Komatsu Forklift Truck FE25-2 FE30-2 service & repair manual

Description Komatsu Forklift Truck FE25-2 FE30-2 service & repair manual

Komatsu Forklift Truck FE25-2, FE30-2 pdf workshop service manual

Serial numbers 320001 and up

Technical documentation, specifications, troubleshooting, maintenance, testing, adjusting, electrical wiring diagrams, hydraulic schematics, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and Foreword
Foreword, Safety, Basic Information
How to Read the Shop Manual
Safety Notice for Operation
Precautions to Prevent Fire
Procedures If Fire Occurs
Precautions When You Discard Waste Materials
Precautions When You Handle Hydraulic Equipment
Precautions When You Disconnect and Connect Pipings
Precautions When You Handle Electrical Equipment
Practical Use of KOMTRAX
Disconnect and Connect Push-Pull Type Coupler
Precautions for Disconnection and Connection of Connectors
Standard Torque Table
Conversion Table
Abbreviation List

Specifications
Specification Drawing
Weight Table
Fuel, Coolant, Lubricant

Structure and Function
Charge System
Layout Drawing of Charge System
Component Parts of Charge System
Boot-up System
Layout Drawing of Boot-up System
System Operating Lamp System
Emergency Stop Switch
ID Key System
Component Parts of Boot-Up System
Control System
Layout Drawing of Control System
Monitor Panel System
KOMTRAX System
Seat Belt Interlock System
Impact Detection System
Inclination Warning System
Fall Detection System
Component Parts of Control System
Hydraulic System
Layout Drawing of Hydraulic System
Lift Interlock System
Component Parts of Hydraulic System
Power Train System
Layout Drawing of Power Train System
Operation of Power Train System
Directional Lever Warning System
Travel Interlock System
Travel Speed Limit System at Lifting Height
Reverse Travel Control System on Slope
Power Assist System on Slope
Component Parts of Power Train System
Work Equipment System
Layout Drawing of Work Equipment System
Structure of Valve Control
Steering System
Layout Drawing of Steering System
Steering Column
EPACS System
Turning Speed Limit System
Component Parts of Steering System
Brake System
Layout Drawing of Brake System
Parking Brake Warning System
Parking Brake Dragging Warning System
Component Parts of Brake System
Undercarriage and Frame
Frame
Tires
Work Equipment
Structure of Work Equipment
Function of Work Equipment
CAB Related Parts
Head Guard
CAB

Standard Value Table
Standard Value Table for Machine
Standard Value Table for Vehicle: FE25-2
Standard Value Table for Vehicle: FE30-2
Procedures To Measure Performance

Testing and Adjusting
Precautions Before Work
Related Information on Testing and Adjusting
Tools for Testing and Adjusting
Power Train
Adjust Accelerator Pedal
Examine Oil Level in Differential Case, Change Oil
Steering System
Examine Play of Steering Wheel
Adjust Tire Angle Sensor
Brake System
Adjust Parking Brake Lever
Adjust Brake Pedal
Examine and Adjust Brake Pedal Angle Sensor
Examine and Adjust Disc Brake
Bleed Air from Brake Circuit
Examine Brake Performance
Hydraulic System
Release Remained Pressure in Hydraulic Circuit
Examine Steering Circuit Oil Pressure
Measure Oil Pressure of Work Equipment
How to Examine Oil Level in Hydraulic Tank, Change Oil
Bleed Air from Hydraulic Circuit
Lower Fork Manually
Work Equipment
Examine and Adjust Work Equipment Lever
Examine Hydraulic Drift and Forward Tilt of Work Equipment
Adjust Mast
Adjust Lifting Height Detection Sensor
Adjust Finger Board
Electrical System
Examine Fuse
Clean and Replace Filter of Stationary Battery Charger
Replace Packing of Battery Charger Plug
Excamine Strong Electric Terminal of Charge Plug on Forklift Truck
Excamine Strong Electric Terminal of Charge Plug on Charger
Set and Operate Monitor Pane
How to Start Up KOMTRAX Terminal

Troubleshooting
Precautions Before Work
Related Information to Troubleshooting
General Troubleshooting Points
Sequence of Events in Troubleshooting
Checks Before Troubleshooting
Inspection Procedure Before Troubleshooting
Test in Accordance with Testing Procedure
Preparation for Troubleshooting of Electrical System
Procedure for Troubleshooting
Symptom and Troubleshooting Numbers
Information Shown in Troubleshooting Table
Connector List (FE25-2) (Head Guard Specification)
Connector Layout (FE25-2) (Head Guard Specification)
Connector List (FE25-2) (Cab Specification)
Connector Layout (FE25-2) (Cab Specification)
Connector List (FE30-2) (Head Guard Specification)
Connector Layout (FE30-2) (Head Guard Specification)
Connector List (FE30-2) (Cab Specification)
Connector Layout (FE30-2) (Cab Specification)
Connector Contact Connection Table
T-Branch Box and T-Branch Adapter Table
Fuse Location Table
Failure Code Table
Troubleshooting by Failure Code (Display of Code)
Troubleshooting of Electrical System (E-Mode)
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)

Disassembly and Assembly
Precautions Before Work
Related Information on Disassembly and Assembly
How to Read This Manual
Coating Materials List
Special Tool List
Sketches of Special Tools
Prepare
Drain and Add Hydraulic Oil
Power Train
Remove and Install Front Axle Assembly
Remove and Install Axle Housing Assembly
Disassemble and Assemble Axle Housing Assembly
Disassemble and Assemble Differential Assembly
Remove and Install Parking Brake Assembly
Disassemble and Assemble Parking Brake Assembly
Remove and Install Parking Brake Lever
Brake System
Remove and Install Brake Master Cylinder Assembly
Disassemble and Assemble Brake Master Cylinder Assembly
Steering System
Remove and Install Steering Cylinder Assembly
Disassemble and Assemble Steering Cylinder Assembly
Remove and Install Orbitrol Valve Assembly
Disassemble and Assemble Orbitrol Valve Assembly
Undercarriage and Frame
Remove and Install Counterweight Assembly (Head Guard Specification)
Remove and Install Counterweight Assembly (Cab Specification)
Remove and Install Battery Hood Assembly (Head Guard Specification)
Remove and Install Battery Hood Assembly (Cab Specification)
Remove and Install Rear Axle Assembly
Disassemble and Assemble Rear Axle Assembly
Hydraulic System
Remove and Install Control Valve Assembly
Disassemble and Assemble Control Valve Assembly
Remove and Install Hydraulic Tank Assembly
Disassemble and Assemble Steering and Work Equipment Pump Assembly
Work Equipment
Remove and Install Mast Assembly
Disassemble and Assemble Mast Assembly
Remove and Install Lift Cylinder Assembly
Disassemble and Assemble Lift Cylinder Assembly
Remove and Install Tilt Cylinder Assembly
Disassemble and Assemble Tilt Cylinder Assembly
CAB Related Parts
Remove and Install Operator Seat
How to Remove and Install Seat Belt
Remove and Install Head Guard Assembly
Remove and Install Operator Cab Assembly
Electrical System
Remove and Install Pump Motor Assembly
Remove and Install Battery Assembly (Head Guard Specification)
Remove and Install Battery Assembly (Cab Specification)
Disassemble and Assemble Battery Assembly (108V/180Ah) (FE25-2)
Disassemble and Assemble Battery Assembly (120V/180Ah) (FE30-2)
Disassemble and Assemble Battery Assembly (108V/240Ah) (FE25-2)
Disassemble and Assemble Battery Assembly (120V/240Ah) (FE30-2)
Remove and Install Charge Cable on ForkliftTruck (Head Guard Specification)
Remove and Install Charge Cable on ForkliftTruck (Cab Specification)
Remove and Install Charge Cable (L-Shaped Leg Charger Side)
Remove and Install Charge Cable (U-Shaped Leg Charger Side)
Remove and Install Stationary Charger Ferrite Core (L-Shape Leg Charger)
Remove and Install Stationary Charger Ferrite Core (U-Shape Leg Charger)
Remove and Install Master Controller
Remove and Install Travel Inverter
Remove and Install Pump Inverter
Remove and Install Power Supply Controller
Remove and Install Contactor
Remove and Install Monitor Panel Assembly
Remove and Install KOMTRAX Terminal
Remove and Install Combination Switch Assembly

Maintenance Standard
Explanation of Terms for Maintenance Standard
Power Train
Maintenance Standard of Front Axle: FE25-2 (Single Tire Specification)
Maintenance Standard of Front Axle: FE25-2 (Double Tire and Wide Tire Specification)
Maintenance Standard of Front Axle: FE30-2
Maintenance Standard for Differential
Maintenance Standard of Final Drive: FE25-2 (Single Tire Specification)
Maintenance Standard of Final Drive: FE25-2 (Double Tire and Wide Tire Specification)
Maintenance Standard of Final Drive: FE30-2
Maintenance Standard for Travel Motor
Maintenance Standard for Pump Motor
Steering System
Maintenance Standard for Steering Cylinder
Brake System
Maintenance Standard for Brake Pipe
Maintenance Standard for Front Brake
Maintenance Standard for Parking Brake
Maintenance Standard for Brake Master Cylinder
Undercarriage and Frame
Maintenance Standard for Rear Axle
Maintenance Standard of Frame
Hydraulic System
Maintenance Standard for Hydraulic Tank
Maintenance Standard for Control Valve
Maintenance Standard of Tilt Cylinder
Maintenance Standard for Lift Cylinder
Work Equipment
Maintenance Standard of Mast
Maintenance Standard of Board

Others
Precautions Before Work
Heater System
PTC Heater Component Parts
System Diagram of Heater System
Function of Heater System
Operation of Heater System
Collision Detection System
Precautions for Collision Detection System
Structure and Operation of Collision Detection System
Examine and Adjust Collision Detection System
Troubleshooting of Collision Detection System
Disassemble and Assemble Collision Detection System
Yearly Inspection Criteria

Circuit Diagrams
How to Read the Codes for Electric Cable
Hydraulic Circuit Diagram
Symbols Used in Hydraulic Circuit Diagram
Hydraulic Circuit Diagram (at Right Turn)
Hydraulic Circuit Diagram (at Lift Raise)
Electrical Circuit Diagram
Symbols Used in Electric Circuit Diagram
Electrical Circuit Diagram (Head Guard Specification)
Electrical Circuit Diagram (Head Guard Specification) (L-Shaped Leg Charger)
Electrical Circuit Diagram (Head Guard Specification) (U-Shaped Leg Charger)
Electrical Circuit Diagram (Cab Spec)
Electrical Circuit Diagram (Cab Specification) (L-Shaped Leg Charger)
Electrical Circuit Diagram (Cab Specification) (U-Shaped Leg Charger)
Electrical Circuit Diagram (Forklift Truck with Collision Detection System)