Format: PDF (Printable Document)
File Language: English
File Pages: 147
File Size: 3.44 MB (Speed Download Link)
Brand: Komatsu
Model: FD150-6, FD180-6, FD200Z-6, FD200-6, FD250Z-6 Forklift Truck
Book No: TEN00561-00
Type of Document: Operation and Maintenance Manual
$ 40
These Komatsu FD150-6 through FD250Z-6 diesel forklifts usually live in tough yards, ports, steel plants, and lumber or container terminals, moving heavy loads all day. This Operation and Maintenance Manual is what I’d keep on hand to set a sane service rhythm, so the truck doesn’t fail in the middle of a tight loading window. When a driver reports slow mast lift or the machine feels “lazy” under load, I use this manual to walk through the basic checks in order, verify the daily/weekly items, and decide if it’s a simple adjustment, a filter issue, or time to schedule deeper shop work.
Applications & Use Cases
FAQ
Q: Can I keep this manual on a tablet in the yard?
A: Yes, it’s practical to use digitally; you can zoom diagrams and search quickly while standing at the truck.
Q: Is it worth printing parts of it?
A: I’d print the inspection and service-interval pages to hang in the shop and keep a clean copy in the service truck.
Safety Note
Always follow the manual’s lockout, support, and parking procedures before working under or around the mast and chassis.
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 …………………………………………………………………………………………. 1-16
10. Stopping and parking ……………………………………………………………………………………… 1-23
11. Inspection and maintenance ……………………………………………………………………………. 1-25
12. Structure and stability of the lift truck (to prevent lift truck from tipping!) ……. 1-33
13. Safety label sticking positions ………………………………………………………………………… 1-37
13.1 Safety label sticking positions ………………………………………………………………… 1-37
13.2 Introduction of safety devices (option) ……………………………………………………. 1-39
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- 5
6. CONTENTS
0-7
6. CONTENTS
16. Operation ………………………………………………………………………………………………………… 2-21
16.1 Check before operation ………………………………………………………………………….. 2-21
16.2 Mounting/dismounting ……………………………………………………………………………. 2-35
16.3 Operator’s seat position adjustment ……………………………………………………….. 2-35
16.4 Starting lift truck off ……………………………………………………………………………….. 2-36
16.5 Starting, inching on slope ………………………………………………………………………. 2-39
16.6 Turning ………………………………………………………………………………………………….. 2-40
16.7 Temporary stopping and parking ……………………………………………………………. 2-41
16.8 Load handling operation (fork specification) …………………………………………… 2-43
16.9 Load handling operation (side shift fork mover specification)…………………. 2-44
16.10 Check after operation ……………………………………………………………………………… 2-46
16.11 Safety …………………………………………………………………………………………………….. 2-47
17. Cold weather operation ………………………………………………………………………………….. 2-48
17.1 Preparations for low temperature …………………………………………………………… 2-48
17.2 Precautions after completion of operations …………………………………………….. 2-49
18. Actions in engine overheating ………………………………………………………………………… 2-50
19. Long-term storage ………………………………………………………………………………………….. 2-51
19.1 Before storage ……………………………………………………………………………………….. 2-51
19.2 During storage ……………………………………………………………………………………….. 2-51
19.3 After storage ………………………………………………………………………………………….. 2-52
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- 8
23. Periodic replacement of safety critical parts ……………………………………………………. 3- 9
24. Maintenance schedule chart ……………………………………………………………………………. 3-10
25. Maintenance ……………………………………………………………………………………………………. 3-14
25.1 First one month or initial 200 hours service …………………………………………… 3-14
25.2 Check before operation ………………………………………………………………………….. 3-15
25.3 2-weekly/100 hours service …………………………………………………………………….. 3-15
25.4 Monthly/200 hours service ……………………………………………………………………… 3-15
25.5 3-monthly/600 hours service …………………………………………………………………… 3-25
25.6 6-monthly/1200 hours service …………………………………………………………………. 3-28
25.7 Yearly/2400 hours service ………………………………………………………………………. 3-35
25.8 2-years/4800 hours service ……………………………………………………………………… 3-35
26. Replacement procedure …………………………………………………………………………………… 3-36
26.1 Replacing fuses ………………………………………………………………………………………. 3-36
26.2 Replacing tires ……………………………………………………………………………………….. 3-37
26.3 Replacing lamps …………………………………………………………………………………….. 3-38
27. Washing lift truck ……………………………………………………………………………………………. 3-39
TECHNICAL DATA
28. Technical data …………………………………………………………………………………………………. 4-
