AIS LUINYA FRU OY SW YVIPIAGOBGOyY \ ) susssepsese tt om073 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 Precawne, (ent and aan) = (00 ps A WARNING Read and observe all warnings on this unit before operating it. DO NOT operate this equipment unless all fac- tory-installed guards and shields are properly i sin KOMATSU ISSUED: FEBRUARY 2004 Komatsu Forklift USA, Inc.Buwe Déiet H's = 6" eee SE eee eeKomatsu Forklift U.S.A,, Ine DataKom Publishing Corporation fe YY Attn: Technical Publications 14481 Lochridge Blvd., Bldg 2 Covington, Georgia 30014 PROPOSAL FOR MANUAL ie REVISIONSICORRECTIONS Date L individual's Name Company Name [Department [Street Address City, State & ZIP MVoice Phone [Book description Originator Fax Phone [Truck model & S/N [Problem location and description. Altach supporting photo, sketch or other material as necessary. [Book or Tech Bulletin No. ‘Section No, andlor Name Page No, Item No, (if parts book) Item Description (if in parts book) ‘Corrective Action and Date Fax this completed form to: 770-385-4838 TPC_KFI-1_021202OM073 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 unless 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 Bivd., 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 AX and BX The “Name Plate / Data Plate’ is located on the top of the lift truck hood to the right of the operator's seat, The lift truck mode! can be determined by viewing the information on this name plate. AX and BX lift 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: 1 23 4 5 6 1 2 4 6 6 Type of | Type of Load Designations UL Rating Model Vehicle Motive | Capacity Change Power | (Model: tbs) | | Number F= | G=Gasor| 15.3,000 | S= Cushion tre type LS=LPG | 1 = Original Forklit LP engine Special (Anti. | model built ck Hasta 18H oh onan | Sp D= Diesel 2,9,etc, = engine 204,000 | T= Torqflow-type power | US=Gas or | Changes in shit iranswitorque con- | Diesel Spe- | models 255,000 | verier cial ante | Spark) | 306,000 | G=Clutch-type manual | trans widry, single-cisc | clutch i504 ‘OMO73 = AXIBX Op & MaintFORKLIFT IDENTIFICATION This Page Intentionally Left Blank OMO073 — AX/BX Op & Maint0. CONTENTS CONTENTS 0. Contents... 4. Foreword .. 2, Safety Information... 3. Running in New Lift Truct 3.1. Running in New Lift Truck. ce 0 3.2 First Month Service (or initial 200 hours service) for new lt truck 0. 3.3 Model Line Up. 0. 4. Warranty and Service for New Lift Truck... 4,1 Komatsu Forklift Genuine Parts 5. Location of Plates 5.1 Lift Truck Serial Number Plate Position .......:0:csussunssnnniisiie . ont SAFETY 6. Safety Management 7. Safe Travel 10. Inspection and Maintenance. 11. Structure and Stability of the Lift Truc! (To prevent lift truck from tipping) 12. Safety Label Sticking Positions. OPERATION (Gasoline!LPG/Diesel engine trucks) 13. Overview of Lift THUCK ...j.oscceneennenne aE fa 13.1 General View of Lift Truck . 22 13.2 Instruments and Controls... 23 13.3. Federal EPA Emission Control Statement for Off-Road LS! (Nor-Diesel) En (K21 and K25 Engines)..... 24 13.4. Federal EPA Emission Control Statement for Off-Road Diesel Engines (4D94E Engines) 2- 6 414. Explanation of Components... 10 15. Operation 2-24 15.1 Check Before Operation 224 15.2 Mounting/Dismounting ..... sone snsnnneannnne . 2-32 Continued on Next Page OMO73 = AX/BX Op & Maint 021704 o-40. CONTENTS. 16. Operation (Continued) 15.3 Operator's Seat Position Adjustment.......000 SHOOT 2-32 15.4 Placing Lift Truck in Motion ..-..0.000 . ose son anannn meee 288 15.5 Starting and Inching on Slope ...sssnesinstnnnsnsennnnnsennietinnnsseny 2.37 15.6 Turing 238 15.7 Temporary Stopping and Parking so nanemenensemnnanneccsl 2:38 15.8 Fork Spread Adjustment... . tees BAO 15.9 Load Handling Operation... —_ az : si 244 15.10 Check After Operation AIS 5 2.45 16. Cold Weather Operation. 16.1 Preparations for Low Temperature... eT i : 16.2 Precautions After Completion of Operations......:..sesiensisnsneneisurnenmssn 2-46 17. Handling in Heavy-Duty Conditions. 17.1. Precautions When Using in Heavy Duty Conditions 2-48 17.2. Cleaning Inside of Cooling System... oo 2-48 17.3. Clean Radiator FINS «00. 7 2-48 17.4 Check Fan Belt Tension... oi coaitiomacaseN RTS IA 17.5. Action When Engine has Overheated.... pecans . M8 48. Long-Term Storag: 18.1 Before Storage i neessesnnnsne saa . 2-50 16.2 During Storage Se ee 2-50 18.3 Affer Storage wun. . MAINTENANCE (Gasoline/LPG/Diesel engine trucks) 19. Outline of Service 19.1 Suitable Oil. 20. Lubricant List 20.1 AX - Gasoline/LPG Engine Lift Truck. ea oone 20.2 BX - Gasoline/LPG Engine Lift Truck...... it 3 20,3 BX - Diesel Engine Lift Truck 3 20.4 Oil and Greasing Chart (Oil, Grease Locations and Inspection and Maintenance intervals) 37 21, Service Data . 21.4 AX- Service Data - All Models... ‘i 28 21.2 BX - Service Data (Gasoline/_PG Engine Lift Truck)... ocean “310 213 BX - Service Data (Diesel Engine Lift Truck) 312 21.4 Torque List sarnsscaascesiaasa ON 22, Periodic Replacement of Safety Critical Parts. 23. Maintenance Schedule Chart 24, Maintenance (All Model 24.1 First Month or Initial 200 Hours Service, 24.2 Check Before Operation ... : ~— . 24.3 Every 2 Weeks or Every 100 Hours Service 3.25 Continued on Next Page OMO73 = AX/BX Op & Maint0. CONTENTS 24. Maintenance (All Models)(Continued) 24.4 Every Month of Every 200 Hours SrViCE....0c. es snnnnen nese iansinnne #25 24,5 Every 500 Hours Service ou... LEAS aE STO 246 Every 3 Months or Every 800 Hours Service... ebasasanunrayastyan 3:32 24.7 Every 1,000 Hours Service (EPA and Diesel Engines)... uses nsensisnsnnsnnnn 334 248 Every 6 Months or Every 1,200 Hours Service a 3-34 24.9 Every 2,000 Hours Service 337 24.10 Every Year or Every 2,400 HOUIS SEIVICE nen senennenanesnnnsne SBT 24.11 Every 18 Months or Every 3,600 Hours Service occ. ue erst asionennned OO. 26. Replacement Procedures... 25.1. Replacing Fuses and Relays 3:39 25.2 Replacing Tires...» ernie 3a 25.3 Replacing Lamps... eee 3 3-42, TECHNICAL DATA 26. Technical Data... AX Lift Trucks (gasoline/LPG engines) BX Lift Trucks (diesel engines) sree . BX Lift Trucks (gasoline/LPG engines)... sie M073 = AX/BX Op & Maint 021704 03THIS PAGE INTENTIONALLY LEFT BLANK This Page Intentionally Left Blank oa oiia04 OMO73 = AX/BX Op & MaintFOREWORD A Warnine READ AND FOLLOW ALL SAFETY PRECAU- TIONS. FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR DEATH. 0-51. FOREWORD ‘This manual provides rules and guidelines which will help you use this lit 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 lif truck can Cause a serious accident if they are not done in the manner described in this manual Bx WARNING '® Improper operation and maintenance of this lift truck can be hazardous and could result in serious Injury of death ¢ Operators and maintenance personnel should read this manual thoroughly before beginning opera. 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. If this manual has been lost, or has become dirty or worn and cannot be read, request ‘manual from your Komatsu Forkiift distributorideater, ‘@ Komatsu Forklift delivers lift 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 | truck nas 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. If there ig 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 lit 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 litt truck or for questions regarding information in this manual Information on safety is given in the SAFETY, OPERATION and MAINTENANCE sections throughout thie manual; please read it carefully and completely. ‘eplacement 0-6 "011404 (OM073 — AX/BX Op & Maint2. SAFETY INFORMATION ‘Most accidents are caused by a failure to follow fundamental safety rules for the operation and maintenance of lit trucks ‘To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the lift truck before operating and performing maintenance. Do not operate or carry out maintenance of this lit truck unless you are sure that you understand the explanations and procedures completely. To identify safety messages in this manual and on lft ruck labels, the following signal words are used ‘These safety messages oF labels describe precautions that must be taken to A DANGER | 294 a hazard which carries a sericus risk of serious injury or death ‘These safety messages oF labels usually describe precautions that must be taken A WARNING, | *° 2048 hazard which may lead to serious injury or death This word is used on safety messages and safety labels for hazards which could A CAUTION | fesutininiury o damage to the tt truck or surrounding property if the hazard is not avoided. NOTICE ] ‘This word is used for precautions that may not ead to damage or fallure, but which — must be taken fo 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 lift truck may not include all possible safety pre- cautions. I any procedures or actions not specifically recommended or allowed in this manual are used, itis your responsi- billy to be sure that you and others can do such procedures and actions safely and without damaging the lit truck Ifyou are unsure about the safety of some procedures, contact your Komatsu Forklift distributor/deaier. ‘The procedures and precautions given in this manual apply only to intended uses of the lift ruck, If you use your lif truck for ary unintended use that is not specifically prohibited, you must be sure that itis safe for you and others, Inno event should you or othars engage in prohibited uses or actions as described in this manual M073 - AX/BX Op & Maint 071404 0-73. RUNNING IN A NEW LIFT TRUCK 3.4. RUNNING IN A NEW LIFT TRUCK Your Komatsu Forklift truck has been thoroughly adjusted and tested before shioment However, operating the lit truck under severe conditions at the beginning can adversely affect performance and shorten the lf 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 lif truck, carry out the following maintenance only after the first month or 200 hours. Unit Check items Remarks, ‘Change ailin engine oil pan Page 3-21 Replace ail fiter element Page 3-21 ‘Check & adjust engine valve clearance Tighten (retorque) engine cylinder head bots Engine Check spark plugs for burning of elec trode, burning of insulator Renee Check & clean arr fiter element Page 3-26 ‘Check ignition timing Check & adjust alternator bet (dave ; belt} tension Panezzs: ‘Change transmission fluid TOROFLOW _ Page 3:23 Kenemiasion Clean strainer Differential Change oil Page 3.24 ‘Change oil Replace line ite Hydraulic tank Page 3-20 1 Clean insice tank Perticlarly lug (hub) ruta, overhead guard Mise bolts & nuts Tighten maunting bolt, backrest mountng bolts, anc ‘operator's seat mourting bolts “Other Refer to ‘Check Before Operaton” Page 2-21 O8 021704 0MO73 — AX/BX Op & Maint3. RUNNING IN A NEW LIFT TRUCK 3.3. MODEL LINE UP APPLICABLE “EPA” LIFT TRUCK MODELS Model Description saline Engine} FGISHC-I7 3,000 capac, Clutch Spec, Preumate Tre FGISHT-I7 3,000 Ib capacity, Torjlow Spec; Pheumatc Tre FGISHTLEAT 3,000 ib, capacity, Torefow Spec, UP Special, Prourvaic Tire FGISST-A7 ib. capacty. re [FGIsSTLSAT | 10001 capacity. ‘Cushion Tie - FGIGHT-17 3.500 1b, capacity Toraiow Spec, Pneumatic Tre FGTHTLS-1T 3,500 1b, capacty, Torgiow Spec, UP Special, Pneumatic Tre FG1aST-17 3,500. capacty, Toralow Spec, Cushion Tire FGISTLS.I7 3,500 1b capacity, Toraflow Spee, LP Special, Cushion Tire BX (K24 and K25 Gasoline Engin FG20C-14 4,000 16. ity, KOT Engine, Clutch Spec, Pneumatic Tire FG20T-14 4,000 1b. capacity, K21 Engine, Toraliaw Spec, Pneumatic Tire FG20TUS-14 4,000 tb. capacity, K27 Engine, Torqtiow Spec, Gasoline Special, Pneumatic Tre FG20TLS-14 4,000 to. capacity, K21 Engine, Torgiiow Spec, LP Special, Pneumatic Tire: [FezosT-44 7000 fb. capacity, K21 Engine, Toralow Spee, Cushion Tre | FezosTus-1a | a0 21 Engine, Toriow Spec, Gasoline Special, Cushion Tire | FG20STLS-14 4,000 1b capacity, K2T Engine, Torgilow Spec. [P Special. Cushion Tire FG20HT- 14 4,000 ip, capacity, K25 Engine, Toraiiow Spec, Preumatic Tre [ FG20RTLS-14 %.000-b capaci, 25 Engine. Towglow Spec. UP Special, Preuriaie Tis FG208HT- 14 {000 Tb, capacity, K25 Engine, Toreflow Spec, Cushion Tire FGDSC-14 $030 fb. capaci, K21 Engine, Clutch Spec. Preumatic Tre ————SSS~S~*S [FG2eT-14 | S000 capaiy, K2T Engine “Torlow Spec, Pretimatic T FG25TUS-14 5,000 16, capaci, K2T Encine, ToraTow Spec, Gasoline Specall Preumatic Tre FG25TLS-14 ‘5,000 ib, capacity, K21 Engine, Torgiiow Spec, LP Special, Preumatic Tire FG2e6T 14 5,000 b. capaci, K2i Engine, Tralew Spec, Cushion Tire | FG2ssTUS-14 5,000 Ib, capacity, K21 Engine, Torqflow Spec, Gasoline Special, Cushion Tire [FGRSSTLS-id [5.000 Tb. capaci, K21 Engine, Toralow Spec, LP Special, Cushion Tre FG25HT- 14 ‘5,000 tb, capacity. K25 Engine, Torgfiow Spec, Pneumatic Tire FO2SHTUS- 4 °5,000 1b. capacily. K25 Engine, Torqlow Spec, Gasoline Special. Preumatic FORGHTLS-14 5,000 1b, capadlly, K25 Engine, Torqlow Spec, LP Special, Preumatic Tire [FoassHraa | spaniy, K25 Engine, ‘Toralew Spec, Cushion Ti [FG2SSHTLS-14 '5.000 1. capaciy. K25 Engine. Toralow Spec. LP Special, Cushion Tire FG30C-14 6,000 ib capacity, K21 Engine, Clutch Spec, Pneumatic Tire FG3ONT-4 ¥25 Engre,Torgiow Spec, Preumatic TYE tr 6,000 1b, capacity, K25 Engne, Torqlew Epec, Gassiine Special Preumatié Tre F | 6.000 Ib. capacity, K25 Engine, Toralow Spec, LP Special, Pneumatic Tire | FG30SHT-14— “ushion FG3OSHTUS-14 {6.000 fb capacity, K25 Engire,Torafow Spec, LP Special, Cushion Te BX (4D94E Diesel Engine) | FozoT 4 4,000 ib capasliy,Diesal,Tarjlow Spec, Pheumatic Tre FORE 5,000 ib, capasliy, Diesel, Torlow Spec, Pneumatic Tre FO26TUS-14 5.000 |b. capacity, Diesel Special, Toraflow Spec. Pneumatic Tire FOROT-14 “6.00015, capacity, Diesel. Toraow Spec. Pneumatic Tre OMO73 — AX/BX Op & Maint (022004 0-9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, as the parts builtin the new lift 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 Forklit war- pee ranty wil not be applicable, Always use genuine Komatsu Forklit parts when replacing parts \ er (011404 OMO73 — AX/BX Op & Maint5. LOCATION OF PLATES LIFT TRUCK SERIAL NO. PLATE POSITION . Nameplate location: Nameplate ‘The nameplate is installed on the top of the hood on the fight side of the operator's seal, ‘The serial number is located on the nameplate. . Embossed serial number location: ‘The embossed serial number is stamped on top of the front fender on the lett side of the lift truck In addition, the UL license is installed to the left of the front side of the dashboard, ‘The engine serial number is stamped in the position shown below (Left and (Right inthe ciagram are as follows einneesed (Lefy, Lett side of engine. serial number (Right): Right side of engine. ‘Aceiv0aa Gasoline engine (AX, BX) Diesel engines only K2VKID ENGINE SERRAL NO_STANP Engine 4D94E number (Right) botiom of . Contacting Komatsu Forklift: When contacting a Komatsu Forklift distributoridealer for parts ordenng or problem consultation, always. give the lit truck serial number embossed on the lift truck NOTICE Tal care not to damage or remove the embossed serial number. M073 — AX/BX Op & Maint 011404 0-115. LOCATION OF PLATES THIS PAGE INTENTIONALLY LEFT BLANK 0-12 011404 ~ OMO073 - AX/BX Op & MaintSAFETY A WARNING READ AND FOLLOW ALL SAFETY PRECAU- TIONS. FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR DEATH. 116. SAFETY MANAGEMENT SAFETY MANAGEMENT A WARNING | OPERATION MANUAL AND SAFETY LABELS Read the instructions in this Manual and the Safety Labels attached to the various parts of the li truck, and make sure that you understand and follow them, If you do not understand or do not fol- tow the insiructions, this vil lead to improper operation which may lead to damage, personal injury ‘or death Be sure that you understand the proper method of using the lift truck and the procedure for carry- ing 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 Marual or Safety Labels have been lost or become dirty and cannot be read, obtain replacements from your Komatsu Forkift distibutoridealer and attach the Safely Labels in the specified posi tions. AA WARNING | OPERATING aUALIFICATIONS This lift truck should be operated only by qualified personnel, Be sure you have proper qualiica: tions before operating the lift truck When operating this lift truck, even if you have experience in operating other iif trucks, obtain instructions from an authorized person who has experience in operating this lift truck or the same type of lif truck A WARNING | CLOTHING AND PERSONAL PROTECTIVE ITEMS ‘Avoid loose clothing, jewelry, and loose jong hair. They se can catch on controls or in moving parts and cause serious injury or death ‘Always wear a hard hat and safety boots. Depending on the working conditions, wear other safety equipment as well (BQ WARNING | OVERHEAD GuaRD, LoD BackREsT Do not use this lift truck untess it is equipped with the overhead guard and load backrest shipped with the lit truck from the factory by Komatsu Forklift 12 omt4ca M073 — AX/BX Op & Maint6. SAFETY MANAGEMENT A WARNING | UNAUTHORIZED MODIFICATION + Any modification made without authorization from Komatsu Forklft can create hazards, + Before making any modification whatsoever, consult your Komatsu Forklift distributor/dealer, Komatsu Forklift will not be responsible for any damage, injury or death caused by any unautho- tized 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 caroon monoxide. There is a danger that this wi cause gas poisoning which may result in serious injury or death ® (AX WARNING | FIRE EXTINGUISHER AND FIRST AID KIT + Ifany abnormality in the li truck occurs, stop operation immediately, park the lit truck in a safe place and safe condition, then contact the person in charge + Be sure that fre extinguishers have been provided and that you read the labels (o ensure that you know how to use them, + Know what to do in the event of a fire + Be sure that you know the phone numbers of persons you stiould contact in case of an emer- gency + Provide a first aid kit at the storage point + Do not use the lift truck ifit is leaking fuel, Inform the person on charge of the nature of the abnor- ‘mality, and repair the leakage before using the tit truck, + Do not leave the lift truck with the engine running ‘Always apply the parking brake securely, lower the forks to the ground, stop the engine, and rernove the key betore leaving the lift truck M073 ~ AX/BX Op & Maint o1n404 136, SAFETY MANAGEMENT A WARNING | SAFETY RULES + Do not operate the li 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, o maintenance of the lif truck, always follow all work shop rules, safety regulations and precautions. + During operation, always pay attention to safely and be careful of pedestrians, trafic and other surrounding conditions, A 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. A WARNING | TRAVELING REGULATIONS ON PUBLIC ROADS + Do not travel on public roads unless you comply with local, state or other laws which regulate such activity + Always observe all affic regulations when operating the lift truck + Donot drive on public roads with the it truck loaded + Do not tow other machines on public roads. (Do not tow otter machines even when not on public roads), + Always carry your driver's license when traveling on public roads ‘Ax WARNine | SAFETY Equipment + The overhead guard is installed to protect the operator from falling objects. it is designed to with~ sland the force of light boxes or small packages. It is not designed to withstand every possible Impact. Aways be careful to prevent damage or injury from falling objects. WARNING | TIRE FENDERS + The tire fenders prevent objects from being thrown up by the tires. When changing from a single tire to a double tre arrangement on your forklift truck, always extend the tire fenders to cover the adcitional ties. 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, incorrect. ~~ Z correct 14 ‘oria04 OMO073 — AXIBX Op & Maint6. SAFETY MANAGEMENT A WARNING | SAFE WORKING AREA ‘Always work on level surfaces and wipe up all oll or grease from the ground. When working on quays, platforms, docks or other places where there is a danger of falling, set up blocks to prevent the lift truck from going over the edge. Put warning signs up in dangerous places to wam the operator not to approach. Mark the travel 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 AX WARNING | CLEAN OPERATOR'S COMPARTMENT Keep the operator's compartment clean and tidy, Be sure to clean up all oil or mud. If the opera. {or’s hand oF foot slips, this may lead to a serious accident Do not leave too's or spare paris lying around in the operator's compartment, They may damage ‘of obstruct the control levers or pedals, Aways 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 safely {in confined areas, position a signal person and carry out operations in accordance with hisiher instructions. When carrying out operations on roads, put up fences around the working area and carry out oper ations in accordance with instructions ‘rom the signal person AX WARNING | REDUCE LOAD FOR LIFT TRUCKS WITH ATTACHMENT The permissible load for any Ift trucks equipped with an attachment is lower than the permissible load for the standard ift truck, Reason. 1) The permissible load musi be reduced by an amount equivalent to the weight cf the attach- ‘ment itself, 2) Because of the thickness of the attachment, the load center moves forward, Always observe the permissible load as stated on the capacity plate (also called “nameplate") strictly (this plate Is stuck to the lif truck or the attachment), Never exceed the permissible load. AA WARNING | “NOsUMP START” SAFETY PLATE (DECAL) + DONOT JUMP START the engine by short circuiting the starting motor terminals, + This SAFETY PLATE (DECAL) Is located on the top center of the starter's magnet switch + If your machine is not equipped with this SAFETY PLATE, install a new plate (decal) in the specified location after cleaning the surface. OMO073 — AX/BX Op & Maint ci1404 75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 it is easy for the vapors to accumulate in low places (holes, road surface depressions, otc,). This can create a fire or explosion hazard, Be extremely carefull mM ek _©O AA WARNING | NO STARTING Alps Engine starting aids are highly flammable and may cause an explosion, Do not use starting aids to start the engine. AA WARNING | +?6 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 with 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 uel 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 filed with fuel past the 80% liquid level + Ensure there are NO SOURCES OF IGNITION nearby before beginning 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 fuel 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 utilize a UL listed LPG tank, 16 omnaoa M073 = AX/BX Op & Maint7. 7. SAFE TRAVEL SAFE TRAVEL AX WARNING | PRECAUTIONS WHEN STARTING ENGINE Before starting the engine, always check that the parking brake \s applied and that the directional and speed fevers are in neutral Depress the clutch pedal (for clutch type irucks), or the brake pedal (for TORQFLOW transmission trucks), firmly, 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 seal or steering whee! during operation is dangerous and it may cause you to lose your balance or fo operate the lit truck improperly Before starting the engine, check that the surrounding area is safe. ALWAYS SIT IN THE OPERATOR'S SEAT when starting the engine Before starting the engine, sound the horn to warn people in the aan area With large-sized lf trucks, get off the lif truck and walk around it to check that no one is near the ‘engine compartment, ties or counterweight, then get on the lit truck, sit in the operator's seat. and start the engine. PRECAUTIONS WHEN OPERATING DIRECTIONAL OR A WARNING SPEED LEVERS When switching between FORWARD and REVERSE, always stop the lift truck. It is dangerous to change the direction of travel suddenly or when the lit truck is moving. When operating the directional lever or speed lever, always depress the clutch pedal before mov- ing the lever (for clutch type lif trucks) {Wine lever is moved without disengaging the clutch, the it ruck will move suddenly and may couse injury A WARNING | TIPPING If the load-engaging means or load is raised, the center of ‘gravity of the lift truck will also rise and increase the danger of the iff truck tipping, Do not turn the lit truck when the forks are raised high Do not suddenly raise the forks or tit the mast to the front or rear when the forks are loaded. There is danger that the lit truck wal tip, Reduce speed before turning the lft truck. In particular, when traveling unloaded, the rear of the lit truck is heavy, Ifthe lft 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 ite M073 — AX/BX Op & Maint ovia0a reti SAFE TRAVEL AA WARNING | TRAVEL ON sLoPes Do not tum, oF travel across or at an angle on slopes. There is danger that the it truck wil tip. Before starting to crive up a slope, stop the lit truck and adjust the cloarance between the ground surface and the bottom of the forks 80 that the bottom ofthe 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 FORWARD up the slope and in REVERSE down the slope with the load upgrade. When unloaded: Travel in REVERSE up the slope and FORWARD down the siope with the load engaging means downgrade. When traveling down slopes, use the braking force of the engine together with the foot brake, and travel siowly down the slope. AA WARNING | °° NOT JUMP OFF LIFT TRUCK EVEN IF IT TIPS NEVER JUMP OFF the lift truck even if t seems that it wil tip. Always do as follows: Hold the steering wheel securely. Stay in the operator's seat. Brace your legs. I you jump off the lift truck when it turns over, there is dangor 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 lift truck after it has stopped Always wear the seat bell correctly. ST ate dl Don mh mynd Sita dun bowen Kac0449 1-8 011404 OM073 — AX/BX Op & Maint7. SAFE TRAVEL WARNING | ROAD SHOULDER + There is danger that soft road shoulders may collapse, 0 do not go near ther with the lift ruck + Always maintain a safe distance from the edge of road f L shoulders and platforms, AREA THAT CAN BE SEEN WHEN, CYLINDER IS NOT INSTALLED. ror 4-10 012804 M073 — AX/BX Op & MaintA WARNING 7. SAFE TRAVEL WHEN FRONT VIEW IS POOR + Ifthe view to the front is obstructed by the load tum to the rear and ori + When criving in reverse with a high load, use a signal person to ensure the safety of the load and the safety in the surroundin /e the forklift truck in reverse, 9 area A WARNING CHECK BEFORE STARTING start the lit truck unt al + Ifanything abnormal is f + When checking the lit truck before starting, follow the procedure given in this Manual, and do not the checks have been completed, found, inform the person in charge and carry out the necessary repairs AX WARNING LAMPS Check that the lamps light up correctly. Replace any broken or inoperative bulbs, A WaRNING KEEP HANDS FREE FROM OIL AND WATER + Do not drive the lift truck if your hands are wet or covered with oil. Your hands wil slip on the work ‘equipment contro! levers or directional lever, and this may cause a serious accident. Ad WARNING MOUNTING AND DISMOUNTING NEVER jump on or off the lift truck. + When getting on or off the lif truck, always stop the lift truck and use the hancraits and steps to ensure that you support yourself + Never hold any control levers or the steering wheel when getting on or off the lit truck. + I there is any oli, grease or mud on the handrails or sleps, wipe it off immediately. Always keep these parts clean. Repait any damage. Avira M073 = AX/BX Op & Mi faint o1raca - wt7. SAFE TRAVEL A WARNING | ALWAYS SIT IN OPERATOR'S SEAT + Never operate the litt ruck from outside the operator's compart- —— meni + Always keep your body under the overhead guard. + Do not extand your arms and lags outside the operator's com- partment. awete A WARNING | SEATBELT + Always wear your seat belt correctly when cn the operator's seat, ‘The seat belt will reduce the risk of injury, Ae 2: Zo + Always check the seat belt mounts and check for any damage to the seat belt itself. f any abnormality is found, repair or replace the seat belt immediately. A WARNING | SAFETY WHEN STARTING + Before starting and moving the lift truck, check that the surround ing area is sa + Belore moving the lif truck, raise the forks (approx. 6 in. (20cm) from the ground surface), and tit the mast back WR + Before moving the lift truck, release the parking brake So na he 4 A WARNING | BRAKING WHEN TRAVELING + Do not stop the engine when traveling. If the engine is stopped, the power steering (for lft trucks with power steering) and power brake (for trucks with power brakes) will not work, + Ifthe inching pedal is depressed, the braking effect of the engine willbe lost. + Donot use the brake excessively. Do not rest your foot on the brake pedal or inching pedal uniess you are operating it Ifyou do, the brake will overheat and the braking effect will be lost, For TORQFLOW lift trucks, if you leave your foot on the inching pedal, the muttiple disc clutch inside the transmission will overheat. In the worst case, the clutch discs will be deformed and the ‘clutch wall not function normally. 1-12 ~ 01f404 OMO73 — AX/BX Op & Maint__7. SAFE TRAVEL A WARNING | SAFETY DURING TRAVEL Keep a clear view of the path of travel and observe for other trafic, personnal and safe clearances, Yield the right of way to pedestrians, When passing oncoming vehicles, reduce speed and keep a safe distance from the other vehicle. In places where there are speed limits, obsarve the speed limit and maintain a safe distance from other vehicles. A WARNING | CONFIRMING SAFETY + When traveling, always pay careful attenton 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 when entering or leaving narrow roads, stop and sound the hom to confirm safety before driving on, + Even if you sound the horn, not everyone in the surround: ing area will necessarily hear it. Aways pay careful atten- tton to the movements of people in the surrounding area + When crossing roads or turning corners, slop and confirm safety before continuing, + Always pay careful attention to the movements of peopie 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 to erive the lit truck on soft ground + Avoid curbs, rails, ditches or other obsiacles, and do not travel directly over them. + Do not travel on slippery roads or other sliopery surfaces + When entering buidings, check the weight hit of the floor and be careful not fo exceed the limit AX WARNING | GIVE PRIORITY To LOADED LIFT TRUCKS + When traveling on slopes or in confined areas, unloaded lif trucks should always give the right of way to loaded trucks OM073 — AX/BX Op & Maint 011404 4437. SAFE TRAVEL A WARNING | HEIGHT OR WIDTH LIMITS en gong n or out of places with height or with iit Ensure that there is ample height and wicth for the lif truck 10 pass + Do not extend your hands or legs outside the lift tuck: + Check that the surrounding area is safe + 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 wil! swing far out. Keep an ample clearance from walls and other objects to ensure safety. + When turing, travel slowly and be careful that the front or tear wheels do not come off the ground. When tuming on sof! foad shoulders, there is danger that the rear wheels may ‘come off the road shoulder and cause the lift truck to tip. A WARNING | STOPPING DISTANCE + When traveling downnil, it requires a longer distance for the Ift truck to stop than when traveling on level ground, + When traveling downhill, reduce the speed and make sure that you have ample room at the bot- tom of the siope to stop. = When traveling on wet surfaces, it requires. a longer distance to stop than when traveling on nor mal road surfaces. Always have ample room to stop, A WARNING | NO TOWING IF there is any problem with the brakes or steering system of your if tuck, do not use another lit truck to tow it ‘There is dangor that the lift truck may run away. 444 oraoa ‘OM073 — AXIBX Op & Maint8. LOADING OPERATIONS 8 LOADING OPERATIONS A WARNING | NO OVERLOADING + Do not load the lif truck over the capacity set forth in the load capacity chart, If the rear wheels come off the ground because of overloading, the lit truck cannot travel or tur. ‘There Is also danger that it may tip. ‘Always check the load capacity chart to confirm the loading capacity A WARNING | DON’T GO UNDER FORKS + Never allow anyone to go under the load-engaging means or load when itis raised The area under the forks is a danger area. If the 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 i even if it is elevated, stuck or caught in the up-posttion. It may fall down suddenly at any moment oO ‘0817970 A WARNING | 0ONOTLIFT PEOPLE ON FORKS + Do not use the forks to lit people. If the person falls from the forks he/she may be seriously injured S$ OMO73 = AX/BX Op & Maint 11404 1158. LOADING OPERATIONS A WARNING | 8 CAREFUL NOT TO GET CAUGHT OR FALL + Never put your hands or feet into the mast siructure, There is dan~ ger that you will get caught in moving parts and be seriously injured, + Do not use the mast, load backrest or dashboard as @ ladder or step, If you slip, there is danger that you will fal. (4) woo A WARNING | OPERATE FROM OPERATOR'S COMPARTMENT + Always operate the mast and forks from the operator's compartment A WARNING | NO UNSTABLE Loaps + Make sure that the center of gravity of the load is in line with the center of the lift truck. Do not carry loads off-center. There is danger that unbalanced loads may cause the lift truck to 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 it in position and take steps to prevent the load from collapsing or falling, i + When carrying stacked loads, tie with rope or otherwise wasn secure it to prevent the load trom falling 1-16 ortaoa M073 = AX/BX Op & Maint8, LOADING OPERATIONS A WARNING | 20 NOT LOAD ABOVE HEIGHT OF LOAD BACKREST + Koop the height of the load within the height of the load back- resi. Do not carry any load that is higher than the load back- resi. If the load is higher than the load backrest, there is danger that it wll fall back on top of the operator. This may lead to serious injury or death. 701350 A WARNING | °O NOT TILT MAST FORWARD WHEN LOADED + Do not tilt the mast forward when the forks are loaded and raised, There is danger that the load may fall and that the lift truck may tip. + Donot travel with the mast tilled forward, + Donot load and unload on slopes, AX WARNING | KEEP TENSION ON CHAIN + Ifthe mast rail or forks catch in a load or on a shelf, slack in the lift chain may be created, resulting in danger that the load may fall and the lif truck tip, ‘Always be careful that there is no slack in the chain when pulling the forks out from a pallet or shelf. M073 — AX/BX Op & Maint ‘012104 178. LOADING OPERATIONS A WARNING | USE ONLY FOR INTENDED PURPOSES Do not use the lift truck for anything other than the intended use (loading operations using the forks), + Do not use the forks to open or close the doors of railroad ‘ars or warehouses, + Do not push any other vehicle + Do not hook ropes or cables on the forks and use the forks to lit loads. + Do not use the drawbar pin for towing operations ‘AA WARNING | LEVER OPERATION + Be careful not to operate the lever by mistake, There is danger that the forks or work equipment ‘may cause serious injury. *+ Do not operate the levers when getting off the iit truck A WARNING | USING DRaWBAR PIN Do not use the drawbar pin for towing othr lft trucks, for being towed by other lft trucks, or for liting operations. +The drawbar pin insialled to the rear of the counterweight is Used only to free the truck when the tires have become stuck in mud of in a ditch and the lif truck cannot move, or when loading the lift truck on to a trailer or truck, DRAWBAR PIN gee 7005 1-18 oni40a OMO073 = AX/BX Op & Maint8, LOADING OPERATIONS AA WARNING | FIT FORKS SECURELY In Position + When adjusting the position (width) of the forks, be careful ‘no! fo get your hands caught + After adjusting, check that the forks are held securely in posl- tion by the fork stopper. If the forks are not held in position, there is a danger that the forks may move when the lit truck is traveling and the load may falloff A CAUTION | A0JUST CHAIN + Be sure the tension of the left and right chains is the same. (See CHECK BEFORE OPERATION). Ifthe tension is not the same, the load will be unbalanced even if it is loaded correctly in the center, and there is danger that the lift truck may tip. (For details of adjustment, see page 2-20), OMO073 - AX/BX Op & Maint 011404 1788. LOADING OPERATIONS A WARNING | BE CAREFUL OF FORK TIPS + 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. If the forks slip out, there is danger that the lif truck or object may move unexpectedly WARNING | PEOPLE IN WORKING AREA + Dornot allow anyone except the signal person in the working area + Dornot let any person or another lit truck come ciose during operation + When working with a signal person, aiways follow their instructions. AX WARNING | USE STRONG PALLETS AND SkiIDS Always be sure thal the pallets and skids have ample strength. if broken or damaged pallets or skids are used, there is a risk that the load may fall A WARNING | HANDLING LONG OR WIDE LOADS + Be extremely careful when carrying long or wide loads, Raise the toad slowly and be careful not to touch anything in the surrounding area, + Keep the load as low as possible and be sure to maintain the balance, + When turing, operate slowly and be careful not to let the load move. 120 71404 M073 — AX/BX Op & Maint8. LOADING OPERATIONS A WARNING | OVERHEAD OBJECTS + Be careful not to let the mast, overhead guard or load contact electrical winng, pipes, sprinklers or roof beams. If the truck hits such objects. there is a risk that the load will fall or the tit truck will tip. When the forks are raised, the mast height increases, £0 be paticularly careful when the forks are raised Ay WARNING | "oPUSHING + Donot use the forks to push or pull loads. There is a risk that the load will be damaged or fal A WARNING | PRECAUTIONS WHEN LOADING / UNLOADING Do not let anyone place a load on the forks, Do not let anyone remove a load directly 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 lift truck may move unexpectedly, causing the load to fall and crush the person, OM073—AX/BX Op & Maint S(T 404 7219. STOPPING AND PARKING 9. STOPPING AND PARKING A WARNING | PRECAUTIONS WHEN STOPPING OR PARKING Observe the following procedure when stopping or parking the lift truck 1) Stop the lift truck on level ground, 2) Apply the parking brake securely to make sure that the lift truck cannot move 3) Set the directional lever and the speed lever to neutral 4) Lower the forks to the ground, 5) Turn the key switch OFF to stop the engine. 6) Remove the key from the key switch, Then get off the lit truck A WARNING | PARKING + Park the lift truck in the specified place. + Park the lift truck on a firm surface, + Do not park near any emergency exit, stairway, fire extinguisher or other safety equipment. Park the lit truck in a piace where it will not obstruct pedestrians or other vehicles, + Never park the lift truck near any flammable object + When parking the lift truck on a slope, park as specified above (PRECAUTIONS WHEN STOP- PING OR PARKING), then put blocks under the tires to prevent the lift truck from moving, + Do not park near any holes for construction or elevator shafts, I LPG leaks, ii can accumulate and cause fire or explosion 1-22 071404 M073 — AX/BX Op & Maint9. STOPPING AND PARKING A WARNING | PARKING MACHINE AFTER FAILURE If the lift truck has suffered a failure and the lift truck must be parked without lowering the forks, put markers on the tips of the forks and take steps to prevent pecestrians or other veh les from hitting the forks, + Select a parking place where people or vehicles do not pass, ‘and stop the lift truck 0 that it is difficult for anyone to go under the forks, (The area under the forks is a DANGER zone) + Place a stand or something similar under the inner mast ral ‘forks to prevent unexpected crop of the forks. + Remove the kay 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 ovt404 123410. INSPECTION AND MAINTENANCE 10. INSPECTION AND MAINTENANCE A WARNING | USE QUALIFIED PERSONNEL FOR INSPECTION AND MAINTENANCE Only persons authorized by the owner or operator of the equipment and having proper certification {local or naticnal) may carry out inspection, maintenance and repairs of the lift truck, It inspection, maintenance or repair work is carried out incorrectly itis very dangerous, A WARNING | MAINTENANCE LOCATION When carrying out inspection and maintenance, use a level, dry, dust-fee area {the work is cartied out inside a building, make sure that there is ample ventiation A WARNING | PRECAUTIONS FOR INSPECTION AND MAINTENANCE To be prepared in the event of a fire, have a fire extinguisher nearby and make sure that you know how to use it Before carrying out inspection, lower the forks to the ground and stop the machine. Do not run the engine unless it is necessary. Place the directional lover, epoed lever and work equipment control levers in neutral PRECAUTIONS WHEN CARRYING OUT INSPECTION A WARNING AND MAINTENENCE Whe off any oll or grease. Immediately wipe up any oll that has leaked, If the It truck is dirty, it becomes difficult or impossible to find cracks or other problems. Always clean the lift 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, oli or grease. There is danger that it may catch fire. Wear suitable clothes for the job, Use suitable safety and protective equipment (hard hat, safety boots, safety glasses, gloves) for the job. (When working on top ofthe it truck, be careful not to fal Do not put your feet under the forks, When opening or closing the floor plate or engine hood, be careful not to get your hands or body caught When 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, ‘After repairing, make sure that the trouble has been corrected by performing a trial run. Dunng the trial run, start and operate the Ift truck carefully because it's possible that the trouble has not been fully corrected or that defective parts have not been removed. 124 11404 M073 — AX/BX Op & Maint10. INSPECTION AND MAINTENANCE A CAUTION | USE SUITABLE TOOLS + Always use tools that are suited for inspection and main- tenance + It is extremely dangerous to use broken tools oF tools =, designed for another purpose, AA WARNING | PEPLACE SAFETY CRITICAL PARTS PERIODICALLY + Even if no abnormality is found, always replace safety critical parts periodically, As time passes, those parts deteriorate and may cause fire or failure in the work equipment system. The list of safety critical parts is on page 3-15. + However, if these parts show any abnormality before the replacement interval has passed, they should be repaired or replaced immediately, WARNING | PRECAUTIONS WITH HIGH TEMPERATURE COOLANT + Immediately after using the lift truck, the engine coolant is at high temperature (HOT!) and high pressure, Do not remove the radiator cap under these conditions. Hot water may spurt out and cause bums, + When removing the radiator cap, use a rag and tum it slowly to release the intemal pressure, Wiss bss + When checking the coolant level, stop the engine and wait for PoE DELETE the engine 10 cool down before checking For Ht trucks — evipped wth a subank of reserva, check the level inthe su-tank + When adding water on lift trucks equipped with a sub-tank, ‘add the water to the sub-tank M073 — AX/BX Op & Maint a6 8410. INSPECTION AND MAINTENANCE TEMPERATURE OIL + Immediately after using the lit truck, the olf is at high temper- ature. Do not drain the ol or replace the filter when the oll is ht. 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, crain oll or carry out mainte nance oF inspection before completely releasing the intemal pressure, + foil is leaking under high pressure from holes, it is danger- ous if the jet of high-pressure oll hits your skin or eyes, ‘Always wear safety glasses anc thick gloves, and use a piece of cardboard or a sheet of plywood to check for oil leakage. + Release the intemal pressure before chacking the accumu: tor piping, + you are hit by @ jel of high-pressure oil, consult a doctor immediately WARNING | ROTATING FAN AND BELT A WARNING | PRECAUTIONS WITH HIGH PRESSURE, HIGH INCORRECT —” CORRECT is = + 11s 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 * Always stop the engine before inspecting rotating parts. When inspecting the areas around rotating parts, do not allow anything to come close which may get caught 1-26 oia04 OMO73 = AX/BX Op & Maint10. INSPECTION AND MAINTENANCE A WARNING | 8E CAREFUL NOT TO GET CAUGHT OR FALL + NEVER put your hands or feet into the mast structure. There is danger that you wil get caught in moving parts and be seri- ously injured, + Donot use the mast, load backrest or dashboard as a ladder. Ifyou slip, there is danger that you wil fall A DANGER | CHECKING AND INFLATING TIRES + Ifthe tire inflation pressure is low, it wil affect truck stabilty, However, do not inflate the tires immediately, The inflation pres- sure may have gone down because of damage to the rim. Ifthe rim ls damaged or cracked and the tires are inflated, there is danger that the rim vill break when the tire is under high pres- sue, 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 tir. + Suitable qualifications are needed for tire inflation work on a lit truck. Itis net ike an automobile. Always have the work carried ‘out by properly qualified personnel. + The tire inflation pressure on a forklift 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 weer safely glasses to protect your eyes M073 — AX/BX Op & Maint o1ra04 ed10, INSPECTION AND MAINTENANCE AX WARNING | HANDLING TIRES Disassembly and assembly of tires should be carried out by a te dealer The tre pressure is extremely high, so caution is needed when handling tres. + The whee! is fitted with mounting (lug) nuts. I also has rim nuts and bolts used to join the nm halves. When removing the tire from the lif ruck, do not loosen the rim nuts and bolts, The tire is under high pressure, and there is a significant risk that the rim nuts and bolts may fy off. Relieve tire inflation pressure before removing + When the tires have been repiaced, carry out a test drive and check again for eny loose mounting bolts. If the tightening torque is iow, tighten to the specified torque. A WARNING | JACKING UP LIFT TRUCK (when checking or replacing tires) + Do not go under the fork lit truck when its jacked up, + Check the following before jacking up the lift truck. (For detalis, see 3-page 41) 1) Check that there is no one on the jift truck. 2) Check that there is no load on the forks. + When jacking up. stop when the tires come of the ground sur- face, Put blocks under both sides of the frame to prevent the lift truck from coming down + Put blocks under any tires contacting the ground fo prevent the It truck from moving. 0150 A WARNING | LIFTING LIFT TRUCK (when checking tires) + Lift truck stinging work should be carried out by @ quelified person who has completed a course in correct Hting meth- 0s + Fitwire ropes to the specified iting points. + When lifing the lift truck, check that the wire ropes have ample strengtn and are not damaged. + Block the tires contacting the ground to prevent the lift truck from moving + Insert blocks to prevent the lift truck from coming down, + Do not go under the lit truck curing the lifting operation + If the specified liting 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- terwerant 128 oni40a OMO73 - AX/BX Op & Maint10. INSPECTION AND MAINTENANCE BA WARNING | B47TERY HAZARD PREVENTION + Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. f you spill electrolyte on yourself, immediately flush the area with a large quantity of water. + Battery electrolyte can cause blindness if splashed into the eyes. If electrolyte gets into your eyes, flush them immediately with large quantities of water and consult a doctor al once, + Ifyou accidentally dnnk electrolyte, drink a large quantity of water or milk mixed with beaten egg white or vegetable oll. Cali a doctor or poison control center immediately. + When working with batteries, ALWAYS wear safety glasses or goggles. + Balteries generate hydrogen gas. Hydrogen gas is highly EXPLOSIVE, and is easily ignited with a ‘small spark or flame. Do no! smoke or create any spark near a battery. + Before working with batteries, stop the engine and turn the starting switch to the OFF position + When removing the battery, remove the cable from the negative (-) terminal first, When installing the battery, install the cable to the positive (+) terminal frst, This prevents possible sparks or arcing betwoen the positive termi- \ nal and the positive cable + Avoid short-circuting the battery terminals through accidental contact with tools or other metal objects across the terminals, i + Tighten the battery terminals securely. Loose terminals can generate sparks and lead to an explosion. + When removing or installing the battery, confirm which is the positive (+) terminal and which is the negative (-) terminal, Be Careful not to connect the cables to the opposite / incorrect ter- CHECK BATTERY rminals, + Tighten the battery caps securely. ceeNay + When cleaning the battery, leave the battery caps tightened me) arrery| BA WARNING | PONOT PUT METAL OBJECTS ON TOP OF BATTERY Never place any metal objects on top of the battery, Ther cuit and start a fire. A WARNING | CHANGING LPG FUEL TANKS Only trained and certified personnel may change LPG tanks. ‘Turn ignition switch to the OFF position, ‘Change LPG tanks in designated and well ventilated area approved for this operation Check LPG tank and lines for fuel leaks. Ensure no sparks, flame or ignition sources are present ‘Once the full tank is in place, ensure it is mounted correctly and securely. Check all connections. Do not attempt to start the truck unti all LPG odor is gone, Ifthe truck is hard to start, contact a certified mechanic {0 repair the problem. Tag the truck ‘Out of Service’ until properly repaired. danger that they will cause a short cir- OMO73 - AX/BX Op & Maint ‘011404 729