Komatsu FG50-7, FG60-7, FG70-7, FG70-8, FD50-7, FD60-7, FD70-7, FD50-8, FD60-8, FD80-8 Forklift Truck Index:

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