SM RB 70

INTRODUCTION
Most accident happens due to the disregard of basic safety rules or

precautions. In order to prevent accidents, the factors which may cause
accidents must be avoided beforehand.
For this reason, please read this manual and fully understand the
precautions for safety and the proper procedures and directions for
inspection and maintenance before starting operation.
Performing maintenance and repair without adequate knowledge may

cause inadvertent accidents.
It is not possible to cover all the possible cases of accidents in

this "SERVICE MANUAL". Therefore, attention should be given
to precautions other than the ones mentioned in this "SERVICE
MANUAL". Especially, when repair and maintenance work which are not
covered in this "SERVICE MANUAL" are carried out, always work under
the direction of an instructor who understands the matter.
USING THE "SERVICE MANUAL"
This Service Manual will give explanation on how to maintain and inspect NICHIYU forklift trucks of
RB10/15-70 RBC7/9/10-70 series.
Since the parts used in this machine are subject to change for the sake of better quality, performance
enhancement, and safety, some portions of the contents and illustrations of the "SERVICE MANUAL"
may not be identified.
Directions with and marks are very important, and must be followed.
Indicates a potentially hazardous situation which, if not avoided,

DANGER could result in death or serious injury.
You shall observe this instruction.
Indicates a potentially hazardous situation which, if not avoided,

WARNING could result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, may

CAUTION result in minor or moderate injury.
Indicates suggestions, tips and hints related to the safety of a

NOTE
operator and maintain of truck.
1. Personnel this "SERVICE MANUAL" is aimed at:

This "SERVICE MANUAL" is directed at personnel who possess sufficient knowledge and technical
expertise. If you do not understand any of the contents of this "SERVICE MANUAL", perform operation
under the guidance of personnel who does.
2. Conditions of a facility
The work conditions described in the "SERVICE MANUAL" are written on the assumption that the work
is performed at a shop where standard facilities and tools for the maintenance of NICHIYU ELECTRIC
LIFT TRUCKS are available.
For safe and reliable maintenance, the work should be performed at a shop where the facilities are
equivalent to these described in the "SERVICE MANUAL" or better, and the instructions described
should be strictly followed.
Copyright© 2006
NIPPON YUSOKI CO., LTD.
All Rights Reserved
CONTENTS - WORKSHOP
SAFETY WORK 1 3 .LOAD WHEEL 29

1. Precautions for safe inspection 3-1.Name ............................................................ 29
and maintenance work .................................. 1 3-1-1.Load wheel - main part names 29
Maintenance shops 1 3-2.Disassembly and reassembly ...................... 30
Work clothing 2 3-3.Inspection and adjustment ............................... 31
Tools and gauges 2 3-3-1.Load wheel - Inspection 31
Safety work 2 3-3-2.Pin, tilt - Inspection 31
Parts 3
Repair of electrical components 3
Hydraulics 4
Tightening torque 4 4 .BRAKE 32
2.Safety labels ................................................... 5 4-1.Disassembly and reassembly ...................... 32
3.Model name and serial numbers ........................ 9 4-1-1.Brake ass'y - removal and installation 32
4.Caution for maintenance .................................... 10 4-1-2.Brake ass'y- disassembly and reassembly 33
5.Tightening torque for bolts ................................ 13 4-2.Inspection and adjustment ........................... 34
6.Maintenance tools and inspection devices ....... 14 4-2-1.Brake ass'y - inspection 34
4-2-2.Air gap - adjustment 34
4-3.Troubleshooting ............................................ 35
1 .GENERAL 16
2-1.Name ............................................................ 19 5 . HYDRAULIC SYSTEM 36
2-2.Disassembly and reassembly. ...................... 20
5-1.Hydraulic circuit ............................................ 36
2-2-1.Drive unit - removal and installation 20
2-2-2.Drive unit - disassembly and reassembly 24
2-3.Inspection and adjustment ........................... 27
2-3-1.Gears - inspection and replacement 27 5a. HYDRAULIC PUMP 37
2-3-2.Drive wheel - inspection 27 5a-1.Name .......................................................... 37
2-4.Troubleshooting ............................................ 28 5a-2.Disassembly and reassembly .................... 38
2-4-1.Drive unit - troubleshooting 28 5a-2-1.Hydraulic pump - removal and installation 38
5a-3.Inspection and adjustment ......................... 41
5a-3-1.Hydraulic pump - inspection 41
2 .DRIVE UNIT 19 5a-4.Troubleshooting .......................................... 42
5a-4-1.Hydraulic pump - troubleshooting 42
2-1.Name ............................................................ 19
2-2.Disassembly and reassembly. ...................... 20
2-2-1.Drive unit - removal and installation 20
5b. OIL TANK AND OIL PIPING 43
2-2-2.Drive unit - disassembly and reassembly 24
2-3.Inspection and adjustment ........................... 27 5b-1.Disassembly and reassembly .................... 43
2-3-1.Gears - inspection and replacement 27 5b-1-1.Oil tank - removal and installation 43
2-3-2.Drive wheel - inspection 27 5b-1-2.Oil tank - disassembly and reassembly 45
2-4.Troubleshooting ............................................ 28 5b-1-3.Oil piping replacement - precautions 47
2-4-1.Drive unit - troubleshooting 28 5b-2.Inspection and adjustment ......................... 48
5b-2-1.Oil tank - inspection and cleaning 48
5b-2-2.Oil - inspection 48
5b-2-3.Recommended oil 48
5b-2-4.Oil quantity 49
5b-3.Troubleshooting .......................................... 49
5c. CONTROL VALVE 50 6 . MAST 66
5c-1.Disassembly and reassembly ..................... 51 6-1.Name ............................................................ 66
5c-1-1.Control valve - removal and installation 51 6-2.Disassembly and reassembly ...................... 68
5c-2.Inspection and replacement ....................... 52 6-2-1.Lift table ass'y - removal 68
5c-2-1.Relief pressure - measurement and adjustment 52 6-2-2.Mast ass'y - removal 70
5c-3.Troubleshooting .......................................... 53 6-2-3.Lift table ass'y and mast - installatio0n 72
5c-3-1.Control valve - troubleshooting 53 6-2-4.Mast - disassembly and reassembly 74
6-2-5.Fork - disassembly and reassembly 76
5d. CYLINDER 54 6-3-1.Mast, lift table and roller shaft -
rs
inspection 77
5d-1.Location and name ..................................... 54
te ale
6-3-2.Back shoe - inspection 78
5d-1-1.Lift cylinder 54 6-3-3.Lift chain - inspection and replacement 78
5d-2.Disassembly and reassembly ................... 57 6-3-4.Chain bolt - inspection 78
5d-2-1.Lift cylinder(Std mast) - removal bu e 57
tri d D
6-3-5.Chain wheel - inspection 79
5d-2-2..Lift cylinder(M mast) - removal 59 6-3-6.Hose pulley - inspection 79
5d-2-3.Lift cylinder - installation and adjustment 61 6-3-7.Roller - inspection and replacement 79
D ize
5d-2-4.Lift cylinder - 6-3-8.Side roller - adjustment 79

disassembly and reassembly 62 6-3-9.Fork - inspection and adjustment 80
ot or
5d-3.Inspection and adjustment ......................... 64 6-3-10.Shaft, fork - inspection 81

is
N uth
5d-3-1.Cylinder - inspection 64 6-3-11.Rack sensor(RBC) - adjustment 82

5d-3-2.Piston rod - inspection 64 6-3-12.Lift chain - adjustment 83
5d-3-3.Drift of tilt and lift lowering - inspection 64
D rA
6-3-13.Mast inclination -
5d-4.Troubleshooting .......................................... 65 inspection and adjustment 83
fo
5d-4-1.Cylinder - troubleshooting 65 6-3-14Adjustment of the slack of chain detector 84

o
y
6-4-1.Mast, lift table, fork - troubleshooting 85

nl
O
7 . LIFT TABLE ASS'Y 86

7-1.Name ............................................................ 86
7-2.Disassembly and reassembly ...................... 88
7-2-1 Lift table - removal and installation 88
7-2-2 Brake ass'y - removal and installation 90
7-2-3 Side guard - removal and installation 91
7-3-1.Control panel ass'y
- installation and adjustment 92
7-3-2.Guard comp.,side
- installation and adjustment 92
7-3-3.Brake switch - installation and adjustment 93
7-3-4.Safety belt - inspection 94
7-4.Lift table ass'y - troubleshooting 96
8 . MOTOR 97 10 .ELECTRIC PARTS 119
8-1.Name ............................................................ 97 10-1.Location and name ................................... 119
8-1-1.Traction motor - main part names 97
8-1-2. Hydraulic motor - main part names 97
8-1-3.EPS motor - main part names 98
8-1-4.Motors - specifications 98 10a. CONTROL UNIT 120
8-2.Disassembly and reassembly ...................... 99 10a-1.Name ...................................................... 120
8-2-1.Traction motor - removal and installation 99 10a-2.Disassembly and reassembly ................ 121
8-2-2.Hydraulic motor - 10a-2-1.Control unit - removal and installation 121
removal and installation 100 10a-2-2.Control unit -
8-2-3.EPS motor - removal and installation 102 disassembly and reassembly 123
8-2-4.Traction motor - disassembly and reassembly 103 10a-3.Inspection, replacement and attention ... 125
8-2-5.EPS motor - disassembly and reassembly 104 10a-3-1.Contactor - check and replacement 125
10a-3-2.FET Module
8-3.Inspection and adjustment ......................... 105 - inspection and replacement 126
8-3-1. Rotor comp. - inspection and replacement 10a-3-3.Capacitor - check and replacement 127
(Traction and Hydraulic motor) 105 10a-3-4.Fuse - replacement 128
8-3-2. Armature comp. (EPS motor) - 10a-3-5.EPS controller - specification 129
inspection and replacement 106
8-3-3. Brush, brush holder and spring
(EPS motor) - inspection and replacement 108
8-3-4. Motor ass'y - inspection 10b. FAN 130
(Traction motor and Hydraulic motor) 110
8-3-5. Motor ass'y(EPS motor) - inspection 111 10b-1.Disassembly and reassembly ................ 130
8-3-6. Oil seal and permanent magnet 112 10b-1-1.Fan - removal and installation 130
8-4. Troubleshooting ......................................... 112
8-4-1. Motor - troubleshooting 112
10c. STEERING ANGLE POTENTIOMETER 131
9 . CONTROL PANEL ASS'Y 113
10c-1.Disassembly and reassembly ................. 131
10c-1-1.Steering angle potentiometer -
9-1.Name .......................................................... 113
disassembly and reassembly 131
9-2.Disassembly and reassembly .................... 114
10c-2.Checking and adjustment ....................... 131
9-2-1.Control panel - disassembly and reassembly 114
10c-2-1.Adjustment of the steering angle
9-2-2.Steering Sub ass'y -
potentiometer 131
9-2-3.Accelerator Sub ass'y -
9-3.Inspection and adjustment ......................... 117
9-3-1. Pin(1),(2),accelerator - inspection 117
9-3-2. Bushing - inspection 117
9-3-3. Steering potentiometer - adjusting 117
9-3-4. Accelerator potentiometer - adjusting 117
9-4. Troubleshooting ......................................... 118
9-4-1. Control panel ass'y - troubleshooting 118
10d. CHARGER 132 11 .AUTO PALLET LOCK 147
10d-1.Disassembly and reassembly ................ 132
11-1. Auto pallet lock - function......................... 147
10d-1-1. Charger ass'y
11-1-1. Pallet lock - function 147
- disassembly and reassembly 132
11-1-2. Detecting error 148
l
10d-1-2. Transformer
11-1-3. Waring buzzer
ria
- disassembly and reassembly 133 148
10d-1-3. Charger - specifications 134 11-2.Disassembly and reassembly ................... 149
10d-1-4. Charger switch - specifications 134 11-3.Inspection and replacement ..................... 151
10d-2.Inspection and replacement ................... 135 11-3-1. Pallet lock function - ichecking 151
.c T
10d-2-1. Magnetic contactor - inspection 135 11-3-2. Pallet lock - disassembly and reassembly 151
10d-2-2. Plug comp. and receptacle 11-3-3. Adjustment of the cylinder detector 152
- inspection and replacement 135 11-3-4. Adjustment of the pallet detector 153
F11-3-5. Adjustment of the pallet lock 154
om
10d-2-3. Link fuse and fusebase - inspection 135
10d-2-4. Transformer - inspection z D 136 11-4. Inspection and check after adjustment .... 154
10d-3-5. Diode - inspection 136 11-4-1. Check(general mode) 154
10d-3.Inspection and adjustment 11-4-2. Check of the pallet detector 155
after assembly ..................... 137 11-4-3. Check of the pallet lock potentiometer 155
P
11-4-4. Check of the cylinder detector 155
ard
10d-3-1. Sensor - inspection 137
10d-3-2. Inspection of timer 137 11-5. Troubleshooting ....................................... 156
10d-4.Voltage tap ............................................. 138 11-5-1. Auto pallet lock - troubleshooting 156
w.p m
10d-4-1. Power voltage - check 138

10d-4-2. Power voltage - selection 138
i
dfw
10d-4-3. Switching the voltage tap 139 12 .SERVICE DATA 157

ww o
10d-4-4. Replacement of link fuse 139

12-1. Standard work hours ............................... 157
cuC
10e. BATTERY 140
10e-1.Disassembly and reassembly ................ 140

10e-1-1.Battery ass'y - removal and installation 140
Do
10e-2.Inspection and adjustment ..................... 141

10e-2-1.Battery - Inspection and adjustment 141
10e-2-2.Battery - cleaning 142
10f. LIFT HEIGHT ENCODER 143

10f-1.Disassembly and reassembly ................. 143
10f-2.Inspection and replacement .................... 145
10f-2-1. Lift height encoder - adjustment 145
SAFETY WORK
1. Precautions for safe inspection and maintenance work
Maintenance shops
CAUTION Facilities with adequate space and level

surfaces:
 The floor area of the shop (location) where
l
ria
inspection and maintenance are performed
must have adequate floor space, and have level
surfaces without holes.
.c T
If these conditions are not met, unexpected
accidents, such as a roll-over of the forklift
truck, may result.
F
om
CAUTION WELL-VENTILATED AREA
z D
Work such as welding painted components or
P
sanding down coated parts should be carried
ard
out in well-ventilated areas.
If this is not observed, harmful toxic gas or dust
w.p m
may be inhaled.
i
dfw
ww o
CAUTION L O C AT I O N E Q U I P P E D W I T H F I R E
cuC
EXTINGUISHING EQUIPMENT
 Equipment such as first-aid boxes and fire
extinguishers should be nearby when work is
performed.
Do
CAUTION SAFE AND WELL-LIGHTED AREA

The work area should be safe and well lighted.
When working inside the machine or underneath
of it, always use a safety lamp with a shielded
light bulb.
If this is not observed, leaked oil may catch fire
when a light bulb pops.
CAUTION PROPER ARRANGEMENT

Arrange and clean always at a working place to
work safety.
Especially, arrange disassembled parts well.
1
SAFETY WORK
Work clothing
CAUTION The worker should wear a hat, work clothes, and

safety shoes that are suitable for safe work. The
work clothes should be close-fitting.
If this is not observed, loose clothing may
become caught in a machine, resulting in
serious injury.
l
ria
Tools and gauges
CAUTION Always use tools that are suitable for the work
.c T
being performed. Use proper size tools when
tightening and loosening the parts of the forklift
F
om
truck.
Failure to observe the above could result in
z D
serious injury or damage to machines.
P
ard
CAUTION  Prepare tools and gauges before starting to
work.
w.p m
i
Safety work
dfw
ww o
cuC
WARNING  When hoisting a forklift truck or a heavy

component, use ropes or cable with correct
capacity.
Do not use ropes or cables which are kinked.
Do
WARNING After lifting or jacking up a forklift truck, support

it with safety blocks or rigid stands.
WARNING
Prevent tires from moving with wheel chocks etc.
WARNING When working under a forklift truck, use a pit or

proper safety precautions.
2
SAFETY WORK
Parts
CAUTION  When replacing any parts, be sure to use

NICHIYU genuine parts.
CAUTION When replenishing battery electrolyte, be sure to
l
use refined or distilled water.
ria
Repair of electrical components
.c T
CAUTION
F
om
 Be sure to disconnect the battery plug and
discharge the capacitors in the control unit
z D
when replacing electrical component.
P
ard
CAUTION Be sure to jack up the drive wheel when trouble
w.p m
shooting electrical operations.

i
dfw
ww o
NOTE Record the places of lead wire connection when

cuC
disassembling.
CAUTION CHARGING BATTERY

 Batteries produce flammable gas during
Do
charging. Do not allow batteries in the vicinity of

fire or flames.
aFailure to observe the above could result in an
explosion.
CAUTION  Diluted sulfuric acid is used as the battery's

electrolyte . Keep clothing and skin away from
contact with battery fluid.
aIf this is not observed, the fluid may corrode
clothing or cause burns.
3
SAFETY WORK
Hydraulics
CAUTION When removing the hydraulic pipes, cap them

to prevent dust from entering into the hydraulic
components and pipes.
CAUTION
l
 When disassembling and assembling the
ria
hydraulic components, work at clean place and
do not damage the parts.
.c T
Tightening torque
F
om
z D
CAUTION  Observe tightening torque specified in this
P
manual.
ard
If not specified, refer to the table [Tightening
torque for bolts]. See page 14
w.p m
i
dfw
ww o
cuC
Do
4
SAFETY WORK
2. Safety labels
The illustration below shows the location of safety labels for safe operation.
Always protect the safety labels from contamination and damage. If they are damaged or
lost, replace with new ones.
Drive front
2 4
l
7
ria
9
.c T
F 6
om
3
Fork front z D 10
1
P
8
ard
w.p m
5
i
dfw
ww o
cuC
415W002
*This illustration shows RB10, Drive front type.
No. Parts No. Parts Name Q'ty Notes

(1) 50004-11790 Plate, instruction 1 Caution in operation
Do
(2) 24700-06980 Plate, Warning 1 Wear safety belt

(3) 50004-65050 Plate, Warning 2 No person on/under forks
(4) 50004-65060 Plate, Warning 1 Caution for fingers
(5) 24700-06990 Plate, Caution 1 Caution in the charge
(6) 38540-00520 Plate, Caution 1 Caution for battery
(7) 24700-04630 Plate, Caution 1 Electric shock attention
(8) 50002-95620 Plate, Lubrication 1 Lubrication
(9) 24700-04610 Label, hook 2 Hook position
(10) 54000-92410 Plate, Caution 1 Back up battery
5
SAFETY WORK
1
CAUTION 9. Do not make a sudden start,stop or turn.
10.Do not operate or park on an incline.
1.Only a trained and authorized operator shall operate this truck.
11.Do not travel while the forks are in the raised position.
2.Prior to operation,read the operator's manual carefully for safe
and efficient operation. 12.Do not overload.Failure to observe the rated capacity
3.Carry out the daily inspection before operation. can cause to tip over.
Do not operate the lift truck until repairing if any damage or 13.Do not carry the off-center load.
fault are found. 14.Lifting and lowering should be done on the flat floor.
4.Use the fuse with prescribed amps for replacement. 15.Lower the fork slowly when loading.
5.Always wear a helmet and safety belt. Apply the safety guard 16.Stop the lowering operation immediately when the fork
while operation. hang up the rack and/or load and lift the forks
6.Make sure the accelerator grip is in neutral position before turning slowly to prevent unstable position.
on the key switch. 17.When getting off the lift truck, lower the forks on the
7.Do not operate any functions from outside of floor,turn off the key switch and remove the key.
the operator's compartment.
8.Never allow anyone to ride on the lift truck other than operator. 50004-11790
l
ria
2 3
.c T
WARNING
F
om
z D
P
ard
w.p m
24700-06980
i
dfw
ww o
cuC
警告
WARNING
Do
50004-65050
5
Fire hazards !
1. Always charge the battery in well ventilated area.
DO NOT smoke, keep flames away.
2. DO NOT use equipment that is liable to

produce sparkes, in this area.
3. Open the battery cover while charging battery.
24700-06990
6
SAFETY WORK
GASES produced by this battery can be explosive.

Cigarettes, flames or sparks could cause battery to explode.
Make sure batteries are stored and charged in a well—ventilayed area.
Batteries contain SULFURIC ACID can cause severe burns.
Avoid contact with skin, eyes or clothing.
In event of accident flush with water and call a physician immediately.
Wear rubber gloves to prevent ELECTRIC SHOCK during checking.
and maintaining.
Keep out of reach of children.
IMPORTANT POINT FOR MAINTENANCE
1. Keep the electrolyte level at proper height. (EX.) VENT PLUG
l
(When electrolyte decreased, fill purified water White
ria
line
and stop filling immediately if confirmed the white line of the
float as shown herein, for over—filling causes overflow.)
2. Always give the battery an adequate charge and
FLOAT
do not use the battery at overdischarged condition.
3. Keep the surface of battery clean and dry.
.c T
8 7
F
om
LUBRICATION 1200HOUR
600HOUR z D
点検給油表 200HOUR
25HOUR
始業点検
pre-operation check
P
PALETTE LOCK FORK SUPPORT SHAFT
CG CG
パレットロックフォークサポートシャフト
ard
SAFTY BELT & GUARD DRIVING SYSTEM
MO
安全ベルト＆ガード操作系
BRAKE PEDAL HOSE PULLEY

MO MO
w.p m
ブレーキペダルホースプーリー
MAST LIFT CHAIN

CG CG
マストリフトチェーン
i
OIL TANK BATTERY
FO FO W
dfw
オイルタンクバッテリ
ww o
OIL FILTER BRAKE

24700-04630
オイルフィルタブレーキ
STEERING GEAR DRIVE ASS'Y

cuC
CG GO GO
ステアリングギヤドライブASS'Y
: LUBRICATION CG : CHASSIS GREASE FO : FORK OIL

給油
: REPLACE
シャーシグリース
MO : MACHINE OIL
フォークオイル
W : REFINED WATER
9
交換マシンオイル精製水
: CHECK AND ADJUSTMENT GO : GEAR OIL
点検・調整ギャ−オイル 50002-95620-A （和、英）
Do
10
バッテリプラグを抜いたまま
長期間（約１ヶ月以上）車両を
放置しないでください。内部 24700-04610
データの消失により、起動でき
なくなります。
注 DO NOT leave the battery

plug disconnected for more
than one month, or the
意 truck becomes unoperable
for loss of stored data.
54000-92410
7
SAFETY WORK
3. Model name and serial numbers

Model name
Name plate
LOAD CHART
MODEL LIFT HEIGHT
mm
MAXIMUM kg mm
CAPACITY kg
LOAD/LC
LIFT HEIGHT
l
kg mm
ria
SERIAL NO. MFG.YEAR
SERVICE WEIGHT
W/O BATTERY
VOLTAGE V LOAD CENTER mm
BATTERY WEIGHT MIN. kg
.c T
RB
RBC
F
om
Capacity code z D 7 : 700kg (RBC)
9 : 900kg (RBC)
10 : 1000kg (RBC/RB)
P
15 : 1500kg (RB)
ard
D : Drive front
w.p m
F : Fork front
i
Model No.
dfw
ww o
B : Large capacity battery equipped

cuC
C : Stationary charger
D : Dust resistant
(Built-in charger)
Maximum lifting height [cm]

Do
Mast type M : Three stage full free lift (triplex) mast

(Full visibility mast)
CS : Cold storage use for -35

W : Wide straddle leg
FCS : Cold storage use for -50
RP : Rust resistant
DP : Damp resistant
8
SAFETY WORK
Serial numbers
No. Serial numbers Stamped position
1 Serial No. of a truck Stamped on the name plate.
2 Serial No. of a chassis Stamped on the battery compartment.
3 Serial No. of a mast Stamped on the mast name plate.
4 Serial No. of a front axle Stamped on the left front axle.
l
5 Serial No. of a traction motor Stamped on the motor name plate.
ria
6 Serial No. of a hydraulic motor Stamped on the motor name plate.
7 Serial No. of a EPS motor Stamped on the motor name plate.
.c T
8 Serial No. of a lift cylinders Stamped on the lift cylinders.
F
om
Location of serial numbers
z D
P
ard
LOAD CHART
MODEL LIFT HEIGHT
mm
MAXIMUM kg mm
CAPACITY kg
LOAD/LC
LIFT HEIGHT kg mm
8
⑧
w.p m
SERIAL NO. MFG.YEAR

SERVICE WEIGHT
W/O BATTERY
VOLTAGE V LOAD CENTER mm
BATTERY WEIGHT MIN. kg

i
dfw
5
⑤
ww o
①
1
3
③
cuC
2
②
7
⑦
Do
6
⑥
4
④
*This illustration shows RB10, Drive front type. 415W004
9
SAFETY WORK
4. Cautions for maintenance

General precautions
 When replacing any parts, be sure to use genuine
NICHIYU parts.
 When parts are assembled, always replace old
packing and O-rings with new ones. In addition, be
sure to apply a light coat of grease on the O-rings and
oil seals before installing them.
l
 As shown in the illustration, face the flat side of the
ria
Retainer for Retainer for
C-shape retainer in the direction the force is applied a groove a hole
when installed.
.c T
F
om
152E101
z D
 As shown in the illustration, face the slit side in the
direction the force is applied when driving in a spring
P
pin.
ard
w.p m
i
dfw
ww o
152E102
cuC
 The split pin must be replaced with a new one and split
so it will not come out.
Do
152E103
 When using a thrust washer with oil grooves cut,

Oil grooves
observe the direction of installation.
152E104
 When connecting and disconnecting couplers of

electrical harnesses, always disconnect the battery
plug.
10
SAFETY WORK
Using liquid packing

 Scraping before application of seal
Remove the sealer adhered on the mating surface of the
casing using a scraper or equivalent tool. Be careful not
to make scratches of 0.3 mm or deeper. If scratches are
Scraper
made, repair the area using an oil stone.
l
ria
152E105
 Applying liquid packing
.c T
1. Wipe off the mating surfaces using a cloth soaked in
gasoline to remove oil and contamination.
Do not use kerosene, light oil, or crude oil.
F
om
Cut the nozzle at the
2. Cut
z D
the nozzle of the liquid gasket tube at about the
second section so that the bead width will be 3 to 3.5
second section
P
mm. 3 - 3.5 mm
ard
Mating surface Liquid packing
152E106
w.p m
3. Attach a key for rolling up the tube, and apply the liquid
i
gasket to the mating surface while rolling up the tube.
dfw
ww o
Do not smooth out the bead; doing so may cause

leakage. Not Good
cuC
When applying the liquid gasket to bolt holes, apply it 3 -3.5 mm

Key to evacuate
on the internal portion of the mating surface. liquid packing
Good
152E107
Do
4. Close the mating surfaces within 15 minutes after the

Apply liquid packing
liquid gasket is applied.
Within 15 minutes
5. When tightening the bolts, always tighten temporarily
Assembly
first, and then tighten them gradually, moving from one to
the next in a diagonal pattern. Wait for 30 minutes or more
Filling oil/Operation
6. Wait for more than 30 minutes before adding oil or
operating the machine.
Failure to do so may cause oil leakage.
11
SAFETY WORK
 Deterioration of liquid packing
1. Once the tube has been opened, the liquid gasket If the oil has separated, the
anchoring the tip part of the nozzle might be cured and gasket has deteriorated.
deteriorated. Squeeze out that portion and discard it Squeeze out the
bead about 20 mm
before reusing the gasket. and check.
152E108
l
ria
2. If oil (filler) was separated from the liquid gasket and
the gasket appears shiny when it is squeezed out, this
indicates that the liquid gasket has deteriorated.
.c T
Although the oil may have been separated from a
liquid gasket opened before its expiration date, this is
not an indication of deterioration.
F
om
CAUTION
z D
If the state of the gasket is normal, it will be
cured within approximately 2 hours. However, a
P
deteriorated gasket will not.
ard
w.p m
i
dfw
ww o
cuC
Do
12
SAFETY WORK
5. Tightening torque for bolts
Classification of bolt 4T 8T Brass Stainless
SCM435
Material of bolt SS400
(S55C)
BsBM2S-0 SUS304
Nominal Pitch *1
of bolt Tightening torque *2 Unit : N m{kgf m}
(mm) (mm)
l
0.6 1.3 0.4 0.5
M3 0.5
ria
{0.06} {0.14} {0.04} {0.05}
1.4 3.2 1.0 1.0
M4 0.7 {0.14} {0.33} {0.10} {0.11}
.c T
2.7 6.4 1.8 2.0
M5 0.8
rs
{0.28} {0.66} {0.19} {0.21}
te ale
4.7 10 3.1 3.6
M6 1.0
F
om
{0.48} {1.1} {0.32} {0.37}
bu e11
z D 26 7.8 9.0
tri d D
M8 1.25
{1.1} {2.7} {0.80} {0.92}
22 55 15 18
D ize P
M 10 1.25 {2.3} {5.7} {1.6} {1.9}
ard
39 98 29 33
ot or
M 12 1.25 {4.0} {10} {3.0} {3.4}

w.p m
is
N uth
62 150 47 53
(M 14) 1.5 {6.3} {16} {4.8} {5.4}
i
D rA
dfw
ww o
97 240 73 81
M 16 1.5 {9.9} {25} {7.5} {8.3}
fo
cuC
o
180 500 140 150

y
M 20 1.5 {19} {51} {15} {16}

nl
O
250 670 200 220

(M 22) 1.5 {26} {69} {21} {23}
320 840 250 280
M 24 2.0
Do
{33} {86} {26} {29}

640 1600 530 570
M 30 2.0 {66} {170} {54} {58}
*1. In the table above, the thread pitches of bolt diameters M3 to M8 are for coarse
screw threads and those of bolt diameters M10 or larger are for fine threads
according to our specifications.
*2. The tolerance range of tightening torque is to be +/- 10% of the reference values
given above. (The tolerance range is determined according to experience, related
standards, and records provided by other companies.)
13
SAFETY WORK
6. Maintenance tools and inspection devices

The table shows tools/devices required for inspection and maintenance.
Type No. Tool/Device name Detail
1 Doubleended spanner 6x7, 8x10, 11x13, 12x14, 17x19, 22x24
2 Single-ended spanner 24, 27, 30, 32
3 Offset wrench 10x12, 14x17, 22x24, 23x26
4 Extension bar 12.7x150mm
5 Box socket 12.7x10, 12, 13, 14, 17, 19, 21, 22, 23, 24, 26, 27, 30, 32
l
6 Adjust wrench 300mm
ria
7 Hexangular wrench
8 Screwdriver (+)100, 150, 200, (-)100, 150, 200
9 Hammer 1P
10
.c T
Shockless hammer
11 Radio pliers 150mm
Maintenance
tools 12 Cutting pliers 150mm
13
F
om
Pliers 150mm
14 Nippers z D 150mm
15 Water pliers 250mm
16 Pressure pliers
P
17 Snap ring pliers
ard
18 Gear puller For outward form 30～150mm
19 Pipe wrench 200, 350, 900
w.p m
20 Scraper
21 Monkey wrench
i
dfw
22 Chisel
ww o
23 File
cuC
24 Thickness gauge 0.03～3mm

25 Measure 300mm、1000mm
26 Tape measure 10m
Resistor
27 (For discharging procedur) 20Wx50　 or 50Wx10 or 10Wx15
28 Digital tester
29 Clamp tester
Do
30 Analog clamp ammeter Hioki 3109-01

31 Digital clamp ammeter Hioki 3209AC/DC high tester/Yokogawa CL-612(for measuring solenoid valve current)
Megger
Inspection 32 (For inspection of insulation)
devices 33 Oil pressure gauge 25MPa
34 Thermometer Alcohol thermometer
35 Hydrometer Suction type
36 Color tester Color check
37 Stopwatch
38 Torque wrench 0.5～1.5, 3～15, 40～200, 150～800Nm（preset type）
39 Dial gauge
40 Spring scale
41 Angle gauge
14
15
MEMO
Do
cuC
ww o
w.p m
dfw
i P
z Dard F
.c T
om ria
l
1. GENERAL
1- 1. Appearance
RB
2. DRIVE UNIT
7
6
3. LOAD WHEEL
5 Hydraulic
system 4. BRAKE
l
ria
5a. HYDRAULIC
5d PUMP
.c T
9 5b.OIL TANK AND
OIL PIPING
F
om
4 5c. HYDRAULIC
11
z D 2 PUMP
10
5d.CYLINDER
P
ard
5c
6. MAST
w.p m
7.LIFT TABLE
i
3
dfw
ASS'Y
ww o
8
5b
cuC
5a 8. MOTOR
RBC 9.CONTROL
5b PANEL ASS'Y
10
10. ELECTRIC
Do
10 PARTS (*)
11. AUTO PALET
LOCK
12. SERVICE
DATA
152W003
* 10. ELECTRIC PARTS : See page 119.
16
1 GENERAL
1- 2. Specitications
RB10/15 (DRIVE FRONT)
E RB10/15 (FORK FRONT)
E
J
J
l
C C
.c T
ria
F
om
z D
F
F
P
ard
B
B
H
H
w.p m G
G
A A
i
dfw
ww o
M K I M K I
cuC
L L
D D
Do
17
GENERAL 1
MODELS RB10 RB15

Capacity Kg 1000 1500
Load center A mm 600
Lift height B mm 3000 3000
T r a v e l Laden Km/h 8.0 7.5

speed Unladen Km/h 9.0 8.0
Laden mm/s 220 200
Lift speed
Unladen mm/s 330 320
l
Min. turning radius C mm 1420 1520
ria
Overall length D mm 2455 2560
Overall width E mm 1090
Raised F mm 5080
.c T
Overall height Lowered G mm 2140
Mast H mm 2095
Fork length I mm
F 920
om
Fork spread J
iz D mm 560 - 750 610 - 750
Wheel base K mm 1210 1315
Front overhang L mm 130
P
Rear overhang M mm 195
ard
Service weight(W/O Batt.) Kg 1740 1890
Dirve(Rubber) ø 330 x 145 x 1
.p m
Tyres
Load(Urethane) ø 152 x 90 x 2 ø 152 x 109 x 2
Inverter control
dfw
Travel/Hydraulic
o
Control
EPS Chopper control
cuC
Travel 2.6
Motor Hydraulic Kw 8.8
EPS 0.30
ww
Battery (48V) 5HR 201Ah 210Ah

Charger(3 phase 200V) Automatic stationary charger 3.8KVA
Do
w
*Subject to change without notice for improvement.
18
2. DRIVE UNIT
2- 1. Name
 Main parts of Drive unit
Support, drive
EPS motor
l
Cover, EPS
.c T
ria
Cover, EPS Gear(2), steering
F
om
Gear(2)
z D
Support, gear case
P
ard
Gear(1)
Gear, steering
Gear, driven
w.p m
Coupling
i
dfw
Pinion, spiral bevel

ww o
Cover
Gear, counter
Pinion, drive
cuC
Nut comp.,hard lock

Do
Gear, spiralbevel
Case, gear
Shaft, drive wheel
415W010
19
DRIVE UNIT 2
2- 2. Disassembly and reassembly

CAUTION  Lift or jack up the forklift truck and support it with safety blocks or rigid
stands.
 Be sure to
 Record places of lead wire connections before disassembling.
 When disassembling hydraulic pipes, cover them with caps so that
dust doesn't enter.
 Be sure to disconnect the battery plug.
l
2-2-1. Drive unit - removal and installation
ria
NOTE RB is different in the procedure of removing drive unit to RBC.
.c T
1. Remove the following parts and device before remove the drive unit.
1. Open the "Cover, top".
F
om
 Removing the drive unit 1 z D Cover, top
P
ard
w.p m
i
dfw
ww o
cuC
415W025
RB 2. Remove the fitting bolts to remove the drive unit.

Do
 Removing the drive unit 2
Fitting bolt
Cover, body
415W019
20
2 DRIVE UNIT
RBC 2. Open the cover and side.

3. Disconnect the lead wires of transformer.
4. Remove the fitting nut and remove transformer and "cover,
transformer
CAUTION Record places of lead wire connections before

removing.
 Removing the drive unit 2
l
ria
Cover,
Transformer
Cover, Side
.c T
Fitting nut
F
om
Transformer
z D
P
ard
Lead wire
w.p m
i
dfw
ww o
415W020
cuC
Do
21
DRIVE UNIT 2
2. Remove the drive wheel.

 Removing the drive wheel
CAUTION When Installing Drive wheel, tighten the bolts
with cone washer first.
Drive wheel
l
ria
Cone washer
.c T
1 Tightening torque
90 - 100N m
{9-10 kgf m}
F
om
z D Tightening torque
415W018
P
5. Remove drive unit.  Removing the drive unit 3
ard
1. Install the tool to hoist traction motor.
Tool to hoist traction motor
w.p m
2.Remove the lead wires.

(Install to Erectromagnetic brake)
3.Remove the fitting bolts (4 bolts) of drive unit .
i
dfw
4.Hoist the drivie unit with traction motor.

ww o
cuC
CAUTION Record places of lead wire connections before M20X1.5 Nut

415W016
removing.
Hoist
Lead wires
(Erectromagnetic
brake) Lead wires
Do
(Traction motor)
Drive unit
Fitting bolt
415W015
22
2 DRIVE UNIT
4. Remove traction motor.  Removing the traction motor

1. Remove the fitting bolts. Hoist
Tool to hoist
2. Install the tool to hoist traction motor. traction motor
3. Hoist the traction motor with Brake.
Traction
motor
l
.c T
ria
F
om
z D
P
ard
1 Fitting bolt (M8)
Tightening 23.4 - 28.6 N m
w.p m
torque {2.34 - 2.92 kgf m}

2 Spline G
i
dfw
Apply grease
ww o
: Tightening torque
cuC
G : Apply grease 415W017
* Install the drive unit in reverse order of removal.

CAUTION When Installing Drive wheel, tighten the bolts
Do
23
DRIVE UNIT 2
2-2-2. Drive unit - disassembly and reassembly

EPS gear and etc.
 Disassembling and reassembling the drve unit (1)
EPS gear box

Gear oil Oil q'ty (L)
*SAE #80W 0.35
Breather, air
*S.A.E.#: Society of Automotive Engineers
number
l
ria
Cover, EPS
.c T
EPS motor
F
om
Gear(2)
z D
Gear(1)
Cover, EPS and Support, drive B

P
ard
Apply THREEBOND [#1212] on
mating surfaces.
w.p m
i
Support, drive
dfw
ww o
cuC
Gear(2), Steering
Do
Gear, Steering
: Tightening torque Seal, oil B G

B : Apply THREEBOND Apply grease on the lip of the oil
G : Apply grease seal and THREEBOND [#1104]
N : Not reusable
around it.
415W011
CAUTION In case that OIL SEALS, O RINGS, BEARINGS were removed, they should
be replaced to new ones.
24
2 DRIVE UNIT
Support, cover and etc.

 Disassembling and reassembling the drive unit (2)
Traction motor
Fitting bolt (M8)
Tightening 23.4 - 28.6 N m
torque {2.34 - 2.92 kgf m}
Nut, hardlock
l
ria
Tightening 200 - 220 N m
torque {20 - 22 f m}
CS
After Install , tighten nut so that
pre-load of the bearings are within
.c T
above.
Set screw L
F
om
Install the lock nut to overlap one of
z D Potentiometer the eight holes (M8) tap and the hole
of the lock plate, so that pre-load of
the bearings are within above.
Nipple, Then apply LOCTITE [#242] to the
P
Grease set screw to tighten.
ard
To body
Gear(2),
Plug, screw
w.p m
steering
Bearing G
i
Fill grease up between the bearings.
dfw
ww o
Plug, screw
A Pre-load
40 - 50 N m
cuC
Breather, air Measure at [A].

{4.0 - 5.0 kgf m}
Support,
Gearcase
Ring, O G
Apply grease.
Do
2 Gauge, level B
Apply THREEBOND [#1104].
Plug, screw B
Apply THREEBOND [#1104], or
Case, gear tape.
Gear box
Cover Gear oil Oil q'ty (L)

*SAE #80W 2.2
: Tightening torque Packing, cover
B : Apply THREEBOND *S.A.E.#: Society of Automotive
Engineers number
G : Apply grease
N : Not reusable 451W012
CAUTION In case that OIL SEALS, O RINGS, BEARINGS were removed, they should be replaced to new
ones.
25
DRIVE UNIT 2
Gears and etc.

 Disassembling and reassembling the drive unit (3)
Coupling G
Apply grease on a part of spline.
Support, gear case
Tightening torque
180 - 200 N m
{18 - 20 kgf m}
Caulk after adjusting the pre-load.
l
ria
Gear, driven Pre-load
Measure at 35-40 N
teeth of "Gear,
driven". {3.5-4 kgf}
.c T
Tightening torque
Pinion, Gear, 90 - 100 N m
drive counter
F {9 - 10 kgf m}
om
z D
Housing.,
bearing
P
1 Shim
ard
To adjust the pre-load
w.p m
i
dfw
ww o
Back lash
cuC
0.1 - 0.3 mm
Case, gear B Pre-load

Measure at a 170-180 N
hub bolt [B]. {17-18 kgf}
Do
2 Seal, oil B G
Apply grease on the lip of the oil
seal and THREEBOND [#1104]
around it.
2 Nut comp., hard lock L
Tightening torque 70-80 N m
Shaft, drive (Convex side) {7-8 kgf m}
wheel
: Tightening torque (Concave side) {12-13 kgf m}
B : Apply THREEBOND Apply LOCTITE [#242].
G : Apply grease
L : Apply LOCTITE
CAUTION In case that OIL SEALS, O RINGS, BEARINGS were removed, they should be replaced to new ones.
26
2 DRIVE UNIT
2- 3. Inspection and adjustment

2-3-1. Gears - Inspection and replacement
Check point Solution
Gearing
Wear
In case of beyond repair,
Scoring
replace as a set.
Pitting
l
ria
Damage of Splines
 Inspection of gears
Gear, driven
Coupling
.c T
Gear, counter
F Pinion,
om
spiral bevel
Cover, EPS
z D Pinion, drive
Gear(2)
P
ard
Gear(1)
Gear, steering
Gear(2), steering
w.p m
Gear, bevel
i
dfw
Shaft, drive wheel

ww o
cuC
415W014
2-3-2. Drive wheel - Inspection

Do
 Check for wear and scoring.

 Inspection of drive wheel
<Specifications>
[mm]
Specific
Item Models Wear limit
Dimension
Drive wheel RB10/15
330( D) x 145(W) 275
[ DxW] RBC7/9/15
121W136
27
DRIVE UNIT 2
2- 4. Troubleshooting
2-4-1. Drive unit - troubleshooting
No. Symptom Problem Solution
1. No good gearing or teeth wear of spiral bevel gear and Adjust or
spiral bevel pinion replace
2. No good gearing or teeth wear of counter gear and
Replace
drive pinion
3. No good gearing or wear of counter gear and driven
l
Replace
gear
ria
Continuous noise
1
while traveling 4. No good adjustment or wear of spiral bevel gear Adjust or
bearing replace
5. No good adjustment or wear of spiral bevel pinion Adjust or
.c T
bearing replace
rs
Clean and
6. Lack of gear oil or foreign material in gear case
replenish
te ale F
om
1. Damage of bearings due to excess pre-load Replace
2 Gear case heat
bu e
2. Too small back lash of spiral bevel gear and spiral
z D Adjust
tri d D
bevel pinion
Vibration while 1. Flat spot on drive wheel Replace

D ize P
3
traveling
ard
2. Cracks on wheel Replace
ot or
Abnormal noise 1. Chocks or coring on drive wheel Replace

4
w.p m
is
N uth
while traveling 2. Abnormal noise from traction motor Inspect

i
1. Wear of oil seal Replace
D rA
dfw
ww o
2. Looseness of gear case support bolts, or damage of

5 Gear oil leakage Replace
O-ring
fo
cuC
3. Looseness of gear case cover bolts, or damage of

o
Replace
y
packing
nl
Slipping of drive 1. No good adjustment of control linkage Adjust

O
6 wheel when
accelerating 2. Abnormal wear of drive wheel Replace
Do
28
3. LOAD WHEEL
3- 1. Name
3-1-1. Load wheel - main part names
 Main parts of the load wheel
l
ria
Load wheel,
.c T
Pin, tilt
F
om
z D
P
ard
w.p m
i
dfw
ww o
Straddle leg
cuC
415W025
Do
29
LOAD WHEEL 3

stands.
 Disassenbly of the load wheel
l
ria
Bearing G
Fill grease up between the bearings.
Load wheel
.c T
Pin, tilt
F
om
z D
P
ard
w.p m
Straddle leg
i
dfw
ww o
G : Apply grease
N : Not reusable
cuC
415W026
CAUTION In case that BEARINGS were removed, they should be replaced to new ones.
After filling grease, check for smooth rotation of the load wheel.
Do
30
3 LOAD WHEEL

3-3-1. Load wheel - Inspection
1. Check for wear and scoring.  Inspection of load wheel
<Specifications> [mm]
Applicable Specific
Item Wear limit
models Dimension
RB10
Load wheel 152( D) x 90(W) 130
RBC7/9/10
l
[ D x W]
RB15 152( D) x 109(W) 130
ria
2. Check for lubrication and smooth rotation.
.c T
121W140
F
om
3-3-2. Pin, tilt - Inspection z D
1. Check for wear.  Inspection of pin, tilt
<Specifications>
P
[mm]
ard
Applicable Specific
Item Wear limit
models Dimension
w.p m
Pin, tilt RB10/15

30 29.8
[ D x W] RBC7/9/10
i
dfw
ww o
415W024
cuC
Do
31
4. BRAKE
stands.
 Be sure to
l
ria
4-1-1. Brake ASS'Y - removal and installation
 Removal and installation of brake ASS'Y
.c T
Fitting torque
Screw, cap
88.2 - 108 N m
F
om
{9.0 - 11.0 kgf m}
z D
Brake ASS'Y,
P
magnet
ard
w.p m
i
dfw
ww o
Key
cuC
Traction motor
Do
: Tightening torque
415W028
32
4 BRAKE
4-1-2. Brake - disassembly and reassembly
 Disassembling and reassembling the brake ASS'Y
Spline hub Torque adjusting ring
Armature Lining
l
ria
Screw, cap
Magnet
.c T
F
om
Adjusting
sleeve
z D
415W040
P
ard
w.p m
i
dfw
ww o
cuC
Do
33
BRAKE 4

4-2-1. Brake ASS'Y - inspection
 Inspection of friction
Armature
<Checking item>
(0.2mm)
Air gap
1 Operation of ON-OFF
2 Abnormal sound
l
ria
3 Abnormal heat
4
alien substance or oils are stuck to friction(magnet,
armature) .
.c T
5 Air gap between magnet and armature is too widen.
Magnet
415W038
F
om
z D
P
4-2-2. Air gap - adjustment  Adjusting the air gap
ard
Air gap (0.2mm)

1. Loosen the adjusting sleeve to adjust the air gap using
w.p m
Screw, cap
the clearance gage.
i
2. Tighten the screw and cap.
dfw
ww o
cuC
Adjusting
sleeve
CAUTION Adjusting the air gap is impossible after
Do
415W039
tightening the magnet.
34
4 BRAKE

1. The travel condition is not met Adjust / replace
Cannot release
1 2. Failure of microswitch wiring Replase wires.
the brake
3. Failure of brake power supply Inspect / repair
1. The brake air gap is too large Adjust
l
Insufficient brake
2
ria
release 2. Low battery voltage Inspect / repair
1. Failure of exciting circuit Inspect / repair
3 Ineffective brake
2. Abnormality of brake Replace
.c T
Abnormal noise 1. Rotor and fitting flange are in
Repair
4 from brake contact.
Abnormal of brake 2. Abnormal of brake
F Replace
om
z D
P
ard
w.p m
i
dfw
ww o
cuC
Do
35
5. HYDRAULIC SYSTEM
5- 1. Hydraulic circuit
Fuse valve
l
ria
Lift cylinder 5a
.c T
A
5b
Lift solenoid valve
F
om
5c
Manual down valve
(Emergency handle)
z D T
5d
P
ard
w.p m
i
dfw
PG
ww o
Relief valve
P
cuC
T
Do
0MPa
415W162
36
5a HYDRAULIC PUMP
5a. HYDRAULIC PUMP

5a- 1. Name
 Main parts of hydraulic pump
Cushion(2)
l
Bracket,
ria
cushion
.c T
F Hydraulic motor
om
z D
P
ard
Cushion(1)
w.p m
i
Bracket, motor
dfw
ww o
cuC
Coupling, pump
Do
Hydraulic pump
* This illustration showes Model RB. 415W029
<Hydraulic pump type>

Applicable model Type
RB10/15
TMG1-15
RBC7/9/10
37
HYDRAULIC PUMP 5a
5a- 2. Disassembly and reassembly

stands.
 Apply wheel chocks to tyres to prevent the truck from moving.
 When disconnecting hydraulic pipes, cap them to prevent dust from
entering into hydraulic components and pipes.
l
ria
5a-2-1. Hydraulic pump - removal and installation
NOTE RB is different in the procedure of removing hydraulic motor to RBC.
.c T
1. Remove the following parts and device.
F
om
RB 1. Open 'Cover, top". z D
2. Remove the fitting bolt to remove "Cover, body".
Refer to "2-2-1. Drive unit removal and installation 1".

P
ard
RBC 1. Open 'Cover, top".
w.p m
2. Open 'Cover, side".

i
dfw

ww o
cuC
2. Disconnect the lead wires of control valve and hydraulic motor".
CAUTION Record places of lead wire connections before removing.

Do
38
5a HYDRAULIC PUMP
3. Remove the high pressure hose and low pressure hose..

CAUTION Before disconnecting the high pressure pipe or the high
pressure hose, turn the emergency handle (refer to the page
52) to release the high pressure in the hydraulic piping.
RB * Only for RB.

4. Disconnect the U nut to remove "Bracket, valve" with control valve from
the body.
5. Disconnect the U nut to remove "Bracket, cushion" and "Bracket,
l
motor" from the body.
ria
6. Remove the hydraulic motor with the hydraulic pump".
7. Disconnect the fitting bolt to remove the hydraulic pump".
.c T
 Removing the hydraulic pump ASS'Y
F
om
 U nut (M12)
RB
1 Tightening torque
Bracket, valve
z D Emergency handle
Control valve
36 - 43 N m
{3.6 - 4.3 kgf m}
P
ard
High pressure hose
(From mast piping)
w.p m
High pressure hose

i
dfw
(From hydraulic pump )

ww o
Low pressure hose

(From oil tank)
cuC
Bracket, cushion
Hydraulic motor
Do
Lead wires
Bracket, motor
Coupling, pump MG
spline : Apply molybdenum grease

High pressure hose
 Fitting bolt (M10)

Hydraulic pump Tightening torque
Low pressure hose 20 - 24 N m
(From oil tank)
: Tightening torque {2.0 - 2.4 kgf m}
MG : Apply molybdenum grease
39
HYDRAULIC PUMP 5a
 Removing the hydraulic pump ASS'Y

RBC
Bracket, cushion
 U nut (M12)
1 Tightening torque
36 - 43 N m
{3.6 - 4.3 kgf m}
Low pressure hose
l
(From oil tank) Hydraulic motor
ria
High pressure hose
(From hydraulic pump)
Lead wires
.c T
Bracket, motor
F
om
Control valve
z D (From oil tank)
Low pressure hose

Low pressure hose
P
Coupling, pump MG
ard
(From mast spline : Apply molybdenum grease
piping)
High pressure hose
w.p m

Hydraulic pump Tightening torque
i
dfw
ww o
20 - 24 N m
{2.0 - 2.4 kgf m}
cuC
Do
: Tightening torque
MG : Apply molybdenum grease 415W051
40
5a HYDRAULIC PUMP
7. Remove the elbow and the O ring nipple.  Removing the hydraulic pump
8. Remove the coupling.

Coupling
CAUTION Do not disassemble "Pump, gear". pump
When damaged, replace the whole pump assembly.

Elbow
O ring
nipple
l
ria
: Tightening torque
N : Not reusable
.c T
2 Flat key ( 4 x 4 x 16)
Attachments for pump
* Install the hydraulic pump in reverse order of removal.
F 1 Tightening torque
om
CAUTION In case that OIL SEALS, O RINGS, BEARINGS were
z D 36 - 43 N m
removed, they should be replaced to new ones. {3.6 - 4.3 kgf m}
P
ard
w.p m
5a- 3. Inspection and adjustment

i
dfw
ww o
5a-3-1. Hydraulic pump - inspection

cuC
 Install the hydraulic pump on a truck and check the function by actual lift speed.
CAUTION Measure Lift speed after raising the temperature

of Hydraulic oil by operating several times.
Do
<Specific lift speed> [mm/sec]

Lift speed
Applicable model
Unladen Laden
RB10 330 220
RB15 320 200
RBC7 330 240
RBC9 330 220
RBC10 330 220
41
5a- 4. Troubleshooting
5a-4-1. Hydraulic pump - troubleshooting
1. Shortage of hydraulic oil Replenish
1 No oil is pumped out. Inspect and
2. Clogging of the suction hose.
clean
1. Damage of the oil seal Replace
2. Damage of the gasket (O ring) Replace
l
2 Oil leakage
ria
3. No good tightening or damage of the cover and Retighten or
the body, or fitting surface is worn or damaged replace
1. Wear of the bearing, gear and body Replace
.c T
2. Mixture of air
Replenish
 Shortage of hydraulic oil
Retighten
3 Pressure is not raised.  Air mixed from the suction hose connection.
F Replace
om
 Damage of the seal kit (oil seal, O ring)
3. No good adjustment of the relief pressure of the
z D Adjust
control valve
Correct or
P
1. Crushed in the suction hose
replace
ard
2. Clogging of the filter Clean
w.p m
3. Air mixed from the suction hose connection Retighten

4 Abnormal noise 4. Air mixed from the oil seal Replace
i
dfw
ww o
Withdraw air
5. Air in the hydraulic oil
or replace
cuC
6. Shortage of the hydraulic oil Replenish

7. High temperature of viscosity of hyraulic oil Replace
1. Contaminated oil Replace
5 High oil temperature 2. High viscosity of hydraulic oil Replace

Do
Observe
3. Overwork
specification
Replace or
No rotation of hydraulic 1. Failure or defective adjustment of the lift switch.
6 adjust
motor
2. Blow out of the main fuse Replace
42
5b OIL TANK AND OIL PIPING
5b. OIL TANK AND OIL PIPING

5b- 1. Disassembly and reassembly
CAUTION  Apply wheel chocks to tyres to prevent the truck from moving.
 Retract the mast and lower forks to the ground when draining hydraulic oil.
 When disconnecting hydraulic pipes, cap them to prevent dust from entering
into hydraulic components and pipes.
 Wind seal tape on the thread of filters and the plug, and be sure to tighten them when installing them.
l
ria
5b-1-1. Oil tank - removal and installation
.c T rs
te ale F
om
RB10/15
bu e
z D
tri d D
1. Open 'Cover, top".
D ize P
2. Disconnect the fitting bolt to remove "Cover, body".
ard
ot or

w.p m
is
N uth
2. Remove the low pressure hose.

i
D rA
dfw
3. Disconnect the bolts of "Band, tank" to remove the oil tank.

ww o fo
* As for CS and FCS, remove the fitting bolts of the oil tank to remove
cuC
o
the oil tank..

y
nl
 Removing the oil tank

O
Low pressure hose

(From control valve)
RB
Do
Low pressure hose

(From control
valve)
Low pressure hose

Fitting bolt Band, (From control
tank valve)
Oil tank
415W052
43
* Install the oil tank in reverse order of removal.
OIL TANK AND OIL PIPING 5b
RBC7/9/10
1. Open 'Cover, top".
2. Open "Cover, side".

3. Disconnect the fitting bolts of the oil tank.
l
4. Disconnect the U nut to remove "Bracket, transformer" with transformer,
ria
"Cover, transformer" and "Band, tank".
5. Remove the oil tank.
.c T
5b
 Removing the oil tank
F
om
RBC Low pressure hose
z D
(From control valve)
Low pressure hose Hose

P
ard
(From hydraulic pump
and control valve)
Oil tank
w.p m
Band, tank
i
dfw
ww o
Cover, transformer
cuC
Fitting bolt
Do
Fitting nut
Transformer
Bracket, transformer
* Install the oil tank in reverse order of removal.
44
5b-1-2. Oil tank - disassembly and reassembly

Std
 Disassembling and reassembling the oil tank
Hose S
Apply the seal into the insert nozzle
of the hose.
Gauge, oil
l
ria
Cover, tank(2)
.c T
F
om
Cover, tank(1)
Gasket(1)
z D
P
ard
Filter, return
Cap, tank
w.p m
Gasket(2)
i
dfw
ww o
valve, check
cuC
Oil tank
Do
S : Apply seal
NOTE The removing of "Valve, check" needs a special tool, and they
cannnot be removed only in the tank.
45
CS, FCS
 Disassembling and reassembling the oil tank
Cover, tank(2)
Viewed from A
Gauge, level B
Apply THREEBOND [#1104]
l
ria
valve, check
Filter, return
Pipe, saction
.c T
Gasket(2)
F
om
Gauge, oil
z D Filter, saction
P
ard
w.p m
i
dfw
Oil tank
ww o
cuC
Do
B :Apply THREEBOND
415W031
46
5b-1-3. Oil piping replacement - precautions

Pay attention to the following refering to "Hydraulic circuit" on
page 36 when replacing the hydraulic device or hoses..
NOTE Wrap sealant tape around the screws of the connector of hoses before connection.
CAUTION Use applicable hoses for the pressure.

Unexpected force may be applied.
l
.c T
ria
152E125
Do not fit short hoses in the length.

Hose might be damaged due to sharp bending.
F
om
z D
P
ard
152E126
w.p m
Do not fit a hose with twisting. Pay attention that hoses can twist by using even
if it was not twisted when connected.
i
dfw
ww o
Twisting can be known with the letters on the surface of hoses.
Letters
cuC
Letters
152E127
Do
47
5b- 2. Inspection and adjustment

5b-2-1. Oil tank - cleaning and check
2. Remove the cover.
3. Remove the filters.
4. Clean with compressed air and check the filter for
l
clogging and damage.
ria
If the filter is clogged or damaged, replace it.
5. Remove any dart or foreign material from the oil tank.
.c T
5b-2-2. Oil - inspection
F
om
 Put some hydraulic oil out in a test tube and compare
with new oil to check.
z D
P
<Specific oil conditions>
ard
Appearance Smell Conditions Countermeasure
w.p m
Transparent, and color is

Good Good. Usable.
not different.
i
dfw
Transparent, ,but color is Check viscosity.

ww o
Good Different oil mixed.

light. If good, it is usable.
cuC
Color changed into milky Separate water. Then, it is

Good Air and/or water are mixed.
white. usable.
Color changed into dark
Bad Inferior with oxidizing. Oil change
brown.
Transparent, ,but with
Do
Good Foreign article mixed. Filter it. Then, it is usable.

small black spots.
5b-2-3. Recommended oil
<Recommended oil>
Specification Recommended Oil
Shell : Tellus Oils 32
Standard ESSO : Power lex 32
Mobile : Hydraulic oil 28
Shell : Tellus T15
FCS
ESSO : Univis 43
48
5b-2-4. Oil quantity
CAUTION  Before checking oil level, lower the fork on the

flat ground.
 Adjust the oil level within proper range of the
level gauge.
NOTE Oil in pipings and cylinders ( 5-10 L) is excluded

from the following quantity.
l
ria
<Specifications (Std/CS/FCS) >
Applicable model Oil quantity Level gauge
.c T
RB10 9.0 L Within
HIGH and
LOW under
RB15 12.0 L
condition that
Ffork is on the
om
RBC7/9/10 9.0 L ground
 Oil quantity
z D
P
ard
Std
w.p m
Level gauge RB15 (Std) CS, FCS

i
dfw
ww o
HIGH
cuC
HIGH
LOW
LOW
Level gauge
Do
415W054
5b- 3. Troubleshooting
Inspect and retighten the fitting
1 Bubbled 1. Mixture of air
hose.
1. Air and water are mixed. Oil change
Oil colorl is
2 2. Inferior with oxidizing or foreign
changed. Oil change
material mixed.
49
5c. CONTROL VALVE
5c- 1. Disassembly and reassembly
stands.
l
ria
5c-1-1. Control valve - removal and installation
.c T
RB10/15
F
om
 Removing and instllation the control valve
z D
Valve ASS'Y, control
P
ard
w.p m
High pressure hose

(From mast piping)
i
dfw
ww o
cuC
High pressure hose

Low pressure hose
(From oil tank) Bracket, valve
Transmitter, pressure
Do
 Lock nut
Tightening torque
6.9 - 8.8 N m
{70 - 90 kgf m}
: Tightening torque
415W064
* Install the control valve in reverse order of removal. 50

5c CONTROL VALVE
RBC7/9/10
 Removing and instllation the control valve
Valve ASS'Y, control  Lock nut

Tightening torque
6.9 - 8.8 N m
{70 - 90 kgf m}
l
.c T
ria
Transmitter, pressure
F
om
z D Low pressure hose
(From oil tank)
P
ard
High pressure hose
Bracket, valve
w.p m

i
dfw
ww o
cuC
Low pressure hose

Low pressure hose (From oil tank)
High pressure hose
(From mast piping)
: Tightening torque 415W069

Do
51
CONTROL VALVE 5c
5c- 2. Inspection and adjustment

5c-2-1. Relief pressure - measurement and adjustment
CAUTION Use 20MPa(200kgf/cm2) pressure guage that is equipped  Measuring relief pressure
the damper.
Pressure
guage
1. Turn off the key switch. Push and pull each levers
several times to lower pressure in the pipings.
2. Remove the plug of Lift section, and install the
l
Damper
ria
pressure gauge with the adapter.
3. Turn on the key switch, and pull the Lift lever to the
stroke end.
Then read the indication of pressure gauge.
.c T
Installing
<Specification>
Applicable model Relief pressure
F
om
Adapter
415W062
RB10/15 13.7MPa(140kgf/cm2)
z D
RBC7/9/10 15.7MPa(160kgf/cm2)
P
ard
If the relief pressure is deviated from the above specification,
adjust the pressure using the adjusting screw.
w.p m
i
dfw
 Adjusting relief pressure

ww o
cuC
Emergency handle
Adjusting screw
Relief valve
Do
 Lock nut (M6)

Tightening torque
6.9 - 8.8 N m
{70 - 90 kgf m}
Put off the plug and

install pressure gauge.
: Tightening torque
415W061
CAUTION The adjusting screw needs only to be turned slightly

to make an adjustment.
52
5c CONTROL VALVE
5c- 3. Troubleshooting
5c-3-1. Control valve - troubleshooting

1. Failure of the pump Replace
2. Shortage of hydraulic oil Replenish

Lifting can not
1
l
work. 3. Failure of control valve solenoid wiring Replace
ria
4. Failure of the lift switch Replace
Load of rated 1. Failure of the relief valve Adjust or replace
.c T
2 capacity can not
be lifted. 2. Failure of the pump Clean or replace
1. Overdischarge of the battery Charge
F
om
2. Damage of the packing in the cylinder Replace
3
Lifting speed is too
z D
3. Low relief pressure
4. Failure of the pump
Adjust or replace
Clean or replace
slow.
P
ard
5. Clogging of the filter in the tank Clean or replace
6. No good adjustment of the hydraulic chopper Adjust
w.p m

i
1. Damage of the Cylinder or the Piston Replace
dfw
ww o
Too much drifting

4 2. Damage of the packing of Piston Replace
of lifting
cuC
3. Foreign article mixed in the valve Clean or replace

Too much shaking
5 1. Failure of the lift pressure sensor Replace
of lifting
1. Damefe of the O ring or the wiper Replace
6 Oil leakage
2. Looseness of the relief valve Tighten
Do
53
5d. CYLINDER
5d- 1. Name
5d-1-1. Lift cylinder
Std Mast
 Main parts of lift cylinder (Std mast)
l
ria
Valve, check
Bush
.c T
Kit, head
Bearing, cushion
F
om
spacer
Tube ass'y, cylinder

z D 5d
P
Rod ass'y, piston
ard
w.p m
i
dfw
ww o
cuC
415W056
Do
54
5d CYLINDER
M Mast
 Main parts of lift cylinder 1st (M mast)
Valve, check
Plate
Bearing, cushion
Kit,cylinder head
l
ria
.c T
Rod ass'y, piston
F
om
z D Valve, down safety
P
Plug
ard
415W057
w.p m
 Main parts of lift cylinder 2nd (M mast)

i
dfw
Valve, check
ww o
Bush
cuC
Kit, head
Bearing, cushion
MLH=6000
spacer
spacer
Do
Rod ass'y, piston
Applicable M mast
model Lifting height
RB15 4000 - 6000
RB10 4000 - 5000
RBC7/9/10 4000 - 5000
415W058
55
CYLINDER 5d
 Main parts of lift cylinder 2nd (M mast)
Bush
Kit, head
Bearing, cushion
spacer
l
ria
Tube ass'y
cylinder (L/R) Cylinder (L/R) ass'y, lift
.c T
F
om
Applicable M mast
z D model Lifting height
RB10 5300 - 6000
P
ard
415W059
w.p m
i
dfw
ww o
cuC
Do
56
5d CYLINDER
5d- 2. Disassembly and reassembly

stands.
l
5d-2-1. Lift cylinder (Std mast) - removal
ria
1. Remove the lift table ASS'Y.
Refer to "6-2-1. Lift table ASS'Y removal".
.c T
2. Raise the inner mast about 50mm by operating lift lever.
F
3. Support the bottom of inner mast with a wood block or wire rope.
om
z D
4. Remove fitting bolt(*1),fitting bolt(*2), "Plate, lock", and "Bolt adjust".
* When mast lifting height is more than 4300, remove the bolt with "Head rod"
P
ard
put on the piston rod.
w.p m
 Removing the lift cylinder(Std mast) 1 Std mast

i
dfw
ww o
Fitting bolt(*2)
Plate, lock
cuC
Fitting bolt(*1)
Inner mast Bolt, adjust

Do
Fitting bolt(*1)
Outer mast
Outer mast
Head, rod
Piston rod
415W063
57
CYLINDER 5d
4. Remove the hydrauic pipes.

5. Remove "Band, cylinder" and band to remove lift cylinder.
l
ria
 Removing the lift cylinder(Std mast) 2 Std mast
Inner mast Outer mast
te ale
.c T rs
F
om
bu e
z D
tri d D
D ize P
ard
Band, cylinder
ot or
w.p m
is
N uth
Lift cylinder
i
D rA
dfw
ww o fo
cuC
o
y
nl
O
Band
Do
Tee
High pressure hose

High pressure hose (To control valve)
Valve, fuse
415W041
58
5d CYLINDER
5d-2-2. Lift cylinder (M mast) - Removal

1. Remove the lift table ASS'Y.
Refer to "6-2-1. Lift table ASS'Y removal".
2. Raise the middle mast about 50mm by operating lift lever.
3. Support the bottom of middle mast with a wood block or wire rope.
4. Remove fitting bolt(*1),fitting bolt(*2), "Plate, lock", and "Bolt adjust".
l
ria
 Removing the lift cylinder(M mast) 1 M mast
Fitting bolt(*2)
.c T
Plate, lock
F Fitting bolt(*1)
om
Middle mast
z D
P
Bolt, adjust
ard
Fitting bolt(*1)
w.p m
Outer mast
i
dfw
ww o
cuC
415W042
Do
59
CYLINDER 5d
4. Remove the hydraulic pipes.

5. Remove "Band, cylinder" and band to remove lift cylinder.
l
ria
 Removing the lift cylinder(M mast) 2
M mast
.c T
Inner mast
F
om
Outer mast
Middle mast
z D
P
ard
w.p m
Band, cylinder
i
dfw
ww o
cuC
Lift cylinder
Band
Do
Valve, fuse
Pipe Comp.
High pressure hose
(To control valve)
High pressure hose
Nipple(1)
415W043
60
5d CYLINDER
5d-2-3. Lift cylinder - installation and adjustment

1. Install the lift cylinder in reverse order of removal.
2. Operate the lift lever to make sure if both right and left cylinder rods
have no clearance at the stroke end.
If clearance is found, loosen the fitting bolt to adjust by the adjust bolt.
When it leans to the right from body side, tighten the adjust bolt.
When it leans to the left from body side, loosen the adjust bolt.
l
 Adjusting the lift cylinder
ria
Plate, lock
.c T
Fitting bolt (*1)
Inner mast Bolt, adjust
F
om
(Middle mast)
z D
P
ard
Outer mast
w.p m
i
dfw
ww o
415W067
cuC
3. Install and fix the "plate, lock".

Do
61
CYLINDER 5d
5d-2-4. Lift cylinder - disassembly and reassembly

1. Vise the cylinder tube.
CAUTION Do not vise "head, cylinder".
2. Remove the "head, cylinder" with a hook wrench.
Vise
l
ria
Hook wrench
 The lift cylinder (Std mast) and the lift cylinder 2nd (M mast)
.c T
- Disassembling and reassembling
F
om
Head, cylinder B
z D Apply THREEBOND[#1901] on
MLH6000 threads when tightening.
Tightening torque
P
196 45.1 N m
ard
{20 4.6 kgf m}
w.p m
i
Tightening torque
dfw
ww o
3.92 0.98 N m
{0.4 0.1 kgf m}
cuC
: Tightening torque
B : Apply THREEBOND
Applicable M mast
Do
RB15 4000 - 6000

RB10 4000 - 5000
RBC7/9/10 4000 - 5000
62
5d CYLINDER
 Disassembling and reassembling the lift cylinder 1st(M mast)
Head, cylinder B
Apply THREEBOND[#1901] on
threads when tightening.
CAUTION Tightening torque

343 78.5 N m
Supply new hydraulic {35 8.0 kgf m}
oil to the rod (front)
side of the objective
l
cylinders after
ria
installing the rod
when assembling.
The amount of the Tightening torque
.c T
hydraulic oil to be 3.92 0.98 N m
supplied : 100 ml {0.4 0.1 kgf m}
F
om
: Tightening torque z D
B : Apply THREEBOND
P
ard
 Disassembling and reassembling the lift cylinder 2nd (M mast)
w.p m
Head, cylinder B
i
dfw
Apply THREEBOND[#1901] on
ww o
threads when tightening.

Tightening torque
cuC
196 45.1 N m
{20 4.6 kgf m}
Do
Applicable M mast
RB10 5300 - 6000
: Tightening torque
B : Apply THREEBOND * This illustration shows the left side.
63
CYLINDER 5d
5d- 3. Inspection and adjustment

5d-3-1. Cylinder comp. - inspection
1. Check inside of the outer tube for rusting and damage.
5d-3-2. Piston rod - inspection

1. Check for rusting and damage.  Measuring deflection
If rusting or damaged, grind them with oil stone till they Dial gauge
l
ria
will not be felt by fingers.
2. Check deflection of the piston rod.
.c T
Deflection limit 1.0 mm (1/2 of gauge indication)
F
om
Piston rod
CAUTION Use at least 3 points to measure deflection.

z D 152T018
P
5d-3-3. Drift of lift lowering - inspection
ard
After replacing packings or a cylinder, measure drift of lift lowering.
w.p m
If it is over the specific drift of lift lowering, must be inspected again.

i
dfw
1. Load the maximum weight, and then raise the fork Measuring drift of lift lowering
ww o
about 70 cm from the ground.

cuC
Viewed from A
2. Draw a base line from the inner mast to the outer mast. Inner mast
3. Measure the drift of lift lowering 5 minutes later.
Draw a
<Specifications> base line
Std mast M mast

Do
Drift of lift
Applicable Drift of lilt lowering Applicable Drift of lilt lowering lowering
model [mm/5min] model [mm/5min]
Outer mast
RB10 20 RB10 30
RB15 30 RB15 40
RBC7 20 RBC7 30
RBC9 20 RBC9 30
RBC10 20 RBC10 30
A
Drift of lift
lowering
CAUTION When measure drift of lift lowering at the inner

mast. the specification is 1/2 times of the above
value .
70cm
152W074
64
5d CYLINDER
5d- 4. Troubleshooting
5d-4-1. Cylinder - troubleshooting
Oil leakage from 2. Looseness of the cylinder head Tighten
1
the cylinder head
Repair or
3. Damage on the rod
replace
l
Oil leakage from
2 1. Damage of the welded part Repair
ria
cylinder comp.
Too much drifting Repair or
3 2. Damage of the cylinder.
of lifting replace
.c T
3. Foreign article mixed in the valve Clean
1. Bend of the rod Replace
F
om
Vibration of
4 cylinder while 2. Shortage of the hydraulic oil in the tank Replenish
operating
z D
3. Air from the fitting of the piping Tighten
1. Over-discharge of the battery Charge
P
ard
2. Lack of displacement of the pump Replace
Clean or
3. Clogging of the filter in the tank
w.p m
replace
Slow speed of the
5 4. Low relief pressure Adjust
cylinder rod
i
dfw
5. Damage of the packing of the piston Replace

ww o
6. No good adjustment of the hydraulic chopper Adjust

cuC
Abnormal loweing 1. Stick ot the hydraulic hose of the return side Replace
6
speed 2. Failure of the height sensor Replace
Do
Cylinder is not Inspect or

7 2. Failure wiring of the lift switch
extended/retracted repair
3. Blow out of the main fuse Replace
65
6. MAST
6- 1. Name
Std Mast
 Main parts of Std mast
Lift table ass'y
l
ria
Inner mast
Lift cylinder
.c T
Lift chain
F
om
z D
P
ard
w.p m
Fork
i
dfw
ww o
Outer mast
cuC
Do
415W045
66
6 MAST
M Mast
Lift table ass'y
Lift chain
Middle mast
Inner mast
l
Middle mast
ria
Lift chain
.c T
F
om
Lift cylinder 1st
Fork
z D
P
Lift cylinder 2nd
ard
Outer mast
w.p m
i
dfw
ww o
cuC
Do
415W046
67
MAST 6

stands.
l
ria
6-2-1. Lift table ass'y - removal
1. Move the mast vertically and lower fork on the ground.
.c T
2. Remove the lift chain.
Std mast
F
om
1. Slacken off the lift chain to disconnect the nut on the side of outer
mast. z D
2. Remove the nut on the side of lift table ass'y, "dog(L/R)", spacer,
spring and slack of chain detector.
P
ard
M mast
1. Remove cotter pins on the side of lift table ass'y
w.p m
2. Slacken off the lift chain to disconnect the nut and cap on the side of
inner mast.
i
dfw
3. Remove the nut on the side of lift table ass'y, "dog(1)", spacer, spring
ww o
and slack of chain detector.

cuC
CAUTION Be careful not to damage the slack of chain detector.

Nuts should be screwed on the chain anchor bolt to prevent
damage to the thread part.
Do
3. Remove the lift chain to the side of lift table ass'y.

4. Disconnect the wiring connector of the lift table ass'y.
CAUTION Record places of lead wire connections before removing.
5. Raise the inner mast to the height that lift table ass'y can be removed.
6. Move the truck forward or move the lift table ass'y.
7. Lower the inner mast.
68
6 MAST
 Removing the lift table ass'y Std mast
Inner mast
Outer mast
Lift chain
l
Lift table ass'y
Nut
ria
Nut
.c T
Harness, table
F
om
Harness, mast(1)
Spring
z D Spacer G
Nut Dog L(R) Apply grease
P
Slack of chain detector
ard
(See6-3-14.)
w.p m
 Removing the lift table ass'y M mast

i
dfw
ww o
cuC
Inner mast
Lift chain
Do
Lift table ass'y
Nut
Cap
Harness, table
Harness, mast(2)
Spring
Spacer G
Nut Apply grease
Dog(1)
Pin, cotter Slack of chain detector
(See6-3-14.)
69
MAST 6
6-2-2. MAST ass'y - removal

1. Tilt the mast vertically.
 Hoisting the mast ass'y
2. Hoist the mast ass'y until the wire ropes are just
stretched .
l
.c T
ria
3. Disconnect the wiring connector of the mast ass'y.
415W068
CAUTION
F
Record places of lead wire connections before removing.
om
z D
4. Disconnect high pressure hoses.
P
ard
w.p m
i
5. Remove the outer mast.
dfw
ww o
1. Remove "Block, mast surport" and shims.

cuC
2. Remove "screw, set" to loosen the jam nut,
CAUTION Be sure to note the number and thickness of shims when removing them.
Do
6. Move the truck to remove mast ass'y.
70
6 MAST
Removing mast
Outer mast
l
.c T
ria
Shim
F
om
Block,
mast support
z D
P
ard
Shim Jam nut
Harness, mast(1)
Svrew set (Harness, mast(2))
w.p m
i
dfw
ww o
Body, harness
Jam nut
cuC
Screw set
To high pressure hose

control valve
Do
415W070
71
MAST 6
6-2-3. Lift table, mast - installation

 Install the lift table ass'y and mast ass'y in reverse
order of removal.
However install the mast adjusting as the following
procedure.
1. Adjust "Shim(1)" to install the mast in the center of the

body and make sure of no clearance between support pin
of the outer mast and "Block, mast support".
l
2. Measure
ria
the angle on the flat floor and adjust. as
following.
Adjust right/left tilt
.c T
 Adjusting right/left tilt of
mast
1. Attach the plumb on the side of mast.
F
2. Measure from the front and adjust the right/left tilt D
om
within 3mm at the point about 1000mm lower by shim.
z D
P
D
ard
w.p m
1000mm
i
dfw
ww o
D 3mm
cuC
Plumb 415W033
 Adjusting front/rear tilt

Adjust front/rear tilt of mast
1. Attach the bob on the front of mast. chassis side
Do
2. Measure from the side and adjust the front/rear tilt E

5±1mm degree at the point about 1000mm lower by
"screw set"*1(4 screws) on the lower of the outer mast.
3. Tighten "screw set"*2 (2 screws) on the lower of the
chassis. E
1000mm
E 3mm
Plumb
415W034
72
6 MAST
Installing the mast
Shim(1)
Block, mast support

Screw set *1
Outer mast
Shim
l
ria
Screw set *2
Chssis
.c T
415W071
F
om
3. After installation, adjust refering to "6-3-7. Roller adjust", "6-3-8. Side roller adjust",
z D
"6-3-12. Lift chain adjust" and "6-3-13. Mast inclination - inspection and adjust",.
P
ard
w.p m
i
dfw
ww o
cuC
Do
73
MAST 6
6-2-4. Mast - disassembly and reassembly

CAUTION  Be sure to note the number and thickness of shims when removing them.
Disassembling and reassembling the Std mast
Lift table ass'y (See "7'). 1 Sliding part G

Apply grease on a part of sliding.
l
ria
2 Shim, roller
Note the number and thickness.
.c T rs
Chain wheel (See 6-3-5.)
te ale F
om
bu e
z D Chain
tri d D
Side roller (See 6-3-3.)
(6-3-8.)
D ize P
ard
ot or
w.p m
is
N uth
i
D rA
dfw
ww o
Slack of chain
detector
fo
(See 6-3-14.) Back

cuC
shoe
o
y
(See 6-3-2)
nl
O
Roller (See 6-3-7.)

Fork (See 6-3-9.)
Do
3 Shim, Back shoe

Adjust the clearance less than 0.5mm,
note the number and thickness.
4 Shim
G : Apply grease
N : Not reusable
415W087
74
6 MAST
Disassembling and reassembling the Std mast

1 Sliding part G
Apply grease on a part of sliding.
2 Shim, roller
Back Chain wheel (See 6-3-5.)

shoe
(See 6-3-2)
Hose pully(See 6-3-6.)
l
ria
Chain
.c T
(See 6-3-3.)
F
om
z D
P
Slack of chain
ard
detector
Side roller (See 6-3-14.)
(6-3-8.)
w.p m
Roller (See 6-3-7.)

i
dfw
ww o
Lift table ass'y (See "7').

cuC
Do
Fork (See 6-3-9.)
3 Shim, Back shoe

Adjust the clearance less than 0.5mm,
note the number and thickness.
4 Shim
5 Spacer G
G : Apply grease Apply grease.
75
MAST 6
6-2-5. Fork - disassembly and reassembly

Disassembling and reassembling the fork
Holder, spring
Fork sensor
(See 6-3-3.) Spring
l
ria
bracket, switch
Shaft, fork (See 6-3-10.)
.c T
F
om
z D
P
ard
Shim, fork
w.p m
Fork (See 6-3-9.) Install the fork not to put it

between "Holder, spring" and fork,
i
dfw

ww o
cuC
415W089
NOTE RB has no fork sensor.

Do
76
6 MAST

6-3-1. Mast , lift table and roller shaft - inspection
1. Check if welded parts are cracked with color check.
CAUTION Use welding rods of low hydrogen type(Z3212 D5016) when

re-welding on Mast channels and/or Roller shafts.
 Inspection of mast, lift table and roller shaft Std mast
l
ria
Roller shaft
(both side)
.c T
F
om
z D
P
ard
w.p m
Mast channel
Mast channel
i
dfw
Roller shaft
ww o
(both side)
Roller shaft
cuC
(both side) 415W090
M mast
Roller shaft
(both side)
Roller shaft
(both side)
Do
Mast channel
Roller shaft
(both side) Mast channel
Roller shaft (both side) Mast channel
Roller shaft (both side)
415W091
77
MAST 6
6-3-2. Back shoe - inspection

1. Check the back shoe for wear.  Inspection of back shoe
Specific thickness [A] Wear limit A
3 2.5
152T022
l
6-3-3. Lift chain - inspection and replacement
ria
1. Check the elongation of lift chain.  Inspection of lift chain
Measure the length per 20 links at the part which are
.c T
used frequently.
<Specifications>
F
om
Lift chain (1st/2nd) (mm) P
Specific
dimension
Elogation
limit
z D
Pitch [P] Remarks
Leaf chain#50
P
381 389 19.05
(BL634)
ard
Lift chain (1st) (RBC7/9 M mast) (mm)
2210167
Specific Elogation
w.p m
Pitch [P] Remarks

dimension limit
Leaf chain#50
i
381 389 15.875
dfw
(BL534)
ww o
cuC
2. Check lift chains for deformation and damage.

If it is jolted, replace it.
3. Check for lubrication.
Apply grease on chains.
Do
6-3-4. Chain bolt - inspection  Inspection of chain bolt
1. Check connecting part ( ) for jolt.

If it is jolted, replace it.
2. Check for damage of threads.
2210168
78
6 MAST
6-3-5. Chain wheel - inspection

1. Check the outer surface for deformation and the Inspection of chain wheel
bearing for function.
152T025
l
6-3-6. Hose pulley - inspection
ria
1. Check for wear. Inspection of hose pulley
.c T
Item Specific diameter [ d]
F
om
Hose pulley 29
z D d
152T026
P
ard
6-3-7. Roller - inspection
w.p m
1. Measure the clearance between outer diameter of

rollers and mast rails.
i
dfw
If over the specific clearance, replace it.

ww o
cuC
Item Specific clearance
Mast roller 1.5
Lift roller 0.5
Do
2. Check for function and jolt.
6-3-8. Side roller - adjustment  Adjusting the side roller
 If the clearance between the lift table ass'y and the Lift table
inner mast, adjust it. ASS'Y
1 Adjustment procedure Adjust bolt
Side roller
1. Move the fork on the ground.
2. Tighten the adjust bolt so that the side roller touches
the inner mast.
415W049
79
MAST 6
6-3-9. Fork - inspection and replacement

1 Inspection
Leveling
1. Check for transformation and leveling.
Item Specific dimension
Leveling of fork tips 10
Opening of fork tips 15
l
Opening
.c T
ria
F
om
z D Bending
P
ard
w.p m
415W094
i
2. Check for wear and cracks.
dfw
ww o
CAUTION  If cracked, replace them and never use them

cuC
after repairing.
 Check for cracks by using color check.
2 Adjustment the height of fork

Do
1. Adjust the fork by using "Shim, fork" so that the point

of fork is 5-10mm higher than botom of it and the
difference between right and left in height of point is
less than 5mm. Shim, fork
Fork
415W073
80
6 MAST
3 Adjustment width of fork

1. Loosen the fitting bolt *1.
2.Slide to the right and left to adjust the width.
3.Adjust the width of the lock bar to fit for the fork by
loosening or tightening the bolt.
Refer to "11.the auto pallet lock".
l
ria
 Adjusting the width of the fork
.c T
Fitting bolt *2 Arm(2), lock
F
om
z D Fitting bolt *1
P
Pallet lock bar
ard
w.p m
i
dfw
ww o
Fork
cuC
415W159
6-3-10. Shaft, fork - inspection

Do
1. Check for wear.
 Inspection of the shaft, fork
Applicable Specific
Item Wear limit
model diameter
Shaft,fork RB10/15
42 41
[ d] RBC7/9/10 D
415W072
81
MAST 6
6-3-11. Fork sensor - adjustment (RBC)

1. Adjust the fitting raising the top of fork so that the fork sensor
operates when "Holder, spring" touches A side. And ajust so that there
is clearance between "Holde, spring" and A.
2. After installation apply LOCTITE[#242] or equivalence
for it on the screw and tighten the torque.
l
ria
 Adjusting the fork sensor
Lift table  rack sensor

124
.c T
Screw L
A
Holder, spring {0.5-0.6 kgf m}
F
om
Apply LOCTITE [#242] or
z D equivalence for it.
128
P
ard
w.p m
Spring Fork
: Tightening torque
i
L : Apply LOCTITE
dfw
361S139
ww o
cuC
Do
82
6 MAST
6-3-12. Lift chain - adjustment

 Measure the deflection of lift chains, and if over
specific one, adjust it.
<Specifications> 0-20mm
1. Extend the mast and lower the fork on the flat floor.
1000mm
2. Push the chain at approx. 1000mm height of lift chains
and measure it. Nut
l
ria
Lock nut
Item Specific dimension

Deflection 0 - 20
.c T
3.If over the specific deflection, loosen the nut to adjust. 152T143
F
om
z D
6-3-13. Mast inclination - inspection and adjustment
P
ard
 Check for the following in case the inner mast was
w.p m
inclined when lifting forks to the stroke end. Mast facing

i
1. Lift forks a little and check if the tension of each lift
dfw
ww o
chain is the same.

Refer to "6-3-12. Lift chain - adjustment".
cuC
2. Lift forks and check if the lift bracket touches the inner
mast.
3. Check if cylinder rods stop at the same time when
Do
lifting forks to the stroke end.

152T033
If defects are found, adjust refering "5d-2-3. Lift cylinder

- installation and adjutment"..
83
MAST 6
6-3-14. Adjustment of the slack of chain detector

Std Mast
1. Loosen the chain and tighten the fitting nut of lift chain Slack of chain detector
- adjustment
on the mast side until spring shrinks 5 mm.
2. Stretch the chain and confirm the space A is 10mm Chain anchor bolt
3. Adjust the detecitng switch so that the clearance B Chain anchor
A
between "Dog(L/R) and the nut is 3mm and the roller is
pushed half it when the switch turnes on
l
DogL(R)
ria
4.Loosen the chain and confirm the switch turns on and
Spring
the chain anchor bolt touches chain anchor before
spring streches fully.
B
5. Adjust the fitting nut of lift chain on the mast side so
.c T
Pressed
that the upper side of fork is 60 mm height from the half
floor. Detecitng
switch
F 415W035
om
M Mast z D
Chain on the 2nd side
P
1. Tighten the nut so that outer mast, middle mast and Slack of chain detector
- adjustment
ard
inner mast are the same height.
2. Adjust the nut so that the space A is 10mm Chain anchor
bolt
w.p m
3. Adjust the detecitng switch so that the clearance B

between "Dog2(L/R) and the nut is 3mm and the roller
i
dfw
is pushed half it when the switch turnes on Chain anchor Jam nut
ww o

cuC
the chain anchor bolt touches chain anchor before Dog(2)
A
L(R)
5. Adjust the fitting nut of lift chain on the mast side so Spring
B
that the upper side of fork is 60 mm height from the

Nut
floor. Detecitng
switch
Do
415W036
Chain on the 1st side

Slack of chain detector
1. Loosen the chain and tighten the fitting nut of lift chain - adjustment
on the mast side until spring shrinks 5 mm. Chain anchor
2. Stretch the chain and confirm the space A is 10mm bolt
Chain anchor
A
3. Adjust the detecitng switch so that the clearance B

between "Dog(1) and the nut is 3mm and the roller is
Dog(1)
pushed half it when the switch turnes on
Spring
the chain anchor bolt touches chain anchor before
B
Pressed Nut
5. Adjust the fitting nut of lift chain on the mast side so half
that the upper side of fork is 60 mm height from the Detecitng

switch
floor.
415W037
84
6 MAST
6-4-1. Mast, lift table, fork - troubleshooting
Inner mast lifts up
1 together with lift 1. Improper clearance of lift rollers and/or side rollers Adjust
table.
1. Improper clearance of lift rollers and/or side rollers Adjust
Lifting and lowing
l
2 of lift table is not 2. No good function of rollers Replace
ria
smooth.
3.Chain wheel support and guide shaft don't slide
Repair
smoothly.
Lift table is 1. Too large clearance of side rollers Adjust
.c T
3
inclined. 2. Unequal tension of L.H. and R.H. chain Adjust
Lifting and lowing 1. Improper clearance between rollers and mast Adjust
4 of inner mast is
F
om
not smooth. 2. Extending of the lift cylinder rod is not simultaneous. Adjust
Inner mast is
5 inclined at extended
position.
z D
1. No good adjustment of shims for installing the chassis Replace
P
Repair or
1. Bending of fork
ard
Not getting the Replace
6 same level of fork 2. One side load on fork Proper work
tips.
w.p m
3. Unfit for shims of fork Adjust

i
dfw
ww o
cuC
Do
85
7. LIFT TABLE ASS'Y
7- 1. Name
Drive front
 Main parts of drive front
Table Comp., lift
l
.c T
ria
Safety belt
Net,guard
F
om
z D Control panel
(Refer to "9.control
panel".)
P
Guard Comp.,
ard
side
w.p m
Backet
i
dfw
ww o
cuC
Do
Pedal, brake
Mat, floor
415W074
86
7 LIFT TABLE ASS'Y
Fork front
 Main parts of fork front
Table Comp., lift
l
Safety belt
ria
Net,guard
Guard Comp.,
side
.c T
Cushion, body
F
om
Control panel
(Refer to "9.control panel".)
z D Post, steering
P
ard
w.p m
i
dfw
ww o
Backet
cuC
Mat, floor Pedal, brake

Do
415W075
87
LIFT TABLE ASS'Y 7

stands.
Apply wheel chocks to tyres to prevent the truck from moving.
Record places of lead wire connections before disassembling.
Be sure to disconnect the battery plug.
7-2-1. Lift table - disassembly and reassembly
l
ria
Disassembling and reassembling the lift table (Drive front)
.c T rs
Net,guard CS/FCS Bolt L
te ale
Apply LOCTITE [#242] .
F
om
Rope
bu e z D Table Comp., lift

tri d D
Safety belt
D ize P
ard
ot or
Bracket,
controll
w.p m
is
N uth
Bracket,
Backet steering(2)
i
D rA
dfw
ww o fo
cuC
o
y
Bracket,
nl
steering(1)
O
Cover, table
Do
Guard,
center
Mounted center guard
L : Apply LOCTITE 415W150
88
7 LIFT TABLE ASS'Y
Disassembling and reassembling the lift table (Fork front)
CS/FCS
Net,guard
Rope
Bolt L
l
Bracket, Apply LOCTITE [#242] .
ria
control
Bracket,
.c T
steering(2)
F
om
Post, z D
steering
Safety belt
Body,
P
cushion
ard
Bracket,
steering(1)
w.p m
Backet
i
dfw
ww o
Cover, table
cuC
Cover, steering post

Do
Table Comp., lift
L : Apply LOCTITE
415W152
89
LIFT TABLE ASS'Y 7
7-2-2. Brake ASS'Y - disassembly and reassembly

Disassembling and reassembling the brake
Mat, floor
l
Plate, floor
.c T
ria
F
om
Horn
Pad, pedal
Pedal, brake
z D
Brake switch
P
ard
Bracket, brake
w.p m
Spring
i
dfw
ww o
cuC
CS/FCS
Pedal, brake
Pedal, brake
Brake switch
Table Comp., lift
Do
Bracket, brake
* This illustration shows drive front.

415W151
The install positon of brake

NOTE As for fork front, the direction of brake ass'y is oppsite to (Fork front)
it of drive front. Refer to the right drawing.
Horn
Brake
415W153
90
7 LIFT TABLE ASS'Y
7-2-3. Side guard - disassembly and reassembly

Disassembling and reassembling the side guard
1 Pin, guard, U nut LU
Adjust the U nut not to fall down naturally
when the angle (B) of "Guard comp.,
side" is 60-90°, and apply the lubricant
Guard Comp., side

(1)/(2)/(3)
U nut
l
ria
Limit switch
Screw L
5-6N m
.c T
tightening
torque {0.5 - 0.6 kgf m}
Apply LOCTITE [#242] or equivalence
for it, and connect so that the
Spring, conical
F
om
dimensions C = 22mm.
Pin, guard z D Bracket, switch
P
After install the micro switch,install
ard
"guard comp., side" vertically
w.p m
2 Setting screw, Jam nut

Install "guard comp., side" to fall
i
dfw
horizontally.
ww o
cuC
View from A
Bracket,
switch
Do
Setting screw
Jam nut
Guard Comp., side
: Fitting torque (1)/(2)/(3)
LU : Apply lubricant
L : Apply LOCTITE
415W154
91
LIFT TABLE ASS'Y 7

7-3-1. Control panel ASS'Y - installation and adjustment
1. Fix the harness of control panel ass'y in the
state "Bracket, steering(2)" is installed at
the highest position. Installation of control panel ass'y
Refer to "9.Control panel ass'y".
control panel ass'y
2. Adjust so that "Bracket, steering(2)" is
l
ria
installed midway (A = 65mm).
.c T
Bracket,
steering (2)
fitting hole
for adjusting
F height
om
Bracket,
z D steering (1)
415W161
P
ard
7-3-2. Guard comp., side - inspection and adjustment
w.p m
1. Adjust the installation of the limit switch so that

Adjustment of guard comp.,
i
dimension A is 22mm.
dfw
side
ww o
2. Confirm the limit switch is turned on in the state of

raising "Guard Comp.,side" and there is clearance. Limit, switch Bracket, switch
cuC
Screw
3. Adjust by "set screw" so that "Guard comp., side" is
horizontal in the state of lowering. Guard Comp.,
A side
4. Adjust the installation of "Bracket, switch" so that
B
"Guard comp., side" is vertical in the state of raising.
5. Adjust by U nut so that "Guard Comp., side" does not
Do
fall down naturally when the angle B is 60 - 90 . Set screw
U nut 415W156
: Fitting torque
L : Apply LOCTITE
Limit switch
Screw L
tightening 5-6N m
torque {0.5 - 0.6 kgf m}
Apply LOCTITE [#242] or equivalence
for it.
92
7 LIFT TABLE ASS'Y
7-3-3. Brake switch - inspection and adjustment

1. Adjust the installation so that the switch is turned on or
turned off when A is within the following value.
<Specifications>
Applicble model A
Std 30 - 40 [mm]
CS/FCS 30 - 45 [mm]
l
ria
2. Confirm there is play in the brake switch in the state
"Pedal, brake" is raising.
3. After adjusting apply LOCTITE [#242] or equivalence
for it and tighten by the regular torque..
.c T
F
om
 Adjusting the brake switchz D
Pad, pedal
P
ard A
 Brake switch
w.p m
Screw L
5-6 N m
i
Tightening torque
dfw
ww o
{0.5-0.6 kgf m}
Apply LOCTITE [#242] or
cuC
Bracket, brake equivalence for it.
Pedal, brake
: Tightening torque
L : Apply LOCTITE * This illustration shows type of STD. 415W157
Do
93
LIFT TABLE ASS'Y 7
7-3-4. Safety belt - inspection

 Be sure to inspection before using or periodically, and according to the
CAUTION
following check point dispose or replace a new one or the part.
Be sure to inspection according to the following check point at least
once a month.
Even though the damage is not so badly as the standard disposal, stop
using it immediately.
If abnormality should occur while using, stop using immediately and
inspect again.
l
ria
 The safety belt that is given a shock should be disposed though its
appearance is good.
＜ Standard disposal ＞ 1
.c T
Inspection item Standard disposal
1.Belt rope is not reeled off and not reel.
2.when reeling off the belt rope strongly, locking operation is not work.
F
om
3.Damage (broken, crack) of case
1 Belt rope reel
4.Rust of metalic parts
z D
5.Fitting screws are dropped out.
6.Switching button is damaged or not smooth.
P
1. Padding of belt is exposed for the cause of wear.
ard
2. Cut or scrach mor than 2 mm
Wear, scrach and cut
w.p m
3. Burned scar, meltdown mor than 2 mm

i
dfw
ww o
2 Belt rope 4. Medicine or paint are stuck, fadded or harden

cuC
5. Transformation
6. Tube is torn.
7. Thread is exposed.
1. Crack
Do
2. Cut Inside of hook

3. Cut or scrach more than 1 mm outside of hook
4. Safety devise doesnot work smoothly.
3. hook
5. Rust or transformation
6. Thimble is lost.
7. Caulking area of rivet - wear out, looseness
8. Spring is broken or lost strengh.
1. Crack
2. Engaging area of belt is worn away
4. buckle 3. Rust or transformation
4. Looseness of belt
5. Caulking area of rivet - wear out, looseness
5. Sewing part of buckle 1. Thread of buckle is cut for the cause of wear.
1. Cut or scrach more than 3 mm in the belt.
2. Both side of belt is wear out.
6. Copper belt
3. Medicine or paint are stuck, fadded or meltdown.
4. Belt on the part of tightening buckle is damaged.
94
7 LIFT TABLE ASS'Y
＜ Stndard disposal ＞ 2
Inspection item Standard disposal
1. Crack
2.Scrach is over 1 mm in depth.
7 D ring
3.Transformation
4.Rust is terrible.
8 D ring stopper 1. D ring stopper is cracking and cannnot fix the D ring.
9 Point stopper 1.A point stopper is lost and belt gets frayed.
 l Inspection of saftey belt
l
ria
6.Copper belt
.c T
1.Belt rope reel
F
om
9.Point stopper z D 2.belt rope
8.D ring stopper

P
ard
7. D ring
3.hook
w.p m
4.Buckle 5.Buckle sewing part

i
415W093
dfw
ww o
＜ Safety belt specification ＞

cuC
Use environment -10 - 50

Limit weight of a operator Max. 120kg
Regular Elastic belt rope once in two years

replacement Copper belt once in three years
Do
NOTE
The operator who is weight over 120 kilograms
should use the usual rope type.
95
LIFT TABLE ASS'Y 7
7-4-1. Lift table ass'y - troubleshooting
1. No good adjustment of limit switch Adjust

Traveling can not
1 work by using 2. No good function of limitswitch Replace
brake pedal
Adjust
3.No good function of electromagnetic brake.
Replace
l
ria
Brake pedal
2 1.Damage of spring Replace
doesnot return.
Brake pedal is
3 1. Wear of bush. Replace
rickety
.c T
Lifting traveling 1. No good adjustment of limit switch Adjust
4 cannot work by
operating guard. 2. No good of limit switch Replace
Drifting naturally
F
om
1. No good adjustment of U nut Adjust
5 when guard is
raising 2. Wear of bush.
z D Replace
Belt rope is not
6 1. Failure of the belt rope reel. Replace
rewinded.
P
ard
w.p m
i
dfw
ww o
cuC
Do
96
8. MOTOR
8- 1. Name
8-1-1. Traction motor - main parts name
Main parts of traction motor
Housing, sensor
l
Terminal comp.
ria
Cover, end
.c T
Bearing comp.,
sensor
F
om
z D
P
Cover(D), end
ard
Stator comp.
Rotor sub ass'y

w.p m
i
dfw
415W076
ww o
8-1-2. Hydraulic motor - main parts name

cuC
Main parts of hydraulic motor
Housing, sensor
Terminal comp.
Do
Cover, end
Bearing comp.,
sensor
Cover(D), end Stator comp.
Rotor sub ass'y
415W077
97
MOTOR 8
8-1-3. EPS motor - main parts name

Main parts of EPS motor
Brush comp.
ブラシComp. Cover, brush
カバー, ブラシ
Yoke ass'y
ヨークASS�Y
Wire comp., lead

ワイヤComp., リード
Armature comp.
アーマチュアComp.
l
ria
Cover
カバー,D(D)
Holder comp., brush
ホルダーComp., ブラシ
.c T
F
om
121W343
8-1-4. Motors - specifications

z D
P
Traction motor
ard
w.p m
Applicable model Type Remarks

RB10/15 AT26A2R/10-4 2.6kW, 30V, 60min
i
dfw
RB10/15 (dust-proof) AT26A2RA/10-4 2.6kW, 30V, 60min

ww o
RBC7/9/10 AT26A1R/5-8 2.6kW, 15V, 60min

cuC
RBC7/9/10 (dust-proof) AT26A1RA/5-8 2.6kW, 15V, 60min
Hydraulic motor
Applicable model Type Remarks
Do
RB10/15 AH88B2/N 8.8kW, 30V, 10min

RB10/15 (dust-proof) AH88B2A/N 8.8kW, 30V, 10min
RBC7/9/10 AH50A1 6.0kW, 15V, 5min
RBC7/9/10 (dust-proof) AH50A1A 6.0kW, 15V, 5min
EPS motor
Applicable model Parts No. Remarks Manufacturer
37410-01470 300W, DC48V, 2900rpm, 60min Fujii
37410-00990 300W, DC48V, 2900rpm, 60min NIkko
RB10/15 (48V) 37410-01280 300W, DC48V, 2900rpm, 60min TD drive
<enhancement specification>
70000-05230 Eiko
550W, DC48V, 3340rpm, 60min
RBC7/9/10 (24V) 70000-05230 Use as 250W, DC24V Eiko
98
8 MOTOR

CAUTION  Lift or jack up the forklift truck and support it with safety blocks or rigid stands.
Apply wheel chocks to tyres to prevent the truck from moving.
l
8-2-1 Traction motor - removal and installation
ria
1. Remove drive unit.  Removing the travel motor
Refer to "2-2-1. Drive unit - removal and installation".
.c T
Brake
2. Remove traction motor.
F
om
3. Remove brake. z D
Refer to "4-4-1. Brake ASS'Y- removal and installation". Traction motor
P
ard
w.p m
i
dfw
ww o
cuC
: Tightening torque
1 Fitting bolts (M8)

Tightening 23.4 - 28.6N m
Do
torque {2.34- 2.92kgf m}

2 Spline G
Apply grease on a part of spline.
Hoisting the only traction motor

NOTE Even the only travel motor can be removed.
Hoist
But in this case remove the obstructive parts
Traction motor
first.
* Install the drive unit in reverse order of removal.

CAUTION Be sure to tighten the screws for installing
brake .
Tool to hoist
When Installing Drive wheel, tighten the bolts traction motor
99 415W080
MOTOR 8
8-2-2. Hydraulic motor - removal and installation

1. Remove the following parts before removing the hydraulic motor.

CAUTION Before disconnecting the high pressure pipe or the high pressure hose,
turn the emergency handle (refer to the page 52) to release the high
pressure in the hydraulic piping.
l
1. Remove the high pressure hose and the low pressure hose.
ria
2. Remove "cover, motor" to disconnect the lead wires of the hydraulic motor.
3. Disconnect the connector of "bearing comp., sensor".
RB * Only for RB.
.c T
2. Remove the bracket, cushion with control valve from the body.
Refer to "5a-2-1. Hydraulic pump removal and installation 4".
F
om
3. Remove the hydraulic motor. z D
1. Disconnect the U nut to remove "bracket, cushion" from the chassis.
2. Remove the U nut and cushion(1)
P
3. Hoist the hydraulic motor with the hydraulic pump.
ard
4. Remove the bolt, cushion and remove the bracket, cushion and cushion(2) from
the hydraulic motor.
w.p m
Removing the hydraulic motor

i
Bolt, cushion
dfw
ww o
RB Control valve Tightening torque

36 - 43 N m
cuC
High pressure
hose { 3.6 - 4.3Kgf m }
Cushion(2)
Low pressure hose U nut (M12)

High pressure hose 1 Tightening torque
Do
36 - 43 N m
Low pressure
hose { 3.6 - 4.3Kgf m }
Bracket, cushion
Bracket, motor Lead wire
High pressure hose
Hydraulic pump
Cushion(1)
Low pressure hose
100
8 MOTOR
Removing the hydraulic motor

RBC Bracket,
cushion Bolt, cushion
Tightening torque
36 - 43 N m
{ 3.6 - 4.3Kgf m }
Cushion(2)
Hydraulic motor
l
ria
Lead wire
.c T
Low pressure
hose
High pressure hose
F
om
Hydraulic pump
Cushion(1) z D U nut (M12)
1 Tightening torque
P
36 - 43 N m
ard
{ 3.6 - 4.3Kgf m }
Control valve
w.p m
i
dfw
ww o
Bracket, motor
Low pressure hose
Low pressure hose
cuC
* Install the hydraulic motor in reverse order of removal.

Do
101
MOTOR 8
8-2-3. EPS motor - removal and installation
1. Disconnect the connectors for EPS motor.
2. Remove the fitting bolts of EPS motor to remove EPS motor.
 Removing the EPS motor
EPS motor
l
Connector
ria
Fitting bolt
.c T
Drive unit
F
om
z D
P
ard
w.p m
Cover, EPS B
Apply THREEBOND[#1212] or an
i
equivalent product on the mating
dfw
ww o
surfaces.
cuC
B : Apply THREEBOND 415W079
* Install the EPS motor in reverse order of removal.

Do
102
8 MOTOR
8-2-4 Traction and hydraulic motor - disassembly

and reassembly
Disassembling and reassembling the traction motor Bolt & Cover, end L
Apply LOCTITE[#648], [#262] or
an equivalent product in tapped
holes of "Cover, end".
( )
Tightening torque
13.5 N m±10%
l
Bearing comp.,
ria
sensor
Housing, sensor
Terminal comp.
te ale
.c T rs
Cover, end
F
om
bu ez D
tri d D
D ize P
ard
ot or
w.p m
is
N uth
i
D rA
dfw
ww o fo
cuC
o
y
nl
O
Stator comp.
Do
Rotor sub ass'y
Load wire
The color of glass tube covered
Cover(D), end
lead wire is as follows
U phase : Red
: Tightening torque V phase : White
N : Not reusable
W phase: Blue
103
MOTOR 8
8-2-5. EPS motor - disassembly and reassembly

CAUTION Mark the yoke and "Cover, end" before removing the bolts.
Disassembling and reassembling the EPS motor

Cover, end
ホルダーComp., ブラシ
Cover, brush
カバー, ブラシ
Yoke
ヨーク
ボルト
Bolt
l
.c T
ria
Marking
マーク
F
om
z D * This illustration shows Fujii made.
121W344
P
ard
w.p m
i
dfw
ww o
cuC
Do
104
8 MOTOR

8-3-1. Rotor comp. - inspection and replacement
(Traction and Hydraulic motor)
1 Inspection of damage Rotor comp. (Traction motor)
1. Check the rotor comp. for damage, especially by
burning.
If it is damaged, replace it.
l
ria
2 Inspection of spline
1. Check for wear of spline. Rotor comp.
If it is extremely worn, replace it. Spline
.c T
2210102
Rotor comp. (Hydraulic motor)
F
om
z D
P
ard
3 Inspection of ball bearing Rotor comp.
Spline
w.p m
2210121
1. Check fitting part in "cover, end" and "cover(D), end".

If loose, replace it.
i
dfw
ww o
Inspection of fitting parts (Traction motor) Inspection of fitting parts (Hydraulic motor)
Bearing, radial ball Bearing, radial ball Bearing, radial ball Bearing, radial ball
cuC
Do
Cover(D), end Cover, end Cover(D), end Cover, end

121W210 121W211
Replacing the "Bearing comp.,

CAUTION  When replacing the "bearing comp., sensor", sensor"
be very careful to not damage the sensor.
If the sensor is damaged, the motor will not
operate normally.
 Do not touch directly connector pins of lead Sensor
wire terminal, because you may generate the
effect of static electricity . 2210144
105
MOTOR 8
8-3-2. Armature comp. (EPS motor) - inspection and replacement
1 Inspection of damage Inspection of armature comp.

1. Check the armature for damage, especially by Armature comp.
burning.
If it is damaged, replace it. Gear
If the surface of Commutator is damaged, repair or
replace it.
l
2 Inspection of gear
ria
1. Check for wear of gear.
If it is extremely worn, replace it. 461E252
.c T
3 Inspection of ball bearing
Inspection of fitting parts
F
om
1. Check fitting part in "cover(C) ass'y, end" and
Bearing, radial ball Bearing, radial ball
cover(D). z D
If loose, replace it.
P
ard
w.p m
Cover(C) ass'y, end

i
dfw
Cover(D)
ww o
2210169
cuC
4 Commutator of insulation
 Check the commutator for damage, especially by

Inspection of commutator
burning. If it is damaged, repair or replace it.
Do
<Repairing prucedure>
1. Grind the surface of commutator
CAUTION When grinding, be sure to take out the core of the

armature shaft. 152T035
106
8 MOTOR
2.Cut the commutator

Repairing limit of cpmmutator
3. Give the last brush to the surface of commutator with
sand paper [#400].
<Repairing limit>
 Repairing limit of the commutator [mm]
Normal dimention Reparing limit
Applicable motor
( D) ( D)
EPS motoe 49 47
152T036
l
ria
 Repairing limit of the commutator [mm] Cutting of commutator
Applicable motor Normal value of cutting
.c T
EPS motor 0.8 - 0.85
F
om
5 Inspection of insulation
z D 152T037
P
Inspection of insulation
ard
 Measure the insulation between Commutator and
Positive
Armature shaft.
w.p m
CAUTION Clean up by compressed air before measuring.

i
dfw
ww o
Negative
<Resistance>
cuC
TOOL SPECIFIC RESISTANCE 152T038
Tester ( 1 x1k range)
Megger 0.5 M or greater (DC500V)

Do
107
MOTOR 8
8-3-3. Brush, brush holder and spring (EPS motor)

- inspection and replacement
1 Inspection of brush wear Inspection of brush wear

1. Measure (A). Brush
If it is less than 15 mm, replace it.
UNIT : mm
Applicable Normal dimention Wearing limit
Part number Manufacturer
l
model (H) [A]
ria
37410-01470 14.5 8 Fujii Wearing limit
Brush holder
RB10/15 37410-00990 19 13 Nikko Brush
Spring
.c T
37410-01280 19 9 TDdrive
RBC7/9/10 70000-05230 20 9 Eiko
F
om
z D Commutator
2210135
P
2 Inspection of contacting surface of brush
ard
 If the contacting surface is not good, repair it as Inspection of contacting
w.p m
follows. surface of brush

i
dfw
ww o
cuC
Good Not Good Not Good
Brush
Commutator
152T042
Do
<Repairing procedure>
1. Insert a sand paper [#400] between COMMUTATOR
Repairing surface of brush
and BRUSH.
(File surface toward BRUSH.) Brush
2. Grind the contacting surface by moving a sand paper Sand paper

or rotating COMMUTATOR by hand.
3. Clean up with compresses air after repairing.
Commutator
152T059
108
8 MOTOR
4 Inspection of force of spring
 Hook a spring scale to SPRING and pull towards arrow Inspection of force of spring
mark. Then make sure of equal force on 2 springs.
<Specific force of SPRING>

Motor Specific force Spring
EPS motor 5-8 N (0.5-0.8 kg·f)
l
ria
CAUTION If SPRING and/or brush holder were rusted,
replace them.
.c T
152T060
F
om
z D
P
ard
w.p m
i
dfw
ww o
cuC
Do
109
MOTOR 8
8-3-4. Motor ass'y - inspection

(Traction motor and Hydraulic motor)
Inspect the following after assembling.
1 Abnormal noise check

 Operate the motor. Make sure there is no abnormal
noise.
CAUTION When performing a motor test, be sure to
l
ria
securely fix the motor to a work bench.
The motor will move suddenly when it is started.
<Checking procedure>
.c T
1. Be sure to secure the motor ass'y to a work bench.
2. Use the battery of the forklift truck to carry out testing.
F
om
3. Connect wires as follows.
4. Operate traction motor and hydraulic motor slowly at the
z D
chassis side, and make sure the motors are performing
without abnormal noise.
P
ard
 Traction motor
1) Connect the U1 cable from the chassis to the U1 terminal in the motor.
w.p m
2) Connect the V1 cable from the chassis to the V1 terminal in the motor.
3) Connect the W1 cable from the chassis to the W1 terminal in the motor.
i
dfw
ww o
4) Connect the lead wire for the speed sensor from the chassis
(water proof type 4P) to the lead wire for the speed sensor in the motor
cuC
(water proof type 4P).

 Hydraulic motor
1) Connect the U2 cable from the chassis to the U2 terminal in the motor.
2) Connect the V2 cable from the chassis to the V2 terminal in the motor.
3) Connect the W2 cable from the chassis to the W2 terminal in the motor.
Do
4) Connect the lead wire for the speed sensor from the chassis
(water proof type 4P) to the lead wire for the speed sensor in the motor
(water proof type 4P).
CAUTION If an extension cable is necessary, make one from the following parts:
1) Main cables for motor (3 cables)
2
1. Cable type : WTC, Cable size : 38 mm
2. Terminal : 38-S8
2) Lead wires for speed sensor (4 wires)
2
1. Lead wire : AVS- 0.5 mm
2. Receptacle : AMP171662-1
3. Tab : AMP173600-1
4. "Housing, cap 4P" : 37010-20940(AMP174259-2)
5. "Housing, plug 4P" : 37010-20890(AMP174257-2)
110
8 MOTOR
2 Inspection of insulation Inspection of insulation
 Measure the insulation between terminals and

stator comp. with Megger.
Terminal
<Resistance>
Tool Specific resistance
Megger 0.5 M or greater (DC500V)
<Measuring procedure>
Stator comp.
l
1. Apply earth probe (negative [-]) of Megger to the
ria
stator comp.
415W082
2. Apply line probe (positive [+]) of Megger to each

terminal.
.c T
8-3-5. Motor ass'y(EPS motor) - inspection
F
om
Inspect the following after assembling.
1 Abnormal noise and arc

z D
 Operate the motor. Then make sure that abnormal
P
noise is not heard and arc of brushes is not seen.
ard
CAUTION When performing a motor test, be sure to
w.p m
securely fix the motor to a work bench.

The motor will move suddenly when it is started.
i
dfw
ww o
cuC
1. Be sure to secure EPS motor ass'y to a work bench.

2. Apply 1/4 voltage of the battery (about 12V) to carry out testing.
3. Connect wires as follows.
1) Connect lead wire (GREEN or WHITE) with positive (+)
terminal of battery.
Do
2) Connect lead wire (YELLOW or BLACK) with negative (-)

terminal of battery.
2 Inspection of insulation
 Measure the insulation between terminals and yoke Inspection of insulation
with Megger.
<Resistance>
Terminal
Tool Specific resistance Yoke
Megger 0.1M or greater (DC500V)
1. Apply earth probe (negative [-]) of Megger to the yoke.
2. Apply line probe (positive [+]) of Megger to each
terminal of connector plug.
152T058
111
MOTOR 8
8-3-6. Oil seal and permanent magnet(EPS motor)

1 Oil seal
 Check Oil seal for wear and damage.
If worn or damaged, replace it.
2 Permanent magnet
l
 Check permanent magnets of Yoke for damage or
ria
sticking metallic dust.
If sticking metallic dust, remove it with compressed air.
If damaged, replace the ASS'Y.
.c T
F
om
8- 4. Troubleshooting z D
8-4-1. Motor - troubleshooting
P
ard
1. Damage of bearing Replace
w.p m
1 Abnormal noise Repair or

2. Armature shaft is not centered
replace
i
dfw
ww o
Remarkable
2 1. No good rotating Replace
temperature rise
cuC
Abnormal noise or 1. Wear of serration of Armature shaft or coupling Replace

3 temperature rise 2. No good adjustment or wear of gears or failure of
after installing Replace
bearings in the drive unit
The motor does 1. Damage of sensor bearing Replace

4
not turn correctly. 2. No good contact with the lead wire from the sensor Repair
Do
112
9. CONTROL PANEL ASS'Y
9- 1. Name
Button Switch Lift switch

Display Emergency (Horn) comp. (Up)
Knob stop switch
l
ria
Accelerator grip
.c T
Lift switch
Handle (Down)
F
om
z D Pallet lock
confirmartion lamp
P
ard
Seat switch
(switching mode) Key switch Switch(Opt) Lock mode switch
(Pallet lock)
w.p m
415W083
i
dfw
ww o
cuC
Do
113
CONTROL PANEL ASS'Y 9

9-2-1. Control panel - disassembly and reassembly

 Disassembly and reassembly of Control panel
l
ria
Lock mode switch
Sheet switch
(switching mode) Switch Comp., toggle
.c T
Turn the screw to A side.
Lamp comp.
Switch, push button
Panel, control(1)
F
om
Panel, control(2)
z D
P
ard
Display
Switch comp., toggle
(direction switch)
w.p m
Switch
i
dfw
(Horn)
ww o
Board comp.,
printed
cuC
Bracket, control
Panel, control(3)
Do
Key switch
Board comp.,
display
CS/FCS
Cover,
display board
415W112
114
9 CONTROL PANEL ASS'Y
9-2-2. Steering SUB ASS'Y - disassembly and reassembly

 Disassembly and reassembly of Steering SUB ASS'Y
Knob (A)
Cap
Knob (B)
l
Cover, handle(2)
ria
Plate, handle(1) Panel SUB ASS'Y, control
.c T
F
om
z D Oil seal
The inside of lip:Apply grease
G
P
Housing, bearing(1)
ard
Lever
Screw(M5) B
Apply THREEBOND [#1401].
w.p m
Bearing
i
dfw
B L
ww o
Plate Screw(M4)
Potentiometer Apply THREEBOND [#1401] or
cuC
LOCTITE [#242].
Stopper
Nut LU
Pin: apply the lubricant
Stopper Screw LU
Do
Trapezoidal screw: apply the lubricant

Bearing
U nut (3 points)
Housing, bearing(2) Tighten equally so that steering
strengh is 0.5kg at B point.
Bracket, control At that time, knock its against
upper and under stopper, and
check the steering wheel does not
G : Apply grease become heavy.
LU : Apply lubricant
B : Apply THREEBOND
L : Apply LOCTITE
N : Not reusable
415W113
CAUTION In case that oil seal, O ring and bearing were removed, they should be replaced to new ones.
115
9-2-3. Accelerator SUB ASS'Y - disassembly and reassembly

 Disassembly and reassembly of Accelerator SUB ASS'Y
Bracket, controller
1 Screw(M4&M5) L
Pin(2), accelerator
l
ria
Bracket, accelerator Connect so that accelerator rotate
smoothly.
.c T
Pin(1), accelerator Cover, lift(1),(2)
Install not to be inside of B side
Arm,
potentiometer
F
om
Bracket, Cover, lift(1),(2)
potentiometer
z D Install not to be inside of B side
P
ard
Potentiometer
Grip B
w.p m
Apply THREEBOND BAMPER

[#1564] .
i
dfw
ww o
cuC
Screw(M3) L
Switch, push
button(up, down) handle Apply LOCTITE [#242] .
Spring, accelerator G
Do
Apply grease
Spring setting direction
(See from A side.)
Bracket,
accelerator Spring
Cover, lift(1)
Grip side Outside Inside
handle
Potentiometer handle
Cover, lift(2)
B : Apply bonding agent
G : Apply grease
L : Apply LOCTITE
415W014
116
9 CONTROL PANEL ASS'Y

CAUTION Apply wheel chocks to tyres to prevent the truck from moving.
9-3-1. Pin (1), (2), accelerator- inspection

1. Check for wear. Inspection of pin(1), accelerator
l
ria
Item Specific diameter Wear limit
.c T
Pin(1), (2)
rs
14 13.8
415W115
accelerator [ D]
te ale
Inspection of pin(2), accelerator
F
om
z D bu e
tri d D
D ize
P
ard
415W116
ot or
9-3-2. Bushing - inspection

w.p m
is
N uth
Inspection of bushing
i
1. Check for wear.
D rA
dfw
ww o
fo
cuC
d
o
Item Specific diameter Wear limit

y
nl
O
361S036
Bushing [ d] 14 14.2
Do
9-3-3. Adjustment of the steering wheel

potentiometer
Refer to "Trouble shooting".
9-3-4. Adjustment of the accelerator

potentiometer
Refer to "Trouble shooting".
117
9-4-1. Control panel ass'y - troubleshooting
1. Wear of bearing Replace
1 Steering wheel is 2. Damage of oil seal Replace
heavy
3. No good adjusting of U nut Adjust
l
.c T
ria
F
om
z D
P
ard
w.p m
i
dfw
ww o
cuC
Do
118
10. ELECTRIC DEVICES
10- 1. Name
 Main controller
Main contactor MPU board
a l
page 125. refer to
om ri
Lift height encoder troubleshooting p.2
EPS board Fuse
r F
T
Refer to page 143. page 129. page 128.
iza D
d.c
P
Battery Fan
w.p om
dfw
Refer to page 130.

C
Refer to page 140. Transformer

cu
Charger
ww
Do
Refer to page 132.
Refer to page 132.

Potentiometer
RBC Transformer
Refer to page 155.

Battery Fan
415W105
119
10a. CONTROL UNIT
10a- 1. Name
 Main parts
Upside
(8) Fuse
(1) Sensor, current (2) Module, FET (6) Contactor
*BN-325A
l
.c T
ria
F
om
z D
P
ard
(4) Sink., heat (3) Board comp., (5) Condenser comp. (8) Fuse (7) Board comp.,
MPU *BN-325A EPS
w.p m
i
415W101
dfw
ww o
No. Part name number Remarks

cuC
(1) Sensor, current 4 Travel2/Hydraulic2

(2) Module, FET 2
(3) Board comp., MPU 1 Travel/Hydraulic
(4) Sink, heat 1
(5) Condenser comp. 1 80V/4700 F×9
Do
(6) Contactor 1
(7) Board comp., EPS 1
(8) Fuse 1 Main/325A
(9) Fuse 1 Charger/100A
120
10a CONTROL UNIT
10a- 2. Disassembly and reassembly

10a-2-1. Control unit - removal and installation

1. Remove the following parts and devices.
l
ria
RB 1. Open 'Cover, top".
2. Remove the fitting bolt to remove "Cover, body".
.c T
RBC 1. Open 'Cover, top".
2. Open 'Cover, side".
F
om
2. The following parts and components should be removed before removing the control
unit.
z D
P
1. Remove 'Cover, unit".
ard
2. Disconnect the wiring of the control unit.
w.p m
NOTE The following indicates stamping for each wiring.

i
dfw
ww o
Stamping Connected to
cuC
+ Battery (+)
- Battery (-)
PC Contactor
NA Control unit (-)
T+ Control unit travel(+), transformer(+)

Do
T- Transformer(-)
H+ Control unit hydraulic(+)
U1, V1, W1 Each phase on control unit travel/tractioin motor
U2, V2, W2 Each phase on control unit hydraulic/hydraulic motor
3. Remove fitting bolts to remove the control unit.
121
CONTROL UNIT 10a
3. The following parts and components should be removed before removing the MPU
board.
1. Disconnect the coneccters of the MPU board.

2. Disconnect the fitting bolt of "Bracket, board" to remove the MPU
board.
 Removing the control unit
Cover, unit
l
ria
Fitting bolt
.c T
F
om
Control unit
z D
P
ard
Fitting bolt
Bracket, board
w.p m
MPU board
i
dfw
ww o
* This illustration shows model RB.

415W021
cuC
* Install the control unit in reverse order of removal.

Do
122
10a CONTROL UNIT
10a-2-2. Control unit - disassembly and reassembly
 Disassembling and reassembling the control unit (1)
Sink, heat 1 Module., IGBT C

Board comp., EPS
Apply conductive compound
[G-747](Shin-Etsu silicones) on all
l
mating surfaces to "Sink, heat".
ria
Tightening torque
.c T
3.5-4.5 N m
Module., FET {0.36-0.49 kgf m}
(travel)
F
om
z D Board comp., MPU
Module., FET
Sensor, (hydraulic)
current
P
ard
w.p m
Sensor, current
i
dfw
ww o
Bracket ,board
cuC
 Main terminal (M6)

2 Tightening torque
3.5-4.5 N m
{0.36-0.49 kgf m}
Do
: Tightening torque
C : Apply compound 415W143
123
CONTROL UNIT 10a
 Disassembling and reassembling the control unit (2)

Contactor Tightening torque
12.7-14.7 N m
l
ria
Terminal comp.,
Fuse
.c T
Fuse (325A)
Fuse (100A)
F
om
z D
P
ard
w.p m
i
dfw
ww o
cuC
Condensor comp.,
Do
124
10a CONTROL UNIT
10a- 3. Inspection, replacement and attention

CAUTION  Apply wheel chocks to tyres to prevent the
Discharging the capacitor
truck from moving.
 Record places of lead wire connections before Battery[-]
disassembling. Line
 Be sure to discharge the capacitor of control

unit. Battery[+]
Line
 Refer to <Capacitor - discharging procedure>
l
ria
415W148e
.c T
10a-3-1. Contactor - check and replacement
CAUTION  Be sure to disconnect the battery plug.
F Checking the contactor
om
 Record places of lead wire connections before
z D
disassembling.
1 Checking procedure
P
ard
1. Remove nut and washer to check the contactor for
damage, especially by burning.
w.p m
If it is damaged, replace it.

i
dfw
ww o
CAUTION There are possibility that high pressure is left

in the hydraulic piping. Take care the high
cuC
pressure oil when you remove the hose.
415W145
<Type of contactor>
Do
Applicable Tightening torque

Type Voltage
model 12.7-14.7 N m
RB10/15 CP23N-A44 48V
: Tightening torque
RBC7/9/10 CP23N-A24 24V
2. As for main terminl (M6), apply the fitting torque

indicated in the right table.
125
CONTROL UNIT 10a
10a-3-2. FET module - inspection and replacement

1. Perform a continuity test of the semiconductors,
at test points 1 - 6 in the following table, by using  Inspection of "FET module"
continuity check mode of a digital tester. (Do not use
the resistance range because you can not get correct
D2-W
conclusion about the continuity.) W
When the circuit is conducting at any one test point, D2-V
N V
the buzzer sounds. In this case, replace the "FET
module" (Travel or Hydraulic). The "FET module"
l
U D2-U
D1-U,V,W
ria
which has the continuity is damaged. P
* Plus side (+) * Minus side (-)
.c T
Terminals touched with Terminals touched with
the tester the tester
G2-W
1 P(D1-U) G1-U
G2-V
F
om
2 P(D1-V) G1-V G2-U
3 P(D1-W) z D G1-W G1-W
G1-U G1-V
4 U(D2-U) G2-U
461S005
5 V(D2-V) G2-V
P
6 W(D2-W) G2-W
ard
* Either plus (+) or minus (-) can be used.
Perform a continuity test.
w.p m
 "FET module " circuit

i
dfw
ww o
P
cuC
D1 D1 D1
G1 G1
G1
U V W
Do
D2 D2 D2
G2 G2
G2
N
121W276
NOTE This is a simple check, and it is impossible to

conclude for details whether it is normal condition
or not.
126
10a CONTROL UNIT
2. If you find the continuity at any one test point, check Inspection of
the MPU board(PB105-xxx) at the same time because "module,FET" (2)
Main terminal area
there is a high possibility that the electric devices in
Installation area
these boards are damaged by electric surge.
3. When installing the "FET module" to the "heat sink",

be sure to apply conductive compound [G-747] (Shin-
Etsu silicones) evenly over the surface.
4. Apply the tightening torque shown on the right to the
l
Main terminal area
main terminal area (M6) and the installation area
ria
461S007
(M6). Main terminal area (M6)

Installation area (M6)
Tightening torque (M6)
.c T
3.5-4.5 N m
CAUTION Do not touch any terminals of "FET Module" {0.36-0.49 kgf m}
with your hand. Otherwise, the elements can be
F : Tightening torque
om
destroyed by static electricity.
z D
P
ard
10a-3-3. Capacitor - check and replacement
w.p m
<Appearance check>
i
dfw
ww o
Check for the damage such as bulge and burst. If you Checking the capacitor
find any problems at any one capacitor, replace the all

cuC
Analog tester
capacitors (9pcs.) and in this case, check for the damage
of the capacitor (270μF) in the power steering controller,
too.
CAUTION Use an analog tester to check the capacitor.

Do
1. Discharge the each capacitor by using a resistor.

461E115
For the discharge procedure, see the following

"<Capacitor - discharging procedure>".
2. Set the tester to resistance ( ) X 1k .
3. Apply the (+) tester probe to the (+) pole of the
capacitor, and the (-) tester probe to the (-) pole.
4. First, the tester reads a few k , then reads .
CAUTION This is a simple check, and it is impossible

to conclude for details whether it is normal
condition or not.
127
CONTROL UNIT 10a
<Discharging procedure> Discharging the capacitor

1. Prepare a resistor (20W, 50 or 50W, 10 or 10W,
15 ).
2. Fit terminals of the resistor to terminals of the capacitor.
l
ria
152E118
10a-3-4. Fuse - replacement
.c T
1. Be sure to replace Fuse with the specific capacity one.
Fuse type
<Fuse type>
F
om
Application
z D Capacity
325A,
Travel/Hydraulic fuse
Travel / Hydraulic F1 325A
P
ard
Transformer 100A
w.p m
2. Be sure to tighten the nuts after replacing it.

i
dfw
ww o
100A,
Transformer fuse
cuC
415W146
Do
128
10a CONTROL UNIT
10a-3-5. EPS board - specification

Applicable model Type Voltage Current limitation  EPS board
RB10/15 PBC106-21 48V 35A
RBC7/9/10 PBC106-20 24V 42A
l
ria
Wire [Blue] : to capacitor
(B-).
.c T
To EPS motor(2P-X)
Wire [Red] : to contactor(B+).
F
om
z D 415W147
P
ard
w.p m
i
dfw
ww o
cuC
Do
129
10b. FAN
10b- 1. Disassembly and reassembly
10b-1-1. Fan - removal and installation
 Removing the fan
Cover, unit
a l
om ri
T
r F
iza D
Bracket, fan
d.c
P
Guard, finger
Fan
w.p om
dfw
cu C ww
* This illustration shows model RB.

Do
415W023
130
10c. STEERING ANGLE POTENTIOMETER
10c- 1. Disassembly and reassembly
10c-1-1. The steering angle potentiometer -
l
disassembly and reassembly
om ri
a
 Removing and installation of steering angle potentiometer
T
Bracket,
potentiometer
r F
Potentiometer
iza D steering angle
d.c potentiometer
P
w.p om
dfw
cu C ww
Do
415W102
10c- 2. Checking and adjustment

10c-2-1. Adjustment of the steering angle potentiometer
Refer to "Troubleshooting"
131
10d. CHARGER (Only for trucks with charger)
10d- 1. Disassembly and reassembly
CAUTION  Do not misconnect lead wires to each part.
 Check for the misconnection of lead wires.
 Securely tighten the connection of lead wires.
 Insert insulation tubes for the terminals of lead wires in order to keep
them away from metal parts.
l
10d-1-1. Charger ass'y - disassembly and reassembly
om ri
a
 Disassembly and reassembling the charger ass'y (only for trucks with charger)
T
Sensor, magnetic
r F
iza D Bracket, sensor
Sensor comp., magnetic
d.c
P
Cover, switch board
Board comp., printed

w.p om
Sheet, switch
dfw
Fuse comp.
C
Panel, charger
cu
To contactor
ww
Socket
Do
Switch, magnet
To fuse
Socket
Harness, BC
Relay
To harness, body Switch and LED

To socket
415W117
132
10d CHARGER
10d-1-2. Transformer - disassembly and reassembly

 Removing the transformer (only for trucks with charger)
Cover,
RB RBC transformer
Bracket, controller Bracket,

transformer
U nut.
l
ria
U nut.
Transformer
te ale
.c T rs
Transformer
F
om
bu e
z D
tri d D
415W118
D ize P
ard
 Disassembly and reassembling the transformer (only for trucks with charger)
ot or
w.p m
is
N uth
Secondary coil
i
D rA
dfw
Primary coil
ww o fo
cuC
o
y
nl
Output terminal (-),

O
M8
Do
Output terminal (+), M8
Diode
415W106
133
CHARGER 10d
10d-1-3. Charger - specifications

< 3 200V>
Power Applicable Battery capacity
voltage model capacity transformer link fuse remarks
201Ah(Std)
RB10
240Ah(Opt) 3.0kVA T0224-1023, T0224-1024 10A
210Ah(Std)
RB15
210Ah(Opt) 4.3kVA Quick charge
201Ah(Opt) T0224-0344, T0224-0345,
l
RB10 4.3kVA 15A Quick charge
240Ah(Opt) T0224-0346, T0224-0347
ria
280Ah(Opt) 4.3kVA
RB15
280Ah(Opt) 5.2KVA T0224-0348, T0224-0349 15A Quick charge
.c T
200V 250Ah(Std) 1.8kVA T1124-0017 10A
RBC7
250Ah(Opt) 3.0kVA Quick charge
T1124-0225, T1124-0226,
RBC7/10 390Ah(Opt) 3.0kVA
F 10A
om
T1124-0227, T1124-0228
390Ah(Std) z D3.0kVA
RBC9
445Ah(Opt) 3.4kVA
P
RBC7/9/10 390Ah(Opt) 3.4kVA T1124-0229, T1124-0230 10A Quick charge
ard
RBC10 445Ah(Std) 3.4kVA
RBC9/10 445Ah(Opt) 3.7kVA T1124-0306 10A Quick charge
w.p m
i
dfw
ww o
10d-1-4. Charger switch - specifications

cuC
Applicable model specifications Number of Parts number Type

switch
RB10/15
No stop switch 2 54000-82780 PB105-73
RBC7/9/10
Do
134
10d CHARGER
10d- 2. Inspection and replacement

10d-2-1. Magnetic contactor - inspection
1. Check for burns and damage to contacts.
 Inspection magnetic contactor
Magnetic contactor
l
ria
415W107
.c T
10d-2-2. Plug comp. and receptacle
F
om
1. Check for burns and discoloration on the receptacle
z D  Inspection of plug comp. and receptacle
terminal.
If there are any burns, discoloration, or ratting in the Receptacle
P
terminal, replace both the plug comp. and receptacle.
ard
2. Check the earth wire fitting nuts for loosening.
w.p m
Earth wire
i
dfw
ww o
Fitting nut
cuC
Plug comp.
415W108
10d-2-3. Link fuse and fuse base - inspection

Do
1. Check link fuses for blow outs and discoloration.

 Inspection of link fuse and fuse base
2. Check fuse fitting screws for loosening.
Link fuse
Fitting screw
415W109
135
CHARGER 10d
10d-2-4. Transformer - inspection

1. Check for damage and dirt.  Transformer insulation measurement
If there is a lot of dirt, clean it away with compressed air. Megger
2. Measure the insulation resistance.
Specific parameter for Transformer
5M or greater
insulation resistance
CAUTION ● Be sure to disconnect the battery plug before
l
measuring.
ria
● If using a megger, do not touch the measuring
terminals. 415W120
.c T
1. Remove all diodes.
2. Use a megger to measure the following locations and
check the insulation.
F
om
● Between the primary and secondary coils
z D
● Between the primary coil and the chassis
● Between the secondary coil and the chassis

P
ard
10d-2-5. Diode - inspection
w.p m
1. Measure the resistance value and check the diode.

i
● Specific resistance value  Checking the diode
dfw
ww o
Terminal Tester
Resistance Diode
[+]Positive [-]Negative
cuC
Anode Cathode
Cathode Anode 10-100k
NOTE ● The values indicated in ( ) are checked by a

Do
digital tester (KAISE SK 7711) as a reference. K A

● Each resistance value varies depending on the
type of tester.
A K
<Measuring procedure> 415W121
1. Set the tester knob to the resistance ( ) x 1 range.

2. Short-circuit the tester rod to set the needle to 0.
3. Place the tester rod against the element to check it.
136
10d CHARGER
10d- 3. Inspection and adjustment after assembly

CAUTION ● Confirm that the earth terminal of the plug
comp. and receptacle and the chassis are
conducting. (1 range:0 )
● The inspecton and replacement should be
done in a place which is well ventilated and

kept away from fire.
l
ria
10d-3-1. Sensor - inspection
1. Open "cover, top".
 Sensor adjustment
.c T
2. Confirm LED on "sensor, magnetic" lights after "cover,
top" is closed. Cover, top
3. If the LED does not light, adjust the fitting of "sensor,
F
om
magnetic" .
40
z D
15
<Refelence value> Magnet,rubber
P
The distance between LED lights when the
ard
sensor and magnet distance is within 40mm
Sensor,
magnetic
w.p m
i
dfw
Bracket, switch
ww o
Chassis
cuC
(side)
415W110
10d-3-2. Inspection of timer

Do
Refer to "Troubleshooting"
137
CHARGER 10d
10d-4 Voltage tap

10d-4-1. Power voltage - check
NOTE ● Measure the power voltage at the charging
section without running the charger.
● Measure the voltage for 1 minute. The highest
voltage obtained is the power voltage

● If three-phase input power is used, the
average of the highest voltages in each phase
l
ria
(U-V, U-W and V-W) is the power voltage.
CAUTION The measurerment should be made when the perepheral
.c T
facilities are not used, such as during the noon recess or
while the charger is in use.
F
om
10d-4-2. Power voltage - selection
z D Tap connection position
Secondary
2次コイルcoil
<Input voltage: 200V>
P
Primary
1次コイル coil
ard
Power voltage (V) Voltage tap
199 or lower 200 V
w.p m
200 － 209 210 V

210 － 219 220 V
i
dfw
ww o
cuC
Tap connection
タップ接続位置 position
121W232
Chassis side
Do
3-core cable
Vinyl caps are (VCT)
placed on for The body side and the
unused taps. transformer side are
secured together using
a ring by terminal
Washer
Nut
Mark band indicates the
tap voltage. Glass tube
Transformer side 461E116
138
10d CHARGER
10d-4-3. Switching the voltage tap

CAUTION Before changing the voltage tap and replacing
the link fuse, be sure to disconnect the AC
plug from the receptacle, disconnect the
battery plug and discharge the capacitors in
the control unit.
Securely tighten the screw for the ring terminal
210V
so it will not be loosened. 200V
Factory setting
l
(220V)
1. Loosen the screw and remove the ring terminal.
ria
2. Reconnect it to the tap conforming to the power
voltage and secure the ring terminal together with
bolts and nuts.
.c T
 Factory setting: 220V
461E117
F
om
10d-4-4. Replacement of link fuse z D
(three-phase voltage)
P
CAUTION Be sure to disconnect AC plug.
ard
 If the screws are not securely tightened,
contact failure could result, causing
w.p m
malfunctioning.
i
dfw
1. Loosen the screw and replace the link fuse.

ww o
<Applicable fuse>
cuC
Applicable Power supply voltage

Battery capacity Remaks
model 200V/220V
201Ah(Std)
RB10
240Ah(Opt) 10A
210Ah(Std)
RB15 Link fuse
Do
210Ah(Opt) Quick charge

Securely tighten
201Ah(Opt) the screw.
RB10 Quick charge
240Ah(Opt) 15A 415W109
280Ah(Opt)
RB15
250Ah(Std)
RBC7
RBC7/10 390Ah(Opt)
390Ah(Std)
RBC9 10A
445Ah(Opt)
RBC7/9/10 390Ah(Opt) Quick charge
RBC10 445Ah(Std)
RBC9/10 445Ah(Opt) Quick charge

139
10e. BATTERY
10e-1 Disassembly and reassembly
CAUTION  Turn off the key switch and disconnect the battery plug before working.
 Be careful not to be wet with electrolyte to the body.
 If the electrrolyte would come into eye, wash eye with fine water, and
go to doctor.
 The inspection battery should be done in a place which is well
ventilated and kept away from fire.
a l
10e-1-1. Battery - removal and installation
om ri
T
 Removing and installation the battery
r F
RB iza D
d.c Battery ASS'Y
P
w.p om
dfw
cu C ww
Do
RBC
Battery ASS'Y
Case, battery(L)
(R)
415W129
140
10e BATTERY
10e-2 Inspection and adjustment

10e-2-1. Battery - inspection and adjustment
1 Inspection of quantity of electrolyte and  Inspection of electrolyte level
replenishment Appropriate level
1. Disconnect the battery plug.
2. Open the battery cover and set the stopper.
l
3. Check electrolyte level.
ria
<Specification> Proper level of electrolyte
 If the red float can seen, electrolyte level is correct.
.c T
If not, replenish with refined or distilled water.
F
om
z D
P
ard
Lowest level of electrolyte
Refined water
w.p m
<Replenishing with refined water>

 Replenishing procedure
1. Remove the lid of the plastic tank, dip the hose with a
i
dfw
lid into the tank deeply and tighten it up..

ww o
Bottle Lidden hose

2. Open the cap and put another end of the hose into the
Hose
cuC
battery sell.
Pinch-cock
3. Open the pinch-cock and press the tank at the both
sides sveral times. Cap
4. Refined water will flow into the cell by siphon action.
5. Close the pinch-cock to stop replenishing just before Vent plug
Do
the red-float touches the indicating plate of the cap.
Cap
White line Float
Battery
Level of
electrolyte
461E254
141
BATTERY 10e
2 Measurement of specific gravity of electrolyte in each cell

<Reading hydrometer>
1. Take reading at contacting line of electrolyte and the  Measurement of specific
gravity
tube.
2. Difference between max. and min.pecific gravity shall Thermo
Hydrometer
meter
温度計比重計
be less than 0.05
Difference between max. and min. Less than 0.5

specific gravity
<Recharging procedure>
a l
1. Carry out equalizing charging.
2. Check specific gravity at each cell after equalizing
om ri
carge and make sure the difference is within standard
 Conversion
T
value.
As specific gravity of electrolyte is based on the value 1.330
at 20 ,convert measured specific gravity. 1.310
r F
1.300 1.290
<How to convert to specific gravity at 20 > 1.290
Specific gravity at 20
Specific gravity at 20
1.280 1.270
iza D
1. Measure temperature of electrolyte.
1.270
1.260 1.250
d.c 1.250
1.240 1.230
P
CAUTION Use thermometer to measire. 1.230
1.220 1.210
1.210
1.200 1.190
2. Measure specific gravity of electrolyte. 1.190 1.170
1.180
w.p om
3. Measured specific gravity dhall be converted to the 1.170

1.160
1.150
value at 20 . 1.150
50 40 30 20 10 0 -10 -20
dfw
[Conversion formula] Temperature

S20=St+0.0007(t-20)
C
S20:specific gravity converted at 20 .

St: Measured specific gravity
cu
t : Temperature of electrolyte.
10e-2-2. Battery - cleaning

ww
Do
1 Cells, connectors and terminals

1. Keep dry, When they get wet, clran with adry cloth or
blow out with compressed air.
2. If they are rusted, clean with a wire brush or a sand
paper.
2 Cleaning vent plug

1. Turn the vent plug counter-clockwise to remove.
2. Clean it with a detergent so that red-float is visible .
3. Securely fasten the vent plug that it ill fit well with the
cell cover on installation.
NOTE If the swanacrew part is damaged, replace the plug

comp. with ne one.
142
10f. LIFT HEIGHT ENCODER
10f- 1. Disassembly and reassembly
CAUTION Apply wheel chocks to tyres to prevent the truck from moving.
l
ria
 Disassembling and reassembling the lift height encoder
Inner mast
(middle mast)
.c T
F
om
z D Outer mast
Magnet
P
ard
Sensor comp.
w.p m
magnetic
i
dfw
Pulley, wire
ww o
Bracket, sensor
Spacer
cuC
Bearing sensor
Housing sensor Insert into "Housing, sensor" and
Bracket, wire
press "pulley, wire" in it.
Do
Wire LU
Apply lubricant (colorless)

Spring
LU : Apply lubricant 415W085
CAUTION When pressing "Pulley, wire" into "Bearing sensor", don't give pressure
to the sensor.
143
LIFT HEIGHT SENSOR 10f
M mast
"Bracket, wire"(up) is different from (down) in point of
both sides(left and right position) of it.
Put the wire around "pulley, wire" to install "Bracket,
wire"
Bracket, wire(up)
CAUTION Be sure not to put the wire in reverse, or the wire will be
rubbed.
l
ria
Outside
Pulley, wire
Wire
.c T
F
om
z D Bracket,
wire(down)
inside
P
ard
w.p m
i
415W160
dfw
ww o
cuC
Do
144
10f LIFT HEIGHT SENSOR
10f- 2. Check and adjustment

10f-2-1. Lift height encoder - adjustment
1 Adjustment of magnet sensor
1. Adjust the sensor so that a clearance between sensor Height C[m]
and magnet (A) is 5 - 8mm. 3500 1.33
2. Confirm the datum point is detected. 4000 1.48
4300 1.58
STD mast
l
4500 1.68
ria
Confirm the height shows 0.06m and the datum point is
detected when the lift is lowest. 4700 1.73
5000 1.83
M mast
.c T
5300 1.93
Lower the lift from 2nd stage and confirm the height
5500 2.03
shows C[m] and the datum point is detected when the
F
om
2nd cylinder stroke shows 0. 5700 2.08
z D 6000 2.28
3. If the datum point is not detected, loosen the fitting
bolt of sensor and make the sensor approach the
P
magnet to detect the datum point.
ard
4. Adjust the height of lift.
Refer to "6-3-9. Fork - check and adjustment" and

w.p m
"6-3-14 Slack of chain detector".

i
dfw
5. Raise the lift from the lowest position and measure the
ww o
height of lift when the height shows 0.07m (M mast:

cuC
C+0.01m). Confirm the height is within 70 - 100m (M

mast :C+0.03m).
CAUTION If the height is out of the regular range, prestop

may not operate at the height set up.
Do
6. When loosen the fitting bolt of sensor to adjust, apply

LOCTITE to the bolt.
145
LIFT HEIGHT SENSOR 10f
2 Adjust the spring

1. Adjust the nut so that the length of spring (D) is 55mm.
Adjusting lift height detecting sensor
Viewed from B A
Bracket comp. magnet
magnet
B
Fitting bolt
l
ria
Pulley, wire
Bracket, sensor
Wire
.c T
Wire
Spring
F
om
z D Nut
D
P
ard
415W086
w.p m
i
dfw
ww o
cuC
Do
146
11. AUTO PALLET LOCK
11- 1. Auto pallet lock - function
11-1-1. Pallet lock - function
The pallet lock detects a pallet by pushing "Bar,
 Operating pallet lock
lock(1),(2)", and fixes the pallet with "Arm, lock".
l
 "Bar, lock(1),(2)" starts moving at 30 - 40 N.
ria
 Adjust is necessary in case of the height of pallet.
Refer to "11-3.Check and adjustment" Lock mode Release
switch (OFF)
 Turn the lock mode switch to the Lock position
.c T
(ON) normally. In case of compulsory cancel, turn
Lock(ON)
it to the Release position (OFF).
F
om
z D Lock confirmation
lamp
CAUTION Around the end of pallet is unstable in the state

415W123
P
of lock cancel, so pay attention.
ard
w.p m
Lock confirmation lamp

i
dfw
ww o
 Lock confirmation lamp shows the state of pallet lock.

cuC
<Lamp status>
Pallet lock Lamp
Pallet lock ON Turn on
Pallet lock OFF Turn off
Power cylinder is working Flash at 0.5 seconds interval
Do
147
AUTO PALLET LOCK 11
11-1-2. Detecting error

<Error>
Error State
Cylinder detctor error Turn on for more than1 seconds on the state of lock.
Pallet lock potentiometer error Output of potentiometer is out of the regular value
FET error Abnormal FET
Cylinder initialize error
Over electric current or operating cylinder for more than
Cylinder lock error
6 seconds.
l
Cylinder lock cancel error
ria
When detecting these errors, "E40" is indicated on the
screen, and power cylinder stops.
te ale
.c T rs
F
om
11-1-3. Warning buzzer
bu e
z D
tri d D
 When the following condition is realized, the warning
buzze sounds.
D ize P
The buzzer sounds three times at 0.2 seconds interval,
ard
2 seconds is 1 cycle.
ot or
w.p m
is
N uth
Condition Contents
i
D rA
Refer to "11-1-2.Detecting
dfw
Detecting error
ww o
error"
fo
The lifting height is over the The guard is opened and

cuC
value is set by prestop pallet lock is canceled.

o
y
nl
O
● Warning buzzer cycle

Do
　：Buzzer ON （0.2sec.)
　：Buzzer OFF（0.2sec.)
　：Buzzer Stop（1 sec.)
Time
1 cycle(2 seconds）
148
11 AUTO PALLET LOCK

stands.
l
Auto pallet lock - removing and installing 1
ria
Potentiometer
Plate,
Switch
Bracket, Screw(M4) L
Switch
.c T
Lever, switch
Rod(2) Pin, link(1)
F
om
Rod(1)
Arm(2),lock
Arm(1),lock
z D Pin,rod(1)
Link, cylinder
P
ard
Magnet
CylinderComp., power
w.p m
Bar,lock(1)
Pin, link(2)
i
dfw
ww o
CS/FCS
Heater Comp.
cuC
Bar,lock(2)
1 Shim
base, lock Adjust the clearance between brock
Pin, link(1)
of "Base,lock" and "Link, cylinder"
Shaft, arm less than 0.5mm, note the number
Do
and thickness.
View from A
Lever, switch
Potentiometer
Lift table
Shaft
marking surface 2 Bolt, w/washer(M6&M10)
CS,FCS: Bolt and spring washer
149
AUTO PALLET LOCK 11
Auto pallet lock - removing and installing 2
Sensor Comp., magnetic

(pallet detector)
Sensor Comp., magnetic
(cylinder detector)
Bracket,
cover(2) Bracket,
sensor(1) Bracket,
sensor(2)
l
ria
To haeness,
accelerator
CS/FCS
.c T
3 Bolt, w/washer(M6&M10)
CS,FCS: Bolt and spring washer
F
om
z D
P
ard
w.p m
i
Base, lock
dfw
ww o
cuC
Bracket,
cover(1)
415W131
Do
150
11 AUTO PALLET LOCK

11-3-1. Pallet lock function - checking
1 Checking procedure
1. Insert the fork into the pallet fully.
2. Lift up over the prestop height.
3. Move the pallet and confirm "Arm, lock" certainly holds
the pallet.
l
If the pallet moves extensively, adjust refer to
ria
"11-3-2. Pallet lock adjusting mode","11-3-2. Pallet lock
adjusting mode","11-3-3. Cylinder detector adjusting"
and "11-3-5. Pallet lock potentiometer adjusting".
.c T
F
om
z D
11-3-2. Pallet lock - disassembly and reassembly
P
ard
Display board
1 Setting procedure
F01
1. Set rotary switch RS1 on the display board to "0".
CDE
23
w.p m
2. Set the lock mode switch to "Release".
456
AB
789
3. Turn off the key switch..
i
dfw
ww o
Set RS1 to "0".

cuC
Lock mode
switch Release
Lock
Do
4. Set rotary switch RS1 on the display board to "A". 415W190
5. Turn on the key switch and the "Cylinder detector

adjustment" is appeared on the display.
Display board
Press button, and the screen changes to "Pallet
detector adjustment", then "Potentiometer adjustment". F01
CDE
23
456
AB
789
Set RS1 to "A".
151
AUTO PALLET LOCK 11
11-3-3. Adjustment of the cylinder detector

1 Adjusting procedure
1. Set the cylinder detector adjustment and the following
screen appears.
 Cylinder detector adjustment
l
ria
415T043
2. Adjust the installation of cylinder detector to display
.c T
"ON" (Buzzer).
<Specifications>
F
om
A 17 - 25 [mm]
Cylinder detector adjustment

z D
P
ard
Cylinder detector Link, cylinder
Lock bar
w.p m
Fork upside
A
i
dfw
ww o
cuC
Bracket, sensor(1)
415W134
Do
152
11 AUTO PALLET LOCK
11-3-4. Adjustment of the pallet detector

1.Press button,and the following screen appears.
 Pallet detecor adjustment
l
ria
415T044
2.Adjust the installation of pallet detector to display "ON"
.c T
(buzzer).
<Specifications>
F
om
A z D 5 - 9 [mm]
P
Pallet detector adjustment
ard
Arm, lock(1)
w.p m
Lock bar
i
dfw
ww o
Fork upside
A
cuC
Bracket, sensor(2) Arm, lock(2)

Magnet Pallet detector
415W132
Do
153
AUTO PALLET LOCK 11
11-3-5. Adjustment of the pallet lock potentiometer

1.Press button, and the following screen appears.
 Potentiometer adjustment
l
ria
415T045
2.Adjust the installation of potentiometer to display "245±

5" (buzzer).
.c T
Pallet lock potentiometer adjustment
Pallet lock potentiometer
Moving angle
F
om
Bracket, switch Rod(2)
z D Arm, lock(1)
P
ard
w.p m
Lock bar
i
415W133
dfw
ww o
cuC
11- 4. Inspection and check after adjustment

After adjustment, be sure to check.
11-4-1. Check (general mode)

Do
F01
CDE
23
456
AB
789
2. Set the lock mode switch to "Lock".
3. Turn off the key switch. Set RS1 to "0".
154
11 AUTO PALLET LOCK
11-4-2. Check of the pallet detector

1. Lift up over the prestop height.
2. Put the lock bar downward by hand without pallet.
3. Check the motion of lock bar.
Lock mode
NOTE  Normal : Lock motion ⇒ release ⇒ Lock release switch Release
motion ⇒ Lock cancel status Lock

 Abnormal : Lock motion ⇒ Swing ⇒ Repeating
the lock release motion
l
ria
4. In case of abnormal condition, readjust in accordance
with "11-3-4 Adjustment of the pallet detector".
415W190
.c T
11-4-3. Check of the pallet lock potentiometer
1. Lift down under the prestop height.
F
om
2. Lift up with a pallet over the prestop height.
z D
 Normal : Lock release status ⇒ Lock motion ⇒

NOTE
P
Lock status
ard
 Abnormal a): Not operating the lock bar.
b):Lock motion ⇒ Swing ⇒ Lock
w.p m
release
i
motion ⇒ Lock release status
dfw
ww o
4. In case of a), readjust in accordance with "11-3-5

cuC
Adjustment of the pallet lock potentiometer".

In case of b), readjust in accordance with "11-3-4
Adjustment of the pallet ldetector".
11-4-4. Check of the cylinder detector

Do
1. Lift down under the prestop height.

NOTE  Normal : Lock status ⇒ Lock release motion ⇒

⇒ Lock release status
 Abnormal : Lock status ⇒ Lock release motion
Lock motion ⇒ Lock status
3. In case of abnormal condition, readjust in accordance

with "11-3-3 Adjustment of the cylinder detector".
CAUTION Do not touch the pallet lock equipment while

the lock bar is moving.
155
AUTO PALLET LOCK 11
11-5-1. Auto pallet lock - troubleshooting
1. No good adjusting of rod Adjust
1 Pallet cannot be Replace
2. Detecting error
locked. Adjust
3. No good power cylinder Replace
l
Pallet lock cannot Replace
ria
2 1. Detecting error
be released. Check
.c T
NOTE  In case that error is detected once, even if the condition is
recovered , the error number can not be cleared unless the
F
om
key switch is turned off.
 Pallet lock condition will be released by pulling the fork from
z D
the pallet or turning on the lock mode switch to Release
position after lifting down under the prestop height.
P
ard
w.p m
i
dfw
ww o
cuC
Do
156
12. SERVICE DATA
12- 1. Standard work hours
1. Work is shown "replacement, removal or installation"
(R/R/I), "adjustment" or "check".
In case of calculating work hours, add the job
incidental on the main job to the main job.
l
"For example, in case that side cover should be
ria
removed at first, 0.1 hours should be added as
incidental work."
.c T
2. Unit of work hours
"The work hours are based on decimal system."
"(0.1 hour as minimum, and less than 0.1 hour shall be
F
om
raise to unit (0.1))"
"For example, 0.5=30 minutes, 1.0=1 hour"
z D
3. Combined jobs (In case that there are some main
P
ard
jobs)
For combined jobs select necessary job items and
w.p m
sum them up.

i
dfw
4. The set up time is not included the work hours.

ww o
cuC
Do
157
SERVICE DATA 12
Rate (hour)
Group Work Job
RB10 RB15 RBC7/9/10
Drive gear oil 0.4 0.4 0.4
Hydraulic oil, oil filter 0.8 0.8 0.8
Replace
Hydraulic oil, oil filter (resin) 0.7 0.7 0.7
Maintenance
Hydraulic oil 0.4 0.4 0.4
Lubricant 0.3 0.3 0.3
R/R/I
Battery electrolyte 0.2 0.2 0.2
Cover, top 0.1 0.1 0.1
Hinge, top cover 0.1 0.1 0.1
Cover, body 0.1 0.1 -
l
Cover(2),(3), side - -
ria
Bracket, controller 0.5 0.5 0.5
Bracket, plug - -
Frame R/R/I
Bracket, transformer - - 0.5
.c T
Cover Comp., battery 0.3 0.3 -
roller base or battery base Comp. 0.3 0.3 -
Roller or bearing (2 pieces)
F
*Add 0.1 Hrs every time 2 pieces are added. 0.7 0.7 -
om
Potentiometer R/R/I
z Dangle potentiometer
Drive ass'y (with traction motor)

0.3
2.0
0.3
2.0
0.3
2.0
R/R/I
P
Traction motor 0.5 0.5 0.5
ard
Oil leakage from Drive gear case and 0.02 0.02 0.02
Drive ass'y Check
unusual noise
w.p m
Unusual noise, oil level, fouling,

Check
oil leakage, and fitting bolt looseness 0.1 0.1 0.1
i
Drive ass'y (with traction motor) 3.5 3.0 3.0
dfw
Drive support R/R/I

ww o
Drive support (EPS) 1.7 1.5 1.5

Shaft, drive wheel 1.5 1.5 1.5
Wheel shaft R/R/I
cuC
Oil seal 0.5 0.5 0.5

Drive ass'y (with traction motor) 3.5 3.0 3.0
Drive support (EPS) 1.7 1.7 1.7
Steering gear R/R/I
Steering gear 1.3 1.3 1.3
Bearing, oil seal 0.7 0.7 0.7
Coupling R/R/I Coupling 1.7 1.7 1.7
Drive wheel comp. 0.4 0.4 0.4
Do
R/R/I Wheel hub or wheel 0.7 0.7 0.7

Drive unit
Wheel hub (1 piece) 0.1 0.1 0.1
Check Hub bolt/nut damage and looseness 0.1 0.1 0.1
Load wheel (1 piece) 0.3 0.3 0.3
Load wheel R/R/I
Wheel hub or wheel 0.7 0.7 0.7
Drive wheel, load wheel Check Crack, damage and wear 0.2 0.2 0.2
Lead pipe
Lubrication piping R/R/I
*Add 0.2 Hrs every time 1 pieces are added. 0.4 0.4 0.4
Control panel(1)(2)(3) 0.5 0.5 0.5
Bracket, control 0.7 0.7 0.7
Steering ass'y 0.7 0.7 0.7
Steering R/R/I Steering shaft 0.7 0.7 0.7
Steering wheel replacement 0.5 0.5 0.5
Torque sensor ass'y 0.3 0.3 0.3
Measuring Potentiometer voltage 0.5 0.5 0.5
158
12 SERVICE DATA
Rate (hour)
Group Work Job
RB10 RB15 RBC7/9/10
Steering handle play
Check Knob damage 0.2 0.2 0.2
Steering
Looseness in mounting area, jolt
Check Fitting bolt looseness and dropped off 0.1 0.1 0.1
Brake spring 0.2 0.2 0.2
R/R/I Bracket, brake 0.4 0.4 0.4
Pad 0.4 0.4 0.4
Adjustment Brake 0.2 0.2 0.2
Brake system
Brake release, lock condition
l
Timing of switch
ria
Check 0.1 0.1 0.1
Pad trailing, thickness
Damage, wear and fitting bolt looseness
Pedal pad 0.1 0.1 0.1
R/R/I Spring(Pedal) 0.2 0.2 0.2
.c T
Microswitch (Pedal) 0.2 0.2 0.2
Brake linkage
Damege, looseness and jolt 0.02 0.02 0.02
Check Pedal play, clearance and
F
om
brake responsetime 0.03 0.03 0.03
z DReturn filter 0.4 0.4 0.4
Saction filter 0.7 0.7 0.7
R/R/I Level gauge 0.2 0.2 0.2
P
Oil tank Resinous oil tank 0.4 0.5
ard
Oil tank 0.5 0.6 0.6
Oil level and fouling, if there is any moisture 0.3 0.3 0.3
Check
w.p m
Filter fouling, clogging, and damage 1.0 1.0 1.0

Hydraulic motor ass'y (with pump) 1.0 1.0 1.0
i
Hydraulic pump ass'y 0.6 0.6 0.6
dfw
R/R/I
ww o
Coupling 0.2 0.2 0.2

Hydraulic pump
Seal kit 1.2 1.2 1.2
cuC
Oil leakage, unusual vibration, and

Check 0.02 0.02 0.02
unusual noise
L.P.hose(between hydraulic tank and pump) 0.6 0.6 0.6
H.P.hose(between pump and control valve) 0.7 0.7 0.7
Frame piping R/R/I
Pipe Comp., return(between pump and
control valve)
Do
Controlvalve 0.7 0.7 0.7

Wiper, O ring (Blunger section 1 piece) 0.6 0.6 0.6
Spring, spring sheet (Blunger 1 piece) 0.6 0.6 0.6
R/R/I Relief valve 0.4 0.4 0.4
L.P.hose(between control valve and
Control valve
hydraulic tank) 0.9 0.9 0.9
Transmitter, plessure(1 piece) 0.5 0.5 0.5
Adjustment Solenoid current 0.3 0.3 0.3
Actuation, oil leakage, and fitting bolt
Check
looseness 0.02 0.02 0.02
Lift cylinder ass'y (1 piece) 0.8 0.8 0.8
Lift cylinder and Lift cylinder ass'y (2 piece) 1.2 1.2 1.2
R/R/I
piping (P mast) H.P. hose (1 piece) 0.3 0.3 0.3
Fuse valve 0.3 0.3 0.3
159
SERVICE DATA 12
Rate (hour)
Group Work Job
RB10 RB15 RBC7/9/10
Check Oil leakage,deformation, damage,looseness 0.1 0.1 0.1
Scratch, aging,twisting, oil leakage,
mounting condition, and bolt/nut looseness 0.1 0.1 0.1
Lift cylinder and
Operation, bending, dent, crack, fitting bolt
piping (P mast) Check
looseness 0.1 0.1 0.1
Drift of lowering (mm/10min) 0.2 0.2 0.2
Drift of tilt (mm/5min)
Lift cylinder ass'y(1st) (1 piece) 1 1 1
Lift cylinder ass'y (2nd)(1 piece) 0.6 0.6 0.6
l
Lift cylinder ass'y (2nd)(2 piece) 0.9 0.9 0.9
ria
H.P. hose (1 piece) 0.3 0.3 0.3
R/R/I
L.P. hose (1 piece) 0.3 0.3 0.3
Pipe Comp.(with hose guide) 0.4 0.4 0.4
.c T
Flow control valve 0.2 0.2 0.2
Lift cylinder and
Fuse valve 0.2 0.2 0.2
piping (M mast)
Check Oil leakage,deformation, damage,looseness 0.1 0.1 0.1
F
Operation, dent,crack,deflection,
om
scrach,fitting bolt looseness 0.1 0.1 0.1
Check
z D
Crack,damage,aging,twisting,oil leakage,
mounting condition, and bolt/nut looseness 0.1 0.1 0.1
Drift of lowering ( mm/10min) 0.3 0.3 0.3
P
ard
Drift of tilt ( mm/5min) 0.2 0.2 0.2
Mast ass'y 0.8 0.8 0.8
Table Comp. , lift 0.5 0.5 0.5
w.p m
Mast roller (2 piece) 0.3 0.3 0.3

Back shoe(2 piece) 0.6 0.6 0.6
i
dfw
Chain suport Comp. 0.2 0.2 0.2

ww o
Hose Pulley (1 piece) 0.2 0.2 0.2

Chain wheel (1 piece) 0.5 0.5 0.5
cuC
R/R/I
Lift chain (1 piece)(with anchor bolt) 0.6 0.6 0.6
Roller (lift table upside) 0.6 0.6 0.6
Roller (lift table downside) 0.6 0.6 0.6
Sided roller (lift table) 0.3 0.3 0.3
Fork (2 pieces) 0.3 0.3 0.3
Mast(P mast)
Do
Fork shaft 0.1 0.1 0.1
Lift table jolt, welding area crack 0.02 0.02 0.02

Chain tension, extension, crack,
Check deformation, damage, and wear, 0.1 0.1 0.1
Chain wheel deformation,damage,and jolt
Fork deformation, wear, and crack 0.03 0.03 0.03
Bracket deformation, crack, damage, 0.2 0.2 0.2

Check roller wear, jolt and jolt, pin area crack
Locking pin deformation, wear, and crack 0.1 0.1 0.1
160
12 SERVICE DATA
Rate (hour)
Group Work Job
RB10 RB15 RBC7/9/10
Mast ass'y 0.8 0.8 0.8
Table Comp. , lift 0.4 0.4 0.4
Roller(mast) (2 piece) 1.2 1.2 1.2
Back shoe (Right and left between inner
and middle masts) 0.5 0.5 0.5
R/R/I
Back shoe (Right and left between
middle and outer masts) 1 1 1
2nd cylinder rod head 0.2 0.2 0.2
Lift roller(2 piece) 0.6 0.6 0.6
l
Sided roller (2 piece) 0.6 0.6 0.6
ria
Lift chain (1st cylinder)(1 piece) 0.4 0.4 0.4
Lift chain (2nd cylinder)(1 piece) 0.7 0.7 0.7
Chain suport (1st cylinder) 0.6 0.6 0.6
.c T
Chain suport (1st cylinder)(2 piece) 0.2 0.2 0.2
R/R/I Hose pulley (1st cylinder) 0.2 0.2 0.2
Mast(M mast)
Chain wheel (middle masr) 0.6 0.6 0.6
Hose pulley
F 0.3 0.3 0.3
om
Fork (2 pieces)
z D 0.3 0.3 0.3
Fork shaft 0.3 0.3 0.3
Lift table jolt, welding area crack 0.02 0.02 0.02
Chain tension, extension, crack,
P
ard
Check deformation, damage, and wear, 0.1 0.1 0.1
Chain wheel deformation,damage,and jolt
Fork deformation, wear, and crack 0.03 0.03 0.03
w.p m
Bracket deformation, crack, damage,

roller wear, jolt and jolt, pin area crack 0.2 0.2 0.2
i
dfw
Locking pin deformation, wear, and crack

ww o
Check
Fork tip opening and leveling
Bottom area, upper hock area and under 0.1 0.1 0.1
cuC
hock area crack wear

Net, guard 0.2 0.2 0.2
Guard Comp., side 0.3 0.3 0.3
Guard, center
Cover, table
Bracket, steering(1),(2) 0.2 0.2 0.2
Do
R/R/I Post, steering

Lift table ass'y Cover, steering post
Plate, floor 0.1 0.1 0.1
Mat, floor 0.1 0.1 0.1
Safety belt 0.1 0.1 0.1
Microswitch 0.2 0.2 0.2
Check Safety belt damage 0.02 0.02 0.02
Check Bolt looseness. fitting bolt looseness
161
SERVICE DATA 12
Rate (hour)
Group Work Job
RB10 RB15 RBC7/9/10
Base, lock 0.5 0.5 0.5
Arm, lock(1),(2) 0.5 0.5 0.5
Bar, lock(1),(2) 0.2 0.2 0.2
Rod(1),(2) 0.2 0.2 0.2
Spring 0.4 0.4 0.4
R/R/I
Pin, shaft, bushing,spacer
Auto pallet lock
Cylinder Comp., power 0.5 0.5 0.5
Heater Comp.
Sensor Comp., magnetic 0.5 0.5 0.5
l
ria
Potentiometer 0.5 0.5 0.5
Check Auto pallet lock operation 0.1 0.1 0.1
Check Bolt looseness, fitting bolt looseness 0.2 0.2 0.2
Traction motor ass'y (with drive unit)
.c T
Bearing, sensor 0.3 0.3 0.3
Cover, end 0.3 0.3 0.3
R/R/I
Bearing (2 pieces) 0.5 0.5 0.5
F
om
Seal, oil 0.2 0.2 0.2
Traction motor
Stator comp.
z D 0.5 0.5 0.5
Bolt looseness, fitting bolt looseness 0.2 0.2 0.2
Motor rotation condition (low speed, inter
Check
mediate speed, high speed, acceleration),
P
ard
unusual noise,unusual smell
Hydraulic motor ass'y (with pump) 1.0 1.0 1.0
Bearing, sensor 0.3 0.3 0.3
w.p m
Cover, end 0.3 0.3 0.3

R/R/I
i
dfw
Seal, oil 0.2 0.2 0.2

ww o
Hydraulic motor Stator comp. 0.5 0.5 0.5

Bolt looseness, fitting bolt looseness 0.2 0.2 0.2
cuC
Motor rotation condition

Check (low speed, inter mediate speed, high
speed, acceleration),
unusual noise,unusual smell
EPS motor ass'y 0.3 0.2 0.2
Armature ass'y 0.8 0.7 0.7
Do
R/R/I
Electric power steering
Carbon brush (all) 0.6 0.5 0.5
(EPS) motor
EPS motor unusual noise,unusual smell 0.02 0.02 0.02
Check
EPS motor brush wear 0.03 0.03 0.03
Check Brush wear, contacy, commutator burnout 0.2 0.2 0.2
0.8 0.8 0.8
Control unit ass'y
0.3 0.3 0.3
Main contactor
FET module
Control unit R/R/I 0.7 0.7 0.7
*Add 0.2 Hrs every time 1 pieces are added.
Sensor comp., current (1 piece)
0.6 0.6 0.6
*Add 0.3 Hrs every time 1 pieces are added.
162
12 SERVICE DATA
Rate (hour)
Group Work Job
RB10 RB15 RBC7/9/10
Condenser comp. (9pieces) 1.0 1.0 1.0
R/R/I
MPU board (travel/hydraulic) 0.2 0.2 0.2
Looseness and burnout in terminal area,
Check
fitting bolt looseness 0.1 0.1 0.1
Looseness in terminal contact area,
Check 0.03 0.03 0.03
looseness in wiring mounting area
Control unit [Over current limiter]
Motor maximum current value
(for travel A) (for hydraulic A)
Check
l
[Safety device] Contactor operation 0.2 0.2 0.2
ria
Wiring looseness, damage and
clamp condition
Bracket, Accelerator ass'y 0.3 0.3 0.3
Spring 0.3 0.3 0.3
.c T
R/R/I Handle or lever 0.3 0.3 0.3
rs
Accelerator ass'y Potentiometer
te ale
Lift switch ass'y
F
om
Accelerator ass'y operation condition 0.02 0.02 0.02
Check
bu e
Lift switch ass'y operation condition
z D
tri d D
Control panel ass'y 0.5 0.5 0.5
MPU board (display) 0.2 0.2 0.2
D ize P
Key switch 1 1 1
R/R/I
ard
Horn button ass'y 0.3 0.3 0.3
ot or
Control panel Switch 0.3 0.3 0.3

0.8 0.8 0.8
w.p m
LCD display unit

is
N uth
Turn signal lamp damage, operating

0.02 0.02 0.02
i
Check condition, and mounting condition
D rA
dfw
ww o
Instruments operation
R/R/I MPU board(EPS) 0.2 0.2 0.2
fo
cuC
Looseness in gear box mounting area

Electric power steering
o
Check Interference with chassis 0.02 0.02 0.02

y
nl
Right and left steering angle 0.02 0.02 0.02

Horn 0.3 0.3 0.3
O
Head light 0.1 0.1 0.1

Micro switch(ruck sensor)
R/R/I
Do
Micro switch(chain looseness detection)

Bearing sensor(lift height detection)
Sensor Comp.,magnetic(lift height detection)
Fuse fitting looseness, capacity adequacy
0.1 0.1 0.1
Warning device damage, operating condition
Others
and mounting condition
(elecrric parts)
Rear view mirror and reflecting mirror fouling,
damage and reflecting condition
Check Lightning system operation and mounting condition
Direction indicator operation and mounting
condition
Display board and instruments damage and
mounting condition
Operation, water infiltration
163
SERVICE DATA 12
Rate (hour)
Group Work Job
RB10 RB15 RBC7/9/10
Removing, installation and replacement of
0.2 0.2 0.2
battery
R/R/I
Battery(measuring specific gravity, replenishing
0.6 0.6 0.6
water and clean up)
Electrolyte level 0.1 0.1 0.1
Terminal looseness, damage, and wear
Battery
Terminal Container damage and electrolyte leakage
Check Temperature and specific gravity after charging
(Max. ,Min. )
l
Lp plug and cord damage and looseness
ria
Each elecric battery voltage
Check 0.1 0.1 0.1
(Max. ,Min. )
.c T
F
om
z D
P
ard
w.p m
i
dfw
ww o
cuC
Do
164
CONTENTS - TROUBLESHOOTING
1. Adjustment of SICOS-AC 1 2. Troubleshooting 39

1-1. Explanation of the SICOS-AC ....................... 1 2-1. Self diagnosis function ................................ 39
1-1-1. Basic control board construction 1 2-1-1. Display 39
1-1-2. Travel/ Hydraulic board 2 2-1-2. Error messages and Display conditions 41
l
1-1-3. Display board 2 2-2. Error history memory ................................... 43
ria
1-1-4. Board comp., EPS 3 2-2-1. Error history memory 1 43
1-1-5. Rotary switch on the display board 4 2-2-2. Error history memory 2 44
1-1-6. Adjustment Standards List for RB-70 series 5 2-2-3. Clearing the error history memory
1-1-7. Confirmation of other services 6 (memory initialization) 46
.c T
1-2. SICOS-AC check and adjustment ................. 8 2-3. I/O Check .................................................... 47
1-2-1. Chassis insulation check 8 2-3-1. I/O check mode display method 47
1-2-2. Model setting check and adjustment 8 2-3-2. I/O port table 49
1-2-3. Current detector check 10
F
om
1-2-4. Safety monitor symbol check and adjustment14
z D
1-2-5. Switch back (plugging/ regenerative) 3. Wiring (Diagrams) 51
braking force adjustment 15
1-2-6. Regenerative braking force check and adjustment16 3-1. RB/RBC-70 System wiring ......................... 51
P
1-2-7. Hydraulic setting check and adjustment 17 3-2. RB/RBC-70 Body wiring ............................. 52
ard
1-2-8. Optional setting check and adjustment 18 3-2-1. RB10/15-70 52
1-2-9. Adjustment of the accelerator potentiometer 19 3-2-2. RBC7/9/10-70 53
w.p m
1-2-10. Prestop/travel reduction/lift stopping height check 3-3. RB/RBC-70 Body harness ......................... 54
and adjustment (Only for rquiring) 20 3-3-1. RB10/15-70 54
i
1-2-11. Load sensor check and adjustment 21 3-3-2. RBC7/9/10-70 55
dfw
ww o
1-2-12. Adjustment of the steering wheel 3-4. RB/RBC-70 Controller wiring ..................... 56
potentiometer 3-5. RB/RBC-70 Controller harness .................. 57
cuC
30 3-6. RB/RBC-70 Control panel wiring ................ 58

1-2-13. Adjustment of the steering angle 3-7. RB/RBC-70 Control panel harness ............ 59
potentiometer 3-8. RB/RBC-70 Accelerator wiring ................... 60
31
3-9. RB/RBC-70 Table harness ......................... 61
1-2-14. Safety device working check 33
3-10. RB/RBC-70 Mast harness ........................ 62
1-2-15. Hour meter working check 35
3-10-1. Harness, mast : P mast 62
Do
1-2-16. Turn signal lamp working check 35

3-10-2. Harness, mast : M mast 63
1-2-17. Cooling fan working check 36
3-10-3. Harness, mast (3) : P mast 64
1-2-18. Turning speed reduction (optional or especial
3-10-4. Harness, mast (4) : M mast 65
model) adjustment and working check 36
3-10-5. Harness, mast (n) : Std 66
1-2-19. Checking the function of auto power off 36
3-10-6. Harness, mast (n) : ACS/RP 67
1-2-20. Built-in charger working check 37
3-11. RB/RBC-70 BC wiring .............................. 68
3-11-1. RB10/15-70 : 3 phase, 200V 68
3-11-2. RBC7/9/10-70 : 3 phase, 200V 69
3-12. RB/RBC-70 BC harness ........................... 70
3-12-1. RB10/15-70 : 3 phase, 200V 70
3-12-2. RBC7/9/10-70 : 3 phase, 200V 71
1. Adjustment of the SICOS-AC
1- 1. Explanation of the SICOS-AC
1-1-1. Basic control board construction
As shown in the figure below, the SICOS-AC uses the
display board as the central point for connecting all other
boards for the exchange of data. In addition, all control
boards use a one-chip CPU (with flash ROM) as their
l
ria
main CPUs, so their ROM can not be removed.
Travel/Hydraulic board (MPU board)
.c T
Switch
Display unit
board
F
CPU for travel motor
om
Display board
z D
CPU for hydraulic motor
P
ard
w.p m
EPS/charger
i
control board
dfw
ww o
415T123E
cuC
Do
1
1 Adjustment of SICOS-AC
1-1-2. Travel/ Hydraulic board

<Type : PB105-XXX>
 This board controls the traction motor and the hydraulic motor.
(P7)7V power supply

(P15)15V power supply
Travel CPU drive
Hydraulic CPU drive
connector for Personal computer
CN5 CN6
l
ria
PB105-XXX
HYD
TRV
P15
P7
Travel CPU
Hydraulic CPU
.c T
F
om
CN1 CN2 CN3 CN4
z D
P
415T073E
Body harness
ard
w.p m
i
1-1-3. Display board
dfw
ww o
<Type : PB104-XXX>
cuC
 This board controls sharing the data with other boards

and the screen display.
(P7)7V power supply
CPU drive
Do
Buzzer [RS1] :Rotary switch for monitor selection
PB104-XXX
F 0 12
B C DE
34 56
7 8 9A
Connector for
Personal computer
CPU
CN1 CN2
Body harness 415T074E
2
Adjustment of SICOS-AC 1
1-1-4. Board comp., EPS

<Type : PBC106-XXX>
 This board controls sharing the data with other boards,
and EPS motor.
Body harness
AA MP
l
ria
Terminal Color of wire
(ADJ1) (ADJ2)
Harness
(to EPS motor)
A white
(ADJ1) (ADJ2)
Electrolytic
.c T
capacitor AA black
MP red
F K1 blue
om
A K1 CPU 415T146E
NOTE
z D
 ADJ2 lights only when applying 48.0V(24.0V)
between CN1-1 AND CN1-13.
P
ard
 ADJ1 lights only when applying 58.0V(28.8V)
between CN1-14 and CN1-13.
w.p m
i
Normal condition while turning on the key switch
dfw
ww o
LED Travel/Hydraulic board Display board

cuC
P7 lighting lighting
P15 lighting
TRV blinking
HYD blinking
CPU blinking
Do
CAUTION  When the MPU board or Display board

are replaced, specification such as model
setting and option setting has changed. After
replacement of the board, adjust the settings
in accordance with this manual.
 In case of changing the settings for the rotary
switches, be sure to turn off the key switch
once before changing them.
3
1-1-5. Rotary switch on the Display board

The rotary switch (RS1) on the display board is used for selecting the displays and
adjustments shown in the table below.
 RS1 setting functions
RS1 Functions Remarks
MONITORING OK After turning on the key switch, this message is displayed.

Meters (Battery discharge, Speed, Hour, Error,
Normal screen
Clock)
l
Hour meter check Total, travel and hydraulic hour meters appear.
ria
Date and time setting Set the time.
0
Power mode setting Select ECONOMY, NORMAL or POWER
Hour meter,odometer,hieght,clock Select the hour meter, odometer, height or clock
.c T
Display brightness setting BRIGHTNESS (0-7 intensity of back light)
Adjustment of regenerative brake
Select NON, LOW, MID or HIGH
when accelerator is released
F
om
1 Monitor symbol setting
z D STEER, LOAD, TRV, HYD
2 Model setting RB / RBC MAST type
Plugging strength setting 0 - 32
3
P
Braking strength setting 0 - 32
ard
Set the hydraulic speed correspond to travel speed
4 Hydraulic speed setting
(0 - 32)
w.p m
5
6 Option setting Set the options.
i
dfw
ww o
7 Voltage, current and temperature check

8 RAM and I/O memory data check
cuC
Error history memory 1 Displays the details of the 9 latest cases

9
Error history memory 2 Records all past errors
A Auto pallet lock adjustment Set the auto pallet lock
B Turning speed reduction 0 - 15
Set prestop, lift stop position, travel reduction or
Do
C Height setting
stop
D Load metor setting Calibration of load
E Memory initial Clear the error history
F Normal screen 2 No errors are displayed on the screen of RS0
4
[Confirmation]
voltage Model 4 3 1
SPD-L SPD-M SPD-H PLUGG BRAKE
TRAVEL
Do
HYD STEER LOAD Travel speed Lift speed
LIFT LIFT LIFT ING TRQ
RBC7 32 26 20 32 32 ○ ○ ○ × 9.0/8.5 330/240
Travel speed（P mode）
24V RBC9 ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ 9.0/8.0 330/220
　unladen / laden
RBC10 ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ 9.0/8.0 330/220 Hydraulic speed（P mode)
RB10 ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ 9.0/8.0 330/220 　unladen / laden　
48V
cuC
RB15 ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ 8.0/7.5 320/200
ww o
w.p m
dfw
i P
z D
Memory initial （Display RS1-E）
ard
Option setting （Display RS1-6）
F
Travel mode :NORMAL LIFT LOCK OFF
.c T
Lift lock at over discharge
Brightness :5 HOUR METER 1 Hour meter count
1-1-6. Adjustment Standards List for RB-70 series
Neutral regenerative brake :MID

om
meter mode :HR(hour meter)
Error history :Clear Symbol （Display RS1-1）
ria
*HOUR METER（Hour meter count）setting LOAD OFF Warning of over load
1：Key switch
2：Actual operation time (motor operation time)
l
5
1-1-7. Confirmation of other services
Display
<Confirmation>
After pushing button, button and button
together for more than 3 seconds, the following screen is
displayed.
l
 Model confirmation
ria
The model set by rotary switch
"2" on the display board is
.c T
displayed.
415T098
F
om
 Software number confirmation
z D The software program numbers
: T (travel)
P
H (hydraulic)
ard
E (EPS)
D (display)
w.p m
415T099
are displayed.
i
dfw
ww o
 Buzzer mode setting

Buzzer mode setting is highlighted.
cuC
 Set buzzer mode by pressing

" " or " " button (OFF/ ON).
ON : Normal
OFF: Turns off all the buzzer
152T036
sound except blinker sound

Do
 Rotary SW mode setting
 Rotary switch mode setting is

blinking.
 Set rotary switch mode by pressing
" " or " " button (OFF/ ON).
ON : Normal
OFF: The rotary switch is disabled
(Return to normal screen)
and the setting number of
rotary switch is able to change
by mode select button.
6
CAUTION  When the connection is failure between

Display board, Travel/Hydraulic board and
EPS/charger board, software numbers are not
displayed.
 If buzzer mode is set to OFF at this time, all
the buzzer sound except blinker sound is
turned off.
 If rotary SW mode is set to OFF, the rotary SW
is disabled on the board. You can change the
rotary SW setting by "keeping pressing down
l
ria
button for more than 3 seconds while
pressing button" or "keeping pressing
down button for more than 3 seconds
.c T
while pressing button".
F
om
z D
P
ard
w.p m
i
dfw
ww o
cuC
Do
7
1- 2. SICOS-AC check and adjustment

CAUTION  Even when the key switch is turned off each
board has battery voltage, be sure to pull out Display board
the battery plug before work. F01

 After finishing the setting, be sure to return
CDE
23
456
rotary switch RS1 to "0".
AB
789
 Before measuring current, change the mode
depending on the objects. Return RS1 to "0".
l
ria
Motor current AC mode
Battery current DC mode
.c T
F
om
1-2-1. Chassis insulation check z D
P
1. Disconnect the battery plug.
ard
2 Use a tester to measure the insulation resistance
between positive (+) terminal of the chassis battery
w.p m
plug and chassis, between negative (-) terminal of the

chassis battery plug and chassis.
i
dfw
ww o
Specification 1M or greater
cuC
1-2-2. Model setting check and adjustment

Do
CAUTION Ne ver mistake the model setting of RB

or RBC because the main device can be
destroyed by the voltage control.
Display board
F01
CDE
23
2 Turn on the key switch and the model confirmation

456
AB
screen is displayed. 789

3.Confirm that the model type is set correctly.
Set RS1 to "2".
8
<Adjusting procedure> Display board

F01
2. Turn on the key switch and the following screen
CDE
23
456
appears.
AB
789
3. Press either or button to set model "RB" or
"RBC". Set RS1 to "2".
4. Press button to move the blinking icon to the item of
load.
5.Press either or button to set the load.
6.Press button to move the blinking icon to the item of
l
front direction setting.
ria
7.Press either or button to set "DRV" or "FRK".
.c T
 Model confirmation (RB)
F
om
z D 415T029
P
ard
 Model confirmation (RBC)
w.p m
i
dfw
ww o
415T028
cuC
8. Press button and the following screen appears.

9.Press either or button to set "P"(P mast) or
"M" (M mast).
10.Press either or button to set the height of
mast.
Do
 Mast type setting
415T030
NOTE  After setting, be sure to set the key switch to

OFF/ON.
 When change model or mast type, the item of
height and overload are set to intial value.
 After changing type of model and mast, be
sure to set the item of height and overload.
9
1-2-3. Current detector check

Traction motor current check
<Measuring point>
IU: traction motor U phase electric current (V phase or
W phase is also possible.)
<Measuring conditions>
Specific gravity of the battery electrolyte : over 1.25 at 20
l
ria
<Measuring instrument>
Alternating current (AC) mode
CN1
.c T
RD 10A
RDGN
F 10A
om
RDBK 10A
z D <1>
325A 100A
<10>
VA
BKWH
P
Traction motor U phase NA <2> <11>
ard
Board comp., MPU
Analog clamp
w.p m
ammeter
U1 V1 W1 U2 V2 W2
<4> <5> <6> <7> <8> <9>

i
dfw
ww o
CN1 CN2 CN3 CN4

cuC
Harness,body Main contorller

415T076E
CAUTION When measuring AC motor current, use the

Do
recommended ammeter below:

Recommended ammeter :
Hioki 3109-01 (Analog)
Hioki 3209 AC/DC high tester (Digital)
CAUTION When measuring travel/hydraulic motor current

using Hioki 3209 AC/DC (Digital), you need to:
1. Use AC + DC mode
2. Use H mode (do not use AUTO range)
3. Use SLOW response
10
<Checking procedure> Display board

F01
CDE
23
456
appears and "T" blinks.
AB
789
Set RS1 to "7".

NOTE If "T" is not blinking, press or button to
make it blink.
l
 Voltage, current, and temperature checking screen.
.c T
ria
Display
415T124
Traction motor current.
F
om
3. Not rotate the accelerator grip, check if the traction
z D
motor current (MC) shows 000A.
P
4. Jack up the drive wheel and depress the brake pedal
ard
and rotate the accelerator grip.
w.p m
NOTE When measuring, be sure to jack up the drive

i
dfw
wheel.
ww o
cuC
6. At this condition, check if the traction motor current

(MC) shows a traction motor current (IU) meter value
within ±20A
Do
11
Hydraulic motor current check
<Measuring point>
IU: hydraulic motor U phase electric current (V phase or
W phase is also possible.)
Specific gravity of the battery electrolyte : over 1.25 at 20
<Measuring instrument>
l
ria
Alternating current (AC) mode
CN1
.c T
RD 10A
RDGN 10A
RDBK 10A
<1>
F
om
325A 100A
<10>
VA
Traction motor U phase

z D NA <2> <11>
BKWH
P
Board comp., MPU
ard
Analog clamp
ammeter
U1 V1 W1 U2 V2 W2
w.p m
<7> <8> <9>

<4> <5> <6>
i
CN1 CN2 CN3 CN4
dfw
ww o
Harness,body Main contorller

cuC
415T077E
CAUTION When measuring AC motor current, use the

recommended ammeter below:
Recommended ammeter :
Do
Hioki 3109-01 (Analog)

Hioki 3209 AC/DC high tester (Digital)
CAUTION When measuring travel/hydraulic motor current

using Hioki 3209 AC/DC (Digital), you need to:
1. Use AC + DC mode
2. Use H mode (do not use AUTO range)
3. Use SLOW response
12
Display board
1. Set rotary switch RS1 on the display board to "C",
set the lift stopping height higher than mast highest F01
CDE
23
height.
456
AB
789
CAUTION Set up the lift stopping height higher than mast
Set RS1 to "C".
highest height, otherwise, cannot get lift relief
condition by working the lift limit function.
Display board
l
2. Set rotary switch RS1 on the display board to "7",
F01
ria CDE
23
456
AB
789
.c T
Set RS1 to "7".
rs
te ale
appears and "T" blinks.
F
om
4. Press either or button to make "H" blink.
bu e
z D
tri d D
 Voltage, current, and temperature checking screen.
D ize P
ard
ot or
w.p m
is
N uth
Display Hydraulic motor current.

i
D rA
dfw
415T125
ww o fo
5. Not push the lift-up switch, check if the hydraulic motor

cuC
current (MC) shows 000A.

o
y
nl
6. Push the lift-up switch until lift relief condition (lift

O
stroke end).
Do
7. At this lift relief current, check if the hydraulic motor

current (MC) shows a hydraulic motor current (IU)
meter value within 20A.
Display board
Set rotary switch RS1 on the display board to "C", and
return lift stopping height to the former value. F01
CDE
23
456
AB
8.Set rotary switch RS1 on the display board to "C", and 789
return the setting of the lift stopping height.
Set RS1 to "C".
13
1-2-4. Safety monitor symbol check and

adjustment

F01
CDE
23
456
AB
789
appears.
3. Confirm that the parameter items are set to the same Set RS1 to "1".
l
ria
as the values on the "Adjustment Standards List" on
page 4.
 Monitoring symbol setting screen
.c T
F
om
z D TRAVEL
HYD
P
415T120
ard
w.p m
STEERING
i
OVER LOAD
dfw
ww o
415T121
cuC
<Adjusting procedure>
1. Press button to move the blinking icon to the each
Do
item.
2. Press button to turn the item "ON".
3. Press button to turn the item "OFF". Display board
4. Turn off the key switch and return rotary switch RS1
F01
on the display board to "0".
CDE
23
456
5. Turn on the key switch again.

AB
789
It indicates the symbols set to "ON" at the monitoring
symbol setting screen. Return RS1 to "0".
415T140
14
1-2-5. Switch back (plugging/ regenerative)

braking force adjustment
<Standard parameter>
 Refer to the Adjustment Standards List on page 4.
 Flat ground, unladen, and full speed
 Specific gravity of the battery electrolyte : 1.25 or over
l
ria
(at 20°C)

.c T
F01
CDE
23
456
AB
F
789
om
appears. z D Set RS1 to "3".
 Plugging strength / braking strength setting screen

P
ard
w.p m
i
415T034
dfw
Plugging strength setting (blinking)

ww o
cuC
3. Confirm that the "PLG" parameter is blinking.
NOTE If the PLG parameter is not blinking, press

button.
Do
4. Press button to increase the braking force.

5. Press button to decrease the braking force.
NOTE When the communication between display board

and travel/hydraulic is failure (Data line is down),
these parameter cannnot be set.
15
1-2-6. Regenerative braking force check

and adjustment
1. Select the "NON" at the regenerative brake setting.
2. Travel forward in a moderate speed and return the
accelerator grip to neutral position.
3. Release the brake pedal lightly.
l
4. Confirm that braking force (regenerative brake) is
ria
applied lightly.
.c T
Display board
F
om
F01
CDE
23
z D
456
AB
789
P
appears.
ard
Set RS1 to "3".
 Plugging / braking strength setting screen

w.p m
i
dfw
ww o
cuC
415T035
Setting of braking strength blinks.
3. Press button to move the blinking icon to the "BRK"

Do
parameter.
4. Press button to increase the braking force
(regenerative brake).
5. Press button to decrease the braking force
(regenerative brake).

and travel/hydraulic board is failure (Data line is
down), these parameter cannnot be set.
16
1-2-7. Hydraulic setting check and adjustment

1. Set rotary switch RS1 on the display board to "4". F01
CDE
23
456
AB
789
appears.
3. Confirm that the parameter items are set to the same Set RS1 to "4".
as the values on the "Adjustment Standards List" on
l
page 4.
ria
 Hydraulic speed setting screen
.c T
Setting of hydraulic speed limit (when
traveling speed 0-3km/h) blinks.
 Set by pushing or button (0-32).
F
om
z D 415T036
P
ard
w.p m
traveling speed 3-6km/h) blinks.

415T037
i
dfw
ww o
cuC

traveling speed over 6km/h) blinks.
415T038
Do

parameter.
2. Press button to increase the parameter.
3. Press button to decrease the parameter.

and travel/hydraulic board is failure (Data line is
down), these parameter cannnot be set.
17
1-2-8. Optional setting check and adjustment

F01
CDE
23
456
AB
789
appears.
3. Confirm that the options are set correctly. Set RS1 to "6".
l
 Optional setting screen
ria
variable ON/OFF(blinking)
.c T
F
om
M
415T039
z D
P
ard
w.p m
415T040
i
dfw
ww o
Standard
Optional setting mode Remarks
setting
cuC
ON : Lift locks when only one red segment

LIFT LOCK Lift interrupt OFF
is left on battery discharge indicator.
1 : Key switch ON
METER Hour meter count 1 2 : Actual operation time
(motor operation time)
Do
item.
2. Press button to select the item "ON" or "2".
2. Press button to select the item "OFF" or "1".
18
1-2-9. Adjustment of the accelerator potentiometer

F01
CDE
23
456
AB
789
appears.
Set RS1 to "8".
 Data address setting
l
.c T
ria
415T041
F
om
3. Press , or button to select "I/O", "T", and
"W0028". z D
(Refer to "2-3. I/O check" on page 49 for setting.)
4.Confirm that the applicable "I/O data" is as follows at
P
the neutral position of accelerator grip.
ard
w.p m
 I/O Data
i
dfw
ww o
I/O data
cuC
01EC
415T042
0214
Do
<Adjustment procedure> Tester

1. Disconnect the 4P plug and insert the adaptor for Accelerator
potentiometer
measuring the voltage by tester.
2.Turn on the key switch to apply 5V power supply to the
WH
RD
BU
BK
potentiometer.
Tester
3. Measure the output voltage between White/Yeliow pole (+)
[WHYE] line and Black/Yellow[BKYE] line by the tester.
4.Adjust the potentiometer by loosing the screw so that 4P
the output voltage is 2.5±0.1V at the neutral position of Tester pole (-)
WHYE
RDYE
BUYE
BKYE
accelerator grip.
415W084E
19
1-2-10. Pre-stop / travel reduction / lift stopping height

check and adjustment (only for requiring)
1. Set rotary switch RS1 on the display board to "C".
F01
2.Turn on the key switch and the following screen
CDE
23
456
appears.
AB
789
3. Press button to display the setting screen.
4.Set the height by lifting up or down. Set RS1 to "C".
l
5.Press button to set. The parameter is displayed on
ria
the upper row then setting finishes.
 Prestop height 1(low) setting screen The parameter blinks.
.c T
 Set the height by lifting up or down
 Set by pushing button to set.
The parameter is displayed on the upper
row then setting finishes.
F
om
z D
 Travel reduction height setting screen
415T046
The parameter blinks.

P
ard
w.p m
415T047
 Travel stop height setting screen

i
dfw
ww o

cuC

415T048
 Prestop height 2(high) setting screen

Do

415T049
 Lift up stop height 1 setting screen The parameter blinks.

415T050
 Lift up stop height 2 setting screen The parameter blinks.

. The parameter is displayed on the upper
20
415T051
1-2-11. Load sensor check and adjustment
Sensor AD setting in unladen

condition (1st stage)
1. Set rotary switch RS1 on the display board to "D".
F01
CDE
23
456
appears.
AB
789
l
3.Lift up about 50cm in unladen condition and sensor AD
ria
blinks. Set RS1 to "D".
 Sensor AD in unladen setting screen
.c T
F
om
z D
Sensor AD(blinking)
415T001
P
4.Wait for about 5 seconds until sensor AD stops blinking.
ard
5. Confirm that "<" is blinking.
w.p m
i
dfw
ww o
cuC
415T002
(blinking) Sensor AD(highlight)
⑥ Press button to set. The parameter is displayed on

Do
memory(highlight)
415T003
(highlight) Sensor AD(highlight)
NOTE Cannot press button while sensor AD is

blinking.
21
Sensor AD setting in unladen

condition (2nd stage) (M mast)
Display board
1. Set rotary switch RS1 on the display board to "D". F01
CDE
23
2. Turn on the key switch and press button , and the
456
AB
following screen appears.
789
3.Lift up until 2nd stage in unladen condition and sensor

Set RS1 to "D".
AD blinks.
l
ria
 Sensor AD in unladen setting screen
.c T
F
om
415T004
Sensor AD(blinking)
z D
P
ard
w.p m
i
dfw
ww o
415T005
cuC

memory(highlight)
Do
415T006

blinking.
22
Sensor AD setting in laden condition

(1st stage)
Display board
1. Set rotary switch RS1 on the display board to "D". F01
CDE
23
2. Turn on the key switch and press button twice and
456
AB
the following screen appears.
789
3.Press or button to set the load parameter (in

Set RS1 to "D".
the10Kg unit). Press button to move the blinking
l
icon to next digit.
ria
 Sensor AD in laden setting screen
load setting in laden condition
.c T
F
om
z D 415T007
P
ard
w.p m
415T008
i
dfw
ww o
cuC
415T009
NOTE It is possible to set load parameter in the 10 Kg

unit.
Do
4.Lift up about 50cm in laden condition at 1st stage and

sensor AD blinks.
415T010
Sensor AD (blinking)
23

415T011
l
ria
memory(highlight)
.c T
F
om
415T012

z D
P
ard
blinking.
w.p m
i
dfw
ww o
cuC
Do
24
Over load warning setting

1. Set rotary switch RS1 on the display board to "D".
F01
2. Turn on the key switch and press button 3 times
CDE
23
456
and the following screen appears.
AB
789
3.Press or button to set the over load parameter
(in the 1Kg unit). After setting the last digit, press Set RS1 to "D".
button to finish.
l
ria
 Over load setting screen
.c T
415T013
F
om
z D
P
415T014
ard
w.p m
i
dfw
ww o
415T015
cuC
415T016
Display board
NOTE It is possible to set load parameter in the 1 Kg
Do
F01
unit.
CDE
23
456
AB
4. Turn off the key switch and return rotary switch RS1 on 789
the display board to "0".
Set RS1 to "0".
6. Turn on the key switch and press button and the
Display board
7.Set the overload to "ON".. F01
CDE
23
456
 Monitor symbol setting screen

AB
789
Set RS1 to "1".
Set the overload to "ON".

415T017
25
NOTE  Overload is displayed as following " the fixed

load > overload warning value"
 The fixed load includes "table + operator + inner
mast and so on (at 2nd stage of M mast)".
 When set rotary switch RS1 on the display
board to "2" to set model type, overload warning
value is set automatically to the maximum load
of the selected model type. (It is different from
FBT-70(110% of maximum load).
l
.c T
ria
 Model type confirmation screen (RB)
Display board
F01
F
om CDE
23
456
AB
z D 415T029
789
Set RS1 to "2".

P
Model type
ard
<Inspection procedure>
w.p m
 In the load screen, confirm the displayed load with

loading the weight which is found the value in
i
dfw
advance.
ww o
(Refer to "Load sensor" on next page.)

cuC
<Standard inspection>
 The displayed load is within ± 5 % of the actual load.
Do
26
Load sensor
<Confirmation procedure>
1. Set rotary switch RS1 on the display board to "0". Display board
2. When travel/hydraulic operation is stopped, the
F01
CDE
23
456
AB
 Load display screen 789
Set RS1 to "0".
l
ria
415T020
3. Wait for about 5 seconds until the load parameter stops

blinking.
.c T
F
om
z D
load(blinking)
4. Confirm the fixed load parameter.
415T021
P
ard
w.p m
415T022
load(lighting)
i
dfw
ww o
NOTE Load parameter keeps on changing until the blinking stops.The fixed load
cuC
after blinking stops can change only when it corresponds to the following
condition.
 When the difference of the fixed load and the current load becomes to be
within ± 50 Kg.
 When the difference of load for 100ms at last time and for 100 ms at this
Do
time is more than ± 4 kg.
NOTE  The minus value of load is also displayed.(to a minimum of - 50 Kg.)

 The load parameter will be displayed rather lightly after lifting down and
rather heavily after lifting up.
 The load parameter does not change even though the operator gets on and
off.
 The fixed load changes every time even though the same load is loaded.
 The load parameter is not displayed when memory value is not set.
415T023
non parameter condition 27

Zero adjustment of load sensor

(Net weight)
2. Turn on key switch and the following screen appears.
3. Stop travel/hydraulic operation.
Display board
4. Wait for about 5 seconds until the load parameter
stops blinking. F01
CDE
23
 Load display screen
l AB
456
ria
789
Set RS1 to "0".
.c T rs
415T024
te ale
load(blinking)
F
om
5.Press button after the blinking is stopped.
bu e
z D
tri d D
symbol of the net weight
D ize P
ard
ot or
w.p m
is
N uth
i
D rA
dfw
415T025
ww o
Zero adjustment (blinking)

fo
cuC
o
y
NOTE
nl
 Net weight is excluded "Table + operator + inner

O
mast and so on (at 2nd stage of M mast).

 Net weight setting cannot be set or canceled
until the load parameter stops blinking.
Do
 If the weight is not set at the load sensor setting

(Set rotary switch RS1 on the display board to
"D".), the load parameter is not displayed.
28
Cancel of load sensor zero adjustment

<Cancel procedure>
3. Stop travel/hydraulic operation. Display board
4. Wait for about 5 seconds until the load parameter
stops blinking. F01
CDE
23
456
 Load display screen
AB
789
l
ria
symbol of the net weight
Set RS1 to "0".
.c T
415T025
F
om
Zero adjustment(blinking)
5.Press
z D
button when brinking stops and load display
is settled.
P
ard
w.p m
i
dfw
ww o
415T024
load(blinking)
cuC
NOTE The load parameter when the net weight setting is

canceled is not actual load but dummy .
Do
29
1-2-12. Adjustment of the steering wheel potentiometer

1. Set rotary switch RS1 on the display board to "8". Display board
F01
CDE
23
456
 Address setting screen
AB
789
Set RS1 to "8".
l
ria
415T061
3. Press , or button to select "I/O", "E" and to
.c T
set the data address "W001E".
F
om
Confirm that the applicable "I/O data" are as following
table. z D
P
ard
Steering position I/O data
01EC
w.p m
Neutral
0214
i
dfw
031D
ww o
Right side end

0373
cuC
0090
Left side end
00E6
Do
 I/O data
415T062E
30
<Adjustment procedure>
1. Disconnect the 4P plug and insert the adaptor for
measuring the voltage by tester.
Steering wheel
2. Turn on the key switch to apply 5V power supply to the Tester potentiometer
potentiometer.
3. M e a s u r e t h e o u t p u t v o l t a g e b e t w e e n W h i t e /
WH
RD
BU
BK
Red[WHRD] line and Black/Red[BKRD] line by the
tester. Tester 4P
pole (+)
4. Adjust the potentiometer by loosing the screw so that
the output voltage are as following table.
l WHRD
BKRD
ria
RD
Steering position output voltage Tester pole (-)
Neutral 2.5±0.1V 415T079E
Right side end 4.1±0.2V
.c T
Left side end 0.9±0.2V
F
om
1-2-13. Adjustment of the steering angle
z D
potentiometer
P
ard
Display board
F01
CDE
23
w.p m
456
AB
789
i
dfw
ww o
2. Turn on key switch and the following screen appears. Set RS1 to "8".
cuC
 Address setting screen

Do
415T063
3. Press , or button to select "I/O", "E" and to

set the data address "W001C".
4.Confirm that the applicable "I/O data" is as follows at
the neutral position.
(drive wheel direction is straight)
 I/O data DATA

01F0
0210
415T064E
31
<Adjustment procedure>
Tester
1.Disconnect the 3P plug and insert the adaptor for
steering angle
measuring the voltage by tester. potentiometer
2. Turn on the key switch to apply 5V power supply to the
potentiometer.
WH
WH
WH
3. M e a s u r e t h e o u t p u t v o l t a g e b e t w e e n Ye l l o w / Tester
pole (+) 3P
Blue[YEBU] line and Yellow/Black[YEBK] line by the [YEBU]
tester.
4.Adjust the potentiometer by loosing the bolt so that the
YERD
YEBK
YEBU
output voltage is 2.5±0.1V at the neutral position.(drive Tester pole (-)
l
[YEBK]
ria
wheel direction is straight)
321S227E
.c T
F
om
z D
P
ard
w.p m
Loosen the bolt

i
dfw
ww o
cuC
Do
32
1-2-14. Safety device working check

NOTE When model/mast type is not set, all operations don't work.
Safety guard working check

<Adjusting procedure >
1. Open the safety guard.
2.Operate travel or hydraulic.
l
3.Confirm neutral safety works and travel/hydraulic
ria
operation doesn't work.
4. Confirm the warning symbol is displayed on the screen.
 Warning screen
.c T
F
om
z D 415T065
Travel neutral safety working check

P
ard
1. Turn on the key switch with rotating the accelerator
w.p m
grip.
i
2.Confirm neutral safety works and travel doesn't work.
dfw
ww o

 Warning screen
cuC
Do
415T066
Hydraulic neutral safety working check

1. Turn on the key switch with pushing the lift switch.
2.Confirm neutral safety works and lift operation doesn't
work.
 Warning screen
415T067
33
Fork sensor working check(only for RBC)

1. Disconnect the connector of fork sensor.
2.Confirm lift down function and travel operation doesn't
work.
 Warning screen
l
ria
415T068
.c T
Slack of chain detector
F
om
1. Disconnect the connector of detection switch.
z D
2.Confirm slack of chain is detected and lift down function
and travel operation doesn't work.
P
ard
 Slack of chain warning screen (Table side)
w.p m
i
dfw
ww o
cuC
415T069
 Slack of chain warning screen (Mast side) *Only for M mast

Do
415T070
Ceiling detector (Option)

1. Turn on the ceiling detector.
2.Confirm lift up function doesn't work.
 Warning screen
415T071
34
1-2-15. Hour meter working check

1. Connect the connector terminal as following.
NOTE Connector terminal

Position : in the control panel
wire color: "Black/White" = "Bue/Black"
l
ria
Control panel
.c T
F
om
Blue/Black
z D 415T144 Black/White
415T145
2. Confirm that the hourglass symbol on the display blinks

P
when the key switch is turned on.
ard
w.p m
CAUTION After completing the check, be sure that the

connector terminal is left unplugged until the
i
dfw
ww o
forklift is delivered to the customer.

cuC
1-2-16. Turn signal lamp working check

Do
1. When the turn signal switch is turned on, confirm that

the turn signal lamp lights and a buzzer sounds at the
same time.
35
1-2-17. Cooling fan working check

1. Confirm that the cooling fan is working during travel or
hydraulic operation.
2. While travel and hydraulic operation are stopped,
confirm that the cooling fan is stopping when the
temperature inside the control unit is 35°C or lower,
and that it is working when the temperature inside the
control unit is 40°C or higher.
l
ria
1-2-18. Turning speed reduction (optional or especial
model) adjustment and working check
.c T
F
om
1. Set rotary switch RS1 on the display board to "B". Display board
2. Turn on the key switch and the turning speed reduction

z D F01
screen appears.
CDE
23
456
3.Press either or button to adjust the parameter
AB
P
789
(0 - 16Km/h).
ard
Set RS1 to "B".
 Press button to increase the parameter.
w.p m
 Press button to decrease the parameter.

i
dfw
ww o
1. Turn the steering wheel until right end or left end.

2. Travel with accelerating by slow degrees.
cuC
3.Confirm the speed limitation is applied.
1-2-19. Checking the function of auto power off

Do
1. Turn on the key switch.
2. Confirm that the main contactor is turned off by keeping
no operation for 15 minutes.
36
1-2-20. Built-in charger working check
End timer working check

<Checking procedure >
1. Leave the top cover open.
2.Connect the AC plug to the charge outlet on the body.
3. When push the AUTO button, charging starts.Confirm
the charge current flow to the battery.
l
ria
Total timer working check
.c T
F
om
1.Connect the AC plug to the charge outlet on the body
2.Press and hold the Auto Button for at least 3 seconds,
z D
and the mode change to the test mode. (At the same
time auto LED flashes at 1 second interval.)
P
3. Confirm charging stops about 90 seconds later and
ard
auto LED flashes at 0.5 second interval.
.
w.p m
<Total timer>
Magnetic Auto Equal
i
Checking procedure
dfw
contactor LED LED

ww o
1 Connect the battery plug. OFF

cuC
2 Connect the AC plug to charge plug. OFF

Press and hold the When pressed ON
3 Auto Button for at
least 3 seconds. 3 seconds later ON
When auto LED starts flashing, release the
4 ON
auto button
The check will end approximately 90 seconds
Do
5 OFF
after Auto LED begins flashing.
:On
:Off
:Blinking
Auto charge lamp
Auto charge button
Equal charge lamp
Equal charge button
415T082
37
Charge inter lock working check

<Checking procedure >
1. Leave the top cover close.
2.Connect the AC plug.(At this time All of LED on the
charge interlock switch are turned off.)
3. Confirm the charge current does not flow to the battery
even though auto button and equal button are pushed.
l
.c T
ria
F
om
z D
P
ard
w.p m
i
dfw
ww o
cuC
Do
38
2. Troubleshooting
2- 1. Self diagnosis function
2-1-1. Display
If abnormalities or errors are detected with the self-
diagnosis function, the following symbols and error
number will be displayed on the screen.
l
 The applicable abnormality and/or error symbol will
ria
blink on the display.
 The applicable error number will be displayed. (If
multiple abnormalities and/or errors are detected, the
.c T
applicable error numbers will be displayed in order.)
Travel system errors
F
om
z D The service (spanner) mark blinks.
The abnormality or error number blinks.

P
ard
w.p m
The travel symbol blinks.

152T081
i
dfw
ww o
Hydraulic (including AOS) system errors

cuC
The service (spanner) mark blinks.

Do
The hydraulic symbol blinks.

152T082
Steering (EPS) system errors

The steering symbol blinks.

152T083
39
2 Troubleshooting
Other errors
The other abnormality or error number

blinks.
152T084
Multiple abnormalities and/or errors
l
ria
The detected abnormality and/or error

numbers are displayed in the order they are
.c T
detected.
F
152T085
om
All of the symbols for the detected abnormalities
and/or errors blink.
z D
P
NOTE  If the following abnormalities and/or errors
ard
o c c u r, t r a v e l , h y d r a u l i c s a n d E P S a r e
interlocked.
w.p m
B11-B14: (FET U-W, CURRENT-TRAVEL)

i
dfw
C21-C24 : (FET U-W,CURRENT-HYD)

ww o
D30 : (FET-EPS)
cuC
G60-G62 : (FAIL CURRENT)
The , and buttons are disabled while

the self-diagnosis screen is displayed.
 The warning messege is not displayed while Display board
Do
the self-diagnosis screen is displayed.

 If rotary switch RS1 on the display board is F01
CDE
23
set to F, the self-diagnosis screen will not

456
AB
be displayed. (The normal screen will be 789

displayed.)
Set RS1 to "F".
 When the abnormalities and/or errors are
resolved, the display will return to the normal
screen.
40
Troubleshooting 2
2-1-2. Error messages and Display conditions

Error
Error Message (nondisplay) Probable Cause
Number
A01 A01:CONTAFTOR-MAIN Main contact is open circuit.
B19 B19:FAIL OPERATION - TRAVEL Travel operation is failure.
B10 B10:FUSE-MAIN Blown main fuse
B11 B11:FET U - TRAVEL Travel U phase FET is failure.
B12 B12:FET V - TRAVEL Travel V phase FET is failure.
l
B13 B13:FET W - TRAVEL Travel W phase FET is failure.
ria
B14 B14:SENSOR-CURRENT - TRAVEL Current sensor U phase or V phase for travel is failure.
B15 B15:ACCELERATOR Accelerator is failure.
C29 C29:FAIL OPERATION - HYD. Hydraulic operation is failure.
.c T
Valve does not shut off for contamination so that lift is
C20 C20:VALVE - CONTAMINATION
in sudden descent.
C21 C21:FET U - HYD. Hydraulic U phase FET is failure.
F
om
C22 C22:FET V - HYD. z D Hydraulic V phase FET is failure.
C23 C23:FET W - HYD. Hydraulic W phase FET is failure.
C24 C24:SENSOR-CURRENT - HYD. Current sensor U phase or V phase for hydraulic is failure.
P
C25 C25:SWITCH - LIFT
ard
Lift push button switch is failure.
FET for Electric Power Steering control is failure.

D30 D30:TR - EPS MAIN
(Decelerates by half)
w.p m
Steering sensor for Electric Power Steering control is

D31 D31:SENSOR-STEERING - EPS MAIN
failure.
i
dfw
ww o
Drive sensor for Electric Power Steering control is

D32 D32:SENSOR-DRIVE - EPS MAIN
failure.
cuC
D33 D33:BREAKAGE - EPS Wire for Electric Power Steering motor breaks.
D39 D39:FAIL OPERATION - EPS Electric Power Steering motor stops.
E40 E40:PALLET LOCK When cylinder lock is ON, cylinder insertion is detected.
Output voltage of pressure sensor is under 0.5V or

F41 F41:SENSOR-PRESSURE - HYD.
over 4.5V.
Do
F42 F42:ENCODER-HYD. - MAST Encoder for detecting lift height is failure.
41
2 Troubleshooting
Error Error Message (nondisplay) Probable Cause

Number
G60 *FAIL CURRENT - TRAVEL* Traction motor current is out of range.
G61 *FAIL CURRENT - HYD.* Hydraulic motor current is out of range.
G62 *FAIL CURRENT - EPS* Electric Power Steering motor current is out of range.
G63 *FAIL VOLTAGE - TRAVEL* Battery voltage is out of range.
G64 *FAIL VOLTAGE - HYD.* Battery voltage is out of range.
G66 *FAIL TEMPERATURE - TRAVEL* Traction motor temperature is out of range.
G67 *FAIL TEMPERATURE - HYD.* Hydraulic motor temperature is out of range.
l
G68 *FAIL MAIN BOARD* The power supply in the MPU board is out of range.
ria
The connection is failure between display board and
G70 *FAIL BUS SYSTEM - TRAVEL*
MPU board for travel.
G71 *FAIL BUS SYSTEM - HYD.*
.c T
MPU board for hydraulic.
rs
G72 *FAIL BUS SYSTEM - EPS*
EPS board.
te ale F
om
W05 *REDUCE THE LOAD* Overload
W07
bu e
*CHARGE THE BATTERY*
z D The battery must be recharged.
tri d D
W10 *SET MODEL* The forklift models must be select.
The accelerator was depressed when the key was

D ize P
W11 *RELEASE ACCELE TO NEUTRAL*
turned on.
ard
The hydraulic switch was turned on when the key was
ot or
W12 *OFF HYD. SWITCH TO NEUTRAL*

turned on.
w.p m
is
N uth
W13 *SET SAFETY GUARD ON* The safety guard is not set.
i
W14 *CEILING DETECTION* Detection of ceiling.
D rA
dfw
ww o
W15 *CHAIN SLACK - TABLE* The chain of table side is slacken.

fo
W16 *CHAIN SLACK - MAST* The chain of mast side is slacken.

cuC
o
W17 *SENSOR-FORK* Fork sensor is failure.

y
nl
note) marked error numbers are not displayed.

Only the symbols are displayed.
O
Do
42
Troubleshooting 2
2- 2. Error history memory

2-2-1. Error history memory 1
<The 9 most recently detected errors/ abnormalities>
F01
CDE
23
appears.
456
AB
789
NOTE  To view less than the nine most recent errors/
l
Set RS1 to "9".
abnormalities, place the blinking cursor on the
ria
last error/abnormality and press button to go
to "Previously detected errors/abnormalities".
 If there are no errors/abnormalities, press
.c T
button to go to "Previously detected errors/
abnormalities".
F
om
 The 9 most recently detected errors/abnormalitiesz D  Error/abnormality details
Number of times the error/abnormality
The most recent error/abnormality blinks as "A01".
occurred when it was detected
P
ard
w.p m
152T087 152T088
i
dfw
Error/abnormality detection total key-on hours.

ww o
The second error/abnormality blinks as "G65".

cuC
Do
152T089 152T090
152T091
152T092
The ninth error/abnormality blinks as "E40".
The next page is "Previously detected errors/abnormalities (1)"

43
2 Troubleshooting
2-2-2. Error history memory 2

<Previously detected errors/abnormalities (1)>
 Rotary switch RS1 on the display board : 9
NOTE  If there are no previous errors/abnormalities F01
CDE
23
displayed in the list, press button to go to
456
AB
"Previously detected errors/abnormalities (2)". 789
 If the same error/abnormality was detected
RS1="9".
multiple times previously, the data of the
l
most recent detection will be displayed under
ria
"Error/abnormality details".
 Blinking : Indicates the position of cursor.
Highlighted : Only highlighted numbers are
.c T
memorized as error items.
 Previously detected errors/abnormalities (1)  Error/abnormality details
F
om
The previous page is "The 9 most recently detected errors/
z D
abnormalities".
Number of times the error/abnormality
P
ard
w.p m
i
dfw
152T093 152T094
ww o

cuC
 Previously detected errors/abnormalities (2)

Do
152T095 152T096
The next page is "Previously detected errors/abnormalities (3)".
The next page is "Previously detected errors/abnormalities (4)".
44
Troubleshooting 2
<Previously detected errors/abnormalities (4)>

 Rotary switch RS1 on the display board : 9
F01
NOTE If the same error/abnormality was detected
CDE
23
456
multiple times previously, the data of the most
AB
789
recent detection will be displayed under "Error/
abnormality details". RS1="9"
 Previously detected errors/abnormalities (4)  Error/abnormality details
l
ria
The previous page is "Previously detected errors/
abnormalities (1)". Number of times the error/abnormality
Error/abnormality number display
.c T
F
om
z D
152T097
152T098
P
ard
w.p m
 Previously detected errors/abnormalities (5)

i
dfw
ww o
cuC
152T099
152T100
Do
45
2 Troubleshooting
2-2-3. Clearing the error history memory

(memory initialization)
1. Set rotary switch RS1 on the display board to "E".
2. Turn on the key switch. F01
CDE
23
3. The following screen appears and memory initialization
456
AB
is complete. 789
4. Return rotary switch RS1 on the display board to "0".
Set RS1 to "E".
l
ria
 Memory Initialization Completion Screen
.c T
F
om
152T101
z D
P
NOTE
ard
The following items are returned to their initial
values:
w.p m
 Travel mode : N (NORMAL)

 Meter mode : TIME
i
dfw
 Neutral regenerative brake : MID

ww o
 Error history : All clear

cuC
 BRIGHTNESS (back light brightness) : 5

Do
46
Troubleshooting 2
2- 3. I/O Check
2-3-1. I/O check mode display method
F01
CDE
23
456
AB
2. Turn on the key switch the following screen appears. 789
3. Press button to enter the I/O check mode. The "I/O"

Set RS1 to "8".
l
icon will blink.
ria
 RAM . I/O selection
 Current device blinks.
.c T
 Select "I/O" by pushing or button.
F
om
 CPU selection
z D The I/O icon highlights.
P
 The current CPU blinks.
ard
 Press either or button to select a
CPU.
TR : Travel
w.p m
HY : Hydraulic
PS : Power steering
 Data length setting
i
dfw
ww o
The I/O icon highlights.

cuC
The selected CPU highlights.
 The W(double-byte) blinks. (not variable)
 Data address setting

Do
 "0" blinks. (not variable)
 "0" blinks. (not variable)
(continues on next page)
47
2 Troubleshooting
(continued from previous page)
 The data address (single-byte high) blinks.

 Press either or button to set the
data address (0-F).
l
ria
 The data address (single-byte low) blinks.

 Press either or button to set the
.c T
data address (0-F).
F
om
 I/O data iz D I/O data is displayed.
 The current data address is displayed.

P
ard
The I/O data is displayed.
152T086
.p m
Return to RAM.I/O selection

dfw
o
cuC
ww
Do
w
48
Troubleshooting 2
2-3-2. I/O port table

Travel CPU
 I/O port table
Port No. last_digits I/O Contents Remarks
IN Motor rotary encoder A 0 - 5V
W0000 2
IN Motor rotary encoder B 0 - 5V
W000A A/D Motor U phase electric current 2.5V ±1.75V = ±700A
l
0 - 5V = 0 - 27.7V(RB7/9)
ria
W000C A/D Battery voltage
/ 0 - 55V(RB10 /15)
W000E A/D Power supply observation (V15)
W0012 A/D Motor W phase electric current 2.5V ±1.75V = ±700A
.c T
W0014 A/D FET temperature sensor 0 - 5V
W0016 A/D Auxiliary AD input 1 0 - 5V
W001A MTU Motor rotary encoder Counter value
F
om
W0028 A/D Accelerator voltage 1 0 - 5V
z D
P
ard
w.p m
Hydraulic CPU
i
dfw
 I/O port table

ww o

cuC
IN motor rotary encoder A 0 - 5V

W0000 2
IN motor rotary encoder B 0 - 5V
OUT Lift solenoid valve L : ON
Not used
W0006 1
Not used
Do
Not used
W000A A/D Motor U phase electric current 2.5V ±1.75V = ±700A
0 - 5V = 0 - 27.7V(RB7/9)
W000C A/D Battery voltage
/ 0 - 55V(RB10 /15)
W000E A/D Lift pressure sensor 0.5 - 4.5V 0 - 20MPa
W0012 A/D Motor W phase electric current 2.5V ±1.75V = ±700A
W0014 A/D FET temperature sensor 0 - 5V
W0016 A/D Main device voltage 0 - 65V
49
2 Troubleshooting
Display CPU
 I/O port table
W001A A/D Steering potentiometer 0 - 5V
Potentiometer for detecting pallet
W001C A/D 0 - 5V
lock
l
W001E A/D Power cylinder current 0 - 5V
ria
W0020 A/D Auxiliary input 0 - 5V
H: when the sensor for
W0012 1 IN Fork sensor detecting fork running on is
turning on
.c T
F
om
z D
EPS CPU
P
ard
 I/O port table
w.p m
Port No. I/O Contents Remarks

W000E A/D EPS motor current detection 0 - 5V
i
dfw
ww o
W0010 A/D Battery voltage detection in charging 0 - 5V

W0012 A/D Pole changing voltage detection 0 - 5V
cuC
W0014 A/D Battery voltage detection 0 - 5V

W0016 A/D Adjustment of pole changing point 0 - 5V
W0018 A/D Temperature sensor (detect 5 ) 0 - 5V
W001A A/D Adjustment of battery voltage 0 - 5V
W001C A/D Steering angle potentiometer 0 - 5V
Do
W001E Steering wheel potentiometer 0 - 5V
50
3. Wiring (Diagrams)
PB105-00A/01A PB105-00A/01A Chassis side Table side
2
RBC7/9/10 Battery (24V)
Line Connector Line Connector
No. CN Pin No. No. CN Pin No.
RDWH
V N 2 4 3 2 4
PB105-00A/01A PB104-75/76
RDGN
RDWH
RDWH
BKWH
RB10/15
BKWH
Line Connector Line Connector
Battery (48V) RD
RPA 1 107 Power supply No. CN Pin No. No. CN Pin No.
Traction motor BKRD
WH RNA 1 108 GND
V N RA1 2 93 A phase signal Connect and start hourmeter counting.
speed sensor BUWH
RB1 2 101 B phase signal BUBK
1 1 AH 2 20 Hour meter counting
VA NA GNRD RDYE
F 4 7 Main fuse YERD TPU 4 23 Power supply RDYE
RDYE TIU BK TIU 4 24 Signal F+ 2 75 Fan SW1 2 9 Height of lifting up when stop
AD2 1 122 Capacity voltage Traction TNU 4 25 GND BKYE
SW3 2 11 Ceiling detector
BU RDBK X2 F- 2 76
F1 MC C 4 6 Main contactor contact current sensor BU TPW 4 29 Power supply Fan
+ TIV BKRD TIW 4 30 Signal RDBK
TNW 4 31 GND M
BK
100 V 22 F AN0 1 56 GND

325A 80V, 4700 F (x9)
Horn switch
Traction FET BNYE
THD 4 22 Signal Horn SW9 2 26 Spare input 1
WHBU T-FET BKYE WHBK
MC MC+ 4 2 Main contactor THN 4 28 GND Turn signal H SW10 2 27 Spare input 2
BNWH temperature sensor SW11 1 49 Spare input 3
MC- 4 3 lamp SW12 1 50 Spare input 4
Left RDYE
RDYE TSL WLR 2 71 Turn signal lamp (Left) Turn signal Left RDYE
RPA 1 132 Power supply
TIU Hydraulic motor BKYE
WHBK RNA 1 123 GND lamp switch TSR 1 45 Turn signal lamp switch (Left)
RA2 1 127 A phase signal Right RDBU
WHYE
TSUN 4 11 U phase lower source speed sensor BUBK
RB2 1 134 B phase signal TSL WLL 2 70 Turn signal lamp (Right) Right BUYE
BUYE TSL 1 46 Turn signal lamp switch (Right)
TGUN 4 10 U phase lower gate RDYE *Only for trucks with head lamp (mast)
U1 BKYE YERD HPU 3 56 Power supply
WHRD
Mode selection switch
TSUP 4 9 U phase upper source HIU BK HIU 3 57 Signal FL+ 2 72 Lamp
V1 RDYE Hydraulic HNU 3 58 GND + BU
TGUP 4 8 U phase upper gate RDBK WHBK BS1 2 17 Up
current sensor BU HPW 3 64 Power supply X3 FL- 2 73
HIV BKRD HIW 3 65 Signal
Lamp - RD Reference:
TIV HNW 3 66 GND BS2 2 18 Down
WHRD Right Harness mark/color
W1 TSVN 4 15 V phase lower source BNRD HL M YE
Traction BURD Hydraulic FET H-FET BKRD HHD 3 55 Signal BKRD BS3 2 19 ‘M’ Red RD
TGVN 4 14 V phase lower gate HHN 3 63 GND
motor BKRD Traction temperature sensor HL
Left Black BK
TSVP 4 13 V phase upper source motor RDGN Green GN
RD
TGVP 4 12 V phase upper gate Lift pressure HTM YEBK HTP 2 90 Power supply
RD
BKWH HTD 1 131 Signal HPA 2 28 Power supply Yellow YE
sensor HTN 2 98 GND BK HNA 2 29 GND
BUWH White WH
WH *Only for trucks with backward accessory Display WHBU TXA 2 31 Board Display
Brown BN
TSWN 4 19 W phase lower source RDWH RXA 2 30 Board Display
BNRD module
FET module BUWH
TGWN 4 18 W phase lower gate BKWH RPA
RNA
1
1
133
124
Power supply
GND
FK+ 2 77 Backward (fork side) output Blue BU
BKWH Lift height encoder WH
RA3 1 128 A phase signal BNBK Gray GY
TSWP 4 17 W phase upper source BUWH X4 FK- 2 78
RB3 1 135 B phase signal
RDWH * Only for trucks with M mast Backward accessory Pink PK
TGWP 4 16 W phase upper gate BN Accelerator potentiometer Orange OG
Prestop BU RDYE
PS 1 119 Prestop WHYE AP0 1 55 Power supply
AD0 1 63 Signal Ex) BKWH (=Black/White)
HIU *Only for trucks with forward accessory
WHYE
HSUN 3 41 U phase lower source GNRD BUYE Black colored harness with White line.
BUYE DV+ 2 79 Forward (drive wheel side) output BKYE AD1 1 65 Signal
HGUN 3 40 U phase lower gate AN1 1 64 GND
U2 BKYE GNWH
HSUP 3 39 U phase upper source X5 DV- 2 80 YEBU
RDYE
Forward accessory SW2 2 10 Foot brake
V2 HGUP 3 38 U phase upper gate RDBU RD Slack of chain GN YEBK YERD
CS 1 120 SW4 2 12 Safety guard detector
Open when slacking detector
HIV
WHRD
HSVN 3 45 V phase lower source BN Lift up switch
W2 LS 1 129 Lift origin
Hydraulic BURD
HGVN 3 44 V phase lower gate *Only for trucks with turning alarm chime AP1 1 57 Power supply
motor BKRD Hydraulic T1 2 87 Travel inhibitor White line
HSVP 3 43 V phase upper source BURD Up1 WHRD
motor TL 2 95 Traveling speed reduction T+ 2 81 Turning alarm chime LU1 2 23 Lift up1
RD BK Up2 BURD
HGVP 3 42 V phase upper gate RNA 2 85 GND BUBK LU2 2 24 Lift up2
X6 T- 2 82
Turning alarm chime
WH BU Lift down switch
HSWN 3 49 W phase lower source RPA 2 84 Encoder power supply CH
FET module Down1 WHBK Black color
RDWH
BUWH LD1 2 21 Lift down1
HGWN 3 48 W phase lower gate
BKWH Down2 BUBK
HSWP 3 47 W phase upper source SW1 2 96 Spare input 1 *Only for trucks with descent alarm chime LD2 2 22 Lift down2
RDWH 2 Traction YERD
HGWP 3 46 W phase upper gate AD1 2 99 Spare AD input 1 LD+ 1 111 Descent alarm chime
YEBK * Only for cold storage trucks
GNWH X7 LD- 1 112
MB+ 2 67 Electro magnetic brake SW2 1 130 Spare input 2 Descent alarm chime Heater
SOL WHGN Hydraulic YE
MB- 2 68 SW3 1 121 Spare input 3 CH
BUBK WHBU
GNWH SW8 2 16 Slack of chain detector
LV+ 1 109 Lift solenoid valve * Open when slacking
SOL WHGN R1+ 1 113 Spare output 1
LV- 1 110 YEBK WHYE
WHGN R1- 1 114 FRK 2 25 Fork sensor
BKWH CNL1 2 100 * Open when grounding
NB 4 1 Control power supply(-) GNWH
RDWH CNH1 2 92 R2+ 1 115 Spare output 2 Steering potentiometer * Only for RBC trucks
VB 2 74 Control power supply(+) Hydraulic
RD
RDWH
BKWH
CNL2 1 126 R2- 1 116 AP2 1 58 Power supply
Data line (CAN) WHRD AD2 1 66 Signal
RDGN CNH2 1 125 R3+ 1 117 Spare output 3
VBM 2 91 Battery voltage 2 4
CNL3 2 97 R3- 1 118 BKRD
AN2 1 59 GND
PB106-20/21 CNH3 2 89
Connector
Line 1 2 3 4 5 6
No. CN Pin No. RDGN AP3 1 60 Power supply
PB106-20/21 PB104-75/76 GNWH
GNWH
WHGN
AD3 1 68 Signal
BKWH
RDBK
RDWH
RDGN
F2 Line Connector Line Connector
RDGN
VB 1 1 Battery voltage No. CN Pin No. No. CN Pin No.
10A BU BKWH
K1 EPS power supply(-) AN3 1 67 GND
YERD CNL1 2 33
RD Steering angle YEBU AP1 1 16 Power supply
MP EPS power supply(+) AD1 1 5 Signal CNH1 2 32 Data line (CAN) WHRD
potentiometer YEBK CNL2 2 35 SW5 2 13 Cylinder detector
EPS motor AN1 1 17 GND WHBK
CNH2 2 34 SW6 2 14 Lock mode switch
PA WH VB 1 36 Battery voltage WHGN
A EPS output Charge switch and LED SW7 2 15 Pallet detector
BK
AA YERD
Auto X1 R1+ 1 39 Power supply relay
Emergency switch
BUWH BNYE
AUT 1 7 Auto charge switch BNYE LED 2 6 Pallet lock confirmation lamp
R1- 1 40
Auto BURD Key switch RDYE Pallet lock confirmation lamp
BU LED1 1 3 Auto charge LED KSW 1 37 Control power supply(+)
IN 1 20 Charger interlock
Equalizing BNWH
RD
BKWH
* Only for trucks with fwd/bwd accessory
WH EQU 1 19 Equalizing charge switch
VN 1 10 Switch GND VN 1 38 Control power supply(-) Backward accessory switch
X1 BNBK
Interlock switch Equalizing BNRD BN FWD 1 47 Backward (fork side) input
LED2 1 15 Equalizing charge LED KST 1 43 Key switch start * ON when open
RDYE RDWH Forward accessory switch
RY 1 14 Relay MP 2 1 Power cylinder power supply(+) GNBK
BKWH BCK 1 48 Forward (driving wheel side) input
BUYE * ON when open
Mctt. MC 1 2 Mctt. Power cylinder K 2 2 Power cylinder power supply(-)
F4 M
BK
EP 2 3 Power cylinder output (expand)
* Only for trucks with head lamp/rear lamp
RD OUT 1 9 Spare output
WH * Only for trucks with head guard
10A BK CT 2 4 Power cylinder output (contract)
P5 1 21 External 5V VN 1 13 Switch GND Lamp
GNWH
WHGN
X Heater Right
P5 1 22 External 5V WHGN
CANL 1 6
R2+ 1 41 Spare output Rear lamp switch HL
GNWH Data line (CAN) R2- 1 42
AC relay Charger CANH 1 18 * Only for cold storage trucks Left
SW13 1 51 Spare input 3 HL
5 6 Head lamp switch
RDWH
BKWH
RDGN
SW14 1 52 Spare input 4

YEBK
SW15 1 53 Spare input 5 HL 1 44 Lamp switch
RDWH
BKWH
RDGN
RDBK
<Note> 2 3 4 AD5 1 61 Spare input AD
1. Terminal symbol
1 2 3 4
2 : Plug (without plating) AMP 170020-3
2 : Receptacle (without plating) AMP 170021-3
RB/RBC-70 System wiring 3- 1.

2. Dot-dot-dash lines and dashed lines indicate the use of optional eauipment.
3. About the expression about travelling direction of relevant to options, drive
wheel side is regarded as the advance side.
54000-58563-0E
51
52
Table
Water proof
4P
* Only for RBC F-70 trucks Pallet detector
CN2 CN1 2 2
BKWH
* Only for RBC D-70 trucks
2 2
WHGN
Display board Turn signal Horn
Steering comp. lamp switch switch Cylinder detector BKWH
2 2
Emergency Water
proof 12 P 10 P 4P WHRD
3 Wiring (Diagrams)
switch 2 2
Water proof Water Horn
Lift up switch proof
BKWH
Display 7
WHBK
*Option Foot 7
Lift down switch
2 2 2 2 brake
Fork sensor Water proof
2P
BKWH
RDWH
GNWH
WHGN
Accelerator
Fork sensor
* Only for cold storage
trucks 2 2
BKWH
Optional switch RDWH
2 2
Heater 2P
2P
WH
Water proof
Pallet lock 2P Power cylinder
Water proof
Pallet lock
Key switch mode switch confirmation LED
Water proof
8P
* Only for RBC F-70 trucks Harness, table

Control panel
2P
2P
Water proof
proof
Water
2P 2P
WH WH
*Option *Option
Slack of Slack of
chain chain
detector detector
YEBU
BKWH
RDWH
WHYE
BKWH
WHBU
RDWH
WHRD
Harness, head 2P 2P
Harness, head
lamp (Right) lamp (Left)
Water proof
Water proof
2 2 2
2 2 2 2 2
BK
BK
WH
WH
2 2 2 2
2 2 Pallet lock Pallet lock 2 2

Safety
Key switch
confirmation lamp mode switch Safety
guard guard
Lamp Lamp
8P
Optional switch
proof
Water
Head guard (Right) Head guard (Left)

Accelerator
* Only for trucks with
* Only for trucks with head lamp (head guard)
head lamp (head guard)
Lift down switch
Display Harness, mast (2)
Lift up switch * Only for M mast
Mast (Right) Emergency Mast (Left)
switch
Horn Turn signal Display board Steering
* Only for M mast * Only for M mast
Lift origin Lift height switch lamp switch comp.
switch encoder
CN1 CN2
Slack of Slack of
chain Turn Turn chain
detector Lamp signal Pre stop detector signal Lamp detector
lamp lamp
2P 4P 2 2 2 2 Control panel 2 2 2 2
Water proof
Water proof
2 2 2 2 * Only for RBC D-70 trucks 2 2 2 2
BK
BK
RD
GN
RD
WH
GN
WH
Harness, mast (3) Harness, mast (4)

2P 3P 2P
Water proof
Water proof
Water proof
4P 12P 10P 8P
Water proof
Water proof
Water proof
Water proof
Harness, mast (1)
+
Battery (48V)
-
- +
- +
3P
EPS
Water proof
<2> <1>
board
Water
proof
sensor
comp.
Pressure
<Note>
Main controller assembly

7
2
2
Lift solenoid
2P-X
2P
valve
<4>
U1
Fan
3P
2P <5>
: Plug
WH V1
2. Terminal symbol
12P
<6>
proof
Water
Sensor W1
Electro magnetic
325A
4P CN1
CN1
comp., <7>
magnetic brake U2 NA VA
Water proof
CN2
1. <n> shows lead wire No.
<8> <2>
V2
CN3 <11>
Bearing 2P
100A
sensor <9> WH
Fuse W2
AUTO
CN4
EQUAL
W1 V1 U1
4P
: Receptacle AMP 41729
54000-58583-0E
<10> <1>
<6>
<5>
<4>
Charger,
Water proof
Fan relay
AMP 170020-3
AMP 170002-5
AMP 170003-5
: Receptacle AMP 170021-3
switch EPS
FET module
10A
10A
Bearing motor 4P MPU board comp.

RD
sensor Traction motor

BK
RDBK
RDGN
RDYE
BKWH
W2 V2 U2
Magnetic
the part of moving, with edge and of heat source.
4P
contactor
<9>
<8>
<7>
Water proof
Charger panel Hydraulic motor

RB10/15-70
3. All electrical wires should be fixed to prevent contacting to
options, driving wheel side is regarded as the advance side.

4. About the expression about travelling direction of relevant to
* Only for trucks

with charger steering angle Transformer
sensor * Only for trucks * Only for trucks * Only for trucks * Only for trucks * Only for trucks
* Only for trucks with charger with lamp with backward with forward with turning with descent
Harness, body (mast side) accessory accessory alarm chime alarm chime
2 2 2 2
YE
BN
BU
<10>
GN
+ 2 2
4P 4P 4P 4P 4P
6P RD BK WH GN YE
WH
BKWH
RDWH
Primary
Rectifier
Secondary
<11>
Red
Pink
Blue
Gray
Black
White
-
Green
Brown
Yellow
Reference:
PK
YE
BK
BU
BN
GY
RD
GN
Orange OG
WH
Harness mark/color
Ex) BKWH (=Black/White)
RB/RBC-70 Body wiring

Black colored harness with White line.
Black color
White line
3- 2.
3-2-1.
Table
Water proof
4P
* Only for RBC F-70 trucks Pallet detector
CN2 CN1 2 2
BKWH
* Only for RBC D-70 trucks
2 2
WHGN
Display board Turn signal Horn
Steering comp. lamp switch switch Cylinder detector BKWH
2 2
Emergency Water
proof 12 P 10 P 4P 2 2
WHRD
switch
Water proof Water Horn
Lift up switch proof
BKWH
Display 7
WHBK
*Option Foot 7
Lift down switch
2 2 2 2 brake
Fork sensor Water proof
2P
BKWH
RDWH
GNWH
WHGN
Accelerator * Only for cold storage
Fork sensor
trucks BKWH
2 2
Optional switch RDWH
2 2
Heater 2P
2P
WH
Water proof
2P Power cylinder
Pallet lock
Water proof
Pallet lock
Key switch mode switch confirmation LED
Water proof
8P
* Only for RBC F-70 trucks Harness, table

Control panel
2P
2P
Water proof
proof
Water
2P 2P
WH WH
*Option *Option
Slack of Slack of
chain chain
detector
YEBU
detector
BKWH
RDWH
WHYE
BKWH
WHBU
RDWH
WHRD
Harness, head 2P 2P
Harness, head
lamp (Right) lamp (Left)
Water proof
Water proof
2 2 2
2 2 2 2 2
BK
BK
WH
WH
2 2 2 2
2 2
Pallet lock Pallet lock Key switch 2 2
Safety confirmation lamp mode switch Safety
guard guard
Lamp Lamp
Optional switch 8P
proof
Water
Head guard (Right) Accelerator Head guard (Left)

* Only for trucks with
* Only for trucks with head lamp (head guard)
head lamp (head guard) Lift down switch
Display
Harness, mast (2)
Lift up switch * Only for M mast
Emergency
Mast (Right) switch Mast (Left)
Horn Turn signal Display board Steering
* Only for M mast switch lamp switch comp. * Only for M mast
Lift origin Lift height
switch encoder CN1 CN2
Slack of Slack of
chain Turn Turn chain
detector Lamp signal Pre stop detector signal Lamp detector
lamp lamp
2P 4P 2 2 2 2
Control panel 2 2 2 2
Water proof
Water proof
2 2 2 2
* Only for RBC D-70 trucks 2 2 2 2
BK
BK
RD
GN
RD
WH
GN
WH
Harness, mast (3) Harness, mast (4)

2P 3P 2P
Water proof
Water proof
Water proof
4P 12P 10P 8P
Water proof
Water proof
Water proof
Water proof
Harness, mast (1)

3P
Water proof
EPS board comp.

Water
proof
Transformer
sensor
Pressure
Lift solenoid * Only for trucks with charger

<Note>

7
2
2
2P
valve
<10>
Bearing + <4>
U1
sensor
<5>
: Plug
V1
2. Terminal symbol
W2 V2 U2
Primary
Rectifier
<6>
Secondary
<11> W1
4P
<9>
<8>
<7>
325A
- CN1
Water proof
CN1
<7> NA
U2 VA
CN2
1. <n> shows lead wire No.
<8> <2>
Fuse Hydraulic motor V2
CN3 <11>
100A
<9>
Sensor comp., W2
CN4
magnetic 12P
: Receptacle AMP 41729
3P <10> <1>
Water proof
AMP 170020-3
AMP 170002-5
AMP 170003-5
: Receptacle AMP 170021-3
Fan relay FET module

10A
10A
MPU board comp.

4P
RD
Magnetic
RDBK
BK
RDGN
RDYE
BKWH
contactor
the part of moving, with edge and of heat source.
2P-X
AUTO
3. All electrical wires should be fixed to prevent contacting to
EQUAL
2P
WH
Charger,
switch 2P
54000-58573-0E
Electro magnetic 4P WH * Only for trucks * Only for trucks * Only for trucks * Only for trucks * Only for trucks
brake Harness, body with lamp with backward with forward with turning with descent
(mast side) accessory accessory alarm chime alarm chime
Water proof
2 2 2 2
Bearing
YE
BN
BU
GN
<2> <3> sensor <1> <3>

2 2
+
+
4P 4P 4P 4P 4P
- -
W1 V1 U1 6P RD BK WH GN YE
Fan WH
BKWH
RDWH
+
+
<6>
<5>
<4>
- -
EPS
Charger panel motor
* Only for trucks Traction motor
with charger
4P
RBC7/9/10-70
+
+
- -
Water proof
Red
Battery
Pink
Blue
Gray
steering angle Battery

Black
White
Green
Brown
Yellow
(12V) sensor (12V)

Reference:
PK
YE
BK
BU
BN
GY
RD
GN
Orange OG
WH
Harness mark/color

RB/RBC-70 Body wiring

Black color
White line
3- 2.
3-2-2.
Wiring (Diagrams) 3
53
3 Wiring (Diagrams)
<Note>
1. Terminal symbol
Sumitomo 6189-0131 102 2 : Receptacle (without plating) AMP 170021-3 2. Leed wires : AVSS 0.5mm 2
RDGN 15 103
1 A 54B 104 Sleeve (for single wire) AMP 170899-1 3. : Braided wires under 25mm pitch.
YEBK 15 Water proof 3 1
G Charger interlock BKWH 15
2
3
A 55B
A 56B Plug 3P 2
RD 21
105
106 15
Sleeve (for double wire)
: Receptacle
AMP 170890-1
Sumitomo 1500-0110
4. All pin layout shows the view from terminal insert side.
5. Write or impress the letters and figures with undamped ink.
107 D 5A
BKRD 21 Sumitomo 7165-0118 (Seal)
108 D 6A 6. Pay attention to the pin layout.
N Pressure sensor 21 : Receptacle (without plating) AMP 316836-1
7. About the expression about travelling direction of relevant
3 2 1 (See note 4) GNWH
WHGN
23 109 I 3A 1 22 : Receptacle (with plating)
AMP 1376700-1
AMP 1123343-2 to options, mast side is regarded as the advance side.
23 110 I 4A
YERD 23 111 Z 33A AMP 1318143-2 8. The relay should be clamped to the harness.
AMP 174357-2 YEBK
AMP 174352-2 23 112 Z 34A 23 : Receptacle (without plating) AMP 1123343-1 9. Connect the relay(Ca1a-DC24V) to the harness.
I Lift solenoid valve
Water proof 113 108 107 106 105 104 103 102
GNWH AMP 1318143-1 10. Fuses should be placed in a circle as shown in the figure below left.
Plug 3P 24 1 A 3B Water proof 114 118 117 116 115 114 113 112 111 110 109
WHGN Plug 2P
2 1 115
24 : Receptacle AMP 171630-1 11. Treat the divergence point of wires as shown in the figure below right.
24 2 A 4B (See note 4)
116 128 127 126 125 124 123 122 121 120 119 AMP 171699-1
80A 85B 117
12. Attach the cover(sleeve) for receptacle.
135 134 133 132 131 130 129 24 : Tab AMP 171661-1
Point "b" B 118
AMP 173706-1
84B
AMP 900324-4 (Stopper) Fuse
BU AMP 025(064) series connector 10A
B 119
22 M 17A AMP 172888-2 (Stopper) Heat contraction tube with resin (Colorless)
RD 120 M
22 19A 1123337-1 (34P) 10A
1 2 3 BKYE 25 : Receptacle AMP 175062-1 ES1000-1 (Tyco Elec. Raychem)
123
22 F 10A
RDYE AMP 173681-1 or equivalent
24 24 24
WHBK
22
132 F
127
22
9A
F 11A
CN1 26 : Receptacle (without plating) AMP 170384-2 8
RDBK
WH
BU
BUBK 134 F
22 12A
BKWH 18 : Pressed sleeve JST P1.25
124
22 M 14A
RDWH 12 : Pressed sleeve JST P2
WHBK
RDYE
BUBK
22
133 M 13A
BKYE
WH : Terminal 2-8 P terminal

BUWH
128
22 M 15A 8 Clamp
135 M
22 16A : Terminal 1.25-8
GNWH 125
22 Point "b" 37B
8
24 24 24 24
WHGN 126 Point "b"
22 36B
1 3 2 4 BN 22
129 M 20A 2 : Shur plug (without plating) AMP 170020-3
A A 121
RDYE 22 122 Sleeve (for single wire) AMP 170887-1
K 61A
9B 11B Sleeve (for double wire) AMP 170888-1
BUWH
A
130
YERD
BKRD
YEBU
YEBK
A A
J Fan relay YEBK 22 131 N 55A MPU board
WH
RD
10B 12B
(See note 4,6,8,9) GNWH 21 (See note 3,4,5,6)
24 24 24 24 24 24 24 67 E 1A
WHGN 21 68 E 2A
AMP 174257-2
BUWH
BNWH
RDGN
1 3 2 1 3 2 4
RDYE
BURD
BNRD
BUYE
69
RDBU
L
21 70 M 25A
B
RD
RD
B B A A
BK
Water proof
Plug 4P 42B 44B 5B 7B
1 2 RDYE
WHRD
21 71 M 24A Fan EPS
25 25 25 25 25 25 25 25 25 25 3 4 WHBK
21 72 Z 57A
(See note 3,4,6)
B A A 21 73 Z 26A
1 2 3 4 5 6 8 7 9 12 10 11
K B B B B
2 1
43B 6B 8B
AMP 172134-2
Plug RDWH 2 61B K Fuse Reference:
Harness mark/color
GNWH
WHGN
23 74 J 82H
81C 40B 45B 46B 51B 4 3 AMP 174357-2 AMP 174257-2 4P RDYE 23 75 J 22A
1 A (See note 10) 12 11 10 9 8 7 6 5 4 3 2 1
BK BKYE Red RD
K M B B B 23 76 J 23A 2 8 24 23 22 21 20 19 18 17 16 15 14 13
Water proof Water proof BNRD 23 77 Z 27A 83D 80D Black BK
81A 67A 41B 47B 48B 26 26 82G 22B BNBK
RDYE
Plug 3P Plug 4P 23 78 Z 28B 73 72 71 70 69 68 67 L,Z Point "b" AMP 025(064) series connector Green GN
GNRD AMP 172130-1
AMP 040 series Speed sensor 1 2 Point "b", A A
GNWH
23 79 Z 29A 85 84 83 82 81 80 79 78 77 76 75 74 8 8 1318917-1 Yellow YE
F 52A 23B 23 80 Z 30A
Multi lock connetcor (Mark I)
174045-2 (Hydraulic) A BURD
BUBK
23 81 Z 31A 93 92 91 90 89 88 87 86 Plug White WH
(See note 3,4,6)
3 2 1 1B 2 1
4 3
L A 23 82 Z 32A 101 100 99 98 97 96 95 94 2P
WH
CN1 Brown BN
RDBK
BK
BK
83
BKWH
(12P) A 1 3 2 4
84 Blue BU
26 26 26 26 BK 23 85 Point "a" 21A 52B 35C 42A 45A 41A 46A 51A 37D 85A Gray GY
2B AMP 025(064) series connector
Steering angle Speed sensor 1123338-1 (35PA) J K H C C C C Point "b" G Pink PK
10A
10A
6 5 4 3 2 1 H sensor AMP 172130-1
D (traction) 83C 44A 43A 40A 47A 48A 36D 84A Orange OG
RDBK
RDYE
BKYE
RDWH
86
Plug
12 11 10 9 8 7 2P (See note 3,4,6) WH 22
87
88 M 18A
CN2 Point "a", K H H C C C Point "b" G
BK
WH 89 1 2 8 4 1 5 16 17 7 14 2 19 3 15 13 6 18 10 20 9 11 12 21 22 23 24
RDGN C,C
22 90 N 54A 26 26 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22
RDGN 35B 18 81B 18
C Charger 1 GNWH
22 91 K 35A
RDGN
YEBU
YERD
YEBK
BUWH
RDYE
BUYE
BNWH
BURD
BNRD
BK
WHGN
GNWH
WH
BU
22 92 Point "b" 37A
WH 22 93 D 7A
(See note 4) 2
BKWH
RDBK
94
RD
RDGN
RDGN
RDGN
95
96
Electo magnet 97
E brake (See note 8) BKWH 22 98
99
N 56A
WHGN 22
(See note 3,4,6) BUWH 22
100
101 D 8A
Point "b" 36A White line
100 50
Black color
Point "b"
80B Point "b" 1 24

RDBK
AMP 174982-2 82K Point "a" 5 24
RDWH
RDGN Point "a"
67B C 2 24
Water proof 4 3 2 1 83A M 6 24
BKWH
Plug 8P 8 7 6 5 3 Stopper
60B Z 7 24
WH
WHGN
Point "a" (See note 11) Table 36C Point "b" 4 24
37C Point "b" 8 24
GNWH
To Point "b"
To Point "b"
To A
To Z
To L
19B A 1 24
RD
Chain looseness 53A M 6 24
RDBU
WH 0
AMP 174655-2
10
18B A 2 24
RDWH
RDWH
BKWH
BK
BKRD
Height 1m 21C Point "a" 7 24

BK
Water proof 5 4 3 2 1 82L Point "a" 3 24

RDWH
Plug 10P 10 9 8 7 6 8 Stopper
24B A 4 24
RDYE
Turn signal lamp(Left)
GNWH
RDWH
RDWH
WHRD
RDWH
RDWH
RDWH
18 18 12 18 18
WHBK
GNRD
RDWH
BNRD
BURD
BKRD
BNBK
BUBK
YERD
82I Point "a" 9 24
YEBK
Mast (Left) BKRD
GN
GN
62B Point "a" 5 24
BN
BU
RDWH
BN
BKWH
BU
YE
RDGN
YE
Lamp BKWH
RDWH
RDWH
RDWH
RDWH
RDWH
BKRD
BKRD
BKWH
BKWH
BKWH
BK
BK
BK
BK
83F 10 24
Point "a"
2 2 2 26 26 26 26 2 26 26 26 26 2 26 26 26 26 2 26 26 26 26 2 26 26 26 26
WHGN
GNWH
RDWH
BKWH
RDBK
RDBU
To M
To M
To M
To M
To M
To M
To M
To M
To M
To M
To M
To M
To M
To M
53B M 1 24 1 3 2 4 1 3 2 4 1 3 2 4 1 3 2 4 1 3 2 4
Chain looseness 21D Point "a" 7 24
BK
WH
BU K Z Point "a" A Z Z A Z Z A Z Z A Z Z A
17B A 2 24
BK 35D 83F 62A 26B 63B 63A 28B 64B 64A 30B 65B 65A 32B 66B 66A 34B
AMP 174661-2 Press top 21B Point "a" 8 24
RDWH 2 26 26 26 26 26
Point "b" (See note 11)
Water proof 6 5 4 3 2 1
82M Point "a" 3 24
9 Stopper 1 2 3 4 5 6
Z Z,Z A Z,Z A Z,Z A Z,Z A Z, Point "b" A
RDWH See note 12 82N 82B 57B 82C 27B 82D 29B 82E 31B 82F 33B
Plug 12P 12 11 10 9 8 7 13B A 4 24 Z,Z Point "b"
RDWH BKWH M
RDWH RDWH To Z Height detect sensor
14B A 10 24
BUWH
To J To point "a" 16B A 5 24 60C 82A 37E
18
RDWH Mast (Right) WH
To point "a" 15B A 11 24 Point "b" K,Z Point "b" AMP 172134-9 AMP 172134-2 AMP 172134-1 AMP 172134-4 AMP 172134-7
20B A 6 24
BN
WHGN WHGN Lift origin BK 80C 83E 36E
To A To B 21E
Point "a"
12 24 Plug Plug Plug Plug Plug
WHGN 4P 1 2 4P 1 2 4P 1 2 4P 1 2 4P 1 2
WHGN
18
WHGN To Z RD BK WH GN YE
To A To M 3 4 3 4 3 4 3 4 3 4
AMP 171898-1
GNWH GNWH 25B A 1 24
RDBU Lamp (mast) Bawkward (fork side) Forward (driving wheel Turning alarm chime Descent alarm chime
To A GNWH To B Turn signal lamp(Right) RDWH Plug accessory side) accessory
18 To Z AMP 174257-2 82J Point "a" 3 24
1 2 3
GNWH GNWH BKRD 6P
Z
To A To M 62C Point "a" 2 24
Water proof 2 1
Lamp 83B Point "a" 4 24
BKWH WH 4 5 6 Optional equipment
RDBK Plug 4P 4 3
RDBK RDBK To K Other equipment (See note 4,6,7)
To G 18 To M
RDBK
To Z Mast (Left)
M Mast
(See note 3,4,6,7)
RB/RBC-70 Body harness 3- 3.

RB10/15-70 3-3-1.
54000-58826-0E
54
Wiring (Diagrams) 3
Reference: <Note>
Harness mark/color 1. Terminal symbol
Red RD 102 2 : Receptacle (without plating) AMP 170021-3 2. Leed wires : AVSS 0.5mm 2
103
Black BK 104 Sleeve (for single wire) AMP 170899-1 3. : Braided wires under 25mm pitch.
Green GN 105 Sleeve (for double wire) AMP 170890-1 4. All pin layout shows the view from terminal insert side.
Yellow YE RD 21
106 15 : Receptacle Sumitomo 1500-0110 5. Write or impress the letters and figures with undamped ink.
107 D 5A
White WH Sumitomo 6189-0131 BKRD 21 Sumitomo 7165-0118 (Seal)
RDGN 15
108 D 6A 6. Pay attention to the pin layout.
Brown BN 1 A 54B 21 : Receptacle (without plating) AMP 316836-1
Water proof 3 1 7. About the expression about travelling direction of relevant
1
YEBK 15
Blue BU BKWH 15
2 A 55B
Plug 3P 2 GNWH AMP 1376700-1
3 A 56B 23 109 I 3A
: Receptacle (with plating) AMP 1123343-2 to options, mast side is regarded as the advance side.
Gray GY WHGN 23 110 I 4A
22
YERD AMP 1318143-2 8. The relay should be clamped to the harness.
Pink PK 23 111 Z 33A
N Pressure sensor YEBK 23 112 Z 34A 23 : Receptacle (without plating) AMP 1123343-1 9. Connect the relay(Ca1a-DC24V) to the harness.
Orange OG
G Charger interlock (See note 4)
113
114
108 107 106 105 104
118 117 116 115 114 113 112 111 110 109
103 102
24 : Receptacle
AMP 1318143-1
AMP 171630-1
10. Fuses should be placed in a circle as shown in the figure below (left side).
Ex) BKWH (=Black/White) 115 11. Treat the divergence point of wires as shown in the figure below (right side).
116 128 127 126 125 124 123 122 121 120 119 AMP 171699-1
Black colored harness with White line. 12. Attach the cover(sleeve) for receptacle.
117 135 134 133 132 131 130 129 24 AMP 171661-1
118
3 2 1 AMP 173706-1
AMP 900324-4 (Stopper) Fuse
BU AMP 025(064) series connector 10A
AMP 174357-2 AMP 174352-2 119 22 M 17A AMP 172888-2 (Stopper) Heat contraction tube with resin (Colorless)
RD 120 M 22 19A 1123337-1 (34P) 10A
GNWH Water proof BKYE 25 : Receptacle AMP 175062-1 ES1000-1 (Tyco Elec. Raychem)
Water proof 24 1 A 3B 123 22 F 10A
WHGN 2 1 RDYE AMP 173681-1 or equivalent
Plug 3P 24 2 A 4B Plug 2P
WHBK
132 F
127
22
22
9A
F 11A
CN1 26 : Receptacle (without plating) AMP 170384-2 8
BUBK 134 F 22 12A
80A 85B BKWH 18 : Pressed sleeve JST P1.25
White line
I Lift solenoid valve
124 22 M 14A
Point "b" B RDWH 133 M 22 13A
12 : Pressed sleeve JST P2
WH : Terminal 2-8 P terminal
128 22 M 15A 8 Clamp
J Fan relay
84B
(See note 4) BUWH
B GNWH
135 M 22 16A
8 : Terminal 1.25-8
125 22 Point "b" 37B
(See note 4,6,8,9) WHGN 22
126 Point "b" 36B
1 2 3
BN 129 22 M 20A 2 : Shur plug (without plating) AMP 170020-3
24 24 24
Black color 121
RDYE 22 122 Sleeve (for single wire) AMP 170887-1
K 61A
Sleeve (for double wire) AMP 170888-1
RDBK
WH
BU
1 2
A
130
3 4 YEBK 22 131 N 55A MPU board
AMP 172134-2 GNWH 21 (See note 3,4,5,6)
67 E 1A
WHGN 21 68 E 2A
Plug
4P 69
RDBU
L
21 70 M 25A
B
BK RDYE
WHRD
21 71 M 24A Fan EPS
82G 22B 21 72 Z 57A
WHBK 21 73 Z 26A
(See note 3,4,6)
K Fuse
Point "b", A A
52A
L
23B
A
RDWH
RDYE
23 74 J 82H 2 1
61B
A (See note 10) 12 11 10 9 8 7 6 5 4 3 2 1
23 75 J 22A
BKYE 23 76 J 23A 2 8 24 23 22 21 20 19 18 17 16 15 14 13
1 3 2 4
WHBK
BUWH
BNWH
RDYE
BNRD
BUBK
RDGN
BKYE
83D 80D
RDYE
BURD
BNRD
BUYE
23 77 Z 27A
BNBK
RDYE
26 26 26 26 73 72 71 70 69 68 67 AMP 025(064) series connector
RD
RD
23 78 Z 28B L,Z Point "b"

BK
GNRD 23 79 Z 29A AMP 172130-1

24 24 24 24 25 25 25 25 25 25 25 25 25 25 GNWH 23 80 Z 30A
85 84 83 82 81 80 79 78 77 76 75 74 8 8 1318917-1
BURD
RDBK
RDYE
BKYE
RDWH
1 3 2 4 23 81 Z 31A 93 92 91 90 89 88 87 86 Plug
1 2 3 4 5 6 8 7 9 12 10 11 BUBK
A A K B B B B
23 82 Z 32A 101 100 99 98 97 96 95 94 2P
WH
CN1
RDBK
BK
BK
83
BKWH
9B 11B 81C 40B 45B 46B 51B 84
BK 23 85 Point "a" 21A 52B 35C 42A 45A 41A 46A 51A 37D 85A
A A K M B B B AMP 025(064) series connector
1123338-1 (35PA) J K H C C C C Point "b" G
10A
10A
10B 12B 81A 67A 41B 47B 48B
86 83C 44A 43A 40A 47A 48A 36D 84A
AMP 174257-2 AMP 040 series
Multi lock connetcor (Mark I)
WH 22
87
88 M 18A
CN2 Point "a", K H H C C C Point "b" G
BK
Water proof 174045-2 89 1 2 8 4 1 5 16 17 7 14 2 19 3 15 13 6 18 10 20 9 11 12 21 22 23 24
RDGN C,C
Plug 4P (See note 8) 22 90 N 54A 26 26 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22
RDGN 22 91 K 35A 35B 18 81B 18
(12P) GNWH
RDGN
YEBU
YERD
YEBK
BUWH
RDYE
BUYE
BNWH
BURD
BNRD
BK
WHGN
GNWH
WH
BU
22 92 Point "b" 37A
WH 22 93 D 7A
BKWH
RDBK
2 1 94
RD
RDGN
RDGN
RDGN
4 3 95
6 5 4 3 2 1 96
12 11 10 9 8 7 97
BKWH 22 98 N 56A
99
Speed sensor WHGN 22 100 Point "b" 36A
F (Hydraulic) C Charger
BUWH 22 101 D 8A
(See note 3,4,6) (See note 4)

100 100
80B Point "b" 1 24

RDBK
RDWH
AMP 174982-2
67B C
82K Point "a" 5 24
2 24
RDGN Point "b"
Water proof 4 3 2 1 83A M 6 24
BKWH
Plug 8P 8 7 6 5 3 Stopper
WH
Point "a" (See note 11)
60B Z 7 24
36C Point "b" 4 24
WHGN
To Point "b"
To Point "b"
Table GNWH
37C Point "b" 8 24
To A
To Z
To L
0
19B A 1 24
RD
10 Point "a"
RDWH
RDWH
BKWH
BKRD
Chain looseness RDBU
BK
53A 6 24
M
WH
AMP 174655-2 18B A 2 24
BK
Height 1m 21C Point "a" 7 24
RDWH
Water proof 5 4 3 2 1 82L Point "a" 3 24 18 18 12 18 18
Plug 10P 10 9 8 7 6 8 Stopper
24B A 4 24
RDYE
Turn signal lamp(Left) RDWH
RDWH
RDWH
RDWH
RDWH
RDWH
BKRD
BKRD
BKWH
BKWH
BKWH
BK
BK
BK
BK
82I Point "a" 9 24
Mast (Left) 62B Point "a" 5 24
BKRD
Lamp 83F 10 24
BKWH
Point "a"
To M
To M
To M
To M
To M
To M
To M
To M
To M
To M
To M
To M
To M
To M
GNWH
RDWH
WHRD
RDWH
RDWH
RDWH
WHBK
GNRD
RDBU
RDWH
BNRD
BURD
BKRD
BNBK
BUBK
YERD
YEBK
53B M 1 24
Chain looseness BK
GN
GN
BN
BU
RDWH
BN
BKWH
21D Point "a" 7 24
BU
YE
RDGN
YE
17B A 2 24
BU
GNWH
WHGN
BK
BUWH
YERD
BKRD
YEBU
YEBK
AMP 174661-2 Press top 21B Point "a" 8 24

RDWH
WH
RD
82M Point "a" 3 24 2 2 2 26 26 26 26 2 26 26 26 26 2 26 26 26 26 2 26 26 26 26 2 26 26 26 26

Point "b"
WHGN
GNWH
RDWH
BKWH
Water proof (See note 11)
RDBK
6 5 4 3 2 1 9 Stopper
RDWH 24 24 24 26 26 24 24 24 24 1 3 2 4 1 3 2 4 1 3 2 4 1 3 2 4 1 3 2 4
Plug 12P 12 11 10 9 8 7 13B A 4 24
14B A 10 24
BKWH
WH
Height detect sensor BUWH 1 3 2 1 2 1 3 2 4 RDWH K Z Point "a" A Z Z A Z Z A Z Z A Z Z A
Mast (Right) 16B A 5 24
WH
To J RDWH RDWH
15B A 11 24 B B A A A To point "a" 18 To Z 35D 83F 62A 26B 63B 63A 28B 64B 64A 30B 65B 65A 32B 66B 66A 34B
BN To point "a" RDWH 2 26 26 26 26 26
20B A 6 24 Z Z,Z A Z,Z A Z,Z A Z,Z A Z, Point "b" A
Lift origin 21E 12 24
BK 42B 44B 1B 5B 7B
1 2 3 4 5 6
Point "a" WHGN WHGN 82N 82B 57B 82C 27B 82D 29B 82E 31B 82F 33B
B A A A
To A To B See note 12 Z,Z Point "b"
WHGN M
43B 2B 6B 8B To A WHGN
18
WHGN
To M To Z 60C 82A 37E
RDBU Point "b" K,Z Point "b" AMP 172134-9 AMP 172134-2 AMP 172134-1 AMP 172134-4 AMP 172134-7
Turn signal lamp(Right)
25B A 1 24
RDWH AMP 174357-2 AMP 172130-1 AMP 174257-2
AMP 174257-2 82J Point "a" 3 24 GNWH GNWH
BKRD Plug To A GNWH To B 80C 83E 36E
62C Point "a" 2 24 Water proof Water proof To A 18 Plug Plug Plug Plug Plug
Water proof 2 1
Lamp BKWH 2P GNWH GNWH 4P 1 2 4P 1 2 4P 1 2 4P 1 2 4P 1 2
83B Point "a" 4 24 Plug 3P Plug 4P To M To Z
Plug 4P 4 3 WH RD 3 4 BK 3 4 WH 3 4 GN 3 4 YE 3 4
RDBK RDBK AMP 171898-1
To G To K Lamp (mast) Bawkward (fork side) Forward (driving wheel Turning alarm chime Descent alarm chime
Mast (Left)
M Mast 3 2 1 1 2 1
To M
RDBK
18
RDBK
To Z
Plug
6P 1 2 3
accessory side) accessory
Z
2 4 3
(See note 3,4,6,7) WH 4 5 6 Optional equipment
Other equipment (See note 4,6,7)
Steering angle Electo magnet Speed sensor
H sensor E brake D (traction)
RB/RBC-70 Body harness 3- 3.

(See note 3,4,6) (See note 3,4,6)
RBC7/9/10-70 3-3-2.
54000-58806-0E
55
<Note>
1. Symbol
n : Terminal (Pressed terminal)
2. Tightening torque for the FET.

Main terminal(M6) and mounting(M6) : 3.5-4.5N·m
3. Tightening torque for the contactor.
Main terminal(M8) : 12.7-14.7N·m
4. The "Wire, lead" should be connect to "Module, FET"
Traction FET after be penetrated to the current sensor.
See note 2 Temperature sensor

Do
See note 3
Current sensor (Traction FET)
(Traction U phase)
Current sensor
(Traction V phase)
U1
cu
4P
6 12P
V1
C
4P
6 8
3
ww
W1
8
4
6 GNRD
2P
U2
w.p om
Reference:
4P
MPU board comp. 6 12P Harness mark/color
54000-59200-0E
8 2P Red RD
WH Black BK
V2 6
Green GN
Yellow YE
4P
6 White WH
dfw P RD (KIV3.5mm) 2
Brown BN
BU
Current sensor W2 Blue BU
Harness, controller (Hydraulic U phase) Gray GY
6 6 Pink PK
2P Orange OG
Current sensor
BU (KIV3.5mm) 2
(Hydraulic V phase) Ex) BKWH (=Black/White)

iza D
Clamp 1 place with wire ties.
Wire, lead
r F
Hydraulic FET
Temperature sensor BKWH
(See note 4)
(Hydraulic FET) White line
d.c T
RB/RBC-70
Black color
om ri
a
Controller wiring
l
3- 4.
Wiring (Diagrams) 3
56
Wiring (Diagrams) 3
See note 4
D Current sensor
(Traction V phase)
See note 4 917354-1(AMP)
D
See note 4 E Current sensor
(Traction U phase)
TV
XHP-4(JST)
C Traction
FET
1
7
2
8
3
9
4
10
5
11 12
6
TU 1 2 3 4
XHP-4(JST) 12P
Temperature sensor
1 2 3 4
4P B (Traction FET)
l
27B 31B 35B 29B 33B 36B
177898-1(AMP)
ria
A A A A A A
4P 45B
A
Pay attention to 26B 30B 34B 28B 32B 35B 1 2
43B 44B
the pin layout
A A A A A A
42B 2P
A A 1 7 2 8 3 9 4 10 5 11 6 12
A
40B 41B 1 2 3 4 38B 39B
15 15 15 15 15 15 15 15 15 15 15 15
10 10 10
A A A A
RD
RDYE
WHYE
RDWH
BKYE
BUYE
BURD
BKWH
WH
WHRD
BUWH
BKRD
BU#
BKRD#
RDBK#
1 2 3 4 1 2
10 10 10 15 15
.c T
YERD#
RDYE#
BK#
BKYE
BNYE
F
om
1123340-1(AMP)
A MPU board 1123341-1(AMP)
iz D
37 36 35 34 33 32
47 46 45 44 43 42 41 40 39 38
7 6 5 4 3 2 1 Reference:
58 57 56 55 54 53 52 51 50 49 48
17 16 15 14 13 12 11 10 9 8 Harness mark/color
66 65 64 63 62 61 60 59 Red RD
25 24 23 22 21 20 19 18 Black BK
31 30 29 28 27 26 Green GN
P
Yellow YE
35P White WH
ard
Brown BN
Blue BU
1A 3A 5A 7A 9A 11A 14A 16A 19A 31P Gray GY
H H H H H H Pink PK
I F G 21A 23A 25A 27A 29A 31A 33A 35A 37A 39A 41A 44A Orange OG
2A 4A 6A 8A 10A 12A 13A 15A 17A 18A 20A
J K K C C C C C C B E D
H H H H H H I F F G G Ex) BKWH (=Black/White)
22A 24A 26A 28A 30A 32A 34A 36A 38A 40A 42A 43A 45A
w.p m
32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 63 56 57 58 59 60 61 62 64 65 66 Black colored harness with White line.
23 23 23 23 23 23 23 23 23 23 22 22 22 22 22 22 22 22 22 22 K J C C C C C C B E E D D
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 28 23 24 25 26 27 29 30 31
BKWH
RDYE
BUYE
BKRD
RD
BU#
BNRD
BKYE
YERD#
BKRD
WHRD
RDYE#
BK#
BKRD#
WHYE
BURD
RDWH
BUWH
WH
RDBK#
21 21 21 21 21 23 23 23 23 23 23 23 23 23 23 22 22 22 22 22 22 22 22 22 22
RDYE
RD
BNWH
GNRD
BKYE
BUYE
BURD
BKYE
RDYE#
WH
BU#
BNYE
YERD#
WHBU
BKWH
BU
BUWH
WHYE
BKRD
WHRD
BKWH
RDBK#
BKRD#
RDWH
BK#
dfw
White line
ww o Pay attention to the pin layout
Black color
Pay attention to the pin layout
cuC
Current sensor See note 4
See note 4
G (Hydraulic V phase) H
917354-1(AMP)
See note 4 F
Current sensor
(Hydraulic U phase) H Hydraulic FET 1
7
2
8
3
9
4
10
5
11
6
12
Temperature sensor
HU
XHP-4(JST)
1 2 3 4 I (Hydraulic FET) J Main power supply K Contactor <Note>
12P
177898-1(AMP) 1. Lead wire
1 2 3 4 marked with ‘#’ : AVSS 0.3mm 2
4P
1 2 24B 25B 172130-1(AMP) not any mentioned : AVSS 0.5mm
2
1B 5B 9B 3B 7B 11B
Do
20B A A A A A A 2P A A 1 2. All pin layout shows the view from terminal insert side.
4P
A
2B 6B 10B 4B 8B 12B
21B 6 8
2 3. : Braided wires under 25mm pitch.
Pay attention to
18B 19B A A A A A A 13B 14B 4. Impress or write marks on connectors with undamped ink as
17B the pin layout A Plug
indicated in the pin cunfiguration.
GNRD
BU
2P
A A 1 7 2 8 3 9 4 10 5 11 6 12 A A WH
A 6
15B 16B 1 2 3 4
15 15 15 15 15 15 15 15 15 15 15 15
1 2 1 2 5. Pay attention to the pin layout.
10 10 10 15 15
A A
A A 6. All of the mark bands indicated in this diagram are not necessary.
BKRD
BKWH
RDWH
WHRD
BURD
BUWH
RD
WH
BKYE
RDYE
WHYE
BUYE
BU#
BKRD#
BKRD
BNRD
RDBK#
22B 23B However according to circumstances, in case of the mentioned

BKWH
1 2 3 4
10 10 10 wire color is not usable, it is possible to indicate the wire color on
3 3
black wire by using mark band.
BK#
YERD#
RDYE#
(In this case, obtain our company’s consent beforehand)

WHBU
BNWH
RB/RBC-70
Controller harness 3- 5.
54000-59192-2E
57
3 Wiring (Diagrams)
10P
Water proof
l
12P
ria
Water proof
Harness, table
4P
2 1
Control panel top view
Water proof
35PB 35PA
.c T
Stopper
CN2 CN1 side
rs
Relay
Emergency Horn Turn signal

Potentiometer switch lamp switch
te ale
Board comp., display switch
Water
4P Display board
F
proof
om
bu e
Steering 4 4 Switch, push button
iz D
4P 4P Right Left
tri d D
WHBK
RDWH
RDGN
RD BK
RDBK
RDYE
BUYE
Water
RD
Reference: 4P proof
Steering
6P
Harness mark/color Display
Red RD potentiometer Power Potentiometer
D ize P
Black
Green
BK
GN
supply relay
ard
Yellow YE
Display
White WH
4P
Brown BN
Blue BU
ot or
Gray GY Board comp., printed
Pink PK Mode selection switch
Orange OG
* Optional equipment (See note 3)
Accelerator
w.p m
is
N uth
Ex) BKWH (=Black/White) Connect and start 1 BKWH
Black colored harness with White line. BUBK potentiometer
hourmeter counting 1 Harness, control panel
Water proof Harness, lift switch
RDGN
Battery power supply 2
RDWH
Key switch power supply 2
D rA
BKWH 6P
dfw
Battery GND 2
White line
ww o
Lamp switch (ON with key switch PS and short circuit)
Bwd accessory switch (OFF with key switch PS and short circuit)
Fwd accessory switch (OFF with key switch PS and short circuit)
2
2
2
YEBK
BNBK
GNBK
Stopper side
Pallet lock Pallet lock

RDWH (*Option)
BKWH (*Option)
2 2
BU
BU
mode switch confirmation lamp
fo
OFF
2 2
Accelerator assembly
cuC
Black color * Only for cold storage trucks
o ON <Note>
RD
Switch comp., toggle
BU
Lamp comp. 1. Terminal symbol
RDWH
BNWH
WH
y
Spare (Mast suspender) 2 2 : Plug AMP 170020-3

WHBU
Spare (Head guard Left) 2 AMP 170002-5
nl
WHYE
Spare (Head guard Left) 2
RDWH
2 : Receptacle AMP 170021-3
WHRD
Spare (Head guard Left) 2 2 2
BNYE
AMP 170003-5
YEBU : Terminal 1.25-4
Spare (Head guard Right) 2 2
O
2 4
BKWH
2 2 2. All electrical wires should be fixed to prevent contacting to
2 2 WHBK the part of moving, with edge and of heat source.
Do
Switch comp., key

Key switch
RB/RBC-70
Control panel wiring 3- 6.
54000-75951-1E
58
Wiring (Diagrams) 3
RDGN
WHBK
Z 19D
K Horn switch Reference:
A 24B See note 4 Harness mark/color
Red RD
Black BK
<Note> Green GN
1. : Braided wires under 25mm pitch. Yellow YE
2. All pin layout shows the view from terminal insert side. BUYE 3 L 28B Turn signal White WH
3. Pay attention to the pin layout.
4. When installing electric wires to the terminal, solder them
RDWH
RDYE
2
1
C 50G
L 27B
G lamp switch Brown
Blue
BN
BU
See note 4 Gray GY
l
with strands of lead wires are hooked to the hole. Pink PK
Orange OG
ria
Stopper side
5. Impress or write figures on connectors with undamped ink.
6. Attach the cover(sleeve) for shur receptacle. Black colored harness with White line.
7. Connect “ 42 relay”. 12B L 1 10
WHBU
8. Tied to the harness. BUWH
13B L 2 10
RDGN
9. Covered by corrugated tube with both end tied up.
10. Cover heat contraction tube on the “ 35 36 sleeve” part
1 2 3 4 5 6
15B L
14B L 3 10
RD
BK RD
4 A,Z 19B
M Emergency switch
E Display
4 10
4 H 26A
BKWH
for insulation as shown in the figure below. 51G Z 5 10
RDWH
See note 2 50D Z 6 10
Heat contraction tube(Colorless) BKWH White line
14 C 51I AMP 174262-2
.c T
BU WHRD
16B L 1 11
24 L 4B
RD BURD
1 2 3 4 17B L 2 11
L 5B Water proof 3 2 1
See note 6 YE 4 3
18B L WHBK
F Mode selection switch
3 11
4 4 L 6B Plug 6P 6 5 4
BKWH BUBK
51E I 4 11
4 5 L 7B Black color
See note 2
Sleeve P1.25
25B L
51F Z,E 1
1
BKWH
BUBK RDWH
Stopper 6
2 J,G 50F
C Lift switch
See note 6 See note 2
BKWH 2 51H
RDGN Point "a",C
F
19C M,K 2
om
RDWH RDYE
50C N,F 2 WH N 21C AMP 172130-1
BKWH 52B A 2 3 2
51E 2
29B L,A Point "a",Z 2 YEBK
BNBK
Y Head guard 61A A
60A A 2
WHBU
WHYE RD
4 Plug
4P
1 2
30B L 2 2
3 1 M 26B 3 4
GNBK WHRD RD
* Optional equipment 31B L 2 62A A 2
BN
iz D
Z Hourmeter counting H Key switch
YEBU 3 3 L 20B
63A A 2
See note 2,3

BKWH
Pallet lock 51C
I
2
mode switch 22B L Point "a",F WHBK RDYE
2
4 2 L 8B AMP 174257-2
P
Pallet lock RDWH BKYE
J confirmation lamp
50E 2
BNYE BUYE
4 3 L 9B Water proof 2 1
ard
23B L Point "a",C
L 10B Plug 4P 4 3 Point "a"
2 4 1
WHYE L 11B
See note 8 4 4
RDWH
AMP 172130-1 To J RDWH
RDYE Accelerator RDWH 18 To A
N
Power
supply relay 1 2 Plug
Point "a",Z 21B L,H 1
50C 3
3
3
RDWH D potentiometer To N
4P YERD See note 1,2,3
3 4 32B L 2 3
See note 4,5,7,8 WH
w.p m
33B L
BNYE
4 3
AMP 174257-2 1B L
RD Point "a" See note 9
2 4
BKRD 300 To I
BKWH
BKWH
2 1 Water proof 2B L 3 4 BKWH To A
To C 12
4 3 Plug 4P WHRD BKWH
3B L 4 4 To Z
dfw
BKWH
To L
ww o B Steering potentiometer
See note 1,2,3
1 Stopper
cuC
GNWH
WHGN
GNWH
WHGN
RDWH
WHRD
WHRD
WHBU
WHBU
BUWH
BKWH
WHBK
WHBK
WHYE
BURD
YERD
BNYE
BUBK
BUBK
WH
RD
RD
BU
BK
YE
BK
GNWH
WHGN
GNWH
GNWH
WHGN
GNWH
RDWH
WHRD
WHRD
RDWH
WHRD
WHBU
WHBU
WHBK
BKWH
BKWH
WHYE
WHYE
BKWH
WHYE
RDGN
RDGN
RDGN
BKWH
BKWH
GNBK
RDBK
RDBK
RDYE
YERD
RDYE
RDYE
BKRD
YERD
YEBK
BNYE
BUYE
BNBK
BUYE
YEBU
YEBK
BKYE
21 21 21 21 21 23 23 23 23 23 23 22 22 22 22 22 22 22 22 22 22 22 22 22 22 22
WH
WH
RD
BK
BN
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
21 21 21 21 21 23 23 23 23 23 23 22 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
A A A A F F C C A E E A
36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 64 57 58 59 61 62 63 56 65 66 68 69 70 60 67 38A 36A 44A 45A 16A 18A 6A 4A 43A 15A 13A 35A 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4
K Z L L L L L L L Point "a" Z Y Y
A Point "a" N Z G Z D B D D A A A A J A A I A F Z C C E E A
39A 37A 23A 40A 41A 22A 42A 17A 25A 7A 5A 14A 12A 34A 24A 29C 35B 37B 39B 41B 43B 45B 47B 50A 52A 61B 63B
49B 51B 33A 29A 28A 31A 9A 1A 11A 10A 48A 47A M L L L L L L L L Y Y
N N H G Z D B B A Point "a"
19A 49A 34B 36B 38B 40B 42B 44B 46B 48B 51A 60B 62B
21A 32A 20A 27A 30A 8A 2A 3A 46A
2
Do
1 1 2 3 4 5 1 2 3 4 5 6 1 2
6 5 4 3 2 1 CN2 6 7 8 9 10 7 8 9 10 11 12 3 4
16 15 14 13 12 11 10 9 8 7
42 41 40 39 38 37 36 CN1
54 53 52 51 50 49 48 47 46 45 44 43 L Display board 27 26 25 24 23 22 21 20 19
35 34 33 32 31 30
18 17
29 28
AMP 174657-2 AMP 174663-2 AMP 174259-2
62 61 60 59 58 57 56 55 See note 1,2,3,5 Water proof Water proof Water proof
70 69 68 67 66 65 64 63 CAP 10P CAP 12P CAP 4P
A Harness, table
Power supply relay Model See note 2
Ca1a-DC24V RBC-70
Ca1a-DC48V-N RB -70
RB/RBC-70
Control panel harness 3- 7.
E0000-14373-1E
59
Lift up switch
Harness, lift switch BU1 Up 1 BU2
4 4
(BK)
BU1 4
Up 2 4
BU3
Do
(GN)
Water proof
Cap Reference:
Switch, push button
Harness mark/color
6P Red RD
cu Black BK
RDWH BU Lift down switch Green GN
2 2 Yellow YE
BKWH BU BU1 4 Down 1 4
BU4 White WH
2 2
ww C BU1 4
(BK)
Down 2
(GN)
4
BU5 Surface B
Brown
Blue
Gray
Pink
Orange OG
BN
BU
GY
PK

To “Harness, control panel” Black colored harness with White line.
Switch, push button
w.p om
54000-75940-2E
Accelerator assembly
Surface A White line
dfw P
iza D Heater comp.
* Only for cold storage trucks. Black color
RB/RBC-70
<Note>
1. Terminal symbol
4 : Terminal 1.25-4
r F
4. In case of RB-70 trucks, install in order to cover
both of surface A and surface B.
2 : Shur plug (without plating) 170002-5 5. The color of the push button for lift means color
170020-3
d.c
of the part shown in the figure below.
Sleeve (for single wire)
Sleeve (for double wire)
170887-1
170888-1
T
(There is no distinction between terminal numbers,
there is no problem to wire to whichever.)
Accelerator wiring
2 : Shur receptacle (without plating) 170003-5
170021-3 This part
Sleeve (for single wire) 170889-1
om ri
Sleeve (for double wire) 170890-1
2. All electrical wires should be fixed to prevent contacting to the part of
moving, with edge and of heat source.
3. When connecting the pressed terminal to the push button switch for lift,
pay attention to prevent contacting to the case of the accelerator, to
a l
prevent shorting out between terminals.
3- 8.
Wiring (Diagrams) 3
60
Wiring (Diagrams) 3
Reference:
Harness mark/color
Red RD
AMP 174352-2 Black BK
AMP 174257-2
GNWH RDGN Green GN
24 1 A 11B Water proof 17B A 2 24
<Note> BKWH 2 1 2 1 Water proof BKWH Yellow YE
24 2 21C Plug 2P 18B A 3 24
1. Terminal symbol Point "a" 4 3 Plug 4P GNWH White WH
l
19B A 1 24
H Foot brake
2 : Receptacle (without plating) AMP 170021-3 4 Stopper Brown BN
Sleeve (for single wire) AMP 170899-1 Pallet lock Blue BU
G potentiometer
ria
Sleeve (for double wire) AMP 170890-1 See note 4 Gray GY
7 : Receptacle (with sleeve) AMP 41729 Pink PK
RDWH A, Point "a" See note 3,4,5
24 : Receptacle AMP 171630-1 2 20B Orange OG
AMP 171699-1 BKWH 2 21B Optional equipment
GNWH
Z3
A, Point "a"
24 : Tab AMP 171631-1 WHGN
2
2
A,B 5B
A,B 6B
(Table) Ex) BKWH (=Black/White)
AMP 173600-1
F
AMP 900324-4 (Stopper S)
AMP 172888-2 (Stopper) Pallet dector
16B A 1 2
WHGN
19 : Terminal JST P5.5 BKWH
21O E,Y2 2 2
18 : Terminal JST P2
.c T
2. Leed wires : AVSS 0.5mm 2
3. : Braided wires under 25mm pitch.
AMP 174257-2 White line
4. All pin layout shows the view from terminal insert side. WHRD
5. Pay attention to the pin layout.
WHBU
WHYE
24
24
1
2 Z2 31A
Z2 30A
Water proof 2 1 E Cylinder detector 15B A
21N C,F
1
2
2
2
BKWH
WHRD Plug 4P 4 3
6. About the expression about travelling direction of relevant YEBU
24 3 Z2 32A
24 4 Z1 33A
to options, mast side is regarded as the advance side.
7. Treat the divergence point of wires and the insertion part of RDGN 24 1 B 1A Black color
the electrolytic capacitor as shown in the figure below. WHBK 24 2 2A
RDBK Point "b"
F
YEBK
24 3 B 3A AMP 174655-2
WHBK
om
24 4 4A
Heat contraction tube with resin (Colorless) WHYE GNWH YEBK
C Horn
Point "a" 2B A 1 7
14B A 1 24 24 5 Z3 5A Water proof 5 4 3 2 1 24 1 Y1 23B
ES1000-1 (Tyco Elec. Raychem) 23A Y2 2 24
YEBK WHGN 24 6 Z3 6A Plug 10P 10 9 8 7 6 BKWH BKWH 24 2 F 21P
or equivalent BK 24 7 D 7A
21M D,E 2 7
WH 24 8 D 8A
RDWH
AMP 174352-2 BKWH
24 9
Point "a"
20C AMP 174352-2
24 10 21F
Point "a"
Water proof
iz D
Water proof 2 1
2 1
50
P terminal Plug 2P Plug 2P
GNWH 24 1 H 11A
Y1 Fork sensor (Right) YERD 24 2 J1 12A
Point “b”
Capacitor
Vinyl tube (Heatproof type)
(Cover to wire) See note 4,6
WHBU
WHYE
WHRD
24
24
3
4 Y1 14A
K1 13A
AMP 174661-2
AMP 172130-1 Y2 Fork sensor (Left)
24 5 E 15A 1 Plug WH
Vinyl tube (Heatproof type) WHGN Water proof
8B A 1 26
BK See note 4,6
Heat contraction tube (Colorless) 24 6 F 16A 6 5 4 3 2 1 2P 7B A 2 26
RDGN Plug 12P 2 WH
(Cover to splicing) BKWH
24 7 G 17A 12 11 10 9 8 7
ES1000-2 (Tyco Elec.
P
24 8 G 18A
Raychem) or equivalent GNWH 24 9 G 19A
RDWH 24 10 Z3 20A
D Power cylinder
BKWH
ard
WH
24 11 Z3 21A
Harness, Point "a", B RDWH
50
A control panel
24 12 B 22A 20F 2
21L 2
BKWH
See note 4 Point "a", C
P1.25 See note 4 RDBK 24 1 A 3B
200 200 RDWH
RDGN
24 5 D 20G AMP 174984-2
24 2 A 1B
BKWH 24 6 21H 1 2 3 4 Water proof
Point "a"
Stopper
WH 24
3 5 6 7 8 CAP 8P
w.p m
7 A 22B
WHGN 24 4 Z3 6C
GNWH 24
Point "a" Point “b” See note 7
8 Z3 5C
B Harness, mast
Point "a"
To C
To C
See note 7 See note 4,5
To Z1 RDWH RDWH
dfw
To D
To A RDWH
BKWH
WHBK
18
RDWH
ww o To Z3 RDWH To Z2
To A YEBK
18
YEBK To I2
+
To I1 YEBK
cuC
To A BKWH BKWH To D
* Optional equipment RDWH To Z3 BKWH BKWH To B
RDWH
BKWH
2 Point "a" 20E * Optional equipment
To D
To A
Z1 BKWH BKWH
Z2
20D Point "a" 2 19 2 Point "a", I2 21I
Head guard (Right) 21E I1 2
BKWH
YEBU
To H
To I1 BKWH BKWH To Z2
To K2
WHBU
WHYE
2 A 30B Head guard (Left)
33B A 2 2 A 31B
WHRD 2 A 32B
AMP 172130-1 AMP 172130-1

4B Point "a" 1 26
YEBK WHBU 24 1 A 13B 24B K1 1 24
BUBK YEBK 26 1 Point "a" 4C
1 Plug BKWH BUBK BKWH BKWH Plug 1
2P 21D 2 26 24 2 K2 24A 21G Point "a" 2 24 26 2 Z2,J2 21J 2P
2 WH Point "a", Z1 WH 2
I1 Head guard (Right)

AMP 174352-2 AMP 174352-2 I2 Head guard (Left)
Water proof Water proof See note 4,6
See note 4,6 2 1
Plug 2P Plug 2P
2 1
AMP 174352-2 Slack of chain Slack of chain AMP 174352-2

Water proof 12B A 1 24
YERD K1 detector (Right) K2 detector (Left) BKWH 24 1 I2 21K Water proof
Do
2 1
Plug 2P YEBK YEBK 2 1
25A J2 2 24 24 2 J1 25B Plug 2P
See note 4,6 See note 4,6
J2 Safety guard (Left)

J1 Safety guard (Right) See note 4,6
See note 4,6
RB/RBC-70 Table harness 3- 9.

54000-75894-1E
61
AMP 174982-2 AMP 174984-2
4 3 2 1 8P 8P 1 2 3 4
8 7 6 5 5 6 7 8
Cap Cap
Do
Water proof Water proof
AMP 174257-2 AMP 174663-2

cu C
2 1 4P 12P 1 2 3 4 5 6
4 3 7 8 9 10 11 12
ww
Cap Cap
E0000-14681-0E
AMP 174352-2 AMP 174259-2
w.p om
2 1
2P 4P 1 2
Cap Cap 3 4
Water proof
dfw P
Water proof
1
iza D
1
<Note>
1
1
r F 1. Terminal symbol
AMP 174657-2
d.c
T
Harness, mast : P mast

1
1 10P
1 2 3 4 5
1 Cap 6 7 8 9 10
om ri
1
Water proof
a l
Wiring (Diagrams) 3
RB/RBC-70 Mast harness 3-10.

3-10-1.
62
63
AMP 174982-2 AMP 174984-2
4 3 2 1 8P 8P 1 2 3 4
8 7 6 5 5 6 7 8
Plug Cap
Do
3 Wiring (Diagrams)
AMP 174982-2 AMP 174984-2
4 3 2 1 8P 8P 1 2 3 4
8 7 6 5 5 6 7 8
Plug Cap
cu
ww C AMP 174257-2
AMP 174357-2
3P 3 2 1
AMP 174663-2
Plug 12P 1 2 3 4 5 6
2 1 4P
Cap 7 8 9 10 11 12
4 3
E0000-14701-0E
Plug Water proof
AMP 174352-2 AMP 174657-2 Water proof
Water proof
w.p om
2 1
2P 10P 1 2 3 4 5
AMP 174352-2
6 7 8 9 10
Plug Cap
2P AMP 174259-2
Water proof
1
1
Water proof
dfw P 2 1
Plug
Water proof
4P
Cap
1 2
3 4
1
AMP 174352-2
1
1
iza D
1
Water proof
2 1
2P 1
<Note>
r F Plug 1
Water proof
1. Terminal symbol
d.c
T
Harness, mast : M mast

om ri
a l

3-10-2.
Pay attention to
the pin layout
Pay attention to
the pin layout Stopper 1 1 2 3 4 5 6
7 8 9 10 11 12
Stopper 7
AMP 174257-2
4
RD Stopper 2
1
BK Stopper 8 AMP 174663-2
2 1 4P 3 4
4 3 WH
Do
Plug 2 4 Stopper 3
4
YE Stopper 9 12P
4
Water proof RD 4 4 CAP
AMP 174352-2
BK 4 10
cu YE 4 5
BN Water proof
2P 1 4 WH 4
2 1 11
Plug
Water proof
2 4
GN
ww C BN
GN
4
4
6
12
1
BK
1 2
WH 3 4
E0000-12282-0E
1
1
RD AMP 174259-2
w.p om
1
GN BK 4 1
WH 4 3 4P
RD 4
dfw P GN 4
2
4
CAP
Water proof
iza D
r F d.c T
Note) All pin layout shows the view from terminal insert side.
Harness, mast (3) : P mast

om ri
a l
Wiring (Diagrams) 3

3-10-3.
64
65
Note) All pin layout shows the view from terminal insert side.
Do
3 Wiring (Diagrams)
Brown
4 1
Yellow 1 2 3 4 5
4
cu 6
6 7 8 9 10
Stopper 2
AMP 174352-2
ww C VCTF0.75mm 2 6P
Stopper 7
Stopper 3
Stopper 8
AMP 174657-2
Black
4 4 10P
Brown White
4 4
E0000-12331-0E
2 1 2P 1 9 CAP
Plug Yellow Red
2 4 4 5
w.p om
Green
4 10
Water proof
Water proof
1
dfw
Black
White
P
Red
1
Green
iza D
1
r F
d.c T
Harness, mast (4) : M mast

om ri
a l

3-10-4.
4 3 2 1
8 7 6 5 1 2 3 4
5 6 7 8
24
(1) (1) 24
1 1
AMP 174982-2 (2) (2) AMP 174984-2
2 24 24 2
Do
3 Stopper Stopper 3
24
(3) (3) 24
8P 4 4 8P
24
(4) (4) 24
Plug 5 5 Cap
24
(5) (5) 24
6 6
cu 7 24
(6) (6) 24 7
Water proof (7) Enter “ETFE0.5mm 2, 0.3mm 2 ” (7) Water proof
8 24 24 8
into “hose, H.P.”
ww C
E0000-14852-0E
w.p om
<Note>
dfw P
2. When using the lead wires of same color, mark the number mentioned in ( ).
3. Prevent water infiltration at both ends of the hose by rolling vinyl tape as shown
in the figure below (left side).
iza D
4. Seal by the silicone adhesive or the hot melt on the electric wire drawer part of
r F
the connector as shown in the figure below (right side).
Seal the oblique line part.
To prevent water infiltration, roll
the black vinyl tape with half-lap. Disposal for the diameter of Housing
electric wire is smaller than
d.c
Harness, mast (n) : Std

T
the fit size of the seal
Housing
om ri
a l
Wiring (Diagrams) 3

3-10-5.
66
67
4 3 2 1
8 7 6 5 1 2 3 4
5 6 7 8
4
White (1) White (1) 4
1 1
AMP 174982-2 Black (2) Black (2) AMP 174984-2
2 4 4 2
3 Stopper Stopper 3
Do
3 Wiring (Diagrams)
4
White# (4) White# (4) 4
8P 4 4 8P
4
Red (5) Red (5) 4
Plug 5 5 Cap
4
Blue (6) Blue (6) 4
6 6
Brown (7) Brown (7)
cu
Water proof
7 4 4 7
Water proof
4
Black# (8) Enter “ETFE0.5mm 2, 0.3mm 2 ” Black# (8)
8 4 8
into “hose, H.P.”
ww C
E0000-14862-0E
w.p om
<Note>
dfw
P
2. When using the lead wires of same color, mark the number mentioned in ( ).
3. Prevent water infiltration at both ends of the hose by rolling vinyl tape as shown
in the figure below (left side).
iza D
4. Seal by the silicone adhesive or the hot melt on the electric wire drawer part of
the connector as shown in the figure below (right side).
To prevent water infiltration, roll
r F
Seal the oblique line part.
Disposal for the diameter of
the black vinyl tape with half-lap. Housing
electric wire is smaller than
d.c
the fit size of the seal
T
Housing
Harness, mast (n) :ACS/RP

om ri
a l

3-10-6.
Do
To primary
transformer side
12P To body harness
Connector Fuse Contactor
AC BK BK 12 11
3 WH 14 13 Primary
cu Harness, BC WH
transformer
200V RD RD 16 15 side
EPS controller
Relay Line Connector
RD
WH
GN
Printed board comp. X No. CN Pin No.
RD
ww C Battery +
RD
RDYE1
Mctt
RDGN
BUYE
To the
MC 1 2 Mctt.
Key switch
RD RD
3 3 RD1 RDYE
Battery + RY 1 14 Power supply
54000-60270-3E
WH Swictch and LED
WH WH Auto BUWH #
3 3 AUT 1 7 Auto
7P
w.p om
BURD #
LED1 1 3 LED1
Equalizing BNWH #
BK BK EQU 1 19 Equalizing
3 3 BNRD #
LED2 1 15 LED2
Fuse STP 1 8 Rapid
RD
WH
7
7
11
13
12
14
7
7
RD
GN
dfw
Socket
P <Note>
1. Lead wires (Not any mentioned)
BK #
System wiring
LED3
VN
1
1
4
13
LED3
Switch GND
BK BK : AVS/AVSS 0.5mm 2
7 15 16 7
: AVS/AVSS 0.3mm 2
RD
iza D
19 20
: KIV 0.75mm 2
: KIV 2mm 2
Magnet switch
A B WH
r F 2. Terminals
7 : Receptacle AMP41729
3. Connect wires to the socket as shown in the
below figure.
7
7
n Wire Screw
: Pressed terminal JST
Eyelet
BK 3. Install and ground the ground terminal of socket(Green)
d.c
RDYE
BUYE
to the panel as shown in the below figure.
LY
Relay
T
After assembling, confirm enduring conductance between
the ground terminal and the charger panel.
Panel
Terminal
a. Length of the bare part of the line : 10 mm
RB10/15-70: 3 phase,200V
RB/RBC-70 BC wiring
<GN> Green b.The tightening torque for the screws : 0.98 - 1.18Nm
4 Plug
om ri
Pressed terminal
a Install with spring washer and with nut
(Not use “Washer, plane” and “Washer, lock”.)
l
Wiring (Diagrams) 3
3-11.
3-11-1.
68
69
Reference:
Harness mark/color
Red RD
Black BK
Green GN
Yellow YE
White WH
Brown BN
Blue BU RD Fuse
Gray GY Connector Fuse Contactor
Pink PK RD RD AC BK BK 12 11
3 3 Primary
Orange OG 3 transformer
WH WH 14 13
WH side
Ex) BKWH (=Black/White) 200V RD RD 16 15
Do
EPS controller
3 Wiring (Diagrams)
Black colored harness with White line. WH WH
WH
RD
Relay Line Connector
3 3
GN
X No. CN Pin No.
RDYE1 BUYE
BK BK Mctt MC 1 2 Mctt.
3 3 RD
Battery + RDGN
To key switch
White line
Magnet switch
RD1 RDYE
Battery + RY 1 14 Power supply
BK
RD
WH
12P To body harness Switch and LED
cuC
7 7 7 Auto BUWH#
Black color AUT 1 7 Auto
RDYE BURD#
11 13 15 19 A 7 LED1 1 3 LED1
Equalizing BNWH#
BUYE EQU 1 19
ww o
Equalizing
12 14 16 20 B 7
BNRD#
LED2 1 15 LED2
7 7 7
54000-61110-3E
Printed board STP 1 8 Rapid
BK
RD
GN
comp. LED3 1 4 LED3
w.p m
BK#
VN 1 13 Switch GND
To primary <Note>
transformer side 1. Lead wires (Not any mentioned) System wiring
: AVS/AVSS 0.5mm 2
: AVS/AVSS 0.3mm 2
dfw P
7P : KIV 0.75mm 2
: KIV 2mm 2
2. Terminals 3. Connect wires to the socket as shown in the
7 : Receptacle AMP41729 below figure.
Socket
n Wire Screw
: Pressed terminal JST
LY Eyelet
iza D
relay 3. Install and ground the ground terminal of socket(Green)
RD to the panel as shown in the below figure.
Terminal
After assembling, confirm enduring conductance between
the ground terminal and the charger panel.
WH Panel a. Length of the bare part of the line : 10 mm
rd. F
Green b.The tightening torque for the screws : 0.98 - 1.18Nm
Plug
BK
GN
Pressed terminal
RB/RBC-70 BC wiring
com Tr
4
Install with spring washer and with nut
RBC7/9/10-70: 3 phase,200V
(Not use “Washer, plane” and “Washer, lock”.)
ia l
3-11.
3-11-2.
Reference: 3B RDGN
Harness mark/color
D,F
Red RD
Black BK 17B
20B 4B
C Fuse RDYE1 NC RDYE
Green GN
D,F
Yellow YE 1B NO 2B
White WH 18B 4 RD RD1
C
Brown BN
D
Blue BU
Gray GY 19B 4
18C 17C
RD
WH RD
Do
RD
Pink PK E
Orange OG 13A
4
WH
E
WH
Ex) BKWH (=Black/White) Wiring of relay
Black colored harness with White line. 4 14A
BK
E
cu 4 15A
RD
4
RD
WH
7
White line
C WH
BK
RDYE1
7
7
C 17A
C 19A
C 18A
D Contactor
BK
7
ww
F 20A
BUYE 7 A 5B
Black color
54000-60263-0E
w.p om
RD 16 A 1B
RD1 16 A 2B
RDGN 16 A 3B
RD 16 C 17C F LY Relay
WH 16 C 18C
RDYE 16 A 4B See note 5
A RDYE1 16 D 20B
LY relay should be
clamped here
dfw P
RDGN
BUWH#
BNWH#
BURD#
BUYE
BNRD#
BK#
BUWH#
BURD#
BK#
RD
RD1
RDYE
BNWH#
BNRD#
Should be clamped
25 25 25 25 25 25 25 25 25 25 10 10 10 10 10
iza D
1 2 3 4 5 6 8 10 11 7 9 12 1 2 3 5 4 6 7
F F B B B <Note>
A A
F
2A
F
4A
D
6A
B
7A
B
12A
A
8B
A
9B
A
r F 1. Lead wire
: AVSS0.5mm 2
1A 3A 5A 8A 9A
6B 7B 12B
RD
: AVSS0.3mm 2
AMP 040 series
d.c
2
Multi lock connector (Mark I)
174058-2
(12P)
7P
WH
BK
GN
GN
T : KIV0.75mm
: KIV2mm
2
RB10/15-70: 3 phase,200V
7 6 5 4 3 2 1 2. All pin layout shows the view from terminal insert side.
3. About the wiring of LY relay, see the upper figure.
1 2 3 4 5 6 4
om ri
RB/RBC-70 BC harness
7 8 9 10 11 12 B Switch and LED 4. At mentioned places, the coating should be teared off
See note 4
A Harness, body
C
13B
C
14B
C
15C
E
16B
E
16A
a 10mm from the end of the electric wire.
5. Clamp the clamp of LY relay in order the relay terminal
to face to arrow A direction.
l
E Socket
Wiring (Diagrams) 3
3-12.
3-12-1.
70
71
3B RDGN
Reference:
Harness mark/color 20B 4B
Red RD RDYE1 NC RDYE
Black BK
1B NO 2B
Green GN C Fuse D Contactor RD RD1
Yellow YE Should be clamped C
White WH E
Brown BN 18C 17C
Blue BU 13A WH RD
RD
Gray GY 17A F,C 7
E RD
Pink PK 17B D 4
Orange OG 4 14A
E
WH Wiring of relay
18A F,C 7
Ex) BKWH (=Black/White) WH
18B D 4
3 Wiring (Diagrams)
Black colored harness with White line. 4 15A
RD
BK 19A C 7
4 19B D 4
WH
BK
20A F 7
RDYE1 E Socket
5B A 7
BUYE
White line
GN
Should be clamped 4 E 16A
Black color GN
E 16B
BK
C 15B
WH
C 14B
54000-61022-0E
A RD
C 13B
See note 4
WH
RD
RDGN
RD1
RD
RDYE1
RDYE
RDGN
BUWH#
BUYE
BNWH#
BURD#
BNRD#
BK#
RD
RD1
RDYE
25 25 25 25 25 25 25 25 25 25 16 16 16 16 16 16 16
1 2 3 4 5 6 8 10 11 7 9 12
F F B B B A D A
BUWH#
BURD#
BK#
BNWH#
BNRD#
2A 4A 6A 7A 12A 4B 17C 2B
<Note>
10 10 10 10 10 1. Lead wire
F F D B B D D A A
1 2 3 5 4 6 7
1A 3A 5A 8A 9A 20B 18C 3B 1B : AVSS0.5mm 2
A A
AMP 040 series : AVSS0.3mm 2
Multi lock connector (Mark I) F LY Relay 8B 9B 2
174058-2 A A A
: KIV0.75mm
See note 5 2
6B 7B 12B : KIV2mm
(12P)
7P 2. All pin layout shows the view from terminal insert side.
1 2 3 4 5 6
3. About the wiring of LY relay, see the upper figure.
7 8 9 10 11 12 4. At mentioned places, the coating should be teared off
7 6 5 4 3 2 1
10mm from the end of the electric wire.
5. Clamp the clamp of LY relay in order the relay terminal
A Harness, body
B Switch and LED to face to arrow A direction.
RBC7/9/10-70: 3 phase,200V
RB/RBC-70 BC harness
3-12.
3-12-2.
a l
om ri
T
r F
iza D
d.c
P
w.p om
dfw
cu
wwC
Do
Reproduction prohibited
First printing : November 2006
Issued by : Nippon Yusoki Co., Ltd

Edited by : Overseas division
Nippon Yusoki Co., Ltd.

SM RB 70

Uploaded by

Copyright:

Available Formats

SM RB 70

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SM RB 70

Uploaded by

Copyright:

Available Formats

INTRODUCTION

Most accident happens due to the disregard of basic safety rules or

Performing maintenance and repair without adequate knowledge may

It is not possible to cover all the possible cases of accidents in

Indicates a potentially hazardous situation which, if not avoided,

Indicates a potentially hazardous situation which, if not avoided,

Indicates a potentially hazardous situation which, if not avoided, may

Indicates suggestions, tips and hints related to the safety of a

1. Personnel this "SERVICE MANUAL" is aimed at:

SAFETY WORK 1 3 .LOAD WHEEL 29

5d-2-4.Lift cylinder - 6-3-8.Side roller - adjustment 79

5d-3.Inspection and adjustment ......................... 64 6-3-10.Shaft, fork - inspection 81

5d-3-1.Cylinder - inspection 64 6-3-11.Rack sensor(RBC) - adjustment 82

5d-4-1.Cylinder - troubleshooting 65 6-3-14Adjustment of the slack of chain detector 84

6-4-1.Mast, lift table, fork - troubleshooting 85

7 . LIFT TABLE ASS'Y 86

F11-3-5. Adjustment of the pallet lock 154

10d-4-1. Power voltage - check 138

10d-4-3. Switching the voltage tap 139 12 .SERVICE DATA 157

10d-4-4. Replacement of link fuse 139

10e. BATTERY 140

10e-1.Disassembly and reassembly ................ 140

10e-2.Inspection and adjustment ..................... 141

10f. LIFT HEIGHT ENCODER 143

CAUTION Facilities with adequate space and level

CAUTION SAFE AND WELL-LIGHTED AREA

CAUTION PROPER ARRANGEMENT

CAUTION The worker should wear a hat, work clothes, and

WARNING  When hoisting a forklift truck or a heavy

WARNING After lifting or jacking up a forklift truck, support

WARNING When working under a forklift truck, use a pit or

CAUTION  When replacing any parts, be sure to use

CAUTION When replenishing battery electrolyte, be sure to

shooting electrical operations.

NOTE Record the places of lead wire connection when

CAUTION CHARGING BATTERY

charging. Do not allow batteries in the vicinity of

CAUTION  Diluted sulfuric acid is used as the battery's

CAUTION When removing the hydraulic pipes, cap them

*This illustration shows RB10, Drive front type.

No. Parts No. Parts Name Q'ty Notes

(2) 24700-06980 Plate, Warning 1 Wear safety belt

2. DO NOT use equipment that is liable to

3. Open the battery cover while charging battery.

GASES produced by this battery can be explosive.

BRAKE PEDAL HOSE PULLEY

MAST LIFT CHAIN

OIL FILTER BRAKE

STEERING GEAR DRIVE ASS'Y

: LUBRICATION CG : CHASSIS GREASE FO : FORK OIL

注 DO NOT leave the battery

3. Model name and serial numbers

BATTERY WEIGHT MIN. kg

B : Large capacity battery equipped

Maximum lifting height [cm]

Mast type M : Three stage full free lift (triplex) mast

CS : Cold storage use for -35

1 Serial No. of a truck Stamped on the name plate.

2 Serial No. of a chassis Stamped on the battery compartment.