Bra14e1 02

Sec00_AR14_E.
fm 1 ページ２００８年３月３日月曜日午後６時２８分
BRA14E1-02
ELECTRIC REACH TRUCK
AR50 Series
FB10RL(F)/13RL(F)/15RL(F)/18RL(F)-14 M245-140001 and up

FB10RW/13RW/15RW-14 M245-140001 and up
AR-14_E.book 2 ページ２００７年１０月３日水曜日午後４時５９分
PRECAUTIONS WHEN PERFORMING THE SERVICE WORK
Always pay attention to “Safety” before starting any work — this is important.
Never attempt any work where danger to yourself or to other persons.
Whenever work requiring safety precautions are described in this manual, a flag mark
inserted, always make double sure that safety measures are taken.
Other unmarked work, should always be performed after studying and using your
common sense to prevent accidents.
DESCRIPTION OF THE SYMBOLS
The symbols described below are used in this manual for convenience and better understanding.
Symbol Item Description
Safety Special safety precautions are needed to perform the work.
Note Special technical precautions are needed to perform the work
Tightening torque Fastening parts that require specified tightening force when assembling.
Weight Weight of parts or systems
Places to be coated with adhesives, etc. when assembling

Coat
Filling Oil filling and its amount
00-2 AR50 Series

SECTION INDEX
00. FOREWORD
10. GENERAL AND SPECIFICATIONS
20. TESTING AND ADJUSTING
30. REMOVAL AND INSTALLATION
40. DISASSEMBLY AND ASSEMBLY
50. MAINTENANCE STANDARD
60. STRUCTURE AND FUNCTION
70. TROUBLESHOOTING
80. YEARLY INSPECTION CRITERIA
90. CONVERSION TABLE
APPENDIX
AR50 Series 00-3

10. GENERAL AND SPECIFICATIONS

SPECIFICATION.........................................................................10-2
SAFETY ITEMS FOR MAINTENANCE ......................................10-7
STANDARD TIGHTENING TORQUE FOR BOLTS ..................10-14
STANDARD TIGHTENING TORQUE FOR PIPE JOINTS .......10-15
HOW TO USE LOCTITE...........................................................10-16
AR50 Series 10-1

SPECIFICATION GENERAL AND SPECIFICATIONS
SPECIFICATION
1.Main specification
1.2 Model Manufacturer's Designation FB10RL-14, FB10RLF-14 FB13RL-14, FB13RLF-14
1.3 Power Type Electric, Diesel, Gasoline, LPG, Cable Electric Electric
Characteristics
1.4 Operation Type Pedestrian, Driver Standing, Sitting, Order Picking Standing Standing
1.5 Rated Capacity Q1 Rated Capacity kg 1000 1250
1.6 Load Center c Load Center mm 500 500
1.6.1 Alternative Capacity Q2 Capacity@600mm Load Center kg 870 1080
1.8 Load Distance x Front Axle Center to Fork Face mm 175 175
1.9 Wheelbase y mm 1110 1250
2.1 Service Weight Including Min. Capacity Battery, see line 6.5 kg 2020 2035
2.4 Front kg 2555 2855
Loaded
2.4.1 Axle Loading Mast/Forks Rear kg 465 430
2.4.2 Extended Front kg 905 890
Weight
Unloaded
2.4.3 Rear kg 1115 1145
2.5 Front kg 1940 2020
Loaded
2.5.2 Retracted Front kg 690 635
Unloaded
2.5.3 Rear kg 1330 1400
3.1 Tyre Type Solid Solid
3.2 Front φ 260 x 120 φ 260 x 120
3.3 Tyre Size Rear φ 360 x 180 φ 360 x 180
Tyre
3.4 Additional Wheels φ 127 x 90 φ 127 x 90

3.5 Number of Wheel Front/Rear(*=driven) 2/1*+2 2/1*+2
3.6 Tread, Front b10 mm 975 975
3.7 Tread, Rear b11 mm – –
4.1 Tilting Angle α/β Forward/Backward degree 3/5 3/5
4.2 Mast Height, Lowered h1 with Std. Mast mm 1995 1995
4.3 Std. Free Lift h2 with Std. Mast, from Ground mm 105 105
4.4 Std. Lift Height h3 with Std. Mast, from Ground mm 3000 3000
4.5 Mast Height, Extended h4 with Std. Mast mm 3935 3935
4.7 Height, Overhead Guard h6 mm 2250 2250
4.19 Length, with Std. Forks l1 mm 1905 1905
4.21 Width, at Tyre b1 mm 1095 1095
Dimenshions
4.22 Forks s/e/l Thickness/Width/Length mm 35x100x850 35x100x850

4.23 Fork Carriage Class ISO 2328, Type A/B/no Pin Mount Pin Mount
4.24 Width, Fork Carriage b3 mm 750 750
4.26 Width, between Reach Legs b4 mm 752 752
4.28 Reach Travel l4 mm 440 580
4.31 m1 under the Mast mm 75 75
Ground Clearance
4.32 m2 at the center of Wheelbase mm 80 80
4.33 Right Angle Stacking Ast with L1000 x W1200 pallet mm 2275 2310
4.34 Aisle Ast with L1200 x W800 pallet mm 2340 2355
4.35.1 Turning Radius Wa mm 1325 1465
4.35.2 Wb mm 670 555
4.37 Length, without Forks /7 1470 1610
5.1 Travel Speed (FWD) Loaded/Unloaded km/h 9.5/10.5 9.5/10.5
5.2 Lifting Speed Loaded/Unloaded mm/s 350/540 320/540
5.3 Lowering Speed Loaded/Unloaded mm/s 500/550 460/550
Performance
5.4 Reach Speed Loaded/Unloaded mm/s 300/300 300/300

5.6 Max. Drawbar Pull 3min rating N 5880 5880
5.8 Max. Gradeability Unloaded 1.5km/h, 3min rating % 32 31
5.10 Service Brake Operation/Control Mechanical, Disc Mechanical, Disc
5.11 Parking Brake Operation/Control Mechanical, Disc Mechanical, Disc
5.12 Steering Operation/Control Electric Power Steering Electric Power Steering
6.1 Drive Motor (AC) 60min rating kW 4.5 4.5
6.2 Pump Motor (AC) 5min rating kW 9 9.0
6.2.1 PS Motor (DC) 60min rating kW 0.3 0.3
Drive
6.4 Battery Voltage V 48 48

6.4.1 Battery Capacity, Min. Ah/5-hour 201 201
6.4.2 Battery Capacity, Max. Ah/5-hour 240 240
6.5 Battery Weight, Min. Capacity kg 365 365
8.1 Drive Motor Control MOS-FET inverter MOS-FET inverter
8.1.1 Pump Motor Control MOS-FET inverter MOS-FET inverter
Others
8.1.2 PS Motor Control MOS-FET chopper MOS-FET chopper

8.2 Relief Pressure for Attachment bar 167 167
8.2.1 Hydraulic Tank Capacity Ltr 16 16
4.33 and 4.34 Values are not including a cliearance. See Aisle width section for detail.
10-2 AR50 Series

GENERAL AND SPECIFICATIONS SPECIFICATION
1.2 Model Manufacturer's Designation FB15RL-14, FB15RLF-14 FB18RL-14, FB18RLF-14

Characteristics
2.4 Front kg 3245 3620
Loaded
Weight
Unloaded
2.4.3 Rear kg 1265 1330
2.5 Front kg 2360 2465
Loaded
Unloaded
2.5.3 Rear kg 1505 1610
3.2 Front φ 254 x 114 φ 254 x 120
Tyre

3.7 Tread, Rear b11 mm - -
Dimenshions

Ground Clearance
4.35.2 Wb mm 555 555
Performance

6.2 Pump Motor (AC) 5min rating kW 9.0 9.0
Drive

Others

4.33 and 4.34 Values are not including a cliearance. See Aisle width section for detail
AR50 Series 10-3

1.2 Model Manufacturer's Designation FB10RW-14 FB13RW-14

Characteristics
2.4 Front kg 2560 2860
Loaded
Weight
Unloaded
2.4.3 Rear kg 1110 1140
2.5 Front kg 1945 2025
Loaded
Unloaded
2.5.3 Rear kg 1325 1395
3.2 Front φ 260 x 120 φ 260 x 120
Tyre

3.7 Tread, Rear b11 mm - -
Dimenshions

Ground Clearance
4.35.2 Wb mm 670 555
Performance

6.2 Pump Motor (AC) 5min rating kW 9.0 9.0
Drive

Others

10-4 AR50 Series

GENERAL AND SPECIFICATIONS SPECIFICATION
1.2 Model Manufacturer's Designation FB15RW-14

1.3 Power Type Electric, Diesel, Gasoline, LPG, Cable Electric
Characteristics
1.4 Operation Type Pedestrian, Driver Standing, Sitting, Order Picking Standing
1.5 Rated Capacity Q1 Rated Capacity kg 1500
1.6 Load Center c Load Center mm 500
1.6.1 Alternative Capacity Q2 Capacity@600mm Load Center kg 1300
1.8 Load Distance x Front Axle Center to Fork Face mm 175
1.9 Wheelbase y mm 1350
2.1 Service Weight Including Min. Capacity Battery, see line 6.5 kg 2220
2.4 Front kg 3250
Loaded
2.4.1 Axle Loading Mast/Forks Rear kg 470
2.4.2 Extended Front kg 955
Weight
Unloaded
2.4.3 Rear kg 1265
2.5 Front kg 2365
Loaded
2.5.1 Axle Loading Mast/Forks Rear kg 1355
2.5.2 Retracted Front kg 720
Unloaded
2.5.3 Rear kg 1500
3.1 Tyre Type Solid
3.2 Front φ 254 x 114
3.3 Tyre Size Rear φ 330 x 145
Tyre
3.4 Additional Wheels φ 150 x 80

3.5 Number of Wheel Front/Rear(*=driven) 2/1*+2
3.6 Tread, Front b10 mm 975
3.7 Tread, Rear b11 mm -
4.1 Tilting Angle α/β Forward/Backward degree 3/5
4.2 Mast Height, Lowered h1 with Std. Mast mm 1995
4.3 Std. Free Lift h2 with Std. Mast, from Ground mm 105
4.4 Std. Lift Height h3 with Std. Mast, from Ground mm 3000
4.5 Mast Height, Extended h4 with Std. Mast mm 3935
4.7 Height, Overhead Guard h6 mm 2250
4.19 Length, with Std. Forks l1 mm 2005
4.21 Width, at Tyre b1 mm 1080
Dimenshions
4.22 Forks s/e/l Thickness/Width/Length mm 35x100x850

4.23 Fork Carriage Class ISO 2328, Type A/B/no Pin Mount
4.24 Width, Fork Carriage b3 mm 750
4.26 Width, between Reach Legs b4 mm 752
4.28 Reach Travel l4 mm 580
4.31 m1 under the Mast mm 75
Ground Clearance
4.32 m2 at the center of Wheelbase mm 80
4.33 Right Angle Stacking Ast with L1000 x W1200 pallet mm 2405
4.34 Aisle Ast with L1200 x W800 pallet mm 2450
4.35.1 Turning Radius Wa mm 1560
4.35.2 Wb mm 555
4.37 Length, without Forks /7 1710
5.1 Travel Speed (FWD) Loaded/Unloaded km/h 9.5/10.5
5.2 Lifting Speed Loaded/Unloaded mm/s 320/540
5.3 Lowering Speed Loaded/Unloaded mm/s 460/550
Performance
5.4 Reach Speed Loaded/Unloaded mm/s 300/300

5.6 Max. Drawbar Pull 3min rating N 6080
5.8 Max. Gradeability Unloaded 1.5km/h, 3min rating % 29
5.10 Service Brake Operation/Control Mechanical, Disc
5.11 Parking Brake Operation/Control Mechanical, Disc
5.12 Steering Operation/Control Electric Power Steering
6.1 Drive Motor (AC) 60min rating kW 4.5
6.2 Pump Motor (AC) 5min rating kW 9.0
6.2.1 PS Motor (DC) 60min rating kW 0.3
Drive
6.4 Battery Voltage V 48

6.4.1 Battery Capacity, Min. Ah/5-hour 280
6.4.2 Battery Capacity, Max. Ah/5-hour 390
6.5 Battery Weight, Min. Capacity kg 495
8.1 Drive Motor Control MOS-FET inverter
8.1.1 Pump Motor Control MOS-FET inverter
Others
8.1.2 PS Motor Control MOS-FET chopper

8.2 Relief Pressure for Attachment bar 167
8.2.1 Hydraulic Tank Capacity Ltr 16
AR50 Series 10-5

2. Allowable Load Table
Kg FB18RL Kg Kg
1800 FB15RL 1800 FB15RS 1800 FB15RW/RP
1500
FB14RL 1500
FB13RS 1500
FB13RW/RP
FB13RL FB10RS FB10RW/RP
1200 FB10RL 1200 FB09RS 1200
900 900 900
600 600 600
400 mm 400 mm 400 mm

500 600 800 1000 1200 500 600 800 1000 1200 500 600 800 1000 1200
3. Dimension Diagram
B3
B1
Wa
L4
h1
h4
h3
h1
h2
M2
L1
10-6 AR50 Series

GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE
SAFETY ITEMS FOR MAINTENANCE

FOR SAFETY OPERATION
USE QUALIFIED PERSONNEL FOR INSPECTION AND MAINTENANCE
• Only persons authorized by the owner or operator of the equipment and having proper certification (local or national)
may carry out inspection, maintenance and repairs of the lift truck.
If inspection, maintenance, or repair work is carried out incorrectly, it is very dangerous.
MAINTENANCE LOCATION
• When carrying out inspection and maintenance, use a level, dry, dust-free area.
• If the work is carried out inside a building, make sure that there is ample ventilation.
• Keep the maintenance work shop neat and implement the work safely.
PRECAUTIONS FOR INSPECTION AND MAINTENANCE
• To be prepared in the event of a fire, have a fire extinguisher nearby and make sure that you know how to use it.
• Before carrying out inspection, lower the forks to the ground and stop the machine.
• Before starting the inspection, turn OFF the key switch and pull it out.
• Keep turning OFF the key switch except when needed.
• Place the card showing ÅgUnder inspectionÅh on the operatorÅfs seat or the operation panel.
• Keep plugging out the battery plug except when needed.
• Place the directional lever, speed lever, and work equipment control levers in neutral.
• Place the chocks under the wheels to fix them.
AR50 Series 10-7

SAFETY ITEMS FOR MAINTENANCE GENERAL AND SPECIFICATIONS
PRECAUTIONS WHEN CARRYING OUT INSPECTION AND MAINTENANCE
• Wipe off any oil or grease. Immediately wipe up any oil that has leaked.
• If the lift truck is dirty, it becomes difficult or impossible to find cracks or other problems. Always clean the lift truck
before starting inspection.
• Do not smoke or allow any flame to exist under any circumstances.
• Do not use any cloth which is soaked in fuel, oil, or grease. There is danger that it may catch fire.
• Wear suitable clothes for the job.
• When working on top of the lift truck, be careful not to fall.
• Do not put your feet under the forks.
• When opening or closing the floor plate or engine hood, be careful not to get your hands or body caught.
• When carrying out inspection with the forks raised, insert a stand under the inner mast to prevent the forks and mast
from dropping.
• Before performing the inspection work in between the mast and the body, ensure to disconnect the battery plug.
Otherwise if the reach mechanism accidentally moves, you will be trapped, resulting in injury or death.
• When carrying out job with another worker, decide who is the leader and carry out the job in accordance with
instructions from that person.
• After repairing, make sure that the trouble has been corrected by performing a trial run.
• During the trial run, start/operate the lift truck carefully because it is possible that the trouble has not been fully
corrected or that defective parts have not been removed.
WARNING CLOTHING AND PERSONAL PROTECTIVE ITEMS
• Avoid loose clothing, jewelry, and loose long hear.

They can catch control or in moving parts and cause serious injury or
death.
• Always wear a hard hat and safety boots.
• Depending on the working conditions, wear other safety equipment in
addition to the hard hat and safety boots.
USE SUITABLE TOOLS
• Always use tools that are suited for inspection and maintenance.
It is extremely dangerous to use broken tools or tools designed for another
purpose.
REPLACE SAFETY CRITICAL PARTS PERIODICALLY
• Even if no abnormality is found, always replace safety critical parts periodically.

As time passes, these parts deteriorate and may cause fire of failure in the work equipment system.
• However, if these parts show any abnormality before the replacement interval has passed, they should be repaired or
replaced immediately.
10-8 AR50 Series

PRECAUTIONS WITH HIGH PRESSURE, HIGH TEMPERATURE OIL
• Immediately after using the lift truck, the oil is at high temperature.
Do not drain the oil or replace the filter when the oil is hot. Hot oil
may spurt out and cause burns.
• When carrying out inspection and maintenance, wait for the oil
temperature to go down, and carry out the operation in the order
given in this manual.
• Do not forget that the work equipment circuits are always under
pressure. Do not add oil, drain oil, or carry out maintenance or
inspection before completely releasing the internal pressure.
• If oil is leaking under high pressure from small holes, it is
dangerous if the jet of high-pressure oil hits your skin or eyes.
Always wear safety glasses and thick gloves, and use a piece of
cardboard or a sheet of plywood to check for oil leakage.
• Release the internal pressure before checking the accumulator
piping.
• If you are hit by a jet of high pressure oil, consult a doctor
immediately.
BE CAREFUL NOT TO GET CAUGHT OR FALL
• Never put your hands or feet into the mast structure. There is danger
that you will get caught in moving parts and be seriously injured.
• Do not use the mast as a ladder. If you slip, there is danger that you will
fall.
AR50 Series 10-9

JACKING UP LIFT TRUCK (when checking or replacing tires)
• Do not go under the forklift truck when it is jacked up.

• Check the following before jacking up the lift truck.
1) Check that there is no one on the lift truck.
2) Check that there is no load on the forks.
• When jacking up, stop when the tires come off the ground surface.
Put blocks under both sides of the frame to prevent the lift truck
from coming down.
• Put blocks under any tires contacting the ground to prevent the lift
truck from moving.
LIFTING LIFT TRUCK (when checking tires)
• Lift truck slinging work should be carried out by a qualified person who has completed a course in correct lifting
methods.
• Fit wire ropes to the specified lifting points.
• When lifting the lift truck, check that the wire ropes have ample
strength and are not damaged.
• Block the tires contacting the ground to prevent the lift truck from
moving.
• Insert blocks to prevent the truck from coming down.
• Do not go under the lift truck during the lifting operation.
• If the specified lifting point is the counterweight, check that the
counterweight mounting bolts are tightened to the specified torque
before carrying out the lifting operation. check also that there is no
damage to the lifting portion on the counterweight.
SLINGING VEHICLE (for loading it on trailer, etc.)
• Never sling the vehicle by the head guard.

If the vehicle needs to be slung often, a special sling device is
necessary. In this case, consult your distributor.
• The vehicle shall be slung by a person who has completed a
course of slinging work.
• Install wires to the specified sling parts.
• Use wires which is free of defect and has sufficient strength to sling
the vehicle.
10-10 AR50 Series

BATTERY HAZARD PREVENTION
• Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill electrolyte
on yourself, immediately flush the area with a large quantity of water.
• Battery electrolyte can cause blindness if splashed into the eyes. If electrolyte gets into your eyes, flush them
immediately with large quantities of water and consult a doctor at once.
• If you accidentally drink electrolyte, drink a large quantity of water, or milk mixed with beaten eggwhite or vegetable
oil. Call a doctor or poison prevention center immediately.
• When working with batteries, ALWAYS wear safety glasses or
goggles.
• Batteries generate hydrogen gas. Hydrogen gas is highly
EXPLOSIVE, and is easily ignited with a small spark or flame. Do
not smoke or create any spark near the battery.
• Before working with batteries, stop the engine and turn the starting
switch to the OFF position.
• When removing the battery, remove the cable from the negative
terminal first. When installing the battery, install the cable to the
positive terminal first.
• Avoid short-circuiting the battery terminals through accidental
contact with tools or other metal objects across the terminals.
• Tighten the battery terminals securely. Loose terminals can
generate sparks and lead to an explosion.
• When removing or installing the battery, confirm which is the
positive terminal and negative terminal. Be careful not to
connect the cables to the opposite terminals.
• Tighten the battery caps securely.
• When cleaning the battery, leave the battery caps tightened.
• For drawing out or pushing in the battery, refer to “Chapter 30
Removal/Installation”.
DO NOT PUT METAL OBJECTS ON TOP OF BATTERY
• Never place any metal objects on top of the battery. There is danger that they will cause a short circuit and start a
fire.
AR50 Series 10-11

PRECAUTIONS WHEN CHARGING
• Before recharging, confirm that the electrolyte level is appropriate. If it is lacking, refill the distilled water or pure
water.
• Recharge the battery in a well-ventilated, rain-sheltered (humidity), dust-free and clean place.
• When starting the recharge, if the battery electrolyte temperature is higher than 35 °C, leave the battery in the
shadow and recharge the battery after the temperature drops.
• When the protection fuse in the battery charger blows out, ensure to use our companyÅfs genuine parts.
(For fuse replacement, refer to ÅgChapter 20 Inspection/AdjustmentÅh.
• As the high explosive hydrogen gas is produced from the battery, keep
away the battery from open fire while recharging or after charged.
• If the top surface of battery is dirty, the battery life will be shortened.
Before recharging, clean it with a moistened cloth. If cleaned with a dry
cloth or chemical fiber cloth or dusted with a duster, the static electricity
generated causes the explosion.
• If the incorrectly adjusted voltage tap of power supply is used for a long
period of time, the battery charger may be damaged. Adjust the power
supply tap periodically.
• Use the cable and the wall outlet of power supply at the facility side (building) of which capacity is greater than the
maximum input current of the charger. If the capacity is insufficient, it will cause fire.
• When plugging or unplugging the cord, hold the cable by the plug.
Do not pull the cord. If done so, the cord will be broken.
• The loose plugging the plug in the outlet, the damaged contact terminal or the damaged power cord may heat up,
causing fire. Check them. If damaged, repair it.
• As large current flows when recharging, plug the cord directly in the determined outlet. Do not extend the cord or do
not use the multiple tap.
• As large current flows when recharging, do not plug out the cord directly from the outlet. To stop the recharging, push
the automatic charging button or the uniform charging button of which the charge display lamp lights.
FUSE REPLACEMENT
When replacing the fuse, ensure to perform the procedure below.

1 Set the key switch to OFF.
2 Disconnect the battery plug.
3 Replace the fuse.
WASTE MATERIALS
• Obey appropriate laws and regulations when disposing of harmful

objects such as oil, filters, and batteries.
10-12 AR50 Series

BATTERY REMOVAL/INSTALLATION
• In the state that the mast is completely retracted, press down the battery lock pedal to the lowest position.
• Ensure to perform the battery removal/installation in the unload state.
• Operate while confirming the hose movement.
CAUTION AT DISASSEMBLY/ASSEMBLY
• When disassembling, remember the locations of parts and the direction of shaft. Keep screws and shafts in the
empty box for re-use.
• Use the wooden hammer when removing the bracket or hit lightly evenly with the wooden hammer when installing.
Do not use the metal hammer. If you use the metal hammer, the parts may be cracked.
• Clean the disassembled parts. Check abnormalities. If any part is lacking or broken, replenish or replace it.
• After assembled, confirm that parts are not left and screws are firmly tightened.
CAUTION AT MOTOR DISASSEMBLING
• Handle with care not to damage the parts. Especially, do not stick water, dust or sand to the stator coil and pivot as
well as scar.
• Dust the coil with a dry cloth or soft brush. Do not rub with a hard material or wipe with gasoline, kerosene or solvent.
If used, it damages the insulation.
• Tighten securely the terminals. Insulate the connected parts with the insulation tape.
• For storage of the motor, select a place where it is dry and free from humidity, dust, alkali and other toxic gas.
• Apply the rust preventive to the shaft end and wrap the motor with an oil paper or vinyl cloth.
CAUTION AT MOTOR INSTALLATION
• Wipe out dust on motor installing portions (flange surface, shafts) with a clean cloth and apply the grease if
necessary. Connect it smoothly.
• When connecting, do not push it in forcibly.
• Do not rub or apply force to the wires leading from the motor. Do not carry the motor, holding the wires leading from
the motor. Do not assist when hanging it up. It leads to the serious trouble.
• When hanging up or down the motor, ensure to use the motor hanging bolt.
• After installing the motor, confirm that the shaft rotates when rotated by hand.
AR50 Series 10-13

STANDARD TIGHTENING TORQUE FOR BOLTS GENERAL AND SPECIFICATIONS
STANDARD TIGHTENING TORQUE FOR BOLTS

TIGHTENING TORQUE when using torque wrench or spanner shall be in accordance with Table. This torque shall be
used when TIGHTENING TORQUE of especially narrow range is required.
1. In the case of using impact wrenches or 2. In the case of using torque wrenches
spanners
Unit: kgm (Nm) [ft. lb] Unit: kgm (Nm) [ft. lb]
Width across flats S43C, SMn34CH SMn40CH, Width across flats mm S43C, SMn34CH SMn40CH,
SCM3H SCM3H
Thread mm (in) or superior ones Thread (in) or superior ones
dia. dia.
mm (in) Conven- ISO mm (in) Conven- ISO
tional Range Torget tional Range Torget
threads threads threads threads
6 10 10 0.9 – 1.5 1.2 6 10 10 1.2 – 1.5 1.35

(0.24) (0.39) (0.39) (8.8 – 15) (12) (0.24) (0.39) (0.39) (12 – 15) (13.2)
[6.5 – 11] [8.7] [8.7 – 11] [9.8]
8 14 13 1.5 – 3.5 2.5 8 14 13 2.8 – 3.5 3.2
(0.31) (0.55) (0.51) (15 – 34) (25) (0.31) (0.55) (0.51) (27 – 34) (31)
[11 – 25] [18] [20 – 25] [23]
10 17 17 3.5 – 7.5 5.5 10 17 17 6 – 7.5 6.7
(0.39) (0.67) (0.67) (34 – 74) (54) (0.39) (0.67) (0.67) (59 – 74) (66)
[25 – 54] [40] [43 – 54] [48]
12 19 19 5.5 – 12.5 9.0 12 19 19 10 – 12.5 11.5
(0.47) (0.75) (0.75) (54 – 123) (88) (0.47) (0.75) (0.75) (98 – 123) (113)
[40 – 90] [65] [72 – 90] [83]
14 21 22 8.5 – 20.0 14.0 14 21 22 16 – 20.0 18
(0.55) (0.83) (0.87) (83 – 196) (137) (0.55) (0.83) (0.87) (157 – 196) (177)
[61 – 145] [101] [116 – 145] [130]
16 23 24 15.0 – 31.5 23.5 16 23 24 25 – 31.5 28.5
(0.63) (0.91) (0.94) (147 – 309) (230) (0.63) (0.91) (0.94) (245 – 309) (279)
[108 – 228] [170] [181 – 228] [206]
18 26 27 20.5 – 43.5 32.0 18 26 27 35 – 43.5 39
(0.71) (1.02) (1.06) (201 – 427) (314) (0.71) (1.02) (1.06) (343 – 427) (382)
[148 – 315] [231] [253 – 315] [282]
20 29 30 32.5 – 62.0 47.0 20 29 30 50 – 62.0 56
(0.79) (1.14) (1.18) (319 – 608) (461) (0.79) (1.14) (1.18) (490 – 608) (549)
[235 – 448] [340] [362 – 448] [405]
22 32 32 48.0 – 84.5 66.5 22 32 32 67.5 – 84.5 76
(0.87) (1.26) (1.26) (471 – 829) (652) (0.87) (1.26) (1.26) (662 – 829) (745)
[347 – 611] [481] [488 – 611] [550]
24 35 36 60.0 – 105 82.5 24 35 36 84 – 105 94.5
(0.94) (1.38) (1.42) (588 – 1030) (809) (0.94) (1.38) (1.42) (824 – 1030) (927)
[434 – 759] [597] [608 – 759] [684]
27 41 41 90.0 – 150 120 27 41 41 120 – 150 135
(1.06) (1.61) (1.61) (883 – 1471) (1177) (1.06) (1.61) (1.61) (1177 – 1471) (1324)
[651 – 1085] [668] [868 – 1085] [976]
30 46 46 115 – 195 155 30 46 46 155 – 195 175
(1.18) (1.81) (1.81) (1128 – 1912) (1520) (1.18) (1.81) (1.81) (1520 – 1912) (1716)
[832 – 1410] [1121] [1121 – 1410] [1266]
33 50 50 150 – 250 200 33 50 50 200 – 250 225
(1.30) (1.97) (1.97) (1471 – 2452) (1961) (1.30) (1.97) (1.97) (1961 – 2452) (2206)
[1085 – 1808] [1447] [1447 – 1808] [1627]
36 54 55 190 – 310 250 36 54 55 250 – 310 280
(1.42) (2.13) (2.17) (1863 – 3040) (2452) (1.42) (2.13) (2.17) (2452 – 3040) (2746)
[1374 – 2242] [1808] [1808 – 2242] [2025]
39 58 60 230 – 370 300 39 58 60 295 – 370 335
(1.54) (2.28) (2.36) (2256 – 3628) (2942) (1.54) (2.28) (2.36) (2893 – 3628) (3285)
[1664 – 2676] [2170] [2134 – 2676] [2423]
a This table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are to be used, or
which requir to tighten to otherwise specified torque.
Conventional screw threads ISO screw threads
10-14 AR50 Series

GENERAL AND SPECIFICATIONS STANDARD TIGHTENING TORQUE FOR PIPE JOINTS
STANDARD TIGHTENING TORQUE FOR PIPE JOINTS
Elbows, nipples and unions
Width across flats B mm 22 30 36

(inch) (0.866) (1.181) (1.417)
Width D mm 19 22 30
(inch) (0.748) (0.866) (1.181)
Tightening torque Nm {kgm} 29.4 – 39.2 {3 – 4} 78.5 – 103 {8 – 10.5} 117.7 – 161.8 {12 – 16.5}
[ft.Ib] [21.7 – 28.9] [57.9 – 75.9] [86.8 – 119.3]
Port size
3/4-16UNF 13/16-12UNF 15/16-12UNF
(inch)
Tightening torque Nm {kgm} 68.6 – 73.6 {7 – 7.5} 117.7 – 161.8 {12 – 16.5} 107.9 – 147{11 – 15}
[ft.Ib] [50.6 – 54.2] [86.8 – 119.3] [79.5 – 108.4]
High-pressure rubber hoses, pipes and sleeve nuts
Width across flats B (mm) 19 24 27 32 36

(inch) (0.748) (0.945) (1.063) (1.260) (1.417)
Bore A mm 14 18 22 24 30
(inch) (0.551) (0.709) (0.866) (0.945) (1.181)
Tightening torque Nm {kgm} 19.6 – 29.4 {2 – 3} 23.5 – 68.6 {3 – 7} 58.8 – 98.1 {6 – 10} 107.9 – 166.7 {11 – 17} 147– 206 {15–21}
[ft.Ib] [14.5 – 21.7] [21.7 – 50.6] [43.7 – 72.3] [79.6 – 122.9] [108.52 – 151.8]
AR50 Series 10-15

HOW TO USE LOCTITE GENERAL AND SPECIFICATIONS
HOW TO USE LOCTITE
Procedure for using LOCTITE

4. Assembly
After applying LOCTITE, tighten the screw or fit the
Male side
shaft to the hole as usual. (When using LOCTITE
Degreasing Air drying for structures or LOCTITE of instant glue type, press
Female the mating parts lightly (about 49 kPa {0.5 kgf/cm2}).
side
Removal of parts
Leaving Applying
Assembly When screws and shafts are secured with LOC-
LOCTITE
TITE, they usually can be removed with common
tools such as spanners, wrenches, pulley pullers,
etc. If LOCTITE is so strong that a part may be bro-
1. Degreasing and cleaning ken when it is removed, heat it (to 200 - 250°C) with
1) Clean the parts in trichloroethylene, acetone, a soldering iron, gas torch, etc., and you can
ether, alkaline solution, etc. which are highly remove it easily. It is generally difficult to dissolve
volatile. LOCTITE in chemical solutions.
2) Degrease the parts as perfectly as possible.
3) Since gasoline, light oil, kerosene, etc. are not When assembling again
highly volatile, they are not recommended. If it
1) If a LOCTITE film on threads is broken, it is left
is obliged to use them, dry them completely.
as white powder on the threads. In this case,
4) If the mating parts are made of thermosetting you can apply LOCTITE again to the threads
resin, treat them with LOQUICK PRIMER after without removing the white powder.
degreasing them.
2) If shafts or flanges secured with LOCTITE are
disconnected, LOCTITE remaining on them
2. Air drying may need to be removed to maintain dimen-
sional accuracy. You can remove the remain-
1) Wait until the cleaning fluid dries out.
ing LOCTITE easily, however, with a wire
2) If the parts are treated with LOQUICK brush, etc.
PRIMER, do not wipe them but dry them in air
3) If plates secured with LOCTITE need to be
for 5 - 10 minutes. (If LOCTITE is used before
assembled again after they are separated, be
LOQUICK PRIMER dries out, its effect is low-
sure to remove all the hardened LOCTITE and
ered.)
roughen the mating surfaces with sandpaper.
3. Applying LOCTITE
Apply LOCTITE to either or both of the threads or
the shaft and hole to be fitted by amount to fill the
clearance between them by one of the following
methods.
• Applying directly from LOCTITE container nozzle
• Dipping (For threads. Use receiving pan.)
• Tumbling
• Brushing (For shaft and hole. Use receiving
pan.)
• Sponge
• Automatic applier
Do not mix metallic foreign matter in LOCTITE or
return LOCTITE used in a pan to the container.
10-16 AR50 Series

Sec20_AR14_E.fm 1 ページ２００８年３月３日月曜日午後２時３分
20. TESTING AND ADJUSTING

SERVICE DATA ..........................................................................20-2
BATTERY....................................................................................20-4
VEHICLE MOUNTED TYPE CHARGER ....................................20-6
INSTALLATION TYPE CHARGER..............................................20-7
HYDRAULIC OIL TANK ..............................................................20-8
TRANSFER CASE....................................................................20-10
FUSE REPLACEMENT ............................................................20-11
DISC BRAKE ............................................................................20-13
MAST, ROLLER SUPPORT......................................................20-14
EPS TORQUE SENSOR ..........................................................20-17
METER PANEL .........................................................................20-18
OPERATION OF METER PANEL .............................................20-19
LIMIT CURRENT (LOCK CURRENT) ......................................20-22
SPECIFIED LUBRICANT AND GREASE .................................20-23
OIL AND GREASE CHART ......................................................20-24
WEIGHT GAUGE (LOAD METER) ...........................................20-25
AR50 Series 20-1

SERVICE DATA TESTING AND ADJUSTING
SERVICE DATA
Equip Location of Content of inspection Unit Value

men inspection
Height of brush More than 13
EPS motor
Spring force of brush More than 2.45 {More than 0.25}
317 to 351 A (peak)
Limit current of travel motor
(224 to 247 A (rms))
Speed control
Limit current of cargo-handling A 319 to 390 A (peak)
equipment
motor (226 to 276 A (rms))
Motor
Limit current of steering motor 30 ± 1.5 A

For power circuit 325
For EPS main circuit 40
Fuse For controller control circuit A 10
For light lamps and accessory
10
circuit
Battery Voltage of each cell V More than 2
Front (load) —
Travel equipment
Clip bolt, tightening

Nm
torque of hub bolt/ 98 to 123
Rear (drive) {kgm}
nut {10 to 12.5}
Steering wheel Play in rotational direction 10 to 20

RL RS RW, RP
1.0 t: 1,325 0.9 t: 1,260 1.0 t: 1,325
Steering equipment
Minimum rotational diameter 1.3 t: 1,465 1.0 t: 1,325 1.3 t: 1,465

mm
Wheel of steering 1.5 t: 1,560 1.3 t: 1,465 1.5 t: 1,560
1.8 t: 1,715 1.5 t: 1,560
Difference in right and left
Å}50
minimum rotational diameters
In neutral: 4 ± 0.3
Power steering
Voltage* V Right turn: 4 ± 0.3 → 7 (It changes smoothly.)
equipment
Left turn: 4 ± 0.3 → 1 (It changes smoothly.)
* : When using the EPS voltage checker
20-2 AR50 Series

TESTING AND ADJUSTING SERVICE DATA
Equip Location of Content of inspection Unit Value

men inspection
Play of brake pedal 0 to 10
mm
Pedal height 60 to 70
Brake pedal
Stop ability of foot Load Within 2.5 (At 9.5km/h)
m
brake Unload Within 5 (At 10.5km/h)
Control equipment
Load Stop at 0.15 (8.5°)

Parking brake tan θ
Unload Stop at 0.2 (11.2°)
Clearance between cam and
0
adjuster screw
Spring installation length 120 ± 2
Disc brake mm
Reference
11
Brake pad thickness
Allowable limit 4
Thickness of fork 0.9 to 1.5 t: 35
(reference value) 1.8 t: 38
0.9t: More than 30
Cargo handling equipment
Wear of fork (Allowable limit) 1.0 to 15t: Mire than 31

Fork mm 1.8t: More than 35
Opening of tip (Allowable limit) 35
Difference of height of tip
15
(Allowable limit)
mm/
Length of chain (Allowable limit) number 275.5/17 (leaf)
Lift chain of links
Stretch of chain (Allowable limit) % 2
300 to 350
Hydraulic equipment
Hydraulic pump Lift elevating speed (At unload) mm/S

(It differs in models.)
Natural falling Inner mast natural falling mm/min Within 30/15
Lift 16.7{170}
Control valve relief MPa
pressure {kgf/m2}
Tilt 16.7{170}
AR50 Series 20-3

BATTERY TESTING AND ADJUSTING
BATTERY
CAUTION WHEN HANDLING THE BATTERY

1. Emergency care when the battery electrolyte is spilled
If you spill the electrolyte on your eyes, skin or cloth, flush it with large amount of water. If the electrolyte enters in
your eyes, consult a doctor immediately.
2. Restricted fire
Do not make a short circuit or spark. Keep away tobacco and fire from the battery.
3. Avoidance of electric shock
Wear the gloves to prevent electric shock when performing the maintenance and inspection.
4. Ventilation
Ventilate well when the battery is used or not used.
CHECK OF BATTERY SOLUTION

Check by the battery solution level indicator
Water Re-fill Display
The battery solution level indicator (battery icon) (1) lights and is
displayed.
1 a In the above state, re-fill water immediately. (Refer to [How to

re-fill water in the battery] mentioned below.)
a If the battery with lack of battery solution is used, the life of
battery will be shortened.
Therefore, be sure to re-fill water.
a If a battery other than the standard one or option is used, the
battery solution level indicator cannot be used.
Check using the battery electrolyte level indicator stick

Before starting the work, be sure to disconnect the battery plug from
1 the plug at the vehicle side.
1. Stopper
2. Cap
3. Float (red color)
Before the float (red color) indicates the lowest level of battery
2
electrolyte, re-fill water. (Refer to [How to re-fill water in the battery]
3 When the stopper (1) of float (3) touches the cap (2) (when the
gap a=0 is achieved in the left figure), the battery electrolyte
level is lowest.
a Depending on battery manufacturers, the cap differs in shape.
20-4 AR50 Series

TESTING AND ADJUSTING BATTERY
HOW TO RE-FILL WATER IN THE BATTERY

Before starting the work, be sure to disconnect the battery plug from
the plug at the vehicle side.
A. Re-filling water
B. Re-filling is finished.
1. Open the lid of battery cap and re-fill water in the battery.
2. When the white line appears, stop re-filling immediately.

a Do not continue re-filling after the white line appears, it
White line
A B leads to the overflow of electrolyte.
3. After finishing the work, connect the battery plug again.
CHECK OF SPECIFIC GRAVITY OF BATTERY ELECTROLYTE

As the specific gravity of battery electrolyte changes, along with the
temperature, read the specific gravity and electrolyte temperature
and convert it to the value equivalent at 20°C, using the conversion
table.
How to read the table

(Example)When the temperature of battery electrolyte is 10°C and
reading on the specific gravity meter is 1.252, the specific
gravity converted to the equivalent at 20°C is 1.250.
Appropriate specific gravity (when converted at 20°C)
Specific gravity when fully charged 1.280 – 1.290

Specific gravity when discharged (80%
discharge/when discharge warning lamp lights) 1.170 – 1.180
The specific gravity of battery differs somewhat in manufacturer and

type.
AR50 Series 20-5

VEHICLE MOUNTED TYPE CHARGER TESTING AND ADJUSTING
VEHICLE MOUNTED TYPE CHARGER
Indication on the
model plate
1
A BCD
A
B
C
D
2
RL type
ADJUSTMENT OF POWER SOURCE VOLTAGE TAP

1. Measure the power source voltage to be used for charging.
a As the power source voltage varies in daytime/midnight and

summer/winter, measure the maximum power source
voltage during charging.
2. According to the table below, select the wire suitable for the
measured voltage from the wire (1) of charger transformer.
a Depending on the power source frequency, the wire to be
connected differs.
Range of Voltage
Tap
50 Hz 60 Hz
A 195 V: 190 – 199 V
B 195 V: 190 – 199 V 205 V: 200 – 209 V
C 205 V: 200 – 209 V 215 V: 210 – 219 V
D 215 V: 210 – 219 V
3. Connect the selected wire to the wire (2) leading from the elec-
tro magnetic switch.
If the charger is used for long period of time in the state

that the power source voltage tap is incorrectly
adjusted, the charger may burn. Therefore, adjust the
tap of power source voltage periodically.
20-6 AR50 Series

TESTING AND ADJUSTING INSTALLATION TYPE CHARGER
INSTALLATION TYPE CHARGER
1. Charging Transformer
2. Electro-magnetic Switch
a The actual location of charging transformer and electro-

magnetic switch is different from the illustration.
ADJUSTMENT OF POWER SOURCE VOLTAGE TAP

1. Measure the voltage of power source to be used for charging.
a As the power source voltage varies in daytime/midnight and

summer/winter, measure the maximum power source volt-
age during charging.
2. According to the table below, select one each of wire suitable

for the measured voltage from A, B and C.
Power Source Voltage (V) Indication on wire

190 – 199 195
200 – 209 205
210 – 219 215
220 – 229 225
3. Connect the selected wires to the wires D leading from the

electro-magnetic switch respectively.
If the charger is used for long period of time in the state

that the power source voltage tap is incorrectly
adjusted, the charger may burn. Therefore, adjust the
tap of power source voltage periodically.
AR50 Series 20-7

HYDRAULIC OIL TANK TESTING AND ADJUSTING
HYDRAULIC OIL TANK
HYDRAULIC OIL REPLACEMENT, LINE-FILTER REPLACEMENT, STRAINER CLEANING

1. Remove the battery
a Refer to [Battery Replacement] in this chapter.
2. Remove the drain plug (1) and drain the hydraulic oil. After
drained, tighten the drain plug.
3. Remove the steering wheel (2) and the panel (3).
2
3
4. Remove the tank cover (5).

6 5
20-8 AR50 Series

TESTING AND ADJUSTING HYDRAULIC OIL TANK
5. Remove the strainer (7) and wash it in the flushing oil.

6. After washing, blow air to the strainer form inner side to dry it.
Then, install it.
7 7. Remove the line-filter (8) and install a new line-filter.
8. Refill the specified amount of hydraulic oil from the filler port (6)
and the check the level with the oil gauge (4).
Amount of hydraulic oil: 16
9. Operate the cylinder (lift, tilt and reach) to the stroke end 5 to 6
times to let air out.
AR50 Series 20-9

TRANSFER CASE TESTING AND ADJUSTING
TRANSFER CASE
OIL LEVEL CHECK

1. Remove the level plug (1) and check the oil level in the level
plug hole.
2. If it is lacking, refill the oil.
OIL REPLACEMENT
1. Remove the drain plug (2) and drain the oil.
2. After drained, tighten the drain plug.

3. Refill the specified amount of oil in the level plug hole.
Amount of oil: 3.5
20-10 AR50 Series

TESTING AND ADJUSTING FUSE REPLACEMENT
FUSE REPLACEMENT
REPLACEMENT PROCEDURE
1. Sit on the operatorÅfs seat and operate the reach lever to
extend the mast. (Reach-out)
2. Turn the key switch to [O] (OFF) and disconnect the battery
plug.
3. Loosen the knobs fixing the front panel at two locations.
4. Lower the front panel downward (1). Open the upper side of
the front panel toward you (2) and remove it, lifting upward (3).
2
5. If the fuse shown below blows out, replace it with the one
4 having the identical capacity.
Capacity
Name of circuit protected Color
(For truck)
3 Light lamp, accessory circuit (1) 10A Red
Controller control circuit (2) 10A Red
EPS (3) 40A —
2 Power circuit (4) 325A —
1
Never use the wire or a fuse other than the one with
specified capacity. Otherwise, it exceeds the standard value.
AR50 Series 20-11

FUSE REPLACEMENT TESTING AND ADJUSTING
6. Open the cap of fuse holder and remove the fuse in it. Confirm
visually the blown-out fuse.
a The sample marked with X in figure at the left hand side
shows the blown-out fuse.
7. Hook the front panel to the bar (1) at the frame side, turn it
toward the truck (2) and lift it upward (3).
2 Then, tighten the fixing knobs.
1
3
20-12 AR50 Series

TESTING AND ADJUSTING DISC BRAKE
DISC BRAKE
DISC BRAKE ADJUSTMENT PROCEDURE

1. Set the spring height H of brake to 120 mm.
2. Assemble the brake rod and set the brake pedal height to 60 to
e 70 mm.
a d
h 3. Loosen the adjuster bolt c beforehand and adjust the turn-
buckle e so that the brake bar a becomes perpendicular (90 ±
2°).
c
b
4. Last, adjust the adjuster bolt c so that the clearance between

the adjuster bolt and the cam b becomes “0”.
60 ~ 70 mm 5. Apply KES 07.881 lithium grease (G2-LI) the contacting
surfaces of adjuster bolt c and cam b.
6. Be careful not to stick oil to the disc surface (surface d).
25 ~ 30 mm
BRAKE SWITCH ADJUSTMENT PROCEDURE

Confirm that the switch turns on when the rear surface of pedal
comes to the height of 25 to 30 mm from the floor.
a When assembling, apply the lithium grease (G2-LI) to the

sliding portion of link.
AR50 Series 20-13

MAST, ROLLER SUPPORT TESTING AND ADJUSTING
MAST, ROLLER SUPPORT
1. Outer roller
㪭 1) Roller selection
䌢 Select a roller so that the dimension V in the figure at the
left hand side becomes 9.9 ± 10.6 mm and values at right
䌢㪈 and left are identical. The target is 9.9 mm.
㫊㫋㪸㫅㪻㪸㫉㪻㩷㫊㪿㫀㫄㩷㪊㪅㪇
㪫㪿㫀㪺㫂㫅㪼㫊㫊㩷㫆㪽㩷 2) Shim adjustment
At the maximum height of high lifting, adjust using the
shims of same thickness at the right and left sides so that
the clearance b1 between the rail and the roller becomes
0 to 0.5 mm when contacting closely the roller to the rail.
2. Inner roller
1) Roller selection
Select a roller so that the dimension a in the figure at the
䌢㪉
left hand side becomes 0.1 to 0.5 mm.

2) Shim adjustment
㫊㫋㪸㫅㪻㪸㫉㪻㩷㫊㪿㫀㫄㩷㪉㪅㪌
At the maximum height of high lifting, adjust using the

㪫㪿㫀㪺㫂㫅㪼㫊㫊㩷㫆㪽㩷
shims of same thickness at the right and left sides so that

㪸 the clearance b2 between the rail and the roller becomes
0 to 0.5 mm when contacting closely the roller to the rail.
a No plays of roller and pin are allowed.
3. Roller support roller (Upper side)

㪼
1) Roller selection
Select a roller so that the dimension e in the figure at the
2) Shim adjustment
㪽㪊
In the state of the uppermost height of support, adjust

using the shims of same thickness at the right and left
sides so that the clearance f3 between the rail and the
roller becomes 0.4 to 0.7 mm.
4. Reach leg roller (Front side)

㪻 1) Roller selection
Select a roller so that the dimension a in the figure at the
㪽
2) Screw adjustment
In the state of reach-out, adjust by screwing same amount
㪹㪊
at right and left sides so that the roller touches lightly the
rail (b3 is 0.1 to 0.3 mm) when contacting closely the roller
㪻 to the rail.
20-14 AR50 Series

TESTING AND ADJUSTING MAST, ROLLER SUPPORT
5. Reach leg roller (Rear side)

㪼 1) Roller selection
2) Shim adjustment
In the state of reach-out, adjust using the shims of same
㫊㫋㪸㫅㪻㪸㫉㪻㩷㫊㪿㫀㫄㩷㪌㪅㪉
㪹㪋
thickness at the right and left so that the roller touches

㪫㪿㫀㪺㫂㫅㪼㫊㫊㩷㫆㪽㩷
lightly the rail (b4 is 0.1 to 0.3 mm) when contacting

closely the roller to the rail.
6. Roller support roller (Middle)

㪼
1) Roller selection
2) Shim adjustment
㪽㪉
In the state of the uppermost height of support, adjust

using the shims of same thickness at the right and left
sides so that the clearance f2 between the rail and the
roller becomes 0.1 to 0.4 mm.
7. Roller support roller (Lower side)

㪼
1) Roller selection
㪺

2) Shim adjustment
Adjust inserting a shim to eliminate the play of roller.
Adjust using the shims of same thickness at the right and
left sides so that c in the figure at the left hand side
becomes 0 mm.
8. Roller support side roller

㪿㪼㫀㪾㪿㫋㩷㪊㪉㫄㫄㪅
㪪㫋㪸㫅㪻㪸㫉㪻㩷㫊㪼㫋
1) Bolt adjustment
In the state of the uppermost height of support, tighten
bolts same amount at back and forth sides simultaneously
so that the clearance f4 between the rail and the roller
becomes 0 to 0.2 mm and the set height becomes
identical at the right and left sides.
䌦4
AR50 Series 20-15

MAST, ROLLER SUPPORT TESTING AND ADJUSTING
LIFT CHAIN
1. Adjust the chain stopper so that the lowest surface of fork
matches with the floor.
㪠㫅㫅㪼㫉㩷㫄㪸㫊㫋
㪽 2. At the maximum height of high lifting, confirm that the inner
mast does not lean to the right and left sides.
3. If leaned, loosen the chain by a mount of f when the fork
descends at the lower rail side a as shown in the figure at the
㪸㪹 light hand.
㪹㩷㫊㫀㪻㪼㩷㪺㪿㪸㫀㫅
㪝㫆㫉㫂
㪝㫃㫆㫆㫉
20-16 AR50 Series

TESTING AND ADJUSTING EPS TORQUE SENSOR
EPS TORQUE SENSOR
VOLTAGE CHECK
Battery built in the case 2.0 V × 5 pieces = 10 V

Or external power source 10 V
When the EPS operation trouble occurs, set the starter switch to OFF and perform the following check.
1. 8V stable current 4. At the left turn (When turning the steering wheel right)
Connect as shown above and turn the volume knob After adjusted in the neutral position, when turning the
so that the voltage between terminals and steering wheel left, if the voltage between terminals
becomes 8 V. and varies smoothly to 1 V, it is normal.
4 ± 0.3 V → 1 V
Normal Value
(The voltage changes smoothly.)
2. In the neutral (When the steering wheel is not turned) 5. Right turn → Neutral
When the steering wheel is in the neutral position, if After turning the steering wheel right and releasing
the voltage between terminals and is 4.3 V ± the hand off, when retuned to the neutral position, if
0.3 V, it is normal. If not, adjust using the shim (A) the voltage between terminals and becomes
so that the voltage becomes normal. 4 V ± 0.3 V. (Measure several times)
(The 0.1 mm thick shim changes 0.07 V.)
Normal Value 7 V → 4 ± 0.3 V
Normal Value 4 ± 0.3 V
3. At the right turn (When turning the steering wheel right) 6. Left turn → Neutral
After adjusted in the neutral position, when turning the After turning the steering wheel left and releasing
steering wheel right, if the voltage between terminals the hand off, when retuned to the neutral, if the
and varies smoothly to 7 V, it is normal. voltage between terminals and becomes 4 V
± 0.3 V. (Measure several times)
4 ± 0.3 V → 7 V
Normal Value
(The voltage changes smoothly.) Normal Value 1 V → 4 ± 0.3 V
GREASING
Use the MOLY SPEED GREASE No.0 (SUMICO LUBRICANT CO., LED) for torque sensor and actuator.
In the maintenance, check that the grease is applied to parts in the sensor. If necessary, grease them.
AR50 Series 20-17

METER PANEL TESTING AND ADJUSTING
METER PANEL
OPERATION CHECK OF METER PANEL WARNING LIGHT

1. Disconnect the battery plug from the plug at the vehicle side.
2. When re-connecting the battery plug, if all of the indicators of

meter panel light for one second, the warning light and display
are normal.
a In this method, a problem (For example, abnormality of sensor
or wiring) other than the meter display cannot be checked.
20-18 AR50 Series

TESTING AND ADJUSTING OPERATION OF METER PANEL
OPERATION OF METER PANEL
By operating switches (1), (2), (3), and (4) on the meter panel, per-
form the settings and adjustments of speed limit / traveling power /
lift speed, select the display of date-time / hour meter and adjust it.
a To operate the switch on the panel, touch it lightly by finger.

If the following operations are performed during setting, the
setting cannot be renewed. In this case, start settings from the
beginning.
• When the key switch is set to "Q" (OFF) or driving operation
is performed:
4 3 2 1
• When the switch is not operated for 30 second:
SELECTION OF DATE-TIME / HOUR METER

Every time when pressing the select switch (shift switch) (1) of date-
time / hour meter, the display of [date-time] and [hour meter] is
swapped.
a The hour meter can be displayed up to 99999.9 hours at the

maximum by 0.1 hours (6 minutes) increment.
a The selection during operation is impossible.
a The time is displayed in 24 hours.
a The working hour of traveling and cargo operation can be man-
1 aged as an option.
SETTING OF DATE-TIME
1. Keep pressing the mode / set select switch (4) for more than 2
seconds. (To enter the vehicle speed limit mode)
2. Press the mode / set select switch (4) once more to enter the
date-time adjusting mode.
The calendar year (lowermost two digits) - month date - time is
displayed and the calendar year blinks.
3. To change the calendar year, press the power select switch
(up-switch) (3) or vehicle speed limit select switch (down-
switch) (2).
4 3 2
4. After setting, press the date-time / hour meter select switch

(shift switch) (1). Then, the display of month blinks and the
month can be changed. By pressing the switch (2) or (3),
change the month in the same manner as done in the calendar
year change.
5. According to the procedure, press the switches (1), (2) and (3),
and set the displays in orders of calendar year o month o
date o hour o minute.
3 2 1
AR50 Series 20-19

OPERATION OF METER PANEL TESTING AND ADJUSTING
ON / OFF SETTING OF VEHICLE SPEED LIMIT FUNCTION - SETTING OF VEHICLE SPEED

LIMIT VALUE
ON / OFF Setting of Vehicle Speed Limit Function
Every time when pressing the vehicle speed limit select switch
5 (down-switch) (2), the vehicle speed limit function is switched to the
enable (ON) or disable (OFF).
When setting to the enable (ON) by pressing the switch, the vehicle
speed limit indicator (5) (turtle icon) is displayed and the value of
vehicle speed limit at this moment blinks for two seconds at the
same time.
a The initial set value of vehicle speed limit is 15 km/h.

2
Setting of Vehicle Speed Limit Value
1. Keep pressing the mode / set select switch (4) for more than 2
seconds. (The vehicle speed limit mode is displayed and the
vehicle speed limit value blinks.)
2. To change the value of vehicle speed limit, press the power

select switch (up-switch) (3) or vehicle speed limit select switch
(down-switch) (2).
The speed can be set within the range of 5 – 7 km/h by incre-
ment of 1km/h.
4 3 2
3. After determining the value of vehicle speed limit, press the
mode / set select switch (4) at last.
After blinking, the value of vehicle speed limit is set.
TRAVEL / CARGO HANDLING POWER SETTING

The vehicle traveling and performance of cargo operation can be set
to three steps of L, M and H.
1. Every time when pressing the power select switch (up-switch)

(3), the power mode selected changes in the following orders.
(Blinking State)
a L o M o H o Go off o L…
4 3
2. When the mode / set select switch (4) is pressed in either state
of L, M or H, setting is completed and blinking stops.
L M H Go off Power Mode Content
Even at low speed, the cargo
L Low Power operation - traveling is possible and
the energy can be saved.
The cargo operation - traveling
M Middle Power suitable for normal work can be
performed.
The vehicle can travel strongly at
high speed and the high performance
H High Power of cargo operation can be achieved.
The battery consumption increases.
Characteristics desired by a user can
Go-off User Mode be obtained by setting with the
service tool.
a When requesting the setting in the user mode, consult the

KOMATSU LIFT sales and service agent.
20-20 AR50 Series

TESTING AND ADJUSTING OPERATION OF METER PANEL
LIFT SPEED ADJUSTMENT

This function adjusts the lift speed to meet the requirements such as
swiftness and prudence for cargo operation. The lift speed can be
set arbitrarily to 1 to 100%. 100% is the maximum speed.
1. Press the power select switch (UP switch) (3) and then press
the mode/select switch (4) after the display of travel power
indicator goes off. (The user mode is set.)
2. Keep pressing the mode / set select switch (4) for 2 seconds.
(The mode becomes the vehicle speed limit mode.)
4 3 2 1 3. Press the shift switch (1) several times.
(The display changes to the lift speed setting mode.)
The display below appears on the date-time display area and
the numeral part blinks.
a Example of display: LIFT-SPd-95
4. By pressing the up-switch (3) or down-switch (2), change the

numerals to the desired value (%).
5. After changing the value to the desired lift speed, press the
mode / set select switch (4) to set it.
6. In addition, press the mode/select switch (4) twice so that the
menu returns to the normal one.
(The menu returns to the date-time setting mode at the first
switch-pressing and then to the normal one at the second
switch-pressing.)
a In considering the lift speed and working hour, the appropriate
adjustment range is 60 to 95%.
If set low, the lift operation may fail. If set too low or too high,
the capable working hour will decrease.
a Corresponding to the state of vehicle with load or without load,
the lift speed of battery powered fork lift varies.
However, the speed undulation arising from the load fluctuation
cannot be eliminated by the adjustment function of lift speed.
a The set lift speed is enabled only when selecting the state that
the power mode display area on the meter panel goes off (In
the state of user mode).
When switching the power mode to L. M or H, the lift speed of
L, M or H is the initially set lift speed.
a When selecting the state that the power mode display area on
the meter panel goes off (In the state of user mode), the set lift
speed is enabled. But, the travel power is set to the M mode
same as the factory setting.
To adjust the lift speed only while keeping the H or L travel
power mode, set the set value of H or L travel power mode to
the user mode with the service tool.
AR50 Series 20-21

LIMIT CURRENT (LOCK CURRENT) TESTING AND ADJUSTING
LIMIT CURRENT (LOCK CURRENT)

1. Park the fork lift truck on a flat place and place the chocks (1)
under the load wheel.
2. Extend the mast. (Reach-out)

3. Place the wooden block (2) in the reach legs.
If operating accidentally the mast retraction (reach-in), to
prevent your body from being caught in the mast and the
frame, place the wooden block as a stopper.
4. Place the wooden block (3) under the frame at the right and left
sides to float the front wheel from the ground.
(Only when measuring the travel limit current)
5. Turn the tilt lever to the forward and lower the fork to the
ground.
6. Disconnect the wiring of brake switch and short it to 0 V.
Or remove the center plate and push in the brake switch lever
1
(Electrically the brake is open.)
7. Set the current meter (clamp tester) to the cable of motor to be
measured and measure the limit current under the measuring
3
2 condition shown on the table below.
8. After finishing the check, connect the wiring of brake switch
1 again.
Motor Measuring condition Measuring cable Clamp setting Judging limit current
Set the power mode to H and turn fully the forward/
DC 1000 A
backward lever to the forward without stepping
peak range 317 to 351 A (peak)
Travel down the brake pedal. DU, DV, DW
(AC 1000 A (224 to 247 A (rms))
(The drive wheel does not rotate.)
peak range)
At this moment, measure the current.
Set the power mode to H and turn fully the tilt lever
DC 1000 A
to the forward to tilt the mast forward. At this
Cargo- peak range 319 to 390 A (peak)
moment, measure the current. PU, PV, PW
handling (AC 1000 A (226 to 276 A (rms))
(Set the tilt parameter to the factory setting (=100%)
peak range)
when implementing.)
Measure the current when turning the steering Cables of
EPS As usual 30 A ± 1.5 A
wheel right or left fully. EPS motor
20-22 AR50 Series

TESTING AND ADJUSTING SPECIFIED LUBRICANT AND GREASE
SPECIFIED LUBRICANT AND GREASE
OIL
• As the work equipment is used under severe conditions (high temperature, high pressure), the oil deteriorates as it is
used. Use the oil suitable for the grade and operating temperature described in the Shop Manual.
Even if the oil is not contaminated, ensure to replace the oil at the specified time.
• As the oil is equivalent to the blood to the human being, handle the oil with care to prevent the entry of impurity (water,
metal debris and dust). Most of mechanical troubles arise from the entry of impurity.
Especially, when storing or refilling, handle the oil with care to prevent the entry of impurity.
• Do not mix the oil of different grade or different makes.
• Refill the specified amount of oil.
Too much oil or too little oil causes trouble.
• If the oil in the work equipment becomes unclear, the entry of water or air in the circuit is suspected.
Consult with our sales dealer.
• Whenever replacing the oil, ensure to replace the related filter at the same time.
LIST OF LUBRICANT AND OIL

a Ensure to use the KOMATSU UTILITY genuine products.
The oil and grease are available at KOMATSU UTILITY Sales and Service dealers..
Ambient temperature
Cold-strage
Lubrication point Type of fluid model Lift Truck Standard spec. Lift Truck Capacity
C
Transfer case Gear oil SAE75 3.4
SAE5W-CD
Hydraulic tank Hydraulic oil* 16
SAE10W-CD
Each greasing Lithium grease NLGI No. 2

point
SAE5W-CD
SAE10W-CD
Each lubricating
Engine oil*
point
SAE30W-CD
SAE10-30SD
*: Use CD or higher grade oil.
AR50 Series 20-23

OIL AND GREASE CHART TESTING AND ADJUSTING
OIL AND GREASE CHART
Tip of tilt cylinder rod Fork shaft

Reach cylinder pin Reach leg inner surface,
rotating surface
Lift chain
Mast carriage side roller
Control lever link
Guide bar
Brake link
Steering gear, Hydraulic oil reservoir
Joint spline
Transfer Brake pedal

Brake cam Suspension
L type
Check every day W type
Every 2 weeks (100 hours)
Every 1 month (200 hours)
Caster bracket Every 3 months (600 hours)
(L type) Every 6 months (1,200 hours)
: Check and add fluid if necessary

Symbol Type of fluid
: Total oil change or greasing and application
Symbol EO Engine oil
: Figure inside the box shows the number of GO Gear oil
places to apply oil HO or grease to HO Hydraulic oil
G Grease
20-24 AR50 Series

TESTING AND ADJUSTING WEIGHT GAUGE (LOAD METER)
WEIGHT GAUGE (LOAD METER)
WARNING
• The display of load weight varies during traveling. Be sure to stop the reach truck on a flat location and confirm the
load weight.
• The over-load alarm load weight is set heavier than the maximum load weight in the initial setting.
When the alarm buzzer beeps, reduce the load immediately to avoid the overturn of reach truck.
INTRODUNCTION
The weight gauge is set to meet the specification of reach truck when shipped.
If a customer request of the load weight change of over-load alarm or the set value change after the replacement of mast
or attachment, re-set referring to this manual.
WEIGHT GAUGE FUNCTION

The weight gauge has the following functions.
• Load Weight Display Function: It displays the load weight on the meter panel.
• Over-load Alarm Function: When the load weight exceeds the preset alarm load weight, the alarm buzzer beeps,
telling the over-load to the operator.
ITEM TO BE PREPARED
• PC service tool
CHANGE OF SET VALUE WHEN REPLACING THE MAST OR ATTACHMENT

When replacing the mast or attachment, set the following items, using the PC service tool. Otherwise, the weight gauge
does not function properly.
• Setting of load weight display

• Setting of over-load alarm
a In case of no replacement of mast or attachment, it is not necessary to change the setting. Because the initial setting
is implemented to meet the type of the mast or attachment mounted on the reach truck when shipped,
Procedure of set value change

1. Set the key switch to the [O] (OFF) position.
2. Remove the front panel.

3. Connect the service tool to the connector (1) for PC service
tool.
AR50 Series 20-25

WEIGHT GAUGE (LOAD METER) TESTING AND ADJUSTING
4. Set the key switch to the [ | ] (ON) position.

• Even if the PC service tool is connected, if it cannot commu-
nicate with the control unit, the short-circuit of CAN commu-
nication line is suspected. After repairing the CAN
communication line, implement the setting.
5. Select the [Weight Gauge (Load meter)] (2) in the PC service

2 tool menu.
6. Set the load weight display in the following procedure.
Depending on the type of mast replaced, read the values on
the table 1 and change each set value of [weight gauge] in the
PC service tool menu.
(Example of entering the set value of [FV mast] which is lower
than 6.0M)
1) Lift cylinder pressure receiving area: 15.9
2) Zero point set hydraulic pressure: 13.43
3) Coefficient of load weight calculation: 1
4) Switch-over of hydraulic pressure acquisition: 1
Table 1
FV mast TFV FFV

Item Unit
Lower than 6.0M 6.0M mast mast
1. Cylinder pressure receiving area (per one piece) cm2 15.9 19.63 33.18 38.48
2. Zero point set hydraulic pressure kgf/cm2 13.43 12.68 11.93 10.44
3. Coefficient of load weight calculation – 1 1 0.5 0.5
4. Switch-over of hydraulic pressure acquisition – 1 1 1 1
5. Over-load alarm ON/OFF – 0 0 0 0
7. Set the over-load alarm in the following procedure.

Depending on the type of mast or attachment, read the set
value on the load weight table affixed to the reach truck and set
each set value of [Weight Gauge] in the PC service tool menu.
• Switch-over of over-load alarm function ON/OFF:
0 OFF)/1 (ON)
• Over-load alarm load weight:
Over-load alarm load weight shown on the load weight table
• Over-load alarm OFF load weight difference:
The ton-converted value (divided by 1000) of maximum load
weight (kg) shown on the load weight table x 0.2
Example)
Maximum load weight 1900kg divided by 1000 = 1.91 ton
1.9ton x 0.2 = 0.38 ton
Over-load alarm OFF load weight difference = 0.38
20-26 AR50 Series

Sec20_AR14_E.fm 27 ページ２００８年３月３日月曜日午後２時２２分
TESTING AND ADJUSTING WEIGHT GAUGE (LOAD METER)
• Before setting, confirm that the load weight table

affixed to the reach truck meets the specification of
reach truck.
• When changing the over-load alarm load weight, do
not set the value greater than the maximum load
weight of reach truck.
a Since the weight gauge is the optional specification, if the data

writing is done by clicking the button normally displayed in the
initial setting menu of service tool, the set value of weight
gauge will be cleared.
AR50 Series 20-27

30. REMOVAL AND INSTALLATION

LIFT CYLINDER .........................................................................30-2
FORK CARRIAGE ......................................................................30-4
MAST ..........................................................................................30-5
TRANSFER.................................................................................30-7
BATTERY (SIDE DRAW TYPE)................................................30-21
BATTERY (FRONT SIDE-DRAW TYPE) ..................................30-23
DRIVE WHEEL (FOR RL TYPE) ..............................................30-29
AR50 Series 30-1

LIFT CYLINDER REMOVAL AND INSTALLATION
LIFT CYLINDER
REMOVAL
The procedure for removal of the lift cylinder on one side is
explained below as an example.
1. Place chocks (1) under the load wheels and drive wheel.
2. Extend the mast (reach-out).

3. Place a wooden block (2) (15 x 15 cm, 63 cm long) on the
reach legs.
A suitable block should be provided between the mast
and frame as a stopper to protect personal from being
trapped between the mast and frame when the mast is
inadvertently retracted (reach-in).
1
2 1
4. Remove the lift cylinder installation bolt (3)

5. Operate the lift operating lever to raise the inner mast.
6. Apply a wooden block (4) under the inner mast.
7. Operate the lift operating lever to lower the lift cylinder rod.
8. Further operate the lift operating lever several times to elimi-

nate any pressure remaining in the piping. Then remove the
piping at the arrow position in the drawing.
a Plug immediately after disconnecting the piping to

prevent hydraulic oil from flowing away and dust from
entering.
30-2 AR50 Series

REMOVAL AND INSTALLATION LIFT CYLINDER
9. Remove the mounting bolts (5) for cylinder clamp.

10. Remove the cylinder(6).
20 kg (High Lifting Height 3 m)
INSTALLATION
For installation, reverse the removal procedure.
AR50 Series 30-3

FORK CARRIAGE REMOVAL AND INSTALLATION
FORK CARRIAGE
REMOVAL
1. Place chocks (1) under the load wheels and drive wheel.
2. Extend the mast (reach-out).

3. Using a crane, lift the fork carriage by about 30 cm.
1 – 1.5 t 160 kg
1.8 t 180 kg
4. Remove the cotter pin (2) and pull out the pin (3). Then, sepa-
rate the chain and remove the chain from the chain roller.
5. Operate the lift operating lever to raise the inner mast so that
the fork carriage can be removed.
6. Operate the crane to pull the fork carriage out of the vehicle in
the forward direction.
INSTALLATION
For installation, reverse the removal procedure.
30-4 AR50 Series

REMOVAL AND INSTALLATION MAST
MAST
REMOVAL
1. Park the machine in a flat place.
2. Place chocks (1) under the load and drive wheels.

3. Push the power-cut-off button to disconnect the battery plug.
Then, remove the battery from the vehicle using the battery
stand.
(Refer to the section on battery removal.)
4. Hoist the roller support, using the crane, and place the wooden
block (2) under the roller support.
2
1
1
5. Remove the reach cylinder pin (3).
6. Hoist the roller support, using the crane. After loosening the lift
chain, place the wooden block (4) in between the mast and the
chain.
7. Lower down the roller support, using the crane. Then, pinch the
wooden block with the mast and the lift chain to fix it.
8. Operate the operating lever to reliev any pressure remaining in
4 the piping.
9. Remove the drain plug on the hydraulic tank to drain the
hydraulic oil. After draining, replace the plug.
10. Remove the piping.
a After removing the pipings, attach a blank plug to the
piping to prevent loss of hydraulic oil and entry of dust.
AR50 Series 30-5

MAST REMOVAL AND INSTALLATION
11. Remove the sling. Attach a hook to the outer mast, hoist it
using the crane and keep it suspended.
12. Remove the stopper bolt (5) at the tip of reach leg at right and
left sides.
13. Operate the crane to pull the mast out of the vehicle in the for-
ward direction.
1.0 t, 1.3 t 545 kg

1.4 t, 1.5 t 560 kg
5 1.8 t 570 kg
INSTALLATION
Install in reverse steps and note the following points.
㪼 1. Reach leg roller (Rear side)
1) Selection of roller
Select a roller so that the clearance e between rail and
roller is 0.1 to 0.5 mm.
2) Shim adjustment
Adjust using the shims of same thickness for right and left
㪹㪋
STD SHIM THICKNESS
sides so that the roller touches the rail lightly (b4 is 0.1 to
0.3 mm) when contacting closely the roller to the rail in the
reach-out state.
㪌㪅㪉
2. Reach leg roller (Front side)

㪻 1) Selection of roller
Select a roller so that the dimension d in the figure at the
left hand side is 0.1 to 0.5 mm.
㪽
2) Screw adjustment
Set in the reach-out state so that the clearance f between
㪹㪊
mast and leg rail becomes identical at right and left sides.
Adjust by turning the screws at right and left sides by the
㪻 same amount so that the roller touches lightly to the rail
(b3 is 01 to 0.3 mm.) when contacting closely the roller to
the rail.
30-6 AR50 Series

REMOVAL AND INSTALLATION TRANSFER
TRANSFER
REMOVAL (RL TYPE)
1 1. Remove the mast and the battery.

(Refer to “Removal of mast” and “Removal of battery” in this
A chapter.)
a When removing the transfer, the frame is slung up with

the crane.
At this moment, to prevent accident from occurring,
remove the mast and the battery beforehand.
2. Remove by widening two claws at the portion B on the back

B side. Remove the claws at the portion A, steering plate and the
steering cover (1).
3. Remove the fixing bolts (2) and then the steering (3).
2
3
4. Hoist the rear inspection door (4) with the crane to remove it.
25 kg
AR50 Series 30-7

TRANSFER REMOVAL AND INSTALLATION
5. Remove six bolts and then the panel (5).
6. Remove three bolts and then the bracket (6).
7. Remove the speed sensor connectors (7) of drive motor at two

7
locations, temperature sensor connector (8) and connector (9)
of EPS assembly.
Connector (9): 2P connector for motor power supply
3P connector for torque sensor
30-8 AR50 Series

8. Remove two EPS fixing bolts and then the EPS assembly (10)
while lifting upward and pulling out backward.
20 kg
10
9. Remove the piping (11) of main pump at two locations.
11
10. Remove the wiring (12) of pump motor at three locations and
the speed sensor connector (13) at two locations.
12
13
AR50 Series 30-9

11. Remove three pump motor fixing nuts and hoist the pump
15 motor (16) with bracket (14) and main pump (15) installed
using the crane to remove the pump motor.
46 kg
16
14
12. Disconnect the wiring (DU, DV and DW cables) of drive motor

DW DV DU
at the controller block.
13. Remove the cotter pin (17) and then the brake linkage.
17
30-10 AR50 Series

14. Remove four drive motor fixing bolts. Hoist the drive motor (18)
with brake installed using the crane and pull it out backward.
50 kg
18
15. Hook the head guard and hoist it with the crane. While hoisting
the head guard, remove four transfer fixing bolts (19).
19
19
AR50 Series 30-11

16. Fix the transfer not to fall down.
17. Hoist the frame with the crane and remove the transfer from
the lower side of frame.
1.0 t, 1.3 t 810 kg

1.4 t, 1.5 t 860 kg
1.8 t 920 kg
30-12 AR50 Series

REMOVAL (RW TYPE)
1 1. Remove the mast and the battery.

(Refer to “Removal of mast” and “Removal of battery” in this
A chapter.)
a When removing the transfer, the frame is slung up with

the crane.
At this moment, to prevent accident from occurring,
remove the mast and the battery beforehand.
2. Remove by widening two claws at the portion B on the back

B side. Remove the claws at the portion A, steering plate and the
steering cover (1).
3. Remove the fixing bolts (2) and then the steering (3).
2
3
4. Hoist the rear inspection door (4) with the crane to remove it.
5. Remove six bolts and then the panel (5).
AR50 Series 30-13

6. Remove three bolts and then the bracket (6).
7. Remove two speed sensor connectors (7) of drive motor and

the temperature sensor connector (8).
7
8
8. Remove the connector (9) of EPS assembly.

Connector (9): 2P connector for motor power supply
3P connector for torque sensor
30-14 AR50 Series

9. Remove two EPS fixing bolts and then the EPS assembly (10).
10
10. Remove the piping (11) of main pump at two locations.
11
11. Remove the wiring (12) of pump motor at three locations and
the speed sensor connector (13) at two locations.
12
13
AR50 Series 30-15

12. Remove three pump motor fixing nuts and hoist the pump
15 motor (16) with bracket (14) and main pump (15) installed,
using the crane to remove the pump motor.
46 kg
16
14
13. Disconnect the wiring (DU, DV and DW cables) of drive motor

DW DV DU
at the controller block.
14. Remove the cotter pin (17) and separate the brake linkage.
17
30-16 AR50 Series

15. Remove four drive motor fixing bolts. Hoist the drive motor (18)
with brake installed with the crane and pull it out backward.
50 kg
18
16. Remove the fixing bolt and then the side panel (19).
19
17. Hook the head guard and hoist it with the crane. While hoisting
the head guard, remove eight transfer fixing bolts (20).
20
AR50 Series 30-17

18. Fix the transfer not to fall down.
19. Hoist the frame with the crane and remove the transfer from
the lower side of frame.
1.0 t, 1.3 t 810 kg

1.4 t, 1.5 t 860 kg
1.8 t 920 kg
30-18 AR50 Series

INSTALLATION
Install in reverse steps and note the following points.
1. Tightening torque of transfer fixing bolts (1) (RL type).

1
245 – 309 Nm
Transfer fixing bolt
{25 – 31.5 kgm}
2. Tightening torque of suspension fixing bolt (2) (RW type)
245 – 309 Nm
2 Suspension fixing bolt
{25 – 31.5 kgm}
3. Drive motor joint

• Facing up the larger diameter side of hole, assemble it.
• Apply the grease (G2-LI) to the spline portion (3).
AR50 Series 30-19

4. Tightening torque of drive motor fixing bolt (4)
RL Type 98 – 123 Nm
Drive motor fixing bolt
4 {10 – 12.5 kgm}
50 kg
RS Type
5. Adjustment of brake pedal

(Refer to “Chapter 20 Inspection/Adjustment”.)
6. EPS actuator
Apply the MOLI DRY SPRAY 5510 to the spline portion.
30-20 AR50 Series

REMOVAL AND INSTALLATION BATTERY (SIDE DRAW TYPE)
BATTERY (SIDE DRAW TYPE)
REMOVAL
When performing the battery draw operation, ensure to
1 set the fork lift truck in the unload state.
1. Confirm that the accelerator lever and the work equipment

control lever in the neutral position.
Then, turn the key switch to [ | ] (ON).
2. Lift up the fork 15 to 20 cm from the ground.

3. Turn the reach lever (1) toward you to retract the mast to the
operatorÅfs seat side completely.
4. In the state that the mast is completely retracted, step down the
battery lock pedal (2) to the lowest position.
Ensure to step down the battery lock pedal to the lowest
2
position. Otherwise, it leads to damage to the battery.
5. While stepping down the lock release pedal, turn the reach
lever forward to push out the mast.
The battery case (3) is drawn out together with the mast. (The
figure at the left hand side shows the drawn-out battery case
(3).)
6. Separate the battery plug.

7. Disconnect the battery cable from the fork lift truck and remove
the hose from the hose guide.
AR50 Series 30-21

BATTERY (SIDE DRAW TYPE) REMOVAL AND INSTALLATION
8. Hoisting four holes of battery case (3) with the lifting sling,
replace the battery.
a For battery mass, refer to the table below.
Voltage Battery Capacity Mass

3 165 Ah 320 kg
201 Ah 365 kg
48 V
210 Ah 440 kg
280 Ah 495 kg
INSTALLATION
1. Park the fork lift truck on a flat place.
2. Install the battery on the fork lift truck.

At this moment, install prudently so that the battery case fits in
4
the tray.
3. Confirm that the hydraulic hose sits on the hose guide (4) of
battery case.
a If the hydraulic hose is dislocated from the hose guide,
place it on the hose guide.
4. Connect the battery plug to the fork lift truck.

Ensure to thread the battery cable in between the cable guide
(5) and the frame.
(Except RW type)
Install the battery cable in the torsion-free state.
5
5. Pull slowly the reach lever (1) toward you.

1 The battery case is drawn in together with the mast.
6. Operate the reach lever (1) until the mast is completely drawn
in.
Then, the battery is locked and fixed to the fork lift truck.
When operating the reach, be positioned properly in the
operator's compartment.
30-22 AR50 Series

REMOVAL AND INSTALLATION BATTERY (FRONT SIDE-DRAW TYPE)
BATTERY (FRONT SIDE-DRAW TYPE)
REMOVAL
When performing the battery draw operation, ensure to
1 set the fork lift truck in the unload state.
1. Confirm that the accelerator lever and the work equipment

control lever are in the neutral position.
Then, turn the key switch to [|] (ON).
2. Lift up the fork 15 to 20 cm from the ground.

3. Turn the reach lever (1) toward you to retract the mast to the
operatorÅfs seat side completely.
4. In the state that the mast is completely retracted, step down the
battery lock pedal (2) to the lowest position.
Ensure to step down the battery lock pedal to the lowest
2
position. Otherwise, it leads to damage to the battery.
5. While stepping down the lock release pedal, turn down the
reach lever forward to push out the mast.
The battery case (3) is drawn out together with the mast. (The
figure at the left hand side shows the drawn-out battery case
(3).)
6. Separate the battery plug (12) using the battery plug release
lever (4).
AR50 Series 30-23

BATTERY (FRONT SIDE-DRAW TYPE) REMOVAL AND INSTALLATION
7. Release the tray door catch (5).
8. Open the tray door (6).
9. Turn the tray door stopper (7) to fix it to the tray.
10. Aligning the positioning pole (8) at the battery stand (or carrier)
with the positioning pole (9) at the tray side, insert the hook at
the tip of battery (or carrier) in the groove at the tray side.
30-24 AR50 Series

11. Release the stopper (10) at the tray side and the stopper (11)
at the stand (or carrier) side.
12. Draw out the battery case (3).

13. Hoisting four holes of battery case (3) with the lifting sling,
replace the battery.
a For battery mass, refer to the table below.
Voltage Battery Capacity Mass

165 Ah 320 kg
201 Ah 365 kg
48 V
210 Ah 440 kg
280 Ah 495 kg
AR50 Series 30-25

INSTALLATION
1. Park the fork lift truck on a flat place.
2. Move the battery stand (or carrier) on which the battery is

placed.
3. Aligning the positioning pole (8) at the battery stand (or carrier)
with the positioning pole (9) at the tray side, insert the hook at
the tip of battery (or carrier) in the groove at the tray side.
4. Release the stopper (11) at the battery stand (or carrier).
5. Place the battery case (3) on the tray side.
6. Lock the stopper (10) at the tray side and the stopper (11) at
the stand (or carrier) side.
30-26 AR50 Series

7. Elevate the battery stand (or carrier) 80 mm and move it from

the tray.
8. Turn the tray door stopper (7) to release it from the tray.
9. Close the tray door (6).
10. Lock the tray door catch (5).
AR50 Series 30-27

11. Connect the battery plug (12).
12. Confirm that the hydraulic hose sits on the hose guide (4) of
battery case.
a If the hydraulic hose is dislocated from the hose guide,
13 place it on the hose guide.
13. Connect the battery plug to the fork lift truck.

Ensure to thread the battery cable in between the cable guide
lock (14) and the frame. (Except RW type)
Install the battery cable in the torsion-free state.
14
14. Pull slowly the reach lever (1) toward you. Then, the battery is
1 pulled in together with the mast.
15. Operate the reach lever (1) until the mast is completely pulled
in and stops.
The battery case is locked and fixed to the fork lift truck.
When operating the reach, be positioned properly in the
operator's compartment.
30-28 AR50 Series

REMOVAL AND INSTALLATION DRIVE WHEEL (FOR RL TYPE)
DRIVE WHEEL (FOR RL TYPE)
REMOVAL
1. Park the machine in a flat place and place car stops under the
front and backside of the load wheel.
Jack up the frame so that the drive wheel should be 120 mm
above the ground. (Use the frame lifting fitting.)
After the jack-up, apply a square timber to the bottom of the
frame for safety.
2. Turn the drive wheel 90° so that it can face sideways, and then
remove the mounting bolts.
3. Draw the wheel through the hole on the skirt.
INSTALLATION
1. Raise the wheel and assemble it to the transfer by pushing
bottom of the tire with your knee.
2. Tighten the four bolts on the wheel.
AR50 Series 30-29

40. DISASSEMBLY AND ASSEMBLY

TRANSFER.................................................................................40-2
EPS ACTUATOR ......................................................................40-13
BRAKE SYSTEM ......................................................................40-37
CONTROL VALVE.....................................................................40-39
LIFT CYLINDER .......................................................................40-40
TILT CYLINDER........................................................................40-43
REACH CYLINDER ..................................................................40-44
MAST ........................................................................................40-45
DRIVE MOTOR.........................................................................40-46
PUMP MOTOR .........................................................................40-47
EPS MOTOR.............................................................................40-48
AR50 Series 40-1

TRANSFER DISASSEMBLY AND ASSEMBLY
TRANSFER
STRUCTURE
RW type
Turning bearing
Support L-support
Turning bearing
Turning gear
Steering shaft gear

Upper cover
Motorshaft gear
Intermediate gear
Pinion shaft
Drive shaft
Drain plug
Side cover
Bevel gear
40-2 AR50 Series

DISASSEMBLY AND ASSEMBLY TRANSFER
DISASSEMBLY
1. Support
1
1) Remove the joint (1).
2
2) Remove the screw (2), nut (3) and plate (4).
3
5 3) Remove the support (5).
4
2. Side cover
1) Remove six bolts (6) and then the side cover (7).
a Remove the drain plug (8) to drain oil beforehand.
3. Turning gear
1) Remove four bolts (9).
9
2) Remove the Turning gear (10) and the oil seal (11).
10
11
AR50 Series 40-3

4. Upper cover
1) Remove eight bolts (12) and then the upper cover (13).
12
13
5. Motor shaft gear, intermediate gear

1) Remove the motor shaft gear (13).
13 2) Remove the intermediate gear (14).
14
6. Pinion shaft assembly
15 1) Remove four bolts (15).

2) Remove the pinion shaft assembly (16) by hitting from the
bottom side.
16
40-4 AR50 Series

7. Drive shaft, drive gear

1) Remove the lock nut (17).
19
18 2) Remove the drive gear (18) and the drive shaft (19).
17
ASSEMBLY
1. Bearing, outer-lace, oil seal
3 Drive the outer-laces (1) and (2) of bearing and the oil seal (3)
2 in the case.
G2-LI (Lip portion)

1 standard specification
Oil seal (3)
GLT2-LI (Lip portion)
cold storage specification
Liquid gasket LG-5 (Outer circumference)
2. Drive shaft, drive gear

Assemble the drive shaft (4) and the drive gear (5) in the case
4 and tighten the lock nut (6) so that the torque of the bearing
5 becomes as shown below.
After tightening the lock nut, caulk it.
6
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
Startup torque At the screw hole portion of drive shaft
120 – 151 N {12.2 – 15.4 kgf}
3. Pinion shaft sub-assembly

Adjust using the shim (7) so that the startup torque of bearing
8 becomes as shown below.
And assemble the pinion shaft assembly.
1.5 – 2.9 Nm {0.15 – 0.30 kgm}

Startup torque At the hole portion of cage bolt
24.5 – 49 N {2.5 – 5.0 kgf}
7
147 – 196 Nm {15 – 20 kgm}
Lock nut (8)
(After tightening the lock nut, caulk it.)
AR50 Series 40-5

4. Pinion shaft assembly, shim
11 1) Assemble the pinion shaft assembly (9) and the shim (10)
in the case.
a For amount of shim, refer to step 3 in “Note when
assembling”.
10
9 2) Adjust the backlash and tooth contact.
a Refer to steps 4 and 5 in “Note when assembling”.
3) Apply LOCTITE to the bolt (11) and tighten it.
Bolt (11) LOCTITE #271
Tightening torque 59 – 74 Nm {6.0 – 7.5 kgm}
5. Intermediate gear, motor shaft gear

1) Drive the bearing (12) in the case.
14 2) Assemble the intermediate gear (13) in the case.
13
3) Assemble the motor shaft gear (14) in the case.
12
6. Side cover
Install the side cover (15) to the case with the bolt (16).
Bolt (16) LOCTITE #271
16 Plug (17) LG-5 to the screwed portion
15
17
40-6 AR50 Series

7. Upper cover
18 Install the O ring (19) to the upper cover (18). Then, install the
20
upper cover to the case with eight bolts (20).
Plug (21) Apply LG-5 to the screwed portion

21
19
8. Turning gear, oil seal, turning bearing

1) Install the turning gear (22) with four bolts (23).
23 25
Turning gear (22) Apply the NI GU TITE M grease No.2.
24 2) Drive the oil seal (24).

22
Oil seal (24) G2-LI (lip surface)
3) Drive the turning bearing (25).
Clearance of roller Fill G2-LI in it.
AR50 Series 40-7

9. Support
31 27
1) Drive the bearing outer-laces (27) and (28) in the support
(26).
26 2) Assemble the steering shaft (29) and the bearing (30) in
30 the support (26) and fix them with the snap ring (31).
3) Assemble the support (26) in the upper cover (18).
28
29 18
10. Turning bearing, plate, nut, screw

1) Drive the turning bearing (32).
36
35 Clearance of roller Fill G2-LI in it.
34
2) Assemble the plate (33) and tighten the nut (34) so that
33
the startup torque of turning bearing becomes as shown
32
below.
14.7 – 17.6 Nm {1.5 – 1.8 kgm}

Startup torque In the center of steering pinion gear
81.3 – 97.0 N {8.3 – 9.9 kgf}
3) Apply LOCTITE to the screw (35) and tighten it.
Screw (35) LOCTITE #271
4) Assemble the joint (36).
Spline teeth surface Apply the NI GU TITE M grease No.2.
40-8 AR50 Series

STARTUP TORQUE
1. Turning bearing block
As the startup torque can be changed by the degree of nut
tightening, adjust by tightening the nut so that the startup
torque becomes 14.7 to 17.6 Nm {1.5 to 1.8 kgm} (81.3 to
97.0 N {8.3 to 9.9 kgf}) in the center of steering pinion gear.
2. Drive shaft bearing block

As the startup torque can be changed by the degree of nut
tightening, adjust by tightening the nut so that the startup
torque becomes 7.8 to 9.8 Nm {0.8 to 1.0 kgm} (by hooking the
spring scale to the hole for drive wheel fixing bolt of drive shaft
120 to 151 N {12.2 to 15.4 kgf}).
AR50 Series 40-9

CALCULATING THE SHIMS INSERT AMOUNT

1. Pinion shaft section (Shims amount: S1)
1) Read the number (a) marked on the housing.
(A number is marked along the pinion mounting position
on the upper part of the housing.)
2) Take out the pinion shaft from the housing and measure
distance B using a height gauge to the second decimal
place.
3) Insert the value of distance B into the following expression
and calculate the value of (b).
b = (B – 152.15) × 100
Example: When B is 157.55

b = (152.55 – 152.15) × 100 = 40
4) Read the numbers (c and d) marked on the pinion shaft.

5) Insert the values of the (a) to (d) calculated above to the
following expression and calculate the thickness of the
pinion shaft mounting shim S1 (round the calculated value
off to one decimal place).
a+b+c+d
S1 = 0.25 +
100
6) Mount the shim of S1 on the pinion shaft and put it into the
housing (the thickness of the shim must be the same for
the right and left of pinion shaft).
Shim (thickness. S1)
40-10 AR50 Series

2. Bevel gear section (Shims amount: S2)

1) Read the number (e) marked on the housing.
2) Read the number (f) marked on the perimeter of the gear.
3) Press the bearing in the direction of the arrow without a
backlash and measure height G using a height gauge to
the second decimal place.
4) Insert the value of G into the following expression and
calculate the value of (g).
g = (33.7 – G) × 100
Example: When G is 33.56

g = (33.7 – 33.5) × 100 = 15
5) Insert the values of the (e), (f) and (g) calculated above
into the following expression and calculate the shim
thickness S2 for the back of the bevel gear (round the
calculated value off to one decimal place)
e+f+g
S2 = 0.29 +
100
6) Mount the shim of S2 on the bevel gear and put it into the
housing.
3. Checking backlash
1) After assembling the bevel gear and pinion shaft, measure
the backlash.
2) The backlash must be in the range between 0.06 and
0.25.
3) If the backlash is not in the correct range, adjust the
thickness of the shim (S2) used for the bevel gear.
AR50 Series 40-11

4. Check the tooth contact

1) Appropriate tooth contact
1) Tooth contact to be corrected

Move the gear in the direction of the arrow.
2) Cross contact
Since these conditions cannot rallly be corrected, use
gear without an adjustment unless the small or big end.
3) Miss contact
40-12 AR50 Series

DISASSEMBLY AND ASSEMBLY EPS ACTUATOR
EPS ACTUATOR
STRUCTURE
E.P.S. Motor
Slider case
Sensor
Shim Piston roller
Piston roller
shaft
Gear case cover

Piston case
Upper bushing Shaft B
Piston
Slider
Lower bushing
Plug
Spring
Slider roller shaft
Spacer
Slider roller Shaft A
Intermediate gear
E䊥䊮䉫
Gear
Gear case
AR50 Series 40-13

EPS ACTUATOR DISASSEMBLY AND ASSEMBLY
DISASSEMBLY
Note on assembling
(1) The actuator is a precision instrument. When disassembling the actuator, never force the parts by a screwdriver on a
machined area because it must not be gouged or scratched Place a soft plastic sheet on the work bench.
(2) Take care to prevent grease flowing out of the actuator when it is assembled.
(3) Work should be performed on a work bench (Special Tool No. 11).
1. Remove the Sensor

1
Remove the bolt (1) and then the sensor (2) with shim (3).
2. Remove the piston case

Never force the piston case off the slider case by inserting a
Guide (SST9) screwdriver between them.
As shown in left figure, insert a guide (4) between the cases
and fall the guide to separate them.
a As the sealing agent is applied, it is hard to remove it. But,

never remove forcibly with a screwdriver.
40-14 AR50 Series

3. Removing the slider case

Remove the four bolts and tap the seal of the sealing
compound with a plastic hammer to remove the slider case (5),
as shown in the left figure.

5 never remove forcibly with a screwdriver.
4. Remove the EPS motor

Remove three EPS motor fixing screws and rotate the motor
while hitting with the plastic hammer the flange portion of motor
marked with arrows in the figure 4-1. And make it in the state
shown in figure 4-2.
Fig. 4-1
By hitting the motor flange portion marked with arrow in figure

4-2 from the bottom with the plastic hammer, disengage the
EPS motor from bearing and remove it.

never remove forcibly with a screwdriver.
Fig. 4-2
AR50 Series 40-15

5. Removing the gear case cover
a Take care to prevent grease splashing.
a This work should be done by two people.
1) Remove the gear case cover fixing bolts.
2) Place the case horizontally as shown in the figure at the

6 left hand side. One person holds the case by hand.
Apply the dolly block to the location marked with arrow
and hit the dolly block with the hammer to separate the
gear case cover (6) from the gear case (7).
3) Hit with the plastic hammer the output shaft (8) that is
marked with arrow in the figure at the left hand side and
disengage the shaft from the bearing.
4) Remove the gear case cover (6) from the gear case (7).
6
7
8
40-16 AR50 Series

6. Intermediate gear, output gear, spacer

Remove the intermadiate gear (9), output gear (10) and spacer
11 (11).
9
a Take care not to make scars on the gear teeth surface and
the mechanically finished surface of gear case.
10
7. Bearing, oil sea

13 Remove the bearing (13) and the oil seal (12) from the gear
case.
7
a Take care not to make scars on the mechanically finished
surface of gear case.
12
8. Output shaft
Remove the snap ring (14) first and then the output shaft (8)
from the gear case cover by hitting with the plastic hammer as
shown in the figure at the left hand side.
14
9. Slider roller shaft, slider

Remove the slider roller shaft (15) by turning with a nipper and
then the slider (16).
a As LOCTITE is applied to the slider roller shaft, it is hard

to remove it. As the slider roller shaft is damaged when
removed, it cannot be re-used.
AR50 Series 40-17

a If the slider roller shaft (15) cannot be removed, replace it

with a set of parts A to E shown left figure.
A (16)
C (15)
D
E
B (8)
JUDGING STANDARDS FOR PARTS

Referring to “Chapter 50 Maintenance Standard”, judge parts.
40-18 AR50 Series

ASSEMBLY
Note on assembling
(1) Assemble on the work bench (special tool No.11).
(2) Use MOLY SPEED GREASE No. 0 (SUMICO LUBRICATION

CO., LTD)
Special tool
No.11
1. Oil seal, bearing

2 1) Drive the oil seal (1).
3 2) Drive the bearing (2).
Seal insertion depth 6mm
It should not protrude from the case edge surface.
2. Output gear
4 1) Grease in the gear case (3).
2) Assemble the output gear (4) in the gear case.
3
MOLY
SPEED
GREASE
No. 0
AR50 Series 40-19

3. Intermediate gear
5
6 1) Drive the bearing (6) in the intermadiate gear (5) and
assemble them in the gear case.
MOLY SPEED 2) Grease again as shown in the figure at the left hand side.
GREASE No. 0
3) Apply the sealing agent (THREEBOND #1215) to the

mating face of the gear case cover.
THREEBOND #1215
4. Output shaft sub-assembly

Drive the pin (8) in the output shaft (7) with the special tools
(No.1 and No.8).
40-20 AR50 Series

5. Gear case cover, sub-assembly of output shaft

1) Drive the bearing (10) in the gear case cover (9) and fix it
7 with the snap ring (11).
2) Assemble the output shaft (7) in the gear case cover (9)
11
and fix it with snap ring (12).
10 9
12
6. (Gear case cover/output shaft), spacer

7
9 1) Attach the guide stick to the gear case (3).
2) Inserting the spacer (13) in the output shaft (7), install it to
the (gear case cover/output shaft).
13 a Be careful for the spacer not to drop.
7. Dowel pin
Drive the dowel pin, using the special tool No. 7.
8. EPS motor
1) Apply the sealing agent (THREEBOND #1215) to the EPS
Motor bracket and assemble it.
a Wipe out the seeped extra sealing agent.
EPS motor
AR50 Series 40-21

2) Tighten the fixing bolts evenly in the numbered orders in

the figure at the left hand side several times.
5 1
14.7 – 34.3 Nm {1.5 – 3.5 kgm}
3 (Target: 24.5 Nm {2.5 kgm})
Motor
4 2
9. Input shaft sub-assembly

1) Drive three pins in the input shaft (14), using the special
tools No1, No.2 and No.12.
A: 4.1 +0.02
–0 (Drive with the special tool No.2)
B: 4.5 +0.02
–0 (Drive with the special tool No.1)
2) Apply the grease (MOLY SPEED GREASE No. 0) to the

shaded area in the figure at the left hand side.
40-22 AR50 Series

10. Slider sub-assembly

Apply the grease (MOLY SPEED GREASE No. 0) to the
shaded area. Apply grease thinly to the inner surface of slider
too.
Set the slider (15) to the output shaft and confirm that the slider
moves smoothly without being caught.
15
11. Slider roller shaft sub-assembly

1) Drive the roller (17) in the shaft (16), using the special
tools No.4 and No. 6.
2) Install the E ring (18).
a Confirm that the E ring is securely installed.
12. Slider, slider roller shaft

1) Assemble the slider (15) to the output shaft.
2) Apply a little amount of LOCTITE #271 to the screwed
portion of slider roller shaft (16).
15
a Do not apply too much LOCTITE.
LOCTITE #271
AR50 Series 40-23

3) To make it easier to install the slider roller shaft (16), float

the slider a little and install the slider roller shaft (16) to the
output shaft. Then, tighten it.
a When installing the slider roller shaft, be careful for

LOCTITE not to stick to the slider.
4) Confirm that the clearance between the pin of output shaft

and the slider is more than 0.5mm.
(See the figure at the left hand side.)
13. Spring
Set the spring (19) in the slider (15) as shown in the figure at
the left hand side.
14. Input shaft

Assemble the input shaft (20) as shown in the figure at the left
hand side.
a Assemble the input shaft (20) so that the pin at the lower
side enters in the cut portion of spring and the pin at the
upper side enters in the cut portion of slider.
40-24 AR50 Series

15. Confirmation of operation

1) Fix the output shaft with the shaft (21) so that it does not
rotate.
2) Thread the shaft (22) in the input shaft as shown in the
figure at the left hand side.
Turn a little in right and left directions and confirm that it
returns smoothly.
3) Apply the grease (MOLY SPEED GREASE No. 0) to the

oblong hole of slider and slider roller.
16. Slider case

Apply the sealing agent (THREEBOND #1215) to the shaded
portion. Assemble the slider case and tighten the fixing bolts
tentatively.
a Wipe off the seeped sealing agent
17. Bearing, spacer, shim, snap ring

1) Drive the bearing.
AR50 Series 40-25

2) Insert the shim and spacer.
a Thickness of shim
Insert the shim so that the clearance between the
shim and the snap ring becomes 0.2mm.
3) Insert the snap ring.
4) Drive the bearing.

Apply the a Apply the sealing agent (THREEBOND #1215) to the
sealing agent outer-lace and inner-lace of bearing.
(THREEBOND
#1215).
40-26 AR50 Series

18. Snap ring

Assemble the snap ring.
a The clearance between the snap ring and the bearing

exists.
(See the figure at the left hand side.)
19. Slider case fixing bolt

Tighten evenly the slider case fixing bolts that are tentatively
tightened several times.
14.7 – 34.3 Nm {1.5 – 3.5 kgm}

(Target: 24.5 Nm {2.5 kgm})
20. Startup torque

20 cm
Confirm that the startup torque is normal.
Startup torque 49.2 Nm {4 kgm}
20 kg
AR50 Series 40-27

21. Piston sub-assembly

1) Inject the bushings (2 pieces) from the lower side of piston
case (23), using the special tools No.9 and No.10.
2) Drive the piston roller shaft (25) in the piston roller (24),
using the special tool No. 5.
3) Place the piston in the piston case and confirm that the
piston moves lightly.
4) Apply LOCTITE #271 to the screwed portion of piston
roller shaft (25) and screw it in the piston.
1.96 – 2.45 Nm {0.2 – 0.25 kgm}
a Screw it in with care for LOCTITE not to stick to the

sliding surface of the piston.
5) Drive the plug in the piston case (23).
40-28 AR50 Series

6) Inject a little amount of grease (MOLY SPEED GREASE

No. 0) in the piston case and confirm that the piston
moves smoothly.
a Do not inject too much grease.
7) Apply the sealing agent (THREEBOND #1215) to the

shaded area in figure at the left hand side.
22. Piston case

1) Install the piston case (23) to the slider case (26).
26
a The piston roller should be securely installed in the
23
groove of slider.
2) Tighten tentatively the fixing screw (28) and drive the pin
(27), using the special tool No.3. Then, tighten the fixing
screw (28).
1.96 – 2.45 Nm {0.2 – 0.25 kgm}
28
27
AR50 Series 40-29

23. Sensor shim adjustment
Battery built in the case 2.0 V × 5 pieces = 10 V

Or external power source 10 V
1) Attach the sensor to the piston case using the 8) When the measured voltage is outside of the
mounting screw. range, increase or decrease the shim quantity
2) Set the EPS voltage checker as shown in the so that the voltage falls into the range.
drawing above.
When the voltage is Decrease the shim
3) Turn the EPS voltage checker volume so that the above the range amount
voltage on terminals and becomes 8 V.
When the voltage is Increase the shim
4) Measure the voltage between terminals below the range amount
and . This voltage is regarded as V1.
[Varying quantity of shim by 0.1 mm results in 0.07 V change in the voltage.]
5) Insert the value of V1 to the following
expression and calculate the shim quantity (T) 9) Insert the bar to the input shaft and, while
of shim A. turning the input shaft with hand, measure the
voltage between terminals and again.
T = (4 – V1) / 0.7 (mm)
4 ± 0.3 V
Voltage value
6) Remove the sensor. (at rotation of the input shaft)
Place the shim corresponding to quantity T,
a In case the voltage at certain position is
and then attach the sensor to the piston case
out of the range, adjust the shim so that
again.
all measured voltages are within the
7) Measure the voltage between terminals range at any given position.
and again, and make sure the voltage is
within the range given below.
Voltage value 4 ± 0.3 V (At neutral)
40-30 AR50 Series

10) Secure the output shaft so that it will not rotate. 11) Secure the output shaft again as done in step
Turn the input shaft to right or left, then move 10 above. Rotate the input shaft to its right and
your hand off the input shaft to let it move left extreme positions. Then, measure the
freely. After the input shaft is returned to its voltages between terminals and at 6 to
original position by the spring force (it is 8 positions along the circumference and make
neutral then), measure the voltage between sure that they are all within the range.
terminals and several times.
Make sure measured voltages are within the Voltage Full clockwise rotation: 7 ± 0.4 V
range given below. value Full Counter clockwise rotation: 1 ± 0.4 V
Clockwise rotation → neutral:

Voltage 7 V → 4 ± 0.3 V Voltage Decrease shim
value (V)
Counter clockwise rotation → neutral: 7.4
1 V → 4 ± 0.3 V Right extreme
6.6
a In case the voltage does not fall in the Increase shim
range, adjust the shim or replace the
slider.
4.3
3.7 Neutral
Decrease shim
1.4
Left extreme
0.6
Increase shim
AR50 Series 40-31

SPECIAL TOOL LIST
SST1 – 5
SST No. φA φB φC φD a b c d
SST1 4.0 +0.01 7.0 ± 0 1 15 20 4.5 +0.02 10.0 +0.05 30.0 15.0
–0 –0 –0
SST2 4.0 +0.01 7 0 ± 0.1 15 20 4.1 +0.02 10.0 +0.05 80.0 10.0
–0 –0 –0
SST3 4.0 +0.01 9.0 ± 0 1 15 20 3.5 +0.02 20.0 +0.05 70.0 10.0
–0 –0 –0
SST4 5.2 +0 10.0 15 20 10.0 +0 15.0 +0 75.0 10.0

–0.1 –0.1 –0.1
SST5 5.2 +0 10.0 15 20 15.0 +0 20.0 +0 70.0 10.0

–0.1 –0.1 –0.1
SST6
40-32 AR50 Series

SST7
SST8
AR50 Series 40-33

SST9
SST10
40-34 AR50 Series

SST11 (main assembly bench)
Weld A on the back of the B with a 1 mm spigot joint, so that the height of the A is 21 mm.
Surfaces of B and C shall be machined to VV after welding D x 3.
The side plate is not needed
AR50 Series 40-35

SST12
40-36 AR50 Series

DISASSEMBLY AND ASSEMBLY BRAKE SYSTEM
BRAKE SYSTEM
STRUCTURE
Adjusting screw
Remove the bolt
Brake spring
Pad
Brake spring
Disc brake
Pad
Adjusting screw
Remove the bolt
Cam
Support
Pin
AR50 Series 40-37

BRAKE SYSTEM DISASSEMBLY AND ASSEMBLY
DISASSEMBLY
1. Loosen the Brake spring Lock nut (1) on the brake springs to
1 make the brake inoperative.; Then remove the brake spring
Lock nut and the brake spring (2).
2. Remove the bolt (3) and remove the pad (4).

3
3. Remove the pin (5), the adjusting screw (6), and the cam (7).
6
a Do not grip the cam with pliers.
5 7

ASSEMBLY
Assembly of the disk brake is the reverse of the disassembly
procedure.
Pay attention to the following:
1. Fill the cam with grease (G2-LI).
2. Pad mounting bolt tightening torque:
Pad mounting bolt 17.7 – 26.5 Nm {1.8 – 2.7 kgm}
a Take care not to smear oil on the pad friction face or the
disk.
Grease the perimeter of the cam 3. Referring to “Chapter 20 Inspection/Adjustment”, adjust the
disc brake, brake pedal and linkage.
40-38 AR50 Series

DISASSEMBLY AND ASSEMBLY CONTROL VALVE
CONTROL VALVE
D
E
B
A
CAUTIONS FOR DISASSEMBLY AND ASSEMBLY

1. Tightening torque
A Spring sheet fixing screw tightening torque 18.6 Nm {1.90 kgm}
B M8 19 Nm {1.94 kgm}
Valve fixing nut tightening torque
C M10 46 Nm {4.7 kgm}
D Seal plate fixing screw tightening torque 2.9 Nm {0.3 kgm}
E Socket head bolt tightening torque 9 – 11 Nm {0.9 – 1.11 kgm}
M4 2.7 – 3 Nm {0.28 – 0.31 kgm}
F Solenoid valve mounting tightening torque
1/4-16UNF 27.5 – 33.4 Nm {2.80 – 3.40 kgm}
G Nut, valve 10 – 12 Nm {1.0 – 1.2 kgm}
Shut-off valve mounting tightening torque
H Plug 39 ± 1 Nm {3.87 – 4.08 kgm}
2. Repair scratches on the spool and body interiors by 4. Wash metallic parts in kerosene, gas oil, or
polishing them with a fine grindstone or an abrasive trichlene Coat them with hydraulic oil by spraying
cloth. with air.
3. Wash rubber parts in hydraulic oil. Grease them 5. Keep away from fire.
before mounting. Assemble them by taking care not
to damage them.

AR50 Series 40-39

LIFT CYLINDER DISASSEMBLY AND ASSEMBLY
LIFT CYLINDER
STRUCTURE
(More than 4 m)
1. Cylinder 7. O-ring 13. Collar
2. Piston rod 8. U-ring 14. O-ring
3. Cylinder head 9. Backup ring
4. Bushing 10. Bushing
5. U-ring 11. Bearing
6. Wiper seal 12. Snap ring
40-40 AR50 Series

DISASSEMBLY AND ASSEMBLY LIFT CYLINDER
(Less than 4 m)
1. Cylinder 7. O-ring 13. Collar
2. Piston rod 8. U-ring 14. O-ring
3. Cylinder head 9. Backup ring 15. Check valve
4. Bushing 10. Bushing 16. Plug
5. X-ring 11. Bearing 17. Gasket
6. Wiper seal 12. Snap ring
AR50 Series 40-41

LIFT CYLINDER DISASSEMBLY AND ASSEMBLY
Item Unit High Lifting Height 3 to 3.5m High Lifting Height Higher than 4.7m
Cylinder outer diameter mm φ 52 φ 57
Cylinder inner diameter mm φ 45 φ 50
Piston rod diameter mm φ 35 φ 40
a Numbers in the figure correspond to numbers in the exploded view in the previous page.
a The lift cylinder of RW and RL (3 to less than 4m) fork lift trucks differs in shape from that in the above figure.
Judging standard
Judging Standard
Sym
Check Item Basic dimension Allowable limit Treatment
bol
(mm) (mm)
Clearance between High lifting height: 3 – 4.5 m 0.06 – 0.235 0.4 Replace a
A
piston rod and bushing High lifting height: higher than 4.7m 0.04 – 0.023 0.35 bushing.
Clearance between High lifting height: 3 – 4.5 m 0.05 – 0.30 0.5 Replace a
B
piston ring and cylinder High lifting height: higher than 4.7m 0.05 – 0.035 0.5 piston ring.
40-42 AR50 Series

DISASSEMBLY AND ASSEMBLY TILT CYLINDER
TILT CYLINDER
Cylinder outside diameter 65 mm
Cylinder inside diameter 50 mm
Piston rod outside diameter 25 mm
Stroke 43 mm

AR50 Series 40-43

REACH CYLINDER DISASSEMBLY AND ASSEMBLY
REACH CYLINDER
O. D of cylinder 60 mm (2.36 in)
I. D. of cylinder 50 mm (1.97 in)
O. D. of Rod 30 mm (1.18 in)
Stroke Listed below

40-44 AR50 Series

DISASSEMBLY AND ASSEMBLY MAST
MAST
STRUCTURE

ADJUSTMENT AT ASSEMBLY
Referring to “Chapter 20 Inspection/Maintenance”, adjust.
AR50 Series 40-45

Drive Motor DISASSEMBLY AND ASSEMBLY
DRIVE MOTOR
STRUCTURE
4 5
8 6
1. Frame 5. Shaft
2. Stator 6. Temperature Sensor
3. Rotor 7. Speed Sensor
4. Bracket (Connection side) 8. Bracket (Opposite to the connection side)
40-46 AR50 Series

DISASSEMBLY AND ASSEMBLY Pump Motor
PUMP MOTOR
STRUCTURE
4 5
8 6
1. Frame 5. Shaft
AR50 Series 40-47

EPS MOTOR DISASSEMBLY AND ASSEMBLY
EPS MOTOR
STRUCTURE
40-48 AR50 Series

DISASSEMBLY AND ASSEMBLY EPS MOTOR
DISASSEMBLY
1. Remove the brush band.
2. Remove the M4 screw and raise the brush spring to take out
the brush.
3. Remove the through bolt and remove the rear and front
brackets.
a Gently lift and remove the brackets without wrenching
them off
4. Hold the front part of the armature and firmly pull the armature
straight out.
a Take care not to damage the armature and magnet. Make
sure that dust or metal powder has not accumulated on
the magnet.
AR50 Series 40-49

EPS MOTOR DISASSEMBLY AND ASSEMBLY

ASSEMBLY
Carry out assembly in the reverse order to removal, paying attention
to the following points.
1. Direction of yoke
Note the front and rear sides of the yoke.
2. Inserting armature shaft

When inserting the armature shaft into the yoke, take care to
avoid injury to the hands as the armature shaft will be drawn
toward the magnet on the inner surface of the yoke. Also care
should be taken so that the commutator faces are not
damaged.
3. Movement of brushes
Place the brushes in the brush holder. With the brush springs
set, confirm that the brushes move smoothly in the holder.
4. Positioning notches
Align the notches provided on the yoke and rear bracket for
assembly.
40-50 AR50 Series

DISASSEMBLY AND ASSEMBLY EPS MOTOR
INSPECTION AFTER ASSEMBLY

1. Rotation
Remove set of brush springs from the brushes and hold the
brushes 10 mm above the commutator face.
Then, turn the armature shaft by hand and confirm that it turns
smoothly.
2. Insulation resistance
As illustrated, set the (–) ground probe of the megohmmeter to
the through-bolt and the (+) line to the connector pin. Make
sure the insulation resistance measurement reads the
specified value.
Specified Over 0.5 MΩ

value (DC 500 V megohmmeter)
3. No-load operation
With power supplied at 12 V, perform no-load operation to
check the points below.
1) That the motor rotates smoothly.

2) That no sparking is generated from the contact faces of
the brushes and commutator.
AR50 Series 40-51

50. MAINTENANCE STANDARD

TRANSFER.................................................................................50-2
DRIVE WHEEL ...........................................................................50-3
LOAD WHEEL ............................................................................50-3
SUSPENSION AND CASTER WHEEL ......................................50-4
CASTER WHEEL........................................................................50-5
FRONT DRAW TRAY .................................................................50-7
BATTERY INTERLOCK MICRO-SWITCH .................................50-8
FLOOR PLATE ASSEMBLY (RL TRUCK) ..................................50-9
BRAKE......................................................................................50-10
EPS ACTUATOR ......................................................................50-11
CONTROL VALVE SWITCH .....................................................50-13
CONTROL VALVE ....................................................................50-14
LIFT CYLINDER .......................................................................50-15
REACH CYLINDER ..................................................................50-16
TILT CYLINDER........................................................................50-17
MAST ........................................................................................50-17
DRIVE MOTOR.........................................................................50-18
PUMP MOTOR .........................................................................50-20
POWER STEERING (EPS) MOTOR ........................................50-22
CONTROLLER .........................................................................50-24
AR50 Series 50-1

TRANSFER MAINTENANCE STANDARD
TRANSFER
Judgment criteria
Symbol Check item Treatment
Standard size (mm) Allowable limit (mm)
Backlash between motor shaft gear

A – 0.4 or less
and intermediate gear
Replacement
Backlash between pinion shaft gear
B – 0.4 or less
and intermediate gear
Adjust using
Backlash between pinion shaft and
C – 0.1–0.25 shim (S2) for
drive gear
drive gear
– Bearings Shall be free from play or flaws Replacement
50-2 AR50 Series

MAINTENANCE STANDARD DRIVE WHEEL
DRIVE WHEEL
Judgment criteria
RS, RW type 330 274

Outside diameter of
A Replace
drive wheel
RL type 360 289
LOAD WHEEL
G.L
Judgment criteria
0.9 t – 1.3 t 260 217

Outside diameter of
A Replace
load wheel
1.4 t – 1.8 t 254 229
AR50 Series 50-3

SUSPENSION AND CASTER WHEEL MAINTENANCE STANDARD
SUSPENSION AND CASTER WHEEL
RS, RW TYPE
㩿㪪㪼㫋㩷㫃㪼㫅㪾㫋㪿㩷㫆㪽㩷㫊㫋㫆㫇㫇㪼㫉㩷㪹㫆㫃㫋㪀
245 – 309 Nm {25 – 31.5 kgm}
㪉㪌㪅㪌
Z
X-X
245 – 309 Nm {25 – 31.5 kgm}
Y
X
98 – 123 Nm {10 – 12.5 kgm}

㪌㪇㪅㪌
㪈㪈㪏㫧㪈
24.5
(Set length of stopper bolt)
Z
Y
Judgment criteria
RS, RW type 150 120

Outside diameter of
A Replace
caster wheel
RL type 127 102
50-4 AR50 Series

MAINTENANCE STANDARD CASTER WHEEL
CASTER WHEEL
RL TYPE
Bracket
Damper (E)
Rubber
B C
Support
Upper shim
Dust seal Lower

shim
Plate
D
Rod head A
Judgment criteria
A Outside diameter of caster wheel 127 102
B Shaft outside diameter 25 24.8
C Bush inside diameter 25 25.2 Replacement
D Free length of caster wheel spring 70 67
E Damper (Unable to disassemble) Appearance, no crack, no scar, no oil leakage
AR50 Series 50-5

CASTER WHEEL MAINTENANCE STANDARD
SHIM ADJUSTMENT (RIGHT CASTER BRACKET)
Right caster bracket
Left caster wheel

Drive wheel allowable wear 35 mm
Caster wheel allowable wear 12.5 mm
Upper shim
12 mm 12 mm
12 mm 12 mm
Lower shim
Allowable wear
When replacing a tire due to wear, the shim adjustment of right caster bracket may be necessary.
(When replacing a tire, the adjustment of left caster wheel is not necessary.)
In case of following replacement, as the drive tire may slip, according to the following adjustment, perform the shim
adjustment.
<A> When replacing the drive wheel and the right caster wheel with new ones at the same time.
→ The adjustment is not necessary.
<B> When replacing the drive wheel only with a new one. → The adjustment is necessary.
<C> When replacing the right caster with a new one

→ Depending on the extent of wear of drive wheel, the adjustment is necessary.
To meet the wear of drive wheel, perform the shim adjustment.
Shim adjustment at tire replacement
<A> <B> <C>

Replace the drive Replace the caster wheel only.
wheel. Replace the drive Wear of drive wheel <Reference>
Replace the caster wheel only.
0 to 16.5 mm 16.5 to 33 mm New truck
wheel.
Adjustment is not Adjustment is Adjustment is not Adjustment is
necessary. necessary. necessary. necessary.
Upper shim (mm) 12 24 12 0 12
Lower shim (mm) 12 0 12 24 12
50-6 AR50 Series

MAINTENANCE STANDARD Front Draw Tray
FRONT DRAW TRAY
adjustment bolt b
adjustment bolt a
G2-LI
Adjust so that the dimension C becomes

0 to 0.5mm. (The pedal should move smoothly.)
X
ADJUSTMENT
1. Adjustment of play of tray at front and rear
1) Push the tray in the depth of frame rear block and link it with the pedal link.
2) Draw out the tray and touch the head of bolt (a) to the rear block, eliminating the play of pedal.
3) Rotate counterclockwise the bolt two turns (turn back) and fix it with the lock nut.
2. Adjustment of tray push-in bolt (Portion P)
1) Reach in and rotate the bolt until the head of bolt touches the rubber (stopper).
2) Reach out and rotate the bolt two turns and fix it with the lock nut.
3. Adjustment of play of tray at right and left.
1) Push the tray to the right side.
2) Loosen the nylon nut fixing the adjustment plate and screw in the adjustment bolt (b) until it touches the edge of
guide leg.
3) Turn back the adjustment bolt (b) (counterclockwise) 1.5 turns and fix it with the lock nut.
AR50 Series 50-7

Battery Interlock Micro-switch MAINTENANCE STANDARD
BATTERY INTERLOCK MICRO-SWITCH
RL type
ADJUSTMENT
1. Adjust so that the limit switch turns on when the dimension A1, which is the difference between point E and point F,
is 9 mm (Faces A and B are in parallel.).
2. Adjust the length of stopper D so that the limit switch C turns off when the dimension A2, which is the difference
between point E and point F, is 23.5 mm.
RW type
ADJUSTMENT
1. Adjust so that the limit switch turns on when the dimension A1, which is the difference between point E and point F,
is 1 mm (Faces A and B are in parallel.).
2. Adjust the length of stopper D so that the limit switch C turns off when the dimension A2, which is the difference
between point E and point F, is 13 mm.
50-8 AR50 Series

MAINTENANCE STANDARD FLOOR PLATE ASSEMBLY (RL TYPE)
FLOOR PLATE ASSEMBLY (RL TYPE)
Switch
5 mm
(at both right and left)
㪈㪉㪊
㪭㫀㪼㫎㪼㪻㩷㪽㫉㫆㫄
㪼㫅㪾㪸㪾㪼㫄㪼㫅㫋
ADJUSTMENT
1. Adjust the plate C so that the roller B turns on when the roller comes to the position A and the roller B turns off when
depressing the roller 10 mm. At this moment, the switch B should not be forcibly pressed.
2. After installing the floor plate, check the conduction between above connector pins.
When the floor is open When the floor is stepped down
Pins 2 and 3 only are conducted. Pins 1 and 3 only are conducted.
3. Fill the lithium grease (G2-LI) in.

Before connecting the truck, grease it.
(Fill GLT2-LI for cold storage type truck.)
4. Adjust so that the clearance between the floor plate and the center panel becomes 5 mm.
AR50 Series 50-9

BRAKE MAINTENANCE STANDARD
BRAKE
Pedal Block Brake Pad
Pad
a Ensure to replace 2 sheets

E
of brake pad as a pair.
Judgment criteria
Replace 2
A Thickness of brake pad 11 4
sheets as a pair.
B Surface of cam to contact to adjusting screw • It is not worn to the extent of metal
exposure.
C Surface of adjusting screw to contact to cam • No scar is found.
D Outer diameter of brake pedal shaft 16 More than 15.8 Replacement
E Inner diameter of bushing 16 Less than 16.2
— Thickness of brake disc Å| More than 7
50-10 AR50 Series

MAINTENANCE STANDARD EPS ACTUATOR
EPS ACTUATOR
'
$
&
'
O
<
O <
<
AR50 Series 50-11

EPS ACTUATOR MAINTENANCE STANDARD
Judgment criteria
A Gear case machining surface Shall be free from flaws or bruising
B Gear case cover machining surface Shall be free from flaws or bruising
Replacement
C Piston sliding surface Shall be free from flaws
D Piston case sliding surface Shall be free from flaws
Replace
together
E Bush sliding surface Shall be free from flaws or abnormal wear
with piston
case
F1 Slit width 4.0–4.2 4.2 or less

F Slider
Replacement
– Gears No flaw, bruise on tooth surface
– Bearings Shall turn smoothly
50-12 AR50 Series

MAINTENANCE STANDARD CONTROL VALVE SWITCH
CONTROL VALVE SWITCH
G2-LI (GLT2-LI for cold storage type truck)

0.5 - 1 mm
Maximum 2.5 Nm {25 kgcm}
LOCKTITE #271
ADJUSTMENT
1. Adjust the lift potentio meter so that the output becomes 2.5V ± 0.1V when the lever is in the neutral position.
Then, turn the lever backward and confirm that the output is 1.2V ± 0.1V.
Return the lever in the neutral position again and confirm that output is 2.5 ± 0.1V
2. Adjust the micro-switches of tilt, reach and attachment so that they turn on within the stroke of 15 to 25 from the lever
neutral position.
AR50 Series 50-13

CONTROL VALVE MAINTENANCE STANDARD
CONTROL VALVE
C
B
Judgment criteria
Standard size Allowable limit
(mm) (mm)
A Spool return spring 56.8 More than 51
B Check valve spring 25.4 23

Spring free length
C Tilt lock spring 26 23.5 Replacement
D Load check spring 26.7 24
E Spool and housing No flash, no scar
F Relief valve set pressure 16.7 MPa (170 kgf/cm2) Adjustment
50-14 AR50 Series

MAINTENANCE STANDARD LIFT CYLINDER
LIFT CYLINDER
HIGH LIFTING HEIGHT LOWER THAN 4.7M
Judgment criteria
Replace the
A Clearance between piston rod and bushing 0.06 – 0.235 Less than 0.4
bushing
Replace the
B Clearance between cylinder and piston ring 0.05 – 0.30 Less than 0.5
piston ring
HIGH LIFTING HEIGHT HIGHER THAN 4.7M
Judgment criteria
Check item Treatment
Replace the
Clearance between piston rod and bushing 0.04 – 0.023 0.35
bushing
Replace the
Clearance between piston ring and cylinder 0.05 – 0.035 0.5
piston ring
AR50 Series 50-15

REACH CYLINDER MAINTENANCE STANDARD
REACH CYLINDER
235 ± 53.9 Nm {24 ± 5.5 kgm}

149 ± 27.5 Nm
THREE BOND # 1902 (THREADS) {15.2 ± 2.8 kgm}
Judgment criteria
A Clearance between cylinder head and piston rod 0.19 max. 0.35 max.
B Cylinder head Wear variation should be 0.15 max.
Should be free of dents, flaws, or bent that

C Piston rod
could adversely affect normal operation
Replacement
D Clearance between cylinder and piston 0.19 max. 0.35 max.
E Piston Sliding section should be free of flaws
F Cylinder Sliding section should be free of flaws
List of reach cylinder strokes
Type 09R 10R 13R 14R 15R 18R
StrokesÅimmÅj 380 440 580 480 580 730
50-16 AR50 Series

MAINTENANCE STANDARD TILT CYLINDER
TILT CYLINDER
Judgment criteria
Clearance between cylinder head and

A 0.121–0.210 0.3 Replacement
piston rod
MAST
Judgment criteria
Check item Treatment
Standard size (mm) Repair limit (mm)
0.5–1.0
To side 2.0 (0.08) Shim adjustment
(0.02–0.04)
Clearance between outer
and inner masts
0.1–0.3 Replace with the
To front/rear 2.0 (0.08)
(0.004–0.012) oversize roller
0.5–2.0
To side 2.0 (0.08) Shim adjustment
(0.02–0.08)
Clearance between inner mast and
roller support
0.1–0.3 Replace with the
To front/rear 2.0 (0.08)
(0.04–0.012) oversize roller
Clearance between reach leg 0.1–0.5 Replace with the

Vertical 2.0 (0.08)
and mast support (0.004–0.02) oversize roller
AR50 Series 50-17

Drive Motor MAINTENANCE STANDARD
DRIVE MOTOR
STRUCTURE
4 5
8 6
1. Frame 5. Shaft
50-18 AR50 Series

MAINTENANCE STANDARD Drive Motor
MAINTENANCE
1. Routine Maintenance
1) Maintenance at operation
Check Item Check Location Criteria Treatment

No change comparing with normal If dust is heavily
Environment
Dust Motor frame operation. Normal temperature rise. accumulated, stop and
Visual check. clean it.
Foreign No change comparing with normal Recover to the normal

matters, Motor frame operation. state.
spray, liquid Visual check.
No vibration different from normal one or If values exceed the

Motor frame
Vibration no increase of amplitude. level allowed, stop and
Bearing, cover, etc Visual check. Hearing check. eliminate the cause.
No sound different from normal one or no If the operation is

Motor frame increase of noise level. Compare with new
Foreign Noise affected, stop and
Bearing, cover, etc one by using a hearing stick. eliminate cause.
Hearing check.
2) Maintenance at stop
Looseness, sticking of dust and rust should not

Tightening Tightening exist. Tighten. Clean. Paint.
portion screws Visual check. Hitting sound check.
Connection should be correct.

Connection Connected parts should not be loose. Tighten. Check the
block They should be insulated. insulation.
Visual check.
Terminal
Connection No damage on sheath (cladding). Repair at the special
block of terminal Visual check. factory.
and harness
Dust sticking.
Iron core Clean.
Visual check.
Stator and rotor
assembly Coil and Clean.
Insulating resistance is more than 1 MΩ.
insulation of Dry by heating.
(Measure at 500 V mega.)
connected part Vanish work.
Confirmation of Remove foreign

Speed sensor No sticking of foreign matters
gap matters.
Reference value
Temperature Measure the At 20°C: 11.7 – 14.3 kΩ
sensor resistance. At 25°C: 9.7 – 11.8 kΩ
Dust, discolor, peeling and rust should not exist. Rust prevention.
Paint Damage Visual check. Re-paint.
Clean.
Dirt, dust Dirt, sticking of dust and rust should not exist.
Cleaning Rust prevention.
accumulation Visual check. Re-paint.
AR50 Series 50-19

Pump Motor MAINTENANCE STANDARD
PUMP MOTOR
STRUCTURE
4 5
8 6
1. Frame 5. Shaft
50-20 AR50 Series

MAINTENANCE STANDARD Pump Motor
MAINTENANCE
1. Routine Maintenance
1) Maintenance at operation

No change comparing with normal If dust is heavily
Environment
Dust Motor frame operation. Normal temperature rise. accumulated, stop and
Visual check. clean it.
Foreign No change comparing with normal Recover to the normal

matters, Motor frame operation. state.
spray, liquid Visual check.
No vibration different from normal one or If values exceed the

Motor frame
Vibration no increase of amplitude. level allowed, stop and
Bearing, cover, etc Visual check. Hearing check. eliminate the cause.
No sound different from normal one or no If the operation is

Motor frame increase of noise level. Compare with new
Foreign Noise affected, stop and
Bearing, cover, etc one by using a hearing stick. eliminate cause.
Hearing check.
2) Maintenance at stop
Looseness, sticking of dust and rust should not

Tightening Tightening exist. Tighten. Clean. Paint.
portion screws Visual check. Hitting sound check.
Connection should be correct.

Connection Connected parts should not be loose. Tighten. Check the
block They should be insulated. insulation.
Visual check.
Terminal
Connection No damage on sheath (cladding). Repair at the special
block of terminal Visual check. factory.
and harness
Dust sticking.
Iron core Clean.
Visual check.
Stator and rotor
assembly Coil and Clean.
Insulating resistance is more than 1 MΩ.
insulation of Dry by heating.
(Measure at 500 V mega.)
connected part Vanish work.
Confirmation of Remove foreign

Speed sensor No sticking of foreign matters
gap matters.
Reference value
Temperature Measure the At 20°C: 11.7 – 14.3 kΩ
sensor resistance. At 25°C: 9.7 – 11.8 kΩ
Dust, discolor, peeling and rust should not exist. Rust prevention.
Paint Damage Visual check. Re-paint.
Clean.
Dirt, dust Dirt, sticking of dust and rust should not exist.
Cleaning Rust prevention.
accumulation Visual check. Re-paint.
AR50 Series 50-21

POWER STEERING (EPS) MOTOR MAINTENANCE STANDARD
POWER STEERING (EPS) MOTOR
A: Commutator O.D. F: Brush spring pressing force
B: Depth of mica
50-22 AR50 Series

MAINTENANCE STANDARD POWER STEERING (EPS) MOTOR
G: Brush height E: Insulation of holder ring
D: Insulation of armature
Judgment criteria (mm)

Sym
Check item Measuring instrument Treatment
bol
Standard size Repair limit
A Outside diameter of commutator Calipers 30.5 29.5 Replace
Undercut the mica

and polish the
B Depth of mica Calipers 0.6 – 0.8 0.2 or more surface of the
commutator with No.
400 sandpaper.
C Bend of armature shaft Dial gauge 0.06 or less 0.2 or less
0.5 MΩ
D Insulation of armature –
or more
Megohmmeter
E Insulation of field coil
(DC 500 V)
Replace
0.5 MΩ
F Insulation of holder ring –
or more
2.5 N
G Pressing force of brush spring Spring balance 3.9 N {0.4 kgf}
{0.25 kgf}
H Height of brush Calipers 19 13
AR50 Series 50-23

CONTROLLER MAINTENANCE STANDARD
CONTROLLER
Item Specification
Input Voltage 48 V
Traveling 224 – 247 A
Lock current value Hydraulic Pressure 226 – 276 A
EPS 30 ± 1.5 A
Traveling Less than 50ms

Shutdown time when the output circuit shorts
Hydraulic Pressure Less than 50ms
Rated Voltage 48 V
Coil Suction Voltage 36 V

Main contact (MC)
Open Voltage 9V
Maximum Shutdown Current 2,000 A
50-24 AR50 Series

60. STRUCTURE AND FUNCTION

TRANSFER.................................................................................60-2
CASTER WHEEL........................................................................60-6
SUSPENSION ............................................................................60-7
BRAKE........................................................................................60-8
EPS (ELECTRIC POWER STEERING)......................................60-9
CONTROL VALVE ....................................................................60-12
HYDRAULIC CIRCUIT DIAGRAM ............................................60-13
FREE LIFT MAST .....................................................................60-14
FV MAST (STD)........................................................................60-16
VT MAST ..................................................................................60-18
FORK CARRIAGE ....................................................................60-20
CONTROLLERS .......................................................................60-21
FR ACCELERATOR..................................................................60-26
CHARGER (MOUNTED ON TRUCK SYSTEM) (OPTION)......60-27
BATTERY CHARGER (STATIONARY TYPE) (OPTION) .........60-31
ELECTRICAL CIRCUIT DIAGRAM ..........................................60-34
AR50 Series 60-1

TRANSFER STRUCTURE AND FUNCTION
TRANSFER
RL type
A-A
GO75 (3.4 )
LG-5
A A
LOCTITE #271
LG-5 LOCTITE #271

5.9 – 11.8 Nm
{0.6 – 1.2 kgm}
Assemble so that R comes

to this position.
60-2 AR50 Series

STRUCTURE AND FUNCTION TRANSFER
More than 2 (flat portion) More than 1 (flat portion)

These portions should These portions should
contact at three locations. contact at three locations.
Z Y
In the center of steering pinion gear
81.3 – 97.0 N {8.3 – 9.9 kgf }
14.7 – 17.6 Nm
Startup torque
{1.5 – 1.8 kgm}
NLGI NO.2
(SAE J 310a) LOCTITE #271
G2-LI
147 – 196 Nm {15 – 20 kgm}
NLGI NO.2
(SAE J 310a)
Startup 1.5 – 2.9 Nm

torque {0.15 – 0.30 kgm}
LG-5
Measurement b
Case stamp a
Shaft stamp d
Shaft stamp c

torque {0.8 – 1.0 kgm}
G2-LI
Gear stamp h Bearing measurement g
Case stamp d
AR50 Series 60-3

TRANSFER STRUCTURE AND FUNCTION
RW type
LG-5
GO75 (3.4 )
LOCTITE #271
1+..'8'.
LG-5 LOCTITE #271
5.9 – 11.8 Nm
{0.6 – 1.2 kgm}
Assemble so that R comes

to this position.
60-4 AR50 Series

STRUCTURE AND FUNCTION TRANSFER
More than 2 (flat portion) More than 1 (flat portion)

These portions should These portions should
contact at three locations. contact at three locations.
Z Y
In the center of steering pinion gear
81.3 – 97.0 N {8.3 – 9.9 kgf }
LOCTITE #271
torque {1.5 – 1.8 kgm}
G2-LI
NLGI NO.2
(SAE J 310a) NLGI NO.2
(SAE J 310a)
147 – 196 Nm {15 – 20 kgm}

torque {0.15 – 0.30 kgm}
LG-5
Measurement b
Case stamp a
Shaft stamp d
Shaft stamp c
Gear
Startup 7.8 – 9.8 Nm stamp h Bearing measurement g
torque {0.8 – 1.0 kgm} G2-LI
Case stamp d
AR50 Series 60-5

CASTER WHEEL STRUCTURE AND FUNCTION
CASTER WHEEL
RL type
9 *: Unable to disassemble the damper
Bracket
5
8
Cap
Damper* Pin
G2-LI
G2-LI
Nut
Washer
Rubber
Stud Bearing
Damper
Link
Support Bracket
Bearing
Dust seal
Bracket Seal
Plate
Bracket
Rod head G2-LI

147 – 309 Nm
{15 – 31.5 kgm}
Plate 39 – 49 Nm
{4 – 5 kgm}
Washer
Bracket
Spring
Link
Bracket
Bushing
G2-LI
Bearing
Cut View of Damper

Snap ring
(Unable to disassemble the damper)
Bracket
60-6 AR50 Series

STRUCTURE AND FUNCTION SUSPENSION
SUSPENSION
RW type
㩿㪪㪼㫋㩷㫃㪼㫅㪾㫋㪿㩷㫆㪽㩷㫊㫋㫆㫇㫇㪼㫉㩷㪹㫆㫃㫋㪀
245 – 309 Nm {25 – 31.5 kgm}
㪉㪌㪅㪌
Z
X-X
245 – 309 Nm {25 – 31.5 kgm}
Y
X
98 – 123 Nm {10 – 12.5 kgm}

㪌㪇㪅㪌
㪈㪈㪏㫧㪈
24.5
Z
Y
AR50 Series 60-7

BRAKE STRUCTURE AND FUNCTION
BRAKE
Lock securely the nuts at both ends.
196 – 245Nm {20 – 25 kgm}
Adjust the shim so that the

difference between the center
of rotor and the center of brake 34.3 – 73.5 Nm {3.5 – 7.5 kgm}
is within ± 0.5mm.
After tightening the bolt, confirm

that the lever rotates smoothly.
G2-LI
60-8 AR50 Series

STRUCTURE AND FUNCTION EPS (Electric Power Steering)
EPS (ELECTRIC POWER STEERING)
OPERATION PRINCIPLE OF EPS

1. As shown in the left figure, the input shaft of the EPS is
connected to the output shaft via the torque sensor, and the
output shaft is connected to the EPS motor via the actuator.
Controller
Steering wh 2. When the steering wheel is turned, torsion is generated

between the input and output shafts.
Input shaft Then the torque sensor converts this torsion to an electric
signal and sends it to the controller
Torque
sensor EPS motor
3. The controller drives the EPS motor by using the energy from
the battery to rotate the output shaft in the direction in which
Output Actuator
the input shaft rotates (to eliminate the torsion of the shafts).
shaft
Battery Joint
Steering gear 4. The rotation of the output shaft is transmitted to the tire through
the steering gears.
HOW THE STEERING WHEEL TURNING FORCE IS KEPT APPROPRIATE

1. The torque sensor contains the ends of the input and output
shafts, a spring and a pin fitted on the both shafts.
2. Turning the steering wheel rotates the input shaft.
3. The pin fitted on the input and output shafts widens the
opening of the spring. This produces a reaction force, which
becomes the steering wheel operating force.
AR50 Series 60-9

EPS (Electric Power Steering) STRUCTURE AND FUNCTION
HOW THE ELECTRIC SIGNAL IS GENERATED IN THE TORQUE SENSOR

1. Turning the steering wheel rotates the input shaft against the
output shaft.
2. The pin (A) rotates the slider (B).
3. The slider (B) rotates and moves up and down along the roller
(C) fitted on the output shaft.
4. The piston (D) moves up and down.
5. The vertical motion of the piston (D) varies the resistance value
of sensor (E) and the electric signal sent to the controller
changes.
OPERATION PRINCIPLE OF EPS CONTROLLER

The EPS controller uses four semiconductor switches called the
FET to control the EPS motor, as shown in the following figure.
This controller with a DC chopper like the work chopper uses

semiconductor switches 1 and 2 to switch the rotation of the
steering wheel between the clockwise and counterclockwise
directions.
For clockwise rotation

With switch 2 and 3 off, the controller turns on switch 1 and uses
switch 4 to control the chopper.
The electric current flows in the direction indicated by the arrows on
the solid line, as shown in the right figure.
For counterclockwise rotation

With switches 1 and 4 off, the controller turns on switch 2 and uses
the switch 3 to control the chopper
The electric current flows in the direction indicated by the arrows on
the broken line, i.e., it flows into the EPS motor in the reverse
direction to that when the steering wheel is turned clockwise.
60-10 AR50 Series

CONTROL VALVE STRUCTURE AND FUNCTION
CONTROL VALVE
Poppet
Y㪄Y
Housing
A B
Spool Spool
Y Y
L
H
Lift
C H C
L
Cap
Tilt
Reach
Relief valve
Relief set pressure: 16.67 MPa {170 kh/cm2}
60-12 AR50 Series

Sec60_AR14_E.fm 13 ページ２００７年１０月１８日木曜日午後４時１８分
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM
Emergency
let-down valve
Lift lock Lift lock

poppet valve
solenoid valve
A3
Tilt cylinder
B2
A2
B1
A1
Reach cylinder
Relief valve
16.7 Mpa
{170 kgf/cm2 }
Lift cylinder
P T
Down control
valve
More than FV 4.0m
Down safety valve Lift turn
AR50 Series 60-13

FREE LIFT MAST STRUCTURE AND FUNCTION
FREE LIFT MAST
60-14 AR50 Series

STRUCTURE AND FUNCTION FREE LIFT MAST
AR50 Series 60-15

FV MAST (STD) STRUCTURE AND FUNCTION
FV MAST (STD)
60-16 AR50 Series

STRUCTURE AND FUNCTION FV MAST (STD)
AR50 Series 60-17

VT MAST STRUCTURE AND FUNCTION
VT MAST
60-18 AR50 Series

STRUCTURE AND FUNCTION VT MAST
AR50 Series 60-19

FORK CARRIAGE STRUCTURE AND FUNCTION
FORK CARRIAGE
60-20 AR50 Series

STRUCTURE AND FUNCTION CONTROLLERS
CONTROLLERS
OUTLINE
The main control equipment, which consists of the following equipment, controls the travel motor, hydraulic motor and
speed control of electric power steering (EPS) motor.
1. Main controller ...................... It is divided into the inverter control block, contact block and command/signal
communication control block.
It controls the travel motor, hydraulic motor, meter panel display and performs the
diagnosis.
2. EPS controller ........................ It controls the EPS motor.

3. FR accelerator ........................This equipment outputs to the main controller the voltage corresponding to the switch
to select forward or backward and the lever operating angle.
4. Other........................................ Torque sensor for EPS
THE PRINCIPLE OF MOTOR TRANSMISSION

Three phase induced motor is used for driving motor, hydraulic motor, and the speed control system is alternating inverter
system.
Inverter is a power converter to change direct current to alternating current of any voltage and frequency. It converts
battery power (direct current) to three phase alternating current, by changing the three switches, and controls the motor
efficiency by changing the shape (frequency and the height of the wave) of sine waves of the three phase alternating
current.
Speed Control of Induced Motor with Inverter
DC (*1) AC
PWM
Machine
Inverter 0
Battery (reverse conversion) Induced
DC Motor
0
Single phase and three phase
alternating current of variable
voltage and variable frequency
(ex: 6 Hz - 120 Hz)
*1. The unit to convert alternating current to direct current. Loaded on AC controller.
AR50 Series 60-21

CONTROLLERS STRUCTURE AND FUNCTION
MOTOR POWER CIRCUIT CONNECTION (DRIVING, OIL PRESSURE, EPS MOTOR CIRCUITS)
The illustration below is simply showing machine style point of contact for the points of contact of power module and power
transistor, without fuse, electric current sensor or condenser.
Main contactor (MD) and PS contactor (MPS) are usually closed, when they are opened and the key-switch is ON.
*1
DU (ON/OFF) signal
F R
Drive DV
motor IM *1
DW
F/R signal
Print
(ON/OFF) signal
card
*1 Accelerator signal
(ON/OFF) signal
*1
PU (ON/OFF) signal
Pump PV
motor IM *1
PW Lift signal
Print
(ON/OFF) signal
card
Tilt
SW
*1 Reach
signal
ATT
(ON/OFF) signal
FUSE
(ON/OFF) signal
L. H. R. H.
EPS DCM Print

motor card Torque sensor
signal
FUSE MD
(ON/OFF) signal
Battery
*1. Switching over the switch (FET) creates alternating current, and rotates alternating current motor. (Signal)
60-22 AR50 Series

OPERATION OUTLINE OF DRIVING MOTOR

Driving Motor (AC) Operation Outline
No. Basic operation item Method Operation and signal to perform
1 Forward rotation Change the F signal or R signal of F Forward Reverse

and reverse order of and R lever
rotation of motor three phase Flow the sine wave Flow the sine wave
(forward and electricity to CPU sends signals to electricity, shift by 120° electricity, shift by 120°
reverse) flow to stator power module based on in the order of coil U in the order of coil U
the signals, to change the coil V coil W, coil V coil W,
order of three phase
electricity Sine wave 1 cycle is 360° Sine wave 1 cycle is 360°
lu lu
lv lv
lw lw
HJZ04907
2 Acceleration and Change the Accelerator Motor speed Regulating speed Motor power cycle
deceleration of frequency of voltage
motor RPM three phase
(increase and electricity to CPU sends ON
decrease of vehicle flow to stator signal to Fast
speed) power OFF
module
based on
the voltage,
to change
the ON
frequency of
three phase Slow OFF
electricity.
HJZ04908
3 Increase and Change the Loading

decrease of motor electricity condition Motor
Accelerating Duty
torque (rotation value of voltage 0V small
force) three phase condition
Current motor
(When power is electricity to electricity S
needed, such as flow to stator
starting, Motor Ampere
CPU calculates
accelerating and these data, ampere 0 A small
Motor
ascending) sends signals
torque Motor Duty
to power 0V
module so as to voltage large
create
necessary
torque, to L Motor Ampere
change the ampere 0 A large
current value of
three phase HJZ04909
electricity.
AR50 Series 60-23

CONTROLLERS STRUCTURE AND FUNCTION
(Reference) Comparison of DC Motor and AC Motor
Comparing item DC motor AC motor
Motor structure Complicated Rather simple
Non-contact style with semiconductor

Rectification (commutation) Contact style with brush and
(single phase or multi phase alternating
mechanism commutator
current)
Power maximization Generally difficult Easy
Acceleration Difficult Easy
Deceleration Generally difficult Generally easy
Irregular rotation Generally many Generally few
Irregular torque Generally many Generally few
Output efficiency Generally good Generally bad
Control circuit Rather easy Rather difficult
Vibration and noise while rotating Generally many Generally few
Cleanliness Bad Good
Maintenance Need to maintain brush and commutator Maintenance-free
Life span Short Long
POWER MODULE OF CONTROLLER

For the switching element to control the travel/hydraulic motor, the
Power module
MOS FET (metal oxide semiconductor field effect transistor,
P terminal N terminal hereafter called FET) is adopted. The FET has the same role as the
Gate wire conventional IGBT and transistor and its features are the high
connection
connector switching speed and the compact circuit. As a single element cannot
flow large current, many FETs connected in parallel flow large
current.
Thermister
connection For cargo-handling motor and EPS motor, the DC motor is
connector employed as usual. But, the switching element is changed to the
FET.
U terminal V terminal W terminal
60-24 AR50 Series

CONTROLLING FUNCTION OF CONTROLLER

1. Changeover of driving direction and speed control
Depending on the direction and volume of inclination of forward and reverse lever, change the moving direction of the
vehicle and control the speed.
2. Electric Current Control

Maximum level of electric current to flow in the motor is controlled not to excess the value, which is memorized in
CPU card, to prevent damage on the motor and FET.
3. Temperature Protection
Monitoring the temperature by temperature detect element, equipped near the power module. When the temperature
exceeds 105 °C/160 °C (travel, hydraulic), drop the flow rate and prevent damage from overheat.
4. Driving Control Circuit

When driving power module short occurs, stops driving and loading function.
5. Low Voltage Protection Circuit

When the power supply voltage gets lower than a certain level (excessive electric discharge), stop the vehicle and
protect the controller.
Note) Not for battery protection. To detect excessive electric discharge of battery, check with “Battery Capacity
Meter”.
6. Regulator of Motor for Oil Pressure

Startup Control : Prevent the excessive electric current when startup.
Torque control : It controls the torque corresponding to the EPS torque sensor signal.
Note) The EPS chopper extends the life of EPS motor brush and saves effectively the energy.
Main controller appearance EPS controller appearance
Contactor Travel Cargo-handling

unit unit unit
AR50 Series 60-25

FR ACCELERATOR STRUCTURE AND FUNCTION
FR ACCELERATOR
Cap housing : 174984-2

Inner side housing : 174985-7
Rubber cap : 172748-1
Array of connector terminal
Terminal : 171631-1
Blind cap : 172748-1
(It is inserted in the portion marked with * in the figure at the right hand side.)
6 1
1 Black - Yellow
Blue - Red SW1 SW2
7
2
Connection Grey 3 White Red - White
Red - Black
8
2 3
UL wire 1.5 sq
Backward Forward
AVS wire 0.5 sq
2° + 2.5°, –0.5° toward SW1 with respect to the neutral lever

Micro-switch ON timing
2° + 2.5°, –0.5° toward SW2 with respect to the neutral lever
Accelerator output voltage [V]

Operating angle 46㫦䋫㪉㫦
㪇㫦 Operating angle 46㫦䋫㪉㫦
㪇㫦
7.4
7.15
7
5
3.7
4
Toward SW1 Toward SW2 43 40 30 20 10
(backward) (forward) 10 20 30 4043
3
0.25
0
Output characteristics
60-26 AR50 Series

STRUCTURE AND FUNCTION CHARGER (MOUNTED ON TRUCK SYSTEM) (OPTION)
CHARGER (MOUNTED ON TRUCK SYSTEM) (OPTION)

AUTOMATIC EQUAL CHARGING SYSTEM
MICRO-COMPUTER CHARGER
Since the automatic equal charging method is adopted, if the AUTO
button is pressed everyday, the micro-computer judges and
performs the equal charging whenever necessary.
HOW TO READ THE DISPLAY PANEL

Lamp Charging State
L1 lamp is ON. Charging starts. (20% charged)
L1 and L2 lamps are ON. About 75% charged
L1, L2 and L3 lamps are ON.
L1, L2, L3 and L4 lamps are ON. About 90% charged.
L1, L2, L3, L4 and L5 lamps are ON.
L5 lamp and L6 lamp blinks alternately. It notifies that charging will finish within 30 minutes.
L6 lamp lights. Charging is completed. (About 115% charged)
POWER PLUG
The input cables are connected with screws. Therefore, no plug is
provided.
a The ground wire is marked with [E]. Three other wires (power
cables) have no polarity.
ELECTRO-MAGNETIC BREAKER
The thermal relay is provided to the electro-magnetic breaker as an
over-current protector.
When the over-current flows in the input side of charger for any
reason, the thermal relay activates and the electro-magnetic relay
breaks.
In case of the activated thermal relay, after disconnecting the input

power, push the RESET button of thermal relay until the RESET
button clicks.
[Thermal Relay]
AR50 Series 60-27

CHARGER (MOUNTED ON TRUCK SYSTEM) (OPTION) STRUCTURE AND FUNCTION
WHEN THE ABNORMAL LAMP LIGHTS

When the charging time is abnormally longer than normal, the micro-computer judges it abnormal.
When asked from a customer what action he or she should take in case of “The check lamps are ON”, you can advice
them quickly. Because the trouble can be suspected, judging from the state of lamps.
Display Degree of
Suspected cause
L1 to L6 lamps State of lit lamps trouble
L1 is ON Light The input voltage is not matched or composite causes

L1 to L2 are ON Light described in the table below. Heavy
L1 to L3 are ON Light
The cause will be one of No1 to No.5 listed in the table
L1 to L4 are ON Blink
below. Light
L1 to L5 are ON Blink
No. Suspected cause Treatmen
1 Poor maintenance of power tap Switch the power supply tap to meet the input voltage.
Check that the connector of charger is not loose. Plug out and in the connector
2 Poor contact of connector
twice and clean the connector with the terminal cleaner to restore the contact.
Do not over-discharge.
3 Deterioration of battery
Check the deterioration and damage of battery.
The trouble arises from the

When disconnecting the charging plug during power failure, ensure to press
4 operation when recovering from
the [OFF] switch.
the power failure.
The drop of output is caused by

5 the worn contact of electro- Replace the electro-magnetic breaker.
magnetic breaker.
CONFIRMATION AT TROUBLE
When a user informs of abnormality, confirm the following, suspect the cause and treat it.
1. Lamp display state

Which lamps of L1 to L5 are lit?
Do the abnormal lamps light or blink?
2. How was the battery usage the day before?

Especially over-discharging
3. Do the abnormal lamps light everyday?

In case of first lighting of abnormal lamp, if they blink, observe the condition for a while to find cause.
4. Is the battery new or old?

Depending on userÅfs battery maintenance, the situation differs.
5. Check the specific gravity of electrolyte in each cell and the temperature of electrolyte.
6. For detailed analysis of cause, implement the trouble diagnosis.

a To reset the abnormal display, push the [AUTO] or [EQUAL] button.
60-28 AR50 Series

STRUCTURE AND FUNCTION CHARGER (MOUNTED ON TRUCK SYSTEM) (OPTION)
IMPORTANT ITEM AT USER GUIDANCE

Do not pull out the power plug suddenly during charging.
When interrupting the charge, push the [AUTO] or [EQUAL] button first. Confirm that the lamp blinks and
then pull out the power plug.
APPEAL MODE
This mode is convenient to guide the concrete charge operation and teach how to use the micro-computer charger.
How to operate
Plug the power plug in and push the [AUTO] and [EQUAL] buttons simultaneously for 2 seconds.
• The lamps, which indicates the start of charging to the finish, light in 10 seconds.
OPERATION AT POWER FAILURE

When the power is resumed, the charger automatically re-starts to charge the battery.
a Since the micro-computer checks the amount of charge, the battery is not over-charged.
INFLECTION POINT VOLTAGE

The inflection point voltage that is detected by the micro-computer as a charging time is about 58V. (Same as usual)
ABNORMAL DISPLAY
Lit lamp Charging Condition
• When the voltage does not reach the inflection point within 10 hours since the start of charging, the
lamp lights.
Light
• Charging continues further. And, in case of normal charge, charging stops in 13 hours. In case of equal
charge, charging stops in 15 hours.
• When the voltage does not reach the inflection point within 10 hours since the start of charging, the
lamp lights.
• Charging continues further. When the voltage reaches the inflection point within 13 hours in the normal
Blink charge or within 15 hours in the equal charge, the abnormal lamp blinks.
• In case of normal charge, charging stops in 13 hours. In case of equal charge, charging stops in 15
hours. The lamp is blinking.
amount of charge
Charging current 105 - 135 %

Current/Voltage/Amount
About 62 V
of current flow
58 V
Charging voltage
Inflection point
Time
AR50 Series 60-29

CHARGER (MOUNTED ON TRUCK SYSTEM) (OPTION) STRUCTURE AND FUNCTION
AUTOMATIC EQUAL CHARGING AND EQUAL CHARGING

In the automatic equal charge, charging is normally performed. When charging fully everyday, the equal charging is
performed at 6th automatic charge. At this moment, the auto charge lamp blinks yellow.
When the auto charge button is operated, the auto charge lamp lights yellow, indicating that the charger charges in the
equal charge.
(In case of normal charge, the lamp lights green.)
(Note 1) In the following cases, the time to perform the equal charge is automatically adjusted.
• When charging the battery discharged below 60%.
• When stopping the charge during charging.
• When implementing the equal charge.
(Note 2) When connecting or disconnecting the battery connector, the automatic equal adjustment function, that
memorizes the charger controller, is cleared. The memory of automatic equal adjustment function starts when
connected disconnected.
• When the equal charge is specially required (After re-filling pure water, electrolyte temperature below 10°C), push the
EQUAL button. When pressing the EQUAL button, the EQUAL display lamp changes from “lighting” to “blinking” and
the L1 lamp lights, telling the start of equal charge.
60-30 AR50 Series

STRUCTURE AND FUNCTION BATTERY CHARGER (STATIONARY TYPE) (OPTION)
BATTERY CHARGER (STATIONARY TYPE) (OPTION)

NORMAL EQUAL CHARGING
MICRO COMPUTER BATTERY CHARGER

The stationary battery charger employs the normal equal charging.
Battery charger used for this machine is an automatic type that

5 judges state of the battery with its micro computer to perform an
3
optimum charging.
1. Adjustment of power supply voltage tap

4
Adjust the power supply voltage tap according to the supply
voltage.
1
2. Cord connection
2
1) Turn the key switch off and press the power supply
release button to disconnect the power plug from the
body.
2) Insert the supply cord to the plant power supply and the
output plug cord to battery plug (the plug connected to the
cord from battery).
a When the plug connection is completed, the display panel
normal and equal lamps will flash.
3. Starting the charge

• Select either normal charging or equal charging.
• Normal charging (Daily): Press the normal button for about 1
second to start the normal charging.
• Equal charging (Once a week): Press the equal button to
start the equal charging.
a At start of the charging, the selected button goes on and
the button not selected goes off.
(When the battery charger is used in ordinary
applications, the time required for charging will be
approximately 10 hours.)
a Press the “Stop” button to stop charging during the

course.
Do not try to pull out the plug while the charging is

continued.
• Before pulling out the cord, press the "Stop" button and
make sure the "Normal" and "Equal" buttons are turned on
indicating the initial state has been recovered.
AR50 Series 60-31

BATTERY CHARGER (STATIONARY TYPE) (OPTION) STRUCTURE AND FUNCTION
4. Check of charging status

• The charge monitor lamps will go on in the order of 1st, 2nd
and 3rd lamp, thus informing the charging status.
• When the time is expired and a full charging is completed,
the magnetic switch on AC side will be turned off to finish
the charging.
• When the charging is complete, the selected charging lamp
goes off and the “OK” lamp goes on.
(Three monitor lamps remain in their turned on state.)
5. Abnormality display
• If the charging time is abnormally long, the micro computer
judges it as an abnormal charge, thus stopping the charging
and bringing up the abnormality display.
• Abnormality display: The operation panel “CHECK” lamp
goes on.
a When the “CHECK” lamp went on, stop the charging
and contact a Komatsu dealer.
• The “CHECK” lamp goes off when the battery plug is pulled
out.
6. At power failure
• If a power failure occurred during the charge, the charge will
be stopped temporarily. Upon recovery from the failure, the
charging will be resumed from the point it had left before the
failure.
• However, if the failure duration exceeds an hour, pre-charg-
ing state is brought out, thus disabling the charging upon
recovery from the failure. Press the charging button again
when such state is present.
7. At the end of charging

Make sure that the charging is complete (OK lamp goes on).
60-32 AR50 Series

ELECTRICAL CIRCUIT DIAGRAM STRUCTURE AND FUNCTION
ELECTRICAL CIRCUIT DIAGRAM
60-34 AR50 Series

STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
AR50 Series 60-35

70. TROUBLESHOOTING
DIAGNOSIS TOOL......................................................................70-2
CONFIGURATION PARTS, SENSOR,

UNIT LOCATION DRAWING ......................................................70-3
HARNESS LIST ..........................................................................70-4
LOCATION OF CPU BOARD CONNECTOR .............................70-8
OVERVIEW OF ABNORMAL CODE ..........................................70-9
PREPARATION FOR VOLTAGE CHECK AND

CURRENT CHECK...................................................................70-10
INPUT/OUTPUT SIGNAL OF CONTROLLER..........................70-12
ABNORMAL CODE LIST..........................................................70-17
DIAGNOSTIC PROCEDURE BY
ABNORMAL CODE (ALA CODE) .............................................70-20
ABNORMAL CODE (ERR CODE) ............................................70-23
METER DISPLAY TROUBLE CODE ........................................70-60
TROUBLE WITHOUT ABNORMAL DISPLAY ..........................70-86
METER PANEL.........................................................................70-91
AR50 Series 70-1

DIAGNOSIS TOOL TROUBLESHOOTING
DIAGNOSIS TOOL
a Prepare the tools needed for abnormal diagnosis.
Service Tool • When reading out the abnormal

1) Service Tool Software code, connect it to the data link
3BA-97-71260 connector.
2) CAN Communication • Parameter Setting Personal Computer
Converter (1.5m) • IO Monitor Display Windows2000, XP
3BA-97-71220 • Error History (Prepared by dealers
3) Body Connection • Error Content and its Remedy

Cable (2m)
3BA-97-71230
CD
Analog Tester Check the breaking of wire and

measure the resistance of equipment.
Judge whether the measured item is
good or not.
Wire Lead When measuring the resistance of

wire, insert the wire lead in the
connector.
Connector Jumper Unit It is used when measuring the voltage

3BA-97-99750 at the terminal of control unit.
70-2 AR50 Series

TROUBLESHOOTING CONFIGURATION PARTS, SENSOR, UNIT LOCATION DRAWING
CONFIGURATION PARTS, SENSOR, UNIT LOCATION DRAWING
1) Meter Panel 4) EPS Controller

2) Travel Controller 5) Connector for service tool
3) Cargo Handling Controller 6) Fuse Box Connector
AR50 Series 70-3

HARNESS LIST TROUBLESHOOTING
HARNESS LIST
RL TYPE
70-4 AR50 Series

TROUBLESHOOTING HARNESS LIST
AR50 Series 70-5

HARNESS LIST TROUBLESHOOTING
RW TYPE
70-6 AR50 Series

TROUBLESHOOTING HARNESS LIST
AR50 Series 70-7

LOCATION OF CPU BOARD CONNECTOR TROUBLESHOOTING
LOCATION OF CPU BOARD CONNECTOR
The CPU board controls the controller and the gate drive.
Check visually the harmful scars and damages, serious discoloration and corrosion on the connector block.
Pay attention to the items below when checking.
• Do not touch components on the printed circuit board by hand to avoid damage from static electricity.
• Hold the edge of printed circuit board when handling.
• When carrying or storing the printed circuit board, be sure to pack it in the electrostatic prevention bag.
1. LOCATION OF CONNECTORS ON THE CPU BOARD

CN1: Harness connection connector at the truck side
CNG1 CNG2 DSW2 DSW1 CNF CN2: Harness connection connector at the truck side
CN3: Harness connection connector at the truck side
CN3 CNG1: Power module gate connector
(Connect with the FET module)
CN2 CNG2: Power module gate connector
(Connect with the FET module)
CN1 CNF: Connector for software download (Normally not used)
2. DSW SETTING
The DSW1 is the switch for selecting the travel and cargo handling.
ON KSD04 (The DSW2 is not used.)
DSW-ON position Note: The switch-over of cargo handling and travel cannot be
DSW-OFF position set.
1 2 3 4
DSW1
Setting of travel inverter unit
ON KSD04
DSW-ON position
DSW-OFF position
1 2 3 4
DSW1
Setting of cargo handling inverter unit
3. PIN NO. OF CONNECTOR

CNG1: 6P connector
CNG2: 11P connector
CNG1 CNG2
123456 1 2 3 4 5 6 7 8 9 10 11
Viewed from engagement side of connector
70-8 AR50 Series

TROUBLESHOOTING OVERVIEW OF ABNORMAL CODE
OVERVIEW OF ABNORMAL CODE
ABNORMAL DETECTION
When the abnormality occurs on the truck, the detection of
abnormality is announced by lighting the travel system abnormal
indicator (tire icon) and abnormal occurrence indicator (spanner
icon).
For first 10 seconds, the indicators blink and the alarm beeps.
DISPLAY OF ABNORMAL CODE

Meter Panel
Two types of abnormal code are provided. One is the alarm (ALA)
code and the other is the error (ERR) code.
• When the abnormality, which may occur in the normal operation,
is detected, the alarm (ALA) code is displayed.
• When the trouble occurs on the truck and the traveling and
operation cannot be conducted, the error (ERR) code is
displayed.
Display method using the PC service tool

1. Disconnect the battery plug.
2. Turn off the key switch.
3. Remove the front panel.
4. Connect the service tool to the connector for service tool.
5. Connect the battery plug.
6. Turn on the key switch.
7. Confirm the abnormal code on the service tool connected.
a Even if the service tool is connected, if it does not
communicate with control unit, the short-circuit of CAN
communication line is suspected. Check it.
a Before plugging out or in the CAN communication line
connector, ensure to disconnect the battery plug.
AR50 Series 70-9

PREPARATION FOR VOLTAGE CHECK AND CURRENT CHECK TROUBLESHOOTING
PREPARATION FOR VOLTAGE CHECK AND CURRENT CHECK
When checking the voltage and current, ensure to

prepare as follows.
1. Place chocks (1) under the load wheels.

2. Extend the mast (Reach-out)
4 3. Place the wooden block (2) (15cm square, 63cm in length) in
the reach leg.
When operating accidentally the mast retraction
(reach-in), to prevent your body from trapped in between
the mast and the frame, place the wooden block as a
stopper.
4. Place the wooden blocks (3) under the frame at the right and
left sides to float the wheels from the ground.
5. Remove the front panel (4).
3
2
BATTERY VOLTAGE CHECK

Before starting the diagnosis (abnormal diagnosis) by the abnormal code, check that the truck is in the normal state.
Unless specified, disconnect the battery and perform the abnormal diagnosis.
While performing the abnormal diagnosis, pay attention to safety, supposing that the truck moves (travel,
cargo handling).
1. Check the electrolyte solution level and specific gravity.

Confirm that the value is appropriate.
2. Disconnect the battery plug.

Set the tester to the voltage measuring range. Set the black
lead (-) of tester to the negative polarity plug of battery and the
Red red lead (+) of tester to the positive polarity plug of battery.
(+) Black Then, measure the voltage.
(-)
3. Judge whether the battery is good or not.
Measured Voltage Judging

Battery Voltage: Higher than 48V Good
Battery Voltage: Lower than 48V Not good (Re-charge)
70-10 AR50 Series

TROUBLESHOOTING PREPARATION FOR VOLTAGE CHECK AND CURRENT CHECK
CHECK OF ELECTRICAL PARTS OF CONTROLLER

Looseness of installation block, Poor contact of Connector
If the bolts and nuts fixing the power terminal of controller are
loosened, the heat build-up occurs, resulting in burn. If the
looseness or heat build-up is found, file with a sandpaper and
tighten firmly.
The poor contact of connector may cause the malfunction.
Therefore, remove dust and rust from the connector and plug out
and in the connector 2 to 3 times.
At this moment, check the breaking of lead wire and deformation of
terminal.
Check of the controller-mounted truck
It is very dangerous to touch the electrical parts by hand while the

fork lift truck is electric-powered.
When removing a new part or touching the part, be sure to

disconnect the battery connector and leave it for more than 10
minutes before starting the work.
When measuring in the state that the fork lift truck is electric-
powered, float the drive wheels and fix them firmly not to rotate
when the motor suddenly starts to rotate.
In this state, lock the drive wheels, measure the maximum current
and perform the switch-back operation and hydraulic operation.
FUSE CHECK
Confirm that the fuses is not blown out.
4
2
1
AR50 Series 70-11

INPUT/OUTPUT SIGNAL OF CONTROLLER TROUBLESHOOTING
INPUT/OUTPUT SIGNAL OF CONTROLLER
1. TRAVEL (R) CONTROLLER
CN3D CN2D CN1D
13 14 15 16 17 17 18 19 20 21 22 23 24 22 23 24 25 26 27 28 29 30 31
7 8 9 10 11 12 8 9 10 11 12 13 14 15 16 10 11 12 13 14 15 16 17 18 19 20 21
1 2 3 4 5 6 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9
(Viewed from wire insertion side)
Connector Terminal Input/Output

Signal Name
No. No. (Switch ON, Truck stopped, Reference Voltage)
1 Backward-run switch (DSR) 0V
2 Forward-run (DSF) 0V
3 Main Contactor Coil (–) Contactor ON: About VB – 12V
4 Main Contactor Coil (+) VB
Backward-run SW ON: 12V
5 Buzzer/Chime (F/R1) (At default setting)
6 KEY SW VB
7 VB Battery Voltage
8 Quick Charging Resistor (+) VB × 0.85
9 Quick Charging Resistor (–) VB × 0.85
10 –
11 –
12 GND for Travel Speed A Sensor Shield 0V
13 Travel Speed Sensor A (S) 1.3 – 3.3 V
14 Travel Speed Sensor A (+) 13.5 V
15 SW – GND 0V
16 Battery Draw SW Stored: 0V, Drawn 4.6V
17 Brake SW Step on: 0V, Release: 4.6V
CN1D
18 –
19 Floor SW – a Seated: 0V, Not seated: 4.6V
20 Travel Motor Temperature Sensor (–) 0V
Power supply for Travel Accelerate VR (+)
21 5V
Accelerator Potentiometer
22 –
23 –
24 –
25 GND for Accelerator Shield 0V
26 GND for Travel Motor Speed Sensor Shield 0V
27 Travel Motor Speed Sensor B (S) 1.3 – 3.3 V
28 Travel Motor Speed Sensor B (+) 13.5 V
29 Travel Motor Temperature Sensor (+) At 25°C: About 3.48V *
30 Accelerator GND 0V
2.5 V
Forward-run at higher than 2.5V,
31 Accelerator Potentiometer Signal backward-run at lower than 2.5V,
accelerating command 0 to 100%
variation at 0.52 – 4.48V
*: Depending on the temperature, the voltage varies in the range of 0.2 to 4.8V.
70-12 AR50 Series

TROUBLESHOOTING INPUT/OUTPUT SIGNAL OF CONTROLLER

Signal Name
1 –
2 –
3 FAN Power Supply (negative side) At FAN stop: VB
4 –
5 –
6 –
7 –
8 –
9 –
10 Model Select 2 SW Closed: 0V, Open: 4.6V
11 Model Select 1 SW Closed: 0V, Open: 4.6V
12 –
CN2D
13 –
14 –
15 –
16 –
17 SW – GND 0V
18 Floor SW – b Seated: 4.6V, Not seated: 0V
19 –
20 –
21 –
22 –
23 –
24 –
1 CAN_L2 (MR) 2.4 – 2.6 V
2 CAN_L2 2.4 V
3 CAN_L1 2.4 V
4 –
5 –
6 –
7 CAN COM 0V
8 CAN_H2 2.6 V
CN3D 9 CAN_H1 2.6 V
10 –
11 –
12 –
13 GND for CAN Shield 0V
15 CAN COM 0V
16 –
17 –
AR50 Series 70-13

2. CARGO HANDLING CONTROLLER
CN3P CN2P CN1P
13 14 15 16 17 17 18 19 20 21 22 23 24 22 23 24 25 26 27 28 29 30 31
7 8 9 10 11 12 8 9 10 11 12 13 14 15 16 10 11 12 13 14 15 16 17 18 19 20 21
1 2 3 4 5 6 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9
(Viewed from wire insertion side)

Signal Name
1 –
2 –
3 –
4 –
Forward-run SW ON: 12V
5 Buzzer/Chime (F/R2) (Default setting)
6 KEY SW VB (48 V)
7 VB Battery Voltage
8 –
9 –
10 –
11 –
12 –
13 –
14 –
15 SW GND 0V
CN1P 16 ATT 1 SW Pull the lever: 0V, Return: 4.6V
17 Tilt SW Pull the lever: 0V, Return: 4.6V
18 Lift 2 SW Pull the lever: 0V, Return: 4.6V
19 Lift 1 SW Pull the lever: 0V, Return: 4.6V
20 Pump Motor Temperature Sensor (–) 0V
21 –
22 –
23 –
24 –
25 GND for Hydraulic Analog Directive Shield 0V
26 GND for Pump Motor Speed Sensor Shield 0V
27 Pump Motor Speed Sensor (S) 1.3 – 3.3 V
28 Pump Motor Speed Sensor (+) 13.5 V
29 Pump Motor Temperature Sensor B (+) At 25°C: About 3.48V *
30 Hydraulic Analog Command (COM) 0V
31 Hydraulic Analog Command (S) Lower than 2.0V
*: Depending on the temperature, the voltage varies in the range of 0.2 – 4.8V.
70-14 AR50 Series

TROUBLESHOOTING INPUT/OUTPUT SIGNAL OF CONTROLLER

Signal Name
1 –
2 –
3 –
4 –
5 –
6 Lift Lock Solenoid Output 38.4 V
7 –
8 –
9 –
10 H Meter Startup SW Closed: 0V, Open: 4.6V
11 Reach-in SW Pull the lever: 0V, Return: 4.6V
12 ATT 2 SW Pull the lever: 0V, Return: 4.6V
CN2P
13 GND for Lift Hydraulic Sensor Shield 0V
14 GND for Lift Hydraulic Sensor 0V
15 Lift Hydraulic Sensor (S) 0.5 – 4.5 V
16 Lift Hydraulic Sensor (+) 5V
17 SW GND 0V
18 Automatic High Lifting Select SW Closed: 0V, Open: 4.6V
19 Lift 3 SW Push the lever (Descent): 0V, Return: 4.6V
20 –
21 GND for Lift VR Shield 0V
22 GND for Lift VR 0V
23 Lift VR (S) 2.5 – 1.9 V
24 Lift VR (+) 4.55 V
1 CAN_L2 (MR) 2.4 – 2.6 V
2 CAN_L2 2.4 V
3 CAN_L1 2.4 V
4 –
5 –
6 –
7 CAN_COM 0V
8 CAN_H2 2.6 V
CN3P 9 CAN_H1 2.6 V
10 –
11 –
12 –
15 CAN_COM 0V
16 –
17 –
AR50 Series 70-15

3. EPS CONTROLLER
CN1E
11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 12
(Viewed from the wire insertion side)

Signal Name
1 –
2 CAN_COM 0V
3 CAN_H2 2.6 V
4 CAN_H1 2.6 V
5 GND for CAN shield 0V
6 –
Neutral: 2.5V ± 01. (1.50 – 3.50V)
7 Torque Sensor (S) When turning the steering wheel right,
the voltage decreases.
8 –
9 –
10 –
11 KEY SW VB (48 V)
CN1E 12 GND for CAN shield 0V
13 CAN_L2 (MR) 2.4 – 2.6 V
14 CAN_L2 2.4 V
15 CAN_L1 2.4 V
16 CAN_COM 0V
17 –
18 –
19 –
20 Torque Sensor (–) 0.45 V
21 Torque Sensor (+) 4.55 V
22 –
23 –
24 Battery Voltage VB (48 V)
70-16 AR50 Series

TROUBLESHOOTING ABNORMAL CODE LIST
ABNORMAL CODE LIST
1. ALARM (ALA) CODE

Code No. Content of Detection Remedy If not recovered
Return the accelerator lever to the
The travel is operated during drawing the
ALA-3064 neutral position and pull the battery < 70 – 22 >
battery. in the normal position.
The key switch is turned on when the lift lever is Return the lift lever in the neutral
ALA-5006 position, turn off the key switch and < 70 – 20 >
in the position other than neutral position. turn it on again.
The key switch is turned on when the tilt lever is Return the tilt lever in the neutral
ALA-5007 position, turn off the key switch and < 70 – 20 >
in the position other than neutral position. turn it on again.
The key switch is turned on when the reach Return the reach lever in the neutral
ALA-5008 lever is in the position other than neutral position, turn off the key switch and < 70 – 21 >
position. turn it on again.
The key switch is turned on when the ATT 1 Return the ATT 1 lever in the neutral
ALA-5009 lever is in the position other than neutral position, turn off the key switch and < 70 – 21 >
The key switch is turned on when the ATT 2 Return the ATT 2 lever in the neutral
ALA-500A lever is in the position other than neutral position, turn off the key switch and < 70 – 22 >
2. ERROR (ERR) CODE (ABNORMAL COMMUNICATION)

Diagnostic
Code No. Content of Abnormality Procedure Page
ERR-3083 The communication between travel controller and EPS controller is abnormal. < 70 – 23 >
The communication between travel controller and cargo handling controller is
ERR-3084 < 70 – 25 >
abnormal.
ERR-4081 The communication between EPS controller and travel controller is abnormal. < 70 – 26 >
The communication between EPS controller and cargo handling controller is
ERR-4084 < 70 – 27 >
abnormal.
The communication between cargo handling controller and travel controller is
ERR-5081 < 70 – 28 >
abnormal.
The communication between cargo handling controller and EPS controller is
ERR-5083 < 70 – 29 >
abnormal.
ERR14-8110 The CAN communication process of travel controller is abnormal. < 70 – 30 >
ERR14-8120 The CAN transmission/reception process of travel controller is abnormal. < 70 – 38 >
ERR14-8130 The CAN communication between travel controller and meter panel is abnormal. < 70 – 43 >
ERR14-8140 The CAN transmission of travel controller is abnormal. < 70 – 46 >
ERR20-8110 The CAN communication process of EPS controller is abnormal. < 70 – 32 >
ERR20-8120 The CAN transmission/reception process of EPS controller is abnormal. < 70 – 39 >
ERR20-8130 The CAN communication between EPS controller and meter panel is abnormal. < 70 – 44 >
ERR20-8140 The CAN transmission of EPS controller is abnormal. < 70 – 47 >
ERR30-8110 The CAN communication process of cargo handling is abnormal. < 70 – 34 >
ERR30-8120 The CAN transmission/reception process of cargo handling controller is abnormal. < 70 – 40 >
The CAN communication between cargo handling controller and meter panel is
ERR30-8130 < 70 – 45 >
abnormal.
ERR30-8140 The CAN transmission of cargo handling controller is abnormal. < 70 – 48 >
AR50 Series 70-17

ABNORMAL CODE LIST TROUBLESHOOTING
Diagnostic
ERR40-8110 The CAN communication process of meter panel is abnormal. < 70 – 36 >
ERR40-8120 The CAN transmission/reception process of meter panel is abnormal. < 70 – 41 >
ERR40-8140 The CAN transmission of meter panel is abnormal. < 70 – 49 >
ERR40-8314 The CAN communication between travel controller and meter panel is abnormal. < 70 –51 >
ERR40-8320 The CAN communication between EPS controller and meter panel is abnormal. < 70 – 53 >
The CAN communication between cargo handling controller and meter panel is
ERR40-8330 < 70 – 56 >
abnormal.
ERR40-8510 After key ON, the CAN communication of meter panel is abnormal. < 70 – 57 >
3. ERROR (ERR) CODE (TRAVEL CONTROLLER)

Diagnostic
ERR-3001 Broken main contact, blown-out fuse < 70 – 60 >
ERR-3002 Shorted main contactor < 70 – 60 >
ERR-3004 Low voltage detection (Dropped battery voltage) < 70 – 61 >
ERR-3010 Travel controller (Shorted upper and lower FETs) < 70 – 62 >
ERR-3011 Travel controller (Shorted upper side) < 70 – 63 >
ERR-3012 Travel controller (Shorted lower side) < 70 – 63 >
ERR-3013 Travel controller (Broken U-phase wire) < 70 – 63 >
ERR-3014 Travel controller (Broken V-phase wire) < 70 – 63 >
ERR-3015 Travel controller (Broken W-phase wire) < 70 – 63 >
ERR-3016 Defective quick charge (Defective charging capacitor between P and N) < 70 – 64 >
ALA-3021 Travel controller (Temperature rise) < 70 – 64 >
ERR-3021 Travel controller (Abnormal temperature) < 70 – 65 >
ALA-3031 Travel motor (Temperature rise) < 70 – 65 >
ERR-3031 Travel motor (Abnormal temperature) < 70 – 66 >
ERR-3030 Short-circuit between phases of travel motor (Shorted load) < 70 – 67 >
ERR-3050 Defect of travel controller temperature sensor < 70 – 67 >
ERR-3051 Defect of travel motor temperature sensor < 70 – 68 >
ERR-3052 Defect of travel current sensor (U-phase, W-phase) output < 70 – 68 >
ERR-3053 Defect of travel accelerator, abnormal accelerator switch < 70 – 69 >
ERR-3056 Travel motor speed sensor (Abnormal A-phase output) < 70 – 70 >
ERR-3057 Travel motor speed sensor (Abnormal B-phase output) < 70 – 71 >
ERR-3061 Defect of FR direction switch < 70 – 72 >
ERR-3062 Logic defect of floor switch_a and floor switch_b < 70 – 72 >
ERR-3070 Abnormality of travel controller memory < 70 – 28 >
70-18 AR50 Series

TROUBLESHOOTING ABNORMAL CODE LIST
4. ERROR (ERR) CODE (CARGO HANDLING CONTROLLER)

Diagnostic
ERR-5004 Low voltage detection (Dropped battery voltage) < 70 – 73 >
ERR-5010 Cargo handling controller (Shorted upper and lower FETs) < 70 – 74 >
ERR-5011 Cargo handling controller (Shorted upper side) < 70 – 75 >
ERR-5012 Cargo handling controller (Shorted lower side) < 70 – 75 >
ERR-5013 Cargo handling controller (Broken U-phase wire) < 70 – 75 >
ERR-5014 Cargo handling controller (Broken V-phase wire) < 70 – 75 >
ERR-5015 Cargo handling controller (Broken W-phase wire) < 70 – 75 >
ALA-5021 Cargo handling controller (temperature rise) < 70 – 76 >
ERR-5021 Cargo handling controller (Abnormal temperature) < 70 – 76 >
ERR-5030 Short-circuit between pump motor phases (Shorted load) < 70 – 77 >
ALA-5031 Pump motor (Temperature rise) < 70 – 77 >
ERR-5031 Pump motor (Abnormal temperature) < 70 – 78 >
ERR-5050 Defect of cargo handling controller temperature sensor < 70 – 79 >
ERR-5051 Defect of pump motor temperature sensor < 70 – 79 >
ERR-5052 Defective output of cargo handling current sensor (U-phase, W-phase) < 70 – 80 >
ERR-5053 Defect of lift lever POT < 70 – 80 >
ERR-5057 Defect of pump motor speed sensor < 70 – 81 >
ERR-5058 Defect of load meter pressure sensor < 70 – 81 >
ERR-5070 Abnormal cargo handling controller memory < 70 – 28 >
5. ERROR (ERR) CODE (EPS CONTROLLER)

Diagnostic
ERR-4001 Open fuse (For EPS) < 70 – 82 >
ERR-4004 Dropped battery voltage < 70 – 82 >
ERR-4010 Shorted FET < 70 – 83 >
ERR-4013 Open FET in the EPS unit < 70 – 83 >
ALA-4021 FET temperature rise < 70 – 84 >
ERR-4021 FET temperature rise < 70 – 84 >
ERR-4050 Defect of EPS FET temperature sensor < 70 – 85 >
ERR-4053 POT error < 70 – 85 >
AR50 Series 70-19

DIAGNOSTIC PROCEDURE BY ABNORMAL CODE (ALA CODE) TROUBLESHOOTING
DIAGNOSTIC PROCEDURE BY ABNORMAL CODE (ALA CODE)
Meter Display Code : ALA-5006 Meter Display Code : ALA-5007

Content of Detection Content of Detection
The key switch is turned ON when the lift lever is in the The key switch is turned ON when the tilt lever is in the
position other than neutral. position other than neutral.
Symptom of truck Symptom of truck

• The lift only is inoperable. • The tilt only is inoperable.
• When turning ON the key, the alarm appears • When turning ON the key, the alarm appears
immediately. immediately.
Cause of trouble Cause of trouble

• The lift lever sensor is improperly adjusted. • The tilt lever micro-sensor is improperly adjusted.
• The lift lever sensor is defective. • The tilt lever micro-sensor is defective.
• The harness of lift lever sensor circuit is defective. • The harness of tilt lever micro-sensor circuit is
defective.
Repair Procedure Repair Procedure

1. Confirm that the lift lever sensor signal is inputted. 1. Confirm that the lift lever micro-sensor signal is
Measure the voltage between terminals No.23 and inputted.
No.22 of connector CN2P. Measure the voltage between terminals No.17 and
Normal Value: 2.40 – 2.60 (The lift lever is in the No.15 of connector CN1P.
neutral position.) Normal Value: 4.6V (The tilt lever is in the neutral
2. If the voltage is normal in step 1, replace the cargo position.)
handling controller board. 2. If the voltage is normal in step 1, replace the cargo
3. If the voltage is abnormal in step 1, check the handling controller board.
harness between lever sensor and cargo handling 3. If the voltage is abnormal in step 1, check the
controller and repair it. harness between lever micro-switch and cargo
4. If the voltage is abnormal in step 1 and the harness handling controller and repair it.
is normal in step 3, repair the lever sensor. 4. If the voltage is abnormal in step 1 and the harness
is normal in step 3, repair the lever micro-switch.
70-20 AR50 Series

TROUBLESHOOTING DIAGNOSTIC PROCEDURE BY ABNORMAL CODE (ALA CODE)
Meter Display Code :ALA-5008 Meter Display Code :ALA-5009

The key switch is turned ON when the reach lever is in The key switch is turned ON when the ATT 1 lever is in
the position other than neutral. the position other than neutral.
• The reach only is inoperable. • The ATT 21only is inoperable.
• When turning ON the key, the alarm appears • When turning ON the key, the alarm appears
• The reach lever micro-switch is improperly adjusted. • The ATT 1 lever micro-switch is improperly adjusted.
• The reach lever micro-switch is defective. • The ATT 1 lever micro-switch is defective.
• The harness of reach lever micro-switch circuit is • The harness of ATT 1 lever micro-switch circuit is
defective. defective.
1. Confirm that the reach lever micro-switch signal is 1. Confirm that the ATT 1 lever micro-switch signal is
inputted. inputted.
Measure the voltage between terminals No.11 and Measure the voltage between terminals No.16 and
No.17 of connector CN2P No.15 of connector CN1P.
Normal Value: 4.6V (The reach lever is in the Normal Value: 4.6V (The ATT 1 lever is in the neu-
neutral position.) tral position.)
2. If the voltage is normal in step 1, replace the cargo 2. If the voltage is normal in step 1, replace the cargo
handling controller board. handling controller board.
3. If the voltage is abnormal in step 1, check the 3. If the voltage is abnormal in step 1, check the har-
harness between lever sensor and cargo handling ness between lever micro-switch and cargo han-
controller and repair it. dling controller and repair it.
4. If the voltage is abnormal in step 1 and the harness 4. If the voltage is abnormal in step 1 and the harness
is normal in step 3, repair the lever micro-switch. is normal in step 3, repair the lever micro-switch.
AR50 Series 70-21

DIAGNOSTIC PROCEDURE BY ABNORMAL CODE (ALA CODE) TROUBLESHOOTING
Meter Display Code :ALA-500A Meter Display Code :ALA-3064

The key switch is turned ON when the ATT 2 lever is in The travel operation is performed during drawing the
the position other than neutral. battery.

• The ATT 2 only is inoperable. • Traveling is impossible.
• When turning ON the key, the alarm appears • When operating the accelerator, the alarm appears

• The ATT 2 lever micro-switch is improperly adjusted. • The micro-switch of battery drawing lever is
• The ATT 2 lever micro-switch is defective. improperly adjusted.
• The harness of ATT 2 lever sensor circuit is • The micro-switch of battery drawing lever is
defective. defective.
• The harness of battery drawing lever micro-switch is
defective.
Repair Procedure
Repair Procedure
1. Confirm that the battery drawing lever micro-switch
1. Confirm that the ATT 2 lever micro-switch signal is
signal is inputted.
inputted.
Measure the voltage between terminals No.16 and
Measure the voltage between terminals No.12 and
No.15 of connector CN1D.
No.17 of connector CN2P.
Normal Value: 0V (The battery is stored.)
Normal Value: 4.6V
4.6V (The battery is drawn out.)
(The ATT 2 lever is in the neutral position.)
2. If the voltage is normal in step 1, replace the travel
2. If the voltage is normal in step 1, replace the cargo
controller board.
handling controller board.
3. If the voltage is abnormal in step 1, check the
3. If the voltage is abnormal in step 1, check the
harness between micro-switch and travel controller
harness between lever micro-switch and cargo
and repair it.
handling controller and repair it.
4. If the voltage is abnormal in step 1 and the harness
4. If the voltage is abnormal in step 1 and the harness
is normal in step 3, repair the micro-switch.
is normal in step 3, repair the lever micro-switch.
70-22 AR50 Series

TROUBLESHOOTING DIAGNOSTIC PROCEDURE BY ABNORMAL CODE (ERR CODE)
DIAGNOSTIC PROCEDURE BY ABNORMAL CODE (ERR CODE)
Before implementing the diagnosis, ensure to pull out the battery plug.
Otherwise, the controller and the panel will be damaged. Because even if the key switch is turned off, the
CAN communication is powered.
ERR-3083: ABNORMAL COMMUNICATION BETWEEN TRAVEL CONTROLLER AND

CONTROLLER (WITH THE EPS CONTROLLER)
Content of Trouble Symptom of truck

• Cannot communicate with the EPS controller. • When turning ON the key switch, all functions stop.
• When started normally, the PS feeling deteriorates.
Repair Procedure 2. When the error code ERR-4081 is displayed on the
1. When the error code ERR-5083 is displayed on the meter panel and ERR-3083 is displayed on the
meter panel, the EPS controller is defective. service tool, the harness between travel controller
Or the power supply line to the EPS controller is and EPS controller is defective. Therefore, confirm
defective. that the connector is not disconnected and
terminals of connector are not loose.
Judging: The connector is not disconnected and is not
loosened.
OK: Go to step 3.
NG: After cleaning the connector with the contact
refreshing agent, re-connect the connector.
3. Disconnect the harness from the controller and

measure the resistance between travel controller
and EPS controller.
Judging: Between CN3D terminal No.9 (green) and
CN1E terminal No.3 (green): 0 Ω
Judging : When turning on the key switch Between CN3D terminal No.3 (blue) and
Voltage between terminal 11 of CN1E and CN1E terminal No.14 (blue): 0 Ω
negative terminal of battery: VB
Voltage between terminal 24 of CN1E and
negative terminal of battery: VB
CN1E
1 2 3 4 5 6 7 8 9 10 11
CN1E 12 13 14 15 16 17 18 19 20 21 22 23 24
17 16 15 14 13
1 2 3 4 5 6 7 8 9 10 11
12 11 10 9 8 7
12 13 14 15 16 17 18 19 20 21 22 25 24
6 5 4 3 2 1
To the negative CN3D

line of battery
Viewed from the engagement side of connector

OK: Proceed to step 4.
OK: Replace the EPS controller. NG: Replace or repair the harness.
NG: Repair or replace the harness.
AR50 Series 70-23

DIAGNOSTIC PROCEDURE BY ABNORMAL CODE (ERR CODE) TROUBLESHOOTING
4. Connect the service tool and confirm on the error

history menu that it can communicate with the travel
controller.
OK: Replace the EPS controller.
NG: Replace the travel controller.
How to reset
Turn OFF the key switch.
Remark
When ERR-5083 occurs simultaneously, the EPS
controller board is abnormal.
70-24 AR50 Series

ERR-3084: ABNORMAL COMMUNICATION BETWEEN TRAVEL CONTROLLER AND CARGO

HANDLING CONTROLLER (WITH THE CARGO HANDLING CONTROLLER)

• Cannot communicate with the cargo handling • When turning ON the key switch, all functions stop.
controller. • When started normally, cargo-handling stops.
Repair Procedure 3. Connect the service tool and confirm on the error
1. Check visually that the connectors and terminals of history menu that it can communicate with the travel
travel controller and cargo handling controller are controller.
not disconnected or not loosened. OK: Go to step 4.
Judging: No disconnection of connector and no NG: Replace the travel controller.
looseness of terminal
history menu that it can communicate with the
cargo handling controller.
OK: Poor contact of connector pin (Repair or replace the
harness.)
NG: Replace the cargo handling controller.
How to reset
Remark
OK: Go to step 2.
When ERR-4084 occurs simultaneously, the
NG: After cleaning the connector with the contact harness between travel controller and cargo
refreshing agent, re-connect the connector. handling controller is broken or the cargo handling
controller board is defective.

measure the resistance of harness between travel
controller and cargo handling controller.
CN3P terminal No.8 (green): 0 Ω
Between CN3D terminal No.2 (blue) and
CN3P terminal No.2 (blue): 0 Ω
CN3D CN3P
17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1
OK: Go to step 3.
AR50 Series 70-25

ERR-4081: ABNORMAL COMMUNICATION BETWEEN EPS CONTROLLER AND TRAVEL

CONTROLLER (WITH THE TRAVEL CONTROLLER)

• Cannot communicate with the travel controller. • When turning ON the key switch, all functions stop.
• When started normally, the PS feeling deteriorates.
Repair Procedure
1. Check visually that the connectors and terminals of CN1E
travel controller and EPS controller are not
disconnected or not loosened.
1 2 3 4 5 6 7 8 9 10 11
Judging: No disconnection of connector and no 12 13 14 15 16 17 18 19 20 21 22 23 24
17 16 15 14 13
12 11 10 9 8 7
6 5 4 3 2 1
CN3D
OK: Go to step 3.

history menu that it can communicate with the travel
OK: Go to step 2. controller.
NG: After cleaning the connector with the contact OK: Replace the travel controller.
refreshing agent, re-connect the connector. NG: Replace the EPS controller.
2. Disconnect the harness from the controller and How to reset

measure the resistance of harness between travel Turn OFF the key switch.
controller and EPS controller.
Remark
harness between travel controller and EPS
CN1E terminal No.14 (blue): 0 Ω
controller is broken.
When ERR-5081 occurs simultaneously, the travel
70-26 AR50 Series

ERR-4084: ABNORMAL COMMUNICATION BETWEEN EPS CONTROLLER AND CARGO

HANDLING CONTROLLER (WITH THE CARGO HANDLING CONTROLLER)

• Cannot communicate with the cargo handling • When turning ON the key switch, all functions stop.
controller. • When started up normally, it functions.
Repair Procedure
cargo handling controller, travel controller and EPS
controller are not disconnected or not loosened. 1 2 3 4 5 6 7 8 9 10 11
17 16 15 14 13
12 11 10 9 8 7
6 5 4 3 2 1
CN3P
OK: Go to step 3.

OK: Go to step 2. history menu that it can communicate with the EPS
controller.
NG: After cleaning the connector with the contact
refreshing agent, re-connect the connector. OK: Go to step 4.
NG: Replace the EPS controller.

measure the resistance of harness between EPS 4. Connect the service tool and confirm on the error
controller and cargo handling controller. (Measure history menu that it can communicate with the
while keeping the connector of travel controller con- cargo handling controller.
nected.) OK: Poor contact of connector pin. (Repair or replace
Judging: Between CN3P terminal No.8 (green) and the harness.)
CN1E terminal No.3 (green): 0 Ω NG: Replace the cargo handling controller.
Between CN3P terminal No.2 (blue) and
How to reset
Remark
harness between travel controller and cargo
handling controller is broken or the cargo handling
harness between travel controller and EPS
controller is broken.
AR50 Series 70-27

ERR-3070: ABNORMAL MEMORY IN THE TRAVEL CONTROLLER

ERR-5070: ABNORMAL MEMORY IN THE CARGO HANDLING CONTROLLER

• Abnormal EEPROM in the controller • Normal function (It functions in the fail safe state.)
Repair Procedure
1. Replace the defective controller.
ERR-5081: ABNORMAL COMMUNICATION BETWEEN CARGO HANDLING CONTROLLER

AND TRAVEL CONTROLLER (WITH THE TRAVEL CONTROLLER)

• Cannot communicate with the travel controller. • When turning ON the key switch, all functions stop.
• When started up normally, cargo-handling stops.
Repair Procedure
1. Check visually that the connectors and terminals of CN3D CN3P
cargo handling controller and travel controller are
not disconnected or not loosened. 17 16 15 14 13 17 16 15 14 13
Judging: No disconnection of connector and no 12 11 10 9 8 7 12 11 10 9 8 7
looseness of terminal 6 5 4 3 2 1 6 5 4 3 2 1
OK: Go to step 3.

cargo handling controller.
OK: Go to step 2. OK: Replace the travel controller.
NG: After cleaning the connector with the contact NG: Replace the cargo handling controller.
refreshing agent, re-connect the connector.
How to reset
2. Remove the harness from the controller and
measure the resistance between travel controller
and cargo handling controller.
Judging: Between CN3D terminal No.8 (green) and Remark
CN3P terminal No.8 (green): 0 Ω 1) When ERR-4081 occurs simultaneously, the travel
Between CN3D terminal No.2 (blue) and controller is defective.
CN3P terminal No.2 (blue): 0 Ω 2) When the harness between travel controller and
cargo handling controller is defective, ERR-3084
takes the priority over other codes for display.
70-28 AR50 Series

ERR-5083 ABNORMAL COMMUNICATION BETWEEN CARGO HANDLING CONTROLLER

AND EPS CONTROLLER (WITH THE EPS CONTROLLER)

• Cannot communicate with the EPS controller. • When turning ON the key switch, all functions stop.
• When started up normally, it functions.
Repair Procedure
EPS controller, cargo handling controller and travel
controller are not disconnected or not loosened. 1 2 3 4 5 6 7 8 9 10 11
17 16 15 14 13
12 11 10 9 8 7
6 5 4 3 2 1
CN3P
OK: Go to step 3.
NG: Replace or repair the harness.

OK: Go to step 2.
NG: After cleaning the connector with the contact cargo handling controller.
refreshing agent, re-connect the connector. OK: Go to step 4.
measure the resistance of harness between EPS
controller and cargo handling controller.
history menu that it can communicate with the EPS
Judging: Between CN3P terminal No.8 (green) and controller.
OK: Poor contact of connector pin (Replace or repair the
Between CN3P terminal No.2 (blue/white) and harness.)
CN1E terminal No.14 (blue/white): 0 Ω
How to reset
Remark
1) When ERR-3083 occurs simultaneously, the EPS
controller is defective.
2) When the harness between EPS controller and
cargo handling controller is defective, ERR-4084
takes the priority over other codes for display.
AR50 Series 70-29

ERR14-8110: ABNORMAL CAN COMMUNICATION PROCESS OF TRAVEL CONTROLLER
Content of Trouble
• Poor contact or short-circuit of CAN communication harness
Repair Procedure 3. Disconnect the harness and measure the
1. Check visually that the connectors and terminals of resistance of CAN communication line at the meter
travel controller are not disconnected or not panel side.
loosened. Judging: Between meter panel terminal No.11 (green)
Judging: No disconnection of connector and no and meter pane terminal No.9 (blue):
looseness of terminal 20 kΩ – 100 kΩ
Meter Panel
1 2 3 4 5 6
7 8 9 10 11 12
OK: Go to step 2. OK: Go to step 4.
NG: Clean the connector with the contact refreshing NG: Repair or replace the equipment.
agent and re-connect the connector.
4. Disconnect the harness and measure the
resistance of CAN communication line at the travel
2. Measure the resistance at the terminals of CAN
controller side.
service connector in the state that connectors of all
equipment are connected. Judging: Between CN3D terminal No.9 and CN3D
terminal No.3 (blue): 20 kΩ – 100 kΩ
Judging: Between service tool terminal No.2 (green)
and service tool terminal No.3 (blue):
40 – 70 Ω Travel Controller
CN3D
13 14 15 16 17
Service Tool
7 8 9 10 11 12
1 2 3 4 5 6
2 1
4 3
OK: Go to step 5.
NG: Repair or replace the equipment.
OK: Perform step 3 and later. Perform the short-circuit
test of CAN communication line of harness.
70-30 AR50 Series


resistance of CAN communication line at the cargo
handling controller side.
Judging: Between CN3P terminal No.9 and
CN3P terminal No.3: 20 kΩ – 100 kΩ
Cargo Handling Controller
CN3P
13 14 15 16 17
7 8 9 10 11 12
1 2 3 4 5 6
OK: Go to step 6.

resistance of CAN communication line at the EPS
controller side.
Judging: Between CN1E terminal No.4 and
CN1E terminal No.15: 20 kΩ – 100 kΩ
EPS controller
CN1E
11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 12
OK: Replace the travel controller.

AR50 Series 70-31

ERR20-8110: ABNORMAL CAN COMMUNICATION PROCESS OF EPS CONTROLLER
Content of Trouble
EPS controller are not disconnected or not panel side.
loosened. Judging: Between meter panel terminal No.11 and
Judging: No disconnection of connector and no meter pane terminal No.9: 20 kΩ – 100 kΩ
Meter Panel
1 2 3 4 5 6
7 8 9 10 11 12
OK: Go to step 4.
OK: Go to step 2. NG: Repair or replace the equipment.
NG: Clean the connector with the contact refreshing
agent and re-connect the connector. 4. Disconnect the harness and measure the
controller side.
2. Measure the resistance at the terminals of service
tool. Judging: Between CN3D terminal No.9 and
CN3D terminal No.3: 20 kΩ – 100 kΩ
CN3D
13 14 15 16 17
Service Tool
7 8 9 10 11 12
1 2 3 4 5 6
2 1
4 3
OK: Go to step 5.
test of CAN communication line harness.
70-32 AR50 Series


CN3P
13 14 15 16 17
7 8 9 10 11 12
1 2 3 4 5 6
OK: Go to step 6.

controller side.
EPS controller
CN1E
11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 12

AR50 Series 70-33

ERR30-8110: ABNORMAL CAN COMMUNICATION PROCESS OF CARGO HANDLING

CONTROLLER
Content of Trouble
cargo handling controller are not disconnected or panel side.
not loosened. Judging: Between meter panel terminal No.11 and
Judging: No disconnection of connector No looseness meter pane terminal No.9: 20 kΩ – 100 kΩ
of terminal
Meter Panel
1 2 3 4 5 6
7 8 9 10 11 12
OK: Go to step 4.
OK: Go to step 2. NG: Repair or replace the equipment.
controller side.
tool. Judging: Between CN3D terminal No.9 and
CN3D
13 14 15 16 17
Service Tool
7 8 9 10 11 12
1 2 3 4 5 6
2 1
4 3
OK: Go to step 5.
70-34 AR50 Series


CN3P
13 14 15 16 17
7 8 9 10 11 12
1 2 3 4 5 6
OK: Go to step 6.

controller side.
EPS controller
CN1E
11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 12
OK: Replace the cargo handling controller.

AR50 Series 70-35

ERR40-8110: ABNORMAL CAN COMMUNICATION PROCESS OF METER PANEL
Content of Trouble
meter panel are not disconnected or not loosened. panel side.
Judging: No disconnection of connector and no Judging: Between meter panel terminal No.11 and
looseness of terminal meter panel terminal No.9: 20 kΩ – 100 kΩ
Meter Panel
1 2 3 4 5 6
7 8 9 10 11 12
NG: Clean the connector with the contact refreshing NG: Repair or replace the equipment.
controller side.
tool.
Judging: Between CN3D terminal No.9 and
40 – 70 Ω
Travel Controller
CN3D
Service Tool
13 14 15 16 17
7 8 9 10 11 12
2 1
1 2 3 4 5 6
4 3

OK: Go to step 5.
OK: Perform step 3 and later. Perform the short-circuit NG: Repair or replace the equipment.
70-36 AR50 Series


CN3P
13 14 15 16 17
7 8 9 10 11 12
1 2 3 4 5 6
OK: Go to step 6.

controller side.
EPS controller
CN1E
11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 12
OK: Replace the meter panel.

AR50 Series 70-37

ERR14-8120: ABNORMAL CAN TRANSMISSION/RECEPTION PROCESS OF

TRAVEL CONTROLLER
Content of Trouble
• Poor contact or short-circuit of harness connector of travel controller
• Abnormal travel controller
1. Check visually that the connectors and terminals of resistance of CAN communication line between
travel controller are not disconnected or not travel controller and EPS controller.
loosened. Judging: Between CN3D terminal No.9 (green)
Judging: No disconnection of connector and no and CN1E terminal No.3 (green): 0 Ω
looseness of terminal Between CN3D terminal No.3 (blue) and
CN1E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
17 16 15 14 13
12 11 10 9 8 7
6 5 4 3 2 1
CN3D
OK: Go to step 2.
agent and re-connect the connector. OK: Replace the travel controller.
tool.
4. Measure the resistance of CAN communication line
Judging: Between service tool terminal No.2 (green) between travel controller and cargo handling
and service tool terminal No.3 (blue): controller.
40 – 70 Ω
Service Tool
2 1
4 3 CN3D CN3P
17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1
OK: Go to step 3. Viewed from the engagement side of connector

70-38 AR50 Series


EPS CONTROLLER
Content of Trouble
• Poor contact or short-circuit of harness connector of EPS controller
• Abnormal EPS controller
EPS controller are not disconnected or not EPS controller and meter panel.
loosened. Judging: Between CN1E terminal No.4 (green) and
Judging: No disconnection of connector and no meter panel terminal No.11 (green): 0 Ω
looseness of terminal Between CN1E terminal No.15 (blue) and
meter panel terminal No.9 (blue): 0 Ω
CN1E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
Meter Panel
6 5 4 3 2 1
12 11 10 9 8 7
OK: Go to step 2.
OK: Go to step 4.

tool. 4. Disconnect the harness and measure the
resistance of CAN communication line between
EPS controller and travel controller.
40 – 70Ω Judging: Between CN1E terminal No.3 (green) and
CN3D terminal No.9 (green): 0 Ω
Between CN1E terminal No.14 (blue) and
CN3D terminal No.3 (blue/white): 0 Ω
Service Tool
2 1 CN1E
4 3
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
17 16 15 14 13
12 11 10 9 8 7
Viewed from the engagement side of connector 6 5 4 3 2 1
OK: Go to step 3. CN3D

NG: Repair or replace the harness. Viewed from the engagement side of connector

AR50 Series 70-39


CARGO HANDLING CONTROLLER
Content of Trouble
• Poor contact or short-circuit of harness connector of cargo handling controller
• Abnormal cargo handling controller
cargo handling controller are not disconnected or cargo handling controller and travel controller.
not loosened. Judging: Between CN3P terminal No.8 (green) and
Judging: No disconnection of connector and no CN3D terminal No.8 (green): 0 Ω
looseness of terminal Between CN3P terminal No.2 (blue) and
CN3D terminal No.2 (blue): 0 Ω
CN3D CN3P
17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1

OK: Go to step 2.
NG: Clean the connector with the contact refreshing OK: Replace the cargo handling controller.
agent and re-connect the connector. NG: Repair or replace the harness.

tool
40 – 70 Ω
Service Tool
2 1
4 3
OK: Go to step 3.
70-40 AR50 Series

ERR40-8120: ABNORMAL CAN TRANSMISSION/RECEPTION PROCESS OF METER PANEL

• The meter panel cannot communicate with other • Abnormal meter panel display (The content of display
equipment. cannot be renewed.)
The truck operates normally.
Repair Procedure 3. Measure the resistance of CAN communication line

1. Check visually that the connectors and terminals of between meter panel and EPS controller.
meter panel are not disconnected or not loosened. Judging: Between meter panel terminal No.11 (green)
Judging: No disconnection of connector No looseness and CN1E terminal No.4 (green): 0 Ω
of terminal Between meter panel terminal No.9 (blue) and
CN1E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
Meter Panel
6 5 4 3 2 1
12 11 10 9 8 7
OK: Go to step 2.
agent and re-connect the connector. OK: Go to step 4.

resistance between CAN communication line at the
meter panel side and GND.
40 – 70 Ω Judging: Between meter panel terminal No.6 and meter
panel terminal No.11: More than 1 MΩ
Between meter panel terminal No.6 and meter
panel terminal No.9: More than 1 MΩ
Service Tool
2 1 Meter Panel
4 3
6 5 4 3 2 1
12 11 10 9 8 7

OK: Go to step 3.
NG: Repair or replace the harness. Or perform step 4 OK: Go to step 5.
and later. NG: Replace the meter panel.
AR50 Series 70-41

5. Disconnect the harness and measure the 7. Disconnect the harness and measure the resis-
resistance between CAN communication line at the tance between CAN communication line at the
travel control side and GND. cargo handling controller side and GND.
Judging: Between CN3D terminal No.15 and Judging: Between CN3P terminal No.15 and
CN3D terminal No.9: More than 1 MΩ CN3P terminal No.9: More than 1 MΩ
Between CN3D terminal No.15 and Between CN3P terminal No.15 and
CN3D CN3P
17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1
Viewed from the engagement side of connector Viewed from the engagement side of connector
OK: Go to step 6. OK: Replace the meter panel.

NG: Replace the travel controller. NG: Replace the cargo handling controller.
6. Disconnect the harness and measure the resis-

tance between CAN communication line at the EPS
controller side and GND.
CN1E terminal No.4: More than 1 MΩ
Between CN1E terminal No.2 and
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
CN1E
OK: Go to step 7.
70-42 AR50 Series

ERR14-8130: ABNORMAL CAN COMMUNICATION BETWEEN TRAVEL CONTROLLER AND

METER PANEL
Content of Trouble
• Poor contact or short-circuit of harness connector between travel controller and meter panel
• Abnormal meter panel
travel controller, EPS controller and meter panel are travel controller and meter panel.
not disconnected or not loosened. (Measure while keeping the connector of EPS
controller connected.)
Judging: No disconnection of connector and no
looseness of terminal Judging: Between CN3D terminal No.9 (green)
and meter panel terminal No.11 (green): 0 Ω
CN3D
Meter Panel
17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1
OK: Go to step 2.
AR50 Series 70-43

ERR20-8130: ABNORMAL CAN COMMUNICATION BETWEEN EPS CONTROLLER AND

METER PANEL
Content of Trouble
• Poor contact or short-circuit of harness connector between EPS controller and meter panel
travel controller, EPS controller and meter panel are EPS controller and meter panel.
not disconnected or not loosened. Judging: Between CN1E terminal No.4 (green) and
CN1E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
Meter Panel
6 5 4 3 2 1
12 11 10 9 8 7
OK: Go to step 2.
agent and re-connect the connector. OK: Replace the meter panel.
70-44 AR50 Series

ERR30-8130: ABNORMAL CAN COMMUNICATION BETWEEN CARGO HANDLING

CONTROLLER AND METER PANEL
Content of Trouble
• Poor contact or short-circuit of harness connector between cargo handling controller and meter panel
cargo handling controller, EPS controller and meter cargo handling controller and meter panel.
panel are not disconnected or not loosened. (Measure while keeping the connector of EPS
controller connected.)
looseness of terminal Judging: Between CN3P terminal No.8 (green) and
meter panel terminal No.11 (green): 0 Ω
Between CN3P terminal No.2 (blue) and
CN3P Meter Panel

17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1
OK: Go to step 2.
AR50 Series 70-45

ERR14-8140: ABNORMAL CAN TRANSMISSION OF TRAVEL CONTROLLER
Content of Trouble
• Poor contact or short-circuit of harness connector of travel controller
travel controller are not disconnected or not travel controller and EPS controller.
loosened. Judging: Between CN3D terminal No.9 (green) and
Judging: No disconnection of connector and no CN1E terminal No.3 (green): 0 Ω
looseness of terminal Between CN3D terminal No.3 (blue) and
CN1E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
17 16 15 14 13
12 11 10 9 8 7
6 5 4 3 2 1
CN3D

OK: Go to step 4.

resistance of CAN communication line between
travel controller and cargo handling controller.
40 – 70 Ω Judging: Between CN3D terminal No.8 (green) and
Service Tool
2 1 CN3D CN3P
4 3
17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1
OK: Go to step 3.
70-46 AR50 Series

ERR20-8140: ABNORMAL CAN TRANSMISSION OF EPS CONTROLLER
Content of Trouble
• Poor contact or short-circuit of harness connector of EPS controller
EPS controller are not disconnected or not EPS controller and meter panel.
loosened. Judging: Between CN1E terminal No.4 (green) and
CN1E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
Meter panel
6 5 4 3 2 1
12 11 10 9 8 7

OK: Go to step 2.
OK: Go to step 4.

2. Measure the resistance at the terminals of service resistance of CAN communication line between
tool. EPS controller and travel controller.
Judging: Between service tool terminal No.2 (green) Judging: Between CN1E terminal No.3 (green) and
and service tool terminal No.3 (blue): CN3D terminal No.9 (green): 0 Ω
40 – 70 Ω
Service Tool CN1E
2 1
1 2 3 4 5 6 7 8 9 10 11
4 3 12 13 14 15 16 17 18 19 20 21 22 23 24
17 16 15 14 13
12 11 10 9 8 7
6 5 4 3 2 1

CN3D
NG: Repair or replace the harness. OK: Replace the EPS controller.
AR50 Series 70-47

ERR30-8140: ABNORMAL CAN TRANSMISSION OF CARGO HANDLING CONTROLLER
Content of Trouble
• Poor contact or short-circuit of harness connector of cargo handling controller
cargo handling controller are not disconnected or cargo handling controller and travel controller.
not loosened. Judging: Between CN3P terminal No.8 (green) and
Judging: No disconnection of connector and no CN3D terminal No.8 (green): 0 Ω
looseness of terminal Between CN3P terminal No.2 (blue) and
CN3D CN3P
17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1

OK: Go to step 2.
NG: Clean the connector with the contact refreshing OK: Replace the cargo handling controller.
agent and re-connect the connector. NG: Repair or replace the harness.

tool.
Judging: Between service tool terminal No.2 (green) and
service tool terminal No.3 (blue): 40 – 70 Ω
Service Tool
2 1
4 3
OK: Go to step 3.
70-48 AR50 Series

ERR40-8140: ABNORMAL CAN TRANSMISSION OF METER PANEL
Content of Trouble
• Poor contact or short-circuit of harness connector of meter panel
meter panel are not disconnected or not loosened. EPS controller and meter panel.
Judging: No disconnection of connector and no Judging: Between meter panel terminal No.11 (green)
looseness of terminal and CN1E terminal No.4 (green): 0 Ω
Between meter panel terminal No.9 (blue) and
CN1E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
Meter panel
6 5 4 3 2 1
12 11 10 9 8 7
OK: Go to step 2.
OK: Go to step 4.

tool. 4. Disconnect he harness and measure the resistance
between CAN communication line at the meter
panel side and GND.
40 – 70 Ω Judging: Between meter panel terminal No.6 and
meter panel terminal No.11: More than 1 MΩ
Between meter panel terminal No.6 and
meter panel terminal No.9: More than 1 MΩ
Service Tool
2 1 Meter Panel
4 3 6 5 4 3 2 1
12 11 10 9 8 7

OK: Go to step 3.
NG: Repair or replace the harness. Or perform step 4 OK: Go to step 5.
and later. NG: Replace the meter panel.
AR50 Series 70-49

5. Disconnect the harness and measure the 7. Disconnect the harness and measure the
resistance between CAN communication line at the resistance between CAN communication line at the
travel control side and GND. cargo handling controller side and GND.
Judging: Between CN3D terminal No.15 and Judging: Between CN3P terminal No.15 and
Between CN3D terminal No.15 and Between CN3P terminal No.15 and
CN3D CN3P
17 16 15 14 13 17 16 15 14 13
12 11 10 9 8 7 12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1
OK: Go to step 6. OK: Replace the meter panel.

NG: Replace the travel controller. NG: Replace the cargo handling controller.

resistance between CAN communication line at the
EPS controller side and GND.
Between CN1E terminal No.2 and
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
CN1E
OK: Go to step 7.
70-50 AR50 Series


METER PANEL
Content of Trouble
• Poor contact or short-circuit of CAN communication line (Harness and communication parts in each controller)
Repair Procedure 4. Connect the harness connector to the travel
1. Turn off the key switch and disconnect the battery controller and measure the resistance of CAN
connector. communication line harness between cargo
handling controller and meter panel.
2. Check visually that the connectors and terminals of
travel controller and meter panel are not Judging: Between CN3P terminal No.8 (green)
disconnected or not loosened. and meter panel terminal No.11 (green): 0 Ω
Judging: No disconnection of connector and no Between CN3P terminal No.2 (blue) and
looseness of terminal meter panel terminal No.9 (blue): 0 Ω
CN3P
Meter panel
17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1
OK: Go to step 5
OK: Go to step 3.
5. Connect the harness connectors except meter
panel (Only the meter panel connector is removed.)
3. Connect the harness connector to the EPS and measure the resistance between CAN_H and
controller and measure the resistance of CAN CAN_L at the CAN service connector terminals.
communication line harness between travel Judging: Between service tool terminal No.2 (green)
controller and meter panel. and service tool terminal No.3 (blue):
Judging: Between CN3D terminal No.9 (green) and 100 – 140 Ω
Service Tool
CN3D
Meter Panel 2 1
17 16 15 14 13 4 3
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1
OK: Go to step 6
OK: Go to step 4.
AR50 Series 70-51

6. Connect the harness connector of meter panel

again and measure the resistance between CAN_H
and CAN_L at the CAN service connector
terminals.
40 – 80 Ω
Service Tool
2 1
4 3

NG: Replace the meter panel.
Remark
When ERR40-8320 is displayed simultaneously,
check its abnormal code first.
For repair procedure, refer to the abnormal code
item of ERR40-8320.
70-52 AR50 Series


METER PANEL
Content of Trouble
1. Turn off the key switch and disconnect the battery resistance between connector terminals at the EPS
connector. controller side.
2. Check visually that the connectors and terminals of Judging: Between CN1E terminal No.2 and
EPS controller and meter panel are not CN1Eterminal No.4: 1 MΩ
disconnected or not loosened. Between CN1E terminal No.2 and
Judging: No disconnection of connector and no CN1E terminal No.15: 1 MΩ
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
CN1E
OK: Go to step 5.
OK: Go to step 3. NG: Replace the EPS controller.
resistance between connector terminals at the
3. Disconnect the harness and measure the travel controller side.
resistance of CAN communication line harness Judging: Between CN3D terminal No.15 and
between EPS controller and meter panel. CN3D terminal No.9: 1 MΩ
Judging: Between CN1E terminal No.4 (green) and Between CN3D terminal No.15 and CN3D
meter panel terminal No.11 (green): 0 Ω terminal No.3: 1 MΩ
CN3D
CN1E 17 16 15 14 13
12 11 10 9 8 7
1 2 3 4 5 6 7 8 9 10 11 6 5 4 3 2 1
12 13 14 15 16 17 18 19 20 21 22 23 24
Meter panel
6 5 4 3 2 1
12 11 10 9 8 7
OK: Go to step 6.
OK: Go to step 4.
AR50 Series 70-53

6. Disconnect the harness and measure the 8. Connect the harness connector to the EPS
resistance between connector terminals at the controller and measure the resistance of CAN
cargo handling controller. communication line harness between travel
Judging: Between CN3P terminal No.15 and controller and meter panel.
CN3P terminal No.9: 1 MΩ Judging: Between CN3D terminal No.9 (green) and
Between CN3P terminal No.15 and meter panel terminal No.11(green): 0 Ω
CN3P terminal No.3: 1 MΩ Between CN3D terminal No.3 (blue) and
CN3P
CN3D
Meter Panel
17 16 15 14 13 17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7 12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1

NG: Replace the cargo handling controller. NG: Repair or replace the harness.
7. Disconnect the harness and measure the 9. Connect the harness connector to the travel
meter panel controller side. communication line harness between cargo
Judging: Between meter panel terminal No.6 and handling controller and meter panel.
meter panel terminal No.11: 1 MΩ Judging: Between CN3P terminal No.8 (green) and
Between meter panel terminal No.6 and meter panel terminal No.11(green): 0 Ω
meter panel terminal No.9: 1 MΩ Between CN3P terminal No.2 (blue) and
Meter Panel
CN3P
6 5 4 3 2 1 Meter panel
12 11 10 9 8 7 17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1
OK: Go to step 8.
OK: Go to step 10.
70-54 AR50 Series

10. Connect the harness connectors except the meter

panel again and measure the resistance between
CAN_H and CAN_L at the CAN service connector
terminals.
100 – 140 Ω
Service Tool
2 1
4 3
OK: Go to step 11.

NG: Replace the cargo handing controller.
11. Connect the harness connector of meter panel

again and measure the resistance between CAN_H
terminals.
40 – 80 Ω
Service Tool
2 1
4 3

AR50 Series 70-55

ERR40-8330: ABNORMAL CAN COMMUNICATION BETWEEN CARGO HANDLING

CONTROLLER AND METER PANEL
Content of Trouble
Repair Procedure 4. Connect the harness connectors except the meter
1. Turn off the key switch and disconnect the battery panel again (Only the meter panel connector is
connector. disconnected.) and measure the resistance
between CAN_H and CAN_L at the service
connector terminals.
cargo handling controller and meter panel are not
disconnected or not loosened. Judging: Between service tool terminal No.2 (green) and
Service Tool
2 1
4 3
OK: Go to step 5.
OK: Go to step 3.
NG: Clean the connector with the contact refreshing 5. Connect the harness connector of meter panel
agent and re-connect the connector. again and measure the resistance between CAN_H
terminals.
3. Connect the harness connector to the travel
Judging: Between service tool terminal No.2 (green) and
controller and EPS controller, and measure the
resistance of CAN communication line harness
between cargo handling controller and meter panel.
Judging: Between CN3P terminal No.8 (green) and Service Tool
Between CN3P terminal No.2 (blue) and 2 1
meter panel terminal No.9 (blue): 0 Ω 4 3
CN3P
Meter panel
17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7 Viewed from the engagement side of connector
12 11 10 9 8 7
6 5 4 3 2 1
Remark
Viewed from the engagement side of connector When ERR40-8314 and ERR40-8320 are displayed
simultaneously, check their abnormal codes first.
OK: Go to step 4. For repair procedure, refer to each abnormal code
NG: Repair or replace the harness. item.
70-56 AR50 Series

ERR40-8510: ABNORMAL CAN COMMUNICATION OF METER PANEL AFTER TURNING

ON THE KEY SWITCH
Content of Trouble
• Abnormal communication immediately after turning on the key switch
Repair Procedure 4. Disconnect the harness and measure the resistance
1. Turn off the key switch and disconnect the battery between terminals at the EPS controller side.
connector. Judging: Between CN1E terminal No.2 and
2. Check visually that the connectors and terminals of CN1E terminal No.4: 1 MΩ
meter panel are not disconnected or not loosened. Between CN1E terminal No.2 and
Judging: No disconnection of connector and no CN1E terminal No.15: 1 MΩ
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
CN1E
OK: Go to step 5.
OK: Go to step 3. NG: Replace the EPS controller.
resistance between connector terminals at the
3. Disconnect the harness and measure the travel controller side.
resistance of CAN communication line harness Judging: Between CN3D terminal No.15 and
between EPS controller and meter panel. CN3D terminal No.9: 1 MΩ
Judging: Between CN1E terminal No.4 (green) and Between CN3D terminal No.15 and
meter panel terminal No.11 (green): 0 Ω CN3D terminal No.3: 1 MΩ
CN3D
CN1E 17 16 15 14 13
12 11 10 9 8 7
1 2 3 4 5 6 7 8 9 10 11
6 5 4 3 2 1
12 13 14 15 16 17 18 19 20 21 22 23 24
Meter panel
6 5 4 3 2 1
12 11 10 9 8 7

OK: Go to step 6.
OK: Go to step 4.
AR50 Series 70-57

6. Disconnect the harness and measure the 8. Connect the harness connector to the EPS
cargo handling controller side. communication line harness between travel
Judging: Between CN3P terminal No.15 and controller and meter panel.
CN3P terminal No.9: 1 MΩ Judging: Between CN3D terminal No.9 (green) and
Between CN3P terminal No.15 and meter panel terminal No.11(green): 0 Ω
CN3P terminal No.3: 1 MΩ Between CN3D terminal No.3 (blue) and
CN3P
CN3D
Meter Panel
17 16 15 14 13 17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7 12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1 6 5 4 3 2 1

NG: Replace the cargo handling controller. NG: Repair or replace the harness.
7. Disconnect the harness and measure the 9. Connect the harness connector to the travel
meter panel controller side. communication line harness between cargo
Judging: Between meter panel terminal No.6 and handling controller and meter panel.
meter panel terminal No.11: 1 MΩ Judging: Between CN3P terminal No.8 (green) and
Between meter panel terminal No.6 and meter panel terminal No.11(green): 0 Ω
meter panel terminal No.9: 1 MΩ Between CN3P terminal No.2 (blue) and
Meter Panel
CN3P
6 5 4 3 2 1 Meter panel
12 11 10 9 8 7 17 16 15 14 13
6 5 4 3 2 1
12 11 10 9 8 7
12 11 10 9 8 7
6 5 4 3 2 1
OK: Go to step 8.
OK: Go to step 10.
70-58 AR50 Series

10. Connect the harness connectors except the meter

panel again and measure the resistance between
CAN_H and CAN_L at the CAN service connector
terminals.
and service tool terminal No.3 (green):
100 – 140 Ω
Service Tool
2 1
4 3

AR50 Series 70-59

DIAGNOSTIC PROCEDURE BY METER DISPLAY TROUBLE CODE TROUBLESHOOTING
DIAGNOSTIC PROCEDURE BY METER DISPLAY TROUBLE CODE
Meter Display Trouble Code: ERR-3001 (Travel) Meter Display Trouble Code: ERR-3002 (Travel)
Content of Trouble Content of Trouble
Breaking of main contactor Shorted main contactor
Blown-out fuse
Symptom of truck
Symptom of truck Inoperable travel/cargo handling/EPS
Inoperable travel/cargo handling/ EPS (The main contactor does not open.)
Retry of contactor turning-on process
Troubled set after retry of 5 times Repair Procedure
(The retry is continued after set.) 1. Check the connection of battery cable. (Check the
leaking of + potential to secondary voltage side of
contactor.)
Repair Procedure
2. Check the main contactor (foreign matters in the
1. Check the main contactor (foreign matters in the
contact, mechanical interference). Repair or replace
contact, mechanical interference). Repair or replace
it.
it.
3. Disconnect the harness and check the harness
2. Check and replace the fuse.
between travel controller and contactor coil. Repair
3. Disconnect the harness and check the harness or replace it.
between travel controller and contactor coil. Repair
Judging: Between CN1D terminal No.3 (green/red) and
or replace it.
contactor coil terminal No.2: 0 Ω
Judging: Between CN1D terminal No.3 (green/red) and
Between CN1D terminal No.4 (green/yellow)
contactor coil terminal No.2: 0 Ω
and contactor coil terminal No.1: 0 Ω
Between CN1D terminal No.4 (green/yellow)
and contactor coil terminal No.1: 0 Ω
Main Contactor
CN1D
Main Contactor
CN1D 22 23 24 25 26 27 28 29 30 31
10 11 12 13 14 15 16 17 18 19 20 21 1 2
22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21 1 2
1 2 3 4 5 6 7 8 9 Viewed from the engagement side of connector
Viewed from the engagement side of connector 4. If normal in the above check, replace the travel con-
troller.
4. If normal in the above check, replace the travel con-
troller.
How to reset
How to reset
Remark
None
Remark
In case of broken contactor wire, if succeeded in the
try, the error is reset.
70-60 AR50 Series

TROUBLESHOOTING DIAGNOSTIC PROCEDURE BY METER DISPLAY TROUBLE CODE
Meter Display Trouble Code: ERR-3004 (Travel)

Content of Trouble
The low voltage is detected. (Dropped battery voltage)
Symptom of truck
Inoperable travel/cargo handling/ EPS
(The main contactor is open.)
Repair Procedure
1. Measure the battery voltage. If necessary,
re-charge the battery.
travel controller are not disconnected or not
loosened.
3. Check the harness between the connector CN1D
terminal No.7 of travel controller and the battery.
Repair or replace it.
How to reset
Remark
VB = lower than 28.2V / 800 rms
Lower than 15V / 30 ms detection
AR50 Series 70-61


Content of Trouble 6. Measure the resistance between No.8 and No.9 of
Travel controller (The upper and lower FETs are connector CN1D at the harness side of travel
shorted.) controller.
Symptom of truck
Inoperable travel/cargo handling (The main contactor
does not close.)
CN1D
Repair Procedure 31 30 29 28 27 26 25 24 23 22
1. Disconnect the battery connector and leave the 21 20 19 18 17 16 15 14 13 12 11 10
truck for 10 minutes. 9 8 7 6 5 4 3 2 1
2. Check visually that the copper bar connecting the

travel controller and cargo handling controller and Viewed from engagement side of connector
their mounting bolts (P and N terminals) are not
shorted by foreign matters. 0 Ω or ∞ Ω :
3. Check visually that the U, V and W terminals are Repair or replace the quick charging resistor
not shorted by foreign matters. onnection cable and resistor.
4. Remove the copper bars connecting the About 39 Ω :
controllers and confirm that the P and N terminals Replace the travel controller.
of controller are not shorted, using the tester.
7. If normal in the above check, replace the travel
• The lift lever sensor is improperly adjusted. controller.
• The lift lever sensor is defective.
5. Measure the resistance of harness between the How to reset

harness side of emergency power cut-off button Turn OFF the key switch.
and the travel controller.
Judging: Between emergency power cut-off button
Remark
harness terminal No.2 (red) and
CN1D terminal No.7 (red): 0 Ω As the travel controller and cargo handling controller
are connected via copper bar and the EPS is
connected via fuse, the trouble code 5010 (shorted at
Power Emergency the FET side of cargo handling
Cut-off Button controller) or the trouble code 4001 (The EPS fuse is
open.) appears.
CN1D Besides, if the controller is shorted, the trouble code
3016 (quick charge error) appears as the capacitor
31 30 29 28 27 26 25 24 23 22 1 2
between P and N cannot be charged.
21 20 19 18 17 16 15 14 13 12 11 10 3 4
9 8 7 6 5 4 3 2 1
OK: Go to step 6.
70-62 AR50 Series

ERR-3012 (Travel) ERR-3014 (Travel)
ERR-3015 (Travel)
Travel Controller (The upper side is shorted.)(3011) Travel controller (Broken U phase wire) (3013)
Travel Controller (The lower side is shorted.)(3012) Travel controller (Broken V phase wire) (3014)
Travel controller (Broken W phase wire) (3015)
Symptom of truck
Unable to travel Symptom of truck
Unable to travel
Repair Procedure
1. Disconnect the battery connector and leave the Repair Procedure
truck for 10 minutes. 1. Disconnect the battery connector and leave the
2. Disconnect the motor cable from the U, V and W truck for 10 minutes.
terminals and check the motor cable between P 2. Check the loosened cable tightened at the motor
terminal and N terminal respectively, using the terminal and the breaking of cable.
tester. If leaked, remove or repair. 3. Disconnect the cable from the motor terminal and
3. Confirm that no foreign matters exist on the P and N check the breaking of wire between phases.
terminals and around the U, V and W terminals. (Between U and V phases, Between V and W
(Check visually foreign matters on the printed circuit phases, Between W and U phases)
board.) (The resistance between phases of motor is
4. If normal in the above check, replace the travel normally several tens mΩ.)
controller. • Broken wire: Replace the motor.
• Normal: Replace the travel controller.

How to reset
How to reset
Remark
Check the cable between motor and truck.
Check the leakage of rain-water.
Check foreign matters on the CPU board.
AR50 Series 70-63

Meter Display Trouble Code: ERR-3016 (Travel) Meter Display Trouble Code: ALA-3021 (Travel)
Defect of quick charging (Defect of charging capacitor Travel Controller (Temperature Rise)
between P and N)
Symptom of truck
Symptom of truck Unable to travel
Inoperable travel/cargo handling/EPS (The main The warning is detected over 108°C.
contactor does not close.)
The warning is released below 105°C.
The current cut-off works over 105°C.
Repair Procedure
1. Check the repair procedure of abnormal codes
Repair Procedure
3010.
1. When heavily loaded or operated continuously, stop
2. Check the repair procedure of abnormal code 5010.
the truck to cool down the controller.
3. If normal in the above checks, replace the travel
2. When normally traveling, if the alarm occurs in a
controller.
short period of time, check ERR-3021.
How to reset
How to reset
Can be recovered below 105°C.
Remark
Remark
The trouble codes 3010, 4010 and 5010 also appear.
Resistance / voltage of temperature sensor in the
(About 15 seconds later, they are displayed as the
normal condition
capacitor between P and N cannot be charged.)
25°C: 100 kΩ / 3.2V (± 10 %)
50°C: 36 kΩ / 2.0V (± 10 %)
75°C: 15 kΩ / 1.0V (± 10 %)
100°C: 6.5 kΩ / 0.5V (± 10 %)
Check the insufficient cooling caused by
malfunctioning fan.
70-64 AR50 Series

Meter Display Trouble Code: ERR-3021 (Travel) Meter Display Trouble Code: ALA-3031 (Travel)
Travel Controller (Abnormal Temperature) Travel Controller (Temperature Rise)

Unable to travel Unable to travel
The error is detected over 120°C. The warning is detected over 163°C.
The error is released below 120°C. The warning is released below 160°C.
Repair Procedure
1. Stop the truck to cool down the controller. Repair Procedure
2. Check the mounting of travel controller. 1. When heavily loaded or operated continuously, stop
(Looseness) the truck to cool down the travel motor.
3. Check the fan. Repair or replace it. 2. If the alarm appears in a short period of time in the
4. If normal in the above checks, replace the travel normal operation, check, referring to ERR-3031.
controller as the error arises from the controller.
How to reset
How to reset Can be recovered below 160°C.
Lower the temperature below 120°C and turn OFF the
key switch. Remark
Resistance / voltage of travel motor temperature
Remark sensor in normal condition
Resistance / voltage of travel motor temperature 25°C: 10.7 kΩ / 3.5V (± 10 %)
sensor in normal condition 50°C: 4.4 kΩ / 2.4V (± 10 %)
25°C: 100 kΩ / 3.2V (± 10 %) 100°C: 1.0 kΩ / 0.9V (± 10 %)
50°C: 36 kΩ / 2.0V (± 10 %) 150°C: 0.3 kΩ / 0.3V (± 10 %)
75°C: 15 kΩ / 1.0V (± 10 %)
100°C: 6.5 kΩ / 0.5V (± 10 %)
malfunctioning fan.
AR50 Series 70-65


Content of Trouble How to reset
Travel Motor (Abnormal Temperature) Lower the temperature below 170°C and turn OFF the
key switch.
Symptom of truck
Unable to travel Remark
The error is detected over 175°C. Resistance / voltage of travel motor temperature
sensor in normal condition
The error is released below 175°C.
25°C: 10.7 kΩ / 3.5V (± 10 %)
50°C: 4.4 kΩ / 2.4V (± 10 %)
Repair Procedure 100°C: 1.0 kΩ / 1.9V (± 10 %)
1. Stop the truck to cool down the travel motor. 150°C: 0.3 kΩ / 0.3V (± 10 %)
2. Measure the resistance of harness between travel
controller and travel motor temperature sensor.
Judging: Between CND1 terminal No.20 (yellow/green)
and travel motor temperature sensor terminal
No.1 (yellow/green): 0 Ω
Between CND1 terminal No.29 (yellow/black)
No.2 (yellow/black): 0 Ω
Travel Motor
CN1D temperature Sensor
31 30 29 28 27 26 25 24 23 22 1 2
21 20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
OK: Go to step 3.
3. Measure the resistance / voltage of travel motor

temperature sensor. Replace it. (Check between
terminals No.20 and No.29 of controller connector
CN1D.)
troller.
70-66 AR50 Series

Short-circuit between phases of travel motor (The load Defective travel controller temperature sensor
is shorted.)
Symptom of truck
Symptom of truck The truck can travel normally.
Unable to travel • Operative in the normal temperature
• Fan drive
Repair Procedure
1. Disconnect the battery connector and leave the Repair Procedure
truck for 10 minutes.
1. As the error arises from the controller, replace the
2. Check visually that foreign matters do not exist travel controller.
around the U, V and W terminals of travel controller.
3. Perform the short-circuit test of motor cables
How to reset
(broken cladding, entry of foreign matters).
When recovered to the normal condition, the error
4. Remove the travel motor cable from the travel
code is reset.
controller. Insulate the terminals with the insulation
tape to prevent from touching to the other
controllers, “ + ” and “ - ” terminals. Remark
5. After connecting the battery connector, stand When the abnormality is detected, the voltage of
yourself on the floor plate and turn on the key temperature sensor is lower than 0.2 V or higher than
switch. 4.95 V.
6. Confirm that the error code 3030 disappears.
• It disappears: Replace the travel motor.
• It does not disappear: Replace the travel
controller.
How to reset
Turn ON the key switch.
Remark
As a resistor of several 10 mΩ is connected between
phases of motor, it cannot be checked with the tester.
AR50 Series 70-67

Defective travel motor temperature sensor The output of travel current sensor (U phase, W
phase) is defective.
Symptom of truck
• The truck can travel normally. Symptom of truck
• Operative in the normal temperature Unable to travel
1. Confirm that the temperature sensor connector of 1. Confirm that foreign matters do not exist around the
travel motor is firmly connected. current sensor on the CPU board.
2. Measure the resistance of harness between travel 2. If normal in the above check, replace the travel
controller and travel motor temperature sensor. controller.
Judging: Between CND1 terminal No.20 (yellow/green)

and travel motor temperature sensor terminal How to reset
No.1 (yellow/green): 0 Ω Turn ON the key switch.
Between CND1 terminal No.29 (yellow/black)
Remark
Check visually the current sensor. If it is abnormal,
replace the travel controller.
Travel Motor
CN1D temperature Sensor
31 30 29 28 27 26 25 24 23 22 1 2
21 20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
OK: Go to step 3.
3. Measure the resistance / voltage of travel motor

temperature sensor. Replace it.
controller.
How to reset
When recovered to the normal condition, the error
code is reset.
Remark
When the abnormality is detected, the voltage of travel
motor temperature sensor is lower than 0.15 V or
higher than 4.95 V.
70-68 AR50 Series


Content of Trouble
Defective travel accelerator
Symptom of truck
Unable to travel (Free-run state)
Repair Procedure
1. Confirm that connectors and terminals at the
accelerator side are not disconnected and not
loosened.
2. Measure the resistance of harness between travel
controller and accelerator.
Judging: Between CND1 terminal No.21 (red) and
accelerator terminal No.8 (red): 0 Ω
Between CND1 terminal No.30 (black) and
accelerator terminal No.6 (black): 0 Ω
Between CND1 terminal No.31 (white) and
accelerator terminal No.7 (white): 0 Ω
CN1D Accelerator
31 30 29 28 27 26 25 24 23 22 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10 8 7 6 5
9 8 7 6 5 4 3 2 1

How to reset
Remark
Accelerator voltage in the normal state
• Release the accelerator: 2.5 V
• Fully operate forward: About 4.48 V
• Fully operate backward: About 0.52 V
AR50 Series 70-69


Travel motor speed sensor (The A phase output is When returned to the normal state, the error code is
abnormal.) reset.
Symptom of truck Remark

Unable to travel Voltage at terminal in the normal state
Terminal No.14: When the key switch is turned ON,
Repair Procedure it is about 13.5 V.
Terminal No.13: When the key switch is turned ON
1. Confirm that the connectors and terminals of travel
(stop), it is 1.3 – 3.3 V.
motor speed sensor A phase are not disconnected
or not loosened.
(operating), it is about 2.3 V.
2. Measure the resistance of harness between the (Average voltage when the motor is rotating.)
travel controller and travel motor speed sensor A
phase.
Judging: Between CN1D terminal No.13 (white) and
travel motor speed sensor A terminal No.1
(white): 0 Ω
Between CN1D terminal No.14 (black) and
travel motor speed sensor A terminal No.2
(black): 0 Ω
CN1-D1 Travel Motor

Speed Sensor A
31 30 29 28 27 26 25 24 23 22 1 2
21 20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
OK: Go to step 3.
3. Check the travel motor speed sensor A phase.

4. Check the gear of travel motor (poor mesh of gear
with sensor, entry of magnetic substance). Repair
or replace the motor.
controller.
70-70 AR50 Series


Travel motor speed sensor (The B phase output is When returned to the normal state, the error code is
abnormal.) reset.
Symptom of truck Remark

Unable to travel Voltage at terminal in the normal state
Terminal No.28: When the key switch is turned ON,
Repair Procedure it is about 13.5 V.
1. Confirm that the connectors and terminals of travel
(stop), it is 1.3 – 3.3 V.
motor speed sensor B phase are not disconnected
or not loosened.
2. Measure the resistance of harness between the (Average voltage when the motor is rotating.)
travel controller and travel motor speed sensor B
phase.
Judging: Between CN1D terminal No.27 (white) and
travel motor speed sensor B terminal No.1
(white): 0 Ω
Between CN1D terminal No.28 (black) and
travel motor speed sensor B terminal No.2
(black): 0 Ω
Travel Motor
CN1-D1 Speed Sensor B
31 30 29 28 27 26 25 24 23 22 1 2
21 20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
OK: Go to step 3.
3. Check the travel motor speed sensor B phase.

4. Check the gear of travel motor (poor mesh of gear
with sensor, entry of magnetic substance).
Repair or replace the motor.
controller.
AR50 Series 70-71

Defective FR direction switch Defective logic of floor switch _a and floor switch _b

Unable to travel Inoperable travel/cargo handling

1. Measure the resistance of harness between travel 1. Measure the resistance of harness between travel
controller and FR direction switch. controller and floor switch.
Judging: Between CN1D terminal No. 1 (white/black) Judging: Between CN1D terminal No. 19 (blue/red) and
and accelerator terminal No.2 (white/black): floor switch terminal No.1 (blue/red): 0 Ω
0Ω Between CN2D terminal No. 18 (red/black)
Between CN1D terminal No. 2 (blue) and and floor switch terminal No.2 (red/black): 0 Ω
accelerator terminal No.3 (blue): 0 Ω
CN1D Floor Switch

Accelerator
CN1D
31 30 29 28 27 26 25 24 23 22
21 20 19 18 17 16 15 14 13 12 11 10 1 2 3
9 8 7 6 5 4 3 2 1
31 30 29 28 27 26 25 24 23 22
Viewed from the engagement
21 20 19 18 17 16 15 14 13 12 11 10 4 3 2 1 side of connector
9 8 7 6 5 4 3 2 1 8 7 6 5 24 23 22 21 20 19 18 17
16 15 14 13 12 11 10 9 8 CN2D
7 6 5 4 3 2 1
Viewed from the engagement of connector

OK: Go to step 2.
OK: Go to step 2. NG: Repair or replace the harness.
2. Check the floor switch. Repair or replace it.
2. Check the FR direction switch of accelerator. Repair 3. If normal in the above check, replace the travel con-
or replace it. troller.
troller.
How to reset
When returned to the normal state, the error code is
How to reset reset.
reset.
Remark
When turning ON the floor switch _a and
Remark floor switch _b, it is detected.
When DSF SW and DSR SW are turned on When turning OFF the floor switch _a and
simultaneously, it is detected. floor switch _b, it is detected.
70-72 AR50 Series

Meter Display Trouble Code: ERR-5004 (Cargo Handling)

Content of Trouble
The low voltage is detected. (Dropped battery voltage)
Symptom of truck
Inoperable travel/cargo handling/ EPS
(The main contactor is open.)
Repair Procedure
1. Measure the battery voltage. If necessary,
re-charge the battery.
cargo handling controller are not disconnected or
not loosened.
3. Check the harness between the battery and the
connector CN1-P terminal No.7 of cargo handling
controller. Repair or replace it.
How to reset
Remark
VB = lower than 28.2 V / 800 rms: 48 V specification
Lower than 15V / 30 ms detection
AR50 Series 70-73


Cargo handling controller (The upper and lower FETs Turn OFF the key switch.
are shorted.)
Remark
Symptom of truck As the travel controller and cargo handling controller
Inoperable travel/cargo handling/EPS (The main are connected via the copper bar and the EPS
contactor does not close.) controller is connected via fuse, the trouble codes
3010 (short at the FET side of travel controller) or the
trouble code 4001 (The EPS fuse is open.) appears.
Repair Procedure
Besides, if the controller is shorted, the trouble code
1. Disconnect the battery connector and leave the 3016 (quick charge error) appears as the capacitor
truck for 10 minutes. between P and N cannot be charged.
2. Check visually that the copper bar connecting the
travel controller and cargo handling controller and
their mounting bolts (P and N terminals) are not
shorted by foreign matters.
3. Check visually that the U, V and W terminals are
not shorted by foreign matters.
4. Remove the copper bars connecting the controllers
and confirm that terminals N and P of controller are
not shorted, using the tester.
• Shorted: Replace the shorted controller.
• Not shorted: Check the next item.
5. Perform the conduction (VB line) test of the harness

between the harness of emergency power cut-off
button and the cargo handing controller.
Judging: Between terminal No.2 (red) of harness for
emergency power cut-off button and CN1P
terminal No.7 (red): 0 Ω
Emergency Power
cut-off Button
CN1P
31 30 29 28 27 26 25 24 23 22 1 2
21 20 19 18 17 16 15 14 13 12 11 10 3 4
9 8 7 6 5 4 3 2 1

70-74 AR50 Series

Meter Display Trouble Code: ERR-5011 (Cargo Handling) Meter Display Trouble Code: ERR-5013 (Cargo Handling)
ERR-5012 (Cargo Handling) ERR-5014 (Cargo Handling)
ERR-5015 (Cargo Handling)
Content of Trouble
Cargo Handling Controller (The upper side is shorted.) Content of Trouble
Cargo Handling Controller (The lower side is shorted.) Cargo handling controller (Broken U phase wire)
(ERR-5013)
Symptom of truck Cargo handling controller (Broken V phase wire)

(ERR-5014)
Unable to handle the cargo
Cargo handling controller (Broken W phase wire)
(ERR-5015)
Repair Procedure
1. Disconnect the battery connector and leave the
Symptom of truck
2. Disconnect the motor cables from the U, V and W
terminals and check each motor cable at P and N
terminals, using the tester. If leaked, remove or Repair Procedure
repair it. 1. Disconnect the battery connector and leave the
3. Confirm that no foreign matters exist on the P and N truck for 10 minutes.
terminals and around U, V and W terminals. 2. Check the loosened cable tightened at the motor
(Check visually foreign matters on the CPU board.) terminal and the breaking of cable.
4. If normal in the above check, replace the cargo 3. Remove the cables from the motor terminal and
handling controller. check the breaking of wire between phases.
(Between U and V phases, Between V and W
How to reset phases, Between W and U phases)
(The resistance between phases of motor is
normally several tens mΩ.)
• Broken wire: Replace the motor.
Remark • Normal: Replace the cargo handling controller.
Check the motor cable and truck cable.
Check foreign matters on the printed circuit board. How to reset
AR50 Series 70-75

Meter Display Trouble Code: ALA-5021 (Cargo Handling) Meter Display Trouble Code: ERR-5021 (Cargo Handling)
Cargo Handling Controller (Temperature Rise) Cargo Handling Controller (Abnormal Temperature)

Unable to handle the cargo Unable to handle the cargo
The warning is detected over 108°C. The error is detected over 120°C.
The warning is released below 105°C. The error is released below 120°C.
Repair Procedure
Repair Procedure 1. Stop the truck to cool down the controller.
1. When heavily loaded or operated continuously, stop 2. Check the mounting of cargo handling controller.
the truck to cool down the controller. (Looseness)
2. When normally traveling, if the alarm occurs in a 3. Check the fan. Repair or replace it.
short period of time, check ERR-5021. 4. If normal in the above check, replace the cargo
handling controller.
How to reset
When recovered below 105°C. How to reset
Lower the temperature below 120°C and turn OFF the
Remark key switch.
Resistance / voltage of temperature sensor in the
normal condition Remark
25°C: 100 kΩ / 3.2V (± 10 %) Resistance / voltage of travel motor temperature
50°C: 36 kΩ / 2.0V (± 10 %) sensor in normal condition
75°C: 15 kΩ / 1.0V (± 10 %) 25°C: 100 kΩ / 3.2V (± 10 %)
100°C: 6.5 kΩ / 0.5V (± 10 %) 50°C: 36 kΩ / 2.0V (± 10 %)
Check the insufficient cooling caused by alfunctioning 75°C: 15 kΩ / 1.0V (± 10 %)
fan. 100°C: 6.5 kΩ / 0.5V (± 10 %)
malfunctioning fan.
70-76 AR50 Series

Meter Display Trouble Code: ERR-5030 (Cargo Handling) Meter Display Trouble Code: ALA-5031 (Cargo Handling)
Short-circuit between phases of pump motor Pump Motor (Temperature Rise)
(The load is shorted.)
Symptom of truck
Symptom of truck Unable to handle the cargo
Unable to handle the cargo The warning is detected over 163°C.
The warning is released below 160°C.
Repair Procedure The current cut-off works over 160°C.
1. Disconnect the battery connector and leave the
Repair Procedure
2. Check visually that foreign matters do not exist
1. When heavily loaded or used continuously, stop the
around the U, V and W terminals of cargo handling
truck to cool down the pump motor.
controller.
2. If the alarm appears in a short period of time in the
3. Check short-circuiting between motor cables
normal operation, check, referring to ERR-5031.
(broken cladding, entry of foreign matters).
4. Remove the cargo handling motor cable from the
cargo handling controller. Insulate the terminals of How to reset
cargo handling cable with the insulation tape to Can be recovered below 160°C.
prevent them from touching to other controller, “ + “
polarity and “ - “ polarity.
Remark
5. After connecting the battery connector, be seated
Resistance / voltage of pump motor temperature
on the seat and turn ON the key switch.
Confirm that the error code 5030 disappears.
25°C: 10.7 kΩ / 3.5V (± 10 %)
• It disappears. : Replace the cargo handling
50°C: 4.4 kΩ / 2.4V (± 10 %)
motor.
100°C: 1.0 kΩ / 0.9V (± 10 %)
• It does not disappear. : Replace the cargo
150°C: 0.3 kΩ / 0.3V (± 10 %)
How to reset
Turn ON the key switch.
Remark
As a resistor of several 10 mΩ is connected between
phases of motor, it cannot be checked with the tester.
AR50 Series 70-77


Pump Motor (Abnormal Temperature) Lower the temperature below 175°C and turn OFF the
key switch.
Symptom of truck
Unable to handle the cargo Remark
The error is detected over 175°C. Resistance / voltage of travel motor temperature
The error is released below 175°C.
25°C: 10.7 kΩ / 3.5V (± 10 %)
50°C: 4.4 kΩ / 2.4V (± 10 %)
Repair Procedure 100°C: 1.0 kΩ / 0.9V (± 10 %)
1. Stop the truck to cool down the pump motor. 150°C: 0.3 kΩ / 0.3V (± 10 %)
2. Measure the resistance of harness between the
cargo handling controller and the pump motor
temperature sensor.
Judging: Between CN1P terminal No.20 (yellow/green)
and pump motor temperature sensor terminal
Between CN1P terminal No.29 (yellow/black)
Pump Motor
CN1P Temperature Sensor
31 30 29 28 27 26 25 24 23 22
21 20 19 18 17 16 15 14 13 12 11 10 1 2
9 8 7 6 5 4 3 2 1
OK: Go to step 3.
3. Measure the resistance / voltage of pump motor

temperature sensor and replace it. (Check between
CN1P connector terminals No.20 and No.29 of
controller.)
4. If normal in the above check, replace the cargo
70-78 AR50 Series

Defective cargo handling controller temperature Abnormal pump motor temperature sensor
sensor
Symptom of truck
Symptom of truck The normal cargo handling is operative.
The normal cargo handling is operative. • Operated in the normal temperature.
• Operated in the normal temperature
• Fan drive
Repair Procedure
1. Confirm that the pump motor temperature sensor
Repair Procedure connector is firmly connected.
1. As the error arises from the controller, replace the 2. Check the harness between CN1-P terminals No.
cargo handling controller. 20 / No.29 of cargo handling controller and the
pump motor temperature sensor. Repair or replace
How to reset it.
When returned to the normal state, the error code is Judging: Between CN1P terminal No. 20 (yellow/green)
reset. and pump motor temperature sensor terminal
Between CN1P terminal No. 29 (yellow/black)
Remark
When the abnormality is detected, the temperature No.2 (yellow/black): 0 Ω
sensor voltage is lower than 0.2 V or higher than
4.95 V.
Pump Motor
CN1P Temperature Sensor
31 30 29 28 27 26 25 24 23 22
21 20 19 18 17 16 15 14 13 12 11 10 1 2
9 8 7 6 5 4 3 2 1
AR50 Series 70-79

Defective output of cargo handling current sensor (U Defective lift lever POT
phase, W phase) (POT: POT denotes the potentio meter. It is a fine
volume control.)
Symptom of truck
Symptom of truck
The truck is driven by the lift switch 1 setting value.
Repair Procedure
1. Check that no foreign matters exist around the
current sensor on the CPU board. Repair Procedure
2. If normal in the above check, replace the cargo 1. Confirm that the connectors and terminals of lift
handling controller. lever POT are not disconnected and not loosened.
2. Measure the resistance of harness between the
cargo handling controller and the lift lever POT.
How to reset
Judging: Between CN2P terminal No.22 (black) and
lift lever VR switch terminal No.1 (black): 0 Ω
Between CN2P terminal No.23 (white) and
Remark lift lever VR switch terminal No.2 (white): 0 Ω
Check visually the current sensor. If abnormal, replace Between CN2P terminal No.24 (red) and
the cargo handling controller. lift lever VR switch terminal No.3 (red): 0 Ω
CN2P Lift Lever

VR Switch
24 23 22 21 20 19 18 17 3 2 1
16 15 14 13 12 11 10 9 8
7 6 5 4 3 2 1
OK: Go to step 3.
3. Check the lift lever POT. Repair or replace it.

4. If normal in the above check, replace the cargo
How to reset
reset.
Remark
Voltage at terminal in the normal state
No.22 terminal: 0 V
No.23 terminal: 2.5 – 1.9 V
No.24 terminal: 4.55 V
70-80 AR50 Series

Defective pump motor speed sensor Defective load meter pressure sensor
Unable to handle the cargo Normal operation
1. Confirm that the connectors and terminals of pump 1. Confirm that the connectors and terminals of
motor speed sensor are not disconnected and not pressure sensor are not disconnected and not
loosened. loosened.
2. Measure the resistance of harness between the 2. Measure the resistance of harness between the
cargo handling controller and the pump motor cargo handling controller and the pressure sensor.
speed sensor. Judging: Between CN2P terminal No.14 (black) and
Judging: Between CN1P terminal No.27 (white) and pressure sensor terminal No.3 (black): 0 Ω
pump motor speed sensor terminal No.1 Between CN2P terminal No.15 (white) and
(white): 0 Ω pressure sensor terminal No.2 (white): 0 Ω
Between CN1P terminal No.28 (black) and Between CN2P terminal No.16 (red) and
pump motor speed sensor terminal No.2 pressure sensor terminal No.1 (red): 0 Ω
(black): 0 Ω
Load meter
Pump motor CN2P pressure sensor
CN1P speed sensor
31 30 29 28 27 26 25 24 23 22 1 2 24 23 22 21 20 19 18 17 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10 16 15 14 13 12 11 10 9 8
9 8 7 6 5 4 3 2 1 7 6 5 4 3 2 1
OK: Go to step 3.
NG: Repair or replace the harness. OK: Go to step 3.
3. Check the pump motor speed sensor. Repair or

replace it. 3. Check the pressure sensor. Repair or replace it.
4. Check the gear of motor pump (poor mesh of gear 4. If normal in the above check, replace the cargo
with the sensor, entry of magnetic substance). handling controller.
Repair or replace the motor.
5. If normal in the above check, replace the cargo How to reset
Turn off the key switch.
How to reset
Remark
reset.
Terminal No.14: 0 V
Terminal No.15: 0.5 – 4.5 V
Remark Terminal No.16: 5 V
Speed voltage at terminal in the normal state
Terminal No.28: When the key switch is turned ON, it
is about 13.5 V.
(stop), it is 1.3 – 3.3 V.
(Average voltage when the motor is rotating.)
AR50 Series 70-81

Meter Display Trouble Code: ERR-4001 (EPS) Meter Display Trouble Code: ERR-4004 (EPS)
Blown-out fuse (Open fuse) The low voltage is detected. (Dropped battery voltage)

Inoperable EPS Inoperable EPS

1. Check and confirm that the internal connection 1. Check the battery voltage. If necessary, re-charge
harness is not disconnected and not loosened. the battery.
2. Check and replace the fuse. 2. Check visually the connector and terminals of EPS
3. If normal in the above check, replace the EPS controller are not disconnected and not loosened.
controller. 3. Check the conduction of the harness between the
connector CN1E terminal No.24 of EPS controller
and the battery. Repair or replace it.
How to reset
How to reset
Remark
None
Remark
VB= lower than 28.2 V / 800 rms
70-82 AR50 Series

EPS controller (Upper and lower FETs are shorted.) The transistor (FET) is open
The motor is open.
Symptom of truck
Inoperable travel/cargo handling/EPS Symptom of truck
(The main contactor does not close.) Inoperable EPS
Inoperative EPS (After turning on the main contactor)
Repair Procedure
Repair Procedure 1. Disconnect the battery connector and leave the
1. Disconnect the battery connector and leave the truck for 10 minutes.
truck for 10 minutes. 2. Check that the motor cable connectors are not
2. Check and confirm that the internal connection disconnected and not loosened. Check that the
harnesses are not disconnected and not loosened. cables are not broken.
3. Check the internal connection harnesses with a 3. Disconnect the connectors from the motor terminals
tester. If leaked, repair or replace it. and check the wires between motor terminals are
not broken.
4. Confirm that no foreign matter exists around the
terminals of internal connection harness. • Broken wire: Replace the motor.
• Normal: Replace the EPS controller.
5. If normal in the above check, replace the EPS
controller.
How to reset
How to reset Turn OFF the key switch.
Remark
Remark None
Check foreign matters on the printed circuit board.
AR50 Series 70-83

Meter Display Trouble Code: ERR-4021 (EPS) Meter Display Trouble Code: ALA-4021 (EPS)
The FET temperature is abnormal. The FET temperature rises.

Inoperable EPS Inoperable EPS
The abnormality is detected over 115°C. The abnormality is detected over 100°C.
The error is released below 110°C. The error is released below 95°C.

1. Stop the truck to cool down the controller block. 1. Stop the truck to cool down the controller block.
2. Check the mounting of EPS controller. (Looseness) 2. Check the mounting of EPS controller. (Looseness)
Repair or replace it. Repair or replace it.
3. Check the screws (FET fixing screw on the side of 3. Check the screws (FET fixing screw) on the side of
controller. Repair or replace it. controller. Repair or replace it.
4. Check the fan. Repair or replace it. 4. Check the fan. Repair or replace it.
5. If normal in the above check, replace the EPS 5. If normal in the above check, replace the EPS
controller. controller.
How to reset How to reset

Can be recovered below 100°C. Can be recovered below 95°C.
Remark Remark
As the thermistor is mounted on the circuit board, it As the thermistor is mounted on the circuit board, it
cannot be checked. cannot be checked.
70-84 AR50 Series

Defective FET temperature sensor POT error
Symptom of truck
Symptom of truck Inoperable EPS
Normal steering operation is possible. Repair Procedure
It functions in normal temperature. 1. Confirm that the connectors and terminals of POT
for EPS torque sensor are not disconnected or not
loosened.
Repair Procedure
2. Measure the resistance of harness between EPS
As the error arises from controller, replace the EPS controller and POT for EPS torque sensor.
controller. Judging: Between CN1E terminal No.21 (red/blue) and
EPS torque sensor terminal No.3 (red/blue):
How to reset 0Ω
Between CN1E terminal No.7 (yellow) and
When returned to the normal, the error is reset.
EPS torque sensor terminal No.2 (yellow): 0 Ω
Between CN1E terminal No.20 (black/yellow)
Remark and EPS torque sensor terminal No.1 (black/
None yellow): 0 Ω
CN1E
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
EPS
1 2 3 torque
sensor
OK: Go to step 3.
3. Check the POT for EPS torque sensor.

4. If normal in the above check, replace the EPS
controller.
How to reset
Remark
Terminal No.7: 1.50 – 3.50 V
Terminal No.20: 0.45 V
Terminal No. 21: 4.55 V
AR50 Series 70-85

TROUBLE WITHOUT ABNORMAL DISPLAY TROUBLESHOOTING
TROUBLE WITHOUT ABNORMAL DISPLAY
ALL OF FUNCTIONS ARE INOPERATIVE.

(TRAVEL, CARGO HANDLING, EPS AND METER DISPLAY)
The charger is incorrectly connected. Turn OFF the key switch.
Repair Procedure Remark

1. Check that the charger is correctly connected to VB When replacing the controller, confirm that the
line. connection is correct.
(If the voltage is higher than 68V or the voltage is
lower than 68V, the contactor does not work.)
ALL OF FUNCTIONS ARE INOPERATIVE.

(TRAVEL, CARGO HANDLING, EPS AND METER DISPLAY) (CONTINUED)
The control voltage (VB line, key switch line) is not fed. The control voltage (VB line, key switch line) is not fed.

1. Measure the resistance of harness between the 1. Measure the resistance of harness between the
travel inverter connector CN1D and key switch. travel inverter connector CN1D and key switch.
Judging: Between CN1D terminal No.6 (yellow) and
key switch terminal No.2 (yellow): 0 Ω How to reset
Between CN1D terminal No.7 (red) and Normal recovery
key switch terminal No.2 (red): 0 Ω
Remark
None
CN1D Key switch
31 30 29 28 27 26 25 24 23 22 1
21 20 19 18 17 16 15 14 13 12 11 10 2 3
9 8 7 6 5 4 3 2 1
OK: Replace the key switch.

How to reset
Normal recovery
Remark
None
70-86 AR50 Series

TROUBLESHOOTING TROUBLE WITHOUT ABNORMAL DISPLAY
EVEN IF THE DIRECTION SWITCH OR ACCELERATOR IS OPERATED,

THE TRUCK DOES NOT NORMALLY TRAVEL.
The speed sensor connectors A and B are reversely Accelerator unit and sync signal circuit are abnormal.
connected.
Repair Procedure
Repair Procedure 1. Confirm as follows.
1. Check the connection of connectors A and B of In proportional to the increase of accelerator, the
speed sensors. Re-connect them correctly. controller input accelerator VR voltage increases.
2. Measure the resistance of harness between Confirm that the accelerator switch signal is
connector CN1D and travel motor speed sensor inputted.
A-phase and the resistance of harness between If abnormal, repair or replace the accelerator unit.
connector CN1D and travel motor speed sensor 2. Measure the resistance of harness between travel
B-phase respectively. controller connector CN1D and accelerator unit.
Judging: Between CN1D terminal No.13 (white) and travel Judging: Between CN1D terminal No.1 (white/black) and
motor speed sensor A terminal No.1 (white): 0 Ω accelerator terminal No.2 (white/black): 0 Ω
Between CN1D terminal No.14 (black) and Between CN1D terminal No.2 (blue) and
travel motor speed sensor A terminal No.2 accelerator terminal No.3 (blue): 0 Ω
(black): 0 Ω Between CN1D terminal No.21 (red) and
Between CN1D terminal No.27 (white) and accelerator terminal No.8 (red): 0 Ω
travel motor speed sensor B terminal No.1 Between CN1D terminal No.30 (black) and
(white): 0 Ω accelerator terminal No.6 (black): 0 Ω
Between CN1D terminal No.28 (black) and Between CN1D terminal No.31 (white) and
travel motor speed sensor B terminal No.2 accelerator terminal No.7 (white): 0 Ω
(black): 0 Ω
CN1D Accelerator
Travel motor
CN1D speed sensor A/B
31 30 29 28 27 26 25 24 23 22 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10 8 7 6 5
31 30 29 28 27 26 25 24 23 22 1 2 9 8 7 6 5 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
OK: Replace the accelerator unit.

OK: Confirm the connection of connector.
How to reset
How to reset
Normal recovery
Normal recovery
Remark
Remark
No leak from the signal line
When replacing the motor, confirm the connection to When the wire of accelerator VR is broken, the error is
prevent misconnection. detected.
AR50 Series 70-87

EVEN IF THE DIRECTION SWITCH OR ACCELERATOR IS OPERATED,

THE TRUCK DOES NOT NORMALLY TRAVEL. (CONTINUED)
Incorrect correction of travel motor wires Normal recovery

1. Confirm that the travel motor wire is connected to When replacing the motor, confirm the connection.
the travel controller. If not, correct it.
STOP OF TRUCK DURING TRAVELING

The hyper voltage is detected. Normal recovery

1. Confirm that the battery connector does not poorly Protection when the battery connector is poorly
contact. contacted or disconnected during regeneration
2. Check the harness between VB and terminal No. 7
of connector CN1 on the CPU board. Repair or
replace it.
STEERING IS HEAVY. THE STEERING WHEEL CANNOT BE TURNED.

Shorted PS motor Normal recovery

1. Check the short of PS motor and associated wires. None
70-88 AR50 Series

TROUBLESHOOTING TROUBLE WITHOUT ABNORMAL DISPLAY
EVEN IF THE CARGO HANDLING IS OPERATED, IT DOES NOT FUNCTION.

The pump motor speed sensor connector is reversely Lift lever, work machine SW and signal circuit are
connected. abnormal.

1. Confirm that the pump motor speed sensor is 1. Confirm as follows.
correctly connected. If not, correct it. In proportional to the operation of lift lever in the
2. Measure the resistance of harness between elevating direction, the controller input lift VR
connector CN1P and pump motor speed sensor. voltage decrease.
If abnormal, repair or replace the lift lever POT.
Judging: Between CN1P terminal No.27 (white) and
pump motor speed sensor terminal No.1 2. Measure the resistance of harness between cargo
(white): 0 Ω handling controller connectors CN1P/CN2P and
switches of each work machine respectively.
Between CN1P terminal No.28 (black) and
pump motor speed sensor terminal No.2 Judging: Between CN1P terminal No.17 (green) (tilt
(black): 0 Ω operation) and control valve terminal No.4
(green): 0 Ω
Between CN1P terminal No.16 (white/black)
Pump motor (ATT1 operation) and control valve terminal
CN1P speed sensor No.5 (white/black): 0 Ω
Between CN1P terminal No.12 (yellow/red)
(ATT1 operation) and control valve terminal
31 30 29 28 27 26 25 24 23 22 1 2 No.7 (yellow/red): 0 Ω
21 20 19 18 17 16 15 14 13 12 11 10 Between CN1P terminal No.11 (white) (Reach
9 8 7 6 5 4 3 2 1 operation) and control valve terminal No.6
(green/yellow): 0 Ω
OK: Confirm the connection of connector. Control valve SW
NG: Repair or replace the harness. CN1P
31 30 29 28 27 26 25 24 23 22 4 3 2 1
How to reset 21 20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
8 7 6 5
Normal recovery
Control valve SW
Remark CN2P
None 24 23 22 21 20 19 18 17 4 3 2 1
16 15 14 13 12 11 10 9 8 8 7 6 5
7 6 5 4 3 2 1
Viewed from the engagement
side of connector
OK: Replace the control valve.
How to reset
Normal recovery
Remark
No leak from the signal line.
When the wire of accelerator lever is broken, the error
is detected.
AR50 Series 70-89

EVEN IF THE CARGO HANDLING IS OPERATED,

THE TRUCK DOES NOT NORMALLY TRAVEL. (CONTINUED)
Content of Trouble
The cargo handling motor wires are incorrectly
connected.
Repair Procedure
1. Confirm that the cargo handling motor wires are
correctly connected to the cargo handling controller.
If not, correct it.
How to reset
Normal recovery
Remark
When replacing the motor, confirm the connection.
WHEN OPERATING THE STEERING, HUNTING OF STEERING WHEEL OCCURS.

Content of Trouble
The connector of EPS motor harness is reversely
connected.
Repair Procedure
1. Connect the harness connector correctly.
How to reset
Normal recovery
Remark
Check screws in the EPS unit, fixing locations and
motor relay connector.
70-90 AR50 Series

TROUBLESHOOTING METER PANEL
METER PANEL
SYMPTOM-WISE TROUBLE DIAGNOSIS OF METER PANEL

No. Symptom Page
1 When turning ON the key switch, the meter panel does not function at all. 70-92
2 When connecting the battery, the entire meter panel keeps lighting. 70-92
3 Some segments and warnings do not light when all displays are lit at battery connection. 70-92
4 When turning ON the key switch, the LCD backlight does not light. 70-92
5 The buzzer does not beep during meter operation. 70-93
6 Some parts of LCD segments do not light during meter operation. 70-93
7 The LCD display is not renewed. 70-93
8 When turning OFF the key switch, the meter panel does not go off. 70-93
9 All of LCDs and warning lamps • repeat lighting and going-off. 70-93
10 The neutral safety warning does not light or go off. 70-94
11 The parking warning does not light or go off. 70-94
12 The warning lamp of travel system trouble lights (blinks). 70-94
13 The warning lamp of travel system trouble does not light (blink). 70-94
14 The warning lamp of cargo handling system trouble lights (blinks). 70-95
15 The warning lamp of cargo handling system trouble does not light (blink). 70-95
16 The warning lamp of trouble lights (blinks). 70-95
17 The warning lamp of trouble does not light (blink). 70-95
18 The display of battery remaining goes off or is different from actual remaining. 70-95
19 The display of power is obviously different from the actual power. 70-96
20 The display of forward-run/backward-run goes off or is different from the actual traveling state. 70-96
21 The display of travel speed goes off or is different from the actual speed. 70-96
22 The display (turtle icon) of travel speed limit is different the actual state, 70-96
23 The display cannot be changed to the clock or time cannot be set. 70-97
24 When turning ON the key switch, the display of clock is incorrect. 70-97
25 The display cannot be switched to the key ON time. 70-97
26 The display of key ON time is incorrect or shows [Tol----]. 70-97
27 The display cannot be switched to the [Travel R] time. 70-97
28 The [Travel R] time on the display is not accumulated or [0.0h] remains displayed. 70-97
29 The display cannot be switched to the cargo handling time. 70-98
30 The cargo handling time on the display is not accumulated or [0.0h] remains displayed. 70-98
31 The display cannot be switched to the load meter. 70-98
32 When displaying the load, the value displayed is different from the actual state of vehicle. 70-98
33 The load meter cannot be adjusted to zero. 70-98
34 The history of trouble cannot be displayed. 70-99
35 Even if the button is pressed, the display of trouble history code and hour time at the occurrence cannot be switched. 70-99
36 Even if the button is pressed, the travel speed limit setting (user adjustment mode) cannot be displayed. 70-99
37 The set value of travel speed limit (user adjustment mode) cannot be incremented or decremented with the UP and DOWN buttons. 70-99
38 Even if the MODE button is pressed after changing the value, the travel speed setting (user adjustment mode) cannot be reflected. 70-99
39 Even if the button is pressed, the lift speed setting (user adjustment mode) cannot be displayed. 70-99
40 The set value of lift speed (user adjustment mode) cannot be incremented or decremented with the UP and DOWN buttons. 70-100
41 Even if the MODE button is pressed after changing the value, the lift speed setting (user adjustment mode) cannot be reflected. 70-100
42 Even if the LMH button (UP button) is pressed, the display of power setting cannot be switched. 70-100
43 Even if the MODE button is pressed after changing the value, the power setting cannot be reflected. 70-100
44 Even if the turtle icon button (DOWN button) is pressed, the OF/OFF of travel speed limit cannot be changed. 70-101
45 The meter panel communication error is displayed. ([Err---????] is displayed on LCD.) 70-101
46 The controller communication error is displayed. ([Err---????] is displayed on LCD.) 70-101
AR50 Series 70-91

METER PANEL TROUBLESHOOTING
CONNECTOR PIN ASSIGNMENT

NO Name NO Name
1 6
1 Key switch 7 TMR
2 Presence/Absence of sensor 8 CANL (2)
3 Load meter display switch 9 CANL (1)
4 Battery electrolyte level sensor 10 CANH (2)
7 12 5 GND 11 CANH (1)
AMP 174973-2 6 SW GND 12 BATT
When the CAN termination resistor in the meter panel is used, pin 7 is connected to pin 10 by the harness
at the vehicle side. If the abnormality of CAN communication is suspected on the vehicle in which the
termination resistor in the meter panel is used, before checking the items below, confirm that the
connection mentioned above is implemented on the harness at the vehicle side.
1. When turning ON the key switch, the meter panel does not work at all.
(The LCD is not displayed. The LCD backlight and warning lamps do not light at all.)
Cause Remedy
Is the voltage applied to pin YES Is the voltage 26 - 66 V? YES

(1) and pin (5) and to pin (12) Defective meter panel Replace
and pin (5) of connector?
NO NO
Is the battery voltage YES Breaking of harness

normal? Poor contact of connector Check
Defective key switch
NO
Check
Abnormal battery
Re-charge
2. When the battery is connected, the entire meter panel keeps lighting.
Cause Remedy
Defective meter panel Replace
3. When the battery is connected, all lamps light. But, some segments and some warning lamps do not light.
Cause Remedy
4. After turning ON the key switch, the LCD backlight does not light.
(The LCD display and warning lamps work normally.)
70-92 AR50 Series

Cause Remedy
5. The buzzer does not beep during meter operation.

Cause Remedy
6. Some segments on the LCD do not work during meter operation.

Cause Remedy
7. The LCD display is not renewed.

Cause Remedy
Is the communication data YES Do all controllers output YES

inputted to pins (11) [(10)] normally the communication Defective meter panel Replace
and (9) [(8)] of connector? data?
NO NO
Abnormal controller Check
Breaking of harness
Check
Poor contact of connector
8. When turning OFF the key switch, the display of meter panel does not go off.
Cause Remedy
Is the voltage between pins NO

(1) and (5) of connector 26 - Defective meter panel Replace
66 V?
YES The harness or

connector is shorted Check
Abnormal key switch
9. All of LCD and warning lamps light (AE) and go off repeatedly. The meter panel d o not function normally.
Cause Remedy
Is the voltage between pins (12) NO
and (5) of connector lower than Defective meter panel Replace
26 V?
YES Over-discharge of battery
Re-charge
(Voltage drop of power supply)
AR50 Series 70-93

10. The neutral safety warning lamp does not light or goes off.
Cause Remedy
Is the communication data YES Does the controller normally output YES
inputted to pins (11) [(10)] the communication data according Defective meter panel Replace
and (9) [(8)] of connector? to the state of vehicle?
NO NO
Breaking of harness
Check
11. The parking warning light does not light or does not go off.
Cause Remedy
and (9) [(8)] of connector? to the state of vehicle?
NO NO
Breaking of harness
Check
12. The warning lamp of travel system trouble lights (blinks).

Cause Remedy
Is the trouble code* of travel NO

system displayed on the Defective meter panel Replace
LCD?
YES Other controller

detects the trouble Check
(The meter panel is normal.)
* [ALA---3???] or [Err---3???] is displayed.
13. The warning lamp of travel system trouble does not light (blinks).
Cause Remedy

system displayed on the Normal —
LCD?
YES
70-94 AR50 Series

14. The warning lamp of cargo handling system trouble lights (blinks).
Cause Remedy
Is the trouble code* of cargo NO

handling system displayed on Defective meter panel Replace
the LCD?

detects the trouble. Check
15. The warning lamp of cargo handling system trouble does not light (blink).
Cause Remedy

system displayed on the Normal —
LCD?
YES
16. The warning lamp of trouble lights (blinks).

Cause Remedy
Is the trouble code* of NO

displayed on the LCD?

detects the trouble. Check
* [Err??-????] is displayed.
17. The warning lamp of trouble does not light (blinks).

Cause Remedy
Is the trouble code* of NO

Normal —
displayed on the LCD?
YES
* [Err??---????] is displayed.
18. The display of battery remaining goes off or is obviously different from the actual remaining.
Cause Remedy
and (9) [(8)] of connector? to the state of battery?
NO NO
Breaking of harness
Check
AR50 Series 70-95

19. The display of power is obviously different from the actual power.
Cause Remedy
Is the communication data YES Does the controller normally YES

inputted to pins (11) [(10)] output the communication data Defective meter panel Replace
and (9) [(8)] of connector? according to the state of power?
NO NO
Breaking of harness
Check
20. The display of forward-run/backward-run goes off or is different from the actual state of traveling.
Cause Remedy
and (9) [(8)] of connector? to the actual traveling?
NO NO
Breaking of harness
Check
21. The display of travel speed goes off or is different from the actual travel speed.
Cause Remedy
and (9) [(8)] of connector? to the actual travel speed?
NO NO
Breaking of harness
Check
22. The display of travel speed limit (turtle icon) is different from the actual state.
Cause Remedy
and (9) [(8)] of connector? to the actual set speed limit?
NO NO
Breaking of harness
Check
70-96 AR50 Series

23. The display cannot be switched to the clock or time cannot be set.
Cause Remedy
24. When turning ON the key switch, the display of clock is obviously incorrect.
Cause Remedy
Is the battery without NO

connection* left more than 15 Defective meter panel Replace
days?
YES Discharge of battery for

backing up the
Re-set time
clock in the meter panel
* In the state that the voltage between connector pins 12 and 5 is lower than 26V.
25. The display cannot be switched to the key ON time.

Cause Remedy
26. The display of key ON time is obviously incorrect or shows [Tol-----.-].

Cause Remedy
27. The display cannot be switched to [Travel R] time.

Cause Remedy
28. The display of [Travel R] time is not accumulated or remains [0.0h].

Cause Remedy
Is the communication data YES Does the controller normally YES

inputted to pins (11) [(10)] accumulate the [travel 1] time and Defective meter panel Replace
and (9) [(8)] of connector? output the communication data?
NO NO
Breaking of harness
Check
AR50 Series 70-97

29. The display cannot be switched to the cargo handling time.

Cause Remedy
30. The display of cargo handling time is not accumulated or remains [0.0h].
Cause Remedy
Is the communication data Does the controller normally
YES accumulate the cargo handling time YES
inputted to pins (11) [(10)] Defective meter panel Replace
and (9) [(8)] of connector? and output the communication data?
NO NO
Breaking of harness
Check
31. The display cannot be switched to the load meter.

Cause Remedy
Is the load meter display SW YES

signal inputted to pins (3) and Defective meter panel Replace
(6) of connector?.
NO Breaking of harness
Check
32. When displaying the load meter, the value obviously different from the actual state of vehicle is displayed.
Cause Remedy
Is the communication data Does the controller normally
YES YES
inputted to pins (11) [(10)] output the communication data Defective meter panel Replace
and (9) [(8)] of connector? related to the load meter?
NO NO
Breaking of harness
Check
33. The load meter cannot be adjusted to zero.

Cause Remedy
70-98 AR50 Series

34. The history of trouble cannot be displayed.

Cause Remedy
35. Even if the button is pressed, the display cannot be switched to the code of trouble history and hour time at the occurrence.
Cause Remedy
36. Even if the button is pressed, the travel speed limit setting (user adjustment mode) cannot be displayed.
Cause Remedy
37. Even if the UP and DOWN buttons are pressed,

the travel speed limit setting (user adjustment mode) cannot be incremented or decremented.
Cause Remedy
38. Even if the MODE button is pressed after changing the value,
the travel speed limit setting (user adjustment mode) cannot be reflected.
Cause Remedy
Is the communication data Does the controller normally output
YES the communication data related to YES
and (9) [(8)] of connector? the travel speed limit setting?
NO NO
Breaking of harness
Check
39. Even is the button is pressed, the lift speed setting (user adjustment mode) cannot be displayed.
Cause Remedy
AR50 Series 70-99

40. Even if the UP and DOWN buttons are pressed,

the lift speed limit setting (user adjustment mode) cannot be incremented or decremented.
Cause Remedy
41. Even if the MODE button is pressed after changing the value,
the lift speed limit setting (user adjustment mode) cannot be reflected.
Cause Remedy
and (9) [(8)] of connector? the lift speed limit setting?
NO NO
Breaking of harness
Check
42. Even if the LMH button (UP button) is pressed, the lift power setting (user adjustment mode) cannot be switched.
Cause Remedy
43. Even if the MODE button is pressed after changing the value, the power setting (user adjustment mode) cannot be reflected.
Cause Remedy
and (9) [(8)] of connector? the power speed limit setting?
NO NO
Breaking of harness
Check
70-100 AR50 Series

44. Even if the turtle icon button (DOWN button) is pressed, the ON/OFF of travel speed limit cannot be changed.
Cause Remedy
and (9) [(8)] of connector? the travel speed limit setting?
NO NO
Breaking of harness
Check
45. The meter panel communication error is displayed. ([Err---????] is displayed on the LCD.)
Cause Remedy
Is the communication data YES

and (9) [(8)] of connector?
NO Does the controller normally YES Breaking of harness

output the communication Check
data?
NO
46. The controller communication error is displayed. ([Err??---????] is displayed on the LCD.)
Cause Remedy
The controller
communication Replace
error is detected
AR50 Series 70-101

80. YEARLY INSPECTION CRITERIA

MOTOR.......................................................................................80-2
CONTROL EQUIPMENT ............................................................80-3
BATTERY ...................................................................................80-7
POWER TRANSFER EQUIPMENT............................................80-9
TRAVEL EQUIPMENT................................................................80-9
STEERING EQUIPMENT .........................................................80-11
BRAKING EQUIPMENT ...........................................................80-13
CARGO HANDLING EQUIPMENT ...........................................80-15
HYDRAULIC EQUIPMENT.......................................................80-17
BODY, SAFETY EQUIPMENT, ETC.........................................80-19
TOTAL TEST.............................................................................80-19
AR50 Series 80-1

MOTOR YEARLY INSPECTION CRITERIA
a The check item No. corresponds to No. of specific voluntary check record table.
Equip-
Check Item Check Content
ment
1– 4. Referring to the table below, implement the periodic maintenance.

Truck (Travel/ However, in a dusty and humid place where the operating condition is sever, increase
Cargo Handling) the time of inspection.
Check
Check Item Judging Standard Treatment
Location
No looseness, no stacked dust, no Tightening,
Tightening Tightened
rust cleaning and
part screws
Visual and hitting check painting
Correct connection
Tightening,
No loose connection
Connection insulation
Insulation treatment
check
Terminal Visual check
Joint of termi-
No damage to the cladding Repair in a
nal and har-
Visual check special factory
ness
No stuck dust
Iron Core Cleaning
Visual check
Stator and Cleaning,
rotor assembly Coil and Insulating resistance of more than
heating dry,
insulation of 1MΩ (Measured in 500V mega
varnish
connection range)
treatment
Gap Removal of
Sped sensor No sticking of foreign matter
confirmation foreign matters
Reference Value
Temperature Measurement
sensor of resistance 20C°: 11.7 – 14.3 kΩ
25C°: 9.7 – 11.8 kΩ
No damage, no discolor, no
Anti-corrosion
Paint Damage peeling-off, no rust
Motor
coat
Visual check
Stacked dirt No heavy dirt, no stuck dust, no rust Cleaning,
Cleaning anti-corrosion
and dust Visual check coat, painting
80-2 AR50 Series

YEARLY INSPECTION CRITERIA CONTROL EQUIPMENT
Equip-
ment
5. Controller Check of the motor rotational state

(For travel) 1. The motor rotates smoothly at low, middle and high speed. Its acceleration is
smooth.
2. No abnormal sound
3. No odor
6. Controller Check of the motor rotational state

(For cargo 1. The motor rotates smoothly at low, middle and high speed. Its acceleration is
handling) smooth.
2. No abnormal sound
3. No odor
9. FR switch 1. Operating State

Confirm that the FR switch securely operates from neutral position to F and R.
F/R switch side: male
2. Conduction Test
Confirm that the wirings inside are not broken by performing the conduction test.
Measuring Method Judge 3 2 1
Set the FR lever to F, and
0 Ω: Normal
measure resistance between
pins 1 and 2.
∞: Broken
Set the FR lever to R, and
0 Ω: Normal
measure resistance between
∞: Broken
Control Equipment
pins 1 and 3.
If the wire is broken, replace it.
3. Damage, looseness at the installation

Confirm that no damage exists and the installation is properly tightened.
AR50 Series 80-3

CONTROL EQUIPMENT YEARLY INSPECTION CRITERIA
Equip-
ment
11. Cut-off current 1. Measurement of cut-off current

1) Park the truck on the flat ground. Place the chocks under the load wheels to
lock them.
2) Extend the mast. (Reach-out)
3) Place the wooden block in the reach leg.
When performing accidentally the mast retracting operation (reach-out),

to prevent your body from being trapped in between the mast and the
frame, place the wooden block as a topper.
4) Place the wooden block under both right and left frames to float the truck
from the ground. (Only when measuring the cut-off current at traveling)
5) Tilt the mast forward and lower down the fork on the ground.
6) Disconnect the wiring from the brake switch. (Only when measuring the
cut-off current at traveling)
Or remove the center plate and keep the brake switch lever pushed in
(Electrically, the brake is open.)
7) Set the ammeter (clamp tester) to the cable to be measured and measure
the cut-off current under the condition listed on the table below.
8) After finishing the check, re-connect the wiring to the brake switch.
(Only when measuring the cut-off current at traveling)
Cable to be
Motor Measuring Condition Clamp Setting Cut-off Current
measured
Set the power mode to H
Control Equipment
and turn fully the FR lever DC 1000A

forward without stepping DU peak range 317 – 351A (peak)
Travel on the brake pedal and DV
(AC1000A (224 – 247A (rms))
measure the current. DW
(Stop the drive wheel peak range)
rotation.)
Set the power mode to H
and turn the tilt lever DC 1000A
Cargo forward fully to tilt the PU peak range 319 – 390A (peak)
Han- mast forward and PV
(AC1000A (226 – 276A (rms))
dling measure the current. (Set PW
the tilt parameter to the peak range)
factory setting (100%).)
Turn the steering wheel
Cable of Same as
EPS fully right or left and 30±1.5 A
EPS motor usual
measure the current
12. Safety 1. Operation of contactor

Equipment Check that the arc is generated before the contactor opens.
80-4 AR50 Series

YEARLY INSPECTION CRITERIA CONTROL EQUIPMENT
Equip-
ment
13. Fuse 1. Controller Block

1) Operate the reach lever on the 4
operator’s seat to extend the
mast (reach-out).
2) Turn OFF the key switch and
3
disconnect the battery plug.
3) Loosen the front panel fixing
knob at two locations.
4) Remove the front panel
5) If the fuse below blows out, 2
replace it with the one having
identical capacity. 1
Mark Circuit used Capacity Color
1 Light, accessory circuit 15 A red
2 Controller control circuit 10 A red
3 Power circuit fuse 400 A –
4 EPS fuse 40 A –
2. Installation Type Charger

1) Disconnect the plug of power cord of
charger from the AC outlet.
2) Remove the fuse cover on the front of
Control Equipment
counter.
3) Loosen the nut and replace the fuse.
4) After replacement, tighten the nut
securely.
5
Mark Voltage Battery Capacity (Ah) Capacity
160 – 190 BFS40A
190 – 250 BFS50A

5 48 V
250 – 330
BFS80A
330 – 450
14. Wiring Examine the items below by visual check and touching by finger.
(Including the 1. Damage to the wire harness, loose clamp
charger cord) 2. Loose terminal connection block, state of taping
3. Contact of battery connector, loose bolts
4. Damage to the wire harness sheath (cladding)
AR50 Series 80-5

CHARGING EQUIPMENT YEARLY INSPECTION CRITERIA
Equip-
ment
15 – 17. 1. Check in the appeal mode

1) Plug the power plug in to make the charger chargeable.
Charging
Control Unit 2) Press the AUTO and EQUAL buttons simultaneously for two seconds.
3) If the lamps, that indicate from start to finish of charging, light in sequence in
ten seconds, it is correct.
2. Conduction check of push button on the charger operation block
1) Turn OFF the key switch.
2) Disconnect CN1 (12-pin connector) on the back side of charger operation
panel.
3) Apply the lead of tester (in R range) to each pin (at male side, operation
panel side) of CN1 and measure the conduction while pushing the switch.
Check of conduction
Switch Judging
between (Pin No.)
[AUTO] switch 0 Ω : Normal

[EQUAL] switch ∞ :Bad
Charger Operation Panel

Charging Equipment
3. Confirmation of charger operation in the test mode

1) Turn OFF the key.
2) Plug the charger cord in the AC outlet. (200V)
3) Disconnect the plug for charge mode switch.
4) Press the AUTO button or EQUAL button.
5) The AUTO (or EQUAL) lamp lights, the MGS turns on, and charging actually
starts. Then, the lamps L1 to L6 light in order, and the L5 and L6 blink
alternately. The MGS turns off, the green lamp (or red lamp) lights last and
the charging test finishes.
6) Reset.
Note）In the operation test of charger in the test mode, each operation of
charger is done in 1/60 seconds. Therefore, when finished, the red lamp
may light. This does not indicate the failure of charger but the result that
the battery voltage does not reach the pole changing voltage in the test
charging.
15. Magnet switch 1. Operation

(MGS) 2. Dirt on contact, roughness
80-6 AR50 Series

YEARLY INSPECTION CRITERIA BATTERY
Equip-
ment
18. Electrolyte 1. Check of electrolyte solution

solution (1) stopper 1
(2) cap
(3) float (red color)
3
• Before the float (red) (3)
indicates the lowest level of electrolyte solution, re-fill water
• When the stopper (1) of float (3) touches the cap (2) (Gap a = 0 in the above
figure), the electrolyte solution level is the minimum.
a Depending on battery manufacturer, the cap (2) differs in shape.
2. How to re-fill the battery with

water
A. Re-filling water
B. The re-fill is finished.
Battery
1) Open the cap of battery cap and re-fill the battery with water (pure water).
2) When the white line appears, stop re-filling immediately.
a If re-filling is continued after the appearance of white line, it results in

overflow.
Caution on handling the battery

1) Emergency medical care when pouring the electrolyte solution on your body
Eyes, skin and clothes are contaminated with the electrolyte solution, wash
with a large amount of water.
Especially, for eye, take the diagnosis of medical doctor immediately.
2) Fire inhibited
Do not make short-circuit or spark. Keep away open fire such as tobacco
from the battery.
3) Prevention of electric shock
In the maintenance and check, wear rubber gloves to avoid the electric
shock.
4) Ventilation
Irrespective of truck operation, ventilate the work area fully.
AR50 Series 80-7

BATTERY YEARLY INSPECTION CRITERIA
Equip-
ment
18. Electrolyte 3. Check of specific gravity of

solution electrolyte solution
(Continued) (1) Rubber ball
(2) Feed tube
(3) Outer cylinder
(4) Electrolyte solution
(5) Specific gravity meter
1) Charge the battery fully. After

completing the charging, set the
electrolyte level properly.
2) Measure the specific gravity and
temperature of electrolyte
solution with the specific gravity
meter and thermometer.
3) Enter the values measured in
steps 1) and 2) in the formula
below and calculate S20.
S20 = St + 0.0007 (t – 20)
S20 : specific gravity at 20C°

St : specific gravity at t C°
(measured value)
t : temperature of electrolyte
solution (measured value)
a Normal value:
S20 = 1.27 – 1.29
Battery
4) Perform the measurement and calculation on all of the cells.

a After using the specific gravity meter, wash it with water.
Keep the measured data.
19. Cell (Battery jar) 1. Voltage

Charge the battery fully. After completing the charging, measure the voltage with
the DC voltmeter. The voltage should be more than the value set (2.0 V/ cell) and
voltages of all cells should be almost equal.
2. Damage
20. Terminal 1. Looseness 2. Dirt 3. Damage 4. Corrosion/ Electric erosion
20. Battery case 1. Damage 2. Leakage of electrolyte 3. Damage to cord/connection state
80-8 AR50 Series

YEARLY INSPECTION CRITERIA POWER TRANSFER EQUIPMENT / TRAVEL EQUIPMENT
Equip-
ment
24. Transfer 1. Check the abnormal sound at

traveling.
2. Check of oil leakage
3. Oil Level Check
1) Remove the oil level plug (1)
and check the oil level in the
level plug hole.
2) If the lower part of gear is
submerged in the oil, it is
Power Transfer Equipment
normal.
3) If the oil is not sufficient, remove
the plug (1) of oil filler port and
re-fill the oil through the level 1
plug hole.
4. If the oil is dirty, replace the oil.
1) Remove the drain plug (2) to
drain the oil.
2) After draining the oil, tighten the
drain plug (2).
3) Re-fill the specific amount of oil
through the level plug hole. 2
Amount of oil to be replaced:
3.4 liter.
5. Loose Bolt
Check that the volts are not loosened and tightened properly.
27 – 28. Tire 1. Wear limit of tire
RW type More than 274mm

Outer diameter of drive wheel
RL type More than 290mm
0.9 – 1.3t truck More than 217mm

Outer diameter of load wheel
1.4 – 1.8t truck More than 229mm
RW type More than 120mm

Outer diameter of caster wheel
RL type More than 102mm
2. Crack and damage of tire

Travel Equipment
3. Check visually the abnormal wear of tire.

4. Check visually the biting of metal fragment, stone and foreign matters.
5. Check of rim
1) No crack, no damage and no deformation
2) Rim tightening bolts and nuts should be tightened with the specified
tightening torque.
Drive wheel 98 – 123Nm {10 – 12.5kgm}
Load wheel 1.0 – 4.0Nm {10 – 40kgcm}
Caster wheel RS, RW, RP 157 – 196Nm {16 – 20kgm}
AR50 Series 80-9

TRAVEL EQUIPMENT YEARLY INSPECTION CRITERIA
Equip-
ment
20. Suspension 1. Deformation, crack, damage

Check visually the deformation, crack and damage of suspension arm, spring and
mounting bolt.
2. Looseness of mounting bolt
The mounting bolt should be tightened with the specified tightening torque.
(Suspension mounting bolt) 245 – 309 Nm {25 – 31.5 kgm}
3. Set height of spring
RW type
50.5
24.5
RL type
Travel Equipment
More than 67 mm
80-10 AR50 Series

YEARLY INSPECTION CRITERIA STEERING EQUIPMENT
Equip-
ment
30. Steering wheel 1. Play
Play 10 – 20 mm
㪈㪇䌾㪉㪇㩷㫄㫄
2. Looseness check of
installation block
3. Rattle
Move the steering wheel in the
shaft direction and diameter
direction and check whether the
steering wheel rattles or not.
4. Steering Condition
Travel and steer. And check that any abnormality exists.
36 – 37. 1. Voltage Check

EPS equipment
Steering Equipment
Battery built in the case 2.0V X 5 pieces = 10V

or external power supply 10V
Refer to “EPS torque sensor of Inspection/Check” or “EPS actuator of Assemble/

Disassemble”.
State of steering wheel Normal Voltage
In the neutral position

4 ± 0.3 V
(When the steering wheel is not turned)
Turn right
4 ± 0.3 V → 7 V (It varies smoothly.)
(When turning the steering wheel right)
Turn left
4 ± 0.3 V → 1 V (It varies smoothly.)
(When turning the steering wheel left)
Right turn → Neutral position 7V → 4 ± 0.3 V
Left turn → Neutral position 1V → 4 ± 0.3 V
2. Looseness of tightening portion

The fixing bolt should be tightened with the specified tightening torque
(EPS actuator fixing bolt) 98 – 123 Nm {10 – 12.5 kgm}
AR50 Series 80-11

STEERING EQUIPMENT YEARLY INSPECTION CRITERIA
Equip-
ment
36 – 37. 3. Wear and contact of brush, spring force, dirt, wear and burn of commutator
EPS equipment 1) Limit of brush wear (Height: H measurement)
(Continued)
EPS motor More than 13 mm
2) Check of commutator contact
How to grind the brush

1) Insert the rough sandpaper (#60 – #120) between the commutator and the
brush, touching the grinding surface to the brush.
2) Hold both ends of sandpaper by hand and slide it along the commutator
surface in the direction of circumference so that the brush surface contacts
perfectly the commutator.
3) Repeat the same procedure, using the fine sandpaper (#360).
4) After finishing, clean with the air blower.
4. Measurement of brush spring pushing

force
Steering Equipment
EPS motor 2.5 N {0.25 kgf}
5. Check of dirt on the commutator surface

1) Carbon dirt
2) Dirt on the current collecting part
6. Wear limit of commutator (measurement

of outer diameter)
Truck type 1 – 1.3t truck 1.4 – 1.8t truck
EPS motor More than 29.5 mm More than 29.5 mm
7. Check of commutator burning
80-12 AR50 Series

YEARLY INSPECTION CRITERIA BRAKING EQUIPMENT
Equip-
ment
39 – 40. 1. Pedal height, play

Travel Brake
When in free 60 – 70 mm
Pedal Height (h)
When stepping on Same height as the floor plate
2. Brake open state (Standing type)

When stepping on the brake pedal, confirm that the brake is open (The pad is
detached from the disc completely.)
3. Braking effect
Travel on the dry flat paved road at the maximum speed. Then, stop suddenly
and measure the brake stopping distance.
When unloaded Within 5 m
When loaded Within 2.5 m
4. Brake Switch
Adjust the installation of switch so that the brake switch turns on when the pedal
height becomes as shown below.
Pedal height (When the brake switch turns on) 15 – 20 mm

Braking Equipment
The switch should have the margin stroke of 1.5mm when stepping down the
brake pedal fully.
41. Parking Brake 1. Lock state

When releasing your foot from the brake pedal, it returns smoothly to the height of
pedal in free state and braking works surely.
2. Braking effort
Check that the truck can keep standstill on the slope mentioned below.
When unloaded Slope of more than 20% (11.2 degree)
When loaded Slope of more than 15% (8.5 degree)
42. Linkage Cable 1. Operating Condition

Operate the brake and judge comparing with the feeling in the normal state.
2. Linkage Block
1) Confirm that no rattle and no looseness exist.
2) Confirm that the cotter pin is not broken.
3. No damage to rod, link and cable
AR50 Series 80-13

BRAKING EQUIPMENT YEARLY INSPECTION CRITERIA
Equip-
ment
48 – 49. 1. Thickness of brake pad

Brake Disk, pad
Thickness of More than
brake pad 4 mm
Replace two pads as a pair.
2. Spring installation height (L), clearance (H) between cam and adjuster
screw
L = 120 mm
H=0
Horizontal
H=0
H
Cam Adjuster screw
The cam should be horizontal as shown in the figure. (When the pedal is not
stepped down)
3. Contacting surfaces of cam and adjuster screw
The surfaces should not worn to the extent of exposed metal. No scars on the
Braking Equipment
surfaces are allowed.

4. Thickness of brake disc (T)
Thickness of brake disc (T) More than 7 mm
5. Looseness of brake disc mounting bolt (A)

Check that the brake mounting bolts are tightened with the specified tightening
torque.
196 – 245Nm {20 – 25 kgm}
80-14 AR50 Series

YEARLY INSPECTION CRITERIA CARGO HANDLING EQUIPMENT
Equip-
ment
53 – 54. Fork 1. Damage and wear of fork and fork stopper pin
Check them visually.
2. Deformation of fork
Align the fork in the center of truck and
measure the height difference C and the
open distance.
Height Difference C Within 15 mm
Open Distance Within 35 mm
3. Wear of fork
Measure the thickness A at the root of fork and check it to meet the specification.
0.9 t vehicle More than 30 mm
1.0 – 1.5 t vehicle More than 31 mm
1.8 t vehicle More than 35 mm
4. Crack of fork
Especially, as the force will be concentrated on the location below, check in the
crack search method.
Cargo Handling Equipment
• Root of fork F
• Hook of fork D, E
55. Mast, reach leg, 1. Deformation, crack, damage

roller support Check visually or in the crack search method.
• Cross members of outer mast and inner mast
• Welded portion of reach leg
• Welded portion of lift cylinder guide bar
• Welded portions of outer mast and cylinder support
• Outer mast, inner mast, reach leg
• Welded portion of roller support
2. Rattle of roller bearing
Erect vertically the mast and lift up the fork by 10mm from the ground. Then,
check the clearance between inner mast and roller support and the clearances
between outer mast and inner mast at the front and rear and the right and left
respectively. With this, judge the rattle of roller and rail.
Clearance at front and rear Within 20 mm
Clearance at right and left Within 2.0 mm
3. Crack and damage of roller and roller pin

1) Check visually whether the abnormality exists or not in the roller rolling block
on the inner face of mast.
2) 2) Insert a metal stick of 200 mm in length in between the outer mast and
inner mast, and check the crack and damage of roller and roller pin by
galling.
a If the welded portion of roller pin is suspected, disassemble the mast and
check using the crack search method.
AR50 Series 80-15

CARGO HANDLING EQUIPMENT YEARLY INSPECTION CRITERIA
Equip-
ment
58. Chain 1. Tension

Erect vertically the mast and lift up the fork by 100 mm from the ground. Then,
confirm that the tension is proper by pushing the lift chain in the middle by finger.
Adjustment: Adjust with the chain stopper.
2. Stretch
Measure the length L of 17 links and confirm that it meets the specification.
Length L of 17 links
0.9 – 1.8 t vehicle Within 275.5 mm
3. Deformation, damage, state of lubrication, rust

Check visually.
4. Deformation and damage of anchor bolt
Check visually.
Cargo Handling Equipment
59. Chain wheel 1. Deformation, damage

Check visually.
2. Rattle of bearing
Rotate the chain wheel by hand and check the rattle of bearing.
60 – 61. 1. Looseness, deformation, crack, damage, wear

Attachments Operate the attachment and check visually.
2. State of operation
Check each movement of operation and abnormal sound.
80-16 AR50 Series

Sec80_AR14_E.fm 17 ページ２００７年１０月１８日木曜日午後４時２２分
YEARLY INSPECTION CRITERIA HYDRAULIC EQUIPMENT
Equip-
ment
62. Hydraulic oil 1. Oil leakage from tank, dirt 1

tank filter Check visually.
2. Check of oil level in the tank
1) Perform the reach-in on a flat floor,
lower the fork on the floor and erect the 2
mast vertically.
2) Check that the float of level gauge (G)
on the operator´s seat front step (right
side of truck name plate) is in the
range suitable for high lifting.
3) If the hydraulic oil is lacking, remove
the assist grip (1) and the oil cap (2)
and refill the tank with the hydraulic oil G
through the filler port until the float
reaches the applicable range.
a The applicable range differs depending
on the mast high lifting (specification). Level gauge 3
Confirm that the oil level locates at the
high lifting scale and range indicated
by the mast high lifting and level 4
gauge.
FFV mast (every type) : “5.0” scale (3)

TFV mast (every type) : “5.0” scale (3)
Hydraulic Equipment
Mast of high lifting of higher than 5.0M : “5.0” scale (3)

Mast of high lifting of lower than 4.7M : “4.7” scale (4)
3. Check visually dirt on the filter, blinding and damage.

4. For replacement of hydraulic oil, cleaning of strainer and replacement of
line filter, refer to “Inspection/Adjustment” in chapter 20.
63. Piping (Truck) Pipe, hose, joint

1. Check the crack, damage, torsion and oil leakage.
2. Firmly installed state, no looseness of bolt and nut
(Attachment) Pipe, hose, joint

1. Check the crack, damage, torsion and oil leakage.
2. Firmly installed state, no looseness of bolt and nut
65 Hydraulic pump 1. Check visually the oil leakage.

2. Check the abnormal vibration and abnormal sound by listening.
66. Oil motor 1. Check visually the oil leakage.

(When equipped) 2. Check the abnormal vibration and abnormal sound by listening.
AR50 Series 80-17

HYDRAULIC EQUIPMENT YEARLY INSPECTION CRITERIA
Equip-
ment
67 – 70. Cylinder 1. The operation should be smooth.

2. No oil leakage
3. Check the gouge, crack, bending scratch and looseness of mounting bolt.
Important check location
1) Bending, scar and rust of rod (Check visually or by finger-touching.)
2) Crack of screwed portion of rod (Check visually or by color.)
3) Looseness of lift cylinder mounting bolt
59 – 74 Nm {6 – 7.5 kgm}
71. Naturally 1. Measure the naturally descending amount of lift cylinder.

descending
amount Within 60 mm/15 minutes
Naturally (Fork block)
descend-
ing amount Within 30 mm/15 minutes
(Cylinder block)
Adjustment :If the amount exceeds the specification, replace the packing of
control valve and cylinder.
Hydraulic Equipment
72 – 73. 1. The operation should be smooth.

Direction 2. No oil leakage, no looseness
control valve
(Control valve) 3. Operation of relief valve
After reaching the maximum high lifting height, check by listening to the operating
noise of relief valve.
4. Measurement of relief pressure
1) Remove the piping cover (A) at the
mast side and install the oil pressure
gauge (Maximum hydraulic pressure
25.4MPa {250 kgf/cm2} to the
hydraulic port of piping.
2) Lift up the fork to the maximum high
lifting height and measure the oil Relief pressure
pressure when relieving the oil (at measuring port
lifting, at tilting). Check the measured
oil pressure to meet the specific
pressure.
Specific
16.7 MPa {170 kgf/cm2}
pressure
80-18 AR50 Series

YEARLY INSPECTION CRITERIA BODY, SAFETY EQUIPMENT, ETC. / TOTAL TEST
Equip-
ment
75. Frame, Body 1. Crack, deformation
2. Mounting bolt, loose nut, drop
78. Lifting 1. Crack, damage, deformation

equipment,
anti-slipping 2. Loose mounting bolt
79. Display 1. Damage
2. State of installation
Body, Safety Equipment, etc.
80. Head Guard 1. Looseness of installation block
2. Deformation, crack and damage
82. Lighting sys- 1. Operation of light

tem, meters,
Alarm 2. State of installation, damage, water penetration
3. Operation of meters
83. Mirror, reflector 1. Dirt, damage
2. Mirrored image
84. Greasing 1. Greased state
2. Operation of automatic greasing equipment
85. Function of Confirm by traveling and work test.

each equipment
Total test
AR50 Series 80-19

90. CONVERSION TABLE

MILLIMETERS TO INCHES .......................................................90-2
INCHES TO MILLIMETERS .......................................................90-2
CUBIC METERS TO CUBIC YARDS .........................................90-3
CUBIC YARDS TO CUBIC METERS .........................................90-3
LITER TO U.S. GALLON ............................................................90-4
U.S. GALLON TO LITER ............................................................90-4
LITER TO U.K. GALLON ............................................................90-5
U.K. GALLON TO LITER ............................................................90-5
KILOGRAM TO POUND .............................................................90-6
POUND TO KILOGRAM .............................................................90-6
KG/CM2 TO IB/IN2 ......................................................................90-7

KGM TO FT IB ............................................................................90-8
TEMPERATURE .........................................................................90-9
AR50 Series 90-1

MILLIMETERS TO INCHES
INCHES TO MILLIMETERS CONVERSION TABLE
CONVERSION TABLE
Millimeters to Inches 1mm=0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.881 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 2.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Inches to Millimeters
0.1 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09
0 0.254 0.508 0.762 1.016 1.270 1.524 1.778 2.032 2.286
0.1 2.540 2.794 3.048 3.302 3.556 3.810 4.064 4.318 4.572 4.826
0.2 5.080 5.334 5.588 5.842 6.096 6.350 6.604 6.858 7.112 7.366
0.3 7.620 7.874 8.128 8.382 8.636 8.890 9.144 9.398 9.652 9.906
0.4 10.160 10.414 10.668 10.922 11.176 11.430 11.684 11.938 12.192 12.446
0.5 12.700 12.954 13.208 13.462 13.716 13.970 14.224 14.478 14.732 14.986
0.6 15.240 15.494 15.748 16.002 16.256 16.510 16.764 17.018 17.272 17.526
0.7 17.780 18.034 18.288 18.542 18.796 19.050 19.304 19.558 19.812 20.066
0.8 20.320 20.574 20.828 21.082 21.336 21.590 21.844 22.098 22.352 22.606
0.9 22.860 23.114 23.368 23.622 23.876 24.130 24.384 24.638 24.892 25.146
90-2 AR50 Series

CUBIC METERS TO CUBIC YARDS

CONVERSION TABLE CUBIC YARDS TO CUBIC METERS
Cubic meters to Cubic yards 1m3= 1.308 cu.yd
0 1 2 3 4 5 6 7 8 9
1.31 2.62 3.92 5.23 6.54 7.85 9.16 10.46 11.77
10 13.08 14.39 15.70 17.00 18.31 19.62 20.93 22.24 36.62 24.85
20 26.16 27.47 28.78 30.08 31.39 32.70 34.01 35.32 36.62 27.93
30 39.24 40.55 41.86 43.16 44.47 45.78 47.09 48.40 49.70 51.01
40 52.32 53.63 54.94 56.24 57.55 58.86 60.17 61.48 62.78 64.09
50 65.40 66.71 68.02 69.32 70.63 71.94 73.24 74.56 75.86 77.17
60 78.48 79.79 81.10 82.40 83.71 85.02 86.33 87.64 88.94 90.25
70 91.56 92.87 94.18 95.48 96.79 98.10 99.41 100.72 102.02 103.33
80 104.64 105.95 107.26 108.56 109.87 111.18 112.49 113.80 115.10 116.41
90 117.72 119.03 120.34 121.64 122.95 124.26 125.57 126.88 128.18 129.49
Cubic yards to Cubic meters

0 1 2 3 4 5 6 7 8 9
0.76 1.53 2.29 3.06 3.82 4.59 5.35 6.12 6.88
10 7.65 8.41 9.18 9.94 10.70 11.47 12.23 13.00 13.76 14.53
20 15.29 16.06 16.82 17.59 18.35 19.12 19.88 20.64 21.41 22.17
30 22.94 23.70 24.47 25.23 26.00 26.76 27.53 28.29 29.05 29.82
40 30.58 31.35 32.11 32.88 33.64 34.41 35.17 35.94 36.70 37.47
50 38.23 38.99 39.76 40.52 41.29 42.05 42.82 43.58 44.35 45.11
60 45.88 46.64 47.41 48.17 48.93 49.70 50.46 51.23 51.99 52.76
70 53.52 54.29 55.05 55.82 56.58 57.35 58.11 58.57 59.64 60.40
80 61.17 61.93 62.70 63.46 64.23 64.99 65.76 66.52 67.28 68.05
90 68.81 69.58 70.34 71.11 71.87 72.64 73.40 74.17 74.93 75.70
AR50 Series 90-3

LITER TO U.S GALLON

U.S. GALLON TO LITER CONVERSION TABLE
Liter to U.S. Gallon 1 = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
U.S. Gallon to Liter1 U.S. Gal = 3.7854

0 1 2 3 4 5 6 7 8 9
3.79 7.57 11.36 15.14 18.93 22.71 26.50 30.28 34.07
10 37.85 41.64 45.43 49.21 53.00 56.78 60.57 64.35 68.14 71.92
20 75.71 79.49 83.28 87.06 90.85 94.64 98.42 102.21 105.99 109.78
30 113.56 117.35 121.13 124.92 128.70 132.49 136.27 140.06 143.85 147.63
40 151.42 155.20 158.99 162.77 166.56 170.34 174.13 177.91 181.70 185.49
50 189.27 193.06 196.84 200.63 204.41 208.20 211.98 215.77 219.55 223.34
60 227.12 230.91 234.70 238.48 242.27 246.05 249.84 353.62 257.41 261.19
70 264.98 268.76 272.55 276.33 280.12 283.91 287.69 291.48 295.26 299.05
80 302.83 306.62 310.40 314.19 317.97 321.76 325.55 329.33 333.12 336.90
90 340.69 344.47 348.26 352.04 355.83 359.61 363.40 367.18 370.97 374.76
90-4 AR50 Series

LITER TO U.K GALLON

CONVERSION TABLE U.K. GALLON TO LITER
Liter to U.K. Gallon 1 = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0.200 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
U.K. Gallon to Liter1 U.K. Gal = 4.5461

0 1 2 3 4 5 6 7 8 9
4.55 90.09 13.64 18.18 22.73 27.28 31.82 36.37 40.92
10 45.64 50.01 54.55 59.10 63.65 68.19 72.74 77.28 81.83 86.38
20 90.92 95.47 100.01 104.56 109.11 113.65 118.20 112.74 127.29 131.84
30 136.38 140.93 145.47 150.02 154.57 159.11 163.66 168.21 172.75 177.30
40 181.84 186.39 190.94 195.48 200.03 204.57 209.12 213.67 218.21 222.76
50 227.30 231.85 236.40 240.94 245.49 250.03 254.18 259.13 263.67 268.22
60 272.77 277.31 281.86 286.40 290.95 295.50 300.04 304.59 309.13 313.68
70 318.23 322.77 327.32 331.86 336.41 340.96 345.50 350.05 354.60 359.14
80 363.69 368.23 372.78 377.33 381.87 386.42 390.96 395.51 400.06 404.60
90 409.15 413.69 418.24 422.79 427.33 431.88 436.42 440.97 445.52 450.06
AR50 Series 90-5

KILOGRAM TI POUND
POUND TO KILOGRAM CONVERSION TABLE
Kilogram to Pound 1Kg = 2.2046 Ib
0 1 2 3 4 5 6 7 8 9
2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Pound to Kilogram 1 Ib = 0.4536Kg
0 1 2 3 4 5 6 7 8 9
0.454 0.907 1.361 1.814 2.268 2.722 3.175 3.629 4.082
10 4.536 4.990 5.443 5.897 6.350 6.804 7.257 7.711 8.165 8.618
20 9.072 9.525 9.979 10.433 10.886 11.340 11.793 12.247 12.701 13.154
30 13.608 14.061 14.515 14.969 15.422 15.876 16.329 16.783 17.237 17.690
40 18.144 18.597 19.051 19.505 19.958 20.412 20.865 21.319 21.772 22.226
50 22.680 23.133 23.587 24.040 24.494 24.948 25.401 25.855 26.308 26.762
60 27.216 27.669 28.123 28.576 29.030 29.484 29.937 30.391 30.844 31.298
70 31.752 32.205 32.659 33.112 33.566 34.019 34.473 34.927 35.380 35.843
80 36.287 36.741 37.195 37.648 38.102 38.555 39.001 39.463 39.916 40.370
90 40.823 41.277 41.731 42.184 42.638 43.091 43.545 43.999 44.452 44.906
90-6 AR50 Series

CONVERSION TABLE Kg/cm2 to Ib /in2
Kg/cm2 to Ib/in2 1Kg/cm2 = 14.2233 Ib/in2
0 1 2 3 4 5 6 7 8 9
14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1644 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 1877 1892 1906 1920 1934 1946 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 223 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2360 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3124 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
AR50 Series 90-7

kgm to ft. Ib CONVERSION TABLE
Kgm to ft. Ib 1Kg.m = 7.233 ft. Ib
0 1 2 3 4 5 6 7 8 9
7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.41 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 171.7 1179.0 1186.2 1193.4 1220.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
90-8 AR50 Series

CONVERSION TABLE TEMPERATURE
Temperature
Fahrenheit–Centigrade Conversion. –A simple way to convert a Fahrenheit temperature reading into a Centigrade
temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired it convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
–40.4 –40 –40.9 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.6 17 62.6 11.1 52 125.6 30.6 84 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.8 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 112.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
AR50 Series 90-9


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fm 1 ページ ２００８年３月３日 月曜日 午後６時２８分

ELECTRIC REACH TRUCK

FB10RL(F)/13RL(F)/15RL(F)/18RL(F)-14 M245-140001 and up

PRECAUTIONS WHEN PERFORMING THE SERVICE WORK

DESCRIPTION OF THE SYMBOLS

Symbol Item Description

Safety Special safety precautions are needed to perform the work.

Note Special technical precautions are needed to perform the work

Weight Weight of parts or systems

Places to be coated with adhesives, etc. when assembling

Filling Oil filling and its amount

00-2 AR50 Series

10. GENERAL AND SPECIFICATIONS

20. TESTING AND ADJUSTING

30. REMOVAL AND INSTALLATION

40. DISASSEMBLY AND ASSEMBLY

50. MAINTENANCE STANDARD

60. STRUCTURE AND FUNCTION

80. YEARLY INSPECTION CRITERIA

90. CONVERSION TABLE

AR50 Series 00-3

10. GENERAL AND SPECIFICATIONS

SAFETY ITEMS FOR MAINTENANCE ......................................10-7

STANDARD TIGHTENING TORQUE FOR BOLTS ..................10-14

STANDARD TIGHTENING TORQUE FOR PIPE JOINTS .......10-15

HOW TO USE LOCTITE...........................................................10-16

AR50 Series 10-1

SPECIFICATION GENERAL AND SPECIFICATIONS

3.4 Additional Wheels φ 127 x 90 φ 127 x 90

4.22 Forks s/e/l Thickness/Width/Length mm 35x100x850 35x100x850

5.4 Reach Speed Loaded/Unloaded mm/s 300/300 300/300

6.4 Battery Voltage V 48 48

8.1.2 PS Motor Control MOS-FET chopper MOS-FET chopper

10-2 AR50 Series

GENERAL AND SPECIFICATIONS SPECIFICATION

1.2 Model Manufacturer's Designation FB15RL-14, FB15RLF-14 FB18RL-14, FB18RLF-14

3.4 Additional Wheels φ 127 x 90 φ 127 x 90

4.22 Forks s/e/l Thickness/Width/Length mm 35x100x850 38x100x850

5.4 Reach Speed Loaded/Unloaded mm/s 300/300 300/300

6.4 Battery Voltage V 48 48

8.1.2 PS Motor Control MOS-FET chopper MOS-FET chopper

AR50 Series 10-3

SPECIFICATION GENERAL AND SPECIFICATIONS

1.2 Model Manufacturer's Designation FB10RW-14 FB13RW-14

3.4 Additional Wheels φ 150 x 80 φ 150 x 80

4.22 Forks s/e/l Thickness/Width/Length mm 35x100x850 35x100x850

5.4 Reach Speed Loaded/Unloaded mm/s 300/300 300/300

6.4 Battery Voltage V 48 48

8.1.2 PS Motor Control MOS-FET chopper MOS-FET chopper

10-4 AR50 Series

GENERAL AND SPECIFICATIONS SPECIFICATION

1.2 Model Manufacturer's Designation FB15RW-14

3.4 Additional Wheels φ 150 x 80

4.22 Forks s/e/l Thickness/Width/Length mm 35x100x850

5.4 Reach Speed Loaded/Unloaded mm/s 300/300

6.4 Battery Voltage V 48

8.1.2 PS Motor Control MOS-FET chopper

AR50 Series 10-5

SPECIFICATION GENERAL AND SPECIFICATIONS

2. Allowable Load Table

900 900 900

600 600 600

fm 1 ページ２００８年３月３日月曜日午後６時２８分