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SHOP MANUAL

FD100/115/135/150E/160E-8

SHOP MANUAL FD100/115/135/150E/160E-8 FD100/115 -8 FD135/150E/160E -8 2-4-1 Shiba-koen, Minato-ku, Tokyo105-0011, Japan

FD100/115-8

FD135/150E/160E-8

2-4-1 Shiba-koen, Minato-ku, Tokyo105-0011, Japan
2-4-1 Shiba-koen, Minato-ku, Tokyo105-0011, Japan

Printed in Japan

FD100/115 -8 FD135/150E/160E -8 2-4-1 Shiba-koen, Minato-ku, Tokyo105-0011, Japan Printed in Japan BEE08E1-01

BEE08E1-01

FD100/115 -8 FD135/150E/160E -8 LIFT TRUCK MODEL FD100/115 -8 FD135/150E/160E -8 SERIAL No. M246-7001 and

FD100/115-8

FD135/150E/160E-8

LIFT TRUCK MODEL

FD100/115-8

FD135/150E/160E-8

SERIAL No.

M246-7001 and up M247-7001 and up

ENGINE

SAA6D107E-1-A

SAA6D107E-1-A

SECTION INDEX

00.

FOREWORD

10.

GENERAL AND SPECIFICATIONS

20.

TESTING AND ADJUSTING

30.

REMOVAL AND INSTALLATION

40.

DISASSEMBLY AND ASSEMBLY

50.

MAINTENANCE STANDARD

60.

STRUCTURE AND FUNCTION

70.

TROUBLESHOOTING

80.

CHECK ITEMS FOR EACH EQUIPMENT

90.

CONVERSION TABLE

FOREWORD

To retain the machine and engine in good working conditions for an extended period of time and prevent troubles, appropriate operation, main- tenance 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, troubleshoot- ing, 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.

PRECAUTIONS WHEN PERFORMING THE SERVICE WORK

Always pay attention to “Safety” before starting any work — this is important. Never attempt any work where danger to yourself or to other persons. Whenever work requiring safety precautions are described in this manual, a flag mark inserted, always make double sure that safety measures are taken. Other unmarked work, should always be performed after studying and using your common sense to prevent accidents.

taken. Other unmarked work, should always be performed after studying and using your common sense to

DESCRIPTION OF THE SYMBOLS

The symbols described below are used in this manual for convenience and better understanding.

Symbol

Item

Description

Safety Special safety precautions are needed to perform the work.

Safety

Special safety precautions are needed to perform the work.

Note Special technical precautions are needed to perform the work

Note

Special technical precautions are needed to perform the work

Tightening torque Fastening parts that require specified tightening force when assembling.

Tightening torque

Fastening parts that require specified tightening force when assembling.

Weight Weight of parts or systems

Weight

Weight of parts or systems

Coat Places to be coated with adhesives, etc. when assembling

Coat

Places to be coated with adhesives, etc. when assembling

10. GENERAL AND SPECIFICATIONS

Specifications

10-

2

Periodic replacement of consumable parts

10-

6

Safety items for maintenance

10-

7

Standard tightening torque

10-16

How to use LOCTITE

10-18

SPECIFICATIONS

GENERAL AND SPECIFICATIONS

SPECIFICATIONS

 

1.2

Model

Manufacturer's Designation

 

FD100-8

FD115-8

FD135-8

Characteristics

1.3

Power Type

Electric, Diesel, Gasoline, LPG, Cable

 

Diesel

Diesel

Diesel

1.4

Operation Type

 

Sitting

Sitting

Sitting

1.5

Rated Capacity

Q

   

kg(lb)

10000(22,000)

11500(25,000)

13500(30,000)

1.6

Load Center

c

   

mm(in)

600(24)

600(24)

600(24)

1.8

Load Distance

x

Front Axle Center to Fork Face

 

mm(in)

695(27.4)

715(28.1)

740(29.1)

 

1.9

Wheelbase

y

   

mm(in)

2800(110.2)

2800(110.2)

3100(122.0)

 

2.1

Service Weight

   

kg(lb)

12980(28,620)

14360(31,660)

15480(34,130)

Weight

2.2

 

Loaded

Front

 

kg(lb)

20860(45,990)

23490(51,790)

26450(58,310)

2.2.1

Axle Loading

Rear

 

kg(lb)

2120(4,670)

2370(5,220)

2530(5,580)

2.3

Unloaded

Front

 

kg(lb)

6230(13,730)

6590(14,530)

7110(15,670)

 

2.3.1

 

Rear

 

kg(lb)

6750(14,880)

7770(17,130)

8370(18,450)

 

3.1

Tyre Type

 

Pneumatic

Pneumatic

Pneumatic

3.2

Tyre Size

Front

9.00-20-14PR(I)

10.00-20-14PR(I)

11.00-20-14PR(I)

Tyres

3.3

Rear

9.00-20-14PR(I)

10.00-20-14PR(I)

11.00-20-14PR(I)

3.5

Number of Wheels

Front/Rear (x=driven)

 

4x/2

4x/2

4x/2

 

3.6

Tread, Front

b10

   

mm(in)

1700(66.9)

1700(66.9)

1770(69.7)

3.7

Tread, Rear

b11

   

mm(in)

1900(74.8)

1890(74.4)

1890(74.4)

 

4.1

Tilting Angle

  4.1 Tilting Angle Forward/Backward   degree 6/12 6/12 6/12

Forward/Backward

 

degree

6/12

6/12

6/12

4.2

Mast Height, Lowered

h1

2-stage Mast

 

mm(in)

2890(113.8)

3160(124.4)

3170(124.8)

4.3

Std. Free Lift

h2

2-stage Std. Mast, from Ground

 

mm(in)

0(0.0)

0(0.0)

0(0.0)

4.4

Std. Lift Height

h3

2-stage Std. Mast, from Ground

 

mm(in)

3000(118)

3000(118)

3000(118)

4.5

Mast Height, Extended

h4

2-stage Std. Mast

 

mm(in)

4400(173.2)

4670(183.9)

4680(184.3)

4.7

Height, Overhead Guard

h6

   

mm(in)

2780(109.4)

2800(110.2)

2810(110.6)

Dimensions

4.19

Length, with Std. Forks

L1

   

mm(in)

5465(215.2)

5505(216.7)

5860(230.7)

4.20

Length, to Fork Face

L2

   

mm(in)

4245(167.1)

4285(168.7)

4640(182.7)

4.21

Width, at Tyre

b1

Single

 

mm(in)

2280(89.8)

2310(90.9)

2410(94.9)

         

75x170x1220

75x185x1220

80x185x1220

4.22

Forks

s/e/l

Thickness x Width x Length

 

mm(in)

(3.0x6.7x48.0)

(3.0x7.3x48.0)

(3.1x7.3x48.0)

 

4.23

Fork Carriage Class

     

Pin Mount

Pin Mount

Pin Mount

4.24

Width, Fork Carriage

b2

   

mm(in)

2140(84.3)

2140(84.3)

2210(87.0)

4.31

Ground Clearance

m1

Under Mast

 

mm(in)

250(9.8)

250(9.8)

260(10.2)

4.32

m2

at Center of Wheelbase

 

mm(in)

325(12.8)

345(13.6)

350(13.8)

4.33

Right Angle Stacking Aisle

Ast

plus load length

 

mm(in)

4695(184.8)

4725(186.0)

5090(200.4)

4.35

Turning Radius

Wa

   

mm(in)

4000(157.5)

4010(157.9)

4350(171.3)

         

8.5/18/28

8.5/19/28

9/19.5/27.5

5.1

Travel Speed (FWD)

Loaded,1st/2nd/3rd

 

km/h(mph)

(5.3/11.2/17.4)

(5.3/11.8/17.4)

(5.6/12.1/17.1)

   

9/20/32

9/21/32

9.5/21/32

   

Unloaded,1st/2nd/3rd

 

km/h(mph)

(5.6/12.4/19.9)

(5.6/13.0/19.9)

(5.9/13.0/20.2)

Performance

5.2

Lifting Speed

Loaded/Unloaded

 

mm/s(fpm)

470/500(93/98)

430/450(85/89)

350/375(69/74)

5.3

Lowering Speed

Loaded/Unloaded

 

mm/s(fpm)

400/500(79/98)

400/500(79/98)

400/500(79/98)

5.6

Max. Drawbar Pull

Loaded, 1.5km/h, 3min rating

 

kN(Ib)

89(20,010)

87(19,610)

85(19,150)

5.8

Max. Gradeability

Loaded, 1.5km/h, 3min rating

 

%

40

34

28

5.10

Service Brake

Operation/Control

 

Foot/Hydraulic,

Foot/Hydraulic,

Foot/Hydraulic,

 

Powered

Powered

Powered

5.11

Parking Brake

Operation/Control

 

Hand/Mechanical

Hand/Mechanical

Hand/Mechanical

5.12

Steering

Type

 

Hydraulic Power

Hydraulic Power

Hydraulic Power

Steering

Steering

Steering

 

6.4

Battery

Voltage/ Capacity at 5-hour rating

 

V/Ah

24/80

24/80

24/80

       

KOMATSU

KOMATSU

KOMATSU

7.1

Maker Model

SAA6D107E-1

SAA6D107E-1

SAA6D107E-1

I.C Engine

7.2

Rated Output, SAE net

   

kW(HP)

122(164)

122(164)

122(164)

7.3

Rated RPM

   

min-1

2200

2200

2200

7.3.1

Max. Torque, SAE net

 

Nm@min-1

575(424)@1600

575(424)@1600

575(424)@1600

7.4

No. of Cylinder/ Displacement

 

cm

3 (cu.in)

6/6690(408)

6/6690(408)

6/6690(408)

 

7.6

Fuel Tank Capacity

 

l

(US Gal)

260(69)

260(69)

280(74.0)

Others

8.2

Relief Pressure for Attachment

   

bar(psi)

215(3,100)

215(3,100)

215(3,100)

8.2.1

Hydraulic Tank Capacity

 

l

(US Gal)

170(45)

170(45)

200(53)

8.6

Clutch

 

Torque Converter

Torque Converter

Torque Converter

 

8.7

Transmission

 

TORQFLOW

TORQFLOW

TORQFLOW

Specifications are subject to change without notice. The performance values indicated herein represent nominal values obtained under typical operating conditions.

GENERAL AND SPECIFICATIONS

SPECIFICATIONS

 

1.2

Model

Manufacturer's Designation

 

FD150E-8

FD160E-8

Characteristics

1.3

Power Type

Electric, Diesel, Gasoline, LPG, Cable

 

Diesel

Diesel

1.4

Operation Type

 

Sitting

Sitting

1.5

Rated Capacity

Q

   

kg(lb)

15000(33,000)

16000(35,000)

1.6

Load Center

c

   

mm(in)

600(24)

600(24)

1.8

Load Distance

x

Front Axle Center to Fork Face

 

mm(in)

750(29.5)

750(29.5)

 

1.9

Wheelbase

y

   

mm(in)

3100(122.0)

3100(122.0)

 

2.1

Service Weight

   

kg(lb)

16570(36,530)

17200(37,920)

Weight

2.2

 

Loaded

Front

 

kg(lb)

28740(63,360)

30140(66,450)

2.2.1

Axle Loading

Rear

 

kg(lb)

2830(6,240)

3060(6,750)

2.3

Unloaded

Front

 

kg(lb)

7210(15,900)

7170(15,810)

 

2.3.1

 

Rear

 

kg(lb)

9360(20,640)

10030(22,110)

 

3.1

Tyre Type

 

Pneumatic

Pneumatic

3.2

Tyre Size

Front

11.00-20-16PR(I)

12.00-20-16PR(I)

Tyres

3.3

Rear

11.00-20-16PR(I)

12.00-20-16PR(I)

3.5

Number of Wheels

Front/Rear (x=driven)

 

4x/2

4x/2

 

3.6

Tread, Front

b10

   

mm(in)

1770(69.7)

1770(69.7)

3.7

Tread, Rear

b11

   

mm(in)

1890(74.4)

1870(73.6)

 

4.1

Tilting Angle

  4.1 Tilting Angle Forward/Backward   degree 6/12 6/12

Forward/Backward

 

degree

6/12

6/12

4.2

Mast Height, Lowered

h1

2-stage Std. Mast

 

mm(in)

3270(128.7)

3290(129.5)

4.3

Std. Free Lift

h2

2-stage Std. Mast, from Ground

 

mm(in)

0(0.0)

0(0.0)

4.4

Std. Lift Height

h3

2-stage Std. Mast, from Ground

 

mm(in)

3000(118)

3000(118)

4.5

Mast Height, Extended

h4

2-stage Std. Mast

 

mm(in)

4780(188.2)

4800(189.0)

4.7

Height, Overhead Guard

h6

   

mm(in)

2810(110.6)

2830(111.4)

Dimensions

4.19

Length, with Std. Forks

L1

   

mm(in)

5920(233.1)

6020(237.0)

4.20

Length, to Fork Face

L2

   

mm(in)

4700(185.0)

4800(189.0)

4.21

Width, at Tyre

b1

Single

 

mm(in)

2410(94.9)

2480(97.6)

         

85x190x1220

85x210x1220

4.22

Forks

s/e/l

Thickness x Width x Length

 

mm(in)

(3.3x7.5x48.0)

(3.3x8.3x48.0)

 

4.23

Fork Carriage Class

   

Pin Mount

Pin Mount

4.24

Width, Fork Carriage

b2

   

mm(in)

2210(87.0)

2210(87.0)

4.31

Ground Clearance

m1

Under Mast

 

mm(in)

250(9.8)

270(10.6)

4.32

m2

at Center of Wheelbase

 

mm(in)

350(13.8)

370(14.6)

4.33

Right Angle Stacking Aisle

Ast

plus load length

 

mm(in)

5150(202.8)

5250(206.6)

4.35

Turning Radius

Wa

   

mm(in)

4400(173.2)

4500(177.2)

         

9/19.5/27.5

9.5/20/28

5.1

Travel Speed (FWD)

Loaded,1st/2nd/3rd

 

km/h(mph)

(5.6/12.1/17.1)

(5.9/12.4/17.4)

   

9.5/21/32

10/21.5/32

   

Unloaded,1st/2nd/3rd

 

km/h(mph)

(5.9/13.0/20.2)

(6.2/13.4/20.5)

Performance

5.2

Lifting Speed

Loaded/Unloaded

 

mm/s(fpm)

325/350(64/69)

320/345(63/68)

5.3

Lowering Speed

Loaded/Unloaded

 

mm/s(fpm)

400/400(79/79)

400/400(79/79)

5.6

Max. Drawbar Pull

Loaded, 1.5km/h, 3min rating

 

kN(Ib)

80(18,160)

80(18,030)

5.8

Max. Gradeability

Loaded, 1.5km/h, 3min rating

 

%

25

23

5.10

Service Brake

Operation/Control

 

Foot/Hydraulic,

Foot/Hydraulic,

 

Powered

Powered

5.11

Parking Brake

Operation/Control

 

Hand/Mechanical

Hand/Mechanical

5.12

Steering

Type

 

Hydraulic Power

Hydraulic Power

Steering

Steering

 

6.4

Battery

Voltage/ Capacity at 5-hour rating

 

V/Ah

24/80

24/80

       

KOMATSU

KOMATSU

7.1

Maker Model

SAA6D107E-1

SAA6D107E-1

I.C Engine

7.2

Rated Output, SAE net

   

kW(HP)

122(164)

122(164)

7.3

Rated RPM

   

min-1

2200

2200

7.3.1

Max. Torque, SAE net

 

Nm@min-1

575(424)@1600

575(424)@1600

7.4

No. of Cylinder/ Displacement

 

cm

3 (cu.in)

6/6690(408)

6/6690(408)

 

7.6

Fuel Tank Capacity

 

l

(US Gal)

280(74.0)

280(74)

Others

8.2

Relief Pressure for Attachment

   

bar(psi)

215(3,100)

215(3,100)

8.2.1

Hydraulic Tank Capacity

 

l

(US Gal)

200(53)

200(53)

8.6

Clutch

 

Torque Converter

Torque Converter

 

8.7

Transmission

 

TORQFLOW

TORQFLOW

SPECIFICATIONS

GENERAL AND SPECIFICATIONS

SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series
SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series
SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series
SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series
SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series
SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series
SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series
SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series
SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series
SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series
SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series
SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series
SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series
SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series
SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series
SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series
SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series
SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series
SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series
SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series
SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series
SPECIFICATIONS GENERAL AND SPECIFICATIONS 10-4 EX50 Series

GENERAL AND SPECIFICATIONS

SPECIFICATIONS

GENERAL AND SPECIFICATIONS SPECIFICATIONS EX50 Series 10-5

PERIODIC REPLACEMENT OF CONSUMABLE PARTS

GENERAL AND SPECIFICATIONS

PERIODIC REPLACEMENT OF CONSUMABLE PARTS

For operation safety, never fail to perform periodic main- tenance or make periodic replacement of the consum- able parts listed in the following. These parts may deteriorate in time and are susceptible to wear. It is difficult to estimate the degree of wear at time of periodic maintenance; therefore, even if no appar- ent wear is found, always replace with new parts within the prescribed period of replacement (or earlier if trouble is found). Note that periodic replacement has nothing to do with guarantee service.

No.

Part name

Years elapsed

1

Fuel hose (fuel tank - fuel pre-filter)

2

2

Fuel hose (fuel pre-filter - supply pump)

2

3

Fuel hose (supply pump - fuel main filter)

2

4

Fuel hose (fuel main filter - supply pump)

2

5

Fuel hose (supply pump - common rail overflow)

2

6

Fuel hose (engine - fuel tank)

2

7

Brake hose or tube

2

8

Power steering hose

2

9

Stop lamp switch (hydraulic type switch)

2

10

Rubber parts inside power steering system

2

11

Lift chain

2 – 4

12

Hydraulic hose (for travel, loading & unloading and torque converter)

2

13

Engine high-pressure piping clamp

Every 8000 hours

14

Fuel spray prevention cap

GENERAL AND SPECIFICATIONS

SAFETY ITEMS FOR MAINTENANCE

SAFETY ITEMS FOR MAINTENANCE

FOR SAFETY OPERATION

SAFETY ITEMS FOR MAINTENANCE FOR SAFETY OPERATION USE QUALIFIED PERSONNEL FOR INSPECTION AND MAINTENANCE •

USE QUALIFIED PERSONNEL FOR INSPECTION AND MAINTENANCE

• Only persons authorized by the owner or operator of the equipment and having proper certification (local or national) may carry out inspection, maintenance and repairs of the lift truck. If inspection, maintenance or repair work is carried out incorrectly, it is very dangerous.

 
  MAINTENANCE LOCATION  

MAINTENANCE LOCATION

 

• When carrying out inspection and maintenance, use a level, dry, dust–free area.

• If the work is carried out inside a building, make sure that there is ample ventilation.

 
  PRECAUTIONS FOR INSPECTION AND MAINTENANCE  

PRECAUTIONS FOR INSPECTION AND MAINTENANCE

 

• To be prepared in the event of a fire, have a fire extinguisher nearby and make sure that you know how to use it.

• Before carrying out inspection, lower the forks to the ground and stop the machine.

• Do not run the engine unless it is necessary.

 

• Place the directional lever, speed lever, and work equipment control levers in neutral.

 
   
 
 

PRECAUTIONS WHEN CARRYING OUT INSPECTION AND MAINTENANCE

 

• Wipe off any oil or grease. Immediately wipe up any oil that has leaked. If the lift truck is dirty, it becomes difficult or impossible to find cracks or other problems. Always clean the lift truck before starting inspection.

• Do not smoke or allow any flame to exist under any circumstances. Do not use any cloth which is soaked in fuel, oil, or grease. There is danger that it may catch fire.

• Wear suitable clothes for the job.

 

• Use suitable safety and protective equipment (hard hat, safety boots, safety glasses, gloves) for the job.

• When working on top of the lift truck, be careful not to fall.

 

• Do not put your feet under the forks.

• When opening or closing the floor plate or engine hood, be careful not to get your hands or body caught.

• When carrying out inspection with the forks raised, insert a stand under the inner mast to prevent the forks and mast from dropping.

• When carrying out job with another worker, decide who is the leader and carry out the job in accor- dance with instructions from that person.

• After repairing, make sure that the trouble has been corrected by performing a trial run.

 

• During the trial run, start/operate the lift truck carefully because it is possible that the trouble has not been fully corrected or that defective parts have not been removed.

SAFETY ITEMS FOR MAINTENANCE

GENERAL AND SPECIFICATIONS

SAFETY ITEMS FOR MAINTENANCE GENERAL AND SPECIFICATIONS WARNING CLOTHING AND PERSONAL PROTECTIVE ITEMS • Avoid loose

WARNING CLOTHING AND PERSONAL PROTECTIVE ITEMS

Avoid loose clothing, jewelry, and loose long hear. They can catch control or in moving parts and cause serious injury or death.

Always wear a hard hat and safety boots.

Depending on the working conditions, wear other safety equipment in addition to the hard hat and safety boots.

equipment in addition to the hard hat and safety boots. USE SUITABLE TOOLS • Always use
equipment in addition to the hard hat and safety boots. USE SUITABLE TOOLS • Always use

USE SUITABLE TOOLS

Always use tools that are suited for inspection and maintenance. It is extremely dangerous to use broken tools or tools designed for another purpose.

to use broken tools or tools designed for another purpose.   REPLACE SAFETY CRITICAL PARTS PERIODICALLY
 
  REPLACE SAFETY CRITICAL PARTS PERIODICALLY  

REPLACE SAFETY CRITICAL PARTS PERIODICALLY

 

Even if no abnormality is found, always replace safety critical parts periodically. As time passes, these parts deteriorate and may cause fire of failure in the work equipment system.

However, if these parts show any abnormality before the replacement interval has passed, they should be repaired or replaced immediately.

PRECAUTIONS WITH HIGH TEMPERATURE COOLANT • Immediately after using the lift truck, the engine coolant
PRECAUTIONS WITH HIGH TEMPERATURE COOLANT
• Immediately after using the lift truck, the engine coolant is at high temperature and high pressure. Do
not remove the radiator cap under these conditions.
Hot water may spurt out and cause burns.
• When removing the radiator cap, turn it slowly to
release the internal pressure.
• When checking the coolant level, stop the engine and
wait for the engine and radiator to cool down before
checking. For lift trucks equipped with a subtank or
reservoir, check the level in the subtank.
• When adding water on lift trucks equipped with a sub-
tank, add the water to the subtank.

GENERAL AND SPECIFICATIONS

SAFETY ITEMS FOR MAINTENANCE

GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE PROHIBIT WELDING OF FUEL TANK • Never weld the

PROHIBIT WELDING OF FUEL TANK

Never weld the fuel tank as it may explode.

     
 
  PRECAUTIONS WITH HIGH PRESSURE, HIGH TEMPERATURE OIL  

PRECAUTIONS WITH HIGH PRESSURE, HIGH TEMPERATURE OIL

 

Immediately after using the lift truck, the oil is at high temperature. Do not drain the oil or replace the filter when the oil is hot. Hot oil may spurt out and cause burns.

When carrying out inspection and maintenance, wait for the oil temperature to go down, and carry out the operation in the order given in this manual.

and maintenance, wait for the oil temperature to go down, and carry out the operation in

Do not forget that the work equipment circuits are always under pressure. Do not add oil, drain oil, or carry out maintenance or inspection before com- pletely releasing the internal pressure.

If oil is leaking under high pressure from small holes, it is dangerous if the jet of highpressure oil hits your skin or eyes. Always wear safety glasses and thick gloves, and use a piece of cardboard or

 

a

sheet of plywood to check for oil leakage.

  a sheet of plywood to check for oil leakage.

Release the internal pressure before checking the accumulator piping.

you are hit by a jet of high pressure oil, consult a doctor immediately.

If

When removing a mast or a lift cylinder, always depressurize the hydraulic piping.

 
 

1)

Stop the forklift truck. Lower the fork to the ground. Stop the engine.

2)

3)

Turn the starting switch to the ACC position.

4) Sit on the seat. Operate the lift lever and tilt lever forward and backward 4 to 5 times each to depressurize the hydraulic piping.

No depressurization can be effected by lever operation without sitting on the seat.

No depressurization can be effected by lever operation without sitting on the seat.

SAFETY ITEMS FOR MAINTENANCE

GENERAL AND SPECIFICATIONS

SAFETY ITEMS FOR MAINTENANCE GENERAL AND SPECIFICATIONS ROTATING FAN AND BELT • It is extremely dangerous

ROTATING FAN AND BELT

GENERAL AND SPECIFICATIONS ROTATING FAN AND BELT • It is extremely dangerous if you or any

It is extremely dangerous if you or any tool touches or gets caught in the fan or fan belt when the fan is rotating. Never touch the fan when it is rotating.

Always stop the engine before inspecting rotating parts.

When inspecting the areas around rotating parts, do not allow anything to come close which may get caught.

do not allow anything to come close which may get caught. BE CAREFUL NOT TO GET

BE CAREFUL NOT TO GET CAUGHT OR FALL

Never put your hands or feet into the mast structure. There is danger that you will get caught in moving parts and be serious injured.

Do not use the mast as a ladder. If you slip, there is dan- ger that you will fall.

injured. • Do not use the mast as a ladder. If you slip, there is dan-

GENERAL AND SPECIFICATIONS

SAFETY ITEMS FOR MAINTENANCE

 
   
 
 

CHECKING AND INFLATING TYRES

 

If the tyre inflation pressure is low, it will affect truck stability. However, do not inflate the tyres immedi- ately. The inflation pressure may have gone down because of damage to the rim. If the rim is dam- aged or cracked and the tyres are inflated, there is danger that the rim will break when the tyre is under high pressure, and this may cause personal injury or death.

For safety, when checking tyre pressure, place your body in front of the tread face of the tyre. Do not check from the side face of the tyre.

Suitable qualifications are needed for tyre inflation work. Always have the work carried out by properly qualified personnel.

qualifications are needed for tyre inflation work. Always have the work carried out by properly qualified

The tyre inflation pressure on a forklift truck is several times higher than the pressure on an automobile.

When the tyres are being inflated, there is danger that dirt or dust may be thrown up by the compressed air and enter your eyes, so always wear safety glasses.

air and enter your eyes, so always wear safety glasses. HANDLING TYRES Have a specialist disassemble

HANDLING TYRES

your eyes, so always wear safety glasses. HANDLING TYRES Have a specialist disassemble and assemble the
your eyes, so always wear safety glasses. HANDLING TYRES Have a specialist disassemble and assemble the

Have a specialist disassemble and assemble the tyre. Since the tyre inflation pressure is very high, handle the tyre with extreme care.

Release all the inflation pressure and then remove the tyre. Remove hub nuts (1) and remove the tyre from the machine.

After replacing the tyre, carry out a test run and then check the mounting nuts for looseness again. If the nuts are not tightened sufficiently, retighten them to the specified torque.

Tightening torque: See "Chapter 20, Testing and adjusting, Service data".

SAFETY ITEMS FOR MAINTENANCE

GENERAL AND SPECIFICATIONS

SAFETY ITEMS FOR MAINTENANCE GENERAL AND SPECIFICATIONS JACKING UP LIFT TRUCK (when checking or replacing tyres)

JACKING UP LIFT TRUCK (when checking or replacing tyres)

Do not go under the forklift truck when it is jacked up.

Check the following before jacking up the lift truck. 1) Check that there is no one on the lift truck. 2) Check that there is no load on the forks.

When jacking up, stop when the tyres come off the ground surface. Put blocks under both sides of the frame to prevent the lift truck from coming down.

Put blocks under any tyres contacting the ground to prevent the lift truck from moving.

contacting the ground to prevent the lift truck from moving. LIFTING LIFT TRUCK (when checking tyres)
LIFTING LIFT TRUCK (when checking tyres)  

LIFTING LIFT TRUCK (when checking tyres)

 

Lift truck slinging work should be carried out by a qualified person who has completed a course in correct lifting methods.

Fit wire ropes to the specified lifting points.

When lifting the lift truck, check that the wire ropes have ample strength and are not damaged.

Block the tyres contacting the ground to prevent the lift truck from moving.

• Block the tyres contacting the ground to prevent the lift truck from moving.

Insert blocks to prevent the truck from coming down.

Do not go under the lift truck during the lifting operation.

If the specified lifting point is the counterweight, check that the counterweight mounting bolts are tightened to the specified torque before carrying out the lifting operation. check also that there is no damage to the lifting portion on the counterweight.

GENERAL AND SPECIFICATIONS

SAFETY ITEMS FOR MAINTENANCE

GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE BATTERY HAZARD PREVENTION • Battery electrolyte contains

BATTERY HAZARD PREVENTION

SAFETY ITEMS FOR MAINTENANCE BATTERY HAZARD PREVENTION • Battery electrolyte contains sulfuric acid and can
SAFETY ITEMS FOR MAINTENANCE BATTERY HAZARD PREVENTION • Battery electrolyte contains sulfuric acid and can
SAFETY ITEMS FOR MAINTENANCE BATTERY HAZARD PREVENTION • Battery electrolyte contains sulfuric acid and can

Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill electrolyte on yourself, immediately flush the area with a large quantity of water.

Battery electrolyte can cause blindness if splashed into the eyes. If electrolyte gets into your eyes, flush them immediately with large quantities of water and consult a doctor at once.

If you accidentally drink electrolyte, drink a large quantity of water, or milk mixed with beaten eggwhite or vegetable oil. Call a doctor or poison prevention center immediately.

When working with batteries, ALWAYS wear safety glasses or goggles.

Batteries generate hydrogen gas. Hydrogen gas is highly EXPLOSIVE, and is easily ignited with a small spark or flame. Do not smoke or create any spark near the battery.

Before working with batteries, stop the engine and turn the starting switch to the OFF position.

When removing the battery, remove the cable from the negative terminal first. When installing the

battery, install the cable to the positive terminal first.

Avoid shortcircuiting the battery terminals through accidental contact with tools or other metal objects across the terminals.Tighten the battery terminals securely. Loose terminals can generate sparks and lead to an explosion.

When removing or installing the battery, confirm which is the positive terminal and negative ter- minal. Be careful not to connect the cables to the opposite terminals.

Tighten the battery caps securely.

When cleaning the battery, leave the battery caps tightened.

When cleaning the battery, leave the battery caps tightened. DO NOT PUT METAL OBJECTS ON TOP
When cleaning the battery, leave the battery caps tightened. DO NOT PUT METAL OBJECTS ON TOP
When cleaning the battery, leave the battery caps tightened. DO NOT PUT METAL OBJECTS ON TOP
When cleaning the battery, leave the battery caps tightened. DO NOT PUT METAL OBJECTS ON TOP

DO NOT PUT METAL OBJECTS ON TOP OF BATTERY

Never place any metal objects on top of the battery. There is danger that they will cause a short circuit and start a fire.

SAFETY ITEMS FOR MAINTENANCE

GENERAL AND SPECIFICATIONS

PRECAUTIONS WHEN CHARGING  

PRECAUTIONS WHEN CHARGING

 

When the battery is charged, hydrogen gas is generated and the battery is heated by the chemical change. To prevent the danger of gas explosion, always do as follows.

Carry out the charging operation in a wellventilated place.

Do not smoke or allow any flame.

 

Start the charging operation when the temperature of the battery electrolyte is below 35°C (95 ). (If the temperature goes above 50°C (122°F) during the charging operation, wait for it to go down below 35°C (95°F) before starting charging operation again.)

during the charging operation, wait for it to go down below 35 ° C (95 °

When using a battery charger to charge the battery, take the battery caps off.

STARTING WITH BOOSTER CABLES  

STARTING WITH BOOSTER CABLES

 

ALWAYS wear safety glasses or goggles when starting the lift truck with booster cables.

When starting using the battery of another lift truck, do not allow the two lift trucks to touch. For details of the order of operations when using a booster cable.

Stop the engine before connecting the cables.

 

e extremely careful not to let the cables get caught in the fan or fan belt.

Connect the batteries in parallel: positive to positive and negative to negative. Never connect positive to negative.

negative to negative. Never connect positive to negative. DO NOT PUSH START • Do not push

DO NOT PUSH START

Do not push the lift truck to start the engine. There is danger that the lift truck may suddenly start and operate unexpectedly.

GENERAL AND SPECIFICATIONS

SAFETY ITEMS FOR MAINTENANCE

HANDLING ANTIFREEZE  

HANDLING ANTIFREEZE

 

Antifreeze can be a flammable. Keep away from flame when handling.

Antifreeze is poisonous, so do not drink it. If you drink it by mistake, drink large amounts of water, vomit it out, and get medical attention immediately. Follow safety precautions on container.

immediately. Follow safety precautions on container. WASTE MATERIALS • Comply with appropriate laws and

WASTE MATERIALS

Follow safety precautions on container. WASTE MATERIALS • Comply with appropriate laws and regulations when

Comply with appropriate laws and regulations when disposing of hazardous objects such as oil, fuel, cool- ant, solvent, filters, batteries and CFCs (refrigerant).

STANDARD TIGHTENING TORQUE

GENERAL AND SPECIFICATIONS

STANDARD TIGHTENING TORQUE

Bolts

For unspecified bolts and nuts, use the torques specified in this list. Select a proper torque corresponding to the width across flats (b) of bolts and nuts. When replacing bolts and nuts, always use genuine Komatsu Forklift parts the same size as the previous ones.

Komatsu Forklift parts the same size as the previous ones. Thread diameter of bolt (mm) Width

Thread diameter of bolt (mm)

Width across

 

Tightenng torque

 

flat (mm)

     

(a)

(b)

Nm

   

kgm

lbft

 

6

10

13.2

±

1.4

1.35

± 0.15

9.73

±

1.03

8

13

31.4

±

2.9

3.2

±

0.3

23.2

±

2.1

10

17

65.7

±

6.8

6.7

±

0.7

48.5

±

5.0

12

19

112

±

9.8

11.5

±

1.0

82.6

±

7.2

14

22

177

±

19

18.0

±

2.0

131

±

14

16

24

279

±

29

28.5

±

3

206

±

21

18

27

383

±

39

39

±

3

282

±

29

20

30

549

±

58

56

±

6

405

±

43

22

32

745

±

78

76

±

8

549

±

58

24

36

927

±

98

94.5

±

10

684

±

72

27

41

1320

±

140

135

±

15

973

±

100

30

46

1720

±

190

175

±

20

1270

±

140

33

50

2210

±

240

225

±

25

1630

±

180

36

55

2750

±

290

280

±

30

2030

±

210

39

60

3280

±

340

335

±

35

2420

±

250

GENERAL AND SPECIFICATIONS

STANDARD TIGHTENING TORQUE

Elbows, nipples and unions

Width across flats B (mm) 22 30 36 Width D (mm) 19 22 30 Tightening
Width across flats B (mm)
22
30
36
Width D (mm)
19
22
30
Tightening torqueNm {kgm}
29.4–39.2 {3–4}
78.5–103 {8–10.5}
117.7–161.8 {12–16.5}
Port size (inch)
3/4–16UNF
7/8–14UNF
Tightening torqueNm {kgm}
68.6–73.6 {7–7.5}
78.5–83.3 {8–8.5}

High–pressure rubber hoses, pipes and sleeve nuts

Width across flats B (mm)

19

24

27

32

36

Bore A (mm)

14

18

22

24

30

Tightening torque Nm {kgm}

19.629.4

23.568.6

58.898.1

108167

147206

{23}

{37}

{610}

{1117}

{1521}

 
 

HOW TO USE LOCTITE

GENERAL AND SPECIFICATIONS

HOW TO USE LOCTITE

Procedure for using LOCTITE Male side Degreasing Air drying Female side Applying Leaving Assembly LOCTITE
Procedure for using LOCTITE
Male side
Degreasing
Air drying
Female
side
Applying
Leaving
Assembly
LOCTITE

1. Degreasing and cleaning 1) Clean the parts in trichloroethylene, acetone,

ether, alkaline solution, etc. which are highly vol- atile. Degrease the parts as perfectly as possible.

2)

3) Since gasoline, light oil, kerosene, etc. are not highly volatile, they are not recommended. If it is obliged to use them, dry them completely. 4) If the mating parts are made of thermosetting resin, treat them with LOQUICK PRIMER after degreasing them.

2. Air drying

1)

Wait until the cleaning fluid dries out.

2)

If the parts are treated with LOQUICK PRIMER, do not wipe them but dry them in air for 5 - 10 minutes. (If LOCTITE is used before LOQUICK PRIMER dries out, its effect is lowered.)

3. Applying LOCTITE

Apply LOCTITE to either or both of the threads or the shaft and hole to be fitted by amount to fill the clear- ance between them by one of the following methods.

• Applying directly from LOCTITE container nozzle

• Dipping (For threads. Use receiving pan.)

• Tumbling

• Brushing (For shaft and hole. Use receiving pan.)

• Sponge

• Automatic applier Do not mix metallic foreign matter in LOCTITE or return LOCTITE used in a pan to the container.

4.

Assembly After applying LOCTITE, tighten the screw or fit the shaft to the hole as usual. (When using LOCTITE for structures or LOCTITE of instant glue type, press the mating parts lightly (about 49 kPa {0.5 kgf/cm2}).

Removal of parts When screws and shafts are secured with LOCTITE, they usually can be removed with common tools such as spanners, wrenches, pulley pullers, etc. If LOCTITE is so strong that a part may be broken when it is removed, heat it (to 200 - 250°C) with a soldering iron, gas torch, etc., and you can remove it easily. It is generally difficult to dissolve LOCTITE in chemical solutions.

When assembling again

1)

white powder on the threads. In this case, you can apply LOCTITE again to the threads without remov- ing the white powder.

2) If shafts or flanges secured with LOCTITE are dis- connected, LOCTITE remaining on them may need to be removed to maintain dimensional accuracy. You can remove the remaining LOCTITE easily, however, with a wire brush, etc.

3)

If a LOCTITE film on threads is broken, it is left as

If plates secured with LOCTITE need to be assem- bled again after they are separated, be sure to remove all the hardened LOCTITE and roughen the mating surfaces with sandpaper.

20. TESTING AND ADJUSTING

Service data

20-

2

How to depressurize hydraulic system

20-

4

Engine oil/engine oil filter replacement

20-

5

Replacement of fuel filters

20-

6

Cleaning inside the cooling system

20-

9

Air cleaner 20-10

20-11

Checking compression pressure 20-11 Tightening torque for the cylinder head

Adjusting valve clearance

mounting bolts

20-11

Differential case

20-12

TORQFLOW transmission case 20-13

20-14

Brake cooling oil 20-15 Measuring hydraulic draft/tilt of cylinder 20-16

20-17

Hydraulic tank

Adjusting brake/inching pedal operation

Accumulator for brake 20-19

Adjusting accelerator pedal operation 20-27

Adjusting parking brake

20-27

Bleeding air

20-28

Checking wear of brake disc 20-30

Steering axle

Inspecting the air conditioner (option) 20-32

Battery 20-34 Oil and greasing chart 20-35 Lubricant list 20-36

20-31

SERVICE DATA

TESTING AND ADJUSTING

SERVICE DATA

 

Component

Inspection item

Unit

FD100-8

FD115-8

FD135-8

FD150E-8

FD160E-8

   

Engine model

 

KOMATSU SAA6D107E-1-A

 

Idling speed

rpm

 

700–750

Engine proper

Max. speed

rpm

 

2,375–2,475

Torque converter stall speed

rpm

 

2,000

 

MPa

   

Compression

{kgf/cm²}/ rpm

 

Min. 24 {Min. 246} / 250–280

Engine

Lubricating and

Capacity of engine oil

Engine Lubricating and Capacity of engine oil   20.3
 

20.3

cooling system

Capacity of engine coolant

cooling system Capacity of engine coolant   12.8 (Exhaust capacity of radiator)  
 

12.8 (Exhaust capacity of radiator)

 
 

Fuel system

Injection order

 

1–5–3–6–2–4

Capacity of fuel tank

Capacity of fuel tank 260   280

260

 

280

Intake and

Valve clearance

Intake

mm

 

0.25 (in cold state)

 

exhaust system

Exhaust

mm

 

0.51 (in cold state)

 

Electric system

Specific gravity of battery elec- trolyte

 

Min. 1.24 (20°C)

 
   

Stall speed

rpm

 

2,000

 

MPa

   

Torque converter

Inlet oil pressure

{kgf/cm²}

 

1.2–1.5 {12–15}

 

MPa

   

Outlet oil pressure

{kgf/cm²}

 

0.6–0.73 {6–7.4}

Power train

   

MPa

 

Relief pressure

{kgf/cm²}

 

1.96 {20}

 

MPa

   

TORQFLOW

Clutch actuating pressure

{kgf/cm²}

 

1.35–1.65 {13–16}

 

transmission

 

MPa

   

Lubrication oil pressure

{kgf/cm²}

 

0.6–0.73 {6–7.4}

     

37–40

Capacity of oil

Capacity of oil (including capacity of torque converter, oil cooler and oil pipes)

(including capacity of torque converter, oil cooler and oil pipes)

Differential

Capacity of oil

Differential Capacity of oil   20
 

20

       

kPa

735

690

660

760

690

Travel device

Tyre

Tyre inflation

Front wheel

{kgf/cm²}

{7.5}

{7.0}

{6.75}

{7.75}

{7.0}

pressure

 

kPa

735

690

660

760

690

 

Rear wheel

{kgf/cm²}

{7.5}

{7.0}

{6.75}

{7.75}

{7.0}

Hub nuts

Tightening

Front wheel

Nm {kgfm}

 

441–539 {45–55}

 
 

torque

Rear wheel

Nm {kgfm}

 

441–539 {45–55}

 

TESTING AND ADJUSTING

SERVICE DATA

 

Component

Check item

Unit

FD100-8

FD115-8

FD135-8

FD150E-8

FD160E-8

 

Steering wheel

Play

mm

 

30–60

Rear axle

Turning radius

mm

4,000

4,010

4,350

4,400

4,500

Inching pedal

Stroke

mm

 

83

Steering and braking device

Interlocking stroke

mm

 

50

Brake pedal

Play

mm

 

1–4

Stroke

mm

 

76

 

Cooling oil tank (Wet disc type)

  Cooling oil tank (Wet disc type)   14.5
 

14.5

Operating effort of parking brake lever

Nm

 

Min. 196

{kgfm}

{Min 20}

Gas pressure of brake accu- mulator (Hydraulic drum type)

MPa

 

4.9

Brake

{kgf/cm²}

{50}

 

Gas pressure of brake accu- mulator (Wet disc type)

MPa

 

3.4

{kgf/cm²}

{35}

Tightening torque of back plate mounting bolt

Nm

147–245

 

147–196

{kgfm}

{15–25}

{15–20}

   

Thickness of base

mm

Min. 70

Min. 75

Min. 80

Material–handling device

Fork

Height difference

mm

 

20

Opening at tip

mm

 

50

Chain

Length of 17 links

mm

Max. 660

 

Max. 770

 

Cylinder

Hydraulic drift

mm/15 min

 

50

Hydraulic forward tilt

mm/15 min

 

40

   

MPa

 

21.6

Hydraulic

system

Relief pressure

{kgf/cm 2 }

{220}

 

Quantity of oil

  Quantity of oil 170   200

170

 

200

HOW TO DEPRESSURIZE HYDRAULIC SYSTEM

TESTING AND ADJUSTING

HOW TO DEPRESSURIZE HYDRAULIC SYSTEM

TESTING AND ADJUSTING HOW TO DEPRESSURIZE HYDRAULIC SYSTEM CAUTION When depressurizing the hydraulic system, always

CAUTION

When depressurizing the hydraulic system, always seat yourself on the operator seat before operating the

When depressurizing the hydraulic system, always seat yourself on the operator seat before operating the lever. Or, the shut valve of the hydraulic piping will be closed, disabling depressurization.

seat before operating the lever. Or, the shut valve of the hydraulic piping will be closed,

HOW TO DEPRESSURIZE

1. Stop the forklift truck. Lower the fork to the ground.

2. Stop the engine.

3. Turn the starting switch to the ON (2) position.

4. Sit on the seat. Operate the lift lever and tilt lever for- ward and backward 4 to 5 times each to depressur- ize the hydraulic system.

lever and tilt lever for- ward and backward 4 to 5 times each to depressur- ize
lever and tilt lever for- ward and backward 4 to 5 times each to depressur- ize

TESTING AND ADJUSTING

ENGINE OIL/ENGINE OIL FILTER REPLACEMENT

ENGINE OIL/ENGINE OIL FILTER REPLACEMENT