19.

OUTLINE OF SERVICE
19. OUTLINE OF SERVICE

• Use Komatsu Forklift specified parts and lubricants for replacement.

• When changing or adding oil, use only the oil that is recommended. Do not use a different kind or grade of oil.
• Unless otherwise specified, the oil and coolant used at delivery from the factory shall be as shown in the table
below.

Item Type of fluid

SAE 10W30 (gas/LPG)
Engine oil
SAE 30W (diesel)
Differential case SAE 90
Hydraulic tank ISO # 32 Hydraulic Fluid
TORQFLOW transmission case Dexron Automatic Transmission Fluid
Cooling system Fresh water and Glycol-based Coolant

19.1 OIL
• Since the oil is used for the work equipment, etc., under severe conditions (at high temperature and high pres-
sure), it will deteriorate as operating time passes. Always use an oil matching the grade and working tempera-
tures given in the Operation Manual.
Always replace the oil at specified time intervals even if it is not deteriorated.
• Oil is often compared to human blood.
A lift truck should be maintained with the same care taken for the human body so that impurities (water, metal
chips, dust, etc.) do not enter the lift truck system.
Most lift truck malfunctions are caused by the entry of impurities into the various systems.
Take special care to avoid the entry of impurities during storage and lubrication, etc.
• Never blend oils of different grades or brands.
• Add specified volume of oil.
Too little or too much oil may both cause problems in the fork lift truck.
• If the oil in the work equipment becomes cloudy, it is likely that air or water have entered the circuit. Consult a
Komatsu Forklift dealer.
• When replacing oil, replace the relevant filters at the same time.

19.2 GREASE
• Grease prevents wear and tear and the generation of squeaking noise from the joints, etc.
• Lift trucks are provided with grease nipples in various places. Some of these are not mentioned in this manual
since they are for overhauling purposes and do not require greasing.
If friction is noticed in movable parts after operation, grease them.
• After greasing, wipe off any old grease that is forced out, especially on rotating parts that will be worn by adher-
ing sand and dirt.

19.3 OIL STORAGE AND PRESERVATION

• Store and preserve oil so as to prevent entry of dirt, dust, water or other contaminants.
• When storing oil drums for long periods, place them side-by-side with filler sides facing in the same direction.
If necessary to store drums outdoors, cover them with waterproof sheeting. Ensure that the screw caps (bung
plugs) are tight.
• To prevent oil deterioration during long periods of storage, use drums on a “first-in, first-out” basis.

19.4 FILTERS
• Filters are very important safety items which prevent problems caused by impurities contained in the oil or
hydraulic circuit which sends oil into important units. Periodically replace the filters referring to this manual.
• When replacing oil filters, check for metal powder or shavings deposited on the used filters.
• Do not unpack replacement filters until immediately before installation.
• Always use specified filters.

4-1
20. LUBRICANT LIST

20.1 GASOLINE/LPG ENGINE LIFT TRUCKS

20. LUBRICANT LIST

FG35S/45S-8, FG35BCS/45BCS-8, FG40/40Z/45/50-8

NOTICE

Always use specified oil and grease.

Never use the incorrect kind of brake fluid. Use genuine Komatsu Forklift DOT 3 brake fluid.

Ambient Temperature
Location Type of Fluid -4 14 32 50 68 86°F Capactities
-20 -10 0 10 20 30°C
Engine oil (including filter) 8.5 quarts
Engine oil pan
(SAE10W-30) 8.0 L / 1.8 UK gal.

TORQFLOW DEXRON automatic 17 quarts

transmission case transmission fluid 16.1 L / 3.5 UK gal.

Gear oil (SAE80W) TORQFLOW transmission:

Differential case 13.7 quarts
Gear oil (SAE90W) 13.0 L / 2.85 UK gal.

FG35S/45S, FG35BCS/45BCS,
FG40Z:
11.0 US gal.
Hydraulic tank Hydraulic oil ISO #32 41.64 L / 9.16 UK gal.
FG40/45/50:
8.7 US gal.
32.9 L / 7.25 UK gal.
FG35S/45S, FG35BCS/45BCS,
Gasoline: 87 octane FG40/45/50:
(recommended) 26.5 US gal.
Fuel tank 100 L / 22.0 UK gal.
LPG: HD-5 grade FG40Z:
propane 21.0 US gal.
80 L / 17.5 UK gal.
Brake system Brake fluid (DOT 3) 0.04 US gal. / 0.15 L / 0.033 UK gal.

Lithium grease
Greasing points —
(NLGI No. 2)
Glycol-based coolant
Cooling system Add antifreeze at ambient 3.7 US gal., 14 L, 3.08 UK gal.
temp. 32°F/0°C or below

4-2
 20. LUBRICANT LIST

20.2 DIESEL ENGINE LIFT TRUCKS

FD40/45/50-8, FD40Z-8

NOTICE

• Use low sulfur or ultra low sulfur fuel only.

• Never use fuel mixed with kerosene.
• Always use specified oil and grease. EPA REGULATION
USE LOW SULFUR
FUEL OR ULTRA LOW
SULFUR FUEL ONLY
AE80369C

Never use the incorrect kind of brake fluid. Use genuine Komatsu Forklift DOT 3 brake fluid.

Ambient Temperature
Location Type of Fluid -4 14 32 50 68 86°F Capactities
-20 -10 0 10 20 30°C
Engine oil
(SAE 10W) 4.03 US gal.
Engine oil pan
15.2 L / 3.35 UK gal.
(SAE 30W)

TORQFLOW DEXRON automatic 4.22 US gal.

transmission case transmission fluid 16 L / 3.52 UK gal.
Gear oil (SAE80W) TORQFLOW transmission:
Differential case
Gear oil (SAE90W) 3.43 US gal.13 L / 2.86 UK gal.

14.53 US gal.
Hydraulic tank Hydraulic oil ISO #32
55 L / 12.10 UK gal.

Diesel fuel FD40/45/50:

ASTM D975 No. 2D, 26.4 US gal.
S15, S500 100 L / 22.0 UK gal.
Fuel tank
FD40Z:
ASTM D975 No. 1D, 21.1 US gal. / 80 L /
S15, S500 17.6 UK gal.

Brake system Brake fluid (DOT 3) 0.04 US gal. / 0.15 L / 0.033 UK gal.

Lithium grease
Greasing points —
(NLGI No. 2)

Glycol-based coolant
Cooling system Add antifreeze at ambient 3.7 US gal., 14 L, 3.08 UK gal.
temp. 32°F/0°C or below

4-3
20. LUBRICANT LIST

20.3 OIL AND GREASING CHART

OIL, GREASE LOCATIONS AND INSPECTION AND MAINTENANCE INTERVALS

Daily inspection
Every 2 weeks (100 hours)
Monthly (200 hours)
Every 3 months (600 hours)
Every 6 months (1200 hours)

Check and add fluid if necessary

Change or add oil
Number of places to add oil or grease

Chart symbol Type of fluid

AF Automatic transmission fluid
Diesel engine oil
EO
Gasoline engine oil
GO Gear oil
HO Hydraulic oil
BF Brake fluid
G Grease

4-4
 21. SERVICE DATA

21.1 SERVICE DATA – GASOLINE/LPG ENGINE LIFT TRUCKS

21. SERVICE DATA

Component Inspection item Unit FG35/40/45/50-8, FG40Z-8

Engine model – NISSAN TB45
Idling speed rpm 675 ± 50
Engine Maximum speed (continuous
rpm 3,000
load)
Compression ratio – 8.5
0.59 - 0.67 (11 - 17)
Cooling system Fan belt deflection in. (mm)
finger pressure: 22 ft/lb (98N) (10 kgf)
Injection timing BTDC deg. 10 ± 1
Fuel system Firing order – –
Engine

Injection pressure MPa –

Intake / exhaust Valve Intake in. (mm) 0.014 (0.35) Hot
system clearance Exhaust in. (mm) 0.014 (0.35) Hot
Distributor point gap in. (mm) –
Spark plug gap in. (mm) 0.028 - 0.031 (0.7 - 0.8)
NGK: B-4ES or BPR-4ES (shielded)
Spark plug type –
Electric system Hitachi L47W
Ignition timing (gasoline) BTDC deg./
10 ± 1 / 700
Ignition timing (LPG) rpm
Firing order – 1-5-3-6-2-4
250-15-16PR: 120 (0.83)
Tire inflation Front wheels 8.25-15-12PR: 98 (0.68)
Tires PSI (MPa) 300-15-18PR: 113 (0.78)
Travel system

pressure
Rear wheels 120 (0.83)
Tightening Front wheels
Lug nuts 217 - 361 (294 - 490)
torque Rear wheels
ft/lb (Nm)
Tightening Front wheels –
Rim mating nuts
torque Rear wheels 145 - 217 (196 - 294)
Steering wheel Play 1.2 - 2.4 (30 - 60)
Steering, braking system

Play in. (mm) 0.08 - 0.12 (2 - 3)

Inching pedal
Interconnected travel 1.38 - 1.41 (35 - 41)
Play 0.12 - 0.28 (3 - 7)
Brake pedal Pedal height when pedal is in. (mm)
3.54 - 3.94 (90 - 100)
depressed
Parking brake operating force ft/lb (N) Min. 55 (196)
Brake Tightening torque for back
ft/lb (Nm) 181 - 228 (245 - 309)
plate mounting bolts
FG40Z: Min. 1.77 (45)
Loading equipment

Forks Fork thickness at base of forks

in. (mm) FG40/45/50: Min. 1.97 (50)
Chain Length over 17 links Max. 17.3 (440)

Hydraulic system Relief pressure PSI (MPa) 2,610.7 (18)

4-5
21. SERVICE DATA

(GASOLINE/LPG ENGINE LIFT TRUCKS SERVICE DATA – CONTINUED)

Component Inspection item Unit FG35/40/45/50-8, FG40Z-8
250-15-16PR: 120 (0.83)
Tire inflation Front wheels 8.25-15-12PR: 98 (0.68)
Tires PSI (MPa) 300-15-18PR: 113 (0.78)
pressure
Rear wheels 120 (0.83)
Travel system

Tightening Front wheels

Lug nuts 217 - 361 (294 - 490)
torque Rear wheels
ft/lb (Nm)
Tightening Front wheels –
Rim mating nuts
torque Rear wheels 145 - 217 (196 - 294)
Steering wheel Play 1.2 - 2.4 (30 - 60)
Loading equipment Steering, braking system

Play in. (mm) 0.08 - 0.12 (2 - 3)

Inching pedal
Interconnected travel 1.38 - 1.41 (35 - 41)
Play 0.12 - 0.28 (3 - 7)
Brake pedal Pedal height when pedal is in. (mm)
3.54 - 3.94 (90 - 100)
depressed
Parking brake operating force ft/lb (N) Min. 55 (196)
Brake Tightening torque for back ft/lb
181 - 228 (245 - 309)
plate mounting bolts (Nm)
Fork thickness (at base of FG40Z: Min. 1.77 (45)
Forks
forks) in. (mm) FG40/45/50: Min. 1.97 (50)
Chain Length over 17 links Max. 17.3 (440)

Hydraulic system Relief pressure PSI (MPa) 2,610.7 (18)

4-6
 21. SERVICE DATA

21.2 SERVICE DATA – DIESEL ENGINE LIFT TRUCKS

Component Inspection item Unit FD40/45/50, FD40Z
Engine model – S6D102E (359 cu.in.) (95hp @ 2,150 rpm)
Idling speed rpm 675 - 725
Engine proper Maximum speed rpm 3,000 - 2,400
PSI (MPa)/
Compression 486 (3.35) / 280 - 320
rpm
Engine

0.24 - 0.39 (6 - 10)

Cooling system Fan belt deflection in. (mm)
finger pressure: 17.8 ft/lb (79N) (8 kgf)
Injection timing (at idle) BTDC deg. 1° ATDC (injection pump cam lift 1 mm)
Fuel system Injection order – 1-5-3-6-2-4
Injection pressure PSI (MPa) 2,845 (19.6)
Intake / exhaust Valve Intake in. (mm) 0.0098 (0.25) Cool
system clearance Exhaust in. (mm) 0.020 (0.51) Cool
250-15-16PR: 120 (0.83)
Tire inflation Front wheels PSI 8.25-15-12PR: 98 (0.68)
Tires 300-15-18PR: 113 psi (0.78)
Travel system

pressure (MPa)
Rear wheels 120 (0.83))
Tightening Front wheels
Lug nuts 217 - 361 (294 - 490)
torque Rear wheels ft/lb
Tightening Front wheels (Nm) –
Rim mating nuts
torque Rear wheels 145 - 217 (196 - 294)
Steering wheel Play 1.2 - 2.4 (30 - 60)
Steering, braking system

Play in. (mm) 0.08 - 0.12 (2 - 3)

Inching pedal
Interconnected travel 1.38 - 1.41 (35 - 41)
Play 0.12 - 0.28 (3 - 7)
Brake pedal Pedal height when pedal is in. (mm)
3.54 - 3.94 (90 - 100)
depressed
Parking brake operating
ft/lb (N) Min. 55 (196)
force
Brake
Tightening torque for back ft/lb (Nm) 181 - 228 (245 - 309)
plate mounting bolts
Fork thickness at base of FD40Z: Min.1.77 (45)
Loading equipment

Forks
forks in. (mm) FD40/45/50: Min. 1.97 (50)
Chain Length over 17 links Max. 17.3 (440)

Hydraulic system Relief pressure PSI (MPa) 2,610.7 (18)

4-7
21. SERVICE DATA

21.3 TORQUE LIST

For unspecified bolts and nuts, use the torque specifications in this list.

Select the proper torque corresponding to the width across flats (b) of
bolts and nuts.

When replacing bolts and nuts, always use genuine Komatsu Forklift
parts that match the previous installation in size.

Thread diameter Width across Tightening torque

of bolt (mm) flat (mm)
(a) (b) ft/lb kgfm Nm

6 10 9.73 ± 1.03 1.35 ± 0.15 13.2 ± 1.4

8 13 23.2 ± 2.1 3.2 ± 0.3 31.4 ± 2.9
10 17 48.5 ± 5.0 6.7 ± 0.7 65.7 ± 6.8
12 19 82.6 ± 7.2 11.5 ± 1.0 112 ± 9.8
14 22 131 ± 14 18.0 ± 2.0 177 ± 19

16 24 206 ± 21 28.5 ± 3 279 ± 29

18 27 282 ± 29 39 ± 3 383 ± 39
20 30 405 ± 43 56 ± 6 549 ± 58
22 32 549 ± 58 76 ± 8 745 ± 78
24 36 684 ± 72 94.5 ± 10 927 ± 98

27 41 973 ± 100 135 ± 15 1,320 ± 140

30 48 1,270 ± 140 175 ± 20 1,720 ± 190
33 50 1,630 ± 180 225 ± 25 2,210 ± 240
36 55 2,030 ± 210 280 ± 30 2,750 ± 290
39 60 2,420 ± 250 335 ± 35 3,280 ± 340

4-8
 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

To ensure safety at all times when operating or driving the lift truck, the lift truck user must always carry out periodic
maintenance. In addition, to further improve safety, the user should also perform periodic replacement of parts
given in the table below. These parts, in particular, are closely relate to safety and fire prevention.

The material of these parts may change over time, or they may easily wear or deteriorate. However, it is difficult to
judge the condition of these parts simply by periodic maintenance. The parts listed should always be replaced after
a fixed, specified time has passed, regardless of their condition. This is necessary to ensure that these parts
maintain their full function at all times.

Note that if these parts show any abnormality before the replacement interval has passed, they should be repaired
or replaced immediately.

If the hose clamps show any signs of deterioration, such as deformation or cracking, replace them at the same time
as the hoses.

Note that this periodic replacement is not covered by warranty.

IMPORTANT PARTS LIST

No. Part name Period (Years)

1 Brake valve, wheel cylinder cup and dust seal, etc. 1

2 Brake hose or tube 1-2

3 Power steering hose 2

4 Stop lamp switch (hydraulic type) 2-4

5 Fuel hose 2

6 Rubber parts inside power steering system 2

7 Lift chain 2-4

8 Hydraulic hose for lifting mechanism 1-2

• Use only genuine fuel hose.

• If a poor quality hose is used, plasticizer material or other harmful material from the hose may
contaminate the LPG and cause the injection valve to stick.
This will prevent the engine from starting.

4-9
23. MAINTENANCE SCHEDULE CHART

Perform maintenance at intervals of months or operation hours, whichever occurs first. Refer to service
23. MAINTENANCE SCHEDULE CHART

manual for procedures not detailed here.

Service Item Page

First month or initial 200 hours service (only after the first one month)

Change oil in hydraulic tank, replace line filter, clean strainer, clean inside of tank 4-14

(All) Change oil in engine oil pan and replace engine oil filter cartridge 4-15

(Gasoline engine) Inspect and clean fuel filter sock (not replaceable) 4-16

Check, adjust engine valve clearance 4-16

Tighten (retorque) engine cylinder head bolts 4-16

Change oil in TORQFLOW transmission case, clean TORQFLOW transmission strainer 4-17

Change oil in differential case 4-18

Check spark plugs for burning of electrode, burning of insulator 4-18

Check air cleaner and replace filter when dirty 4-19

Check ignition timing 4-19

Check, adjust alternator belt (drive belt) tension 4-19

Tighten bolts and nuts (especially lug nuts, overhead guard, load backrest, and operator’s seat
4-20
mounting bolts and nuts)

Check before operation items 3-18

Every 2 weeks or every 100 hours service

Grease lift chain 4-21

Every month or every 200 hours service

Check wheel rims for deformation, cracking and damage 4-21

Check wheel bearings for play and abnormal noise 4-21

Check hydraulic cylinders for looseness, deformation, cracking, damage and wear 4-21

Check all piping/tubing/connectors for oil leakage, deformation or damage 4-21

Check operation of hydraulic cylinders 4-21

Check hydraulic drift of lift cylinder 4-21

Check hydraulic drift of tilt cylinders 4-21

Check movement of work equipment control lever(s) 4-21

Check forks and fork stopper for deformation, cracking, damage and wear 4-21

Check forks for unevenness and twisting 4-21

Check mast for deformation, cracking, damage and wear 4-21

Check mast roller for play 4-21

Check chain and chain wheel for deformation, damage, rust and poor lubrication 4-21

4-10
 23. MAINTENANCE SCHEDULE CHART

Service Item Page

Every month or every 200 hours service (continued)

Check chain wheel bearing for play 4-21

Check chain anchor bolt for deformation and damage 4-21

Check gear box for oil leakage, looseness of mount 4-21

Check mounting condition of power steering, check for looseness at connections 4-21

Check brake link for play, looseness, damage and wear 4-21

Check brake piping/tubing for damage, leakage, looseness, contact, looseness of brake tubing clips and
4-22
disconnection at fittings

Check clearance between brake drum and lining, check brake for grabbing, dragging or pulling 4-22

Check shift lever for play, meshing 4-22

Check for oil leakage from transmission and differential cases 4-22

Check oil level in TORQFLOW transmission, add oil as necessary (Do not overfill) 4-22

Check inching pedal height when pedal is depressed 4-22

Change oil in engine oil pan 4-15

Check starting of engine 4-22

(Gas & LPG engines) Check idling speed 4-22

Check, clean radiator fins, check for damage 4-22

Check for catching, stalling and knocking when accelerating 4-22

Check air cleaner and replace filter when dirty 4-19

Check operation of maximum rpm 4-22

Check piping/tubing and connections/fittings for fuel/gas leakage 4-22

(LPG) Check the vaporizer for tar, drain 4-23

Check radiator hoses for cracking, damage 4-23

Check operating condition of radiator cap, check installation 4-23

Check fan for deformation, cracking, and damage 4-23

Check fan for looseness and mounting 4-23

Check, adjust fan belt tension 4-23

Check, adjust alternator belt (drive belt) tension 4-19

Check clearance of distributor points, check contact surface for roughness 4-23

Check spark plugs for burning of electrode, burning of insulator 4-18

(Diesel Engine) Drain water from fuel filter 4-24

Check operation of starting switch; check meshing of pinion gear 4-25

4-11
23. MAINTENANCE SCHEDULE CHART

Service Item Page

Every month or every 200 hours service (continued)

Check specific gravity of battery electrolyte 4-25

Check wiring connections for looseness 4-25

Check ignition timing 4-19

Check overhead guard, load backrest for deformation, cracking, damage and looseness 4-26

Check operator’s seat mount for looseness and damage, check LPG cylinder mounting bracket 4-26

Grease all lubrication points 4-26

Every 500 hours service

(Diesel Engine) Replace fuel filter 4-24

Every 3 months or every 600 hours service

(Diesel engine) Replace engine oil filter cartridge 4-15

Check oil level in transmission case, add oil as necessary 4-17

Check oil level in differential case, add oil as necessary 4-18

Every 6 months or every 1,200 hours service

Check steering link for bending, damage and wear 4-26

Check knuckle for play, deformation and damage 4-26

Check for marked variation in minimum turning radius 4-26

Change oil in TORQFLOW transmission case, clean strainer 4-17

Change oil in differential case 4-18

Replace torque converter oil filter 4-27

Change brake oil/fluid 4-27

Check, adjust valve clearance 4-27

Measure compression pressure 4-27

(Diesel Engine) Check, adjust fuel injection timing, check and inspect fuel injection nozzles 4-27

Check PCV blow-by gas reduction system for clogging, damage 4-27

Check distributor cap centerpiece for wear 4-27

(LPG engine) Replace LPG filter element 4-27

Replace air cleaner filter 4-19

Change oil in hydraulic tank, replace hydraulic line filter, clean hydraulic tank strainer, clean inside of
4-14
hydraulic tank

Every 2,000 hours of service

(LPG engine) Replace LPG mixer air valve diaphragm, under normal operating conditions. Replace
4-27
more often in cold or severe service applications. Replace O-ring for LPG tank valve.

4-12
 23. MAINTENANCE SCHEDULE CHART

Service Item Page

Every 12 months or every 2,400 hours service

Check operation of brake master cylinder, check for oil leakage, damage and wear 4-27

Check operation of wheel cylinders, check for oil leakage, damage and wear 4-27

Check operation of brake drum, check for damage and wear 4-27

Check brake linings for wear 4-27

Check operating condition of brake shoe 4-27

Check brake adjustment lever and ratchet for wear and damage 4-27

Check brake spring for deterioration 4-27

Check brake back plate for deformation and cracking; Check mounting condition 4-27

Check axle for deformation, cracking and damage 4-28

Check mounting condition of differential 4-28

Check root (base) of forks for cracking (use color check) 4-28

Check roller shaft of loading equipment for cracking and damage 4-28

Check mast support for damage and wear 4-28

Check operation of relief valve; check relief pressure 4-28

Replace air breather 4-28

Check distributor cap (gasoline), distributor inside (IC ignition system) for cracking or damage 4-28

Clean inside of fuel tank 4-28

Clean inside of cooling system, clean radiator, replace coolant (glycol-based) 4-28

Check fuel injection pressure, injection amount, injector condition 4-29

(Gasoline engine) Inspect and clean fuel filter sock (not replaceable) 4-16

Tighten (retorque) engine cylinder head bolts 4-16

Check frame and cross member for cracking and damage 4-29

Every 18 months or every 3,600 hours service

Replace spark plugs 4-29

4-13
24. MAINTENANCE

24.1 FIRST MONTH OR INITIAL 200 HOURS SERVICE

24. MAINTENANCE

Carry out this maintenance, for new lift trucks only, after the first one month or initial 200 hours of operation,
whichever comes sooner.

24.1.1 HYDRAULIC EQUIPMENT

„ CHANGE OIL IN HYDRAULIC TANK, REPLACE LINE FILTER, CLEAN STRAINER, CLEAN INSIDE OF
TANK

Watch out for HOT OIL. Immediately after operations, the oil will be very hot. Wait for the oil
temperature to go down before starting this maintenance operation.

1. Remove the drain plug at the bottom of the tank. Then remove the
cover, take out the strainer, and wash it in flushing oil.
2. Clean the inside of the tank, then install the drain plug.
3. After washing the strainer, blow air from the inside of the strainer to
dry it completely, then reinstall the strainer.
4. Replace the line filter, then install the cover.
5. Add the specified amount of ISO # 32 hydraulic oil through the
dipstick hole, then check the oil level with the dipstick.

11.0 U.S. gal.

FG35/45S, FG35/45BCS, FG40Z
(41.6 L, 9.16 UK gal.)
8.70 U.S. gal.
FG40/45/50
(32.9 L, 7.25 UK gal.)
14.53 U.S. gal.
FD40/45/50, FD40Z
(55 L, 12.10 UK gal.)

6. Start the engine, then operate the cylinders (lift, tilt) to the end of
their travel 5 or 6 times to bleed the air.

NOTICE

Always use specified hydraulic oil.

4-14
 24. MAINTENANCE

24.1.2 ENGINE
„ CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE

When carrying out engine maintenance, stop the engine and wait for it to fully cool down.

GASOLINE/LPG ENGINE (TB45)

CHANGE ENGINE OIL (See illustration item 1 for filler
location)
1. Remove the drain plug, drain the oil, then reinstall and tighten
the drain plug.
2. Add the correct amount of specified engine oil.
3. Check the oil level with the dipstick.

NOTICE

Oil refill amount: 8.5 quarts (8.0 L, 1.80 UK gal.) including new oil
filter.

REPLACE ENGINE OIL FILTER (See illustration item 2 for

location)
1. Use a filter wrench to remove the oil filter cartridge.
2. Clean the filter holder on the engine.
3. Coat the threads on the holder and the seal on the new filter with clean engine oil.
4. Install the new filter.

NOTICE

After installing the new oil filter cartridge, start the engine and check for oil leakage around the oil filter
seal and at the oil pan drain plug.

4-15
24. MAINTENANCE

DIESEL ENGINE (S6D102E)

CHANGE ENGINE OIL (See illustration item 1 for filler
location)
1. Remove the drain plug, drain the oil, then reinstall and
tighten the drain plug.
2. Remove the dipstick.
3. Add the specified amount of engine oil. Use care to pre-
vent oil overflow.
4. Check the oil level with the dipstick.

NOTICE

Oil refill amount: 3.04 U.S. gal. (11.5 L, 2.53 UK gal.) (includ-
ing new oil filter)

REPLACE ENGINE OIL FILTER (See illustration item 2

for location)
1. Use a filter wrench to remove the oil filter cartridge.
2. Clean the oil filter holder.
3. Coat the threads of the holder and the new filter seal
with clean engine oil.
4. Install the new oil filter cartridge.

NOTICE

After installing the new oil filter, start the engine and check for oil leakage at the filter seal and the oil pan
drain plug.

„ (GASOLINE ENGINE) INSPECT AND CLEAN FUEL FILTER SOCK

„ CHECK, ADJUST ENGINE VALVE CLEARANCE
„ TIGHTEN (RETORQUE) ENGINE CYLINDER HEAD BOLTS

4-16
 24. MAINTENANCE

24.1.3 POWER TRAIN

„ CHANGE OIL IN TORQFLOW TRANSMISSION CASE, CLEAN TORQFLOW TRANSMISSION STRAINER

Watch out for HOT OIL. Immediately after operations, the oil will be very hot. Wait for the oil
temperature to go down before starting this maintenance operation.

1. Remove the floor plate and check oil with dipstick.

2. If the oil level is low, remove the dipstick and add oil.
3. Remove the drain plug, drain the oil, then reinstall and tighten
the drain plug.
4. Remove the mounting bolts, take out the strainer, and wash it
off in flushing oil.
5. After washing the strainer, blow air from the inside of the
strainer to dry it completely, then reinstall the strainer.
6. Add the specified amount of oil through the oil filler port.
7. After filling with oil, check the oil level.

Specified Oil Refill Amount

TORQFLOW transmission 17 quarts / 4.25 gal.
(including torque converter) (16.1 L, 3.54 UK gal.)

NOTICE

Always use specified oil or DEXRON II Automatic Transmis-

sion Fluid.

4-17
24. MAINTENANCE

„ CHANGE OIL IN DIFFERENTIAL CASE

Watch out for HOT OIL. Immediately after operations, the oil will be very hot. Wait for the oil
temperature to go down before starting this maintenance operation.

CHECK OIL LEVEL

Remove the level plug and check that the oil is near the bottom edge
of the plug hole.
If the oil level is low, remove the oil filler plug and add oil.

CHANGE OIL
1. Remove the oil filler plug, then remove the drain plug and drain
the oil.
2. After draining the oil, reinstall and tighten the drain plug and add
the correct amount of specified oil through the oil filler.
3. Check the oil level after filling with new oil.

Specified Oil Refill Amount

TORQFLOW 3.43 U.S. gal.
transmission lift truck (13 L, 2.86 UK gal.)

NOTICE

Always use specified gear oil (SAE 90). For details, see “LUBRICANT LIST” on page 4-2.

Remark
On the TORQFLOW transmission lift truck, each case has its own special oil, so it is necessary to check and
change the oil in the TORQFLOW transmission case in addition to checking and changing the oil in the differ-
ential case in two separate operations.

„ CHECK SPARK PLUGS FOR BURNING OF ELECTRODE, BURNING OF INSULATOR

1. Remove a spark plug using the plug wrench provided with
the lift truck.
2. Clean off any carbon buildup on the tip of the plug or the
surrounding area. See illustration at right.
3. Measure gap (A) with plug gap gauge.

Specified Spark Plugs

B-4ES
NGK
BPR-4ES (Noise suppression type)
Hitachi L47W

4-18
 24. MAINTENANCE

„ CHECK AIR CLEANER AND REPLACE FILTER WHEN DIRTY

Never clean or replace air cleaner while the engine is running.

• Do not replace an air filter on a diesel engine with a filter intended for a gasoline engine or
vice-versa: radial seal style filters are NOT interchangeable between diesel and gasoline
engines.
• Never clean the radial seal air filter or use compressed air on it; this will damage the filter.
Replace the air filter if dirty.
• It is important that all air cleaner latches are present and in good working condition as they
retain the air filter element in place. DO NOT operate the lift truck unless all latches are present
and in good working condition.

NOTICE

The engine warranty will be voided if improper or aftermarket elements are used.

REPLACE RADIAL SEAL AIR FILTER

1. Release latches to remove air cleaner housing cover.
2. Gently remove filter element, taking care not to dislodge dirt
and dust. Avoid knocking the filter against the housing. If your
air cleaner has a safety filter, replace it every third primary
filter change. Remove the safety filter as you would the
primary filter. Make sure you cover the air cleaner outlet tube
to avoid any unfiltered contaminant dropping into the engine.
3. Thoroughly clean air cleaner housing sealing surface and
outlet tube outer diameter. Then clean the inside of the outlet
tube using a clean cloth.
4. Inspect the old filter for leak clues. A streak of dust on the
clean side of the filter is a telltale sign. Remove any cause of
leaks before installing new filter.
5. Inspect the new filter for damage, paying careful attention to the inside of the open end, which is the sealing
area. Never install a damaged filter.
6. Insert new radial seal filter carefully with open end towards air cleaner housing.
Seat filter completely by hand, making certain it is completely into the air cleaner
housing before securing the cover in place. Each new element sealing surface is
coated with a dry lubricant to aid in sealing. DO NOT USE COVER TO FORCE
FILTER ELEMENT INTO PLACE. THIS WILL DAMAGE THE FILTER AND THE
HOUSING. When seating element, apply hand pressure to outer edge of filter, not
in the flexible center.
7. Once element is seated and sealed, reinstall cover and secure the latches.
8. Check all clamps, bolts and connections for tightness.

„ CHECK IGNITION TIMING

„ CHECK, ADJUST ALTERNATOR BELT (DRIVE BELT) TENSION

4-19
24. MAINTENANCE

24.1.4 GENERAL
„ TIGHTEN BOLTS AND NUTS, ESPECIALLY LUG NUTS, OVERHEAD GUARD, LOAD BACKREST AND
OPERATOR’S SEAT MOUNTING BOLTS AND NUTS

4-20
 24. MAINTENANCE

24.2 CHECK BEFORE OPERATION

For details, see “CHECK BEFORE OPERATION” on page 3-18.

24.3 EVERY 2 WEEKS OR EVERY 100 HOURS SERVICE

24.3.1 LOADING EQUIPMENT
„ GREASE LIFT CHAIN

24.4 EVERY MONTH OR EVERY 200 HOURS SERVICE

24.4.1 TRAVEL EQUIPMENT
„ CHECK WHEEL RIMS FOR DEFORMATION, CRACKING AND DAMAGE
„ CHECK WHEEL BEARINGS FOR PLAY AND ABNORMAL NOISE
24.4.2 HYDRAULIC EQUIPMENT
„ CHECK HYDRAULIC CYLINDERS FOR LOOSENESS, DEFORMATION, CRACKING, DAMAGE AND
WEAR
„ CHECK ALL PIPING/TUBING/CONNECTORS FOR OIL LEAKAGE, DEFORMATION OR DAMAGE
„ CHECK OPERATION OF HYDRAULIC CYLINDERS
„ CHECK HYDRAULIC DRIFT OF LIFT CYLINDER
„ CHECK HYDRAULIC DRIFT OF TILT CYLINDERS
„ CHECK MOVEMENT OF WORK EQUIPMENT CONTROL LEVER(S)

24.4.3 LOADING EQUIPMENT

„ CHECK FORKS AND FORK STOPPER FOR DEFORMATION, CRACKING, DAMAGE AND WEAR
„ CHECK FORKS FOR UNEVENNESS AND TWISTING
„ CHECK MAST FOR DEFORMATION, CRACKING, DAMAGE AND WEAR
„ CHECK MAST ROLLER FOR PLAY
„ CHECK CHAIN AND CHAIN WHEEL FOR DEFORMATION, DAMAGE, RUST AND POOR LUBRICATION
„ CHECK CHAIN WHEEL BEARING FOR PLAY
„ CHECK CHAIN ANCHOR BOLT FOR DEFORMATION AND DAMAGE
24.4.4 STEERING SYSTEM
„ CHECK GEAR BOX FOR OIL LEAKAGE, LOOSENESS OF MOUNT
„ CHECK MOUNTING CONDITION OF POWER STEERING, CHECK FOR LOOSENESS AT CONNECTIONS
„ CHECK BRAKE LINK FOR PLAY, LOOSENESS, DAMAGE
AND WEAR
1. Check the play and the height of the brake pedal when it is
depressed to check that it matches the specified values.

Play 0.12 - 0.28 in. (3 - 7 mm)

Pedal height when depressed 3.54 - 3.94 in. (90 - 100 mm)

2. Test the brake while gradually increasing your speed from a low
speed. Check that the brakes do not pull, grab or drag. If
necessary, adjust the brakes until they apply smoothly.

4-21
24. MAINTENANCE

„ CHECK BRAKE PIPING/TUBING FOR DAMAGE, LEAKAGE, LOOSENESS, CONTACT, LOOSENESS OF

BRAKE TUBING CLIPS AND DISCONNECTION AT FITTINGS

Inspect the lift truck in an area where it will not obstruct other vehicles or workers.

„ CHECK CLEARANCE BETWEEN BRAKE DRUM AND LINING, CHECK BRAKE FOR GRABBING,
DRAGGING OR PULLING

24.4.5 POWER TRAIN

„ CHECK SHIFT LEVER FOR PLAY, MESHING
„ CHECK FOR OIL LEAKAGE FROM TRANSMISSION AND DIFFERENTIAL CASES
„ CHECK OIL LEVEL IN TORQFLOW TRANSMISSION, ADD OIL AS NECESSARY
See “CHANGE OIL IN TORQFLOW TRANSMISSION CASE, CLEAN TORQFLOW TRANSMISSION STRAINER”
on page 4-17 for details.

„ CHECK INCHING PEDAL HEIGHT WHEN PEDAL IS DEPRESSED

24.4.6 ENGINE
„ CHANGE OIL IN ENGINE OIL PAN
See “CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE” on page 4-15

„ CHECK STARTING OF ENGINE

„ (GAS & LPG) CHECK IDLING SPEED
„ CHECK, CLEAN RADIATOR FINS, CHECK FOR DAMAGE

Dirt may fly and get into your eyes, so always wear protective glasses or goggles.

Cleaning
Blow the radiator fins with compressed air, steam or water.

Air pressure 142 psi (0.98 MPa) (10 kgf/cm2)

Steam pressure 56 psi (0.39 MPa) (4 kgf/cm2)

Testing
Check visually to ensure there are no dents or damage to the fins.

„ CHECK FOR CATCHING, STALLING AND KNOCKING WHEN ACCELERATING

„ CHECK AIR CLEANER AND REPLACE FILTER WHEN DIRTY
See “CHECK AIR CLEANER AND REPLACE FILTER WHEN DIRTY” on page 4-19 for details.

„ CHECK OPERATION OF MAXIMUM RPM

„ CHECK PIPING/TUBING AND CONNECTIONS/FITTINGS FOR FUEL/GAS LEAKAGE

4-22
 24. MAINTENANCE

„ (LPG) CHECK THE VAPORIZER FOR TAR; DRAIN

The vaporizer is a device used during LPG operation to control and reduce fuel pressure within the LPG cylinder
and regulate vaporization. Tar, a thick, sticky liquid, is produced during this process and accumulates in the
vaporizer. Excess tar buildup in the vaporizer adversely affects idling speed.

NOTICE

Tar must be drained from the vaporizer at least once per month.

• Ensure that the service valve on the fuel feed line is turned fully to the OFF position.
Otherwise, pressure in the line may cause operator injury when the drain plug is removed.
• Always wear protective glasses or goggles.

1. Run the engine until it is fully warmed up to operating tempera-

ture.
2. As the engine continues to run, close the service valve on the
line from the LP tank.
3. Turn the ignition switch to the OFF position when the engine
stops.
4. Place a rag under the drain valve to catch the draining tar.
5. Remove the drain plug from the bottom of the vaporizer.
6. Reinstall the drain plug after draining the tar onto the rag.

„ CHECK RADIATOR HOSES FOR CRACKING, DAMAGE

„ CHECK OPERATING CONDITION OF RADIATOR CAP, CHECK INSTALLATION
„ CHECK FAN FOR DEFORMATION, CRACKING AND DAMAGE
„ CHECK FAN FOR LOOSENESS AND MOUNTING
„ CHECK, ADJUST FAN BELT TENSION
„ CHECK, ADJUST ALTERNATOR BELT (DRIVE BELT) TENSION
„ CHECK CLEARANCE OF DISTRIBUTOR POINTS, CHECK CONTACT SURFACE FOR ROUGHNESS
„ CHECK SPARK PLUGS FOR BURNING OF ELECTRODE, BURNING OF INSULATOR
See “CHECK SPARK PLUGS FOR BURNING OF ELECTRODE, BURNING OF INSULATOR” on page 4-18 for
details.

4-23
24. MAINTENANCE

„ (DIESEL ENGINE) DRAIN WATER FROM FUEL FILTER

1. Locate the fuel filter (item 1).

2. Loosen the combination sensor plug and drain any water and
sediment accumulated at the bottom of the filter.

NOTICE

• Fuel will also drain out of the fuel filter, so prepare a suitable
container to catch it.
• Always be sure to wipe up any spilled fuel.

24.4.7 (DIESEL ENGINE) REPLACE FUEL FILTER

When carrying out engine maintenance, stop the engine and wait for it to fully cool down.

(See the illustration above for location)

1. Remove the combination sensor plug at the bottom of the cartridge.

2. Use a filter wrench to remove the cartridge.
3. Install the combination sensor plug on the new cartridge.
4. Fill the new cartridge with clean fuel, coat the packing surface with a
thin layer of clean engine oil, then install.
5. Loosen plug (1), then hand-pump knob (2) up and down to bleed air
bubbles from fuel. Continue until no more bubbles come out with the
fuel.
6. Tighten plug (1).

4-24
 24. MAINTENANCE

24.4.8 ELECTRICAL COMPONENTS

„ CHECK OPERATION OF STARTING SWITCH; CHECK MESHING OF PINION GEAR
„ CHECK SPECIFIC GRAVITY OF BATTERY ELECTROLYTE

• Precautions when handling battery:

• Battery electrolyte is dangerous. If it gets into your eyes or on your skin or clothes, wash it
off with large amounts of water quickly. If it gets into your eyes, seek medical attention
immediately.
• Keep away from sparks or flame.
• To avoid gas explosions, do not smoke or cause short circuits or sparks near the battery.

1. Charge the battery, and after charging, check that the battery elec-
trolyte level is correct. If the electrolyte level is below the top of the
electrode plates, add distilled water to the top of the plates. Check
and clean battery caps and terminals. Check the battery case for
cracking and stains caused by leakage.
2. Using a specific gravity meter and thermometer, measure the
specific gravity and temperature of the battery electrolyte.
Insert the values measured in steps 1 and 2 in the formula below
and calculate S20, which is the specific gravity at 68°F (20°C).
S 20 = S t + 0.0007 ( t – 20 )
St: Specific gravity (measured value) at t°C
t: Temperature of battery electrolyte (measured value)

NOTICE

• Normal value: S20 = 1.27 - 1.29

• If specific gravity is below 1.225, check terminals, cables, charging system and repair as
necessary.

3. Charge the battery if necessary.

Specific gravity Charge

Condition of charge
of electrolyte needed?
1.280 Fully charged
No
1.240 1/4 discharged
1.210 1/2 discharged
Yes
1.130 Fully discharged

RELATION BETWEEN SPECIFIC GRAVITY

AND TEMPERATURE OF ELECTROLYTE

„ CHECK WIRING CONNECTIONS FOR LOOSENESS

„ CHECK IGNITION TIMING

4-25
24. MAINTENANCE

24.4.9 GENERAL
„ CHECK OVERHEAD GUARD, LOAD BACKREST FOR DEFORMATION, CRACKING, DAMAGE AND
LOOSENESS
„ CHECK OPERATOR’S SEAT MOUNT FOR LOOSENESS AND DAMAGE, CHECK LPG CYLINDER
MOUNTING BRACKET
„ GREASE ALL LUBRICATION POINTS
1. Mast support (left and right: 2 points)
2. Fork stopper (left and right: 2 points)
3. Front axle support (left and right: 2 points)
4. Steering axle
a. Center pin (front and rear: 2 points)
b. Power Steering cylinder rod (left and right:
2 points)
c. Knuckle joint (left and right: 2 points)
d. King pin (left and right: 4 points)

24.5 EVERY 500 HOURS SERVICE

„ (DIESEL ENGINE) REPLACE FUEL FILTER
See “(DIESEL ENGINE) REPLACE FUEL FILTER” on page 4-24 for details.

24.6 EVERY 3 MONTHS OR EVERY 600 HOURS SERVICE

24.6.1 ENGINE
„ (DIESEL) REPLACE ENGINE OIL FILTER CARTRIDGE
See “CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE” on page 4-15 for details.

24.6.2 POWER TRAIN

„ CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL AS NECESSARY
See “CHANGE OIL IN TORQFLOW TRANSMISSION CASE, CLEAN TORQFLOW TRANSMISSION STRAINER”
on page 4-17 for details.

„ CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL AS NECESSARY

See “CHANGE OIL IN DIFFERENTIAL CASE” on page 4-18 for details.

24.7 EVERY 6 MONTHS OR EVERY 1,200 HOURS SERVICE

24.7.1 STEERING SYSTEM
„ CHECK STEERING LINK FOR BENDING, DAMAGE AND WEAR
„ CHECK KNUCKLE FOR PLAY, DEFORMATION AND DAMAGE
„ CHECK FOR MARKED VARIATION IN MINIMUM TURNING RADIUS
„ CHANGE OIL IN TORQFLOW TRANSMISSION CASE
See “CHANGE OIL IN TORQFLOW TRANSMISSION CASE, CLEAN TORQFLOW TRANSMISSION STRAINER”
on page 4-17 for details.
4-26
 24. MAINTENANCE

„ CHANGE OIL IN DIFFERENTIAL

See “CHANGE OIL IN DIFFERENTIAL CASE” on page 4-18 for details.

„ REPLACE TORQUE CONVERTER OIL FILTER

NOTICE

Replace with specified oil filter.

24.7.2 BRAKE SYSTEM

„ CHANGE BRAKE OIL/FLUID
24.7.3 ENGINE
„ CHECK AND ADJUST VALVE CLEARANCE
„ MEASURE COMPRESSION PRESSURE
„ (DIESEL ENGINE) CHECK AND ADJUST FUEL INJECTION TIMING; CHECK AND INSPECT FUEL
INJECTION NOZZLES
„ CHECK PCV BLOW-BY GAS REDUCTION SYSTEM FOR CLOGGING OR DAMAGE
„ CHECK DISTRIBUTOR CAP CENTERPIECE FOR WEAR
„ (LPG) REPLACE LPG FILTER ELEMENT
„ REPLACE AIR CLEANER ELEMENT
See “CHECK AIR CLEANER AND REPLACE FILTER WHEN DIRTY” on page 4-19 for details.

„ CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC LINE FILTER, CLEAN HYDRAULIC TANK
STRAINER, CLEAN INSIDE OF HYDRAULIC TANK
See “CHANGE OIL IN HYDRAULIC TANK, REPLACE LINE FILTER, CLEAN STRAINER, CLEAN INSIDE OF
TANK” on page 4-14 for details.

24.8 EVERY 2,000 HOURS SERVICE

„ (LPG) REPLACE LPG MIXER AIR VALVE DIAPHRAGM (UNDER NORMAL OPERATING CONDITIONS;
REPLACE MORE OFTEN IN COLD OR SEVERE SERVICE APPLICATIONS) REPLACE O-RING FOR LPG
TANK VALVE

24.9 EVERY YEAR OR 2,400 HOURS SERVICE

„ CHECK OPERATION OF BRAKE MASTER CYLINDER, CHECK FOR OIL LEAKAGE, DAMAGE AND
WEAR
„ CHECK OPERATION OF WHEEL CYLINDERS, CHECK FOR OIL LEAKAGE, DAMAGE & WEAR
„ CHECK OPERATION OF BRAKE DRUM, CHECK FOR DAMAGE AND WEAR
„ CHECK BRAKE LININGS FOR WEAR
„ CHECK OPERATING CONDITION OF BRAKE SHOE
„ CHECK BRAKE ADJUSTMENT LEVER AND RATCHET FOR WEAR AND DAMAGE
„ CHECK BRAKE SPRING FOR DETERIORATION
„ CHECK BRAKE BACK PLATE FOR DEFORMATION AND CRACKING, CHECK MOUNTING CONDITION

4-27
24. MAINTENANCE

24.9.1 TRAVEL SYSTEM

„ CHECK AXLE FOR DEFORMATION, CRACKING AND DAMAGE
„ CHECK MOUNTING CONDITION OF DIFFERENTIAL
„ CHECK ROOT (BASE) OF FORKS FOR CRACKING (USE COLOR CHECK)
„ CHECK ROLLER SHAFT OF LOADING EQUIPMENT FOR CRACKING AND DAMAGE
„ CHECK MAST SUPPORT FOR DAMAGE AND WEAR
24.9.2 HYDRAULIC EQUIPMENT
„ CHECK OPERATION OF RELIEF VALVE, CHECK RELIEF PRESSURE
„ REPLACE AIR BREATHER
24.9.3 ENGINE
„ CHECK DISTRIBUTOR CAP (GASOLINE), DISTRIBUTOR INSIDE (IC IGNITION) FOR CRACKING OR
DAMAGE
„ (ALL) CLEAN INSIDE OF FUEL TANK
„ CLEAN INSIDE OF COOLING SYSTEM, CLEAN RADIATOR, REPLACE COOLANT (GLYCOL-BASED)

• After the engine has been operated, the coolant is HOT. There is a danger of burns and injury if
the cooling water is drained immediately. Always wait for the engine to cool down before
draining the coolant.
• The cleaning operation is carried out with the engine running. The lift truck may move
suddenly and unexpectedly, so never go under the lift truck during this operation. Never go
under the lift truck when the engine is running.
• Do not remove the radiator cap when the engine and coolant is hot. Boiling water and steam
may spurt out. Always wait for the temperature to go down, then turn the radiator cap slowly
to release pressure gradually before removing the cap completely.
• Coolant is flammable. Keep it away from open flame and sparks.

Stop the lift truck on level ground.

1. After the engine has cooled off, open the drain valves at the
bottom of the radiator and the engine cylinder block to drain
the water/coolant mixture.
2. After draining, close the drain valves. Fill the radiator with
fresh water (tap water) and radiator flushing fluid through the
water filler, then run the engine at idling for approximately 15
minutes.
3. Stop the engine, open the drain valves to drain the water, then
add fresh water and run the engine at idling until clean, clear
water comes out of the drain valves (5 - 10 minutes).
4. Stop the engine, drain all the water from the drain valves, then
close the drain valves and fill the radiator with fresh water and glycol-based coolant.

Water and Coolant Capacities

TB45 gas engine 4.5 U.S. gal. (17 L, 3.75 UK gal.)
S6D102E diesel engine 4.75 U.S. gal. (18 L, 3.96 UK gal.)

4-28
 24. MAINTENANCE

NOTICE

• In cold areas, add long-life coolant. (For details, see “COLD WEATHER OPERATION” on page 3-40.
• When not using glycol-based coolant, add rust prevention fluid to the radiator.
• Always use appropriate products for the flushing fluid, rust prevention fluid and glycol-based
coolant.

„ CHECK FUEL INJECTION PRESSURE, INJECTION AMOUNT, INJECTOR CONDITION

„ (GASOLINE ENGINE) INSPECT AND CLEAN FUEL FILTER SOCK
„ TIGHTEN (RETORQUE) ENGINE CYLINDER HEAD BOLTS
24.9.4 GENERAL
„ CHECK FRAME AND CROSSMEMBER FOR CRACKING AND DAMAGE

24.10 EVERY 18 MONTHS OR 3,600 HOURS SERVICE

„ REPLACE SPARK PLUGS

4-29
25. REPLACEMENT PROCEDURES

25.1 REPLACING FUSES

25. REPLACEMENT PROCEDURES

Fuses protect the electrical components and wiring from burning out.

25.1.1 CHASSIS FUSES

NOTICE

• When replacing the fuses, always turn OFF the electric power (turn the starting switch to the OFF
position) first.
• Always replace the fuses with a fuse of the same capacity.

1. Turn the starting switch to the OFF position.

2. Open the cover of the fuse box and replace necessary LIFT TRUCK WITHOUT
fuses inside. OPERATOR PRESENCE SYSTEM
To remove the cover from the fuse box, push the side face
of the cover lightly with your fingers and pull it out.

10
10

10
Check the relationship between the fuses and the electrical
components when replacing. Fuses are numbered from left
to right in the illustration. 10 10 15

Capacity

10
15
15
No. Related Electrical Component
(Amp)
Lift truck without Operator Presence System
(1) 10 Meter
(2) 10 Back-up lamp
(6) 15 Gas (non-diesel trucks only) LIFT TRUCK WITH
OPERATOR PRESENCE SYSTEM
(7) 15 Stop lamp
(8) 15 Lamps
10

15

15

10
(9) 10 Horn
Lift truck with Operator Presence System 7.5 10 15
(1) 10 Meter
7.5

10

15

10

(2) 15 Main relay

(3) 15 Engine controller
(6) 10 Starter relay
(7) 7.5 Mast relay
(8) 10 Stop lamp
(9) 15 Lamps
(10) 10 Horn

4-30
 25. REPLACEMENT PROCEDURES

25.1.2 ENGINE FUSES AND RELAYS – TB45 ENGINE (GAS AND LP)

NOTICE

• When replacing the fuses, always turn OFF the electric power (turn the starting switch to the OFF
position) first.
• Always replace the fuses with a fuse of the same capacity.

The ENGINE fuses and relays are located in separate boxes mounted at one corner of the engine under a
protective metal cover as viewed from the top.

1. Turn the starting switch to the OFF position.

2. Open the engine bonnet and remove the protective metal cover.
3. Remove the cover of the fuse box or relay box and replace the failed component.
To remove the cover from the fuse box or relay box, push the side face of the cover lightly with your fingers and
pull it out.

Check the relationship between the fuses and the electrical components when replacing.

4-31
25. REPLACEMENT PROCEDURES

25.2 REPLACING TIRES

1. Stop the lift truck on a flat, safe area and apply the parking brake.
2. Chock the wheel diagonally across from the wheel to be replaced.

• After confirming that the rim mating bolts are tight, loosen the lug nuts.
• NEVER loosen the rim mating bolts by mistake.

3. Using a lug wrench, loosen the lug nuts until they can be turned by hand.

Jack up the fork lift truck after confirming that the jack will not slip. NEVER place any part of your body
under any part of the fork lift truck!

4. Place the jack on the jacking point and raise the lift truck up until the
wheel to be replaced clears the ground.
5. Remove the lug nuts, then remove the wheel.

Ask a tire and wheel specialist to carry out disassembly and

assembly of tires and wheels.

6. Install the replacement wheel on the hub and hand tighten the lug
nuts to hold the wheel in place.
7. Tighten the lug nuts again with a lug wrench, using a diagonal “criss-
cross” or star pattern, ensuring that the wheel is snugly in place, but
not fully tightened.
8. Let the jack down slowly to lower the lift truck. Tighten the lug nuts to
the specified torque. (For specified torque, see “TORQUE LIST” on
page 4-8.)
9. Adjust the tire inflation pressure to the set pressure (For details of
the set inflation pressure, see “SERVICE DATA” on page 4-5.).

• Always ask a specialist to carry out disassembly of the tires, tubes and rims, and for inflation
of the tires. The tires used on forklift trucks are at a high inflation pressure, so operations with
tires are extremely dangerous.
• The tires are inflated to a high pressure, so deformed or cracked rims are extremely
dangerous.
• Check carefully before inflating tires. NEVER use tires with deformed or cracked rims.
• Before inflating the tires, adjust the pressure of the air compressor to the correct set pressure
so that the tires are not inflated above the set pressure.

4-32
 25. REPLACEMENT PROCEDURES

25.3 REPLACING LAMPS

Check for any blown fuses or disconnections in the wiring harnesses,
and replace the lamps as necessary.

Gas Engine Diesel Engine

Lamp Function Trucks Trucks
(12 Volt System) (24 Volt System)
Head lamp 55 W 70 W
Turn signal lamp 23 W 25 W
Driving (clearance) lamp 8W 5W
Stop lamp 27 W
Back-up lamp 8W
Warning lamp 1.4 W
Meter lighting lamp 3.4 W 3W

4-33
26. LIFT TRUCK WASHING PROCEDURE

26.1 GENERAL PRECAUTIONS

26. LIFT TRUCK WASHING PROCEDURE

When washing your lift truck, observe the following instructions to safeguard the truck.
Wet electrical equipment will result in the lift truck malfunctioning.

• Before washing, ensure that the controller and all other electrical equipment sensitive to water is protected
from water or removed prior to washing and blowing dry. NEVER wash or wet down the areas inside the dash-
board.
• Before washing, make sure that waterproof seals and covers are free from any deterioration and are fitted cor-
rectly in place.
• When using a water stream, use compressed air, an air blower and dry wiping to dry the truck and remove
water droplets before using the truck connectors and electrical components. (Water droplets may run along the
wiring and enter the controller chamber, dashboard or seep into the connectors.)
• If water does get into the controller chamber or dashboard, use a cloth or compressed air to remove the water
before using the truck.
• When removing dirt from electronic parts (such as printed circuit boards), use a commercially available, spray-
type electronic equipment cleaner.

26.2 WASHING INSTRUCTIONS

If water gets into the electrical system (controller, sensor, connectors, etc.) it will cause malfunctions
or operational failure. Do not wash the electrical system with water or high-pressure steam.

1. Turn the starting switch key to the OFF position,

then remove the key.
2. Wash each part (1 to 4 parts in the figure at right),
following the instructions in the table on the
following page.
3. Dry off all wet areas with an air blower.
4. After checking that the washed parts have dried
out, insert the starting switch key and turn it to the
ON position, make sure that there is no abnormal-
ity, and then start operation.

4-34
 26. LIFT TRUCK WASHING PROCEDURE

No. Spot to Wash Washing Method

1 Meter Panel • Wash from above by flushing with water from a hose.
• Use low water pressure from the hose as illustrated below
(parts 1 and 2 only).

• Dashboard Front
2 • Pedals
• Floor Plate

• Wash using high pressure steam or flush with water from a

• Front & Rear Tires
3 hose.
• Front & Rear Axles
• Do not steam or wash the tire angle sensor or electric wiring.

4 Exterior parts other than the above Wash with high pressure steam or flush with water from a hose.

• Never wash the inside of the dashboard.

• When using high pressure steam or water from a hose to
wash the engine room and power train parts under the floor
plate, cover the following parts and components with a
Other Precautions tarpaulin so that they do not get splashed with water:
- the engine and transmission, including the electric wiring
for them.
- electric system parts such as the connector and fuse
box.

4-35
27. CHECKING LPG FUEL SYSTEM FOR LEAKS
27. CHECKING LPG FUEL SYSTEM FOR LEAKS

• See the "Safety" chapter for all safety precautions concerning LPG fuel systems.
• Before testing, make sure the LPG system gas pressure is greater than 90 psi (621 kPa).
• Test all connections, container, valves and fttings with soap and water or equivalent solution. If there are any
leaks, have them repaired by qualified personnel.
• When replacing LPG fuel system components, use Komatsu genuine parts only.

4-36