AMX and BMX Electric Forklift Truck S/N 23001A~ AMX FB15 ... · 1. Internal combustion equipment a. Engine (excluding all accessories and consumable trade parts) b. Torqflow and standard

Read and observe all warnings on this unitbefore operating it.DO NOT operate this equipment unless allfactory-installed guards and shields are properlysecured in place.

WARNING

OPERATION & MAINTENANCE MANUALAMX and BMX Electric Forklift TruckS/N 23001A~

AMXBMX

REVISED: FEBRUARY 2011

OM051R

AMX FB15/18M-3 BMX FB20M-3BMXL FB18MG-3

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The information and specifications contained herein were accurate at the time ofpublication, but may change without notice as required for product improvements.Neither Komatsu Forklift USA, LLC nor its parent company nor any of its subsidiaries willbe held responsible for damages due to misuse or inappropriate use of its products.

© Copyright 2011, Komatsu Forklift USA, LLC. All rights reserved. No part of thisdocument may be photocopied or reproduced in any way without prior written consent ofKomatsu Forklift USA, LLC.

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CONTENTS

3

Contents

FOREWORD1. FOREWORD ................................................................................................................... 1-12. SAFETY INFORMATION ................................................................................................ 1-23. WARRANTY AND SERVICE FOR NEW LIFT TRUCK .................................................. 1-3

3.1 RUNNING IN A NEW LIFT TRUCK..............................................................................................1-33.2 FIRST MONTH OR INITIAL 200 HOURS OF SERVICE FOR NEW LIFT TRUCK......................1-33.3 MODEL LINE UP..........................................................................................................................1-33.4 GENUINE KOMATSU FORKLIFT PARTS ...................................................................................1-33.5 LOCATION OF PLATES ..............................................................................................................1-43.6 CONTACTING KOMATSU FORKLIFT.........................................................................................1-4

SAFETY4. SAFETY MANAGEMENT ............................................................................................... 2-15. SAFE TRAVEL................................................................................................................ 2-56. LOADING OPERATIONS ............................................................................................. 2-127. STOPPING AND PARKING.......................................................................................... 2-188. INSPECTION AND MAINTENANCE ............................................................................ 2-199. STRUCTURE AND STABILITY OF THE LIFT TRUCK................................................ 2-2510. SAFETY LABELS ......................................................................................................... 2-28

OPERATION11. OVERVIEW OF LIFT TRUCK ......................................................................................... 3-1

11.1 GENERAL VIEW OF LIFT TRUCK...............................................................................................3-111.2 INSTRUMENTS AND CONTROLS ..............................................................................................3-2

12. EXPLANATION OF COMPONENTS .............................................................................. 3-312.1 STARTING SWITCH ....................................................................................................................3-312.2 TROUBLE CODE INDICATOR LIGHT (RED WARNING LAMP).................................................3-312.3 COMBINATION HOURMETER/BATTERY DISCHARGE ............................................................3-412.4 LAMP SWITCH.............................................................................................................................3-412.5 FORWARD/REVERSE LEVER ....................................................................................................3-412.6 PARKING BRAKE LEVER ...........................................................................................................3-512.7 ACCELERATOR PEDAL..............................................................................................................3-512.8 BRAKE PEDAL.............................................................................................................................3-512.9 LIFT LEVER .................................................................................................................................3-512.10 TILT LEVER .................................................................................................................................3-512.11 ATTACHMENT LEVER ................................................................................................................3-512.12 ADJUSTABLE STEERING COLUMN ANGLE KNOB ..................................................................3-612.13 HORN ...........................................................................................................................................3-6

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4

12.14 FORK STOPPER .........................................................................................................................3-612.15 OPERATOR’S SEAT (STANDARD EQUIPMENT) ......................................................................3-712.16 STROBE LIGHT OPTION ............................................................................................................3-8

13. CHECKS BEFORE OPERATION ................................................................................... 3-913.1 CHECK BEFORE OPERATION (WITH KEY SWITCH OFF) .......................................................3-913.2 CHECKS AFTER TURNING SWITCH TO THE “ON” POSITION ..............................................3-1613.3 CHECKS WHILE ADVANCING SLOWLY..................................................................................3-1813.4 CHECKS WHILE OPERATING CONTROL LEVERS ................................................................3-18

14. OPERATION ................................................................................................................. 3-1914.1 MOUNTING/DISMOUNTING .....................................................................................................3-1914.2 STARTING THE ELECTRIC LIFT TRUCK.................................................................................3-1914.3 PLACING LIFT TRUCK IN MOTION ..........................................................................................3-2014.4 PLUGGING.................................................................................................................................3-2014.5 STARTING AND INCHING ON SLOPE .....................................................................................3-2014.6 TURNING ...................................................................................................................................3-2114.7 STOPPING AND PARKING .......................................................................................................3-2214.8 LOADING AND UNLOADING OPERATIONS............................................................................3-2314.9 TIRES .........................................................................................................................................3-28

15. COLD WEATHER OPERATION................................................................................... 3-2916. LONG-TERM STORAGE .............................................................................................. 3-30

16.1 BEFORE STORAGE ..................................................................................................................3-3016.2 DURING STORAGE...................................................................................................................3-3016.3 AFTER STORAGE .....................................................................................................................3-30

MAINTENANCE17. OUTLINE OF SERVICE .................................................................................................. 4-1

17.1 OIL................................................................................................................................................4-117.2 GREASE.......................................................................................................................................4-117.3 OIL STORAGE AND PRESERVATION .......................................................................................4-117.4 FILTERS.......................................................................................................................................4-1

18. LUBRICANT LIST........................................................................................................... 4-218.1 LUBRICANT LIST / ELECTRIC LIFT TRUCK ..............................................................................4-218.2 OIL AND GREASING CHART......................................................................................................4-3

19. SERVICE DATA.............................................................................................................. 4-419.1 SERVICE DATA (ELECTRIC LIFT TRUCK) ................................................................................4-419.2 TORQUE LIST..............................................................................................................................4-4

20. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....................................... 4-521. MAINTENANCE SCHEDULE CHART............................................................................ 4-622. MAINTENANCE .............................................................................................................. 4-9

22.1 AFTER FIRST MONTH OR INITIAL 200 HOURS SERVICE.......................................................4-922.2 EVERY TWO WEEKS OR 100 HOURS SERVICE....................................................................4-11

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22.3 EVERY MONTH OR EVERY 200 HOURS SERVICE................................................................4-1222.4 EVERY 3 MONTHS OR 600 HOURS SERVICE........................................................................4-1422.5 EVERY 6 MONTHS OR 1,200 HOURS SERVICE.....................................................................4-1422.6 EVERY 12 MONTHS OR 2,400 HOURS OF SERVICE.............................................................4-15

23. REPLACEMENT PROCEDURES ................................................................................. 4-1623.1 REPLACING FUSES..................................................................................................................4-1623.2 REPLACING TIRES ...................................................................................................................4-1623.3 REPLACING LAMPS..................................................................................................................4-17

24. LIFT TRUCK WASHING PROCEDURE ....................................................................... 4-18

TECHNICAL DATASPECIFICATIONS – FB15M/ME-3, FB18M/ME-3................................................................... 5-1

SPECIFICATIONS – FB18MG/MGE-3, FB20M/ME-3 ............................................................. 5-2

PERFORMANCE – 1.5-TON TRUCKS: FB15M/ME-3 ............................................................ 5-3

PERFORMANCE – 1.8-TON TRUCKS (STANDARD): FB18M/ME-3 ..................................... 5-3

PERFORMANCE – 1.8-TON TRUCKS (EXTENDED FRAME): FB18MG/MGE-3 .................. 5-4

PERFORMANCE – 2.0-TON TRUCKS: FB20M/ME-3 ............................................................ 5-4

MAST DATA – 3,000 LB. CAPACITY UNITS .......................................................................... 5-5



FORKLIFT DIMENSIONAL DIAGRAM (TYPICAL).................................................................. 5-7

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PRODUCT WARRANTY

6

PRODUCT WARRANTY

Class I, IV and V IC

E &

Electric S

it-down Trucks – U

.S.A.

Kom

atsu Forklift U.S.A

., LLCK

PW

CE

RT-S

TD-1

PRO

DU

CT W

AR

RA

NTY – C

LASS I, IV A

ND

VIC

E & ELEC

TRIC

SIT-DO

WN

TRU

CK

SK

omatsu Forklift U

.S.A

., LLC (hereinafter called

KFI) warrants new

equipment to be free from

defects in materials and w

orkmanship under the

conditions of the following provisions.

STAN

DA

RD

WA

RR

AN

TY K

FI Standard Warranty for new

equipment shall

be (12) months or the first 2,000 operating hours

after delivery to the initial purchaser, rental orlessee, w

hichever event shall occur first.

POW

ER TR

AIN

PRO

TECTIO

N

WA

RR

AN

TY K

FI warrants the follow

ing major com

ponents fora period of 730 days or the first 4,000 operatinghours

after delivery

to the

initial purchaser,

rental, or lessee, whichever shall occur first.

1.Internal com

bustion equipment

a.Engine (excluding all accessories andconsum

able trade parts)b.

Torqflow

and standard

transmissions

(excluding dry clutch and components)

c.Torque converter assem

blyd.

Differential

and drive

axle (excluding

brake assembly)

2.B

attery-powered equipm

ent a.

Electric motors (excluding brushes)

b.S

CR

, Transistor & A

C Traction C

ontrol-ler Panel (excluding fuses)

c.C

ontactor panels (excluding contact tipsand sw

itches)d.

Differential

and drive

axle (excluding

brake assembly)

KFI O

BLIG

ATION

K

FI shall have the obligation to repair or replace,at K

FI's option, any defect in material or w

ork-m

anship at no charge, by authorized KFI dealer,

during the specified warranty period.

LIMITATIO

NS A

ND

EXCLU

SION

S This w

arranty is not applicable to or inclusive ofany of the follow

ing:1.

Equipment w

hich has been subjected to alterations and/or m

odifications not approved in w

riting from KFI, neglect, unau-

thorized repair, misuse, accidents, lack of

reasonable proper maintenance, norm

al adjustm

ents, improper repairs or replace-

ments, use of parts w

hich do not conform to

KFI's specifications.

2.N

ormal replacem

ent of any and all consum-

able parts such as, but not limited to light

bulbs, filter elements, hoses, lubricating and

hydraulic oil, and/or parts required to per-form

a regular maintenance service.

3.Tires and tubes.

4.B

atteries for battery-powered trucks.

5.A

ttachments, com

ponents, parts or acces-sories of products or equipm

ent not manu-

factured by KFI.

6.U

sed products or equipment.

LIMITED

LIAB

ILITY 1.

Any and all other express, statutory, and im

plied warranties applicable to the prod-

uct, including, without lim

itation, all implied

warranties of m

erchantability and fitness for use, are expressly disclaim

ed.

2.In no event shall the dealer, its custom

ers or users be entailed to recover incidental or consequential dam

ages, including, but not lim

ited to, damages or inconvenience,

rental or replacement equipm

ent, loss of profits, or other com

mercial loss.

3.KFI neither assum

es nor authorizes any other to assum

e for it any other liability in connection w

ith the sale or service of the equipm

ent.

4.N

o modifications, alterations or changes of

this limited w

arranty is permitted or autho-

rized by KFI-approved dealer.

5.S

ome states prohibit exclusion or lim

itation of im

plied warranty of m

erchantability or fit-ness for a particular purpose, and/or inci-dental or consequential dam

ages, so you m

ay have additional rights.

EPA PR

OD

UC

TS R

efer to the applicable Federal EPA warranty

certificate for emission control w

arranty state-m

ents:

Truck Model

Serial N

umber

Com

pany

City & State

Delivery D

ate

Delivering D

ealer

Gasoline/LP

G engine

EPA

GA

S2007-1

Diesel engine

EPADSL2004-1

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READ AND FOLLOW ALL SAFETY PRECAUTIONS. FAILURE TO DO SO MAY RESULT IN SERIOUS

INJURY OR DEATH.

FOREWORD

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1. FOREWORD

1-1

1. FOREWORD

This manual provides rules and guidelines which will help you use this lift truck safely and effectively.

Always be sure to read and understand this manual thoroughly before operating and performing maintenance.

Some actions involved in operation and maintenance of the lift truck can cause a serious accident if they are notdone in the manner described in this manual.

DIRECTION OF TRUCKThis manual uses the directions left, right, front and rear as they are seen from the operator's seat.

• Improper operation and maintenance of this lift truck can be hazardous and could result inserious injury or death.

• Operators and maintenance personnel should read this manual thoroughly before beginningoperation or maintenance.

• Keep this manual handy and have all personnel read it periodically.• Do not use this lift truck unless you are sure that you understand the contents completely.• If this manual has been lost, or has become dirty or worn and cannot be read, request a

replacement manual from your Komatsu Forklift dealer.• Komatsu Forklift delivers lift trucks that comply with (to the best of our knowledge at the time

of delivery) all applicable regulations and standards of the country to which they have beenshipped. If this lift truck has been purchased in another country or purchased from someonein another country, it may lack certain safety devices and specifications that are necessary foruse in your country. If there is any question about whether your product complies with theapplicable standards and regulations of your country, consult your Komatsu Forklift dealerbefore operating the lift truck.

• Continuing improvements in the design of this lift truck may not be reflected in this manual.Consult Komatsu Forklift or your Komatsu Forklift dealer for the latest available informationon your lift truck or for questions regarding information in this manual.

• Information on safety is given in the SAFETY, OPERATION and MAINTENANCE sectionsthroughout this manual; please read it carefully and completely.

RIGHT

LEFT

FRONT REAR

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2. SAFETY INFORMATION

1-2

2. SAFETY INFORMATION

This OPERATING MANUAL contains information necessary for the operation of a basic fork lift truck. Optionalequipment is sometimes installed that can change some operating characteristics described in this manual. Makesure the necessary instructions are available and understood before operating the lift truck.

Some of the components and systems described in this OPERATING MANUAL will NOT be installed on your unit.If you have a question about any item described, contact your local dealer.

Additional information that describes the safe operation and use of lift trucks is available from the followingsources:

• Employment safety and health standards or regulations• Safety codes and standards, such as: American National Standard, ANSI B56.1, Safety Standard For Low Lift

and High Lift Trucks.• Publications from government safety agencies, government insurers, private insurers and private organiza-

tions, such as: Accident Prevention Manual for Industrial Operations from the National Safety Council.

NOTE: Forklift trucks are not intended for use on public roads.

Most accidents are caused by a failure to follow fundamental safety rules for the operation and maintenance of lifttrucks.

To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the lift truckbefore operating and performing maintenance.

Do not operate or carry out maintenance of this lift truck unless you are sure that you understand the explanationsand procedures completely.

To identify safety messages in this manual and on lift truck labels, the following signal words are used.

These safety messages or labels describe precautions that must be taken toavoid a hazard which carries a serious risk of serious injury or death.

These safety messages or labels usually describe precautions that must be takento avoid a hazard which may lead to serious injury or death.

This word is used on safety messages and safety labels for hazards which couldresult in injury or damage to the lift truck or surrounding property if the hazard isnot avoided.

Safety precautions are described in the SAFETY, OPERATION and MAINTENANCE sections of this manual.

Komatsu Forklift cannot predict every circumstance that might involve a potential hazard in operation andmaintenance. Therefore, the safety messages in this manual and on the lift truck may not include all possiblesafety precautions.

If any procedures or actions not specifically recommended or allowed in this manual are used, it is yourresponsibility to be sure that you and others can do such procedures and actions safely and without damaging thelift truck. If you are unsure about the safety of some procedures, contact your Komatsu Forklift dealer.

The procedures and precautions given in this manual apply only to intended uses of the lift truck. If you use your lifttruck for any unintended use that is not specifically prohibited, you must be sure that it is safe for you and others. Inno event should you or others engage in prohibited uses or actions as described in this manual.

This word is used for precautions that may not lead to damage or failure, but which must be takento avoid actions that could shorten the life of the lift truck.

NOTICE

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3. WARRANTY AND SERVICE FOR NEW LIFT TRUCK

1-3


3.1 RUNNING IN A NEW LIFT TRUCKYour Komatsu lift truck has been thoroughly adjusted and tested before shipment.However, operating the lift truck under severe conditions at the beginning can adversely affect performance andshorten the lift truck life. Be sure to take special care concerning the following items during this initial period ofoperation.• Avoid operation with heavy loads or at high speeds.• Avoid sudden starting or acceleration, unnecessarily abrupt braking and sharp turning, except in the case of

emergency.

3.2 FIRST MONTH OR INITIAL 200 HOURS OF SERVICE FOR NEW LIFT TRUCK

For new lift truck, carry out the following maintenance only after the first month or 200 hours.

3.3 MODEL LINE UP

3.4 GENUINE KOMATSU FORKLIFT PARTSGenuine Komatsu Forklift parts are manufactured from the same materialsand by the same method as the parts built in the new lift truck.

In the event that the customer uses imitation parts, Komatsu Forklift willnot be held accountable for any faults which result from the use of suchimitation parts, and the Komatsu Forklift warranty will not be applicable.

Always use genuine Komatsu Forklift replacement parts.

Unit Check items RemarksTransfer case Change oil

Hydraulic tank

Change oilReplace line filterClean strainerClean inside tank

Other Tighten all bolts and nutsParticularly lug (hub) nuts, overhead guard mounting bolts, backrest mounting bolts, and operator's seat mounting bolts.

Model Applicable lift truckSerial Number

AMX / BMXL / BMX ELECTRIC LIFT TRUCKSDescription

FB15M-3FB15ME-3

23001A and Up

3,000 lb. capacity, cushion tire

FB18M-3FB18ME-3 3,500 lb. capacity, cushion tire

FB18MG-3FB18MGE-3 3,500 lb. capacity, cushion tire, extended battery compartment

FB20M-3FB20ME-3 4,000 lb. capacity, cushion tire

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1-4

3.5 LOCATION OF PLATES3.5.1 LIFT TRUCK SERIAL NUMBERS

3.5.2 DATA PLATE AND EMBOSSED SERIAL NUMBERData plate (nameplate) with vehicle serial number:Installed on the dashboard panel at the far right side.

Embossed vehicle serial number:Located on the floorplate at the far right end.

UL (Underwriters Laboratories) license plate:Installed on the front face of the dashboard panel.

3.6 CONTACTING KOMATSU FORKLIFTWhen contacting a Komatsu Forklift dealer for parts ordering or problem consulting, always give the lift truck modeland serial number embossed on the lift truck.

NOTICE

Take care not to damage the embossed serial number.

RemarkThe serial number is also located on the data plate.

Model Applicable lift truck No.

FB15MA-3 / ME-3FB18M-3 / ME-3FB18MG-3 / MGE-3FB20M-3 / ME-3

23001A and up

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INJURY OR DEATH.

SAFETY

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4. SAFETY MANAGEMENT

2-1


• Read the instructions in this Manual and the Safety Labels attached to the various parts of the lift truck,and make sure that you understand and follow them. If you do not understand or do not follow theinstructions, this will lead to improper operation which may lead to damage, personal injury or death.

• Be sure that you understand the proper method of using the lift truck and the procedure for carrying out aninspection, and ensure that they are carried out safely.

• Read this Manual and the Safety Labels again from time to time. If the Operation and MaintenanceManual or Safety Labels have been lost or become dirty and cannot be read, obtain replacements fromyour Komatsu Forklift dealer and attach the Safety Labels in the specified positions.

OPERATION MANUAL AND SAFETY LABELS

• This lift truck should be operated only by qualified personnel. Be sure you have proper qualificationsbefore operating the lift truck.

• When operating this lift truck, even if you have experience in operating other lift trucks, obtain instructionsfrom an authorized person who has experience in operating this lift truck or the same type of lift truck.

OPERATING QUALIFICATIONS

• Avoid loose clothing, jewelry, and loose long hair. They can catch oncontrols or in moving parts and cause serious injury or death.

• Always wear a hard hat and safety boots.• Depending on the working conditions, wear other safety equipment as

well.

CLOTHING AND PERSONAL PROTECTIVE ITEMS

Do not use this lift truck unless it is equipped with the overhead guard and load backrest shipped with the lifttruck from the factory by Komatsu Forklift.

OVERHEAD GUARD, LOAD BACKREST

• Any modification made without authorization from Komatsu Forklift can create hazards.• Before making any modification whatsoever, consult your Komatsu Forklift dealer. Komatsu Forklift will not

be responsible for any damage, injury or death caused by any unauthorized modification.• Do not install any equipment or parts which obstruct or limit the operator’s view.

UNAUTHORIZED MODIFICATION

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2-2

• If any abnormality in the lift truck occurs, stop operation immediately, parkthe lift truck in a safe place and safe condition, then contact the person incharge.

• Be sure that fire extinguishers have been provided and that you read thelabels to ensure that you know how to use them.

• Know what to do in the event of a fire.• Be sure that you know the phone numbers of persons you should contact in

case of an emergency.• Provide a first aid kit at the storage point.• Do not use the lift truck if it is leaking fuel. Inform the person on charge of

the nature of the abnormality, and repair the leakage before using the lift truck.• Do not leave the lift truck with the engine running. Always apply the parking brake securely, lower the forks

to the ground, stop the engine, and remove the key before leaving the lift truck.

FIRE EXTINGUISHER AND FIRST AID KIT

• Do not operate the lift truck if you are fatigued, or when you have been drinking, or you have taken anymedication which can make you drowsy or sleepy.

• When carrying out operation, inspection, or maintenance of the lift truck, always follow all work shop rules,safety regulations and precautions.

• During operation, always pay attention to safety and be careful of pedestrians, traffic and othersurrounding conditions.

SAFETY RULES

When reversing, depending on the situation, an optional alarm, reversing lamp or rotary lamp should be used.In all cases, be sure to face the rear and check around before traveling in reverse.

CHECK WHEN TRAVELING IN REVERSE

• Do not travel on public roads unless you comply with local, state or other laws which regulate such activity.• Always observe all traffic regulations when operating the lift truck.• Do not drive on public roads with the lift truck loaded.• Do not tow other machines on public roads. (Do not tow other machines even when not on public roads).• Always carry your driver's license when traveling on public roads.

TRAVELING REGULATIONS ON PUBLIC ROADS

• The overhead guard is installed to protect the operator from falling objects. It is designed to withstand theforce of light boxes or small packages. It is not designed to withstand every possible impact.

• Always be careful to prevent damage or injury from falling objects.

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2-3

The tire fenders prevent objects from being thrown up by the tires. When changing from a single tire to adouble tire arrangement on your forklift truck, always extend the tire fenders to cover the additional tires. If thefenders are not extended, small stones and other objects will be thrown up and may injure the operator orother people in the surrounding area.

TIRE FENDERS

• Always work on level surfaces and wipe up all oil or grease from the ground.• When working on quays, platforms, docks or other places where there is a danger of falling, set up blocks

to prevent the lift truck from going over the edge.• Put warning signs up in dangerous places to warn the operator not to approach.• Mark the travel areas clearly and maintain the road surfaces in good condition.• Put up signs to prevent unauthorized machines from entering areas where trucks are being operated.• Ensure that there is adequate lighting to enable operations to be carried out safely.

SAFE WORKING AREA

• Keep the operator's compartment clean and tidy. Be sure to clean up all oil or mud. If the operator's handor foot slips, this may lead to a serious accident.

• Do not leave tools or spare parts lying around in the operator's compartment. They may damage orobstruct the control levers or pedals. Always keep them in the tool box when not being used.

CLEAN OPERATOR'S COMPARTMENT

• Before operation, establish an operating plan and hold a meeting to discuss operating safety.• In confined areas, position a signal person and carry out operations in accordance with his or her

instructions.• When carrying out operations on roads, put up fences around the working area and carry out operations in

accordance with instructions from the signal person.

SAFE OPERATING PLAN

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2-4

• The permissible load for any lift trucks equipped with an attachment is lower than the permissible load forthe standard lift truck. Reasons:1. The permissible load must be reduced by an amount equivalent to the weight of the attachment

itself.2. Because of the thickness of the attachment, the load center moves forward.

• Always observe the permissible load as stated on the capacity plate strictly (this plate is attached to the lifttruck or the attachment). Never exceed the permissible load.

REDUCE LOAD FOR LIFT TRUCKS WITH ATTACHMENT

• Avoid operating or leaving the lift truck outside in wet and rainy weather or snow and icy conditions.• When washing the lift truck, use care to prevent water from contacting electrical parts. If water does come

in contact with the electrical system it may cause the system to operate abnormally and it may becomeimpossible to control the lift truck.

KEEP FREE FROM WATER

• Remove the key from the faulty lift truck and hang signs inthe operator's compartment to prevent its use.

• If the lift truck has suffered a failure and the lift truck must beparked without lowering the forks, put markers on the tips ofthe forks and take steps to prevent pedestrians or othervehicles from hitting the forks.

• Select a parking place where people or vehicles do notpass, and stop the lift truck so that it is difficult for anyone togo under the forks. (The area under the forks is a dangerzone.)

DON'T USE A DEFECTIVE LIFT TRUCK - USE LOCK-OUT TAG-OUT PROCEDURES

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5. SAFE TRAVEL

2-5

5. SAFE TRAVEL

• Always fit your seat belt correctly when operating. If your seat belt is fittedincorrectly, there is danger of serious personal injury if the lift truck should tipover.

• Always check the seat belt mounts and check for any damage to the seat belt.If any abnormality is found, repair or replace the seat belt immediately

WEARING SEAT BELT

• NEVER JUMP OFF the lift truck even if it seems that it will tip. Alwaysdo as follows:1. Hold the steering wheel securely.2. Stay in the operator's seat.3. Brace your legs.

• If you jump off the lift truck when it turns over, there is dangerthat you will be fatally crushed under the lift truck. Always stay inthe operator's compartment if the lift truck turns over, then escapefrom the lift truck after it has stopped.

• Always wear the seat belt correctly.

DO NOT JUMP OFF LIFT TRUCK EVEN IF IT TIPS

Travel Interlock (power transmission cutoff)• 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, the truck is provided with Travel Interlock that makestravel and truck operation impossible if you are not seated properly (Operator Presence System).

• If you operate the lift truck in such a posture that your weight is not properly applied to the seat, likestanding up or leaning forward or sideways, the Travel Interlock begins to alarm in approximately threeseconds and cuts off the transmission of engine power. Then the truck will not move, even if you depressthe accelerator pedal or operate the Forward/Reverse lever.

MAINTAIN PROPER POSTURE WHILE OPERATING

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5. SAFE TRAVEL

2-6

• Depress the brake pedal firmly, then start the unit.• Before starting the unit, always check that the parking brake is applied

and that the directional lever is in neutral.• Adjust the operator's seat and the steering wheel before starting the

unit. Always lock them in position after adjusting. Adjusting the seat orsteering wheel during operation is dangerous as it may cause you tolose your balance or operate the lift truck wrongly.

• When starting the unit, first check that the surrounding area is safe, andsit in the operator's seat.

• Before starting the unit, sound the horn to warn people in the area.• With large-sized lift trucks, get off the lift truck, and walk around it to

check that is no one near the battery compartment, t ires, orcounterweight, then get on the lift truck, sit in the operator's seat, andstart the unit.

PRECAUTIONS WHEN STARTING UNIT

• If a problem occurs on a railroad crossing and the lift truck will not move or cannot be moved, get off andmove away from the lift truck

• In such an emergency, light a flare or smoke candle to warn approaching trains and people in the area thatthere is a broken-down truck on the tracks.

ESCAPING FROM A RAILROAD CROSSING

• If the load-engaging means or load is raised, the center of gravity ofthe lift truck will also rise and increase the danger of the lift trucktipping. Do not turn the lift truck when the forks are raised high.

• Do not suddenly raise the forks or tilt the mast to the front or rear whenthe forks are loaded. There is danger that the lift truck will tip.

• Reduce speed before turning the lift truck. • In particular, when traveling unloaded, the rear of the lift truck is heavy.

If the lift truck is turned at high speed, there is a greater chance oftipping than with the forks loaded.

TIPPING

• When reversing, never depend on the rear view mirror; the operator must visually check behind him. Also,adjust the rear view mirror so that the operator can check from the operator's seat that the area behind thelift truck is safe.

• Always keep the surface of the mirror clean. If the mirror is broken, replace it with a new one (for lift trucksequipped with rear view mirror).

• Check that the lamps light up correctly. Replace any broken bulbs (for lift trucks equipped with lamps).

REARVIEW MIRROR, LAMPS

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5. SAFE TRAVEL

2-7

• Do not turn, or travel across or at an angle on slopes. There is danger thatthe lift truck will tip.

• Before starting to drive up a slope, stop the lift truck and adjust theclearance between the ground surface and the bottom of the forks so thatthe bottom of the forks or pallet do not contact the ground surface or the tipof the fork does not stick into the ground when traveling.

• For safe travel on slopes:

• When traveling downhill, operate the foot brake and drive the lift truckslowly.

• When starting on slopes, the lift truck may start to move down the slopedepending on the amount the pedals are depressed.

• Always leave ample room in front of and behind the lift truck when startingon slopes.

• Be careful of the truck sliding downhill if Travel Interlock is engaged whiletraveling uphill or on a slope. Stay securely in the operator’s seat!

When loaded: Travel FORWARD up the slope and in REVERSE down the slope with the load upgrade.

When unloaded: Travel in REVERSE up the slope and FOR-WARD down the slope with the load-engaging means downgrade.

TRAVEL ON SLOPES

• There is danger that soft road shoulders may collapse, so do not go nearthem with the lift truck.

• Always maintain a safe distance from the edge of road shoulders andplatforms.

ROAD SHOULDER

• If the view to the front is obstructed by the load, turn to the rear anddrive the forklift truck in reverse.

• When driving in reverse with a high load, use a signal person toensure the safety of the load and the safety in the surroundingarea.

WHEN FRONT VIEW IS POOR

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5. SAFE TRAVEL

2-8

• Do not travel on the edge of docks. There is danger that the lifttruck may fall, which may result in serious injury or death.

• Before starting operations, check the load limit for the gangplanks (dockboards), and do not use them if they do not have ample strength to takethe weight of the lift truck when loaded.

• Apply the brakes on the highway truck and block the wheels.• With trailers, use jacks and take steps to prevent the trailer from sinking

when the forklift truck travels on it.• When driving the forklift inside trucks, reduce speed when backing out

and be sure to check that the gangplanks are safe.• Be careful of pedestrians.• Tell the truck driver not to move the truck until the operation is

completed.• If there is some system to secure the truck to the dock, always use this

system. Secure the gangplanks so that they do not slip and fall.

LOADING HIGHWAY TRUCKS OR RAILROAD CARS

FORKLIFT TRUCKS ARE ONE-PERSON MACHINES• Do not allow any other person to ride on

the truck under any circumstances.• Never allow anyone to act as an extra

counterweight.

NO RIDERS

• Before driving in reverse, make sure that there is no one behind thetruck before starting to travel.

• The rear view mirror is simply an aid for checking the rear. Whendriving in reverse, do not use the rear view mirror. Turn to face therear and check the area directly behind the lift truck.

• Even if you sound the backup buzzer, the people behind the truckdo not necessarily hear it. Always check that there is no one behindthe truck before driving the truck.

DRIVING IN REVERSE

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5. SAFE TRAVEL

2-9

When checking the lift truck before starting, follow the procedure given in this Manual, and do not start the lifttruck until all the checks have been completed. If anything abnormal is found, inform the person in charge andcarry out the necessary repairs.

CHECK BEFORE STARTING

• NEVER jump onto or off the lift truck.• When getting on or off the lift truck, always stop the lift truck and use the

handrails and steps to ensure that you support yourself.• Never hold any control levers or the steering wheel when getting on or off the

lift truck.• If there is any oil, grease or mud on the handrails or steps, wipe it off

immediately. Always keep these parts clean. Repair any damage.

MOUNTING AND DISMOUNTING

Do not drive the lift truck if your hands are wet or covered with oil. Your hands will slip on the work equipmentcontrol levers or directional lever, and this may cause a serious accident.

KEEP HANDS FREE FROM OIL AND WATER

Always observe the following:• Never operate the lift truck from outside the operator's compartment.• Always keep your body under the overhead guard.• Do not extend your arms and legs outside the operator's compartment.

ALWAYS SIT IN OPERATOR'S SEAT

• Do not stop the engine when traveling. If the engine is stopped, the power steering (for lift trucks withpower steering) and power brake (for lift trucks with power brakes) will not work.

• Do not use the brake excessively. Do not rest your foot on the brake pedal unless you are operating it. Ifyou do, the brake will overheat and the braking effect will be lost.

BRAKING WHEN TRAVELING

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5. SAFE TRAVEL

2-10

• Before starting and moving the lift truck, check that the surroundingarea is safe.

• Before moving the lift truck, raise the forks (approximately 8 in. (20 cm)from the ground surface), and tilt the mast back.

• Before moving the lift truck, release the parking brake.

SAFETY WHEN STARTING

• When traveling, always pay careful attention to the area aroundyour lift truck, particularly in the direction of travel or whenturning.

• Do not pass other vehicles on narrow roads or at crossings orother places where the view is poor.

• When traveling through crossings or other places where the viewis poor, or when entering or leaving narrow roads, stop andsound the horn to confirm safety before driving on.

• Even if you sound the horn, not everyone in the surrounding areawill necessarily hear it. Always pay careful attention to themovements of people in the surrounding area.

• When crossing roads or turning corners, stop and confirm safetybefore continuing.

• Always pay careful attention to the movements of people in the surrounding area, and take steps toprevent people from entering the working area.

CONFIRMING SAFETY

When traveling on slopes or in confined areas, unloaded lift trucks should always give the right of way toloaded trucks.

GIVE PRIORITY TO LOADED LIFT TRUCKS

When going in or out of places with height or width limits: • Ensure that there is ample height and width for the lift truck to pass.• Do not extend your hands or legs outside the lift truck.• Check that the surrounding area is safe.• Be careful of electric wires and other obstacles inside and outside the

building.

HEIGHT OR WIDTH LIMITS

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5. SAFE TRAVEL

2-11

To ensure safety when driving the lift truck, always pay careful attentionto the following:• Avoid traveling in places which are flooded or where there are holes.• Do not try to drive the lift truck on soft ground.• Avoid curbs, rails, ditches, or other obstacles, and do not travel

directly over them.• Do not travel on slippery road surfaces.• When entering buildings, check the weight limit of the floor and be

careful not to exceed the limit.• Keep a clear view of the path of travel and observe for other traffic,

personnel, and safe clearances.• When passing oncoming vehicles, reduce speed and keep a safe

distance from the other vehicle.• In places where there are speed limits, observe the speed limit and maintain a safe distance from other

vehicles.

SAFETY DURING TRAVEL

• When turning while traveling forward, the counterweight will swingfar out. Keep an ample clearance from walls and other objects toensure safety.

• When turning, travel slowly and be careful that the front or rearwheels do not come off the ground.

• When turning on soft road shoulders, there is danger that the rearwheels may come off the road shoulder and cause the lift truck totip.

PRECAUTIONS WHEN TURNING

• When traveling downhill, it requires a longer distance for the lift truck to stop than when traveling on levelground.

• When traveling downhill, reduce the speed and make sure that you have ample room at the bottom of theslope to stop.

• When traveling on wet surfaces, you will require a longer distance to stop than when traveling on normalroad surfaces. Always have ample room to stop.

STOPPING DISTANCE

If there is any problem with the brakes or steering system of your lift truck, do not use another lift truck to towit because there is the danger that the lift truck may run away.

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6. LOADING OPERATIONS

2-12


• Do not load the lift truck over the capacity set forth in the loadcapacity chart. If the rear wheels come off the ground because ofoverloading, the lift truck cannot travel or turn. There is also dangerthat it may tip.

• Always check the load capacity chart to confirm the loadingcapacity.

NO OVERLOADING

• Never allow anyone to go under the load-engaging means or load when itis raised. The area under the forks is a danger area. If the forks come down,any person under the forks may be crushed, seriously injured orkilled.

• Never allow anyone to go under the load-engaging means or load even if itis elevated, stuck or caught in the up-position as it may fall down suddenlyat any moment.

DO NOT GO UNDER FORKS

Do not use the forks to lift people. Any person that falls from the forks may beseriously injured.

DO NOT LIFT PEOPLE ON FORKS

• Always operate the mast and forks from the operator's compartment.• Do not stand beside the lift truck and operate the levers, or operate the levers through the mast.

OPERATE THE LIFT TRUCK FROM THE OPERATOR'S COMPARTMENTPro

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• Never put your hands or feet into the mast structure. There is danger thatyou will get caught in moving parts and be seriously injured.

• Do not use the mast, load backrest or dashboard as a ladder or step. If youslip, there is danger that you will fall.

BE CAREFUL NOT TO GET CAUGHT OR FALL

• Make sure that the center of gravity of the load is in line with the centerof the lift truck. Do not carry loads off-center. There is danger thatunbalanced loads may cause the lift truck to tip. Place the load so that itcontacts the load backrest.

• Do not handle unstable loads. If there is danger that the load may falloff, secure it in position and take steps to prevent the load fromcollapsing or falling.

• When carrying stacked loads, tie with rope or otherwise secure it toprevent the load from falling.

NO UNSTABLE LOADS

• Keep the height of the load within the height of the load backrest. • Do not carry any load that is higher than the load backrest. If the load

is higher than the load backrest, there is danger that it will fall back ontop of the operator.Carrying a load higher than the load backrest may lead toserious injury or death.

DO NOT LOAD ABOVE HEIGHT OF LOAD BACKREST

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• Do not tilt the mast forward when the forks are loaded and raised.There is danger that the load may fall and that the lift truck may tip.

• Do not travel with the mast tilted forward.• Do not load and unload on slopes.

DO NOT TILT MAST FORWARD WHEN LOADED

• If the mast rail or forks catch in a load or on a shelf, slack in the lift chainmay be created, resulting in danger that the load may fall and the lifttruck tip.

• Always be careful that there is no slack in the chain when pulling theforks out from a pallet or shelf.

KEEP TENSION ON CHAIN

• Do not use the lift truck for anything other than the intended use(loading operations using the forks).

• Do not use the forks to open or close the doors of railroad cars orwarehouses.

• Do not push any other vehicle.• Do not hook ropes or cables on the forks and use the forks to lift

loads.• Do not use the drawbar pin for towing operations.

USE ONLY FOR INTENDED PURPOSES

• Be careful not to operate the lever by mistake or to operate the wrong lever. There is danger that the forksor work equipment may cause serious injury.

• Do not operate the levers when getting off the lift truck.

LEVER OPERATION

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Do not use the drawbar pin for towing other lift trucks, forbeing towed by other lift trucks, or for lifting operations.The drawbar pin installed to the rear of the counterweight is usedonly to free the truck when the tires have become stuck in mud orin a ditch and the lift truck cannot move, or when loading the lifttruck on to a trailer or truck.

USING DRAWBAR PIN

• Adjust the position (spread) of the forks to match the size of theload.

• When adjusting the position (width) of the forks, be careful not to getyour hands caught.

• After adjusting, check that the forks are held securely in position bythe fork stopper. If the forks are not held in position, there is adanger that the forks may move when the lift truck is traveling andthe load may fall off.

FIT FORKS SECURELY IN POSITION

Be sure the tension of the left and right chains is the same. (See “CHECK LIFT CHAIN” on page 3-17.) If thetension is not the same, the load will be unbalanced even if it is loaded correctly in the center, and there isdanger that the lift truck may tip.

ADJUST CHAIN

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• Do not allow the tips of the forks to get close to people. The tipsof the forks are pointed, so there is a risk that they may causeinjury.

• Do not hook the tips of the forks under objects. If the forks slipout, there is danger that the lift truck or object may moveunexpectedly.

BE CAREFUL OF FORK TIPS

• Do not allow anyone except the signal person in the working area. • Do not let any person or another lift truck come close during operation.• When working with a signal person, always follow their instructions.

PEOPLE IN WORKING AREA

• Always be sure that the pallets and skids have ample strength. If broken or damaged pallets or skids areused, there is a risk that the load may fall.

• Always check that the load is positioned securely and safely on the pallet before driving the truck.

USE STRONG PALLETS AND SKIDS

• Be extremely careful when carrying long or wide loads. Raise the loadslowly and be careful not to touch anything in the surrounding area.

• Keep the load as low as possible and be sure to maintain the balance.• When turning, operate slowly and be careful not to let the load move.

HANDLING LONG OR WIDE LOADS

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• Be careful not to let the mast, overhead guard or load contactelectrical wiring, pipes, sprinklers or roof beams. If the truck hits suchobjects, there is a risk that the load will fall or the lift truck will tip.

• When the forks are raised, the mast height increases, so beparticularly careful when the forks are raised.

OVERHEAD OBJECTS

Do not use the forks to push or pull loads. There is a risk that the load willbe damaged or fall.

NO PUSHING

• Do not let anyone place a load on the forks.• Do not let anyone remove a load directly from the forks.• Standing on the forks is dangerous because the forks are slippery and the load may move.• Do not use anyone to keep the load stable. The lift truck may move unexpectedly, causing the load to fall

and crush the person.• If you operate the lift truck in such a posture that your weight is not properly applied to the seat, like

standing up or leaning forward or sideways, Travel Interlock begins to alarm in approximately threeseconds and cuts off the transmission of engine power. Then the truck does not move even if you depressthe accelerator pedal or operate the Forward/Reverse lever.

• The truck will slide downhill if Travel Interlock activates on an uphill grade or a slope.

PRECAUTIONS WHEN LOADING / UNLOADING

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7. STOPPING AND PARKING

2-18

7. STOPPING AND PARKING

Observe the following procedure when stopping or parking the lift truck:1. Stop the lift truck on level ground.2. Apply the parking brake securely to make sure that the lift truck

cannot move.3. Set the directional lever and the speed lever to neutral.4. Lower the forks to the ground.5. Turn the key switch OFF to stop the engine.6. Remove the key from the key switch and get off the lift truck.

PRECAUTIONS WHEN STOPPING OR PARKING

• Park the lift truck in the specified place.• Park the lift truck on a firm surface.• Do not park near any emergency exit, stairway, fire extinguisher or other safety equipment. Park the lift

truck in a place where it will not obstruct pedestrians or other vehicles.• Never park the lift truck near any flammable object.• When parking the lift truck on a slope, park as specified above (PRECAUTIONS WHEN STOPPING OR

PARKING), then put blocks under the tires to prevent the lift truck from moving.• Do not park near any holes for construction or elevator shafts.

PARKING

• If the lift truck has suffered a failure and the lift truck must be parkedwithout lowering the forks, put markers on the tips of the forks and takesteps to prevent pedestrians or other vehicles from hitting the forks.

• Select a parking place where people or vehicles do not pass, and stopthe lift truck so that it is difficult for anyone to go under the forks. (Thearea under the forks is a DANGER zone).

• Place a stand or something similar under the inner mast rail or forks toprevent unexpected drop of the forks.

• Remove the key from the faulty lift truck and hang signs in the operator's compartment to prevent its use.

PARKING MACHINE AFTER FAILURE

Because a stuck fork may drop down unexpectedly, do not go under the fork when it is in this condition. Bevery careful when dealing with this problem to prevent damage or injury, and warn those in the work area.

ABRUPT LOWERING OF STUCK FORK

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8. INSPECTION AND MAINTENANCE

2-19


• Only persons authorized by the owner or operator of the equipment and having proper certification (localor national) may carry out inspection, maintenance and repairs of the lift truck.

• It is very dangerous to carry out inspection, maintenance or repair work incorrectly.

USE QUALIFIED PERSONNEL FOR INSPECTION AND MAINTENANCE

• When carrying out inspection and maintenance, use a level, dry, dust-free area.• If the work is carried out inside a building, make sure that there is ample ventilation.

MAINTENANCE LOCATION

• To be prepared in the event of a fire, have a fire extinguisher nearby and make sure that you know how touse it.

• Before carrying out inspection, lower the forks to the ground, stop the machine, and place the directionallever, speed lever and work equipment control levers in neutral.

• Do not run the engine unless it is necessary.

PRECAUTIONS FOR INSPECTION AND MAINTENANCE

• Always clean the lift truck before starting inspection. Wipe off any oil or grease. Immediately wipe up anyoil that has leaked. If the lift truck is dirty, it becomes difficult or impossible to find cracks or other problems.

• Do not smoke or allow any flame to exist under any circumstances. Do not use any cloth which is soakedin fuel, flammable solvent, oil or grease. There is danger that it may catch fire.

• Wear suitable clothes for the job.• Use suitable safety and protective equipment (hard hat, safety boots, safety glasses, gloves) for the job.• When working on top of the lift truck, be careful not to fall.• Do not put your feet under the forks.• When opening or closing the floor plate or engine hood, be careful not to get your hands or body caught.• When carrying out inspection with the forks raised, insert a stand under the inner mast to prevent the forks

and mast from dropping. • When carrying out the job with another worker, decide who is the leader and carry out the job in

accordance with instructions from that person.• After repairing, make sure that the trouble has been corrected by performing a trial run.• During the trial run, start and operate the lift truck carefully because it is possible that the trouble has not

been fully corrected or that defective parts have not been removed.

PRECAUTIONS WHEN CARRYING OUT INSPECTION AND MAINTENENCE

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• Always use tools that are suited for inspection and maintenance. • It is extremely dangerous to use broken tools or tools designed for

another purpose.

USE SUITABLE TOOLS

Even if no abnormality is found, always replace safety critical parts periodically. As time passes, these partsdeteriorate and may cause fire or failure in the work equipment system. See “SAFETY CRITICAL PARTSLIST” on page 4-5 for the list of safety critical parts. However, if these parts show any abnormality before thereplacement interval has passed, they should be repaired or replaced immediately.

REPLACE SAFETY CRITICAL PARTS PERIODICALLY

• Immediately after using the lift truck, the oil is at high temperature. Donot drain the oil or replace the filter when the oil is hot. Hot oil mayspurt out and cause burns.

• When carrying out inspection and maintenance, wait for the oiltemperature to go down, and carry out the operation in the ordergiven in this manual.

• Do not forget that the work equipment circuits are always underpressure. Do not add oil, drain oil or carry out maintenance orinspection before completely releasing the internal pressure.

• If oil is leaking under high pressure from holes, it is dangerous if thejet of high-pressure oil hits your skin or eyes. Always wear safetyglasses and thick gloves, and use a piece of cardboard or a sheet ofplywood to check for oil leakage.

• Release the internal pressure before checking the accumulatorpiping.

• If you are hit by a jet of high-pressure oil, consult a doctorimmediately.

INCORRECT

CORRECT

PRECAUTIONS WITH HIGH PRESSURE, HIGH TEMPERATURE OIL

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• Never put your hands or feet into the mast structure. There is danger thatyou will get caught in moving parts and be seriously injured.

• Do not use the mast, load backrest or dashboard as a ladder or step. If youslip, there is danger that you will fall.

BE CAREFUL NOT TO GET CAUGHT OR FALL

Disassembly and assembly of tires should be carried out by a tire dealer.• The wheel is fitted with mounting (lug) nuts. Loosen the lug nuts and remove the tire.• When the tires have been replaced, carry out a test drive and check again for any loose mounting bolts. If

the tightening torque is low, tighten to the specified torque.

HANDLING TIRES

• Do not go under the fork lift truck when it is jacked up. Check thefollowing before jacking up the lift truck. (For details, see “REPLACINGTIRES” on page 4-16.).1. Check that there is no one on the lift truck.2. Check that there is no load on the forks.

• When jacking up, stop when the tires come off the ground surface. Putblocks under both sides of the frame to prevent the lift truck fromcoming down.

• Put blocks under any tires contacting the ground to prevent the lift truckfrom moving.

JACKING UP LIFT TRUCK (when checking or replacing tires)

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• Lift truck slinging work should be carried out by a qualified person whohas completed a course in correct lifting methods.

• Fit wire ropes to the specified lifting points.• When lifting the lift truck, check that the wire ropes have ample

strength and are not damaged.• Block the tires contacting the ground to prevent the lift truck from

moving.• Insert blocks to prevent the lift truck from coming down.• Do not go under the lift truck during the lifting operation.• If the specified lifting point is the counterweight, check that the

counterweight mounting bolts are tightened to the specified torquebefore carrying out the lifting operation. Check also that there is nodamage to the lifting portion on the counterweight.

LIFTING LIFT TRUCK (when checking tires)

• Battery electrolyte contains sulfuric acid and can quickly burn the skinand eat holes in clothing. If you spill electrolyte on yourself,immediately flush the area with a large quantity of water.

• Battery electrolyte can cause blindness if splashed into the eyes. Ifelectrolyte gets into your eyes, flush them immediately with largequantities of water and consult a doctor at once.

• If you accidentally drink electrolyte, drink a large quantity of water ormilk mixed with beaten egg white or vegetable oil. Call a doctor orpoison control center immediately.

• When working with batteries, ALWAYS wear safety glasses orgoggles.

• Batteries generate hydrogen gas. Hydrogen gas is highlyEXPLOSIVE, and is easily ignited with a small spark or flame. Do notsmoke or create any spark near a battery.

• Before working with batteries, stop the engine and turn the startingswitch to the OFF position.

• When removing the battery, remove the cable from the negative (-)terminal first. When installing the battery, install the cable to thepositive (+) terminal first. This prevents possible sparks or arcingbetween the positive terminal and the positive cable.

• Avoid short-circuiting the battery terminals through accidental contact with tools or other metal objectsacross the terminals. Tighten the battery terminals securely. Loose terminals can generate sparks andlead to an explosion.

• When removing or installing the battery, confirm which is the positive (+) terminal and which is thenegative (-) terminal. Be careful not to connect the cables to the opposite / incorrect terminals.

• Tighten the battery caps securely.• When cleaning the battery, leave the battery caps tightened.

BATTERY HAZARD PREVENTION

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Never place any metal objects on top of the battery. There is danger that they will cause a short circuit andstart a fire.

DO NOT PUT METAL OBJECTS ON TOP OF BATTERY

Do as follows when replacing a fuse:• Turn the starting switch OFF.• Disconnect the battery plug.• Replace the fuse.

REPLACING A FUSE

Hydrogen gas is generated as the battery charges and the battery is heated by the chemical change. Toprevent the danger of gas explosion, always do as follows.• Before carrying out charging, check that the battery electrolyte level is within the correct range. If the level

is low, add distilled water immediately.• Carry out the charging operation in a clean, dust-free, well-ventilated place.• Start the charging operation when the temperature of the battery electrolyte is below 35 °C(95 °F). • (If the temperature goes above 50 °C (122 °F) during the charging operation, wait for it to go down below

35 °C (95 °F) before starting charging operation again.)• When using a battery charger to charge the battery, take the battery caps off.• Follow the specific operation manual for the battery charger being utilized.• During charging, always open the battery bonnet and lock it.• Explosive gas is produced in the battery during charging. Keep flame away from battery.• Clean the top of the battery and ensure it is kept dry. Confirm that the caps are closed. A dirty top will badly

affect battery life.• If the battery charger is used for a long time with remarkably deviated tap voltage at the power supply, the

charger could burn out. Periodically check facility side voltage and adjust the tap voltage by selectingappropriate taps of power supply.

• Cables, receptacles and safety devices (circuit breaker or fuses) should have a capacity corresponding tomaximum input current to battery charger. Insufficient capacity may cause fire. Maximum input currentvaries depending on battery charger.

• When connecting and disconnecting the plug, always grip the plug body. Do not pull the cable todisconnect the plug as this may break the wires.

• Loosened connections between an outlet and plug, broken contact terminals, damaged power supplycable, etc., can cause a fire due to overheating.

• Thoroughly check for proper connection.• Connect the plug directly to the appropriate outlet because large amount of current flows during charging.• Never use multiple connections to a single outlet nor use cables extended with couplings.

PRECAUTIONS WHEN CHARGING

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• Never hoist the lift truck by the overhead guard. If the truck has to be lifted frequently, it will be necessaryto install special lifting equipment. Please contact your Komatsu Forklift dealer for additional informationon purchasing and installing such equipment.

• Contact your Komatsu Forklift dealer before carrying out lifting operations with a lift truck equipped with anoptional steel cab.

• Fit wire ropes to the specified lifting points.• When lifting the lift truck, check that the wire ropes have ample strength and are not damaged.

HOISTING THE LIFT TRUCK (WHEN LOADING TRAILER, ETC.)

It is dangerous if the brakes do not work because, in this condition, the lift truck cannot be stopped. Always dothe following:• Check the level of the brake fluid periodically.• Always use the specified brake fluid.• Check that the breather of the brake fluid reserve tank is not clogged.• Be careful not to let dirt or dust get into the brake fluid reserve tank.

HANDLING BRAKE FLUID

Obey appropriate laws and regulations when disposing of harmful items andmaterials such as oil, fuel, solvent, filters and batteries.

WASTE MATERIALS

INCORRECT

If water gets into the electrical system (controller, sensor,connectors, etc.) there is the hazard that it wil l causemalfunctions or operational failure. Do not wash the electricalsystem with water or high-pressure steam. For more details onthe wash ing method, see “L IFT TRUCK WASHINGPROCEDURE” on page 4-18.

PRECAUTIONS WHEN WASHING LIFT TRUCKS

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9. STRUCTURE AND STABILITY OF THE LIFT TRUCK

2-25

9. STRUCTURE AND STABILITY OF THE LIFT TRUCKTo prevent the lift truck from tipping, and to operate the lift truck safely, it is important to understand the structure and stability of the lift truck.

A forklift truck consists basically of the lifting mechanism (the forks andmast) at the front and the lift truck itself (with tires) at the rear.The front wheels of the lift truck act as the fulcrum, and the center of gravityof the lift truck and center of gravity of the load are kept in balance.The relationship between the position of the center of gravity of the lift truckand the center of gravity of the load is extremely important for maintainingthe safety of the lift truck.

STRUCTURE OF LIFT TRUCK

The loads carried by forklift trucks come in various shapes (andweights) from boxes to planks and long objects. To judge thestability of the lift truck, it is important to distinguish the position ofthe center of gravity for loads of various shapes.

CENTER OF GRAVITY OF LOAD

For the lift truck to be stable, the position of the combined center ofgravity must be inside the triangle (stable range of center of gravity)formed by the ground contact points of the left and right front tires andthe center of the rear axle.If the position of the overall center of gravity is in front of the front axle,the front tires will form the fulcrum and the lift truck will tip to the front. Ifthe position of the combined center of gravity moves outside the triangleforming the stable area for the center of gravity, the lift truck will tip in thedirection where the combined center of gravity moves outside of thetriangle.

STABLE RANGE OF CENTER OF GRAVITY

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The stability of the lift truck is determined by the position of thecombined center of gravity resulting from the combination of thecenters of gravity of the lift truck and the load.When the lift truck is carrying no load, the center of gravity remainsas it is, but when the lift truck is loaded, the combined center ofgravity becomes the combination of the centers of gravity of both thelift truck and the load.The position of the center of gravity of the load changes according towhether the mast is tilted forward or back or whether the mast israised or lowered.The position of the combined center of gravity of the lift truck isgoverned by the following factors:• Size, weight, shape of load• Lifting height• Tilting angle of mast• Inflation pressure of tires• Acceleration, deceleration, turning radius• Condition of road surface, angle of road• Type of attachments

CENTER OF GRAVITY AND STABILITY

The horizontal distance between the center of gravity of the load on theforks and the load backrest of the forks, or the front face of the forks(whichever is shorter), is called the load center. The maximum load isthe maximum weight of the load that can be loaded at the standard loadcenter. The relationship between the maximum load and the loadcenter is given in the load capacity charts on the nameplate on the lifttruck. If the load center moves to the front of the forks, the overallcenter of gravity also moves to the front, so this means that the loadmust be reduced.

MAXIMUM LOAD (weight and center of gravity of load)

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The allowable load is stamped on the nameplate to show therelationship regarding the position of the load center, theheight of the fork and the maximum load. Before loading theforks, check that the load and load center are within thepermitted range on the stamped allowable load.If the shape of the load is complex, set it so that the heaviestpart of the load is at the center of the forks and set the loadclose to the load backrest.If the forks are loaded more than the allowable value, the drivewheels will float during travel and the steering system will notwork. This is very dangerous. Furthermore, the lift truck will tipover easily under this condition. Therefore, be sure to keepthe load below the allowable value and properly balanced.

ALLOWABLE LOAD

If a stationary object is not subjected to external force, it will remain stationary. In the same way, if a movingobject is not subjected to external force, it will continue to move at the same speed. This is called inertia.Because of inertia, a force is applied towards the rear when the lift truck starts to move, and is appliedtowards the front when the lift truck stops. If the brakes are applied suddenly, there is danger of a large forcebeing applied towards the front which may make the lift truck tip or the load come off the forks.When the lift truck is turned, a centrifugal force is applied to the outside from the center of the turn. This forcepushes the lift truck to the outside and makes it tip. The range of stability to the left and right is particularlysmall, so it is necessary to reduce speed when turning, in order to prevent the lift truck from tipping. If the lifttruck is traveling with a raised load, the position of the overall center of gravity is high, so the danger of tippingto the front, left or right becomes greater.

SPEED AND ACCELERATION

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10. SAFETY LABELS

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10. SAFETY LABELSKeep these and all other labels clean. If any label comes off, stick it on again or replace with a new one.

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10. SAFETY LABELS

2-29

1. Lubrication table2. Never enter the area under the forks and do not ride on forks.

Never permit the operator to stand on the forks and raise or lower himself/herself.

3. No Passengers4. Overhead Guard Strength5. CAUTION - Tipover

• Always wear your seat belt during operations.• If the lift truck tips over, follow these instructions:

- Never jump off the lift truck.- Hold on tight to the wheel.- Brace your feet firmly.- Lean away from the direction of fall.

6. CAUTION for Operation7. DATA PLATE (Top of Dash Panel - Right Side)

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10. SAFETY LABELS

2-30

8. Avoid getting hand caught in mast structure and machinery.

9. BATTERY SIZE DECALContains information on battery size and important specifications.

10. WARNING - LATCHWarnings concerning latch safety and operation.

11. CAUTION - PROHIBIT STEAM WASHINGCaution decal displaying important information concerning electrical parts safety. Do not steam clean, or usesolvents to clean, any electrical lift truck components.

12. WARNING - PARKING BRAKEImportant information about parking the lift truck, leaving the operator’s seat, and use of parking brake.

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INJURY OR DEATH.

OPERATION

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11. OVERVIEW OF LIFT TRUCK

3-1


11.1 GENERAL VIEW OF LIFT TRUCK

1. Mast 7. Forks2. Lift-chain 8. Overhead guard3. Lift cylinder 9. Counterweight4. Load back rest 10. Rear wheel5. Tilt cylinder 11. Front wheel6. Fork carriage

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11.2 INSTRUMENTS AND CONTROLS

NOTICE

Checking for blown bulbs in warning lamps:1. Check that all warning lamps light up when the starting switch is turned ON.2. If any warning lamp does not light up, the bulb for that lamp is blown.

1. Starting switch 2. Trouble Code Indicator (red) 3. Hourmeter/Battery Discharge

Indicator (Combo gauge)4. Lamp OFF/ON switch5. Forward/Reverse lever (includes

PS motor switch/horn switch)

6. Parking brake lever7. Accelerator pedal8. Brake pedal9. Lift lever10. Tilt lever11. Adjustable steering column knob

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12. EXPLANATION OF COMPONENTS

3-3


The following is an explanation of the devices employed to operate the lift truck. To carry out suitable operations correctly and safely, it is important to fully understand the operation of theequipment and the meaning of the various displays.

12.1 STARTING SWITCH

OFF: The key can be inserted or removed. ON: When the key is turned one click to the right, the BDI gauge of thecombination meter lights up and the T -contactor is closed.The operator must be seated for the lift truck to operate.

12.2 TROUBLE CODE INDICATOR LIGHT (RED WARNING LAMP)

The red WARNING lamp (see right) comes on to indicate a “Trouble Code”problem with the lift truck. Error handling is suspended when the key switchis OFF.The warning lamp indicates the error code by displaying a blinking pattern(see below).For information about clearing Operator Presence error 01, see table belowand “HORN ALARM OPERATION (OPERATOR PRESENCE)” on page 3-7.

WARNING LAMP BLINKING PATTERNS AND CODE IDENTIFICATIONThe error code blinkingpattern is defined by thevariables T1a, T1b, T1_2,T2a, T2b and T2_1. Thesevariables can be set by theuser. In the exampleshown on the right, thelamp blinks out Error 22.

WARNING NO. CONDITION CAUSE CORRECTION

01 Neutral Safety/Operator Presence

F/R lever is operated, or accelerator pedal is pressed before starting switch is turned ON. Truck cannot move if this happens.

Return F/R lever to NEUTRAL. Release acceler-ator pedal. Turn switch to ON again.If truck still does not start, contact your dealer.

11 Left traction controller High Temperature

Truck is used in High Temperature environment under high load for long hours. Travel power is reduced in this situation.

Stop truck to reset automatically. Lamp should go off.If this warning is displayed while temperatures are normal, contact your dealer.

12 Left traction motorHigh Temperature

31 Right traction controllerHigh Temperature

32 Right traction motorHigh Temperature

Always before turning the starting switch ON:• Sit firmly in the operator’s seat.• Set F/R lever to NEUTRAL.• Keep your foot off of the accelerator.

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12.3 COMBINATION HOURMETER/BATTERY DISCHARGE INDICATOR (BDI)This combination gauge activates when the key switch is turned ON.The hourmeter records operating time of the lift truck. The BDI portion of the gauge displays the amount of battery chargeremaining in the battery in 10% steps from ZERO to 100%. Theindication level can be adjusted to working conditions. It is set to “K”when new.This display consists of 2 red, 3 yellow and 5 green vertical “LED”bars, and can be used to indicate when recharging is necessary.The gauge can be used on 36 Volt and 48 Volt applications, but isset to 48 Volt when new. To set the gauge for 36 Volt use, changethe connector on the back of the gauge.

LIFT INTERRUPT (LIFT LOCKOUT)When the battery is discharged 80% or more, the Lift Interrupt worksto stop the work equipment. If this function is not desired, changethe connector on the back of the meter.

The gauge can be used on 36 Volt and 48 Volt applications, but isset to 48 Volt when new. To set the gauge for 36 Volt use, changethe connector on the back of the gauge.

12.4 LAMP SWITCHThis switch activates when the key is turned ON. It is a three-position toggle switch with OFF in the center position.

12.5 FORWARD/REVERSE LEVER(Including P/S motor switch and horn switch)

FORWARD - Push lever forwardREVERSE - Pull lever backwardHORN - Pull lever up slightly to sound hornPOWER STEERING MOTOR - The P/S motor operates whenthe lever is placed in FORWARD or REVERSE.

• This lever can be used as an electric brake.• To stop the truck, put the lever in neutral.• When turning the starting switch to ON, put the lever in neutral.

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12.6 PARKING BRAKE LEVERBraking force adjustment:Turn CLOCKWISE to INCREASE braking force.Never adjust the operating force to less than 9 lbs. (4 kg).Always pull the parking lever when getting off the truck.

When the parking brake is OFF, the horn will alarm under thefollowing conditions:• Whenever you turn the starting switch OFF• Whenever the starting switch is ON and you leave the operator’s

seat

NOTICE

You must set the parking brake whenever you turn the starting switch OFF and whenever you leave the operator’s seat or else the horn will alarm.

12.7 ACCELERATOR PEDALWhen turning the starting switch to ON, release the accelerator pedal.There is no relationship between the amount the accelerator pedal isdepressed and the lifting and tilting speed.The maximum travel speed is adjustable. Contact your KomatsuForklift dealer for details.

12.8 BRAKE PEDALThe two-brake-pedal system is optional.

12.9 LIFT LEVERLOWER - Push lever forwardRAISE - Pull lever backward

12.10 TILT LEVERFORWARD - Push lever forwardBACKWARD - Pull lever backward

12.11 ATTACHMENT LEVERIf the truck is equipped with an attachment, an additional lever will bemounted to the right of the tilt lever.

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12.12 ADJUSTABLE STEERING COLUMN ANGLE KNOB

This black knob is located below the dashboard on the right side ofthe steering column.

1. Turn knob COUNTERCLOCKWISE to free column.2. Set column to desired position.3. Turn knob CLOCKWISE to lock column in place.

Check that the steering column is firmly locked by attempting to movethe wheel and column forwards and backwards. It should not move ifproperly locked.Tightening the adjustment knob by hand is adequate to lock thecolumn in place.

12.13 HORNRaise up on the F/R directional lever to sound the horn.

NOTICE


12.14 FORK STOPPERThe fork stopper secures the fork(s) to the fork carriage.

• If the stopper is raised, the fork can be moved to the right or left.Adjust the spread of the forks to properly fit the size of the load.

• After adjusting the fork spread, return the stopper to the originalposition to lock the fork in place before moving the load.

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12.15 OPERATOR’S SEAT (STANDARD EQUIPMENT)

ADJUSTING SEATIt is possible to slide the seat forward or backward 6 in. (152mm) toset it to the optimum position.

Method of adjusting seat position.1. Pull lever to the operator’s left. (In this condition, the seat slides

forward or backward.)2. Set the seat to the optimum position, then release lever. (In this

condition, the seat is locked in position.) Be sure the lever islocked in the right-side position.

HORN ALARM OPERATION (OPERATOR PRESENCE)

NOTICE


This operator’s seat is equipped with a safety switch to detect when the operator is sitting in the seat.

When you leave the seat for more than 3 seconds while driving, the horn will sound, traction power will beinterrupted, and a diagnostic code (01) will flash on the dashboard (see “TROUBLE CODE INDICATOR LIGHT(RED WARNING LAMP)” on page 3-3).

Once you return to the seat the horn alarm will stop, but to clear the flashing diagnostic code and resume travel youmust return the Forward/Reverse switch to neutral.

When leaving the truck, turn the starting switch OFF and engage the parking brake. If you do not engage theparking brake after turning the starting switch OFF or after leaving the seat with the starting switch ON, a warninghorn will sound. The alarm horn will stop sounding when the parking lever is pulled to apply the parking brake.

The horn is activated by the combination of the starting switch, the seat switch and the parking brake switch signalsunder the following check-marked conditions:Starting Switch Position ON OFFSeat Switch ON OFF ON OFFParking Switch ON OFF ON OFF ON OFF ON OFF

Horn sounds after 3 seconds — — � — � — �

• Adjust the seat before starting operations or when changing operators at the beginning of ashift. (Always stop the lift truck before adjusting the seat.)

• Adjust the seat to a position where it is possible to depress the brake pedal fully with yourback against the backrest of the operator’s seat. (Always stop the lift truck before adjustingthe seat.)

Horn used must have a current loading of less than 1.0 AMP (36V/48V combination). If not, the horn button will burn out, or will overheat and weld itself together.

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12.16 STROBE LIGHT OPTIONA flashing red, yellow or blue strobe light is available as an option.This light is mounted on a bracket at the rear of the overhead guard.This light will flash whenever the key is turned to the ON position onthe starting switch.

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13. CHECKS BEFORE OPERATION

3-9


13.1 CHECK BEFORE OPERATION (WITH KEY SWITCH OFF)

Check the lift truck thoroughly. If any abnormality is found, always repair it or consult your Komatsu Forkliftdistributor or dealer.

� CHECK FOR OIL LEAKAGE AND BATTERY FLUID LEAKAGECheck for leakage by conducting a walk-around check.Check the following items, in particular.• Tubing• Hydraulic unit• Cylinder• Control valve• Battery

� CHECK FOR CRACKS AND DAMAGEVisually check for cracks or damage.Check the following items, in particular.• Overhead guard• Forks• Load backrest• Fork carriage• Mast

� CHECK TIRES AND RIMSCheck the tires and rims for the following items:• Excessive wear, deformation, damage and adhesion of foreign matter.• Loose lug (hub) nuts.

Tighten the lug nuts to the specified torque. (See “TORQUE LIST” on page 4-4.)

Tightening torque:

* DO NOT loosen hexagonal socket bolts that are used for rim connecting bolts on pneumatic tire trucks. The nut ends of these bolts are painted RED. Do not CONFUSE THE TWO FASTENERS.

NOTICE

When changing tires always use tires specified by Komatsu Forklift.

Check item Lug (hub) nut tightening torqueFront wheels

120 - 180 ft/lb. (16 - 25 kgfm; 160-250 Nm)*Rear wheel

• Never operate the lift truck before the check operation is completed.• If any abnormality is found during the checks, immediately consult a Komatsu distributor. • Do not operate the lift truck until repaired.

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� CHECK OIL LEVEL IN HYDRAULIC TANK1. Lower the forks fully to the floor and stand the mast

vertically (Perform on flat floor).2. Remove the dipstick (combined with breather) on the

right side of the lift truck.3. Wipe off hydraulic oil with a clean cloth and insert

dipstick into the tank.4. Take out the dipstick again and check to see if the oil

level reads within the normal range.5. If the oil level is low, add genuine Komatsu Forklift

hydraulic oil through the oil filler.

NOTICE

Always use genuine Komatsu Forklift hydraulic oil.

� CHECK FLUID LEVEL IN BRAKE RESERVOIR TANK1. Remove cover plate beneath left side of dashboard.2. Remove the cap.3. If fluid level is low, add genuine Komatsu Forklift

brake fluid.

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� CHECK BATTERY ELECTROLYTE LEVEL

If the battery electrolyte level is below the top of the electrode plates, add distilled water until it reaches the topof the electrode plates.Check the battery case for cracking or stains caused by electrolyte leakage.Clean the battery cap breathers and terminals.

NOTICE

• The shape of the electrolyte indicator differs according to the battery manufacturer.• If the battery electrolyte has spilled or leaked causing the level to go down, have your battery repair

shop add dilute sulfuric acid of the same density.• Do not use a metal funnel when adding distilled water or dilute sulfuric acid.• When charging the battery, the charge must match the condition of the battery (degree of dis-

charge). If this is not done, the battery will become overcharged or undercharged. This will shorten the life of the battery.

* Use of the battery in this condition will make the life of the battery extremely short.

• If the temperature of the electrolyte drops below 41°F (5°C), the efficiency of the battery will be extremely low and the battery will be incompletely charged.

Battery Condition

Discharge rate % S.G. (at 68°F/20°C)0 - 20% 1.280 - 1.25620 - 40% 1.256 - 1.23040 - 60% 1.230 - 1.19460 - 80% 1.194 - 1.176

80 - 100% * 1.176 - 1.150 *

• Battery electrolyte is dangerous. If it gets in your eyes or on your skin or clothes, wash it offwith large amounts of water. In particular, if it gets in your eyes, consult a doctor quickly.

• To avoid gas explosions, do not smoke or cause short circuits or sparks near the battery.• Do not let the electrolyte level get too low.• Always ensure good ventilation even when not using the battery.• Always use rubber gloves when checking or servicing the battery.

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� SPECIFIC GRAVITYMeasuring the S.G. of the battery electrolyteMeasure the S.G. with a hydrometer. The S.G. varies with electrolytetemperature. Measure the temperature of the electrolyte with athermometer.

Conversion FormulaUsing the conversion formula below, calculate the S.G. at 68°F (20°C). Ifthe result of the conversion is in the range of 1.27 to 1.29, the battery isfully charged.

NOTICE

• Measure the S.G. after the battery has been charged and the elec-trolyte level is corrected.

• Wash the hydrometer and thermometer clean after use.

Calculation of S.G.

S20: S.G. at 68°F (20°C) St: S.G. at t°C (measured) t: Temperature of electrolyte (measured)

� CHECK BATTERY CHARGEThe remaining amount of battery charge is indicated as a percentage on the Battery Discharge Indicator(combination gauge). The battery must be charged whenever the battery is discharged 80% and the two reddigits on the left side of the gauge are lit. The Lift Interrupt activates at 80% discharge.

NOTICE

Charge the battery whenever the battery symbol flashes.

S20 St 0.0007 t 20–( )+=

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� ACTIVATION CHARGING OF DRY-CHARGED STORAGE BATTERIES (OPTIONAL)1. Initial Charge (Activating charge)

Preparations and checks prior to initial charging:a. Appearance of storage battery: Carefully check the storage battery case for deformation or damage to the

electrolytic cells and other parts. Damage may have occurred during transit or unpacking.b. Check that the required amount of electrolyte (dilute sulfuric acid) has been supplied.c. Confirm that the electrolyte furnished has a Specific Gravity of 1.279 - 1.281 (at 68°F/20°C).

2. Removing sealBefore filling with electrolyte, strip off the red tape adhered to the vent of the filling cap. This tape is used to preventthe plate from oxidizing during storage. Remove the filling cap from the battery.

3. Filling with ElectrolyteUse a beaker and a non-metallic funnel to feed the liquid into the battery up tothe level shown for each cell of the battery. Let the storage battery stand for atleast one hour after filling with electrolyte. Wait for the electrolyte temperatureto drop below 104°F/40°C, and then start the activating charge.

4. Adjusting Specific Gravity (S.G.)In the final stages of charging, the electrolyte should have a specific gravity close to 1.280 (at 68°F/20°C). Due tovariations in storage conditions, however, the S.G. may vary a little between cells.Once the rise in S.G. has completely stopped in the final stage of charging, the S.G. must be within the range of1.279 to 1.290 (at 68°F/20°C). If the S.G. reading falls outside of that range, it will be necessary to adjust the S.G.of the electrolyte.

• If the reading is below 1.279, add dilute sulfuric acid with a specific gravity of 1.400 (at 68°F/20°C). • If the S.G. reading is above 1.290, add distilled water to bring the S.G. within the specified range.

These adjustments should be carried out while the battery is being charged. After charging for about one hour,confirm that the S.G. has been adjusted to the specified value of 1.280 (at 68°F/20°C).

5. Cleaning off the batteryAfter completing the activation charge operation, wipe up any spilled electrolyte. After cleaning, reinstall the filler-cap. Check to be sure that the red tape has been fully removed from the cap.

6. Precautions while charging the battery• When the electrolyte temperature drops to 104°F (40°C) after filling, start to charge the battery. Do not leave it

standing for a long period of time, after filling with electrolyte, without starting the charging operation.• Where the electrolyte temperature rises to 122°F (50°C) while the battery is being charged, stop charging for a

while and let the temperature drop to 95°F (35°C). This will prevent overheating the battery. To stop charging, turn the charger knob counter-clockwise to the OFF position. When restarting the chargingoperation, after a drop in electrolyte temperature, turn the timer knob clockwise.

• Explosive hydrogen gas is produced by the storage battery during charging. Never allow sparks or flames,or any ignition source, close to the battery.

• Handle the electrolyte with utmost care. If any electrolyte comes in contact with skin or clothing, promptly washaway thoroughly with clean water. Should the electrolyte get into the eyes, wash immediately with clean, freshwater and promptly get medical attention.

Always wear appropriate safety/protectiveequipment for eyes and skin.

NEVER use the battery with the red tape in place on the cap and the vent sealed. This may cause thebattery to explode.

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� CHARGING BATTERY

Precautions on handling of battery1. Perform recharging operations in a clean, well ventilated space.2. Turn starting switch to OFF position and remove the key during recharging operations.3. Remove battery cell caps when recharging. Keep dust and dirt from entering the battery.4. If the electrolyte temperature exceeds 95°F (35°C) before starting recharging operations, wait for the tem-

perature to drop before commencing recharge.5. If the charger fuse blows out, be sure to replace it with a genuine Komatsu Forklift fuse of the same capac-

ity.6. Batteries emit explosive hydrogen gas during recharging. Keep sparks, lighted cigarettes and other ignition

sources away from the recharging area.7. If the electrolyte temperature rises to above 122°F (50°C) during recharging, stop recharging operations

until the electrolyte temperature falls to 95°F (35°C) or below.8. Always keep battery surface clean and tighten securely after recharging is completed.

� DISCHARGING BATTERYThe battery is the power source for the lift truck. The life of the battery can be extended to the maximum byalways keeping the electrolyte and specific gravity at specified levels. The battery life can also be maximizedby always recharging while the voltmeter index stays in the black range. Conversely, excessive discharge, if repeated, will shorten the battery life substantially.Although the discharge rate can be estimated by the voltmeter, a more accurate rate can be obtained bymeasuring the specific gravity (S.G.) of the electrolyte.Apply the S.G. calculated at 68°F (20°C) to the diagram shown at right.• When the S.G. falls to a value of 1.15 to 1.17 at 68°F (20°C), stop

operations and recharge the battery.• For electrolyte S.G. measuring method, see “SPECIFIC GRAVITY”

on page 3-12.• For battery recharging method, see “CHARGING BATTERY” on

page 3-14.

If the battery charger is used for an extended period of time with the voltage tap positionedincorrectly, it may produce a fire hazard.Make periodic checks on the voltage tap of the power source to make sure it is correctly positioned.

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� CHANGING THE BATTERYWhenever the lift truck is required to operate for extended hours, the battery must be replaced with a fullycharged battery to permit operations to continue.

Procedures for changing battery1. Disconnect the battery and remove the connector and cables.2. Open the bonnet and properly secure it in place.3. Pass the crane cables down through the gap in the overhead guard.4. Attach the cable hooks to the battery case and raise it carefully out of the truck.See the following table for battery voltage, capacity and weight for each model.

� CHECK AROUND OPERATOR’S SEAT1. Check to make sure that the operator’s seat is secured in position.2. Check the condition of the seat, seat mounting hardware and seat belts for cracking, damage, fraying or

looseness.

� CHECK PARKING BRAKEThe operating effort required to apply the parking brake should be55 ft/lb (25kg). If it is less than 9 ft/lb (4kg), contact your KomatsuForklift distributor. Turn CLOCKWISE to INCREASE force.

� CHECK HORNCheck that the horn sounds normally when operated.

� CHECK LAMPSCheck that all lamps work properly. Also check to ensure thelenses are clean and that there is no damage to the lights.

� CHECK ACCELERATOR PEDALCheck the accelerator pedal for proper operation.• Make sure that the accelerator pedal, when depressed, operates with ease and does not catch, stick or

hang up.

Battery Voltage, Capacity and Weight

VoltageCapacity (Amp hours/6 hours)

FB15/18M/ME-3 FB18MG/MGE-3 FB20M/ME-336 VOLT - Max. 880 1,100 1,10036 VOLT - Min. 440 675 67548 VOLT - Max. 660 770 77048 VOLT - Min. 330 450 450

WeightMax. lbs. (kg) 2,160 (980) 2,580 (1,170) 2,580 (1,170)Min. lbs. (kg) 1,570 (710) 2,160 (980) 2,160 (980)

Make sure that the battery case is always raised and supported at TWO different points by the cables. After installation, make sure that the battery is secured in the battery compartment, with the stoppers,to limit battery movement to less than 1.5 in. (12.7 mm) in any horizontal direction.

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• Make sure the lift truck accelerates smoothly when the accelerator is depressed.� CHECK BRAKE PEDAL

Check brake pedal operation. Ensure that brakes operateproperly before using lift truck.

� CHECK ABNORMALITIES FOUND ON PREVIOUS DAYIf any abnormality was discovered during the pre-operationchecks on the previous day, check that the repairs have been carried out and that the lift truck is in safe andproper working order.

13.2 CHECKS AFTER TURNING SWITCH TO THE “ON” POSITION� CHECK FOR ABNORMAL SMELL OR VIBRATION

Check for any unusual or abnormal noise or vibration from the hydraulic pump, or a “burning” smell that mayindicate an electrical short circuit.

� CHECK STEERING WHEELCheck the following points.• Play (the play should be 1.2 - 2.4 in. (30 - 60 mm).• There must be no up-down play.

NOTICE

If the steering wheel play is less than or greater than the speci-fied range, contact your Komatsu Forklift dealer immediately for necessary adjustment.Failure to maintain specified adjustments may result in prema-ture wear to the internal steering mechanism.

� CHECK LAMPS AND BACK-UP BUZZER• Check that the lamps light up correctly. Replace any broken bulbs.• For lift trucks equipped with the optional back-up buzzer, check that the back-up buzzer sounds when the

forward/reverse lever is placed in REVERSE.If the back-up buzzer does not sound when the forward/reverse lever is placed in REVERSE, carry outrepairs or replacement immediately.

Pedal height when free 3.94 - 4.33 in. (100 - 110 mm)Play 0.39 - 0.59 in. (10 - 15 mm)Pedal height when depressed (h) 2.36 - 2.76 in. (60 - 70 mm)

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� CHECK LIFT CHAIN

Check lift chain tension1. Lift the forks 4 - 6 in. (10- 15 cm) from the ground.2. Check the right and left deflections of the lift chain by pressing

it at the center with your fingers.The tension is normal when both deflections are approxi-mately equal.

3. If the deflections differ from each other, adjust with the nut ofthe lift chain stopper bolt.

Check elongation of the lift chainMeasure the length over 17 links and check that the length iswithin the following specified value:

If the measurement value exceeds this length, replace the chain.The elongation of the lift chain can also be checked with thefollowing “chain wear scale”.Regular inspection and lubrication of the chains will increase theirservice life and reduce downtime.

If the chains stretch beyond the recommended amount, theyshould be replaced in pairs. Chain stretch can be measured withchain wear scale part no. 661923. Measure the chains according to the instructions printed on thechain wear scale, without a load on the carriage.To check the lift chains, raise the carriage 12 in. (30 cm) off theground to put tension on the chains.

Check the lift chain lubricantSee “LUBRICANT LIST/ELECTRIC LIFT TRUCK” on page 4-2.

Length over 17 links:Max. 10.8 in. (275.5 mm)

• Before checking, set the forward/reversecontrol lever to the neutral position and applythe parking brake.

• NEVER insert feet under the forks.

• The lift chain is liable to break if heavily rusted. • If lubrication is insufficient, apply engine oil to prevent rusting.• Visually check the lift chain for damage or cracks. If any abnormality is found, consult your

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3-18

13.3 CHECKS WHILE ADVANCING SLOWLY� CHECK STEERING WHEEL OPERATION

Check the following items while advancing slowly.• No deviation of steering wheel.• No unstable steering in straight travel.• No feeling of abnormally heavy steering when the steering wheel is turned.

� CHECK BRAKE OPERATIONCheck the following items by depressing the brake pedal to apply the brake while advancing slowly.• The brake is properly applied.• The brake is applied uniformly and does not pull left or right, pulsate or grab.

� CHECK FOR ABNORMAL NOISE, ABNORMAL SMELLCheck that there is no abnormal noise or abnormal smell when traveling at low speed.

13.4 CHECKS WHILE OPERATING CONTROL LEVERS� CHECK OPERATION OF WORK EQUIPMENT

Operate the work equipment control levers from the operator’s seat and check that the forks can be raised andlowered and that the mast can be tilted forward and back smoothly. If there is any abnormality, please contact your Komatsu Forklift distributor immediately.

� CHECK FOR ABNORMAL NOISE, ABNORMAL SMELLOperate the work equipment control levers from the operator’s compartment and check that there is noabnormal noise or abnormal smell during travel.

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14. OPERATION

3-19

14. OPERATION

14.1 MOUNTING/DISMOUNTING

14.2 STARTING THE ELECTRIC LIFT TRUCK1. Place the FORWARD/REVERSE lever in neutral and release the

accelerator pedal.

2. Turn the starting switch to ON. The truck is now ready foroperation.The neutral safety circuit acts to prevent the truck from starting ifthe FORWARD/REVERSE lever is not in neutral or theaccelerator pedal is not released.

3. Release the parking brake and check the surrounding area to besure that the area is clear and it is safe to move the machine.

4. Depress the accelerator pedal to place the lift truck in motion.5. If the combination meter does not light up and the travel and

hydraulic systems are not activated when the starting switch isturned ON, check the battery connector for secure connection.

6. If the indicator blinks but the lift truck does not move off, turnswitch OFF, place F/R lever in NEUTRAL and release theaccelerator pedal. Turn starting switch to ON and try again.

7. If the truck still does not move, contact your Komatsu Forkliftdealer.

• Always mount/dismount only after firstcompletely stopping the lift truck.

• NEVER jump on or off the lift truck as this isvery dangerous.

• Mount and dismount facing the lift truck, usingthe foot of the head guard as shown in theillustration.

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14. OPERATION

3-20

14.3 PLACING LIFT TRUCK IN MOTION

14.4 PLUGGINGWith this truck, if the FORWARD/REVERSE lever is used to changethe direction of travel when the accelerator is depressed, the reversebraking system is activated. If the F/R lever is placed in neutral justbefore the truck stops, it is possible to stop the truck completely.If the accelerator pedal is kept depressed after the reverse brakingsystem has stopped the truck, the truck will then move off in theopposite direction.If this plugging operation is used frequently, or strong plugging isused, it will cause premature wear of the motor brushes. Check themotor brushes more often if this situation exists.

14.5 STARTING AND INCHING ON SLOPE1. When starting the lift truck on a slope, first pull parking brake lever

and check that the lift truck is held in position.

2. Depress accelerator pedal a little at a time, then release theparking brake lever slowly so that the lift truck starts up the slope.

3. When the lift truck starts to move up the slope, release parkingbrake lever fully. Adjust the uphill travel speed with acceleratorpedal.

4. When slowing down or stopping on slopes, gradually releaseaccelerator pedal and depress brake pedal just before stopping.

• When placing the lift truck in motion, check that the area around the lift truck is safe andsound the horn before starting.

• Do not allow anyone to enter the area around the lift truck.• There is a blind-spot behind the lift truck, so be particularly careful when traveling in reverse.• When starting the lift truck, seat yourself using good posture, place the FORWARD-REVERSE

lever in the neutral position and release the accelerator pedal.

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14. OPERATION

3-21

5. After stopping the lift truck, always pull parking brake lever (1)fully.

14.6 TURNING• Operate the steering wheel with the left hand to turn the lift truck.

Steering wheel knobs are illegal in the U.S. as they pose a safetyhazard.

• The lift truck is steered by the rear wheel. This causes the coun-terweight to swing wide when turning. The lift truck and counter-weight can cause injury and damage if they come in contact withpersonnel, objects, walls, etc.

• When traveling forward with the lift truck, keep the truck on theinside of the turn. When driving in reverse, keep the truck to theoutside of the turn. Use care to avoid hitting other objects whenturning.

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14. OPERATION

3-22

14.7 STOPPING AND PARKING1. Release the accelerator pedal and depress the brake pedal to

stop the truck.

2. When the truck is fully stopped, pull the parking brake lever andengage the parking brake.

3. Park the truck in a safe area away from other travel routes.

NOTICE


4. Return FORWARD/REVERSE lever to the NEUTRAL position.

5. If the truck will remain parked for a lengthy period of time, removethe battery plug. Grasp the plug by hand (not the wires) and pull itout to disconnect.

When leaving the truck, lower the forks to theground and tilt the mast forward. Then remove thekey from the starting switch.

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14. OPERATION

3-23

14.8 LOADING AND UNLOADING OPERATIONS

14.8.1 BEFORE LOADING1. Move the lift truck in front of the load and stop.2. Position the mast vertically and lift the forks 4 in. (10 cm)

above the ground.3. Tilt the mast forward.4. Using the fork stopper lever (or knob on some trucks),

pull upwards to release the forks. The forks can bemoved to left or right when released.

5. Adjust the fork spread to correspond with the load size sothat the load center of gravity coincides with thecenterline of the lift truck.

6. Set the mast vertically, lower the lever (or knob) to lockthe forks into position and proceed with loading.

Take extreme care not to get hands or fingerscaught while adjusting the fork spread.

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14. OPERATION

3-24

14.8.2 LOADING

1. Stop slowly when reaching the stacking location.

2. Tilt the mast forward until it is vertical.

3. Raise the load to 2 - 4 in. (5 - 10 cm) above the stacking point.

4. Drive slowly forward.

• Check that there is no danger of collapse or breakage of the load at the loading point.• Check that the loading position is correct.• Never push the load with the fork tips.

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14. OPERATION

3-25

5. Lower the load temporarily to the stacking point.

6. Reverse and slowly withdraw the forks 1/4 to 1/3 of the way outfrom beneath the load.

7. Raise the load again 2 - 4 in. (5 - 10 cm).

8. Position the load correctly above the stacking point.

9. Lower the load to the correct stacking position.

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14. OPERATION

3-26

10. Reverse the lift truck slowly and withdraw the forks fully frombeneath the load.

11. Return the mast to the travelling position.

14.8.3 UNLOADING

12. Stop the lift truck squarely in front of the load.Then bring the mast to a vertical position.

13. Align the forks with the fork insertion point.

• Check that there is no danger of collapse of the load. • Check that the forks are positioned correctly for insertion under the load.• Check that the pallet is in a position where it can be lowered completely.

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14. OPERATION

3-27

14. Drive forward and insert the forks 2/3 to 3/4 of the way under theload, then raise the load 2 - 4 in. (5 - 10 cm).

15. Reverse slowly 6 - 8 in. (15 - 20 cm).

16. Lower the load slowly.

17. Drive forward slowly and insert the forks fully under the load.

18. Raise the load 2 - 4 in. (5 - 10 cm).

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14. OPERATION

3-28

19. Reverse the lift truck to a position where the load can be safelylowered.

20. Lower the load until it is 6 - 8 in. (15 - 20 cm) from the ground.

21. Tilt the mast fully back.

22. Carry the load to the desired location.

14.9 TIRESThis forklift truck uses special tires, designed for electric lift trucks,with low rolling resistance. Use of these special tires enables themachine to provide 100% performance.Use of other tires not recommended for this application, may reducethe operating efficiency and performance of these lift trucks. This willbe seen in operating time per charge and reduced travel speeds.Note that there are other types of tires available, and appropriate, forelectric lift trucks.• Pneumatic rib-lug tires• Elastic cushion rib-lug tires• Cushion tiresContact your Komatsu Forklift distributor for ordering information.

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15. COLD WEATHER OPERATION

3-29

15. COLD WEATHER OPERATION

15.1 PREPARATIONS FOR LOW TEMPERATUREIf the temperature becomes low, it becomes difficult to start the lift truck, and the battery electrolyte may freeze. Toprevent this, do the follwing.

15.1.1 LUBRICANTSChange to lubricants with low viscosity for all components.For details, see “LUBRICANT LIST / ELECTRIC LIFT TRUCK” on page 4-2.

15.1.2 HYDRAULIC OILAlways use genuine Komatsu Forklift oil. This gives better protection against rust than normal hydraulic oil.

15.1.3 BATTERYWhen the ambient temperature drops, the capacity of the battery will also drop. If the battery charge is low, thebattery electrolyte may freeze.• Maintain the battery charge above 75%, and insulate the battery against cold temperature so that the lift truck

can be started easily in the morning.• If distilled water is to be added, to prevent freezing, wait until before starting operations the next morning

before adding the distilled water.

NOTICE

Do not leave the lift truck stopped in a cold warehouse for more than 10 minutes.

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16. LONG-TERM STORAGE

3-30

16. LONG-TERM STORAGE

16.1 BEFORE STORAGE• When putting the lift truck in storage for a long time, wash, clean and dry as specified in “LIFT TRUCK WASH-

ING PROCEDURE” on page 4-18, then house the lift truck in a dry building. Never leave it outdoors.

NOTICE

In case it must be left outdoors, park the lift truck on flat, dry ground, and cover it securely with a water-proof sheet.

• Grease, lubricate or oil all parts all parts as necessary before storage.• Apply a thin coat of grease to the exposed surface of the piston rods of the hydraulic cylinders.• Disconnect battery and battery connections, cover the battery, or remove the battery from the lift truck and

store it separately.

NOTICE

Store battery in a well ventilated location, protected from the weather and other operations.Do not store battery in contact with the ground.

16.2 DURING STORAGE16.2.1 RUST PREVENTIONOperate the lift truck for a short distance once a month so that a new film of oil will be coated over the operatingparts and lubricated surfaces. This prevents loss of the oil film over a long period of storage.Before operating the work equipment, wipe off the coat of grease from the hydraulic cylinders.

16.2.2 CHARGE BATTERYEven if the battery is not used, it will naturally discharge if left for a long period. Always charge the battery once amonth. (See “CHARGING BATTERY” on page 3-14.)

16.3 AFTER STORAGE

NOTICE

If the lift truck has been stored for a long period without being covered or without carrying out the monthly rust prevention operation, do as follows before using it.

• Remove the drain plugs from the hydraulic tank, and drain out any water.• Wipe off the grease from the hydraulic cylinder rods.• Carry out standard check before operation. (See “CHECKS BEFORE OPERATION” on page 3-9.)• Check level of battery charge by checking specific gravity. (See “SPECIFIC GRAVITY” on page 3-12.)• Operate forklift truck at low speed to check operation and ensure working parts are fully lubricated.

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INJURY OR DEATH.

MAINTENANCE

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17. OUTLINE OF SERVICE

4-1

17. OUTLINE OF SERVICE

• Use genuine Komatsu Forklift parts for replacement.• When changing or adding oil, do not use a different type of oil.• Unless otherwise specified, the oil used at delivery from the factory shall be as shown in the table below.

17.1 OIL• Since the oil is used for the work equipment, etc., under severe conditions (at high temperature and high

pressure), it will deteriorate during operations over time.Always use an oil matching the grade and working temperatures given in the operation manual.Always replace oil at the specified period even if not deteriorated.

• Oil is often compared to human blood.A lift truck should be maintained with the same care taken for the human body so that impurities (water, metalchips, dust etc.) do not enter the lift truck system. Most lift truck malfunctions are caused by the entry ofimpurities. Take special care to avoid the entry of impurities during storage and lubrication, etc.

• Never blend oils of different grades or brands.• Add specified volume of oil. Insufficient or excessive amounts of oil may both cause problems.• If the oil in the work equipment becomes cloudy, it is likely that air or water have entered the system. Consult

your Komatsu Forklift distributor.• When replacing oil, replace the relevant filters at the same time.

17.2 GREASE• Grease prevents squeaking or noise from the joints and minimizes wear on the greased parts.• Lift trucks are provided with grease nipples in various places. Some of these are not mentioned in this manual

since they are for overhauling purposes, and do not require greasing.If noise or friction is noticed in movable parts after operation, grease.

• After greasing, wipe off the old grease that is forced out, especially on rotating parts that will be worn byadhering sand and dirt.

17.3 OIL STORAGE AND PRESERVATION• Store and preserve oil so as not to allow entry of any water or dust. Water standing on drum tops can be drawn

into the drum around bung-seals during temperature changes.• When storing oil drums for long periods, place them side by side with the filler sides facing in the same

direction. If necessary to store outdoors, cover them with waterproof sheets.• To prevent deterioration during long-term storage, use drums on a "first in, first out" basis.

17.4 FILTERS• Filters are very important safety items which prevent problems caused by impurities contained in the oil or

hydraulic circuit which sends oil into important units. Periodically replace the filters while referring to thismanual.

• When replacing oil filters, check for metal powder accumulated on the used filters.• Do not unpack replacement filters until immediately before installation.• Always use genuine Komatsu Forklift filters.

Item Type of fluid

Transfer case SAE90 (standard)SAE80 (refrigerator spec.)

Hydraulic tank SAE10W-CD (standard)SAE 5W-CD (refrigerator spec.)

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18. LUBRICANT LIST

4-2

18. LUBRICANT LIST

18.1 LUBRICANT LIST / ELECTRIC LIFT TRUCK

NOTICE

Always use genuine Komatsu Forklift oil and grease.

NOTICE

(Oil and grease are available from your Komatsu Forklift distributor.)

Never use the incorrect kind of brake fluid. Use genuine Komatsu Forklift brake fluid.

Lubrication points

Transfer caseLeft / Right units

0.634 U.S. gal.2.4 L EACH UNIT

Hydraulic system

Hydraulic oil TANK ONLY4.0 U.S. gal. / 15 LTOTAL SYSTEM

4.8 U.S. gal. / 18 L

Brake system Brake fluidSAE70R-1, SAE70R-3 2.71 oz. / 80 cc

Greasing points Lithium greaseNLGI No. 2 —

—

Gear oil

SAE5W-CD

Ambient TemperatureLocation Type of Fluid Capactities-4

-2014-10

320

5010

6820

86°F30°C

SAE10W-CD

SAE5W-CD

SAE10W-CD

SAE30W-CD

Engine oil

SAE80

SAE90

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18. LUBRICANT LIST

4-3

18.2 OIL AND GREASING CHART OIL, GREASE LOCATIONS AND INSPECTION AND MAINTENENCE INTERVALS

Check and add fluid if necessaryChange or add oilShows the number of places to add oil or grease

Symbol Type of fluidEO Engine oilGO Gear oilHO Hydraulic oilBF Brake fluidG Grease

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19. SERVICE DATA

4-4

19. SERVICE DATA

19.1 SERVICE DATA (ELECTRIC LIFT TRUCK)

19.2 TORQUE LISTFor unspecified 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 KomatsuForklift parts the same size as the previous ones.

Component Inspection item Unit ALL MODELS

Lug (hub) nuts Tightening torqueFront wheels

ft/lb 116 - 181 (16 - 26 kgm)Rear wheel

Stee

ring,

bra

king

sys

tem Steering wheel Play in. .394 - .787 (10 - 20 mm)

Brake pedal Play in. .394 - .591 (10 - 15 mm) Pedal height when pedal is depressed in. 2.36 - 2.76 (60 - 70 mm)

Brake

Parking brake operating force lb. 9 - 13 (4 - 6 kg)

Tightening torque for back plate mount-ing bolts ft/lb 72 - 87 (10 - 12 kgm)

Thread diameter of bolt (mm)(a)

Width across flat (mm)(b)

Tightening torqueNm kgfm lb/ft

6 10 13.2 ± 1.4 1.35 ± 0.15 9.73 ± 1.038 13 31.4 ± 2.9 3.2 ± 0.3 23.2 ± 2.110 17 65.7 ± 6.8 6.7 ± 0.7 48.5 ± 5.012 19 112 ± 9.8 11.5 ± 1.0 82.6 ± 7.214 22 177 ± 19 18.0 ± 2.0 131 ± 1416 24 279 ± 29 28.5 ± 3 206 ± 2118 27 383 ± 39 39 ± 3 282 ± 2920 30 549 ± 58 56 ± 6 405 ± 4322 32 745 ± 78 76 ± 8 549 ± 5824 36 927 ± 98 94.5 ± 10 684 ± 7227 41 1320 ± 140 135 ± 15 973 ± 10030 46 1720 ± 190 175 ± 20 1270 ± 14033 50 2210 ± 240 225 ± 25 1630 ± 18036 55 2750 ± 290 280 ± 30 2030 ± 21039 60 3280 ± 340 335 ± 35 2420 ± 250

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20. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

4-5

20. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

To ensure safety at all times when operating or driving the lift truck, the lift truck user must always carry out periodicmaintenance. In addition, to further improve safety, the user should also perform periodic replacement of partsshown in the table below. These parts, in particular, are closely related to safety and fire prevention.

The material of these parts may change over time, or may easily wear or deteriorate. However, as it is difficult tojudge the condition of the parts simply by periodic maintenance, they should always be replaced after a fixed timehas 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 repairedor replaced immediately.

If the hose clamps show any sign of deterioration such as deformation or cracking, replace them at the same timeas the hoses.

Note that the periodic replacement is not covered by warranty.

20.1 SAFETY CRITICAL PARTS LIST

No. Part Name Years Elapsed1 Master cylinder, wheel cylinder cup and dust seal, etc. 12 Brake hose or tube 1 - 23 Brake reservoir tank, tube 2 - 44 Power steering hose 25 Brake switch (hydraulic type) 26 Rubber parts inside power steering system 27 Lift chain 2 - 48 Hydraulic hose for lifting mechanism 1 - 2

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21. MAINTENANCE SCHEDULE CHART

4-6


Perform maintenance at interval of months or operation hours, whichever comes first.

Service Item Page

After first one month or initial 200 hours of service 4-9

Change oil in transfer case (Including differential case) 4-9

Service hydraulic tank 4-10

Check wiring inside motor, tightness of pigtail, looseness of bolts 4-10

Tighten nuts, bolts (especially wheel hub nuts) 4-10

Check before operation. For details, see “CHECK BEFORE OPERATION (WITH KEY SWITCH OFF)” 3-9

Every 2 weeks/100 hours of service 4-11

Grease lift chain 4-11

Check brake link for backlash, looseness, damage and wear 4-11

Check brake tubing for damage, leakage, looseness, contact, looseness of brake pipe clip, disconnec-tion 4-11

Check mounting, check for oil leakage from steering box 4-11

Check clearance between brake drum and lining, check brake for dragging 4-11

Every month/200 hours of service 4-12

Check rims for deformation, cracking or damage 4-12

Check wheel bearings for play and abnormal noise 4-12

Check hydraulic cylinder for looseness, deformation, cracking, damage and wear 4-12

Check tubing for damage, oil leakage and deformation 4-12

Check hydraulic cylinder function 4-12

Check lift cylinder for drift 4-12

Check tilt cylinder for drift 4-12

Check control lever function 4-12

Check forks and fork stopper for deformation, cracking, damage and wear 4-12

Check forks for unevenness and twisting 4-12

Check mast for deformation, cracking, damage and wear 4-12

Check mast roller for play 4-12

Check chain and chain wheel for deformation, damage, rust and poor lubrication 4-12

Check chain wheel bearing for play 4-12

Check chain anchor bolt for deformation, damage 4-12

Check overhead guard and backrest for deformation, cracking, damage and looseness 4-12

Check operator’s seat attachments for looseness and damage 4-12

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4-7

Every month/200 hours of service (Continued)

Grease all lubrication points 4-12

Check FORWARD/REVERSE lever for play and proper operation 4-12

Check battery terminal connections for looseness 4-12

Check top face of the battery and case 4-12

Check contact point of contactors for looseness, damage or wear 4-12

Check contactor coil mount for looseness 4-12

Check lead line connection and looseness of contactor main circuit 4-12

Check microswitch timing and function 4-12

Check microswitch for damage 4-12

Check the mount for looseness 4-12

Check that the controller functions correctly 4-12

Check fuse mount and clamp for looseness 4-12

Check connection of wiring terminal block for looseness and taping condition 4-12

Check for discoloration of battery connector and charger connector, check for proper connection, check wire connecting bolts for looseness and damage 4-12

Check specific gravity of battery electrolyte 4-13

Every 3 months/600 hours of service 4-14

Check transfer case oil level (including differential case) 4-14

Check working voltage of battery voltage sensing relay 4-14

Check contactors for function and timing 4-14

Every 6 months/1,200 hours of service 4-14

Check steering link for bending, damage and wear 4-14

Check steering knuckle for play, deformation and damage 4-14

Check for substantial deviation in minimum turning radius 4-14

Change oil in transfer case (including differential case) 4-14

Service hydraulic tank 4-10

Change brake fluid 4-14

Check motor brush for wear and sliding condition (settling, contact), check for adhesion of dirt, dam-age, streaks on sliding surface, and damage to pigtail 4-14

Check motor brush springs for wear 4-14

Check battery voltage after charging 4-14

Check function of electromagnetic switch on battery charger, check contacts for dirt and roughness 4-14

Service Item Page

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4-8

Every 6 months/1,200 hours of service (Continued)

Check cut-off current (lock current) of controller 4-14

Check harness sheath for damage 4-14

Every 12 months/2,400 hours of service 4-15

Check operation of master cylinder, fluid leakage, damage and wear 4-15

Check operation of wheel cylinder, fluid leakage, damage and wear 4-15

Check brake drum for wear and damage 4-15

Check brake lining for wear 4-15

Check brake shoe operation 4-15

Check brake adjustment lever and ratchet for wear and damage 4-15

Check brake spring for wear 4-15

Check brake backing plate for deformation, cracking and correct mounting method 4-15

Check brake tubing and fittings for air tightness and leakage 4-15

Check axles for deformation, damage and cracking 4-15

Check differential mounting condition 4-15

Check base of forks for cracking (by color check) 4-15

Check lifting mechanism roller shaft for cracking and damage 4-15

Check mast support for damage and wear 4-15

Check relief valve function and relief pressure 4-15

Check frame, crossmembers and other structural members for cracking and damage 4-15

Check motor commutator face for dirt, partial wear and scratching, and check collector for dirt 4-15

Check wiring inside motor, tightness of pig-tail, and for looseness of bolts 4-15

Service Item Page

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22. MAINTENANCE

4-9

22. MAINTENANCE

NOTICE

Contact your Komatsu Forklift distributor regarding any maintenance item that you are not equipped to handle.

22.1 AFTER FIRST MONTH OR INITIAL 200 HOURS SERVICECarry out this maintenance only for new lift trucks after the first month of service, or initial 200 hours, whichevercomes first.

22.1.1 HYDRAULIC EQUIPMENT� CHANGE OIL IN TRANSFER CASE (INCLUDING DIFFERENTIAL CASE)

1. Ensure that the lift truck is on a flat, level surface before proceed-ing.

2. Raise the mast to allow access to the transfer case, then brace itin place with suitable devices capable of supporting it in theraised position.

3. Remove the oil filler plug, then remove the drain plug and drainthe oil.

4. After draining the oil, tighten the drain plug (40 - 60 ft/lb) (6 -8 kgm) and add the specified amount of oil through the oil filler.Do not overfill.

5. After filling with oil, remove the oil level plug to check the oil levelonce more and add more oil only if necessary.

6. Reinstall the oil level plug and oil filler plug.7. Remove the mast braces, lower the mast and resume normal

operation.

NOTICE

Always use genuine Komatsu Forklift gear oil.

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

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22. MAINTENANCE

4-10

� SERVICE HYDRAULIC TANK

NOTICE

Always use genuine Komatsu Forklift hydraulic oil.

1. Remove the drain plug from the bottom of the tank anddrain the oil.

2. Remove the cover and take out the strainer and line filter.3. Wash the strainer in flushing oil, then dry the strainer with

compressed air blown from the inside out. Reinstall thestrainer when it is dry.

4. Replace the line filter with a new Komatsu Forklift linefilter.

5. Clean the inside of the tank, then install the drain plug.6. Add the specified amount of hydraulic oil through the oil

filler, check the oil level with the dipstick and add more oilONLY IF NECESSARY.

7. Turn the starting switch ON, then operate the lift and tiltcylinders to the end of their travel 5 or 6 times to bleedany air.

22.1.2 ELECTRICAL EQUIPMENT� CHECK WIRING INSIDE MOTOR, TIGHTNESS OF PIGTAIL, LOOSENESS OF BOLTS

22.1.3 GENERAL� TIGHTEN NUTS, BOLTS (SPECIFICALLY THE WHEEL LUG NUTS)� CHECK BEFORE OPERATIONFor details, see “CHECK BEFORE OPERATION (WITH KEY SWITCH OFF)” on page 3-9.

Immediately after operations, the oil is HOT. Never change oil immediately after stopping operations.Wait for the oil temperature to cool down before attempting to change oil.

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22. MAINTENANCE

4-11

22.2 EVERY TWO WEEKS OR 100 HOURS SERVICE22.2.1 LOADING EQUIPMENT� GREASE LIFT CHAIN� CHECK BRAKE LINK FOR BACKLASH, LOOSENESS, DAMAGE AND WEAR

1. Check the play and the height of the brake pedal when it isdepressed to check that it is the specified value.

2. Test the brakes while gradually increasing the speed from lowspeed. Check that there is no pulling or dragging of the brakes.If necessary, adjust the brake until it is applied smoothly.

� CHECK BRAKE TUBING FOR DAMAGE, LEAKAGE, LOOSENESS, CONTACT, LOOSENESS OF BRAKE TUBING CLIP, DISCONNECTION

� CHECK MOUNTING, CHECK FOR OIL LEAKAGE FROM STEERING BOX� CHECK CLEARANCE BETWEEN BRAKE DRUM AND LINING, CHECK BRAKE FOR DRAGGING

Play .39 - .59 in. (10 - 15 mm)Pedal height when depressed (h) 2.36 - 2.76 in. (60 - 70 mm)

Inspect the lift truck in an area where it will not obstruct other vehicles or workers.

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22. MAINTENANCE

4-12

22.3 EVERY MONTH OR EVERY 200 HOURS SERVICE22.3.1 TRAVEL EQUIPMENT� CHECK RIMS FOR DEFORMATION, CRACKING AND DAMAGE� CHECK WHEEL BEARINGS FOR PLAY AND ABNORMAL NOISE

22.3.2 HYDRAULIC EQUIPMENT� CHECK HYDRAULIC CYLINDER FOR LOOSENESS, DEFORMATION, CRACKING, DAMAGE AND WEAR� CHECK TUBING FOR DAMAGE, OIL LEAKAGE AND DEFORMATION� CHECK HYDRAULIC CYLINDER FUNCTION� CHECK LIFT CYLINDER FOR DRIFT� CHECK TILT CYLINDER FOR DRIFT� CHECK CONTROL LEVER FUNCTION

22.3.3 LOADING EQUIPMENT� CHECK FORKS AND FORK STOPPER FOR DEFORMATION, CRACKING, DAMAGE AND WEAR� CHECK FORKS FOR UNEVENNESS AND TWISTING� CHECK MAST FOR DEFORMATION, CRACKING, DAMAGE AND WEAR� CHECK MAST ROLLER FOR PLAY� CHECK CHAIN AND CHAIN WHEEL FOR DEFORMATION, DAMAGE, RUST AND POOR LUBRICATION� CHECK CHAIN WHEEL BEARING FOR PLAY� CHECK CHAIN ANCHOR BOLT FOR DEFORMATION, DAMAGE

22.3.4 OTHER EQUIPMENT� CHECK OVERHEAD GUARD AND BACKREST FOR DEFORMATION, CRACKING, DAMAGE AND

LOOSENESS� CHECK OPERATOR’S SEAT ATTACHMENTS FOR LOOSENESS AND DAMAGE� GREASE ALL LUBRICATION POINTS

22.3.5 POWER TRAIN� CHECK FORWARD/REVERSE LEVER FOR PLAY AND PROPER OPERATION

22.3.6 ELECTRIC COMPONENTS� CHECK BATTERY TERMINAL CONNECTIONS FOR LOOSENESS� CHECK TOP FACE OF BATTERY AND CASE� CHECK CONTACT POINT OF CONTACTORS FOR LOOSENESS, DAMAGE AND WEAR� CHECK CONTACTOR COIL MOUNT FOR LOOSENESS� CHECK LEAD LINE CONNECTION AND LOOSENESS OF CONTACTOR MAIN CIRCUIT� CHECK MICROSWITCH TIMING AND FUNCTION� CHECK MICROSWITCH FOR DAMAGE� CHECK THE MOUNT FOR LOOSENESS� CHECK THAT THE CONTROLLER FUNCTIONS CORRECTLY� CHECK FUSE MOUNT AND CLAMP FOR LOOSENESS� CHECK CONNECTION OF WIRING TERMINAL BLOCK FOR LOOSENESS AND TAPING CONDITION� CHECK FOR DISCOLORATION OF BATTERY AND CHARGER CONNECTORS, CHECK FOR PROPER

CONNECTION, AND CHECK CONNECTING BOLTS FOR LOOSENESS AND DAMAGE

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22. MAINTENANCE

4-13

Replace the battery connector or charger connector if they show any discoloration.� CHECK SPECIFIC GRAVITY OF BATTERY ELECTROLYTE

� CHECK SPECIFIC GRAVITY OF BATTERY ELECTROLYTE1. Charge the battery, and after charging, check that the battery electrolyte level is correct.2. Using a specific gravity meter and thermometer, measure the specific gravity and temperature of the battery

electrolyte.3. Insert the values measured in Step 2 in the formula below, and calculate S20.

St: Specific gravity (measured value) at t°Ct: Temperature of battery electrolyte (measured value)S20: Specific gravity at 20°C (68°F)Normal value: S20 = 1.27 through 1.29

4. Charge the battery if necessary.

RELATIONSHIP BETWEEN SPECIFIC GRAVITY AND ELECTROLYTE TEMPERATURE1. Measure and calculate the specific gravity for each battery cell.2. Wash the hydrometer and thermometer with plenty of water after

use.3. Record and store the measured data for future use.

Specific Gravity of Electrolyte

Condition of Charge

ChargingRequired

1.2801.240 Fully charged1/4 discharged No

1.2101.130 1/2 dischargedFully discharged Yes

Precautions when handling the battery:• Battery electrolyte is dangerous. If it gets into your eyes or on your skin or clothing, wash it off

immediately with large amounts of clean water. If electrolyte has contacted your eyes, seekmedical attention immediately.

• Keep away from sparks or open flame. To avoid gas explosions, do not smoke or cause shortscircuits, arcs or sparks near the battery.

S20 St 0.0007 t 20–( )+=

RELATION BETWEEN SPECIFIC GRAVITY AND TEMPERATURE OF ELECTROLYTE

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22. MAINTENANCE

4-14

22.4 EVERY 3 MONTHS OR 600 HOURS SERVICE

22.4.1 POWER TRAIN� CHECK TRANSFER CASE OIL LEVEL (RIGHT AND LEFT UNITS)

22.4.2 ELECTRIC COMPONENTS� CHECK WORKING VOLTAGE OF BATTERY VOLTAGE SENSING RELAY� CHECK CONTACTORS FOR FUNCTION AND TIMING

22.5 EVERY 6 MONTHS OR 1,200 HOURS SERVICE22.5.1 STEERING SYSTEM� CHECK STEERING LINK FOR BENDING, DAMAGE AND WEAR� CHECK STEERING KNUCKLE FOR PLAY, DEFORMATION AND DAMAGE� CHECK FOR SUBSTANTIAL DEVIATION IN MINIMUM TURNING RADIUS

22.5.2 POWER TRAIN� CHANGE OIL IN TRANSFER CASES

For details see “CHANGE OIL IN TRANSFER CASE (INCLUDING DIFFERENTIAL CASE)” on page 4-9.

22.5.3 HYDRAULIC EQUIPMENT� SERVICE HYDRAULIC TANK

For details, see “SERVICE HYDRAULIC TANK” on page 4-10.

� CHANGE BRAKE FLUID

22.5.4 ELECTRIC COMPONENTS� CHECK MOTOR BRUSH FOR WEAR AND SLIDING CONDITION (SETTLING, CONTACT) CHECK FOR

ADHESION OF DIRT, DAMAGE, STREAKS ON SLIDING SURFACE, DAMAGE TO PIGTAIL� CHECK MOTOR BRUSH SPRINGS FOR WEAR� CHECK BATTERY VOLTAGE AFTER CHARGING� CHECK FUNCTION OF ELECTROMAGNETIC SWITCH ON BATTERY CHARGER, CHECK CONTACTS

FOR DIRT AND ROUGHNESS.� CHECK CUT-OFF CURRENT (LOCK CURRENT) OF CONTROLLER� CHECK HARNESS SHEATH FOR DAMAGE

Battery Condition

Discharge Rate (%) Specific Gravity @ 20oC (68oF)0 - 20 1.280 - 1.25620 - 40 1.256 - 1.23040 - 60 1.230 - 1.19460 - 80 1.194 - 1.176

80 - 100 *1.176 - 1.150* Use of battery in this condition greatly shortens battery life.

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22. MAINTENANCE

4-15

22.6 EVERY 12 MONTHS OR 2,400 HOURS OF SERVICE22.6.1 BRAKE SYSTEM� CHECK OPERATION OF MASTER CYLINDER, CHECK FOR FLUID LEAKAGE, DAMAGE AND WEAR� CHECK OPERATION OF WHEEL CYLINDER, CHECK FOR FLUID LEAKAGE, DAMAGE AND WEAR� CHECK BRAKE DRUM FOR WEAR AND DAMAGE� CHECK BRAKE LINING FOR WEAR� CHECK BRAKE SHOE OPERATION� CHECK BRAKE ADJUSTMENT LEVER AND RATCHET FOR WEAR AND DAMAGE� CHECK BRAKE SPRING FOR WEAR� CHECK BRAKE BACKING PLATE FOR DEFORMATION, CRACKING AND CORRECT MOUNTING

CONDITION� CHECK BRAKE TUBING AND FITTINGS FOR AIR TIGHTNESS AND LEAKAGE

22.6.2 POWER TRAIN� CHECK AXLES FOR DEFORMATION, CRACKING AND DAMAGE� CHECK DIFFERENTIAL MOUNTING CONDITION

22.6.3 LOADING EQUIPMENT� CHECK BASE OF FORKS FOR CRACKING (BY COLOR CHECK)� CHECK LIFTING MECHANISM ROLLER SHAFT FOR CRACKING AND DAMAGE� CHECK MAST SUPPORT FOR DAMAGE AND WEAR

22.6.4 HYDRAULIC EQUIPMENT� CHECK RELIEF VALVE FUNCTION AND RELIEF PRESSURE

22.6.5 OTHER SYSTEMS� CHECK FRAME, CROSSMEMBERS AND OTHER STRUCTURAL MEMBERS FOR CRACKING AND

DAMAGE

22.6.6 ELECTRICAL EQUIPMENT� CHECK MOTOR COMMUTATOR FACE FOR DIRT, PARTIAL WEAR AND SCRATCHING� CHECK WIRING INSIDE MOTOR, TIGHTNESS OF PIG-TAIL, AND FOR LOOSENESS OF BOLTS

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23. REPLACEMENT PROCEDURES

4-16


23.1 REPLACING FUSESFuses are used to protect electrical components and wiring from burning out.

1. Turn the starting switch to the OFF position, remove the key, then disconnect the battery plug.2. Access the controller (contactor panel) at the rear of the forklift truck by opening access panel.3. Inspect and replace fuses as necessary. All fuses are located on the contactor panel.

23.2 REPLACING TIRES

1. Put blocks under the tire diagonally opposite to the tire which is tobe replaced.

2. Using a lug nut wrench, loosen lug nuts to a point where they can beturned by hand.

3. Set a jack at the jacking point (see diagram on right), then jack upthe lift truck to a point where the tire comes off the ground.

4. Front tire jacking point (Under outer mast)Rear tire jacking point (Under counterweight)

5. Remove lug nuts (1), then remove the tire and replace it.6. Install the replacement tire and partially tighten lug nuts (1).7. Use the lug nut wrench to tighten lug nuts (1) in turn on opposite

sides (criss-cross pattern) until there is no play in the wheel.8. Lower the jack to lower the lift truck to the ground, then tighten lug

nuts (1) to the specified tightening torque. (For details of thetightening torque, see table at “SERVICE DATA” on page 4-4.)

NOTICE

Always use genuine Komatsu Forklift tires specified for battery-powered lift trucks.

Circuit CapacityF/R controller and Brake switch circuit 10 AMPKey switch 10 AMPLamps and Flasher circuit 15 AMP

When replacing the fuses, always disconnect the battery plug to isolate the power supply. Alwaysreplace the fuses with fuses of the same capacity.

• Stop lift truck on flat, safe area and apply parking brake.• Loosen lug nuts. Never mistakenly loosen axle bolts instead of lug nuts.• Jack up the machine only after confirming that the jack will not slip. • Never enter under the lift truck body. • Never use tires with deformed or cracked rims.• Cushion tires are pressed on to one-piece rims.

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4-17

23.3 REPLACING LAMPS1. Before replacing lamps, check for blown fuses and disconnected wires.2. If a blown fuse is found, replace it as detailed earlier in this section.3. If a wire disconnection is found, turn OFF the lamp switch and reconnect the wiring.4. Refer to table below for correct lamp specifications.

Lamp wattages

Head lamp 45WStop lamp (option) 25WTail lamp (option) 10W

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24. LIFT TRUCK WASHING PROCEDURE

4-18


When you wash your electric lift truck, observe the following instructions to safeguard your truck. Note that wetelectrical equipment will result in the lift truck malfunctioning and possible failure to the electrical controls and/orcomponents.

24.1 GENERAL PRECAUTIONS• DO NOT STEAM CLEAN THIS LIFT TRUCK!• Before washing, ensure that the Controller and all other electrical equipment sensitive to water is protected

from water while washing and blowing dry. NEVER wash or wet down the areas inside the dashboard.• Before washing, make sure that waterproof seals and covers are free from any deterioration and are fitted

correctly in place.• When using a water stream, use compressed air, an air blower and dry wiping to dry the truck and remove

water droplets before using the truck. (Water droplets may run along the wiring and enter the controllerchamber, dashboard or seep into the connectors.)

• If water does get into the controller chamber or dashboard, use a cloth or compressed air to remove the waterbefore using the truck.

• When removing dirt from electronic parts (such as printed circuit boards), use a commercially available, spray-type electronic equipment cleaner.

24.2 WASHING INSTRUCTIONS

1. Turn the starting switch key to the OFFposition, then remove the key.

2. Disconnect the battery plugs.3. Wash each part (1 to 6 parts as shown

in the figure at right), following theinstructions in the table on thefollowing page.

4. Dry off the washed parts.5. After checking that the washed parts

have dried out, insert the startingswitch key and turn it to the ONposition, make sure that there is noabnormality, and then start operation.

When washing your lift truck, observe the following instructions to safeguard the truck. Wet electrical equipment will result in the lift truck malfunctioning.

If water gets into the electrical system (controller, sensor, connectors, etc.) there is the hazard that it will cause malfunctions or operational failure. Do not wash the electrical system with water or high-pressure steam.

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4-19

No. Spot to Wash Washing Method

1 Charger Control Panel • Wash from above by flushing with water from a hose.• Use low water pressure from the hose as illustrated below

(parts 1 and 2 only).2 Meter Panel

3 Dashboard Front

4 Battery • Wipe with a wet cloth.• Keep the battery top clean and dry.

5 • Front & Rear Tires• Front & Rear Axles

• Wash using high pressure steam or flush with water from ahose.

• Do not steam or wash the tire angle sensor or electric wiring.

6 Exterior parts other than the above Wash using high pressure steam or flush with water from a hose.

Other Precautions

• Never wash the inside of the dashboard.• When using high pressure steam or water from a hose to

wash the engine room and power train parts under the floorplate, cover the following parts and components with atarpaulin so that they do not get splashed with water:- the engine and transmission, including the electric wiring

for them.- electric system parts such as the connector and fuse

box.

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NOTES:

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INJURY OR DEATH.

TECHNICAL DATA

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TECHNICAL DATA

5-1

25. TECHNICAL DATA

SPECIFICATIONS – FB15M/ME-3, FB18M/ME-3

GENERAL FB15M/ME-3 FB18M/ME-3

Capacity @ 24 in. (600mm) load center lbs (kg) 3,000 (1,360) 3,500 (1,580)

Height to overhead guard in. (mm) 76.8 (1,950)

Tilting angle (2-stage mast) (fwd/back) degrees (°) 5/7


Carriage width / ITA class in. (mm) 37 in. (940) / ll

Ground clearance under mast (2-stage) in. (mm) 5.5 (140)

Ground clearance under mast (3-stage) in. (mm) 3.5 (90)B

Ground clearance center of frame in. (mm) 3.9 (100)

Steering type Hydraulic

Maximum hydraulic pressure psi (bar) 2,420 (170)

Hydraulic tank capacity U.S. gallons (liters) 4.8 (18)

Hydraulic SCR controller N/A

Load distance from center axle (all masts) in. (mm) 15.3 (390)

SIZE

Battery compartment in. (mm.) 38.78 W x 21.30 L x 24.02 H (985 x 541 x 610)

Wheelbase in. (mm) 51.6 (1,310)

Length to face of forks (2 and 3-stage) in. (mm) 75.0 (1,905) 76.4 (1,940)

Overall width in. (mm) 42.1 (1,070)

Tread (center of tires) front/rear in. (mm) 35.5 / 8.3 (901 / 211)

Outside turning radius (OTR) in. (mm) 58.9 (1,495) 60.8 (1,545)

Right-angle stacking aisle in. (mm) 74.2 (1,885) + load length 76.2 (1,935) + load length

Minimum battery weight lb (kg) 1,570 (710)

Maximum battery weight lb (kg) 2,160 (980)

Service weight (including minimum battery) lb (kg) 7,280 lb. (3,300) 7,710 (3,495)

Tire size, frontin.

18 x 6 x 12.12

Tire size, rear 16 x 5 x 10 1/2 (Double)Prope

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TECHNICAL DATA

5-2

SPECIFICATIONS – FB18MG/MGE-3, FB20M/ME-3

GENERAL FB18MG/MGE-3 FB20M/ME-3

Capacity @ 600-mm (24-in.) load center lb (kg) 3,500 (1,580) 4,000 (1,810)

Height to overhead guard in. (mm) 76.8 (1,950)



Carriage width / ITA class in. (mm) 37.0 (940) / ll



Ground clearance center of frame in. (mm) 3.9 (100)

Steering type Hydraulic

Maximum hydraulic pressure psi (bar) 2,630 (185)

Hydraulic tank capacity U.S. gallons (liters) 4.8 (18)

SCR controller N/A

Load distance from center axle (all masts) in. (mm) 16.3 (415)

SIZE

Battery compartment in. (mm) 39.06 W x 25.04 L x 24.02 H (992 x 636 x 610)

Wheelbase in. (mm) 55.3 (1,405)

Length to face of forks (2 and 3-stage) in. (mm) 80.9 (2,055)

Overall width in. (mm) 42.1 (1,070)

Tread (center of tires) front/rear in. (mm) 34.3 / 8.30 (871 / 211)

Outside turning radius (OTR) in. (mm) 64.6 (1,640)

Right-angle stacking aisle in. (mm)2-stage: 80.9 (2,055) + load length

3-stage: 80.9 (2,055) + load length

Minimum battery weight lb. (mm) 2,160 (980)

Maximum battery weight lb. (mm) 2,580 (1,170)

Service weight (including minimum battery) lb. (mm) 8,560 (3,880) 8,850 (4,015)

Tire size, frontin.

18 x 8 x 12 1/8

Tire size, rear 16 x 5 x 10 1/2 (Double)

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TECHNICAL DATA

5-3

PERFORMANCE – 1.5-TON TRUCKS: FB15M/ME-3

PERFORMANCE – 1.8-TON TRUCKS (STANDARD): FB18M/ME-3

36V 48V

Maximum travel speed, forward, loaded mph (km/h) 9.0 (14.5) 9.0 (14.5)

Maximum travel speed. forward, unloaded mph (km/h) 9.6 (15.5) 9.6 (15.5)

Lifting speeds - loaded / unloaded (2-stage) fpm (mm/s)

Lifting speeds - loaded / unloaded (3-stage) fpm (mm/s) 63 (320) / 98 (500) 83 (420) / 122 (620)

Lowering speeds - loaded / unloaded (2-stage) fpm (mm/s) 98 (500) / 89 (450) 98 (500) / 89 (450)


Maximum drawbar pull - loaded lbs (kg) 2,030 (9,020) 2,030 (9,020)

Gradeability, loaded/unloaded @ 1.5km/h % 17 / 24 17 / 24

Drive motor, 1-hour rating HP / kW 6.44 / 4.8 x 2 Motors

6.44 / 4.8 x 2 Motors

Pump motor, 5-minute rating HP / kW 10.6 / 7.9 13.14 / 9.8

Power steering motor, 1-hour rating HP / kW 0.46 / 0.34 0.6 / 0.45

Minimum battery capacity Ah / 6hr 440 330

Maximum battery capacity Ah / 6hr 880 660

36V 48V



Lifting speeds - loaded / unloaded (2-stage) fpm (mm/s) — —







6.44 / 4.8 x 2 Motors




Maximum battery capacity Ah / 6hr 880 660Prope

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TECHNICAL DATA

5-4

PERFORMANCE – 1.8-TON TRUCKS (EXTENDED FRAME): FB18MG/MGE-3

PERFORMANCE – 2.0-TON TRUCKS: FB20M/ME-3

36V 48V





Lowering speeds - loaded / unloaded (2-stage) fpm (mm/s) — —





6.44 / 4.8 x 2 Motors




Maximum battery capacity Ah / 6hr 1,100 770

36V 48V





Lowering speeds - loaded / unloaded (2-stage) fpm (mm/s) — —





6.44 / 4.8 x 2 Motors




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TECHNICAL DATA

5-5

MAST DATA – 3,000 LB. CAPACITY UNITS

Maximum Fork Heightin. (mm)

Overall Height*Free Lift*in. (mm)

Load Capacities lb (kg)

Loweredin. (mm)

Extended*in. (mm) (36V and 48V)

30D-MS 2-STAGE MAST

105.5 (2,680) 74 (1,880) 153.5 (3,900)

5.5 (140)3,000 (1,350)117.5 (2,964) 80 (2,032) 165.5 (4,204)

129.5 (3,240) 86 (2,184) 177.5 (4,508)

145.5 (3,696) 94 (2,388) 193.5 (4,915) 2,870 (1,300)

35D-MS 2-STAGE FULL FREE LIFT MAST

105.5 (2,680) 74 (1,880) 153.5 (3.900) 24 (610)

3,000 (1,360)117.5 (2,984) 80 (2,032) 165.5 (4,204) 30 (760)

129.5 (3,239) 86 (2,184) 177.5 (4,508) 36 (915)

35D-MT 3-STAGE MAST

158 (4,013) 73 (1,854) 206 (5,232) 25 (635)2,670 (1,210)

170 (4,318) 77 (1,956) 218 (5,537) 29 (740)

185 (4,699) 82 (2,083) 233 (5,918) 34 (865) 2,470 (1,120)

198 (5,029) 87 (2,210) 246 (6,248) 39 (990) 1,980 (900)

216 (5,486) 95 (2,413) 264 (6,706) 47 (1,195) 1,480 (670)

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TECHNICAL DATA

5-6

MAST DATA – 3,500 LB. CAPACITY UNITS

MAST DATA – 4,000 LB. CAPACITY UNITSThe following data is based on 37" 6-Roller Carriage with 48" Load Backrest mounted on FB20M/ME-3 lift truckswith 3.5" ground clearance.


Overall Height*Free Lift*in. (mm)


Loweredin. (mm)

Extended*in. (mm) (36V and 48V)

35D-MS 2-STAGE MAST

105.5 (2,680) 74.0 (1,880) 153.5 (3,900)

5.5 (140)3,500 (1,570)117.5 (2,984) 80.0 (2,032) 165.5 (4,204)

129.5 (3,240) 86.0 (2,184) 177.5 (4,408)

145.5 (3,696) 94 (2,388) 193.5 (4,915) 3,240 (1,470)

35D-MS 2-STAGE FULL FREE LIFT MAST

105.5 (2,680) 74 (1,880) 153.5 (3.900) 24 (610)

3,500 (1,580)117.5 (2,984) 80 (2,032) 165.5 (4,204) 30 (760)

129.5 (3,289) 86 (2,184) 177.5 (4,408) 36 (915)

35D-MT 3-STAGE MAST

158 (4,013) 73 (1,854) 206 (5,232) 25 (635) 3,260 (1,480)

170 (4,318) 77 (1,956) 218 (5,537) 29 (740) 2,780 (1,260)

185 (4,699) 82 (2,083) 233 (5,918) 34 (865) 2,470 (1,120)

198 (5,029) 87 (2,210) 246 (6,248) 39 (990) 2,180 (990)

216 (5,486) 95 (2,413) 264 (6,706) 47 (1,195) 1,590 (720)

* Data of Extended Overall Height and Free Lift includes height of 48.0 in. (1,220mm) load backrest. Without backrest, reduce Extended Height by 27.5 in. (700mm) and increase Free Lift height by same amount.** Load capacity at 610 mm (24 in.) load center with wide-tread tires.


Overall HeightFree Liftin. (mm)


Loweredin. (mm)

Extendedin. (mm) (36V and 48V)

E40-MS 2-STAGE MAST

130 (3,302) 84.5 (2,146) 178 (4,521) 5.5 (140) 4,000 (1,814)

E40-MT 3-STAGE MAST

188.5 (4,788) 83.5 (2,121) 236.5 (6,007) 58.9 (1,496) 4,000 (1,814)Pro

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TECHNICAL DATA

5-7

FORKLIFT DIMENSIONAL DIAGRAM (TYPICAL)

NOTICE

Most values shown in these tables are rounded. Slight differences may exist, when converting between metric, English or Imperial measurements, from those shown.Actual operating conditions may suggest the use of certain options and attachments in order to satisfy your particular requirements. Consult your Komatsu Forklift dealer for specifications, suitability and avail-ability.

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KOMATSU FORKLIFT USA, LLCPro

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Documents

AMX and BMX Electric Forklift Truck S/N 23001A~ AMX FB15 ... · 1. Internal combustion equipment a. Engine (excluding all accessories and consumable trade parts) b. Torqflow and standard