Safe running across every shift on a Komatsu FB15U-12, FB18U-12 or FB20AU-12 electric lift truck is what the 185 pages of operator manual TEN00718-02 are written to secure. Inspection and maintenance takes up roughly a quarter of the book: the walk-around and seat-side start-up checks, the inspection and maintenance schedule chart, lubricant list, alarm and error code procedures, battery charging and replacement, and what to do when the forks fail to lower. Your operators also get the meter panel explained indicator by indicator, the travel and lift interlocks, inching and plugging, plus load center and stability guidance tied to the serial-number load table. Set brake pedal height at 105 mm (4.1 in) with 0 to 4 mm of play, and charge the battery only between 0°C and 40°C (32°F to 104°F). On a late shift it is just you and the truck, with nobody to ask. The bookmarked, text-searchable PDF is bought once and stays yours for this machine.
What's Inside This Komatsu FB15U-12, FB18U-12, FB20AU-12 Operator Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 14-61 | Safety Label (Location Chart, Safety Labels) |
| Operation | 62-99 | Start-Up Inspection, Mounting/Dismounting and Operating Posture Adjustment, Basic Operation, Starting, Traveling, Shifting Direction, Turning, Stopping |
| Inspection and Maintenance | 100-151 | Start-Up Inspection (Checking Abnormalities Detected on the Previous Day, Walk Around a Lift Truck, Inspection Conducted by Opening Cover and Hood, Checking From the Operator Seat, Checking by Setting the Starting Switch to [ | ] Position, Checking While Running the Lift Truck, Checking of Safety Function) |
| Technical Data | 152-153 | Axle Loading, Tire Specifications, Mast Dimensions, Travel Speed, Battery Specifications, Hydraulic System Pressure |
| Attachment | 154-167 | Operation of Side Shift (Attachment Model Plate Location, Serial No., Safety of Attachements) |
| Options | 168-181 | Operation of Automatic Fork Level Stop Function |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Ambient temperature for charging | 0°C - 40°C (32°F - 104°F) | p. 25 |
| Play | 0 - 4 mm {0 - 0.2 in} | p. 109 |
| Pedal height | 105 mm {4.1 in} | p. 109 |
| Travel interlock warning lamp activation delay | 3 seconds | p. 114 |
| Lift interlock warning lamp activation delay | 1 second | p. 114 |
| Fuse 1 Capacity | 2A | p. 125 |
| Fuse 2 Capacity | 10A | p. 125 |
| Tightening torque for hub nuts | 157 - 245 Nm | p. 149 |
| Tightening torque for mast mount bolts | 343 - 427 Nm | p. 143 |
| FB15U/18U/20AU-12 | ||
| Battery Weight | 935 kg {2062 lb} | p. 137 |
| FB15U-12 | ||
| Tightening torque for hub nuts | 157 - 245 Nm | p. 149 |
| Tightening torque for rim mating nuts | 157 - 245 Nm | p. 149 |
Komatsu FB15U-12, FB18U-12, FB20AU-12 Common Problems This Manual Covers
Komatsu FB15U-12 battery plug heating up with electrolyte smelling odd or turning cloudy during charging
Always wear protective glasses, rubber gloves and rubber sole shoes when working on batteries. Stop charging and check the battery plug for heat, then inspect electrolyte level, temperature, odor and turbidity. Check terminals for looseness, corrosion and damage, and note whether charging time has changed. Charge only within an ambient temperature of 0°C to 40°C (32°F to 104°F), as listed on page 25. Report any abnormality before the truck goes back to work.
Manual Section: Action for Abnormalities (Battery)Travel interlock or lift interlock warning lamp comes on during start-up safety function check
When checking the safety function, keep a wide safety space around the lift truck in case it makes a sudden, unexpected movement, and check the surrounding area for people and obstacles. Verify interlock timing during the safety function check on page 114. In the travel interlock check, both the travel and lift interlock warning lamps start flashing about 3 seconds later; in the lift interlock check, both lamps start flashing about 1 second later. If the lamps do not respond that way, tag the truck out of service and report it. Never bypass an interlock to keep a shift moving.
Manual Section: Inspection and Maintenance p. 114Brake pedal feels low or has excessive free play during operator seat start-up check
Measure brake pedal play against 0 to 4 mm and pedal height against 105 mm. Then press the pedal and confirm it sits at 60 mm when depressed. Check that the pedal switch turns ON at 10 mm, as specified on page 109. Inspect the brake reservoir tank level too; it holds 0.4 liters per page 120.
Manual Section: Inspection and Maintenance p. 109Forks stuck in raised position and fail to lower when lift lever is operated
Stop the truck immediately using the emergency stop procedure and leave the load where it is. Put up "No Entry" and "Do Not Use" signs to keep other persons from entering under or in front of the raised fork. Secure the area under and around the raised forks, keep everyone out, and never stand or reach beneath the carriage. Do not try to force the forks down; contact your Komatsu distributor for repair.
Manual Section: Action to Take if the Fork Fails to LowerAlarm code or error code displayed when operating lift, tilt or attachment control levers
Stop operating the levers, set the truck in a safe position and record the exact code shown. Check it against the alarm code and error code procedures on page 140 for lift control, tilt control and attachment levers in the Inspection and Maintenance section. Never keep running a truck with warning device errors; report it to your Komatsu distributor.
Manual Section: Procedures for Alarm Code or Error Code Indication p. 140Lift chains stretched or fork base worn thin found during periodic mast inspection
Measure lift chain length over 17 links and fork thickness at the base, using the limits on page 149. On the FB15U-12, have the chain replaced when it exceeds 275.5 mm and remove forks from service below 30 mm. Check the FB18U-12 and FB20AU-12 limits on the same page before measuring.
Manual Section: Inspection and Maintenance p. 149Frequently Asked Questions
What are the torque specifications for the mast mount bolts on the Komatsu FB15U-12, FB18U-12, and FB20AU-12?
The tightening torque for the mast mount bolts on these lift trucks is 343 - 427 Nm (35 - 43 kgfm, 253 - 315 lbft). p. 143
What is the procedure for adjusting the parking brake lever operating effort?
To adjust the parking brake lever operating effort, use a flat-blade screwdriver to turn the adjust bolt (4) through the window (3) at the bottom of the parking brake lever (2). Turning the bolt clockwise increases the operating force, while turning it counterclockwise decreases it. The reference value for this effort, listed in the service data on page 149, is 98 - 147 N (10 - 15 kgf, 22 - 33 lbf). p. 149
What is the hydraulic oil tank capacity on the Komatsu FB15U-12, FB18U-12, FB20AU-12 electric lift truck?
The hydraulic oil tank capacity for these models is 20 liters (5.3 US gal). If the lift truck is equipped with a 3.0 m (118 in) FV mast, the capacity is 24 liters (6.3 US gal). p. 120
What is the lift chain replacement interval for the Komatsu FB15U-12, FB18U-12, FB20AU-12?
The lift chain is considered a safety critical part and should be replaced every 2 to 4 years, regardless of its condition, to ensure full function is maintained. p. 149
What is the maximum allowable elongation for the lift chain?
The maximum allowable elongation for the lift chain, measured over 17 links, is 275.5 mm (10.9 in) for the FB15U-12 and 330 mm (13 in) for the FB18U-12/20AU-12. p. 149
Is this Komatsu FB15U-12 manual a download or a disc?
Instant PDF download. You get the full 185-page searchable Operator Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Can I print just the pages I need from this Komatsu FB15U-12 manual?
Yes. Print the pages you need for the job in your own shop, and bin them when they get greasy.
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