Komatsu Series 4032 (FB13M-2R, FB15-2R, FB15M-2R, FB16-2R, FB16M-2R, FB18-2R, FB18M-2R, FB20-2R, FB20M-2R) Forklift Truck Complete Workshop Service Repair Manual

Workshop literature Series 4032 FB13M-2R, FB15-2R, FB15M-2R, FB16-2R, FB16M-2R, FB18-2R, FB18M-2R, FB20-2R, FB20M-2R 40328042305 EN Edition 05/2008

Table of contents g 00 General Information Product information ................................................. 00-1 Instruction and maintenance manual ..................................... 00-1 General Forklift Description ............................................ 00-1 Definition of travel direction ............................................ 00-2 Overall dimensions for three-wheel truck .................................. 00-3 Three-wheel truck technical data ........................................ 00-4 Overall dimensions for four-wheel truck ................................... 00-8 Four-wheel truck technical data ......................................... 00-9 Three-wheel truck tyre characteristics ................................... 00-13 Four-wheel truck tyre characteristics .................................... 00-13 Fork lift truck capacities - Model 1300 kg 3 wheels - with vertical masts and forks = 1400 mm max. ......................................................... 00-14 Fork lift truck capacities - Model 1500 kg 3 / 4 wheels - with vertical masts and forks = 1400 mm max. ..................................................... 00-17 Fork lift truck capacities - Model 1600 kg 3 / 4 wheels - with vertical masts and forks = 1400 mm max. ..................................................... 00-20 Fork lift truck capacities - Model 1800 kg 3 / 4 wheels - with vertical masts and forks = 1400 mm max. ..................................................... 00-23 Fork lift truck capacities - Model 2000 kg 3 / 4 wheels - with vertical masts and forks = 1400 mm max. ..................................................... 00-26 Alternative lift characteristics .......................................... 00-29 Abbreviations key .................................................. 00-30 Tyre inflation pressure ............................................... 00-31 Lamps ........................................................... 00-31 Battery dimensions and weights ........................................ 00-31 Internal accessibility ................................................ 00-32 Safety features .................................................... 00-33 Transporting the Forklift .............................................. 00-35 Forklift towing ..................................................... 00-36 Loading and unloading the truck ........................................ 00-37 Safety precautions ................................................. 00-39 Description of safety symbols .......................................... 00-39 Operations Preliminary to Maintenance .................................. 00-39 To avoid accidents .................................................. 00-39 General safety Regulations ........................................... 00-40 Safety Regulations Relative to Operating Materials .......................... 00-42 Workshop literature – 40328042305 EN – 05/2008 I

Table of contents g 01 Service Servicing .......................................................... 01-1 Preliminary operations before commissioning ............................... 01-1 Synoptic Table of Maintenance Operations ................................. 01-1 Supply Table ....................................................... 01-2 02 Diagnostics Diagnostic software ................................................. 02-1 Connection between the diagnostics PC and the forklift ....................... 02-1 Software .......................................................... 02-2 Description of the menus in the WINPCCONSOLE software .................... 02-3 Description of the PARAMETER menu ................................... 02-7 Description of the TESTER menu ....................................... 02-12 TESTER / Diagnostics Function ........................................ 02-13 Parameters ....................................................... 02-16 Introduction ....................................................... 02-16 Parameters of the DUAL AC module ..................................... 02-16 Parameters of the AC2 FLASH module ................................... 02-22 ................................................................ 02-24 ................................................................ 02-25 Parameters of the ECO DISPLAY module ................................ 02-25 Parameterisation of the drive function .................................... 02-29 Parameterisation of the steering function ................................. 02-30 Parameterisation of the electric braking function ............................ 02-31 Parameterisation of the battery state monitoring function ...................... 02-32 Parameterisation of the lifting function ................................... 02-32 Parameterisation of the hydraulically assisted steering function ................. 02-33 Parameterisation of the tilt, side shift (SLI) and 4 th lever functions ............... 02-34 Alarms ........................................................... 02-35 State of the truck during an alarm situation ................................ 02-35 ................................................................ 02-35 ................................................................ 02-36 Alarms list ........................................................ 02-37 Analogue signals .................................................. 02-52 Summary of signals from the analogue transducers ......................... 02-52 II Workshop literature – 40328042305 EN – 05/2008

Table of contents g 11 Traction motor Asynchronous motors ............................................... 11-1 Features of the asynchronous motors .................................... 11-1 Checking the asynchronous motors ...................................... 11-3 Front axle motors ................................................... 11-4 Traction motor technical data ........................................... 11-4 Traction .......................................................... 11-4 Traction motor ...................................................... 11-6 Drive motor checks .................................................. 11-8 Drive motor decomposition ........................................... 11-10 Encoder ......................................................... 11-12 Replacing the traction encoder ......................................... 11-12 Electrical connections of the traction motors ............................... 11-13 Temperature sensor KTY84 ........................................... 11-14 Insulation testing of traction motor ...................................... 11-16 22 Transmission Front axle .......................................................... 22-1 Front axle technical data .............................................. 22-1 Removal of front axle with traction motors .................................. 22-4 Front axle reassembly ................................................ 22-7 Reducer ........................................................... 22-8 Front axle reducer gearbox topography ................................... 22-8 Front axle reduction gear disassembly/reassembly ........................... 22-9 Removal / reassembly of the drive wheel reducer gearbox ..................... 22-10 Check reducer gearbox oil level ........................................ 22-11 Reducer gearbox oil change .......................................... 22-12 31 Truck Counterweight ...................................................... 31-1 Counterweight removal ............................................... 31-1 Counterweight reassembly ............................................ 31-6 Covers ............................................................ 31-8 Cover topography ................................................... 31-8 Side covers removal / reassembly ....................................... 31-9 Battery cover removal / reassembly ..................................... 31-10 Step plate removal / reassembly ........................................ 31-12 Workshop literature – 40328042305 EN – 05/2008 III

Table of contents g Distributor cover removal / reassembly ................................... 31-14 Batteries .......................................................... 31-17 Battery removal .................................................... 31-17 34 Driver’s seat Overhead guard .................................................... 34-1 Removal of the overhead guard ......................................... 34-1 Reassembly of the overhead guard ...................................... 34-3 Fairings ............................................................ 34-4 Removal / reassembly of the steering column panelling ........................ 34-4 Removal / reassembly of the control panel panelling .......................... 34-5 42 Steering system Steering distributor .................................................. 42-1 Steering distributor technical data ....................................... 42-1 Removal / reassembly of the steering distributor ............................. 42-3 Steering distributor pressure switch technical data ........................... 42-5 Replacing the steering distributor pressure switch ............................ 42-6 Steering column .................................................... 42-7 Removal / reassembly of the steering column ............................... 42-7 Fifth-wheel steering axle ............................................ 42-11 Three-wheel truck rear axle technical data ................................ 42-11 Three-wheel truck axle removal ........................................ 42-14 Three-wheel truck axle reassembly ..................................... 42-17 Three-wheel axle disassembly ......................................... 42-19 Three-wheel truck potentiometer technical data ............................ 42-23 Replacement of the three-wheel steering axle potentiometer ................... 42-25 Four-wheel truck axle technical data ..................................... 42-26 Four-wheel axle removal ............................................. 42-27 Four-wheel truck axle reassembly ...................................... 42-28 Four-wheel axle disassembly .......................................... 42-30 Four-wheel truck potentiometer technical data ............................. 42-35 Replacing the four-wheel truck potentiometer .............................. 42-36 Lubricating the steering axle .......................................... 42-41 46 Wheels and tyres General information ................................................. 46-1 Safety regulations for wheels and rims .................................... 46-1 IV Workshop literature – 40328042305 EN – 05/2008

Table of contents g General information for changing tyres .................................... 46-1 Tyrewear check ..................................................... 46-3 Wheel change ...................................................... 46-4 Wheel change ...................................................... 46-4 Wheel decomposition ............................................... 46-7 Disassembly/assembly of tyres on rims with movable flange .................... 46-7 Quick tyres assembly/disassembly ....................................... 46-8 Tightening torques ................................................. 46-10 Check wheel nut tightness (every 10 hours during run-in) ..................... 46-10 49 Braking system Parking brake ...................................................... 49-1 Removal / reassembly of the parking brake lever ............................. 49-1 Parking brake control cable replacement .................................. 49-3 Replacing the parking brake microswitch .................................. 49-5 Parking brake adjustment ............................................. 49-7 Service brake ...................................................... 49-8 Service brake pedal removal ........................................... 49-8 Service brake pedal reassembly ......................................... 49-9 Stop lights microswitch replacement ..................................... 49-10 Replacing the service brake pedal potentiometer ........................... 49-10 Braking group ..................................................... 49-12 Removing / installing the brake group .................................... 49-12 50 Controls Accelerator pedal ................................................... 50-1 Accelerator pedal ................................................... 50-1 Accelerator pedal potentiometer ........................................ 50-1 56 Display elements DISPLAY .......................................................... 56-1 Plate data ......................................................... 56-1 Connector ......................................................... 56-1 Multifunction panel .................................................. 56-2 Setting the date and time .............................................. 56-8 Speed reductions .................................................. 56-12 Functionality of the display buttons ...................................... 56-13 Workshop literature – 40328042305 EN – 05/2008 V

Table of contents g Data modification pushbutton functions .................................. 56-15 Multifunction panel removal / reassembly ................................. 56-16 Alarms .......................................................... 56-17 60 Electronic system Software versions ................................................... 60-1 Reference software versions ........................................... 60-1 Electronic traction system ............................................ 60-2 Characteristics of the electronic drive system ............................... 60-2 Plate data: traction .................................................. 60-3 Connectors ........................................................ 60-3 Closing the general contactor ........................................... 60-6 Thermal sensor operation ............................................. 60-6 Hydraulic functions electronic system ................................. 60-7 Functions of the AC2 module ........................................... 60-7 Plate data: pump .................................................... 60-8 AC2 Connectors .................................................... 60-8 Control of the general contactor ......................................... 60-9 Lowering solenoid valve operation ...................................... 60-10 Thermal sensor operation ............................................ 60-10 Types of hours counters ............................................ 60-11 Types of hour counters: .............................................. 60-11 Hours counter management in case of electronic system replacement ........... 60-11 Resetting the machine hours .......................................... 60-12 Electrical system components ....................................... 60-13 Electronics panel technical data ........................................ 60-13 Electronics panel removal / reassembly .................................. 60-13 Protection of the electrical system ...................................... 60-18 Emergency pushbutton .............................................. 60-19 Replacing the emergency stop button .................................... 60-19 Assembly / disassembly of the lights switch (option) ......................... 60-20 Lamp replacement (if applicable) ....................................... 60-22 Work light replacement procedure (optional) ............................... 60-23 Contactors ....................................................... 60-24 Location of Fuses .................................................. 60-25 Changing a fuse ................................................... 60-26 DC/DC Converter .................................................. 60-27 VI Workshop literature – 40328042305 EN – 05/2008

Table of contents g Buzzer .......................................................... 60-28 Fans ............................................................ 60-28 Encoder description ................................................. 60-28 71 Hydraulic components Hydraulic circuit .................................................... 71-1 Layout of hydraulic parts .............................................. 71-1 Hydraulic system assembly diagram ..................................... 71-2 Pump motor ........................................................ 71-5 Pump motor technical data ............................................. 71-5 Pump motor removal ................................................. 71-6 Pump motor reassembly ............................................. 71-10 Replacing the pump ................................................. 71-11 Replacing the pump motor encoder ..................................... 71-13 Replacing the pump motor temperature sensor ............................. 71-14 Oil tank ........................................................... 71-15 Hydraulic oil tank ................................................... 71-15 Oil tank removal / reassembly ......................................... 71-16 Check hydraulic tank oil level .......................................... 71-19 Hydraulic distributor ................................................ 71-21 Hydraulic distributor technical data ...................................... 71-21 Hydraulic distributor removal / reassembly ................................ 71-22 Replacing the hydraulic distributor probe ................................. 71-25 Valves ............................................................ 71-26 Safety valve (load lowering block) (VBDC) ................................ 71-26 Safety valve layout ................................................. 71-27 Tilt cylinders ....................................................... 71-33 Tilt cylinders ...................................................... 71-33 Tilt cylinder removal / reassembly ....................................... 71-33 Air bleeding of the tilt cylinders ......................................... 71-36 80 Lifts Lifts ............................................................... 80-1 Technical data for service ............................................. 80-1 Lift typologies ...................................................... 80-2 Simplex Lift ........................................................ 80-5 Duplex Lift ......................................................... 80-9 Workshop literature – 40328042305 EN – 05/2008 VII

Table of contents g Triplex Lift ........................................................ 80-14 Load chain locking device ............................................ 80-20 Fork carriage retaining device ......................................... 80-20 Assembly of the mast / carriage support rollers ............................. 80-20 Check ........................................................... 80-22 Disassembly of the Simplex lift cylinder .................................. 80-23 Disassembly of the side cylinders of the Duplex lift .......................... 80-24 Disassembly of the side cylinders of the Triplex lift ........................... 80-26 Duplex / Triplex central cylinder ........................................ 80-28 Limit stop dampers ................................................. 80-30 Disassembly of the fork carriage ........................................ 80-31 Tilt cylinder ....................................................... 80-32 Lift disconnection .................................................. 80-34 Lift reassembly .................................................... 80-37 Air bleeding of the lift cylinders ......................................... 80-38 Lift cylinders ...................................................... 80-40 Annex A Diagrams Wiring diagrams ..................................................... A-1 Electrical circuit diagram 40328020002 .................................... A-1 Electrical connection diagram 40328020001 ................................ A-3 Hydraulic diagrams .................................................. A-5 Hydraulic diagram 40328082502 ......................................... A-5 VIII Workshop literature – 40328042305 EN – 05/2008

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Komatsu Series 4032 (FB13M-2R, FB15-2R, FB15M-2R, FB16-2R, FB16M-2R, FB18-2R, FB18M-2R, FB20-2R, FB20M-2R) Forklift Truck Complete Workshop Service Repair Manual

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