Komatsu Forklift Truck FG10-21 FG15H-21 FG10-21 FG20-17 FG20H-17 FG20N-17 FD20-17 FD20H-17 Operation & Maintenance Manual TEN00556-01 – PDF DOWNLOAD

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Komatsu Forklift Truck FG10-21 FG15H-21 FG10-21 FG20-17 FG20H-17 FG20N-17 FD20-17 FD20H-17 Operation & Maintenance Manual TEN00556-01 – PDF DOWNLOAD

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Komatsu Forklift Truck FG10-21 FG15H-21 FG10-21 FG20-17 FG20H-17 FG20N-17 FD20-17 FD20H-17 Operation & Maintenance Manual TEN00556-01 – PDF DOWNLOAD

Language : English
Pages : 256
Downloadable : Yes
File Type : PDF
Size: 6.53 MB

DESCRIPTION:

Komatsu Forklift Truck FG10-21 FG15H-21 FG10-21 FG20-17 FG20H-17 FG20N-17 FD20-17 FD20H-17 Operation & Maintenance Manual TEN00556-01 – PDF DOWNLOAD

FG10-21 FG15-21 FG18-21
FG15H-21 FG18H-21
FD10-21 FD15-21 FD18-21
FG20-17 FG25-17
FG20H-17 FG25H-17 FG30-17 FG35A-17
FG20N-17 FG25N-17 FG30N-17
FD20-17 FD25-17 FD30-17
FD20H-17 FD25H-17 FD30H-17 FD35A-17

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 FG10-21 FG15H-21 FG10-21 FG20-17 FG20H-17 FG20N-17 FD20-17 FD20H-17 Operation & Maintenance Manual TEN00556-01 – 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 KOMATSU 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 FIRE PREVENTION ——————————————————————————————————— 2-8
2.2.1 ENGINE FIRE PREVENTION ———————————————————————————— 2-8
2.2.1.1 CHECKING BEFORE STARTING THE ENGINE ————————————————— 2-8
2.2.2 PREVENTION FIRES CAUSED BY FUEL OR OIL ——————————————————–2-12
2.2.3 PREVENTION OF FIRE CAUSED BY DEPOSITED OR ADHERED
FLAMMABLE SUBSTANCES ———————————————————————————-2-12
2.2.4 PREVENTION OF FIRE CAUSED BY FAULTY ELECTRICAL WIRING—————————–2-12
2.2.5 PREVENTION OF FIRE CAUSED BY FAULTY PIPING ————————————————-2-12
2.2.6 CLEANING————————————————————————————————————2-13
2.2.7 IF A FIRE BREAKS OUT——————————————————————————————2-14
2.2.8 INSTALLATION OF FIRE EXTINGUISHER(IF EQUIPPED)——————————————–2-15
2.3 BASIC PRECAUTIONS—————————————————————————————————-2-16
2.3.1 FOLLOW RULES —————————————————————————————————2-16
2.3.2 NEVER OPERATE THE BROKEN-DOWN LIFT TRUCK ————————————————2-16
2.3.3 WEAR ADEQUATE CLOTHES AND SAFETY EQUIPMENT FOR OPERATION——————2-17
2.3.4 FIRE EXTINGUISHER AND FIRST AID KIT—————————————————————–2-17
2.3.5 CAUTIONS FOR SAFETY-RELATED EQUIPMENT ——————————————————2-17
2.3.6 PRACTICE SUFFICIENTLY BEFORE OPERATION——————————————————2-17
2.3.7 JUMPING ON AND OFF FROM THE LIFT TRUCK IS STRICTLY PROHIBITED —————–2-18
2.3.8 KEEP THE OPERATOR’S COMPARTMENT AND PLATFORM CLEAN AND TIDY ————-2-18
2.3.9 PRECAUTION WHEN WASHING LIFT TRUCK————————————————————2-18
2.3.10 TO AVOID BURN INJURY————————————————————————————–2-19
2.3.11 FIRE PREVENTION ———————————————————————————————-2-19
2.3.12 IF A FIRE BREAKS OUT —————————————————————————————-2-20
2.3.13 DO NOT MODIFY THE LIFT TRUCK ————————————————————————2-20
2.3.14 DO NOT REMOVE THE OVERHEAD GUARD AND LOAD BACKREST ————————–2-21
2.3.15 SECURE SAFETY AT THE WORKING AREA ————————————————————2-21
2.3.16 ENGINE EXHAUST GAS IS POISONOUS—————————————————————–2-21
2.3.17 ASBESTOS CAUTION——————————————————————————————-2-22
2.3.18 WINDOW WASHER CAUTION——————————————————————————–2-22
CONTENTS INTRODUCTION
1 – 10
2.4 BEFORE STARTING OPERATION———————————————————————————— 2-23
2.4.1 START-UP INSPECTION —————————————————————————————- 2-23
2.4.2 INSPECTION AND ADJUSTMENT BEFORE STARTING ENGINE ———————————- 2-23
2.4.3 START-UP INSPECTION —————————————————————————————- 2-24
2.5 TRAVELING THE LIFT TRUCK—————————————————————————————– 2-25
2.5.1 PREPARATION BEFORE TRAVELING THE LIFT TRUCK——————————————— 2-25
2.5.2 WHILE TRAVELING THE LIFT TRUCK———————————————————————- 2-26
2.5.3 STOPPING AND PARKING ————————————————————————————- 2-32
2.5.4 TOWING————————————————————————————————————– 2-32
2.6 LOAD HANDLING OPERATION—————————————————————————————- 2-33
2.7 PRECAUTIONS FOR INSPECTION AND MAINTENANCE—————————————————– 2-38
2.7.1 ALWAY PERFORM THE START-UP INSPECTION—————————————————— 2-38
2.7.2 PUT UP A WARNING SIGN DURING INSPECTION AND MAINTENANCE ———————– 2-38
2.7.3 KEEP THE WORKING AREA CLEAN AND TIDY ——————————————————— 2-38
2.7.4 CAUTIONS BEFORE INSPECTION AND MAINTENANCE——————————————— 2-39
2.7.5 KEEP UNAUTHORIZED PEOPLE OFF———————————————————————- 2-39
2.7.6 USE OF RIGHT TOOLS AND EQUIPMENT —————————————————————- 2-39
2.7.7 CAUTIONS WHEN WORKING UNDER WORK EQUIPMENT—————————————– 2-39
2.7.8 AVOID GETTING CAUGHT UP BY THE MAST OR FALLING OFF———————————- 2-40
2.7.9 BE CAREFUL OF BOILING COOLANT ———————————————————————- 2-40
2.7.10 BE CAREFUL OF HIGH PRESSURE OIL —————————————————————– 2-41
2.7.11 BEWARE OF ROTATING COOLING FAN AND BELT ————————————————- 2-41
2.7.12 CAUTION WHEN REPAIRING THE ELECTRICAL SYSTEM —————————————- 2-41
2.7.13 CAUTIONS FOR USING COMPRESSED AIR FOR CLEANING ———————————— 2-41
2.7.14 CAUTION WHEN HANDLING BATTERY —————————————————————— 2-42
2.7.15 STRICTLY FOLLOW THE INSTRUCTIONS SHOWN
BELOW TO AVOID GENERATION OF SPARKS ——————————————————- 2-42
2.7.16 CAUTION WHEN CHARGING A BATTERY————————————————————— 2-42
2.7.17 CAUTION WHEN HANDLING TYRES———————————————————————- 2-43
2.7.18 CAUTION IN WASTE DISPOSAL—————————————————————————- 2-44
2.7.19 CAUTION AFTER INSPECTION AND REPAIR ———————————————————- 2-44
2.7.20 PERIODIC INSPECTION OF SAFETY CRITICAL PARTS ——————————————– 2-44
2.8 HOISTING AND TRANSPORTING THE LIFT TRUCK ———————————————————– 2-45
2.8.1 CAUTION WHEN HOISTING THE LIFT TRUCK ———————————————————- 2-45
2.8.2 PRECAUTIONS FOR LOADING AND UNLOADING THE LIFT TRUCK —————————- 2-45
2.9 STRUCTURE AND STABILITY OF THE LIFT TRUCK
(TO PREVENT LIFT TRUCK FROM TIPPING) ——————————————————————– 2-46
2.9.1 LONGITUDINAL STABILITY ———————————————————————————— 2-46
2.9.2 CENTER OF GRAVITY OF A LOAD ————————————————————————– 2-46
2.9.3 COMBINED CENTER OF GRAVITY AND STABILITY
ON THE LOADED LIFT TRUCK —————————————————————————— 2-47
2.9.4 ACTUAL CAPACITY———————————————————————————————– 2-47
2.9.5 SERIAL NO. AND LOAD TABLE——————————————————————————- 2-48
2.9.6 INTRODUCTION OF OPTIONAL SAFETY DEVICE—————————————————— 2-50
2.10 TOWING——————————————————————————————————————— 2-51
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 ——————————————————– 3-23
3.3.4 STARTING AND STOPPING ON SLOPE ——————————————————————- 3-28
INTRODUCTION CONTENTS
1 – 11
3.3.5 INCHING TRAVEL————————————————————————————————–3-29
3.3.6 TURNING ————————————————————————————————————-3-29
3.3.7 OPERATION ON SNOWY AND FROZEN ROADS——————————————————–3-29
3.3.8 TEMPORARY STOPPING AND PARKING ——————————————————————3-30
3.3.9 LOAD HANDLING OPERATION——————————————————————————–3-32
3.3.10 CHECKING AFTER OPERATION —————————————————————————-3-36
3.4 TRANSPORTATION——————————————————————————————————–3-37
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
4.2.3 INSPECTION BY OPENING THE ENGINE HOOD ——————————————————— 4-6
4.2.4 CHECKING FROM THE OPERATOR SEAT —————————————————————-4-11
4.2.5 CHECK BY SETTING THE STARTER SWITCH TO [ | ] (ON) POSITION—————————4-13
4.2.6 CHECKING WITH THE ENGINE STARTED—————————————————————–4-16
4.2.7 CHECKING WHILE TRAVELING SLOWLY——————————————————————4-17
4.2.8 CHECKING BY OPERATING THE WORK EQUIPMENT LEVER ————————————-4-17
4.2.9 CHECKING OF SAFETY FUNCTION ————————————————————————-4-19
4.3 CHECKING AND REPORTING AFTER OPERATION————————————————————-4-20
4.4 SIMPLE MAINTENANCE————————————————————————————————–4-21
4.4.1 GREASES AND FUEL———————————————————————————————4-21
4.4.1.1 BASIC PRECAUTIONS———————————————————————————–4-21
4.4.1.2 LUBRICANT LIST ——————————————————————————————4-24
4.4.1.3 LUBRICANT LIST (GASOLINE ENGINE LIFT TRUCK) (FOR EU) —————————4-25
4.4.1.4 LUBRICANT LIST (DIESEL ENGINE LIFT TRUCK) (FOR EU) ——————————–4-26
4.4.2 AIR CLEANER ELEMENT CLEANING————————————————————————4-28
4.4.3 FUEL FILTER WATER DRAINING AND AIR BLEEDING (DIESEL ENGINE LIFT TRUCK) —-4-29
4.4.4 REPLACING TYRES———————————————————————————————–4-30
4.4.5 ADJUSTING PARKING BRAKE LEVER OPERATING EFFORT—————————————4-32
4.4.6 REPLACING FUSES———————————————————————————————–4-32
4.4.7 REPLACING BULBS———————————————————————————————–4-35
4.5 PROCEDURE FOR A DOWN BATTERY —————————————————————————–4-36
4.6 RUNNING IN COLD WEATHER—————————————————————————————–4-38
4.7 ACTION IN ENGINE OVERHEATING ———————————————————————————4-40
4.8 OPERATING LIFT TRUCKS IN SPECIAL ENVIRONMENT OR IN FORCIBLE WAY———————4-41
4.9 ACTION TO TAKE IF THE FORK FAILS TO LOWER————————————————————-4-42
4.10 WASHING LIFT TRUCK ————————————————————————————————-4-43
4.11 LONG-TERM STORAGE ————————————————————————————————4-44
4.12 HOISTING LIFT TRUCK ————————————————————————————————-4-45
4.13 LOADING AND UNLOADING OF LIFT TRUCK ——————————————————————-4-46
4.14 INSPECTION AND MAINTENANCE SCHEDULE CHART —————————————————–4-47
4.15 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ————————————————-4-53
4.16 SERVICE DATA————————————————————————————————————4-54
5. TECHNICAL DATA —————————————————————————————————————— 5-1
6. EC DECLARATION OF CONFORMITY—————————————————————————————- 6-1
6.1 EC DECLARATION OF CONFORMITY (FG(D)10 – 18-21) ——————————————————- 6-2
6.2 EC DECLARATION OF CONFORMITY (FG(D)20 – 35A-17) —————————————————– 6-3
6.3 EC DECLARATION OF CONFORMITY (FD20 – 35A-17)———————————————————- 6-4
6.4 TIE-DOWN POSITIONS OF LIFT TRUCK —————————————————————————- 6-4
7. LPG FORK LIFT———————————————————————————————————————- 7-1
7.1 CHAPTER CONTENTS—————————————————————————————————– 7-2
7.2 SAFETY LABELS————————————————————————————————————- 7-2
7.2.1 SAFETY LABEL LOCATIONS———————————————————————————— 7-2
7.2.2 SAFETY LABELS —————————————————————————————————- 7-2
7.3 BASIC PRECAUTIONS—————————————————————————————————– 7-3
7.4 OPERATING THE LPG FORKLIFT————————————————————————————– 7-5
7.4.1 PART NAME———————————————————————————————————– 7-5
CONTENTS INTRODUCTION
1 – 12
7.4.2 DESCRIPTION OF COMPONENTS —————————————————————————- 7-6
7.5 REFUELING (LP GAS)—————————————————————————————————- 7-10
7.5.1 REFUELING (LP GAS) BY REPLACING THE LPG CYLINDER————————————— 7-10
7.5.1.1 FORKLIFT W/ SWING BRACKET——————————————————————— 7-10
7.5.1.2 FORKLIFT W/ SWING-DOWN BRACKET ———————————————————- 7-14
7.5.1.3 FORKLIFT W/ DOUBLE CYLINDER BRACKET————————————————— 7-18
7.5.2 REFUELING (LP GAS) THE LPG CYLINDER WHEN MOUNTED ON THE FORKLIFT ——– 7-21
7.6 PRESTART INSPECTION———————————————————————————————— 7-22
7.6.1 INSPECTING THE LPG CYLINDER WHILE MOUNTED ON THE FORKLIFT ——————– 7-22
7.6.2 CHECKING THE CHARGE AND DISCHARGE VALVES———————————————— 7-22
7.6.3 CHECKING THE LPG LEVEL———————————————————————————– 7-23
7.6.4 CHECKING THE HOT WATER HOSE CONNECTION ————————————————– 7-23
7.6.5 CHECKING THE ELECTRICAL WIRING ——————————————————————– 7-23
7.6.6 CHECKING THE HIGH-PRESSURE LINES FOR GAS LEAKS ————————————— 7-24
7.6.7 CHECKING THE COOLANT LEVEL ————————————————————————– 7-25
7.7 OPERATING—————————————————————————————————————– 7-26
7.7.1 STARTING ENGINE W/ LP GAS——————————————————————————- 7-26
7.7.2 STARTING THE ENGINE IN COLD CONDITIONS ——————————————————- 7-29
7.7.3 SWITCHING FUEL FROM LP GAS TO GASOLINE —————————————————— 7-31
7.7.4 SWITCHING FUEL FROM GASOLINE TO LP GAS —————————————————— 7-33
7.7.5 STOPPING LP GAS DRIVEN ENGINES——————————————————————— 7-35
7.7.6 STOPPING GASOLINE DRIVEN ENGINES —————————————————————- 7-36
7.8 BASIC MAINTENANCE ————————————————————————————————— 7-37
7.8.1 CHECK AND DRAINING OF TAR IN THE VAPORIZER ———————————————— 7-37
7.8.2 CLEANING THE LPG FILTER ———————————————————————————- 7-38
7.9 PARKING, DISUSE, STORAGE—————————————————————————————- 7-38
7.10 INSPECTION AND MAINTENANCE SCHEDULE—————————————————————- 7-39
7.11 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ———————————————— 7-40
7.12 SERVICE DATA ———————————————————————————————————– 7-41
8. ATTACHMENT———————————————————————————————————————— 8-1
8.1 OPERATION OF SIDE SHIFT——————————————————————————————— 8-2
8.1.1 ATTACHMENT MODEL PLATE LOCATION, SERIAL NO. ———————————————– 8-2
8.1.2 SAFETY OF ATTACHEMENTS ———————————————————————————- 8-3
8.1.3 SAFETY LABEL —————————————————————————————————— 8-4
8.1.4 FEATURES OF ATTACHMENTS——————————————————————————– 8-6
8.1.5 GENERAL VIEW —————————————————————————————————– 8-7
8.1.6 EXPLANATION OF COMPONENTS—————————————————————————- 8-8
8.1.7 OPERATION——————————————————————————————————— 8-10
8.1.8 INSPECTION AND MAINTENANCE SCHEDULE CHART———————————————- 8-12
8.1.9 MAINTENANCE WORK —————————————————————————————— 8-13
9. OPTIONS——————————————————————————————————————————- 9-1
9.1 HANDLING OF LOAD CHECKER WITH OVERLOAD ALARM ————————————————– 9-2
9.2 HANDLING OF MAST TILT ANGLE METER + AUTO STOP FUNCTION————————————- 9-3
9.3 HANDLING OF LASER LIFT HEIGHT SENSOR——————————————————————— 9-4
9.3.1 MAIN SPECIFICATIONS AND EXPLANATION————————————————————– 9-4
9.3.2 EXPLANATION OF OPERATION——————————————————————————– 9-5
9.3.3 PRECAUTIONS FOR HANDLING——————————————————————————- 9-6
9.4 TRAVEL SPEED LIMITER ————————————————————————————————- 9-8
10. INDEX——————————————————————————————————————————– 10-1

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PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

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