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

1. 10 02 Cubic Meters to Cubic Yards 10 03 Cubic Yards to Cubic Meters 10 03 Liter to U S Gallon 10 04 U S GallontoLiter 10 04 KilogramtoPound 10 05 PoundtoKilogram 10 05 Kilograms per Square Centimeter to Pounds per Square Inch 10 06 Kilogram to Foot Pounds of Force 10 07 Temperature Conversion Chart 10 08 FORKLIFT TRUCKS COVERED IN THIS PUBLICATION S N 130001A KOMATSU MODEL DESIGNATION DESCRIPTION Gasoline and LPG Trucks FG35ST 8 8 000 Ib capacity cushion tire truck 1 speed transmission TB45 FG35BCS 8 8 000 Ib capacity cushion tire truck Box Car Special BCS 1 spd trans TB45 FG45BCS 8 10 000 Ib capacity cushion tire truck Box Car Special BCS 1 spd trans TB45 FG50AT2 8 11 000 Ib capacity pneumatic tire truck long wheelbase 2 spd trans TB45 FD45T 8 10 000 Ib capacity pneumatic tire truck long wheelbase 1 spd trans S6D102E FEDERAL EPA EMISSION CONTROL STATEMENT FOR OFF ROAD LSI NON
2. 06 12 Replacing the Fuel Filter Gasoline Engines 06 13 Replacing the Fuel Filter Diesel Engines 06 14 Replacing Air Cleaner Element TB4SE 06 14 Replacing Air Cleaner Element S6D102E 06 15 Cleaning the Radiator 06 15 Cleaning Radiator Fins isson steeen ker a paia aa I I 9 rn 06 16 Bleeding Air From Brake System 06 16 CHAPTER 07 REMOVAL DISASSEMBLY ASSEMBLY INSTALLATION 07 01 Unit Installation Positions Diagram 07 02 Overall Disassembly and Assembly Flow Chart 07 03 Weight Table Component AssembliesandParts 07 04 Mast Removal Typical 07 05 Engine Engine Removal from Chassis 07 06 Engine Disassembly and Assembly 07 08 Engine Installation liie He 07 08 Transmission and Drive Axle Torque Converter Transmission Drive Axle Removal from Chassis 07 09 Torque Converter Installation
3. 05 04 Inspect Engine FuelSystem 05 05 Inspect Diesel Fuel Injection Nozzles 05 05 Inspect LPG Vaporizer for Tar Buildup TB45E 05 06 Inspect the Blow by Gas Recirculation System TB45E 05 07 Inspect Cooling System and Radiator 05 07 Inspect Cooling Water Level 05 08 InspectfFanAssembly 05 08 Inspect Charging System Wiring 05 08 Inspect Front Axle and Re Torque MountingBolis 05 08 Inspect Rear Axle and Re Torque Mounting Bolts 05 09 InspectWheels 05 09 Inspect Rim Side Ring 05 09 Inspect Wheel Bearings 05 09 Inspect SteeringKnuckles 05 09 Inspect SteeringWheel 05 10 Inspect the Power Steering System 05 10 Inspect Brake System Rods Cables and Links
4. 05 10 Inspect Brake Piping amp Connections 05 10 inspect Brake Master and Wheel Cylinders 05 11 Inspect Brake Shoes andAssociatedParts 05 11 Inspect Brake Drums 05 11 Inspect Brake BackingPlates 05 12 InspectLoadForks 05 12 InspectMast 05 12 Inspect ForkCarriage 05 13 Inspect Lift Chains 05 13 inspect Chain Wheels 05 13 InspectAitachments 05 13 Inspect Hydraulic Tank 05 14 Inspect Chassis and Attachment Piping 05 14 Inspect Hydraulic Pump 05 14 Inspect Lift Cylinder 05 14 Inspect Tilt Cylinders 05 14 Inspect Attachment Cylinders 05 14 Insp
5. 04 03 Adjusting Valve Clearance TB45E 04 04 Adjusting Valve Clearance S6D102E 04 05 Adjustment of Engine Drive Belts TB45E 04 07 Measuring Engine Cylinder Compression TB45E 04 08 Measuring Hydraulic Drift on Lift and Tilt Cylinders 04 09 Mast Adjustment Typical 04 10 Outer and Inner Rollers 04 10 Fork Carriage Typica 04 11 ThrustPadandRail 04 12 Adjusting the Parking Brake Lever 04 15 Adjusting the Accelerator Pedal TB45E 04 15 Accelerator Pedal Position Sensor 04 17 Adjusting the Accelerator Pedal S6D102E 04 18 Measuring Brake Stopping Distance Braking Effect 04 19 Adjusting Inching Brake Pedal Torgflow Trucks 04 19 Adjusting Stop Lamp Switch 04 20 Adjusting Wheel Brake
6. 07 12 Transmission and Drive Axle Installation 07 12 Pedal Assembly Brake Piping Installation 07 12 Brake System Bleeding Air From Lines 07 12 Installing the Counterweight 07 13 Mast Installation Typical 07 14 Steering Axle Steering Axle amp Power Steering Cylinder Removal from Chassis 07 15 Power Steering Cylinder Structure 07 16 Steering Axle Disassembly 07 17 Steering Axle Lubrication and Torque Values 07 18 Steering Axle Checking Specifications 07 19 Steering Axle amp Power Steering Cylinder Installation 07 20 Steering Axle Torque Values 07 21 Wheel Brake Wheel Brake Removal erene nascu tiea pulo Re p P elIBSS RR EI E RARE doa da a a 07 23 Wheel Brake Disassembly Assembly Drawing Cushion 07 24 Wheel Brake Disassembly Assembly Drawing Pneumatic 07 25 Wheel Brake Installation 07 27 Power St
7. 01 32 Safety Label Locations 01 35 CHAPTER 02 GENERAL INFORMATION AND SPECIFICATIONS 02 01 Specifications Mast Data amp Features Indoor Trucks 02 02 Specifications Mast Data amp Features Outdoor Trucks 02 04 Truck Data Tables Cushion Tire Indoor Trucks 02 06 Truck Data Tables Pneumatic Tire Outdoor Trucks 02 10 Periodic Replacement of Consumable Parts 02 20 Standard Tightening Torque for Pipe Joints 02 21 Standard Tightening Torque for Bolts 02 22 CHAPTERO3 SERVICEDATA 03 01 Service Data Gasoline Engine Trucks 03 02 Service Data Diesel Engine Trucks 03 05 CHAPTER 04 TESTING ADJUSTING AND MEASURING 04 01 Checking Engine Oil TB45E 04 02 Adjusting Engine Oil Level 04 02 Adjusting Ignition Timing TB45E 04 02 Adjustment Spark PlugGap TB45E
8. 07 72 Shut offValve 07 73 Service Information 07 73 Hydraulic Pump Gasoline Engines Hydraulic Pump Gasoline Engines Pneumatic 07 75 Hydraulic Pump Disassembly of Rear Pump Section Gasoline Pneumatic 07 76 Hydraulic Pump Disassembly of Front Pump Section Gasoline Pneumatic 07 76 Hydraulic Pump Assembly of Rear Pump Section Gasoline Pneumatic 07 76 Hydraulic Pump Assembly of Front Pump Section Gasoline Pneumatic 07 77 Hydraulic Pump Gasoline Engines Cushion 07 78 Hydraulic Pump Disassembly of Rear Pump Section Gasoline Cushion 07 79 Hydraulic Pump Disassembly of Front Pump Section Gasoline Cushion 07 79 Hydraulic Pump Assembly of Rear Pump Section Gasoline Cushion 07 79 Hydraulic Pump Assembly of Front Pump Section Gasoline Cushion 07 80 Hydraulic Pump Inspection amp Repair Gasoline Cushion 07 80 Hydraulic Pump Diesel Engines Hydraulic Pump Front Unit Diesel Engines 07 82 Hydraulic Pump Disassembly of Front Pump Unit Diesel 07 82 Hydraulic Pump Inspection amp Re
9. YOUR WARRANTY RIGHTS AND OBLIGATIONS The Federal EPA and Komatsu Forklift USA Inc hereinafter referred to as KFI are pleased to explain the emis sion control system warranty on your 2004 or later Diesel heavy duty off road engine All new heavy duty off road engines must be designed built and equipped to meet the 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 Federa EPA exhaust gaseous regulations The difference between current and EPA certified engines is only the labels attached on the engine See available drawing and or illustration of emission label and its location 15 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
10. 07 57 Tilt Cylinder Disassembly 07 57 Tilt Cylinder Parts Inspection 07 58 Tilt Cylinder Reassembly 07 58 Drive Axle Drive Axle Disassembly Assembly Exploded View Pneumatic Trucks 07 60 Drive Axle Assembly Torque Chart Pneumatic Trucks 07 61 Drive Axle Disassembly and Assembly Exploded View Cushion Trucks 07 62 Drive Axle Assembly Torque Chart Cushion Trucks 07 63 Differential Differential TorgFlow Transmission Disassembly and Assembly Exploded View 07 64 Differential TorgFlow Transmission Specifications 07 65 Differential Adjusting 07 66 Differential Assembly 07 70 Hydraulic Control Valve Control Valve Assembly 07 71 Control Valve Work Port Relief 07 72 Setting Pressure on Work Port Relief 07 72 Troubleshooting the Anti Void Feature 07 72 Servicing amp Repair Information
11. 01 SAFETY SECTION A WARNING TRAVEL ON 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 AB801140 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 A WARNING DO NOT JUMP OFF LIFT TRUCK EVEN IF IT TIPS NEVER JUMP OFF the lift truck even if it seems that it will 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 sb i Always wear the seat belt correctly Tsp aver can occur even when unloaded ot fe ak ak M A F om injury ar death We lip over Foi
12. 630 16 945 24 206 21 279 29 28 5 3 00 709 18 1 06 27 282 29 383 39 39 0 3 00 787 20 1 18 30 405 43 549 58 56 0 6 00 866 22 1 26 32 549 58 745 78 76 0 8 00 945 24 1 42 36 684 72 927 98 94 5 10 0 1 06 27 1 61 41 973 100 1 320 140 135 15 1 18 30 1 81 46 1 270 140 1 720 190 175 20 1 30 33 1 97 50 1 630 180 2 210 240 225 25 1 42 36 2 16 55 2 030 210 2 750 290 280 30 1 54 39 2 36 60 2 420 250 3 280 340 335 35 02 22
13. This may lead to serious injury or death AB801350 A 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 AX 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 01 17 AB801370 01 SAFETY SECTION A WARNING USE ONLY FOR INTENDED PURPOSES Do not use the lift truck for anything other than the intended use loading operations using the forks Do not use the forks to open or close the doors of railroad cars 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 A 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 A 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 o
14. 01 33 Stable range AB801818 01 SAFETY SECTION A 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 A CAUTION ALLOWABLE LOAD The allowable load is stamped on the namepiate to show the relationship regarding the position of the load center M NE the height of the fork and the maximum load Before load SE gy l ing the forks check that the load and load center are within Vot RA 0 e pem es the permitted range on the stamped allowable load 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 AB801620 load close to the load backrest FACIES Mm AACHEN ga com src Ague TRUCK EIGHT If the forks are loaded more than the allowable value the CE BERE in drive wheels will float during travel and the steering system E i will not work This is very danger
15. 04 22 Checking Torgflow Clutch Actuation Pressure Pneumatic Trucks 04 23 Checking Torque Converter Stall Speed Pneumatic 04 23 Checking Torgflow Clutch Actuation Pressure Cushion Trucks 04 24 Checking Torque Converter Stall Speed Cushion 04 24 Inching Valve SpoolAdjustment 04 25 Testing Specific Gravity of Battery Electrolyte 04 26 Testing and Adjusting Pneumatic Tire Pressure 04 27 Measuring Minimum Left and Right TurningRadius 04 27 Rear Axle Thrust Clearance Adjustment 04 29 CHAPTERO0O5 INSPECTION unsunao 05 01 Inspect Engine Starting Operation 05 02 inspect Engine Running Condition 05 02 Inspect Air CleanerAssembly 05 02 Inspecting for Loose Cylinder Head Mounting Bolts amp Re Torquing TB45E 05 03 Inspecting for Loose Cylinder Head Mounting Bolts amp Re Torquing S6D102E 05 03 inspect Engine Mounts 05 04 Inspect the Engine Lubricating System
16. 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 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 TRUCK DATA CUSHION TIRE LIFT TRUCKS CON T FG45BCS 8 GENERAL Power Type LPG Operation Type Sit Down Capacity 24 in 600 mm Load Center Ibs kg 10 000 4 535 Load Distance from Center Axle 2 Stage in mm 17 9 455 Load Distance from Center Axle 3 Stage in mm 20 2 515 Wheelbase in mm 63 0 1 600 WEIGHT Service Weight inc 2 Stage STD Mast Forks Ibs kg 15 070 6 835 TIRES Tire Type Cushion Tire Size Front 22 x 6 x 16 Tire Size Rear 18x 7 X 12 1 8 Number of Wheels Front Rear x Driven 4x 2 Tread Center of Tires Front Rear in mm 4
17. from entering the working area AX 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 A 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 A 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 safe Be careful of electric wires and other obstacles inside and outside the building A 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 e 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 AX WARNI
18. 6 273 4 478 6 359 5 880 Cylinder Bore x Stroke in mm 3 9 99 5 X 3 8 96 4 0 102 x 4 7 120 Fuel Tank Capacity U S gallons liters 26 4 100 22 5 85 22 5 85 OTHER Relief Pressure Maximum psi bar 2 700 186 2 700 186 2 700 186 Hydraulic Tank Capacity U S gallons liters 14 5 55 14 5 55 14 5 55 Clutch Torque Converter Transmission TORQFLOW 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 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 15 02 GENERAL INFORMATION amp SPECIFICATIONS TRUCK DATA PNEUMATIC TIRE LIFT TRUCKS CON T FD40T 8 FD40T2 8 GENERAL Capacity 24
19. 8 7 220 8 7 220 Right Angle Stacking Aisle 2 Stage Mast tt in mm Right Angle Stacking Aisle 3 Stage Mast tt in mm Turning Radius Outside in mm PERFORMANCE Travel Speed Forward Loaded Unloaded mph k hr Lifting Speed Loaded Unloaded 2 Stage fpm mm s Lifting Speed Loaded Unloaded 3 Stage fpm mm s Lowering Speed Loaded Unloaded 2 Stg fem mm s Lowering Speed Loaded Unloaded 3 Stg fpm mm s Maximum Drawbar Pull Loaded Ibs kN 8 815 36 3 6 610 29 4 Maximum Gradeability Loaded Unloaded at 1 mph 96 35 22 26121 Service Brake Operation Control Foot Hydraulic Foot Hydraulic Hand Mechanical Hand Mechanical Hydrostatic Power Hydrostatic Power TABLE CONTINUED ON NEXT PAGE Parking Brake Operation Control Steering Type 02 12 Pneumatic 300 x 15 x 18PR 1 7 00 X 12 12PR I 2x12 6 12 6 6 95 0 2 413 178 0 4 520 130 0 3 300 7 0 180 88 8 2 225 124 0 3 150 124 0 3 150 57 1 1 450 46 9 1 190 III 5 5 140 8 7 220 130 9 3 325 130 9 3 325 109 5 2 780 14 9 24 0 16 2 26 0 11 2 18 0 14 3 23 0 14 6 23 5 16 2 26 0 95 480 97 490 91 460 93 470 95 480 85 430 91 460 81 410 8 165 36 3 32 21 Foot Hydraulic Hand Mechanical Hydrostatic Power 02 GENERAL INFORMATION amp SPECIFICATIONS FG40T2 8 FG45T 8 FG45T2 8 DRIVE Battery Voltage Capacity 20 hour rating V
20. 9 24 0 Lifting Speed Loaded Unloaded 2 Stage fpm mm s 79 400 95 480 Lifting Speed Loaded Unloaded 3 Stage fpm mm s 79 400 89 450 Lowering Speed Loaded Unloaded 2 Stg fpm mm s 89 450 89 450 Lowering Speed Loaded Unloaded 3 Stg fpm mm s 95 480 83 420 Maximum Drawbar Pull Loaded Ibs kN 8 370 37 2 Maximum Gradeability Loaded Unloaded at 1 mph 32 27 Service Brake Operation Control Foot Hydraulic Parking Brake Operation Control Hand Mechanical Steering Type Hydrostatic Power TABLE CONTINUED ON NEXT PAGE 02 18 02 GENERAL INFORMATION amp SPECIFICATIONS DRIVE Battery Voltage Capacity 20 hour rating V Ah Engine Model Rated Output SAE Gross HP kW rpm Maximum Torque SAE Gross Ip ft Nm rpm No of Cylinders Displacement Cu in cm Cylinder Bore x Stroke in mm Fuel Tank Capacity OTHER Relief Pressure Maximum psi bar U S gallons liters Hydraulic Tank Capacity U S gallons liters Clutch Transmission Air Cleaner Type FD50AT2 8 FD45T2 8 24170 24170 6D102E 6D102E 95 71 2 150 95 71 2 150 275 372 1 000 275 372 1 000 6 359 5 880 4 0 102 x 4 7 120 ZU 2 700 186 2 700 186 1565 Torque Converter TORQFLOW 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 tab
21. Ah 12 60 Engine Model TB45E TB45E TB45E Rated Output SAE Gross HP kW rpm 95 71 2 400 95 71 2 400 95 71 2 400 Maximum Torque SAE Gross Ib ft Nm rpm 203 275 1 600 203 275 1 600 203 275 1 600 No of Cylinders Displacement cu in cm 6 273 4 478 Cylinder Bore x Stroke in mm 3 9 99 5 x 3 8 96 Fuel Tank Capacity U S gallons liters 26 4 100 26 4 100 26 4 100 OTHER Relief Pressure Maximum psi bar 2 700 186 2 700 186 2 700 186 Hydraulic Tank Capacity U S gallons liters 14 5 55 14 5 55 14 5 55 Clutch Torque Converter Transmission TORQFLOW 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 T Includes 48 in 1 220 mm high Load Backrest Contact your authorized dealer for additi
22. DIESEL ENGINES TB45E ENGINES This section presents information concerning the correct labeling warranty parts and maintenance of TB45E engines in order to comply with the EPA off road large spark ignition LSI engine regulations 1 LABELS REQUIRED AND LABEL LOCATIONS All engines will display the required identification label as follows Note that decal content will vary between gaso line LP snd Dual Fuel engines Location on TB45E Series engines Includes TB45D TB45G and TB45L Series EPA LABEL LOCATION TBASE EPA Emission compliance label DUAL FUEL D SAMPLE shown below EMISSION CONTROL INFORMATION ENGINE FAMILY 4NSXB04 546C ENGINE DISPLACEMENT 4 5 LITER ENGINE MAXIMUM POWER 106 1 HP THIS ENGINE IS CERTIFIED TO OPERATE ON GASOLINE AND LPG ENGINE S USEFUL LIFE IS 5000 HOURS OF OPERATION OR SEVEN YEARS EXHAUST EMISSION CONTROL TYPE MPI TBI TWC HO2S TEST MODE VARIABLE SPEED ONLY 09mm eee NO OTHER ADJUSTMENTS NEEDED OCT THE ENGINE MEETS CALIFORNIA AND U S EPA REGULATIONS NOV FOR 2004 LARGE NONROAD SI ENGINES DEC NISSAN MOTOR CO LTD TB45 D TB45E EPA LABEL 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
23. Sub assembly Assembly 07 127 Output Shaft Sub assembly Adjusting 07 129 Assembly Transmission Case 07 130 Torgflow Transmission Assembly Drawing F1 R1 07 136 Transmission Control Valve Pneumatic 07 137 Transmission Control Valve Specifications 07 138 Transmission Control Valve Removal Pneumatic 07 140 Transmission Control Valve Assembly Drawings Pneumatic 07 140 Transmission Control Valve Troubleshooting Pneumatic 07 145 Torqflow Transmission Torque Converter Cushion Component Parts Drawing 07 147 Parts Specifications a 4 00 50 d ete Mb Re KA 07 148 Hydraulic Circuit Diagram 07 149 Torque Converter Pressure Testing Ports Cushion 07 150 Torque Converter Troubleshooting Chart 07 151 Torgflow Transmission Cushion Disassembly nsna 07 153 Servicing and Inspection 07 159 Assembly llle a hehehe 07 160 Main ShaftAssem
24. 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 A WARNING PRECAUTIONS WHEN OPERATING DIRECTIONAL OR SPEED LEVERS 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 A 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 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
25. for j Wahi the engine to cool down before checking For lift trucks E 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 e SAFETY SECTION PRECAUTIONS WITH HIGH PRESSURE HIGH IN AA WA RNING TEMPERATURE OIL immediately after using the lift truck the oil is at high temper 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 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 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 immediately AA WARNING ROTATING FAN AND BELT It is extremely dangerous if you or any tool touches or gets caught in the fan or fan belt whe
26. hour rating ViAh Engine Model Rated Output SAE Gross Maximum Torque SAE Gross HP kW rpm b ft Nm O rpm No of Cylinders Displacement cu in cm Cylinder Bore x Stroke in mm Fuel Tank Capacity U S galions liters OTHER Relief Pressure Maximum psi bar Hydraulic Tank Capacity U S gallons liters Clutch Transmission Air Cleaner Type FG40T 8 FG40ZT 8 FG40ZT2 8 Tese GIU ES 7075 1600 6 273 4 478 3 9 99 5 x 3 8 96 22 5 85 22 5 85 26 4 100 2 700 186 2 700 186 2 700 186 14565 Torque Converter TORQFLOW 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 f Includes 48 in 1 220 mm high Load Backrest Contact your authorized dealer for additional information Tt Add load length an
27. 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 Size weight shape of load Lifting height Tilting angle of mast e Inflation pressure of tires Acceleration deceleration turning radius Condition of road surface angle of road Type of attachments Center of Combined Center of gravity of center of gravity lift truck gravity of load AB801598 Center of gravity of load Combined center of gravity Center of aravity of lift truck It is assumed that the lift truck body is constant 4880160B A 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 If the position of the overall center of gravity is in front of the front axle the front tires will form the fulcrum and the lift truck will tip to the front 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
28. mm 63 0 1 600 WEIGHT Service Weight inc 2 Stage STD MasUForks Ibs kg 12 960 5 880 13 340 6 050 14 780 6 705 TIRES Tire Size Front 22 x 6 x 16 Dual Tire Size Rear 18x 7 x 12 1 8 Number of Wheels Front Rear x Driven 4x 2 Tread Center of Tires Front Rear in mm 41 9 1 065 39 8 1 010 DIMENSIONS Tilting Angle 2 Stage FV Masts Forward Backward 6 6 Tilting Angle 3 Stage TFV Masts Forward Backward 6 6 Mast Height Lowered 2 Stage Std Mast in mm 95 0 2 410 Mast Height Extended 2 Stage Mast t in mm 178 0 4 520 Maximum Fork Height 2 Stage STD Mast in mm 130 0 3 300 Free Lift Height 2 Stage STD Mast in mm 7 0 180 Height Overhead Guard in mm 83 7 2 125 Length to Fork Face 2 Stage Mast in mm 108 3 2 750 Length to Fork Face 3 Stage Mast in mm 110 6 2 810 Overall Width at Drive Tires in mm 53 9 1 370 Forks Thickness x Width x Length in mm 2 0 x 6 0 x 42 0 50 x 150 x 1 070 Carriage Width ITA Class in mm 41 0 1 040 IIl Ground Clearance under Mast in mm 4 0 100 Ground Clearance Center of Wheelbase in mm 4 9 125 Right Angle Stacking Aisle 2 Stage Mast tt in mm 111 6 2 835 Right Angle Stacking Aisle 3 Stage Mast tt in mm 113 9 2 895 Turning Radius Outside in mm 93 7 2 380 PERFORMANCE Travel Speed Forward Loaded Unloaded mph k hr 9 6 15 5 9 6 15 5 Lifting Speed Loaded
29. number faces upwards for ease of identifi FLAT PAD cation TB45E S NO The S6D102E series engine serial number is stamped on the left side of the engine to the left of the oil filter SSDTQZE LEFT OF OIL FILTER S6D102E S NO NOTICE For EPA TB45E D G L engine related troubleshooting refer to the following manual e TM100 EPA Engine Training Manual NOTICE For EPA S6D102E engine related troubleshooting refer to the following manual e SM140 S6D102E Service Manual CONTENTS Page No INTRODUCTION esseeeeeeee ee ehh hn hh n m srren 1 ENGINE SERIAL NUMBER LOCATION asaa sesos 2 TABLE OF CONTENTS eseses ee tee eee hh hah rt hse ren 3 APPLICABLE EPA LIFT TRUCK MODELS COVERED IN THIS PUBLICATION 9 FEDERAL EPA EMISSION CONTROL STATEMENTS 11 CHAPTER 01 SAFETY SECTION eee hh rrr 01 01 Safety Management 01 02 Safe Travel 01 07 Loading Operations 01 15 Stopping and Parking 01 22 Inspection and Maintenance 01 24 Structure and Stability of the Lift Truck
30. 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 KFl recommends that you retain all receipts and records covering the maintenance on your engine but KFI 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 e Check turbocharger rebuild or replace if necessary Every 2 000 hours Adjust valve clearance Every 2 000 hours Check fuel injection nozzles replace if necessary Every 2 000 hours Keep records to show proof of compliance with the required maintenance practices and intervals As the heavy duty off road engine owner you should however be aware that KFl may deny your war ranty coverage if your heavy duty off road engine or part has failed due to a
31. 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 unti 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 A 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 Carry out the charging operation in a well ventilated place Do not smoke or allow any flame Start the 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 i 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 th
32. prevent the lift truck from moving Lift truck slinging work should be carried out by a qualified person who has completed a course in correct lifting meth ods Fit wire ropes to the specified lifting points When lifting the lift truck check that the wire ropes have ample strength and are not damaged Block the tires contacting the ground to prevent the lift truck from moving Insert blocks to prevent the lift truck from coming down Do not go under the lift truck during the lifting operation If the specified lifting point is the counterweight check that the counterweight mounting bolts are tightened to the speci fied torque before carrying out the lifting operation Check also that there is no damage to the lifting portion on the coun terweight 01 28 AB801530 AB801540 01 SAFETY SECTION A WARNING BATTERY 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 A
33. 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 Itis critically important to remove the lift truck from the tracks as soon as possible AB801180 01 9 01 SAFETY SECTION WARNING NO RIDERS i 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 Lu AD817960A AB801650 WARNING DRIVING IN REVERSE i When driving in REVERSE turn to face the rear and check the area directly behind the lift truck AB801200 A 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 personnel 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 X l AREA THAT CAN BE SEEN WHE
34. unloaded e Don t tisk injury or dealt 4 A Siow dawn betore wuraiag AR AW uf Don t jump Hold on lighif Brace leet Lean away E KACD10449 9 Warning for handling LPG FLAMMABLE GAS Decal Part No 3EB 96 25780 AINED PERSONNI NLY A WA RNIN G pus e on on a a don ER Do not store tank or park truck near heat or ignition sources Avold sparks or open flame Follow filling and operating instructions in parating manual When checking or filling tank No smoking Stop engine Fill in designated area Ta prevent damage to hase or fittings Make sure pin extends through hole in rim of tank Use only tank with part number shown on bracket Flamm abl LP G AS Frost or LPG odor Indicates leak Inspect and repair immediately Do not start engine 3EB 96 25780 KFID10448 10 NO JUMP START Decal Part No 09842 A0481 Located top center of starter solenoid 01 38 01 SAFETY SECTION 11 LPG TANK CHANGE INSTRUCTIONS DECAL On LPG Tank Bracket Base Plate LPG FUEL CYLINDER REPLACEMENT PROCEDURE NO SMOKING DO MOT REPLACE FUEL CYLINDERS IN AREAS THAT HAVE OF FUEL IGNITION CLOSE CYLINDER VALVE AND RUN ENGIXE UNTIL IT STOPS PRIOR TO DISCONNECTING THE FUEL HOSE FROM THE TANK REPLACE FUEL CONTAINER BE SURE TO USE THE CORRECT SIZE AND TYPE PER THE CYLINDER DESCRIPTION PLATE SECURELY MOUNT AND POSITIOK AS FOLLOWS a WITH LOCATING PIN THROUGH POSITIONING HOLE IN C
35. 0 OTHER Relief Pressure Maximum psi bar 2 700 186 2 700 186 2 700 186 Hydraulic Tank Capacity U S gallons liters 14 5 55 14 5 55 14 5 55 Clutch Torque Converter Transmission TORQFLOW 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 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 17 02 GENERAL INFORMATION amp SPECIFICATIONS TRUCK DATA PNEUMATIC TIRE LIFT TRUCKS CON T GENERAL Power Type Diese Diesel Operation Type Sit Down Capacity 24 in 600 mm Load Center Ibs kg 11 000 5 000 Load Distance from Center Axle 2 Stage in mm 21 7 550 Load Distance from Center Axle 3
36. 1 2 01 SAFETY SECTION d WARNING UNAUTHORIZED MODIFICATION Any 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 A WARNING EXHAUST GAS Do not leave the engine running where there is poor ventiliation 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 A0055060 A WARNING FIRE EXTINGUISHER AND FIRST AID KIT any 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 ensure that you know how to use them Know what to do in the event of a fire Be sure that you know the phone numbers of persons you should contact in case of an 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 Do not leave the lift truck with the engine running Alwa
37. 1 9 1 065 39 8 1 010 DIMENSIONS Tilting Angle 2 Stage FV Masts Forward Backward 6 6 Tilting Angle 3 Stage TFV Masts Forward Backward 6 6 Mast Height Lowered 2 Stage Mast in mm 95 0 2 410 Mast Height Extended 2 Stage Mast in mm 178 0 4 520 Maximum Fork Height 2 Stage STD Mast in mm 130 0 3 300 Free Lift Height 2 Stage STD Mast in mm 7 0 180 Height Overhead Guard in mm 83 7 2 125 Length to Fork Face 2 Stage Mast in mm 99 6 2 530 Length to Fork Face 3 Stage Mast in mm 102 3 2 605 Overall Width at Drive Tires in mm 53 9 1 370 Forks Thickness x Width x Length in mm 2 0x 6 0 x 42 0 50 x 150 x 1 070 Carriage Width ITA Class in mm 46 9 1 190 III Ground Clearance under Mast in mm 4 0 100 Ground Clearance Center of Wheelbase in mm 4 9 125 Right Angle Stacking Aisle 2 Stage Mast tt in mm 105 7 2 685 Right Angle Stacking Aisle 3 Stage Mast tt in mm 108 0 2 745 Turning Radius Outside in mm 87 8 2 230 PERFORMANCE Travel Speed Forward Loaded Unloaded mph k hr 9 6 15 5 9 6 15 5 Lifting Speed Loaded Untoaded 2 Stage fpm mm s 93 470 95 480 Lifting Speed Loaded Unloaded 3 Stage fpm mm s 89 450 91 460 Lowering Speed Loaded Unloaded 2 Stg fpm mm s 95 480 85 430 Lowering Speed Loaded Unloaded 3 Stg fpm mm s 91 460 81 410 Maximum Drawbar Pull Loaded Ibs kN 7 500
38. 2 2 02 GENERAL INFORMATION amp SPECIFICATIONS SPECIFICATIONS MAST DATA amp FEATURES CUSHION CON T MAST HEIGHT in mm t MAXIMUM FORK HEIGHT FREE LIFT in mm Lowered Extendedt in mm t in mm in mm FG35 2 Stage Free View FV LIES 0 2 515 0 2 7 0 180 7 0 180 7 0 180 119 0 3 020 131 0 3 330 147 0 3 730 158 0 4 010 170 0 4 320 2 Stage Full Free View FFV 1940 6530 250020 3 Stage Full Free View TFV 78 0 1 980 207 0 5 260 37 0 945 43 0 1 095 51 0 1 295 59 0 1 495 118 0 3 000 130 0 3 300 146 0 3 700 157 0 4 000 159 0 4 040 30 0 760 171 0 4 345 219 0 5 565 34 0 865 185 0 4 700 87 0 2 210 233 0 5 920 39 0 990 197 0 5 005 245 0 6 225 43 0 1 090 217 0 5 510 265 0 6 731 50 0 1 270 57 0 1 450 237 0 6 020 105 0 2 665 285 0 7 240 FG45 2 Stage Free View FV DITE 780 0520 CE 20606240 270650 2 Stage Full Free View FFV 118 0 3 000 85 0 2 160 166 0 4 220 37 0 945 130 0 3 300 91 0 2 310 178 0 4 520 43 0 1 095 146 0 3 700 194 0 4 930 51 0 1 295 157 0 4 000 205 0 5 210 59 0 1 495 3 Stage Full Free View TFV 200699 NOTE Specifications for 4 Stage Full Free View QFV masts not indicated Consult authorized dea
39. 2x 6 0 x 42 0 55 x 2 0 x 6 0 x 42 0 50x 2 0x 6 0 x 42 0 50 x 150 x 1 070 150 x 1 070 150 x 1 070 Carriage Width ITA Class in mm 46 9 1 190 Ill Ground Clearance under Mast in mm 5 5 140 Ground Clearance Center of Wheelbase in mm 6 7 170 Right Angle Stacking Aisle 2 Stage Mast tt in mm 120 2 3 055 Right Angle Stacking Aisle 3 Stage Mast tt in mm 121 5 3 085 Turning Radius Outside in mm 100 2 2 545 PERFORMANCE Travel Speed Forward Loaded Unloaded mph k hr 12 4 20 0 13 7 22 0 Lifting Speed Loaded Unloaded 2 Stage fpm mm s 110 560 116 590 Lifting Speed Loaded Unloaded 3 Stage fpm mm s 102 520 108 550 Lowering Speed Loaded Unloaded 2 Stg fpm mm s 95 480 108 550 Lowering Speed Loaded Unloaded 3 Stg fpm mm s 98 500 89 450 Maximum Drawbar Pull Loaded Ibs kN 9 760 43 4 Maximum Gradeability Loaded Unloaded at 1 mph Yo 52 21 Service Brake Operation Control Foot Hydraulic Parking Brake Operation Control Hand Mechanical Steering Type Hydrostatic Power TABLE CONTINUED ON NEXT PAGE 02 14 02 GENERAL INFORMATION amp SPECIFICATIONS FG50AT2 8 FD40ZT 8 FD402T2 8 DRIVE Battery Voltage Capacity 20 hour rating VIAh 24170 Engine Model S6D102E Rated Output SAE Gross HP kW O rpm 95 71 2 150 Maximum Torque SAE Gross Ib ft Nm O rpm 275 372 1 600 No of Cylinders Displacement cu in cm
40. 33 3 Maximum Gradeability Loaded 29 16 Service Brake Operation Control Foot Hydraulic Parking Brake Operation Control Hand Mechanical Steering Type Hydrostatic Power TABLE CONTINUED ON NEXT PAGE 02 8 02 GENERAL INFORMATION amp SPECIFICATIONS FG45BCS 8 DRIVE Battery Voltage Capacity 20 hour rating WAH O 42 60 mar E MN CMF Rated Output SAE Gross HPWW Opm aaa Manner Ww ID RN No of Cylinders Displacement cu in cm 6 273 4 478 Gemini ma RE OTHER Relief Pressure Maximum psi bar 2 700 186 Hydraulic Tank Capacity U S gallons liters 12 4 47 Clutch Torque Converter Transmission TORQFLOW Air Cleaner Type 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 oper ating 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 Contact your authorized dealer Other mast heights available See MAST DATA CHART for other mast heights Contact your a
41. Federal EPA s stringent anti smog standards Komatsu Forklift USA Inc KFI must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse damage neglect or improper maintenance of your engine Your emission control system may include parts such as the carburetor regulator or fuel injection system ignition system engine computer unit ECM catalytic converter and air induction system Also included may be sensors hoses belts connectors and other emission related assemblies Where a warrantable condition exists an Authorized Komatsu Forklift Dealer will repair your LSI engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE Beginning January 1 2004 off road large spark ignition EPA engines are warranted for the time periods listed below If any emission related part on your engine is defective the part will be repaired or replaced by an Autho rized Komatsu Forklift Dealer OWNER S WARRANTY RESPONSIBILITIES As the off road LSI engine owner you are responsible for the performance of the required maintenance listed in your Operation and Maintenance Manual KFI recommends that you retain receipts covering maintenance on your off road engine but KFI 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 ow
42. 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 AN817980A 01 15 01 SAFETY SECTION A WARNING BE CAREFUL NOT TO GET CAUGHT OR 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 A WARNING OPERATE FROM OPERATOR S COMPARTMENT Always operate the mast and forks from the operator s compartment A WARNING No UNSTABLE LoADS Make sure that the center of gravity of the load is in line with the center of the lift truck Do not carry loads off center There is danger that unbalanced loads may cause the lift truck to tip Place the load so that it contacts the load backrest Do not handle unstable loads If there is danger that the load may fall off secure it in position and take steps to prevent the load from collapsing or falling When carrying stacked loads tie with rope to prevent the load from falling AB801340 01 16 01 SAFETY SECTION A WARNING PO 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
43. LWAYS 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 installing 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 ED paes When cleaning the battery leave the battery caps tightened G AO055100A A WARNING DO NOT PUT METAL OBJECTS ON TOP 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 A WARNING CHANGING LPG FUEL TANKS Only trained and certified personnel may change LPG tanks Turn ignition switch to the OFF
44. MABLE AND CAN CAUSE FIRES AND EXPLOSIONS Carry out refueling away from flames or sparks Stop the engine when refueling After refueling tighten the gas cap securely and wipe up any spilled fuel The 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 A0055020 A0055030 A0055040 AA WARNING NO STARTING AIDS Engine starting aids are highly flammable and may cause an explosion Do not use starting aids to start the engine A WARNING LPG SAFETY FUEL SYSTEM SAFETY Accidents involving fue 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 working on any fuel system Ensure you are wearing proper personal protective equipment Check for fuel leaks before you begin work on any fuel system On LPG 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 on the fuel system LPG is heavier than air and will si
45. N CYLINDER IS NOT INSTALLED JA MD AB80121D 01 10 01 SAFETY SECTION A 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 i 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 i Check that the lamps light up correctly Replace any broken or inoperative bulbs WARNING KEEP HANDS FREE FROM OIL AND WATER i Do not drive the lift truck if your hands are wet or covered with oil Your hands will slip on the work equipment control levers or directional lever and this may cause a serious accident A WARNING MOUNTING AND DISMOUNTING e 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 R
46. NG STOPPING DISTANCE When traveling downhill it requires a longer distance for the lift truck to stop then when traveling on leve 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 A 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 A 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 that it may tip Always check the load capacity chart to confirm the loading capacity AB801180 A 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 d 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 im O AD817970A A WARNING DO NOT
47. OLLAR b WITH SLOT IN FOOTRING OVER LOCATING KEYWAY 4 CONNECT FUEL HOSE OPEM VALVE SLOWLY BO THE HOSE AMD TANK PRESSURE CAN EQUALIZE OR THE VALVE MAY SLUG SHOULD LEAKAGE OCCUR CLOSE VALVE AND HAVE QUALIFIED PERSONNEL MAKE REPAIRS 6 USE FUEL MANUFACTURED TO NATIONAL GAS PROCESSORS ASSOCIATION NOTE THE ABOVE IS PROVIDED AS A GUIDE FOR ADOITIONAL INFORMATION CONSULT THE NATIONAL FIRE PROTECTION ASSOCIATION PAMPHLET 68 FOR THE SAFE BTORAGE AND HANDLING OF LIQUIFIED PETROLEUM GASES oen KFOMO003 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 In low areas The tuei cylinder should be mounted ao that it does not extend outaide the truck and should also be property positioned by using the locating pin or key way The fuel valve should be turned off when the machine is not In service Cast fittings should not be used in the LP GAS system Use only Underwriters Laboratories or Factory Mutual listed LP GAS hoes assembiles where pressure fuel lines are required Ail pipe threaded fittings should be installed using an approved compound Fuel lines should be supported by clamps to minimize chafing and weer 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
48. S6D102E EPA 1 1 EPA EC CERTIFICATION DECAL 2 LOCATIONS SEE ITEM 1 IN PRECEEDING ILLUSTRATION 1 2 EPA EC CERTIFICATION ASSISTANCE PLATE SEE ITEM 2 IN PRECEEDING ILLUSTRATION 1 3 EPA EC CERTIFICATION DATA PLATE SEE ITEM 3 IN PRECEEDING ILLUSTRATION 14 1 EPA EU CERTIFICATION DECAL This engine conforms to 2004 U S EPA and California and EU Stage regulations for heavy duty non road compression ignited diesel cycle engines as applicable THIS ENGINE IS CERTIFIED TO OPERATE ON DIESEL FUEL 2 EPAJEU CERTIFICATION ASSISTANCE PLATE MOMAISG Komatsu Ltd 1 EPA Cert Fantig XXXXXXXXXXXX EU Approval NO XXXeXX XXOOXX XXX XXX XX Gross Rated HP LV XX XX et XXXxrea FRXXXXX Lov Idol RPN XXX rpa CPL XXXX CIDAL XXXX X X Timing BTOC XXdes Firing Order XXXXXX Valve Lash Cold In X XXXem Ex X XXXnm Fuel Rate at Rated HP tV XXXcn3 st 3 EPA EU CERTIFICATION DATA PLATE CIDIL ENGINE SERIAL NO FAMILY KOMATSU PN TENTI 7 result and vrina 15 voided e KOMATSU MODEL i TIMNG TOC n EB it lut rate 234 or altitudes exceed published VALVE LASHJINCH INT EXH TIMING TDC 2 etin values for this node and application COLD MM INT EXH Date of Mfg FIRING ORDER ERR O LOWIDLE RPM Made In JAPAN Z I GROSS RATED HP KW AT RPM S6D102E EPA DECALS 2 WARRANTY The following statement is hereby provided as required by regulations of the United States Environmental Protec tion Agency EPA
49. SERVICE MANUAL SM202 CX20 SERIES FORKLIFT TRUCKS S N 130001A Federal Environmental Protection Agency EPA Emission Control Compliant GASOLINE amp LPG FG35 45ST 8 FG40 45T 2 8 FG35 45BCS 8 FG50AT2 8 FG40ZT 2 8 DIESEL FD40 45T 2 8 FD50AT2 8 FD40ZT 2 8 A 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 CXO Series forklift trucks and the var ious equipment systems inspections sensors diagnostic procedures and diagnostic equipment utilized to maintain adjust and troubleshoot these systems Although refer ence is made to maintenance procedures necessary to perform servicing of this vehicle you should refer to the applicable Operation and Maintenance Manual for these lift trucks for more complete maintenance information Komatsu is involved in a concentrated and highly technical program of designing and developing cleaner burning more efficient and more powerful engines for use in the industrial truck market As a result new computerized sensors systems and diagnostic monitors have been created to make the job of maintaining and repairing these systems simple and e
50. Stage in mm 21 7 550 Wheelbase in mm 78 7 2 000 WEIGHT Service Weight inc 2 Stage STD Mast Forks Ibs kg 16 440 7 455 TIRES Tire Type Pneumatic Tire Size Front 300 x 15 x 18PR 1 Tire Size Rear 7 00 X 12 62PR 1 Number of Wheels Front Rear x 7 Driven 2x12 Tread Center of Tires Front Rear in mm 45 3 1 150 44 1 1 120 DIMENSIONS Tilting Angle 2 Stage FV Masts Forward Backward 6 12 Tilting Angle 3 Stage TFV Masts Forward Backward 6 6 Mast Height Lowered 2 Stage Std Mast in mm 98 5 2 500 Mast Height Extended 2 Stage Mast t in mm 178 0 4 520 Maximum Fork Height 2 Stage STD Mast in mm 130 0 3 300 Free Lift Height 2 Stage STD Mast in mm 7 0 180 Height Overhead Guard in mm 88 8 2 225 Length to Fork Face 2 Stage Mast in mm 124 2 3 155 Length to Fork Face 3 Stage Mast in mm 124 2 3 155 Overall Width at Drive Tires in mm 57 1 1 450 Forks Thickness x Width x Length in mm 2 0 x 6 0 x 42 0 50 x 150 x 1 070 150 x 1 070 Carriage Width ITA Class in mm 46 9 1 190 IV Ground Clearance under Mast in mm 5 5 140 Ground Clearance Center of Wheelbase in mm 8 7 220 Right Angle Stacking Aisle 2 Stage Mast tt in mm 131 1 3 330 Right Angle Stacking Aiste 3 Stage Mast tt in mm 131 1 3 330 Turning Radius Outside in mm 109 5 2 780 PERFORMANCE Travel Speed Forward Loaded Unloaded mph k hr 13 1 21 0 14
51. T LIFT TRUCK FROM TIPPING To operate the lift truck safely it is important to understand the structure and stability of the lift truck A 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 AX CAUTION CENTER OF GRAVITY OF LOAD The loads carried by forklift trucks come in various shapes and weights 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 A 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 of the centers of gravity of the lift truck and the load When the lift truck is carrying no load the center of gravity 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
52. TOMER 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 770 385 4815 Fax phone 770 385 4838 17 01 SAFETY SECTION 1 SAFETY MANAGEMENT WARNING OPERATION MANUAL AND SAFETY LABELS gt 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 perso
53. URE 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 ABB0149B A WARNING ABRUPT LOWERING OF 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 prevent damage or injury and warn those in the work area 01 23 01 SAFETY SECTION 5 INSPECTION AND MAINTENANCE WARNING USE QUALIFIED PERSONNEL FOR INSPECTION AND 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 If inspection maintenance or repair work is carried out incorrectly it is very dangerous i AX WARNING MAINTENANCE LOCATION When carrying out inspection and maintenance use a level dry dust free area fthe work i
54. Unloaded 2 Stage fpm mm s 93 470 95 480 Lifting Speed Loaded Unloaded 3 Stage fpm mm s 89 450 91 460 Lowering Speed Loaded Unloaded 2 Stg fpm mm s 95 480 85 430 Lowering Speed Loaded Untoaded 3 Stg fpm mm s 91 460 81 410 Maximum Drawbar Pull Loaded Ibs kN 7 500 33 3 Maximum Gradeability Loaded Unloaded at 1 mph 32 16 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 V Ah Engine Model Rated Output SAE Gross HP kW rpm Maximum Torque SAE Gross Ib ft Nm O 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 FG45ST 8 FG35ST 8 FG35BCS 8 12 60 12 60 12 60 TB45E TB45E TB45E 95 71 2 400 95 71 2 400 95 71 2 400 203 275 1 600 203 275 1 600 203 275 1 600 6 273 4 478 3 9 99 5 x 3 8 96 Do Tosa pos 2 700 186 2 700 186 2 700 186 12 4 47 12 4 47 12 4 47 Torque Converter TORQFLOW NOTE Most values shown in this publication are rounded Therefore direct conversion between metric and English or
55. 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 i 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 i 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 A WARNING OVERHEAD OBJECTS Be careful not to let the mast overhead 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 AB801450 A 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 AB801460 AX WARNING PRECAUTIONS WHEN LOADING UNLOADING Do not let anyone place a load on the forks Donotlet anyone remove a load directly from the forks Standing on th
56. asy Read this manual carefully refer to it often and learn the repair testing and adjustment procedures to the best of your ability Please note that some illustrations are generic and may not look exactly like your unit in every detail Ensure that when you are working on or around industrial trucks Safety is priority Number One Read understand and obey all WARNINGS and CAUTIONS Follow the instructions and procedures presented in this manual when working on these lift trucks and their systems Damage to the equipment and possible injury to yourself or others may result if these procedures are not adhered to carefully Keep this manual nearby and accessible for use when necessary If this book becomes dirty worn or illegible contact Komatsu for a replacement The procedures outlined in this manual will be updated periodically Be sure that you have the latest revision in order to learn the newest information available Revision dates will be clearly displayed on the lower left hand corner of the cover page This will aid in maintaining your equipment in excellent condition and in ensuring that these lift trucks will operate safely at maximum efficiency ENGINE SERIAL NUMBER LOCATION The TB45E series engine serial number is stamped on a flat machined painted pad on the right side of the engine block just behind the distributor The right side is determined by the operators right side when seated on the lift truck The serial
57. ations for 2 Stage Full Free View FFV masts are not indicated Consult dealer for data and availability t Includes 48 in 1 220mm high load backrest 131 0 3 330 147 0 3 730 158 0 4 010 170 0 4 320 31 5 800 35 5 900 40 5 1 030 44 5 1 130 51 5 1 310 58 5 1 485 159 0 4 040 171 0 4 345 185 0 4 700 197 0 5 005 217 0 5 510 237 0 6 020 130 0 3 300 146 0 3 710 158 0 4 010 169 0 4 290 7 0 180 7 0 180 7 0 180 7 0 180 158 0 4 015 170 0 4 320 185 0 4 700 197 0 5 005 218 0 5 535 236 0 5 995 35 5 900 39 5 1 005 44 5 1 130 48 5 1 230 55 5 1 410 61 5 1 560 119 0 3 020 130 0 3 300 146 0 3 710 159 0 4 040 169 0 4 290 7 0 180 7 0 180 7 0 180 7 0 180 7 0 180 157 0 3 990 170 0 4 320 185 0 4 700 197 0 5 005 33 0 840 37 0 940 42 0 1 070 46 0 1 170 02 5 02 GENERAL INFORMATION amp SPECIFICATIONS TRUCK DATA CUSHION TIRE LIFT TRUCKS INDOOR FG35ST 8 FG35BCS 8 FG45ST 8 GENERAL Operation Type Sit Down Capacity 24 in 600 mm Load Center Ibs kg 10 000 4 535 Load Distance from Center Axle 2 Stage in mm 17 9 455 Load Distance from Center Axle 3 Stage in mm 20 2 515 Wheelbase in
58. bly Reverse 07 161 Main Shaft Assembly Reverse Flowchart 07 162 Main Shaft Assembly Forward 07 163 Main Shaft Assembly Forward Flowchart 07 164 Output Shaft Sub assembly Assembly 07 165 Output Shaft Sub assembly Adjusting 07 167 Transmission Assembly 07 168 Transmission Control Valve Disassembly Cushion 07 171 Transmission Control Valve Diagram Cushion 07 172 Transmission Control Valve Specifications Cushion 07 173 Transmission Control Valve Troubleshooting Cushion 07 174 Torgflow System Troubleshooting Chart 07 174 Combination Switch Component PartsDiagram 07 178 Checking Lighting Turn Signal Switch w o Dimmer 07 179 Checking Lighting Turn Signal Switch w Dimmer 07 180 Checking Lighting Turn Signal Switch 07 181 Checking F R Switch 07 182 Combination Swit
59. buse damage neglect improper maintenance or disapproved modifications e Your engine is designed to operate on commercial diesel fuel only Use of any other fuel in our engine will result in the engine operating in non compliance with the Federal EPA regulations You are responsible for initiating the warranty process It is suggested that you present your heavy duty off road engine to an authorized Komatsu dealer as soon as you become aware that problem exists The warranty repair should be completed by the dealer as expeditiously as possible f 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 s Attachments accessory items or parts not authorized for use by KFI Improper off road engine maintenance repair or abuse e Owner s unreasonable delay in making the product available after being notified of a potential product problem This warranty is in addition to the KF 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 KFI is not responsible for incidental or consequential damages such as downtime or lost use of the forklift truck 16 CUS
60. careful to prevent damage or injury from falling objects A WARNING TIRE FENDERS INCORRECT 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 FENDERS 01 4 01 SAFETY SECTION WARNING SAFE WORKING AREA i Always work on level surfaces and wipe up all oil or grease from the ground When working on quays platforms docks or other places where there is a danger of falling set up blocks to prevent the lift truck from going over the edge Put warning signs up in dangerous places to warn the operator not to approach Mark the travel areas clearly and maintain the road surfaces in good condition Put up signs to prevent unauthorized machines from entering areas where trucks are being operated Ensure that there is adequate lighting to enable operations to be carried out safely WARNING CLEAN OPERATOR S COMPARTMENT i Keep the operator s compartment clean and tidy Be sure to clean up all oil or mud lf the opera tor s 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 le
61. ch Assembly Replacing 07 183 Lighting and F R Switch Replacing 07 184 CHAPTER 08 TROUBLESHOOTING 08 01 Engine Troubleshooting Chart 08 02 Torgflow Troubleshooting Chart Bl n 08 03 Torque Converter Troubleshooting Chart Cushion Trucks 08 06 Torque Converter Troubleshooting Chart Pneumatic Trucks 08 08 Toraflow Control Valve Troubleshooting Chart Cushion 08 10 Torgflow Control Valve Troubleshooting Chart Pneumatic 08 11 Electrical System Troubleshooting Chart 08 12 Steering System Troubleshooting Chart 08 13 Brake System Troubleshooting Chart 08 14 Hydraulic System Troubleshooting Chart 08 16 CHAPTER 09 MASTS Complete Manuals 80D 100D 110D MS Limited Free Lift 2 Stage Mast 80D 100D 110D MT Full Free Lift 3 Stage Mast CHAPTER 10 CONVERSION TABLES MilimeterstoInches 10 02 inches to Millimeters
62. d clearance Contact your authorized dealer 02 11 02 GENERAL INFORMATION amp SPECIFICATIONS TRUCK DATA PNEUMATIC TIRE LIFT TRUCKS CON T FG40T2 8 FG45T 8 Gasoline Gasoline GENERAL Power Type Operation Type FG45T2 8 Gasoline Sit Down 10 000 4 535 21 5 545 21 5 545 78 7 2 000 14 730 6 6800 Capacity 24 in 600 mm Load Center Ibs kg Load Distance from Center Axle 2 Stage in mm Load Distance from Center Axle 3 Stage in mm Wreetbase n WEIGHT Service Weight inc 2 Stage STD Mast Forks Ibs kg TIRES Tire Type 300 x 15 x 18PR I 300 x 15 x 18PR I 7 00 X 12 12PR I 7 00 X 12 12PR 1 Tire Size Front Tire Size Rear Tread Center of Tires Front Rear in mm 45 3 1 150 44 1 1 120 DIMENSIONS Tilting Angle 2 Stage FV Masts Forward Backward Tilting Angle 3 Stage TFV Masts Forward Backward em Mast Height Lowered 2 Stage Std Mast Mast Height Extended 2 Stage Mast t Maximum Fork Height 2 Stage STD Mast in mm in mm Free Lift Height 2 Stage STD Mast in mm Height Overhead Guard in mm Length to Fork Face 2 Stage Mast in mm Length to Fork Face 3 Stage Mast in mm Overall Width at Drive Tires in mm Forks Thickness x Width x Length in mm 2 0 x 6 0 x 42 0 50 x 150 x 1 070 Carriage Width ITA Class in mm Ground Clearance under Mast in mm Ground Clearance Center of Wheelbase in mm
63. e cables Be 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 i 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 i 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 Be 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 AB801560 01 31 01 SAFETY SECTION 6 STRUCTURE AND STABILITY OF THE LIFT TRUCK TO PREVEN
64. e forks is dangerous because the forks are slippery and the load may move Donot 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 A WARNING PRECAUTIONS WHEN STOPPING OR PARKING Observe the following procedure when stopping or parking the lift truck 1 Stop the lift truck on level ground 2 Apply the parking brake securely to make sure that the lift truck cannot move 3 Set the directional lever and the speed lever to neutral 4 Lower the forks to the ground 5 Turn the key switch OFF to stop the engine 6 Remove the key from the key switch Then get off the lift truck ABBO 1480 A WARNING PARKING Park the lift truck in the specified place Park the lift truck on a firm surface Do not park near any emergency exit stairway fire extinguisher or other safety equipment Park the lift truck in a place where it will not obstruct pedestrians or other vehicles Never park the lift truck near any flammable object When parking the lift truck on a slope park as specified above PRECAUTIONS WHEN 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 A WARNING PARKING MACHINE AFTER FAIL
65. e program will reveal such conditions before more serious damage occurs to the truck Period of Part Name Replacement z x and dust seals 02 20 02 GENERAL INFORMATION amp SPECIFICATIONS STANDARD TIGHTENING TORQUE FOR PIPE JOINTS Elbows nipples and unions Width across Flats B mm 36 Width D mm Tightening Torque ft Ibs 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 Port Size in 3 4 16 UNF 7 8 14 UNF Tightening Torque Nm 50 6 54 3 57 9 61 4 x 68 6 73 6 7 7 5 78 5 83 3 8 8 5 kgfm High pressure rubber hoses pipes and sleeve nuts Width across flats B mm Bore A mm Tightening Torque ft Ibs 14 5 21 7 17 3 50 6 434 724 79 7 1232 1084 151 9 Nm kgfm 19 6 294 23 5 68 6 58 8 98 1 108 167 147 206 3 7 6 10 11 17 15 21 02 21 02 GENERAL INFORMATION amp SPECIFICATIONS STANDARD TIGHTENING TORQUE FOR BOLTS b 01 0002 Thread diameter Width across Tightening Torque of bolt in mm flat in mm a o bm um m 236 6 394 10 9 73 1 03 13 2 1 4 1 35 0 15 315 8 512 13 23 2 2 10 314 2 9 3 20 0 30 394 10 669 17 48 5 5 00 65 7 6 8 6 70 0 70 472 12 748 19 82 6 7 20 112 9 8 11 5 1 00 551 14 866 22 131 14 0 177 19 18 0 2 00
66. ect Lift Truck ChassisandFrame 05 14 Inspect Cab IfEguipped 05 14 inspect the Operator s Seat 05 14 Inspect Equipment Used for Accessing the Lift Truck 05 14 Inspect Display Panel eed cede ed E AA V ERE 05 15 Inspect Overhead Guard WA V sa sk LIES aan ae Pre BAY rea T cep er tas 05 15 Inspect Lights Gauges and Warning Devices 05 15 Inspect Rear View Mirror and Reflectors 05 15 CHAPTER 06 MAINTENANCE OPERATIONS 06 01 Lubricant List Gasoline Engine Lift Trucks 06 02 Lubricant List Diesel Engine Lift Trucks 06 03 Periodic Maintenance Chart 06 04 Oil and Greasing Chart sua siso so el EUH ARE aus RA 06 08 Changing Engine Oil and Filter Gasoline LP Engines 06 09 Changing Engine Oil and Filter Diesel Engines 06 10 Changing Gear Oil in Differential Case 06 11 Changing Transmission Fluid in TorqFlow Transmission Case 06 12 Changing Cil in Hydraulic Tank
67. eering Valve Orbital Power Steering Valve Exploded View 07 28 Power Steering Valve Troubleshooting Chart 07 29 Power Steering Valve Disassembly 07 31 Power Steering Valve Cleaning 07 35 Power Steering Valve Assembly 07 36 Power Steering Valve Installation 07 44 Brake Booster and Master Cylinder Brake Master Cylinder 07 45 Brake Master Cylinder Brake Booster Diagram 07 47 Brake Master Cylinder Disassembly 07 48 Brake Booster Unit Disassembly 07 49 Specifications 07 50 Inspection and Testing 07 50 Brake Master Cylinder Assembly 07 52 Brake Booster Assembly 07 52 Power Steering Cylinder Power Steering Cylinder Disassembly and Assembly Exploded View 07 56 Tilt Cylinders Tilt Cylinders Exploded View
68. en carrying out the job with another worker decide who is the leader and carry out the job in accordance with instructions from that person After repairing make sure that the trouble has been corrected by performing a trial run e 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 AX CAUTION USE SUITABLE roots Always use tools that are suited for inspection and mainte nance t is extremely dangerous to use broken tools or tools p designed for another purpose V P A0055120 WARNING REPLACE SAFETY CRITICAL PARTS PERIODICALLY i Even if no abnormality is found always replace safety critical parts periodically As time passes these parts 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 A 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
69. epair any damage AL187320 01 11 01 SAFETY SECTION A 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 i 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 inmediately 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 AB80125B WARNING BRAKING WHEN TRAVELING i 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
70. event the ignition is on without the engine running Check the propane eolenoid or vacuum shutoff valve for leakage as follows Tum fuel cylinder vaive off start and run engine until It stops instali a O to 30 PS pressure gauge per Instruction A or B A Primery test port of singie units consisting of primary and secondary regulators B Between the primary and secondary stage regulators when the propane system consists of two separate Turn cylinder fuel vaive on The pressure gauge should maintain a zero reading It it does not the solenoid valve or vacuum shutoff valve must be repaired or replaced An odor Is added to LP GAS to help detect leeks If gas odor is detected the fuel cylinder supply valve and engine shouid be turned oft Remove ail sources o ignition and ventilate the area Make all of the hoees for wear connections for leaks and all parte for NOTE Fuel hoses have a limited lite expectancy They should be checked tor cracking and drying due to age Hoses with visible signs of age shouid be a Use onty Underwritera Laboratories or Factory Mutual listed LP GAS parte for repiacements NOTE The above information is provided as a guide Consult the National Fire Protection Association pamphlet 58 for the sate storage and handling of liquetied petroleum gases Governmental safety regulations in your locality could vary Check with the authority having jurisdiction to be sure that you meet all of their requirements Con
71. id LPG switching module Mass air flow sensor Throttle chamber lgnition coil Crankshaft position sensor e Camshaft position sensor Distributor Spark plugs EMISSION CONTROL WARRANTY 36 MONTHS OR 4 000 HOURS FOR POWER TRAIN PARTS ntake manifold Exhaust manifold EMISSION CONTROL WARRANTY 60 MONTHS OR 3 500 HOURS FOR GENERAL PARTS e ECM e Catalytic converter e Vaporizer Follow the instructions in the Operations Manual concerning any other maintenance programs not required for EPA compliance For questions and additional information concerning EPA Gasoline Engine Exhaust Regulations contact Komatsu Forklift USA Inc 14481 Lochridge Blvd Bldg 2 Covington GA 30014 4908 Voice phone 770 385 4815 Fax phone 770 385 4838 13 FEDERAL EPA EMISSION CONTROL STATEMENT FOR OFF ROAD DIESEL ENGINES S6D102E 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 S6D102E diesel engines in order to comply with current EPA regulations 1 LABELS REQUIRED AND LABEL LOCATIONS All certified S6D102E diesel engines will display the required identification labels 4 as follows e S6D102E diesel engines Labels will be affixed to all appropriate engines on KFI production trucks Locations on S6D102E Series diesel engines TOP VIEW S6D102E
72. in 600 mm Load Center Ibs kg Load Distance from Center Axle 2 Stage in mm Load Distance from Center Axle 3 Stage in mm Venen m WEIGHT Service Weight inc 2 Stage STD Mast Forks tbs kg TIRES Number of Wheels Front Rear x 7 Driven Tread Center of Tires Front Rear in mm 45 3 1 150 44 1 1 120 DIMENSIONS Tilting Angle 2 Stage FV Masts Forward Backward Tilting Angle 3 Stage TFV Masts Forward Backward Mast Height Lowered 2 Stage Std Mast Mast Height Extended 2 Stage Mast t Maximum Fork Height 2 Stage STD Mast in mm Tam in mm Free Lift Height 2 Stage STO Mast in mm Height Overhead Guard in mm Length to Fork Face 2 Stage Mast in mm Length to Fork Face 3 Stage Mast in mm Overall Width at Drive Tires in mm Forks Thickness x Width x Length in mm 150 x 1 070 150 x 1 070 Carriage Width ITA Class in mm Ground Clearance under Mast in mm Ground Clearance Center of Wheelbase in mm 8 7 220 6 7 170 Right Angle Stacking Aisle 2 Stage Mast tt in mm Right Angle Stacking Aisle 3 Stage Mast tt in mm Turning Radius Outside in mm PERFORMANCE Travel Speed Forward Loaded Unloaded mph k hr Lifting Speed Loaded Unloaded 2 Stage fpm mm s Lifting Speed Loaded Unloaded 3 Stage fpm mm s Lowering Speed Loaded Unloaded 2 Stg fpm mm s Lowering Speed Loaded Unloaded 3 Stg fpm mm s Ma
73. 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 AB801610 01 SAFETY SECTION A 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 The 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 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 A WARNING LIFTING LIFT TRUCK when checking tires Do not go under the fork lift truck when it is jacked up Check the following before jacking up 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 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
74. k Face 3 Stage Mast in mm 122 2 3 105 Overall Width at Drive Tires in mm 57 1 1 450 Forks Thickness x Width x Length in mm 2 0 x 6 0 x 42 0 50 x 150 x 1 070 Carriage Width ITA Class in mm 46 9 1 190 III Ground Clearance under Mast in mm 5 5 140 Ground Clearance Center of Wheelbase in mm 8 7 220 Right Angle Stacking Aisle 2 Stage Mast tf in mm 129 8 3 295 Right Angle Stacking Aisle 3 Stage Mast tt in mm 129 8 3 295 Tuming Radius Outside in mm 108 3 2 750 PERFORMANCE Travel Speed Forward Loaded Unloaded mph k hr 11 8 19 0 12 7 20 5 13 4 21 5 14 3 23 0 11 8 19 0 12 7 20 5 Lifting Speed Loaded Unloaded 2 Stage fpm mm s 95 480 97 490 Lifting Speed Loaded Unloaded 3 Stage fpm mm s 91 460 93 470 Lowering Speed Loaded Unloaded 2 Stg fpm mm s 95 480 85 430 Lowering Speed Loaded Unloaded 3 Stg fpm mm s 91 460 81 410 Maximum Drawbar Pull Loaded Ibs kN 6 830 30 4 6 830 30 4 Maximum Gradeability Loaded Unloaded at 1 mph 32 21 28 22 Service Brake Operation Control Foot Hydraulic Foot Hydraulic Foot Hydraulic Hand Mechanical Hydrostatic Power Parking Brake Operation Contro Hand Mechanical Hand Mechanical Steering Type Hydrostatic Power Hydrostatic Power TABLE CONTINUED ON NEXT PAGE 02 GENERAL INFORMATION amp SPECIFICATIONS DRIVE Battery Voltage Capacity 20
75. le 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 lf 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 derat ing of the capacity Contact 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 19 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 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 maintenanc
76. ler for information and availability t Includes 48 in 1 220mm high load backrest 7 0 180 7 0 180 7 0 180 7 0 180 119 0 3 020 130 0 3 300 146 0 3 710 158 0 4 010 169 0 4 290 34 0 865 36 0 815 43 0 1 090 47 0 1 195 54 0 1 370 60 0 1 525 158 0 164 0 185 0 4 015 4 165 4 700 197 0 5 005 02 3 02 GENERAL INFORMATION amp SPECIFICATIONS SPECIFICATIONS MAST DATA amp FEATURES OUTDOOR PNEUMATIC TRUCKS FG40ZT 8 FG40ZT2 8 FG40T 8 FG40T2 8 FG45T 8 FG45T2 8 FG50AT2 8 FD40ZT 8 FD40ZT2 8 FD40T 8 FD40T2 8 FD45T 8 FD45T2 8 FD50AT2 8 E zT 1 2 SERO ENT 2 Am FGIDMO FG D 45 50 GS DI L 1645 166 3 fy F D LIE i R 108 3 109 4 pa RO JL CLE meee pura Se oer Bae py PNEUMATIC COMPACT UNIT INCH ae Hi Se 18 PNEUMATIC STD 02 0002CX 02 4 02 GENERAL INFORMATION amp SPECIFICATIONS SPECIFICATIONS MAST DATA amp FEATURES PNEUMATIC CON T MAXIMUM FORK HEIGHT FREE LIFT in mm Lowered Extendedt in mm t in mm in mm FG D 40Z 2 Stage Free View FV 7 0 180 7 0 180 7 0 180 7 0 180 3 Stage Full Free View TFV FG D 40 45 2 Stage Free View FV 3 Stage Full Free View TFV FG D 50 2 Stage Free View FV 3 Stage Full Free View TFV 280659 53 0 1350 50 6905 sso 1500 NOTE Specific
77. ler for replacement manuals Check truck before use If truck is in need of repair do nol operate until restored to safe condition Do not start truck if fuel is leaking or has leaked While Q 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 clearances especially forks mast overhead guard and tailswing area Slow down for turns and on uneven or slippery surfaces Avoid running over loose objects Never angle or turn on incline Travel with load uphill when loaded Travel with lifting mechanism downhill when empty Secure dockboard or bridgeplate properly Do not exceed rated capacity Use special care when operating on dockboard or bridgeplate Do not handle unstable loads or loosely stack loads Do not handie loads higher than load backrest Space forks as far as load permita Be sure load is centered and forks are completely under load Never tilt load with mast tilted forward Do not tilt forward when elevated except to pick up or depo
78. 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 AX 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 AX WARNING CONFIRMING SAFETY When traveling always pay careful attention to the area around your lift truck particularly in the direction of travel or when turning Do not pass other vehicles on narrow roads or at crossings or other places where the view is poor When traveling through 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 AB801260 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
79. n 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 01 26 INCORRECT CORRECT A0055190 AB801500A 01 SAFETY SECTION A 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 Do not use the mast as a ladder If you slip there is danger that you will fall B801320 AB801330 A DANGER CHECKING AND INFLATING TIRES If 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 have the work carried out by properly qualified personnel The tire inflation pressure on a forklift truck is several times higher than the pressure on an automobile When the tires are being
80. nal 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 gt 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 i Avoid loose clothing jewelry and loose long hair They can catch on controls or in moving parts and cause ES ag serious injury or death Always wear a hard hat and safety boots t Depending on the working conditions wear other safety EB equipment in addition to the hard hat and safety boots co A 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 0
81. ner you should be aware however that KFl may deny you warranty coverage if your off road large spark ignition engine or a part thereof has failed due to abuse damage neglect improper maintenance or unapproved modifications Your engine is designed to operate on gasoline and or LPG fuel Use of any other fuel may result in your engine no longer operating in compliance with the Federal EPA s emissions requirements You are responsible for initiating the warranty process It is suggested that you present your off road large spark ignition engine to an Authorized Komatsu Dealer as soon as you become aware that a problem exists The war ranty repairs should be completed by the dealer as expeditiously as possible If you have any questions regarding your warranty rights and responsibilities you should contact 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 e Oxygen sensor PCV valve ater temperature Gasoline injector sensor LPG injector LPG pressure sensor LPG soleno
82. nk 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 A 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 UR Depress the clutch pedal for clutch type trucks or the brake pedal for TORQFLOW transmission trucks firmly and then start the engine Adjust the operator s seat and the steering wheel before starting the engine Always lock them in position after adjusting Adjusting the seat or steering wheel during operation is dangerous 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
83. onal information Tt Add load length and clearance Contact your authorized dealer 02 13 02 GENERAL INFORMATION amp SPECIFICATIONS TRUCK DATA PNEUMATIC TIRE LIFT TRUCKS CON T FG50AT2 8 FD4021 8 FD402T2 8 GENERAL Power Type Gasoline Diesel Operation Type Sit Down Capacity 24 in 600 mm Load Center Ibs kg 8 000 3 630 Load Distance from Center Axle 2 Stage in mm 20 0 510 Load Distance from Center Axle 3 Stage in mm 21 3 540 Wheelbase in mm 72 1 1 830 WEIGHT Service Weight inc 2 Stage STD Mast Forks Ibs kg 16 060 7 285 13 180 5 980 13 180 5 980 TIRES Tire Size Front 250 x 15 x 16PR 1 Tire Size Rear 7 00 X 12 12PR 1 Number of Wheels Front Rear x z Driven 2x12 Tread Center of Tires Front Rear in mm 43 7 1 110 44 1 1 120 DIMENSIONS Tilting Angle 2 Stage FV Masts Forward Backward 6 12 Tilting Angle 3 Stage TFV Masts Forward Backward 6 6 Mast Height Lowered 2 Stage Std Mast in mm 92 5 2 350 Mast Height Extended 2 Stage Mast t in mm 179 0 4 545 Maximum Fork Height 2 Stage STD Mast in mm 131 0 3 330 Free Lift Height 2 Stage STD Mast in mm 7 0 180 Height Overhead Guard in mm 86 2 2 190 Length to Fork Face 2 Stage Mast in mm 115 3 2 930 Length to Fork Face 3 Stage Mast in mm 116 6 2 960 Overall Width at Drive Tires in mm 52 8 1 340 Forks Thickness x Width x Length in mm 2
84. ous Furthermore the lift etc Finas truck will tip over easily under this condition Therefore be sure to keep the load below the allowable value and prop A 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 make the lift truck tip or the load come off the forks When the lift truck is turned a centrifugal force is applied to the outside from the center of the turn This force pushes the lift truck to the outside and makes it tip The range of stability to the left and right is particularly small so it is necessary to reduce speed when turning in order to prevent the lift truck from tipping If the lift truck is traveling with a raised load the position of the overall center of gravity is high so the danger of tipping to the front left or right becomes greater 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 a new one Treat ail labels decals in the same way whe
85. pair Procedures Diesel 07 84 Hydraulic Pump Assembly of Front Pump Unit Diese 07 85 Hydraulic Pump Oil Seal Installation Jig Diagram 07 88 Hydraulic Pump Rear Unit Diesel Exploded View 07 89 Hydraulic Pump Disassembly of Rear Pump Unit Diesel 07 90 Hydraulic Pump Inspection amp Repair Procedures Diesel 07 90 Hydraulic Pump Assembly of Rear Pump Unit Diesel 07 91 Hydraulic Pump Testing s zeure wr eera na eR he 07 94 Hydraulic Pump Troubleshooting 07 95 TorqFlow Transmission Torque Converter Pneumatic Torque Converter AssemblyDrawing 07 96 Gear Pump Assembly Exploded View 07 97 Part Specificalions asp assar ciem ene CEDE EUER RE nee 07 98 Torque Converter Assembly 07 99 Pressure and Torque Specifications 07 100 Torque Converter Transmission Control Valve Structure and Function Pneumatic Overview cou ue deseek ve gea kx es uS IAE sk e ween ta ies nna ata 07 100 Handling Precautions sw de sos guess G a Usui bI ep IR ep edu deb xe Res 07 101 Torque ConverterA
86. perations 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 AE817998 01 18 01 SAFETY SECTION A WARNING FIT FORKS SECURELY IN POSITION When adjusting the position width of the forks be careful not to get your hands caught d AB801400 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 tension 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 BECAREFUL OF FORK TIPS i Do not allow the tips of the forks to get close to people The tips of the forks are pointed so there is a risk that they may cause injury Do not 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 i Do not allow
87. s 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 i Wipe off any oil or grease Immediately wipe up any oil that has leaked If the lift truck is dirty it becomes difficult or impossible to find cracks or other problems Always clean the lift truck before starting inspection Do not smoke or allow any flame to exist under any circumstances Do not use any cloth which is soaked in 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 Wh
88. sit 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 cautions Allow no one to stand or pass under or near load or lifting mechanism Never place any part of body into mast structure between mast and truck or outside truck Do not carry passengers on any part of truck Lift no one under any circumstances Do not operate without overhead guard and load backrest Fill fuel or charge battery only in specified place Stop engine when fueling and avoid open flame or sparks and provide adequate ventilation Keep vent caps clear when charging battery Disconnect battery during servicing After Operating Before getting off truck shift F A lever and high low lever clutch type to neutral position fully lower lifting mechanism and pull parking lever securely Shut off power when leaving truck unattended Block wheels when parking on incline Warning for use of split rim Only pneumatic tires Decal Part No 3EB 96 25750 Deflate tire completely before removing rim nuts 3EB 96 25750 KFIO10451 01 37 01 SAFETY SECTION 8 Prevention of tip over Decal Parts No 3EB 96 25730 SM E ha Wii Follow utis seathett ae Tip ovet can occur even when
89. ssembly 07 101 Control Valve Assembly uwo 07 102 Torque Converter Assembly Sectional View 07 104 Assembly Drawing emer kem eem En rx ER Rc Dos en Dari ala e 07 105 Torque Converter Fluid Diagram Pneumatic 07 106 Troubleshooting Chart Torque Converter Pneumatic Trucks 07 107 TorqFlow Transmission Pneumatic Disass mbly sata Dn 07 109 Input Shaft Clutch Pack Exploded View 07 112 Intermediate Shaft Clutch Pack Exploded View 07 114 F1 R1 Transmission Testing 07 116 F1 R1 Transmission Specification Table 07 117 F2 R1 Transmission TENGA Aa aa hn 07 119 F2 R1 Transmission Specification Table 07 120 PrecautionsonAssembly 07 121 Input Shaft Sub assembly Assembly F1 R1 Trucks 07 122 Input Shaft Assembly Flowchart 07 123 Intermediate Shaft Sub assembly Assembly F2 R1 Trucks 07 125 Intermediate Shaft Sub assembly Assembly Flowchart F2 R1 Trucks 07 126 Output Shaft
90. tact the manufacturer for detailed service information SERVICE WORK SHOULD BE PERFORMED BY QUALIFIED PERSONNEL ONLY KFOM0004 01 39 01 SAFETY SECTION 13 LPG FUEL SYSTEM DECALS A LPG LOW FUEL ALARM LIGHT On dashboard to left of steering column OP KFOMO006 B DUAL FUEL SYSTEM FUEL CHANGE OVER INSTRUCTIONS On Air Cleaner housing Not illustrated in Fig AWB2296B FUEL CHANGEOVER INSTRUCTIONS DUAL FUEL SYSTEM CAUTION FLAMMABLE LiGUIDS WHEN SWITCHING FROM LP GAS TO LIQUID FUEL BE SURE THAT THERE 1S NO SPILLAGE OF LIQUID FUEL FROM THE CARBURETOR FLOAT SYSTEM 1 SHUT OFF BOTH FUEL LINES COMPLETELY BY PLACING SWITCH IN THE OFF POSITION 2 START ENGINE AND RUN UNTIL SYSTEM IS PURGED OF ALL FUEL AND STOPS 3 TURN SWITCH TO DESIRED FUEL SELECTION LPG OR GASOLINE 4 START ENGINE AS USUAL KFOMO007 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 KFOMO0009 GASOLINE TANK MUST BE AT LEAST 1 4 FULL WHEN OPERATING ON LPG KFOMO008 01 40 02 GENERAL INFORMATION SPECIFICATIONS MAST DATA amp FEATURES INDOOR CUSHION TRUCK FG35ST 8 FG35BCS 8 H R L amp SPECIFICATIONS FG45ST 8 FG45BCS 8 CUSHION STD UNIT INCH IL CI Li Ci h va L ere 7 SE i 1 MIR a 15 M tis CUSHION BOX CAR SPECIAL 02 0001CX 0
91. ther they are safety related or not if WA zl oce CHENB Dye MUT FRONT SIDETL OF 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 4 Never touch fan when rotating forks and lifting or lowering himself Part No 3EB 96 25770 Never enter the area under the forks Part No 3EB 96 25840 A W A R N N G WARN ING 5 No one is permitted to ride the lift truck together with the operator Part No 3EB 96 25740 AM WARNING 2 Do not put your hand on the mast Warning to avoid getting hand caught Part No 3EB 96 25850 A WARNING 3EB 98 2585 3 Caution before operating machine Part No 3EB 96 25760 Before starting engine Put gearshift lever in neutral Pull parking lever ly eee 3 B 96 25760 01 36 6 Warning for operation Decal Part No 3EB 96 25720 01 SAFETY SECTION SERIOUS INJURY OR DEATH MAY RESULT IF YOU FAIL TO FOLLOW THESE PRECAUTIONS Befor ratin Do not operate or repair truck unless trained and authorized Read and understand all warnings and instructions in manuals and on truck before operating Contact forklift dea
92. tow these 4 cap WM dawa betore burning Turite seatbett hinsteygtinns KACO10449 01 8 01 SAFETY SECTION AX 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 A WARNING LOADING HIGHWAY TRUCKS OR 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 the forklift inside trucks reduce speed when backing out and be sure to check that the gangplanks are safe Be careful of pedestrians Tell the truck driver not to move the truck until the operation is completed If there is some system to secure the truck to the dock always use this system Secure the gangplanks so that they do not slip and fall A WARNING ESCAPING FROM A RAILROAD CROSSING If engine trouble occurs on a railroad crossing and the lift truck cannot move you cannot use the starting motor to move
93. uthorized dealer f 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 9 02 GENERAL INFORMATION amp SPECIFICATIONS TRUCK DATA PNEUMATIC TIRE LIFT TRUCKS GENERAL Operation Type Sit Down Capacity 24 in 600 mm Load Center Ibs kg 9 000 4 080 Load Distance from Center Axle 2 Stage in mm 21 5 545 Load Distance from Center Axle 3 Stage in mm 21 5 545 Wheelbase in mm 78 7 2 000 WEIGHT Service Weight inc 2 Stage STD Mast Forks ibs kg 12 850 5 830 14 030 6 365 TIRES Tire Size Front 250 x 15 x 16PR 1 250 x 15 x 16PR 1 250 x 15 x 16PR I 7 00 X 12 12PR 1 7 00 X 12 12PR 1 7 00 X 12 12PR I Tire Size Rear Number of Wheels Front Rear x Driven 2x12 Tread Center of Tires Front Rear in mm 43 7 1 110 44 1 1 120 45 3 1 150 44 1 1 120 DIMENSIONS Tilting Angle 2 Stage FV Masts Forward Backward 6 12 6 12 6 12 Tilting Angle 3 Stage TFV Masts Forward Backward 6 6 Mast Height Lowered 2 Stage Std Mast in mm 95 0 2 413 Mast Height Extended 2 Stage Mast f in mm 178 0 4 520 Maximum Fork Height 2 Stage STD Mast in mm 130 0 3 300 Free Lift Height 2 Stage STD Mast in mm 7 0 180 Height Overhead Guard in mm 88 8 2 225 Length to Fork Face 2 Stage Mast in mm 122 2 3 105 Length to For
94. vers or pedals Always keep them in the tool box when not being used WARNING SAFE OPERATING PLAN i 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 i 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 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 e 01 5 01 SAFETY SECTION A WARNING FIRE PREVENTION FOR FUEL FUEL IS EXTREMELY FLAM
95. ximum Drawbar Pull Loaded Ibs kN 7 180 31 9 8 360 37 2 Maximum Gradeability Loaded Unloaded at 1 mph Yo 31 22 0 39 22 Service Brake Operation Control Foot Hydraulic Foot Hydraulic Hand Mechanical Hand Mechanical Hydrostatic Power Hydrostatic Power TABLE CONTINUED ON NEXT PAGE Parking Brake Operation Control Steering Type 02 16 FD45T 8 Diesel Sit Down 10 000 4 535 21 5 545 21 5 545 78 7 2 000 15 110 6 855 Pneumatic 300 x 15 x 18PR I 7 00 X 12 12PR 1 2x12 6112 6 6 95 0 2 415 178 0 4 520 130 0 3 300 7 0 180 88 8 2 225 124 0 3 150 124 0 3 150 57 1 1 450 2 0 x 6 0 x 42 0 50 x 150 x 1 070 46 9 1 190 III 5 5 140 8 7 220 130 9 3 325 130 9 3 325 109 5 2 780 11 2 18 0 12 1 19 5 9 3 15 0 10 3 16 5 10 9 17 5 11 8 19 0 91 460 95 480 85 430 91 460 89 450 89 450 91 460 81 410 6 890 30 6 29 21 Foot Hydraulic Hand Mechanical Hydrostatic Power 02 GENERAL INFORMATION amp SPECIFICATIONS FD40T 8 FD40T2 8 FD45T 8 DRIVE Battery Voltage Capacity 20 hour rating VIAh 24170 Engine Model S6D102E Rated Output SAE Gross HP kW rpm 95 71 Q 2 150 Maximum Torque SAE Gross Ib ft Nm rpm 275 372 Q 1 000 No of Cylinders Displacement cu in cm 6 359 5 880 Cylinder Bore x Stroke in mm 4 0 102 x 4 7 120 Fuel Tank Capacity U S gallons liters 26 4 10
96. ys 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 gt 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 i When reversing depending on the situation an optional alarm reversing lamp or rotary lamp should be used In all cases be sure to face the rear and check around before traveling in reverse WARNING TRAVELING REGULATIONS ON PUBLIC ROADS i Always observe all traffic regulations when operating the lift truck Do not drive on public roads with the lift truck loaded Do not tow other machines on public roads Do not tow other machines even when not on public roads Always carry your driver s license when traveling on public roads WARNING SAFETY EQUIPMENT i 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

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

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