ELECTRICAL SYSTEM DESCRIPTION Console BOK. cece e eee eee eee ceeeeee Bel DISASSEMBLY AND REASSEMBLY Console box Components in consoic box Combination meter. 6... see eevee eeeee eee MAJOR ELECTRICAL COMPONENTS Starter switch (with anti-restart lock) -35 Lighting switch - 36 Fuse box .. .37 Spare terminals, - 37 BATTERY MAINTENANCE 2.000 00.000000eeeceeeeceeeeeeceees 8 LAMP BULB SPECIFICATIONS ....... voce eens 39 AC (ADVANCED CONTROL SYSTEM) Nomenclature .. ceveeeeeee B10 Maintenance precautions... 00000... 000eeeecceeeeeeeeeeceeee es see Bl Description - ce vneeeee eee sees FID Operating principles 343 How to set controller . 321 ELECTRICAL SYSTEM SCHEMATIC - 3:27DESCRIPTION Console Box 1 Engine coolant temperature gauge 2 Choke control 3 Fuel gauge 4 Service hour meter 5 OK monitor 6 Starter switen 7 Light switch 8 Puse box 9 Auto-light switch ELECTRICAL SYSTEM OK monitor 2 8 4 8 4 7 9 8 DODOOQOOOO@OE 5i vs Fonction Ne Tar Om | onertiseng [Renata 1 Bake i el nnr a Rea Taw 2 | Powershift wansmission ol temp. indicator light | Normal ‘Overheating ‘Option 2 [low pg nor Hg Eee _| reine Die mi 4 ran ot ring rt |_ Nor) | abana | ng l ema der igh Nera Law 6 _{ Air cleaner element indicator light Nonnal_ Clogged Option 7 [i rnin Nena | Dain war”) ee mae | ie oa vel gie | Nowa tw | Sysen nice gt Nat_—_| Avon ‘How to cleck indicator light bulbs ‘The bulbs are normal if ue indicator lights 1, 2, 6,7 and 9 come ON when the starter switch key is tumed 10 | (ON) position, (The indicator fights wit! go OFF when the engine stats.) 34ELECTRICAL SYSTEM DISASSEMBLY AND REASSEMBLY Console Box 208422 Disassembly Reassembly 1, Disconnect the electrical wires at connectors 1. To reassemble the console box, follow the reverse (in the gasoline models, disconnect the choke of disassembly procedure, cable om the engine side.) 2. Remove screws 2 (fout) securing the cover, 3, Remove screws 3 (six) and separate the froat and rear panels. 4, Remove screws 4 (four) securing the instrument panel. To replace the instrument panel bulbs, remove screws 3 and 4.‘Components in Console Box 1 Power relay 2 Power relay 3 Torn signal relay 4 Glow plug relay (diesel models) ELECTRICAL SYSTEM 2peaes '5 Glow plug timer (diesel models) 6 Light switch 7 Starter switch, 8 FusesELECTRICAL SYSTEM Combination Meter Disassembly 1 205460 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 3 Fuel gauge Be careful not 10 damage the printed circuit when disassembling the combination meter. Bulb replacement Reassembl: . For bulb replacement, remove the socket from the ‘To reassemble the combination meter, follow the printed creuit by tuming it tothe Jef. For con- reverse of disassembly procedure. figuration of the indicator lights, refer to “OK. Monitor.” 3-4ELECTRICAL SYSTEM MAJOR ELECTRICAL COMPONENTS Starter Switch (with Anti-Restart Lock) ‘This switch has a built-in anti-restart lock, so the _the diesel models, | (ON) position of the switch is ‘key cannot be tumed from !(ON) to. (START) —_for energizing the glow plugs. position while the engine is running, The gasoline and diesel models use the same starter switch. In | ©10F (ON) @ (sTaRn a] oseia Coanetion for eatin models Tena |B ™ 5 ey \GonpmO | Faeton bey, | Reb cen | SoReal odton irate oon Soy © (Orr) o 1 ON) —— @ start oe ‘Connection fr diesel models Tein | —__B ui 5 | Fa, oe Ta Bis OO | ES © (OFF) °° Ton — @ (STAR 35ELECTRICAL SYSTEM J Lighting Switch were wan 2) 5] stoke, ma fin.) Fat LAIN - HY 206861 ‘Connection chart Texim | __—& 7 a 7 (Gompoven" | a atiges aae owas poten ay | ie | Hentts | Ooch ns OO 1st orion 2ad position ©. 2ELECTRICAL SYSTEM Fuse Box | [eoae| Amp Creole Backup ghar (wanoa rantni- | Oe Te Sop gis ieee pane gh te ® B | 158 | Souk ammision mdst e~] Spare termi egive them0 eo | 1A | sec 402 only) o— Tea | Taian, eres ih eo working lights (option. BLA | Rend is F | 20a | Conralter o)oa__| Hom [Pac] isa | speetie Pa TE 6a Feo et oe orl Spare Terminals ‘The spare terminal cord extends from the fuse box: in the console box. (Another spare terminal is Jocated on the chassis-side main hamess.) Cond color: Lg (yellowish green) Removing the console box rear panel will expose this spare terminal which is fastened tothe harness protector with vinyl tapeELECTRICAL SYSTEM BATTERY MAINTENANCE 1, State of charge and electrolyte specific gravity adjustment Spepite peri reading State of charge Adjustment 1280 10 1265 Pally charg TF difference in SG, berwern ay iwo cls is 0.020 of sore, effect high current discharge to minimize the Gitference and then recharge batery. Adjist SG. ceriog recharging 1.260 10 1.225 ‘Onerlfcharged Recharge baiery and adjust elecrolyie 8.6. Make sure there le nelter aly component, oasly comected cord nor coroved connection 120 9 below Discharged Recharge battery. Waiference in SG. lrg, adjust it Ging foharsing. If difference in $.G. is A cell with a low S.G. ‘During recharging, adjust S.G. to 1.280 to 1.265_ smote than 0.040 isin stoned condition. | itditlerence i 8. is more tan O40 and a low SG. is Recharge wal vellage | foud in cata esis only. replace haley. afer envi fn GG. sabre ad | avery Tor 120 96 hous, conduct a igh curent discharge ive remained conatet | to for fore than 2 bout 2. Specific gravity reading and state of charge To check the battery for state of charge, take. hydrometer readings om its electrolyte. The battery may be fully charged if the $.G. reading is 1.280 to 1.265 at 20°C (68°F). The state of charge can be told from the way the electrotyte level goes. down to expose the cell plates. IF addition of distilled water is necessary every month or 90, the battery is overcharged. If addition és not required for more than 3 months, itis likely thatthe battery is inadequately charged. 3. Charging precautions (1) Inslow charging, the charging current should be about 1/10 the capacity of the battery 10 bbe charged, In quick charging, the battery capacity in ampere should not be exceeded. During charging, adjust the charging current to prevent the electrolyte temperature from rising beyond 45°C (113°F}. Q @) (4) When connecting the cables to the battery, degin with the cable for the positive (+) terminal, When disconnecting them from the battery, begin with the cable for the negative © temminal. ZXCAUTION Be sure to tum OFF the starter switch and light switch defore disconnecting or connecting the battery cables to prevent the IC regulator from suffering damage.LIGHT BULB SPECIFICATIONS, ELECTRICAL SYSTEM No.of Was Light ‘rise, | Color oftens | T- Shape Remarks A ead igs 2 | cots | oss) EE Bea 2 | Amber fo 3 standart Combination Stated on Sign cron) reread gard Clewance Clee 2 | cooaes | 10 Ge = S To] | ante | os a faneinaticn ‘Tailstop fas . ems cea | Te a | Res ma) CE Backxp : acs 2 | cases | x0 <=} Working igh , erkng he «comes | ss | EA | nine ‘License plate light 1 Colorless 0 <4 Optional 2 | coortes | 38 CR ni | cots | 3 ap} aousee 39AC (ADVANCED CONTROL SYSTEM) ELECTRICAL SYSTEM Nomenclature 2050058, SSS speed pickap option) Sa X WE i i 0 joystick levers (finger-control system) WA Te 3-10Maintenance Precautions ‘The AC model contains a microcomputer. Fol- lowing are the precautions to be observed in performing any maintenance on the AC model. (1) When removing the controller cover, make PToper provisions to keep out rain, washing water splashes and the like, @) After using the controller setting switch, check to make sure the control system is in keeping with the truck specifications. Improper setting of the system will result in inability to lower the forks in an inching manner. (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 eon- troller from the system at its connectors. (4) When handling the controller by hand, never touch its electrical tenminals, or your body charge will rupwre some of the electronic elements in the intemal controller circuits. ELECTRICAL SYSTEM costae 5] 5 8B] oO O oesn0089 aT Gssseges sexing BSTLBS! switches 204909 ontELECTRICAL SYSTEM Description 1. Finger-control system ‘This system, unlike the conventional mechanical ‘contol, is electronically actuated to help reduce the effort required of the operator in moving the con- trol levers for lift, tlt and attachment functions. (Features) (1) The flow regulator valve bas been disconti ued. In this system, the load acting on the lift cytinders is detected to control the flow of oil etuming from the lift cyfinders to prevent the load from lowering unsafely rapidly at the start of lowering. @) In the full free masts, more oil returns from the Ist lit cylinder than from the 2nd lift cylinders to allow the Ist lift cylinder t0 retract faster in order to add to productivity. (B) The lowering speed selector switch insures smooth fork and mast movement no matter how abruptly the operator may move the control levers, ‘This switch is ideal for handling of fragile loads. 3412 Propertioning Sito ygraulle transducer 204001(4) This system provides the following safety functions: ELECTRICAL SYSTEM (@) ‘The lift tilt and attachment functions are not performed even if the control levers are moved when the engine is not running. (©) Tho if, elt and autachment functions are not performed even if the control levers are moved when the safety switch is in ON (pushed) position, (©) 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). ‘The system indicator light Z\ in the OK ‘monitor ales the operator (0 problems ‘occurring in the electrical system and, at the same time, stops function, (If any problem ‘occurs in the lift system, for example, the system becomes inoperative.) 2. Auto-light system ‘The head lights are under the control of switch and sensor, With the auto-light switch ON, the head lights tums ON automatically as the truck is driven. into a dark area. The head lights can be tumed ON or OFF manually. Operating Principles J. 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). @) 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 an ‘output signal. At this point the controller issues an ON signal to the unload solenoid, thereby turning ON this solenoid to introduce hydraulic pressure into the control valve. Tbe system is now ceady to actuate the equipment. ‘The output signal appiies to the proportioning solenoid selected by the direction of theELECTRICAL SYSTEM Joystick movement. Inside the control valve Of that solenoid, its spool is forced to slide, altering the intemal oil passage to direct the oil to the corresponding cylinders. The spool keeps on sliding until it comes to the position at which the pressure of its pilot chamber becomes equal to the force of its centering spring, In the meantime, the cylinder extends or retracts against its load. As the joystick is moved back to its neutral position, the signal to the proportioning solenoid dies to lower the pilot chamber pressure and allow the centering spring to push the spool to its neutral position, ‘whereby the line to the cylinder becomes shut off: the pressure in the line is now trapped, holding the cylinder there, At the same time, the ON signal to the unload solenoid goes OFF, s0 that the part of the system actuating the equipment goes into no-load state, (3) When the joystick is moved in the direction for lowering the forks, the output signal (from the controller) applying to the proportioning solenoid is produced by the lever stroke signal and lift-load 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 oll retumning from the lift cylinders will be ‘constant repardiess of the load acting on these eylinders, (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 ist lift oylinder starts retracting after the 2nd litt cylinders has retracted. As the full free switch. tums ON, the output signal (for controlling the retracting speed of the Ist 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 Ist to 2nd lift cylinders, This feature is for lowering action a4 () Ifthe towering speed selector switch is tumed ON, the effect of a change in lever stroke signal upon the ourput signal is retarded. Thus, with this switch tumed ON, the equipment will not move quickly even if the lever is moved quickly. (© Power supply to the controller is initiated from the starter switch through a 10-Amp fuse and safety switch, Pressing this switch into OFF position shuts down the controller ‘without shuiting down the engine. (7) With the staner switch and safety switch, tamed ON, the unloading solenoid and proportioning solenoid are under control of the joysticks, With the engine shut down (and hhence the hydraulic pump standing stil), the spools in the control valves are inoperative because no pressure develops in their pilot chambers. Consequently, the equipment remains inoperative even when the starter switch and safety switch are turned ON.ELECTRICAL SYSTEM rac (ago) wons hopes ped ‘aoa, 109 (peda wont i pnsiod| ee gjss scare aaa a ee 3 wt senor [V] ane ‘oa ajosu0 Lo ayyeurayys waxsfs [osyuOD-z98 ULL 3-15ELECTRICAL SYSTEM. (8) In addition to the functions explained above, the controler monitors the supply voltage and | ERD Ged) the electrical connections for the control | Robber cover levers (joysticks), solenoids and other inputy output devices, and alerts the operator to problem, if occurs, by flickering the system sonneaes indicator light and tuming ON this ight and also LED (as shown in the chart below). Such . a problem is usually 2 fault in tae hamess or geooce connector and must be located by inspecting. ‘The hydraulic components such as pump, control valve, cic, are not monitored. Sys ‘LED flickering patern Probie detected Bete Wt 2 ee af | (Normal) OFF ey L & ‘Open: oF sror-areut i contol | No power supply Jover (with staner switch in ON | to parca ees position) sysiem g ‘Open: or shorircit n yale | No power suppl 24 4 | tarstcer founaysien | ON J _— Power suply 0 or shorczcit in waved, < sys 30) 4 Seed pp Ott) fee per Supply vlige coo high over 20 | No power supply gees vols grioo low under 8 vols) | coll system 2 ox 5 r Topowe aviy a4 Open- or shorscircuitin solenoid | to pardeular system 2 ‘Contol ever wetal positon i displaced {No power supply & = to panicalar Flickers 4 Open: oF short czcuit i coauol | sym B2 lever (with sare switch in ON position} ie Sea: switch OFF, or open-citeuit_ | No power supply = int oe tomisyiems, | Flickers & LED remains ON Problem in comrolier es NOTE: Any problem does aot cause the engine to shut down, 3462. Auto-light system (1) The auto-tight system tums ON the head ighis automatically when the truck is driven. into a dark area, with the starter switch in (ON) position, the safety switch ON and the auto-light switch ON, The controller is ‘common to this system and the finger-control sysiem but the circuit of this system is independent so the components of these systems do not affect each other in operation. ELECTRICAL SYSTEM Example: The auto-light system functions regardless of ON-OFF of the seat switen, ‘The finger-control_ system functions even if the light sensor is fauity. Light sensor eos) &\ / ay’ Controlter (in-engine com) f Power relay 206428 ‘The controller has no auto-light system diag- nosing function. ‘Major components of auto-light systemELECTRICAL SYSTEM Q) ‘The light sensor is basically a resistance device, whose resistance is compared with that in the variable resistor (the uto-light sensitivity adjusting knob) inside the ‘controller. The sensor resistance increases as brightness decreases. When, in operation, the sensor resistance becomes greater than the resistance in the variable resistor, the ‘comparing circuit energizes the power relay to close its contacts to tum ON the head lights, With auto-ight switch ON, startor switch (ON) and safety switeh ON ‘Gone Goysck) box meoteaee 204997, Operation — 13) With the auto-tight switch tumed 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 ambient ELECTRICAL SYSTEM brightness but this does not affect the light tumed ON by the light switch. With auto-light switch OFF and starter switch and safety switch I (ON) With autolight soitch OFF, starter switch (ON) and safety site ON ena igh deme pce Es Tai ig ‘nent pane ight Consoiebo Cearmce Tight ‘Cente Goysick box = Sly mck a a Power spply - Cd j Operation — 2 319ELECTRICAL SYSTEM (4) Turning OFF the safety switch with the auto- Tight switch ON causes the power relay to remain OFF. Under this condition, all lights OFF, the light switch s effective and can tum ON each selected light, regardless of the safety switch and starter switch, will not come ON. If the auto-light switch is ‘With auto-light switch ON and safety switch OFF ae Gy ox ea ronan : vue pce sears, | sation th rover on il ened Light ee BED 25) Lo Seer a Ws a Corr BAG Le " “Auto-li ("=| oO a Banery seine [-= ows elg— | wind ves ee "| U | ny teaTee a | 201909 Operation — 3 Operation Logic: Taw Iyhrswich ON Autoright sich OFF = we Tiga wich OFF | paren | pouion | OFF | poison | porsca | OFF | poxion | parion Clearance license plate lights ° 2 ° ° ° Tee igs ope >e fe 3-20ELECTRICAL SYSTEM How to Set Controller ‘Set the controller on any of the following ‘occasions: ‘Occasion Seating ‘After mast has been changed, or an optional | Resetting of setting switches equipment added ‘When auto-light system is adjumed ‘Adjustment of Brightness a which light sensor operates ‘After conttol vaive lift section solenoid has | Adjustment of maximum lowering speed (when requires) been replaced (or contol valve replaced) ‘Aer controller asserably has been replaced | + Resetting of seting switches ‘+ Adjasiment of maximum lowering speed (when required) ligt sensor operates (when ‘Soting window (with rubber cover) Contolier checker [e9) CY Se (ib Connectors fool foo) “To be installed with this side up —> Setting window (without rubber cover) Auto-ligh sonsitvigy adjusting knob Lowering speed adjusting nob with this side wp LED (red) eoossess: geoseane Setting switchos (ul inline package) ‘To be instal 324ELECTRICAL SYSTEM 1. Setting switches ‘The controller has 2 total of 16 setting switches. ‘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 patter Black dot indicates switch head.) sere ene eee | brett ERbR bp sae | ym ay velo) | ral) A [=[Q] [at |e10 re Ea pew Note: Options A, Band C will be a introduced in OPTION, CATALOGUE later. wa, [Oren og ese ane [Sos | Le 10 70 een = [60 00. f=] 0) =O) | v=! 0-0]] Tete g) | ew) a (ve 15] | (8) | fer 0 O}) Le Tool) Co [00 aas002 (2) Example of setting 6B Setting ‘Truck: PG1S Be Ne (ot t al No. of spools: 3V ‘Masi: 4V15A (2-stage panoramic) oosooeos Option: Speedometer with indicator light goooocos| Smt vo mah ke S Henic 3-22ELECTRICAL SYSTEM. 2. Failures resulting from incorrect setting (4) ncormec sting for transmission and engine (1) Incorrect setting for truck size (1-ton, 2-ton, ‘Ef the travel specd option is set, the travel speed 3-ton and 3.5A-ton models) ‘will not be read correctly. (@) Incorrect seiting will result in abnormal (5) Incorrect setting for travel speed option lng loweng ped annie el. ASME sung fr YES oft tel ps ‘ vein tag fe pickup (mounted on the transmission) thé nd for rane eoneng sed wil esa act om ae i " a light ZS will flicker but the equipment will be Io mao on moe low-E 2 sang utente Spee ¥ circuit in the travel speed pickup.) (b) If the travel speed option (load meter, indicator Ii (6) Incorrect seting for controller check (Be sure speedometer, travel speed indicator light, leet OFF) tc.) is set, the travel speed will not be read correctly. fits set to ON, the equipment will not be actu- @) Incorrect setting for number of contol valve ated even if the joysticks are operated. spools (a) If the setting is made for the number of spools greater than is actual, the system. indicator Jight A\ will Dicker, and the equipment will not be actuated. (Such a setting is taken as open- of short-circuit in the control valve solenoid or in the Joysticks.) (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 actuated, (3) Incorrect setting for mast (a) A setting for a dual-stage full free mast or Iriple-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 Jowering speed of the Ist lift cylinder will bbe abnormally low. This setting will not affect the lowering speed of the 2nd life cylinders, 3-23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 t0 “8.” (@)_ The lower the figure, the more the lowering speed is decreased, “A” thru “F* mean “10” thru “15.” Use a screwdriver to tum the knob. This knob can be tumed endlessly in both directions, Be careful not to damage the groove of the knob when putting a screwdriver. 4. Auto-light sensitivity adjusting knob (Q) This knob is for adjusting the sensitivity level at which the ato-light system tums ON and (OFF the head lights. (2) The knob has been set as shown. (3) The more the knob is tured to the right, the lower will be the sensitivity at which the system turns ON and OFF the head lights. 1) Use a screwdriver to turn the knob. Be careful not to damage the groove ofthe knob when putting a screwdriver. 324 205004 205005,5. Working precautions (1) When installing the controller, position it correctly. Be careful not to tur upside down, (2) When resetting or adjusting the comrolier on the truck, be sure to tum OFF the starter switch and light switch, (3) When removing the mubber 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.) (@) Be careful not to damage the rubber cover when itis off the controlter, (5) Do not Jet any foreign matter fall tato the controller through setting window. ELECTRICAL SYSTEM 2osoa7 3-25