warn overloading.

You can set the warning load in the range from 0.00 t to 90.74 t.

1. Select the Overload Alarm Value on the Machine Setting menu with buttons F1 and F2 and press button F4, and the display changes to the Setting screen.

2. Change the digit place with buttons F6 and F7 on the setting screen and change the value with buttons F1 and F2.

To return to the Machine Setting menu, press button F3.

O. Alarm Cancel Load Diff This function is available on only lift trucks equipped with the load checker.

You can set the load to turn OFF the overloading warning.

The warning is turned OFF at the weight obtained when subtracting this value from the value set by OVERLOAD WARNING LOAD. You can set the warning load in the range from 0.00 t to 9.07 t.

1. Select the O. Alarm Cancel Load Diff on the Machine Setting menu with buttons F1 and F2 and press button F4, and the display changes to the Setting screen.

2. Change the digit place with buttons F6 and F7 on the setting screen and change the value with buttons F1 and F2.

To return to the Machine Setting menu, press button F3.

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OPERATION

OPERATION

OPERATION OF MONITOR PANEL

Default values list for POWER MODE SETTING and CHASSIS SETTING Menu Power Mode Setting Machine Setting

Item

Set value

Default

Travel Power Mode Set

L: Low, M: Middle, H: High

M

Load Handling Power Mode Set

L: Low, M: Middle, H: High

M

1: Slow to 8: Fast

6

2 to 20 km/h

15

2 to 12 mph

9

Max Speed Limit Set

0 (Invalid), 2 to 20 km/h

0 (Invalid)

Overspeed Alarm Set

0 (Invalid), 2 to 20 km/h

0 (Invalid)

Lift Speed Adjustment

1: Slow to 10: Fast

10

Tilt Speed Adjustment

1: Slow to 10: Fast

10

Overload Alarm Set

Valid/Invalid

Invalid

Overload Alarm Value

0 to 90.74 t

2.45

O. Alarm Cancel Load Diff

0 to 9.07 t

0.45

ES Volume Adjustment Travel Speed (Tortoise) Set

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OPERATION

OPERATION OF MONITOR PANEL

Working Record

3

You can check the record of the operation hours and power consumption.

There are following menu items.

Menu items in operation record ･ Consumed Elec. Power Record (only for the lift truck equipped with KOMTRAX) ･ Operat. Record by Operator (only for the lift truck equipped with ID key system) ･ Operating Record ･ Display Setting (only for the lift truck equipped with KOMTRAX) To perform checking, etc., select the OPERATION RECORD menu by pressing buttons F6 and F7.

To return to USER MENU, press button F3.

Consumed Elec. Power Record You can check the power consumption history in the past 12 hours or past 1 week. (Unit: kWh/h) 1. Select "Consumed Elec. Power Record" on the Working Record menu with buttons F1 and F2 and press button F4, and the Record display screen is displayed.

2. Each time you press button F1, the "Last 12h" and "Last 1wk" are displayed alternately.

To return to the Working Record menu, press button F3.

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OPERATION

OPERATION OF MONITOR PANEL

･ Resetting of history If you press button F8 while the Record is displayed, the display changes to Clear Record screen. To reset the Record data, press button F4.

Operat. Record by Operator This function is available on only lift trucks equipped with the ID key system.

You can check the operation history by the operator (by the KeyID).

1. Select the Operat. Record by Operator on the Working Record menu with buttons F1 and F2 and press button F4, and the Record selection screen is displayed.

To return to the Working Record menu, press button F3.

2. Select a Key-ID you want to check with buttons F1 and F2 and press button F4, and the OPERATION HISTORY screen is displayed. ･ On the OPERATION HISTORY screen, the date, time, and SMR value when the starting switch was turned to " l " (ON) and to "Q" (OFF) are displayed.

To return to the HISTORY SELECTION screen, press button F3.

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OPERATION OF MONITOR PANEL

Operating Record You can check the operation record of the following items in 1 day (from 0 a.m. of the day to 0 a.m. of the next day) or in 1 split (any period of time). ･ Working Hours ･ Actual Working Hours ･ Average Consumed Elec. Power (only for the lift truck equipped with KOMTRAX) ･ Accumulated Consumed Elec. Power (only for the lift truck equipped with KOMTRAX) ･ Charge Electric power 1. Select Operation Record on Working Record menu with buttons F1 and F2, press the button F4, and the screen changes to Operation Record screen.

Displayed content changes according to Consumption Power Set of Display Setting from Working Recordmenu.

2. Select the item of which you want to check the operation record with buttons F1 and F2, and the record of each item is displayed at the bottom of the screen.

When the display of Consumed Electric Power Gauge is set Split Time display, SPLIT is displayed on upper right of Operation Record screen.

Display of split measurement actuated Press the button F8, and the screen changes to the Split Time Information screen. You can check the split measurement condition and can stop the split measurement.

Display of split measurement stopped Press the button F8, and the screen changes to the Split Time Information screen. You can check the split measurement condition and can restart the split measurement.

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OPERATION

OPERATION

OPERATION OF MONITOR PANEL

･ While split measurement is continued The date and time when split measurement was started are displayed.

If you press button F1, the split measurement is stopped.

To return to the Operating Record screen, press button F3.

･ While split measurement is stopped The date and time when split measurement was started and finished are displayed.

If you press button F1, resetting of the split information is confirmed. If you press button F4 and select "YES", the split information saved at present is reset and a new split measurement is started.

To return to the Operating Record screen, press button F3.

DISPLAY SETTING (only for the lift truck equipped with KOMTRAX) You can set power consumption meter display, eco gauge display, target power consumption of eco gauge display.

This screen is displayed only when "Consumption Power Set" is ON. Select "Display Setting" on the Working Record menu with buttons F1 and F2 and press button F4, and the Display Setting menu is displayed.

･ Consumed Electric Power Gauge You can set the power consumption meter displayed in "Working Record" - "Operation Record".

1 Day: Power for the day is displayed.

Split Time: Power for the period from start to stop of split is displayed.

OFF: Power consumption meter is not displayed.

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OPERATION OF MONITOR PANEL

･ Eco Gauge You can turn ON/OFF the ECO gauge display on the standard screen when the starting switch is in " l " (ON) position.

ON: Displays the ECO gauge.

OFF: Does not display the ECO gauge.

･ Eco Gauge Target Value for Consumed Electric Power You can set a target power consumption of the ECO gauge display.

You can set the target value in the range from 0 to 99.9 kW. Select "Eco Gauge Target Value for Consumed Electric Power" on the Display Setting menu with buttons F1 and F2 and press button F4, and the display changes to the Setting screen.

Change the digit place with buttons F6 and F7 on the setting screen and change the value with buttons F1 and F2. Enter with button F4.

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OPERATION

OPERATION

Maintenance

OPERATION OF MONITOR PANEL

3

Reference value of replacement interval and remaining time to replacement for following oil and filter are displayed.

Items in Maintenance menu ･ Hydraulic Oil ･ Brake Oil ･ Transfer Case Oil ･ Hyd. Oil Line Filter ･ Hyd. Oil Tank Breather 1. To perform checking, etc. of each item, select the Maintenance menu with buttons F6 and F7.

2. Select an item with buttons F1 and F2, and the replacement interval of that item and the remaining time before the next replacement are displayed at the bottom of the screen.

To return to the standard screen, press button F3.

･ Maintenance Time Reset When selecting an item with buttons F1 and F2, if you hold down the button for 1 second or more, "Maintenance Time Reset" screen is displayed.

If you press button F4 on the Maintenance Time Reset screen, the confirmation screen is displayed.

If you press button F4 and select "YES" on the confirmation screen, the remaining time is reset and the number of replacement is increased by 1.

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OPERATION

OPERATION OF MONITOR PANEL

Monitor Setting

3

You can set the following items related to display of the monitors.

Items in Monitor Setting menu ･ Screen Adjustment ･ Clock Adjustment ･ Language ･ Unit for Speed/Distance ･ Unit ･ CO2 Emission Ratio To set, select the Monitor Setting menu with buttons F6 and F7.

To return to the standard screen, press button F3.

Screen Adjustment You can adjust the brightness of the monitor panel.

You can set for the DAY MODE and NIGHT MODE separately.

(When headlamp is OFF: DAY MODE, When headlamp is ON: NIGHT MODE) 1. Select the Screen Adjustment on the Monitor Setting menu with buttons F1 and F2 and press button F4, and the Screen Adjustment screen is displayed.

2. Pressing button F6 decreases the brightness level by 1 and pressing button F7 increases the level by 1.

Pressing button F8 returns the brightness level to the default.

To return to the Monitor Setting menu, press button F3.

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OPERATION

OPERATION OF MONITOR PANEL

Clock Adjustment You can set the following items related to date and time.

Items in Clock Adjustment menu ･ GPS Synchronization ･ Calendar ･ Time ･ 12h/24h Mode ･ Daylight Saving Time 1. Select the Clock Adjustment on the Monitor Setting menu with buttons F1 and F2 and press button F4, and the Clock Adjustment menu is displayed.

To return to the Monitor Setting menu, press button F3.

GPS Synchronization (only lift trucks equipped with KOMTRAX) You can select obtaining the date and time by using GPS or setting them manually.

1. Select the GPS Synchronization on the Clock Adjustment menu with buttons F1 and F2 and press button F4, and the GPS Synchronization screen is displayed.

2. Select ON with button F2 and enter with button F4, and the time is obtained/corrected automatically by using GPS. When GPS Synchronization is ON, Calendar and Time screens are disabled.

If you select OFF with button F1 and enter with button F4, GPS is not used and the date and time set on the Calendar and Time screen are used.

To return to the Clock Adjustment menu, press button F3.

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OPERATION OF MONITOR PANEL

Calendar You can set the date.

1. Select the Calendar on the Clock Adjustment menu with buttons F1 and F2 and press button F4, and the Calendar screen is displayed.

2. Select a digit place with buttons F6 and F7 and increase or decrease the value with buttons F1 and F2. You can increase or decrease the value continuously by holding down button F1 of F2.

To return to the Clock Adjustment menu, press button F3.

Time You can set the time.

1. Select the Time on the Clock Adjustment menu with buttons F1 and F2 and press button F4, and the Time screen is displayed.

Select a digit place with buttons F6 and F7 and increase or decrease the value with buttons F1 and F2.

You can increase or decrease the value continuously by holding down button F1 of F2.

Enter the change by pressing button F4.

To return to the Clock Adjustment menu, press button F3.

REMARK The digit positions of the time vary as follows, depending on the set value in "12/24H DISPLAY MODE". ･ In 12H mode: AM0 to PM11 ･ In 24H mode: 0 to 23

12h/24h Mode You can set the display mode of the time.

1. Select the 12h/24h Mode on the Clock Adjustment menu with buttons F1 and F2 and press button F4, and the 12h/24h Mode screen is displayed.

2. Select "12H" with button F2 and enter with button F4, and the clock set in the 12-hour display mode (AM00:00 to PM11:59).

Select "24H" with button F1 and enter with button F4, and the clock set in the 24-hour display mode (00:00 to 23:59).

To return to the Clock Adjustment menu, press button F3.

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OPERATION

OPERATION

OPERATION OF MONITOR PANEL

Daylight Saving Time You can set use of the daylight saving time.

1. Select the Daylight Saving Time on the Clock Adjustment menu with buttons F1 and F2 and press button F4, and the Daylight Saving Time screen is displayed.

2. Select "ON" with button F2 and enter with button F4, and the daylight saving time is enabled.

If you select "OFF" with button F1 and enter with button F4, the daylight saving time is disabled.

To return to the Clock Adjustment menu, press button F3.

Language You can select the language displayed on the monitor.

1. Select the Language on the Monitor Setting menu with buttons F1 and F2 and press button F4, and the Language screen is displayed.

2. Select a language with buttons F1 and F2 and enter with F4, and the language for display is changed.

To return to the Monitor Setting menu, press button F3.

Unit for Speed/Distance You can set the units used for display and calculation of the speed and distance.

1. Select the Unit for Speed/Distance on the Monitor Setting menu with buttons F1 and F2 and press button F4, and the Unit for Speed/Distance screen is displayed.

2. If you select "km/h, km" with button F2 and enter with button F4, "meter" is set as the unit of distance.

If you select "mph, mile" with button F2 and enter with button F4, "mile" is set as the unit of distance.

To return to the Monitor Setting menu, press button F3.

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OPERATION OF MONITOR PANEL

Unit You can select SI or NON-SI units for item other than speed and distance.

1. Select the Unit on the Monitor Setting menu with buttons F1 and F2 and press button F4, and the Unit screen is displayed.

2. If you select "SI" with button F2 and enter with button F4, "SI" unit system is used for the units of items other than speed and distance.

If you select "NON-SI" with button F1 and enter with button F4, "NON-SI" unit system is used for the units of items other than speed and distance.

To return to the Monitor Setting menu, press button F3.

CO2 Emission Ratio This setting is available only when CHARGE POWER SETTING is set to ON. You can set the factor for calculation of the integrated CO 2 discharge.

You can set the factor in the range from 0.000 to 0.999 kgCO2 per kWh. 1. Select the CO2 Emission Ratio on the Monitor Setting menu with buttons F1 and F2 and press button F4, and the CO 2 Emission Ratio screen is displayed.

2. Select a digit place with buttons F6 and F7 and increase or decrease the value with buttons F1 and F2.You can increase or decrease the value continuously by holding down button F1 of F2.

Enter the change by pressing button F4.

To return to the Monitor Setting menu, press button F3.

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OPERATION

OPERATION

CHARGING MODE

OPERATION OF MONITOR PANEL

3

・ For a safe and long period of service life of the battery, pay attentions to the following. The cautions are applicable to both onboard and stationary chargers. ・ The battery is charged by the automatic charging or equalizing charging. Charging time differs by discharged state of the battery. It takes generally 8 - 10 hours to charge the battery of the standard application.

CHARGING METHOD

Timing of charging and charging operation

Automatic charging

･ Automatically selects and performs normal charging or equalizing charging

Equalized charging

･ Performs equalizing charging forcibly.

EQUALIZING CHARGING If the battery is discharged and charged repeatedly, performances of its cells (36 cells for 72-V battery) are dispersed gradually. If dispersion is left as it is, the service life of the battery is shortened. The purpose of the equalizing charging is to eliminate the dispersion by charging the battery longer than the normal charging.

In the automatic charging mode, 1 equalized charging is performed after 6 normal charging are performed continuously.

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OPERATION

OPERATION OF MONITOR PANEL

ID KEY FUNCTION (ONLY LIFT TRUCKS EQUIPPED WITH ID KEY)

3

The lift truck can be operated only with the ID key registered in it.

If an inserted key is not registered, the message that it is not registered as an ID key is displayed.

Even if a registered ID key is inserted, its number may not be read because of a defective chip.

If the ID key system fails, the ID KEY SYSTEM ABNORMALITY screen is displayed.

If the abnormality screen is displayed, contact your Komatsu distributor.

REMARK If a message against a wrong password is displayed, turn the starting switch to "Q" (OFF) position and turn the starting switch to " l " (ON) position again, and then set the password correctly again.

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OPERATION

OPERATION OF MONITOR PANEL

1. Press button F4 to display the PASSWORD DISPLAY screen.

2. Input the registered password.

Select a digit place with buttons F6 and F7 and change the value with buttons F1 and F2, and then enter with button F4.

Password to be input ･ When the monitor panel is replaced: Default password ･ When the ID key controller is replaced: User password

REGISTRATION OF NEW ID KEY To register a new ID key to the lift truck, follow the procedure below.

1. Insert a registered key (gray key) and turn it to " l " (ON) position.

2. The ID Key Setting screen is displayed. Pull out the registered key within 10 seconds and insert a new ID key and turn it to " l " (ON) position, according to the direction shown on the screen.

3. If the new key is registered successfully, the registration completion screen is displayed.

If you replace the registered key with another new key within 10 seconds, you can register continuously.

4. If you perform the registration operation with a key that has been registered, the message that the key is registered already is displayed.

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OPERATION OF MONITOR PANEL

5. If you register a key which is not an ID key or register an ID key which is not readable, the failure screen is displayed.

DELETION OF ID KEY REGISTRATION You can delete registration of the registered ID keys one by one or all together.

DELETION OF REGISTRATION OF SPECIFIC ID KEY 1. Press button F4 on the ID Key Setting screen and select "LIST", and the ID Key List screen is displayed.

2. Select an ID to be deleted with buttons F1 and F2 and hold down button F4 for 2 seconds or more, and the Deletion of Registered Key screen is displayed.

3. Select "YES" with button F4, and you are reconfirmed. Select "YES" again with button F4, and the registration is deleted and the display returns to the ID Key List screen.

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OPERATION

OPERATION

OPERATION OF MONITOR PANEL

DELETION OF ALL REGISTRATION OF ID KEYS 1. While the ID Key Setting screen is displayed, insert a registered key and turn it to " l " (ON) position and to "Q" (OFF) position 5 times repeatedly, and the registration of all the keys is deleted.

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OPERATION

OPERATION

OPERATION START-UP INSPECTION

3

CAUTION ･ Do not operate the lift truck before completing start-up inspection. ･ Report abnormality, if any, immediately to the administrator.

Never operate the lift truck in question until the repair is completed. ･ Be sure to perform the inspection before starting the operation in order to work in safe. ･ For the contents and procedure of start-up inspection and daily inspection, see "INSPECTION AND MAINTENANCE INSPECTION AND MAINTENANCE (4-2 page)".

MOUNTING/DISMOUNTING AND OPERATING POSTURE ADJUSTMENT MOUNTING/DISMOUNTING

CAUTION ･ Mount or dismount the lift truck only after the lift truck comes to a complete stop. ･ Jumping on and off from the lift truck is very dangerous and can cause a serious personal injury or death. Accordingly, never do these operations. ･ Do not hold on the work equipment control levers or steering wheel when mounting or dismounting the lift truck. ･ Keep assist grips (1) and step (2) clean all the time, and repair the damage, if any. ･ Do not use assist grips (1) for any other purpose than mounting or dismounting the lift truck. ･ Always mount and dismount the lift truck from the left side. ･ While mounting or dismounting the lift truck, always support yourself securely with your hands and feet at 3 or more locations; put your left foot on step (2), grab assist grip (1) with your left hand, and grab the backrest or assist grip (3) of the seat with your right hand. ･ If the step is damaged or deformed, do not step on it. If the step is damaged or deformed, repair it immediately. Ask your Komatsu distributor for repair or replacement of the step.

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3

OPERATION

OPERATION

HOW TO ADJUST SEAT POSITION

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. ･ For the seat position when replacing the battery, see "INSPECTION AND MAINTENANCE BATTERY REPLACEMENT (4-52 page)".

1. Set the lift truck in the parking posture. For parking, see "OPERATION TEMPORARY STOPPING, PARKING AND STOPPING (3-61 page)".

2. Take a seat and pull up lever (1). The operator's seat can slide back and forth in this condition.

3. Bring the operator's seat to the optimum position and release the lever (1). The seat is locked in this condition.

4. After adjusting, confirm that the seat is securely locked by pushing/pulling it forwards/backwards.

HOW TO ADJUST BACKREST ANGLE 1. Push back lever (2) backward. The backrest angle can be adjusted in this condition.

2. Adjust the backrest angle and release lever (2).

3. After adjusting, confirm that the backrest is securely locked by pushing and pulling it.

HOW TO ADJUST SEAT SUSPENSION Turn seat cushioning adjustment dial (3) located on the front right side of the operator's seat to select scale (4) to your weight for suspension adjustment.

Turn the dial to the (A) side for lighter weight and to the (B) side for greater weight.

Weight adjustable range: 40 to 120 kg

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OPERATION

OPERATION

FASTENING AND UNFASTENING THE SEAT BELT

CAUTION Always wear your seat belt during operations.

1. Pull tongue (1) out of the belt holder located on the right side of the operator's seat and push it into buckle (2) on the left side until it clicks into place. Tongue (1) is fixed to buckle (2) in this condition.

2. To unfasten, hold the seat belt with your right hand, and push down the red button of buckle (2) with your left hand.

3. The belt is tucked into the holder automatically.

4. While the belt is being tucked in, hold tongue (1) so that the belt is tucked in slowly.

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OPERATION

OPERATION

SEAT BELT INTERLOCK (forklift truck with seat belt interlock)

CAUTION When the seat belt is unfastened during travel, the seat belt interlock is actuated. Forklift truck is decelerated and it may cause the load collapsing.

IMPORTANT Be sure to unfasten the seat belt before you leave the forklift truck.

Otherwise the seat belt interlock is kept actuated, and the batteries will be exhausted early.

The seat belt interlock is a safety auxiliary device that operates the travel interlock and lift interlock if the operator does not wear the seat belt.

When the seat belt interlock is actuated, the seat belt caution lamp lights up on the monitor panel, and the travel interlock and lift interlock displays light up at the same time.

RELEASING SEAT BELT INTERLOCK If the seat belt interlock is released, the lift interlock and travel interlock can be released.

1. Sit on the seat properly and fasten the seat belt.

The seat belt interlock is released.

The lift interlock is released at the same time.

2. Set the directional lever to NEUTRAL position (N).

The travel interlock is released.

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OPERATION

FAILURE IN PROCEDURE FOR FASTENING SEAT BELT If the seat belt fastened state is detected while no one sits on the seat, the seatbelt caution lamp on the monitor panel flashes and the alarm buzzer sounds intermittently.

The travel interlock and the lift interlock are actuated at the same time.

RESTORING FAILURE IN PROCEDURE FOR FASTENING SEAT BELT If the failure in procedure for fastening seat belt is restored and seat belt interlock is released, the lift interlock and travel interlock can be released.

1. Unfasten the seat belt.

The failure in procedure for fastening seat belt is restored, and the display is changed to the seat belt interlock display.

The flashing seat belt caution lamp becomes to stay lit, and the alarm buzzer stops sounding.

2. Sit on the seat properly and fasten the seat belt.

The seat belt interlock is released.

The lift interlock is released at the same time.

3. Set the directional lever to NEUTRAL position (N).

The travel interlock is released.

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OPERATION

OPERATION

TRAVEL LIMIT SPEED AT HIGH LIFT FUNCTION

OPERATION

3

(Forklift truck with seat belt interlock) IMPORTANT Travel limit speed at high lift function does not prevent the lift truck from tipping over when turning or traveling. Do not drive the lift truck when the fork is lifted high.

Travel limit speed at high lift function is used to control the travel speed to lessen the shock caused by the interference of the lifted mast (or backrest for some masts) and the upper part of the entrance, which may occur by mistake when the lift truck with highly lifted fork enters or exits the building.

If the forks are lifted up to the height which the lifting height detection sensor (1) does not detect the detection plate (2), the travel limit speed at high lift function will be actuated.

The travel limit speed at high lift function is actuated when the forks are at the height of 800 mm or more, the travel speed will be limited even if the accelerator pedal is depressed.

Lift truck with triple mast, full free mast For the lift truck with triple mast, when the middle mast is lifted up, the travel limit speed at high lift function is actuated.

For the lift truck with full free mast, when the inner mast is lifted up, the travel limit speed at high lift function is actuated.

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OPERATION

OPERATION

OPERATION AND MAINTENANCE MANUAL STORAGE (RETRACTABLE POCKET BEHIND THE BACKREST)

CAUTION ･ Store the Operation and Maintenance Manual in the retractable pocket behind the operator's seat readily available for reference. ･ If this manual has been lost or has become dirty or worn and cannot be read, request a replacement manual from your Komatsu distributor.

1. Push unlock button (1) of seat back pocket (2) of the operator's seat.

2. Open seat back pocket (2) backward to take out or store the Operation and Maintenance Manual.

An open-type magazine box is installed on outside of seat back pocket (2). You are free to use this box for storing necessary documents, etc.

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OPERATION

OPERATION

ADJUSTING STEERING WHEEL TILT ANGLE

CAUTION ･ Always stop the lift truck completely before adjusting the steering wheel tilt angle. ･ After adjusting, move the steering wheel backward and forward to check that it is locked securely in position.

1. Set the lift truck in the parking posture. For washing the lift truck, see "OPERATION TEMPORARY STOPPING, PARKING AND STOPPING (3-61 page)".

2. Pull up the steering tilt lock lever to (A) position.

3. Move the steering wheel back and forth to select the optimum position.

4. Press down the steering tilt lock lever to (B) position to lock the steering wheel.

Free Lock

After adjusting the steering wheel, confirm that it is firmly locked by pushing and pulling it.

HOW TO CUT POWER SUPPLY

CAUTION When the unexpected electrical abnormality occurs, operator can cut the power supply for electrical circuit (control circuit and drive circuit) by pulling out battery plug (1).

How to reconnect the power supply 1. Check that the parking brake lever is set in the position to the rear direction of the lift truck.

2. Check that the starting switch is in "○" (OFF) position, directional lever and work equipment control lever are in neutral position. Do not put your foot on the accelerator pedal.

3. Insert the battery plug, and the power supply is reconnected.

REMARK Even if the battery plug is pulled out while traveling, the lift truck does not stop immediately.

Depress the brake pedal to stop the lift truck.

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OPERATION

OPERATION

3

SEAT HEATER (Option)

CAUTION ･ In the cases that follow, do not use it to prevent low temperature burn. ･ When a person's ability to sense the temperature is decreased ･ When a person's ability to feel pain is decreased ･ When a person has a delicate skin ･ Do not put a heavy object on the seat heater. Do not stick the seat heater with needles or nails. ･ When you use it, do not put objects which keep heat such as blankets or floor cushions on the seat heater. The seat heater will overheat and it can cause burn injury or failure. ･ Do not use the seat while it is wet. If water or beverage is spilled, immediately wipe it off with a dry cloth and dry it fully. Do not use the seat heater to dry the seat.

Seat heater is operated by seat heater switch.

Each time the seat heater switch is pressed, the display changes ON→OFF→ON in turn.

Check the state of seat heater with the lamp inside the seat heater switch.

Is lit The seat heater is operated.

Not lit The seat heater is stopped.

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OPERATION

OPERATION

3

STARTING AND TRAVEL STARTING

CAUTION ･ Start the lift truck only after sitting down in the operator's seat. ･ Before starting the lift truck, set the directional lever to neutral position, and pull the parking brake lever in the direction to the rear of the lift truck. (Parking brake activated) ･ If you half rise from the seat or if you are not seated properly while traveling uphill, the system cuts off the power and the lift truck may slither down, which can result in an accident such as a crash. Maintain the correct posture while traveling uphill.

1. Pull the parking brake lever to the rear direction of the lift truck.

(Parking brake activated)

Free

Lock

2. Set the directional lever to neutral position.

3. Depress the brake pedal.

REMARK The neutral start function operates if the starting switch is turned to "|" (ON) position when the directional lever is in other than neutral position. For the neutral start function, see "INSPECTION AND MAINTENANCE CHECKING OF NEUTRAL START FUNCTION (4-21 page)".

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OPERATION

OPERATION

4. Turn the starting switch to " | " (ON) position and release it.

Check that the monitor displays.

IMPORTANT Inspection is required if a warning lamp or a indicator lamp does not work. Ask your Komatsu distributor for inspection.

5. Check that system operating lamp (1) at the lower right of the seat is ON.

6. Raise the forks so that the height (A) is 15 to 20 cm from the ground and tilt the mast backward.

7. Set the directional lever to Forward position (F) or Reverse position (R).

8. Keep pressing down the button on tip of the parking brake lever (2), and return the parking brake lever (2) toward the front of the forklift truck to set it to Free position. (Parking brake released)

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Free

Lock

OPERATION

OPERATION

9. Release the brake pedal.

10. Slowly depress the accelerator pedal. The lift truck starts to forward or reverse direction depending on the position of the directional lever.

REMARK ･ Unless starting switch is set to " | " (ON) position under the following conditions, the lift truck does not travel even if accelerator pedal is depressed.

Directional lever: Neutral position Accelerator pedal: Released For the neutral start function, see "INSPECTION AND M A I N T E N A N C E C H E C K I N G O F N E U T R A L S TA RT FUNCTION (4-21 page)". ･ Unless seated in right posture, the lift truck will not travel because of activation of travel interlock function. For the travel interlock, see "OPERATION TRAVEL INTERLOCK FUNCTION (3-63 page)". ･ If truck is traveling with parking brake on, protective function is activated to suppress acceleration performance to prevent wear or failure of brake. If abnormal acceleration performance is detected, stop the truck and allow the brake and motor temperature to cool down sufficiently.

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OPERATION

OPERATION

TRAVELING Increasing or decreasing the depressing amount of acceleration pedal accelerates or decelerates the truck speed of travel. Put your left foot on the floor while traveling.

IMPORTANT Do not keep your foot on the brake pedal while traveling.

Otherwise, wear or failure may occur due to the overheating of brake and motor. If the operator is accustomed to operating the engine-driven torque converter forklift truck or a forklift truck with 2-brake pedal device (if equipped), be careful not to depress the brake habitually with the left foot.

DIRECTIONAL SELECTION 1. Release the accelerator pedal and depress the brake pedal until the lift truck comes to full stop.

2. Switch the directional lever from Forward position (F) to Reverse position (R) or from Reverse position (R) to Forward position (F).

3. Check the direction of travel for safety, release the foot from the brake pedal, and slowly depress the accelerator pedal.

The lift truck starts in the direction selected with the directional lever.

REMARK For more details on forward/reverse selection by plugging operation, see "OPERATION PLUGGING (ELECTRIC BRAKE) (3-59 page)".

STARTING AND STOPPING ON SLOPE 1. When starting the lift truck on a slope, pull the parking brake lever toward the rear of the lift truck up to Lock position. (Parking brake activated) 2. Depress accelerator pedal (1) gradually. When the lift truck starts moving uphill, return the parking brake lever slowly toward the front of the lift truck. (Parking brake released)

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Free

Lock

OPERATION

OPERATION

3. When the lift truck starts moving uphill, release the parking brake lever toward the front of the lift truck up to Free position.

(Parking brake released) Climbing speed can be controlled by the amount of accelerator pedal (1) depressed.

4. When slowing down and stopping the lift truck on a slope, release accelerator pedal (1) gradually and depress brake pedal (2) just before the lift truck stops.

5. After the lift truck stops, be sure to pull the parking brake lever toward the rear of the lift truck up to Lock position. (Parking brake activated)

INCHING TRAVEL ･ Normally carry on inching travel by controlling the depressing effort of accelerator pedal. ･ If obliged to do so because of operating site, loading and lift method and other conditions, depress the brake and accelerator pedals at the same time for inching travel.

IMPORTANT When the brake pedal and accelerator pedal are simultaneously operated (for excessively long duration or in repetition), protective function is activated to suppress acceleration performance to prevent the wear and/or failure of the brake. If abnormal acceleration performance is detected, stop the truck and allow the brake and motor temperature to cool down sufficiently.

REMARK ･ Setting the travel power for the lift truck to "L" level enables smooth take-off and inching travel with ease.

For how to adjust the travel power, see "OPERATION Travel Power Mode Set (3-23 page)". ･ When operating accelerator and brake pedals simultaneously, minimize the depressing effort on the accelerator pedal as much as possible to realize smooth inching travel. ･ Adjusting travel speed while releasing the brake pedal with the accelerator pedal fully depressed often activates overheat preventive function, making the operating time shorter.

PLUGGING (ELECTRIC BRAKE)

CAUTION ･ Plugging enables to change the travel direction of the lift truck by merely operating the directional lever without stopping the lift truck with the brake pedal operation. While performing plugging operation, collision and other critical accidents may occur if the operator fails to check safety in the surrounding areas or fails to fully understand the electric brake performance. ･ Perform plugging operation safely by deciding whether to do it according to the conditions of the operating site. ･ Loaded truck requires longer braking distance. Apply brake earlier with spare time when traveling loaded.

If you set the directional lever to the opposite to the current travel direction, the electric brake is applied to decelerate the truck. If accelerator pedal remains depressed, the truck stops once and then travels in reverse direction. Adjustment of plugging brake (electric brake) force can be adjusted by the depressing amount of the accelerator pedal.

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OPERATION

OPERATION

TURNING

CAUTION Take care that the outside of the counterweight does not hit people or objects around when the lift truck turns.

The lift truck 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 tires. ･ Wear will be less if steered while running at low speed.

OPERATION ON SNOWY AND FROZEN ROADS

CAUTION ･ Be aware that even tire chains or snow tires cannot prevent skidding completely. ･ Tire chains or snow tires may not fit on some model. ･ Use tire chains or snow tires when traveling on snowy or frozen roads. ･ Avoid sudden braking, acceleration, or steering on snowy or frozen roads. Be cautious of accelerator pedal operation as it is dangerous and may cause skidding.

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OPERATION

OPERATION

TEMPORARY STOPPING, PARKING AND STOPPING

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

TEMPORARY STOPPING 1. Release accelerator pedal (1), and fully depress brake pedal (2).

2. After the lift truck stops, pull the parking brake lever toward the rear of the lift truck up to Lock position. (Parking brake activated)

REMARK If the operator stands up or half rises from the seat while the parking brake lever is in Free position, the parking brake warning function activates, and the parking brake warning function sounds the alarm buzzer.

Free

Lock

3. Set the directional lever to the neutral position (N).

REMARK The alarm buzzer sounds for approximately 1 second when the operator stand up or half rise from the seat while the directional lever is at FORWARD or REVERSE position.

The alarm buzzer stops sounding in 1 second. The alarm buzzer sounds and the travel interlock is actuated when the operator stand up or half rise from the seat for 3 seconds or longer.

Sit on the seat correctly again, and set the directional lever to NEUTRAL position.

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OPERATION

OPERATION

PARKING 1. Stop the lift truck on a level ground.

2. Pull the parking brake lever toward the rear of the lift truck up to Lock position. (Parking brake activated) 3. Set the directional lever to neutral position.

4. Tilt the mast forward and lower the forks to the ground.

REMARK If you leave the lift truck without pulling the parking brake lever in the direction to the rear of the lift truck (with the lever in a position other than Lock), an alarm buzzer will sound.

STOPPING 1. Turn the starting switch to "Q" (OFF) position.

2. Pull out the starting switch key and leave the lift truck.

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Free

Lock

OPERATION

TRAVEL INTERLOCK FUNCTION

OPERATION

3

The travel interlock is a safety device that operates when the operator is seated in such a posture that his/her weight is not fully applied to the seat, like standing up or half rising from the seat.

If you keep such posture, the travel interlock activates in approx.

3 seconds and cuts off the driving force. Then the lift truck does not move any more even if you depress the accelerator pedal or operate the directional lever.

While the travel interlock is activated, the travel interlock lamp on the monitor panel light up.

RELEASING TRAVEL INTERLOCK FUNCTION When you seat yourself properly and return the directional lever to neutral position, the lift truck returns to traveling condition.

Restart traveling operation after checking the safety in the surrounding areas.

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OPERATION

OPERATION

LOAD HANDLING OPERATION

CAUTION Take extreme care not to get your hands or fingers caught while adjusting the space between forks.

FORK SPREAD ADJUSTMENT IMPORTANT ･ If forks are not secured, there is the danger that the forks freely move sideways to let the load fall, while the forklift truck is traveling. ･ If fork stopper has not been completely engaged, the forks may fall off.

Before carrying out load handling, always adjust the space between the forks to fit the size of the pallets and loads.

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

2. Position the mast vertically and raise forks at the height (A) of 10 cm (4 in) above the ground.

3. Tilt the mast forward.

4. Pull up the knob of the fork stopper, turn it by 90 deg. to Free position. (In this condition, you can move the forks to the right and left.)

5. Adjust the fork spread corresponding to the load size so that the load center of gravity coincides with the center of the lift truck.

6. Set the mast vertical, turn the fork stopper 90 deg., and lower the knob to the Lock position. (In this condition, the forks are locked in position.)

7. After fork spread adjustment, check that the forks are secured with the fork stopper.

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Free

Lock

OPERATION

OPERATION

If forks are not secured, there is the danger that the forks freely move sideways to let the load fall, while the lift truck is traveling.

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OPERATION

OPERATION

HOW TO OPERATE CONTROL LEVERS

CAUTION Sit in the operator's seat properly and check that the surrounding area is safe before operating the 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 personal injury or death.

LIFT LEVER RAISE: Pull the lever backward LOWER: Push the lever forward

Lower

REMARK ･ You can adjust the rising speed of the forks by adjusting the tilting degree of the lever and setting the lifting speed.

For the adjustment method, see "OPERATION Lift Speed Adjustment (3-27 page)". ･ You can adjust the lowering speed of the forks only by adjusting the tilting degree of the lever.

Raise

TILT LEVER TILT FORWARD: Push the lever forward TILT BACKWARD: Pull the lever backward

Tilt forward

REMARK You can adjust the speed of tilting the forks forward and backward by adjusting the tilting degree of the lever and setting the tilting speed.

For the adjusting method, see "OPERATION Tilt Speed Adjustment (3-27 page)".

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Tilt backward

OPERATION

OPERATION

LOAD HANDLING INTERLOCK If you operate the lift truck in such a posture that your weight is not fully applied to the seat, like standing up or half rising from the seat, the load handling interlock is activated in approx. 3 seconds. Then each motion of the fork and mast is locked and none of them moves any more even if you operate the lift lever or the tilt lever.

While load handling interlock is in operation, the load handling interlock indication on the monitor panel light up. (See the figure at right.)

REMARK If the operator stands up or half rises from the seat while the parking brake lever is in Free position, the parking brake warning function activates, and the parking brake warning function sounds the alarm buzzer.

RELEASING LOAD HANDLING INTERLOCK FUNCTION When you seat yourself properly on the operator's seat, the lift truck is ready for load handling operation again. Restart lift operation after checking the safety in the surrounding areas.

REMARK When you operate the lift lever while the starting switch is at "Q" (OFF) position, the forks do not lower. However, if you sit in the seat correctly and turn the starting switch to " l " (ON) position, you can lower the forks. When the forks are stopped by the auto power-off function, they do not lower even if the starting switch is at " l " (ON) position.

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OPERATION

OPERATION

PICKING UP 1. Approach to the load and stop, and then set the mast vertically.

2. Set the lift truck straight toward the load, and drivel the lift truck forward until the fork is inserted into a pallet by 2/3 to 3/4 of the fork length and lift the load by 5 to 10 cm.

3. Then drive the lift truck in reverse by 10 to 20 cm, lower the load once and then drive the lift truck forward once again until the fork is inserted up to the bottom.

4. Raise the load 5 to 10 cm and drive the lift truck in reverse to a position where the load can be lowered.

5 to 10cm

5. Lower the load to the height of 15 to 20 cm above the ground and tilt the mast back.

15 to 20cm

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OPERATION

OPERATION

STACKING 1. Stand the mast vertically and lift forks 5 to 10 cm past the stacking position. Drive the lift truck forward slowly.

2. Lower the load to the desired place.

3. Pull out the fork by 10 to 20 cm from pallet by driving in reverse, and lift up the load for 5 to 10 cm (2 to 4 in) again. After driving forward to the correct loading position, unload and then drive in reverse slowly until the fork is completely pulled out.

10 to 20cm

5 to 10cm

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OPERATION

CHECKING AFTER OPERATION After all the above procedures have been finished and each part of the lift truck is cleaned, and before it is stored, carry out the inspections on the lift truck.

For details of inspection, see "INSPECTION AND MAINTENANCE CHECKING AND REPORTING AFTER OPERATION (426 page)".

For washing of the lift truck, procedure during cold weather, longterm storage, and loading and unloading of lift truck, see the followings: ･ For washing the lift truck, see "INSPECTION AND MAINTENANCE RUNNING IN COLD WEATHER (4-55 page)". ･ For the procedure during cold weather, see "INSPECTION AND MAINTENANCE RUNNING IN COLD WEATHER (4-55 page)". ･ For the long-term storage, see "INSPECTION AND MAINTENANCE LONG-TERM STORAGE (4-55 page)". ･ For the loading and unloading of lift truck, see "INSPECTION AND MAINTENANCE LOADING AND UNLOADING OF LIFT TRUCK (4-65 page)".

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OPERATION

OPERATION

OPERATION

KOMTRAX

3

(lift truck with KOMTRAX)

WARNING ･ Never disassemble, repair, modify, or move the wireless communication terminal, antenna, or cables.

This may cause failure or fire on the wireless equipment or the forklift truck itself. ･ Near the blasting jobsite, there is a danger of unexpected explosion due to use of the wireless equipment and resulting serious personal injury or death.

If you have to operate the forklift truck within 12 m from the remote-controlled blasting device, the power supply cable of the wireless communication device must be disconnected in advance.

KOMTRAX is a vehicle management system that remotely manages the forklift trucks equipped with the KOMTRAX device by using satellite communication or portable radio communication.

The GPS (Global Positioning System) receiver, and communication system are equipped in the vehicle management system.

The forklift truck information such as the forklift truck maintenance, maintenance management, operating situation management, and forklift truck location management is gathered from the inside network of the forklift truck.

It can be useful for you to perform the vehicle management by yourself. Your Komatsu distributor uses the above forklift truck information for supply of service to the customers, improvement of our products and service, etc.

The type of information which is sent from the forklift truck may vary depending on the forklift truck. For the radio station establishment of KOMTRAX, consult your Komatsu distributor.

POWER SUPPLY FOR KOMTRAX ･ Even when the key in the starting switch is at "Q" (OFF) position., a small amount of electric power is consumed by the KOMTRAX system.

For the long-term storage, see "INSPECTION AND MAINTENANCE LONG-TERM STORAGE (4-55 page)". ･ If the power supply cable of KOMTRAX system device has to be disconnected, contact your Komatsu distributor.

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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 personal injury or death.

4-1

INSPECTION AND MAINTENANCE

INSPECTION AND MAINTENANCE

INSPECTION AND MAINTENANCE INSPECTION AND MAINTENANCE The inspection and maintenance explained in this MAINTENANCE section is only simple works such as "checks before starting" works that the operator is obliged to perform before starting the work and the accompanying works like oil refilling or cleaning, etc. For other inspection and maintenance items not described here, contact Komatsu distributor.

For your safe inspection and maintenance work, "OPERATION PRECAUTIONS FOR INSPECTION AND MAINTENANCE (2-38 page)" carefully read and then carry out inspection and maintenance, observing the given precautions.

Incorrect maintenance and repair service may cause critical accident or shorten lift truck service life. Contact Komatsu distributor for maintenance and repair services.

START-UP INSPECTION 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.

OBLIGATION TO CONDUCT START-UP INSPECTION ･ Be sure to perform the inspection before starting the operation in order to work in safe. ･ Record and store the results of start-up inspection in the inspection record.

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INSPECTION AND MAINTENANCE

START-UP INSPECTION

LIST OF START-UP CHECK POINTS Testing method –

Check points Checking of repaired abnormalities detected on previous day Leakage of oil and battery electrolyte Cracks, damages and the state of mounting (of overhead guard, fork, load backrest, etc.)

Inspection of lift truck posture Looseness of tilt cylinder rod and locknut Walk around the lift truck Contamination and/or damages of lamp, lens, etc.

Looseness of hub nuts and bolts Deformation of tire and rim Tire inflation pressure Fitting of battery plug and chassis side plug State of crack, damage and installation Brake fluid quantity Opening covers and Checking of oil level in hydraulic tank hoods Battery electrolyte level Checking of electric wiring Damages and performance of seat belt Seat and steering wheel adjustment Brake pedal play and height Sitting on the operator's Parking brake lever operating effort seat Horn performance Center mirror dirt, damages and angle Checking the side view mirror (if equipped) Checking of monitor panel warning lamps, indicator lamps, and buzzer Lighting of system operating lamp Operation of directional lever and backup buzzer Turning starting switch to ON position Bbattery charge level ON/OFF of lamps and alarm buzzers Play of steering wheel Operation of steering wheel (runout, unstable driving, and operation state) Operation of brake (depressing allowance, response) Parking brake response Travel slowly Checking of low speed, acceleration, abnormal sound of motor, normal operation Checking of unusual noise and smell Checking of operation of mast, unusual noise, smell Checking of unusual noise and normal rotation of load handling pump motor Operating work equipment Tension of lift chain control lever Checking of lift chain Checking of attachment function and unusual noise and smell Travel interlock function Load handling interlock function Checking of safety function Neutral start function Alarm buzzer function for overlooking of pulling the parking brake Checking seat belt interlock function Checking of safety auxiliary function(forklift truck with Check the travel limit speed at high lift function (Check of operation of the lifting seat belt interlock) height detection sensor) Checking of lift truck with Checking of window washer fluid level, adding of fluid front glass specification Checking of window washer injection state (only lift truck with front Checking of wiping state of windshield wiper glass specification)

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START-UP INSPECTION

INSPECTION AND MAINTENANCE

CHECKING ABNORMALITIES DETECTED ON THE PREVIOUS DAY

4

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

WALK AROUND A FORKLIFT CHECKING FOR LEAKAGE OF OR AND BATTERY ELECTROLYTE ･ Walk around the lift truck to inspect it. ･ Look under the lift truck to check that there is no oil or battery electrolyte leakage.

CHECKING FOR CRACKS, DAMAGES AND THE STATE OF MOUNTING Visually check for any damages, cracks, loose mounting and/or play.

Give priority in checking the following points particularly: ･ Overhead guard ･ Fork ･ Load backrest ･ Fork carriage ･ Mast ･ Chain ･ Hydraulic tank

INSPECTION OF LIFT TRUCK POSTURE Visually inspect whether the lift truck largely leans in longitudinal or lateral direction.

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4

INSPECTION AND MAINTENANCE

START-UP INSPECTION

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

CHECKING FOR CONTAMINATION AND DAMAGES OF LAMP, LENDS, ETC. Visually check for any contamination and damages of lamp, lens, etc.

CHECKING FOR LOOSE HUB NUTS Check for loose hub nuts by tightening them with a wrench.

IMPORTANT Tighten the hub nuts to the specified torque.

For the tightening torque, see "INSPECTION AND MAINTENANCE SERVICE DATA (4-75 page)".

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INSPECTION AND MAINTENANCE

START-UP INSPECTION

CHECKING OF TIRES AND RIMS ･ Visually check for any excessive wear, damages, spikes and other foreign matters stuck to the tires, deformation and damages of the rims, damage and rubber abrasion powder of jointed portion between tire and rim. ･ Replace a tire if the tread depth becomes under 5 mm or if the slip sign (wear limit mark) should appear.

CHECKING OF INFLATION PRESSURE OF TIRES

CAUTION Tires have high pressure air inside. When checking the inflation pressure, position yourself to face the tire tread surface (see the figure at right) while holding the tire air gauge firmly.

Check the tire inflation pressure with the tire air gauge and adjust it to specified pressure. For the tire inflation pressure, see "INSPECTION AND MAINTENANCE SERVICE DATA (4-75 page)".

FITTING OF BATTERY PLUG AND CHASSIS SIDE PLUG Check buttery plug (1), chassis side plug and cable for damage.

Check also fitting portion of the plugs for loosening and/or play. If any abnormality is detected, do not use the lift truck until repair service is completed.

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INSPECTION AND MAINTENANCE

START-UP INSPECTION

CHECKS CONDUCTED BY OPENING COVER AND HOOD

4

HOW TO REMOVE FLOOR PLATE

CAUTION ･ Before removing the floor plate, always turn the starting switch to "Q" (OFF) position. ･ When removing or installing the floor plate, be careful not to get your hand caught.

1. Remove floor plate (1).

2. Disconnect connector (2).

3. Raise the front portion of floor plate (3) from (A) to (B) and move it backward to remove.

CHECKING FOR CRACKS, DAMAGES AND THE STATE OF MOUNTING Vi s u a l l y i n s p e c t w h e t h e r t h e r e a r e n o c r a c k , d a m a g e , deformation, or installation looseness on hydraulic piping, etc.

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INSPECTION AND MAINTENANCE

START-UP INSPECTION

CHECKING OF BRAKE FLUID LEVEL

CAUTION Using wrong brake fluid causes leakage to disable braking function. Always use specified brake fluid (non-mineral oil brake fluid for vehicles).

1. Open up the cover at top left of the dashboard panel, and brake reservoir tank (1) is seen.

2. Check that the fluid level is in the proper range of 12 mm above the bottom of the cap. If the brake fluid level is low, remove the cap and add brake fluid up to the upper limit of the proper range.

IMPORTANT When adding brake fluid, be careful not to allow sands and dirt to enter the brake fluid reservoir tank.

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MA MI

12mm

INSPECTION AND MAINTENANCE

START-UP INSPECTION

CHECKING OF OIL LEVEL IN HYDRAULIC TANK Check if hydraulic oil is filled to the specified level.

1. Set the forks horizontally on the level ground and lower it to the ground.

2. Roll up the rear of floor mat and remove the rear portion of floor plate (2).

3. Pull out integrated cap and oil gauge (1) from oil filler port (3).

Wipe off attached hydraulic oil with a clean cloth and insert it to oil filler port (3).

4. Pull out oil gauge (1) again and check that the stuck oil is within the normal range.

5. When hydraulic oil is in short, refill it to the normal range.

IMPORTANT Always use Komatsu genuine hydraulic oil.

For the type of hydraulic oil, see "INSPECTION AND MAINTENANCE LUBRICANT LIST (4-32 page)".

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INSPECTION AND MAINTENANCE

START-UP INSPECTION

CHECKING OF BATTERY ELECTROLYTE LEVEL

4

CAUTION ･ Battery electrolyte is dangerous object.

If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor. ･ Battery generates the flammable gas. Do not bring any open flame close, otherwise it may explode. ･ Always wear protective eyeglasses, rubber gloves and rubber sole shoes when servicing or inspecting the batteries. ･ Do not operate the monitor panel with a hand wet with the battery electrolyte. The surface sheet of the monitor panel will be deteriorated. ･ Do not use a dry wipe to clean the battery. Use a wet wipe to prevent fire or explosion from.

1. Remove fixing catches (1) of the right and left side covers and open the battery hood toward the front of the lift truck.

2. Remove fixing bar (2) on the reverse side of the hood and hook it to the hole on the right side of the battery to fix the hood.

3. Check the battery electrolyte level by the float in the battery cap.

4. Add distilled water or refined (pure) water before the float (red) reaches the lower limit level.

When the stopper of the float comes in contact with the cap (when clearance "a" in the figure at right becomes 0), the electrolyte is at the lower limit level.

Stopper

Cap Float (Red)

IMPORTANT The shape of the cap is different from a battery manufacturer to another.

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INSPECTION AND MAINTENANCE ･ How to add water Open the battery cap and always add distilled water or refined (pure) water.

If the white line of the float is seen, stop adding water immediately.

START-UP INSPECTION

Lid

IMPORTANT If you continue adding water after the white line is seen, the electrolyte spills. Accordingly, be sure to stop adding water.

[Refiliing water] White line [Refilling water ended]

5. Remove fixing bar (2) from the hole on the right side of the battery, fix it to the holder on the back side of the hood, and close the hood.

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INSPECTION AND MAINTENANCE

START-UP INSPECTION

CHECKING OF ELECTRIC WIRING

4

CAUTION ･ If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly ask your Komatsu distributor to locate the cause and make the repair. ･ Keep the battery top surface clean.

Check for damage and wrong capacity of the fuse and any sign of open or short circuit in the electric wiring.

Check also for loose terminals and tighten any loose parts.

In particular, check the wiring of the "battery", etc.

Be sure to check that there is no inflammable material accumulated around the battery. If any is found, remove immediately.

Contact your Komatsu distributor for investigation and correction of any problems found.

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INSPECTION AND MAINTENANCE

START-UP INSPECTION

CHECKING FROM THE OPERATOR'S SEAT CHECKING OF SEAT BELT Upon sitting on the operator's seat, first check the seat belt. ･ Any damages to the seat belt and/or fittings? ･ Does the seat belt come out and retract smoothly? Does the fitting lock and unlock without abnormality? ･ Does the seat belt lock when pulled suddenly?

CHECKING OF THE SEAT AND STEERING WHEEL POSITION Upon sitting on the operator's seat, check if the pedals, levers and switches can be operated smoothly. For the position of the seat and steering wheel, see "OPERATION HOW TO ADJUST SEAT POSITION (3-47 page)" and "OPERATION ADJUSTING STEERING WHEEL TILT ANGLE (3-53 page)".

CHECKING OF THE BRAKE PEDAL Check the brake pedal for correct application effort, play and for correct dimensions of the pedal height. For the standard values of the play (S1) and pedal height dimensions during braking effort (H), see "INSPECTION AND MAINTENANCE SERVICE DATA (4-75 page)".

CHECKING THE PARKING BRAKE LEVER

CAUTION If parking brake lever operating effort is below the reference value, necessary braking force to meet legal requirements is not available, which may cause serious accidents. Always adjust the braking force up to the reference value.

1. Block the front and rear tires with chocks.

2. Check the operating effort when the parking brake lever is pulled to the rear stroke end of the lift truck (locking position).

Install the push-pull gauge to the center of grip of parking brake lever and measure the operating effort by pulling the parking brake lever to Lock position while holding the pushpull gauge.

For the standard value of the parking brake lever operating effort,see "INSPECTION AND MAINTENANCE SERVICE DATA (4-75 page)".

Free

Lock

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START-UP INSPECTION

3. If the operating effort is below the reference value, adjust it.

For how to adjust the travel power, see "INSPECTION AND MAINTENANCE ADJUSTING PARKING BRAKE LEVER OPERATING EFFORT (4-35 page)".

4. Check if the lever can be pulled fully to the end without resistance and that it returns smoothly.

IMPORTANT If any abnormality is detected, contact your Komatsu distributor for checking.

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

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

CHECKING THE SIDE VIEW MIRROR (IF EQUIPPED) Check if the side view mirror is set at an easy angle for the operator to see the rear. Also check for any dirt or damage.

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INSPECTION AND MAINTENANCE

INSPECTION AND MAINTENANCE

START-UP INSPECTION

CHECKING BY SETTING THE STARTING SWITCH TO [ | ] (ON) POSITION CHECKING OF MONITOR WARNING LAMPS, INDICATOR LAMPS, AND BUZZER 1. Set the directional lever to neutral position.

2. Turn the starting switch to " | " (ON) position, and check that the monitor lights up and the buzzer sounds for 1.0 second.

3. Turn the starting switch to "Q" (OFF) position, and check that the monitor panel lights and it goes off.

4. Turn the starting switch to " | " (ON) position again.

5. Set the directional lever to forward position or reverse position.

If the directional indicator displays " I " or " O ", it is normal.

Also check that backup buzzer sounds when the directional lever is set to reverse position.

REMARK ･ Apply parking brake by pulling the lever to the rear direction of the lift truck to check it. ･ Load handling interlock warning lamp will light up if the operator fails to sit on the seat correctly. For the load handling interlock, see "OPERATION LOAD HANDLING INTERLOCK (3-67 page)".

IMPORTANT Inspection is required if a warning lamp or a indicator lamp does not work. Ask your Komatsu distributor for inspection.

6. Check that system operating lamp (1) on the side of the right step is lit when the starting switch is turned to " | " (ON) position.

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START-UP INSPECTION

CHECKING OPERATION OF LAMPS Inspection of lighting up 1. Turn the starting switch to " | " (ON) position.

(1)position: OFF (2)position: ON

2. Rotate the headlamp switch of combination switch and check function of the lamps at (A), (B), and (C) positions.

Position (A): OFF Position (B): Lighting up of tail lamp, monitor panel, and clearance lamp Position (C): In addition to (B), lighting up of headlamp

3. Pull the directional lever toward the rear of the lift truck and set it to the reverse position (R) and check whether the backup lamp at the rear of the lift truck lights up.

Check also whether the backup buzzer sounds.

(F) position: Forward travel (N) position: Neutral (R) position: Reverse travel

4. Depress the brake pedal and check whether the brake lamp at the rear of the lift truck lights up.

Inspection of flashing 1. Turn the starting switch to " | " (ON) position.

2. Operate the turn signal lamp switch of combination switch forward/backward and check ON/OFF of the lamp at (L) and (R) positions.

(L) position: Left-hand turn signal lamp (front and rear of the lift truck) flashes.

(N) position: Neutral and OFF (R) position: Right-hand turn signal lamp (front and rear of the lift truck) flashes.

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INSPECTION AND MAINTENANCE

INSPECTION AND MAINTENANCE

START-UP INSPECTION

CHECKING WHILE TRAVELING SLOWLY CHECKING THE STEERING WHEEL FOR PLAY ･ Check the play of steering handle by operating it in the direction of a turn. Play should be normal if it is within 10 to 30 mm. ･ Check if it is free of looseness by shaking it in the vertical and 10 to 30mm longitudinal directions.

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

CHECKING THE BRAKE FUNCTION Check the brake response by stepping on the brake pedal while traveling slowly. ･ The brakes are operating effectively. ･ Both brakes are responding, (not just one side).

CHECKING THE PARKING BRAKE RESPONSE Pull the parking brake lever toward the rear of the lift truck while traveling slowly, and then check the following operations. ･ Check whether the lift truck can stop. ･ Check whether the lift truck can maintain the stop position.

CHECKING THE MOTOR DURING LOW SPEED ROTATION AND ACCELERATION During the normal travel, check that the motor does not hunt or stop suddenly.

Check that the lift truck accelerates smoothly when the accelerator pedal is depressed. ･ Conduct the checking in a safe place by paying attention to the surrounding area. ･ When the motor performs very badly at low speed and in the acceleration and if that condition continues, it may damage the motor or confuse the operator's sense of driving, and as a result lead to an unexpected accident. In that case, ask your Komatsu distributor to check the engine as soon as possible.

CHECKING OF UNUSUAL NOISE AND SMELL Check that no unusual noise or smell is emitted while traveling slowly.

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START-UP INSPECTION

INSPECTION AND MAINTENANCE

CHECKING BY OPERATING THE WORK EQUIPMENT CONTROL LEVER CHECKING OF OPERATING STATE, UNUSUAL NOISE AND SMELL OF THE WORK EQUIPMENT ･ Check that the forks lift and lower smoothly and the mast tilts forward and backward smoothly during operation of the work equipment control levers from the operator's seat. Always make full stroke operation of cylinder piston 2 to 3 times everyday before starting work. ･ Check that no unusual noise or smell is emitted while operating the work equipment control levers.

CHECKING THE MOTOR DURING LOW SPEED ROTATION AND ACCELERATION Check that the motor does not hunt or stop suddenly when the levers are operated.

Check that the motor accelerates smoothly. ･ Conduct the checking in a safe place by paying attention to the surrounding area. ･ When the motor performs very badly at low speed and in the acceleration and if that condition continues, it may damage the motor or confuse the operator's sense of driving, and as a result lead to an unexpected accident. In that case, ask your Komatsu distributor to check the engine as soon as possible.

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INSPECTION AND MAINTENANCE

START-UP INSPECTION

CHECKING OF TENSION OF LIFT CHAIN

CAUTION ･ If the chain tension is asymmetrical to the left and right, load would concentrate on the chain of one side to cause it to break, leading to the falling of material and the tipping over of lift truck. ･ To prevent the lift truck from traveling uncontrolled and personnel from being caught by the truck, set the directional lever to NEUTRAL position, pull the parking brake lever toward the rear of the truck, turn the starting switch to "Q" (OFF) position, get off the lift truck, and chock the tires before starting check. ･ Never step the foot under the fork (B) as it may get caught.

1. Raise the fork 5 to 10 cm (2 to 4 in) above from the ground.

(Part A) 2. Press the center of lift chain with a finger and check if the tension is equal to the right and left.

CHECKING OF LIFT CHAIN

CAUTION ･ If the lift chain break, the load may fall down or the lift truck may tip over. When lift chain is found abnormal with damages and cracks, contact your Komatsu 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 lubrication condition of lift chain. If it is in poor condition or rust has generated on the lift chain, apply engine oil, etc. on it.

CHECKING OF ATTAHMENT FUNCTION AND ABNORMAL NOISE AND ODOR (In case of the lift truck with attachment) Check the attachment according to its operating manual.

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INSPECTION AND MAINTENANCE

START-UP INSPECTION

CHECKING OF SAFETY FUNCTION

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 THE TRAVEL INTERLOCK FUNCTION Check the safety function that the travel interlock operates when the operator is away from the seat.

CHECKING PROCEDURE 1. Park the lift truck on a level and flat place and pull the parking brake lever toward the rear of the truck. (Parking brake activated) 2. Set the directional lever to neutral position, and lower the work equipment to the ground.

3. Step the foot off the brake pedal and accelerator pedal.

4. Set the directional lever to forward position, or reverse position and lift the hip from the seat.

5. Check that the travel interlock indication on the monitor panel lights up approximately 3 seconds later.

6. In this state, keep pressing down the button on tip of the parking brake lever, and return the parking brake lever toward the front of the forklift truck (to release the parking brake).

The parking brake warning function sounds the alarm buzzer.

7. Depress the accelerator pedal while half rising from the seat, and check that the lift truck does not travel.

8. Resetting travel interlock function Sit on the seat correctly and set the directional lever to neutral position. The lit travel interlock indication goes out and the forklift truck returns to normal operating conditions.

CHECKING THE LOAD HANDLING INTERLOCK FUNCTION Check the safety function that the lift interlock operates when the operator is away from the seat.

CHECKING PROCEDURE 1. Park the lift truck on a level and flat place and pull the parking brake lever toward the rear of the truck. (Parking brake activated) 2. Set the directional lever to the neutral position, and raise the fork to a position approximately 15 cm 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 load handling interlock indication on the monitor panel lights up approximately 1 second later.

5. Check the following in this state: ･The forks do not rise or lower even if the lift lever is operated. ･The mast does not tilt forward or backward even if the tilt lever is operated.

6. Resetting load handling interlock function.

Take a right posture in the operator's seat. The lit load handling indication goes out and the forklift truck returns to normal operating conditions.

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INSPECTION AND MAINTENANCE

START-UP INSPECTION

CHECKING OF NEUTRAL START FUNCTION This function prevents the forklift truck from starting traveling or operating the work equipment suddenly if the starting switch is turned to "|" (ON) position.

Check that the travel interlock and lift interlock operate if the starting switch key is turned to "|" (ON) position except in NEUTRAL. CHECKING PROCEDURE (Travel) 1. Park the lift truck on a level and flat place and pull the parking brake lever toward the rear of the truck. (Parking brake activated) 2. Set the directional lever to neutral position and turn the starting switch to "Q" (OFF) position.

3. Check that the alarm buzzer sounds when operating the directional lever to forward or reverse position and turning the starting switch to "|" (ON) position.

At the same time, check that the forklift truck does not travel even if the accelerator pedal is depressed.

4. Releasing the neutral start function.

Set the directional lever to neutral position, and the lift truck is restored to the normal state.

CHECKING PROCEDURE (Load handling) 1. Park the lift truck on a level and flat place and pull the parking brake lever toward the rear of the truck. (Parking brake activated) 2. Set the directional lever to neutral position and turn the starting switch to "Q" (OFF) position.

3. The neutral start function operates if the starting switch is turned to "|" (ON) position when the directional lever is in other than neutral position. (Work equipment does not operate) 4. Releasing neutral start function Set the work equipment control lever to neutral position, and the lift truck is restored to the normal state.

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START-UP INSPECTION

INSPECTION AND MAINTENANCE

CHECKING THE WARNING FUNCTION AGAINST OVERLOOKING APPLICATION OF PARKING BRAKE LEVER Check the parking brake warning function that sounds the alarm buzzer when the operator has left the operator's seat when the parking brake lever is in Free position or when the starting switch is turned to "Q" (OFF) position.

CHECKING PROCEDURE 1 1. Park the lift truck on a level and flat place and pull the parking brake lever toward the rear of the truck. (Parking brake activated) 2. Set the directional lever to neutral position.

3. Lower the forks to the ground. Tilt the mast forward until the forks are in contact to the ground.

4. Turn the starting switch to "|" (ON) position and move the directional lever to neutral position. Then move the parking brake lever to Free position while pressing down the button on tip of the parking brake lever, and leave the operator's seat.

5. The alarm buzzer sounds after approximately 3 seconds.

6. Releasing the warning function Pull the parking brake lever to the rear direction of the forklift truck. The alarm buzzer stops sounding and the system returns to normal state.

CHECKING PROCEDURE 2 1. Park the lift truck on a level and flat place and pull the parking brake lever toward the rear of the truck. (Parking brake activated) 2. Set the directional lever to neutral position.

3. Lower the forks to the ground. Tilt the mast forward until the forks are in contact to the ground.

4. Turn the starting switch to "Q" (OFF) position and pull out the starting switch key. Then return the parking brake lever toward the front of the forklift truck while pressing down the button on tip of the parking brake lever. (Parking brake released) 5. Check that the alarm buzzer sounds immediately.

6. Releasing the warning function Pull the parking brake lever to the rear direction of the forklift truck. The alarm buzzer stops sounding and the system returns to normal state.

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INSPECTION AND MAINTENANCE

START-UP INSPECTION

CHECKING OF SAFETY AUXILIARY FUNCTION (forklift truck with seat belt interlock)

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 SEAT BELT INTERLOCK FUNCTION Check the safety auxiliary function that the travel interlock and lift interlock operate when the operator does not wear the seat belt.

Check the safety around the lift truck and check the seat belt interlock function according to the following procedure.

1. Park the forklift truck on a level and flat place.

2. Set the parking brake lever to LOCK position.

The parking brake is applied.

3. Set the directional lever to NEUTRAL position.

4. Release your foot from every pedal and unfasten the seat belt.

Check that the seat belt caution lamp, travel interlock display, and lift interlock display on the monitor panel light up immediately.

5. After the seat belt caution lamp, travel interlock display, and lift interlock display light up, check the following items. ･The forks do not rise or lower even if the lift lever is operated. ･The mast does not tilt forward or backward even if the tilt lever is operated. ･The forklift truck does not travel even if you depress the accelerator pedal while the directional lever is in FORWARD or REVERSE position, and the parking brake lever is in FREE position.

6. After checking the seat belt interlock function, return the forklift truck to normal operating condition according to the following procedure.

1) Sit on the seat properly and wear the seat belt.

The seat belt interlock is released.

The lift interlock is released at the same time.

2) Set the directional lever to NEUTRAL position.

The travel interlock is released and the forklift truck returns to normal operating condition.

7. Turn the starting switch to "○" (OFF) position.

8. Unfasten the seat belt and stand up from the seat.

9. Fasten the seat belt only and sit on the seat.

10. Turn the starting switch to "|" (ON) position.

Check that the travel interlock display and lift interlock display light up, the seat belt caution lamp flashes on the monitor panel, and the alarm buzzer sounds intermittently.

11. Perform the step 5 again.

12. Unfasten the seat belt.

The failure in procedure for fastening seat belt is restored, and the display is changed to the seat belt interlock display.

Check that the flashing seat belt caution lamp becomes to stay lit and the alarm buzzer stops sounding.

13. Return the forklift truck to normal operating condition according to the procedure in step 6.

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START-UP INSPECTION

INSPECTION AND MAINTENANCE

CHECK THE TRAVEL LIMIT SPEED AT HIGH LIFT FUNCTION (Check of operation of the lifting height detection sensor) Check the actuation of the function which limits the maximum travel speed according to the height of forks.

1. Park the forklift truck on a level and flat place.

2. Set the parking brake lever to LOCK position.

The parking brake is applied.

3. Set the directional lever to NEUTRAL position.

4. Release your foot from every pedal.

5. Operate the lift lever to lift the forks up to the height which the lifting height detection sensor does not detect the detection plate.

6. Check that the travel speed is limited if you depress the accelerator pedal gradually while the directional lever is in FORWARD or REVERSE position, and the parking brake lever is in FREE position.

7. Park the forklift truck on a level and flat place.

8. Set the parking brake lever to LOCK position.

The parking brake is applied.

9. Set the directional lever to NEUTRAL position.

10. Release your foot from every pedal.

11. Operate the lift lever to make the forks at height of 15 to 20 cm above the ground.

The lifting height detection sensor detects the detection plate and the travel limit speed at high lift function will be canceled.

12. Check that the lift truck travels without limitation of travel speed if you depress the accelerator pedal gradually while the directional lever is in FORWARD or REVERSE position, and the parking brake lever is in FREE position.

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INSPECTION AND MAINTENANCE

START-UP INSPECTION

CHECKING OF LIFT TRUCK WITH FRONT GLASS SPECIFICATION (ONLY LIFT TRUCK WITH FRONT GLASS SPECIFICATION) CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID ･ Check the water level in window washer tank (1), and if it is insufficient, add the window washer fluid for automobiles. ･ When refilling, be careful not to mix dirt particle into the tank.

INSPECTION OF WINDOW WASHER INJECTION STATE ･ Operate the window washer and check whether the washer fluid is correctly injected. ･ If the injection is abnormal, clean up the washer nozzle hole using a piece of wire or safety pin. ･ If there is no improvement, contact your Komatsu distributor for checking and repairing.

INSPECTION OF WIPING STATE OF WINDSHIELD WIPER ･ Operate the windshield wiper to check each operating and wiping state. ･ Operate the window washer to wet the glass, and check the operation of the windshield wiper. ･ If the windshield wiper does not wipe normally, the glass needs to be cleaned or the wiper blade needs to be replaced. ･ If there is no improvement, contact your Komatsu distributor for checking and repairing.

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CHECKING AND REPORTING AFTER OPERATION

INSPECTION AND MAINTENANCE

CHECKING AND REPORTING AFTER OPERATION 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.

Before turning starting switch to "Q" (OFF) position 1. Check the battery charge level displayed on the monitor.

After turning starting switch to "Q" (OFF) position 1. Check leakage of oil, battery electrolyte, etc.

2. Check the work equipment and exterior parts. Check whether the undercarriage is cracked, damaged, and loosened.

3. Charge the battery.

4. Grease the parts and refill the oil as needed.

5. Remove wastepaper, etc. which can cause a fire.

6. Check the abnormal points detected during the operation.

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INSPECTION AND MAINTENANCE

PERIODICAL INSPECTION

PERIODICAL INSPECTION INSPECTION FOR EVERY 50 HOURS (1 WEEK) Add the following items to the items of START-UP INSPECTION before starting the inspection. See "INSPECTION AND MAINTENANCE INSPECTION AND MAINTENANCE SCHEDULE CHART (4-67 page)".

Contact your Komatsu distributor for other periodical inspection, maintenance, and replacement.

INSPECTING HOSE FOR ATTACHMENT ･ Check whether the hose for attachment is not cracked or damaged. ･ Check whether the hose is not removed from the fixing clamp and hose connection is not loosened. ･ Slightly move the middle of the hose to check the hose tension so that hose connection is not removed.

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INSPECTION AND MAINTENANCE

PERIODICAL INSPECTION

INSPECTION FOR EVERY 100 HOURS (2 WEEKS) Add the following items to the items of START-UP INSPECTION before starting the inspection. See "INSPECTION AND MAINTENANCE INSPECTION AND MAINTENANCE SCHEDULE CHART (4-67 page)".

Contact your Komatsu distributor for other periodical inspection, maintenance, and replacement.

CAUTION ･ ･ ･ ･

Before inspection, be sure to turn the starting switch to "Q" (OFF) position and stop the lift truck.

Before refilling, lower the fork to the ground surface and prepare the stable base.

Do not climb up the lift truck or touch the mast chain. It is dangerous to do so.

Once the chain rusts, its strength significantly lowers. Grease it periodically to prevent lack of oil. Replace the rusted chain immediately.

CHECKING OF LIFT CHAIN ･ Inspect the lift chain and refill the oil.

Use the diesel engine oil for refilling. Use the recommended genuine engine oil. For the type of engine oil, see "INSPECTION AND MAINTENANCE LUBRICANT LIST (4-32 page)".

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INSPECTION AND MAINTENANCE

SIMPLE MAINTENANCE

SIMPLE MAINTENANCE GREASES Basic precautions 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/eye are injured by high-pressure oil, wash the skin/ eye with fresh water and immediately see a doctor.

• For other than leakage that can be checked visually by the appearance, contact your Komatsu distributor For inspection and repair service. ･ Since hydraulic oil, transmission oil, etc. are used under severe conditions (at high temperature and high pressure), they deteriorate as the operation time passes. Therefore oil must be changed periodically. For the standard oil change intervals, see "INSPECTION AND MAINTENANCE OIL AND GREASING CHART (4-31 page)" and "INSPECTION AND MAINTENANCE LUBRICANT LIST (4-32 page)". ･ Always replace oil at the specified period even if not deteriorated. ･ Always use Komatsu genuine engine oil. At shipment from a plant, the lift truck is applied with those oils listed in the "INSPECTION AND MAINTENANCE LUBRICANT LIST (4-32 page)". ･ Never mix oils of different grades (classes) or brands. ･ The engine oil of the lift truck corresponds to the blood of human body. A lift truck should be maintained so that contaminants (water, metal chips, dust, etc.) do not enter the lift truck system. Most lift truck malfunctions are caused by entry of impurities such as dirt, dust, water, etc. Take special care to avoid entry of impurities during storage and lubrication, etc. ･ Refill the oil up to the specified level. Both much higher and lower oil level may cause a failure in the lift truck. ･ If the hydraulic oil has become murky, there is a possibility that either air or water entered into the circuit. If no corrective measures were taken, it may damage the lift truck. In such a case, call your Komatsu distributor for their service. ･ When changing the oil, always replace the related filters at the same time. For oil and filter changes, contact your Komatsu distributor for service.

4 - 29

SIMPLE MAINTENANCE

INSPECTION AND MAINTENANCE

GREASE ･ Grease prevents the joints from seizure, rusting and noise emission. ･ Always use recommended grease and strictly follow the greasing intervals. For the types of grease, see "INSPECTION AND MAINTENANCE LUBRICANT LIST (4-32 page)". ･ 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 and hydraulic circuits from entering important components to cause failure. They require periodical replacement. Call your Komatsu distributor for service. ･ Never have your lift truck parts changed by other than Komatsu distributor. Never reuse filters (cartridge type) after washing. ･ Always use Komatsu genuine filters.

IMPORTANT Some of commercial filters are inferior to the genuine product in performance. Using such filters may affect performance and durability of the lift truck. If Komatsu genuine parts are not used, quality assurance may not apply.

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INSPECTION AND MAINTENANCE

SIMPLE MAINTENANCE

LUBRICANT LIST OIL AND GREASING CHART Tilt cylinder pin

Case

Hydlaulic oil tank

Power steering Cylinder link

Chain

Center pin, King pin

Fork stopper

Mast Front Axle support support

Brake reservoir tank

IMPORTANT Always use Komatsu genuine oil/grease.

To grease the rear axle, turn the steering wheel as shown in the right figure to lean the tires and keep this lift truck posture.

4 - 31

INSPECTION AND MAINTENANCE

SIMPLE MAINTENANCE

LUBRICANT LIST Different uses according to ambient temperature (°C) Lubrication point

Type of oil

-20

-10

0

10

20

30

40 °C

Recommended genuine oil

Standard Drive axle

Gear oil

Hydraulic tank

Hydraulic oil

Brake system

Brake fluid

Greasing points

Grease

Lubrication point

Engine oil

Capacity(l)

GO80W90 HO32R BF3 (DOT3) G2-LI EO10W30DH (SYEO-1030DH)

Hydraulic tank

Model

Drive axle case

At replacement

At disassembly

Brake reservoir tank

FB25-12

5.6l

25.2l

27.9l

0.15l

FB30-12

7.5l

26.0l

29.0l

0.15l

Always use Komatsu genuine oil and grease. (The genuine oils and greases are available at your Komatsu distributor.)

CAUTION Using wrong type brake fluid may cause critical failure to the brake system. Always use specified brake fluid (non-mineral oil brake fluid for vehicles).

4 - 32

INSPECTION AND MAINTENANCE

SIMPLE MAINTENANCE

REPLACING TIRES

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. Never crawl under the lifted truck body. ･ Forklift truck tire inflation pressure is high and dangerous. ･ Do not disassemble/assemble tire, tube or rim, nor fill removed tires from the lift truck with the air. (Special knowledge and techniques are required for these operations. Ask your Komatsu distributor for these services.)

1. Unload the lift truck. Stop it on level, flat and hard road surface. Apply parking brake by pulling the lever to the rear direction of the lift truck. (Parking brake activated) 2. Put blocks under the tire diagonally opposite to the tire which is to be replaced.

3. Always jack a lift truck up by the specified jack up point. ･ For replacing a front tire: Under the outer mast ･ For replacing a rear tire: Under the counterbalance-weight 4. Jack the lift truck up to a level where the tire 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 tire.

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INSPECTION AND MAINTENANCE

SIMPLE MAINTENANCE

5. Replacing tires

WARNING ･ For the tires with contact rim, never loosen the rim bolts for rim joint (deformed bolt) (2) and nuts. ･ For the tires with contact rim, be sure to loosen hub nuts after removing inflation pressure. ･ For safety, when filling a tire with air or replacing it, place your body in front of the tread face of the tire. Do not work from the side of the tire. ･ When adjusting the inflation pressure with an air compressor, adjust the compressor pressure in advance to prevent pressurizing the tire beyond the specified level. ･ Deformed or cracked rim poses a great danger. Before installing a replacement tire, check it thoroughly. Do not use a tire with deformed or cracked rim.

(1) By 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 tire slightly clear the ground.

Remove hub nuts (1) and remove the tire.

6. Install a replacement tire to the hub. Tighten hub nuts (1) temporarily. Tighten the nuts diagonally until the tire does not rattle.

7. Remove the block from under the frame. Lower the jack and tighten hub nuts (1) to the specified torque. For the right tightening torque, see "INSPECTION AND MAINTENANCE SERVICE DATA (4-75 page)".

8. Adjust the tire inflation pressure to specified pressure. For the right tire inflation pressure, see "INSPECTION AND MAINTENANCE SERVICE DATA (4-75 page)".

9. After replacing the tire, have a trial run to check the hub nuts for looseness. Tighten if necessary.

10. When a month (or 200 hours) has passed since tire replacement, check whether the hub nuts is not loosened.

Tighten them if necessary.

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INSPECTION AND MAINTENANCE

SIMPLE MAINTENANCE

ADJUSTING PARKING BRAKE LEVER OPERATING EFFORT

CAUTION Block the front and rear tires before starting adjustment.

1. Set the parking brake lever (2) to the Free position while pressing down the button (1) on tip of the parking brake lever (2).

Free

Lock

2. By using flat-blade screwdriver, turn the adjust bolt (4) through the window (3) at the bottom of the parking brake lever (2) to adjust the operating force to the reference value when the parking brake lever (2) is pulled.

Turn the bolt clockwise: Operating force increases Turn the bolt counterclockwise: Operating force decreases For the reference value of the parking brake lever operating effort, see "INSPECTION AND MAINTENANCE SERVICE DATA (4-75 page)".

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INSPECTION AND MAINTENANCE

SIMPLE MAINTENANCE

REPLACING FUSE FUSE FOR LAMPS,ACCESSORY CIRCUITS AND CONTROL CIRCUITS If the lamps and monitor panel 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 a fuse, always pull out the battery plug (pull it out after the system operating lamp goes off). ･ Only personnel who attended the special instruction course for handling low-voltage devices are allowed to replace fuses. ･ If replaced fuse is blown again, abnormal electric system may be causing the problem. Contact Komatsu distributor for checking.

FUSE 1. Turn the starting switch to "Q" (OFF) position and disconnect the battery plug.

2. Remove L.H. and R.H. side covers (A) and (B).

Fuses are installed in the fuse boxes on the left and right sides of the chassis.

3. Remove the fuse box cover and remove puller (1) attached to the inside of the fuse box.

4. Hold the fuse with puller (1) to remove and visually check if it is blown.

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4

INSPECTION AND MAINTENANCE

SIMPLE MAINTENANCE

5. If a fuse is blown, replace it with spare fuse of same capacity.

4 - 37

INSPECTION AND MAINTENANCE

SIMPLE MAINTENANCE

Locations of fuse boxes ･ Fuse box (1): ･ Fuse box (2):

Contains fuses F102 to F124.

Contains fuses F11 to F15.

Fuse capacity and related electrical component The capacity of each fuse in the fuse boxes and the electrical components related to them are shown below. ･ Fuse (F102 - F124) No. Fuse No. Capacity Color Related electrical component 1 F102 2A Gray Inverter (20 V) line 2 F106 3A Purple Cooling fan 3 F107 3A Purple Monitor key signal 4 F108 2A Gray Starting switch 5 F109 2A Gray Master controller 6 F110 3A Purple Master controller key signal 7 F111 3A Purple Master controller 8 F112 3A Purple Direction switch 9 F113 2A Gray System operating lamp 10 F114 3A Purple – 11 F115 2A Gray Monitor 12 F116 2A Gray – 13 F117 4A Pink Head light, L.H. 14 F118 4A Pink Head light, R.H. Clearance lamp, tail lamp, 15 F119 4A Pink license lamp 16 F120 4A Pink Turn signal lamp 17 F121 4A Pink Strap lamp 18 F122 4A Pink Backup lamp 19 F123 4A Pink Horn 20 F124 4A Pink Backup buzzer ･ Fuse (F11 - F15) No. Fuse No. Capacity Type Tube 1 F11 30 A fuse Tube 2 F12 15 A fuse Tube 3 F13 15 A fuse Tube 4 F14 3A fuse Tube 5 F15 3A fuse

4 - 38

Related electrical component 72 V main power supply Optional DC/DC converter DC/DC converter Travel inverter Load handling pump inverter

INSPECTION AND MAINTENANCE

SIMPLE MAINTENANCE

SLOW-BLOW FUSE LOCATIONS OF SLOW BLOW FUSE

CAUTION Ask your Komatsu distributor for checking and replacement.

If the power is not turned ON when the starting switch is turned to " l " (ON) position, there may be open circuit of the slow-blow fuse. Inspect and replace it.

The slow-blow fuse is located under the floor plate on the right side of the chassis.

1. Remove floor plate (A).

2. Remove contactor cover (B).

When cover (B) is removed, the slow-blow fuse is seen.

Ç ± Ç Ò Ç ¾

Slow-blow fuse capacity and related electrical components The capacity of each slow-blow fuse and the electrical components related to them are shown below. ･ Slow-blow fuses FB25-12

1

Fuse No. F02

2 3

No.

Capacity Color 200 A

–

F03

275 A

–

F04

225 A

–

Related electrical component Charging transformer Power supply for travel motor system Power supply for lifting motor system

FB30-12

1

Fuse No. F02

2 3

No.

Capacity Color 200 A

–

F03

350 A

–

F04

350 A

–

Related electrical component Charging transformer Power supply for travel motor system Power supply for lifting motor system

4 - 39

INSPECTION AND MAINTENANCE

SIMPLE MAINTENANCE

STATIONARY CHARGER

4

1. Disconnect the power cable plug of the charger from the power source.

2. Loosen the nut and replace the fuse.

3. Tighten the nut securely.

FB25-12 Symbol

Voltage

F5

72 V

FB30-12 Symbol

Voltage

F5

72 V

4 - 40

Battery capacity (Ah) 470 360

Capacity

Battery capacity (Ah) 545 450

Capacity

BF100A

BF100A

INSPECTION AND MAINTENANCE

SIMPLE MAINTENANCE

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

CAUTION ･ When replacing the bulb, always pull out the battery plug and turn off the power.

(Pull out the battery plug after the system operating lamp goes off) ･ 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 distributor for checking immediately.

1. Turn the starting switch to "Q" (OFF) position and the lamp switch to OFF position.

2. Remove the lamp lens and replace the bulb.

Lamp name Headlamp Turn signal lamp Clearance lamp Backup lamp Brake lamp

Capacity 70 W (For 24 V) 25 W (For 24 V) Head 5 W/Tail 10 W (For 24 V) 25 W (For 24 V) 25 W (For 24 V)

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INSPECTION AND MAINTENANCE

HANDLING OF BATTERY

HANDLING OF BATTERY Handling of batteries such as recharging, maintenance, storage and disposal are each important for safety.

WARNING ･ Handling error of the battery may cause explosions and other critical injuries. Handle batteries after fully understanding their hazards and mastering the method of handling. ･ When servicing or charging the battery, "SAFETY CAUTION WHEN HANDLING BATTERY (2-43 page)" read thoroughly and fully understand and work safely.

CAUTION CAUTION AGAINST FIRE ･ Batteries generate flammable hydrogen gas. Never smoke cigarette or use fire near the battery. ･ Sparks may ignite and explode the gas. Do not place tools, parts or other metal objects on the battery. ･ To clean the top surface of battery, wipe with wet cloth before recharging. Using dry cloth for wiping, dusting or covering battery with vinyl sheeting generates statistics that may cause explosion. ･ Depending on the weather, environmental, clothing material and other conditions, human bodies may deposit and spark statistics. Therefore, before touching lift truck in charging or after charging, discharge statistic deposit in the human bodies by grounding.

CAUTIONS AGAINST LEAKAGE AND ELECTRIC SHOCK ･ In precaution against leakage of electricity, always keep the top surfaces of batteries clean and dry. ･ Batteries for battery-driven trucks store large energy in high-tension. Beware of the risk of electric shock.

Never allow human body to touch a live part during installation, maintenance, and inspection. ･ Always wear protective glasses, rubber gloves and rubber sole shoes for working on batteries. (They also help protect personnel from direct contact with dilute sulphuric acid.

CAUTIONS AGAINST BATTERY ELECTROLYTE ･ Battery electrolyte contains dilute sulphuric acid, which may cause burns and loss of eyesight.If you spill battery electrolyte on yourself, immediately take off clothes and flush the contact portion of the skin with a large quantity of tap water and consult a doctor. ･ If battery electrolyte gets into your eyes, flush them immediately with fresh tap water for 10 to 15 minutes continually and consult a doctor. ･ If you drink battery electrolyte by accident, either drink a large quantity of water or milk mixed with beaten egg white or salad oil, and then consult a doctor at once. ･ Spilling or leaking battery electrolyte in the surrounding area damage the floor and material, leading to environmental contamination. If contacted by human beings, it may cause burns or injuries. Immediately neutralize battery electrolyte with an acid neutralizing agent (baking soda, calcium hydroxide or sodium carbonate, etc.) and wash it down with large amount of water. ･ Do not operate the monitor panel with a hand wet with the battery electrolyte.

The surface sheet of the monitor panel is deteriorated.

Caution for disconnecting battery plug ･ When repairing the electrical system, be sure to disconnect the battery plug to stop power supply. When disconnecting the battery plug, check that the system operating lamp is OFF.

4 - 42

INSPECTION AND MAINTENANCE

HANDLING OF BATTERY

ACTION FOR ABNORMALITIES ･ Do not drain battery electrolyte, disassemble or repair batteries or battery plugs, which may cause explosion and/or electric shock. ･ If the following abnormalities are detected, contact your Komatsu distributor: Battery plug and charging plug mating become loosened or play is generated. (Plug becomes hot abnormally) Battery electrolyte temperature is high.

Battery electrolyte decreases sharply.

Battery emits odor.

Battery electrolyte is turbid.

Charging requires too long time. (Charging is not completed although the battery was not used till late hours on the preceding day.)

LONG-TERM STORAGE AND DISPOSAL ･ If batteries are left unused for a long time, remove them from the lift truck and store them in a well-ventilated place free from fire. ･ Since lead and diluted sulphuric acid are used in batteries, illegal disposal turns them into hazardous substance to cause environmental pollution. For the disposal of used batteries, contact your Komatsu distributor.

ABOUT BATTERY ･ Use the battery of voltage which is specified on the label (upper right side of dashboard).

CHECKING OF BATTERY ELECTROLYTE LEVEL If battery electrolyte level decreases below the normal range, electrolyte level warning lamp (1) lights up on the monitor panel.

Check the battery electrolyte level of each cell immediately according to the following procedure.

CHECKING PROCEDURE 1. Turn the starting switch to "Q" (OFF) position.

2. Open the battery hood sufficiently, remove the fixing bar on the back side of the hood and hook it to the hole on the right side of the battery, and check that the battery hood does not close.

3. Disconnect the battery plug and the plug on the chassis side. ･ With each battery cap closed, visually inspect the floating condition of the upper part of the float.

If the stopper on the top of the float is in contact with the bottom of the guide, electrolyte has reached below the minimum level. Add distilled water or purified water. (When the electrolyte level is below the minimum level, float does not move down even if you open the cap and push its end down.) ･ If white line of the float is visible, electrolyte is at the maximum level.

Stopper

Cap Float (Red)

4 - 43

INSPECTION AND MAINTENANCE

HANDLING OF BATTERY

Refilling of battery electrolyte If the battery electrolyte level is low, refill it according to the following procedure.

Refilling procedure 1. Place a container filled with distilled or purified water in a location higher than the batteries and connect a hose to it.

(Use a container with a stop valve or install a stop valve to the center of hose.)

2. Open the battery cap and insert the hose end.

3. Open the stop valve to add water.

When the float rises and the white line is seen, close the stop valve immediately. Add water to all the cells in which the electrolyte level is low. If white line of the float is visible, electrolyte is at the maximum level.

4. After adding water, close the battery caps securely and clean the battery top with wet cloth.

5. Connect the battery plug again.

6. Remove the fixing bar from the hole on the right side of the battery, fix it to the holder on the back side of the hood, and close the battery hood. Set the fixing catch securely.

7. Close the container of distilled or purified water. Wind the hose and keep it free of dust.

Lid

[Refiliing water]

CHECKING OF SPECIFIC GRAVITY OF ELECTROLYTE ･ Check the specific gravity of the electrolyte to see if the batteries are charged properly and if there is performance difference among the cells to extend the service life of the batteries. ･ Since the specific gravity of the electrolyte varies with the temperature, convert the specific gravity measured at the current electrolyte temperature into a value at 20 °C according to the conversion table.

How to read table (Example) When the electrolyte temperature is 10 °C and the hydrometer reads 1.252, the specific gravity converted at 20 °C is 1.250.

Proper specific gravity (converted at 20 °C) Specific gravity at full charge

1.280 to 1.290

Specific gravity after discharge (when 80% is discharged and discharge warning lamp lights up)

1.170 to 1.180

The specific gravity of the electrolyte varies more or less, depending on the manufacture and model.

4 - 44

White line [Refilling water ended]

INSPECTION AND MAINTENANCE

HANDLING OF BATTERY

SIMULTANEOUS WATER REFILLING DEVICE

CAUTION Always use distilled or purified water to refill the batteries.

A simultaneous water refilling device can refill every cell of a battery simultaneously.

Refilling procedure 1. Place a container filled with distilled or purified water in a location higher than the batteries and connect a hose to it.

(Use a container with a stop valve or install a stop valve to the center of hose.)

2. Open the battery cap and insert the hose end.

3. Open the stop valve to add water.

When the float rises and the white line is seen, close the stop valve immediately. If white line of the float is visible, electrolyte is at the maximum level.

4. After adding water, close all the battery caps securely and clean the battery top with wet cloth.

TIPS FOR USING BATTERY FOR LONG TIME Battery service life is largely dependent on the quality of maintenance given. Use the battery safely for a long time by following the points below: 1. Avoid over discharge (excessive use of battery). ･ If over discharge warning lamp lights up, immediately stop work and recharge battery. ･ When the operating time is long and there is possible lighting of over discharge warning lamp during operation, perform auxiliary charging during break time.

2. Avoid overcharging (excessive charging). ･ Avoid excessive equalized charging.

(1 equalized charging against 6 normal charging) ･ Charge every 2 to 3 days if daily operating time is short.

3. Always maintain the battery electrolyte level within the specified range.

4. Keep the battery top clean and dry.

4 - 45

INSPECTION AND MAINTENANCE

CHARGING

CHARGING ･ For a safe and long period of service life of the battery, pay attentions to the following. The cautions are applicable to both onboard and stationary chargers. ･ The battery is charged by the automatic charging or equalizing charging. Charging time differs by discharged state of the battery. It takes generally 8 to 10 hours to charge the battery of the standard application.

Charging methods

Timing of charging and charging operation

Automatic charging

･ Automatically selects and performs normal charging or equalizing charging (operation of onboard charger). ･ Press the "AUTOMATIC" button. Equalizing charging is performed automatically according to the charging frequency and charge level.

Equalizing charging

･ Performs equalizing charging forcibly. ･ Press the "EQUALIZING" button.

Charging at longterm storage

･ Charging at storage for 1 month or longer without operation ･ Push "Equalize" button once a month.

(Note) For the battery capacity warning, see "OPERATION WARNING ON BATTERY OVER DISCHARGE (3-17 page)".

REMARK ･ Equalizing charging: If the battery is discharged and charged repeatedly, performances of its cells (36 cells for 72-V battery) are dispersed gradually. If dispersion is left as it is, the service life of the battery is shortened. The purpose of the equalized charging is to eliminate the dispersion by charging the battery longer than the normal charging. ･ Refilling water: Only water in the electrolyte decreases gradually because of water decomposition during charging or evaporation during use. To compensate for the decreased water is "refilling water". When the battery is normal, check the electrolyte level once a week and refill water as necessary. If the battery approaches its service life end, the electrolyte level decreases more quickly.

WARNING ･ Handling error of the battery may cause explosions and other critical injuries. Handle batteries after fully understanding their hazards and mastering the method of handling. ･ When servicing or charging the battery, "SAFETY CAUTION WHEN HANDLING BATTERY (2-43 page)" read thoroughly and fully understand and work safely.

4 - 46

INSPECTION AND MAINTENANCE

CHARGING

CAUTION BEFORE CHARGING BATTERIES ･ Carry on charging in a well-ventilated place sheltered from rainfall. Do not charge the battery near open flame or hazardous substances, in a high humidity place, or in a place splashed with water, which may cause a fire. ･ Before starting charging, turn the starting switch to "Q" (OFF) position first. ･ Open the battery hood sufficiently, remove the fixing bar on the back side of the hood, and hook it to the hole on the right side of the battery to prevent accumulation of hydrogen gas. ･ Be careful not to allow electrolyte to drop below the minimum level. Otherwise, battery may become overheated to cause fire. ･ Before charging the battery, wipe its top surface with a wet cloth. If the battery is wiped with a dry cloth, brushed, or covered with a plastic sheet, static electricity may cause an explosion. ･ Check the plugs and cables of the charger and battery for damage. Check also fitting portion of the connectors for loosening and/or play. If any abnormality is detected, do not use the truck until repair service is completed. ･ When connecting or disconnecting the plug, be sure to relieve the lock by holding the plug body. Pulling cable may cause short circuit of the cable and plug, leading to fires.

Charge ･ While charging and immediately after the battery is charged, surrounding area may be filled with flammable hydrogen gas. Never smoke cigarette or use fire near the battery. ･ Sparks and/or statistics can ignite the gas, as well. Do not handle tools and other metals carelessly in the surrounding area of the lift truck. Before touching the lift truck or charger, discharge static electricity from your body by grounding. ･ When stopping battery charging that is already underway, be sure to disconnect the plug after pressing the STOP button on the battery charger. Sparks may be generated upon pulling out cable to cause burns and fire. ･ Charge battery when the ambient temperature is 0 °C to 40 °C. ･ The battery and charger are so combined that they can charge the battery properly. To avoid fire, do not charge batteries having capacity larger than the rated capacity of charger or batteries of different types. ･ Use the charging cable specified by Komatsu and attached to the lift truck. Do not use cable from other manufacturers or that are different in shape.

INSTALLATION AND EQUIPMENT OF CHARGER ･ Komatsu distributor will adjust the transformer tap of the charger. The customers should not change it, since doing so can overheat the charger and cause a fire. ･ Work on the power supply equipment should be made under the instructions of chief electric engineer or by an electric contractor designated by a power company. ･ Connect the grounding wire to the electrical outlet on the plant side to prevent electrical shock accident. ･ Do not use supply voltage and power receptacles other than those specified. ･ Use the circuit breaker with ground fault circuit interrupter (rated sensitive leakage current 30 mA). ･ Variation of supply voltage must be between 190 V and 219 V (50 Hz/60 Hz). ･ Do not disassemble or modify the charger. ･ The charger is designed and manufactured according to the service life of the lift truck. When discarding a lift truck, discard its charger as well. Do not reuse the charger to prevent an accident.

IMPORTANT ･ Always use distilled or purified water to refill the batteries. If city water, etc. is used, the service life of the battery is shortened. ･ Various additives are on commercial market for the purpose of extending, reviving the battery life or vitalizing the battery. Since some of them do not match the charger, customers should use them on their own risk and responsibility when using.

4 - 47

INSPECTION AND MAINTENANCE

CHARGING

CHARGING WITH STATIONARY CHARGER

4

CAUTION ･ If the charger is used for long hours with the source voltage tap set very badly, it may burn. Accordingly, measure the source voltage periodically and adjust the charger to a proper source voltage tap. ･ The power supply wiring and receptacle on the facility (building) side must have capacity larger than the rating (voltage and current) of the charger.

For rated voltage and rated current of the battery charger, see "TECHNICAL DATA" (page 5-2).

Insufficient capacity of wiring and receptacle can cause a fire. ･ Check that the battery plug is connected securely. If the connection is incomplete, a spark may be generated. ･ Use the output cable plug of stationary charger of the same manufacturer as of battery plug.

This lift truck charger is an automatic charger which judges the condition of the battery and charges the battery properly by using a microcomputer.

1. Remove fixing catches (1) of the right and left side covers and open the hood toward the front of the lift truck.

2. Remove fixing bar (2) on the reverse side of the hood and hook it to the hole on the right side of the battery to fix the hood.

4 - 48

INSPECTION AND MAINTENANCE

CHARGING

CONNECTION OF CABLES 1. Turn the starting switch to "Q" (OFF) position and disconnect battery plug (1) from the chassis.

Disconnect battery plug (1) after system operating lamp (2) goes out.

2. Connect the power cable to the factory power source and connect the output cable plug to the battery plug.

IMPORTANT When the plug is connected, the NORMAL lamp and EQUAL lamp on the display panel flash.

Check that the battery plug is connected securely.

Battery plug Factory power source Power cable Stationary battery charger

Output cable plug Output cable

STARTING OF CHARGING

WARNING Do not disconnect the plug during charging.

1. Select normal charging or equalizing charging.

2. When selecting normal charging (every day), hold down the NORMAL button for approximately 1 second, and the charger starts normal charging.

3. When selecting equalizing charging (every week), hold down the EQUAL button for approximately 1 second, and the charger starts equalizing charging.

4. When the charger stars charging, the lamp of the selected charging (normal or equalizing) lights up and the lamp of the unselected charging goes out.

(It takes approximately 10 hours to charge a battery used under the ordinary condition.)

5. When stopping charging after it is started, press STOP button.

6. When disconnecting the plug, press STOP button and check that NORMAL and EQAUL lamp are lit under the initial state.

4 - 49

CHARGING

CHECKING OF CHARGING STATE 1. The charging progress lamps light up in the order of the 1st, 2nd, and 3rd one to indicate the charging state.

Q:Lamp is ON q:Lamp is OFF

2. When the battery is fully charged, the electromagnetic switch on the AC side is turned OFF automatically. Charging is finished and the lamp of the selected charging (normal or equalizing) goes out and "OK" lamp lights up.

(The 3 charging progress lamps keep lit.)

4 - 50

INSPECTION AND MAINTENANCE

INSPECTION AND MAINTENANCE

CHARGING

DISPLAY OF ABNORMALITY 1. If charging is continued for an abnormally long time, the microcomputer judges charging abnormal and then stops charging and displays abnormality.

2. If charging is abnormal, "CHECK" lamp on the operation panel lights up.

3. If "CHECK" lamp lights up, stop charging and call your Komatsu distributor.

4. Once the battery plug is disconnected, "CHECK" lamp goes out.

WHEN POWER FAILS 1. If the power fails during charging, the charger interrupts charging. If the power restores, the charger restarts and continues charging automatically from the state when it interrupted charging.

2. However, if the power failure continues for more than 1 hour, the charger is returned to the state before it started charging and does not restart charging even if the power restores. In this case, press NORMAL or EQUAL button again.

FINISHING OF CHARGING 1.

2.

3.

4.

5.

6.

Check that charging is completed (OK lamp lights up).

Disconnect the power cable of the charger from the power supply of the building (factory, etc.)

Disconnect the output cable plug of the charger from the battery plug of the lift truck.

Connect the battery plug of the lift truck to the plug on the lift truck side.

Store the output cable of the charger, taking care not to twist it.

Remove the fixing bar from the hole on the right side of the battery, fix it to the holder on the back side of the hood, and close the battery hood. Set the fixing catch securely.

4 - 51

BATTERY REPLACEMENT

BATTERY REPLACEMENT CAUTION Always sling the battery by 4-point sling method.

HOW TO REMOVE BATTERY 1. Place the lift truck on a firm level ground.

2. Lower the forks to the ground.

3. Pull the parking brake lever toward the rear of the lift truck and turn the starting switch to "Q" (OFF) position.

4. Pull up lever (1) and slide the seat to the rear end.

5. Remove overhead guard rear cover (2).

6. Remove fixing catches (3) of the right and left side covers and open hood (4) toward the front of the lift truck.

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INSPECTION AND MAINTENANCE

INSPECTION AND MAINTENANCE

BATTERY REPLACEMENT

7. Open the hood until gas damper (5) on its reverse side is fixed.

1) Be sure to disconnect battery electrolyte level sensor connector (6).

2) Disconnect battery plug (7).

3) Pull out the battery plug to the top of the battery.

Take care not to kink the cable at this time.

IMPORTANT ･ If the battery hood is opened with operator's seat not slid to the end, the operator's seat interferes with the work equipment control lever and may be damaged. ･ If the battery hood is opened with operator's seat not slid to the end, the operator's seat interferes with the work equipment control lever and the battery hood may not be opened sufficiently.

8. Remove rear cover knob (8), then remove cover (9).

9. Insert the wire of the crane into the cut portion of the overhead guard.

10. Install the hook of the wire to the hole of the battery case.

Sling the battery slowly and check that there is clearance between the case bottom and counterweight surface.

At this time, take care that the battery top surface does not exceed mark (10) on the stay at rear right of the overhead guard.

11. Unload the battery from the lift truck.

12. Sling the spare battery and place it on the lift truck.

13. Perform steps 1 to 8 in the reverse order.

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INSPECTION AND MAINTENANCE

BATTERY REPLACEMENT

HOW TO INSTALL BATTERY Install the battery by performing the removal procedure in the reverse order.

WARNING When the lift truck tips over or falls, if the battery comes off, it can cause serious personal injury or death. Set and install fixing catch (1) of battery hood securely as explained below. ･ Unlock the gas spring stopper (vermilion) of battery hood by pushing it toward the front of the lift truck and close the hood.

Set fixing catch (1) securely.

REMARK When replacing the battery in another way, consult your Komatsu distributor.

WEIGHT TABLE OF BATTERY Capacity (Ah)

Weight (kg)

FB25 (Standard battery)

360

1,086

FB25 (Large capacity battery)

470

1,150

FB30 (Standard battery)

450

1,144

FB30 (Large capacity battery)

545

Model

Voltage (V)

72

72 1,245

IMPORTANT Weight of battery is indicated on the nameplate on the side of battery case.

4 - 54

INSPECTION AND MAINTENANCE

RUNNING IN COLD WEATHER

RUNNING IN COLD WEATHER PREPARATIONS FOR LOW TEMPERATURE When the temperature drops, grease and resin become hardened, causing delay of operation, increased battery power consumption and other phenomena. These may cause failure and damage of hydraulic equipment and hoses, early wear and failure due to defective lubrication. Take the following measures: ･ Use greases of low viscosity for low temperature.

For the specified viscosity, see "INSPECTION AND MAINTENANCE LUBRICANT LIST (4-32 page)".

AFTER COLD WEATHER SEASON When the weather becomes milder with the change of season, change back to greases fit to the current temperature.

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

BEFORE STORAGE

4

Clean up the parts, and then store the lift truck indoors after the following processes. If it must unavoidably be left outdoors, park the lift truck on flat ground and cover it with a tarpaulin. ･ Apply grease and change oil without fail. ･ Fully apply grease to the exposed portions of hydraulic cylinder piston rod. ･ Perform equalizing charging of battery. ･ When storing the battery, disconnect the battery plug.

DURING STORAGE

4

･ 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, perform the equalizing charging once a month.

AFTER STORAGE

4

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. If there is water in the oil, change all the oil. ･ Travel the lift truck at low speed to spread oil sufficiently into the transfer.

IMPORTANT When using lift trucks that were not operated once a month to prevent rusting, consult your Komatsu distributor before operation.

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OPERATING LIFT TRUCKS IN SPECIAL ENVIRONMENT OR IN FORCIBLE WAY INSPECTION AND

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.

However, 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 distributor.

EXAMPLES OF SPECIAL ENVIRONMENT OR FORCIBLE USE OF LIFT TRUCK ･ Operating environment where the lift truck has to travel on the roads covered with salt water, chemicals (acid and/or alkaline), solvents, etc. or it is directly poured or attached with them via operator's hands and feet. ･ Environment surrounded by corrosive gases that corrode metal and/or resin. ･ Environment near the sea shore blown by salty wind from the sea. ･ Environment where dew condensation occurs on the lift truck as it travels indoor and outdoor and is exposed to larger temperature difference or environment where ice sticks to it constantly. ･ Environment filled with excessive sludge and those filled with dust, fine dust, and aggressive dust from polishing. ･ Operation by which a lift truck is used for a specific work for extended span of time or used continuously in concentration for a particular work. etc.

IMPORTANT ･ Operating the lift trucks in a special environment or in forcible way excludes them from the object of warranty provided by Komatsu Ltd. ･ There are conditions technologies cannot cover. ･ This lift truck cannot be used in a place where a risk of explosion accompanies as specified by law.

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INSPECTION AND MAINTENANCE

ACTION TO TAKE IF THE FORK FAILS TO LOWER

ACTION TO TAKE IF THE FORK FAILS TO LOWER 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 serious personal injury or death. Never touch the mast, fork, chain and other load handling devices. (Do not shake, touch or pry with a stick or tool) ･ If the fork fails to lower, immediately contact with the administrator or your Komatsu distributor for repair service.

Never use Danger

1. If the fork stops lowering during operation, stop the work immediately.

2. Move the lift truck to a flat place and park it by avoiding emergency exit or fire fighting equipment. For details on parking, see "SAFETY STOPPING AND PARKING (2-31 page)" and "OPERATION TEMPORARY STOPPING, PARKING AND STOPPING (3-61 page)".

3. If the loaded fork should stop operating in raised condition, the load may fall. In this case, secure a wide "No Entry" area around the lift truck or park the lift truck directly facing a stout wall surface.

4 - 57

HOW TO TOW THE LIFT TRUCK OR BE TOWED

INSPECTION AND MAINTENANCE

HOW TO TOW THE LIFT TRUCK OR BE TOWED WARNING Any mistake in the selection of the wire rope or towing bar or in the method of towing, may lead to serious personal injury or death. ･ Be sure to check whether the wire rope for towing has the strength that can withstand the weight of towed lift truck. ･ If cut of strand (A), reduction in diameter (B), and kink (C) are found in the wire rope, the rope may be broken. Never use it. ･ When handling the wire rope, use leather glove. ･ Never tow the lift truck on a slope. ･ Never stand between the towing and towed lift trucks during towing travel. ･ Slowly move the lift truck. Do not suddenly put a load on the wire rope. ･ Make sure that the brake is disabled if there is a failure in the brake system.

IMPORTANT •The lift truck cannot be towed over a long distance but can be towed to the closest place where inspection and maintenance work is can be performed. Do not tow the lift truck over a long distance.

•For the maximum rim pull of the lift truck, see "INSPECTION AND MAINTENANCE TECHNICAL DATA (5-2 page)".

•To tow the failed lift truck, contact your Komatsu distributor.

Do not tow this lift truck unless it is not necessary. To necessarily tow the lift truck, be sure to understand the following precautions. ･ Before releasing the brake, block the tires to prevent the lift truck from moving. Without blocking the tires, the lift truck may move. ･ Towing the lift truck is to move the lift truck at 2 km/h or lower and to transfer to the place a few meters away where the lift truck can be repaired. The lift truck can be towed only in the emergency case. To transfer the lift truck over a long distance, transport it. ･ If the steering wheel or the lift truck brake of the towed lift truck cannot be operated, do not let anyone on the lift truck. ･ Reduce the angle of the towing rope as smaller as possible. Adjust the angle of the center lines of the both lift trucks to 30 deg. or lower. ･ Normally, select the towing lift truck of the same class as the towed lift truck. Check that the towing and towed lift trucks ensure the sufficient brake performance and drawbar horsepower so that the both lift trucks can be controlled on a slope or towing road. ･ To tow the lift truck on a downhill slope, another lift truck may be required behind the towed lift truck to obtain sufficient brake performance and drawbar horsepower. This prevents the lift trucks from losing control. ･ It is impossible to determine the towing required under various conditions in advance. The minimum drawbar horsepower is required on a level and flat ground while the maximum drawbar horsepower is required on a slope or rough ground.

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INSPECTION AND MAINTENANCE

HOW TO TOW THE LIFT TRUCK OR BE TOWED

･ Set the wire rope on positions indicated with an arrow in the right figure.

4 - 59

ELECTRONIC CONTROL SYSTEM

INSPECTION AND MAINTENANCE

ELECTRONIC CONTROL SYSTEM When action level display (1) or alarm monitor (2) is displayed on the monitor display, press switch F3 to display "Error List" screen and check the details and remedy.

For the contents of the action level display and caution lamp, see "INSPECTION AND MAINTENANCE ACTION LEVEL DISPLAY (4-61 page)".

TELEPHONE NUMBER FOR THE POINT OF CONTACT IF AN ERROR OCCURS When an error screen is displayed on the monitor, press the switch F3 to display "Charging Error List" screen and telephone number (3) for the point of contact is displayed in the message column at the bottom of the screen.

REMARK If no point of contact telephone number is registered, no telephone number is displayed.

When it is necessary to register the telephone number, ask your Komatsu distributor to carry out the registration.

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INSPECTION AND MAINTENANCE

ACTION LEVEL DISPLAY

ACTION LEVEL DISPLAY Action level display (1) indicates the level of urgency of the abnormality in the lift truck by "L01" to "L04".

The larger number in the table is, the more serious effects the trouble has on the lift truck if it is left with no remedy.

If the vehicle monitor indicates an action level, check the message displayed on the monitor.

By pressing the switch F3 on the standard screen while the action level is being displayed, the currently occurred error list is displayed.

For the displaying method of failure, see "OPERATION CAUTION CHECK (3-22 page)".

Take appropriate actions following the message displayed on the monitor panel.

List of action level displays and remedies Urgency

High I l | | | O Low

Action level

Buzzer

Alarm monitor

L04

Sounds continuously

Light up in red

Stop the lift truck immediately.

Check the failure code, and ask your Komatsu distributor for the inspection and maintenance.

L03

Sounds intermittently

Light up in red

Stop the operation, move the lift truck to a safe place, and stop the lift truck.

Check the failure code, and ask your Komatsu distributor for the inspection and maintenance.

Light up in red

Stop the work, turn the starting switch to "Q" (OFF) position.

If the condition is not improved, ask your Komatsu distributor for inspection and maintenance.

L02

L01

Sounds intermittently

–

Light up in yellow

Remedy

Some functions may be restricted for use, but the lift truck can operate.

When you finish the operation, always carry out the inspection and maintenance. Ask your Komatsu distributor for inspection and maintenance as needed.

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INSPECTION AND MAINTENANCE

WASHING LIFT TRUCK

WASHING LIFT TRUCK CAUTION ･ Entering of water into the electrical parts (controllers, sensors, connectors) may cause a malfunction, which is dangerous. Do not wash the electrical parts or use a high-pressure washer (steam cleaner) on them. ･ Do not use the high-pressure washer (steam cleaner) directly on the opening of the lift truck (rear of the frame and exhaust outlet on the side). ･ Do not use the high-pressure washer (steam cleaner) directly on the tire angle sensor on the R.H. side of rear axle.

WASHING PROCEDURE 1. For lift truck posture, see "SAFETY" and "STOPPING AND PARKING" (page 2-31) and perform inspection.

(Never wash lift truck with turning the steering and leaning the tires.)

2. Turn the starting switch to "Q" (OFF) position, and pull it out.

3. Disconnect the battery plug.

4. Wash each section ((1) to (6) in the right figure) according to the table below.

Take care to avoid portions for which high-pressure (steam) washing or washing with pressurized water is inhibited.

5. Dry washed sections completely.

If droplets are attached to the electric system, apply dry air blow.

6. After checking that they are dry, turn the starter switch key to " | " (ON) position and test for any abnormality, and then start operation.

4 - 62

Wheel angle sensor

Exhaust outlet (right and left)

INSPECTION AND MAINTENANCE

Fig. No. 1

2

3

WASHING LIFT TRUCK

Sections to wash Monitor panel (Charge operation panel) Resin cover Steering wheel cover Dashboard panel Around work equipment control lever Counterbalance-weight over Battery side cover

How to wash Wipe the surface lightly with wet cloth.

Pour water by the hose from the top to wash.

Apply cloth or soft brush to wash to prevent scratch mark.

Note) Reduce the discharging volume of water as the figure A below. Lower the water pressure for washing.

(Only for No. 2 and 3)

Top of the floor plate Fig. A

4

Battery

Wipe the surface lightly with wet cloth. (To prevent generation of static electricity)

5

Front/Rear tires Drive axle

Apply high-pressure (steam) washing or use hose water for washing.

6

Counterweight

Apply high-pressure (steam) washing or use hose water for washing.

Other matters and cautions

Do not apply high-pressure (steam) washing through the gaps and holes around the dashboard, controller and the work equipment control levers. Also do not wash the section around the pocket for operating manual in the rear of the seat with high-tension (steam) water.

4 - 63

INSPECTION AND MAINTENANCE

HOISTING LIFT TRUCK

HOISTING LIFT TRUCK CAUTION ･ Always attach belts and other slings at the positions designated by this paragraph. ･ Never hoist a lift truck by overhead guard or towing pin, because the truck may fall due to their lack of strength. ･ Hook the sling to the mast after checking that it is securely installed. ･ Never allow other persons to go under or near the lifted truck. It is extremely danger. Serious personal injury or death may occur if the lift truck should fall down.

1. Check the installed state of the mast with the tightening torque of mounting bolts (4 places on the right and left).

Tightening torque for the mast lower mounting bolts FB25 : 245 to 309 Nm {25.0 to 31.5 kgm} FB30 : 343 to 427 Nm {35.0 to 43.5 kgm} 2. Use undamaged sling and wire having sufficient strength.

3. Attach the sling at designated sling positions. ･ For the front, use the top of the outer mast tilted maximum to the rear and holes (2) (2 places, right and left) for lifting.

･ For the rear, use counterweight (2) and rear axle (3).

Always use the sling belts through rear axle (3).

4. When hoisting a lift truck, do not allow the overhead guard and/or cab to contact with sling belts, etc. Adjust the sling length to prevent the lifted truck from being tilted. Do not give impact to it while hoisting.

IMPORTANT The counterweight and weight cover are installed with combination lamp (brake lamp, turn signal lamp and backup lamp), which may be damaged when contacted with sling belt and others for hoisting the rear section. Take preventive measures against damage depending on the circumstances.

4 - 64

INSPECTION AND MAINTENANCE

LOADING AND UNLOADING OF LIFT TRUCK

LOADING AND UNLOADING OF LIFT TRUCK 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 securely and chock the tires. ･ 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 half rising from the seat, the 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 do not have to stand up or half rise from the seat to watch.For the travel interlock, see "OPERATION TRAVEL INTERLOCK FUNCTION (3-63 page)" . ･ When using the ramp, make the gradient gentle, align the center of both the trailer and the lift truck and lock the ramp securely to prevent misalignment. ･ Never correct the course of the lift truck while on the ramps. If course change is required, move off the ramps once and correct the course direction.

1. Arrange for a trailer having adequate loading capacity for the weight and size of a lift truck to transport.

2. Stop the trailer on a level and flat road surface. Apply the parking brake securely and chock the tires.

3. Install the ramp, dock plate, etc. between the loading platform of the trailer and the road surface and fix it securely so that it would not be disengaged.

4. Instruct the trailer operator not to move the trailer until loading/unloading of lift truck is completed.

5. When loading/unloading a lift truck to or from the trailer, drive the lift truck at slow speed by sitting on the seat with right posture.

Ramp

Blocks

4 - 65

LOADING AND UNLOADING OF LIFT TRUCK

6. To prevent a loaded forklift truck from moving during transportation, apply blocks to the tires and secure it with wire rope and/or chain before starting the trailer.

To fixing the lift truck, use the holes on top of the outer mast for hoisting the lift truck.

IMPORTANT When the lift truck needs to be towed with a winch, etc., see "INSPECTION AND MAINTENANCE HOW TO TOW THE LIFT TRUCK OR BE TOWED (4-58 page)".

4 - 66

INSPECTION AND MAINTENANCE

Pallet

INSPECTION AND MAINTENANCE

INSPECTION AND MAINTENANCE SCHEDULE CHART

INSPECTION AND MAINTENANCE SCHEDULE CHART This Inspection and Maintenance Schedule Chart describes the inspection and maintenance items the operator is obligated to perform. ･ For other inspection and maintenance items not described in this manual, contact Komatsu distributor. ･ Incorrect inspection, maintenance and repair services may cause critical accident or shorten lift truck service life. For your safety operation, contact Komatsu distributor for inspection, maintenance and repair services.

INSPECTION AND MAINTENANCE SCHEDULE CHART "Q" indicates the inspection/maintenance cycle and inspection/maintenance hours recommended by KOMATSU. Perform inspection at the cycle which is shorter.

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INSPECTION AND MAINTENANCE

INSPECTION AND MAINTENANCE SCHEDULE CHART

Inspection & Maintenance Intervals (hours)

Power train

Inspection & Maintenance Item

Start-up inspection

Every week

Every 2 weeks

Every 1 month

Every 3 months

After 50 After 100 After 200 After 600 hours hours hours hours

Every 6 months

Every 1 year

Every 2 years

After 1200 hours

After 2400 hours

After 4800 hours

Replacem Mainteent nance Intervals interval (month(s)) (h)

Directional lever Play and engagement condition

Q

Installation condition Front axle

Q

Q Q Q Q

Q

Q

Cracks, damage and deformation Looseness of mounting bolts Unusual noise

Traveling equipment

Oil leakage Hydraulic oil level and contamination Changing oil

Q

Rear axle Crack, damage, deformation, looseness of mounting bolt Center pin play, cap mounting bolt looseness Wheel

Q Q

Tire inflation pressure Tire crack and damage Tire tread depth and abnormal wear Tire condition Play and abnormal noise of front wheel bearing Play and unusual noise of rear wheel bearing Conditions of tires and rims Looseness of hub nuts and bolts Damage of hub nut and bolt Rim deformation, crack and damage Steering wheel Operation state (runout, unstable driving operation state, play) Steering valve

1200

Q Q

Q Q

Q Q

Q

Q

Q Q

Q

Q

Q

Q

Q

Q

Q

Q (*)

Q

Q

Q

Q

Q

Q

Q

Q Q

Mounting portion looseness Oil leakage

(*)

Q Q

Rod and arm

Q

Steering equipment

Looseness, play and damage Knuckle

Q

Joint part play King pin play, unusual noise, crack, damage Wheel

Q

Q Q Q Q

Wheel and alignment Fluctuation in min. turning radius Contact of wheel with another part Power steering cylinder Oil leakage Oil level Mounting condition, connecting part looseness Hose pipe damage

4 - 68

Q

Q Q Q Q

Q

6

INSPECTION AND MAINTENANCE

INSPECTION AND MAINTENANCE SCHEDULE CHART

Inspection & Maintenance Intervals (hours)

Inspection & Maintenance Item

Brake pedal Operation state (response and depression allowance) Play and pedal height when depressed Parking brake Lever operating effort

Braking equipment

Response

Start-up inspection

Every week

Every 2 weeks

Every 6 months

Every 1 year

Every 2 years

After 1200 hours

After 2400 hours

After 4800 hours

Q

Q

Q

Q

Q

Q

Q Q

Q Q

Q Q

Replacem Mainteent nance Intervals interval (month(s)) (h)

Q

Q

Contamination

Q

Q

Q Q

Q Q Q

Changing oil

Q

1200

6

Master cylinder and wheel cylinder Function, wear, and damage Oil leakage and damage of master and wheel cylinders Brake drum and brake shoe Clearance between drum and lining Wear of shoe and lining

Q

Q Q Q Q Q Q

Wear and damage of drum Looseness of drum mounting bolt Wear, damage, and deformation of backup plate and looseness of mounting bolt Fatigue of spring and wear of anchor pin Work equipment operating condition

Loading equipment

Every 3 months

After 50 After 100 After 200 After 600 hours hours hours hours

Rod, cable and link Looseness, play, damage and missing cotter pin Hose and Piping Leakage, damage, and installation condition Reservoir tank Remaining oil level

Every 1 month

Fork Fork and fork stopper deformation, crack and damage Crack and wear at fork bottom and upper and lower hooks (by dye penetration check) Opening, level difference and bend at fork tips Mast and lift bracket Mast deformation, crack, damage and wear Mast roller wear and play and crack of pin Play of mast support portion and looseness of mast cap mounting bolts Chain and chain wheel Crack, deformation, damage and corrosion of chain Deformation, damage and play of chain wheel Chain tension

Q Q Q Q

Q

Q Q Q

Q

Q Q Q

Q

Q Q

Q

Q

Chain elongation Chain lubrication

Q

Q

Q Q 100

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INSPECTION AND MAINTENANCE

INSPECTION AND MAINTENANCE SCHEDULE CHART

Inspection & Maintenance Intervals (hours)

Inspection & Maintenance Item

Load backrest Mounting bolt looseness, crack, damage, and deformation Looseness of tilt cylinder rod and locknut Hydraulic pump Oil leakage, unusual vibration and unusual noise Lift cylinder and tilt cylinder Operating condition and oil leakage Dent, crack, bend, scratch and looseness of mounting bolt Hydraulic drift and hydraulic forward tilt Direction control valve Lo ad Operating condition and oil leakage in Play and looseness of mounting g bolt eq Relief pressure ui Hydraulic tank p Hydraulic tank damage and crack m Changing oil in tank en Tank oil level, contamination and oil t leakage Tank cleaning

Start-up inspection

Every week

Every 2 weeks

Every 1 month

Every 3 months

After 50 After 100 After 200 After 600 hours hours hours hours

Q

Every 6 months

Every 1 year

Every 2 years

After 1200 hours

After 2400 hours

After 4800 hours

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q Q

Q

Q

Q

Q Q Q

Q

Q

Strainer cleaning

Q

Tank and return filter replacement

Q

Braking equipment

Electric al equipment

Attachment hose

Lifting motor Rotation, unusual noise and smell of motor Looseness of mounting bolts Controller Operating condition, unusual noise and smell Maximum motor current Operating condition and timing of contactor Looseness, damage, wear of contactor and looseness of mounting portion Looseness of fuse mounting bolt and matching of capacity Dirt of controller chamber

4 - 70

Q

Q

Q Q Q

Q

Q

Q

Q Q

Q

Q

Q Q

Q

Q

Q Q Q Q Q

Q

1200

6

2400

12

1200

6

Q

Replacement of breather

Piping (Hose and pipe) Piping damage, oil leakage and deformation Piping clip looseness and unfastening Solenoid valve operation, abnormal sound, abnormal heating and oil leakage Travel motor Rotation, unusual noise and smell of the motor Looseness of mounting bolts

Replacem Mainteent nance Intervals interval (month(s)) (h)

Q Q Q

INSPECTION AND MAINTENANCE

INSPECTION AND MAINTENANCE SCHEDULE CHART

Inspection & Maintenance Intervals (hours)

Wiring and sensor

Inspection & Maintenance Item

Start-up inspection

Every week

Every 2 weeks

Every 1 month

Every 3 months

After 50 After 100 After 200 After 600 hours hours hours hours

Wiring Looseness of connecting portions (terminal, connector) Damage, fixing condition, and roughness of wiring harness and power cable Damage and fitting condition of battery connector and plug, and damage and roughness of contact Micro switch and sensor

Every 6 months

Every 1 year

Every 2 years

After 1200 hours

After 2400 hours

After 4800 hours

Replacem Mainteent nance Intervals interval (month(s)) (h)

Q Q Q Q

Operating condition and timing Looseness, damage, and wear of contact Looseness of mounting portion

Q Q

Battery Electrolyte level

Q

Q Q Q

Battery and charging

Specific gravity Voltage Looseness, damage, and roughness of terminal Damage of cell and leakage of electrolyte Connecting condition of connector, damage and looseness of bolts Damage and connective condition of cable Charger Damage, play, and loosening of bolts of charging cable, plug and power receptacle Operating voltage of voltage detector relay Operation of timer and electromagnetic switch, wear Adjustment of power supply voltage tap Looseness, damage, and roughness of terminal Replacement of charging cable

Q Q

Q Q

Q

Q

Q

Q

Q

Q

Q

Q

Q Q

Q

Q Q

Q

Q

Q 2 to 4 years

Q

4800

24 to 48

4 - 71

INSPECTION AND MAINTENANCE

INSPECTION AND MAINTENANCE SCHEDULE CHART

Inspection & Maintenance Intervals (hours)

Inspection & Maintenance Item

Start-up inspection

Every week

Every 2 weeks

Every 1 month

After 50 After 100 After 200 After 600 hours hours hours hours

Chassis Mounting bolt and nut looseness and damage Cracks and deformation Overhead guard Mounting bolt looseness, deformation, damage and crack Seat Operation, mounting bolt looseness, damage, and seat belt damage Alarm

Safety devices for chassis etc.

Operation, sound volume and tone Turn signal and lamp device (headlamp, clearance lamp, brake lamp, backup lamp) lighting up or ON/OFF of the lamps Operation of monitor panel warning lamp Center mirror Contamination, damage, reflection and installation condition Greasing Backup buzzer performance Abnormality found on preceding day Safety device function (Travel interlock, load handling interlock and neutral start) Operation of parking brake reminder alarm buzzer Safety auxiliary function (lift truck with seat belt interlock) Seat belt interlock Travel limit speed at high lift

General test

Lifting height detection sensor

Every 6 months

Every 1 year

Every 2 years

After 1200 hours

After 2400 hours

After 4800 hours

Q Q Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q Q

Q Q Q Q Q Q Q

Locking device Cab window/window washer fluid level, injection state, windshield wiper function and defroster function (only for lift trucks with cab specification and with front glass specification) Function of each device

Q

Unusual vibration, noise, smell and heating

Q

4 - 72

Every 3 months

Q

Q Q

Q

Q

Replacem Mainteent nance Intervals interval (month(s)) (h)

INSPECTION AND MAINTENANCE

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS For using the forklift truck safely for an extended period of time, Komatsu highly recommends the periodic replacement of the defined life and fire prevention-related parts listed in the table of the defined life parts.

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.

When replacing the hose. replace o-ring and gaskets at the same time.

Contact your Komatsu distributor for the replacement of safety critical parts.

Note that the periodic replacement is not covered by warranty.

SAFETY CRITICAL PARTS LIST No.

Periodical replacement parts

1

Brake oil pressure hose

2

Rubber parts of brake master cylinder

3

Wheel cylinder cup, and seals

4

Brake fluid reservoir hose

5

Power steering high pressure circuit hose

6

Rubber parts inside power steering system

7

Lift chain

8

Hydraulic hose (for travel and load handling)

9

Cable (parking brake)

Every 12 months Every 2400hours

Every 2 years Every 4800hours

Others

Q Q Q Q Q Q Every 3 years (7200 h)

Q Q

･ Replacement cycle should be used year-months passed or used hours which is earlier.

4 - 73

INSPECTION AND MAINTENANCE

CONSUMABLE PARTS

CONSUMABLE PARTS Replace consumable parts such as the filter element or air cleaner element at the time of periodic maintenance or before they reach the wear limit. Securely replace the consumable parts to use this lift truck more economically.

For product improvement, the part number may be changed. When ordering parts, inform Komatsu distributor of lift truck serial number and check the latest part number.

CONSUMABLE PARTS CHART

Item

Part No.

Part Name

Q'ty

Replacement Intervals (months)

Hydraulic oil air breather

37B-1PB-4080

Breather

1

Every 2400 hours (12 months)

Hydraulic oil return filter

3EB-66-43630

Element

1

Every 1200 hours (6 months)

Hydraulic tank strainer

34B-66-15180

Strainer

1

-

Drive axle breather

07030-01030

Breather

1

-

4 - 74

INSPECTION AND MAINTENANCE

SERVICE DATA

SERVICE DATA Device

Traveling equipment

Tire

Hub nut

Load handling equipment Steering and Braking system

Rim joint nut

Steering wheel

Brake pedal

Parking brake Fork Chain

Hydraulic system

Inspection item Tire inflation pressure

Tightening torque

Tightening torque

Front wheel Rear wheel Front wheel Rear wheel Front wheel Rear wheel

Play (At the time of a pump operation) Play Height of pedal when depressed Parking brake operating force Installation of back plate Tightening torque of bolt Fork thickness (at base) Length over 17 links

Relief pressure

Unit

FB25-12

FB30-12

kPa{kgf/cm2}

900 {9.00}

800 {8.00}

kPa{kgf/cm2}

1,000 {10.00}

625 {6.25}

245 to 309 {25 to 31.4} 157 to 245 {16 to 25} 196 to 294 {20 to 30} 157 to 196 {16 to 20}

294 to 490 {30 to 50} 157 to 245 {16 to 25}

mm

10 to 30

10 to 30

mm

0 to 4

0 to 4

mm

32 to 52

32 to 52

mm mm

147 to 196 {15 to 20} 157 to 196 {16 to 20} Min. 36 Max. 330

196 to 245 {20 to 25} 157 to 196 {16 to 20} Min. 39.5 Max. 550

MPa{kgf/cm2}

17 to 18.6

17 to 18.6

Nm{kgfm} Nm{kgfm} Nm{kgfm} Nm{kgfm}

N{kgf} Nm{kgfm}

– –

4 - 75

INSPECTION AND MAINTENANCE

SERVICE DATA

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

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

4 - 76

Width across flats (b)mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60

Tightening torque Nm {kgfm} Target value

Allowable range

13 {1.35} 31 {3.2} 66 {6.7} 113 {11.5} 177 {18.0} 279 {28.5} 382 {39.0} 549 {56.0} 745 {76.0} 927 {94.5} 1324 {135.0} 1716 {175.0} 2206 {225.0} 2746 {280.0} 3285 {335.0}

12 to 15 {1.2 to 1.5} 27 to 34 {2.8 to 3.5} 59 to 74 {6.0 to 7.5} 98 to 123 {10.0 to 12.5} 157 to 196 {16.0 to 20.0} 245 to 309 {25.0 to 31.5} 343 to 427 {35.0 to 43.5} 490 to 608 {50.0 to 62.0} 662 to 829 {67.5 to 84.5} 824 to 1030 {84.0 to 105.0} 1177 to 1471 {120.0 to 150.0} 1520 to 1912 {155.0 to 195.0} 1961 to 2452 {200.0 to 250.0} 2452 to 3040 {250.0 to 310.0} 2893 to 3628 {295.0 to 370.0}

TECHNICAL DATA 5

55

5-1

TECHNICAL DATA

TECHNICAL DATA

5-2

Weight

Characteristics

TECHNICAL DATA

1.2 1.3 1.4 1.5 1.6 1.6.1 1.8 1.9 2.1 2.2 2.2.1 2.3 2.3.1 3.1

Model Power Type Operation Type Rated Capacity Load Center Alternative Capacity Load Distance Wheelbase Service Weight Axle Loading Tire Type

Others

Drive

Performance

Dimensions

Tires

3.2

Manufacturer's Designation Electric, Diesel, Gasoline, LPG, Cable Pedestrian, Driver standing, Sitting, Order picking Q Rated Capacity c Rated Load Center Q2 Capacity @600mm Load Center x Front Axle Center to Fork Face y Including Min. Capacity Battery, See line 6.5 Front Loaded Rear Front Unloaded Rear Cushion, Elastic Cushion, Pneumatic, Polyurethane

kg mm kg mm mm kg kg kg kg kg

Front Tire Size

3.3

Rear

3.5 3.6 3.7 4.1 4.2 4.3 4.4 4.5 4.7 4.19 4.20 4.21

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

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

4.22

Forks

s/e/l

4.23 4.24 4.31 4.32 4.33 4.34 4.35

Fork Carriage Class Width, Fork Carriage

Turning Radius

5.1

Travel Speed (FWD)

5.2

Lifting Speed

5.3

Lowering Speed

5.6 5.8

Max. Drawbar Pull Max. Gradeability

ISO 2328, Type A/B/no b3 m1 Under Mast m2 at Center of Wheelbase Ast with L1000 x W1200 pallet Ast with L1200 x W800 pallet Wa Loaded Unloaded Loaded Unloaded Loaded Unloaded Loaded 1.5 km/h, 3 min rating Loaded 1.5 km/h, 3 min rating

5.10

Service Brake

Operation/Type

5.11

Parking Brake

Operation/Control

5.12 6.1 6.2 6.2.1 6.4 6.4.1 6.4.2 6.5

Steering Drive Motor Pump Motor PS Motor Battery Voltage Battery Capacity, Min Battery Capacity, Max Battery Weight

Type 60 min. rating 5 min. rating 60 min. rating

8.1 8.2 8.2.1

Ground Clearance Aisle Width *

Thickness x Width x Length

Min.Capacity Battery, See line 6.4.1

mm mm degree mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm km/h km/h mm/s mm/s mm/s mm/s N %

kW kW kW V Ah/5hr Ah/5hr kg

Drive Motor Control Relief Pressure for Attachment Hydraulic Tank Capacity

Mpa L

FB25-12 Electric Sitting 2500 500 2260 450 1550 3800 5585 715 1520 2280 Pneumatic 23 x 9-1016PR 18 x 7-816PR 2x/2 975 960 6/11 1995 155 3000 4050 2155 3515 2445 1200 40 x 122 x 1070 class2, A 1020 115 110 3840 3970 2120 14.0 16.0 260 550 500 540 10900 16 Foot/ Hydraulic Hand/ Mechanical FHPS 9.6 10.3 72 360 470 1085 AC, MOSFET inverter 18.1 25

FB30-12 Electric Sitting 3000 500 2720 490 1650 4660 6780 880 1935 2725 Pneumatic 28 x 9-1514PR 21 x 8-910PR 2x/2 1005 980 6/11 2065 160 3000 4270 2215 3710 2640 1235 45 x 122 x 1070 class3, A 1060 140 145 4060 4190 2300 13.5 15.5 330 550 420 450 13200 18 Foot/ Hydraulic Hand/ Mechanical FHPS 12.0 13.2 72 450 545 1145 AC, MOSFET inverter 18.1 26

The table above shows the standard specification. The values can be different by the installed options or tire types. *: VDI 2198 includes 200 mm clearance

5-3

INDEX

6

66

6-1

INDEX

INDEX <A>

<G>

About this manual ------------------------------------------------ 1-2 Action level display--------------------------------------------- 4-61 Action to take if the fork fails to lower --------------------- 4-57

General view -------------------------------------------------------3-2 General view of lift truck---------------------------------------3-2 Instruments and controls --------------------------------------3-3 General view of lift truck-----------------------------------------1-5 Application of lift truck -----------------------------------------1-5 Direction of lift truck --------------------------------------------1-5

<B> Basic precautions----------------------------------------------- 2-15 Asbestos caution --------------------------------------------- 2-21 Caution when washing lift truck --------------------------- 2-18 Cautions for safety-related equipment ------------------ 2-17 Do not modify the lift truck---------------------------------- 2-20 Do not remove the overhead guard and load backrest ------------------------------------------------------------------ 2-20 Fire extinguisher and first aid kit -------------------------- 2-16 Fire prevention ------------------------------------------------ 2-19 Follow rules ---------------------------------------------------- 2-15 If a fire breaks out -------------------------------------------- 2-20 Jumping on and off from the lift truck is strictly prohibited ------------------------------------------------------------------ 2-17 Keep the operator’s compartment and platform clean and tidy-------------------------------------------------------------- 2-17 Never operate the broken-down lift truck --------------- 2-16 Practice sufficiently before operation -------------------- 2-17 Secure safety at the working area------------------------ 2-21 To avoid burn injury ------------------------------------------ 2-18 Wear adequate clothes and safety equipment for operation------------------------------------------------------ 2-16 Window washer caution------------------------------------- 2-21 Battery replacement ------------------------------------------- 4-52

<H> Handling of battery --------------------------------------------- 4-42 Hoisting and transporting the lift truck --------------------- 2-47 Caution when hoisting the lift truck ----------------------- 2-47 Cautions for loading and unloading the lift truck ------ 2-47 Hoisting lift truck------------------------------------------------- 4-64 How to read monitor panel -------------------------------------3-9 Average power consumption/Instantaneous power consumption (ECO gauge) ------------------------------- 3-18 Battery discharge indicator (BDI) ------------------------- 3-17 Clock/Hour meter (SMR)/Travel distance (Odometer)/ Caution symbol ---------------------------------------------- 3-12 Current travel speed ----------------------------------------- 3-17 Directional lever position/ Action level display--------- 3-18 General view of monitor panel -------------------------------3-9 Hour meter (SMR) integration state ---------------------- 3-10 Load handling power mode -------------------------------- 3-16 Parking brake indication------------------------------------- 3-10 Travel interlock/Load handling interlock indication --- 3-10 Travel power mode ------------------------------------------- 3-16 How to tow the lift truck or be towed ----------------------- 4-58

<C>

<I>

Charging ---------------------------------------------------------- 4-46 Charging with stationary charger ------------------------- 4-48 Checking and reporting after operation ------------------- 4-26 Consumable parts ---------------------------------------------- 4-74

Inspection and maintenance -----------------------------------4-2 Inspection and maintenance schedule chart------------- 4-67

<E> Electronic control system ------------------------------------- 4-60 Explanation of components ------------------------------------ 3-4 Explanation of operating devices --------------------------- 3-4

<F> Fire prevention ---------------------------------------------------- 2-9 Action if fire occurs ------------------------------------------- 2-14 Battery fire prevention ----------------------------------------- 2-9 Clean ------------------------------------------------------------ 2-14 Fire prevention caused by deposited or adhered flammable substances ------------------------------------ 2-13 Fire prevention caused by oil and grease -------------- 2-13 Fire prevention caused by oil leakage------------------- 2-13 Fire prevention coming from piping ---------------------- 2-14 Fire prevention during charging--------------------------- 2-10 Fire prevention from electrical wiring -------------------- 2-13 For your safety ---------------------------------------------------- 1-3 Safety indicators ------------------------------------------------ 1-4 Signal words ----------------------------------------------------- 1-3

6-2

<L> Load handling operation -------------------------------------- 2-33 Loading and unloading of lift truck-------------------------- 4-65 Long-term storage ---------------------------------------------- 4-55 After storage---------------------------------------------------- 4-55 Before storage ------------------------------------------------- 4-55 During storage ------------------------------------------------- 4-55

<N> Necessary information of lift truck ----------------------------1-7 Memorandum (to be filled by Komatsu distributor) -----1-7 Model and serial number plate location -------------------1-7

<O> Operating lift trucks in special environment or in forcible way ------------------------------------------------------------------- 4-56 Operation --------------------------------------------------------- 3-46 Checking after operation ------------------------------------ 3-70 Handling of KOMTRAX installed lift truck--------------- 3-71 Inching travel --------------------------------------------------- 3-59 KOMTRAX ------------------------------------------------------ 3-71 Load handling operation ------------------------------------ 3-64 Mounting/dismounting and operating posture adjustment ---------------------------------------------------- 3-46

INDEX Operation on snowy and frozen roads ------------------ 3-60 Plugging (Electric brake) ------------------------------------ 3-59 Seat heater ----------------------------------------------------- 3-54 Starting and stopping on slope ---------------------------- 3-58 Starting and travel -------------------------------------------- 3-55 Start-up inspection-------------------------------------------- 3-46 Temporary stopping, parking and stopping ------------ 3-61 Travel interlock function ------------------------------------- 3-63 Travel limit speed at high lift function -------------------- 3-51 Turning ---------------------------------------------------------- 3-60 Operation of monitor panel ----------------------------------- 3-20 Charging mode ------------------------------------------------ 3-41 Clock/hour meter (SMR)/travel distance (odometer) selection------------------------------------------------------- 3-22 ID key function (only lift trucks equipped with ID key) ------------------------------------------------------------------- 3-42 Maintenance --------------------------------------------------- 3-35 Monitor setting ------------------------------------------------- 3-36 Operation mode ----------------------------------------------- 3-20 User menu ------------------------------------------------------ 3-22 Working Record ----------------------------------------------- 3-30

<P> Periodic replacement of safety critical parts ------------- 4-73 Periodical inspection ------------------------------------------- 4-27 Inspection for every 100 hours (2 weeks) -------------- 4-28 Inspection for every 50 hours (1 week) ----------------- 4-27 Precautions for inspection and maintenance ------------ 2-38 Always perform the checks before starting------------- 2-38 Avoid getting caught up by the mast or falling off ---- 2-41 Be careful of high pressure oil ----------------------------- 2-41 Beware of rotating cooling fan ----------------------------- 2-42 Caution after inspection and repair----------------------- 2-46 Caution in waste disposal----------------------------------- 2-46 Caution when handling battery ---------------------------- 2-43 Caution when handling tires-------------------------------- 2-45 Cautions for using compressed air for cleaning------- 2-42 Cautions when replacing the seat ------------------------ 2-42 Cautions when working under work equipment ------- 2-40 Keep the working area clean and tidy ------------------- 2-38 Keep unauthorized people off ----------------------------- 2-40 Periodic replacement of safety critical parts ----------- 2-46 Precautions before inspection and maintenance ----- 2-39 Precautions when installing radio control system ---- 2-42 Put up a warning sign during inspection and maintenance ------------------------------------------------------------------- 2-38 Remove battery plug ----------------------------------------- 2-43 Use of right tools and equipment ------------------------- 2-40

<Q> Qualifications for operation -------------------------------------1-6

Safety labels----------------------------------------------------- 2-4 Service data ------------------------------------------------------4-75 Simple maintenance--------------------------------------------4-29 Adjusting parking brake lever operating effort ---------4-35 Greases----------------------------------------------------------4-29 Replacing bulbs------------------------------------------------4-41 Replacing fuse -------------------------------------------------4-36 Replacing tires -------------------------------------------------4-33 Stationary charger --------------------------------------------4-40 Start-up inspection ---------------------------------------- 2-22,4-2 Checking abnormalities detected on the previous day -------------------------------------------------------------------- 4-4 Checking by operating the work equipment control lever -------------------------------------------------------------------4-18 Checking by setting the starting switch to [ | ] (on) position -------------------------------------------------------------------4-15 Checking from the operator?s seat -----------------------4-13 Checking of lift truck with front glass specification (Only lift truck with front glass specification) ---------------------4-25 Checking of safety auxiliary function ---------------------4-23 Checking of safety function ---------------------------------4-20 Checking while traveling slowly----------------------------4-17 Checks conducted by opening cover and hood -------- 4-7 Walk around a forklift------------------------------------------ 4-4 Structure and stability of the lift truck (to prevent lift truck from tipping) --------------------------------------------------2-48 Allowable load--------------------------------------------------2-49 Center of gravity of a load-----------------------------------2-48 Combined center of gravity and stability on the loaded lift truck ------------------------------------------------------------2-49 Introduction of optional safety auxiliary device --------2-52 Longitudinal stability ------------------------------------------2-48 Serial no. plate and load table -----------------------------2-50

<T> Telephone number for the point of contact if an error occurs ----------------------------------------------------------4-60 Traveling-----------------------------------------------------------2-23 Preparation before traveling the lift truck----------------2-23 Stopping and parking-----------------------------------------2-31 Towing -----------------------------------------------------------2-32 While traveling the lift truck ---------------------------------2-25

<U> Units of measure ------------------------------------------------- 1-5

<W> Warranty and service-------------------------------------------- 1-6 Periodical exchange parts ----------------------------------- 1-6 Use of genuine Komatsu parts and oils ------------------ 1-6 Washing lift truck ------------------------------------------------4-62

<R> Running in cold weather -------------------------------------- 4-55 Running in new lift truck-----------------------------------------1-6 Maintenance for new lift truck--------------------------------1-6 Running in new lift truck---------------------------------------1-6

<S> Safety labels -------------------------------------------------------2-2 Safety label location chart ------------------------------------2-2

6-3

FB25-12, FB30-12 FORKLIFT TRUCK Form No. TEN00722-04

©2021 KOMATSU All Rights Reserved Printed in Japan 03-2021