Komatsu FD100-8 FD115-8 FD135-8 FD150E-8 FD160E-8 Forklift Truck Operation & Maintenance Manual TEN00560-12 – PDF DOWNLOAD

Description

Komatsu FD100-8 FD115-8 FD135-8 FD150E-8 FD160E-8 Forklift Truck Operation & Maintenance Manual TEN00560-12 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu FD100-8 FD115-8 FD135-8 FD150E-8 FD160E-8 Forklift Truck Operation & Maintenance Manual TEN00560-12 – PDF DOWNLOAD

FOREWORD :
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.

TABLE OF CONTENTS:

Komatsu FD100-8 FD115-8 FD135-8 FD150E-8 FD160E-8 Forklift Truck Operation & Maintenance Manual TEN00560-12 – PDF DOWNLOAD

1. FOREWORD 1 1
1.1 ABOUT THIS MANUAL 1 2
1.2 ENGINE MOUNTED ON THIS LIFT TRUCK 1 3
1.2.1 EXHAUST GAS CONTROL 1 3
1.2.2 CERTIFICATION LABEL AFFIXED POSITION 1 3
1.3 FOR YOUR SAFETY 1 4
1.3.1 SIGNAL WORDS 1 4
1.3.2 SAFETY INDICATORS 1 5
1.4 APPLICABLE MODEL AND SERIAL No. 1 6
1.5 GENERAL VIEW OF LIFT TRUCK 1 6
1.5.1 APPLICATION OF LIFT TRUCK 1 6
1.5.2 DIRECTION OF LIFT TRUCK 1 6
1.6 UNITS OF MEASURE 1 6
1.7 QUALIFICATION FOR OPERATION 1 7
1.8 RUNNING IN NEW LIFT TRUCK 1 7
1.8.1 RUNNING IN NEW LIFT TRUCK 1 7
1.8.2 MAINTENANCE FOR NEW LIFT TRUCK 1 7
1.9 WARRANTY AND SERVICE 1 7
1.9.1 PERIODICAL EXCHANGE PARTS 1 7
1.9.2 USE OF GENUINE PARTS AND OILS 1 7
1.10 NECESSARY INFORMATION OF LIFT TRUCK 1 8
1.10.1 MEMORANDUM (To be filled by KOMATSU FORKLIFT distributor) 1 8
1.10.2 MODEL AND SERIAL NO. LOCATION 1 8
1.10.3 ENGINE SERIAL NO. PLATE OR EMBOSSED LOCATION 1 9
1.10.4 FLUORINATED GREENHOUSE GASES 1 9
1.10.5 HOUR METER LOCATION 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 9
2.2.1 FOLLOW RULES 2 9
2.2.2 NEVER OPERATE THE BROKEN DOWN LIFT TRUCK 2 9
2.2.3 WEAR ADEQUATE CLOTHES AND SAFETY EQUIPMENT FOR OPERATION 2 10
2.2.4 FIRE EXTINGUISHER AND FIRST AID KIT 2 10
2.2.5 CAUTIONS FOR SAFETY RELATED EQUIPMENT 2 10
2.2.6 PRACTICE SUFFICIENTLY BEFORE OPERATION 2 10
2.2.7 JUMPING ON AND OFF FROM THE LIFT TRUCK IS STRICTLY PROHIBITED 2 11
2.2.8 KEEP THE OPERATOR’S COMPARTMENT AND PLATFORM CLEAN AND TIDY 2 11
2.2.9 PRECAUTION WHEN WASHING LIFT TRUCK 2 11
2.2.10 TO AVOID BURN INJURY 2 11
2.2.11 FIRE PREVENTION 2 12
2.2.12 IF A FIRE BREAKS OUT 2 13
2.2.13 DO NOT MODIFY THE LIFT TRUCK 2 13
2.2.14 DO NOT REMOVE THE OVERHEAD GUARD AND LOAD BACKREST 2 14
2.2.15 SECURE SAFETY AT THE WORKING AREA 2 14
2.2.16 ENGINE EXHAUST GAS IS POISONOUS 2 15
2.2.17 PRECAUTIONS RELATED TO SPECIAL ENVIRONMENT 2 15
2.2.18 ASBESTOS CAUTION 2 15
2.2.19 WINDOW WASHER CAUTION 2 15
2.3 BEFORE STARTING OPERATION 2 16
2.3.1 START UP INSPECTION 2 16
2.3.2 INSPECTION AND ADJUSTMENT BEFORE STARTING ENGINE 2 16
2.3.3 START UP INSPECTION 2 17
2.4 TRAVELING THE LIFT TRUCK 2 18
2.4.1 PREPARATION BEFORE TRAVELING THE LIFT TRUCK 2 18
2.4.2 WHILE TRAVELING THE LIFT TRUCK 2 19
2.4.3 STOPPING AND PARKING 2 25
2.4.4 TOWING 2 26
2.5 LOAD HANDLING OPERATION 2 27
2.6 PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2 32
2.6.1 ALWAYS PERFORM THE START UP INSPECTION 2 32
2.6.2 PUT UP A WARNING SIGN DURING INSPECTION AND MAINTENANCE 2 32
2.6.3 KEEP THE WORKING AREA CLEAN AND TIDY 2 32
2.6.4 CAUTIONS BEFORE INSPECTION AND MAINTENANCE 2 33
2.6.5 KEEP UNAUTHORIZED PEOPLE OFF 2 33
2.6.6 USE OF RIGHT TOOLS AND EQUIPMENT 2 33
2.6.7 CAUTIONS WHEN WORKING UNDER WORK EQUIPMENT 2 33
2.6.8 AVOID GETTING CAUGHT UP BY THE MAST OR FALLING OFF 2 34
2.6.9 BE CAREFUL OF BOILING COOLANT 2 34
2.6.10 BE CAREFUL OF HIGH PRESSURE OIL 2 35
2.6.11 BEWARE OF ROTATING COOLING FAN AND BELT 2 35
2.6.12 PRECAUTIONS FOR INSTALLING RADIO CONTROL SYSTEM 2 35
2.6.13 CAUTION WHEN REPAIRING THE ELECTRICAL SYSTEM 2 35
2.6.14 CAUTIONS FOR USING COMPRESSED AIR FOR CLEANING 2 35
2.6.15 CAUTIONS WHEN REPLACING THE SEAT 2 36
2.6.16 CAUTION WHEN HANDLING BATTERY 2 36
2.6.17 STRICTLY FOLLOW THE INSTRUCTIONS SHOWN BELOW TO AVOID GENERATION OF
SPARKS 2 36
2.6.18 CAUTION WHEN CHARGING A BATTERY 2 37
2.6.19 CAUTION WHEN HANDLING TIRES 2 37
2.6.20 CAUTION IN WASTE DISPOSAL 2 37
2.6.21 CAUTION AFTER INSPECTION AND REPAIR 2 38
2.6.22 PERIODIC INSPECTION OF SAFETY CRITICAL PARTS 2 38
2.7 HOISTING AND TRANSPORTING THE LIFT TRUCK 2 39
2.7.1 CAUTION WHEN HOISTING THE LIFT TRUCK 2 39
2.7.2 PRECAUTIONS FOR LOADING AND UNLOADING THE LIFT TRUCK 2 40
2.8 STRUCTURE AND STABILITY OF THE LIFT TRUCK (TO PREVENT LIFT TRUCK FROM TIPPING)
2 41
2.8.1 LONGITUDINAL STABILITY 2 41
2.8.2 CENTER OF GRAVITY OF A LOAD 2 41
2.8.3 COMBINED CENTER OF GRAVITY AND STABILITY ON THE LOADED LIFT TRUCK 2 42
2.8.4 ACTUAL CAPACITY 2 42
2.8.5 SERIAL NO. AND LOAD TABLE 2 43
2.8.6 INTRODUCTION OF OPTIONAL SAFETY AUXILIARY DEVICE 2 45
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 11
3.3 OPERATION 3 24
3.3.1 START UP INSPECTION 3 24
3.3.2 MOUNTING / DISMOUNTING AND OPERATING POSTURE ADJUSTMENT 3 24
3.3.3 STARTING, GEAR SHIFTING, AND TRAVELING 3 33
3.3.4 STARTING AND STOPPING ON SLOPE 3 38
3.3.5 INCHING TRAVEL 3 38
3.3.6 TURNING 3 39
3.3.7 OPERATION ON SNOWY AND FROZEN ROADS 3 39
3.3.8 TEMPORARY STOPPING, PARKING AND STOPPING 3 40
3.3.9 LOAD HANDLING OPERATION 3 42
3.3.10 CHECKING AFTER OPERATION 3 46
4. INSPECTION AND MAINTENANCE 4 1
4.1 ABOUT INSPECTION AND MAINTENANCE 4 2
CONTENTS FOREWORD
1 12
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 CONDUCTED BY OPENING COVER AND HOOD 4 6
4.2.4 CHECKING FROM THE OPERATOR SEAT 4 11
4.2.5 CHECK BY SETTING THE STARTING SWITCH TO [ | ] (ON) POSITION 4 13
4.2.6 CHECKING WITH THE ENGINE STARTED 4 16
4.2.7 CHECKING BRAKE ACCUMULATOR 4 17
4.2.8 CHECKING WHILE TRAVELING SLOWLY 4 18
4.2.9 CHECKING BY OPERATING THE WORK EQUIPMENT LEVER 4 18
4.2.10 INSPECTION OF LIFT TRUCK WITH CAB SPECIFICATION AND LIFT TRUCK WITH FRONT
GLASS SPECIFICATION 4 20
4.2.11 CHECKING OF SAFETY FUNCTION 4 21
4.2.12 CHECKING OF SAFETY AUXILIARY FUNCTION 4 22
4.3 CHECKING AND REPORTING AFTER OPERATION 4 25
4.4 SIMPLE MAINTENANCE 4 26
4.4.1 GREASES AND FUEL 4 26
4.4.1.1 BASIC PRECAUTIONS 4 26
4.4.1.2 LUBRICANT LIST (FOR GENERAL, FOR USA) 4 30
4.4.1.3 LUBRICANT LIST (FOR EU) 4 31
4.4.2 AIR CLEANER ELEMENT CLEANING 4 35
4.4.3 FUEL PRE FILTER AIR BLEEDING 4 37
4.4.4 REPLACING TIRES 4 38
4.4.5 ADJUSTING PARKING BRAKE LEVER OPERATING EFFORT 4 40
4.4.6 REPLACING FUSES 4 40
4.4.7 REPLACING BULBS 4 43
4.4.8 CHECKING FOR LOOSE ENGINE HIGH PRESSURE PIPING CLAMPS, HARDENING OF
RUBBER 4 44
4.4.9 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAPS, HARDENING OF RUBBER4 44
4.5 PROCEDURE FOR A DOWN BATTERY 4 45
4.6 RUNNING IN COLD WEATHER 4 47
4.7 ACTION IN ENGINE OVERHEATING 4 49
4.8 OPERATING LIFT TRUCKS IN SPECIAL ENVIRONMENT OR IN FORCIBLE WAY 4 51
4.9 ACTION TO TAKE IF THE FORK FAILS TO LOWER 4 52
4.10 WASHING LIFT TRUCK 4 53
4.11 LONG TERM STORAGE 4 54
4.12 HOISTING LIFT TRUCK 4 55
4.13 LOADING AND UNLOADING OF LIFT TRUCK 4 56
4.14 INSPECTION AND MAINTENANCE SCHEDULE CHART 4 57
4.15 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4 63
4.16 SERVICE DATA 4 64
5. TECHNICAL DATA 5 1
6. EMISSION CONTROL WARRANTY STATEMENT 6 1
7. EC DECLARATION OF CONFORMITY 7 1
7. 1 EC DECLARATION OF CONFORMITY(FD100 160E 8) 7 2
7.2 TIE DOWN POSITIONS OF LIFT TRUCK 7 2
8. ATTACHMENT 8 1
8.1 OPERATION OF SIDE SHIFT 7 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. INDEX 9 1

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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