Komatsu Electronic Equipment for Lift Trucks Manual (FB12-FB15-FB18-FB20-FB22-FB25-FB28-FB30-1R)

12/2001 ELECTRONIC EQUIPMENT FOR LIFT TRUCKS FB 12M-1R FB 15M-1R FB 18M-1R FB 15-1R FB18-1R FB 18H-1R FB 20H-1R FB 20GH-1R FB 22H-1R FB 25-1R FB 28-1R FB 30-1R 1. EDITION 09/2001 Printed No. 604.24.128 Rev. 01-12/2001 FIAT OM CARRELLI ELEVATORI S.p.A.- KOMATSU Division

FIAT OM Carrelli Elevatori S.p.A. - KOMATSU Division Technical Service Via De Gasperi, 7 20020 Lainate (Mi) - Italy Copyright by FIAT OM Carrelli Elevatori S.p.A. Printed in Italy Printed no. 604.24.128 Centrostampa s.n.c. - Brescia INTRODUCTION This publication may contain information that is not up-to-date as a result of modifications made by the constructor, at any time, for technical or trade reasons or to comply with law provisions of the different coun- tries. Descriptions and photos may refer to non-standard e- quipments.

Printed 604.24.126 3 09/2001 Electronic equipment CONTENTS SAFETY REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ELECTRONIC EQUIPMENT FOR FB 12M-1R FB 15M-1R FB 18M-1R FB 15-1R FB18-1R . . . . . . 9 ELECTRONIC EQUIPMENT FOR FB 18H-20H-20GH-1R FB 25H-28H-30H-1R . . . . . . . . . . . . . . . . . 77

Printed 604.24.128 5 09/2001 Electronic equipment FB 12M -1R FB 15M -1R FB 18M-1R FB 15-1R FB18-1R Accidents prevention • Most accidents occurring in workshops are due to non-compliance with some simple care and safety rules. This means that in most cases accidents may be prevented: you just have to anticipate the possible causes and act with the necessary caution. • Remember that it is impossible, with any kind of machinery, no-matter how well designed and manufactured, to rule out any possibilities of accidents. • A careful mechanic is the best guarantee against accidents. • The strict observance of just one elementary safety rule could be enough to avoid many serious accidents. General information Follow carefully the maintenance and servicing procedures. Never perform any cleaning, oiling or maintenance with battery on • Do not wear rings, wrist-watches, jewels, loose or untied clothes, such as ties, torn clothes, scarves, unbuttoned jackets or unzipped blouses, which could get caught into moving parts. • We recommend the use of safety clothings, such as: hard-hats, non-skid shoes, gloves, safety glasses. • Do not perform any servicing on the forklift with people on the seat, unless they are qualified operators, helping with the work to be done. • Do not operate the forklift or use its attachments unless properly seated on the driver's seat. • Stop the engine and make sure that there is no pressure in the hydraulic circuits before removing any plugs or lids. • See the enclosed instructions about this subject. • All the servicing must be performed with the maximum care. • All the stairs and the platforms used in the workshop or on site must comply with all safety rules in force. WATCH OUT FOR THIS SYMBOL It warns about a danger for health and personal safety. It suggests the safety precautions to be taken. It means: "WARNING - BE CAREFUL - IT'S ABOUT YOUR PERSONAL SAFETY" ATTENTION SAFETY REGULATIONS

Printed 604.24.128 6 09/2001 Electronic equipment FB 12M -1R FB 15M -1R FB 18M-1R FB 15-1R FB18-1R • Label all controls to warn that servicing is under way. Block the machine and any equipment to be lifted. • Do not check or fill up the fuel tank, the hydraulic-system oil tank and the battery while smoking, as these fluids are inflammable. • The brakes do not work when manually released for servicing. In this case, the forklift must be fixed with proper blockings. • For towing, use only the appropriate towing points. Carefully do the connections, make sure that the provided pins and/or latches are tightly fastened before towing. Do not stand close to under-stress towing bars, ropes or chains. • To move a broken-down forklift use a truck-trailer or a lowered flat-bed trailer, if available. • To load or unload the forklift from the transportation mean, choose a level area, offering a solid support to the trailer or truck's wheels. • Fix tightly the forklift to the truck or trailer deck and block its wheels. • For electric heaters, battery chargers and the like, use only properly grounded power sources to avoid possible electric shocks. • In case of lifting or moving heavy components, use suitable hoists or similar equipment and have close people move away. • Be careful of people standing nearby. • Never pour gasoline or diesel fuel in open, large and low containers because of the risk of flammable vapours and spillage. • Never use gasoline, diesel fuel or other flammable liquids as cleasing agents: use non-flammable and non- toxic solvents. • When using compressed-air to clean small parts, use safety glasses with lateral guards. • Limit the pressure to max 2.1 bar, according to current local or national rules. • Do not smoke, do not use open flames nor cause sparkles nearby when using easily flammable materials. • Do not use flames to light things up when operating the forklift or when looking for "leaks" from the machine. • Leave all the guards at their proper places when the machine is running. • Do not leave the forklift unattended while running. • Do not leave the driver's seat without pulling the parking brake, after switching off the engine. Take the ignition key off. • Should any parts get stuck, free them only after cutting the engine. • Move very carefully when you have to work under the machine or close to it. • Wear the required safety equipment: hard-hats, safety glasses and shoes. • In case of servicing outside the workshop, move the forklift to a level area and block the wheels. If working on a slope cannot be avoided, first block the truck and then move it on a level area, as soon as it is safe to do so.

Printed 604.24.128 7 09/2001 Electronic equipment FB 12M -1R FB 15M -1R FB 18M-1R FB 15-1R FB18-1R • Do not trust damaged and bent chains or ropes: do not use them in lifting or towing. Handling them, always wear safety gloves. • The chains must be tightly fastened: make sure that the coupling is strong enough to bear the load. No one must stay near the coupling, the chains or the ropes. • The maintenance area must be kept always clean and dry. Clean immediately any water puddles or oil spills. • Do not pile up greasy or oily rags. • Put them in a closed metal container. • Before starting the forklift or the attachments, check, adjust and lock the driver's seat. • Be sure that there are no people within the forklift or the attachments field of action. • Do not carry in your pockets things that may unintentionally fall, into open parts of the machine. • When there is the possibility of being hit by flying metal parts or the like, wear glasses with lateral guards, hard- hats, special shoes and safety gloves. • During welding, safety equipment must be used: dark glasses, hard-hats, overalls, gloves and shoes. Dark glasses shall be used also, by any person standing nearby during welding. • Never look at the welding electric arc without wearing suitable eye protection. • Wire ropes, get frayed with use: when handling them, always wear protection clothing (gloves, glasses, and so on). • Handle every part very carefully. Keep your fingers away from gaps, wheelworks and so on. • Always use approved safety equipment, such as safety glasses, safety shoes. • If you need to work under the forklift, use only the pit or an adequate auto lift. • After each servicing, remove all the tools from the machine; then check for loosen parts or screws. • Before driving on the road at night, check the lights efficiency and position of the lights

Printed 604.24.128 8 09/2001 Electronic equipment FB 12M -1R FB 15M -1R FB 18M-1R FB 15-1R FB18-1R Electric system • When using batteries, remember that the cables must be connected, at both ends, as follows: (+) with (+) and (-) with (-). • Do not short the terminals. The gas released by the battery is highly inflammable. During recharging, leave the battery compartment open so to have a better ventilation and remove the plugs. Never check the battery charge by "bridging" the terminals with metal objects. Avoid sparkles or flames near the battery. • Do not smoke to prevent explosion. • Before any maintenance service, check for any electrolyte leaks: stop these leaks before doing the job. • Before any maintenance service check for shorted components: take care of these short circuits before doing the job. • When recharging batteries in closed rooms, make sure that there is a proper ventilation to prevent accidental explosions due to accumulation of gases released during recharging. Hydraulic system • A fluid leaking from a very small hole may be almost invisible, yet it may be strong enough to penetrate under your skin. In such a situation, if you need to check, use a thin cardboard or a piece of wood. Never check with your bare hands: if skin contact occurs, get immediate medical attention, to avoid serious infections or dermato- sis. • In case the system pressures, use shall be checked only adeguate instruments. Assembling and disassembling • Lift and handle all the heavy components with a suitable lift. Make sure that all the parts are held by suitable slings and hooks. Use the special lifting eyes. Watch out for people near the load to be lifted. • Handle all the parts with great care. Do not put your hands or fingers between componsnts. Wear approved safety clothing, such as safety glasses, gloves and shoes. • Do not twist chains or wire ropes. • Always wear safety gloves when handling cables or chains.

09/2001 ELECTRONIC EQUIPMENT FOR LIFT TRUCKS FB 12M-1R FB 15M-1R FB 18M-1R FB 15-1R FB18-1R FIAT OM CARRELLI ELEVATORI S.p.A.- KOMATSU Division

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Komatsu Electronic Equipment for Lift Trucks Manual (FB12-FB15-FB18-FB20-FB22-FB25-FB28-FB30-1R)

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