MAINTENANCE

READ AND FOLLOW ALL SAFETY PRECAU-

TIONS. FAILURE TO DO SO MAY RESULT IN
SERIOUS INJURY OR DEATH.

3-1
19. OUTLINE OF SERVICE
19. OUTLINE OF SERVICE
Use Komatsu Forklift specified parts and lubricants for replacement.

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

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

Item Type of fluid

Differential case SAE 90

Hydraulic tank SAE 10W-CD

TORQFLOW transmission case SAE 10W-CD

Cooling system Coolant (FAF-NAC)

19.1 SUITABLE OIL

19.1.1 OIL
Since the oil is used for the work equipment, etc., under severe conditions (at high temperature and high 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 a
Komatsu Forklift Truck dealer/distributor.

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

3-2
 19. OUTLINE OF SERVICE

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

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

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

3-3
 20. LUBRICANT LIST
20. LUBRICANT LIST
20.1 GASOLINE/LPG ENGINE LIFT TRUCKS
(FG35/40/45/50-7, FG40Z-7)

NOTICE

Always use specified oil and grease.

Never use the incorrect kind of brake fluid.

Use specified DOT 3 brake fluid.

Ambient Temperature
Lubrication
Type of Fluid Capacities
Points -4 14 32 50 68 86F
-20 -10 0 10 20 30C

Engine oil 2.06 US gallons

Engine oil pan
(SAE 30W-CD) 7.8 L, 1.72 UK gal.

TORQFLOW
DEXRON Automatic 4.22 U.S. gallons
transmission
transmission fluid 16 L, 3.52 UK gal.
case

Gear oil (SAE80W)

TORQFLOW transmission:
Differential
3.43 U.S. gallons
case
13 L, 2.86 UK gal.
Gear oil (SAE90W)

Hydraulic oil 14.53 U.S. gallons

Hydraulic tank
ISO # 32 55 L, 12.10 UK gal.

FG30/40/45/50
Gasoline
26.4 U.S. gal.
87 Octane (recommended)
Fuel tank 100 L, 22.0 UK gal.
LPG
FG40Z
107 Octane Propane
21.1 U.S. gal, 80 L, 17.6 UK gal.

0.040 U.S. gal.

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

Lithium grease
Greasing points
(NLGI No.2)

Coolant
(FAF-NAC) 3.7 U.S. gal.
Cooling system Add antifreeze at ambient 14 l, 3.08 UK gal.
temp 32F/0C or below

3-4
 20. LUBRICANT LIST
20. LUBRICANT LIST
20.2 DIESEL ENGINE LIFT TRUCKS
(FD40/45/50-7, FD40Z-7)

NOTICE

Never use fuel mixed with kerosene.

Always use specified oil and grease.

Never use the incorrect kind of brake fluid.

Use specified DOT 3 brake fluid.

Ambient Temperature
Lubrication
Type of Fluid Capacities
Points -4 14 32 50 68 86F
-20 -10 0 10 20 30C

Engine oil
(SAE 10W) 3.04 U.S. gal.
Engine oil pan
11.5 l, 2.53 UK gal.
(SAE 30W)

TORQFLOW
DEXRON Automatic 4.22 U.S. gal.
transmission
transmission fluid 16 L, 3.52 UK gal.
case

Gear oil (SAE80W) TORQFLOW

transmission:
Differential case
3.43 U.S. gal.
Gear oil (SAE90W) 13 L, 2.86 UK gal.

Hydraulic oil 14.53 U.S. gal.

Hydraulic tank
ISO # 32 55 L, 12.10 UK gal.

FD40/45/50
Diesel fuel 26.4 U.S. gal.
ASTM D975 No. 2 100 L, 22.0 UK gal.
Fuel tank
FD40Z
ASTM D975 No. 1 21.1 U.S. gal, 80 L
17.6 UK gal.

0.040 U.S. gal.

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

Lithium grease
Greasing points
(NLGI No.2)

Coolant
(FAF-NAC) 3.7 U.S. gal.
Cooling system Add antifreeze at ambient 14 L, 3.08 UK gal.
temp 32F/0C or below

3-5
20. LUBRICANT LIST
20. LUBRICANT LIST
20.3 OIL AND GREASING CHART (OIL, GREASE LOCATIONS AND
INSPECTION AND MAINTENANCE INTERVALS)

Chart symbol Type of fluid

Automatic transmission fluid

AF
(As specified / Dexron II)

Diesel engine oil

EO
Gasoline engine oil

GO Gear oil

HO Hydraulic oil

Brake fluid
BF
(As specified / DOT 3)

G Grease

3-6
 21. SERVICE DATA
21. SERVICE DATA
21.1 SERVICE DATA (GASOLINE/LPG ENGINE LIFT TRUCKS)

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

Engine model -- NISSAN TB42

Idling speed rpm 850 - 900

Engine Maximum speed rpm 2,300 -2,400

PSI / rpm 170 PSI / 200 rpm

Compression MPa/rpm 1.2MPa / 200 rpm
kgf/cm2 12 kgf/cm2 / 200 rpm

Lubricating oil lbf 0.59 - 0.67 in.

Fan belt deflection
cooling system mm 11 - 17 mm
(finger pressure: 22 lbf, 98N, 10 kgf)

Injection timing BTDCo --

Engine

Fuel system Injection order -- --

Injection pressure MPa --

Intake / exhaust Valve Intake in. (mm) 0.015 in. (0.38) Warm
system clearance
Exhaust in. (mm) 0.015 in. (0.38) Warm

Distributor point gap mm --

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

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

Spark plug type --
Hitachi: L47W
Electric system
Ignition timing (gasoline) 7 / 700 rpm
BTDCo/
Ignition timing (LPG) rpm 12 / 700 rpm

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

3-7
21. SERVICE DATA

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

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

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

Front wheels 8.25-15-12PR: 98 PSI, 0.68 (7.0 kgf/cm2)
PSI
Tires Tire inflation pressure 300-15-18PR: 113 PSI, 0.78 (8.0 kgf/cm2)
MPa
Travel system

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

Front wheels 217 - 361 ft/lbs

Lug nuts Tightening torque
294 - 490 (30 - 50 kgfm)
Rear wheels
ft/lbs
Front wheels Nm --
Rim mating nuts Tightening torque
145 - 217 ft/lbs
Rear wheels
196 - 294 (20.0 - 30.0 kgfm,)

Steering wheel Play 1.2 - 2.4 in. (30 - 60 mm)

in.
Play 0.08 - 0.12 in. (2 - 3 mm)
Steering, braking system

Inching pedal (mm)

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

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

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

Parking brake operating force lbf (N) Min. 55 lbf (196 N) (20 kgf)
Brake ft/lbs 181 - 228 ft/lbs
Tightening torque for back plate mounting bolts
(Nm) (245 - 309 Nm) (25 - 31.5 kgfm)

FG40Z:
Min. 1.77 in. (45 mm)
Forks Fork thickness (at base of forks)
Loading equipment

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

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

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

3-8
 21. SERVICE DATA
21. SERVICE DATA
21.2 SERVICE DATA (DIESEL ENGINE LIFT TRUCKS)

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

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

Idling speed rpm 675 - 725

Maximum speed rpm 2,300 - 2,400

Engine proper
486 psi / 280 - 320 rpm
PSI
3.35 MPa / 280 - 320 rpm
Compression MPa/rpm
(36 kgf/cm2 / 280 -320 rpm
kgf/cm2
Engine

0.24 - 0.39 in.

Lubricating oil
Fan belt deflection in. (mm) (6 - 10 mm)
cooling system
(finger pressure: 17.8 lbf, 79N, 8 kgf)

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

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

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

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

Intake / exhaust Valve
system clearance Exhaust in. (mm) 0.020 in. (0.51 mm) Cool

3-9
21. SERVICE DATA

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

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

250-15-16PR: 120 PSI (0.83) (8.5 kgf/cm2)

Front wheels 8.25-15-12PR: 98 PSI (0.68) (7.0 kgf/cm2)
PSI
Tires Tire inflation pressure 300-15-18PR: 113 PSI (0.78) (8.0 kgf/cm2)
(MPa)
Travel system

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

Front wheels 217 - 361 ft/lbs

Lug nuts Tightening torque
(294 - 490 Nm) (30 - 50 kgfm,
Rear wheels
ft/lbs
Front wheels Nm --
Rim mating nuts Tightening torque
145 - 217 ft/lbs
Rear wheels
(196 - 294 Nm) (20.0 - 30.0 kgfm)

Steering wheel Play 1.2 - 2.4 in. (30 - 60 mm)

in.
Play 0.08 - 0.12 in. (2 - 3 mm)
(mm)
Steering, braking system

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

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

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

lbf
Parking brake operating force Min. 55 lbf (196 N) (20 kgf)
(N)
Brake
ft/lbs 181 - 228 ft/lbs
Tightening torque for back plate mounting bolts
(Nm) (245 - 309 Nm) (25 - 31.5 kgfm)

FD40Z:
Min.1.77 in. (45 mm)
Forks Fork thickness (at base of forks)
Loading equipment

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

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

PSI 2,610.7 PSI

Hydraulic system Relief pressure
(MPa) (18 MPa) (185 kgf/cm2)

3-10
 21. SERVICE DATA
21. SERVICE DATA
21.3 TORQUE LIST

For unspecified bolts and nuts, use the torque specifications

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

Thread diameter Width across Tightening torque

of bolt (mm) flat (mm)
(a) (b) ft/lbs kgfm Nm

6 10 9.73 + 1.03 1.35 + 0.15 13.2 + 1.4

8 13 23.2 + 2.1 3.2 + 0.3 31.4 + 2.9
10 17 48.5 + 5.0 6.7 + 0.7 65.7 + 6.8
12 19 82.6 + 7.2 11.5 + 1.0 112 + 9.8
14 22 131 + 14 18.0 + 2.0 177 + 19

16 24 206 + 21 28.5 + 3 279 + 29

18 27 282 + 29 39 + 3 383 + 39
20 30 405 + 43 56 + 6 549 + 58
22 32 549 + 58 76 + 8 745 + 78
24 36 684 + 72 94.5 + 10 927 + 98

27 41 973 + 100 135 + 15 1,320 + 140

30 48 1,270 + 140 175 + 20 1,720 + 190
33 50 1,630 + 180 225 + 25 2,210 + 240
36 55 2,030 + 210 280 + 30 2,750 + 290
39 60 2,420 + 250 335 + 35 3,280 + 340

3-11
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
To ensure safety at all times when operating or driving the lift truck, the lift truck user must always carry out periodic
maintenance. In addition, to further improve safety, the user should also perform periodic replacement of parts
given in the table below. These parts, in particular, are closely relate to safety and fire prevention.

The material of these parts may change over time, or they may easily wear or deteriorate. However, it is difficult to
judge the condition of these parts simply by periodic maintenance. The parts listed should always be replaced after
a fixed, specified time has passed, regardless of their condition. This is necessary to ensure that these parts 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 repaired
or replaced immediately.

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

Note that this periodic replacement is not covered by warranty.

IMPORTANT PARTS LIST

No. Part name Years elapsed

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

3-12
 23. MAINTENANCE SCHEDULE CHART
23. MAINTENANCE SCHEDULE CHART
Perform maintenance at intervals of months or operation hours, whichever occurs first.

Service Item Page

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

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

Change oil in engine oil pan 3-17

Replace engine oil filter cartridge 3-17

Check, adjust engine valve clearance 3-17

Tighten (retorque) engine cylinder head bolts 3-17

Clean TORQFLOW transmission strainer 3-17

Change oil in differential case 3-17

Change oil in TORQFLOW transmission case 3-17

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

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

Every 2 weeks or every 100 hours service

Grease lift chain 3-17

Every month or every 200 hours service

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

Check wheel bearings for play and abnormal noise 3-17

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

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

Check operation of hydraulic cylinders 3-18

Check hydraulic drift of lift cylinder 3-18

Check hydraulic drift of tilt cylinders 3-18

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

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

Check forks for unevenness and twisting 3-18

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

Check mast roller for play 3-18

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

Check chain wheel bearing for play 3-18

Check chain anchor bolt for deformation and damage 3-18

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

3-13
23. MAINTENANCE SCHEDULE CHART

Service Items (continued) Page

Every month or every 200 hours service (continued)

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

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

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

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

Check shift lever for play, meshing 3-19

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

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

Check pedal height when inching pedal is depressed 3-19

Check starting of engine 3-19

Check idling speed (Gasoline and LPG) 3-19

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

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

Check and clean air cleaner element 3-20

Check operation of governor (maximum speed) 3-20

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

Check fuel filter and fuel strainer for cracking, damage

3-20
Check and drain water separator (diesel engine lift trucks)

Check radiator hoses for cracking, damage 3-21

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

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

Check fan for looseness and mounting 3-21

Check, adjust fan belt tension 3-21

Check, adjust alternator belt tension 3-21

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

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

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

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

Replace engine oil filter (TB42) 3-21

Replace fuel filter (TB42) 3-22

Check spark plugs (TB42) 3-22

Change governor oil (TB42) 3-22

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

3-14
 23. MAINTENANCE SCHEDULE CHART
Service Items (continued) Page

Every month or every 200 hours service (continued)

Replace engine oil filter (6D102E) 3-23

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

Replace fuel filter (6D102E) 3-24

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

Check specific gravity of battery electrolyte 3-25

Check wiring connections for looseness 3-25

Check ignition timing 3-25

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

Check operators seat mount for looseness and damage; Check LPG cylinder mounting bracket 3-25

Grease all lubrication points 3-26

Every 3 months or every 600 hours service

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

Replace oil filter cartridge 3-26

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

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

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

Every 6 months or every 1,200 hours service

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

Check knuckle for play, deformation and damage 3-26

Check for marked variation in minimum turning radius 3-26

Change oil in differential case 3-27

Change oil in TORQFLOW transmission case 3-28

Replace torque converter oil filter 3-28

Change brake oil/fluid 3-28

Check, adjust valve clearance 3-28

Measure compression pressure 3-28

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

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

Check distributor cap centerpiece for wear 3-29

Replace fuel filter element 3-29

Clean inside of cooling system; Clean radiator 3-29

Replace air cleaner element 3-30

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

3-15
23. MAINTENANCE SCHEDULE CHART

Every 2,000 hours of service

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

Every 2,000 hours of service

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

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

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

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

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

Check brake linings for wear 3-31

Check operating condition of brake shoe 3-31

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

Check brake spring for deterioration 3-31

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

Check air tightness of brake piping/tubing 3-32

Check axle for deformation, cracking and damage 3-32

Check mounting condition of differential 3-32

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

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

Check mast support for damage and wear 3-32

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

Replace air breather 3-32

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

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

Tighten (retorque) engine cylinder head bolts 3-32

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

3-16
 24. MAINTENANCE
24. MAINTENANCE
24.1 FIRST MONTH OR INITIAL 200 HOURS SERVICE
Carry out this maintenance, for new lift trucks only, after the first one month or initial 200 hours of operation,
whichever comes sooner.

(Hydraulic equipment)
24.1.1 CHANGE OIL IN HYDRAULIC TANK, REPLACE LINE FILTER, CLEAN STRAINER, CLEAN INSIDE
OF TANK
For details on replacing and cleaning, see 24.6.16 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC
LINE FILTER, CLEAN HYDRAULIC TANK STRAINER, CLEAN INSIDE OF HYDRAULIC TANK.

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

24.1.3 REPLACE ENGINE OIL FILTER CARTRIDGE

For details on replacing the engine oil filter cartridge, see 24.4.42.2 REPLACE ENGINE OIL FILTER.

24.1.4 CHECK, ADJUST ENGINE VALVE CLEARANCE

24.1.5 TIGHTEN (RETORQUE) ENGINE CYLINDER HEAD BOLTS

(Power train)
24.1.6 CLEAN TORQFLOW TRANSMISSION STRAINER

24.1.7 CHANGE OIL IN DIFFERENTIAL CASE

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

24.1.8 CHANGE OIL IN TORQFLOW TRANSMISSION CASE

For details on changing the oil, see 24.6.5 CHANGE OIL IN TORQFLOW TRANSMISSION CASE.

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

24.2 CHECK BEFORE OPERATION

For details, see 15.1 CHECK BEFORE OPERATION.

24.3 EVERY 2 WEEKS OR EVERY 100 HOURS SERVICE

(Loading equipment)
24.3.1 GREASE LIFT CHAIN

24.4 EVERY MONTH OR EVERY 200 HOURS SERVICE

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

24.4.2 CHECK WHEEL BEARINGS FOR PLAY AND ABNORMAL NOISE

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

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

3-17
24. MAINTENANCE

24.4.5 CHECK OPERATION OF HYDRAULIC CYLINDERS

24.4.6 CHECK HYDRAULIC DRIFT OF LIFT CYLINDER

24.4.7 CHECK HYDRAULIC DRIFT OF TILT CYLINDERS

24.4.8 CHECK MOVEMENT OF WORK EQUIPMENT CONTROL LEVER(S)

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

24.4.10 CHECK FORKS FOR UNEVENNESS AND TWISTING

24.4.11 CHECK MAST FOR DEFORMATION, CRACKING, DAMAGE AND WEAR

24.4.12 CHECK MAST ROLLER FOR PLAY

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

24.4.14 CHECK CHAIN WHEEL BEARING FOR PLAY

24.4.15 CHECK CHAIN ANCHOR BOLT FOR DEFORMATION AND DAMAGE

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

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

CONNECTIONS

24.4.18 CHECK BRAKE LINK FOR PLAY, LOOSENESS,

DAMAGE AND WEAR

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

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

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

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

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

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

LOOSENESS OF BRAKE TUBING CLIPS AND DISCONNECTION AT FITTINGS

3-18
 24. MAINTENANCE

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

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

24.4.22 CHECK FOR OIL LEAKAGE FROM TRANSMISSION AND DIFFERENTIAL CASES

24.4.23 CHECK OIL LEVEL IN TORQFLOW TRANSMISSION, ADD OIL AS NECESSARY

For details on checking the oil level and adding oil, see 24.6.5 CHANGE OIL IN TORQFLOW TRANSMISSION
CASE.

24.4.24 CHECK PEDAL HEIGHT WHEN INCHING PEDAL IS DEPRESSED

(Engine)
24.4.25 CHECK STARTING OF ENGINE

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

24.4.27 CHECK, CLEAN RADIATOR FINS, CHECK FOR DAMAGE

Dirt may fly and get into your eyes, so always

wear protective glasses or goggles.

Cleaning

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

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

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

Testing

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

24.4.28 CHECK FOR CATCHING, STALLING AND KNOCKING WHEN ACCELERATING

3-19
24. MAINTENANCE

(Engine continued)
24.4.29 CHECK AND CLEAN AIR CLEANER ELEMENT

Always wear safety goggles when using compressed

air.

NOTICE

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

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

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

In heavy-duty operating environments or conditions, clean and

replace the element more frequently.

Cleaning
1. Remove the element, blow the element from the inside with
dry compressed air at 98 PSI (0.68 MPa) (7 kgf/cm2) and clean
the entire circumference.

2. After cleaning, reinstall the element.

Testing
Check visually that there is no damage to the element.

24.4.30 CHECK OPERATION OF GOVERNOR

(MAXIMUM SPEED)

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

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

3-20
 24. MAINTENANCE

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

24.4.34 CHECK OPERATING CONDITION OF RADIATOR CAP, CHECK INSTALLATION

24.4.35 CHECK FAN FOR DEFORMATION, CRACKING AND DAMAGE

24.4.36 CHECK FAN FOR LOOSENESS AND MOUNTING

24.4.37 CHECK, ADJUST FAN BELT TENSION

24.4.38 CHECK, ADJUST ALTERNATOR BELT TENSION

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

24.4.40 CHECK CLEARANCE OF DISTRIBUTOR POINTS, CHECK CONTACT SURFACE FOR

ROUGHNESS

24.4.41 CHECK SPARK PLUGS FOR BURNING, BURNING OF INSULATOR

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

24.4.42 CHANGE OIL IN ENGINE OIL PAN

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

GASOLINE/LPG ENGINE (TB42)

NOTICE

Callout numbers in illustration match numbered headings here.

1. CHANGE ENGINE OIL (See item 1 for filler location)
1. Remove the drain plug, drain the oil, then reinstall and
tighten the drain plug.

2. Add the correct amount of specified engine oil.

3. Check the oil level with the dipstick.

NOTICE

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

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

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

2. Clean the filter holder on the engine.

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

4. Install the new filter.

3-21
24. MAINTENANCE

NOTICE

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

3. REPLACE FUEL FILTER

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

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

3. Install the new specified fuel filter element.

NOTICE

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

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

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

on page 3-21 for location)

1. Remove the spark plug using the plug wrench provided

with the lift truck.

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

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

Specified spark plugs

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

Hitachi L47W

5. CHANGE THE GOVERNOR OIL

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

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

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

NOTICE

Use the same oil as used in the oil pan.

(Capacity: 35 - 40 cc).

4. Tighten oil filler plug and oil level plug.

3-22
 24. MAINTENANCE

DIESEL ENGINE (6D102E )

NOTICE

Callout numbers in illustration match numbered headings shown below.

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

1. Remove the drain plug, drain the oil, then reinstall and
tighten the drain plug.

2. Remove the dipstick.

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

oil overflow.

4. Check the oil level with the dipstick.

NOTICE

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

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

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

2. Clean the oil filter holder.

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

4. Install the new oil filter cartridge.

NOTICE

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

3-23
24. MAINTENANCE

(Engine continued)
3. DRAIN WATER FROM FUEL FILTER (see also item 3 in
illustration on page 3-23 for location)

Loosen the combination sensor plug and drain any water

and sediment accumulated at the bottom of the filter.

NOTICE

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

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

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

on page 3-23 for location)

1. Remove the combination sensor plug at the bottom of

the cartridge.

2. Use a filter wrench to remove the cartridge.

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

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

5. Loosen plug (1), then hand-pump knob (2) up and down

to bleed air bubbles from fuel. Continue until no more
bubbles come out with the fuel.

6. Tighten plug (1).

3-24
 24. MAINTENANCE

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

24.4.44 CHECK SPECIFIC GRAVITY OF BATTERY ELECTROLYTE

Precautions when handling battery:

Battery electrolyte is dangerous. If it gets into your eyes or upon your skin
or clothes, wash it off with large amounts of water quickly. If it gets into your
eyes, seek medical attention immediately.
Keep away from sparks or flame.
To avoid gas explosions, do not smoke or cause short circuits or sparks near
the battery.

CHECK SPECIFIC GRAVITY OF BATTERY ELECTROLYTE

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

2. Using a specific gravity meter and thermometer, measure

the specific gravity and temperature of the battery electrolyte.

3. Insert the values measured in Steps 1 and 2 in the formula

below, and calculate S20.
S20 = St + 0.0007 (t - 20)
S20: Specific gravity at 68F (20oC)
St: Specific gravity (measured value) at toC
t: Temperature of battery electrolyte (measured value)
Normal value: S20 = 1.27 - 1.29

4. Charge the battery if necessary.

Specific gravity Condition of Charge

of electrolyte charge needed?

1.280 Fully charged

No
1.240 1/4 discharged

1.210 1/2 discharged

Yes
1.130 Fully discharged

Relation between specific gravity

and temperature of electrolyte
24.4.45 CHECK WIRING CONNECTIONS FOR LOOSENESS

24.4.46 CHECK IGNITION TIMING

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

24.4.48 CHECK OPERATORS SEAT MOUNT FOR LOOSENESS AND DAMAGE,

CHECK LPG CYLINDER MOUNTING BRACKET

3-25
24. MAINTENANCE

24.4.49 GREASE ALL LUBRICATION POINTS

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

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

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

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

24.5 EVERY 3 MONTHS OR EVERY 600 HOURS SERVICE

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

24.5.2 REPLACE OIL FILTER CARTRIDGE

For details on replacing the oil filter cartridge, see 24.4.42.2 CHANGE OIL IN ENGINE OIL PAN.

24.5.3 GREASE FUEL INJECTION PUMP GOVERNOR, CHANGE GOVERNOR OIL

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

24.5.5 CHECK OIL LEVEL IN DIFFERENTIAL CASE, ADD OIL AS NECESSARY

For details on checking and adding oil, see 24.6.4 CHANGE OIL IN DIFFERENTIAL CASE.

24.6 EVERY 6 MONTHS OR EVERY 1,200 HOURS SERVICE

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

24.6.2 CHECK KNUCKLE FOR PLAY, DEFORMATION AND DAMAGE

24.6.3 CHECK FOR MARKED VARIATION IN MINIMUM TURNING RADIUS

3-26
 24. MAINTENANCE

24.6.4 CHANGE OIL IN DIFFERENTIAL CASE

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

CHECK OIL LEVEL

1. Remove the level plug and check that the oil is near
the bottom edge of the plug hole.
If the oil level is low, remove the oil filler plug and add oil.

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

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

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

Specified oil refill amount

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

NOTICE

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

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

3-27
24. MAINTENANCE

(Power train continued)

24.6.5 CHANGE OIL IN TORQFLOW TRANSMISSION CASE

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

CHECK OIL LEVEL

1. Remove the floor plate and check oil with dipstick.

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

CHANGE OIL, CLEAN STRAINER

1. Remove the drain plug, drain the oil, then reinstall and
tighten the drain plug.

2. Remove the mounting bolts, take out the strainer, and

wash it off in flushing oil.

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

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

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

Specified oil refill amount

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

NOTICE

Always use specified oil or DEXRON II Automatic Transmission Fluid.

24.6.6 REPLACE TORQUE CONVERTER OIL FILTER

NOTICE

Replace with specified oil filter.

(Brake system)
24.6.7 CHANGE BRAKE OIL/FLUID

(Engine)
24.6.8 CHECK AND ADJUST VALVE CLEARANCE

24.6.9 MEASURE COMPRESSION PRESSURE

3-28
 24. MAINTENANCE

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

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

24.6.12 CHECK DISTRIBUTOR CAP CENTERPIECE FOR WEAR

24.6.13 REPLACE FUEL FILTER ELEMENT

For details on replacing the fuel filter element, see 24.4.42.3 CHANGE OIL IN ENGINE OIL PAN.

24.6.14 CLEAN INSIDE OF COOLING SYSTEM

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

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

Water and Coolant Capacities

TB42 engine
3.70 U.S. gal. (14 L, 3.08 UK gal.)
6D102E engine

3-29
24. MAINTENANCE

(Engine continued)

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

In cold areas, add long-life coolant.

NOTICE

(For details, see 16. COLD WEATHER OPERATION.

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

24.6.15 REPLACE AIR CLEANER ELEMENT

Never clean or replace air cleaner while the engine

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

REPLACE ELEMENT
1. Remove the air cleaner element.

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

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

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

5. Install a new element.

3-30
 24. MAINTENANCE

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

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

1. Remove the drain plug at the bottom of the tank. Then

remove the cover, take out the strainer, and wash it in
flushing oil.

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

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

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

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

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

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

NOTICE

Always use specified hydraulic oil.

24.7 EVERY 2,000 HOURS OF SERVICE

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

24.8 EVERY YEAR OR 2,400 HOURS OF SERVICE

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

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

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

24.8.4 CHECK BRAKE LININGS FOR WEAR

24.8.5 CHECK OPERATING CONDITION OF BRAKE SHOE

24.8.6 CHECK BRAKE ADJUSTMENT LEVER AND RATCHET FOR WEAR AND DAMAGE

24.8.7 CHECK BRAKE SPRING FOR DETERIORATION

3-31
24. MAINTENANCE

24.8.8 CHECK BRAKE BACK PLATE FOR DEFORMATION AND CRACKING,

CHECK MOUNTING CONDITION

24.8.9 CHECK AIR TIGHTNESS OF BRAKE PIPING/TUBING

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

24.8.11 CHECK MOUNTING CONDITION OF DIFFERENTIAL

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

24.8.13 CHECK ROLLER SHAFT OF LOADING EQUIPMENT FOR CRACKING AND DAMAGE

24.8.14 CHECK MAST SUPPORT FOR DAMAGE AND WEAR

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

24.8.16 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

3-32
 25. REPLACEMENT PROCEDURES
25. REPLACEMENT PROCEDURES
25.1 REPLACING FUSES

NOTICE

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

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

1. Turn the starting switch to the OFF position.

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

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

Fuse capacity and related electrical component

No. Capacity Color Related electrical component

(1) 10 Amp Meters

(2) 10 Amp Red Back-up lamp

(3) 10 Amp Starting relay

(4) 15 Amp Stop lamp

(5) 15 Amp Blue Lamps

(6) 10 Amp Horn

3-33
25. REPLACEMENT PROCEDURES
25. REPLACEMENT PROCEDURES
25.2 REPLACING TIRES

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

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

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

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

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

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

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

Ask a tire and wheel specialist to carry out disassem-

bly and assembly of tires and wheels.

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

7. Tighten the lug nuts again with a lug wrench, using a

diagonal criss-cross or star pattern, ensuring that the wheel
is snugly in place, but not fully tightened.

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

25. REPLACEMENT PROCEDURES

3-34
 25. REPLACEMENT PROCEDURES

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

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

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

25.3 REPLACING LAMPS

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

Gas Engine Trucks Diesel Engine Trucks

Lamp Function
(12 Volt System) (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 3W

3-35