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KOMATSU FH40-1 FH45-1 FH50-1 FH SERIES FORKLIFT TRUCK SERVICE MANUAL – PDF DOWNLOAD

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KOMATSU FH40-1 FH45-1 FH50-1 FH SERIES FORKLIFT TRUCK SERVICE MANUAL – PDF DOWNLOAD

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Description

KOMATSU FH40-1 FH45-1 FH50-1 FH SERIES FORKLIFT TRUCK SERVICE MANUAL – PDF DOWNLOAD

FILE DETAILS:

KOMATSU FH40-1 FH45-1 FH50-1 FH SERIES FORKLIFT TRUCK SERVICE MANUAL – PDF DOWNLOAD

Language : English
Pages : 858
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

KOMATSU FH40-1 FH45-1 FH50-1 FH SERIES FORKLIFT TRUCK SERVICE MANUAL – PDF DOWNLOAD

CONTENTS.................................................................................................................................................................  3
00 Foreword.............................................................................................................................................................. 13
	Safety notice........................................................................................................................................................ 15
	How to read the shop manual.......................................................................................................................................... 26
	Explanation of terms for maintenance standard........................................................................................................................ 28
	Handling of electric equipment and hydraulic component............................................................................................................... 30
	Handling of connectors newly used for engines........................................................................................................................ 39
	How to read electric wire code....................................................................................................................................... 42
	Precautions when carrying out operation.............................................................................................................................. 45
	Standard tightening torque table..................................................................................................................................... 48
	Conversion table..................................................................................................................................................... 52
01 General Information................................................................................................................................................... 57
	Table of Contents.................................................................................................................................................... 58
	Specifications....................................................................................................................................................... 59
		Specification dimensions drawing................................................................................................................................. 59
		Weight table..................................................................................................................................................... 61
		Lubricant list................................................................................................................................................... 62
		List of specified fuel and lubricant............................................................................................................................. 63
10 Structure, function and maintenance standard.......................................................................................................................... 65
	Table of Contents.................................................................................................................................................... 67
	Engine and cooling system............................................................................................................................................ 69
		Engine mount and transfer mount.................................................................................................................................. 69
		Cooling system................................................................................................................................................... 70
	Power train.......................................................................................................................................................... 72
		Power train...................................................................................................................................................... 72
		Power train system diagram....................................................................................................................................... 73
		PTO.............................................................................................................................................................. 74
		HST piping diagram............................................................................................................................................... 77
		HST pump......................................................................................................................................................... 78
		HST motor........................................................................................................................................................ 90
		Axle.............................................................................................................................................................100
		Differential.....................................................................................................................................................101
	Steering system......................................................................................................................................................107
		Steering piping diagram (control valve - power steering cylinder)................................................................................................107
		Orbitrol valve...................................................................................................................................................108
		Power steering cylinder..........................................................................................................................................110
	Brake system.........................................................................................................................................................111
		Brake control....................................................................................................................................................111
		Brake piping diagram (control valve - accumulator)...............................................................................................................112
		Service brake....................................................................................................................................................113
		Accumulator charge valve.........................................................................................................................................115
		Brake valve......................................................................................................................................................120
		Slack adjuster...................................................................................................................................................123
		Accumulator (for brake)..........................................................................................................................................127
		Parking brake....................................................................................................................................................128
	Undercarriage and frame..............................................................................................................................................129
		Rear axle........................................................................................................................................................129
		Hydraulic tank piping diagram....................................................................................................................................130
		Frame............................................................................................................................................................131
	Hydraulic system.....................................................................................................................................................132
		Control valve piping diagram (tank - control valve)..............................................................................................................132
		Work equipment piping diagram (control valve - tilt cylinder/lift cylinder)......................................................................................133
		Attachment piping diagram........................................................................................................................................134
		Work equipment control lever linkage.............................................................................................................................135
		Work equipment and steering pump.................................................................................................................................136
		Control valve....................................................................................................................................................144
		CLSS.............................................................................................................................................................150
		Each function and operation of each valve........................................................................................................................152
	Work equipment.......................................................................................................................................................167
		Tilt cylinder....................................................................................................................................................167
	Electrical system....................................................................................................................................................168
		Electrical control system........................................................................................................................................168
		HST controller...................................................................................................................................................190
		Engine controller................................................................................................................................................192
		Accelerator pedal sensor.........................................................................................................................................194
		EPACS controller.................................................................................................................................................195
		Instrument panel.................................................................................................................................................197
		Pilot box........................................................................................................................................................199
		DC/DC converter..................................................................................................................................................200
		KOMTRAX system...................................................................................................................................................201
		Sensor...........................................................................................................................................................204
		Combination switch...............................................................................................................................................214
		Seat switch......................................................................................................................................................215
		Service switch/Preheater lamp....................................................................................................................................216
		Flasher unit.....................................................................................................................................................217
		Relay box........................................................................................................................................................218
		Relay............................................................................................................................................................219
20 Standard value table..................................................................................................................................................221
	Standard value table.................................................................................................................................................223
30 Testing and adjusting.................................................................................................................................................225
	Table of Contents....................................................................................................................................................226
	Testing and adjusting................................................................................................................................................227
		Check of failure code of engine controller.......................................................................................................................227
		Displaying, setting, checking by using HST controller............................................................................................................230
		Travel speed control function for general operator...............................................................................................................232
		Setting controlled travel speed..................................................................................................................................233
		Maximum travel speed control function............................................................................................................................235
		Banning function of changing controlled travel speed.............................................................................................................238
		Electrical-system abnormality record display function............................................................................................................240
		Mechanical-system abnormality record display function............................................................................................................246
		Adjusting function...............................................................................................................................................247
		Memory clear function............................................................................................................................................254
		Automatic engine stop set interval changing function.............................................................................................................257
		Releasing pressure from hydraulic piping.........................................................................................................................259
		Replacement of engine oil and engine oil filter..................................................................................................................260
		Replacement of fuel filter.......................................................................................................................................262
		Fuel pre-filter water drain......................................................................................................................................264
		Fuel filter air bleeding.........................................................................................................................................265
		Radiator cleaning................................................................................................................................................266
		Air cleaner inspection and element replacement...................................................................................................................267
		Testing and adjusting engine speed...............................................................................................................................268
		Testing and adjusting HST oil pressure...........................................................................................................................270
		Testing work equipment and steering pump oil pressure............................................................................................................273
		Oil level check and changing oil in differential case............................................................................................................274
		Changing PTO oil and cleaning strainer...........................................................................................................................275
		Inspection of hydraulic tank.....................................................................................................................................276
		Measuring brake performance......................................................................................................................................278
		Measurement of wear of service brake disc........................................................................................................................279
		Checking parking brake...........................................................................................................................................280
		Bleeding air.....................................................................................................................................................281
		Adjusting brake pedal............................................................................................................................................282
		Testing and adjusting brake pedal angle sensor linkage...........................................................................................................283
		Initial setting of Orbitrol valve................................................................................................................................285
		Measurement of hydraulic drift and forward tilt down by hydraulic drift of cylinder..............................................................................286
		Lamp display of KOMTRAX terminal.................................................................................................................................287
		KOMTRAX terminal start-up procedure..............................................................................................................................290
40 Troubleshooting.......................................................................................................................................................295
	Table of Contents....................................................................................................................................................296
	Information related to troubleshooting...............................................................................................................................299
		Points to remember when troubleshooting..........................................................................................................................299
		How to proceed in troubleshooting................................................................................................................................300
		Checks before troubleshooting....................................................................................................................................301
		Classification and procedures of troubleshooting.................................................................................................................302
		Phenomena seemed to be failures and troubleshooting Nos..........................................................................................................303
		Information described in troubleshooting table...................................................................................................................306
		Locations of fuses...............................................................................................................................................311
		Connection table for connector pin numbers.......................................................................................................................314
		T-branch box and T-branch adapter table..........................................................................................................................354
	Troubleshooting by failure code (HST controller system)..............................................................................................................357
		Failure code list................................................................................................................................................357
		Failure code [--/AB00MA] Alternator: Malfunction.................................................................................................................360
		Failure code [--/B@CRNS] HST Oil: Overheating....................................................................................................................361
		Failure code [--/2G40ZG] Brake accumulator: Dropped hydraulic pressure...........................................................................................362
		Failure code [--/6091NX] HST oil filter: Clogging................................................................................................................363
		Failure code [12/DDK6KA] FNR lever: Open circuit.................................................................................................................364
		Failure code [12/DDK6KY] FNR lever: Hot short circuit............................................................................................................366
		Failure code [14/DLT4KZ] Travel speed sensor A: Open circuit, ground fault, or hot short circuit.................................................................368
		Failure code [14/DLT6KZ] Travel speed sensor B: Open circuit, ground fault, or hot short circuit.................................................................370
		Failure code [14/DLT4KZ+DLT6KZ] Travel speed sensors A and B: Open circuit, ground fault, or hot short circuit...................................................372
		Failure code [14/DLT4MA] Travel speed sensors A and B: Malfunction...............................................................................................374
		Failure code [14/DLT4LC] Travel speed sensors A and B: Mismatch of rotation speed signals........................................................................375
		Failure code [15/7REXKA] Seat switch: Open circuit...............................................................................................................376
		Failure code [15/7REXKB] Seat switch: Ground fault...............................................................................................................378
		Failure code [18/D5ZTKZ] Pump EPC valve ground return signal: Open circuit or hot short circuit..................................................................380
		Failure code [22/DHHBKX] HST pump A-port pressure sensor: Open circuit or ground fault...........................................................................382
		Failure code [22/DHHBKY] HST pump A-port pressure sensor: Hot short circuit......................................................................................384
		Failure code [23/DHHCKX] HST pump B-port pressure sensor: Open circuit or ground fault...........................................................................386
		Failure code [23/DHHCKY] HST pump B-port pressure sensor: Hot short circuit......................................................................................388
		Failure code [25/DK70KZ] Brake pedal angle sensor: Open circuit or ground fault..................................................................................390
		Failure code [25/DK70KY] Brake pedal angle sensor: Hot short circuit.............................................................................................392
		Failure code [26/DGS1KA] HST oil temperature sensor: Open circuit................................................................................................394
		Failure code [26/DGS1KB] HST oil temperature sensor: Ground fault................................................................................................396
		Failure code [27/AB00KZ] Alternator R signal circuit: Open circuit or ground fault...............................................................................398
		Failure code [27/AB00KY] Alternator R signal circuit: Hot short circuit..........................................................................................400
		Failure code [28/DHPCKZ] Lift cylinder pressure sensor: Open circuit or ground fault.............................................................................402
		Failure code [28/DHPCKY] Lift cylinder pressure sensor: Hot short circuit........................................................................................404
		Failure code [29/DH2FKZ] Brake charge pressure sensor: Open circuit or ground fault..............................................................................406
		Failure code [29/DH2FKY] Brake charge pressure sensor: Hot short circuit.........................................................................................408
		Failure code [32/DXATKA] HST pump forward travel EPC solenoid valve: Open circuit................................................................................410
		Failure code [32/DXATKB] HST pump forward travel EPC solenoid valve: Ground fault................................................................................412
		Failure code [32/DXATKY] HST pump forward travel EPC solenoid valve: Hot short circuit...........................................................................414
		Failure code [33/DXAUKA] HST pump reverse travel EPC solenoid valve: Open circuit................................................................................416
		Failure code [33/DXAUKB] HST pump reverse travel EPC solenoid valve: Ground fault................................................................................418
		Failure code [33/DXAUKY] HST pump reverse travel EPC solenoid valve: Hot short circuit...........................................................................420
		Failure code [34/DXAVKA] HST motor EPC solenoid valve: Open circuit..............................................................................................422
		Failure code [34/DXAVKB] HST motor EPC solenoid valve: Ground fault..............................................................................................424
		Failure code [34/DXAVKY] HST motor EPC solenoid valve: Hot short circuit.........................................................................................426
		Failure code [35/D110KZ] HST controller power relay: Open circuit or hot short circuit...........................................................................428
		Failure code [35/D110KB] HST controller power relay: Ground fault................................................................................................430
		Failure code [37/DW9NKA] Work equipment lock solenoid valve: Open circuit........................................................................................432
		Failure code [37/DW9NKB] Work equipment lock solenoid valve: Ground fault........................................................................................434
		Failure code [37/DW9NKY] Work equipment lock solenoid valve: Hot short circuit...................................................................................436
		Failure code [38/DW9MKA] Lift lock solenoid valve: Open circuit..................................................................................................438
		Failure code [38/DW9MKB] Lift lock solenoid valve: Ground fault..................................................................................................440
		Failure code [38/DW9MKY] Lift lock solenoid valve: Hot short circuit.............................................................................................442
		Failure code [39/D140KB] Starter relay: Ground fault.............................................................................................................444
		Failure code [39/D140KY] Starter relay: Hot short circuit........................................................................................................446
		Failure code [47/D161KA] Backup buzzer and backup lamp relay: Open circuit.......................................................................................448
		Failure code [47/D161KB] Backup buzzer and backup lamp relay: Ground fault.......................................................................................450
		Failure code [47/D161KY] Backup buzzer and backup lamp relay: Hot short circuit..................................................................................452
		Failure code [48/DV00KB] Warning buzzer: Ground fault............................................................................................................454
		Failure code [48/DV00KY] Warning buzzer: Hot short circuit.......................................................................................................456
		Failure code [49/D19UKA] Pump EPC valve ground cutout relay: Open circuit........................................................................................458
		Failure code [49/D19UKB] Pump EPC valve ground cutout replay: Ground fault.......................................................................................460
		Failure code [49/D19UKY] Pump EPC valve ground cutout relay: Hot short circuit...................................................................................462
		Failure code [52/DAJ0KK] HST controller: Drop of power voltage...................................................................................................464
		Failure code [53/DAJ2KK] HST controller: Drop of load power supply voltage.......................................................................................466
		Failure code [54/7REHKA] Accessory input circuit 2 (KEY_ACC_SIGNAL): Open circuit................................................................................468
		Failure code [55/DAJ5KX] HST controller sensor 5 V-power supply: Ground fault or hot short circuit...............................................................470
		Failure code [56/7REAKA] Accessory input circuit 1 (KEY_SIGNAL): Open circuit....................................................................................472
		Failure code [62/DB2RKR] CAN communication (between HST controller and engine controller): Communication failure (Component system failure)......................474
		Failure code [63/DAJ000] HST Controller: Memory error............................................................................................................476
		Failure code [63/DAJ0KT] HST Controller: Memory error............................................................................................................476
	Troubleshooting by failure code (EPACS controller system)............................................................................................................477
		Display of EPACS controller failure code.........................................................................................................................477
		Failure code [LED: OFF] EPACS controller abnormality.............................................................................................................478
		Failure code [LED: 1 flashing] Initialization is not completed...................................................................................................479
		Failure code [LED: 2 flashings] Controller is being initialized..................................................................................................480
		Failure code [LED: 3 flashings] Steering wheel angle sensor abnormality..........................................................................................481
		Failure code [LED: 4 flashings] Tire angle sensor abnormality....................................................................................................482
	Troubleshooting for electrical system (E-mode).......................................................................................................................484
		Information described in troubleshooting table...................................................................................................................484
		E-1 Engine does not start........................................................................................................................................485
		E-2 Engine preheater does not operate............................................................................................................................490
		E-3 Parking brake reminder alarm does not sound or does not stop sounding........................................................................................492
		E-4 EPACS is abnormal............................................................................................................................................494
		E-5 Headlamp, clearance lamp, tail lamp and license plate lamp do not light up or go off.........................................................................497
		E-6 Turn signal lamps do not light up or go off..................................................................................................................503
		E-7 Brake lamps do not light up or go off........................................................................................................................506
		E-8 Backup lamps do not light up or go off.......................................................................................................................508
		E-9 Backup buzzer does not sound or does not stop sounding.......................................................................................................510
		E-10 Horn does not sound or does not stop sounding...............................................................................................................512
		E-11 Fuel level is not displayed normally........................................................................................................................514
		E-12 Engine coolant temperature level is not displayed normally..................................................................................................516
		E-13 All of indicator and warning lamps of instrument panel do not light up when starting switch is turned to the ON position....................................518
		E-14 When starting switch is turned to the ON position, all of indicator and warning lamps of pilot box do not light up..........................................525
		E-15 When starting switch is turned to the ON position, preheater lamp does not light up.........................................................................530
		E-16 When starting switch is turned to the ON position, alarm buzzer does not sound..............................................................................532
		E-17 ยฑ Backup lamp of instrument panel does not light up.........................................................................................................534
		E-18 Charge warning lamp lights up while engine is running.......................................................................................................536
		E-19 HST oil temperature warning lamp lights up while engine is running..........................................................................................538
		E-20 HST oil filter clogging warning lamp lights up while engine is running......................................................................................539
		E-21 Engine oil pressure warning lamp lights up while engine is running..........................................................................................540
		E-22 Sedimenter (water separator) warning lamp lights up while engine is running.................................................................................541
		E-23 Abnormality warning lamp lights up while engine is running..................................................................................................542
		E-24 Engine abnormality warning lamp lights up while engine is running...........................................................................................544
		E-25 Travel speed restriction cannot be released or enabled......................................................................................................545
		E-26 Impossible to select HST controller failure display mode, HST controller adjustment mode, speed limit setting mode, or engine stop time auto-change mode....547
		E-27 ยฑ KOMTRAX system does not operate normally..................................................................................................................550
	Troubleshooting for hydraulic and mechanical system (H-mode).........................................................................................................552
		How to use troubleshooting table.................................................................................................................................552
		Hydraulic and mechanical system diagram..........................................................................................................................554
		Table of failure modes and causes................................................................................................................................556
		H-1 Lift truck cannot travel.....................................................................................................................................560
		H-2 Slow travel speed............................................................................................................................................561
		H-3 Insufficient towing force....................................................................................................................................562
		H-4 Engine stops during traveling, or engine speed drops excessively.............................................................................................563
		H-5 HST (hydraulic) oil temperature is too high..................................................................................................................564
		H-6 Impossible steering..........................................................................................................................................565
		H-7 Response is low during turning...............................................................................................................................566
		H-8 Steering is heavy............................................................................................................................................567
		H-9 Unstable during turning......................................................................................................................................568
		H-10 When steering wheel is released it does not return to neutral or it rotates by itself.......................................................................569
		H-11 Steering wheel is turned in reverse or it kicks (while work equipment is operated)..........................................................................569
		H-12 Large shock is made when steering wheel is returned.........................................................................................................570
		H-13 EPACS does not work.........................................................................................................................................571
		H-14 Steering wheel vibrates.....................................................................................................................................572
		H-15 Steering system makes abnormal sound........................................................................................................................572
		H-16 Oil leaks from steering circuit.............................................................................................................................572
		H-17 Service brake does not work or its performance is low.......................................................................................................573
		H-18 Service brake is not reset or it drags......................................................................................................................574
		H-19 Parking brake does not work or its performance is low.......................................................................................................575
		H-20 Parking brake is not reset or it drags......................................................................................................................576
		H-21 Abnormal noise around the work equipment or steering pump...................................................................................................577
		H-22 Engine speed drops excessively or stops during work equipment operation or wheel steering...................................................................578
		H-23 Fine control performance of entire work equipment is low or response is low.................................................................................579
		H-24 Work equipment cannot be locked (and the equipment operates when operator leaves)...........................................................................580
		H-25 Control valve lever does not move smoothly and it is heavy..................................................................................................581
		H-26 Lift cylinder and fork do not lift..........................................................................................................................582
		H-27 Lifting speed or power of lift cylinder and fork is insufficient............................................................................................583
		H-28 Forklift speed lowers at specific height....................................................................................................................584
		H-29 Lift cylinder natural drift is large........................................................................................................................585
		H-30 Lift cylinders do not come down.............................................................................................................................586
		H-31 Fork lowering speed is low or high or fine control performance is low or response is low....................................................................587
		H-32 Mast does not tilt forward or backward......................................................................................................................588
		H-33 Forward/backward tilting speed or force of mast is insufficient.............................................................................................589
		H-34 Tilting speed lowers halfway................................................................................................................................590
		H-35 Tilt cylinder natural forward drift is large................................................................................................................591
		H-36 Mast is unstable during travel with load....................................................................................................................592
		H-37 Work equipment is heavy when work equipment and steering are operated simultaneously........................................................................593
		H-38 Steering is heavy when work equipment and steering are operated simultaneously..............................................................................594
50 Disassembly and assembly..............................................................................................................................................595
	Table of Contents....................................................................................................................................................596
	Related information on disassembly and assembly......................................................................................................................597
		How to read this manual..........................................................................................................................................597
		Coating materials list...........................................................................................................................................598
		Special tools list...............................................................................................................................................601
		How to use Loctite...............................................................................................................................................603
	Engine and cooling system............................................................................................................................................604
		Removal and installation of fuel supply pump assembly............................................................................................................604
		Removal and installation of fuel injector assembly...............................................................................................................608
		Removal and installation of cylinder head assembly...............................................................................................................612
		Removal and installation of radiator assembly....................................................................................................................623
		Removal and installation of aftercooler assembly.................................................................................................................625
		Removal and installation of oil cooler assembly..................................................................................................................628
		Removal and installation of engine and pump assembly.............................................................................................................629
		Removal and installation of starting motor assembly..............................................................................................................637
	Power train..........................................................................................................................................................640
		Removal and installation of front axle and HST motor assembly....................................................................................................640
		Disassembly and assembly of front axle assembly..................................................................................................................643
		Removal and installation of PTO assembly.........................................................................................................................644
		Disassembly and assembly of PTO assembly.........................................................................................................................645
		Disassembly and assembly of differential assembly................................................................................................................648
		Disassembly and assembly of axle housing assembly................................................................................................................661
		Disassembly and assembly of parking brake assembly...............................................................................................................668
		Disassembly and assembly of rear axle assembly...................................................................................................................669
		Disassembly and assembly of power steering cylinder assembly.....................................................................................................672
		Disassembly and assembly of brake pedal assembly.................................................................................................................674
	Undercarriage and frame..............................................................................................................................................675
		Removal and installation of counterweight assembly...............................................................................................................675
		Removal and installation of head guard assembly..................................................................................................................677
		Removal and installation of hood assembly........................................................................................................................681
	Hydraulic system.....................................................................................................................................................683
		Removal and installation of HST pump assembly....................................................................................................................683
		Removal and installation of HST motor assembly...................................................................................................................687
		Removal and installation of work equipment and steering pump assembly............................................................................................688
		Removal and installation of control valve assembly...............................................................................................................690
		Disassembly and assembly of control valve assembly...............................................................................................................692
		Disassembly and assembly of orbitrol valve assembly..............................................................................................................698
		Disassembly and assembly of tilt cylinder assembly...............................................................................................................705
	Electrical system....................................................................................................................................................710
		Removal and installation of engine controller assembly...........................................................................................................710
		Removal and installation of HST controller assembly..............................................................................................................712
		Removal and installation of KOMTRAX terminal assembly............................................................................................................713
		Disassembly and assembly of combination switch assembly..........................................................................................................714
80 Yearly inspection criteria............................................................................................................................................715
	Yearly inspection criteria...........................................................................................................................................717
90 Circuit diagrams......................................................................................................................................................737
	Hydraulic Circuit Diagram............................................................................................................................................739
	Electric circuit diagram (1/4).......................................................................................................................................741
	Electric circuit diagram (2/4).......................................................................................................................................743
	Electric circuit diagram (3/4).......................................................................................................................................745
	Electric circuit diagram (4/4).......................................................................................................................................747
	Connector list and layout............................................................................................................................................749
100 Masts & Work Equipment...............................................................................................................................................751
	80D/100D/110D-MS 2-STAGE MASTS.......................................................................................................................................753
		INTRODUCTION.....................................................................................................................................................754
		INSTALLATION INSTRUCTIONS........................................................................................................................................755
		PERIODIC MAINTENANCE.............................................................................................................................................760
		TROUBLESHOOTING..................................................................................................................................................761
		SERVICE..........................................................................................................................................................762
	80D/100D/110D-MT 3-STAGE MASTS.......................................................................................................................................781
		INTRODUCTION.....................................................................................................................................................782
		INSTALLATION INSTRUCTIONS........................................................................................................................................783
		PERIODIC MAINTENANCE.............................................................................................................................................798
		TROUBLESHOOTING..................................................................................................................................................799
		SERVICE..........................................................................................................................................................800
	D-SERIES SIDESHIFTER.................................................................................................................................................827
	E-SERIES SIDESHIFTER.................................................................................................................................................843

DESCRIPTION:

KOMATSU FH40-1 FH45-1 FH50-1 FH SERIES FORKLIFT TRUCK SERVICE MANUAL – PDF DOWNLOAD

General precautions
1) Before carrying out any greasing or repairs, read all the safety labels stuck to the lift truck. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
A. Always wear safety glasses when hitting parts with a hammer.
B. Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator’s compartment.
5) Only qualified workers must carry out work and operation which require license or qualification.
6) Keep all tools in good condition. Learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, lift truck, service car, etc.
7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
8) Before starting work, warm up your body thoroughly to start work under good condition.
9) Avoid working continuously for long hours and take rests at proper intervals to keep the good condition. Take rests in a fixed safe place

S.S 31/12/24

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