Komatsu FG40Z-10, FG35-10, FG40-10, FG45-10, FG50A-10, FD40Z-10, FD35-10, FD40-10, FD45-10, FD50A-10, FD40YZ Operation and Maintenance Manual AEC10E1-02

Description

• Model List:
  • FG40Z-10 Forklift Truck
  • FG35-10 Forklift Truck
  • FG40-10 Forklift Truck
  • FG45-10 Forklift Truck
  • FG50A-10 Forklift Truck
  • FD40Z-10 Forklift Truck
  • FD35-10 Forklift Truck
  • FD40-10 Forklift Truck
  • FD45-10 Forklift Truck
  • FD50A-10 Forklift Truck
  • FD40YZ-10 Forklift Truck
  • FD35Y-10 Forklift Truck
  • FD40Y-10 Forklift Truck
  • FD45Y-10 Forklift Truck
  • FD50AY-10 Forklift Truck

• 1. INTRODUCTION
• 1.1. INTRODUCTION
• 1.2. ABOUT THIS MANUAL
• 1.3. ENGINE MOUNTED ON THIS LIFT TRUCK
• 1.3.1. EXHAUST GAS CONTROL (APPLIED TO DIESEL ENGINE LIFT TRUCK)
• 1.3.2. CERTIFICATION LABEL AFFIXED POSITION
• 1.4. FOR YOUR SAFETY
• 1.4.1. SIGNAL WORDS
• 1.4.2. SAFETY INDICATORS
• 1.5. APPLICABLE MODEL AND SERIAL NO.
• 1.6. GENERAL VIEW OF LIFT TRUCK
• 1.6.1. APPLICATION OF LIFT TRUCK
• 1.6.2. DIRECTION OF LIFT TRUCK
• 1.7. UNITS OF MEASURE
• 1.8. QUALIFICATIONS FOR OPERATION
• 1.9. RUNNING IN NEW LIFT TRUCK
• 1.9.1. RUNNING IN NEW LIFT TRUCK
• 1.9.2. MAINTENANCE FOR NEW LIFT TRUCK
• 1.10. WARRANTY AND SERVICE
• 1.10.1. PERIODICAL EXCHANGE PARTS
• 1.10.2. USE OF GENUINE KOMATSU UTILITY PARTS AND OILS
• 1.10.3. ENGINE MOUNTED ON THIS LIFT TRUCK
• 1.11. NECESSARY INFORMATION OF LIFT TRUCK
• 1.11.1. MEMORANDUM (TO BE FILLED BY KOMATSU FORKLIFT DISTRIBUTOR)
• 1.11.2. MODEL AND SERIAL NO. PLATE LOCATION
• 1.11.3. ENGINE SERIAL NO. PLATE OR STAMPING LOCATION
• 1.11.4. HOUR METER LOCATION
• 1.12. CONTENTS
• 2. SAFETY
• 2.1. SAFETY
• 2.2. SAFETY LABEL
• 2.2.1. SAFETY LABEL LOCATION CHART
• 2.2.2. SAFETY LABELS
• 2.3. BASIC PRECAUTIONS
• 2.3.1. FOLLOW RULES
• 2.3.2. NEVER OPERATE THE BROKENDOWN LIFT TRUCK
• 2.3.3. WEAR ADEQUATE CLOTHES AND SAFETY EQUIPMENT FOR OPERATION
• 2.3.4. FIRE EXTINGUISHER AND FIRST AID KIT
• 2.3.5. CAUTIONS FOR SAFETYRELATED EQUIPMENT
• 2.3.6. PRACTICE SUFFICIENTLY BEFORE OPERATION
• 2.3.7. JUMPING ON AND OFF FROM THE LIFT TRUCK IS STRICTLY PROHIBITED
• 2.3.8. KEEP THE OPERATORS COMPARTMENT AND PLATFORM CLEAN AND TIDY
• 2.3.9. CAUTION WHEN WASHING LIFT TRUCK
• 2.3.10. TO AVOID BURN INJURY
• 2.3.11. FIRE PREVENTION
• 2.3.12. IF A FIRE BREAKS OUT
• 2.3.13. DO NOT MODIFY THE LIFT TRUCK
• 2.3.14. DO NOT REMOVE THE OVERHEAD GUARD AND LOAD BACKREST
• 2.3.15. SECURE SAFETY AT THE WORKING AREA
• 2.3.16. ENGINE EXHAUST GAS IS POISONOUS
• 2.3.17. ASBESTOS CAUTION
• 2.3.18. WINDOW WASHER CAUTION
• 2.4. BEFORE STARTING OPERATION
• 2.4.1. STARTUP INSPECTION
• 2.4.2. INSPECTION AND ADJUSTMENT BEFORE STARTING ENGINE CHECK THE FOLLOWINGS BEFORE STARTING THE ENGINE
• 2.4.3. STARTUP INSPECTION
• 2.5. TRAVELLING THE LIFT TRUCK
• 2.5.1. PREPARATION BEFORE TRAVELLING THE LIFT TRUCK
• 2.5.2. WHILE TRAVELING THE LIFT TRUCK
• 2.5.3. STOPPING AND PARKING
• 2.5.4. TOWING
• 2.6. LOAD HANDLING OPERATION
• 2.7. PRECAUTIONS FOR INSPECTION AND MAINTENANCE
• 2.7.1. BE SURE TO PERFORM THE STARTUP INSPECTION AND THE PERIODIC VOLUNTARY INSPECTION
• 2.7.2. PUT UP A WARNING SIGN DURING INSPECTION AND MAINTENANCE
• 2.7.3. KEEP THE WORKING AREA CLEAN AND TIDY
• 2.7.4. PRECAUTIONS BEFORE INSPECTION AND MAINTENANCE
• 2.7.5. KEEP UNAUTHORIZED PEOPLE OFF
• 2.7.6. USE OF RIGHT TOOLS AND EQUIPMENT
• 2.7.7. CAUTIONS WHEN WORKING UNDER WORK EQUIPMENT
• 2.7.8. AVOID GETTING CAUGHT UP BY THE MAST OR FALLING OFF
• 2.7.9. BE CAREFUL OF BOILING COOLANT
• 2.7.10. BE CAREFUL OF HIGH PRESSURE OIL
• 2.7.11. BEWARE OF ROTATING COOLING FAN AND BELT
• 2.7.12. PRECAUTIONS FOR INSTALLING RADIO CONTROL SYSTEM
• 2.7.13. CAUTION WHEN REPAIRING THE ELECTRICAL SYSTEM
• 2.7.14. CAUTIONS FOR USING COMPRESSED AIR FOR CLEANING
• 2.7.15. CAUTIONS WHEN REPLACING THE SEAT
• 2.7.16. CAUTION WHEN HANDLING BATTERY
• 2.7.17. STRICTLY FOLLOW THE INSTRUCTIONS SHOWN BELOW TO AVOID GENERATION OF SPARKS
• 2.7.18. CAUTION WHEN CHARGING A BATTERY
• 2.7.19. CAUTION WHEN HANDLING TYRES
• 2.7.20. CAUTION IN WASTE DISPOSAL
• 2.7.21. CAUTION AFTER INSPECTION AND REPAIR
• 2.7.22. PERIODIC INSPECTION OF SAFETY CRITICAL PARTS
• 2.8. HOISTING AND TRANSPORTING THE LIFT TRUCK
• 2.8.1. CAUTION WHEN HOISTING THE LIFT TRUCK
• 2.8.2. CAUTIONS FOR LOADING AND UNLOADING THE LIFT TRUCK
• 2.9. STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING)
• 2.9.1. LONGITUDINAL STABILITY
• 2.9.2. CENTER OF GRAVITY OF A LOAD
• 2.9.3. COMBINED CENTER OF GRAVITY AND STABILITY ON THE LOADED LIFT TRUCK
• 2.9.4. ACTUAL CAPACITY
• 2.9.5. SERIAL NO. PLATE AND LOAD TABLE
• 2.9.6. INTRODUCTION OF OPTIONAL SAFETY DEVICE
• 3. OPERATION
• 3.1. OPERATION
• 3.2. GENERAL VIEW
• 3.2.1. GENERAL VIEW OF LIFT TRUCK
• 3.2.2. INSTRUMENTS AND CONTROLS
• 3.3. EXPLANATION OF COMPONENTS
• 3.3.1. METER PANEL
• 3.3.2. OPERATING DEVICES
• 3.4. OPERATION
• 3.4.1. STARTUP INSPECTION
• 3.4.2. MOUNTING/DISMOUNTING AND OPERATING POSTURE ADJUSTMENT
• 3.4.3. STARTING, GEAR SHIFTING, AND TRAVELING
• 3.4.4. STARTING AND STOPPING ON SLOPE
• 3.4.5. INCHING TRAVEL
• 3.4.6. TURNING
• 3.4.7. OPERATION ON SNOWY AND FROZEN ROADS
• 3.4.8. TEMPORARY STOPPING, PARKING AND STOPPING
• 3.4.9. LOAD HANDLING OPERATION
• 3.4.10. CHECKING AFTER OPERATION
• 4. INSPECTION AND MAINTENANCE
• 4.1. INSPECTION AND MAINTENANCE
• 4.2. INSPECTION AND MAINTENANCE
• 4.3. STARTUP INSPECTION
• 4.3.1. CHECKING ABNORMALITIES DETECTED ON THE PREVIOUS DAY
• 4.3.2. WALK AROUND A LIFT TRUCK
• 4.3.3. INSPECTION BY OPENING COVER AND HOOD
• 4.3.4. CHECKING FROM THE OPERATOR SEAT
• 4.3.5. CHECK BY SETTING THE STARTING SWITCH TO (ON) POSITION
• 4.3.6. CHECKING WITH THE ENGINE STARTED
• 4.3.7. CHECKING THE BRAKE ACCUMULATOR
• 4.3.8. CHECKING WHILE TRAVELING SLOWLY
• 4.3.9. CHECKING BY OPERATING THE WORK EQUIPMENT LEVER
• 4.3.10. CHECKING OF SAFETY FUNCTION
• 4.4. CHECKING AND REPORTING AFTER OPERATION
• 4.5. SIMPLE MAINTENANCE
• 4.5.1. GREASES AND FUEL
• 4.5.1.1. BASIC PRECAUTIONS
• 4.5.1.2. LUBRICANT LIST (FG40Z, FG35, FG40, FG45, FG50A)
• 4.5.1.3. LUBRICANT LIST (FD40Z, FD35, FD40, FD45, FD50A)
• 4.5.1.4. LUBRICANT LIST (FD40ZY, FD35Y, FD40Y, FD45Y, FD50AY)
• 4.5.2. AIR CLEANER ELEMENT INSPECTION AND CLEANING
• 4.5.3. FUEL FILTER AIR BLEEDING (FD40Z, FD35, FD40, FD45, FD50A)
• 4.5.4. FUEL FILTER AIR BLEEDING (FD40Z, FD35, FD40, FD45, FD50A/REF)
• 4.5.5. FUEL FILTER WATER DRAINING AND AIR BLEEDING (FD40ZY, FD35Y, FD40Y, FD45Y, FD50AY)
• 4.5.6. REPLACING TYRES
• 4.5.7. ADJUSTING PARKING BRAKE LEVER OPERATING EFFORT
• 4.5.8. REPLACING FUSE
• 4.5.9. REPLACING BULBS
• 4.5.10. CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER (FD40Z, FD35, FD40, FD45, FD50A)
• 4.5.11. CHECKING FOR HARDENING OF ENGINE CONTROLLER MOUNT RUBBER AND LOOSE MOUNTING (FD40Z, FD35, FD40, FD45, FD50A)
• 4.6. PROCEDURE FOR A DOWN BATTERY
• 4.7. RUNNING IN COLD WEATHER
• 4.8. PROCEDURE WITH OVERHEATED ENGINE
• 4.9. OPERATING LIFT TRUCKS IN SPECIAL ENVIRONMENT OR IN FORCIBLE WAY
• 4.10. ACTION TO TAKE IF THE FORK FAILS TO LOWER
• 4.11. WASHING LIFT TRUCKS
• 4.12. LONGTERM STORAGE
• 4.13. HOISTING LIFT TRUCK
• 4.14. LOADING AND UNLOADING OF LIFT TRUCK
• 4.15. INSPECTION AND MAINTENANCE SCHEDULE CHART
• 4.16. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
• 4.17. SERVICE DATA
• 5. TECHNICAL DATA
• 5.1. TECHNICAL DATA
• 6. INDEX
• 6.1. INDEX