VEHICLE ELECTRICAL COMPONENTS

Console Box ............................................................................................ 2 – 1

Functions of Central Vehicle Monitor System ............................................ 2 – 1 2
Electrical Components in Console Box ..................................................... 2 – 5
Disassembly and Reassembly .................................................................. 2 – 6
Direction Lever ........................................................................................ 2– 7
Accelerator Control ............................................................................... 2– 8
Key Switch ............................................................................................... 2– 9
Lighting Switch ....................................................................................... 2– 9
Fuses ......................................................................................................... 2 – 10
Lamp Specification Chart .................................................................... 2 – 10
Troubleshooting of Lighting and Horn Systems ............................ 2 – 11
 VEHICLE ELECTRICAL COMPONENTS

Console Box 1

1 Central vehicle monitoring system 6

(CVMS)
2 Mode selector button 2
3 Steering tilt lever
4 Key switch 5
5 Lighting switch (option)
3
6 Mode check button
4

NOTE
103043
For setting the clock and selection of KPH or MPH,
refer to “Selection of KPH or MPH” and “Setting the
clock”.

Functions of Central Vehicle Monitor System (CVMS)

9 8

10

1 2 3 4 5 6 7

Operations 211131

No. Monitor name When OFF When ON or flashing Remarks

1 Service indicator Starts flashing 20 hours before set time. Remains ON when set time is reached.
Seat belt warning Seat belt is fastened. Seat belt is not
light fastened when
2 operator sits on seat
(seat switch is turned
on).

2-1
VEHICLE ELECTRICAL COMPONENTS

No. Monitor name When OFF When ON or flashing Remarks

Controller/motor Controller, drive motors and Overheating Overheating causes a
overheat indicator pump motor in normal significant output loss. When
3 temperature component temperature returns
to normal levels, output power
returns.
Remaining Normal battery condition Flashing indicates
battery charge battery needs to be
warning light recharged soon.
4 ON indicates battery
needs to be recharged
and lifting function
inoperable.
5 Brake fluid level indicator Normal fluid level Low fluid level
6 Parking brake warning Parking brake disengaged Parking brake
light engaged
7 Malfunction lamp Normal Vehicle malfunction
Speedometer
8 KPH, MPH
Error indicator
Battery discharge When no bars show, vehicle is drivable but lifting Indicates remaining battery
9
indicator function is inoperable. power.
Hour meter 1 2 3 4 5
Advances every 0.1 hour
10
(Number advances every 6 minutes.)
Hour indication

2-2
 VEHICLE ELECTRICAL COMPONENTS

Selection of KPH or MPH

1. Apply the parking brake.
2. Place the direction lever in NEUTRAL.
3. Turn the key switch to the I (ON) position. Button 1 Button 2

4. Push and hold button 1 for one to two seconds.

NOTICE: Display will show KPH and a 24-hour clock
until it is changed. When MPH is selected, the
clock will change to a 12-hour clock.

Setting the clock 103043

1. Apply the parking brake.
2. Place the direction lever in NEUTRAL.
3. Turn the key switch to the I (ON) position.
4. Push and hold button 1 until the minutes’ display
flashes.
5. Release button 1.
6. Adjust the minutes with button 2.
7. Push button 1 and release when the hours’ display
flashes.
8. Adjust the hour with button 2.
9. Push button 1 to lock in the time.

2-3
VEHICLE ELECTRICAL COMPONENTS

Error code display

Indication Condition

E Indicator flickers if seat switch is turned off during driving operation. Then,
indicator turns on when seat switch is turned on again. Indicator turns off when
direction lever and accelerator pedal are returned.

E 0 ON Right drive motor overheated

E 1 ON Left drive motor overheated

E 2 ON Pump motor overheated

E 5 ON Right traction inverter overheated

E 6 ON Left traction inverter overheated

E 7 ON Pump inverter overheated

H 1 ON Faulty setting of lift lever

H 2 ON Faulty setting of tilt lever

H 3 ON Faulty setting of attachment 1 lever

H 4 ON Faulty setting of attachment 2 lever

H 5 ON Faulty setting of attachment 3 lever

(L) Indicator flickers if seat switch is turned off during lifting operation.
Then, H1 to H5 turn on when seat switch is turned on again. Indicator turns off
when lifting operation is suspended.

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 VEHICLE ELECTRICAL COMPONENTS

Electrical Components in Console Box

Horn cable

Monitor cable
2

Direction lever switch cable

1

211132

1 Key switch
2 Lighting switch (option)

2-5
VEHICLE ELECTRICAL COMPONENTS

Disassembly and Reassembly

Disassembly

2
6

4
211133

Sequence
1 Console box (front panel) 5 Console box (rear panel)
2 Central vehicle monitor panel 6 Key switch
3 Direction lever 7 Light switch
4 Steering tilt lever

Disassembly procedure
(1) Remove the front panel and monitor panel from the
console box.
(2) Disconnect the harness connectors from the horn and T-nut
direction lever.
(3) Remove the screw from the steering tilt lever, and Steering tilt
remove the lever from the rear panel of the console lever
box. Screw
(4) Remove the rear panel.
211134

Reassembly
Follow the disassembly procedure in reverse.

2-6
 VEHICLE ELECTRICAL COMPONENTS

Direction Lever

Structure

211135

1 Lever 3 Connector
2 Harness 4 Screw

2-7
VEHICLE ELECTRICAL COMPONENTS

Accelerator Control

Accelerator pedal

Initial position

Stopper bolt
1.5 to 2.5
Lock nut

Switching position
of idle switch
Floor plate
30 to 32 mm
(1.18 to 1.26 in.)
Accelerator lever

Accelerator

Adjusting screw

Position meter
211136

Adjustment procedure
(1) Disconnect the battery plug.
(2) Set the stopper bolt to 30 to 32 mm (1.18 to 1.26 in.)
from the floor to the upper face of bolt.
(3) Adjust the mounting angle of the position meter using
the adjusting screw so the switch inside the position
meter turns on when the accelerator lever is moved 1.5°
to 2.5° from the initial position. 206805B

Make sure the inside switch turns ON by checking the

continuity between the two terminals (indicated by
arrows) by using an ohmmeter.

2-8
 VEHICLE ELECTRICAL COMPONENTS

Key Switch
Terminal B M
Connection Main fuse
Logic card
destination Battery
● (OFF) ●
I (ON) ● ●

206806

Lighting Switch (option)

Terminal 2 5 3 6
Connection Battery Battery Head Working
destination lamps lamp 2
6 3 5 2 3
OFF ● ●
5
ON (1) ● ● ● 21 6
ON (2) ● ● ● ●

Head
Lamp Fuse
Working
Lamp

211137

2-9
VEHICLE ELECTRICAL COMPONENTS

Fuses
Capacity (A) Location Main connecting device
500 Drive motor
Contactor assembly
500 Pump motor
15 Key switch, Lighting switch
Fuse holder
10 Power relay

NOTE

Refer to Parts Manual for proper replacement fuses.

Lamp Specification Chart

Item Bulb
Quantity Bulb color Remarks
Lamp 36 V/48 V External diagram

Head lamps (option) 2 Clear 45 W

Working lamp (option) 1 Clear 45 W

205833

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 VEHICLE ELECTRICAL COMPONENTS

Troubleshooting of Lighting and Horn Systems

Complaint Possible cause Remedy

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

e) Bulbs burnt out Replace.

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

Will not light a) Lighting switch defective Replace.

b) Bulbs burnt Replace.
Other lamps

Working lamp will a) Working lamp switch defective Correct if improperly

not light installed: replace if
internally defective.
b) Bulbs burnt out Replace.

Will not give blast a) Fuse blown Check and replace.

of sound b) Open or short in circuit Repair or replace.
c) Horn switch defective Replace.
Horn

d) Horn defective Replace.

e) Horn button defective Repair or replace.

Will give an offensive a) Horn switch defective Replace.

blast of sound b) Horn defective Replace.

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