Technical Service Data - Komatsu Forklift USA, Inc. v3.1
Contents
1. 7200 j i Oe 3500 Komatsu Forklift U S A Inc Master Service Manual 2000 08 04 75 F code PS Section C code P2 0 Service Schedule Version no 002 76 T code 395 396 397 398 399 2 Planned Maintenance Procedures This section describes how to perform the services listed in the Schedule of Planned Maintenance Operations As with the Schedule this section is subdivided into service intervals 2 1 Services Performed Daily or Every 8 Operating Hours The daily inspection is to be made by the operator prior to each operating shift It is the operator s responsibility to report any defects to the proper authorities The truck should not be operated until it has been inspected and repaired by a trained qualified and authorized technician The operator is ultimately responsible for the safe operation of reach truck 2 1 1 Battery Discharge Indicator with slow down The battery discharge indicator indicates the current charge status of truck s battery See Battery Discharge Indicator Parameter Adjustment on page 384 1 Full charge battery 1 2 Half charged battery 0 Discharged battery The battery discharge indicator has an integrated cut out function that slows down truck s lift function when a predetermined charge level has been reached This prevents overloading the battery and increases the operating economy of truck When the battery has reache2. Item Work Required Interval in Hours Interval in Days Weeks Months Chassis ns Check truck identification plate for legibility 0000 2 Check for damage and cracks 0000 3 Retighten truck body bolts to chassis 0000 4 Check cover screws _ Operator Controls 0640 1 Check travel direction speed TX selectors for operation operation 1700 zl Motors 1700 1 Check for arcing due to poor connections 1700 2 Check tightness on all connections 1700 4 Check torque of motor bolts 1700 5 Check for abnormal noise in motor bearings X 1700 3 Clean motor of dirt and dust x TI X 1700 6 Blow carbon copper and plastic MR particle accumulations from the motor using compressed air 1700 7 F Check electrical armature see page 138 1700 8 Check brushes see page 135 S 2550 Drive Gear m um 2550 1 Check for oil leakage X 3300 Brake hr 7 3300 1 Clean dust and debris X 3300 2 Check brake shoes for wear O Komatsu Forklift U S A Inc Master Service Manual 2000 08 04 71 F code Section C code PS P2 0 Service Schedule Version no T code 002 395 396 397 398 399 Item Work Required Interval in Hours Interval in
3. 3 Sudden temperature changes continuous in door outdoor movement that is refrigeration plant etc e Routine inspection every 480 hours 4 months 80 Master Service Manual 2000 08 04 KOMATSU Komatsu Forklift U S A Inc F code Section C code PS P2 0 Service Schedule Version no T code 002 395 396 397 398 399 2 4 Services Performed Annually or Every 1440 Operating Hours The annual planned maintenance service will take a longer period of time to complete than does the monthly service This would be a good time to arrange other repairs that have been noted on the monthly service 2 4 1 Inspection All services and inspections listed for the daily and monthly inspection should be performed at this time The inspection procedure should be more thorough and minor deficiencies should be corrected 2 4 2 Transmission The transmission fluid should be drained once a year The drain port is located on the lower portion of the side cover opposite the drive tire Remove bolt to drain transmission fluid Flush transmission case Pour a clean solution into the fill port accessed from the battery compartment With the drive tire off the floor allow solution to run out of drain port while transmission is running Stop flushing when the solution runs clean Allow the solution to drain well before replacing drain plug bolt Replace drain plug bolt Refill transmission with proper clean oil before operating truck 2 4 3
4. 30A S N 27135001 UP part number 25275 13 30A S N 27091000 27135000 part number 122308 300 16 4 x 38 8 x 32 0 416 x 985 x 812 21 0 x 38 8 x 32 0 533 x 985 x 812 16 4 x 38 8 x 32 0 416 x 985 x 812 21 0 x 38 8 x 32 0 533 x 985 x 812 36 V 1240 36 V 1240 16 5 inch 2000 ib 907 mm 2300 Ib 1043 mm 16 5 inch 2000 Ib 907 mm 2300 Ib 1043 mm Any 16 5 inch 21 0 inch 21 0 inch 2000 Ib 907 mm 2600 Ib 1179 mm 2400 Ib 1089 mm 2300 Ib 1043 mm 2900 Ib 1315 mm 2900 Ib 1315 mm DRIVING SPEEDS 24 V 6 0 mph Without load 36 V 6 5 mph 36 V 6 5 mph 36 V 6 5 mph 24 V 5 5 mph With rated load 36 V 6 0 mph 36 V 6 0 mph 36 V 6 0 mph Komatsu Forklift U S A Inc Master Service Manual 2001 09 18 59 F code Section C code PS M2 0 Technical Service Data Version no T code 003 395 396 397 398 399 MODEL FR18S 2A FR15DR 2A FR23S 2A AE L LIFTING LOWERING TIME a 24 V 60 fpm Lift without load 36 V 80 fpm 36 V 94 fpm 36 V 94 fpm T 24 V 40 fpm Lift with rated load 36 V 60 fpm 36 V 60 fpm 36 V 60 fpm Lower without load T w electrical valve mn 30 Tpm ao pm Lower with rated load 80 fom 95 fom 95 fom electrical valve l CURRENT READINGS i Driving without 24 V 140 amp isad 36 V 140 amp 36 V 150 amp 36 V 15
5. 72 Master Service Manual 2000 08 04 F code Section C code PS P2 0 Version no T code 002 395 396 397 398 399 Item Work Required Interval in Hours 8 30 120 240 360 720 1440 4320 Interval in Days Weeks Months a d 1w im 2m 3m 6m 12m 36m 5400 3 Check contactor tips et T 5400 4 Check contactor tips for free movements i 5400 5 Check all cable insulation for X damage 5400 6 Check power safety control X X system on the transistor regulator see page 363 5710 Electronic Card 5710 1 Check for connections in harness connectors 6000 Hydraulic System 6000 1 Check hoses and connections for leakage damage 6000 3 Check oil tank for cracks leaks and mounting 6000 4 Check correct oil level 6000 5 Change hydraulic oil 6000 6 Change hydraulic filter element 7100 Mast 7100 1 Check for damage and cracks 7100 2 Retighten mast mounting bolts 7100 3 Check clearance of rollers 7100 4 Check lateral play of inner section 7100 5 Check for wear on lift chains and chain rollers Check adjustment of lift chains 7100 6 7100 7 Clean amp lube lift chains 7100 8 Clean amp lube mast columns 7100 9 Lube chain sheaves _ 7210 Side Shifter 7210 1 Check torque of lower hook mounting
6. 5 gal 19 liters HYDRAULIC UNIT AMBIENT TEMPERATURES 5 gal 19 liters SCHO Standard and corrosion continuous operation see page 68 above 23 F 5 C Sunoco TH 58 Master Service Manual 2001 09 18 KOMATSU F code PS Section C code M2 0 Technical Service Data Version no 003 T code 395 396 397 398 399 MODEL FR18S 2A FR15DR 2A FR23S 2A Cold Storage see page 68 Continuous operation 5 F 15 C ATF intermittent operation 13 F 25 C Freezer continuous operation Texaco 15 To 31 F 35 C see page 70 a FUSES Drive motor circuit Pump motor circuit 425A 24V part number 305656 002 355A 36V part number 305656 001 Control circuit 15A FR18S 2A part number 122308 150 S N 27091000 27135000 10A part number 25275 12 S N 27135001 UP 250A fuses part number 305656 000 2 250A fuses F3 amp F4 part number 2 250A fuses F3 amp F4 part number 305656 000 305656 000 15A FR23S 2A part number 122308 150 on Sum part number 25275 12 10A part number 25275 12 S N 27135001 UP Steering circuit BATTERIES Dimension Wx L x H 14 4 x 38 8 x 32 0 355 x 985 x 812 inches mm 16 4 x 38 8 x 32 0 416 x 985 x 812 Capacity Max 24 V 1395 Amp hrs 36 V 1240 4 SONS 14 5 inch Weight Minimum 1600 Ib 726 mm 2300 Ib 1043 mm
7. Application Operation To 5 F 15 C Operation area Above Intermittent Operation To 31 F 23 F 5 C To 13 F 25 C 35 C E Mobiltemp Bearings and A Grease Mystik JT 6 l m JT 6 SHC 32 bushings B Hydraulic oil Sunoco TH ATF Texaco 15 nyaraulie 7 system m E SAB ee SAE 80 ATF Gears D Motor Oil 10 W40 amp 10W40 10 W 40 Chains Mast Molykote Molykote columns E Grease 200025 Molykote 200025 200025 Reach Sideshift Mast columns E Grease 49670 00 49670 00 49670 00 Reach Sideshit Refer to section 10000 of Parts Book for special lubricants 84 Master Service Manual 2000 08 04 Komatsu Forklift U S A Inc F code PS Section C code Oil and Grease Specifications Version no 001 2 Grease Location Points Master Service Manual 2000 08 04 T code 395 396 397 398 399 85 F code Section C code PS P4 0 Oil and Grease Specifications Version no T code 001 395 396 397 398 399 3 Mast Adjustment Points 86 Master Service Manual 2000 08 04
8. Battery At approximately 1500 hours contact an authorized battery dealer to determine the overall condition of the battery Determine if the battery needs to be washed down This can only be done by properly trained gualified and authorized technician Master Service Manual 2000 08 04 81 F code PS Section C code P2 0 Service Schedule Version no 002 82 T code 395 396 397 398 399 2 4 4 Hydraulic System The hydraulic system should be drained flushed and refilled and the pressure relief valve setting should be checked and adjusted This will maintain proper lubrication properties within the system To drain reservoir remove reservoir filter assembly Siphon oil from reservoir and purge oil out of hydraulic system Fill reservoir with proper clean oil Operate the raise and lower function several times to purge air from the system Check oil level Put rated truck capacity load on forks and adjust pressure relief valve if necessary so that truck will lift rated load 2 4 5 Brakes Follow procedures for brake removal before inspecting Remove brake assembly and inspect friction disc for wear The friction disc should be replaced once thickness is 0 25 inch 6 mm or less The armature and magnetic coil should be adjusted if machine will not meet stopping and holding specifications The air gap should not exceed 0 018 inch 0 46 mm and should remain within 0 003 inch 0 076 mm throughout the circumferen
9. 000 68 Section P1 0 T code C code 2 Lubricants 2 1 Standard For reach trucks in their standard design under continuous operation the recommended ambient temperature is 23 F 5 C These trucks should apply to the following guidelines Parked outside storage when not in use e Charging and maintenance work to be done outside storage 2 2 Corrosion In an environment where a damp wet or corrosive condition exits these trucks apply to the following guidelines e All hardware coated with LPS Rust Inhibitor during and or after assembly e Sealed components switches push pull cables sensors etc where appropriate e Grease fittings provided on axle and other pivot points e Plated pins shafts and linkage where required e All electrical connections coated with Dow Corning No 4 compound during assembly e Lift chains coated with Libriplate chain protectant e Components coated with LPS Cold Galvanize where appropriate e Components adjustable features bearing races etc coated with Antisieze where appropriate 2 3 Cold Storage To prevent moisture contamination in the electrical system trucks equipped with cold storage conditioning packages have electrical compound applied to all electrical connections during assembly For cold storage reach trucks with continuous operation the recommended ambient temperature is 5 F 15 C Cold storage trucks should apply to the following guidelines Master Servi
10. 398 399 MODEL FR18S 2A FR15DR 2A FR23S 2A WHEELS Drive wheel 13 5 x 5 5 x 10 0 13 5 x 5 5 x 10 0 13 5 x 5 5 x 10 0 inch mm 342 9 x 139 7x 254 342 9 x 139 7x 254 342 9 x 139 7x 254 Baa cpu c SE Drive wheel weight without 240 Mast 330 Mast 402 Mast load with battery 3175 Ib 1440 kg 3595 Ib 1630 kg 3875 1757 mm i ree Drive wheel weight with rated load 240 Mast 330 Mast 402 Mast and battery 2670 Ib 1211 mm 3184 Ib 1444 mm Torque drive tire lug nut 95 ft lb 129 Nem Load wheel 127 x 91 mm Load wheel weight with rated load 6975 lbs 3163807 g HYDRAULIC UN M at work pressure 24V Power 36 V 9 8Kw 13 1 hp Revolutions minute 2200 rpm 5 0 x 3 6 inches 127 x 91 mm 5 0 x 3 6 inches 127 x 91 mm IT 36 V 2550 rpm 36 V SSS HRS 2550 rpm Duty factor 20 on 5 min cycles e 20 on 5 min cycles 20 on 5 min cycles Minimum brush length 0 8 inch 20 mm 0 62 inch 16 mm 0 62 inch 16 mm Minimum commutator diameter 2 90 inches 74 mm 2 80 inches 71 mm 2 80 inches 71 mm Minimum brush spring tension 6 4 oz 180 g 40 oz 1120 9 40 oz 1120 g Pressure at rated load 2450 psi 2400 psi 2450 psi 24 V 13 cc Pump displacement 36 V 19 cc 36 V 27 cc 36 V 27 cc Tank volume 5 gal 19 liters
11. PS Contents Section P Version no T code 000 Contents Section P 1 Planned Maintenance P1 0 INTRODUCTION MAINTENANCE P2 0 SERVICE SCHEDULE P3 0 LUBRICATION CHART P4 0 OIL AND GREASE SPECIFICATIONS Master Service Manual 2000 08 04 63 KOMATSU Komatsu Forklift U S A Inc F code Section C code PS P1 0 Introduction Maintenance Version no T code 000 Introduction Maintenance The schedules of maintenance and lubrication given in this section of the Service Manual cover up to one year s operation of a truck These schedules are based on hourly usage and can be adapted to suit most normal one shift patterns The following hourly usage figures have been used when calculating the schedule Single shift 30 hours per week usage Double shift 60 hours per week usage Triple shift 90 hours per week usage The schedules are intended only as a guide not as a rigid structure Operators of trucks may wish to adapt them to local requirements but it is emphasized that the schedules represent minimum manufacturer requirements and all items should be included in a service program to ensure minimum downtime and a high safety status of the equipment e Use only spare parts approved by Komatsu Forklift e Always clean the equipment and carry out a full safety check after service Master Service Manual 2000 08 04 65 F code Section C code PS P1 0 Introduction Maintenance Version no T code 000 1 Jacking Truc
12. bolts Inspect hydraulic hoses Inspect cylinder and fittings 7210 2 7210 3 Komatsu Forklift U S A Inc Master Service Manual 2000 08 04 73 F code Section C code PS P2 0 Service Schedule Version no T code 002 395 396 397 398 399 Item Work Required Interval in Hours 18 Interval in Days Weeks Months 1d 7210 4 Grease lower hook where pads X slide 7210 5 Check thickness of upper pads 7210 6 Check thickness of lower pads 7210 7 Replace upper and lower pads 7310 Lift Cylinder T2 7310 1 Check for leakage JF E 7310 2 Check mounting i 7400 Lifting Device E 7400 1 Check clearance of fork carriage 7400 2 Check fork carriage for damage and cracks 7400 3 Check forks for wear and cracks T 7400 4 Check reach attachment for ES i damage and cracks EE 7400 5 Check reach attachment for proper reach stroke and timing 7400 6 Checkreachattachmentfor E d damaged retract bumpers 7400 7 Lube all grease fittings on reach X attachment 74 Master Service Manual 2000 08 04 F code Section C code PS K TSU Service Schedule Version no 002 T code 395 396 397 398 399 7310 7100 ya 5400 S 5300
13. with grease see page 84 The total number of grease fittings depends on truck options when built see page 83 A truck with a cold storage freezer use or corrosive environment application package will have more grease fittings than a standard truck Look for flush type grease fittings on the load wheel axles Regular fittings may be found on the transmission mounting bearing and mast chain sheave shafts 2 2 11 Pivot Points There are pivot points and other items that need to be lubricated but do not have grease fittings Lubricate these non greasable wear points with a drip oil can using 10 weight machine oil Master Service Manual 2000 08 04 79 F code Section C code PS P2 0 Service Schedule Version no T code 002 395 396 397 398 399 2 3 Services Performed Every 480 or 960 Operating Hours The planned maintenance service should be performed by a trained qualified and authorized technician 2 3 1 Drive Motor Since the operating environment of material handling equipment varies widely the following recommendations are suggested for periodic maintenance inspections for the drive motor armature e Normal Service 8 hours per day operation e Routine inspection every 960 hours 8 months e Severe Service 24 hours of daily operation 1 Dusty or sandy locations such as a cement plant lumber or flour mills coal dust or stone crushing areas 2 High temperature areas such as steel mills foundries etc
14. 0 amp Driving with rated 24 V 160 amp bad 36 V 165 amp 36 V 170 amp 36 V 170 amp Lifting without i 24 V 7 eli ata load 36 V 240 amp 36 V 320 amp 36 V 320 amp Lifting with rated 24V i load 36 V 415 amp 36 V 570 amp 36 V 570 amp Master Service Manual 2001 09 18 60 KOMATSU Komatsu Forklift U S A Inc F code Section C code PS M3 0 Ordering Spare Parts Version no T code 001 Ordering Spare Parts 1 Locate fault on truck 2 Identify truck model serial number and battery voltage 3 Locate page with the exploded diagram and find the item number for the part reguired 4 Locate item number in table Select the column for actual truck model and serial number The following is an explanation of a serial number FRS 27 265 4 2 001 Number of unit for that day Model series Day of year of manufacture Year of manufacture Decade of manufacture Model 2 FR18S 2A FR23S 2A 3 FR15DR 2A 4 24 volt 6 35 volts 7 1997 8 1998 etc 12198 2 199 3 200 FRS FR18S 2A amp FR23S 2A FRD FR15DR 2A 5 Note part number 6 Call your local Komatsu Forklift Dealer and state the part number 7 f truck model serial number or article number cannot be found call your local Komatsu Forklift Dealer for assistance Master Service Manual 2000 08 04 KOMATSU Komatsu Forklift U S A Inc F code Section C code
15. Days Weeks Months 3300 3 Check correct clearance of electrical brake and brake shoes 3300 4 Check brake operation Wheels debris Remove all string wrapping and 3500 2 Check all wheels for wear 3500 3 Grease load wheel bearings 3500 4 Grease caster and caster wheels 4100 Steering Wheel x 4100 1 Check fasteners 4100 2 Check ease of steering 5110 Battery 12 15 mm above cell plates 5110 1 Electrolyte level 0 50 0 625 inch 5110 2 Check all connections battery battery and charger plugs 5110 3 Check all cell and link covers intact 5110 4 Check battery specific gravity 5200 Instrument Panel 5200 1 Check battery indicator and hour meter for correct operation 5300 Electrical Control System 5300 1 Check key switch X 5300 2 Check brake micro switch X 5300 3 Check control wiring harness for X proper routing E S 5300 4 Examine negative cable and X wires from the battery to the main electronic card A5 5300 5 Check red emergency stop switch X for operation E 5400 Electrical Panel SDN zn zs 5400 1 Cleaning and mounting to PI D I X chassis 5400 2 Check tightness on al O X connections
16. KOMATSU F code Section C code PS M2 0 Technical Service Data Version no T code 003 395 396 397 398 399 Technical Service Data MODEL FR18S 2A FR15DR 2A FR23S 2A DRIVE MOTOR Type Series DC Series DC Series DC Power ENG RCM farm MC EL Duty factor 1 Hour Continuous 1 Hour Continuous Minimum brush length AA 0 8 inch 20 mm 1 Hour Continuous 0 8 inch 20 mm Minimum commutator diameter 2 90 inches 74 mm 2 90 inches 74 mm 0 8 inch 20 mm 2 90 inches 74 mm Minimum brush spring tension 6 4 oz 180 grams 6 4 oz 180 grams 6 4 oz 180 grams TRANSMISSION GEAR i Vertical motor spiral Vertical motor spiral 1 Vertical motor spiral Type bevel output bevel output bevel output Gear ratio 4757 17 57 17 57 Oil volume 1 gai 4 liters 1 gal 4 liters 1 gal 4 liters TRANSMISSION GEAR AMBIENT TEMPERATURES Standard and corrosion continuous operation see page 68 above 23 F 5 C SAE 80W90 Cold Storage see page 68 Continuous operation 5 F 15 C Intermittent operation 13 F 25 C SAE 80W 90 Freezer continuous operation To 31 F 35 C see page 70 ATF Komatsu Forklift U S A Inc Master Service Manual 2001 09 18 57 F code Section C code PS M2 0 Technical Service Data Version no T code 003 395 396 397
17. ce 2 4 6 Lift and Carriage Chains Lift and carriage chains should be checked every 720 hours A chain gauge should be used to check stretch of the links To adjust inner columns loosen jam nut and tighten chains equally until the top of the columns are level in the fully lowered position Retighten jam nut and torque Carriage chains should be adjusted in the fully lowered position Adjust chains until the top of forks are 2 0 inches 50 8 mm off of the floor Master Service Manual 2000 08 04 F code Section C code PS P3 0 Version no T code 001 395 396 397 398 399 Lubrication Chart BAR pa Pos No Service Point Interval Running Hours Lubricant Pod See Approved Oils and 360 h 720 h 1440 h raso Gh Dae ad Wheel bearings _ LE Mast beam Lifting chains Hydraulic system Steering bearings Drive gear T IN BON L Lubrication C Check O Oil change Truck Lubrication Points Komatsu Forklift U S A Inc Master Service Manual 2000 08 04 83 F code Section C code PS P4 0 Oil and Grease Specifications Version no T code 001 395 396 397 398 399 Oil and Grease Specifications 1 Approved Oils and Grease Specification C S S FSS Standard and Coirosion Cold Storage Freezer Lubricant Continuous Continuous Operation Continuous
18. ce Manual 2000 08 04 F code Section C code PS P1 0 K TSU Introduction Maintenance Version no T code 000 e Trucks completely dry prior to commencing the continuous stay in the cold storage e Parked inside the cold storage for operator breaks e Charging and maintenance work done outside the cold storage e Trucks completely dry before returning to continuous cold storage operation For cold storage reach trucks with intermittent operation the recommended ambient temperature is 13 F 25 C Trucks apply to the following guidelines e Surface condensation occurs wet trucks should neither remain idle in the cold storage for no longer than 10 minutes nor operate inside the cold storage for extended periods e Condensation must not be allowed to freeze on the truck at any time e Park outside the cold storage for operator breaks e Charging and maintenance work to be done outside the cold storage Items included in the cold storage package are as follows e All corrosion conditioning items e Sealed components used in all non heated locations e Heavy duty mechanical switches used where appropriate e Thermostat controlled heaters used to prevent moisture buildup in electrical component areas e Heaters located around the electronic card the drive and lift power controllers the steering tachometer and hydraulic control potentiometers e Windshield replaced with a screen e Hydraulic fluid in lift auxiliary system cha
19. d a charge level equivalent to 70 discharge a warning signal is given via flashing lights A further 10 of the battery s capacity can then be used before the battery discharge indicator slows down the lift function 2 1 2 Hydraulic System Inspect entire truck for leaks especially around hydraulic pump assembly and lift cylinders Any sign of oil on the floor under truck is an indication that truck may be leaking hydraulic oil or transmission fluid Report any problems to the proper authorities and DO NOT operate truck until it has been inspected and repaired by a trained qualified and authorized technician Master Service Manual 2000 08 04 KOMATSU Komatsu Forklift U S A Inc F code Section C code PS P2 0 Service Schedule Version no T code 002 395 396 397 398 399 2 1 3 Frame Sheet Metal Inspect truck for loose damaged or missing parts All shields must be in place and functional Report any problems to the proper authorities DO NOT operate truck until it has been inspected and repaired by a trained qualified and authorized technician 2 1 4 Wheels Tires Inspect wheels and tires for wear and damage Trash that is wrapped around wheels and axles will cause premature tire wear and bearing damage The floors should be kept clear of trash to prevent damage to wheels and tires 2 1 5 Functions Operations Test truck for the proper operation of all functions including the travel controls lift and lower
20. functions brakes and emergency disconnect button Safety devices must be operational Report any problems to the proper supervisors DO NOT operate truck until it has been inspected and repaired by a trained qualified and authorized technician 2 2 Services Performed Monthly or Every 120 Operating Hours The monthly planned maintenance service should be performed by a trained qualified and authorized technician 2 2 1 Inspection All services and inspections listed above for the daily inspection should be performed at this time The inspection procedure should be more thorough and minor deficiencies should be corrected 2 2 2 Transmission Inspect for oil leakage 2 2 3 Brakes When the foot is lifted from the brake pedal it should stop a fully loaded truck at full speed in approximately one truck length Master Service Manual 2000 08 04 77 F code PS Section C code P2 0 Service Schedule Version no 002 78 T code 395 396 397 398 399 2 2 4 Battery Contact your battery dealer for specific instructions on care and maintenance of the battery An average battery will have a specific gravity of 1 170 at the 80 discharged level However there are many different batteries on the market Only the battery manufacturer can accurately determine the fully charged and 80 charged levels Contact the battery manufacturer for this information 2 2 5 Electrical Connections Check that all electrical con
21. k Off The Floor To perform maintenance that reguires the truck to be lifted from the floor observe the proper safety precautions as follows Adjustment bolt 1 Lower the forks completely Remove any load 2 Turn key switch OFF and disconnect battery Pivot plate connector from the truck 3 If possible stabilize the top of the mast with an overhead chain hoist 4 Before jacking the truck check the stop block and adjustment bolt on the pivot plate to make sure j they are in good condition If the block or adjustment bolt are excessively worn or missing take the truck out of service and contact your local Komatsu Forklift Product Support Representative 5 Place the jack under the designated jacking points Jack only in these areas 4 4 Elevate Rear of Truck 1 Place the jack in the designated jacking position 2 Jack the rear of the truck so the drive tire is off the floor no more than 3 inches 76 mm 3 Block truck in place 66 Master Service Manual 2000 08 04 F code Section C code PS P1 0 KOMATSU Introduction Maintenance Version no T code 000 1 2 Elevate Either Side of Truck 1 Place the jack in the designated jacking position 2 Jack the side of the truck so that the load wheel is off the floor no more than 0 50 inch 12 7 mm 3 Block truck in place Komatsu Forklift U S A Inc Master Service Manual 2000 08 04 67 F code PS Introduction Maintenance Version no
22. nections are clean and tight Plug in connectors should be unplugged and plugged back in to clean terminals If the truck is equipped with any of the cold storage freezer use or corrosive environment application packages the di electric compound in the plug in connectors should be renewed 2 2 6 Contactor Tips NOT Sealed Inspect contactor tips for arcing pitting or burning Minor pitting of the tips is not a problem However if tips are pitted through the tip to the copper bar tips should be replaced DO NOT file tips Replace tips only in complete sets Some contactors have concealed tips or fully sealed so tips cannot be replaced 2 2 7 Motor Brushes The drive motor and pump motor are eguipped with a brush wear sensor which will indicate when brushes need replacing For minimum brush length see page 57 As a rule of thumb brushes should be replaced if brush spring is within 0 0625 inch 1 59 mm of touching brush holder 2 2 8 Drive Motor Blow out drive motor fan and vents Check for any signs of oil on drive motor fan and air vents Check for any damage to fan or air vents Master Service Manual 2000 08 04 KOMATSU Komatsu Forklift U S A Inc F code Section C code PS P2 0 Service Schedule Version no T code 002 395 396 397 398 399 2 2 9 Hydraulic Reservoir Check fluid level in the hydraulic reservoir 2 2 10 Frame Lube The pressure type grease fittings zerk fittings should be lubricated
23. nged to ATF e Anti seize compound used on the control console vertical adjustment bar e Standard grease replaced with Mobiltemp SHC 32 lubricating grease Komatsu Forklift U S A Inc Master Service Manual 2000 08 04 69 F code PS Introduction Maintenance Version no 000 70 Section P1 0 T code C code 2 4 Freezer Storage To prevent moisture contamination in the electrical system trucks equipped with freezer storage conditioning packages have electrical compound applied to all electrical connections during assembly For freezer storage reach trucks with continuous operation the recommended ambient temperature is 31 F 35 C Trucks should apply to the following guidelines e Trucks must be parked inside the freezer for operator breaks e Trucks stay in the freezer during battery charging or change out If truck is removed from freezer for maintenance work or battery charging it must be completely dry before reentering the continuous shift in the freezer Items included in the freezer storage package are as follows e All cold storage items contained e Transmission fluid in the lift auxiliary system will be changed to Texaco 15 e Cooling fan in the component compartment will be disconnected Master Service Manual 2000 08 04 F code PS KOMATSU Version no 002 Service Schedule Section C code P2 0 Service Schedule T code 395 396 397 398 399 1 Planned Maintenance Schedule
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