Format: PDF (Printable Document)
File Language: English
File Pages: 169
File Size: 4.16 MB (Speed Download Link)
Brand: Komatsu
Model: FG50-7, FG60-7, FG70-7, FG70-8, FD50-7, FD60-7, FD70-7, FD50-8, FD60-8, FD80-8 Forklift Truck
Book No: TEN00576-00
Type of Document: Operation and Maintenance Manual
$ 40
These Komatsu FG/FD series forklifts spend their lives loading trucks, feeding production lines, and shuttling pallets in yards and warehouses, often in dust, temperature swings, and stop‑start abuse. This Operation and Maintenance Manual helps you set a steady service rhythm so the truck is ready every shift, instead of breaking down at the dock. When a driver reports sluggish lifting or odd steering feel, this is what I’d use to walk through basic checks, line up the right inspections, and decide if it’s a quick adjustment or needs shop time.
Applications & Use Cases
FAQ
Q: Can I keep this manual on a tablet in the shop?
A: Yes, it’s handy to zoom diagrams and search terms, then print only the pages you’re working from.
Q: Is it still worth printing parts of it?
A: I print the maintenance charts and keep them in a plastic sleeve on the wall near the service bay.
Safety Note
Always lock out, chock, and support the forklift securely before working under the mast or chassis.
1. Foreword ………………………………………………………………………………………………………. 0- 1
2. Safety information ………………………………………………………………………………………… 0- 2
3. Running in new lift truck ………………………………………………………………………………. 0- 3
3.1 Running in new lift truck ………………………………………………………………………. 0- 3
3.2 First month service
(or initial 200 hours service) for new lift truck ………………………………………. 0- 3
3.3 Model line up……………………………………………………………………………………….. 0- 3
4. Warranty and service for new lift truck ………………………………………………………… 0- 4
4.1 KOMATSU FORKLIFT Genuine Parts …………………………………………………….. 0- 4
5. Location of plates …………………………………………………………………………………………. 0- 5
5.1 Lift truck serial No. plate position …………………………………………………………. 0- 5
SAFETY
7. Safety management ………………………………………………………………………………………. 1- 2
8. Safe travel …………………………………………………………………………………………………….. 1- 7
9. Loading operations ……………………………………………………………………………………….. 1-16
10. Stopping and parking ……………………………………………………………………………………. 1-23
11. Inspection and maintenance ………………………………………………………………………….. 1-25
12. Structure and stability of the lift truck (to prevent lift truck from tipping!) ….. 1-34
13. Safety label sticking positions ………………………………………………………………………. 1-38
13.1 Safety label sticking positions ………………………………………………………………. 1-38
13.2 Introduction of safety devices (option) ………………………………………………….. 1-41
OPERATION
14. General view …………………………………………………………………………………………………. 2- 2
14.1 General view of lift truck ………………………………………………………………………. 2- 2
14.2 Instruments and controls ……………………………………………………………………… 2- 3
15. Explanation of components …………………………………………………………………………… 2- 4
16. Operation ………………………………………………………………………………………………………. 2-21
16.1 Check before operation ………………………………………………………………………… 2-21
16.2 Mounting/dismounting ………………………………………………………………………….. 2-35
16.3 Operator’s seat adjustment …………………………………………………………………… 2-35
16.4 Starting lift truck off ……………………………………………………………………………… 2-36
16.5 Starting, inching on slope …………………………………………………………………….. 2-41
16.6 Turning ………………………………………………………………………………………………… 2-42
16.7 Temporary stopping and parking ………………………………………………………….. 2-43
16.8 Fork spread adjustment ………………………………………………………………………… 2-45
16.9 Load handling operation ………………………………………………………………………. 2-46
16.10 Check after operation ……………………………………………………………………………. 2-47
17. Cold weather operation ………………………………………………………………………………….. 2-48
17.1 Preparations for low temperature …………………………………………………………… 2-48
17.2 Precautions after completion of operations …………………………………………….. 2-49
18. Action in engine overheating ………………………………………………………………………….. 2-50
19. Long-term storage ………………………………………………………………………………………….. 2-51
19.1 Before storage ……………………………………………………………………………………….. 2-51
19.2 During storage ……………………………………………………………………………………….. 2-51
19.3 After storage ………………………………………………………………………………………….. 2-52
MAINTENANCE
20. Outline of service ………………………………………………………………………………………….. 3- 2
20.1 Suitable oil …………………………………………………………………………………………… 3- 2
21. Lubricant list …………………………………………………………………………………………………. 3- 4
21.1 Gasoline engine lift truck ……………………………………………………………………… 3- 4
21.2 Diesel engine lift truck ………………………………………………………………………….. 3- 5
21.3 Oil and greasing chart (Oil, grease locations and inspection and
maintenance intervals) ………………………………………………………………………….. 3- 6
22. Service data ………………………………………………………………………………………………….. 3- 8
22.1 Service data (Gasoline engine lift truck) ……………………………………………….. 3- 8
22.2 Service data (Diesel engine lift truck) ……………………………………………………. 3-10
22.3 Torque list ……………………………………………………………………………………………. 3-12
23. Periodic replacement of safety critical parts ……………………………………………………. 3-13
24. Maintenance schedule chart ……………………………………………………………………………. 3-14
6. CONTENTS
0-9
25. Maintenance ……………………………………………………………………………………………………. 3-18
25.1 First one month or initial 200 hours service …………………………………………… 3-18
25.2 Check before operation ………………………………………………………………………….. 3-19
25.3 2-weekly/100 hours service …………………………………………………………………….. 3-19
25.4 Monthly/200 hours service ……………………………………………………………………… 3-19
25.5 3-monthly/600 hours service …………………………………………………………………… 3-32
25.6 6-monthly/1200 hours service …………………………………………………………………. 3-32
25.7 Yearly/2400 hours service ……………………………………………………………………….. 3-39
25.8 2-yearly/4800 hours service …………………………………………………………………….. 3-40
26. Replacement procedure …………………………………………………………………………………… 3-41
26.1 Replacing fuses ………………………………………………………………………………………. 3-41
26.2 Replacing tires ……………………………………………………………………………………….. 3-42
26.3 Replacing lamps …………………………………………………………………………………….. 3-43
26.4 Washing lift truck …………………………………………………………………………………… 3-44
TECHNICAL DATA
27. Technical data ……………………………………………………………………………………………….. 4- 2
EMISSION CONTROL SYSTEM WARRANTY STATEMENT
28. Emission control system warranty statement ………………………………………………… 5- 2
28.1 S(A)6D102E-2 ………………………………………………………………………………………… 5- 2
28.2 TB45(EPA) ……………………………………………………………………………………………… 5- 8
