Komatsu BBX50 Series User manual

SERVICE MANUAL
ISSUED DECEMBER 2005
Read and observe all warnings on this unit
before operating it.
DO NOT operate this equipment unless all
factory installed guards and shields are
properly secured in place.
WARNING
BBX50 SERIES ELECTRIC FORKLIFT TRUCKS - S/N 090001A~
FB20/25/30/32SH-6
FB20/25/30/32SHE-6
FB20/25SHG-6
FB20/25SHGE-6
SM150
BBX50
Komatsu Forflift USA, Inc.

1
CONTENTS
Page No.
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . 5
APPLICABLE LIFT TRUCK MODELS COVERED IN THIS PUBLICATION .. . . . . . . . . . . . . . . . . . . . 6
CHAPTER 01 - SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .
Safety Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 01-1
Safe Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 01-5
Loading Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 01-13
Stopping and Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 01-19
Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 01-20
Structure and Stability of the Lift Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 01-26
CHAPTER 10 - GENERAL INFORMATION AND SPECIFICATIONS . . . . . . .. . . . . . . . . . . . . . . . . 10-1
Dimensions and Specifications (FB20SH-6 (36V & 48V)). . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 10-2
Dimensions and Specifications (FB20SHG-6 (36V & 48V)) . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 10-4
Dimensions and Specifications (FB25SH-6 (36V & 48V)). . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 10-6
Dimensions and Specifications (FB25SHG-6 (36V & 48V)) . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 10-8
Dimensions and Specifications (FB30SH-6 (36V & 48V)). . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 10-10
Dimensions and Specifications (FB32SH-6 (36V & 48V)). . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 10-12
Periodic Replacement of Consumable Parts . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 10-14
Standard Tightening Torque for Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 10-15
Standard Tightening Torque for Pipe Joints . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 10-16
How to Use Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 10-17
Conversion Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 10-18
CHAPTER 20 - TESTING AND ADJUSTING. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 20-1
Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 20-2
Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 20-3
Controller Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 20-3
Checking Controller Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 20-3
Wiring of Type EE Truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 20-4
Location of Connectors & Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 20-5
Selecting Optional Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 20-6
Optional Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 20-7
Display Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 20-8
User Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 20-8
Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-10
Service Mode Adjustment Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-14
Details of Each Setting / Adjustment Item . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-15
Checking by Switch Monitor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-18
Checking Switches (Sensors). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-19
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-21
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-22
Traction AC Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-23
Assembling/Disassembling Procedures . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-25
Pump AC Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-26
Assembling/Disassembling Procedures . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-27
Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-29
Temperature Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-31

2
Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-32
Maintenance and Inspection of Motors. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-33
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-34
Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-35
Brake Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-37
Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-38
Parking Brake Lever - Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-39
Hydraulic Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-40
Bleeding Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 20-41
CHAPTER 30 - REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 30-1
Arrangement of Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 30-2
Weight of Each Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 30-3
Power Train (Front Axle - Transfer Case - Traction Motor). . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 30-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 30-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 30-8
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 30-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 30-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 30-10
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 30-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 30-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 30-12
Hydraulic Pump - Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 30-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 30-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 30-13
Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 30-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 30-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 30-14
CHAPTER 40 - DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 40-1
Transfer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 40-2
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 40-2
Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 40-8
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 40-8
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 40-9
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 40-9
Brake Master Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 40-10
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 40-10
Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 40-12
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 40-12
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 40-13
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 40-13
Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 40-16
Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 40-16
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 40-17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 40-17
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 40-17
Hydraulic Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 40-19
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 40-19
Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 40-20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 40-21
Control Valve (Typical 3-Spool). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 40-23
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 40-24

3
Traction Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 40-25
Pump Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 40-26
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 40-27
Judging Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 40-28
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 40-29
CHAPTER 50 - MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 50-1
Transfer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 50-2
Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 50-3
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 50-4
Brake Master Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 50-5
Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 50-6
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 50-7
Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 50-9
Mast, Fork Carriage and Fork. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 50-10
Traction Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 50-11
Pump Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 50-12
Maintenance and Inspection of Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 50-13
CHAPTER 60 - STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 60-1
Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 60-2
Overview and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 60-2
Outside View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 60-2
Control Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 60-3
Hydraulic Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 60-3
Motor Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 60-4
Connection Diagram - Motor Power Circuits . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 60-4
Overview of AC Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 60-5
Overview of FET Power Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 60-6
Control Functions of Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 60-7
Travel Interlock (Power Shutdown) . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 60-8
Load Handling Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 60-9
Lift Interrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 60-10
Travel Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 60-10
High Mast Tilt Speed Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 60-11
Seat Brake Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 60-12
FR-Related Power Steering Control Option. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 60-12
Seat Switch Related Headlight Option. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 60-12
Protective Functions of Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 60-13
Thermal Cutback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 60-13
Overcurrent Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 60-14
Low Voltage Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 60-14
Overvoltage Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 60-14
Performance Characteristics Setup Function. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 60-14
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 60-15
Table of Character Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 60-28
CHAPTER 70 - TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 70-1
Preparation for Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 70-2
Before Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 70-2
Checking Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 70-3
Checking Insulation Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 70-3
Connector Terminals & Location of Controller . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 70-3
Failure Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 70-4

4
Self-Diagnosis Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 70-4
Control Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 70-5
Classification of Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 70-6
Failure Analysis with No Error Code. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 70-7
Checking In-Line Fuses on Harness . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 70-8
Precautions for Cable Check & Voltage Measurement. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 70-9
Checking Controller CPU PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-10
Initialization of Adjustments / Settings . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-12
Precautions for Replacing CPU PCB . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-13
Pin Assignment of Connector on Truck Side Wire Harness . . . . . . . . .. . . . . . . . . . . . . . . . 70-14
Electric Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-16
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-18
Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-20
Overview and Features of Controller . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-20
Structure of Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-20
Checking Electric Parts of Controller . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-24
Loose Parts and Poor Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-25
Checking On-Board Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-25
Removing CPU PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-25
Removing Power Supply PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-25
Connector Location and Pin Number of CPU PCBS . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-26
Connector Location and Pin Number of Power Supply PCB . . . . . . . .. . . . . . . . . . . . . . . . 70-28
Checking FET Power Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-29
Checking Main Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-31
Checking Main Contactor (MD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-32
Checking Capacitor PCBS (CD, CP) . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-32
Checking Current Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-33
Checking Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-34
Checking Resistors (R1/R2) for Fans. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-34
Checking Resistor (RCH) for Capacitor PCB . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-34
Connector Voltage Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-35
Controller System Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-42
Error Code List and Check Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-44
Motor (Traction and Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-50
Problems and Corrective Actions. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-50
Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-52
Trouble Diagnosis Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 70-52
CHAPTER 80 - YEARLY INSPECTION CRITERIA . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 80-1
Inspection Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 80-2
APPENDIX 1 - MAST SERVICE MANUALS . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .
E Series MD Masts - Full Free Lift 2-Stage. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .
E Series MS Masts - Limited Free Lift 2-Stage. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .
E Series MT Masts - Full Free Lift 3-Stage. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .

6
FORKLIFT TRUCKS
COVERED IN THIS PUBLICATION
BBX50 S/N 090001A~
KOMATSUMODEL
DESIGNATION DESCRIPTION
Electric Lift Trucks
FB20SH-6 4,000 lb. Capacity, Cushion Tire, High Option
FB20SHE-6 4,000 lb. Capacity, Cushion Tire, High Option, EE Rated
FB20SHG-6 4,000 lb. Capacity, Cushion Tire, High Option, Extended Frame
FB20SHGE-6 4,000 lb. Capacity, Cushion Tire, High Option, Extended Frame, EE Rated
FB25SH-6 5,000 lb. Capacity, Cushion Tire, High Option
FB25SHE-6 5,000 lb. Capacity, Cushion Tire, High Option, EE Rated
FB25SHG-6 5,000 lb. Capacity, Cushion Tire, High Option, Extended Frame
FB25SHGE-6 5,000 lb. Capacity, Cushion Tire, High Option, Extended Frame, EE Rated
FB30SH-6 6,000 lb. Capacity, Cushion Tire, High Option
FB30SHE-6 6,000 lb. Capacity, Cushion Tire, High Option, EE Rated
FB32SH-6 6,500 lb. Capacity, Cushion Tire, High Option
FB32SHE-6 6,500 lb. Capacity, Cushion Tire, High Option, EE Rated

SAFETY MANAGEMENT
1-1
SAFETY MANAGEMENT
• Read the instructions in this Manual and the Safety Labels attached to the various parts of the lift truck,
and make sure that you understand and follow them. If you do not understand or do not follow the
instructions, this will 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 carrying out
an inspection, and ensure that they are carried out safely.
• Read this Manual and the Safety Labels again from time to time. If the Operation and Maintenance
Manual or Safety Labels have been lost or become dirty and cannot be read, obtain replacements from
your Komatsu Forklift dealer and attach the Safety Labels in the specified positions.
OPERATION MANUAL AND SAFETY LABELS
• This lift truck should be operated only by qualified personnel. Be sure you have proper qualifications
before operating the lift truck.
• Using this lift truck without due care and attention may lead to injury or even death of you or others.
Be sure that you read this manual thoroughly and understand the explanations completely before you
use this lift truck or carry out maintenance on it.
• When you start to use this lift truck, be sure that you carry out ample practice so that you become
accustomed to each part of the equipment. Even when you have become accustomed to handling the lift
truck, always drive carefully and do not try to force the truck beyond its capacity. Failure to observe these
precautions may lead to serious personal injury or accident.
• For those operators who have recently obtained qualifications to operate lift trucks, always seek the
advice of experienced operators or instructors in the methods of operating and loading the lift truck.
• For those operating more than one lift truck, even if the model is the same specification, remember that
each truck differs slightly in the performance and reaction of the brakes, accelerator, and loading system.
When changing from one truck to another, always be sure that you become accustomed to the
performance of the truck before operating it. The feeling when operating the brakes is particularly
important.
• When operating this lift truck, even if you have experience in operating other lift trucks, obtain instruction
from an authorized person who has experience in operating this lift truck or the same type of lift truck.
OPERATION QUALIFICATIONS
• Avoid loose clothing, jewelry, and loose long hair. They 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.
CLOTHING AND PERSONAL PROTECTIVE ITEMS

SAFETY MANAGEMENT
1-2
• Do not use this lift truck unless it is equipped with the overhead guard and load backrest shipped with the
lift truck from the factory by Komatsu Forklift.
OVERHEAD GUARD, LOAD BACKREST
• Any modification made without authorization from Komatsu Forklift can create hazards.
• Before making any modification whatsoever, consult your Komatsu Forklift dealer. Komatsu Forklift will
not be responsible for any damage, injury or death caused by any unauthorized modification.
• Do not install any equipment or parts which obstruct or limit the operator’s view.
UNAUTHORIZED MODIFICATION
• If any abnormality in the lift truck occurs, stop operation immediately, park
the lift truck in a safe place and safe condition, then contact the person in
charge.
• Be sure that fire extinguishers have been provided and that you read the
labels to 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 should contact in
case of an emergency.
• Provide a first aid kit at the storage point.
• Do not use the lift truck if it is leaking fuel. Inform the person on charge of the nature of the abnormality,
and repair the leakage before using the lift 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 remove the key before leaving the lift truck.
FIRE EXTINGUISHER AND FIRST AID KIT
• Do not operate the lift truck if you are fatigued, or when you have been drinking, or you have taken any
medication which can make you drowsy or sleepy.
• When carrying out operation, inspection, or maintenance of the lift truck, always follow all work shop
rules, safety regulations and precautions.
• During operation, always pay attention to safety and be careful of pedestrians, traffic and other
surrounding conditions.
SAFETY RULES
• The overhead guard is installed to protect the operator from falling objects. It is designed to withstand the
force of light boxes or small packages. It is not designed to withstand every possible impact.
• Always be careful to prevent damage or injury from falling objects.
SAFETY EQUIPMENT

SAFETY MANAGEMENT
1-3
• 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.
CHECK WHEN TRAVELING IN REVERSE
• Do not travel on public roads unless you comply with local, state or other laws which regulate such
activity.
• Always observe all traffic regulations when operating the lift truck.
• Do not drive on public roads with the lift truck loaded.
• Do not tow other machines on public roads. (Do not tow other machines even when not on public roads).
• Always carry your driver's license when traveling on public roads.
TRAVELING REGULATIONS ON PUBLIC ROADS
The tire fenders prevent objects from being thrown up by the tires. When changing from a single tire to a
double tire arrangement on your forklift truck, always extend the tire fenders to cover the additional tires. If
the fenders are not extended, small stones and other objects will be thrown up and may injure the operator
or other people in the surrounding area.
TIRE FENDERS
• Always work on level surfaces and wipe up all oil 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 warn 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.
SAFE WORKING AREA

SAFETY MANAGEMENT
1-4
• Keep the operator's compartment clean and tidy. Be sure to clean up all oil or mud. If the operator's hand
or foot slips, this may lead to a serious accident.
• Do not leave tools or spare parts lying around in the operator's compartment. They may damage or
obstruct the control levers or pedals. Always keep them in the tool box when not being used.
CLEAN OPERATOR'S COMPARTMENT
• Before operation, establish an operating plan and hold a meeting to discuss operating safety.
• In confined areas, position a signal person and carry out operations in accordance with his or her
instructions.
• When carrying out operations on roads, put up fences around the working area and carry out operations
in accordance with instructions from the signal person.
SAFE OPERATING PLAN
• The permissible load for any lift trucks equipped with an attachment is lower than the permissible load for
the standard lift truck. Reason:
1. The permissible load must be reduced by an amount equivalent to the weight of the attachment
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 lift truck or the attachment). Never exceed the permissible load.
REDUCE LOAD FOR LIFT TRUCKS WITH ATTACHMENT
• Avoid operating or leaving the lift truck outside in wet and rainy weather or snow and icy conditions.
• When washing the lift truck, use care to prevent water from contacting electrical parts. If water does come
in contact with the electrical system it may cause the system to operate abnormally and it may become
impossible to control the lift truck.
KEEP FREE FROM WATER
You must follow lockout or tagout procedures to control hazardous energy during the inspection, servicing
and maintenance operations of your lift truck as defined in the Occupational Health and Safety
Administration (OSHA) Standard 29 CFR 1910.147.
• When there are deficiencies or any mechanical defect that would prevent the safe operation of the truck:
1. Remove the lift truck from service and park it.
2. Initiate lockout or tagout procedures according to the safety policy in place in your facility until the
repairs are completed.
• When service personnel outside your facility are involved in the inspection, servicing and maintenance
operations of your lift truck:
1. Inform the outside employer of your lockout or tagout procedures. The outside employer must also
inform you of their procedures.
2. Ensure that your employees understand and comply with the restrictions and prohibitions of the out-
side employer's energy control program.
USE LOCKOUT OR TAGOUT PROCEDURES

SAFE TRAVEL
1-5
SAFE TRAVEL
• Always fit your seat belt correctly when operating. If your seat belt is
fitted incorrectly, there is danger of serious personal injury if the lift
truck should tip over.
• Always check the seat belt mounts and check for any damage to the
seat belt. If any abnormality is found, repair or replace the seat belt
immediately.
WEARING SEAT BELT
• NEVER JUMP OFF the lift truck even if it seems that it will tip.
Always do as follows:
1. Hold the steering wheel securely.
2. Stay in the operator's seat.
3. Brace your legs.
•If you jump off the lift truck when it turns over, there is danger
that you will be fatally crushed under the lift truck. Always stay in
the operator's compartment if the lift truck turns over, then escape
from the lift truck after it has stopped.
• Always wear the seat belt correctly.
DO NOT JUMP OFF LIFT TRUCK EVEN IF IT TIPS

SAFE TRAVEL
1-6
• Depress the brake pedal firmly, then start the unit.
• Before starting the unit, always check that the parking brake is applied
and that the directional lever is in neutral.
• Adjust the operator's seat and the steering wheel before starting the
unit. Always lock them in position after adjusting. Adjusting the seat or
steering wheel during operation is dangerous as it may cause you to
lose your balance or operate the lift truck wrongly.
• When starting the unit, first check that the surrounding area is safe,
and sit in the operator's seat.
• Before starting the unit, sound the horn to warn people in the area.
• With large-sized lift trucks, get off the lift truck, and walk around it to
check that is no one near the battery compartment, tires, or
counterweight, then get on the lift truck, sit in the operator's seat, and
start the unit.
PRECAUTIONS WHEN STARTING UNIT
• When switching between FORWARD and REVERSE, always stop the lift truck first. It is dangerous to
change the direction of travel suddenly or when the lift truck is moving.
• If the lever is moved without disengaging the clutch, the lift truck will move suddenly and may cause
injury.
PRECAUTIONS WHEN OPERATING DIRECTIONAL LEVER
• If unit trouble occurs on a railroad crossing and the lift truck will not move or cannot be moved, get off and
move away from the lift truck
• In such an emergency, light a flare or smoke candle to warn approaching trains and people in the area
that there is a broken-down truck on the tracks.
ESCAPING FROM A RAILROAD CROSSING
• 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 lift truck
tipping. Do not turn the lift truck when the forks are raised high.
• Do not suddenly raise the forks or tilt the mast to the front or rear
when the forks are loaded. There is danger that the lift truck will tip.
• Reduce speed before turning the lift truck.
• In particular, when traveling unloaded, the rear of the lift truck is
heavy. If the lift truck is turned at high speed, there is a greater
chance of tipping than with the forks loaded.
TIPPING

SAFE TRAVEL
1-7
• Do not turn, or travel across or at an angle on slopes. There is danger that
the lift truck will tip.
• Before starting to drive up a slope, stop the lift truck and adjust the
clearance between the ground surface and the bottom of the forks so that
the bottom of the forks or pallet do not contact the ground surface or the tip
of the fork does not stick into the ground when traveling.
• For safe travel on slopes:
• When traveling downhill, operate the foot brake and drive the lift truck
slowly.
• When starting on slopes, the lift truck may start to move down the slope
depending on the amount the pedals are depressed.
• Always leave ample room in front of and behind the lift truck when starting
on slopes.
• Be careful that the lift truck may slip down due to power shutdown when
the travel interlock is activated during travel on a slope or hill.
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 slope with the load-
engaging means downgrade.
TRAVEL ON SLOPES
• There is danger that soft road shoulders may collapse, so do not go near
them with the lift truck.
• Always maintain a safe distance from the edge of road shoulders and
platforms.
ROAD SHOULDER

SAFE TRAVEL
1-8
• Do not travel on the edge of docks. There is danger that the lift
truck may fall, which may result in serious injury or death.
• Before starting operations, check the load limit for the gangplanks
(dock boards), and do not use them if they do not have ample strength
to take the weight of the lift truck when loaded.
• Apply the brakes on the highway truck and block the wheels.
• With trailers, use jacks and take steps to prevent the trailer from sinking
when the forklift truck tr3avels on it.
• When driving the forklift inside trucks, reduce speed when backing out
and be sure to check that the gangplanks are safe.
• Be careful of pedestrians.
• Tell the truck driver not to move the truck until the operation is
completed.
• If there is some system to secure the truck to the dock, always use this
system. Secure the gangplanks so that they do not slip and fall.
LOADING HIGHWAY TRUCKS OR RAILROAD CARS
•FORKLIFT TRUCKS ARE ONE-PERSON MACHINES.
• Do not allow any other person to ride on
the truck under any circumstances.
• Never allow anyone to act as an extra
counterweight.
NO RIDERS
• Before driving in reverse, make sure that there is no one behind
the truck before starting to travel.
• The rear view mirror is simply an aid for checking the rear.
When driving in reverse, do not use the rear view mirror. Turn to
face the rear and check the area directly behind the lift truck.
• Even if you sound the backup buzzer, the people behind the truck
do not necessarily hear it. Always check that there is no one
behind the truck before driving the truck.
DRIVING IN REVERSE

SAFE TRAVEL
1-9
• If the view to the front is obstructed by the load, turn to the rear
and drive the forklift truck in reverse.
• When driving in reverse with a high load, use a signal person to
ensure the safety of the load and the safety in the surrounding
area.
WHEN FRONT VIEW IS POOR
• When checking the lift truck before starting, follow the procedure given in this Manual, and do not start
the lift truck until all the checks have been completed.
• If anything abnormal is found, inform the person in charge and carry out the necessary repairs.
CHECK BEFORE STARTING
• When reversing, never depend on the rear view mirror; the operator must visually check behind him.
Also, adjust the rear view mirror so that the operator can check from the operator's seat that the area
behind the lift truck is safe.
• Always keep the surface of the mirror clean. If the mirror is broken, replace it with a new one (for lift
trucks equipped with rear view mirror).
• Check that the lamps light up correctly. Replace any broken bulbs (for lift trucks equipped with lamps).
REARVIEW MIRROR, LAMPS
• NEVER jump onto or off the lift truck.
• When getting on or off the lift truck, always stop the lift truck and use the
handrails and steps to ensure that you support yourself.
• Never hold any control levers or the steering wheel when getting on or off
the lift truck.
• If there is any oil, grease or mud on the handrails or steps, wipe it off
immediately. Always keep these parts clean. Repair any damage.
MOUNTING AND DISMOUNTING
• Do not drive the lift truck if your hands are wet or covered with oil. Your hands will slip on the work
equipment control levers or directional lever, and this may cause a serious accident.
KEEP HANDS FREE FROM OIL AND WATER

SAFE TRAVEL
1-10
Always observe the following:
• Never operate the lift truck from outside the operator's compartment.
• Always keep your body under the overhead guard.
• Do not extend your arms and legs outside the operator's compartment.
ALWAYS SIT IN OPERATOR'S SEAT
Travel Interlock (power shutdown)/Load Handling interlock
• If an operator operates the lift truck without being seated in good posture or
leaves operator's seat during operation, this may cause an accident. To
prevent this, the lift truck is equipped with Travel Interlock (power shutdown)
and Load Handling Interlock functions to disable travel and Load Handling
Interlock functions unless the lift truck is operated in good posture.
• During standstill and traveling, if you leave the operator's seat or have bad
posture with no weight applied to the seat during work, the Travel Interlock is
activated about 3 seconds later, shutting off the power of the lift truck. The lift
truck no longer moves even if you operate the accelerator pedal or forward-
reverse lever.
At the same time, the Load Handling Interlock is also activated 3 seconds later during traveling, or one
second later during stand still, disabling all operations of the mast and forks. The lift lever is mechanically
locked out to inhibit operation. Even if the tilt lever or attachment lever is operated, no hydraulic power is
transmitted.
Do not leave operator's seat with the lift lever activated.
• If you leave operator's seat with the lift lever turned to the lowering position, the lift truck does not stop
lowering.
USE GOOD POSTURE WHILE OPERATING LIFT TRUCK
• Before starting and moving the lift truck, check that the surrounding
area is safe.
• Before moving the lift truck, raise the forks (approximately 6 - 8 in.
(15 - 20 cm) from the ground surface), and tilt the mast back.
• Before moving the lift truck, release the parking brake.
SAFETY WHEN STARTING

SAFE TRAVEL
1-11
• Do not turn the key switch OFF during traveling. If the key switch is turned OFF, the power steering (for
lift trucks with power steering) and power brake (for lift trucks with power brakes) will not work.
• Do not use the brake excessively. Do not rest your foot on the brake pedal unless you are operating it. If
you do, the brake will overheat and the braking effect will be lost.
BRAKING WHEN TRAVELING
• When traveling, always pay careful attention to the area around
your lift 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 horn to confirm safety before driving on.
• Even if you sound the horn, not everyone in the surrounding
area will necessarily hear it. Always pay careful attention to the
movements of people in the surrounding area.
• When crossing roads or turning corners, stop and confirm safety
before continuing.
• Always pay careful attention to the movements of people in the surrounding area, and take steps to
prevent people from entering the working area.
CONFIRMING SAFETY
To ensure safety when driving the lift truck, always pay careful attention
to the following:
• Avoid traveling in places which are flooded or where there are holes.
• Do not try to drive the lift truck on soft ground.
• Avoid curbs, rails, ditches, or other obstacles, and do not travel
directly over them.
• Do not travel on slippery road surfaces.
• When entering buildings, check the weight limit of the floor and be
careful not to exceed the limit.
• Keep a clear view of the path of travel and observe for other traffic,
personnel, and safe clearances.
• When passing oncoming vehicles, reduce speed and keep a safe
distance from the other vehicle.
• In places where there are speed limits, observe the speed limit and
maintain a safe distance from other vehicles.
SAFETY DURING TRAVEL
• When traveling on slopes or in confined areas, unloaded lift trucks should always give the right of way to
loaded trucks.
GIVE PRIORITY TO LOADED LIFT TRUCKS

SAFE TRAVEL
1-12
When going in or out of places with height or width limits:
• Ensure that there is ample height and width for the lift truck to pass.
• Do not extend your hands or legs outside the operator’s
compartment or the area covered by the overhead guard (safe area).
• Check that the surrounding area is safe.
• Be careful of electric wires and other obstacles inside and outside
the building.
HEIGHT OR WIDTH LIMITS
• When turning while traveling forward, the counterweight will swing
far out. Keep an ample clearance from walls and other objects to
ensure safety.
• When turning, travel slowly and be careful that the front or rear
wheels do not come off the ground.
• When turning on soft road shoulders, there is danger that the rear
wheels may come off the road shoulder and cause the lift truck to
tip.
PRECAUTIONS WHEN TURNING
• When traveling downhill, it requires a longer distance for the lift truck to stop than when traveling on level
ground.
• When traveling downhill, reduce the speed and make sure that you have ample room at the bottom of the
slope to stop.
• When traveling on wet surfaces, it requires a longer distance to stop than when traveling on normal road
surfaces. Always have ample room to stop.
STOPPING DISTANCE
• If there is any problem with the brakes or steering system of your lift truck, do not use another lift truck to
tow it. There is danger that the lift truck may run away.
NO TOWING

LOADING OPERATIONS
1-13
LOADING OPERATIONS
• Do not load the lift truck over the capacity set forth in the load
capacity chart. If the rear wheels come off the ground because of
overloading, the lift truck cannot travel or turn. There is also
danger that it may tip.
• Always check the load capacity chart to confirm the loading
capacity.
NO OVERLOADING
• Never allow anyone to go under the load-engaging means or load when it is
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 even if it is
elevated, stuck or caught in the up-position. It may fall down suddenly at any
moment.
DO NOT GO UNDER FORKS
• Do not use the forks to lift people. If the person falls from the forks he/she may
be seriously injured.
DO NOT LIFT PEOPLE ON FORKS

LOADING OPERATIONS
1-14
•Never put your hands or feet into the mast structure. There is danger
that you will get caught in moving parts and be seriously injured.
• Do not use the mast, load backrest or dashboard as a ladder or step. If you
slip, there is danger that you will fall.
BE CAREFUL NOT TO GET CAUGHT OR FALL
• 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.
• When carrying stacked loads, tie with rope or otherwise secure it to
prevent the load from falling.
NO UNSTABLE LOADS
• Always operate the mast and forks from the operator's compartment.
•Do not stand beside the lift truck and operate the levers, or operate the levers through the mast.
OPERATE THE LIFT TRUCK FROM THE OPERATOR'S
COMPARTMENT