Chapter 3 ELECTRIC SYSTEM

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

1.1 Gasoline Model........................................................................................................ 3-1
1.2 Diesel Model............................................................................................................ 3-2
1.3 Gasoline and Diesel Models.................................................................................... 3-3
2. Structure .................................................................................................. 3-4
2.1 Console Box ............................................................................................................ 3-4
2.2 Main Electrical Components.................................................................................... 3-6
2.3 Table of Lamps...................................................................................................... 3-17
3. Console Box .......................................................................................... 3-18
3.1 Disassembly .......................................................................................................... 3-18
3
4. Battery Maintenance ............................................................................. 3-19
4.1 State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment ..................... 3-19
4.2 Specific Gravity Reading and State of Charge ...................................................... 3-19
4.3 Charging Precautions ............................................................................................ 3-19
5. Instrument Panel ................................................................................... 3-20
5.1 Instrument Panel Screen Components.................................................................. 3-20
5.2 Basic Screen Display............................................................................................. 3-21
5.3 Basic Operation ..................................................................................................... 3-25
5.4 When an Error Occurs........................................................................................... 3-29
5.5 Warning Lamps ..................................................................................................... 3-31
5.6 Optional Functions................................................................................................. 3-32
5.7 Hour Meters........................................................................................................... 3-33
5.8 Troubleshooting..................................................................................................... 3-35
6. Wire Color .............................................................................................. 3-36
6.1 List of Wire Colors ................................................................................................. 3-36
7. Troubleshooting.................................................................................... 3-37
7.1 Starter System....................................................................................................... 3-37
7.2 Gauges .................................................................................................................. 3-37
7.3 Lighting System ..................................................................................................... 3-38
8. 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

To engine harness
Earth

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 switch
Seat
To armrest
(FC model only)

Harness B Back-up buzzer

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 (+)

Earth
Glow timer
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

Horn harness Select switch

Control valve
FC Output unit
MC

Output harness

Control valve Control valve

Transmission
Parking brake valve FC Armrest
FC control lever
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 8 3 1
1 Water temperature gauge 2
2 Fuel gauge
3 Hour meter, warning lamps
ᵮ

ᵦᶐ
N

4 Instrument panel
ᵤ ᵦ
6
ᵣᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾ ᵡ

5 Key switch
6 Light switch, turn signal switch
7 Direction Lever
8 Speedometer

7
5

214140

3-4
 ELECTRIC SYSTEM

2.1.1 Function of Instrument Panel

A B C D E F G H I J K

L M N O
214141

Ref. Name of indicators and warning lamps When turned off When glows or blinks Remark
This lamp glows when the parking
A Parking brake warning lamp Normal -
brake is applied.
This lamp glows when the seat belt is
B Seat belt warning lamp Fastened -
not fastened.
This lamp glows when charging is not
normal.
C Charge warning lamp Normal charging -
(This lamp glows all the time while
the engine is stopped.)
This lamp glows when a minor failure
D Multi-purpose warning lamp Normal occurs or operating cautions are -
issued.
Torque converter oil temperature warn- This lamp glows when the torque con-
E Normal temperature -
ing lamp verter oil temperature is not normal.
This lamp glows when the engine oil
pressure is low.
F Engine oil pressure warning lamp Normal -
(This lamp glows all the time while
the engine is stopped.)
This lamp glows when the engine is
G Engine warning lamp Normal -
failed.
This lamp glows when the glow plug
H Glow pilot indicator lamp Preheating completed -
heating is ON.
This lamp glows when sudden accel-
eration or full reverse (shifting of
I ProShiftTM indicator lamp - Option
travel to the opposite direction) acti-
vates protective function.
When mast interlock is activated
J Mast interlock indicator lamp - -
(glows)
K Cursor buttons - - -
L Fuel gauge Indicates remaining fuel amount with key in "ON" position -
M LCD screen - - -
N Water temperature gauge Indicates water temperature with key in "ON" position -
O Enter/display button - - -

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 auto-
matic 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 pre-
vents 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 electri-
cally connected to the engine so that the | (ON) key
switch position turns on the glow plugs.

(OFF)
(ON)
ST M
(START)

G B
215358

Connection Table
Terminal G B M ST Key in and out
OFF Yes
ON (when operating) ○--------- -----------○ No
START
○--------- -----------○----------- -----------○ No
(when starting engine)

3-6
 ELECTRIC SYSTEM

2.2.2 Combination switch

(1) Light switch, turn signal switch

Forward of truck
Light switch
turn signal lever

10°
OFF N

10°
R

OFF 1
25° 25 2
°2
5 ° 3

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

L-1 T-3
T-2 L-2

Horn contact

Light switch connector

Terminal L-1 L-2 L-3

Target Tail,
Power Head lamp
Knob position clearance lamp

OFF
1
2

Turn signal switch connector

Terminal T-1 T-2 T-3

Target Turn signal Turn signal
Flash unit
Lever position lamp (Right) lamp (Left)
R (Right)
N (Neutral)
L (Left)

215359

3-7
ELECTRIC SYSTEM

(2) Direction switch

Forward of truck
Forward-reverse selector lever (FNR)

F
10°

N OFF
10°

Forward-reverse
shift change switch (FNR)

5
4

1 2
3

Connection table

Terminal 1 2 3 4 5
Wire color
L/B B L/R B L/W
Lever position
F (Forward)
N (Neutral)
R (Reverse)

215360

3-8
 ELECTRIC SYSTEM

2.2.3 Horn
Check that the horn activates when applying the spec-
ified voltage to both terminals of the horn, T1 and T2.
Replace the horn if it does not activate or its sound is Up
unusual.
Operating voltage: DC12V (Gasoline and diesel mod-
els)
T1

Note: The proper installation of the horn to the lift

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

T2 Coil
215361

2.2.4 Tank unit

Illustration shows gasoline model. (2.41 in.)
61.2 mm

F
242.7 mm
(9.56 in.)

424.2 mm
(16.7 in.)

3/4

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 (49.5) 32 (19) 10

+12 +1.0
Tolerance (Ω) – ±3 –
+2 - 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 Push rod
the push rod protrusion is at the specified value.
Measure the insulation resistance value across the ter-
minals when the push rod is pushed in.
Replace the stop lamp switch if its measured insula-
tion resistance value is less than the value below. 4 mm 2 mm
(0.16 in.) (0.08 in.)
1 M Ω or more
Insulation resistance value M10×1.25
(at 500 V megger) 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
Body
(resistance value). 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 60 ± 0.2 65 ± 0.2 80 ± 0.2 100 ± 0.3 125 ± 0.3 130 ± 0.3
[°C (°F)] (140 ± 0.36) (149 ± 0.36) (176 ± 0.36) (212 ± 0.54) (257 ± 0.54) (266 ± 0.54)
Standard resis-
80 ± 10 67 ± 7.8 40.6 ± 3.7 22.2 ± 1.4 11.3 ± 0.4 10 ± 0.3
tance value (Ω)

Diesel model
Temperature 50 60 ± 0.2 80 100 106 ± 0.3 120
[°C (°F)] (122) (140 ± 0.36) (176) (212) (222.8 ± 0.54) (248)
Standard resis-
(80) 56.3 ± 5 (29.5) (16.5) 14.3 ± 0.5 (10)
tance value (Ω)

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 Terminal Body
value is less than the value below.

1 M Ω or more
Insulation resis-
(with contact point OFF)
tance value
(with 500 V megger)

Internal resistance: 0.5 Ω 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 N·m

Tightening torque (3.2 to 4.8 kgf·m)
[23.2 to 34.8 lbf·ft]
215365

Replace the thermoswitch if it is dropped or abused.

Technical data
122 ± 3°C
OFF to ON
Operating (251.6 ± 5.4°F)
temperature 115 °C (239 °F)
ON to OFF
or higher
Insulation resistance
1 M Ω or more
(with contact point OFF)

2.2.8 Parking brake switch

Measure the insulation resistance between each ter-
minal.
(1) Parking switch at pulled position

Between terminals B and W P

Insulation
100 M Ω or more (at 500 V megger)
resistance

Pull Push
(2) Parking switch at pushed position
6 mm (0.24 in.) (Stroke)
Between terminals B and R
Insulation
100 M Ω or more (at 500 V megger)
resistance

Operation method: Push-pull operation

Contact resistance: 1a-ab W B R

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 Ignition relay EGI relay

Flasher relay ETC motor relay MAIN/C relay

Back-up lamp relay
Fuel pump relay EGI relay
Warning buzzer relay

Relay box 1 Relay box 2

(Gasoline model only)

215367

3-12
 ELECTRIC SYSTEM

(1) Relay box 1

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

″‵‪‪‥․․‣‒‿•․
․‧․‥• ‸‽‣‣•
‵‴‣⁓›‟⁄‟‣․⁈

‫‣‫‬″•‧‟•‣
••
Coil rating [at 20°C (68°F)]
Truck model

‼″⁂″⁀
Item
Gasoline and diesel models
Rated operating voltage DC12 V
Working voltage DC3.0 to 7.0 V
Open-circuit voltage DC1.2 to 3.9 V
Coil resistance 80 Ω ± 10% z
Rated exciting current 168 mA ± 10%

‪
 ‪

‥•
X
‥•
‪‧ ‪
 ‪‧ ‪


Connection diagram
Y (Bottom view)

215368

CM relay (Warning buzzer relay)

Coil rating [at 20°C (68°F)]

Truck model
Item
Gasoline and diesel models ․‧․‥•
‸‽‣․″
‫‣‫‬″•…‟•‣
••
″‵‿‥․․․‣‒‿‣․
Rated operating voltage DC12 V
Working voltage DC 30 to 7 V
Open-circuit voltage DC 0.5 to 3.1 V
Coil resistance 120 Ω ± 10%
Rated exciting current 117.6 mA ± 10%
z

‪‧
‪‧
‪
 ‥•
‥•
X
‪
⁓ ‪


‪

‪


Connection diagram
Y (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 20°C (68°F)] ‸‽‣․″
‫‣‫‬″•…‟•‣
••
″‵‿‥․․․‣‒‿‣․
Truck model
Item
Gasoline model
Rated operating voltage DC12 V
Working voltage DC 30 to 7 V
Open-circuit voltage DC 0.5 to 3.1 V
z
Coil resistance 120 Ω ± 10%
Rated exciting current 117.6 mA ± 10%

‪‧
‪‧
‪
 ‥•
‥•
X
‪
⁓ ‪


‪

‪


Connection diagram
Y (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 4
and a voltage of 24 V is applied between terminals 4 5
and 3, there should be continuity between 6 and termi-
3
nal 3 for 6 seconds. Replace the glow timer with a new
one if it does not function properly. 6
Initial characteristic (Normal temperature and humidity,
Vcc=12 V)
1.4
Preglow timer 6.0 ± 0 sec
Environmental characteristic (-30°C to 70°C, Vcc=7 V
to 15 V)
2.0
Preglow timer 6.0 ± 0.6 sec
OFF
ON
Key switch ST

5 4
Glow
relay 6 Controller
Battery 3
DC12V Glow Lamp
plug

Connection diagram
215371

2.2.11 Glow relay (diesel model)

(1) Apply an ohmmeter across terminal 3 and termi-
nal 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 stan-
dard resistance value.

Coil resistance 13 Ω

(2) Measure the insulation resistance value between

terminal 1 and terminal 2.
Replace the coil if its measured insulation resis- 1
tance value is less than the value below. 3

1 M Ω or more
Insulation resistance value
(at 500 V megger)
2 4
Rated voltage: DC12V

Connection diagram

1 3
2 4

215372

3-15
ELECTRIC SYSTEM

2.2.12 Fuse box

Fuse box

Illustration shows diesel model

Working lamp
15A
Back-up lamp
15A A/C Head lamp
20A 15A
Instrument panel Stop lamp
10A 10A
Spare ETC Wiper Horn *1 *1
Glow timer 15A 10A EGI EGI
*1 15A
10A
20A 30A 30A 30A
VCM
20A Fuse puller

10A
15A *2
SBF 100A SBF 100A SBF 50A
Spare Glow
Alternator
Battery
*1: Gasoline model only
*2: Diesel model only

215373

3-16
 ELECTRIC SYSTEM

2.3 Table of Lamps

Valve
Item Quantity Lens color LED color Remark
Illustration

Head lamp 16 Colorless Colorless Standard

Turn signal
2 Amber Colorless
lamp
Option
Combination
(Installed to
lamp (front)
head guard)
Clearance
2 Amber Colorless
lamp

Type of
lamps

Turn signal
8 Amber Yellow Standard
lamp

Combination Tail and

8 Red Red Standard
lamp (rear) stop lamp

Back-up
12 Colorless Colorless Standard
lamp

3-17
ELECTRIC SYSTEM

3. Console Box
3.1 Disassembly

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

Condition Adjustment
at 20°C (68°F)
If the difference in S.G. between any two cells is 0.020 or less,
continue to use as is.
1.280 to 1.265 Good 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.
Recharge battery to adjust electrolyte S.G. Check for any
1.260 to 1.225 Half charged short-circuited cables or corroded cable connections in the
electrical system.
Recharge battery.
1.220 (0.2) or less 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.
If the difference in S.G. is between 1.280 and 1.265.
It is caused when electrolyte
more than 0.040. If the difference in S.G. is more than 0.040 and a low S.G. is
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 over-
charged. If the electrolyte amount remains sufficient
for more than three months, the battery may dis-
charge.

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 - +
45°C (113°F).
(4) When connecting cables to battery terminals, Identification
always connect the (+) terminal first, and when
disconnecting, remove the (-) terminal first.
(5) Ventilate well during the battery charge because
55D23L (Gasoline)
hydrogen gas is generated.

130E41L (Diesel)

Be sure to turn OFF the key switch and light switch

215375
before disconnecting or connecting the battery cables.
(This prevents damage to the IC regulator.)

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 Up button

Down button

LCD screen Enter/display button

215114

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

gauge area, travel direction area, symbol mark area, Travel Symbol mark Time/hour meter
hour meter area, and water temperature gauge area. direction (Optional feature) display
The main area is divided into two parts: right and left.

Note: The instrument panel has functions below to

protect circuits in the panel.

Instrument panel internal

-
(ambient) temperature
85°C (185°F) or higher LCD screen is not displayed.
105°C (221°F) or higher Backlight goes off.

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

and water temperature mark on the LCD from
inside.
Fuel gauge Main display Water temperature
b) Warnings are not automatically turned off for
gauge
safety reasons.
215115
c) When the temperature is extremely low [0°C
(32°F) or below], the response of the LCD dis-
play is slower.

3-20
 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.
Note: Speed meter display

Actual speed Display

0.1 to 1.0 km/h 1 km/h
(0.06 to 0.62 Mph) (0.62 Mph)
1.1 to 2.0 km/h 2 km/h
(0.68 to 1.24 Mph) (1.24 Mph)
• •
• •
• •
• •
215119
24.1 to 25.0 km/h 25 km/h
(14.97 to 15.53 Mph) (15.53 Mph)

Speed display value is rounded to a higher number.

5.2.3 Fuel gauge

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

Note:
E (Empty) remaining amount
With fuel gauge image
Truck model Remaining amount
14.3 liter
4.0 to 5.5 ton (872.6 cu.in.)
or less

Note: LPG dual fuel truck shows gasoline remaining

amount only.

Without fuel gauge image (LE models) 215120

3-22
 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 tempera-
ture gauge shown on the LCD.

215121

Engine coolant temperature - the number of dots in the gauge

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

44 dots
Number of dots in the gauge (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

0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 (°C)
0 50 68 86 104 122 140 158 176 194 212 230 248 266 (°F)

Engine coolant temperature (°C) [°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
High speed limit display

Low speed symbol 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 ٤ button, which are Up button
located on the right side of the instrument panel. The
operation of each button varies with the item being dis-
played on the screen. Down button
Button operation is available only when the key
switch is in the ON position and not available Enter/display
when the engine is running. Note that adjustment button
of screen contrast and selection between the hour
meter display and the time display are available
even when the engine is running.
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 con-
trast can be adjusted while the engine is running.

Button Press Display

ٌ Light → Dark
Short
ٖ Dark → Light

Note: The screen becomes dark when the tempera-

ture inside the instrument panel (ambient tem-
perature) 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 con-
trast can be adjusted while the engine is running. With Time/hour meter
a short press of the ٤ button, the display alternately
changes between the hour meter and the clock time.
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

٤ Short Hour meter ←→ clock

(with clock time 215126
12-hour mode display
Long
display) ٌ ←→24-hour mode display

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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). Blinking

Button Press Display

٤ Short Clock time blink

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

Button Press Display

215127
٤ Long Time unit adjust mode

(4) Time unit adjustment

Button Press Display

Digits to be adjusted is blinking
01→12 or 24
Short
ٌ (one hour at each press)
Long 01→12 or 24 (continuous)
12 or 24→01
Short
ٖ (one hour at each press)
Long 12 or 24→01 (continuous)
After adjusting, change to the min-
٤ Short
ute adjust mode.
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 01→59 (one minute at each press) Digits to be adjusted is blinking
ٌ
Long 00→59 (continuous)
Short 59→00 (one minute at each press)
ٖ
Long 59→00 (continuous)
After adjusting, change to the
٤ Short
standard screen.

Note: • Second time display is not available. 215129

• 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.

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 ELECTRIC SYSTEM

5.3.5 How to display the hour meter

Turn the key switch to the ON position. Screen con-
trast can be adjusted while the engine is running. With Hour meter
a short press of the ٤ button, the display alternately
changes between the clock time and the hour meter.

Button Press Display

٤ Short Clock ←→ 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 Key-on time display
long press of the ٌ button.

Button Press Display

Key-on time
↓
ٌ Long Engine-on time Engine-on time display
↓
Seat switch-on time

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 display

Seat switch-on time: Accumulated time the operator

has seated.
This is helpful in comparing the actual working hours 215131

to the actual hours of operation.

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
Up button
error history display.

Button Press Display Down button

ٌٖ٤ Multiple Error history

Enter/display
Error message displays only the F error codes. Error button
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 215125
erased.

Note: Use the service tool to erase the error message

being displayed.

To change the error code display, operate the

Error history Hour meter Error code
ٖ or the ٌ button.
Button Press Display

ٌ Old → New
Short
ٖ New → Old

A long press on the three buttons at the same time

returns to the standard display screen.
Error history display
Button Press Display With , buttons,
error record on the
ٌٖ٤ Multiple Standard display screen 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 Engine warning lamp glows
by placing the key switch to the ON position after solv-
ing 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 fail-
ures, serious failures, and minor failures.

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 Warning lamps within the dotted line boxes blink
is reversed. Also all warning lamps shown in the figure
(right) will 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 Multi-purpose warning lamp glows
is reversed. Also the 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 Name Indicated condition

This lamp glows when the water in the fuel filter

Fuel filter warning lamp
needs to be drained. (diesel model)

This lamp glows when the coolant level is low.

Low coolant level warning lamp
(option)

This lamp glows when the air cleaner element is

Clogged air cleaner element warning lamp
clogged. (option)

When fuel level is low (on E level)

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

On the LPG model, this lamp glows when the LPG

LPG level warning lamp
level becomes low. (option)

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 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 warn- This lamp glows when the parking brake is
Red All models (Standard)
ing lamp applied.

Seat belt warning This lamp glows when the seat belt is not
Red All models (Standard)
lamp fastened.

This lamp glows when charging is not nor-

Charge warning mal.
Red All models (Standard)
lamp (Glows/the lamp glows all the time while the
engine is stopped)

Multi-purpose warn- This lamp glows when a minor failure occurs

Red All models (Standard)
ing lamp or operating cautions are issued.

Torque converter oil

This lamp glows when the torque converter Powershift transmission
temperature warn- Red
oil temperature is not normal. models (Standard)
ing lamp

This lamp glows when the engine oil pres-

Engine oil pressure sure is low.
Red All models (Standard)
warning lamp (Glows/the lamp glows all the time while the
engine is stopped)

Electronic control gaso-

Engine warning
Amber This lamp glows when the engine is failed. line engine models
lamp
(Standard)

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

This lamp glows when sudden acceleration

ProShiftTM indicator
Amber or full reverse (shifting of travel to the oppo- Option
lamp
site direction) activates protective function.

Mast interlock indi-

Amber When mast interlock is activated (glows) All models (Standard)
cator lamp

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ELECTRIC SYSTEM

5.6 Optional Functions

The following optional functions are available: pass-
word authentication, service interval display, over-
speed 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 pre-
vent unauthorized persons from driving the lift
truck. To operate the lift truck, input a 4 digit pass-
word correctly.
(2) Inputting a password
(a) Turn the key switch to the ON position. When

To standard screen
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
215140
Short "←", 9 to 0, and one at a time
ٖ
Long "←", 0 to 9, incrementally

٤ Short Enter (to move to next digit)

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

b) Proceed to the next digit with pressing the
٤ button. After inputting number at the 4th
digit, press the ٤ 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 regis-
tered 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 pass-
word again.
215141
Use the service tool to setup the password
expiration time. (For details, see the service
tool manual.)

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 ELECTRIC SYSTEM

(3) For password registration, change, and cancella-

tion, 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 Service interval display
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.)

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
ProShiftTM control indication 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.)
Note: ONLY service engineers should set up and per-
form 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 instru-
ment panel. (For details, refer to "5.3.6 How to change
types of hour meters")
ŒThree 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 (F-
73) occurs if a time difference in hour meter read-
ings (key-on time) is detected between the instru-
ment 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 (F-
73) 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 or-
der 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

5.8 Troubleshooting
Symptom
Fuel gauge is not displayed.
Lift truck stops, out of gas, even
though the fuel gauge indicates
that some fuel remains.
Back-up lamp is turned off.
LCD is not displayed.
Display changing speed is slow.
LCD screen is too dark.
LCD screen is too light.
Button press (long) is ineffective.
Time becomes 00:00 AM.
Password "0000" and "1111" can-
not be registered.
Overload warning function is not
available.
Exterior alarm lamps do not glow. Trigger speed setting should be 25 km/h (15.5
(Warning buzzer does not acti-
vate.)
Error (F-73) occurs.
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.
Displays of fuel gauge and water
temperature gauge blink.
Note: The conditions above occur due to the characteristics of each of the materials used in the equipment, there-
fore they are not defective.
ELECTRIC SYSTEM
Possible cause Remedy
On the LPG fuel model, the fuel gauge is not dis-
-
played.
On the gasoline LPG dual fuel model, the fuel
Check LPG fuel warning for LPG
gauge shows only gasoline amount. LPG
amount running short.
amount is not shown.
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.
breakage.
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.
When the temperature on the instrument panel
becomes low [0 °C (32 °F) or lower], the screen
-
changing speed becomes slow due to the char-
acteristic of LCD.
Display becomes dark when the temperature on
the instrument panel becomes high (105°C
Adjust contrast with buttons.
[221°F] or higher) due to the characteristic of
LCD.
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.
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.
When the battery is changed, the time resets. Refer to "5.3.4" to adjust the time.
You cannot register "0000" and "1111." -
This function is only available for the lift trucks Use the load meter display option
with the load meter display option. (Manufacturer's option)
Check that the exterior alarm
MPH) or less and trigger load setting should be
function is correctly set up.
5.5 ton or less (depending on the truck models).
This is caused by a difference in hour meter
Use the service tool for transfer-
readingsbetween the VCM and the instrument
ring hour meter properly.
panelwhen the hour meter is transferred.
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.
Check the fuel sensor and the water tempera-
ture sensor and all the connected wires to both -
sensors for electrical short circuit.
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

Color
Wire 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

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 ELECTRIC SYSTEM

7. Troubleshooting
7.1 Starter System

Symptom Possible cause Remedy

Battery discharge Recharge or replace
Short or open circuit Repair or replace
Starter won't crank the
Poor continuity in starter switch Replace
engine even if the key
switch is turned ON. Defective starter or starter relay Replace
Key switch
Neutral switch is not in the neutral Move the direction lever to neutral
position. position.
Engine won't stop even Short or open circuit Repair or replace
if the key switch is
turned OFF. Engine stop solenoid defect Replace or adjust

7.2 Gauges

Symptom Remedy
M/P - Water temperature meter disconnection
1 Check that the connectors are properly jointed.
2 Check the conductivity.
Indicated value is low.
3 Check the display with the water temperature sensor being warmed.
4 Replace the water temperature sensor.
Water tem- 5 Replace the instrument panel.
perature
gauge Check the part number.
1 Check that the parts meet the specification.
Indicated value is inaccurate.
2 Check that the connectors are properly jointed.
3 Replace the water temperature sensor.
M/P - Water temperature meter disconnection
Indicated value blinks.
1 Correction of the short circuit.
Improper setting.
Indicated value is not
1 LPG model does not show the value.
displayed.
2 Incorrect VCM setting.
Check the part number.
1 Check that the parts meet the specification.
Fuel gauge
Indicated value is inaccurate. 2 Check that the connectors are properly jointed.
3 Replace the fuel sensor.
4 Remove fuel tank cap assembly and check it for bent float.
1 Correction of the short circuit.
Indicated value blinks.
2 Remove fuel tank cap assembly and check the wirings in the tank.

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ELECTRIC SYSTEM

7.3 Lighting System

Symptom Possible cause Remedy

Battery discharge Recharge or replace
Blown out fuses Check and replace
Lamp does not glow Short or open circuit Repair or replace
(blink) when the key Remove corrosion from the terminal or
switch is turned ON. Defective grounding wire
retighten.
Defective switch conductivity Replace
Lamps (in Burned out bulbs Replace
general)
Weak battery Check and recharge
Defective switch contact Repair or replace
Lamp glows (blinks) Contact failure terminals Repair
dimly. Dirty lenses Clean
Lenses with water drops Dry and replace the packings.
Bulb's service life expired Replace
Defective light switch conductivity Replace
Head lamp Lamp does not glow.
Burned out bulbs Replace
Defective turn signal switch Replace
Lamp does not blink. Defective turn signal relay Replace
Burned out bulbs Replace
Will not go out. Defective turn signal relay Replace
Turn
signal Bulb wattage is less than the specified Replace it with a specified wattage
lamps Lamp blinks too slowly. value. bulb.
Defective turn signal relay Replace
Bulb wattage is more than the specified Replace it with a specified wattage
Lamp blinks too fast. value. bulb.
Defective turn signal relay Replace
Correct the lamp if it is improperly
Other Back-up lamp does not Defective back-up lamp switch installed, or replace the lamp if it is
lamps glow. internally defective.
Burned out bulbs Replace
Blown out fuses Check and replace
Short or open circuit Repair or replace
Horn does not activate. Defective horn switch Replace
Horn Defective horn Replace
Defective horn button Repair or replace
Defective horn switch Replace
Offensive sound
Defective horn Replace

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 ELECTRIC SYSTEM

Symptom Possible cause Remedy

Alternator belt Slippage Adjust the tension.
Starter coil has defective grounding wire
Repair or replace
or open circuit.
Open-circuited rotor coil Replace
Alternator
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
Regulator Regulating voltage is too low Adjust
Shortage or inappropriate amount of elec-
Refill or adjust the S.G.
Weak trolyte
battery Battery
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 Repair
terminal.
Blown out fuses in the above mentioned
Replace fuse or repair the holder's
Wiring circuit or poorly-jointed connections on the
contact part.
holder.
Open or loose connection between the
regulator terminal F and alternator termi- Repair
nal F
Incorrect connection or short circuit
Repair
between regulator IC and F terminals
Wiring
Battery Defective grounding wire of regulator ter-
Repair
overcharge minal F
Open-circuited pressure coil Replace
Regulator
Regulating voltage is too high. Adjust

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ELECTRIC SYSTEM

8. Electrical Schematic

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