Komatsu FB25-12 ForkLift Truck Shop Manual SEN06482-01 – PDF DOWNLOAD

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Komatsu FB25-12 ForkLift Truck Shop Manual SEN06482-01 – PDF DOWNLOAD

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Komatsu FB25-12 ForkLift Truck Shop Manual SEN06482-01 – PDF DOWNLOAD

SERIAL NUMBERS 100001 and up

How to read the shop manual
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the lift truck.
10. Structure, function and maintenance standard
This section explains the structure and function. The structure and function sub-section explains
the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. For troubleshooting “S mode” related to the engine, see Engine.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
60. Maintenance standard
This section gives maintenance standard values of each component. The maintenance standard
sub-section explains the criteria and remedies for disassembly and service.
80. Yearly inspection criteria
This section explains the items, contents and criteria of the specific self-imposed inspection.
90. Diagrams and drawings (Chassis)
This section gives hydraulic circuit diagrams and electrical circuit diagrams.

TABLE OF CONTENTS:

Komatsu FB25-12 ForkLift Truck Shop Manual SEN06482-01 – PDF DOWNLOAD

00 Index and foreword 9
Table of contents 10
Foreword, safety, and general information 18
Safety notice 18
How to read the shop manual 28
Explanation of terms for maintenance standard 30
Handling of electric equipment and hydraulic component 32
How to read electric wire code 41
Precautions when carrying out operation 44
Standard tightening torque table 47
Conversion table 51
01 Specification 57
Contents 58
Specifications 59
Specification dimensions drawing 59
Specifications 61
Weight table 62
Table of fuel, coolant, and lubricants 64
10 Structure and function 65
Contents 66
Power train 67
Power train components 68
Front axle 69
Differential 72
Travel motor 74
Pump motor 75
Steering system 76
Steering piping diagram 76
Orbitrol valve 77
Power steering cylinder 79
Brake system 80
Brake control 80
Wheel brake 81
Brake master cylinder 82
Undercarriage and frame 83
Rear axle 83
Frame 84
Hydraulic system 85
Control valve piping diagram (tank to control valve) 85
Work equipment piping diagram (control valve to tilt cylinder/lift cylinder) 86
Attachment piping diagram 87
Work equipment control lever linkage 88
Hydraulic tank 89
Hydraulic pump 90
Control valve 91
Work equipment 104
Mast 104
Electrical system 110
Electrical control system 110
System component parts 120
Monitor system 131
KOMTRAX system 132
Sensor and switch 135
20 Standard value table 147
Contents 148
Standard value table 149
Standard value table 149
30 Testing and adjusting 151
Contents 152
Related information on testing and adjusting 153
Tools for testing and adjusting 153
Power train 154
Adjusting accelerator pedal 154
Oil level check and changing oil indifferential case 156
Brake system 157
Adjusting parking brake lever 157
Adjusting brake pedal 158
Adjusting wheel brake 160
Bleeding air from brake piping 162
Measuring brake performance 163
Hydraulic system 164
Releasing pressure fromhydraulic piping 164
Testing steering oil pressure 165
Testing work equipment oilpressure 166
Checking oil level and change oilin hydraulic tank 168
Bleed air from lift cylinder 170
Emergency operation when liftlowering cannot be operated 171
Work equipment 173
Testing and adjusting workequipment lever 173
Measurement of amount ofhydraulic drift and forward drift ofhydraulic cylinder 175
Adjusting mast 176
Adjusting fork carriage 179
Electrical system 182
Checking battery electrolyte level 182
Checking fuse 184
Adjusting the charger to thesource voltage tap 186
Special functions of monitor panel 187
40 Troubleshooting 267
Contents 268
Information related to troubleshooting 272
Points to remember when troubleshooting 272
How to proceed in troubleshooting 273
Checks before troubleshooting 275
Classification and procedures of troubleshooting 276
Symptoms and troubleshooting numbers 277
Information described in troubleshooting table 279
Locations of fuses 281
Relay box arrangement and locations 284
Connector list 285
Terminal compositions of travel inverter and pump inverter 291
Location and removal of battery plug 292
Connector connection by pin No 293
T-box and T-adapter list 336
Failure codes table 339
Troubleshooting by failure code 346
Failure code [7REXKA] DISC) Seat SW 346
Failure code [7REXKB] SHORT) Seat SW 348
Failure code [989L00] Lock Caution 1 350
Failure code [989M00] Lock Caution 2 350
Failure code [989N00] Lock Caution 3 351
Failure code [B@GBZK] LOW) BATTERY LIQUID 352
Failure code [D160KB] SHORT) Back Lamp RLY 354
Failure code [D19RKY] SHORT_P) Cooling FAN1 RLY 366
Failure code [D160KY] SHORT_P) Back Lamp RLY 356
Failure code [D19VKB] SHORT) Cooling FAN2 RLY 370
Failure code [D161KB] SHORT) Back Alarm RLY 358
Failure code [D161KY] SHORT_P) Back Alarm RLY 360
Failure code [D19VKA] DISC) Cooling FAN2 RLY 368
Failure code [D19RKA] DISC) Cooling FAN1 RLY 362
Failure code [D19RKB] SHORT) Cooling FAN1 RLY 364
Failure code [D19VKY] SHORT_P) Cooling FAN2 RLY 372
Failure code [D811MC] ABNL) KOMTRAX 374
Failure code [D862KA] DISC) GPS Antenna 375
Failure code [D8ALKA] DISC) SYS-OPE Lamp (KMTX) 376
Failure code [D8ALKB] SHORT) SYS-OPE Lamp (KMTX) 378
Failure code [D8AQK4] ABNL) CAN COMM 2 (KMTX) 380
Failure code [D8AQKR] ABNL) CAN COMM (KMTX) 382
Failure code [DAF0KT] ABNL) EEPROM (MON) 382
Failure code [DAF0MB] ABNL) Monitor ROM 383
Failure code [DAF0MC] ABNL) Monitor 383
Failure code [DAF3KK] LOW) Power Source (MON) 384
Failure code [DAFGMC] ABNL) GPS Module 386
Failure code [DAFLKA] DISC) SYS-OPE Lamp (MON) 388
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) 390
Failure code [DAFQKR] ABNL) CAN COMM (MON) 392
Failure code [DBN000] ABNL) EEPROM (M/C) 392
Failure code [DBN0KT] ABNL) EEPROM (M/C) 393
Failure code [DBN0MC] RESET) Controller (M/C) 393
Failure code [DBN2KK] Load Power Source Low (M/C) 394
Failure code [DBN3KK] LOW) Power Source (M/C) 396
Failure code [DBN5KX] OUT OF RNG) Sensor Power1 398
Failure code [DBN6KX] OUT OF RNG) Sensor Power2 400
Failure code [DBN9KQ] ABNL) Model Selection Line 402
Failure code [DBNCMA] MISMATCH) OPT-Setting (M/C) 404
Failure code [DBNEKR] ABNL) CAN COMM (for TRV) 405
Failure code [DBNFKR] ABNL) CAN COMM (for PMP) 409
Failure code [DBNHKA] DISC) MC2 Output (M/C) 412
Failure code [DBNHKB] MC2 Enable Command Output Ground Fault (M/C) 414
Failure code [DBNHKY] SHORT_P) MC2 Output (M/C) 416
Failure code [DBNJKB] SHORT) Operating States 418
Failure code [DBNJKY] SHORT_P) Operating States 419
Failure code [DBNKKA] DISC) CutOFF OutSide 420
Failure code [DBNKKB] SHORT) CutOFF OutSide 421
Failure code [DBNKKY] SHORT_P) CutOFF OutSide 422
Failure code [DBNLKA] DISC) Sys-Ope Lamp 424
Failure code [DBNLKB] SHORT_P) Sys- Ope Lamp 426
Failure code [DBNMKA] DISC) ENABLE TRV-INV (M/C) 428
Failure code [DBNMKB] SHORT) ENABLE TRV-INV (M/C) 429
Failure code [DBNNKA] DISC) ENABLE PMP-INV (M/C) 430
Failure code [DBNNKB] SHORT) ENABLE PMP-INV (M/C) 431
Failure code [DBNPKA] DISC) AC INPUT LINE (M/C) 432
Failure code [DBNRKR] ABNL) CAN COMM (M/C) 433
Failure code [DBNTKA] DISC) Key Signal 436
Failure code [DBNUKA] DISC) MC2-CUT CONTACTOR 438
Failure code [DBNUKB] SHORT) MC2-CUT CONTACTOR 440
Failure code [DBNUKY] SHORT_P) MC2-CUT CONTACTOR 442
Failure code [DBNVMA] ABNL) Start-up Signal 444
Failure code [DDK6KA] DISC) Direction Lever 445
Failure code [DDK6KY] SHORT_P) Direction Lever 448
Failure code [DFC1KA] DISC) Lift lever POT 450
Failure code [DFC1KB] SHORT) Lift lever POT 452
Failure code [DGE5KA] DISC) Air Temp Sensor 454
Failure code [DGE5KB] SHORT) Air Temp Sensor 455
Failure code [DHPCKA] DISC) HYDR-PRESS SNSR 456
Failure code [DHPCKB] SHORT) HYDR-PRESS SNSR 458
Failure code [DJK1KA] DISC) Load Current Sensor 460
Failure code [DJK1KB] SHORT) Load Current Sensor 462
Failure code [DJK1MA] INIT) Load Current Sensor 464
Failure code [DK10KA] DISC) Accelerator POT 466
Failure code [DK10KB] SHORT) Accelerator POT 468
Failure code [DK11KA] DISC) Accelerator POT2 470
Failure code [DK11KB] SHORT) Accelerator POT2 472
Failure code [DK13KX] OUT OF RNG) Accelerator SNSR 474
Failure code [DK13L8] Defective Accelerator Pedal Angle Sensor 474
Failure code [DK30MA] Malfunction of Steering Angle Sensor 476
Failure code [DK5YMA] ABNL) Tire Sensor 478
Failure code [DV00KB] SHORT) Buzzer Output 480
Failure code [DW9MKA] DISC) Lift Lock Solenoid 481
Failure code [DW9MKB] SHORT) Lift Lock Solenoid 482
Failure code [DW9MKY] SHORT_P) Lift Lock Solenoid 483
Failure code [DWP0KA] DISC) Steering SOL 484
Failure code [DWP0KB] SHORT) Steering SOL 486
Failure code [F7FQKR] ABNL) CAN COMM (IDKey) 488
Failure code [F7G0MC] ABNL) ID Key Antenna 490
Failure code [GF11KG] HIGH) Power Source (TRV-INV) 492
Failure code [GF11KK] LOW) Power Source (TRV-INV) 494
Failure code [GF12KA] DISC) U Phase (TRV-INV) 496
Failure code [GF13KA] DISC) V Phase (TRV-INV) 498
Failure code [GF14KA] DISC) W Phase (TRV-INV) 500
Failure code [GF15KQ] MISMATCH) Capacity (TRV-INV) 502
Failure code [GF16KA] DISC) MC2 Line (TRV-INV) 503
Failure code [GF16KB] SHORT) MC2 Line (TRV-INV) 506
Failure code [GF17MA] ABNL) Quick Charge (TRV-INV) 508
Failure code [GF18KQ] MISMATCH) Func SEL (TRV-INV) 512
Failure code [GF1AMA] ABNL) Current SNSR (TRV-INV) 514
Failure code [GF1BMA] ABNL) Temp Sensor (TRV-INV) 514
Failure code [GF1C00] HIGH) Temp of TRV-INV 515
Failure code [GF1CNS] OVER) Temp of TRV-INV 515
Failure code [GF1DMA] MISMATCH) MC2 Info (TRV-INV) 516
Failure code [GF1EKT] ABNL) EEPROM (TRV-INV) 518
Failure code [GF1FMA] ABNL) KEY-POWER (TRV-INV) 520
Failure code [GF1JKA] DISC) Output Power (TRV-INV) 522
Failure code [GF1LKB] SHORT) FET (TRV-INV) 524
Failure code [GF1MKB] SHORT) Upper FET (TRV-INV) 526
Failure code [GF1NKB] SHORT) Lower FET (TRV-INV) 528
Failure code [GF1QKR] ABNL) CAN COMM (TRV-INV) 530
Failure code [GF21KG] HIGH) Power Source (PMP-INV) 532
Failure code [GF21KK] LOW) Power Source (PMP-INV) 534
Failure code [GF22KA] DISC) U Phase (PMP-INV) 536
Failure code [GF23KA] DISC) V Phase (PMP-INV) 537
Failure code [GF24KA] DISC) W Phase (PMP-INV) 538
Failure code [GF25KQ] MISMATCH) Capacity (PMP-INV) 540
Failure code [GF26KA] DISC) MC2 Line (PMP-INV) 542
Failure code [GF26KB] SHORT) MC2 Line (PMP-INV) 546
Failure code [GF27MA] ABNL) Quick Charge (PMP-INV) 548
Failure code [GF2AMA] ABNL) Current SNSR (PMP-INV) 551
Failure code [GF2BMA] ABNL) Temp Sensor (PMP-INV) 551
Failure code [GF2C00] HIGH) Temp of PMP-INV 552
Failure code [GF2CNS] OVER) Temp of PMP-INV 552
Failure code [GF2EKT] ABNL) EEPROM (PUMP INV) 553
Failure code [GF2FMA] ABNL) KEY-POWER (PMP-INV) 554
Failure code [GF2JKA] DISC) Output Power (PMP-INV) 556
Failure code [GF2LKB] SHORT) FET (PMP-INV) 558
Failure code [GF2MKB] SHORT) Upper FET (PMP-INV) 560
Failure code [GF2NKB] SHORT) Lower FET (PMP-INV) 562
Failure code [GF2QKR] ABNL) CAN COMM (PMP-INV) 564
Failure code [GF30KB] SHORT) Travel Motor 566
Failure code [GF31MA] ABNL) Temp SNSR (TRV-MOT) 568
Failure code [GF3200] HIGH) Temp of TRV-MOT 570
Failure code [GF32NS] OVER) Temp of TRV-MOT 570
Failure code [GF33MA] ABNL) Rotation SNSR (TRV-MOT) 572
Failure code [GF50KB] SHORT) Pump Motor 574
Failure code [GF51MA] ABNL) Temp Sensor (PMP-MOT) 576
Failure code [GF5200] HIGH) Temp of PMP-MOT 578
Failure code [GF52NS] OVER) Temp of PMP-MOT 578
Failure code [GF53MA] ABNL) Rotation SNSR (PMP-MOT) 580
Troubleshooting for hydraulic and mechanical system (E-mode) 582
E-1 Lift truck does not start 582
E-2 When starting switch is turned to ON position, monitor panel is notdisplayed 584
E-3 When starting switch is turned to ON position, alarm buzzer doesnot sound 588
E-4 Parking brake reminder alarm does not sound or does not stopsounding 590
E-5 Horn does not sound or does not stop sounding 593
E-6 EPACS is abnormal 596
E-7 Travel speed restriction cannot be released or enabled 598
E-8 Monitor panel cannot be set in controller failure display mode,controller adjustment mode, or travel speed limit setting mode 598
E-9 Headlamp, clearance lamp, tail lamp, and license plate lamp do notlight up or do not go out 599
E-10 Turn signal lamps do not light up or do not go out 604
E-11 Brake lamps do not light up or do not go out 608
E-12 Backup lamp does not light up or does not go out 610
E-13 Backup buzzer does not sound or does not stop sounding 613
E-14 KOMTRAX system does not operate normally 616
Troubleshooting for hydraulic and mechanical system (H-mode) 617
How to use troubleshooting table 617
Hydraulic and mechanical system diagram 620
Table of failure modes and causes 622
H-1 Lift truck does not turn 625
H-2 Turning response is poor 626
H-3 Steering wheel is heavy to turn 627
H-4 Unstable during turning 628
H-5 When steering wheel is released, it does not return to neutral or itrotates by itself 629
H-6 Steering wheel is turned in reverse or it kicks(while work equipment is operated) 629
H-7 Large shock is made when steering wheel is returned 630
H-8 EPACS does not work 631
H-9 Steering wheel vibrates 631
H-10 Steering system makes abnormal sound 632
H-11 Oil leaks from steering circuit 632
H-12 Service brake does not work or its performance is low 633
H-13 Service brake is not released or it drags 634
H-14 Parking brake does not work or its performance is low 635
H-15 Parking brake is not released or drags 636
H-16 Unusual noise is heard from around work equipment and steeringpump 637
H-17 Fork lowering lock does not work (Fork lowers when operatorleaves operator’s seat) 638
H-18 Control valve lever does not move smoothly and it is heavy 639
H-19 Lift cylinder and fork are not raised 640
H-20 Lifting speed or power of lift cylinder and fork is insufficient 641
H-21 Fork lifting speed lowers at specific height 642
H-22 Hydraulic drift of lift cylinder is large 643
H-23 Lift cylinders do not come down 644
H-24 Fork lowering speed is low or high or fine control performance islow or response is low 645
H-25 Mast does not tilt forward nor backward 646
H-26 Forward/backward tilting speed or force of mast is insufficient 647
H-27 Tilting speed lowers halfway 648
H-28 Hydraulic drift of tilt cylinder (forward tilting) is large 649
H-29 Mast is unstable during travel with load 650
H-30 Steering is heavy when work equipment and steering are operatedsimultaneously 651
50 Disassembly and assembly 653
Contents 654
General information on disassembly and assembly 655
How to read this manual 655
Coating materials list 657
Special tools list 661
Sketches of special tools 663
Power train 670
Removal and installation of frontaxle assembly 670
Disassembly and assembly offront axle assembly 673
Removal and installation of pumpmotor 699
Steering system 701
Removal and installation of powersteering cylinder assembly 701
Disassembly and assembly ofpower steering cylinder assembly 702
Disassembly and assembly ofwheel brake assembly 704
Removal and installation ofOrbitrol valve assembly 709
Disassembly and assembly ofOrbitrol valve assembly 711
Brake system 717
Removal and installation of brakemaster cylinder assembly 717
Disassembly and assembly ofbrake master cylinder assembly 720
Removal and installation of parkingbrake lever 722
Undercarriage and frame 725
Removal and installation of rearaxle assembly 725
Disassembly and assembly ofrear axle assembly 727
Removal and installation of counterweightassembly 734
Removal and installation of hoodassembly 735
Hydraulic system 736
Removal and installation ofhydraulic tank assembly 736
Removal and installation of controlvalve assembly 739
Disassembly and assembly ofcontrol valve assembly 742
Removal and installation of liftcylinder assembly 750
Disassembly and assembly of liftcylinder assembly 752
Removal and installation of tiltcylinder assembly 756
Disassembly and assembly of tiltcylinder assembly 757
Disassembly and assembly ofhydraulic pump assembly 759
Cab and its attachments 761
Removal and installation of operator’sseat assembly 761
Removal and installation of seatbelt assembly 762
Removal and installation of headguard assembly 763
Work equipment 767
Removal and installation of mastassembly 767
Disassembly and assembly ofmast assembly 769
Electrical system 772
Removal and installation of batteryassembly 772
Removal and installation ofmaster controller assembly 773
Removal and installation ofinverter assembly 774
Removal and installation of monitorpanel assembly 779
Removal and installation of KOMTRAXterminal 781
Removal and installation of combinationswitch assembly 782
60 Maintenance standard 785
Contents 786
Power train 788
Front axle 788
Differential 792
Travel motor 794
Pump motor 796
Steering system 798
Power steering cylinder 798
Brake system 799
Brake control 799
Wheel brake 800
Brake master cylinder 802
Undercarriage and frame 803
Rear axle 803
Hydraulic system 804
Hydraulic tank 804
Control valve 805
Work equipment 808
Tilt cylinder 808
Lift cylinder 809
Mast 810
Board 814
80 Yearly inspection criteria 817
Contents 818
Yearly inspection criteria 819
Yearly inspection criteria 819
90 Diagrams and drawings 837
Contents 838
Hydraulic diagrams and drawings 839
Symbols used in hydraulic circuit diagrams 839
Hydraulic circuit diagram 0
Electrical diagrams and drawings 841
Symbols used in electrical circuit diagrams 841
Electric circuit diagram 0
Index 845
Colophon 852

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