Komatsu FORKLIFT TRUCK FE25G-2 FE30G-2 Shop Manual WEN00008-03 PDF

Description

Komatsu FORKLIFT TRUCK FE25G-2 FE30G-2 Shop Manual WEN00008-03 – PDF DOWNLOAD

FILE DETAILS:

Komatsu FORKLIFT TRUCK FE25G-2 FE30G-2 Shop Manual WEN00008-03 – PDF DOWNLOAD

Language : English
Pages :2024
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu FORKLIFT TRUCK FE25G-2 FE30G-2 Shop Manual WEN00008-03 – PDF DOWNLOAD

SERIAL NUMBERS FE25G-320001
FE30G-320001 and up

Foreword, Safety, Basic Information
How to Read the Shop Manual
• Some of the attachments and optional parts in this shop manual are not available in some regions. If you
wish to use such items, consult Komatsu.
• Materials and specifications are subject to change without notice.
• Drawings and photos in this shop manual show the typical model. Some of them will possibly show a different
shape from the actual forklift truck.
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

TABLE OF CONTENTS:

Komatsu FORKLIFT TRUCK FE25G-2 FE30G-2 Shop Manual WEN00008-03 – PDF DOWNLOAD

SERIAL NUMBERS FE25G-320001
FE30G-320001 and up

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 52
Disconnect and Connect Connector with Housing to Rotate 56
Standard Torque Table 57
Conversion Table 64
Abbreviation List 69
01 Specifications 73
Table of Contents 74
Specifications 75
Specification Drawing 75
Specification Drawing: FE25G-2 75
Specification Drawing: FE30G-2 77
Specifications 79
Specifications: FE25G-2 79
Specifications: FE30G-2 83
Weight Table 87
Weight Table: FE25G-2 87
Weight Table: FE30G-2 89
Fuel, Coolant, Lubricant 90
Lubrication Chart 90
List of Specified Lubricant 92
10 Structure and Function 93
Table of Contents 94
Charge System 97
Layout Drawing of Charge System 97
Component Parts of Charge System 98
Battery Assembly 98
BMS 101
Boot-up System 103
Layout Drawing of Boot-up System 103
System Operating Lamp System 104
System Diagram of System Operating Lamp System 104
Function of Operation Lamp System 104
Operation of System Operating Lamp System 104
Emergency Stop Switch 106
Function of Emergency Stop Switch 106
Operation of Emergency Stop Switch 106
ID Key System 107
System Diagram of ID Key System 107
Function of ID Key System 107
Operation of ID Key System 108
Component Parts of Boot-Up System 109
ID Key Controller 109
ID Key Antenna 111
Control System 112
Layout Drawing of Control System 112
Monitor Panel System 113
System Diagram of Monitor Panel System 113
Function of Monitor Panel System 113
KOMTRAX System 115
System Diagram of KOMTRAX System 115
Function of KOMTRAX System 115
Seat Belt Interlock System 116
System Diagram of Seat Belt Interlock System 116
Function of Seat Belt Interlock System 117
Operation of Seat Belt Interlock System 117
Impact Detection System 118
System Diagram of Impact Detection System 118
Function of Impact Detection System 118
Operation of Impact Detection System 118
Inclination Warning System 120
System Diagram of Inclination Warning System 120
Function of Inclination Warning System 120
Operation of Inclination Warning System 120
Fall Detection System 122
Function of Fall Detection System 122
Operation of Fall Detection System 122
Component Parts of Control System 123
Monitor Panel 123
KOMTRAX Terminal 139
Master Controller 141
MC2 Contactor 145
Power Supply Controller 146
Travel Inverter 150
Pump Inverter 153
Accelerator Pedal 156
Hydraulic System 157
Layout Drawing of Hydraulic System 157
Lift Interlock System 158
System Diagram of Lift Interlock System 158
Function of Lift Interlock System 159
Operation of Lift Interlock System 159
Component Parts of Hydraulic System 160
Hydraulic Tank 160
Pump Motor 161
Steering and Work Equipment Pump 162
Control Valve 164
Power Train System 182
Layout Drawing of Power Train System 182
Operation of Power Train System 183
Directional Lever Warning System 184
System Diagram of Directional Lever Warning System 184
Function of Directional Lever Warning System 184
Operation of Directional Lever Warning System 184
Travel Interlock System 186
System Diagram of Travel Interlock System 186
Function of Travel Interlock System 187
Operation of Travel Interlock System 187
Travel Speed Limit System at Lifting Height 188
System Diagram of Travel Speed Limit System at Lifting Height 188
Function of Travel Speed Limit System at Lifting Height 188
Operation of Travel Speed Limit System at Lifting Height 189
Reverse Travel Control System on Slope 190
System Diagram of Reverse Travel Control System 190
Function of Reverse Travel Control System on Slope 191
Operation of Reverse Travel Control System on Slope 191
Power Assist System on Slope 192
System Diagram of Power Assist System on Slope 192
Function of Power Assist System on Slope 192
Operation of Power Assist System on Slope 193
Component Parts of Power Train System 194
Travel Motor 194
Front Axle 196
Differential 203
Final Drive 205
Combination Switch 207
Work Equipment System 208
Layout Drawing of Work Equipment System 208
Structure of Valve Control 209
Steering System 210
Layout Drawing of Steering System 210
Steering Column 211
Structure of Steering Column 211
EPACS System 212
System Diagram of EPACS System 212
Function of EPACS System 212
Operation of EPACS System 212
Turning Speed Limit System 213
System Diagram of Turning Speed Limit System 213
Function of Turning Speed Limit System 214
Operation of Turning Speed Limit System 214
Component Parts of Steering System 215
Orbitrol Valve 215
Rear Axle 217
Brake System 218
Layout Drawing of Brake System 218
Parking Brake Warning System 219
System Diagram Parking Brake Warning System 219
Function of Parking Brake Warning System 219
Operation of Parking Brake Warning System 220
Parking Brake Dragging Warning System 221
System Diagram of Parking Brake Dragging Warning System 221
Function of Parking Brake Dragging Warning System 221
Operation of Parking Brake Dragging Warning System 221
Component Parts of Brake System 223
Brake Reservoir Tank 223
Brake Master Cylinder 224
Front Brake 226
Parking Brake 228
Undercarriage and Frame 229
Frame 229
Structure of Frame 229
Tires 230
Structure of Bias Tire 230
Work Equipment 231
Structure of Work Equipment 231
Function of Work Equipment 232
CAB Related Parts 233
Head Guard 233
Structure of Head Guard 233
Function of Head Guard 233
CAB 234
Structure of Cab 234
Function of Cab 234
20 Standard Value Table 235
Table of Contents 236
Standard Value Table for Machine 237
Standard Value Table for Machine: FE25G-2 237
Standard Value Table for Machine: FE30G-2 241
Procedures To Measure Performance 244
30 Testing and Adjusting 245
Table of Contents 246
Precautions Before Work 248
Related Information on Testing and Adjusting 249
Tools for Testing and Adjusting 249
Power Train 250
Adjust Accelerator Pedal 250
How to Adjust Accelerator Pedal 250
Examine Oil Level in Differential Case, Change Oil 252
How to Examine Oil in Differential Case 252
How to Change Oil in Differential Case 253
Steering System 254
Examine Play of Steering Wheel 254
Examine Play of Steering Wheel 254
Adjust Tire Angle Sensor 255
How to Adjust Tire Angle Sensor 255
Brake System 256
Adjust Parking Brake Lever 256
How to Adjust Parking Brake Lever 256
Adjust Brake Pedal 257
How to Adjust Height and Play of Brake Pedal 257
Examine and Adjust Brake Pedal Angle Sensor 258
How to Examine Brake Pedal Angle Sensor 258
How to Adjust Brake Pedal Angle Sensor 258
Examine and Adjust Disc Brake 259
How to Adjust Clearance of Disc Brake 259
How to Examine Disc Brake Wear Volume 262
Bleed Air from Brake Circuit 263
How to Bleed Air from Brake Circuit 263
Examine Brake Performance 265
How to Examine Brake Performance 265
Hydraulic System 266
Release Remained Pressure in Hydraulic Circuit 266
How to Release Remained Pressure from Hydraulic Circuit 266
Examine Steering Circuit Oil Pressure 267
Examine Steering Circuit Oil Pressure 267
Measure Oil Pressure of Work Equipment 270
How to Measure Pressure of Work Equipment Pump 270
How to Examine Oil Level in Hydraulic Tank, Change Oil 273
Examine Oil Level In Hydraulic Tank 273
How to Replace Hydraulic Oil 273
Bleed Air from Hydraulic Circuit 275
Bleed Air from Lift Cylinder 275
How to Bleed Air from Tilt Cylinder 275
How to Bleed Air from Attachment Cylinder 275
Lower Fork Manually 276
How to Lower Fork Manually 276
How of Restore Lift Quick Drop Valve 278
Work Equipment 279
Examine and Adjust Work Equipment Lever 279
How to Examine Micro Switch 279
How to Adjust Potentiometer 280
Examine Hydraulic Drift and Forward Tilt of Work Equipment 281
How to Examine Hydraulic Drift and Forward Tilt of Work Equipment 281
Adjust Mast 283
How to Adjust Runout of Mast 283
How to Select Main Roller of Outer Mast and Adjust Shimsd 284
How to Adjust Shim on Stripe 285
How to Select Main Roller of Inner Mast and Adjust Shims 285
How to Adjust Shim on Clamp 286
Adjust Lifting Height Detection Sensor 287
How to Adjust Lifting Height Detection Sensor (Forklift Truck with Double-Mast) 287
How to Adjust Lifting Height Detection Sensor (Forklift Truck with Triple-Mast) 289
Adjust Finger Board 291
How to Adjust Shim on Main Roller Below Finger Board 291
How to Adjust Shim on Main Roller Above Finger Board 292
How to Adjust Finger Board Main Roller (Inclination Roller) in Middle 292
How to Adjust Shim on Finger Board Side Roller 292
How to Adjust Finger Board Side Roller and Main Roller (Inclination Roller) in Middle 293
How to Adjust Finger Board Chain 293
Electrical System 294
Examine Fuse 294
How to Test Blade Fuse 294
How to Test Tube Fuse 295
How to Test Slow-Blow Fuse (Controller) 296
Set and Operate Monitor Pane 298
Operator Mode and Service Mode of Monitor Panel 298
Operator Mode 301
Service Mode 304
How to Start Up KOMTRAX Terminal 401
40 Troubleshooting 407
Table of Contents 408
Precautions Before Work 416
Related Information to Troubleshooting 417
General Troubleshooting Points 417
Sequence of Events in Troubleshooting 419
Checks Before Troubleshooting 421
Inspection Procedure Before Troubleshooting 422
Walk-around Check 422
Test in Accordance with Testing Procedure 423
Examine Oil Level In Hydraulic Tank 423
Examine Hydraulic Oil Strainer and Line Filter 423
Examine Oil Level in Differential Case 424
How to Examine Electrical Components 425
Preparation for Troubleshooting of Electrical System 428
Preparation for Troubleshooting of Monitor Panel 428
Preparation for Troubleshooting of Travel Inverter 428
Preparation for Troubleshooting of Pump Inverter 428
Preparation for Troubleshooting of Power Supply Controller 428
Preparation for Troubleshooting of Master Controller 429
Preparation for Troubleshooting of KOMTRAX Terminal 429
How to Disconnect and Connect Connector with a Special Lock 429
Procedure for Troubleshooting 430
Symptom and Troubleshooting Numbers 435
Information Shown in Troubleshooting Table 440
Connector List (Head Guard Specification) 442
Connector Layout (Head Guard Specification) 448
Connector List (Cab Specification) 454
Connector Layout (Cab Specification) 461
Connector Contact Connection Table 467
T-Branch Box and T-Branch Adapter Table 510
Fuse Location Table 516
Failure Code Table 522
Troubleshooting by Failure Code (Display of Code) 538
Failure Code [989L00] 538
Failure Code [989M00] 539
Failure Code [989N00] 540
Failure Code [D160KB] 541
Failure Code [D160KY] 543
Failure Code [D161KB] 545
Failure Code [D161KY] 547
Failure Code [D162KA] 549
Failure Code [D162KB] 551
Failure Code [D162KY] 553
Failure Code [D19HKA] 555
Failure Code [D19HKB] 557
Failure Code [D19HKY] 559
Failure Code [D19SKB] 561
Failure Code [D19SKY] 563
Failure Code [D1HBKA] 565
Failure Code [D1HBKB] 568
Failure Code [D1HBKY] 570
Failure Code [D1HPKB] 572
Failure Code [D1HPKY] 574
Failure Code [D1HQKB] 575
Failure Code [D1HQKY] 577
Failure Code [D1HRKB] 578
Failure Code [D1HRKY] 580
Failure Code [D1J1KA] 581
Failure Code [D1J1KB] 583
Failure Code [D1J1KY] 585
Failure Code [D1J2KA] 587
Failure Code [D1J2KB] 589
Failure Code [D1J2KY] 591
Failure Code [D5XWKA] 593
Failure Code [D5XWKY] 597
Failure Code [D5XXKA] 599
Failure Code [D5XXKY] 601
Failure Code [D610KF] 602
Failure Code [D6L1KA] 604
Failure Code [D6L1KB] 605
Failure Code [D6L2KA] 606
Failure Code [D6L2KB] 607
Failure Code [D6L3KB] 608
Failure Code [D6L4KT] 609
Failure Code [D6L5KE] 610
Failure Code [D6L5KF] 611
Failure Code [D6L5KR] 612
Failure Code [D6L6MA] 613
Failure Code [D6L7MA] 614
Failure Code [D6L8KR] 615
Failure Code [D6L9KR] 616
Failure Code [D6LAKR] 617
Failure Code [D6LBNS] 618
Failure Code [D6LCNS] 619
Failure Code [D6LDNS] 620
Failure Code [D6LENS] 621
Failure Code [D6LFKA] 622
Failure Code [D6LGKA] 623
Failure Code [D6LHNS] 624
Failure Code [D6LJNS] 625
Failure Code [D6LKKA] 626
Failure Code [D6LLKA] 627
Failure Code [D6LMKA] 628
Failure Code [D6LNKA] 629
Failure Code [D6LNNS] 630
Failure Code [D6LPNS] 631
Failure Code [D811MC] 632
Failure Code [D862KA] 633
Failure Code [D8ALKA] 634
Failure Code [D8ALKB] 636
Failure Code [D8AQK4] 637
Failure Code [D8AQKR] 641
Failure Code [DAF0KT] 642
Failure Code [DAF0MB] 643
Failure Code [DAF0MC] 644
Failure Code [DAF3KK] 645
Failure Code [DAFGMC] 647
Failure Code [DAFLKA] 648
Failure Code [DAFLKB] 650
Failure Code [DAFQKR] 651
Failure Code [DBN000] 652
Failure Code [DBN0KT] 653
Failure Code [DBN0MC] 654
Failure Code [DBN2KK] 655
Failure Code [DBN3KK] 658
Failure Code [DBN4KX] 660
Failure Code [DBN5KX] 662
Failure Code [DBN6KX] 664
Failure Code [DBN9KQ] 667
Failure Code [DBNCMA] 668
Failure Code [DBNEKR] 669
Failure Code [DBNFKR] 673
Failure Code [DBNGKR] 676
Failure Code [DBNJKB] 678
Failure Code [DBNJKY] 679
Failure Code [DBNKKA] 680
Failure Code [DBNKKB] 681
Failure Code [DBNKKY] 682
Failure Code [DBNLKA] 683
Failure Code [DBNLKB] 685
Failure Code [DBNQKR] 687
Failure Code [DBNRKR] 690
Failure Code [DBNSKA] 695
Failure Code [DBNSKB] 697
Failure Code [DBNSKY] 698
Failure Code [DBNTKA] 699
Failure Code [DBNVMA] 701
Failure Code [DBNYKA] 703
Failure Code [DDDQKA] 705
Failure Code [DDDTKA] (Forklift Truck Without Seat Belt Interlock System) 707
Failure Code [DDDTKA] (Forklift Truck with Seat Belt Interlock System) 709
Failure Code [DDDTKB] (Forklift Truck Without Seat Belt Interlock System) 711
Failure Code [DDDTKB] (Forklift Truck with Seat Belt Interlock System) 713
Failure Code [DDDUKA] (Forklift Truck Without Seat Belt Interlock System) 715
Failure Code [DDDUKA] (Forklift Truck with Seat Belt Interlock System) 717
Failure Code [DDDUKB] (Forklift Truck Without Seat Belt Interlock System) 719
Failure Code [DDDUKB] (Forklift Truck with Seat Belt Interlock System) 721
Failure Code [DDDVKA] (Forklift Truck Without Seat Belt Interlock System) 723
Failure Code [DDDVKA] (Forklift Truck with Seat Belt Interlock System) 725
Failure Code [DDDVKM] (Forklift Truck Without Seat Belt Interlock System) 728
Failure Code [DDDVKM] (Forklift Truck with Seat Belt Interlock System) 730
Failure Code [DDK6KA] 733
Failure Code [DDK6KY] 736
Failure Code [DFC1KA] 738
Failure Code [DFC1KB] 741
Failure Code [DHPCKA] 743
Failure Code [DHPCKB] 746
Failure Code [DJK100] 748
Failure Code [DJK1KN] 749
Failure Code [DK10KA] 750
Failure Code [DK10KB] 752
Failure Code [DK11KA] 754
Failure Code [DK11KB] 756
Failure Code [DK13KX] 758
Failure Code [DK13L8] 759
Failure Code [DK30MA] 760
Failure Code [DK40KA] 762
Failure Code [DK40KY] 765
Failure Code [DK40MA] 767
Failure Code [DK5YMA] 768
Failure Code [DK80MA] 770
Failure Code [DQA1KM] 772
Failure Code [DQA1KR] 773
Failure Code [DQA1KT] 776
Failure Code [DQA2KM] 778
Failure Code [DQA2KR] 779
Failure Code [DQA2KT] 782
Failure Code [DUS1KA] 784
Failure Code [DUS1KY] 786
Failure Code [DUS6KA] 788
Failure Code [DUS6KB] 790
Failure Code [DUS6KY] 792
Failure Code [DUS7KA] 794
Failure Code [DUS7KB] 796
Failure Code [DUS7KY] 798
Failure Code [DV00KB] 800
Failure Code [DV01KA] 801
Failure Code [DV01KB] 803
Failure Code [DV01KY] 805
Failure Code [DV02KA] 807
Failure Code [DV02KB] 809
Failure Code [DV02KY] 811
Failure Code [DW9MKA] 813
Failure Code [DW9MKB] 815
Failure Code [DW9MKY] 817
Failure Code [DWP0KA] 818
Failure Code [DWP0KB] 820
Failure Code [E111KM] 822
Failure Code [E111KQ] 823
Failure Code [E111KR] 824
Failure Code [E111MC] 825
Failure Code [E112KK] 826
Failure Code [F1A100] 828
Failure Code [F7FQKR] 830
Failure Code [F7G0MC] 834
Failure Code [FJAA00] 835
Failure Code [FJAB00] 836
Failure Code [FJAC00] 837
Failure Code [FJB1KM] 838
Failure Code [FJBAKR] 839
Failure Code [GF01KH] 843
Failure Code [GF01KL] 844
Failure Code [GF01KU] 845
Failure Code [GF02KG] 846
Failure Code [GF02KH] 847
Failure Code [GF02KL] 848
Failure Code [GF02KU] 849
Failure Code [GF02N7] 850
Failure Code [GF02N8] 851
Failure Code [GF02NA] 852
Failure Code [GF02NR] 853
Failure Code [GF02NS] 854
Failure Code [GF02NV] 855
Failure Code [GF02ZS] 856
Failure Code [GF02ZT] 857
Failure Code [GF02ZU] 858
Failure Code [GF10KN] 859
Failure Code [GF11KG] 862
Failure Code [GF11KK] 864
Failure Code [GF12KA] 866
Failure Code [GF13KA] 868
Failure Code [GF14KA] 870
Failure Code [GF15KQ] 872
Failure Code [GF16KA] 874
Failure Code [GF16KB] 877
Failure Code [GF17MA] 880
Failure Code [GF18KQ] 884
Failure Code [GF1AMA] 886
Failure Code [GF1BMA] 887
Failure Code [GF1C00] 888
Failure Code [GF1CNS] 889
Failure Code [GF1EKT] 890
Failure Code [GF1FMA] 891
Failure Code [GF1JKA] 893
Failure Code [GF1LKB] 895
Failure Code [GF1MKB] 897
Failure Code [GF1NKB] 900
Failure Code [GF1QKR] 903
Failure Code [GF20KN] 906
Failure Code [GF21KG] 909
Failure Code [GF21KK] 911
Failure Code [GF22KA] 913
Failure Code [GF23KA] 915
Failure Code [GF24KA] 917
Failure Code [GF25KQ] 919
Failure Code [GF26KA] 921
Failure Code [GF26KB] 924
Failure Code [GF27MA] 927
Failure Code [GF28KQ] 931
Failure Code [GF2AMA] 933
Failure Code [GF2BMA] 934
Failure Code [GF2C00] 935
Failure Code [GF2CNS] 936
Failure Code [GF2EKT] 937
Failure Code [GF2FMA] 938
Failure Code [GF2JKA] 940
Failure Code [GF2LKB] 942
Failure Code [GF2MKB] 944
Failure Code [GF2NKB] 947
Failure Code [GF2QKR] 950
Failure Code [GF30KB] 952
Failure Code [GF31MA] 954
Failure Code [GF3200] 956
Failure Code [GF32NS] 957
Failure Code [GF33MA] 958
Failure Code [GF50KB] 960
Failure Code [GF51MA] 962
Failure Code [GF5200] 964
Failure Code [GF52NS] 965
Failure Code [GF53MA] 966
Failure Code [GFA0KB] 968
Failure Code [GFA0PK] 971
Failure Code [GFA8ZC] 972
Failure Code [GFA9KA] 973
Failure Code [GFA9KB] 975
Failure Code [GFAAKA] 976
Failure Code [GFACNU] 977
Failure Code [GFAG00] 978
Failure Code [GFAHKL] 980
Failure Code [GFAHKU] 981
Failure Code [GFAJKE] 982
Failure Code [GFAJKN] 984
Failure Code [GFAKKU] 986
Failure Code [GFALKN] 987
Failure Code [GFALNS] 989
Failure Code [GFALZC] 990
Failure Code [GFAMMN] 992
Failure Code [GFAMMR] 993
Failure Code [GFAMNS] 996
Failure Code [GFANKA] 997
Failure Code [GFAQKR] 999
Failure Code [GFBQKR]1001
Failure Code [GFBRKR]1003
Failure Code [GFD6MA]1005
Failure Code [GFDAKG]1006
Failure Code [GFDAKN]1008
Failure Code [GFDAKP]1011
Failure Code [GFDAKY]1014
Failure Code [GFDDKG]1016
Failure Code [GFDDKN]1018
Failure Code [GFDDKP]1021
Failure Code [GFDEKN]1024
Failure Code [GFDGKB]1027
Failure Code [GFDGKG]1029
Failure Code [GFDGKP]1031
Failure Code [GFDKKB]1033
Failure Code [GFDKKG]1035
Failure Code [GFDKKN]1037
Failure Code [GFDKKP]1039
Failure Code [GFDKKY]1041
Failure Code [GFDLKN]1043
Failure Code [GFDNKG]1045
Failure Code [GFDNKN]1052
Failure Code [GFDNKP]1062
Failure Code [GFDRKK]1063
Failure Code [GFDRKU]1065
Failure Code [GFDSKK]1067
Failure Code [GFDSKU]1069
Failure Code [GFDUN7]1071
Failure Code [GFDUN8]1072
Failure Code [GFDVN8]1073
Failure Code [GFEAKA]1074
Failure Code [GFEAKB]1075
Failure Code [GFEBKB]1076
Failure Code [GFF0KB]1077
Failure Code [GFF0PK]1080
Failure Code [GFF8ZC]1081
Failure Code [GFF9KA]1082
Failure Code [GFF9KB]1084
Failure Code [GFFAKA]1085
Failure Code [GFFCNU]1086
Failure Code [GFFG00]1087
Failure Code [GFFHKL]1089
Failure Code [GFFHKU]1090
Failure Code [GFFJKE]1091
Failure Code [GFFJKN]1093
Failure Code [GFFKKU]1095
Failure Code [GFFLKN]1096
Failure Code [GFFLNS]1098
Failure Code [GFFLZC]1099
Failure Code [GFFMMN]1101
Failure Code [GFFMMR]1102
Failure Code [GFFMNS]1105
Failure Code [GFFNKA]1106
Failure Code [GFFQKR]1108
Troubleshooting of Electrical System (E-Mode)1110
Lift Truck Does Not Start1110
Battery is Not Charged1112
When Starting Switch is Turned on, Monitor Panel is Not Shown1114
When Starting Switch is Turned on, Alarm Buzzer Does Not Sound1118
Parking Brake Alarm Does Not Operate Or Does Not Stop1120
Horn Does Not Sound1123
Horn Does Not Stop1126
EPACS is Abnormal1128
Travel Speed Limit Cannot be Released or Enabled1130
Monitor Panel Cannot be Set in Controller Failure Display Mode, Controller Adjustment Mode, or Travel Speed Limit Setting Mode1131
Headlamp, Clearance Lamp, Tail Lamp, and License Plate Lamp Do Not Come on or Do Not Go off1132
Turn-Signal-Lamps Do Not Come on or Do Not Go off1138
Brake Lamp Does Not Come On or Go Out1143
Backup Lamp Does Not Come On or Stays Lit1146
Backup Buzzer Does Not Sound or Continues to Sound1150
KOMTRAX System Does Not Operate Correctly1153
Alarm Lamp 1 Does Not Come On1154
Alarm Lamp 2 Does Not Come On1156
Alarm Lamp 1 Does Not Go Off1158
Alarm Lamp 2 Does Not Go Off1160
Alarm Buzzer 1 Does Not Operate1162
Alarm Buzzer 2 Does Not Operate1164
Alarm Buzzer 1 Does Not Stop1166
Alarm Buzzer 2 Does Not Stop1168
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)1170
How to Use Troubleshooting Table1170
System Diagram of Hydraulic and Mechanical System1173
Failure Mode and Cause Table1175
Lift Truck Does Not Turn1182
Turning Response is Unsatisfactory1183
Steering Wheel is Heavy to Operate1184
Lift Truck Is Unstable During Turning1185
When Steering Wheel is Released, it Does Not Return To Neutral or it Turns by Itself1186
Steering Wheel is Turned in Reverse or it Kicks (in Combined Operation with Work Equipment)1187
Large Shock Is Made When Steering Wheel Is Returned1188
EPACS Does Not Work1189
Steering Wheel Vibrates1190
Unusual Noise is Heard from Steering1191
Oil Leaks from Steering Circuit1192
Service Brakes Do Not Operate or are Weak1193
Service Brakes are Not Released or Drag1194
Parking Brake Does Not Operate or is Weak1195
Parking Brake is Not Released or Drags1196
Unusual Noise is Heard from Around Steering and Work Equipment Pump1197
Fork Lowering Lock Does Not Work (Fork Lowers When Operator is Off from Operator Seat)1198
Control Valve Lever Does Not Move Smoothly and it is Heavy to Operate1199
Lift Cylinder And Fork Do Not Rise1200
Lifting Speed or Power of Lift Cylinder and Fork is Insufficient1201
Fork Lifting Speed Lowers at Specific Height1203
Hydraulic Drift of Lift Cylinder is Large1204
Lift Cylinders Do Not Lower1205
Fork Lowering Speed is Low, High, or Fine Control Performance is Low or Response is Low1206
Mast Does Not Tilt Forward and Rearward1207
Forward, Rearward Tilting Speed or Force of Mast is Insufficient1208
Tilt Speed Decreases During Tilt1209
Hydraulic Drift of Tilt Cylinder (Forward Tilting) is Large1210
Mast is Unstable During Travel with Load1211
Steering Operation is Heavy When Work Equipment and Steering are Operated Simultaneously1212
50 Disassembly and Assembly1213
Table of Contents1214
Precautions Before Work1217
Related Information on Disassembly and Assembly1218
How to Read This Manual1218
Coating Materials List1219
Special Tool List1224
Sketches of Special Tools1228
Prepare1233
Drain and Add Hydraulic Oil1233
How to Drain Hydraulic Oil1233
How to Add Hydraulic Oil1235
Power Train1236
Remove and Install Front Axle Assembly1236
Remove Front Axle Assembly1237
Install Front Axle Assembly1240
Remove and Install Axle Housing Assembly1242
How to Remove Axle Housing Assembly1242
How to Install Axle Housing Assembly1245
Disassemble and Assemble Axle Housing Assembly (FE25G-2)1247
How to Disassemble Axle Housing Assembly (FE25G-2)1248
How to Assemble Axle Housing Assembly (FE25G-2)1252
Disassemble and Assemble Axle Housing Assembly (FE30G-2)1259
How to Disassemble Axle Housing Assembly (FE30G-2)1260
How to Assemble Axle Housing Assembly (FE30G-2)1264
Disassemble and Assemble Differential Assembly1270
How to Disassemble Differential Assembly1271
How to Assemble Differential Assembly1279
Remove and Install Parking Brake Assembly1289
How to Remove Parking Brake Assembly1289
Install Parking Brake Assembly1292
Disassemble and Assemble Parking Brake Assembly1293
Disassemble Parking Brake Assembly1293
Assemble Parking Brake Assembly1295
Remove and Install Parking Brake Lever1298
How to Remove Parking Brake Lever1298
How to Install Parking Brake Lever1302
Brake System1306
Remove and Install Brake Master Cylinder Assembly1306
How to Remove Brake Master Cylinder Assembly1307
How to Install Brake Master Cylinder Assembly1310
Disassemble and Assemble Brake Master Cylinder Assembly1314
How to Disassemble Brake Master Cylinder Assembly1314
How to Assemble Brake Master Cylinder Assembly1315
Steering System1316
Remove and Install Steering Cylinder Assembly1316
How to Remove Steering Cylinder Assembly1316
How to Install Steering Cylinder Assembly1319
Disassemble and Assemble Steering Cylinder Assembly1321
Disassemble Steering Cylinder Assembly1321
Assemble Steering Cylinder Assembly1323
Remove and Install Orbitrol Valve Assembly1325
How to Remove Orbitrol Valve Assembly1325
How to Install Orbitrol Valve Assembly1329
Disassemble and Assemble Orbitrol Valve Assembly1333
How to Disassemble Orbitrol Valve Assembly1334
How to Assemble Orbitrol Valve Assembly1337
Undercarriage and Frame1341
Remove and Install Counterweight Assembly (Head Guard Specification)1341
How to Remove Counterweight Assembly (Head Guard Specification)1341
How to Install Counterweight Assembly (Head Guard Specification)1345
Remove and Install Counterweight Assembly (Cab Specification)1349
How to Remove Counterweight Assembly (Cab Specification)1349
How to Install Counterweight Assembly (Cab Specification)1355
Remove and Install Battery Hood Assembly (Head Guard Specification)1359
How to Remove Battery Hood Assembly (Head Guard Specification)1359
How to Install Battery Hood Assembly (Head Guard Specification)1363
Remove and Install Battery Hood Assembly (Cab Specification)1366
How to Remove Battery Hood Assembly (Cab Specification)1366
How to Install Battery Hood Assembly (Cab Specification)1373
Remove and Install Rear Axle Assembly1378
Remove Rear Axle Assembly1378
Install Rear Axle Assembly1381
Disassemble and Assemble Rear Axle Assembly1383
How to Disassemble Rear Axle Assembly1383
How to Assemble Rear Axle Assembly1387
Hydraulic System1392
Remove and Install Control Valve Assembly1392
How to Remove Control Valve Assembly1392
How to Install Control Valve Assembly1395
Disassemble and Assemble Control Valve Assembly1398
How to Disassemble Control Valve Assembly1398
How to Assemble Control Valve Assembly1401
Remove and Install Hydraulic Tank Assembly1405
How to Remove Hydraulic Tank Assembly1405
How to Install Hydraulic Tank Assembly1407
Disassemble and Assemble Steering and Work Equipment Pump Assembly1409
How to Disassemble Steering and Work Equipment Pump Assembly1409
How to Assemble Steering and Work Equipment Pump Assembly1410
Work Equipment1412
Remove and Install Mast Assembly1412
How to Remove Mast Assembly1412
How to Install Mast Assembly1415
Disassemble and Assemble Mast Assembly1417
How to Disassemble Mast Assembly1417
How to Assemble Mast Assembly1420
Remove and Install Lift Cylinder Assembly1423
How to Remove Lift Cylinder Assembly1423
How to Install Lift Cylinder Assembly1425
Disassemble and Assemble Lift Cylinder Assembly1427
Disassemble Lift Cylinder Assembly1427
How to Assemble Lift Cylinder Assembly1429
Remove and Install Tilt Cylinder Assembly1431
How to Remove Tilt Cylinder Assembly1431
How to Install Tilt Cylinder Assembly1433
Disassemble and Assemble Tilt Cylinder Assembly1434
How to Assemble Tilt Cylinder Assembly1434
How to Assemble Tilt Cylinder Assembly1436
CAB Related Parts1437
Remove and Install Operator Seat1437
How to Remove Operator Seat1437
How to Install Operator Seat1439
How to Remove and Install Seat Belt1440
How to Remove Seat Belt1440
How to Install Seatbelt1441
Remove and Install Head Guard Assembly1442
How to Remove Head Guard Assembly1442
How to Install Head Guard Assembly1450
Remove and Install Operator Cab Assembly1458
How to Remove Operator Cab Assembly1458
How to Install Operator Cab Assembly1470
Electrical System1482
Remove and Install Pump Motor Assembly1482
How to Remove Pump Motor Assembly1482
How to Install Pump Motor Assembly1484
Remove and Install Battery Assembly (Head Guard Specification)1487
How to Remove Battery Assembly (Head Guard Specification)1489
How to Install Battery Assembly (Head Guard Specification)1493
Remove and Install Battery Assembly (Cab Specification)1495
How to Remove Battery Assembly (Cab Specification)1497
How to Install Battery Assembly (Cab Specification)1503
Remove and Install Charge Inlet Assembly (Head Guard Specification)1507
How to Remove Charge Inlet Assembly (Head Guard Specification)1507
How to Install Charge Inlet Assembly (Head Guard Specification)1509
Remove and Install Charge Inlet Assembly (Cab Specification)1511
How to Remove Charge Inlet Assembly (Cab Specification)1511
How to Install Charge Inlet Assembly (Cab Specification)1514
Disassemble and Assemble Charge Inlet Assembly1517
Disassemble Charge Inlet Assembly1517
How to Assemble Charge Inlet Assembly1519
Remove and Install BMS1521
How to Remove BMS1521
How to Install Blade Side Shift Cylinder1524
Remove and Install Master Controller1526
How to Remove Master Controller1526
How to Install Master Controller1530
Remove and Install Travel Inverter1534
How to Remove Travel Inverter1534
How to Install Travel Inverter1537
Remove and Install Pump Inverter1539
How to Remove Pump Inverter1539
How to Install Pump Inverter1542
Remove and Install Power Supply Controller1544
How to Remove Power Supply Controller1544
How to Install Power Supply Controller1547
Remove and Install Contactor1549
How to Remove Contactor1549
How to Install Contactor1552
Remove and Install Monitor Panel Assembly1554
How to Remove Monitor Panel Assembly1554
How to Install Monitor Panel Assembly1557
Remove and Install KOMTRAX Terminal1560
How to Remove KOMTRAX Terminal1560
How to Install KOMTRAX Terminal1562
Remove and Install Combination Switch Assembly1564
How to Remove Combination Switch Assembly1564
How to Install Combination Switch Assembly1567
60 Maintenance Standard1571
Table of Contents1572
Explanation of Terms for Maintenance Standard1573
Power Train1575
Maintenance Standard of Front Axle: FE25G-2 (Single Tire Specification)1575
Maintenance Standard of Front Axle: FE25G-2 (Double Tire and Wide Tire Specification)1577
Maintenance Standard of Front Axle: FE30G-21579
Maintenance Standard for Differential1581
Maintenance Standard of Final Drive: FE25G-2 (Single Tire Specification)1583
Maintenance Standard of Final Drive: FE25G-2 (Double Tire and Wide Tire Specification)1585
Maintenance Standard of Final Drive: FE30G-21587
Maintenance Standard for Travel Motor1589
Maintenance Standard for Pump Motor1591
Steering System1593
Maintenance Standard for Steering Cylinder1593
Brake System1594
Maintenance Standard for Brake Pipe1594
Maintenance Standard for Front Brake1595
Maintenance Standard for Parking Brake1596
Maintenance Standard for Brake Master Cylinder1597
Undercarriage and Frame1598
Maintenance Standard for Rear Axle1598
Maintenance Standard of Frame1600
Hydraulic System1601
Maintenance Standard for Hydraulic Tank1601
Maintenance Standard for Control Valve1602
Maintenance Standard of Tilt Cylinder1607
Maintenance Standard for Lift Cylinder1609
Work Equipment1611
Maintenance Standard of Mast1611
Maintenance Standard of Board1615
80 Others1619
Table of Contents1620
Precautions Before Work1621
Stationary Charger1622
Precautions for Stationary Charger1622
Structure and Operation of Stationary Charger1623
Structure of Stationary Charger1623
Specifications of Stationary Charger1624
Function of Stationary Charger1625
Input and Output Signals of Stationary Charger1625
Examine and Adjust Stationary Battery Charger1626
Clean and Replace Filter of Stationary Battery Charger1626
Individual Charge Battery1628
Set Breaker Capacity1630
Troubleshooting for Stationary Battery Charger1631
Related Information to Troubleshooting1631
Troubleshooting by Failure Code (Display of Code)1636
Disassemble and Assemble Stationary Charger1702
Remove and Install Power Supply Module Cooling Fan1702
Remove and Install Battery Charge Cable Assembly1705
Remove and Install Cable Gland1709
Remove and Install Contactor1712
Remove and Install Contactor Cooling Fan1714
Remove and Install EMC Filter1716
Remove and Install Fuse and Charge Relay1718
Remove and Install Liquid Crystal Panel, Lamps, and Switches1722
Remove and Install Cable Holder1730
Remove and Install Charge Plug Cap1732
Remove and Install Battery Charger Plug Unlock Pin1734
Remove and Install Charge Plug End1736
Heater System1742
PTC Heater Component Parts1742
System Diagram of Heater System1743
Function of Heater System1744
Operation of Heater System1745
Collision Detection System1746
Precautions for Collision Detection System1746
Structure and Operation of Collision Detection System1747
Layout Drawing of Collision Detection System1747
System Diagram of Collision Detection System1749
Function of Collision Detection System1750
Operation of Collision Detection System1750
Component Parts of Collision Detection System1755
Examine and Adjust Collision Detection System1762
Examine Fuse1762
Service Mode1762
Troubleshooting of Collision Detection System1769
Related Information to Troubleshooting1769
Troubleshooting by Failure Code (Display of Code)1782
Troubleshooting of Electrical System (E-Mode)1845
Disassemble and Assemble Collision Detection System1861
Remove and Install Collision Detection System (Head Guard Specification)1861
Remove and Install Collision Detection System (Cab Specification)1886
Yearly Inspection Criteria1923
Yearly Inspection Criteria: FE25G-2, FE30G-21923
90 Circuit Diagrams1943
Table of Contents1944
How to Read the Codes for Electric Cable1945
Hydraulic Circuit Diagram1949
Symbols Used in Hydraulic Circuit Diagram1949
Hydraulic Circuit Diagram1953
Hydraulic Circuit Diagram (at Right Turn)1955
Hydraulic Circuit Diagram (at Lift Raise)1957
Electrical Circuit Diagram1959
Symbols Used in Electric Circuit Diagram1959
Electrical Circuit Diagram (Head Guard Specification) (1/12)1963
Electrical Circuit Diagram (Head Guard Specification) (2/12)1965
Electrical Circuit Diagram (Head Guard Specification) (3/12)1967
Electrical Circuit Diagram (Head Guard Specification) (4/12)1969
Electrical Circuit Diagram (Head Guard Specification) (5/12)1971
Electrical Circuit Diagram (Head Guard Specification) (6/12)1973
Electrical Circuit Diagram (Head Guard Specification) (7/12)1975
Electrical Circuit Diagram (Head Guard Specification) (8/12)1977
Electrical Circuit Diagram (Head Guard Specification) (9/12)1979
Electrical Circuit Diagram (Head Guard Specification) (10/12)1981
Electrical Circuit Diagram (Head Guard Specification) (11/12)1983
Electrical Circuit Diagram (Head Guard Specification) (12/12)1985
Electrical Circuit Diagram (Cab Specification)(1/12)1987
Electrical Circuit Diagram (Cab Specification)(2/12)1989
Electrical Circuit Diagram (Cab Specification)(3/12)1991
Electrical Circuit Diagram (Cab Specification)(4/12)1993
Electrical Circuit Diagram (Cab Specification)(5/12)1995
Electrical Circuit Diagram (Cab Specification)(6/12)1997
Electrical Circuit Diagram (Cab Specification)(7/12)1999
Electrical Circuit Diagram (Cab Specification)(8/12)2001
Electrical Circuit Diagram (Cab Specification)(9/12)2003
Electrical Circuit Diagram (Cab Specification)(10/12)2005
Electrical Circuit Diagram (Cab Specification)(11/12)2007
Electrical Circuit Diagram (Cab Specification)(12/12)2009
Index2011

IMAGES PREVIEW OF THE MANUAL:

S.M 27/12/24