Fb25ex 11

TEN00568-04
Operation & Maintenance Manual
ELECTRIC LIFT TRUCK

FB09EX /14EX-11
FB15EX/18EX-11
FB15EXG/18EXG-11
FB20EX/25EX-11
FB20EXG/25EXG-11
FB30-11
WARNING
Unsafe use of this lift truck may
cause serious injury or death.
Operators and maintenance per-
sonnel must read this manual and
be sure that they understand its
contents before operating, in-
specting, or carrying out mainte-
nance on this lift truck. This
manual should be kept near the
lift truck for reference and peri-
odically reviewed by all opera-
tors and maintenance personnel
who will come into contact with
it.
ORIGINAL
INTRODUCTION 1
11
1-1
ABOUT THIS MANUAL INTRODUCTION
INTRODUCTION 1
ABOUT THIS MANUAL 1
This manual describes procedures for proper operation, inspection, and maintenance of this lift truck, and rules you
must follow for your safety.
Some actions involved in operation and maintenance of the lift truck can cause a serious accident if they are not
done in the manner described in this manual.
WARNING
This manual describes fundamental prohibitions and precautions for operations, inspections, and maintenance of this lift truck.
Failure to follow these instructions will result in a serious bodily injury or damage.
Operators and service staffs must follow the followings before conducting operations, inspections, and maintenance of this lift
truck.
Operators must understand this manual for conducting safety control of this lift truck.
• Read this manual carefully and understand it fully.
• Make sure you fully understand the instructions and safety indicators of this manual.
Be sure to store this manual in the designated location for the Operation and Maintenance Manual as shown below, so that it will
be available for the concerned persons repeatedly as needed.
If this manual has been lost or has become dirty or worn and cannot be read, request a replacement manual from your KOMATSU
FORKLIFT distributor.
When you transfer this lift truck to others, make sure to attach this manual together.
Continuing improvements in the design of this lift truck may not be reflected in this manual. Consult Komatsu Ltd. FORKLIFT
COMPANY or your KOMATSU FORKLIFT distributor for the latest available information on your lift truck or for questions regarding
information in this manual.
TYPE A
Storage location for Operation and Maintenance Manual
• Retractable pocket behind the operator's seat (1)
TYPE B
Storage location for Operation and Maintenance Manual
• Operator’s seat back literature storage area (2)
1-2
INTRODUCTION FOR YOUR SAFETY
FOR YOUR SAFETY 1
For your safety, the information of possible hazards and how to avoid them are provided on this manual and with
the safety indicators attached to this lift truck.
SIGNAL WORDS 1
The following signal words indicate the possible hazard which leads bodily injury.
For this lift truck and this manual, the following signal words are used depending on the degree of possible hazard.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
Example of safety message using signal word
CAUTION
Entering of water into the electrical parts (controllers, sensors, connectors) may cause a malfunction, which is dangerous. Do
not wash the electrical parts or use a high-pressure washer (steam cleaner) on them.
Other signal words

Besides the above signal words, the followings indicate precautions you must take for the lift truck as well as useful
information.
NOTICE - - - - - - The lift truck can get damaged or shortens its service life when handled incorrectly.
REMARKS - - - - Useful information.
1-3
FOR YOUR SAFETY INTRODUCTION
SAFETY INDICATORS 1
Safety indicators are used in the various locations of the lift truck to indicate the possible hazards to the concerned
persons during operations, inspections, and maintenances. This lift truck employs [verbal safety indicator] and
[pictorial safety indicator] for safety indicators.
EXAMPLE OF VERBAL SAFETY INDICATOR

There are safety indicators which consist of drawing and words in addition to verbal-only safety indicators.
EXAMPLE OF PICTORIAL SAFETY INDICATOR

The pictorial safety indicators indicate the hazard equivalent to the signal words. Illustrations are used for these
safety indicators to tell the operators and service staffs clearly of the existence and content of a hazard.
In addition, there are pictorial indicators which simply indicate the prohibition content as well as indicators which
comply with the international standards.
Komatsu Ltd. FORKLIFT COMPANY cannot predict every circumstance that the customers will experience.
Therefore the precautions in this manual and on the lift truck may not include all possible safety precautions.
When carrying out any procedures or actions which are not specifically recommended or allowed in this manual,
it is your responsibility to carry out such procedures and actions safely.
The explanations, numeric vales, and illustrations of this manual are based on the information at the time of
publication. Continuing improvements in the design of this lift truck may not be reflected in this manual.
Consult KOMATSU FORKLIFT distributor for the latest available information or for questions regarding this
manual.
1-4
INTRODUCTION APPLICABLE MODEL AND SERIAL No.
APPLICABLE MODEL AND SERIAL No. 1
This Operation and Maintenance Manual applies to the following lift trucks.
Model type Serial No.

FB09EX/FB10EX/14EX/15EX/18EX-11 M191-807001 and up
FB15EXG/FB18EXG-11 M192-807001 and up
FB20EX/25EX-11 M194-819236 and up
FB20EXG/FB25EXG-11 M195-819236 and up
FB30-11 M244-819236 and up
GENERAL VIEW OF LIFT TRUCK 1
APPLICATION OF LIFT TRUCK 1
This lift truck is intended to use mainly for the following work.
• Load handling with the forks of the lift truck.
DIRECTION OF LIFT TRUCK 1
This manual determines the left and right directions and fore and aft directions as seen from the operator's seat.
Right
Front Rear
Left
UNITS OF MEASURE 1
This manual uses the international system of units (SI) for units of measure.
Also the gravitational system of units, conventionally used, are provided as { } for reference.
1-5
QUALIFICATION FOR OPERATION INTRODUCTION
QUALIFICATION FOR OPERATION 1
WARNING
Only the trained and qualified persons are allowed to operate this lift truck. Operation by unqualified persons may result in serious
injury or death.
RUNNING IN NEW LIFT TRUCK 1
RUNNING IN NEW LIFT TRUCK 1
Your KOMATSU FORKLIFT truck has been thoroughly adjusted and tested before shipment. However, operate
moderately during the first one month (or initial 200 hours) until each part of the lift truck comes into stable.
Operating the lift truck under severe conditions at the beginning can adversely affect performance and shorten the
lift truck life.
Be sure to run in the lift truck, taking special care concerning the followings.
• Idle the engine for 5 minutes after starting it up.
• Do not operate with heavy loads or at high speeds.
• Avoid sudden starting, acceleration, braking, and sharp turning.
MAINTENANCE FOR NEW LIFT TRUCK 1
For new lift truck, carry out the followings after the first month or 200 hours: Replacement of oil and cleaning of
filters, retightening of bolts and nuts. Have your lift truck serviced by KOMATSU FORKLIFT distributor.
WARRANTY AND SERVICE 1
PERIODICAL EXCHANGE PARTS 1
Other than those specified by the law, KOMATSU FORKLIFT designates " periodical exchange parts. "
Deterioration of such parts is unavoidable over time but is critical for safety and therefore must be replaced
periodically. Replace those parts at the designated periods regardless of their appearance. For the periodic
replacement of safety critical parts, see the Section "PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
(PAGE 4-23)".
USE OF GENUINE PARTS AND OILS 1
Any problem caused by the use of other than Genuine Parts (including oils) warranted by KOMATSU FORKLIFT
is not covered by the warranty.
1-6
INTRODUCTION NECESSARY INFORMATION OF LIFT TRUCK
NECESSARY INFORMATION OF LIFT TRUCK 1
When you need maintenance of the lift truck or order parts, please provide KOMATSU FORKLIFT distributor with
necessary information of the lift truck such as model type, serial No., attachment, option, etc.
MEMORANDUM (To be filled by KOMATSU FORKLIFT distributor) 1
Model type
Serial No.
Attachment/option
Distributor
Address
Telephone, fax No.
Service person in charge
Sales representative in charge
MODEL AND SERIAL NO. LOCATION 1
LIFT TRUCK SERIAL NO. PLATE LOCATION(1)

On front left of dashboard .
FB09EX - 25EXG
LIFT TRUCK EMBOSSED SERIAL NO. LOCATION(2)

Besides the serial No. plate, serial No. is also embossed on the top
of the left-side front wheel fender .
Example of embossed mark: M *** - ######
Serial No. is shown as # after the hyphen.
FB30
1-7
CONTENTS INTRODUCTION
CONTENTS
1. INTRODUCTION --------------------------------------------------------------------------------------------------------------------- 1-1
ABOUT THIS MANUAL ---------------------------------------------------------------------------------------------------------- 1-2
FOR YOUR SAFETY ------------------------------------------------------------------------------------------------------------- 1-3
SIGNAL WORDS ------------------------------------------------------------------------------------------------------------ 1-3
SAFETY INDICATORS----------------------------------------------------------------------------------------------------- 1-4
APPLICABLE MODEL AND SERIAL No.------------------------------------------------------------------------------------ 1-5
GENERAL VIEW OF LIFT TRUCK-------------------------------------------------------------------------------------------- 1-5
APPLICATION OF LIFT TRUCK----------------------------------------------------------------------------------------- 1-5
DIRECTION OF LIFT TRUCK -------------------------------------------------------------------------------------------- 1-5
UNITS OF MEASURE ------------------------------------------------------------------------------------------------------------ 1-5
QUALIFICATION FOR OPERATION ----------------------------------------------------------------------------------------- 1-6
RUNNING IN NEW LIFT TRUCK ---------------------------------------------------------------------------------------------- 1-6
RUNNING IN NEW LIFT TRUCK ---------------------------------------------------------------------------------------- 1-6
MAINTENANCE FOR NEW LIFT TRUCK----------------------------------------------------------------------------- 1-6
WARRANTY AND SERVICE --------------------------------------------------------------------------------------------------- 1-6
PERIODICAL EXCHANGE PARTS ------------------------------------------------------------------------------------- 1-6
USE OF GENUINE PARTS AND OILS -------------------------------------------------------------------------------- 1-6
NECESSARY INFORMATION OF LIFT TRUCK -------------------------------------------------------------------------- 1-7
MEMORANDUM (To be filled by KOMATSU FORKLIFT distributor)------------------------------------------- 1-7
MODEL AND SERIAL NO. LOCATION -------------------------------------------------------------------------------- 1-7
2. SAFETY--------------------------------------------------------------------------------------------------------------------------------- 2-1
SAFETY LABEL -------------------------------------------------------------------------------------------------------------------- 2-2
SAFETY LABEL LOCATION CHART----------------------------------------------------------------------------------- 2-2
SAFETY LABELS ------------------------------------------------------------------------------------------------------------ 2-4
BASIC PRECAUTIONS ---------------------------------------------------------------------------------------------------------- 2-9
FOLLOW RULES ------------------------------------------------------------------------------------------------------------ 2-9
NEVER OPERATE THE BROKEN-DOWN LIFT TRUCK --------------------------------------------------------- 2-9
WEAR ADEQUATE CLOTHES AND SAFETY EQUIPMENT FOR OPERATION ------------------------ 2-10
FIRE EXTINGUISHER AND FIRST AID KIT------------------------------------------------------------------------ 2-10
CAUTIONS FOR SAFETY-RELATED EQUIPMENT ------------------------------------------------------------- 2-10
PRACTICE SUFFICIENTLY BEFORE OPERATION------------------------------------------------------------- 2-10
JUMPING ON AND OFF FROM THE LIFT TRUCK IS STRICTLY PROHIBITED ------------------------ 2-11
KEEP THE OPERATOR'S COMPARTMENT AND PLATFORM CLEAN AND TIDY -------------------- 2-11
PRECAUTION WHEN WASHING LIFT TRUCK------------------------------------------------------------------- 2-11
TO AVOID BURN INJURY ---------------------------------------------------------------------------------------------- 2-11
FIRE PREVENTION------------------------------------------------------------------------------------------------------- 2-12
IF A FIRE BREAKS OUT ------------------------------------------------------------------------------------------------ 2-13
INSTALLATION OF FIRE EXTINGUISHER(IF EQUIPPED) --------------------------------------------------- 2-13
DO NOT MODIFY THE LIFT TRUCK--------------------------------------------------------------------------------- 2-14
DO NOT REMOVE THE OVERHEAD GUARD AND LOAD BACKREST ----------------------------------- 2-14
SECURE SAFETY AT THE WORKING AREA--------------------------------------------------------------------- 2-14
ASBESTOS CAUTION --------------------------------------------------------------------------------------------------- 2-15
WINDOW WASHER CAUTION ---------------------------------------------------------------------------------------- 2-15
START-UP INSPECTION------------------------------------------------------------------------------------------------------ 2-16
TRAVELING THE LIFT TRUCK---------------------------------------------------------------------------------------------- 2-17
PREPARATION BEFORE TRAVELING THE LIFT TRUCK ---------------------------------------------------- 2-17
WHILE TRAVELING THE LIFT TRUCK ----------------------------------------------------------------------------- 2-18
STOPPING AND PARKING--------------------------------------------------------------------------------------------- 2-23
TOWING --------------------------------------------------------------------------------------------------------------------- 2-24
LOAD HANDLING OPERATION--------------------------------------------------------------------------------------------- 2-24
PRECAUTIONS FOR INSPECTION AND MAINTENANCE ---------------------------------------------------------- 2-29
ALWAY PERFORM THE START-UP INSPECTION-------------------------------------------------------------- 2-29
PUT UP A WARNING SIGN DURING INSPECTION AND MAINTENANCE------------------------------- 2-29
KEEP THE WORKING AREA CLEAN AND TIDY----------------------------------------------------------------- 2-29
CAUTIONS BEFORE INSPECTION AND MAINTENANCE ---------------------------------------------------- 2-30
KEEP UNAUTHORIZED PEOPLE OFF ----------------------------------------------------------------------------- 2-30
USE OF RIGHT TOOLS AND EQUIPMENT------------------------------------------------------------------------ 2-30
1-8
INTRODUCTION CONTENTS
CAUTIONS WHEN WORKING UNDER WORK EQUIPMENT -------------------------------------------------2-31

AVOID GETTING CAUGHT UP BY THE MAST OR FALLING OFF ------------------------------------------2-31
BE CAREFUL OF HIGH PRESSURE OIL ---------------------------------------------------------------------------2-32
BEWARE OF ROTATING COOLING FAN---------------------------------------------------------------------------2-32
CAUTIONS FOR USING COMPRESSED AIR FOR CLEANING ----------------------------------------------2-32
CAUTIONS WHEN REPLACING THE SEAT -----------------------------------------------------------------------2-32
REMOVING THE BATTERY PLUG------------------------------------------------------------------------------------2-33
CAUTION WHEN HANDLING BATTERY ----------------------------------------------------------------------------2-33
CAUTION WHEN HANDLING TIRES ---------------------------------------------------------------------------------2-35
CAUTION IN WASTE DISPOSAL --------------------------------------------------------------------------------------2-36
CAUTION AFTER INSPECTION AND REPAIR --------------------------------------------------------------------2-36
PERIODIC INSPECTION OF SAFETY CRITICAL PARTS ------------------------------------------------------2-36
HOISTING AND TRANSPORTING THE LIFT TRUCK -----------------------------------------------------------------2-37
CAUTION WHEN HOISTING THE LIFT TRUCK-------------------------------------------------------------------2-37
PRECAUTIONS FOR LOADING AND UNLOADING THE LIFT TRUCK ------------------------------------2-37
STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING) --2-38
LONGITUDINAL STABILITY --------------------------------------------------------------------------------------------2-38
CENTER OF GRAVITY OF A LOAD ----------------------------------------------------------------------------------2-38
COMBINED CENTER OF GRAVITY AND STABILITY ON THE LOADED LIFT TRUCK----------------2-39
ACTUAL CAPACITY -------------------------------------------------------------------------------------------------------2-39
SERIAL NO. PLATE AND LOAD TABLE-----------------------------------------------------------------------------2-40
INTRODUCTION OF OPTIONAL SAFETY DEVICE --------------------------------------------------------------2-44
3. OPERATION -------------------------------------------------------------------------------------------------------------------------- 3-1
GENERAL VIEW------------------------------------------------------------------------------------------------------------------- 3-2
GENERAL VIEW OF LIFT TRUCK ------------------------------------------------------------------------------------- 3-2
INSTRUMENTS AND CONTROLS ------------------------------------------------------------------------------------- 3-3
EXPLANATION OF COMPONENTS ----------------------------------------------------------------------------------------- 3-5
EXPLANATION OF CONTROLS AND GAUGES ------------------------------------------------------------------- 3-5
SINGLE ACTION WATER REFILLER --------------------------------------------------------------------------------3-22
FORK STOPPER -----------------------------------------------------------------------------------------------------------3-22
OPERATOR'S COMPARTMENT---------------------------------------------------------------------------------------------3-23
ADJUSTING POSITION OF STEERING WHEEL------------------------------------------------------------------3-30
STARTING LIFT TRUCK OFF ------------------------------------------------------------------------------------------3-31
NEUTRAL SAFETY --------------------------------------------------------------------------------------------------3-32
TRAVEL INTERLOCK FUNCTION (FB30)---------------------------------------------------------------------3-33
STARTING ON SLOPE ---------------------------------------------------------------------------------------------------3-33
NORMAL RUNNING -------------------------------------------------------------------------------------------------------3-34
SHIFTING GEAR -----------------------------------------------------------------------------------------------------3-34
INCHING ----------------------------------------------------------------------------------------------------------------3-34
PLUGGING-------------------------------------------------------------------------------------------------------------------3-35
STOPPING -------------------------------------------------------------------------------------------------------------3-36
REVERSING -----------------------------------------------------------------------------------------------------------3-36
TURNING ---------------------------------------------------------------------------------------------------------------------3-36
TRAVELING OVER RAMPS---------------------------------------------------------------------------------------------3-37
TEMPORARY STOPPING AND PARKING--------------------------------------------------------------------------3-37
WHEN LEAVING THE LIFT TRUCK UNATTENDED -------------------------------------------------------3-37
PARKING BRAKE ALARM BUZZER (FB30) ------------------------------------------------------------------3-38
LONG-TERM PARKING --------------------------------------------------------------------------------------------3-38
FORK SPREAD ADJUSTMENT ----------------------------------------------------------------------------------------3-38
LOAD HANDLING OPERATION ---------------------------------------------------------------------------------------3-39
OPERATION OF CONTROL LEVERS--------------------------------------------------------------------------3-39
LIFT INTERLOCK FUNCTION (FB30) --------------------------------------------------------------------------3-39
PICKING UP -----------------------------------------------------------------------------------------------------------3-40
STACKING -------------------------------------------------------------------------------------------------------------3-40
BATTERY CHARGING----------------------------------------------------------------------------------------------------------3-41
CHARGING BY STATIONARY BATTERY CHARGER -----------------------------------------------------------3-41
REPLACING BATTERY---------------------------------------------------------------------------------------------------3-46
MAINTAINING LONG BATTERY LIFE--------------------------------------------------------------------------------3-48
1-9
CONTENTS INTRODUCTION
LIFT TRUCKS WITH COLD-STORAGE MODEL------------------------------------------------------------------------ 3-49

EXPLANATION OF LIFT TRUCKS WITH COLD-STORAGE MODEL--------------------------------------- 3-49
PRECAUTIONS FOR USE ---------------------------------------------------------------------------------------- 3-49
PRECAUTIONS FOR CHARGING ------------------------------------------------------------------------------ 3-49
SUITABLE LUBRICANT ------------------------------------------------------------------------------------------- 3-49
OTHER ----------------------------------------------------------------------------------------------------------------- 3-49
LONG-TERM STORAGE ------------------------------------------------------------------------------------------------------ 3-50
BEFORE STORAGE ------------------------------------------------------------------------------------------------------ 3-50
DURING STORAGE ------------------------------------------------------------------------------------------------------ 3-50
AFTER STORAGE -------------------------------------------------------------------------------------------------------- 3-50
4. MAINTENANCE----------------------------------------------------------------------------------------------------------------------- 4-1
CHECK BEFORE OPERATION------------------------------------------------------------------------------------------------ 4-2
CHECK BEFORE OPERATION (WITH KEY SWITCH OFF)----------------------------------------------------- 4-2
CHECK AFTER STARTING (WITH KEY SWITCH ON) ----------------------------------------------------- 4-7
CHECK WHILE ADVANCING SLOWLY ----------------------------------------------------------------------- 4-10
CHECK OF WORK EQUIPMENT OPERATION ------------------------------------------------------------- 4-10
CHECK AFTER OPERATION ------------------------------------------------------------------------------------------------ 4-11
OUTLINE OF SERVICE-------------------------------------------------------------------------------------------------------- 4-12
SUITABLE OIL-------------------------------------------------------------------------------------------------------------- 4-12
OIL ----------------------------------------------------------------------------------------------------------------------- 4-12
GREASE --------------------------------------------------------------------------------------------------------------- 4-12
OIL STORAGE AND PRESERVATION ------------------------------------------------------------------------ 4-12
FILTERS --------------------------------------------------------------------------------------------------------------- 4-13
LUBRICANT LIST---------------------------------------------------------------------------------------------------------------- 4-14
LUBRICANT LIST---------------------------------------------------------------------------------------------------------- 4-14
OIL AND GREASING CHART (OIL, GREASE LOCATIONS AND INSPECTION AND MAINTENANCE
INTERVALS) ------------------------------------------------------------------------------------------------------- 4-15
OIL AND GREASING CHART (OIL, GREASE LOCATIONS AND INSPECTION AND MAINTENANCE
INTERVALS) (FOR EU) ----------------------------------------------------------------------------------------- 4-16
INSPECTION AND MAINTENANCE SCHEDULE CHART ----------------------------------------------------------- 4-17
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ------------------------------------------------------- 4-23
MAINTENANCE ------------------------------------------------------------------------------------------------------------------ 4-24
CHECK BRAKE LINK FOR BACKLASH, LOOSENESS, DAMAGE AND WEAR ------------------------- 4-24
CHANGE OIL IN TRANSFER CASE (INCLUDING DIFFERENTIAL CASE) ------------------------------- 4-24
CHECK TRANSFER CASE OIL LEVEL ----------------------------------------------------------------------- 4-24
CHANGE OIL IN TRANSFER CASE --------------------------------------------------------------------------- 4-24
CHANGE HYDRAULIC TANK ------------------------------------------------------------------------------------------ 4-25
CHECK BATTERY VOLTAGE AFTER CHARGING -------------------------------------------------------------- 4-26
SELECTION OF CHARGER POWER SUPPLY VOLTAGE TAP --------------------------------------------- 4-27
REPLACING FUSES------------------------------------------------------------------------------------------------------ 4-28
AREA UNDER FLOOR PLATE----------------------------------------------------------------------------------- 4-28
STATIONARY CHARGER ----------------------------------------------------------------------------------------- 4-29
CONTROLLER ------------------------------------------------------------------------------------------------------- 4-30
REPLACING TIRES------------------------------------------------------------------------------------------------------- 4-31
TIRE FOR BATTERY-POWERED LIFT TRUCK ------------------------------------------------------------ 4-31
REPLACING LAMPS ----------------------------------------------------------------------------------------------------- 4-32
WASHING LIFT TRUCK ------------------------------------------------------------------------------------------------------- 4-33
SERVICE DATA------------------------------------------------------------------------------------------------------------------ 4-34
SERVICE DATA------------------------------------------------------------------------------------------------------------ 4-34
TORQUE LIST-------------------------------------------------------------------------------------------------------------- 4-36
5. TECHNICAL DATA------------------------------------------------------------------------------------------------------------------- 5-1
TECHNICAL DATA ---------------------------------------------------------------------------------------------------------------- 5-2
6. EC DECLARATION OF CONFORMITY ---------------------------------------------------------------------------------------- 6-1
EC DECLARATION OF CONFORMITY(FB20EX-30-11)---------------------------------------------------------------- 6-2
TIE-DOWN POSITIONS OF LIFT TRUCK ---------------------------------------------------------------------------------- 6-2
7. ATTACHMENT ------------------------------------------------------------------------------------------------------------------------ 7-1
OPERATION OF SIDE SHIFT-------------------------------------------------------------------------------------------------- 7-2
ATTACHMENT MODEL PLATE LOCATION, SERIAL NO.------------------------------------------------------- 7-2
1 - 10
INTRODUCTION CONTENTS
SAFETY OF ATTACHEMENTS ----------------------------------------------------------------------------------------- 7-3

SAFETY LABEL-------------------------------------------------------------------------------------------------------------- 7-4
FEATURES OF ATTACHMENTS --------------------------------------------------------------------------------------- 7-6
GENERAL VIEW------------------------------------------------------------------------------------------------------------- 7-7
EXPLANATION OF COMPONENTS ----------------------------------------------------------------------------------- 7-8
OPERATION -----------------------------------------------------------------------------------------------------------------7-10
INSPECTION AND MAINTENANCE SCHEDULE CHART ------------------------------------------------------7-12
MAINTENANCE WORK---------------------------------------------------------------------------------------------------7-13
8. OPTIONS------------------------------------------------------------------------------------------------------------------------------- 8-1
HANDLING CLAMP OPEN GUARD------------------------------------------------------------------------------------------ 8-2
9. INDEX ----------------------------------------------------------------------------------------------------------------------------------- 7-1
1 - 11
SAFETY 2
22
WARNING
Please be sure that you fully understand this manual and the precautions
related to safety for the lift truck.
When operating, inspecting, or servicing the lift truck, always follow these
precautions strictly.
2-1
SAFETY LABEL SAFETY
SAFETY 2
SAFETY LABEL 2
Followings are the safety labels used for this lift truck.
• Make sure that you understand the exact locations of the safety labels, the contents of the danger, and how to
avoid them.
• Keep the safety labels clean so that it can be easily seen at all times. Do not use organic solvent or gasoline for
cleaning. Or the safety label may come unstuck.
• If the safety label is damaged, lost, or become unreadable, replace it with a new one. Before placing an order
to KOMATSU FORKLIFT distributor, check the part No. of safety label referring to this manual or the replacing
label itself.
• Concerning labels other than the safety labels, use these in the same way.
SAFETY LABEL LOCATION CHART 2
FB09EX-FB18EXG FB30
Front
2-2
SAFETY SAFETY LABEL
No. Safety labels name Position
Prohibit the operators from riding on the

1 Outside of left and right outer masts
forks and lifting/lowering themseves
2 Caution to avoid getting hand caught Rear side of tilt stay and head stay
3 Caution when hoisting the lift truck Rear left side of operator’s seat
4 Caution when closed the battery hood Top surface of battery hood (right side of operator’s seat)
5 Caution before operation Top surface of battery hood (right side of operator’s seat)
6 Seating capacity Top surface of battery hood (right side of operator’s seat)
7 Precaution when washing lift truck Top surface of battery hood (right side of operator’s seat)
8 Caution when handling battery Inside of battery hood
9 Caution for explosion of gas spring (*1) Gas spring
Front right inside of overhead guard (FB30)

Avoiding danger if lift truck tips over during
10
operations
Front left inside of overhead guard (FB09E-FB25EXG)
Take a right posture while operating lift truck

11 Rear rigth inside of overhead guard
(*2)
KOMATSU FORKLIFT reserves the right to change or add to these safety label requirements and label contents.
*1 : For EU specification only
*2 : FB30 only
2-3
SAFETY LABEL SAFETY
SAFETY LABELS 2
(1) Prohibit the operators from riding on the forks and lifting/
lowering themselves (3EB-96-25131)
• Never enter the area under the forks.
(2) Caution to avoid getting hand caught (3EB-96-25121)

• Do not place your hands.
2-4
SAFETY SAFETY LABEL
(3) Caution when hoisting the lift truck (3BA-96-59131) (3BA-96-

72640)
• Never lift the truck by the overhead guard.
(For EU FB30 only)
(4) Caution when closed the battery hood (3BA-96-36230) (3BB-

96-56570)
• Do not catch a hand in a battery hood.
• Lock the hood securely.
(For EU)
2-5
SAFETY LABEL SAFETY
(5) Caution before operation (3EB-96-25721) (3EB-96-54120)

• Be sure to read the Operation and Maintenance Manual
thoroughly before operating, servicing, disassembling,
assembling or transporting.
(For EU)
(For EU)
(6) Seating capacity (3EB-96-54110)

• Never allow any other person to ride with you on the lift truck
for whatever reasons.
• Do not use anyone for a counterbalance-weight.
2-6
SAFETY SAFETY LABEL
(7) Precaution when washing lift truck (3BB-96-36830) (37B-

1QC-5030)
• For washing the lift trucks, see the Section "WASHING LIFT
TRUCK (PAGE 4-33)".
(For EU)
(8) Caution when handling battery (3BB-96-36840) (09664-

60001)
(Shape and layout may vary depending on the battery
supplier.)
• For handling of the battery, see the Section "FIRE
PREVENTION (PAGE 2-12)" and "CAUTION WHEN
HANDLING BATTERY (PAGE 2-33)".
(For EU)
2-7
SAFETY LABEL SAFETY
(9) Caution for explosion of gas spring (09659-A0641) (*) (For EU)
• There is the hazard of explosion causing injury.
• Do not disassemble the gas spring, make holes in it, weld it,
cut it, hit it, bring it near flame.
* : For EU specification only
(10)Avoiding danger if lift truck tips over during operations (3EB-96-32610)
IF THE LIFT TRUCK SEEMS TO TIP OVER ANY

BEFORE OPERATION:
MOMENT DURING OPERATION:
1. Always use your seat belt when operating. 3. Do not jump off the lift truck.
2. Read and understand the Operation and 4. Lean yourself in the opposite direction to the tipping
Maintenance Manual. of the lift truck.
5. Grip the steering wheel tightly.
6. Brace yourself with both feet to support your body.
(11) Do not place your hands.Take a right posture while operating lift truck (3EB-96-59231) (*)
• If you operate the lift truck in such a posture that your weight is not properly applied to the seat, like standing
up or leaning forward/backward or sideways, the power will be cut off in approx. three seconds, making
travel and lift truck operation impossible. Take a right posture while operating.
It is especially dangerous when you operate like this on an uphill. Due to the power is cut off, the lift truck
will slither down even if you depress the accelerator pedal, which can lead an accident such as crash or
falling off.
* : FB30 only
2-8
SAFETY BASIC PRECAUTIONS
BASIC PRECAUTIONS 2
FOLLOW RULES 2
• Only the trained and qualified persons are allowed to operate

this lift truck.
• Fully understand and follow this operation and maintenance
manual.
• Do not operate the lift truck when you are ill conditioned, taking
medicine that causes drowsiness, under the influence of
alcohol, or mentally unstable.
• Plan safety work beforehand.

Before operation, make up an operating plan that fits the
workplace conditions, type and capacity of the lift truck, and the
load conditions.
In confined areas or when loading/unloading large items,
position a signal person and carry out operations in accordance
with their instructions.
• During operation, safety must be your primary responsibility
ensuring the safety of those you are working around, the lift
truck, yourself, and other property in the work area.
NEVER OPERATE THE BROKEN-DOWN LIFT TRUCK 2
• If any abnormality is detected during the start-up inspection or

during the operation (noise, vibration, odor, maladjusted gauge,
smoke, oil leak, or erroneous indication of warning device or
use
Never
monitor), report the administrator immediately and take

adequate corrective actions.
Danger
• Do not operate the lift truck until the abnormality is corrected.
• Remove the key from the faulty lift truck and put up signs in the
operator's compartment to prevent its use.
• If the lift truck has a failure and must be parked without lowering
the forks, put markers on the tips of the forks and take steps to
prevent pedestrians or other vehicles from hitting the forks.
• Select a parking place where people or vehicles do not pass.
Take measures to prevent anyone to go under the forks. (Space
under lifted forks is dangerous zone.)
2-9
BASIC PRECAUTIONS SAFETY
WEAR ADEQUATE CLOTHES AND SAFETY EQUIPMENT FOR OPERATION 2
• Avoid loose clothing and accessories. It is dangerous when they

catch on control levers and projections.
• Long, loose hair can be caught in a rotating part. Long hair must
be tied back.
• Always wear a safety helmet and safety shoes. Wear other
safety equipment appropriate for the working conditions or as
may be required by your administrator.
• Check that the safety equipment works properly before use.
FIRE EXTINGUISHER AND FIRST AID KIT 2
• In preparation for a fire or bodily injury, check the locations of fire

extinguisher and first aid kit, and be familiar with the usage.
CAUTIONS FOR SAFETY-RELATED EQUIPMENT 2
• Confirm that all protective guards, covers, and mirrors are

properly mounted. Repair them immediately when broken.
• Be sure that you fully understand the usage of safety-related
equipment.
• Never remove the safety-related equipment. Keep them fully
functional at any time.
• Do not operate this lift truck if the overhead guard or load
backrest has been or appears to have been damaged or
loosened until repairs have been made by your authorized
KOMATSU FORKLIFT distributor.
PRACTICE SUFFICIENTLY BEFORE OPERATION 2
• Take sufficient time for practice until you become familiar with
the operation of each component before starting the actual
operation.
• Even after you become familiar with it, operate with caution and
avoid harsh operation. Or it can cause a bodily injury or damage.
• Each lift truck is more or less peculiar in the performance of
brake, accelerator, and load handling device even though it is
the same model type. When you changeover the lift trucks,
understand the peculiarity of each lift truck before stating
operation. Be especially careful with brake, since its
performance varies by individual lift truck.
2 - 10
JUMPING ON AND OFF FROM THE LIFT TRUCK IS STRICTLY PROHIBITED 2
• Never jump on or off the lift truck. It is extremely dangerous.

• Even if the lift truck accidentally starts to move without operator
onboard, never attempt to jump on the lift truck to stop.
• Always mount and dismount the lift truck from the left side.
• While mounting and dismounting the lift truck, always support
yourself securely with your hands and feet at more than 3
locations; put your left foot on the step, grab the assist grip
(handrail) with your left hand, and grab the backrest or hip
support of the seat with your right hand.
• Do not hold on the control levers or steering wheel when
mounting or dismounting the lift truck.
KEEP THE OPERATOR'S COMPARTMENT AND PLATFORM CLEAN AND TIDY 2
• Always keep the operator's compartment and platform (assist

grip, step, floor) clean and tidy. Oil, mud or dust attached, or
spare parts or tools left lying around in the operator's
compartment may cause the operator's hand or foot slips or the
clothes get caught, which will lead a falling accident or
erroneous operation.
PRECAUTION WHEN WASHING LIFT TRUCK 2
• Entering of water into the electrical parts (controllers, sensors,

connectors) may cause a malfunction, which is dangerous. Do
not wash the electrical parts or use a high-pressure washer
(steam cleaner) on them. For washing the lift trucks, see the
Section "WASHING LIFT TRUCK (PAGE 4-33)".
TO AVOID BURN INJURY 2
HIGH TEMPERATURE PARTS AND OIL

• To prevent burns caused by high temperature parts such as
motor, controller, charger, etc., or by the spurt of oil, carry out
inspection and maintenance work after these parts cool down
and can be touched safely with bare hands.
2 - 11
FIRE PREVENTION 2
FIRE CAUSED BY HYDROGEN GAS EMITTED FROM BATTERIES

• Batteries generate flammable hydrogen gas.
• Never smoke or allow any flame near the battery.
• Sparks may ignite the gas. Do not place tools, parts or other
metal objects on the battery.
• Charge batteries always in a well-ventilated place with the
battery hood open.
• If flammables are deposited or attached to around the motor or
batteries,they may cause fire. Remove the deposits and
attached material from the above locations.
FIRE CAUSED BY OIL AND GREASES

Oil and greases, window washer fluid, etc. are flammable, so keep
them away from open flame.
Strictly follow the instructions shown below.
• Do not smoke or allow any flame near oil, antifreeze or window
washer fluid or clothes soaked in them.
• Tighten caps securely.
• Do not spill oil and greases on the overheated surface or
electrical system components.
• Store oil and greases in a well-ventilated dark cold place.
• Store oil and grease in a designated place. Keep unauthorized
people off the storage.
• Wipe off the spilled oil and greases.
• Put clothes soaked in oil and other flammable objects in a
secure container and store them in a safe place.
• Also, be cautious and take measures for fires that may be
ignited with a spark or flame when handling equipment and
devices for inspection and/or maintenance.
Failure to comply with these safety policies may result in serious
injury or death.
2 - 12
FIRE CAUSED BY DEPOSITS AND FOULING OF FLAMMABLE OBJECTS

• If flammables are deposited or attached to around the motor or
batteries, they may cause fire. Remove the deposits and
attached material from the above locations.
FIRE FROM ELECTRICAL WIRING

Short-circuiting of the electrical wiring may cause a fire.
• Clean all the electrical wiring connections, and fix them firmly.
• Check daily for looseness, wear and damage of the wiring. Re-
tighten the loose connector and wiring clamp. Damaged wiring
must be repaired or replaced by KOMATSU FORKLIFT
distributor.
FIRE FROM PIPING

• Make sure that the clamp, guard and cushion of the hose and
tube are fixed securely. Loose hose or tube may get damaged
by vibration during operation or by rubbing against other parts,
and cause the high pressure fluid to spurt out which may lead a
fire or bodily injury.
IF A FIRE BREAKS OUT 2
• If a fire breaks out, press emergency stop button (red), cut off the
electric circuit and stop the machine.
• Do not jump off the lift truck in a rush. Support yourself securely
with handrails and steps to evacuate.
INSTALLATION OF FIRE EXTINGUISHER(IF EQUIPPED) 2
• If equipped, a fire extinguisher is provided. (1 kg)

See the instruction plate attached on the fire extinguisher about
how to use it.
2 - 13
DO NOT MODIFY THE LIFT TRUCK 2
• Contact KOMATSU FORKLIFT distributor in advance for any

modification (installation, removal and modification) of the lift
truck, attachment or option. It may cause safety hazard and may modify
violate the law.

• KOMATSU FORKLIFT will not be responsible for any bodily
injury, damage or failure which results from the modification
made without prior consent of KOMATSU FORKLIFT in writing.
DO NOT REMOVE THE OVERHEAD GUARD AND LOAD BACKREST 2
• Do not remove the overhead guard or load backrest, which are

installed to protect the operator from falling objects.
• Do not operate 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.
• The overhead guard is built in compliance with the safety
standards. However, it is not designed to withstand every
possible impact. Always be careful to prevent damage or injury
from falling objects.
SECURE SAFETY AT THE WORKING AREA 2
• Working on a rough surface can result in bodily injuries such as

backache. Always keep the passages and work areas flat and
smooth without bump.
• Wipe up all spill oil or grease from the ground to prevent tip over
or collision due to slipping.
• When working on platforms, docks, quays, or other places
where there is 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 traffic areas clearly, and establish a clear traffic rule
such as temporary stop line, speed limit, no-entry area for other
vehicles and pedestrians.
• Provide adequate lighting for safety operations.
2 - 14
ASBESTOS CAUTION 2
• Non-Genuine Parts (unspecified parts of KOMATSU

FORKLIFT) such as clutch disc, brake lining, gasket and
packing may contain asbestos. Use Genuine Parts.
• All the parts used in this lift truck are asbestos-free.
WINDOW WASHER CAUTION 2
• Use the window washer which contains ethyl alcohol.

• Never use the window washer containing methanol which is
harmful to eyes.
2 - 15
START-UP INSPECTION SAFETY
START-UP INSPECTION 2
ALWAYS CONDUCT A START-UP INSPECTION IN THE BEGINNING OF THE DAY FOR YOUR SAFETY
OPERATION OF THE LIFT TRUCK
• For details of the inspection, see the Section "CHECK BEFORE
OPERATION (PAGE 4-2)".
• Do not operate the lift trucks before completing start-up
inspection.
• Report abnormality, if any, immediately to the administrator.
Never operate the lift truck in question until the repair is
completed.
CAUTIONS FOR OPERATING STARTING SWITCH, STARTING THE LIFT TRUCK AND OPERATING WORK
EQUIPMENT
• When operating the starting switch, always seat yourself
properly on the operator's seat, apply the parking brake lever
and turn the starting switch ON.
• Before starting the lift truck or operating the work equipment
(mast, fork, etc.), check the safety in the surrounding areas and
sit in the operator's seat.
• Before moving the lift truck or operating the work equipment,
sound the horn to warn people around.
CAUTIONS WHEN CHECKING SAFETY FUNCTION

• Before checking safety function, retain wide safety space
around the lift truck in case it makes a sudden, unexpected
movement. Check that the area is free of people and obstacles.
(Apply travel interlock, lift interlock, neutral safety and parking
brake.)
*All car standard installation only of neutral safety
CAUTION IN COLD WEATHER

• Immediately upon starting operation for the day in cold weather,
travel and lifting speed may be slow or steering effort may be
heavier or steering movement may change suddenly, leading to
accident. Operate the lift truck carefully until oil and machine
components warm up properly.
CAUTION ON WINDY DAYS

• On a windy day, the stability of lift truck and load are affected by
the wind.
Take extreme care when picking and placing a load at high lift.
In addition, take measures to prevent the load from being blown
down by the wind.
2 - 16
SAFETY TRAVELING THE LIFT TRUCK
TRAVELING THE LIFT TRUCK 2
PREPARATION BEFORE TRAVELING THE LIFT TRUCK 2
USE THE SEAT BELT

• Always fit the seat belt properly before operation. FB09EX-25EXG
• Not using the seat belt properly may result in serious bodily
injuries if the lift truck tips over.
• Make sure the seat belt is free from damage and flaw.
FB30
TAKE A RIGHT POSTURE ON THE SEAT

• If you operate the lift truck when you are not seated properly or
off the seat, an accident may happen unexpectedly. To forestall
such a possible accident, this lift truck is provided with TRAVEL
INTERLOCK and LIFT INTERLOCK that make traveling and lift
truck operation disabled if you are not seated properly.
For details, see "TRAVEL INTERLOCK FUNCTION (FB30)
(PAGE 3-33)" and "LIFT INTERLOCK FUNCTION (FB30)
(PAGE 3-39)".
TAKE A RIGHT POSTURE WHILE OPERATING

• Do not stick the hand or foot outside the machine body.
• Always keep your body under the overhead guard.
2 - 17
TRAVELING THE LIFT TRUCK SAFETY
BEFORE TRAVELING THE LIFT TRUCK, CHECK THE SAFETY OF SURROUNDING AREA
• Before starting to travel the lift truck, check that the surrounding
area is clear of obstructions such as pedestrians, other trucks
and loads.
• Raise the forks approximately 15 to 20 cm (6 to 8 in) from the
ground and tilt the mast back.
• Sound the horn areas as may be needed.
15 to 20 cm
(6 to 8 in)
OPERATE LIFT TRUCK EQUIPPED WITH SOLID TIRES FOR USE ON PNEUMATIC TIRE RIMS
(NON-PUNCTURE) ACCORDING TO THE FOLLOWING
• Solid Tires For Use On Pneumatic Tire Rims (non-puncture)
has more remarkable increase of internal heat generation in the
traveling than pneumatic type tire (pneumatic filling). Never
travel continuously for a long time in the work with load on the
tire such as overload, high-speed travel, and repeated opera-
tion of steering.
If the degree of heat generation of the tire is high, it easily
causes premature wear, rim displacement, etc. by rubber deteri-
oration.
WHILE TRAVELING THE LIFT TRUCK 2
BE ALWAYS CONSCIOUS OF SAFETY WHILE TRAVELING

• Avoid sudden starting, braking, or making sharp turns.
• Keep a clear view of the path of travel.
• 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.
• When traveling, always pay careful attention to the area around
your lift truck, particularly in the direction of travel or when
turning.
• Do not attempt to pass another lift truck or vehicle on a narrow
path or on a spot of limited view like a crossing.
• When passing through a crossing or turning a corner, or when
traveling into a narrow path, stop the lift truck once to check the
safety. Sound the horn to warn people around if necessary.
• 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.
• Do not allow people to enter the working area.
• When traveling on a slope or through a crowded spot, always
give way to a loaded lift truck.
2 - 18
DO NOT ALLOW ANY PASSENGER

• Never allow any other person to ride with you on the lift truck for
whatever reasons.
• Do not use anyone for a counterbalance-weight.
NEVER TURN OFF THE STARTING SWITCH WHILE TRAVELING

• If the starting switch is turned to OFF while traveling, the power
steering effort may become felt heavier, which is dangerous.
OPERATING BRAKE PEDAL

• Allow plenty of time for brake operation depending on the
situation, as the road surface and weight of the load affect the
stopping distance. Longer distance is required to stop on a
downhill, wet or slippery surfaces, and with heavy load.
DO NOT KEEP YOUR FOOT ON THE BRAKE PEDAL WHILE TRAVELING

• If you travel the lift truck with your foot on the brake pedal,
brakes may not work satisfactorily or wear out earlier. If this
situation continues, overheat protection function may work to
deteriorate the accelerating performance. Keep your foot off the
brake pedal during normal traveling.
WHEN BACKING UP THE LIFT TRUCK, CHECK REVERSE DIRECTION VISUALLY

• When backing up the lift truck, always look back and make a
direct visual check on the rear of the lift truck. The rear view
mirror is simply an auxiliary aid for checking the rear. When
reversing, do not depend on the rear view mirror alone for
checking safety.
• Even if you sound the backup buzzer, the people behind the lift
truck do not necessarily hear it. Always visually check directly
with your own eyes that there is no one behind the lift truck while
traveling.
2 - 19
WHEN CARRYING A HIGH LOAD, USE A SIGNAL PERSON OR TRAVEL BACKWARD

• If the view to the front is obstructed by the load, operate the lift
truck in reverse while minding safety in the area the lift truck is
heading to, or have a signal person to guide the travel.
DO NOT TRAVEL THE LIFT TRUCK WHEN THE FORKS ARE RAISED HIGH
• If loaded or unloaded, raising the forks also raises the center of
gravity of the lift truck increasing a risk of tipping over. Do not
travel the lift truck with the up-raised forks. (During a travel, keep
the forks approx. 15 - 20 cm above the ground with the mast
tilted backward.)
NEVER JUMP OFF THE LIFT TRUCK WHEN THE LIFT TRUCK SEEMS TIPPING OVER
(1) Always use your seat belt during operations for your safety if
lift truck should tip over.
(2) To avoid tipping over and other accidents, carry on proper
operation, inspection and maintenance work, read and
understand the Operation and Maintenance Manual.
(3) Do not jump off the lift truck if the lift truck seems tipping over.
Or you may be crushed by the lift truck resulting a serious
bodily injury.
(4) Lean yourself in the opposite direction to the direction the lift
truck is tipping.
(5) Grip the steering wheel tightly.
(6) Brace yourself with both feet to support your body.
• Practice this series of actions from time to time to master how to

act in emergency situations.
2 - 20
WHEN MAKING A TURN, BE CAREFUL OF THE SWINGING TAIL

• The lift truck has rear steering wheels. Be careful as if behaves
differently from passenger cars.
• When turning while traveling forward, the counterbalance-
weight will swing far out. Keep an ample clearance from walls to
ensure safety.
PAY CAREFUL ATTENTION TO THE LIFT TRUCK'S MAX. HEIGHT AND WIDTH
• Ensure that there is ample height and width for the lift truck to
pass.
• Keep clearance from the doors, ceiling, wirings and pipes.
• Be careful with the height of the mast and load backrest when
the forks go up.
DO NOT TRAVEL ON ROUGH OR SLIPPERY ROAD

• Do not try to travel on bumpy or soft ground. It can lead to a
serious accident when you lose steering control or the tires stuck
in the mud.
• Avoid traveling on the slippery road covered with water and oil.
You will lose brake or steering control.
OBSERVE THE WEIGHT LIMIT

• Do not allow overweight on the floors and roads where weight
limit is specified.
DO NOT TRAVEL DIRECTLY OVER OBSTACLES ON THE ROAD

• Avoid clutter, curbs, rails, ditches, or other obstacles, and do not
travel directly over them. Also, the impact applied when traveling
over obstacles can result in bodily injuries such as backache.
2 - 21
TRAVELING ON A ROAD SHOULDER IS STRICTLY PROHIBITED

• There is danger that soft road shoulders may collapse. Do not
approach them.
• Always maintain a safe distance from the edge of road
shoulders and platforms to prevent the lift truck from falling off.
CAUTION WHEN TRAVELING ON SLOPES

• Do not turn, or traverse or be careful for the approach/departure
angle on slopes. The lift truck may tip over.
• Before traveling uphill, stop the lift truck and adjust the fork
clearance between the ground. Keep the bottom of the forks or
pallet off the ground or prevent the tips of the forks from sticking
into the ground when traveling.
• For safe travel on slopes

When loaded: Travel forward uphill and in reverse downhill. When loaded
When unloaded: Travel in reverse uphill and forward downhill.
• On a down slope, depress the brake pedal and travel slow.
• Lifting the hip up during uphill travel activates travel interlock to
cut off drive power. This causes the lift truck to slither down even
if accelerator pedal is stepped on, leading to possible collision or
tipping over. Take a right posture while operating. For more
details on the function of travel interlocking, see "TRAVEL
INTERLOCK FUNCTION (FB30) (PAGE 3-33)".
When unloaded
2 - 22
EXERCISE CARE WHEN TRAVELING INTO A RAILWAY WAGON OR CONTAINER

• Check that brake and block are applied to the wagons, trailers,
and containers to stop them.
• Tell the carrier drivers not to move their vehicles until the load
handling operation is completed.
• Ramps used for approaching the wagon and/or trailers must
stand the travels of loaded lift trucks.
• Engage the ramps securely to wagons and trainers.
• Do not travel at the edge of the platforms or loading docks, or
there is a danger of the lift truck falling down.
STOPPING AND PARKING 2
FOLLOW THE STEPS FOR STOPPING AND PARKING

1. Stop the lift truck on a firm level ground.
2. Apply the parking brake lever to prevent the lift truck from
moving.
3. Set the forward/reverse control rever to N (Neutral).
4. Tilt the mast forward and lower the forks to the floor.
5. Turn the starting switch key to the OFF position.
6. Pull out the starting key and leave the lift truck.
PARK THE LIFT TRUCK IN A SAFE PLACE

• Park the lift truck on a firm level ground.
• Do not stop or park near any emergency exit or other safety
equipment. Stop or park the lift truck in a place where it will not
obstruct pedestrians or other vehicles.
• Do not park the lift truck on a slope. If parking on a slope is
unavailable, apply blocks to the tires.
2 - 23
LOAD HANDLING OPERATION SAFETY
TOWING 2
BE CAREFUL WHEN USING THE DRAWBAR PIN

• The drawbar pin is provided for being towed by the wrecking car
when the tires are stuck in a ditch or mud.
• Do not use it for towing or hoisting.
• The drawbar pin can be used for an anchor point of this lift truck
when being transported by a truck.
DO NOT TOW A DISABLED LIFT TRUCK

• If there is any problem with the brakes or steering system of your
lift truck, do not use tow is with another lift truck. There is a
danger that disabled the lift truck may move accidentally.
LOAD HANDLING OPERATION 2
SIT ON THE SEAT CORRECTLY FOR LOAD HANDLING OPERATION

• To avoid accidents, Load Handling Interlock activates to disable
the load handling operation when you are not seated properly or
off the seat. For more details on the function of load handling
interlocking, see "LIFT INTERLOCK FUNCTION (FB30) (PAGE
3-39)".
DO NOT ALLOW ANYONE IN THE WORKING AREA EXCEPT THE SIGNAL PERSON
• To avoid accidents, keep unauthorized people and other vehicle
off the working area except a signal person during the load
handling operation.
• Use a signal person when it is necessary to ensure visibility or
for other safety reasons.
• When working with a signal person, always follow his/her
instructions.
DO NOT GO UNDER THE LIFTED FORKS

• The lifted forks may accidentally fall down to cause serious
injuries to person below, of any. Keep everyone away from
under the lifted forks.
2 - 24
SAFETY LOAD HANDLING OPERATION
WORKING ON THE FORKS IS STRICTLY PROHIBITED

• Do not directly place a load manually on the forks.
• Do not directly remove a load manually from the forks.
• Do not step on the forks to handle a load. The load may slip
down the forks.
• Do not hold the load on the forks by hands. Sudden lift truck
movement may cause the load to fall on the person below.
BE CAREFUL NOT TO GET CAUGHT IN THE MAST STRUCTURE

• Never put your hands, feet, or other body parts into the mast
structure. There is a danger that you may get caught in moving
parts and be seriously injured.
• Do not stand between mast and operator's compartment as you
may be crushed and be seriously injured or killed.
• Always operate the mast and forks from the operator's
compartment.
DO NOT CLIMB ON THE MAST OR LOAD BACKREST

• If you climb on the mast or load backrest, there is a danger of
being caught in the moving parts or fall off.
USE A PALLET OR SKID OF AMPLE STRENGTH

• Always use the pallets and skids of robust construction. Do not
use broken or damaged pallets or skids.
• Before traveling, always check that the load is positioned
securely and safely on the pallet.
2 - 25
HANDLE A LONG OR WIDE LOAD WITH EXTRA CARE

• Be extremely careful when carrying long or wide loads. Lift the
load slowly without hitting anything in the surrounding area.
• When switching direction, keep the load as low as possible and
maintain the balance.
BE CAREFUL WITH THE MAST HEIGHT

• As the forks go up, the mast height increases. Be mindful of this
face during the operation.
• Take care not to hit with the mast electric wirings, piping,
sprinklers, beams in the ceiling, etc. If such hitting occurs, there
is a danger that the load on the forks drops off or the lift truck tips
over.
OVERLOADING IS STRICTLY PROHIBITED

• Overloading may cause the rear wheels come off the ground,
and the lift truck loses the balance and tips over. Do not load the
lift truck over the max. capacity shown in the load table. For
details, see "ACTUAL CAPACITY (PAGE 2-39)" and "SERIAL
NO. PLATE AND LOAD TABLE (PAGE 2-40)".
DO NOT TILT THE MAST FORWARD WITH A LOAD ON THE FORKS

• Do not tilt the mast forward with the load raised. Do not raise the
load with the mast tilted forward. Or the load may fall or the lift
truck may tip over. Do not travel with the mast tilted forward.
2 - 26
SAFETY LOAD HANDLING OPERATION
DO NOT HANDLE A LOAD IN AN INSECURE MANNER

• 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.
• Secure the load in position to prevent collapsing or falling. Do
not handle unstable loads.
• Place the load so that it makes contact with the load backrest.
DO NOT LOAD AND UNLOAD ON SLOPES

• Loading or unloading on the slopes may cause the lift truck to
lose its balance and tip over.
DO NOT LOWER THE LOADED FORKS HASTILY

• Do not operate the forks roughly or make a sudden stop.
Sudden lowering may cause the collapsing or falling of the load,
and the lift truck may go off balance and tip over.
DO NOT HANDLE A LOAD EXCEEDING THE LOAD BACKREST HEIGHT

• If the load is higher than the load backrest, there is danger that
it may fall back on the operator. Do not handle a load exceeding
the load backrest height.
2 - 27
DO NOT PRY SOMETHING WITH THE TIPS OF THE FORK

• Or the hooked object may suddenly come off the tip and be
damaged. The reaction may result in an unexpected motion of
the lift truck or load and the risk to the safety.
DO NOT USE THE FORKS TO PUSH OR PULL A LOAD

• There is a risk that the load will be damaged or fall.
DO NOT USE THE LIFT TRUCK FOR ANY OTHER PURPOSE

• Do not use the lift truck for any other purpose than load handling
using forks or attachments.
• Do not open or close the doors of railroad cars or warehouses
with the forks.
• Do not push or pull any other vehicle.
• Do not lift loads suspended from the fork with ropes. The rope
may slip, come off, break, or even cause cracks on the forks.
Also the lift truck may lose its balance and tip over as the load
swings.
2 - 28
SAFETY PRECAUTIONS FOR INSPECTION AND MAINTENANCE
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2
ALWAY PERFORM THE START-UP INSPECTION 2
• This Operation and Maintenance Manual provides only the

simple inspection and maintenance information that operators
can perform relatively easily. For inspection and maintenance
that requires a trained, skilled and qualified personnel, contact
your KOMATSU FORKLIFT distributor.
• Do not operate the lift trucks before completing start-up
inspection.
• Report abnormality, if any, immediately to the administrator. Do
not operate faulty lift truck until the repair is completed.
• Incorrect inspection, maintenance and repair services may
cause critical accident or shorten machine service life. For your
safety operation, contact KOMATSU FORKLIFT distributor for
inspection, maintenance and repair services.
PUT UP A WARNING SIGN DURING INSPECTION AND MAINTENANCE 2
• Put up a warning sign on the steering wheel or load handling

lever during inspection and maintenance work. Put up the sign
around the lift truck, if necessary.
• Do not let any other person than the inspector or maintenance
staff start lift truck or touch the load handling lever during Do not operate
inspection and maintenance. Or serious injuries may result.
When jointly making inspection or maintenance with other
personnel, name the leader and follow his/her instructions.
KEEP THE WORKING AREA CLEAN AND TIDY 2
• Keep the working area clean and tidy. Get obstacles out of the
way. Wipe off any grease or oil.
• Perform the work on level surface with ample space.
• If the work is carried out inside a building, keep it well-ventilated.
2 - 29
PRECAUTIONS FOR INSPECTION AND MAINTENANCE SAFETY
CAUTIONS BEFORE INSPECTION AND MAINTENANCE 2
• Arrange for a fire extinguisher. Know the location and how to use
it.
• Arrange the lift truck for inspection and/or maintenance as
follows:
1. Lower the forks to the floor.
2. Apply the parking lever. (Parking brake activated)
3. Set the operating lever and forward/reverse control rever to N
(Neutral) position.
4. Turn the starting switch to OFF position to cut off power.
• Do not allow anyone with loose clothing or long loose hair near
the mast while operation.
• Wear adequate working clothes and protective items (safety
helmet, safety shoes, goggles and gloves).
• Block the front and rear tires.
KEEP UNAUTHORIZED PEOPLE OFF 2
• No unauthorized person is allowed near the lift truck under

maintenance service.
USE OF RIGHT TOOLS AND EQUIPMENT 2
• Use a suitable tool correctly. Do not use broken or deformed

tools, or wrong tools designed for another purpose, or a serious
accident may result.
2 - 30
CAUTIONS WHEN WORKING UNDER WORK EQUIPMENT 2
• Block the forks and mast to prevent falling before working under
the raised forks. Otherwise a serious accident may result.
AVOID GETTING CAUGHT UP BY THE MAST OR FALLING OFF 2
• Do not put your hands, feet, or other body parts into the mast
structure. Or you may be caught by the mast parts.
• Do not stand between mast and operator's compartment as you
may be crushed and be seriously injured or killed.
• Always operate the mast and forks from the operator's
compartment.
• Do not climb on the mast load backrest or on top of the

dashboard. You may slip and fall or get caught in the moving
parts. Use a stepladder for inspection and maintenance at
elevated level.
2 - 31
BE CAREFUL OF HIGH PRESSURE OIL 2
Remember that the hydraulic system is constantly under pressure.

Check the hydraulic system for no pressure before checking or
replacing piping or hose, or a serious accident may result. Follow
the instructions below:
• When checking hydraulic piping or hose for leakage, don't touch
it directly by hand. The pipe or hose may be pressurized.
• If your skin and/or eye are injured by high-pressure oil, wash it
with fresh water and immediately see a physician.
BEWARE OF ROTATING COOLING FAN 2
• Keep hand off the rotating fan.
CAUTIONS FOR USING COMPRESSED AIR FOR CLEANING 2
• The dust particles may cause a serious bodily injury if

compressed air is used for cleaning.
• Always wear protective gears such as goggles, dust mask, and
gloves.
CAUTIONS WHEN REPLACING THE SEAT 2
Seat is equipped with important safety functions:

• Seat belt and support to operator's body
• Travel and lift interlock function switches(FB30)
• Storage case for instruction manual
Always use Genuine Seat for replacement.
2 - 32
REMOVING THE BATTERY PLUG 2
• When repairing the electrical system, disconnect the battery

plug to stop power supply.
• Do not start repairing electrical system by merely depressing
emergency stop button.
CAUTION WHEN HANDLING BATTERY 2
Handling error of batteries may cause explosions, fires and other

critical injuries. Handle batteries after fully understanding how to
handle and their hazards.
• Batteries generate flammable hydrogen gas and may explode in
contact with fire. Always keep the battery hood open while
charging batteries.
• Do not smoke or allow any flame near the battery.
• Sparks may ignite the gas. Do not place tools, parts or other
metal objects on the battery.
• To clean the battery surface, use wet piece of cloth. Dry cloth
may generate static and cause explosion.
• Depending on the weather, environmental, clothing material and
other conditions, human bodies may deposit and spark
statistics. Therefore, before touching lift truck being charged or
after charging, discharge statistic deposit in the human bodies
by grounding.
• Batteries for battery-driven lift trucks store large energy in high-
tension. Beware of the risk of electric shock and burns. Be
careful to keep human bodies from touching energized portion
during maintenance, inspection and/or installation or removal.
• Battery electrolyte contains sulfuric acid, and can quickly burn

the skin and eat holes in clothing. Always wear protective
glasses, rubber gloves and rubber sole shoes for maintenance
inspection.
2 - 33
• If battery electrolyte gets into your eyes, flush them immediately

with fresh tap water for 10 to 15 minutes continually and consult
a doctor.
• If you spill battery electrolyte on yourself, immediately take off
clothes and flush the contact portion of the skin with a large
quantity of tap water and consult a doctor.
• If one swallows battery electrolyte by mistake, drink a large
amount of water or milk mixed with white of raw eggs or salad oil
and consult a doctor at once.
• If battery electrolyte is spilt or leaked in the surrounding area,
neutralize the area with neutralizing agents (baking soda,
calcium hydroxide or sodium carbonate, etc.) and wash it down
with large amount of water. Or floor surfaces and cargoes will be
damaged.
• Do not drain battery electrolyte or disassemble or repair
batteries, which is dangerous.
• If the following abnormalities are detected, please call your
KOMATSU FORKLIFT distributor for service:
If battery plug and charging plug mating become loosened or
play is generated (Plug becomes abnormally heated).
If battery electrolyte temperature is high or electrolyte level
drops sharply.
If charging requires too long time (Charging is not completed
although the battery was not used till late hours on the
preceding day).
2 - 34
CAUTION WHEN HANDLING TIRES 2
The lift truck tires are very highly pressurized with the air. Do not
mishandle, or the tires may burst, be damaged or the rim may
break into pieces causing a serious injury. For your safety, follow
the instructions shown below.
• Do not disassemble/assemble tire, tube or rim, nor inflate
removed tires with the air.
• For safety, when filling a tire with air or replacing it, place your
body in front of the tread face of the tire (see the figure at right).
Do not work from the side of the tire.
• When removing the tire with divided rim from the lift truck,
always loosen the hub nuts (1) after depressurizing the tire.
Do not loosen the rim bolt (irregular shape) (2) of the divided rim.
For the tire replacement, see "REPLACING TIRES (PAGE 4-
31)".
• Always use the specified tire of KOMATSU FORKLIFT, and

observe the specified tire inflation pressure. For the right tire
inflation pressure, see "SERVICE DATA (PAGE 4-34)".
• When filling up the tires, make sure no one is around and use a
clip-on air chuck that can be fixed to the air valve. Fill up the tire
while checking with an air gauge to avoid over inflation.
• The rim will not " fit " the tire if either the tire or rim is defective,
or if it is not properly assembled. To fit, the rim must contact with
the tire evenly around the circumference. Contact your
KOMATSU FORKLIFT distributor as needed.
2 - 35
CAUTION IN WASTE DISPOSAL 2
Take full cautions for waste disposal to prevent environment

pollution.
• Always drain waste fluid such as oil and battery electrolyte into
containers like cans and tanks. (Do not drain the battery
electrolyte into metallic containers. Always use plastic
containers.) Do not pour on the ground or into rivers, drains,
seas or lakes.
• Comply strictly with applicable laws and regulations when
disposing of harmful objects such as oil, solvent, filters, batteries
and refrigerant (CFCs).
CAUTION AFTER INSPECTION AND REPAIR 2
• Wipe off the spilt oil and grease immediately. If the lift truck is
dirty, it becomes difficult or impossible to find cracks or other
problems.
• Test the lift truck upon completion of the repair to check if there
is no abnormality.
PERIODIC INSPECTION OF SAFETY CRITICAL PARTS 2
• To ensure the safety and long service life of the lift truck, be sure
to perform lubrication, inspection and maintenance regularly.
Especially the safety critical parts, must be replaced regularly.
• Quality of these parts may change over time or deteriorate, wear
or fatigue as they are repeatedly used, causing serious bodily
injuries and damages. Furthermore, the remaining service life of
such parts is usually hard to determine for operators or during
visual inspection.
• Replace the safety critical parts with a new one periodically even
if no anomaly is found.
• Replace the safety critical parts immediately when any
abnormality is found, even if the replacement interval is not up
yet.
• For details of safety critical parts, see "PERIODIC
REPLACEMENT OF SAFETY CRITICAL PARTS (PAGE 4-23)".
REMARK
• This Operation and Maintenance Manual does not describe the
details on how to inspect or replace the safety critical parts.
• Inspection and replacement of the safety critical parts, and
refilling of greases must be done by KOMATSU FORKLIFT
distributor.
2 - 36
SAFETY HOISTING AND TRANSPORTING THE LIFT TRUCK
HOISTING AND TRANSPORTING THE LIFT TRUCK 2
CAUTION WHEN HOISTING THE LIFT TRUCK 2
• Never lift up by the overhead guard.

• Before lifting-up, Check that the mounting bolts of mast and
counterbalance-weight are tightened to the specified torque.
• To hoist the lift truck, hook on the holes on the top of the outer
mast for the front.
• For the rear, use the counterbalance-weight and rear axle. (*)
• Do not go under the lifted truck.
• Use undamaged sling and wire having sufficient strength.
* : To hoist FB20EX-FB25EXG for EU specification, sling them
with holes at the rear of the over head guard.
REMARK
A safety label seen on the right is stuck to the position where the
sling is put on to hoist the truck.
PRECAUTIONS FOR LOADING AND UNLOADING THE LIFT TRUCK 2
Loading and unloading a lift truck to and from a trailer always

involve a hazard of the lift truck tipping over or falling off by
handling error. Follow the instructions below:
• Stop the trailer on level, flat road. Always apply parking brake.
Apply blocks to the tires. Ramp
• Use ramps or dock plate of appropriate length, width and
strength. Secure it tightly to prevent it from being dislocated or
disengaged.
• Take a right posture on the seat while operating. Blocks
• If you operate the lift truck in such a posture that your weight is
not properly applied to the seat, like standing up or leaning
forward or sideways, Travel Interlock activates to cut off the
transmission of engine power. Then the lift truck may slither
down even if the accelerator pedal is stepped on or an uphill.
Operate the lift truck assisted by a signal person if necessary so
that you don't have to stand up or lean forward or sideways to
watch. For more details on the function of travel interlocking, see
"TRAVEL INTERLOCK FUNCTION (FB30) (PAGE 3-33)".
• When using the ramps, set them in gentle gradient, align the
center of both the trailer and the lift truck and lock securely to
prevent misalignment.
• Do not change the course of the lift truck while on the ramps. If
course change is needed, move off the ramps once and make
another uphill travel on them in right direction.
2 - 37
STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING) SAFETY
STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT

TRUCK FROM TIPPING) 2
To operate the lift truck safely, it is important to understand the structure and stability of the lift truck.
LONGITUDINAL STABILITY 2
• The front wheels of the lift truck act as a fulcrum, and the load
weight and the weight on the rear wheels are kept in balance to
prevent the lift truck from falling forward.
• When an overbalanced load weight is applied, the rear wheels Load
will be raised off the ground. It is very dangerous and poses a

high risk of serious accident like tipping over.
Weight on
Load weight Fulcrum the rear wheels
CENTER OF GRAVITY OF A LOAD 2
• The shapes of loads carried by lift trucks vary from boxes to planks and long objects.
• To judge the stability of the lift truck, it is important to determine the position of the center of gravity for loads of
various shapes.
Center of gravity Center of gravity
2 - 38
SAFETY STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING)
COMBINED CENTER OF GRAVITY AND STABILITY ON THE LOADED LIFT TRUCK 2
COMBINED CENTER OF GRAVITY

• The center of gravity of the loaded lift truck shifts to a combined Combined center of gravity at
high lifting height Center of gravity
center of gravity of both the lift truck and the load. When the load of load
is raised, its center of gravity will rise, hence the combined
center of gravity will also rise. Combined center of
gravity at low lifting
height
Center of gravity of
lift truck
COMBINED CENTER OF GRAVITY AND STABILITY

The higher the position of the center of gravity, the worse the
longitudinal and lateral stabilities become. In addition, swaying or
shock encountered during traveling or load handling will have a
larger impact on the stability of the lift truck.
Stability of the lift truck also changes depending on the following
factors.
• Size, weight, shape of load (position of center of gravity etc.)
• Lifting height
• Tilting angle of mast
• Inflation pressure of tires
• Acceleration, deceleration and turning speed when traveling
and load handling
• Road condition and gradient
• Type of attachments
Do not travel with the forks (load) raised. Do not make sharp turns
or apply sudden brakes. Do not raise or tilt the forks abruptly. There
are dangerous and poses a high risk of serious accident like tipping
over.
ACTUAL CAPACITY 2
• The horizontal distance from the position of the center of gravity

of a load on the forks to the upright load backrest of the fork is
called a load center. Actual capacity means the maximum
weight of a load that can be loaded at a certain load center.
• The load table is given in the name plate accessible from the
operator's seat. The table shows the relationship between the
actual capacity and load center.
• When the load center shifts toward the fork tips, the load weight
(mass) has to be decreased in the actual operation to maintain
the balance. Load center : Small Load center : Large
Load : Large Load : Small
2 - 39
SERIAL NO. PLATE AND LOAD TABLE 2
LOAD CAPACITY CHART (FB09EX-FB25EXG)

This shows the relationship between the position of the load center
and the maximum load. Before loading the forks, check that the
load and load center (B) are within the permitted range on the load
capacity (A) chart.
If the shape of the load is complex, set so that the heaviest part of
the load is at the center of the forks and set the load close to the
load backrest.
-=
METHOD OF READING LOAD CHART (FB09EX-FB25EXG)

The load chart given here is an example. Always follow the load
chart stuck to the truck when carrying out operation.
1. Permissible load
2. Distance from perpendicular front face of forks to center of
load
3. Permissible load curve when a mast with a maximum lifting
height of 4.0 m or less is installed
4. Max. allowable load curve when the lift truck is equipped with
a mast of the max. mast height of higher than 4.5 m but lower
than 5.0 m
5. Example: When the load center is 50 cm with a 5 m maximum
lifting height mast installed, the permissible load is 1.45 tons.
6. Even if the load center is less than 50 cm, the permissible load
(1.45 tons) does not change.
7. If forks are installed and the load center is 80 cm, the -=
permissible load becomes approx. 1.0 ton.
2 - 40
SERIAL NO. PLATE FOR GENERAL (FB09EX-FB25EXG)/EU (FB09EX-FB18EXG)

• The serial No. plate for USA is shown at right.
SERIAL NO. PLATE FOR EU (FB20EX-FB25EXG)

• The serial No. plate for EU is shown at right.
2 - 41
EXPLANATION OF LOAD TABLE (FB30)

• In the load table of the serial No. plate, actual capacity and
maximum load (2) are shown in relation to load center (1).
• Actual capacity and maximum load are determined according to
each model on the condition of the specifications shown in area
(3).
• Before loading, make sure that the load center and the load are
well within the range of capacity.
• When the load is in a complex shape, pull the load so that the
heaviest portion of the load comes to closer to the load backrest
and the lateral center comes to the two forks center.
• Should a load be loaded beyond the range of capacity, it would
pose a big danger to the lift truck as the rear wheels (for
steering) may lift off the ground, letting the operator lose control
of steering, or the lift truck may tip over. Always keep the load
within the range of capacity.
• Work within the specification ranges given in the serial No. plate
attached to the lift truck. Replace the broken or unreadable
serial No. plate. Call your KOMATSU FORKLIFT distributor for a
new serial No. plate.
EXAMPLE OF LOAD CENTER AND ACTUAL CAPACITY (FB30)

• The areas (1) and (2) in the example provide the following
information:
When the load center is 500 mm
- - - Maximum capacity : 1,900 kg (*1)
When the load center is 600 mm - - - - -Capacity : 1,720 kg
When the load center is 1,000 mm - - - Capacity : 1,260 kg
*1: Even when the load center is smaller than 500 mm, the
maximum capacity is 1,900 kg.
• The area (3) shows the main specifications of the model.

Max. lifting height :3m
Attachment : Side Shifter
Front wheel tread : 955 mm
Mast rear tilting angle : 10 degrees
Front wheel size, inflation pressure : 200/50 - 10, no inflation (*2)
Rear wheel size, inflation pressure : 16 x 6 - 8, no inflation
*2: Solid Tires For Use On Pneumatic Tire Rims (non-puncture) in this example, does not require air inflation.
2 - 42
• The following symbols indicate the types of attachment if any.
Symbol Symbol
Attachment Attachment
Type Capacity Type Capacity
Side shifter F S * * * * Pusher P A * * * *
Fork positioner F M * * * * Clamp C * * * * *
Load stabilizer F T * * * * Roll clamp R S * * * *
Hinged fork H F * * * * Rotating fork R F * * * *
Push pull P P * * * * Ram L * * * * *
* marks in the chart will be replaced with alphabets and numbers which stand for types and capacities of the
attachment.
Numbers are not necessarily in 6 digits.
LOAD CAPACITY WHEN EQUIPPED WITH ATTACHMENT AND / OR HIGH MAST

• Please note that the lift truck equipped with attachments and/or
high mast has a smaller maximum capacity and actual capacity
than the standard lift truck.
• Follow the load limit as indicated in the load table of the serial
No. plate.
LOAD TABLE AND LOAD CAPACITY FOR DETACHABLE AND INSERT-TYPE ATTACHMENTS
• For some detachable attachments, additional load table is
provided at a certain place of the lift truck. In this case, follow the
instructions in the table when installing such an attachment.
• For insert-type bucket and fork extension sleeve, calculate the
capacity as follows: Subtract the weight of insert-type bucket or
fork extension sleeve from the capacity on the chart.
• To check if weight of the insert-type bucket or fork extension
sleeve must be considered, refer to the label attached on the
right side of the operator's seat.
OTHER INFORMATION ON THE SERIAL NO. PLATE (FB30)

• The area (4) shows other basic information of the lift truck.
Model
Serial No.
Date of manufacture
Unladen mass
Unladen mass without battery
Battery mass max/min
Battery voltage
• [ - ] means that no information is required.
• Logo and the company name are shown on the top and bottom
of the serial No. plate.
2 - 43
INTRODUCTION OF OPTIONAL SAFETY DEVICE 2
Various safety devices are available as options. The devices listed

below are only examples. Contact your KOMATSU FORKLIFT
distributor for more information.
Note that the devices and equipment may not be effective
depending on the usage and working conditions. Follow the
instruction of the safety control personnel for installation.
• Working lamp : Top and rear
• Warning for traveling (forward/reverse) or approach
: Chime, revolving warning lamp
• Handling of high/wide item : High or wide load backrest and
finger board (fork carriage)
• Better visibility : Rear view mirror
• Fire extinguisher
etc.
2 - 44
OPERATION 3
13
OPERATION
WARNING
When operating the lift truck, always strictly follow these precautions. Failing
to heed this warning may result in serious injuries.
3-1
GENERAL VIEW OPERATION
GENERAL VIEW 3
GENERAL VIEW OF LIFT TRUCK 3
(1)Mast
(2)Lift chain
(3)Lift cylinder
(4)Back rest
(5)Tilt cylinder (10)Head lamp
(6)Fork carriage (11)Operator's seat
(7)Fork (12)Battery hood
(8)Head guard (13)Counterbalance-weight
(9)Turn signal lamp (14)Rear wheel
(15)Front wheel
(Including some optional parts)
3-2
OPERATION GENERAL VIEW
INSTRUMENTS AND CONTROLS 3
• OPERATOR'S COMPARTMENT
Lift truck with proportinal solenoid valve (For FB30 only ) Lift truck with standard valve
(1)Key switch (7)Accelerator pedal

(2)Forward/reverse control lever (8)Brake pedal
(3)Meter panel (9)Steering column lock lever
(4)Parking brake lever (10)Lift control lever
(5)Horn button (11)Tilt control lever
(6)Combination switch (Lighting switch, turn signal switch) (12)Emergency stop switch
REMARK
Each number above corresponds with that in “EXPLANATION OF CONTROLS AND GAUGES (PAGE3-5)“.
3-3
GENERAL VIEW OPERATION
• DETAILS OF METER PANEL
(a)Battery electrolyte level indicator (h)Travel system failure indicator

(b)Battery discharge indicator (i)Hydraulic system failure indicator
(c)Display (j)Power steering system failure indicator
(d)Parking brake indicator (k)Travel power indicator
(e)Speedometer (l)Mode button
(f)Speed limit indicator (m)Item button
(g)Failure indicator (n)Set value button
3-4
OPERATION EXPLANATION OF COMPONENTS
EXPLANATION OF COMPONENTS 3
The following is an explanation of the devices employed to operate the lift truck.
To carry out suitable operations correctly and safely, it is important to understand fully the method of operating the
equipment and the meanings of the displays.
EXPLANATION OF CONTROLS AND GAUGES 3
KEY SWITCH
CAUTION
When the key switch is turned ON, always set the forward/reverse control lever to the NEUTRAL position without depressing the
accelerator pedal.
This switch (1) sets the lift truck ready for operation.
OFF: The engine starting switch key may be pushed in or pulled
out at this position.
ON : When setting the engine starting switch key to the “ON“
position by turning one stage to the right from the “OFF“
position, the lift truck is set ready for operation.
FORWARD/REVERSE CONTROL LEVER
CAUTION
When turning the starting switch ON, always set the directional lever to neutral, and keep your foot off the accelerator pedal.
This lever (2) is used to switch between forward and reverse.

F: FORWARD
N: NEUTRAL
R: REVERSE
NOTICE
• Plugging operation allows smooth braking, stopping and reversing. (See “PLUGGING (PAGE3-35)“.)
• Set the lever to N (NEUTRAL) position when stopping the lift truck.
• When the key switch is turned to ON, set the lever to N (NEUTRAL) position.
3-5
EXPLANATION OF COMPONENTS OPERATION
METER PANEL
(a)Battery electrolyte level indicator (h)Travel system failure indicator

(b)Battery discharge indicator (i)Hydraulic system failure indicator
(c)Display (j)Power steering system failure indicator
(d)Parking brake indicator (k)Travel power indicator
(e)Speedometer (l)Mode button
(f)Speed limit indicator (m)Item button
(g)Failure indicator (n)Set value button
• Checking meter panel display

Display on the meter panel is normal if all the displays appear for 1.5 seconds after the engine starting switch key
is turned ON. If any of them does not appear, there is a possibility that meter panel (3) is damaged. In that case,
call your KOMATSU FORKLIFT distributor.
BATTERY ELECTROLYTE LEVEL INDICATOR

(For lift trucks equipped with battery electrolyte level sensor)
This is an indicator (a) which warns of need for refilling the battery
with electrolyte. When the battery electrolyte amount drops below
the specified level, indicator (a) lights on to warn the operator.
NOTICE
• If the above warning is given, add distilled water immediately. (For
details of the method of adding distilled water, see “CHECKING
ELECTROLYTE LEVEL (PAGE4-4)“.)
• If the lift truck is used when the battery electrolyte level is low, the life
of the battery will be greatly reduced, so always add distilled water
immediately.
• If any battery other than the standard battery or optional battery is
used, the battery electrolyte level indicator cannot be used.
3-6
BATTERY DISCHARGE INDICATOR

This displays (b) the remaining capacity of the battery in 10 steps. As the battery is discharged, the display lamps
go out in turn from the top.
When the battery is fully charged, all 10 display lamps light up.
When the residual battery capacity goes down below 30%, the 3rd
bar from the bottom lights on and the lowest two bars begin to flash,
warning that the battery is to be charged soon.
When the residual battery capacity goes further down exceeding a

20% level, the lowest two bars begin to flash alternately and an
alarm buzzer sounds at an interval of 2 minutes for 5 seconds each
time to warn that the battery charging time has come around.
When that happens, lose no time in charging the battery.
NOTICE
• The display is given when the remaining battery capacity drops below 20% (the bottom 2 lamps flash in turn) and the alarm
buzzer sounds (5 seconds every 2 minutes) continue until the remaining battery capacity is restored to more than 21%.
• Excessively discharging the battery (continuing operations even when the remaining battery charge has dropped below
20%) will greatly reduce the life of the battery. Always stop operations immediately and charge the battery.
• A lift interrupt function which stops loading operations if the remaining battery charge drops below 20% is available as an
option. For details, please contact your KOMATSU FORKLIFT distributor.
3-7
DISPLAY
The hour meter display, failure display, and adjustment mode display are given (c).
Hour meter display

• The time that the starting switch has been kept at the ON position is calculated and displayed.
• The display is in units of 0.1 hours with a maximum of 199999.9 h.
When the starting switch is turned ON, the starting switch ON time, travel time, and loading time are displayed at
1 second intervals.
REMARK
See each item for explanation of the failure display and adjustment mode.
PARKING BRAKE INDICATOR

When the starting switch is ON and the parking brake is applied,
the parking brake indicator (d) flashes.
NOTICE
If it is attempted to drive the lift truck without releasing the parking brake,
the alarm buzzer will sound, so release the parking brake immediately or
stop the lift truck.
3-8
SPEEDOMETER
This meter (e) digitally displays the travel speed in units of 1 km/h.
NOTICE
If any tires other than the standard or optional tires are installed, there may
be an error in the travel speed displayed.
TRAVEL SPEED LIMIT INDICATOR

When the travel speed limit indicator function is actuated, the
tortoise mark (travel speed limit indicator (f)) lights up. (For details
of the travel speed limit function, see “SETTING TRAVEL SPEED
LIMIT (PAGE3-15)“.)
NOTICE
When the tortoise mark (travel speed limit condition) lights up, the travel
speed will not go above the set value.
FAILURE INDICATOR FUNCTION

If any abnormality occurs on the lift truck, and it is necessary to
carry out inspection and maintenance, an abnormality display
(content of failure, error code, action) is given on the display.
At the same time, a symbol and spanner mark(failure indicator (g))
are displayed to inform the location of the failure.
(The indicator will flash and the alarm will sound for 10 seconds to
inform the operator.)
NOTICE
If “CALL YOUR SERVICE“ is given on the display, contact your KOMATSU FORKLIFT distributor, inform the content of the display,
and ask for inspection.
3-9
If the following error codes are displayed, take the action given in the table.
Error code list

Error code Cause Remady
If the lift truck is stopped for 30 minutes, it becomes
Battery excessively discharged (drop in
E21 possible to travel, so move to a charging point and
remaining capacity of battery)
charge the battery immediately.
Put the forward/reverse control lever to the neutral
E23 Neutral safety function actuated position and withdraw the foot from the accelerator
pedal. Then the neutral safety function is released.
E24 Rise in travel controller temperature
Reduce the load and continue with the work.
E25 Rise in travel motor temperature
E26 Abnormal temperature of travel controller If the warning display is given, leave the starting switch
E28 Abnormal temperature of travel motor at the ON position for a short time (20 - 30 minutes).
If the display does not go out even when the lift truck is
left for 20 - 30 minutes, contact your KOMATSU
E55 Rise in EPS contoroller temperature FORKLIFT distributor immediately and ask for
inspection.
E32 Abnormality in main controller(load) The emergency switch is being pressed, so reset it.
TRAVEL SYSTEM FAILURE INDICATOR

If any abnormality occurs in the travel system of the lift truck, and
it is necessary to carry out inspection and maintenance, an
abnormality display (content of failure, error code, remedy) is given
on the display.
At the same time, the failure is indicated by the tire mark(travel
system failure indicator (h)) and spanner mark(failure indicator
(g)).
(The indicator flashes and the alarm sound for 10 seconds.)
3 - 10
HYDRAULIC SYSTEM FAILURE INDICATOR

If any abnormality occurs in the hydraulic system of the lift truck,
and it is necessary to carry out inspection and maintenance, an
on the display.
At the same time, the failure is indicated by the fork mark(hydraulic
system failure indicator (i)) and spanner mark(failure indicator (g)).
(The indicator flashes and the alarm sounds for 10 seconds.)
POWER STEERING SYSTEM FAILURE INDICATOR

If any abnormality occurs in the travel system of the lift truck, and
it is necessary to carry out inspection and maintenance, an
on the display.
At the same time, the failure is indicated by the steering wheel
mark(power steering system failure indicator (j)) and spanner
mark(failure indicator (g)).
(The indicator flashes and the alarm sounds for 10 seconds.)
TRAVEL POWER INDICATOR

The acceleration power when starting is indicated in eight stages
(k).
For details of adjusting and setting the acceleration power, see
“SETTING DRIVE POWER (PAGE3-14)“.
3 - 11
MODE BUTTON
This button (i) is used to switch the display and select the adjustable items.
Press the button to switch to each adjustment mode.
For details of the method of setting each set item, see the section on setting to each adjustment mode from the
hourmeter display.
MODE TABLE
ITEM BUTTON
This button (m) is used to select the set item if there are multiple set values in each set item.
The set item changes when the button is pressed. A flashing display is given for items that can be set.
SET VALUE BUTTON

This button (n) is used to change the set value in each set item.
Each time the button is pressed, the display changes for the set conditions of the flashing item (the items that can
be set).
3 - 12
METER PANEL OPERATION
SWITCHING FROM HOUR METER DISPLAY (STANDARD DISPLAY) TO EACH ADJUSTMENT MODE
1. Turn the starting switch to the ON position, then return the
forward/reverse control lever and work equipment control
levers to neutral.
2. Every time the mode button is pressed, the display changes to
each adjustment mode in the sequence shown with an arrow.
(See “MODE TABLE (PAGE3-12)“)
3. To return to the hourmeter display, do one of the following.
1) Do not carry out any adjustment operation for more than 60
seconds.
2) To operate any one of the following.
•Forward/reverse control lever
•Work equipment control lever
•Accelerator pedal
3) Turn the starting switch OFF and ON again.
4) To try all the adjustment modes with the mode button.
3 - 13
SETTING DRIVE POWER

The acceleration power of the lift truck can be adjusted in eight stages.
8 Powerful drive assured in the maximum acceleration speed. *Default setting for FB30
7 I
6 | *Default setting for FB09EX - 25EXG
5 |
Setting
4 |
3 |
2 O
1 Good energy saving with minimum acceleration speed.
1. Press the mode button once and change the display to the
drive power setting mode.
2. When the set value button is pressed, the set value of the
flashing display changes.
3. When the set value is decided, press the mode button to
confirm. (It will then switch to the next setting mode.)
NOTICE
• If any button except the mode button is used to return to the hourmeter
display, the setting will not be updated.
• When POWER is selected for the setting, the working volume per hour
increases, but the working hour is shortened instead.
• Default setting is 8 for FB30 and 6 for FB09EX - 25EXG.
3 - 14
SETTING LIFT SPEED

The lift speed can be selected from mode 1 and mode 2 and can be adjusted to eight stages.
1. Press the mode button three times to change the display to the
list speed 1 setting mode.
3. When the set value is decided, press the mode button for
execution. (The display changes to the lift speed 2 setting
mode.)
4. When the set value is decided for lift speed 2, too, press the
mode selector button for execution. (The display changes to
the next setting mode.)
NOTICE
• Select the same set value both for lift speed 1 and for lift speed 2. If
different values are selected, the larger set value is given a priority.
SETTING TILT SPEED

The tilt speed can be adjusted in eight stages.
1. Press the mode button 5 times to change the display to the tilt
speed setting display.
NOTICE
If any button except the mode button is used to return to the hourmeter
SETTING TRAVEL SPEED LIMIT

The maximum travel speed can be set between 5 and 15 km/h in ten stages.
1. Press the mode selector button 6 times to change the display
to the travel speed setting mode.
NOTICE
3 - 15
SETTING OVERSPEED ALARM

When this setting is made, this excessive speed alarm sounds warning if the lift truck exceeds the speed range of
5 to 15 km/h.
1. Press the mode button 7 times to change the display to the
excessive speed alarm setting.
2. When the set value button is pressed, the flashing display
switches in turn between “SET ON“ and “SET OFF“.
REMARK
When “SET ON“ is displayed, the existing setting for the travel
speed limit lights up.
3. To change the set value, select “SET ON“ in Step 2, then press
the item button to make the travel speed limit setting portion
flash.
4. When it flashes, press the set value button to change to the
new set value.
NOTICE
• The travel speed data can be changed only when the travel speed set
limit value portion is flashing.
SETTING ACCELERATION NEUTRAL REGENERATION

When this setting is made, a braking effect similar to the engine brake is available during travel only by releasing
the accelerator pedal.
1. Press the mode button 8 times to set the display to the
acceleration neutral regeneration setting mode.
2. When the set value button is pressed, the flashing display
switches in turn between “SET ON“ and “SET OFF“.
NOTICE
3 - 16
SETTING PRESENT TIME

Use this when correcting the date, day, or time given on the display.
NOTICE
The set date, day, and time are used as the data for calculating the time of completion of charging for timer charging, so be sure
to set them correctly.
1. Press the mode button 9 times to set the display to the present
time setting mode.
2. When the set value button is pressed, the item on the flashing
display changes.
When the item button is pressed, the flashing changes in
order from year (last 2 digits), month, date, day, hour, and
minute
The setting can be changed for the flashing portion.
3. When each item is decided, press the mode button to confirm.

(It will return to the hourmeter display.)
NOTICE
If any button except the mode button is used to return to the hourmeter display, the setting will not be updated.
3 - 17
PARKING BRAKE LEVER

This lever (4) serves to lock the parking brake.
LOCK: The parking brake is applied and locks the front wheels.
FREE: The parking brake is released. To release the parking
brake, release the lever from a notch by pressing a button
on top of the lever and return it to the FREE position.
HORN BUTTON
Press the button (5) in the center of the steering wheel to sound the
horn.
COMBINATION SWITCH
LIGHTING SWITCH
This switch (6) is used to turn on the lamps.
Position 1 (OFF):Parking lamp (side clearance lamp) and front
lamps are OFF
Position 2 :Parking lamp (side clearance lamp) lights up
Position 3 :Parking lamp (side clearance lamp) stays lighted
up, and front lamp lights up
TURN SIGNAL SWITCH

This switch (6) is used to flash the indicator lamps.
This makes the turn signal indicator lamp flash.
Left turn (L) : Push lever forward
Right turn (R): Pull lever back
REMARK
This lever is equipped with an auto-return mechanism, so the lever
will return automatically to the neutral position (N).
3 - 18
ACCELERATOR PEDAL
CAUTION
Do not rest the foot on the brake pedal while stepping on the accelerator pedal.
This pedal(7) is used to control the drive speed.

The speed varies corresponding to the amount the pedal is
depressed.
In plugging operation, the braking force of the electric brake also
varies. (See “PLUGGING (PAGE3-35)“.)
Pedal depressing amount Drive speed Electric braking force

Large Increases Increases
Small Decreases Decreases
NOTICE
• Always release the accelerator pedal before turning the key switch ON.
• The operating (lifting or tilting) speed is not related to the pedal depressing amount.
BRAKE PEDAL
CAUTION
Be sure to release the accelerator pedal when depressing the brake pedal.
This pedal (8) is used to reduce the speed or stop the lift truck.
NOTICE
When the pedal is depressed lightly, the electric brake is activated. As the
pedal is further depressed, the mechanical brake (wheel brake) begins to
work, providing a strong braking force in combination.
3 - 19
STEERING COLUMN LOCK LEVER

When the lever (9) is in the FREE position, the steering column can
be adjusted to the front and rear, and up and down.
FREE: The lock is released and the position of the steering column
can be adjusted.
LOCK: The lock is applied and the steering column is held in
position.
NOTICE
For details of the method of adjustment, see “ADJUSTING POSITION OF
STEERING WHEEL (PAGE3-30)“.
LIFT CONTROL LEVER
CAUTION
Always sit in the operator's seat and check that the surrounding area is safe Lower
before operating the work equipment control levers.
Raise
This lever (10) is used to raise or lower the forks.
LOWER: Push the lever forward.
RAISE : Pull the lever back.
REMARK
The lifting and lowering speed changes according to the amount Lower
the lever is operated.
Lower
Raise
Raise
3 - 20
TILT CONTROL LEVER
CAUTION
Always sit in the operator's seat and check that the surrounding area is safe
Forward
before operating the work equipment control levers.
Backward
This lever (11) is used to tilt the mast forward and backward.
FORWARD : Push the lever forward. Forward
BACKWARD: Pull the lever back.
REMARK
The tilting forward and back speed changes according to the
amount the lever is operated.
Backward
Forward
Backward
EMERGENCY STOP SWITCH

In cases of emergency, press this button(12) to cut the power
supply to the control circuit of the starting switch and controller in
order to stop the lift truck.
To cancel, turn the starting switch to the OFF position, return the
directional lever to neutral, apply the parking brake, check that
everything is safe, keep the button pressed and turn it to the right
to return it.
3 - 21
SINGLE ACTION WATER REFILLER 3
(Option)
CAUTION
When refilling with water, be sure to use either distilled water or purified water.
With this device it is possible to add distilled water to all the battery
cells at the same time.
Method of adding water

Connect the hose from the water filler tank to the water supply port
at the battery end, then turn the valve to supply water.
NOTICE
• Always watch the condition of the battery floats (red) when adding
water.
• When all the floats are at the FULL position, close the valve
immediately and stop the supply of water.
• Put the water supply tank at a position higher than the battery.
FORK STOPPER 3
LOCK position: The forks are secured to the fork carriage. Always
use this position during operations.
FREE position: The forks can be moved to the left and right, so it
is possible to adjust the spread of the forks to
match the size of the load.
NOTICE
For details of adjustment, see “FORK SPREAD ADJUSTMENT (PAGE3-38)“.
3 - 22
OPERATION OPERATOR'S COMPARTMENT
OPERATOR'S COMPARTMENT 3
MOUNTING/DISMOUNTING
CAUTION
• Mount or dismount the lift truck only after the lift truck comes to a
complete stop.
• Never jump on or off the lift truck. It is extremely dangerous.
• Do not hold on the control levers or steering wheel when mounting or
dismounting the lift truck.
• Keep the handrails (assist grips) and step clean all the time, and repair
the damage, if any.
• Do not use the handrails (assist grips) for any other purpose than
mounting or dismounting the lift truck.
• Always mount and dismount the lift truck from the left side.
• While mounting or dismounting the lift truck, always support
yourself securely with your hands and feet at more than 3
locations; put your left foot on the step (2), grab the assist grip
(1) with your left hand, and grab the backrest or hip support (3)
of the seat with your right hand.
SEAT POSITION ADJUSTMENT (FB09EX - 25EXG )
CAUTION
• Adjust the seat position before getting on the lift truck, or at the time of
operator change. (Adjust only when the lift truck is at a complete
standstill.)
• Adjust the seat position so that you can fully depress the brake pedal
while reclining yourself against the backrest.
1. Park the lift truck. For details on parking, see "TEMPORARY

STOPPING AND PARKING (PAGE 3-37)".
2. Take a seat and pull the lever to the left. (The operator's seat
can slide back and forth in this condition.)
3. Bring the operator's seat to the optimum position and release
the lever .The seat is locked in this condition.
4. After adjusting the seat, check that it is firmly locked by pulling
it forwards/backwards.
3 - 23
OPERATOR'S COMPARTMENT OPERATION
BACKREST ANGLE ADJUSTMENT (FB09EX - 25EXG )

(suspension seat only)
1. Pull up the lever. The backrest angle can be adjusted in this
condition.
2. Adjust the backrest angle and release the lever. After adjusting
the backrest, check that it is firmly locked by pushing and
pulling it.
SUSPENSION ADJUSTMENT (FB09EX - 25EXG )

(suspension seat only)
Turn the adjustment knob on the right side of the operator's seat to
adjust the suspension to match your weight.
Adjust as follows:
To INCREASE the weight setting, turn to the RIGHT
To DECREASE the weight setting, turn to the LEFT
Weight adjustment range: 50 - 120 kg (110 - 265lb)
3 - 24
FASTENING AND UNFASTENING THE SEAT BELT (FB09EX - 25EXG )
CAUTION
Always wear your seat belt during operations.
1. Pull the belt out from the holder at the right side of the seat,
then insert the tongue into the buckle until a click is heard. (In
this condition the seat belt is locked in position.)
The seat belt is designed to give a shock in the holder when

the belt locks. The same shock may occasionally be felt if the
belt locks when it is pulled out of the holder.
If this happens, grip the tongue end of the belt with both hands,
pull up strongly, and when the belt loosens, pull the belt out
again slowly.
2. To release the lock, hold the tongue portion of the belt with your
right hand, then press the red button in the buckle with your left
hand.
3. The belt will automatically be wound into the holder.
When this happens, hold the belt and let it wind in slowly.
With the suspension seat, it is also possible to adjust the

suspension to match the operator's weight in addition to
adjusting the fore-and-aft position and reclining angle.
3 - 25
SEAT POSITION ADJUSTMENT(FB30)
CAUTION
• Adjust the seat position before getting on the lift truck, or at the time of
operator change. (Adjust only when the lift truck is at a complete
standstill.)
• Adjust the seat position so that you can fully depress the brake pedal
while reclining yourself against the backrest.
TYPE A
2. Take a seat and pull the lever (1) to the left. (The operator's
seat can slide back and forth in this condition.)
the lever (1).The seat is locked in this condition.
TYPE B
2. Take a seat and pull up lever (1).
This will allow movement of the seat forward or back.
the lever (1).The seat is locked in this condition.
BACKREST ANGLE ADJUSTMENT

TYPE A
1. Pull up the lever (2). The backrest angle can be adjusted in this
condition.
2. Adjust the backrest angle and release the lever (2). After
adjusting the backrest, check that it is firmly locked by pushing
and pulling it.
3 - 26
TYPE B
1. Pull up the lever (2). The backrest angle can be adjusted in this
condition.
2. Adjust the backrest angle and release the lever (2). After
adjusting the backrest, check that it is firmly locked by pushing
and pulling it.
SUSPENSION ADJUSTMENT
TYPE A
Turn the seat cushioning adjustment dial (3) located on the front
right side of the operator's seat to select the scale to your weight (4)
for suspension adjustment.
Turn the dial to the (A) side for lighter weight and to the (B) side for
heavier weight.
Weight adjustable range: 50 - 120kg (110 - 265lb)
TYPE B
Push the weight adjustment lever (3) at the rear left of the seat and
set scale (4) to your weight.
If the lever is pushed, the scale is set to heavier weight. To set the
scale to light weight, push the lever to the bottom once.
Weight adjustable range: 50 to 130 kg
3 - 27
FASTENING AND UNFASTENING THE SEAT BELT(FB30)
CAUTION
Always wear your seat belt during operations.
TYPE A
1. Pull the tongue (1) out of the belt holder located on the left side
of the operator's seat and push it into the buckle (2) on the right
until it clicks into place.The safety seat belt is locked in this
condition.
TYPE B
TYPE A
2. To unfasten, hold the belt with your left hand, and push down
the red button of the buckle (2) with your right hand.
3. The belt is tucked into the holder automatically.
While the belt is being tucked in, hold tongue (1) so that the
belt is tucked in slowly.
TYPE B
3 - 28
OPERATOR'S COMPARTMENT
OPERATION AND MAINTENANCE MANUAL STORAGE

OPERATOR’S SEAT BACK LITERATURE STORAGE AREA FOR THE OPERATION AND MAINTENANCE MANUAL
CAUTION
• Store the Operation and Maintenance Manual in the literature storage
area behind the operator's seat readily available for reference.
• If this manual has been lost or has become dirty or worn and cannot be
read, request a replacement manual from your KOMATSU FORKLIFT
distributor.
TYPE A
1. Push unlock button (1) of the pocket behind the operator's
seat backrest.
2. Open pocket (2) backward to take out or store the Operation
and Maintenance Manual.
An open-type magazine box is provided in the outer side of this

storage. You are free to use this box for storing necessary
documents, etc.
TYPE B
1. Peel off Velcro (1) of the upper cover of the literature storage
area and open zipper (2).
2. Store or take out the Operation and Maintenance Manual.
3. Close zipper (2) and fasten upper Velcro (1) to lower Velcro
(3).
3 - 29
ADJUSTING POSITION OF STEERING WHEEL 3
CAUTION
Never adjust the position of the steering wheel when the lift truck is moving.
1. Park the lift truck. (For details, see “TEMPORARY STOPPING

AND PARKING (PAGE3-37)“.)
2. Pull the lock lever up (FREE position).
3. Move the steering wheel to the front or rear, or up and down to
select the optimum position.
4. Pull the lock lever down (LOCK position) to lock the steering
wheel in the selected position.
5. Move the steering wheel to the front and rear, and up and down
to check that it is held securely in position.
3 - 30
STARTING LIFT TRUCK OFF 3
Proportinal solenoid valve

CAUTION
• Ensure safety around the lift truck and sound the horn before advancing.
• Ensure no one accesses the area around the lift truck.
• When reversing the lift truck, pay special attention to the dead area at the
rear of the lift truck.
• When turning the starting switch ON, always sit in the operator's seat,
set the directional lever to neutral, and remove your foot from the
accelerator pedal.
1. Check that the forward/reverse control lever (1) is at the

neutral position.
2. Check that the parking brake lever (2) is pulled and that the
parking brake is applied.
Standard valve
3. Release the accelerator pedal (3) and turn the key switch ON.
4. Pull the work equipment control levers (5) back, raise the forks
approx. 20 cm (8 in) from the ground, then tilt the mast back. LOW
RAI
3 - 31
5. Release the parking brake lever (2). Proportinal solenoid valve

6. Place the forward/reverse control lever (1) in the travel position
(FORWARD/REVERSE).
7. Depress the accelerator pedal (3) to move the lift truck off in
the direction of travel (FORWARD/REVERSE).
Standard valve
NEUTRAL SAFETY 3
When the starting switch is set to ON position with the forward/reverse control lever set to F (Forward) or R
(Reverse) or the accelerator pedal depressed, the meter panel displays an error code and the lift truck becomes
unable to travel.
RELEASING NEUTRAL SAFETY

When you seat yourself properly and perform the following operation with the starting switch ON position. The error
code in the meter panel disappears. Then the truck is ready for travel or load handling again. Restart operation after
checking the safety in the surrounding areas.
Operation triggers error code

How to release neutral safety
(activates neutral safety)
Starting switch is set to ON with the forward/
A reverse control lever set to F (Forward) or R Move the forward-reverse lever back to neutral.
(Reverse).
Key switch is set to ON with the accelerator
B Release the accelerator pedal.
pedal depressed.
Move the forward/reverse control lever back to
C Combination of A and B
neutral, and release the accelerator pedal.
3 - 32
TRAVEL INTERLOCK FUNCTION (FB30) 3
This safety device disables the operation of lift truck if you are
seated in such a posture that your weight is not fully applied to the
seat, like standing up or leaning forward or sideways. If you take
such posture, the travel interlock activates in approx. three
seconds. The transmission of engine power is cut off and the lift
truck does not move any more even if you depress the accelerator
pedal or operate the forward/reverse control lever.
RELEASING TRAVEL INTERLOCK FUNCTION

When you seat yourself properly and return the forward/reverse control lever to N (Neutral) position, the lift truck
returns to traveling condition. Restart traveling operation after checking the safety in the surrounding areas.
Traveling Interlock does not brake the lift truck forcibly.
STARTING ON SLOPE 3
1. When starting the lift truck on an incline, set the lift truck to the
parking condition. (For details, see Section “TEMPORARY
STOPPING AND PARKING (PAGE3-37)“.)
2. Place the forward/reverse control lever in FORWARD when
starting the lift truck.
3. Depress accelerator pedal (3) gradually and slowly release
parking brake lever (1).
4. When the lift truck begins climbing the incline, fully release
parking lever (1). The advancing speed is adjusted by the
amount the accelerator pedal (3) is depressed.
5. To reduce the speed or stop the lift truck, release the
accelerator pedal (3) gradually and depress brake pedal (2)
immediately before stopping.
NOTICE
• If traveling is continued without first fully releasing parking brake lever (1), the traction motor will overheat. The moment a
burning smell is noticed, stop the lift truck and allow the motor to cool.
• On a gentle incline, the lift truck can be started by quickly changing over from depressing brake pedal (2) while the lift truck
is stopped, to depressing the accelerator pedal (3).
In this case, as the lift truck may backwards, secure sufficient distance to the front and rear to assure safety.
• If you drive the lift truck on a slope continuously or frequently, excessive load is applied on the travel motor, which generates
heat or an abnormal smell in due course. If that happens, stop the lift truck immediately and let the travel motor cool down.
3 - 33
NORMAL RUNNING 3
CAUTION
• Be sure to release the accelerator pedal when the lift truck is running and you depress the brake pedal. You have to be
particularly careful of an engine type lift truck (equipped with a torque converter) as you may be familiar with a practice of
applying the brake with the left foot with that type of lift truck.
• Be particularly careful again of a lift truck equipped with a 2-pedal brake (optional) as you are likely to step on the accelerator
pedal and brake pedal at the same time.
When the accelerator pedal and brake pedal are depressed together, the brake lamps light on even when the lift
truck is running. Take care to avoid that because that is undesirable from the standpoints of fuel saving, loss of lift
truck operating hour and battery service life.
SHIFTING GEAR 3
The travel speed changes in proportion to an amount of the

accelerator pedal being depressed.
The larger this amount is, the faster the travel speed becomes.
The smaller this amount is, the slower the travel speed becomes.
INCHING 3
When an output level of the travel power indicator on the meter panel is lowered, crawling becomes easier only with
operation of the accelerator pedal. This practice of crawling is usually employed in the following situations. (See
“TRAVEL POWER INDICATOR (PAGE3-11)“)
• When you raise the mast high, or when you travel the lift truck forward or back it up for loading or unloading, there
is a shock from within the lift truck. Crawling using this function is effective in order to minimize the shock for
keeping safety.
• In particular when you travel the lift truck through a narrow passage or on the floor of rough surface which turns
the lift truck into an unsteady posture, crawling using this function is effective.
It is possible to run the lift truck at a crawling speed by depressing the brake pedal and the accelerator pedal
together, but this practice should be used only where it is unavoidable to do so due to the pressing situations at the
worksite such as.
• When starting up the lift truck on a slope (this practice is prohibited in principle)
• When reducing the travel speed to an appropriate crawling speed before a stop line depending on the work
speed and travel distance so as to adjust the timing for loading / unloading and running at the same time.
3 - 34
NOTICE
When there is no way to avoid depressing the brake pedal and the accelerator together, be careful with the following points.
• Try to minimize the time of using both pedals together.
• Do not step on the accelerator pedal more deeply than necessary. (If the brake pedal is depressed lightly, so is the
accelerator pedal, too.)
• When depressing the brake pedal deeply to stop the lift truck, never keep the accelerator pedal depressed.
• When running the lift truck at a crawling speed and noticing an abnormal smell and heat from the lift truck, the travel motor
has overheated. Stop the lift truck immediately and let the travel motor cool down.
• It is recommended to install a travel motor protective unit in case an unspecified number of operators use the lift truck or the
correct operation method is hardly followed. (For installation of the travel motor protective unit, call your KOMATSU
FORKLIFT distributor.)
PLUGGING 3
CAUTION
If the plugging operation is continued after the truck lift has stopped, the
truck will start to move in the opposite direction from the direction that it
was traveling.
Plugging means an operation to set the forward/reverse control

lever to the position opposite to the travel direction while the
accelerator pedal is depressed during travel.
Plugging generates electric braking force
NOTICE
When carrying out the plugging operation with the lift truck loaded, operate
carefully to prevent the load from collapsing.
3 - 35
STOPPING 3
CAUTION
The braking distance is increased when driving with a load. To secure
sufficient braking distance, allow sufficient space in the forward and
backward directions.
The lift truck can be brought to a stop by making plugging operation

and then turning the forward/reverse control lever to the neutral
position just before stopping.
REVERSING 3
Continue plugging operation to move the lift truck in the opposite

direction after stopping.
NOTICE
The braking force of the electric brake varies corresponding to the amount
the accelerator pedal is depressed.
(The larger the depressing amount, the stronger the braking force.)
TURNING 3
CAUTION
Take care to avoid the outside of the counterbalance-weight hitting against objects when turning.
Operate steering wheel knob with the left hand.
When turning, keep to the inner side when advancing and outer
side when reversing, considering the properties of the rear steering
system.
NOTICE
If the lift truck is to be steered while stopped, a large steering force is
required.
In this case, depress the accelerator pedal slightly and operate the steering
wheel while inching, to allow it to be rotated smoothly.
3 - 36
TRAVELING OVER RAMPS 3
CAUTION
The use of this function is accompanied by a shock the strength of which varies depending on the height of a step, so be
cautious of possible collapse of the load (if present) and safety around.
This lift truck is equipped with power max. function which enables it to climb over a step.
1. Bring the front tires to the step.

2. After checking that the surrounding area is safe, depress the
accelerator pedal.
3. Hold the accelerator pedal fully depressed. Then the engine
power rises in 0.6 second and enables the lift truck to climb
over a step higher than normal.
NOTICE
If you repeat this practice continuously or frequently, the travel motor will overheat, generating heat or an abnormal smell. If that
happens, stop the lift truck immediately and let the travel motor cool down.
TEMPORARY STOPPING AND PARKING 3
CAUTION
Select a parking area well away from the driving area.
1. Release the foot from accelerator pedal (1).

2. Depress brake pedal (2) steadily.
3. After stopping the lift truck, pull parking brake lever (3) to apply
the brake.
4. Move forward/reverse control lever (4) to the neutral position.
WHEN LEAVING THE LIFT TRUCK UNATTENDED 3
When leaving the lift truck, always perform the following procedure.
1. Lower the forks to the ground.
2. Tilt the mast full forward.
3. Turn the key switch to OFF and remove the key.
3 - 37
PARKING BRAKE ALARM BUZZER (FB30) 3
When the parking brake lever is in the FREE position, and if you take a posture that your weight is not fully applied
to the seat, like standing up or leaning forward or sideways, the parking brake alarm buzzer sounds in 3 seconds.
When it does take the following actions.
When leaving the truck lift: Pull the parking brake lever to the LOCK position.
When continuing to operate the truck lift: Take a right posture in the operator's seat.
REMARK
If no corrective measures are taken, the buzzer stops in 5 seconds.
LONG-TERM PARKING 3
If the lift truck is parked for a long time, grip the battery plug by hand
and pull it out.
FORK SPREAD ADJUSTMENT 3
CAUTION
Take extreme care not to get hands or fingers caught while moving the forks.
1. Move the lift truck in front of the load, and stop.

2. Position the mast vertically and lift the forks 10cm (4 in) above
the ground.
3. Tilt the mast forward.
4. Pull up the knob of the fork stopper and turn it 90 degrees to
the FREE position. (In this condition, the forks can be moved
to the left or right.)
5. Adjust the fork spread corresponding to the load size so that
the center of gravity of the load coincides with the center of the
lift truck.
6. Set the mast vertical, lower the knob, and turn the fork stopper
90 degrees to the LOCK position. (In this condition, the forks
are locked in position.)
3 - 38
LOAD HANDLING OPERATION 3
CAUTION
Sit in the operator's seat and check that the surrounding area is safe before operating the lever.
NOTICE
The work equipment does not pick up speed even if the accelerator is depressed.
Adjust the work equipment speed by changing a shift amount of the work equipment control levers (lift lever, tilt lever and
attachment lever).
OPERATION OF CONTROL LEVERS 3
LIFT CONTROL LEVER

Lower
Raise : Pull the lever backward.
Lower : Push the lever forward.
REMARK
A rising and lowering speed of the forks can be adjusted by tilting
lever. Raise
TILT CONTROL LEVER

Forward
Tilt forward : Push the lever forward.
Tilt backward : Pull the lever backward.
REMARK
Forward and backward tilting speed of the forks can be adjusted by
tilting lever. Backward
LIFT INTERLOCK FUNCTION (FB30) 3
This safety device disables lift operation of the lift truck if you are
seated in such a posture that your weight is not fully applied to the
seat, like standing up or leaning forward or sideways. If you take
such posture, the lift interlock activates in approx three second.
Each operation of fork and mast is locked and the lift truck
becomes inoperable even if lift or tilt control lever is operated.
RELEASING LIFT INTERLOCK FUNCTION

When you seat yourself properly on the operator's seat, the lift truck returns to condition ready for lift operation.
Restart lift operation after checking the safety in the surrounding areas.
3 - 39
PICKING UP 3
1. Insert the fork up to the bottom.

2. If the fork cannot be inserted up to the bottom at one go, drive
the lift truck forward until the fork is inserted into a pallet by
2/3 to 3/4 of the fork length and lift the load by 5 - 10 cm.
Then drive the lift truck backward by 10 - 20 cm, lower the load
once and then drive the lift truck once again until the fork is
inserted up to the bottom.
3. Raise the load 5 - 10 cm and reverse the lift truck to a position

where the load can be lowered.
5 - 10 cm
4. Lower the load to the height of 15 - 20 cm above the ground

and tilt the mast back.
15 - 20 cm
STACKING 3
1. Stand the mast vertically and lift forks 5 - 10 cm past the

stacking position. Advance the lift truck slowly.
2. Lower the load once to the desired place.
3. Pull the fork out of the pallet.
3 - 40
OPERATION BATTERY CHARGING
BATTERY CHARGING 3
CAUTION
When charging the battery, read “CAUTION WHEN HANDLING BATTERY (PAGE2-33)“ in SAFETY carefully and understand the
instructions fully for the safety work.
CHARGING BY STATIONARY BATTERY CHARGER 3
(Option)
CAUTION
• If the charger is used for a long time with a remarkably deviated tap voltage at the power supply, there is danger that the charger
will burn out. Periodically measure the power source voltage and select a suitable power source voltage tap.
• For the power source of the facility (building), it is necessary to have cables and receptacles of a higher capacity than the rated
voltage and current of the charger. If the capacity is too low, there is danger of fire.
The charger for this lift truck is an automatic charger which uses a microcomputer to judge the condition of the
battery and charge to a suitable condition.
SELECT POWER SOURCE VOLTAGE TAP

Select the power source voltage tap to match the power source
voltage. (For details, see “SELECTION OF CHARGER POWER
SUPPLY VOLTAGE TAP (PAGE4-27)“.)
3 - 41
BATTERY CHARGING OPERATION
OPEN BATTERY HOOD

Open the battery hood and check that the hood is held in position
by the stopper at the center of the gas damper.
CONNECT CABLE
1. Turn the key switch OFF and disconnect the battery plug from
the battery.
2. Insert power cord of stationary charger into the factory power

source, and insert plug of output cord into battery plug.
NOTICE
When the plugs are connected, the NORMAL lamp and EQUAL lamp on the
display panel flash.
3 - 42
START BATTERY CHARGING
WARNING
Do not remove the charger cable or plug during the charging operation.
1. Select normal charging or equalizing charging.

2. NORMAL charging (daily): Press the NORMAL button for
approx. 1 second to start normal charging.
3. EQUALIZING charging (weekly): Press the EQUAL button for
approx. 1 second to start equalizing charging.
4. When charging starts, the lamp for the selected type of
charging (NORMAL or EQUALIZING) lights up; the lamp for
the type of charging not selected goes out.
(The time needed for charging when the lift truck has been
used under normal conditions is approx. 10 hours.)
5. To interrupt the charging, press the STOP button.
6. Before disconnecting the plug, press the STOP button and
check that the NORMAL and EQUAL lamps are lighted up, and
that the charger has returned to the original condition.
If this is not done, the system may burn out due to defective
contact during long-term operation because of damage to the
terminal of the output cable plug.
CHECK CONDITION OF CHARGE

1. The charging time lamps light up in turn (1st -> 2nd -> 3rd) to
indicate the progression of charging.
Q: Lamp lights up
q: Lamp goes out
3 - 43
2. When the charging time has passed and the battery is fully
charged, the magnet switch on the AC side automatically goes
off. At completion of the charging, the lamp for the selected
charging (NORMAL or EQUALIZING) goes out and the OK
lamp lights up. (The 3 charging time lamps stay lighted up.)
ERROR DISPLAY
1. If charging takes an abnormally long time, the microcomputer
recognizes it as an abnormality in the battery charger, so it
stops the charging and gives the error display.
2. Error display: The CHECK lamp on the control panel lights up.
3. When the CHECK lamp lights up, stop charging and please
contact your KOMATSU FORKLIFT distributor.
4. Pull the battery plug out temporarily to turn off the CHECK
lamp.
3 - 44
POWER FAILURE
1. If there is a power failure during the charging operation, the charging stops while the power is down. When the
power is restored, charging will continue in the same mode as before the power failure.
2. However, if the power failure lasts for more than 1 hour, the charging condition is set to the condition before
the start of charging. Even if the power is restored, charging does not continue. In this case, press the
NORMAL or EQUALIZING button again.
COMPLETION OF CHARGING
1. Check that charging is completed (the OK lamp lights up).
2. Disconnect the power supply cable for the charger from the building power source (factory, etc.).
3. Disconnect the output cable plug of the charger from the lift truck battery plug.
4. Connect the lift truck battery plug to the chassis plug.
5. Wind the output cable of the charger, taking care not to twist it.
3 - 45
REPLACING BATTERY 3
CAUTION
Always raise the battery at 4 points.
If the lift truck is operated for a long time on one day and it is
necessary to replace the battery during the day, replace the battery
as follows.
1. Pull out the battery plug.
2. Tilt the steering wheel forward.

Set the steering wheel lock lever to the FREE position, tilt the
steering wheel forward, then set the lever to the LOCK
position again.
3. Open the left and right battery side covers.
3 - 46
4. Release the battery hood catch.
5. Open the battery hood and check that the battery hood is held
in position by the stopper and will not close.
6. Pass the crane wire through the cut-out portion of the

overhead guard.
7. Fit the hooks on the wire in the holes in the battery case as
shown in the diagram at the above right, raise the battery
slowly, remove it from the chassis, and lower it to the ground.
8. Raise the spare battery and install it on the lift truck.
3 - 47
BATTERY WEIGHT TABLE

(Reference)
Lift truck Capacity (Ah) Weight (kg) Voltage
FB09EX/14EX 330 625
400 700
FB09EX/14EX
485 770
FB15EX/18EX
545 845
FB15EXG/18EXG 700 1115
FB20EX 450 820 48 V
565 905
FB20EX/25EX 600 945
700 1035
935 1375
FB20EXG/25EXG
1080 1605
450
FB30 1500 72V
545
NOTICE
Check the battery capacity on the supplier's nameplate at the front of the battery case. (The weight differs according to the battery
supplier. For details, contact the battery supplier.)
MAINTAINING LONG BATTERY LIFE 3
1. Never excessively discharge the battery. (Never use for long time.)
• When the residual capacity of the battery goes down below 20%, stop the work immediately and charge
the battery. To check the residual capacity of the battery, see “BATTERY DISCHARGE INDICATOR
(PAGE3-7)“.
• Charge the battery corresponding to work load.
For example: If work load is likely to increase in the afternoon,
additionally charge the battery during lunch
break.
2. Always keep the electrolyte at the specified level.
If there is insufficient electrolyte, add distilled water. (See
“CHECKING ELECTROLYTE LEVEL (PAGE4-4)“.)
3. Clean the top of the battery and keep it dry. (Wipe dirt off with a wet cloth.)
(See “CAUTION WHEN HANDLING BATTERY (PAGE2-
33)“.)
3 - 48
OPERATION LIFT TRUCKS WITH COLD-STORAGE MODEL
LIFT TRUCKS WITH COLD-STORAGE MODEL 3
EXPLANATION OF LIFT TRUCKS WITH COLD-STORAGE MODEL 3
This lift truck is specifically designed for loading operation in and out of cold storage, and is suitable for up to
-35°C (-31ºF).
NOTICE
When the lift truck continually enters/exits a cold storage or refrigerated warehouse for loading operation, there is a possibility
of electrical failure or premature corrosion in the lift truck caused by condensation due to temperature fluctuation. In such case,
the water and rust-proofed lift truck with cold-storage model should be used.
PENGUIN DECAL FOR LIFT TRUCKS WITH COLD-STORAGE MODEL

To identify lift trucks with cold-storage model, a penguin decal is
adhered to the lift truck body.
PRECAUTIONS FOR USE 3
• Allot approx. the same time to operations both inside/outside cold storage. Limit time for one operation in a cold
storage to 30 minutes max.
• Never leave the lift truck in a cold storage for more than 10 minutes.
• Do not use the lift truck in a cold storage of -36ºC (-32.8ºF) or less.
PRECAUTIONS FOR CHARGING 3
CAUTION
• When charging, always use a stationary battery charger at a location outside the cold storage.
• Do not place the charger near the entrance of cold storage.
The large temperature difference near the entrance may cause corrosion on complex mechanical components in the charger
due to moisture, resulting in malfunction.
SUITABLE LUBRICANT 3
NOTICE
Use lubricants having low temperature resistance. (See “LUBRICANT LIST (PAGE4-14)“.)
OTHER 3
NOTICE
Never use the standard specification lift truck in a cold storage.
3 - 49
LONG-TERM STORAGE OPERATION
LONG-TERM STORAGE 3
BEFORE STORAGE 3
When not using the lift truck for a long time, perform the following.
• After washing/drying each part, house the lift truck in a dry building.
NOTICE
If it must unavoidably be left outdoors, park the lift truck on flat ground and cover it with a tarpaulin.
• Completely lubricate and change the oil.

• Apply a thin coating of grease to metal surfaces of hydraulic piston rods.
• Disconnect the negative battery terminals and cover the battery, or remove it from the lift truck and store it
separately.
NOTICE
Select a battery storage area out of direct sunlight which is well ventilated and protected from rain.
DURING STORAGE 3
• Rust prevention operation

Operate the lift truck once a month during storage so that a
new film of oil will be coated over the movable parts and
component surfaces.
• Charging battery
The battery will naturally discharge when the lift truck is not
operated.
Perform equalizing charging once a month in summer and
o n c e e v e r y t w o m o n t h s i n w i n t e r. ( S e e “ B AT T E RY
CHARGING (PAGE3-41)“.)
AFTER STORAGE 3
When using the lift truck after long-term storage (e.g., when stored uncovered or when monthly rust prevention
operation is not done), do as follows.
• Remove the drain plug of the hydraulic tank and drain the penetrated water.
• Wipe off grease from hydraulic cylinder rods.
• Measure the specific gravity of the battery electrolyte to check the charging state.
• Move the lift truck at low speed to cause the oil to flow in the interior of the transfer unit.
3 - 50
MAINTENANCE 4
14
MAINTENANCE
WARNING
When operating the lift truck, always strictly follow these precautions. Failing
to heed this warning may result in serious injuries.
4-1
CHECK BEFORE OPERATION MAINTENANCE
CHECK BEFORE OPERATION 4
CAUTION
• Never operate the lift truck before the check before operation is completed.
• If any abnormality is found during checking, immediately consult a KOMATSU FORKLIFT distributor and do not operate the lift
truck until repaired.
• Oil leakage can cause a lift truck fire.
Check the lift truck thoroughly. If any abnormality is found, always repair it or consult your KOMATSU FORKLIFT
distributor.
CHECK BEFORE OPERATION (WITH KEY SWITCH OFF) 4
CHECK OF ANY ABNORMALITY FOUND ON PREVIOUS DAY

Re-check any repaired part which was found to be faulty during the previous day's checking and operation of the
lift truck.
CHECK FOR OIL LEAKAGE AND BATTERY FLUID LEAKAGE

Check for leakage by conducting a walk-around check.
Check the following items, in particular.
• Tubing
• Hydraulic unit
• Cylinder
• Control valve
• Battery
CHECK FOR CRACKS AND DAMAGE

Visually check for cracks and damage.
Particularly check the following items.
• Head guard
• Fork
• Load backrest
• Fork carriage
• Mast
CHECKING OF LOOSE HUB NUTS

Check for loose hub nuts by tightening them with a wrench.
NOTICE
Tighten the hub nuts to the specified torque.
For the right tightening torque, see "SERVICE DATA (PAGE4-34)".
4-2
MAINTENANCE CHECK BEFORE OPERATION
CHECKING OF TIRES AND RIMS

• Visually check for any excessive wear, damages, spikes and
other foreign matters stuck to the tires, deformation and
damages of the rims, damage and rubber abrasion powder of
jointed portion between tire and rim.
• Replace a tire if the tread depth becomes under 5 mm (0.2 in) or
if the slip sign (wear limit mark) should appear.
CHECKING OF INFLATION PRESSURE OF TIRES
CAUTION
Tires have high pressure air inside. When checking the inflation pressure,
position yourself to face the tire tread surface (see the figure at right) while
holding the tire air gauge firmly.
Check the tire inflation pressure with the tire air gauge and adjust
it to specified pressure. For the right tire inflation pressure, see
“SERVICE DATA (PAGE4-34)“.
CHECK OIL LEVEL IN HYDRAULIC TANK

1. Open the inspection cover and pull out the dipstick.
2. Wipe off the oil from the dipstick with a clean cloth, then insert
the dipstick inside the tank.
3. Take the dipstick out again and check that the oil is at the
proper level (see diagram on right).
4. If the oil level is low, add genuine hydraulic oil through the oil
filler.
NOTICE
Always use genuine hydraulic oil.
4-3
CHECK FLUID PEDAL IN BRAKE RESERVOIR TANK

1. Look through the inspection window to check that the oil level
is in the suitable level.
2. If there is insufficient fluid, add genuine brake fluid.
MAX
NOTICE
Suitabl level
Always use genuine brake fluid.
MIN
3. Install the cap.
CHECKING ELECTROLYTE LEVEL
CAUTION
• First aid procedure when exposed to electrolyte.
If the electrolyte touches the eyes, skin or clothes, wash it off thoroughly with plenty of water. Especially if electrolyte enters
the eyes, immediately consult a doctor.
• Never generate short circuiting or sparking and never bring a flame, such as cigarette, near the battery.
• Be sure to wear goggles, safety gloves and rubber-soled shoes at the time of battery maintenance.
1. Open the battery hood, and check that the battery hood is held
in position by the stopper at the center of the gas damper and
does not close.
2. Check the fluid level with the float (1) in the battery cap.
3. Add water before float (1) (red) lowers to the minimum level.
(See below.)
The float stopper (2) touches the cap (3) at the minimum level
(clearance a = 0 in the right figure).
NOTICE
The shape of the cap differs according to the battery supplier.
4-4
• Method of adding water:

Connect the hose from the water filler tank to the battery water filler
port, open cover (1), then turn the valve and add water.
Never continue to add water after the white line (2) appears.
Excessive water will cause electrolyte spillage.
(A): Adding water

(B): Water filling completed
NOTICE
If water continues to be added after the white line appears, electrolyte will
overflow. Never add water excessively.
4. When closing the battery hood, support the hood with your
right hand and push the center of the damper with your left
hand to release the stopper, then close the hood slowly.
CHECKING OF SEAT BELT

Upon sitting on the operator seat, first check the seat belt.
• Check the seat belt webbing and buckle, etc. are free from
damage, wear or fray.
• Does the seat belt come out and retract smoothly? Does the
fitting lock and unlock without abnormality?
• Does the seat belt lock when pulled suddenly?
4-5
CHECK BRAKE PEDAL
Check the brake pedal for abnormal resistance or catching when depressing.
Check that the pedal play and height when depressed meet the following values.
Play 2 - 6 mm (0.08 - 0.24 in)

Pedal height (H) 130 - 140 mm (5.1 - 5.5 in)
1 ton: Above 81 mm
(3.2 in)
Pedal height when depressed (H2)
2 - 3 ton: Above 79 mm
(3.1 in)
Switch ON position 20 - 30 mm (0.8 - 1.2 in)
The height for the pedal when depressed is the height when the
floor mat is removed.
CHECK PARKING BRAKE

Check that the operating effort of the parking brake lever is normal.
For the standard value of the parking brake lever operating effort,
see “SERVICE DATA (PAGE4-34)“.
NOTICE
If the operating effort is less than standard value, please contact your
CHECK HORN
Press the horn button and check that the horn sounds normally.
4-6
CHECK AFTER STARTING (WITH KEY SWITCH ON) 4
CAUTION
When the key switch is turned ON, always set the forward/reverse control
lever to the NEUTRAL position without depressing the accelerator pedal.
NOTICE
Read “MOUNTING/DISMOUNTING (PAGE3-23)“, “SEAT POSITION
ADJUSTMENT (FB09EX - 25EXG ) (PAGE3-23)“,"SEAT POSITION
ADJUSTMENT(FB30) (PAGE3-26)" and “STARTING LIFT TRUCK OFF
(PAGE3-31)“, then check the following items.
CHECK REMAINING BATTERY CHARGE

Check the remaining battery charge with the battery discharge
indicator. If the display shows that the battery should be charged,
charge the battery immediately.
(For details of the method of charging, see “BATTERY CHARGING
(PAGE3-41)“.)
CHARGE BATTERY DISPLAY:
The bottom 2 lamps on the liquid crystal display flash in turn and
the alarm buzzer sounds for 5 seconds every 2 minutes.
(The buzzer continues until the remaining battery capacity is
restored to more than 21%.)
NOTICE
Even if you are engaged in operations, if the charge battery display
appears, charge the battery immediately.
CHECK STEERING WHEEL

Check the following items.
• Play (normally 30 - 60 mm (1.2 - 2.4 in))
• No upward/downward backlash
CHECK OF LAMPS
Check that the head lamp and turn signal lamp function normally.
Check for dirt and damage.
4-7
CHECK REARVIEW MIRROR

(For lift trucks equipped with rearview mirror)
Check the following items.
• Angle suitable for rear view
• No dirt or damage
CHECK BUCKUP BUZZER

(For lift trucks equipped with backup buzzer)
CAUTION
Release the accelerator pedal and apply the parking brake before carrying out this inspection.
Check that the backup buzzer sounds when the forward/reverse control lever is placed in REVERSE.
If the backup buzzer does not sound when the forward/reverse control lever is placed in REVERSE, carry out
repairs or replacement.
4-8
CHECK LIFT CHAIN TENSION
CAUTION
• Set the forward/reverse control lever to the “NEUTRAL“ position and apply the parking brake. Then perform checking.
• Never insert feet under the forks.
1. Raise the fork from the ground.

Lift amount “A“: 10 - 15 cm (4 - 6 in)
2. Check the right and left deflections of the lift chain by pressing
it at the center.
The tension is normal when both deflections are
approximately equal.
3. If the deflections differ from each other, adjust with the nut of
the lift-chain stopper bolt.
NOTICE
Make sure that the chain tension is the same on the left and right.
If the tension is not the same, the load will be unevenly balanced even if it
is set in the center of the lift truck, and there is danger that the chain may
break or the lift truck may tip over.
CHECK ELONGATION OF THE LIFT CHAIN
CAUTION
• Set the forward/reverse control lever to the “NEUTRAL“ position and apply the parking brake. Then perform checking.
• Never insert feet under the forks.
NOTICE
If the measurement value exceeds this range, replace the chain.
Measure the length over 17 links and check that the length is within
the specified value.
For the standard length over 17 links, see “SERVICE DATA
(PAGE4-34)“.
4-9
CHECK THE LIFT CHAIN LUBRICANT
CAUTION
• The lift chain is liable to snap if heavily rusted. If lubrication is insufficient, apply engine oil to prevent rusting.
• Visually check the lift chain for damage or cracks. If any abnormality is found, consult your KOMATSU FORKLIFT distributor.
If there is insufficient lubrication, apply engine oil.
NOTICE
Use genuine engine oil.
(See “LUBRICANT LIST (PAGE4-14)“.)
CHECK WHILE ADVANCING SLOWLY 4
CHECK STEERING WHEEL OPERATION

Check the following items while advancing slowly.
• No deviation of steering wheel.
• No unstable steering in straight drive.
• No feeling of abnormally-heavy steering when the steering
wheel is turned.
CHECK OF BRAKE OPERATION
Check the following items by depressing the brake pedal to apply the brake while advancing slowly.
• The brake is properly applied.
• The brake is applied uniformly.
CHECK FOR ABNORMAL SOUND OR ODOR

Check that no abnormal sound or odor is generated while advancing slowly.
CHECK MOTOR REVOLUTION

Check the following item while advancing slowly.
• Check that the drive motor rotates smoothly.
• Check that the power steering motor rotates smoothly.
CHECK OF WORK EQUIPMENT OPERATION 4
CHECK THE WORK EQUIPMENT OPERATION

Check that the forks lift and lower smoothly and the mast tilts forward and backward smoothly during operation of
the work equipment lever from the operator seat.
NOTICE
If any abnormality is found, please contact your KOMATSU FORKLIFT distributor immediately.
CHECK FOR ABNORMAL SOUND OR ODOR

Check that no abnormal sound or odor is produced while operating the work equipment from the operator seat.
CHECK MOTOR REVOLUTION

Check that the hydraulic motor rotates smoothly while operating the work equipment from the operator seat.
4 - 10
MAINTENANCE CHECK AFTER OPERATION
CHECK AFTER OPERATION 4
On completion of operation, wipe off any dirt and dust. Before storage, check for the following items.
1. Oil leakage or battery fluid leakage from the units.
2. Cracks or damage.
3. Check faults found during operation and report them to the person responsible for the lift truck.Be sure to place
a sign or other notice identifying "Do Not Use". (if necessary)
4. Lubricate the units (if necessary).
4 - 11
OUTLINE OF SERVICE MAINTENANCE
OUTLINE OF SERVICE 4
• Use Genuine Parts for replacement.

• When changing or adding oil, do not use a different type of oil.
• Unless otherwise specified, the oil and coolant used at delivery
from the factory shall be as shown in the table below.
Item Type of fluid

GO80
Transfer case
GO80W90
HO32R(standard spec.)
Hydraulic tank
HO15(refrigerator spec.)
SUITABLE OIL 4
OIL 4
CAUTION
Dirty oil has an extremely bad effect on the proportional solenoid valve.
Not only will the proportional valve not work properly, it may also become impossible to repair it.
Always use the specified oil and change it at the specified interval.
• Since the oil is used for the work equipment, etc., under severe conditions (at high temperature and high
pressure), it will deteriorate as the operation time passes.
Always use an oil matching the grade and working temperatures given in the operation manual.
Always replace oil at the specified period even if not deteriorated.
• A lift truck should be maintained so that contaminants (water, metal chips, dust, etc.) do not enter the lift truck
system. Most lift truck malfunctions are caused by entry of impurities such as dirt, dust, water, etc. Take special
care to avoid entry of impurities during storage and lubrication, etc.
• Never blend oils of different grades or brands.
• Add specified volume of oil. Insufficient or excessive amounts of oil may both cause problems.
• If the oil in the work equipment becomes cloudy, it is likely that air or water have entered the circuit. Consult your
• When replacing oil, replace the relevant filters at the same time.
GREASE 4
• Grease prevents the generation of squeaking or noise from the joints, etc.
• Lift trucks are provided with grease nipples in various places. Some of these are not mentioned in this manual
since they are for overhauling purposes, and do not require greasing.
If friction is noticed in movable parts after operation, grease.
• After greasing, wipe off old grease forced out, especially on rotating parts that will be worn by adhering sand and
dirt.
OIL STORAGE AND PRESERVATION 4
• Store and preserve oil so as not to allow entry of any water or dust.
• When storing oil drums for long periods, place them side by side with the filler sides facing in the same direction.
If necessary to store outdoors, cover them with waterproof sheets.
• To prevent deterioration during long-term storage, use drums on a “first in, first out“ basis.
4 - 12
MAINTENANCE OUTLINE OF SERVICE
FILTERS 4
• Filters are very important safety items which prevent problems caused by impurities contained in the oil or
hydraulic circuit which sends oil into important units. Periodically replace the filters referring to this manual.
• When replacing oil filters, check for metal powder accumulated on the used filters.
• Do not unpack replacement filters until immediately before installation.
• Always use Genuine Filters.
4 - 13
LUBRICANT LIST MAINTENANCE
LUBRICANT LIST 4
LUBRICANT LIST 4
Oil and grease are available from KOMATSU FORKLIFT distributors.

Consult your KOMATSU FORKLIFT distributor.
Ambient temperature (°C)

-40 -22 -4 -14 32 50 68 86 °F Recommended
Lubrication point Type of oil
-40 -30 -20 -10 0 10 20 30 °C genuine oil
Cold Storage Standard
GO80
Transfer case Gear oil
GO80W90
HO15
Hydraulic tank Hydraulic oil
HO32R
Brake system Brake oil BF3
Each greasing
Grease GLT2-LI
points
EO5-CD
Each lubrication
Engine oil EO10-CD
point
EO30-CD
hydrauric
Model Transfer case Overall oil amount when the Brake system
Tank capacity
FV 3 m mast is installed
7.0 liters 18 liters 22 liters 0.4 liters
FB09EX - 18EX
1.8 US gal 4.8 US gal 5.8 US gal 0.10 US gal
FB15EXG/FB18EXG
1.6 UK gal 4.0 UK gal 4.8 UK gal 0.09 UK gal
FB20EX/FB25EX
2.1 US gal 5.6 US gal 5.8 US gal 0.10 US gal
FB20EXG/FB25EXG
FB30 2.1 US gal 7.9 US gal 8.2 US gal 0.10 US gal
4 - 14
MAINTENANCE LUBRICANT LIST
OIL AND GREASING CHART (OIL, GREASE LOCATIONS AND INSPECTION AND
MAINTENANCE INTERVALS) 4
: Check and add fluid if necessary

Symbol Type of oil
Q: Change or add oil
EO Engine oil
: Shows the number of places to add oil or grease
GO Gear oil
HO Hydraulic oil
BF Brake fluid
G Grease
4 - 15
LUBRICANT LIST MAINTENANCE
OIL AND GREASING CHART (OIL, GREASE LOCATIONS AND INSPECTION AND
MAINTENANCE INTERVALS) (FOR EU) 4
Chain
Fork stopper
Transfer case
Tilt cylinder pin
Mast support
Brake reservoir tank
Hydraulic tank
EPS actuator
Bell-crank pin
Center pin
King pin
King pin
Daily inspection
Once every 2 weeks (100 hours)
Monthly (200 hours)
3-monthly (600 hours)
6-monthly (1200 hours)
4 - 16
MAINTENANCE INSPECTION AND MAINTENANCE SCHEDULE CHART
INSPECTION AND MAINTENANCE SCHEDULE CHART 4
This Inspection and Maintenance List describes those inspection and maintenance items operator can perform
himself and rough standard timing for doing them.
• For other inspection and maintenance items not described in this manual, contact KOMATSU FORKLIFT
distributor.
• Incorrect inspection, maintenance and repair services may cause critical accident or shorten machine service
life. For your safety operation, contact KOMATSU FORKLIFT distributor for inspection, maintenance and repair
services.
4 - 17
INSPECTION AND MAINTENANCE SCHEDULE CHART MAINTENANCE
INSPECTION AND MAINTENANCE SCHEDULE CHART

[Q] indicates the inspection and maintenance service items recommended by KOMATSU FORKLIFT.
Inspection & Maintenance Intervals (hours) Replace-

ment
Inspection & Maintenance Item Start-up Every2weeks Every 1 Every 3 Every 6 Every 1 year Intervals
month months months
Inspection (100h) (200h) (600h) (1200h) (2400h) (month)
Checking of repaired abnormalities detected on
Q
previous day
Visual inspection (Walk around a lift truck for visual
inspection.)
• Leakage of water and oil from various sections, Q
loosening of various sections, cracks, lubrication of
various sections
Front axle
Cracks, damage and deformation Q
Loosening of mount bolts and nuts Q
Abnormal noise Q
Oil leakage Q Q Q Q Q
TRAVELING EQUIPMENT
Gear oil level and contamination Q Q Q

Oil replacement Q Q 6
Rear axle
Cracks, damage and deformation Q
Loosening of mount bolts Q
Wheels (tires and rims)
Inflation pressure of tires Q Q Q Q Q
Tire crack, damage and uneven wear Q Q Q Q Q
Tire tread depth Q Q Q Q Q
Pinching of metallic pieces, pebbles and foreign
Q Q Q Q Q
matters
Loosening of wheel nuts and bolts Q Q Q Q Q
Deformation, cracks and damage to rims, discs and
Q Q Q Q Q
side rings
Play and abnormal noise of wheel bearing Q Q Q Q
4 - 18
Steering wheel
Operating state of steering wheel (run out, unstable
Q Q Q Q Q
driving and steering effort)
Amount of play, loosening and run-out Q Q Q Q Q
Steering valve
Oil leakage Q Q Q Q
Loosening and falling of mount bolts and nuts Q Q Q Q
Power steering
Rotation, abnormal noise and odor of the motor Q Q
EPS actuator installation state and looseness at the
Q Q
STEERING SYSTEM
connection
Wear on brush, contact and damage of spring Q Q
Stains and wear on motor commutator Q Q
Knuckle
Play of king pin, joint and bearing Q Q Q Q
Cracks and damage Q Q
Tie rod
Cracks, damage, play and cracks of boots
Q Q
Loosening and falling of mount nuts
Steering mechanism
Minimum turning radius and steering angle Q
Loosening and falling of stopper bolts Q
Interference of steering wheel Q
Cylinder, hose and piping
Damage, cracking and aging of hose and piping Q Q Q Q
Looseness and interference Q Q Q Q
4 - 19

ment
Inspection & Maintenance Item Start-up Every2weeks Every 1 Every 3 Every 6 Every 1 year Intervals
month months months
Inspection (100h) (200h) (600h) (1200h) (2400h) (month)
Brake pedal
Play and clearance between the floor when depressed Q Q Q Q Q
Braking effect Q Q Q Q Q
Abnormality at depressing the brake pedal (mixing of air) Q
Parking Brake
Drawing force and operation of release button Q Q Q Q Q
Braking effect Q Q Q Q
Wear and damage of link and pin Q
BRAKING SYSTEM
Rod link and cable

Run-out, looseness, damage and missing cotter pin Q Q Q Q
Piping
Leakage Q Q Q Q Q
Damage and cracks Q Q Q Q
Loosening, falling and interference of clamp Q Q
Brake (hydraulic type)
Operating state of master cylinder and wheel cylinder Q
Oil leakage from and damage to master and wheel Q Q Q Q Q
cylinders
Wheel cylinder mount bolts Q
Brake fluid level and contamination in the reservoir tank Q Q Q Q Q
Replacement of brake fluid Q Q 6
Brake disc
Wear of disc Q
Lifting equipment in general
Operation and function of lifting equipment Q Q Q Q Q
Fork
Deformation, crack and wear of fork stopper pin Q Q Q Q Q
Opening of fork ends, height difference and bending Q Q Q Q
Crack at the root of fork and cracks of upper and lower
Q Q Q Q
hooks
Checking of cracks using defect detector, etc. Q
LIFTING EQUIPMENT
Wear Q
Mast
Deformation, crack and damage of the mast Q Q Q Q
Play of roller bearing Q Q Q Q
Cracks and damage of welded portion of roller shaft Q Q Q Q
Play and damage of mast support portion
Q Q Q Q
Loosening of mast support mounting bolts
Chain
Chain tension Q Q Q Q Q
Chain elongation Q Q
Cracks, deformation, damage and corrosion of chain Q Q Q Q Q
Chain lubrication Q Q Q Q Q
Deformation, damage and play of chain wheel Q Q Q Q
Deformation, damage and loosening of chain stopper Q Q Q Q
Hydraulic oil
HYDRAULIC SYSTEM
Hydraulic oil level and contamination Q Q Q Q Q

Replacement of oil in the tank Q Q 6
Tank cleaning Q Q
Clogging of air breather Q Q
Line filter and strainer
Clogging and damage of strainer Q Q
Contamination, clogging and damage of line filter Q Q
Replacement of line filter Q Q 6
4 - 20

Every 1 Every 3 Every 6 ment
Inspection & Maintenance Item Start-up Every2 weeks Every 1 year Intervals
month months months
Inspection (100h) (2400h) (month)
(200h) (600h) (1200h)
Piping (hose and piping)
Cracks, damage, aging, chaps, twists and the state of mounting Q Q Q Q
Loosening and falling of pipe clamps Q Q Q Q
Hydraulic pump
HYDRAULIC SYSTEM
Abnormal vibration and noise Q Q Q Q

Lift cylinder and tilt cylinder
Operating condition Q Q Q Q Q
Cylinder drift and tilt by itself Q Q Q Q
Dents, cracks, bends and scratches Q Q Q Q
Wear of tilt cylinder mount pins and loosening of mount bolts Q Q Q Q Q
Operating valve, and operating valve lever
Operating condition and play Q Q Q Q
Relief pressure Q
Solenoid valve
Operation, abnormal noise and heat and oil leakage Q
Traveling motor
Rotation, abnormal noise and odor of the motor Q Q Q
Attachment of foreign matters and damage Q Q Q
Lifting motor
Rotation, abnormal noise and odor of the motor Q Q Q
Attachment of foreign matters and damage Q Q Q
MOTOR
Wear on brush, sliding state, deposition of foreign

substance, and presence/absence of damages and Q Q
streaks
Damages on spring Q Q
Stains, frictions or streaks on motor commutator Q
Stains on collector Q
Looseness on wiring inside motor Q Q
Looseness of pig-tail Q Q
WIRING AND SENSOR CONTROL SYSTEM
Controller
Operating condition, abnormal noise and odor Q Q
Maximum motor current Q Q
Operating timing of contactor Q Q
Loosening, damage, wear of contactor and loosening of Q Q
mount
Loosening of fuse mount bolts Q Q
Wiring
Loosening of connecting sections (terminal, connector) Q Q
Damage, state of fixing and friction of wire harness and power
cable
Q Q
Damage and state of engagement of battery connector and plug Q Q
Micro switch and sensor
Operating condition and timing Q Q Q Q
Loosening, damage and wear of contact Q
Loosening of mount Q Q Q Q
4 - 21

Every 1 Every 3 Every 6 ment
Inspection & Maintenance Item Start-up Every2weeks Every 1 year Intervals
month months months
Inspection (100h) (2400h) (month)
(200h) (600h) (1200h)
Battery
Electrolyte level Q Q Q Q Q
BATTERY AND CHARGER
Electrolyte specific gravity Q Q Q Q

Voltage Q Q
Loosening and corrosion of terminal Q Q
Damage of cell and leakage of electrolyte Q
State of connection of connector, damage and loosening of bolts Q Q Q Q
Cleaning of top surfaces Q Q Q Q
Charger
Damage, play, and loosening of bolts of plug and receptacle Q Q Q Q
Operating voltage of voltage sensing relay Q Q
Timer operation, magnet switch operation and wear Q Q
Adjustment of supply voltage tap Q Q
Frame
Cracks and deformation Q
Loosening and falling of mount bolts of sections Q
Seat
Operating condition of seat belt lock Q Q
Function of buckle or retractor Q Q Q
Open seam of seat belt webbing Q Q
Display board
Damage and the state of mounting Q
TRUCK BODY AND SAFETY DEVICES
Overhead guard and load backrest

Loosening of mount bolts and nuts Q Q Q Q
Cracks, deformation and damage Q Q Q Q Q
Lighting device, warning devices (horn and backup buzzer)
and turn signal lamp, etc.
Operation (lighting and flashing state) and the state of
Q Q Q
mounting
Contamination and damage of lens of various lamps, and
Q Q Q
infiltration of water
Sound level of warning device (horn) Q
Instruments
Operating condition Q Q
Rear-view mirror and reflector
Contamination, damage and state of reflection Q Q
Number plate
Contamination and damage Q Q Q
lubricant
Lubricating state of various sections Q Q Q Q
Safety function
Travel interlock function Q Q Q Q Q
Lift interlock function Q Q Q Q Q
Neutral safety function Q Q Q Q Q
Warning against overlooking application of parking brake
Q Q Q Q Q
lever
Conduct traveling and lifting tests and verify functions
COMPREHENSIVE TEST
Operation of various devices Q Q Q Q Q

Abnormal vibration, noise, odor and heating Q Q Q Q Q
4 - 22
MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4
For your safety use of lift trucks, you are requested to always implement periodic replacement of parts listed in the
Periodic Replacement of Safety Critical Parts below related particularly to the safety and fires.
The material of these parts may change over time, or may easily wear or deteriorate. However, as it is difficult to
judge the condition of the parts simply by periodic maintenance, they should always be replaced after a fixed time
has passed, regardless of their condition. This is necessary to ensure that their full function is always maintained.
However, if these parts show any abnormality before the replacement interval has passed, they should be repaired
or replaced immediately.
If the hose clamps show any sign of deterioration such as deformation or cracking, replace them with the hoses at
the same time.
Note that the periodic replacement is not covered by warranty.
IMPORTANT PARTS LIST

No. Part name Years elapsed
1 Master cylinder, wheel cylinder cup and dust seal, etc. 1
2 Brake hose or tube 1-2
3 Reservoir tank and tube 2-4
4 Power steering hose 2
5 Rubber parts inside power steering system 2
6 Lift chain 2-4
7 Hydraulic hose for lifting mechanism 1-2
4 - 23
MAINTENANCE MAINTENANCE
MAINTENANCE 4
CHECK BRAKE LINK FOR BACKLASH, LOOSENESS, DAMAGE AND WEAR 4
WARNING
Inspect the lift truck in an area where it will not obstruct other vehicles or workers.
1. Check play and depressing height of brake pedal and make

sure they are set to the specified values.
Play 2 - 6 mm (0.08 - 0.24 in)

Pedal height (H) 130 - 140 mm (5.1 - 5.5 in)
1 ton: Above 81 mm
(3.2 in)
Pedal height when depressed (H2)
2 - 3 ton: Above 79 mm
(3.1 in)
Switch ON position 20 - 30 mm (0.8 - 1.2 in)
2. Test the brake while gradually increasing the advancing speed

from the low speed. Check for non-uniform braking or
dragging. If necessary, adjust the brake until it is applied
smoothly.
CHANGE OIL IN TRANSFER CASE (INCLUDING DIFFERENTIAL CASE) 4
CHECK TRANSFER CASE OIL LEVEL 4
1. Remove the level plug.

2. Check that the oil level is near the bottom of the level plug hole.
3. If the oil level is low, remove the oil filler plug and add gear oil.
CHANGE OIL IN TRANSFER CASE 4
1. Remove the oil filler plug, then remove the drain plug and drain
the oil.
2. After draining the oil, tighten the drain plug and add the
specified amount of oil through the oil filler.
3. After refilling with oil, check the oil level at the level plug to
confirm that the oil level is correct.
For the right amount of replacement oil, see “LUBRICANT
LIST (PAGE4-14)“.
NOTICE
Always use genuine gear oil.
4 - 24
CHANGE HYDRAULIC TANK 4
WARNING
Immediately after operations, the oil is at high temperature. Wait for the temperatureto go down before starting this operation.
1. Remove the drain plug and drain the oil, then tighten the drain plug.
2. Remove the cover, then take out the strainer and line filter.
3. Wash the strainer in flushing oil, then blow the strainer with compressed air from the inside to dry it completely,
and install it again.
4. Replace the line filter with a new part.
5. Add the specified amount of hydraulic oil through the oil filler, then check the oil level with the oil gauge.
For the right amount of replacement oil, see “LUBRICANT LIST (PAGE4-14)“.
6. Operate the cylinders (lift, tilt) to the end of their stroke 5 or 6 times to bleed the air.
NOTICE
Always use genuine hydraulic oil.
4 - 25
CHECK BATTERY VOLTAGE AFTER CHARGING 4
CAUTION
• First aid procedure when exposed to electrolyte.
If electrolyte splashes over the eyes, skin or clothes, wash off with plenty of water. Immediately consult a doctor if the
electrolyte gets in the eyes.
• To prevent fire
Never generate short circuiting or sparking and never bring a flame, such as cigarette, near the battery.
• To avoid electric shock
Be sure to wear goggles, safety gloves and rubber-soled shoes at the time of battery maintenance.
• Ventilation
Provide sufficient ventilation whether operating or not.
CHECK SPECIFIC GRAVITY OF ELECTROLYTE

1. Charge the battery. After charging, maintain normal fluid level.
2. With a hydrometer and thermometer, measure the specific
gravity and temperature of the electrolyte.
3. Determine S20 by substituting the values measured in steps 1
and 2 for St and t in the following formula.
S20 = St + 0.0007 (t - 20)

where
S20: Specific gravity at 20 ºC
St: Specific gravity at t ºC (measurement)
t: Temperature of electrolyte (measurement)
Standard value: S20 = 1.27 to 1.29
4. Measure and calculate the specific gravity for all cells.

NOTICE
• After use, wash hydrometer with water.
• Measured data should be stored.
4 - 26
SELECTION OF CHARGER POWER SUPPLY VOLTAGE TAP 4
(Reference)
CAUTION
• For the power source of the facility (building), it is necessary to have cables and receptacles of a higher capacity than the rated
voltage and current of the charger.
If the capacity is too low, there is danger of fire.
• f the charger is used for a long time with a remarkably deviated tap voltage at the power supply, there is danger that the charger
will burn out. Periodically measure the power source voltage and select a suitable power source voltage tap.
STATIONARY CHARGER
1. Measure the voltage of the power source to be used with the
charger.
NOTICE
The primary side voltage fluctuates between day and night, and between
summer and winter, so measure the maximum voltage of the power source
during the charging operation.
2. From the table below select one cable each from A, B, and C
which matches the maximum measured voltage of the power
source.
Maximum measured Display value

power source voltage (V) of cable (A)
190 - 199 195
200 - 209 205
210 - 219 215
220 - 229 225
3. Connect the selected cables to cables (D) from the

electromagnetic switch.
4 - 27
REPLACING FUSES 4
AREA UNDER FLOOR PLATE 4
CAUTION
When replacing fuses, always disconnect the battery plug to isolate the power supply.
1. Turn the key switch OFF, then disconnect the battery plug.
2. Remove the floor plate.
3. Open the cap of the fuse holder, then take out the fuse and
replace it.
Symbol Circuit Capacity

SF1 Chassis control circuit 10 A
SF2 Accessory circuit 15 A
4 - 28
STATIONARY CHARGER 4
1. Disconnect the charger power cable plug from the power

source.
2. Loosen the nut, then remove the fuse and replace it.
3. After replacing the fuse, tighten the nut securely.
FB09EX - FB18EX, FB15EXG, FB18EXG
Symbol Voltage Battery capacity (Ah) Capacity

330
BFS80A
400
485
BFS100A
545
F4 48V 565
600
700 BFS150A
935
1080
FB20EX, FB25EX, FB20EXG, FB25EXG, FB30
Symbol Voltage Battery capacity (Ah) Capacity

330
BFS80A
400
485
BFS100A
545
48V 565
F5 600
700 BFS150A
935
1080
450
72V BF150A
545
4 - 29
CONTROLLER 4
If the fuse blows, the error code is displayed on the monitor in the operator's compartment. Inform your KOMATSU
FORKLIFT distributor of the error code that is displayed.
Error code Applicable fuse

E20 F1 (fuse for travel circuit)
E32 F2 (fuse for hydraulic circuit)
E52 F3 (fuse for PS circuit)
- F4 (fuse for charge circuit)
For the error codes in the above table, other causes are also possible, so please contact your KOMATSU
FORKLIFT distributor for inspection.
Symbol Circuit Capacity

48LF-225A (1 - 1.75 ton)
F1 Travel circuit 48LF-325A (2 - 2.5 ton)
96LF-275 (3.0 ton)
48LF-225A (1 - 2.5 ton)
F2 Hydraulic circuit
96LF-200A (3.0 ton)
48LF-40A (1 - 2.5 ton)
F3 PS circuit
96LF-40A (3.0 ton)
48LF-225A (1 - 2.5 ton)
F4 Charge circuit
96LF-200A (3.0 ton)
4 - 30
REPLACING TIRES 4
WARNING
• After confirming that the rim nuts are not loose, loosen the hub nuts.
• Never mistakenly loosen the rim nuts instead of the hub nuts.
• Jack up the lift truck after confirming that the jack will not slip. Never go under the lift truck body.
• Deformation or cracking of the tires is very dangerous because the tires are inflated at high pressure. Before inflating the
tires, always check the condition carefully. Never used a cracked tire or a tire with a deformed rim.
• Before starting work, set the pressure of the air compressor to the specified value to avoid applying excessive pressure.
1. Stop the lift truck on flat ground in a safe area and apply the
parking brake.
2. Put blocks under the tire diagonally opposite to the tire which
is to be replaced.
3. Using a hub nut wrench, loosen the hub nuts to a point where
they can be turned by hand.
4. Set a jack at the jacking point (see diagram on right), then jack
up the lift truck to a point where the tire comes off the ground.
(A): Front tire jacking point (Under outer mast)
(B): Rear tire jacking point (Under counterbalance-weight)
5. Remove the hub nuts, then remove the tire and replace it.
6. Install the replacement tire and partially tighten the hub nuts.
7. Tighten the hub nuts in turn on opposite sides until there is no
play in the wheel.
8. Lower the jack to lower the lift truck to the ground, then tighten
the hub nuts to the specified tightening torque. (For details of
the tightening torque, see “SERVICE DATA (PAGE4-34)“.)
9. Adjust the inflation pressure of the tire to the specified
pressure. (For details of the inflation pressure, see “SERVICE
DATA (PAGE4-34)“.)
TIRE FOR BATTERY-POWERED LIFT TRUCK 4
Battery-powered lift trucks are equipped with suitable tires having

minimal rolling resistance.
When replacing tires, always use Genuine Tires for battery-
powered lift trucks.
NOTICE
• If the lift truck is equipped with inappropriate tires for battery-powered
lift trucks, it could cause a reduction of operating hours and driving
speed per one charging.
• If wishing to use Solid Tires For Use On Pneumatic Tire Rims (non-
puncture) which do not require air pressure on a battery-powered lift
truck, consult a KOMATSU FORKLIFT distributor.
4 - 31
REPLACING LAMPS 4
1. Check that fuses are not blown and wires are not disconnected.
2. If disconnection is found, turn OFF the lamp switch and replace the lamp.
Name of lamp Capacity

Head lamp 40W (48V)
Turn signal lamp 25W (48V)
Clearance lamp 8W (48V)
Number plate lamp (option) 10W (48V)
Backup lamp 8W (48V)
Stop lamp 25W (48V)
Working lamp (option) 45W (48V)
4 - 32
MAINTENANCE WASHING LIFT TRUCK
WASHING LIFT TRUCK 4
CAUTION
If water gets into the electrical system (controller, sensor, connector, etc.), there is ahazard that it will cause malfunctions or
miss-movement. Do not use flushing water or highpressuresteam to wash the electrical system.
Step for Washing

1. Turn the starting switch key to the "OFF" position, then remove the key.
2. Disconnect the battery plugs.
3. Wash each part q to y parts in the figure at right), following the instructions in thetable below.
4. Dry off the washed parts.
5. After checking that the washed parts have dried out, connect the battery plugs, insert thestarting switch key
and turn it to the "ON" position then make sure that there is no abnormality,and then start operation.
No. Spot to wash Washing Method

Charger Control Wash by spraying water with a hose from above.
1 Panel(Battery charger (Note)In washing, 0 the flow of water to lower water pressure as illustrated below
may be Optional) (only for 1, 2 and 3 parts).
2 Meter Panel
3 Dashboard Front
4 Battery Wipe with wet cloth. (Keep the battery top clean and dry.)
Front & Rear Tires Wash with high pressure steam or flushing water from a hose.
5
Front & Rear Axles (Note)Do not use high pressu0re steam or flushing water for the electric wirings.
Exterior parts other
6 Wash with high pressure steam or flushing water from a hose.
than the above
1. Never wash the inside of the dashboard.
2. When using high pressure steam or flushing water from a hose to washthe
Other Precautions underpart of the floor plate (power train parts), cover the electricsystem parts like
the motor, electric wirings, connector, fusebox, etc. with a tarpaulin so that those
parts do not get splashed withwater.
4 - 33
SERVICE DATA MAINTENANCE
SERVICE DATA 4
SERVICE DATA 4
FB15EX FB18EX
Inspection item Unit FB09EX FB10EX FB14EX
FB15EXG FB18EXG
KPa
Front wheel 700 {7.0} 700 {7.0} 700 {7.0} 700 {7.0}
{kgf/cm2}
Tire inflation pressure
KPa
Rear wheel 800 {8.0} 800 {8.0} 800 {8.0} 900 {9.0}
{kgf/cm2}
Tightening torque for Front wheel Nm {kgfm} 196 - 245 {20 - 25}
hub nuts Rear wheel Nm {kgfm} 98 - 147 {10 - 15}
Tightening torque for rim Front wheel Nm {kgfm} 98 - 123 {10 - 12.5} - -
mating nuts Rear wheel Nm {kgfm} 59 - 74 {6 - 7.5}
Play of steering wheel mm (in) 30 - 60 (1.2 - 2.4)
Play of brake pedal mm (in) 2 - 6 (0.08 - 0.24)
Tightening torque of back plate
Nm {kgfm} 157 - 196 {16 - 20}
mounting bolt
Operating force of parking brake
Nm {kgfm} Min. 147 {15}
lever
Relief valve set pressure (control MPa
17.6 {180}
valve) {kgf/cm2}
Elongation of lift chain
mm (in) Max. 275.5 (10.8)
(length over 17 links)
Min. 30 Min. Min.
Fork thickness (at base) mm (in) Min. 26 (1.02)
(1.18) 30(1.18) 33(1.30)
Pump motor mm (in) Min. 22 (0.87)
Brush height Power steering
mm (in) Min. 13 (0.51)
motor
4 - 34
MAINTENANCE SERVICE DATA
FB20EX FB25EX
Inspection item Unit FB30
FB20EXG FB25EXG
Front wheel KPa {kgf/cm2} 900 {9.0} 800 {8.0}
Tire inflation pressure
Rear wheel KPa {kgf/cm } 2 1000 {10.0} 625 {6.25}
Tightening torque for hub Front wheel Nm {kgfm} 196 - 245 {20 - 25} 294 - 490 {30 - 50}
nuts Rear wheel Nm {kgfm} 196 - 245 {20 - 25} 196 - 245 {20 - 25}
Tightening torque for rim Front wheel Nm {kgfm} -
mating nuts Rear wheel Nm {kgfm} 157 - 196 {16 - 20} -
Play of steering wheel mm (in) 30 - 60 (1.2 - 2.4)
Play of brake pedal mm (in) 2 - 6 (0.08 - 0.24)
Tightening torque of back plate mounting
Nm (kgfm} 157 - 196 {16 - 20}
bolt
Operating force of parking brake lever Nm {kgfm} Min. 196 {20}
MPa
Relief valve set pressure (control valve) 17.6 {180}
{kgf/cm2}
Elongation of lift chain
mm (in) Max. 330 (13.0) Max. 550 (21.7)
(length over 17 links)
Fork thickness (at base) mm (in) Min. 33(1.30) Min. 36.5 (1.44) Min. 39.5(1.56)
Pump motor mm (in) Min. 22 (0.87)
Brush height
Power steering motor mm (in) Min. 13 (0.51)
4 - 35
SERVICE DATA MAINTENANCE
TORQUE LIST 4
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 Parts the
same size as the previous ones.
Thread diameter Width across Tightening torque

of bolt (mm) flat (mm)
(a) (b) Nm kgfm 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
4 - 36
TECHNICAL DATA 5
15
TECHNICAL DATA
5-1
TECHNICAL DATA TECHNICAL DATA
TECHNICAL DATA 5
Item Unit FB09EX-11 FB10EX-11 FB14EX-11 FB15EX-11 FB18EX-11

• Performance
Rated capacity kg (lb) 900 (2000) 1000 (2200) 1350 (3000) 1500 (3300) 1750 (3900)
Load center mm (in) 500 (20) 500 (20) 500 (20) 500 (20) 500 (20)
Std. mast lift height A mm (in) 3000 (118) 3000 (118) 3000 (118) 3000 (118) 3000 (118)
Lifting speed (loaded) mm/s (fpm) 360 (71) 360 (71) 350 (69) 340 (67) 340 (67)
km/h
Travel speed (unloaded) 17.0 (10.6) 17.0 (10.6) 17.0 (10.6) 17.0 (10.6) 17.0 (10.6)
(mph)
Max. gradeability (loaded) % (degree) 27.0 (15.5) 22.0 (12.5) 20.0 (11.5) 19.0 (11.0) 17.0 (9.5)
• Dimensions, weight
Overall length (with std. forks) B mm (in) 2775 (109.3) 2775 (109.3) 2930 (115.4) 2930 (115.4) 2915 (114.9)
Overall width (at tire, single) C mm (in) 1070 (42.1) 1070 (42.1) 1070 (42.1) 1115 (43.9) 1115 (43.9)
Overall Mast lowered mm (in) 1970 (77.6) 1970 (77.6) 1970 (77.6) 1970 (77.6) 1970 (77.6)
height Overhead guard D mm (in) 2095 (82.5) 2095 (82.5) 2095 (82.5) 2095 (82.5) 2095 (82.5)
Free lift (overall mast height) E mm (in) 135 (5.3) 135 (5.3) 140 (5.5) 140 (5.5) 140 (5.5)
Fork length F mm (in) 770 (30.3) 770 (30.3) 920 (36.2) 920 (36.2) 920 (36.2)
Wheelbase G mm (in) 1250 (49.2) 1250 (49.2) 1250 (49.2) 1250 (49.2) 1250 (49.2)
Service weight
kg (lb) 2340 (5200) 2510 (5535) 2715 (5987) 2905 (6406) 3050 (6725)
(with standard|attery)
• Motor output
Drive kw/h AC 7.3 AC 7.3 AC 7.3 AC 7.3 AC 7.3
Pump kw/5min DC 9.0 DC 9.0 DC 9.0 DC 9.0 DC 9.0
PS kw/h DC 0.4 DC 0.4 DC 0.4 DC 0.4 DC 0.4
• Tire size
Front tires - 6.00-9-10PR 6.00-9-10PR 6.00-9-10PR 21x8-9-14PR 21x8-9-14PR
Rear tires - 5.00-8-8PR 5.00-8-8PR 5.00-8-8PR 5.00-8-8PR 5.00-8-10PR
• Vibration
VIBRATION in accordance with
m/s 2
- - - - -
EN 13059
The uncertainty of measurement - - - - -
5-2
Item Unit FB15EXG-11 FB18EXG-11 FB20EX-11 FB25EX-11

• Performance
Rated capacity kg (lb) 1500 (3300) 1750 (3900) 2000 (4410) 2500 (5513)
Load center mm (in) 500 (20) 500 (20) 500 (20) 500 (20)
Std. mast lift height A mm (in) 3000 (118) 3000 (118) 3000 (118) 3000 (118)
Lifting speed (loaded) mm/s (fpm) 340 (67) 340 (67) 290 260
Travel speed (unloaded) km/h (mph) 17.0 (10.6) 17.0 (10.6) 16.5 (10.3) 16.0 (9.9)
Max. gradeability (loaded) % (degree) 19.0 (11.0) 17.0 (9.5) 19.0 (11.0) 16.0 (9.0)
Overall length (with std. forks) B mm (in) 3150 (124.1) 3150 (124.1) 3175 (125.1) 3365 (132.6)
Overall width (at tire, single) C mm (in) 1115 (43.9) 1115 (43.9) 1165 (45.9) 1165 (45.9)
Overall Mast lowered mm (in) 1970 (77.6) 1970 (77.6) 1995 (78.6) 1995 (78.6)
height Overhead guard D mm (in) 2095 (82.5) 2095 (82.5) 2125 (83.7) 2125 (83.7)
Free lift (overall mast height) E mm (in) 140 (5.5) 140 (5.5) 150 (5.9) 155 (6.1)
Fork length F mm (in) 920 (36.2) 920 (36.2) 920 (36.2) 1070 (42.2)
Wheelbase G mm (in) 1470 (57.9) 1470 (57.9) 1400 (55.2) 1400 (55.2)
Service weight
kg (lb) 3105 (6847) 3305 (7288) 3530 (7784) 3960 (8732)
(with standard battery)
• Motor output
Drive kw/h AC 7.3 AC 7.3 AC 10.3 AC 10.3
Pump kw/5min DC 9.0 DC 9.0 DC 10.0 DC 10.0
PS kw/h DC 0.4 DC 0.4 DC 0.6 DC 0.6
• Tire size
Front tires - 21x8-9-14PR 21x8-9-14PR 23x9-10-16PR 23x9-10-16PR
Rear tires - 5.00-8-8PR 5.00-8-10PR 18x7-8-16PR 18x7-8-16PR
• Vibration
VIBRATION in accordance with EN
m/s 2
- - 0.8 0.8
13059
The uncertainty of measurement - - 0.5 0.5
5-3
Item Unit FB20EXG-11 FB25EXG-11 FB30-11

• Performance
Rated capacity kg (lb) 2000 (4410) 2500 (5513) 3000 (6615)
Load center mm (in) 500 (20) 500 (20) 500 (20)
Std. mast lift height A mm (in) 3000 (118) 3000 (118) 3000 (118)
Lifting speed (loaded) mm/s (fpm) 290 260 260
Travel speed (unloaded) km/h (mph) 16.5 (10.3) 16.0 (9.9) 14.0 (8.7)
Max. gradeability (loaded) % (degree) 19.0 (11.0) 16.0 (9.0) 16.0 (9.0)
Overall length (with std. forks) B mm (in) 3325 (131) 3480 (137.1) 3590 (141.4)
Overall width (at tire, single) C mm (in) 1165 (45.9) 1165 (45.9) 1235 (48.7)
Overall Mast lowered mm (in) 1995 (78.6) 1995 (78.6) 2015 (79.4)
height Overhead guard D mm (in) 2250 (88.7) 2250 (88.7) 2240 (88.3)
Free lift (overall mast height) E mm (in) 150 (5.9) 155 (6.1) 155 (6.1)
Fork length F mm (in) 920 (36.2) 1070 (42.2) 1070 (42.2)
Wheelbase G mm (in) 1550 (61.1) 1550 (61.1) 1600 (63.0)
Service weight
kg (lb) 4110 (9063) 4260 (9393) 5090 (11223)
(with standard|attery)
• Motor output
Drive kw/h AC 10.3 AC 10.3 AC 9.7
Pump kw/5min DC 10.0 DC 10.0 DC 12.6
PS kw/h DC 0.6 DC 0.6 DC 0.6
• Tire size
Front tires - 23x9-10-16PR 23x9-10-16PR 28x9-15-14PR
Rear tires - 18x7-8-16PR 18x7-8-16PR 21x8-9-10PR
• Vibration
VIBRATION in accordance with EN
m/s 2
0.8 0.8 0.9
13059
The uncertainty of measurement 0.5 0.5 0.6
5-4
EC DECLARATION OF
CONFORMITY 6
67
6-1
EC DECLARATION OF CONFORMITY(FB20EX-30-11) EC DECLARATION OF CONFORMITY
EC DECLARATION OF CONFORMITY 6
EC DECLARATION OF CONFORMITY(FB20EX-30-11) 6
We, Komatsu Ltd. of which registered office is at 110 Yokokura-Shinden, Oyama-shi, Tochigi-ken 323-8567, Japan,
hereby declare under our sole responsibility that the following machines
Category : Forklift Truck

(I.C. engine type, self-propelled counterbalanced truck )
Manufacturer : Komatsu Ltd, Tochigi, Japan
Type : FB20EX-11, FB25EX-11, FB20EXG-11, FB25EXG-11, FB30-11
meet the requirements of the latest valid version of Machinery Directive 2006/42/EC and EMC Directive 2004/108/
EC by complying with the harmonized standards and equivalent as attached.
TIE-DOWN POSITIONS OF LIFT TRUCK 6
When transporting the lift truck, bind it by either of the following two methods.
1. Chock the rear wheels and fix the two holes on both sides of the mast head stay and the hooks of the truck bed
with wire ropes or chains.
2. Fix the two holes on both sides of the mast head stay and the front hooks of the truck bed, and fix the mast
board and two rear hooks of the truck bed.
Truck bed
Truck bed
6-2
ATTACHMENT 7
77
WARNING
In this section, only the attachment parts different from the standard lift truck
are described. For the parts not shown in this section, see the explanation of
the standard lift truck.
7-1
OPERATION OF SIDE SHIFT ATTACHMENT
ATTACHMENT 7
OPERATION OF SIDE SHIFT 7
ATTACHMENT MODEL PLATE LOCATION, SERIAL NO. 7
ATTACHMENT MODEL PLATE LOCATION

The attachment model is stamped on the nameplate stuck to a conspicuous place of each attachment.
The location of the name plate may differ according to the model of the machine. In cases where a combination
of side shift and another attachment are used, the name plate is attached on the attachment installed in front of the
side shift.
Side shift
Fork mover
MODEL and SERIAL NO. are stamped on the nameplate.
Komatsu Ltd. Japan
7-2
ATTACHMENT OPERATION OF SIDE SHIFT
SAFETY OF ATTACHEMENTS 7
OPERATION MANUAL FOR LIFT TRUCK

Prior to using this attachment, be sure to read the operation manual for the lift truck and understand its contents
as well.
STRICT OBSERVANCE OF ALLOWABLE LOAD AND CENTER OF GRAVITY

• Never carry a load exceeding an allowable load. Follow the Load Table pasted to the driver's seat.
• When traveling, center the load with the lift truck so that the load will not be shifted to either side.
PRECAUTIONS FOR HANDLING SIDE SHIFT

• Do not shift the fork while it is loaded and lifted high (150 cm or higher above the floor) unless the safety is
secured by a stand under the fork etc.
• Do not shift the fork abruptly while it is loaded and lifted high.
• Eliminate eccentricity of the load before lifting it or traveling, and do not shift the fork while traveling with the load.
• Do not use the fork for a purpose other than the normal work, such as pushing a cargo on the side of the lift truck
by moving the fork.
PRECAUTIONS FOR HANDLING FORK POSITIONER

• Arrange the load evenly and set the right and left forks symmetrically before starting work.
• Do not move the fork while it is loaded.
• Do not clamp a cargo with the fork.
• Do not use the fork for a purpose other than the normal work, such as pushing a cargo on the side of the lift truck
by moving the fork.
INTENDED USE ONLY

Do not use the hydraulic cylinders for a purpose other than the normal work, such as pulling, pushing, or sling a
thing by utilizing their force.
7-3
SAFETY LABEL 7
Keep this label clean. If it has peeled off, stick it again or replace it with a new one.
STUCK LOCATION OF SAFETY LABEL
7-4
Precautions for handling side shift Precautions for handling fork positioner (fork mover)
(45A-1ZP-2150) (45A-1ZP-2160)
Precautions for handling side shift with fork positioner

(fork mover with shift) (45A-1ZP-2170)
7-5
FEATURES OF ATTACHMENTS 7
These attachments are suitable for the following works.
Attachment Suitable Work

The entire finger bar moves to the left and
Side shift right and can perform loading/unloading
without changing a lift truck position.
Fork mover The fork distance can be adjusted in line with
(Hydraulic) a load size.
7-6
GENERAL VIEW 7
The shape may differ according to the model.
SIDE SHIFT
(1) Hose pulley (4) Shift cylinder

(2) Backrest (5) Fork
(3) Finger bar
FORK MOVER
(1) Hose pulley (4) Fork mover cylinder

(2) Backrest (5) Fork
(3) Finger bar
7-7
EXPLANATION OF COMPONENTS 7
CAUTION
Before operating any lever, sit on the operator seat and confirm the safety around the lift truck.
EXPLANATION OF OPERATING DEVICES

SIDE SHIFT
(1) Lift control lever
(2) Tilt control lever
(3) Side shift control lever
REMARK
Operating speeds depend on engine speed and movement of
control lever.
7-8
FORK MOVER
(1) Lift control lever
(2) Tilt control lever
(3) Mover control lever (Left fork)
(4) Mover control lever (Right fork)
REMARK
Operating speeds depend on engine speed and movement of
control lever.
7-9
OPERATION 7
LOADING AND UNLOADING

SIDE SHIFT WORK
1. Stop the machine in front of the load and set the forks
horizontal.
2. Align the center of shift frame and load by operating the shift
lever.
3. Insert the forks into the pallet and raise the load about 10 cm
(4 in). Drive slowly in reverse, then lower the load to 15 –
20 cm (6 – 8 in) from the ground.
4. Watch the shift indicator at the rear of the finger bar and align
the center of the shift frame and the finger bar, then tilt the mast
back.
7 - 10
FORK MOVER OPERATION

1. Stop the machine in front of the load and set the forks
horizontal. Raise the forks until they are level with the slots in
the load.
2. Operate the fork move control lever and align the space
between the forks to match the slots in the load.
3. Drive the machine forward and insert the forks fully, then raise
the load about 10 cm (4 in) and drive the machine in reverse.
4. Lower the load to 15 – 20 cm (6 – 8 in) from the ground. Then

tilt the mast back to the travel position.
7 - 11
INSPECTION AND MAINTENANCE SCHEDULE CHART 7
Since the attachments, as well as the lift truck, need the following inspections, place an order for check of them and
the lift truck with your Komatsu distributor.
Start-up Every month Every year

Component Inspection & Maintenance Item
inspection (200 h) (2400 h)
Fork unit
Damage and installed condition of fork Q
Crack at fork base Q
Operation of cylinders and oil leakage from them Q
Hydraulic unit Loose mounting parts of cylinder Q
Damage of and oil leakage from hoses Q
Grease supply to grease fittings Q
Shift device Deformation and damage of shift frame Q
Damage of shift roller Q
Fork mover Grease supply to grease fittings Q
device Deformation and damage of fork mounting shafts Q
7 - 12
MAINTENANCE WORK 7
EVERY 1-MONTH OR EVERY 200-HOUR MAINTENANCE WORK

GREASING SIDE SHIFT
Grease the parts indicated with the arrows.
The shift roller needs to be greased, too, depending on the model.
GREASING FORK MOVER

Grease the parts indicated with the arrows.
7 - 13
OPTIONS 8
88
WARNING
In this section, only the optional parts different from the standard lift truck are
described. For the parts not shown in this section, see the explanation of the
standard lift truck.
8-1
HANDLING CLAMP OPEN GUARD OPTIONS
OPTIONS 8
HANDLING CLAMP OPEN GUARD 8
Clamp open guard is a device to prevent the clamp (attachment) from releasing the clamped load unexpectedly if
the control lever moves suddenly.
CAUTION
• Operate control lever only while the operator is sitting down in the operator's seat when the clamp is open.
You cannot clamp the load if the operator is not seated.
• This device cannot be removed according to the following regulations.
• ISO 3691-1
• When red lamp (3) which indicates that the clamp can be open lights up without pressing clamp open button (1), CLAMP OPEN
GUARD device may have an abnormality. In this case, stop the loading work and contact your Komatsu distributor .
OPERATION PROCEDURE
When releasing the load from clamped condition
1. Press clamp open button (1) attached to the knob of control
lever (2) while the operator is sitting down in the operator's
seat.Red lamp (3) lights up to indicate that clamp can be open.
2. Operate clamp control lever (2) forward while pressing clamp

open button (1).The load is released.
When clamping the road

• Operate control lever (2) backward without pressing clamp open
button (1).The load is clamped.
The load can be clamped as well when you operate control lever
(2) backward while pressing clamp open button (1).
8-2
INDEX 7
17
9-1
INDEX
INDEX
<A> OIL AND GREASING CHART (OIL, GREASE
ABOUT THIS MANUAL -------------------------------------1-2 LOCATIONS AND INSPECTION AND MAINTENANCE
ADJUSTING POSITION OF STEERING WHEEL ----- 3-30 INTERVALS) ------------------------------------------- 4-15
APPLICABLE MODEL AND SERIAL No. ----------------1-5 OIL AND GREASING CHART (OIL, GREASE
ATTACHMENT -----------------------------------------------7-2 LOCATIONS AND INSPECTION
AND MAINTENANCE INTERVALS)
(FOR EU) ----------------------------------------------- 4-16
<B>
BASIC PRECAUTIONS -------------------------------------2-9
BATTERY CHARGING ----------------------------------- 3-41 <M>
MAINTAINING LONG BATTERY LIFE ----------------- 3-48
MAINTENANCE ------------------------------------------- 4-24
<C> MOUNTING/DISMOUNTING ---------------------------- 3-23
CHARGING BY STATIONARY
BATTERY CHARGER --------------------------------- 3-41
CHECK AFTER OPERATION --------------------------- 4-11 <N>
CHECK BEFORE OPERATION ---------------------------4-2 NECESSARY INFORMATION OF LIFT TRUCK --------1-7
MEMORANDUM (To be filled by
KOMATSU FORKLIFT distributor)---------------------1-7
<E> MODEL AND SERIAL NO. LOCATION-----------------1-7
EC DECLARATION OF CONFORMITY ------------------6-2 NEUTRAL SAFETY --------------------------------------- 3-32
EXPLANATION OF COMPONENTS----------------------3-5 NORMAL RUNNING -------------------------------------- 3-34
EXPLANATION OF CONTROLS AND GAUGES -------3-5
EXPLANATION OF LIFT TRUCKS
WITH COLD-STORAGE MODEL -------------------- 3-49 <O>
OPERATION ----------------------------------------------- 3-23
OPERATION OF SIDE SHIFT -----------------------------7-2
<F> OPERATORS COMPARTMENT ------------------------ 3-22
FOR YOUR SAFETY ----------------------------------------1-3 OUTLINE OF SERVICE ---------------------------------- 4-12
SAFETY INDICATORS -----------------------------------1-4
SIGNAL WORDS ------------------------------------------1-3
FORK SPREAD ADJUSTMENT ------------------------- 3-38 <P>
FORK STOPPER ------------------------------------------ 3-22 PARKING BRAKE ALARM BUZZER (FB30) ---------- 3-38
FORWARD/REVERSE CONTROL LEVER --------------3-5 PERIODIC REPLACEMENT OF SAFETY CRITICAL
PARTS -------------------------------------------------- 4-23
PLUGGING ------------------------------------------------- 3-35
<G> PRECAUTIONS FOR INSPECTION
GENERAL VIEW ---------------------------------------------3-2 AND MAINTENANCE --------------------------------- 2-29
GENERAL VIEW OF LIFT TRUCK ------------------ 3-2,1-5
APPLICATION OF LIFT TRUCK -------------------------1-5
DIRECTION OF LIFT TRUCK ----------------------------1-5 <Q>
QUALIFICATION FOR OPERATION ---------------------1-6
<H>
HOISTING AND TRANSPORTING <R>
THE LIFT TRUCK -------------------------------------- 2-37 REPLACING BATTERY ---------------------------------- 3-46
REPLACING FUSES -------------------------------------- 4-28
AREA UNDER FLOOR PLATE ------------------------ 4-28
<I> CONTROLLER ------------------------------------------- 4-30
INSTRUMENTS AND CONTROLS -----------------------3-3 STATIONARY CHARGER------------------------------ 4-29
REPLACING LAMPS ------------------------------------- 4-32
<L> REPLACING TIRES --------------------------------------- 4-31
LIFT ---------------------------------------------------------- 3-39 TIRE FOR BATTERY-POWERED LIFT TRUCK ---- 4-31
LIFT INTERLOCK FUNCTION --------------------------- 3-39 RUNNING IN NEW LIFT TRUCK -------------------------1-6
LIFT TRUCKS WITH COLD-STORAGE MODEL ----- 3-49 MAINTENANCE FOR NEW LIFT TRUCK -------------1-6
LOAD HANDLING OPERATION ----------------- 3-39,2-24 RUNNING IN NEW LIFT TRUCK------------------------1-6
LONG-TERM STORAGE --------------------------------- 3-50
AFTER STORAGE --------------------------------------- 3-50 <S>
BEFORE STORAGE ------------------------------------ 3-50 SAFETY LABEL ---------------------------------------------2-2
DURING STORAGE ------------------------------------- 3-50 SERVICE DATA ------------------------------------------- 4-34
LUBRICANT LIST ----------------------------------------- 4-14 SERVICE DATA ----------------------------------------- 4-34
LUBRICANT LIST ---------------------------------------- 4-14 TORQUE LIST ------------------------------------------- 4-36
SINGLE ACTION WATER REFILLER ------------------ 3-22
9-2
INDEX
STARTING LIFT TRUCK OFF ---------------------------3-31

START-UP INSPECTION ---------------------------------2-16
STRUCTURE AND STABILITY OF THE LIFT TRUCK
(TO PREVENT LIFT TRUCK FROM TIPPING) ----2-38
SUITABLE OIL ---------------------------------------------4-12
<T>
TECHNICAL DATA ----------------------------------------- 5-2
TEMPORARY STOPPING AND PARKING ------------3-37
TRAVEL INTERLOCK FUNCTION (FB30) -------------3-33
TRAVELING OVER RAMPS -----------------------------3-37
TRAVELING THE LIFT TRUCK --------------------------2-17
TURNING ---------------------------------------------------3-36
<U>
UNITS OF MEASURE -------------------------------------- 1-5
USE OF GENUINE PARTS AND OILS ------------------ 1-6
<W>
WARRANTY AND SERVICE ------------------------------ 1-6
PERIODICAL EXCHANGE PARTS--------------------- 1-6
WASHING LIFT TRUCK ----------------------------------4-33
9-3
FB09 - 30-11 FORKLIFT TRUCK
Form No. TEN00568-04
©2014 KOMATSU
All Rights Reserved
Printed in Japan 04-14

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TEN00568-04

Operation & Maintenance Manual

ELECTRIC LIFT TRUCK

ABOUT THIS MANUAL 1

• Read this manual carefully and understand it fully.

FOR YOUR SAFETY 1

Example of safety message using signal word

Other signal words

REMARKS - - - - Useful information.

EXAMPLE OF VERBAL SAFETY INDICATOR

EXAMPLE OF PICTORIAL SAFETY INDICATOR

APPLICABLE MODEL AND SERIAL No. 1

Model type Serial No.

GENERAL VIEW OF LIFT TRUCK 1

APPLICATION OF LIFT TRUCK 1

DIRECTION OF LIFT TRUCK 1

QUALIFICATION FOR OPERATION 1

RUNNING IN NEW LIFT TRUCK 1

RUNNING IN NEW LIFT TRUCK 1

MAINTENANCE FOR NEW LIFT TRUCK 1

WARRANTY AND SERVICE 1

PERIODICAL EXCHANGE PARTS 1

USE OF GENUINE PARTS AND OILS 1

NECESSARY INFORMATION OF LIFT TRUCK 1

MEMORANDUM (To be filled by KOMATSU FORKLIFT distributor) 1

MODEL AND SERIAL NO. LOCATION 1

LIFT TRUCK SERIAL NO. PLATE LOCATION(1)

LIFT TRUCK EMBOSSED SERIAL NO. LOCATION(2)

CAUTIONS WHEN WORKING UNDER WORK EQUIPMENT -------------------------------------------------2-31

LIFT TRUCKS WITH COLD-STORAGE MODEL------------------------------------------------------------------------ 3-49

SAFETY OF ATTACHEMENTS ----------------------------------------------------------------------------------------- 7-3

SAFETY LABEL LOCATION CHART 2

No. Safety labels name Position

Prohibit the operators from riding on the

8 Caution when handling battery Inside of battery hood

9 Caution for explosion of gas spring (*1) Gas spring

Front right inside of overhead guard (FB30)

Take a right posture while operating lift truck

(2) Caution to avoid getting hand caught (3EB-96-25121)

(3) Caution when hoisting the lift truck (3BA-96-59131) (3BA-96-

(For EU FB30 only)

(4) Caution when closed the battery hood (3BA-96-36230) (3BB-

(5) Caution before operation (3EB-96-25721) (3EB-96-54120)

(6) Seating capacity (3EB-96-54110)

(7) Precaution when washing lift truck (3BB-96-36830) (37B-

(8) Caution when handling battery (3BB-96-36840) (09664-

(10)Avoiding danger if lift truck tips over during operations (3EB-96-32610)

IF THE LIFT TRUCK SEEMS TO TIP OVER ANY

• Only the trained and qualified persons are allowed to operate

• Plan safety work beforehand.

NEVER OPERATE THE BROKEN-DOWN LIFT TRUCK 2

• If any abnormality is detected during the start-up inspection or

monitor), report the administrator immediately and take

WEAR ADEQUATE CLOTHES AND SAFETY EQUIPMENT FOR OPERATION 2

• Avoid loose clothing and accessories. It is dangerous when they

FIRE EXTINGUISHER AND FIRST AID KIT 2

• In preparation for a fire or bodily injury, check the locations of fire

CAUTIONS FOR SAFETY-RELATED EQUIPMENT 2

• Confirm that all protective guards, covers, and mirrors are

PRACTICE SUFFICIENTLY BEFORE OPERATION 2

JUMPING ON AND OFF FROM THE LIFT TRUCK IS STRICTLY PROHIBITED 2

• Never jump on or off the lift truck. It is extremely dangerous.

KEEP THE OPERATOR'S COMPARTMENT AND PLATFORM CLEAN AND TIDY 2