Description

KOMASTU DF20 25 30(N) 35A OPERATION MANUAL

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KOMASTU DF20 25 30(N) 35A OPERATION MANUAL contains high quality images, diagrams, instructions to help you to operate, maintenance, diagnostic, and repair your machine. This document is printable, without restrictions, contains searchable text and bookmarks for easy navigation.

KOMASTU DF20 25 30(N) 35A OPERATION MANUAL includes:

Numbered table of contents easy to use so that you can find the information you need fast.
Detailed sub-steps expand on repair procedure information.
Numbered instructions guide you through every repair procedure step by step.
Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
Notes, cautions and warnings throughout each chapter pinpoint critical information.
Bold figure number help you quickly match illustrations with instructions.
Detailed illustrations, drawings and photos guide you through every procedure.
Enlarged inset helps you identify and examine parts in detail.

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TABLE OF CONTENT OF THE KOMASTU DF20 25 30(N) 35A OPERATION MANUAL

CONTENTS 1
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

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

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