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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

3

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

Structure 2. turn signal switch Direction Lever Speedometer 8 3 2 1 ᵮ N ᵦᶐ ᵤ ᵦ ᵣᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾ ᵡ 6 7 5 214140 3-4 .1 Console Box 4 1 2 3 4 5 6 7 8 Water temperature gauge Fuel gauge Hour meter.ELECTRIC SYSTEM 2. warning lamps Instrument panel Key switch Light switch.

3-5 . (This lamp glows all the time while the engine is stopped. - Normal charging This lamp glows when charging is not normal. (This lamp glows all the time while the engine is stopped. Name of indicators and warning lamps A Parking brake warning lamp B Seat belt warning lamp C Charge warning lamp D Multi-purpose warning lamp E Torque converter oil temperature warning lamp When turned off When glows or blinks Remark Normal This lamp glows when the parking brake is applied.ELECTRIC SYSTEM 2. - Normal temperature This lamp glows when the torque converter oil temperature is not normal. - I ProShiftTM - This lamp glows when sudden acceleration or full reverse (shifting of travel to the opposite direction) activates protective function. - - F Engine oil pressure warning lamp Normal This lamp glows when the engine oil pressure is low. - Fastened This lamp glows when the seat belt is not fastened.) G Engine warning lamp Normal This lamp glows when the engine is failed.1 Function of Instrument Panel A B C L D E F G H I J K N M O 214141 Ref.1.) - Normal This lamp glows when a minor failure occurs or operating cautions are issued. Option J Mast interlock indicator lamp - When mast interlock is activated (glows) - K Cursor buttons - - - L Fuel gauge indicator lamp M LCD screen N Water temperature gauge O 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. - H Glow pilot indicator lamp Preheating completed This lamp glows when the glow plug heating is ON.

so the key switch cannot be turned from the | (ON) to the (START) position while the engine is running. The gasoline model is also equipped with an automatic fuel cut engine stop mechanism.2.-----------○ No 3-6 . (OFF) (ON) M ST (START) G B 215358 Connection Table Terminal G B M ST OFF Key in and out Yes ON (when operating) ○--------- -----------○ No START (when starting engine) ○--------- -----------○----------.1 Key switch The diesel model uses a distributor type injection pump.2 Main Electrical Components 2. (Key switch with anti-restart lock) This key switch has an anti-restarting function. Its starter switch is equipped with an automatic fuel cut engine stop mechanism. The gasoline and diesel models use the same key switch. This switch has a built-in anti-restart lock. the key switch is electrically connected to the engine so that the | (ON) key switch position turns on the glow plugs. On the diesel model. This prevents engine trouble or starter breakage caused by an operator's improper operation when starting the engine.ELECTRIC SYSTEM 2.

turn signal switch Forward of truck Light switch turn signal lever L 10° N OFF 10° R OFF 1 25° 25 2 °2 5 ° 3 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.2. 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 .2 Combination switch (1) Light switch.ELECTRIC SYSTEM 2.

ELECTRIC SYSTEM (2) Direction switch Forward of truck Forward-reverse selector lever (FNR) 10° F N 10° OFF R Forward-reverse shift change switch (FNR) 5 4 2 1 3 Connection table Terminal Wire color Lever position 1 2 3 4 5 L/B B L/R B L/W F (Forward) N (Neutral) R (Reverse) 215360 3-8 .

5 The number in parenthesis is a reference value.4 Tank unit 3/4 424. T1 and T2.0.2. 1/2 Pressure relief valve 1/4 Fuel pump Fuel filter E Fuel suction strainer Referential Standards Float position E 1/4 1/2 3/4 F Standard resistance value (Ω) 80 (49.2 mm (2. T2 Down Vent hole T1 Contact Coil T2 215361 2.41 in.) F 242. 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.0 .3 Horn Check that the horn activates when applying the specified voltage to both terminals of the horn. Replace the horn if it does not activate or its sound is unusual.2 mm (16.) Illustration shows gasoline model. 215362 3-9 .) 61.5) 32 (19) 10 Tolerance (Ω) +12 +2 – ±3 – +1.ELECTRIC SYSTEM 2.56 in.7 in.2.7 mm (9.

3 ± 0.4 11.3 (266 ± 0.3 ± 5 (29.54) 130 ± 0.54) 125 ± 0.5 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.3 (212 ± 0.54) 80 ± 10 67 ± 7.2. Note: The illustration is for gasoline models.8 40.) 1 M Ω or more (at 500 V megger) M10×1.25 OFF ON 215363 Rated voltage: DC12V 2.5 (10) Standard resistance value (Ω) Diesel model 3-10 .54) 120 (248) Standard resistance value (Ω) (80) 56.6 ± 3.3 (257 ± 0.2 (140 ± 0.36) 65 ± 0.36) 80 ± 0.36) 100 ± 0.5) 14.) 4 mm (0.8 ± 0.2 (176 ± 0.2 (149 ± 0.3 (222.5) (16.3 Temperature [°C (°F)] 50 (122) 60 ± 0. 215364 Gasoline model Temperature [°C (°F)] 60 ± 0.16 in.36) 80 (176) 100 (212) 106 ± 0.6 Thermoswitch (Engine cooling water temperature) (1) Apply an ohmmeter between the terminal and body of the sending unit and check for continuity (resistance value).2 ± 1. Insulation resistance value 2 mm (0. Push rod Measure the insulation resistance value across the terminals when the push rod is pushed in. Body Terminal (2) Replace the sending unit if there is no continuity or the resistance value measured is outside the standard resistance value.2. Replace the stop lamp switch if its measured insulation resistance value is less than the value below.08 in.7 22.2 (140 ± 0.3 ± 0.4 10 ± 0.ELECTRIC SYSTEM 2.

7 Thermoswitch (T/C oil) Apply an ohmmeter between the terminal and body and check for continuity (resistance value).8 lbf·ft] Tightening torque 215365 Replace the thermoswitch if it is dropped or abused.8 kgf·m) [23.6 ± 5.24 in.4°F) ON to OFF 115 °C (239 °F) or higher Insulation resistance (with contact point OFF) 1 M Ω or more 2.5 Ω or less (with contact point ON) Allowable load: 0. tighten it to the specified torque.2 to 34. (1) Parking switch at pulled position Between terminals B and W Insulation resistance P 100 M Ω or more (at 500 V megger) Push Pull (2) Parking switch at pushed position 6 mm (0.5 A Note: When installing the thermoswitch. Terminal Body 1 M Ω or more (with contact point OFF) (with 500 V megger) Insulation resistance value Internal resistance: 0.) (Stroke) Between terminals B and R Insulation resistance 100 M Ω or more (at 500 V megger) Operation method: Push-pull operation Contact resistance: 1a-ab W B R 215366 3-11 . 31. Technical data Operating temperature OFF to ON 122 ± 3°C (251.ELECTRIC SYSTEM 2.1 N·m (3.4 to 47.2. Replace the thermoswitch if its measured insulation resistance value is less than the value below.2.2 to 4.8 Parking brake switch Measure the insulation resistance between each terminal.

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 .2.ELECTRIC SYSTEM 2.

and starter relay) DC12 V Working voltage DC3.1 V 120 Ω ± 10% 117.0 V Open-circuit voltage DC1.6 mA ± 10% z ‪‧ ‪‧ ‪
 ‥• ‥• X ‪
⁓ ‪
 ‪
 Y ‪
 Connection diagram (Bottom view) 215370 3-13 .9 V Coil resistance 80 Ω ± 10% Rated exciting current z 168 mA ± 10% ‪
 ‪
 ‥• X ‥• ‪
 ‪‧ ‪
 ‪‧ Connection diagram (Bottom view) Y 215368 CM relay (Warning buzzer relay) Coil rating [at 20°C (68°F)] 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.ELECTRIC SYSTEM (1) Relay box 1 Item Truck model Gasoline and diesel models Rated operating voltage ‫‣‫‬″•‧‟•‣
•• Coil rating [at 20°C (68°F)] ‼″⁂″⁀ ‵‴‣⁓›‟⁄‟‣․⁈ ″‵‪‪‥․․‣‒‿•․ ․‧․‥• ‸‽‣‣• CB relay (Ignition relay. back-up lamp relay.0 to 7.2 to 3.

MAIN/C relay.ELECTRIC SYSTEM (2) Relay box 2 (gasoline models only) CM relay (EGI relay.5 to 3. ETC motor relay.6 mA ± 10% ‪‧ ‪‧ ‪
 ‥• ‥• X ‪
⁓ ‪
 ‪
 Y ‪
 Connection diagram (Bottom view) 215370 3-14 .1 V 120 Ω ± 10% z 117. and fuel pump relay) ․‧․‥• ‸‽‣․″ ‫‣‫‬″•…‟•‣
•• ″‵‿‥․․․‣‒‿‣․ Coil rating [at 20°C (68°F)] 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.

4 5 3 6 Initial characteristic (Normal temperature and humidity.ELECTRIC SYSTEM 2. Insulation resistance value Rated voltage: DC12V 1 3 1 M Ω or more (at 500 V megger) 2 4 Connection diagram 1 3 2 4 215372 3-15 .4 0 sec Environmental characteristic (-30°C to 70°C.6 sec OFF ON Key switch ST 5 Glow relay Battery DC12V 6 4 Controller 3 Glow plug Lamp Connection diagram 215371 2.0 ± 1. Replace the glow timer with a new one if it does not function properly. Coil resistance 13 Ω (2) Measure the insulation resistance value between terminal 1 and terminal 2. Vcc=12 V) Preglow timer 6. Replace the coil if its measured insulation resistance value is less than the value below. there should be continuity between 6 and terminal 3 for 6 seconds.2.2.0 0. Replace the coil if there is no continuity or the resistance value measured is out of standard resistance value.0 ± 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 3.11 Glow relay (diesel model) (1) Apply an ohmmeter across terminal 3 and terminal 4 and measure the resistance value of the relay coil. Vcc=7 V to 15 V) Preglow timer 6.

ELECTRIC SYSTEM 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 .2.

3 Table of Lamps Item Head lamp Turn signal lamp Quantity Lens color LED color 16 Colorless Colorless 2 Amber Colorless Valve Illustration Remark Standard Option (Installed to head guard) Combination lamp (front) Clearance lamp 2 Amber Colorless Turn signal lamp 8 Amber Yellow Standard 8 Red Red Standard 12 Colorless Colorless Standard Type of lamps Combination Tail and stop lamp lamp (rear) Back-up lamp 3-17 .ELECTRIC SYSTEM 2.

(4) Disconnect the electrical wiring from connector 1.1.1 Disassembly 5 2 4 3 1 216938 3. follow the removal sequence in reverse. 3. remove cover (U-Fr) 4.3 Installation For installation. (3) Remove the screw and then. (2) Remove the screw and then.1.2 Removal sequence (1) Remove the screw using a Phillips screwdriver and remove cover 2. and remove the cable from the ground side of the battery. Console Box 3. then remove console box assembly 5. 3-18 . 3.1 Preparation Place the key switch to the OFF position.1.ELECTRIC SYSTEM 3. remove cover (U-Re) 3. (5) Remove the bolt.

2 Specific Gravity Reading and State of Charge To tell whether a battery is fully charged. 1.) Adjustment Specific gravity reading at 20°C (68°F) Condition Adjustment 1.G.G.) 215375 3-19 . the charging current should be about 1/10 the capacity of the battery being charged.G. discharge the battery in an efficient manner. Recharge battery. continue to use as is. Battery Maintenance 4.G. charge the battery to adjust the electrolyte S. between any two cells is 0. within one month it may be overcharged. (3) During charging. the battery capacity in ampere (A) should not be exceeded. remove the (-) terminal first. 4.020 or less. (2) In quick charging.220 (0. If the difference in S. adjust the charging current so that the electrolyte temperature does not exceed 45°C (113°F). between 1.G.1 State of Charge and Electrolyte Specific Gravity (S.260 to 1. leaks or electrolyte rate is too found in any of the cells. (5) Ventilate well during the battery charge because hydrogen gas is generated. If the electrolyte amount remains sufficient for more than three months.G. If the electrolyte in the battery cell decreases to the level where the pole plates are exposed. If the battery recovers.G. (This prevents damage to the IC regulator.G.040.265 Good If the difference in S.280 and 1. the battery may discharge. always connect the (+) terminal first. If the difference is more than 0. charge the battery to adjust the electrolyte S. of each cell with hydrometer or the electrolyte reduction speed. is more than 0.280 to 1.G. Conduct a high current discharge test after leaving the battery for 12 to 96 hours. Battery low (caution required) If the difference in S. is more than 0.G. Recharge the battery until its voltage and S.020.G. Check for any short-circuited cables or corroded cable connections in the electrical system. and when disconnecting.G. A cell with a low S. 4. may Charge the battery to adjust the electrolyte S. high or too low. replace the battery with a new one.040 and a low S. is too much. check the electrolyte S.ELECTRIC SYSTEM 4. (4) When connecting cables to battery terminals.3 Charging Precautions (1) In slow charging.265.2) or less Recharge battery to adjust electrolyte S. - + Identification 55D23L (Gasoline) 130E41L (Diesel) Be sure to turn OFF the key switch and light switch before disconnecting or connecting the battery cables. stabilize and remain constant for more than 2 hours. is It is caused when electrolyte If the difference in S.225 Half charged 1. It should read cause a short circuit.G.

ELECTRIC SYSTEM 5. Warning lamps Down button Up button Enter/display button LCD screen 215114 The LCD screen consists of six areas: main area. b) Warnings are not automatically turned off for safety reasons. and enter/display button. The main area is divided into two parts: right and left. fuel gauge area. hour meter area. 3-20 Fuel gauge Main display Water temperature gauge 215115 . Instrument Panel 5. and water temperature gauge area. travel direction area. Instrument panel internal (ambient) temperature - 85°C (185°F) or higher LCD screen is not displayed. LCD (Liquid crystal display) screen. symbol mark area. the response of the LCD display is slower. Note: a) Back-up light illuminates both the fuel mark and water temperature mark on the LCD from inside.1 Instrument Panel Screen Components Instrument panel screen consists of warning lamps. Travel direction Symbol mark (Optional feature) Time/hour meter display Note: The instrument panel has functions below to protect circuits in the panel. and ٌ and ٖ buttons. 105°C (221°F) or higher Backlight goes off. c) When the temperature is extremely low [0°C (32°F) or below].

215118 3-21 . LCD screen displays the brand logo screen.2. the brand logo screen is displayed for 2 seconds while lamp check is being executed. Also. error history is displayed with the press of a button. 215117 (3) Usual display screen The screen is changed to the usual display screen that shows the conditions of truck. the password authentication screen.2 Basic Screen Display 5.ELECTRIC SYSTEM 5.1 LCD screen display with the engine key in ON position With the engine key turned to ON position. and the usual display screen in sequence. (1) Brand logo screen When the engine key is turned to ON position. 215116C (2) Password authentication screen (Display by optional function) Inputting the password registered in advance makes possible to operate the forklift truck.

5 ton 14.) or less With fuel gauge image Note: LPG dual fuel truck shows gasoline remaining amount only. After that.1 to 1.06 to 0.in.0 km/h (14.24 Mph) • • • • 24.24 Mph) 2 km/h (1. Without fuel gauge image (LE models) 3-22 215120 .97 to 15.6 cu.2.62 Mph) 1 km/h (0.62 Mph) 1.3 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.53 Mph) 215119 Speed display value is rounded to a higher number.0 to 5. Fuel gauge Note: E (Empty) remaining amount Truck model Remaining amount 4.2 Speed meter display This display shows current lift truck speed.ELECTRIC SYSTEM 5. Speed meter display Note: Actual speed Display 0.1 to 25.3 liter (872.0 km/h (0. the remaining amount is displayed for 2 minutes on average.53 Mph) • • • • 25 km/h (15.1 to 2.68 to 1.2. 5.0 km/h (0.

2 °F) or higher • Gasoline model: Approx.6 °F) or higher 0 0 10 20 30 40 50 60 70 80 90 100 0 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 .2.the number of dots in the gauge Range displayed on LCD screen (50 to 120°C) [122 to 248°F] 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 (228.4 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.ELECTRIC SYSTEM 5. 215121 Engine coolant temperature . 107 °C (224.

For setting up the speed restriction function. see the service tool manual. High speed symbol Low speed symbol High speed limit display Low speed limit display 215152 H/L selector switch 215153 3-24 . •Gasoline model includes this function as standard equipment.) Note: •Service engineers should perform the speed restriction function setup.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.ELECTRIC SYSTEM 5.2. H/L selector switch is used to change between high and low speeds. (For details. use the service tool.

With a short press of the ٤ button. the clock display alternately changes between 12-hour and 24-hour mode. Time/hour meter With a long press of the ٌ button while the clock is displayed.3 Basic Operation 5. Button Press Display ٤ Short Hour meter ←→ clock Long 12-hour mode display ←→24-hour mode display (with clock time display) ٌ 215126 3-25 . 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. Screen contrast can be adjusted while the engine is running. 5.ELECTRIC SYSTEM 5. and the screen becomes light when the temperature is low. The operation of each button varies with the item being displayed on the screen. Button Press Display Light → Dark ٌ Short Dark → Light ٖ Note: The screen becomes dark when the temperature inside the instrument panel (ambient temperature) is high. 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. Enter/display button 215125 Short press of button Press button for less than two seconds. 5.2 How to adjust the screen contrast Turn the key switch to the ON position. the display alternately changes between the hour meter and the clock time. which are located on the right side of the instrument panel.3. Screen contrast can be adjusted while the engine is running. ٖ button. Multiple button presses All buttons pressed at the same time for more than two seconds.3.1 How to use operation buttons There are three types of manual operation buttons: ٌ button. and ٤ button.3.3 How to display the clock time Turn the key switch to the ON position. Long press of button Press button for more than two seconds.

3. • When a battery is changed. (2) Select clock time display (when the hour meter is being displayed). the display automatically returns to the standard screen. Button Press Display ٤ Long Time unit adjust mode 215127 (4) Time unit adjustment Button ٌ ٖ ٤ Press Display Short 01→12 or 24 (one hour at each press) Long 01→12 or 24 (continuous) Short 12 or 24→01 (one hour at each press) Long 12 or 24→01 (continuous) Short After adjusting. change to the minute adjust mode. Button Press Display ٤ Short Clock time blink Blinking (3) Select time adjust mode and unit adjust mode. change to the standard screen. (5) Minute adjustment Button ٌ ٖ ٤ Press Display Short 01→59 (one minute at each press) Long 00→59 (continuous) Short 59→00 (one minute at each press) Long 59→00 (continuous) Short After adjusting. Note: • Second time display is not available. the time resets. • Precision errors are one minute or less per month. • If more than 3 minutes have passed since the last button operation. Be sure to set the time after changing a battery. • If the engine is started during the setup procedure. 11:00 AM changes to 00:00 PM at noon. the setup being made is cancelled and the display returns to the standard screen.ELECTRIC SYSTEM 5.4 How to set up the clock time (1) Turn the key switch to the ON position. 3-26 Digits to be adjusted is blinking 215129 . Digits to be adjusted is blinking 215128 Note: When the time display is set to the 12-hour mode display.

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. Seat switch-on time: Accumulated time the operator has seated. and seat switch-on time. 0. Screen contrast can be adjusted while the engine is running.3. Engine-on time: Accumulated engine operation time. 3-27 . There are three counters: key-on time. This is helpful in comparing the actual working hours to the actual hours of operation. • Warranty is terminated based on the key-on time. With a short press of the ٤ button.6 How to change types of hour meters Turn the key switch to the ON position. engine-on time. Button Press Display ٤ Short Clock ←→ hour meter Hour meter 215130 5.ELECTRIC SYSTEM 5.3.1 hour is added. The counter display changes with a long press of the ٌ button. This is helpful in comparing the wear of engine related parts to the actual engine operation hours. Seat switch-on time display 215131 Note: • When six minutes have passed. the display alternately changes between the clock time and the hour meter.5 How to display the hour meter 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. Error codes are displayed from the latest error ( -1) up to the past 32 errors ( -32). buttons.ELECTRIC SYSTEM 5. Button Press Display ٌٖ٤ Multiple Error history Up button Down button Enter/display button Error message displays only the F error codes. • If the engine is started during the setup procedure. the setup being made is cancelled and the display returns to the standard screen. 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. the display automatically returns to the standard screen. error record on the display changes. operate the ٖ or the ٌ button. Button Press Display ٌٖ٤ Multiple Standard display screen Error history display With .7 How to display the error history Turn the key switch to the ON position.3. 215125 Note: Use the service tool to erase the error message being displayed. To change the error code display. When there is no error record Note: • If more than 3 minutes have passed since the last button operation. Oldest data (error) exceeding the limit (32 errors) is automatically erased. 215134 3-28 . 215133 The illustration shows the error history screen when there is no error record.

4.) Refer to the engine service manual for the error codes related to engine troubles (error codes from ECM). 215135 5. and the black and white in the error code display is reversed. serious failures. 5. 215136 3-29 . and the black and white in the error code display is reversed.4 When an Error Occurs When an error occurs. Also all warning lamps shown in the figure (right) will blink.ELECTRIC SYSTEM 5. The priority order of the error display is: engine failures.4. Engine warning lamp glows When an engine failure occurs.1 When an engine failure occurs The corresponding error code is displayed in the main area. the corresponding error code is displayed on the screen. the error code alternately changes between black characters on a white background to white characters on a black background. and minor failures. the error code alternately changes between black characters on a white background and white characters on a black background. (The error code remains displayed until the cause of the trouble is solved. Warning lamps within the dotted line boxes blink When a serious failure occurs.2 When a serious failure occurs The corresponding error code is displayed in the main area. Also the engine warning lamp glows. 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.

Also the multi-purpose warning lamp glows. (option) Clogged air cleaner element warning lamp This lamp glows when the air cleaner element is clogged.4. (diesel model) Low coolant level warning lamp This lamp glows when the coolant level is low. 215137 5. Multi-purpose warning lamp glows Note: The minor failure display is also shown when the fuel gauge reaches the empty level (E). and the black and white in the error code display is reversed.4 Error symbols Error symbols displayed in the main area are as follows: Symbol 3-30 Name Indicated condition Fuel filter warning lamp This lamp glows when the water in the fuel filter needs to be drained.) LPG level warning lamp On the LPG model. The error code and symbol alternately change between black characters/lines on a white background to white characters/lines on a black background.4. (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 LPG level becomes low. this lamp glows when the gasoline level becomes low.ELECTRIC SYSTEM 5. (option) .3 When a minor failure occurs The corresponding error code is displayed in the main area.

(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. All models (Standard) Charge warning lamp Red This lamp glows when charging is not normal. Electronic control gasoline engine models (Standard) Glow pilot indicator lamp Amber This lamp glows when the glow plug heating Diesel engine models is ON. (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. Option Mast interlock indicator lamp Amber When mast interlock is activated (glows) All models (Standard) 3-31 .5 Warning Lamps The function of each warning lamp is shown in the table below. Torque converter oil temperature warning lamp Red This lamp glows when the torque converter oil temperature is not normal. All models (Standard) Seat belt warning lamp Red This lamp glows when the seat belt is not fastened.ELECTRIC SYSTEM 5. Powershift transmission models (Standard) Engine oil pressure warning lamp Red This lamp glows when the engine oil pressure is low. (Standard) ProShiftTM indicator lamp Amber This lamp glows when sudden acceleration or full reverse (shifting of travel to the opposite direction) activates protective function. Lamp Name Color Glow (blink) condition Model applicable Parking brake warning lamp Red This lamp glows when the parking brake is applied.

If not. (a) Turn the key switch to the ON position. an "NG" message appears followed by the password input display. (b) Password input procedure is shown in the table below. press the ٤ button for entry. 5. (For details. 9 to 0.6 Optional Functions The following optional functions are available: password authentication. see the service tool manual. 0 to 9. With "NG" message. the operator does not need to enter the password again. Note that special devices are required on the lift truck for load meter display. Button ٌ ٖ ٤ Press Display Short 0 to 9. incrementally Short "←". incrementally Short Enter (to move to next digit) To standard screen (2) Inputting a password 215140 Note: a) Select "←" to return the previous digit. and "←".6. and speed restrictions. but the lift truck will neither travel nor operate. exterior alarm. When the password input screen is displayed after the brand logo screen. ProShiftTM control display. Note: a) In case of an emergency or when the registered password is forgotten. one at a time Long 0 to 9. After inputting number at the 4th digit. exterior alarm. Use the service tool to setup the password expiration time. and "←". load meter display. input a 4 digit password correctly. enter the password. overload warning.1 Password authentication (Dealer option) (1) Purpose and function The password authentication is designed to prevent unauthorized persons from driving the lift truck. and ProShiftTM control display. and one at a time Long "←". overspeed warning. an "OK" message is displayed. overload warning. b) Proceed to the next digit with pressing the ٤ button. but if it is within 3 minutes after the key switch is turned to the OFF position. (For electronic gasoline engine and electronic diesel engine models only) b) Password input is necessary when starting the operation. the engine can be started. To operate the lift truck. service interval display.) 3-32 215141 . c) When the password is correctly inputted. enter "1111" so that the screen shown on the right will appear and minimized use of travel and operation will be available.ELECTRIC SYSTEM 5.

(For details.) Note: • Password registration. For setting up the service interval display. (For details. Note that service interval symbol will not be displayed if this setup is not installed. 5. change.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. Engine-on time and Seat switch-on time (1) Key-on time meter reading is controlled by both the instrument panel and the VCM. 215151 5. 3-33 . see the service tool manual. use the service tool. use the service tool.) Service interval display Note: • ONLY service engineers should set up and perform the service interval display setting. change or cancellation should be performed by service personnel.) ProShiftTM control indication lamp Note: ONLY service engineers should set up and perform the ProShiftTM control display setting.7 Hour Meters 5. see the service tool manual. refer to "5.6 How to change types of hour meters") ŒThree meters: Key-on time. For setting up the ProShiftTM control display.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.3.6. see the service tool manual. (2) Hour meter reading of engine-on time and seat switch-on time are controlled by the instrument panel only. 215142 5. • Password registration of "0000" or "1111" are not available. An error (F73) occurs if a time difference in hour meter readings (key-on time) is detected between the instrument panel and the VCM. Register a different 4-digit password. use the service tool. (For details. •Up to 32 different passwords can be registered to support different truck operations.7.6.ELECTRIC SYSTEM (3) For password registration. (For details.1 Hour meter reading system Three hour meter readings are available on the instrument panel. and cancellation.

Note: • When replacing the instrument panel with a new one. The error recovery procedure may overwrite the hour meter reading of smaller value in order to erase the difference in reading. Step 2 Follow the above procedure (2) for replacing the VCM with a new one. b) If a secondhand instrument panel and/or VCM are used from another lift truck.2 Replacement for the instrument panel and/or the VCM When replacing the instrument panel or the VCM with a new one. (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.) 3-34 .) 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. (For details. (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.) 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. Note: a) When replacing the instrument panel and/or the VCM. (After the replacement.ELECTRIC SYSTEM 5. Use the service tool to solve the cause of the error. hour meter readings of engine on-time and seat switch-on time will return to zero in the new instrument panel. 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. DO NOT conduct an error recovery procedure to the instrument panel or the VCM if they are replaced with used ones. be sure to observe the instructions below to transfer the hour meter data to the new instrument panel or the VCM. see the service tool manual.7. be sure to replace them with new ones. (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. see the service tool manual. the error (F73) occurs. only the hour meter of key-on time is transferred to the new instrument panel. (For details. so that the hour meter data (key-on time) stored in the instrument panel is transferred to the memory in the VCM.

vate. Password "0000" and "1111" cannot be registered. Display becomes light when the temperature on the instrument panel becomes low [0 °C (32 °F) Adjust contrast with buttons. Error (F-73) occurs. Turn the key switch to the OFF When the engine is running. LCD is not displayed. then turn the key switch to the ON position. ton is ineffective. On the LPG fuel model. LCD contrast may be adjusted to minimum.ELECTRIC SYSTEM 5. breakage. Display changing speed is slow. You cannot register "0000" and "1111. out of gas. the fuel gauge is not displayed. LPG amount is not shown. Use the load meter display option (Manufacturer's option) Exterior alarm lamps do not glow. LCD screen is too dark. LCD screen is too light. On the gasoline LPG dual fuel model.3. - Use the service tool for transferring hour meter properly. the screen changing speed becomes slow due to the characteristic of LCD. When the temperature on the instrument panel becomes low [0 °C (32 °F) or lower]. Check LPG fuel warning for LPG amount running short. [221°F] or higher) due to the characteristic of LCD. - Refer to "5. Check the fuel sensor and the water temperature sensor and all the connected wires to both sensors for electrical short circuit. therefore they are not defective.5 Check that the exterior alarm (Warning buzzer does not actiMPH) or less and trigger load setting should be function is correctly set up. higher to prevent the LCD from breakage. This is caused by a difference in hour meter readingsbetween the VCM and the instrument panelwhen the hour meter is transferred. the time resets. Start the setup procedure from the beginning. long press of a but. Note: The conditions above occur due to the characteristics of each of the materials used in the equipment." Overload warning function is not available. Trigger speed setting should be 25 km/h (15. This function is only available for the lift trucks with the load meter display option. 3-35 . Back-up lamp is turned off when the temperature on the instrument panel becomes high (105°C Rest the lift truck in the shade to [221°F] or higher) to prevent the lamp from cool off. When the battery is changed.) 5. Time becomes 00:00 AM. Button press (long) is ineffective. or lower] due to the characteristic of LCD. even though the fuel gauge indicates that some fuel remains. the fuel gauge shows only gasoline amount.4" to adjust the time. or if the engine is started during the setup procedure. the screen returns to the standard screen even though the setup of the error history and the exterior alarm function is half finished. Repeat the setup procedure from the begging. - Displays of fuel gauge and water temperature gauge blink.position once to stop the engine.8 Troubleshooting Symptom Possible cause Remedy Fuel gauge is not displayed. Back-up lamp is turned off. 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.5 ton or less (depending on the truck models). - Lift truck stops. During the time setup. the setup being conducted becomes ineffective and its screen returns to the standard screen. Adjust contrast with buttons. Display becomes dark when the temperature on the instrument panel becomes high (105°C Adjust contrast with buttons. If the buttons are left untouched for more than three minutes.

Be careful that allowable current of solid wires and that of strand wires are different even if they are of the same diameter.1 List of Wire Colors Wire color 3-36 Color English B BLACK W WHITE R RED G GREEN Y YELLOW BR BROWN L BLUE LG LIGHT GREEN OR ORANGE P PINK GY GRAY SB LIGHT BLUE PU PURPLE .ELECTRIC SYSTEM 6. B / W Marked color Ground color Note: For wiring identification. Wire Color Wire colors listed in the table below show standard colors (base colors). the same wiring color must be used for the circuit between the power supply and the load. 6. 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.

2 Gauges Symptom Remedy M/P . 2 Incorrect VCM setting. Improper setting. Move the direction lever to neutral position. 1 Correction of the short circuit. 2 Check that the connectors are properly jointed. 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. 2 Check that the connectors are properly jointed. Fuel gauge Indicated value is inaccurate. M/P . Check the part number. 4 Replace the water temperature sensor. 3 Replace the water temperature sensor. Indicated value is inaccurate.Water temperature meter disconnection Indicated value is low. Indicated value is not displayed. Short or open circuit Repair or replace Engine stop solenoid defect Replace or adjust 7. Indicated value blinks.Water temperature meter disconnection 1 Correction of the short circuit. 5 Replace the instrument panel. Water temperature gauge 1 Check that the connectors are properly jointed. Check the part number. 2 Check the conductivity. 1 Check that the parts meet the specification. 1 LPG model does not show the value. Troubleshooting 7. 3-37 . Engine won't stop even if the key switch is turned OFF.1 Starter System Symptom Key switch Starter won't crank the engine even if the key switch is turned ON. 3 Check the display with the water temperature sensor being warmed. 1 Check that the parts meet the specification. 3 Replace the fuel sensor. Indicated value blinks. 2 Remove fuel tank cap assembly and check the wirings in the tank.ELECTRIC SYSTEM 7. 4 Remove fuel tank cap assembly and check it for bent float.

Defective turn signal relay Lamp blinks too fast. Burned out bulbs Horn Remedy Battery discharge Bulb wattage is less than the specified Lamp blinks too slowly. Lamp does not blink.3 Lighting System Symptom Lamp does not glow (blink) when the key switch is turned ON. Head lamp Lamp does not glow. 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.ELECTRIC SYSTEM 7. Defective turn signal relay Replace Correct the lamp if it is improperly installed. value. Turn signal lamps Will not go out. or replace the lamp if it is internally defective. Bulb wattage is more than the specified value. 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. Back-up lamp does not Defective back-up lamp switch glow. 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. Lamps (in general) Lamp glows (blinks) dimly. Other lamps Possible cause Replace Defective horn Replace Defective horn button Repair or replace Defective horn switch Replace Defective horn Replace . 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.

Adjust 3-39 . 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.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. Short-circuited or open-circuited diode Replace Regulating voltage is too low Adjust Shortage or inappropriate amount of elecRefill or adjust the S. replace brushes if worn. 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 or replace Open-circuited rotor coil Replace Poorly-seated brushes on slip rings Clean holder and polish slip rings. holder. Defective brush movement Adjust.G. Repair Blown out fuses in the above mentioned Replace fuse or repair the holder's circuit or poorly-jointed connections on the contact part.

Electrical Schematic 3-40 .ELECTRIC SYSTEM 8.

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