AEC10E1-02

FG(D)35/50A-10
Operation & Maintenance Manual

FORKLIFT TRUCK

FG40Z-10
FG35/40/45-10
FG50A-10
FD40Z-10
FD35/40/45-10
FD50A-10
FD40YZ-10
FD35Y/40Y/45Y-10
FD50AY-10
WARNING
Unsafe use of this lift truck may
cause serious injury or death.
Operators and maintenance per-
sonnel must read this manual and
be sure that they understand its
2-4-1 Shiba-koen, Minato-ku, Tokyo105-0011, Japan contents before operating, in-
specting, or carrying out mainte-
nance on this lift truck. This
manual should be kept near the
lift truck for reference and peri-
odically reviewed by all opera-
tors and maintenance personnel
who will come into contact with

PRINTED IN JAPAN
2 it.

1)0150101)10001
INTRODUCTION 1

21

1-1
1.1 ABOUT THIS MANUAL INTRODUCTION

1. INTRODUCTION
1.1 ABOUT THIS MANUAL
This manual describes procedures for proper operation, inspection, and maintenance of this lift truck, and rules
you must follow for your safety. Most accidents are caused by a failure to follow fundamental safety precautions
for the operation, inspection, and maintenance of lift trucks. Also, knowing the possible hazards in advance will
help to avoid accidents.

WARNING
This manual describes fundamental prohibitions and precautions for operations, inspections, and maintenance of
this lift truck. Failure to follow these instructions will result in a serious bodily injury or damage.
Operators and service staffs must follow the followings before conducting operations, inspections, and maintenance
of this lift truck.
Administrators must understand this manual for conducting safety control of this lift truck.

･ Read this manual carefully and understand it fully.

･ Make sure you fully understand the instructions and safety labels of this manual.

Be sure to store this manual in the designated location for the Operation and Maintenance Manual as shown below,
so that it will be available for the concerned persons repeatedly as needed.
If this manual has been lost or has become dirty or worn and cannot be read, request a replacement manual from
your KOMATSU FORKLIFT distributor.
When you transfer this lift truck to others, make sure to attach this manual together.

Continuing improvements in the design of this lift truck may not be reflected in this manual. Consult Komatsu Utility
Co., Ltd. FORKLIFT COMPANY or your KOMATSU FORKLIFT distributor for the latest available information on your
lift truck or for questions regarding information in this manual.

Storage location for Operation and Maintenance Manual

･ Retractable pocket behind the operator's seat (1)

1-2
INTRODUCTION 1.2 ENGINE MOUNTED ON THIS LIFT TRUCK

1.2 ENGINE MOUNTED ON THIS LIFT TRUCK

1.2.1 EXHAUST GAS CONTROL (APPLIED TO DIESEL ENGINE LIFT TRUCK)
The engine mounted on this lift truck is approved by the following diesel engine exhaust gas control standards.
(1) STAGE IIIA provided in Directive 2004/26/EC (For EU)

1.2.2 CERTIFICATION LABEL AFFIXED POSITION

1-3
1.3 FOR YOUR SAFETY INTRODUCTION

1.3 FOR YOUR SAFETY

For your safety, the information of possible hazards and how to avoid them are provided on this manual and with
the safety labels attached to this lift truck.

1.3.1 SIGNAL WORDS

The following signal words indicate the possible hazard which leads bodily injury.
For this lift truck and this manual, the following signal words are used depending on the degree of possible
hazard.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.

Example of safety message using signal word

CAUTION
Do not open the radiator cap immediately after the engine stops,
since the coolant temperature is very high. Steam or boiling
water may spurt out, causing bu rn s. After th e co o la nt
temperature has gone down, turn the cap slowly to release the
pressure before removing it.

OTHER SIGNAL WORDS

Besides the above signal words, the followings indicate precautions you must take for the lift truck as well as
useful information.

NOTICE . . . . . . The lift truck can get damaged or shortens its service life when handled incorrectly.

REMARK. . . . . Useful information.

1-4
INTRODUCTION 1.3 FOR YOUR SAFETY

1.3.2 SAFETY INDICATORS

Safety indicators are used in the various locations of the lift truck to indicate the possible hazards to the
concerned persons during operations, inspections, and maintenances. This lift truck employs [verbal safety
indicator] and [pictorial safety indicator] for safety indicators.

EXAMPLE OF VERBAL SAFETY INDICATOR

There are safety indicators which consist of drawing and words in addition to verbal-only safety indicators.

EXAMPLE OF PICTORIAL SAFETY INDICATOR

The pictorial safety indicators indicate the hazard equivalent to the signal words. Drawings are used for these
safety indicators to tell the operators and service staffs clearly of the existence and content of a hazard.
The safety indicators used in this lift truck comply with the standard pictorial safety indicator established by Japan
Industrial Vehicles Association.
In addition, there are pictorial indicators which simply indicate the prohibition content as well as indicators which
comply with the international standards. (The content of hazard is located in the top or left, and the content of
hazard inside the triangle, and the item number in the bottom.)

Komatsu Forklift cannot predict every circumstance that the customers will experience. Therefore the precautions
in this manual and on the lift truck may not include all possible safety precautions.
When carrying out any procedures or actions which are not specifically recommended or allowed in this manual,
it is your responsibility to carry out such procedures and actions safely.
The explanations, numeric vales, and illustrations of this manual are based on the information at the time of
publication. Continuing improvements in the design of this lift truck may not be reflected in this manual.
Consult KOMATSU FORKLIFT distributor for the latest available information or for questions regarding this
manual.

1-5
1.4 APPLICABLE MODEL AND SERIAL NO. INTRODUCTION

1.4 APPLICABLE MODEL AND SERIAL NO.

This Operation and Maintenance Manual applies to the following lift trucks.

Model type Serial No.

FG40Z-10 M251-133001 and up
FG35/40/45/50A-10 M253-133001 and up
FD40Z-10 M250-133001 and up
FD35/40/45/50A-10 M252-133001 and up
FD40ZY-10 M250-133001 and up
FD35Y/40Y/45Y/50AY-10 M252-133001 and up

1.5 GENERAL VIEW OF LIFT TRUCK

1.5.1 APPLICATION OF LIFT TRUCK
This lift truck is intended to use mainly for the following work.
･ Load handling with the forks of the lift truck

1.5.2 DIRECTION OF LIFT TRUCK

This manual determines the left and right directions and fore and aft directions as seen from the operator's seat.

Right

Front Rear

Left

1.6 UNITS OF MEASURE

This manual uses the international system of units (SI) for units of measure.
Also the gravitational system of units, conventionally used, are provided as { } for reference.

1-6
INTRODUCTION 1.7 QUALIFICATIONS FOR OPERATION

1.7 QUALIFICATIONS FOR OPERATION

WARNING
Only the trained and qualified persons are allowed to operate this lift truck. Operation by unqualified persons may
result in serious injury or death.

1.8 RUNNING IN NEW LIFT TRUCK

1.8.1 RUNNING IN NEW LIFT TRUCK
Your Komatsu Forklift truck has been thoroughly adjusted and tested before shipment. However, operate
moderately during the first one month (or initial 200 hours) until each part of the lift truck comes into stable.
Operating the lift truck under severe conditions at the beginning can adversely affect performance and shorten
the lift truck life.

Be sure to run in the lift truck, taking special care concerning the followings.
･ Idle the engine for 5 minutes after starting it up.
･ Do not operate with heavy loads or at high speeds.
･ Avoid sudden starting, acceleration, braking, and sharp turning.

1.8.2 MAINTENANCE FOR NEW LIFT TRUCK

For new lift truck, carry out the followings after the first month or 200 hours: Replacement of Oil and cleaning of
filters, retightening of bolts and nuts. Have your lift truck serviced by KOMATSU FORKLIFT distributor.

1.9 WARRANTY AND SERVICE

1.9.1 PERIODICAL EXCHANGE PARTS
Other than those specified by the law, Komatsu Forklift designates "periodical exchange parts." Deterioration of
such parts is unavoidable over time but is critical for safety and therefore must be replaced periodically. Replace
those parts at the designated periods regardless of their appearance. For the periodic replacement of safety
critical parts, see "4.15 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS (PAGE 4-64)".

1.9.2 USE OF GENUINE KOMATSU UTILITY PARTS AND OILS

Any problem caused by the use of other than genuine Komatsu Utility parts (including oils) warranted by Komatsu
Utility is not covered by the warranty.

1.9.3 ENGINE MOUNTED ON THIS LIFT TRUCK

Special knowledge and skills and the service tools for the electronic control are required for inspection and
maintenance of the engine mounted on this lift truck. If the engine seems to be troubled, stop the work and
contact your KOMATSU FORKLIFT distributor.

1-7
1.10 NECESSARY INFORMATION OF LIFT TRUCK INTRODUCTION

1.10 NECESSARY INFORMATION OF LIFT TRUCK

When you need maintenance of the lift truck or order parts, please provide KOMATSU FORKLIFT distributor with
necessary information of the lift truck such as model type, serial No., engine serial No., attachment, option, etc.

1.10.1 MEMORANDUM (TO BE FILLED BY KOMATSU FORKLIFT DISTRIBUTOR)

Model type
Serial No.
Engine serial No.

Attachment/option

Name of Distributor
Address
Telephone, fax No.
Service person in charge
Sales representative in charge

1.10.2 MODEL AND SERIAL NO. PLATE LOCATION

SERIAL NO. PLATE LOCATION
Located in the right top of the dashboard.

SERIAL NUMBER STAMPING LOCATION

Besides the serial No. plate is also stamped on the top of the left-
side front wheel fender.
Example of stamping mark: M***-######
The manufacturing number is shown as # after the hyphen.

1-8
INTRODUCTION 1.10 NECESSARY INFORMATION OF LIFT TRUCK

1.10.3 ENGINE SERIAL NO. PLATE OR STAMPING LOCATION

Engine serial number is shown either by the plate or stamping in the location below.

･ Gasoline engine (EBT-TB45-1A)

･ Gasoline engine (EBT-TB45-1B)
･ Gasoline engine (EBT-TB45-1C)

･ Diesel engine (SAA4D95LE-5-A)

･ Diesel engine (S4D95LE-3)

1.10.4 HOUR METER LOCATION

Located in the center of the instrument panel over the steering
wheel.

1-9
CONTENTS INTRODUCTION

CONTENTS
1. INTRODUCTION --------------------------------------------------------------------------------------------------------------------- 1-1
1.1 ABOUT THIS MANUAL ----------------------------------------------------------------------------------------------------- 1-2
1.2 ENGINE MOUNTED ON THIS LIFT TRUCK -------------------------------------------------------------------------- 1-3
1.2.1 EXHAUST GAS CONTROL (APPLIED TO DIESEL ENGINE LIFT TRUCK) ------------------------- 1-3
1.2.2 CERTIFICATION LABEL AFFIXED POSITION -------------------------------------------------------------- 1-3
1.3 FOR YOUR SAFETY -------------------------------------------------------------------------------------------------------- 1-4
1.3.1 SIGNAL WORDS ----------------------------------------------------------------------------------------------------- 1-4
1.3.2 SAFETY INDICATORS --------------------------------------------------------------------------------------------- 1-5
1.4 APPLICABLE MODEL AND SERIAL NO. ------------------------------------------------------------------------------ 1-6
1.5 GENERAL VIEW OF LIFT TRUCK--------------------------------------------------------------------------------------- 1-6
1.5.1 APPLICATION OF LIFT TRUCK --------------------------------------------------------------------------------- 1-6
1.5.2 DIRECTION OF LIFT TRUCK------------------------------------------------------------------------------------- 1-6
1.6 UNITS OF MEASURE ------------------------------------------------------------------------------------------------------- 1-6
1.7 QUALIFICATIONS FOR OPERATION ---------------------------------------------------------------------------------- 1-7
1.8 RUNNING IN NEW LIFT TRUCK ----------------------------------------------------------------------------------------- 1-7
1.8.1 RUNNING IN NEW LIFT TRUCK -------------------------------------------------------------------------------- 1-7
1.8.2 MAINTENANCE FOR NEW LIFT TRUCK --------------------------------------------------------------------- 1-7
1.9 WARRANTY AND SERVICE ---------------------------------------------------------------------------------------------- 1-7
1.9.1 PERIODICAL EXCHANGE PARTS------------------------------------------------------------------------------ 1-7
1.9.2 USE OF GENUINE KOMATSU UTILITY PARTS AND OILS --------------------------------------------- 1-7
1.9.3 ENGINE MOUNTED ON THIS LIFT TRUCK------------------------------------------------------------------ 1-7
1.10 NECESSARY INFORMATION OF LIFT TRUCK-------------------------------------------------------------------- 1-8
1.10.1 MEMORANDUM (TO BE FILLED BY KOMATSU FORKLIFT DISTRIBUTOR) -------------------- 1-8
1.10.2 MODEL AND SERIAL NO. PLATE LOCATION------------------------------------------------------------- 1-8
1.10.3 ENGINE SERIAL NO. PLATE OR STAMPING LOCATION --------------------------------------------- 1-9
1.10.4 HOUR METER LOCATION -------------------------------------------------------------------------------------- 1-9
1.10.4 CONTENTS -------------------------------------------------------------------------------------------------------------- 1-10
2. SAFETY--------------------------------------------------------------------------------------------------------------------------------- 2-1
2.1 SAFETY LABEL --------------------------------------------------------------------------------------------------------------- 2-2
2.1.1 SAFETY LABEL LOCATION CHART --------------------------------------------------------------------------- 2-2
2.1.2 SAFETY LABELS ---------------------------------------------------------------------------------------------------- 2-4
2.2 BASIC PRECAUTIONS ----------------------------------------------------------------------------------------------------- 2-8
2.2.1 FOLLOW RULES----------------------------------------------------------------------------------------------------- 2-8
2.2.2 NEVER OPERATE THE BROKEN-DOWN LIFT TRUCK-------------------------------------------------- 2-8
2.2.3 WEAR ADEQUATE CLOTHES AND SAFETY EQUIPMENT FOR OPERATION ------------------- 2-9
2.2.4 FIRE EXTINGUISHER AND FIRST AID KIT ------------------------------------------------------------------ 2-9
2.2.5 CAUTIONS FOR SAFETY-RELATED EQUIPMENT-------------------------------------------------------- 2-9
2.2.6 PRACTICE SUFFICIENTLY BEFORE OPERATION ------------------------------------------------------- 2-9
2.2.7 JUMPING ON AND OFF FROM THE LIFT TRUCK IS STRICTLY PROHIBITED----------------- 2-10
2.2.8 KEEP THE OPERATOR'S COMPARTMENT AND PLATFORM CLEAN AND TIDY------------- 2-10
2.2.9 CAUTION WHEN WASHING LIFT TRUCK ----------------------------------------------------------------- 2-10
2.2.10 TO AVOID BURN INJURY ------------------------------------------------------------------------------------- 2-11
2.2.11 FIRE PREVENTION --------------------------------------------------------------------------------------------- 2-11
2.2.12 IF A FIRE BREAKS OUT --------------------------------------------------------------------------------------- 2-12
2.2.13 DO NOT MODIFY THE LIFT TRUCK ----------------------------------------------------------------------- 2-12
2.2.14 DO NOT REMOVE THE OVERHEAD GUARD AND LOAD BACKREST-------------------------- 2-13
2.2.15 SECURE SAFETY AT THE WORKING AREA------------------------------------------------------------ 2-13
2.2.16 ENGINE EXHAUST GAS IS POISONOUS ---------------------------------------------------------------- 2-13
2.2.17 ASBESTOS CAUTION ------------------------------------------------------------------------------------------ 2-14
2.2.18 WINDOW WASHER CAUTION ------------------------------------------------------------------------------- 2-14
2.3 BEFORE STARTING OPERATION ------------------------------------------------------------------------------------ 2-15
2.3.1 START-UP INSPECTION ---------------------------------------------------------------------------------------- 2-15
2.3.2 INSPECTION AND ADJUSTMENT BEFORE STARTING ENGINE CHECK THE FOLLOWINGS
BEFORE STARTING THE ENGINE --------------------------------------------------------------------------- 2-15
2.3.3 START-UP INSPECTION ---------------------------------------------------------------------------------------- 2-16
2.4 TRAVELLING THE LIFT TRUCK --------------------------------------------------------------------------------------- 2-17

1 - 10
INTRODUCTION CONTENTS

2.4.1 PREPARATION BEFORE TRAVELLING THE LIFT TRUCK--------------------------------------------2-17

2.4.2 WHILE TRAVELING THE LIFT TRUCK-----------------------------------------------------------------------2-18
2.4.3 STOPPING AND PARKING --------------------------------------------------------------------------------------2-24
2.4.4 TOWING---------------------------------------------------------------------------------------------------------------2-24
2.5 LOAD HANDLING OPERATION ----------------------------------------------------------------------------------------2-25
2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE------------------------------------------------------2-30
2.6.1 BE SURE TO PERFORM THE START-UP INSPECTION AND THE PERIODIC VOLUNTARY
INSPECTION---------------------------------------------------------------------------------------------------------2-30
2.6.2 PUT UP A WARNING SIGN DURING INSPECTION AND MAINTENANCE ------------------------2-30
2.6.3 KEEP THE WORKING AREA CLEAN AND TIDY ----------------------------------------------------------2-30
2.6.4 PRECAUTIONS BEFORE INSPECTION AND MAINTENANCE ---------------------------------------2-31
2.6.5 KEEP UNAUTHORIZED PEOPLE OFF-----------------------------------------------------------------------2-31
2.6.6 USE OF RIGHT TOOLS AND EQUIPMENT -----------------------------------------------------------------2-31
2.6.7 CAUTIONS WHEN WORKING UNDER WORK EQUIPMENT------------------------------------------2-31
2.6.8 AVOID GETTING CAUGHT UP BY THE MAST OR FALLING OFF-----------------------------------2-32
2.6.9 BE CAREFUL OF BOILING COOLANT -----------------------------------------------------------------------2-32
2.6.10 BE CAREFUL OF HIGH PRESSURE OIL ------------------------------------------------------------------2-33
2.6.11 BEWARE OF ROTATING COOLING FAN AND BELT --------------------------------------------------2-33
2.6.12 PRECAUTIONS FOR INSTALLING RADIO CONTROL SYSTEM -----------------------------------2-33
2.6.13 CAUTION WHEN REPAIRING THE ELECTRICAL SYSTEM -----------------------------------------2-33
2.6.14 CAUTIONS FOR USING COMPRESSED AIR FOR CLEANING -------------------------------------2-34
2.6.15 CAUTIONS WHEN REPLACING THE SEAT --------------------------------------------------------------2-34
2.6.16 CAUTION WHEN HANDLING BATTERY -------------------------------------------------------------------2-34
2.6.17 STRICTLY FOLLOW THE INSTRUCTIONS SHOWN BELOW TO AVOID GENERATION OF
SPARKS -------------------------------------------------------------------------------------------------------------2-34
2.6.18 CAUTION WHEN CHARGING A BATTERY ---------------------------------------------------------------2-35
2.6.19 CAUTION WHEN HANDLING TYRES-----------------------------------------------------------------------2-35
2.6.20 CAUTION IN WASTE DISPOSAL-----------------------------------------------------------------------------2-36
2.6.21 CAUTION AFTER INSPECTION AND REPAIR-----------------------------------------------------------2-36
2.6.22 PERIODIC INSPECTION OF SAFETY CRITICAL PARTS---------------------------------------------2-36
2.7 HOISTING AND TRANSPORTING THE LIFT TRUCK ------------------------------------------------------------2-37
2.7.1 CAUTION WHEN HOISTING THE LIFT TRUCK -----------------------------------------------------------2-37
2.7.2 CAUTIONS FOR LOADING AND UNLOADING THE LIFT TRUCK -----------------------------------2-37
2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK
(TO PREVENT LIFT TRUCK FROM TIPPING) ---------------------------------------------------------------------2-38
2.8.1 LONGITUDINAL STABILITY -------------------------------------------------------------------------------------2-38
2.8.2 CENTER OF GRAVITY OF A LOAD ---------------------------------------------------------------------------2-38
2.8.3 COMBINED CENTER OF GRAVITY AND STABILITY ON THE LOADED LIFT TRUCK --------2-39
2.8.4 ACTUAL CAPACITY -----------------------------------------------------------------------------------------------2-39
2.8.5 SERIAL NO. PLATE AND LOAD TABLE ---------------------------------------------------------------------2-40
2.8.6 INTRODUCTION OF OPTIONAL SAFETY DEVICE ------------------------------------------------------2-41
3. OPERATION -------------------------------------------------------------------------------------------------------------------------- 3-1
3.1 GENERAL VIEW-------------------------------------------------------------------------------------------------------------- 3-2
3.1.1 GENERAL VIEW OF LIFT TRUCK ------------------------------------------------------------------------------ 3-2
3.1.2 INSTRUMENTS AND CONTROLS------------------------------------------------------------------------------ 3-3
3.2 EXPLANATION OF COMPONENTS ------------------------------------------------------------------------------------ 3-6
3.2.1 METER PANEL ------------------------------------------------------------------------------------------------------- 3-6
3.2.2 OPERATING DEVICES -------------------------------------------------------------------------------------------3-12
3.3 OPERATION ------------------------------------------------------------------------------------------------------------------3-16
3.3.1 START-UP INSPECTION -----------------------------------------------------------------------------------------3-16
3.3.2 MOUNTING/DISMOUNTING AND OPERATING POSTURE ADJUSTMENT ----------------------3-16
3.3.3 STARTING, GEAR SHIFTING, AND TRAVELING ---------------------------------------------------------3-20
3.3.4 STARTING AND STOPPING ON SLOPE --------------------------------------------------------------------3-28
3.3.5 INCHING TRAVEL --------------------------------------------------------------------------------------------------3-29
3.3.6 TURNING -------------------------------------------------------------------------------------------------------------3-29
3.3.7 OPERATION ON SNOWY AND FROZEN ROADS --------------------------------------------------------3-29
3.3.8 TEMPORARY STOPPING, PARKING AND STOPPING -------------------------------------------------3-30
3.3.9 LOAD HANDLING OPERATION --------------------------------------------------------------------------------3-32

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CONTENTS INTRODUCTION

3.3.10 CHECKING AFTER OPERATION---------------------------------------------------------------------------- 3-35

4. INSPECTION AND MAINTENANCE -------------------------------------------------------------------------------------------- 4-1
4.1 INSPECTION AND MAINTENANCE------------------------------------------------------------------------------------- 4-2
4.2 START-UP INSPECTION--------------------------------------------------------------------------------------------------- 4-2
4.2.1 CHECKING ABNORMALITIES DETECTED ON THE PREVIOUS DAY------------------------------- 4-4
4.2.2 WALK AROUND A LIFT TRUCK --------------------------------------------------------------------------------- 4-4
4.2.3 INSPECTION BY OPENING COVER AND HOOD ---------------------------------------------------------- 4-7
4.2.4 CHECKING FROM THE OPERATOR SEAT---------------------------------------------------------------- 4-12
4.2.5 CHECK BY SETTING THE STARTING SWITCH TO [ | ] (ON) POSITION ------------------------- 4-14
4.2.6 CHECKING WITH THE ENGINE STARTED ---------------------------------------------------------------- 4-17
4.2.7 CHECKING THE BRAKE ACCUMULATOR----------------------------------------------------------------- 4-18
4.2.8 CHECKING WHILE TRAVELING SLOWLY ----------------------------------------------------------------- 4-19
4.2.9 CHECKING BY OPERATING THE WORK EQUIPMENT LEVER------------------------------------- 4-19
4.2.10 CHECKING OF SAFETY FUNCTION ----------------------------------------------------------------------- 4-21
4.3 CHECKING AND REPORTING AFTER OPERATION ------------------------------------------------------------ 4-22
4.4 SIMPLE MAINTENANCE ------------------------------------------------------------------------------------------------- 4-23
4.4.1 GREASES AND FUEL -------------------------------------------------------------------------------------------- 4-23
4.4.1.1 BASIC PRECAUTIONS ---------------------------------------------------------------------------------- 4-23
4.4.1.2 LUBRICANT LIST (FG40Z, FG35, FG40, FG45, FG50A)--------------------------------------- 4-26
4.4.1.3 LUBRICANT LIST (FD40Z, FD35, FD40, FD45, FD50A)---------------------------------------- 4-28
4.4.1.4 LUBRICANT LIST (FD40ZY, FD35Y, FD40Y, FD45Y, FD50AY)------------------------------ 4-30
4.4.2 AIR CLEANER ELEMENT INSPECTION AND CLEANING--------------------------------------------- 4-32
4.4.3 FUEL FILTER AIR BLEEDING (FD40Z, FD35, FD40, FD45, FD50A)-------------------------------- 4-34
4.4.4 FUEL FILTER AIR BLEEDING (FD40Z, FD35, FD40, FD45, FD50A/*REF) ----------------------- 4-35
4.4.5 FUEL FILTER WATER DRAINING AND AIR BLEEDING (FD40ZY, FD35Y, FD40Y, FD45Y,
FD50AY) -------------------------------------------------------------------------------------------------------------- 4-36
4.4.6 REPLACING TYRES ---------------------------------------------------------------------------------------------- 4-37
4.4.7 ADJUSTING PARKING BRAKE LEVER OPERATING EFFORT -------------------------------------- 4-39
4.4.8 REPLACING FUSE ------------------------------------------------------------------------------------------------ 4-40
4.4.9 REPLACING BULBS ---------------------------------------------------------------------------------------------- 4-43
4.4.10 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER
(FD40Z, FD35, FD40, FD45, FD50A) ----------------------------------------------------------------------- 4-44
4.4.11 CHECKING FOR HARDENING OF ENGINE CONTROLLER MOUNT RUBBER AND LOOSE
MOUNTING (FD40Z, FD35, FD40, FD45, FD50A) ------------------------------------------------------ 4-44
4.5 PROCEDURE FOR A DOWN BATTERY----------------------------------------------------------------------------- 4-45
4.6 RUNNING IN COLD WEATHER ---------------------------------------------------------------------------------------- 4-47
4.7 PROCEDURE WITH OVERHEATED ENGINE --------------------------------------------------------------------- 4-49
4.8 OPERATING LIFT TRUCKS IN SPECIAL ENVIRONMENT OR IN FORCIBLE WAY-------------------- 4-51
4.9 ACTION TO TAKE IF THE FORK FAILS TO LOWER ------------------------------------------------------------ 4-52
4.10 WASHING LIFT TRUCKS----------------------------------------------------------------------------------------------- 4-53
4.11 LONG-TERM STORAGE------------------------------------------------------------------------------------------------ 4-54
4.12 HOISTING LIFT TRUCK ------------------------------------------------------------------------------------------------ 4-55
4.13 LOADING AND UNLOADING OF LIFT TRUCK------------------------------------------------------------------- 4-56
4.14 INSPECTION AND MAINTENANCE SCHEDULE CHART----------------------------------------------------- 4-57
4.15 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ------------------------------------------------ 4-64
4.16 SERVICE DATA ----------------------------------------------------------------------------------------------------------- 4-65
5. TECHNICAL DATA------------------------------------------------------------------------------------------------------------------- 5-1
6. INDEX ----------------------------------------------------------------------------------------------------------------------------------- 6-1

1 - 12
 SAFETY 1

22

WARNING
Please be sure that you fully understand this manual and the
precautions related to safety for the lift truck.
When operating, inspecting, or servicing the lift truck, always strictly
follow these precautions. Failing to heed this warning may result in
serious injuries.

2-1
2.1 SAFETY LABEL SAFETY

2. SAFETY
2.1 SAFETY LABEL
Followings are the safety labels used for this lift truck.
･ Make sure that you understand the exact locations of the safety labels, the contents of the danger, and how to
avoid them.
･ Keep the safety labels clean so that it can be easily seen at all times. Do not use organic solvent or gasoline
for cleaning. Or the safety label may come unstuck.
･ If the safety label is damaged, lost, or become unreadable, replace it with a new one. Before placing an order
to KOMATSU FORKLIFT distributor, check the part No. of safety label referring to this manual or the replacing
label itself.
･ Concerning labels other than the safety labels, use these in the same way.
2.1.1 SAFETY LABEL LOCATION CHART

Inside of engine hood Inside of engine hood

2-2
SAFETY 2.1 SAFETY LABEL

No. Safety label name Position

1 Caution to avoid getting hand caught. Rear side of outer mast stay and head stay
Prohibit the operators from riding on the forks and
2 Outside of left and right outer masts
lifting/lowering themselves
Upper part of mast and top of counterbalance-
3 Hoist the lift truck by designated positions
weight
4 Jump start prohibited Starting motor (Inside of engine hood)
Avoiding danger if lift truck tips over during
5 Right inside front of overhead guard
operations
6 Take a right posture while operating lift truck. Right inside rear of overhead guard
7 Caution when hoisting the lift truck Right rear inside of overhead guard (Upper part)
8 Caution for operation Right rear inside of overhead guard (Lower part)
9 Seating capacity Top of engine hood (Right side of operator's seat)
10 Caution when washing lift truck (*) Inside of engine hood
11 Caution to avoid getting caught Inside of engine hood

KOMATSU FORKLIFT reserves the right to change or add to these safety label requirements and label contents.
* Lift truck equipped with OPS (Operator presence sensing system). Optional to FD40ZY, FD35Y, FD40Y, FD45Y,
FD50AY.

2-3
2.1 SAFETY LABEL SAFETY

2.1.2 SAFETY LABELS

(1) Caution to avoid getting hand caught (3EB-96-25121)
･ Do not place your hands.

(2) Prohibit the operators from riding on the forks and lifting/
lowering themselves (3EB-96-25131)
･ Never enter the area under the forks.

(3) Hoist the lift truck by designated positions (3BA-96-59140)

(4) Jump start prohibited (09842-A0481)

･ Start the engine only after sitting down in the operator's
seat.
･ Do not attempt to start the engine by intentionally
shortcircuiting the engine starting circuit. Such a
malpractice can cause a serious bodily injury and fire.

2-4
SAFETY 2.1 SAFETY LABEL

(5) Avoiding danger if lift truck tips over during operations (3EB-96-32610)

BEFORE OPERATION: IF THE LIFT TRUCK SEEMS TO TIP OVER ANY

MOMENT DURING OPERATION:
1. Always use your seat belt when operating. 3. Do not jump off the lift truck.
2. Read and understand the Operation and 4. Lean yourself in the opposite direction to the tipping
Maintenance Manual. of the lift truck.
5. Grip the steering wheel tightly.
6. Brace yourself with both feet to support your body.

(6) Take a right posture while operating lift truck (3EB-96-59231)

･ If you operate the lift truck in such a posture that your weight is not properly applied to the seat, like
standing up or leaning forward/backward or sideways, the power will be cut off in approx. three seconds,
making travel and lift truck operation impossible. Take a right posture while operating.
It is especially dangerous when you operate like this on an uphill. Due to the power is cut off, the lift truck
will slither down even if you depress the accelerator pedal, which can lead an accident such as crash or
falling off.

(7) Caution when hoisting the lift truck (3EB-96-31710)

･ Never lift the truck by the overhead guard.

2-5
2.1 SAFETY LABEL SAFETY

(8) Caution before operation (3EB-96-54120)

(9) Seating capacity (3EB-96-54110)

(10) Caution when washing lift truck (37B-1QC-5030)

(11) Caution to avoid getting caught (37B-1QL-5030)

･ Keep hand off the rotating fan.

2-6
SAFETY 2.1 SAFETY LABEL

(12) Caution when handling battery (3BB-96-36840)

(Shape and layout may vary depending on the battery
supplier.)

(13) Caution before operation (09651-A0481)

( C a u t i o n l a b e l m a y b e a t ta c h e d d e p e n d i n g o n t h e
specifications.)
･ Warning: Be sure to read the Operation and Maintenance
Manual thoroughly before operating, serving,
disassembling, assembling or transporting.

2-7
2.2 BASIC PRECAUTIONS SAFETY

2.2 BASIC PRECAUTIONS

2.2.1 FOLLOW RULES
･ Only the trained and qualified persons are allowed to operate
this lift truck.
･ Fully understand and follow this operation and maintenance
manual.
･ Do not operate the lift truck when you are ill conditioned, taking
medicine that causes drowsiness, under the influence of
alcohol, or mentally unstable.

･ Plan safety work beforehand.

Before operation, make up an operating plan that fits the
workplace conditions, type and capacity of the lift truck, and the
load conditions.
In confined areas or when loading/unloading large items,
position a signal person and c a r ry o u t o p e ra t i on s i n
accordance with their instructions.
･ During operation, safety must be your primary responsibility
ensuring the safety of those you are working around, the lift
truck, yourself, and other property in the work area.

2.2.2 NEVER OPERATE THE BROKEN-DOWN LIFT TRUCK

･ If any abnormality is detected during the start-up inspection or
during the operation (noise, vibration, odor, maladjusted
gauge, smoke, oil leak, or erroneous indication of warning
Never use

device or monitor), report the administrator immediately and

take adequate corrective actions.
Danger

･ Do not operate the lift truck until the abnormality is corrected.

･ Remove the key from the faulty lift truck and put up signs in the
operator's compartment to prevent its use.
･ 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 vehicles
from hitting the forks.
･ Select a parking place where people or vehicles do not pass.
Take measures to prevent anyone to go under the forks.
(Space under lifted forks is dangerous zone.)

2-8
SAFETY 2.2 BASIC PRECAUTIONS

2.2.3 WEAR ADEQUATE CLOTHES AND SAFETY EQUIPMENT FOR OPERATION

･ Avoid loose clothing and accessories. It is dangerous when
they catch on control levers and projections.
･ Long, loose hair can be caught in a rotating part. Long hair
must be tied back.
･ Always wear a safety helmet and safety shoes. Wear other
safety equipment appropriate for the working conditions or as
may be required by your administrator.
･ Check that the safety equipment works properly before use.

2.2.4 FIRE EXTINGUISHER AND FIRST AID KIT

･ In preparation for a fire or bodily injury, check the locations of
fire extinguisher and first aid kit, and be familiar with the usage.

2.2.5 CAUTIONS FOR SAFETY-RELATED EQUIPMENT

･ Confirm that all protective guards, covers, and mirrors are
properly mounted. Repair them immediately when broken.
･ Be sure that you fully understand the usage of safety-related
equipment.
･ Never remove the safety-related equipment. Keep them fully
functional at any time.
･ Do not operate this lift truck if the overhead guard or load
backrest has been or appears to have been damaged or
loosened until repairs have been made by your authorized
KOMATSU FORKLIFT distributor.

2.2.6 PRACTICE SUFFICIENTLY BEFORE OPERATION

･ Take sufficient time for practice until you become familiar with
the operation of each component before starting the actual
operation.
･ Even after you become familiar with it, operate with caution and
avoid harsh operation. Or it can cause a bodily injury or
damage.
･ Each lift truck is more or less peculiar in the performance of
brake, accelerator, and load handling device even though it is
the same model type. When you changeover the lift trucks,
understand the peculiarity of each lift truck before stating
operation. Be especially careful with brake, since its
performance varies by individual lift truck.

2-9
2.2 BASIC PRECAUTIONS SAFETY

2.2.7 JUMPING ON AND OFF FROM THE LIFT TRUCK IS STRICTLY PROHIBITED
･ Never jump on or off the lift truck. It is extremely dangerous.
･ Even if the lift truck accidentally starts to move without operator
onboard, never attempt to jump on the lift truck to stop.
･ Always mount and dismount the lift truck from the left side.
･ While mounting and dismounting the lift truck, always support
yourself securely with your hands and feet at more than 3
locations; put your left foot on the step, grab the assist grip
(handrail) with your left hand, and grab the backrest or hip
support of the seat with your right hand.
･ Do not hold on the control levers or steering wheel when
mounting or dismounting the lift truck.

2.2.8 KEEP THE OPERATOR'S COMPARTMENT AND PLATFORM CLEAN AND TIDY
･ Always keep the operator's compartment and platform (assist
grip, step, floor) clean and tidy. Oil, mud or dust attached, or
spare parts or tools left lying around in the operator's
compartment may cause the operator's hand or foot slips or the
clothes get caught, which will lead a falling accident or
erroneous operation.

2.2.9 CAUTION WHEN WASHING LIFT TRUCK

･ Entering of water into the electrical parts (controllers, sensors,
connectors) may cause a malfunction, which is dangerous. Do
not wash the electrical parts or use a high-pressure washer
(steam cleaner) on them.
For washing the lift trucks, see "4.10 WASHING LIFT TRUCKS
(PAGE 4-53)".

2 - 10
SAFETY 2.2 BASIC PRECAUTIONS

2.2.10 TO AVOID BURN INJURY

HIGH TEMPERATURE COOLANT
･ Immediately after the lift truck is used, the cooling water is at a
high temperature, so there is always the danger of burns if you
open the radiator cap as steam or boiling water may spurt out.
Turn the radiator cap slowly, while releasing the residual
pressure, after the coolant temperature has gone down
sufficiently.

HIGH TEMPERATURE PARTS AND OIL

･ To prevent burns with the high temperature parts or by the
spurt of oil, carry out inspection and maintenance work after
these parts cool down and can be touched safely with bare
hands.

2.2.11 FIRE PREVENTION

FIRE WITH FUEL AND OIL
Fuel, oil, antifreeze, window washer fluid, etc. are flammable, so
keep them away from open flame.
Follow the instructions shown below:
･ Do not smoke or allow any flame near fuel, oil, antifreeze or
window washer fluid or clothes soaked in them.
･ Stop the engine before refilling fuel.
･ Do not leave the area while refilling fuel or oil.
･ Tighten the fuel cap and oil cap securely.
･ Do not spill fuel on the overheated surface or electrical system
components.
･ Store fuel and oil in a well-ventilated dark cold place.
･ Store fuel and oil in a designated place. Keep unauthorized
people off the storage.
･ Wipe off the spilled fuel, oil, and grease after refilling.
･ Put clothes soaked in oil and other flammable objects in a
secure container and store them in a safe place.
･ Also, be cautious and take measures for fires that may be
ignited with a spark or flame when handling equipment and
devices for inspection and/or maintenance.
Failure to comply with these safety policies may result in serious
injury or death.

2 - 11
2.2 BASIC PRECAUTIONS SAFETY

FIRE CAUSED BY DEPOSITS AND FOULING OF FLAMMABLE OBJECTS

･ Deposits or fouling of flammable objects in the engine exhaust
manifold, muffler, exhaust pipe, near the battery, and inside the
under cover may cause a fire. Remove the deposits and
attached material from the above locations.

FIRE FROM ELECTRICAL WIRING

Short-circuiting of the electrical wiring may cause a fire.
･ Clean all the electrical wiring connections, and fix them firmly.
･ Check daily for looseness, wear and damage of the wiring.
Retighten the loose connector and wiring clamp. Damaged
wiring must be repaired or replaced by KOMATSU FORKLIFT
distributor.

FIRE FROM PIPING

･ Make sure that the clamp, guard and cushion of the hose and
tube are fixed securely. Loose hose or tube may get damaged
by vibration during operation or by rubbing against other parts,
and cause the high pressure fluid to spurt out which may lead a
fire or serious bodily injury.

2.2.12 IF A FIRE BREAKS OUT

･ If a fire breaks out, return the starting switch to the [Q] (OFF)
position to stop the engine.
･ Do not jump off the lift truck in a rush. Support yourself securely
with handrails and steps to evacuate.

2.2.13 DO NOT MODIFY THE LIFT TRUCK

･ Contact KOMATSU FORKLIFT distributor in advance for any
modification (installation, removal and modification) of the lift
modify
truck, attachment or option. It may cause safety hazard and
may violate the law.
･ KOMATSU FORKLIFT will not be responsible for any bodily
injury, damage or failure which results from the modification
made without consent of KOMATSU FORKLIFT in writing.

2 - 12
SAFETY 2.2 BASIC PRECAUTIONS

2.2.14 DO NOT REMOVE THE OVERHEAD GUARD AND LOAD BACKREST

･ Do not remove the overhead guard or load backrest, which are
installed to protect the operator from falling objects.
･ Also do not use the lift truck not equipped with overhead guard
or load backrest.
･ The overhead guard is built in compliance with the safety
standards. However, it is not designed to withstand every
possible impact. Always be careful to prevent damage or injury
from falling objects.

2.2.15 SECURE SAFETY AT THE WORKING AREA

･ Working on a rough surface can result in bodily injuries such as
backache.
Always keep the passages and work areas flat and smooth
without bump.
･ Wipe up all spill oil or grease from the ground to prevent tip
over or collision due to slipping.
･ When working on platforms, docks, quays, or other places
where there is 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 traffic areas clearly, and establish a clear traffic rule
such as temporary stop line, speed limit, no-entry area for other
vehicles and pedestrians.
･ Provide adequate lighting for safety operations.

2.2.16 ENGINE EXHAUST GAS IS POISONOUS

･ Do not leave the engine running where there is poor ventilation.
The engine exhaust gas contains carbon monoxide. There is
danger that this will cause gas poisoning. Open the windows
and doors for ventilation.

2 - 13
2.2 BASIC PRECAUTIONS SAFETY

2.2.17 ASBESTOS CAUTION

･ Non-Genuine Parts (unspecified parts of KOMATSU
FORKLIFT) such as clutch disc, brake lining, gasket and
packing may contain asbestos. Use Genuine Parts.
･ All the parts used in this lift truck are asbestos-free.

2.2.18 WINDOW WASHER CAUTION

･ Use the window washer which contains ethyl alcohol.
･ Never use the window washer containing methanol which is
harmful to eyes.

2 - 14
SAFETY 2.3 BEFORE STARTING OPERATION

2.3 BEFORE STARTING OPERATION

2.3.1 START-UP INSPECTION
ALWAYS CONDUCT A START-UP INSPECTION IN THE BEGINNING OF THE DAY FOR YOUR SAFETY
OPERATION OF THE LIFT TRUCK
･ For details of the inspection, see "4.1 INSPECTION AND
MAINTENANCE (PAGE 4-2)".

2.3.2 INSPECTION AND ADJUSTMENT BEFORE STARTING ENGINE CHECK THE

FOLLOWINGS BEFORE STARTING THE ENGINE
･ Check for coolant level, fuel level and oil level in the engine oil
pan, and clogging in the air cleaner.
･ Adjust the seat (seat position, backrest angle, etc.), steering
wheel position and center mirror, and make sure the locks are
secured.

CAUTION WHEN STARTING THE ENGINE

･ Before starting the engine, check that the parking brakes are
set, and that the forward/reverse lever and high/low speed
levers are in the neutral position.
･ When starting the engine, first check that the surrounding area
is safe, and sit in the operator's seat.
･ Sound the horn before starting the engine to warn people
around.

･ Do not start the engine by short-circuiting the engine starting

circuit. Such an act may cause a serious bodily injury or fire.
･ Do not start the engine by pushing the lift truck.

2 - 15
2.3 BEFORE STARTING OPERATION SAFETY

CAUTION IN COLD WEATHER

･ Allow sufficient time for warming-up the engine in cold weather.
If the engine is insufficiently warmed-up, the lift truck may move
slow or change its motion suddenly which will result in an
accident.
･ For operation and maintenance, see "3.3.3 STARTING, GEAR
SHIFTING, AND TRAVELING (PAGE 3-20)" and "4.6
RUNNING IN COLD WEATHER (PAGE 4-47)".

2.3.3 START-UP INSPECTION

CHECK THE FOLLOWING BEFORE STARTING THE OPERATION
･ Check the operating conditions of the lamps and warning lights
on the instrument panel.
･ Make sure that the traveling and load handling interlock
function properly.
･ This lift truck is provided with TRAVEL INTERLOCK and LIFT
INTERLOCK that make travel and truck operation impossible
when you are not seated properly. See "TRAVEL INTERLOCK
(PAGE 3-27)" and "LIFT INTERLOCK (PAGE 3-33)".
･ If any fault is found (noise, vibration, heat, odor, maladjusted
gauge, oil leak, or fuel leak), be sure to repair the fault before
starting the operation.

2 - 16
SAFETY 2.4 TRAVELLING THE LIFT TRUCK

2.4 TRAVELLING THE LIFT TRUCK

2.4.1 PREPARATION BEFORE TRAVELLING THE LIFT TRUCK
USE THE SEAT BELT
･ Always fit the seat belt properly before operation.
･ Not wearing the seat belt properly may result in serious bodily
injuries if the lift truck tips over.
･ Make sure the seat belt is free from damage and flaw.

TAKE A RIGHT POSTURE ON THE SEAT

･ If you operate the lift truck when you are not seated properly or
off the seat, an accident may happen unexpectedly. To forestall
such a possible accident, this lift truck is provided with TRAVEL
INTERLOCK and LIFT INTERLOCK that make traveling and lift
truck operation disabled if you are not seated properly.
For travel interlock, see "TRAVEL INTERLOCK (PAGE 3-27)".
For lift interlock, see "LIFT INTERLOCK (PAGE 3-33)".

TAKE A RIGHT POSTURE WHILE OPERATING

･ Do not stick the hand or foot outside the lift truck body.
･ Always keep your body under the overhead guard.

2 - 17
2.4 TRAVELLING THE LIFT TRUCK SAFETY

BEFORE TRAVELING THE LIFT TRUCK, CHECK THE SAFETY OF SURROUNDING AREA
･ Before starting to travel the lift truck, check that the surrounding
area is clear of obstructions such as pedestrians, other trucks
and loads.
･ Raise the forks approx. 15 - 20 cm (6 - 8 in) from the ground
and tilt the mast back.
･ Sound the horn areas as may be needed.
15 - 20 cm
(6 - 8 in)

2.4.2 WHILE TRAVELING THE LIFT TRUCK

AVOID SUDDEN STARTING OR SUDDEN FORWARD-REVERSE DIRECTIONAL CHANGE
･ Stop the lift truck before changing the forward/reverse travel
direction.

BE ALWAYS CONSCIOUS OF SAFETY WHILE TRAVELING

･ Avoid sudden starting, braking, or making sharp turns.
･ Keep a clear view of the path of travel.
･ 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.
･ When traveling, always pay careful attention to the area around
your lift truck, particularly in the direction of travel or when
turning.
･ Do not attempt to pass another lift truck or vehicle on a narrow
path or on a spot of limited view like a crossing.
･ When passing through a crossing or turning a corner, or when
traveling into a narrow path, stop the lift truck once to check the
safety. Sound the horn to warn people around if necessary.
･ Even if you sound the horn, not everyone in the surrounding
area will necessarily hear it. Always pay careful attention to the
movements of people in the surrounding area.
･ Do not allow people to enter the working area.
･ When traveling on a slope or through a crowded spot, always
give way to a loaded lift truck.

2 - 18
SAFETY 2.4 TRAVELLING THE LIFT TRUCK

DO NOT ALLOW ANY PASSENGER

･ Never allow any other person to ride with you on the lift truck
for whatever reasons.
･ Do not use anyone for a counterbalance-weight.

NEVER TURN OFF THE STARTING SWITCH WHILE TRAVELING

･ If the starting switch is turned to [Q] (OFF) while traveling, the
power steering effort may become felt heavier, which is
dangerous.

DO NOT KEEP YOUR FOOT ON THE INCHING PEDAL WHILE TRAVELING

･ Keep your foot off the inching pedal in the normal traveling.
Otherwise the brake will overheat and the braking effect may
be lost.
･ Depressing the pedal engages the clutch halfway, which
makes the engine brake ineffective.
･ This can cause the transmission to overheat, leading the
overheat of transmission fluid, and wear or seizure of the
multiple clutch plates.

OPERATING BRAKE PEDAL

･ Allow plenty of time for brake operation depending on the
situation, as the road surface and weight of the load affect the
stopping distance. Longer distance is required to stop on a
downhill, wet or slippery surfaces, and with heavy load.

WHEN BACKING UP THE LIFT TRUCK, CHECK REVERSE DIRECTION VISUALLY

･ When backing up the lift truck, always look back and make a
direct visual check on the rear of the lift truck. The center mirror
is simply an auxiliary aid for checking the rear. When reversing,
do not depend on the center mirror alone for checking safety.
･ Even if you sound the backup buzzer, the people behind the lift
truck do not necessarily hear it. Always visually check directly
with your own eyes that there is no one behind the lift truck
while traveling.

2 - 19
2.4 TRAVELLING THE LIFT TRUCK SAFETY

WHEN CARRYING A HIGH LOAD, USE A SIGNAL PERSON OR TRAVEL BACKWARD

･ If the view to the front is obstructed by the load, operate the lift
truck in reverse while minding safety in the area the lift truck is
heading to, or have a signal person to guide the travel.

PAY SPECIAL ATTENTION TO THE REARVIEW WITH A LPG CYLINDER-INSTALLED (GASOLINE ENGINE)
LIFT TRUCK
･ The installed LP gas cylinder partially blocks the rear view and poses a danger of hitting people around or piled
commodities, or run against a nearby building. Have this in mind and check the rear view without fail.
･ When installing optional warning devices (reverse warning flasher, back-up assist mirror, etc), call your
KOMATSU FORKLIFT distributor for details.

LP gas cylinder

Area that can be seen when

cylinder is installed

Area that can be seen when

cylinder is not installed

DO NOT TRAVEL THE LIFT TRUCK WHEN THE FORKS ARE RAISED HIGH
･ If loaded or unloaded, raising the forks also raises the center of
gravity of the lift truck increasing a risk of tipping over. Do not
travel the lift truck with the up-raised forks. (During a travel,
keep the forks approx. 15 - 20 cm (6 - 8 in) above the ground
with the mast tilted backward.)

2 - 20
SAFETY 2.4 TRAVELLING THE LIFT TRUCK

NEVER JUMP OFF THE LIFT TRUCK WHEN THE LIFT TRUCK SEEMS TIPPING OVER
(1) Always use your seat belt during operations for your safety if
lift truck should tip over.
(2) To avoid tipping over and other accidents, carry on proper
operation, inspection and maintenance work, read and
understand the Operation and Maintenance Manual.
(3) Do not jump off the lift truck if the lift truck seems tipping
over. Or you may be crushed by the lift truck resulting a
serious bodily injury.
(4) Lean yourself in the opposite direction to the direction the lift
truck is tipping.
(5) Grip the steering wheel tightly.
(6) Brace yourself with both feet to support your body.

･ Practice this series of actions from time to time to master how

to act in emergency situations.

WHEN MAKING TURN, BE CAREFUL OF THE SWINGING TAIL

･ The forklift has rear steering wheels. Be careful as if behaves
differently from passage cars.
･ When turning while traveling forward, the counterbalance-
weight will swing far out. Keep an ample clearance from walls
to ensure safety.

PAY CAREFUL ATTENTION TO THE LIFT TRUCK'S MAX. HEIGHT AND WIDTH
･ Ensure that there is ample height and width for the lift truck to
pass.
･ Keep clearance from the doors, ceiling, wirings and pipes.
･ Be careful with the height of the mast and load backrest when
the forks go up.

2 - 21
2.4 TRAVELLING THE LIFT TRUCK SAFETY

DO NOT TRAVEL ON ROUGH OR SLIPPERY ROAD

･ Do not try to travel on bumpy or soft ground. It can lead a
serious accident when you lose steering control or the tyres
stuck in the mud.
･ Avoid traveling on the slippery road covered with water and oil.
You will lose brake or steering control.

OBSERVE THE WEIGHT LIMIT

･ Do not allow overweight on the floors and roads where weight
limit is specified.

DO NOT TRAVEL DIRECTLY OVER OBSTACLES ON THE ROAD

･ Avoid clutter, curbs, rails, ditches, or other obstacles, and do
not travel directly over them. Also, the impact applied when
traveling over obstacles can result in bodily injuries such as
backache.

TRAVELING ON A ROAD SHOULDER IS STRICTLY PROHIBITED

･ There is danger that soft road shoulders may collapse. Do not
approach them.
･ Always maintain a safe distance from the edge of road
shoulders and platforms to prevent the lift truck from falling off.

EMERGENCY ACTION AT A RAILWAY CROSSING

･ If the lift truck becomes immovable due to an engine trouble at
a railway crossing, etc., the truck cannot be moved with the cell
motor as on a passenger vehicle. (Because of the activation of
the neutral safety switch.)
･ In such an emergency, burn a safety flare or take a similar
action to inform the neighboring object like an approaching
train of the failure of the lift truck.

2 - 22
SAFETY 2.4 TRAVELLING THE LIFT TRUCK

CAUTION WHEN TRAVELING ON SLOPES

･ Do not turn, or traverse or be careful for the approach/
departure angle on slopes. The lift truck may tip over.
･ Before starting to travel 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 or the tip of the fork does not stick into the ground
when traveling.

･ For safe travel on slopes

When loaded
When loaded : Travel forward uphill and in reverse
downhill.
When unloaded : Travel in reverse uphill and forward
downhill.

･ On a down slope, travel down slowly using the engine as a

brake.
･ If you are not properly seated, the travel interlock activates to
cut off the engine power, resulting the truck may slither down When unloaded
on a slope. Take a right posture while operating. For the travel
interlock, see "TRAVEL INTERLOCK (PAGE 3-27)".

EXERCISE CARE WHEN TRAVELING INTO A RAILWAY WAGON OR CONTAINER

･ Check that brake and block are applied to the wagons, trailers,
and containers to stop them.
･ Tell the carrier drivers not to move their vehicles until the load
handling operation is completed.
･ Ramps used for approaching the wagon and/or trailers must
stand the travels of loaded lift trucks.
･ Engage the ramps securely to wagons and trailers.
･ Do not travel at the edge of the platforms or loading docks, or
there is a danger of the lift truck falling down.

2 - 23
2.4 TRAVELLING THE LIFT TRUCK SAFETY

2.4.3 STOPPING AND PARKING

FOLLOW THE STEPS FOR STOPPING AND PARKING
1. Stop the lift truck on level ground.
2. Apply the parking brake lever to prevent the lift truck from Free
moving.
3. Set the forward-reverse lever to the neutral position Lock

4. Tilt the mast forward and lower the forks to the floor.
5. Turn the starting switch key to the [Q] (OFF) position.
6. Pull out the starting switch key and leave the lift truck.

PARK THE LIFT TRUCK IN A SAFE PLACE

･ Park the lift truck on a firm level ground.
･ Do not stop or park near any emergency exit or other safety
equipment. Stop or park the lift truck in a place where it will not
obstruct pedestrians or other vehicles.
･ Do not park the lift truck on a slope. If there is no way to avoid
parking on a slope, apply blocks to the tyres.

2.4.4 TOWING
BE CAREFUL WHEN USING THE DRAWBAR PIN
･ The drawbar pin is provided for being towed by the wrecking
car when the tyres are stuck in a ditch or mud.
･ Do not use it for towing or hoisting.
･ The drawbar pin can be used for an anchor point of this lift
truck when being transported by a truck.

DO NOT TOW A DISABLED LIFT TRUCK

･ If there is any problem with the brakes or steering system of
your lift truck, do not use tow with another lift truck. There is a
danger that disabled the lift truck may move accidentally.

2 - 24
SAFETY 2.5 LOAD HANDLING OPERATION

2.5 LOAD HANDLING OPERATION

SIT ON THE SEAT CORRECTLY FOR LOAD HANDLING OPERATION
･ To avoid accidents, Lift Interlock activates to disable the load
handling operation when you are not seated properly or off the
seat. For the lift interlock, see "LIFT INTERLOCK (PAGE 3-
33)".

DO NOT ALLOW ANYONE IN THE WORKING AREA EXCEPT THE SIGNAL PERSON
･ To avoid accidents, keep unauthorized people and other
vehicle off the working area except a signal person during the
load handling operation.
･ Use a signal person when it is necessary to ensure visibility or
for other safety reasons.
･ When working with a signal person, always follow their
instructions.

DO NOT GO UNDER THE LIFTED FORKS

･ There is a danger of serious bodily injury under lifted forks that
a person can be crushed under the forks when they come
down. Keep everyone away from under the lifted forks.

WORKING ON THE FORKS IS STRICTLY PROHIBITED

･ Do not directly place a load manually on the forks.
･ Do not directly remove a load manually from the forks.
･ Do not step on the forks to handle a load. The load may slip
down the forks.
･ Do not hold the load on the forks by hands. Sudden lift truck
movement may cause the load to fall on the person below.

2 - 25
2.5 LOAD HANDLING OPERATION SAFETY

BE CAREFUL NOT TO GET CAUGHT IN THE MAST STRUCTURE

･ Never put your hands, feet, or other body parts into the mast
structure. There is a danger that you may get caught in moving
parts and be seriously injured.
･ Do not stand between mast and operator's compartment as
you may be crushed and be seriously injured or killed.
･ Always operate the mast and forks from the operator's
compartment.

DO NOT CLIMB ON THE MAST OR LOAD BACKREST

･ If you climb on the mast or load backrest, there is a danger of
being caught in the moving parts or fall off.

USE A PALLET OR SKID OF AMPLE STRENGTH

･ Always use the pallets and skids of robust construction. Do not
use broken or damaged pallets or skids.
･ Before traveling, always check that the load is positioned
securely and safely on the pallet.

2 - 26
SAFETY 2.5 LOAD HANDLING OPERATION

HANDLE A LONG OR WIDE LOAD WITH EXTRA CARE

･ Be extremely careful when carrying long or wide loads. Lift the
load slowly without hitting anything in the surrounding area.
･ When switching direction, keep the load as low as possible and
maintain the balance.

BE CAREFUL WITH THE MAST HEIGHT

･ As the forks go up, the mast height increases. Be mindful of
this face during the operation.
･ Take care not to hit with the mast electric wirings, piping,
sprinklers, beams in the ceiling, etc. If such hitting occurs, there
is a danger that the load on the forks drops off or the lift truck
tips over.

OVERLOADING IS STRICTLY PROHIBITED

･ Overloading may cause the rear wheels come off the ground,
and the lift truck loses the balance and tips over. Do not load
the lift truck over the max. capacity shown in the load table. For
the capacity, see "2.8.4 ACTUAL CAPACITY (PAGE 2-39)".
For the load table, see "2.8.5 SERIAL NO. PLATE AND LOAD
TABLE (PAGE 2-40)".

DO NOT TILT THE MAST FORWARD WITH A LOAD ON THE FORKS

･ Do not tilt the mast forward with the load raised. Do not raise
the load with the mast tilted forward. Or the load may fall or the
lift truck may tip over.
･ Do not travel with the mast tilted forward.

2 - 27
2.5 LOAD HANDLING OPERATION SAFETY

DO NOT HANDLE A LOAD IN AN INSECURE MANNER

･ 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.
･ Secure the load in position to prevent collapsing or falling. Do
not handle unstable loads.
･ Place the load so that it makes contact the load backrest.

DO NOT LOAD AND UNLOAD ON SLOPES

･ Loading or unloading on the slopes may cause the lift truck to
lose its balance and tip over.

DO NOT LOWER THE LOADED FORKS HASTILY

･ Do not operate the forks roughly or make sudden stop. Sudden
lowering may cause the collapsing and falling of the load, and
the lift truck may go off balance and tip over.

DO NOT HANDLE A LOAD EXCEEDING THE LOAD BACKREST HEIGHT

･ If the load is higher than the load backrest, there is danger that
it may fall back on the operator. Do not handle a load
exceeding the load backrest height.

2 - 28
SAFETY 2.5 LOAD HANDLING OPERATION

DO NOT PRY SOMETHING WITH THE TIPS OF THE FORK

･ Otherwise the hooked object can suddenly come off the tip,
and the reaction causes big danger to the lift truck as well as to
the hooked object.

DO NOT USE THE FORKS TO PUSH OR PULL A LOAD

･ There is a risk that the load will be damaged or fall.

DO NOT USE THE LIFT TRUCK FOR ANY OTHER PURPOSE

･ Do not use the lift truck for any other purpose than load
handling using forks or attachments.
･ Do not open or close the doors or railroad cars or warehouses
with the forks.
･ Do not push or pull any other vehicle.
･ Do not lift loads suspended from the fork with ropes. The rope
may slip, come off, break, or even cause cracks on the forks.
Also the lift truck may lose its balance and tip over as the load
swings.

2 - 29
2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE SAFETY

2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE

2.6.1 BE SURE TO PERFORM THE START-UP INSPECTION AND THE PERIODIC
VOLUNTARY INSPECTION
･ This Operation and Maintenance Manual provides only the
simple inspection and maintenance information that operators
can perform relatively easily. For inspection and maintenance
that requires a trained, skilled and qualified personnel, contact
your KOMATSU FORKLIFT distributor.
･ Do not operate the lift trucks before completing start-up
inspection.
･ Report abnormality, if any, immediately to the administrator. Do
not operate faulty lift truck until the repair is completed.
･ Incorrect inspection, maintenance and repair services may
cause critical accident or shorten machine service life. For your
safety operation, contact KOMATSU FORKLIFT distributor for
inspection, maintenance and repair services.

2.6.2 PUT UP A WARNING SIGN DURING INSPECTION AND MAINTENANCE

･ Put up a warning sign on the steering wheel or load handling
lever during inspection and maintenance work. Put up the sign
around the lift truck, if necessary.
･ Do not let any other person than the inspector or maintenance
staff start the engine or touch the load handling lever during Do not operate

inspection and maintenance. Or serious injuries may result.

When jointly making inspection or maintenance with other
personnel, name the leader and follow their instructions.

2.6.3 KEEP THE WORKING AREA CLEAN AND TIDY

･ Perform the work on level surface with ample space.
･ Keep the working area clean and tidy. Get obstacles out of the
way. Wipe off any grease or oil.
･ If the work is carried out inside a building, keep it well-
ventilated.

2 - 30
SAFETY 2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE

2.6.4 PRECAUTIONS BEFORE INSPECTION AND MAINTENANCE

･ Arrange for a fire extinguisher. Know the location and how to
use it.
･ Do not allow anyone with loose clothing or long loose hair near
the mast while operation.
･ Wear adequate working clothes and protective items (safety
helmet, safety shoes, goggles and gloves).
･ Lower the forks to the ground, pull the parking brake lever in
the direction to the rear of the lift truck, set all the lever to the
neutral positions, then turn the starting switch to [Q] (OFF)
position to stop the engine.
･ Block the front and rear tyres.

2.6.5 KEEP UNAUTHORIZED PEOPLE OFF

･ No unauthorized person is allowed near the lift truck under
maintenance service.

2.6.6 USE OF RIGHT TOOLS AND EQUIPMENT

･ Use a suitable tool correctly. Do not use broken or deformed
tools, or wrong tools designed for another purpose, or a serious
accident may result.

2.6.7 CAUTIONS WHEN WORKING UNDER WORK EQUIPMENT

･ Block the forks and mast to prevent falling before working
under the raised forks. Otherwise, a serious accident may
result.

2 - 31
2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE SAFETY

2.6.8 AVOID GETTING CAUGHT UP BY THE MAST OR FALLING OFF

･ Do not put your hands, feet, or other body parts into the mast
structure. Or you may be caught by the mast parts.
･ Do not stand between mast and operator's compartment as
you may be crushed and be seriously injured or killed.
･ Always operate the mast and forks from the operator's
compartment.

･ Do not climb on the mast load backrest or on top of the

dashboard. You may slip and fall or get caught in the moving
parts. Use a stepladder for inspection and maintenance at
elevated level.

2.6.9 BE CAREFUL OF BOILING COOLANT

･ Immediately after using the lift truck, the engine cooling water
is at high temperature and high pressure. Do not remove the
radiator cap under these conditions or it may cause burns.
･ When removing the radiator cap, turn it slowly to release the
internal pressure after the coolant temperature has gone down
sufficiently.

2 - 32
SAFETY 2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE

2.6.10 BE CAREFUL OF HIGH PRESSURE OIL

Remember that the hydraulic system is constantly under
pressure. Check the hydraulic system for no pressure before
checking or replacing piping or hose, or a serious accident may
result. Follow the instructions below:
･ When checking hydraulic piping or hose for leakage, don't
touch it directly by hand. The pipe or hose may be pressurized
and can be dangerous.
･ If your skin and/or eye are injured by high-pressure oil, wash it
with fresh water and immediately see a doctor.

2.6.11 BEWARE OF ROTATING COOLING FAN AND BELT

･ Keep hand off the rotating fan or fan belt.
･ Always stop the engine before opening the engine hood. Only
the authorized people are allowed to open the engine hood.

2.6.12 PRECAUTIONS FOR INSTALLING RADIO CONTROL SYSTEM

When installing the radio control system, observe the following
since it affects the electronic control system depending on its
location.
･ Install the antenna to a place as far apart from the control unit
(engine controller and lift truck controller) as possible such as
the operator cab top.
･ Install the antenna feeder line at least 20 cm (8 in) apart from
the control unit.
･ Adjust the antenna and feeder line to eliminate radio
interference.

2.6.13 CAUTION WHEN REPAIRING THE ELECTRICAL SYSTEM

･ When repairing the electrical system, disconnect the cable of
the negative (-) terminal to stop power supply.

2 - 33
2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE SAFETY

2.6.14 CAUTIONS FOR USING COMPRESSED AIR FOR CLEANING

･ The dust particles may cause a serious bodily injury if
compressed air is used for cleaning.
･ Always wear protective gears such as goggles, dust mask, and
gloves.

2.6.15 CAUTIONS WHEN REPLACING THE SEAT

Seat is equipped with important safety functions:
･ Seat belt and support to operator's body
･ Travel and lift interlock function switches
･ Storage case for instruction manual
Always use Genuine Seat for replacement.

2.6.16 CAUTION WHEN HANDLING BATTERY

Batteries generate flammable hydrogen gas and may explode.
Battery electrolyte also contains dilute sulfuric acid. If you make a
mistake in handling, it may cause personal injuries, explosions
and fires. Strictly follow the instructions shown below.
･ Do not use or charge the battery if the battery electrolyte level
is below the lower level. This may cause battery may
explosion. Check the electrolyte level regularly to maintain it
between the lower level and upper level. If the level is low, refill
distilled water.
･ When handling the battery, always wear safety glasses and
rubber gloves.
･ Do not smoke or allow any flame near the battery.
･ If you spill battery electrolyte on yourself, immediately flush the
part with a large quantity of tap water.
･ If battery electrolyte gets into your eyes, flush them
immediately with fresh tap water and see a doctor.
･ When inspecting or handling the battery, the starting switch
must be turned to the [Q] (OFF) position.

2.6.17 STRICTLY FOLLOW THE INSTRUCTIONS SHOWN BELOW TO AVOID GENERATION

OF SPARKS
･ Do not place tools or other metal objects on the battery. They
may accidentally contact the positive (+) and negative (-)
terminals of the battery.
･ When disconnecting the battery cables, always disconnect the
cable of the negative (-) terminal first. Conversely, when
connecting them again, connect the cable of the positive (+)
terminal first.

2 - 34
SAFETY 2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE

2.6.18 CAUTION WHEN CHARGING A BATTERY

･ When the battery is charged, flammable hydrogen gas is
generated.
･ Remove the battery from the lift truck, and open the battery cap
in a well-ventilated place before charging.
･ Tighten the battery cap securely.
･ Fix the battery in place securely.

2.6.19 CAUTION WHEN HANDLING TYRES

The lift truck tyres are very highly pressurized with the air. Do not
mishandle, or the tyres may burst, be damaged or the rim may
break into pieces causing a serious injury. For your safety, follow
the instructions shown below.
･ Do not disassemble/assemble tyre, tube or rim, nor inflate
removed tyres with the air.
･ For safety, when filling a tyre with air or replacing it, place your
body in front of the tread face of the tyre (see the figure at
right). Do not work from the side of the tyre.

･ When removing the tyre with divided rim from the lift truck,
always loosen the hub nuts (1) after depressurizing the tyre. Do
not loosen the rim bolt (irregular shape) (2) of the divided rim.
For the tyre replacement, see "4.4.6 REPLACING TYRES
(PAGE 4-37)".

･ Always use the specified tyre of KOMATSU FORKLIFT, and

observe the specified tyre inflation pressure.
･ For the right tyre inflation pressure, see "4.16 SERVICE DATA
(PAGE 4-65)".
･ When filling up the tyres, make sure no one is around and use
a clip-on air chuck that can be fixed to the air valve.
Fill up the tyre while checking with an air gauge to avoid over
inflation.
･ The rim will not "fit" the tyre if either the tyre or rim is defective,
or if it is not properly assembled. To fit, the rim must contact
with the tyre evenly around the circumference. Contact your
KOMATSU FORKLIFT distributor as needed.

2 - 35
2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE SAFETY

2.6.20 CAUTION IN WASTE DISPOSAL

Take full cautions for waste disposal to prevent environment
pollution.
･ Always drain waste fluid such as oil, fuel, coolant and battery
electrolyte into containers like cans and tanks. (Do not drain
the battery electrolyte into metallic containers. Always use
plastic containers.) Do not pour on the ground or into rivers,
drains, seas or lakes.
･ Comply strictly with appropriate laws and regulations when
disposing of harmful objects such as oil, fuel, coolant, solvent,
filters, batteries and refrigerant (CFCs).

2.6.21 CAUTION AFTER INSPECTION AND REPAIR

･ Wipe off the spilt oil and grease immediately. If the lift truck is
dirty, it becomes difficult or impossible to find cracks or other
problems.
･ Test the lift truck upon completion of the repair to check if there
is no abnormality.

2.6.22 PERIODIC INSPECTION OF SAFETY CRITICAL PARTS

･ To ensure the safety and long service life of the lift truck, be
sure to perform lubrication, inspection and maintenance
regularly. Especially the safety critical parts, must be replaced
regularly.
･ Quality of these parts may change over time or deteriorate,
wear or fatigue as they are repeatedly used, causing serious
bodily injuries and damages. Further more, the remaining
service life of such parts is usually hard to determine for
operators or during visual inspection.
･ For details of safety critical parts, see "4.15 PERIODIC
REPLACEMENT OF SAFETY CRITICAL PARTS (PAGE 4-
64)".
･ Replace the safety critical parts with a new one periodically
even if no anomaly is found.
･ Replace the safety critical parts immediately when any
abnormality is found, even if the replacement interval has not
passed yet.

REMARK
･ This Operation and Maintenance Manual does not describe the
details on how to inspect or replace the safety critical parts.
･ Inspection and replacement of the safety critical parts, and
refilling of greases must be done by KOMATSU FORKLIFT
distributor.

2 - 36
SAFETY 2.7 HOISTING AND TRANSPORTING THE LIFT TRUCK

2.7 HOISTING AND TRANSPORTING THE LIFT TRUCK

2.7.1 CAUTION WHEN HOISTING THE LIFT TRUCK
･ Never lift up by the overhead guard.
･ Before lifting-up, check that the mounting bolts of mast and
counterbalance-weight are tightened to the specified torque.
Tightening torque for the counterbalance-weight mount bolts
: 588 - 784 Nm {60 - 80 kgfm}
Tightening torque for the mast lower mount bolts
: 343 - 427 Nm {35 - 43.5 kgfm}

･ To hoist the lift truck, hook on the lifting hole on the top of the
outer mast for the front, and the lifting hole on the top of the
counterbalance-weight for the rear.
･ Do not go under the lifted truck.
･ Use undamaged sling and wire, having sufficient strength.
･ If the lift truck has to be lifted frequently, it is necessary to install (18 in)
special lifting equipment, so please contact your KOMATSU
FORKLIFT distributor.

2.7.2 CAUTIONS FOR LOADING AND UNLOADING THE LIFT TRUCK

The work of loading and unloading a lift truck on a trailer always
involves a hazard that the lift truck tips over or falls off if you make
a mistake in handling. Follow the instructions shown below:
･ Stop the trailer on level, flat road surface. Apply parking brake
without fail and apply blocks to the tires. Ramp
･ Use ramps or dock plate of appropriate length, width and
strength. Secure it tightly to prevent it from being dislocated or
disengaged.
･ Take a right posture on the seat while operating. Blocks
If you operate the lift truck in a posture that your weight is not
properly applied to the seat, like standing up or leaning forward
o r s i d e w a y s , t r a v e l i n t e rl o c k f u n c t i o n s t o c u t o ff t h e
transmission of engine power. Then the lift truck may slither
down if the accelerator pedal is stepped on an uphill or a slope.
Operate the lift truck assisted by a signal person if necessary
so that you do not have to stand up or lean forward or sideways
to watch. For the travel interlock, see "TRAVEL INTERLOCK
(PAGE 3-27)".
･ When using the ramps, set them in gradient gentle, align the
center of both the trailer and the lift truck and lock securely to
prevent misalignment.
･ Do not change the course of the lift truck while on the ramps. If
course change is needed, move off the ramps once and make
another uphill travel on them in right direction.

2 - 37
2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING) SAFETY

2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT

LIFT TRUCK FROM TIPPING)
To operate the lift truck safely, it is important to understand the structure and stability of the lift truck.

2.8.1 LONGITUDINAL STABILITY

･ The front wheels of the lift truck act as a fulcrum, and the load
weight and the weight on the rear wheels are kept in balance to
prevent the lift truck from falling forward.
Load
･ When an overbalanced load weight is applied, the rear wheels
will be raised off the ground. It is very dangerous and poses a
high risk of serious accident like tipping over.

Weight on
Load weight Fulcrum the rear wheels

2.8.2 CENTER OF GRAVITY OF A LOAD

･ The shapes of loads carried by lift trucks vary from boxes to planks and long objects.
･ To judge the stability of the lift truck, it is important to determine the position of the center of gravity for loads of
various shapes.

Center of gravity Center of gravity

2 - 38
SAFETY 2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING)

2.8.3 COMBINED CENTER OF GRAVITY AND STABILITY ON THE LOADED LIFT TRUCK
COMBINED CENTER OF GRAVITY
･ The center of gravity of the loaded lift truck shifts to a combined Combined center of gravity Center of gravity
center of gravity of both the lift truck and the load. When the at high lifting height of load

load is raised, its center of gravity will raise, hence the

Combined center of
combined center of gravity will also raise. gravity at low lifting
height

Center of gravity
of lift truck

COMBINED CENTER OF GRAVITY AND STABILITY

The higher the position of the center of gravity, the worse the
longitudinal and lateral stabilities become. In addition, swaying or
shock encountered during traveling or load handling will have a
larger impact on the stability of the lift truck.
Stability of the lift truck also changes depending on the following
factors.
･ Size, weight, shape of load (position of center of gravity etc.)
･ Lifting height
･ Tilting angle of mast
･ Inflation pressure of tyres
･ Acceleration, deceleration and turning speed when traveling
and load handling
･ Road condition and gradient
･ Type of attachments

Do not travel with the forks (load) raised. Do not make sharp turns
or apply sudden brakes. Do not raise or tilt the forks abruptly.
There are dangerous and poses a high risk or serious accident
like tipping over.

2.8.4 ACTUAL CAPACITY

･ Actual capacity means the maximum weight of a load that can
be loaded at a certain load center. The horizontal distance from
the position of the center of gravity of a load on the forks to the
upright load backrest of the fork is called a load center.
･ The load table is given in the serial No. plate accessible from
the operator's seat. The table shows the relationship between
the actual capacity and load center.
･ When the load center shifts toward the fork tips, the load weight
(mass) has to be decreased in the actual operation to maintain
the balance.
Load center : Small Load center : Large
Load : Large Load : Small

2 - 39
2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING) SAFETY

2.8.5 SERIAL NO. PLATE AND LOAD TABLE

EXPLANATION OF LOAD TABLE
･ In the load table of the serial No. plate, actual capacity and
maximum load (2) are shown in relation to load center (1).
･ Actual capacity and maximum load are determined according
to each model on the condition of the specifications shown in
area (3).
･ Before loading, make sure that the load center and the load are
well within the range of capacity.
･ When the load is in a complex shape, pull the load so that the
heaviest portion of the load comes to closer to the load
backrest and the lateral center comes to the two forks center.
･ Should a load be loaded beyond the range of capacity, it would
pose a big danger to the lift truck as the rear wheels (for
steering) may lift off the ground, letting the operator lose control
of steering, or the lift truck may tip over. Always keep the load
within the range of capacity.
･ Work within the specification ranges given in the serial No.
plate attached to the lift truck. Replace the broken or
unreadable serial No. plate. Call your KOMATSU FORKLIFT
distributor for a new serial No. plate.

EXAMPLE OF LOAD CENTER AND ACTUAL CAPACITY

･ The areas (1) and (2) in the example provide the following
information:
When the load center is 600 mm (23 in)
. . . . . Maximum load capacity: 4,000 kg (*1)
When the load center is 800 mm (31 in)
. . . . . Actual capacity: 3,400 kg
When the load center is 1,200 mm (47 in)
. . . . . Actual capacity: 2,620 kg
*1: Even when the load center is smaller than 600 mm (23 in),
the maximum capacity is 4,000 kg.
･ The area (3) shows the main specifications of the model.
Max. lifting height : 3 m (118 in)
Attachment : None
Front wheel tread : 1,115 mm (44 in)
Mast rear tilting angle : 6°
Front wheel size, inflation pressure
: 250-15-16PR, No inflation pressure (*2)
Rear wheel size, inflation pressure
: 7.0012-12PR, No inflation pressure (*2)
*2: Pneumatic cushion tyre in this example, which does not
require air inflation.
･ The following symbols indicate the types of attachment if any.
Symbol Symbol
Attachment Attachment
Type Capacity Type Capacity
Side shifter F S * * * * Clamp C * * * * *
Fork positioner F M * * * * Roll clamp R S * * * *
Load stabilizer F T * * * * Rotating fork R F * * * *
Hinged fork H F * * * * Ram L * * * * *
Push pull P P * * * * Hook K * * * * *
Pusher P A * * * *
* marks in the chart will be replaced with alphabets and numbers which stand for types and capacities of the
attachment. Numbers are not necessarily in 6 digits.

2 - 40
SAFETY 2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING)

LOAD CAPACITY WHEN EQUIPPED WITH ATTACHMENT AND/OR HIGH MAST

･ Please not that the lift truck equipped with attachment and/or
high mast has a fewer maximum capacity and actual capacity
that the standard lift truck.
･ Follow the load limit as indicated in the load table of the serial
No. plate.

LOAD TABLE AND LOAD CAPACITY FOR DETACHABLE AND INSERT-TYPE ATTACHMENTS
･ For some detachable attachments, additional load table is
provided at a certain place of the lift truck. In this case, follow
the instructions in the table when installing such an attachment.
･ For insert-type bucket and fork extension sleeve, calculate the
capacity as follows: Subtract the weight of insert-type bucket or
fork extension sleeve from the capacity on the chart.
･ To check if weight of the insert-type bucket or fork extension
sleeve must be considered, refer to the label attached on the
right side of the operator's seat.

OTHER INFORMATION ON THE SERIAL NO. PLATE

･ The area (4) shows other basic information of the lift truck.
Model
Serial No.
Date of manufacture
Unladen mass
･ [-] means that no information is required.
･ Logo and the company name are shown on the top and bottom
of the serial No. plate.

2.8.6 INTRODUCTION OF OPTIONAL SAFETY DEVICE

Various safety devices are available as options. The devices
listed below are only examples. Contact your KOMATSU
FORKLIFT distributor for more information.
Note that the devices and equipment may not be effective
depending on the usage and working conditions. Follow the
instruction of the safety control personnel for installation.
･ Working lamp: Top and rear
･ Warning for traveling (forward/reverse) or approach
: Chime, revolving warning lamp and flash light
･ Handling of high/wide item
: Higher or wide load backrest and finger board (fork carriage)
･ Speed warning: Speedometer and alarm buzzer
･ Load indicator/warning: Load sensor
･ Better visibility: Center mirror and under view mirror
･ Fire extinguisher
etc.

2 - 41
 OPERATION 3

23

WARNING
Please be sure that you fully understand this manual and the
precautions related to safety for the lift truck.
When operating the lift truck, always strictly follow these precautions.
Failing to heed this warning may result in serious injuries.

3-1
3.1 GENERAL VIEW OPERATION

3. OPERATION
3.1 GENERAL VIEW
3.1.1 GENERAL VIEW OF LIFT TRUCK

(1) Mast (10) Rear combination lamps (turn signal lamp, back-
(2) Lift chain up lamp, brake lamp, and tail lamp)
(3) Lift cylinder (11) Counterbalance-weight
(4) Center mirror (12) Fuel filler
(5) Head lamp (13) Rear wheel
(6) Turn signal lamp and clearance lamp (parking (14) Engine hood
lamp) (15) Tilt cylinder
(7) Overhead guard (16) Front wheel
(8) Assist grip (17) Fork
(9) Operator's seat (18) Fork carriage
(19) Load backrest

3-2
OPERATION 3.1 GENERAL VIEW

3.1.2 INSTRUMENTS AND CONTROLS

･ OPERATOR'S COMPARTMENT

(1) Forward/reverse lever (7) Tift control lever

(2) Steering wheel knob (8) Parking brake lever
(3) Horn switch (9) Inching pedal
(4) Steering wheel (10) Brake pedal
(5) Combination switch (head lamp switch and turn (11) Starting switch
signal switch) (12) Accelerator pedal
(6) Lift control lever (13) Tiltable steering wheel lock lever

3-3
3.1 GENERAL VIEW OPERATION

･ METER PANEL (FG/FD40Z, FG/FD35, FG/FD40, FG/FD45, FG/FD50A)

(1) Fuel gauge (7) Lift interlock warning lamp

(2) Neutral indicator lamp/Travel interlock warning (8) Engine failure indicator
lamp (9) Failure indicator
(3) Engine oil pressure warning lamp (10) Engine coolant temperature gauge
(4) Charge warning lamp (11) Optional meter
(5) Operation indicator (12) Glow indicator (Diesel engine lift truck only)
(6) Hour meter

3-4
OPERATION 3.1 GENERAL VIEW

･ METER PANEL (FD40ZY, FD35Y, FD40Y, FD45Y, FD50AY)

(1) Fuel gauge (7) Lift interlock warning lamp (*)

(2) Neutral indicator lamp (8) Sedimenter warning lamp
(2) Neutral indicator lamp/Travel interlock warning (8) Sedimenter warning lamp/Failure indicator (*)
lamp (*) (9) Glow indicator
(3) Engine oil pressure warning lamp (10) Engine coolant temperature gauge
(4) Charge warning lamp (11) Optional meter
(5) Operation indicator (12) Engine preheater switch
(6) Hour meter
* Lift truck equipped with OPS (Operator presence sensing system).

3-5
3.2 EXPLANATION OF COMPONENTS OPERATION

3.2 EXPLANATION OF COMPONENTS

The followings explain the necessary devices employed to
operate the lift truck.
To carry out suitable operations correctly and safely, it is important
to fully understand the method of operating the equipment and
the meanings of the displays.

3.2.1 METER PANEL

METER LAMPS
Each meter is provided with lamp for easy view at night. The
lamps turn on with the lighting switch on, regardless the starting
switch position.

NOTICE
How to check a blown bulb of each warning light
1. With the engine stopped, check that the warning lights
light up when the starting switch is turned to the [ | ] (ON).
2. If there is any warning light that does not light up, check if
the bulb is blown. When the warning light lights up during
operation, it indicates an abnormality. You should take
corrective actions. Contact your KOMATSU FORKLIFT
distributor immediately.

FUEL GAUGE
Fuel gauge displays the approximate remaining amount of fuel.
Check the fuel amount on a level surface.
Check the remaining fuel level with the starting switch in the [ | ]
(ON) position.
Position (A): it indicates that there is little fuel left.
Position (B): it indicates that the fuel tank is full now.
Do not use up all the fuel. Fill the fuel tank before the fuel runs
out.

NEUTRAL INDICATOR LAMP

Neutral indicator lamp indicates that the forward/reverse lever is
in the neutral position.
With the starting switch key in the [ | ] (ON) position, this lamp
lights up when the forward/reverse lever is in the neutral position,
and goes off when it is either in the forward or reverse position.
Before starting up the engine, be sure to turn the starting switch is
in the [ | ] (ON) position and check that this lamp is on.

3-6
OPERATION 3.2 EXPLANATION OF COMPONENTS

TRAVEL INTERLOCK WARNING LAMP

This indicator lamp doubles as the neutral indicator lamp.
It begins to flash when travel interlock activates, cutting off the
transmission of engine power.
When you seat yourself properly and return the forward/reverse
lever to the neutral position, the flashing lamp goes off and the lift
truck is now ready for travel again.
For the travel interlock, see "TRAVEL INTERLOCK (PAGE 3-27)".

ENGINE OIL PRESSURE WARNING LAMP

This warning lamp indicates abnormality of the engine lubricating
oil pressure.
This lamp lights up when the starting switch is turned to the [ | ]
(ON) position, and goes off after the engine startup.
When it lights up during operation, stop the engine and check the
engine lubrication system, oil pan oil level, etc.

CHARGE WARNING LAMP

This warning lamp indicates abnormality of the alternator
charging system while the engine is running.
This lamp lights up when the starting switch is turned to the [ | ]
(ON) position, and goes off after the engine startup.
When it lights up during operation, check the V-belt for looseness
and the electrical system for any abnormality.

OPERATION INDICATOR
An hourglass symbol on the left side of the hour meter indicates
that the hour meter is functioning.
This symbol flashes when the starting switch is turned to the [ | ]
(ON) position, and goes off after the engine startup.

3-7
3.2 EXPLANATION OF COMPONENTS OPERATION

HOUR METER
Hour meter begins to work when the starting switch is turned to
the [ | ] (ON) position, and indicates the cumulative value of
operating hours.
(While the hour meter is in operation, the operation indicator
keeps flashing.)
Use this meter for checking the periodic inspection intervals and
operation hours.
The last digit advances by 1 (meaning 0.1 hour) when the starting
switch is kept in the [ | ] (ON) position for 6 minutes.

LIFT INTERLOCK WARNING LAMP (*)

It begins to flash when Load Handling Interlock activates,
stopping the operation of forks and mast.
When you seat yourself properly on the operator's seat, the lamp
stops flashing and the lift truck is now ready for load handling
operation again. For the lift interlock, see "LIFT INTERLOCK
(PAGE 3-33)".
* Optional to FD40ZY, FD35Y, FD40Y, FD45Y, FD50AY.

REMARK
If optional, the lift interlock warning lamp is not displayed.

ENGINE FAILURE INDICATOR

This indicator lamp lights up or flashes if any abnormality occurs
to the engine.

NOTICE
If the lamp lights up or flashes during operation, stop
operation immediately and report to the administrator or
contact your KOMATSU FORKLIFT distributor for checkup.
The protection system may stop the engine or take another
protective action, depending on the abnormality.

REMARK
The mark shown at right is displayed on some lift truck models.

3-8
OPERATION 3.2 EXPLANATION OF COMPONENTS

SEDIMENTER WARNING LAMP (FD40ZY, FD35Y, FD40Y, FD45Y, FD50AY)

This w arning lamp lights up when there is some water
accumulated in the fuel filter. If the lamp lights up, drain water
from the fuel filter. If water is left inside the fuel filter, the functions
of the fuel injection pump and injection nozzles will likely be
lowered. For the draining of fuel filter, see "4.4.5 FUEL FILTER
WATER DRAINING AND AIR BLEEDING (FD40ZY, FD35Y,
FD40Y, FD45Y, FD50AY) (PAGE 4-36)".

SEDIMENTER WARNING LAMP (ALSO FUNCTION AS A FAILURE INDICATOR)

(FD40ZY, FD35Y, FD40Y, FD45Y, FD50AY)
･ This warning lamp lights up when there is some water
accumulated in the fuel filter. If the lamp lights up, drain water
from the fuel filter. If water is left inside the fuel filter, the
functions of the fuel injection pump and injection nozzles will
likely be lowered. For the draining of fuel filter, see "4.4.5 FUEL
FILTER WATER DRAINING AND AIR BLEEDING (FD40ZY,
FD35Y, FD40Y, FD45Y, FD50AY) (PAGE 4-36)".
･ This lamp also flashes when the traveling or load handling
interlock does not function properly

NOTICE
If the lamp flashes during operation, stop operation
immediately and report to the administrator or contact your
KOMATSU FORKLIFT distributor for checkup.

FAILURE INDICATOR
This indicator lights up or flashes if any abnormality occurs to the
control system.

NOTICE
If the lamp lights up or flashes during operation, stop
operation immediately and report to the administrator or
contact your KOMATSU FORKLIFT distributor for checkup.

3-9
3.2 EXPLANATION OF COMPONENTS OPERATION

GLOW INDICATOR (FD40ZY, FD35Y, FD40Y, FD45Y, FD50AY)

This indicator acts to indicate that the engine is being preheated.
This lamp keeps lighting while the preheater switch is held down.

ENGINE COOLANT TEMPERATURE GAUGE

The engine coolant temperature gauge indicates the engine
cooling water temperature with a needle.
White range : Normal
Red range : Overheat

NOTICE
I f the indica tor e nte rs th e re d ran ge , sto p t he w ork
immediately and park the lift truck in a safe place. Then take
corrective actions against engine overheating.
For the engine overheating, see "4.7 PROCEDURE WITH
OVERHEATED ENGINE (PAGE 4-49)".

GLOW INDICATOR (FD40Z, FD35, FD40, FD45, FD50A)

This indicator acts to indicate that the engine is being preheated.
This lamp keeps lighting while the lift truck is preheated
automatically and goes off when preheating is finished.

3 - 10
OPERATION 3.2 EXPLANATION OF COMPONENTS

ENGINE PREHEATER SWITCH (FD40ZY, FD35Y, FD40Y, FD45Y, FD50AY)

This switch is the power switch of the engine preheater.
In cold weather, push this switch to preheat the engine.

LOAD METER (OPTION)

This load meter measures an approximate load on the forks and
displays the value in tons.
When this meter is installed, the engine coolant temperature
gauge is moved to the place of optional meter.

OTHER OPTIONAL METERS

The optional meters below are installed to the locations as shown
at the right figure.
･ Speedometer
･ TORQFLOW transmission oil temperature gauge
･ Engine coolant temperature gauge (when the lift truck is
equipped with a load gauge)

3 - 11
3.2 EXPLANATION OF COMPONENTS OPERATION

3.2.2 OPERATING DEVICES

STARTING SWITCH
This switch turns on and off the engine.
(1) [Q] position : You can insert and pull out the starting switch
key at the OFF position.
(2) [ | ] position : The electric circuits are switched on at the ON
position.
(3) [ | ] position : The starter begins to rotate to start-up the
engine at the START position. When the engine
has started up, release the engine starting
switch key. The key automatically returns to the
(2) position.

REMARK
When restarting the engine by turning the starting switch to the
[ | ] (START) position, return it to the [Q] (OFF) position and then
turn it to the [ | ] (START) position.

NOTICE
Do not leave the starting switch key in the [ | ] (ON) position
while the engine is not running. The battery capacity goes
down, making it difficult to start up the engine.

HORN SWITCH
Press the switch in the middle of the steering wheel to sound the
horn.

FORWARD/REVERSE LEVER
This lever acts to change the travel direction (forward/reverse) of
Forward
the lift truck.
F (forward)
z N (neutral) Neutral
R (reverse)

REMARK
Reverse
The engine cannot be started if this lever is not at the [z] N
(neutral) position.

3 - 12
OPERATION 3.2 EXPLANATION OF COMPONENTS

FORWARD/REVERSE LEVER (ALSO FUNCTION AS A GEARSHIFT LEVER) (4.5 AND 5 TON LIFT TRUCKS)
This lever acts to change the travel direction (forward/reverse)
and the gearshit mode of the lift truck. Forward 2nd

F2 (forward 2nd)
Forward 1st
F1 (forward 1st)
z N (neutral)
R (reverse) Neutral

REMARK Reverse
･ To shift the gear to F2 (forward 2nd), lift up the forward/reverse
lever (also function as a gearshift lever) and push it forward.
･ The engine cannot be started if this lever is not at the [z] N
(neutral) position.

COMBINATION SWITCH (HEAD LAMP SWITCH AND TURN SIGNAL SWITCH)

This lever incorporates the head lamp switch and the turn signal
switch.

HEAD LAMP SWITCH

When turning the switch to the arrow marks, the lamps light up
and go off as follows.

Meter lamp, clearance lamp

No. Head lamp
and tail lamp
1 OFF OFF
2 OFF ON
3 OFF ON
Lo ON (Low beam) (*) ON
4
Hi ON (High beam) (*) ON

* Applied to Dimmer type.

TURN SIGNAL SWITCH

Left turn (L) : Push lever forward Forward
Right turn (R) : Pull lever backward

This lever will automatically return to the neutral position when the
steering wheel is turned back.

Backward

3 - 13
3.2 EXPLANATION OF COMPONENTS OPERATION

PARKING BRAKE LEVER

This lever is used to operate the parking brake.
Pulling back the parking brake lever fully will set the parking Free
brake. (Lock position)
To release the parking brake, press and hold the button on top of Lock
the lever, and return the lever forward. (Free position)
Button
REMARK
A reminder buzzer sounds when the parking brake is not applied.

ACCELERATOR PEDAL
This pedal adjusts the engine speed.
The engine speed increases in response to the amount of the
pedal depressed.

BRAKE PEDAL
This pedal is used to stop or decelerate traveling the lift truck.

INCHING PEDAL
This pedal adjusts the travel speed during a very low speed travel
such as for load handling operation.
Depressing this pedal slightly engages the clutch halfway, and the
lift truck will crawl along. Further depressing this pedal applies the
brake by working with the brake pedal. Depressing this pedal to
the full disengages the clutch completely.

3 - 14
OPERATION 3.2 EXPLANATION OF COMPONENTS

LIFT CONTROL LEVER

This is a lever to raise or lower the forks with. Lower

Raise : Pull the lever backward.

Lower : Push the lever forward.

Raise

TILT CONTROL LEVER

This lever tilts the mast back and forth. Tilt forward

Tilt forward : Push the lever forward.

Tilt backward : Pull the lever backward.

Tilt backward

STEERING WHEEL AND STEERING WHEEL KNOB

･ The steering wheel changes the direction of the lift truck to the
right and left.
･ Hold the knob on the steering wheel with your left hand for
operation.

TILTABLE STEERING WHEEL LOCK LEVER

･ This lever adjusts the tilt angle (up/down) of the steering wheel.
･ Pulling this lever up can adjust the steering wheel tilt angle.
Pushing the lever down locks the steering wheel.

Lock
Free

3 - 15
3.3 OPERATION OPERATION

3.3 OPERATION
3.3.1 START-UP INSPECTION

CAUTION
･ Do not operate the lift truck before completing start-up
inspection.
･ Report abnormality, if any, immediately to the administrator.
Never operate the lift truck in question until the repair is
completed.

For your safe operation, always make the start-up inspection.

For details about the start-up inspection and daily maintenance,
see "4.2 START-UP INSPECTION (PAGE 4-2)".

3.3.2 MOUNTING/DISMOUNTING AND OPERATING POSTURE ADJUSTMENT

MOUNTING/DISMOUNTING

CAUTION
･ Mount or dismount the lift truck only after the lift truck comes to a
complete stop.
･ Never jump on or off the lift truck. It is extremely dangerous.
･ Do not hold on the control levers or steering wheel when
mounting or dismounting the lift truck.
･ Keep the handrails (assist grips) and step clean all the time, and
repair the damage, if any.
･ Do not use the handrails (assist grips) for any other purpose than
mounting or dismounting the lift truck.

･ Always mount and dismount the lift truck from the left side.
･ While mounting or dismounting the lift truck, always support
yourself securely with your hands and feet at more than 3
locations; put your left foot on step (2), grab assist grip (1) with
your left hand, and grab the backrest or hip support (3) of the
seat with your right hand.

3 - 16
OPERATION 3.3 OPERATION

SEAT POSITION ADJUSTMENT

CAUTION
･ Adjust the seat position before getting on the lift truck, or at the
time of operator change. (Adjust only when the lift truck is at a
complete standstill.)
･ Adjust the seat position so that you can fully depress the brake
pedal while reclining yourself against the backrest.

1. Park the lift truck. For details on parking, see "3.3.8

TEMPORARY STOPPING, PARKING AND STOPPING
(PAGE 3-30)".
2. Take a seat and pull lever (1) to the left. The operator's seat
can slide back and forth in this condition.
3. Bring the operator's seat to the optimum position and release
lever (1). The sea is locked in this condition.
4. After adjusting the seat, check that it is firmly locked by pulling
it forwards/backwards.

HOW TO ADJUST BACKREST ANGLE

1. Pull up lever (2). The backrest angle can be adjusted in this
condition.
2. Adjust the backrest angle and release lever (2).
After adjusting the backrest, confirm that it is firmly locked by
pushing and pulling it.

HOW TO ADJUST SUSPENSION

Turn seat cushioning adjustment dial (3) located on the front right
side of the operator seat to select scale (4) to your weight for
suspension adjustment.
Turn the dial to the (A) side for lighter weight and to the (B) side
for greater weight.
Weight adjustable range: 50 - 120 kg

3 - 17
3.3 OPERATION OPERATION

FASTENING AND UNFASTENING THE SEAT BELT

CAUTION
Always wear your seat belt during operations.

1. Pull tongue (1) out of the belt holder located on the left side of
the operator's seat and push it into buckle (2) on the right until
it clicks into place. Tongue (1) is fixed to buckle (2) in this
condition.

2. To unfasten, hold the seat belt with your left hand, and push
down the red button of buckle (2) with your right hand.
3. The belt is tucked into the holder automatically.
While the belt is being tucked in, hold tongue (1) so that the
belt is tucked in slowly.

OPERATION AND MAINTENANCE MANUAL STORAGE (RETRACTABLE POCKET BEHIND THE

BACKREST)

CAUTION
･ Store the Operation and Maintenance Manual in the retractable
pocket behind the operator's seat readily available for reference.
･ If this manual has been lost or has become dirty or worn and
cannot be read, request a replacement manual from your
KOMATSU FORKLIFT distributor.

1. Push unlock button (1) of the pocket behind the operator's

seat backrest.
2. Open pocket (2) backward to take out or store the Operation
and Maintenance Manual.

An open-type magazine box is provided in the outer side of this

storage. You are free to use this box for storing necessary
documents, etc.

3 - 18
OPERATION 3.3 OPERATION

ADJUSTING STEERING WHEEL TILT ANGLE

CAUTION
･ Always stop the lift truck completely before adjusting the
position of the steering wheel.
･ After adjusting, move the steering wheel backward and forward
to check that it is locked securely in position.

1. Park the lift truck. For details on parking, see "3.3.8

TEMPORARY STOPPING, PARKING AND STOPPING
(PAGE 3-30)".
2. Pull up tiltable steering wheel lock lever (1) to the (A) position.
3. Move the steering wheel back and forth to select the optimum
position.
4. Push down tiltable steering wheel lock lever (1) to the (B)
Lock
position to lock the steering wheel. Free
5. After adjusting the steering wheel, confirm that it is firmly
locked by pushing and pulling it.

3 - 19
3.3 OPERATION OPERATION

3.3.3 STARTING, GEAR SHIFTING, AND TRAVELING

STARTING ENGINE

WARNING
･ Do not attempt to start the engine by short-circuiting the engine
starting circuit. Such a malpractice can cause a serious bodily
injury and fire.

CAUTION
･ Start the engine only after sitting down in the operator's seat.
･ Before starting the engine, move the forward/reverse lever to the
N (neutral) position, and pull the parking brake lever in the
direction to the rear of the lift truck. (Parking brake activated)
･ Exhaust gas is toxic. When starting engine indoor or in a poorly-
ventilated site, take extreme care for ventilation.
･ If you lean forward or sideways, or if you are not seated properly
while operating the lift truck on an uphill, the system will cut off
power to the engine and the lift truck may slither down, which
can result in an accident or a crash. Maintain the correct right
posture while traveling uphill.

GASOLINE ENGINE LIFT TRUCK (FG40Z, FG35, FG40, FG45, FG50A)

1. Set forward/reverse lever (1) to the N (neutral) position.
Forward

REMARK
The engine does not start unless forward/reverse lever (1) is set
in the N (neutral) position.
Neutral

Reverse

2. Apply parking brake by pulling the lever to the rear direction of

the lift truck. (Parking brake being applied) Free

Lock

3. Depress the brake pedal.

REMARK
The engine does not start unless the brake pedal is depressed.

NOTICE
If the engine starts while the brake pedal is not depressed,
the lift truck is abnormal. Stop the work immediately and
contact your KOMATSU FORKLIFT distributor.

3 - 20
OPERATION 3.3 OPERATION

4. Turn the starting switch key to the [ | ] (START) position (3)

with the foot off the accelerator pedal, and the engine will start
up.
5. When the engine has started up, release the key immediately.
The key will automatically return to the [ | ] (ON) position (2).
Make sure the key is kept in this position while the engine is
running.
6. Warm-up the engine.
The warming-up run is terminated automatically after the
engine has warmed-up.

NOTICE
･ The starting switch key must be at the [Q] (OFF) position (1)
while the engine is not running. Do not leave the starting
switch key in the [ | ] (ON) position (2). The battery capacity
goes down, making it difficult to start up the engine.
･ Limit the use of the starting motor within 10 seconds and
do not let it run continuously beyond 10 seconds.
･ Wait for another 20 seconds before using the starting
motor again.
･ Do not turn the starting switch key to the [ | ] (START)
position (3) while the engine is running.

3 - 21
3.3 OPERATION OPERATION

DIESEL ENGINE LIFT TRUCK (FD40Z, FD35, FD40, FD45, FD50A)

1. Set forward/reverse lever (1) to the N (neutral) position.
Forward

REMARK
The engine does not start unless forward/reverse lever (1) is set
in the N (neutral) position.
Neutral

Reverse

2. Apply parking brake by pulling the lever to the rear direction of

the lift truck. (Parking brake being applied)
Free

Lock

3. Depress the brake pedal.

REMARK
The engine does not start unless the brake pedal is depressed.

NOTICE
If the engine starts while the brake pedal is not depressed,
the lift truck is abnormal. Stop the work immediately and
contact your KOMATSU FORKLIFT distributor.

4. Turn the starting switch key to the [ | ] (ON) position (2) and
release it. The glow indicator on the side of the starting switch
lights up and automatic preheating starts.
• Preheating time
The necessary preheating time varies depending on the
ambient temperature and engine temperature. The
automatic preheating time is set as shown below. If the
engine is started while preheating, the preheating is
terminated automatically.
-5°C or over : Preheating not required
-5 - 10°C : 5 - 15 seconds
-20°C or below : 30 seconds

5. When the glow indicator turns out, the preheating is

completed.

3 - 22
OPERATION 3.3 OPERATION

6. Turn the starting switch key to the [ | ] (START) position (3) to

start the engine.

REMARK
To improve durability by improving the engine lubrication
performance at cold start, no fuel is fed to the engine for 3
seconds immediately after turning the starting switch key to the
[ | ] (START) position. Therefore, the engine does not start during
this period. Hold the starting switch key in the [ | ] (START)
position to keep the starting motor turning until the engine starts.

7. When the engine has started up, release the key immediately.
The key will automatically return to the [ | ] (ON) position (2).
Make sure the key is kept in this position while the engine is
running.

8. Warm-up the engine.

The warming-up run is terminated automatically after the
engine has warmed-up.

NOTICE
・ The starting switch key must be at the [Q] (OFF) position
(1) while the engine is not running. Do not leave the
starting switch key in the [ | ] (ON) position (2). The battery
capacity goes down, making it difficult to start up the
engine.
・ Limit the use of the starting motor within 10 seconds and
do not let it run continuously beyond 10 seconds.
・ Wait for another 20 seconds before using the starting
motor again.
・ Do not turn the starting switch key to the [ | ] (START)
position (3) while the engine is running.

AUTOMATIC WARMING-UP RUN

Starting the engine with the engine coolant temperature being at
45°C or lower sets the engine automatically to warming-up run
(engine speed: 1,000 rpm). The automatic warming-up run is
Engine speed

cancelled when the engine coolant temperature reaches 50°C or

higher. (Engine speed: 800 rpm)

REMARK
If the accelerator pedal is kept depressed fully for 3 seconds, the
Engine coolant temperature
automatic warming-up run is cancelled.

3 - 23
3.3 OPERATION OPERATION

DIESEL ENGINE LIFT TRUCK (FD40ZY, FD35Y, FD40Y, FD45Y, FD50AY)

1. Set forward/reverse lever (1) to the N (neutral) position.
Forward

REMARK
The engine does not start unless forward/reverse lever (1) is set
in the N (neutral) position.
Neutral

Reverse

2. Apply parking brake by pulling the lever to the rear direction of

the lift truck. (Parking brake being applied)
Free

Lock

3. Depress the brake pedal.

REMARK
The engine does not start unless the brake pedal is depressed.

NOTICE
If the engine starts while the brake pedal is not depressed,
the lift truck is abnormal. Stop the work immediately and
contact your KOMATSU FORKLIFT distributor.

4. Turn the starting switch key to the [ | ] (ON) position (2). If the
ambient temperature is below 0°C and the engine does not
start easily, hold down preheater switch (4) to preheat the
engine. If preheating starts, glow indicator (5) in the instrument
panel lights up.
• Preheating time
The necessary preheating time depends on the ambient
temperature. Use the followings as rough guide.
0 - 10°C : 15 - 20 seconds
-20°C or below : 30 seconds

3 - 24
OPERATION 3.3 OPERATION

5. After the above preheating time, preheating is finished.

Release preheater switch (4).
Turn the starting switch key to the [ | ] (START) position (3) to
start the engine.
6. When the engine has started up, release the key immediately.
The key will automatically return to the [ | ] (ON) position (2).
Make sure the key is kept in this position while the engine is
running.
7. Warm-up the engine.
Continue with a warming-up run for a while without placing
your foot on the accelerator pedal.

NOTICE
・ The starting switch key must be at the [Q] (OFF) position
(1) while the engine is not running. Do not leave the
starting switch key in the [ | ] (ON) position (2). The battery
capacity goes down, making it difficult to start up the
engine.
・ Limit the use of the starting motor within 10 seconds and
do not let it run continuously beyond 10 seconds.
・ Wait for another 20 seconds before using the starting
motor again.
・ Do not turn the starting switch key to the [ | ] (START)
position (3) while the engine is running.

3 - 25
3.3 OPERATION OPERATION

STARTING LIFT TRUCK OFF

1. Depress the inching pedal and move the forward/reverse lever
to either the forward [] (F(*)) or reverse [] (R) position.
Forward

Neutral

Reverse

* (F1/Forward 1st) on FG45, FG50A, FD45, FD50A, FD45Y,

FD50AY Forward 2nd

Forward 1st

Neutral

Reverse

2. Return the parking brake lever in the direction of the front of

the lift truck to the free position. (Parking brake released) Free

NOTICE Lock
･ If you travel the lift truck with the parking brake lever
pulled in the direction to the rear of the lift truck, the brake
will overheat and the braking effect may be lost. Also it
accelerates wear on the brakes.
･ If you had traveled long distance with this condition, have
y ou r l i ft t r u c k i n s p e c t e d b y K O M AT S U F O R K L I F T
distributor.

3. Check that the direction of travel and the area around the lift
truck are safe.
4. Slowly return inching pedal (4) while depressing accelerator
pedal (3) gently to start the lift truck. Release inching pedal (4)
when the lift truck starts.

NOTICE
Do not rest the foot on the inching pedal or brake pedal
except when so required.

3 - 26
OPERATION 3.3 OPERATION

TRAVEL INTERLOCK
This safety device disables operation of the lift truck if you are
seated in such a posture that your weight is not fully applied to the
seat, like standing up or leaning forward or sideways. If you take
such posture, the travel interlock activates in approx. three
seconds and cuts off the transmission of engine power. Then the
lift truck does not move any more even if you depress the
accelerator pedal or operate the forward/reverse lever. (*)
* Optional to FD40ZY, FD35Y, FD40Y, FD45Y, FD50AY.

While travel interlock is activated, the travel interlock warning

lamp on the instrument panel flashes. (The lamp doubles as the
neutral indicator lamp.)

RELEASING TRAVEL INTERLOCK FUNCTION

When you seat yourself properly and return the forward/reverse
lever to N (neutral) position, the truck returns to traveling
condition. Restart traveling operation after checking the safety
in the surrounding areas.

This traveling interlock does not brake the lift truck forcibly.

GEAR SHIFTING (4.5 AND 5 TON LIFT TRUCKS)

While depressing the accelerator pedal, set the forward/reverse
lever (also function as a gearshift lever) from F1 (forward 1st) Forward 2nd
position to F2 (forward 2nd) position.
Forward 1st
Lever position Gearshift mode
F1 1st gear fixed
Neutral
F2 2nd gear fixed

NOTICE
Always start the lift truck in the 1st gear.

3 - 27
3.3 OPERATION OPERATION

SHIFTING DIRECTION

1. Release accelerator pedal (1), and fully depress brake pedal

(2).

2. After the lift truck stops completely, move the forward/reverse

Forward
lever from the forward [] (F (*)) to reverse [] (R) position or
vise versa.
* (F1/forward 1st) on FG45, FG50A, FD45, FD50A, FD45Y,
FD50AY
Neutral
NOTICE
Shift the direction only after the lift truck stops completely.
Reverse

3.3.4 STARTING AND STOPPING ON SLOPE

1. When starting off the lift truck on an upslope, pull the parking
brake lever in the direction to the rear of the truck. (Parking Free
brake activated)
2. When climbing uphill while depressing accelerator pedal (1) Lock
gradually, return the parking brake lever gradually toward the
front of the truck. (Parking brake released)

3. When the lift truck has gained some speed, release the
parking brake lever completely. (Parking brake released)
C l i m b i n g s p e e d c a n b e c o nt r o l l e d b y t h e a m o u nt o f
accelerator pedal (1) depressed.
4. When slowing down or stopping the lift truck on an upslope,
release accelerator pedal (1) gradually and depress brake
pedal (2) immediately before the lift truck stops.
5. After the lift truck stops completely, pull the parking brake lever
to the rear direction of the lift truck. (Parking brake activated)

3 - 28
OPERATION 3.3 OPERATION

3.3.5 INCHING TRAVEL

CAUTION
Never carry out inching by depressing accelerator pedal (1) and
adjusting the amount brake pedal (2) depressed.

Engaging the clutch halfway with inching pedal (3) enables the
truck to crawl along.

NOTICE
･ Traveling a long distance while the clutch is half engaged
can cause damage to the truck, so limit such travel to the
shortest time necessary (less than 10 seconds).
･ Do not hold your foot rested on inching pedal (3) while
traveling. You may unintentionally engage the clutch half
way, which can cause damage to the lift truck.

3.3.6 TURNING

CAUTION
Take care to avoid the outside of the counterbalance-weight hitting
against people and objects around when turning.

The lift truck has rear steering wheels. When turning, keep to the
inner side when advancing and outer side when reversing.

REMARK
･ Turning the steering wheel with the lift truck stand still
(stationary steering) will accelerate wear of the tyres.
･ Turning the steering wheel as traveling low speed will help to
reduce this problem.

3.3.7 OPERATION ON SNOWY AND FROZEN ROADS

CAUTION
･ Be aware that even tyre chains or snow tyres cannot prevent
skidding completely.
･ Tyre chains or snow tyres may not fit on some model.

･ Wears tyre chains or snow tyres when traveling on snowy or

frozen roads.
･ Avoid sudden braking, acceleration, or steering on snowy or
frozen roads. Be cautious of accelerator pedal operation as it is
dangerous and may cause skidding.

3 - 29
3.3 OPERATION OPERATION

3.3.8 TEMPORARY STOPPING, PARKING AND STOPPING

CAUTION
Select a parking area well away from the traffic areas.

TEMPORARY STOPPING
1. Release accelerator pedal (1), and fully depress brake pedal
(2).

2. After the lift truck comes to a stop, apply the parking brake by
pulling the parking brake lever in the direction to the rear of the Free
lift truck. (Parking brake activated)
After the lift truck stops, move the forward/reverse lever to the Lock
N (neutral) position.

REMARK
When the parking brake lever is in the Free position, and if you
take a posture that your weight is not fully applied to the seat, e.g.
leaving the operator's seat or leaning forward or sideways, the
parking brake alarm buzzer begins to sound. When it does, take
the following actions.

When leaving the lift truck: Pull the parking brake lever in the rear
direction of the lift truck to the Lock
position.
When continuing to operate the lift truck: Seat yourself properly.

3 - 30
OPERATION 3.3 OPERATION

PARKING
1. Stop the lift truck on level ground.
2. Pull the parking brake lever to the rear direction of the lift truck. Free
(Parking brake activated)
3. Set the forward/reverse lever to the N (neutral) position. Lock

4. Tilt the mast forward and lower the forks to the ground.
5. Turn the starting switch key to the [Q] (OFF) position.
6. Pull out the starting switch key and leave the lift truck.

REMARK
If you leave the lift truck without pulling the parking brake lever in
the direction to the rear of the lift truck (at a position other than the
Lock position), an alarm buzzer will sound.

STOPPING
1. Run the engine at low idle for about 5 minutes to cool the
engine down gradually.
2. Turn the starting switch key to [Q] (OFF) position (1) to stop
the engine.
3. Pull out the starting switch key.

NOTICE
･ Since sudden stopping before engine cooling shortens the
engine parts service life, avoid sudden stopping unless in
an emergency.
･ If the engine is overheated, do not stop the engine
suddenly but stop it after gradual cooling at a medium
speed.

3 - 31
3.3 OPERATION OPERATION

3.3.9 LOAD HANDLING OPERATION

FORK SPREAD ADJUSTMENT
Before carrying out load handling, always adjust the space
between the forks to fit the size of the pallets and loads.

CAUTION
Take extreme care not to get hands or fingers caught while fork
spread adjustment.

1. Move the lift truck in front of the load, and stop.

2. Position the mast vertically and raise the forks 10 cm (4 in) Free
above the ground.
3. Tilt the mast forward.
4. Pull up the knob of the fork stopper and turn it 90 degrees to
Lock
the Free position. (In this condition, the forks can be moved to
the left or right.)
5. Adjust the fork spread corresponding to the load size so that
the load center of gravity coincides with the center of the lift
truck.
6. Set the mast vertical, turn the fork stopper 90 degrees, and
lower the knob to the Lock position. (In this condition, the forks
are locked in position.)
7. After fork spread adjustment, check that the forks are secured
with the fork stopper.
If forks are not secured, there is the danger that the forks
freely move sideways to let the load fall, while the lift truck is
traveling.

3 - 32
OPERATION 3.3 OPERATION

HOW TO OPERATE CONTROL LEVERS

CAUTION
Sit in the operator's seat properly and check that the surrounding area is safe before operating the lever.
Operating the lift truck when you are not seated properly or operating it from outside the operator's compartment
can result in erroneous operation, and may result in serious injuries.

LIFT CONTROL LEVER

Raise : Pull the lever backward. Lower
Lower : Push the lever forward

REMARK
･ The rising speed of the forks can be adjusted with the extent of
lever tilting and the degree of accelerator pedal depressed.
･ The lowering speed of the forks can be adjusted with only the
extent of lever tilting. Raise

TILT CONTROL LEVER

Tilt forward : Push the lever forward Tilt forward
Tilt backward : Pull the lever backward

REMARK
The forward and backward tilting speed of the forks can be
adjusted with the extent of lever tilting and the degree of
accelerator pedal depressed.
Tilt backward

LIFT INTERLOCK
If you operate the lift truck in such a posture that your weight is
not fully applied to the seat, like standing up or leaning forward or
sideways, the Load Handling Interlock is activated in approx.
three seconds. Then each motion of the fork and mast is locked
and none of them moves any more even if you operate the lift
control lever or the tilt control lever. (*)
* Optional to FD40ZY, FD35Y, FD40Y, FD45Y, FD50AY.

While lift interlock is in operation, the lift interlock warning lamp on

the instrument panel flashes. (See the figure at right.)

RELEASING LIFT INTERLOCK FUNCTION

When you seat yourself properly on the operator's seat, the lift
truck is ready for load handling operation again. Restart lift
operation after checking the safety in the surrounding areas.

3 - 33
3.3 OPERATION OPERATION

PICKING UP
1. Insert the fork up to the bottom.
2. If the fork cannot be inserted up to the bottom at one go, drive
the lift truck forward until the fork is inserted into a pallet by 2/3
to 3/4 of the fork length and lift the load by 5 - 10 cm (2 - 4 in).

Then drive the lift truck backward by 10 - 20 cm (4 - 8 in),

lower the load once and then drive the lift truck once again
until the fork is inserted up to the bottom.

3. Raise the load 5 - 10 cm (2 - 4 in) and reverse the lift truck to a

position where the load can be lowered.

5 - 10 cm
(2 - 4 in)

4. Lower the load to the height of 15 - 20 cm (6 - 8 in) above the

ground and tilt the mast back.

15 - 20 cm (6 - 8 in)

STACKING
1. Stand the mast vertically and lift forks 5 - 10 cm (2 - 4 in) past
the stacking position. Advance the lift truck slowly.
2. Lower the load to the desired place.
3. Pull the fork out of the pallet.

3 - 34
OPERATION 3.3 OPERATION

3.3.10 CHECKING AFTER OPERATION

After all the above inspections have been finished and each part
of the lift truck is cleaned, and before it is stored, carry out the
following inspections.

1. Leakage of fuel, water, and battery electrolyte.

2. Cracks or damage.
3. Check faults found during operation and report them to the
administrator. Be sure to place a sign or other notice
identifying "Do Not Use". (if necessary)
4. Lubricate the units (if necessary)

For the procedure during cold weather, procedure with

overheated engine, long-term storage, and loading and unloading
of lift truck, refer to the followings:

･ For washing the lift truck, see "4.10 WASHING LIFT TRUCKS
(PAGE 4-53)".
･ For the procedure during cold weather, see "4.6 RUNNING IN
COLD WEATHER (PAGE 4-47)".
･ For the procedure with overheated engine, see "4.7
PROCEDURE WITH OVERHEATED ENGINE (PAGE 4-49)".
･ For the long-term storage, see "4.11 LONG-TERM STORAGE
(PAGE 4-54)".
･ For the loading and unloading of lift truck, see "4.13 LOADING
AND UNLOADING OF LIFT TRUCK (PAGE 4-56)".

3 - 35
INSPECTION AND
MAINTENANCE 1

44

WARNING
Please be sure that you fully understand this manual and the
precautions related to safety for the lift truck.
When inspecting or servicing the lift truck, always strictly follow these
precautions. Failing to heed this warning may result in serious
injuries.

4-1
4.1 INSPECTION AND MAINTENANCE INSPECTION AND MAINTENANCE

4. INSPECTION AND MAINTENANCE

4.1 INSPECTION AND MAINTENANCE

This inspection and maintenance document describes start-up inspection mandatory for the operators and
replenishment of oil, cleaning of filters and other related simple maintenance work. For other inspection and
maintenance items not described here, contact KOMATSU FORKLIFT distributor.
For your safe inspection and maintenance work, carefully read "2.6 PRECAUTIONS FOR INSPECTION AND
MAINTENANCE (PAGE 2-30)" and then carry out inspection and maintenance, observing the given precautions.

･ Incorrect maintenance and repair service may cause critical accident or shorten lift truck service life. Contact
KOMATSU FORKLIFT distributor for maintenance and repair services.

4.2 START-UP INSPECTION

CAUTION
･ Do not operate the lift trucks before completing start-up inspection.
･ Report abnormality, if any, immediately to the administrator. Never operate the lift truck in question until the repair
is completed.

OBLIGATION TO CONDUCT START-UP INSPECTION

･ For your safe operation, always conduct a start-up inspection of the lift truck before starting operation for the
day.
･ Record and store the results of start-up inspection in the inspection record.

4-2
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION

LIST OF START-UP CHECK POINTS

Item Check points

- Checking of repaired abnormalities detected on previous day
Leakage of oil, fuel, coolant and battery electrolyte
Cracks, damages and the state of mounting (of overhead guard, fork, load
backrest, etc.)
Loose tilt cylinder rod lock nuts
Walk around the lift
Contamination and/or damages of lamp, lens, etc.
truck
Contamination and/or damages of reflector
Loose hub nuts
Deformed or damaged tyres and rims
Inflation pressure of tyres
Hydraulic oil level
Engine oil level and contamination
Battery electrolyte level
Opening the covers
Coolant level
and hoods
Drainage of fuel pre-filter
Checking of water separator
Oil level in TORQFLOW transmission case
Damages and performance of seat belt
Seat and steering wheel adjustment
Brake pedal play and height
Sitting on the operator
Inching pedal play and height
seat
Parking brake lever operating effort
Horn performance
Center mirror contamination, damages and angle
Performance of warning lamps on the meter panel (Check by turning the starter
switch ON and OFF)
Turning the starting
Operation of lamps
switch to ON position
Fuel level
Backup buzzer performance
Startup condition and abnormal sound
Abnormal noise and vibration
Start the engine Exhaust gas color and sound
Play of steering wheel
Checking of brake accumulator
Operating state of steering wheel (runout and unstable driving)
Brake operating condition (response)
Travel slowly
Inching operating condition (letting out the clutch, slip, inching travel)
Low speed travel and accelerating state
Operating work Mast operating condition
equipment lever Tension, damages and rusted condition of lift chain
Travel interlock function (*)
Checking of safety Lift interlock function (*)
function Neutral safety function
Overlooking application of parking brake, warning buzzer function
* Lift truck equipped with OPS (Operator presence sensing system). Optional to FD40ZY, FD35Y, FD40Y,
FD45Y, FD50AY.

4-3
4.2 START-UP INSPECTION INSPECTION AND MAINTENANCE

4.2.1 CHECKING ABNORMALITIES DETECTED ON THE PREVIOUS DAY

Check again the abnormal points detected during the operation
and closing inspection on the preceding day. Double check that
no abnormality persists to exist.

4.2.2 WALK AROUND A LIFT TRUCK

CHECKING FOR LEAKAGE OF FUEL, WATER, OR BATTERY ELECTROLYTE
･ Walk around the lift truck to inspect it.
･ Look under the lift truck to check for oil or water leakage.

CHECKING FOR CRACKS, DAMAGES AND THE STATE OF MOUNTING

Visually check for any damages, cracks, loose mounting and/or
play.
Give priority in checking the following points particularly:
･ Overhead guard
･ Fork
･ Load backrest
･ Fork carriage
･ Mast
･ Fuel tank
･ Hydraulic oil tank

CHECKING FOR LOOSE TILT CYLINDER ROD AND LOCK NUTS

Visually check if the tilt cylinder rod and the rod head are rotating
in loose condition or if lock nut (1) is loosened.

4-4
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION

CHECKING FOR CONTAMINATION AND/OR DAMAGES OF LAMP, LENDS, ETC.

Visually check for any contamination and/or damages of lamp,
lens, etc.

CONTAMINATION AND/OR DAMAGES OF REFLECTOR

Visually check reflectors for any contamination and/or damages.

CHECKING FOR LOOSE HUB NUTS

Check for loose hub nuts by tightening them with a wrench.
NOTICE
Tighten the hub nuts to the specified torque.
For the tightening torque, see "4.16 SERVICE DATA (PAGE 4-
65)".

4-5
4.2 START-UP INSPECTION INSPECTION AND MAINTENANCE

CHECKING OF TYRES AND RIMS

･ Visually check for any excessive wear, damages, spikes and
other foreign matters stuck to the tyres, deformation and
damages of the rims.
･ Replace a tyre if the tread depth becomes under 5 mm or if the
slip sign (wear limit mark) should appear.

CHECKING OF INFLATION PRESSURE OF TYRES

CAUTION
Tyres have high pressure air inside. When checking the inflation
pressure, position yourself to face the tyre tread surface (see the
figure at right) while holding the tyre air gauge firmly.

Check the tyre inflation pressure with the tyre air gauge and
adjust it to specified pressure. For the tyre inflation pressure, see
"4.16 SERVICE DATA (PAGE 4-65)".

4-6
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION

4.2.3 INSPECTION BY OPENING COVER AND HOOD

CAUTION
･ Before opening the engine hood, always stop the engine.
･ Be careful not to have hand caught when opening/closing the
engine hood.

HOW TO OPEN THE ENGINE HOOD

1. Push up lever (1) on the front left side of the engine hood to
unlock the hood.

2. Push up the engine hood until red stopper (2) of the engine
hood supporting stay is set.

HOW TO CLOSE THE ENGINE HOOD

1. Press in the red stopper of supporting stay (by the portion
stamped "PRESS") to the arrow direction (backward), while
closing the engine hood slowly with other hand.
2. Check that the engine hood is closed completely and locked.

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4.2 START-UP INSPECTION INSPECTION AND MAINTENANCE

CHECKING OF OIL LEVEL IN HYDRAULIC TANK

Check if hydraulic oil is filled to the specified level.
1. Lower the forks fully to the floor and hold the mast vertical on
a flat site.
2. Withdraw the oil gauge on the R.H. side of the lift truck body.
Wipe hydraulic oil off the oil gauge with a clean cloth and
insert the gauge into the tank. Correct
3. Pull out the oil level gauge again and check that the stuck oil range
is within the normal range.
4. When hydraulic oil is low, replenish it. If the oil is spilt, wipe it
off completely.

NOTICE
Always use Komatsu Utility genuine hydraulic oil.

CHECKING THE ENGINE OIL LEVEL IN THE OIL PAN

1. Check if the engine oil is within the normal range.
2. Withdraw the oil gauge. Wipe hydraulic oil off the oil gauge
with a clean cloth and insert the gauge back into the tank.
Correct
3. Pull out the oil level gauge again and check that the stuck oil range
is within the normal range.
4. When hydraulic oil is low, replenish it. If the oil is spilt, wipe it
off completely.

NOTICE
･ When the engine oil is considerably contaminated or has
been discolored, replace with new oil.
･ Always use Genuine Engine oil.

4-8
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION

CHECKING OF BATTERY ELECTROLYTE LEVEL

CAUTION
Batteries generate flammable hydrogen gas and may explode.
Battery electrolyte also contains dilute sulfuric acid. If you make a
mistake in handling, it may cause personal injuries, explosions and
fires. Strictly follow the instructions in "2.6.16 CAUTION WHEN
HANDLING BATTERY (PAGE 2-34)".

･ Check whether the battery electrolyte level is within the normal

range between the upper limit line (A) and lower limit line (B). If
the level is low, refill it with distilled water until the level reaches
the upper limit line (A).
･ Always keep the breather and terminal of the battery cap on Correct
the top of the battery clean with no dust attachment. range

NOTICE
･ If the battery electrolyte has spilled and the level has gone
down, have your battery repair shop add dilute sulphuric
acid of the same density.
･ Do not use a metal funnel when adding distilled water or
dilute sulphuric acid.

CHECKING OF COOLANT LEVEL

CAUTION
Do not open the radiator cap immediately after the engine stops,
since the coolant temperature is very high. Steam or boiling water
may spurt out, causing burns. After the coolant temperature has
gone down, turn the cap slowly to release the pressure before
removing it.

･ Check whether the coolant level is within the normal range, i.e.
between "FULL" and "LOW" when the coolant in the radiator
reservoir tank in the engine sub-hood is in a cooled state.
･ If not in correct range, refill coolant to FULL position.
･ Check the radiator and radiator hose for any water leakage. FULL

Correct
range
LOW

･ When the cooling water in the sub-tank is all gone, open

radiator cap (1) to refill the radiator tank and sub-tank with
coolant.

REMARK
Radiator cap (1) is on the right side of the diesel engine lift truck
and on the left side of the gasoline engine lift truck.

4-9
4.2 START-UP INSPECTION INSPECTION AND MAINTENANCE

DRAINAGE OF FUEL PRE-FILTER (FD40Z, FD35, FD40, FD45, FD50A)

CAUTION
･ Beware the engine is high-temperature immediately after
stopping. Drain water and/or bleed air after the engine
temperature has lowered sufficiently.
･ When draining water from the fuel pre-filter, fuel is also drained.
Always wipe spilt fuel off and keep it away from open flame.

1. Open the engine hood.

2. Loosen drain plug (1) on the bottom of the fuel pre-filter and
drain water and sediments deposited.
3. After draining, tighten the drain plug securely.

CHECKING OF WATER SEPARATOR (FD40Z, FD35, FD40, FD45, FD50A/*REF)

CAUTION
･ Beware the engine is high-temperature immediately after
stopping. Drain water and/or bleed air after the engine
temperature has lowered sufficiently.
･ When draining water, fuel is also drained. Receive them in a oil
pan. Always wipe spilt fuel off and keep it away from open flame.

The water separator is used to separate water from fuel. Drain

water according to the following steps when the float (2) exceeds
the line (1). Water separator

DRAIN WATER
1. Open the engine hood.
2. Loosen drain plug (3) and drain the trapped water until float
(2) reaches bottom.
3. After draining, tighten drain plug (3) securely.

NOTICE
If air leaks into the fuel circuit during draining water, bleed
air, see "4.4.4 FUEL FILTER AIR BLEEDING (FD40Z, FD35,
FD40, FD45, FD50A/*REF) (PAGE 4-35)".

*REF (Reliable-Extra-Filtration)
: This specification provides an additional main filter
and a filter with the water separation function for
the inferior fuel.

4 - 10
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION

CHECKING OIL LEVEL IN TORQFLOW TRANSMISSION CASE

CAUTION
Immediately after using the lift truck, the oil temperature is high.
Start the work after the temperature has lowered.

1. Roll up the rear of floor mat and remove the floor plate.
2. Pull out oil gauge (1) to check the oil level.
3. If the engine oil level is low, remove oil filler cap (2) and add Correct
oil. range

NOTICE
･ If the engine oil is spilt, wipe it off completely.
･ Always use Komatsu Utility genuine engine oil.

4 - 11
4.2 START-UP INSPECTION INSPECTION AND MAINTENANCE

4.2.4 CHECKING FROM THE OPERATOR SEAT

CHECKING OF SEAT BELT
Upon sitting on the operator seat, first check the seat belt.
･ Any damages to the seat belt and/or fittings?
･ Does the seat belt come out and retract smoothly? Does the
fitting lock and unlock without abnormality?
･ Does the seat belt lock when pulled suddenly?

CHECKING OF THE SEAT AND STEERING WHEEL POSITION

Upon sitting on the operator seat, check if the pedals, levers and
switches can be operated smoothly. For the position of the seat
and steering wheel, see "SEAT POSITION ADJUSTMENT (PAGE
3-17)" and "ADJUSTING STEERING WHEEL TILT ANGLE
(PAGE 3-19)".

CHECKING OF THE BRAKE PEDAL

Check the brake pedal for correct application effort, play and for
correct dimensions of the pedal height. For the standard values of
the play (S1) and pedal height dimensions during braking effort
(H), see "4.16 SERVICE DATA (PAGE 4-65)".

CHECKING OF THE INCHING PEDAL

Check the brake pedal for correct application effort, play and for
correct interlocked stroke with the brake pedal. For the standard
values of the play (S2) and the interlocked stroke dimension (S3),
see "4.16 SERVICE DATA (PAGE 4-65)".

4 - 12
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION

CHECKING THE PARKING BRAKE LEVER

CAUTION
If parking brake lever operating effort is below the reference value,
necessary braking force to meet legal requirements is not available,
which may cause serious accidents. Always adjust the braking
force up to the reference value.

1. Check the operating effort when the parking brake lever is

operated to the rear stroke end of the lift truck (locking Free
position).
2. If the operating effort is below the reference value, adjust it. Lock
For how to adjust the travel power, see "4.4.7 ADJUSTING
PARKING BRAKE LEVER OPERATING EFFORT (PAGE 4-
39)".
3. Check if the lever can be pulled fully to the end without
resistance and that it returns smoothly.
NOTICE
If any abnormality is detected, contact your KOMATSU
FORKLIFT distributor for checking.

CHECKING THE HORN

Check if the horn sounds normally when switched ON.

CHECKING THE CENTER MIRROR

Check if the mirror is set at an easy angle for the operator to see
the rear. Also check for any contamination or damages.

4 - 13
4.2 START-UP INSPECTION INSPECTION AND MAINTENANCE

4.2.5 CHECK BY SETTING THE STARTING SWITCH TO [ | ] (ON) POSITION

CHECKING PERFORMANCE OF WARNING LAMPS ON THE METER PANEL
Check that the following lamps are ON when the starting switch is Engine oil pressure Charge warning
set to the [ | ] (ON) position: engine oil pressure warning, charge warning lamp lamp
warning, lift interlock (*1) warning and the safety control system
abnormality warning (*2).

REMARK
･ Lift interlock failure indicator will flash if the operator fails to sit Lift interlock Failure
warning lamp (*1, *2) indicator (*2)
on the seat correctly. For the lift interlock (*1), see "LIFT
INTERLOCK (PAGE 3-33)".
･ The engine failure indicator varies with the lift truck model. For
the engine failure indicator, see "3.2.1 METER PANEL (PAGE
3-6)".

Engine failure
*1 Optional to FD40ZY, FD35Y, FD40Y, FD45Y, FD50AY. indicator (*2)
If optional, the lift interlock warning lamp is not displayed.
*2 Applied to FG/FD40Z, FG/FD35Z, FG/FD40, FG/FD45, FG/
FD50A.

NEUTRAL INDICATOR LAMP

The neutral indicator lamp is functioning normally if it lights up as
the starting switch is set to the [ | ] (ON) position, and goes off
when forward/reverse lever is set to forward (Forward) or rear
(Reverse).

ENGINE COOLANT TEMPERATURE GAUGE

The engine coolant temperature gauge is normal if its pointer
points to the left when the engine is cold, and points at the white
range when the lift truck is in operation.

4 - 14
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION

SEDIMENTER WARNING LAMP (FD40ZY, FD35Y, FD40Y, FD45Y, FD50AY)

･ This lamp is functioning normally if it lights up when the starting
switch is turned to the [ | ] (ON) position, and goes off after the
engine startup.
･ If the lamp remains lit after the engine starts, drain water from
the fuel filter. For the draining of fuel filter, see "4.4.5 FUEL
FILTER WATER DRAINING AND AIR BLEEDING (FD40ZY,
FD35Y, FD40Y, FD45Y, FD50AY) (PAGE 4-36)".

REMARK
The mark shown at right is displayed on the lift truck equipped
with OPS (Operator presence sensing system).

CHECKING OPERATION OF LAMPS

･ Check if the head lamps, clearance lamps, turn signal lamps,
brake lamps and backup lamp work normally.

4 - 15
4.2 START-UP INSPECTION INSPECTION AND MAINTENANCE

CHECKING OF FUEL TANK LEVEL AND REPLENISHMENT

CAUTION
･ Before refilling fuel, always stop the engine and keep fire away.
･ When refilling fuel, never let the fuel overflow. This may cause a
fire. If the fuel is spilt, wipe it off completely.

Check the fuel gauge to see if the fuel tank contains enough fuel
for the day's work.
･ When fuel level gauge needle points to (A), the fuel tank is full.
･ If the fuel level is low, stop the engine and refill fuel from the
fuel filler port. For the type of fuel, see "LUBRICANT LIST
(PAGE 4-27)".
･ When refilling, remove dirt in and around the filler port cap (1)
to prevent the dirt from entering the fuel tank.
･ After refilling, tighten the filler port cap (1) securely and wipe off
spilt fuel without fail.

NOTICE
For a diesel engine lift truck, observe the following.
･ Always use diesel oil for the fuel.
･ To ensure good fuel consumption characteristics and
exhaust gas characteristics, the engine mounted on this
machine uses an electronically controlled high-pressure
fuel injection device. This device requires high precision
parts and lubrication, so if low viscosity fuel with low
lubricating ability is used, the durability may drop
markedly.

REMARK
The following indicate approximate fuel capacity when the fuel
gauge needle points at the center of the scale:

Model Center (l) Full (l)

4 ton (Compact model lift truck) 35 76

3.5 to 5 ton (Standard model lift truck) 43 98

Compact model: FG/FD40Z - 10

CHECKING BACKUP BUZZER PERFORMANCE

CAUTION
Check the backup buzzer performance under the following
conditions:
･ Pull the parking brake lever in the direction to the rear of the
machine and step on the inching pedal.

Check that the backup buzzer sounds when the forward/reverse

lever is set to the R (reverse) position.

4 - 16
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION

4.2.6 CHECKING WITH THE ENGINE STARTED

CAUTION
Exhaust gas is toxic. When starting engine indoors or in a poorly-ventilated site, take extreme care for ventilation.

CHECKING OF ENGINE STARTUP CONDITION AND ABNORMAL SOUND

･ When starting the engine, check for abnormal noise and startup condition.
･ Check that no abnormal sound is emitted during idling and slightly higher revolution.
･ When engine starts with abnormal sound, it may be damaged if that condition is allowed to persist. Contact
your KOMATSU FORKLIFT distributor for checking at an early date.

CHECKING THE GOING OFF OF WARNING LAMPS ON THE METER PANEL

･ Check that the warning lamps on the meter panel go off immediately upon starting the engine.
･ Engine abnormality warning lamp may goes off with slight time lag, which does not mean a failure.

CHECKING ABNORMAL NOISE AND VIBRATION

Check in particular that there is no abnormal noise or abnormal vibration from the engine or hydraulic pump.

CHECKING ENGINE EXHAUST GAS COLOR

･ Check if the color of exhaust gas is not in black or white.
･ Check the exhaust sound for any abnormality.

REMARK
･ For diesel engines, some black or white exhaust gas may be emitted immediately after the engine start, which
is not abnormal.
･ Black or white exhaust may be caused by the following:
Black: Incomplete combustion
White: Engine oil scraped up or scraped down

CHECKING THE STEERING WHEEL FOR PLAY

･ Check the play of steering handle by operating it in the
direction of a turn. Play should be normal if within 10 - 30 mm
(0.4 - 1.2 in). 10 - 30 mm
･ Check if it is free of looseness by shaking it in the vertical and (0.4 - 1.2 in)
longitudinal directions.

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4.2 START-UP INSPECTION INSPECTION AND MAINTENANCE

4.2.7 CHECKING THE BRAKE ACCUMULATOR

CAUTION
･ A brake trouble may cause a serious accident.
･ If the alarm buzzer does not sound, sounds early or does not stop sounding, never move the lift truck but contact
your KOMATSU FORKLIFT distributor immediately.

Check the remaining pressure in the accumulator with the alarm

buzzer.
1. Park the truck in a level and safe place and pull the parking
brake lever toward the rear direction of the lift truck. Free

Lock

2. Set the forward/reverse lever in the N (neutral) position and

Forward
depress the accelerator pedal and rotate the engine at full
throttle for about 1 minute to fill the accumulator with oil
pressure.

Neutral

Reverse

3. Stop the engine, turn the starting switch to the [ | ] (ON)

position, and depress the brake pedal to check the operation
of the alarm buzzer.

Number of times of stepping down the brake pedal until the alarm
buzzer starts sounding

Number of times of stepping

Judgment
down the pedal
Min. 10 times Normal
Max. 10 times Abnormal

REMARK
･ When the remaining pressure in the brake accumulator is smaller than a certain value, the alarm buzzer
sounds.
･ Each time you step down the brake pedal once, the remaining pressure in the accumulator will reduce.
･ It is normal that, when the accumulator is filled with oil pressure after being fully rotated for a minute, the alarm
buzzer does not sound until the brake pedal is stepped down 10 times. This means that it could be fully filled
with oil pressure because the accumulator is normal. On the other hand, when the alarm buzzer sounds before
the brake pedal is stepped down 10 times, the accumulator could not be fully filled with oil pressure, and the
accumulator is judged to be abnormal.

4 - 18
INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION

4.2.8 CHECKING WHILE TRAVELING SLOWLY

CHECKING THE STEERING WHEEL FUNCTION
Check the following points by operating the wheel while traveling slowly. Make sure that:
･ The steering wheel does not have any 'play'.
･ The steering wheel is stable (ie: does not move left or right) when the lift truck traveling in a straight line.
･ The steering wheel does not have any abnormal swing or does not seem heavy when it is turned.

CHECKING THE BRAKE FUNCTION

Check the brake response by stepping on the brake pedal while traveling slowly.
･ The brakes are operating effectively.
･ Both brakes are responding, (not just one side).

CHECKING THE INCHING PEDAL FUNCTION

Check the inching function by stepping on the inching pedal while traveling slowly.
･ Can the travel speed be adjusted according to the stepping effort of the inching pedal?
･ Does the lift truck stop when the inching pedal is fully stepped on?

CHECKING THE ENGINE DURING LOW SPEED TRAVEL AND

ACCELERATION
Check the engine revolution for any irregularity or stall upon stopping the truck after normal traveling.
Check that the truck accelerates smoothly when the accelerator pedal is depressed.
･ Conduct the checking in a safe place by paying attention to the surrounding area.
･ When the lift truck has seriously adverse conditions in the low speed travel and acceleration, it may damage
the engine, confuse the operator's driving sense, degrade braking effect and lead to other unexpected
accidents if such engine conditions are allowed to persist. Contact your KOMATSU FORKLIFT distributor for
checking at an early date.

CHECKING OF ABNORMAL NOISE AND ODOR

Check that no abnormal sound or odor is emitted while traveling slowly.

4.2.9 CHECKING BY OPERATING THE WORK EQUIPMENT LEVER

CHECKING OF MAST FUNCTION AND ABNORMAL NOISE AND ODOR
･ Check that the forks lift and lower smoothly and the mast tilts forward and backward smoothly during operation
of the work equipment lever from the operator seat. Always make full stroke operation of cylinder piston two to
three times everyday before starting work.
･ Check that no abnormal sound or odor is emitted while operating the work equipment lever.

4 - 19
4.2 START-UP INSPECTION INSPECTION AND MAINTENANCE

CHECKING OF TENSION OF LIFT CHAIN

CAUTION
･ If the chain tension is asymmetrical to the left and right, load
would concentrate on the chain of one side to cause it to break,
leading to the falling of material and the tipping over of lift truck.
･ To prevent the lift truck from traveling uncontrolled or the
checking personnel from being caught by the truck, set the
forward/reverse lever to the neutral position, pull the parking
brake lever in the direction of the truck, stop the engine, and
alight from the truck before starting check.
･ Never step the foot under the fork as it may get caught.

1. Raise the fork 5 - 10 cm (2 - 4 in) from the ground. (Part A)

2. Press the center of lift chain with a finger and check if the
tension is equal to the right and left.

CHECKING OF LIFT CHAIN

CAUTION
･ If the lift chain break, the load may fall down or the lift truck may
tip over. When lift chain is found abnormal with damages and
cracks, please contact your KOMATSU FORKLIFT distributor for
replacement of the lift chain.
･ Rust on the lift chain is a cause of damages and cracks. Take rust
preventive measures at an early date to keep rust off.

1. Visually check lift chain for any damages, cracks and rust.
2. Check the state of lubrication of lift chain. If it is in poor state
or rust has generated on the lift chain, apply engine oil, etc.
on it.

CHECKING OF ATTACHMENT FUNCTION AND ABNORMAL NOISE AND ODOR (FOR LIFT TRUCK WITH
ATTACHMENTS)
Check the attachment according to its operating manual.

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INSPECTION AND MAINTENANCE 4.2 START-UP INSPECTION

4.2.10 CHECKING OF SAFETY FUNCTION

CAUTION
･ Check this function by placing the lift truck on a level, hard flat road surface.
･ Secure enough traveling space without human beings and other obstacles around the lift truck.

CHECKING THE TRAVEL INTERLOCK FUNCTION

Check the safety function by which the machine becomes disabled to travel when the operator is away from the
seat.

CHECKING PROCEDURE
1. Park the lift truck on a level and flat place and pull the parking brake lever toward the rear of the truck.
(Parking brake activated)
2. Set the forward/reverse lever to the N (neutral) position, and raise the forks 15 cm (6 in) above the ground.
3. Step the foot off the brake pedal, inching pedal and accelerator pedal.
4. Set the forward/reverse lever to F (forward) or R (reverse) and lift the hip from the seat.
5. Check that the travel interlock warning lamp (with N mark) on the meter panel starts flashing about 3 seconds
later.
6. In this state, return the parking brake lever in the direction of the front of the lift truck. (Parking brake
released)
7. Depress the accelerator pedal with your hip lifted from the seat, and check that the lift truck does not travel.
8. Resetting travel interlock function
Sit on the seat correctly and set the forward/reverse lever to N (neutral) position. Flashing travel interlock
warning lamp turn out and the lift truck returns to normal operating conditions.

CHECKING THE LIFT INTERLOCK FUNCTION

Check the safety function by which the lift operation becomes disabled when the operator is away from the seat.

CHECKING PROCEDURE
1. Park the lift truck on a level and flat place and pull the parking brake lever toward the rear of the truck.
(Parking brake activated)
2. Set the forward/reverse lever to the neutral position, and raise the fork to a position about 1 m (40 in) from the
ground which is visible to the operator.
3. Step foot from every pedal and lift the hip from the seat.
4. Check that the lift interlock warning lamp on the meter panel starts flashing about 3 seconds later.
5. Check the following in this state:
･The forks do not rise or lower if the lift lever is operated.
･The mast does not tilt forward or backward if the tilt lever is operated.
6. Resetting lift interlock function.
Take a right posture in the operator's seat. Flashing lift interlock warning lamp turn out and the lift truck
returns to normal operating conditions.

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4.3 CHECKING AND REPORTING AFTER OPERATION INSPECTION AND MAINTENANCE

CHECKING OF NEUTRAL SAFETY FUNCTION

Check the neutral safety function to prevent the risk of the lift truck suddenly traveling when the engine is started
with the forward/reverse lever set in either forward (F) or reverse (R) position.

CHECKING PROCEDURE
1. Park the lift truck on a level and flat place and pull the parking brake lever toward the rear of the truck.
(Parking brake activated)
2. Set the forward/reverse lever to N (neutral) and stop the engine.
3. Check that the starting motor does not run and the engine does not start when the starting switch is set to the
[ | ] (START) position with the brake pedal depressed and the forward/reverse lever set to either forward (F)
or reverse (R) position.
4. Releasing neutral safety function
Set the forward/reverse lever to the neutral position and the system is reset to the normal condition. When
the starting switch is turned to the [ | ] (START) position with the brake pedal depressed, the engine starts.

CHECKING THE WARNING BUZZER AGAINST OVERLOOKING APPLICATION OF PARKING BRAKE LEVER
Check the warning function that sounds buzzer if operator left the seat without pulling the parking brake lever
toward the rear of the lift truck.

CHECKING PROCEDURE
1. Park the lift truck on a level and flat place and pull the parking brake lever toward the rear of the truck.
(Parking brake activated)
2. Set the forward/reverse lever to the neutral position, and lower the forks to the ground. Tilt the mast forward
until the fork is in contact with the ground.
3. Stop the engine. Pull out the starting switch. Return the parking brake lever toward the forward of the lift truck
(parking brake release) and leave the seat.
4. Check that the warning buzzer sounds about 3 seconds later.
5. Stopping the sound of warning buzzer
Pull the parking brake lever to the rear direction of the lift truck. The buzzer stops sounding and the system
returns to normal state.

4.3 CHECKING AND REPORTING AFTER OPERATION

Checking and reporting after the day's operation are important job for getting the lift truck ready for operation on
the following day. Before washing and storing the lift truck after the day's operation, take the following check
procedure and always report to the administrator on the finding.

1. Checking of leakage of oil, fuel, coolant, battery electrolyte, etc.

2. Checking of cracks, damages and loosened parts, etc.
3. Grease up and lubricate the parts if necessary
4. Checking of abnormal points detected during the operation

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INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE

4.4 SIMPLE MAINTENANCE

4.4.1 GREASES AND FUEL
4.4.1.1 BASIC PRECAUTIONS
When refilling greases according to "Start-up inspection" and/or
"Checking after operation", do so by understanding the following
basic cautions for required greases.

OIL

CAUTION
･ When checking leakage from hydraulic piping or hose, do not
touch it directly by hand. The pipe or hose may be pressurized
and can be dangerous.
･ If your skin and/or eye are injured by high-pressure oil, wash the
skin/eye with fresh water and immediately see a doctor.
･ For other than leakage that can be checked visually by the
appearance, contact your KOMATSU FORKLIFT distributor for
inspection and repair service.

･ Since engine oil, hydraulic oil, TORQFLOW transmission oil,

gear oil, etc. are used under severe conditions (at high
temperature and high pressure), they deteriorate as the
operation time passes. Therefore oil must be changed
periodically. For the standard oil change intervals, see " OIL
AND GREASING CHART (OIL, GREASE LOCATIONS AND
INSPECTION AND MAINTENANCE INTERVALS) (PAGE 4-
26)" and "LUBRICANT LIST (PAGE 4-27)".
･ Always replace oil at the specified period even if not
deteriorated.
･ Always use Komatsu Utility genuine engine oil. At shipment
from a plant, the lift truck is applied with those oils listed in the
"LUBRICANT LIST (PAGE 4-27)".
･ Never mix oils of different grades (classes) or brands.
･ A lift truck should be maintained so that contaminants (water,
metal chips, dust, etc.) do not enter the lift truck system. Most
lift truck malfunctions are caused by entry of impurities such as
dirt, dust, water, etc. Take special care to avoid entry of
impurities during storage and lubrication, etc.
･ Add specified volume of oil. Insufficient or excessive amounts
of oil may both cause problems.
･ If the hydraulic oil has become murky, there is a possibility that
either air or water entered into the circuit. If no corrective
measures were taken, it may damage the lift truck. In such a
case, call your KOMATSU FORKLIFT distributor for their
service.
･ When replacing oil, replace the relevant filters at the same
time. For oil and filter changes, contact your KOMATSU
FORKLIFT distributor for service.

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4.4 SIMPLE MAINTENANCE INSPECTION AND MAINTENANCE

FUEL

CAUTION
Unless KOMATSU FORKLIFT-designated fuel is used, the engine emission cleanliness cannot be maintained within
required environmental standard. For environmental and your health protection, always use designated fuel.

･ At the end of the day's work, fill the fuel tank to full. Reducing the air inside the fuel tank helps reduce mixture
in the fuel of condensed moisture from the air.
･ Since the fuel pump is a precision machine, it may fail to operate if fuel containing moisture and/or impurities is
used. Take special care to avoid entry of moisture and impurities during storage and lubrication.
･ Always use fuel of appropriate grade from among those listed in the "LUBRICANT LIST (PAGE 4-27)".
･ When a diesel engine runs out of fuel or has its filters replaced, the fuel circuit has to be purged.

COOLING WATER (COOLANT AND DILUTED WATER)

CAUTION
･ After the engine stops, the coolant temperature is very high, and high pressure is accumulated inside the radiator.
Do not remove the radiator cap under these conditions or it may cause burns. After the coolant temperature has
gone down, turn the cap slowly to release the pressure before removing it.
･ Undiluted Supercoolant is flammable. So keep it away from open flame.
･ Dilute the coolant according to the ambient temperature before applying to the radiator. Use distilled or soft water
for dilution. Most of Japanese supply water is soft except a part of supply water, well water, small-scale water-
supply system and river water, which are hard water. Hard water contains high mineral contents (calcium and
magnesium). These contents are deposited inside the radiator as water stain and scale, causing an overheat of
engine. They are difficult to remove. For the radiator, it is recommended to use diluted water having total hardness
of 100 ppm (mg/l) or under.
･ This lift truck is filled with Komatsu Utility genuine Supercoolant (FAF-NAC). This Supercoolant has other
important function as the corrosion inhibitor of the cooling system than antifreeze function.
Continue to use this Supercoolant in an area where antifreeze is not required.
Using other brand of coolant may cause critical failure to the cooling system including the engine.
･ Komatsu Utility genuine Supercoolant is good for continual use for two years or 4,000 service hours.
･ Apply different mixing ratio for the Supercoolant according to the outside temperature.
For the right mixing ratio, see "4.6 RUNNING IN COLD WEATHER (PAGE 4-47)".
･ Shortage of coolant causes engine overheating and corrosive defect of cooling circuit due to the mixing of the air.

CAUTIONS WHEN REFILLING OR REPLACING COOLANT

･ If coolant is added quickly through a hose etc., bubbles will be mixed in it. Accordingly, add slowly. (Adding ratio:
Max. 3l/min)
･ After adding coolant to the specified level, run the engine at low idle with the radiator cap off for 5 - 10 minutes to
release the air in the system and then stop the engine and check the coolant level again.
･ Fill the reservoir tank with coolant to the specified level, too.

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INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE

GREASE
･ Grease prevents the joints from seizure, rusting and noise emission.
･ Always use recommended grease and strictly follow the greasing intervals. For the types of grease, see
"LUBRICANT LIST (PAGE 4-27)".
･ Wipe clean old grease extracted after greasing. Wipe grease off with particular care from sections where
attached sands and dirt promote the wear of the rotating units.

FILTERS
･ Filters are very important items which prevent impurities contained in the oil, fuel and hydraulic circuits from
entering important machine components to cause failure. They require periodical replacement. Call your
KOMATSU FORKLIFT distributor for service.
･ Never have your lift truck parts changed by other than KOMATSU FORKLIFT distributor. Never reuse filters
(cartridge type) after washing.
･ Always use Komatsu Utility genuine filters.

NOTICE
･ Special filter of high-efficiency filtration property is adopted for the genuine Komatsu Utility fuel filter
cartridges. Always use genuine Komatsu Utility parts for replacement. (Diesel engine lift truck)
･ The common rail fuel injection system adopted for this lift truck is configured with components of
higher accuracy compared with conventional injection pumps and nozzles. Using other fuel filter
cartridges than genuine Komatsu Utility parts may cause mixing of foreign matters, leading to a failure
of injection system. Never use substitute parts. (Diesel engine lift truck)
･ For inspection and maintenance of the fuel system, more care should be given for the mixing of
foreign matters than before. Attached dirt, if any, must be fully washed off using engine oil.
･ Some of commercial filters are inferior to the genuine product in performance. Using such filters may
affect performance and durability of the lift truck. If Komatsu Utility genuine parts are not used, quality
assurance may not apply.

4 - 25
4.4 SIMPLE MAINTENANCE INSPECTION AND MAINTENANCE

4.4.1.2 LUBRICANT LIST (FG40Z, FG35, FG40, FG45, FG50A)

OIL AND GREASING CHART (OIL, GREASE LOCATIONS AND INSPECTION AND MAINTENANCE INTERVALS)

Chain Differential case

TORQFLOW
Fork stopper transmission case

Mast support Tilt cylinder pin

Hydraulic oil tank

Front axle support

Drive shaft

Center pin, king pin Engine oil pan

Power steering
Cylinder link
Daily inspection
Once every 2 weeks (100 hours)

Every 1 month (200 hours)

Every 3 months (600 hours)
Every 6 months (1200 hours)

E : Check and add fluid if necessary

Q : Total oil change or greasing and application Symbol Type of fluid
T : Figure inside the box shows the number of places to add oil EO Engine oil
or grease to. MO Engine oil
GO Gear oil
HO Hydraulic oil
G Lithium grease

4 - 26
INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE

LUBRICANT LIST

Ambient Temperature
Lubrication point Type of oil
–30 –20 –10 0 10 20 30 40 °C

Engine oil pan Gasoline engine oil SAE10W30SJ (*1)

TORQFLOW transmission case Engine oil SAE J300 10W (*2)

Differential case Gear oil SAE J306 80W

Hydraulic oil tank Hydraulic oil SAE10WCD

Fuel tank Gasoline

Greasing points Lithium grease G2-LI

Cooling system Supercoolant FAF-NAC

*1 Use API SJ or higher grade oil. SAE : Society of Automotive Engineers

*2 Use API CD or higher grade oil. ASTM : American Society of Testing and Material
API : American Petroleum Institute

Capacity (l) Engine oil pan TORQFLOW

Hydraulic oil
transmission Differential case Fuel tank Cooling system
EBT-TB45-1A tank
Model case
4 ton
(Compact model 57 76
lift truck)
8.4 12 10 16
3.5 to 5 ton
(Standard model 74 98
lift truck)

NOTICE
Always use Komatsu Utility genuine parts for greases.

4 - 27
4.4 SIMPLE MAINTENANCE INSPECTION AND MAINTENANCE

4.4.1.3 LUBRICANT LIST (FD40Z, FD35, FD40, FD45, FD50A)

OIL AND GREASING CHART (OIL, GREASE LOCATIONS AND INSPECTION AND MAINTENANCE INTERVALS)

Chain Differential case

TORQFLOW
Fork stopper transmission case

Tilt cylinder pin

Mast support

Front axle support Hydraulic oil tank

Drive shaft

Center pin, king pin Engine oil pan

Power steering
Cylinder link
Daily inspection
Once every 2 weeks (100 hours)
Every 1 month (200 hours)
Every 3 months (500 hours)
Every 3 months (600 hours)
Every 6 months (1200 hours)

E : Check and add fluid if necessary

Q : Total oil change or greasing and application Symbol Type of fluid
T : Figure inside the box shows the number of places to add oil EO Diesel engine oil
or grease to. MO Engine oil
GO Gear oil
HO Hydraulic oil
G Lithium grease

4 - 28
INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE

LUBRICANT LIST

Ambient Temperature
Lubrication point Type of oil
–30 –20 –10 0 10 20 30 40 °C

Engine oil pan Diesel engine oil SAE10W40 (*1)

TORQFLOW transmission case Engine oil SAE J300 10W (*2)

Differential case Gear oil SAE J306 80W

Hydraulic oil tank Hydraulic oil SAE10WCD

ASTM Grade No.1-D S15

ASTM Grade No.1-D S500
Fuel tank Diesel fuel
ASTM Grade No.2-D S15
ASTM Grade No.2-D S500

Greasing points Lithium grease G2-LI

Cooling system Supercoolant FAF-NAC

*1 Use API CF-4 or higher grade oil. SAE : Society of Automotive Engineers
*2 Use API CD or higher grade oil. ASTM : American Society of Testing and Material
API : American Petroleum Institute

Capacity (l) Engine oil pan TORQFLOW

Hydraulic oil
transmission Differential case Fuel tank Cooling system
SAA4D95LE-5-A tank
Model case
4 ton
(Compact model 57 76
lift truck)
11 12 10 9
3.5 to 5 ton
(Standard model 74 98
lift truck)

NOTICE
･ Always use diesel oil for the fuel.
･ To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine
mounted on this machine uses an electronically controlled high-pressure fuel injection device. This
device requires high precision parts and lubrication, so if low viscosity fuel with low lubricating ability
is used, the durability may drop markedly.

4 - 29
4.4 SIMPLE MAINTENANCE INSPECTION AND MAINTENANCE

4.4.1.4 LUBRICANT LIST (FD40ZY, FD35Y, FD40Y, FD45Y, FD50AY)

OIL AND GREASING CHART (OIL, GREASE LOCATIONS AND INSPECTION AND MAINTENANCE INTERVALS)

Chain Differential case

TORQFLOW
Fork stopper transmission case

Mast support Tilt cylinder pin

Front axle support Hydraulic oil tank

Drive shaft

Center pin, king pin Engine oil pan

Power steering
Cylinder link
Daily inspection
Once every 2 weeks (100 hours)

Every 1 month (200 hours)

Every 3 months (600 hours)
Every 6 months (1200 hours)

E : Check and add fluid if necessary

Q : Total oil change or greasing and application Symbol Type of fluid
T : Figure inside the box shows the number of places to add oil EO Diesel engine oil
or grease to. MO Engine oil
GO Gear oil
HO Hydraulic oil
G Lithium grease

4 - 30
INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE

LUBRICANT LIST

Ambient Temperature
Lubrication point Type of oil
–30 –20 –10 0 10 20 30 40 °C

Engine oil pan Diesel engine oil SAE10W40 (*)

TORQFLOW transmission case Engine oil SAE J300 10W (*)

Differential case Gear oil SAE J306 80W

Hydraulic oil tank Hydraulic oil SAE10WCD

ASTM Grade No.1-D S15

ASTM Grade No.1-D S500
Fuel tank Diesel fuel
ASTM Grade No.2-D S15
ASTM Grade No.2-D S500

Greasing points Lithium grease G2-LI

Cooling system Supercoolant FAF-NAC

* Use API CD or higher grade oil. SAE : Society of Automotive Engineers

ASTM : American Society of Testing and Material
API : American Petroleum Institute

Capacity (l) Engine oil pan TORQFLOW

Hydraulic oil
transmission Differential case Fuel tank Cooling system
S4D95LE-3 tank
Model case
4 ton
(Compact model 57 76
lift truck)
11 12 10 9
3.5 to 5 ton
(Standard model 74 98
lift truck)

NOTICE
･ Always use diesel oil for the fuel.
･ Always use Komatsu Utility genuine parts for greases.

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4.4 SIMPLE MAINTENANCE INSPECTION AND MAINTENANCE

4.4.2 AIR CLEANER ELEMENT INSPECTION AND CLEANING

CAUTION
･ Physical injuries may be caused by being caught by the fan or in
the belt while the engine is running. Always stop the engine
before removing or cleaning the air cleaner element.
･ While cleaning the element, dust may fly out to enter the eye or
be inhaled. Always wear safety goggles, dust mask and other
protective gears. Clean the element in a place where no other
persons are endangered by it.

INSPECTION
Open the engine hood. If the red piston is projected into the
transparent portion of dust indicator (1), clean the air cleaner
element.

NOTICE
Do not clean the element before the red piston is projected
into the transparent portion of dust indicator (1). If the
element is cleaned frequently before the red piston is
projected, the air cleaner performance is not used fully and
the cleaning efficiency is lowered.

CLEANING METHOD FOR OUTER ELEMENT

1. Open the engine hood, remove 3 latches (2), and remove
cover (3).

2. Take out outer element (4).

NOTICE
Never remove inner element (5). Dirt will enter and cause an
engine trouble.

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INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE

3. Clean the inside of the air cleaner body and cover (3).

NOTICE
When cleaning cover (3), do not remove evacuator valve (6).

4. Blow dry compressed air (Max. 0.69 MPa {7 kgf/cm2}) from

inside of the element along the pleats. Next, blow along the
outside pleats, and then blow from inside again.

NOTICE
･ Do not clean and reuse inner element (5). When replacing
outer element (4), replace the inner element with new one,
too.
･ If the red piston of dust indicator (1) is projected
immediately after outer element (4) is cleaned, replace
both inner and outer elements with new ones.

5. After cleaning the element, irradiate its inside with a light bulb
to check. If it has a small hole or a thin part, replace it.

NOTICE
･ When cleaning the element, do not hit it or strike it against
something.
･ If pleats, gasket, or seal of the element has damaged, do
not use it.
･ Keep an unused element wrapped and store it in dry place.

6. Set cleaned outer element (4), install cover (3), and secure it
with latches (2).
7. Push the button of dust indicator (1) to return the red piston.

REMARK
･ Always use genuine Komatsu Utility parts for the elements.
･ When replacing outer element (4), replace inner element (5),
too. Contact your KOMATSU FORKLIFT distributor for the
replacement of elements.

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4.4 SIMPLE MAINTENANCE INSPECTION AND MAINTENANCE

4.4.3 FUEL FILTER AIR BLEEDING (FD40Z, FD35, FD40, FD45, FD50A)

1. Loosen air bleeding plug (2) of the bracket of fuel pre-filter (1).
2. Loosen and pull out the knob (3) of the priming pump. Operate
it forward and backward.
3. Check that fuel flows out of air bleeding plug (2) and then
tighten plug (2).
Tightening torque of air bleeding plug (2)
: 7.8 - 9.8 Nm {0.8 - 1.0 kgfm}

4. Loosen air bleeding plug (5) of fuel main filter (4).

5. Loosen and pull out the knob (3) of the priming pump. Operate
it forward and backward.
6. Check that fuel flows out of air bleeding plug (5) and then
tighten plug (5).
Tightening torque of air bleeding plug (5)
: 7.8 - 9.8 Nm {0.8 - 1.0 kgfm}
7. Turn the starting switch key to the [ | ] (START) position to start
the engine.

REMARK
･ If the engine does not start, the air may have not been bled
thoroughly. Repeat from step 1.
･ Fuel pre-filter (1) and fuel main filter (4) do not need to be
removed.
･ If the machine runs out of fuel, operate priming pump knob (3)
to bleed the air.
･ Contact your KOMATSU FORKLIFT distributor for the
replacement of fuel pre-filter (1) and fuel main filter (4).

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INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE

4.4.4 FUEL FILTER AIR BLEEDING (FD40Z, FD35, FD40, FD45, FD50A/*REF)

1. Loosen air bleeding plug (2) of the bracket of fuel pre-filter (1).
2. Loosen and pull out the knob (3) of the priming pump. Operate
it forward and backward.
3. Check that fuel flows out of air bleeding plug (2) and then
tighten plug (2).
Tightening torque of air bleeding plug (2)
: 7.8 - 9.8 Nm {0.8 - 1.0 kgfm}

4. Loosen air bleeding plug (4) of the first fuel main filter.
5. Loosen and pull out the knob (3) of the priming pump. Operate
it forward and backward.
6. Check that fuel flows out of air bleeding plug (4) and then
tighten plug (4).
Tightening torque of air bleeding plug (4)
: 7.8 - 9.8 Nm {0.8 - 1.0 kgfm}

7. Loosen air bleeding plug (5) of the second fuel main filter.
8. Loosen and pull out the knob (3) of the priming pump. Operate
it forward and backward.
9. Check that fuel flows out of air bleeding plug (5) and then
tighten plug (5).
Tightening torque of air bleeding plug (5)
: 7.8 - 9.8 Nm {0.8 - 1.0 kgfm}
10. Turn the starting switch key to the [ | ] (START) position to start
the engine.

REMARK
･ If the engine does not start, the air may have not been bled
thoroughly. Repeat from step 1.
･ Fuel pre-filter (1) and each fuel main filter do not need to be
removed.
･ If the machine runs out of fuel, operate priming pump knob (3)
to bleed the air.
･ Contact your KOMATSU FORKLIFT distributor for the
replacement of fuel pre-filter (1) and each fuel main filter.

*REF (Reliable-Extra-Filtration)
: This specification provides an additional main filter and a
filter with the water separation function for the inferior fuel.

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4.4 SIMPLE MAINTENANCE INSPECTION AND MAINTENANCE

4.4.5 FUEL FILTER WATER DRAINING AND AIR BLEEDING (FD40ZY, FD35Y, FD40Y, FD45Y,
FD50AY)

CAUTION
･ Beware the engine is high-temperature immediately after
stopping. Drain water and/or bleed air after the engine
temperature has lowered sufficiently.
･ When draining water from the fuel filter, fuel is also drained.
Always wipe spilt fuel off and keep it away from open flame.

When the sedimenter warning lamp flashed, water is settled on

the bottom of fuel filter casing beyond the specified limit. Drain
water according to the following procedure:

1. Loosen the drain plug (also working as the sensor) (1) on the
bottom of the fuel filter and drain water deposited.
2. After draining, tighten the drain plug (1) securely.

3. Bleeding air
Loosen plug (2) and move knob (3) up and down. Check that
no more air bubbles come out and tighten plug (2).
Tightening torque of air bleeding plug (2)
: 24.5 - 34.3 Nm {2.5 - 3.5 kgfm}

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INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE

4.4.6 REPLACING TYRES

WARNING
･ Beware of danger of being caught by the jack if it came away.
When lifting the lift truck with a jack, check that the jack is firmly
in place. Never crawl under the lifted truck body.
･ Forklift truck tire air pressure is high and dangerous.
･ Do not disassemble/assemble tyre, tube or rim, nor fill removed
tyres from the lift truck with the air. (These works require special
equipment and skill. Persons engaged in this work are required
to receive mandatory special training according to Industrial
Safety and Health Law.)

1. Unload the lift truck. Stop it on level, flat and hard road
surface. Apply parking brake by pulling the lever to the rear
direction of the lift truck. (Parking brake activated)
2. Put blocks under the tyre diagonally opposite to the tyre
which is to be replaced.
3. Always jack a lift truck up by the specified jack up point.

･ For replacing a front tyre: Under the outer mast

･ For replacing a rear tyre: Under the counterbalance-weight

4. Jack the lift truck up to a level where the tyre is still slightly in
contact with the ground.
Place a block under the lift truck frame for preventing the
falling.
Place the block in front when replacing a front wheel, and in
the rear when replacing a rear tire.

4 - 37
4.4 SIMPLE MAINTENANCE INSPECTION AND MAINTENANCE

5. Replacing tyres

WARNING
･ For a tyre with divided ring rim, never loosen rim jointing bolts
(special bolt) (2) and nuts.
･ Always loosen the hub nuts of the tyre with divided ring rim after
depressurizing it.
･ For safety, when filling a tyre with air or replacing it, place your
body in front of the tread face of the tyre. Do not work from the
side of the tyre.
･ When adjusting the air pressure with an air compressor, adjust
the compressor pressure in advance to prevent pressurizing the
tyre beyond the specified level.
･ Deformed or cracked rim poses a great danger. Before installing
a replacement tyre, check it thoroughly. Do not use a tyre with
deformed or cracked rim.

(1) Using a hub nut wrench or other tool, loosen the hub nuts
(1) until they can be turned manually.
(2) Jack the lift truck up until the tyre slightly clear the ground.
Remove hub nuts (1) and remove the tyre.

6. Install a replacement tyre to the hub. Tighten hub nuts (1)

temporarily. Tighten the nuts diagonally until the tyre does not
rattle.
7. Remove the block from under the frame. Lower the jack and
tighten hub nuts (1) to the specified torque. For the right
tightening torque, see "4.16 SERVICE DATA (PAGE 4-65)".
8. Adjust the tyre inflation pressure to specified pressure. For
the right tyre inflation pressure, see "4.16 SERVICE DATA
(PAGE 4-65)".
9. After replacing the tyre, have a trial run to check the hub nuts
for looseness. Tighten if necessary.

4 - 38
INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE

4.4.7 ADJUSTING PARKING BRAKE LEVER OPERATING EFFORT

CAUTION
Block the front and rear tires before starting adjustment.

Install a spring scale to the center of grip of parking brake lever

and measure the tensile operating force to the rear direction of
the lift truck. If the operating force is not within the range of
reference value, adjust it by turning the adjust bolt.

HOW TO ADJUST
1. Press push button (1) and set parking brake lever (2) to the
front direction (releasing position) of the lift truck.
Free

Lock

2. Using flat-blade screwdriver, turn the adjust bolt (4) through

the window (3) at the bottom of the parking brake lever (2) to
adjust the operating force to the reference value when the
parking brake lever (2) is pulled.
Turn the bolt clockwise: Operating force increases
Turn the bolt counterclockwise: Operating force decreases

For the reference value of the parking brake lever operating effort,
see "4.16 SERVICE DATA (PAGE 4-65)".

4 - 39
4.4 SIMPLE MAINTENANCE INSPECTION AND MAINTENANCE

4.4.8 REPLACING FUSE

If the lamps and indicator lamps fail to light up or the control
system fails to operate, there is a possibility that fuses may be
blown. Check fuses that protect each equipment and system for
blowing.

CAUTION
･ When replacing the fuses, always turn off the electric power (turn
the starting switch to the [Q] (OFF) ) position before replacing.
･ Always use fuse of same capacity for replacement.
･ If replaced fuse is blown again, abnormal electric system may be
causing the problem. Contact KOMATSU FORKLIFT distributor
for checking.

GASOLINE ENGINE LIFT TRUCK

1. Turn the starting switch to the [Q] (OFF) position.
2. Open the engine hood. Fuses are installed in the fuse box in
front of the battery to the left hand side of the lift truck body.
Large capacity fuses are installed in relay box 1 (1) and relay
box 2 (2).
3. Remove fuse box cover (3) and remove puller (4) attached to
the inside of the fuse box.
4. Hold the fuse with the puller to remove and visually check if it
is blown.

5. If a fuse is blown, replace it with spare fuse of same capacity.

4 - 40
INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE

RESPECTIVE FUSES AND THE DEVICES THEY PROTECT

･ Fuse box

Fuse capacity and related electrical component

No. Capacity Color Related electrical component
1 15A Blue EGI 1 (Engine controller ignition 1)
2 10A Red EGI 2 (Engine controller ignition 2)
3 15A Blue ETC (Electronic throttle chamber)
4 15A Blue Head lamp
5 10A Red Clearance lamp and brake lamp
6 10A Red Horn and horn relay
7 10A Red Meter and turn signal lamp
8 10A Red OPS system (Interlock)
9 10A Red ISO controller
10 10A Red Fuel injection system
11 10A Red Fuel pump
12 10A Red Starting motor
13 10A Red Mast lock and control valve
The unmarked fuses (10A × 1, 15A × 1) are spares.

･ Relay box 1

Fuse capacity and related electrical component

No. Capacity Related electrical component
14 - F (Forward circuit)
15 - R (Reverse circuit)
16 - F2 (Forward 1st/2nd shifting circuit)
17 - Parking
18 - Mast lock and control valve solenoid
19 - OPS main
20 40A ACC (Accessory)
21 40A Starting motor
22 120A Battery

･ Relay box 2

Fuse capacity and related electrical component

No. Capacity Related electrical component
23 - EGI 1 (Engine controller ignition 1)
24 - EGI 2 (Engine controller ignition 2)
25 - ETC motor (Electronic throttle chamber)
26 - Fuel pump
27 - Neutral relay
28 - Starting motor relay

4 - 41
4.4 SIMPLE MAINTENANCE INSPECTION AND MAINTENANCE

DIESEL ENGINE LIFT TRUCK

1. Turn the starting switch to the [Q] (OFF) position.
2. Open the engine hood. Fuses are installed in the fuse box in
front of the battery to the left hand side of the lift truck body.
Large capacity fuses are installed in relay box (3).
3. Remove fuse box cover (1) and remove puller (2) attached to
the inside of the fuse box.
4. Hold the fuse with the puller to remove and visually check if it
is blown.

5. If a fuse is blown, replace it with spare fuse of same capacity.

･ Fuse box
Fuse capacity and related electrical component
No. Capacity Color Related electrical component
1 30A Green Engine controller (*1)
2 15A Blue Head lamp
3 10A Red Clearance lamp and brake lamp
4 10A Red Horn and horn relay
5 10A Red Meter and turn signal lamp
6 10A Red OPS system (Interlock) (*2)
7 10A Red ISO controller
8 10A Red Starting motor
9 10A Red Mast lock and control valve solenoid
10 15A Blue Fuel cut solenoid (*3)
The unmarked fuses (10A × 2, 15A × 1) are spares.
*1 Applied to FD40Z, FD35, FD40, FD45, FD50A.
*2 Optional to FD40ZY, FD35Y, FD40Y, FD45Y, FD50AY.
*3 Applied to FD40ZY, FD35Y, FD40Y, FD45Y, FD50AY.

4 - 42
INSPECTION AND MAINTENANCE 4.4 SIMPLE MAINTENANCE

･ Relay box
Fuse capacity and related electrical component
No. Capacity Related electrical component
11 - F (Forward circuit)
12 - R (Reverse circuit)
13 - F2 (Forward 1st/2nd shifting circuit)
14 - Parking (*1), Heater (*3)
15 - Mast lock and control valve solenoid (*2)
16 - OPS main (*2)
17 40A ACC (Accessory)
18 40A Starting motor
19 120A Battery
*1 Applied to FD40Z, FD35, FD40, FD45, FD50A.
*2 Optional to FD40ZY, FD35Y, FD40Y, FD45Y, FD50AY.
*3 Applied to FD40ZY, FD35Y, FD40Y, FD45Y, FD50AY.

4.4.9 REPLACING BULBS

If a lamp fails to light up, it may be caused by burnt bulb beside
blown fuse. Replace the bulb after checking if the fuse is blown.

CAUTION
･ Always use bulb of same capacity for replacement.
･ If replaced bulb still fails to light up, abnormal electrical system
may be causing the problem. Contact your KOMATSU FORKLIFT
distributor for checking immediately.

1. Turn the starting switch to the [Q] (OFF) position, and the
lamp switch to the OFF position.
2. Remove the lamp lens and replace the bulb.

Lamp name Capacity

Head lamp 55 W (For 12V)
Turn signal lamp 23 W (For 12V)
Clearance lamp 8 W (For 12V)
Backup lamp 8 W (For 12V)
Stop lamp 23 W (For 12V)
Warning lamp 1.4 W (For 12V)
Meter lamp 1.4 W (For 12V)

4 - 43
4.4 SIMPLE MAINTENANCE INSPECTION AND MAINTENANCE

4.4.10 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF

RUBBER (FD40Z, FD35, FD40, FD45, FD50A)
The fuel spray prevention caps (* 10 places) on the fuel injection piping and both ends of the high-pressure piping
act to prevent the fuel from coming into contact with high-temperature parts of the engine and causing a fire if the
fuel should leak or spray out. Check visually and touch by hand to check that there are no missing caps, loose
clips or hardening of the rubber. If there are any problems, the parts must be replaced. Contact KOMATSU
FORKLIFT distributor for inspection and repair.

4.4.11 CHECKING FOR HARDENING OF ENGINE CONTROLLER MOUNT RUBBER AND

LOOSE MOUNTING (FD40Z, FD35, FD40, FD45, FD50A)
Check visually and touch by hand to check that there are no hardening or damage of the engine controller mount
rubber (4 places) or loose mounting nuts. If there are any problems, the parts must be replaced. Contact
KOMATSU FORKLIFT distributor for inspection and repair.

4 - 44
INSPECTION AND MAINTENANCE 4.5 PROCEDURE FOR A DOWN BATTERY

4.5 PROCEDURE FOR A DOWN BATTERY

If a battery is down, the lift truck can be started by using the

battery of other truck via booster cables.

CAUTIONS ON CONNECTING/DISCONNECTING BOOSTER CABLES

CAUTION
･ When connecting the booster cables, never connect its positive
(+) and negative (-) terminals.
･ When starting the engine using the booster cables, always wear
protective goggles and rubber gloves.
･ When using other lift truck for starting engine, be careful not to
allow the normal lift truck to make contact with faulty lift truck.
Batteries generate hydrogen gas. Hydrogen gas is highly
explosive, and is easily ignited with a small spark emitted near
the battery.
･ Turn the starting switch to the [Q] (OFF) position on both the
normal and faulty lift trucks when the booster cables are
connected. Or the lift trucks may make a sudden movement when
the power supply is connected.
･ Do not make mistake about the right connection of the booster
cables. Start with the positive (+) terminal for connection.
Conversely, start with the negative (-) terminal (grounding side)
for disconnection. When making connection, the final length of
cable is connected to the engine block of the faulty lift truck
emitting the sparks. Make connection to a spot as separated from
the battery as possible on the engine block.
･ When disconnecting the booster cables, never allow the clip to
contact with other clip or the lift truck.
･ The mating battery for booster connection must have same
voltage as one on the faulty lift truck.

BOOSTER CABLE CONNECTION

Turn the starting switch to the [Q] (OFF) position on both the
normal and faulty lift trucks. Then set the forward/reverse lever to
neutral. Check if the parking brake lever is ON and connect the
cable according to the numbers in the figure in that order.
1. Connect the clip of booster cable (A) to the positive (+)
terminal of the faulty lift truck. Battery of Battery of
2. Connect the other clip of booster cable (A) to the positive (+) normal lift truck faulty lift truck
terminal of the normal lift truck.
3. Connect the clip of booster cable (B) to the negative (-) Engine block of faulty lift truck
terminal of the normal lift truck.
4. Connect the other clip of booster cable (B) to the engine block
of the faulty lift truck.

4 - 45
4.5 PROCEDURE FOR A DOWN BATTERY INSPECTION AND MAINTENANCE

NOTICE
• Use appropriate size of booster cables and clips for the
size of battery.
• For the normal lift truck, use battery of same capacity as
that on the faulty lift truck.
• Check that the cables and clips are free from damages and
corrosion
• Connect the clip securely to the mating terminal or block.

STARTING ENGINE

CAUTION
Check if both normal and faulty lift trucks for their forward-reverse
travel lever being set to the neutral position and the parking brakes
to ON.

1. Check that clips are securely connected to the battery

terminals.
2. Start the engine on the normal lift truck and raise the speed to
full (maximum revolution).
3. Turn the starting switch on the faulty lift truck to [ | ]" (START)
to start engine.
If the engine fails to start, try again after two minutes or over.

REMOVING THE BOOSTER CABLES

When the engine has started, remove the booster cables in
reverse order to the connection.
1. Disconnect the clip of booster cable (B) from the engine block
of the faulty lift truck.
2. Disconnect the clip of booster cable (B) from the negative (-)
terminal of the normal lift truck.
3. Disconnect the other clip of booster cable (A) from the
positive (+) terminal of the normal lift truck. Battery of Battery of
4. Disconnect the other clip of booster cable (A) from the normal lift truck faulty lift truck
positive (+) terminal of the faulty lift truck.
Engine block of faulty lift truck

4 - 46
INSPECTION AND MAINTENANCE 4.6 RUNNING IN COLD WEATHER

4.6 RUNNING IN COLD WEATHER

PREPARATIONS FOR LOW TEMPERATURE

When the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as
follows.

FUEL, LUBRICANT AND HYDRAULIC OIL

Use fuel, lubricant and oil of low viscosity.
For the specified viscosity, see "LUBRICANT LIST (PAGE 4-27)".

COOLANT

CAUTION
･ Supercoolant is toxic. Protect your skin and/or from it. If exposed to it, wash the skin/eye with fresh water and
immediately see a physician.
･ For disposing Supercoolant-added waste coolant drained during the replacement of coolant and the repair of
radiator, contact a disposal specialist or your KOMATSU FORKLIFT distributor. Supercoolant is toxic, so be sure
not drain it to the drainage ditch or the ground.
･ Undiluted Supercoolant is flammable. Keep it away from fire. Don't smoke while handling it.

NOTICE
Use Komatsu Utility genuine Supercoolant (FAF-NAC). Other brands than Komatsu Utility genuine
Supercoolant are not recommended as principle.

When the lift truck is shipped out from the factory, it is filled with Supercoolant of concentration applicable to the
outside temperature of -20°C.
When the ambient temperature should fall below -20°C, raise the concentration of the coolant according to the
following table.

Diluted concentration for Supercoolant (FAF-NAC)

Minimum temperature (°C) -10 -15 -20 -25 -30 -35
Concentration (%) 30 35 40 45 50 55

Cautions when refilling or replacing coolant

･ Dilute the coolant with distilled water or supply water (soft water) to an appropriate concentration for use.
･ Check the radiator, water pump and hoses for any water leakage.
･ Drain all coolant and flush the inside of the system before adding new coolant.

4 - 47
4.6 RUNNING IN COLD WEATHER INSPECTION AND MAINTENANCE

BATTERY

CAUTION
･ Batteries generate flammable gas. Keep it away from open flame.
･ Battery electrolyte is hazardous substance. Protect your skin and/or from it. If exposed to it, wash the skin/eye
with large amount of fresh water and immediately see a physician.
･ Battery electrolyte is hazardous substance, so be sure not drain it to the drainage ditch or the ground.
･ Battery electrolyte dissolves the coating. If attached to the lift truck, wash it down with water immediately.
･ If battery is frozen, do not charge it or start the engine using other power supply. Or the battery may explode.

･ When the temperature drops, the battery performance is deteriorated, making engine start difficult.
Insufficiently charged battery electrolyte may freeze. Get ready for the start in the following morning by
charging the battery close to 100% at the day's end.
･ Since battery performance remarkably drops as the temperature drops, remove it from the lift truck, place it in
a warmer place overnight and install it the following morning. (Particularly when the temperature is low or the
lift truck is not to be used for some period)
･ If the battery electrolyte level is low, refill distilled water before starting operation the next morning. To prevent
freezing during the night, do not refill electrolyte after the end of operation.

REMARK
For finding the battery charge level, measure the specific gravity
of battery electrolyte and convert it according to the following
table.

Electrolyte temperature
Battery (°C) 20 0 -10 -20
charge level (%)
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26

PRECAUTIONS AFTER COMPLETION OF OPERATIONS

Drain water to prevent water deposited in the fuel pipe from freezing.
For the draining of the sedimenter of diesel engine lift truck, see " DRAINAGE OF FUEL PRE-FILTER (FD40Z,
FD35, FD40, FD45, FD50A) (PAGE 4-10)".

WHEN COLD SEASON IS OVER

When the weather becomes milder with the change of season, do as follows
･ Change oil of respective devices and fuel to those of specified viscosity according to the "LUBRICANT LIST
(PAGE 4-27)".

4 - 48
INSPECTION AND MAINTENANCE 4.7 PROCEDURE WITH OVERHEATED ENGINE

4.7 PROCEDURE WITH OVERHEATED ENGINE

CAUTION
When overheated, opening the radiator reservoir tank or radiator
cap immediately after stopping engine let steam spurt out to cause
burns. Do not open the cap until the engine cools down.

ENGINE OVERHEATING PREVENTION SYSTEM

If the pointer of the water temperature gauge approaches the red
range as the result of excessive rising of the engine coolant
temperature, automatic function is activated to prevent the engine
overheating. The abnormality warning lamp either lights up or
flashes, engine speed being controlled and held at a specific level
if the accelerator pedal is pressed on. Do not apply undue load to
the truck. Wait till the engine water temperature gauge pointer
starts lowering.

NOTICE
If the lamp lights up or flashes during operation, stop
operation immediately and report to the administrator or
contact your KOMATSU FORKLIFT distributor for checkup.
The protection system may stop the engine or take another
protective action, depending on the abnormality.

ACTION WHEN ENGINE HAS OVERHEATED

When the engine has overheated and the coolant temperature
gauge points the red range, do not panic and take the following
actions:
1. Park the lift truck in a safe place.
2. Keep the engine running at low idling.
If the cooling fan is not running, stop the engine immediately.
3. When the water temperature gauge enters the white range,
stop the engine.
4. Check the followings after the engine has fully cooled down
･ Is the coolant level right?
･ Is the fan belt not sheared or loosened?
･ Is the engine oil level right?
･ Isn't the radiator clogged?
5. If coolant or engine oil level is low, refill to appropriate level.
In the case of other failure or the cause of overheat is
unknown, contact the administrator, stop using the lift truck
and call your KOMATSU FORKLIFT distributor.

4 - 49
4.7 PROCEDURE WITH OVERHEATED ENGINE INSPECTION AND MAINTENANCE

CLEANING INSIDE THE COOLING SYSTEM

If water stain and/or rust is generated inside the cooling system,
cooling efficiency is deteriorated, causing overheat.
As the cooling system requires periodical inspection and washing
using radiator detergent liquid, please call KOMATSU FORKLIFT
distributor for maintenance service.

CLEANING OF RADIATOR FINS

CAUTION
To prevent flying objects from getting into your eyes, always wear
protective glasses or goggles when cleaning.

Clogged radiator fins can cause engine overheat. Clean them by

blowing the air, steam or water.
Remove cleaning window cover (1). Set the air or steam pressure
to the following value, insert the nozzle through the cleaning
window, and blow air or steam at right angles to the radiator.
Air pressure : Max. 0.98 MPa {10 kgf/cm2}
Steam pressure : Max. 0.39 MPa {4 kgf/cm2}

4 - 50
INSPECTION AND MAINTENANCE 4.8 OPERATING LIFT TRUCKS IN SPECIAL ENVIRONMENT OR IN FORCIBLE WAY

4.8 OPERATING LIFT TRUCKS IN SPECIAL ENVIRONMENT OR IN

FORCIBLE WAY
This lift truck is designed and tested to cover most customers' uses under general application or environment.
Under some special working environment or condition that requires mode of operation quite punishing to the lift
truck, abnormality and degradation occur to it including early failures, shorter service life, persisting failure to
certain parts and failure of usually fault-free parts and components.
When the lift truck is used under special environment or in forcible way, it requires to receive maintenance and
various other measures appropriate to a lift truck subjected to such hard and trying operating conditions. For
more details, call your KOMATSU FORKLIFT distributor.

EXAMPLES OF SPECIAL ENVIRONMENT OR FORCIBLE USE OF LIFT TRUCK

･ Operating environment where the lift truck has to travel on the roads covered with salt water, chemicals (acid
and/or alkaline), solvents, etc. or it is directly poured or attached with them via operator's hands and feet.
･ Environment surrounded by corrosive gases that corrode metal and/or resin.
･ Environment near the sea shore blown by salty wind from the sea
･ Environment where dew condensation occurs to the lift truck as it travels indoor and outdoor by getting sharp
temperature difference or environment where it is constantly soaked with water.
･ Environment filled with excessive sludge and those filled with dust, fine dust, and aggressive dust from
polishing.
･ Using lift truck for other application than original designed.
･ Operation by which a lift truck is used for a specific work for extended span of time or used continuously in
concentration for a particular work.
･ Application inhibited by this operating manual.
･ Others

NOTICE
• Operating the lift trucks in a special environment or in forcible way excludes them from the object of
warranty provided by Komatsu Utility Co., Ltd.
• There are conditions technologies cannot cover.
• This lift truck cannot be used under a condition to which a risk of explosion accompanies.

4 - 51
4.9 ACTION TO TAKE IF THE FORK FAILS TO LOWER INSPECTION AND MAINTENANCE

4.9 ACTION TO TAKE IF THE FORK FAILS TO LOWER

CAUTION
･ If the fork stops lowering during operation, stop the work
immediately. Never use this lift truck until repaired.
･ Put up "No Entry" and "Never use" signs to keep other persons
from entering under or in front of the raised fork.
･ The lift truck may suddenly start moving leading to a critical
accident. Do not touch the mast, fork, chain and other load
handling devices. (Do not shake, touch or pry with a stick or tool)
･ Immediately contact with the administrator or your KOMATSU
FORKLIFT distributor for repair service.

1. If the fork stops lowering during operation, stop the work

immediately.
2. Move the lift truck in question to a flat place and park it by

Never use
avoiding emergency exit or fire fighting equipment. For details
on parking, see "2.4.3 STOPPING AND PARKING (PAGE 2-

Danger
24)" and "3.3.8 TEMPORARY STOPPING, PARKING AND
STOPPING (PAGE 3-30)".
3. If the loaded fork should stop operating in raised condition,
secure wide "No Entry" area around the lift truck or park the lift
truck directly facing a stout wall surface in checking a risk of
falling load to the ground.

4 - 52
INSPECTION AND MAINTENANCE 4.10 WASHING LIFT TRUCKS

4.10 WASHING LIFT TRUCKS

CAUTION
If water gets into the electrical system (controller, sensor,
connector, etc.), there is a hazard that it will cause malfunctions or
miss-movement. Do not wash the electrical parts or use a high-
pressure washer (steam cleaner) on them.

WASHING PROCEDURE
1. Turn the starting switch key to the [Q] (OFF) position, then
remove the key.
2. Wash each section ((1) to (4) in the figure at right)) according
to the table below.
3. Dry washed sections completely.
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 abnormality, and then start
operation.

No. Sections to wash Washing Method

Wash by spraying water with a hose from above.
1 Meter panel Note) Reduce the discharging volume of water as the figure below. Lower the water
pressure for washing.
(Only for No. 1 and 2)

Dashboard Front
2 Pedals
Floor Plate

Wash with high pressure steam or flushing water from a hose.

Front/Rear tyres
3 Note) Do not use high pressure steam or flushing water for the tyre angle sensor and
Front and Rear axles
electric wirings.
Exterior parts other than
4 Wash with high pressure steam or flushing water from a hose.
the above
1. Never wash the inside of the dashboard.
2. Before washing the inside of the engine hood (engine room) and the floor plate,
Other Precautions lower (power line) with high-pressure (steam) or hose water, cover up the engine
transmission, the surrounding wiring, connector controller, fuse box and other
electrical parts with waterproof sheeting.

4 - 53
4.11 LONG-TERM STORAGE INSPECTION AND MAINTENANCE

4.11 LONG-TERM STORAGE

Store lift trucks as follows when storing them for a long period (over one month).

BEFORE STORAGE
After washing and cleaning respective parts, implement the following maintenance service before storing the lift
trucks indoor: If it must unavoidably be left outdoors, park the lift truck on flat ground and cover it with a tarpaulin.
･ Fill up the fuel tank to full. This helps prevent water deposit.
･ Apply grease and change oil without fail.
･ Fully apply grease to the exposed portions of hydraulic cylinder piston rod.
･ Disconnect the negative (-) terminal of the battery and cover it or remove it from the lift truck and store indoors.
･ To prevent freezing, use Komatsu Utility genuine Supercoolant (FAF-NAC) (concentration 40% or upward).

DURING STORAGE

CAUTION
If it is necessary to carry out the rust prevention operation indoors, open the doors and windows to improve
ventilation and prevent gas poisoning.

･ During storage, always operate and move the lift truck once a month to retain the lubricated sections fully
covered under oil film.
･ When operating work equipment, wipe the applied grease off the hydraulic cylinder piston rod.
･ As the battery discharges naturally, charge it once a month.

AFTER STORAGE
When using lift trucks after some long period of storage, implement the following service before proceeding to
operation.
･ Wipe the applied grease off the hydraulic cylinder piston rod.
･ Apply grease and oil to necessary sections without fail.
･ When a lift truck has been in storage for a long period, moisture in the air is mixed in oil. Check oil of respective
sections before and after starting engine. If water is mixed in oil, change oil completely.

NOTICE
･ When using lift trucks that were not operated once a month to prevent rusting, consult your KOMATSU
FORKLIFT distributor before operation.
･ Before starting work, be sure to perform the start-up inspection. For the start-up inspection, see "4.2
START-UP INSPECTION (PAGE 4-2)".

4 - 54
INSPECTION AND MAINTENANCE 4.12 HOISTING LIFT TRUCK

4.12 HOISTING LIFT TRUCK

CAUTION
･ Hook the sling to the designated holes on the top of the mast and
the counterbalance-weight.
･ Overhead guard and the cab mount (for a cab specification lift
truck) have no strength to hoist the lift truck. Never use them for
hoisting lift truck, or there is a danger of falling.
･ Hook the sling to the mast and counterbalance-weight after
checking that they are securely installed.
･ Never allow other persons to go under or near the lifted truck.

1. The sling hooking positions are the holes on the top of the
outer mast and the counterbalance-weight.
2. Check that the mast and counterbalance-weight are securely
installed.
Tightening torque for the counterbalance-weight mount bolt
: 588 - 784 Nm {60 - 80 kgfm}
Tightening torque for the mast lower mount bolts
: 343 - 427 Nm {35 - 43.5 kgfm}

3. Use undamaged sling and wire, having sufficient strength.

4. When hoisting a lift truck, do not allow the overhead guard
and/or cab to make contact with wire, etc. Adjust the wire
length to prevent the lift truck from being tilted. Do not give
impact to it while hoisting.

4 - 55
4.13 LOADING AND UNLOADING OF LIFT TRUCK INSPECTION AND MAINTENANCE

4.13 LOADING AND UNLOADING OF LIFT TRUCK

CAUTION
The work of loading and unloading a lift truck on a trailer always
involves a hazard that the lift truck tips over or falls off if you make a
mistake in handling.
Strictly follow the instructions shown below.
･ Stop the trailer on level, flat road surface. Apply parking brake
without fail and apply blocks to the tires.
･ Use ramps or dock plate of sufficient length, width and sufficient
strength. Secure it tightly to prevent it from being dislocated or
disengaged.
･ Take a right posture on the seat while operating.
If you operate the lift truck in a posture that your weight is not
properly applied to the seat, like standing up or leaning forward
or sideways, the travel interlock functions to cut off the
transmission of engine power. Then the lift truck may slither
down if the accelerator pedal is stepped on an uphill or a slope.
Operate the lift truck assisted by a signal person if necessary so
that you do not have to stand up or lean forward or sideways to
watch. For the travel interlock, see " TRAVEL INTERLOCK (PAGE
3-27)".
･ When using the ramp, make the gradient gentle, align the center
of both the trailer and the lift truck and lock the ramp securely to
prevent misalignment.
･ Never correct the course of the lift truck while on the ramps. If
course change is required, move off the ramps once and correct
the course direction.

1. Arrange for a trailer having adequate loading capacity for the

weight and size of a lift truck to transport.
2. Stop the trailer on level and flat road surface. Apply parking
brake without fail and apply blocks to the tyres.
3. Install the ramp, dock plate, etc. between the loading platform Ramp
of the trailer and the road surface and fix it securely so that it
would not be disengaged.
4. Instruct the trailer operator not to move the trailer until
loading/unloading of lift truck is completed. Blocks
5. When loading/unloading a lift truck to or from the trailer, drive
the lift truck at slow speed by sitting on the seat with right
posture.
6. To prevent a loaded forklift truck from moving during
transportation, apply blocks to the tyres and secure it with
wire rope and/or chain before starting the trailer.

4 - 56
INSPECTION AND MAINTENANCE 4.14 INSPECTION AND MAINTENANCE SCHEDULE CHART

4.14 INSPECTION AND MAINTENANCE SCHEDULE CHART

･ For other inspection and maintenance items not described in this manual, contact KOMATSU FORKLIFT
distributor.
･ Incorrect inspection, maintenance and repair services may cause critical accident or shorten lift truck service
life. For your safety operation, contact KOMATSU FORKLIFT distributor for inspection, maintenance and
repair services.

INSPECTION AND MAINTENANCE SCHEDULE CHART

[Q] indicates the intervals and time of inspection and maintenance by operating hours recommended by Komatsu
Utility.

Inspection & Maintenance Intervals (hours)

Mainte- Replace-
Every 2 Every 1 Every 3 Every 6 Every 1 Every 2 nance by ment
Inspection & Maintenance Item
At start-up weeks month months months year years operating Intervals
(100 h) (200 h) (600 h) (1200 h) (2400 h) (4800 h) time (month(s))
(h)
Engine proper
Startup condition and abnormal sound Q Q Q
Operation of preheater plug and heater Q Q
Exhaust gas color and sound Q Q Q Q
Idling speed Q Q Q Q
No-load max. speed Q
Acceleration Q Q Q Q
Tightening condition of cylinder head and
Q
manifold mounting bolts
Valve clearance Q Q 2000
Compression pressure Q 2000
Turbo-charger
Engine

Abnormal vibration, noise, gas leakage,

Q
lubricating oil leakage
Looseness of clamp, deterioration of hose Q 1000
Exhaust muffler and pipe
Gas leakage, looseness, damage Q Q
Engine mount
Crack, abnormal sound, deformation,
looseness and falling of bracket, damage and Q
deterioration of vibration proof rubber
Air cleaner
Contamination and damage of element Q Q Q
Crack, deformation and damage of case Q Q Q
Air cleaner element replacement Q 1200 6

4 - 57
4.14 INSPECTION AND MAINTENANCE SCHEDULE CHART INSPECTION AND MAINTENANCE

Inspection & Maintenance Intervals (hours)

Mainte- Replace-
Every 2 Every 1 Every 3 Every 6 Every 1 Every 2 nance by ment
Inspection & Maintenance Item
At start-up weeks month months months year years operating Intervals
(100 h) (200 h) (600 h) (1200 h) (2400 h) (4800 h) time (month(s))
(h)
Lubrication system
Oil level and contamination Q Q Q
Oil leakage Q Q Q Q
Oil pan oil replacement (*3) (*6) Q 500 3
Oil pan oil replacement
Q 200 1
(Gasoline engine lift truck) (*4)
Oil filter cartridge replacement (*6) Q 500 3
Oil filter cartridge replacement
Q 200 1
(Gasoline engine lift truck)
Fuel system
Fuel leakage Q Q Q Q
Fuel filter contamination and clogging Q
Fuel filter crack and damage Q
Fuel pre-filter water drain (*6) Q
Water separator water drain (*5) Q
Fuel pre-filter cartridge replacement (*1) Q 500
Fuel main filter cartridge replacement (*2) Q 1000
Fuel filter element cleaning
Q
(Gasoline engine lift truck)
Engine

Fuel tank crack and damage Q

Fuel tank oil level Q
Fuel tank cleaning Q
Checking for loose high-pressure piping
Q 4000
clamps, hardening of rubber (*6)
High-pressure piping clamps replacement (*6) 8000 24
Checking for missing fuel spray prevention
Q 4000
cap, hardening of rubber (*6)
Ignition system
Ignition timing Q Q
Ignition plug burn and damage Q Q
Distributor cap crack and damage Q
Contact point gap and burn Q
Cord damage and fitting Q
High-pressure fuel gas system
Gas leakage, feed pipe crack and damage,
gas cylinder mounting part looseness and Q Q
damage
Positive crankcase ventilation
Valve operation, piping clogging and damage Q

*1 Make initial replacement 250 hours after using the pre-filter cartridge on a new lift truck.
(Applied to models FD40Z, FD35, FD40, FD45, FD50A and their REF specification models.)
*2 Make initial replacement 500 hours after using the main filter cartridge on a new lift truck.
(Applied to models FD40Z, FD35, FD40, FD45, FD50A and their REF specification models.)
(Two fuel main filters are installed on the REF specification model.)
*3 Always use Komatsu Utility-designated oil for the diesel engine.
*4 Always use Komatsu Utility-designated oil for the gasoline engine.
*5 Applied to the REF specification models of FD40Z, FD35, FD40, FD45, FD50A.
*6 Applied to models FD40Z, FD35, FD40, FD45, FD50A and their REF specification models.

4 - 58
INSPECTION AND MAINTENANCE 4.14 INSPECTION AND MAINTENANCE SCHEDULE CHART

Inspection & Maintenance Intervals (hours)

Mainte- Replace-
Every 2 Every 1 Every 3 Every 6 Every 1 Every 2 nance by ment
Inspection & Maintenance Item
At start-up weeks month months months year years operating Intervals
(100 h) (200 h) (600 h) (1200 h) (2400 h) (4800 h) time (month(s))
(h)
Cooling system
Coolant level and contamination Q
Water leakage Q Q Q
Contamination, hose damage and
Q
deterioration, radiator cap function
Belt deflection, wear and damage Q Q Q Q
Fan cover crack, deformation and looseness Q
Engine

Engine controller
Mounting parts looseness, mount rubber crack
Q
and damage
Checking of water pump Q 4000
Carbon monoxide emission prevention device
Carbon monoxide emission prevention device
function, mounting part looseness, and Q
damage
Piping damage and mounting condition Q
Checking of starting motor Q 4000
Charger function Q
Electric devices

Battery
Oil level Q Q Q
Loosening and corrosion of terminal Q Q
Electrical wiring
Connecting part looseness and damage Q Q Q
Transmission
Oil level Q Q Q Q
Oil leakage and contamination Q Q Q Q
Inching pedal operating condition Q
Pedal height Q
Oil replacement Q 1200 6
Strainer replacement Q 1200 6
Line filter cartridge replacement Q 1200 6
Differential gear
Power train

Oil level Q Q Q Q
Oil leakage and contamination Q Q Q Q
Oil replacement Q 1200 6
Shift lever
Play and engagement condition Q
Installation condition Q
Forward/Reverse Lever
Lighting of neutral lamp Q
Drive shaft
Connecting part looseness Q Q
Runout, play, damage, crack and bearing play Q

4 - 59
4.14 INSPECTION AND MAINTENANCE SCHEDULE CHART INSPECTION AND MAINTENANCE

Inspection & Maintenance Intervals (hours)

Mainte- Replace-
Every 2 Every 1 Every 3 Every 6 Every 1 Every 2 nance by ment
Inspection & Maintenance Item
At start-up weeks month months months year years operating Intervals
(100 h) (200 h) (600 h) (1200 h) (2400 h) (4800 h) time (month(s))
(h)
Front axle
Crack, damage, deformation, mounting bolt
Q
looseness
Rear axle
Crack, damage, deformation, mounting bolt
Q
looseness
Traveling equipment

Center pin play, cap mounting bolt looseness Q

Wheel
Tyre inflation pressure Q Q Q Q
Tyre crack and damage Q Q Q Q
Tyre tread depth and abnormal wear Q Q Q Q
Play and abnormal noise of front wheel
Q Q Q
bearing
Play and abnormal noise of rear wheel bearing Q Q
Wheel installation condition Q
Disc and wheel nut and bolt looseness Q Q Q
Disc and wheel deformation, crack and
Q Q
damage
Steering wheel
Steering condition, tilt position adjustment and
Q Q Q
tilt position adjustment
Play, rattle, runout, unstable driving, returning
Q Q Q
condition, wheel play and rattle
Steering valve
Mounting part looseness Q
Oil leakage Q Q
Steering system

Rod and Arm

Looseness, play and damage Q Q
Knuckle
Connecting part play Q Q
King pin play, abnormal sound, crack, damage Q Q
Wheel
Fluctuation in min. turning radius Q
Contact of wheel with another part Q
Power steering cylinder
Oil leakage Q Q Q
Mounting condition, connecting part looseness Q Q
Hose pipe damage Q Q

4 - 60
INSPECTION AND MAINTENANCE 4.14 INSPECTION AND MAINTENANCE SCHEDULE CHART

Inspection & Maintenance Intervals (hours)

Mainte- Replace-
Every 2 Every 1 Every 3 Every 6 Every 1 Every 2 nance by ment
Inspection & Maintenance Item
At start-up weeks month months months year years operating Intervals
(100 h) (200 h) (600 h) (1200 h) (2400 h) (4800 h) time (month(s))
(h)
Brake pedal
Stroke and braking effect Q Q Q
Play and pedal height when depressed Q Q Q Q
Inching pedal operation Q
Brake disc
Disc wear and damage Q
Parking Brake
Operating effort Q Q Q Q
Braking effect Q Q Q Q
Rod, cable and link
Looseness, play, damage and missing cotter
Q
pin
Hose and Piping
Leakage, damage, and installation condition Q Q Q
Braking system

Reservoir Tank (Hydraulic tank)

Oil level Q Q Q Q
Contamination Q Q
Oil replacement Q 1200 6
Slack adjuster
Function, wear, damage and pipe crack Q
Oil leakage Q
Brake Valve
Abnormal sound, oil leakage, wear and
Q
damage
Operating condition Q
Accumulator for the brake
Checking of accumulator Q
Checking of sealed gas pressure and filling Q 2400
Center brake, drum and lining
Clearance and drum mounting part looseness Q Q
Spring fatigue, drum crack, damage, wear,
Q
lining peeling, damage and wear
Work equipment operating condition Q Q Q
Fork
Fork and fork stopper deformation, crack and
Q Q Q
Loading equipment

damage
Crack and wear at fork bottom and upper and
Q
lower hooks (by dye penetration check)
Opening, level difference and bend at fork tips Q
Mast and lift bracket
Mast deformation, crack, damage and wear Q Q Q
Mast roller wear and play and rack of pin Q
Play of mast support portion and loosening of
Q
mast cap mounting bolts

4 - 61
4.14 INSPECTION AND MAINTENANCE SCHEDULE CHART INSPECTION AND MAINTENANCE

Inspection & Maintenance Intervals (hours)

Mainte- Replace-
Every 2 Every 1 Every 3 Every 6 Every 1 Every 2 nance by ment
Inspection & Maintenance Item
At start-up weeks month months months year years operating Intervals
(100 h) (200 h) (600 h) (1200 h) (2400 h) (4800 h) time (month(s))
(h)
Chain and chain wheel
Crack, deformation, damage and corrosion of
Q Q
chain
Deformation, damage and play of chain wheel Q
Chain tension Q Q Q
Chain elongation Q
Chain lubrication Q 100
Load backrest
Mounting bolt looseness, crack, damage, and
Q Q Q
deformation
Loosening of tilt cylinder rod and locknut Q
Hydraulic pump
Oil leakage, abnormal vibration and abnormal
Q Q Q
sound
Lift cylinder and tilt cylinder
Operating condition and oil leakage Q Q Q
Loading equipment

Dent, crack, bend, scratch and loosening of

Q Q
bolt
Hydraulic drift and hydraulic forward tilt Q
Direction control valve Q
Operating condition and oil leakage Q Q Q
Play and loosening of mounting bolt Q Q
Relief pressure Q
Hydraulic oil tank
Hydraulic oil tank damage and crack Q
Replacement of oil in the tank Q 1200 6
Tank oil level, contamination and oil leakage Q Q Q
Tank cleaning Q
Air breather replacement Q 2400 12
Line filter replacement Q 1200 6
Strainer cleaning Q
Hydraulic piping
Piping damage, oil leakage and deformation Q Q Q
Piping clip looseness and unfastening Q Q
Solenoid valve operation, abnormal sound,
Q
abnormal heating and oil leakage

4 - 62
INSPECTION AND MAINTENANCE 4.14 INSPECTION AND MAINTENANCE SCHEDULE CHART

Inspection & Maintenance Intervals (hours)

Mainte- Replace-
Every 2 Every 1 Every 3 Every 6 Every 1 Every 2 nance by ment
Inspection & Maintenance Item
At start-up weeks month months months year years operating Intervals
(100 h) (200 h) (600 h) (1200 h) (2400 h) (4800 h) time (month(s))
(h)
Main body
Mounting bolt and nut looseness and damage Q Q
Cracks and deformation Q
Overhead guard
Mounting bolt looseness, deformation,
Q Q Q
damage and crack
Seat
Operation, mounting bolt looseness damage,
Q Q
and seat belt damage
Directional signal lamp
Lighting or flashing condition, contamination
Q Q Q
Safety devices, chassis, etc.

and damage
Alarm
Operation, sound volume and tone Q Q Q
Lighting device
(Head lamp, clearance lamp, brake lamp,
backup lamp) Lighting or flashing condition, Q Q Q
contamination and damage
Instrument function, mounting condition,
Q Q Q
breakage and water entry
Center mirror
Contamination, damage, reflection and
Q Q Q
installation condition
Lubrication Q Q
Backup buzzer performance Q
Display board damage and installation
Q
condition
Abnormality found on preceding day Q
Safety device function
(Travel lock, lift interlock and neutral safety) Q
Warning buzzer operation Q
Function of each device Q Q Q
Comprehensive Test

Abnormal vibration, noise, odor and heating Q

4 - 63
4.15 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS INSPECTION AND MAINTENANCE

4.15 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

For your safety use of lift trucks, you are requested to always implement periodic replacement of parts listed in
the Periodic Replacement of Safety Critical Parts below related particularly to the safety and fires.
The material of these parts may change over time, or may easily wear or deteriorate. However, as it is difficult to
judge the condition of the parts simply by periodic maintenance, they should always be replaced after a fixed time
has passed, regardless of their condition. This is necessary to ensure that their full function is always maintained.
However, 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 sign of deterioration such as deformation or cracking, replace them with the hoses
at the same time.
Note that the periodic replacement is not covered by warranty.

IMPORTANT PARTS LIST

No. Part name Years elapsed
1 Fuel hose (Fuel tank - Fuel pre-filter) (*) 2
2 Fuel hose (Fuel pre-filter - Fuel main filter) (*) 2
3 Fuel hose (Supply pump inlet) (*) 2
4 Fuel hose (Engine - Fuel tank) 2
5 Brake hose or tube 2
6 Brake tank and tube 2
7 Power steering hose 2
8 Stop lamp switch (hydraulic type) 2
9 Rubber parts inside power steering system 2
10 Lift chain 2-4
11 Hydraulic hose (For travel, load handling and torque converter) 2
12 Engine high-pressure piping clamp (*) (8000 hours)
13 Fuel spray prevention cap (*) (8000 hours)
14 Engine oil filter hose (Engine - Filter hose) 2
15 Engine controller mount rubber (*) 2

* Applied to diesel engine lift truck

4 - 64
INSPECTION AND MAINTENANCE 4.16 SERVICE DATA

4.16 SERVICE DATA

Service data (Gasoline engine lift truck)
Device Inspection item Unit FG40Z-10 FG35-10 FG40-10
Engine model - EBT-TB45-1A
Idling speed rpm 700 - 800
Engine proper
Max. speed rpm 2350 - 2450
Compression MPa {kgf/cm2}/rpm 1.19 {12.1}/200
Fan belt tension
Lubricating oil
(98 N {10 kgf} finger mm 15 - 17
cooling system
pressure)
Injection timing deg-BTDC -
Engine

Fuel system Injection order - -

Injection pressure MPa {kgf/cm2} -
Intake, exhaust Intake mm 0.35 (Warm)
Valve clearance
system Exhaust mm 0.35 (Warm)
Distributor point gap - -
Spark plug gap mm mm 0.8 - 0.9
Electric system Spark plug type - NGK-BPR4ES-D
Ignition timing deg-BTDC /rpm 10/750
Firing order - 1-5-3-6-2-4
Tyre inflation Front kPa {kgf/cm2} 835 {8.5} 685 {7.0} 785 {8.0}
Traveling equipment

Tyre
pressure Rear kPa {kgf/cm2} 835 {8.5} 835 {8.5} 835 {8.5}
Front Nm {kgfm} 294 - 490 {30 - 50}
Hub nut Tightening torque
Rear Nm {kgfm} 294 - 490 {30 - 50}
Front Nm {kgfm} 294 - 490 {30 - 50}
Rim mating
Tightening torque
nuts Rear Nm {kgfm} 294 - 490 {30 - 50}
Play (At the time of a pump
Steering wheel mm 10 - 30
operation)
Play mm 0-4
Steering and brake systems

Inching pedal
Interconnected stroke mm 53 - 57
Play mm 0-4
Brake pedal Height of pedal when
mm 82 - 86
depressed
Parking brake operating
N {kgf} 54 {5.5}
force
Installation of back plate
Parking brake Nm {kgfm} 59- 74 {6 - 7.5}
Tightening torque of bolt
Brake accumulator gas
MPa {kgf/cm2} 3.43±0.1 {35±1.0}
pressure (20°C)
Fork Fork thickness (at base) mm Min. 48 Min. 48 Min. 50
Loading equipment

Chain Length over 17 links mm Max. 440

Hydraulic
Relief pressure MPa {kgf/cm2} 20.6 {210}
system

4 - 65
4.16 SERVICE DATA INSPECTION AND MAINTENANCE

Device Inspection item Unit FG45-10 FG50A-10

Engine model - EBT-TB45-1A
Idling speed rpm 700 - 800
Engine proper
Max. speed rpm 2350 - 2450
Compression MPa {kgf/cm2}/rpm 1.19 {12.1}/200
Fan belt tension
Lubricating oil
(98 N {10 kgf} finger mm 15 - 17
cooling system
pressure)
Injection timing deg-BTDC -
Engine

Fuel system Injection order - -

Injection pressure MPa {kgf/cm2} -
Intake, exhaust Intake mm 0.35 (Warm)
Valve clearance
system Exhaust mm 0.35 (Warm)
Distributor point gap - -
Spark plug gap mm mm 0.8 - 0.9
Electric system Spark plug type - NGK-BPR4ES-D
Ignition timing deg-BTDC/rpm 10/750
Firing order - 1-5-3-6-2-4
Tyre inflation Front kPa {kgf/cm2} 785 {8.0} 785 {8.0}
Traveling equipment

Tyre
pressure Rear kPa {kgf/cm2} 835 {8.5} 980 {10.0}
Front Nm {kgfm} 294 - 490 {30 - 50}
Hub nut Tightening torque
Rear Nm {kgfm} 294 - 490 {30 - 50}
Front Nm {kgfm} 294 - 490 {30 - 50}
Rim mating
Tightening torque
nuts Rear Nm {kgfm} 294 - 490 {30 - 50}
Play (At the time of a pump
Steering wheel mm 10 - 30
operation)
Play mm 0-4
Steering and brake systems

Inching pedal
Interconnected stroke mm 53 - 57
Play mm 0-4
Brake pedal Height of pedal when
mm 82 - 86
depressed
Parking brake operating
N {kgf} 54 {5.5}
force
Installation of back plate
Parking brake Nm {kgfm} 59- 74 {6 - 7.5}
Tightening torque of bolt
Brake accumulator gas
MPa {kgf/cm2} 3.43±0.1 {35±1.0}
pressure (20°C)
Fork Fork thickness (at base) mm Min. 50 Min. 50
Loading equipment

Chain Length over 17 links mm Max. 440

Hydraulic
Relief pressure MPa {kgf/cm2} 20.6 {210}
system

4 - 66
INSPECTION AND MAINTENANCE 4.16 SERVICE DATA

Service data (Diesel engine lift truck)

Device Inspection item Unit FD40Z-10 FD35-10 FD40-10
Engine model - SAA4D95LE-5-A
Idling speed rpm 800±25
Engine proper
Max. speed rpm 2550±25
Compression MPa {kgf/cm2}/rpm Min. 2.9 {Min. 30}/150 - 250
Fan belt tension
Lubricating oil
(58.8N {Approx. 6 kgf} mm 7 - 10
cooling system
finger pressure)
Injection timing deg-BTDC Electronic control system
Engine

Fuel system Injection order - 1-2-4-3

Injection pressure MPa {kgf/cm2} 25.4 - 108 {250 - 1100}
Intake, exhaust Valve clearance Intake mm 0.35 (Cold)
system Exhaust mm 0.50 (Cold)
Distributor point gap - -
Spark plug gap mm mm -
Electric system Spark plug type - -
Ignition timing deg-BTDC/rpm -
Firing order - -
Tyre inflation Front kPa {kgf/cm2} 835 {8.5} 685 {7.0} 785 {8.0}
Traveling equipment

Tyre
pressure Rear kPa {kgf/cm2} 835 {8.5} 835 {8.5} 835 {8.5}
Front Nm {kgfm} 294 - 490 {30 - 50}
Hub nut Tightening torque
Rear Nm {kgfm} 294 - 490 {30 - 50}
Front Nm {kgfm} 294 - 490 {30 - 50}
Rim mating
Tightening torque
nuts Rear Nm {kgfm} 294 - 490 {30 - 50}
Play (At the time of a pump
Steering wheel mm 10 - 30
operation)
Play mm 0-4
Steering and brake systems

Inching pedal
Interconnected stroke mm 53 - 57
Play mm 0-4
Brake pedal Height of pedal when
mm 82 - 86
depressed
Parking brake operating
N {kgf} 54 {5.5}
force
Installation of back plate
Parking brake Nm {kgfm} 59- 74 {6 - 7.5}
Tightening torque of bolt
Brake accumulator gas
MPa {kgf/cm2} 3.43±0.1 {35±1.0}
pressure (20°C)
Fork Fork thickness (at base) mm Min. 48 Min. 48 Min. 50
Loading equipment

Chain Length over 17 links mm Max. 440

Hydraulic
Relief pressure MPa {kgf/cm2} 20.6 {210}
system

4 - 67
4.16 SERVICE DATA INSPECTION AND MAINTENANCE

Device Inspection item Unit FD45-10 FD50A-10

Engine model - SAA4D95LE-5-A
Idling speed rpm 800±25
Engine proper
Max. speed rpm 2550±25
Compression MPa {kgf/cm2}/rpm Min. 2.9 {Min. 30}/150 - 250
Fan belt tension
Lubricating oil
(58.8N {Approx. 6 kgf} mm 7 - 10
cooling system
finger pressure)
Injection timing deg-BTDC Electronic control system
Engine

Fuel system Injection order - 1-2-4-3

Injection pressure MPa {kgf/cm2} 25.4 - 108 {250 - 1100}
Intake, exhaust Intake mm 0.35 (Cold)
Valve clearance
system Exhaust mm 0.50 (Cold)
Distributor point gap - -
Spark plug gap mm mm -
Electric system Spark plug type - -
Ignition timing deg-BTDC/rpm -
Firing order - -
Tyre inflation Front kPa {kgf/cm2} 785 {8.0} 785 {8.0}
Traveling equipment

Tyre
pressure Rear kPa {kgf/cm2} 835 {8.5} 985 {10.0}
Front Nm {kgfm} 294 - 490 {30 - 50}
Hub nut Tightening torque
Rear Nm {kgfm} 294 - 490 {30 - 50}
Front Nm {kgfm} 294 - 490 {30 - 50}
Rim mating
Tightening torque
nuts Rear Nm {kgfm} 294 - 490 {30 - 50}
Play (At the time of a pump
Steering wheel mm 10 - 30
operation)
Play mm 0-4
Steering and brake systems

Inching pedal
Interconnected stroke mm 53 - 57
Play mm 0-4
Brake pedal Height of pedal when
mm 82 - 86
depressed
Parking brake operating
N {kgf} 54 {5.5}
force
Installation of back plate
Parking brake Nm {kgfm} 59- 74 {6 - 7.5}
Tightening torque of bolt
Brake accumulator gas
MPa {kgf/cm2} 3.43±0.1 {35±1.0}
pressure (20°C)
Fork Fork thickness (at base) mm Min. 50 Min. 50
Loading equipment

Chain Length over 17 links mm Max. 440

Hydraulic
Relief pressure MPa {kgf/cm2} 20.6 {210}
system

4 - 68
INSPECTION AND MAINTENANCE 4.16 SERVICE DATA

Device Inspection item Unit FD40ZY-10 FD35Y-10 FD40Y-10

Engine model - S4D95LE-3
Idling speed rpm 800+50
0
Engine proper
Max. speed rpm 2650±50
Compression MPa {kgf/cm2}/rpm Min. 2.9 {Min. 30}/150 - 250
Fan belt tension
Lubricating oil
(58.8N {Approx. 6 kgf} mm 7 - 10
cooling system
finger pressure)
Injection timing deg-BTDC 5±0.75°
Engine

Fuel system Injection order - 1-2-4-3

Injection pressure MPa {kgf/cm2} 20.1 - 21.1 {205 - 215}
Intake, exhaust Valve clearance Intake mm 0.35 (Cold)
system Exhaust mm 0.50 (Cold)
Distributor point gap - -
Spark plug gap mm mm -
Electric system Spark plug type - -
Ignition timing deg-BTDC/rpm -
Firing order - -
Tyre inflation Front kPa {kgf/cm2} 835 {8.5} 685 {7.0} 785 {8.0}
Traveling equipment

Tyre
pressure Rear kPa {kgf/cm2} 835 {8.5} 835 {8.5} 835 {8.5}
Front Nm {kgfm} 294 - 490 {30 - 50}
Hub nut Tightening torque
Rear Nm {kgfm} 294 - 490 {30 - 50}
Front Nm {kgfm} 294 - 490 {30 - 50}
Rim mating
Tightening torque
nuts Rear Nm {kgfm} 294 - 490 {30 - 50}
Play (At the time of a pump
Steering wheel mm 10 - 30
operation)
Play mm 0-4
Steering and brake systems

Inching pedal
Interconnected stroke mm 53 - 57
Play mm 0-4
Brake pedal Height of pedal when
mm 82 - 86
depressed
Parking brake operating
N {kgf} 54 {5.5}
force
Installation of back plate
Parking brake Nm {kgfm} 59- 74 {6 - 7.5}
Tightening torque of bolt
Brake accumulator gas
MPa {kgf/cm2} 3.43±0.1 {35±1.0}
pressure (20°C)
Fork Fork thickness (at base) mm Min. 48 Min. 48 Min. 50
Loading equipment

Chain Length over 17 links mm Max. 440

Hydraulic
Relief pressure MPa {kgf/cm2} 20.6 {210}
system

4 - 69
4.16 SERVICE DATA INSPECTION AND MAINTENANCE

Device Inspection item Unit FD45Y-10 FD50AY-10

Engine model - S4D95LE-3
Idling speed rpm 800 +50
0
Engine proper
Max. speed rpm 2650±50
Compression MPa {kgf/cm2}/rpm Min. 2.9 {Min. 30}/150 - 250
Fan belt tension
Lubricating oil
(58.8N {Approx. 6 kgf} mm 7 - 10
cooling system
finger pressure)
Injection timing deg-BTDC 5±0.75°
Engine

Fuel system Injection order - 1-2-4-3

Injection pressure MPa {kgf/cm2} 20.1 - 21.1 {205 - 215}
Intake, exhaust Intake mm 0.35 (Cold)
Valve clearance
system Exhaust mm 0.50 (Cold)
Distributor point gap - -
Spark plug gap mm mm -
Electric system Spark plug type - -
Ignition timing deg-BTDC/rpm -
Firing order - -
Tyre inflation Front kPa {kgf/cm2} 785 {8.0} 785 {8.0}
Traveling equipment

Tyre
pressure Rear kPa {kgf/cm2} 835 {8.5} 985 {10.0}
Front Nm {kgfm} 294 - 490 {30 - 50}
Hub nut Tightening torque
Rear Nm {kgfm} 294 - 490 {30 - 50}
Front Nm {kgfm} 294 - 490 {30 - 50}
Rim mating
Tightening torque
nuts Rear Nm {kgfm} 294 - 490 {30 - 50}
Play (At the time of a pump
Steering wheel mm 10 - 30
operation)
Play mm 0-4
Steering and brake systems

Inching pedal
Interconnected stroke mm 53 - 57
Play mm 0-4
Brake pedal Height of pedal when
mm 82 - 86
depressed
Parking brake operating
N {kgf} 54 {5.5}
force
Installation of back plate
Parking brake Nm {kgfm} 59- 74 {6 - 7.5}
Tightening torque of bolt
Brake accumulator gas
MPa {kgf/cm2} 3.43±0.1 {35±1.0}
pressure (20°C)
Fork Fork thickness (at base) mm Min. 50 Min. 50
Loading equipment

Chain Length over 17 links mm Max. 440

Hydraulic
Relief pressure MPa {kgf/cm2} 20.6 {210}
system

4 - 70
INSPECTION AND MAINTENANCE 4.16 SERVICE DATA

BOLT TIGHTENING TORQUE

･ For unspecified metric bolts and nuts, use the torques specified
in this list.
･ Select a proper torque corresponding to the width across flats
(b) of bolts and nuts.
･ When replacing bolts and nuts, always use genuine Komatsu
Utility parts of the same size as the previous ones.

Thread outside diameter Width across flats Tightening torque Nm {kgfm}

(a) mm (b) mm Within target Allowable range
6 10 13 {1.35} 12 - 15 {1.2 - 1.5}
8 13 31 {3.2} 27 - 34 {2.8 - 3.5}
10 17 66 {6.7} 59 - 74 {6.0 - 7.5}
12 19 113 {11.5} 98 - 123 {10.0 - 12.5}
14 22 177 {18.0} 157 - 196 {16.0 - 20.0}
16 24 279 {28.5} 245 - 309 {25.0 - 31.5}
18 27 382 {39.0} 343 - 427 {35.0 - 43.5}
20 30 549 {56.0} 490 - 608 {50.0 - 62.0}
22 32 745 {76.0} 662 - 829 {67.5 - 84.5}
24 36 927 {94.5} 824 - 1030 {84.0 - 105.0}
27 41 1324 {135.0} 1177 - 1471 {120.0 0- 150.0}
30 46 1716 {175.0} 1520 - 1912 {155.0 - 195.0}
33 50 2206 {225.0} 1961 - 2452 {200.0 - 250.0}
36 55 2746 {280.0} 2452 - 3040 {250.0 - 310.0}
39 60 3285 {335.0} 2893 - 3628 {295.0 - 370.0}

4 - 71
TECHNICAL DATA 5

25

5-1
 TECHNICAL DATA

5. TECHNICAL DATA

5-2
TECHNICAL DATA

GASOLINE ENGINE LIFT TRUCK

1.2 Model Manufacturer's Designation FG40Z-10 FG35-10 FG40-10

1.3 Power Type Electric, Diesel, Gasoline, LPG, Cable Gasoline Gasoline Gasoline
Characteristics

1.4 Operation Type Sitting Sitting Sitting

1.5 Rated Capacity Q Rated Capacity kg 4000 3500 4000
1.6 Load Center c Rated Load Center mm 500 600 600
1.8 Load Distance x Front Axle Center to Fork Face mm 540 575 580
1.9 Wheelbase y mm 1800 2000 2000
2.1 Service Weight kg 5685 5740 6215
2.2 Front kg 7935 8080 8885
Weight

Loaded
2.2.1 Rear kg 1250 1160 1330
Axle Loading
2.3 Front kg 2215 2525 2525
Unloaded
2.3.1 Rear kg 3470 3215 3690
3.1 Tyre Type Pneumatic Pneumatic Pneumatic
3.2 Front 250-15-16PR(I) 8.25-15-12PR(I) 300-15-18PR(I)
Tyre Size
3.3 Rear 7.00-12-12PR(I) 7.00-12-12PR(I) 7.00-12-12PR(I)
Tyres

3.5 Number of Wheel Front/Rear (x=driven) 2×/2 2×/2 2×/2

3.6 Tread, Front b10 mm 1115 1115 1150
3.7 Tread, Rear b11 mm 1120 1120 1120
4.1 Tilting Angle α/β Forward/Backward degree 6/12 6/12 6/12
4.2 Mast Height, Lowered h1 2-stage Mast mm 2100 2105 2105
4.3 Std. Free Lift h2 2-stage Std. Mast, from Ground mm 155 155 160
4.4 Std. Lift Height h3 2-stage Std. Mast, from Ground mm 3000 3000 3000
4.5 Mast Height, Extended h4 2-stage Std. Mast mm 4130 4130 4130
4.7 Height, Overhead Guard h6 mm 2210 2250 2250
4.19 Length, with Std. Forks l1 mm 4025 4155 4220
Dimensions

4.20 Length, to Fork Face l2 mm 2955 3085 3150

4.21 Width, at Tyre b1 Single mm 1350 1350 1450
4.22 Forks s/e/l Thickness × Width × Length mm 50×150×1070 50×150×1070 50×150×1070
4.23 Fork Carriage Class ISO 2328, Type A/B/no Class3, A Class3, A Class3, A
4.24 Width, Fork Carriage b3 mm 1190 1190 1190
4.31 m1 Under Mast mm 140 145 145
Ground Clearance
4.32 m2 at Center of Wheelbase mm 175 225 220
4.33 Right Angle Stacking Ast with L1000 × W1200 pallet mm 4120 4305 4350
4.34 Aisle Ast with L1200 × W800 pallet mm 4320 4505 4550
4.35 Turning Radius Wa mm 2580 2730 2770
Loaded, 1st/2nd km/h 19.0/- 19.5/- 19.5/-
5.1 Travel Speed (FWD)
Unloaded, 1st/2nd km/h 19.0/- 19.5/- 19.5/-
Loaded mm/s 510 510 510
5.2 Lifting Speed
Unloaded mm/s 510 510 510
Performance

Loaded mm/s 500 500 500

5.3 Lowering Speed
Unloaded mm/s 500 500 500
5.6 Max. Drawbar Pull Loaded kN 24 24 24
5.8 Max. Gradeability Loaded % 28 25 25
5.10 Service Brake Operation/Type Foot/Wet disc Foot/Wet disc Foot/Wet disc
5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical Hand/Mechanical
5.12 Steering Type FHPS FHPS FHPS
6.4 Battery Voltage/Capacity at 5-hour rating V/ah 12/64 12/64 12/64
NISSAN NISSAN NISSAN
7.1 Maker Model
TB45 TB45 TB45
7.2 Rated Output, SAE net kW 62.5 62.5 62.5
I.C Engine

7.3 Rated RPM min-1 2400 2400 2400

7.3.1 Max. Torque, SAE net Nm@min-1 275@1600 275@1600 275@1600
No. of Cylinder/
7.4 cm3 6-4478 6-4478 6-4478
Displacement
7.6 Fuel Tank Capacity Ltr 76 98 98
Relief Pressure for
Others

8.2 bar 206 206 206

Attachment
8.7 Transmission TORQFLOW TORQFLOW TORQFLOW
Machine Directive 98/37/EEC SOUND PRESSURE level at driver's ear (LPA)*1 dB(A) 108 108 108
VIBRATION in accordance with EN 13059 (m/s2)*2 m/s2 1.14 1.14 1.14
*1: Persistent sound pressure level to en 12053. the persistent sound level is a value determined according to the standard and takes into account the sound pressure level during driving, lifting and on idle.
The sound pressure level is measured at the driver`s ear.
*2: The vibration level in this manual is a value determined according to the EN13059 standard, and it differs from the daily exposure limit value for whole-body vibration set by the directive 2002/44/EC.
The personal vibration load to the driver for one work day must be determined, if necessary, at the site of operation to take all other influencing factors such as road stretch, intensity of operation, etc., into
consideration.

5-3
 TECHNICAL DATA

1.2 Model Manufacturer's Designation FG45-10 FG50A-10

1.3 Power Type Electric, Diesel, Gasoline, LPG, Cable Gasoline Gasoline
Characteristics

1.4 Operation Type Sitting Sitting

1.5 Rated Capacity Q Rated Capacity kg 4500 5000
1.6 Load Center c Rated Load Center mm 600 600
1.8 Load Distance x Front Axle Center to Fork Face mm 590 575
1.9 Wheelbase y mm 2000 2000
2.1 Service Weight kg 6800 7240
2.2 Front kg 9915 10785
Weight

Loaded
2.2.1 Rear kg 1385 1455
Axle Loading
2.3 Front kg 2735 2850
Unloaded
2.3.1 Rear kg 4065 4390
3.1 Tyre Type Pneumatic Pneumatic
3.2 Front 300-15-18PR(I) 300-15-18PR(I)
Tyre Size
3.3 Rear 7.00-12-12PR(I) 7.00-12-14PR(I)
Tyres

3.5 Number of Wheel Front/Rear (x=driven) 2×/2 2×/2

3.6 Tread, Front b10 mm 1150 1150
3.7 Tread, Rear b11 mm 1120 1120
4.1 Tilting Angle α/β Forward/Backward degree 6/12 6/12
4.2 Mast Height, Lowered h1 2-stage Mast mm 2205 2205
4.3 Std. Free Lift h2 2-stage Std. Mast, from Ground mm 145 145
4.4 Std. Lift Height h3 2-stage Std. Mast, from Ground mm 3000 3000
4.5 Mast Height, Extended h4 2-stage Std. Mast mm 4130 4345
4.7 Height, Overhead Guard h6 mm 2250 2250
4.19 Length, with Std. Forks l1 mm 4270 4405
Dimensions

4.20 Length, to Fork Face l2 mm 3200 3185

4.21 Width, at Tyre b1 Single mm 1450 1450
4.22 Forks s/e/l Thickness × Width × Length mm 55×150×1070 55×150×1220
4.23 Fork Carriage Class ISO 2328, Type A/B/no Class3, A Class4, A
4.24 Width, Fork Carriage b3 mm 1190 1270
4.31 m1 Under Mast mm 145 145
Ground Clearance
4.32 m2 at Center of Wheelbase mm 220 220
4.33 Right Angle Stacking Ast with L1000 × W1200 pallet mm 4410 4425
4.34 Aisle Ast with L1200 × W800 pallet mm 4610 4625
4.35 Turning Radius Wa mm 2820 2850
Loaded, 1st/2nd km/h 16.5/24.0 15.5/24.5
5.1 Travel Speed (FWD)
Unloaded, 1st/2nd km/h 16.5/24.0 15.5/24.5
Loaded mm/s 440 440
5.2 Lifting Speed
Unloaded mm/s 440 440
Performance

Loaded mm/s 500 500

5.3 Lowering Speed
Unloaded mm/s 500 500
5.6 Max. Drawbar Pull Loaded kN 28 28
5.8 Max. Gradeability Loaded % 26 25
5.10 Service Brake Operation/Type Foot/Wet disc Foot/Wet disc
5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical
5.12 Steering Type FHPS FHPS
6.4 Battery Voltage/Capacity at 5-hour rating V/ah 12/64 12/64
NISSAN NISSAN
7.1 Maker Model
TB45 TB45
7.2 Rated Output, SAE net kW 62.5 62.5
I.C Engine

7.3 Rated RPM min-1 2400 2400

7.3.1 Max. Torque, SAE net Nm@min-1 275@1600 275@1600
No. of Cylinder/ 3
7.4 cm 6-4478 6-4478
Displacement
7.6 Fuel Tank Capacity Ltr 98 98
Relief Pressure for
Others

8.2 bar 206 206

Attachment
8.7 Transmission TORQFLOW TORQFLOW
Machine Directive 98/37/EEC SOUND PRESSURE level at driver's ear (LPA)*1 dB(A) 108 108
VIBRATION in accordance with EN 13059 (m/s2)*2 m/s2 1.14 1.14
*1: Persistent sound pressure level to en 12053. the persistent sound level is a value determined according to the standard and takes into account the sound pressure level during driving, lifting and on idle.
The sound pressure level is measured at the driver`s ear.
*2: The vibration level in this manual is a value determined according to the EN13059 standard, and it differs from the daily exposure limit value for whole-body vibration set by the directive 2002/44/EC.
The personal vibration load to the driver for one work day must be determined, if necessary, at the site of operation to take all other influencing factors such as road stretch, intensity of operation, etc., into
consideration.

5-4
TECHNICAL DATA

DIESEL ENGINE LIFT TRUCK

1.2 Model Manufacturer's Designation FD40Z-10 FD35-10 FD40-10

1.3 Power Type Electric, Diesel, Gasoline, LPG, Cable Diesel Diesel Diesel
Characteristics

1.4 Operation Type Sitting Sitting Sitting

1.5 Rated Capacity Q Rated Capacity kg 4000 3500 4000
1.6 Load Center c Rated Load Center mm 500 600 600
1.8 Load Distance x Front Axle Center to Fork Face mm 540 575 580
1.9 Wheelbase y mm 1800 2000 2000
2.1 Service Weight kg 5735 5790 6270
2.2 Front kg 7980 8115 8920
Weight

Loaded
2.2.1 Rear kg 1255 1175 1350
Axle Loading
2.3 Front kg 2260 2560 2560
Unloaded
2.3.1 Rear kg 3475 3230 3710
3.1 Tyre Type Pneumatic Pneumatic Pneumatic
3.2 Front 250-15-16PR(I) 8.25-15-12PR(I) 300-15-18PR(I)
Tyre Size
3.3 Rear 7.00-12-12PR(I) 7.00-12-12PR(I) 7.00-12-12PR(I)
Tyres

3.5 Number of Wheel Front/Rear (x=driven) 2×/2 2×/2 2×/2

3.6 Tread, Front b10 mm 1115 1115 1150
3.7 Tread, Rear b11 mm 1120 1120 1120
4.1 Tilting Angle α/β Forward/Backward degree 6/12 6/12 6/12
4.2 Mast Height, Lowered h1 2-stage Mast mm 2100 2105 2105
4.3 Std. Free Lift h2 2-stage Std. Mast, from Ground mm 155 155 160
4.4 Std. Lift Height h3 2-stage Std. Mast, from Ground mm 3000 3000 3000
4.5 Mast Height, Extended h4 2-stage Std. Mast mm 4130 4130 4130
4.7 Height, Overhead Guard h6 mm 2210 2250 2250
4.19 Length, with Std. Forks l1 mm 4025 4155 4220
Dimensions

4.20 Length, to Fork Face l2 mm 2955 3085 3150

4.21 Width, at Tyre b1 Single mm 1350 1350 1450
4.22 Forks s/e/l Thickness × Width × Length mm 50×150×1070 55×150×1070 55×150×1070
4.23 Fork Carriage Class ISO 2328, Type A/B/no Class3, A Class3, A Class3, A
4.24 Width, Fork Carriage b3 mm 1190 1190 1190
4.31 m1 Under Mast mm 140 145 145
Ground Clearance
4.32 m2 at Center of Wheelbase mm 175 225 220
4.33 Right Angle Stacking Ast with L1000 × W1200 pallet mm 4120 4305 4350
4.34 Aisle Ast with L1200 × W800 pallet mm 4320 4505 4550
4.35 Turning Radius Wa mm 2580 2730 2770
Loaded, 1st/2nd km/h 18.0/- 18.5/- 18.0/-
5.1 Travel Speed (FWD)
Unloaded, 1st/2nd km/h 19.0/- 19.5/- 19.0/-
Loaded mm/s 540 540 540
5.2 Lifting Speed
Unloaded mm/s 560 560 560
Performance

Loaded mm/s 500 500 500

5.3 Lowering Speed
Unloaded mm/s 500 500 500
5.6 Max. Drawbar Pull Loaded kN 27 27 27
5.8 Max. Gradeability Loaded % 30 28 28
5.10 Service Brake Operation/Type Foot/Wet disc Foot/Wet disc Foot/Wet disc
5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical Hand/Mechanical
5.12 Steering Type FHPS FHPS FHPS
6.4 Battery Voltage/Capacity at 5-hour rating V/ah 12/64 12/64 12/64
KOMATSU KOMATSU KOMATSU
7.1 Maker Model
SAA4D95LE-5-A SAA4D95LE-5-A SAA4D95LE-5-A
7.2 Rated Output, SAE net kW 59.7 59.7 59.7
I.C Engine

7.3 Rated RPM min-1 2400 2400 2400

7.3.1 Max. Torque, SAE net Nm@min-1 321@1600 321@1600 321@1600
No. of Cylinder/ 3
7.4 cm 4-3260 4-3260 4-3260
Displacement
7.6 Fuel Tank Capacity Ltr 76 98 98
Relief Pressure for
Others

8.2 bar 206 206 206

Attachment
8.7 Transmission TORQFLOW TORQFLOW TORQFLOW
Machine Directive 98/37/EEC SOUND PRESSURE level at driver's ear (LPA)*1 dB(A) 109 109 109
VIBRATION in accordance with EN 13059 (m/s2)*2 m/s2 1.14 1.14 1.14
*1: Persistent sound pressure level to en 12053. the persistent sound level is a value determined according to the standard and takes into account the sound pressure level during driving, lifting and on idle.
The sound pressure level is measured at the driver`s ear.
*2: The vibration level in this manual is a value determined according to the EN13059 standard, and it differs from the daily exposure limit value for whole-body vibration set by the directive 2002/44/EC.
The personal vibration load to the driver for one work day must be determined, if necessary, at the site of operation to take all other influencing factors such as road stretch, intensity of operation, etc., into
consideration.

5-5
 TECHNICAL DATA

1.2 Model Manufacturer's Designation FD45-10 FD50A-10

1.3 Power Type Electric, Diesel, Gasoline, LPG, Cable Diesel Diesel
Characteristics

1.4 Operation Type Sitting Sitting

1.5 Rated Capacity Q Rated Capacity kg 4500 5000
1.6 Load Center c Rated Load Center mm 600 600
1.8 Load Distance x Front Axle Center to Fork Face mm 590 575
1.9 Wheelbase y mm 2000 2000
2.1 Service Weight kg 6855 7295
2.2 Front kg 9950 10820
Weight

Loaded
2.2.1 Rear kg 1405 1475
Axle Loading
2.3 Front kg 2770 2885
Unloaded
2.3.1 Rear kg 4085 4410
3.1 Tyre Type Pneumatic Pneumatic
3.2 Front 300-15-18PR(I) 300-15-18PR(I)
Tyre Size
3.3 Rear 7.00-12-12PR(I) 7.00-12-14PR(I)
Tyres

3.5 Number of Wheel Front/Rear (x=driven) 2×/2 2×/2

3.6 Tread, Front b10 mm 1150 1150
3.7 Tread, Rear b11 mm 1120 1120
4.1 Tilting Angle α/β Forward/Backward degree 6/12 6/12
4.2 Mast Height, Lowered h1 2-stage Mast mm 2205 2205
4.3 Std. Free Lift h2 2-stage Std. Mast, from Ground mm 145 145
4.4 Std. Lift Height h3 2-stage Std. Mast, from Ground mm 3000 3000
4.5 Mast Height, Extended h4 2-stage Std. Mast mm 4130 4345
4.7 Height, Overhead Guard h6 mm 2250 2250
4.19 Length, with Std. Forks l1 mm 4270 4405
Dimensions

4.20 Length, to Fork Face l2 mm 3200 3185

4.21 Width, at Tyre b1 Single mm 1450 1450
4.22 Forks s/e/l Thickness × Width × Length mm 55×150×1070 55×150×1220
4.23 Fork Carriage Class ISO 2328, Type A/B/no Class3, A Class4, A
4.24 Width, Fork Carriage b3 mm 1190 1270
4.31 m1 Under Mast mm 145 145
Ground Clearance
4.32 m2 at Center of Wheelbase mm 220 220
4.33 Right Angle Stacking Ast with L1000 × W1200 pallet mm 4410 4425
4.34 Aisle Ast with L1200 × W800 pallet mm 4610 4625
4.35 Turning Radius Wa mm 2820 2850
Loaded, 1st/2nd km/h 14.5/24.0 14.5/24.0
5.1 Travel Speed (FWD)
Unloaded, 1st/2nd km/h 15.5/25.0 15.5/25.0
Loaded mm/s 470 470
5.2 Lifting Speed
Unloaded mm/s 480 480
Performance

Loaded mm/s 500 500

5.3 Lowering Speed
Unloaded mm/s 500 500
5.6 Max. Drawbar Pull Loaded kN 33 33
5.8 Max. Gradeability Loaded % 29 28
5.10 Service Brake Operation/Type Foot/Wet disc Foot/Wet disc
5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical
5.12 Steering Type FHPS FHPS
6.4 Battery Voltage/Capacity at 5-hour rating V/ah 12/64 12/64
KOMATSU KOMATSU
7.1 Maker Model
SAA4D95LE-5-A SAA4D95LE-5-A
7.2 Rated Output, SAE net kW 59.7 59.7
I.C Engine

7.3 Rated RPM min-1 2400 2400

7.3.1 Max. Torque, SAE net Nm@min-1 321@1600 321@1600
No. of Cylinder/ 3
7.4 cm 4-3260 4-3260
Displacement
7.6 Fuel Tank Capacity Ltr 98 98
Relief Pressure for
Others

8.2 bar 206 206

Attachment
8.7 Transmission TORQFLOW TORQFLOW
Machine Directive 98/37/EEC SOUND PRESSURE level at driver's ear (LPA)*1 dB(A) 109 109
VIBRATION in accordance with EN 13059 (m/s2)*2 m/s2 1.14 1.14
*1: Persistent sound pressure level to en 12053. the persistent sound level is a value determined according to the standard and takes into account the sound pressure level during driving, lifting and on idle.
The sound pressure level is measured at the driver`s ear.
*2: The vibration level in this manual is a value determined according to the EN13059 standard, and it differs from the daily exposure limit value for whole-body vibration set by the directive 2002/44/EC.
The personal vibration load to the driver for one work day must be determined, if necessary, at the site of operation to take all other influencing factors such as road stretch, intensity of operation, etc., into
consideration.

5-6
TECHNICAL DATA

DIESEL ENGINE LIFT TRUCK

1.2 Model Manufacturer's Designation FD40ZY-10 FD35Y-10 FD40Y-10

1.3 Power Type Electric, Diesel, Gasoline, LPG, Cable Diesel Diesel Diesel
Characteristics

1.4 Operation Type Sitting Sitting Sitting

1.5 Rated Capacity Q Rated Capacity kg 4000 3500 4000
1.6 Load Center c Rated Load Center mm 500 600 600
1.8 Load Distance x Front Axle Center to Fork Face mm 540 575 580
1.9 Wheelbase y mm 1800 2000 2000
2.1 Service Weight kg 5700 5755 6235
2.2 Front kg 8560 8100 8905
Weight

Loaded
2.2.1 Rear kg 1140 1155 1330
Axle Loading
2.3 Front kg 2250 2545 2545
Unloaded
2.3.1 Rear kg 3450 3210 3690
3.1 Tyre Type Pneumatic Pneumatic Pneumatic
3.2 Front 250-15-16PR(I) 8.25-15-12PR(I) 300-15-18PR(I)
Tyre Size
3.3 Rear 7.00-12-12PR(I) 7.00-12-12PR(I) 7.00-12-12PR(I)
Tyres

3.5 Number of Wheel Front/Rear (x=driven) 2×/2 2×/2 2×/2

3.6 Tread, Front b10 mm 1115 1115 1150
3.7 Tread, Rear b11 mm 1120 1120 1120
4.1 Tilting Angle α/β Forward/Backward degree 6/12 6/12 6/12
4.2 Mast Height, Lowered h1 2-stage Mast mm 2100 2105 2105
4.3 Std. Free Lift h2 2-stage Std. Mast, from Ground mm 155 155 160
4.4 Std. Lift Height h3 2-stage Std. Mast, from Ground mm 3000 3000 3000
4.5 Mast Height, Extended h4 2-stage Std. Mast mm 4130 4130 4130
4.7 Height, Overhead Guard h6 mm 2210 2250 2250
4.19 Length, with Std. Forks l1 mm 4025 4155 4220
Dimensions

4.20 Length, to Fork Face l2 mm 2955 3085 3150

4.21 Width, at Tyre b1 Single mm 1350 1350 1450
4.22 Forks s/e/l Thickness × Width × Length mm 50×150×1070 55×150×1070 55×150×1070
4.23 Fork Carriage Class ISO 2328, Type A/B/no Class3, A Class3, A Class3, A
4.24 Width, Fork Carriage b3 mm 1190 1190 1190
4.31 m1 Under Mast mm 140 145 145
Ground Clearance
4.32 m2 at Center of Wheelbase mm 175 225 220
4.33 Right Angle Stacking Ast with L1000 × W1200 pallet mm 4190 4375 4420
4.34 Aisle Ast with L1200 × W800 pallet mm 4320 4505 4550
4.35 Turning Radius Wa mm 2580 2730 2770
Loaded, 1st/2nd km/h 18.0/- 18.5/- 18.0/-
5.1 Travel Speed (FWD)
Unloaded, 1st/2nd km/h 19.0/- 19.5/- 19.0/-
Loaded mm/s 460 460 460
5.2 Lifting Speed
Unloaded mm/s 480 480 480
Performance

Loaded mm/s 500 500 500

5.3 Lowering Speed
Unloaded mm/s 500 500 500
5.6 Max. Drawbar Pull Loaded kN 25 25 25
5.8 Max. Gradeability Loaded % 29 29 26
5.10 Service Brake Operation/Type Foot/Wet disc Foot/Wet disc Foot/Wet disc
5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical Hand/Mechanical
5.12 Steering Type FHPS FHPS FHPS
6.4 Battery Voltage/Capacity at 5-hour rating V/ah 12/64 12/64 12/64
KOMATSU KOMATSU KOMATSU
7.1 Maker Model
S4D95LE-3 S4D95LE-3 S4D95LE-3
7.2 Rated Output, SAE net kW 58.8 58.8 58.8
I.C Engine

7.3 Rated RPM min-1 2350 2350 2350

7.3.1 Max. Torque, SAE net Nm@min-1 286@1600 286@1600 286@1600
No. of Cylinder/ 3
7.4 cm 4-3260 4-3260 4-3260
Displacement
7.6 Fuel Tank Capacity Ltr 76 98 98
Relief Pressure for
Others

8.2 bar 206 206 206

Attachment
8.7 Transmission TORQFLOW TORQFLOW TORQFLOW

5-7
 TECHNICAL DATA

1.2 Model Manufacturer's Designation FD45Y-10 FD50AY-10

1.3 Power Type Electric, Diesel, Gasoline, LPG, Cable Diesel Diesel
Characteristics

1.4 Operation Type Sitting Sitting

1.5 Rated Capacity Q Rated Capacity kg 4500 5000
1.6 Load Center c Rated Load Center mm 600 600
1.8 Load Distance x Front Axle Center to Fork Face mm 590 575
1.9 Wheelbase y mm 2000 2000
2.1 Service Weight kg 6820 7260
2.2 Front kg 9935 10805
Weight

Loaded
2.2.1 Rear kg 1385 1455
Axle Loading
2.3 Front kg 2760 2870
Unloaded
2.3.1 Rear kg 4060 4390
3.1 Tyre Type Pneumatic Pneumatic
3.2 Front 300-15-18PR(I) 300-15-18PR(I)
Tyre Size
3.3 Rear 7.00-12-12PR(I) 7.00-12-14PR(I)
Tyres

3.5 Number of Wheel Front/Rear (x=driven) 2×/2 2×/2

3.6 Tread, Front b10 mm 1150 1150
3.7 Tread, Rear b11 mm 1120 1120
4.1 Tilting Angle α/β Forward/Backward degree 6/12 6/12
4.2 Mast Height, Lowered h1 2-stage Mast mm 2205 2205
4.3 Std. Free Lift h2 2-stage Std. Mast, from Ground mm 145 145
4.4 Std. Lift Height h3 2-stage Std. Mast, from Ground mm 3000 3000
4.5 Mast Height, Extended h4 2-stage Std. Mast mm 4130 4345
4.7 Height, Overhead Guard h6 mm 2250 2250
4.19 Length, with Std. Forks l1 mm 4270 4405
Dimensions

4.20 Length, to Fork Face l2 mm 3200 3185

4.21 Width, at Tyre b1 Single mm 1450 1450
4.22 Forks s/e/l Thickness × Width × Length mm 55×150×1070 55×150×1220
4.23 Fork Carriage Class ISO 2328, Type A/B/no Class3, A Class4, A
4.24 Width, Fork Carriage b3 mm 1190 1270
4.31 m1 Under Mast mm 145 145
Ground Clearance
4.32 m2 at Center of Wheelbase mm 220 220
4.33 Right Angle Stacking Ast with L1000 × W1200 pallet mm 4480 4625
4.34 Aisle Ast with L1200 × W800 pallet mm 4610 4645
4.35 Turning Radius Wa mm 2820 2850
Loaded, 1st/2nd km/h 14.5/24.0 14.5/24.0
5.1 Travel Speed (FWD)
Unloaded, 1st/2nd km/h 15.5/25.0 15.5/25.0
Loaded mm/s 455 455
5.2 Lifting Speed
Unloaded mm/s 480 480
Performance

Loaded mm/s 500 500

5.3 Lowering Speed
Unloaded mm/s 500 500
5.6 Max. Drawbar Pull Loaded kN 31 31
5.8 Max. Gradeability Loaded % 29 28
5.10 Service Brake Operation/Type Foot/Wet disc Foot/Wet disc
5.11 Parking Brake Operation/Control Hand/Mechanical Hand/Mechanical
5.12 Steering Type FHPS FHPS
6.4 Battery Voltage/Capacity at 5-hour rating V/ah 12/64 12/64
KOMATSU KOMATSU
7.1 Maker Model
S4D95LE-3 S4D95LE-3
7.2 Rated Output, SAE net kW 58.8 58.8
I.C Engine

7.3 Rated RPM min-1 2350 2350

7.3.1 Max. Torque, SAE net Nm@min-1 286@1600 286@1600
No. of Cylinder/ 3
7.4 cm 4-3260 4-3260
Displacement
7.6 Fuel Tank Capacity Ltr 98 98
Relief Pressure for
Others

8.2 bar 206 206

Attachment
8.7 Transmission TORQFLOW TORQFLOW

5-8
INDEX 6

26

6-1
 INDEX

INDEX
<A> <H>
About this manual ------------------------------------------------ 1-2 Hoisting and transporting the lift truck --------------------- 2-37
Action to take if the fork fails to lower --------------------- 4-52 Caution when hoisting the lift truck ----------------------- 2-37
Applicable model and serial No. ------------------------------ 1-6 Cautions for loading and unloading the lift truck ------ 2-37
Hoisting lift truck------------------------------------------------- 4-55
<B>
Basic precautions------------------------------------------------- 2-8 <I>
Asbestos caution --------------------------------------------- 2-14 Inspection and maintenance -----------------------------------4-2
Caution when washing lift truck --------------------------- 2-10 Inspection and maintenance schedule chart------------- 4-57
Cautions for safety-related equipment -------------------- 2-9 Introduction ---------------------------------------------------------1-2
Do not modify the lift truck---------------------------------- 2-12
Do not remove the overhead guard and
<L>
load backrest ------------------------------------------------ 2-13
Load handling operation -------------------------------------- 2-25
Engine exhaust gas is poisonous ------------------------ 2-13
Loading and unloading of lift truck-------------------------- 4-56
Fire extinguisher and first aid kit ---------------------------- 2-9
Long-term storage ---------------------------------------------- 4-54
Fire prevention ------------------------------------------------ 2-11
Follow rules ------------------------------------------------------ 2-8
How to select window washer solution------------------ 2-14 <N>
If a fire breaks out -------------------------------------------- 2-12 Necessary information of lift truck ----------------------------1-8
Jumping on and off from the lift truck is Engine serial number plate or stamping location -------1-9
strictly prohibited-------------------------------------------- 2-10 Hour meter location --------------------------------------------1-9
Keep the operator’s compartment and Memorandum ----------------------------------------------------1-8
platform clean and tidy ------------------------------------ 2-10 Model and serial No. plate location-------------------------1-8
Never operate the broken-down lift truck ----------------- 2-8
Practice sufficiently before operation ---------------------- 2-9
Secure safety at the working area------------------------ 2-13
<O>
To avoid burn injury ------------------------------------------ 2-11 Operating lift trucks in special environment or
Wear adequate clothes and safety equipment in forcible way------------------------------------------------ 4-51
for operation --------------------------------------------------- 2-9 Operation ---------------------------------------------------- 3-2,3-16
Before starting operation ------------------------------------- 2-15 Checking after operation ------------------------------------ 3-35
Inspection and adjustment before starting engine Inching travel --------------------------------------------------- 3-29
check the followings before starting the engine----- 2-15 Load handling operation ------------------------------------ 3-32
Start-up inspection -------------------------------------2-15,2-16 Mounting/dismounting and
operating posture adjustment ---------------------------- 3-16
Operation on snowy and frozen roads------------------- 3-29
<C> Starting and stopping on slope ---------------------------- 3-28
Checking and reporting after operation ------------------- 4-22 Starting, gear shifting, and traveling --------------------- 3-20
Start-up inspection-------------------------------------------- 3-16
<E> Temporary stopping, parking and stopping ------------ 3-30
Turning----------------------------------------------------------- 3-29
Engine mounted on this lift truck------------------------------ 1-3
Certification label affixed position -------------------------- 1-3
Exhaust gas control (applied to diesel engine <P>
lift truck) --------------------------------------------------------- 1-3 Periodic replacement of safety critical parts ------------- 4-64
Explanation of components ------------------------------------ 3-6 Precautions for inspection and maintenance ------------ 2-30
Meter panel ------------------------------------------------------ 3-6 Avoid getting caught up by the mast or falling off----- 2-32
Operating devices -------------------------------------------- 3-12 Be careful of boiling coolant -------------------------------- 2-32
Be careful of high pressure oil ----------------------------- 2-33
<F> Be sure to perform the start-up inspection and
the periodic voluntary inspection------------------------ 2-30
For your safety ---------------------------------------------------- 1-4
Beware of rotating cooling fan and belt ----------------- 2-33
Safety indicators ------------------------------------------------ 1-5
Caution after inspection and repair----------------------- 2-36
Signal words ----------------------------------------------------- 1-4
Caution in waste disposal----------------------------------- 2-36
Caution when charging a battery ------------------------- 2-35
<G> Caution when handling battery ---------------------------- 2-34
General view------------------------------------------------------- 3-2 Caution when handling tyres ------------------------------- 2-35
General view of lift truck -------------------------------------- 3-2 Caution when repairing the electrical system---------- 2-33
Instruments and controls ------------------------------------- 3-3 Cautions for using compressed air for cleaning------- 2-34
General view of lift truck ---------------------------------------- 1-6 Cautions when replacing the seat ------------------------ 2-34
Application of lift truck ----------------------------------------- 1-6 Cautions when working under work equipment ------- 2-31
Direction of lift truck -------------------------------------------- 1-6 Keep the working area clean and tidy ------------------- 2-30

6-2
INDEX

Keep unauthorized people off ----------------------------- 2-31 Checking while traveling slowly----------------------------4-19
Periodic inspection of safety critical parts -------------- 2-36 Checking with the engine started -------------------------4-17
Precautions before inspection and maintenance ----- 2-31 Inspection by opening cover and hood ------------------- 4-7
Precautions for installing radio control system -------- 2-33 Walking around a lift truck ----------------------------------- 4-4
Put up a warning sign during inspection and Structure and stability of the lift truck (to prevent
maintenance ------------------------------------------------- 2-30 lift truck from tipping) ---------------------------------------2-38
Strictly follow the instructions shown below to avoid Actual capacity-------------------------------------------------2-39
generation of sparks --------------------------------------- 2-34 Center of gravity of a load-----------------------------------2-38
Use of right tools and equipment ------------------------- 2-31 Combined center of gravity and stability on
Procedure for a down battery -------------------------------- 4-45 the loaded lift truck------------------------------------------2-39
Procedure with overheated engine ------------------------- 4-49 Introduction of optional safety device --------------------2-41
Longitudinal stability ------------------------------------------2-38
Serial No. plate and load table-----------------------------2-40
<Q>
Qualifications for operation -------------------------------------1-7
<T>
Traveling the lift truck ------------------------------------------2-17
<R> Preparation before traveling the lift truck----------------2-17
Running in cold weather -------------------------------------- 4-47
Stopping and parking-----------------------------------------2-24
Running in new lift truck-----------------------------------------1-7
Towing -----------------------------------------------------------2-24
Maintenance for new lift truck--------------------------------1-7
While traveling the lift truck ---------------------------------2-18
Running in new lift truck---------------------------------------1-7

<U>
<S> Units of measure ------------------------------------------------- 1-6
Safety ----------------------------------------------------------------2-2
Safety label ---------------------------------------------------------2-2
Safety label location chart ------------------------------------2-2 <W>
Safety labels -----------------------------------------------------2-4 Warranty and service-------------------------------------------- 1-7
Service data ------------------------------------------------------ 4-65 Engine mounted on this lift truck --------------------------- 1-7
Simple maintenance ------------------------------------------- 4-23 Periodical exchange parts ----------------------------------- 1-7
Adjusting parking brake lever operating effort --------- 4-39 Use of genuine Komatsu Utility parts and oils ---------- 1-7
Air cleaner element inspection and cleaning ---------- 4-32 Washing lift trucks-----------------------------------------------4-53
Checking for hardening of engine controller
mount rubber and loose mounting
(FD40Z, FD35, FD40, FD45, FD50A) ----------------- 4-44
Checking for missing fuel spray prevention cap,
hardening of rubber
(FD40Z, FD35, FD40, FD45, FD50A) ----------------- 4-44
Checking the brake accumulator-------------------------- 4-18
Fuel filter air bleeding
(FD40Z, FD35, FD40, FD45, FD50A) ----------------- 4-34
Fuel filter air bleeding
(FD40Z, FD35, FD40, FD45, FD50A/*REF) --------- 4-35
Fuel filter water draining and air bleeding
(FD40ZY, FD35Y, FD40Y, FD45Y, FD50AY) ------- 4-36
Greases and fuel---------------------------------------------- 4-23
Basic precautions ------------------------------------------- 4-23
Lubricant list
(FD40Z, FD35, FD40, FD45, FD50A) ----------------- 4-28
Lubricant list
(FD40ZY, FD35Y, FD40Y, FD45Y, FD50AY) ------- 4-30
Lubricant list
(FG40Z, FG35, FG40, FG45, FG50A) ---------------- 4-26
Replacing bulbs ----------------------------------------------- 4-43
Replacing fuse------------------------------------------------- 4-40
Replacing tyres ------------------------------------------------ 4-37
Start-up inspection------------------------------------------------4-2
Check by setting the starter switch
to [ | ] (ON) position----------------------------------------- 4-14
Checking abnormalities detected on
the previous day-----------------------------------------------4-4
Checking by operating the work equipment lever ---- 4-19
Checking from the operator seat-------------------------- 4-12
Checking of safety function--------------------------------- 4-21

6-3
FG(D)35/50A-10 FORKLIFT TRUCK

Form No. AEC10E1-02

PRINTED IN JAPAN