ELECTRICAL SYSTEM

Description .................................................................................................................................. 3 - 1
Console Box ........................................................................................................................ 3 - 1
Electrical Components Mounted on Body .......................................................................... 3 - 2 3
Suggestions for Removal and Installation .................................................................................. 3 - 3
Console box .......................................................................................................................... 3 - 3

Disassembly and Reassembly .................................................................................................... 3- 4

Console Box ........................................................................................................................ 3- 4
Components in Console Box................................................................................................ 3- 5
Combination Meter .............................................................................................................. 3- 6

Major Electrical Components .................................................................................................... 3- 7

Starter Switch (with Anti-restart Lock)................................................................................ 3- 7
Lighting Switch ................................................................................................................... 3- 8
Fuse Box .............................................................................................................................. 3- 9
Spare Terminals .................................................................................................................... 3- 9

Batteries ...................................................................................................................................... 3 - 10

Light Bulb Specifications .......................................................................................................... 3 - 11

AC (Advanced Control System) ................................................................................................ 3- 12

Nomenclature........................................................................................................................ 3- 12
Maintenance Precautions...................................................................................................... 3- 13
Description............................................................................................................................ 3- 14
Operating Principles ............................................................................................................ 3- 15
How to Set Controller .......................................................................................................... 3- 23

Troubleshooting .......................................................................................................................... 3- 28
Starter System ...................................................................................................................... 3- 28
Gauges .................................................................................................................................. 3- 28
Lighting System.................................................................................................................... 3- 29
Battery .................................................................................................................................. 3- 30
Advanced Control System.................................................................................................... 3- 31
1. Preparatory Steps .......................................................................................................... 3- 31
2. Connecting the Checker to the Controller .................................................................... 3- 33
3. Troubleshooting Cases as Examples.............................................................................. 3- 34
4. How to Move the Mast in an Emergency...................................................................... 3- 47
5. How to Clean Harness Connectors and System Components ...................................... 3- 51
6. Troubleshooting Guide for Solenoid Control Valves .................................................... 3- 52

Electrical Schematic.................................................................................................................... 3 - 57
 ELECTRICAL SYSTEM

Description
Console Box 5 4

1 Engine coolant temperature gauge

1 ▲
2 Choke control (Gasoline models)
3
3 Fuel gauge ▲

▲
4 Service hourmeter

▲
5 OK monitor
6 Starter switch
7 Light switch 7

▲
8 Fuse box 2
6

▲
9 Auto-light switch •
8 9

▲
207219

OK Monitor

1 2 3 4 5 6 7 8 9

▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲

207220
Function

No. Indicator light OFF On or flickering Remarks

1 Powershift transmission oil temp. indicator light Normal Overheating Option
2 Air cleaner element indicator light Normal Clogged Option
3 Brake fluid level indicator light Normal Low
4 Engine oil pressure indicator light Normal Low
5 Alternator not charging indicator light Normal Abnormal
Heating
6 Glow plug indicator light completed Heating Diesel models
7 Fuel filter indicator light Normal Drain water Diesel models
8 System indicator light Normal Abnormal Option
9 Engine coolant level indicator light Normal Low

How to check indicator light bulbs

The bulbs are normal if the indicator lights 1, 2, 3, 7 and 9 come ON when the starter switch key
is turned to ❙ (ON) position. (The indicator lights will go OFF when the engine starts.)

3-1
ELECTRICAL SYSTEM

Electrical Components Mounted on Body

8 1 2 5 11 3 4

9
B

C
12

A
10
7
6

1
207212

1 Main harness 9 Power relay (AC vehicle)

2 Fusible link (R.H.) 10 Alternator relay
3 Fusible link (L.H.) 11 Engine cover harness
4 Fuse 12 System harness
5 Fuse A: to Forward/Reverse lever
6 Diode B: to Turn signal switch
7 Diode assembly C: to Ignition coil
8 Diode

3-2
 ELECTRICAL SYSTEM

Suggestions for Removal and Installation

Console Box
Removal

4 5

1
207210

Start by:
Turn off the starter switch, and disconnect the
negative (grounding) cable from the battery.
Removal sequence
1. Disconnect the electrical wires at
connectors 1. (In the gasoline models,
disconnect the choke cable on the engine
side.)
2. Remove screws on cover 2 using a flat-tip
screwdriver, and remove the cover.
3. Remove screws on cover (U-RE) 3, and
remove the cover.
4. Remove screws on cover (U-FR) 4, and
remove the cover.
5. Disconnect the electrical wires at connectors,
and remove directional lever 5.
6. Remove bolts on console box assembly 6, and
remove the console box assembly.
Installation
Follow the removal sequence in reverse.

3-3
ELECTRICAL SYSTEM

Disassembly and Reassembly

Console Box

3
207175

Disassembly Reassembly
1. Remove screws 1 (two) securing the cover. To reassemble the console box, follow the
(Use a flat-tip screwdriver) reverse of disassembly sequence.
2. Remove screws 2 (six) and separate the front
and rear panels.
3. Remove screws 3 (four) securing the instru-
ment panel.

NOTE
To replace the instrument panel bulbs, remove
screws 2 and 3.

3-4
 ELECTRICAL SYSTEM

Components in Console Box

9
6

3
2

1 7

207176

1 Power relay 6 Light switch

2 Power relay 7 Starter switch
3 Turn signal relay 8 Fuses
4 Glow plug relay (diesel models) 9 Auto-light switch
5 Glow plug relay (diesel models)

3-5
ELECTRICAL SYSTEM

Combination Meter
Disassembly

2
3

8
9
206480

Sequence
1 Instrument panel 6 Meter case
2 Dial 7 Printed circuit
3 Engine coolant temperature gauge 8 Bulb
4 Service hour meter 9 Socket
5 Fuel gauge

CAUTION
Be careful not to damage the printed circuit
when disassembling the combination meter.

Reassembly
To reassemble the combination meter, follow
the reverse of disassembly sequence.
Bulb replacement
For bulb replacement, remove the socket from
the printed circuit by turning it counterclock-
wise. For configuration of the indicator lights,
refer to “OK Monitor.”

3-6
 ELECTRICAL SYSTEM

Major Electrical Components

Starter Switch (with Anti-restart Lock)
This switch has a built-in anti-restart lock, so
the key cannot be turned from ❙ (ON) to
(START) position while the engine is run-
ning. The gasoline and diesel models use the
same starter switch. In the diesel models, ❙
(ON) position of the switch is for energizing the
glow plugs.

(OFF)
(ON)

(START) B

203561A
Connection for gasoline models
Terminal B M S
Starter, neutral switch
Key Component Fuse box, battery, Fuse box, fuel-cut (powershift transmis-
position alternator solenoid sion models)
(OFF)
❙ (ON)
(START)

Connection for diesel models

Terminal B M S
Fuse box, glow Fuse box, fuel-cut
Key Component plug relay, battery solenoid, glow plug timer, Neutral switch,
position alternator glow plug timer relay glow plug timer
(OFF)
❙ (ON)
(START)

3-7
ELECTRICAL SYSTEM

Lighting Switch

OFF 1st 2nd Knob position

8 (0.3)
8 (0.3)
Stroke, mm (in.)

206481

Connection chart
Terminal B T H P
Tail lamps, licence
Knob Component Battery plate lamp, Head lamps Turn signal lamps,
position (fuse) instrument lamp clearance lamps
(OFF)
1st position
2nd position

3-8
 ELECTRICAL SYSTEM

Fuse Box

Code Amp Circuit

Backup lamps (manual transmission
A 10A
models), stop lamps
A
Instrument panel lamp, turn signal
B B 15A lamps, backup lamps (powershift
C transmission models)
D C 15A
Spare terminal, engine thermo
E switch
F Tail lamps, clearance lamps,
D 15A
working lamps (option)
G
E 15A Head lamps
H
F 10A Spare fuse
J
G 10A Horn
H 15A Spare fuse
J 10A Spare fuse

101441D

Spare Terminals
The spare terminal cord extends from the fuse box
in the console box. (Another spare terminal is
located on the chassis-side main harness.)
The spare power supply terminal cord measuring
approximately 50 mm (2 in.) extends from the
junction of the transmission power supply located
on the right side of the main harness. This termi-
nal is secured to the main harness with red vinyl
tape.

Cord color: Lg (light green)

Removing the console box rear panel will expose

this spare terminal which is fastened to the harness
protector with vinyl tape.
Spare
terminal

207209

3-9
ELECTRICAL SYSTEM

Batteries
1. Electrolyte specific gravity (S.G.) reading and battery condition

Electrolyte S.G. reading

Battery condition Adjustment
at 20°C (68°F)

1.280 to 1.265 Battery is fully or well Check each cell for S.G.
charged.

1.260 to 1.225 Battery is half charged. Recharge the battery. Make sure there is neither faulty
component, short-circuited cord nor corroded connection in
the system.

1.220 or lower Battery is discharged. Recharge the battery. If difference in S.G. among the cell
is large, adjust the S.G. during recharging.

When S.G. difference A cell with a low S.G. Recharge until voltage and S.G. stabilize and have remained
among cells is more is in shorted condition. constant for at least 2 hours.
than 0.040 Some electrolyte has During recharging, adjust the S.G. to anywhere between
been lost. Too much 1.280 and 1.265.
electrolyte, or water in If difference in S.G. among the cells is more than 0.040 and
electrolyte, too. a low S.G. is found in certain cells only, replace the battery.

2. Relationship between electrolyte specific
gravity and charging rate
To check the battery for charging, take hydrometer
readings on its electrolyte: the battery may be
deemed to be fully charged if the readings are
between 1.280 and 1.265 at normal temperature. The
tendency of the charging system can be told from the
way the electrolyte level goes down to expose cell
plates. If refilling (with distilled water) is necessary
every month or so, the system is tending to
over-charge the battery. If refilling is not required for
over 3 months, it is likely that the system is
inadequately charging.
3. Precautions for battery charging
(1) In slow-charging a dead battery, the charging
current should be about 1/10 the capacity of the
battery to be charged.
(2) In quick-charging a battery, the battery capacity
in ampere should not be exceeded.
(3) During charging, adjust the charging current to
prevent the battery electrolyte temperature from
rising beyond 45°C (113°F).
(4) When connecting the cables to the battery, begin
with the cable for the positive (+) terminal.
When disconnecting them from the battery, begin
with the cable for the negative (-) terminal.
CAUTION
Be sure to turn off the starter switch and
lighting switch before disconnecting or
connecting the battery cables to prevent the
IC regulator from suffering damage.

3-10
 ELECTRICAL SYSTEM

Light Bulb Specifications

No. of Color of Watts
Light bulbs Shape Remarks
bulbs lens 12 V

Head lamps 2 Colorless 55

Turn
signal 2 Amber 27 Optional
Combination lamps
lamps (front)
Clearance Optional
2 Colorless 10
lamps
Turn
signal 2 Amber 23
lamps

Combination Tail/stop
lamps 2 Red 8/23
lamps (rear)

Backup
lamps 2 Colorless 10

Working lamps 4 Colorless 55 Optional

(front and rear)

License plate lamps 1 Colorless 10 Optional

Instrument panel lamps 2 Colorless 3.8

OK monitor indicator lamps 11 Colorless 3

204964

3-11
ELECTRICAL SYSTEM

AC (Advanced Control System)

Nomenclature

1
8

2
9

3
10

11 4

12
6

205003A

1 Full free switch (for full free mast) 7 Seat switch

2 System indicator light 8 Lowering speed selector switch
3 Light sensor 9 Safety switch
4 Auto-light switch 10 Controller
5 Solenoid control valve 11 Joystick levers (finger-control system)
6 Hydraulic (pressure) transducer 12 Travel speed pickup (option)

3-12
 ELECTRICAL SYSTEM

Maintenance Precautions
The AC model contains a microcomputer. Follow-
ing are the precautions to be observed in perform-
ing any maintenance on the AC model.
(1) When removing the controller cover, make
proper provisions to keep out rain, washing
water splashes and the like.
(2) After using the controller setting switch, check
to make sure the control system is in keeping
▲
with the truck specifications.
Controller 101489
NOTE
Improper setting of the system will result in
inability to lower the forks in an inching man-
ner. (See “How to Set Controller.”)

(3) Before performing repairs which require

welding, be sure to disconnect the cable from
the battery positive (+) terminal and the con-
troller from the system at its connectors.
(4) When handling the controller by hand, never
Setting
touch its electrical terminals, or your body switches
charge will rupture some of the electronic ele- 204989
ments in the internal controller circuits.

3-13
ELECTRICAL SYSTEM

Description
1. Finger-control system
This system, unlike the conventional mechanical
control, is electronically actuated to help reduce
the effort required of the operator in moving the
control levers for lift, tilt and attachment func-
tions.

101466

[Features] Proportioning
(1) The flow regulator valve has been discontin- solenoids
ued. In this system, the load acting on the lift Hydraulic
cylinders is detected to control the flow of oil transducer
returning from the lift cylinders to prevent the
load from lowering unsafely rapidly at the
start of lowering.

Unload solenoid
204991

(2) In the full free masts, more oil returns from the
1st lift cylinder than from the 2nd lift cylinders
to allow the 1st lift cylinder to retract faster in
order to add to productivity.
(3) The lowering speed selector switch insures
smooth fork and mast movement no matter
how abruptly the operator may move the con- ON
trol levers. This switch is ideal for handling of
fragile loads.
OFF

ON: 350 mm/s (69 fpm)

OFF: 500 mm/s (98 fpm)

204992

3-14
 ELECTRICAL SYSTEM

(4) This system provides the following safety functions:

(a) The lift, tilt and attachment functions are
not performed even if the control levers are
moved when the engine is not running.
(b) The lift, tilt and attachment functions are
not performed even if the control levers are
moved when the safety switch is in ON
(pushed) position.
(c) The lift, tilt and attachment functions are
not performed even if the control levers are
moved when the seat switch is not ON (the
operator is not seated).
(d) The system indicator light in the OK
monitor alerts the operator to problems
occurring in the electrical system and, at
the same time, stops function. (If any prob-
lem occurs in the lift system, for example,
the system becomes inoperative.)

2. Auto-light system
The head lamps are under the control of switch and
sensor. With the auto-light switch ON, the head
lamps turns ON automatically as the truck is dri-
ven into a dark area. The head lamps can be turned
ON or OFF manually.

101489

Operating Principles
1. Finger-control system
(1) The system is activated by turning ON the
safety switch (when the engine is running and
the seat switch is ON (when the operator is
seated).
(2) As the control levers (joysticks) are moved to
operate the equipment (mast and forks), the
amount of lever movement will be translated
into an electrical signal: this signal goes into
the controller, in which it is converted to and
output signal. At this point the controller
issues and ON signal to the unload solenoid,
thereby turning ON this solenoid to introduce
hydraulic pressure into the control valve. The
system is now ready to actuate the equipment.
The output signal applies to the proportioning
solenoid selected by the direction of the joy-
stick movement. Inside the control valve of
that solenoid, its spool is forced to slide, alter-
ing the internal oil passage to direct the oil to
the corresponding cylinders. The spool keeps

3-15
ELECTRICAL SYSTEM

on sliding until it comes to the position at (6) Power supply to the controller is initiated
which the pressure of its pilot chamber from the starter switch through a 10-Amp
becomes equal to the force of its centering fuse and safety switch. Pressing this switch
spring. In the meantime, the cylinder into OFF position shuts down the controller
extends or retracts against its load. As the without shutting down the engine.
joystick is moved back to its neutral posi- (7) With the starter switch and safety switch
tion, the signal to the proportioning sole- turned ON, the unloading solenoid and pro-
noid dies to lower the pilot chamber pres- portioning solenoid are under control of the
sure and allow the centering spring to push joysticks. With the engine shut down (and
the spool to its neutral position, whereby hence the hydraulic pump standing still),
the line to the cylinder becomes shut off: the spools in the control valves are inopera-
the pressure in the line is now trapped, tive because no pressure develops in their
holding the cylinder there. At the same pilot chambers. Consequently, the equip-
time, the ON signal to the unload solenoid ment remains inoperative even when the
goes OFF, so that the part of the system starter switch and safety switch are turned
actuating the equipment goes into no-load ON.
state.
(3) When the joystick is moved in the direction
for lowering the forks, the output signal
(from the controller applying to the propor-
tioning solenoid is produced by the lever
stroke signal and liftload pressure signal
coming from the Hydraulic transducer.
With this signal, the proportioning solenoid
operates to position the valve spool in such
a way that the flow of oil returning from the
lift cylinders will by constant regardless of
the load acting on these cylinders.
(4) The full free mast is equipped with a full
free switch. This switch is a sort of detector
designed to go ON just when the 1st lift
cylinder starts retracting after the 2nd lift
cylinders has retracted. As the full free
switch turns ON, the output signal (for con-
trolling the retracting speed of the 1st lift
cylinder) changes to that for controlling the
retracting speed of the 2nd lift cylinders, so
that there will be no appreciable changes in
lowering speed during the transition from
1st to 2nd lift cylinders. This feature is for
lowering action only: the output signal
remains unaffected for lifting action.
(5) If the lowering speed selector switch is
turned ON, the effect of a change in lever
stroke signal upon the output sinal is retard-
ed. Thus, with this switch turned ON, the
equipment will not move quickly even if
the lever is moved quickly.

3-16
 Finger-control system schematic

Safety switch (OFF)

Control (joystick) box
Control Lowering Safety
Console box lever speed selector switch
(joystick) switch (ON)
System
indicator Power supply
light
Seat switch
Starter (ON)
switch ON-OFF signal
(ON)
Lever stroke signal
Fuse ON-OFF signal
10A
Power supply
ON-OFF signal

Proportioning Power supply

solenoid
Proportioning

3-17
Full free solenoid
Battery
switch (full Spool Pilot pressure
free mast) passage Controller
Solenoid
control Centering
Unload valve spring
solenoid
Pilot pressure pas-
sage Setting
window
Detail of control valve
Lift cylinder ON-OFF signal
Flow control signal
Hydraulic
transducer Lift load pressure signal
(for lift line
only)

Hydraulic
pump

204993
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM

(8) In addition to the functions explained above,

the controller monitors the supply voltage and LED (red)
the electrical connections for the control levers Rubber cover
(joysticks), solenoids and other input/output
devices, and alerts the operator to a problem,
if occurs, by flickering the system indicator
light and turning ON this light and also LED
(as shown in the chart below). Such a problem
is usually a fault in the harness or connector
and must be located by inspecting. The 204994
hydraulic components such as pump control
valve, etc. are not monitored.
System
LED flickering pattern Problem detected Effect indicator
light
LED flickers

1.2 sec. 1.2 1.2 1.2

(Normal) OFF

Open- or short-circuit in No power supply

control lever (with starter to particular
LED flickers

0.3 2.1 0.3 2.1 switch in ON position) system

Open- or short-circuit in No power supply
ON
hydraulic transducer to lift system
Power supply to
Open- or short-circuit in
systems not
travel speed pickup (option)
affected
Supply voltage too high (over No power supply
LED flickers

0.6 0.6 20 volts or too low under 8 to all systems

volts)
ON
No power supply
Open- or short-circuit in
to particular
solenoid
system
1.2 0.6 0.6 0.6 0.6 1.2 No power supply
Control lever neutral position
LED flickers

to particular
displaced
system
Flickers
Open- or short-circuit in
control lever (with starter
switch in ON position)
LED flickers

1.2 0.6 0.3 0.9 0.3 0.9 0.3 0.3

Seat switch OFF, of open- No power supply
circuit in it to all systems Flickers

LED remains ON Problem in controller

NOTE: Any problem does not cause the engine to shut down.
204995

3-18
 ELECTRICAL SYSTEM

2. Auto-light system
(1) The auto-light system turns ON the head Example: The auto-light system functions
lamps automatically when the truck is dri- regardless of ON-OFF of the seat
ven into a dark area, with the starter switch switch. The finger-control system
in ❙ (ON) position, the safety switch ON and functions even if the light sensor is
the auto-light switch ON. The controller is faulty.
common to this system and the finger-con-
trol system but the circuit of the system is
independent so the components of these
systems do not affect each other in opera-
tion.

Light sensor Controller (in engine room)

207235 101489

Auto-light switch Power relay

102454 207223

Major Components of Auto-light System

NOTE
The controller has no auto-light system diag-
nosing function

3-19
ELECTRICAL SYSTEM

(2) The light sensor is basically a resistance device,

whose resistance is compared with that in the vari-
able resistor (the auto-light sensitivity adjusting
knob) inside the controller. The sensor resistance
increases as brightness decreases. When, in opera-
tion, the sensor resistance becomes greater than the
resistance in the variable resistor, the comparing cir-
cuit energizes the power relay to close its contacts
to turn ON the head lamps.

With auto-light switch ON, starter switch

❙ (ON) and safety switch ON

Control (joystick) box

Head lamp Safety switch
License plate (ON)
lamp
Tail lamp Power supply
Instrument panel lamp
Console box
Clearance Light
lamp B PHT switch

Starter
switch (ON)
10A Controller
(ON)
Auto-light
20A adjusting knob
Auto-light
switch (ON)
Battery
Setting
Dark window
Light
sensor Power relay
(ON)

204997A

Operation — 1

3-20
 ELECTRICAL SYSTEM

(3) With the auto-light switch turned OFF, the
light switch can be used to turn ON a light
selected by the position of this switch. Even
under this condition, the power relay goes
ON or OFF in response to changes in ambi-
ent brightness but this does not affect the
light turned ON by the light switch. With
auto-light switch OFF and starter switch
and safety switch ❙ (ON)

With auto-light switch OFF, starter

switch ❙ (ON) and safety switch ON

Control (joystick) box

Head lamp License plate Safety switch
lamp (ON)
Tail lamp Power supply
Instrument panel lamp
Console box
Clearance Light
B PHT switch
lamp
Starter
switch (ON)

10A Controller
(ON)
20A
Auto-light
switch (OFF)
Battery
Setting
Dark window
Light
sensor Power
relay (ON)

204998A

Operation — 2

3-21
ELECTRICAL SYSTEM

(4) Turning OFF the safety switch with the light switch is OFF, the light switch is effec-
auto-light switch ON causes the power tive and can turn ON each selected light,
relay to remain OFF. Under this condition, regardless of the safety switch and starter
all lamps will not come ON. If the auto- switch.

With auto-light switch ON and safety

switch ON
Control (joystick) box
Head lamp
License plate Safety switch
lamp (OFF)
Tail lamp Power supply

Console box
Clearance Light
lamp B PHT switch
Starter
switch

10A Controller
(OFF)
20A
Auto-light
switch (ON)
Battery Setting
Dark window

Light
sensor Power
relay

204999A

Operation — 3

Operation logic:
Auto-light switch ON
Auto-light switch OFF
Dark Bright
1st 2nd 1st 2nd 1st 2nd
Light switch OFF OFF OFF
position position position position position position
Clearance/tail/
license plate lamps
Head lamps

3-22
 ELECTRICAL SYSTEM

How to Set Controller

Set the controller on any of the following occa-
sions:

Occasion Setting
After mast has been changed, or an optional Resetting of setting switches
equipment added
When auto-light system is adjusted Adjustment of brightness at which light sensor operates
After control valve lift section solenoid has Adjustment of maximum lowering speed (when required)
been replaced (or control valve replaced)
After controller assembly has been replaced • Resetting of setting switches
• Adjustment of maximum lowering speed (when
required)
• Adjustment of brightness at which light sensor operates
(when required)

Setting window
(with rubber cover)

Controller checker
To be installed with this side up →

connection jack (with

rubber cover)

Connectors

Setting window (without rubber cover)

Auto-light sensitivity adjusting knob
To be installed with this side up

Lowering speed adjusting knob

LED (red)
→

Setting switches (dual inline package)

205000

3-23
ELECTRICAL SYSTEM

1. Setting switches
The controller has a total of 16 setting switches.

NOTE
Use a screwdriver to move each switch. The
switch is made of resin; be careful not to dam-
age the switch head in setting.

205001
(1) Switch setting pattern (Black dot indicates
switch head.)

Option A Option B Not used Transmission Engine Not used Be sure to

(to be set (to be set set to OFF
to NO) to NO) Manual Gasoline Controller
Setting Setting check
Yes Yes D G ON

No No T D OFF
Diesel
Powershift
OFF

Up
Note: Options A, B and C will be
introduced in OPTION
8
7
6
5
4
3
2
1

CATALOGUE later.

OFF
8
7
6
5
4
3
2
1

Speedo-
meter
with Option C
No. of Pattern
indicator (to be set spools Truck Pattern
light to NO) Mast Pattern
2V 15K to 18K
(option) 2-stage
panora-
mic 3V 20K to 25K

Yes 2-stage
Yes full free 4V 30K
No No 3-stage 5V 35K
full free

205002

(2) Example of setting Setting

Truck: GP15K No No T G OFF
No. of spools: 3V
Mast: 4V15A (2-stage panoramic)
Option: Speedometer with indicator light

205053
Speedometer No Dual- 3V 1-ton
option stage class
Yes panoramic

3-24
 ELECTRICAL SYSTEM

2. Failures resulting from incorrect setting (5) Incorrect setting for travel speed option
(1) Incorrect setting for truck size (1-ton, 2-ton, If the setting is made for YES of the trame
3-ton and 3.5-ton models) speed pickup (mounted on the transmis-
(a) Incorrect setting will result in abnormal sion) though such a device is not installed,
lowering speed and inching feel. If a set- the system indicator light will flicker
ting for a 1-ton model is made on a 33-ton but the equipment will be actuated. (This
mode, for example, the lowering speed setting is taken as open- of short-circuit in
will be abnormally low. If a setting for a the travel speed pickup.)
3-ton model is made on a 1-ton model,the (6) Incorrect setting for controller check (Be
lowering speed will be abnormally high. sure to set to OFF.)
(b) If the travel speed option (load meter, If it is set to ON, the equipment will not be
speedometer, travel speed indicator light, actuated even if the joysticks are operated.
etc.) is set, the travel speed will not be
read correctly.
(2) Incorrect setting for number of control
valve spools
(a) If the setting is made for the number of
spools greater than is actual, the system
indicator light will flicker, and the
equipment will not be actuated. (Such a
setting is taken as open- or short circuit in
the control valve solenoid or in the joy-
sticks.)
(b) If the setting is made for the number of
spools less than is actual, only the devices
equal to the number of the set spools will
be actuates.
(3) Incorrect setting for mast
(a) A setting for a dual-stage full free mast or
triple-stage full free mast on a truck with
dual-stage panoramic mast will not affect
the lowering speed.
(b) If the setting is made for dual-stage
panoramic mast on a truck with dual-stage
full free or triple-stage full free mast, the
lowering speed of the 1st lift cylinder will
be abnormally low. This setting will not
affect the lowering speed of the 2nd lift
cylinders.
(4) Incorrect setting for transmission and
engine
If the travel speed option is set, the travel
speed will not be read correctly.

3-25
ELECTRICAL SYSTEM

3. Lowering speed adjusting knob

(1) This knob is for increasing or decreasing the
maximum lowering speed.
(2) The arrow of the knob has been set to “8”.
(3) The lower the figure, the more the lowering
speed is decreased. “A” thru “F” mean “10”
thru “15”.

NOTE
1) Use a screwdriver to turn the knob. 205004
2) This knob can be turned endlessly in both
directions.
3) Be careful not to damage the groove of
the knob when putting a screwdriver.

4. Auto-light sensitivity adjusting knob

(1) This knob is for adjusting the sensitivity level
at which the auto-light system turns ON and
OFF the head lamps.
(2) The knob has been set as shown.
(3) The more the knob is turned to the right, the
lower will be the sensitivity at which the sys-
tem turns ON and OFF the head lamps.

NOTE 205005
1) Use a screwdriver to turn the knob.
2) Be careful not to damage the groove of the
knob when putting a screwdriver.

3-26
 ELECTRICAL SYSTEM

5. Working precautions
(1) When installing the controller, position it cor-
rectly. Be careful not to turn upside down.
(2) When resetting or adjusting the controller on
the truck, be sure to turn OFF the starter
switch and light switch.
(3) When removing the rubber cover, check to see
if the sealing label was removed before. (If
this label shows a sign of removal, ask the user
for removal of the label.) Sealing label
205037
(4) Be careful not to damage the rubber cover
when it is off the controller.
(5) Do not let any foreign matter fall into the con-
troller through setting window.

3-27
ELECTRICAL SYSTEM

Troubleshooting
Starter System

Complaints Possible causes Remedies

Starter will not a) Dead or weak batter Recharge or replace.
crank engine b) Short or open in circuit Repair or replace.
c) Poor continuity in starter switch Replace.
Starter switch

d) Starter and starter relay defective Replace.

e) Forward-reverse lever not in neutral position Move the lever to
neutral position.
Turning off starter a) Open or short in circuit Repair or replace.
switch will not stop b) Engine stop solenoid defective Replace or readjust.
engine c) Control timer defective Replace.

Gauges

Complaints Possible causes Remedies

Will not indicate a) Open or short circuit Repair or replace.
at all
Temperature gauges

b) Gauge internally defective Replace.

c) Gauge unit defective Replace
Will not indicate a) Gauge or gauge unit not of the type called for Replace.
accurately b) Loose terminal connection Repair.
Will indicate higher a) Ground between gauge and gauge unit grounded Repair.
temperature than is b) Gauge internally defective Replace.
actual

Will not indicate a) Open or short circuit Repair or replace.

at all b) Gauge internally defective Replace.
c) Gauge unit defective Replace.
Will not indicate a) Gauge or gauge unit not of the type called for Replace.
accurately b) Loose terminal connection Retighten.
Fuel gauge

Will indicate “Full” a) Circuit between gauge and gauge unit open Repair.
regardless of or shot
amount of fuel left b) Gauge internally defective Replace.
in tank
c) Gauge unit defective Replace.

Will indicate a) Circuit between gauge and gauge unit grounded Repair.
“Empty” regardless b) Gauge unit defective Replace.
of the amount of c) Gauge internally defective Replace.
fuel left in tank

3-28
 ELECTRICAL SYSTEM

Lighting System

Complaints Possible causes Remedies

Will not light a) Dead or weak battery Recharge or replace.
b) Fuses blown out Check and replace.
c) Open or short in circuit Repair or replace.
d) Poor grounding Clean ground spot and
re-make connection.
Lamps-general

e) Bulbs burnt out Replace.

Will light dimly a) Dead or weak battery Check and recharge.
b) Burned contact points in switches Repair or replace.
c) Loose terminals Retighten.
d) Dirty lenses Clean.
e) Waterdrops inside lenses Dry and replace
packings.
f) Bulbs expired service life Replace.
lamps
Head

Will not light a) Lighting switch defective Replace.

b) Bulbs burnt out Replace.

Will not flicker a) Turn signal relay defective Replace.

b) Bulbs burnt Replace.
Turn signal lamps

Will not go out a) Turn signal switch defective Replace

b) Turn signal relay defective Replace.
Will flicker too a) Wrong wattage of bulbs Replace.
slow b) Weak battery Recharge or replace.
c) Turn signal relay defective Replace.
Will flicker too fast a) Wrong wattage of bulbs Replace.
b) Turn signal relay defective Replace.
Backup lamps will a) Backup lamp switch defective Correct if improperly
not light installed: replace if
Other lamps

internally defective.
b) Bulbs burnt out Replace.
License number a) Lighting switch defective Replace.
plate lamps will not
light b) Bulb burnt out Replace
Will not give blast a) Fuse blown out Check and replace.
of sound b) Open or short in circuit Repair or replace.
c) Horn switch defective Replace.
Horn

d) Horn defective Replace.

e) Horn button defective Repair or replace.
Will give ugly blast a) Horn switch defective Replace.
of sound b) Horn defective Replace.

3-29
ELECTRICAL SYSTEM

Battery

Complaints Possible causes Remedies

Tends to run down a) Drive belt slipping Readjust.
rapidly * Alternator
b) Stator coil grounded or open-circuited Repair or replace.
c) Rotor coil open Replace.
d) Brushes poorly seating on slip rings Replace brushes if worn.
Clean holder and polish
slip rings.
e) Diode ruptured Replace.
* Regulator
f) Regulated voltage setting too low Readjust.
* Battery
g) Not enough electrolyte or wrong proportion of Refill and check specific
acid to water gravity.
h) Battery cell plates deteriorated (forming, possibly Replace.
internal short-circuit)
i) Terminal connections loose Clean and retighten.
* Wiring
j) Open or loose connection between starter switch Repair.
and regulator IC terminal
k) Fuse blown, or loosely set in holder Replace and repair.
l) Open or loose connection between F terminals of Repair.
regulator and alternator
Tends to get overcharged * Wiring
a) Regulator IC and F terminals shorted or miswired Repair.
b) Poor grounding of regulator F terminal Repair.
* Regulator
c) Pressure coil open-circuited Replace.
d) Regulated voltage too high Readjust.

3-30
 ELECTRICAL SYSTEM

Advanced Control System

1. Preparatory steps
(1) This system comes into operation when the
starter switch is turned to the ON position and
the safety switch is turned ON. The finger
control comes into operation after the seat
switch has been closed (the operator has been
seated) and the engine has been started.
(2) Before deciding to replace a blown fuse,
check to be sure that the harness connectors in
the power line are all in sound condition, free
of any sign of short-circuit.
(3) The use of the test-use connector (special
tool) is prescribed for checking the connector- Tester prods
to-connector (special tool) is prescribed for
checking the connector-to-connector lines for
continuity and for reading the voltage across Test-use connector
two terminals and the ohmic resistance of a
line.
(4) The controller’s capabilities include that of
self-diagnosis (for the control system only)
function. By this function, any trouble symp-
tom occurring in energized state goes into
memory as trouble data. (This memory capa-
bility is limited, however, to the latest single
205038
case of trouble symptom for one input/output
channel: previous symptoms are not memo-
rized, meaning that their chronological order
and data are not traceable). The trouble symp-
tom data, limited as above, can be read out
through the controller checker. If, however,
any of the following steps is taken, the stored
data will be erased and lost:

(a) Disconnecting battery lead from the
battery terminal, positive (+) or nega-
tive (–).
(b) Uncoupling CN1 or CN4 connector
on the console box.
(c) Removing the 10-A fuse (6th fuse as
counted from top) in the fuse box.
(d) Uncoupling CN53 connector on the
controller.
(e) Turning starter switch or safety switch
ON and OFF twice in succession.
(Turning the switch in this manner is
the same thing as performing the
cycle of energizing and de-energizing
the controller twice in succession.)

3-31
ELECTRICAL SYSTEM

(5) When coupling or uncoupling a connector, (6) Before starting troubleshooting work,
make sure that the starter switch is OFF. check to be sure that the following condi-
Never try to insert or pull off the connector tions are met on the machine side:
half forcibly or its pins will suffer damage.
When coupling a connector, be sure that the
inserted half snaps into its self-locking
position.

Conditions in
Check item What to check Remedy
the machine
Starter switch OFF Hydraulic line Hoses, pipes and connectors for Repair leaking or
Safety switch OFF damage and sign of leak. damaged parts.
Hydraulic devices Check control valve and hydraulic Repair damaged
cylinders for damage and oil leaks. or leaking parts,
if any.
Electrical connectors Check connectors for tightness, burns Repair.
and wires and breakage; check wires for insulator
stripping and signs of rubbing.
Power source voltage Check to be sure that voltage is at least Correct alternator
10 V as read across battery’s terminals. or battery if this
voltage is too low.
Engine at standstill System check lamp Check to be sure the lamp goes ON and Replace lamp
Starter switch ON OFF properly; if not, check its bulb. bulb if blown.
Safety switch ON Auto-light unit After making sure check light bulb is Refer to Case 1
OK, see if auto-light works properly. and 2.
LED indicator (red) Be sure that red LEDs go ON and OFF Proper functioning
in the controller correctly. of LED indicator
is essential to
troubleshooting.
Trouble-data reading Connect controller checker to controller (Proper function-
function of controller and check its input and output actions. ing of controller
is essential to
troubleshooting.)
Engine running Hydraulic devices With your hands kept off control levers, Refer to the sec-
Safety switch ON see if solenoid valves and hydraulic tions dealing with
pump are making any abnormal sound. control valve and
hydraulic pump,
respectively.
Operate control lever to see if any (Proper function
abnormal sound, indicative of flow of solenoid valves
throttling, comes from control solenoid is essential to
valve or from any other solenoid valve. troubleshooting.)
Check to see if unload solenoid valve
operates properly, in response to a lever
being moved.

3-32
 ELECTRICAL SYSTEM

Conditions in
Check item What to check Remedy
the machine
Engine running Work attachments Check each work attachment for the
Safety switch ON following:
(a) Does it work properly? Refer to Case 3.
(b) Does it “inch” properly? Refer to Case 4.
(c) Does mast go down with proper
speed? Refer to Case 5.
(d) (Full-free mast)
When lowering, do 1st and 2nd
lift cylinders move with the
same descending speed? Refer to Case 6.

2. Connecting the Checker to the Controller

(1) Remove the controller cover.

205039

(2) Remove the rubber cap.

Rubber cap

205040

3-33
ELECTRICAL SYSTEM

(3) Plug the checker cable into the controller and Checker cable
checker.
Special tool needed
Controller checker 91105-00100
Checker cable 91105-00300 Controller checker

NOTE
Pushing each plug end fully into the socket.

(4) First, turn ON the starter switch, and then the 205041
checker’s power switch. After this, select the
forklift menu (by referring to the checker
instruction book).

NOTE
Before plugging in or unplugging the checker
cable, be sure to have the starter switch turned
OFF.

3. Troubleshooting Cases as Examples

(1) Explanatory notes and reminders
(a) In the text and diagrams to follow, electrical
connectors are abbreviated CN. An individ-
ual CN will be identified by a number suffix
(used in the electrical wiring and connection
diagrams).
(b) In the flowchart diagrams, the numerical
notation in the box, , is a circuit num-
ber. The terminals of a connector too will be
identified by circuit numbers. As to the con-
figuration of terminals in each connector,
refer to the wiring diagram.
(c) The wiring diagrams show the connector’s
Male Female
terminal configuration on its male side:
remember, the configuration on the female (As seen from the connector’s end face)
side is a mirror image of the male-side con- 205042
figuration.

3-34
 ELECTRICAL SYSTEM

(d) In the trouble cases cited hereunder, “check

the connector coupling” means “uncouple and
then couple the connector, inserting the con-
nector, inserting the connector half all the way
to self-locking position.”
(e) In the trouble cases cited, “continuity check” Component Trouble symptom
will be directed for some harnesses. This
direction applies also to “check the connector Control levers Short-circuit
coupling”: when checking a connector as in Solenoid valves Short-circuit, oil leakage
(d), above, be sure to check the connector for
circuit continuity immediately after coupling NOTE
it.
(f) When reading a voltage with a circuit tester, For the method of deleting the data stored
be sure to discriminate polarities, (+) and (–), in the controller, refer to (a) thru (e), 1. (4).
so that the tester will not suffer internal dam-
age.
(g) Trouble data stored in the controller, as
explained in 1. (4), can be read out by the con-
troller checker. Such a read-out is the “data on
trouble as was” and must not be interpreted as
data on the trouble confirmed to exist. To
illustrate this point, assume that the data are
currently displayed in the form shown on the
right and that the indicated faulty conditions
have already been corrected by repair. In this
case, the work attachment in question remains
inoperative. Thus, it is important that, each
time a detected malcondition is corrected and
eliminated, the trouble data be changed
promptly to reflect the correction effected.

3-35
ELECTRICAL SYSTEM

(h) Not withstanding what is said in (g), above,

the “data on past trouble,” as read into the
checker from the controller, can be useful
information in checking for such malcondi-
tions (like an open due to loose contact in a
circuit) as may not show up later at the time of
performing a troubleshooting work. The dia-
gram, below, illustrates and example of pre-
carious type of malcondition:

The malcondition on the left, detected at the

An open time of trouble occurrence, will go into the
data as “open-circuit” if it happens to present
an open.
Work device
Trouble symptom data Open-circuit
Controller

Controller checker

Supposing that, as you start the troubleshooting

work with the controller checker, the near-open
fault happens to be in a precariously closed
condition: then, the controller checker will
A near-open fault
indicate the circuit of the device in question as
normal whereas the data held in the controller
reads “open-circuit” for that device.
Work device
Trouble symptom data Device
Controller Past Open-circuit
Now Normal

205043

3-36
 Note: Circuit Nos. are indicated by small-character numbers.
Auto-light System Schematic

Control (joystick) box

Head lamp
Safety switch

Tail lamp License plate lamp Power supply

Instrument panel lamp

Console box
Clearance Light
lamp B P H T Sensitivity
switch
adjusting
Starter knob
(2) Auto-light System Troubleshooting

switch Turn-ON

Bright Dark

3-37
10A 201

Controller
20A
Auto-light
switch Battery 182
OFF ON 183
Setting 186
window 187
169
177
173
184
Light
sensor
Power
relay ON or OFF signal
184
173
177
169

206475
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM

(a) Case 1 : Head lamps will not go ON in darkness.

Troubleshooting procedure

Is the LED (red) ON in the NO Refer to Case 7:

controller? “Controller’s LED (red) will not go ON.”
Yes

Do the head lamps go ON

Yes Set the sensitivity to make the lamps turn ON
when the sensitivity is re-
at the desired degree of darkness.
adjusted?
NO

Do the head lamps go ON Check CN51, CN52 and CN53 for continuity.
when circuit 173 (CN51) is Yes If these connectors are OK, it means that the
grounded (shorted to the controller is in faulty condition and needs to
ground)? (Does this shorting be replaced.
cause the power relay to trip ?)
No

Have circuit 184 shorted to
circuit 201 at the male side
of CN4. Then, ground circuit
173 : will this turn ON the
head lamps?
Check the circuits of power relay and auto
No light switch (in the console box) for continu-
ity. As necessary, repair or replace.
Yes
Check harness B for continuity and repair
faulty part or line, if any.

3-38
 ELECTRICAL SYSTEM

(b) Case 2: Head lamps will not go OFF when bright.

Troubleshooting procedure

Is the LED (red) ON in the NO Refer to Case7:

controller? “Controller’s LED (red) will not go ON.”
Yes

Do the head lamps go OFF

Yes Set the sensitivity so that the lamps will go
when the sensitivity is re-
OFF at the desired degree of darkness.
adjusted?
NO

Do the head lamps go OFF Yes Is the resistance through CN52 (between cir-
when CN51 is disconnected? cuits 177 and 169 ) less than 20 kilohms?
No
No Yes
Do the head lamps go OFF
when CN4 is disconnected?
Check the light sensor
No Yes circuit for continuity
and repair or replace.
Check power relay and
auto light switch (in
the console box) for Check CN51, CN52 and
short-circuit, and repair CN53. If these connectors
or replace. are OK, it means the con-
troller is in faulty condition
and needs to be replaced.
See if circuit 173 of
harness B is shorted to
chassis or to ground cir-
cuit and, if so, repair.

3-39
 Control System Schematic

Control (joystick) box

Control Lowering speed

Console box lever selector switch
Safety
ELECTRICAL SYSTEM

(joystick)
System switch
indicator Power supply
light Seat switch
Starter switch
ON or OFF signal
Lever position signal
ON or OFF signal
(3) Control System Troubleshooting

10A

Lift cylinder

3-40
Full free Proportioning
switch (full solenoid Controller
free mast
only)

Unload Control
solenoid valve
unit Setting
ON or OFF signal window
Flow control signal
Hydraulic transducer Lift load hydraulic pressure signal
(for lift only)
Travel speed pickup (OP.)
Hydraulic
pump

Speed signal

205045

(a) Case 3: No motion of hydraulic cylinders.
Is the system check lamp ON or
OFF?
Stays ON or flickers
Re-set.
NO Is the controller set to match
the machine specification?
Yes
Connect the checker to the con-
troller and read out the current trou-
ble data.
Are all input trouble data (on a lever), No
as read by the checker, normal?
Yes
Are all input trouble data (on the sen-
sor), as read, normal?
Yes
Are all output trouble data (standard),
as read, normal?
Yes
Are all output trouble data (on the work
attachment), as read, normal? (This No
does not apply to the two-element con-
trol valve unit.)
Yes
Read the past trouble data into the
checker.
Are all input trouble data (on the lever), No
as read, normal?
Yes
Are all input trouble data (on the sen-
sor), as read, normal?
Yes
Are all output trouble data (standard),
as read, normal?
Yes
Are all output trouble data (on the
attachment), as read, normal?
Yes
To deal with an internal malcondition of
any solenoid control valve, refer to the
section on solenoid control valves. If
necessary, contact the manufacturer.
ELECTRICAL SYSTEM
Troubleshooting procedure
OFF Move the control lever: does throttling The control
noise or any other abnormal noise come Yes valve is inter-
from the control valve? (Does the unload nally in faulty
solenoid operate?) condition.
No
Is the controller’s LED (red) ON or OFF?
Flicker Stays ON Stays OFF
Refer to Refer to
Case 8. Case 7.
Check the harness and connectors of the
lever in question for continuity. If open-cir-
cuit condition is noted, replace the lever
assembly.
No
Check for continuity the harness and con-
nectors of the component in question
(hydraulic transducer, switch or optional
No
pulse generator). If open-circuit is noted,
replace the component. (“Soft-touch
switch” is an option.)
Check for continuity the harness and con-
nectors of the solenoid in question. If open-
circuit is noted, replace the solenoid.
(Refer to the section on solenoid control
valves.)
Check for continuity the harness and con-
nectors of the lever in question. if short-cir-
cuit is noted, replace the lever assembly.
No
Check for continuity the harness and con-
nectors of the component in question
(hydraulic transducer, switch and optional
pulse generator). If short-circuit is noted,
replace the component. (“Soft-touch
N
o
switch” is an option. )
No
Check for continuity the harness and con-
nectors of the solenoid in question and, if
short-circuit is noted, replace the solenoid.
(Refer to the section on solenoid control
valves.)
3-41
ELECTRICAL SYSTEM

(b) Case 4 : No inching motion of hydraulic cylinders

Troubleshooting procedure

Does abnormal noise issue out when the mast Yes Check for hitching, sticking and rat-
is operated with normal working speed? tling. Repair to smoothen the move-
ments.
No

Is the controller set to match the machine No

specifications? Re-set.

Yes

Connect the checker to the controller and read

“Input state (1)” into the checker. Check to be
sure that the data, as read, indicate the control
lever voltage to be 2.50 ± 0.16 volts.

Move the control lever slowly back and forth

and read the voltage rise smoothly to these
values? The cause is a malcondition within
Forward . . . . . . . 0.10 volt No
the solenoid control valve. If neces-
Backward . . . . . 4.73 ± 0.01 volts sary, contact the manufacturer.
Test the control lever, as above, twice or
thrice, to be sure there is no jump or dip in the
rising voltage indication.

Yes
Check the harness and connectors of
the lever in question for continuity. If
discontinuity is noted, replace the
lever assembly.

3-42
 ELECTRICAL SYSTEM

(c) Case 5: The maximum lowering speed of the mast is too high (or too low).

Troubleshooting procedure

Is the controller set to match the machine No

specifications? Re-set

Yes

Is the adjusting knob (for the max. lowering Yes

speed of the mast) effective in adjusting this (End)
speed of the mast?

No

Connect the checker to the controller and read

out “Input state (1)” into the checker.

Reset the fork on the floor to slacken the lift

chain. Raise the mast slowly until the chain No If the solenoid control valve is to
becomes taut to start pulling the fork up blame, contact the manufacturer.
(holding the mast in vertical position with no
load on the fork). During this process, read
the hydraulic pressure: will the pressure* rise * This range, 1961 kPa (20
kgf/cm ) [284 psi] applic-
2
from 1961 kPa (20 kgf/cm2) [284 psi] without
able to the reference lift
any faltering? (Repeat the above process
truck. For any other truck
twice or thrice to be sure that the pressure will
than this, check the range
rise smoothly, without any jump or dip.)
specified for it.
Yes

Check for continuity the harness and connec-

tors of the hydraulic transducer circuit.
Assuming that the circuit is OK, if the trouble
(too fast or too slow speed) persists, replace
the hydraulic transducer.

3-43
ELECTRICAL SYSTEM

(d) Case 6: During the lowering action of a full free-lift mast, 1st and 2nd lift cylinders differ in actu-
ating speed.

Troubleshooting procedure

Is the controller set to match the machine No

Re-set.
specifications?

Yes

Connect the checker to the controller and read

out “Input state (2)” into the checker.

Operate the mast: see if the full free-lift

switch indication make an ON-to-OFF change
when 2nd cylinder starts rising from its fully Yes
retracted position. Will the change occur? Contact the manufacturer.
(Test twice or thrice to be sure of the switch
action.)
No

Check for continuity the harness and connec-

tors of the full free-lift switch circuit. As nec-
essary, replace the switch.

3-44
 ELECTRICAL SYSTEM

(e) Case 7: Controller’s LED (red) will not go ON.

Troubleshooting procedure

NG
Check the fuse. Is the fuse OK or NG? Replace the fuse, and check the
harnesses for open or short.
OK

Read the voltage between ground and Is the voltage between circuit
circuits 182 and 183 (CN53). Is the No 201 on the male side of CN4 and
reading at least 10 volts? (Is power ground at least 10 volts?
being supplied to the controller?)
Yes No
Yes

Is there continuity between circuits Check the power supply

186 and 187 and the ground? circuit (inside the con-
sole box) for continuity.
No Repair and correct an
Yes
open if any.
Check to be sure that CN51,
CN52 and CN53 are all in Is there continuity between circuit 201
sound condition. If the trouble (on the female side of CN4) and circuits
persists, replace the controller. 182 and 183 (at CN53)?

Yes No

While making sure that each

connector is coupled up tight,
check to see if the LED turns
ON; if not, contact the manu-
facturer.

Check harness B for continuity. Yes Is there continuity between circuits 183
Repair and correct an open, if any. and 201 at the male side of CN54?

No

Check the safety switch and engine hood

harness for open-circuit. Repair and correct
an open if any, or replace the switch as nec-
essary.

3-45
ELECTRICAL SYSTEM
(f) Case 8: Controller’s LED (red) will remain ON.
Troubleshooting procedure
Read the voltage between circuits
182 and 183 (CN53) and circuits
186 and 187 (ground). Is the
reading at least 10 volts?
(Is power being supplied to the
controller?)
Yes
Check to be sure that CN51,
CN52 and CN53 are all in
sound condition. If the trouble
persists, replace the controller.
Check harness B for continuity.
Repair and correct an open, if any.
No Is the voltage between circuit 201 on the
male side of CN4 and ground at least 10
volts?
Yes No
Check the power supply
circuit (inside the console
box) for continuity. Repair
and correct an open if any.
Is the resistance between circuit 201 (on the
female side of CN4) and circuits 182 and 183
(at CN53) less than 0.1 ohm?
Yes No
While making sure that each
connector is coupled up tight,
check to see if the LED turns
ON; if not, contact the manufac-
turer.
Yes If the resistance between circuits 183 and 201
on the male side of CN54 less than 0.05 ohm?
No
Check the safety switch and engine hood har-
ness for open-circuit. Repair and correct an
open if any, or replace the switch as necessary.
3-46
 ELECTRICAL SYSTEM

4. How to Move the Mast in an Emergency

If the truck fails while at work and, you then have
to drive it (if the engine is OK) or tow it to some Lift section
distant place or to the repair shop, do the following Tilt section
steps:
2
(1) Mast lowering
(a) Loosen lock nut 1 on the lift section of the
contrl valve. 1
(b) Using an Allen wrench, slowly loosen screw
2. This causes the mast to go down by grav-
ity: tighten screw 2 and the mast will stop.

CAUTION
Before doing these steps, be sure that there is
no one standing under the mast.

(c) Tighten lock nut 1.

205008
CAUTION
Leaving nut 1 loose is dangeraous: the mast
might suddenly start going down by itself.

(2) Lifting, tilting or auxiliary function

CAUTION
Steps (a) thru (i), below, are dangerous for the
following actions:

Action Remarks
Mast will move in free-falling
Lowering the mast
manner.
Dumping the hinged
fork (or bucket) Jerky dumping action.
Dumping the dump (The load will fall off.)
fork (or bucket)
Releasing clamped
The load will fall.
load

3-47
ELECTRICAL SYSTEM

(a) Remove the unload solenoid connector of

the control valve. Remove the proportional Proportioning solenoid connectors
solenoid connector on that end of the control




















valve which is for the action you need. Tilt forward Attachment 1
(b) Using a circuit tester, check the two sole- Mast down Attachment 2
Attachment 3
noids (unload solenoid and proportional
solenoid) for short or open. The faulted
solenoid, if any, must be replaced by a new Operates
when lever
one at this time. (If the proportional sole- is pushed.
noid, from which you pulled off the connec-
tor half, is faulty, you may replace it tem- ↑
porarily by another solenoid in place on the From
bottom
control valve.) to top

Unload Operates
solenoid when lever
connector is pushed.

Mast up Attachment 3
Attachment 2
Tilt backward
Attachment 1




















Proportioning solenoid connectors
205009

(c) To the two connector halves, from which the

female halves were disconnected in step (a), Red (+)
above, couple the female halves of the emer-
gency-use harness (special tool), as shown. Emergency harness Black (–)

Special tool needed

Emergency-use harness 91105-00400
Alligator clip

(d) Connect the “black” alligator clip (of the

other end of the harness) to the negative (–)
terminal of the battery: have the other (red)
alligator clip put on the harness, as shown. 205010
(e) Start up the engine.

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 ELECTRICAL SYSTEM

(f) Hold the engine in idling condition. Look

around the machine to be sure no one stands
near the truck. Now, take off the “red” alli-
gator clip and touch the battery’s positive (+)
terminal with it: as you do so, the action you Black (–)
need (corresponding to that of the propor-
tional solenoid now connected to the battery)
Red (+)
will start: the action will stop as you remove
the “red” clip from the terminal.

CAUTION
1) Do not keep touching the battery terminal
(+) with the “red” alligator clip, or the
solenoid will get burned. Touch intermit-
tently.
2) You may raise the engine speed while 205011
intermittently energizing the solenoid but
do so cautiously, keeping an eye on the
action in progress.

(g) If the desired action does not occur in step

(f), above, it means that there is some mal-
condition inside the control valve.
(h) Stop the engine, and remove the emergency-
use harness.
(i) Re-couple the connectors of unload solenoid
and proportioning solenoid.

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ELECTRICAL SYSTEM

(3) How to cope with a failed (open-circuited)

seat switch
Your troubleshooting investigation might reveal
that the seat switch is open-circuited or otherwise
faulted and will not function.
In such a case, you can create a temporary circuit
continuity through the seat switch line. The
method is explained in this illustration. The seat
switch is a security part. Be sure to replace it by a
new one as soon as possible.

Two connectors are in the seat

switch line at the indicated loca-
tion. Open these connectors,
and couple up the male and
female connector halves to form
a circuit bypassing the seat
switch.

205012

CAUTION
Illustrated above is a first-aid method permis-
sible only in an emergency situation. Be sure
to restore the seat switch line to the normal
hookup after replacing the failed switch.

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 ELECTRICAL SYSTEM

5. How to Clean Harness Connectors and

System Components
(1) Open-circuit trouble is often due to the harness
connectors and components in dirty condition:
dust, together with greasy matter, forms grime
which, in time, penetrates electrical connec-
tions, resulting in loose metal-to-metal contact
or, for worse, electrical sepatation of surfaces Electronic parts
in contact. For this reason, it is essential that cleaner
the connectors and components be cleaned at 205046
each periodic inspection and at the time of ser-
vicing the machine. Instead of a commonly
used solvent, use Electronic parts cleaner (in
the manner illusrated on the right).
Electronic pars
ThreeBond 29B
cleaner

NOTE
The cleaner liquid is volatile. All you have to
do is just give a strong spray to wash off
grime. No need to wipe off the sprayed liq-
uid.

(2) After checking the connector for continuity,

wash it as above. Then, uncouple the connec-
tor and spray Contact surface activator onto
contact surfaces. Now, install and remove the Electronic parts
connector several times to wet the surfaces cleaner
thoroughly with the activator liquid. After
coupling up the connector so sprayed on,
check to be sure that it is in locked state.
Contact surfaces ThreeBond 2501S
activator (aerosol)

NOTE
Do not spray too much: bear in mind that this
spray liquid reacts with some resins (plastic
materials).

Contact surface
activator 205047

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