When a Torqflow transmission starts slipping or the wet disc brakes lose accumulator charge, this Komatsu FD160E-8 service manual PDF sorts it out in 344 factory pages (OEM ID BEE08E1-01), covering five diesel forklift truck variants from the FD100-8 to the FD160E-8. Electrical circuit diagrams are split by brake type, manual or Torqflow transmission, and with or without KOPS, so you trace your own truck's harness, while hydraulic circuit diagrams follow oil from the pumps through the control valve to the lift and tilt cylinders. Disassembly and assembly fills nearly a third of the book, from torque converter and clutch packs to the brake valve and mast shim and chain adjustment. Set relief pressure at 21.6 MPa (220 kgf/cm2) and refill the engine with 20.3 L of oil at each change. A parked lift truck costs you every shift it sits. Bookmarked and text-searchable, this PDF takes you from failure code to a truck lifting loads again.
What's Inside This Manual
| System | Pages | Key Topics |
|---|
| General Information & Specifications | 39-50 | Specifications, Periodic Replacement of Consumable Parts, Standard Tightening Torque (Bolts, Elbows, Nipples and Unions), How to Use Loctite |
| Testing & Adjusting | 51-82 | Service Data, Depressurize Hydraulic System, Replace Engine Oil/Engine Oil Filter (Change Engine Oil) |
| Inspection | 83-114 | Weight Table, Inspection Checklist by Component, Removal and Installation of Components, Removal and Installation Flow Chart |
| Disassembly and Assembly | 115-212 | Torque Converter |
| Maintenance Standard | 213-246 | Engine and Electrical Parts, Accelerator Pedal, Speedometer Sensor, Location of Switches and Sensors, Torque Converter, Torqflow Transmission, Transmission Control Valve |
| Structure and Function | 247-316 | Power Train Diagram (Hydraulic Drum Brake, Wet Disc Brake), Torque Converter, Torqflow Transmission - 1/3, Torqflow Transmission - 2/3 |
| Troubleshooting | 317-332 | Troubleshooting Tool and Failure Codes (Functions of Troubleshooting Tool, Using the Troubleshooting Tool) |
| Conversion Tables | 333-344 | Millimeters to Inches, Cubic Meters to Cubic Yards, Liter to U.S. Gallon |
Quick Reference Specifications
| Specification | Value | Page |
|---|
| Tightening torque for 6mm bolt | 13.2±1.4 Nm | p. 48 |
| Tightening torque for 8mm bolt | 31.4±2.9 Nm | p. 48 |
| Relief pressure | 21.6 MPa (220 kgf/cm2) | p. 54 |
| Engine oil capacity | 20.3 l | p. 88 |
| Engine Oil Capacity (Replacement) | 5.36 US gal (20.3 L) | p. 56 |
| Accumulator charge cut-in pressure | 5.88 MPa | p. 73 |
| Accelerator pedal angle (Neutral) | 45 ± 2 ° | p. 215 |
| Accelerator pedal angle (Maximum) | 17 ± 2 ° | p. 215 |
| Torque Converter Stall Speed | 2,000 rpm | p. 53 |
| Engine Idling Speed | 700-750 rpm | p. 53 |
| Engine Max Speed | 2,375-2,475 rpm | p. 53 |
| Hydraulic System Relief Pressure | 21.6 MPa {220 kgf/cm2} | p. 54 |
