Komatsu FB25-12 100001 & Up SEN06482-01 (Preview)
00 Index and foreword
Table of contents
Foreword, safety, and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
How to read electric wire code
Precautions when carrying out operation
Standard tightening torque table
Conversion table
01 Specification
Contents
Specifications
Specification dimensions drawing
Specifications
Weight table
Table of fuel, coolant, and lubricants
10 Structure and function
Contents
Power train
Power train components
Front axle
Differential
Travel motor
Pump motor
Steering system
Steering piping diagram
Orbitrol valve
Power steering cylinder
Brake system
Brake control
Wheel brake
Brake master cylinder
Undercarriage and frame
Rear axle
Frame
Hydraulic system
Control valve piping diagram (tank to control valve)
Work equipment piping diagram (control valve to tilt cylinder/lift cylinder)
Attachment piping diagram
Work equipment control lever linkage
Hydraulic tank
Hydraulic pump
Control valve
Work equipment
Mast
Electrical system
Electrical control system
System component parts
Monitor system
KOMTRAX system
Sensor and switch
20 Standard value table
Contents
Standard value table
Standard value table
30 Testing and adjusting
Contents
Related information on testing and adjusting
Tools for testing and adjusting
Power train
Adjusting accelerator pedal
Oil level check and changing oil indifferential case
Brake system
Adjusting parking brake lever
Adjusting brake pedal
Adjusting wheel brake
Bleeding air from brake piping
Measuring brake performance
Hydraulic system
Releasing pressure fromhydraulic piping
Testing steering oil pressure
Testing work equipment oilpressure
Checking oil level and change oilin hydraulic tank
Bleed air from lift cylinder
Emergency operation when liftlowering cannot be operated
Work equipment
Testing and adjusting workequipment lever
Measurement of amount ofhydraulic drift and forward drift ofhydraulic cylinder
Adjusting mast
Adjusting fork carriage
Electrical system
Checking battery electrolyte level
Checking fuse
Adjusting the charger to thesource voltage tap
Special functions of monitor panel
40 Troubleshooting
Contents
Information related to troubleshooting
Points to remember when troubleshooting
How to proceed in troubleshooting
Checks before troubleshooting
Classification and procedures of troubleshooting
Symptoms and troubleshooting numbers
Information described in troubleshooting table
Locations of fuses
Relay box arrangement and locations
Connector list
Terminal compositions of travel inverter and pump inverter
Location and removal of battery plug
Connector connection by pin No.
T-box and T-adapter list
Failure codes table
Troubleshooting by failure code
Failure code [7REXKA] DISC) Seat SW
Failure code [7REXKB] SHORT) Seat SW
Failure code [989L00] Lock Caution 1
Failure code [989M00] Lock Caution 2
Failure code [989N00] Lock Caution 3
Failure code [B@GBZK] LOW) BATTERY LIQUID
Failure code [D160KB] SHORT) Back Lamp RLY
Failure code [D19RKY] SHORT_P) Cooling FAN1 RLY
Failure code [D160KY] SHORT_P) Back Lamp RLY
Failure code [D19VKB] SHORT) Cooling FAN2 RLY
Failure code [D161KB] SHORT) Back Alarm RLY
Failure code [D161KY] SHORT_P) Back Alarm RLY
Failure code [D19VKA] DISC) Cooling FAN2 RLY
Failure code [D19RKA] DISC) Cooling FAN1 RLY
Failure code [D19RKB] SHORT) Cooling FAN1 RLY
Failure code [D19VKY] SHORT_P) Cooling FAN2 RLY
Failure code [D811MC] ABNL) KOMTRAX
Failure code [D862KA] DISC) GPS Antenna
Failure code [D8ALKA] DISC) SYS-OPE Lamp (KMTX)
Failure code [D8ALKB] SHORT) SYS-OPE Lamp (KMTX)
Failure code [D8AQK4] ABNL) CAN COMM. 2 (KMTX)
Failure code [D8AQKR] ABNL) CAN COMM. (KMTX)
Failure code [DAF0KT] ABNL) EEPROM (MON)
Failure code [DAF0MB] ABNL) Monitor ROM
Failure code [DAF0MC] ABNL) Monitor
Failure code [DAF3KK] LOW) Power Source (MON)
Failure code [DAFGMC] ABNL) GPS Module
Failure code [DAFLKA] DISC) SYS-OPE Lamp (MON)
Failure code [DAFLKB] Operating Lamp Short Circuit (MON)
Failure code [DAFQKR] ABNL) CAN COMM. (MON)
Failure code [DBN000] ABNL) EEPROM (M/C)
Failure code [DBN0KT] ABNL) EEPROM (M/C)
Failure code [DBN0MC] RESET) Controller (M/C)
Failure code [DBN2KK] Load Power Source Low (M/C)
Failure code [DBN3KK] LOW) Power Source (M/C)
Failure code [DBN5KX] OUT OF RNG) Sensor Power1
Failure code [DBN6KX] OUT OF RNG) Sensor Power2
Failure code [DBN9KQ] ABNL) Model Selection Line
Failure code [DBNCMA] MISMATCH) OPT-Setting (M/C)
Failure code [DBNEKR] ABNL) CAN COMM. (for TRV)
Failure code [DBNFKR] ABNL) CAN COMM. (for PMP)
Failure code [DBNHKA] DISC) MC2 Output (M/C)
Failure code [DBNHKB] MC2 Enable Command Output Ground Fault (M/C)
Failure code [DBNHKY] SHORT_P) MC2 Output (M/C)
Failure code [DBNJKB] SHORT) Operating States
Failure code [DBNJKY] SHORT_P) Operating States
Failure code [DBNKKA] DISC) CutOFF OutSide
Failure code [DBNKKB] SHORT) CutOFF OutSide
Failure code [DBNKKY] SHORT_P) CutOFF OutSide
Failure code [DBNLKA] DISC) Sys-Ope. Lamp
Failure code [DBNLKB] SHORT_P) Sys- Ope. Lamp
Failure code [DBNMKA] DISC) ENABLE TRV-INV (M/C)
Failure code [DBNMKB] SHORT) ENABLE TRV-INV (M/C)
Failure code [DBNNKA] DISC) ENABLE PMP-INV (M/C)
Failure code [DBNNKB] SHORT) ENABLE PMP-INV (M/C)
Failure code [DBNPKA] DISC) AC INPUT LINE (M/C)
Failure code [DBNRKR] ABNL) CAN COMM. (M/C)
Failure code [DBNTKA] DISC) Key Signal
Failure code [DBNUKA] DISC) MC2-CUT CONTACTOR
Failure code [DBNUKB] SHORT) MC2-CUT CONTACTOR
Failure code [DBNUKY] SHORT_P) MC2-CUT CONTACTOR
Failure code [DBNVMA] ABNL) Start-up Signal
Failure code [DDK6KA] DISC) Direction Lever
Failure code [DDK6KY] SHORT_P) Direction Lever
Failure code [DFC1KA] DISC) Lift lever POT
Failure code [DFC1KB] SHORT) Lift lever POT
Failure code [DGE5KA] DISC) Air Temp. Sensor
Failure code [DGE5KB] SHORT) Air Temp. Sensor
Failure code [DHPCKA] DISC) HYDR-PRESS SNSR
Failure code [DHPCKB] SHORT) HYDR-PRESS SNSR
Failure code [DJK1KA] DISC) Load Current Sensor
Failure code [DJK1KB] SHORT) Load Current Sensor
Failure code [DJK1MA] INIT) Load Current Sensor
Failure code [DK10KA] DISC) Accelerator POT
Failure code [DK10KB] SHORT) Accelerator POT
Failure code [DK11KA] DISC) Accelerator POT2
Failure code [DK11KB] SHORT) Accelerator POT2
Failure code [DK13KX] OUT OF RNG) Accelerator SNSR
Failure code [DK13L8] Defective Accelerator Pedal Angle Sensor
Failure code [DK30MA] Malfunction of Steering Angle Sensor
Failure code [DK5YMA] ABNL) Tire Sensor
Failure code [DV00KB] SHORT) Buzzer Output
Failure code [DW9MKA] DISC) Lift Lock Solenoid
Failure code [DW9MKB] SHORT) Lift Lock Solenoid
Failure code [DW9MKY] SHORT_P) Lift Lock Solenoid
Failure code [DWP0KA] DISC) Steering SOL
Failure code [DWP0KB] SHORT) Steering SOL
Failure code [F7FQKR] ABNL) CAN COMM. (IDKey)
Failure code [F7G0MC] ABNL) ID Key Antenna
Failure code [GF11KG] HIGH) Power Source (TRV-INV)
Failure code [GF11KK] LOW) Power Source (TRV-INV)
Failure code [GF12KA] DISC) U Phase (TRV-INV)
Failure code [GF13KA] DISC) V Phase (TRV-INV)
Failure code [GF14KA] DISC) W Phase (TRV-INV)
Failure code [GF15KQ] MISMATCH) Capacity (TRV-INV)
Failure code [GF16KA] DISC) MC2 Line (TRV-INV)
Failure code [GF16KB] SHORT) MC2 Line (TRV-INV)
Failure code [GF17MA] ABNL) Quick Charge (TRV-INV)
Failure code [GF18KQ] MISMATCH) Func.SEL (TRV-INV)
Failure code [GF1AMA] ABNL) Current SNSR (TRV-INV)
Failure code [GF1BMA] ABNL) Temp. Sensor (TRV-INV)
Failure code [GF1C00] HIGH) Temp. of TRV-INV
Failure code [GF1CNS] OVER) Temp. of TRV-INV
Failure code [GF1DMA] MISMATCH) MC2 Info (TRV-INV)
Failure code [GF1EKT] ABNL) EEPROM (TRV-INV)
Failure code [GF1FMA] ABNL) KEY-POWER (TRV-INV)
Failure code [GF1JKA] DISC) Output Power (TRV-INV)
Failure code [GF1LKB] SHORT) FET (TRV-INV)
Failure code [GF1MKB] SHORT) Upper FET (TRV-INV)
Failure code [GF1NKB] SHORT) Lower FET (TRV-INV)
Failure code [GF1QKR] ABNL) CAN COMM. (TRV-INV)
Failure code [GF21KG] HIGH) Power Source (PMP-INV)
Failure code [GF21KK] LOW) Power Source (PMP-INV)
Failure code [GF22KA] DISC) U Phase (PMP-INV)
Failure code [GF23KA] DISC) V Phase (PMP-INV)
Failure code [GF24KA] DISC) W Phase (PMP-INV)
Failure code [GF25KQ] MISMATCH) Capacity (PMP-INV)
Failure code [GF26KA] DISC) MC2 Line (PMP-INV)
Failure code [GF26KB] SHORT) MC2 Line (PMP-INV)
Failure code [GF27MA] ABNL) Quick Charge (PMP-INV)
Failure code [GF2AMA] ABNL) Current SNSR (PMP-INV)
Failure code [GF2BMA] ABNL) Temp. Sensor (PMP-INV)
Failure code [GF2C00] HIGH) Temp. of PMP-INV
Failure code [GF2CNS] OVER) Temp. of PMP-INV
Failure code [GF2EKT] ABNL) EEPROM (PUMP INV)
Failure code [GF2FMA] ABNL) KEY-POWER (PMP-INV)
Failure code [GF2JKA] DISC) Output Power (PMP-INV)
Failure code [GF2LKB] SHORT) FET (PMP-INV)
Failure code [GF2MKB] SHORT) Upper FET (PMP-INV)
Failure code [GF2NKB] SHORT) Lower FET (PMP-INV)
Failure code [GF2QKR] ABNL) CAN COMM. (PMP-INV)
Failure code [GF30KB] SHORT) Travel Motor
Failure code [GF31MA] ABNL) Temp. SNSR (TRV-MOT)
Failure code [GF3200] HIGH) Temp. of TRV-MOT
Failure code [GF32NS] OVER) Temp. of TRV-MOT
Failure code [GF33MA] ABNL) Rotation SNSR (TRV-MOT)
Failure code [GF50KB] SHORT) Pump Motor
Failure code [GF51MA] ABNL) Temp. Sensor (PMP-MOT)
Failure code [GF5200] HIGH) Temp. of PMP-MOT
Failure code [GF52NS] OVER) Temp. of PMP-MOT
Failure code [GF53MA] ABNL) Rotation SNSR (PMP-MOT)
Troubleshooting for hydraulic and mechanical system (E-mode)
E-1 Lift truck does not start.
E-2 When starting switch is turned to ON position, monitor panel is notdisplayed
E-3 When starting switch is turned to ON position, alarm buzzer doesnot sound
E-4 Parking brake reminder alarm does not sound or does not stopsounding
E-5 Horn does not sound or does not stop sounding
E-6 EPACS is abnormal
E-7 Travel speed restriction cannot be released or enabled
E-8 Monitor panel cannot be set in controller failure display mode,controller adjustment mode, or travel speed limit setting mode
E-9 Headlamp, clearance lamp, tail lamp, and license plate lamp do notlight up or do not go out
E-10 Turn signal lamps do not light up or do not go out
E-11 Brake lamps do not light up or do not go out
E-12 Backup lamp does not light up or does not go out
E-13 Backup buzzer does not sound or does not stop sounding
E-14 KOMTRAX system does not operate normally
Troubleshooting for hydraulic and mechanical system (H-mode)
How to use troubleshooting table
Hydraulic and mechanical system diagram
Table of failure modes and causes
H-1 Lift truck does not turn
H-2 Turning response is poor.
H-3 Steering wheel is heavy to turn.
H-4 Unstable during turning.
H-5 When steering wheel is released, it does not return to neutral or itrotates by itself.
H-6 Steering wheel is turned in reverse or it kicks(while work equipment is operated).
H-7 Large shock is made when steering wheel is returned.
H-8 EPACS does not work.
H-9 Steering wheel vibrates.
H-10 Steering system makes abnormal sound.
H-11 Oil leaks from steering circuit.
H-12 Service brake does not work or its performance is low.
H-13 Service brake is not released or it drags.
H-14 Parking brake does not work or its performance is low.
H-15 Parking brake is not released or drags.
H-16 Unusual noise is heard from around work equipment and steeringpump
H-17 Fork lowering lock does not work (Fork lowers when operatorleaves operator’s seat)
H-18 Control valve lever does not move smoothly and it is heavy.
H-19 Lift cylinder and fork are not raised.
H-20 Lifting speed or power of lift cylinder and fork is insufficient
H-21 Fork lifting speed lowers at specific height.
H-22 Hydraulic drift of lift cylinder is large.
H-23 Lift cylinders do not come down.
H-24 Fork lowering speed is low or high or fine control performance islow or response is low.
H-25 Mast does not tilt forward nor backward.
H-26 Forward/backward tilting speed or force of mast is insufficient.
H-27 Tilting speed lowers halfway
H-28 Hydraulic drift of tilt cylinder (forward tilting) is large
H-29 Mast is unstable during travel with load
H-30 Steering is heavy when work equipment and steering are operatedsimultaneously
50 Disassembly and assembly
Contents
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Power train
Removal and installation of frontaxle assembly
Disassembly and assembly offront axle assembly
Removal and installation of pumpmotor
Steering system
Removal and installation of powersteering cylinder assembly
Disassembly and assembly ofpower steering cylinder assembly
Disassembly and assembly ofwheel brake assembly
Removal and installation ofOrbitrol valve assembly
Disassembly and assembly ofOrbitrol valve assembly
Brake system
Removal and installation of brakemaster cylinder assembly
Disassembly and assembly ofbrake master cylinder assembly
Removal and installation of parkingbrake lever
Undercarriage and frame
Removal and installation of rearaxle assembly
Disassembly and assembly ofrear axle assembly
Removal and installation of counterweightassembly
Removal and installation of hoodassembly
Hydraulic system
Removal and installation ofhydraulic tank assembly
Removal and installation of controlvalve assembly
Disassembly and assembly ofcontrol valve assembly
Removal and installation of liftcylinder assembly
Disassembly and assembly of liftcylinder assembly
Removal and installation of tiltcylinder assembly
Disassembly and assembly of tiltcylinder assembly
Disassembly and assembly ofhydraulic pump assembly
Cab and its attachments
Removal and installation of operator’sseat assembly
Removal and installation of seatbelt assembly
Removal and installation of headguard assembly
Work equipment
Removal and installation of mastassembly
Disassembly and assembly ofmast assembly
Electrical system
Removal and installation of batteryassembly
Removal and installation ofmaster controller assembly
Removal and installation ofinverter assembly
Removal and installation of monitorpanel assembly
Removal and installation of KOMTRAXterminal
Removal and installation of combinationswitch assembly
60 Maintenance standard
Contents
Power train
Front axle
Differential
Travel motor
Pump motor
Steering system
Power steering cylinder
Brake system
Brake control
Wheel brake
Brake master cylinder
Undercarriage and frame
Rear axle
Hydraulic system
Hydraulic tank
Control valve
Work equipment
Tilt cylinder
Lift cylinder
Mast
Board
80 Yearly inspection criteria
Contents
Yearly inspection criteria
Yearly inspection criteria
90 Diagrams and drawings
Contents
Hydraulic diagrams and drawings
Symbols used in hydraulic circuit diagrams
Hydraulic circuit diagram
Electrical diagrams and drawings
Symbols used in electrical circuit diagrams
Electric circuit diagram
Index
Colophon
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