ELECTRICAL SYSTEM

SECTION EL
CONTENTS
PRECAUTIONS/ELECTRICAL COMPONENT PARTS 2 HORN 23
Precautions 2 Wiring Diagram - HORN - 23
Electrical Component Parts 2 FUSES 24
LOCATION OF ELECTRICAL UNITS 4 Removal. 24
HARNESS LAYOUT 5 Installation 24
Outline 5 Inspection 25
Chassis Harness 6 Optional Fuses 25
Guard Harness 8 Fusible Link 25
Tail Harness 8 LIGHTING SYSTEM 26
POWER SUPPLY ROUTING 9 Specifications 26
Schematic 9 Headlamp 26
Wiring Diagram - POWER - 10 Front Turn Signal Lamp 26
HEADLAMP 12 Rear Combination Lamp 27
Wiring Diagram - H/LAMP - 12 Back Operation Lamp 27
EXTERIOR LAMP 13 METER PANEL. 28
Turn Signal LamplWiring Diagram - TURN - 13 Meter Panel 28
Tail LamplWiring Diagram - TAIL - 14 Key Switch 29
Stop LamplWiring Diagram - STOP/L - 15 Lighting Switch (Option) 29
Back-up LamplWiring Diagram - BACKIL - 16 Turn Signal Switch (Option) 29
Back Operation LamplWiring Diagram Battery Disconnect Switch 30
- BOL - 17 MISCELLANEOUS ELECTRICAL PARTS 31
WARNING LAMPS AND CHIME 18 Flasher Units (Option) 31
Warning LampslWiring Diagram - WARN - 18 Horn Relay 31
Warning Chime/Schematic 19 Horn and Horn Switch 31
Warning ChimelWiring Diagram - CHIME - 20
 PRECAUTIONS/ELECTRICAL COMPONENT PARTS

Precautions
CAUTION:
• When performing removal and installation procedures, be
sure to turn key switch to OFF and disconnect battery plug.
• When replacing a fuse or a bulb for accessories, alway use
one of specified capacity.

Electrical Component Parts

Description Application
Traction motor DC series motor
Motors Pump motor DC compound motor
Power steering motor DC series motor
Microcomputer controller performing drive/loading
Main controller chopper control, regenerative braking control, and field-
weakening control
Controller
Performs battery charger control and adjusting value
Meter print board change, and communicates such changed values to
main controller.
Consisting of variable resistor detecting accelerator
Accelerator
pedal angle and switch
Having variable resistor detecting brake pedal angle,
Brake sensor
which determines the strength of regenerative braking
Hydraulic sensing switch (Assembled within
Controller Steering switch
ORBITROl)
periph-
erals Displays battery capacity meter, speedometer and
LCD symbol display
warning lights.
Displays cumulative operating hours (with key ON,
driving and loading hours), clock and warning
LCD letter display
message, and adjusts acceleration level of traction/
loading.
Battery plug 160A for 80V
Key switch Power switch for control and accessory equipment
Forward-reverse (FR) Actuates contactor and back buzzer, and blinks backup
switch lamp.
Turn signal switch Flashes turn signal lamp.
Lighting switch Illuminates headlamps and back operation lamp
Horn switch Sounds horn.
Operated by loading lever, and turns pump motor (lift
Control valve switch
Switches, switch, tilt switch, etc.)
sensors Operates when brake pedal is depressed. Activates
and relays regenerative braking at vehicle speed of 3 km/h
Stop lamp switch
(2 MPH) or more and illuminates stop lamp. Release
bypass contactor to hold power down.
Turns on when parking brake is applied with key switch
Parking brake switch
on (parking brake warning lamp illuminates).
Illuminates wrench light when brake fluid level in reser-
Brake fluid level sensor
voir is excessively lowered.
Horn relay Operates horn.
Bimetal switch, controlling turn signal lamp flashing
Flasher unit Option
cycle
Horn Horn Sounds when horn switch on steering wheel is pushed.
buzzer Back buzzer Sounds when FR switch is set to "R".
Headlamp 25W x 2
Front turn signal lamp 25W x 2
lamps Stop/tail: 25W x 2/1 OW x 2
Rear combination lamp
Turn signal: 25W x 2, Reverse: 10W x 2
Back operation lamp 25W x 1

EL-2
 PRECAUTIONS/ELECTRICAL COMPONENT PARTS
Electrical Component Parts (Cont'd)
Description Application
Battery Separate type battery
Permits charging with one touch operation
charger charger
(with electronically controlled double timer).
and bat- (IC double timer type)
tery Battery 80V
Contains blade fuses for control and accessories
Fuse box
(SA, etc.).
Protects wiring harness when short circuit accident
Fuses Fusible link
through body occurs.
Protects each circuit of traction motor, pump motor,
Fuse for main circuit
and PS motor.

CAUTION:
Some optional parts may not be prepared depending on vehicle
models.

EL-3
 LOCATION OF ELECTRICAL UNITS

Headlamp

Back operation lamp

Meter printed board

Rear combination lamp

LCD letter display

Accelerator Back buzzer

Seat switch

Controller

ELM0141

Turn signal switch (OPT)

Relay block (Horn, Flasher unit, Stop lamp,

Parking brake, ect)
Control valve switch

Power steering motor

Traction motor

Pump motor

Battery disconnecting switch

ELM0142

EL-4
 HARNESS LAYOUT

Outline

Guard harness RH

Guard harness LH

Tail harness

Control valve
switch harness

ELM0143

EL-5
HARNESS LAYOUT

Chassis Harness

ELM0144

EL-6
 HARNESS LAYOUT
Chassis Harness (Cont'd)

~ : To controller (836) : To power supply relay-2

@) : To controller (B37) : To back-up lamp relay-2

@) :To fusible link (B38) : To stop lamp relay

@) :To fusible link (839) :To stop lamp relay

@) : To rear combination lamp LH (840) : To parking brake relay

~ : To rear combination lamp LH @) :To parking brake relay

~ : To rear combination lamp LH (842) : To flasher unit

~ : To rear combination lamp LH (843) : To horn

~ : To rear combination lamp LH (844) : To horn

~: To fuse (845) : To back-up lamp relay-1

~ : To back buzzer (846) : To back-up lamp relay-1

(@ :To back buzzer (847) : To power supply relay-1

~ : To back buzzer (848) . To power supply relay-1

~ : To tail harness (849) : To horn relay

@) :To tail harness (850) : To guard harness RH

~ : To rear combination lamp RH ~ : To guard harness RH

~ : To rear combination lamp RH (852) : To guard harness RH

~ : To rear combination lamp RH ( B53) : To diode (OPT)

@) :To rear combination lamp RH (854) : To diode (OPT)

(820) : To rear combination lamp RH (855) : Option (fuse)

@) :To battery switch (856) : Option (speed warning)

(822) : To seat switch (857) : To parking brake switch

( 823) : To seat switch (858) : To parking brake switch

(824) : To seat switch (BS9) : To parking brake warning buzzer (OPT)

(825) : To brake sensor (860) : To fuse box

(826) : To stop lamp switch @) : To guard harness LH

(827) : To accelerator (862) : To guard harness LH

(B28) : To control valve harness (863) : To guard harness LH

(829) : To brake fluid level switch (864) : To horn switch

(B30) : To brake fluid level switch (865) : To horn switch

@) : To speed sensor-A (B66) : To turn signal switch (RH F&R lever)

(B32) : To speed sensor-B (867) : To FR switch

(833) : To PS pressure switch (868) : To turn signal switch (LH F&R lever)

(834) : To PS pressure switch (869) : To lighting switch

(835) : To diode (OPT) (870) : To combination switch

@) :To key. switch

ELM0145

EL-7
 HARNESS LAYOUT

Guard Harness

~ : To body harness

@) :To body harness

(]D : To body harness

~ : To head lamp RH

@) :To head lamp RH

~ : To turn signal lamp RH

~ : To turn signal lamp RH

GD : To body harness
~ ; To body harness
RH
( G1 0) : To body harness
LH
@ill : To head lamp LH

(G12) ; To head lamp LH

Front @) : To turn signal lamp LH

(G14) ; To turn signal lamp LH

ELM0146

Tail Harness

CB :To body harness

CE) : To body harness
CE) : To back operation lamp

GD : To back operation lamp

ELM0147

EL-8
 POWER SUPPLY ROUTING

Schematic

z
o
;::0::
uw
«f--
o::W
f--:::;;

.!:!~
.0
.- -'"
VJ C
:J._
l>---'

W
Z
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Z
o
f--
D-
o

Z
0::
o
I

Lf)~ III ~
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------{S}- ~~
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Z

v "0
III ~

,---
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0
VJ f--
~
-
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I
I
"0
I III
VJ
:;)

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z

0::
w
--'
--'
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0::
f--
Z
o
u

II

ELM0148

EL-9
 POWER SUPPLY ROUTING

Wiring Diagram - POWER -

"~T~'" BATTERY EL-POWER-01

BNoI B

g g •• I : OPTION LINE

rHlB=ERY I l~ROLLER
LfifJ SWITCH 1..----------gJ
~@D6 e~@ e~
BfN i : r. it: FUSIBLE
I
BR
FUSIBLE
LINK LINK

W~Nextpage ~
[I]
~
m
B B

BNoI b..- B. {STOP/L-01, WARN-01,

TRAG-01, 02, PUMP-01

H/LAMP-01, TURN-01, 02
TAIL-01, STOP/L-01,
B• tt~~~~ci~~
c~,J~51~d2,
03,
{ HORN-01, TRAC-02, 03,
LG RNoI W/R GY PUMP-01, PST-01

••
••
•• 1. GY • {TURN-01, BACKlL-01,

•••
CHIME-01

•• •
W/R. {WARN-01,
HORN-01
CHIME-03,

••
•• RNoI• { H/LAMP-01, TAIL-01,
STOPIL-01, BOL-01

••
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • LG • Not used

ELM0149

EL-10
 POWER SUPPLY ROUTING
Wiring Diagram - POWER - (Cont'd)

EL-POWER-02
Preceding page ~w "

•• I : OPTION LINE

GY OR L
•
••
••
••
•••
•••
....... L. Not used

.. OR+ WARN-01

TURN-01, BACKIL-01,
GY+ WARN-01, CHIME-01, 03
{ TRAC-01, PUMP-01,
PST-01

ELM0150

EL-11
 HEADLAMP

Wiring Diagram - H/LAMP -

EL-H/LAMP-01
Refer to EL-POWER-01.

RfW

LIGHTING
SWITCH
@@

~
OR

•I ... ...
._OR+ To EL-TAIL-01

I
R
I
R
,4.,,@D ,4.,,@2)
I~I@ I~I@D

;!
R R

Jru HEAD
LAMP
LH
HEAD
LAMP
RH

~~
B
@D,@)
~
B
@,@

~: ~:
I",,"-
__...
__
B B

_
.I @
B~G
~
.G+TOEL-POWER-01
(FUSIBLE LINK 00 )

~~)200 W

,----------,
: ~@
L
~@) :
J
~@ I!TI@Q)

,----------1
: 1illJ@IT)
L
~@) :
J

ELM0151

EL-12
 EXTERIOR LAMP

Turn Signal LamplWiring Diagram - TURN -

EL-TURN-01
5A ] Refer to El-POWER-01
m
GY GY

1
122
__ ....__ BR ~ Next page
DIODE
@)
l
~

D
B 121
POWER SUPPLY
RElAY-2
~ @
~
B

.._---. I @
~ .To
B~ G
El-POWER-01
(FUSIBLE LINK @) )

r--------------,
~@D
rn W
:rt@)
I~l
~@):
WWI
~@
Ww
-ffii@
00 W
1 - ,

ElM0152

EL-13
 EXTERIOR LAMP

Tail LamplWiring Diagram - TAIL -

EL-TAIL-01
Refer to EL-POWER-01.

LIGHTING
SWITCH
@)

--
r------I
OR OR

221
COMBINATION
REAR
LAMP LH
(TAIL LAMP)
I:1: I COMBINATION
REAR
LAMP RH
(TAIL LAMP)

~ ~@,~ ~~,(~
B B

1 ------1

@)
" B .JifsO'- G G. To EL-POWER-01
~ (FUSIBLE LINK ~ )

m@)
200 W

:~~~~:
-----------, 1-----8"---1

L J
: ~@)
L
fl@: J

ELM0153

EL-14
 EXTERIOR LAMP

Stop LamplWiring Diagram - STOP/L -

EL-STOP/L-01
Refer to EL-POWER-01.

RIW
I

1
203
DIODE
@

~
P P

l-!I ----e-----.
P

~
STOP
LAMP
DEPRESSED SWITCH
~
RELEASED

~ P P
B

I~IREAR COMBINATION
LAMP LH
(STOP LAMP)
I~IREAR COMBINATION
LAMP RH
(STOP LAMP)
~@,@ ~ @]),@
B B

I@
..------e- B~ G G. To EL-POWER-01
~ (FUSIBLE LINK lID )

@
B~ BR BR. To EL-POWER-01
~ (FUSIBLE LINK [Q] )

r--------------, ....
---------1
:~@)
I~L
~@:
WWI
Jfoi@
~W
I
1 Hill@])
'__ --
~
~@2)
1
I
1
1 --- 1

.... ---------,
1 ~ I
I@I@ ~@I
1- 1

ELM0154

EL-15
 EXTERIOR LAMP

Back-up LamplWiring Diagram - BACKIL -

EL-BACK/L-01
Refer to EL-POWER-02. Refer to EL-POWER-01.

GY

KEY
SWITCH
<ED

---'--1 P

122
DIODE
@)
ON ON ~tlvITCH
~
'@0 ~
'- OFF ./ B
REVERSE FORWARD

~
GY

~GYoB>N"" ,." L

(WJ ~
B
~
121
POWER SUPPLY
RELAY-2
@)

I
..----e--- @
B ~G +(~uEiJ:~V~J:KOiID)
r--------------,
~@D
120 W ~(@
661662 W ~(@
662661 W
:A@
I~L
JFoL@:
rm::JWI
(FR LEVER LH) (FR LEVER RH)
1 ---------,

~@
920 W ~@)
922 W @J~

ELM0155

EL-16
 EXTERIOR LAMP

Back Operation LamplWiring Diagram - BOL -

EL-BOL-01
Refer to EL-POWER-01.

RIW

I
LIGHTING
ON SWITCH
@g)
OFF

~
R

~(3)
I
R

I~IGD
R

291
I
R

BACK
OPERATION
LAMP
;
f9a71@)'@
~
B

I
B
~Cill
119a7I1~
'-ir' ~
B

I ________
@)
B..fr9so'L.
~
G G. To EL-POWER-01
(FUSIBLE LINK rnl )

.....
---------1

291220 @@ Eill@E) I Q I
IEill@) ~@I
200 W
'_- - - - - - - - - I

ELM0156

EL-17
 WARNING LAMPS AND CHIME

Warning LampslWiring Diagram - WARN -

EL-WARN-01
Refer to EL-POWER-02.

OR

Refer to EL-POWER-01.

KEY CONTROLLER
SWITCH
@D COMM COMM @ W/R
DATA(RX DATA(TX

~ ~
~ uw UB
P
T
EE-TURN-01+ P ••

~
I
I
Y OR

~ ~
uw
I I UB

~
KEY-ON POWER SOURCE COMM COMM
SIGNAL VOLTAGE (RECEPTION) (TRANSMISSION) METER
PRINTBOARD
LOW BRAKE PARKING BRAKE (~)
FLUID LEVEL WARNING
GND GND SIGNAL SIGNAL

~u;n
B B
u;JJ
P
~
L

PARKING
BRAKE
SWITCH
(~),@)

~
G

BRAKE
FLUID PARKING
L G. To EL-CHIME-03

LEVEL BRAKE
LOW SWITCH RELAY
@).@ @D,@)
I~I

..-----1 ~
B

111
.-. I I
T
@)

@
B.m;rg.:;;"I-sO
~ G ........ToEL-POWER-01
.,.... (FUSIBLE LINK

B ...lFn'7ri1. G ........To
970
EL-POWER-01
[ill)

I ~ .,.... (FUSIBLE LINK 1m )

nro=I@D r---------
1-[ill1@
I ~(~ ..:
tTIm W

r--------------, 1----------,
:A@D
I~L
-ii@):
WWI
I JiL@)rfal'@)11
100 W I!lJ
rillI@ B
1 --- 1 I I
... _----------

ELM0158

EL-18
 WARNING LAMPS AND CHIME

Warning Chime/Schematic

I
()
~t:
UJ5:
CIJCIJ

UJ
-'
-~
<D
ClJ
Z
::J_
u..-,
I
~
()
f--
~
CIJ
,....
cr
u..

Z N
0
Cl
cr
cr
u..
u..
~
cr
UJ
I -'
() 0 0 -'
u.. 0
>-t: cr
f--
UJ5: UJ
~CIJ u.. CIJ
Z
u.. cr 0
0 UJ
()

>
UJ

~ cr
Z (')
UJ 0
~
<D <D

<l:

ELM0160

EL-19
 WARNING LAMPS AND CHIME

Warning ChimelWiring Diagram - CHIME -

EL-CHIME-01
Refer to EL-POWER-02. Refer to EL-POWER-Ol.

GY

KEY
ON SWITCH
@l)
OFF

~
P
I ___
e------------
I P

rr£=TI
POWER SUPPLY
RELAY. 1
@),@
ON 4 ON
------- FR
4 4 P
SWITCH ~

1 I 1.---------
" .... OFF OFF ... / @) 122
L BR
REVERSE FORWARD
DIODE
@)
~
GY
~
R
BR -{3> Next page
~

I_ D
B 121
POWER SUPPLY
RELAY-2

e-------..
~ (@

---GY-[9-Next page ~
B

I
GY

ffi ffi
R
"--e
I
REVERSE
SW
SIGNAL
FORS~RD
SIGNAL
CONTROLLER
@ I
_

I
_____
@
B ...m;;rgw.50
~
G. To EL-POWER-Ol
(FUSIBLE LINK ([) )

m@) nron@) nron@)

rn W ~W
(FR LEVER LH)
~W
(FR LEVER RH)

r--------------,
:A@
I~L
JiroL@) :
Lm:jWI
~@
00 W
-ffii@)
OOw
1 ---------,

ELM0161

EL-20
 WARNING LAMPS AND CHIME
Warning ChimelWiring Diagram - CHIME -
(Cont'd)

EL-CHIME-02

GY L

1
367 366
BACK-UP LAMP
DIODE RELAY-2
@) ~ @Z)
~
~ ~ GY
B B
~
BACK BUZZER
@),@,@

~I~
B B

.. • ._.
@)
B ~G. T~uEs~:L~vrfNRKO£iJ)

r--------------l 1- - - -- - - - - - - - -- - ~

:~@
I~L
JiL@):
OOWI 1
Jii@Z)
Ww
Jii@)
00 W
: ~@D
L
~@) lQ)@: _

1 ---

ELM0162

EL-21
 WARNING LAMPS AND CHIME
Warning ChimelWiring Diagram - CHIME -
(Cant'd)

EL-CHIME-03
Refer to EL -POWER-02. Refer to EL-POWER-01.

PARKING
KEY BRAKE
SWITCH SWITCH
@ill @,@0

u;n
P

I .. _____________ W+ To EL-WARN-01

i-, G

0
P P
~
KEY
m
KEY
81
PARKING BRAKE
WARNING BUZZER
SW SW
CONTROLLER
@)
@,@
SEAT ~
SW W/R

I
lbjdl
,
RIB

W/R

SEAT SWITCH
(~),@,@)

1
@)
B ..l'Fairg<n1-so G + To EL-POWER-01
~ (FUSIBLE LINK rnJ )

~------------------------- i-~----------~
m@)
~W
I
I
385@0
380 W
~@I
I
1 I

....
-------------1
Jrai(~)
Ww : ~@)
1
~@)
--
~@): 1

ELM0163

EL-22
 HORN

Wiring Diagram - HORN -

EL-HORN-01

Refer to EL-POWER-01.

W/R

W/R

~
HORN
n RELAY
U @

HORN
ON SWITCH
@.@)
QJ
~
S
431
HORN
@.@)

....
-
• I @)
s.Ji9'so1.G
~
G. To EL-POWER-01
(FUSISLE LlNK@])

,----------1 ,----------,
430 ~
432431 W : ~@)
L
@]@: J
: ~@)
L
~@) :
J

ELM0164

EL-23
 FUSES

NOTE:
For removal, installation and inspection procedures of motor control
fuses, refer to CS section.

Removal
1. Remove counter weight cover fixing bolt, then open cover.

2. Remove fuse box cover by pushing and turning the hook on

cover.
CAUTION:
Be careful not to damage cover.
3. Take out fuse extractor equipped with inside of cover and remove
fuse with fuse extractor.
CAUTION:
Draw out fuse toward you.

Installation
1. Always use a fuse of specified capacity.
2. Return fuse extractor to original position and install fuse in
reverse order of removal.

Installation frame
NOTE:
• When removing fuse box, disconnect harness connector and
remove fuse box cover. Insert a small screwdriver into hook to
Fr
unlock, then remove fuse box from bracket.
• When installing fuse box, insert part to be fitted into bracket and
LH securely lock with hook.

ELM0166

EL-24
 FUSES

Inspection
Check for blown fuse by referring to the right side of the figure.
Replace blown fuse with a new one.
CAUTION:
• When replacing fuse, always use one of specified capacity,
indicated on the fuse capacity label.

o
00 00
• If fuse blows again after replacing, electrical trouble is con-
sidered. Immediately inspect and eliminate cause of the
trouble.
(+) -}
o 0
Power Fuse
ELM0167 No. Applicable parts
supply capacity (A)
1 5 Controller, reverse relay

72 - 2 5 Meter
c:::::r::=:J 80V 3 Not used
CI:J
4 5 Option (for 72 - 80V)
r::::I::::J
~ 5 5 Option (for 48V)
CI::::J 6 5 Headlamp, tail lamp, stop lamp
c:c:J 48V 7 5 Horn, PKB buzzer
CI:=J Turn signal lamp, reverse lamp, back buzzer,
8 5
CLJ back operation lamp

ELT0009
Optional Fuses
When optional parts or non-factory-installed parts are installed, insert
a fuse of specified capacity in place.

INSTAllATION
Insert fuse into optional fuse position in fuse box.
NOTE:
Connect harness connector corresponding to optional connector.

INSPECTION
Refer to the above "Inspection".

Fusible Link
NOTE:
One fusible link is installed respectively in control circuit and acces-
sory circuit of meter board.

INSPECTION
1. Remove counter weight cover fixing bolt, then open cover.

--- ---
ELM0168

2. Check for blown fusible link using circuit tester.

CAUTION:
If fusible link is blown, replace with a new one of specified
capacity. Also, check related electrical parts to determine the
cause of problem, and repair if necessary.

Identification color Size (mm2) Application

Brown 0.3 Control circuit

Green 0.5 Accessory circuit

EL-25
 LIGHTING SYSTEM

Rear Combination Lamp

To replace bulb, loosen the two lamp retaining screws and remove
lamp. Then remove the screws and remove bulb.
To remove protector, remove lamp and the two protector retaining
bolts. Then remove protector.

Protector

Rear

~v/
//
;:m()~()~~ "«)

ELM0172

Back Operation Lamp

~ CAUTION:
~RearPillar
• Install lens with water-drain hole facing down.
• Adjust lamp aim so that axis of light is 5 to 10 degrees
toward center line of vehicle.
NOTE:
r---J1 For replacement of bulb, refer to "Headlamp".

1---
~
800k o"rnOO" I,m,
ELM0173

EL-27
 METER PANEL

Meter Panel
REMOVAL
1. Remove the four upper cover screws.

2. Remove the eight rear cover screws, then remove rear cover and
disconnect key switch connector.

3. Remove the four lower meter panel screws and disconnect har-
ness connector of meter board, then remove lower meter panel.

NOTE:
When replacing meter print board, remove the eight meter print board
retaining screws, then remove meter print board.
Meter print board

0," ~
')0 )

==".~ o ~

ELT0024

4.
5.
Remove the four upper panel retaining bolts.
Disconnect connectors to lighting switch (option) and back opera-
tion lamp switch (option), then remove panel.
CAUTION:
Avoid steam cleaning of meter panel because of electronic
parts.

INSTAllATION
Install meter panel in reverse order of removal.

EL-28
 METER PANEL

Key Switch
REMOVAL
1. Remove rear cover. Refer to "Meter Panel".
2. Disconnect harness connector.
3. Remove ring nut and remove key switch from rear cover.

INSTAllATION
Install key switch in reverse order of removal.

INSPECTION
OFF ON
Check continuity between terminals using circuit tester (0 range).

0-0: Continuity
ELT0028

Lighting Switch (Option)

REMOVAL
1. Remove rear cover. Refer to "Meter Panel".
2. Remove switch knob by pushing it in and turning it left.
3. Disconnect harness connector.
4. Remove ring nut, then remove lighting switch.

INSTAllATION
Install lighting switch in reverse order of removal.
ELT0029

12 INSPECTION
Position
--,-,
l l Check continuity between terminals using circuit tester (0 range).
il il
.; .;
_f)

Position
Position Continuity
Terminal
----------- 1 2
1 ( (
1 1-2-3
2 (

3 ( (
4 (
2 1-3-4
ELM0174

Turn Signal Switch (Option)

REMOVAL
1. Remove meter panel. Refer to "Meter Panel".
2. Disconnect harness connector.
3. Remove the two turn signal switch retaining screws, then remove
switch from steering column.

INSTAllATION
Install switch in reverse order of removal.
ELM0122

EL-29
 METER PANEL
Turn Signal Switch (Option) (Cant' d)
NOTE:
When installing turn signal switch, keep clearance of approximately
16 mm (0.63 in) between steering wheel lower end and turn signal
switch bracket upper end.

16 mm
(0.63 in)

ELT0033

INSPECTION
Check continuity between each terminal using circuit tester (Q range)
while placing switch in L, Nand R positions.

Posi-
L N R tion
Continuity

1 L 1-3

2 N No continuity

3 R 1-2

ELT0034

Battery Disconnect Switch

Disconnecting
. switch

W 1: From battery 80V

. 2: To main fuse
. 3: From battery 48V
4: To fuse box 48V

1 cr---<j2 i cr--o 2

3 cr---<j2 . cr--o 4

ELM0175

EL-30
 MISCELLANEOUS ELECTRICAL PARTS

Flasher Units (Option)

SPECIFICATIONS
Rated voltage (V) 48
Specified load (W) 50
Number of flashes (Times/ min.) 60 - 120
Voltage drop (V) 1.6

INSPECTION
• Perform flasher unit inspection by checking the number of flashes
Flasher unit
under specified laden condition with electrical load (all lamps)
applied.
• Check circuit fuses (5A) for abnormalities.

Horn Relay
SPECIFICATIONS
Rated voltage (V) 48
Specified amperage (W) 2
Operational voltage (V) 28 - 56

Power supply relay 2

ELM0176

INSPECTION
• Check for broken coil using circuit tester.

---.5E • Check continuity between contacting side terminals (]) and CD

using circuit tester (0 range) while applying or releasing battery
voltage to/from coil side terminals CD and (]).

4~~lDC'
: """ diagram

CID 1 ~ EL T0039

Horn and Horn Switch

INSPECTION
• Check horn sound by pushing horn switch while turning steering
wheel from lock to lock.
• Remove steering wheel (Refer to ST section) and visually check
horn brush for wear or damage.

EL-31
 ”

Jun. 30, 2000

APPLIED MODEL: P01, P02, Q02 and C01
APPLIED AREA: All

SUBJECT: Battery Cable for Battery-less Truck

If you use the long battery cable to operate or transport the truck with external battery,
it is possible that the internal components of controller may be damaged by the high
voltage induced by the long battery cable.
The damage of the components will appear soon or later depending on the operational
condition.
So, we ask you to perform either of the following countermeasure on all places where
the battery-less truck is transferred, such as factory, port, dealer and others.

1. COUNTERMEASURE
1) Make total battery cable length less than 6.0 meters.
Total battery cable lengths are sum of battery cable both the positive side and
the negative side, including external extension battery cable.
The total length of the extension cables should be 2.1 meters, as the total
length of the original battery cables is maximum 3.9 meters.

2) If 1) is not available, install the condenser to the location of less than total
length 6.0 meters from controller.
The connecting cables for the condenser should be total length of less than 1.0
meter and the area of more than 22 mm2.
The condenser should satisfy the following specification.
 Condenser specification
Voltage More than 450 V
Capacity More than 85(F) x Y (meters) 1
1 : Y (meters) are total battery cable length from controller to temporary
external battery.
Example) If Y = 8 meters, the condenser capacity 85 x 8 = more than 680F

2. CAUTION
1) Please route the positive and negative extension cables for the temporary
external battery together.
2) Please use the extension cables so as not to coil the bundled cables.

3. ADOPTION
As soon as possible.
Original cable for the truck
ne00479 Pagina 1 4-9-2007
Service Bulletin

Issue: SB-QX-OP-0701
Date : August 2007

Model : QX
Subject : Rear wiper motor short circuit

Outline:
We have received reports from the field that short circuits from the rear wiper motor to the
frame have occurred. The cause was a poor insulation from the wiper motor to the metal
panel, creating not enough clearance. In that case the wiper motor body comes into contact
with the metal panel and thus creating a short circuit.

Modification:
To prevent the possible short circuit from the rear wiper motor to the frame, insulation has
been improved.
A plastic disc has been added on the wiper motor axle to enlarge clearance between the
metal panel and the wiper motor body. By adding the disc it was also necessary to enlarge
the bolt securing the wiper motor reaction arm and an additional nut was added.

Metal Panel
Plastic disc
added

Screw changed from

M6x35 to M6x40 and
nut added

Interchangeability:

Yes

Applied chassis models:

Introduction in production: 16 July 2007

Chassis Serial Numbers: Q02-703651, GQ02-701663
Cabin Serial Numbers: Q02 275, GQ02 206

The information in this bulletin should not be interpreted as basis for claims, unless so designated.
Whenever you order parts, refer to the parts bulletin, not to this Service Bulletin

SB-QX-OP-0701 Rear wiper motor short circuit.doc Page 1 of 1 04/09/2007