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Komatsu FB20A-12, FB20AF-12, FB20AG-12 Electric Forklift Shop Manual (BBA12E1-14)

Format: PDF (Printable Document)

File Language: English

File Pages: 476

File Size: 23.51 MB (Speed Download Link)

Brand: Komatsu

Model: FB20A-12, FB20AF-12, FB20AG-12 Electric Forklift

Book No: BBA12E1-14

Type of Document: Shop Manual

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Komatsu FB20A-12, FB20AF-12, FB20AG-12 Electric Forklift Shop Manual (BBA12E1-14)

These Komatsu FB20A-12, FB20AF-12, FB20AG-12 electric forklifts are warehouse and dock workhorses, doing tight aisle work, loading trucks, and feeding production lines. The people who reach for a Shop Manual are the ones actually tearing into motors, controllers, brakes, and hydraulics, not just doing daily checks. They’re usually trying to chase down weird electrical faults, fix intermittent drive issues, or rebuild major components without guesswork. If that sounds like your day, you’re in the right ballpark.

What this manual helps you do

  • Trace electric drive and control faults using wiring diagrams and step‑by‑step troubleshooting logic.
  • Check and adjust steering, mast, and brake systems after repairs so the truck tracks and stops correctly.
  • Follow teardown and reassembly sequences for drive units, hydraulic components, and major mechanical assemblies.
  • Diagnose battery, contactor, and controller issues that cause no‑lift, no‑drive, or random error codes.
  • Handle periodic workshop services with the right inspection points and adjustment procedures for these models.

Who this is for

This is a workshop‑level Shop Manual for the Komatsu FB20A-12, FB20AF-12, FB20AG-12 Electric Forklift, reference BBA12E1-14. It suits field techs, shop mechanics, and fleet maintenance leads who already know basic forklift safety and want factory‑style repair info. If you just need daily checks or operator training, you want the Operation/Operator manual instead.

FAQ

Q: Is this a PDF I can search and print?

A: Yes, it’s a PDF you can search by keyword and print pages or sections for use in the shop.

Q: Does it go deep enough for full rebuilds?

A: These shop manuals usually cover diagnostic procedures, disassembly/assembly steps, and adjustment points for workshop‑level repairs on these electric forklifts.

Q: How do I know it matches my exact truck?

A: Check that your nameplate says Komatsu FB20A-12, FB20AF-12, or FB20AG-12 and that your truck falls under the BBA12E1-14 reference; if your model code is different, you’ll need the matching manual for that variant.

Bottom line: if you’re repairing or troubleshooting these specific Komatsu FB20A/AF/AG-12 electric forklifts in a shop or field setting, this is the manual you want; if you’re just operating them, keep looking for the operator/OM book instead.

📘 Show Index

Table of Contents:

  • 00. FOREWORD
    • SECTION INDEX
  • 10. GENERAL AND SPECIFICATIONS
    • OUTSIDE VIEW
    • SPECIFICATIONS
    • PERIODIC REPLACEMENT OF CONSUMABLE PARTS
    • SAFETY ITEMS FOR MAINTENANCE
    • STANDARD TIGHTENING TORQUE FOR BOLTS
    • STANDARD TIGHTENING TORQUE FOR PIPE JOINTS
    • HOW TO USE LOCTITE
  • 20. TESTING AND ADJUSTING
    • SERVICE DATA
    • METHOD OF RELEASING THE PRESSURE IN THE HYDRAULIC PIPING
    • LIFT INTERRUPT FUNCTION
    • HOW TO START UP THE HOUR METER
    • SEATBELT INTERLOCK FUNCTION
    • LIFTING HEIGHT TRAVEL SPEED LIMIT
    • METER PANEL
    • OPERATION OF METER PANEL
    • BATTERY
    • FUSE
    • TRANSFER CASE
    • VEHICLE MOUNTED TYPE CHARGER
    • INSTALLATION TYPE CHARGER
    • ADJUSTMENT OF WET TYPE BRAKE AND PARKING BRAKE
    • WET TYPE BRAKE
    • HYDRAULIC OIL TANK
    • MAST
    • LIFTING HEIGHT DETECTION SENSOR
    • FINGER BAR
    • NATURALLY DESCENDING AMOUNT OF HYDRAULIC OIL CYLINDER, MEASUREMENT OF NATURALLY FORWARD TILTING AMOUNT
    • AIR BLEEDING
    • LIST OF LUBRICANT AND GREASE
  • 30. REMOVAL AND INSTALLATION
    • UNIT LOCATION DIAGRAM
    • UNIT MASS
    • DRAWING OF DISASSEMBLY/ASSEMBLY
    • MAST
    • CHAIN (DOUBLE MAST)
    • CHAIN (TRIPLE MAST)
    • LIFT CYLINDER
    • DRIVE AXLE
    • STEERING AXLE
    • REAR AXLE
    • BATTERY
    • HYDRAULIC PUMP AND PUMP MOTOR
    • VEHICLE MOUNTED CHARGER
  • 40. DISASSEMBLY AND ASSEMBLY
    • DRIVE AXLE
    • TRANSFER
    • BRAKE WHEEL CYLINDER
    • BRAKE MASTER CYLINDER
    • STEERING GEAR BOX
    • ORBITROL
    • POWER STEERING CYLINDER
    • STEERING AXLE
    • REAR AXLE
    • LIFT CYLINDER
    • TILT CYLINDER
    • HYDRAULIC PUMP
    • CONTROL VALVE
    • DRIVE MOTOR
    • PUMP MOTOR
  • 50. MAINTENANCE STANDARD
    • DRIVE AXLE
    • BRAKE MASTER CYLINDER
    • STEERING AXLE
    • REAR AXLE
    • LIFT CYLINDER
    • TILT CYLINDER
    • CONTROL VALVE
    • HYDRAULIC PUMP
    • MAST, FINGER BAR, FORK
    • DRIVE MOTOR
    • PUMP MOTOR
  • 60. STRUCTURE AND FUNCTION
    • BRAKE
    • HYDRAULIC CIRCUIT DIAGRAM
    • CONTROL VALVE
  • 70. TROUBLESHOOTING
    • DIAGNOSIS TOOL
    • CONFIGURATION PARTS, SENSOR, UNIT LOCATION DRAWING
    • LOCATION DRAWING
    • HARNESS LIST
    • LOCATION OF CPU BOARD CONNECTOR
    • OVERVIEW OF ABNORMAL CODE
    • PREPARATION FOR VOLTAGE CHECK AND CURRENT CHECK
    • INPUT/OUTPUT SIGNAL OF CONTROLLER
    • ABNORMAL CODE LIST
    • DIAGNOSTIC PROCEDURE BY ABNORMAL CODE (ALA CODE)
    • DIAGNOSTIC PROCEDURE BY ABNORMAL CODE (ERR CODE)
    • DIAGNOSTIC PROCEDURE BY METER DISPLAY TROUBLE CODE
    • TROUBLE WITHOUT ABNORMAL DISPLAY
    • PROPORTIONAL SOLENOID VALVE CONTROLLER
    • ADJUSTMENT PROCEDURE OF TILT AUTOMATIC HORIZONTAL (OPTION)
    • METER PANEL
  • 80. YEARLY INSPECTION CRITERIA
    • MOTOR
    • CONTROL EQUIPMENT
    • CHARGE CONTROL UNIT
    • BATTERY
    • POWER TRANSFER EQUIPMENT
    • TRAVELING EQUIPMENT
    • STEERING EQUIPMENT
    • BRAKING EQUIPMENT
    • CARGO HANDLING EQUIPMENT
    • HYDRAULIC EQUIPMENT
    • BODY, SAFETY EQUIPMENT, ETC
    • TOTAL TEST
  • 90. CONVERSION TABLE
    • MILLIMETERS TO INCHES
    • INCHES TO MILLIMETERS
    • CUBIC METERS TO CUBIC YARDS
    • CUBIC YARDS TO CUBIC METERS
    • LITER TO U.S. GALLON
    • U.S. GALLON TO LITER
    • LITER TO U.K. GALLON
    • U.K. GALLON TO LITER
    • KILOGRAM TO POUND
    • POUND TO KILOGRAM
    • KG/CM2 TO IB/IN2
    • KGM TO FT IB
    • TEMPERATURE
  • APPENDIX
    • 3BA-97-99310 (INPUT CAP PRESS-FITTING JIG)
    • 3BA-97-99320 (INPUT OIL SEAL PRESS-FITTING JIG)
    • 3BA-97-99330 (INPUT HUB BEARING PRESS-FITTING JIG)
    • 3BA-97-99710(INPUT GEAR/BEARING PRESS-FITTING JIG)
    • 3BA-97-99720 (MULTIPLE DISC ALIGNMENT JIG)
    • 3BA-97-99730 (MULTIPLE HOLDER CLEARANCE ALIGNING JIG)
    • 3BA-97-99740 (3 WHEEL REAR AXLE PRESS-FITTING JIG)
    • 3BA-97-99760 (3 WHEEL REAR AXLE SENSOR ALIGNMENT JIG)
    • SERVICE TOOL CONFIGURATION
    • ELECTRIC WIRING DIAGRAM (BUILD IN CHARGER)
    • ELECTRIC WIRING DIAGRAM (BUILD IN CHARGER)
    • ELECTRIC WIRING DIAGRAM (BUILD IN CHARGER)
    • ELECTRIC WIRING DIAGRAM (MACHINE WITH SEATBELT INTERLOCK SYSTEM AND HIGH MAST TRAVEL SPEED LIMIT SYSTEM
    • ELECTRIC WIRING DIAGRAM (1/2) (MACHINE WITH SEATBELT INTERLOCK SYSTEM AND HIGH MAST TRAVEL SPEED LIMIT SYSTEM)
    • ELECTRIC WIRING DIAGRAM (2/2) (MACHINE WITH SEATBELT INTERLOCK SYSTEM AND HIGH MAST TRAVEL SPEED LIMIT SYSTEM)
    • ELECTRIC WIRING DIAGRAM (STATIONARY CHARGER)
    • ELECTRIC WIRING DIAGRAM (STATIONARY CHARGER)
    • ELECTRIC WIRING DIAGRAM (STATIONARY CHARGER)

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