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warning service manual - Komatsu Forklift USA, Inc. v3.1

1. 801340 AB801350 BE CAREFUL OF THE FORK TIPS Do not allow the tips of the forks to get close to people The tips of the forks are pointed so there is a risk that they may cause injury Do not attempt to hook something with the tips of the fork otherwise the hooked object can suddenly come off the tip and the reaction can cause danger to the lift truck as well as to the hooked object WARNING DON T USE THE FORK TO PUSH OR PULL A LOAD There is a risk that the load will be damaged or fall DON T TILT THE MAST FORWARD WITH A LOAD ON THE FORK Do not tilt the mast forward with the load raised Do not raise the load when the mast is tilted forward There is danger of the load falling or the truck tipping over Do not travel with the mast tilted forward Do not load and unload on slopes BE CAREFUL OF SLACK IN THE HOIST CHAINS If there is any slack in the chain the mast rail or forks may catch in the load or a shelf and there is danger that the load may fall and the lift truck tip Always be careful that there is no slack in the chain when pulling the forks out from pallet or shelf 1 3 LOADING OPERATIONS B801430
2. 5 13 INSPECT ale eee XM 5 13 INSPECT TILT 5 5 14 INSPECT ATTACHMENT CYLINDERS IF EQUIPPED 5 14 INSPECT LIFT TRUCK CHASSIS AND 5 14 INSPECT CAB IF 5 14 INSPECT THE OPERATOR S 5 14 5 89 1 VERICLE CONTROELER ic Rad DE a 5 14 5 39 2 KOMATSU OPERATOR PRESENT SYSTEM KOPS 5 14 5 39 3 CONTROLLER TROUBLESHOOTING 5 16 INSPECT EQUIPMENT USED FOR ACCESSING THE LIFT TRUCK 5 18 INSPECT DISPLAY PANEG foe te SEA E 5 18 INSPECT OVERHEAD GUARD 5 18 INSPECT LIGHTS GAUGES AND WARNING DEVICES 5 18 INSPECT REAR VIEW MIRROR AND 5 5 18 INSPECT SPEED amp FORWARD REVERSE LEVERS MANUAL TRANSMISSION 5 19 5 45 1 HIGH LOW 5 19 5 45 2 FORWARD REVERSE LEVER 5 19 MAINTENANCE OPERATIONS 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 LUBRICANT LIST 21 AND K25
3. 11 APPLICABLE BX20 EPA LIFT TRUCK MODELS 17 1 SAFETY 1 1 SAFETY MANAGEMENT 1 2 1 2 SAFE TRAVELS uhi ueque bee Rx edit ee ens 1 6 1 3 LOADING OPERATIONS 4 1 14 1 4 SAFETY IN PERIODIC 1 19 1 5 TOWING ten odi S Ii ideis 1 25 1 6 STRUCTURE AND STABILITY OF THE LIFT 1 26 1 7 SAFETY daret ate M Ne eei ecl edu 1 29 1 8 OPTIONAL 1 35 TET REARCEBAMP bes EA RI ERA OP KR 1 35 1 8 2 HIGH LOAD 1 35 1 8 3 WIDE FORK CARRIAGE aed ae XH ae ada EET REY 1 35 18 4 AUDIBLE SPEED ALARM 1 35 1 8 5 5 1 1 35 2 GENERAL INFORMATION 8 SPECIFICATIONS 21 SPECIFICATIONS MAST DATA amp FEATURES INDOOR amp OUTDOOR TRUCKS 2 2 2 2 SPECIFICATIONS MAST DATA amp 5 2 3 2 3 TRUCK DATA PNEUMATIC LIFT TRUCKS OUTDOOR 2 4 2 4 TRUCK DAT
4. AB801460 AB801360 91100624 1 3 LOADING OPERATIONS DON T USE THE LIFT TRUCK IMPROPERLY Do not use the lift truck for any other purpose than was originally intended the loading work using the fork or attachments Do not use the forks to open or close the doors of railroad cars or warehouses Do not push any other vehicle Do not hook ropes on the forks and use the forks to lift loads Do not use the drawbar pin for towing operations 1 18 AB801380 1 4 SAFETY IN PERIODIC MAINTENANCE WARNING PERIODIC MAINTENANCE WORK MUST BE CARRIED OUT BY QUALIFIED PERSONNEL Only persons authorized by the owner or operator of the equipment and having proper certification local or national may carry out inspection maintenance and repairs of the lift truck If inspection maintenance or repair work is carried out incorrectly it may create a hazardous condition WARNING DESIGNATE A LOCATION FOR PERIODIC MAINTENANCE WORK 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 WARNING PRECAUTIONS BEFORE PERIODIC MAINTENANCE WORK Read rules and regulations for safety control safe driving and loading and unloading operation carefully and understand them fully To be prepared for a fire have a fire extinguisher nearby and make sure t
5. daten e Erud 5 8 5 18 INSPECT THE POWER STEERING 5 8 5 9 5 18 1 POWER STEERING OIL 55 5 9 519 INSPECT BRAKE SYSTEM RODS CABLES AND 5 9 4 5 20 5 21 5 22 5 23 5 24 5 25 5 26 5 27 5 28 5 29 5 30 5 31 5 32 5 33 5 34 5 35 5 36 5 37 5 38 5 39 5 40 5 41 5 42 5 43 5 44 5 45 INSPECT BRAKE PIPING AND 6 5 9 INSPECT BRAKE MASTER AND WHEEL CYLINDERS 5 10 INSPECT BRAKE SHOES AND ASSOCIATED 5 5 10 INSPECT BRAKE DRUMS 5 10 INSPECT BRAKE BACKING PLATES 5 11 INSPECT LOAD FORKS ee eae i Se ee a da 5 11 INSPECT MAST sri edo sta sk ate pter Fus Boe b eat 5 11 INSPECT FORK 5 12 INSPECT LIFT 8 5 12 INSPECT CHAIN 6 5 13 INSPECT ATTACHMENTS 5 13 INSPECT HYDRAULIC 5 13 INSPECT CHASSIS AND ATTACHMENT 5 13 INSPECT HYDRAULIC PUMP
6. dA fessum det tuse dud trou 1122 INSTALLATION 5 8 118 PERIODIC MAINTENANCE 254426 rb stews TROUBLESHOOTING 45102 da Ging tee E APPENDICES APPENDIX 1 SCHEMATICS APPENDIX 2 HYDRAULIC CIRCUIT DIAGRAM APPENDIX 3 PEDAL ADJUSTMENT DIAGRAM APPENDIX 4 TROUBLESHOOTING DIAGRAM APPENDIX 5 K21 K25 ENGINE MANUAL PRE EPA 2007 APPENDIX 6 TB94 L E ENGINE MANUAL INTRODUCTION This Service Manual has been developed as an information resource to help the reader learn about understand repair and maintain the BX20 Series forklift trucks and the vari ous equipment systems inspections sensors diagnostic procedures and diagnostic equipment utilized to maintain adjust and troubleshoot these systems Although refer ence is made to maintenance procedures necessary to perform servicing of this vehicle you should refer to the applicable Operation and Maintenance Manual for these lift trucks for more complete maintenance information Komatsu is involved in a concentrated and highly technical program of designing and developing cleaner burning more efficient and more powerful engines for use in the industrial truck market As a result new computerized sensors systems and diagnostic monitors have been created to make the job of maintaining and repairing these
7. 4 8 49 MEASURE HYDRAULIC DRIFT ON LIFT amp TILT CYLINDERS 4 8 4 10 ADJUST THE ACCELERATOR PEDAL 4 9 4 11 THROTTLE POSITION SENSOR SYSTEM 4 10 4 12 ACCELERATOR PEDAL POSITION 5 4 11 413 ADJUST THE CLUTCH BRAKE PEDAL MANUAL TRANSMISSION 4 12 454341 CLUTCH PEDAL Mei 4 12 4 13 2 BRAKE PEDAL od s sara aunt ala 4 12 414 CHECK BRAKE FLUID neue e 4 14 415 MEASURE BRAKE STOPPING DISTANCE BRAKING 4 14 446 ADJUST THE STOP LAMP SWITCH 412525045 a 4 14 417 ADJUST THE INCHING BRAKE PEDAL TORQFLOW TRUCKS 4 15 BRAKE PEDAL Le RA DU ONE DE 4 15 4 17 2 INCHING PEDAL o custodes caer tart Mure aet su ci dice eile ars 4 15 4 17 3 INCHING PEDAL BRAKE PEDAL INTERCONNECTED TRAVEL 4 15 4 18 CHECK TORQFLOW CLUTCH ACTUATION 4 17 4 19 CHECK TORQUE CONVERTER STALL 4 17 4 20 TEST SPECIFIC GRAVITY OF BATTERY 4 18 421 CHECK TIRES AND ADJUST PNEUMATIC TIRE 5 4 19 4 22 MEASURE MINIMUM LEFT AN
8. 7 27 7 13 2 STEERING AXLE 7 27 7 13 8 INSTALL STEERING AXLE 7 31 STEERING AXLE LUBRICATION AND 5 7 32 7 14 1 STEERING AXLE LUBRICATION 7 32 7 14 2 HUB BEARING PRELOAD ADJUSTMENT 7 32 7 14 8 TOE IN SPECIFICATION CUSHION TIRE 7 32 7 14 4 TURNING ANGLE 7 33 POWER STEERING VALVE 7 36 POWER STEERING VALVE TROUBLESHOOTING 7 37 7 16 1 REMOVE POWER STEEERING 7 39 7 16 2 DISASSEMBLE POWER STEERING VALVE 7 39 7 16 3 ASSEMBLE POWER STEERING VALVE 7 46 7 16 4 INSTALL POWER STEERING 7 58 POWER STEERING 2 22 2 22 7 59 WHEEL BRAKE ido smi Ro Gas 7 60 7 18 1 WHEEL BRAKE 7 60 7 18 2 WHEEL BRAKE DISASSEMBLY 7 61 7 18 3 ASSEMBLE WHEEL BRAKE 7 63 7 18 4 AXLE SHAFT AND FRONT WHEEL INSTALLATION 7 65 7 19 7 20 7 21 7 22 7 23
9. 1 33 1 7 SAFETY LABELS 14 Slide seat forward prior to opening bonnet 15 Fuel type b a GASOLINE FUEL y DIESEL FUEL EPA REGULATION USE LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY 3EB 96 A7910 SAFETY LABEL ORDERING INFORMATION Use the chart below to order the safety labels described above LABEL ORDER PART NO _ 09842 A0481 3EB 96 A5111 3EB 96 A5821 3EB 96 A5910 3EB 96 A5920 3EB 96 A5931 3EB 96 A5940 3EB 96 A5960 OO oa BR OJN 3EB 96 A6120 e 3EB 96 A5970 37B 1QT A030 N 3EB 96 25520 96 5951 AR 3EB 96 A7560 a 37B 1QA 3010 b 37B 1QB 3010 c 3EB 96 A7910 1 34 1 8 OPTIONAL EQUIPMENT Various safety devices are available as options If operating conditions demand it please install these devices The devices listed below are only examples Various other devices are also available For details please contact your Komatsu Forklift dealer 1 8 1 REAR LAMP Install this when carrying out operations at night which require the rear area to be lighted The law demands that sufficient lighting be provided to ensure safety 1 8 2 HIGH LOAD BACKREST This improves the support for high loads and improves the stability of the load 1 8 3 WIDE FORK CARRIAGE This improves the support for wide load and improv
10. 1 27 1 6 STRUCTURE AND STABILITY OF THE LIFT TRUCK SPEED AND ACCELERATION If a stationary object is not subjected to external force it will remain stationary In the same way if a moving object 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 applied towards the front when the lift truck stops If the brakes are applied suddenly there is danger of a large force being applied towards the front which may make the lift truck tip or the load to be expelled When the lift truck is turned a centrifugal force is applied to the outside from the center of the turn This force pushes the lift truck to the outside and makes it tip The range of stability to the left and right is particularly small so it is necessary to reduce speed when turning in order to prevent the lift truck from tipping If the lift truck is traveling with a raised load the position of the overall center of gravity is high so the danger of tipping to the front left or right becomes greater 1 28 1 7 SAFETY LABELS Keep safety and other labels clean If a label comes off stick it on again or replace with a new Overhead guard On dash to right On engine inside right of steering column 8 1 Right side 9 E of bonnet 11 12 Inside rear right stay Outside both 5 outer masts Over
11. warrants the following emission related parts Oxygen sensor e PCV valve Gasoline injector sensor LPG injector LPG pressure sensor LPG solenoid LPG switching module Mass air flow sensor Throttle chamber Ignition coil e Crankshaft position sensor Camshaft position sensor Distributor e Spark plugs EMISSION CONTROL WARRANTY 36 MONTHS OR 4 000 HOURS FOR POWER TRAIN PARTS ntake manifold Exhaust manifold EMISSION CONTROL WARRANTY 60 MONTHS OR 3 500 HOURS FOR GENERAL PARTS ECM Catalytic converter Vaporizer NOTICE Follow the instructions in the Operations Manual concerning any other maintenance programs not required for EPA compliance For questions and additional information concerning EPA Diesel Engine Exhaust Regulations contact Komatsu Forklift USA Inc 14481 Lochridge Blvd Bldg 2 Covington GA 30014 4908 Voice phone 770 385 4815 Fax phone 770 385 4838 13 FEDERAL EPA EMISSION CONTROL STATEMENTS FEDERAL EPA EMISSION CONTROL STATEMENT FOR OFF ROAD DIESEL ENGINES 4D94E ENGINES Exhaust emissions produced by diesel engines are regulated by the United States Environmental Protection Agency EPA This section presents information concerning the correct labeling warranty parts and maintenance of 4D94E diesel engines in order to comply with current EPA regulations 1 LABELS REQUIRED AND LABEL LOCATIONS All certified 4D94E diesel en
12. 7 24 7 25 7 26 7 27 7 28 7 29 7 30 7 31 7 32 CLUTCH TRANSMISSION 2 7 65 7 19 1 DISASSEMBLE CLUTCH TRANSMISSION AFTER REMOVAL 7 65 7 19 2 TEST CLUTCH 7 69 7 19 3 ASSEMBLE CLUTCH 7 71 DRIVE AXLE C gd aa secos ed iste Eats 7 75 DIFFERENTIAL DIRECT DRIVE 58 1581 7 79 ADJUST DIRECT DRIVE DIFFERENTIAL 7 81 DIFFERENTIAL TORQFLOW 5 5 7 85 7 23 1 DISSASSEMBLE TORQFLOW TRANSMISSION DIFFERENTIAL 7 86 7 28 2 ASSEMBLE TORQFLOW TRANSMISSION DIFFERENTIAL 7 88 ADJUST RING GEAR 7 92 TORQFLOW TRANSMISSION W TORQUE 7 97 7 25 1 EXPLANATION OF OPERATION OF TRANSMISSION HYDRAULIC CIRCUIT 7 101 DISASSEMBLE TORQFLOW 5 7 106 TORQUE CONVERTER DISASSEMBLY 7 108 7 27 1 DISASSEMBLE TORQUE 7 108 7 27 2 ASSEMBLE TORQUE 7 108 TORQFLOW TRANSMISSION DISASSEMBLY 7 109 7 28 1 DISASSEMBLE T
13. Always use the specified brake fluid Check that the breather of the brake fluid reserve tank is not clogged Becareful not to let dirt or dust get into the brake fluid reserve tank WARNING BE CAREFUL OF BOILING ENGINE COOLANT Immediately after using the lift truck the engine coolant is at high temperature and high pressure Do not remove the radiator cap under these conditions as hot water may spurt out and cause burns When removing the radiator cap turn it slowly to release the internal pressure When checking the coolant level stop the engine and wait for the engine and radiator to cool down before checking 9JM01067 1 20 1 4 SAFETY IN PERIODIC MAINTENANCE BE CAREFUL OF HIGH PRESSURE AND HIGH TEMPERATURE HYDRAULIC OIL Immediately after using the lift truck the oil is at high temperature Do not drain the oil or replace the filter when the oil is hot as hot oil may spurt out and cause burns Wait for the truck temperature to go down before carrying out the inspection and maintenance work Do not forget that the work equipment circuits are always under pressure Do not add oil drain oil or carry out maintenance or inspection before completely releasing the 9JM01453 internal pressure e If oil is leaking under high pressure from small holes it is dangerous if the jet of high pressure oil hits your skin or eyes Always wear safety glasses and thick gloves and use A a piece of car
14. Your emission control system may include parts such as fuel injection pump Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists an authorized Komatsu dealer will repair the heavy duty off road engine at no cost to the owner including diagnosis parts and labor Now KFI hereby certifies that diesel engines for lift trucks produced 2004 model year and after shall be regu lated by Federal EPA exhaust gaseous regulations The difference between current and EPA certified engines is only the label attached on the engine See available drawing and or illustration of emission label and its location MANUFACTURER S WARRANTY COVERAGE Beginning January 1 2004 heavy duty off road EPA engines are warranted for a period of five 5 years or three thousand 3 000 hours of operation whichever occurs first If any emission related part on your engine is defec tive the part will be repaired or replaced by at an authorized Komatsu Forklift dealer EMISSION RELATED PARTS Fuel injection pump Fuel injection nozzles Turbocharger OWNER S WARRANTY RESPONSIBILITIES As the heavy duty off road engine owner you are responsible for the performance of the required maintenance listed in owner s manual Instruction Manual recommends that you retain all receipts and records covering the maintenance on your engine but cannot deny warranty solely for the lack of receipt
15. 6 TRANSMISSION AND DRIVE 7 8 7 3 1 CLUTCH TORQUE CONVERTER TRANSMISSION DRIVE AXLE REMOVAL 7 8 DISASSEMBLE CLUTCH MANUAL TRANSMISSION 5 7 12 ASSEMBLE CLUTCH MANUAL TRANSMISSION 7 15 7 5 1 CLUTCH INSTALLATION MANUAL TRANSMISSION TRUCKS 7 16 7 5 2 BLEED AIR FROM 7 16 INSTALL TORQUE CONVERTER deci Ug 7 16 INSTALL TRANSMISSION AND DRIVE 7 16 INSTALL PEDAL ASSEMBLY amp BRAKE 7 16 BRAKE MASTER CYLINDER 7 17 7 9 1 DISASSEMBLE BRAKE MASTER CYLINDER 7 18 7 9 2 ASSEMBLE BRAKE MASTER CYLINDER 7 20 CLUTCH MASTER CYLINDER MANUAL SHIFT TRUCKS 7 21 CLUTCH RELEASE CYLINDER 22222 202 Cin tech pp 7 22 7 11 1 DISASSEMBLE CLUTCH RELEASE CYLINDER 7 23 7 11 2 CLUTCH RELEASE CYLINDER SPECIFICATIONS 7 24 7 11 3 ASSEMBLE CLUTCH RELEASE CYLINDER 7 24 BLEED AIR FROM BRAKE SYSTEM LINES 7 25 STEERING AXLE eur tet oh Ged ee ashe 7 27 7 13 1 STEERING AXLE 6
16. PERIODIC MAINTENANCE JACKING UP THE LIFT TRUCK FOR INSPECTION AND REPLACEMENT OF TIRES A WARNING Do not go under the forklift truck when it is jacked up Check the following before jacking up the lift truck Check that there is no one on the lift truck 8 Check that there is no load on the forks When jacking up stop when the tires come off the ground surface Put blocks under both sides of the frame to prevent the lift truck from coming down Put a tire stopper behind the tires in contact with the floor so that the lift truck will not move freely AB801530 PRECAUTIONS WHEN USING BOOSTER JUMPER CABLES ALWAYS wear safety glasses or goggles when starting the lift truck with booster cables When starting using the battery of another lift truck do not allow the two lift trucks to touch Stop the engine before connecting the cables Be extremely careful not to let the cables get caught in the fan or fan belt Ensure that the cables are hooked up correctly positive to positive and negative to negative Never let the positive and negative terminals contact each other WARNING SAFE HANDLING OF WASTES FROM LIFT TRUCK Obey appropriate laws and regulations when disposing of harmful objects such as oil filters and batteries PRECAUTIONS FOR WASHING LIFT TRUCK WITH 55555555 69 R X If water gets into the electrical system controller sensor connectors etc t
17. WARRANTY RIGHTS AND OBLIGATIONS All off road large spark ignition LSI engines must be designed built and equipped to meet the Federal EPA s stringent anti smog standards Komatsu Forklift USA Inc KFI must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse damage neglect or improper maintenance of your engine Your emission control system may include parts such as the carburetor regulator or fuel injection system ignition System engine computer unit ECM catalytic converter and air induction system Also included may be sensors hoses belts connectors and other emission related assemblies Where a warrantable condition exists an Authorized Komatsu Forklift Dealer will repair your LSI engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE Beginning January 1 2004 off road large spark ignition EPA engines are warranted for the time periods listed below If any emission related part on your engine is defective the part will be repaired or replaced by an Autho rized Komatsu Forklift Dealer OWNER S WARRANTY RESPONSIBILITIES As the off road LSI engine owner you are responsible for the performance of the required maintenance listed in your Operation and Maintenance Manual recommends that you retain receipts covering maintenance on your off road engine but cannot deny war ranty solely for the l
18. inspection with the forks raised insert a stand under the inner mast to prevent the forks and mast from dropping Before starting the inspection and maintenance work disconnect the cable from the battery negative terminal When carrying out job with another worker decide who is the leader and carry out the job in accordance with instructions from that person After finishing repair work perform a test drive of the lift truck During the trial run start 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 1 19 1 4 SAFETY IN PERIODIC MAINTENANCE WARNING PERIODIC INSPECTION OF CRITICAL REPLACEMENT PARTS Replace critical safety parts with a new one periodically even if no defect is found Parts tend to deteriorate as time goes by and can cause fire or failure in the work equipment system However if these parts show any abnormality before the replacement interval has passed they should be repaired or replaced immediately WARNING USE OF PROPER TOOLS AND EQUIPMENT Always use tools that are suited for inspection and maintenance It is extremely dangerous to use broken tools or tools designed for another purpose WARNING SAFE HANDLING OF BRAKE OIL It is dangerous if the brakes do not work because in this condition the lift truck cannot be stopped Always do the following e Check the level of the brake fluid periodically
19. on the nameplate On some detachable type attachments and inserting type attachments there is an additional load capacity chart or attachment weight label provided at a certain place Follow the instructions in the chart or the label when installing such an attachment WARNING UNAUTHORIZED MODIFICATION Do not install any additional equipment parts or the like on the lift truck or modify the lift truck without prior written consent from Komatsu Forklift An additional counterweight or unauthorized modification of the lift truck can bring about a negative effect on the stability or strength of the lift truck and can also impair its safety Do not install any equipment or parts which obstruct or limit the operator s view WARNING DON T REMOVE THE OVERHEAD GUARD AND LOAD BACKREST The overhead guard is installed to protect the operator from falling objects It is designed to withstand the force 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 Do not use a Komatsu lift truck when it is equipped with a non genuine overhead guard or load backrest Note Komatsu lift trucks are usually equipped with the optimum overhead guard and load backrest when they are shipped out of Komatsu Forklift plants DON T USE DEFECTIVE LIFT TRUCK USE LOCK OUT TAG OUT PROCEDURES WARNING Remove the key from the faulty lift truck an
20. poor ventilation The engine exhaust gas contains carbon monoxide which can cause gas poisoning and result in serious injury or death A WARNING 0055060 FIRE IS STRICTLY PROHIBITED DURING REFUELING Fuel is extremely flammable and can cause fires and explosions Carry out refueling away from flames or sparks Stop the engine when refueling After refueling tighten the gas cap securely and wipe up any spilled fuel A0055040 9JL00626 1 1 SAFETY MANAGEMENT FIRE FIRST AID AND GENERAL SAFETY When you feel something unusual occurring with the lift truck promptly stop working move the lift truck to a safe place for parking stop the engine for safety Then report to the supervisor Be sure that fire extinguishers have been provided and that you read the labels 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 0055070 Provide a first aid kit at the storage point If a fuel leak is discovered do not operate the lift truck Be sure to make repairs stopping the leak before starting the operation again while reporting the trouble to the supervisor LPG FUEL SYSTEM SAFETY Accidents involving fuel systems are always dangerous and can cause fire and explosion serious injury death and property damage Keep the following points in mind when working with fuel systems LPG i
21. the cable of the positive terminal first Avoid short circuiting the battery terminals through accidental contact with tools or other metal objects across the terminals Tighten the battery terminals securely Loose terminals can generate sparks and lead to an explosion When connecting the disconnected battery cables again be sure which is the positive terminal and which is the negative terminal in order to avoid improper connection Tighten the battery caps securely When cleaning the battery leave the battery caps tightened Do not put a metallic tool or plate on the battery terminals by accident There is danger that such a metallic object could cause short circuiting leading to a fire PRECAUTIONS WHEN CHARGING BATTERIES When the battery is charged hydrogen gas is generated and the battery is heated by the chemical change To prevent the danger of gas explosion always do as follows Before charging the battery check that the battery electrolyte level stays within the specified range If the electrolyte is found insufficient add distilled or purified water without fail Carry out the charging operation in a well ventilated place Do not smoke or allow any flame or ignition source Start to charge the battery when the battery electrolyte temperature is below 35 C 95 F If the electrolyte temperature is above 50 C 122 F wait until it goes below 35 C 95 F When using a battery charger to charge the b
22. 5 6 2 LUBRICANT LIST AD94E 6 3 OIL AND GREASING 6 4 CHANGE ENGINE OIL AND FILTER GASOLINE LP 5 6 5 DIFFERENTIAL CASE f acto UA eR C EE UL E aps 6 6 6 5 1 CHECK DIFFERENTIAL OIL LEVEL 6 6 6 5 2 CHANGE DIFFERENTIAL 1 6 6 TORQFLOW TRANSMISSION 6 7 6 6 1 CHECK TORQFLOW TRANSMISSION FLUID LEVEL 6 7 6 6 2 CHANGE TORQFLOW TRANSMISSION FLUID amp CLEAN THE STRAINER 6 7 CHANGE OIL IN HYDRAULIC 6 8 REPLACE THE FUEL 6 9 CLEAN AND OR REPLACE AIR CLEANER 6 9 7 REMOVAL DISASSEMBLY ASSEMBLY amp INSTALLATION 7 1 7 2 7 3 7 4 7 5 7 6 7 7 7 8 7 9 7 10 7 14 7 12 7 13 7 15 7 16 7 47 7 18 OVERALL DISASSEMBLY AND ASSEMBLY 7 2 ENGINE a egal Mic he na Aes ce wel a 7 5 724 ENGINE REMOVAL 2 ou DOE du cau iiM adit 7 5 72 2 ENGINE DISASSEMBLY AND 7 6 72 8 ENGINE INSTALLATION 7
23. 7 124 HYDRAULIC CONTROL VADE fate ehh otia DEA 7 127 HYDRAULIC 2 7 128 7 31 1 DISSASSEMBLE HYDRAULIC 7 128 7 31 2 REPLACE HYDRAULIC PUMP 1 7 130 7 31 3 REPLACE FRONT AND REAR E SEAL AND BACK UP RING 7 130 7314 REPLACE 7 131 7 31 5 ASSEMBLE HYDRAULIC 7 131 Wan Nett he nets 7 132 7 32 1 DISASSEMBLE TILT 7 132 7 32 2 INSPECT TILT CYLINDER PARTS 7 133 7 32 3 ASSEMBLE TILT CYEINDER Rh eee 7 134 7 33 REMOVE MAST hash ap Netila kadar WEAR TRUE ahaa tea TBA INSTALL MAG Tantus ae tas ted gus dios 36 JIETAYEINDERS 12252 d aseo cd Sct aad dac edo ec 7 35 1 REMOVE LIFT CYLINDER c URS d 7 35 2 INSTALL LIFT CYLINDER pda 7 35 3 DISASSEMBLE LIFT 7 35 4 ASSEMBLE LIFT 7 36 CYLINDER SEAL SERVICE 5 7 36 1 DISPLACEMENT DESIGN WITH PISTON
24. 7 36 2 PISTON DESIGN WITH NO DOWNSTROKE CUSHIONING TBE SIDESHIPIER G sacos Lngd Soke hasce 7 37 1 REPLACE CYLINDER HEAD 8 7 37 2 SERVICE CYLINDER HEAD 50D 55D 60D MS LIMITED FREE LIFT 2 STAGE MASTS Bi INTRODUCTION denis cea pectet 82 INSTALLATION 5 8 3 PERIODIC MAITENANGE toi accio Ves aet dad re Nata TROUBLESHOOTING Pc ates dame aditus aie Made qucd cs sa ard 50D 55D 55ND 60D MD FULL FREE LIFT 2 STAGE MAST 84 INTRODUCTION nw tetas tutu ee dard dtes plata sd 9 2 INSTALLATION INSTRUCTIONS Meet EAS 9 3 PERIODIC MAINTENANCE bua sq udi esa wis MIT eee 9 4 TROUBLESHOOTING s a o aaaeeeaeo EEEE EEEE EEEE SSERUIGES qu uo Dc 50D 55D 60D MT FULL FREE LIFT 3 STAGE MAST 10 4 INSTALLATION INSTRUCTIONS oot escis ce ela gather qi gestita bust 10 2 PERIODIC MAINTENANCE bat ttu patella d as cbe 103 TROUBLESHOOTING 234m ctm ide cadis 104 SERVICE 45D 55D MQ QUAD MAST 11 4
25. 96 A6120 1 7 SAFETY LABELS WARNING Deflate tire completely before removing rim nuts 3EB 96 A5970 10 Warning for use of split rim pneumatic tires only 11 Replace overhead guard if damaged WARNING This overhead guard offers reasonable protection to operator from falling objects but cannot protect against every possible impact Impact test rating 16000 foot pounds 37B 1QT A030 12 Method of hoisting the lift truck Never use the overhead guard to lift the truck 3EB 96 25520 13 Warning for handling LPG FLAMMABLE GAS on LP tank bracket A WARNING Only TRAINED and CERTIFIED personnel may change LPG tanks Close fuel valve on tank when parking truck Do not store tank or park truck near heat or ignition sources Avoid sparks and open flames Do not smoke Follow filling and operating instructions in Operation and Maintenance Manual Close fuel valve on tank Run engine until it stops before disconnecting fuel hose Remove tank from truck and fill in designated area Properly position tank using locating pin and ensure that it does Flammable not extend outside of truck LP Gas Close fuel valve on tank and securely connect fuel hose Frost or LPG odor indicates leak immediately close fuel valve and contact qualified personnel to make repair Do not start engine Comply with National Fire Protection Association pamphlet 58 for safe storage and handling of liquefied petroleum gases 3EB 96 A5951
26. A CUSHION TIRE LIFT TRUCKS 2 11 2 5 PERIODIC REPLACEMENT OF CONSUMABLE 2 13 2 6 STANDARD TIGHTENING TORQUE FOR PIPE JOINTS 2 14 2 7 STANDARD TIGHTENING TORQUE FOR BOLTS 2 15 3 SERVICE DATA 3 1 SERVICE DATA GASOLINE ENGINE TRUCKS PNEUMATIC 3 2 3 2 SERVICE DATA GASOLINE ENGINE LIFT TRUCKS CUSHION 3 5 3 3 SERVICE DATA DIESEL ENGINE LIFT 3 8 4 TEST ADJUST AND MEASURE 4 1 ADJUST IGNITION 4 2 4 2 ADJUST INJECTION TIMING MARK DIESEL 4 2 4 3 ADJUST NO LOAD ROTATING SPEED DIESEL ONLY 4 3 4 4 ADJUST SPARK PLUG 4 3 4 5 ADJUST VALVE CLEARANCE 4 4 451 GASOLINE 1 4 4 45 2 sch ins anced be ahead Ae had eee 4 5 4 6 ADJUST FAN BELT TENSION 4 6 4 7 MEASURE ENGINE CYLINDER 4 6 41 GASOLINE ENGINE tu asuma sya bind edes thn th caus 4 6 472 DIESEL ENGINE eh abe 4 7 48 ADJUST THE PARKING BRAKE LEVER
27. D RIGHT TURNING RADIUS 4 19 423 MEASURE HYDRAULIC CONTROL VALVE RELIEF PRESSURE 4 20 INSPECTION 5 1 INSPECT ENGINE STARTING 5 2 52 INSPECT ENGINE RUNNING CONDITION 00 00 00 cece 5 2 53 INSPECT AIR CLEANER ASSEMBLY 5 2 5 3 1 CLEANING THE FILTER ELEMENT 5 2 54 INSPECT FOR LOOSE CYLINDER HEAD MOUNTING BOLTS amp RE TORQUE 5 3 55 ENGINE MOUNTS 5 3 56 INSPECT THE ENGINE LUBRICATING 5 3 57 INSPECT ENGINE FUEL SYSTEM wh ok 5 3 58 INSPECT LPG VAPORIZER FOR TAR BUILDUP 5 4 59 INSPECT THE BLOW BY GAS RECIRCULATION 6 5 5 5 5 10 INSPECT COOLING SYSTEM AND RADIATOR 5 6 5 11 INSPECT CHARGING SYSTEM 5 6 5 12 INSPECT LPG VAPORIZER FOR TAR BUILDUP EVERY MONTH 5 6 5 13 INSPECT THE BLOW BY GAS RECIRCULATION 5 6 5 14 INSPECT COOLING SYSTEM AND RADIATOR 5 8 5 15 INSPECT CHARGING SYSTEM 5 8 S46 INSPECT STEERING 1 9 mc a E eR dte a ei dco o esca 5 8 5 17 INSPECT STEERING WHEEL
28. E TRAVEL BE AWARE OF THE LIFT TRUCK S MAXIMUM HEIGHT AND WIDTH Ensure that there is ample height and width for the lift truck to pass Do not extend your hands or legs outside the operator s compartment or the area covered by the overhead guard safe area Check that the surrounding area is safe Be careful of electric wires and other obstacles inside and outside the building WHEN DRIVING UP OR DOWN A SLOPE EXERCISE EXTRA CARE Do not turn or travel across or at an angle on slopes There is danger that the lift truck will tip over Before starting to drive up a slope stop the lift truck and adjust the clearance between the ground surface and the bottom of the forks so that the bottom of the forks or pallet do not contact the ground surface or the tip of the fork does not stick into the ground when traveling For safe travel on slopes When Travel forward up the slope and in reverse loaded down the slope with the load upgrade When Travel in reverse up the slope and forward unloaded down the slope with the load engaging means downgrade downslope drive down slowly and use the foot brake When starting on slopes the lift truck may start to move down the slope depending on the amount the pedals are depressed Always leave ample room in front of and behind the lift truck when starting on slopes Be careful of the truck sliding downhill if Travel Interlock is engaged while traveling up
29. G Keep a clear view of the path of travel and watch 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 When traveling always pay careful attention to the area around your lift truck particularly in the direction of travel or when turning Do not attempt to pass another lift truck or vehicle on a narrow path or on a spot of limited view like a crossing When passing through an area of limited view like a crossing or when running into a narrow path sound the horn and check the surroundings for safety Even if you sound the horn not everyone in the surrounding area will necessarily hear it Always pay careful attention to the movements of people in the surrounding area When crossing a passage or turning at a corner stop the lift truck once to confirm the safety around Always pay careful attention to the movements of people in the surrounding area and take steps to prevent people from entering the working area When traveling on a slope or through a crowded spot always give way yield to a loaded lift truck AB801260 DO NOT DRIVE ON ROUGH GROUND OR SURFACE 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 obs
30. ORQFLOW TRANSMISSION OIL PUMP 7 109 7 28 2 ASSEMBLE TORQFLOW TRANSMISSION OIL PUMP 7 109 7 28 3 REMOVE COUNTER 6 7 110 7 28 4 DISASSEMBLE INPUT SHAFT 7 111 7 28 5 ASSEMBLE INPUT SHAFT 7 111 7 28 6 DISASSEMBLE MAIN SHAFT AND CLUTCH DRUM 7 112 7 28 7 ASSEMBLE MAIN SHAFT AND CLUTCH DRUM 7 112 7 28 8 ASSEMBLE FORWARD AND REVERSE 7 113 7 28 9 MEASURE TORQFLOW TRANSMISSION CLUTCH PACK END GAP 7 113 7 28 10 DISASSEMBLE CLUTCH RETURN SPRING 7 114 7 28 11 ASSEMBLE CLUTCH RETURN SPRING 7 115 7 28 12 DISASSEMBLE OUTPUT 7 115 7 28 13 ASSEMBLE OUTPUT GEAR 7 115 7 28 14 REMOVE FILTER 7 116 7 28 15 INSTALL OIL FILTER tina drca AE 7 116 7 28 16 REMOVE TRANSMISSION CASE 7 116 7 28 17 INSTALL TRANSMISSION CASE MAGNETS 7 116 TORQFLOW TRANSMISSION CONTROL 7 118 7 29 1 DISASSEMBLE TORQFLOW TRANSMISSION CONTROL VALVE 7 123 7 20 2 ASSEMBLE TORQFLOW TRANSMISSION CONTROL VALVE
31. SM122 SERVICE MANUAL BX20 SERIES FORKLIFT TRUCKS Federal Environmental Protection Agency EPA Emission Control Compliant S N 580001A Gasoline amp LPG FG20 25 30 35S H T C LS US 14 FG20 25 30C 14 FG20 25T US LS 14 FG20 25 30HT US LS 14 Diesel FD20 25 30T US 14 WARNING Read and observe all warnings on this unit before operating it DO NOT operate this equipment unless all factory installed guards and shields are properly KOMATSU REVISED JANUARY 2008 Komatsu Forklift USA Inc The information and specifications contained herein were accurate at the time of publication but may change without notice as required for product improvements Neither Komatsu Forklift USA Inc nor its parent company nor any of its subsidiaries will be held responsible for damages due to misuse or inappropriate use of its products Requests for information comments and other inquiries should be sent to Komatsu Forklift USA Inc 14481 Lochridge Blvd Bldg 2 Covington Georgia 30014 4908 Voice phone 770 385 4815 Fax phone 770 385 4838 Copyright 2008 Komatsu Forklift USA Inc All rights reserved No part of this document may be photocopied or reproduced in any way without prior written consent of Komatsu Forklift USA Inc 5 lh aniepisjye mI 9 ENGINE SERIAL NUMBER LOCATION 10 FEDERAL EPA EMISSION CONTROL STATEMENTS
32. UL or Factory Mutual listed LPG parts 1 5 1 2 SAFE TRAVEL JUMPING ON AND OFF THE LIFT TRUCK IS STRICTLY PROHIBITED C When getting in or out of the lift truck be sure to first stop the truck and use the handrails assist grip as well as the step to hold yourself securely Donothold on to or pull yourself up with the control levers or steering wheel when getting on or off the lift truck Keep the handrails assist grip clean all the time and repair any damage DON T TRY TO OPERATE THE LIFT TRUCK FROM OUTSIDE Always keep your body under the overhead guard Do not put your hand or foot out of the overhead guard You must be properly seated in the operator s seat when operating any function of the lift truck 00003 A WARNING 4 AB801240 MAINTAIN PROPER POSTURE WHILE OPERATING Travel Interlock power transmission cutoff and Lift Tilt Interlock Option Ifyou 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 and Lift Tilt Interlock that make travel and truck operation impossible if you are not seated properly Operator Presence System e Ifyou 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 the Travel Interlock begins to alarm in approximately three seconds and
33. ack of receipts or for your failure to ensure the performance of all scheduled maintenance As the off road large spark ignition engine owner you should be aware however that may deny you warranty coverage if your off road large spark ignition engine or a part thereof has failed due to abuse damage neglect improper maintenance or unapproved modifications Your engine is designed to operate on gasoline and or LPG fuel Use of any other fuel may result in your engine no longer operating in compliance with the Federal EPA s emissions requirements You are responsible for initiating the warranty process It is suggested that you present your off road large spark ignition engine to an Authorized Komatsu Dealer as soon as you become aware that a problem exists The war ranty repairs should be completed by the dealer as expeditiously as possible If you have any questions regarding your warranty rights and responsibilities you should contact the Komatsu Product Support Dept at 1 770 385 4815 In addition to the standard warranty periods the components listed below are covered by the following specific warranty periods 12 FEDERAL EPA EMISSION CONTROL STATEMENTS EMISSION CONTROL WARRANTY 36 MONTHS OR 2 500 HOURS FOR GENERAL PARTS For the first 2 500 operating hours or for a period of thirty six months from the date of the first use by the original purchaser from an Authorized Komatsu Forklift Dealer whichever occurs first
34. as it may cause you to lose your balance or operate the lift truck in an unsafe manner Before starting the engine first check that the surrounding area is safe and sit securely in the operator s seat Sound the horn before starting the engine to warn people around you Do not attempt to start the engine by intentionally short circuiting the engine starting circuit Do not attempt to jump start the lift truck CHECK AND ADJUST THE REAR VIEW MIRROR AND LAMPS 1 2 SAFE TRAVEL AB801650 9JL00776 AB801120 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 the lift truck is safe Always keep the surface of the mirror clean If the mirror is broken replace it with a new one Check that all lamps light up correctly Replace any broken bulbs for lift trucks equipped with lamps 1 7 1 2 SAFE TRAVEL PERFORM A SAFETY CHECK BEFORE STARTING THE LIFT TRUCK Before starting the lift truck check that the surrounding area is safe Before moving the lift truck raise the forks approximately 15 to 20 cm 6 8 in from the ground surface and tilt the mast back UG n e When ready to move release the parking brake 157 20cm I 80125 WARNING SAFETY CONSCIOUS WHILE DRIVIN
35. attery take the battery caps off SAFE HANDLING OF ANTI FREEZE Antifreeze can be a flammable Keep away from flame when handling Antifreeze is poisonous so do not drink it If you drink it by mistake drink large amounts of water vomit it out and get medical attention immediately Follow safety precautions on container 1 24 1 5 TOWING HOW TO MOVE A DISABLED LIFT TRUCK Use extra care when towing a lift truck if there is a problem with any the following a Brakes do not operate correctly b Steering does not operate correctly c Tires are damaged d Traction conditions are poor a The lift truck must be moved on a steep grade If the steering pump motor does not operate steering control of the lift truck can be slow This can make the control of the lift truck difficult If there is no power there is no power steering DO NOT tow the lift truck if there is no power Poor traction can cause the disabled lift truck or towing vehicle to slide Steep grades will require additional brake force to stop the lift truck Never carry a disabled lift truck unless the lift truck MUST be moved and cannot be towed The lift truck used to carry the disabled lift truck MUST have a rated capacity equal to or greater than the weight of the disabled lift truck The capacity must be for a load center equal to half the width of the disabled lift truck See the nameplate of the approximate total weight The forks must extend the full width of the di
36. ble occurs on a railroad crossing and the lift truck does not move it is impossible to use the starting motor as can be done on standard shift automobile This is because a neutral safety switch is installed In such an emergency light a flare or smoke candle to warn approaching trains and people in the area that there is a broken down truck on the tracks DON T USE THE DRAWBAR PIN FOR OTHER THAN IT S INTENDED PURPOSE Do not use the drawbar pin for any other towing purpose than to bail out a stuck lift truck or to be towed by another lift truck or to be hoisted The towing pin at the back of the counterweight is provided to pull out the lift truck when it has gotten stuck in dirt or a ditch as well as when it is being loaded on a truck Drawbar pin 9 100815 1 13 1 3 LOADING OPERATIONS PRECAUTIONS FOR LOADING AND UNLOADING 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 three seconds and cuts off the transmission of engine power Then the truck does not move even if you depress the accelerator pedal or operate the forward reverse lever The truck will slide downhill if Travel Interlock activates on an uphill grade or a slope Select flat and solid ground for loading and unloading Avoid a road shoulder or a place near a cliff Use ramps of sufficient len
37. cking the rims for damage If a rim is damaged or cracked when a tire is inflated there is danger that the rim will break under the high pressure of the tire resulting in personal injury or death For safety when checking tire pressure place your body in front of the tread face of the tire Do not check from the side face of the tire Always have tire inflation work carried out by properly qualified personnel The tire inflation pressure on a forklift truck is several times higher than the pressure on an automobile so exercise caution when handling tires When the tires are being inflated there is danger that dirt or dust may be thrown up by the compressed air and enter your eyes so always wear safety glasses 9JL00164 HANDLING OF TIRES Disassembly and assembly of tires should be carried out by a qualified tire dealer The tire inflation pressure is extremely high so caution is needed when handling tires When removing a tire do so only after the internal air is released Loosen hub nut 1 to remove the tire from the chassis Never loosen rim nuts 2 if installed because it is very dangerous to do so After replacing the tires make a trial run to make sure that 829590 there are no loose hub nuts If the tightening torque is not sufficient further tighten the hub nuts to the specified torque 1 22 1 4 SAFETY IN
38. cting as a fulcrum On the other hand when a position of the combined center of gravity shifts outside of a Combined center of gravity stable range of the center of gravity the lift truck will overturn in the direction of shifting 9 100629 ACTUAL CAPACITY The horizontal distance from the position of the center of gravity of a load on the fork to the upright load backrest of the fork is called a load center Actual capacity means the maximum weight of a load that can be loaded at a certain load center A load capacity chart is given in the name plate The chart shows the relationship between the actual capacity and a load center As a load center shifts toward the fork tips so does the position of the combined center of gravity too Therefore the load has to be AB801620 decreased accordingly in the actual operation When the lift truck is equipped with an attachment or when the mast is raised high the actual capacity is reduced Take this fact into consideration in such a case LOAD CAPACITY CHART In the load capacity chart capacity is shown in relation to load center Capacity values are determined according to each model on the condition of the specifications shown on the plate Before proceeding to loading a load make sure that the load center and the load are well within the confines of capacity When the load is in a complex shape pull
39. cuts off the transmission of engine power Then the truck will not move even if you depress the accelerator pedal or operate the forward reverse lever Additionally Lift Tilt Interlock locks lifting lowering and tilting operations Even if you operate the lift lever or tilt lever these functions will not work The lever for an attachment is not equipped with this function A SUDDEN SHIFT OF THE F R LEVER IS DANGEROUS To change the travel direction stop the lift truck completely and then operate the F R lever 9JL00836 1 6 DON T ALLOW A PASSENGER THE TRUCK Never allow any other person to ride with you on the lift truck Do not use anyone for a makeshift human counterweight BE SURE TO WEAR THE SAFETY SEAT BELT Always fit your seat belt correctly when operating If your seat belt is fitted incorrectly there is danger of serious personal injury if the lift truck should tip over 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 CHECK THE SURROUNDINGS FOR SAFETY BEFORE STARTING UP THE ENGINE Before stating the engine check that the parking brake is set and that the directional and speed levers are in the neutral position Adjust the operator s seat and the steering wheel before starting the engine Always lock them in position after adjusting Adjusting the seat or steering wheel during operation is dangerous
40. d hang signs in the operator s compartment to prevent its use If the lift truck has suffered a failure and the lift truck must be parked without lowering the forks put markers on the tips of the forks and take steps to prevent pedestrians or other vehicles from hitting the forks Select a parking place where people or vehicles do not pass and stop the lift truck so that it is difficult for anyone to AB80149B go under the forks The area under the forks is a danger zone 1 3 1 1 SAFETY MANAGEMENT PRECAUTIONS WHEN REFUELING LPG TRUCKS Only trained and authorized personnel may fill or change LPG tanks When checking or filling tank do not smoke stop the engine and fill only at designated safe areas preferably outdoors Follow the filling and operating instructions in this manual Before filling and reuse check tanks for damage to valves fittings and gauges or dirt in the openings LPG is heavier than air and will sink to the lowest area possible Avoid parking near areas near floor drains lubrication pits or other areas where escaped fuel may collect Ensure that the tank is securely mounted Do not completely fill the tank to prevent overflow and fire hazard when the LPG expands If there is LPG odor or frost on the fuel tank do not start the engine Park and tag the truck and have qualified personnel inspect and repair the fuel system ENGINE EXHAUST GAS IS POISONOUS Do not leave the engine running where there is
41. dboard or a sheet of plywood to check for oil leakage f you are hit by a jet of high pressure oil consult a doctor Mz immediately A WARNING A0055190 BE CAREFUL OF THE ROTATING COOLING FAN AND BELT Itis extremely dangerous if part of your body or a tool in your hand gets caught up in the rotating fan or fan belt Never touch them when rotating When inspecting rotating parts do so only after the engine comes to a stop When inspecting the areas around rotating parts do not allow anything to come close which may get caught 91100625 A WARNING JUMP STARTING THE ENGINE IS PROHIBITED Do not push the lift truck to start the engine There is danger that the lift truck may suddenly start and operate unexpectedly 1 21 1 4 SAFETY IN PERIODIC MAINTENANCE AVOID THE DANGER OF GETTING CAUGHT UP OR FALLING OFF Never put your hands or feet into the mast structure There is danger that you will get caught in moving parts and be seriously injured Do not use the mast as a ladder If you slip there is danger that you will fall AB801320 WARNING 18601380 INSPECTION AND INFLATION OF TIRES If the tire inflation pressure is low it will affect truck stability However do not inflate the tires before che
42. e Manual or safety labels have been lost or have become dirty and cannot be read obtain replacements from your Komatsu Forklift dealer and attach the safety labels in the specified positions WARNING MAKE SAFETY PLANS BEFOREHAND 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 her instructions WARNING FOLLOW THE SAFETY RULES IN PLACE Do not operate the lift truck if you are fatigued or when you have been drinking or have taken any medication which can make you 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 and other surrounding conditions WARNING ENSURE SAFETY AT THE WORKING AREA Always work on level surfaces and wipe up all oil or grease from the ground When working on quays platforms or docks or other places where there is danger of falling set up blocks to prevent the lift truck from going over the edge Put warning signs up in dangerous places to warn the operator not to approach Mark the travel areas clearly and maintain the road surface in good condition Put up signs to prevent unauthorized lift trucks from entering areas where lift trucks are being operated Ensure that there is adequate
43. es the stability 1 8 4 AUDIBLE SPEED ALARM When the lift truck exceeds the preset speed a buzzer sounds to warn the operator 1 8 5 WARNING LAMPS The following warning lamps may be added to the instrument panel Battery electrolyte level warning lamp Air cleaner element clogging warning lamp Radiator cooling water level warning lamp 1 35 1 8 OPTIONAL EQUIPMENT 1 36
44. gines will display the required identification label as follows e AD94E diesel engines Labels will be affixed to all appropriate engines on production trucks Location on 4D94E Series diesel engines EMISSION CONTROL LABEL IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMS TO 2004 MODEL YEAR U S EPA REGULATIONS LARGE NONROAD AND COMPRESSION IGNITION ENGINES THIS ENGINE IS CERTIFIED TO OPERATE ON US2D FUEL ENGINE FAMILY 4YDXL2 78P4N DISPLACEMENT 2 776 LITERS ENGINE MODEL 4TNE94 1B EMISSION CONTROL SYSTEM EM FUEL RATE 47 2 STROKE 44 6 kW 2450 RPM REFER OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS E gt YANMAR DIESEL ENGINE Co Ltd 010565 14 FEDERAL EPA EMISSION CONTROL STATEMENTS 2 WARRANTY The following statement is hereby provided as required by regulations of the United States Environmental Protec tion Agency EPA YOUR WARRANTY RIGHTS AND OBLIGATIONS The Federal EPA and Komatsu Forklift USA Inc hereinafter referred to as KFI are pleased to explain the emis sion control system warranty on your 2004 or later Diesel heavy duty off road engine All new heavy duty off road engines must be designed built and equipped to meet the stringent anti smog standards must warrant the emission control system on your engine for the period of time listed below provided there has been no abuse damage neglect or improper maintenance of your engine
45. gth width and strength Moreover set them securely so that they will not shift or be displaced Always operate the mast and forks from the operator s compartment Be careful not to operate the lever by mistake There is danger that the forks or work equipment may cause serious injury KEEP UNAUTHORIZED PEOPLE OUT OF WORKING AREA AND ENSURE A SIGNAL PERSON IS ON DUTY Donotallow anyone in the working area except the signal person Do not let any person or other lift truck come close during operation When working with a signal person always follow their instructions Blocks 9EL00837 WARNING NEVER GO BENEATH RAISED FORKS The space under a lifted fork is an area of danger so never allow anyone to go under the fork There is a danger of personal injury to any person who could be crushed under the forks when they come down STANDING ON THE FORK S IS STRICTLY PROHIBITED Donotlet anyone place a load on the forks Donotlet anyone directly remove the load from the forks Standing on the forks is dangerous because the forks are slippery and the load may move Donotuse anyone to keep the load stable The lift truck may move unexpectedly causing the load to fall and crush the person AB801310 1 3 LOADING OPERATIONS WARNING BE CAREFUL NOT TO GET CAUGHT IN THE MAST STRUCTURE Never put your hands or feet into the ma
46. hat you know how to use it Before carrying out inspection lower the forks to the ground and stop the machine Before starting the inspection and maintenance work turn the engine starting switch to the OFF position and keep the engine at a standstill Keep the engine starting switch in the OFF position except when otherwise required in order to keep the engine at a standstill Set the MAINTENANCE IN PROGRESS sign in a place in the operator s compartment or near the control panel where it is easy to see Set the forward reverse lever high low speed lever and work equipment lever each to the neutral position Apply the parking brakes and put stoppers chocks both before and behind the tires PRECAUTIONS DURING PERIODIC MAINTENANCE WORK Wipe off any oil or grease Immediately wipe up any oil that has leaked If the lift truck is dirty it becomes difficult or impossible to find cracks or other problems Always clean the lift truck before starting inspection Do not smoke or allow any flame to exist under any circumstances Do not use any cloth which is soaked in oil or grease There is danger that it may catch fire Wear adequate working clothes and protective equipment hard hat safety shoes goggles and gloves 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
47. he latest maintenance methods and procedures Owners and others who desire to perform their own work should purchase a service manual and obtain current service information from their KFI engine dealer NOTICE Follow the instructions in the Operations Manual concerning any other maintenance programs not required for EPA compliance For questions and additional information concerning EPA Diesel Engine Exhaust Regulations contact Komatsu Forklift USA Inc 14481 Lochridge Blvd Bldg 2 Covington GA 30014 4908 Voice phone 770 385 4815 Fax phone 770 385 4838 16 APPLICABLE BX20 EPA LIFT TRUCK MODELS APPLICABLE BX20 EPA LIFT TRUCK MODELS Model Description Gasoline Models FG20C 14 4 000 Ib capacity K21 Engine Clutch Spec Pneumatic Tire FG20T 14 4 000 Ib capacity K21 Engine Torqflow Spec Pneumatic Tire FG20TUS 14 4 000 Ib capacity K21 Engine Torqflow Spec Gasoline Special Pneumatic Tire FG20TLS 14 4 000 Ib capacity K21 Engine Torqflow Spec LP Special Pneumatic Tire FG20ST 14 4 000 Ib capacity K21 Engine Torqflow Spec Cushion Tire FG20STUS 14 4 000 Ib capacity K21 Engine Torqflow Spec Gasoline Special Cushion Tire FG20STLS 14 4 000 Ib capacity K21 Engine Torqflow Spec LP Special Cushion Tire FG20HT 14 4 000 Ib capacity K25 Engine Torqflow Spec Pneumatic Tire FG20HTLS 14 4 000 Ib capacity K25 Eng
48. head guard 2 inside left Rear outer 7 mast stay 3 Inside front left stay Outside both front stays 10 Inside rear tire rims 6 Top of radiator shroud 9JL00853 Details and ordering information for labels are given in the following sections 1 29 1 7 SAFETY LABELS 1 Jump start prohibited Start the engine only after sitting down in the operator s seat Do not attempt to start the engine by short circuit ing the engine starting circuit Such an act may cause serious bodily injury or fire iS 09842 A0481 2 Avoiding danger if lift truck overturns during operations Tip over can occur even when unloaded Don t risk injury or death 7 Slow down before turning 7 96 5111 Buckle seatbelt 4 instructuions Don t jump Hold on tight Brace feet Lean away WARNING a b d If the steering is operated suddenly during operations there is danger that the lift truck may lose its balance and tip over To avoid this danger always observe the following precautions strictly a Always wear your seat belt during operations b Never jump off the lift truck c Hold on tight to avoid falling out and having the lift truck fall on top of you d B
49. here is the hazard that it will cause malfunctions or operational failure Do not wash the electrical system with water or high pressure steam For more details on the washing method see LIFT TRUCK WASHING PROCEDURE on page 3 35 9JM01063 1 23 1 4 SAFETY IN PERIODIC MAINTENANCE SAFE HANDLING OF BATTERIES Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing If you spill battery electrolyte on yourself immediately shed the clothes flush y the part with a large quantity of tap water and then consult a doctor Should battery electrolyte get into your eyes flush them immediately with fresh tap water for 10 to 15 minutes and Should you drink battery electrolyte by accident either drink Q then consult a doctor at once a large quantity of water or milk mixed with beaten egg white or salad oil and then consult a doctor at once Be sure to wear goggles safety gloves and rubber soled shoes at the time of battery maintenance Do not smoke or create any spark near the battery Batteries generate hydrogen gas Hydrogen gas is highly EXPLOSIVE and is easily ignited with a small spark or flame When inspecting or handling the battery do so only after turning the engine starting switch key to the OFF position and stopping the engine When disconnecting the battery cables disconnect the cable of the negative terminal first Conversely when connecting them again connect
50. hill or on a slope Stay securely in the operator s seat 801 150 1 10 WHEN MAKING A TURN BE CAREFUL OF THE SWINGING COUNTERWEIGHT Remember that a fork lift truck steers with the rear wheels not the front wheels It will not drive like an automobile When turning while traveling forward the counterweight will swing far out Keep an ample clearance from walls to ensure safety When turning travel slowly and be careful that the front or rear wheels do not come off the ground When turning on soft road shoulders there is danger that the rear wheels may come off the road shoulder and cause the lift truck to tip ANY OPERATION THAT MIGHT OVERTURN THE LIFT TRUCK IS STRICTLY PROHIBITED If the load engaging means or load is raised the center of gravity of the lift truck will also rise and increase the danger of the lift truck tipping 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 when the 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 of tipping than when traveling with the forks loaded WHEN BACKING UP THE LIFT TRUCK VISUALLY CHECK BEHIND THE TRUCK Before backing the lift truck make sure that there is no one behind the truck bef
51. ine Torqflow Spec LP Special Pneumatic Tire FG20SHT 14 4 000 Ib capacity K25 Engine Torqflow Spec Cushion Tire FG25C 14 5 000 Ib capacity K21 Engine Clutch Spec Pneumatic Tire FG25T 14 5 000 Ib capacity K21 Engine Torqflow Spec Pneumatic Tire FG25TUS 14 5 000 Ib capacity K21 Engine Torqflow Spec Gasoline Special Pneumatic Tire FG25TLS 14 5 000 Ib capacity K21 Engine Torqflow Spec LP Special Pneumatic Tire FG25ST 14 5 000 Ib capacity K21 Engine Torqflow Spec Pneumatic Tire FG25STUS 14 5 000 Ib capacity K21 Engine Torqflow Spec Gasoline Special Cushion Tire FG25STLS 14 5 000 Ib capacity K21 Engine Torqflow Spec LP Special Cushion Tire FG25HT 14 5 000 Ib capacity K25 Engine Torqflow Spec Pneumatic Tire FG25HTUS 14 5 000 Ib capacity K25 Engine Torqflow Spec Gasoline Special Pneumatic FG25HTLS 14 5 000 Ib capacity K25 Engine Torqflow Spec LP Special Pneumatic Tire FG25SHT 14 5 000 Ib capacity K25 Engine Torqflow Spec Cushion Tire FG25SHTLS 14 5 000 Ib capacity K25 Engine Torqflow Spec LP Special Cushion Tire FG30C 14 6 000 Ib capacity K21 Engine Clutch Spec Pneumatic Tire FG30HT 14 6 000 Ib capacity K25 Engine Torqflow Spec Pneumatic Tire FG30HTUS 14 6 000 Ib capacity K25 Engine Torqflow Spec Gasoline Special Pneumatic Tire FG30HTLS 14 6 000 Ib capacity K25 Engine Torqflow Spec LP Special Pneu
52. ine will be lost Do not use the brakes unnecessarily or too frequently If your lift truck is a TORQFLOW transmission type and you rest your foot on the inching pedal during operations the multiple clutch plates of the transmission will overheat deforming the clutch plates and causing them to malfunction in the worst case PAY SPECIAL ATTENTION TO THE REAR VIEW WITH AN LPG CYLINDER INSTALLED GASOLINE ENGINE LIFT TRUCK The installed LP gas cylinder partially blocks the rear view and poses a danger of hitting people piled commodities or contact with nearby objects Therefore install backup warning devices backup alarm buzzer rotating warning lamp etc or backup safety checking devices such as a rear view mirror in order to warn people nearby and check for safe conditions in the area of the truck When installing optional warning devices call your Komatsu Forklift dealer for details LP gas cylinder that can be seen cylinder is installed m 12 that can be seen cylinder is not installed 7 80121 REQUIRED BRAKING DISTANCE DIFFERS DEPENDING THE ROAD CONDITIONS When traveling downhill it requires a longer distance for the lift truck to stop than when traveling on level ground When traveling downhill reduce the speed and make sure that you have ample room at the bottom of the slope to stop Traveling on wet surfaces requires a longer distance to stop than when traveling on normal
53. l care when operating on dockboard or bridgeplate Do not handle unstable loads or loosely stacked loads Do not handle loads higher than load backrest Space forks as far as load permits Be sure load is centered and forks are completely under load Never tilt load with mast tilted forward Do not tilt forward when elevated except to pick up or deposit load Travel load or lifting mechanism low and tilted back Tipover can occur if operated improperly Do not jump if truck begins to tipover Hold on firmly and lean away from point of impact Avoid being trapped between truck and ground General Precautions Allow no one to stand or pass under or near load or lifting mechanism Never place any part of body into mast structure between mast and truck or outside truck Do not carry passengers on any part of truck Lift no one under any circumstances Do not operate without overhead guard and load backrest Fill fuel or charge battery only in specified place Stop engine when fueling and avoid open flame or sparks and provide adequate ventilation Keep vent caps clear when charging battery Disconnect battery during servicing After Operating Before getting off truck shift F R lever and high low lever clutch type to neutral position fully lower lifting mechanism and pull parking lever securely Shut off power when leaving truck unattended Block wheels when parking on incline 3EB
54. lighting to enable safe operations to be performed WARNING WEAR SAFETY CLOTHES WHILE IN OPERATION Avoid loose clothing jewelry and loose long hair which can catch on controls 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 in addition to the hard hat and safety boots 1 1 SAFETY MANAGEMENT WARNING KEEP THE OPERATOR S COMPARTMENT CLEAN AND CLEAR Keep the operator s compartment clean and tidy Be sure to clean up all oil or mud If the operator s hand or foot slips it could lead to a serious accident Do not leave tools or spare parts lying around in the operator s compartment always keep them in the tool box when not being used They may damage or obstruct the control levers or pedals Do not drive the lift truck if your hands are wet or covered with oil Your hands will slip on the work equipment control levers or directional lever and could cause a serious accident WARNING REDUCE LOAD FOR LIFT TRUCKS WITH ATTACHMENT The permissible load for lift trucks equipped with any attachment is lower than the permissible load for the standard lift truck the reasons being 1 The overall permissible load is lowered by as much as the weight of an attachment itself 2 The load center shifts toward the front due to the thickness of an attachment Follow the load limit as indicated in the load capacity chart
55. matic Tire FG30SHT 14 6 000 Ib capacity K25 Engine Torqflow Spec Cushion Tire FG30SHTLS 14 6 000 Ib capacity K25 Engine Torqflow Spec LP Special Cushion Tire Diesel Models FD20T 14 4 000 Ib capacity 4D94E Engine Torqflow Trans Diesel Pneumatic Tire FD20TUS 14 4 000 Ib capacity 4D94E Engine Torqflow Trans Diesel Special Pneumatic Tire FD25T 14 5 000 Ib capacity 4D94E Engine Torqflow Trans Diesel Pneumatic Tire FD25TUS 14 5 000 Ib capacity 4D94E Engine Torqflow Trans Diesel Special Pneumatic Tire FD30T 14 6 000 Ib capacity 4D94E Engine Torqflow Trans Diesel Pneumatic Tire FD30TUS 14 6 000 Ib capacity 4D94E Engine Torqflow Trans Diesel Special Pneumatic Tire 17 NOTES 1 SAFETY 1 1 SAFETY MANAGEMENT WARNING FOLLOW THE INSTRUCTIONS IN THE OPERATION AND MAINTENANCE MANUAL AS WELL AS ON THE SAFETY LABELS Read the instructions in this manual and the safety labels attached to various parts of the lift truck and make sure that you understand and follow them If you do not understand or do not follow the instructions this will lead to improper operation which may result in personal injury or damage Be sure that you understand the proper method of using the lift truck and the procedure for carrying out an inspection and ensure that they are carried out safely Read this manual and safety labels again from time to time If the Operation and Maintenanc
56. mpleted by the dealer as expeditiously as possible f you have any questions regarding your warranty rights and responsibilities you should contact the authorized dealer LIMITATIONS KFI is not responsible for resultant damages to an emission related part or component resulting from Any application or installation deems improper as explained in the Instruction Manual Attachments accessory items or parts not authorized for use by KFI mproper off road engine maintenance repair or abuse Owner s unreasonable delay in making the product available after being notified of a potential product problem This warranty is in addition to the standard warranty applicable to the off road engine product involved Remedies under this warranty are limited to the provision of material and services as specified herein is not responsible for incidental or consequential damages such as downtime or lost use of the forklift truck CUSTOMER ASSISTANCE EMISSION CONTROL SYSTEMS WARRANTY Komatsu Forklift aims to ensure that the Emission Control Systems Warranty is properly administered In the event that you do not receive the warranty service to which you believe you are entitled under the Emission Control Sys tems Warranty call or write to your Komatsu Forklift Dealer Authorized dealers are recommended for major maintenance and repair work as they are staffed with trained per sonnel proper tools and are aware of t
57. ng the hooks on the counterweight to hoist the lift truck check beforehand that the counterweight mounting bolts are tightened to the specified torque and that there is no abnormality on the hooks PWNS 1 25 1 6 STRUCTURE AND STABILITY OF THE LIFT TRUCK To operate the lift truck safely it is important to understand the structure and stability of the lift truck This section will educate the operator in methods to prevent tipping over the lift truck STRUCTURE OF LIFT TRUCK Forklift trucks basically consist of a lifting mechanism fork and mast and a main body vehicle The front wheels act as a fulcrum and the center of gravity of the lift truck and that of the load are kept in balance The relationship between the positions of these two centers of gravity plays a very important role for the safety of the lift truck CENTER OF GRAVITY OF LOAD The loads carried by forklift trucks come in various shapes from boxes to planks and long objects To judge the stability of the lift truck it is important to distinguish the position of the center of gravity for loads of various shapes CENTER OF GRAVITY AND STABILITY The stability of the lift truck is determined by the position of a combined center of gravity resulting from combining the centers of gravity of the lift truck and the load When the lift truck is carrying no load the center of gravity of the lift truck remains unchanged On the other hand when it i
58. ngine Model number is on the left pad and NUMBER the Engine Serial number is on the right pad Ds 00 0001 10 FEDERAL EPA EMISSION CONTROL STATEMENTS FEDERAL EPA EMISSION CONTROL STATEMENT FOR OFF ROAD LSI NON DIESEL ENGINES K21 AND K25 ENGINES This section presents information concerning the correct labeling warranty parts and maintenance of K21 and K25 engines in order to comply with the EPA off road large spark ignition LSI engine regulations 1 LABELS REQUIRED AND LABEL LOCATIONS All K series engines will display the required identification label as follows Location on K21 K25 Series engines EPA LABEL LOCATION TOP VIEW OF ENGINE K21 K25 EPA Emission compliance label SAMPLE shown below M e o N N 4 375 inch 111 125 mm EMISSION CONTROL INFORMATION ENGINE FAMILY 4NSXB02 147C ENGINE DISPLACEMENT 2 1 LITER ENGINE MAXIMUM POWER 55 7 HP THIS ENGINE IS CERTIFIED TO OPERATE ON LPG ENGINE S USEFUL LIFE IS 5000 HOURS OF OPERATION OR SEVEN YEARS EXHAUST EMISSION CONTROL TYPE TBI TWC 25 TEST MODE VARIABLE SPEED ONLY 0 38 MM HOT THIS ENGINE MEETS CALIFORNIA AND U S EPA REGULATIONS FOR 2004 LARGE NONROAD ENGINES NISSAN MOTOR CO LTD K21L 11 FEDERAL EPA EMISSION CONTROL STATEMENTS 2 WARRANTY The following statement is hereby provided as required by regulations of the United States Environmental Protec tion Agency EPA YOUR
59. ore starting to travel The rear view mirror is simply an aid for checking the rear When driving in reverse do not use the rear view mirror Turn to face the rear and check the area directly behind the lift truck for safe unobstructed travel Even if you sound the backup buzzer the people behind the truck may not necessarily hear it Always check that there is no one behind the truck before driving the truck For lift trucks equipped with backup buzzer DON T USE A LIFT TRUCK TO TOW ANOTHER BROKEN DOWN LIFT TRUCK If there is any problem with the brakes or steering system of your lift truck do not use another lift truck to tow it as there is danger that the lift truck may run out of control 1 2 SAFE TRAVEL AB801290 AB801130 AB801200 1 2 SAFE TRAVEL WHEN CARRYING A HIGH LOAD USE A SIGNAL PERSON OR DRIVE BACKWARDS WARNING APPLY THE BRAKES CORRECTLY WHILE RUNNING If the view to the front is obstructed by the load turn to the rear and drive the lift truck in reverse When driving in reverse with a high load use a signal person to ensure the safety of the load and the safety in the surrounding area 801220 Do not stop the engine while the truck is in motion When the engine is not running the operating efforts for power steering and power brakes if present increase Thus it is dangerous to stop the engine while running If the inching pedal is depressed the braking effect of the eng
60. race yourself with both feet to support your body e Lean in the opposite direction from the direction in which the lift truck is tipping Items b through e are instructions for when the lift truck tips over 3 Using the parking brake AY WARNING Pull parking brake to locked position and shut off power before leaving seat When parked with the power on place high low and forward reverse lever in neutral If force required to engage brake is low less than 44 Ibs chock wheels when parking truck and contact forklift dealer for service See manual for details 3EB 96 A5821 1 30 1 7 SAFETY LABELS 4 Seating capacity One No passengers allowed 3EB 96 A5910 5 Prohibit the operator from standing on the forks Never enter the area under the forks AX WARNING LI 3EB 96 A5920 6 Use caution to avoid getting hand caught in fan not shown P N 3EB 96 A5931 7 Use caution to avoid getting hand caught E AWARNING 3EB 96 A5940 1 31 1 7 SAFETY LABELS 8 Caution before operating machine 9 Warning for operation A WARNING Before starting engine Put gearshift lever in neutral Pull parking lever to locked position 3EB 96 A5960 A WARNING SERIOUS INJURY OR DEATH MAY RESULT IF YOU FAIL TO FOLLOW THESE PRECAUTIONS Before Operating Do not operate or repair truck unle
61. road surfaces Always leave ample room to stop 1 2 SAFE TRAVEL FOLLOW THESE STEPS FOR PARKING 1 Stop the lift truck on level ground 2 Apply the parking brake securely to make sure that the lift truck cannot move Set the directional lever and speed lever to neutral Tilt the mast forward and lower the fork to the floor Turn the starting switch to the OFF position Pull out the starting switch key and leave the lift truck LPG trucks close fuel valve on fuel tank after parking 9 the lift truck 91100777 WARNING ABB01480 PARK THE LIFT TRUCK IN A SAFE PLACE 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 heat ignition sources or any flammable object If there is no way to avoid parking on a slope immobilize the lift truck by putting blocks under the tires in addition to normal parking procedures LPG trucks LPG is heavier than air and will sink to the lowest area possible Avoid parking near areas near floor drains or lubrication pits where escaped fuel may collect WARNING SHOULD THE LIFT TRUCK BECOME INOPERATIVE IN A DANGEROUS PLACE LIKE A RAILROAD CROSSING LET ALL PEOPLE AROUND KNOW IMMEDIATELY If engine trou
62. s and records or for your failure to ensure the performance of all scheduled maintenance For your reference the following is an emission control maintenance schedule for certified Diesel engines Check oil level and coolant level Everyday Change of lubricating Every 200 hours Change lubricating oil filter Every 200 hours Initial adjustment of valve clearance Every 200 hours Change fuel filter Every 500 hours Check turbocharger rebuild or replace if necessary Every 2 000 hours e Adjust valve clearance Every 2 000 hours Check fuel injection nozzles replace if necessary Every 2 000 hours Keep records to show proof of compliance with the required maintenance practices and intervals e As the heavy duty off road engine owner you should however be aware that may deny your war ranty coverage if your heavy duty off road engine or part has failed due to abuse damage neglect improper maintenance or disapproved modifications 15 FEDERAL EPA EMISSION CONTROL STATEMENTS Your engine is designed to operate on commercial diesel fuel only Use of any other fuel in our engine will result in the engine operating in non compliance with the Federal EPA regulations You are responsible for initiating the warranty process It is suggested that you present your heavy duty off road engine to an authorized Komatsu dealer as soon as you become aware that problem exists The warranty repair should be co
63. s carrying a load the center of gravity of the lift truck shifts to a combined center of gravity from the centers of gravity of both the lift truck and the load The position of the center of gravity of a load changes as the mast is tilted back or forth or it is raised or lowered The position of the combined center of gravity also changes depending on 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 1 26 EN AB801570 Center of Combined gravity of center o lift truck gravity 801580 Center of gravity of load Combined center of gravity Center of gravity of AB80159B Center of gravity of load lift truck AB80160B 1 6 STRUCTURE AND STABILITY OF THE LIFT TRUCK STABLE RANGE OF CENTER OF GRAVITY For the lift truck to remain stable the combined center of gravity Stable range of the lift truck must come within a stable range of the center of gravity i e a triangle formed by three points of the right and left front wheels in contact with the floor and the center of the rear axle When a position of the combined center of gravity shifts beyond the front axle the lift truck will tip over in the forward direction with the front wheels a
64. s heavier than air and will sink to the lowest area possible Avoid parking truck in areas near floor drains or lubrication pits where escaped fuel may collect Store all LPG cylinders OUTDOORS in a secured area and safe from any vehicle traffic NEVER WELD ON AN LPG PRESSURE VESSEL STORAGE TANK OR CYLINDER Ensure that the fuel tank is properly mounted See Maintenance chapter Always use a UL listed LPG tank Before working on the LPG fuel system Read understand and remember relevant information in standard 58 of the NATIONAL FIRE PROTECTION AGENCY Ensure you are wearing proper personal protective equipment Ensure there are NO SOURCES OF IGNITION nearby Ensure your work area is adequately ventilated Keep in mind that LPG is stored under high pressure and ensure that the LPG fuel storage container valve is turned OFF closed and pressure is released from the lines Disconnect the battery Test for fuel leaks DO NOT work on the system if the fuel storage container is filled with fuel past the 8096 liquid level Before testing make sure the system gas pressure is greater than 90 psi 621 kPa Test all connections container valves and fittings with soap and water or equivalent solution If there are any leaks have them repaired by qualified personnel When replacing LPG fuel system components Do not use cast fittings Use only UL or Factory Mutual listed LPG hose assemblies in the pressure fuel line Use only
65. sabled lift truck Center the weight of the disabled lift truck on the forks and be careful not to the damage the under side of the lift truck WARNING HOW TO TOW THE LIFT TRUCK The towed lift truck must have an operator Tow the lift truck slowly Raise the carriage and mast channels and secure from moving If another lift truck is used tow the disabled lift truck that lift truck must have an equal or larger capacity than the disabled lift truck Install an approximate half capacity load on the forks of the lift truck that is being used to tow the disabled lift truck This half capacity load will increase the traction of the lift truck Keep the load as low as possible 5 Use a towing link made of steel that attaches to the tow pins in the counterweights of both lift trucks HOISTING LIFT TRUCK Never lift the truck by the overhead guard If the truck has to be lifted frequently it is necessary to install special lifting equipment so please contact your Komatsu Forklift dealer 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 Never go under the lifted truck If the specified lifting point is the counterweight check that the counterweight mounting bolts are tightened to the specified torque before carrying out the lifting operation Check also that there is no damage to the lifting portion on the counterweight When usi
66. ss trained and authorized Read and understand all warnings and instructions in manuals and on truck before operating Dealers have replacement manuals Check truck before use If truck is in need of repair do not operate until restored to safe condition Do not start truck if fuel is leaking or has leaked Use attachments for intended purpose only While Operating Operate truck only from operator s seat Sit firmly in the seat with good posture while driving Leaving the seat or sitting improperly for approximately 3 seconds may cause the drive system to disengage Unintended truck movement like rolling on an incline may occur Keep truck under control at all times Do not overload truck Check capacity plate for load weight and load center Avoid any sudden starts stops turn or change of direction Obey traffic safety rules Yield right of way to pedestrians Keep clear view of travel path If load being carried blocks forward view travel with load trailing Slow down and sound horn when vision is blocked Watch clearances especially forks mast overhead guard and tailswing area Slow down for turns and on uneven or slippery surfaces Avoid running over loose objects Never angle or turn on incline Travel with load uphill when loaded Travel with lifting mechanism downhill when empty Secure dockboard or bridgeplate properly Do not exceed rated capacity Use specia
67. st structure There is danger that you will get caught in moving parts and be seriously injured WARNING DON T CLIMB ON THE MAST OR LOAD BACKREST If you climb on the mast or load backrest there is a danger that you could get caught up in the moving parts or fall off 801320 WARNING USE A PALLET OR SKID OF SUFFICIENT STRENGTH Always be sure that the pallets and skids have ample strength If broken or damaged pallets or skids are used there is a risk that the load may fall Always check that the load is positioned securely and safely on the pallet before moving the truck AB801330 WARNING HANDLE A LONG OR WIDE LOAD WITH EXTRA CARE Be extremely careful when carrying long wide loads Raise the load slowly 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 shift or move AB801440 1 15 1 3 LOADING OPERATIONS WATCH OUT OVERHEAD As the fork goes up the mast height increases Be mindful of this fact during the operation Take care so that the mast or the overhead guard will not hit electric wiring piping sprinklers beams in the ceiling and so on If such contact occurs there is the danger that the load on the fork may fall off or the lift truck may tip over OVERLOADING IS STRICTLY PROHIBITED Do no
68. systems simple and easy Read this manual carefully refer to it often and learn the repair testing and adjustment procedures to the best of your ability Please note that some illustrations are generic and may not look exactly like your unit in every detail Ensure that when you are working on or around industrial trucks Safety is priority Number One Read understand and obey all WARNINGS and CAUTIONS Follow the instructions and procedures presented in this manual when working on these lift trucks and their systems Damage to the equipment and possible injury to yourself or others may result if these procedures are not adhered to carefully Keep this manual nearby and accessible for use when necessary If this book becomes dirty worn or illegible contact Komatsu for a replacement The procedures outlined in this manual will be updated periodically Be sure that you have the latest revision in order to learn the newest information available Revision dates will be clearly displayed on the lower left hand corner of the cover page This will aid in maintaining your equipment in excellent condition and in ensuring that these lift trucks will operate safely at maximum efficiency ENGINE SERIAL NUMBER LOCATION The K21 K25 engine serial number is stamped on an angled and machined pad on the right side of the engine block in the center just beneath the valve cover The machined boss is split vertically by a groove ENGINE SERIAL The E
69. t load the lift truck over the maximum capacity shown in the load capacity chart otherwise there is the danger that the rear wheels may come off the ground the operator may lose control of the lift truck and the truck may tip over Moreover the load on the forks can collapse Never exceed the max load shown in the load capacity chart on the nameplate A WARNING DON T HANDLE A LOAD IN AN INSECURE MANNER Make sure that the center of gravity of the load is in line with the center of the lift truck Do not carry loads off center There is danger that unbalanced loads may cause the lift truck to tip Place the load so that it contacts the load backrest Do not handle unstable loads If there is danger that the load may fall off secure it in position and take steps to prevent the load from collapsing or falling DON T HANDLE A LOAD EXCEEDING THE LOAD BACKREST HEIGHT 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 on top of the operator resulting in serious injury or death 1 16 AB801450
70. tacles 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 AB801270 1 8 DRIVING ON A ROAD SHOULDER IS STRICTLY PROHIBITED There is a danger that soft road shoulders may collapse so do not go near them Always maintain a safe distance from the edge of road shoulders and platforms WHEN DRIVING INTO A RAILWAY CAR TRUCK OR CONTAINER EXERCISE EXTRA CARE Do not travel on the edge of docks There is a danger that the lift truck may fall which may result in serious injury or death Before starting operations check the load limit for the gangplanks and do not use them if they do not have ample strength to take the weight of the lift truck when loaded Apply the brakes on the truck and block the wheels before driving the forklift into the truck When driving into 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 1 9 1 2 SAFE TRAVEL AB801180 AB801170 1 2 SAF
71. the load closer to the load backrest so that the heaviest portion of the load comes to the fork center Should a load be loaded beyond the confines of capacity it would pose a serious danger to the lifting truck as the rear wheels for steering are likely to lift off the ground causing the operator to lose control of steering To make the things still worse the lift truck will likely tip over while in operation Therefore always make sure that the load is absolutely within the confines of capacity ft USA Ini LISTED ABOVE 15 WITH MAST VERTICAL THIS TRUCK MEETS ANSI ASME 656 1 LOAD CENTER AND ACTUAL CAPACITY A nameplate shown at right is just an example In the actual operation follow the instructions on a nameplate of the actual lift truck An example here shows a nameplate for a lift truck which has a mast of max fork height of 3 0 m and which is not equipped with any attachment 1 When the load center is 500 mm 2 Capacity 2 500 kg 1 When the load center is 600 mm 2 Capacity 2 250 kg 1 When the load center is 1 000 mm 2 Capacity 1 620 kg 00123 Even when the load center is shorter than 500 mm the actual capacity is 2 500 2 It is required to replace the present nameplate with a new one when the present nameplate is broken or has become difficult to read In that case call your Komatsu Forklift dealer asking for a new replacement nameplate

warning service manual - Komatsu Forklift USA, Inc. v3.1

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