Komatsu FH35-1 FH40-1 FH45-1 FH50-1 Forklift Truck Operation & Maintenance Manual TEN00716-03 – PDF DOWNLOAD

Description

Komatsu FH35-1 FH40-1 FH45-1 FH50-1 Forklift Truck Operation & Maintenance Manual TEN00716-03 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu FH35-1 FH40-1 FH45-1 FH50-1 Forklift Truck Operation & Maintenance Manual TEN00716-03 – PDF DOWNLOAD

INTRODUCTION:
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.

HANDLING OF NEW LIFT TRUCK:

New lift truck has been thoroughly adjusted and tested before shipment. However, operate moderately during the
first 1 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.
･After starting the engine, run it at idle for approximately 5 minutes (warm-up operation).
･Do not operate with heavy loads or at high speeds.
･Avoid sudden starting, acceleration, braking, and sharp turning

TABLE OF CONTENTS:

Komatsu FH35-1 FH40-1 FH45-1 FH50-1 Forklift Truck Operation & Maintenance Manual TEN00716-03 – PDF DOWNLOAD

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
QUALIFICATIONS FOR OPERATION 1 6
HANDLING OF NEW LIFT TRUCK 1 7
HANDLING OF NEW LIFT TRUCK 1 7
MAINTENANCE FOR NEW LIFT TRUCK 1 7
WARRANTY AND SERVICE 1 7
PERIODICAL EXCHANGE PARTS 1 7
USE OF GENUINE KOMATSU PARTS AND OILS 1 7
ENGINE MOUNTED ON THIS LIFT TRUCK 1 7
NECESSARY INFORMATION OF LIFT TRUCK 1 8
MEMORANDUM (TO BE FILLED BY KOMATSU FORKLIFT DISTRIBUTOR) 1 8
MODEL AND SERIAL NUMBER PLATE LOCATION 1 8
ENGINE SERIAL NUMBER PLATE OR STAMPING LOCATION 1 9
HOUR METER LOCATION 1 9
SAFETY 2 1
SAFETY LABEL 2 2
SAFETY LABEL LOCATION CHART 2 3
SAFETY LABEL 2 6
FIRE PREVENTION 2 10
ENGINE FIRE PREVENTION 2 10
CHECKING BEFORE STARTING THE ENGINE 2 10
PREVENTION FIRES CAUSED BY FUEL OR OIL 2 12
PREVENTION OF FIRE CAUSED BY DEPOSITED OR ADHERED FLAMMABLE SUBSTANCES 2 12
PREVENTION OF FIRE CAUSED BY FAULTY ELECTRICAL WIRING 2 12
PREVENTION OF FIRE CAUSED BY FAULTY PIPING 2 12
CLEANING 2 13
BASIC PRECAUTIONS 2 15
FOLLOW RULES 2 15
NEVER OPERATE THE BROKEN DOWN LIFT TRUCK 2 16
WEAR ADEQUATE CLOTHES AND SAFETY EQUIPMENT FOR OPERATION 2 16
FIRE EXTINGUISHER AND FIRST AID KIT 2 16
CAUTIONS FOR SAFETY RELATED EQUIPMENT 2 16
PRACTICE SUFFICIENTLY BEFORE OPERATION 2 17
JUMPING ON AND OFF FROM THE LIFT TRUCK IS STRICTLY PROHIBITED 2 17
KEEP THE OPERATOR’S COMPARTMENT AND PLATFORM CLEAN AND TIDY 2 17
CAUTION WHEN WASHING LIFT TRUCK 2 18
TO AVOID BURN INJURY 2 19
FIRE PREVENTION 2 19
IF A FIRE BREAKS OUT 2 20
DO NOT MODIFY THE LIFT TRUCK 2 21
DO NOT REMOVE THE OVERHEAD GUARD AND LOAD BACKREST 2 21
SECURE SAFETY AT THE WORKING AREA 2 21
ENGINE EXHAUST GAS IS TOXIC 2 22
ASBESTOS CAUTION 2 22
WINDOW WASHER CAUTION 2 22
START UP INSPECTION 2 23
TRAVELING THE LIFT TRUCK 2 25
PREPARATION BEFORE TRAVELLING THE LIFT TRUCK 2 25
WHILE TRAVELING THE LIFT TRUCK 2 26
STOPPING AND PARKING 2 32
LOAD HANDLING OPERATION 2 33
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2 38
ALWAYS PERFORM THE START UP INSPECTION 2 38
PUT UP A WARNING SIGN DURING INSPECTION AND MAINTENANCE 2 38
KEEP THE WORKING AREA CLEAN, TIDY AND VENTILATED 2 38
PRECAUTIONS BEFORE INSPECTION AND MAINTENANCE 2 39
KEEP UNAUTHORIZED PEOPLE OFF 2 40
USE OF PROPER TOOLS 2 40
CAUTIONS WHEN WORKING UNDER WORK EQUIPMENT 2 40
AVOID GETTING CAUGHT UP BY THE MAST OR FALLING OFF 2 41
BE CAREFUL OF HIGH TEMPERATURE COOLANT 2 41
BE CAREFUL OF HIGH PRESSURE OIL 2 42
BE CAREFUL OF ROTATING COOLING FAN AND BELT 2 42
PRECAUTIONS FOR INSTALLING RADIO CONTROL SYSTEM 2 42
CAUTION WHEN REPAIRING THE ELECTRICAL SYSTEM 2 42
CAUTIONS FOR USING COMPRESSED AIR FOR CLEANING 2 43
CAUTIONS WHEN REPLACING THE SEAT 2 43
CAUTION WHEN HANDLING BATTERY 2 43
STRICTLY FOLLOW THE INSTRUCTIONS SHOWN BELOW TO AVOID GENERATION OF SPARKS
CAUTION WHEN CHARGING A BATTERY 2 44
CAUTION WHEN HANDLING TIRES 2 44
CAUTION WHEN HANDLING ACCUMULATOR/GAS SPRING 2 45
CAUTION IN WASTE DISPOSAL 2 46
CAUTION AFTER INSPECTION AND REPAIR 2 46
PERIODIC INSPECTION OF SAFETY CRITICAL PARTS 2 46
HOISTING AND TRANSPORTING THE LIFT TRUCK 2 47
CAUTION WHEN HOISTING THE LIFT TRUCK 2 47
CAUTIONS FOR LOADING AND UNLOADING THE LIFT TRUCK 2 47
STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING) 2 48
LONGITUDINAL STABILITY 2 48
CENTER OF GRAVITY OF A LOAD 2 48
ACTUAL CAPACITY 2 49
SERIAL NO. PLATE AND LOAD TABLE 2 50
INTRODUCTION OF OPTIONAL SAFETY DEVICE 2 53
TOWING 2 54
OPERATION 3 1
GENERAL VIEW 3 2
GENERAL VIEW OF LIFT TRUCK 3 2
INSTRUMENTS AND CONTROLS 3 3
EXPLANATION OF COMPONENTS 3 5
METER PANEL 3 5
OPERATING DEVICES 3 11
OPERATION 3 15
START UP INSPECTION 3 15
MOUNTING/DISMOUNTING AND OPERATING POSTURE ADJUSTMENT 3 15
STARTING ENGINE/ WARM UP OPERATION/ MOVING OFF/TRAVELING 3 20
WARM UP OPERATION 3 22
WARM UP OPERATION OF HYDRAULIC COMPONENTS 3 23
STARTING AND STOPPING ON SLOPE 3 26
TURNING 3 27
OPERATION ON SNOWY AND FROZEN ROADS 3 27
TEMPORARY STOPPING, PARKING AND STOPPING 3 28
LIFT OPERATION 3 30
CHECKING AFTER OPERATION 3 34
SPEED LIMITER FUNCTION 3 35
TRAVEL SPEED LIMIT CHANGE PROHIBITION FUNCTION (FOR ADMINISTRATOR) 3 38
MAXIMUM TRAVEL SPEED LIMITER FUNCTION (FOR ADMINISTRATOR) 3 38
AUTO ENGINE STOP FUNCTION 3 39
TRANSPORTATION 3 40
SECURING LIFT TRUCK 3 41
HANDLING OF KOMTRAX INSTALLED MAICHINE 3 45
INSPECTION AND MAINTENANCE 4 1
INSPECTION AND MAINTENANCE 4 2
START UP INSPECTION 4 2
CHECKING ABNORMALITIES DETECTED ON THE PREVIOUS DAY 4 5
WALK AROUND A LIFT TRUCK 4 5
INSPECTION BY OPENING COVER AND HOOD 4 8
CHECKING FROM THE OPERATOR’S SEAT 4 14
CHECK BY SETTING THE STARTING SWITCH TO [ | ] (ON) POSITION 4 16
CHECKING WITH THE ENGINE STARTED 4 20
CHECKING OF BRAKE ACCUMULATOR 4 21
CHECKING WHILE TRAVELING SLOWLY 4 22
CHECKING BY OPERATING THE WORK EQUIPMENT LEVER 4 22
CHECKING OF SAFETY FUNCTION 4 24
INSPECTION OF LIFT TRUCK WITH CAB SPECIFICATION AND LIFT TRUCK WITH FRONT GLASS
SPECIFICATION (ONLY FOR LIFT TRUCKS WITH CAB SPECIFICATION AND WITH FRONT GLASS
SPECIFICATION) 4 26
CHECKING AND REPORTING AFTER OPERATION 4 27
PERIODICAL INSPECTION 4 28
INSPECTION FOR EVERY 50 HOURS (1 WEEK) 4 28
INSPECTION FOR EVERY 100 HOURS (2 WEEKS) 4 29
SIMPLE MAINTENANCE 4 30
GREASES AND FUEL 4 30
BASIC PRECAUTIONS 4 30
LUBRICANT LIST 4 35
CHECKING OF DIFFERENCIAL OIL LEVEL AND REFILLING 4 38
FUEL PREFILTER AIR BLEEDING 4 41
REPLACING TIRES 4 42
TYPE OF REFRIGERANT GAS 4 43
ADJUSTING PARKING BRAKE LEVER OPERATING EFFORT 4 44
REPLACING FUSE 4 45
REPLACING BULB 4 48
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER 4 49
CHECKING FOR HARDENING OF ENGINE CONTROLLER MOUNT RUBBER
AND LOOSE MOUNTING 4 49
PROCEDURE FOR A DOWN BATTERY 4 50
RUNNING IN COLD WEATHER 4 52
LONG TERM STORAGE 4 54
PROCEDURE WITH OVERHEATED ENGINE 4 55
OPERATING LIFT TRUCKS IN SPECIAL ENVIRONMENTOR IN FORCIBLE WAY 4 57
ACTION TO TAKE IF THE FORK FAILS TO LOWER 4 58
HOW TO TOW THE LIFT TRUCK OR BE TOWED 4 59
WHEN THE ENGINE CAN BE OPERATED 4 60
WHEN THE ENGINE CANNOT BE OPERATED 4 60
EMERGENCY TRAVEL OPERATION 4 61
WASHING LIFT TRUCKS 4 61
HOISTING LIFT TRUCK 4 62
LOADING AND UNLOADING OF LIFT TRUCK 4 63
INSPECTION AND MAINTENANCE SCHEDULE CHART 4 65
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4 74
CONSUMABLE PARTS 4 75
OTHER PARTS 4 76
SERVICE DATA 4 78
TECHNICAL DATA 5 1
INDEX 6

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• This is the SAME MANUAL used by the dealerships to diagnose your vehicle
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