Professional Documents
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Chapter 3 Electric System
Chapter 3 Electric System
Main harness
Harness, rear
combination
Harness, front
combination
Harness, front
combination
213457
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ELECTRIC SYSTEM
Starter switch
QGS Controller
Key
Main harness
Harness,
rear combination
Select switch
Harness, front
combination
Input unit
VCM(Vehicle control module)
Clip
Battery seat
Consult Connector
ECM DCM
(Gasoline (Diesel engine
Connector Harness, front engine control control module)
bracket combination module)
Horn
Output unit
Fuse box, Fuse
Transmission
213458
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ELECTRIC SYSTEM
2. Structure
2.1 Console Box
1 Water temperature gauge 4 3 1
2 Fuel gauge 2
3 Hour meter, various warning lamps
ᵮ
4 Instrument panel N
ᵦᶐ
5 Starter switch
ᵤ ᵦ
6
ᵣᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾᴾ ᵡ
7
5
214140
3-3
ELECTRIC SYSTEM
A B C D E F G H I J K
L M N O
214141
Description of function
Inspection method of blown bulbs for instrument panel
All warning and indicator lamps are normal, if they glow, when the starter switch is turned to the (ON) position.
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ELECTRIC SYSTEM
(OFF)
(ON)
ST M
(START)
G B
213459
Connection Table
Key insertion/
Terminal G B M ST
removal
OFF Yes
ON (when operating) ○--------- -----------○ No
START
○--------- -----------○----------- -----------○ No
(when starting engine)
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ELECTRIC SYSTEM
Light switch/
turn signal lever
Boot
Horn contact
Boot
Direction lever
Forward of truck
Lighting switch,
turn signal switch
Forward-reverse
selector switch
Light switch/
Shift change switch turn signal switch
(F, N, R)
4 T-3 L-2
T-1 L-4
2
T-2
L-1 L-3
5
1 3
Horn contact
Horn
213460
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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
abnormal.
Operating voltage: DC12V
(Gasoline and diesel trucks)
Note: The installed position is that of an actual truck
as shown in the illustration.
213463
2.2.4 Tank unit
(7..
'/26;
Referential Standards
Float position E 1/4 1/2 3/4 F
Standard resistance
80 49.5 32 19 10
value (ohm)
+12 +1.0
Tolerance (ohm) 㧙 ±3 㧙
+2 -0.5
213464
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ELECTRIC SYSTEM
activating position
energization)
(emergency
Indicator ON
(0.12 ± 0.08)
3±2
213465
2.2.6 Stop lamp switch
Connect a tester across the terminals and check that
Unit: mm (in.)
the lamps turn ON and OFF when the amount of the
push rod extended projection is within the specified M10 × 1.25
value. Push
Measure the insulation resistance value across the ter- rod
minals when the push rod is pushed in.
Replace the switch if the measured insulation resis- 4 2
tance value is less than the value listed below. (0.16) (0.08)
Insulation 1 M ohm or more
resistance value (with megger tester at 500V) OFF ON
213466
Rated voltage DC12V
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ELECTRIC SYSTEM
Forward of truck
F Forward
(10㩩) (10㩩)
N Neutral
R Reverse
Connector of
FNR switch
Connector of FNR switch
Connection table
Terminal 1 2 3 4 5
213467
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ELECTRIC SYSTEM
2.2.8 Thermoswitch
(Engine cooling water temperature)
(1) Apply an ohmmeter between the terminal and
body of the sender unit and check for continuity
(resistance value). Body Terminal
213470
Gasoline-engine truck
°C 60 ± 0.2 65 ± 0.2 80 ± 0.2 100 ± 0.3 125 ± 0.3 130 ± 0.3
Temperature
(°F) (140 ± 32.36) (1496 ± 32.36) (176 ± 32.36) (212 ± 32.54) (257 ± 32.54) (266 ± 32.54)
Standard resistance
80 ± 10 67 ± 7.8 40.6±2.7 22.2±1.4 11.3±0.4 10 ± 0.3
value (ohm)
Diesel-engine truck
°C 50 ± 0.2 60 ± 0.2 80 ± 0.2 100 ± 0.3 105 ± 0.3 120 ± 0.3
Temperature
(°F) (122 ± 32.36) (140 ± 32.36) (176 ± 32.36) (212 ± 32.54) (221 ± 32.54) (248 ± 32.54)
Standard resistance
80 ± 10 56.3 ± 5 29.5 ± 2.5 16.5 ± 0.8 14.3 ± 0.5 10 ± 0.3
value (ohm)
Technical data
122 ± 3°C
OFF to ON
Operating (251 ± 5.4°F)
temperature 115 °C (239°F)
ON to OFF
or higher
Insulation resistance
1 M ohm or more
(with contact point OFF)
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ELECTRIC SYSTEM
Connection diagram
(Bottom view)
215202
(2) CM relay
Coil rating [at 20 °C(68°F)]
Truck type
Items Gasoline and diesel
engine lift trucks
Rated operating voltage DC12V
Working voltage DC 3.0 to 7 V
Open-circuit voltage DC 0.5 to 3.1 V
Coil resistance 120 ohm ±10%
Rated exciting current 117.6 mA±10%
Connection diagram
(Bottom view)
215203
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ELECTRIC SYSTEM
Water temperature
Items ON time
(Resistance value)
Connector A Connector B
-15°C(5°F)
10.0 ± 2.0 sec. 1 2 3
(12.1 K ohm)
Glow lamp 㧭
0°C (5.9 K ohm) 6.4 ± 1.3 sec.
Glow plug
+10°C(50°F) 㧮
3.0 ± 0.6 sec.
(3.8 K ohm) 4 5 6
Rated voltage: DC12V Connector A Connector B
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ELECTRIC SYSTEM
Working lamp
15A
A/C
Back up/Others 20A
Head lamp
15A
15A Stop lamp
Instrument panel
10A 10A
QGS ETC Wiper Horn
Spare EGI
10A 15A 15A 10A
VCM 30A 30A EGI
20A
20A 30A
Fuse puller
10A 15A
SBF 100A SBF 100A SBF 50A
Spare Battery Alternator Glow
213480
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ELECTRIC SYSTEM
Turn signal
2 Amber
lamp
Standard
Combination (Installed on
Lamp (front) the Head
guard)
Clearance
2 Colorless
lamp
Type of lamp
Turn signal
2 Amber Standard
lamp
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ELECTRIC SYSTEM
3. Console Box
3.1 Disassembly
2
5
213483
3.1.1 Start by
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) Disconnect the electrical wiring from connector 1.
(2) Remove the screw using a Phillips screwdriver
and remove cover 2.
(3) Remove the screw and then, remove cover
(U-Re) 3.
(4) Remove the screw and then, remove cover
(U-Fr) 4.
(5) Remove direction lever (FNR lever), turn signal
lever 5.
(6) Remove the bolt and then, remove console box
assembly 6.
3.1.3 Installation
To install, follow the removal sequence in reverse.
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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 difference in S.G. between any two cells is 0.020 or less,
continue to use as it is.
1.280 to 1.265 Good
if the difference is greater than 0.020, apply the high rated dis-
charge to correct, then charge the battery referring to the S.G.
Recharge battery and adjust electrolyte S.G. Make sure there
1.260 to 1.225 Half charged is neither faulty components, loosely connected cables nor
corroded connections.
Recharge battery.
1.220 or less Low battery, requiring cares
If difference in S.G. is large, adjust it during recharging.
Recharge until voltage and S.G. stabilize and have remained
A cell with a low S.G. is in constant for more than 2 hours.
If difference in S.G. is shorted condition. During recharging, adjust S.G. between 1.280 and 1.265.
more than 0.040 Electrolyte leakage or exces- If difference in S.G. is more than 0.040 and a low S.G. is found
sive/diluted electrolyte in certain cells only, replace battery. After leaving battery for
12 to 96 hours, conduct a high current discharge test.
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ELECTRIC SYSTEM
5. Instrument Panel
5.1 Instrument Panel Screen Element
Instrument panel screen consists of warning lamps,
LCD (Liquid Crystal Display) screen, and ٌ and
ٖ buttons, and enter/display switch button
215114
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ELECTRIC SYSTEM
215116C
215117
215118
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ELECTRIC SYSTEM
215119
19.1 - 20.0 km/h 20 km/h
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ELECTRIC SYSTEM
215121
44 dots
Number of dots in the gauge (Dots)
40
Range of overheating (red zone)
30 29 dots
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)
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ELECTRIC SYSTEM
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ٌ Light → Dark
Short
ٖ Dark → Light
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ELECTRIC SYSTEM
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ELECTRIC SYSTEM
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, and with a long press of the Key-on time display
ٌ button, the display changes.
Button Press Display
Key-on time
↓
ٌ Long Engine-on time
↓ Engine-on time display
Seat switch-on time
Key-on time:
Total hours of engine key switch On time
Engine-on time: Total hours of engine running time
→This will be helpful to figure out the engine running Seat switch-on time display
hours for the maintenance of engine related parts.
Seat switch-on time:
Total hours of the operator has seated. 215131
→This will be helpful to figure out the actual operation
hours for the check of real working hours.
Note: 1. When six minutes have elapsed, 0.1 hour is
added.
2. Warranty period shall be based on the key-on
time.
3. The key-on time shall be used for entries in
commercial paper (trading paper).
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ELECTRIC SYSTEM
button
215125
The display order of error code can be changed with
short press of ٌ or ٖ button.
Error history Hour meter Error code
Button Press Display
ٌ Old → New
Short
ٖ New → Old
215133
Figure shows the error history screen when there is no
record of error.
Note: 1. If elapsed time is 3 minutes or more after the When there is no error record
last button operation is performed, the screen
returns to the standard screen automatically.
2. Starting the engine while using the error his-
tory display cancels the data and the display
returns to the standard screen.
215134
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ELECTRIC SYSTEM
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ELECTRIC SYSTEM
215137
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ELECTRIC SYSTEM
Brake fluid level warning lamp When brake fluid level is low (option)
Clogged air cleaner element warning lamp When air cleaner element is clogged (option)
LPG level warning lamp When LPG level is low (LPG models) (option)
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ELECTRIC SYSTEM
Electronic gasoline
Engine check When the engine is failed
Amber engine models
lamp (glows)
(Standard)
To standard screen
the password input screen is displayed after
the brand logo screen, enter the password.
(b) Password input procedure
Button Press Display
Short 0 to 9, and “←”,one at a time
ٌ Long 0 to 9, and “←”, incrementally
Short “←”, 9 to 0, one at a time
ٖ Long “←”, 0 to 9, incrementally 215140
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ELECTRIC SYSTEM
215142
5.6.3 Over speed warning (Dealer option)
When the pre-set speed limit is exceeded, the image
Over speed warning
of the speedometer display in the LCD screen alter- The display (value)
nately changes between black characters on a white changes between black on
white and white on black.
background and white characters on a black back-
ground. Also warning buzzer activates. Service tool is
required to set up the over speed warning.
(For details, see the service tool manual.)
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ELECTRIC SYSTEM
215144
5.6.5 Overload warning display (Maker option)
When the pre-set load limit is exceeded, the image of
the speedometer display in the LCD screen alternately Overload warning display
Numeric changes between
changes between black characters on a white back- black on white and
ground and white characters on a black background. white on black.
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ELECTRIC SYSTEM
216630
5.6.7 Speed restriction (Maker option)
Speed restrictions that limits maximum speed (for both
high and low speeds) can be pre-set. H/L selector
switch is used to change between high and low
speeds. Service tool is required to set up the speed
limits. (For details, see the service tool manual.)
Note: Speed limit setting should be performed by ser-
vice personnel.
215153
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ELECTRIC SYSTEM
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ELECTRIC SYSTEM
5.8 Troubleshooting
Condition Explanation Countermeasures
Small and big special lift trucks that can
Speedometer is not displayed. drive on public roads do not show the Use the speedometer on head guard.
speedometer.
Fuel gauge is not displayed. LPG truck does not show the fuel gauge. -
The fuel gauge shows some On gasoline LPG dual fuel lift truck, the
remaining fuel, but the lift truck fuel gauge shows only gasoline amount. For LPG low fuel, use LPG fuel warning.
stops with no fuel. LPG amount is not shown.
The back-up lamp is turned off when the
internal temperature of the instrument Move the lift truck to shade and cool
Back-up lamp is turned off.
panel is high (105°C) [221°F]or higher to down.
prevent the back-up lamp from breakage.
The LCD is turned off when the internal
temperature of the instrument panel is Move the lift truck to shade and cool
high (85°C) [185°F]or higher to prevent down.
LCD is not displayed. the LCD from breakage.
LCD contrast may be adjusted to mini-
Adjust contrast with buttons.
mum.
When the instrument panel temperature
The display changing speed is is low (0 °C or lower)[32°F or lower], the
-
slow. speed is slow for one of LCD characteris-
tics.
The display becomes dark when the
LCD screen is too dark. instrument panel temperature is high, for Adjust contrast with buttons.
one of the LCD characteristics.
The display becomes light when the
LCD screen is too light. instrument panel temperature is low, for Adjust contrast with buttons.
one of the LCD characteristics.
When the engine is running, long push of Stop the engine, and place the engine
Button press (long) is invalid.
button is invalid. key switch in the ON position.
When the battery is changed, the time
Time becomes 00:00 AM. Refer to “5.3.4” to adjust the time.
resets.
Password “0000” and “1111” can
You can not register “0000” and “1111.” -
not be registered.
This function is available only for the Select the load meter display option
Overload warning function is not
trucks with load instrument display (maker option) for overload warning dis-
available.
option. play.
A trigger speed setting should be 20 km/
Alarm lamp of exterior alarm func-
h or lower, and a trigger load setting Check to see if exterior alarm function is
tion does not glow. (The buzzer
should be 3.5 ton or less (depending on correctly set up.
does not activate.)
the type of trucks).
This error message is for the instrument Using the service tool, update the hour
Error (F-73) occurs.
panel and hour meter update error. meter appropriately.
During setup procedures, if there is no
During the time setup, the screen
operation of buttons for three minutes or
returns to the standard screen
more, or if the engine is started, the setup
while the setups of the error his- -
being conducted becomes invalid and
tory and the exterior alarm have
the standard screen will appear. Repeat
not been completed.
the setup procedure from the beginning.
Electrical short circuit is suspected,
Display of fuel gauge and water check the wiring and interconnection of
-
temperature gauge are blinking. fuel sensor and water temperature sen-
sor.
Note: The phenomena above are not problems. They are characteristics of the equipment.
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ELECTRIC SYSTEM
6. Wire Color
Wire colors listed in the table below show standard colors (base colors). For wiring composed of two colors, the first
color shows a base color and the second color a marking color.
Example: The wire color of B/W shows that its base color is B with a marking W.
B㧛W
Marked color
Ground color
Note: For wiring identification, the same color, in principle, must be used for the circuit from the power supply to the
load.
Be careful that allowable current differs between solid wires and stranded wires even if they are of the same
gauge.
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ELECTRIC SYSTEM
7. Troubleshooting
7.1 Starter System
Weak or dead battery Recharge or replace.
Short or open circuit Repair or replace.
Poor continuity in starter switch Replace.
Starter will not crank engine.
Starter or starter relay defective Replace.
Starter switch Direction lever not in neutral Move the direction lever to
position (Powershift truck) neutral position.
Short or open circuit Repair or replace.
Turning off key switch will not
Engine stop solenoid defect Replace or adjust.
stop engine.
Control timer defect Replace.
7.2 Gauges
M/P - Water temperature meter connection defect
1 Check the connectors.
2 Check the conductivity.
Indicated temperature is low.
3 Check the display with warmed water temperature sensor.
4 Replace the water temperature sensor.
Water tempera- 5 Replace the instrument panel.
ture gauge Check the part number.
1 Check the part specification.
Will not indicate accurately.
2 Check the connectors.
3 Replace the water temperature sensor.
M/P - Water temperature meter connection defect
The indication value blinks.
1 Correct the short circuit.
Setting is not proper.
Indication value is not dis- 1 LPG truck do not show the value.
played.
2 VCM setting is not correct.
Check the part number.
1 Check the part specification.
Fuel gauge 2 Check the connectors.
Will not indicate accurately.
3 Replace the water temperature sensor.
4 Remove fuel tank cap assembly and check such items as bent
float.
1 Correct the short circuit.
The indication value blinks.
2 Remove fuel tank cap assembly and check wirings in the tank.
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