Komatsu FH100-1 FH120-1 FH135-1 FH160-1 Forklift Truck Operation & Maintenance Manual PEN00925-03 – PDF DOWNLOAD

Description

Komatsu FH100-1 FH120-1 FH135-1 FH160-1 Forklift Truck Operation & Maintenance Manual PEN00925-03 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu FH100-1 FH120-1 FH135-1 FH160-1 Forklift Truck Operation & Maintenance Manual PEN00925-03 – PDF DOWNLOAD

SERIAL NUMBERS:
FH100-7001 以降
FH120-7001 以降
FH135-7001 以降
FH160-7001 以降

READ THIS MANUAL:

• This manual gives details of the operation and methods of inspection and maintenance for this forklift truck that
  must be observed in order to use the forklift truck safely. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of forklift trucks.
• Read, understand and follow all precautions and warnings in this manual and on the forklift truck before performing
  operation and maintenance. Failure to follow these instructions will result in property damage or serious
  personal injury or death.
  Komatsu cannot predict every circumstance that might involve a potential hazard when the forklift truck is used.
• Therefore, the safety messages in this manual and on the forklift truck may not include all possible safety precautions.
• If you perform any operation, inspection, or maintenance under conditions that are not described in this manual,
  understand that it is your responsibility to take the necessary precautions to ensure safety.
• If you transfer this forklift truck to others, be sure to attach this manual.
  Always keep this Operation and Maintenance Manual in the storing location so that all relevant personnel can
  read it at any time.

TABLE OF CONTENTS:

Komatsu FH100-1 FH120-1 FH135-1 FH160-1 Forklift Truck Operation & Maintenance Manual PEN00925-03 – PDF DOWNLOAD

FOREWORD 1-1
READ THIS MANUAL 1-7
SAFETY INFORMATION 1-8
ENGINE MOUNTED ON THIS FORKLIFT TRUCK 1-9
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION 1-9
GENERAL VIEW OF FORKLIFT TRUCK 1-10
MAIN USE OF FORKLIFT TRUCK 1-10
DIRECTIONS OF FORKLIFT TRUCK 1-10
LICENSE FOR OPERATION, TESTING AND MAINTENANCE 1-11
HANDLE NEW FORKLIFT TRUCK 1-11
MAINTENANCE FOR NEW FORKLIFT TRUCK 1-11
WARRANTY AND SERVICE 1-12
DEFINED LIFE PARTS 1-12
USE OF GENUINE KOMATSU PARTS AND OILS 1-12
ENGINE MOUNTED ON THIS FORKLIFT TRUCK 1-12
NECESSARY INFORMATION OF FORKLIFT TRUCK 1-13
LOCATION OF MODEL AND SERIAL NO PLATE 1-13
LOCATION OF SERIAL NUMBER STAMPING 1-13
LOCATION OF ENGINE NUMBER PLATE 1-13
HOUR METER LOCATION 1-14
YOUR DISTRIBUTOR 1-14
ABBREVIATION LIST 1-15
SAFETY 2-1
SAFETY LABELS 2-2
LOCATION OF SAFETY LABELS 2-3
CONTENTS OF SAFETY LABELS 2-7
PREVENT FIRE 2-13
PREVENT FIRE ON ENGINE 2-13
FIRE WITH FUEL AND OIL 2-14
FIRE WITH ACCUMULATION OF COMBUSTIBLE MATERIAL 2-14
FIRE FROM ELECTRICAL WIRING 2-15
FIRE FROM PIPING 2-15
FIRE AROUND THE FORKLIFT TRUCK DUE TO HIGHLY HEATED EXHAUST GAS 2-15
ACTIONS IF FIRE OCCURS 2-15
CLEANING 2-16
BASIC PRECAUTIONS 2-17
FOLLOW RULES 2-17
NEVER OPERATE THE BROKEN-DOWN FORKLIFT TRUCK 2-17
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT 2-18
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 2-18
PRECAUTIONS FOR SAFETY-RELATED EQUIPMENT 2-18
PRACTICE SUFFICIENTLY BEFORE OPERATION 2-18
NO JUMPING ON OR OFF FORKLIFT TRUCK 2-19
KEEP OPERATOR’S COMPARTMENT AND PLATFORM CLEAN AND TIDY 2-19
PRECAUTIONS WHEN WASHING FORKLIFT TRUCK 2-19
PREVENT BURN INJURY 2-20
UNAUTHORIZED MODIFICATION 2-20
DO NOT REMOVE OVERHEAD GUARD AND LOAD BACKREST 2-20
ENSURE SAFETY OF WORKPLACE 2-21
PRECAUTIONS FOR VENTILATING ROOM 2-22
PRECAUTIONS RELATED TO SPECIAL ENVIRONMENT 2-22
BEWARE OF ASBESTOS DUST 2-22
CHECKS BEFORE STARTING 2-23
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE 2-23
PRECAUTIONS WHEN STARTING ENGINE 2-23
PRECAUTIONS WHEN CHECKING SAFETY FUNCTION 2-23
TABLE OF CONTENTS FOREWORD
1-2
IN COLD WEATHER 2-23
PRECAUTIONS WHEN CLEANING CAB GLASS 2-24
PRECAUTIONS WHEN TRAVELING 2-25
PREPARATION BEFORE TRAVELING 2-25
WHILE DRIVING FORKLIFT TRUCK 2-26
STOPPING AND PARKING 2-31
TOWING AND BEING TOWED 2-31
PRECAUTIONS FOR LOAD HANDLING OPERATION 2-32
SIT ON SEAT PROPERLY WHEN PERFORMING LOAD HANDLING OPERATION 2-32
DO NOT ALLOW ANYONE IN WORKING AREA EXCEPT SIGNAL PERSON 2-32
DO NOT GO UNDER FORKS 2-32
NEVER PERFORM WORKS ON FORKS 2-32
AVOID GETTING CAUGHT BY MAST 2-33
DO NOT CLIMB ON MAST OR LOAD BACKREST 2-33
USE PALLET OR SKID OF AMPLE STRENGTH 2-33
HANDLE LONG OR WIDE LOAD WITH EXTRA CARE 2-34
BE CAREFUL OF MAST HEIGHT 2-34
NEVER OVERLOAD FORKLIFT TRUCK 2-34
DO NOT TILT MAST FORWARD WITH A LOAD LIFTED 2-34
DO NOT HANDLE LOAD IN INSECURE MANNER 2-35
DO NOT LOAD AND UNLOAD ON SLOPES 2-35
DO NOT LOWER LOADED FORKS HASTILY 2-35
DO NOT HANDLE LOAD EXCEEDING LOAD BACKREST HEIGHT 2-35
DO NOT PRY LOAD WITH FORK TIPS 2-35
DO NOT USE FORKS TO PUSH OR PULL LOAD 2-36
DO NOT USE FORKLIFT TRUCK FOR ANY OTHER PURPOSE 2-36
PRECAUTIONS FOR STRONG WIND 2-36
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2-37
BE SURE TO PERFORM START-UP INSPECTION 2-37
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE 2-37
KEEP WORK PLACE CLEAN, TIDY AND VENTILATED 2-37
PRECAUTIONS BEFORE INSPECTION AND MAINTENANCE 2-38
ONLY AUTHORIZED PERSONNEL 2-39
USE PROPER TOOLS 2-39
PRECAUTIONS WHEN WORKING UNDER WORK EQUIPMENT 2-39
AVOID GETTING CAUGHT BY MAST OR FALLING OFF 2-40
PRECAUTIONS FOR HIGH-TEMPERATURE COOLANT 2-40
PRECAUTIONS FOR HIGH-PRESSURE OIL 2-41
BE CAREFUL OF ROTATING FAN AND FAN BELT 2-41
PRECAUTIONS WHEN INSTALLING RADIO CONTROL SYSTEM 2-41
PRECAUTIONS WHEN REPAIRING ELECTRICAL SYSTEM 2-41
PRECAUTIONS WHEN USING COMPRESSED AIR FOR CLEANING 2-41
PRECAUTIONS WHEN REPLACING SEAT 2-42
PRECAUTIONS WHEN HANDLING BATTERY 2-42
PRECAUTIONS WHEN CHARGING BATTERY 2-42
PRECAUTIONS WHEN HANDLING TIRES 2-43
PRECAUTIONS WHEN HANDLING ACCUMULATOR AND GAS SPRING 2-43
MAINTENANCE OF AIR CONDITIONER 2-43
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 2-44
PRECAUTIONS AFTER INSPECTION AND REPAIR 2-44
METHOD FOR SELECTING WINDOW WASHER FLUID 2-44
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS 2-44
PRECAUTIONS FOR DEF 2-45
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 2-45
PRECAUTIONS FOR ADDING 2-45
PRECAUTIONS FOR STORING 2-45
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 2-45
OTHER PRECAUTIONS 2-45
FOREWORD TABLE OF CONTENTS
1-3
HOIST AND CARRY FORKLIFT TRUCK 2-46
PRECAUTIONS WHEN HOISTING FORKLIFT TRUCK 2-46
PRECAUTIONS FOR LOADING AND UNLOADING FORKLIFT TRUCK 2-46
STRUCTURE AND STABILITY OF FORKLIFT TRUCK (TO PREVENT FORKLIFT TRUCK FROM TIPPING)
2-47
LONGITUDINAL STABILITY 2-47
CENTER OF GRAVITY OF A LOAD 2-47
COMBINED CENTER OF GRAVITY AND STABILITY ON LOADED FORKLIFT TRUCK 2-48
ALLOWABLE LOAD 2-48
SERIAL NO PLATE AND LOAD TABLE 2-49
INTRODUCTION OF OPTIONAL SAFETY AUXILIARY DEVICE 2-51
OPERATION 3-1
GENERAL VIEW 3-2
FORKLIFT TRUCK EQUIPMENT NAME 3-2
CONTROLS AND GAUGES NAMES 3-4
EXPLANATION OF COMPONENTS 3-6
EXPLANATION OF OPERATING DEVICES 3-6
MONITOR PANEL 3-17
FUNCTION BUTTON 3-19
AFTERTREATMENT DEVICES REGENERATION DISPLAY 3-19
ENGINE COOLANT TEMPERATURE GAUGE 3-20
FUEL GAUGE 3-21
FUEL CONSUMPTION GAUGE AND LOAD CHECKER DISPLAY 3-22
DEF LEVEL GAUGE 3-24
ECO GAUGE 3-25
PREHEATING DISPLAY 3-25
SPEEDOMETER 3-25
DIRECTIONAL LEVER POSITION DISPLAY 3-27
TRAVEL INTERLOCK DISPLAY 3-27
HST OIL TEMPERATURE GAUGE 3-28
LIFT INTERLOCK DISPLAY 3-28
REAR WHEEL STEERING ANGLE GAUGE 3-29
PARKING BRAKE DISPLAY 3-30
PARKING BRAKE WARNING DISPLAY 3-30
SEATBELT CAUTION LAMP 3-31
HOUR METER (SMR) INTEGRATION STATE 3-31
CLOCK, HOUR METER (SMR), ODOMETER DISPLAY 3-32
KOMTRAX MESSAGE DISPLAY 3-33
LIGHT REMINDER CAUTION LAMP 3-33
WARNING DISPLAY 3-34
AUTOMATIC ENGINE STOP DISPLAY 3-44
DEF LOW LEVEL GUIDANCE 3-45
ENGINE STOP OPERATION DURING THE AFTERTREATMENT DEVICES REGENERATION GUIDANCE
3-46
USER MENU 3-47
HANDLE UREA SCR SYSTEM WARNING 3-64
PROCEDURE FOR MANUAL STATIONARY REGENERATION 3-67
PROCEDURE FOR SETTING AFTERTREATMENT DEVICES REGENERATION DISABLE 3-70
PROCEDURE FOR CANCELING AFTERTREATMENT DEVICES REGENERATION DISABLE 3-74
OPERATION OF UREA SCR SYSTEM 3-75
IN COLD WEATHER 3-75
INDUCEMENT STRATEGY WHEN THE DEF TANK LEVEL BECOMES LOW 3-76
INDUCEMENT STRATEGY WHEN ABNORMALITIES ARE DETECTED IN THE UREA SCR SYSTEM
DEVICE (EXCLUDING EGR SYSTEM FAILURE) 3-79
INDUCEMENT STRATEGY WHEN ABNORMALITIES ARE FOUND IN THE EGR VALVE SYSTEM BY
THE UREA SCR SYSTEM DEVICE 3-82
TEMPORARY RESTORATION FROM INDUCEMENT 3-84
INDUCEMENT STRATEGY FOR ABNORMALITIES RECURRENCES WITHIN 40 HOURS 3-87
TABLE OF CONTENTS FOREWORD
1-4
DEF FILTER 3-87
KOMTRAX 3-88
POWER SUPPLY FOR KOMTRAX 3-88
FORKLIFT TRUCK OPERATIONS AND CONTROLS 3-89
CHECKS BEFORE STARTING 3-89
METHOD FOR GETTING ON/OFF FORKLIFT TRUCK 3-89
METHOD FOR ADJUSTING POSTURE WHEN OPERATING FORKLIFT TRUCK 3-90
METHOD FOR STARTING ENGINE, WARM-UP OPERATION, MOVING OFF, AND TRAVELING 3-96
METHOD FOR MOVING OFF, DECELERATING, AND STOPPING FORKLIFT TRUCK ON SLOPES
3-106
METHOD FOR STEERING FORKLIFT TRUCK 3-108
PRECAUTIONS WHEN OPERATING FORKLIFT TRUCK ON SNOWY AND FROZEN ROADS 3-108
METHOD FOR TEMPORARY STOPPING, PARKING AND STOPPING OF FORKLIFT TRUCK 3-109
LOAD HANDLING OPERATION 3-113
CHECK AFTER FINISHING WORK 3-118
HANDLE HEATER 3-119
EXPLANATION OF HEATER COMPONENTS 3-119
METHOD FOR USING HEATER 3-121
HANDLE AIR CONDITIONER 3-123
EXPLANATION OF AIR CONDITIONER COMPONENTS 3-123
METHOD FOR OPERATING AIR CONDITIONER 3-128
HANDLE REARVIEW MONITOR 3-136
EXPLANATION OF REARVIEW MONITOR COMPONENTS 3-136
MAINTENANCE 4-1
CHECK AND MAINTENANCE 4-2
CHECKS BEFORE STARTING 4-2
CHECKS BEFORE STARTING 4-4
CHECK ABNORMALITIES DETECTED ON THE PREVIOUS DAY 4-4
WALK AROUND CHECK OF FORKLIFT TRUCK 4-4
INSPECTION BY OPENING COVER 4-8
CHECK FROM OPERATOR’S SEAT 4-21
CHECK WHILE STARTING SWITCH IS AT ON POSITION 4-26
CHECK WHILE ENGINE IS RUNNING 4-36
METHOD FOR CHECKING WHILE TRAVELING SLOWLY 4-39
METHOD FOR CHECKING BY OPERATING WORK EQUIPMENT CONTROL LEVER 4-40
CHECK SAFETY FUNCTION 4-42
CHECK SAFETY AUXILIARY FUNCTION 4-45
INSPECTION OF FORKLIFT TRUCK WITH CAB SPECIFICATION AND FORKLIFT TRUCK WITH
FRONT GLASS SPECIFICATION 4-46
CHECK AND REPORT AFTER FINISHING WORK 4-47
CHECKS BEFORE STOPPING ENGINE 4-47
INSPECTION AND CHECK AFTER STOPPING ENGINE 4-47
LOCK 4-48
PERIODIC CHECKS 4-49
EVERY 50 HOURS (1 WEEK) MAINTENANCE 4-49
EVERY 100 HOURS (2 WEEKS) MAINTENANCE 4-50
SIMPLE MAINTENANCE 4-51
LUBRICANTS AND FUEL 4-51
METHOD FOR BLEEDING AIR FROM FUEL CIRCUIT 4-60
METHOD FOR CHECKING AND CLEANING AIR CLEANER ELEMENT 4-61
METHOD FOR CHECKING FAN BELT TENSION AND AUTO-TENSIONER, REPLACING FAN BELT
AND AUTO-TENSIONER 4-65
METHOD FOR CHECKING FOR HARDENING OF ENGINE CONTROLLER MOUNT RUBBER AND
LOOSE MOUNTING 4-67
METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER
4-67
METHOD FOR CHECKING DIFFERENCIAL OIL LEVEL, ADDING OIL 4-68
METHOD FOR REPLACING TIRES 4-70
FOREWORD TABLE OF CONTENTS
1-5
METHOD FOR ADJUSTING PARKING BRAKE LEVER OPERATING EFFORT 4-72
SYSTEM OPERATING LAMP 4-73
METHOD FOR REPLACING FUSE 4-74
METHOD FOR REPLACING SLOW-BLOW FUSE 4-81
METHOD FOR REPLACING BULBS 4-82
METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER 4-83
ACTIONS IF BATTERY RUNS OUT 4-84
PRECAUTIONS FOR CONNECTING OR DISCONNECTING JUMPER CABLES 4-84
PROCEDURE FOR CONNECTING JUMPER CABLES 4-85
METHOD FOR STARTING ENGINE 4-85
PROCEDURE FOR DISCONNECTING JUMPER CABLES 4-85
COLD WEATHER OPERATION 4-86
COLD WEATHER OPERATION INFORMATION 4-86
FUEL AND LUBRICANTS 4-86
COOLANT 4-86
DEF 4-86
BATTERY 4-87
PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER 4-87
AFTER COLD WEATHER SEASON 4-87
PRECAUTIONS FOR LONG-TERM STORAGE 4-88
PREPARATION FOR LONG-TERM STORAGE 4-88
MAINTENANCE DURING LONG-TERM STORAGE 4-88
STARTING FORKLIFT TRUCK AFTER LONG-TERM STORAGE 4-89
ACTIONS IF ENGINE HAS OVERHEATED 4-90
ENGINE OVERHEATING PREVENTION SYSTEM 4-90
METHOD FOR TAKING ACTIONS IF ENGINE HAS OVERHEATED 4-90
METHOD FOR CLEANING INSIDE OF COOLING SYSTEM 4-91
METHOD FOR CLEANING AFTERCOOLER FIN, OIL COOLER FIN, AND RADIATOR FIN 4-91
OPERATE FORKLIFT TRUCKS IN SPECIAL ENVIRONMENT OR IN FORCIBLE WAY 4-92
METHOD FOR TAKING ACTIONS IF FORK FAILS TO LOWER 4-93
PRECAUTIONS WHEN TOWING VEHICLE OR IT IS TOWED IN EMERGENCY 4-94
TOW FORKLIFT TRUCK WHOSE ENGINE CANNOT BE STARTED 4-95
METHOD FOR TRAVELING IN EMERGENCY 4-96
METHOD FOR WASHING FORKLIFT TRUCK 4-97
HOIST FORKLIFT TRUCK 4-99
LOADING AND UNLOADING WITH TRAILER 4-100
PROCEDURE FOR LOADING FORKLIFT TRUCK 4-101
METHOD FOR SECURING FORKLIFT TRUCK 4-102
PROCEDURE FOR UNLOADING FORKLIFT TRUCK 4-103
MAINTENANCE SCHEDULE 4-104
MAINTENANCE SCHEDULE CHART 4-104
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS 4-117
DEFINED LIFE PARTS LIST 4-117
CONSUMABLE PARTS 4-118
CONSUMABLE PARTS LIST 4-118
SERVICE DATA 4-119
SERVICE DATA: FH100-1 4-119
SERVICE DATA: FH120-1 4-120
SERVICE DATA: FH135-1 4-121
SERVICE DATA: FH160-1 4-122
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS 4-123
SPECIFICATIONS 5-1
SPECIFICATIONS 5-2
SPECIFICATIONS: FH100-1 5-2
SPECIFICATIONS: FH120-1 5-5
SPECIFICATIONS: FH135-1 5-8
SPECIFICATIONS: FH160-1 5-11
INDEX 6-1

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