Komatsu FD100-7 Install guide

PRECAUTIONS WHEN PERFORMING THE SERVICE WORK
Always pay attention to “Safety” before starting any work — this is important.
Never attempt any work where danger to yourself or to other persons.
Whenever work requiring safety precautions are described in this manual, a flag mark
inserted, always make double sure that safety measures are taken.
Other unmarked work, should always be performed after studying and using your
common sense to prevent accidents.
DESCRIPTION OF THE SYMBOLS
The symbols described below are used in this manual for convenience and better understanding.
Symbol Item Description
Safety Special safety precautions are needed to perform the work.
Note Special technical precautions are needed to perform the work
Tightening torque Fastening parts that require specified tightening force when assembling.
Weight Weight of parts or systems
Coat Places to be coated with adhesives, etc. when assembling
00-2 EX20 Series

SECTION INDEX
00. FOREWORD
10. GENERAL AND SPECIFICATIONS
20. TESTING AND ADJUSTING
30. REMOVAL AND INSTALLATION
40. DISASSEMBLY AND ASSEMBLY
50. MAINTENANCE STANDARD
60. STRUCTURE AND FUNCTION
70. TROUBLESHOOTING
80. CONVERSION TABLE
EX20 Series 00-3

10. GENERAL AND SPECIFICATIONS
Specifications..........................................................10- 2
Periodic replacement of consumable parts.............10- 5
Safety items for maintenance .................................10- 6
Standard tightening torque for bolts........................10-14
Standard tightening torque for pipe joints................10-15
EX20 Series 10-1

GENERAL AND SPECIFICATIONS
10-2 EX20 Series
SPECIFICATIONS
s
6
˚
12
˚
h
4
h
1
h
3
m
1
y
2
x
m
2
h
6
b
11
W
a
e
b
1
b
10
b
3
4
800
(
10560
)
5800
(
12760
)
6800
(
14960
)
8
7
00
(
19140
)
1
0000
600
(
24
)
800
(
31
)
12
00
(
47
)
1
600
(
63
)
2
000
(
79
)
600
(
24
)
12
00
(
47
)
1
600
(
63
)
2
000
(
79
)
mm
(
in
)
mm
(
in
)
5800
(
12760
)
(
14300
)
7
900
(
17380
)
1
0000
(
22000
)
11
500
k
g
(lb
)
k
g
(lb
)
FD1
00
FD11
5
C
apacit
y
600
(
24
)
800
(
31
)
12
00
(
47
)
1
600
(
63
)
2
000
(
79
)
600
(
24
)
800
(
31
)
12
00
(
47
)
1
600
(
63
)
2
000
(
79
)
mm
(
in
)
7
300
(
16060
)
8600
(
18920
)
1
0
4
00
(
22880
)
1
3000
(
28600
)
1
5000
(
33000
)
mm
(
in
)
k
g
(lb
)
6600
(
14520
)
77
00
(
16940
)
9300
(
20460
)
117
00
(
25740
)
1
3500
(
29700
)
k
g
(lb
)
FD1
35
FD1
50E
C
apacit
y
C
apacit
y
Load
C
ente
r
Load
C
ente
r
600
(
24
)
800
(
31
)
12
00
(
47
)
1
600
(
63
)
2
000
(
79
)
mm
(
in
)
7
800
(
17160
)
9
2
00
(
20240
)
11
000
1
3900
(
35200
)
k
g
(lb
)
FD1
60E
Load
C
ente
r
SPECIFICATIONS

GENERAL AND SPECIFICATIONS
EX20 Series 10-3
1.2
1.3
1.4
1.5
1.6
1.8
1.9
2.1
2.2
2.2.1
2.3
2.3.2
3.1
3.2
3.3
3.5
3.6
3.7
4.1
4.2
4.3
4.4
4.5
4.7
4.19
4.20
4.21
4.22
4.23
4.24
4.31
4.32
4.33
4.35
5.1
5.1.1
5.2
5.3
5.6
5.8
5.10
5.11
5.12
6.4
7.1
7.2
7.3
7.3.1
7.4
7.6
8.2
8.2.1
8.6
8.7
Model
Power Type
Operation Type
Rated Capacity
Load Center
Load Distance
Wheelbase
Service Weight
Axle Loading
Tyre Type
Tyre Size
Number of Wheel
Tread, Front
Tread, Rear
Tilting Angle
Mast Height, Lowered
Std. Free Lift
Std. Lift Height
Mast Height, Extended
Height, Overhead Guard
Length, with Std. Forks
Length, to fork face
Width, at tyre
Forks
Fork Carriage Class
Width, Fork Carriage
Ground Clearance
Right Angle Stacking Aisle
Turning Radius
Travel Speed(FWD)
Lifting Speed
Lowering Speed
Max. Drawbar Pull
Max. Gradeability
Service Brake
Parking Brake
Steering
Battery
Maker/Model
Rated Output, SAE gross
Rated Speed
Max Torque, SAE gross
No. of Cylinder/Displacement
Fuel Tank Capacity
Relief Pressure for Attachment
Hydraulic Tank Capacity
Clutch
Transmission
FD100-7
Diesel
Sitting
10000(22,000)
600(24)
695(27.4)
2800(110.2)
12800(28,220)
20720(45,680)
2080(4,586)
6095(13,440)
6705(14,780)
Pneumatic
9.00-20-14PR(I)
9.00-20-14PR(I)
4x/2
1700(66.9)
1900(74.8)
6/12
2890(113.8)
0(0.0)
3000(118)
4400(173.2)
2780(109.4)
5465(215.2)
4245(167.1)
2280(89.8)
75x170x1220(3.0x6.7x48.0)
Pin Mount
2140(84.3)
250(9.8)
325(12.8)
6115(240.7)
4000(157.5)
8.5/18/28(5.3/11.2/17.4)
9/20/32(5.6/12.4/19.9)
470/500(93/98)
400/500(78.7/98.4)
112(25,132)
38
Foot/Hydraulic, Powered
Hand/Mechanical
Hydraulic Power Steering
24/100
ISUZU 6BG1T
119(160)
2200
540(398)@1600
6/6494(396)
260(68.7)
215(3,118)
150(39.6)
Torque Converter
TORQFLOW
FD115-7
Diesel
Sitting
11500(25,000)
600(24)
715(28.1)
2800(110.2)
14200(31,310)
23430(51,655)
2270(5,004)
6530(14,400)
7670(16,910)
Pneumatic
10.00-20-14PR(I)
10.00-20-14PR(I)
4x/2
1700(66.9)
1890(74.4)
6/12
3160(124.4)
0(0.0)
3000(118)
4670(183.9)
2800(110.2)
5485(215.9)
4265(167.9)
2310(90.9)
75x185x1220(3.0x7.3x48.0)
Pin Mount
2140(84.3)
250(9.8)
345(13.6)
6135(241.5)
4000(157.5)
8.5/19/28(5.3/11.8/17.4)
9/21/32(5.6/13.0/19.9)
430/450(85/89)
400/500(78.7/98.4)
108(24,339)
32
Foot/Hydraulic, Powered
Hand/Mechanical
Hydraulic Power Steering
24/100
ISUZU 6BG1T
119(160)
2200
540(398)@1600
6/6494(396)
260(68.7)
215(3,118)
150(39.6)
Torque Converter
TORQFLOW
FD135-7
Diesel
Sitting
13500(30,000)
600(24)
740(29.1)
3100(122.0)
15400(33,950)
26450(58,312)
2450(5,401)
7115(15,686)
8285(18,265)
Pneumatic
11.00-20-14PR(I)
11.00-20-14PR(I)
4x/2
1770(69.7)
1890(74.4)
6/12
3170(124.8)
0(0.0)
3000(118)
4680(184.3)
2810(110.6)
5860(230.7)
4640(182.7)
2410(94.9)
80x185x1220(3.1x7.3x48.0)
Pin Mount
2200(86.6)
260(10.2)
350(13.8)
6460(254.3)
4300(169.3)
9/19.5/27.5(5.6/12.1/17.1)
9.5/21/32.5(5.9/13.0/20.2)
350/375(69/74)
400/500(78.7/98.4)
105(23,677)
28
Foot/Hydraulic, Powered
Hand/Mechanical
Hydraulic Power Steering
24/100
ISUZU 6BG1T
119(160)
2200
540(398)@1600
6/6494(396)
280(74.0)
215(3,118)
180(47.6)
Torque Converter
TORQFLOW
Manufacturer's Designations
Electric, Diesel, Gasoline, LPG, Cable
Pedestrian, Drive Standing, Sitting, Order Picking
Q Rated Capacity
c Rated Load Center
x Front Axle Center to Fork Face
y
Loaded
Unloaded
Front
Rear
Front/Rear(x=driven)
b10
b11
h1
h2
h3
h4
h6
l1
l2
b1
s/e/l
ISO 2328, Type A/B/no
b3
m1
m2
Ast
Wa
Loaded, 1st/2nd/3rd
Unloaded, 1st/2nd/3rd
Loaded/Unloaded
Loaded/Unloaded
Loaded
Loaded 1.6km/h, 3min rating
Operation/Control
Operation/Control
Type
Voltage/Capacity at 5-hour rating
kg(lb)
mm(in)
mm(in)
mm(in)
kg(lb)
kg(lb)
kg(lb)
kg(lb)
kg(lb)
mm(in)
mm(in)
degree
mm(in)
mm(in)
mm(in)
mm(in)
mm(in)
mm(in)
mm(in)
mm(in)
mm(in)
mm(in)
mm(in)
mm(in)
mm(in)
mm(in)
km/h(mph)
km/h(mph)
mm/s(fpm)
mm/s(fpm)
kN(lb)
%
V/Ah
kW(HP)
min
-1
N-m(lbft)@min
-1
cm3(cu.in)
Ltr(US gal)
bar(psi)
Ltr(US gal)
CharacteristicsWeightTyresDemensionsPerformanceDriveOthers
Specifications are subject to change without notice.
The performance values indicated herein represent nominal values obtained under typical operating conditions.
Front
Rear
Front
Rear
Forward/Backward
with Std. Mast
with Std. Mast from Ground
with Std. Mast from Ground
with Std. Mast
Thickness/Width/Lengh
Under the Mast
at the center of wheelbase
SPECIFICATIONS

GENERAL AND SPECIFICATIONS
10-4 EX20 Series
1.2
1.3
1.4
1.5
1.6
1.8
1.9
2.1
2.2
2.2.1
2.3
2.3.2
3.1
3.2
3.3
3.5
3.6
3.7
4.1
4.2
4.3
4.4
4.5
4.7
4.19
4.20
4.21
4.22
4.23
4.24
4.31
4.32
4.33
4.35
5.1
5.1.1
5.2
5.3
5.6
5.8
5.10
5.11
5.12
6.4
7.1
7.2
7.3
7.3.1
7.4
7.6
8.2
8.2.1
8.6
8.7
Model
Power Type
Operation Type
Rated Capacity
Load Center
Load Distance
Wheelbase
Service Weight
Axle Loading
Tyre Type
Tyre Size
Number of Wheel
Tread, Front
Tread, Rear
Tilting Angle
Mast Height, Lowered
Std. Free Lift
Std. Lift Height
Mast Height, Extended
Height, Overhead Guard
Length, with Std. Forks
Length, to fork face
Width, at tyre
Forks
Fork Carriage Class
Width, Fork Carriage
Ground Clearance
Right Angle Stacking Aisle
Turning Radius
Travel Speed(FWD)
Lifting Speed
Lowering Speed
Max. Drawbar Pull
Max. Gradeability
Service Brake
Parking Brake
Steering
Battery
Maker/Model
Rated Output, SAE gross
Rated Speed
Max Torque, SAE gross
No. of Cylinder/Displacement
Fuel Tank Capacity
Relief Pressure for Attachment
Hydraulic Tank Capacity
Clutch
Transmission
FD150E-7
Diesel
Sitting
15000(33,000)
600(24)
750(29.5)
3100(122.0)
16500(36,380)
28755(63,390)
2745(6,052)
7225(15,930)
9275(20,450)
Pneumatic
11.00-20-16PR(I)
11.00-20-16PR(I)
4x/2
1770(69.7)
1890(74.4)
6/12
3270(128.7)
0(0.0)
3000(118)
4780(188.2)
2810(110.6)
5920(233)
4700(185)
2410(94.9)
85x190x1220(3.3x7.5x48.0)
Pin Mount
2200(86.6)
250(9.8)
350(13.8)
6520(256.7)
4350(171.3)
9/19.5/27.5(5.6/12.1/17.1)
9.5/21/32.5(5.9/13.0/20.2)
330/350(65/69)
450/450(88.6/88.6)
105(23,677)
25
Foot/Hydraulic, Powered
Hand/Mechanical
Hydraulic Power Steering
24/100
ISUZU 6BG1T
119(160)
2200
540(398)@1600
6/6494(396)
280(74.0)
215(3,118)
180(47.6)
Torque Converter
TORQFLOW
FD160E-7
Diesel
Sitting
16000(35,000)
600(24)
750(29.5)
3100(122.0)
17050(37,590)
30120(66,400)
2930(6,460)
7155(15,770)
9895(21,810)
Pneumatic
12.00-20-16PR(I)
12.00-20-16PR(I)
4x/2
1770(69.7)
1870(73.6)
6/12
3290(129.5)
0(0.0)
3000(118)
4800(189.0)
2830(111.4)
6020(237)
4800(189)
2480(97.6)
85x210x1220(3.3x8.3x48.0)
Pin Mount
2200(86.6)
270(10.6)
370(14.6)
6670(262.6)
4500(177.2)
9.5/20/28(5.9/12.4/17.4)
10/21.5/33(6.2/13.4/20.5)
320/345(63/68)
450/450(88.6/88.6)
100(22,487)
23
Foot/Hydraulic, Powered
Hand/Mechanical
Hydraulic Power Steering
24/100
ISUZU 6BG1T
119(160)
2200
540(398)@1600
6/6494(396)
280(74.0)
215(3,118)
180(47.6)
Torque Converter
TORQFLOW
Manufacturer's Designations
Electric, Diesel, Gasoline, LPG, Cable
Pedestrian, Drive Standing, Sitting, Order Picking
Q Rated Capacity
c Rated Load Center
x Front Axle Center to Fork Face
y
Loaded
Unloaded
Front
Rear
Front/Rear(x=driven)
b10
b11
h1
h2
h3
h4
h6
l1
l2
b1
s/e/l
ISO 2328, Type A/B/no
b3
m1
m2
Ast
Wa
Loaded, 1st/2nd/3rd
Unloaded, 1st/2nd/3rd
Loaded/Unloaded
Loaded/Unloaded
Loaded
Loaded 1.6km/h, 3min rating
Operation/Control
Operation/Control
Type
Voltage/Capacity at 5-hour rating
kg(lb)
mm(in)
mm(in)
mm(in)
kg(lb)
kg(lb)
kg(lb)
kg(lb)
kg(lb)
mm(in)
mm(in)
degree
mm(in)
mm(in)
mm(in)
mm(in)
mm(in)
mm(in)
mm(in)
mm(in)
mm(in)
mm(in)
mm(in)
mm(in)
mm(in)
mm(in)
km/h(mph)
km/h(mph)
mm/s(fpm)
mm/s(fpm)
kN(lb)
%
V/Ah
kW(HP)
min
-1
N-m(lbft)@min
-1
cm3(cu.in)
Ltr(US gal)
bar(psi)
Ltr(US gal)
CharacteristicsWeightTyresDemensionsPerformanceDriveOthers
Front
Rear
Front
Rear
Forward/Backward
with Std. Mast
with Std. Mast from Ground
with Std. Mast from Ground
with Std. Mast
Thickness/Width/Lengh
Under the Mast
at the center of wheelbase
SPECIFICATIONS

GENERAL AND SPECIFICATIONS
EX20 Series 10-5
PERIODIC REPLACEMENT OF CONSUMABLE PARTS
For operation safety, never fail to perform periodic main-
tenance or make periodic replacement of the consum-
able parts listed in the following.
These parts may deteriorate in time and are susceptible
to wear. It is difficult to estimate the degree of wear at
time of periodic maintenance; therefore, even if no appar-
ent wear is found, always replace with new parts within
the prescribed period of replacement (or earlier if trouble
is found).
Note that periodic replacement has nothing to do with
guarantee service.
No. Part name Period of
replacement
1 Master cylinder and wheel cylinder cups, dust seals Every 1 year
2 Brake hose or tube Every 2 years
3 Brake reservior tank and tube Every 2 to 4 years
4 Power steering hose Every 2 years
5 Stop lamp switch (Oil pressure type) Every 2 years
6 Fuel hose Every 2 years
7 Rubber parts of power steering Every 2 years
8 Lift chain Every 3 years
9 Hose of load handing Every 2 years
PERIODIC REPLACEMENT OF CONSUMABLE PARTS

GENERAL AND SPECIFICATIONS
10-6 EX20 Series
SAFETY ITEMS FOR MAINTENANCE
SAFETY ITEMS FOR MAINTENANCE
FOR SAFETY OPERATION
USE QUALIFIED PERSONNEL FOR INSPECTION AND MAINTENANCE
• Only persons authorized by the owner or operator of the equipment and having proper certification
(local or national) may carry out inspection, maintenance and repairs of the lift truck.
If inspection, maintenance, or repair work is carried out incorrectly, it is very dangerous.
MAINTENANCE LOCATION
• When carrying out inspection and maintenance, use a level, dry, dust–free area.
• If the work is carried out inside a building, make sure that there is ample ventilation.
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 lever, speed lever, and work equipment control levers in neutral.
PRECAUTIONS WHEN CARRYING OUT INSPECTION AND MAINTENANCE
• Wipe off any oil or grease. Immediately wipe up any oil that has leaked.
If the lift 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, oil, 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 of the lift truck, be careful not to fall.
• 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 job with another worker, decide who is the leader and carry out the job in accor-
dance with instructions from that person.
• After repairing, make sure that the trouble has been corrected by performing a trial run.
• During the trial run, start/operate the lift truck carefully because it is possible that the trouble has not
been fully corrected or that defective parts have not been removed.

GENERAL AND SPECIFICATIONS
EX20 Series 10-7
SAFETY ITEMS FOR MAINTENANCE
USE SUITABLE TOOLS
• Always use tools that are suited for inspection and
maintenance.
It is extremely dangerous to use broken tools or tools
designed for another purpose.
REPLACE SAFETY CRITICAL PARTS PERIODICALLY
• Even if no abnormality is found, always replace safety critical parts periodically.
As time passes, these parts deteriorate and may cause fire of failure in the work equipment system.
• However, if these parts show any abnormality before the replacement interval has passed, they
should be repaired or replaced immediately.
PRECAUTIONS WITH HIGH TEMPERATURE COOLANT
• Immediately after using the lift truck, the engine coolant is at high temperature and high pressure. Do
not remove the radiator cap under these conditions.
Hot water may spurt out and cause burns.
• When removing the radiator cap, turn it slowly to
release the internal pressure.
• When checking the coolant level, stop the engine and
wait for the engine and radiator to cool down before
checking. For lift trucks equipped with a subtank or
reservoir, check the level in the subtank.
• When adding water on lift trucks equipped with a sub-
tank, add the water to the subtank.

GENERAL AND SPECIFICATIONS
10-8 EX20 Series
SAFETY ITEMS FOR MAINTENANCE
PRECAUTIONS WITH HIGH PRESSURE, HIGH TEMPERATURE OIL
• Immediately after using the lift truck, the oil is at high temperature. Do not drain the oil or replace the
filter when the oil is hot. Hot oil may spurt out and cause burns.
• When carrying out inspection and maintenance,
wait for the oil temperature to go down, and carry
out the operation in the order given in this manual.
• Do not forget that the work equipment circuits are
always under pressure. Do not add oil, drain oil, or
carry out maintenance or inspection before com-
pletely releasing the internal pressure.
• If oil is leaking under high pressure from small
holes, it is dangerous if the jet of high–pressure oil
hits your skin or eyes. Always wear safety glasses
and thick gloves, and use a piece of cardboard or
a sheet of plywood to check for oil leakage.
• Release the internal pressure before checking the
accumulator piping.
• If you are hit by a jet of high pressure oil, consult a
doctor immediately.
ROTATING FAN AND BELT
• It is 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 it is
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.

GENERAL AND SPECIFICATIONS
EX20 Series 10-9
SAFETY ITEMS FOR MAINTENANCE
BE CAREFUL NOT TO GET CAUGHT OR FALL
• Never put your hands or feet into the mast structure.
There is danger that you will get caught in moving parts
and be serious injured.
• Do not use the mast as a ladder. If you slip, there is dan-
ger that you will fall.
CHECKING AND INFLATING TIRES
• If the tire inflation pressure is low, it will affect truck stability. However, do not inflate the tires immedi-
ately. The inflation pressure may have gone down because of damage to the rim. If the rim is dam-
aged or cracked and the tires are inflated, there is danger that the rim will break when the tire is under
high pressure, 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 tire.
• Suitable qualifications are needed for tire inflation work.
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, so always wear safety glasses.

GENERAL AND SPECIFICATIONS
10-10 EX20 Series
SAFETY ITEMS FOR MAINTENANCE
HANDLING TIRES
Disassembly and assembly of tires should be carried out by tire dealer.
The tire inflation pressure is extremely high, so caution is needed when handling tires.
• The wheel is fitted with mounting nuts. It also has rim nuts and bolts used to join the rim halves. When
removing the tire from the lift truck, do not loosen the rim nuts and bolts. The tire is under high pres-
sure, and there is a significant risk that the rim nuts and bolts may fly off. Relief tire inflation pressure
before removing.
• When the tires have been replaced, carry out a test drive and check again for any loose mounting
nuts. If the tightening torque is low, tighten to the specified torque.
JACKING UP LIFT TRUCK (when checking or replacing tires)
• Do not go under the forklift truck when it is jacked up.
• Check the following before jacking up the lift truck. (For details, see page 3–41.)
1) Check that there is no one on the lift truck.
2) Check that there is no load on the forks.
• When jacking up, stop when the tires come off the
ground surface. Put blocks under both sides of the
frame to prevent the lift truck from coming down.
• Put blocks under any tires contacting the ground
to prevent the lift truck from moving.
LIFTING LIFT TRUCK (when checking tires)
• Lift truck slinging work should be carried out by a
qualified person who has completed a course in
correct lifting methods.
• Fit wire ropes to the specified lifting points.
• When lifting the lift truck, check that the wire ropes
have ample strength and are not damaged.
• Block the tires contacting the ground to prevent
the lift truck from moving.
• Insert blocks to prevent the truck from coming
down.
• Do not go under the lift truck during the lifting
operation.
• If the specified lifting point is the counterweight,
check that the counterweight mounting bolts are
tightened to the specified torque before carrying
out the lifting operation. check also that there is no
damage to the lifting portion on the counterweight.

GENERAL AND SPECIFICATIONS
EX20 Series 10-11
BATTERY HAZARD PREVENTION
• Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If 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 at once.
• If you accidentally drink electrolyte, drink a large quantity of water, or milk mixed with beaten eggwhite
or vegetable oil. Call a doctor or poison prevention center immediately.
• When working with batteries, ALWAYS wear safety glasses or goggles.
• Batteries generate hydrogen gas. Hydrogen gas is highly EXPLOSIVE, and is easily ignited with a
small spark or flame. Do not smoke or create any spark near the 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
first.
• Avoid short–circuiting the battery terminals through
accidental contact with tools or other metal objects
across the terminals.Tighten the battery terminals
securely. Loose terminals can generate sparks and
lead to an explosion.
• When removing or installing the battery, confirm
which is the positive terminal and negative ter-
minal. Be careful not to connect the cables to the
opposite terminals.
• Tighten the battery caps securely.
• When cleaning the battery, leave the battery caps
tightened.
DO NOT PUT METAL OBJECTS ON TOP OF BATTERY
• Never place any metal objects on top of the battery. There is danger that they will cause a short circuit
and start a fire.
SAFETY ITEMS FOR MAINTENANCE

GENERAL AND SPECIFICATIONS
10-12 EX20 Series
SAFETY ITEMS FOR MAINTENANCE
PRECAUTIONS WHEN CHARGING
When the battery is charged, hydrogen gas is generated and the battery is heated by the chemical
change. To prevent the danger of gas explosion, always do as follows.
• Carry out the charging operation in a well–ventilated place.
• Do not smoke or allow any flame.
• Start the charging operation when the temperature of the battery electrolyte is below 35°C (95 ). (If
the temperature goes above 50°C(122°F) during the charging operation, wait for it to go down below
35°C(95°F) before starting charging operation again.)
• When using a battery charger to charge the battery, take the battery caps off.
STARTING WITH BOOSTER CABLES
• ALWAYS wear safety glasses or goggles when starting the lift truck with booster cables.
• When starting using the battery of another lift truck, do not allow the two lift trucks to touch. For details
of the order of operations when using a booster cable.
• Stop the engine before connecting the cables.
• e extremely careful not to let the cables get caught in the fan or fan belt.
• Connect the batteries in parallel: positive to positive and negative to negative. Never connect positive
to negative.
DO NOT PUSH START
• Do not push the lift truck to start the engine. There is danger that the lift truck may suddenly start and
operate unexpectedly.
HANDLING BRAKE FLUID
It is dangerous if the brakes do not work because in this condition, the lift truck cannot be stopped.
Always do the following.
• Check the level of the brake fluid periodically.
• Always use the specified brake fluid.
• Check that the breather of the brake fluid reserve tank is not clogged.
• Be careful not to let dirt or dust get into the brake fluid reserve tank.

GENERAL AND SPECIFICATIONS
EX20 Series 10-13
HANDLING ANTIFREEZE
• Antifreeze can be a flammable. Keep away from flame when handling.
• Antifreeze is poisonous, so do not drink it. If you drink it by mistake, drink large amounts of water,
vomit it out, and get medical attention immediately. Follow safety precautions on container.
WASTE MATERIALS
• Obey appropriate laws and regulations when disposing
of harmful objects such as oil, fuel, solvent, filters, and
batteries.
SAFETY ITEMS FOR MAINTENANCE

GENERAL AND SPECIFICATIONS
10-14 EX20 Series
STANDARD TIGHTENING TORQUE FOR BOLTS
For unspecified bolts and nuts, use the torques specified
in this list.
Select a proper torque corresponding to the width across
flats (b) of bolts and nuts.
When replacing bolts and nuts, always use genuine
Komatsu Forklift parts the same size as the previous
ones.
Thread diameter
of bolt (mm)
(a)
Width across
flat (mm)
(b)
Tightenng torque
Nm Kgm lbft
6 10 13.2 ± 1.4 1.35 ± 0.15 9.73 ± 1.03
8 13 31.4 ± 2.9 3.2 ± 0.3 23.2 ± 2.1
10 17 65.7 ± 6.8 6.7 ± 0.7 48.5 ± 5.0
12 19 112 ± 9.8 11.5 ± 1.0 82.6 ± 7.2
14 22 177 ± 19 18.0 ± 2.0 131 ± 14
16 24 279 ± 29 28.5 ± 3 206 ± 21
18 27 383 ± 39 39 ± 3 282 ± 29
20 30 549 ± 58 56 ± 6 405 ± 43
22 32 745 ± 78 76 ± 8 549 ± 58
24 36 927 ± 98 94.5 ± 10 684 ± 72
27 41 1320 ± 140 135 ± 15 973 ± 100
30 46 1720 ± 190 175 ± 20 1270 ± 140
33 50 2210 ± 240 225 ± 25 1630 ± 180
36 55 2750 ± 290 280 ± 30 2030 ± 210
39 60 3280 ± 340 335 ± 35 2420 ± 250
STANDARD TIGHTENING TORQUE FOR BOLTS

GENERAL AND SPECIFICATIONS
EX20 Series 10-15
STANDARD TIGHTENING TORQUE FOR PIPE JOINTS
Elbows, nipples and unions
High–pressure rubber hoses, pipes and sleeve nuts
Width across flats B (mm) 22 30 36
Width D (mm) 19 22 30
Tightening torqueNm {kgm} 29.4–39.2 {3–4} 78.5–103 {8–10.5} 117.7–161.8 {12–16.5}
Port size (inch) 3/4–16UNF 7/8–14UNF –
Tightening torqueNm {kgm} 68.6–73.6 {7–7.5} 78.5–83.3 {8–8.5} –
Width across flats B (mm) 19 24 27 32 36
Bore A (mm) 14 18 22 24 30
Tightening torque Nm {kgm} 19.6–29.4
{2–3} 23.5–68.6 {3–7} 58.8–98.1 {6–10} 108–167 {11–17} 147–206 {15–21}
STANDARD TIGHTENING TORQUE FOR PIPE JOINTS