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KOMATSU FE25-2 FE30-2 FORKLIFT TRUCK SHOP MANUAL WEN00009-03 – PDF DOWNLOAD
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Description
KOMATSU FE25-2 FE30-2 FORKLIFT TRUCK SHOP MANUAL WEN00009-03 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU FE25-2 FE30-2 FORKLIFT TRUCK SHOP MANUAL WEN00009-03 – PDF DOWNLOAD
Language : English
Pages : 2034
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU FE25-2 FE30-2 FORKLIFT TRUCK SHOP MANUAL WEN00009-03 – PDF DOWNLOAD
Cover.......................................................................................................................................... 1 00 Index and Foreword..................................................................................................................... 3 Index................................................................................................................................. 4 Foreword, Safety, Basic Information................................................................................................... 16 How to Read the Shop Manual....................................................................................................... 16 Safety Notice for Operation....................................................................................................... 18 Precautions to Prevent Fire....................................................................................................... 28 Procedures If Fire Occurs......................................................................................................... 29 Precautions When You Discard Waste Materials...................................................................................... 30 Precautions When You Handle Hydraulic Equipment................................................................................... 31 Precautions When You Disconnect and Connect Pipings............................................................................... 33 Precautions When You Handle Electrical Equipment.................................................................................. 39 Practical Use of KOMTRAX.......................................................................................................... 41 Disconnect and Connect Push-Pull Type Coupler..................................................................................... 42 How to Disconnect and Connect Type 1 Push-Pull Type Coupler................................................................... 42 How to Disconnect and Connect Type 2 Push-Pull Type Coupler................................................................... 43 How to Disconnect and Connect Type 3 Push-Pull Type Coupler................................................................... 44 Precautions for Disconnection and Connection of Connectors........................................................................ 46 Disconnect and Connect Deutsch Connector...................................................................................... 50 How to Disconnect and Connect Slide Lock Type Connector....................................................................... 51 Disconnect and Connect Connector with Lock to Pull............................................................................ 52 How to Disconnect and Connect Connector with Lock to Push..................................................................... 53 Disconnect and Connect Connector with Housing to Rotate....................................................................... 55 Standard Torque Table............................................................................................................. 56 Conversion Table.................................................................................................................. 63 Abbreviation List..................................................................................................................... 68 01 Specifications......................................................................................................................... 71 Table of Contents..................................................................................................................... 72 Specifications........................................................................................................................ 73 Specification Drawing............................................................................................................. 73 Specification Drawing: FE25-2................................................................................................. 73 Specification Drawing: FE30-2................................................................................................. 75 Specifications.................................................................................................................... 77 Specifications: FE25-2........................................................................................................ 77 Specifications: FE30-2........................................................................................................ 81 Weight Table...................................................................................................................... 85 Weight Table: FE25-2.......................................................................................................... 85 Weight Table: FE30-2.......................................................................................................... 87 Fuel, Coolant, Lubricant.......................................................................................................... 88 Lubrication Chart............................................................................................................. 88 List of Specified Lubricant................................................................................................... 90 10 Structure and Function................................................................................................................. 91 Table of Contents..................................................................................................................... 92 Charge System......................................................................................................................... 95 Layout Drawing of Charge System................................................................................................... 95 Component Parts of Charge System.................................................................................................. 96 Battery Assembly (FE25-2) (108V/180Ah)........................................................................................ 96 Battery Assembly (FE25-2) (108V/240Ah)........................................................................................ 99 Battery Assembly (FE30-2) (120V/180Ah)........................................................................................ 102 Battery Assembly (FE30-2) (120V/240Ah)........................................................................................ 105 MC4 Contactor................................................................................................................. 108 Stationary Charger............................................................................................................ 109 Boot-up System........................................................................................................................ 117 Layout Drawing of Boot-up System.................................................................................................. 117 System Operating Lamp System...................................................................................................... 118 System Diagram of System Operating Lamp System................................................................................ 118 Function of Operation Lamp System............................................................................................. 118 Operation of System Operating Lamp System..................................................................................... 118 Emergency Stop Switch............................................................................................................. 120 Function of Emergency Stop Switch............................................................................................. 120 Operation of Emergency Stop Switch............................................................................................ 120 ID Key System..................................................................................................................... 121 System Diagram of ID Key System............................................................................................... 121 Function of ID Key System..................................................................................................... 121 Operation of ID Key System.................................................................................................... 122 Component Parts of Boot-Up System................................................................................................. 123 ID Key Controller............................................................................................................. 123 ID Key Antenna................................................................................................................ 125 Control System........................................................................................................................ 126 Layout Drawing of Control System.................................................................................................. 126 Monitor Panel System.............................................................................................................. 127 System Diagram of Monitor Panel System........................................................................................ 127 Function of Monitor Panel System.............................................................................................. 127 KOMTRAX System.................................................................................................................... 129 System Diagram of KOMTRAX System.............................................................................................. 129 Function of KOMTRAX System.................................................................................................... 129 Seat Belt Interlock System........................................................................................................ 130 System Diagram of Seat Belt Interlock System.................................................................................. 130 Function of Seat Belt Interlock System........................................................................................ 131 Operation of Seat Belt Interlock System....................................................................................... 131 Impact Detection System........................................................................................................... 132 System Diagram of Impact Detection System..................................................................................... 132 Function of Impact Detection System........................................................................................... 132 Operation of Impact Detection System.......................................................................................... 132 Inclination Warning System........................................................................................................ 134 System Diagram of Inclination Warning System.................................................................................. 134 Function of Inclination Warning System........................................................................................ 134 Operation of Inclination Warning System....................................................................................... 134 Fall Detection System............................................................................................................. 136 Function of Fall Detection System............................................................................................. 136 Operation of Fall Detection System............................................................................................ 136 Component Parts of Control System................................................................................................. 137 Monitor Panel................................................................................................................. 137 KOMTRAX Terminal.............................................................................................................. 154 Master Controller............................................................................................................. 156 MC2 Contactor................................................................................................................. 161 Power Supply Controller....................................................................................................... 162 Travel Inverter............................................................................................................... 166 Pump Inverter................................................................................................................. 169 Accelerator Pedal............................................................................................................. 172 Hydraulic System...................................................................................................................... 173 Layout Drawing of Hydraulic System................................................................................................ 173 Lift Interlock System............................................................................................................. 174 System Diagram of Lift Interlock System....................................................................................... 174 Function of Lift Interlock System............................................................................................. 175 Operation of Lift Interlock System............................................................................................ 175 Component Parts of Hydraulic System............................................................................................... 176 Hydraulic Tank................................................................................................................ 176 Pump Motor.................................................................................................................... 177 Steering and Work Equipment Pump.............................................................................................. 178 Control Valve................................................................................................................. 180 Power Train System.................................................................................................................... 198 Layout Drawing of Power Train System.............................................................................................. 198 Operation of Power Train System................................................................................................... 199 Directional Lever Warning System.................................................................................................. 200 System Diagram of Directional Lever Warning System............................................................................ 200 Function of Directional Lever Warning System.................................................................................. 200 Operation of Directional Lever Warning System................................................................................. 200 Travel Interlock System........................................................................................................... 202 System Diagram of Travel Interlock System..................................................................................... 202 Function of Travel Interlock System........................................................................................... 203 Operation of Travel Interlock System.......................................................................................... 203 Travel Speed Limit System at Lifting Height....................................................................................... 204 System Diagram of Travel Speed Limit System at Lifting Height................................................................. 204 Function of Travel Speed Limit System at Lifting Height....................................................................... 204 Operation of Travel Speed Limit System at Lifting Height...................................................................... 205 Reverse Travel Control System on Slope............................................................................................ 206 System Diagram of Reverse Travel Control System............................................................................... 206 Function of Reverse Travel Control System on Slope............................................................................ 207 Operation of Reverse Travel Control System on Slope........................................................................... 207 Power Assist System on Slope...................................................................................................... 208 System Diagram of Power Assist System on Slope................................................................................ 208 Function of Power Assist System on Slope...................................................................................... 208 Operation of Power Assist System on Slope..................................................................................... 209 Component Parts of Power Train System............................................................................................. 210 Travel Motor.................................................................................................................. 210 Front Axle.................................................................................................................... 212 Differential.................................................................................................................. 219 Final Drive................................................................................................................... 221 Combination Switch............................................................................................................ 223 Work Equipment System................................................................................................................. 224 Layout Drawing of Work Equipment System........................................................................................... 224 Structure of Valve Control........................................................................................................ 225 Steering System....................................................................................................................... 226 Layout Drawing of Steering System................................................................................................. 226 Steering Column................................................................................................................... 227 Structure of Steering Column.................................................................................................. 227 EPACS System...................................................................................................................... 228 System Diagram of EPACS System................................................................................................ 228 Function of EPACS System...................................................................................................... 228 Operation of EPACS System..................................................................................................... 228 Turning Speed Limit System........................................................................................................ 229 System Diagram of Turning Speed Limit System.................................................................................. 229 Function of Turning Speed Limit System........................................................................................ 230 Operation of Turning Speed Limit System....................................................................................... 230 Component Parts of Steering System................................................................................................ 231 Orbitrol Valve................................................................................................................ 231 Rear Axle..................................................................................................................... 233 Brake System.......................................................................................................................... 234 Layout Drawing of Brake System.................................................................................................... 234 Parking Brake Warning System...................................................................................................... 235 System Diagram Parking Brake Warning System................................................................................... 235 Function of Parking Brake Warning System...................................................................................... 235 Operation of Parking Brake Warning System..................................................................................... 236 Parking Brake Dragging Warning System............................................................................................. 237 System Diagram of Parking Brake Dragging Warning System....................................................................... 237 Function of Parking Brake Dragging Warning System............................................................................. 237 Operation of Parking Brake Dragging Warning System............................................................................ 237 Component Parts of Brake System................................................................................................... 239 Brake Reservoir Tank.......................................................................................................... 239 Brake Master Cylinder......................................................................................................... 240 Front Brake................................................................................................................... 242 Parking Brake................................................................................................................. 244 Undercarriage and Frame............................................................................................................... 245 Frame............................................................................................................................. 245 Structure of Frame............................................................................................................ 245 Tires............................................................................................................................. 246 Structure of Bias Tire........................................................................................................ 246 Work Equipment........................................................................................................................ 247 Structure of Work Equipment....................................................................................................... 247 Function of Work Equipment........................................................................................................ 248 CAB Related Parts..................................................................................................................... 249 Head Guard........................................................................................................................ 249 Structure of Head Guard....................................................................................................... 249 Function of Head Guard........................................................................................................ 249 CAB............................................................................................................................... 250 Structure of Cab.............................................................................................................. 250 Function of Cab............................................................................................................... 250 20 Standard Value Table................................................................................................................... 251 Table of Contents..................................................................................................................... 252 Standard Value Table for Machine...................................................................................................... 253 Standard Value Table for Vehicle: FE25-2.......................................................................................... 253 Standard Value Table for Vehicle: FE30-2.......................................................................................... 257 Procedures To Measure Performance................................................................................................. 260 30 Testing and Adjusting.................................................................................................................. 261 Table of Contents..................................................................................................................... 262 Precautions Before Work............................................................................................................... 264 Related Information on Testing and Adjusting.......................................................................................... 265 Tools for Testing and Adjusting................................................................................................... 265 Power Train........................................................................................................................... 266 Adjust Accelerator Pedal.......................................................................................................... 266 How to Adjust Accelerator Pedal............................................................................................... 266 Examine Oil Level in Differential Case, Change Oil................................................................................ 268 How to Examine Oil in Differential Case....................................................................................... 268 How to Change Oil in Differential Case........................................................................................ 269 Steering System....................................................................................................................... 270 Examine Play of Steering Wheel.................................................................................................... 270 Examine Play of Steering Wheel................................................................................................ 270 Adjust Tire Angle Sensor.......................................................................................................... 271 How to Adjust Tire Angle Sensor............................................................................................... 271 Brake System.......................................................................................................................... 272 Adjust Parking Brake Lever........................................................................................................ 272 How to Adjust Parking Brake Lever............................................................................................. 272 Adjust Brake Pedal................................................................................................................ 273 How to Adjust Height and Play of Brake Pedal.................................................................................. 273 Examine and Adjust Brake Pedal Angle Sensor....................................................................................... 274 How to Examine Brake Pedal Angle Sensor....................................................................................... 274 How to Adjust Brake Pedal Angle Sensor........................................................................................ 274 Examine and Adjust Disc Brake..................................................................................................... 275 How to Adjust Clearance of Disc Brake......................................................................................... 275 How to Examine Disc Brake Wear Volume......................................................................................... 278 Bleed Air from Brake Circuit...................................................................................................... 279 How to Bleed Air from Brake Circuit........................................................................................... 279 Examine Brake Performance......................................................................................................... 281 How to Examine Brake Performance.............................................................................................. 281 Hydraulic System...................................................................................................................... 282 Release Remained Pressure in Hydraulic Circuit.................................................................................... 282 How to Release Remained Pressure from Hydraulic Circuit....................................................................... 282 Examine Steering Circuit Oil Pressure............................................................................................. 283 Examine Steering Circuit Oil Pressure......................................................................................... 283 Measure Oil Pressure of Work Equipment............................................................................................ 286 How to Measure Pressure of Work Equipment Pump................................................................................ 286 How to Examine Oil Level in Hydraulic Tank, Change Oil............................................................................ 289 Examine Oil Level In Hydraulic Tank........................................................................................... 289 How to Replace Hydraulic Oil.................................................................................................. 289 Bleed Air from Hydraulic Circuit.................................................................................................. 291 Bleed Air from Lift Cylinder.................................................................................................. 291 How to Bleed Air from Tilt Cylinder........................................................................................... 291 How to Bleed Air from Attachment Cylinder..................................................................................... 291 Lower Fork Manually............................................................................................................... 292 How to Lower Fork Manually.................................................................................................... 292 How of Restore Lift Quick Drop Valve.......................................................................................... 294 Work Equipment........................................................................................................................ 295 Examine and Adjust Work Equipment Lever........................................................................................... 295 How to Examine Micro Switch................................................................................................... 295 How to Adjust Potentiometer................................................................................................... 296 Examine Hydraulic Drift and Forward Tilt of Work Equipment........................................................................ 297 How to Examine Hydraulic Drift and Forward Tilt of Work Equipment............................................................. 297 Adjust Mast....................................................................................................................... 299 How to Adjust Runout of Mast.................................................................................................. 299 How to Select Main Roller of Outer Mast and Adjust Shimsd..................................................................... 300 How to Adjust Shim on Stripe.................................................................................................. 301 How to Select Main Roller of Inner Mast and Adjust Shims...................................................................... 301 How to Adjust Shim on Clamp................................................................................................... 302 Adjust Lifting Height Detection Sensor............................................................................................ 303 How to Adjust Lifting Height Detection Sensor (Forklift Truck with Double-Mast)............................................... 303 How to Adjust Lifting Height Detection Sensor (Forklift Truck with Triple-Mast)............................................... 305 Adjust Finger Board............................................................................................................... 307 How to Adjust Shim on Main Roller Below Finger Board.......................................................................... 307 How to Adjust Shim on Main Roller Above Finger Board.......................................................................... 308 How to Adjust Finger Board Main Roller (Inclination Roller) in Middle......................................................... 308 How to Adjust Shim on Finger Board Side Roller................................................................................ 308 How to Adjust Finger Board Side Roller and Main Roller (Inclination Roller) in Middle......................................... 309 How to Adjust Finger Board Chain.............................................................................................. 309 Electrical System..................................................................................................................... 310 Examine Fuse...................................................................................................................... 310 How to Test Blade Fuse........................................................................................................ 310 How to Test Tube Fuse......................................................................................................... 311 How to Test Slow-Blow Fuse (Controller)....................................................................................... 312 How to Test Slow-Blow Fuse (Safety Device).................................................................................... 313 Clean and Replace Filter of Stationary Battery Charger............................................................................ 315 How to Clean and Replace Filter of Stationary Battery Charger................................................................. 315 Replace Packing of Battery Charger Plug........................................................................................... 317 How to Replace Packing of Battery Charger Plug................................................................................ 317 Excamine Strong Electric Terminal of Charge Plug on Forklift Truck................................................................ 319 How to Excamine Strong Electric Terminal of Charge Plug on Forklift Truck..................................................... 319 Excamine Strong Electric Terminal of Charge Plug on Charger....................................................................... 320 How to Excamine Strong Electric Terminal of Charge Plug on Charger............................................................ 320 Set and Operate Monitor Pane...................................................................................................... 321 Operator Mode and Service Mode of Monitor Panel............................................................................... 321 Operator Mode................................................................................................................. 324 Service Mode.................................................................................................................. 327 How to Start Up KOMTRAX Terminal.................................................................................................. 436 40 Troubleshooting........................................................................................................................ 441 Table of Contents..................................................................................................................... 442 Precautions Before Work............................................................................................................... 449 Related Information to Troubleshooting................................................................................................ 450 General Troubleshooting Points.................................................................................................... 450 Sequence of Events in Troubleshooting............................................................................................. 452 Checks Before Troubleshooting..................................................................................................... 454 Inspection Procedure Before Troubleshooting....................................................................................... 455 Walk-around Check............................................................................................................. 455 Test in Accordance with Testing Procedure......................................................................................... 456 Examine Oil Level In Hydraulic Tank........................................................................................... 456 Examine Hydraulic Oil Strainer and Line Filter................................................................................ 456 Examine Oil Level in Differential Case........................................................................................ 457 How to Examine Electric Equipment............................................................................................. 458 Preparation for Troubleshooting of Electrical System.............................................................................. 461 Preparation for Troubleshooting of Monitor Panel.............................................................................. 461 Preparation for Troubleshooting of Travel Inverter............................................................................ 461 Preparation for Troubleshooting of Pump Inverter.............................................................................. 461 Preparation for Troubleshooting of Power Supply Controller.................................................................... 461 Preparation for Troubleshooting of Master Controller.......................................................................... 462 Preparation for Troubleshooting of KOMTRAX Terminal........................................................................... 462 How to Disconnect and Connect Connector with a Special Lock................................................................... 462 Procedure for Troubleshooting..................................................................................................... 463 Symptom and Troubleshooting Numbers............................................................................................... 468 Information Shown in Troubleshooting Table........................................................................................ 473 Connector List (FE25-2) (Head Guard Specification)................................................................................ 475 Connector Layout (FE25-2) (Head Guard Specification).............................................................................. 482 Connector List (FE25-2) (Cab Specification)....................................................................................... 489 Connector Layout (FE25-2) (Cab Specification)..................................................................................... 496 Connector List (FE30-2) (Head Guard Specification)................................................................................ 503 Connector Layout (FE30-2) (Head Guard Specification).............................................................................. 510 Connector List (FE30-2) (Cab Specification)....................................................................................... 517 Connector Layout (FE30-2) (Cab Specification)..................................................................................... 524 Connector Contact Connection Table................................................................................................ 531 T-Branch Box and T-Branch Adapter Table........................................................................................... 574 Fuse Location Table............................................................................................................... 580 Failure Code Table................................................................................................................ 586 Troubleshooting by Failure Code (Display of Code)..................................................................................... 600 Failure Code [989L00]............................................................................................................. 600 Failure Code [989M00]............................................................................................................. 601 Failure Code [989N00]............................................................................................................. 602 Failure Code [D160KB]............................................................................................................. 603 Failure Code [D160KY]............................................................................................................. 605 Failure Code [D161KB]............................................................................................................. 607 Failure Code [D161KY]............................................................................................................. 609 Failure Code [D162KA]............................................................................................................. 611 Failure Code [D162KB]............................................................................................................. 613 Failure Code [D162KY]............................................................................................................. 615 Failure Code [D19HKA]............................................................................................................. 617 Failure Code [D19HKB]............................................................................................................. 619 Failure Code [D19HKY]............................................................................................................. 621 Failure Code [D19SKB]............................................................................................................. 623 Failure Code [D19SKY]............................................................................................................. 625 Failure Code [D1H0KA]............................................................................................................. 627 Failure Code [D1H0KB]............................................................................................................. 629 Failure Code [D1HBKA]............................................................................................................. 631 Failure Code [D1HBKB]............................................................................................................. 634 Failure Code [D1HBKY]............................................................................................................. 636 Failure Code [D1HDKA]............................................................................................................. 638 Failure Code [D1HDKB]............................................................................................................. 640 Failure Code [D1HDKY]............................................................................................................. 642 Failure Code [D1HPKB]............................................................................................................. 644 Failure Code [D1HPKY]............................................................................................................. 646 Failure Code [D1HQKB]............................................................................................................. 647 Failure Code [D1HQKY]............................................................................................................. 649 Failure Code [D1HRKB]............................................................................................................. 650 Failure Code [D1HRKY]............................................................................................................. 652 Failure Code [D1J1KA]............................................................................................................. 653 Failure Code [D1J1KB]............................................................................................................. 655 Failure Code [D1J1KY]............................................................................................................. 657 Failure Code [D1J2KA]............................................................................................................. 659 Failure Code [D1J2KB]............................................................................................................. 661 Failure Code [D1J2KY]............................................................................................................. 663 Failure Code [D5XWKA]............................................................................................................. 665 Failure Code [D5XWKY]............................................................................................................. 669 Failure Code [D5XXKA]............................................................................................................. 671 Failure Code [D5XXKY]............................................................................................................. 673 Failure Code [D61000]............................................................................................................. 674 Failure Code [D610KE]............................................................................................................. 676 Failure Code [D610KF]............................................................................................................. 677 Failure Code [D610KL]............................................................................................................. 678 Failure Code [D610KU]............................................................................................................. 680 Failure Code [D610NS]............................................................................................................. 682 Failure Code [D610ZU]............................................................................................................. 683 Failure Code [D811MC]............................................................................................................. 686 Failure Code [D862KA]............................................................................................................. 687 Failure Code [D8ALKA]............................................................................................................. 688 Failure Code [D8ALKB]............................................................................................................. 690 Failure Code [D8AQK4]............................................................................................................. 691 Failure Code [D8AQKR]............................................................................................................. 695 Failure Code [DAF0KT]............................................................................................................. 696 Failure Code [DAF0MB]............................................................................................................. 697 Failure Code [DAF0MC]............................................................................................................. 698 Failure Code [DAF3KK]............................................................................................................. 699 Failure Code [DAFGMC]............................................................................................................. 701 Failure Code [DAFLKA]............................................................................................................. 702 Failure Code [DAFLKB]............................................................................................................. 704 Failure Code [DAFQKR]............................................................................................................. 705 Failure Code [DBN000]............................................................................................................. 706 Failure Code [DBN0KT]............................................................................................................. 707 Failure Code [DBN0MC]............................................................................................................. 708 Failure Code [DBN2KK]............................................................................................................. 709 Failure Code [DBN3KK]............................................................................................................. 712 Failure Code [DBN4KX]............................................................................................................. 714 Failure Code [DBN5KX]............................................................................................................. 716 Failure Code [DBN6KX]............................................................................................................. 718 Failure Code [DBN7KA]............................................................................................................. 721 Failure Code [DBN7KB]............................................................................................................. 724 Failure Code [DBN9KQ]............................................................................................................. 726 Failure Code [DBNCMA] (Serial Number: 320001 to 322981)........................................................................... 727 Failure Code [DBNCMA] (Serial Number: 322982 and Up).............................................................................. 727 Failure Code [DBNEKR]............................................................................................................. 728 Failure Code [DBNFKR]............................................................................................................. 732 Failure Code [DBNGKR]............................................................................................................. 735 Failure Code [DBNJKB]............................................................................................................. 737 Failure Code [DBNJKY]............................................................................................................. 738 Failure Code [DBNKKA]............................................................................................................. 739 Failure Code [DBNKKB]............................................................................................................. 740 Failure Code [DBNKKY]............................................................................................................. 741 Failure Code [DBNLKA]............................................................................................................. 742 Failure Code [DBNLKB]............................................................................................................. 744 Failure Code [DBNQKR]............................................................................................................. 746 Failure Code [DBNRKR]............................................................................................................. 749 Failure Code [DBNSKA]............................................................................................................. 754 Failure Code [DBNSKB]............................................................................................................. 755 Failure Code [DBNSKY]............................................................................................................. 756 Failure Code [DBNTKA]............................................................................................................. 757 Failure Code [DBNVMA]............................................................................................................. 759 Failure Code [DBNYKA]............................................................................................................. 761 Failure Code [DDDQKA]............................................................................................................. 763 Failure Code [DDDTKA] (Forklift Truck Without Seat Belt Interlock System)......................................................... 765 Failure Code [DDDTKA] (Forklift Truck with Seat Belt Interlock System)............................................................ 767 Failure Code [DDDTKB] (Forklift Truck Without Seat Belt Interlock System)......................................................... 769 Failure Code [DDDTKB] (Forklift Truck with Seat Belt Interlock System)............................................................ 771 Failure Code [DDDUKA] (Forklift Truck Without Seat Belt Interlock System)......................................................... 773 Failure Code [DDDUKA] (Forklift Truck with Seat Belt Interlock System)............................................................ 775 Failure Code [DDDUKB] (Forklift Truck Without Seat Belt Interlock System)......................................................... 777 Failure Code [DDDUKB] (Forklift Truck with Seat Belt Interlock System)............................................................ 779 Failure Code [DDDVKA] (Forklift Truck Without Seat Belt Interlock System)......................................................... 781 Failure Code [DDDVKA] (Forklift Truck with Seat Belt Interlock System)............................................................ 783 Failure Code [DDDVKM] (Forklift Truck Without Seat Belt Interlock System)......................................................... 786 Failure Code [DDDVKM] (Forklift Truck with Seat Belt Interlock System)............................................................ 788 Failure Code [DDK6KA]............................................................................................................. 791 Failure Code [DDK6KY]............................................................................................................. 794 Failure Code [DFC1KA]............................................................................................................. 796 Failure Code [DFC1KB]............................................................................................................. 799 Failure Code [DGA1MA]............................................................................................................. 801 Failure Code [DGA2MA]............................................................................................................. 803 Failure Code [DGA3MA]............................................................................................................. 805 Failure Code [DGA4MA]............................................................................................................. 807 Failure Code [DGA9MA]............................................................................................................. 809 Failure Code [DHPCKA]............................................................................................................. 811 Failure Code [DHPCKB]............................................................................................................. 814 Failure Code [DJK1KA]............................................................................................................. 816 Failure Code [DJK1KB]............................................................................................................. 818 Failure Code [DJK1MA]............................................................................................................. 820 Failure Code [DJK200]............................................................................................................. 821 Failure Code [DJK2MA]............................................................................................................. 823 Failure Code [DJK2NA]............................................................................................................. 825 Failure Code [DK10KA]............................................................................................................. 827 Failure Code [DK10KB]............................................................................................................. 829 Failure Code [DK11KA]............................................................................................................. 831 Failure Code [DK11KB]............................................................................................................. 833 Failure Code [DK13KX]............................................................................................................. 835 Failure Code [DK13L8]............................................................................................................. 836 Failure Code [DK30MA]............................................................................................................. 837 Failure Code [DK40KA]............................................................................................................. 839 Failure Code [DK40KY]............................................................................................................. 842 Failure Code [DK40MA]............................................................................................................. 844 Failure Code [DK5YMA]............................................................................................................. 845 Failure Code [DK80MA]............................................................................................................. 847 Failure Code [DQA1KM]............................................................................................................. 849 Failure Code [DQA1KR]............................................................................................................. 850 Failure Code [DQA1KT]............................................................................................................. 853 Failure Code [DQA2KM]............................................................................................................. 855 Failure Code [DQA2KR]............................................................................................................. 856 Failure Code [DQA2KT]............................................................................................................. 859 Failure Code [DUS1KA]............................................................................................................. 861 Failure Code [DUS1KY]............................................................................................................. 863 Failure Code [DUS6KA]............................................................................................................. 865 Failure Code [DUS6KB]............................................................................................................. 867 Failure Code [DUS6KY]............................................................................................................. 869 Failure Code [DUS7KA]............................................................................................................. 871 Failure Code [DUS7KB]............................................................................................................. 873 Failure Code [DUS7KY]............................................................................................................. 875 Failure Code [DV00KB]............................................................................................................. 877 Failure Code [DV01KA]............................................................................................................. 878 Failure Code [DV01KB]............................................................................................................. 880 Failure Code [DV01KY]............................................................................................................. 882 Failure Code [DV02KA]............................................................................................................. 884 Failure Code [DV02KB]............................................................................................................. 886 Failure Code [DV02KY]............................................................................................................. 888 Failure Code [DW9MKA]............................................................................................................. 890 Failure Code [DW9MKB]............................................................................................................. 892 Failure Code [DW9MKY]............................................................................................................. 894 Failure Code [DWP0KA]............................................................................................................. 895 Failure Code [DWP0KB]............................................................................................................. 897 Failure Code [E111KM]............................................................................................................. 899 Failure Code [E111KQ]............................................................................................................. 900 Failure Code [E111KR]............................................................................................................. 901 Failure Code [E111MC]............................................................................................................. 902 Failure Code [E112KK]............................................................................................................. 903 Failure Code [F1A100]............................................................................................................. 905 Failure Code [F7FQKR]............................................................................................................. 907 Failure Code [F7G0MC]............................................................................................................. 911 Failure Code [FJAA00]............................................................................................................. 912 Failure Code [FJAB00]............................................................................................................. 913 Failure Code [FJAC00]............................................................................................................. 914 Failure Code [FJB1KM]............................................................................................................. 915 Failure Code [FJBAKR]............................................................................................................. 916 Failure Code [GB11KA]............................................................................................................. 920 Failure Code [GB11KB]............................................................................................................. 922 Failure Code [GB11KY]............................................................................................................. 924 Failure Code [GF10KN]............................................................................................................. 926 Failure Code [GF11KG]............................................................................................................. 929 Failure Code [GF11KK]............................................................................................................. 931 Failure Code [GF12KA]............................................................................................................. 933 Failure Code [GF13KA]............................................................................................................. 935 Failure Code [GF14KA]............................................................................................................. 937 Failure Code [GF15KQ]............................................................................................................. 939 Failure Code [GF16KA]............................................................................................................. 941 Failure Code [GF16KB]............................................................................................................. 944 Failure Code [GF17MA]............................................................................................................. 947 Failure Code [GF18KQ]............................................................................................................. 951 Failure Code [GF1AMA]............................................................................................................. 953 Failure Code [GF1BMA]............................................................................................................. 954 Failure Code [GF1C00]............................................................................................................. 955 Failure Code [GF1CNS]............................................................................................................. 956 Failure Code [GF1EKT]............................................................................................................. 957 Failure Code [GF1FMA]............................................................................................................. 958 Failure Code [GF1JKA]............................................................................................................. 960 Failure Code [GF1LKB]............................................................................................................. 962 Failure Code [GF1MKB]............................................................................................................. 964 Failure Code [GF1NKB]............................................................................................................. 967 Failure Code [GF1QKR]............................................................................................................. 970 Failure Code [GF20KN]............................................................................................................. 973 Failure Code [GF21KG]............................................................................................................. 976 Failure Code [GF21KK]............................................................................................................. 978 Failure Code [GF22KA]............................................................................................................. 980 Failure Code [GF23KA]............................................................................................................. 982 Failure Code [GF24KA]............................................................................................................. 984 Failure Code [GF25KQ]............................................................................................................. 986 Failure Code [GF26KA]............................................................................................................. 988 Failure Code [GF26KB]............................................................................................................. 991 Failure Code [GF27MA]............................................................................................................. 994 Failure Code [GF28KQ]............................................................................................................. 998 Failure Code [GF2AMA].............................................................................................................1000 Failure Code [GF2BMA].............................................................................................................1001 Failure Code [GF2C00].............................................................................................................1002 Failure Code [GF2CNS].............................................................................................................1003 Failure Code [GF2EKT].............................................................................................................1004 Failure Code [GF2FMA].............................................................................................................1005 Failure Code [GF2JKA].............................................................................................................1007 Failure Code [GF2LKB].............................................................................................................1009 Failure Code [GF2MKB].............................................................................................................1011 Failure Code [GF2NKB].............................................................................................................1014 Failure Code [GF2QKR].............................................................................................................1017 Failure Code [GF30KB].............................................................................................................1019 Failure Code [GF31MA].............................................................................................................1021 Failure Code [GF3200].............................................................................................................1023 Failure Code [GF32NS].............................................................................................................1024 Failure Code [GF33MA].............................................................................................................1025 Failure Code [GF50KB].............................................................................................................1027 Failure Code [GF51MA].............................................................................................................1029 Failure Code [GF5200].............................................................................................................1031 Failure Code [GF52NS].............................................................................................................1032 Failure Code [GF53MA].............................................................................................................1033 Failure Code [GFA0NA].............................................................................................................1035 Failure Code [GFA1KG].............................................................................................................1037 Failure Code [GFA1KN].............................................................................................................1039 Failure Code [GFA2KB].............................................................................................................1041 Failure Code [GFA2MA].............................................................................................................1043 Failure Code [GFA3MA].............................................................................................................1045 Failure Code [GFA4KK].............................................................................................................1047 Failure Code [GFA5KA].............................................................................................................1050 Failure Code [GFA5KB].............................................................................................................1053 Failure Code [GFA6KA].............................................................................................................1055 Failure Code [GFA7NX].............................................................................................................1057 Failure Code [GFA8MC].............................................................................................................1059 Failure Code [GFABMA].............................................................................................................1061 Failure Code [GFAD00].............................................................................................................1063 Failure Code [GFADNT].............................................................................................................1065 Failure Code [GFAEMA].............................................................................................................1067 Failure Code [GFAF00].............................................................................................................1069 Failure Code [GFAFNT].............................................................................................................1071 Failure Code [GFAG00].............................................................................................................1073 Failure Code [GFAMKM].............................................................................................................1075 Failure Code [GFAMMB].............................................................................................................1076 Failure Code [GFAQKR] (L-shaped Leg Battery Charger)..............................................................................1077 Failure Code [GFAQKR] (U-shaped Leg Battery Charger)..............................................................................1079 Failure Code [GFB8MC] (FE25-2)....................................................................................................1081 Failure Code [GFB8MC] (FE30-2)....................................................................................................1083 Failure Code [GFBQKR].............................................................................................................1085 Failure Code [GFBRKR] (L-shaped Leg Battery Charger)..............................................................................1087 Failure Code [GFBRKR] (U-shaped Leg Battery Charger)..............................................................................1089 Failure Code [GFD6MA].............................................................................................................1091 Failure Code [GFDAKG].............................................................................................................1092 Failure Code [GFDAKN].............................................................................................................1094 Failure Code [GFDAKP].............................................................................................................1097 Failure Code [GFDAKY].............................................................................................................1100 Failure Code [GFDDKG].............................................................................................................1102 Failure Code [GFDDKN].............................................................................................................1104 Failure Code [GFDDKP].............................................................................................................1107 Failure Code [GFDEKN].............................................................................................................1110 Failure Code [GFDGKB].............................................................................................................1113 Failure Code [GFDGKG].............................................................................................................1115 Failure Code [GFDGKP].............................................................................................................1117 Failure Code [GFDKKB].............................................................................................................1119 Failure Code [GFDKKG].............................................................................................................1121 Failure Code [GFDKKN].............................................................................................................1123 Failure Code [GFDKKP].............................................................................................................1125 Failure Code [GFDKKY].............................................................................................................1127 Failure Code [GFDLKN].............................................................................................................1129 Failure Code [GFDNKG].............................................................................................................1131 Failure Code [GFDNKN].............................................................................................................1138 Failure Code [GFDNKP].............................................................................................................1148 Failure Code [GFDRKK].............................................................................................................1149 Failure Code [GFDRKU].............................................................................................................1151 Failure Code [GFDSKK].............................................................................................................1153 Failure Code [GFDSKU].............................................................................................................1155 Failure Code [GFDUN7].............................................................................................................1157 Failure Code [GFDUN8].............................................................................................................1158 Failure Code [GFDVN8].............................................................................................................1159 Failure Code [GFDXKB] (FE25-2)....................................................................................................1160 Failure Code [GFDXKB] (FE30-2)....................................................................................................1161 Failure Code [GFDXKN] (FE25-2)....................................................................................................1163 Failure Code [GFDXKN] (FE30-2)....................................................................................................1164 Failure Code [GFDYKN] (FE25-2)....................................................................................................1166 Failure Code [GFDYKN] (FE30-2)....................................................................................................1167 Failure Code [GFEAKA].............................................................................................................1169 Failure Code [GFEAKB].............................................................................................................1170 Failure Code [GFEBKB].............................................................................................................1171 Troubleshooting of Electrical System (E-Mode).........................................................................................1172 Lift Truck Does Not Start.........................................................................................................1172 Battery is Not Charged............................................................................................................1174 When Starting Switch is Turned on, Monitor Panel is Not Shown.....................................................................1178 When Starting Switch is Turned on, Alarm Buzzer Does Not Sound....................................................................1183 Parking Brake Alarm Does Not Operate Or Does Not Stop.............................................................................1185 Horn Does Not Sound...............................................................................................................1188 Horn Does Not Stop................................................................................................................1191 EPACS is Abnormal.................................................................................................................1193 Travel Speed Limit Cannot be Released or Enabled..................................................................................1195 Monitor Panel Cannot be Set in Controller Failure Display Mode, Controller Adjustment Mode, or Travel Speed Limit Setting Mode....1196 Headlamp, Clearance Lamp, Tail Lamp, and License Plate Lamp Do Not Come on or Do Not Go off.......................................1197 Turn-Signal-Lamps Do Not Come on or Do Not Go off.................................................................................1203 Brake Lamp Does Not Come On or Go Out.............................................................................................1208 Backup Lamp Does Not Come On or Stays Lit.........................................................................................1211 Backup Buzzer Does Not Sound or Continues to Sound................................................................................1215 KOMTRAX System Does Not Operate Correctly.........................................................................................1218 Alarm Lamp 1 Does Not Come On.....................................................................................................1219 Alarm Lamp 2 Does Not Come On.....................................................................................................1221 Alarm Lamp 1 Does Not Go Off......................................................................................................1223 Alarm Lamp 2 Does Not Go Off......................................................................................................1225 Alarm Buzzer 1 Does Not Operate...................................................................................................1227 Alarm Buzzer 2 Does Not Operate...................................................................................................1229 Alarm Buzzer 1 Does Not Stop......................................................................................................1231 Alarm Buzzer 2 Does Not Stop......................................................................................................1233 Troubleshooting for Hydraulic and Mechanical Systems (H Mode).........................................................................1235 How to Use Troubleshooting Table..................................................................................................1235 System Diagram of Hydraulic and Mechanical System.................................................................................1238 Failure Mode and Cause Table......................................................................................................1240 Lift Truck Does Not Turn..........................................................................................................1247 Turning Response is Unsatisfactory................................................................................................1248 Steering Wheel is Heavy to Operate................................................................................................1249 Lift Truck Is Unstable During Turning.............................................................................................1250 When Steering Wheel is Released, it Does Not Return To Neutral or it Turns by Itself..............................................1251 Steering Wheel is Turned in Reverse or it Kicks (in Combined Operation with Work Equipment).......................................1252 Large Shock Is Made When Steering Wheel Is Returned...............................................................................1253 EPACS Does Not Work...............................................................................................................1254 Steering Wheel Vibrates...........................................................................................................1255 Unusual Noise is Heard from Steering..............................................................................................1256 Oil Leaks from Steering Circuit...................................................................................................1257 Service Brakes Do Not Operate or are Weak.........................................................................................1258 Service Brakes are Not Released or Drag...........................................................................................1259 Parking Brake Does Not Operate or is Weak.........................................................................................1260 Parking Brake is Not Released or Drags............................................................................................1261 Unusual Noise is Heard from Around Steering and Work Equipment Pump...............................................................1262 Fork Lowering Lock Does Not Work (Fork Lowers When Operator is Off from Operator Seat)............................................1263 Control Valve Lever Does Not Move Smoothly and it is Heavy to Operate.............................................................1264 Lift Cylinder And Fork Do Not Rise................................................................................................1265 Lifting Speed or Power of Lift Cylinder and Fork is Insufficient..................................................................1266 Fork Lifting Speed Lowers at Specific Height......................................................................................1268 Hydraulic Drift of Lift Cylinder is Large.........................................................................................1269 Lift Cylinders Do Not Lower.......................................................................................................1270 Fork Lowering Speed is Low, High, or Fine Control Performance is Low or Response is Low...........................................1271 Mast Does Not Tilt Forward and Rearward...........................................................................................1272 Forward, Rearward Tilting Speed or Force of Mast is Insufficient..................................................................1273 Tilt Speed Decreases During Tilt..................................................................................................1274 Hydraulic Drift of Tilt Cylinder (Forward Tilting) is Large.......................................................................1275 Mast is Unstable During Travel with Load..........................................................................................1276 Steering Operation is Heavy When Work Equipment and Steering are Operated Simultaneously..........................................1277 50 Disassembly and Assembly...............................................................................................................1279 Table of Contents.....................................................................................................................1280 Precautions Before Work...............................................................................................................1284 Related Information on Disassembly and Assembly.......................................................................................1285 How to Read This Manual...........................................................................................................1285 Coating Materials List............................................................................................................1286 Special Tool List.................................................................................................................1291 Sketches of Special Tools.........................................................................................................1295 Prepare...............................................................................................................................1301 Drain and Add Hydraulic Oil.......................................................................................................1301 How to Drain Hydraulic Oil....................................................................................................1301 How to Add Hydraulic Oil......................................................................................................1303 Power Train...........................................................................................................................1304 Remove and Install Front Axle Assembly............................................................................................1304 Remove Front Axle Assembly....................................................................................................1305 Install Front Axle Assembly...................................................................................................1308 Remove and Install Axle Housing Assembly..........................................................................................1310 How to Remove Axle Housing Assembly...........................................................................................1310 How to Install Axle Housing Assembly..........................................................................................1313 Disassemble and Assemble Axle Housing Assembly (FE25-2)...........................................................................1315 How to Disassemble Axle Housing Assembly (FE25-2).............................................................................1316 How to Assemble Axle Housing Assembly (FE25-2)................................................................................1320 Disassemble and Assemble Axle Housing Assembly (FE30-2)...........................................................................1327 How to Disassemble Axle Housing Assembly (FE30-2).............................................................................1328 How to Assemble Axle Housing Assembly (FE30-2)................................................................................1332 Disassemble and Assemble Differential Assembly....................................................................................1338 How to Disassemble Differential Assembly......................................................................................1339 How to Assemble Differential Assembly.........................................................................................1347 Remove and Install Parking Brake Assembly.........................................................................................1357 How to Remove Parking Brake Assembly..........................................................................................1357 Install Parking Brake Assembly................................................................................................1360 Disassemble and Assemble Parking Brake Assembly...................................................................................1361 Disassemble Parking Brake Assembly............................................................................................1361 Assemble Parking Brake Assembly...............................................................................................1363 Remove and Install Parking Brake Lever............................................................................................1366 How to Remove Parking Brake Lever.............................................................................................1366 How to Install Parking Brake Lever............................................................................................1370 Brake System..........................................................................................................................1374 Remove and Install Brake Master Cylinder Assembly.................................................................................1374 How to Remove Brake Master Cylinder Assembly..................................................................................1374 How to Install Brake Master Cylinder Assembly.................................................................................1378 Disassemble and Assemble Brake Master Cylinder Assembly...........................................................................1382 How to Disassemble Brake Master Cylinder Assembly.............................................................................1382 How to Assemble Brake Master Cylinder Assembly................................................................................1383 Steering System.......................................................................................................................1384 Remove and Install Steering Cylinder Assembly.....................................................................................1384 How to Remove Steering Cylinder Assembly......................................................................................1384 How to Install Steering Cylinder Assembly.....................................................................................1387 Disassemble and Assemble Steering Cylinder Assembly...............................................................................1389 Disassemble Steering Cylinder Assembly........................................................................................1389 Assemble Steering Cylinder Assembly...........................................................................................1391 Remove and Install Orbitrol Valve Assembly........................................................................................1393 How to Remove Orbitrol Valve Assembly.........................................................................................1393 How to Install Orbitrol Valve Assembly........................................................................................1396 Disassemble and Assemble Orbitrol Valve Assembly..................................................................................1400 How to Disassemble Orbitrol Valve Assembly....................................................................................1401 How to Assemble Orbitrol Valve Assembly.......................................................................................1404 Undercarriage and Frame...............................................................................................................1408 Remove and Install Counterweight Assembly (Head Guard Specification)..............................................................1408 How to Remove Counterweight Assembly (Head Guard Specification)...............................................................1408 How to Install Counterweight Assembly (Head Guard Specification)..............................................................1410 Remove and Install Counterweight Assembly (Cab Specification).....................................................................1412 How to Remove Counterweight Assembly (Cab Specification)......................................................................1412 How to Install Counterweight Assembly (Cab Specification).....................................................................1415 Remove and Install Battery Hood Assembly (Head Guard Specification)...............................................................1418 How to Remove Battery Hood Assembly (Head Guard Specification)................................................................1418 How to Install Battery Hood Assembly (Head Guard Specification)...............................................................1421 Remove and Install Battery Hood Assembly (Cab Specification)......................................................................1424 How to Remove Battery Hood Assembly (Cab Specification).......................................................................1424 How to Install Battery Hood Assembly (Cab Specification)......................................................................1429 Remove and Install Rear Axle Assembly.............................................................................................1433 Remove Rear Axle Assembly.....................................................................................................1433 Install Rear Axle Assembly....................................................................................................1436 Disassemble and Assemble Rear Axle Assembly.......................................................................................1438 How to Disassemble Rear Axle Assembly.........................................................................................1438 How to Assemble Rear Axle Assembly............................................................................................1442 Hydraulic System......................................................................................................................1447 Remove and Install Control Valve Assembly.........................................................................................1447 How to Remove Control Valve Assembly..........................................................................................1447 How to Install Control Valve Assembly.........................................................................................1450 Disassemble and Assemble Control Valve Assembly...................................................................................1453 How to Disassemble Control Valve Assembly.....................................................................................1453 How to Assemble Control Valve Assembly........................................................................................1456 Remove and Install Hydraulic Tank Assembly........................................................................................1460 How to Remove Hydraulic Tank Assembly.........................................................................................1460 How to Install Hydraulic Tank Assembly........................................................................................1462 Disassemble and Assemble Steering and Work Equipment Pump Assembly................................................................1464 How to Disassemble Steering and Work Equipment Pump Assembly..................................................................1464 How to Assemble Steering and Work Equipment Pump Assembly.....................................................................1465 Work Equipment........................................................................................................................1467 Remove and Install Mast Assembly..................................................................................................1467 How to Remove Mast Assembly...................................................................................................1467 How to Install Mast Assembly..................................................................................................1470 Disassemble and Assemble Mast Assembly............................................................................................1472 How to Disassemble Mast Assembly..............................................................................................1472 How to Assemble Mast Assembly.................................................................................................1475 Remove and Install Lift Cylinder Assembly.........................................................................................1478 How to Remove Lift Cylinder Assembly..........................................................................................1478 How to Install Lift Cylinder Assembly.........................................................................................1480 Disassemble and Assemble Lift Cylinder Assembly...................................................................................1481 Disassemble Lift Cylinder Assembly............................................................................................1481 How to Assemble Lift Cylinder Assembly........................................................................................1483 Remove and Install Tilt Cylinder Assembly.........................................................................................1485 How to Remove Tilt Cylinder Assembly..........................................................................................1485 How to Install Tilt Cylinder Assembly.........................................................................................1487 Disassemble and Assemble Tilt Cylinder Assembly...................................................................................1488 How to Assemble Tilt Cylinder Assembly........................................................................................1488 How to Assemble Tilt Cylinder Assembly........................................................................................1490 CAB Related Parts.....................................................................................................................1491 Remove and Install Operator Seat..................................................................................................1491 How to Remove Operator Seat...................................................................................................1491 How to Install Operator Seat..................................................................................................1493 How to Remove and Install Seat Belt...............................................................................................1494 How to Remove Seat Belt.......................................................................................................1494 How to Install Seatbelt.......................................................................................................1495 Remove and Install Head Guard Assembly............................................................................................1496 How to Remove Head Guard Assembly.............................................................................................1496 How to Install Head Guard Assembly............................................................................................1504 Remove and Install Operator Cab Assembly..........................................................................................1512 How to Remove Operator Cab Assembly...........................................................................................1512 How to Install Operator Cab Assembly..........................................................................................1524 Electrical System.....................................................................................................................1536 Remove and Install Pump Motor Assembly............................................................................................1536 How to Remove Pump Motor Assembly.............................................................................................1536 How to Install Pump Motor Assembly............................................................................................1539 Remove and Install Battery Assembly (Head Guard Specification)....................................................................1541 How to Remove Battery Assembly (Head Guard Specification).....................................................................1542 How to Install Battery Assembly (Head Guard Specification)....................................................................1545 Remove and Install Battery Assembly (Cab Specification)...........................................................................1547 How to Remove Battery Assembly (Cab Specification)............................................................................1548 How to Install Battery Assembly (Cab Specification)...........................................................................1552 Disassemble and Assemble Battery Assembly (108V/180Ah) (FE25-2)...................................................................1556 How to Disassemble Battery Assembly (108V/180Ah) (FE25-2).....................................................................1557 How to Assemble Battery Assembly (108V/180Ah) (FE25-2)........................................................................1561 Disassemble and Assemble Battery Assembly (120V/180Ah) (FE30-2)...................................................................1565 How to Disassemble Battery Assembly (120V/180Ah) (FE30-2).....................................................................1566 How to Assemble Battery Assembly (120V/180Ah) (FE30-2)........................................................................1571 Disassemble and Assemble Battery Assembly (108V/240Ah) (FE25-2)...................................................................1575 How to Disassemble Battery Assembly (108V/240Ah) (FE25-2).....................................................................1576 How to Assemble Battery Assembly (108V/240Ah) (FE25-2)........................................................................1581 Disassemble and Assemble Battery Assembly (120V/240Ah) (FE30-2)...................................................................1585 How to Disassemble Battery Assembly (120V/240Ah) (FE30-2).....................................................................1586 How to Assemble Battery Assembly (120V/240Ah) (FE30-2)........................................................................1591 Remove and Install Charge Cable on ForkliftTruck (Head Guard Specification).......................................................1596 How to Remove Charge Cable on ForkliftTruck (Head Guard Specification)........................................................1596 How to Install Charge Cable on ForkliftTruck (Head Guard Specification).......................................................1603 Remove and Install Charge Cable on ForkliftTruck (Cab Specification)..............................................................1608 How to Remove Charge Cable on ForkliftTruck (Cab Specification)...............................................................1608 How to Install Charge Cable on ForkliftTruck (Cab Specification)..............................................................1615 Remove and Install Charge Cable (L-Shaped Leg Charger Side).......................................................................1621 How to Remove Charge Cable (L-Shaped Leg Charger Side)........................................................................1621 How to Install Charge Cable (L-Shaped Leg Charger Side).......................................................................1623 Remove and Install Charge Cable (U-Shaped Leg Charger Side).......................................................................1625 How to Remove Charge Cable (U-Shaped Leg Charger Side)........................................................................1625 How to Install Charge Cable (U-Shaped Leg Charger Side).......................................................................1627 Remove and Install Stationary Charger Ferrite Core (L-Shape Leg Charger)..........................................................1629 How to Remove Stationary Charger Ferrite Core (L-Shape Leg Charger)...........................................................1629 How to Install Stationary Charger Ferrite Core (L-Shape Leg Charger)..........................................................1630 Remove and Install Stationary Charger Ferrite Core (U-Shape Leg Charger)..........................................................1631 How to Remove Stationary Charger Ferrite Core (U-Shape Leg Charger)...........................................................1631 How to Install Stationary Charger Ferrite Core (U-Shape Leg Charger)..........................................................1632 Remove and Install Master Controller..............................................................................................1633 How to Remove Master Controller...............................................................................................1633 How to Install Master Controller..............................................................................................1637 Remove and Install Travel Inverter................................................................................................1641 How to Remove Travel Inverter.................................................................................................1641 How to Install Travel Inverter................................................................................................1644 Remove and Install Pump Inverter..................................................................................................1646 How to Remove Pump Inverter...................................................................................................1646 How to Install Pump Inverter..................................................................................................1649 Remove and Install Power Supply Controller........................................................................................1651 How to Remove Power Supply Controller.........................................................................................1651 How to Install Power Supply Controller........................................................................................1654 Remove and Install Contactor......................................................................................................1656 How to Remove Contactor.......................................................................................................1656 How to Install Contactor......................................................................................................1659 Remove and Install Monitor Panel Assembly.........................................................................................1662 How to Remove Monitor Panel Assembly..........................................................................................1662 How to Install Monitor Panel Assembly.........................................................................................1665 Remove and Install KOMTRAX Terminal...............................................................................................1668 How to Remove KOMTRAX Terminal................................................................................................1668 How to Install KOMTRAX Terminal...............................................................................................1670 Remove and Install Combination Switch Assembly....................................................................................1672 How to Remove Combination Switch Assembly.....................................................................................1672 How to Install Combination Switch Assembly....................................................................................1675 60 Maintenance Standard...................................................................................................................1679 Table of Contents.....................................................................................................................1680 Explanation of Terms for Maintenance Standard.........................................................................................1681 Power Train...........................................................................................................................1683 Maintenance Standard of Front Axle: FE25-2 (Single Tire Specification)............................................................1683 Maintenance Standard of Front Axle: FE25-2 (Double Tire and Wide Tire Specification)..............................................1685 Maintenance Standard of Front Axle: FE30-2........................................................................................1687 Maintenance Standard for Differential.............................................................................................1689 Maintenance Standard of Final Drive: FE25-2 (Single Tire Specification)...........................................................1691 Maintenance Standard of Final Drive: FE25-2 (Double Tire and Wide Tire Specification).............................................1693 Maintenance Standard of Final Drive: FE30-2.......................................................................................1695 Maintenance Standard for Travel Motor.............................................................................................1697 Maintenance Standard for Pump Motor...............................................................................................1699 Steering System.......................................................................................................................1701 Maintenance Standard for Steering Cylinder........................................................................................1701 Brake System..........................................................................................................................1702 Maintenance Standard for Brake Pipe...............................................................................................1702 Maintenance Standard for Front Brake..............................................................................................1703 Maintenance Standard for Parking Brake............................................................................................1704 Maintenance Standard for Brake Master Cylinder....................................................................................1705 Undercarriage and Frame...............................................................................................................1706 Maintenance Standard for Rear Axle................................................................................................1706 Maintenance Standard of Frame.....................................................................................................1708 Hydraulic System......................................................................................................................1709 Maintenance Standard for Hydraulic Tank...........................................................................................1709 Maintenance Standard for Control Valve............................................................................................1710 Maintenance Standard of Tilt Cylinder.............................................................................................1715 Maintenance Standard for Lift Cylinder............................................................................................1717 Work Equipment........................................................................................................................1719 Maintenance Standard of Mast......................................................................................................1719 Maintenance Standard of Board.....................................................................................................1723 80 Others.................................................................................................................................1727 Table of Contents.....................................................................................................................1728 Precautions Before Work...............................................................................................................1729 Heater System.........................................................................................................................1730 PTC Heater Component Parts........................................................................................................1730 System Diagram of Heater System...................................................................................................1731 Function of Heater System.........................................................................................................1732 Operation of Heater System........................................................................................................1733 Collision Detection System............................................................................................................1734 Precautions for Collision Detection System........................................................................................1734 Structure and Operation of Collision Detection System.............................................................................1735 Layout Drawing of Collision Detection System..................................................................................1735 System Diagram of Collision Detection System..................................................................................1737 Function of Collision Detection System........................................................................................1738 Operation of Collision Detection System.......................................................................................1738 Component Parts of Collision Detection System.................................................................................1743 Examine and Adjust Collision Detection System.....................................................................................1750 Examine Fuse..................................................................................................................1750 Service Mode..................................................................................................................1750 Troubleshooting of Collision Detection System.....................................................................................1757 Related Information to Troubleshooting........................................................................................1757 Troubleshooting by Failure Code (Display of Code).............................................................................1772 Troubleshooting of Electrical System (E-Mode).................................................................................1835 Disassemble and Assemble Collision Detection System...............................................................................1851 Remove and Install Collision Detection System (Head Guard Specification)......................................................1851 Remove and Install Collision Detection System (Cab Specification).............................................................1880 Yearly Inspection Criteria............................................................................................................1922 Yearly Inspection Criteria: FE25-2, FE30-2........................................................................................1922 90 Circuit Diagrams.......................................................................................................................1943 Table of Contents.....................................................................................................................1944 How to Read the Codes for Electric Cable..............................................................................................1945 Hydraulic Circuit Diagram.............................................................................................................1949 Symbols Used in Hydraulic Circuit Diagram.........................................................................................1949 Hydraulic Circuit Diagram.........................................................................................................1953 Hydraulic Circuit Diagram (at Right Turn).........................................................................................1955 Hydraulic Circuit Diagram (at Lift Raise).........................................................................................1957 Electrical Circuit Diagram............................................................................................................1959 Symbols Used in Electric Circuit Diagram..........................................................................................1959 Electrical Circuit Diagram (Head Guard Specification) (1/13)......................................................................1963 Electrical Circuit Diagram (Head Guard Specification) (2/13)......................................................................1965 Electrical Circuit Diagram (Head Guard Specification) (3/13)......................................................................1967 Electrical Circuit Diagram (Head Guard Specification) (4/13)......................................................................1969 Electrical Circuit Diagram (Head Guard Specification) (5/13)......................................................................1971 Electrical Circuit Diagram (Head Guard Specification) (6/13)......................................................................1973 Electrical Circuit Diagram (Head Guard Specification) (7/13)......................................................................1975 Electrical Circuit Diagram (Head Guard Specification) (8/13)......................................................................1977 Electrical Circuit Diagram (Head Guard Specification) (9/13) (L-Shaped Leg Charger)...............................................1979 Electrical Circuit Diagram (Head Guard Specification) (9/13) (U-Shaped Leg Charger)...............................................1981 Electrical Circuit Diagram (Head Guard Specification) (10/13).....................................................................1983 Electrical Circuit Diagram (Head Guard Specification) (11/13).....................................................................1985 Electrical Circuit Diagram (Head Guard Specification) (12/13).....................................................................1987 Electrical Circuit Diagram (Head Guard Specification) (13/13).....................................................................1989 Electrical Circuit Diagram (Cab Spec) (1/13)......................................................................................1991 Electrical Circuit Diagram (Cab Spec) (2/13)......................................................................................1993 Electrical Circuit Diagram (Cab Spec) (3/13)......................................................................................1995 Electrical Circuit Diagram (Cab Spec) (4/13)......................................................................................1997 Electrical Circuit Diagram (Cab Spec) (5/13)......................................................................................1999 Electrical Circuit Diagram (Cab Spec) (6/13)......................................................................................2001 Electrical Circuit Diagram (Cab Spec) (7/13)......................................................................................2003 Electrical Circuit Diagram (Cab Spec) (8/13)......................................................................................2005 Electrical Circuit Diagram (Cab Specification) (9/13) (L-Shaped Leg Charger)......................................................2007 Electrical Circuit Diagram (Cab Specification) (9/13) (U-Shaped Leg Charger)......................................................2009 Electrical Circuit Diagram (Cab Spec) (10/13).....................................................................................2011 Electrical Circuit Diagram (Cab Spec) (11/13).....................................................................................2013 Electrical Circuit Diagram (Cab Spec) (12/13).....................................................................................2015 Electrical Circuit Diagram (Cab Spec) (13/13).....................................................................................2017 Electrical Circuit Diagram (Forklift Truck with Collision Detection System).......................................................2019 Index......................................................................................................................................2021
DESCRIPTION:
KOMATSU FE25-2 FE30-2 FORKLIFT TRUCK SHOP MANUAL WEN00009-03 – PDF DOWNLOAD
Composition of Shop Manual
This shop manual contains the necessary technical information for services done in a shop. These are classified
as follows to make the manual easier to use.
00 Index and Foreword
This section explains the index, foreword, safety and basic information.
01 Specification
This section explains the specifications of the forklift truck.
10 Structure and Function
This section explains the structure and function of each system. The “Structure and Operation” section is a useful reference material for you to understand the structure of each device better. It also is useful to do a troubleshooting.
20 Standard Value Table
This section explains the standard values for new forklift truck and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to give the standard values in testing and adjusting and to judge parts in troubleshooting.
30 Testing and Adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and methods to adjust each part. The standard values and judgement criteria for troubleshooting in “Testing and Adjusting” are given in the standard value table. Use them together.
40 Troubleshooting
This section explains how to find out defective parts when a failure occurs and how to do remedies. The troubleshooting is divided by failure modes.
50 Disassembly and Assembly
This section explains the special tools and procedures to remove, install, disassemble, and assemble each component, and the precautions required for safe work. In addition, tightening torques, and quantity and weight of coating material, oil, grease, and coolant necessary for these works are also shown.
60 Maintenance Standard
This section explains the maintenance standard values of each device. The judgment criteria and remedies for disassembly and maintenance are shown in the maintenance standard section.
80 Appendix
This chapter explains the items that follow.
• Devices which cannot be classified into sections are explained as others in this section. The structure, operation, test, adjustment, and troubleshooting for those are explained together.
• This section explains the items, contents and criteria of the special self-imposed inspection.
90 Circuit Diagrams
This section gives hydraulic circuit diagrams and electrical circuit diagrams
S.S 27/12/24
