Introduction, Service Manual - Komatsu Forklift USA, Inc. v3.1
Contents
1. Inc Master Service Manual 2000 08 04 31 Komatsu Forklift U S A Inc F code Section C code M1 0 General Product Information Version no T code 001 395 396 397 398 399 General Product Information 1 Presentation of the Rider Trucks The FR18S 23S 2A are battery powered reach trucks The FR15DR 2A is a battery powered deep reach truck These trucks are intended solely to be operated handling pallets or similar load carriers indoors The trucks are equipped with a steering wheel with all the controls for operating within easy access The trucks have various maximum lifting capacities review data plate on the truck to note the maximum lifting capacity and are equipped with a 24V or 36V electrical system Speed of the truck is regulated by means of a transistor controller to provide infinite control of acceleration and speed while driving The forks and auxiliary functions are controlled by means of a transistor controller Control of the lift and auxiliary functions are done electrically with the levers on the control pod Control of the speed and positioning of the forks when stacking is done by the position of the levers The trucks can be fitted with different accessories including sideshifter warning light lights fan package travel alarm and adjustable driving lights The trucks can be specially equipped to work in cold conditions 1 1 Truck Side Views The terms rearward and forward used indicate2. A Shank diameter C Type of thread D Shank length B Number of threads per unit of length B A Thread size Pitch C Length Master Service Manual 2002 01 16 F code Section C code M1 1 K Inch SAE and Metric Fasteners Version no T code 002 3 Strength Identification The most common property classes for metric fasteners are 8 8 and 10 9 The property class is marked with a number on the head of the cap screw or on a nut Property classes less then 8 8 are often not marked Grades for inch bolts go from 2 to 8 Grade 2 fasteners normally do not have marks The following tables show the marks that identify the grades and property classes for different fasteners Komatsu Forklift U S A Inc Master Service Manual 2002 01 16 47 F code Section C code M1 1 Inch SAE and Metric Fasteners Version no T code 002 Table 1 Bolt and Screw Designations Types of Inch Fasteners Metric Fasteners Strength Levels SAE Grades Strength Levels Property Classes Fasteners 7 Markings Not Required 4 6 4 8 5 8 8 8 as PTT POOT N q q Ce Sn LA D nu Ye 7 10 9 amp Cap Screws cm Hex Head Flange Screws Da Same As Above 9 8 12 9 PFTS PTS P Markings for size Hex Head Bolts a ay Je3 M5 and Larger 12 Point Flange Screws Ca HATE PLT H Hex Socket Head Cap Screws 5 1 a Markings Not Required 48 Master Service Manual 2002 0
3. meter 3 280 feet ft yards 0 914 meters m meter 1 094 yards yd miles 1 609 kilometers km kilometer 0 621 miles mi ie 2e MASS Multiply By ToGe Multiply By ToGet ounces oz 2849 grams g grams 0 035 ounces 0z l pounds Ib 0 454 kilograms kg kilograms 2 205 pounds Ib fons 2000 Ib 907 18 kilograms kg kilograms 0 001 tons 2000 lb tons 2000 Ib 0 907 metric ton t metricton 1 102 tons 2000 ib POWER Multiply By p To Get Multiply By To Get horsepower 0 746 kilowatts KW kilowatts 1 34 horse power hp PRESSURE Multiply By To Get Multiply By To Get pounds in 6 895 kilopascal kPa kilopascals 0 145 pounds in psi pounds in 0007 megapascal MPa megapascals 145 04 pounds in psi Komatsu Forklift U S A Inc Master Service Manual 2002 01 16 55 F code Section C code M1 1 Inch SAE and Metric Fasteners Version no T code 002 TEMPERATURE Multiply To Get Multiply By To Get Fahrenheit 0 56 Celsius C Celsius x Fahrenheit 32 1 8 F TORQUE Multiply By ToGet Multiply By To Get inch pound 0 113 Newton meter Newton 8 851 inch pounds Nem meter in 1b feet pound 1 356 Newton meter _ Newton 0 738 foot pounds Nem meter ft ib VELOCITY Multiply By To Get Multiply B
4. 2065 2323 3250 3700 2397 2729 Property class 8 8 Protective Treatment CMHC Specification H zinc phosphate applies also to internally threaded fasteners made of property class 8 material Property class 10 9 Protective Treatment CMHC Specification H zinc phosphate applies also to internally threaded fasteners made of property class 10 material Property class 12 9 Protective Treatment CMHC Specification H zinc phosphate applies also to internally threaded fasteners of property class 12 material 52 Master Service Manual 2002 01 16 KOMATSU Truck Torque Specifications F code Section C code M1 1 Inch SAE and Metric Fasteners Version no T code 002 Description Torque Specification Steering motor gear mounting bolt Motor terminals Motor pole piece screws Pump motor mounting bolts 88 in ib 10 Nem 140 in Ib 15 82 Nem 250 300 in Ib 28 33 Nem 14 18 ft lb 19 24 Nem Pump motor electrical power cable nuts 100 120 in lb 11 3 13 6 Nem Drive motor mounting bolts Transmission mounting bolts 50 59 ft lb 68 80 Nem 20 25 ft lb 30 35 Nem Drive wheel nuts Overhead guard mounting bolts Drive axle retaining bolts fa ne 200 ft lb 271 Nem 65 ft lb 88 Nem 81 ft lb 109 Nem Steering gear ring bolts 50 59 ft lb 6
5. Nem Mast mounting plate bolts Sideshifter lower hook bolts Sideshifter lower hook set screw FR18S 2A S N 27091 000 28075000 FR23S 2A S N 2709 1000 28266000 FR15DR 2A S N 27091000 28266000 85 ft lb 115 Nem 55 ft lb 74 Nem 42 ft lb 57 Nem Sideshifter lower hook bolts Sideshifter lower hook set screw Sideshifter safety screw Sideshifter cylinder hydraulic fittings FR18S 2A S N 28075001 UP FR23S 2A S N 28266001 UP FR15DR 2A S N 28266001 UP Reach outer arm jam nut FR18S 2A E 65 ft lb 88 Nem 21 ft lb 28 Nem 70 ft lb 95 Nem 56 ft lb 76 Nem Noe Ne Su out mn 34 36 ft lb 47 Nem Loctite 243 Reach outer arm jam nut FR18S 23S 2A FR15DR 2A Loctite 243 54 Master Service Manual 2002 01 16 F code Section C code M1 1 KOMATSU Inch SAE and Metric Fasteners Version no T code 002 4 Conversion of Metric and English Units a AREA i Multiply By ToGe Multiply By To Get inches 6 451 centimeters cm centimeters 0 155 inches in meters m meters 10 764 feet ff i _ LINEAR Multiply By ToGet Multiply By ToGet inches 25 4 millimeters mm millimeter 0 039 inches in feet 7 0 305 meters m
6. metric system used is described as SI International System of Units also called SI in all languages The SI system of measurement is described in ISO Standard 1000 1973 Komatsu Forklift U S A Inc Master Service Manual 2002 01 16 45 F code Section C code Inch SAE and Metric Fasteners Version no 002 46 T code o 13 THREAD oa METRIC 2 Nomenclature Threads The thread design is specified by a series of numbers and letters for inch and metric fasteners see figure below The diameter of the shank of the fastener is shown first in the series e g M12 12 mm M20 20 mm 1 2 1 2 inch 3 4 3 4 inch 1 0 inch 7 x 13 UNC THREAD DIA x NO OF THREADS PER INCH 1 15 M12 x 1 75 mm THREAD iw mm DIA x THREAD PITCH mm mm The number of threads per inch is normally not shown for inch nomenclature and only the UNC Unified National Coarse or UNF Unified National Fine is shown This number of threads per inch is not shown because a UNC or UNF fastener has a standard number of threads per inch for a specific diameter The length of a shank is often indicated as part of the description of a fastener This length is shown in inches for inch fasteners and in millimeters for metric fasteners A cap screw will have the following description Inch Metric 1 2 x 13 UNC x 1 1 2 M12 x 1 75 x 50 A B D A B C
7. the front and back side of the truck as viewed from the operator s line of sight for proper operation of truck The terms right hand and left hand used indicate the right and left side of the truck as viewed from the operator s line of sight for proper operation of truck Left Side Rearward Forward Right Slde Master Service Manual 2000 08 04 33 F code Section C code M1 0 General Product Information Version no T code 001 395 396 397 398 399 34 1 2 Open Back Compartment The truck compartment has an open back design The United States Department of Labor Occupational Safety and Health Administration OSHA has determined that when a stand up narrow aisle lift truck tips over the operator should be trained to step off the truck The open back design allows the operator to make the quickest exit from the truck should the truck begin to tip over or fall from an elevated height such as a loading dock or ramp The ease of entering and exiting the open back design also minimizes operator fatigue 4 hs y LA y Open back compartment 1 3 Intended Truck Application Gr The trucks are solely designed and manufactured to handle goods The trucks should be fitted with the appropriate accessories relevant to the application Master Service Manual 2000 08 04 F code Section C code M1 0 K General Product Information Version no T code 001 395 396 397 398 3
8. to provide access for servicing Pedal Brake pedal 10 Control console 11 The control console can be adjusted to a suitable height and angle to obtain a comfortable working position The steering hydraulic functions horn parking brake preset height travel direction key switch and any extra hydraulic functions are all controlled from this console The position of the console may be set in 1 of 3 positions forward facing 45 degrees or side stance Instrument panel This provides information on the truck s running hours time display error codes travel direction parking brake steering angle and battery status 12 Mast The mast is a clear view model Master Service Manual 2000 08 04 KOMATSU Komatsu Forklift U S A Inc F code Section C code M1 0 General Product Information Version no T code 001 395 396 397 398 399 13 Electronics The electronics are in a protected compartment 14 Control circuit fuse for fuse size and part number see page 59 15 Steering circuit fuse for fuse size and part number see page 59 16 Drive motor fuse for fuse size and part number see page 59 17 Pump motor fuse for fuse size and part number see page 59 18 Right foot pedal An operator must keep all of his or her body in the operator s compartment at all times The area of the operator s compartment in the truck is designed so that an operator can do so A red triangle reminder light will b
9. 1 16 KOMATSU Types of Fasteners F code Section C code M1 1 Inch SAE and Metric Fasteners Version no T code 002 Table 2 Stud and Nut Designations Inch Fasteners Strength Levels SAE Grades Markings Not Required Metric Fasteners Strength Levels Property Classes Markings Not Required 2 O PE UD Hex Nuts 5 OOO TT oes HEE Hex Slotted Nuts Markings Not Required JASNA Hex Flange Nuts Komatsu Forklift U S A Inc Markings Not Required Master Service Manual Toa 8 9 10 12 4 6 4 8 5 8 TE 9 8 2 for size for size M5 and ge or Optional Geometric Symbols for Size M5 through M11 ONLY 5 A 9 CE ED CD CSD D D 5 8 9 10 12 2002 01 16 49 C code F code Section M1 1 Inch SAE and Metric Fasteners Version no T code 002 Types of Fasteners Table 3 Torque Nut Designations Inch Fasteners Strength Levels SAE Grades TT All Metal Prevailing Torque Nuts B A C TD D CD r e TA Metric Fasteners Strength Levels Property Classes SRN All Metal Pre vailing Torque Flange Nuts 50 ER ER Master Service Manual 2002 01 16 KOMATSU Types of Fasteners F code Section C code M1 1 Inch SAE and Metric Fasteners Version no T code 002 Table 4 Torque Nut with Nylon Insert Design
10. 8 80 Nem Steer motor shaft Loctite 243 Drive tire lug nut 95 ft lb 129 Nem Transmission axle bearing preload 9 14 in Ib 1 01 1 58 Nem Transmission bevel gear nut 90 ft lb 122 Nem Transmission pinion nut 410 120 ft lb 149 162 Nem Transmission pinion bearing preload 5 8 in lb 0 56 0 90 Nem Transmission cover bolts 48 ft lb 24 Nem Transmission case Loctite 515 Hydraulic collar mounting bolts 4 ___ 44 4 in lb 5 01 Nem Tilt cylinder piston nut FR23S 2A FR15DR 2A 60 65 ft lb 81 88 Nem Lift chain adjusting nuts and locknuts 200 ft lb 271 Nem Control valve assembly hose fastener nut Control valve double solenoid screw and mounting screw Control valve plug Control valve block screw Control valve spring ball screw L 480 25 in Ib 54 Nem 14 75 ft lb 20 Nem 11 06 ft lb 15 Nem 5 9 ft lb 8 Nem 8 85 ft lb 12 Nem Komatsu Forklift U S A Inc Master Service Manual 2002 01 16 53 F code Section C code M1 1 Inch SAE and Metric Fasteners Version no T code 002 l Truck Torque Specifications Description Torque Specification lk Lower mast mounting bolts Overhead guard post base bolts 400 ft lb 543 Nem 25 ft lb 34 Nem Reach cylinder piston locknut FR18S 23S 2A FR15DR 2A 47 94 ft lb 65
11. 99 1 4 Prohibited Truck Application The trucks are designed for handling goods indoors It is not permitted to use the trucks for other purposes including the following e As a towing tractor for trailers e To tow other trucks e To transport lift passengers e To drive on gravel or grass 1 5 Truck Data The following table provides information regarding some technical data which is of value with daily use of the trucks i T Truck FR18S 2A FR23S 2A FR15DR 2A data Lifting capacity ci rated load 3500 4500 3000 Ib kg 1587 2041 1360 Lift height 192 270 210 402 210 402 inches mm 4876 6858 5334 10210 5334 10210 Operating K es speed without 36 He 36 Volt 36 Volt load mph 6 5 mph 6 5 mph 6 5 mph enemy j 24 Volt Re i Operating 5 5 moh speed with eile 36Volt 36 Volt load mph soo 6 0mph 6 0mph JEEE 6 0 mph HNR e p Service weight 240 Mast 210 Mast 330 Mast without battery 5595 5915 6945 Ib kg 2537 2682 l 3150 Service weight Above Above including battery es nn battery weight battery Ib kg weight 2600 min l 2 cee ease The lifting capacity lifting height and weight of the truck can be found on the truck data plate Komatsu Forklift U S A Inc Master Service Manual 2000 08 04 35 F code Section C code M1 0 General Product Information Version no T code 001 395 396 397 398 3
12. 99 1 6 FR18S 2A Dimensions The following diagram shows external dimensions for the FR18S 2A truck in its standard design q ji a Oo 3 3 16 0 s De 32 0 812 mm 71 78 44 mm Ge mm to x 4 0 101 mm 50 0 1270 mm Forks 30 36 42 44 48 29 5 749 mm 3 Iv 4 5 5 139 mm 7 enr i 1833 mm B 5 7 144 mm 23 0 584 mm y 48 0 1219 mm 95 0 2413 mm OALH Free Lift Height 5 0 127 mm a 57 45 sr 1459 mm 231 mm 10 Gradient Performance Loaded 36 Master Service Manual 2000 08 04 F code Section C code M1 0 K General Product Information Version no T code 001 395 396 397 398 399 1 7 FR23S 2A Dimensions The following diagram shows external dimensions for the FR23S 2A truck in its standard design NRG 85 5 5 139 mm 40 5 8 0 er 1028 mm 1 75 44 mm 203 mm mm 31 x 4 0 101 mm to Eoo 29 5 42 44 48 Forks 30 36 749 mm 1270 mm 5 5 mm 7 6 193 mm A 45 5 jat w 22 0 558 mm 48 0 121 95 0 2413 mm ta 11 5 OALH Step Height 3 Ge a Free Lift Battery y Roller 7 0 177 mm Height 5 0 127 mm 1524mm 10 Gradi
13. KOMATSU Komatsu Forklift U S A Inc F code Section C code Introduction Service Manual Version no T code 395 396 397 398 399 Introduction Service Manual The information in this Service Manual covers models FR18S 23S 2A and FR15DR 2A Federal and State laws require that operators be completely trained in the safe operation of trucks in accordance with OSHA regulation 1910 178 An Operator s Manual is sent with every Komatsu forklift truck when it is manufactured If the Operator s Manual is missing from the truck a new manual may be obtained by contacting Komatsu Forklift U S A Inc 14481 Lochridge Blvd Bldg 2 Covington Georgia 300014 770 788 3612 This Service Manual is not a training manual The information contained in this service manual is intended as a guide to help trained qualified and authorized technicians safely service the truck The Service Manual is divided into four separate sections which cover needed information for servicing the truck types The main subject for each of the sections are as described below SECTION SUBJECT M MACHINE INFORMATION P PLANNED MAINTENANCE S SERVICE INSTRUCTIONS O OPTIONS Master Service Manual 2000 08 04 29 F code Section C code K Contents Section M Version no 001 T code Contents Section M 1 Machine Information M1 0 GENERAL PRODUCT INFORMATION M2 0 TECHNICAL SERVICE DATA M3 0 ORDERING SPARE PARTS Komatsu Forklift U S A
14. ations Inch Fasteners Strength Levels SAE Grades TD Nylon Insert Pre vailing Torque Nuts Markings Not Required En Nylon Insert Pre vailing Torque Flange Nuts Komatsu Forklift U S A Inc Markings Not Required Metric Fasteners Strength Levels Property Classes Master Service Manual 2002 01 16 51 F code Section C code M1 1 Inch SAE and Metric Fasteners Version no T code 002 Table 5 Fastener Torque Values Property Class Property Class Property Class Size and Pitch 8 8 10 9 12 9 agra ss ni AR ET FE Nem in lb Nem in Ib Nem F ALINE TARET oo ca M5 x 0 8 5 6 44 53 7 8 62 71 8 10 71 88 M6 x 1 8 10 71 88 12 14 106 124 14 16 124 142 M8 x 1 25 20 25 177 221 30 35 ee 4 8 3 A sus SR Se ee ss Nem ft lb Nem ft lb Nem ft lb ee pe M8 x 1 25 nent ern eee 22 26 34 40 26 30 M10 x 1 5 40 45 30 33 60 65 44 48 70 75 52 55 M12 x 1 75 70 80 30 33 100 110 74 81 115 130 85 96 M14 x2 110 125 52 59 155 180 114 133 180 210 133 155 ns est L ste M16 x 2 170 190 125 140 240 270 177 199 280 320 207 236 M20 x 2 5 340 380 251 280 450 500 332 369 550 600 406 443 ARE is mee M24 x 3 580 650 428 479 800 900 590 664 900 1050 664 774 x M30 x 3 5 1150 1300 848 959 1600 1800 1180 1328 1850 2100 1364 1549 M36 x 4 2000 2250 1479 1660 2800 3150
15. e displayed on the instrument panel if the right foot pedal is not depressed This feature reinforces that the operator must take advantage of the area of the operator s compartment and keep all of his or her body in the compartment 19 Emergency stop The emergency stop switch will stop all control and power functions Master Service Manual 2000 08 04 43 F code Section C code M1 0 General Product Information Version no T code 395 396 397 398 399 Main Components of Truck 44 Master Service Manual 2000 08 04 F code Section C code M1 1 K Inch SAE and Metric Fasteners Version no T code 002 Inch a and Metric Fasteners tt cl 1 Introduction Threaded fasteners such as bolts nuts cap screws and studs are made to specifications that describe the mechanical strength and hardness of the fastener A fastener used in a design application is selected in accordance with its specifications Parts used on this truck are purchased from many countries Many of these fasteners are similar but cannot be used as direct replacements Service persons must use replacement fasteners that have the same specifications Fasteners made to each specification have identification marks for that specification This specification is commonly called grade for SAE standards and property for metric standards This section describes the identification of some common fasteners The
16. ent Performance Loaded 37 Komatsu Forklift U S A Inc Master Service Manual 2000 08 04 F code Section C code General Product Information Version no T code 001 395 396 397 398 399 1 8 FR15DR 2A Dimensions The following diagram shows external dimensions for the FR15DR 2A truck in its standard design 8 5 215 mm to J 29 5 749 mm Us PS nn ne Nr eur f 5 5 139 mm 40 5 4 75 44 mm 32 0 812 MM 1028 mm 31 0 x 4 0 101 mm nie AU bes Forks 30 36 42 44 48 30 0 1270mm amp x aa cs Je 5 5 139 mm et 74 6 A 1894 mm 46 0 53 4 1356 mm Max Reach 1168 mm A 13 3 337 mm f 2 2e il B EE 39 7 1008 mm A _ __Max Stroke 48 0 95 0 2413 mm 11 5 292 mm Step 7 0 Height 177 mm Battery a ae Roller i Height 2 0 50 mm 1 t 60 0 231 mm 1524 mm 10 Gradient Performance Loaded 38 Master Service Manual 2000 08 04 F code Section C code M1 0 General Product Information Version no T code 001 395 396 397 398 399 1 11 Data Plate The illustration below shows the data plate used on the truck TT rs i ri Model Serial Number Cop Lbs A B Cc CoS co i o ru Truck Wr Less Bott Lbs Battery Wi Mox Lbs Battery Wiy Min Lbs Use UL Class i DC Vottaga Battery Type Max Amp Hours
17. momma he f oJ OO ery Truck as ruted at factory conforms to requirements of Port IN of ASME 8561 1993 306040 070 Le ee Legend Truck model number Truck serial number Weight less battery Maximum battery weight Minimum battery weight Truck voltage DC Battery type UL class Battery maximum AMP hours Truck type 10 Mast serial number 11 Attachment 12 Maximum degree rear tilt 13 Truck capacity J O O1 BB ND Komatsu Forklift U S A Inc Master Service Manual 2000 08 04 41 F code Section C code General Product Information Version no 001 42 T code 395 396 397 398 399 2 1 Main Components Hydraulic valve The valves are located to provide easy access Battery 24 36V with different capacities and weights Battery connector The truck is connected to the battery through the battery connector When charging the battery do not connect the battery charger to the battery connector at the truck chassis Hydraulic unit Pump motor and hydraulic pump are an integrated unit Drive unit with brake Drive motor gears drive wheel and electrical brake combined in the drive unit Electrical steering A servo steer motor drives a gear ring enabling the drive unit to be rotated through 360 degrees in either direction Data plate See Data Plate on page 41 Cover Removable
18. y miles hour 1 609 kilometer hour kilometer 0 621 km h hour VOLUME Multiply By ToGet Multiply By To Get inches 16 387 centimeters cm centimeters 0 061 inches in inches 0 016 liters liters 61 024 inches in quarts U S 0 946 lites liters 1 057 quarts U S qt quarts U S 0 83 quarts Imp qt quarts Imp 1 205 quarts US qt 3 gallons U S 3 785 liters liters gallons U S a gal gallons US 0 83 gallons Imp gal gallons Imp 1 205 gallons U S gal ounces 29 57 milliliters ml milliliters 0 034 ounces oz 56 Master Service Manual 2002 01 16
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