Model:
FBRJ-2R Series Forklift Trucks
Covered Models:
FB12RJ-2R, FB14RJ-2R, FB16RJ-2R, FB20RJ-2R
Controller Codes:
References specific controller codes like FPS A10, LAS 8U61, and converters 1U6/2U3, which are critical for identification and service.
Market Segment:
Electric forklift trucks for material handling in various industrial and commercial environments.
Target Application:
Designed for demanding industrial applications requiring reliable and efficient material handling solutions, from warehousing and manufacturing to logistics.
Target Audience:
Owner-operators, maintenance technicians, service departments requiring in-depth knowledge of Komatsu FBRJ-2R series forklifts.
Repair Philosophy:
Emphasizes 'step-by-step instruction' with 'highly detailed exploded pictures & diagrams' to ensure correct and efficient repair execution.
Manual Benefit:
Cost-effective solution for maintaining optimal performance, ensuring longevity, and minimizing downtime.
Industry Context:
Competes with electric forklift models from manufacturers like Toyota, Mitsubishi, Hyster, and Yale, emphasizing efficiency, operator comfort, and advanced electronic control.
Coverage Areas:
Complete factory service, repair, and workshop procedures
Completeness:
The manual is described as 'complete' and covering 'every single detail on your machine,' signifying its comprehensive nature.
Estimated Page Count:
A comprehensive manual of this nature typically exceeds 500 pages, though an exact figure is not provided. The depth of coverage suggests a substantial document.
Systems Covered:
Drive motor, drive wheel, gear system, electro-magnetic parking brake, generator service brake, hydraulic/mechanical service brake, steering system, electrical components, travel and pump controller (FPS A10), load handling controls module (LAS 8U61), converters (1U6/2U3), display (8A5), CAN bus, supply and emergency-stop circuit, single-lever potentiometers (2R9-2R13), inductive proximity switches, travel transducer (1U20), DC/DC converter (U30), height measuring system (8B21), foot pedal adjustment, hydraulic functions, chassis valve block, reach carriage valve block, additional hydraulics valve block, line break protection, lowering brake valve, load holding valve, hydraulic pump, tank indicator, tank, runback filter, lubrication plan, service software, error codes, Winflash, height preselection.
Hydraulic Systems:
Extensive coverage of hydraulic systems, including valve blocks (chassis, reach carriage, additional hydraulics), line break protection, lowering brake valve, load holding valve, hydraulic pump, and tank components.
Braking System Details:
Comprehensive coverage of all braking systems, including the electro-magnetic parking brake, regenerative braking (generator service brake), and conventional hydraulic/mechanical service brakes, with specific diagnostic and repair procedures.
Procedures Included:
Complete disassembly and reassembly, maintenance, troubleshooting, repair, component replacement, system diagnostics, electrical schematics, hydraulic diagrams.
Electrical Repair:
Detailed guidance for electrical component troubleshooting and repair, including a specific chapter on 'Guide to the electrical components'.
Technical Depth:
Comprehensive, detailed step-by-step instructions, exploded views, diagrams, and photos suitable for both DIY users and experienced mechanics.
Diagram Quality:
High-quality diagrams and exploded pictures are explicitly mentioned, critical for visual understanding of complex assemblies and procedures.
File Quality:
High-quality diagrams and text, searchable PDF for efficient information retrieval.
Search Functionality:
The PDF format enables the use of Acrobat's search feature, allowing users to quickly locate specific terms, part numbers, or procedures.
Digital Advantages:
Offers space savings and the ability to print only necessary sections, making it more convenient and eco-friendly than traditional printed manuals.
Print Usability:
Printable pages (individual or entire manual) for hands-on use.
Content Organization:
Numbered table of contents for quick navigation, clear chapter breakdowns.
Power Source:
Electric (Battery-powered)
Primary Drive Components:
AC drive motors (details specific to each model within manual)
Control Modules:
Features specialized control modules such as the Travel and Pump Controller (FPS A10) and Load Handling Controls Module (LAS 8U61) for optimized electric powertrain and hydraulic operation.
Power Conversion:
Includes coverage of DC/DC converters (U30), essential for managing power distribution within the electric forklift's systems.
Drive Transducer:
Chapter 20 covers the 'Travel transducer 1U20', essential for accurate speed and travel control of the forklift.
Lifting Capacity:
Nominal capacities ranging from 1200 kg to 2000 kg (1.2 to 2.0 metric tons) based on model designations (FB12RJ, FB14RJ, FB16RJ, FB20RJ).
Mast Configurations:
Various mast options (e.g., Duplex, Triplex) with different lift heights and collapsed heights will be detailed in the manual.
Operational Weight:
While specific weights are not provided in the product description, the manual will contain detailed information on vehicle weight, battery weight, and load capacities crucial for safe operation and transport.
Braking Systems Covered:
Electro-magnetic parking brake, generator service brake (regenerative), hydraulic/mechanical service brake.
Electrical Safety Features:
Supply and emergency-stop circuit, DC/DC converter for power management.
Programmable Logic:
Features advanced electronic control systems like the Travel and Pump Controller (FPS A10) and Load Handling Controls Module (LAS 8U61), providing precise operational control and efficiency.
Data Bus:
Utilizes CAN bus (Chapter 15) for efficient and reliable communication between various control modules and components.
Display Unit:
Includes a display unit (Chapter 14) for providing operational status, error messages, and potentially diagnostic information to the operator.
Height Control:
Includes a 'Height measuring system' (Chapter 22) and 'Height preselection' (Chapter 41), indicating advanced features for precise load positioning.
Service Software:
Chapter 38 covers 'Service Software' and Chapter 40 covers 'Winflash', indicating advanced diagnostic and firmware update capabilities.
Control Elements:
Features like single-lever potentiometers (Chapter 18) and foot pedal adjustments (Chapter 23) for fine-tuning operator input and ergonomics.
Potentiometer Types:
Details specific potentiometer part numbers (2R9-2R13) used for throttle or hydraulic control inputs, allowing for precise part replacement.
Operator Display:
The 'Display 8A5' component suggests an integrated information display for the operator, likely providing crucial operational data.
Lubrication Plan:
Detailed lubrication plan is included in Chapter 37, essential for maintaining component longevity and performance.
Routine Maintenance:
The manual will detail scheduled maintenance tasks, including inspections, adjustments, and component replacements at specified operating hours or time intervals.
Hydraulic Fluid:
Specific hydraulic fluid types, viscosity grades, and capacities will be specified in the manual, crucial for the hydraulic system's correct operation.
Lubricant Types:
The lubrication plan will specify appropriate greases and oils for various moving parts, critical for preventing wear and ensuring smooth operation.
Troubleshooting Guide:
Chapter 39 on 'Error Codes' and the comprehensive troubleshooting procedures throughout the manual are vital for identifying and resolving common operational issues.
Diagnostic Tools:
The inclusion of 'Service Software' and 'Winflash' implies the need for, and detailed instructions on using, specialized diagnostic tools for advanced troubleshooting and software updates.
Battery Service:
While not explicitly listed as a chapter, battery care, charging, and maintenance are critical for electric forklifts and would typically be covered under general maintenance or electrical system sections.
Manufacturer:
Komatsu, a globally recognized manufacturer of construction, mining, and industrial equipment, known for robust and reliable machinery.
Product Type:
Represents Komatsu's electric counterbalance forklift truck line, designed for efficiency and maneuverability.
Technological Advancements:
The '2R' designation and the detailed coverage of electronic control modules, CAN bus, and advanced sensors indicate a model series incorporating modern forklift technology.
