These Komatsu FB25-12, FB30-12 electric forklifts are warehouse and yard machines that spend their lives loading trucks, feeding production lines, and shuttling pallets. The Komatsu FB25-12, FB30-12 Electric Forklift Shop Manual (SEN06636-10) is what shops reach for when a truck is down, not when someone just needs basic operating tips. People usually buy this to cut diagnostic time, plan repairs, and keep parts and labor scheduled instead of firefighting breakdowns.
What this manual helps you do
- Trace electric drive and hydraulic faults using step-by-step diagnostic procedures and wiring references.
- Check removal and installation sequences for major components so your techs don’t waste time guessing the order.
- Follow inspection and adjustment procedures that keep the trucks in spec and reduce repeat comebacks.
- Diagnose error codes and abnormal behaviors in the electric powertrain and control system with structured workflows.
- Handle scheduled workshop-level maintenance using the same kind of guidance most dealer shops rely on.
Who this is for
This is aimed at field techs, shop mechanics, and fleet managers who schedule and oversee workshop repairs. Operators or trainees looking for basic controls and daily checks will be happier with an Operation & Maintenance manual, not this shop manual.
FAQ
Q: Is this a searchable PDF I can print from?
A: Yes, it’s typically provided as a PDF you can search on-screen and print specific sections for the shop.
Q: Does it go deep enough for full tear-downs?
A: The Shop Manual for Komatsu FB25-12, FB30-12 Electric Forklift walks through diagnostic procedures, disassembly sequences, and reference torque tables used during workshop-level repairs.
Q: How do I know it matches my exact truck variant?
A: Check your forklift’s model designation and compare it to FB25-12 or FB30-12 and the book reference SEN06636-10 on your existing documentation or data plate.
Bottom line: if you’re planning or performing real repairs on FB25-12 or FB30-12 units, this is the right manual; if you just need operating instructions or basic service intervals, keep looking for the O&M book instead.
📘 Show Index
Table of Contents:
- 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
- Oil and greasing chart
- 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
- 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
- Electrical system
- Electrical control system
- System component parts
- Monitor system
- KOMTRAX system
- Sensor and switch
- 20 Standard value table
- Contents
- Standard value table
- 30 Testing and adjusting
- Contents
- Precautions before work
- Related information on testing and adjusting
- Tools for testing and adjusting
- Power train
- Adjusting accelerator pedal
- Oil level check and changing oil in differential 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 from hydraulic piping
- Testing steering oil pressure
- Testing work equipment oil pressure
- Checking oil level and change oil in hydraulic tank
- Bleed air from lift cylinder
- Emergency operation when lift lowering cannot be operated
- Work equipment
- Testing and adjusting work equipment lever
- Measurement of amount of hydraulic drift and forward drift of hydraulic cylinder
- Adjusting mast
- Adjusting the lifting height detection sensor
- Adjusting fork carriage
- Electrical system
- Checking battery electrolyte level
- Checking fuse
- Adjusting the charger to the source voltage tap
- Special functions of monitor panel
- 40 Troubleshooting
- Contents
- Precautions before work
- 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
- 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 [D160KY] SHORT_P) Back Lamp RLY
- Failure code [D161KB] SHORT) Back Alarm RLY
- Failure code [D161KY] SHORT_P) Back Alarm RLY
- Failure code [D19RKA] DISC) Cooling FAN1 RLY
- Failure code [D19RKB] SHORT) Cooling FAN1 RLY
- Failure code [D19RKY] SHORT_P) Cooling FAN1 RLY
- Failure code [D19SKB] SHORT) Forward Alarm RLY
- Failure code [D19SKY] SHORT_P) Forward Alarm RLY
- Failure code [D19VKA] DISC) Cooling FAN2 RLY
- Failure code [D19VKB] SHORT) Cooling FAN2 RLY
- Failure code [D19VKY] SHORT_P) Cooling FAN2 RLY
- Failure code [D1HBKA] Open Circuit of Main Contactor 2
- Failure code [D1HBKB] Ground Fault of Main Contactor 2
- Failure code [D1HBKY] Short Circuit of Main Contactor 2
- Failure code [D1HPKB] SHORT) Speed Alarm RLY 1
- Failure code [D1HPKY] SHORT_P) Speed Alarm RLY 1
- Failure code [D1HQKB] SHORT) Speed Alarm RLY 2
- Failure code [D1HQKY] SHORT_P) Speed Alarm RLY 2
- Failure code [D1HRKY] SHORT_P) Speed Alarm RLY 3
- Failure code [D5XWKA] DISC) SeatBelt Error Sig
- Failure code [D5XWKY] SHORT_P) SeatBelt Error Sig
- Failure code [D5XXKA] DISC) S/Belt IL Valid Sig
- Failure code [D5XXKY] SHORT_P) S/Belt IL Valid Sig
- 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] System 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 (FB25-12)
- Failure code [DBN9KQ] ABNL) Model Selection Line (FB30-12)
- 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 [DDDQKA] DISC) HIGH LIFTING HIGHT2 SW
- Failure code [DDDTKA] DISC) Seat SW1
- Failure code [DDDTKA] DISC) Seat SW1 (European specification (including Turkey)) (Serial No.: 104201 and up)
- Failure code [DDDTKB] SHORT) Seat SW1
- Failure code [DDDTKB] SHORT) Seat SW1 (European specification (including Turkey)) (Serial No.: 104201 and up)
- Failure code [DDDUKA] DISC) Seat SW2
- Failure code [DDDUKA] DISC) Seat SW2 (European specification (including Turkey)) (Serial No.: 104201 and up)
- Failure code [DDDUKB] SHORT) Seat SW2
- Failure code [DDDUKB] SHORT) Seat SW2 (European specification (including Turkey)) (Serial No.: 104201 and up)
- Failure code [DDDVKA] ABNL) Seat SW
- Failure code [DDDVKA] ABNL) Seat SW (European specification (including Turkey)) (Serial No.: 104201 and up)
- Failure code [DDDVKM] OPE-ERROR) Seat SW
- Failure code [DDDVKM] OPE-ERROR) Seat SW (European specification (including Turkey)) (Serial No.: 104201 and up)
- 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 [DJK2KA] DISC) Charge 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 [GF28KQ] MISMATCH) Func. SEL (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 not displayed
- E-3 When starting switch is turned to ON position, alarm buzzer does not sound
- E-4 Parking brake reminder alarm does not sound or does not stop sounding
- 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 not light 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 it rotates 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 steering pump
- H-17 Fork lowering lock does not work (Fork lowers when operator leaves 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 is low 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 operated simultaneously
- 50 Disassembly and assembly
- Contents
- Precautions before work
- 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 front axle assembly
- Disassembly and assembly of front axle assembly
- Removal and installation of pump motor
- Steering system
- Removal and installation of power steering cylinder assembly
- Disassembly and assembly of power steering cylinder assembly
- Disassembly and assembly of wheel brake assembly
- Removal and installation of Orbitrol valve assembly
- Disassembly and assembly of Orbitrol valve assembly
- Brake system
- Removal and installation of brake master cylinder assembly
- Disassembly and assembly of brake master cylinder assembly
- Removal and installation of parking brake lever
- Undercarriage and frame
- Removal and installation of rear axle assembly
- Disassembly and assembly of rear axle assembly
- Removal and installation of counterweight assembly
- Removal and installation of hood assembly
- Hydraulic system
- Removal and installation of hydraulic tank assembly
- Removal and installation of control valve assembly
- Disassembly and assembly of control valve assembly
- Removal and installation of lift cylinder assembly
- Disassembly and assembly of lift cylinder assembly
- Removal and installation of tilt cylinder assembly
- Disassembly and assembly of tilt cylinder assembly
- Disassembly and assembly of hydraulic pump assembly
- Cab and its attachments
- Removal and installation of operator's seat assembly
- Removal and installation of seat belt assembly
- Removal and installation of seat belt assembly (European specification (including Turkey)) (Serial No.: 104201 and up)
- Removal and installation of head guard assembly
- Work equipment
- Removal and installation of mast assembly
- Disassembly and assembly of mast assembly
- Removal and installation of chain(double mast)
- Removal and installation of chain(triple mast)
- Electrical system
- Removal and installation of battery assembly
- Removal and installation of master controller assembly
- Removal and installation of inverter assembly
- Removal and installation of monitor panel assembly
- Removal and installation of KOMTRAX terminal
- Removal and installation of combination switch assembly
- 60 Maintenance standard
- Contents
- Power train
- Front axle
- Differential
- Travel motor
- Pump motor
- Steering system
- Brake system
- Brake control
- Wheel brake
- Brake master cylinder
- Undercarriage and frame
- Hydraulic system
- Hydraulic tank
- Control valve
- Work equipment
- Tilt cylinder
- Lift cylinder
- Mast
- Board
- 80 Yearly inspection criteria
- Contents
- Precautions before work
- 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
Komatsu
