🏷️ Basic Information Identification Make: Komatsu Model: 4016 Series Forklift Trucks Specific Models Covered: FB12M-2R, FB15M-2R, FB18M-2R Product Type: Complete Workshop Service Repair Manual 👋 Introduction Market Position Category: Electric Counterbalance Forklift Trucks Application: Designed for indoor material handling in warehouses, manufacturing facilities, and distribution centers. Competitive Analysis Key Competitors: Toyota, Mitsubishi, Hyster, Yale, Crown Key Features Series Features: Komatsu's 4016 series are known for their robust construction, reliable electric drive systems, and operator-friendly design, offering a balance of performance and efficiency. Model Differentiation: FB12M-2R, FB15M-2R, and FB18M-2R typically denote variations in lifting capacity (e.g., 1.2, 1.5, 1.8 metric tons). 📋 Manual Details Coverage Areas General Coverage: Comprehensive service and repair information for the specified Komatsu forklift models. Model Specific Coverage: Detailed procedures and specifications tailored for the FB12M-2R, FB15M-2R, and FB18M-2R variants. Page Count Estimated Page Count: High (typically 500+ pages for a complete workshop manual) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital Format (likely PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine, transmission (including hydrostatic, electric motor if applicable), drive axle, differential. Hydraulic System: Hydraulic pump, control valves, cylinders, hoses, filters, hydraulic fluid specifications, troubleshooting. Electrical System: Battery, starter, alternator, wiring diagrams, fuses, relays, control modules, sensors, lighting systems. Chassis And Frame: Frame construction, steering system, braking system, suspension components, mast assembly, counterweight. Operator Compartment: Controls, seat, safety restraints, instrument panel, operator comfort features. Procedures Included Scheduled Maintenance: Recommended service intervals, lubrication points, fluid checks, filter replacements. Troubleshooting: Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides. Major Repairs: Engine overhauls, transmission rebuilds, hydraulic system component replacement, brake system repairs. Component Disassembly And Assembly: Step-by-step instructions with torque specifications for all major components. Diagnostic Codes: Explanation of diagnostic trouble codes (DTCs) and their corresponding troubleshooting steps. Technical Depth Depth: Comprehensive, covering from basic maintenance to complete overhauls and advanced diagnostics. Diagnostics: Detailed diagnostic flowcharts, component testing procedures, and electrical system analysis. Rebuilds: Full rebuild specifications for engine, transmission, and hydraulic components. Specifications: Includes all necessary torque values, clearances, fluid capacities, and electrical resistance values. 📊 Manual Specifications File Format Format: Digital Downloadable (PDF Recommended for Searchability and Portability) Print Quality Quality: High-resolution, clear text and diagrams for easy readability and printing. Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Electric Motor Drive System Motor Details: AC Drive Motors for traction and hydraulic functions, offering regenerative braking and precise control. Performance Performance Characteristics: Smooth acceleration, responsive lifting and lowering, efficient operation, low noise and emissions. Fuel System Power Source: High-capacity industrial battery pack (e.g., lead-acid, optional lithium-ion). Battery Specifications: Capacity and voltage dependent on configuration; manual will detail charging systems and battery maintenance. 🔧 Transmission Standard Type: Electric Drive with AC motor and reduction gearbox. Optional Optional Features: Regenerative braking, variable speed control. Features Control System: Electronic control unit (ECU) managing motor speed, acceleration, and regenerative braking. 📐 Dimensions Exterior Overall Dimensions: Varies by specific model and mast configuration; manual will provide detailed dimensions including length, width, and height. Mast Height: Various mast heights (e.g., duplex, triplex) available; manual details collapsed and extended heights. Cargo Lifting Capacity: FB12M-2R (1.2 Tonne), FB15M-2R (1.5 Tonne), FB18M-2R (1.8 Tonne) nominal capacity. Weights Operating Weight: Typically ranges from 2,500 kg to 4,000 kg depending on model and battery. Turning Radius: Designed for maneuverability in tight spaces; manual will specify. 🛡️ Safety Features Ratings Safety Compliance: Meets relevant industry safety standards (e.g., ANSI, ISO) for forklift operation. Active Features Operational Safety: Automatic parking brake, speed reduction in turns, overload protection (depending on configuration). Passive Features Operator Protection: Overhead guard, seatbelt, operator presence sensing system. Visibility: Optimized mast design and operator visibility for safe load handling. 💡 Technology Features Infotainment Operator Interface: Instrument panel with battery charge indicator, hour meter, warning lights, and possibly diagnostic display. Driver Assistance Assist Features: Regenerative braking, smooth acceleration/deceleration control, operator presence system. Connectivity Diagnostic Tools: Requires specialized diagnostic equipment and software for advanced electronic system troubleshooting, which this manual would reference. 🔧 Maintenance Service Intervals Daily Checks: Fluid levels (hydraulic, brake), tire condition, battery connections, lift mechanism. Preventive Maintenance Schedule: The manual will outline specific intervals for lubrication, filter changes (hydraulic, drive motor, controller), brake inspections, and electrical system checks (e.g., every 250, 500, 1000 operating hours). Fluid Specifications Hydraulic Fluid: Komatsu recommends specific hydraulic fluids (e.g., Komatsu genuine hydraulic oil or equivalent meeting ISO VG 32/46 standards). Capacity and replacement intervals will be detailed. Brake Fluid: DOT 3 or DOT 4 brake fluid (if applicable, depending on brake system design). Known Issues Common Wear Items: Fork bushings, steer axle components, hydraulic hoses, battery terminals, contactors. Electrical Diagnostics: Potential issues with motor controllers, sensors, or wiring harness integrity over time. Manual provides detailed diagnostic steps. 📚 Vehicle History Brand...