FB10RL (F) /13RL (F) /15RL (F) /18RL (F) - FB10RW/13RW/15RW-: Electric Reach Truck

ARA14E1-04
FB10R/18R-14
Operation & Maintenance Manual
ELECTRIC REACH TRUCK

FB10RL(F)/13RL(F)/15RL(F)/18RL(F)-14
FB10RW/13RW/15RW-14
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
contents before operating, in-
2-4-1 Shiba-koen, Minato-ku, Tokyo105-0011, Japan 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
4 it.
PRINTED IN JAPAN
12-07(YC)03004
INTRODUCTION 1
11
1-1
1.1 ABOUT THIS MANUAL INTRODUCTION
1. INTRODUCTION 1
1.1 ABOUT THIS MANUAL 1
This manual describes procedures for proper operation, inspection, and maintenance of this lift truck, and rules
you must follow for your safety.
Some actions involved in operation and maintenance of the lift truck can cause a serious accident if they are not
done in the manner described in this manual.
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.
Operators 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 indicators of this manual.
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 Forklift or your
Komatsu Forklift distributor for the latest available information on your lift truck or for questions regarding information in this
manual.
1-2
INTRODUCTION 1.2 FOR YOUR SAFETY
1.2 FOR YOUR SAFETY 1

For your safety, the information of possible hazards and how to avoid them are provided on this manual and with
the safety indicators attached to this lift truck.
1.2.1 SIGNAL WORDS 1

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
WARNING death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in
CAUTION minor or moderate injury.
Example of safety message using signal word
CAUTION
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.
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.
1-3
1.2 FOR YOUR SAFETY INTRODUCTION
1.2.2 SAFETY INDICATORS 1

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. Illustrations are used for these
safety indicators to tell the operators and service staffs clearly of the existence and content of a hazard.
In addition, there are pictorial indicators which simply indicate the prohibition content as well as indicators which
comply with the international standards.
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.
1-4
INTRODUCTION 1.3 APPLICABLE MODEL AND SERIAL No.
1.3 APPLICABLE MODEL AND SERIAL No. 1

This Operation and Maintenance Manual applies to the following lift trucks.
Model type Serial No.

FB10RL (F) /10RW-14
FB13RL (F) /13RW-14
M245-140001 and up
FB15RL (F) /15RW-14
FB18RL (F) -14
RL: Center drive type (L type)

RW: Wide type (W type)
(F): Cold storage type forklift
1.4 GENERAL VIEW OF THE LIFT TRUCK 1

1.4.1 APPLICATION OF THE LIFT TRUCK 1
This lift truck is intended to use mainly for the following work.
• Load handling with the forks of the lift truck.
1.4.2 DIRECTION OF THE LIFT TRUCK 1

This manual determines the left and right directions and front and rear directions as seen from the operator's
compartment.
Right
Front Rear
Left
1.5 UNITS OF MEASURE 1

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.
1-5
1.6 QUALIFICATION FOR OPERATION INTRODUCTION
1.6 QUALIFICATION FOR OPERATION 1

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.
1.7 RUNNING IN THE NEW LIFT TRUCK 1

1.7.1 RUNNING IN NEW THE LIFT TRUCK 1
Your Komatsu Forklift truck has been thoroughly adjusted and tested before shipment. However, operate
moderately during the first one month (or 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.
1.7.2 MAINTENANCE FOR THE NEW LIFT TRUCK 1

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.
1.8 WARRANTY AND SERVICE 1

1.8.1 PERIODICAL REPLACEMENT PARTS 1
Other than those specified by the law, Komatsu Forklift designates " periodical replacement 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 the Section "4.18 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS (PAGE 4-
64)".
1.8.2 USE OF GENUINE KOMATSU FORKLIFT PARTS AND OILS 1

Any problem caused by the use of other than genuine Komatsu Forklift parts (including oils) warranted by
Komatsu Forklift is not covered by the warranty.
1-6
INTRODUCTION 1.9 NECESSARY INFORMATION OF THE LIFT TRUCK
1.9 NECESSARY INFORMATION OF THE LIFT TRUCK 1

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., attachment, option, etc.
1.9.1 MEMORANDUM (To be filled by Komatsu Forklift distributor) 1

Model type
Serial No.
Attachment/option
Distributor
Address
Telephone, fax No.
Service person in charge
Sales representative in charge
1.9.2 MODEL AND SERIAL NO. LOCATION 1

LIFT TRUCK SERIAL NO. PLATE LOCATION
The serial number plate locates by the steering wheel at the left
side of operator's compartment.
LIFT TRUCK EMBOSSED SERIAL NO. LOCATION

Besides the serial No. plate, the serial No. is also embossed on
the front of frame over the battery.
Example of embossed mark: M *** - #######
Serial No. is shown as # after the hyphen.
1-7
1.10 CONTENTS INTRODUCTION
1.10 CONTENTS
1. INTRODUCTION --------------------------------------------------------------------------------------------------------------------- 1-2
1.1 ABOUT THIS MANUAL ----------------------------------------------------------------------------------------------------- 1-2
1.2 FOR YOUR SAFETY -------------------------------------------------------------------------------------------------------- 1-3
1.2.1 SIGNAL WORDS ----------------------------------------------------------------------------------------------------- 1-3
1.2.2 SAFETY INDICATORS --------------------------------------------------------------------------------------------- 1-4
1.3 APPLICABLE MODEL AND SERIAL NO. ------------------------------------------------------------------------------ 1-5
1.4 GENERAL VIEW OF THE LIFT TRUCK -------------------------------------------------------------------------------- 1-5
1.4.1 APPLICATION OF THE LIFT TRUCK -------------------------------------------------------------------------- 1-5
1.4.2 DIRECTION OF THE LIFT TRUCK------------------------------------------------------------------------------ 1-5
1.5 UNITS OF MEASURE ------------------------------------------------------------------------------------------------------- 1-5
1.6 QUALIFICATION FOR OPERATION ------------------------------------------------------------------------------------ 1-6
1.7 RUNNING IN NEW LIFT TRUCK ----------------------------------------------------------------------------------------- 1-6
1.7.1 RUNNING IN THE NEW LIFT TRUCK-------------------------------------------------------------------------- 1-6
1.7.2 MAINTENANCE FOR THE NEW LIFT TRUCK -------------------------------------------------------------- 1-6
1.8 WARRANTY AND SERVICE ---------------------------------------------------------------------------------------------- 1-6
1.8.1 PERIODICAL REPLACEMENT PARTS ------------------------------------------------------------------------ 1-6
1.8.2 USE OF GENUINE KOMATSU FORKLIFT PARTS AND OILS ------------------------------------------ 1-6
1.9 NECESSARY INFORMATION OF THE LIFT TRUCK -------------------------------------------------------------- 1-7
1.9.1 MEMORANDUM (TO BE FILLED BY KOMATSU FORKLIFT DISTRIBUTOR) ---------------------- 1-7
1.9.2 MODEL AND SERIAL NO. LOCATION------------------------------------------------------------------------- 1-7
2. SAFETY--------------------------------------------------------------------------------------------------------------------------------- 2-2
2.1 SAFETY LABEL --------------------------------------------------------------------------------------------------------------- 2-2
2.1.1 SAFETY LABEL LOCATION CHART --------------------------------------------------------------------------- 2-2
2.1.2 SAFETY LABEL ------------------------------------------------------------------------------------------------------ 2-4
2.2 BASIC PRECAUTIONS ----------------------------------------------------------------------------------------------------- 2-9
2.2.1 FOLLOW RULES----------------------------------------------------------------------------------------------------- 2-9
2.2.2 NEVER OPERATE THE BROKEN-DOWN LIFT TRUCK------------------------------------------------ 2-10
2.2.3 WEAR ADEQUATE CLOTHES AND SAFETY EQUIPMENT FOR OPERATION ----------------- 2-10
2.2.4 FIRE EXTINGUISHER AND FIRST AID KIT ---------------------------------------------------------------- 2-10
2.2.5 CAUTIONS FOR SAFETY-RELATED EQUIPMENT------------------------------------------------------ 2-11
2.2.6 PRACTICE SUFFICIENTLY BEFORE OPERATION ----------------------------------------------------- 2-11
2.2.7 JUMPING ON AND OFF FROM THE LIFT TRUCK IS STRICTLY PROHIBITED----------------- 2-11
2.2.8 KEEP THE OPERATOR'S COMPARTMENT AND PLATFORM CLEAN AND TIDY------------- 2-11
2.2.9 PRECAUTION WHEN WASHING THE LIFT TRUCK ---------------------------------------------------- 2-12
2.2.10 TO AVOID BURN INJURY ------------------------------------------------------------------------------------- 2-12
2.2.11 FIRE PREVENTION --------------------------------------------------------------------------------------------- 2-12
2.2.12 IF A FIRE BREAKS OUT --------------------------------------------------------------------------------------- 2-13
2.2.13 DO NOT MODIFY THE LIFT TRUCK ----------------------------------------------------------------------- 2-14
2.2.14 DO NOT REMOVE THE OVERHEAD GUARD AND LOAD BACKREST-------------------------- 2-14
2.2.15 DRIVING THIS FORKLIFT TRUCK ON THE PUBLIC ROAD IS PROHIBITED------------------ 2-14
2.2.16 CAUTION ON WATER DROPLET --------------------------------------------------------------------------- 2-14
2.2.17 SECURE SAFETY AT THE WORKING AREA------------------------------------------------------------ 2-15
2.2.18 ASBESTOS CAUTION ------------------------------------------------------------------------------------------ 2-15
2.3 START-UP INSPECTION------------------------------------------------------------------------------------------------- 2-16
2.4 TRAVELING THE LIFT TRUCK----------------------------------------------------------------------------------------- 2-17
2.4.1 PREPARATION BEFORE TRAVELING THE LIFT TRUCK--------------------------------------------- 2-17
2.4.2 WHILE TRAVELING THE LIFT TRUCK ---------------------------------------------------------------------- 2-18
2.4.3 STOPPING AND PARKING ------------------------------------------------------------------------------------- 2-22
2.4.4 TOWING -------------------------------------------------------------------------------------------------------------- 2-23
2.5 LOAD HANDLING OPERATION---------------------------------------------------------------------------------------- 2-24
2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE SAFETY ---------------------------------------- 2-29
2.6.1 ALWAYS PERFORM THE START-UP INSPECTION ---------------------------------------------------- 2-29
2.6.2 PUT UP A WARNING SIGN DURING INSPECTION AND MAINTENANCE ----------------------- 2-29
2.6.3 KEEP THE WORKING AREA CLEAN AND TIDY --------------------------------------------------------- 2-29
2.6.4 CAUTIONS BEFORE INSPECTION AND MAINTENANCE--------------------------------------------- 2-30
2.6.5 KEEP UNAUTHORIZED PEOPLE OFF ---------------------------------------------------------------------- 2-30
2.6.6 USE OF RIGHT TOOLS AND EQUIPMENT ---------------------------------------------------------------- 2-30
1-8
INTRODUCTION 1.10 CONTENTS
2.6.7 CAUTIONS WHEN WORKING UNDER WORK EQUIPMENT------------------------------------------2-31

2.6.8 AVOID GETTING CAUGHT UP BY THE MAST OR FALLING OFF-----------------------------------2-31
2.6.9 BE CAREFUL OF HIGH PRESSURE OIL --------------------------------------------------------------------2-32
2.6.10 BEWARE OF ROTATING COOLING FAN -----------------------------------------------------------------2-32
2.6.11 CAUTIONS FOR USING COMPRESSED AIR FOR CLEANING -------------------------------------2-32
2.6.12 REMOVING THE BATTERY PLUG --------------------------------------------------------------------------2-33
2.6.13 CAUTION WHEN HANDLING BATTERY-------------------------------------------------------------------2-33
2.6.14 CAUTION ON STORING THE BATTERY ------------------------------------------------------------------2-34
2.6.15 CAUTION IN WASTE DISPOSAL-----------------------------------------------------------------------------2-34
2.6.16 CAUTION AFTER INSPECTION AND REPAIR-----------------------------------------------------------2-35
2.6.17 PERIODIC INSPECTION OF SAFETY CRITICAL PARTS---------------------------------------------2-35
2.7 HOISTING AND TRANSPORTING THE LIFT TRUCK ------------------------------------------------------------2-36
2.7.1 CAUTION WHEN HOISTING THE LIFT TRUCK -----------------------------------------------------------2-36
2.7.2 PRECAUTIONS FOR LOADING AND UNLOADING THE LIFT TRUCK -----------------------------2-36
2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK
(TO PREVENT THE LIFT TRUCK FROM TIPPING)---------------------------------------------------------------2-37
2.8.1 LONGITUDINAL STABILITY -------------------------------------------------------------------------------------2-37
2.8.2 CENTER OF GRAVITY OF A LOAD---------------------------------------------------------------------------2-37
2.8.3 COMBINED CENTER OF GRAVITY AND STABILITY ON THE LOADED LIFT TRUCK --------2-38
2.8.4 ACTUAL CAPACITY -----------------------------------------------------------------------------------------------2-39
2.8.5 SERIAL NO. AND LOAD TABLE--------------------------------------------------------------------------------2-40
2.8.6 INTRODUCTION OF OPTIONAL SAFETY DEVICE ------------------------------------------------------2-41
3. OPERATION -------------------------------------------------------------------------------------------------------------------------- 3-2
3.1 GENERAL VIEW-------------------------------------------------------------------------------------------------------------- 3-2
3.1.1 GENERAL VIEW OF THE LIFT TRUCK ----------------------------------------------------------------------- 3-2
3.1.2 GENERAL VIEW OF THE OPERATION EQUIPMENT ---------------------------------------------------- 3-3
3.2 EXPLANATION OF COMPONENTS ------------------------------------------------------------------------------------ 3-4
3.2.1 HOW TO READ METER PANEL -------------------------------------------------------------------------------- 3-4
3.2.2 HOW TO OPERATE METER PANEL -------------------------------------------------------------------------3-12
3.2.3 OPERATING DEVICES -------------------------------------------------------------------------------------------3-15
3.2.4 DRAWING OUT AND PULLING IN THE BATTERY -------------------------------------------------------3-22
3.3 OPERATION ------------------------------------------------------------------------------------------------------------------3-24
3.3.1 START-UP INSPECTION -----------------------------------------------------------------------------------------3-24
3.3.2 MOUNTING/DISMOUNTING AND OPERATING POSTURE ADJUSTMENT ----------------------3-24
3.3.3 BASIC OPERATION -----------------------------------------------------------------------------------------------3-25
3.3.3.1 STARTING ---------------------------------------------------------------------------------------------------3-25
3.3.3.2 TRAVELING--------------------------------------------------------------------------------------------------3-26
3.3.3.3 TURNING -----------------------------------------------------------------------------------------------------3-26
3.3.3.4 PLUGGING---------------------------------------------------------------------------------------------------3-27
3.3.3.5 STOPPING ---------------------------------------------------------------------------------------------------3-27
3.3.3.6 TEMPORARY STOPPING AND PARKING----------------------------------------------------------3-28
3.3.4 OPERATION ACCORDING TO THE CIRCUMSTANCE -------------------------------------------------3-29
3.3.4.1 TRAVELING ON SLOPES -------------------------------------------------------------------------------3-29
3.3.4.2 INCHING TRAVEL -----------------------------------------------------------------------------------------3-30
3.3.4.3 PLUGGING (ELECTRIC BRAKE) ----------------------------------------------------------------------3-31
3.3.4.4 OPERATION ON SNOWY AND FROZEN ROADS -----------------------------------------------3-31
3.3.5 TRAVEL INTERLOCK FUNCTION -----------------------------------------------------------------------------3-32
3.3.6 BASIC LIFT OPERATION ----------------------------------------------------------------------------------------3-33
3.3.6.1 HOW TO OPERATE CONTROL LEVERS -----------------------------------------------------------3-33
3.3.6.2 FORK SPREAD ADJUSTMENT ------------------------------------------------------------------------3-34
3.3.6.3 PROCEDURE FOR PICKING UP AND STACKING-----------------------------------------------3-35
3.3.7 LIFT INTERLOCK FUNCTION ----------------------------------------------------------------------------------3-36
3.3.8 CHECKING AFTER OPERATION ------------------------------------------------------------------------------3-36
3.4 THE LIFT TRUCKS WITH COLD-STORAGE MODEL ------------------------------------------------------------3-37
4. INSPECTION AND MAINTENANCE -------------------------------------------------------------------------------------------- 4-2
4.1 ABOUT INSPECTION AND MAINTENANCE ------------------------------------------------------------------------- 4-2
4.2 START-UP INSPECTION -------------------------------------------------------------------------------------------------- 4-2
4.2.1 CHECKING ABNORMALITIES DETECTED ON THE PREVIOUS DAY ------------------------------ 4-4
1-9
1.10 CONTENTS INTRODUCTION
4.2.2 WALK AROUND THE LIFT TRUCK ----------------------------------------------------------------------------- 4-4

4.2.3 INSPECTION CONDUCTED BY DRAWING OUT THE BATTERY ------------------------------------- 4-6
4.2.4 CHECKING FROM OPERATOR COMPARTMENT--------------------------------------------------------- 4-8
4.2.5 CHECKING BY SETTING THE STARTING SWITCH TO [ | ] (ON) POSITION-------------------- 4-10
4.2.6 CHECKING WHILE RUNNING THE LIFT TRUCK -------------------------------------------------------- 4-11
4.2.7 CHECKING OF SAFETY FUNCTION------------------------------------------------------------------------- 4-13
4.3 CHECKING AND REPORTING AFTER OPERATION ------------------------------------------------------------ 4-15
4.4 SIMPLE MAINTENANCE ------------------------------------------------------------------------------------------------- 4-16
4.4.1 GREASES AND FUEL -------------------------------------------------------------------------------------------- 4-16
4.4.1.1 BASIC PRECAUTIONS ---------------------------------------------------------------------------------- 4-16
4.4.1.2 LUBRICANT LIST------------------------------------------------------------------------------------------ 4-18
4.4.2 JACKING-UP -------------------------------------------------------------------------------------------------------- 4-20
4.4.3 REPLACING FUSE ------------------------------------------------------------------------------------------------ 4-21
4.4.4 REPLACING BULBS ---------------------------------------------------------------------------------------------- 4-24
4.5 HANDLING OF BATTERIES--------------------------------------------------------------------------------------------- 4-25
4.6 CHARGING------------------------------------------------------------------------------------------------------------------- 4-29
4.6.1 OPERATION OF ON-BOARD TYPE BATTERY CHARGER (OPTION) ----------------------------- 4-31
4.6.2 OPERATION OF STATIONARY BATTERY CHARGER (OPTION)----------------------------------- 4-37
4.7 REPLACING OF BATTERY---------------------------------------------------------------------------------------------- 4-40
4.8 REPLACING OF BATTERY
(IN CASE OF BATTERY FRONT TO SIDE REMOVAL STRUCTURE) (OPTION FOR RL) ------------ 4-44
4.9 RUNNING IN COLD WEATHER ---------------------------------------------------------------------------------------- 4-51
4.10 OPERATING THE LIFT TRUCKS IN SPECIAL ENVIRONMENT OR IN FORCIBLE WAY ----------- 4-51
4.11 ACTION TO TAKE IF THE FORK FAILS TO LOWER ---------------------------------------------------------- 4-52
4.12 PROCEDURES FOR ALARM CODE OR ERROR CODE INDICATION ----------------------------------- 4-53
4.13 WASHING THE LIFT TRUCK------------------------------------------------------------------------------------------ 4-55
4.14 LONG-TERM STORAGE------------------------------------------------------------------------------------------------ 4-56
4.15 HOISTING THE LIFT TRUCK------------------------------------------------------------------------------------------ 4-57
4.16 LOADING AND UNLOADING OF THE LIFT TRUCK------------------------------------------------------------ 4-58
4.17 INSPECTION AND MAINTENANCE SCHEDULE CHART----------------------------------------------------- 4-59
4.18 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ------------------------------------------------ 4-64
4.19 SERVICE DATA ----------------------------------------------------------------------------------------------------------- 4-65
5. TECHNICAL DATA------------------------------------------------------------------------------------------------------------------- 5-2
6. INDEX ----------------------------------------------------------------------------------------------------------------------------------- 6-2
1-10
SAFETY 2
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 follow these
precautions strictly.
2-1
2.1 SAFETY LABEL SAFETY
2. SAFETY 2
2.1 SAFETY LABEL 2
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 2
2-2
SAFETY 2.1 SAFETY LABEL
No. Safety labels name Position
1 Caution before operation. Left side of operator' s compartment.
2 Do not operate LIFT TRUCK from out side. Right side of front panel.
3 Do not enter when reaching out mast. Outer side of mast, right hand.
Do not go under the lifted forks.

4 Outer side of mast, right and left.
Working on the forks is strictly prohibited.
5 Caution when handling battery. Rightside of battery case front.
6 Caution to avoid getting hand caught. Rear side of inner mast and outer mast.
Caution on drawing out and pulling in the

7 In front of operator's compartment.
battery.
Inner right side of frame. <L type only>

8 Caution on threading the battery cable.
(Right side of battery compartment)
9 Do not touch the exposed terminals. Inner side of inspection door.
10 Precaution when washing lift truck. Left side of operator's compartment.
11 Caution on hoisting the forklift truck. In front of operator's compartment.
12 Emergency power cut-off button. Right side of emergency power cut-off button.
13 Caution to avoid getting caught. Right upper side of fan duct.
2-3
2.1.2 SAFETY LABEL 2

1. Caution before operation (3EB-96-54120)
( C a u t i o n l a b e l m ay b e a t t a 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
M a n u a l t h o r o u g h l y b e fo r e o p e r a t i n g , s e r v i c i n g ,
disassembling, assembling or transporting.
3EB-96-54120
2. Do not of operate lift truck from out side.

(3LA-96-13250)
3LA-96-13250
3. Do not enter between mast and chassis. (3LA-96-13260)
3LA-96-13260
2-4
4. Do not go under the lifted forks.

Working on the forks is strictly prohibited.
(3EB-96-25131)
3EB-96-25131
5. Caution when handling battery (3BB-96-36840)

(Shape and layout may vary depending on the battery
supplier.)
2-5
6. Caution to avoid getting hand caught (3EB-96-25121)

• Do not place your hands.
7. Caution on drawing out and pulling in the battery

(3LA-96-34440)
3LA-96-34440
8. Caution on threading the battery cable

(3LA-96-34430)
(L type only)
3LA-96-34430
9. Do not touch the exposed terminal (3LA-96-13220)
3LA-96-13220
2-6
10. Precaution when washing lift truck (37B-1QC-5030)
11. Caution when hoisting the lift truck (3LA-96-34460)
3LA-96-34460
12. Emergency power cut-off button (3BA-96-72620)
2-7
13. Caution to avoid getting caught (37B-1QL-5030)

• Keep hand off the rotating fan.
2-8
SAFETY 2.2 BASIC PRECAUTIONS
2.2 BASIC PRECAUTIONS 2

2.2.1 FOLLOW RULES 2
• 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 carry out operations
in 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.
2-9
2.2 BASIC PRECAUTIONS SAFETY
2.2.2 NEVER OPERATE THE BROKEN-DOWN LIFT TRUCK 2

• If any abnormality is detected during the start-up inspection or
during the operation (noise, vibration, odor, maladjusted gauge,
Never
use
smoke, oil leak, or erroneous indication of warning 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 a failure and 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.)
2.2.3 WEAR ADEQUATE CLOTHES AND SAFETY EQUIPMENT FOR OPERATION 2

• 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 2

• In preparation for a fire or bodily injury, check the locations of
fire extinguisher and first aid kit, and be familiar with the usage.
2-10
2.2.5 CAUTIONS FOR SAFETY-RELATED EQUIPMENT 2

• 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 2

• 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.
2.2.7 JUMPING ON AND OFF FROM THE LIFT TRUCK IS STRICTLY PROHIBITED 2
• 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.
• 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 2
Always keep the operator's compartment and platform (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.
2-11
2.2.9 PRECAUTION WHEN WASHING THE LIFT TRUCK 2

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 the Section
"4.13 WASHING LIFT TRUCK (PAGE 4-55)".
2.2.10 TO AVOID BURN INJURY 2

HIGH TEMPERATURE PARTS AND OIL
To prevent burns caused by high temperature parts such as
motor, controller, charger, etc., 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 2

FIRE CAUSED BY HYDROGEN GAS EMITTED FROM BATTERIES
• Batteries generate flammable hydrogen gas.
• Never smoke or allow any flame near the battery.
• Sparks may ignite the gas. Do not place tools, parts or other
metal objects on the battery.
• Charge batteries always in a well-ventilated place with the
battery hood open.
2-12
FIRE CAUSED BY OIL AND GREASES

Oil and greases, window washer fluid, etc. are flammable, so
keep them away from open flame.
Strictly follow the instructions shown below.
• Do not smoke or allow any flame near oil, antifreeze or window
washer fluid or clothes soaked in them.
• Tighten caps securely.
• Do not spill oil and greases on the overheated surface or
electrical system components.
• Store oil and greases in a well-ventilated dark cold place.
• Store oil and grease in a designated place. Keep unauthorized
people off the storage.
• Wipe off the spilled oil and greases.
• 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.
FIRE CAUSED BY DEPOSITS AND FOULING OF FLAMMABLE OBJECTS

If flammables are deposited or attached to around the motor or
batteries, they may cause 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
bodily injury.
2.2.12 IF A FIRE BREAKS OUT 2

• If a fire breaks out, press emergency stop button (red), cut off
the electric circuit and stop the machine.
• Do not jump off the lift truck in a rush. Support yourself
securely with handrails and steps to evacuate.
2-13
2.2.13 DO NOT MODIFY THE LIFT TRUCK 2

• Contact Komatsu Forklift distributor in advance for any
modification (installation, removal and modification) of the lift
truck, attachment or option. It may cause safety hazard and modify
may violate the law.

• Komatsu Forklift will not be responsible for any bodily injury,
damage or failure which results from the modification made
without prior consent of Komatsu Forklift in writing.
2.2.14 DO NOT REMOVE THE OVERHEAD GUARD AND LOAD BACKREST 2

• Do not remove the overhead guard or load backrest, which are
installed to protect the operator from falling objects.
• Do not operate this lift truck unless it is equipped with the
overhead guard and load backrest shipped with the lift truck
from the factory by Komatsu Forklift.
• 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 DRIVING THIS FORKLIFT TRUCK ON THE PUBLIC ROAD IS PROHIBITED 2

• Since the reach type forklift truck does not fully meet the [Safety
Standard of Road Transportation Vehicle Law], driving the forklift
truck is not allowed. If you drive, you will violate the [Safety
Standard of Road Transportation Vehicle Law and Road Traffic
Law Violation].
2.2.16 CAUTION ON WATER DROPLET 2

• Avoid using or leaving the forklift truck in the open air when raining.
• When washing the forklift truck, avoid splashing water directly to
the electrical parts. If a water droplet contacts the electrical
system, the electrical system may malfunction, resulting in the
failure of forklift truck control.
2-14
2.2.17 SECURE SAFETY AT THE WORKING AREA 2

• 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.
2.2.18 ASBESTOS CAUTION 2

• Non-genuine parts (unspecified parts of Komatsu Forklift) such
as clutch disc, brake lining, gasket and packing may contain
asbestos. Use genuine Komatsu Forklift parts.
• All the parts used in this lift truck are asbestos-free.
2-15
2.3 START-UP INSPECTION SAFETY
2.3 START-UP INSPECTION 2

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 the Section "4.1 ABOUT
INSPECTION AND MAINTENANCE (PAGE 4-2)".
• 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.
CAUTIONS FOR OPERATING STARTING SWITCH, STARTING THE LIFT TRUCK AND OPERATING WORK
EQUIPMENT
• When operating the starting switch, be positioned properly in
the operator's compartment, take your foot off the brake pedal
with the accelerator lever positioned in the neutral and turn the
starting switch to ON.
• Before starting the lift truck or operating the work equipment
(mast, fork, etc.), check the safety in the surrounding areas and
sit in the operator's compartment.
• Before moving the lift truck or operating the work equipment,
sound the horn to warn people around.
CAUTIONS WHEN CHECKING SAFETY FUNCTION

Before checking safety function, retain wide safety space
around the lift truck in case it makes a sudden, unexpected
movement. Check that the area is free of people and obstacles.
(Apply travel interlock, lift interlock, neutral safety and parking
brake.)
CAUTION IN COLD WEATHER

• Immediately upon starting operation for the day in cold weather,
travel and lifting speed may be slow or steering effort may be
heavier or steering movement may change suddenly, leading to
accident. Operate the lift truck carefully until oil and machine
components warm up properly.
• For the method of maintenance, see "4.4 SIMPLE
MAINTENANCE (PAGE 4-16)" and "4.9 RUNNING IN COLD
WEATHER (PAGE 4-51)".
2-16
SAFETY 2.4 TRAVELING THE LIFT TRUCK
2.4 TRAVELING THE LIFT TRUCK 2

2.4.1 PREPARATION BEFORE TRAVELING THE LIFT TRUCK 2
POSITION YOURSELF PROPERLY IN THE OPERATOR’S COMPARTMENT
If you operate the forklift truck when you are not properly
inposition, you may suffer unexpectedly from an accident,
resulting in injury. To prevent this from occurring, the forklift truck
is provided with the functions ([TRAVEL INTERLOCK] and [LIFT
INTERLOCK]) to disable traveling and lift-handling unless you are
positioned properly.
For details, see "3.3.5 TRAVEL INTERLOCK FUNCTION (PAGE
3-32)" and "3.3.7 LIFT INTERLOCK FUNCTION (PAGE
3-36)".
BEFORE TRAVELING THE LIFT TRUCK, CHECK THE SAFETY OF SURROUNDING AREA
• Raise the fork by 30 to 35 cm from the ground and tilt it
backward.
• Before starting to travel the lift truck, check that the surrounding
area is clear of obstructions such as pedestrians, other trucks
and loads.
• Sound the horn areas as may be needed.
2-17
2.4 TRAVELING THE LIFT TRUCK SAFETY
2.4.2 WHILE TRAVELING THE LIFT TRUCK 2

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.
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.
DO NOT STICK THE HAND OR FOOT OUTSIDE THE MACHINE BODY

• When driving, do not protrude your hand, elbow, foot or head
outside the truck. If you do so, will be in danger of yourself
being hit by an obstacle such as shelve or pillar.
NEVER TURN OFF THE STARTING SWITCH WHILE TRAVELING

• If the starting switch is turned to [ ] (OFF) while traveling, the
power steering effort may become felt heavier, which is
dangerous.
2-18
BRAKE OPERATION
As the braking distance differs depending on the road conditions
and weight of load, perform the brake operation such as plugging
earlier than usual, keep with enough distance. For plugging, refer
to "OPERATION 3.3.4.3 PLUGGING (ELECTRIC BRAKE) (PAGE
3-31)".
When traveling on a downhill, wet road or slippery road or loading
a heavy cargo, the braking distance is longer that otherwise.
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.In case of the
forklift truck equipped with back-mirror, as the back-mirror only
assists you to see the rear view, do not rely on the back-mirror
for your confirming the rear 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.
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.
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 above the ground or top of
the reach-leg with the mast tilted backward.)
• Do not make a sudden lift-up and lift-down of a fork or a sudden
front-tilt and rear-tilt. Otherwise, the forklift truck may overturn.
• Decelerate enough before turning. Especially, when no cargo is
loaded, as the rear of forklift truck is heavy, if turn when
traveling at high speed, overturning may occur much easily
than when loaded.
2-19
WHEN MAKING A TURN, BE CAREFUL OF THE SWINGING TAIL

• The lift truck has rear steering wheels. Be careful as if behaves
differently from passenger cars.
• When turning while traveling forward, the
counterbalanceweight will swing far out. Keep an ample
clearance from walls to ensure safety.
• Turn slowly with caution for front wheel or rear wheel not to
derail from the road. Do not drive and operate the forklift truck
so that it overturns on the soft edge of road.
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.
DO NOT TRAVEL ON ROUGH OR SLIPPERY ROAD

• Do not try to travel on bumpy or soft ground. It can lead to a
serious accident when you lose steering control or the tires
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.
2-20
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.
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 traveling uphill, stop the lift truck and adjust the fork
clearance between the ground. Keep the bottom of the forks or
pallet off the ground or prevent the tips of the forks from
sticking 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.
• When starting on the slope, as the forklift truck may move

backward depending on the effort of stepping on the pedal,
keep enough margin at back and forth.
• When stopping on the downhill, a stopping distance is longer
than on the flat road. When unloaded
2-21
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 trainers.
• Do not travel at the edge of the platforms or loading docks, or
there is a danger of the lift truck falling down.
2.4.3 STOPPING AND PARKING 2

FOLLOW THE STEPS FOR STOPPING AND PARKING
1. Stop the lift truck on a firm level ground.
2. Take your foot off the brake pedal and make the forklift truck
complete stop. (The parking brake works.)
3. Set the accelerator lever in the neutral position.
4. Tilt the fork forward and lower it to the ground.

5. Turn the starting switch key to the [ ] (OFF) position.
6. Pull out the starting 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 parking on a slope is
unavailable, apply blocks to the tires.
2-22
2.4.4 TOWING 2
DO NOT TOW A DISABLED LIFT TRUCK
If there is any problem with the brakes or steering system of your
lift truck, do not tow with another lift truck. There is a danger that
disabled the lift truck may move accidentally.
2-23
2.5 LOAD HANDLING OPERATION SAFETY
2.5 LOAD HANDLING OPERATION 2

BE POSITIONED CORRECTLY IN THE COMPARTMENT FOR LOAD HANDLING OPERATION
To avoid accidents, Load Handling Interlock activates to disable
the load handling operation when you are not positioned properly
or off the correct compartment area.
For more details on the function of load handling interlocking, see
"3.3.7 LIFT INTERLOCK FUNCTION (PAGE 3-36)".
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 his/her
instructions.
DO NOT GO UNDER THE LIFTED FORKS

The lifted forks may accidentally fall down to cause serious
injuries to person below, of any. 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.
2-24
SAFETY 2.5 LOAD HANDLING OPERATION
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.
2-25
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

• When the forks are raised, the mast height increases. Be
particularly careful when the forks are raised.
• 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 details,
see "2.8.4 ACTUAL CAPACITY (PAGE 2-39)" and "2.8.5 SERIAL
NO. AND LOAD TABLE (PAGE 2-40)".
DO NOT TILT THE FORK FORWARD WITH A LOAD ON THE FORKS

Do not tilt the fork forward with the load raised. Do not raise the
load with the fork tilted forward. Or the load may fall or the lift truck
may tip over. Do not travel with the fork tilted forward.
2-26
SAFETY 2.5 LOAD HANDLING OPERATION
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 with 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 a sudden stop.
Sudden lowering may cause the collapsing or 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.
2-27
DO NOT PRY SOMETHING WITH THE TIPS OF THE FORK

Or the hooked object may suddenly come off the tip and be
damaged. The reaction may result in an unexpected motion of the
lift truck or load and the risk to the safety.
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 of 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.
2-28
SAFETY 2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE SAFETY
2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE SAFETY 2

2.6.1 ALWAYS PERFORM THE START-UP INSPECTION 2
• 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 2

• 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 as well, if necessary.
• Do not let any other person than the inspector or maintenance
staff start truck 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 his/her instructions.
2.6.3 KEEP THE WORKING AREA CLEAN AND TIDY 2

• Keep the working area clean and tidy. Get obstacles out of the
way. Wipe off any grease or oil.
• Perform the work on level surface with ample space.
• If the work is carried out inside a building, keep it well
ventilated.
2-29
2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE SAFETY SAFETY
2.6.4 CAUTIONS BEFORE INSPECTION AND MAINTENANCE 2

• Arrange for a fire extinguisher. Know the location and how to use
it.
• Arrange the lift truck for inspection and/or maintenance as follows:
1.Lower the forks to the floor.
2.Take your foot off the brake pedal.
(Parking brake activated)
3.Set the operating lever and forward/reverse switch to N
(Neutral) position.
4.Turn the starting switch to [ ] (OFF) position to cut off power
• 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).
• Block the front and rear tires.
2.6.5 KEEP UNAUTHORIZED PEOPLE OFF 2

No unauthorized person is allowed near the lift truck under
maintenance service.
2.6.6 USE OF RIGHT TOOLS AND EQUIPMENT 2

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.
2-30
2.6.7 CAUTIONS WHEN WORKING UNDER WORK EQUIPMENT 2

Block the forks and mast to prevent falling before working under
the raised forks. Otherwise a serious accident may result.
2.6.8 AVOID GETTING CAUGHT UP BY THE MAST OR FALLING OFF 2

• 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.
2-31
2.6.9 BE CAREFUL OF HIGH PRESSURE OIL 2

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.
• If your skin and/or eye are injured by high-pressure oil, wash it
with fresh water and immediately see a physician.
2.6.10 BEWARE OF ROTATING COOLING FAN 2

• Keep hand off the rotating fan.
2.6.11 CAUTIONS FOR USING COMPRESSED AIR FOR CLEANING 2

• 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.
2-32
2.6.12 REMOVING THE BATTERY PLUG 2

• When repairing the electrical system, set the starting switch to
the position [ ] (OFF) and remove the battery plug to cut off
the current and then repair.
• Do not start repairing electrical system by merely depressing
emergency stop button.
2.6.13 CAUTION WHEN HANDLING BATTERY 2

Handling error of batteries may cause explosions, fires and other
critical injuries. Handle batteries after fully understanding how to
handle and their hazards.
• Batteries generate flammable hydrogen gas and may explode
in contact with fire. Always keep the battery hood open while
charging batteries.
• Do not smoke or allow any flame near the battery.
• Sparks may ignite the gas. Do not place tools, parts or other
metal objects on the battery.
• To clean the battery surface, use wet piece of cloth. Dry cloth
may generate static electricity and cause explosion.
• Depending on the weather, environmental, clothing material
and other conditions, human bodies may deposit and spark
static electricity. Therefore, before touching lift truck being
charged or after charging, discharge static electricity deposit in
the human bodies by grounding.
• Batteries for battery-driven lift trucks store large energy in
high-voltage. Beware of the risk of electric shock and burns.
Be careful to keep human bodies from touching energized
portion during maintenance, inspection and/or installation or
removal.
• Battery electrolyte contains sulfuric acid, and can quickly burn

the skin and eat holes in clothing. Always wear protective
glasses, rubber gloves and rubber sole shoes for maintenance
inspection.
2-33
• If battery electrolyte gets into your eyes, flush them

immediately with fresh tap water for 10 to 15 minutes
continually and consult a doctor.
• If you spill battery electrolyte on yourself, immediately take off
clothes and flush the contact portion of the skin with a large
quantity of tap water and consult a doctor.
• If one swallows battery electrolyte by mistake, drink a large
amount of water or milk mixed with white of raw eggs or salad
oil and consult a doctor at once.
• If battery electrolyte is spilt or leaked in the surrounding area,
neutralize the area with neutralizing agents (baking soda,
calcium hydroxide or sodium carbonate, etc.) and wash it down
with large amount of water. Or floor surfaces and cargoes will
be damaged.
• Do not drain battery electrolyte or disassemble or repair
batteries, which is dangerous.
• If the following abnormalities are detected, please call your
Komatsu Forklift distributor for service:
If battery plug and charging plug mating become loosened or
play is generated (Plug becomes abnormally heated). If
battery electrolyte temperature is high or electrolyte level
drops sharply.
If charging requires too long time (Charging is not completed
although the battery was not used till late hours on the
preceding day).
2.6.14 CAUTION ON STORING THE BATTERY 2

• When pulling in the battery, pull the reach lever toward you until
the mast is completely retracted and comes to a complete stop.
Then, the battery is fixed.
• For drawing out and pulling in the battery, refer to OPERATION
3.2.4 DRAWING OUT AND PULLING IN THE BATTERY (page
3-22).
2.6.15 CAUTION IN WASTE DISPOSAL 2

Take full cautions for waste disposal to prevent environment
pollution.
• Always drain waste fluid such as oil and battery electrolyte into
containers like cans and tanks. Do not pour on the ground or
into rivers, drains, seas or lakes.
• Comply strictly with applicable laws and regulations when
disposing of harmful objects such as oil, solvent, filters,
batteries and refrigerant (CFCs).
2-34
2.6.16 CAUTION AFTER INSPECTION AND REPAIR 2

• 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.
2.6.17 PERIODIC INSPECTION OF SAFETY CRITICAL PARTS 2

• 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. Furthermore, the remaining
service life of such parts is usually hard to determine for
operators or during visual inspection.
• 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 is not up
yet.
• For details of safety critical parts, see "4.18 PERIODIC
REPLACEMENT OF SAFETY CRITICAL PARTS (PAGE 4-
64)".
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.
2-35
2.7 HOISTING AND TRANSPORTING THE LIFT TRUCK SAFETY
2.7 HOISTING AND TRANSPORTING THE LIFT TRUCK 2

2.7.1 CAUTION WHEN HOISTING THE LIFT TRUCK 2
• To hoist the forklift truck, hook on the hole (1) on the top of
outer mast for the front. For the rear, use the frame of head
guard.
• Do not go under the lifted truck. (1)
• Use undamaged sling and wire having sufficient strength. For
the hoisting of lift truck, see "4.15 HOISTING LIFT TRUCK
(PAGE 4-57)".
2.7.2 PRECAUTIONS FOR LOADING AND UNLOADING THE LIFT TRUCK 2

Loading and unloading a lift truck to and from a trailer always
involve a hazard of the lift truck tipping over or falling off by Winch
handling error. Follow the instructions below: wire
• Stop the trailer on level, flat road. Always apply parking brake.
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.
• When using the ramps, set them in gentle gradient, align the Blocks Blocks
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. For details of
safety critical parts, see "4.16 LOADING AND UNLOADING
OF LIFT TRUCK (PAGE 4-58)".
• When loading the forklift truck on a trailer, use the winch of
trailer.
2-36
SAFETY 2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT THE LIFT TRUCK FROM TIPPING)
2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK

(TO PREVENT THE LIFT TRUCK FROM TIPPING) 2
To operate the lift truck safely, it is important to understand the structure and stability of the lift truck.
2.8.1 LONGITUDINAL STABILITY 2

• 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.
• When an overbalanced load weight is applied, the rear wheels Load
will be raised off the ground. It is very dangerous and poses a
high risk of serious accident like tipping over.
Fulcrum
Load weight Weight on the rear wheel
2.8.2 CENTER OF GRAVITY OF A LOAD 2

• 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
2-37
2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT THE LIFT TRUCK FROM TIPPING) SAFETY
2.8.3 COMBINED CENTER OF GRAVITY AND STABILITY ON THE LOADED LIFT TRUCK 2
COMBINED CENTER OF GRAVITY
The center of gravity of the loaded lift truck shifts to a combined
Center of gravity lift truck Center of gravity of load
center of gravity of both the lift truck and the load. When the load
is raised, its center of gravity will rise, hence the combined center Combined center of gravity
of gravity will also rise.
Combined center of gravity at Center of gravity

high lifting height of load
Center of
gravity of
lift truck
Combined center of gravity at low lifting height
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 tires
• 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 of serious accident
like tipping over.
SATABILITY TRIANGLE OF CENTER OF GRAVITY

To stabilize the forklift truck, the combined center of gravity should
be located within the stability triangle where the triangle is formed Stability triangle
by the contacts of tires of right and left front wheels and the center
of rear wheel axle.
If the combined center of gravity comes before the front wheel

axle, the forklift truck leans forward as the front wheels work as a
fulcrum. If the combined center of gravity moves out of the
stability triangle, the forklift truck overturns in the direction to
which the combined center of gravity moves. Combined center of gravity
2-38
2.8.4 ACTUAL CAPACITY 2

• 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. Actual capacity means the
maximum weight of a load that can be loaded at a certain load
center.
• The load table is given in the name plate accessible from the
operator's compartment. 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 THE LIFT TRUCK FROM TIPPING) SAFETY
2.8.5 SERIAL NO. AND LOAD TABLE 2

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 500 mm - - - - Maximum capacity :
1,900 kg (*1)
When the load center is 600 mm - - - - Capacity : 1,720 kg
When the load center is 1,000 mm - - - Capacity : 1,260 kg
*1: Even when the load center is smaller than 500 mm, the
maximum capacity is 1,900 kg.
• The area (3) shows the main specifications of the model.

Max. lifting height : 3m
Attachment : FSH2A1
• Front wheel tread : 955 mm
Mast rear tilting angle : 10°
Front wheel size : 200/50 - 10 x 114
• Rear wheel size : 16 x 16 - 8
• The following symbols indicate the types of attachment if any.
Symbol Symbol
Attachment Attachment
Type Capacity Type Capacity
Side shifter F S * * * * Pusher P A * * * *
Fork positioner F M * * * * Clamp C * * * * *
Load stabilizer F T * * * * Roll clamp R S * * * *
Hinged fork H F * * * * Rotating fork R F * * * *
Push pull P P * * * * Ram L * * * * *
* 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
LOAD CAPACITY WHEN EQUIPPED WITH ATTACHMENT AND / OR HIGH MAST

• Please note that the lift truck equipped with attachments and/or
high mast has less maximum capacity and actual capacity than
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 compartment.
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
Unladen mass without battery
Battery mass max/min
Battery voltage
• [ - ] 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 2

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: High or wide load backrest and
finger board (fork carriage)
• Load indicator/warning : Load sensor
• Better visibility : Rear view mirror
• Fire extinguisher
etc.
2-41
OPERATION 3
33
WARNING
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
3.1 GENERAL VIEW 3
3.1.1 GENERAL VIEW OF THE LIFT TRUCK 3
(10) L Type
(1)
(9)
(2)
(11)
(16) (15) (16)

(3)
(6) W Type
(12)
(7) (13)
(5)
(4)
(8)
(15) (16)
(14)
(1) Mast (9) Overhead guard

(2) Lift chain (10) Head lamp
(3) Lift cylinder (11) Turn signal lamp (Optional)
(4) Reach cylinder (12) Battery
(5) Tilt cylinder (13) Reach leg
(6) Load backrest (14) Load wheel
(7) Fork carriage (15) Drive wheel
(8) Fork (16) Caster wheel
3-2
OPERATION 3.1 GENERAL VIEW
3.1.2 GENERAL VIEW OF THE OPERATION EQUIPMENT 3
(17) (5) (6) (7)

(3) (12) (4) (2) (8)
(9)
(14)
(1)
(10)
(21)
(15)
(16) (18)
(13)
(11)
(20) (19) (1)
(1) Key switch (11)Brake pedal

(2) Lamp switch (12)Turn signal switch (Optional)
(3) Meter panel (BDI, hours meter display, trouble (13)Battery lock pedal
code display, adjustment mode display) (14)Assist grip
(4) Emergency power cut-off button (15)Hydraulic level gauge
(5) Lift lever (16)Rear door
(6) Tilt lever (17)Paper binder
(7) Reach lever (18)Hip support
(8) Horn button (19)Charger panel (Optional)
(9) Accelerator lever (20)Floor plate (Interlock switch)
(10)Steering wheel (21)Battery plug
3-3
3.2 EXPLANATION OF COMPONENTS OPERATION
3.2 EXPLANATION OF COMPONENTS 3

The followings explain the necessary devices employed to operate the lift truck.
To carry out speedy 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 HOW TO READ METER PANEL 3

OVERALL VIEW OF METER PANEL
(6) (5) (13) (14) (7) (12) (10)
(3)
(8)
(2)
(9)
(1)
1 (11)
(4)
(18) (17) (16) (15)
(1) Battery electrolyte level warning lamp (10)Speedometer

<<In this forklift, it is not used.>> (11)Date and time/Hour meter/Error code
(2) Parking brake indicator lamp (12)Forward/reverse indicator
(3) Neutral safety/Travel interlock warning lamp (13)Hour meter indicator
(4) Abnormality warning lamp (14)Travel power indicator
(5) Abnormal travel system warning lamp (15)Date and time/Hour meter select switch (shift
(6) Abnormal lift system/Lift interlock warning lamp switch)
(7) BDI (16)Travel speed control select switch
(8) Travel speed control indicator (17)Power select switch
(9) Fork level indicator (18)MODE/SET select switch
<<In this forklift, it is not used.>>
• When battery plug is connected, all the indicators on the meter panel light up for about 1 second, which does
not mean a failure.
• Naming in the (parentheses) of switches (15), (16) and (17) (shift switch, down switch and up switch
respectively) is used for indicating various adjustments and setting along with the MODE/SET select switch
(18).
3-4
OPERATION 3.2 EXPLANATION OF COMPONENTS
BATTERY ELECTROLYTE LEVEL WARNING LAMP (1)
CAUTION
Using batteries with reduced electrolyte may cause a fire or explosion and
sharply reduces the battery service life. If battery level warning lamp lights
up, promptly refill electrolyte.
The warning lamp (1) is not used in this forklift truck.

(1)
REMARK
For the level of battery electrolyte, confirm the display lamp of
battery electrolyte indicator in the battery case.
For the battery electrolyte indicator, refer to "4.2.3 INSPECTION
CONDUCTED BY DRAWING OUT THE BATTERY (pages 4-6).
PARKING BRAKE INDICATOR LAMP (2)

The parking display lamp (2) lights when the starting switch is in
the position of [ | ] (ON) to tell that the parking brake is applied. (2)
NEUTRAL SAFETY/TRAVEL INTERLOCK WARNING LAMP (3)

This warning lamp (3) lights up when the following illegal
operating procedures are taken. (3)
• When the accelerator lever is turned forward or backward
before turning the starting switch to [ | ] (ON), the warning lamp
lights.
In this state, even if the accelerator lever is turned, the forklift
truck does not travel.
When the accelerator lever is returned to the neutral position, the
warning lamp goes off and the state to be able to travel is
recovered.
Travel interlock warning lamp (3) starts flashing about 3 seconds

after the lift truck detects that the operator is in or not in the
correct position of the compartment.
While travel interlock warning lamp is flashing, the lift truck is
disabled to travel even if the accelerator pedal is stepped on.
When operator replaces himself correctly, the warning lamp turns
out and the lift truck returns to operable condition. For more
details on travel interlocking, see "3.3.5 TRAVEL INTERLOCK
FUNCTION (PAGE 3-32)".
3-5
ABNORMALITY WARNING LAMP (4)

This warning lamp (with wrench mark) (4) lights up if any
abnormal condition occurs to the lift truck, requiring checking and (4)
maintenance service. If abnormality occurs, the lamp flashes for
initial 10 seconds, simultaneously sounding warning buzzer.
REMARK
When any abnormality occurs, an error code or alarm code will
be displayed on the display (11) of "Date and Time/Hour
Meter". If error code "Err---****" appears, the lift truck may
require repair service. Stop the work and contact your Komatsu
Forklift distributor for service. For details of alarm code, see (11)
"4.12 PROCEDURES FOR ALARM CODE OR ERROR CODE

INDICATION (PAGE 4-53)".
ABNORMAL TRAVEL SYSTEM WARNING LAMP (5)

This warning lamp (with tire mark) (5) lights up if any abnormal
(5)
condition occurs to the travel system of a lift truck, requiring
checking and maintenance service. If abnormality occurs, the
lamp flashes for initial 10 seconds, simultaneously sounding
warning buzzer.
REMARK
When any abnormality occurs, a wrench mark will appear on
Maintenance lamp (4) and an error code or alarm code will be
displayed on the display of "Date and Time/Hour Meter" (11). If
error code "Err---****" appears, the lift truck may require repair
service. Stop the work and contact your Komatsu Forklift
distributor for service. (4)
For details of alarm code, see "4.12 PROCEDURES FOR
ALARM CODE OR ERROR CODE INDICATION (PAGE 4-53)". (11)
3-6
ABNORMAL LIFT SYSTEM/LIFT INTERLOCK WARNING LAMP (6)

This warning lamp (with fork mark) (6) lights up if any abnormal
condition occurs to the lift system of a lift truck, requiring checking (6)
and maintenance service. If abnormality occurs, the lamp flashes
for initial 10 seconds, simultaneously sounding warning buzzer.
REMARK
When any abnormality occurs, a wrench mark will appear on
Maintenance lamp (4) and an error code or alarm code will be
displayed on the display of "Date and Time/Hour Meter" (11). If
error code "Err---****" appears, the lift truck may require repair
service. Stop the work and contact your Komatsu Forklift
distributor for service. (6) (4)
ALARM CODE OR ERROR CODE INDICATION (PAGE 4-53)". (11)
Lift interlock warning lamp (6) with fork starts flashing mark about
1 seconds after the lift truck detects that the operator is not in the
correct position. While the warning lamp flashes, work equipment
will not operate even if the control lever is operated.
When operator replaces himself correctly, the warning lamp turns
out and the lift truck returns to operable condition. For more
details, see "3.3.7 LIFT INTERLOCK FUNCTION (PAGE 3-36)".
BDI (7)
Indicates electric power stored in the battery in 10 levels. As the
(7)
battery discharges power, the indication turns out sequentially
from F side.
When fully charged, the meter indicates all 10 levels.
3-7
WARNING ON BATTERY OVER DISCHARGE

1. When the remaining capacity of battery reaches 30% or less,
the meter indicates the need for recharging as follows:
• Portion (A) from the 4th level on to F side turns out.
• The 3rd level (B) from E side lights up, while the portion (C)
for the 1st and 2nd levels flashes alternately.
2. When the battery capacity falls below 20%, the meter

indicates the arrival of recharging time as follows:
• The 3rd level (B) from E side turns out, while the portion
(C) for the 1st and 2nd levels flashes alternately.
• Warning buzzer (Peep, peep, peep) is sounded for 5
seconds to warn over discharge. Warning sound is
repeated every 2 minutes.
NOTICE
Continuing work after over discharge (battery capacity below 20%)
reduces the service life of battery sharply. Stop the work immediately
and recharge battery.
REMARK
• Over discharge indication and warning sound will continue
until the battery capacity is recovered to 20% and above
after recharging.
• For the protection of battery, "Lift interrupt function" can be
optionally installed to disable lift work when the battery
capacity drops below 20%. Contact your Komatsu distributor
for consultation.
3-8
TRAVEL SPEED CONTROL INDICATOR (8)

This indicator (8) is displayed when travel speed control function
is working. Travel speed control function controls travel speed to (8)
low for safety.
Pressing travel speed control select switch (16) displays travel

(8)
speed control indicator (with tortoise mark) (8) and the truck can
travel only at a set travel speed or lower. Pressing this switch
again releases this function and indication.
Controlled travel speed can be set according to the operating
condition. For how to set this method, see "SETTING OF TRAVEL
SPEED CONTROL FUNCTION ON-OFF AND TRAVEL SPEED
CONTROL VALUE (PAGE 3-13)".
(16)
FORK LEVEL INDICATOR (9)
The warning lamp (9) is not employed in this forklift truck. (9)
SPEEDOMETER (10)
This meter digitally indicates travel speed in units of 1 km/h.
NOTICE
If other tires than standard or optional tires are used, also when the
tires are worn, speedometer may indicate error.
(10)
3-9
DATE AND TIME/HOUR METER/ERROR CODE (11)

• Normally indicates date and time.
For how to set date and time and select display mode, see (11)
" S E L E C T I O N O F DAT E A N D T I M E / H O U R M E T E R
INDICATION (PAGE 3-12)".
• Pressing Date and Time/Hour Meter select switch (15) displays
hour meter.
For how to set date and time, see "SETTING OF DATE AND
TIME (PAGE 3-13)".
• On adjustment mode for performance and function, respective
adjustment values are displayed. see "3.2.2 HOW TO
OPERATE METER PANEL (PAGE 3-12)".
(11)
• Error code or alarm code will appear if any abnormality occurs.
REMARK
If failure occurs to a lift truck, error code or alarm code is
displayed on date and time/hour meter display (11). If error
code "Err---****" appears, the lift truck may require repair
service. Stop the work and contact your Komatsu Forklift (15)
distributor for service.
ALARM CODE OR ERROR CODE INDICATION (PAGE 4-53)".
FORWARD/REVERSE INDICATOR (12)

This indicator (12) displays the forward travel (↑) or backward
travel (↓), synchronized with the accelerator lever position. But,
when in the neutral position, nothing is displayed.
(12)
(12)
3-10
HOUR METER INDICATOR (13)

This indicator (13) indicates a hourglass mark when starting
switch is set to [ | ] (ON). Hour meter is being added up under this (13)
condition.
TRAVEL POWER INDICATOR (14)

This indicator (14) indicates acceleration power at takeoff in 3
levels. (14)
• L : Low power
• M: Middle power
• H: High power
3-11
3.2.2 HOW TO OPERATE METER PANEL 3

Operating meter panel switches (15), (16), (17) and (18) enables
to set and adjust travel speed control, travel power and lift speed,
and select and adjust date and time/hour meter indication.
NOTICE
Always operate panel switches by touching them lightly with fingertip.
When the following operation is made during setup, the update will be
disabled. In this case, please do the setting from the begining.
(18) (17) (16) (15)
• When starting switch is set to [ ] (OFF) or driving operation is
made.
• When switch is not operated continually for 30 seconds or more.
SELECTION OF DATE AND TIME/HOUR METER INDICATION

Each pressing of date and time/hour meter select switch (shift
switch) (15) changes the [Date and Time] and [Hour Meter]
indication alternately.
REMARK
• Hour meter indicates maximum 99999.9 hours in units of 0.1
hour (6 min.).
• Selection is disabled during operation.
• Time is indicated in 24-hour system. (15)
• Operating time in travel and lifting can be optionally
managed.
For installation of this option, please contact your Komatsu
Forklift distributor.
3-12
SETTING OF DATE AND TIME

1. Press MODE/SET select switch (18) for 2 seconds or longer.
(Travel speed control mode sets in)
2. Pressing MODE/SET select switch (18) again changes the
mode to Date and Time adjustment. Second half of Christian
Year, date and time are indicated with the year flashing.
3. Press either power select switch (up switch) (17) or travel
speed control select switch (down switch) (16) to change the
year.
(18) (17) (16)
4. When the year is fixed, press date and time/hour meter select
switch (shift switch) (15). The month flashes and be ready for
selecting right month. Operate switches (16) and (17) to
change monthly indication same way as for the year.
5. This way, press switches (15), (16) and (17) to set the
Christian year → month → day → hour → minute indication in
this order.
6. Press the MODE/SET select switch (18) to fix the setting.
(18) (17) (16) (15)
SETTING OF TRAVEL SPEED CONTROL FUNCTION ON-OFF AND TRAVEL SPEED CONTROL VALUE
SETTING TRAVEL SPEED CONTROL FUNCTION ON-OFF
Each pressing of travel speed control select switch (down switch)
(16) selects ON (effect) and OFF (release) of travel speed control (8)
function alternately.
When the switch is turned ON, travel speed control indicator (8)
(with tortoise mark) appears. Simultaneously set controlled travel
speed flashes for 2 seconds.
REMARK (16)
Controlled travel speed is initially set to 15 km/h.
SETTING OF TRAVEL SPEED CONTROL VALUE

(Travel speed control mode sets in and travel speed control
value flashes.)
2. Press either power select switch (up switch) (17) or travel
speed control select switch (down switch) (16) to change the
control value for travel speed. Travel speed can be selected
for 5 km/h or above and can be set in units of 1 km/h.
3. Determine the travel speed value and press MODE/SET
(18) (17) (16)
select switch (18) lastly. Travel speed control indicator stops
flashing and the control value is now set up.
3-13
SETTING OF TRAVEL POWER

Travel and lift performance of the lift truck can be set to 3 levels of
L, M and H.
1. Each pressing of power select switch (up switch) (17)
changes over the power mode selection as follows: (Flashing
condition)
• L → M → H → Indicator turning out → L
2. Pressing MODE/SET select switch (18) on either one of the
levels, L, M or H, completes setting and the indicator stops
flashing. (18) (17)
Power mode Content

Enables smooth travel at low
L Low power
speed with good energy-saving.
Provides travel performance
M Middle power
adequate for normal operation.
Increases speed and provides
powerful travel and lift
H High power performance.
Battery power consumption
increases.
Using the service tool, user The indicator
L M H turns out
OFF User mode preference settings can be
obtained.
LIFTING SPEED ADJUSTMENT

This function can change the lifting speed and processing speed
according to the speed and carefulness needed for the operation.
Speed is adjustable optionally from 1 – 100%. 100% is maximum
speed.
1. Press the power select switch (Up switch) (17) and set the
indicator turning-out mode. Then, press MODE/SET select
switch (18).
(Travel speed control mode sets in) (18) (17) (16) (15)
3. Press shift switch (15) once. (This enters lift speed setting
mode.) The following appears to the date and time indicator
with the numerical portion flashing:
4. Example of display: LIFT-SPd-95 4. Press either up-switch
(17) or down-switch (16) to set to a desired value (%).
5. After changing the lift speed to the desired value, press the
MODE/SET select switch (18) twice to fix it.
3-14
REMARK
• The travel power is set to either of L, M and H, the lift speed
set mode is not available. Set the travel power setting to the
The indicator
indicator turning-out mode and fix it. Then, adjust the lift L M H turns out
speed.
• Considering lift speed and operating time, adequate range of
adjustment shall be 60 – 100%. Low speed setting may
disable lifting. Excessively low or high setting reduces
operating time.
• Battery-powered lift truck produces different lifting speed
when loaded or non-loaded. This difference cannot be
eliminated since this is the lifting speed adjust function.
3.2.3 OPERATING DEVICES 3

STARTING SWITCH
This switch prepares the lift truck for operation.
(1)
(1) [ ] position: enables to insert and pull out the starting (2)
switch key.
(2) [ | ] position: indicates ON position and the lift truck is ready
for operation.
REMARK
• Auto Power-off Function
When not operated for 15 minutes, the power is automatically
turned off and the meter panel display goes off. To turn on the
power again, return the starting switch to the OFF position
once and turn it to the ON position.
LAMP SWITCH
This switch (2) turns on the head lamp.
ON : The head lamp lights.

OFF : The head lamp turns out.
NOTICE
While re-charging, be sure to turn off the lamp switch.
3-15
HORN SWITCH
To sound the horn, push this switch on the dashboard
BRAKE PEDAL
This pedal is used to stop or decelerate the forklift truck.
NOTICE
The brake pedal also works as a parking brake.
When making a complete stop of forklift truck and an operator leaves
the operator's compartment, the depressed pedal returns automatically
and the brake works.
TURN SIGNAL SWITCH (Option)
Right turn (R): Turn this switch to the right.

Left turn (L): Turn this switch to the left. Left turn Right turn
NOTICE
While re-charging, be sure to set this switch in the neutral position.
3-16
ACCELERATOR LEVER
This lever controls the travel speed.
• The travel speed varies in proportional to the amount of lever
turning.
• When plugging, the braking force of electric brake also varies.
For plugging, refer to "OPERATION 3.3.4.3 PLUGGING
(ELECTRIC BRAKE) (Page 3-31).
Amount of lever Braking force of electric

Travel speed
turning brake
Greater Faster Stronger
Smaller Slower Weaker
REMARK
• Neutral Regeneration
When setting the accelerator lever to the neutral position, the
travel speed will be decelerated.
NOTICE
• When stopped, set the accelerator lever to the neutral position.
• When setting the starting switch to the [ | ] (ON) position, the
accelerator lever should be positioned in the neutral.
LIFT CONTROL LEVER

This lever controls the fork to raise and lower.
Raise: Pull the lift control lever backward.

Lower: Push the lift control lever forward.
TILT CONTROL LEVER

This lever controls the fork to tilt forward and tilt backward.
Tilt forward: Push the tilt control lever forward.

Tilt backward: Pull the tilt control lever backward.
3-17
REACH CONTROL LEVER

This lever controls the mast to move forward and backward.
Move forward: Push the reach control lever forward.

Move backward: Pull the reach control lever backward.
STEERING WHEEL AND STEERING WHEEL KNOB

The steering wheel controls the forklift truck to move in the
direction of right or left.
• Grip the knob on the steering wheel by your left hand for
operation.
EMERGENCY POWER CUT-OFF BUTTON

Press this button (red) in emergency to cut off power supply to
starting switch and controller circuit.
CAUTION
To recover from the power shut-off state, be sure to perform in the manner
below for safety.
How to reconnect the power

1. Turn the starting switch to [ ] (OFF) position and set the
accelerator control lever in the neutral position.
2. Take your foot off the brake pedal. (The parking brake works.)
3. Turn the button clockwise. The pushed button pops up and
power supply is connected again.
4. Turn the starting switch to [ | ] (ON) position so that the power
is reconnected and the forklift truck becomes ready to
operate.
REMARK
• Even if the emergency power cut-off button is pressed, the
power supply to lightings such as front lamp is not cut off.
• Even if the emergency power cut-off button is pressed during
traveling, the electric brake does not work.
To stop the forklift truck, take your foot off the brake pedal.
3-18
REAR ACCESS DOOR
CAUTION
Do not close the door with your fingers inserted in the hole of door. Your
fingers will be caught between the door and the lever and you will suffer
from injury.
HOW TO OPEN THE DOOR

Insert your fingers in the hole of door, pull the lever inside toward
you to unlock and open the door.
HOW TO CLOSE THE DOOR

Push and close the door by hand until the door is locked.
ASSIST GRIP
This grip (14) is for balancing your body.
(14)
3-19
HYDRAULIC LEVEL GAUGE

This gauge (15) indicates the amount of hydraulic oil.
To make the work equipment properly function, it is important to
maintain the hydraulic oil.
(15)
The forklift truck adopts the direct view type for checking the
amount oil and dirt at a glance.
Before starting the work, be sure to check the amount of oil and
dirt.
BATTERY LOCK PEDAL

The battery lock pedal locks or unlocks the battery. For operation
of pedal, refer to "OPERATION 3.2.4 DRAWING OUT AND
(1)
PULLING IN THE BATTERY (Page 3-22)".
When the battery lock pedal is in up (1): The battery is locked.

When the battery lock pedal is stepped down (2): The battery is
unlocked. (2)
NOTICE
Never operate the battery lock pedal except checking and replacing the
battery.
Do not operate the battery lock pedal during traveling.
PAPER BINDER
Use the binder (17) for binding the documents.
(17)
3-20
HIP SUPPORT
The hip suppor t (18) suppor ts the operator's body when
operating. The position of hip support can be adjusted up and (18)
(17)
down by loosening two bolts (A) in the center of hip support.
(A)
CHARGER PANEL
The charger panel (19) is the operation panel for battery charging.
Fo r u s a g e o f t h e p a n e l , r e fe r t o " I N S P E C T I O N A N D (19)
MAINTENANCE 4.6 CHARGING (Page 4-29)".
FLOOR PLATE
Ride properly on the floor plate and perform the travel and lift
handling operation.
REMARK
Unless you ride correctly and operate, you will suffer from an
accident. To prevent this from occurring, the forklift truck is
equipped with the function to disable the traveling and lift
handling operation ([TRAVEL INTERLOCK] and [LIFT
INTERLOCK]). (20)
For travel interlock, refer to "OPERATION 3.3.5 TRAVEL
INTERLOCK FUNCTION (Page 3-32)". For lift handling
interlock, refer to "OPERATION 3.3.7 LIFT INTERLOCK
FUNCTION (Page 3-36)".
3-21
3.2.4 DRAWING OUT AND PULLING IN THE BATTERY 3

When charging, inspecting and replacing the batter y and
performing the check and maintenance of electric equipment,
draw out and pull in the battery in the manner below.
HOW TO DRAW OUT THE BATTERY
CAUTION
• Step down the battery lock pedal to the lowest level. If not, it may lead
to damage when operated.
• If you operate abruptly the reach lever, the lift truck may be shaken.
• Before drawing out the battery, be sure to unload the cargo.
• When operating the reach, position yourself correctly and operate.
1. Park the forklift truck on a flat location.

2. After confirming that the accelerator lever and control lever
are in the neutral state, turn the starting switch to
[ | ] (ON).
3. Lift up the fork 5 to 20 cm from the ground or the top of the
reach-leg.
4. Operate the reach lever toward you and retract completely the
mast to the operator's side.
5. Step down the battery lock pedal to the lowest position with
the mast completely retracted.
6. While stepping down the battery lock pedal, push the reach
lever forward to push out the mast. Then, the battery is drawn
out.
3-22
HOW TO PULL IN THE BATTERY
CAUTION
• When operating the reach, be positioned correctly in the compartment
and operate.
• Perform the work while watching the hose from the operator’s
compartment.
• If you operate abruptly the reach lever, the forklift truck will be shaken.
• When pulling in the battery, if the hydraulic oil hose is not sitting
correctly on the hose guide of battery case, the hose may be damaged
by being caught by the body of forklift truck.
• Keep operating the reach lever until the mast is completely retracted
and stopped.
1. Confirm that the hydraulic hose is sitting on the hose guide

(1) of battery case. (If the hydraulic hose comes off, put it
back on the hose guide.)
(1)
2. Pull slowly the reach lever toward you. The battery is pulled in
together with the mast.
Check if the hydraulic oil hose does not disconnect from the
compartment while operating.
3. Keep operating the reach lever until the mast is completely
retracted and stopped. Then, the battery is fixed to the body
of forklift truck.
REMARK
Unless the battery is securely locked, the travel interlock
operates, resulting in failure of travel.
Therefore, when pulling in the battery, keep operating the reach
lever until the mast is completely retracted and stopped.
3-23
3.3 OPERATION OPERATION
3.3 OPERATION 3
3.3.1 START-UP INSPECTION 3
CAUTION
• Do not operate the lift truck before completing the 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 content and procedure of inspection before starting the
work, refer to "INSPECTION AND MAINTENANCE 4.1 ABOUT
INSPECTION AND MAINTENANCE (Page 4-2)."
3.3.2 MOUNTING/DISMOUNTING AND OPERATING POSTURE ADJUSTMENT 3

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 to 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.
• Clean always the assist grip and floor plate. If damaged, repair it.
3-24
OPERATION 3.3 OPERATION
3.3.3 BASIC OPERATION 3

3.3.3.1 STARTING 3
CAUTION
• When starting up, be sure to position yourself in the operator's
compartment and operate.
• Start up in the following conditions.
Accelerator lever : neutral
Brake lever : Do not step on [ | ].
(Parking brake activated)
Starting switch : [ | ] (ON) position
• Start after checking the safety of surrounding areas.
• Do not turn the starting switch to the [ ] (OFF) position. Otherwise,
steering wheel operating effort becomes heavier, causing collision and/
or tipping over.
1. After confirming that the accelerator, lift, tilt or reach lever and
work equipment are positioned in the neutral, turn the starting
switch to Neutral
[ | ] (ON).
2. Pull the lift, tilt and reach levers toward you, retract the mast,
tilt the lift backward and lift up the fork 15 to 20 cm from the
ground.
3. Step down on the brake pedal with your left foot.
3-25
4. To start, turn gradually the accelerator lever in the traveling

direction. The travel speed can be adjusted by turning the
accelerator lever.
REMARK
• Unless turning the starting switch to [ | ] (ON) in the
conditions below, even if the accelerator lever is turned, the
forklift truck does not travel.
Accelerator lever: Neutral
Brake pedal: Not stepping on.
• Unless seated in right posture, engine will not start because
of activation of travel interlock function. For more details on
travel interlocking, see "3.3.5 TRAVEL INTERLOCK
FUNCTION (PAGE 3-32)".
3.3.3.2 TRAVELING 3
By the amount of increase or decrease of turning the accelerator
lever, the forklift truck accelerates or decelerates.
3.3.3.3 TURNING 3
CAUTION
When turning, be careful for the forklift truck not to hit a person and
obstacles in surrounding.
• To turn the lift truck, decelerate travel speed fully in advance.

• To turn during forward travel, keep the lift truck body closer to
the inside of the corner, and to turn during reverse travel, to the
outside of the corner.
REMARK
Frequent steering operation with the lift truck in stationary
position accelerates wear of tires. Wear will be less if steered Closer to
the inside
while running at low speed.
3-26
3.3.3.4 PLUGGING 3
CAUTION
If you keep plugging after the forklift truck stops, the forklift truck travels
in the reverse direction.
Operating the accelerator lever in the reverse direction to the

direction of travel during traveling is called the plugging operation.
At this moment the electric brake works.
3
3.3.3.5 STOPPING 3
CAUTION
• Sudden braking may cause accidents due to collapse of cargo or
slipping.
• Longer braking distance is required to stop when loaded, on a downhill,
wet or frozen surfaces. Apply brake earlier with spare time when
traveling on such road surfaces.
Slow down fully the travel speed to stop at the target position,
return the accelerator lever to the neutral position and take your
foot off the brake pedal so that the forklift truck makes a complete Neutral
stop.
3-27
3.3.3.6 TEMPORARY STOPPING AND PARKING 3

CAUTION
• Do not park the forklift truck on a slope. If parking on a slope is
unavoidable, place chocks to the wheels.
• If the fork cannot be lowered due to trouble, attach a mark on the tip of
fork to warn other trucks and pedestrians against collision. Moreover,
take measures not to allow anyone to enter under the raised fork.
TEMPORARY STOPPING PROCEDURES

1. When temporarily stopping the forklift truck, choose a hard
and flat location that does not hinder traffic.
2. After stopped, take your foot off the brake pedal. (The parking
brake works.)
3. Lower the fork to the ground and tilt it forward.
PARKING PROCEDURES
After completing the above mentioned [temporary stopping]
procedures 1 to 3.
4. Turn the starting switch to the [ ] (OFF) position.
5. Pull out the starting switch key and leave the lift truck.
3-28
3.3.4 OPERATION ACCORDING TO THE CIRCUMSTANCE 3

3.3.4.1 TRAVELING ON SLOPES 3
CAUTION
• Do not turn, or travel across or at an 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.
• Unless you are positioned correctly when climbing an uphill, the travel
interlock works and the power will shut down. Because of this, even if
the accelerator lever is turned down, the forklift truck may slide down,
resulting in collision or overturn.
Therefore, be positioned correctly in the operator's compartment and
operate so that the travel interlock does not work.
For travel interlock function, refer to "3.3.5 TRAVEL INTERLOCK
TRAVEL DIRECTION WHEN LOADED OR UNLOADED

• To prevent cargo from collapsing and apply brake effectively, When loaded
travel in the following direction when the lift truck is loaded or
unloaded:
When loaded : Travel forward uphill and in reverse downhill.

When unloaded : Travel in reverse uphill and forward downhill.
• When descending a downhill, travel slowly, applying the brake

only.
NOTICE When unloaded

Driving continuously without stepping down the brake pedal
completely will cause the motor to overheat.
If abnormal odor is sensed, stop the forklift truck and cool down the
motor.
3-29
STARTING ON SLOPE
IN CASE OF CLIMBING
1. When starting on an uphill, take your foot off the brake pedal
(1). (The parking brake works.) (1)
2. While turning the accelerator lever (2) in the direction to the
direction of climbing, step down the brake pedal (Release).
3. When starting to climb the uphill, step down completely the
brake pedal (1) to the lowest position. Control the speed of
climbing on the uphill by adjusting the amount of turning the
accelerator lever.
4. To decelerate or accelerate on the uphill, return gradually the
accelerator lever (2) and take your foot off the brake pedal (1)
just before the forklift truck stops.
(2)
NOTICE
Driving continuously without stepping down the brake pedal
completely will cause the motor to overheat.
If abnormal odor is sensed, stop the forklift truck and cool down the
motor.
IN CASE OF DESCENDING
When descending a downhill, travel slowly, applying the
brake only.
3.3.4.2 INCHING TRAVEL 3

Normally, perform the inching travel by adjusting the amount of
turning the accelerator lever.
REMARK
• Setting the travel power for the lift truck to [L] level enables
smooth take-off and inching travel with ease. For how to
adjust it, see "SETTING OF TRAVEL POWER (PAGE 3-14)".
3-30
3.3.4.3 PLUGGING (ELECTRIC BRAKE) 3
CAUTION
• If you keep plugging after the forklift truck stops, the forklift truck
travels in the reverse direction to the direction of travel. Therefore,
when making the plugging operation, unless the operator takes
measures to check safety in surroundings or understands the
performance of electric brake, a collision or critical accidents may
occur.
• Carry on plugging operation safely by deciding whether to do it
according to the conditions of the operating site.
• Loaded lift truck requires longer braking distance. Apply brake earlier
with spare time when traveling loaded.
When turning the accelerator lever in the reverse direction to the

direction of travel, the electric brake is applied and the forklift truck
decelerates. If you keep turning the accelerator lever, the forklift
truck stops once and starts to travel in the reverse direction. The
degree of plugging force (electric brake) can be controlled by
adjusting the amount of turning the accelerator lever.
3.3.4.4 OPERATION ON SNOWY AND FROZEN ROADS 3

Do not travel on snowy and frozen roads. Avoid the sudden
braking, acceleration, or steering on snowy and frozen roads. To
avoid slipping or skidding, operate prudently the accelerator lever
and brake pedal.
3-31
3.3.5 TRAVEL INTERLOCK FUNCTION 3

This safety device disables the operation of forklift truck if you
leave the operator's compartment or are seated in such posture
as that your weight is not applied to the floor plate. If you take
such posture, the travel interlock activates in approx. 3 seconds
and the driving force to the forklift truck is shut off. And the forklift
truck does not move anymore even if you operate the accelerator
lever.
While travel interlock is activated, the travel interlock warning

lamp (the lamp doubles as the neutral safety warning lamp)
flashes.
RELEASING TRAVEL INTERLOCK FUNCTION

To resume the travel operation, position yourself correctly in the
operator's compartment and return the accelerator lever to the
neutral position. After checking safety in surroundings, restart
the travel operation.
Traveling Interlock does not brake the lift truck forcibly.
3-32
3.3.6 BASIC LIFT OPERATION 3

3.3.6.1 HOW TO OPERATE CONTROL LEVERS 3
WARNING
• Operate the lever after positioning yourself properly in the operator's
compartment and checking safety in surroundings.
• Operating in the state that the operator is not properly seated or
operating from out-of-forklift truck may result in serious injury due to
inadvertent operation.
• Loading persons on the forks or pallet or allowing them under the
raised forks or cargo or inserting hand, foot and body between the mast
and load backrest may cause critical injuries and accident, which is
extremely dangerous.
LIFT CONTROL LEVER

The lift control lever (10) controls the fork to raise or lower. (a)
(c)
(e)
Raise: Pull the lever backward.
Lower: Push the lever forward. (b)
(d)
(f)
(10)
(11) (12)
REMARK (f)
(e)
A rising and lowering speed of the forks can be adjusted by
tilting lever.
(b)
(a)
(c)
(d)
TILT CONTROL LEVER

The tilt control lever (11) controls the fork to tilt forward or tilt
backward.
Tilt forward: Push the lever forward.

Tilt backward: Pull the lever backward.
REMARK
Forward and backward tilting speed of the forks can be
adjusted by tilting lever.
3-33
REACH LEVER
The reach lever (12) controls the mast to move forward and backward.
Move forward (e):Push the reach lever forward.

Move backward (f):Pull the reach lever backward.
REMARK
The fork's backward/forward moving speed can be controlled
by adjusting the amount of turning the reach lever.
3.3.6.2 FORK SPREAD ADJUSTMENT 3

Before carrying out load handling, always adjust the space
between the forks to fit the size of the pallets and loads.
CAUTION
Hands and fingers may be caught.
1. Move the lift truck in front of the load, and stop.

2. Position the mast vertically and raise the forks 10 cm above (1)
the ground.
3. Forward-tilt the fork.
4. Remove the knob of fork stopper (1). (In this state, the fork
can move right or left.)
5. Adjust the fork spread corresponding to the load size so that
the center of gravity of the load coincides with the center of
the lift truck.
6. Insert the fork stopper (1) and make the lock state. (In this
state, the fork is locked.)
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.
3-34
3.3.6.3 PROCEDURE FOR PICKING UP AND STACKING 3

PICKING UP
1. Move the forklift truck to the front of a cargo, level horizontally

the fork and insert the fork as far as it goes to its root and lift
up the cargo 5 to 10 cm again.
2. Retract fully the mast, lower the cargo to a height of 35 to 40

cm from the ground or the top of the reach-leg and tilt
backward fully the fork.
STACKING
1. Level horizontally the fork, lift up the cargo 5 to 10 cm from
the stacked position and advance the forklift truck.
2. Then, reach out the mast to the correct stacking position and
unload the cargo.
3. Retract quietly the mast until the fork is completely pulled out
and set the fork to the travel position.
3-35
3.3.7 LIFT INTERLOCK FUNCTION 3

This lift interlock disables the lift handling operation if you leave
the operator's compartment or positioned in such posture as that
your weight is not applied to the floor plate properly. If you take
such posture, the travel interlock activates in approx. 3 seconds
and each function of fork and mast is locked. And the fork and
mast do not work even if you operate the lift control lever and tilt
control lever.
While lift interlock is activated, the lift interlock warning lamp (the
lamp doubles as error warning lamp of lift system) on the meter
panel flashes.
RELEASING LIFT INTERLOCK FUNCTION

To resume the lift operation, position yourself correctly in the
operator's compartment. After checking safety in surroundings,
restart the lift operation.
3.3.8 CHECKING AFTER OPERATION 3

After all the job have been finished and each part of the lift truck is
cleaned, carry out the following inspections.
1. Leakage of fuel, 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)
See "INSPECTION AND MAINTENANCE" section for further

information and procedure for maintenance such as checking and
charging battery, maintenance of lift truck and greasing.
3-36
OPERATION 3.4 THE LIFT TRUCKS WITH COLD-STORAGE MODEL
3.4 THE LIFT TRUCKS WITH COLD-STORAGE MODEL 3

CAUTION
• Always recharge batteries outside the cold storage and/or freezing
chamber using a stationary battery charger.
• Do not install the stationary charger near the entrance to the freezing
chamber and/or cold storage. Area near to the entrance has sharp
temperature difference, which causes dewing that degrades
mechanical parts, leading to fire and/or leakage and failure of charger.
LIFT TRUCKS WITH COLD-STORAGE MODEL

• Lift trucks with cold-storage model is a lift truck designed for
work involving entrance-exit to and from freezing chamber of
–35°C.
• To tell the lift trucks with cold-storage model at a glance, a
penguin decal is pasted on both sides of the lift truck.
• Battery charger for the lift trucks with cold-storage model is
stationary battery charger instead of on-board type battery
charger.
NOTICE
When engaged in an operation that requires entries and exists to and
from the cold storage and/or freezing chamber, a dewing problem
occurs because of low temperature and the temperature difference.
Because dewing may cause electrical fault and/or fault by rust, always
use lift trucks with cold-storage model with waterproof and antirust
treatment.
WORKING TIME AND CONDITION INSIDE COLD STORAGE AND/OR FREEZING CHAMBER
To avoid adverse impact to lift trucks from dewing and low
temperature, use the trucks by observing the following working
time:
• Ratio for working time inside and outside cold storage and/or
freezing chamber shall be about the same.
• Limit one continuous working time in the cold storage or
freezing chamber within 1 hour.
• Refrain from parking or leaving a lift truck 10 minutes or longer
inside the cold storage and/or freezing chamber.
• Do not use the lift trucks inside the cold storage and/or freezing
chamber with the temperature of –35°C.
SELECTION OF OIL AND GREASE

• Select oil and grease by considering the lowering of
temperature inside the cold storage and/or freezing chamber in
addition to the ambient temperature conditions.
• The lowering of oil and grease temperature differs depending
on the ratio of working time inside and outside cold storage
and/or freezing chamber and the content of work. For the type
of oil and grease, see the "LUBRICANT LIST (PAGE 4-19)".
3-37
INSPECTION AND
MAINTENANCE 4
44
WARNING
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 ABOUT INSPECTION AND MAINTENANCE INSPECTION AND MAINTENANCE
4. INSPECTION AND MAINTENANCE 4

4.1 ABOUT INSPECTION AND MAINTENANCE 4
This inspection and maintenance manual 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, peruse "2.6 PRECAUTIONS FOR INSPECTION AND
MAINTENANCE SAFETY (PAGE 2-29)". Carry on inspection and maintenance service with care.
Incorrect maintenance and repair service may cause critical accident or shorten machine service life. Contact
Komatsu Forklift distributor for maintenance and repair services.
4.2 START-UP INSPECTION 4
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 and battery electrolyte
Cracks, damages and the state of mounting (of overhead guard, fork, load
backrest, etc.)
Walk around a lift truck Deformation, crack and wear of fork stopper pin
Contamination and/or damages of lamp, lens, etc.
Looseness of rim fixing bolt
Deformed or damaged tyres and rims
Battery electrolyte level
Drawing out the battery
Performance of warning lamps on the instrument panel
Amount and dirt of hydraulic oil
Checking from operator’s Brake pedal play and height
compartment Horn performance
Rear view mirror contamination, damages and angle
Operation of back buzzer
Turn the starting switch
Battery charge level
to ON position
Operation of lamps
Play of steering wheel
Operating state of steering wheel (runout and unstable driving)
Rotational state, foreign noise and odor of power steering motor
Brake operating condition (response)
While running the lift
Mast operating condition
truck
Operation and function of work equipment
Attachment operating condition (For the lift truck mounted with an attachment)
Tension, damages and rusted condition of lift chain
Abnormal noise, vibration and odor
Travel interlock function
Checking of safety
Lift interlock function
function
Neutral safety function
4-3
4.2 START-UP INSPECTION INSPECTION AND MAINTENANCE
4.2.1 CHECKING ABNORMALITIES DETECTED ON THE PREVIOUS DAY 4

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 THE LIFT TRUCK 4

CHECKING FOR LEAKAGE OF OIL AND BATTERY ELECTROLYTE
• Walk around the lift truck to check for leakage of oil, fuel,
coolant and battery electrolyte.
• Look under the lift truck to check for oil or water leakage.
CHECKING OF 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
4-4
CONTAMINATION AND/OR DAMAGES OF LAMP, LENS, ETC

Visually check lamp, lens, etc. for any contamination and/or
damages.
CHECKING OF RIM AND TIRE

Check the following items.
• Looseness of rim fixing bolt (Except load wheel)
• Excessive wear, damage, spikes and foreign matters stuck to
the tyres
• Deformation and damage of rim
NOTICE
Tighten the rim fixing bolt with the specified tightening torque.
For tightening torque, refer to "INSPECTION AND MAINTENANCE 4.19
SERVICE DATA (Page 4-65).
L type
Drive wheel (1)
Caster wheel (2)
(2) (1) (2)
W type
Drive wheel (1)
Caster wheel (2)
(1) (2)
4-5
4.2.3 INSPECTION CONDUCTED BY DRAWING OUT THE BATTERY 4

CHECKING OF BATTERY ELECTROLYTE LEVEL
CAUTION
• Batteries generate flammable hydrogen gas and may explode. Do not
bring lit cigarette and other fire near the batteries. Do not allow short
circuit or sparks to occur nearby.
• Battery electrolyte contains diluted sulphuric acid, which may cause
burns and injuries. If exposed to electrolyte, wash the eye(s), skin and
clothes with large amount of fresh water and consult a doctor.
• Always wear protective glasses, rubber gloves and rubber sole shoes
for maintenance inspection of batteries.
• For drawing out and pulling in the battery, refer to "OPERATION 3.2.4
DRAWING OUT AND PULLING IN THE BATTERY (Page 3-22)".
1. Draw out the battery.

2. Check the amount of battery electrolyte in either of manners
below.
• Check by the battery electrolyte level indicator. Indicator
The green light lights:Normal

The red lamp blinks: Lack of battery electrolyte
• Check using the battery electrolyte level indicating stick

Stopper
When the stopper of float contacts the cap (when the gap a=0
in the right figure), the level of battery electrolyte is lowest.
a
Before the float (red color) shows the lowest level, refill water.
Cap
Float (red)
3. If the battery electrolyte is below the standard level, refill the

distilled water or purified water. For checking and refill, refer
to "INSPECTION AND MAINTENANCE: CHECKING OF
BATTERY ELECTROLYTE LEVEL (Page 4-26)".
4. After finishing the check and refill, pull in the battery.
4-6
CHECKING OPERATION OF METER PANEL WARNING LAMP

1. Turn the starting switch to [ ] (OFF) position to disconnect
the battery plug placed inside the window of the trucks left
side, and the plug off the truck side.
2. Connect the battery plug again. If all the indicators on the

meter panel light up for about 1 second, the warning lamp
and the display are normal.
REMARK
This checking method is not applicable to checking other units
than the meter panel indicators for any problem (for example
abnormality of sensors or wiring).
4-7
4.2.4 CHECKING FROM OPERATOR COMPARTMENT 4

CHECKING OF HYDRAULIC OIL
1. Reach-in and lower the fork to the floor where it is horizontal.
2. Check that the amount of hydraulic oil is within the normal
(1)
range needed for lifting high on the level gauge on the upper
part of the front step of operator's seat.
3. If the hydraulic oil is insufficient, remove the assist grip (1),
open the oil cap (2) and fill the KOMATSU UTILITY genuine
hydraulic oil in the filler port to the proper level.
(2)
• The normal range differs depending on the mast lifting height

(specification). Confirm that the oil is filled to the normal level.
• FFV mast (every type): "5.0" scale (1)

Level gauge
• TFV mast (every type): "5.0" scale (1) (1)
• FV mast lifting higher than 5.0m: "5.0" scale (1)
• FV mast lifting lower than 4.7m "4.7" scale (2)
(2)
NOTICE
• If the oil is split, wipe it off completely.
• For hydraulic oil, be sure to use the KOMATSU UTILITY genuine
hydraulic oil.
• The above checking and level gauge reading are just a guide to feed
hydraulic oil.
Control the supply of hydraulic oil checking that air is not
incorporated.
4-8
CHECKING THE BRAKE PEDAL
CAUTION
If the pedal height becomes higher, it is a sign that the brake pad is worn.
When the pedal height exceeds pedal height below (when in free), the
brake system needs the adjustment. Please contact our sales dealer.
• Check the brake pedal for abnormal braking effort or

interruption in depression.
• Check that the play of pedal and the pedal height when (h)
depressed shall indicate the following values:
When in free 60 to 70 (mm)

Pedal height (h) When stepping Same height as the
down floor plate
CHECKING THE HORN

Check if the horn sounds normally when switched ON.
CHECKING THE REAR VIEW MIRROR

(Forklift truck equipped with rear view 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.
4-9
4.2.5 CHECKING BY SETTING THE STARTING SWITCH TO [ | ] (ON) POSITION 4

CHECKING OF ACCELERATOR LEVER, METER PANEL INDICATION AND BACK BUZZER
CAUTION
When operating the accelerator lever, confirm safety in
surroundings and check in the state that the brake pedal is
not stepped down (The parking brake works.).
1. When the accelerator lever is positioned in the neutral, turn

the starting switch to [ | ] (ON). If the neutral safety waning
lamp [N] does not light on the meter panel, the system is
normal.
2. In the state that the brake pedal is not stepped down (The
parking brake works.), turn the accelerator lever to the
forward (travels forward) or backward (travels backward). If [ ↑
] or [ ↓ ] appears on the forward/backward indicator, the
system is normal. When turning the accelerator lever to the
backward, confirm that the buzzer sounds simultaneously.
REMARK
Unless you are positioned correctly in the operator's
compartment, the travel interlock warning lamp and lift interlock
warning lamp blink. For travel interlock, refer to "OPERATION
3.3.5 TRAVEL INTERLOCK FUNCTION (Page 3-32"). For lift
interlock, refer to "OPERATION 3.3.7 LIFT INTERLOCK
CHECKING OF BATTERY CHARGE LEVEL

When starting switch is set to [ | ] (ON) position, battery charge
level (charged state) is indicated on the BDI.
Check if the batteries are fully charged.
CHECKING OPERATION OF LAMPS

• Check if the head lamps and turn-signal lamps (forklift truck
equipped with the turn-signal lamps) work normally.
4-10
4.2.6 CHECKING WHILE RUNNING THE LIFT TRUCK 4

CHECK THE STEERING WHEEL FOR PLAY
• Check the play of steering wheel by operating it in the direction
of a turn. If the play (A) is 10 to 20 mm, it is normal.
• Check if it is free of looseness by shaking it in the vertical and
longitudinal directions. (A)
CHECKING OF THE STEERING WHEEL FUNCTION

Check the following points by operating the wheel while traveling
slowly:
• If the steering wheel has play.
• If the steering wheel is stable while driving straight and doesn’t
turn right or left.
• If there is any feeling of abnormally heavy steering or abnormal
swing when the steering wheel is turned.
CHECKING OF BRAKE FUNCTION

While traveling slowly, take your foot off the brake pedal and
check the braking effect.
• If the brake fully effective.
• If only one side of the brake is responding
CHECKING OF MAST FUNCTION

Be positioned in the operator's compartment, operate the work
equipment and check that the fork lifts up and down and tilts
forward and backward and the mast moves back and forth. Make
sure that the cylinder piston stroke operates fully 2 to 3 times.
CHECKING OF ATTACHMENT FUNCTION (FOR THE LIFT TRUCK WITH AN ATTACHMENT)

Check the attachment according to its operating manual.
4-11
CHECKING OF LIFT CHAIN TENSION, DAMAGE AND RUST
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,
contact your Komatsu Forklift distributor for replacement of the lift
chain. Some of the causes for sheared lift chain are abnormal tension
of the R.H. and/or L.H. chains, and damage and cracks due to rust.
• To prevent injuries or an accident from occurring, set the accelerator
lever in the N (neutral) position and take your foot off the brake pedal to
stop. And then, step down the forklift truck and check the forklift truck
starting from the front.
CHECKING OF TENSION OF CHAIN

1. Lift the fork 10 to 15 cm from the ground. (Portion 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 RUST, CRACKS AND DAMAGE TO THE CHAINS

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 (A)
or rust has generated on the lift chain, apply engine oil, etc.
on it.
CHECKING OF ABNORMAL NOISE, VIBRATION AND ODOR

Check for abnormal sound, vibration and/or odor during travel or
lift operation.
4-12
4.2.7 CHECKING OF SAFETY FUNCTION 4

CAUTION
When checking safety function, retain wide safety space around the lift truck in case it makes a sudden, unexpected movement.
Always check the surrounding area for people and obstacles.
CHECKING OF TRAVEL INTERLOCK FUNCTION

Check the safety function to disable the lift truck to travel or lift when the operator is away from the compartment.
CHECKING PROCEDURE
1. Park the forklift truck on the horizontal, flat and solid place and take your foot off the brake pedal. (The
parking brake works.)
2. Set the accelerator lever in the N (neutral) position, turn the starting switch to [ | ] (ON) and lift up the fork
about 15 cm from the ground.
3. Release your hand off the accelerator lever and step down the operator's seat.
4. Check that the travel interlock warning lamp (with N mark) and lift interlock warning lamp (with fork mark) on
the meter panel start flashing about 3 seconds later.
5. Releasing travel interlock function
Be compartment correctly in the operator's compartment so that the blinking travel interlock warning lamp
and lift interlock warning lamp go off and the normal operation is resumed.
CHECKING OF LIFT INTERLOCK FUNCTION

Check the safety function to disable the lift operation when the operator is away from the seat.
CHECKING PROCEDURE
1. Park the forklift truck on the horizontal, flat and hard place and take your foot off the brake pedal. (The
2. Turn the starting switch to [ | ] (ON) and lift up the fork, which can be seen from the operator's seat, about 1 m
from the ground.
3. Release your hand off all of levers and step down the operator's seat.
4. Confirm that the travel interlock warning lamp (with N mark) and lift interlock warning lamp (with fork mark)
blink in about 3 seconds.
5. Check the following in this state:
• The forks do not rise or lower if the lift control lever is operated.
• The fork does not tilt forward or lift backward if the tilt control lever is operated.
• Even if the reach lever is operated, the mast does not move back and forth.
• Attachment does not operate if the attachment lever is operated. (For the lift truck mounted with an
attachment)
6. Be positioned correctly in the operator's compatment so that the blinking travel interlock warning lamp and lift
interlock warning lamp go off and the normal operation is resumed.
4-13
CHECKING OF NEUTRAL SAFETY FUNCTION

This safety function prevents the forklift truck from suddenly traveling when turning the starting switch to [ | ] (ON)
position with the accelerator lever set to the forward or backward. Confirm that the forklift truck does not travel
when the accelerator lever is set to positions other than neutral.
CHECKING PROCEDURE
1. Park the forklift truck on the horizontal, flat and solid place and take your foot off the brake pedal. (The
3. Turn the accelerator lever to the forward or backward and turn the starting switch to [ | ] (ON) position.
Confirm that the forklift truck does not travel even if the accelerator lever is operated.
4. Check that neutral safety warning lamp (with N mark) lights up.
5. Releasing neutral safety function.
Be positioned correctly in the operator's compartment so that the neutral safety warning lamp goes off and
the normal operation is resumed.
To travel, step down the brake pedal (The parking brake is released.) and turn the accelerator lever to the
forward or backward.
4-14
INSPECTION AND MAINTENANCE 4.3 CHECKING AND REPORTING AFTER OPERATION
4.3 CHECKING AND REPORTING AFTER OPERATION 4
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 and battery electrolyte.

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.
4-15
4.4 SIMPLE MAINTENANCE INSPECTION AND MAINTENANCE
4.4 SIMPLE MAINTENANCE 4

4.4.1 GREASES AND FUEL 4
4.4.1.1 BASIC PRECAUTIONS 4
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,
call your Komatsu Forklift distributor for inspection and repair service.
• Since the hydraulic oil and gear oil are used under severe
conditions (at high temperature and high pressure), they
deteriorate as the operation times goes. Therefore, the oil must
be replaced periodically. For standard oil replacement, refer to
"INSPECTION AND MAINTENANCE: OIL AND GREASE
CHART (Page 4-18)" and "INSPECTION AND MAINTENANCE:
LUBRICANT LIST (Page 4-19)".
• Replace periodically the oil at the specified period of time even
if not deteriorated.
• For replacement oil, use the KOMATSU UTILITY genuine oil.
The oil listed on "INSPECTION AND MAINTENANCE:
LUBRICANT LIST (Page 4-19)" is employed at factor y
shipment.
• Never mix oils of different grade (class) or brand.
• 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
dir t, 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
4-16
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 type of grease, see the
"INSPECTION AND MAINTENANCE: LUBRICANT LIST (Page 4-19)".
• 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 and hydraulic circuits from entering
important machine components to cause failure. They require periodical replacement. Call your Komatsu Forklift
Cautions when replacing filters by other than Komatsu Forklift distributor or yourself.
• Never reuse filters (cartridge type) after washing.
• When replacing oil filters, check for metal powder, etc. accumulated on the used filters. If metal powder is
detected, investigation for the cause and countermeasures are necessary.
• Do not unpack replacement filters until immediately before installation.
NOTICE
• For replacement filter, use the KOMATSU UTILITY genuine filter.
• Some of commercially available filters are inferior to the genuine product in performance. Using such filters may affect the
performance and durability of forklift truck. If KOMATSU UTILITY genuine parts are not used, the quality assurance may
not apply to.
4-17
4.4.1.2 LUBRICANT LIST 4

OIL AND GREASE CHART
Tip of tilt cylinder rod Fork shaft

Reach cylinder pin Reach leg inner surface,
rotating surface
Lift chain
Mast carriage side roller
Control lever link
Guide bar
Brake link
Steering gear, Hydraulic oil reservoir
Joint spline
Transfer Brake pedal
Brake cam Suspension
L type
Check every day W type
Every 2 weeks (100 hours)
Every 1 month (200 hours)
Caster bracket Every 3 months (600 hours)
(L type) Every 6 months (1,200 hours)
: Check and add fluid if necessary

: Total oil change or greasing and application Symbol Symbol Type of fluid
: Figure inside the box shows the number of places to apply oil EO Engine oil
HO or grease to GO Gear oil
HO Hydraulic oil
G Grease
4-18
LUBRICANT LIST
Ambient temperature
Cold-strage
Lubrication point Type of fluid model Lift Truck Standard spec. Lift Truck Capacity
C
Transfer case Gear oil SAE75 3.4
SAE5W-CD
Hydraulic tank Hydraulic oil* 16
SAE10W-CD
Each greasing Lithium grease NLGI No. 2

point
SAE5W-CD
SAE10W-CD
Each lubricating
Engine oil*
point
SAE30W-CD
SAE10-30SD
*: Use CD or higher grade oil
For lubricant, use the KOMATSU UTILITY genuine products. (The oil and grease are available at the KOMATSU
UTILITY Sales and Service dealers.)
4-19
4.4.2 JACKING-UP 4
CAUTION
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. Do not crawl
under the lifted truck body.
1. Unload the cargo from the forklift truck. Stop the forklift truck
on the horizontal, flat and solid place and take your foot off
the brake pedal. (The parking brake works.)
2. Place a chock the wheel diagonally opposite to the wheel to
be jacked up.
3. When jacking up, place the jack to the jack-up point.
Front - - - - -Lower part of leg frame
Rear - - - - -Lower part of body
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.
REMARK
When jacking up the front, put it under the front side. When
jacking up the rear, put it under the rear side.
4-20
4.4.3 REPLACING FUSE 4

FUSE FOR LAMPS, ACCESSORY CIRCUITS AND CONTROL CIRCUITS
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
• Perform the reach operation of mast (extending, extracting), being
seated in the operator’s compartment.
• When replacing fuse, always disconnect the battery plug to turn the
power OFF.
• 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.
1. Position yourself in the operator's compartment and operate

the reach lever to extend the mast. (Reach-out)
2. Set the starting switch to [ ] (OFF) position and disconnect
the battery plug.
3. Loosen the front panel fixing knobs at two locations.
Fixing
4. Lower the front panel downward (1) and open it toward you
(2) from the upper side. Then, raise it upward (3) and remove (2)
it.
(3)
(1)
5. If a fuse below is blown, replace it with a spare one with

(4)
identical capacity.
Name of protected circuit Capacity Color

Lamps and accessory circuit (1) 10A Red (3)
Controller control circuit (2) 10A Red

EPS (3) 40A -
Power circuit (4) 325A - (2) (1)
4-21
6. Open the cap of fuse holder and remove the fuse from the
fuse holder. Then, check visually the fuse for blowing.
• The example marked with X shown at the right side in
figure is the blown-out fuse.
7. Hook the front panel to the bar (1) at the frame side, turn it
toward the forklift truck, lift it upward (3) and tighten the fixing (2)
knob.
(3)
(1)
4-22
POWER CIRCUIT FUSE

To investigate the reason for the fuse blow, please contact
Komatsu Forklift distributor for checking and replacement of the
fuse.
STATIONARY BATTERY CHARGER
CAUTION
• Always use fuse of same capacity for replacement.
• If replaced fuse is blown again, abnormal electric system may be
causing the problem. Please contact Komatsu Forklift distributor for
checking.
1. Disconnect the power cord plug of charger from the power

supply receptacle.
2. Remove the fuse cover in front.
3. Loosen the nut and replace the fuse.
• To order fuse for replacement, advise the type of charger
or type number of removed fuse to your Komatsu Forklift
distributor.
Voltage Battery Capacity Fuse type No.

Stationary Battery Charger
160 - 190 (Ah) BFS40A
190 - 250 (Ah) BFS50A

48V
250 - 330 (Ah) BFS80A
330 - 450 (Ah) BFS80A
4. After replacement, tighten the fuse tightening nut securely

and install the fuse cover.
4-23
4.4.4 REPLACING BULBS 4

If lamps fail to light up, it may be caused by blown fuse or
disconnection of wiring beside burnt bulb. Determine the cause.
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 [ ] (OFF) position, and the

lamp switch to the OFF position.
2. Remove the lamp lens and replace the bulb.
Lamp name Capacity

Head lamp 40W (For 48V)
Turn signal lamp 25W (For 48V)
4-24
INSPECTION AND MAINTENANCE 4.5 HANDLING OF BATTERIES
4.5 HANDLING OF BATTERIES 4
Handling of batteries such as recharging, maintenance, storage and disposal are each important for safety.
Handle them carefully by fully understanding cautions concerning fire, electric shock, battery electrolyte,
abnormal action, storage and disposal.
WARNING
• Handling error of batteries may cause explosions and other critical injuries. Handle batteries after fully understanding their
hazards and mastering the method of handling.
• When carrying on maintenance or recharging of batteries, read thoroughly and fully understand "2.6.13 CAUTION WHEN
HANDLING BATTERY (PAGE 2-33)".
CAUTION
CAUTION AGAINST FIRE
• Batteries generate flammable hydrogen gas. Do not smoke cigarette or use fire near the batteries.
• Otherwise, sparks may ignite and explode the gas. Do not place tools, parts or other metal objects on the battery.
• To clean the top surface of battery, wipe with wet cloth before recharging. Using dry cloth for wiping, dusting or covering
battery with vinyl sheeting generates statistics that may cause explosion.
• Depending on the weather, environmental, clothing material and other conditions, human bodies may deposit and spark
statistics. Therefore, before touching lift truck in charging or after charging, discharge statistic deposit in the human bodies
by grounding.
CAUTION AGAINST LEAKAGE AND ELECTRIC SHOCK

• In precaution against leakage of electricity, always keep the top surfaces of batteries clean and dry.
• Batteries for battery-driven lift trucks store large energy in high-tension. Beware of the risk of electric shock. Never allow
human body to touch conductive portions during installation, maintenance and inspection service.
• Always wear protective glasses, rubber gloves and rubber sole shoes for working on batteries. (They also help protect
personnel from direct contact with diluted sulphuric acid.
CAUTION AGAINST BATTERY ELECTROLYTE

• Battery electrolyte contains diluted sulphuric acid, which may cause burns and loss of eyesight. If you spill battery
electrolyte on yourself, immediately take off clothes and flush the contact portion of the skin with a large quantity of tap water
and consult a doctor.
• If battery electrolyte gets into your eyes, flush them immediately with fresh tap water for 10 to 15 minutes continually and
consult a doctor.
• If you swallow battery electrolyte by accident, either drink a large quantity of water or milk mixed with beaten egg white or
salad oil, and then consult a doctor at once.
• Spilling or leaking battery electrolyte in the surrounding area damage the floor and material, leading to environmental
contamination. If contacted by human beings, it may cause burns or injuries. Immediately neutralize battery electrolyte with
an acid neutralizing agent (baking soda, calcium hydroxide or sodium carbonate, etc.) and wash it down with large amount of
water.
4-25
4.5 HANDLING OF BATTERIES INSPECTION AND MAINTENANCE
ACTION FOR ABNORMALITIES

• Do not drain battery electrolyte, disassemble or repair batteries or battery plugs, which may cause explosion and/or electric
shock.
• If the following abnormalities are detected, call your Komatsu Forklift distributor for service:
Battery plug and charging plug mating become loosened or play is generated. (Plug becomes abnormally heated)
Battery electrolyte temperature is high.
Battery electrolyte decreases sharply.
Battery emits odor.
Battery electrolyte becomes turbid.
Charging requires too long time. (Charging is not completed although the battery was not used till late hours on the
preceding day.)
LONG-TERM STORAGE AND DISPOSAL

• If batteries are not to be used for an extended period of time, remove them from the lift truck and store them in a well-
ventilated place free from fire.
• Since lead and diluted sulphuric acid are used in batteries, illegal disposal turns them into hazardous substance to cause
environmental pollution. For the disposal of used batteries, contact your Komatsu Forklift distributor.
CHECKING OF BATTERY ELECTROLYTE LEVEL

If the battery electrolyte level drops below the normal range, the Indicator
red lamp on the battery electrolyte level indicator blinks. Check
the battery electrolyte in all of the cells in the procedure below.
CAUTION
For drawing out and pulling in the battery, refer to "OPERATION 3.2.4
DRAWING AND PULLING IN THE BATTERY (Page 3-22)".
CHECKING PROCEDURE
1. Draw out the battery.
3. Disconnect the battery plug and the plug on the lift truck.
• With each battery cap closed, visually inspect the floating
Stopper
condition of the upper portion of the float.
If the stopper on the top of the float is in contact with the
bottom of the guide, electrolyte has reached below the
a
minimum level. Refill electrolyte. (When it is below the
minimum level, float does not move downward even if the
top end of the float is pushed by opening the cap.
• If white line of the float is visible, electrolyte has reached Cap
the maximum level. Float (red)
4-26
INSPECTION AND MAINTENANCE 4.5 HANDLING OF BATTERIES
REFILL OF BATTERY ELECTROLYTE

Check the battery electrolyte level. If in short, refill electrolyte to
the batteries according to the following procedures:
PROCEDURE FOR REFILL OF WATER

1. Place a container with distilled or purified water in a location
higher than the batteries and connect a hose to it. Use the
container with stop valve or install the stop valve in the center Lid
of hose.
2. Open the battery cap lid and insert the hose end.
3. Open the stop valve and refill water.
When the white line comes into view with the rising float,
immediately close the stop valve. Refill every cell in short of
electrolyte. When the white line is observed, electrolyte has
reached the highest level.
4. After refill of water, close the battery cap lid securely and wipe
the top surface of battery with wet cloth.
5. Connect the battery plug again.
6. Unlock the gas spring stopper (bright red) of battery hood by
pushing it to the rear of the lift truck and close the hood. Refilling water
Check that the lock lever is securely locked.
7. Close the container of distilled or purified water. Wind the White line
Refilling water ended
hose and keep it free of dust.
CHECKING OF SPECIFIC GRAVITY OF ELECTROLYTE

• Check the specific gravity of electrolyte to see if recharging is
done appropriately and cells do not have perfor mance
difference and so forth in order to get the longer service life
from the batteries.
• Since specific gravity of electrolyte differs by the temperature,
read the specific gravity and liquid temperature and convert the
gravity to 20 °C according to a conversion table.
HOW TO READ THE TABLE

(Example) If the battery electrolyte temperature is 10 °C and the
specific gravimeter reads 1.252, gravity converted to 20 °C shall
be 1.250.
Appropriate specific gravity (when converted to 20 °C)

Specific gravity when fully charged 1.280 – 1.290
Specific gravity when discharged (80 % discharge/
1.170 – 1.180
discharge warning lamp lighting)
Battery specific gravity may slightly differ by supplier and/or type.
4-27
4.5 HANDLING OF BATTERIES INSPECTION AND MAINTENANCE
SINGLE ACTION WATER REFILLER (OPTION)
CAUTION
Always use distilled or purified water for water refilling of battery.
Single action water refiller can refill every cell of a battery

simultaneously.
WATER REFILLING PROCEDURE

1. Place a container with distilled or purified water in a location
higher than the batteries and connect a hose to it. Use the
container with stop valve or install the stop valve in the center
of hose.
2. Open the battery cap lid and insert the hose end.
3. Open the stop valve and refill water.
When the white line comes into view with the rising float,
immediately close the stop valve. When the white line is
observed, electrolyte has reached the highest level.
4. After refill of water, close the battery cap lid securely and wipe
the top surface of battery with wet cloth.
TIPS FOR USING BATTERY LONG TIME

Battery service life is largely dependent on the quality of
maintenance given. Use the battery safely for a long time by
following the points below:
1. Avoid over discharge (excessive use of battery).
• If discharge warning lamp lights up, immediately stop work
and recharge battery.
• When the operating time is long and there is possible
lighting of discharge warning lamp during operation, carry
on recharging using break time.
2. Avoid overcharging (excessive charging).
• Avoid excessive equalizing charging.
• Make one equalizing charging once a week or two for an
on board type battery charger, and once a month for a
stationary battery charger.
• Charge every two to three days if daily operating time is
short.
3. Always maintain battery electrolyte level within the specified
range.
4. Always keep the top surface of battery clean and dry.
4-28
INSPECTION AND MAINTENANCE 4.6 CHARGING
4.6 CHARGING 4
• For a safe and long period of service life of battery, give cautions to the following points: Cautions are
commonly applicable to both the on-board type battery charger and stationary battery chargers.
• Charging consists of automatic charging, equalizing charging, auxiliary charging and charging for long storage.
Charging time differs by discharged state of each battery. It takes generally 8 – 10 hours to charge batteries of
standard application.
Types of
Timing of charging and charging operation
charging
• Automatically judges and selects ordinary charging or equalized charging and
Automatic
charges accordingly (operation of on-board type battery charger).
charging
• Press [AUTO] button.
• Charges power at the end of normal work or when battery capacity warning (see
Ordinary
note) is indicated.
charging
• Press [AUTO] button.
Equalized • Forcibly carries out equalized charging.
charging • Press [EQUAL] button.
• Additional charging to replenish battery capacity by using lunchtime and other break.
Auxiliary charging • Press [AUTO] or [NORMAL] button.
• When ending auxiliary charging, press [STOP] button.
Charging for
• Charging before storing battery without using for one month and over.
long-term storage
• Press [EQUAL] button every month.
of battery
Note: For the battery capacity warning, see "WARNING ON BATTERY OVER DISCHARGE (PAGE 3-8)".
REMARK
• Equalized charging: After repetition of discharging and charging, performance of individual cells (24 cells
for 48V battery) gradually dispersed increasingly. Allowing them to go unattended will
give adverse effect to their life. It is the purpose of equalized charging to eliminate
dispersion by giving longer charging time than for ordinary charging. Optimal intervals
for conducting the equalized charging shall be one week or two.
• Auxiliary charging : If charging on the preceding day is good enough for carrying on the work for the day,
it is more effective to avoid auxiliary charging in extending battery service life.
(Unnecessary charging and forcible operation give adverse effect on the life of
battery.)
• Refilling water : Battery loses water gradually through water decomposition during charging and
evaporation during use. "Refilling water" refers to refilling decreased portion of water.
With normal battery, check electrolyte level once a week and refill water as may be
required.
• When the end of battery service life approaches, decrease of electrolyte is quickened.
WARNING
• Handling error of batteries may cause explosions and other critical injuries. Handle batteries after fully understanding their
hazards and mastering the method of handling.
• When carrying on maintenance or recharging of batteries, read thoroughly and fully understand "SAFETY 2.6.13 CAUTION
WHEN HANDLING BATTERY (PAGE 2-33)".
4-29
4.6 CHARGING INSPECTION AND MAINTENANCE
CAUTION
BEFORE CHARGING BATTERIES
• Carry on charging in a well-ventilated place sheltered from rainfall. Do not recharge batteries near fire or hazardous
substances, in place of high humidity or place splashed by water, which may cause fire.
• Before starting charging, first set the starting switch to [ ] position.
• Open the battery hood fully, lock the gas spring stopper (bright red) and prevent hydrogen gas from being accumulated.
• Be careful not to allow electrolyte to drop below minimum level. Otherwise, battery may become overheated to cause fire.
• Wipe the top surface of battery before recharging to prevent statistic accidents that occur during cleaning.
• Check the charger, battery plugs and cable for damage. Check also engaged portion of connector for loosening and/or play. If
any abnormality is detected, do not use the lift truck until repair service is completed.
• Insert or pull out plug by holding its main body. Pulling the lug by cable may cause short circuit of the cable and plug, leading
to fires.
CHARGING
• During or immediately after the battery is charged, surrounding area may be filled with flammable hydrogen gas. Never
smoke or use fire near the battery.
• Sparks and/or statistics may ignite the gas. Do not handle tools and other metal carelessly in the surrounding area of the lift
truck. Ground and release statistics charged to human bodies before touching the lift truck or charger.
• To interrupt charging, press "STOP" button of the charger, then pull out the plug. Sparks may be generated upon pulling out
cable to cause burns and fire.
• Charge battery when the ambient temperature reads 0 ºC – 40 ºC.
• Battery and charger form a set to enable optimal charging. To avoid fire, do not charge batteries outside the rated capacity of
charger or different types of batteries.
INSTALLATION AND EQUIPMENT OF CHARGER

• Transformer tap adjustment for charger shall be carries out by your Komatsu Forklift distributor. To avoid the risk of fire due
to overheated charger, do not modify the charger by yourself.
• Work on the power supply equipment should be made under the instructions of chief electric engineer or by an electric
contractor designated by a power company.
• Connect the grounding wire to the electrical outlet on the plant side to prevent electrical shock accident.
• Do not use supply voltage and receptacles other than those specified.
• Use earth leakage breaker for the breaker.
• Variation of supply voltage shall be ± 10%.
• Do not disassemble or modify the charger.
• Charger is designed and manufactured according to the life of lift truck. To prevent accident, dispose the charger on
conventional lift truck simultaneously with the disposal of the lift truck. Do not use it continually.
NOTICE
• Always use distilled or purified water for refilling water. Using tap water and other may affect the battery service life
adversely.
• Various additives are on commercial market for the purpose of extending, reviving or vitalizing battery life. Some of them
do not match the charger and customers should use them on their own risk and responsibility.
4-30
4.6.1 OPERATION OF ON-BOARD TYPE BATTERY CHARGER (OPTION) 4

Connect the charging plug to the on-board type battery charger,
and push either [AUTO] or [EQUAL] button to automatically carry
on optimal charging.
CAUTION
To avoid hazards of fires due to corrosion or degraded insulation, always
use a stationary battery charger under the following environment:
• Freezing chamber or cold storage environment
• Environment where water attaches to the device
• Environment where metal-corrosive chemicals are in the vicinity
• Salt water environment
OVERALL VIEW OF ON-BOARD TYPE BATTERY CHARGER

(1) Charging cord (3) (4) (2)
(2) Charging plug
(3) Power supply plug
(4) Receptacle on the lift truck (5)
(5) AC power receptacle
(1)
NAME OF CHARGE OPERATION PANEL
(2) (3) (4) (5) (6)
(7)
(1)
(11)
(8) (9) (10) (12)
(1) Charge level L1 lamp (7) CHECK lamp

(2) Charge level L2 lamp (8) OFF button
(3) Charge level L3 lamp (9) AUTO lamp
(4) Charge level L4 lamp (10) AUTO button
(5) Charge level L5 lamp (11) EQUAL lamp
(6) Charge complete L6 lamp (12) EQUAL button
4-31
AUTOMATIC CHARGING PROCEDURES

1. Park the lift truck in the place where the AC power source is (3) (4) (2)
installed.
3. If battery electrolyte level is lower than the minimum line, refill (5)
distilled or purified water to specified range. For the checking
o f e le c t r o l y t e l eve l , s e e " C H E C K I N G O F B AT TE RY
ELECTROLYTE LEVEL (PAGE 4-8)".
4. Connection of charging cord (1)
1) Turn the breaker/switch of AC power source ON.
2) Insert the power plug (3) of charging cord (1) to the AC
power receptacle (5).
3) Insert securely the charging plug (2) to the power
receptacle on the forklift truck.
(4) (2)
When power is ON, AUTO lamp (green) (9) and EQUAL lamp
(green) (11) flash. (Standby state for charging)
REMARK
If the lamps does not flash, check if the AC power supply
(11)
breaker/switch is ON and that the charging cord is correctly
connected.
(9)
5. Start charging (5) (6)

Press "AUTO" (10) button.
AUTO lamp (9) lights up continually, EQUAL lamp (11) goes
out and automatic charging starts.
At the same time charge level L1 lamp (yellow) (1) lights up. (11)
(1)
6. Progress of charging
As charging progresses, charge level lamps are sequentially
light up in rising order starting with charge level L1 lamp to
indicate the progress of charging. (9) (10)
• Rough indication of charge level
Lit up to charge level L2 lamp (2) : charged about 30%
Charge complete L6 lamp (6) lights up: charged about
100%
About 30 minutes before charging is completed, charge level
L5 lamp (5) and charge complete L6 lamp (6) start flashing
alternately.
4-32
7. When charging is completed, charging automatically stops, (6)

charge complete L6 lamp (green) (6) lights up and AUTO
lamp (9) goes out. (Charging completed)
8. Withdrawal of charger
1) Turn the AC power breaker/switch on the building OFF. Or (7)
pull out the power plug.
2) Pull out charging plug. Arrange charging cable for storage
by avoiding twists.
(9)
NOTICE
If CHECK lamp (red) (7) lights up during charging or at the completion
of charging, take necessary measures by referring to "ACTIONS AT
ABNORMALITIES (PAGE 4-39)".
REMARK
• To interrupt charging, press OFF button (8).
• This charger is enabled to automatically effect equalized
charging depending on the charging frequency and charging
level by merely pressing AUTO button (10). When the device
is switched automatically to equalized charging, color of
AUTO lamp (9) turns orange.
(8) (9) (10)
4-33
EQUALIZED CHARGING (FORCIBLE)

NOTICE
Do not make equalized charging beyond necessity, which may reduce
the life of battery. If sharp dispersion of performance is detected among
individual cells upon checking specific gravity of electrolyte, eliminate
the dispersion of specific gravity by conducting equalized charging as
basic procedure. Check specific gravity periodically and find out
intervals for equalized charging optimal to the working conditions.
When AUTO button (10) is pressed for charging, the controller

automatically judges the mode for ordinary charging or equalized
charging. Therefore, normally it is not necessary to press EQUAL
button (12) for charging. Carry out equalized charging by
operating this EQUAL button in the following cases:
• When charging battery following customer's intervals for
maintenance management at each weekend, alternating
weekend, before a long weekend and so forth without carrying
on equalized charging using AUTO button (10). (10) (12)
• When electrolyte is refilled.
• When resuming use of a lift truck that has been in storage for
an extended period of time.
• When the lift truck was used close to the limit of its battery
capacity due to heavy load for the day.
PROCEDURES FOR EQUALIZED CHARGING

1. Park the lift truck in the place where the AC power source is (3) (4) (2)
installed.
3. If battery electrolyte level is lower than the minimum line, refill (5)
4. Connection of charging cord (1)
1) Turn the breaker/switch of AC power source ON.
2) Insert the power plug (3) of charging cord (1) to AC power
receptacle.
3) Insert charging plug (2) securely to the power receptacle
(4) on the lift truck.
When power is ON, AUTO lamp (green) (9) and EQUAL lamp
(green) (11) flash. (Standby state for charging)
REMARK
If the lamps does not flash, check if the AC power supply
(11)
breaker/switch is ON and that the charging cord is correctly
connected.
(9)
4-34
5. Start charging (2) (4) (6)

Press EQUAL button (12).
Of the flashing AUTO lamp (9) and EQUAL lamp (11) in
green, EQUAL lamp (11) only changes to continual lighting in
green. Also, charge level L1 lamp (1) lights up in yellow and (11)
(1)
forcible equalized charging starts.
As charging progresses, charge level lamps are sequentially
lit up in rising order starting with charge level L1 lamp to (9) (12)
indicate the progress of charging.
Charge complete L6 lamp (6) lights up: charged about
100%
About 30 minutes before charging is completed, charge level
L5 lamp (5) and charge complete L6 lamp (6) start flashing
alternately.
7. When charging is completed, charging automatically stops, (5) (6)
charge complete L6 lamp (green) (6) lights up and EQUAL
lamp (11) goes out. (Charging completed)
by avoiding twists.
NOTICE
If CHECK lamp (red) (7) lights up during charging or at the completion
of charging, take necessary measures by referring to "ACTIONS AT
ABNORMALITIES (PAGE 4-39)".
REMARK
To interrupt charging, press OFF button (8).
SELECTION OF AUTO AND EQUAL CHARGING

Pressing EQUAL button (12) or AUTO button (10) during charging
changes mode from AUTO to EQUAL or EQUAL to AUTO while
charging continues.
(10) (12)
4-35
ACTIONS AT ABNORMALITIES
POWER FAILURE DURING CHARGING
AUTO lamp (9) or EQUAL lamp (11) remains lit as before the (2) (3) (4) (5) (6)
power failure. Depending on then charge level, either one of the
charge lamps L1 (1) to L5 (5) will flash. (Figure at right shows an
example where power failure occurred when the charge level is at
L3 (3) during auto charging.) (11)
(1)
The operation panel and charger after recovery from the power
failure will be as follows depending on the length of duration of
power failure: (9)
Power failure
State of operation panel and charger
time
1 hour or less Charging resumes automatically
Charging not resumed
1 hour or more AUTO lamp (9) and EQUAL lamp (11) flash,
indicating standby condition for charging
WHEN INSPECTION LAMP LIGHTS UP

If charging controller judges the need for checking charger or
battery, it stops charging, simultaneously lighting or flashing
CHECK lamp (7).
(7)
Content of abnormality and
State of lamps
possible causes
ON Failure of charger, etc.
Over discharge during work on the
preceding day (8)
Flashing
Degradation of battery
Drop of supply voltage (check voltage tap)
NOTICE
• For other failures than "over discharge on the preceding day",
contact Komatsu Forklift distributor for inspection and repair.
• To reset the inspection lamp indication, press OFF button (8).
4-36
4.6.2 OPERATION OF STATIONARY BATTERY CHARGER (OPTION) 4

OVERALL VIEW OF STATIONARY BATTERY CHARGER
(1) Stationary battery charger

(2) Charging cord (5) (3)
(3) Charging plug
(4) Power supply cord
(5) AC power receptacle
(4)
(3)
(1)
(2)
NAME OF CHARGE OPERATION PANEL
(6)
(5)
(7)
(4)
(8)
(3)
(2) (9)
(1) (10)
(1) STOP button (6) CHECK lamp

(2) EQUAL button (7) Charge complete OK lamp
(3) EQUAL lamp (8) Charge level lamp 1
(4) NORMAL button (9) Charge level lamp 2
(5) NORMAL lamp (10) Charge level lamp 3
4-37
CHARGING PROCEDURES
1. Park the lift truck in the place where a stationary battery
charger is installed.
3. If battery electrolyte level is lower than the minimum line, refill
4. Connection of charging cord
1) Turn the starting switch to [ ] (OFF) position. (5) (3)
2) Insert the plug of input power cord (4) in the receptacle (5)
of factory power source.
3) Insert the plug of output cord (2) in the charging plug (3)
(4)
(3)
at the left side of operator's seat.
(1)
• When the connection of plugs is completed, the
ORDINARY and EQUAL lamps on the display panel blink. (2)
• Before charging the battery, be sure to check that the
battery electrolyte level is within the specified range.
5. Start charging
Pressing NORMAL button (4) or EQUAL lamp (2) starts
ordinary or equalized charging.
(4)
Pressed lamp lights up and other lamp goes out.
As charging progresses, charge level lamp 1 (10), charge
level lamp 2 (9) and charge level lamp 3 (8) lights up (2)
sequentially.
Lit up to charge level lamp 2 (9) : charged about 30%
Lit up to charge level lamp 3 (8) : charged about 80%
Charge complete OK lamp (7) lights up : charged about
100%
7. When charging is completed, charging automatically stops
and charge complete OK lamp (7) lights up. (Charging
completed)
by avoiding twists.
NOTICE
• Always operate the buttons with fingertip.
• f Do not press NORMAL and EQUAL buttons longer than 5 seconds.
Pressing them longer than 5 seconds calls in Test mode, which
disables charging.
REMARK
• Press [NORMAL] button upon completing ordinary work.
4-38
• Equalized charging is implemented to eliminate performance

dispersion among the batter y cells. This charging is
implemented in principle when dispersion in specific gravity
of respective cells becomes excessive.
• Although implementation intervals for equalized charging
varies depending on the type of battery and its use, it is
recommended to implement equalized charging weekly or by
every two weeks. Measure specific gravity periodically to
decide on implementation intervals for equalized charging.
Implement equalized charging at least once a month.
• Since equalized charging takes longer time, it is
recommended to select a weekend for equalized charging
when no work is expected on the following day. At the same
time, remember to clean the top surface of the battery.
Press EQUAL button once every week or two.

When using the lift truck by giving the battery auxiliary charging
almost daily, implement equalized charging once a week. When
using the lift truck without auxiliary charging, implement equalized
charging once every two weeks.
ACTIONS AT ABNORMALITIES
WHEN INSPECTION LAMP LIGHTS UP
• If charging time is excessively long, the charger controller (6)
judges it as abnormality and stops charging, lighting the
CHECK lamp (6).
• f If the CHECK lamp (6) lights up, stop charging and contact
your Komatsu Forklift distributor.
POWER FAILURE DURING CHARGING

When power failure occurs, the operation panel indication and
operating state of charger will be as follows depending on the (5)
length of duration of power failure:
Power failure
State of operation panel and charger
time
(3)
1 hour or less Charging resumes automatically
Charging not resumed
NORMAL lamp (5) and EQUAL lamp (3)
1 hour or more
flash, entering standby condition for
charging
4-39
4.7 REPLACING OF BATTERY INSPECTION AND MAINTENANCE
4.7 REPLACING OF BATTERY 4
CAUTION
• Battery is heavy stuff. Careless handling during replacing may lead to
serious physical injuries. Understand how to handle lift truck and lift
devices and replace battery carefully.
• Perform the battery replacement on a flat place.
Implement conversion of battery when:

• To extend daily operating time.
• To use spare battery.
• For long-term storage, inspection and maintenance.
CAUTION
• If you operate abruptly the reach lever, the forklift truck may be shaken.
• When operating the reach lever, be positioned correctly in the operator's
1. Park the forklift truck on the flat place.

2. Confirm that the accelerator lever and the work equipment 1
control lever in the neutral position.
Then, turn the key switch to [ | ] (ON).
3. Lift up the fork 15 to 20 cm from the ground.
4. Turn the reach lever (1) toward you to retract the mast first to
the operator’s seat side completely.
5. In the state that the mast is completely retracted, step down

the battery lock pedal (2) to the lowest position.
2
4-40
INSPECTION AND MAINTENANCE 4.7 REPLACING OF BATTERY
6. While stepping down the lock release pedal, turn the reach
lever forward to push out the mast.
The battery case (3) is drawn out together with the mast. (The
figure at the left hand side shows the drawn-out battery case
(3).)
7. Separate the battery plug.

8. Disconnect the battery cable from the lift truck and remove
the hose from the hose guide.
REPLACE BATTERY
WARNING
• Hoist the battery with caution not to catch the hose.
• A person, who finishes the slinging skill course and has the license of
crane operator, should perform slinging.
• When replacing the battery using the forklift, use the attachment
suitable for the fork.
1. Hoisting four holes of battery case (3) with the lifting sling,
replace the battery.
For battery mass, refer to the table below.
REMARK 3
When replacing battery by other methods, contact your
Komatsu Forklift distributor.
WEIGHT OF BATTERY
Capacity Weight Voltage
Model
(Ah) (kg) (V)
201 365
FB10RL (F)/RW -14
225 385
FB13RL (F)/RW -14
240 400
48
280 495
FB15RL (F)/RW -14
312 530
FB18RL (F)/RW -14
370 585
4-41
4.7 REPLACING OF BATTERY INSPECTION AND MAINTENANCE
HOW TO MOUNT BATTERY
CAUTION
• Install the battery for the cable not to be twisted.
• Put the battery cable inner side of guide bar.
1. Park the lift truck on a flat place.

At this moment, install prudently so that the battery case fits
in the tray.
4
2. Confirm that the hydraulic hose sits on the hose guide (4) of
battery case.
NOTICE
If the hydraulic hose is dislocated from the hose guide, place it on the
hose guide.
3. Connect the battery plug to the lift truck.

Ensure to put the battery cable in between the cable guide (5)
and the frame. (Except RW type)
4-42
INSPECTION AND MAINTENANCE 4.7 REPLACING OF BATTERY
CAUTION
• Perform the work while watching the hose from the driving seat.
• When pulling in the battery, if the hydraulic hose is not sitting correctly
on the hose guide of battery case, the hose may be damaged by being
caught by the body of forklift truck.
and stopped.

2. Pull slowly the reach lever (2) toward you. The battery is
pulled in together with the mast. 2
Check if the hydraulic hose does not disconnect from hose
guide while operating the operator’s compartment.
of forklift truck.
REMARK
4-43
4.8 REPLACING OF BATTERY (IN CASE OF BATTERY FRONT TO SIDE REMOVAL STRUCTURE) (OPTION FOR RL) INSPECTION AND MAINTENANCE
4.8 REPLACING OF BATTERY (IN CASE OF BATTERY FRONT TO SIDE REMOVAL STRUCTURE) (OPTION FOR RL)4
CAUTION
• Battery is heavy stuff. Careless handling during conversion may lead to
serious physical injuries. Understand how to handle lift truck and lift
devices and convert battery carefully.
• Perform the battery replacement on a flat place.
Implement conversion of battery when:

• To extend daily operating time.
• To use spare battery.
• For long-term storage, inspection and maintenance.
CAUTION
• If you operate abruptly the reach lever, the forklift truck may be shaken.
• When operating the reach, seat yourself correctly and operate
1. Park the forklift truck on the flat place.

2. Confirm that the accelerator lever and the work equipment 1
control lever in the neutral position.
Then, turn the key switch to [ | ] (ON).
3. Lift up the fork 15 to 20 cm from the ground.
4. Turn the reach lever (1) toward you to retract the mast to the
operatorAfs seat side completely.
5. In the state that the mast is completely retracted, step down

the battery lock pedal (2) to the lowest position.
2
4-44
INSPECTION AND MAINTENANCE 4.8 REPLACING OF BATTERY (IN CASE OF BATTERY FRONT TO SIDE REMOVAL STRUCTURE) (OPTION FOR RL)
6. While stepping down the lock release pedal, turn down the
reach lever forward to push out the mast.
The battery case (3) is drawn out together with the mast. (The
figure on the left shows the drawn-out battery case (3).)
7. Separate the battery plug (12) using the battery plug release
lever (4).
8. Release the tray door catch (5).
9. Open the tray door (6).
10. Turn the tray door stopper (7) to fix it to the tray.
4-45
11. Aligning the positioning pole (8) at the battery stand (or
carrier) with the positioning pole (9) at the tray side, insert the
hook at the tip of battery (or carrier) in the groove at the tray
side.
CAUTION
• Confirm that the hook of battery stand (carrier) is securely inserted in
the groove of tray.
• Use the battery stand (carrier) suitable for the truck.
12. Release the stopper (10) at the tray side and the stopper (11)
at the stand (or carrier) side.
13. Draw out the battery case (3).
14. Lock the stopper (11) at the battery stand (or carrier).
11
10
4-46
IN CASE OF BATTERY STAND

• Hoist four holes of battery case with the sling and replace the
battery with a new one.
WARNING
• Hoist the battery with caution not to catch the hose.
• A person, who finishes the slinging skill course and has the license of
crane operator, should perform slinging.
• When replacing the battery using the forklift, use the attachment
suitable for the fork.
IN CASE OF BATTERY CARRIER

• Confirm that the stopper at the leading edge of carrier is
securely locked.
• Lift the carrier 80mm and move the battery.
CAUTION
When mounting the battery on the carrier, ensure to set the stopper before
moving.
WEIGHT OF BATTERY LIST

Capacity Weight Voltage
Model
(Ah) (kg) (V)
201 365
FB10RL (F)/RW -14
225 385
FB13RL (F)/RW -14
240 400
48
280 495
FB15RL (F)/RW -14
312 530
FB18RL (F)/RW -14
370 585
NOTICE
Weight of battery is indicated on the serial No. plate on the side of
battery case.
4-47
INSTALLATION 4
1. Park the lift truck on a flat place.
2. Move the battery stand (or carrier) on which the battery is
placed.
3. Aligning the positioning pole (1) at the battery stand (or
carrier) with the positioning pole (2) at the tray side, insert the
hook at the tip of battery (or carrier) in the groove at the tray
side.
4. Release the stopper (11) at the battery stand (or carrier).
5. Place the battery case (4) on the tray side.
6. Lock the stopper (5) at the tray side and the stopper (6) at the
stand (or carrier) side.
7. Elevate the battery stand (or carrier) 80 mm and move it from

the tray.
4-48
8. Turn the tray door stopper (7) to release it from the tray.
9. Close the tray door (8).
10. Lock the tray door catch (9).
11. Connect the battery plug (10).
CAUTION
• Install the battery for the cable not to be twisted.
• Put the battery cable inner side of guide bar.
12. Confirm that the hydraulic hose sits on the hose guide (11) of
battery case.
11
NOTICE
If the hydraulic hose is dislocated from the hose guide, place it on the
hose guide.
4-49
CAUTION
• Perform the work while watching the hose from the driving seat.
• When pulling in the battery, if the hydraulic oil hose is not sitting
correctly on the hose guide of battery case, the hose may be damaged
by being caught by the body of forklift truck.
and stopped.

2. Pull slowly the reach lever (2) toward you. The battery is
pulled in together with the mast. 2
Check if the hydraulic hose does not disconnect from hose
guide while operating the operator’s compartment.
of forklift truck.
REMARK
4-50
INSPECTION AND MAINTENANCE 4.9 RUNNING IN COLD WEATHER
4.9 RUNNING IN COLD WEATHER 4
PREPARATIONS FOR LOW TEMPERATURE

When the temperature drops, grease and resin become hardened, causing delay of operation, increased battery
power consumption and other phenomena. These may cause failure and damage of hydraulic equipment and
hoses, early wear and failure due to defective lubrication. Take the following measures:
• Use greases of low viscosity for low temperature.

For the specified viscosity, see the "LUBRICANT LIST (PAGE 4-19)".
WHEN COLD SEASON IS OVER

When the weather becomes milder with the change of season, change back to greases fit to the current
temperature.
4.10 OPERATING THE LIFT TRUCKS IN SPECIAL ENVIRONMENT OR IN

FORCIBLE WAY 4
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 indirectly 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. For the lift trucks with
cold-storage model, see "3.4 THE LIFT TRUCKS WITH COLD-STORAGE MODEL (PAGE 3-37)".
• 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 Forklift.
• There are conditions technologies cannot cover.
• This lift truck cannot be used under a condition to which a risk of explosion accompanies.
4-51
4.11 ACTION TO TAKE IF THE FORK FAILS TO LOWER INSPECTION AND MAINTENANCE
4.11 ACTION TO TAKE IF THE FORK FAILS TO LOWER 4
CAUTION
• If the fork stops lowering during operation, stop the work immediately.
Never use this lift truck until repaired.
• Put up "No Entry" and "Do Not 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.
Never
use
2. Move the lift truck in question to a flat place and park it by
avoiding emergency exit or fire fighting equipment. For details
on parking, see "2.4.3 STOPPING AND PARKING (PAGE 2-
Danger
22)" and "3.3.3.6 TEMPORARY STOPPING AND PARKING
(PAGE 3-28)".
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 4.12 PROCEDURES FOR ALARM CODE OR ERROR CODE INDICATION
4.12 PROCEDURES FOR ALARM CODE OR ERROR CODE INDICATION 4
CAUTION
• If "ALA---****" (alarm code) appears on the meter panel while using this lift truck, promptly proceed to take measures as
described in this paragraph.
• If "Err---****" or Err---****" (error code) appears on the meter panel, promptly contact your Komatsu Forklift distributor for
appropriate measures.
If failure occurs to a lift truck, error code or alarm code is

(3) (4) (2)
displayed on date and time/hour meter display (1).
• "Err---****" or "Err---****" (error code): Failure is suspected.
(1)
• "ALA---****" (alarm code): This is not a failure.
REMARK
Error warning lamp (2) lights up if abnormality occurs. At the
same time, lift system error warning lamp (3) or travel system
error warning lamp (4) will lights up.
NOTICE
• If "Err---****" or Err---****" (error code) appears, stop work and contact your Komatsu Forklift distributor to inform the
error code.
• If "ALA---****" (alarm code) appears, the following may be causing problem: Take action corresponding with the item in
the following table.
• If alarm code is frequently indicated, some other cause may be involved. Stop the work and contact your Komatsu Forklift
distributor to inform the alarm code.
4-53
4.12 PROCEDURES FOR ALARM CODE OR ERROR CODE INDICATION INSPECTION AND MAINTENANCE
4
Alarm Code Cause Action
The temperature of power module in the travel
ALA-3021 Rest the forklift truck.
controller is rising.
ALA-3031 The temperature of travel motor is rising. Rest the forklift truck.
The accelerator lever is operated during drawing the

ALA-3064 Confirm that the battery is stored.
battery.
ALA-4021 Abnormal temperature in the EPS controller Rest the forklift truck.
The lift lever is set in position other than N and the Return the lift lever to the neutral position and turn the
ALA-5006
starting switch is turned to [ | ] (ON). starting switch from [ ] (OFF) to [ | ] (ON).
The tilt lever is set in position other than N and the Return the tilt lever to the neutral position and turn the
ALA-5007
starting switch is turned to [ | ] (ON). starting switch from [ ] (OFF) to [ | ] (ON).
The reach lever is set in position other than N and Return the reach lever to the neutral position and turn
ALA-5008
the starting switch is turned to [ | ] (ON). the starting switch from [ ] (OFF) to [ | ] (ON).
Return the attachment 1 lever to the neutral position

The attachment 1 lever is set in position other than
ALA-5009 and turn the starting switch from [ ] (OFF) to [ | ]
N and the starting switch is turned to [ | ] (ON).
(ON).
Return the attachment 2 lever to the neutral position

The attachment 2 lever is set in position other than
ALA-500A and turn the starting switch from [ ] (OFF) to [ | ]
N and the starting switch is turned to [ | ] (ON).
(ON).
The temperature of power module in the lift handling

ALA-5021 Rest the forklift truck.
controller is rising.
ALA-5031 The temperature of lift handling motor is rising. Rest the forklift truck.
4-54
INSPECTION AND MAINTENANCE 4.13 WASHING THE LIFT TRUCK
4.13 WASHING THE LIFT TRUCK 4

CAUTION
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.
WASHING PROCEDURE
1. Turn the starting switch to the [ ] (OFF) position. Pull out the key.
2. Pull out battery plug.
3. Wash each section ((1) to (6) in the figure below) according to the table below.
Take care to avoid portions for which high-pressure (steam) washing or washing with pressurized water is
inhibited.
4. Dry washed sections completely.
If droplets are attached to the electric system, apply dry air blow.
5. After checking that they are dry, insert the battery plug, turn the starting switch to [ | ] (ON) position and test
for any abnormality before proceeding to operation.
2
4
6
1
5 3
No. Sections to wash How to wash

Meter panel
1 Wipe the surface lightly with wet cloth.
Charge operation panel
Pour water by the hose from the top to wash.
Apply cloth or soft brush to wash to prevent scratch mark.
Note: Reduce the discharging volume of water as the figure A below. Lower the water
pressure for washing. (Only for No. 2 and 3)
2 Front side of dashboard
Fig. A
Apply high-pressure (steam) washing or use hose for washing except the following:
• High-pressure washing inhibited sections :
3 Inside of floor plate
Wipe wiring, connectors, inlet/outlet ports for motor wiring and
hydraulic hose with wet cloth or wash with non-pressurized water.
4 Battery Wipe the surface lightly with wet cloth. (To prevent generation of statistic)
Front/Rear tyres Front Apply high-pressure (steam) washing or use hose water for washing. (Excluding below)
5
and Rear axles Motor Note) Do not apply the high-pressure (steam) washing or hose-water washing to the wired parts.
Other and body outside
6 Apply high-pressure (steam) washing or use hose water for washing.
surfaces
1. Do not wash the inside of dashboard.
2. When performing the high-pressure (steam) washing or hose-water washing to the
Other matters and cautions lower part of floor plate (power line block), protect the motor and electric parts such as
surrounding wiring, connector and fuse box by covering them with the water-proof
sheets before implementation.
4-55
4.14 LONG-TERM STORAGE INSPECTION AND MAINTENANCE
4.14 LONG-TERM STORAGE 4
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.
• Apply grease and change oil without fail.
• Fully apply grease to the exposed portions of hydraulic cylinder piston rod.
• Carry out equalized charging of battery.
• Store the battery after disconnecting battery plug.
DURING STORAGE
• 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.
4-56
INSPECTION AND MAINTENANCE 4.15 HOISTING THE LIFT TRUCK
4.15 HOISTING THE LIFT TRUCK 4
CAUTION
• Always attach belts and other slings at the position designated by this
paragraph.
• Do not hoist a lift truck by overhead guard cab (for machine with cab
specifications) or towing pin because the truck may fall due to their lack
of strength.
• Hook the sling to the mast after checking that it is securely installed.
• Never allow other persons to go under or near the lifted truck. It is
extremely dangerous. Serious accident may occur if the truck should
fall down.
1. Use undamaged sling and wire having sufficient strength.
2. Attach the sling at designated sling positions.

• To hoist the forklift truck, hook on the hole (1) (2 locations
at right and left) on the top of retracted outer mast for the
(1)
front.
• For the rear, use the frame of head guard.
3. When hoisting, adjust the length of sling belt for the forklift
truck not to lean, and avoid giving shock to it.
NOTICE
As the head lamp is equipped to the head guard, the sling belt for rear-
hoisting may damage the head lamp by contacting it. Therefore, take
measures to protect the head lamp.
4-57
4.16 LOADING AND UNLOADING OF LIFT TRUCK INSPECTION AND MAINTENANCE
4.16 LOADING AND UNLOADING OF LIFT TRUCK 4
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 tyres.
• f Use ramps or dock plate of sufficient length, width and sufficient
strength. Secure it tightly to prevent it from being dislocated or
disengaged.
• 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.
• When loading the forklift truck on a trailer, use the winch of trailer.
1. Arrange for a trailer having adequate loading capacity for the

weight and size of a lift truck to transport. Winch
2. Stop the trailer on level, flat road surface. Apply parking brake wire
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 Blocks
5. When loading or unloading the forklift truck on/from the trailer,
position yourself in the operator's compartment correctly and
travel slowly the forklift truck.
6. To prevent a loaded lift truck from moving during
transportation, apply blocks to the tyres and secure it with
wire rope and/or chain before starting the trailer.
4-58
INSPECTION AND MAINTENANCE 4.17 INSPECTION AND MAINTENANCE SCHEDULE CHART
4.17 INSPECTION AND MAINTENANCE SCHEDULE CHART 4
This Inspection and Maintenance List describes those inspection and maintenance items operator can perform
himself and rough standard timing for doing them.
• For other inspection and maintenance items not described in this manual, contact Komatsu Forklift distributor/
dealer.
• 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.
4-59
4.17 INSPECTION AND MAINTENANCE SCHEDULE CHART INSPECTION AND MAINTENANCE
INSPECTION AND MAINTENANCE SCHEDULE CHART
[ ] indicates the inspection and maintenance service items recommended by KOMATSU UTILITY.
Inspection & Maintenance Intervals (hours) Replace

ment
Inspection & Maintenance Item Start-up Every 2 Every 1 Every 3 Every 6 Every 1 Interval
Inspectio weeks month months months year s
n (100h) (200h) (600h) (1200h) (2400h) (month)
Checking of repaired abnormalities detected on
previous day
Visual inspection (Walk around a lift truck for visual
inspection.)
• Water leak, oil leak, looseness, crack,
lubrication and greasing in each part
Transfer case
Cracks, damage and deformation
POWER TRAIN
Loosening of mount bolts and nuts

Abnormal noise
Oil leakage
Oil level and contamination
Oil replacement 6
Travel linkage
Play, foreign noise, crack, damage and deformation
TRAVELING EQUIPMENT
Looseness of mounting bolt

Wheels (tyres and rims)
Tyre crack, damage and uneven wear
Tyre tread depth
Pinching of metallic pieces, pebbles and foreign
matters
Loosening of wheel nuts and bolts
Deformation, cracks and damage to rims, discs
and side rings
Play and abnormal noise of wheel bearing
Steering wheel
Shaky, pulling to, heavy, return
Amount of play, loosening and run-out
EPS actuator
STEERING SYSTEM
Installation state, operating state

Greasing 24
Power steering motor
Rotation state
Power steering motor brush
Wear, contact
Power steering motor spring
Fatigue
Power steering motor commutator
Dirt, wear
4-60
Inspection & Maintenance Intervals (hours) Replacem

Start-up Every 2 Every 1 Every 3 Every 6 Every 1 ent
Inspection & Maintenance Item Intervals
Inspectio weeks month months months year
n (100h) (200h) (600h) (1200h) (2400h) (month)
Brake pedal
Play, pedal height, heaviness, catching
Braking effect
BRAKING SYSTEM
Brake link
Operating condition, play, looseness
Brake cam
Gap
Brake disc
State of installation, wear, damage
Brake pad
Operating condition, wear
Brake spring
Fatigue
Lifting equipment in general
Operation and function of lifting equipment
Fork
Deformation, crack and wear of fork stopper pin
Opening of fork ends, height difference and
bending
Crack at the root of fork and cracks of upper and
lower hooks
Checking of cracks using defect detector, etc.
Mast
LIFTING EQUIPMENT
Deformation, crack and damage of the mast

Play of roller bearing
Cracks and damage of welded portion of roller
shaft
Play and damage of mast support portion
Loosening of mast support mounting bolts
Chain
Chain tension
Chain elongation
Cracks, deformation, damage and corrosion of
chain
Chain lubrication
Deformation, damage and play of chain wheel
Deformation, damage and loosening of chain
stopper
Reach leg
Deformation, crack and damage of reach leg
State of reach installation
Hydraulic oil reservoir
HYDRAULIC SYSTEM
Oil leakage
Engine oil level and contamination
Replacement of oil in the tank 6
Tank cleaning
Clogging of air breather
Line filter and strainer
Clogging and damage of strainer
Contamination, clogging and damage of line filter
Replacement of line filter 6
4-61
4.17 INSPECTION AND MAINTENANCE SCHEDULE CHART INSPECTION AND MAINTENANCE
Inspection & Maintenance Intervals (hours) Replace

Start-up Every 2 Every 1 Every 3 Every 6 Every 1 ment
n (100h) (200h) (600h) (1200h) (2400h) (month)
Piping (hose and piping)
Crack, damage, aging, break, torsion
Oil leakage
Loosening and falling of pipe clamps
Hydraulic pump
Oil leakage
HYDRAULIC SYSTEM
Abnormal vibration and noise

Lift cylinder and tilt cylinder
Operating condition
Oil leakage
Cylinder drift and tilt by itself
Dents, cracks, bends and scratches
Control valve, and control valve lever
Operating condition and play
Oil leakage
Loosening of mount bolts
Relief pressure
Solenoid valve
Operation, abnormal noise and heat and oil leakage
Traveling motor
Rotation, abnormal noise and odor of the motor
Attachment of foreign matters and damage
MOTOR

Lifting motor
Rotation, abnormal noise and odor of the motor
Attachment of foreign matters and damage
Controller (Travel, hydraulic, EPS)
CONTROL SYSTEM
Operating condition, abnormal noise and odor

Maximum motor current
Contactor
Operating timing of contactor
Loosing, damage, wear of contactor and loosening
of mount
Fuse
Battery
Electrolyte level
BATTERY AND CHARGER
Electrolyte specific gravity

Voltage
Loosening and corrosion of terminal
Damage of cell and leakage of electrolyte
State of connection of connector, damage and loosening of bolts
Cleaning of top surfaces
Charger
Operating voltage of voltage sensing relay
Damage to charging plug and receptacle, looseness of bolt
Operation, damage and wear of magnet switch
Adjustment of supply voltage tap
Wiring
WIRING AND SENSOR
Loosening of connecting sections (terminal, connector)

Damage, state of fixing and friction of wire harness and power cable
Damage and state of engagement of battery connector and plug
Micro switch and sensor
Operating condition and timing
Loosening, damage and wear of contact
4-62
Inspection & Maintenance Intervals (hours) Replacem

Start-up Every 2 Every 1 Every 3 Every 6 Every 1 ent
n (100h) (200h) (600h) (1200h) (2400h) (month)
Frame
Cracks and deformation
Loosening and falling of mount bolts of sections
Overhead guard and load backrest
Loosening of mount bolts and nuts
TRUCK BODY AND SAFETY DEVICES
Cracks, deformation and damage

Lighting device, warning devices (horn and backup
buzzer) and turn signal lamp, etc.
Operation (lighting and flashing state) and the state
of mounting
Contamination and damage of lens of various
lamps, and infiltration of water
Sound level of warning device (horn)
Instruments
Operating condition
Rear-view mirror and reflector
Contamination, damage and state of reflection
lubricant
Lubricating state of various sections 1
Safety function
Travel interlock function
Lift interlock function
Neutral safety function
Conduct traveling and lifting tests and verify functions
COMPREHENSIVE TEST
Operation of various devices

Abnormal vibration, noise, odor and heating
4-63
4.18 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS INSPECTION AND MAINTENANCE
4.18 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4
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 Hydraulic hose for lifting mechanism 1–2
2 Lift chain 2–4
4-64
INSPECTION AND MAINTENANCE 4.19 SERVICE DATA
4.19 SERVICE DATA 4

SERVICE DATA 4
Inspection item Unit FB10RW – 15RW FB10RL (F) – 18RL (F)
Drive mm More than 15
Tyre tread depth Load mm More than 10
Caster mm More than 10
Tightening torque of wheel Drive Nm{kgfm} 98-123 (10-12.5)
mounting bolt Caster Nm{kgfm} 147-196 (15-20)
Play of steering wheel mm 10-20
Brake pedal play mm 0-10
Brake pedal height mm 60-70
Brake pad thickness mm More than 4
Elongation of lift chain
mm Less than 275.5
(length over 17 links)
Relief valve set pressure mPa{kgf/cm2} 16.7(170)
Fork thickness (at base) 0.9 – 1.5 ton : More than 35
mm
-In case of standard forklift truck- 1.8 ton : More than 38
Motor brush height EPS mm More than 13
CHARGER SOURCE [VOLTAGE] SPECIFICATIONS 4

Battery Maximum input electricity [kVA] Input voltage
Charger type
Voltage [V] Capacity [Ah/5h] (50/60 Hz) Three-phase [V]
190 to 250 2.8 / 2.8
250 to 330 4.5 / 4.5 200 to 230
330 to 450 5.9 / 6.2
Stationary 48
160 to 250 2.9 / 2.6
250 to 330 3.7 / 3.3 340 to 460
330 to 450 6.6 / 5.9
4-65
4.19 SERVICE DATA INSPECTION AND MAINTENANCE
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. b
• When replacing bolts and nuts, always use genuine Komatsu
Forklift parts of the same size as the previous ones.
Thread outside Tightening torque Nm {kgm}

Width across
diameter (a)
flat (b) mm Within target allowable range
mm
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 – 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}
4-66
TECHNICAL DATA 5
55
5-1
5. TECHNICAL DATA TECHNICAL DATA
5. TECHNICAL DATA 5
e
b10
b4
b3
b1
Wb
Wa
h4
L
h3
h1
h6
L4
β
h2
m2
m1
α
y
L7
L1
5-2
TECHNICAL DATA 5. TECHNICAL DATA
1.2 Model Manufacturer's Designation FB10RL-14, FB10RLF-14 FB13RL-14, FB13RLF-14

1.3 Power Type Electric, Diesel, Gasoline, LPG, Cable Electric Electric
Characteristics
1.4 Operation Type Pedestrian, Driver Standing, Sitting, Order Picking Standing Standing
1.5 Rated Capacity Q1 Rated Capacity kg 1000 1250
1.6 Load Center c Load Center mm 500 500
1.6.1 Alternative Capacity Q2 Capacity@600mm Load Center kg 870 1080
1.8 Load Distance x Front Axle Center to Fork Face mm 175 175
1.9 Wheelbase y mm 1110 1250
2.1 Service Weight Including Min. Capacity Battery, see line 6.5 kg 2020 2035
2.4 Front kg 2555 2855
Loaded
2.4.1 Axle Loading Mast/Forks Rear kg 465 430
2.4.2 Extended Front kg 905 890
Weight
Unloaded
2.4.3 Rear kg 1115 1145
2.5 Front kg 1940 2020
Loaded
2.5.2 Retracted Front kg 690 635
Unloaded
2.5.3 Rear kg 1330 1400
3.1 Tyre Type Solid Solid
3.2 Front φ 260 x 120 φ 260 x 120
3.3 Tyre Size Rear φ 360 x 180 φ 360 x 180
Tyre
3.4 Additional Wheels φ 127 x 90 φ 127 x 90

3.5 Number of Wheel Front/Rear(*=driven) 2/1*+2 2/1*+2
3.6 Tread, Front b10 mm 975 975
3.7 Tread, Rear b11 mm – –
4.1 Tilting Angle α/β Forward/Backward degree 3/5 3/5
4.2 Mast Height, Lowered h1 with Std. Mast mm 1995 1995
4.3 Std. Free Lift h2 with Std. Mast, from Ground mm 105 105
4.4 Std. Lift Height h3 with Std. Mast, from Ground mm 3000 3000
4.5 Mast Height, Extended h4 with Std. Mast mm 3935 3935
4.7 Height, Overhead Guard h6 mm 2250 2250
4.19 Length, with Std. Forks l1 mm 1905 1905
4.21 Width, at Tyre b1 mm 1095 1095
Dimenshions
4.22 Forks s/e/l Thickness/Width/Length mm 35x100x850 35x100x850

4.23 Fork Carriage Class ISO 2328, Type A/B/no Pin Mount Pin Mount
4.24 Width, Fork Carriage b3 mm 750 750
4.26 Width, between Reach Legs b4 mm 752 752
4.28 Reach Travel l4 mm 440 580
4.31 m1 under the Mast mm 75 75
Ground Clearance
4.32 m2 at the center of Wheelbase mm 80 80
4.33 Right Angle Stacking Ast with L1000 x W1200 pallet mm 2275 2310
4.34 Aisle Ast with L1200 x W800 pallet mm 2340 2355
4.35.1 Turning Radius Wa mm 1325 1465
4.35.2 Wb mm 670 555
4.37 Length, without Forks /7 1470 1610
5.1 Travel Speed (FWD) Loaded/Unloaded km/h 9.5/10.5 9.5/10.5
5.2 Lifting Speed Loaded/Unloaded mm/s 350/540 320/540
5.3 Lowering Speed Loaded/Unloaded mm/s 500/550 460/550
Performance
5.4 Reach Speed Loaded/Unloaded mm/s 300/300 300/300

5.6 Max. Drawbar Pull 3min rating N 5880 5880
5.8 Max. Gradeability Unloaded 1.5km/h, 3min rating % 32 31
5.10 Service Brake Operation/Control Mechanical, Disc Mechanical, Disc
5.11 Parking Brake Operation/Control Mechanical, Disc Mechanical, Disc
5.12 Steering Operation/Control Electric Power Steering Electric Power Steering
6.1 Drive Motor (AC) 60min rating kW 4.5 4.5
6.2 Pump Motor (AC) 5min rating kW 9 9.0
6.2.1 PS Motor (DC) 60min rating kW 0.3 0.3
Drive
6.4 Battery Voltage V 48 48

6.4.1 Battery Capacity, Min. Ah/5-hour 201 201
6.4.2 Battery Capacity, Max. Ah/5-hour 240 240
6.5 Battery Weight, Min. Capacity kg 365 365
8.1 Drive Motor Control MOS-FET inverter MOS-FET inverter
8.1.1 Pump Motor Control MOS-FET inverter MOS-FET inverter
Others
8.1.2 PS Motor Control MOS-FET chopper MOS-FET chopper

8.2 Relief Pressure for Attachment bar 167 167
8.2.1 Hydraulic Tank Capacity Ltr 16 16
4.33 and 4.34 Values are not including a cliearance. See Aisle width section for detail
5-3
1.2 Model Manufacturer's Designation FB15RL-14, FB15RLF-14 FB18RL-14, FB18RLF-14

Characteristics
2.4 Front kg 3245 3620
Loaded
Weight
Unloaded
2.4.3 Rear kg 1265 1330
2.5 Front kg 2360 2465
Loaded
Unloaded
2.5.3 Rear kg 1505 1610
3.2 Front φ 254 x 114 φ 254 x 120
Tyre

3.7 Tread, Rear b11 mm - -
Dimenshions

Ground Clearance
4.35.2 Wb mm 555 555
Performance

6.2 Pump Motor (AC) 5min rating kW 9.0 9.0
Drive

Others

5-4
TECHNICAL DATA 5. TECHNICAL DATA
1.2 Model Manufacturer's Designation FB10RW-14 FB13RW-14

Characteristics
2.4 Front kg 2560 2860
Loaded
Weight
Unloaded
2.4.3 Rear kg 1110 1140
2.5 Front kg 1945 2025
Loaded
Unloaded
2.5.3 Rear kg 1325 1395
3.2 Front φ 260 x 120 φ 260 x 120
Tyre

3.7 Tread, Rear b11 mm - -
Dimenshions

Ground Clearance
4.35.2 Wb mm 670 555
Performance

6.2 Pump Motor (AC) 5min rating kW 9.0 9.0
Drive

Others

5-5
1.2 Model Manufacturer's Designation FB15RW-14

1.3 Power Type Electric, Diesel, Gasoline, LPG, Cable Electric
Characteristics
1.4 Operation Type Pedestrian, Driver Standing, Sitting, Order Picking Standing
1.5 Rated Capacity Q1 Rated Capacity kg 1500
1.6 Load Center c Load Center mm 500
1.6.1 Alternative Capacity Q2 Capacity@600mm Load Center kg 1300
1.8 Load Distance x Front Axle Center to Fork Face mm 175
1.9 Wheelbase y mm 1350
2.1 Service Weight Including Min. Capacity Battery, see line 6.5 kg 2220
2.4 Front kg 3250
Loaded
2.4.1 Axle Loading Mast/Forks Rear kg 470
2.4.2 Extended Front kg 955
Weight
Unloaded
2.4.3 Rear kg 1265
2.5 Front kg 2365
Loaded
2.5.1 Axle Loading Mast/Forks Rear kg 1355
2.5.2 Retracted Front kg 720
Unloaded
2.5.3 Rear kg 1500
3.1 Tyre Type Solid
3.2 Front φ 254 x 114
3.3 Tyre Size Rear φ 330 x 145
Tyre
3.4 Additional Wheels φ 150 x 80

3.5 Number of Wheel Front/Rear(*=driven) 2/1*+2
3.6 Tread, Front b10 mm 975
3.7 Tread, Rear b11 mm -
4.1 Tilting Angle α/β Forward/Backward degree 3/5
4.2 Mast Height, Lowered h1 with Std. Mast mm 1995
4.3 Std. Free Lift h2 with Std. Mast, from Ground mm 105
4.4 Std. Lift Height h3 with Std. Mast, from Ground mm 3000
4.5 Mast Height, Extended h4 with Std. Mast mm 3935
4.7 Height, Overhead Guard h6 mm 2250
4.19 Length, with Std. Forks l1 mm 2005
4.21 Width, at Tyre b1 mm 1080
Dimenshions
4.22 Forks s/e/l Thickness/Width/Length mm 35x100x850

4.23 Fork Carriage Class ISO 2328, Type A/B/no Pin Mount
4.24 Width, Fork Carriage b3 mm 750
4.26 Width, between Reach Legs b4 mm 752
4.28 Reach Travel l4 mm 580
4.31 m1 under the Mast mm 75
Ground Clearance
4.32 m2 at the center of Wheelbase mm 80
4.33 Right Angle Stacking Ast with L1000 x W1200 pallet mm 2405
4.34 Aisle Ast with L1200 x W800 pallet mm 2450
4.35.1 Turning Radius Wa mm 1560
4.35.2 Wb mm 555
4.37 Length, without Forks /7 1710
5.1 Travel Speed (FWD) Loaded/Unloaded km/h 9.5/10.5
5.2 Lifting Speed Loaded/Unloaded mm/s 320/540
5.3 Lowering Speed Loaded/Unloaded mm/s 460/550
Performance
5.4 Reach Speed Loaded/Unloaded mm/s 300/300

5.6 Max. Drawbar Pull 3min rating N 6080
5.8 Max. Gradeability Unloaded 1.5km/h, 3min rating % 29
5.10 Service Brake Operation/Control Mechanical, Disc
5.11 Parking Brake Operation/Control Mechanical, Disc
5.12 Steering Operation/Control Electric Power Steering
6.1 Drive Motor (AC) 60min rating kW 4.5
6.2 Pump Motor (AC) 5min rating kW 9.0
6.2.1 PS Motor (DC) 60min rating kW 0.3
Drive
6.4 Battery Voltage V 48

6.4.1 Battery Capacity, Min. Ah/5-hour 280
6.4.2 Battery Capacity, Max. Ah/5-hour 390
6.5 Battery Weight, Min. Capacity kg 495
8.1 Drive Motor Control MOS-FET inverter
8.1.1 Pump Motor Control MOS-FET inverter
Others
8.1.2 PS Motor Control MOS-FET chopper

8.2 Relief Pressure for Attachment bar 167
8.2.1 Hydraulic Tank Capacity Ltr 16
5-6
INDEX 6
66
6-1
INDEX
INDEX
16
<A> <E>
ABOUT INSPECTION AND MAINTENANCE ------------- 4-2 EXPLANATION OF COMPONENTS ------------------------3-4
ABOUT THIS MANUAL ----------------------------------------- 1-2
ACTION TO TAKE IF THE FORK FAILS
<F>
TO LOWER -------------------------------------------------- 4-52
FIRE EXTINGUISHER AND FIRST AID KIT ------------ 2-10
ACTUAL CAPACITY------------------------------------------- 2-39
FIRE PREVENTION ------------------------------------------- 2-12
ALWAYS PERFORM THE START-UP INSPECTION---- 2-29
FOLLOW RULES -------------------------------------------------2-9
APPLICABLE MODEL AND SERIAL NO.------------------ 1-5
FOR YOUR SAFETY --------------------------------------------1-3
APPLICATION OF THE LIFT TRUCK ---------------------- 1-5
FORK SPREAD ADJUSTMENT ---------------------------- 3-34
ASBESTOS CAUTION---------------------------------------- 2-15
AVOID GETTING CAUGHT UP BY THE MAST OR
FALLING OFF ----------------------------------------------- 2-31 <G>
GENERAL VIEW --------------------------------------------------3-2
<B> GENERAL VIEW OF THE LIFT TRUCK--------------1-5, 3-2
GENERAL VIEW OF THE OPERATION EQUIPMENT ----3-3
BASIC LIFT OPERATION------------------------------------ 3-33
GREASES AND FUEL ---------------------------------------- 4-16
BASIC OPERATION------------------------------------------- 3-25
BASIC PRECAUTIONS--------------------------------- 2-9, 4-16
BE CAREFUL OF HIGH PRESSURE OIL --------------- 2-32 <H>
BEWARE OF ROTATING COOLING FAN -------------- 2-32 HANDLING OF BATTERIES--------------------------------- 4-25
HOISTING AND TRANSPORTING THE LIFT TRUCK --- 2-36
<C> HOISTING THE LIFT TRUCK ------------------------------- 4-57
HOW TO OPERATE CONTROL LEVERS --------------- 3-33
CAUTION AFTER INSPECTION AND REPAIR-------- 2-35
HOW TO OPERATE METER PANEL --------------------- 3-12
CAUTION IN WASTE DISPOSAL-------------------------- 2-34
HOW TO READ METER PANEL -----------------------------3-4
CAUTION ON STORING THE BATTERY --------------- 2-34
CAUTION ON WATER DROPLET------------------------- 2-14
CAUTION WHEN HANDLING BATTERY---------------- 2-33 <I>
CAUTION WHEN HOISTING THE LIFT TRUCK ------ 2-36 IF A FIRE BREAKS OUT ------------------------------------- 2-13
CAUTIONS BEFORE INSPECTION INCHING TRAVEL --------------------------------------------- 3-30
AND MAINTENANCE ------------------------------------- 2-30 INSPECTION AND MAINTENANCE ------------------------4-2
CAUTIONS FOR SAFETY-RELATED EQUIPMENT ----- 2-11 INSPECTION AND MAINTENANCE
CAUTIONS FOR USING COMPRESSED AIR SCHEDULE CHART --------------------------------------- 4-59
FOR CLEANING-------------------------------------------- 2-32 INSPECTION CONDUCTED BY DRAWING OUT
CAUTIONS WHEN WORKING UNDER WORK THE BATTERY ------------------------------------------------4-6
EQUIPMENT ------------------------------------------------ 2-31 INTRODUCTION--------------------------------------------------1-2
CENTER OF GRAVITY OF A LOAD ---------------------- 2-37 INTRODUCTION OF OPTIONAL SAFETY DEVICE -- 2-41
CHARGING ------------------------------------------------------ 4-29
CHECKING ABNORMALITIES DETECTED
ON THE PREVIOUS DAY---------------------------------- 4-4
<J>
CHECKING AFTER OPERATION ------------------------- 3-36 JACKING-UP ---------------------------------------------------- 4-20
CHECKING AND REPORTING AFTER OPERATION --- 4-15 JUMPING ON AND OFF FROM THE LIFT TRUCK IS
CHECKING BY SETTING THE STARTING SWITCH STRICTLY PROHIBITED --------------------------------- 2-11
TO [ | ] (ON) POSITION----------------------------------- 4-10
CHECKING FROM OPERATOR COMPARTMENT----- 4-8 <K>
CHECKING OF SAFETY FUNCTION--------------------- 4-13 KEEP THE OPERATOR'S COMPARTMENT AND
CHECKING WHILE RUNNING THE LIFT TRUCK ---- 4-11 PLATFORM CLEAN AND TIDY------------------------- 2-11
COMBINED CENTER OF GRAVITY AND KEEP THE WORKING AREA CLEAN AND TIDY------ 2-29
STABILITY ON THE LOADED LIFT TRUCK-------- 2-38 KEEP UNAUTHORIZED PEOPLE OFF ------------------ 2-30
<D> <L>
DIRECTION OF THE LIFT TRUCK-------------------------- 1-5 LIFT INTERLOCK FUNCTION ------------------------------ 3-36
DO NOT MODIFY THE LIFT TRUCK --------------------- 2-14 LOAD HANDLING OPERATION---------------------------- 2-24
DO NOT REMOVE THE OVERHEAD GUARD LOADING AND UNLOADING OF THE LIFT TRUCK - 4-58
AND LOAD BACKREST ---------------------------------- 2-14 LONGITUDINAL STABILITY--------------------------------- 2-37
DRAWING OUT AND PULLING IN THE BATTERY -- 3-22 LONG-TERM STORAGE ------------------------------------- 4-56
DRIVING THIS FORKLIFT TRUCK LUBRICANT LIST ---------------------------------------------- 4-18
ON THE PUBLIC ROAD IS PROHIBITED ----------- 2-14
6-2
INDEX
<M> <S>
MAINTENANCE FOR THE NEW LIFT TRUCK-----------1-6 SAFETY ------------------------------------------------------------ 2-2
MEMORANDUM (TO BE FILLED BY KOMATSU SAFETY INDICATORS ----------------------------------------- 1-4
FORKLIFT DISTRIBUTOR) --------------------------------1-7 SAFETY LABEL -------------------------------------------- 2-2, 2-4
MODEL AND SERIAL NO. LOCATION ---------------------1-7 SAFETY LABEL LOCATION CHART----------------------- 2-2
MOUNTING/DISMOUNTING AND OPERATING SECURE SAFETY AT THE WORKING AREA ----------2-15
POSTURE ADJUSTMENT ------------------------------- 3-24 SERIAL NO. AND LOAD TABLE----------------------------2-40
SERVICE DATA -------------------------------------------------4-65
SIGNAL WORDS------------------------------------------------- 1-3
<N>
SIMPLE MAINTENANCE -------------------------------------4-16
NECESSARY INFORMATION OF THE LIFT TRUCK --1-7
STARTING--------------------------------------------------------3-25
NEVER OPERATE THE BROKEN-DOWN
START-UP INSPECTION----------------------- 2-16, 3-24, 4-2
LIFT TRUCK ------------------------------------------------- 2-10
STOPPING -------------------------------------------------------3-27
STOPPING AND PARKING ----------------------------------2-22
<O> STRUCTURE AND STABILITY OF THE LIFT TRUCK ---2-37
OPERATING DEVICES --------------------------------------- 3-15
OPERATING THE LIFT TRUCKS IN SPECIAL <T>
ENVIRONMENT OR IN FORCIBLE WAY------------ 4-51
TECHNICAL DATA ---------------------------------------------- 5-2
OPERATION ----------------------------------------------- 3-2, 3-24
TEMPORARY STOPPING AND PARKING --------------3-28
OPERATION ACCORDING TO THE
THE LIFT TRUCKS WITH COLD-STORAGE MODEL ---3-37
CIRCUMSTANCE ------------------------------------------ 3-29
TO AVOID BURN INJURY------------------------------------2-12
OPERATION OF ON-BOARD TYPE
TOWING-----------------------------------------------------------2-23
BATTERY CHARGER (OPTION)----------------------- 4-31
TRAVEL INTERLOCK FUNCTION -------------------------3-32
OPERATION OF STATIONARY
TRAVELING ------------------------------------------------------3-26
BATTERY CHARGER (OPTION)----------------------- 4-37
TRAVELING ON SLOPES------------------------------------3-29
OPERATION ON SNOWY AND FROZEN ROADS --- 3-31
TRAVELING THE LIFT TRUCK -----------------------------2-17
TURNING ---------------------------------------------------------3-26
<P>
PERIODIC INSPECTION OF <U>
SAFETY CRITICAL PARTS------------------------------ 2-35
USE OF GENUINE KOMATSU FORKLIFT PARTS
PERIODIC REPLACEMENT OF
AND OILS ------------------------------------------------------ 1-6
SAFETY CRITICAL PARTS------------------------------ 4-64
USE OF RIGHT TOOLS AND EQUIPMENT-------------2-30
PERIODICAL REPLACEMENT PARTS --------------------1-6
PLUGGING------------------------------------------------------- 3-27
PLUGGING (ELECTRIC BRAKE) -------------------------- 3-31 <W>
PRACTICE SUFFICIENTLY BEFORE OPERATION ----- 2-11 WALK AROUND THE LIFT TRUCK------------------------- 4-4
PRECAUTION WHEN WASHING THE LIFT TRUCK ---- 2-12 WARRANTY AND SERVICE---------------------------------- 1-6
PRECAUTIONS FOR INSPECTION AND WASHING THE LIFT TRUCK--------------------------------4-55
MAINTENANCE SAFETY -------------------------------- 2-29 WEAR ADEQUATE CLOTHES AND SAFETY
PRECAUTIONS FOR LOADING AND EQUIPMENT FOR OPERATION -----------------------2-10
UNLOADING THE LIFT TRUCK------------------------ 2-36 WHILE TRAVELING THE LIFT TRUCK-------------------2-18
PREPARATION BEFORE TRAVELING
THE LIFT TRUCK ------------------------------------------ 2-17
PROCEDURE FOR PICKING UP AND STACKING--- 3-35
PROCEDURES FOR ALARM CODE OR
ERROR CODE INDICATION ---------------------------- 4-53
PUT UP A WARNING SIGN DURING INSPECTION
AND MAINTENANCE-------------------------------------- 2-29
<Q>
QUALIFICATION FOR OPERATION ------------------------1-6
<R>
REMOVING THE BATTERY PLUG------------------------ 2-33
REPLACING BULBS------------------------------------------- 4-24
REPLACING FUSE -------------------------------------------- 4-21
REPLACING OF BATTERY-------------------------- 4-40, 4-44
RUNNING IN COLD WEATHER---------------------------- 4-51
RUNNING IN NEW LIFT TRUCK-----------------------------1-6
RUNNING IN THE NEW LIFT TRUCK ----------------------1-6
6-3
FB10R/18R-14 FORKLIFT TRUCK
Form No. ARA14E1-04
Komatsu Utility Co., Ltd. FORKLIFT COMPANY

2-4-1 Shiba-koen, Minato-ku, Tokyo 105-0011, Japan

FB10RL (F) /13RL (F) /15RL (F) /18RL (F) - FB10RW/13RW/15RW-: Electric Reach Truck

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ARA14E1-04

ELECTRIC REACH TRUCK

• Read this manual carefully and understand it fully.

1.2 FOR YOUR SAFETY 1

1.2.1 SIGNAL WORDS 1

Example of safety message using signal word

Other signal words

REMARK - - - - - - Useful information.

1.2.2 SAFETY INDICATORS 1

EXAMPLE OF VERBAL SAFETY INDICATOR

EXAMPLE OF PICTORIAL SAFETY INDICATOR

1.3 APPLICABLE MODEL AND SERIAL No. 1

Model type Serial No.

RL: Center drive type (L type)

1.4 GENERAL VIEW OF THE LIFT TRUCK 1

1.4.2 DIRECTION OF THE LIFT TRUCK 1

1.5 UNITS OF MEASURE 1

1.6 QUALIFICATION FOR OPERATION 1

1.7 RUNNING IN THE NEW LIFT TRUCK 1

1.7.2 MAINTENANCE FOR THE NEW LIFT TRUCK 1

1.8 WARRANTY AND SERVICE 1

1.8.2 USE OF GENUINE KOMATSU FORKLIFT PARTS AND OILS 1

1.9 NECESSARY INFORMATION OF THE LIFT TRUCK 1

1.9.1 MEMORANDUM (To be filled by Komatsu Forklift distributor) 1

1.9.2 MODEL AND SERIAL NO. LOCATION 1

LIFT TRUCK EMBOSSED SERIAL NO. LOCATION

2.6.7 CAUTIONS WHEN WORKING UNDER WORK EQUIPMENT------------------------------------------2-31

4.2.2 WALK AROUND THE LIFT TRUCK ----------------------------------------------------------------------------- 4-4

2.1.1 SAFETY LABEL LOCATION CHART 2

No. Safety labels name Position

1 Caution before operation. Left side of operator' s compartment.

Do not go under the lifted forks.

5 Caution when handling battery. Rightside of battery case front.

Caution on drawing out and pulling in the

Inner right side of frame. <L type only>

9 Do not touch the exposed terminals. Inner side of inspection door.

10 Precaution when washing lift truck. Left side of operator's compartment.

11 Caution on hoisting the forklift truck. In front of operator's compartment.

13 Caution to avoid getting caught. Right upper side of fan duct.

2.1.2 SAFETY LABEL 2

2. Do not of operate lift truck from out side.

3. Do not enter between mast and chassis. (3LA-96-13260)

4. Do not go under the lifted forks.

5. Caution when handling battery (3BB-96-36840)

6. Caution to avoid getting hand caught (3EB-96-25121)

7. Caution on drawing out and pulling in the battery

8. Caution on threading the battery cable

9. Do not touch the exposed terminal (3LA-96-13220)

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

11. Caution when hoisting the lift truck (3LA-96-34460)

12. Emergency power cut-off button (3BA-96-72620)

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

2.2 BASIC PRECAUTIONS 2

• Plan safety work beforehand.

• During operation, safety must be your primary responsibility

2.2.2 NEVER OPERATE THE BROKEN-DOWN LIFT TRUCK 2

2.2.3 WEAR ADEQUATE CLOTHES AND SAFETY EQUIPMENT FOR OPERATION 2