Electrical System p9000

Chapter 3 ELECTRIC SYSTEM
1.
Chassis Electrical Devices Wiring Outline ........................................... 3-1

1.1
1.2
1.3
2.
Structure .................................................................................................. 3-4

2.1
2.2
2.3
3.
List of Wire Colors ................................................................................................. 3-36
Troubleshooting.................................................................................... 3-37
7.1
7.2
7.3
8.
Instrument Panel Screen Components.................................................................. 3-20

Basic Screen Display............................................................................................. 3-21
Basic Operation ..................................................................................................... 3-25
When an Error Occurs........................................................................................... 3-29
Warning Lamps ..................................................................................................... 3-31
Optional Functions................................................................................................. 3-32
Hour Meters........................................................................................................... 3-33
Troubleshooting..................................................................................................... 3-35
Wire Color .............................................................................................. 3-36

6.1
7.
State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment ..................... 3-19
Specific Gravity Reading and State of Charge ...................................................... 3-19
Charging Precautions ............................................................................................ 3-19
Instrument Panel ................................................................................... 3-20

5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
6.
Disassembly .......................................................................................................... 3-18
Battery Maintenance ............................................................................. 3-19

4.1
4.2
4.3
5.
Console Box ............................................................................................................ 3-4

Main Electrical Components.................................................................................... 3-6
Table of Lamps...................................................................................................... 3-17
Console Box .......................................................................................... 3-18

3.1
4.
Gasoline Model........................................................................................................ 3-1

Diesel Model............................................................................................................ 3-2
Gasoline and Diesel Models.................................................................................... 3-3
Starter System....................................................................................................... 3-37

Gauges .................................................................................................................. 3-37
Lighting System ..................................................................................................... 3-38
Electrical Schematic ............................................................................. 3-40
ELECTRIC SYSTEM
Chapter 3 ELECTRIC SYSTEM
1. Chassis Electrical Devices Wiring Outline

1.1 Gasoline Model
Instrument panel
Head lamp
Front
combination lamp
Rear combination lamp
Front
combination harness
Rear combination harness
Seat
Seat switch
To armrest
(FC model only)
Harness B
Back-up buzzer
Stop lamp switch
Transmission
control solenoid
VCM
(Vehicle control module)
Relay box
Fuse box
Thermoswitch
Battery
Battery cable (+)
Battery cable (-)

To engine harness
To starter
Earth
To engine harness
ECM (Engine control module)

215355
3-1
ELECTRIC SYSTEM
1.2 Diesel Model
Instrument panel
Head lamp
Front
combination lamp
Rear combination lamp
Front
combination harness
Rear combination harness
Seat
Seat switch
To armrest
(FC model only)
Back-up buzzer
Harness B
Stop lamp switch
Transmission
control solenoid
VCM
(Vehicle control module)
OCM
(Option control module)
(Wet disc brake only)
Fuse box
Thermoswitch
(Sending unit)
Relay box
DCM
(Diesel control module)
(Wet disc brake only)
Battery
Battery cable (+)
Glow timer
Earth
Glow relay
Battery cable (-)
To starter
215356
3-2
ELECTRIC SYSTEM
1.3 Gasoline and Diesel Models
Console Box
Instrument panel
Combination switch
Parking brake switch

Warning buzzer
Key switch
Horn
Select switch
Horn harness
Control valve
FC
MC
Output unit
Output harness
Control valve
Control valve
Transmission
Parking brake valve
FC control lever
FC Armrest
Input unit
Harness
Parking brake
pressure switch
Speed sensor
Thermoswitch (T/C oil)

215357
3-3
ELECTRIC SYSTEM
2. Structure
2.1 Console Box
4
1
2
3
4
5
6
7
8
Water temperature gauge

Fuel gauge
Hour meter, warning lamps
Instrument panel
Key switch
Light switch, turn signal switch
Direction Lever
Speedometer
7
5
214140
3-4
ELECTRIC SYSTEM
2.1.1 Function of Instrument Panel
O
214141
Ref. Name of indicators and warning lamps

A
Parking brake warning lamp
Seat belt warning lamp
Charge warning lamp
Multi-purpose warning lamp
Torque converter oil temperature warning lamp
When turned off
When glows or blinks
Remark
Normal
This lamp glows when the parking

brake is applied.
Fastened
This lamp glows when the seat belt is

not fastened.
Normal charging
This lamp glows when charging is not

normal.
(This lamp glows all the time while
the engine is stopped.)
Normal
This lamp glows when a minor failure

occurs or operating cautions are
issued.
Normal temperature
This lamp glows when the torque converter oil temperature is not normal.
Engine oil pressure warning lamp
Normal
This lamp glows when the engine oil

pressure is low.
(This lamp glows all the time while
the engine is stopped.)
Engine warning lamp
Normal
This lamp glows when the engine is

failed.
Glow pilot indicator lamp
Preheating completed
This lamp glows when the glow plug

heating is ON.
ProShiftTM
This lamp glows when sudden acceleration or full reverse (shifting of

travel to the opposite direction) activates protective function.
Option
Mast interlock indicator lamp
When mast interlock is activated

(glows)
Cursor buttons
Fuel gauge
indicator lamp
LCD screen
Enter/display button
Indicates remaining fuel amount with key in "ON" position

-
Indicates water temperature with key in "ON" position

-
Description of function
Inspection method for blown bulbs of instrument panel
All the warning and indicator lamps are normal if they glow when the key switch is turned to the | (ON) position.
3-5
ELECTRIC SYSTEM
2.2 Main Electrical Components

2.2.1 Key switch
The diesel model uses a distributor type injection
pump. Its starter switch is equipped with an automatic
fuel cut engine stop mechanism.
The gasoline model is also equipped with an automatic fuel cut engine stop mechanism.
(Key switch with anti-restart lock)
This key switch has an anti-restarting function.
This switch has a built-in anti-restart lock, so the key
switch cannot be turned from the | (ON) to the
(START) position while the engine is running. This prevents engine trouble or starter breakage caused by an
operator's improper operation when starting the
engine.
The gasoline and diesel models use the same key
switch. On the diesel model, the key switch is electrically connected to the engine so that the | (ON) key
switch position turns on the glow plugs.
(OFF)
(ON)
M
ST
(START)
B
215358
Connection Table
Terminal
ST
OFF
Key in and out

Yes
ON (when operating)
---------
-----------
No
START
(when starting engine)
---------
---------------------- -----------
No
3-6
ELECTRIC SYSTEM
2.2.2 Combination switch

(1) Light switch, turn signal switch
Forward of truck
Light switch
turn signal lever
L
10
N
OFF
10
R
OFF
1
25 25
2
2
5
Light switch
turn signal switch connector
T-1
L-3
L-1
T-3
T-2
L-2
Horn contact
Light switch connector
Terminal
Target
Knob position
L-1
L-2
L-3
Power
Tail,
clearance lamp
Head lamp
T-1
T-2
T-3
Flash unit
Turn signal
lamp (Right)
Turn signal
lamp (Left)
OFF
1
2
Turn signal switch connector

Terminal
Target
Lever position
R (Right)
N (Neutral)
L (Left)
215359
3-7
ELECTRIC SYSTEM
(2) Direction switch
Forward of truck
Forward-reverse selector lever (FNR)
10
F
N
10
OFF
Forward-reverse
shift change switch (FNR)
4
2
1
3
Connection table
Terminal
Wire color
Lever position
L/B
L/R
L/W
F (Forward)
N (Neutral)
R (Reverse)
215360
3-8
ELECTRIC SYSTEM
2.2.3 Horn
Check that the horn activates when applying the specified voltage to both terminals of the horn, T1 and T2.
Replace the horn if it does not activate or its sound is
unusual.
Up
Operating voltage: DC12V (Gasoline and diesel models)
T1
Note: The proper installation of the horn to the lift

truck is shown in the illustration.
T2
Down
Vent hole
T1
Contact
Coil
T2
215361
2.2.4 Tank unit
3/4
424.2 mm
(16.7 in.)
F
242.7 mm
(9.56 in.)
61.2 mm
(2.41 in.)
Illustration shows gasoline model.
1/2
Pressure relief valve

1/4
Fuel pump
Fuel filter
Fuel suction strainer
Referential Standards
Float position
1/4
1/2
3/4
Standard resistance value ()
80
(49.5)
32
(19)
10
Tolerance ()
+12
+2
+1.0
- 0.5
The number in parenthesis is a reference value.
215362
3-9
ELECTRIC SYSTEM
2.2.5 Stop lamp switch

Apply an ohmmeter across the terminals and check
that the stop lamp switch is turned ON and OFF when
the push rod protrusion is at the specified value.
Push rod
Measure the insulation resistance value across the terminals when the push rod is pushed in.
Replace the stop lamp switch if its measured insulation resistance value is less than the value below.
Insulation resistance value
2 mm
(0.08 in.)
4 mm
(0.16 in.)
1 M or more
(at 500 V megger)
M101.25
OFF
ON
215363
Rated voltage: DC12V

2.2.6 Thermoswitch (Engine cooling water temperature)
(1) Apply an ohmmeter between the terminal and
body of the sending unit and check for continuity
(resistance value).
Body
Terminal
(2) Replace the sending unit if there is no continuity

or the resistance value measured is outside the
standard resistance value.
Note: The illustration is for gasoline models.
215364
Gasoline model
Temperature
[C (F)]
60 0.2
(140 0.36)
65 0.2
(149 0.36)
80 0.2
(176 0.36)
100 0.3
(212 0.54)
125 0.3
(257 0.54)
130 0.3
(266 0.54)
80 10
67 7.8
40.6 3.7
22.2 1.4
11.3 0.4
10 0.3
Temperature
[C (F)]
50
(122)
60 0.2
(140 0.36)
80
(176)
100
(212)
106 0.3
(222.8 0.54)
120
(248)
(80)
56.3 5
(29.5)
(16.5)
14.3 0.5
(10)
Diesel model
3-10
ELECTRIC SYSTEM
2.2.7 Thermoswitch (T/C oil)

Apply an ohmmeter between the terminal and body
and check for continuity (resistance value). Replace
the thermoswitch if its measured insulation resistance
value is less than the value below.
Terminal
Body
1 M or more
(with contact point OFF)
(with 500 V megger)
Internal resistance: 0.5 or less (with contact point

ON)
Allowable load: 0.5 A
Note: When installing the thermoswitch, tighten it to
the specified torque.
31.4 to 47.1 Nm
(3.2 to 4.8 kgfm)
[23.2 to 34.8 lbfft]
Tightening torque
215365
Replace the thermoswitch if it is dropped or abused.

Technical data
Operating
temperature
OFF to ON
122 3C
(251.6 5.4F)
ON to OFF
115 C (239 F)
or higher
Insulation resistance
(with contact point OFF)
1 M or more
2.2.8 Parking brake switch

Measure the insulation resistance between each terminal.
(1) Parking switch at pulled position
Between terminals B and W
Insulation
resistance
100 M or more (at 500 V megger)

Push
Pull
(2) Parking switch at pushed position
6 mm (0.24 in.) (Stroke)
Between terminals B and R

Insulation
resistance
100 M or more (at 500 V megger)
Operation method: Push-pull operation

Contact resistance: 1a-ab
215366
3-11
ELECTRIC SYSTEM
2.2.9 Relay box
Relay box 2
(Gasoline model only)
Relay box 1
Illustration shows gasoline model
Starter relay
Flasher relay
EGI relay
Ignition relay
Back-up lamp relay
ETC motor relay
MAIN/C relay
Fuel pump relay
Warning buzzer relay
Relay box 1
EGI relay
Relay box 2
(Gasoline model only)
215367
3-12
ELECTRIC SYSTEM
(1) Relay box 1
Item
Truck model
Gasoline and diesel models
Rated operating voltage
Coil rating [at 20C (68F)]
CB relay (Ignition relay, back-up lamp relay, and

starter relay)
DC12 V
Working voltage
DC3.0 to 7.0 V
Open-circuit voltage
DC1.2 to 3.9 V
Coil resistance
80 10%
Rated exciting current
168 mA 10%
Connection diagram
(Bottom view)
215368
CM relay (Warning buzzer relay)

Item
Working voltage
Coil resistance
Truck model
Gasoline and diesel models
DC12 V
DC 30 to 7 V
DC 0.5 to 3.1 V
120 10%
117.6 mA 10%
Connection diagram
(Bottom view)
215370
3-13
ELECTRIC SYSTEM
(2) Relay box 2 (gasoline models only)
CM relay (EGI relay, MAIN/C relay, ETC motor relay,
and fuel pump relay)

Item
Working voltage
Coil resistance
Truck model
Gasoline model
DC12 V
DC 30 to 7 V
DC 0.5 to 3.1 V
120 10%
117.6 mA 10%
Connection diagram
(Bottom view)
215370
3-14
ELECTRIC SYSTEM
2.2.10 Glow timer (diesel model)

Inspecting the output time when key switch is turned to
ON
When a tester is applied to terminal 6 and terminal 3
and a voltage of 24 V is applied between terminals 4
and 3, there should be continuity between 6 and terminal 3 for 6 seconds. Replace the glow timer with a new
one if it does not function properly.
4
5
3
6
Initial characteristic (Normal temperature and humidity,

Vcc=12 V)
Preglow timer 6.0
1.4
0
sec
Environmental characteristic (-30C to 70C, Vcc=7 V

to 15 V)
Preglow timer 6.0
2.0
0.6
sec
OFF
ON
Key switch
ST
Glow
relay
Battery
DC12V
Controller
3
Glow
plug
Lamp
Connection diagram
215371
2.2.11 Glow relay (diesel model)

(1) Apply an ohmmeter across terminal 3 and terminal 4 and measure the resistance value of the
relay coil. Replace the coil if there is no continuity
or the resistance value measured is out of standard resistance value.
Coil resistance
13
(2) Measure the insulation resistance value between

terminal 1 and terminal 2.
Replace the coil if its measured insulation resistance value is less than the value below.
Rated voltage: DC12V
1
3
1 M or more
(at 500 V megger)
4
Connection diagram
1
215372
3-15
ELECTRIC SYSTEM
2.2.12 Fuse box
Fuse box
Illustration shows diesel model
Working lamp
15A
Back-up lamp
A/C
20A
15A
Instrument panel
10A
Spare
Glow timer
10A
VCM
20A
*1
20A 30A
ETC
15A
Wiper
15A
Head lamp
15A
Stop lamp
10A
Horn
*1
*1
EGI EGI
10A
30A 30A
Fuse puller
10A
15A
Spare
SBF 100A
Battery
SBF 100A
Alternator
*2
SBF 50A
Glow
*1: Gasoline model only
*2: Diesel model only
215373
3-16
ELECTRIC SYSTEM
2.3 Table of Lamps

Item
Head lamp
Turn signal
lamp
Quantity
Lens color
LED color
16
Colorless
Colorless
Amber
Colorless
Valve
Illustration
Remark
Standard
Option
(Installed to
head guard)
Combination
lamp (front)
Clearance
lamp
Amber
Colorless
Turn signal
lamp
Amber
Yellow
Standard
Red
Red
Standard
12
Colorless
Colorless
Standard
Type of
lamps
Combination Tail and

stop lamp
lamp (rear)
Back-up
lamp
3-17
ELECTRIC SYSTEM
3. Console Box
3.1 Disassembly
5
216938
3.1.1 Preparation
Place the key switch to the OFF position, and remove the cable from the ground side of the battery.
3.1.2 Removal sequence

(1) Remove the screw using a Phillips screwdriver and remove cover 2.
(2) Remove the screw and then, remove cover (U-Re) 3.
(3) Remove the screw and then, remove cover (U-Fr) 4.
(4) Disconnect the electrical wiring from connector 1.
(5) Remove the bolt, then remove console box assembly 5.
3.1.3 Installation
For installation, follow the removal sequence in reverse.
3-18
ELECTRIC SYSTEM
4. Battery Maintenance
4.1 State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment
Specific gravity reading
at 20C (68F)
Condition
Adjustment
1.280 to 1.265
Good
If the difference in S.G. between any two cells is 0.020 or less,

continue to use as is.
If the difference is more than 0.020, discharge the battery in
an efficient manner. If the battery recovers, charge the battery
to adjust the electrolyte S.G.
1.260 to 1.225
Half charged
1.220 (0.2) or less
Recharge battery to adjust electrolyte S.G. Check for any

short-circuited cables or corroded cable connections in the
electrical system.
Recharge battery.
Battery low (caution required) If the difference in S.G. is too much, charge the battery to
adjust the electrolyte S.G.
Recharge the battery until its voltage and S.G. stabilize and
remain constant for more than 2 hours.
A cell with a low S.G. may
Charge the battery to adjust the electrolyte S.G. It should read
cause a short circuit.
between 1.280 and 1.265.
If the difference in S.G. is
It is caused when electrolyte
If the difference in S.G. is more than 0.040 and a low S.G. is
more than 0.040.
leaks or electrolyte rate is too
found in any of the cells, replace the battery with a new one.
high or too low.
Conduct a high current discharge test after leaving the battery
for 12 to 96 hours.
4.2 Specific Gravity Reading and State of Charge

To tell whether a battery is fully charged, check the
electrolyte S.G. of each cell with hydrometer or the
electrolyte reduction speed. If the electrolyte in the
battery cell decreases to the level where the pole
plates are exposed, within one month it may be overcharged. If the electrolyte amount remains sufficient
for more than three months, the battery may discharge.
4.3 Charging Precautions

(1) In slow charging, the charging current should be
about 1/10 the capacity of the battery being
charged.
(2) In quick charging, the battery capacity in ampere
(A) should not be exceeded.
(3) During charging, adjust the charging current so
that the electrolyte temperature does not exceed
45C (113F).
(4) When connecting cables to battery terminals,
always connect the (+) terminal first, and when
disconnecting, remove the (-) terminal first.
(5) Ventilate well during the battery charge because
hydrogen gas is generated.
Identification
55D23L (Gasoline)
130E41L (Diesel)
Be sure to turn OFF the key switch and light switch

before disconnecting or connecting the battery cables.
(This prevents damage to the IC regulator.)
215375
3-19
ELECTRIC SYSTEM
5. Instrument Panel
5.1 Instrument Panel Screen Components
Instrument panel screen consists of warning lamps,
LCD (Liquid crystal display) screen, and and
buttons, and enter/display button.
Warning lamps
Down button
Up button
Enter/display button
LCD screen
215114
The LCD screen consists of six areas: main area, fuel

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

protect circuits in the panel.
Instrument panel internal
(ambient) temperature
85C (185F) or higher
LCD screen is not displayed.
105C (221F) or higher
Backlight goes off.
Note: a) Back-up light illuminates both the fuel mark

and water temperature mark on the LCD from
inside.
b) Warnings are not automatically turned off for
safety reasons.
c) When the temperature is extremely low [0C
(32F) or below], the response of the LCD display is slower.
3-20
Fuel gauge
Main display
Water temperature
gauge
215115
ELECTRIC SYSTEM
5.2 Basic Screen Display

5.2.1 LCD screen display with the engine key in ON position
With the engine key turned to ON position, LCD
screen displays the brand logo screen, the password
authentication screen, and the usual display screen in
sequence. Also, error history is displayed with the
press of a button.
(1) Brand logo screen
When the engine key is turned to ON position, the
brand logo screen is displayed for 2 seconds
while lamp check is being executed.
215116C
(2) Password authentication screen

(Display by optional function)
Inputting the password registered in advance
makes possible to operate the forklift truck.
215117
(3) Usual display screen

The screen is changed to the usual display screen
that shows the conditions of truck.
215118
3-21
ELECTRIC SYSTEM
5.2.2 Speed meter display

This display shows current lift truck speed.
Speed meter display
Note:
Actual speed
Display
0.1 to 1.0 km/h

(0.06 to 0.62 Mph)
1 km/h
(0.62 Mph)
1.1 to 2.0 km/h

(0.68 to 1.24 Mph)
2 km/h
(1.24 Mph)
24.1 to 25.0 km/h

(14.97 to 15.53 Mph)
25 km/h
(15.53 Mph)
215119
Speed display value is rounded to a higher number.

5.2.3 Fuel gauge
This gauge shows the remaining amount of fuel (gasoline or diesel fuel). It shows the remaining amount of
fuel just after the key switch is turned to the ON position. After that, the remaining amount is displayed for 2
minutes on average.
Fuel gauge
Note:
E (Empty) remaining amount
Truck model
Remaining amount
4.0 to 5.5 ton
14.3 liter
(872.6 cu.in.)
or less
With fuel gauge image
Note: LPG dual fuel truck shows gasoline remaining

amount only.
Without fuel gauge image (LE models)
3-22
215120
ELECTRIC SYSTEM
5.2.4 Water temperature display

This display shows engine coolant temperature.
Note: The graph below shows the relation between

engine coolant temperature and water temperature gauge shown on the LCD.
215121
Engine coolant temperature - the number of dots in the gauge

Range displayed on
LCD screen (50 to 120C)
[122 to 248F]
Diesel model
Gasoline model
50
Number of dots in the gauge (Dots)
44 dots
40
Range of overheating (red zone)
30
29 dots
Pertinent range of temperature (rough standard for diesel/gasoline model)
20
10
Overheat (red zone) temperature
Diesel model: Approx. 109 C (228.2 F) or higher
Gasoline model: Approx. 107 C (224.6 F) or higher
10
20
30
40
50
60
70
80
90
100
50
68
86
104
122
140
158
176
194
212
Engine coolant temperature (C) [F]
110
230
120
130 (C)
248
266 (F)
215122
3-23
ELECTRIC SYSTEM
5.2.5 Speed restriction function (Manufacturer's option for Diesel model only)
Speed restriction function will limit both high and low
pre-set speed as a maximum speed limit. H/L selector
switch is used to change between high and low
speeds. For setting up the speed restriction function,
use the service tool. (For details, see the service tool
manual.)
Note: Service engineers should perform the speed
restriction function setup.
Gasoline model includes this function as
standard equipment.
High speed symbol
Low speed symbol
High speed limit display
Low speed limit display 215152
H/L selector switch
215153
3-24
ELECTRIC SYSTEM
5.3 Basic Operation

5.3.1 How to use operation buttons
There are three types of manual operation buttons:
button, button, and button, which are
located on the right side of the instrument panel. The
operation of each button varies with the item being displayed on the screen.
Up button
Down button
Button operation is available only when the key

switch is in the ON position and not available
when the engine is running. Note that adjustment
of screen contrast and selection between the hour
meter display and the time display are available
even when the engine is running.
Enter/display
button
215125
Short press of button

Press button for less than two seconds.
Long press of button

Press button for more than two seconds.
Multiple button presses

All buttons pressed at the same time for more than two
seconds.
5.3.2 How to adjust the screen contrast
Turn the key switch to the ON position. Screen contrast can be adjusted while the engine is running.
Button
Press
Display
Light Dark
Short
Dark Light
Note: The screen becomes dark when the temperature inside the instrument panel (ambient temperature) is high, and the screen becomes light
when the temperature is low.
5.3.3 How to display the clock time
Turn the key switch to the ON position. Screen contrast can be adjusted while the engine is running. With
a short press of the button, the display alternately
changes between the hour meter and the clock time.
Time/hour meter
With a long press of the button while the clock is

displayed, the clock display alternately changes
between 12-hour and 24-hour mode.
Button
Press
Display
Short
Hour meter clock
Long
12-hour mode display

24-hour mode display
(with clock time

display)
215126
3-25
ELECTRIC SYSTEM
5.3.4 How to set up the clock time

(1) Turn the key switch to the ON position.
(2) Select clock time display (when the hour meter is
being displayed).
Button
Press
Display
Short
Clock time blink
Blinking
(3) Select time adjust mode and unit adjust mode.

Button
Press
Display
Long
Time unit adjust mode
215127
(4) Time unit adjustment

Button
Press
Display
Short
0112 or 24
(one hour at each press)
Long
0112 or 24 (continuous)
Short
12 or 2401
(one hour at each press)
Long
12 or 2401 (continuous)
Short
After adjusting, change to the minute adjust mode.
Digits to be adjusted is blinking
215128
Note: When the time display is set to the 12-hour

mode display, 11:00 AM changes to 00:00 PM
at noon.
(5) Minute adjustment
Button
Press
Display
Short
0159 (one minute at each press)
Long
0059 (continuous)
Short
5900 (one minute at each press)
Long
5900 (continuous)
Short
After adjusting, change to the

standard screen.
Note: Second time display is not available.

If more than 3 minutes have passed since the
last button operation, the display automatically
returns to the standard screen.
Precision errors are one minute or less per
month.
When a battery is changed, the time resets.
Be sure to set the time after changing a
battery.
If the engine is started during the setup
procedure, the setup being made is cancelled
and the display returns to the standard screen.
3-26
Digits to be adjusted is blinking
215129
ELECTRIC SYSTEM
5.3.5 How to display the hour meter

Turn the key switch to the ON position. Screen contrast can be adjusted while the engine is running. With
a short press of the button, the display alternately
changes between the clock time and the hour meter.
Button
Press
Display
Short
Clock hour meter
Hour meter
215130
5.3.6 How to change types of hour meters

Turn the key switch to the ON position. There are three
counters: key-on time, engine-on time, and seat
switch-on time. The counter display changes with a
long press of the button.
Button
Press
Display
Long
Key-on time
Engine-on time
Seat switch-on time
Key-on time display
Engine-on time display
Key-on time: Accumulated key switch ON time.

Engine-on time: Accumulated engine operation time.
This is helpful in comparing the wear of engine related
parts to the actual engine operation hours.
Seat switch-on time: Accumulated time the operator
has seated.
This is helpful in comparing the actual working hours
to the actual hours of operation.
Seat switch-on time display
215131
Note: When six minutes have passed, 0.1 hour is

added.
Warranty is terminated based on the key-on
time.
3-27
ELECTRIC SYSTEM
5.3.7 How to display the error history

Turn the key switch to the ON position. A long press
on the three buttons at the same time brings up the
error history display.
Button
Press
Display
Multiple
Error history
Up button
Down button
Enter/display
button
Error message displays only the F error codes. Error

codes are displayed from the latest error (
-1) up to the past 32 errors ( -32). Oldest data
(error) exceeding the limit (32 errors) is automatically
erased.
215125
Note: Use the service tool to erase the error message

being displayed.
To change the error code display, operate the
or the button.
Button
Press
Error history
Hour meter
Error code
Display
Old New
Short
New Old
A long press on the three buttons at the same time

returns to the standard display screen.
Button
Press
Display
Multiple
Standard display screen
Error history display

With , buttons,
error record on the
display changes.
215133
The illustration shows the error history screen when

there is no error record.
When there is no error record
Note: If more than 3 minutes have passed since the

last button operation, the display automatically
returns to the standard screen.
If the engine is started during the setup
procedure, the setup being made is cancelled
and the display returns to the standard screen.
215134
3-28
ELECTRIC SYSTEM
5.4 When an Error Occurs

When an error occurs, the corresponding error code is
displayed on the screen. The error code will be erased
by placing the key switch to the ON position after solving the cause of the trouble and then by turning the
key switch to the OFF position. (The error code
remains displayed until the cause of the trouble is
solved.)
Refer to the engine service manual for the error codes
related to engine troubles (error codes from ECM).
The priority order of the error display is: engine failures, serious failures, and minor failures.
Engine warning lamp glows
When an engine failure occurs, the error code alternately

changes between black characters on a white background
and white characters on a black background.
215135
5.4.1 When an engine failure occurs

The corresponding error code is displayed in the main
area, and the black and white in the error code display
is reversed. Also the engine warning lamp glows.
5.4.2 When a serious failure occurs

is reversed. Also all warning lamps shown in the figure
(right) will blink.
Warning lamps within the dotted line boxes blink
When a serious failure occurs, the error code alternately

changes between black characters on a white background
to white characters on a black background.
215136
3-29
ELECTRIC SYSTEM
5.4.3 When a minor failure occurs

is reversed. Also the multi-purpose warning lamp
glows.
Multi-purpose warning lamp glows
Note: The minor failure display is also shown when

the fuel gauge reaches the empty level (E).
The error code and

symbol alternately
change between black
characters/lines on a
white background to
white characters/lines
on a black background.
215137
5.4.4 Error symbols

Error symbols displayed in the main area are as follows:
Symbol
3-30
Name
Indicated condition
Fuel filter warning lamp
This lamp glows when the water in the fuel filter

needs to be drained. (diesel model)
Low coolant level warning lamp
This lamp glows when the coolant level is low.

(option)
Clogged air cleaner element warning lamp
This lamp glows when the air cleaner element is

clogged. (option)
Low fuel level warning lamp
When fuel level is low (on E level)

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

level becomes low. (option)
ELECTRIC SYSTEM
5.5 Warning Lamps

The function of each warning lamp is shown in the
table below.
Lamp
Name
Color
Glow (blink) condition
Model applicable
Parking brake warning lamp
Red
This lamp glows when the parking brake is

applied.
All models (Standard)
Seat belt warning

lamp
Red
This lamp glows when the seat belt is not

fastened.
Charge warning
lamp
Red
This lamp glows when charging is not normal.

(Glows/the lamp glows all the time while the
engine is stopped)
Multi-purpose warning lamp
Red
This lamp glows when a minor failure occurs

or operating cautions are issued.
Torque converter oil

temperature warning lamp
Red
This lamp glows when the torque converter

oil temperature is not normal.
Powershift transmission
models (Standard)
Engine oil pressure

warning lamp
Red
This lamp glows when the engine oil pressure is low.

(Glows/the lamp glows all the time while the
engine is stopped)
Engine warning
lamp
Amber
This lamp glows when the engine is failed.
Electronic control gasoline engine models

(Standard)
Glow pilot indicator

lamp
Amber
This lamp glows when the glow plug heating Diesel engine models
is ON.
(Standard)
ProShiftTM indicator
lamp
Amber
This lamp glows when sudden acceleration

or full reverse (shifting of travel to the opposite direction) activates protective function.
Option
Mast interlock indicator lamp
Amber
When mast interlock is activated (glows)
3-31
ELECTRIC SYSTEM
5.6 Optional Functions

The following optional functions are available: password authentication, service interval display, overspeed warning, load meter display, overload warning,
exterior alarm, ProShiftTM control display, and speed
restrictions. Note that special devices are required on
the lift truck for load meter display, overload warning,
exterior alarm, and ProShiftTM control display.
5.6.1 Password authentication (Dealer option)
(1) Purpose and function
The password authentication is designed to prevent unauthorized persons from driving the lift
truck. To operate the lift truck, input a 4 digit password correctly.
(a) Turn the key switch to the ON position. When
the password input screen is displayed after
the brand logo screen, enter the password.
(b) Password input procedure is shown in the table
below.
Button
Press
Display
Short
0 to 9, and "", one at a time
Long
0 to 9, and "", incrementally
Short
"", 9 to 0, and one at a time
Long
"", 0 to 9, incrementally
Short
Enter (to move to next digit)
To standard screen
(2) Inputting a password
215140
Note: a) Select "" to return the previous digit.

b) Proceed to the next digit with pressing the
button. After inputting number at the 4th
digit, press the button for entry.
c) When the password is correctly inputted, an
"OK" message is displayed. If not, an "NG"
message appears followed by the password
input display. With "NG" message, the engine
can be started, but the lift truck will neither
travel nor operate.
Note: a) In case of an emergency or when the registered password is forgotten, enter "1111" so
that the screen shown on the right will appear
and minimized use of travel and operation will
be available. (For electronic gasoline engine
and electronic diesel engine models only)
b) Password input is necessary when starting
the operation, but if it is within 3 minutes after
the key switch is turned to the OFF position,
the operator does not need to enter the password again.
Use the service tool to setup the password
expiration time. (For details, see the service
tool manual.)
3-32
215141
ELECTRIC SYSTEM
(3) For password registration, change, and cancellation, use the service tool.
(For details, see the service tool manual.)
Note: Password registration, change or cancellation
should be performed by service personnel.
Password registration of "0000" or "1111" are
not available.
Register a different 4-digit password.
Up to 32 different passwords can be registered
to support different truck operations.
5.6.2 Service interval display (Dealer option)
Service interval display will notify an operator of the
scheduled inspections and maintenance when the
hour counter reaches to pre-set number of hours.
Note that service interval symbol will not be displayed
if this setup is not installed. For setting up the service
interval display, use the service tool. (For details, see
the service tool manual.)
Service interval display
Note: ONLY service engineers should set up and

perform the service interval display setting.
215142
5.6.3 ProShiftTM control display (Manufacturer's option)

The ProShiftTM control display will notify an operator of
the lift truck condition by the ProShiftTM control lamp
glowing when a protective function activates against a
full reverse or sudden acceleration. For setting up the
ProShiftTM control display, use the service tool. (For
details, see the service tool manual.)
ProShiftTM control indication lamp
Note: ONLY service engineers should set up and perform the ProShiftTM control display setting.
215151
5.7 Hour Meters

5.7.1 Hour meter reading system
Three hour meter readings are available on the instrument panel. (For details, refer to "5.3.6 How to change
types of hour meters")
Three meters: Key-on time, Engine-on time and Seat
switch-on time
(1) Key-on time meter reading is controlled by both
the instrument panel and the VCM. An error (F73) occurs if a time difference in hour meter readings (key-on time) is detected between the instrument panel and the VCM.
(2) Hour meter reading of engine-on time and seat
switch-on time are controlled by the instrument
panel only.
3-33
ELECTRIC SYSTEM
5.7.2 Replacement for the instrument panel and/or the VCM

When replacing the instrument panel or the VCM with
a new one, be sure to observe the instructions below
to transfer the hour meter data to the new instrument
panel or the VCM.
(1) Replacing the instrument panel only
The error (F-73) occurs if a time difference in hour
meter readings (key-on time) is more than 24
hours when replacing the instrument panel with a
new one. Use the service tool to solve the cause
of the error, so that the hour meter data (key-on
time) stored in the instrument panel is transferred
to the memory in the VCM. (For details, see the
service tool manual.) Turn the key switch to the
ON and OFF for a couple of times to make sure
the hour meter reading is successfully transferred
and the error (F-73) disappeared.
(2) Replacing VCM only
The error (F-73) occurs if a time difference in hour
meter readings (key-on time) is more than 24
hours when replacing the VCM with a new one.
Use the service tool to solve the cause of the
error, so that the hour meter data (key-on time)
stored in the instrument panel is transferred to the
memory in the VCM. (For details, see the service
tool manual.) Turn the key switch to the ON and
OFF for a couple of times to make sure the hour
meter reading is successfully transferred and the
error (F-73) disappeared.
(3) Replacing both the instrument panel and the VCM
Step 1
Follow the above procedure (1) for replacing the
instrument panel with a new one.
Step 2
Follow the above procedure (2) for replacing the
VCM with a new one.
Note: a) When replacing the instrument panel and/or
the VCM, be sure to replace them with new
ones.
b) If a secondhand instrument panel and/or VCM
are used from another lift truck, the error (F73) occurs.
DO NOT conduct an error recovery procedure
to the instrument panel or the VCM if they are
replaced with used ones.
The error recovery procedure may overwrite
the hour meter reading of smaller value in order to erase the difference in reading.
Note: When replacing the instrument panel with a
new one, only the hour meter of key-on time is
transferred to the new instrument panel.
(After the replacement, hour meter readings of
engine on-time and seat switch-on time will
return to zero in the new instrument panel.)
3-34
ELECTRIC SYSTEM
5.8 Troubleshooting
Symptom
Possible cause
Remedy
Fuel gauge is not displayed.
On the LPG fuel model, the fuel gauge is not displayed.
Lift truck stops, out of gas, even

though the fuel gauge indicates
that some fuel remains.
On the gasoline LPG dual fuel model, the fuel

gauge shows only gasoline amount. LPG
amount is not shown.
Back-up lamp is turned off.
Back-up lamp is turned off when the temperature

on the instrument panel becomes high (105C
Rest the lift truck in the shade to
[221F] or higher) to prevent the lamp from
cool off.
breakage.
LCD is not displayed.
Check LPG fuel warning for LPG

amount running short.
LCD is turned off when the internal temperature

Rest the lift truck in the shade to
of the instrument panel is high 85 C (185 F) or
cool off.
higher to prevent the LCD from breakage.
LCD contrast may be adjusted to minimum.
Adjust contrast with buttons.
Display changing speed is slow.
When the temperature on the instrument panel

becomes low [0 C (32 F) or lower], the screen
changing speed becomes slow due to the characteristic of LCD.
LCD screen is too dark.
Display becomes dark when the temperature on

the instrument panel becomes high (105C
Adjust contrast with buttons.
[221F] or higher) due to the characteristic of
LCD.
LCD screen is too light.
Display becomes light when the temperature on

the instrument panel becomes low [0 C (32 F) Adjust contrast with buttons.
or lower] due to the characteristic of LCD.
Button press (long) is ineffective.
Turn the key switch to the OFF

When the engine is running, long press of a but- position once to stop the engine,
ton is ineffective.
then turn the key switch to the ON
position.
Time becomes 00:00 AM.
When the battery is changed, the time resets.
Password "0000" and "1111" cannot be registered.
You cannot register "0000" and "1111."
Overload warning function is not

available.
This function is only available for the lift trucks

with the load meter display option.
Refer to "5.3.4" to adjust the time.

Use the load meter display option
(Manufacturer's option)
Exterior alarm lamps do not glow. Trigger speed setting should be 25 km/h (15.5
Check that the exterior alarm
(Warning buzzer does not actiMPH) or less and trigger load setting should be
function is correctly set up.
vate.)
5.5 ton or less (depending on the truck models).
Error (F-73) occurs.
This is caused by a difference in hour meter

readingsbetween the VCM and the instrument
panelwhen the hour meter is transferred.
During the time setup, the screen

returns to the standard screen
even though the setup of the error
history and the exterior alarm
function is half finished.
If the buttons are left untouched for more than

three minutes, or if the engine is started during
the setup procedure, the setup being conducted
becomes ineffective and its screen returns to the
standard screen. Start the setup procedure from
the beginning. Repeat the setup procedure from
the begging.
Displays of fuel gauge and water

temperature gauge blink.
Check the fuel sensor and the water temperature sensor and all the connected wires to both
sensors for electrical short circuit.
Use the service tool for transferring hour meter properly.
Note: The conditions above occur due to the characteristics of each of the materials used in the equipment, therefore they are not defective.
3-35
ELECTRIC SYSTEM
6. Wire Color
Wire colors listed in the table below show standard colors (base colors). For wiring composed of two colors, first
color shows the base color and second color the marked color.
Example: The wire color of B/W shows that its base color is B with a marking W.
B / W
Marked color
Ground color
Note: For wiring identification, the same wiring color must be used for the circuit between the power supply and the
load.
Be careful that allowable current of solid wires and that of strand wires are different even if they are of the same
diameter.
6.1 List of Wire Colors

Wire color
3-36
Color
English
BLACK
WHITE
RED
GREEN
YELLOW
BR
BROWN
BLUE
LG
LIGHT GREEN
OR
ORANGE
PINK
GY
GRAY
SB
LIGHT BLUE
PU
PURPLE
ELECTRIC SYSTEM
7. Troubleshooting
7.1 Starter System
Symptom
Key switch
Starter won't crank the

engine even if the key
switch is turned ON.
Engine won't stop even

if the key switch is
turned OFF.
Remedy
Possible cause
Battery discharge
Recharge or replace
Short or open circuit
Repair or replace
Poor continuity in starter switch
Replace
Defective starter or starter relay
Replace
Neutral switch is not in the neutral

position.
Move the direction lever to neutral

position.
Repair or replace
Engine stop solenoid defect
Replace or adjust
7.2 Gauges
Symptom
Remedy
M/P - Water temperature meter disconnection
Indicated value is low.
Water temperature
gauge
Check that the connectors are properly jointed.
Check the conductivity.
Check the display with the water temperature sensor being warmed.
Replace the water temperature sensor.
Replace the instrument panel.
Check the part number.

Indicated value is inaccurate.
Indicated value blinks.
Check that the parts meet the specification.
Replace the water temperature sensor.
M/P - Water temperature meter disconnection

1
Correction of the short circuit.
Improper setting.
Indicated value is not
displayed.
LPG model does not show the value.
Incorrect VCM setting.
Check the part number.

Fuel gauge
Indicated value is inaccurate.
Indicated value blinks.
Check that the parts meet the specification.
Replace the fuel sensor.
Remove fuel tank cap assembly and check it for bent float.
Correction of the short circuit.
Remove fuel tank cap assembly and check the wirings in the tank.
3-37
ELECTRIC SYSTEM
7.3 Lighting System

Symptom
Lamp does not glow

(blink) when the key
switch is turned ON.
Lamps (in
general)
Lamp glows (blinks)

dimly.
Head lamp Lamp does not glow.
Lamp does not blink.
Turn
signal
lamps
Will not go out.
Recharge or replace
Blown out fuses
Check and replace
Repair or replace
Defective grounding wire
Remove corrosion from the terminal or

retighten.
Defective switch conductivity
Replace
Burned out bulbs
Replace
Weak battery
Check and recharge
Defective switch contact
Repair or replace
Contact failure terminals
Repair
Dirty lenses
Clean
Lenses with water drops
Dry and replace the packings.
Bulb's service life expired
Replace
Defective light switch conductivity
Replace
Burned out bulbs
Replace
Defective turn signal switch
Replace
Defective turn signal relay
Replace
Burned out bulbs
Replace
Replace
3-38
Replace
Replace it with a specified wattage
bulb.
Replace
Correct the lamp if it is improperly
installed, or replace the lamp if it is
internally defective.
Replace
Blown out fuses
Check and replace
Repair or replace
Horn does not activate. Defective horn switch
Offensive sound
Replace it with a specified wattage

bulb.
Bulb wattage is more than the specified

value.
Back-up lamp does not Defective back-up lamp switch

glow.
Burned out bulbs
Horn
Remedy
Battery discharge
Bulb wattage is less than the specified

Lamp blinks too slowly. value.
Lamp blinks too fast.
Other
lamps
Possible cause
Replace
Defective horn
Replace
Defective horn button
Repair or replace
Defective horn switch
Replace
Defective horn
Replace
ELECTRIC SYSTEM
Symptom
Alternator belt
Alternator
Regulator
Weak
battery
Battery
Wiring
Battery
overcharge
Wiring
Regulator
Possible cause
Remedy
Slippage
Adjust the tension.
Starter coil has defective grounding wire

or open circuit.
Repair or replace
Open-circuited rotor coil
Replace
Poorly-seated brushes on slip rings
Clean holder and polish slip rings.
Defective brush movement
Adjust, replace brushes if worn.
Short-circuited or open-circuited diode
Replace
Regulating voltage is too low
Adjust
Shortage or inappropriate amount of elecRefill or adjust the S.G.

trolyte
Defective cell plates (internal short-circuit) Replace
Poorly-jointed connections on terminals
Clean and tighten
Disconnection or poor connection

between the key switch and regulator IC
terminal.
Repair
Blown out fuses in the above mentioned

Replace fuse or repair the holder's
circuit or poorly-jointed connections on the
contact part.
holder.
Open or loose connection between the
regulator terminal F and alternator terminal F
Repair
Incorrect connection or short circuit

between regulator IC and F terminals
Repair
Defective grounding wire of regulator terminal F
Repair
Open-circuited pressure coil
Replace
Regulating voltage is too high.
Adjust
3-39
ELECTRIC SYSTEM
8. Electrical Schematic
3-40
ELECTRIC SYSTEM
Replace this page with file 99739-89110s_01.pdf
3-41
ELECTRIC SYSTEM
3-42
ELECTRIC SYSTEM
3-43
ELECTRIC SYSTEM
3-44
ELECTRIC SYSTEM
3-45
ELECTRIC SYSTEM
3-46
ELECTRIC SYSTEM
3-47
ELECTRIC SYSTEM
3-48

Electrical System p9000

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Electrical System p9000

Hochgeladen von

Copyright:

Verfügbare Formate

Chapter 3 ELECTRIC SYSTEM

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

Structure .................................................................................................. 3-4

List of Wire Colors ................................................................................................. 3-36

Instrument Panel Screen Components.................................................................. 3-20

Wire Color .............................................................................................. 3-36

Instrument Panel ................................................................................... 3-20

Disassembly .......................................................................................................... 3-18

Battery Maintenance ............................................................................. 3-19

Console Box ............................................................................................................ 3-4

Console Box .......................................................................................... 3-18

Gasoline Model........................................................................................................ 3-1

Starter System....................................................................................................... 3-37

Electrical Schematic ............................................................................. 3-40

1. Chassis Electrical Devices Wiring Outline

Battery cable (-)

ECM (Engine control module)

1.2 Diesel Model

Rear combination harness

Battery cable (-)

1.3 Gasoline and Diesel Models

Parking brake switch

Thermoswitch (T/C oil)

Water temperature gauge

2.1.1 Function of Instrument Panel

Ref. Name of indicators and warning lamps

Parking brake warning lamp

Seat belt warning lamp

Charge warning lamp

Multi-purpose warning lamp

Torque converter oil temperature warning lamp

When turned off

When glows or blinks

This lamp glows when the parking

This lamp glows when the seat belt is

This lamp glows when charging is not

This lamp glows when a minor failure

Engine oil pressure warning lamp

This lamp glows when the engine oil

Engine warning lamp

This lamp glows when the engine is

Glow pilot indicator lamp

This lamp glows when the glow plug

This lamp glows when sudden acceleration or full reverse (shifting of

Mast interlock indicator lamp

When mast interlock is activated

Water temperature gauge

Indicates remaining fuel amount with key in "ON" position

Indicates water temperature with key in "ON" position

2.2 Main Electrical Components

Key in and out

2.2.2 Combination switch

Turn signal switch connector

Operating voltage: DC12V (Gasoline and diesel models)

Note: The proper installation of the horn to the lift

2.2.4 Tank unit

Illustration shows gasoline model.

Pressure relief valve

Fuel suction strainer

Standard resistance value ()

The number in parenthesis is a reference value.

2.2.5 Stop lamp switch

Rated voltage: DC12V

(2) Replace the sending unit if there is no continuity