Komatsu FD100-7, FD115-7, FD135-7, FD150E-7, FD160E-7 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 ………………………………………………………………………………………… 1-15
10. Stopping and parking …………………………………………………………………………………….. 1-21
11. Inspection and maintenance …………………………………………………………………………… 1-23
12. Structure and stability of the lift truck (to prevent lift truck from tipping!) …… 1-32
13. Safety label sticking positions ……………………………………………………………………….. 1-36
13.1 Safety label sticking positions ……………………………………………………………….. 1-36
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
0-7
6. CONTENTS
16. Operation ……………………………………………………………………………………………………….. 2-17
16.1 Check before operation …………………………………………………………………………. 2-17
16.2 Mounting/dismounting …………………………………………………………………………… 2-33
16.3 Operator’s seat and tiltable steering wheel position adjustment ……………. 2-34
16.4 Starting lift truck off ………………………………………………………………………………. 2-36
16.5 Starting, inching on slope ……………………………………………………………………… 2-40
16.6 Turning …………………………………………………………………………………………………. 2-41
16.7 Temporary stopping and parking …………………………………………………………… 2-42
16.8 Fork spread adjustment …………………………………………………………………………. 2-44
16.9 Load handling operation ……………………………………………………………………….. 2-45
16.10 Check after operation …………………………………………………………………………….. 2-46
17. Cold weather operation …………………………………………………………………………………. 2-47
17.1 Preparations for low temperature ………………………………………………………….. 2-47
17.2 Precautions after completion of operations ……………………………………………. 2-48
18. Actions in engine overheating ……………………………………………………………………….. 2-49
19. Long-term storage …………………………………………………………………………………………. 2-50
19.1 Before storage ………………………………………………………………………………………. 2-50
19.2 During storage ………………………………………………………………………………………. 2-50
19.3 After storage …………………………………………………………………………………………. 2-51
MAINTENANCE
20. Outline of service …………………………………………………………………………………………… 3- 2
20.1 Suitable oil ……………………………………………………………………………………………. 3- 2
21. Lubricant list ………………………………………………………………………………………………….. 3- 4
21.1 Lubricant list …………………………………………………………………………………………. 3- 4
21.2 Oil and greasing chart (Oil, grease locations and inspection and
maintenance intervals) …………………………………………………………………………… 3- 5
22. Service data …………………………………………………………………………………………………… 3- 6
22.1 Service data ………………………………………………………………………………………….. 3- 6
22.2 Torque list …………………………………………………………………………………………….. 3- 7
23. Periodic replacement of safety critical parts …………………………………………………… 3- 8
24. Maintenance schedule chart …………………………………………………………………………… 3- 9

25. Maintenance …………………………………………………………………………………………………… 3-13
25.1 First one month or initial 200 hours service ………………………………………….. 3-13
25.2 Check before operation …………………………………………………………………………. 3-14
25.3 2-weekly/100 hours service ……………………………………………………………………. 3-14
25.4 Monthly/200 hours service …………………………………………………………………….. 3-14
25.5 3-monthly/600 hours service ………………………………………………………………….. 3-23
25.6 6-monthly/1200 hours service ………………………………………………………………… 3-24
25.7 Yearly/2400 hours service ……………………………………………………………………… 3-30
25.8 2-yearly/4800 hours service ……………………………………………………………………. 3-32
26. Replacement procedure ………………………………………………………………………………….. 3-33
26.1 Replacing fuses ……………………………………………………………………………………… 3-33
26.2 Replacing tires ………………………………………………………………………………………. 3-34
26.3 Replacing lamps ……………………………………………………………………………………. 3-35
27. Washing lift truck …………………………………………………………………………………………… 3-36
TECHNICAL DATA
28. Technical data ………………………………………………………………………………………………… 4- 2
EMISSION CONTROL SYSTEM WARRANTY STATEMENT
29. Emission control system warranty statement ………………………………………………… 5- 2
29.1 Emission label and others ……………………………………………………………………… 5- 8