Format: PDF (Printable Document)
File Language: English
File Pages: 155
File Size: 4.29 MB (Speed Download Link)
Brand: Komatsu
Model: FD100-7, FD115-7, FD135-7, FD150E-7, FD160E-7 Forklift Truck
Book No: AEE07E1-04
Type of Document: Operation and Maintenance Manual
$ 40
These big Komatsu FD100-7 through FD160E-7 forklifts usually live in harsh yards, ports, and mills, lifting heavy loads all day on rough ground. This Operation and Maintenance Manual is what I’d keep on hand to set a solid service rhythm, so the truck starts every shift and doesn’t surprise you with breakdowns. When a driver reports slow lifting or odd noises from the mast at full height, this is the book I’d use to walk through the basic checks, trace the issue, and decide if it’s something we can correct on-site or if it needs deeper shop work.
Applications & Use Cases
FAQ
Q: Can I keep this manual on a tablet in the cab?
A: Yes, a digital copy is handy; just make sure it’s saved offline so you’re not stuck if there’s no signal.
Q: Is it worth printing sections of this manual?
A: Printing the daily checks and service schedules is useful for posting in the shop or on a clipboard for operators to sign off.
Safety Note
Always follow the manual’s safety procedures and lockout instructions before inspecting, adjusting, or servicing these forklifts.
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
