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Komatsu FB25-12,FB30-12 Forklift Truck Shop Manual SEN06636-08 PDF

Komatsu FB25-12,FB30-12 Forklift Truck Shop Manual SEN06636-08 PDF

Name: Komatsu FB25-12,FB30-12 Forklift Truck Shop Manual SEN06636-08 PDF
SKU: 885212
Availability: InStock

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Komatsu FB25-12,FB30-12 Forklift Truck Shop Manual SEN06636-08 – PDF DOWNLOAD

SERIAL NUMBERS

FB25-100001 and up
FB30-100001 and up

Category: komatsu Tags: Komatsu FB25-12 FB30-12 Forklift Truck Shop Manual, Komatsu FB25-12 FB30-12 Forklift Truck Shop Manual SEN06636-08 -, Komatsu FB25-12 FB30-12 Forklift Truck Shop Manual SEN06636-08 - PDF DOWNLOAD Vendor: ShopFloorPDFs

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Description

Description

Komatsu FB25-12,FB30-12 Forklift Truck Shop Manual SEN06636-08 – PDF DOWNLOAD

FILE DETAILS:

Komatsu FB25-12,FB30-12 Forklift Truck Shop Manual SEN06636-08 – PDF DOWNLOAD

Language : English
Pages : 1042
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu FB25-12,FB30-12 Forklift Truck Shop Manual SEN06636-08 – PDF DOWNLOAD

SERIAL NUMBERS

FB25-100001 and up
FB30-100001 and up

Cover . 1
00 Index and foreword . 3
Table of contents . 4
Foreword, safety, and general information . 12
Safety notice . 12
How to read the shop manual . 22
Explanation of terms for maintenance standard . 24
Handling of electric equipment and hydraulic component 26
How to read electric wire code 35
Precautions when carrying out operation . 38
Standard tightening torque table 41
Conversion table 45
01 Specification 51
Contents 52
Specifications 53
Specification dimensions drawing 53
Specifications 55
Weight table 56
Oil and greasing chart 57
Table of fuel, coolant, and lubricants 58
10 Structure and function . 59
Contents 60
Power train . 61
Power train components 62
Front axle 63
Differential 67
Travel motor 70
Pump motor 71
Steering system . 72
Steering piping diagram . 72
Orbitrol valve 73
Power steering cylinder . 75
Brake system 76
Brake control . 76
Wheel brake . 77
Brake master cylinder . 79
Undercarriage and frame . 80
Rear axle . 80
Frame . 81
Hydraulic system 82
Control valve piping diagram (tank to control valve) 82
Work equipment piping diagram (control valve to tilt cylinder/lift cylinder) 83
Attachment piping diagram . 84
Work equipment control lever linkage 85
Hydraulic tank 86
Hydraulic pump 87
Control valve . 88
Work equipment 102
Mast 102
Electrical system . 108
Electrical control system . 108
System component parts 124
Monitor system 137
KOMTRAX system 139
Sensor and switch . 142
20 Standard value table . 157
Contents 158
Standard value table 159
Standard value table 159
30 Testing and adjusting 161
Contents 162
Precautions before work . 163
Related information on testing and adjusting 164
Tools for testing and adjusting . 164
Power train . 165
Adjusting accelerator pedal . 165
Oil level check and changing oil in differential case . 167
Brake system 168
Adjusting parking brake lever . 168
Adjusting brake pedal . 169
Adjusting wheel brake . 171
Bleeding air from brake piping 173
Measuring brake performance . 174
Hydraulic system 175
Releasing pressure from hydraulic piping 175
Testing steering oil pressure . 176
Testing work equipment oil pressure . 177
Checking oil level and change oil in hydraulic tank . 179
Bleed air from lift cylinder 181
Emergency operation when lift lowering cannot be operated . 182
Work equipment 184
Testing and adjusting work equipment lever 184
Measurement of amount of hydraulic drift and forward drift of hydraulic cylinder 186
Adjusting mast 187
Adjusting the lifting height detection sensor . 190
Adjusting fork carriage . 193
Electrical system . 196
Checking battery electrolyte level 196
Checking fuse . 198
Adjusting the charger to the source voltage tap . 200
Special functions of monitor panel 201
40 Troubleshooting 289
Contents 290
Precautions before work . 295
Information related to troubleshooting 296
Points to remember when troubleshooting . 296
How to proceed in troubleshooting . 297
Checks before troubleshooting . 299
Classification and procedures of troubleshooting 300
Symptoms and troubleshooting numbers 301
Information described in troubleshooting table 303
Locations of fuses 305
Relay box arrangement and locations . 308
Connector list 310
Location and removal of battery plug 324
Connector connection by pin No 325
T-box and T-adapter list 368
Failure codes table . 371
Troubleshooting by failure code . 378
Failure code [7REXKA] DISC) Seat SW . 378
Failure code [7REXKB] SHORT) Seat SW 380
Failure code [989L00] Lock Caution 1 382
Failure code [989M00] Lock Caution 2 382
Failure code [989N00] Lock Caution 3 383
Failure code [B@GBZK] LOW) BATTERY LIQUID . 384
Failure code [D160KB] SHORT) Back Lamp RLY 386
Failure code [D160KY] SHORT_P) Back Lamp RLY 389
Failure code [D161KB] SHORT) Back Alarm RLY . 392
Failure code [D161KY] SHORT_P) Back Alarm RLY . 395
Failure code [D19RKA] DISC) Cooling FAN1 RLY 398
Failure code [D19RKB] SHORT) Cooling FAN1 RLY . 401
Failure code [D19RKY] SHORT_P) Cooling FAN1 RLY . 404
Failure code [D19SKB] SHORT) Forward Alarm RLY 407
Failure code [D19SKY] SHORT_P) Forward Alarm RLY 409
Failure code [D19VKA] DISC) Cooling FAN2 RLY 411
Failure code [D19VKB] SHORT) Cooling FAN2 RLY . 414
Failure code [D19VKY] SHORT_P) Cooling FAN2 RLY . 417
Failure code [D1HBKA] Open Circuit of Main Contactor 2 420
Failure code [D1HBKB] Ground Fault of Main Contactor 2 422
Failure code [D1HBKY] Short Circuit of Main Contactor 2 . 424
Failure code [D1HPKB] SHORT) Speed Alarm RLY 1 426
Failure code [D1HPKY] SHORT_P) Speed Alarm RLY 1 428
Failure code [D1HQKB] SHORT) Speed Alarm RLY 2 430
Failure code [D1HQKY] SHORT_P) Speed Alarm RLY 2 432
Failure code [D1HRKY] SHORT_P) Speed Alarm RLY 3 434
Failure code [D5XWKA] DISC) SeatBelt Error Sig 436
Failure code [D5XWKY] SHORT_P) SeatBelt Error Sig . 440
Failure code [D5XXKA] DISC) S/Belt IL Valid Sig . 442
Failure code [D5XXKY] SHORT_P) S/Belt IL Valid Sig 444
Failure code [D811MC] ABNL) KOMTRAX . 446
Failure code [D862KA] DISC) GPS Antenna . 447
Failure code [D8ALKA] DISC) SYS-OPE Lamp (KMTX) . 448
Failure code [D8ALKB] SHORT) SYS-OPE Lamp (KMTX) 450
Failure code [D8AQK4] ABNL) CAN COMM. 2 (KMTX) 452
Failure code [D8AQKR] ABNL) CAN COMM. (KMTX) 454
Failure code [DAF0KT] ABNL) EEPROM (MON) 454
Failure code [DAF0MB] ABNL) Monitor ROM . 455
Failure code [DAF0MC] ABNL) Monitor . 455
Failure code [DAF3KK] LOW) Power Source (MON) . 456
Failure code [DAFGMC] ABNL) GPS Module 458
Failure code [DAFLKA] DISC) SYS-OPE Lamp (MON) 460
Failure code [DAFLKB] System Operating Lamp Short Circuit (MON) . 462
Failure code [DAFQKR] ABNL) CAN COMM. (MON) . 464
Failure code [DBN000] ABNL) EEPROM (M/C) 464
Failure code [DBN0KT] ABNL) EEPROM (M/C) 465
Failure code [DBN0MC] RESET) Controller (M/C) . 465
Failure code [DBN2KK] Load Power Source Low (M/C) . 466
Failure code [DBN3KK] LOW) Power Source (M/C) . 468
Failure code [DBN5KX] OUT OF RNG) Sensor Power1 . 470
Failure code [DBN6KX] OUT OF RNG) Sensor Power2 . 472
Failure code [DBN9KQ] ABNL) Model Selection Line (FB25-12) 474
Failure code [DBN9KQ] ABNL) Model Selection Line (FB30-12) 476
Failure code [DBNCMA] MISMATCH) OPT-Setting (M/C) . 478
Failure code [DBNEKR] ABNL) CAN COMM. (for TRV) . 479
Failure code [DBNFKR] ABNL) CAN COMM. (for PMP) . 483
Failure code [DBNHKA] DISC) MC2 Output (M/C) 486
Failure code [DBNHKB] MC2 Enable Command Output Ground Fault (M/C) 489
Failure code [DBNHKY] SHORT_P) MC2 Output (M/C) . 492
Failure code [DBNJKB] SHORT) Operating States . 495
Failure code [DBNJKY] SHORT_P) Operating States . 496
Failure code [DBNKKA] DISC) CutOFF OutSide 497
Failure code [DBNKKB] SHORT) CutOFF OutSide . 498
Failure code [DBNKKY] SHORT_P) CutOFF OutSide . 499
Failure code [DBNLKA] DISC) Sys-Ope. Lamp . 500
Failure code [DBNLKB] SHORT_P) Sys- Ope. Lamp . 502
Failure code [DBNMKA] DISC) ENABLE TRV-INV (M/C) 504
Failure code [DBNMKB] SHORT) ENABLE TRV-INV (M/C) . 505
Failure code [DBNNKA] DISC) ENABLE PMP-INV (M/C) 506
Failure code [DBNNKB] SHORT) ENABLE PMP-INV (M/C) . 507
Failure code [DBNPKA] DISC) AC INPUT LINE (M/C) . 508
Failure code [DBNRKR] ABNL) CAN COMM. (M/C) . 509
Failure code [DBNTKA] DISC) Key Signal 512
Failure code [DBNUKA] DISC) MC2-CUT CONTACTOR . 514
Failure code [DBNUKB] SHORT) MC2-CUT CONTACTOR 516
Failure code [DBNUKY] SHORT_P) MC2-CUT CONTACTOR 518
Failure code [DBNVMA] ABNL) Start-up Signal . 520
Failure code [DDDQKA] DISC) HIGH LIFTING HIGHT2 SW 522
Failure code [DDDTKA] DISC) Seat SW1 524
Failure code [DDDTKA] DISC) Seat SW1 (European specification (including Turkey)) (Serial No.: 104201 and up) 526
Failure code [DDDTKB] SHORT) Seat SW1 . 528
Failure code [DDDTKB] SHORT) Seat SW1 (European specification (including Turkey)) (Serial No.: 104201 and up) . 530
Failure code [DDDUKA] DISC) Seat SW2 532
Failure code [DDDUKA] DISC) Seat SW2 (European specification (including Turkey)) (Serial No.: 104201 and up) 534
Failure code [DDDUKB] SHORT) Seat SW2 . 536
Failure code [DDDUKB] SHORT) Seat SW2 (European specification (including Turkey)) (Serial No.: 104201 and up) . 538
Failure code [DDDVKA] ABNL) Seat SW . 540
Failure code [DDDVKA] ABNL) Seat SW (European specification (including Turkey)) (Serial No.: 104201 and up) . 542
Failure code [DDDVKM] OPE-ERROR) Seat SW 544
Failure code [DDDVKM] OPE-ERROR) Seat SW (European specification (including Turkey)) (Serial No.: 104201 and up) 546
Failure code [DDK6KA] DISC) Direction Lever . 548
Failure code [DDK6KY] SHORT_P) Direction Lever 552
Failure code [DFC1KA] DISC) Lift lever POT 554
Failure code [DFC1KB] SHORT) Lift lever POT . 556
Failure code [DGE5KA] DISC) Air Temp. Sensor 558
Failure code [DGE5KB] SHORT) Air Temp. Sensor . 559
Failure code [DHPCKA] DISC) HYDR-PRESS SNSR . 560
Failure code [DHPCKB] SHORT) HYDR-PRESS SNSR 562
Failure code [DJK1KA] DISC) Load Current Sensor . 564
Failure code [DJK1KB] SHORT) Load Current Sensor 566
Failure code [DJK1MA] INIT) Load Current Sensor . 568
Failure code [DJK2KA] DISC) Charge Current Sensor . 569
Failure code [DK10KA] DISC) Accelerator POT . 571
Failure code [DK10KB] SHORT) Accelerator POT 573
Failure code [DK11KA] DISC) Accelerator POT2 575
Failure code [DK11KB] SHORT) Accelerator POT2 . 577
Failure code [DK13KX] OUT OF RNG) Accelerator SNSR 579
Failure code [DK13L8] Defective Accelerator Pedal Angle Sensor 579
Failure code [DK30MA] Malfunction of Steering Angle Sensor 580
Failure code [DK5YMA] ABNL) Tire Sensor . 582
Failure code [DV00KB] SHORT) Buzzer Output 584
Failure code [DW9MKA] DISC) Lift Lock Solenoid 585
Failure code [DW9MKB] SHORT) Lift Lock Solenoid . 586
Failure code [DW9MKY] SHORT_P) Lift Lock Solenoid . 587
Failure code [DWP0KA] DISC) Steering SOL 588
Failure code [DWP0KB] SHORT) Steering SOL . 590
Failure code [F7FQKR] ABNL) CAN COMM. (IDKey) . 592
Failure code [F7G0MC] ABNL) ID Key Antenna 594
Failure code [GF11KG] HIGH) Power Source (TRV-INV) 596
Failure code [GF11KK] LOW) Power Source (TRV-INV) . 599
Failure code [GF12KA] DISC) U Phase (TRV-INV) . 602
Failure code [GF13KA] DISC) V Phase (TRV-INV) . 604
Failure code [GF14KA] DISC) W Phase (TRV-INV) . 606
Failure code [GF15KQ] MISMATCH) Capacity (TRV-INV) 608
Failure code [GF16KA] DISC) MC2 Line (TRV-INV) 610
Failure code [GF16KB] SHORT) MC2 Line (TRV-INV) . 614
Failure code [GF17MA] ABNL) Quick Charge (TRV-INV) 617
Failure code [GF18KQ] MISMATCH) Func. SEL (TRV-INV) . 622
Failure code [GF1AMA] ABNL) Current SNSR (TRV-INV) 624
Failure code [GF1BMA] ABNL) Temp. Sensor (TRV-INV) 624
Failure code [GF1C00] HIGH) Temp. of TRV-INV 625
Failure code [GF1CNS] OVER) Temp. of TRV-INV 625
Failure code [GF1DMA] MISMATCH) MC2 Info (TRV-INV) 626
Failure code [GF1EKT] ABNL) EEPROM (TRV-INV) 629
Failure code [GF1FMA] ABNL) KEY-POWER (TRV-INV) . 630
Failure code [GF1JKA] DISC) Output Power (TRV-INV) 632
Failure code [GF1LKB] SHORT) FET (TRV-INV) 635
Failure code [GF1MKB] SHORT) Upper FET (TRV-INV) 638
Failure code [GF1NKB] SHORT) Lower FET (TRV-INV) 641
Failure code [GF1QKR] ABNL) CAN COMM. (TRV-INV) . 644
Failure code [GF21KG] HIGH) Power Source (PMP-INV) 646
Failure code [GF21KK] LOW) Power Source (PMP-INV) . 649
Failure code [GF22KA] DISC) U Phase (PMP-INV) . 652
Failure code [GF23KA] DISC) V Phase (PMP-INV) . 654
Failure code [GF24KA] DISC) W Phase (PMP-INV) . 656
Failure code [GF25KQ] MISMATCH) Capacity (PMP-INV) 658
Failure code [GF26KA] DISC) MC2 Line (PMP-INV) 660
Failure code [GF26KB] SHORT) MC2 Line (PMP-INV) . 664
Failure code [GF27MA] ABNL) Quick Charge (PMP-INV) 667
Failure code [GF28KQ] MISMATCH) Func. SEL (PMP-INV) . 672
Failure code [GF2AMA] ABNL) Current SNSR (PMP-INV) 674
Failure code [GF2BMA] ABNL) Temp. Sensor (PMP-INV) 674
Failure code [GF2C00] HIGH) Temp. of PMP-INV 675
Failure code [GF2CNS] OVER) Temp. of PMP-INV 675
Failure code [GF2EKT] ABNL) EEPROM (PUMP INV) . 676
Failure code [GF2FMA] ABNL) KEY-POWER (PMP-INV) . 678
Failure code [GF2JKA] DISC) Output Power (PMP-INV) 680
Failure code [GF2LKB] SHORT) FET (PMP-INV) 683
Failure code [GF2MKB] SHORT) Upper FET (PMP-INV) 686
Failure code [GF2NKB] SHORT) Lower FET (PMP-INV) 689
Failure code [GF2QKR] ABNL) CAN COMM. (PMP-INV) . 692
Failure code [GF30KB] SHORT) Travel Motor . 694
Failure code [GF31MA] ABNL) Temp. SNSR (TRV-MOT) 696
Failure code [GF3200] HIGH) Temp. of TRV-MOT 698
Failure code [GF32NS] OVER) Temp. of TRV-MOT 698
Failure code [GF33MA] ABNL) Rotation SNSR (TRV-MOT) . 700
Failure code [GF50KB] SHORT) Pump Motor . 702
Failure code [GF51MA] ABNL) Temp. Sensor (PMP-MOT) 704
Failure code [GF5200] HIGH) Temp. of PMP-MOT 706
Failure code [GF52NS] OVER) Temp. of PMP-MOT 706
Failure code [GF53MA] ABNL) Rotation SNSR (PMP-MOT) . 708
Troubleshooting for hydraulic and mechanical system (E-mode) 710
E-1 Lift truck does not start . 710
E-2 When starting switch is turned to ON position, monitor panel is not displayed . 712
E-3 When starting switch is turned to ON position, alarm buzzer does not sound 716
E-4 Parking brake reminder alarm does not sound or does not stop sounding . 718
E-5 Horn does not sound or does not stop sounding . 721
E-6 EPACS is abnormal . 726
E-7 Travel speed restriction cannot be released or enabled 728
E-8 Monitor panel cannot be set in controller failure display mode, controller adjustment mode, or travel speed limit setting mode 728
E-9 Headlamp, clearance lamp, tail lamp, and license plate lamp do not light up or do not go out 729
E-10 Turn signal lamps do not light up or do not go out . 736
E-11 Brake lamps do not light up or do not go out . 742
E-12 Backup lamp does not light up or does not go out . 744
E-13 Backup buzzer does not sound or does not stop sounding . 748
E-14 KOMTRAX system does not operate normally . 752
Troubleshooting for hydraulic and mechanical system (H-mode) 753
How to use troubleshooting table 753
Hydraulic and mechanical system diagram . 756
Table of failure modes and causes . 758
H-1 Lift truck does not turn 761
H-2 Turning response is poor 762
H-3 Steering wheel is heavy to turn . 763
H-4 Unstable during turning . 764
H-5 When steering wheel is released, it does not return to neutral or it rotates by itself 765
H-6 Steering wheel is turned in reverse or it kicks (while work equipment is operated) 765
H-7 Large shock is made when steering wheel is returned . 766
H-8 EPACS does not work . 767
H-9 Steering wheel vibrates . 767
H-10 Steering system makes abnormal sound . 768
H-11 Oil leaks from steering circuit 768
H-12 Service brake does not work or its performance is low 769
H-13 Service brake is not released or it drags 770
H-14 Parking brake does not work or its performance is low 771
H-15 Parking brake is not released or drags . 772
H-16 Unusual noise is heard from around work equipment and steering pump 773
H-17 Fork lowering lock does not work (Fork lowers when operator leaves operator’s seat) 774
H-18 Control valve lever does not move smoothly and it is heavy . 775
H-19 Lift cylinder and fork are not raised 776
H-20 Lifting speed or power of lift cylinder and fork is insufficient . 777
H-21 Fork lifting speed lowers at specific height . 778
H-22 Hydraulic drift of lift cylinder is large 779
H-23 Lift cylinders do not come down 780
H-24 Fork lowering speed is low or high or fine control performance is low or response is low . 781
H-25 Mast does not tilt forward nor backward 782
H-26 Forward/backward tilting speed or force of mast is insufficient 783
H-27 Tilting speed lowers halfway . 784
H-28 Hydraulic drift of tilt cylinder (forward tilting) is large 785
H-29 Mast is unstable during travel with load . 786
H-30 Steering is heavy when work equipment and steering are operated simultaneously . 787
50 Disassembly and assembly . 789
Contents 790
Precautions before work . 791
General information on disassembly and assembly . 792
How to read this manual . 792
Coating materials list 794
Special tools list 798
Sketches of special tools . 801
Power train . 809
Removal and installation of front axle assembly . 809
Disassembly and assembly of front axle assembly . 812
Removal and installation of pump motor 855
Steering system . 858
Removal and installation of power steering cylinder assembly 858
Disassembly and assembly of power steering cylinder assembly 860
Disassembly and assembly of wheel brake assembly 862
Removal and installation of Orbitrol valve assembly . 872
Disassembly and assembly of Orbitrol valve assembly . 875
Brake system 881
Removal and installation of brake master cylinder assembly 881
Disassembly and assembly of brake master cylinder assembly 884
Removal and installation of parking brake lever . 886
Undercarriage and frame . 889
Removal and installation of rear axle assembly 889
Disassembly and assembly of rear axle assembly 891
Removal and installation of counterweight assembly 898
Removal and installation of hood assembly . 899
Hydraulic system 901
Removal and installation of hydraulic tank assembly . 901
Removal and installation of control valve assembly 905
Disassembly and assembly of control valve assembly 908
Removal and installation of lift cylinder assembly 915
Disassembly and assembly of lift cylinder assembly 917
Removal and installation of tilt cylinder assembly 921
Disassembly and assembly of tilt cylinder assembly 922
Disassembly and assembly of hydraulic pump assembly . 924
Cab and its attachments . 926
Removal and installation of operator’s seat assembly 926
Removal and installation of seat belt assembly 927
Removal and installation of seat belt assembly (European specification (including Turkey)) (Serial No.: 104201 and up) 928
Removal and installation of head guard assembly . 929
Work equipment 934
Removal and installation of mast assembly . 934
Disassembly and assembly of mast assembly . 937
Electrical system . 940
Removal and installation of battery assembly 940
Removal and installation of master controller assembly 942
Removal and installation of inverter assembly . 943
Removal and installation of monitor panel assembly 950
Removal and installation of KOMTRAX terminal 952
Removal and installation of combination switch assembly . 953
60 Maintenance standard . 957
Contents 958
Power train . 960
Front axle 960
Differential 966
Travel motor 968
Pump motor 970
Steering system . 972
Power steering cylinder . 972
Brake system 973
Brake control . 973
Wheel brake . 974
Brake master cylinder . 976
Undercarriage and frame . 977
Rear axle . 977
Hydraulic system 978
Hydraulic tank 978
Control valve . 979
Work equipment 982
Tilt cylinder . 982
Lift cylinder . 983
Mast 984
Board . 988
80 Yearly inspection criteria . 991
Contents 992
Precautions before work . 993
Yearly inspection criteria 994
Yearly inspection criteria 994
90 Diagrams and drawings 1013
Contents 1014
Hydraulic diagrams and drawings .1015
Symbols used in hydraulic circuit diagrams 1015
Hydraulic circuit diagram .1017
Electrical diagrams and drawings 1019
Symbols used in electrical circuit diagrams .1019
Electric circuit diagram 1023
Index .1035

DESCRIPTION:

Komatsu FB25-12,FB30-12 Forklift Truck Shop Manual SEN06636-08 – PDF DOWNLOAD

SERIAL NUMBERS

FB25-100001 and up
FB30-100001 and up

1. General precautions:

appropriate handling causes an extreme danger. Read and understand what is described in the operation and maintenance manual before operating the lift truck. Read and understand what is described in this manual before starting the work.

1) Before performing any greasing or repairs, read all the safety labels stuck to the lift truck. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.

2) Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Smoke only in the areas provided for smoking. Never smoke while working.

3) When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing. q Always wear the protective eyeglasses when hitting parts or tools with a hammer. q Always wear the protective eyeglasses when grinding parts with a grinder, etc.

4) When performing any work with 2 or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.

5) Only the approved personnel can do the work in a closed environment or in a prohibited area.

6) If performing the work or operation which requires licenses or qualifications, always have a qualified person perform it.

7) Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.

8) If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.

9) Before starting work, warm up your body thoroughly to start work under good condition.

10) Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.

11) When you work in high places, use a platform.

12) Before you start the work, use the personal fall-arrest equipment to prevent falling. There is a danger of personal accident that you fall by slipping.

13) Always do the work correctly. If you find the unsafe behavior of co-worker, give him/her a notice and stop it.

14) Because there is a danger that you are caught, be very careful when the work is done in dangerous areas such as: when you go in the range where the lifted load possibly falls, or when you stand directly in front of tire, or when you are near the sliding parts.

15) When you handle chemical materials (such as nitrogen gas), see the MSDS (safety data sheet) and local guidelines, and get the important information (such as a safe handling method). Also, put on applicable protective equipment (such as protective goggles, gloves, and masks)

16) If necessary, cut out all the power sources (electricity, oil pressure, compressed air, etc.) before you start the work. If the vehicle has a lock mechanism, set it to the LOCK position and install the warning tag in a position where it is easy to see. Do not release the lock until the work is completed.

2. Preparation:

1) Before adding oil or making any repairs, place the lift truck on a firm and level ground, and apply the parking brake and chock the wheels to prevent the lift truck from moving.

2) Before starting work, lower the work equipment (mast) to the ground. If it is not possible to lower the work equipment to the ground, insert the lock pin or use blocks to prevent the work equipment from falling.

3) When performing the disassembling or assembling work, support the lift truck securely with blocks, jacks, or stands before starting the work.

4) Remove all of mud and oil from the steps or other places used to get on and off the lift truck completely. Always use the handrails, ladders of steps when getting on or off the lift truck. Never jump on or off the lift truck.

3. Precautions during work

1) Before disconnecting or removing components of the oil or water or air circuits, first release the remaining pressure completely from the circuit. When removing the oil filter cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out.

2) Before starting the work, disconnect the battery terminal. Be sure to remove the negative end (-) of the battery cable first.

3) The hoist or crane must be used to sling the components weighing 20 kg or heavier. Check the slings (wire rope, nylon sling, chain and hook) for damage before the work. Use the slings with ample capacity and install them to the proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

4) When removing a cover which is under internal pressure or under reaction force of a spring, always leave 2 bolts in diagonal positions. Loosen those 2 bolts gradually and alternately to release the pressure, and then remove the cover.

5) When removing the part, be careful not to break or damage the electrical wiring. The damaged wiring may cause electrical fires.

G.B 28/12/24

Komatsu FB25-12,FB30-12 Forklift Truck Shop Manual SEN06636-08 PDF

Komatsu FB25-12,FB30-12 Forklift Truck Shop Manual SEN06636-08 – PDF DOWNLOAD

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Komatsu FB25-12,FB30-12 Forklift Truck Shop Manual SEN06636-08 – PDF DOWNLOAD

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