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19.

OUTLINE OF SERVICE

19. OUTLINE OF SERVICE

Use Komatsu Forklift specified parts and lubricants for replacement.

When changing or adding oil, use only the oil that is recommended. Do not use a different kind or grade of oil.

Unless otherwise specified, the oil and coolant used at delivery from the factory shall be as shown in the table
below.
Item
Differential case

Type of fluid
SAE 90

Hydraulic tank

SAE 10W-CD

TORQFLOW transmission case

SAE 10W-CD

Cooling system

Coolant (FAF-NAC)

19.1 SUITABLE OIL


19.1.1 OIL
Since the oil is used for the work equipment, etc., under severe conditions (at high temperature and high pressure), it will deteriorate as operating time passes. Always use an oil matching the grade and working temperatures given in the Operation Manual.
Always replace the oil at specified time intervals even if it is not deteriorated.

Oil is often compared to human blood.


A lift truck should be maintained with the same care taken for the human body so that impurities (water,
metal chips, dust, etc.) do not enter the lift truck system.
Most lift truck malfunctions are caused by the entry of impurities into the various systems.
Take special care to avoid the entry of impurities during storage and lubrication, etc.

Never blend oils of different grades or brands.

Add specified volume of oil.


Too little or too much oil may both cause problems in the fork lift truck.

If the oil in the work equipment becomes cloudy, it is likely that air or water have entered the circuit. Consult a
Komatsu Forklift Truck dealer/distributor.

When replacing oil, replace the relevant filters at the same time.

3-2

19. OUTLINE OF SERVICE


19.1.2 GREASE
Grease prevents wear and tear and the generation of squeaking noise from the joints, etc.

Lift trucks are provided with grease nipples in various places. Some of these are not mentioned in this manual
since they are for overhauling purposes and do not require greasing.
If friction is noticed in movable parts after operation, grease them.

After greasing, wipe off any old grease that is forced out, especially on rotating parts that will be worn by adhering sand and dirt.

19.1.3
Store and preserve oil so as to prevent entry of dirt, dust, water or other contaminants.

When storing oil drums for long periods, place them side-by-side with filler sides facing in the same direction.
If necessary to store drums outdoors, cover them with waterproof sheeting. Ensure that the screw caps
(bung plugs) are tight.

To prevent oil deterioration during long periods of storage, use drums on a first-in, first-out basis.

19.1.4 FILTERS
Filters are very important safety items which prevent problems caused by impurities contained in the oil or
hydraulic circuit which sends oil into important units. Periodically replace the filters referring to this manual.

When replacing oil filters, check for metal powder or shavings deposited on the used filters.

Do not unpack replacement filters until immediately before installation.

Always use specified filters.

3-3

20. LUBRICANT LIST

20. LUBRICANT LIST


20.1 GASOLINE/LPG ENGINE LIFT TRUCKS
(FG35/40/45/50-7, FG40Z-7)
NOTICE
Always use specified oil and grease.

Never use the incorrect kind of brake fluid.


Use specified DOT 3 brake fluid.

Ambient Temperature
Lubrication
Points

Type of Fluid

-4
-20

14
-10

32
0

50
10

68
20

86F
30C

Capacities

Engine oil pan

Engine oil
(SAE 30W-CD)

2.06 US gallons
7.8 L, 1.72 UK gal.

TORQFLOW
transmission
case

DEXRON Automatic
transmission fluid

4.22 U.S. gallons


16 L, 3.52 UK gal.

Gear oil (SAE80W)


Differential
case
Gear oil (SAE90W)
Hydraulic tank

Hydraulic oil
ISO # 32

Fuel tank

Gasoline
87 Octane (recommended)
LPG
107 Octane Propane

Brake system

Brake fluid (DOT 3)

Greasing points

Lithium grease
(NLGI No.2)

Cooling system

Coolant
(FAF-NAC)
Add antifreeze at ambient
temp 32F/0C or below

3-4

TORQFLOW transmission:
3.43 U.S. gallons
13 L, 2.86 UK gal.
14.53 U.S. gallons
55 L, 12.10 UK gal.
FG30/40/45/50
26.4 U.S. gal.
100 L, 22.0 UK gal.
FG40Z
21.1 U.S. gal, 80 L, 17.6 UK gal.
0.040 U.S. gal.
0.15 L, 0.033 UK gal.

3.7 U.S. gal.


14 l, 3.08 UK gal.

20. LUBRICANT LIST

20. LUBRICANT LIST


20.2 DIESEL ENGINE LIFT TRUCKS
(FD40/45/50-7, FD40Z-7)
NOTICE

Never use fuel mixed with kerosene.


Always use specified oil and grease.

Never use the incorrect kind of brake fluid.


Use specified DOT 3 brake fluid.

Ambient Temperature
Lubrication
Points

Engine oil pan

Type of Fluid

Engine oil
(SAE 10W)

-4
-20

14
-10

32
0

50
10

68
20

86F
30C

Capacities

3.04 U.S. gal.


11.5 l, 2.53 UK gal.

(SAE 30W)
TORQFLOW
transmission
case

DEXRON Automatic
transmission fluid

4.22 U.S. gal.


16 L, 3.52 UK gal.

Gear oil (SAE80W)

Gear oil (SAE90W)

TORQFLOW
transmission:
3.43 U.S. gal.
13 L, 2.86 UK gal.

Hydraulic oil
ISO # 32

14.53 U.S. gal.


55 L, 12.10 UK gal.

Differential case

Hydraulic tank

Fuel tank

Diesel fuel
ASTM D975 No. 2
ASTM D975 No. 1

Brake system

Brake fluid (DOT 3)

Greasing points

Lithium grease
(NLGI No.2)

Cooling system

Coolant
(FAF-NAC)
Add antifreeze at ambient
temp 32F/0C or below

FD40/45/50
26.4 U.S. gal.
100 L, 22.0 UK gal.
FD40Z
21.1 U.S. gal, 80 L
17.6 UK gal.
0.040 U.S. gal.
0.15 L, 0.033 UK gal.

3.7 U.S. gal.


14 L, 3.08 UK gal.

3-5

20. LUBRICANT LIST

20. LUBRICANT LIST


20.3

OIL AND GREASING CHART (OIL, GREASE LOCATIONS AND


INSPECTION AND MAINTENANCE INTERVALS)

Chart symbol
AF

Type of fluid
Automatic transmission fluid
(As specified / Dexron II)
Diesel engine oil

EO
Gasoline engine oil

3-6

GO

Gear oil

HO

Hydraulic oil

BF

Brake fluid
(As specified / DOT 3)

Grease

21. SERVICE DATA

21. SERVICE DATA


21.1

SERVICE DATA (GASOLINE/LPG ENGINE LIFT TRUCKS)

Component

Unit of
Measure

FG35/40/45/50-7, FG40Z-7

--

NISSAN TB42

Idling speed

rpm

850 - 900

Maximum speed

rpm

2,300 -2,400

PSI / rpm
MPa/rpm

170 PSI / 200 rpm


1.2MPa / 200 rpm

kgf/cm2

12 kgf/cm2 / 200 rpm

lbf
mm

0.59 - 0.67 in.


11 - 17 mm
(finger pressure: 22 lbf, 98N, 10 kgf)

Injection timing

BTDCo

--

Injection order

--

--

MPa

--

Intake

in. (mm)

0.015 in. (0.38) Warm

Exhaust

in. (mm)

0.015 in. (0.38) Warm

Distributor point gap

mm

--

Spark plug gap

mm

0.028 - 0.031 in. (0.7 - 0.8 mm)

Spark plug type

--

NGK: B-4ES or BPR-4ES (shielded)


Hitachi: L47W

Inspection item
Engine model

Engine

Compression

Engine

Lubricating oil
cooling system

Fuel system

Fan belt deflection

Injection pressure
Intake / exhaust
system

Valve
clearance

Electric system
Ignition timing (gasoline)
Ignition timing (LPG)
Firing order

BTDCo/

7 / 700 rpm

rpm

12 / 700 rpm

--

1-5-3-6-2-4

3-7

21. SERVICE DATA


21.1

SERVICE DATA (GASOLINE/LPG ENGINE LIFT TRUCKS) (Continued)

Component

Unit of
Measure

Inspection item

FG35/40/45/50-7, FG40Z-7
250-15-16PR: 120 PSI, 0.83 (8.5 kgf/cm2)

Front wheels

Travel system

Tires

Lug nuts

Tire inflation pressure

PSI
MPa

120 PSI, 0.83 (8.5 kgf/cm2)

Front wheels

217 - 361 ft/lbs


294 - 490 (30 - 50 kgfm)

Tightening torque
Front wheels

ft/lbs
Nm

Tightening torque

Steering, braking system


Loading equipment

3-8

Play
Play

Inching pedal

1.2 - 2.4 in. (30 - 60 mm)


in.
(mm)

Interconnected travel
Play

-145 - 217 ft/lbs


196 - 294 (20.0 - 30.0 kgfm,)

Rear wheels
Steering wheel

300-15-18PR: 113 PSI, 0.78 (8.0 kgf/cm2)

Rear wheels

Rear wheels

Rim mating nuts

8.25-15-12PR: 98 PSI, 0.68 (7.0 kgf/cm2)

0.08 - 0.12 in. (2 - 3 mm)


1.38 - 1.41 in. (35 - 41 mm)
0.12 - 0.28 in. (3 - 7 mm)

Pedal height when pedal is depressed

in.
(mm)

3.54 - 3.94 in. (90 - 100 mm)

Parking brake operating force

lbf (N)

Min. 55 lbf (196 N) (20 kgf)

Tightening torque for back plate mounting bolts

ft/lbs
(Nm)

181 - 228 ft/lbs


(245 - 309 Nm) (25 - 31.5 kgfm)

in.
(mm)

FG40Z:
Min. 1.77 in. (45 mm)
FG40/45/50:
Min. 1.97 in. (50 mm)

Brake pedal

Brake

Forks

Fork thickness (at base of forks)

Chain

Length over 17 links

Hydraulic system

Relief pressure

Max. 440 (17.3 in.)


PSI
(MPa)

2,610.7 PSI (18 MPa) (185 kgf/cm2)

21. SERVICE DATA

21. SERVICE DATA


21.2

SERVICE DATA (DIESEL ENGINE LIFT TRUCKS)

Component

Unit of
Measure

FD40/45/50, FD40Z

--

6D102E (359 cu.in.)(95hp @ 2,150 rpm)

Idling speed

rpm

675 - 725

Maximum speed

rpm

2,300 - 2,400

Inspection item
Engine model

Engine proper

PSI
MPa/rpm

Compression

Engine

kgf/cm2
Lubricating oil
cooling system

Fuel system

(36 kgf/cm2 / 280 -320 rpm

Fan belt deflection

in. (mm)

0.24 - 0.39 in.


(6 - 10 mm)
(finger pressure: 17.8 lbf, 79N, 8 kgf)

Injection timing (at idle)

BTDCo

1 ATDC (injection pump cam lift 1 mm)

--

1-5-3-6-2-4

PSI (MPa)

2,845 PSI (19.6 MPa) (200 kgf/cm2)

Intake

in. (mm)

0.0098 in. (0.25 mm) Cool

Exhaust

in. (mm)

0.020 in. (0.51 mm) Cool

Injection order
Injection pressure

Intake / exhaust
system

486 psi / 280 - 320 rpm


3.35 MPa / 280 - 320 rpm

Valve
clearance

3-9

21. SERVICE DATA


21.2

SERVICE DATA (DIESEL ENGINE LIFT TRUCKS) (Continued)

Component

Unit of
Measure

Inspection item

FD40/45/50, FD40Z
250-15-16PR: 120 PSI (0.83) (8.5 kgf/cm2)

Front wheels

Travel system

Tires

Lug nuts

Tire inflation pressure

PSI
(MPa)

120 PSI (0.83 MPa) (8.5 kgf/cm2)

Front wheels

217 - 361 ft/lbs


(294 - 490 Nm) (30 - 50 kgfm,

Tightening torque
Front wheels

ft/lbs
Nm

Tightening torque

Steering, braking system

Play
Play

Inching pedal
Play
Pedal height when pedal is depressed
Parking brake operating force

in.
(mm)

0.08 - 0.12 in. (2 - 3 mm)


1.38 - 1.41 in. (35 - 41 mm)

in.
(mm)

0.12 - 0.28 in. (3 - 7 mm)


3.54 - 3.94 in. (90 - 100 mm)

lbf
(N)

Min. 55 lbf (196 N) (20 kgf)

ft/lbs
(Nm)

181 - 228 ft/lbs


(245 - 309 Nm) (25 - 31.5 kgfm)

in.
(mm)

FD40Z:
Min.1.77 in. (45 mm)
FD40/45/50:
Min. 1.97 in. (50 mm)

Brake
Tightening torque for back plate mounting bolts

Loading equipment

1.2 - 2.4 in. (30 - 60 mm)

Interconnected travel
Brake pedal

-145 - 217 ft/lbs


(196 - 294 Nm) (20.0 - 30.0 kgfm)

Rear wheels
Steering wheel

300-15-18PR: 113 PSI (0.78) (8.0 kgf/cm2)

Rear wheels

Rear wheels

Rim mating nuts

8.25-15-12PR: 98 PSI (0.68) (7.0 kgf/cm2)

Forks

Fork thickness (at base of forks)

Chain

Length over 17 links

Hydraulic system

Relief pressure

3-10

Max. 440 (17.3 in.)


PSI
(MPa)

2,610.7 PSI
(18 MPa) (185 kgf/cm2)

21. SERVICE DATA

21. SERVICE DATA


21.3

TORQUE LIST

For unspecified bolts and nuts, use the torque specifications


in this list.
Select the proper torque corresponding to the width across
flats (b) of bolts and nuts.
When replacing bolts and nuts, always use genuine Komatsu
Lift Truck parts that match the previous installation in size.

Thread diameter
of bolt (mm)
(a)

Width across
flat (mm)
(b)

Tightening torque
ft/lbs

kgfm

Nm

6
8
10
12
14

10
13
17
19
22

9.73 + 1.03
23.2 + 2.1
48.5 + 5.0
82.6 + 7.2
131 + 14

1.35 + 0.15
3.2 + 0.3
6.7 + 0.7
11.5 + 1.0
18.0 + 2.0

13.2 + 1.4
31.4 + 2.9
65.7 + 6.8
112 + 9.8
177 + 19

16
18
20
22
24

24
27
30
32
36

206 + 21
282 + 29
405 + 43
549 + 58
684 + 72

28.5 + 3
39 + 3
56 + 6
76 + 8
94.5 + 10

279 + 29
383 + 39
549 + 58
745 + 78
927 + 98

27
30
33
36
39

41
48
50
55
60

973 + 100
1,270 + 140
1,630 + 180
2,030 + 210
2,420 + 250

135 + 15
175 + 20
225 + 25
280 + 30
335 + 35

1,320 + 140
1,720 + 190
2,210 + 240
2,750 + 290
3,280 + 340

3-11

22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

22.

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

To ensure safety at all times when operating or driving the lift truck, the lift truck user must always carry out periodic
maintenance. In addition, to further improve safety, the user should also perform periodic replacement of parts
given in the table below. These parts, in particular, are closely relate to safety and fire prevention.
The material of these parts may change over time, or they may easily wear or deteriorate. However, it is difficult to
judge the condition of these parts simply by periodic maintenance. The parts listed should always be replaced after
a fixed, specified time has passed, regardless of their condition. This is necessary to ensure that these parts maintain their full function at all times.
Note that if these parts show any abnormality before the replacement interval has passed, they should be repaired
or replaced immediately.
If the hose clamps show any signs of deterioration, such as deformation or cracking, replace them at the same time
as the hoses.
Note that this periodic replacement is not covered by warranty.

IMPORTANT PARTS LIST


No.

Part name

Years elapsed

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

Brake hose or tube

Power steering hose

Stop lamp switch (hydraulic type)

Fuel hose

Rubber parts inside power steering system

Lift chain

2-4

Hydraulic hose for lifting mechanism

1-2

3-12

1
1-2
2
2-4

23. MAINTENANCE SCHEDULE CHART

23. MAINTENANCE SCHEDULE CHART


Perform maintenance at intervals of months or operation hours, whichever occurs first.
Service Item

Page

First month or initial 200 hours service (only after the first one month)
Change oil in hydraulic tank, replace line filter, clean strainer, clean inside of tank

3-17

Change oil in engine oil pan

3-17

Replace engine oil filter cartridge

3-17

Check, adjust engine valve clearance

3-17

Tighten (retorque) engine cylinder head bolts

3-17

Clean TORQFLOW transmission strainer

3-17

Change oil in differential case

3-17

Change oil in TORQFLOW transmission case

3-17

Tighten bolts and nuts (especially lug nuts, overhead guard, load backrest operators seat mounting bolts and nuts)

3-17

Check before operation items (for details, see 15.1 CHECK BEFORE OPERATION)

3-17

Every 2 weeks or every 100 hours service


Grease lift chain

3-17

Every month or every 200 hours service


Check wheel rims for deformation, cracking and damage

3-17

Check wheel bearings for play and abnormal noise

3-17

Check hydraulic cylinders for looseness, deformation, cracking, damage and wear

3-17

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

3-17

Check operation of hydraulic cylinders

3-18

Check hydraulic drift of lift cylinder

3-18

Check hydraulic drift of tilt cylinders

3-18

Check movement of work equipment control lever(s)

3-18

Check forks and fork stopper for deformation, cracking, damage and wear

3-18

Check forks for unevenness and twisting

3-18

Check mast for deformation, cracking, damage and wear

3-18

Check mast roller for play

3-18

Check chain and chain wheel for deformation, damage, rust and poor lubrication

3-18

Check chain wheel bearing for play

3-18

Check chain anchor bolt for deformation and damage

3-18

Check gear box for oil leakage, looseness of mount

3-18

3-13

23. MAINTENANCE SCHEDULE CHART

Service Items (continued)

Page

Every month or every 200 hours service (continued)


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

3-18

Check brake link for play, looseness, damage and wear

3-18

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

3-18

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

3-19

Check shift lever for play, meshing

3-19

Check for oil leakage from transmission and differential cases

3-19

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

3-19

Check pedal height when inching pedal is depressed

3-19

Check starting of engine

3-19

Check idling speed (Gasoline and LPG)

3-19

Check, clean radiator fins, check for damage

3-19

Check for catching, stalling and knocking when accelerating

3-19

Check and clean air cleaner element

3-20

Check operation of governor (maximum speed)

3-20

Check piping/tubing and connections/fittings for fuel/gas leakage

3-20

Check fuel filter and fuel strainer for cracking, damage


Check and drain water separator (diesel engine lift trucks)

3-20

Check radiator hoses for cracking, damage

3-21

Check operating condition of radiator cap, check installation

3-21

Check fan for deformation, cracking, and damage

3-21

Check fan for looseness and mounting

3-21

Check, adjust fan belt tension

3-21

Check, adjust alternator belt tension

3-21

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

3-21

Check clearance of distributor points, check contact surface for roughness

3-21

Check spark plugs for burning, burning of insulator

3-21

Change oil in engine oil pan (Gasoline and LPG trucks with TB42 engines)

3-21

Replace engine oil filter (TB42)

3-21

Replace fuel filter (TB42)

3-22

Check spark plugs (TB42)

3-22

Change governor oil (TB42)

3-22

Change oil in engine oil pan (Diesel engine trucks with 6D102E engines)

3-23

3-14

23. MAINTENANCE SCHEDULE CHART


Service Items (continued)

Page

Every month or every 200 hours service (continued)


Replace engine oil filter (6D102E)

3-23

Drain water from fuel filter (6D102E)

3-24

Replace fuel filter (6D102E)

3-24

Check operation of starting switch; check meshing of pinion gear

3-25

Check specific gravity of battery electrolyte

3-25

Check wiring connections for looseness

3-25

Check ignition timing

3-25

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

3-25

Check operators seat mount for looseness and damage; Check LPG cylinder mounting bracket

3-25

Grease all lubrication points

3-26

Every 3 months or every 600 hours service


Drain water from water separator and replace fuel filter cartridge (diesel engine lift trucks)

3-26

Replace oil filter cartridge

3-26

Grease fuel injection pump governor, change governor oil

3-26

Check oil level in transmission case, add oil as necessary

3-26

Check oil level in differential case, add oil as necessary

3-26

Every 6 months or every 1,200 hours service


Check steering link for bending, damage and wear

3-26

Check knuckle for play, deformation and damage

3-26

Check for marked variation in minimum turning radius

3-26

Change oil in differential case

3-27

Change oil in TORQFLOW transmission case

3-28

Replace torque converter oil filter

3-28

Change brake oil/fluid

3-28

Check, adjust valve clearance

3-28

Measure compression pressure

3-28

Check, adjust fuel injection timing, check and inspect fuel injection nozzles (diesel)

3-29

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

3-29

Check distributor cap centerpiece for wear

3-29

Replace fuel filter element

3-29

Clean inside of cooling system; Clean radiator

3-29

Replace air cleaner element

3-30

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

3-31

3-15

23. MAINTENANCE SCHEDULE CHART

Every 2,000 hours of service


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

3-31

Every 2,000 hours of service


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

3-31

Every 12 months (year) or every 2,400 hours service


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

3-31

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

3-31

Check operation of brake drum, check for damage and wear

3-31

Check brake linings for wear

3-31

Check operating condition of brake shoe

3-31

Check brake adjustment lever and ratchet for wear and damage

3-31

Check brake spring for deterioration

3-31

Check brake back plate for deformation and cracking; Check mounting condition

3-32

Check air tightness of brake piping/tubing

3-32

Check axle for deformation, cracking and damage

3-32

Check mounting condition of differential

3-32

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

3-32

Check roller shaft of loading equipment for cracking and damage

3-32

Check mast support for damage and wear

3-32

Check operation of relief valve; Check relief pressure

3-32

Replace air breather

3-32

Replace water separator (diesel); Clean inside of fuel tank (gasoline/LPG and diesel lift trucks)

3-32

Check fuel injection pressure, injection amount, injector condition

3-32

Tighten (retorque) engine cylinder head bolts

3-32

Check frame and cross member for cracking and damage

3-32

3-16

24. MAINTENANCE

24. MAINTENANCE
24.1

FIRST MONTH OR INITIAL 200 HOURS SERVICE

Carry out this maintenance, for new lift trucks only, after the first one month or initial 200 hours of operation,
whichever comes sooner.
(Hydraulic equipment)
24.1.1
CHANGE OIL IN HYDRAULIC TANK, REPLACE LINE FILTER, CLEAN STRAINER, CLEAN INSIDE
OF TANK
For details on replacing and cleaning, see 24.6.16 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC
LINE FILTER, CLEAN HYDRAULIC TANK STRAINER, CLEAN INSIDE OF HYDRAULIC TANK.
(Engine)
24.1.2
CHANGE OIL IN ENGINE OIL PAN
For details on changing the oil, see 24.4.42.1 CHANGE OIL IN ENGINE OIL PAN.
24.1.3
REPLACE ENGINE OIL FILTER CARTRIDGE
For details on replacing the engine oil filter cartridge, see 24.4.42.2 REPLACE ENGINE OIL FILTER.
24.1.4

CHECK, ADJUST ENGINE VALVE CLEARANCE

24.1.5

TIGHTEN (RETORQUE) ENGINE CYLINDER HEAD BOLTS

(Power train)
24.1.6
CLEAN TORQFLOW TRANSMISSION STRAINER
24.1.7
CHANGE OIL IN DIFFERENTIAL CASE
For details on changing the oil, see 24.6.4 CHANGE OIL IN DIFFERENTIAL CASE.
24.1.8
CHANGE OIL IN TORQFLOW TRANSMISSION CASE
For details on changing the oil, see 24.6.5 CHANGE OIL IN TORQFLOW TRANSMISSION CASE.
(General)
24.1.9

24.2

TIGHTEN BOLTS AND NUTS (ESPECIALLY LUG NUTS, OVERHEAD GUARD, LOAD BACKREST
AND OPERATORS SEAT MOUNTING BOLTS AND NUTS)

CHECK BEFORE OPERATION

For details, see 15.1 CHECK BEFORE OPERATION.

24.3

EVERY 2 WEEKS OR EVERY 100 HOURS SERVICE

(Loading equipment)
24.3.1
GREASE LIFT CHAIN

24.4

EVERY MONTH OR EVERY 200 HOURS SERVICE

(Travel equipment)
24.4.1
CHECK WHEEL RIMS FOR DEFORMATION, CRACKING AND DAMAGE
24.4.2

CHECK WHEEL BEARINGS FOR PLAY AND ABNORMAL NOISE

(Hydraulic equipment)
24.4.3
CHECK HYDRAULIC CYLINDERS FOR LOOSENESS, DEFORMATION, CRACKING, DAMAGE
AND WEAR
24.4.4

CHECK ALL PIPING/TUBING/CONNECTORS FOR OIL LEAKAGE, DEFORMATION OR DAMAGE

3-17

24. MAINTENANCE
24.4.5

CHECK OPERATION OF HYDRAULIC CYLINDERS

24.4.6

CHECK HYDRAULIC DRIFT OF LIFT CYLINDER

24.4.7

CHECK HYDRAULIC DRIFT OF TILT CYLINDERS

24.4.8

CHECK MOVEMENT OF WORK EQUIPMENT CONTROL LEVER(S)

(Loading equipment)
24.4.9
CHECK FORKS AND FORK STOPPER FOR DEFORMATION, CRACKING, DAMAGE AND WEAR
24.4.10

CHECK FORKS FOR UNEVENNESS AND TWISTING

24.4.11

CHECK MAST FOR DEFORMATION, CRACKING, DAMAGE AND WEAR

24.4.12

CHECK MAST ROLLER FOR PLAY

24.4.13

CHECK CHAIN AND CHAIN WHEEL FOR DEFORMATION, DAMAGE, RUST AND POOR
LUBRICATION

24.4.14

CHECK CHAIN WHEEL BEARING FOR PLAY

24.4.15

CHECK CHAIN ANCHOR BOLT FOR DEFORMATION AND DAMAGE

(Steering system)
24.4.16
CHECK GEAR BOX FOR OIL LEAKAGE, LOOSENESS OF MOUNT
24.4.17

CHECK MOUNTING CONDITION OF POWER STEERING, CHECK FOR LOOSENESS AT


CONNECTIONS

24.4.18

CHECK BRAKE LINK FOR PLAY, LOOSENESS,


DAMAGE AND WEAR

Checking
1. Check the play and the height of the brake pedal when it is
depressed to check that it matches the specified values.
Play

0.12 - 0.28 in. (3 - 7 mm)

Pedal height
when depressed

3.54 - 3.94 in. (90 - 100 mm)

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

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

24.4.19

3-18

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


LOOSENESS OF BRAKE TUBING CLIPS AND DISCONNECTION AT FITTINGS

24. MAINTENANCE
24.4.20

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

(Power train)
24.4.21
CHECK SHIFT LEVER FOR PLAY, MESHING
24.4.22

CHECK FOR OIL LEAKAGE FROM TRANSMISSION AND DIFFERENTIAL CASES

24.4.23
CHECK OIL LEVEL IN TORQFLOW TRANSMISSION, ADD OIL AS NECESSARY
For details on checking the oil level and adding oil, see 24.6.5 CHANGE OIL IN TORQFLOW TRANSMISSION
CASE.
24.4.24

CHECK PEDAL HEIGHT WHEN INCHING PEDAL IS DEPRESSED

(Engine)
24.4.25

CHECK STARTING OF ENGINE

24.4.26

CHECK IDLING SPEED (GASOLINE AND LPG ENGINE EQUIPPED LIFT TRUCKS)

24.4.27

CHECK, CLEAN RADIATOR FINS, CHECK FOR DAMAGE

Dirt may fly and get into your eyes, so always


wear protective glasses or goggles.

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

142 PSI (0.98 MPa) (10 kgf/cm2)

Steam pressure

56 PSI (0.39 MPa) (4 kgf/cm2)

Testing
Check visually to ensure there are no dents or damage to the fins.
24.4.28

CHECK FOR CATCHING, STALLING AND KNOCKING WHEN ACCELERATING

3-19

24. MAINTENANCE
(Engine continued)
24.4.29
CHECK AND CLEAN AIR CLEANER ELEMENT

Always wear safety goggles when using compressed


air.

NOTICE

If oil, grease or carbon is stuck to the element, clean the element


with special element cleaner. Follow the instructions provided
with the cleaner.

Do not remove the inner element (diesel engine trucks).

In heavy-duty operating environments or conditions, clean and


replace the element more frequently.

Cleaning
1. Remove the element, blow the element from the inside with
dry compressed air at 98 PSI (0.68 MPa) (7 kgf/cm2) and clean
the entire circumference.
2. After cleaning, reinstall the element.
Testing
Check visually that there is no damage to the element.
24.4.30

CHECK OPERATION OF GOVERNOR


(MAXIMUM SPEED)

24.4.31

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

24.4.32

CHECK FUEL FILTER AND FUEL STRAINER FOR CRACKING, DAMAGE


CHECK AND DRAIN WATER SEPARATOR (DIESEL ENGINE LIFT TRUCKS)

3-20

24. MAINTENANCE
(Engine continued)
24.4.33
CHECK RADIATOR HOSES FOR CRACKING, DAMAGE
24.4.34

CHECK OPERATING CONDITION OF RADIATOR CAP, CHECK INSTALLATION

24.4.35

CHECK FAN FOR DEFORMATION, CRACKING AND DAMAGE

24.4.36

CHECK FAN FOR LOOSENESS AND MOUNTING

24.4.37

CHECK, ADJUST FAN BELT TENSION

24.4.38

CHECK, ADJUST ALTERNATOR BELT TENSION

24.4.39

CHECK DISTRIBUTOR CAP (GASOLINE), DISTRIBUTOR INSIDE (IC IGNITION SYSTEM)


FOR CRACKING OR DAMAGE

24.4.40

CHECK CLEARANCE OF DISTRIBUTOR POINTS, CHECK CONTACT SURFACE FOR


ROUGHNESS

24.4.41

CHECK SPARK PLUGS FOR BURNING, BURNING OF INSULATOR


For details on checking spark plugs / insulators, see 24.4.42.4 CHANGE OIL IN ENGINE OIL PAN.

24.4.42

CHANGE OIL IN ENGINE OIL PAN

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

GASOLINE/LPG ENGINE (TB42)


NOTICE
Callout numbers in illustration match numbered headings here.
1. CHANGE ENGINE OIL (See item 1 for filler location)
1. Remove the drain plug, drain the oil, then reinstall and
tighten the drain plug.
2. Add the correct amount of specified engine oil.
3. Check the oil level with the dipstick.
NOTICE
Oil refill amount:

2.05 U.S. GALLONS (7.8 L, 1.72 UK gal.)

2. REPLACE ENGINE OIL FILTER (See item 2 for location)


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

3-21

24. MAINTENANCE

NOTICE
After installing the new oil filter cartridge, start the engine and check for oil leakage around the oil filter
seal and at the oil pan drain plug.
3. REPLACE FUEL FILTER
1. Loosen the nut, remove the glass bowl and take out the filter element.
2. Drain out any water and clean out any dirt accumulated at the bottom.
3. Install the new specified fuel filter element.
NOTICE

Check the packing at the glass bowl. Replace if necessary.


After replacing, check for fuel leakage around the glass bowl and at the hose mount. Correct if
necessary.

4. CHECK SPARK PLUGS (See also item 4 in illustration


on page 3-21 for location)
1. Remove the spark plug using the plug wrench provided
with the lift truck.
2. Clean off any carbon buildup on the tip of the plug or the
surrounding area. See illustration at right.
3. Measure gap (A) with plug gap gauge.
Specified spark plugs
NGK

B-4ES
BPR-4ES (Noise suppression type)

Hitachi

L47W

5. CHANGE THE GOVERNOR OIL


1. Loosen the drain plug and drain the oil, then install
and tighten the drain plug.
2. Remove the oil filler plug and oil level plug.
3. Add oil through the oil filler hole until oil flows from the
oil level hole, then install the oil filler plug and oil level plug.
NOTICE
Use the same oil as used in the oil pan.
(Capacity: 35 - 40 cc).
4. Tighten oil filler plug and oil level plug.

3-22

24. MAINTENANCE
DIESEL ENGINE (6D102E )
NOTICE
Callout numbers in illustration match numbered headings shown below.
1. CHANGE ENGINE OIL (see item 1 for filler location)
1. Remove the drain plug, drain the oil, then reinstall and
tighten the drain plug.
2. Remove the dipstick.
3. Add the specified amount of engine oil. Use care to prevent
oil overflow.
4. Check the oil level with the dipstick.
NOTICE
Oil refill amount:

3.04 U.S. gallons (11.5 L, 2.53 UK gal.)

2. REPLACE ENGINE OIL FILTER (see item 2 for location)


1. Use a filter wrench to remove the oil filter cartridge.
2. Clean the oil filter holder.
3. Coat the threads of the holder and the new filter seal with
clean engine oil.
4. Install the new oil filter cartridge.
NOTICE
After installing the new oil filter, start the engine and check for oil leakage at the filter seal and the oil pan
drain plug.

3-23

24. MAINTENANCE
(Engine continued)
3. DRAIN WATER FROM FUEL FILTER (see also item 3 in
illustration on page 3-23 for location)
Loosen the combination sensor plug and drain any water
and sediment accumulated at the bottom of the filter.
NOTICE

Fuel will also drain out of the fuel filter, so prepare a


suitable container to catch it.
Always be sure to wipe up any spilled fuel.

4. REPLACE FUEL FILTER (See also item 4 in illustration


on page 3-23 for location)
1. Remove the combination sensor plug at the bottom of
the cartridge.
2. Use a filter wrench to remove the cartridge.
3. Install the combination sensor plug on the new cartridge.
4. Fill the new cartridge with clean fuel, coat the packing
surface with a thin layer of clean engine oil, then install.
5. Loosen plug (1), then hand-pump knob (2) up and down
to bleed air bubbles from fuel. Continue until no more
bubbles come out with the fuel.
6. Tighten plug (1).

3-24

24. MAINTENANCE
(Electrical components)
24.4.43
CHECK OPERATION OF STARTING SWITCH; CHECK MESHING OF PINION GEAR
24.4.44

CHECK SPECIFIC GRAVITY OF BATTERY ELECTROLYTE

Precautions when handling battery:


Battery electrolyte is dangerous. If it gets into your eyes or upon your skin
or clothes, wash it off with large amounts of water quickly. If it gets into your
eyes, seek medical attention immediately.
Keep away from sparks or flame.
To avoid gas explosions, do not smoke or cause short circuits or sparks near
the battery.
CHECK SPECIFIC GRAVITY OF BATTERY ELECTROLYTE
1. Charge the battery, and after charging, check that the battery electrolyte level is correct.
2. Using a specific gravity meter and thermometer, measure
the specific gravity and temperature of the battery electrolyte.
3. Insert the values measured in Steps 1 and 2 in the formula
below, and calculate S20.
S20 = St + 0.0007 (t - 20)
S20:

Specific gravity at 68F (20oC)

St:
Specific gravity (measured value) at toC
t:
Temperature of battery electrolyte (measured value)
Normal value: S20 = 1.27 - 1.29
4. Charge the battery if necessary.
Specific gravity
of electrolyte

Condition of
charge

Charge
needed?

1.280
1.240

Fully charged
1/4 discharged

No

1.210
1.130

1/2 discharged
Fully discharged

Yes

Relation between specific gravity

and temperature of electrolyte


24.4.45

CHECK WIRING CONNECTIONS FOR LOOSENESS

24.4.46

CHECK IGNITION TIMING

(General)
24.4.47
24.4.48

CHECK OVERHEAD GUARD, LOAD BACKREST FOR DEFORMATION, CRACKING,


DAMAGE AND LOOSENESS
CHECK OPERATORS SEAT MOUNT FOR LOOSENESS AND DAMAGE,
CHECK LPG CYLINDER MOUNTING BRACKET

3-25

24. MAINTENANCE
24.4.49

GREASE ALL LUBRICATION POINTS

LUBRICATION POINTS
1. Mast support (left and right: 2 points)
2. Fork stopper (left and right: 2 points)
3. Front axle support (left and right: 2 points)
4. Steering axle
(a) Center pin (front and rear: 2 points)
(b) P.S. cylinder rod (left and right: 2 points)
(c) Knuckle joint (left and right: 2 points)
(d) King pin (left and right: 4 points)

24.5

EVERY 3 MONTHS OR EVERY 600 HOURS SERVICE

24.5.1

DRAIN WATER FROM WATER SEPARATOR AND REPLACE FUEL FILTER CARTRIDGE
(DIESEL ENGINE LIFT TRUCKS)
For details on draining the water and changing the filter, see 24.4.42.1 CHANGE OIL IN ENGINE OIL PAN.
24.5.2
REPLACE OIL FILTER CARTRIDGE
For details on replacing the oil filter cartridge, see 24.4.42.2 CHANGE OIL IN ENGINE OIL PAN.
24.5.3

GREASE FUEL INJECTION PUMP GOVERNOR, CHANGE GOVERNOR OIL

(Power train)
24.5.4
CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL AS NECESSARY
For details on checking and adding oil, see 24.6.4 CHANGE OIL IN DIFFERENTIAL CASE and 24.6.5 CHANGE
OIL IN TORQFLOW TRANSMISSION CASE.
24.5.5
CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL AS NECESSARY
For details on checking and adding oil, see 24.6.4 CHANGE OIL IN DIFFERENTIAL CASE.

24.6

EVERY 6 MONTHS OR EVERY 1,200 HOURS SERVICE

(Steering system)
24.6.1
CHECK STEERING LINK FOR BENDING, DAMAGE AND WEAR
24.6.2

CHECK KNUCKLE FOR PLAY, DEFORMATION AND DAMAGE

24.6.3

CHECK FOR MARKED VARIATION IN MINIMUM TURNING RADIUS

3-26

24. MAINTENANCE
24.6.4

CHANGE OIL IN DIFFERENTIAL CASE

Watch out for HOT OIL. Immediately after operations, the oil will be very hot. Wait for
the oil temperature to go down before starting this maintenance operation.
CHECK OIL LEVEL
1. Remove the level plug and check that the oil is near
the bottom edge of the plug hole.
If the oil level is low, remove the oil filler plug and add oil.
CHANGE OIL
1. Remove the oil filler plug, then remove the drain plug and
drain the oil.
2. After draining the oil, reinstall and tighten the drain plug and
add the correct amount of specified oil through the
oil filler.
3. After filling with new oil, check the oil level.
Specified oil refill amount
TORQFLOW
transmission lift truck

3.43 U.S. gal. (13 L, 2.86 UK gal.)

NOTICE
Always use specified gear oil (SAE 90). For details, see 20. LUBRICANT LIST.
REMARK
On the TORQFLOW transmission lift truck, each case has its own special oil, so it is necessary to check and
change the oil in the TORQFLOW transmission case in addition to checking and changing the oil in the differential
case in two separate operations.

3-27

24. MAINTENANCE
(Power train continued)
24.6.5
CHANGE OIL IN TORQFLOW TRANSMISSION CASE

Watch out for HOT OIL. Immediately after operations, the oil will be very hot. Wait for
the oil temperature to go down before starting this maintenance operation.
CHECK OIL LEVEL
1. Remove the floor plate and check oil with dipstick.
2. If the oil level is low, remove the dipstick and add oil.
CHANGE OIL, CLEAN STRAINER
1. Remove the drain plug, drain the oil, then reinstall and
tighten the drain plug.
2. Remove the mounting bolts, take out the strainer, and
wash it off in flushing oil.
3. After washing the strainer, blow air from the inside of the
strainer to dry it completely, then reinstall the strainer.
4. Add the specified amount of oil through the oil filler port.
5. After filling with oil, check the oil level.
Specified oil refill amount
TORQFLOW transmission
(including torque converter)

3.17 U.S. gal. (12 L, 2.64 UK gal.)

NOTICE
Always use specified oil or DEXRON II Automatic Transmission Fluid.
24.6.6

REPLACE TORQUE CONVERTER OIL FILTER

NOTICE
Replace with specified oil filter.

(Brake system)
24.6.7
CHANGE BRAKE OIL/FLUID
(Engine)
24.6.8

CHECK AND ADJUST VALVE CLEARANCE

24.6.9

MEASURE COMPRESSION PRESSURE

3-28

24. MAINTENANCE
24.6.10

CHECK AND ADJUST FUEL INJECTION TIMING; CHECK AND INSPECT FUEL INJECTION
NOZZLES (DIESEL)

24.6.11

CHECK PCV BLOW-BY GAS REDUCTION SYSTEM FOR CLOGGING OR DAMAGE

24.6.12

CHECK DISTRIBUTOR CAP CENTERPIECE FOR WEAR

24.6.13
REPLACE FUEL FILTER ELEMENT
For details on replacing the fuel filter element, see 24.4.42.3 CHANGE OIL IN ENGINE OIL PAN.
24.6.14

CLEAN INSIDE OF COOLING SYSTEM

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

CLEAN RADIATOR
Stop the lift truck on level ground.
1. After the engine has cooled off, open the drain valves at the
bottom of the radiator and the engine cylinder block to drain
the water/coolant mixture.
2. After draining, close the drain valves. Fill the radiator with
fresh water (tap water) and radiator flushing fluid through the
water filler, then run the engine at idling for approximately 15
minutes.
3. Stop the engine, open the drain valves to drain the water,
then add fresh water and run the engine at idling until
clean, clear water comes out of the drain valves
(5 - 10 minutes).
4. Stop the engine, drain all the water from the drain valves,
then close the drain valves and fill the radiator with fresh water
and long-life coolant.
Water and Coolant Capacities
TB42 engine
3.70 U.S. gal. (14 L, 3.08 UK gal.)
6D102E engine

3-29

24. MAINTENANCE
(Engine continued)

Coolant is flammable. Keep it away from open flame and sparks.

In cold areas, add long-life coolant.


NOTICE

(For details, see 16. COLD WEATHER OPERATION.


When not using long-life coolant, add rust prevention fluid to the radiator.
Always use appropriate products for the flushing fluid, rust prevention fluid and long-life coolant.

24.6.15

REPLACE AIR CLEANER ELEMENT

Never clean or replace air cleaner while the engine


is running.
If compressed air is used to clean the element,
dust will fly and there is danger that it may get
into your eyes.
Always wear safety goggles.

REPLACE ELEMENT
1. Remove the air cleaner element.
2. Remove the nut and take out the inner element (if equipped).
3. Cover the air connector end with a clean cloth or tape.
4. Clean the inside of the body, then remove the cover fitted in
Step 3.
5. Install a new element.

3-30

24. MAINTENANCE
(Hydraulic equipment)
24.6.16
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC LINE FILTER, CLEAN HYDRAULIC
TANK STRAINER, CLEAN INSIDE OF HYDRAULIC TANK

Watch out for HOT OIL. Immediately after operations, the oil will be very hot. Wait for
the oil temperature to go down before starting this maintenance operation.
1. Remove the drain plug at the bottom of the tank. Then
remove the cover, take out the strainer, and wash it in
flushing oil.
2. Clean the inside of the tank, then install the drain plug.
3. After washing the strainer, blow air from the inside of the strainer to
dry it completely, then reinstall the strainer.
4. Replace the line filter, then install the cover.
5. Add the specified amount of hydraulic oil through the dipstick hole,
then check the oil level with the dipstick.
Refill amount: 14.53 U.S. gal. (55 L, 12.10 UK gal.)
6. Start the engine, then operate the cylinders (lift, tilt) to the end of
their travel 5 or 6 times to bleed the air.
NOTICE
Always use specified hydraulic oil.

24.7 EVERY 2,000 HOURS OF SERVICE


24.7.1

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

24.8 EVERY YEAR OR 2,400 HOURS OF SERVICE


24.8.1

CHECK OPERATION OF BRAKE MASTER CYLINDER, CHECK FOR OIL LEAKAGE,


DAMAGE AND WEAR

24.8.2

CHECK OPERATION OF WHEEL CYLINDERS, CHECK FOR OIL LEAKAGE, DAMAGE & WEAR

24.8.3

CHECK OPERATION OF BRAKE DRUM, CHECK FOR DAMAGE AND WEAR

24.8.4

CHECK BRAKE LININGS FOR WEAR

24.8.5

CHECK OPERATING CONDITION OF BRAKE SHOE

24.8.6

CHECK BRAKE ADJUSTMENT LEVER AND RATCHET FOR WEAR AND DAMAGE

24.8.7

CHECK BRAKE SPRING FOR DETERIORATION

3-31

24. MAINTENANCE
24.8.8

CHECK BRAKE BACK PLATE FOR DEFORMATION AND CRACKING,


CHECK MOUNTING CONDITION

24.8.9

CHECK AIR TIGHTNESS OF BRAKE PIPING/TUBING

(Travel system)
24.8.10
CHECK AXLE FOR DEFORMATION, CRACKING AND DAMAGE
24.8.11

CHECK MOUNTING CONDITION OF DIFFERENTIAL

24.8.12

CHECK ROOT (BASE) OF FORKS FOR CRACKING (USE COLOR CHECK)

24.8.13

CHECK ROLLER SHAFT OF LOADING EQUIPMENT FOR CRACKING AND DAMAGE

24.8.14

CHECK MAST SUPPORT FOR DAMAGE AND WEAR

(Hydraulic equipment)
24.8.15
CHECK OPERATION OF RELIEF VALVE, CHECK RELIEF PRESSURE
24.8.16
(Engine)
24.8.17

REPLACE AIR BREATHER


REPLACE WATER SEPARATOR (DIESEL), CLEAN INSIDE OF FUEL TANK (GASOLINE AND
DIESEL LIFT TRUCKS)

24.8.18

CHECK FUEL INJECTION PRESSURE, INJECTION AMOUNT, INJECTOR CONDITION

24.8.19

TIGHTEN (RETORQUE) ENGINE CYLINDER HEAD BOLTS

(General)
24.8.20

CHECK FRAME AND CROSSMEMBER FOR CRACKING AND DAMAGE

3-32

25. REPLACEMENT PROCEDURES

25. REPLACEMENT PROCEDURES


25.1

REPLACING FUSES

NOTICE

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

The fuses are used to protect the electrical components and wiring from burning out.
1. Turn the starting switch to the OFF position.
2. Open the cover of the fuse box and replace necessary fuses inside.
To remove the cover from the fuse box, push the side face of the cover
lightly with your fingers and pull it out.
Check the relationship between the fuses and the electrical components when replacing.

Fuse capacity and related electrical component


No.

Capacity

Color

Related electrical component

(1)

10 Amp

(2)

10 Amp

(3)

10 Amp

Starting relay

(4)

15 Amp

Stop lamp

(5)

15 Amp

(6)

10 Amp

Meters
Red

Blue

Back-up lamp

Lamps
Horn

3-33

25. REPLACEMENT PROCEDURES

25. REPLACEMENT PROCEDURES


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

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

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

Jack up the fork lift truck after confirming that the jack will not slip. NEVER place
any part of your body under any part of the fork lift truck!
4. Place the jack on the jacking point and raise the lift truck up
until the wheel to be replaced clears the ground.
5. Remove the lug nuts, then remove the wheel.

Ask a tire and wheel specialist to carry out disassembly and assembly of tires and wheels.

6. Install the replacement wheel on the hub and hand tighten the
lug nuts to hold the wheel in place.
7. Tighten the lug nuts again with a lug wrench, using a
diagonal criss-cross or star pattern, ensuring that the wheel
is snugly in place, but not fully tightened.
8. Let the jack down slowly to lower the lift truck. Tighten the
lug nuts to the specified torque.
(For specified torque, see 21. SERVICE DATA.)

25. REPLACEMENT PROCEDURES

3-34

25. REPLACEMENT PROCEDURES

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

9. Adjust the tire inflation pressure to the set pressure.


(For details of the set inflation pressure, see 21. SERVICE DATA.)

25.3

REPLACING LAMPS

Check for any blown fuses or disconnections in the wiring harnesses,


and replace the lamps as necessary.

Gas Engine Trucks


(12 Volt System)

Diesel Engine Trucks


(24 Volt System)

Head lamp

55 W

70 W

Turn signal lamp

23 W

25 W

8 W

5 W

Lamp Function

Driving (clearance) lamp


Stop lamp

27 W

Back-up lamp

8 W

Warning lamp

1.4 W

Meter lighting lamp

3.4 W

3W

3-35