Komatsu FD60 70 80-10 Forklift Truck Operation & Maintenance Manual TEN00721-06 – PDF DOWNLOAD

Description

Komatsu FD60 70 80-10 Forklift Truck Operation & Maintenance Manual TEN00721-06 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu FD60 70 80-10 Forklift Truck Operation & Maintenance Manual TEN00721-06 – PDF DOWNLOAD

FOREWORD:
1.1 ABOUT THIS MANUAL:

• This manual describes procedures for proper operation, inspection, and maintenance of this lift truck, and rules
  you must follow for your safety.
• Most accidents are caused by a failure to follow fundamental safety precautions
  for the operation, inspection, and maintenance of lift trucks. Also, knowing the possible hazards in advance will
  help to avoid accidents

TABLE OF CONTENTS:

Komatsu FD60 70 80-10 Forklift Truck Operation & Maintenance Manual TEN00721-06 – PDF DOWNLOAD

COVER 1
CONTENTS 13
FOREWORD 2
1 FOREWORD 3
1 1 ABOUT THIS MANUAL 3
1 2 ENGINE MOUNTED ON THIS LIFT TRUCK 4
1 2 1 EXHAUST GAS CONTROL 4
1 2 2 CERTIFICATION LABEL AFFIXED POSITION 4
1 3 FOR YOUR SAFETY 5
1 3 1 SIGNAL WORDS 5
1 3 2 SAFETY INDICATORS 6
1 4 APPLICABLE MODEL AND SERIAL NO 8
1 5 GENERAL VIEW OF LIFT TRUCK 8
1 5 1 APPLICATION OF LIFT TRUCK 8
1 5 2 DIRECTION OF LIFT TRUCK 8
1 6 UNITS OF MEASURE 8
1 7 QUALIFICATIONS FOR OPERATION 9
1 8 RUNNING IN NEW LIFT TRUCK 9
1 8 1 RUNNING IN NEW LIFT TRUCK 9
1 8 2 MAINTENANCE FOR NEW LIFT TRUCK 9
1 9 WARRANTY AND SERVICE 10
1 9 1 PERIODICAL EXCHANGE PARTS 10
1 9 2 USE OF GENUINE KOMATSU PARTS AND OILS 10
1 9 3 ENGINE MOUNTED ON THIS LIFT TRUCK 10
1 10 NECESSARY INFORMATION OF LIFT TRUCK 11
1 10 1 MEMORANDUM (TO BE FILLED BY KOMATSU FORKLIFT DISTRIBUTOR) 11
1 10 2 MODEL AND SERIAL NO PLATE LOCATION 11
1 10 3 ENGINE SERIAL NO PLATE OR STAMPING LOCATION 12
1 10 4 HOUR METER LOCATION 12
SAFETY 18
2 SAFETY 19
2 1 SAFETY LABEL 19
2 1 1 SAFETY LABEL LOCATION CHART 19
2 1 2 SAFETY LABEL 21
2 2 BASIC PRECAUTIONS 27
2 2 1 FOLLOW RULES 27
2 2 2 NEVER OPERATE THE BROKEN-DOWN LIFT TRUCK 27
2 2 3 WEAR ADEQUATE CLOTHES AND SAFETY EQUIPMENT FOR OPERATION 28
2 2 4 FIRE EXTINGUISHER AND FIRST AID KIT 28
2 2 5 CAUTIONS FOR SAFETY-RELATED EQUIPMENT 28
2 2 6 PRACTICE SUFFICIENTLY BEFORE OPERATION 28
2 2 7 JUMPING ON AND OFF FROM THE LIFT TRUCK IS STRICTLY PROHIBITED 29
2 2 8 KEEP THE OPERATOR’S COMPARTMENT AND PLATFORM CLEAN AND TIDY 29
2 2 9 CAUTION WHEN WASHING LIFT TRUCK 29
2 2 10 TO AVOID BURN INJURY 30
2 2 11 FIRE PREVENTION 30
2 2 12 IF A FIRE BREAKS OUT 31
2 2 13 INSTALLATION OF FIRE EXTINGUISHER(IF EQUIPPED) 31
2 2 14 DO NOT MODIFY THE LIFT TRUCK 32
2 2 15 DO NOT REMOVE THE OVERHEAD GUARD AND LOAD BACKREST 32
2 2 16 SECURE SAFETY AT THE WORKING AREA 32
2 2 17 ENGINE EXHAUST GAS IS POISONOUS 33
2 2 18 PRECAUTIONS RELATED TO SPECIAL ENVIRONMENT 33
2 2 19 ASBESTOS CAUTION 33
2 2 20 WINDOW WASHER CAUTION 33
2 3 BEFORE STARTING OPERATION 34
2 3 1 START-UP INSPECTION 34
2 3 2 INSPECTION AND ADJUSTMENT BEFORE STARTING ENGINE CHECK THE FOLLOWING BEFORE STARTING THE ENGINE 34
2 3 3 START-UP INSPECTION 35
2 4 TRAVELLING THE LIFT TRUCK 36
2 4 1 PREPARATION BEFORE TRAVELLING THE LIFT TRUCK 36
2 4 2 WHILE TRAVELING THE LIFT TRUCK 37
2 4 3 STOPPING AND PARKING 43
2 4 4 TOWING 44
2 5 LOAD HANDLING OPERATION 45
2 6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 50
2 6 1 BE SURE TO PERFORM THE START-UP INSPECTION AND THE PERIODIC VOLUNTARY INSPECTION 50
2 6 2 PUT UP A WARNING SIGN DURING INSPECTION AND MAINTENANCE 50
2 6 3 KEEP THE WORKING AREA CLEAN AND TIDY 50
2 6 4 PRECAUTIONS BEFORE INSPECTION AND MAINTENANCE 51
2 6 5 KEEP UNAUTHORIZED PEOPLE OFF 51
2 6 6 USE OF RIGHT TOOLS AND EQUIPMENT 51
2 6 7 CAUTIONS WHEN WORKING UNDER WORK EQUIPMENT 51
2 6 8 AVOID GETTING CAUGHT UP BY THE MAST OR FALLING OFF 52
2 6 9 BE CAREFUL OF BOILING COOLANT 52
2 6 10 BE CAREFUL OF HIGH PRESSURE OIL 53
2 6 11 BEWARE OF ROTATING COOLING FAN AND BELT 53
2 6 12 PRECAUTIONS FOR INSTALLING RADIO CONTROL SYSTEM 53
2 6 13 CAUTION WHEN REPAIRING THE ELECTRICAL SYSTEM 53
2 6 14 CAUTIONS FOR USING COMPRESSED AIR FOR CLEANING 54
2 6 15 CAUTIONS WHEN REPLACING THE SEAT 54
2 6 16 CAUTION WHEN HANDLING BATTERY 54
2 6 17 STRICTLY FOLLOW THE INSTRUCTIONS SHOWN BELOW TO AVOID GENERATION OF SPARKS 54
2 6 18 CAUTION WHEN CHARGING A BATTERY 55
2 6 19 CAUTION WHEN HANDLING TIRES 55
2 6 20 CAUTION IN WASTE DISPOSAL 56
2 6 21 CAUTION AFTER INSPECTION AND REPAIR 56
2 6 22 PERIODIC INSPECTION OF SAFETY CRITICAL PARTS 56
2 7 HOISTING AND TRANSPORTING THE LIFT TRUCK 57
2 7 1 CAUTION WHEN HOISTING THE LIFT TRUCK 57
2 7 2 CAUTIONS FOR LOADING AND UNLOADING THE LIFT TRUCK 58
2 8 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING) 59
2 8 1 LONGITUDINAL STABILITY 59
2 8 2 CENTER OF GRAVITY OF A LOAD 59
2 8 3 COMBINED CENTER OF GRAVITY AND STABILITY ON THE LOADED LIFT TRUCK 60
2 8 4 ACTUAL CAPACITY 60
2 8 5 SERIAL NO PLATE AND LOAD TABLE 61
2 8 6 INTRODUCTION OF OPTIONAL SAFETY AUXILIARY DEVICE 62
2 9 TOWING 63
OPERATION 64
3 OPERATION 65
3 1 GENERAL VIEW 65
3 1 1 GENERAL VIEW OF LIFT TRUCK 65
3 1 2 INSTRUMENTS AND CONTROLS 66
3 2 EXPLANATION OF COMPONENTS 68
3 2 1 METER PANEL 68
3 2 2 OPERATING DEVICES 74
3 2 3 REMOVING AND INSTALLATION OF ATTACHMENTS 79
3 3 OPERATION 83
3 3 1 START-UP INSPECTION 83
3 3 2 MOUNTING/DISMOUNTING AND OPERATING POSTURE ADJUSTMENT 83
3 3 3 STARTING ENGINE, STARTING, GEAR SHIFTING, AND TRAVELING 90
3 3 4 STARTING AND STOPPING ON SLOPE 94
3 3 5 INCHING TRAVEL 95
3 3 6 TURNING 95
3 3 7 OPERATION ON SNOWY AND FROZEN ROADS 96
3 3 8 TEMPORARY STOPPING, PARKING AND STOPPING 96
3 3 9 LOAD HANDLING OPERATION 98
3 3 10 CHECKING AFTER OPERATION 101
INSPECTION AND MAINTENANCE 102
4 INSPECTION AND MAINTENANCE 103
4 1 INSPECTION AND MAINTENANCE 103
4 2 START-UP INSPECTION 103
4 2 1 CHECKING ABNORMALITIES DETECTED ON THE PREVIOUS DAY 105
4 2 2 WALK AROUND A LIFT TRUCK 105
4 2 3 INSPECTION BY OPENING COVER AND HOOD 108
4 2 4 CHECKING FROM THE OPERATOR SEAT 113
4 2 5 CHECK BY SETTING THE STARTING SWITCH TO [ | ] (ON) POSITION 115
4 2 6 CHECKING WITH THE ENGINE STARTED 118
4 2 7 CHECKING THE BRAKE ACCUMULATOR 119
4 2 8 CHECKING WHILE TRAVELING SLOWLY 120
4 2 9 CHECKING BY OPERATING THE WORK EQUIPMENT LEVER 120
4 2 10 CHECKING OF SAFETY FUNCTION 122
4 2 11 CHECKING OF SAFETY AUXILIARY FUNCTION 124
4 3 CHECKING AND REPORTING AFTER OPERATION 125
4 4 SIMPLE MAINTENANCE 126
4 4 1 GREASES AND FUEL 126
4 4 2 AIR CLEANER ELEMENT CLEANING 134
4 4 3 FUEL FILTER AIR BLEEDING 136
4 4 4 FUEL FILTER AIR BLEEDING (*REF) 137
4 4 5 REPLACING TIRES 138
4 4 6 TYPE OF REFRIGERANT GAS 139
4 4 7 ADJUSTING PARKING BRAKE LEVER OPERATING EFFORT 140
4 4 8 REPLACING FUSE 141
4 4 9 REPLACING BULBS 145
4 4 10 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER 146
4 4 11 CHECKING FOR HARDENING OF ENGINE CONTROLLER MOUNT RUBBER AND LOOSEN MOUNTING 147
4 5 PROCEDURE FOR A DOWN BATTERY 148
4 6 RUNNING IN COLD WEATHER 150
4 7 PROCEDURE WITH OVERHEATED ENGINE 152
4 8 OPERATING LIFT TRUCKS IN SPECIAL ENVIRONMENT OR IN FORCIBLE WAY 154
4 9 ACTION TO TAKE IF THE FORK FAILS TO LOWER 155
4 10 WASHING LIFT TRUCKS 156
4 11 LONG-TERM STORAGE 157
4 12 HOISTING LIFT TRUCK 158
4 13 LOADING AND UNLOADING OF LIFT TRUCK 159
4 14 INSPECTION AND MAINTENANCE SCHEDULE CHART 160
4 15 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 166
4 16 SERVICE DATA 167
TECHNICAL DATA 170
5 TECHNICAL DATA 171
EMISSION CONTROL WARRANTY STATEMENT 174
6 EMISSION CONTROL WARRANTY 175
EC DECLARATION OF CONFORMITY 180
7 EC DECLARATION OF CONFORMITY 181
7 1 EC DECLARATION OF CONFORMITY(FD60-80-10) 181
7 2 TIE-DOWN POSITIONS OF LIFT TRUCK 181
ATTACHMENT 182
8 ATTACHMENT 183
8 1 OPERATION OF SIDE SHIFT 183
8 1 1 ATTACHMENT MODEL PLATE LOCATION, SERIAL NO 183
8 1 2 SAFETY OF ATTACHEMENTS 184
8 1 3 SAFETY LABEL 185
8 1 4 FEATURES OF ATTACHMENTS 187
8 1 5 GENERAL VIEW 188
8 1 6 EXPLANATION OF COMPONENTS 189
8 1 7 OPERATION 191
8 1 8 INSPECTION AND MAINTENANCE SCHEDULE CHART 193
8 1 9 MAINTENANCE WORK 194
OPTIONS 196
9 OPTIONS 197
9 1 OPERATION OF FULLY AUTOMATIC TRANSMISSION 197
9 1 1 GENERAL VIEW 197
9 1 2 EXPLANATION OF COMPONENTS 198
9 2 HANDLING CLAMP OPEN GUARD 200
INDEX 202
INDEX 203

Customer Support: [email protected]

PLEASE NOTE:

• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
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