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1. carry out any maintenance work on the truck unless you have the correct training and knowledge to do so Keep the area where you carry out service clean Oil or water makes the floor slippery Never wear loose objects or jewelry when working on the truck 66 Maintenance A WARNING Short circuiting burns When working with the truck s electrical system short circuiting burns can occur if a metal object comes into contact with live electrical connections Remove watches rings or other types of metal jewelry e Always switch OFF the trucks power supply before opening the covers on the drive unit or electrical systems e Always disconnect the battery by pulling out the battery connector when carrying out maintenance work on the truck unless otherwise stated in this publication or the Service Manual e Relieve the system pressure slowly before starting work on the truck s hydraulic systems e Use paper or a rigid sheet of cardboard when checking for oil leakage Never use your hand e Bear in mind that the oil in the transmission or the hydraulic system can be hot AX WARNING Risk of burns Hot transmission and hydraulic oil Let the truck cool before changing the oil e Only fill the hydraulic system with new clean oil Oil should meet KOMATSU cleanliness specification 12 00 002 Contact your KOMATSU representative for assistance or 67 Maintenance more information A WARNING The hydraulic syst
2. e Carry out the daily service at the start of the day or shift before the truck is used The daily service is a simple safety and function control as shown in the chart e You need no tools to carry out the service checks e If you fail to carry out the daily service the safety and reliability of the truck can be affected A WARNING Never neglect the daily service and safety checks Serious accidents can occur Always report any faults or damage to your supervisor without delay Never use a truck that does not function properly 62 Daily service safety checks Daily service safety checks A WARNING DO NOT continue to operate the truck when it is not functioning properly 63 Daily service safety checks toe Check points Action Hydraulic system Check for oil leakage hoses and floor Lifting device Check for damage noise function Battery Check acid level charge and condition See Battery Maintenance section 4 Battery cables and Check for breakage cutting or connections damage 5 Chassis Check for damage remove dirt and debris 6 Covers guards Check for damage ensure placement 7 Drive unit Inspect abnormal noises and leakage 8 Wheels Check for damage remove oil metal chips and debris 9 Hand brake Check its function 10 Direction speed Check its function control 11 Hydraulic function Check its function 12 Reverser switch Check its f
3. should be rinsed OFF immediately Wash thoroughly with soap and water If the fluid has come into contact with the eyes wash the eyes immediately using an eye shower Contact a doctor ALWAYS WEAR PROTECTIVE GLASSES AND PROTECTIVE GLOVES WHEN CHECKING THE BATTERY Each week e Remove all cell caps NOTE This does not apply to batteries with level caps or central filling e Check the fluid level in the cells and note any cells that consume more than a normal amount of fluid e Fill using distilled water The fluid level should be 1 4 in 10 15 mm above the cell plates e Refit all of the cell caps e Rinse off and dry the battery 60 Battery Each month e Measure the temperature in one of the center cells immediately after charging The temperature should not exceed 122 F 50 C e Measure the density of the battery fluid using an acid tester Hold the acid tester absolutely vertical and extract sufficient fluid so that the hydrometer float moves freely e Adjust specific gravity with temperatures based on the chart below Temperature Gravity 77 F 25 2 C 1 280 A WARNING Battery manufactories maintenance and charging procedures must be followed Battery acid is very corrosive and must be immediately cleaned up after spillage 61 Daily service safety checks ee Daily service safety checks e The operator is responsible for the daily service and care of the truck
4. 2 Hydraulic system C O B 3 Travel brake 4 Drive gear C O C 5 Hinges L D 6 Steering bearings L A 7 Gear ring L A L Lubrication C Check O Oil change 76 Maintenance NEE Ee EE MMII O Approved Oils and Grease Specification Pos Lubricant Above Below Below Application 5F 15 C 5 F 15 C 10 F 23 C area Tex Ref C amp Tex Ref C amp Tex Ref C amp Bearings and A Grease d C 880 C 880 C 880 bushings B Hydraulic oil Sunoco TH Sunoco TH Texaco 15 Piyaraulig system C PN SAE 80W 90 SAE75W SAE75W Gears D Motor oil SAE 40 SAE5W 20 SAE5W 20 Pivot Oil should meet KOMATSU cleanliness specification 12 00 002 Contact your KOMATSU representative for assistance or for more information Lubrication chart location points 77 Transporting and storing the truck nC EE H Transporting and storing the truck Truck s standard dimensions and weight NOTE The truck s dimensions and weight can vary with different accessories Truck s dimensions and weight Truck data MWL22 Height 50 4 in 1280 mm Width 30 0 in 762 mm Length this length is with 48 in 77 6 in 1219 2 mm forks 1971 mm Minimum battery weight 350 Ib 158 9 kg Service weight without battery 850 Ib this weight is with 48 in 1219 2 385 9 kg mm forks 78 Transporting and storing the truck Lifting the truck e Lift the truck from the marke
5. Battery Battery Type of battery e Check that the battery used in this truck is the correct voltage as shown on the truck s data plate Use a traction battery having a weight within the minimum maximum values stated on the data plate Changing the battery e Only replace the battery with a battery of the same weight as the original The battery weight affects the truck s stability and its braking capacity Information on the lowest permitted battery weight can be found on the truck s data plate A WARNING Risk of moving the center of gravity A battery weight that is too low gives impaired stability and braking capacity The battery weight must be in accordance with the information on the truck s data plate When changing the battery proceed as follows e Park truck at battery removal station e Turn OFF key and remove e Push the emergency disconnect button to the OFF position to stop hourmeter from running e Disconnect the battery connector from the battery e Remove battery stops 55 Battery e Slide out the discharged old battery then slide in the new battery e Connect battery and truck connectors e Connect the battery connector and truck connector Risk of short circuiting WARNIN A g The cables can be damaged and cause a short circuit Ensure the battery cables are not crushed e Push the emergency disconnect button to the ON position e Install battery stops If the truck
6. d lifting points when lifting using a lifting device A WARNING Risk of overturning The truck can overturn if lifted from the wrong lifting points Always lift the truck from the marked lifting points A WARNING Risk of overturning The truck can overturn if lifted incorrectly Always lift the truck secured to and with the center of gravity between the lifting truck s forks 79 Transporting and storing the truck Towing and transporting a disabled truck AM WARNING DO NOT tow a disabled truck It is not recommended to tow a disabled lift truck Transporting and storing the truck Storing the truck Take the following action if the truck is not used for one week or more Battery e Recharge the battery fully and carry out usual battery maintenance e Maintenance charge the battery every 3rd month and check the fluid level Hydraulic system e Change the oil in the hydraulic system when stored for periods longer then 1 year See the oil specification in the section Maintenance and lubrication chart Drive unit e Block up the truck s drive section to take the load off the drive wheel and load wheels when storing for periods longer than one week Starting after a period of disuse e Before the truck is put into operation after a period of disuse it should undergo a function and safety check as stated in the section Daily service safety checks e When stored for a period greater then 3 months carry ou
7. em can be damaged If oil is contaminated hydraulic components can be damaged Always use new and clean oil in the hydraulic system e Store and dispose of changed oil in accordance with local regulations e Do not dump solvents which are used for cleaning washing into drains that are not intended for this purpose Follow the local regulations that apply for disposal e When working underneath the truck support the truck on trestle blocks A WARNING Risk of crushing A badly supported truck can fall Never work under a truck that is not supported on trestle blocks and secured by a lifting device 68 Maintenance EE EE EE EE EE _______ ______ ____ __z__ Maintenance that can be carried out by driver The Daily service Safety checks as set out in the check list Maintenance points with intervals 1 day 1 week and 1 month as set out in the Maintenance chart may be carried out by the driver without more knowledge than that provided by the Operator s Manual Other maintenance points as set out in the Maintenance chart may only be carried out by personnel who have completed maintenance training for this type of truck Maintenance that may be carried out by trained maintenance personnel All maintenance points as set out in the Maintenance chart If you are uncertain regarding working procedures consult the Service Manual for the truck Other service and repair work e In addition to the maintenance poin
8. ents ventilation above the battery e Turn key switch to the OFF position e Remove the battery connector from the truck s connector e Make sure the battery charger is switched OFF e Connect the battery connector to charger connector e Never connect charger connector to truck connector e Switch ON the battery charger A WARNING During the charging process oxygen and hydrogen gases are always formed in the battery Short circuits open flames and sparks in the vicinity of the battery can cause an EXPLOSION Always switch OFF the charger current BEFORE removing the battery connector Provide good ventilation especially if the battery is recharged in a confined area During charging e After approximately ten minutes make sure that the ammeter indicates a normal reading and that the control lamp is ON 58 Battery After charging e Make sure that the ammeter indicates an insignificant or no reading and that maintenance charge lamp is ON if equipped e Switch OFF the charger e Disconnect the battery connector from charger connector Risk of short circuiting CA GAUTION The terminals can otherwise be damaged inside and result in a subsequent short circuit Do not pull the cables to disconnect from the charger 59 Battery Battery maintenance Carry out battery maintenance after recharging Corrosive acid WARNING A The battery fluid contains sulfuric acid Fluid spilled on skin
9. ical components e Blow electric motors dry using compressed air AX WARNING Compressed air used for cleaning MUST be reduced to less than 30 psi and then only with effective chip guarding and personal protective equipment e Clean the electrical panels electronic boards contacts connector solenoid valves etc using a damp cloth anda cleaning agent e Do not spray or pressure wash in the compartment NOTE Risk of short circuiting Electrical components can be damaged Do not break the warranty seal on the electronic board 71 Maintenance f Maintenance chart PM Interval A 5 Hours or 1 Day E 500 Hours or 6 Months B 20 Hours or 1 Week F 1000 Hours or 12 Months C 80 Hours or 1 Month G 3000 Hours or 36 Months D 250 Hours or 3 Months No Action A B C D E F G 1 0 Chassis 1 1 Check that the truck s data plate is X legible 1 2 Check the cover screws X 1 3 Check door lock X 1 4 Check wear on battery stop X 1 5 Check for damage and crack formation X 1 6 Check fork frame mounting X 2 0 Motors 2 1 Check for loose connections X 2 2 Clean motor X 2 3 Check mounting bolts X 2 4 Check for abnormal bearing noise X 2 5 Check brush wear X 3 0 Drive unit 3 1 Check for leakage X 3 2 Check oil level X 3 3 Check for noises X 3 4 Check the mounting on support X 4 0 Wheels 4 1 Remove s
10. ons for X leakage 10 2 Check hoses for wear and damage X 10 3 Check oil tank for cracks leaks and X mounting 10 4 Check oil level X 10 5 Change oil X 11 0 Cylinder 11 1 Check for leakage X 11 2 Check the mountings X 12 0 Lift devices 12 1 Check for damage and cracks X 12 2 Check for play on the pull rods X 12 3 Check the electrical limit switch X function 12 4 Check for wear to the forks and other X lifting devices 12 5 Lube all grease fittings X 13 0 Controls 13 1 Check handle mounting 13 2 Check the handle brake lever switches 13 3 Check travel direction speed control 13 4 Check horn button function 13 5 Check hydraulic button functions x IE IE IE x lt 13 6 Check the handle control switches 14 0 Gauge 14 1 Check dash display X 15 0 Brake Levers 15 2 Check handle brake levers X 16 0 Key switch toggle switch 16 1 Check switch function X 74 Maintenance R No Action AIBICIDIEIFJG 17 0 Emergency stop switch 17 1 Check the emergency stop switch X as K gt 19 Maintenance chart 75 Maintenance Lubrication chart Pos l Interval Running hours No Service point Lubricant 500h 1000h 3000h 1 Wheel bearings L A
11. should tip over the battery can fall out if the battery stops have not been installed Make sure the battery stops have been installed Falling battery WARNING A When charging the battery it can be dropped Always lift battery using an approved lifting device and use a battery yoke intended for the battery 56 Battery Charging the battery D D General prohibition When recharging the battery it is absolutely forbidden to smoke or use an open flame Use an automatic charger intended for recharging traction batteries The charger must have an automatic maintenance charging feature for a certain period after the main charging period has been completed This eliminates the risk of over charging the battery and the need to monitor the charging procedure is reduced to a minimum The charger shall have a minimum charging current of Battery Ah Charger A 300 480 50 70 480 730 80 110 730 900 130 150 Corrosive acid WARNIN A G The battery fluid contains sulfuric acid Fluid spilled on skin should be rinsed OFF immediately Wash thoroughly with soap and water If the fluid has come into contact with the eyes wash the eyes immediately using an eye shower Contact a doctor AND PROTECTIVE GLOVES WHEN CHECKING THE BATTERY 57 ALWAYS WEAR PROTECTIVE GLASSES Battery EER EE EE EE EE Pre charging e Park the truck in the assigned charging area e Ensure nothing prev
12. t preventive maintenance as stated in the instructions 500 hours interval 81 Recyling Discarding Recycling Discarding ds Batteries are hazardous to the environment and should be returned to the manufacturer for recycling Discarding the battery When the working life of the battery in the truck is at an end change to a new battery or if the entire truck is to be scrapped special regard to environmental risks shall be taken when disposing recycling batteries Spent batteries shall be returned sent to the manufacturer of the battery or its representatives see the label on the battery for disposal recycling You can also return batteries to your local KOMATSU representative who will then return the battery to the manufacturer Scrapping the truck The truck consists of parts that contain recyclable metals and plastics Below is a list of those materials used in the truck s sub systems Chassis Chassis Steel Drive unit Steel and cast material Bushings lron copper Finish Epoxy polyester Wheels Polyurethane 82 Recyling Discarding Hydraulic system Oil tank Steel Pump unit Steel and aluminium Hoses Rubber and steel Cylinders Steel Electrical system Cables Copper cores with PVC sheaths Electronic board Reinforced fiberglass circuit board laminate Motors Steel and copper 83
13. tring amp debris X 4 2 Check all wheels for wear X 4 3 Check that all wheels rotate and axles X are fitted correctly 4 4 Check all wheels for loose screws X 72 Maintenance No Action A B C D E F G 4 5 Grease load wheel bearings X 4 6 Grease caster and caster wheels X 4 7 Dismantle and lubricate all wheel X bearings 5 0 Brake 5 1 Clean X 5 2 Check shoes and discs for wear X 5 3 Check correct clearance brake X 5 4 Check brake operation X 6 0 Electrical panel 6 1 Clean and check the mounting X 6 2 Tighten cable connections X 6 3 Check contactor tips X 6 4 Check the contactor tips for free X movements 6 5 Check all cable insulation for damage X 7 0 Electronic card 7 1 Check for connections in harness X connectors 8 0 Electronic control system 8 1 Check key switch X 8 2 Check brake switch X 8 3 Check control wiring harness for X proper routing 9 0 Battery 9 1 Check electrolyte level 1 2 5 8 in X 10 15 mm above cell plate 9 2 Check the connections on battery X truck and charger 9 3 Check all cells and pole guards X 9 4 Check the fluid density and X temperature 9 5 Check power cables are not cut or X frayed 73 Maintenance a No Action A B C D E F G 10 0 Hydraulic system 10 1 Check hoses and connecti
14. ts in the Maintenance chart all service and repair work should be carried out by personnel with special training for this type of truck 69 Maintenance Cleaning and washing General Cleaning and washing the truck is important to ensure the truck will operate safely and reliably e Carry out general cleaning and washing weekly NOTE Risk of short circuiting The electrical system can be damaged Disconnect the battery before washing by pulling out the battery connector Do not spray water directly into the electrical compartments of the truck External cleaning e Remove debris etc from the wheels daily e Use a degreasing agent diluted to a suitable concentration e Rinse off loose grime using warm water NOTE Mechanical components can be damaged After washing the truck should be lubricated as set out in the chapter Maintenance and Lubrication chart Cleaning the motor compartment e Cover the electric motors electrical compartments connectors and valves before washing 70 Maintenance uaaal e Clean carefully using the minimum of water and detergent Never pressure wash or steam clean in the compartments NOTE Risk of short circuiting The electrical system can be damaged Electrical components must not be cleaned with a high pressure washing unit e Clean the motor compartment using a degreasing agent diluted to a suitable concentration e Rinse off loose grime using warm water Electr
15. unction 13 Horn Check its function 14 Running time Inform your supervisor if your truck is ready for a schedule maintenance check See Maintenance section 15 Emergency stop Check its function switch 16 Key switch toggle Check its function switch 17 High speed switch Check its function If any of the functions fail to operate properly inform your supervisor or maintenance personnel to have the truck repaired 64 Daily service safety checks EE EE EE EE EE EE EE EE EER _ Special eduipment Your truck may have been fitted with optional or special equipment that requires a routine check To ensure safe operation consult with your supervisor and your KOMATSU representative about routine checks 65 Maintenance ee If Maintenance General information Under normal conditions ensure the truck is given a regular maintenance service after every 500 driving hours The truck s safety efficiency and service life is dependent on the service and maintenance it is given Only use KOMATSU approved spare parts when service and repair work are carried out KOMATSU recommends that you contact your KOMATSU representative to set up a service and maintenance agreement to ensure your truck s operating economy and safety Safety regulations with maintenance work Only personnel that have been trained in the service and repair of this type of truck are authorized to carry out service and repair work Do not

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