Komatsu Forklift Truck FD100/115-8 FD135/150E/160E-8 Shop Manual PDF

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Komatsu Forklift Truck FD100/115-8 FD135/150E/160E-8 Shop Manual – PDF DOWNLOAD

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Komatsu Forklift Truck FD100/115-8 FD135/150E/160E-8 Shop Manual – PDF DOWNLOAD 

Language : English
Pages : 336
Downloadable : Yes
File Type : PDF

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Komatsu Forklift Truck FD100/115-8 FD135/150E/160E-8 Shop Manual – PDF DOWNLOAD

LIFT TRUCK MODEL                         SERIAL No. ENGINE
FD100/115-8 7001 and up                  SAA6D107E-1-A
FD135/150E/160E-8 7001 and up      SAA6D107E-1-A 

FOREWORD:

• To retain the machine and engine in good working conditions for an
  extended period of time and prevent troubles, appropriate operation, maintenance
  inspection, troubleshooting and repair services must be conducted.
• This shop manual mainly describes, among those works, the outline,
  inspection and maintenance, removal and installation, disassembly and
  assembly, maintenance standards, structure and functions, troubleshooting,
  and the annual inspection criteria.
• For the engine main body, see Engine Shop Manual 6D107E-BE1.
• This shop manual is intended for providing service staff with correct product
  knowledge and method of repair work to improve repair quality by correctly
  judging the machine conditions. Fully understand the content of this manual
  and make the most use of it.

TABLE OF CONTENTS:

Komatsu Forklift Truck FD100/115-8 FD135/150E/160E-8 Shop Manual – PDF DOWNLOAD

LIFT TRUCK MODEL                         SERIAL No. ENGINE
FD100/115-8 7001 and up                  SAA6D107E-1-A
FD135/150E/160E-8 7001 and up      SAA6D107E-1-A

BEE08E1-09 1
SECTION INDEX 3
FOREWORD 5
DESCRIPTION OF THE SYMBOLS 6
10 GENERAL AND SPECIFICATIONS 7
SPECIFICATIONS 8
PERIODIC REPLACEMENT OF CONSUMABLE PARTS 12
SAFETY ITEMS FOR MAINTENANCE 13
STANDARD TIGHTENING TORQUE 22
HOW TO USE LOCTITE 24
20 TESTING AND ADJUSTING 25
SERVICE DATA 26
HOW TO DEPRESSURIZE HYDRAULIC SYSTEM 28
ENGINE OIL/ENGINE OIL FILTER REPLACEMENT 29
REPLACEMENT OF FUEL FILTERS 30
CLEANING INSIDE THE COOLING SYSTEM 33
AIR CLEANER 34
ADJUSTING VALVE CLEARANCE 35
CHECKING COMPRESSION PRESSURE 35
TIGHTENING TORQUE FOR THE CYLINDER HEAD MOUNTING BOLTS 35
DIFFERENTIAL CASE 36
TORQFLOW TRANSMISSION CASE 37
CHECKING AND REPLACING ALTERNATOR BELT 38
CHECKING AND REPLACING AUTO-TENSIONER 40
HYDRAULIC TANK 42
BRAKE COOLING OIL(WET DISC BRAKE TYPE) 43
MEASURING HYDRAULIC DRAFT / TILT OF CYLINDER 44
ADJUSTING BRAKE/INCHING PEDAL OPERATION(HYDRAULIC DRUM BRAKE TYPE) 45
ADJUSTING BRAKE/INCHING PEDAL OPERATION(WET DISC BRAKE TYPE) 46
ACCUMLATOR FOR BRAKE 47
ADJUSTING ACCELERATOR PEDAL OPERATION 55
ADJUSTING PARKING BRAKE 55
BLEEDING AIR 56
CHECKING WEAR OF BRAKE DISC(WET DISC BRAKE TYPE) 58
STEERING AXLE 59
INSPECTING THE AIR CONDITIONER (OPTION) 60
BATTERY 62
OIL AND GREASING CHART 63
LUBRICANT LIST 64
30 REMOVAL AND INSTALLATION 65
GENERAL LOCATIONS 66
WEIGHT TABLE 68
REMOVAL AND INSTALLATION OF UNIT 70
FLOW CHART 72
MAST 73
PROCEDURES FOR ADJUSTING TILT CYLINDER 74
POWER TRAIN 75
BRAKE SYSTEM 78
WORK EQUIPMENT CONTROL LEVER 79
40 DISASSEMBLY AND ASSEMBLY 81
TORQUE CONVERTER 82
TORQFLOW TRANSMISSION 88
DRIVE AXLE 112
DIFFERENTIAL 118
STEERING AXLE 124
PARKING BRAKE 125
WHEEL BRAKE 126
BRAKE / INCHING PEDAL 129
BRAKE VALVE 131
POWER STEERING VALVE 137
LIFT CYLINDER 156
TILT CYLINDER 158
POWER STEERING CYLINDER 166
CONTROL VALVE 168
MAST 172
TABLE OF SPECIAL TOOLS 176
50 MAINTENANCE STANDARD 181
ENGINE AND ELECTRICAL PARTS 182
ACCELERATOR PEDAL 182
SPEEDOMETER SENSOR (OPTION) 183
LOCATION OF SWITCHES AND SENSORS 184
TORQUE CONVERTER 188
TORQFLOW TRANSMISSION 189
TRANSMISSION CONTROL VALVE 190
DRIVE SHAFT 191
DIFFERENTIAL 192
FINAL DRIVE 194
REAR AXLE 196
STEERING 197
FRAME 198
BRAKE PEDAL 199
BRAKE VALVE 201
FRONT BRAKE 203
PARKING BRAKE 206
CONTROL VALVE 208
PRIORITY VALVE 210
LIFT CYLINDER 211
TILT CYLINDER 212
POWER STEERING CYLINDER 213
WORK EQUIPMENT 214
60 STRUCTURE AND FUNCTION 215
POWER TRAIN DIAGRAM 216
TORQUE CONVERTER 218
TORQFLOW TRANSMISSION 219
AUTOMATIC TRANSMISSION (OPTION) 225
DRIVE AXLE 231
STEERING AXLE 232
STEERING SYSTEM 233
BRAKE 238
HYDRAULIC PUMPS 252
TORQUE CONVERTER CHARGING PUMP 252
LIFT CYLINDER 253
TILT CYLINDER 253
METER PANEL 254
AS CONTROLLER (FORKLIFT TRUCK WITH SEAT BELT INTERLOCK) 257
HYDRAULIC CIRCUIT DIAGRAMS OF WORK EQUIPMENT, STEERING SYSTEM AND BRAKE 261
ELECTRICAL CIRCUIT DIAGRAM 265
70 TROUBLESHOOTING 289
FUNCTIONS OF TROUBLESHOOTING TOOL AND CHECK OF FAILURE CODE 290
FAILURE CODE TABLE 296
TORQUE CONVERTER 298
CONTROL VALVE 301
80 CHECK ITEMS FOR EACH EQUIPMENT 303
CHECK ITEMS FOR EACH EQUIPMENT 304
Engine 304
Power train 309
Travel system 313
Steering system 315
Braking system 317
Loading system 320
Hydraulic system 322
Chassis, safety system 325
Overrall test 325
90 CONVERSION TABLE 327
Millimeters to Inches 328
Inches to Millimeters 328
Cubic meters to Cubic yards 329
Cubic yards to Cubic meters 329
Liter to U S Gallon 330
U S Gallon to Liter 330
Liter to U K Gallon 331
U K Gallon to Liter 331
Kilogram to Pound 332
Pound to Kilogram 332
kg/cm2 to Ib/in2 333
kgm to Ft Ib 334
Temperature 335

S.V 14/12/24