Home

SERVICE MANUAL - Komatsu Forklift USA, Inc. v3.1

1. 3 1 1 Introduction 3 mh hn 4 1 2 Special 4 1 3 Tool Requirements 1 4 2 1 Truck System 2 5 2 2 Mounting Bracket Installation 2 5 2 3 Mast Installation 6 2 4 Inspection amp 7 2 5 Internal Reeving installation 2 0 eet eee bees 9 3 1 Periodic 2 2 1 10 4 0 Troubleshooting 2 1 5 1 0 1 2 12 5 2 1 24 1 2 13 5 3 Lowering Control Valve 0 22 5 4 Carriage 24 5 5 Mast Uprights 28 5 6 2 32 Masts 30D 35D 40D 50D 55D 60D MS 2 Stage Masts
2. 3 1 111 4 1 2 Special 2 4 2 1 Truck System 2 5 2 2 Mounting Bracket Installation 1 2 22 2 5 2 3 Mast Installation 2 6 2 4 Inspection amp 2 7 2 5 Internal Reeving Installation mor 9 3 1 Periodic 2 14 4 0 Troubleshooting 2 15 5 1 16 5 2 Cylinders 2 17 5 3 Lowering Control 2 21 5 4 Carriage 1 22 5 5 Mast Uprights 27 5 6 4 1 32 30D 35D 40D 50D 55D 60D MT 3 Stage Masts Contents 3
3. 07 62 Brake Master Cylinder 07 63 Clutch Master Cylinder Clutch Master Cylinder Manual Shift Trucks Exploded View 07 64 Clutch Release Cylinder Clutch Release Cylinder Exploded 07 65 Clutch Release Cylinder Disassembly 07 66 Clutch Release Cylinder Specifications 07 67 Clutch Release Cylinder Assembly 0 0 0 0 0 2 cc cece cee cent een 07 67 Power Steering Cylinder Power Steering Cylinder Disassembly and Assembly 07 69 Tilt Cylinders Tilt Gylinders mne Soe Lk queso uic E AE V at 07 70 Tilt Cylinder Disassembly 8 07 71 Tilt Cylinder Parts 07 71 Tilt Cylinder 07 72 Clutch Transmission Clutch Transmission Disassembly After Removal from 07 73 Clutch Transmission 07 77 Clutch Transmission Assembly 5 07 79 Clutch Transmission Cross Sectional View 07 82 Drive Axle Drive Axle Disassembly and Assembly
4. 04 14 Checking Tires and Adjusting Pneumatic Tire lt 04 15 Measuring Minimum Left and Right Turning lt 04 15 Measure Hydraulic Control Valve Relief Pressure 04 16 CHAPTER 05 5 05 01 Inspect Engine Starting Operation 05 02 Inspect Engine Running 05 02 Inspect Air Cleaner Assembly 5 05 02 Inspecting for Loose Cylinder Head Mounting Bolts amp 05 02 Inspect Engine 5 05 03 Inspect the Engine Lubricating 05 03 inspect Engine Fuel 05 03 Inspect LPG Vaporizer for Tar Buildup 05 03 Inspect the Blow by Gas Recirculation System 05 04 Inspect Cooling System and 05 05 Inspect Charging System 05 05 Inspect Front Axle and Re Torque Mounting
5. 2 04 02 Adjusting Spark Plug 04 02 Adjusting Valve Clearance 2 04 02 Adjustment of Fan 04 03 Measuring Engine Cylinder 04 04 Measuring Hydraulic Drift on Lift amp Tilt Cylinders 04 04 Adjusting the Parking Brake 04 05 Adjusting the Accelerator 04 06 Throttle Position Sensor 04 07 Accelerator Pedal Position 04 08 Adjusting the Clutch Brake Pedal Manual Transmission 04 09 Measuring Brake Stopping Distance Braking 04 10 Adjusting the Stop Lamp 04 11 Adjusting the Inching Brake Pedal TorgFlow 04 11 Checking Toraflow Clutch Actuation Pressure 04 13 Checking Torque Converter Stall 04 13 Testing Specific Gravity of Battery
6. 07 26 Steering Axle Assembly Cushion Trucks 07 27 Steering Axle 07 28 Wheel Brake Wheel Brake 07 30 Wheel Brake Disassembly 07 31 Wheel Brake Structure 07 32 Wheel Brake Specifications Checking 07 33 Wheel Brake 07 33 Power Steering Valve OSPC Power Steering Valve Exploded 07 36 Power Steering Valve Troubleshooting 07 37 Power Steering Valve Disassembly Photo 07 40 Power Steering Valve 07 47 Power Steering Valve Assembly nauuna naaraana rere 07 47 Power Steering Valve 1 5 07 59 Brake Master Cylinder Brake Master 07 60 Brake Master Cylinder 07 61 Brake Master Cylinder 0
7. 06 01 Lubricant List K21 06 02 Oil and Greasing 06 03 Changing Engine and Filter Gasoline LP Engines 06 04 Changing Gear Oil in Differential 06 05 Changing Transmission Fluid TorqFlow Transmission 06 06 Changing Cil in Hydraulic 06 07 Replacing the Fuel 06 08 Cleaning and or Replacing Air Cleaner 06 08 CHAPTER 07 REMOVAL DISASSEMBLY ASSEMBLY INSTALLATION 07 01 Overall Disassembly and Assembly 07 02 Weight Table Component Assemblies and 07 04 Engine Engine Removal from 07 05 Engine Disassembly and Assembly lees 07 07 Engine 2 4 07 07 Transmission and Drive Axle Clutch Torque Converter Transmission Drive Axle Removal from Chassis 07 09 Mast Removal
8. 00 0001 TRANSMISSION DATA PLATE Example 37B 1ZB Y2195 120 9 1 Transmission Transmission Part No Serial No 00 0002 Location on transmission On top of the torque converter bell housing Transmission Serial No Example 9Y2195 1st character Year of manufacture 2nd character Month of manufacture 1 January 2 February 3 March etc x Octo ber Y November Z December 3rd character Monthly serial number S N 9Y2195 was manufactuered in November 1999 and was transmission no 2 195 for that month NOTICE For EPA engine related troubleshooting refer to the following manuals TM100 EPA Engine Training Manual separate from this book e 5 300 21 25 Engine Service Manual follows the chassis mast section of this book CONTENTS Page No INTRODUCTION ec rex er Se aed ac HRS 1 ENGINE SERIAL NUMBER LOCATION 2 TABLE OF CONTENTS eru reu te RU RR RR agus cai aere EE Sialic EG quo 3 APPLICABLE EPA LIFT TRUCK MODELS COVERED IN THIS PUBLICATION 9 FEDERAL EPA EMISSION CONTROL 5 8 sais 14 CHAPTER 01 SAFETY SECTION 01 01 Safety 1 01 02 Safe Travel oa s VR ites ee ee 01 07 Loadin
9. 07 10 Clutch Disassembly Manual Transmission Exploded View 07 14 Clutch Specifications Manual Transmission 07 15 Clutch Assembly Manual Transmission 07 17 Clutch Installation Manual lt 5 55 07 18 Clutch Piping Bleeding Air from 07 18 Torque Converter Installation 07 18 Transmission and Drive Axle Installation 07 18 Pedal Assembly Brake Piping Installation 07 18 Brake System Bleeding Air From Lines 07 19 Mast Installation 07 20 Steering Axle Steering Axle Removal from 07 21 Steering Axle Disassembly Exploded View Pneumatic 07 22 Steering Axle Disassembly Exploded View Cushion Trucks 07 23 Steering Axle Specifications 07 24 Steering Axle Lubrication and Adjustments 07 24 Steering Axle Assembly Pneumatic Trucks
10. 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 A WARNING JACKING UP LIFT TRUCK when checking or replacing tires Do not go under the fork lift truck when it is jacked up Check the following before jacking the lift truck For details see page 3 41 1 Check that there is no one on the lift truck 2 Check that there is no load on the forks e When jacking up stop when the tires come off the ground sur face Put blocks under both sides of the frame to prevent the lift truck from coming down Put blocks under any tires contacting the ground to prevent the lift truck from moving A WARNING LIFTING LIFT TRUCK when checking tires Lift truck slinging work should be carried out by a qualified person who has completed a course in correct lifting meth ods e Fit wire ropes to the specified lifting points e 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 Donot 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 speci fied torque before carrying out the lifting operation
11. 05 05 Inspect Rear Axle and Re Torque Mounting Bolts 05 05 Inspect 1 4 05 06 Inspect Steering 2 4 05 06 Inspect Steering 05 06 Inspect the Power Steering System 05 06 inspect Brake System Rods Cables and Links 05 07 Inspect Brake Piping amp 5 05 07 Inspect Brake Master and Wheel Cylinders 05 07 Inspect Brake Shoes and Associated Parts 05 07 Inspect Brake 2 0 05 08 Inspect Brake Backing 05 08 Inspect Load 1 05 08 Inspect 1 7 2 05 08 Inspect Fork 1 2 05 09 Inspect Lift 05 09 Inspect Chain 05 10 Insp
12. A TP 1 terminal 50 At idle after warm up About 0 60v TP 1 terminal 50 IGN ON engine OFF w pedal released About 0 75v 50 63 TP 1 terminal 50 IGN ON engine OFF w pedal depressed fully About 0 75v TP 1 terminal 50 At 2 000 rpm About 0 70v TP 2 terminal 69 At idle after warm up About 4 50v TP 2 termina 69 IGN ON engine OFF w pedal released About 4 35v TP 2 terminal 69 IGN ON engine OFF ECM0101 wi pedal depressed About 4 35v TP 2 terminal 69 At 2 000 rpm About 4 40v sure that there is no moisture around connector when removing and installing throttle posi tion sensor connector If there are any water drops completely wipe them off not apply voltage to throttle position sensor terminal Perform Throttle Valve Closed Position Learning if disconnecting connector Perform Throttle Valve Closed Position Learning and Idle Air Volume Learning if replacing electric throttle control actuator See Publication TM100 K21 K25 Engine Training Manual 04 7 04 TESTING ADJUSTING AND MEASURING ACCELERATOR PEDAL POSITION SENSOR 1 Service Tool Data Monitor Display At idle after warming up At approx 2 000 rpm Approx 0 6V Approx 0 3V Monitor item Approx 0 65V Approx 0 35V ETC Acceleration sensor 1 ETC Acceleration sensor 2 2 Control Unit Input Output Signal Specifications Measure voltage between terminals shown below and gro
13. Raise the forks to maximum lifting height and measure the pressure when the oil is relieved RENTON HOSE FROM The oil relief pressure reading should match the specified peg HYDRAULIC relief pressure specified in the table below PUMP 2 625 psi 18 1 MPa Relief set pressure 185 kgf cm 04 16
14. WARNING NO JUMP START SAFETY PLATE DECAL i DO NOT JUMP START the engine by short circuiting the starting motor terminals This SAFETY PLATE DECAL is located on the top center of the starter s magnet switch If your machine is not equipped with this SAFETY PLATE install a new plate decal in the specified location after cleaning the surface 01 5 01 SAFETY SECTION WARNING FIRE PREVENTION FOR FUEL FUEL IS EXTREMELY FLAMMABLE AND CAN CAUSE FIRES AND EXPLOSIONS 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 specific gravity of LPG is heavier than air so it is easy for the vapors to accumulate in low places holes road surface depressions etc This can create a fire or explosion hazard Be extremely careful 0055020 0055030 A0055040 WARNING No STARTING 05 Engine starting aids are highly flammable and may cause an explosion Do not use starting aids to start the engine WARNING LPG SAFETY 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 Read understand and remember relevant information in the NATIONAL FIRE PROTECTION AGENCY NFPA standard for fuel in use Do this BEFORE wor
15. careful not to let dirt or dust get into the brake fluid reserve tank 01 30 01 SAFETY SECTION A WARNING HANDLING ANTIFREEZE Antifreeze can be 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 A CAUTION WASTE MATERIALS Obey appropriate laws and regulations when disposing of harmful items and materials such as oil fuel solvent filters and batteries INCORRECT ABBO1580 01 31 01 SAFETY SECTION 6 STRUCTURE AND STABILITY OF THE LIFT TRUCK TO PREVENT LIFT TRUCK FROM TIPPING To operate the lift truck safely it is important to understand the structure and stability of the lift truck AX CAUTION STRUCTURE OF LIFT TRUCK A forklift truck consists basically of the lifting mechanism the forks and mast 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 gravity of 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 truck and the center of gravity of the load is extremely important for maintaining the safety of the lift truck A CAUTION CENTER OF GRAVITY OF LOAD The loads carried by forklift trucks come in various shapes and we
16. Continued 03 2 03 SERVICE DATA TRAVEL SYSTEM Inflation Pressure TIRES psi MPa 98 6 0 68 Tread Depth Minimum 063 1 6 at tread width 1 4 Front Wheels Ib ft Nm 113 6 180 1 154 245 HUB NUT Tightening Torque Rear Wheels Ib ft Nm 61 2 108 4 83 147 RIM MATING Front Wheels Ib ft Nm 64 9 90 7 88 123 Tightening Torque NUT Rear Wheels Ib ft Nm 43 5 54 6 59 74 Component Check Item STEERING BRAKING SYSTEMS gt ce ern SEAT POWER STEER ING RELIEF Relief Pressure Psi MPa 1 073 3 7 4 VALVE STEERING WHEEL Play 1 2 2 4 30 60 Minimum Turning Radius 76 6 1 945 78 0 1 980 STEERING AXLE Support Thrust Clearance 0 028 0 7 97012073 INCHING PEDAL Interconnected Travel in mm 1 85 2 09 47 53 y in mm 0 51 0 67 13 17 BRAKE PEDAL I D Pedal Height when Depressed 3 15 3 54 80 90 Brake Fluid Capacity 158 015 BRAKE Parking Brake Operating Force 55 1 245 Torque for Back Plate Mtg Bolt 108 4 144 5 147 196 6 56 2 0 NAMES NEGET mimm Amount of Opening at Tip 1 4 35 Maximum CHAIN 13 1 332 Maximum 20 50 Maximum Hydraulic Drift Lift Cylinder in mm 15 Minutes CYLINDER Hydraulic Drift Tilt Cylinder in mm 18 deem f MAIN RELIEF VALVE HYDRAULIC SYSTEM Relief Pressure 2 6
17. IGN ON engine OFF wi pedal released About 0 30v APPS 2 term 98 IGN ON engine OFF ECM0103 wl pedal depressed About 2 00v APPS 2 term 98 At 2 000 rpm About 0 35v Do not apply voltage to accel pedal sensor terminal Do not disassemble accelerator work unit ADJUSTING THE CLUTCH BRAKE PEDAL MANUAL TRANSMISSION Clutch Pedal 1 Adjust the clutch pedal stopper bolt A so that the released pedal height See illustration is 7 87 in 200mm 2 Then loosen the locknut on the clutch master cylinder rod and adjust the rod to provide a pedal free play of 0 12 0 20 in 3 5mm TOP VIEW Brake Pedal 1 Adjust the brake pedal stopper bolt B so that so that the released pedal height is 8 67 in 220mm 2 Then loosen the locknut on the brake master cylinder rod and adjust the rod to provide a pedal free play of 0 51 0 67 in 13 17mm 3 Pedal depressed height should be 3 15 3 54 in 80 90 mm Brake Fluid 3 Check the brake fluid level and add if necessary DOT 3 brake fluid 04 0013 04 9 04 TESTING ADJUSTING AND MEASURING CLUTCH TYPE TRUCK OPERATING EFFORT 66 IbJf 240N 30kgf MEASURING BRAKE STOPPING DISTANCE BRAKING EFFECT Using a qualified forklift truck driver perform this test safely on a flat dry open paved surface Accelerate the truck to maximum speed then stop the machine suddenly Check for steering wheel pull to the right or left Check for a dr
18. Length to Fork Face 2 Stage Mast in mm 89 0 2 260 Length to Fork Face 3 Stage Mast in mm 89 1 2 265 Overall Width at Drive Tires in mm 42 1 1 070 Forks Thickness x Width x Length in mm 1 6 x 4 0 x 42 0 40 x 100 x 1 070 Carriage Width ITA Class in mm 41 0 1 040 II Ground Clearance under Mast in mm 5 5 140 Ground Clearance Center of Wheelbase in mm 5 3 135 Right Angle Stacking Aisle 2 Stage Mast tt mm 93 8 2 380 Right Angle Stacking Aisle 3 Stage Mast t mm 93 9 2 385 Turning Radius Outside in nm 76 6 1 945 78 0 1 980 PERFORMANCE Travel Speed Forward Loaded Unloaded mph k hr 11 5 18 5 12 1 19 5 11 8 19 0 12 4 20 0 Lifting Speed Loaded Unloaded 2 Stage fpm mm s 135 685 138 700 123 625 126 640 Lifting Speed Loaded Unloaded 3 Stage mm s 132 670 136 690 116 590 120 610 Lowering Speed Loaded Unioaded 2 Stg fpm mm s 98 500 89 450 96 490 89 450 Lowering Speed Loaded Unloaded 3 Stg fpm mm s 96 490 79 400 98 500 69 350 Maximum Drawbar Pull Loaded Ibs kN 3 210 15 4 3 730 16 6 3 730 16 6 Maximum Gradeability Loaded Unloaded at 1 mph 96 35 21 Service Brake Operation Contro Foot Hydraulic Parking Brake Operation Control Hand Mechanical Steering Type Hydrostatic Power TABLE CONTINUED ON NEXT PAGE 02 4 02 GENERAL INFORMATION amp SPECIF
19. 1 1 0 2 4 1 2 Special 11 4 4 2 2 4 2 1 Truck System sr 5 2 2 Mounting Bracket Installation bees 5 2 3 Mast Installation ssec Rh Iu oe 6 2 4 Inspection amp 7 2 5 Internal Reeving Installation 2 9 3 1 Periodic 2 4 2 16 4 0 Troubleshooting 2 2 17 5 1 2 18 5 2 Cylinders eet rl 19 5 3 Lowering Control 1 29 5 4 Carriage 4 4 30 5 5 Mast Uprights 34 5 6 11 42 42 APPENDIX 1 ELECTRICAL SCHEMATICS 17 x 11 Contents 4 AX20 BX20
20. Bin 80125 WARNING BRAKING WHEN TRAVELING Do not stop the engine when traveling If the engine is stopped the power steering for lift trucks with power steering and power brake for trucks with power brakes will not work If the inching pedal is depressed the braking effect of the engine will be lost Do not use the brake excessively Do not rest your foot on the brake pedal or inching pedal unless you are operating it If you do the brake will overheat and the braking effect will be lost For TORQFLOW lift trucks if you leave your foot on the inching pedal the multiple disc clutch inside the transmission will overheat In the worst case the clutch discs will be deformed and the clutch will not function normally 01 12 01 SAFETY SECTION WARNING SAFETY DURING TRAVEL Keep a clear view of the path of travel and observe for other traffic personnel and safe clearances Yield the right of way to pedestrians 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 A WARNING CONFIRMING SAFETY When traveling always pay careful attention to the area around your lift truck particularly in the direction of travel or EU when turning Do not pass other vehicles on narrow roads or at crossings or other places where the view is poor When traveling throu
21. Do not smoke or allow any flame Startthe charging operation when the temperature of the battery electrolyte is below 95 F 35 C If the electrolyte temperature goes above 122 F 50 C during the charging operation wait for it to go down below 95 F 35 C before starting charging operation again When using a battery charger to charge the battery take the battery caps off WARNING STARTING WITH BOOSTER CABLES ALWAYS wear safety glasses or goggles when starting the lift truck with booster jumper 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 extremely careful not to let the cables get caught in the fan or fan belt Connect the batteries in parallel positive to positive and negative to negative NEVER connect positive to negative DO NOT short circuit the starter terminals to start a forklift truck WARNING DO NOT PUSH START Do not push the lift truck to start the engine There is danger that the lift truck may suddenly start and operate unexpectedly WARNING HANDLING BRAKE FLUID It is dangerous if the brakes do not work because in this condition the lift truck cannot be stopped Always do the 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
22. 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 with the forks loaded Always ensure that the hood is properly latched AB801130 01 7 01 SAFETY SECTION AX WARNING TRAVEL sLoPES Do not turn or travel across or at an angle on slopes There is danger that the lift truck will tip 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 48801140 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 FORWARD down the slope with the load engaging means downgrade When traveling down slopes use the braking force of the engine together with the foot brake and travel slowly down the slope AB801150 WARNING NOT JUMP OFF LIFT TRUCK EVEN IF IT TIPS NEVER JUMP OFF the lift truck even if it seems that it w
23. 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 or cables on the forks and use the forks to lift loads Do not use the drawbar pin for towing operations AB801380 WARNING LEVER OPERATION Be careful not to operate the lever by mistake There is danger that the forks or work equipment may cause serious injury Do not operate the levers when getting off the lift truck WARNING USING DRAWBAR PIN Do not use the drawbar pin for towing other lift trucks for being towed by other lift trucks or for lifting operations The drawbar pin installed to the rear of the counterweight is used only to free the truck when the tires have become stuck in mud or in a ditch and the lift truck cannot move or when loading the lift truck on to a trailer or truck DRAWBAR PIN aegazagg 01 18 01 SAFETY SECTION WARNING FIT FORKS SECURELY IN POSITION When adjusting the position width of the forks be careful not to get your hands caught A8801400 After adjusting check that the forks are held securely in posi tion by the fork stopper If the forks are not held in position there is a danger that the forks may move when the lift truck is traveling and the load may fall off AE81800B A CAUTION ADJUST CHAIN Be sure the tension of the left and right chains is the same See CHECK BEFORE OPERATION If the tensio
24. SAFETY SECTION WARNING HAZARD PREVENTION Battery electrolyte contains sulfuric acid and can quickly burn the skin and 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 If electrolyte gets into your eyes flush them immediately with large quantities of water and consult a doctor at once If you accidentally drink electrolyte drink a large quantity of water or milk mixed with beaten egg white or vegetable oil Call a doctor or poison control center immediately When working with batteries ALWAYS wear safety glasses or goggles Batteries generate hydrogen gas Hydrogen gas is highly EXPLOSIVE and is easily ignited with a small spark or flame Do not smoke or create any spark near a battery Before working with batteries stop the engine and turn the starting switch to the OFF position When removing the battery remove the cable from the nega tive terminal first When installing the battery install the cable to the positive terminal first This prevents possible sparks or arcing between the positive terminal and the positive cable 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 removing or inst
25. EPA off road large spark ignition LSI engine regulations 1 LABELS REQUIRED AND LABEL LOCATIONS All 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 w T 2 w 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 HO2S TEST MODE VARIABLE SPEED ONLY THIS ENGINE MEETS CALIFORNIA AND U S EPA REGULATIONS FOR 2004 LARGE NONROAD ENGINES NISSAN MOTOR CO LTD K21L 11 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 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 re
26. Exploded View Pneumatic Trucks 07 83 Drive Axle Assembly Torque Chart Pneumatic 07 84 Drive Axle Disassembly and Assembly Exploded View Cushion Trucks 07 85 Drive Axle Assembly Torque Chart Cushion 5 07 86 Differential Differential Direct Drive Transmission 07 87 Differential Direct Drive Testing 07 88 Differential Direct Drive 07 89 Differential Direct Drive Assembly Drawing 07 92 Differential TorqFlow Transmission Disassembly and Assembly Exploded View 07 93 Differential TorqFlow Transmission Disassembly 07 94 Differential TorqFlow Transmission Assembly Procedure 07 94 Pinion Assembly Exploded 07 97 Pinion Assembly Disassembly Procedure 07 98 Pinion Assembly Assembly 07 98 Adjusting Ring Gear Backlash 07 102 Differential Pinion Shaft Lock Nut Special 07 103 Diffe
27. cylinder There is a DANGER that you may get your hands or feet caught in the mast Always use a strong stable stand when measuring Before measuring check that the hydraulic oil level is correct and that the hydraulic oil is not dirty or mixed with any other brand of oil Always carry out the measurement on flat horizontal ground in front of a strong plat form which will support the truck if it should tip over towards the front 04 4 04 TESTING ADJUSTING AND MEASURING MEASURING PROCEDURE 1 Place aioad on the lifting forks equal to or slightly less than the specified lifting capacity of the truck 2 Secure the load to the lift truck with wire 3 Bring the truck to a stop about 20 in 500mm in front of the platform 4 Operate the lift and tilt repeatedly to bring the oil temperature to 122 F 50 C SET MAST 5 Raise the load about 60 in 1 500mm and set the mast PERPENDICULAR perpendicular to the ground 6 Wait for 3 minutes Then place a ruler against the lift cylinder piston rod and make a mark 7 Measure the hydraulic drift over the next 15 minutes HYDRAULIC DRIFT 20 in 15 min OF LIFT CYLINDER 50 mm 15 min MARK LIFT CYLINDER Mast 8 Wait for 3 minutes Then place a ruler against the tilt cylinder piston rod and make a mark MAST TILT CYLINDER 9 Measure the hydraulic drift over the next 15 minutes RULER MARK OF LIFT CYLINDER 45mm 15 min 04 00
28. delay in making the product available after being notified of a potential product problem This warranty is in addition to the KFI 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 the 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 38
29. ensure that you know how to use them Know what to do in the event of a fire sure that you know the phone numbers of persons you should contact in case of an emer gency 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 abnor mality and repair the leakage before using the lift truck Donotleave 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 01 3 01 SAFETY SECTION WARNING SAFETY RULES Do not operate the lift truck if you are fatigued or when you have been drinking or you have taken any medication 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 other surrounding conditions WARNING CHECK WHEN TRAVELING IN REVERSE When reversing depending 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 WARNING TRAVELING REGULATIONS ON PUBLIC ROADS Always observe all traffic regulations when operating the lift truck Do not drive on p
30. guard or load contact electrical wiring pipes sprinklers or roof beams If the truck hits such objects 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 be particularly careful when the forks are raised 801450 WARNING NO PUSHING Do not use the forks to push or pull loads There is a risk that the load will be damaged or fall 801480 WARNING PRECAUTIONS WHEN LOADING UNLOADING Do not let anyone place load on the forks Do not let anyone remove a load directly from the forks e 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 01 21 01 SAFETY SECTION 4 STOPPING AND PARKING WARNING PRECAUTIONS WHEN STOPPING PARKING Observe the following procedure when stopping or parking the lift truck Stop the lift truck on level ground Apply the parking brake securely to make sure that the lift truck cannot move Set the directional lever and the speed lever to neutral Lower the forks to the ground Turn the key switch OFF to stop the engine Remove the key from the key switch Then get off the lift truck 801480 WARNING PARKING Park the lift truck in the specified place Park the lift truck on a firm surface Do n
31. nameplate to show the relationship regarding the position of the load center eee the height of the fork and the maximum load Before load _ ing the forks check that the load and load center are within moos a camem 735 the permitted range on the stamped allowable load TETEE If the shape of the load is complex set it so that the heavi est part of the load is at the center of the forks and set the 8801620 close to backrest GApACITIES UATH ATTACHMENTS OR CORKS USTED ABGVE TAUCK WEIGHT If the forks are loaded more than the allowable value the fias Tuck MEETS 9 8 o drive wheels will float during travel and the steering system E we will not work This is very dangerous Furthermore the lift eius truck will tip over easily under this condition Therefore be sure to keep the load below the allowable value and prop AX WARNING 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 mak
32. releasing the internal pressure For details on releasing the oil pressure see page 3 37 If oil is leaking under high pressure from holes it is danger CORRECT ous if the jet of high pressure oil hits your skin or eyes Always wear safety glasses and thick gloves and use a piece of cardboard or a sheet of plywood to check for oil leakage Release the internal pressure before checking the accumula tor piping If you are hit by a jet of high pressure oil consult a doctor LY immediately 0055190 WARNING ROTATING FAN AND BELT it is extremely dangerous if you or any too touches or gets caught in the fan or fan belt when the fan is rotating Never touch the fan when it is rotating Always stop the engine before inspecting rotating parts When inspecting the areas around rotating parts do not allow anything to come close which may get caught 801500 01 26 01 SAFETY SECTION WARNING HANDLING TIRES Disassembly and assembly of tires should be carried out by a tire dealer The tire pressure is extremely high so caution is needed when handling tires wheel is fitted with mounting lug nuts It also has rim nuts and bolts used to join the rim halves When removing the tire from the lift truck do not loosen the rim nuts and bolts The tire is under high pressure and there is a significant risk that the rim nuts and bolts may fly off Relieve tire inflation pressure before removing
33. the SST Once correct values have been achieved tighten the two adjusting screws See next page You may also be able to achieve the correct voltage values by adjusting the linkage rod Simply loosen the two lock nuts and rotate the threaded union to shorten or lengthen the rod length NOTE Do not disassemble the sensor 04 6 04 TESTING ADJUSTING AND MEASURING THROTTLE POSITION SENSOR SYSTEM 1 Service Tool Data Monitor Display At idle after warming up Approx 0 6V Approx 4 5V 2 Control Unit Input Output Signal Specifications Measure voltage between terminals shown below and ground using a circuit tester Monitor item At approx 2 000 rpm Approx 0 7V Approx 4 4V ETC Throttle sensor 1 pedal released ETC Throttle sensor 2 pedal depressed fully Terminal At approx 2 000 rpm Approx 0 6V Approx 0 7V Throttle position sensor 2 pedal depressed fully Approx 4 5V Approx 4 4V 3 Circuit Diagram Throttle Power supply 1 position n Signal 1 4 sensori Ground s Accelerator pedal Throttle iti position Signal 2 2 nave 225 252 7514 hrottle contro motor ES 11217 QHD 5 BU Throttle contro motor relay Electric throttle contro actuator 4 Component Parts Inspection THROTTLE POSITION SENSOR 1 2 ELECTRIC THROTTLE CONTROL ACTUATOR ASSEMBLY Check voltage between ECCS C U terminal 50 69 and ground Ly a CONNECT 7
34. 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 When carrying stacked loads tie with rope to prevent the load from falling AB801340 01 16 01 SAFETY SECTION WARNING NOT LOAD ABOVE HEIGHT OF LOAD BACKREST Keep the height of the load within the height of the load back rest Do not carry any load that is higher than the load back rest If the load is higher than the load backrest there is danger that it will fall back on top of the operator This may lead to serious injury or death 801350 WARNING DO NOT TILT MAST FORWARD WHEN LOADED 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 88801380 WARNING KEEP TENSION ON CHAIN 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 a pallet or shelf AB801370 01 17 01 SAFETY SECTION WARNING USE ONLY FOR INTENDED PURPOSES Do not use the lift truck for anything other than the intended use loading operations using the forks
35. turn the fuel supply on The compiete LP GAS system should be inspected periodically Check all hoees for wear connections for leaks and all parta for damage NOTE Fuel hoses have a limited life expectancy They should be checked for cracking end drying due to age Hoses with visible signs of age should be replaced Use only Underwriters Laboratories or Factory Mutual listed LP GAS parts for replacements NOTE The above information is provided as a guide Consult the National Fire Protection pamphiet 58 for the safe storage and handling of liquefied petroleum gases Governmental safety regulations in your locality very Check with the authority having jur sdiction to be sure that you meet all of their requirements Contact the manufacturer for detailed service Information SERVICE WORK SHOULD BE PERFORMED BY QUALIFIED PERSONNEL ONLY 0004 01 39 01 SAFETY SECTION 13 LPG FUEL SYSTEM DECALS LPG LOW FUEL ALARM LIGHT On dashboard to left of steering column OP 0006 B DUAL FUEL SYSTEM FUEL CHANGE OVER INSTRUCTIONS Air Cleaner housing Not illustrated in Fig AWB2296B FUEL CHANGEOVER INSTRUCTIONS DUAL FUEL SYSTEM CAUTION FLAMMABLE LIQUIDS WHEN SWITCHING FROM LP GAS TO LIQUID FUEL BE SURE THAT THERE Is IS NOT SPILLAGE OF LIQUID FUEL FROM THE CARBURETOR 1 SHUT OFF BOTH FUEL LINES COMPLETELY BY PLACING SWITCH IN THE OFF POSITION 2 START ENGINE AND RUN UNTIL SYSTEM IS PURGED OF AL
36. 0 182 7 Hydraulic Tank Capacity U S gallons liters 5 8 22 Clutch Torque Converter Transmission TORQFLOW Air Cleaner Type Cyclone pax 2 ru NOTE Most values shown in this publication are rounded Therefore direct conversion between metric and English or Impe rial may be slightly different than displayed in this table The performance of the machines is affected by the condition of the vehicle and how it is equipped as well as the nature and condition of the operating area If these specifications are critical or if your needs exceed the specifications shown here discuss the proposed application with your authorized dealer Optional masts attachments longer load dimensions and higher lifting heights may result in derating of the capacity Con tact your authorized dealer Other mast heights available See MAST DATA CHART for other mast heights Contact your authorized dealer T Includes 48 in 1 220 mm high Load Backrest Contact your authorized dealer for additional information tt Add load length and clearance Contact your authorized dealer 02 7 02 GENERAL INFORMATION amp SPECIFICATIONS PERIODIC REPLACEMENT OF CONSUMABLE PARTS For operational safety always perform specified periodic maintenance and be sure to replace all consum able parts listed in the table below following the recommended schedule These parts may deteriorate in time and are susceptible to wear It is difficult to estimate the degree of wear at
37. 10 18 Oil Capacity 9 25 35 03 3 03 SERVICE DATA SERVICE DATA GASOLINE ENGINE LIFT TRUCKS CUSHION Component ENGINE ENGINE LUBRICATING COOLING SYS TEMS FUEL SYSTEM INTAKE EXHAUST SYS TEMS ELECTRICAL SYSTEM POWER TRAIN TORQUE CONVERTER TORQFLOW TRANSMISSION DIFFERENTIAL Check Item Maximum Speed Torque Converter Stall Speed psi rpm Engine Oil Capacity qts L Engine Oil Pressure 178 F 80 C psi kPa Coolant Capacity Radiator Cap Pres sure qts L Fan Belt Tension in mm Fuel Type Injection Timing BTDC Injection Order Injection Pressure psi MPa Intake Battery Electrolyte Specific Gravity Inlet Port Oil Pressure Outlet Port Oil Pressure psi MPa Relief Pressure psi MPa psi rpm MPa rpm Valve Clearance Clutch Actuation Pressure Lubricating Oil Pressure psi MPa Oil Capacity qts L Oil TORQFLOW qts 1 il Capaci CLUTCH ats 1 Continued 03 4 FG15S 17 c c o 2 dm FG18S 17 E K21 700 No Load 3 600 Instantaneous Continuous Load 3 000 2 100 100 rpm 178 250 1 2 250 3 91 3 7 wi Filter 3 59 3 4 w o Filter Idle 14 22 98 At 2 000 rpm 39 8 45 5 274 313 2 4 9 1 12 8 psi 0 9 kgf cm 0 47 0 55 12 14 Finger Pressure 98N Unleaded Regular Gasoline 89 Octane Variable Co
38. 5 6 010 246 5 6 260 89 5 2 275 97 5 2 475 264 5 6 720 106 5 2 705 283 5 7 200 NOTE Specifications for 4 Stage Full Free View QFV masts are not indicated Please consult your authorized dealer for information and availability Cushion Trucks Only 02 3 FREE LIFT in mm 41 5 1 055 49 5 1 255 58 5 1 485 02 GENERAL INFORMATION amp SPECIFICATIONS TRUCK DATA PNEUMATIC TIRE LIFT TRUCKS OUTDOOR FG15HC 17 FG15HT 17 FG18HT 17 GENERAL Capacity 24 600 mm Load Center Ibs kg 3 500 1 580 Load Distance from Center Axle 2 Stage in mm 15 8 400 Load Distance from Center Axle 3 Stage in mm 15 9 405 Wheelbase in mm 54 1 1 375 WEIGHT Service Weight inc 2 Stage STD MastvForks Ibs kg 5 860 2 660 5 930 2 690 6 380 2 895 TIRES Tire Size Front 6 50 10 10PR 1 Tire Size Rear 5 00 8 8PR 1 Number of Wheels Front Rear x Driven 2x 2 Tread Center of Tires Front Rear in mm 35 0 890 35 0 890 DIMENSIONS Tilting Angle 2 Stage FV Masts Forward Backward 6 8 Tilting Angle 3 Stage TFV Masts Forward Backward 6 6 Mast Height Lowered 2 Stage Mast in mm 85 5 2 170 Mast Height Extended 2 Stage Mast t in mm 176 0 4 470 Maximum Fork Height 2 Stage STD Mast in mm 128 0 3 250 Free Lift Height 2 Stage STD Mast in mm 5 5 140 Height Overhead Guard in mm 79 7 2 025
39. 5 4815 Fax phone 770 385 4838 16 01 SAFETY SECTION 1 SAFETY MANAGEMENT A WARNING OPERATION MANUAL AND SAFETY LABELS 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 fol low the instructions 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 carry ing out an inspection and ensure that they are carried out safely e Read this Manual and the Safety Labels again from time to time If the Operation and Maintenance Manual or Safety Labels have been lost or become dirty and cannot be read obtain replacements from your Komatsu Forklift distributor dealer and attach the Safety Labels in the specified posi tions WARNING OPERATING QUALIFICATIONS This lift truck should be operated only by qualified personnel Be sure you have proper qualifica tions before operating the lift truck When operating this lift truck even if you have experience in operating other lift trucks obtain instructions from an authorized person who has experience in operating this lift truck or the same type of lift truck WARNING CLOTHING AND PERSONAL PROTECTIVE ITEMS Avoid loose clothing jewelry and loose long hair They can catch on controls or in moving pa
40. ADJUSTING THE PARKING BRAKE LEVER 1 Release the parking brake lever in forward position 2 Using a screwdriver press down the adjustment button A Keep it pushed down and rotate it to adjust the operating effort required to set the parking brake Specified Force 55 Ib f 245 N 25 kg 3 After adjusting align the hexagonal portion of the adjustment button A to match the hexagonal hole in the tip of the grip B Remove the screwdriver 4 With parking brake applied check that the parking brake can hold the lift truck while stopped on a slope as shown in the table below 04 0010 Lift truck unloaded Lift truck loaded 10 slope or higher 8 5 slope or higher 04 5 04 TESTING ADJUSTING AND MEASURING ADJUSTING THE ACCELERATOR PEDAL The AX20 Series forklift trucks are equipped with an electronic Throttle Position Sensor TPS and an Accelerator Pedal Position Sensor APPS These sensors must be adjusted while using a Service Support Tool SST Diagnostic Monitor The stopper bolt located on the floor plate directly beneath the toe area of the pedal is factory preset at 1 93 in 49mm With the stopper bolt at the specified height the released pedal height should be 5 08 in 129mm To adjust the Throttle Position Sensor to the proper voltage values loosen the two adjuster screws on the TPS and gently rotate the TPS clockwise or counter clockwise while observing the voltage readings on
41. BETWEEN SIDEWALL AND CENTER LINE OF TIRE Check tread depth and if the depth of tread is less than 0 63 in 1 6mm replace the tire s 04 0021 MEASURING MINIMUM LEFT AND RIGHT TURNING RADIUS NOTE A qualified forklift truck driver must be used for this operation 1 Attach a piece of chalk securely to the end of a stick or rod Attach it to the outermost side of the counterweight with the chalk contacting the ground Be sure to perform this operation on a clean level surface so that the chalk mark can be observed 2 Instruct the operator to turn the lift truck in the tightest right turn possible with the chalk marking a circle on the ground In a different spot perform the same operation while turning left Measure the diameter of the circles The measurements should fall within the specified limits in the table below Adjustments can be made by turning the stopper bolts Loosen the jam nut and adjust the stopper bolt in or out as necessary to obtain the specified turning radius Tighten the jam nut when done gU dU 1 5 ton Within 76 6 in 1 945mm 5 Within 67 9 in 1 725mm 596 1 8 ton Within 78 0 in 1 980mm 5 Within 69 7 in 1 770mm 596 Difference between right amp left turn diameters Within 3 9 in 100mm 04 15 04 TESTING ADJUSTING AND MEASURING MEASURE HYDRAULIC CONTROL VALVE RELIEF PRESSURE 1 Install an oil pressure gauge to the relief measurement port A as shown in the figure at right
42. CAUTION STABLE RANGE OF CENTER OF GRAVITY For the lift truck to be stable the position of the combined center of gravity must be inside the triangle stable range of center of gravity formed by the ground contact points of the left and right front tires and the center of the rear axle Stable range 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 AB80161B the front If the position of the combined center of gravity moves outside the triangle forming the stable area for the center of gravity the lift truck will tip in the direction where the combined center of gravity moves outside of the triangle 01 33 01 SAFETY SECTION CAUTION MAXIMUM LOAD weight and center of gravity of load The horizontal distance between the center of gravity of the load on the forks and the load backrest of the forks or the front face of the forks whichever is shorter is called the load cen o ter The maximum load is the maximum weight of the load that can be loaded at the standard load center The relationship between the maximum load and the load center is given in the load capacity charts on the nameplate on the lift truck If the load center moves to the front of the forks the overall center of gravity also moves to the front so this means that the load must be reduced CAUTION ALLOWABLE LOAD The allowable load is stamped on the
43. Check also that there is no damage to the lifting portion on the coun terweight AB801530 AB801540 01 28 01 SAFETY SECTION WARNING BE CAREFUL NOT TO GET CAUGHT OR FALL NEVER put your hands or feet into the mast structure There is danger that you will get caught in moving parts and be seri ously injured AB801320 Do not use the mast as a ladder If you slip there is danger that you will fall AB801330 A DANGER CHECKING AND INFLATING TIRES f the tire inflation pressure is low it will affect truck stability However do not inflate the tires immediately The inflation pres sure may have gone down because of damage to the rim if the rim is damaged or cracked and the tires are inflated there is danger that the rim will break when the tire is under high pres sure and this may cause 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 Suitable qualifications are needed for tire inflation work Always 3 0150 have work carried out by properly qualified personnel tire inflation pressure on a forklift truck is several times higher than the pressure on an automobile 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 Always wear safety glasses to protect your eyes 01 27 01
44. DXL2 78P4N DISPLACEMENT 2 776 LITERS ENGINE MODEL 4TNE94 1B EMISSION CONTROL SYSTEM EM FUEL RATE 47 2 MM3 STROKE 44 6 kW 2450 RPM REFER OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS YANMAR DIESEL ENGINE Co Ltd KFIO10565A 14 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 Federa EPA and Komatsu Forklift USA Inc hereinafter referred to as KF I 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 EPA s stringent anti smog standards KFI 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 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 in 2004 model year and after shall be regu lated by Federal EPA exhaust gaseous regulat
45. EPA T C GASOLINE SHEET 1 A 1 AX20 BX20 EPA GASOLINE SHEET 2 A 2 20 20 EPA GASOLINE SHEET 3 A 3 20 20 EPA LP SHEET 1 A 4 AX20 BX20 EPA 5 2 A 5 AX20 BX20 EPA T C 5 3 A 6 AX20 BX20 EPA T C DUAL FUEL SHEET 1 A 7 AX20 BX20 EPA T C DUAL FUEL SHEET 2 A 8 AX20 BX20 EPA T C DUAL FUEL SHEET 3 A 9 AX20 BX20 EPA T C LP UL LPS SHEET 1 A 10 AX20 BX20 EPA T C LP UL LPS SHEET 2 11 AX20 BX20 EPA T C LP UL LPS SHEET A 12 APPENDIX 2 TORQFLOW TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM FOLDOUT APPLICABLE AX20 EPA LIFT TRUCK MODELS FG18STLS 17 3 500 Ib capacity K21 Engine Torqflow Spec LP Special Cushion Tire 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
46. ICATIONS DRIVE Battery Voltage Capacity 20 hour rating VIAh Engine Model Rated Output SAE Gross HP kW rpm Maximum Torque SAE Gross Ib ft Nm rpm No of Cylinders Displacement cu in cm Cylinder Bore x Stroke in mm Fuel Tank Capacity U S gallons liters OTHER Relief Pressure Maximum psi bar Hydraulic Tank Capacity U S gallons liters Clutch Transmission Air Cleaner Type FG15HC 17 FG15HT 17 41126 2 065 3 5 89 x 3 3 83 9 8 37 Synchromesh FG18HT 17 12141 K21 65 7 49 2 900 145 197 1 600 2 650 182 7 8 2 31 Torque Converter TORQFLOW Cyclone NOTE Most values shown in this publication are rounded Therefore direct conversion between metric and English or Imperial may be slightly different than displayed in this table The performance of the machines is affected by the condition of the vehicle and how it is equipped as well as the nature and condition of the operating area If these specifications are critical or if your needs exceed the specifications shown here discuss the proposed application with your authorized dealer Optional masts attachments longer load dimensions and higher lifting heights may result in derating of the capacity Con tact your authorized dealer Other mast heights available See MAST DATA CHART for other mast heights Contact your authorized dealer Tf Includes 48 in 1 220 mm high Load Backrest Contact your authoriz
47. ISTANCES LOADING SYSTEM i Relief Pressure psi MPa Oil Capacity gal L Thickness at Fork Root in mm mi m m 03 5 03 SERVICE DATA FG18S 17 ill N A N A 115 8 180 7 157 245 N A N A N A 1 073 3 7 4 1 2 2 4 30 60 67 9 1 725 69 7 1 770 0 028 0 7 12 20 3 5mm 0 08 0 12 2 3 1 85 2 09 47 53 0 51 0 67 13 17 3 15 3 54 80 90 158 0 15 55 1 245 108 4 144 5 147 196 14 7 4 5 6 56 2 0 1 26 32 Minimum 1 34 34 Minimum 0 6 15 Maximum 1 4 35 Maximum 13 1 332 Maximum 20 50 Maximum 15 Minutes 1 8 45 Maximum 15 Minutes 2 650 18 2 9 25 35 04 TESTING ADJUSTING AND MEASURING ADJUSTING IGNITION TIMING Ignition timing is automatically set at 0 by the Electronic Control Unit ECU and it is not adjustable With the Special Service Tool SST attached and operating the ignition timing may be temporarily changed for diagnostic purposes but once the SST is disconnected from the unit the ignition timing will default back to 0 ADJUSTING SPARK PLUG GAP 1 Using a proper spark plug removal tool remove the spark plug s 2 Carefully remove any soot or carbon buildup adhered to INSULATOR TERMINAL the spark plug tip and surrounding area 3 Ifthe plug is burned or shows electrode damage replace the spark plug s 4 Measure the gap A with a gap gauge 5 Set spark pl
48. L FUEL AND STOPS 3 TURN SWITCH TO DESIRED FUEL SELECTION LPG OR GASOLINE 4 START ENGINE AS USUAL 0007 14 FUEL LEVEL REQUIREMENTS GASOLINE AND LPG On dashboard over Fuel Gauge Dual Fuel applications only THIS GAGE NOT IN USE USE TANK GAGE DO NOT REMOVE 0009 GASOLINE MUST BE ATLEAST 1 4 FULL WHEN OPERATING ON LPG KFOM0008 01 40 02 GENERAL INFORMATION amp SPECIFICATIONS SPECIFICATIONS MAST DATA amp FEATURES INDOOR amp OUTDOOR TRUCKS FG15HC 17 FG18HT 17 FG15HT 17 FG18ST 17 FG15ST 17 PNEUMATIC TRUCK SHOWN OVERALL WIDTH DRIVE TIRES a 2 eo 5 I ui o e ui MAST HEIGHT EXTENDED MAXIMUM FORK HEIGHT MAST HEIGHTLOWERED WHEEL BASE FORK LENGTH E LENGTH TO FORK FACE 0 85 02 2 02 GENERAL INFORMATION amp SPECIFICATIONS SPECIFICATIONS MAST DATA amp FEATURES CON T MAXIMUM FORK HEIGHT in mm 106 0 2 690 116 0 2 945 128 0 3 250 106 0 2 690 116 0 2 945 128 0 3 250 158 5 4 025 170 5 4 330 188 5 4 790 198 5 5 040 216 5 5 500 235 5 5 980 MAST HEIGHT in mm Lowered Extended in mm in mm Free View FG15 18 17 2 Stage Free View FV 154 0 3 910 164 0 4 165 176 0 4 470 2 Stage Full Free View FFV 164 0 4 165 176 0 4 470 3 Stage Full Free View TFV 218 5 5 550 85 5 2 170 236
49. NGINE Continuous Load 3 000 Torque Converter Stall Speed 2 100 100 rpm Compression psi rpm 178 250 MPa rpm 121260 qts 1 3 91 3 7 w Filter 3 59 3 4 w o Filter Idle 14 22 98 At 2 000 rpm 39 8 45 5 274 313 Engine Oil Capacity LUBRICATING Engine Oil Pressure 178 80 C psi kPa COOLING SYS TEMS Coolant Capacity Radiator Cap Press qts L 2 4 9 1 12 8 psi 0 9 kg cm Coolant Capacity Racietor Press Fan Belt Tension in mm 0 47 0 55 12 14 Finger Pressure 98N Unleaded Regular Gasoline 89 Variable Controlled by ECU INTAKE 015 0 38 w Engine Warm EXHAUST SYS Valve Clearance TEM 015 0 38 w Engine Warm 2509 POWER TRAIN IN Stall Speed omm 2 100 100 rpm TORQUE 91 4 156 6 0 63 1 08 1 000 CONVERTER let Port Oil Pressure 127 6 177 0 0 88 1 22 2 000 Outlet Port Oil Pressure psi MPa 35 5 63 8 0 245 0 440 Relief Pressure psi MPa 153 74 1 06 91 4 156 6 1 000 psi rpm 0 63 1 08 1 000 TORQFLOW Clutch Actuation Pressure MPa rpm 127 6 176 9 2 000 TRANSMISSION 0 88 1 22 2 000 Lubricating Oil Pressure psi MPa 14 5 56 6 0 1 0 39 Oil Capacity qts L 12 68 12 Including Torque Converter TORQFLOW qts L 6 34 6 DIFFERENTIAL Oil Capacity Clutch Type qts L 13 74 13 inc Direct Drive Trans
50. NTHS OR 3 500 HOURS FOR GENERAL PARTS ECM e 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 a aa 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 engines will display the required identification labe as follows 4D94E diesel engines Labels will be affixed to all appropriate engines on KFI production trucks Location on 4D94E Series diesel engines EMISSION CONTROL LABEL 18 amp it b unm n a i EEG amp 42 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 4Y
51. RE LRL USD ng 07 124 TorqFlow Transmission Disassembly Con t 07 125 TorqFlow Transmission Input Shaft Exploded 07 126 TorqFlow Transmission Main Shaft and Clutch 07 127 TorqFlow Transmission Forward and Reverse Gear 07 128 Measuring Clutch Pack End 07 129 TorqFlow Transmission Clutch Return 5 07 130 TorqFlow Transmission Output 07 130 TorqFlow Transmission Oil 07 133 TorqFlow Transmission Case 07 133 TorqFlow Transmission Gear Backlash Specifications 07 134 TorqFlow Transmission Control Valve Spring Fatigue 07 135 TorqFlow Transmission Control Valve Assembly Exploded 07 137 TorqFlow Transmission Control Valve 07 140 TorqFlow Transmission Control Valve 07 140 CHAPTER 08 MASTS 08 01 Masts 35D 40D 50D 55D 60D MD Series 2 Stage Masts
52. SERVICE MANUAL Sen AX20 SERIES FORKLIFT TRUCKS Federal Environmental Protection Agency EPA Emission Control Compliant AX20 FG15 18 S H 17 S N 670001A CHASSIS 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 secured in place KOMATSU Komatsu Forklift USA Inc ISSUED NOVEMBER 2004 INTRODUCTION This Service Manual has been developed as an information resource to help the reader learn about understand repair and maintain the AX20 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 Forklift 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 systems simple and easy Read this manual carefully refer to it often and learn the repair testing and a
53. agging feel to the brakes Listen for abnormal noise or grinding Measure the stopping distance using an assistant Stopping distances should be within specified limits shown in the table below DARN Within 14 7 ft 4 5m at 12 4 mph 20 km h Within 6 56 ft 2 0m at 6 2 mph 10 km h With truck unloaded With truck loaded 04 10 ADJUSTING THE STOP LAMP SWITCH 1 2 ADJUSTING THE INCHING BRAKE PEDAL TORQFLOW TRUCKS Brake Pedal 1 2 3 Inching Pedal 1 04 TESTING ADJUSTING AND MEASURING After adjusting the brake pedal height set the gap D to 0 02 0 06 in 0 5 1 5mm Coat the sliding portion of the link with lithium grease Link Ratio Clutch Brake Pedals 6 11 When assembling coat the sliding portion of the link with lithium grease Set the brake pedal stopper bolt A so that the brake pedal released height is 7 8 in 198mm Loosen the rod adjuster nut and rotate the rod to my fs set the play at 0 51 0 67 13 17mm hn Mrd Tighten the adjuster nut and recheck i Adjust the inching pedal stopper bolt B to set the inching pedal released height at 8 16 in 207mm BRAKE MASTER CYLINDER 04 0016 04 11 04 TESTING ADJUSTING AND MEASURING Inching Pedal Brake Pedal Interconnected Travel 1 Adjust the stopper bolt C See Figure 04 0017 SIDE VIEW to set the brake pedal so that it travels 1 85 2 09 in 47 53mm down f
54. aiso be property positioned by using the locating pin or key way The tue valve should be turned off when the machine is not In service Cast fittings should not be used In the LP GAS system Use onty Underwriters Laboratories or Factory Mutual listed LP GAS hose assembiles where pressure fuel lines are required All pipe thresded fittings should be installed using an approved seating Fuel ines should be supported by clamps to minimize chating and wear The LP GAS solenoid valve should be wired to an automatic shut off switch oil pressure or vacuum to prevent leakage of gas in the event the ignition is on without the engine running Check the propane solenoid or vacuum shutoff valve for leakage as follows Turn fuel cylinder valve off start and run engine until it stope Install 0 to 30 PSI pressure gauge per instruction A or B A Primary test port of single units consisting of primary and secondary regulators B Between the primary and secondary stage regulators when the propane system consists of two separate regulators Turn cylinder tuel valve on The pressure gauge should maintain zero reading If It does nol the solenoid valve or vacuum shutoff valve must be repaired or repiaced An odor is added to LP GAS to help detect leaks If gas odor detected the fuel cylinder supply valve and engine should be turned off Remove ali sources of ignition and ventilate the area Make all of the necessary repairs before you
55. alling the battery confirm which is the CHECK BATTERY positive terminal and which is the negative terminal Be TERMINAL careful not to connect the cables to the opposite incorrect ter MARKINGS minals Tighten the battery caps securely When cleaning the battery leave the battery caps tightened AO055100A WARNING PUT METAL OBJECTS OF BATTERY Never place any metal objects on top of the battery There is danger that they will cause a short cir cuit and start a fire WARNING CHANGING LPG FUEL TANKS Only trained and certified personnel may change LPG tanks Turn ignition switch to the OFF position Change LPG tanks in designated and well ventilated area approved for this operation Check LPG tank and lines for fuel leaks Ensure no sparks flame or ignition sources are present Once the full tank is in place ensure it is mounted correctly and securely Check all connections Do not attempt to start the truck until all LPG odor is gone If the truck is hard to start contact a certified mechanic to repair the problem Tag the truck Out of Service until properly repaired 01 29 01 SAFETY SECTION WARNING PRECAUTIONS WHEN CHARGING 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 e Carry out the charging operation a well ventilated place
56. and sleeve nuts Width across flats B mm Bore A mm 108 4 151 9 147 206 15 21 14 5 21 7 17 3 50 6 434 724 79 7 123 2 19 8 29 4 23 5 68 6 58 8 98 1 108 167 2 3 3 7 6 10 11 17 Tightening Torque ft Ibs Nm kgfm 02 9 02 GENERAL INFORMATION amp SPECIFICATIONS STANDARD TIGHTENING TORQUE FOR BOLTS For unspecified bolts and nuts use the torque values specified in this list Select a proper torque value corresponding to the width across 0 the flats b of the bolt or nut When replacing bolts and nuts always use the manufacturer s specified part s of the same size and strength as the original a parts 01 0002 Thread diameter Width across Tightening Torque of bolt in mm flat in mm 9 73 1 03 1 35 0 15 23 2 2 10 3 20 0 30 48 5 5 00 6 70 0 70 82 6 7 20 11 5 1 00 131 14 0 18 0 2 00 206 21 279 29 28 5 3 00 282 29 383 39 39 0 3 00 405 43 549 58 56 0 6 00 549 58 745 78 76 0 8 00 684 72 927 98 94 5 10 0 973 100 1 320 140 135 15 1 270 140 1 720 190 175 20 1 630 180 2 210 240 225 25 2 030 210 2 750 290 280 30 2 420 250 3 280 340 335 35 02 10 03 SERVICE DATA SERVICE DATA GASOLINE ENGINE TRUCKS PNEUMATIC Component Check Item Unit 15 17 18 17 ENGINE Idling Speed 700 No Load 3 600 Maximum Speed rpm Instantaneous E
57. deteriorate and may 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 PRECAUTIONS WITH HIGH TEMPERATURE COOLANT immediately after using the lift truck the engine coolant is at high temperature HOT and high pressure Do not remove the radiator cap under these conditions Hot water may spurt out and cause burns When removing the radiator cap use a rag and turn it slowly to release the internal pressure When checking the coolant level stop the engine and wait for the engine to cool down before checking For lift trucks equipped with a sub tank or reservoir check the level in the sub tank When adding water on lift trucks equipped with a sub tank add the water to the sub tank 01 25 01 SAFETY SECTION WARNING PRECAUTIONS WITH HIGH PRESSURE HIGH TEMPERATURE OIL Immediately after using the lift truck the oil is at high temper INCORRECT ature Do not drain the oil or replace the filter when the oil is hot Hot oil may spurt out and cause burns When carrying out inspection and maintenance wait for the oil temperature to go down and carry out the operation in the order given in this manual Do not forget that the work equipment circuits are always under pressure Do not add oil drain oil or carry out mainte nance or inspection before completely
58. djustment 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 Forklift for a replacement The procedures out lined 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 dis played 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 The Engine Model number is on the left pad and ENGINE SERIAL the Engine Serial number is on the right pad ee
59. dly Do not continue this operation for more than a few seconds at a time Warm engine up to normal operating temperature Hold down brake pedal and place in gear Depress the accelerator pedal fully and run at maximum speed While at maximum speed check the rpm with a tachometer 21 Maximum Governed Speed 2 950 3 000 rpm Torque Converter Stall Speed 2 100 100 rpm Main Pressure 92 5 psi 6 5 kgf cm 750 rpm 177 8 psi 12 5 kgf cm 2 000 rpm Lube Pressure 30 50 psi 2 1 3 5 kgf cm 04 13 04 TESTING ADJUSTING AND MEASURING TESTING SPECIFIC GRAVITY OF BATTERY ELECTROLYTE WARNING Precautions when handling a battery Battery electrolyte is dangerous If it gets into your eyes or on your skin or clothing wash it off with large amounts of fresh water quickly If it gets into your eyes seek med ical attention immediately WEAR ADEQUATE EYE AND HAND PROTECTION WHEN HANDLING BATTERIES AND WHEN CHECKING BATTERY ELECTROLYTE Keep away from sparks flames any ignition source To avoid gas explosions do not smoke or cause a short circuit or spark near the bat tery Do not lay tools or metal objects on top of the battery 1 Charge the battery and after charging check that the battery electrolyte fluid level is correct If the electrolyte level in the battery is below the top of the electrode plates add distilled water to the top of the plates Do not overfill 2 Check and clean ba
60. e 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 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 overail center of gravity is high so the danger of tipping to the front left or right becomes greater 01 34 01 SAFETY SECTION SAFETY LABEL LOCATIONS Keep these labels clean If a label decal comes off stick it on again in the same location or replace with new one Treat all labels decals in the same way whether they are safety related or not oa L Ap D sy a MALI PA ote iL Fo ofl H y Q a i i ra SHROUD SHROUD INSIDE OF ENGINE HOOD OUTSIDE OF LEFT AND RIGHT OUTER MASTS LEFT AND RIGHT OUTER RIMS OF LEFT AND FRONT WHEELS RIGHT REAR WHEELS AWB2296B See following pages for labels corresponding to numbered locations in Figure above 01 35 01 SAFETY SECTION 1 Prohibit the operator from riding on the forks and lifting or lowering himself Never enter the area under the forks Part No 3EB 96 25840 AWARNINCG 2 Do not put your hand on the mast Warning to avoid gett
61. ect 05 10 Inspect Hydraulic 05 10 Inspect Chassis and Attachment 05 10 Inspect Hydraulic 2 05 10 Inspect Lift 05 10 Inspect Tilt 05 10 Inspect Attachment 05 10 Inspect Lift Truck Chassis and 05 10 Inspect Cab If Equipped e 05 10 Inspect the Operator s Seat 05 11 Inspect Equipment Used for Accessing the Lift 05 11 Inspect Display 1 05 11 Inspect Overhead 05 11 Inspect Lights Gauges and Warning Devices 05 11 Inspect Rear View Mirror and Reflectors 05 11 Inspect Speed and Forward Reverse Levers Manual Shift Transmission 05 12 CHAPTER 06 MAINTENANCE OPERATIONS
62. ed dealer for additional information tt Add load length and clearance Contact your authorized dealer 02 5 02 GENERAL INFORMATION amp SPECIFICATIONS TRUCK DATA CUSHION TIRE LIFT TRUCKS GENERAL Power Type Gasoline Operation Type Sit Down Capacity 24 600 mm Load Center Ibs kg 3 500 1 580 Load Distance from Center Axle 2 Stage mm 15 4 390 Load Distance from Center Axle 3 Stage in mm 15 4 390 Wheelbase in mm 47 2 1 200 WEIGHT Service Weight inc 2 Stage STD Mast Forks Ibs kg 6 450 2 925 TIRES Tire Type Cushion Tire Size Front 18 0 x 6x 12 1 8 Tire Size Rear 14 x4 1 2x 8 Number of Wheels Front Rear x 7 Driven 2x 2 Tread Center of Tires Front Rear in mm 32 1 815 32 1 815 DIMENSIONS Tilting Angle 2 Stage FV Masts Forward Backward 717 Tilting Angle 3 Stage TF V Masts Forward Backward 715 Mast Height Lowered 2 Stage Mast in mm 83 5 2 120 Mast Height Extended 2 Stage Mast t in mm 176 0 4 470 Maximum Fork Height 2 Stage STD Mast in mm 128 0 3 250 Free Lift Height 2 Stage STD Mast in mm 5 5 140 Height Overhead Guard in mm 77 6 1 970 Length to Fork Face 2 Stage Mast in mm 80 9 2 055 Length to Fork Face 3 Stage Mast in mm 80 9 2 055 Overail Width at Drive Tires mm 38 0 965 Forks Thickness x Width x Length in mm 1 6 x 4 0 x 42 0 40 x 100 x 1 070 Carriage Width ITA C
63. ent damage or injury and warn those in the work area 01 23 01 SAFETY SECTION 5 INSPECTION AND MAINTENANCE WARNIN USE QUALIFIED PERSONNEL FOR INSPECTION AND G MAINTENANCE 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 e If inspection maintenance or repair work is carried out incorrectly it is very dangerous WARNING MAINTENANCE LOCATION gt When carrying out inspection and maintenance use a level dry dust free area e Ifthe work is carried out inside a building make sure that there is ample ventilation WARNING PRECAUTIONS FOR INSPECTION AND MAINTENANCE i To be prepared in the event of a fire have a fire extinguisher nearby and make sure that you know how to use it Before carrying out inspection lower the forks to the ground and stop the machine Do not run the engine unless it is necessary Place the directional lever speed lever and work equipment control levers in neutral WARNING PRECAUTIONS WHEN CARRYING OUT INSPECTION AND MAINTENENCE Wipe off oil or grease Immediately wipe up any 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 circumstance
64. g Operations e ed dey M GA ERE Saye 01 15 Stopping and Parking iy eee Bae ROG WAN AR 01 22 Inspection and 01 24 Structure and Stability of the Lift 01 32 Safety Label Locations Dr aep RR opes S E Rees 01 35 CHAPTER 02 GENERAL INFORMATION AND SPECIFICATIONS 02 01 Specifications Mast Data amp Features Indoor amp Outdoor 02 02 Truck Data Tables Pneumatic Tire Trucks 02 04 Truck Data Tables Cushion Tire Trucks 02 06 Periodic Replacement of Consumable Parts 02 08 Standard Tightening Torque for Pipe Joints 02 09 Standard Tightening Torque for Bolts 02 10 CHAPTER 03 SERVICE 03 01 Service Data Gasoline Engines Pneumatic Trucks 03 02 Service Data Gasoline Engines Cushion Trucks 03 04 CHAPTER 04 TESTING ADJUSTING AND MEASURING 04 01 Adjusting Ignition 0
65. gh crossings or other places where the view is poor or when entering or leaving narrow roads stop and sound the horn to confirm safety before driving on Even if you sound the horn not everyone in the surround ing area will necessarily hear it Always pay careful atten ABB01280 tion to the movements of people in the surrounding area When crossing roads or turning corners stop and confirm safety before continuing Always pay careful attention to the movements of people in the surrounding area and take steps to prevent people from entering the working area WARNING SAFETY DURING TRAVEL 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 AB801270 WARNING GIVE PRIORITY TO LOADED LIFT TRUCKS When traveling on slopes or in confined areas unloaded lift trucks should always give the right of way to loaded trucks 01 13 01 SAFETY SECTION WARNING HEIGHT OR WIDTH LIMITS 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 e Check that the surrounding area is
66. gulator 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 KF recommends that you retain receipts covering maintenance on your off road engine but cannot deny war ranty solely for the lack 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 KFI 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
67. he 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 AB801180 WARNING ESCAPING FROM RAILROAD CROSSING If engine trouble occurs a railroad crossing and the lift truck cannot move you cannot use the starting motor to move the truck as can be done in automobiles The lift truck s neutral safety switch prevents this action In such an emergency light a flare or smoke candle to warn approaching trains vehicles and pesons n the area that there is a broken down truck on the tracks It is critically important to remove the lift truck from the tracks as soon as possible 01 9 01 SAFETY SECTION WARNING NO RIDERS 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 AD817960A AB801650 WARNING DRIVING IN REVERSE When driving in REVERSE turn to face the rear check the area directly behind the lift truck 801200 WARNING OBSTRUCTION OF REAR VIEW WHEN USING LP GAS FUEL The LP gas cylinder partially blocks the view to the rear so there is danger of hitting pe
68. ights 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 AB801570 AB801580 01 32 01 SAFETY SECTION CAUTION CENTER OF GRAVITY AND STABILITY The stability of the lift truck is determined by the position of the combined center of gravity resulting from the combination Ni of the centers of gravity of the lift truck and the load gravity of centerof gravity When the lift truck is carrying no load the center of gravity lift truck aravity of load remains as it is but when the lift truck is loaded the com bined center of gravity becomes the combination of the cen ters of gravity of both the lift truck and the load The position of the center of gravity of the load changes according to whether the mast is tilted forward or back or whether the mast is raised or lowered The position of the combined center of gravity of the lift truck is governed by the following factors Center of s Size weight shape of load loa Lifting height e Tilting angle of mast Combined center Inflation pressure of tires Gravity Acceleration deceleration turning radius Centarot Condition of road surface angle of road aravitv of of attachments lift truck It is assumed that the lift truck is constant 28801608 A
69. ill tip Always do as follows Hold the steering wheel securely Stay in the operator s seat Brace your legs If you jump off the lift truck when it turns over there is danger that you will be fatally crushed under the lift truck Always stay in the operator s compartment if the lift truck turns over then escape from the lift truck after it has stopped Always wear the seat belt correctly Tip aver can occur evan when unloaded S risk injury or deat 4 Slew down belare burning EE In case of Asm tip over Follow these Butkie insteuctinns 010449 01 8 01 SAFETY SECTION WARNING ROAD SHOULDER There is danger that soft road shoulders may collapse so do not go near them with the lift truck Always maintain a safe distance from the edge of road shoulders and platforms AB801180 WARNING LOADING HIGHWAY TRUCKS RAILROAD CARS Do not travel on the edge of docks There is danger that the lift truck may fall which may result in serious injury or death Before starting operations check the load limit for the gang planks dock boards 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 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 AB801170 When driving t
70. ing hand caught Part No 3EB 96 25850 3 Caution before operating machine Part No 3EB 96 25760 Before starting engine Pyt gearshift lever in neutral Pull parking lever rely 3EB 96 25760 A WARNING 3EB 98 2585 01 36 4 Never touch fan when rotating Part No 3EB 96 25770 o A 3EB 98 25770 5 No one is permitted to ride the lift truck together with the operator Part No 3EB 96 25740 Warning for operation Decal Part No 3EB 96 25720 01 SAFETY SECTION A WARNING SERIOUS INJURY OR DEATH MAY RESULT IF YOU FAIL TO FOLLOW THESE PRECAUTIONS Befor ratin Do operate or repair truck unless trained authorized Read and understand all warnings and instructions in manuals and on truck before operating Contact forklift dealer for 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 While 2 Operate truck only from operator s seat 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 c
71. ions 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 KF recommends that you retain all receipts and records covering the maintenance on your engine but cannot deny warranty solely for the lack of receipts 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 Ever
72. king on any fuel system Ensure you are wearing proper personal protective equipment e Check for fuel leaks before you begin work on any fuel system OnLPG systems DO NOT work on the system if the fuel storage container is filled with fuel past the 80 liquid level Ensure there are NO SOURCES OF IGNITION nearby before beginning work Be sure your work area is adequately ventilated Disconnect the battery before working the fuel system LPG is heavier than air and will sink to the lowest area possible Avoid areas near floor drains or lubrication pits where escaped fuel may collect LPG is stored under high pressure Ensure the LPG fuel storage container valve is turned OFF closed and pressure is released from the lines before working on system Store all LPG cylinders OUTDOORS is a secured area and safe from any vehicle traffic NEVER WELD ON AN LPG PRESSURE VESSEL STORAGE TANK OR CYLINDER LPG fuel tanks mounted horizontally MUST BE positioned properly See MAINTENANCE Section Always utilize a UL listed LPG tank 01 6 01 SAFETY SECTION 2 SAFE TRAVEL WARNING PRECAUTIONS WHEN STARTING ENGINE Before starting the engine always check that the parking brake is applied and that the directional and speed levers are in neutral ENS Depress the clutch pedal for clutch type trucks or the brake pedal for TORQFLOW transmission trucks firmly and then start the engine Adjust the ope
73. lass in mm 37 0 940 Il Ground Clearance under Mast in mm 3 5 90 Ground Cleararice Center of Wheelbase in mm 4 0 100 Right Angle Stacking Aisle 2 Stage Mast tt mm 85 1 2 160 Right Angle Stacking Aisle 3 Stage Mast tt mm 85 1 2 160 Turning Radius Outside in mm 69 7 1 770 PERFORMANCE Travel Speed Forward Loaded Unloaded mph k hr 10 3 16 5 10 3 16 5 Lifting Speed Loaded Unloaded 2 Stage fpm mm s 123 625 126 640 Lifling Speed Loaded Unloaded 3 Stage fpm mm s 116 590 120 610 Lowering Speed Loaded Unloaded 2 Stg fpm mm s 97 490 89 450 Lowering Speed Loaded Unloaded 3 Stg fpm mm s 98 500 69 350 Maximum Drawbar Pull Loaded Ibs kN 4 610 20 5 Maximum Gradeability Loaded 37 18 Service Brake Operation Control Foot Hydraulic Parking Brake Operation Control Hand Mechanical Steering Type Hydrostatic Power TABLE CONTINUED ON NEXT PAGE 02 6 02 GENERAL INFORMATION amp SPECIFICATIONS DRIVE Battery Voltage Capacity 20 hour rating VIAh 12 41 Engine Model K21 K21 Rated Output SAE Gross HP kW 60 1 45 2 950 60 1 45 2 950 Maximum Torque SAE Gross Ib ft Nm rpm 115 156 1 600 No of Cylinders Displacement cu in cm 41126 2 065 Cylinder Stroke nm 3 5 89 3 3 83 Fuel Tank Capacity U S gallons liters 6 6 25 OTHER Relief Pressure Maximum psi bar 2 65
74. learances especially forks mast overhead guard and tailswing area Slow down tor 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 special care when operating on dockboard or bridgeplate Do not handie unstable loads or loosely stack loads Do not handie loads higher than load backrest Space forks as far as load permits Ee 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 tip over 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 cap
75. n is not the same the load will be unbalanced even if it is loaded correctly in the center and there is danger that the lift truck may tip For details of adjustment see page 2 26 01 19 01 SAFETY SECTION WARNING BE CAREFUL OF FORK TIPS 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 hook the tips of the forks under objects If the forks slip out there is danger that the lift truck or object may move unexpectedly AB801430 WARNING PEOPLE IN WORKING AREA 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 WARNING USE STRONG PALLETS AND SKIDS 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 WARNING HANDLING LONG OR WIDE LOADS Be extremely careful when carrying long or 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 move AB801440 01 20 01 SAFETY SECTION WARNING OVERHEAD OBJECTS Be careful not to let the mast overhead
76. ntrolled by ECU 4 2 1 3 50 8 PSI 350 KPa 6 6 25 015 0 38 w Engine Warm 015 0 38 w Engine Warm 035 0 9 P N 22401 FU412 0 700 1 3 4 2 1 240 2100 100 rpm 91 4 156 6 0 63 1 08 1 000 127 6 177 0 0 88 1 22 2 000 35 5 63 8 0 245 0 440 153 74 1 06 91 4 156 6 1 000 0 63 1 08 1 000 127 6 176 9 2 000 0 88 1 22 2 000 14 5 56 6 0 1 0 39 12 68 12 Including Torque 6 34 6 13 74 13 Inc Direct Drive Trans Component Check ltem Unit FG15S 17 TRAVEL SYSTEM TIRES HUB NUT STEERING BRAKING SYSTEMS POWER STEER ING RELIEF VALVE STEERING WHEEL CLUTCH PEDAL INCHING PEDAL BRAKE PEDAL BRAKE BRAKE FORK CHAIN CYLINDER MAIN RELIEF VALVE HYDRAULIC SYSTEM Tread Depth in mm Front Wheels Ib ft Nm Tightening Torque Rear Wheels Ib ft Nm Front Wheels ib ft Nm RIM MATING NUT Tightening Torque Rear Wheels Ib ft Nm psi MPa Inflation Pressure LE tire s psi MPa Relief Pressure psi MPa mm 3 3 Minimum Turning Radius STEERING AXLE Support Thrust Clearance in mm Play in mm Play in mm Interconnected Travel in mm in 5 3 3 00 Height when Depressed Brake Fluid Capacity qts L Parking Brake Operating Force Ibf Torque for Back Plate Mtg Bolt tb ft Nm STOPPING Unloaded D
77. oid 01 38 01 SAFETY SECTION 11 LPG TANK CHANGE INSTRUCTIONS DECAL On LPG Tank Bracket Base Plate FUEL CYLINDER REPLACEMENT PROCEDURE 1 NO SMOKING DO REPLACE FUEL CYLINDERS iN AREAS THAT HAVE A SOURCE OF FUEL IGNITION 2 CLOSE CYLINDER VALVE AND RUN ENGINE UNTIL IT STOPS PRIOR TO DISCONNECTING THE FUEL HOSE FROM THE TANK 3 REPLACE FUEL CONTAINER BE SURE TO USE THE CORRECT SIZE AND PEA THE CYLINDER DESCRIPTION PLATE SECURELY MOUNT AND POSITION AS FOLLOWS E WITH LOCATING PIN THROUGH POSITIONING HOLE IN COLLAR b WITH SLOT IN FOOTRING OVER LOCATING KEYWAY 4 CONNECT FUEL VALVE SLOWLY SO THE HOSE AND TANK PRESSURE CAN EQUALCE OR THE VALVE MAY SLUG SHOULD LEAKAGE OCCUR CLOSE VALVE AND HAVE QUALIFIED PERSONNEL MAKE REPAIRS 8 USE FUEL MANUFACTURED NATIONAL GAS PROCESSORS ASSOCIATION THD 3 SPECIFICATION NOTE THE ABOVE iS PROVIDED AS A GUIDE FOR ADDITIONAL INFORMATION CONSULT THE NATIONAL FIRE PROTECTION ASSOCIATION PAMPHLET 56 FOR THE SAFE STORAGE AND HANDLING OF LIQUIFIED PETROLEUM GASES ed 0003 12 LPG SAFETY MAINTENANCE DECAL Right side of seat on hood upper surface RECOMMENDED SAFETY MAINTENANCE PROCEDURE FOR LP GAS FUELED FORKLIFT TRUCKS WARNING LP GAS is a combustible fuel that is heavier than air Escaping gas may accumulate low areas The fuel cylinder should be mounted so that It does not extend outside the truck and should
78. ot 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 STOP PING 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 If LPG leaks it can accumulate and cause fire or explosion 01 22 01 SAFETY SECTION WARNING PARKING MACHINE AFTER FAILURE 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 vehi cles 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 go under the forks The area under the forks is a DANGER zone Place a stand or something similar under the inner mast rail or forks to prevent 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 8801498 WARNING ABRUPTLOWERING STUCK FORK Because a stuck fork may drop down unexpectedly do not go under the fork when it is in this con dition Be very careful when dealing with this problem to prev
79. pment control levers or directional lever and this may cause a serious accident WARNING MOUNTING AND DismouNTING NEVER jump on 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 AL187320 01 11 01 SAFETY SECTION WARNING ALWAYS SIT IN OPERATOR S SEAT Never operate the lift truck from outside the operator s compart ment Always keep your body under the overhead guard Do not extend your arms and legs outside the operator s com partment AB801240 WARNING SEAT BELT Always wear your seat belt correctly when on the operator s seat The seat belt will reduce the risk of injury Always check the seat belt mounts and check for any damage to the seat belt itself If any abnormality is found repair or replace the seat belt immediately AB801700A WARNING SAFETY WHEN STARTING i Before starting and moving the lift truck check that the surround ing area is safe Before moving the lift truck raise the forks approx 8 in 20cm from the ground surface and tilt the mast back Before moving the lift truck release the parking brake Tilt back 20cm
80. rator 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 and it may cause you to lose your balance or to operate the lift truck improperly Before starting the engine check that the surrounding area is safe ALWAYS SIT IN THE OPERATOR S SEAT when starting the engine Before starting the engine 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 no one is near the engine compartment tires or counterweight then get on the lift truck sit in the operator s seat and start the engine AB801120 Do not attempt to start the engine by short circuiting the engine starting circuit Such an act may cause a serious bodily injury or fire WARNIN PRECAUTIONS WHEN OPERATING DIRECTIONAL OR deser d When switching between FORWARD and REVERSE always stop the lift truck It is dangerous to change the direction of travel suddenly When operating the directional lever or speed lever always depress the clutch pedal before mov ing the lever for clutch type lift trucks If the lever is moved without disengaging the clutch the lift truck will move suddenly and may cause injury WARNING TIPPING 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
81. rential Adjustment Nut Special 07 104 Hydraulic Control Valve Hydraulic Control Valve 3 Spool Type Exploded View 07 106 Hydraulic Pump Hydraulic Pump 21 0 Aluminum 07 107 Hydraulic Pump 5 07 107 Hydraulic Pump Replacement of Seals 07 109 Hydraulic Pump Assembly 9 07 110 TorqFlow Transmission TorqFlow Transmission w Torque 07 111 TorqFlow Transmission Main 07 112 TorqFlow Transmission Disassembly Exploded 07 113 TorqFlow Transmission Hydraulic Circuit 07 117 TorqFlow Transmission Explanation of Operation of Hydraulic 07 118 TorqFlow Transmission Dimensional Diagram 07 122 TorqFlow Transmission Torque Converter TorqFlow Transmission Torque Converter 07 123 TorqFlow Transmission Oil Pump TorqFlow Transmission Oil 07 124 Oil Pump Disassembly 07 124 Oil Pump Assemblys asas VER
82. rom the released position before interlocking with the inching pedal Link Ratios Inching Pedal Brake Pedal 04 0017 OPERATING EFFORT 66 1 ibJf 240N 30kgf WHEN SHOE CLEARANCE IS 0 03 in 0 74mm S OPERATING EFFORT 66 116 7 2403 3090 WHEN SHOE CLEARANCE IS 0 03 in 0 74mm 04 12 04 TESTING ADJUSTING AND MEASURING CHECKING TORQFLOW CLUTCH ACTUATION PRESSURE When carrying out the following tests and checks apply the parking brake securely and block the lift truck wheels Watch out for sudden lift truck movement Place the FORWARD REVERSE lever at the FORWARD or REVERSE position Fully depress the accelerator pedal and measure the pressure at the Clutch Pressure Sensing Port in the top of the transmission See Figure 04 0019 TOP VIEW INCHING SHIFT Units psi Mpa kgf cm I rpm 91 4 156 6 0 63 1 08 6 5 11 0 1 000 Clutch Actuation Pressure Pedal Released 127 6 177 0 88 1 22 9 0 12 5 2 000 2n MAIN PRESS CLUTCH PRESSURE NOTE The pressures displayed in the table above refer to pressures measured with ORT SENSING PORT the Inching Pedal released When the ELECTRIC SHIFT TYPE 5 16 UNF24 pedal is depressed the pressures should all drop to zero CHECKING TORQUE CONVERTER STALL SPEED NOTE This operation raises the transmission fluid temperature rapi
83. rsonnel or products or buildings in the surrounding area Install backup warning devices backup buzzer rotating backup lamp etc or backup confirmation devices rear view mirror etc to warn personnel in the surrounding area and to confirm that the area to the rear is safe Please contact your Komatsu Forklift distributor dealer for details of installing such optional safety and warning equipment LP GAS CYLINDER AREA THAT CAN BE SEEN WHEN CYLINDER IS INSTALLED i N j AREA THAT CAN BE SEEN WHEN CYLINDER IS NOT INSTALLED Ai AB80121D 01 10 01 SAFETY SECTION WARNING WHEN FRONT VIEW IS POOR If the view to the front is obstructed by the load turn to the rear and drive the forklift 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 AB801220 WARNING CHECK BEFORE STARTING gt When checking the lift truck before starting follow the procedure given in this Manual and do not start the lift truck until all the checks have been completed If anything abnormal is found inform the person in charge and carry out the necessary repairs WARNING LAMPS Check that the lamps light up correctly Replace any broken or inoperative bulbs WARNING KEEP HANDS FREE FROM OIL AND WATER Do not drive the lift truck if your hands are wet or covered with oil Your hands will slip on the work equi
84. rts and cause ES 3 serious injury or death 4 i Always wear a hard hat and safety boots amp Depending on the working conditions wear other safety EB equipment in addition to the hard hat and safety boots co f Qs 2 40055010 WARNING OVERHEAD GUARD LOAD BACKREST Do not use this lift truck unless it is equipped with the overhead guard and load backrest shipped with the lift truck from the factory by Komatsu Forklift 01 2 01 SAFETY SECTION WARNING UNAUTHORIZED MODIFICATION modification made without authorization from Komatsu Forklift can create hazards Before making any modification whatsoever consult your Komatsu Forklift distributor dealer Komatsu Forklift will not be responsible for any damage injury or death caused by any unautho rized modification Do not install any equipment or parts which obstruct or limit the operator s view WARNING EXHAUST GAS Do not leave the engine running where there is poor ventiiiation The engine exhaust gas contains carbon monoxide There is a danger that this will cause gas poisoning which may result in serious injury or death 0055060 WARNING FIRE EXTINGUISHER AND FIRST AID KIT abnormality in the lift truck occurs stop operation immediately park the lift truck in a safe place and safe condition then contact the person in charge Be sure that fire extinguishers have been provided and that you read the labels to
85. s Do not use any cloth which is soaked in fuel flammable solvent oil or grease There is danger that it may catch fire e 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 e 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 01 24 01 SAFETY SECTION d CAUTION USE SUITABLE TOOLS Always use tools that are suited for inspection and mainte nance t is extremely dangerous to use broken tools or tools AE E I designed for another purpose of A0055120 A WARNING REPLACE SAFETY CRITICAL PARTS PERIODICALLY Even if no abnormality is found always replace safety critical parts periodically As time passes these parts
86. s clear when charging battery Disconnect battery during servicing fter rati 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 oft power when leaving truck unattended Block wheels when parking on incline Warning for use of split rim Only pneumatic tires Decal Part No 3EB 96 25750 Defiate tire completely before removing rim nuts 3EB 96 26750 10451 01 37 01 SAFETY SECTION 8 Prevention of tip over Decal Parts No 3EB 96 25730 Tsp aver can ottor even when unloaded f e tisk injury or degli Es s Er 010449 9 Warning for handling LPG FLAMMABLE GAS Decal Part No 3EB 96 25780 TRAINED PERSONNEL ONLY Close fuel valve on tank when parking truck not store tank or park truck near heat or Ignition sources Avold sparks or open flame Foflow filling and operating instructions in operating manual When checking or filling tank No smoking Step engine Fill in designated area prevent damage to hese or fittings Make sure pin extends through hole in rim of tank Use tank with part number shown on bracket Frost or LPG odor indicates and repair immediately Flammable LP GAS Do not start engine MAN KFIO10448 10 NO JUMP START Decal Part No 09842 A0481 Located top center of starter solen
87. safe careful of electric wires and other obstacles inside and outside the building AX WARNING PRECAUTIONS WHEN TURNING When turning while traveling forward the counterweight will swing far out Keep an ample clearance from walls and other objects 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 AB801290 WARNING STOPPING plsTANcE When traveling downhill it requires a longer distance for the lift truck to stop then when traveling on level ground When traveling downhill reduce the speed and make sure that you have ample room at the bot tom of the slope to stop When traveling on wet surfaces it requires a longer distance to stop then when traveling on nor mal road surfaces Always have ample room to stop WARNING NO TOWING If there is any problem with the brakes or steering system of your lift truck do not use another lift truck to tow it There is danger that the lift truck may run away 01 14 01 SAFETY SECTION 3 LOADING OPERATIONS AX WARNING No OVERLOADING Do not load the lift truck over the capacity set forth in the load capacity chart If the rear wheels come off the ground because of overloading the lift truck cannot travel or turn There is also danger
88. tering areas where trucks are being operated Ensure that there is adequate lighting to enable operations to be carried out safely WARNING CLEAN OPERATOR S COMPARTMENT Keep the operator s compartment clean and tidy Be sure to clean up all oil or mud If the opera tors hand or 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 or obstruct the control levers or pedals Always keep them in the tool box when not being used WARNING SAFE OPERATING PLAN 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 When carrying out operations on roads put up fences around the working area and carry out oper ations in accordance with instructions from the signal person WARNING REDUCE LOAD FOR LIFT TRUCKS WITH ATTACHMENT The permissible load for any lift trucks equipped with an attachment is lower than the permissible load for the standard lift truck Reason 1 The permissible load must be reduced by an amount equivalent to the weight of the attach ment itself 2 Because of the thickness of the attachment the load center moves forward Always observe the permissible load table strictly this table is stuck to the lift truck or the attach ment Never exceed the permissible load
89. that it may tip Always check the load capacity chart to confirm the loading capacity AB801190 WARNING DON T GO UNDER FORKS Never allow anyone to go under the load engaging means or load when it is raised The area under the forks is a danger area If the forks come down the person under the forks may be crushed or seriously injured or killed Never allow anyone to go under the load engaging means or load even if it is elevated or sticked It may fall down suddenly at any moment AD817970A A WARNING PO NOT LIFT PEOPLE ON FORKS Do not use the forks to lift people If the person falls from the forks he she may be seriously injured AD817980A 01 15 01 SAFETY SECTION WARNING BE CAREFUL CAUGHT FALL Never put your hands or feet into the mast structure There is dan ger that you will get caught in moving parts and be seriously injured AB801320 Donotuse the mast as a ladder If you slip there is danger that you will fall AB801330 WARNING OPERATE FROM OPERATOR S COMPARTMENT Always operate the mast and forks from the operator s compartment WARNING No UNSTABLE Loans 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
90. the time of your periodic maintenance therefore even if no wear is apparent always replace the items with new parts within the scheduled period Consumable parts must certainly be replaced sooner than the recommended intervals if wear damage or malfunction occurs earlier An effective and timely inspection and maintenance program will reveal such conditions before more serious damage occurs to the truck Period of Part Name Replacement z 9 Brake Master Cylinderand Wheel Cylinder caps Every 1 year and dust seals Brake hoses and tubes Every 1to 2 years Brake reservoir tank and tube Every 2 to 4 years Power steering hose Every 2 years Stop lamp switch Oil pressure type Every 2 years Fuel hoses Every 2 to 4 years Rubber parts of power steering assembly Every 2 years Lift chain s Every 2 to 4 years nN OD oO BI wl hd Load handling hoses Every 1 to 2 years 02 8 02 GENERAL INFORMATION amp SPECIFICATIONS STANDARD TIGHTENING TORQUE FOR PIPE JOINTS Elbows nipples and unions Width across Flats mm Width D mm Tightening Torque ft lbs 21 7 28 9 57 9 75 9 86 8 119 3 Nm kgfm 29 4 39 2 3 4 78 5 103 8 10 5 117 7 161 8 12 16 5 Size in 3 4 16 UNF 7 8 14 UNF Tightening Torque Nm 50 6 54 3 57 9 61 4 _ 68 6 73 6 7 7 5 78 5 83 3 8 8 5 kgfm High pressure rubber hoses pipes
91. ttery caps and terminals 3 Check the battery case for cracking damage or stains caused by leakage If you notice white crusty deposits around the base of the battery or on the battery tray there may be a ieakage problem 4 Using a Specific Gravity Meter and a thermometer measure the specific gravity and temperature of the electrolyte Write them down 5 Insert the values obtained in Step 4 into the formula shown below and calculate 520 Soo St 0 0007 t 20 59 Specific gravity at 68 20 C St Specific gravity measured value at t C actual measured temperature t Temperature of battery electrolyte as measured in the battery Normal value 520 1 27 1 29 If specific gravity is below 1 225 check terminals cables and charina em and repair as needed RELATIONSHIP BE TWEENSPEGIFIC GRAVITY AND ELECTROLYTE TEMPERATURE 04 14 04 TESTING ADJUSTING AND MEASURING CHECKING TIRES AND ADJUSTING PNEUMATIC TIRE PRESSURE Check pneumatic tire pressure before each daily forklift operation using an accurate tire pressure gauge Add or remove air from the tires as required to meet the specified pressure Front Tires Rear Tire s 98 6 psi 0 68MPa 7 0 kgf cm 98 6 psi 0 68MPa 7 0 kgf cm Check all tires for cuts and cracks in tread and sidewalls abnormal wear uneven or stepped wear metal pieces and CHECK TREAD DEPTH MIDWAY debris stuck in tires Replace severely damaged or worn tires
92. ublic 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 WARNING SAFETY EQUIPMENT The overhead guard is installed to protect the operator from falling objects It is designed to with stand 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 WARNING TRE FENDERS INCORRECT FENDERS The tire fenders prevent objects from being thrown up by the tires When changing from a single tire to a double tire arrangement on your forklift truck always extend the tire fenders to cover the additional tires If the fenders are not extended small stones and other objects will be thrown up and may injure the operator or other people in the surrounding area CORRECT FENDERS 01 4 01 SAFETY SECTION WARNING SAFE WORKING AREA Always work on level surfaces and wipe up ail 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 en
93. ug gap to 031 035 in 0 8 0 9 mm PLUG GAP Spark Plugs Replace every 18 months 3 600 hours Part Number 22401 FU412 04 0001 GAP 0 31 0 35 in 0 8 04 0022 ADJUSTING VALVE CLEARANCE 1 Remove the cylinder head valve cover 0 2 Rotate the crankshaft aligning the timing mark white dot FRONT COVER on the crankshaft pulley with the raised boss on the front RAISED BOSS cover as shown at right 3 Check that No 1 cylinder or No 4 cylinder is at piston compression Top Dead Center TDC Both intake and RCE exhaust valves for that cylinder should be fully closed at TDC TIMING MARK 4 Adjust valve clearance starting with the valves for the WHITE cylinder at TDC NOTE When No 1 cylinder is at TDC Adjust the valve clearance of the valves marked X ENGINE FIRING ORDER 1 3 4 2 Cylinder No Exhaust valve Intake valve 04 TESTING ADJUSTING AND MEASURING in the table above Then rotate the crankshaft revolution clockwise facing the pulley and adjust the clearance on the valves marked O in the table When No 4 cylinder is at TDC Adjust the valve clearance of the valves marked O in the table above Then rotate the crankshaft one revolution clockwise and adjust the valves marked with an 5 Loosen the locknut 1 of adjustment screw 2 Then adjust the clearance between valve stem 3 and rocker arm 4
94. ully open position Depress the throttle accelerator pedal to the fully open position 8 Crank the engine over and read the gauge NOTE Keep the engine cranking rpm at about 250 This is normal cranking rpm at full charge Complete the compression measurement process as quickly as possible COMPRESSION Ord or Standard K21 178 psi 1 230 kPa 250 rpm 9 The compression pressure differences between cylinders must not exceed 14 2 psi 250 rpm If any cylinder produces an extremely low compression pressure reading put a small amount of oil into the cylinder through the spark plug hole and remeasure e If the pressure rises after adding oil to the cylinder the piston ring is worn or damaged ifthe pressure remains unchanged after adding oil the valve is stuck or is not sealing correctly If low compression pressure is observed in two adjacent cylinders and the pressure is not restored after adding oil to those cylinders the head gasket is leaking In this case oil and water may enter into the combustion chamber f the engine RPM is not in the specified range 250 rpm check the battery specific gravity MEASURING HYDRAULIC DRIFT ON LIFT amp TILT CYLINDERS PRECAUTIONS WHEN MEASURING DRIFT When measuring drift never allow anyone to go under the load Do not put your feet on the mast stays or dashboard or climb up when measuring the hydraulic drift of the lift
95. und using a circuit tester Terminal Signal name At Idle At approx 2 000 rpm MEME Asseniorpeiipemiewwiguad 83 Accelerator pedal position sensor 2 ground Approx OV When the accelerator pedal is depressed slowly from the fully closed position the voltage must increase in proportion to the opening of the throttle Ignition switch ON engine stopped tona ame Ignition switch ON engine stopped 9 Accelerator pedal is fully released Accelerator pedal position sensor 1 signal Approx 0 6V Accelerator pedal position sensor 2 signal Approx 0 3V 3 Circuit Diagram Ignition switch ON engine stopped Accelerator pedal is fully depressed Approx 4 2V Approx 2V Terminal Power supply 6 Accelerator peda position sensor 1 e Signal 1 Accelerator peda position sensor 2 1 Accelerator work unit Power supply 04 8 04 TESTING ADJUSTING AND MEASURING 4 Component Parts inspection ACCELERATOR PEDAL POSITION SENSORS APPS 1 2 ACCELERATOR WORK UNIT Check voltage between ECM terminal 106 98 and ground CONNECT 7 A APPS 1 terminal 106 At idle About 0 60v APPS 1 term 106 IGN ON engine OFF wi pedal depressed About 0 60v 106 98 APPS 1 term 106 IGN ON engine OFF wi pedal released About 4 20v APPS 1 term 106 At 2 000 rpm About 0 65v APPS 2 term 98 At idle About 0 30v APPS 2 term 98
96. using a straight bladed screwdriver on the adjustment screw When properly adjusted the feeler gauge should have a snug sliding fit but should not grab or bind the gauge 6 After adjusting the clearance to specification tighten the locknut while holding the adjusting screw in position to lock down the adjustment screw See Fig 04 0003 Recheck the clearance 7 Reinstall the two valve cover bolts and washers and tighten to 10 11 6 ft Ibs 13 7 15 7 Nm The valve clearance must be finally adjusted when the engine is fully warmed up Adjusting the valves in a cold state after assembly will make final adjustments easier ADJUSTMENT OF FAN BELT Inspect and adjust fan accessory belt with engine stopped 1 Visually check for damage cracks wear and oil smears 2 Ensure that the belt is not bottoming out in the pulley 3 Check belt deflection by pressing on the belt at the center between the pulleys FAN BELT DEFLECTION 22 Ibf 98N 10 kg 43 51 in 11 13 mm Pressing Force Fan Belt Deflection 04 3 04 TESTING ADJUSTING AND MEASURING MEASURING ENGINE CYLINDER COMPRESSION 1 Start the engine and fully warm it up until the coolant water temperature reaches 167 185 F 75 85 Stop the engine Release the fuel pressure Remove the spark plugs Screw the end of the compression gauge into the cylinder spark plug hole to be measured Set the throttle valve to the f
97. y 2 000 hours Adjust valve clearance Every 2 000 hours Check fuel injection nozzles replace if necessary Every 2 000 hours 15 Keep records to show proof of compliance with the required maintenance practices and intervals As the heavy duty off road engine owner you should however be aware that KFI 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 e Your engine is designed to operate on commercial diesel fuel only Use of any other fuel 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 completed by the dealer as expeditiously as possible e If you have any questions regarding your warranty rights and responsibilities you should contact the authorized KFI dealer LIMITATIONS KFI is not responsible for resultant damages to an emission related part or component resulting from Any application or installation KFI deems improper as explained in the Instruction Manual Attachments accessory items or parts not authorized for use by KFI Improper off road engine maintenance repair or abuse Owner s unreasonable
98. 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 Komatsu s Prod uct 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 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 KFI warrants the following emission related parts Oxygen sensor PCV valve Wale tslemperature Gasoline injector sensor LPG injector LPG pressure sensor LPG solenoid LPG switching module Mass air flow sensor Throttle chamber Ignition coil Crankshaft position sensor Camshaft position sensor Distributor Spark plugs EMISSION CONTROL WARRANTY 36 MONTHS OR 4 000 HOURS FOR POWER TRAIN PARTS Intake manifold Exhaust manifold EMISSION CONTROL WARRANTY 60 MO

SERVICE MANUAL - Komatsu Forklift USA, Inc. v3.1

Contents

Download Pdf Manuals

Related Search

Related Contents