Komatsu Forklift Truck FD100-8 FD115-8 FD135-8 FD150E-8 FD160E-8 service & repair manual

Description Komatsu Forklift Truck FD100-8 FD115-8 FD135-8 FD150E-8 FD160E-8 service & repair manual

Komatsu Forklift Truck FD100-8, FD115-8, FD135-8, FD150E-8, FD160E-8 pdf workshop service manual

Serial numbers:
7001 and up

Technical documentation, specifications, troubleshooting, maintenance, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
GENERAL INFORMATION & SPECIFICATIONS
1.1 SPECIFICATIONS
1.2 PERIODIC REPLACEMENT OF CONSUMABLE PARTS
1.3 STANDARD TIGHTENING TORQUE
1.4 HOW TO USE LOCTITE

TESTING & ADJUSTING
2.1 SERVICE DATA
2.2 DEPRESSURIZE HYDRAULIC SYSTEM
2.3 REPLACE ENGINE OIL/ENGINE OIL FILTER
2.4 REPLACE FUEL FILTERS
2.5 CLEAN INSIDE THE COOLING SYSTEM
2.6 AIR CLEANER
2.7 ADJUST VALVE CLEARANCE
2.8 CHECK COMPRESSION PRESSURE
2.9 TIGHTEN CYLINDER HEAD MOUNTING BOLTS
2.10 DIFFERENTIAL CASE
2.11 TORQFLOW TRANSMISSION CASE
2.12 SERVICE HYDRAULIC TANK
2.13 REPLACE BRAKE COOLING OIL (WET DISC BRAKE)
2.14 MEASURE HYDRAULIC DRIFT OF LIFT AND TILT CYLINDERS
2.15 ADJUST BRAKE/INCHING PEDAL (HYDRAULIC DRUM BRAKE)
2.16 ADJUST BRAKE/INCHING PEDAL (WET DISC BRAKE)
2.17 ACCUMULATOR FOR BRAKE
2.18 ADJUST ACCELERATOR PEDAL OPERATION
2.19 ADJUST PARKING BRAKE
2.20 BLEEDING AIR
2.21 CHECK WEAR OF BRAKE DISC (WET DISC BRAKE)
2.22 ADJUST STEERING AXLE
2.23 INSPECT THE AIR CONDITIONER (OPTION)
2.24 INSPECT BATTERY
2.25 OIL AND GREASING CHART
2.26 LUBRICANT LIST

INSPECTION
3.1 GENERAL LOCATIONS
3.2 WEIGHT TABLE
3.3 INSPECTION CHECKLIST BY COMPONENT
3.4 REMOVAL AND INSTALLATION OF COMPONENTS
3.5 REMOVAL AND INSTALLATION FLOW CHART
3.6 MAST
3.7 POWER TRAIN
3.8 BRAKE SYSTEM (HYDRAULIC DRUM BRAKE)
3.9 WORK EQUIPMENT CONTROL LEVER

DISASSEMBLY AND ASSEMBLY
4.1 TORQUE CONVERTER
4.2 TORQFLOW TRANSMISSION
4.3 HYDRAULIC PUMPs
4.4 DRIVE AXLE
4.5 STEERING AXLE
4.6 PARKING BRAKE
4.7 WHEEL BRAKE
4.8 BRAKE / INCHING PEDAL
4.9 BRAKE VALVE
4.10 POWER STEERING VALVE
4.11 POWER STEERING VALVE
4.12 LIFT CYLINDER
4.13 TILT CYLINDER
4.14 POWER STEERING CYLINDER
4.15 CONTROL VALVE
4.16 MAST
4.17 TABLE OF SPECIAL TOOLS
4.18 TABLE OF SPECIAL TOOLS FOR POWER STEERING CYLINDER

MAINTENANCE STANDARD
5.1 ENGINE AND ELECTRICAL PARTS
5.2 ACCELERATOR PEDAL
5.3 SPEEDOMETER SENSOR (OPTION)
5.4 LOCATION OF SWITCHES AND SENSORS
5.5 TORQUE CONVERTER
5.6 TORQFLOW TRANSMISSION
5.7 TRANSMISSION CONTROL VALVE
5.8 DRIVE SHAFT
5.9 DIFFERENTIAL
5.10 FINAL DRIVE
5.11 REAR AXLE
5.12 STEERING
5.13 FRAME
5.14 BRAKE PEDAL
5.15 BRAKE VALVE
5.16 FRONT BRAKE
5.17 PARKING BRAKE
5.18 CONTROL VALVE
5.19 PRIORITY VALVE
5.20 LIFT CYLINDER
5.21 TILT CYLINDER
5.22 POWER STEERING CYLINDER
5.23 WORK EQUIPMENT

STRUCTURE AND FUNCTION
6.1 POWER TRAIN DIAGRAM
6.2 TORQUE CONVERTER
6.3 TORQFLOW TRANSMISSION - 1/3
6.4 TORQFLOW TRANSMISSION - 2/3
6.5 TORQFLOW TRANSMISSION - 3/3
6.6 INCHING VALVE
6.7 AUTOMATIC TRANSMISSION (OPTION)
6.8 DRIVE AXLE - HYDRAULIC DRUM BRAKE
6.9 STEERING AXLE
6.10 STEERING SYSTEM
6.11 HYDRAULIC CIRCUIT DIAGRAMS OF STEERING SYSTEM AND CYLINDER
6.12 HYDRAULIC DRUM BRAKE
6.13 WET DISC BRAKE
6.14 HYDRAULIC PUMPS
6.15 TORQUE CONVERTER CHARGING PUMP
6.16 LIFT CYLINDER
6.17 TILT CYLINDER
6.18 METER PANEL
HYDRAULIC CIRCUIT DIAGRAMS
ELECTRICAL CIRCUIT DIAGRAMS

TROUBLESHOOTING
7.1 TROUBLESHOOTING TOOL AND FAILURE CODEs
7.2 INDICATING FAILURE CODE WITH METER PANEL
7.3 TABLE OF TROUBLESHOOTING TOOL FAILURE CODES
7.4 TORQUE CONVERTER TROUBLESHOOTING TABLE
7.5 CONTROL VALVE TROUBLESHOOTING TABLE

CONVERSION TABLES

Engine SAA6D107E-1-A workshop service manual