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 Komatsu FD100-8 to FD160E-8 Series 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 |
Komatsu FD100-8 to FD160E-8 Series Common Problems This Manual Covers
Komatsu FD100-8 torque converter power not transmitted, truck will not drive with engine running
Check the torque converter oil level first and add oil if it is low, following the table on page 327. If there is still no pressure, inspect the piping and joints for damage. Then disassemble and check the gear pump, drive portion, regulator valve piston and spring. Replace any broken input plate, shaft, gear or spline you find.
Manual Section: Torque Converter Troubleshooting Table p. 327Torque converter output drops with low hydraulic pressure and weak travel power
Check the oil level and add oil, then check the suction piping joints and gaskets for air leaks per page 327. Verify the specified oil is in use, and change it if not. Check the main pressure regulator valve setting against 1.5 MPa (15.3 kg/cm²) on page 126. Then disassemble to inspect the gear pump, regulator spring, piston and seal rings.
Manual Section: Torque Converter Troubleshooting Table p. 327Torque converter producing abnormal noise with engine running, sounding like cavitation or internal contact
Check the oil level and the suction piping for air leaks first, because the table on page 328 lists cavitation from either one as the first cause. Add oil or replace leaking parts. Tighten any loose bolts. If the noise persists, disassemble and inspect the gear pump, the impeller for deformation, the input plate, gears, bearings and splines. Replace worn or broken parts.
Manual Section: Torque Converter Troubleshooting Table p. 328Transmission trouble indicator LED flashing red seven times and truck disabled to travel
Check the 1st speed solenoid harness for an open circuit first. Then check the 1st speed solenoid for an open or grounded condition, following the order on page 260. Next check the power supply cut relay and F/R cut relay contacts and solenoids. If all of those pass, check the controller's relay drive transistor and replace the controller. Reset by turning the key switch.
Manual Section: Automatic Transmission Troubleshooting p. 260Truck travels in reverse but will not travel forward, with no trouble LED code
Check the F solenoid first and replace it if it is open. Then check the F switch signal line and replace the harness if it is disconnected, in the order given on page 262. If both pass, check the F/R switch for an open F contact and replace it. The controller cannot detect this fault, so check each item yourself.
Manual Section: Automatic Transmission Troubleshooting p. 262Engine abnormality warning lamp lit and failure code unknown without the troubleshooting tool
Turn the key switch OFF, then swap cap (1A) on connector (1) with cap (2A) on connector (2) as shown on page 322. With the engine stopped and the key ON, count the lamp blinks and match the code to the table on page 325 (for example, 115 is the NE and Bkup speed sensors). Put the caps back before starting, because the manual says not to start or run the engine with them swapped (page 322).
Manual Section: Indicating Failure Code with Meter Panel p. 322Frequently Asked Questions
How do I reset the error codes on my Komatsu forklift?
To reset an error code, stop the engine, return the shift lever to the neutral position, and re-start the engine. The controller will then reset the abnormality to enable operation. If the LED continues to flash after this reset, there may be a persistent machine problem requiring further troubleshooting. p. 259
How do I bleed the fuel system on my Komatsu forklift?
To bleed the fuel system, fill the fuel tank to full, then loosen and pull out the feed pump knob (2). Operate the knob forward and backward until you feel resistance, then push it back and tighten it. This procedure applies to both the fuel pre-filter and the fuel main filter. p. 58
What's the engine oil filter replacement specification for Komatsu FD100-8, FD115-8, FD135-8, FD150E-8, FD160E-8, EX50?
The engine oil capacity for replacement is 5.36 US gallons (20.3 liters). After installing a new filter cartridge, start the engine and check the filter mounting face for any oil leakage. p. 56
What is the cylinder head mounting bolt torque on Komatsu FD100-8, FD115-8, FD135-8, FD150E-8, FD160E-8, EX50?
The tightening torque for the cylinder head mounting bolts is specified in the SAA6D107E-1-A Engine Shop Manual (SM229). p. 60
What is the standard engine valve clearance on the Komatsu FD100-8, FD115-8, FD135-8, FD150E-8, FD160E-8, EX50?
For the FD100/115, FD135/150E, and FD160E models, the intake valve clearance is 0.0098 in (0.25 mm) and the exhaust valve clearance is 0.020 in (0.51 mm), both measured in a cold state. p. 87
How will I receive this Komatsu FD100-8 Service Manual?
Delivery is instant: a 344-page searchable PDF is yours the second checkout clears. Laptop, tablet, or phone, all fine.
Am I able to print pages from this Komatsu FD100-8 manual?
Yes. Print a chapter or just the pages for the job at hand, for use in your own shop. Any home or office printer works.
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