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Chapter 3 ELECTRIC SYSTEM

1.

Chassis Electrical Devices Wiring Outline ........................................... 3-1


1.1
1.2
1.3

2.

Structure .................................................................................................. 3-4


2.1
2.2
2.3

3.

List of Wire Colors ................................................................................................. 3-36

Troubleshooting.................................................................................... 3-37
7.1
7.2
7.3

8.

Instrument Panel Screen Components.................................................................. 3-20


Basic Screen Display............................................................................................. 3-21
Basic Operation ..................................................................................................... 3-25
When an Error Occurs........................................................................................... 3-29
Warning Lamps ..................................................................................................... 3-31
Optional Functions................................................................................................. 3-32
Hour Meters........................................................................................................... 3-33
Troubleshooting..................................................................................................... 3-35

Wire Color .............................................................................................. 3-36


6.1

7.

State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment ..................... 3-19
Specific Gravity Reading and State of Charge ...................................................... 3-19
Charging Precautions ............................................................................................ 3-19

Instrument Panel ................................................................................... 3-20


5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8

6.

Disassembly .......................................................................................................... 3-18

Battery Maintenance ............................................................................. 3-19


4.1
4.2
4.3

5.

Console Box ............................................................................................................ 3-4


Main Electrical Components.................................................................................... 3-6
Table of Lamps...................................................................................................... 3-17

Console Box .......................................................................................... 3-18


3.1

4.

Gasoline Model........................................................................................................ 3-1


Diesel Model............................................................................................................ 3-2
Gasoline and Diesel Models.................................................................................... 3-3

Starter System....................................................................................................... 3-37


Gauges .................................................................................................................. 3-37
Lighting System ..................................................................................................... 3-38

Electrical Schematic ............................................................................. 3-40

ELECTRIC SYSTEM
Chapter 3 ELECTRIC SYSTEM

1. Chassis Electrical Devices Wiring Outline


1.1 Gasoline Model

Instrument panel
Head lamp

Front
combination lamp
Rear combination lamp
Front
combination harness
Rear combination harness
Seat

Seat switch
To armrest
(FC model only)

Harness B
Back-up buzzer
Stop lamp switch

Transmission
control solenoid

VCM
(Vehicle control module)

Relay box
Fuse box
Thermoswitch
Battery
Battery cable (+)

Battery cable (-)


To engine harness
To starter
Earth

To engine harness

ECM (Engine control module)


215355

3-1

ELECTRIC SYSTEM

1.2 Diesel Model

Instrument panel
Head lamp
Front
combination lamp
Rear combination lamp
Front
combination harness

Rear combination harness

Seat

Seat switch
To armrest
(FC model only)

Back-up buzzer

Harness B
Stop lamp switch
Transmission
control solenoid

VCM
(Vehicle control module)

OCM
(Option control module)
(Wet disc brake only)

Fuse box
Thermoswitch
(Sending unit)

Relay box

DCM
(Diesel control module)
(Wet disc brake only)

Battery
Battery cable (+)
Glow timer

Earth

Glow relay

Battery cable (-)

To starter
215356

3-2

ELECTRIC SYSTEM

1.3 Gasoline and Diesel Models

Console Box
Instrument panel
Combination switch

Parking brake switch


Warning buzzer

Key switch

Horn
Select switch

Horn harness

Control valve
FC

MC

Output unit

Output harness

Control valve

Control valve

Transmission
Parking brake valve
FC control lever

FC Armrest
Input unit

Harness

Parking brake
pressure switch

Speed sensor

Thermoswitch (T/C oil)


215357

3-3

ELECTRIC SYSTEM

2. Structure
2.1 Console Box
4

1
2
3
4
5
6
7
8

Water temperature gauge


Fuel gauge
Hour meter, warning lamps
Instrument panel
Key switch
Light switch, turn signal switch
Direction Lever
Speedometer

7
5

214140

3-4

ELECTRIC SYSTEM

2.1.1 Function of Instrument Panel

O
214141

Ref. Name of indicators and warning lamps


A

Parking brake warning lamp

Seat belt warning lamp

Charge warning lamp

Multi-purpose warning lamp

Torque converter oil temperature warning lamp

When turned off

When glows or blinks

Remark

Normal

This lamp glows when the parking


brake is applied.

Fastened

This lamp glows when the seat belt is


not fastened.

Normal charging

This lamp glows when charging is not


normal.
(This lamp glows all the time while
the engine is stopped.)

Normal

This lamp glows when a minor failure


occurs or operating cautions are
issued.

Normal temperature

This lamp glows when the torque converter oil temperature is not normal.

Engine oil pressure warning lamp

Normal

This lamp glows when the engine oil


pressure is low.
(This lamp glows all the time while
the engine is stopped.)

Engine warning lamp

Normal

This lamp glows when the engine is


failed.

Glow pilot indicator lamp

Preheating completed

This lamp glows when the glow plug


heating is ON.

ProShiftTM

This lamp glows when sudden acceleration or full reverse (shifting of


travel to the opposite direction) activates protective function.

Option

Mast interlock indicator lamp

When mast interlock is activated


(glows)

Cursor buttons

Fuel gauge

indicator lamp

LCD screen

Water temperature gauge

Enter/display button

Indicates remaining fuel amount with key in "ON" position


-

Indicates water temperature with key in "ON" position


-

Description of function
Inspection method for blown bulbs of instrument panel
All the warning and indicator lamps are normal if they glow when the key switch is turned to the | (ON) position.

3-5

ELECTRIC SYSTEM

2.2 Main Electrical Components


2.2.1 Key switch
The diesel model uses a distributor type injection
pump. Its starter switch is equipped with an automatic
fuel cut engine stop mechanism.
The gasoline model is also equipped with an automatic fuel cut engine stop mechanism.
(Key switch with anti-restart lock)
This key switch has an anti-restarting function.
This switch has a built-in anti-restart lock, so the key
switch cannot be turned from the | (ON) to the
(START) position while the engine is running. This prevents engine trouble or starter breakage caused by an
operator's improper operation when starting the
engine.
The gasoline and diesel models use the same key
switch. On the diesel model, the key switch is electrically connected to the engine so that the | (ON) key
switch position turns on the glow plugs.
(OFF)
(ON)
M

ST
(START)

B
215358

Connection Table
Terminal

ST

OFF

Key in and out


Yes

ON (when operating)

---------

-----------

No

START
(when starting engine)

---------

---------------------- -----------

No

3-6

ELECTRIC SYSTEM

2.2.2 Combination switch


(1) Light switch, turn signal switch
Forward of truck

Light switch
turn signal lever
L

10
N

OFF

10
R

OFF

1
25 25

2
2
5

Light switch
turn signal switch connector
T-1
L-3
L-1

T-3

T-2

L-2

Horn contact
Light switch connector
Terminal
Target
Knob position

L-1

L-2

L-3

Power

Tail,
clearance lamp

Head lamp

T-1

T-2

T-3

Flash unit

Turn signal
lamp (Right)

Turn signal
lamp (Left)

OFF
1
2

Turn signal switch connector


Terminal
Target
Lever position
R (Right)
N (Neutral)
L (Left)
215359

3-7

ELECTRIC SYSTEM
(2) Direction switch

Forward of truck
Forward-reverse selector lever (FNR)

10

F
N

10

OFF

Forward-reverse
shift change switch (FNR)

4
2

1
3

Connection table
Terminal
Wire color

Lever position

L/B

L/R

L/W

F (Forward)
N (Neutral)
R (Reverse)
215360

3-8

ELECTRIC SYSTEM

2.2.3 Horn
Check that the horn activates when applying the specified voltage to both terminals of the horn, T1 and T2.
Replace the horn if it does not activate or its sound is
unusual.

Up

Operating voltage: DC12V (Gasoline and diesel models)

T1

Note: The proper installation of the horn to the lift


truck is shown in the illustration.
T2
Down
Vent hole
T1

Contact
Coil

T2

215361

2.2.4 Tank unit

3/4

424.2 mm
(16.7 in.)

F
242.7 mm
(9.56 in.)

61.2 mm
(2.41 in.)

Illustration shows gasoline model.

1/2

Pressure relief valve


1/4

Fuel pump
Fuel filter

Fuel suction strainer

Referential Standards
Float position

1/4

1/2

3/4

Standard resistance value ()

80

(49.5)

32

(19)

10

Tolerance ()

+12
+2

+1.0
- 0.5

The number in parenthesis is a reference value.

215362

3-9

ELECTRIC SYSTEM

2.2.5 Stop lamp switch


Apply an ohmmeter across the terminals and check
that the stop lamp switch is turned ON and OFF when
the push rod protrusion is at the specified value.

Push rod

Measure the insulation resistance value across the terminals when the push rod is pushed in.
Replace the stop lamp switch if its measured insulation resistance value is less than the value below.
Insulation resistance value

2 mm
(0.08 in.)

4 mm
(0.16 in.)

1 M or more
(at 500 V megger)

M101.25

OFF

ON
215363

Rated voltage: DC12V


2.2.6 Thermoswitch (Engine cooling water temperature)
(1) Apply an ohmmeter between the terminal and
body of the sending unit and check for continuity
(resistance value).

Body

Terminal

(2) Replace the sending unit if there is no continuity


or the resistance value measured is outside the
standard resistance value.
Note: The illustration is for gasoline models.

215364

Gasoline model
Temperature
[C (F)]

60 0.2
(140 0.36)

65 0.2
(149 0.36)

80 0.2
(176 0.36)

100 0.3
(212 0.54)

125 0.3
(257 0.54)

130 0.3
(266 0.54)

80 10

67 7.8

40.6 3.7

22.2 1.4

11.3 0.4

10 0.3

Temperature
[C (F)]

50
(122)

60 0.2
(140 0.36)

80
(176)

100
(212)

106 0.3
(222.8 0.54)

120
(248)

Standard resistance value ()

(80)

56.3 5

(29.5)

(16.5)

14.3 0.5

(10)

Standard resistance value ()

Diesel model

3-10

ELECTRIC SYSTEM

2.2.7 Thermoswitch (T/C oil)


Apply an ohmmeter between the terminal and body
and check for continuity (resistance value). Replace
the thermoswitch if its measured insulation resistance
value is less than the value below.

Terminal

Body

1 M or more
(with contact point OFF)
(with 500 V megger)

Insulation resistance value

Internal resistance: 0.5 or less (with contact point


ON)
Allowable load: 0.5 A
Note: When installing the thermoswitch, tighten it to
the specified torque.
31.4 to 47.1 Nm
(3.2 to 4.8 kgfm)
[23.2 to 34.8 lbfft]

Tightening torque

215365

Replace the thermoswitch if it is dropped or abused.


Technical data
Operating
temperature

OFF to ON

122 3C
(251.6 5.4F)

ON to OFF

115 C (239 F)
or higher

Insulation resistance
(with contact point OFF)

1 M or more

2.2.8 Parking brake switch


Measure the insulation resistance between each terminal.
(1) Parking switch at pulled position
Between terminals B and W
Insulation
resistance

100 M or more (at 500 V megger)


Push

Pull

(2) Parking switch at pushed position

6 mm (0.24 in.) (Stroke)

Between terminals B and R


Insulation
resistance

100 M or more (at 500 V megger)

Operation method: Push-pull operation


Contact resistance: 1a-ab

215366

3-11

ELECTRIC SYSTEM

2.2.9 Relay box

Relay box 2
(Gasoline model only)

Relay box 1

Illustration shows gasoline model

Starter relay
Flasher relay

EGI relay

Ignition relay

Back-up lamp relay

ETC motor relay

MAIN/C relay

Fuel pump relay

Warning buzzer relay

Relay box 1

EGI relay

Relay box 2
(Gasoline model only)

215367

3-12

ELECTRIC SYSTEM
(1) Relay box 1

Item

Truck model
Gasoline and diesel models

Rated operating voltage

Coil rating [at 20C (68F)]

CB relay (Ignition relay, back-up lamp relay, and


starter relay)

DC12 V

Working voltage

DC3.0 to 7.0 V

Open-circuit voltage

DC1.2 to 3.9 V

Coil resistance

80 10%

Rated exciting current

168 mA 10%

Connection diagram
(Bottom view)

215368

CM relay (Warning buzzer relay)


Coil rating [at 20C (68F)]
Item
Rated operating voltage
Working voltage
Open-circuit voltage
Coil resistance
Rated exciting current

Truck model
Gasoline and diesel models

DC12 V
DC 30 to 7 V
DC 0.5 to 3.1 V
120 10%
117.6 mA 10%

Connection diagram
(Bottom view)

215370

3-13

ELECTRIC SYSTEM
(2) Relay box 2 (gasoline models only)
CM relay (EGI relay, MAIN/C relay, ETC motor relay,
and fuel pump relay)

Coil rating [at 20C (68F)]


Item
Rated operating voltage
Working voltage
Open-circuit voltage
Coil resistance
Rated exciting current

Truck model
Gasoline model
DC12 V
DC 30 to 7 V
DC 0.5 to 3.1 V
120 10%

117.6 mA 10%

Connection diagram
(Bottom view)

215370

3-14

ELECTRIC SYSTEM

2.2.10 Glow timer (diesel model)


Inspecting the output time when key switch is turned to
ON
When a tester is applied to terminal 6 and terminal 3
and a voltage of 24 V is applied between terminals 4
and 3, there should be continuity between 6 and terminal 3 for 6 seconds. Replace the glow timer with a new
one if it does not function properly.

4
5
3
6

Initial characteristic (Normal temperature and humidity,


Vcc=12 V)
Preglow timer 6.0

1.4
0

sec

Environmental characteristic (-30C to 70C, Vcc=7 V


to 15 V)
Preglow timer 6.0

2.0
0.6

sec
OFF

ON

Key switch

ST

Glow
relay
Battery
DC12V

Controller
3

Glow
plug

Lamp

Connection diagram
215371

2.2.11 Glow relay (diesel model)


(1) Apply an ohmmeter across terminal 3 and terminal 4 and measure the resistance value of the
relay coil. Replace the coil if there is no continuity
or the resistance value measured is out of standard resistance value.
Coil resistance

13

(2) Measure the insulation resistance value between


terminal 1 and terminal 2.
Replace the coil if its measured insulation resistance value is less than the value below.
Insulation resistance value

Rated voltage: DC12V

1
3

1 M or more
(at 500 V megger)

4
Connection diagram
1

215372

3-15

ELECTRIC SYSTEM

2.2.12 Fuse box

Fuse box
Illustration shows diesel model

Working lamp
15A

Back-up lamp

A/C
20A

15A
Instrument panel
10A

Spare

Glow timer
10A
VCM
20A

*1
20A 30A

ETC
15A

Wiper
15A

Head lamp
15A
Stop lamp
10A
Horn
*1
*1
EGI EGI
10A
30A 30A
Fuse puller

10A

15A
Spare

SBF 100A
Battery

SBF 100A
Alternator

*2
SBF 50A
Glow
*1: Gasoline model only
*2: Diesel model only

215373

3-16

ELECTRIC SYSTEM

2.3 Table of Lamps


Item

Head lamp

Turn signal
lamp

Quantity

Lens color

LED color

16

Colorless

Colorless

Amber

Colorless

Valve
Illustration

Remark

Standard

Option
(Installed to
head guard)

Combination
lamp (front)
Clearance
lamp

Amber

Colorless

Turn signal
lamp

Amber

Yellow

Standard

Red

Red

Standard

12

Colorless

Colorless

Standard

Type of
lamps

Combination Tail and


stop lamp
lamp (rear)

Back-up
lamp

3-17

ELECTRIC SYSTEM

3. Console Box
3.1 Disassembly
5

216938

3.1.1 Preparation
Place the key switch to the OFF position, and remove the cable from the ground side of the battery.

3.1.2 Removal sequence


(1) Remove the screw using a Phillips screwdriver and remove cover 2.
(2) Remove the screw and then, remove cover (U-Re) 3.
(3) Remove the screw and then, remove cover (U-Fr) 4.
(4) Disconnect the electrical wiring from connector 1.
(5) Remove the bolt, then remove console box assembly 5.

3.1.3 Installation
For installation, follow the removal sequence in reverse.

3-18

ELECTRIC SYSTEM

4. Battery Maintenance
4.1 State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment
Specific gravity reading
at 20C (68F)

Condition

Adjustment

1.280 to 1.265

Good

If the difference in S.G. between any two cells is 0.020 or less,


continue to use as is.
If the difference is more than 0.020, discharge the battery in
an efficient manner. If the battery recovers, charge the battery
to adjust the electrolyte S.G.

1.260 to 1.225

Half charged

1.220 (0.2) or less

Recharge battery to adjust electrolyte S.G. Check for any


short-circuited cables or corroded cable connections in the
electrical system.

Recharge battery.
Battery low (caution required) If the difference in S.G. is too much, charge the battery to
adjust the electrolyte S.G.

Recharge the battery until its voltage and S.G. stabilize and
remain constant for more than 2 hours.
A cell with a low S.G. may
Charge the battery to adjust the electrolyte S.G. It should read
cause a short circuit.
between 1.280 and 1.265.
If the difference in S.G. is
It is caused when electrolyte
If the difference in S.G. is more than 0.040 and a low S.G. is
more than 0.040.
leaks or electrolyte rate is too
found in any of the cells, replace the battery with a new one.
high or too low.
Conduct a high current discharge test after leaving the battery
for 12 to 96 hours.

4.2 Specific Gravity Reading and State of Charge


To tell whether a battery is fully charged, check the
electrolyte S.G. of each cell with hydrometer or the
electrolyte reduction speed. If the electrolyte in the
battery cell decreases to the level where the pole
plates are exposed, within one month it may be overcharged. If the electrolyte amount remains sufficient
for more than three months, the battery may discharge.

4.3 Charging Precautions


(1) In slow charging, the charging current should be
about 1/10 the capacity of the battery being
charged.
(2) In quick charging, the battery capacity in ampere
(A) should not be exceeded.
(3) During charging, adjust the charging current so
that the electrolyte temperature does not exceed
45C (113F).
(4) When connecting cables to battery terminals,
always connect the (+) terminal first, and when
disconnecting, remove the (-) terminal first.
(5) Ventilate well during the battery charge because
hydrogen gas is generated.

Identification

55D23L (Gasoline)
130E41L (Diesel)

Be sure to turn OFF the key switch and light switch


before disconnecting or connecting the battery cables.
(This prevents damage to the IC regulator.)

215375

3-19

ELECTRIC SYSTEM

5. Instrument Panel
5.1 Instrument Panel Screen Components
Instrument panel screen consists of warning lamps,
LCD (Liquid crystal display) screen, and and
buttons, and enter/display button.

Warning lamps

Down button

Up button

Enter/display button

LCD screen

215114

The LCD screen consists of six areas: main area, fuel


gauge area, travel direction area, symbol mark area,
hour meter area, and water temperature gauge area.
The main area is divided into two parts: right and left.

Travel
direction

Symbol mark
(Optional feature)

Time/hour meter
display

Note: The instrument panel has functions below to


protect circuits in the panel.
Instrument panel internal
(ambient) temperature

85C (185F) or higher

LCD screen is not displayed.

105C (221F) or higher

Backlight goes off.

Note: a) Back-up light illuminates both the fuel mark


and water temperature mark on the LCD from
inside.
b) Warnings are not automatically turned off for
safety reasons.
c) When the temperature is extremely low [0C
(32F) or below], the response of the LCD display is slower.

3-20

Fuel gauge

Main display

Water temperature
gauge
215115

ELECTRIC SYSTEM

5.2 Basic Screen Display


5.2.1 LCD screen display with the engine key in ON position
With the engine key turned to ON position, LCD
screen displays the brand logo screen, the password
authentication screen, and the usual display screen in
sequence. Also, error history is displayed with the
press of a button.
(1) Brand logo screen
When the engine key is turned to ON position, the
brand logo screen is displayed for 2 seconds
while lamp check is being executed.

215116C

(2) Password authentication screen


(Display by optional function)
Inputting the password registered in advance
makes possible to operate the forklift truck.

215117

(3) Usual display screen


The screen is changed to the usual display screen
that shows the conditions of truck.

215118

3-21

ELECTRIC SYSTEM

5.2.2 Speed meter display


This display shows current lift truck speed.
Speed meter display

Note:
Actual speed

Display

0.1 to 1.0 km/h


(0.06 to 0.62 Mph)

1 km/h
(0.62 Mph)

1.1 to 2.0 km/h


(0.68 to 1.24 Mph)

2 km/h
(1.24 Mph)

24.1 to 25.0 km/h


(14.97 to 15.53 Mph)

25 km/h
(15.53 Mph)

215119

Speed display value is rounded to a higher number.


5.2.3 Fuel gauge
This gauge shows the remaining amount of fuel (gasoline or diesel fuel). It shows the remaining amount of
fuel just after the key switch is turned to the ON position. After that, the remaining amount is displayed for 2
minutes on average.

Fuel gauge

Note:
E (Empty) remaining amount
Truck model

Remaining amount

4.0 to 5.5 ton

14.3 liter
(872.6 cu.in.)
or less

With fuel gauge image

Note: LPG dual fuel truck shows gasoline remaining


amount only.

Without fuel gauge image (LE models)

3-22

215120

ELECTRIC SYSTEM

5.2.4 Water temperature display


This display shows engine coolant temperature.
Water temperature gauge

Note: The graph below shows the relation between


engine coolant temperature and water temperature gauge shown on the LCD.

215121

Engine coolant temperature - the number of dots in the gauge


Range displayed on
LCD screen (50 to 120C)
[122 to 248F]

Diesel model
Gasoline model

50

Number of dots in the gauge (Dots)

44 dots

40
Range of overheating (red zone)

30

29 dots

Pertinent range of temperature (rough standard for diesel/gasoline model)

20

10
Overheat (red zone) temperature
Diesel model: Approx. 109 C (228.2 F) or higher
Gasoline model: Approx. 107 C (224.6 F) or higher

10

20

30

40

50

60

70

80

90

100

50

68

86

104

122

140

158

176

194

212

Engine coolant temperature (C) [F]

110
230

120

130 (C)

248

266 (F)
215122

3-23

ELECTRIC SYSTEM

5.2.5 Speed restriction function (Manufacturer's option for Diesel model only)
Speed restriction function will limit both high and low
pre-set speed as a maximum speed limit. H/L selector
switch is used to change between high and low
speeds. For setting up the speed restriction function,
use the service tool. (For details, see the service tool
manual.)
Note: Service engineers should perform the speed
restriction function setup.
Gasoline model includes this function as
standard equipment.

High speed symbol

Low speed symbol

High speed limit display

Low speed limit display 215152

H/L selector switch

215153

3-24

ELECTRIC SYSTEM

5.3 Basic Operation


5.3.1 How to use operation buttons
There are three types of manual operation buttons:
button, button, and button, which are
located on the right side of the instrument panel. The
operation of each button varies with the item being displayed on the screen.

Up button
Down button

Button operation is available only when the key


switch is in the ON position and not available
when the engine is running. Note that adjustment
of screen contrast and selection between the hour
meter display and the time display are available
even when the engine is running.

Enter/display
button

215125

Short press of button


Press button for less than two seconds.

Long press of button


Press button for more than two seconds.

Multiple button presses


All buttons pressed at the same time for more than two
seconds.
5.3.2 How to adjust the screen contrast
Turn the key switch to the ON position. Screen contrast can be adjusted while the engine is running.
Button

Press

Display
Light Dark

Short
Dark Light

Note: The screen becomes dark when the temperature inside the instrument panel (ambient temperature) is high, and the screen becomes light
when the temperature is low.
5.3.3 How to display the clock time
Turn the key switch to the ON position. Screen contrast can be adjusted while the engine is running. With
a short press of the button, the display alternately
changes between the hour meter and the clock time.

Time/hour meter

With a long press of the button while the clock is


displayed, the clock display alternately changes
between 12-hour and 24-hour mode.
Button

Press

Display

Short

Hour meter clock

Long

12-hour mode display


24-hour mode display

(with clock time


display)

215126

3-25

ELECTRIC SYSTEM

5.3.4 How to set up the clock time


(1) Turn the key switch to the ON position.
(2) Select clock time display (when the hour meter is
being displayed).
Button

Press

Display

Short

Clock time blink

Blinking

(3) Select time adjust mode and unit adjust mode.


Button

Press

Display

Long

Time unit adjust mode

215127

(4) Time unit adjustment


Button

Press

Display

Short

0112 or 24
(one hour at each press)

Long

0112 or 24 (continuous)

Short

12 or 2401
(one hour at each press)

Long

12 or 2401 (continuous)

Short

After adjusting, change to the minute adjust mode.

Digits to be adjusted is blinking

215128

Note: When the time display is set to the 12-hour


mode display, 11:00 AM changes to 00:00 PM
at noon.
(5) Minute adjustment
Button

Press

Display

Short

0159 (one minute at each press)

Long

0059 (continuous)

Short

5900 (one minute at each press)

Long

5900 (continuous)

Short

After adjusting, change to the


standard screen.

Note: Second time display is not available.


If more than 3 minutes have passed since the
last button operation, the display automatically
returns to the standard screen.
Precision errors are one minute or less per
month.
When a battery is changed, the time resets.
Be sure to set the time after changing a
battery.
If the engine is started during the setup
procedure, the setup being made is cancelled
and the display returns to the standard screen.

3-26

Digits to be adjusted is blinking

215129

ELECTRIC SYSTEM

5.3.5 How to display the hour meter


Turn the key switch to the ON position. Screen contrast can be adjusted while the engine is running. With
a short press of the button, the display alternately
changes between the clock time and the hour meter.
Button

Press

Display

Short

Clock hour meter

Hour meter

215130

5.3.6 How to change types of hour meters


Turn the key switch to the ON position. There are three
counters: key-on time, engine-on time, and seat
switch-on time. The counter display changes with a
long press of the button.
Button

Press

Display

Long

Key-on time

Engine-on time

Seat switch-on time

Key-on time display

Engine-on time display

Key-on time: Accumulated key switch ON time.


Engine-on time: Accumulated engine operation time.
This is helpful in comparing the wear of engine related
parts to the actual engine operation hours.
Seat switch-on time: Accumulated time the operator
has seated.
This is helpful in comparing the actual working hours
to the actual hours of operation.

Seat switch-on time display

215131

Note: When six minutes have passed, 0.1 hour is


added.
Warranty is terminated based on the key-on
time.

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ELECTRIC SYSTEM

5.3.7 How to display the error history


Turn the key switch to the ON position. A long press
on the three buttons at the same time brings up the
error history display.
Button

Press

Display

Multiple

Error history

Up button
Down button

Enter/display
button

Error message displays only the F error codes. Error


codes are displayed from the latest error (
-1) up to the past 32 errors ( -32). Oldest data
(error) exceeding the limit (32 errors) is automatically
erased.

215125

Note: Use the service tool to erase the error message


being displayed.
To change the error code display, operate the
or the button.
Button

Press

Error history

Hour meter

Error code

Display
Old New

Short
New Old

A long press on the three buttons at the same time


returns to the standard display screen.
Button

Press

Display

Multiple

Standard display screen

Error history display


With , buttons,
error record on the
display changes.

215133

The illustration shows the error history screen when


there is no error record.

When there is no error record

Note: If more than 3 minutes have passed since the


last button operation, the display automatically
returns to the standard screen.
If the engine is started during the setup
procedure, the setup being made is cancelled
and the display returns to the standard screen.

215134

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ELECTRIC SYSTEM

5.4 When an Error Occurs


When an error occurs, the corresponding error code is
displayed on the screen. The error code will be erased
by placing the key switch to the ON position after solving the cause of the trouble and then by turning the
key switch to the OFF position. (The error code
remains displayed until the cause of the trouble is
solved.)
Refer to the engine service manual for the error codes
related to engine troubles (error codes from ECM).
The priority order of the error display is: engine failures, serious failures, and minor failures.

Engine warning lamp glows

When an engine failure occurs, the error code alternately


changes between black characters on a white background
and white characters on a black background.
215135

5.4.1 When an engine failure occurs


The corresponding error code is displayed in the main
area, and the black and white in the error code display
is reversed. Also the engine warning lamp glows.

5.4.2 When a serious failure occurs


The corresponding error code is displayed in the main
area, and the black and white in the error code display
is reversed. Also all warning lamps shown in the figure
(right) will blink.

Warning lamps within the dotted line boxes blink

When a serious failure occurs, the error code alternately


changes between black characters on a white background
to white characters on a black background.

215136

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ELECTRIC SYSTEM

5.4.3 When a minor failure occurs


The corresponding error code is displayed in the main
area, and the black and white in the error code display
is reversed. Also the multi-purpose warning lamp
glows.

Multi-purpose warning lamp glows

Note: The minor failure display is also shown when


the fuel gauge reaches the empty level (E).

The error code and


symbol alternately
change between black
characters/lines on a
white background to
white characters/lines
on a black background.
215137

5.4.4 Error symbols


Error symbols displayed in the main area are as follows:
Symbol

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Name

Indicated condition

Fuel filter warning lamp

This lamp glows when the water in the fuel filter


needs to be drained. (diesel model)

Low coolant level warning lamp

This lamp glows when the coolant level is low.


(option)

Clogged air cleaner element warning lamp

This lamp glows when the air cleaner element is


clogged. (option)

Low fuel level warning lamp

When fuel level is low (on E level)


(On the LPG/gasoline dual fuel model, this lamp
glows when the gasoline level becomes low.)

LPG level warning lamp

On the LPG model, this lamp glows when the LPG


level becomes low. (option)

ELECTRIC SYSTEM

5.5 Warning Lamps


The function of each warning lamp is shown in the
table below.
Lamp

Name

Color

Glow (blink) condition

Model applicable

Parking brake warning lamp

Red

This lamp glows when the parking brake is


applied.

All models (Standard)

Seat belt warning


lamp

Red

This lamp glows when the seat belt is not


fastened.

All models (Standard)

Charge warning
lamp

Red

This lamp glows when charging is not normal.


(Glows/the lamp glows all the time while the
engine is stopped)

All models (Standard)

Multi-purpose warning lamp

Red

This lamp glows when a minor failure occurs


All models (Standard)
or operating cautions are issued.

Torque converter oil


temperature warning lamp

Red

This lamp glows when the torque converter


oil temperature is not normal.

Powershift transmission
models (Standard)

Engine oil pressure


warning lamp

Red

This lamp glows when the engine oil pressure is low.


(Glows/the lamp glows all the time while the
engine is stopped)

All models (Standard)

Engine warning
lamp

Amber

This lamp glows when the engine is failed.

Electronic control gasoline engine models


(Standard)

Glow pilot indicator


lamp

Amber

This lamp glows when the glow plug heating Diesel engine models
is ON.
(Standard)

ProShiftTM indicator
lamp

Amber

This lamp glows when sudden acceleration


or full reverse (shifting of travel to the opposite direction) activates protective function.

Option

Mast interlock indicator lamp

Amber

When mast interlock is activated (glows)

All models (Standard)

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ELECTRIC SYSTEM

5.6 Optional Functions


The following optional functions are available: password authentication, service interval display, overspeed warning, load meter display, overload warning,
exterior alarm, ProShiftTM control display, and speed
restrictions. Note that special devices are required on
the lift truck for load meter display, overload warning,
exterior alarm, and ProShiftTM control display.
5.6.1 Password authentication (Dealer option)
(1) Purpose and function
The password authentication is designed to prevent unauthorized persons from driving the lift
truck. To operate the lift truck, input a 4 digit password correctly.
(a) Turn the key switch to the ON position. When
the password input screen is displayed after
the brand logo screen, enter the password.
(b) Password input procedure is shown in the table
below.
Button

Press

Display

Short

0 to 9, and "", one at a time

Long

0 to 9, and "", incrementally

Short

"", 9 to 0, and one at a time

Long

"", 0 to 9, incrementally

Short

Enter (to move to next digit)

To standard screen

(2) Inputting a password

215140

Note: a) Select "" to return the previous digit.


b) Proceed to the next digit with pressing the
button. After inputting number at the 4th
digit, press the button for entry.
c) When the password is correctly inputted, an
"OK" message is displayed. If not, an "NG"
message appears followed by the password
input display. With "NG" message, the engine
can be started, but the lift truck will neither
travel nor operate.
Note: a) In case of an emergency or when the registered password is forgotten, enter "1111" so
that the screen shown on the right will appear
and minimized use of travel and operation will
be available. (For electronic gasoline engine
and electronic diesel engine models only)
b) Password input is necessary when starting
the operation, but if it is within 3 minutes after
the key switch is turned to the OFF position,
the operator does not need to enter the password again.
Use the service tool to setup the password
expiration time. (For details, see the service
tool manual.)

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215141

ELECTRIC SYSTEM
(3) For password registration, change, and cancellation, use the service tool.
(For details, see the service tool manual.)
Note: Password registration, change or cancellation
should be performed by service personnel.
Password registration of "0000" or "1111" are
not available.
Register a different 4-digit password.
Up to 32 different passwords can be registered
to support different truck operations.
5.6.2 Service interval display (Dealer option)
Service interval display will notify an operator of the
scheduled inspections and maintenance when the
hour counter reaches to pre-set number of hours.
Note that service interval symbol will not be displayed
if this setup is not installed. For setting up the service
interval display, use the service tool. (For details, see
the service tool manual.)

Service interval display

Note: ONLY service engineers should set up and


perform the service interval display setting.
215142

5.6.3 ProShiftTM control display (Manufacturer's option)


The ProShiftTM control display will notify an operator of
the lift truck condition by the ProShiftTM control lamp
glowing when a protective function activates against a
full reverse or sudden acceleration. For setting up the
ProShiftTM control display, use the service tool. (For
details, see the service tool manual.)

ProShiftTM control indication lamp

Note: ONLY service engineers should set up and perform the ProShiftTM control display setting.

215151

5.7 Hour Meters


5.7.1 Hour meter reading system
Three hour meter readings are available on the instrument panel. (For details, refer to "5.3.6 How to change
types of hour meters")
Three meters: Key-on time, Engine-on time and Seat
switch-on time
(1) Key-on time meter reading is controlled by both
the instrument panel and the VCM. An error (F73) occurs if a time difference in hour meter readings (key-on time) is detected between the instrument panel and the VCM.
(2) Hour meter reading of engine-on time and seat
switch-on time are controlled by the instrument
panel only.

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ELECTRIC SYSTEM

5.7.2 Replacement for the instrument panel and/or the VCM


When replacing the instrument panel or the VCM with
a new one, be sure to observe the instructions below
to transfer the hour meter data to the new instrument
panel or the VCM.
(1) Replacing the instrument panel only
The error (F-73) occurs if a time difference in hour
meter readings (key-on time) is more than 24
hours when replacing the instrument panel with a
new one. Use the service tool to solve the cause
of the error, so that the hour meter data (key-on
time) stored in the instrument panel is transferred
to the memory in the VCM. (For details, see the
service tool manual.) Turn the key switch to the
ON and OFF for a couple of times to make sure
the hour meter reading is successfully transferred
and the error (F-73) disappeared.
(2) Replacing VCM only
The error (F-73) occurs if a time difference in hour
meter readings (key-on time) is more than 24
hours when replacing the VCM with a new one.
Use the service tool to solve the cause of the
error, so that the hour meter data (key-on time)
stored in the instrument panel is transferred to the
memory in the VCM. (For details, see the service
tool manual.) Turn the key switch to the ON and
OFF for a couple of times to make sure the hour
meter reading is successfully transferred and the
error (F-73) disappeared.
(3) Replacing both the instrument panel and the VCM
Step 1
Follow the above procedure (1) for replacing the
instrument panel with a new one.
Step 2
Follow the above procedure (2) for replacing the
VCM with a new one.
Note: a) When replacing the instrument panel and/or
the VCM, be sure to replace them with new
ones.
b) If a secondhand instrument panel and/or VCM
are used from another lift truck, the error (F73) occurs.
DO NOT conduct an error recovery procedure
to the instrument panel or the VCM if they are
replaced with used ones.
The error recovery procedure may overwrite
the hour meter reading of smaller value in order to erase the difference in reading.
Note: When replacing the instrument panel with a
new one, only the hour meter of key-on time is
transferred to the new instrument panel.
(After the replacement, hour meter readings of
engine on-time and seat switch-on time will
return to zero in the new instrument panel.)

3-34

ELECTRIC SYSTEM

5.8 Troubleshooting
Symptom

Possible cause

Remedy

Fuel gauge is not displayed.

On the LPG fuel model, the fuel gauge is not displayed.

Lift truck stops, out of gas, even


though the fuel gauge indicates
that some fuel remains.

On the gasoline LPG dual fuel model, the fuel


gauge shows only gasoline amount. LPG
amount is not shown.

Back-up lamp is turned off.

Back-up lamp is turned off when the temperature


on the instrument panel becomes high (105C
Rest the lift truck in the shade to
[221F] or higher) to prevent the lamp from
cool off.
breakage.

LCD is not displayed.

Check LPG fuel warning for LPG


amount running short.

LCD is turned off when the internal temperature


Rest the lift truck in the shade to
of the instrument panel is high 85 C (185 F) or
cool off.
higher to prevent the LCD from breakage.
LCD contrast may be adjusted to minimum.

Adjust contrast with buttons.

Display changing speed is slow.

When the temperature on the instrument panel


becomes low [0 C (32 F) or lower], the screen
changing speed becomes slow due to the characteristic of LCD.

LCD screen is too dark.

Display becomes dark when the temperature on


the instrument panel becomes high (105C
Adjust contrast with buttons.
[221F] or higher) due to the characteristic of
LCD.

LCD screen is too light.

Display becomes light when the temperature on


the instrument panel becomes low [0 C (32 F) Adjust contrast with buttons.
or lower] due to the characteristic of LCD.

Button press (long) is ineffective.

Turn the key switch to the OFF


When the engine is running, long press of a but- position once to stop the engine,
ton is ineffective.
then turn the key switch to the ON
position.

Time becomes 00:00 AM.

When the battery is changed, the time resets.

Password "0000" and "1111" cannot be registered.

You cannot register "0000" and "1111."

Overload warning function is not


available.

This function is only available for the lift trucks


with the load meter display option.

Refer to "5.3.4" to adjust the time.


Use the load meter display option
(Manufacturer's option)

Exterior alarm lamps do not glow. Trigger speed setting should be 25 km/h (15.5
Check that the exterior alarm
(Warning buzzer does not actiMPH) or less and trigger load setting should be
function is correctly set up.
vate.)
5.5 ton or less (depending on the truck models).
Error (F-73) occurs.

This is caused by a difference in hour meter


readingsbetween the VCM and the instrument
panelwhen the hour meter is transferred.

During the time setup, the screen


returns to the standard screen
even though the setup of the error
history and the exterior alarm
function is half finished.

If the buttons are left untouched for more than


three minutes, or if the engine is started during
the setup procedure, the setup being conducted
becomes ineffective and its screen returns to the
standard screen. Start the setup procedure from
the beginning. Repeat the setup procedure from
the begging.

Displays of fuel gauge and water


temperature gauge blink.

Check the fuel sensor and the water temperature sensor and all the connected wires to both
sensors for electrical short circuit.

Use the service tool for transferring hour meter properly.

Note: The conditions above occur due to the characteristics of each of the materials used in the equipment, therefore they are not defective.

3-35

ELECTRIC SYSTEM

6. Wire Color
Wire colors listed in the table below show standard colors (base colors). For wiring composed of two colors, first
color shows the base color and second color the marked color.
Example: The wire color of B/W shows that its base color is B with a marking W.
B / W

Marked color
Ground color

Note: For wiring identification, the same wiring color must be used for the circuit between the power supply and the
load.

Be careful that allowable current of solid wires and that of strand wires are different even if they are of the same
diameter.

6.1 List of Wire Colors


Wire color

3-36

Color
English

BLACK

WHITE

RED

GREEN

YELLOW

BR

BROWN

BLUE

LG

LIGHT GREEN

OR

ORANGE

PINK

GY

GRAY

SB

LIGHT BLUE

PU

PURPLE

ELECTRIC SYSTEM

7. Troubleshooting
7.1 Starter System
Symptom

Key switch

Starter won't crank the


engine even if the key
switch is turned ON.

Engine won't stop even


if the key switch is
turned OFF.

Remedy

Possible cause
Battery discharge

Recharge or replace

Short or open circuit

Repair or replace

Poor continuity in starter switch

Replace

Defective starter or starter relay

Replace

Neutral switch is not in the neutral


position.

Move the direction lever to neutral


position.

Short or open circuit

Repair or replace

Engine stop solenoid defect

Replace or adjust

7.2 Gauges
Symptom

Remedy
M/P - Water temperature meter disconnection

Indicated value is low.

Water temperature
gauge

Check that the connectors are properly jointed.

Check the conductivity.

Check the display with the water temperature sensor being warmed.

Replace the water temperature sensor.

Replace the instrument panel.

Check the part number.


Indicated value is inaccurate.

Indicated value blinks.

Check that the parts meet the specification.

Check that the connectors are properly jointed.

Replace the water temperature sensor.

M/P - Water temperature meter disconnection


1

Correction of the short circuit.

Improper setting.
Indicated value is not
displayed.

LPG model does not show the value.

Incorrect VCM setting.

Check the part number.


Fuel gauge

Indicated value is inaccurate.

Indicated value blinks.

Check that the parts meet the specification.

Check that the connectors are properly jointed.

Replace the fuel sensor.

Remove fuel tank cap assembly and check it for bent float.

Correction of the short circuit.

Remove fuel tank cap assembly and check the wirings in the tank.

3-37

ELECTRIC SYSTEM

7.3 Lighting System


Symptom

Lamp does not glow


(blink) when the key
switch is turned ON.
Lamps (in
general)

Lamp glows (blinks)


dimly.

Head lamp Lamp does not glow.

Lamp does not blink.

Turn
signal
lamps

Will not go out.

Recharge or replace

Blown out fuses

Check and replace

Short or open circuit

Repair or replace

Defective grounding wire

Remove corrosion from the terminal or


retighten.

Defective switch conductivity

Replace

Burned out bulbs

Replace

Weak battery

Check and recharge

Defective switch contact

Repair or replace

Contact failure terminals

Repair

Dirty lenses

Clean

Lenses with water drops

Dry and replace the packings.

Bulb's service life expired

Replace

Defective light switch conductivity

Replace

Burned out bulbs

Replace

Defective turn signal switch

Replace

Defective turn signal relay

Replace

Burned out bulbs

Replace

Defective turn signal relay

Replace

3-38

Replace
Replace it with a specified wattage
bulb.

Defective turn signal relay

Replace
Correct the lamp if it is improperly
installed, or replace the lamp if it is
internally defective.
Replace

Blown out fuses

Check and replace

Short or open circuit

Repair or replace

Horn does not activate. Defective horn switch

Offensive sound

Replace it with a specified wattage


bulb.

Bulb wattage is more than the specified


value.

Back-up lamp does not Defective back-up lamp switch


glow.
Burned out bulbs

Horn

Remedy

Battery discharge

Bulb wattage is less than the specified


Lamp blinks too slowly. value.
Defective turn signal relay
Lamp blinks too fast.

Other
lamps

Possible cause

Replace

Defective horn

Replace

Defective horn button

Repair or replace

Defective horn switch

Replace

Defective horn

Replace

ELECTRIC SYSTEM

Symptom
Alternator belt

Alternator

Regulator
Weak
battery

Battery

Wiring

Battery
overcharge

Wiring

Regulator

Possible cause

Remedy

Slippage

Adjust the tension.

Starter coil has defective grounding wire


or open circuit.

Repair or replace

Open-circuited rotor coil

Replace

Poorly-seated brushes on slip rings

Clean holder and polish slip rings.

Defective brush movement

Adjust, replace brushes if worn.

Short-circuited or open-circuited diode

Replace

Regulating voltage is too low

Adjust

Shortage or inappropriate amount of elecRefill or adjust the S.G.


trolyte
Defective cell plates (internal short-circuit) Replace
Poorly-jointed connections on terminals

Clean and tighten

Disconnection or poor connection


between the key switch and regulator IC
terminal.

Repair

Blown out fuses in the above mentioned


Replace fuse or repair the holder's
circuit or poorly-jointed connections on the
contact part.
holder.
Open or loose connection between the
regulator terminal F and alternator terminal F

Repair

Incorrect connection or short circuit


between regulator IC and F terminals

Repair

Defective grounding wire of regulator terminal F

Repair

Open-circuited pressure coil

Replace

Regulating voltage is too high.

Adjust

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ELECTRIC SYSTEM

8. Electrical Schematic

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ELECTRIC SYSTEM
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