19. OUTLINE OF SERVICE

3-2

19. OUTLINE OF SERVICE• Use Komatsu Forklift specified parts and lubricants for replacement.

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

• Unless otherwise specified, the oil and coolant used at delivery from the factory shall be as shown in the tablebelow.

19.1 SUITABLE OIL

19.1.1 OIL• Since the oil is used for the work equipment, etc., under severe conditions (at high temperature and high pres-

sure), it will deteriorate as operating time passes. Always use an oil matching the grade and working tempera-tures given in the Operation Manual.Always replace the oil at specified time intervals even if it is not deteriorated.

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

• Never blend oils of different grades or brands.

• Add specified volume of oil.Too little or too much oil may both cause problems in the fork lift truck.

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

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

Item Type of fluid

Differential case SAE 90

Hydraulic tank SAE 10W-CD

TORQFLOW transmission case SAE 10W-CD

Cooling system Coolant (FAF-NAC)

19. OUTLINE OF SERVICE

3-3

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

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

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

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

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

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

19.1.4 FILTERS• Filters are very important safety items which prevent problems caused by impurities contained in the oil or

hydraulic circuit which sends oil into important units. Periodically replace the filters referring to this manual.

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

• Do not unpack replacement filters until immediately before installation.

• Always use specified filters.

20. LUBRICANT LIST

3-4

20. LUBRICANT LIST20.1 GASOLINE/LPG ENGINE LIFT TRUCKS

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

Always use specified oil and grease.

Never use the incorrect kind of brake fluid. Use specified DOT 3 brake fluid.

NOTICE

Lubrication Points Type of Fluid

Ambient Temperature

Capacities -4 14 32 50 68 86ºF -20 -10 0 10 20 30ºC

Engine oil pan Engine oil(SAE 30W-CD)

2.06 US gallons7.8 L, 1.72 UK gal.

TORQFLOWtransmission case

DEXRON Automatictransmission fluid

4.22 U.S. gallons16 L, 3.52 UK gal.

Differential case

Gear oil (SAE80W)

Gear oil (SAE90W)

TORQFLOW transmission:3.43 U.S. gallons

13 L, 2.86 UK gal.

Hydraulic tank Hydraulic oil ISO # 32

14.53 U.S. gallons55 L, 12.10 UK gal.

Fuel tank

Gasoline87 Octane (recommended)LPG107 Octane Propane

FG30/40/45/5026.4 U.S. gal.

100 L, 22.0 UK gal.FG40Z

21.1 U.S. gal, 80 L, 17.6 UK gal.

Brake system Brake fluid (DOT 3) 0.040 U.S. gal. 0.15 L, 0.033 UK gal.

Greasing points Lithium grease(NLGI No.2) —

Cooling system

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

3.7 U.S. gal. 14 l, 3.08 UK gal.

20. LUBRICANT LIST

3-5

20. LUBRICANT LIST20.2 DIESEL ENGINE LIFT TRUCKS

(FD40/45/50-7, FD40Z-7)

• Never use fuel mixed with kerosene.• Always use specified oil and grease.

Never use the incorrect kind of brake fluid. Use specified DOT 3 brake fluid.

NOTICE

Lubrication Points Type of Fluid

Ambient TemperatureCapacities -4 14 32 50 68 86ºF

-20 -10 0 10 20 30ºC

Engine oil pan

Engine oil(SAE 10W)

(SAE 30W)

3.04 U.S. gal.11.5 l, 2.53 UK gal.

TORQFLOWtransmission case

DEXRON Automatictransmission fluid

4.22 U.S. gal.16 L, 3.52 UK gal.

Differential case

Gear oil (SAE80W)

Gear oil (SAE90W)

TORQFLOWtransmission:3.43 U.S. gal.

13 L, 2.86 UK gal.

Hydraulic tank Hydraulic oilISO # 32

14.53 U.S. gal.55 L, 12.10 UK gal.

Fuel tank

Diesel fuelASTM D975 No. 2

ASTM D975 No. 1

FD40/45/5026.4 U.S. gal.

100 L, 22.0 UK gal.FD40Z

21.1 U.S. gal, 80 L 17.6 UK gal.

Brake system Brake fluid (DOT 3) 0.040 U.S. gal. 0.15 L, 0.033 UK gal.

Greasing points Lithium grease(NLGI No.2) —

Cooling system

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

3.7 U.S. gal.14 L, 3.08 UK gal.

20. LUBRICANT LIST

3-6

20. LUBRICANT LIST20.3 OIL AND GREASING CHART (OIL, GREASE LOCATIONS AND

INSPECTION AND MAINTENANCE INTERVALS)

Chart symbol Type of fluid

AF Automatic transmission fluid(As specified / Dexron II)

EODiesel engine oil

Gasoline engine oil

GO Gear oil

HO Hydraulic oil

BF Brake fluid(As specified / DOT 3)

G Grease

21. SERVICE DATA

3-7

21. SERVICE DATA21.1 SERVICE DATA (GASOLINE/LPG ENGINE LIFT TRUCKS)

Component Inspection item Unit of Measure FG35/40/45/50-7, FG40Z-7

Engi

ne

Engine

Engine model -- NISSAN TB42

Idling speed rpm 850 - 900

Maximum speed rpm 2,300 -2,400

CompressionPSI / rpmMPa/rpmkgf/cm2

170 PSI / 200 rpm1.2MPa / 200 rpm

12 kgf/cm2 / 200 rpm

Lubricating oilcooling system Fan belt deflection lbf

mm0.59 - 0.67 in.

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

Fuel system

Injection timing BTDCo --

Injection order -- --

Injection pressure MPa --

Intake / exhaustsystem

Valve clearance

Intake in. (mm) 0.015 in. (0.38) Warm

Exhaust in. (mm) 0.015 in. (0.38) Warm

Electric system

Distributor point gap mm --

Spark plug gap mm 0.028 - 0.031 in. (0.7 - 0.8 mm)

Spark plug type -- NGK: B-4ES or BPR-4ES (shielded) Hitachi: L47W

Ignition timing (gasoline)

Ignition timing (LPG)

BTDCo/ rpm

7° / 700 rpm

12° / 700 rpm

Firing order -- 1 - 5 - 3 - 6 - 2 - 4

21. SERVICE DATA

3-8

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

Component Inspection item Unit of Measure FG35/40/45/50-7, FG40Z-7

Trav

el s

yste

m

Tires Tire inflation pressureFront wheels PSI

MPa

250-15-16PR: 120 PSI, 0.83 (8.5 kgf/cm2)8.25-15-12PR: 98 PSI, 0.68 (7.0 kgf/cm2)300-15-18PR: 113 PSI, 0.78 (8.0 kgf/cm2)

Rear wheels 120 PSI, 0.83 (8.5 kgf/cm2)

Lug nuts Tightening torqueFront wheels

ft/lbsNm

217 - 361 ft/lbs294 - 490 (30 - 50 kgfm) Rear wheels

Rim mating nuts Tightening torque

Front wheels --

Rear wheels 145 - 217 ft/lbs196 - 294 (20.0 - 30.0 kgfm,)

Stee

ring,

bra

king

sys

tem

Steering wheel Playin.

(mm)

1.2 - 2.4 in. (30 - 60 mm)

Inching pedalPlay 0.08 - 0.12 in. (2 - 3 mm)

Interconnected travel 1.38 - 1.41 in. (35 - 41 mm)

Brake pedalPlay in.

(mm)

0.12 - 0.28 in. (3 - 7 mm)

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

Brake

Parking brake operating force lbf (N) Min. 55 lbf (196 N) (20 kgf)

Tightening torque for back plate mounting bolts ft/lbs(Nm)

181 - 228 ft/lbs(245 - 309 Nm) (25 - 31.5 kgfm)

Load

ing

equi

pmen

t Forks Fork thickness (at base of forks) in.(mm)

FG40Z:Min. 1.77 in. (45 mm)

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

Chain Length over 17 links Max. 440 (17.3 in.)

Hydraulic system Relief pressure PSI (MPa) 2,610.7 PSI (18 MPa) (185 kgf/cm2)

21. SERVICE DATA

3-9

21. SERVICE DATA21.2 SERVICE DATA (DIESEL ENGINE LIFT TRUCKS)

Component Inspection item Unit of Measure FD40/45/50, FD40Z

Engi

ne

Engine proper

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

Idling speed rpm 675 - 725

Maximum speed rpm 2,300 - 2,400

CompressionPSI

MPa/rpmkgf/cm2

486 psi / 280 - 320 rpm3.35 MPa / 280 - 320 rpm

(36 kgf/cm2 / 280 -320 rpm

Lubricating oilcooling system Fan belt deflection in. (mm)

0.24 - 0.39 in.(6 - 10 mm)

(finger pressure: 17.8 lbf, 79N, 8 kgf)

Fuel system

Injection timing (at idle) BTDCo 1° ATDC (injection pump cam lift 1 mm)

Injection order -- 1 - 5 - 3 - 6 - 2 - 4

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

Intake / exhaust system

Valve clearance

Intake in. (mm) 0.0098 in. (0.25 mm) Cool

Exhaust in. (mm) 0.020 in. (0.51 mm) Cool

21. SERVICE DATA

3-10

21.2 SERVICE DATA (DIESEL ENGINE LIFT TRUCKS) (Continued)

Component Inspection item Unit of Measure FD40/45/50, FD40Z

Trav

el s

yste

m

Tires Tire inflation pressureFront wheels PSI

(MPa)

250-15-16PR: 120 PSI (0.83) (8.5 kgf/cm2)8.25-15-12PR: 98 PSI (0.68) (7.0 kgf/cm2)300-15-18PR: 113 PSI (0.78) (8.0 kgf/cm2)

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

Lug nuts Tightening torqueFront wheels

ft/lbsNm

217 - 361 ft/lbs(294 - 490 Nm) (30 - 50 kgfm, Rear wheels

Rim mating nuts Tightening torque

Front wheels --

Rear wheels 145 - 217 ft/lbs(196 - 294 Nm) (20.0 - 30.0 kgfm)

Stee

ring,

bra

king

sys

tem

Steering wheel Playin.

(mm)

1.2 - 2.4 in. (30 - 60 mm)

Inching pedalPlay 0.08 - 0.12 in. (2 - 3 mm)

Interconnected travel 1.38 - 1.41 in. (35 - 41 mm)

Brake pedalPlay in.

(mm)

0.12 - 0.28 in. (3 - 7 mm)

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

Brake

Parking brake operating force lbf(N) Min. 55 lbf (196 N) (20 kgf)

Tightening torque for back plate mounting bolts ft/lbs (Nm)

181 - 228 ft/lbs(245 - 309 Nm) (25 - 31.5 kgfm)

Load

ing

equi

pmen

t Forks Fork thickness (at base of forks) in. (mm)

FD40Z:Min.1.77 in. (45 mm)

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

Chain Length over 17 links Max. 440 (17.3 in.)

Hydraulic system Relief pressure PSI (MPa)

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

21. SERVICE DATA

3-11

21. SERVICE DATA21.3 TORQUE LIST

For unspecified bolts and nuts, use the torque specificationsin this list.Select the proper torque corresponding to the width acrossflats (b) of bolts and nuts.When replacing bolts and nuts, always use genuine KomatsuLift Truck parts that match the previous installation in size.

Thread diameterof bolt (mm)

(a)

Width acrossflat (mm)

(b)

Tightening torque

ft/lbs kgfm Nm

68

101214

1013171922

9.73 + 1.0323.2 + 2.148.5 + 5.082.6 + 7.2131 + 14

1.35 + 0.153.2 + 0.36.7 + 0.711.5 + 1.018.0 + 2.0

13.2 + 1.431.4 + 2.965.7 + 6.8112 + 9.8177 + 19

1618202224

2427303236

206 + 21282 + 29405 + 43549 + 58684 + 72

28.5 + 339 + 356 + 676 + 8

94.5 + 10

279 + 29383 + 39549 + 58745 + 78927 + 98

2730333639

4148505560

973 + 1001,270 + 1401,630 + 1802,030 + 2102,420 + 250

135 + 15175 + 20225 + 25280 + 30335 + 35

1,320 + 1401,720 + 1902,210 + 2402,750 + 2903,280 + 340

22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

3-12

22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTSTo ensure safety at all times when operating or driving the lift truck, the lift truck user must always carry out periodicmaintenance. In addition, to further improve safety, the user should also perform periodic replacement of partsgiven in the table below. These parts, in particular, are closely relate to safety and fire prevention.

The material of these parts may change over time, or they may easily wear or deteriorate. However, it is difficult tojudge the condition of these parts simply by periodic maintenance. The parts listed should always be replaced aftera fixed, specified time has passed, regardless of their condition. This is necessary to ensure that these parts main-tain their full function at all times.Note that if these parts show any abnormality before the replacement interval has passed, they should be repairedor replaced immediately.

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

Note that this periodic replacement is not covered by warranty.

IMPORTANT PARTS LIST

No. Part name Years elapsed

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

2 Brake hose or tube 1 - 2

3 Power steering hose 2

4 Stop lamp switch (hydraulic type) 2 - 4

5 Fuel hose 2

6 Rubber parts inside power steering system 2

7 Lift chain 2 - 4

8 Hydraulic hose for lifting mechanism 1 - 2

23. MAINTENANCE SCHEDULE CHART

3-13

23. MAINTENANCE SCHEDULE CHARTPerform maintenance at intervals of months or operation hours, whichever occurs first.

Service Item Page

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

Change oil in hydraulic tank, replace line filter, clean strainer, clean inside of tank 3-17

Change oil in engine oil pan 3-17

Replace engine oil filter cartridge 3-17

Check, adjust engine valve clearance 3-17

Tighten (retorque) engine cylinder head bolts 3-17

Clean TORQFLOW transmission strainer 3-17

Change oil in differential case 3-17

Change oil in TORQFLOW transmission case 3-17

Tighten bolts and nuts (especially lug nuts, overhead guard, load backrest operator’s seat mounting bolts and nuts) 3-17

Check before operation items (for details, see “15.1 CHECK BEFORE OPERATION”) 3-17

Every 2 weeks or every 100 hours service

Grease lift chain 3-17

Every month or every 200 hours service

Check wheel rims for deformation, cracking and damage 3-17

Check wheel bearings for play and abnormal noise 3-17

Check hydraulic cylinders for looseness, deformation, cracking, damage and wear 3-17

Check all piping/tubing/connectors for oil leakage, deformation or damage 3-17

Check operation of hydraulic cylinders 3-18

Check hydraulic drift of lift cylinder 3-18

Check hydraulic drift of tilt cylinders 3-18

Check movement of work equipment control lever(s) 3-18

Check forks and fork stopper for deformation, cracking, damage and wear 3-18

Check forks for unevenness and twisting 3-18

Check mast for deformation, cracking, damage and wear 3-18

Check mast roller for play 3-18

Check chain and chain wheel for deformation, damage, rust and poor lubrication 3-18

Check chain wheel bearing for play 3-18

Check chain anchor bolt for deformation and damage 3-18

Check gear box for oil leakage, looseness of mount 3-18

23. MAINTENANCE SCHEDULE CHART

3-14

Service Items (continued) Page

Every month or every 200 hours service (continued)

Check mounting condition of power steering, check for looseness at connections 3-18

Check brake link for play, looseness, damage and wear 3-18

Check brake piping/tubing for damage, leakage, looseness, contact, looseness of brake tubing clips and disconnec-tion at fittings 3-18

Check clearance between brake drum and lining, check brake for grabbing, dragging or pulling 3-19

Check shift lever for play, meshing 3-19

Check for oil leakage from transmission and differential cases 3-19

Check oil level in TORQFLOW transmission, add oil as necessary (Do not overfill) 3-19

Check pedal height when inching pedal is depressed 3-19

Check starting of engine 3-19

Check idling speed (Gasoline and LPG) 3-19

Check, clean radiator fins, check for damage 3-19

Check for catching, stalling and knocking when accelerating 3-19

Check and clean air cleaner element 3-20

Check operation of governor (maximum speed) 3-20

Check piping/tubing and connections/fittings for fuel/gas leakage 3-20

Check fuel filter and fuel strainer for cracking, damageCheck and drain water separator (diesel engine lift trucks) 3-20

Check radiator hoses for cracking, damage 3-21

Check operating condition of radiator cap, check installation 3-21

Check fan for deformation, cracking, and damage 3-21

Check fan for looseness and mounting 3-21

Check, adjust fan belt tension 3-21

Check, adjust alternator belt tension 3-21

Check distributor cap (gasoline), distributor inside (IC ignition system) for cracking or damage 3-21

Check clearance of distributor points, check contact surface for roughness 3-21

Check spark plugs for burning, burning of insulator 3-21

Change oil in engine oil pan (Gasoline and LPG trucks with TB42 engines) 3-21

Replace engine oil filter (TB42) 3-21

Replace fuel filter (TB42) 3-22

Check spark plugs (TB42) 3-22

Change governor oil (TB42) 3-22

Change oil in engine oil pan (Diesel engine trucks with 6D102E engines) 3-23

23. MAINTENANCE SCHEDULE CHART

3-15

Every month or every 200 hours service (continued)

Replace engine oil filter (6D102E) 3-23

Drain water from fuel filter (6D102E) 3-24

Replace fuel filter (6D102E) 3-24

Check operation of starting switch; check meshing of pinion gear 3-25

Check specific gravity of battery electrolyte 3-25

Check wiring connections for looseness 3-25

Check ignition timing 3-25

Check overhead guard, load backrest for deformation, cracking, damage and looseness 3-25

Check operator’s seat mount for looseness and damage; Check LPG cylinder mounting bracket 3-25

Grease all lubrication points 3-26

Every 3 months or every 600 hours service

Drain water from water separator and replace fuel filter cartridge (diesel engine lift trucks) 3-26

Replace oil filter cartridge 3-26

Grease fuel injection pump governor, change governor oil 3-26

Check oil level in transmission case, add oil as necessary 3-26

Check oil level in differential case, add oil as necessary 3-26

Every 6 months or every 1,200 hours service

Check steering link for bending, damage and wear 3-26

Check knuckle for play, deformation and damage 3-26

Check for marked variation in minimum turning radius 3-26

Change oil in differential case 3-27

Change oil in TORQFLOW transmission case 3-28

Replace torque converter oil filter 3-28

Change brake oil/fluid 3-28

Check, adjust valve clearance 3-28

Measure compression pressure 3-28

Check, adjust fuel injection timing, check and inspect fuel injection nozzles (diesel) 3-29

Check PCV blow-by gas reduction system for clogging, damage 3-29

Check distributor cap centerpiece for wear 3-29

Replace fuel filter element 3-29

Clean inside of cooling system; Clean radiator 3-29

Replace air cleaner element 3-30

Change oil in hydraulic tank, replace hydraulic line filter, clean hydraulic tank strainer, clean inside of hydraulic tank 3-31

Service Items (continued) Page

23. MAINTENANCE SCHEDULE CHART

3-16

Every 2,000 hours of service

Replace LPG mixer air valve diaphragm, under normal operating conditions. Replace more often in cold or severe service applications. Replace O-ring for LPG tank valve. 3-31

Every 2,000 hours of service

Replace LPG mixer air valve diaphragm (normal operating conditions). Replace more often in cold or severe service applications. Replace O-ring for LPG tank valve. 3-31

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

Check operation of brake master cylinder, check for oil leakage, damage and wear 3-31

Check operation of wheel cylinders, check for oil leakage, damage and wear 3-31

Check operation of brake drum, check for damage and wear 3-31

Check brake linings for wear 3-31

Check operating condition of brake shoe 3-31

Check brake adjustment lever and ratchet for wear and damage 3-31

Check brake spring for deterioration 3-31

Check brake back plate for deformation and cracking; Check mounting condition 3-32

Check air tightness of brake piping/tubing 3-32

Check axle for deformation, cracking and damage 3-32

Check mounting condition of differential 3-32

Check root (base) of forks for cracking (use color check) 3-32

Check roller shaft of loading equipment for cracking and damage 3-32

Check mast support for damage and wear 3-32

Check operation of relief valve; Check relief pressure 3-32

Replace air breather 3-32

Replace water separator (diesel); Clean inside of fuel tank (gasoline/LPG and diesel lift trucks) 3-32

Check fuel injection pressure, injection amount, injector condition 3-32

Tighten (retorque) engine cylinder head bolts 3-32

Check frame and cross member for cracking and damage 3-32

24. MAINTENANCE

3-17

24. MAINTENANCE24.1 FIRST MONTH OR INITIAL 200 HOURS SERVICECarry out this maintenance, for new lift trucks only, after the first one month or initial 200 hours of operation, whichever comes sooner.

(Hydraulic equipment)24.1.1 CHANGE OIL IN HYDRAULIC TANK, REPLACE LINE FILTER, CLEAN STRAINER, CLEAN INSIDE

OF TANKFor details on replacing and cleaning, see “24.6.16 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULICLINE FILTER, CLEAN HYDRAULIC TANK STRAINER, CLEAN INSIDE OF HYDRAULIC TANK”.

(Engine)24.1.2 CHANGE OIL IN ENGINE OIL PANFor details on changing the oil, see “24.4.42.1 CHANGE OIL IN ENGINE OIL PAN”.

24.1.3 REPLACE ENGINE OIL FILTER CARTRIDGEFor details on replacing the engine oil filter cartridge, see “24.4.42.2 REPLACE ENGINE OIL FILTER”.

24.1.4 CHECK, ADJUST ENGINE VALVE CLEARANCE

24.1.5 TIGHTEN (RETORQUE) ENGINE CYLINDER HEAD BOLTS

(Power train)24.1.6 CLEAN TORQFLOW TRANSMISSION STRAINER

24.1.7 CHANGE OIL IN DIFFERENTIAL CASE For details on changing the oil, see “24.6.4 CHANGE OIL IN DIFFERENTIAL CASE”.

24.1.8 CHANGE OIL IN TORQFLOW TRANSMISSION CASEFor details on changing the oil, see “24.6.5 CHANGE OIL IN TORQFLOW TRANSMISSION CASE”.

(General)24.1.9 TIGHTEN BOLTS AND NUTS (ESPECIALLY LUG NUTS, OVERHEAD GUARD, LOAD BACKREST

AND OPERATOR’S SEAT MOUNTING BOLTS AND NUTS)

24.2 CHECK BEFORE OPERATIONFor details, see “15.1 CHECK BEFORE OPERATION”.

24.3 EVERY 2 WEEKS OR EVERY 100 HOURS SERVICE

(Loading equipment)24.3.1 GREASE LIFT CHAIN

24.4 EVERY MONTH OR EVERY 200 HOURS SERVICE

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

24.4.2 CHECK WHEEL BEARINGS FOR PLAY AND ABNORMAL NOISE

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

AND WEAR

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

24. MAINTENANCE

3-18

24.4.5 CHECK OPERATION OF HYDRAULIC CYLINDERS

24.4.6 CHECK HYDRAULIC DRIFT OF LIFT CYLINDER

24.4.7 CHECK HYDRAULIC DRIFT OF TILT CYLINDERS

24.4.8 CHECK MOVEMENT OF WORK EQUIPMENT CONTROL LEVER(S)

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

24.4.10 CHECK FORKS FOR UNEVENNESS AND TWISTING

24.4.11 CHECK MAST FOR DEFORMATION, CRACKING, DAMAGE AND WEAR

24.4.12 CHECK MAST ROLLER FOR PLAY

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

24.4.14 CHECK CHAIN WHEEL BEARING FOR PLAY

24.4.15 CHECK CHAIN ANCHOR BOLT FOR DEFORMATION AND DAMAGE

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

24.4.17 CHECK MOUNTING CONDITION OF POWER STEERING, CHECK FOR LOOSENESS AT CONNECTIONS

24.4.18 CHECK BRAKE LINK FOR PLAY, LOOSENESS, DAMAGE AND WEAR

Checking1. Check the play and the height of the brake pedal when it is

depressed to check that it matches the specified values.

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

24.4.19 CHECK BRAKE PIPING/TUBING FOR DAMAGE, LEAKAGE, LOOSENESS, CONTACT, LOOSENESS OF BRAKE TUBING CLIPS AND DISCONNECTION AT FITTINGS

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

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

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

24. MAINTENANCE

3-19

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

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

24.4.22 CHECK FOR OIL LEAKAGE FROM TRANSMISSION AND DIFFERENTIAL CASES

24.4.23 CHECK OIL LEVEL IN TORQFLOW TRANSMISSION, ADD OIL AS NECESSARYFor details on checking the oil level and adding oil, see “24.6.5 CHANGE OIL IN TORQFLOW TRANSMISSIONCASE”.

24.4.24 CHECK PEDAL HEIGHT WHEN INCHING PEDAL IS DEPRESSED

(Engine)24.4.25 CHECK STARTING OF ENGINE

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

24.4.27 CHECK, CLEAN RADIATOR FINS, CHECK FOR DAMAGE

Cleaning

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

Testing

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

24.4.28 CHECK FOR CATCHING, STALLING AND KNOCKING WHEN ACCELERATING

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

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

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

24. MAINTENANCE

3-20

(Engine continued)24.4.29 CHECK AND CLEAN AIR CLEANER ELEMENT

• If oil, grease or carbon is stuck to the element, clean the elementwith special element cleaner. Follow the instructions providedwith the cleaner.

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

• In heavy-duty operating environments or conditions, clean andreplace the element more frequently.

Cleaning1. Remove the element, blow the element from the inside with

dry compressed air at 98 PSI (0.68 MPa) (7 kgf/cm2) and cleanthe entire circumference.

2. After cleaning, reinstall the element.

TestingCheck visually that there is no damage to the element.

24.4.30 CHECK OPERATION OF GOVERNOR(MAXIMUM SPEED)

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

24.4.32 CHECK FUEL FILTER AND FUEL STRAINER FOR CRACKING, DAMAGECHECK AND DRAIN WATER SEPARATOR (DIESEL ENGINE LIFT TRUCKS)

NOTICE

Always wear safety goggles when using compressedair.

24. MAINTENANCE

3-21

(Engine continued)24.4.33 CHECK RADIATOR HOSES FOR CRACKING, DAMAGE

24.4.34 CHECK OPERATING CONDITION OF RADIATOR CAP, CHECK INSTALLATION

24.4.35 CHECK FAN FOR DEFORMATION, CRACKING AND DAMAGE

24.4.36 CHECK FAN FOR LOOSENESS AND MOUNTING

24.4.37 CHECK, ADJUST FAN BELT TENSION

24.4.38 CHECK, ADJUST ALTERNATOR BELT TENSION

24.4.39 CHECK DISTRIBUTOR CAP (GASOLINE), DISTRIBUTOR INSIDE (IC IGNITION SYSTEM) FOR CRACKING OR DAMAGE

24.4.40 CHECK CLEARANCE OF DISTRIBUTOR POINTS, CHECK CONTACT SURFACE FOR ROUGHNESS

24.4.41 CHECK SPARK PLUGS FOR BURNING, BURNING OF INSULATORFor details on checking spark plugs / insulators, see “24.4.42.4 CHANGE OIL IN ENGINE OIL PAN”.

24.4.42 CHANGE OIL IN ENGINE OIL PAN

GASOLINE/LPG ENGINE (TB42)

Callout numbers in illustration match numbered headings here.1. CHANGE ENGINE OIL (See item 1 for filler location)1. Remove the drain plug, drain the oil, then reinstall and

tighten the drain plug.

2. Add the correct amount of specified engine oil.

3. Check the oil level with the dipstick.

Oil refill amount: 2.05 U.S. GALLONS (7.8 L, 1.72 UK gal.)

2. REPLACE ENGINE OIL FILTER (See item 2 for location)1. Use a filter wrench to remove the oil filter cartridge.

2. Clean the filter holder on the engine.

3. Coat the threads on the holder and the seal on the new filter with clean engine oil.

4. Install the new filter.

NOTICE

NOTICE

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

24. MAINTENANCE

3-22

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

3. REPLACE FUEL FILTER

1. Loosen the nut, remove the glass bowl and take out the filter element.

2. Drain out any water and clean out any dirt accumulated at the bottom.

3. Install the new specified fuel filter element.

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

4. CHECK SPARK PLUGS (See also item 4 in illustration on page 3-21 for location)

1. Remove the spark plug using the plug wrench provided with the lift truck.

2. Clean off any carbon buildup on the tip of the plug or thesurrounding area. See illustration at right.

3. Measure gap (A) with plug gap gauge.

5. CHANGE THE GOVERNOR OIL

1. Loosen the drain plug and drain the oil, then install and tighten the drain plug.

2. Remove the oil filler plug and oil level plug.

3. Add oil through the oil filler hole until oil flows from the oil level hole, then install the oil filler plug and oil level plug.

Use the same oil as used in the oil pan. (Capacity: 35 - 40 cc).

4. Tighten oil filler plug and oil level plug.

NOTICE

NOTICE

Specified spark plugs

NGK B-4ESBPR-4ES (Noise suppression type)

Hitachi L47W

NOTICE

24. MAINTENANCE

3-23

DIESEL ENGINE (6D102E )

Callout numbers in illustration match numbered headings shown below.

1. CHANGE ENGINE OIL (see item 1 for filler location)

1. Remove the drain plug, drain the oil, then reinstall andtighten the drain plug.

2. Remove the dipstick.

3. Add the specified amount of engine oil. Use care to prevent oil overflow.

4. Check the oil level with the dipstick.

Oil refill amount: 3.04 U.S. gallons (11.5 L, 2.53 UK gal.)

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

1. Use a filter wrench to remove the oil filter cartridge.

2. Clean the oil filter holder.

3. Coat the threads of the holder and the new filter seal withclean engine oil.

4. Install the new oil filter cartridge.

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

NOTICE

NOTICE

NOTICE

24. MAINTENANCE

3-24

(Engine continued)3. DRAIN WATER FROM FUEL FILTER (see also item 3 in

illustration on page 3-23 for location)

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

• Fuel will also drain out of the fuel filter, so prepare a suitable container to catch it.

• Always be sure to wipe up any spilled fuel.

4. REPLACE FUEL FILTER (See also item 4 in illustration on page 3-23 for location)

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

2. Use a filter wrench to remove the cartridge.

3. Install the combination sensor plug on the new cartridge.

4. Fill the new cartridge with clean fuel, coat the packing surface with a thin layer of clean engine oil, then install.

5. Loosen plug (1), then hand-pump knob (2) up and downto bleed air bubbles from fuel. Continue until no more bubbles come out with the fuel.

6. Tighten plug (1).

NOTICE

24. MAINTENANCE

3-25

(Electrical components)24.4.43 CHECK OPERATION OF STARTING SWITCH; CHECK MESHING OF PINION GEAR

24.4.44 CHECK SPECIFIC GRAVITY OF BATTERY ELECTROLYTE

CHECK SPECIFIC GRAVITY OF BATTERY ELECTROLYTE

1. Charge the battery, and after charging, check that the battery electrolyte level is correct.

2. Using a specific gravity meter and thermometer, measurethe specific gravity and temperature of the battery electrolyte.

3. Insert the values measured in Steps 1 and 2 in the formulabelow, and calculate S20.S20 = St + 0.0007 (t - 20)

S20: Specific gravity at 68°F (20oC)St: Specific gravity (measured value) at toCt: Temperature of battery electrolyte (measured value)

Normal value: S20 = 1.27 - 1.29

4. Charge the battery if necessary.

Relation between specific gravityand temperature of electrolyte

24.4.45 CHECK WIRING CONNECTIONS FOR LOOSENESS

24.4.46 CHECK IGNITION TIMING

(General)24.4.47 CHECK OVERHEAD GUARD, LOAD BACKREST FOR DEFORMATION, CRACKING,

DAMAGE AND LOOSENESS

24.4.48 CHECK OPERATOR’S SEAT MOUNT FOR LOOSENESS AND DAMAGE,CHECK LPG CYLINDER MOUNTING BRACKET

Specific gravityof electrolyte

Condition ofcharge

Chargeneeded?

1.2801.240

Fully charged1/4 discharged No

1.2101.130

1/2 dischargedFully discharged Yes

Precautions when handling battery:• Battery electrolyte is dangerous. If it gets into your eyes or upon your skin

or clothes, wash it off with large amounts of water quickly. If it gets into your eyes, seek medical attention immediately.

• Keep away from sparks or flame.• To avoid gas explosions, do not smoke or cause short circuits or sparks near

the battery.

24. MAINTENANCE

3-26

24.4.49 GREASE ALL LUBRICATION POINTS

LUBRICATION POINTS1. Mast support (left and right: 2 points)

2. Fork stopper (left and right: 2 points)

3. Front axle support (left and right: 2 points)

4. Steering axle(a) Center pin (front and rear: 2 points)(b) P.S. cylinder rod (left and right: 2 points)(c) Knuckle joint (left and right: 2 points)(d) King pin (left and right: 4 points)

24.5 EVERY 3 MONTHS OR EVERY 600 HOURS SERVICE

24.5.1 DRAIN WATER FROM WATER SEPARATOR AND REPLACE FUEL FILTER CARTRIDGE (DIESEL ENGINE LIFT TRUCKS)

For details on draining the water and changing the filter, see “24.4.42.1 CHANGE OIL IN ENGINE OIL PAN”.

24.5.2 REPLACE OIL FILTER CARTRIDGEFor details on replacing the oil filter cartridge, see “24.4.42.2 CHANGE OIL IN ENGINE OIL PAN”.

24.5.3 GREASE FUEL INJECTION PUMP GOVERNOR, CHANGE GOVERNOR OIL

(Power train)24.5.4 CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL AS NECESSARYFor details on checking and adding oil, see “24.6.4 CHANGE OIL IN DIFFERENTIAL CASE” and “24.6.5 CHANGEOIL IN TORQFLOW TRANSMISSION CASE”.

24.5.5 CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL AS NECESSARY For details on checking and adding oil, see “24.6.4 CHANGE OIL IN DIFFERENTIAL CASE”.

24.6 EVERY 6 MONTHS OR EVERY 1,200 HOURS SERVICE

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

24.6.2 CHECK KNUCKLE FOR PLAY, DEFORMATION AND DAMAGE

24.6.3 CHECK FOR MARKED VARIATION IN MINIMUM TURNING RADIUS

24. MAINTENANCE

3-27

24.6.4 CHANGE OIL IN DIFFERENTIAL CASE

CHECK OIL LEVEL1. Remove the level plug and check that the oil is near

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

CHANGE OIL1. Remove the oil filler plug, then remove the drain plug and

drain the oil.

2. After draining the oil, reinstall and tighten the drain plug andadd the correct amount of specified oil through theoil filler.

3. After filling with new oil, check the oil level.

Always use specified gear oil (SAE 90). For details, see “20. LUBRICANT LIST”.

REMARKOn the TORQFLOW transmission lift truck, each case has its own special oil, so it is necessary to check andchange the oil in the TORQFLOW transmission case in addition to checking and changing the oil in the differentialcase in two separate operations.

Specified oil refill amount

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

NOTICE

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

24. MAINTENANCE

3-28

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

CHECK OIL LEVEL1. Remove the floor plate and check oil with dipstick.

2. If the oil level is low, remove the dipstick and add oil.

CHANGE OIL, CLEAN STRAINER1. Remove the drain plug, drain the oil, then reinstall and

tighten the drain plug.

2. Remove the mounting bolts, take out the strainer, andwash it off in flushing oil.

3. After washing the strainer, blow air from the inside of the strainer to dry it completely, then reinstall the strainer.

4. Add the specified amount of oil through the oil filler port.

5. After filling with oil, check the oil level.

Always use specified oil or DEXRON II Automatic Transmission Fluid.

24.6.6 REPLACE TORQUE CONVERTER OIL FILTER

Replace with specified oil filter.

(Brake system)24.6.7 CHANGE BRAKE OIL/FLUID

(Engine)24.6.8 CHECK AND ADJUST VALVE CLEARANCE

24.6.9 MEASURE COMPRESSION PRESSURE

Specified oil refill amount

TORQFLOW transmission(including torque converter) 3.17 U.S. gal. (12 L, 2.64 UK gal.)

NOTICE

NOTICE

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

24. MAINTENANCE

3-29

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

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

24.6.12 CHECK DISTRIBUTOR CAP CENTERPIECE FOR WEAR

24.6.13 REPLACE FUEL FILTER ELEMENTFor details on replacing the fuel filter element, see “24.4.42.3 CHANGE OIL IN ENGINE OIL PAN”.

24.6.14 CLEAN INSIDE OF COOLING SYSTEM

CLEAN RADIATORStop the lift truck on level ground.1. After the engine has cooled off, open the drain valves at the

bottom of the radiator and the engine cylinder block to drain the water/coolant mixture.

2. After draining, close the drain valves. Fill the radiator withfresh water (tap water) and radiator flushing fluid through thewater filler, then run the engine at idling for approximately 15minutes.

3. Stop the engine, open the drain valves to drain the water,then add fresh water and run the engine at idling until clean, clear water comes out of the drain valves(5 - 10 minutes).

4. Stop the engine, drain all the water from the drain valves, then close the drain valves and fill the radiator with fresh water and long-life coolant.

Water and Coolant Capacities

TB42 engine3.70 U.S. gal. (14 L, 3.08 UK gal.)

6D102E engine

• After the engine has been operated, the coolant is HOT. There is a danger of burns and injury if the cooling water is drained immediately. Always wait for the engine to cool down before draining the coolant.

• The cleaning operation is carried out with the engine running. The lift truck may move suddenly and unexpectedly, so never go under the lift truck during this operation. Never go under the lift truck when the engine is running.

• Do not remove the radiator cap when the engine and coolant is hot. Boiling water and steam may spurt out. Always wait for the temperature to go down, then turn the radiator cap slowly to release pressure gradually before removing the cap completely.

24. MAINTENANCE

3-30

(Engine continued)

• In cold areas, add long-life coolant.

(For details, see “16. COLD WEATHER OPERATION”.• When not using long-life coolant, add rust prevention fluid to the radiator.• Always use appropriate products for the flushing fluid, rust prevention fluid and long-life coolant.

24.6.15 REPLACE AIR CLEANER ELEMENT

REPLACE ELEMENT1. Remove the air cleaner element.

2. Remove the nut and take out the inner element (if equipped).

3. Cover the air connector end with a clean cloth or tape.

4. Clean the inside of the body, then remove the cover fitted in Step 3.

5. Install a new element.

NOTICE

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

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

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

• Always wear safety goggles.

24. MAINTENANCE

3-31

(Hydraulic equipment)24.6.16 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC LINE FILTER, CLEAN HYDRAULIC

TANK STRAINER, CLEAN INSIDE OF HYDRAULIC TANK

1. Remove the drain plug at the bottom of the tank. Then remove the cover, take out the strainer, and wash it influshing oil.

2. Clean the inside of the tank, then install the drain plug.

3. After washing the strainer, blow air from the inside of the strainer todry it completely, then reinstall the strainer.

4. Replace the line filter, then install the cover.

5. Add the specified amount of hydraulic oil through the dipstick hole,then check the oil level with the dipstick.

Refill amount: 14.53 U.S. gal. (55 L, 12.10 UK gal.)

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

Always use specified hydraulic oil.

24.7 EVERY 2,000 HOURS OF SERVICE

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

24.8 EVERY YEAR OR 2,400 HOURS OF SERVICE

24.8.1 CHECK OPERATION OF BRAKE MASTER CYLINDER, CHECK FOR OIL LEAKAGE, DAMAGE AND WEAR

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

24.8.3 CHECK OPERATION OF BRAKE DRUM, CHECK FOR DAMAGE AND WEAR

24.8.4 CHECK BRAKE LININGS FOR WEAR

24.8.5 CHECK OPERATING CONDITION OF BRAKE SHOE

24.8.6 CHECK BRAKE ADJUSTMENT LEVER AND RATCHET FOR WEAR AND DAMAGE

24.8.7 CHECK BRAKE SPRING FOR DETERIORATION

NOTICE

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

24. MAINTENANCE

3-32

24.8.8 CHECK BRAKE BACK PLATE FOR DEFORMATION AND CRACKING, CHECK MOUNTING CONDITION

24.8.9 CHECK AIR TIGHTNESS OF BRAKE PIPING/TUBING

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

24.8.11 CHECK MOUNTING CONDITION OF DIFFERENTIAL

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

24.8.13 CHECK ROLLER SHAFT OF LOADING EQUIPMENT FOR CRACKING AND DAMAGE

24.8.14 CHECK MAST SUPPORT FOR DAMAGE AND WEAR

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

24.8.16 REPLACE AIR BREATHER

(Engine)24.8.17 REPLACE WATER SEPARATOR (DIESEL), CLEAN INSIDE OF FUEL TANK (GASOLINE AND

DIESEL LIFT TRUCKS)

24.8.18 CHECK FUEL INJECTION PRESSURE, INJECTION AMOUNT, INJECTOR CONDITION

24.8.19 TIGHTEN (RETORQUE) ENGINE CYLINDER HEAD BOLTS

(General)24.8.20 CHECK FRAME AND CROSSMEMBER FOR CRACKING AND DAMAGE

25. REPLACEMENT PROCEDURES

3-33

25. REPLACEMENT PROCEDURES25.1 REPLACING FUSES

• When replacing the fuses, always turn OFF the electric power (turn the starting switch to the OFF position) first.

• Always replace the fuses with a fuse of the same capacity.

The fuses are used to protect the electrical components and wiring from burning out.

1. Turn the starting switch to the OFF position.

2. Open the cover of the fuse box and replace necessary fuses inside.To remove the cover from the fuse box, push the side face of the cover lightly with your fingers and pull it out.

Check the relationship between the fuses and the electrical com-ponents when replacing.

NOTICE

Fuse capacity and related electrical component

No. Capacity Color Related electrical component

(1) 10 Amp

Red

Meters

(2) 10 Amp Back-up lamp

(3) 10 Amp Starting relay

(4) 15 Amp

Blue

Stop lamp

(5) 15 Amp Lamps

(6) 10 Amp Horn

25. REPLACEMENT PROCEDURES

3-34

25. REPLACEMENT PROCEDURES25.2 REPLACING TIRES

1. Stop the lift truck on a flat, safe area and apply the parking brake.

2. Chock the wheel diagonally across from the wheel to be replaced.

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

4. Place the jack on the jacking point and raise the lift truck up until the wheel to be replaced clears the ground.

5. Remove the lug nuts, then remove the wheel.

6. Install the replacement wheel on the hub and hand tighten the lug nuts to hold the wheel in place.

7. Tighten the lug nuts again with a lug wrench, using a diagonal “criss-cross” or star pattern, ensuring that the wheelis snugly in place, but not fully tightened.

8. Let the jack down slowly to lower the lift truck. Tighten thelug nuts to the specified torque.(For specified torque, see “21. SERVICE DATA”.)

25. REPLACEMENT PROCEDURES

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

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

Ask a tire and wheel specialist to carry out disassem-bly and assembly of tires and wheels.

25. REPLACEMENT PROCEDURES

3-35

9. Adjust the tire inflation pressure to the set pressure.(For details of the set inflation pressure, see “21. SERVICE DATA”.)

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

Lamp Function Gas Engine Trucks(12 Volt System)

Diesel Engine Trucks(24 Volt System)

Head lamp 55 W 70 W

Turn signal lamp 23 W 25 W

Driving (clearance) lamp 8 W 5 W

Stop lamp 27 W

Back-up lamp 8 W

Warning lamp 1.4 W

Meter lighting lamp 3.4 W 3 W

• Always ask a specialist to carry out disassembly of the tires, tubes and rims, and for inflation of the tires. The tires used on forklift trucks are at a high inflation pressure, so operations with tires are extremely dangerous.

• The tires are inflated to a high pressure, so deformed or cracked rims are extremely dangerous.Check carefully before inflating tires. NEVER use tires with deformed or cracked rims.

• Before inflating the tires, adjust the pressure of the air compressor to the correct set pressure so that the tires are not inflated above the set pressure.