MWU VIWILUGSGY LIDLOINUA suse SVN 0m073 OPERATION & MAINTENANCE MANUAL AX and BX FORKLIFT TRUCKS Federal Environmental Agency (EPA) Emission Control-Compliant AX S/N 670001A~ BX S/N 580001A~ AX-Gasoline &LPG FG15/18(S)(H)-17 BX - Gasoline & LPG FG20/25/30(S)(H)-14 BX - Diesel FD20/25/30-14 Siw Prosaune (front and war) = (00 py AX WARNING Read and observe all wamings on this unit before operating it. DO NOT operate this equipment unless all fac- tory-installed guards and shields are properly secured in place, KOMATSU ISSUED: FEBRUARY 2004 Komatsu Forklift USA, Inc.Dies soden id Ne a Re Pheeh st k eh BERTIE Oe rw ElsemsKomatsu Forklift U.S.A., Inc DataKom Publishing Corporation fe MAAN U Attn: Technical Publications: 14481 Lochridge Bivd., Bldg 2 Covington, Georgia 30014 PROPOSAL FOR MANUAL MSA REVISIONS/CORRECTIONS [Date L lindividual’s Name \Company Name [Department (Street Address (City, State & ZIP Noice Phone Fax Phone [Book description [Truck model & SIN (Problem location and description. Altach supporting photo, sketch or other material as necessary. [Book or Tech Bulletin No, ‘Section No. and/or Name [Page No Item No. (iFparts book) nem Description (fin parts book) ‘Corrective Action and Date Fax this completed form to: 770-385-4838 TPC_KFI_021202oOm073 OPERATION & MAINTENANCE MANUAL AX and BX FORKLIFT TRUCKS Federal Environmental Protection Agency (EPA) Emission-Control Compliant AX SIN 670001A~ BX S/N 580001A~ AX - Gasoline & LPG FG15/18(S)(H)-17 BX - Gasoline & LPG FG20/25/30(S)(H)-14 BX - Diesel FD20/25/30-14 AX BX A WARNING Read and observe all warnings on this unit before operating it. DO NOT operate this equipment uniess all fac- tory-installed guards and shields are properly secured in place. KOMATSU ISSUED: FEBRUARY 2004 Komatsu Forklift USA, Inc.The information and specifications contained herein were accurate at the time of publica~ tion, but may change without notice as required for product improvements. Neither Komatsu Forklift USA, Inc., nor its parent company nor any of its subsidiaries will be held responsible for damages due to misuse or inappropriate use of its products. Requests for information, comments and other inquiries should be sent to: Komatsu Forklift USA, Inc, 14481 Lochridge Blvd., Bldg. #2 Covington, Georgia 30014-4908 Voice phone: (770) 385-4815 Fax phone: (770) 385-4838 © Copyright 2004, Komatsu Forklift USA, Inc. All rights reserved. No part of this docu- ment may be photocopied or reproduced in any way without prior written consent of Komatsu Forklift USA, Inc.FORKLIFT IDENTIFICATION The ‘Name Plate / Data Piate” is located on the top of the lift truck hood to the right of the operator's seat. The lift truck model can be determined by viewing the information on this name plate. AX and BX lit truck model designations are dispayed as shown in the following table. Komatsu Current Production Model Coding System Internal Combustion Engine Trucks Class IV (cushion tire) and Class V (pneumatic tire) Example: F G 20 SHTLS -14 Positions: 123 4 5 6 4 2 3 ] 4 5 6 type ot | Type ot Load ignations UL Rating Model Vehicle | Motive | Capacity Change Power | (Model: ibs) __ Number Fe | G=Gasor | 15 3,000 | S = Cushion ure type LS=LPG += Orginal | Forklift | LP engine Special (Anti- | model built | tuck 18 3,500 | tstH¥= High performance | Sperk) D=Desel 2,3,etc, = engine 20. 4,000 | T= Torafow-type power- | US= Gas.or | Changes in shit trans witorque con- | Diesel Spe- | models 25 5,000 | verter cial (Anti | Spark) | trans wicry, single-cisc pers Cr OMO73 = AX/BX Op & MaintFORKLIFT IDENTIFICATION This Page Intentionally Left Blank M073 — AXIBX Op & Maint0. CONTENTS CONTENTS ©. Contents 1. Foreword .. 2. Safety Information... o- 3. Running in New Lift Truck.. oO 3.1 Running in New Lift Truck... ii 0. 0 0. 3.2. First Month Service (or initial 200 hours service) for new lift truck 3.3 Model Line Up. 4, Warranty and Service for New Lift Truch 4.1 Komatsu Forklift Genuine Pats ...sccccsnsniiniinnieinnninanniinmnniennneeO® 10 5. Location of Plates. 5.1 Lift Truck Serial Number SAFETY 6. Safety Management. 7. Safo Travel.. 8. Loading Operations. Cc sa sates soc tAB 9. Stopping and Parking.. 4-22 10. Inspection and Maintenanc 1-24 4-32 14. Structure and Stability of the Lift Truck... (To prevent lit truck from tipping) 12. Safety Label Sticking Positions OPERATION (Gasoline/LPGiDiesel engine trucks) 13, Overviow of Lift Truck .. 2.2 13.1 General View of Lift Truck. 22 13.2 Instruments and Controls.. 23 13.3 Federal EPA Emission Control Statement for Off-Road LSI (Non-Diesel) Engines (K21 and K25 Engines)... 2 13.4 Federal EPA Emission Control Statoent for Off-Road Diese! Engines (4D94E Engines) 2- 14, Explanation of Components... 16. Operation ...... i eee sinter AT 15,1 Check Before Operation... me i 224 15.2 Mounting/Dismounting 2.32 Continued on Next Page OMOT3 — AX/BX Op & Maint 21704 0-10. CONTENTS 16. 7. 18. Operation (Continued) 15.3 Operator's Seat Position Adjustment 2.32 45.4 Placing Lift Truck in Motion meena ie rennin nnn nee BD 16.5 Starting and Inching On Slope sav .inss FRNA TATIONS 2.37 15.6 Turning 2.38 15.7 Temporary Stopping and Parking. orasratthtsceransarseesnent nn 88 15.8 Fork Spread AdJUSIMENE sense 2-40 15.8 Load Handling Operation 5 sn BA 16.10. Check After Operation .. ee i sn 25 Cold Weather Operation... 2-46 16.1 Preparations for Low Temperature. se SLURRED 2.46 4162 Precautions After Completion of Operations 2-46 Handling in Heavy-Duty Conditions....... a 2887 17.1 Precautions When Using in Heavy Duty Conditions... ..nsunnmunnuinnien 2-48 17.2. Cleaning Inside of Cooling System... eceeaeasesaenteei 2.48 17.3. Clean Radiator Fins i 2-48 17.4 Check Fan Belt Tension «0.0.0 zs meanness EMS, 17.5 Action When Engine has Overheated 0.00 2.48 Long-Term Storage 18.1 Before Storage 2-50 18.2 During StorBg€ nse nss sean st SS 2-60 18.3 After SOFAGE oe nen 251 MAINTENANCE (Gasoline/LPG/Diesel engine trucks) 19. 24. 22, 23, 24, 0-2 Outline of Service 19.1 Suitable Oil Lubricant List. 34 20.1. AX - Gasoline/LPG Engine Lift Truck 34 20.2 BX - GasolinelLPG Engine Lift TUCK ...ocusnennnunnnaraneninnnnain 3-6 20.3 BX - Diesel Engine Lift Truck 36 204 Ol and Greasing Chart (il, Grease Locations and Inspection and Maintenance Intervals) 37 Service Data... r 21.1. AX- Service Data - All Modals. 38 21.2 BX - Service Data (Gasoline/l. PG Engine Lift Tuck) .....1s0.s 3-10 21.3 BX - Service Data (Diesel Engine Lift Truck)... bouninunniinn nana 3-12 21.4 Torque List 314 Periodic Replacement of Safety Critical Parts... ccccnnemnennnnnnnnnnnnennnenesnnens SS Maintenance Schedule Chart... Maintenance (All Models). ss . one B20 24.1 First Month or Initial 200 Hours Service. 3-20 24.2 Check Betore Operation .....- nite soe 2S 24.3. Every 2 Weeks of Every 100 Hours Service 3-25 Continued on Next Page o2i704 M073 = AXIBX Op & Maint0, CONTENTS 24, Maintenance (All Models)(Continued) 24.4 Every Month of Evety 200 Hours Service. sunnmnnunnnnnninn inne $25 24.5 Every 500 Hours Service 3:32 24.6 Every 3 Months or Every 600 Hours Service... 3-32 24.7 Every 1,000 Hours Service (EPA and Diesel Engines)... - os 34 24.8 Every 6 Months or Every 1,200 Hours Service 3:34 24.9 Every 2,000 Hours Service... — 3:37 24.10 Every Year of Every 2,400 HOutS SEMICE oes nnnnninnnnnnninnnnennennn 387 24,11. Every 18 Months or Every 3,600 Hours Service 3:38 26, Replacement Procedure: 25.1 Replacing Fuses and RelaYS ...c..1nssnmnnnn 25.2 Replacing Tires...... ssn sn 25.3 Replacing Lamps TECHNICAL DATA 26, Technical Data.. 2 AX Lift Trucks (gasoline/LPG engines) oso ..nnnnnn : ee a2 BX Lif Trucks (diesel engines) - 45 BX Lift Trucks (gasoline/LPG engines) ssi. isnrn nn 46 OMO73 — AXIBX Op & Maint - 021704 03THIS PAGE INTENTIONALLY LEFT BLANK This Page Intentionally Left Blank 0-4 ‘ort4o4 ‘0M073 = AX/BX Op & MaintFOREWORD WARNING READ AND FOLLOW ALL SAFETY PRECAU- TIONS. FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR DEATH. 051, FOREWORD This manual provides rules and guidelines which vail help you use this Wit truck safely and effectively. Always be sure to read and understand this manual thoroughly before operating and performing maintenance. ‘Some actions Involved in operation and maintenance of the lit truck can cause a serious accident if they are not done in the manner described in this manual fy WARNING © Improper operation and maintenance of this lift truck can be hazardous and could result in serious. injury or death © Operators and maintenance personnel should tion or maintenance. Keep this manual handy and have all personnel read it periodically. Do not use this lift truck unless you are sure that you understand the contents completely. I this manual has been lost, or has become dirty or worn and cannot be read, request a replacement manual from your Komatsu Forklift distributor/dealer, © Komatsu Forkiift delivers lit trucks that comply with (to the best of our knowledge at the time of deliv- ery) all applicable regulations and standards of the country to which they have been shipped. If this Wife ruck has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. f there is any question about whether your product complies with the applicable standards and regulations of your country, consult your Komatsu Forklift distributor/dealer before operating the lft truck. ¢ Continuing improvements in the design of this lift truck may not be reflected In this manual. Consult Komatsu Forklift or your Komatsu Forklift distributoridealer for the latest available information on ‘your lift truck or for questions regarding information in this manual, © Information on safety is given in the SAFETY, OPERATION and MAINTENANCE sections throughout this manual; please read it carefully and completely. .d this manual thoroughly before beginning oper 06 ‘o1t40a OMO073 — AX/BX Op & Maint2. SAFETY INFORMATION Most accidents trucks, To avoid accidents, read, understand and follow all precautions and warnings inthis manual and on the tit tuck before operating and performing maintenance Do not operate or cary out meintenance ofthis ft tuck unless you are sure that you understand the explanations and procedures completely To wentity safety messages in this manual and on li truck labels, the folowing signal words are used caused by a failure to follow fundamental safety rules for the operation and maintenance of ift These safety messages of labels describe precautions that must be taken to avoid a hazard which carn 7 Y A DANGER fh carries a serious risk of serious injury or death, ‘These safely messages or labels usually describe precautions that must be taken A WARNING, | !2°¥24 a hazard which may lead to serious injury or death. ‘This word is used on safely messages and safety labels for hazards which could BA CAUTION | titeioy sr oamage ote mises or sarounang propery Wine nazar = rot evoided NOTICE ‘This word is used for precautions that may not lead to damage or failure, but which, must be taken to avoid actions that could shorten the life of the lit ruck Safety precautions are described in the SAFETY, OPERATION and MAINTENANCE sections of this manual Komatsu Forklift cannot predict every circumstance that might involve a potential hazard in operation and mainte- ance. Therefore, the safety messages in this manual and on the lif truck may not include all possible safety pre- cautions. If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsi- billy o be sure that you and others can 6o such procedures an actions safely and wthout damaging the It truck If you are unsure about the safety of some procedures, contact your Komatsu Forklift distributor/dealer. ‘The procedures and precautions given in this manual apply only to intended uses ofthe lit truck. If you use your lif truck for any unintended use that is not specifically prohibited, you must be sure that it's safe for you and others, Inno event should you or others engage in prohibited uses or actions as described in this manual OM073 — AX/BX Op & Maint 011404 0-73. RUNNING IN A NEW LIFT TRUCK 3.1 RUNNING IN A NEW LIFT TRUCK Your Komatsu Forklift ruck has been thoroughly adjusted and tested before shipment However, operating the lif truck under severe conditions a! the beginning can adversely affect performance and shorten the lif truck life. Be sure to take special care conceming the following items during this intial period of operation. © Avoid operation with heavy loads or at high speeds, © Avoid sudden starting or acceleration, unnecessarily abrupt braking and sharp turning, except in the case of ‘emergency 3.2 FIRST MONTH OF SERVICE (OR INITIAL 200 HOURS OF SERVICE) FOR NEW LIFT TRUCK For new lt ruck, carry out the following maintenance only after the first month or 200 hours. Unit "Cheek items | ~Romarks ‘Change cilin engine oil pan piace otf Page 321 ‘Check & adjust engine vaive cleerance Tighten (retorque) engine eylinder head bolts Engne Check spark plugs for burning of elec: - trode, burning of insulator Eee Check & clean air fter element Page 3-28 Checkigntiontimng {Check & adjust alternator belt (drive : belt tension Eee ‘Change transmission fic ToRarLoWw ranks ransmission Geansidrer Diflerential ‘Change oil Page 324 Replace ine riter Hyeraule tank Page 3-20 Clean straner Clean inside tank Particularly lug (hub) nuts, overhead quart Misc. bois & nuts Tiobten ‘mounting bots, backrest mounting batts, and peratar's seat mounting bolts Refer to “Check Before Operation’ —_| Page 2.21 0-8 021704 (OMO073 — AX/BX Op & Maint3. RUNNING IN A NEW LIFT TRUCK 3.3. MODEL LINE UP APPLICABLE “EPA” LIFT TRUCK MODELS ‘Model Description [AX (K21 Gasoline Engine) ——— SS FGISHC-17 3,000 1b apaciy, Clutch Spec: Phaumnatic Tie FGI6HT-T7 [8.0001b capaci, Toralow Spec, Pheumatc Tre FGISHTLST7 '5,00015 capaciy, Torqlow Spec. LP Special, Pheuratic Tire FGISST.i7 5.00015 capacity, Tarafow Spec, Cushion Tie [Forsstis-i7 ;D00 Tb. capacity, Torafow Spec, LP Speci, Cushion Tre : FGieHT-i7 5,50015 capaciy, Terqfow Spec, Paaumai Tre FOTOHTLS-17 T.5001b capaciy, Torafow Spec, UP Specal Preumatic Tre FGTEST.AT ‘,50DTB- capaci, Toraaw Spec, Cushion Tie FOieST.S TT '3,5001b capaci. Torafow Spec, LP Speci. Cashion Tre BX(K2i and K26Gasolinc Engines) = sitsi‘“‘“~*~‘“‘*~‘s‘“‘~;*;*;*™ [ Fe206-14 0001. capacity, KET Engine, Chich Spee Pheumabe Tre Faz0T-4 2.00015 capaciy, K2T Engine, Torion Spec, Pneumatic Tre FO20TUS-14 400016. capaciy, K2T Enaine, Toralow Spec, Gasoline Special, Preanalic Tre [Fo2ortsa 39001 capacity, K2T Engh, Terglow Spec. UP Special, Phounate Tre GzOST-4 700015 capac K2T Engine, Toraiow Spec, Cushion Tre | Fo20sTus-14 4.0001, capociy, K21 Engine, Torallow Spec, Gasoline Speci Cushion Tre | FGDOSTLS-T4 ‘00 b-capaciy, K2T Engin, Torqiow Spec. LP Special Custvon Tire FOROHT 14 000 lb, capeciy,K2E Enaine. Toralow Spec. PreumalicTie [FouOHTUS-14 .000 ib, capaciy, K25 Engi, Tordlow Spee. LP Specal Pheumave TS | Fe20sHT-i4 4.000 Ib. capaciy, K25 Engine Torjtow Spec. Cushion Tire [FG26C-14 | 6,000 b. capaci, K2T Engine, Chtch Sooo, Pneumate Tre FOI6T-14 5.0001 capaciy, K2T Engine, Toralow Spec, Pneumenic Tre FORBTUB-T4 ,0001b,capeciy,K21 Engine, Tordlow Spec, Gasoline Special, Pheumae Tre FGDBTUS-14 0001, eapaciy, K21 Engine, Tergtow Spec, UP Special, Phaumate Tre | Feasst-14 5.0001. capacity, K2T Engine, Torttow Spec, Cushion Tie [Fores TUS-T7 5,0001b. capacity K2i Engr, Terqlow Spec, Gasoline Specs, Cushion TS FSDESTLS TA ‘5.00018 capacity K2 Engr, Trgfow Spec, [P Spec, Custvon Tire FORT 4 5,000 1b, eapaciy, K25 Engr, Teralow Spec, Pneumatic Tre - FODEHTUS.Ta 5.00015 capaaiy K25 Enpie, Tenftow Spec, Gasoine Specal, Preumave | FGRsHTLS-14 | 6,000, capacity, K25 Engie, Teratow Spec, LP Specel Pheumatc Tre SH [ Foa0c-14 —~/ 6,000'b. capacity, KOT FGa0HT- 14 ,0001b capacity K25 Engne, Terqfow Spec, Preurvale We FOSOHTUS-14 6.00016. capocity, K25 Enane, Toralow Spec, Gasoline Special Preumaté Tre FORORTLS-14 [5.000 capacity K25 Engne, Terafow Spec, LP Special, Preumtc Tre FOROSHT-1a 8,000 capacity, K25 Engre, Torafow Spec, Cushion Tre | FGS0SHTLS-14 | 6,000 1b. capacity K25 Engine, Torqfow Spec, LP Special, Cushion Tre Engine) 40001, capacity, Diesel, Torafiow Spec, Preumaic Tre 10015. capacity Diesel, Torgfow Spec, Preumat 6,000, capacity Ciesel Special, Torqfow Spec. Preumalic Twe 16.000 1b, capacity Diesel, Torafiow Spec, Preumatc Tire ‘OMO73 — AX/BX Op & Maint 022004 o94. WARRANTY AND SERVICE FOR NEW LIFT TRUCK 4.1 KOMATSU FORKLIFT GENUINE PARTS Komatsu Forklift genuine parts are manufactured from the same materials. and by the same methods, es the perts builtin the new lit truck. In the event that the customer uses imitation parts, Komatsu Forklift will not be held accountable for any faults which result from the use of such imitation parts, and Komatsu Forklift war- ranty will not be applicable. Always use genuine Komatsu Forklift parts when replacing parts. 0-40 011404 ‘OM073 ~ AX/BX Op & MaintGasoline engine (AX, BX) 5. LOCATION OF PLATES LIFT TRUCK SERIAL NO. PLATE POSITION Nameplate location: “The nameplate is installed on the top of the hood on the fight side of the operator's seat ‘The serial number is lacated on the nameplate Embossed serial number location: ‘The embossed serial number is stamped on top of the front fender on the if side ofthe it truck In addition, the UL icense is installed tothe let of the front side of the dashboard ‘The engine serial number is stamped in the position shown below (Lett) ond (Right) in the diagram are as fotows (Let) Laf side of engine (Right: Right sido of engine. Nameplate — / serial number Acii7a8a 21IK25 ENGINE SERIAL NO. STAMP NoTice Contacting Komatsu Forkl When contacting a Komatsu Forklift distributor/dealer for parts ordering or problem consultation, always Give the lift ruck serial number embossed on the lift truck ‘Take care not to damage of remove the embo: od serial number. OM073 — AX/BX Op & Maint 11404 0-115, LOCATION OF PLATES THIS PAGE INTENTIONALLY LEFT BLANK | 12, ora04 ~ OMO73 = AX/BX Op & Maint 2SAFETY A WARNING READ AND FOLLOW ALL SAFETY PRECAU- TIONS. FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR DEATH. A6. SAFETY MANAGEMENT 6. SAFETY MANAGEMENT AA WARNING | OPERATION MANUAL AND SAFETY LABELS + Read the instructions in this Manual and the Safely Labels attached to the various parts of the lit truck, and make sure that you understand and follow them. if you do not understand or do not fol- low the instructions, this will lead to improper operation which may lead fo damage, personal injury or death + Be sure that you understand the proper method of using the lif truck and the procedure for carry: lng out an inspection, and ensure that they are carried out safely. + Read this Manual and the Safety Labels again from time to time. Ifthe Operation and Maintenance Manual or Safely Labels have been fost or become dirty and cannot be read, obtain replacements from your Komatsu Forklift distributor/dealer and attach the Safety Labels in the specified posi tions A WARNING | OPERATING QUALIFICATIONS + This lift truck should be operated only by qualified personnel. Be sure you have proper qualifica- tions before operating the lit truck + When operating this lit truck, even if you have experience in operating other lit trucks, obtain instructions from an authorized person who has experience in operating this lift truck or the same type of lift ruck. “BA WARNING | CLOTHING AND PERSONAL PROTECTIVE ITEMS ‘Avoid loose clothing, jewelry, and loose long hair. They = ‘can catch on conirols or in moving parts and cause . J serious injury or death, + Always wear a hard hat and safety boots. + Depending on the working conditions, wear other safety ‘equipment as well AA WARNING | OVERHEAD GUARD, LOAD BACKREST + Do not use this lift truck unless it is equipped with the overhead guard and load backrest shipped withthe lift truck from the factory by Komatsu Forklift 12 otto ‘ONO73 = AX/BX Op & Maint6. SAFETY MANAGEMENT AA WARNING | UNAUTHORIZED MoDIFICATION + Any modification made without authorization from Komatsu Forklift can create hazards, + Before making any modification whatsoever, consult your Komatsu Forklift distnibutor/dealer, Komatsu Forkiit will not be responsible for any damage, injury or death caused by any unautho- rized modification + Do not install any equipment or parts which obstruct or limit the operator's view. A WARNING | EXHAUST GAS + Do not leave the engine running where there is poor ventilation, The engine exhaust gas contains carbon monoxide. There is & danger that this will cause gas poisoning which may result in Serious injury or death A WARNING | FIRE EXTINGUISHER AND FIRST AID KIT + Ifany abnormally in the lift truck occurs, stop operation immediately, park the it tuck in a sate place and safe conditon, then contact the person in charge. + Be sure thet fre extinguishers have been provided and that you read the labels to ensure that you know how to use them + Kiow what todo inthe event ofa fre + Be sure that you know the phone numbers of persons you should contact in case of an emer- gency. + Provide first aid kita the storage point. + Dornot use the lit trick i tis leaking fuel. Infor the person on charge of the nature of the abnor mally, and repair the leakage before using the lit truck. + Do not leave the tft ruck withthe engine running Always apply the parking brake securely, lower the forks to the ground, stop the engine, and remove the key before leaving the If ruck ‘ari404 13 OMmo73 =6. SAFETY MANAGEMENT A WARNING | SAFETY RULES = Do not operate the lift truck if you are fatigued, or when you have been drinking, or you have taken any medication which can make you drowsy or sleepy. = When carrying out operation, inspection, or maintenance of the lift truck, always follow all work shop tules, safety regulations and precautions + During operation, always pay attention to safety and be careful of pedestrians, traffic and other surrounding conditions. “AA WARNING | CHECK WHEN TRAVELING IN REVERSE + When reversing, depending on the situation, an optional alarm, reversing lamp or rotary lamp should be used. In all cases, be sure to face the rear and check around before traveling in reverse. AA WARNING | TRAVELING REGULATIONS ON PUBLIC ROADS + Do net travel on public roads unless you comply with local, state or other laws which regulate such activity. + Always observe all trafic regulations when operating the lft truck. + Donet drive on public roads with the lift truck loaded. + Do rnot tow other machines on public roads. (Do not tow other machines even when not on public roads), + Always carry your driver's license when traveling on public roads A WARNING | SAFETY EQUIPMENT + ‘The overhead guard is installed to protect the operator from falling objects. Its designed to with- stand the force of light boxes or small packages. itis not designed to withstand every possible impact. Always be careful fo prevent damage or injury trom falling objects, 2a WARNING | TIRE FENDERS + The tire fenders pravent objects from being thrown up by the tires. When changing from a single tire to a double tire arrangement on your forklft truck, always extend the tire fencers to cover the acitional tires. If the fenders are not extended, small stones and other objects will be thrown up ‘and may injure the operator or other people in the surrounding area connect 14 ‘OT404 OM073 — AX/BX Op & Maint6. SAFETY MANAGEMENT A WARNING | SAFE WORKING AREA ‘Always work on level surfaces and wipe up all oil or grease from the ground, When working on quays. platforms, docks or other places vere there is a danger of falling, set up blocks to prevent the lif truck from going over the edge. Put warning signs up in dangerous places to warn the operator not to approach ‘Mark the vavel areas clearly and maintain the road surfaces in good condition Put up signs to prevent unauthorized machines from entering areas where trucks are being operated Ensure that there is adequate lighting to enable operations to be carried out safely, A WARNING | CLEAN OPERATOR'S COMPARTMENT Keep the operator's compartment ean and tidy. Be sure to clean up all oll or mud, If the opera- tor's hand oF foot slips, this may lead to a serious accident. Do not leave tools or spare parts lying around in the operator's compartment. They may damage ‘or obstruct the control levers or pedals. Always keep them in the tool box when not being used, A WARNING | SAFE OPERATING PLAN Before operation, establish an operating plan and hold a meeting to discuss operating safety In confined areas, position a signal person and carry out operations in accordance with his/her instructions. ‘When carrying out operations on roads, put up fences around the working area and carry out oper- ations in accordance with instructions from the signal person. A WARNING | REDUCE LOAD FOR LIFT TRUCKS WITH ATTACHMENT The permissible load for any lift trucks equipped with an attachment is lower than the permissible load for the standard lift truck. Reason 1) The permissible load must be reduced by an amount equivalent to the weight of the attach- ‘ment itset. 2) Because of the thickness of the attachment, the load center moves forward. ‘Always observe the permissible load as stated on the capacity pate (also called “nameplate") strictly (this plate is stuck to the lif truck or the attachment), Never exceed the permissibie load AX WARNING | “NO JUMP START” SAFETY PLATE (DECAL) ‘new piate (decal) in the specified location after cleaning the surface, | + Donor sume staRr te engine by shor creutng he stating mator terminal, + This SAFETY PLATE (DECAL, is located onthe top carter of the state's magnet sch, + your machine s ol eauipped wih this SAFETY PLATE. insal a OM073 — AX/BX Op & Maint ‘O714046. SAFETY MANAGEMENT “A WARNING | FIRE PREVENTION FoR FUEL FUEL IS EXTREMELY FLAMMABLE AND CAN CAUSE FIRES AND EXPLOSIONS + Carry out refueling away from flames or sparks, + Stop the engine when refueling + After refueling, tighten the gas cap securely and wipe up any spilled fuel ‘The specific gravity of LPG is heavier than air, so itis easy for the vapors to accumulate in low places (holes, road surface depressions, efc.). This can create a fire or explosion hazard, Be extremely careful! “ ak OO A WARNING | NO STARTING AIDS Engine starting aids are highly flammable and may cause an explosion. Do not use starting aids to start the engine, A WARNING | LPG SAFETY / FUEL SYSTEM SAFETY Accidents involving fuel systems are always dangerous and can cause fire and explosion, serious injury, death and property damage, Keep the following points in mind when working vith fuel systems. + Read, understand and remember relevant information in the NATIONAL. FIRE PROTECTION AGENCY (NFPA) standard for fuel in use. Do this BEFORE working on any fue! system + Ensure you are wearing proper personal protective equipment + Check for fuel leaks before you begin work on any fuel system (On LPG systems, DO NOT work on the system if the fuel storage container is fi the 80% liquid level + Ensure there are NO SOURCES OF IGNITION nearby before baginning work + Be sure your work area is adequately ventilated. + Disconnect the battery before working on the fuel system, + LPG is heavier than air and will sink to the lowest area possible, Avoid areas near floor drains or lubrication pits where escaped fue! may collect. + LPG is stored under high pressure, Ensure the LPG fuel storage container valve is turned OFF (Closed), and pressure is released from the lines, before working on system, + Store all LPG cylinders OUTDOORS in a secured area and safe from any vehicle traffic + NEVER WELD ON AN LPG PRESSURE VESSEL, STORAGE TANK OR CYLINDER, + LPG fuel tanks mounted horizontally MUST BE positioned properly, See MAINTENANCE Section, + Always utlize a UL listed LPG tank 1d with fuel past 16 ort404 OMO073 — AX/BX Op & Maint7. SAFE TRAVEL 7. SAFE TRAVEL AX WARNING | PRECAUTIONS WHEN STARTING ENGINE + Before starting the engine, always check that the parking brake {is applied and that the directional and speed levers are in neutral Depress the clutch pedal (for clutch type trucks), or the brake pedal (for TORQFLOW transmission trucks), frmiy, and then start the engine, + Adjust the operator's seat and the steering wheel before starting the engine. Always lock them in position after adjusting. Adjusting the seat or steering wheel during operation is dangerous and it may cause you to lose your balance or to operate the lit truck improperly. + Before starting the engine, check that the surrounding area is safe, ALWAYS SIT IN THE OPERATOR'S SEAT ‘when siarting the engine. + Before starting the engine, sound the horn to warn people in the area + With large-sized lit trucks, get off the it truck and walk around it to check that no one is near the ‘engine compartment, tires or counterweight, then get on the lif truck, sit in the operator's seat, and start the engine, PRECAUTIONS WHEN OPERATING DIRECTIONAL OR A WARNING | CpEED LEVERS + When switching between FORWARD and REVERSE, alvays stop the lit truck. Its dangerous to change the direction of travel suddeniy or when the lit ruck is moving + When operating the directional lever or speed lever, always depress the clutch pedal before mov- ing the lever (for clutch type if trucks) Ifthe lever is moved without disengaging the clutch, the lit truck will move suddenly and may cause injury A WARNING | TIPPING + If the load-engaging means or load is raised, the center of gravity of the lift truck wil also rise and increase the danger of the lift truck tipping. Oo not turn the It truck when the forks are raised high, + Do not suddeniy raise the forks or tit the mast to the front or rear when the forks are loaded. There is danger that the Hi truck wal tip + Reduce speed before tuning the If truck. In particular, when traveling unloaded, the rear of the lift truck is heavy, ‘+ ifthe li truck is turned at high speed, there is a greater chance of tipping than with the forks loaded. + Always ensure that the hood is propery latched. OMO073 — AXIBX Op & Maint ‘it404 177. SAFE TRAVEL A WARNING | TRAVEL ON SLOPES Do net turn, or travel across or at an angle on slopes, There Is danger that the lift truck wil tip Before starting to drive up a slope, stop the lif ruck and adjust the clearance between the ground surface and the bottom of the forks 0 that the bottom of the forks or pallet do not contact the ground surface or the tip of the fork does not stick into the ground when traveling For safe travel on slopes When loaded: Travel FORWARO up the slope and in REVERSE down the siope with the load upgrade, When unloaded Travel in REVERSE up the slope and FORWARD dovn the slope with the load- engaging means downgrade. When traveling down slopes use the braking force of the engine together with the foot brake, and travel slowly down the, slope. AA WARNING | 9° NOT JUMP OFF LIFT TRUCK EVEN IF IT TIPS NEVER JUMP OFF the it ruck even iit seems that it wl tp, Aways do as follows: 18 Hold the steering wheel securely, Stay In the operator's seat Brace your legs. Hf you jump off the lift truck when it turns over, there is danger that you will be fatally crushed under the lift truck, ‘Always stay in the operator's compartment if the lift truck turns over, then escape from the lif truck after it has stopped. Always wear the seat belt correctly Site sent on 11404 OM073 — AX/BX Op & Maint7. SAFE TRAVEL AQ WARNING | ROAD SHOULDER + There is danger that soft road shoulders may collapse, 0 do not go nea ther wh te hf tuck “> + Always maintan a safe cstance from the edge of road shoulders and platforms by rT | fi A WARNING | LOADING HIGHWAY TRUCKS OR RAILROAD CARS. + Do not travel on the edge of docks. There is dangor that the lift truck may fall, which may result in serious injury or death. + Before starting operations, check the load limit for the gang: pplanks (dock boards), and do not use them if they do not have ample strength to take the weight of the lit truck when loaded, + Apply the brakes on the highway truck and block the wheels. + With trailers, use jacks and take steps fo prevent the trailer from sinking when the forklit truck travels on it ‘When driving the forklift inside trucks, reduce speed when amon backing out and be sure fo check that the gangplanks are sate, + Be careful of pedestrians. + Tell the truck driver not io move the truck until the operation is ‘completed. + I there is some system to secure the truck to the dock always use this system. Secure the gangplanks so that they do net slip and fal A WARNING | ESCAPING FROM A RAILROAD CROSSING + Ifengine trouble occurs on a railroad crossing and the lit tuck cannot move, you cannot use the starting motor to move the truck as can be done in automobiles. The lift ttuck’s neutral safety switch prevents this action. + Insuch an emergency, ight a flare or smoke candle, to warn approaching trains, vehicles and per- sons in the araa that there is a broken down truck on the tracks, + tis enticaly important to remove the lif truck from the tracks as soon as possible OM073 — AXIBX Op & Maint ir 187. SAFE TRAVEL A WARNING | NO RIDERS FORKLIFT TRUCKS ARE ONE-PERSON MACHINES Do not allow any other person to ride on the truck under any circumstances, Never allow anyone to act as an exira counterweight Aper7960 & WARNING | DRIVING IN REVERSE + When diving in REVERSE, turn to face the rear and check the area directly behind the lift truck. 15001200 OBSTRUCTION OF REAR VIEW A WARNING | (WHEN USING LP GAS FUEL + Th LP gas cylinder may partially block the view to the rear, 80 extra care is required to minimize the potential danger of hitting personnel, products or buildings in the sutrouncing area, Always turn to face the rear to check directly behind the lit truck when driving in reverse direction, Wf appropriate for your environment, you should consider installing backup warning devices (backup buzzer, rotating backup lamp, etc.) or backup confirmation devices (rear view mirror, etc.) to warn personnel in the surrounding area and to confirm that the area to the rear is safe, LP GAS CYLINDER AREA THAT CAN BE SEEN WHEN CYLINOER IS INSTALLED. AREA THAT CAN BE SEEN WHEN, CYLINDER IS NOTINSTALLED i Ranvier 4-40 012804 OMO73 — AX/BX Op & MaintA WARNING | WHEN FRONT VIEW IS POOR ‘+ Ifthe view to the front is obstructed by the load, turn to the rear and crive the forkift truck in reverse, + When driving in reverse with a high load use a signal person to ensure the safety of the load and the safety in the surrounding area. AA WARNING | CHECK BEFORE sTaRTING Start the lit truck until al the checks have been completed, A WARNING | ‘Aves A WARNING | MOUNTING AND DISMOUNTING + NEVER jump on or off the lift truck. + When getting on or off the Hit ruck, always stop the It tiuck and use the handrails and steps to ensure that you support yourself + Never hold any control levers or the steering wh getting on or off the lit truck, + If there is any ol, grease or mud on the handrails or steps, wipe it off immediately. Always keep these parts lean. Repair any damage. I when OMO073 = AX/BX Op & Maint ~ 011404 7. SAFE TRAVEL + When checking the lit truck before starting, follow the procedure given in this Manual, and do not + Manything abnormal is found, inform the person in charge and carry out the necessary repairs, + Check that the lamps light up correctly. Replace any broken or inoperaiive bulbs, A WARNING | KEEP HANDS FREE FROM OIL AND WATER + Donot drive the it truck if your hands are wet or covered with oi, Your hands vil slip on the work equipment control levers or directional lever, and this may cause a serious accident7. SAFE TRAVEL A WARNING | ALWAYS SIT IN OPERATOR'S SEAT + Never operate the lift truck from outside the operator's compart- ment + Always keep your body under the overhead guard + Do not extend your arms and legs outside the operator's com partment A WARNING | SEATBELT + Always wear your seat belt correctly when on the operator's seat ‘The seat bel will reduce the risk of injury. - ZL. a oo the seat belt immediately, + Always check the seat belt mounts anc check for any damage to : the seat belt itself. If any abnormality is found, repair or replace WARNING | SAFETY WHEN STARTING + Before starting and moving the tif truck, check that the surround- ing area is safe + Before moving the lif ruck, raise the forks (approx. 8 in, (20cm) from the ground surface), and tit the mast back + Before moving the lif truck, release the parking brake, A WARNING | BRAKING WHEN TRAVELING + Do not stop the engine when traveling. If the engine is stopped, the power steering (for lif trucks vith power steering) and power brake (For trucks with power brakes) will not work + Ifthe inching pedal is depressed, the braking effect of the engine will be lost + Donot use the brake excessively. Do not rest your foot on the brake pedal or inching pedal unless you are operating i you do. the brake will overheat and the braking effect wil be lost. For TORQFLOW it trucks, if you leave your foot on the inching pedal, the multiple disc clutch inside the transmission will overheat. In the worst case, the clutch discs will be deformed and the clutch will not function normaly 112 ~ OTTADA OMO73 = AX/BX Op & Maint7. SAFE TRAVEL ‘AA WARNING | S4FETY DURING TRAVEL Keep a clear view of the path of travel and observe for other traffic, personnel and safe clearances. Yield the right of nay to pedestrians, When passing oncoming vehicles, reduce speed and keep a safe distance from the other vehicle, In places where there are speed limits, observe the speed limit and maintain a safe distance from other vehicles, A WARNING | CONFIRMING SAFETY + When traveling, always pay careful attention to the area around your lit truck, particularly in the direction of travel or when turning + Do not pass other vehicles on narrow roads or at crossings or other places where the view is poor + When traveling through crossings or other places where the view is poor, or viten entering or leaving nartow roads, stop and sound the hom to confirm safely before driving on + Even if you sound the horn, not everyone in the surround- ing area will necessarily hear it, Always pay careful atten- tion to the movements of people in the surrounding area. + When crossing roads or turning corners, stop and confirm safety before continuing + Always pay careful attention to the movements of people in the surrounding area, and take steps to prevent people from entering the working area. A WARNING | SAFETY DURING TRAVEL + Avoid traveling in places which are flooded or where there are holes. + Do not try 10 drve the lit truck on soft ground + Avoid curbs, rails, ditches or other obstacles, and do not travel directly over them. + Do not travel on slippery roads or other slippery surfaces, + When entering buildings, check the weigh! limit of the floor and be careful not to exceed tne limit A WARNING | GIVE PRIORITY TO LOADED LIFT TRUCKS + When traveling on slopes or in confined areas, unloaded lift trucks should always give the right of way to loaded trucks M073 — AX/BX Op & Maint 11404 4B7. SAFE TRAVEL WARNING | HEIGHT OR WIDTH LimiTs ‘When going in or out of places with height or width limits: + Ensure that there is ample height and width forthe lift truck to pass, + Do not extend your hands or legs outside the lift tuck + Check that the surrounding area is sate + Be careful of electric wires and other obstacles inside and outside the building, (BA WARNING | PRECAUTIONS WHEN TURNING + When turning while traveling forward, the counterweight will ‘swing far out, Keep an ample clearance from walls and other objects fo ensure safety. + When turning, travel slowly and be careful that the front or rear wheels do not come off the ground. When turning on soft road shoulders, there is danger that the rear wheels may come off the road shoulder and cause the lit truck to tip ‘AA WARNING | STOPPING DISTANCE + When traveling downhill, it requires a longer distance for the lift truck to stop than when traveling (on level ground. + When traveling downhill, reduce the speed and make sure that you hi tom of the slope to stop, + When traveling on wet surfaces, tt requires a longer distance to stop than when traveling on nor mal road surfaces. Alvays have ample room to stop, fe ample room at the bot- A WARNING | NO TOWING If there is any problern with the brakes or steering system of your lift truck, do not use another lit truck totow i ‘There is danger that the lit truck may run away 44 ‘011404 ‘AX/BX Op & Maint8, LOADING OPERATIONS 8, LOADING OPERATIONS WARNING | NO OVERLOADING + Bo not load the lift truck over the capacity set forth in the load capacity chart, If the rear wheels come off the ground because of overloading, the lift truck cannot travel or tum, ‘There is also danger that it may tip. + Always check the load capacity chart fo confirm the foading capacty t Bx WARNING | ONT Go UNDER FoRKs Never alow anyone fo go under the loadeengaging means or load when ts ised The area under the forks fsa danger area. Ifthe forks — come down, the person under the forks may be crushed, or seriously injured or killed. + Never allow anyone to go under the load-engaging means or load ‘even if it is elevated, stuck or caught n the up-position, It may fall down suddenly al any moment, oO ‘aoerrara S&S A WARNING | 20 NOT LIFT PEOPLE ON FORKS + Do net use the forks to lit people. If the person fas from the forks he/she may be seriously injured. S M073 — AX/BX Op & Maint 11404 7188. LOADING OPERATIONS + Never put your hands or feet into the mast structure, There Is dan- ger that you will get caught in moving parts and be seriously injured. A WARNING | 58E CAREFUL NOT To GET CAUGHT OR FALL + Do not use the mast, load backrest or dashboard as a ladder or step. If you slip, there is danger that you wil fall A WARNING | NO UNSTABLE LOADS + Make sure that the center of gravity of the load is in tine with the center of the it truck. Do not carry loads off-center. There is danger that unbalanced loads may cause the lift truck 10 tip. + Place the load so that it contacts the load backrest. + Do not handle unstable loads. If there is danger that the load ‘may fall off, secure itn position and take steps to prevent the Joad from collapsing or faling, + When carrying stacked loads, tie with rope or otherwse ‘secure it to prevent the load from falling 1-16 O1i404 A WARNING | OPERATE FROM OPERATOR'S COMPARTMENT + Always operate the mast and forks from the operator's compartment, (0M073 — AX/BX Op & Maint8, LOADING OPERATIONS A WARNING | PO NOT LOAD ABOVE HEIGHT OF LOAD BACKREST + Keep the height of the ioad within the height of the load back- \ rest. Do not carry any load that is higher than the load back. rest. If the load is higher than the load backrest, there is danger that it will fall back on top of the operator. This may lead to serious injury or death. A WARNING | PO NOT TILT MAST FORWARD WHEN LOADED + Do not tit the mast forward when the forks are loaded and raised, There is danger that the load may fall and that the it truck may tp. + Do not travel withthe mast tite foward + De not load and unload on slopes AA WARNING | KEEP TENSION ON CHAIN + Ifthe mast ral or forks catch in a load or on a shelf, slack in the it chain may be created, resulting in danger that the load ‘may fall and the lift truck tip, ‘Always be careful hat thete is no slack in the chain when palling the forks out from a pallet or shel OMO073 — AX/BX Op & Maint 121048. LOADING OPERATIONS 2 WARNING + Do not use the tif truck for anything other than the intendect use (loading operations using the forks) + Do not use the forks to open or close the doors of railroad cars or warehouses, + Do not push any ather vehice. + Do not hook ropes or cables on the forks and use the forks fo lit toads, + Do not use the drawbar pin for towing operations, A WARNING may cause serious injury WARNING A waning Do not use the towing other lift trucks, for being towed by other lift trucks, or for lifting operations. + The drawbar pin installed to the rear of the counterweight is used only to free the truck when the tres have become stuck in mud or in a ditch and the lif truck cannot move, or when ‘oading the lif truck on to a trailer or truck USE ONLY FOR INTENDED PURPOSES LEVER OPERATION + Be careful not to operate the lever by mistake. There is danger that the forks or work equipment + Do not operate the levers when getting off the lit truck, USING DRAWBAR PIN fawoar pin for DRAWBAR PIN o1i404 0M073 = AX/BX Op & Maint8. LOADING OPERATIONS AA WARNING | FIT FORKS SECURELY IN POSITION + When adjusting the position (wicth) of the forks, be careful _ + not to get your hands caught + Atler adjusting, check thai the forks are held securely in pos! tion by the fork stopper, Ifthe forks are not held in position there is a danger that the forks may move when the lift truck Is traveling and the load may fall of, A CAUTION | A0vUST CHAIN + Be sure the tension of the left and right chains is the same. (See CHECK BEFORE OPERATION). the tension is not the same, the load wil be unbalanced even fit is waded correctly in the center, ‘and there is danger that the lft ruck may tip. (For details of adjustment, see page 2: OM073 = AX/BX Op & Maint 014g 1-198, LOADING OPERATIONS AA WARNING | 8& CAREFUL OF FORK Ties + Do not allow the tips of the forks to get close to people. ‘The tips of the forks are pointed, so there is a risk that they may cause injury + Do not hook the tips of the forks Under objects. the forks slip out, there is danger that the lit truck or object, may move unexpectedly A WARNING | PEOPLE IN WORKING AREA + Donnot allow anyone except the signal person in the working area. + Do not let any person or another It truck come close during operation, + When working with a signal person, always follow their instructions, skids are used, there is a isk that the load may fall A WARNING | HANDLING LONG or WIDE LOADS + Be extremely careful when carrying long or wide loads. Raise the load siowy and be careful no! to touch anything in the surrounding area, + Keep the load as low as possible and be sure to maintain the balance, + When tuming, operate slowly and be careful not to lel the load move AA WARNING | USE STRONG PALLETS AND skins. + Always be sure that the pallets and skids have ample strength. If broken or damaged pallets or 720 0rT404 OMO73 — AX/BX Op & Maint8, LOADING OPERATIONS A WARNING | OVERHEAD OBJECTS + Be careful not to let the mast, overhead guard or load contact electrical wiring, pipes, sprinklers or root beams. If the truck hits such abjects, there is 2 risk that the load will fall or the lift truck will tip. When the forks are raised, the mast height increases, 80 be particularly careful when the forks are raised A WARNING | NO PUSHING + Dono! use the forks to push or pull loads. There is a risk that the load wil be camaged or fall A WARNING | PRECAUTIONS WHEN LOADING / UNLOADING Do not let anyone place a load on the forks. Do not let anyone remove 2 load cirecty from the forks, Standing on the forks is dangerous because the forks are slippery and the load may move. Do not use anyone to keep the load stable The lit ruck may move unexpectedly, causing the load to fall and crush the person 121 OM073 = AXIBX Op & Maint9. STOPPING AND PARKING 9. STOPPING AND PARKING A WARNING | PRECAUTIONS WHEN STOPPING OR PARKING Observe the following procedure when stopping or parking the lit truck: 1) Stop the lift truck on level ground 2) Apply the parking brake securely to make sure that the If truck cannot move 3), Set the directional lever and the speed lever to neutral 4) Lower the forks to the ground, 5) Tum the key switch OFF to stop the engine, 6) Remove the key from the key switch, Then get off the it truck A WARNING | PARKING ‘+ Park the lift truck in the specified place. + Park the lit truck on a firm surface. + Do not park near any emergency ext, stairway, fre extinguisher or other safety equipment. Park the lif truck in a place where it wll not obstruct pedestrians or other vehicles, + Never park the lit truck near any flammable object, + When parking the iif truck on a slope, park as specified above (PRECAUTIONS WHEN STOP- PING OR PARKING). then put blocks under the tires to prevent the lift ruck from moving, + Donet park near any holes for construction or elevator shafs. LPG leaks, it can accumulate and ‘cause fire or explosion, 722 ‘o1i404 OMO073 — AX/BX Op & Maint9. STOPPING AND PARKING A WARNING | PARKING MACHINE AFTER FAILURE + Ifthe it truck has suffered a failure and the fit truck must be parked without lonering the forks, put markers on the tips of the forks and take steps to prevent pedestrians or other vehi- cles from hitting the forks. + Select a parking place where people or vehicles do not pass, and stop the lift truck so that it's difficult for anyone fo go under the forks. (The area under the forks is a DANGER zone) + Place a stand or something similar under the inner mast rail (r forks to prevent unexpected drop of the forks, + Remove the key from the faulty lift truck and hang signs in the ‘operator's compartment to prevent its use. A WARNING | ABRUPT LOWERING OF STUCK FORK + Because a stuck fork may drop down unexpectedly, do not go under the fork when itis in this con- dition, + Be very careful when dealing with this problem to prevent damage or injury, and warn those in the work area, M073 — AX/BX Op & Maint 11404410. INSPECTION AND MAINTENANCE 10. INSPECTION AND MAINTENANCE USE QUALIFIED PERSONNEL FOR INSPECTION AND A WARNING | iAiNTENANCE Only persons authorized by the owner or operator of the equipment and having proper certification (local or national) may carry out inspection, maintenance and repairs of the lif truck. inspection, maintenance or repair work is cartied out incorrectly, itis very dangerous. A WARNING | MAINTENANCE LOCATION nen carrying out inspection and maintenance, use a level, dry, dust-iree area Ifthe work is carried out inside a building, make sure that there is ample ventilation, A WARNING | PRECAUTIONS FOR INSPECTION AND MAINTENANCE ‘To be prepared in the event of a fire, have a fe extinguisher nearby and make sure that you know how to use it Before carrying out inspection, jower the forks to the ground and stop the machine, Do not run the engine unless it is necessary Place the directional lever, speed lever and work equipment control levers in neutral PRECAUTIONS WHEN CARRYING OUT INSPECTION A WARNING | iNND MAINTENENCE Wipe off any oil or grease. Immediately wipe up any oll that has leaked. Ifthe lift ruck is dirty, it becomes difficult or impossibie to find cracks or other problems. Always clean the lit truck before starting inspection, Do not smoke or allow any flame to exist under any circumstances. Do not use any cloth which is Soaked in fuel, flammable solvent, oil or grease There is danger that t may catch fire Wear suitable clothes for the job, Use suitable safety and protective equipment (hard hal, safety boots, safety olasses, gloves) for the job. When working on top of the lif truck, be careful not to fal, Do not put your feet under the forks \unen opening oF closing the floor plate or engine hood, be careful not to get your hands or body caught. men carrying out inspection with the forks raised, insert a stand under the inner mast to prevent the forks and mast from dropping When carrying out the job with another worker, decide who is the leader and carry out the job in accordance with instructions from that person. Aer repairing, make sure that the trouble has been corrected by performing a trial run, During the trai run, start and operate the lift truck carefully because i is possible that the trouble has not been fully corrected or that defective parts have nt been removed. 1-24 011404 ‘OM073 — AX/BX Op & MaintA CAUTION 10. INSPECTION AND MAINTENANCE USE SUITABLE TOOLS + Always use tools that are suited for inspection and main- + {tis extremely dangerous to use broken tools oF tools =a designed for another pur A WARNING these paris deteriorate: + However, if these parts A WARNING Immediately after using high temperature (HOT! out and cause burns. pose, REPLACE SAFETY CRITICAL PARTS PERIODICALLY Even if no abnormality is found, always replace safety critical parts periodically As time passes, ‘and may cause fire or failure in the work equipment system. The list of safety critical parts is on page 3-15, show any abnormality before the replacement interval has passed, they should be repaired or replaced immediately. PRECAUTIONS WITH HIGH TEMPERATURE COOLANT the Hit truck, the engine coolant is at ad hgh pressure Do rot remove the radiator cap under these corsltons. Hot water may spurt Sey «When remoung the racator cap, use a rag and tur it slowly to roleens the nian roan psllllishtiss, + When checking the cool lant level, stop the engine and wait for the engine to cool down before checking, For lift trucks ane equipped with a sub-tank or reservoir, check the level in the ssub-tank When adding water on lit trucks equipped with @ sub-tank, add the water to the sub-tank. M073 — AXIBX Op & faint oade10, INSPECTION AND MAINTENANCE “BA WARNING | PRECAUTIONS WITH HIGH PRESSURE, HIGH TEMPERATURE OIL Immediately after using the lft truck, the oil is at high temper- aiure. Do not drain the oll or replace the filter when the ail is INCORRECT hot, Hot oil may spurt out and cause burns, When carrying out inspection and maintenance, wait for the oll temperature to go down, and carry out the operation in the ‘order given in this manual Do not forget that the work equipment circuits are always under pressure, Do not add oil, drain oll or carty out mainte ‘nance or inspection before completely releasing the internal pressure If oll is leaking under high pressure from holes, it is danger: —” us if the jet of high-pressure oll hits your skin or eyes, CORRECT ‘Always wear safety glasses and thick gloves, and use a piece of cardboard or a sheet of plywood to check for ol leakage. Release the internal pressure before checking the accurnula- tor piping. If you are hit by a jet of high-pressure oil, consult a doctor immediately, A WARNING | ROTATING FAN AND BELT tis extremely dangerous if you or any tool touches or gets caught in the fan or fan belt when the fan is rotating, Never touch the fan when itis rotating Aiways stop the engine before inspecting rotating parts. When inspecting the areas around rotating parts, do not allow anything fo come close which may get caught, 1-26 o1t404 ‘OM073 — AX/BX Op & Maint10, INSPECTION AND MAINTENANCE A WARNING | BE CAREFUL NOT TO GET CAUGHT OR FALL + NEVER put your hands or feet into the mast structure. There ‘is danger that you will get caught in moving parts and be seri- ously injured, + Donot use the mast, load backrest or dashboard as a ladder, you slip, there is danger that you wil fll A DANGER | CHECKING AND INFLATING TIRES + Ifthe tire inflation pressure is low, it will affect truck stability, However, do not inflate the ties immediately. The inflation pres- sure may have gone down because of damage to the rim Ifthe fim is damaged or cracked and the tires are inflated, there is danger that the rim will break when the tire is under high pres- sure, and this may cause personal injury or death + For safety, when checking tire pressure, place your body in front of the tread face of the tire. Do not check from the side face of the tr + Suitable qualifications are needed for tire inflation work on a lit truck. It's not like an automobile. Always have the work carried ‘out by properly qualified personne. + The tire inflation pressure on a forkilt truck is several times higher than the pressure on an automobile. When the tires are being inflated, there is danger that dirt or dust may be thrown up by the compressed air and enter your eyes. Always wear satety glasses to protect your eyes, \\ OMO73 = AX/BX Op & Maint ‘11404 72710. INSPECTION AND MAINTENANCE A WARNING | HANDLING TIRES Disassembly and assembly of tires should be cared out by a tire dealer, ‘The tite pressure is extremely high, 80 caution is needed when handling tires. +The whee! is fitted with mounting (lug) nuts. It also has rim nuts and bolts used to join the rim halves, When removing the tire from the lift truck, do not loosen the rim nuts and bolts, The tire is Under high pressure, and there is a significant risk that the rim quts and bolts may fly off. Relieve ‘ire inflation pressure before removing, ‘When the tires have been replaced, carry out a test drive and check again for any loose mounting bolts. Ifthe tightening torque is low, tighten to the specified torque: replacing tires) + Do not go under the fork i tuck when I's jacked up. + Check the folowing before jacking up the it truck. (For deta, see 3-page 41) 41) Check that there is no one on the lit ruck 2) Check that there is no load on the forks + When jacking up, stop when the tires come off the ground sur- face, Put biocks Under both sides of the frame to prevent the lit tiuck from coming down + Put blocks Under any tires contacting the ground to prevent the lift ruck from mving + Lift truck slinging work should be carried out by a qualified person who has completed a course in correct liting meth: ods. + Fit wire ropes to the spectfied liting points, + When lifting the lift truck, check that the wire ropes have ample strength and are not damaged. + Block the tires contacting the ground to prevent the lit truck from moving. + Insert blocks to prevent the lif truck from coming down, + Do not go under the lit truck during the lifting operation. + Ifthe specified lifting point is the counterweight. check that the counterweight mounting bolts are tightened to the speci fied torque before carrying out the lifting operation. Check also that there is no damage to the lifting portion on the coun- terweight 428 ova0M A WARNING | /ACKING UP LIFT TRUCK (when checking or A WARNING | L'FTING LIFT TRUCK (when checking tires) AXIBX Op & Maint10. INSPECTION AND MAINTENANCE A WARNING | BATTERY HAZARD PREVENTION + Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in elothing. If ‘you spil electro on yourself, immediately fish the area wth a large quantity of water + Battary electiolyte can cause bindness i splashed into the eyes. If electrolyte gets into your eyes, flush them immediately with large quantities of water and consult a doctor a! once, + Ifyou accidentally drink electrolyte, drink a large quantity of water or rik mixed with beaten egg \white oF vegetable oll, Calla doctor or poison control center immediately + When working with batteries, ALWAYS wear safely glasses or goggles. + Batteries generate hydrogen gas, Hydrogen gas is highly EXPLOSIVE, and is easily ignted with a ‘small spark or lame, Do not smoke or create any spark near a battery + Before working with batteries, stop the engine and turn the starting swatch fo the OFF position + When removing the battery, emove the cable from the negative (-) terminal first. When instaling the battery, install the cable to the positive (+) terminal frst. This prevents possible sparks or arcing between the positive termi- nal and the positive cable. + Avoid shortcirculting the battery terminals through accidental Contact with tools or other metal objects across the terminals. + Tighten the battery terminals securely Loose terminals can generate sparks and lead to an expiosion + When removing or installing the battery, confirm which is the postive (+) terminal and which is the negative (-) terminal. Be ‘eareful not fo connect the cables to the opposite /incocrect ter. CHECK BATTERY mia: TERMINAL + Tighten the battery caps securely NaRNINGS: When cleaning the battery, leave the battery caps tightened, A | OQg-hO arrest ‘Ac05809 A WARNING | PO NOT PUT METAL OBJECTS ON TOP OF BATTERY Never place any metal objects on top of the battery. There cuit and start a fire A WARNING | CHANGING LPG FUEL TANKS ‘Only trained and certified personnel may change LPG tanks. ‘Tum ignition switch to the OFF postion. Change LPG tanks in designated and well ventilated area approved for this operation Check LPG tank and lines for fuel leaks. Enaure no sparks, flame or ignition sources are present Once the ful tank's in place, ensure itis mounted correctly and securely. Check all connections. Do not attempt to start the truck until all LG odor is gone. ifthe truck is hard to star, contact a certified mechanic to repair the problem. Tag the truck ‘Out of ‘Sorvice" until properly repaired danger that they will cause a short cir- OMO073 = AXIBX Op & Maint ‘11404 1-2910. INSPECTION AND MAINTENANCE AA WARNING | PRECAUTIONS WHEN CHARGING When the battery is charged, hydrogen gas is generated and the battery is heated by the chemical change. To prevent the danger of gas explosion, aways do as follows: + Carry out the charging operation in a well-ventilated place, + Do not smoke or allow any flame, + Start the charging operation when the temperature of the battery electrolyte is below 95° F (35° C), Ifthe electrolyte temperature goes above 122° F (50° C) during the charging operation, wait for to go down below 85° F (35° C) before starting charging operation again + When using a battery charger to charge the battery, take the battery caps off A WARNING | STARTING WITH BOOSTER CABLES ALWAYS wear safety glasses or goggles when starting the if truck with booster (jumper) cables When starting using the battery of another it truck, do not allow the two lit trucks to touch. ‘Stop the engine before connecting the cables. Be extremely careful not tole! the cables get caught in the fan or fan belt, Connect the batteries in parallel; positive-to-positive and negative-to-negatve. NEVER connect postive to negative + DO NOT short-circuit the starter terminals to start a forklift truck A WARNING | 20 NOT PUSH START + Do not push the lit truck to start the engine. There is danger that the lift ruck may suddenly start and operate unexpectedly, A WARNING | HANDLING BRAKE FLUID I is dangerous if the brakes do not work because, in this condition, the lif truck cannot be stopped, ‘Always do the following + Check the level of the brake fluid periodically, ‘Aways use the specified brake fluid, + Check that the breather of the brake fluid reserve tank is not clogged. + Be careful not to let dirt or cust get nto the brake fluid reserve tank, 1-30 OMO073 ~ AX/BX Op & Maint40. INSPECTION AND MAINTENANCE BA WARNING | HANDLING ANTIFREEZE ‘Antifreeze can be flammable. Keep avray from flame when handling, ‘Antifreeze is poisonous, £0 do not drink it If you drink it by mistake, drink large amounts of water, ‘vornit it out, and get medical attention immediately, Follow safety precautions on container. A CAUTION | WASTE MATERIALS ‘Obey appropriate laws and regulations when disposing of harmful items and materials such as oil, fuel, solvent, fiters and batteries, INCORRECT ‘OMO73 — AXIBX Op & Maint oiaca Ta41. STRUCTURE AND STABILITY OF THE LIFT TRUCK 11. STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING) ‘To operate the lift truck safely, it is important to understand the structure and stability of the lift truck, CAUTION | STRUCTURE OF LIFT TRUCK AA forklift truck consists basically of the lifting mechanism (the forks and mast) al the front and the it truck itself (with tes) at the rear, ‘The front wheels of the lift truck act as the fulcrum, and the center of gravity of the lit truck and center of gravity of the load are kept in balance, ‘The relationship between the position of the center of gravity of the tit truck and the center of gravity of the load is extremely Important for maintaining the safety of the ult truck ‘The loads carried by forklift trucks come in various shapes (and weights) from boxes to planks and tong objects, To judge the stability of the lift truck, it is important to distinguish shapes, 1-32 01ta0a m4 the position of the center of gravity for loads of vanous = |__ A CAUTION | CENTER OF GRAVITY OF LOAD OM073 = AX/BX Op & Maint11, STRUCTURE AND STABILITY OF THE LIFT TRUCK The stabilly of the lit truck is determined by the position of the combined center of gravity resulting from the combination Of the centers of gravity ofthe lit truck and the load, When the lif truck is carrying no load, the center of gravity remains as itis, but when the If truck is loaded, the com- bined center of gravity becomes the combination of the cen- ters of gravity of both the lif truck and the load ‘The position of the center of gravity of the load changes according to whether the mast Is tied forward or back or whether the mast is raised or lowered. ‘The position of the combined center of gravity of the lift truck is governed by the following factors: +” Size, weight, shape of load Lifting height Tiling angle of mast Inflation pressure of tres Acceleration, deceleration, tuming radius Condition of road surface, angle of road ‘Type of attachments ‘AA CAUTION | CENTER OF GRAVITY AND STABILITY Gontor of Combined Centar of farveyof Genter ot Gravity ite few Flan combines Caner of ‘ravty of Ws eonunvod Hr he MI track body 8 constant. AAO CAUTION | STABLE RANGE OF CENTER OF GRAVITY Stable range For the lit truck to be stable, the position of the combined center of (gravity must be inside the triangle (stable range of center of gravity) formed by the ground contact points of the left and right front tres. ‘and the center of the rear axle, IF the position of the overall center of gravity is in front of the front axle, the front tires will form the fulcrum and the lit truck wil tip to the front. If the position of the combined center of gravity moves. ‘outside the triangle forming the stable area for the center of gravity, the lift truck will tp in the direction where the combined center of gravity moves outside of the triangle, M073 = AX/BX Op & Maint ‘01140411, STRUCTURE AND STABILITY OF THE LIFT TRUCK AA CAUTION | MAXIMUM LOAD (weight and center of gravity of load) ‘The horizontal distance between the center of gravity of the load on the forks and the load backrest of the forks, oF the front face of the forks (whichever is shorter}, is called the load cen- ter ‘The maximum load is the maximum weight of the foad that can be loaded at the standard load center. The relationship ‘8001620 between the maximum load and the load center is given in the load capacity charts on the nameplate on the lif truck. If the load center moves to the front of the forks. the overall center of, gravity also moves to the front, so this means that the load must be reduced A CAUTION | ALLOWABLE Load ‘The allowable load is stamped on the namepiate to show the relationship regarding the position of the load center, the height of the fork and the maximum load. Before load- ing the forks, check that the load and load center are within the permitted range on the stamped allowable load. Ifthe shape of the load is complex, set itso tha the heavi- ‘est part of the load is at the center of the forks and set the load close to the load backrest. If the forks are loaded more than the allowable value, the drive wheels wil float during travel and the steering system vill not work, This is very dangerous, Furthermore, the lit ‘ruck wil tip over easily under this condition. Therefore, be sure fo keep the load below the allowable value and prop- erly balanced, A WARNING | SPEED AND ACCELERATION Ia stationary object is not subjected to external force, it will remain stationary, In the same way, if a moving object is not subjected to extemal force, it wil continue to move at the same speed. This is called inertia Because of inertia, a force is applied towards the rear when the lft ruck starts to move, and is applied towards the front when the If truck stops. If the brakes are applied suddenly, there is danger of a large force being applied towards the front which may make the lift ruck tip or the load come off the forks. When the lift truck is turned, a centrifugal force is applied to the outside from the center of the turn ‘This force pushes the lit truck to the outside and makes it tip The range of stabil to the left and right is particularly small, so itis necessary to reduce speed when tuming, in order to prevent the lift truck from tipping. if the lit truck is traveling with a raised load, the position of the overall center of geavity s high, so the danger of tipping to the front, eft or right becomes greater, 134 1404 ‘OM073 = AX/BX Op & Maint412. SAFETY LABEL STICKING POSITIONS 12.1 SAFETY LABEL STICKING POSITIONS Keep these labels clean. If a label (decal) comes off, stick it on again in the same location or replace with @ evr one. Treat all labels (decals) in the same way, whether they are safety related or not LJ Fron spe 7 / orownoun CA i \A) coutsie oF uerrano| IOHTOUTER MASTS co NM | \ } SHROUD INSIDE é Nf orien ooo) las 1 f i K LerTaNo RH urea ris oF er FRONT WHEELS QNORITREARWAEELS yang See following pages for labels corresponding to numbered locations in figure above. M073 = AX/BX Op & Maint ‘o11404 1-3512. SAFETY LABEL STICKING POSITIONS 4. Prohibit the operator from riding on the 4 Never touch fan when rotating ind lifting or lowering himself. (Part No, 3EB-96-A5930) rea under the forks. 5 Noone is permitted to ride the it {ruck together with the operator. (Part No, 3EB-96-A58 10) 2. Do not put your hand on the mast! (Warning to avoid getting hand caught) (Part No. 3EB-96-A5940) Before starting engine * Put gearshift lever in neutral * Pull parking lever to locked position. EE-96-A5960 138 “011404 OMO73 = AX/BX Op & Maint12, SAFETY LABEL STICKING POSITIONS 8. Waming for operation (decal) (Part No. 368-96-A5890) SERIOUS INJURY OR DEATH MAY RESULT IF YOU FAIL TO FOLLOW THESE PRECAUTIONS! Before Operating = Do nto took unease rine and auhoied. “Road ane uncer al warnings ane acon manual on rok botore operating rs have replace ranaa ruck bere ie ck sinned ol ep, no operate ul esiored fo ule cencion + Do not start truck # fuel is leaking or has leaked. Use attachments for intended purpose only. ‘Operate tuck ely trom operator's seat. “op truck under convo a al ines, ‘ Dovmotovet fad ruck. Check capacity pate fr foad woight and load center + Avoid any sudden stars, stops, tune or change of direction + Obey vahic sun es i rah of wae pocetars. * Keep clear view o ravi path I 'oad being carried bicexs forward view, vel wih oad iain, + Slow down and scund torn whon vsicnis block, alc clearances, expecially fxs, mast, overnead quaré anc talowing area, low down 1! ts and on unoven of sippry suaces ‘Avot runing ove lose objets. “ever angler tr on nine ‘Travel wih oad ul when ade rave wih Ming mechan dewrhié wh amply. Secure dockbeardo:oniggeplte propery. De nol excood raed capac, “Mh ere whrOperaig on nou rape. = Dont hare unatadio ads ote stack eee +p not hale lads her than oad backs. + Spe forks as ar asad per. Deflate tire completely before removing rim nuts. 16-96-8070, + Bo ure nd is cnntorad an forks are completely under lone + Never lift Jond with mas ied forward * Da not tit forward when elevated except to pick up oF depos load. - Travel with loud or ing mechanism low ané tite back, + Tipover can goed operated improper. De not jump i truck begins to Held on fimly and fan away trom point ol impect ‘Avie Doing tapped betwaen tick and ground + Alow noone to stan or pas under oF rea ote or Cee a marereten + Naver place ary par o mast structure, tatwogn mast a ruck of tse truck «Do ot cary passengers on ay pat of ruck, "Lt ane under any crcunstace “Dono operate without overhead guard and Pun rig bate oni soso i + il ual ot chase batiory onl inspected place "Slop eng wren fueling and avod cgen fae or spars, tnd provide adequate venation Keep vot cape ear whon charging battery. "Disconnect batry during server ‘aver (clotn type) to neural pos iy iting chart, and pull parking leer cure. «Shut of power when leaving tuck nationded + Block wheels when parking on incline 3EB-96-A5900 Warning for use of split rim (pneumatic tires only)(decalp (Part No. 3EB-96-A5970) 0M073 = AX/BX Op & Maint o1r404 13712. SAFETY LABEL STICKING POSITIONS 8. Prevention of tip-over (decal) (Parts No, 3EB-96-A5111) ‘9. Warning for handling LPG/FLAMMABLE GAS (decal) (Part No. 3EB-96-A5950) Ao g Peete 4 EMMA Do rot start onpne 10. "NO JUMP START” docal (Part No. 09842-A0481) Located top center of starter solenoid. ‘S 09842-A0481 1-38 ~ 011404 TRAINED PERSONNEL ONLY! Poirier renin) Pent coer ny etc e ee car cinerea ieee Tr Peer es one ft Segura Miecn tion Porat ‘0M073 — AX/BX Op & Maint12. SAFETY LABEL STICKING POSITIONS 41, LPG TANK CHANGE INSTRUCTIONS DECAL (On LPG Tank Bracket Base Plate) (Part No. 3EB-05-F5690) 3EB-05-F5680 12, LPG SAFETY MAINTENANCE DECAL (Right side of s ton hood upper surface) (Part No, 3EB-05-F5730) SAFETY MAINTENANCE PROCEDURE FOR LP GAS FUELED FORKLIFT TRUCKS. Res See atic ng cornet Se SS ree ener Ea een TT a Feeetac ee epeenenares + Soeecemreevemmorecvameninene! eS ‘ea ‘SERVICE WORK SHOULD. “QUALIFIED PERSONNEL ONLY. M073 — AX/BX Op & Maint ome ~~12. SAFETY LABEL STICKING POSITIONS 13, LPG FUEL SYSTEM DECALS ‘A. LPG LOW FUEL ALARM LIGHT (On dashboard to left of steering column)(OP) B. DUAL-FUEL SYSTEM FUEL CHANGE-OVER INSTRUCTIONS (On air cleaner housing) (Part No, 3EB-95-A5790) FUEL CHANGEOVER INSTRUCTIONS DUAL FUEL SYSTEM 1. TURN OFF IGNITION SWITCH TO STOP ENGINE, 2, TURN SWITCH TO DESIRED FUEL SELECTION, LPG OR GASOLINE. 3, START ENGINE AS USUAL. NOTE: WHEN TURNING KEY TO ANOTHER FUEL SELECTION WHILE ENGINE IS RUNNING, ENGINE WILL CONTINUE TO USE INITIAL, FUEL SELECTION, sk Ga Rat, 14. FUEL LEVEL REQUIREMENTS - GASOLINE AND LPG (On dashboard over Fuel Gauge) (Dual-Fuel applications only) /AMIS GAGES, y GASOLINE TANK Must / / NOTIN USE. \ BE AT LEAST 1/4 FULL USE TANK GAGE | WHEN OPERATING as ce DONOT Sn \ REMOVE / Dual-Fuel Truck LPG Fuol Truck 4-40 oFi408 (OMO73 — AXIBX Op & MaintOPERATION READ AND FOLLOW ALL SAFETY PRECAU- TIONS. FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR DEATH. 2413. OVERVIEW OF LIFT TRUCK 13.1 GENERAL VIEW OF LIFT TRUCK os200101, ‘Mast Lif-chain Lift cylinder Back rest Tilt eylinder Fork carriage Fork Head guard 22 021704 ‘Turn signal lamp (option) Head lamp (option) Operator's seat Engine hood Counterneight Rear wheel Front whee! M073 - AXIBX Op & Maint13. OVERVIEW OF LIFT TRUCK 13.2. INSTRUMENTS AND CONTROLS (AX & BX) 6 10 9 "1 5 3,4 22 23 16 15 24 21 2 20 49 ‘AE803100F ‘See "Explanation of Components” (page 2-10) for detalis, 1. Stating switch 10. Engine water temperature gauge 19. Accelerafor pedal 2. Operation indeator(aispiays during 11. Fuel gauge 20. Brake peda operation) 3, Glowindeator (diesal only) 12, Hern button 21 Inching pedal (TORAFLOW ‘vansmission) Clutch pedal (cluteh-type truck) 4, ECU Failure waming lamp (gas only) 19. FORWARD/REVERSE swatch 22 LM\lever (TORGFLOW tansmission) 6. Sediment warning lamp (ciesel) 14, FORWARO/REVERSE lever 23. Titlevor (dlutch-ype ruck) 6. Charging warang lamp 15 HIGHAOW speed lever 24. Tilatle steeting wheel lock lever (cluten-type bt ack) 7. Engine oll pressure waminglamp 16 Combinatian ight svatch (hur-signal 25. LPG low-fuel alain light lamp and lamp ONIOFF switch) (optional) 8, Broke fuid level warning lamp 17. Parking brake lever 8. Hourmeter 18 Fuse box ‘Method of checking for blown bulbs in warning lamps. 4. Check that all warning lamps light up when the starting switch is turned ON. 2. any warning lamp does not light up, the bulb for that lamp is blown. OMO073-AX/BX Op&Maint ——S~«NO 2313, OVERVIEW OF LIFT TRUCK 13.3 FEDERAL EPA EMISSION CONTROL STATEMENT FOR OFF-ROAD LSI (NON-DIESEL) ENGINES (K21 AND K25 ENGINES) ‘This section presents information conceming the correct labeling, warranty, parts and maintenance of K21 and K25 engines in order to comply with the EPA off-road, large-spark-ignition (LSI) engine regulations 4. LABELS REQUIRED AND LABEL LOCATIONS. All °K" sens engines wil display the required identification label as follows. Location on K21/K25 Series engines: EPA LABEL LOCATION (TOP VIEW OF ENGINE) KOK EPA Emission compliance label (SAMPLE shown below) eee [EMISSION CONTROL INFORMATION "TTC ENGINE DISPLACEMENT 211 ENGINE MAXRVUM POWER: 8 HP THIS ENGINE 1 CERTIFIED TO OPERATE ON LPO. ENGINE'S USEFUL LIFE Is S00 HOURS OF OPERATION OR SEVEN YEARS EXHAUST EMSSIONCONTROL TYPE: Ti, NMC, HO2S, TEST MODE. VARIABLE-SPEED ONLY [THs ENGINE METS CALIFORNIA AND US. EPA REGULATIONS. [FOR 2008 LARGE WONROAD ENGINES CHISSAN MOTOR CO, LTD | _K2TC Sesaeh Sem (HoT) a Oz 24 21604 ~— OMO73 = AX/BX Op & Maint43. OVERVIEW OF LIFT TRUCK 2. WARRANTY ‘The following statement is hereby provided as required by regulations of the United States Environmental Protec tion Agency (EPA), YOUR WARRANTY RIGHTS AND OBLIGATIONS ‘All oft-road large spark-ignition (LSI) engines must be designed, built and equipped to meet the Federal EPA's stringent anti-smog standards. Komatsu Forklift USA, Inc. ("KFI") must warrant the emission contro! system on your engine for the periods of time listed below provided there has been no abuse, damage, neglect or improper maintenance of your engine, ‘Your emission contro! system may include parts such as the carburetor, regulator or fuet-injection system, ignition system, engine computer unit (ECM), catalytic converter and air induction system Also included may be sensors, hoses, bells, connectors and other emission-related assemblies, Where a warrantable condition exists, an Authorized Komatsu Forklift Dealer wil repair your LSI engine at no cost to you, including diagnosis, parts and labor MANUFACTURER'S WARRANTY COVERAGE Beginning January 1, 2004 off-road large spark-ignition EPA engines are warranted for the time periods listed below, If any emission-related part on your engine is defective, the part will be repaired or replaced by an Autho- rized Komatsu Forklift Dealer, OWNER’S WARRANTY RESPONSIBILITIES ‘As the offroad LSI engine owner, you are responsible for the performance of the required maintenance listed in your Operation and Maintenance Manual, KF! recommends that you retain receipts covering maintenance on your off-road engine, but KF! cannot deny war ranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. ‘As the off-road large spark-ignition engine ovmner, you should be aware, however, that KFI may deny you warranty ‘coverage if your offroad large spark-ignition engine, or a part thereof, has failed due to abuse, damage, neglect, Improper maintenance or unapproved modifications, ‘Your engine is designed to operate on gasoline andior LPG fuel, Use of any other fuel may result in your engine no. longer operating in compliance with the Federal EPA's emissions requirements, You ate responsible for initiating the warranty process. it is suggested that you present your off-road large spark- ignition engine to an Authorized Komatsu Dealer as soon as you become aware that a problem ests The war- ‘anty repairs should be completed by the dealer as expeditiously as possible, Iyou have any questions regarding your warranty rights and responsibilties, you should contact Komateu's Prod: uct Support Dept. at 1-770-385-4815 {In adition to the standard warranty periods, the components listed below are covered by the following specific ‘warranty periods. M073 — AX/BX Op & Maint 024704 2513, OVERVIEW OF LIFT TRUCK EMISSION CONTROL WARRANTY ~ 36 MONTHS OR 2,500 HOURS FOR GENERAL PARTS. For the first 2,500 operating hours, or for @ period of thity-six months from the date of the first use by the original purchaser from an Authorized Komatsu Forklift Dealer, whichever occurs firs, KFI warrants the following emission-related parts: + Oxygen sensor + PCV valve + Water temperature sensor + Gasoline injactor + LPG injector + LPG prossure sensor + LPG solenoid + LPG switching module + Mass air flow sensor + Thiottle chamber + Ignition coi + Crankshaft position sensor ‘+ Camshaft position sensor + Distributor + Spark plugs EMISSION CONTROL WARRANTY ~ 36 MONTHS OR 4,000 HOURS FOR POWER TRAIN PARTS + Intake manifold + Exhaust manifold EMISSION CONTROL WARRANTY ~ 60 MONTHS OR 3,500 HOURS FOR GENERAL PARTS. + ECM + Catalytic converter + Vaporizer [nonce | Follow the instructions in the Operations Manual concerning any other maintenance programs not required for EPA compliance. For questions and additional information concerning EPA Diesel Engine Exhaust Regulations, contact: Komatsu Forklift USA. Inc, 11448 1 Lochridge Biv6., Big, #2 Covington, GA 30014-4908 Voice phone: (770) 385-4815 Fax phone: (770) 385-4838, 26 021704 ~ OMO73 — AX/BX Op & Maint13, OVERVIEW OF LIFT TRUCK 13.4 FEDERAL EPA EMISSION CONTROL STATEMENT FOR OFF-ROAD DIESEL ENGINES (4D94E ENGINES) Exhaust emissions produced by clesel engines are regulated by the United States Environmental Protection ‘Agency (EPA) This section presents information conceming the correct labeling, warranty parts and maintenance (of 4D94E diesel engines in order to comply with current EPA regulations. 1. LABELS REQUIRED AND LABEL LOCATIONS, Allcertfied 4D94E diesel engines will display the required identification label as follows: + AD94E diesel engines: Labels willbe affixed to all appropriate engines on KF production trucks Location on 4DS4E Series diesel engines: EMISSION CONTROL LABEL IMPORTANT ENGINE INFORMATION [THE ENE covFORWS TO 204 WCOEL YEARS. EPAREGULATIONS| ERRGE NONROAD AND COMPRESSION GATTON ENGWES rite ENOINE 18 CERTFIED To OPERATE ON “US20" FUEL ENGREFAMLY «YOXL27aPaN [NONE FAMLy «vOXL27apan_BPLACENENT 2776LTERS——] [svone woe. amicsi 6 —enissiow cowTaOL sys TENE] FUEL RATE GTO SHOE gat NT ZIP awoanwstments (E}YANMAR DIESEL ENGINE Co, Lid ‘0M073 — AX/BX Op & Maint 21704 2713. OVERVIEW OF LIFT TRUCK 2. WARRANTY ‘The following statement is hereby provided as required by regulations of the United States Environmental Protec tion Agency (EPA) YOUR WARRANTY RIGHTS AND OBLIGATIONS The Federal EPA and Komatsu Forklift USA. Inc. (hereinafter referred to as "KF I") are pleased to explain the emis- ‘Sion contro! system warranty on yaur 2004 or later Diesel heavy duty off-road engine. All new, heavy-cty off:1o20 ‘engines must be designed, built and equipped to meet the EPA's stringent anti-smog standards. KF must warrant the emission control system on your engine for the period of time listed below, provided there has been no abuse, damage, neglect or improper maintenance of your engine, ‘Your emission control system may include parts such as fuel injection pump. Also included may be hoses, belts, connectors and other emission-related assemblies, Where a warrantable condition exists, an authorized Komatsu dealer will repair the heavy-duty offroad engine at no cost to the owner, including diagnosis, parts and labor, Now. KF! hereby certifies that diesel engines for lift trucks produced in 2004 model year and after shall be regu- lated by Federal EPA exhaust gaseous regulations. The difference between current and EPA-certfied engines is only the label attached on the engine. See available drawing andor ilustration of emission label and its location MANUFACTURER'S WARRANTY COVERAGE Beginning January 1, 2004 heavy-duty off-foad EPA engines are warranted for a period of five (5) years, or three- thousand (3,000) hours of operation, whichever occurs first. If any emission-related part on your engine is dofec- tive, the part will be repaired or replaced by at an authorized Komatsu Forklift dealer EMISSION-RELATED PARTS. + Fue! injection pump + Fuel injection nozzles + Turbocharger OWNER’S WARRANTY RESPONSIBILITIES As the heavy-duty offroad engine owner, you are responsible for the performance of the required maintenance. listed in owner's manual (Instruction Manual). KFI recommends that you retain all receipts and racords covering the ‘maintenance on your engine, but KFI cannot deny warranty solely for the lack of receipts and records or for your failure to ensure the performance of all scheduled maintenance. For your reference, the following is an emission, Control maintenance schedule for certified Diesel engines, + Check oil level and coolant level - Everyday + Change of lubricating ~ Every 200 hours + Change lubricating oil fiter ~ Every 200 hours + Initial adjustment of valve clearance = Every 200 hours, + Change fuel fier ~ Every 00 hours + Check turbocharger, rebuild or replace ifnecessary~ Every 2,000 hours + Adjust valve clearance ~ Every 2,000 hours Check fuel injection nozzles, replace if necessary — Every 2,000 hours o2iToa (0MO073 = AX/BX Op & Maint13, OVERVIEW OF LIFT TRUCK Keep records to show proof of compliance witn the required maintenance practices and intervals, + As the heavy-duty offroad engine owner you should, however, be aware that KFI may deny your war- ranty coverage if your heavy-duty off-road engine or part has failed due fo abuse, damage, neglect improper maintenance or disapproved modifications + Your engine is designed to operate on commercial diesel fuel only. Use of any other fuel in our engine will result n the engine operating in non-compliance with the Federal EPA regulations You are responsible for initiating the warranty process, It's Suggested that you present your heavy duty offroad engine to an authorized Komatsu dealer as soon as you become aware that problem exists. ‘The warranty repair should be completed by the dealer as expeditiously as possible + if you have any questions regarding your warranty rights and responsibilities, you should contact the authorized KFI dealer LIMITATIONS KF! is not responsible for resultant damages to an emission-related part or component resulting from: + Any application or installation KF! deems improper as explained in the instruction Manual + Attachments, accessory items or parts not authorized for use by KF + Improper off-road engine maintenance, repair or abuse. + Qwner's unreasonable delay in making the product available atter being notified of a potential product problem. ‘This warranty is in adehtion to the KF! standard warranty applicable to the off-road engine product involved, Remedies under this warranty are limited to the provision of material and services as specified herein, KF! is not ‘responsible for incidental or consequential damages, such as downtime or lost use of the forklift truck, CUSTOMER ASSISTANCE - EMISSION CONTROL SYSTEMS WARRANTY Komatsu Forklift aims to ensure that the Emission Control Systems Warranty is properly administered. In the event that you do not receive the warranty service to which you believe you are entitled under the Emission Control Sys~ tems Warranty. call or write to your Komatsu Forkit Dealer. ‘Authorized dealers are recommended for major maintenance and repair work, as they are staffed with trained per- sonnel, proper tools and are aware of the latest maintenance methods and procedures. Owners and others who ‘Gesire to perform their own work should purchase a service manual and obtain current service information from their KFI engine dealer. [wore | Follow the instructions in the Operations Manual concerning any other maintenance programs not required for EPA compliance, For questions and additional information concerning EPA Dlosel Engine Exhaust Regulations, contact: Komatsu Forklit USA, Inc. 14481 Lochridge Blvd., Bldg. #2 ‘Covington, GA 30014-4908 Voice phone: (770) 986-4615 Fax phone: (770) 385-4838 M073 = AX/BX Op & Maint ~ 021704 2914. EXPLANATION OF COMPONENTS ‘The following is an explanation of the devices shown on page 2-3 and which are employed to operate the lift truck ‘To carty out suitable operations correctly and safely. itis important to understand fully the method of operating the equipment and the meanings of the displays, ‘See page 2-3 for exact locat 4. STARTING SWITCH This is used to start and stop the engine + Clutch-type lift truck: OFF ow ‘When starting the engine, place the forwardireverse . contro lever and highvfow speed contro lever at tho

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