Komatsu Forklift Truck FG10-20 FG15H-20 FD10-20 FG20-16 FG20H-16 FG20N-16 FD20-16 FD20H-16 FD20N-16 Operation & Maintenance Manual AEB16E1-12 – PDF DOWNLOAD

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Komatsu Forklift Truck FG10-20 FG15H-20 FD10-20 FG20-16 FG20H-16 FG20N-16 FD20-16 FD20H-16 FD20N-16 Operation & Maintenance Manual AEB16E1-12 – PDF DOWNLOAD

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Komatsu Forklift Truck FG10-20 FG15H-20 FD10-20 FG20-16 FG20H-16 FG20N-16 FD20-16 FD20H-16 FD20N-16 Operation & Maintenance Manual AEB16E1-12 – PDF DOWNLOAD

Language : English
Pages : 171
Downloadable : Yes
File Type : PDF
Size: 2.59 MB

DESCRIPTION:

Komatsu Forklift Truck FG10-20 FG15H-20 FD10-20 FG20-16 FG20H-16 FG20N-16 FD20-16 FD20H-16 FD20N-16 Operation & Maintenance Manual AEB16E1-12 – PDF DOWNLOAD

FG10-20 FG15-20 FG18-20
FG15H-20 FG18H-20
FD10-20 FD15-20 FD18-20
FG20-16 FG25-16
FG20H-16 FG25H-16 FG30-16 FG35A-16
FG20N-16 FG25N-16 FG30N-16
FD20-16 FD25-16 FD30-16
FD20H-16 FD25H-16 FD30H-16 FD35A-16
FD20N-16 FD25N-16 FD30N-16

1. INTRODUCTION 
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.
Some actions involved in operation and maintenance of the lift truck can cause a serious accident if they are not
done in the manner described in this manual.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu Forklift Truck FG10-20 FG15H-20 FD10-20 FG20-16 FG20H-16 FG20N-16 FD20-16 FD20H-16 FD20N-16 Operation & Maintenance Manual AEB16E1-12 – PDF DOWNLOAD

1. INTRODUCTION———————————————————————————————————————- 1-1
1.1 ABOUT THIS MANUAL—————————————————————————————————— 1-2
1.2 FOR YOUR SAFETY——————————————————————————————————— 1-3
1.2.1 SIGNAL WORDS —————————————————————————————————– 1-3
1.2.2 SAFETY INDICATORS ——————————————————————————————— 1-4
1.3 APPLICABLE MODEL AND SERIAL No.——————————————————————————- 1-5
1.4 GENERAL VIEW OF LIFT TRUCK————————————————————————————— 1-5
1.4.1 APPLICATION OF LIFT TRUCK ——————————————————————————— 1-5
1.4.2 DIRECTION OF LIFT TRUCK————————————————————————————- 1-5
1.5 UNITS OF MEASURE ——————————————————————————————————- 1-6
1.6 QUALIFICATION FOR OPERATION ———————————————————————————— 1-6
1.7 RUNNING IN NEW LIFT TRUCK —————————————————————————————– 1-6
1.7.1 RUNNING IN NEW LIFT TRUCK——————————————————————————— 1-6
1.7.2 MAINTENANCE FOR NEW LIFT TRUCK ——————————————————————— 1-6
1.8 WARRANTY AND SERVICE———————————————————————————————– 1-6
1.8.1 PERIODICAL EXCHANGE PARTS—————————————————————————— 1-6
1.8.2 USE OF GENUINE PARTS AND OILS————————————————————————- 1-6
1.9 NECESSARY INFORMATION OF LIFT TRUCK ——————————————————————— 1-7
1.9.1 MEMORANDUM (To be filled by KOMATSU FORKLIFT distributor) ———————————– 1-7
1.9.2 MODEL AND SERIAL NO. LOCATION————————————————————————- 1-7
1.9.3 ENGINE SERIAL NO. PLATE OR EMBOSSED LOCATION ——————————————— 1-8
1.9.4 HOUR METER LOCATION —————————————————————————————- 1-8
CONTENTS————————————————————————————————————————– 1-9
2. SAFETY ——————————————————————————————————————————— 2-1
2.1 SAFETY LABEL ————————————————————————————————————— 2-2
2.1.1 SAFETY LABEL LOCATION CHART ————————————————————————— 2-2
2.1.2 SAFETY LABELS—————————————————————————————————– 2-4
2.2 BASIC PRECAUTIONS—————————————————————————————————— 2-8
2.2.1 FOLLOW RULES —————————————————————————————————– 2-8
2.2.2 NEVER OPERATE THE BROKEN-DOWN LIFT TRUCK————————————————– 2-8
2.2.3 WEAR ADEQUATE CLOTHES AND SAFETY EQUIPMENT FOR OPERATION —————— 2-9
2.2.4 FIRE EXTINGUISHER AND FIRST AID KIT —————————————————————— 2-9
2.2.5 CAUTIONS FOR SAFETY-RELATED EQUIPMENT ——————————————————- 2-9
2.2.6 PRACTICE SUFFICIENTLY BEFORE OPERATION ——————————————————- 2-9
2.2.7 JUMPING ON AND OFF FROM THE LIFT TRUCK IS STRICTLY PROHIBITED —————–2-10
2.2.8 KEEP THE OPERATOR’S COMPARTMENT AND PLATFORM CLEAN AND TIDY ————-2-10
2.2.9 PRECAUTION WHEN WASHING LIFT TRUCK ————————————————————2-10
2.2.10 TO AVOID BURN INJURY ————————————————————————————–2-11
2.2.11 FIRE PREVENTION———————————————————————————————–2-11
2.2.12 IF A FIRE BREAKS OUT —————————————————————————————-2-12
2.2.13 DO NOT MODIFY THE LIFT TRUCK ————————————————————————2-12
2.2.14 DO NOT REMOVE THE OVERHEAD GUARD AND LOAD BACKREST ————————–2-13
2.2.15 SECURE SAFETY AT THE WORKING AREA————————————————————-2-13
2.2.16 ENGINE EXHAUST GAS IS POISONOUS —————————————————————–2-13
2.2.17 ASBESTOS CAUTION ——————————————————————————————-2-14
2.2.18 WINDOW WASHER CAUTION ——————————————————————————–2-14
2.3 BEFORE STARTING OPERATION ————————————————————————————-2-15
2.3.1 START-UP INSPECTION —————————————————————————————–2-15
2.3.2 INSPECTION AND ADJUSTMENT BEFORE STARTING ENGINE ———————————–2-15
2.3.3 START-UP INSPECTION —————————————————————————————–2-16
2.4 TRAVELING THE LIFT TRUCK——————————————————————————————2-17
2.4.1 PREPARATION BEFORE TRAVELING THE LIFT TRUCK———————————————-2-17
2.4.2 WHILE TRAVELING THE LIFT TRUCK———————————————————————–2-18
2.4.3 STOPPING AND PARKING ————————————————————————————–2-24
2.4.4 TOWING —————————————————————————————————————2-24
2.5 LOAD HANDLING OPERATION—————————————————————————————–2-25
2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE——————————————————2-30
CONTENTS INTRODUCTION
1 – 10
2.6.1 ALWAY PERFORM THE START-UP INSPECTION —————————————————— 2-30
2.6.2 PUT UP A WARNING SIGN DURING INSPECTION AND MAINTENANCE ———————– 2-30
2.6.3 KEEP THE WORKING AREA CLEAN AND TIDY ——————————————————— 2-30
2.6.4 CAUTIONS BEFORE INSPECTION AND MAINTENANCE——————————————— 2-31
2.6.5 KEEP UNAUTHORIZED PEOPLE OFF ———————————————————————- 2-31
2.6.6 USE OF RIGHT TOOLS AND EQUIPMENT —————————————————————- 2-31
2.6.7 CAUTIONS WHEN WORKING UNDER WORK EQUIPMENT —————————————– 2-31
2.6.8 AVOID GETTING CAUGHT UP BY THE MAST OR FALLING OFF ———————————- 2-32
2.6.9 BE CAREFUL OF BOILING COOLANT ———————————————————————- 2-32
2.6.10 BE CAREFUL OF HIGH PRESSURE OIL—————————————————————— 2-33
2.6.11 BEWARE OF ROTATING COOLING FAN AND BELT ————————————————- 2-33
2.6.12 CAUTION WHEN REPAIRING THE ELECTRICAL SYSTEM —————————————- 2-33
2.6.13 CAUTIONS FOR USING COMPRESSED AIR FOR CLEANING ———————————— 2-33
2.6.14 CAUTION WHEN HANDLING BATTERY —————————————————————— 2-34
2.6.15 STRICTLY FOLLOW THE INSTRUCTIONS SHOWN BELOW TO AVOID GENERATION
OF SPARKS ——————————————————————————————————– 2-34
2.6.16 CAUTION WHEN CHARGING A BATTERY————————————————————— 2-34
2.6.17 CAUTION WHEN HANDLING TIRES ———————————————————————– 2-35
2.6.18 CAUTION IN WASTE DISPOSAL —————————————————————————- 2-36
2.6.19 CAUTION AFTER INSPECTION AND REPAIR ———————————————————- 2-36
2.6.20 PERIODIC INSPECTION OF SAFETY CRITICAL PARTS ——————————————– 2-36
2.7 HOISTING AND TRANSPORTING THE LIFT TRUCK———————————————————— 2-37
2.7.1 CAUTION WHEN HOISTING THE LIFT TRUCK———————————————————– 2-37
2.7.2 PRECAUTIONS FOR LOADING AND UNLOADING THE LIFT TRUCK —————————- 2-37
2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM
TIPPING) ———————————————————————————————————————- 2-38
2.8.1 LONGITUDINAL STABILITY————————————————————————————- 2-38
2.8.2 CENTER OF GRAVITY OF A LOAD ————————————————————————– 2-38
2.8.3 COMBINED CENTER OF GRAVITY AND STABILITY ON THE LOADED LIFT TRUCK ——- 2-39
2.8.4 ACTUAL CAPACITY ———————————————————————————————– 2-39
2.8.5 SERIAL NO. AND LOAD TABLE ——————————————————————————- 2-40
2.8.6 INTRODUCTION OF OPTIONAL SAFETY DEVICE—————————————————— 2-42
2.9 TOWING ———————————————————————————————————————– 2-43
3. OPERATION ————————————————————————————————————————— 3-1
3.1 GENERAL VIEW————————————————————————————————————— 3-2
3.1.1 GENERAL VIEW OF LIFT TRUCK——————————————————————————- 3-2
3.1.2 INSTRUMENTS AND CONTROLS —————————————————————————— 3-3
3.2 EXPLANATION OF COMPONENTS————————————————————————————- 3-5
3.2.1 METER PANEL——————————————————————————————————–3-5
3.2.2 OPERATING DEVICES ——————————————————————————————— 3-9
3.2.3 REMOVING AND INSTALLATION OF ATTACHMENTS ———————————————— 3-14
3.3 OPERATION—————————————————————————————————————— 3-17
3.3.1 START-UP INSPECTION—————————————————————————————– 3-17
3.3.2 MOUNTING/DISMOUNTING AND OPERATING POSTURE ADJUSTMENT———————- 3-17
3.3.3 STARTING, GEAR SHIFTING, AND TRAVELING ——————————————————– 3-21
3.3.4 STARTING AND STOPPING ON SLOPE——————————————————————– 3-26
3.3.5 INCHING TRAVEL————————————————————————————————– 3-27
3.3.6 TURNING ————————————————————————————————————- 3-27
3.3.7 OPERATION ON SNOWY AND FROZEN ROADS ——————————————————- 3-27
3.3.8 TEMPORARY STOPPING AND PARKING—————————————————————— 3-28
3.3.9 LOAD HANDLING OPERATION——————————————————————————– 3-30
3.3.10 CHECKING AFTER OPERATION —————————————————————————- 3-34
3.4 TRANSPORTATION——————————————————————————————————– 3-35
4. INSPECTION AND MAINTENANCE——————————————————————————————— 4-1
4.1 ABOUT INSPECTION AND MAINTENANCE————————————————————————–4-2
4.2 START-UP INSPECTION ————————————————————————————————— 4-2
4.2.1 CHECKING ABNORMALITIES DETECTED ON THE PREVIOUS DAY——————————-4-4
4.2.2 WALK AROUND A LIFT TRUCK ———————————————————————————4-4
INTRODUCTION CONTENTS
1 – 11
4.2.3 INSPECTION BY OPENING THE ENGINE HOOD ——————————————————— 4-6
4.2.4 CHECKING FROM THE OPERATOR SEAT—————————————————————–4-10
4.2.5 CHECK BY SETTING THE STARTER SWITCH TO [ | ] (ON) POSITION —————————4-12
4.2.6 CHECKING WITH THE ENGINE STARTED—————————————————————–4-15
4.2.7 CHECKING WHILE TRAVELING SLOWLY——————————————————————4-16
4.2.8 CHECKING BY OPERATING THE WORK EQUIPMENT LEVER————————————–4-16
4.2.9 CHECKING OF SAFETY FUNCTION————————————————————————–4-18
4.3 CHECKING AND REPORTING AFTER OPERATION————————————————————-4-19
4.4 SIMPLE MAINTENANCE ————————————————————————————————–4-20
4.4.1 GREASES AND FUEL ———————————————————————————————4-20
4.4.1.1 BASIC PRECAUTIONS ———————————————————————————–4-20
4.4.1.2 LUBRICANT LIST ——————————————————————————————-4-23
4.4.2 AIR CLEANER ELEMENT CLEANING ————————————————————————4-25
4.4.3 FUEL FILTER WATER DRAINING AND AIR BLEEDING (DIESEL ENGINE LIFT TRUCK)—-4-26
4.4.4 REPLACING TIRES————————————————————————————————-4-27
4.4.5 ADJUSTING PARKING BRAKE LEVER OPERATING EFFORT—————————————4-29
4.4.6 REPLACING FUSES ———————————————————————————————–4-29
4.4.7 REPLACING BULBS————————————————————————————————4-31
4.5 PROCEDURE FOR A DOWN BATTERY——————————————————————————4-32
4.6 RUNNING IN COLD WEATHER —————————————————————————————–4-34
4.7 ACTION IN ENGINE OVERHEATING———————————————————————————-4-36
4.8 OPERATING LIFT TRUCKS IN SPECIAL ENVIRONMENT OR IN FORCIBLE WAY ——————–4-37
4.9 ACTION TO TAKE IF THE FORK FAILS TO LOWER ————————————————————-4-38
4.10 WASHING LIFT TRUCK————————————————————————————————–4-39
4.11 LONG-TERM STORAGE————————————————————————————————-4-40
4.12 HOISTING LIFT TRUCK————————————————————————————————–4-41
4.13 LOADING AND UNLOADING OF LIFT TRUCK——————————————————————–4-42
4.14 INSPECTION AND MAINTENANCE SCHEDULE CHART —————————————————–4-43
4.15 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ————————————————-4-49
4.16 SERVICE DATA ————————————————————————————————————4-50
5. TECHNICAL DATA——————————————————————————————————————- 5-1
6. INDEX———————————————————————————————————————————— 6-1

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