🏷️ Basic Information Identification Make: Komatsu Model: Series 4022 (FB20H-2R, FB20HG-2R) & Series 4023 (FB25H-2R, FB30H-2R) Forklift Truck Codes Internal Model Codes: FB20H-2R, FB20HG-2R, FB25H-2R, FB30H-2R 👋 Introduction Market Position Market Segment: Electric counterbalanced forklifts, designed for indoor material handling in warehousing, manufacturing, and distribution centers. Competitive Analysis Competitors: Toyota, Hyster-Yale, Crown, Mitsubishi Logisnext, Nissan Forklift. Key Features Product Focus: Reliability, maneuverability, energy efficiency, operator comfort and safety, suitable for various load capacities. 📋 Manual Details Coverage Areas Covered Models: Komatsu Series 4022 (FB20H-2R, FB20HG-2R), Series 4023 (FB25H-2R, FB30H-2R) Applicable Serial Number Ranges: Specific serial number ranges for each sub-model will be critical and should be detailed in the manual. Page Count Estimated Page Count: Likely 500+ pages (typical for comprehensive service manuals) Manual Type Manual Type: Service Repair Manual Language Language: English (typical for Komatsu service documentation) Format Format: Digital (likely PDF), potentially available in print 📖 Manual Coverage Systems Covered Powertrain: Electric motor(s), drive axle, braking system, steering system Hydraulic System: Lift and tilt mechanisms, power steering, ancillary hydraulics (if applicable) Electrical System: Battery, charging system, motor controllers, control panel, lighting, sensors, wiring diagrams Chassis And Frame: Frame structure, mast assembly, carriage, forks, counterweight Operator Station: Controls, seat, safety guards, dashboard Steering System: Hydraulic power steering components, steering motor, linkage, and associated sensors. Braking System: Service brakes (typically drum or disc, depending on configuration), parking brake mechanism, and hydraulic brake actuation. Cooling System: If applicable, for electronic components or specific hydraulic fluid cooling. Operator Controls: Lever and pedal functions for lift, tilt, sideshift (if equipped), steering, and drive. Procedures Included Maintenance: Scheduled maintenance checks, lubrication points, filter replacement, battery care Disassembly And Assembly: Detailed step-by-step instructions for major component removal and installation Troubleshooting: Diagnostic procedures for common faults and error codes Repair And Overhaul: Component-specific repair instructions, including seal replacement, bearing service, and motor refurbishment Calibration And Adjustment: Procedures for setting hydraulic pressures, control linkages, and electronic parameters Electrical Diagnostics: Detailed troubleshooting guides for electrical faults, including sensor testing, wiring continuity checks, and controller logic analysis. Mast And Forks: Inspection, lubrication, roller adjustment, seal replacement, and fork inspection/replacement procedures. Component Replacement: Detailed instructions for replacing major components like drive motors, hydraulic pumps, controllers, cylinders, and sensors. Safety System Checks: Procedures for testing operator presence system, parking brake, and interlocks. Technical Depth Depth Of Information: Comprehensive, covering routine maintenance to major component overhauls and complex diagnostics. Diagnostic Tools Required: Likely requires proprietary Komatsu diagnostic software and interface tools for advanced troubleshooting and parameter adjustments. Repair Manual Scope: Complete rebuild procedures for main hydraulic pumps, drive motors, and steering units. 📊 Manual Specifications File Format File Format: Likely PDF with searchable text and high-resolution diagrams. Print Quality Print Quality: High-resolution for clear diagrams and text reproduction if printed. Binding Type Binding Type: N/A (for digital format); if printed, typically comb-bound or perfect-bound for workshop use. Paper Type Paper Type: N/A (for digital format); if printed, typically durable, coated paper for workshop environments. ⚙️ Engine Specifications Primary Engine Powertrain Type: Electric Drive System (AC or DC motors, specific type would depend on exact configuration). Controller Type: AC or DC motor controller, often with advanced regenerative braking and diagnostics capabilities. Performance Motor Ratings: Variable power output for drive and hydraulic functions, optimized for efficiency and performance based on model capacity (e.g., 2.0-3.0 ton range). Fuel System Energy Source: Battery (Lead-acid or Lithium-ion, depending on configuration and era). 🔧 Transmission Standard Drive System: Direct drive or single-speed reduction gearboxes for drive motors. Optional Hydraulic Transmission: No traditional transmission; hydraulic pump driven by electric motor for lift/tilt functions. Features Electronic Control: Sophisticated electronic control units (ECUs) manage motor speed, torque, regenerative braking, and hydraulic flow. 📐 Dimensions Exterior Typical Dimensions: Varies significantly by specific model (e.g., FB20H vs. FB30H). Expect compact designs for maneuverability. Overall Length, Width, and Turning Radius are critical specifications detailed in the manual. Tire Specifications: Typically solid or cushion tires; specific size (e.g., front/rear tire dimensions) detailed in manual. Lift Height Options: Various mast configurations available (e.g., Duplex, Triplex) offering different lift heights, all specified. Cargo Load Capacity: 2000 kg (2.0 ton) for FB20H/FB20HG, 2500 kg (2.5 ton) for FB25H, 3000 kg (3.0 ton) for FB30H. Weights Operating Weight: Typically ranges from 3,500 kg to 5,000 kg depending on battery and mast configuration. Exact weight specified in manual. 🛡️ Safety Features Ratings Safety Standards: Compliance with relevant industry safety standards (e.g., ANSI/ITSDF B56.1, EN standards). Active Features Operational Safety: Automatic parking brake, speed reduction in turns, load sensing hydraulics, operator presence system (OPS). Passive Features Structural Safety: Operator protective structure (overhead guard), seat belts, mast guards, fork stops. 💡 Technology Features Infotainment Operator Interface: Basic LCD display for operational status, battery level, hour meter, and fault codes. No advanced infotainment systems. Driver Assistance Operational Assistance: Electronic control systems for smooth...