Komatsu FH35-2 FH40-2 FH45-2 FH50-2 Forklift Truck Operation & Maintenance Manual PEN00963-02 – PDF DOWNLOAD

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Komatsu FH35-2 FH40-2 FH45-2 FH50-2 Forklift Truck Operation & Maintenance Manual PEN00963-02 – PDF DOWNLOAD

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Komatsu FH35-2 FH40-2 FH45-2 FH50-2 Forklift Truck Operation & Maintenance Manual PEN00963-02 – PDF DOWNLOAD

SERIAL NUMBERS
FH35-140001 and up
FH40-140001 and up
FH45-140001 and up
FH50-140001 and up

FOREWORD :
BEFORE READING THIS MANUAL:

• This manual describes procedures for proper operation, inspection, and maintenance of this forklift 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 forklift trucks. Also, knowing the possible hazards in
  advance will help to avoid accidents.

HANDLING OF NEW FORKLIFT TRUCK:
Komatsu thoroughly adjusts and tests any and every new forklift truck before shipment. However, operate it
moderately for the first month (or initial 200 hours) of use until each part of the forklift truck comes to operate
stably.
Operating the forklift truck under severe conditions at the beginning can adversely affect the performance and
shorten the forklift truck life.
Be sure to perform the running-in of the forklift 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 moving off, acceleration, braking, and sharp turning.

TABLE OF CONTENTS:

Komatsu FH35-2 FH40-2 FH45-2 FH50-2 Forklift Truck Operation & Maintenance Manual PEN00963-02 – PDF DOWNLOAD

PEN00963-02 1
FOREWORD 2
BEFORE READING THIS MANUAL 3
FOR YOUR SAFETY 4
SIGNAL WORDS 4
SAFETY INDICATORS 5
ENGINE MOUNTED ON THIS FORKLIFT TRUCK 6
EXHAUST GAS REGULATION 6
CERTIFICATION LABEL AFFIXED POSITION 6
APPLICABLE MODEL AND SERIAL NO 7
GENERAL VIEW OF FORKLIFT TRUCK 7
APPLICATION OF FORKLIFT TRUCK 7
DIRECTION OF FORKLIFT TRUCK 7
UNITS OF MEASURE 7
QUALIFICATIONS FOR OPERATION 8
HANDLING OF NEW FORKLIFT TRUCK 8
MAINTENANCE OF NEW FORKLIFT TRUCK 8
WARRANTY AND SERVICE 8
PERIODIC REPLACEMENT PARTS 8
USE OF GENUINE KOMATSU PARTS AND OILS 8
ENGINE MOUNTED ON THIS FORKLIFT TRUCK 8
NECESSARY INFORMATION OF FORKLIFT TRUCK 9
MODEL AND SERIAL NO PLATE LOCATION 9
ENGINE SERIAL NUMBER PLATE OR STAMPING LOCATION 9
HOUR METER LOCATION 10
MEMORANDUM (TO BE FILLED BY A KOMATSU DISTRIBUTOR) 10
TABLE OF CONTENTS 11
SAFETY 16
SAFETY LABELS 17
SAFETY LABEL LOCATION CHART 18
SAFETY LABELS 21
FIRE PREVENTION 25
PREVENTION OF FIRE ON ENGINE 25
CHECKS BEFORE STARTING ENGINE 25
FIRE WITH FUEL AND OIL 26
FIRE CAUSED BY ACCUMULATION OF COMBUSTIBLE MATERIAL 27
FIRE FROM ELECTRICAL WIRING 27
FIRE FROM PIPING 27
CLEANING 27
BASIC PRECAUTIONS 28
FOLLOW RULES 28
NEVER OPERATE A BROKEN DOWN FORKLIFT TRUCK 28
WEAR ADEQUATE CLOTHES AND SAFETY EQUIPMENT FOR OPERATION 29
FIRE EXTINGUISHER AND FIRST AID KIT 29
CAUTIONS FOR SAFETY-RELATED EQUIPMENT 29
PRACTICE SUFFICIENTLY BEFORE OPERATION 29
JUMPING ON AND OFF FROM THE FORKLIFT TRUCK IS STRICTLY PROHIBITED 30
KEEP THE OPERATOR’S COMPARTMENT AND PLATFORM CLEAN AND TIDY 30
CAUTION WHEN WASHING FORKLIFT TRUCK 30
TO AVOID BURN INJURY 31
FIRE PREVENTION 31
IF A FIRE BREAKS OUT 32
DO NOT MODIFY THE FORKLIFT TRUCK 32
DO NOT REMOVE THE OVERHEAD GUARD AND LOAD BACKREST 32
SECURE SAFETY AT THE WORKING AREA 33
ENGINE EXHAUST GAS IS TOXIC 33
PRECAUTIONS RELATED TO SPECIAL ENVIRONMENT 33
ASBESTOS CAUTION 33
WINDOW WASHER CAUTION 33
START-UP INSPECTION 34
CHECK AND ADJUSTMENT BEFORE STARTING ENGINE 34
CAUTIONS WHEN STARTING THE ENGINE 34
CAUTION WHEN CHECKING SAFETY FUNCTION 35
CAUTION IN COLD AREAS 35
PRECAUTIONS FOR TRAVEL 36
PREPARATION BEFORE DRIVING THE FORKLIFT TRUCK 36
WHILE DRIVING THE FORKLIFT TRUCK 37
STOPPING AND PARKING 43
TOWING 43
PRECAUTIONS FOR LOAD HANDLING OPERATION 44
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 49
ALWAYS PERFORM THE START-UP INSPECTION 49
PUT UP A WARNING TAG DURING INSPECTION AND MAINTENANCE 49
KEEP THE WORKING AREA CLEAN AND TIDY 49
PRECAUTIONS BEFORE INSPECTION AND MAINTENANCE 50
KEEP UNAUTHORIZED PERSON OFF 51
USE OF PROPER TOOLS 51
CAUTIONS WHEN WORKING UNDER WORK EQUIPMENT 51
AVOID GETTING CAUGHT UP BY THE MAST OR FALLING OFF 52
BE CAREFUL OF HIGH-TEMPERATURE COOLANT 52
BE CAREFUL OF HIGH PRESSURE OIL 53
BE CAREFUL OF ROTATING COOLING FAN AND BELT 53
PRECAUTIONS FOR INSTALLING RADIO CONTROL SYSTEM 53
CAUTION WHEN REPAIRING THE ELECTRICAL SYSTEM 53
CAUTIONS FOR USING COMPRESSED AIR FOR CLEANING 54
CAUTIONS WHEN REPLACING THE SEAT 54
CAUTION WHEN HANDLING BATTERY 54
STRICTLY FOLLOW THE INSTRUCTIONS SHOWN BELOW TO AVOID GENERATION OF SPARKS 55
CAUTION WHEN CHARGING A BATTERY 55
CAUTION WHEN HANDLING TIRES 55
CAUTION WHEN HANDLING ACCUMULATOR/GAS SPRING 55
CAUTION IN WASTE DISPOSAL 56
CAUTION AFTER INSPECTION AND REPAIR 56
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS 56
HOISTING AND TRANSPORTING THE FORKLIFT TRUCK 57
CAUTION WHEN HOISTING THE FORKLIFT TRUCK 57
CAUTIONS FOR LOADING AND UNLOADING THE FORKLIFT TRUCK 58
STRUCTURE AND STABILITY OF THE FORKLIFT TRUCK (TO PREVENT FORKLIFT TRUCK FROM TIPPING) 59
LONGITUDINAL STABILITY 59
CENTER OF GRAVITY OF A LOAD 59
COMBINED CENTER OF GRAVITY AND STABILITY ON THE LOADED FORKLIFT TRUCK 60
ACTUAL CAPACITY 60
SERIAL NO PLATE AND LOAD TABLE 61
INTRODUCTION OF OPTIONAL SAFETY AUXILIARY DEVICE 63
TOWING 64
OPERATION 66
GENERAL VIEW 67
GENERAL VIEW OF FORKLIFT TRUCK 67
INSTRUMENTS AND CONTROLS 68
EXPLANATION OF COMPONENTS 69
EXPLANATION OF OPERATING DEVICES 69
OPENING AND CLOSING CAB DOOR (FOR FORKLIFT TRUCKS WITH CAB SPECIFICATION ONLY) 73
CAB DOOR HANDLE 73
OPEN KNOB FOR CAB DOOR 73
OPEN LOCK FOR CAB DOOR 74
UNLOCK KNOB FOR SLIDE WINDOW OF CAB 74
OPEN LOCK KNOB FOR CAB ALTERNATE EXIT DOOR 75
HOW TO READ MONITOR PANEL 76
OVERALL VIEW OF MONITOR PANEL 76
HOW TO OPERATE METER PANEL 93
SELECT FUEL CONSUMPTION GAUGE/ LOAD CHECKER 93
SELECT CLOCK/ HOUR METER (SMR)/ TRAVEL DISTANCE (ODOMETER) 93
SELECT TRAVEL SPEED LIMIT (TORTOISE) ON/OFF 93
USER MENU 94
Travel Speed (Tortoise) Set 97
Max Speed Limit Set 98
Overspeed Alarm Set 98
Load Checker Buzzer Set 98
Load Checker Buzzer Value 99
L Buzzer Cancel Load Diff 99
Automatic Engine Stop Time Set 99
DEFAULT VALUE LIST FOR MACHINE SETTING 100
Average Fuel Consumption Logs 101
Operat Record by Operator 102
Operation Record [1 DAY/SPLIT] 103
Display Setting 104
Maintenance 106
ID KEY FUNCTION (ONLY FORKLIFT TRUCKS EQUIPPED WITH ID KEY) 111
OPERATION 114
START-UP INSPECTION 114
GETTING ON/OFF THE FORKLIFT TRUCK AND OPERATING POSTURE ADJUSTMENT 114
STARTING ENGINE/WARM-UP OPERATION/MOVING OFF/TRAVELING 121
WARM-UP OPERATION 123
WARM-UP OPERATION OF HYDRAULIC COMPONENTS 124
STARTING AND STOPPING ON SLOPE 128
TURNING 129
OPERATION ON SNOWY AND FROZEN ROADS 129
TEMPORARY STOPPING, PARKING AND STOPPING 130
LOAD HANDLING OPERATION 132
CHECKING AFTER OPERATION 136
KOMTRAX 137
POWER SUPPLY FOR KOMTRAX 137
INSPECTION AND MAINTENANCE 138
INSPECTION AND MAINTENANCE 139
START-UP INSPECTION 139
CHECKING ABNORMALITIES DETECTED ON THE PREVIOUS DAY 142
FORKLIFT TRUCK WALK AROUND CHECK 142
CHECKS PERFORMED WITH COVERS AND HOODS BEING OPENED 145
CHECKS WHILE BEING SEATED ON OPERATOR’S SEAT 153
CHECKS WITH STARTING SWITCH SET AT “|” (ON) POSITION 155
CHECKS WITH ENGINE STARTED 159
CHECKING BRAKE ACCUMULATOR 160
CHECKS WHILE DRIVING FORKLIFT TRUCK SLOWLY 161
CHECKS WHILE OPERATING WORK EQUIPMENT CONTROL LEVER 161
CHECKING OF SAFETY FUNCTION 163
CHECKING OF SAFETY AUXILIARY FUNCTION 165
CHECKING FORKLIFT TRUCKS WITH CAB SPECIFICATION AND THOSE WITH FRONT GLASS SPECIFICATION (Only for forklift trucks with cab specification and with front glass specification) 166
CHECKING AND REPORTING AFTER OPERATION 167
PERIODICAL INSPECTION 168
INSPECTION FOR EVERY 50 HOURS (1 WEEK) 168
INSPECTION FOR EVERY 100 HOURS (2 WEEKS) 169
SIMPLE MAINTENANCE 170
GREASES AND FUEL 170
BASIC PRECAUTIONS 170
LUBRICANT LIST 174
INSPECTION OF DIFFERENCIAL OIL LEVEL AND REFILLING 178
AIR CLEANER ELEMENT INSPECTION AND CLEANING 179
CHECKNG FAN BELT TENSION AND REPLACING AUTO-TENSIONER 181
FUEL FILTER AIR BLEEDING 183
REPLACING TIRES 184
ADJUSTING PARKING BRAKE LEVER OPERATING EFFORT 186
REPLACING FUSE 187
REPLACING BULBS 190
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP AND HARDENING OF RUBBER 191
CHECKING FOR HARDENING OF ENGINE CONTROLLER MOUNT RUBBER AND LOOSE MOUNTING 191
PROCEDURE FOR A DOWN BATTERY 192
RUNNING IN COLD WEATHER 194
LONG-TERM STORAGE 196
PROCEDURE WITH OVERHEATED ENGINE 197
OPERATING FORKLIFT TRUCKS IN SPECIAL ENVIRONMENT OR IN FORCIBLE WAY 199
ACTION TO TAKE IF THE FORK FAILS TO LOWER 200
HOW TO TOW FORKLIFT TRUCK OR BE TOWED 201
WHEN ENGINE CAN RUN 202
WHEN ENGINE CANNOT RUN 202
EMERGENCY TRAVEL OPERATION 203
WASHING FORKLIFT TRUCK 203
HOISTING FORKLIFT TRUCK 204
LOADING AND UNLOADING OF FORKLIFT TRUCK 206
INSPECTION AND MAINTENANCE SCHEDULE CHART 207
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS 214
CONSUMABLE PARTS 215
SERVICE DATA 216
SPECIFICATIONS 219
DIESEL ENGINE FORKLIFT TRUCK 220
INDEX 222
INDEX 223

PLEASE NOTE:

• This is the SAME MANUAL used by the dealerships to diagnose your vehicle
• No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
• Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
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