Komatsu FH60-2 FH70-2 FH80-2 Forklift Truck Operation & Maintenance Manual PEN00922-02 – PDF DOWNLOAD

FOREWORD 1-1
READ THIS MANUAL 1-7
SAFETY INFORMATION 1-8
GENERAL VIEW OF FORKLIFT TRUCK 1-9
MAIN USE OF FORKLIFT TRUCK 1-9
DIRECTIONS OF FORKLIFT TRUCK 1-9
LICENSE FOR OPERATION, TESTING AND MAINTENANCE 1-10
HANDLE NEW FORKLIFT TRUCK 1-10
MAINTENANCE FOR NEW FORKLIFT TRUCK 1-10
WARRANTY AND SERVICE 1-10
DEFINED LIFE PARTS 1-10
USE OF GENUINE KOMATSU PARTS AND OILS 1-10
ENGINE MOUNTED ON THIS FORKLIFT TRUCK 1-10
NECESSARY INFORMATION OF FORKLIFT TRUCK 1-11
LOCATION OF MODEL AND SERIAL NO PLATE 1-11
LOCATION OF SERIAL NUMBER STAMPING 1-11
LOCATION OF ENGINE NUMBER PLATE 1-11
HOUR METER LOCATION 1-12
YOUR DISTRIBUTOR 1-12
ABBREVIATION LIST 1-13
SAFETY 2-1
SAFETY LABELS 2-2
LOCATION OF SAFETY LABELS 2-3
CONTENTS OF SAFETY LABELS 2-5
PREVENT FIRE 2-9
PREVENT FIRE ON ENGINE 2-9
FIRE WITH FUEL AND OIL 2-10
FIRE WITH ACCUMULATION OF COMBUSTIBLE MATERIAL 2-10
FIRE FROM ELECTRICAL WIRING 2-11
FIRE FROM PIPING 2-11
ACTIONS IF FIRE OCCURS 2-11
CLEANING 2-11
BASIC PRECAUTIONS 2-12
FOLLOW RULES 2-12
NEVER OPERATE THE BROKEN-DOWN FORKLIFT TRUCK 2-12
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT 2-13
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT 2-13
PRECAUTIONS FOR SAFETY-RELATED EQUIPMENT 2-13
PRACTICE SUFFICIENTLY BEFORE OPERATION 2-13
NO JUMPING ON OR OFF FORKLIFT TRUCK 2-14
KEEP OPERATOR’S COMPARTMENT AND PLATFORM CLEAN AND TIDY 2-14
PRECAUTIONS WHEN WASHING FORKLIFT TRUCK 2-14
PREVENT BURN INJURY 2-14
UNAUTHORIZED MODIFICATION 2-15
DO NOT REMOVE OVERHEAD GUARD AND LOAD BACKREST 2-15
ENSURE SAFETY OF WORKPLACE 2-16
PRECAUTIONS FOR VENTILATING ROOM 2-16
PRECAUTIONS RELATED TO SPECIAL ENVIRONMENT 2-16
BEWARE OF ASBESTOS DUST 2-16
CHECKS BEFORE STARTING 2-17
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE 2-17
PRECAUTIONS WHEN STARTING ENGINE 2-17
PRECAUTIONS WHEN CHECKING SAFETY FUNCTION 2-17
IN COLD WEATHER 2-17
PRECAUTIONS WHEN CLEANING CAB GLASS 2-17
PRECAUTIONS WHEN TRAVELING 2-18
TABLE OF CONTENTS FOREWORD
1-2
PREPARATION BEFORE TRAVELING 2-18
WHILE DRIVING FORKLIFT TRUCK 2-19
STOPPING AND PARKING 2-24
TOWING AND BEING TOWED 2-24
PRECAUTIONS FOR LOAD HANDLING OPERATION 2-25
SIT ON SEAT PROPERLY WHEN PERFORMING LOAD HANDLING OPERATION 2-25
DO NOT ALLOW ANYONE IN WORKING AREA EXCEPT SIGNAL PERSON 2-25
DO NOT GO UNDER FORKS 2-25
NEVER PERFORM WORKS ON FORKS 2-25
AVOID GETTING CAUGHT BY MAST 2-26
DO NOT CLIMB ON MAST OR LOAD BACKREST 2-26
USE PALLET OR SKID OF AMPLE STRENGTH 2-26
HANDLE LONG OR WIDE LOAD WITH EXTRA CARE 2-27
BE CAREFUL OF MAST HEIGHT 2-27
NEVER OVERLOAD FORKLIFT TRUCK 2-27
DO NOT TILT MAST FORWARD WITH A LOAD LIFTED 2-27
DO NOT HANDLE LOAD IN INSECURE MANNER 2-28
DO NOT LOAD AND UNLOAD ON SLOPES 2-28
DO NOT LOWER LOADED FORKS HASTILY 2-28
DO NOT HANDLE LOAD EXCEEDING LOAD BACKREST HEIGHT 2-28
DO NOT PRY LOAD WITH FORK TIPS 2-28
DO NOT USE FORKS TO PUSH OR PULL LOAD 2-29
DO NOT USE FORKLIFT TRUCK FOR ANY OTHER PURPOSE 2-29
PRECAUTIONS FOR STRONG WIND 2-29
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2-30
BE SURE TO PERFORM START-UP INSPECTION 2-30
DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE 2-30
KEEP WORK PLACE CLEAN, TIDY AND VENTILATED 2-30
PRECAUTIONS BEFORE INSPECTION AND MAINTENANCE 2-31
ONLY AUTHORIZED PERSONNEL 2-32
USE PROPER TOOLS 2-32
PRECAUTIONS WHEN WORKING UNDER WORK EQUIPMENT 2-32
AVOID GETTING CAUGHT BY MAST OR FALLING OFF 2-33
PRECAUTIONS FOR HIGH-TEMPERATURE COOLANT 2-33
PRECAUTIONS FOR HIGH-PRESSURE OIL 2-34
BE CAREFUL OF ROTATING FAN AND FAN BELT 2-34
PRECAUTIONS WHEN INSTALLING RADIO CONTROL SYSTEM 2-34
PRECAUTIONS WHEN REPAIRING ELECTRICAL SYSTEM 2-34
PRECAUTIONS WHEN USING COMPRESSED AIR FOR CLEANING 2-34
PRECAUTIONS WHEN REPLACING SEAT 2-34
PRECAUTIONS WHEN HANDLING BATTERY 2-35
PRECAUTIONS WHEN CHARGING BATTERY 2-35
PRECAUTIONS WHEN HANDLING TIRES 2-36
PRECAUTIONS WHEN HANDLING ACCUMULATOR AND GAS SPRING 2-36
MAINTENANCE OF AIR CONDITIONER 2-36
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 2-37
PRECAUTIONS AFTER INSPECTION AND REPAIR 2-37
METHOD FOR SELECTING WINDOW WASHER FLUID 2-37
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS 2-37
HOIST AND CARRY FORKLIFT TRUCK 2-38
PRECAUTIONS WHEN HOISTING FORKLIFT TRUCK 2-38
PRECAUTIONS FOR LOADING AND UNLOADING FORKLIFT TRUCK 2-38
STRUCTURE AND STABILITY OF FORKLIFT TRUCK (TO PREVENT FORKLIFT TRUCK FROM TIPPING)
LONGITUDINAL STABILITY 2-39
CENTER OF GRAVITY OF A LOAD 2-39
COMBINED CENTER OF GRAVITY AND STABILITY ON LOADED FORKLIFT TRUCK 2-40
ALLOWABLE LOAD 2-40

SERIAL NO PLATE AND LOAD TABLE 2-41
INTRODUCTION OF OPTIONAL SAFETY AUXILIARY DEVICE 2-43
OPERATION 3-1
GENERAL VIEW 3-2
FORKLIFT TRUCK EQUIPMENT NAME 3-2
CONTROLS AND GAUGES NAMES 3-3
EXPLANATION OF COMPONENTS 3-5
EXPLANATION OF OPERATING DEVICES 3-5
MONITOR PANEL 3-16
FUNCTION BUTTON 3-17
ENGINE COOLANT TEMPERATURE GAUGE 3-17
FUEL GAUGE 3-18
FUEL CONSUMPTION GAUGE AND LOAD CHECKER DISPLAY 3-19
ECO GAUGE 3-21
PREHEATING DISPLAY 3-21
SPEEDOMETER 3-22
DIRECTIONAL LEVER POSITION DISPLAY 3-24
TRAVEL INTERLOCK DISPLAY 3-24
HST OIL TEMPERATURE GAUGE 3-25
LIFT INTERLOCK DISPLAY 3-25
PARKING BRAKE DISPLAY 3-26
PARKING BRAKE WARNING DISPLAY 3-26
SEATBELT CAUTION LAMP 3-27
HOUR METER (SMR) INTEGRATION STATE 3-27
CLOCK, HOUR METER (SMR), ODOMETER DISPLAY 3-28
KOMTRAX MESSAGE DISPLAY 3-29
LIGHT REMINDER CAUTION LAMP 3-29
WARNING DISPLAY 3-30
AUTOMATIC ENGINE STOP DISPLAY 3-38
USER MENU 3-39
KOMTRAX 3-56
POWER SUPPLY FOR KOMTRAX 3-56
FORKLIFT TRUCK OPERATIONS AND CONTROLS 3-57
CHECKS BEFORE STARTING 3-57
METHOD FOR GETTING ON/OFF FORKLIFT TRUCK 3-57
METHOD FOR ADJUSTING POSTURE WHEN OPERATING FORKLIFT TRUCK 3-58
METHOD FOR STARTING ENGINE, WARM-UP OPERATION, MOVING OFF, AND TRAVELING 3-63
METHOD FOR MOVING OFF, DECELERATING, AND STOPPING FORKLIFT TRUCK ON SLOPES
3-72
METHOD FOR STEERING FORKLIFT TRUCK 3-74
PRECAUTIONS WHEN OPERATING FORKLIFT TRUCK ON SNOWY AND FROZEN ROADS 3-74
METHOD FOR TEMPORARY STOPPING, PARKING AND STOPPING OF FORKLIFT TRUCK 3-75
LOAD HANDLING OPERATION 3-77
CHECK AFTER FINISHING WORK 3-81
HANDLE HEATER 3-82
EXPLANATION OF HEATER COMPONENTS 3-82
METHOD FOR USING HEATER 3-83
HANDLE AIR CONDITIONER 3-84
EXPLANATION OF AIR CONDITIONER COMPONENTS 3-84
METHOD FOR OPERATING AIR CONDITIONER 3-86
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 AND HOOD 4-8
CHECK FROM OPERATOR’S SEAT 4-19
TABLE OF CONTENTS FOREWORD
1-4
CHECK WHILE STARTING SWITCH IS AT ON POSITION 4-22
CHECK WHILE ENGINE IS RUNNING 4-26
METHOD FOR CHECKING WHILE TRAVELING SLOWLY 4-29
METHOD FOR CHECKING BY OPERATING WORK EQUIPMENT CONTROL LEVER 4-30
CHECK SAFETY FUNCTION 4-32
INSPECTION OF FORKLIFT TRUCK WITH CAB SPECIFICATION AND FORKLIFT TRUCK WITH
FRONT GLASS SPECIFICATION 4-36
CHECK AND REPORT AFTER FINISHING WORK 4-37
CHECKS BEFORE STOPPING ENGINE 4-37
INSPECTION AND CHECK AFTER STOPPING ENGINE 4-37
LOCK 4-38
PERIODIC CHECKS 4-39
EVERY 50 HOURS (1 WEEK) MAINTENANCE 4-39
EVERY 100 HOURS (2 WEEKS) MAINTENANCE 4-41
SIMPLE MAINTENANCE 4-42
LUBRICANTS AND FUEL 4-42
METHOD FOR BLEEDING AIR FROM FUEL CIRCUIT 4-49
METHOD FOR CHECKING AND CLEANING AIR CLEANER ELEMENT 4-50
METHOD FOR CHECKING FAN BELT TENSION AND AUTO-TENSIONER, REPLACING FAN BELT
AND AUTO-TENSIONER 4-55
METHOD FOR CHECKING FOR HARDENING OF ENGINE CONTROLLER MOUNT RUBBER AND
LOOSE MOUNTING 4-57
METHOD FOR CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER
METHOD FOR CHECKING DIFFERENCIAL OIL LEVEL, ADDING OIL 4-58
METHOD FOR REPLACING TIRES 4-60
METHOD FOR ADJUSTING PARKING BRAKE LEVER OPERATING EFFORT 4-62
METHOD FOR REPLACING FUSE 4-63
METHOD FOR REPLACING SLOW-BLOW FUSE 4-67
METHOD FOR REPLACING BULBS 4-68
METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER 4-69
ACTIONS IF BATTERY RUNS OUT 4-70
PRECAUTIONS FOR CONNECTING OR DISCONNECTING JUMPER CABLES 4-70
PROCEDURE FOR CONNECTING JUMPER CABLES 4-71
METHOD FOR STARTING ENGINE 4-71
PROCEDURE FOR DISCONNECTING JUMPER CABLES 4-71
COLD WEATHER OPERATION 4-72
COLD WEATHER OPERATION INFORMATION 4-72
FUEL AND LUBRICANTS 4-72
COOLANT 4-72
BATTERY 4-73
PRECAUTIONS AFTER DAILY WORK COMPLETION IN COLD WEATHER 4-73
AFTER COLD WEATHER SEASON 4-73
PRECAUTIONS FOR LONG-TERM STORAGE 4-74
PREPARATION FOR LONG-TERM STORAGE 4-74
MAINTENANCE DURING LONG-TERM STORAGE 4-74
STARTING FORKLIFT TRUCK AFTER LONG-TERM STORAGE 4-74
ACTIONS IF ENGINE HAS OVERHEATED 4-75
ENGINE OVERHEATING PREVENTION SYSTEM 4-75
METHOD FOR TAKING ACTIONS IF ENGINE HAS OVERHEATED 4-75
METHOD FOR CLEANING INSIDE OF COOLING SYSTEM 4-76
METHOD FOR CLEANING AFTERCOOLER FIN, OIL COOLER FIN, AND RADIATOR FIN 4-76
OPERATE FORKLIFT TRUCKS IN SPECIAL ENVIRONMENT OR IN FORCIBLE WAY 4-78
METHOD FOR TAKING ACTIONS IF FORK FAILS TO LOWER 4-79
PRECAUTIONS WHEN TOWING VEHICLE OR IT IS TOWED IN EMERGENCY 4-80
TOW FORKLIFT TRUCK WHOSE ENGINE CANNOT BE STARTED 4-81
METHOD FOR TRAVELING IN EMERGENCY 4-82
METHOD FOR WASHING FORKLIFT TRUCK 4-83
HOIST FORKLIFT TRUCK 4-84
LOADING AND UNLOADING WITH TRAILER 4-86
PROCEDURE FOR LOADING FORKLIFT TRUCK 4-87
METHOD FOR SECURING FORKLIFT TRUCK 4-88
PROCEDURE FOR UNLOADING FORKLIFT TRUCK 4-89
MAINTENANCE SCHEDULE 4-90
MAINTENANCE SCHEDULE CHART 4-90
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS 4-102
DEFINED LIFE PARTS LIST 4-102
CONSUMABLE PARTS 4-103
CONSUMABLE PARTS LIST 4-103
SERVICE DATA 4-104
SERVICE DATA: FH60-2 4-104
SERVICE DATA: FH70-2 4-105
SERVICE DATA: FH80-2 4-106
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS 4-107
SPECIFICATIONS 5-1
SPECIFICATIONS 5-2
SPECIFICATIONS: FH60-2 5-2
SPECIFICATIONS: FH70-2 5-5
SPECIFICATIONS: FH80-2 5-8
INDEX 6-1