Confidential

New 2.5t 4-wheel Electric Trucks

FB25-12
Service training
2. Structure and function

04/07/2013
Product Support Department
Forklift Marketing Division
Komatsu Ltd.

1
１．Outline
・Equipment layout 3
・Hydraulic circuit 4
・Electrical system configuration 5
・Fuses / relays 6-8
・Controller layout 9
・Charging and water refilling/ 10 - 12
Battery replacement /
Power shut-off unit

２．Structure
・Battery 13
・Motor 14 - 15 (Page19 △1 Correction)

・Drive axle / Tire / Rear axle 16 - 20

・Accelerator 21
・Hydraulic system / Steering system 22 - 23
・Control valve / Tilt cylinder 24 - 25
・Frame 26
・Mast 27
・Optional harness (power supply) 28 - 29

３．Others
・Interchangeability of old and new model 30 - 31
2
FB25-12/FB25EX-11 Equipment layout comparison
FB25-12 Master controller
Battery compartment

（ Manual valve ）
The battery is

Control valve
located at the
rear end of the
truck, reducing
truck weight.
Drive motor

Pump motor Controllers and

electrical
Hydraulic oil tank Transformer Hydraulic pump components located
in the right side
FB25EX-11 Hydraulic pump Pump motor
intensively.
（ Manual valve ）

Battery compartment
Control valve

Hydraulic oil tank

Drive motor

EPS motor
Main controller

Sub-controller Transformer
3
Hydraulic circuit ・ Fully hydraulic power steering ・ Orbit roll/steering cylinder added
(FHPS) adopted ・ Change to manual control valve
・ Changed to manual valve with built-in priority valve

Manual valve
with a built-in
priority valve

Steering valve

Steering cylinder

4
Electrical system configuration ・ In-house production of key components ・ Komatsu electric components adopted
・ Battery and powertrain of 72V
・ Components common with 3 ton truck
・ Electrical component of 24V
FB25-12
Power supply DC 72V DC/DC Power supply DC 24V
CAN Converter CAN
communication communication
Wiper

Travel Pump Master Monitor KOMTRAX ID key

inverter inverter controller panel (OPT) (OPT) Light

Steering Accelerator signal Warning buzzer GPS antenna ・

・
signal Control valve lever signal Communications antenna ・
Output signal (relay)
・
Battery Komatsu electrical
Drive Pump
components
motor motor

FB25EX-11
Power supply DC 48V
Serial
Communication
Main Meter Wiper
Sub-controller
controller ・System controller panel
・Multi-controller
Accelerator signal Light
Steering signal Control valve lever signal
Drive Pump EPS ・
Battery Output signal (relay) Proportional solenoid valve
・
motor motor motor output signal ・
5
 Structure & Function
Truck body right side Truck body left side

Fuse 1 Transformer tap adjustment

Fuse 2 Fuse 3

Fuse 1 Fuse 3

F203
F202
F114 F124 F201
F113 F123
F112 F122
F111 F121
F110 F120 Fuse 2
F109 F119
F108 F118 F11
F107 F117
F106 F116 F12
F102 F115
F13
F14
F15

6
 Structure & Function **
Slow Blow Fuse Replacement Floor plate
1 2

Master
controller

Resin clip

Controller cover

3
1Remove the floor plate.
F03 2 Remove the fixing of master
controller, and remove the
plastic grip, so as to shift back
F04 the controller cover.

F02

7
 Structure & Function **
Relay
The relay was stored in relay BOX.
（Right side of chassis）

Relay BOX

8
 Structure & Function **
Controller layout
Placed in the truck right side

Master controller
(Floor lower right)
Heat sink DC/DC converter
Cooling fan

Heat sink
Pump inverter

Travel inverter

9
 Structure & Function
Charging, refilling of water/battery replacement
The opening direction of the hood has been changed towards the front of the truck.
The battery replacement direction has been changed towards the rear end of the truck.
■ Charging and rehydration procedure
(1) Remove two hood locks, right and left.
(2) Open the hood towards the front of the truck.
(3) Remove the fixed bar of the hood back.
And hang it to the hole on the battery right side so as to fix the hood.

Fixed bar

(Gas damper)

Hood locks, right and left

10
 Structure & Function
Charging, refilling of water/battery replacement
The battery replacement direction has been changed towards the rear of the truck.
■ Battery replacement procedure (6) Disconnect the battery liquid level sensor.
(1) Slide back the seat to the rearmost position. (7) Disconnect the battery connector, and pull out
(2) Remove the overhead guard rear cover. the battery cable up to the battery top.
(3) Remove two hood locks, right and left. [Note] Pull the battery connector
(4) Open the hood toward the front of the truck. after the operation lamp goes off.
(5) Fully open the hood until lock gas damper (8) Remove the counter weight cover. (Remove three knob bolts)
is locked. (9) Perform the battery replacement by using a crane.

Overhead guard rear cover

Lock gas damper Battery connector

Extract the battery towards

the rear of the truck.

Lift the battery up.

Right step section

Hood locks, Battery cable ※ Operation lamp

right and left Counter weight cover
Battery fluid level sensor
11
 Structure & Function
Power shut-off unit
Power shut-off unit has been changed to the grip connector from the switch.
FB25-12 FB25EX-11

Connector with grip located at operator's Switch on dashboard cover section

foot on the right side of the truck
1) Purpose of power shut-off
When an unintended behavior occurs by the operator due to the electronic
control equipment failure, the truck will stop and shut off the power supply.
2) Location of power shut-off unit compared with other manufacturers
① In the case that the battery connector is arranged outside of the truck,
the power shut-off unit is not equipped with the truck.
② In the case that the battery connector is arranged on inside of the truck,
the power shut-off unit is equipped with the truck.

12
 Structure & Function
Battery FB25-12 FB25EX-11

1. Voltage has been changed from 48V to 72V.

The battery has been unified to 72V in order to standardize components as a new series model.
FB25-12 FB30 FB25EX-11 FB30-11
72V 72V 48V 72V
ﾊﾞｯﾃﾘ電圧
Battery voltage

2. Battery capacity Assembly weight

13
 Structure & Function
Drive Motor
Drive motor has been changed from induction motor (IM) to
permanent magnet type synchronous motor (PM).
IMPORTANT
Maintenance services cannot be performed after
disassembly in order to prevent intrusion of dust into the
motor. Also, there is no internal parts setup individually.
Therefore, the replacement of motor will be done by
motor assembly basis.

1. Frame 4. Bracket 7. Resolver

2. Stator 5. Shaft 8. Bracket
3. Rotor 6. Temperature 9. Magnet
sensor

14
 Structure & Function
Pump Motor
Pump motor has been changed from induction motor (IM) to
permanent magnet type synchronous motor (PM).
IMPORTANT
Maintenance services will not be performed after
disassembly so as to prevent intrusion of dust into the
motor. Also, there is no internal parts setup individually.
Therefore, the replacement of motor will be done by
motor assembly basis.

1. Frame 4. Bracket 7. Resolver

2. Stator 5. Shaft 8. Bracket
3. Rotor 6. Temperature 9. Magnet
sensor

15
 Structure & Function
Drive axle/Tire
There are two types of drive axle: one is for single tire and the other is for single wide tread and double tires.
These two axles are not compatible for different number of the rim holes.

For single tire Single tire (center

sprit rim 6 holes)

FB25EX-11
FB25EX-11 (940)
(940) (1165)
(1165)

For single wide tread and double tires

FB25EX-11
(1055)
(1280)

FB25EX-11
(1155)
(1545)
FB25EX-11
(1155)
(1545)

[Note] Elastic cushion tire rib lug pattern will be made by Bridgestone or Dunlop.
Aichi made is not available as optional.
16
 Structure & Function
Structural comparison with current machine
FB25-12 single tire Current machine FB25EX-11
2-stage 3-stage
1 Motor Drive 23” center 1 Motor Drive reduction 23” side ring rim
reduction
split rim

Z Z

Dry drum brake

Φ279.4X55・L783 Dry drum brake
(Improvement in initial Φ279.4X55・L706
familiarity)

Six hub bolts 11hub bolts

(6 holes rim) (11 holes rim)
Z Z
17
 Structure & Function
For single tire, and for single wide tread and double tire, the following parts are different.
FB25-12 single tire FB25-12 single wide tread and double tire

Tube Hub drum Seal Tube Hub drum Seal

Bearing
Bearingﾞ Bolt
Bolt
Serration bolt
washer

Seal
Nut
Nut
Plate
O-ring

Torque shaft Plate Torque shaft Serration bolt

Rim mounting surface 960 Rim mounting surface 962

18
 Structure & Function
Optional tire setup ●：標準タイヤ
◎：オプション メーカ指定しない場合に装着されるタイヤ
○：オプション メーカ指定
タイヤサイズ タイヤ種類 メーカ
ダンロップ アイチ ＢＳ
前輪 ニューマチック シングルタイヤ 23X9-10-16PR リブラグ
● ○
タイヤ
スノー
◎
シングルワイドトレッド 23X9-10-16PR リブラグ
◎
ダブルタイヤ 6.50-10-10PR リブラグ
◎
スノー
◎
ニューマチック型 シングルタイヤ 23X9-10 リブラグ
◎ ◎ ○
クッションタイヤ
(ユニークタイヤ） ホワイトＵラグ
○ ◎
グリーンＵラグ
○ ◎
シングルワイドトレッド 23X9-10 リブラグ
◎ ◎
ダブルタイヤ 6.50-10 リブラグ
◎ ◎
後輪 ニューマチック 18X7-8-16PR リブラグ
● ○
タイヤ
スノー
◎
ニューマチック型 18X7-8 リブラグ
◎ ◎ ○
クッションタイヤ
(ユニークタイヤ） ホワイトＵラグ
○ ◎
グリーンＵラグ
○ ◎

IMOPRTANT
[Link] the FB25-12, when installed elastic cushion tires, it has been confirmed that a sort of noise was generated during turning,
which might be caused by the bad matching between the truck body and the shape of the Aichi elastic cushion rib lug rear
wheel tread pattern. Therefore, it is not recommended to mount the above tire on the FB25-12.
2. Rather than a problem with the tire, it is a noise problem generated due to the bad matching of the truck body definitely.
There is no problem in the current machine FB25EX-11.

19
 Structure & Function
Rear axle
Potentiometer
Changed from EPS to FHPS (fully hydraulic power steering).
Adoption of double rod cylinder
Adoption of tire angle sensor (potentiometer)

Flat portion of the

insertion hole of the
potentiometer shaft
must be oriented
toward the outside of
the truck.

Double rod cylinder

20
 Structure & Function
Accelerator
Operation of the accelerator has been changed from the pedal integrated type to the link type.
IMPORTANT
At the time of replacing and disassembly, you need to adjust the potentiometer.

FB25-12 FB25EX-11

Pedal

Stopper
bolt

Rod

Potentiometer

21
 Structure & Function
Hydraulic system
Control valve has been changed to the manual valve with built-in valves of the following.
Down control valve and priority valve (new)

Orbit roll Control

valve

Hydraulic
oil tank

Pump

22
 Structure & Function
Steering system
Steering system has been changed to the fully hydraulic power steering (FHPS).
FB25-12 FB25EX-11

Power steering gear box

Orbit roll

Drag link
Hydraulic hose EPS actuator

Double rod cylinder

23
 Structure & Function
Control valve
Control valve has been changed from the electromagnetic proportional valve
to the manual valve with built-in down control valve and the priority valve.
Emergency lift-down operation
[Link] the nut of the emergency valve.
[Link] the lift lock release screw until it stops
by turning to the right.
[Link] the lift lever downward so as to
emergency valve lowering the mast.
Recovery
[Link] the lift lock release screw to the left
until it stops.
2. Tighten the nut of the emergency valve.
(Tightening torque: 8 - 10N · m)
IMORTANT
Never remove the emergency valve.

lift lock release screw

emergency valve

nut

24
 Structure & Function
Tilt cylinder
Adoption of the spherical bushing on the bottom side.
(Conventional spherical bushing on the head side)
Spherical bushing

Bushing(Rubber) Collar

Collar

25
 Structure & Function
Frame
Frame structure has been changed.

FB25-12 FB25EX-11

26
 Structure & Function
Mast & Attachment
The cross-section of mast rail (outer/inner) has been changed to those of exclusive for 2.5 ton forklift.
Attachment has been standardized with those of engine powered truck. (Standard board is non-common.)
Cylinder with internal drain type has been adopted. (Common with those of engine powered truck.)
Cylinder return piping
Without return piping With return piping Remarks
Free The tank will be changed
view 3 - 3.5 m 4 m and over depending on the availability of
mast return piping.

Without return With return

piping （STD) piping

27
 Structure & Function
Optional harness /optional power supply
[Link] add-on harness
2. In order to mount windshield with wiper and fender working lamp,
you need to add an optional DC/DC converter. (1) Front body
(2) Rear ceiling
(3) Rear body

①Windshield
前面ｶﾞﾗｽ
Rear combination
後照灯
lamps

ﾌｪﾝﾀﾞ作業灯
Fender working ﾋﾞｰｺﾝﾗﾝﾌﾟ
Flash beacon
OPTｱﾄﾞｵﾝﾊｰﾈｽ
Optional add-on harness
Chime
ﾁｬｲﾑ (2)
各SW
Switches
ﾘﾚｰBOX
Relay box OPT
Optional add-
(1) ｼｰﾄﾋｰﾀ
Seat heater (3)
ｱﾄﾞｵﾝﾊｰﾈｽ
on harness

車検なし
Rear assist grip
ﾘｱｱｼｽﾄｸﾞﾘｯﾌﾟ&ﾎｰﾝ
with horn button
STDﾒｲﾝﾊｰﾈｽ
Standard main harness 車検あり
Rear assist grip
Load checker
荷重計 ﾘｱｱｼｽﾄｸﾞﾘｯﾌﾟ&ﾎｰﾝ
with horn button
Standard
STD STDDC/DC
Standard
IDIDｷｰ
key relay box
ﾘﾚｰBOX1個 converter
DCDCｺﾝﾊﾞｰﾀ 番号灯（車検用）
number plate lamp
(1 box)
KOMTRAX
KOMTRAX
Discharge OPT
Optional DC/DC
放電電流ｾﾝｻ converter
DCDCｺﾝﾊﾞｰﾀ
current sensor

28
 Structure & Function
Optional harness
Installation of hood front bracket optional relay box and optional fuse box
Passing through the frame of the right, and leading to the optional switches of
the right side of the large color monitor.
Optional switches Cover

Connection of
･ Windshield
･ Working lamp

Optional relay box

Optional fuse box

Optional DC/DC converter

Connection of
･ Flush beacon
･ Rear combination lamps
･ Chime

29
 Structure & Function
Interchangeability of old and new model: Part 1

30
 Structure & Function
Interchangeability of old and new model: Part 2

31