TOYOTA I.E.

STEP

STEP3 Certification Examination

Electric forklift

VALIDITY TERM
January, 2017
 160 100
No. of 2016
No. Section Contents
question Selection
19 1 0. Introduction Formula of power *
20 1 0. Introduction Series circuit *
21 1 0. Introduction Ohm's low *
24 1 0. Introduction Voltage drop in series circuit *
27 1 0. Introduction Current in pararell circuit *
7 5 1. Motor Advantage of AC motor *
12 10 1. Motor Characteristics of AC motor *
25 1 1. Motor Motor measurement *
4 5 3. Controller 8FBN OPS function *
5 10 3. Controller Characteristics of 8FBN *
11 8 3. Controller Basic troubleshooting procedure *
14 10 3. Controller Troubleshooting of 7FB *
23 1 3. Controller Symbol of pump contactor *
29 1 3. Controller Troubleshooting of simple circuit *
30 1 3. Controller Symbol of electric element *
16 10 4. Steering EHPS of 7FB *
3 5 6. F&A equipment Function of 8FBN display *
18 9 6. F&A equipment Function of charger *
28 1 6. F&A equipment Function of relay *
2 8 7. Hydraulic syste 8FBN hydraulic circuit *
15 10 7. Hydraulic syste OCV circuit of 7FB *
19 1 The formula for calculating power is Power = ( ).

a) Amps x Watts
b) Amps x Volts
Answer
c) Ohms x Volts
d) Amps x Ohms

20 2 In a series circuit ( ) is the same in any part of the circuit.

a) Resistance
b) Power
Answer
c) Voltage
d) Current

21 3 According to Ohms Law, you must multiply ( ) in order to determine the circuit
voltage.

a) Voltage x Resistance
b) Voltage x Current
Answer
c) Current x Resistance
d) All other answers are incorrect.

24 4 The sum of voltage drops in a series circuit equals ( ).

a) Voltage drop across the largest load

b) Voltage drop across the smallest load
c) Source voltage
d) Shunt circuit voltage
Answer

27 5 Technician X says that adding more branches to a parallel circuit reduces total circuit
resistance.
Technician Y says that adding more branches to a parallel circuit increases the total
current in the circuit.
Who is right?

a) Technician X
b) Technician Y
Answer
c) Both X and Y
d) Neither X nor Y
7 6
The following sentence explains about the advantage of AC induction motor used in 7FB series.

Fill the appropriate word in each blank from " a " to " e ".

1) More reliable than a ( a ) motor due to its simpler structure.

2) ( b ) size of an AC induction motor allows improved performance while maintaining
the size of a product.
3) Because it is practically ( c )-free with no ( d ) or commutator, it does not require
maintenance cost for replacing ( d ) and is environment-friendly.
4) Without the need for the maintenance above, it can be more flexibly placed and designed.
5) Using a ( e )-phase alternating current expands the control range of the motor and
enables the control that has been impossible (such as power control).

Answer column

a b
c d
e

12 7 The following sentence explains characteristics of AC induction motor.

Write the appropriate word in each blank from " a " to " j ".

The characteristics of the AC induction motor are "rotation speed and output torque" and
"rotation speed and ( a )."
The figure below shows the changes in the the motor torque and motor current observed
as the motor, after power-on, starts, accelerates, and reaches a constant speed.
The ( b ) is the highest at startup and decreases as the ( c ) speed increases.
In contrast, the ( d ) increases as the ( e ) speed increases and decreases when a certain
( f ) speed is exceeded. The motor begins to run at a ( g ) speed when the load torque and
the motor torque balance with each other. The current at this point is the load current.
A change in the load torque changes the motor current and ( h ).
The motor cannot run if the load torque is larger than the ( i ) torque of the motor.
If the motor torque is larger than the load torque, the rotation speed ( j ) according to
the difference between them. The motor torque gradually increases as the rotation speed increases
and then decreases after the maximum torque is reached.
 Answer column

a b
c d
e f
g h
i j

25 8 The motor in the circuit runs slow. A voltmeter indicates 12.6 volts as shown.
Technician X says that a bad ground at the motor could be the cause.
Technician Y says that high resistance in the circuit from the battery to the motor could be
the cause.
Who is right?

Answer
4 9 The following sentence explains OPS function of 8FBN series.
Write the appropriate word in each blank from "a" to "e".

1) Travel OPS
When the controller detects the seat switch being turned off for two seconds,
the drive motor stops after acting as the ( a ) brake.
Travel OPS is released by returning the direction lever and ( b ) pedal to the neutral position
and turning on the seat switch.

2) Hydraulic function OPS

When the controller detects the seat switch being turned off for two seconds,
all the ( c ) operations are stopped by valve control.
For this model, hydraulic function OPS is released by returning all the ( d ) to the neutral positions
and turning on the seat switch.

3) OPS operation information function

When the controller detects that the seat switch is turned off, the onboard buzzer in the display
sounds (pi-) for one second and the ( e ) indicator shows up on the display in advance of
OPS activation.
If the operator notices it and is seated again in 2 seconds, the OPS will not activate.
As long as the seat is not taken (seat switch is off), the ( e ) indicator remains lit to inform
the operator that the OPS is activated.
Answer column

a b
c d
e

5 10 The following sentences explain some of the characteristics of 8FBN series.

Write the appropriate word in each blank from " a " to " j ".

1) Regenerative brake system

When the accelerator is released during travelling, the regenerative brake works and recovers
electric braking energy into the ( a ). It increases the ( b ) time, extends the life of the brakes
and brings a smooth and powerful deceleration feeling.
This regenerative brake works even when the direction lever is the neutral position.
The adjustment of this regenerative brake feeling is obtained by using the ( c ) function
of the display.
2) Maximum speed limitation function
If the maximum speed limit is set, this function prevents the vehicle from running at speed higher
than the speed limit. It relieves the operator from the need to finely adjust the ( d ) in order to
observe the speed limit, and the administrator from the need to keep watch on the speed limit.
The speed limit can be adjusted in steps of 1 km/h starting at 2 km/h, using the ( c ) function
of the display.
3) Power steering function
This model has the hydraulic power steering. Hydraulic oil is supplied to the power steering circuit
from the oil pump connected to the pump motor. On this model, the amount of hydraulic oil supply is
controlled depending on the steering wheel ( e ).
Thereby, the starting feeling of steering is improved. Hydraulic oil is also supplied continuously
when the ( f ) is operated, or while the vehicle is traveling.
4) Power keep function
The power keep function is provided to maintain the battery performance even when the battery is
significantly ( g ). This function works only in P, S and E modes, and it can be disabled
using the ( c ) function (option setting function) of the display.
5) Over-discharge warning function
If traveling or ( h ) operation is carried out while the battery capacity is at the over-discharge
warning level, a ( i ) and audible warning will be given to inform the operator that the battery is
overdischarged. In addition to that, a limit will be placed on the vehicle performance.
Through these operations, the battery is protected and the operator is prompted to ( j )
the battery.

Answer column

a b
c d
e f
g h
i j
11 11 The following flow is ”Basic checking operation procedure” for electric forklift.
Write the correct word in each blank from " a " to " h ".

Answer column

a b
c d
e f
g h
14 12 The following sentence is the troubleshooting procedure of power supply system for 7FB series.
Write the appropriate word in each blank from " a " to " j ".
Symptom: Vehicle moves but display has no illumination
[Identifying failure range]
The first thing is to check and understand the power supply line on the system circuit.
And compare and check the vehicle's symptom to narrow the failure range.
For this symptom, it is understood that the ( a ) board has power supplied and the ( b )V
and 15 V power supply circuits of the ( c ) board are normal because the vehicle moves.
It is estimated that the defect exists in the range from the DC/MD board to the ( d ).
When the power supply system fails, an ( e ) may not be displayed; therefore, the failure range
is identified from the vehicle's symptom.
[Inspection]
While the test lead (black) of a circuit tester is placed on the ( f ) terminal, measure the voltage
sequentially from the battery side to check the end of the ( g ) side electricity.
For this symptom, check the ( h ) level line.
For example, if the voltage of the DC/MD board outlet (Inspection (1) in the diagram) is 15 V and
the voltage of the CPU board inlet (Inspection (2) in the diagram) is ( i ) V, disconnection between
them is assumed. Finally, check the ( j ) of the corresponding harness to identify
the defective spot.
 Answer column

a b
c d
e f
g h
i j

23 13 The hydraulic pump contactor is designated as ( ).

a) DMP
b) MP
Answer
c) TMP
d) CSP

29 14 In the circuit shown, the light glows dimly. The first voltmeter reading (V1) is 0.0 volts.
The second voltmeter (V2) reads 7.5 volts. The third voltmeter (V3) reads 4.5 volts.
The problem might be ( ).

a) The fuse is defective

b) The bulb has too little resistance
c) The switch has too much resistance
d) The battery is weak

Answer

30 15 The symbols shown above are used on Toyota wiring diagrams to indicate ( ).
a) a LED and transistor
b) a Zener diode and lamp
Answer
c) a Zener diode and transistor
d) a diode and thermistor
16 16 The following figure shows the oil pressure system of EHPS (Electrically Controlled fully-hydraulic
Power Steering) adopted on 7FB series.
Write the word or parts name in the answer column except No. 6, 8, 9 and 14.

Answer column

1 2
3 4
5 6
7 8
9 10
11 12
13 14
3 17 The following figure shows the display used in 8FBN series.
Answer the meaning for each symbol from " a" to " e ".

symbol Indicator Meaning (What happens on a truck if this indicator appears?)

e
18 18 The following sentence explains about the timer of charger.
Write the appropriate words in each blank from " a " to " i ".

The battery charge timer consists of three timers: main timer, safety timer and total timer.
The last two are double safety timers activated to cancel charging in an abnormal situation.
1) Main Timer
This performs charge control dividing a charging period into the beginning and
ending phases at the polarity inversion point ( a ).
The charging time of the ending phase is set by the main timer. This charging time is
calculated from the time required for the beginning phase of ( b ).
2) Safety Timer
If the battery ( c ) voltage does not increase by some reason for a long time from
the start of ( d ), and does not reach the polarity inversion point voltage,
the charge will be stopped after the total time since the start of charging reaches a certain
period of time.
This timer is activated to stop charging when the battery voltage still does not reach
the polarity inversion point voltage after ( e ) hours from the start of charging.
The activation of this timer may indicate abnormality in the main circuit.
An abnormality in the main circuit may be preventing power voltage increase.
The main causes of this problem include a ( f ) setting failure, diode puncture,
power voltage failure (lack of phase), transformer failure, and ( g ) switch contact failure.
3) Total Timer
If the main timer does not stop charging by some reason after a long time has passed
from the start of charging, the charge will be stopped by this timer after the total time
since the start of charging reaches a certain period of time.
This timer is activated to stop charging when a charge is still not ended after ( h ) hours

from the start of charging.

The activation of this timer may indicate abnormality in the control circuit.
As well as preventing ( i ), this timer will prevent a risk of fire.

Answer column

a b
c d
e f
g h
i
28 19 Select the correct answer.
a) Terminal 1 is connected to terminal 5 until energized, then terminal 1 is connected to
terminal 4.
b) Terminal 3 is connected to terminal 5 until energized, then terminal 3 is connected to
terminal 4.
c) Terminal 4 is connected to terminal 5 until energized, then terminal 4 is connected to
terminal 3.
d) Terminal 4 is connected to terminal 3 until energized, then terminal 4 is connected to
terminal 5.

Answer
2 20 The figure below show the hydraulic circuit of 8FBN series.
Write the parts name in each blank from " a " to " h ".

Answer column

a b
c d
e f
g h
15 21 The following figure shows the oil control valve circuit of 7FB series.
Fill the appropriate word (parts name) in each blank except No. 2, 6, 9 and 13.

Answer column

1 2
3 4
5 6
7 8
9 10
11 12
13 14
ons
een
 Reference pages of step
technical information book

STEP Chapter Page

19 1 The formula for calculating power is Power = ( ). 2 1 61

a) Amps x Watts
b) Amps x Volts
Answer b)
c) Ohms x Volts
d) Amps x Ohms

20 2 In a series circuit ( ) is the same in any part of the circuit. 2 1 64

a) Resistance
b) Power
Answer d)
c) Voltage
d) Current

21 3 According to Ohms Law, you must multiply ( ) in order to determine the circuit 2 1 61
voltage.
a) Voltage x Resistance
b) Voltage x Current
Answer c)
c) Current x Resistance
d) All other answers are incorrect.

24 4 The sum of voltage drops in a series circuit equals ( ). 2 1 61

a) Voltage drop across the largest load

b) Voltage drop across the smallest load
c) Source voltage
d) Shunt circuit voltage
Answer c)

27 5 Technician X says that adding more branches to a parallel circuit reduces total circuit
resistance.
Technician Y says that adding more branches to a parallel circuit increases the total
current in the circuit.
Who is right?

a) Technician X
b) Technician Y
Answer c)
c) Both X and Y
d) Neither X nor Y

7 6 1 2 100
The following sentence explains about the advantage of AC induction motor used in 7FB series.

Fill the appropriate word in each blank from " a " to " e ".

1) More reliable than a ( a ) motor due to its simpler structure.

2) ( b ) size of an AC induction motor allows improved performance while maintaining
the size of a product.
3) Because it is practically ( c )-free with no ( d ) or commutator, it does not require
maintenance cost for replacing ( d ) and is environment-friendly.
4) Without the need for the maintenance above, it can be more flexibly placed and designed.
5) Using a ( e )-phase alternating current expands the control range of the motor and
enables the control that has been impossible (such as power control).
 Answer column

a DC b Compact
c maintenance d brushes
e three

12 7 The following sentence explains characteristics of AC induction motor. 2 2 249

Write the appropriate word in each blank from " a " to " j ".

The characteristics of the AC induction motor are "rotation speed and output torque" and
"rotation speed and ( a )."
The figure below shows the changes in the the motor torque and motor current observed
as the motor, after power-on, starts, accelerates, and reaches a constant speed.
The ( b ) is the highest at startup and decreases as the ( c ) speed increases.
In contrast, the ( d ) increases as the ( e ) speed increases and decreases when a certain
( f ) speed is exceeded. The motor begins to run at a ( g ) speed when the load torque and
the motor torque balance with each other. The current at this point is the load current.
A change in the load torque changes the motor current and ( h ).
The motor cannot run if the load torque is larger than the ( i ) torque of the motor.
If the motor torque is larger than the load torque, the rotation speed ( j ) according to
the difference between them. The motor torque gradually increases as the rotation speed increases
and then decreases after the maximum torque is reached.

Answer column

a current b current
c rotation d torque
e rotation f rotation
g constant h speed
i starting j increases
25 8 The motor in the circuit runs slow. A voltmeter indicates 12.6 volts as shown.
Technician X says that a bad ground at the motor could be the cause.
Technician Y says that high resistance in the circuit from the battery to the motor could be
the cause.
Who is right?

Answer Technician x

4 9 The following sentence explains OPS function of 8FBN series. NMF 8FBN15-30 2-21 - 2-25
Write the appropriate word in each blank from "a" to "e". Electric Control Functions

1) Travel OPS
When the controller detects the seat switch being turned off for two seconds,
the drive motor stops after acting as the ( a ) brake.
Travel OPS is released by returning the direction lever and ( b ) pedal to the neutral position
and turning on the seat switch.

2) Hydraulic function OPS

When the controller detects the seat switch being turned off for two seconds,
all the ( c ) operations are stopped by valve control.
For this model, hydraulic function OPS is released by returning all the ( d ) to the neutral positions
and turning on the seat switch.

3) OPS operation information function

When the controller detects that the seat switch is turned off, the onboard buzzer in the display
sounds (pi-) for one second and the ( e ) indicator shows up on the display in advance of
OPS activation.
If the operator notices it and is seated again in 2 seconds, the OPS will not activate.
As long as the seat is not taken (seat switch is off), the ( e ) indicator remains lit to inform
the operator that the OPS is activated.
Answer column

a regenerative b accelerator
c load handling (material handling) d levers
e OPS

5 10 The following sentences explain some of the characteristics of 8FBN series. 8FBN new model features (PE321 page
Write the appropriate word in each blank from " a " to " j ".

1) Regenerative brake system

When the accelerator is released during travelling, the regenerative brake works and recovers
electric braking energy into the ( a ). It increases the ( b ) time, extends the life of the brakes
and brings a smooth and powerful deceleration feeling.
 This regenerative brake works even when the direction lever is the neutral position.
The adjustment of this regenerative brake feeling is obtained by using the ( c ) function
of the display.
2) Maximum speed limitation function
If the maximum speed limit is set, this function prevents the vehicle from running at speed higher
than the speed limit. It relieves the operator from the need to finely adjust the ( d ) in order to
observe the speed limit, and the administrator from the need to keep watch on the speed limit.
The speed limit can be adjusted in steps of 1 km/h starting at 2 km/h, using the ( c ) function
of the display.
3) Power steering function
This model has the hydraulic power steering. Hydraulic oil is supplied to the power steering circuit
from the oil pump connected to the pump motor. On this model, the amount of hydraulic oil supply is
controlled depending on the steering wheel ( e ).
Thereby, the starting feeling of steering is improved. Hydraulic oil is also supplied continuously
when the ( f ) is operated, or while the vehicle is traveling.
4) Power keep function
The power keep function is provided to maintain the battery performance even when the battery is
significantly ( g ). This function works only in P, S and E modes, and it can be disabled
using the ( c ) function (option setting function) of the display.
5) Over-discharge warning function
If traveling or ( h ) operation is carried out while the battery capacity is at the over-discharge
warning level, a ( i ) and audible warning will be given to inform the operator that the battery is
overdischarged. In addition to that, a limit will be placed on the vehicle performance.
Through these operations, the battery is protected and the operator is prompted to ( j )
the battery.

Answer column

a battery b operating
c service d accelerator
e speed f direction lever
g discharged h load handling
i visual j charge

11 11 The following flow is ”Basic checking operation procedure” for electric forklift. 3 3 7

Write the correct word in each blank from " a " to " h ".
 Answer column

a error code b failure

c input d output
e sensor f Controller
g actuator h harness, Harness

14 12 The following sentence is the troubleshooting procedure of power supply system for 7FB series. 3 3 10

Write the appropriate word in each blank from " a " to " j ".
Symptom: Vehicle moves but display has no illumination
[Identifying failure range]
The first thing is to check and understand the power supply line on the system circuit.
And compare and check the vehicle's symptom to narrow the failure range.
For this symptom, it is understood that the ( a ) board has power supplied and the ( b )V
and 15 V power supply circuits of the ( c ) board are normal because the vehicle moves.
It is estimated that the defect exists in the range from the DC/MD board to the ( d ).
When the power supply system fails, an ( e ) may not be displayed; therefore, the failure range
is identified from the vehicle's symptom.
[Inspection]
While the test lead (black) of a circuit tester is placed on the ( f ) terminal, measure the voltage
sequentially from the battery side to check the end of the ( g ) side electricity.
For this symptom, check the ( h ) level line.
For example, if the voltage of the DC/MD board outlet (Inspection (1) in the diagram) is 15 V and
the voltage of the CPU board inlet (Inspection (2) in the diagram) is ( i ) V, disconnection between
them is assumed. Finally, check the ( j ) of the corresponding harness to identify
the defective spot.
 Answer column

a CPU b 20
c DC/MD d display
e error code f N1
g positive (plus) h 16
i 0 j continuity

23 13 The hydraulic pump contactor is designated as ( ).

a) DMP
b) MP
Answer b)
c) TMP
d) CSP

29 14 In the circuit shown, the light glows dimly. The first voltmeter reading (V1) is 0.0 volts.
The second voltmeter (V2) reads 7.5 volts. The third voltmeter (V3) reads 4.5 volts.
The problem might be ( ).

a) The fuse is defective

b) The bulb has too little resistance
c) The switch has too much resistance
d) The battery is weak

Answer c)

30 15 The symbols shown above are used on Toyota wiring diagrams to indicate ( ).
a) a LED and transistor
b) a Zener diode and lamp
Answer a)
c) a Zener diode and transistor
d) a diode and thermistor

16 16 The following figure shows the oil pressure system of EHPS (Electrically Controlled fully-hydraulic 2 4 50

Power Steering) adopted on 7FB series.

Write the word or parts name in the answer column except No. 6, 8, 9 and 14.
 Answer column

1 Steering wheel 2 Steering angle sensor

3 PS valve 4 Knob offset compensation valve
5 Controller 6
7 Speed sensor 8
9 10 PS motor
11 PS pump 12 Hydraulic oil tank
13 Rear axle cylinder 14

3 17 The following figure shows the display used in 8FBN series. RM 8FBN15-30 4-3 - 4-7
Answer the meaning for each symbol from " a" to " e ".

symbol Indicator Meaning (What happens on a truck if this indicator appears?)

OPS indicator
a When the operator leaves the operation seat, this indicator lights up
and the buzzer sounds for 1 second.

Overheat warning indicator

If the temperature of the controller, motor driver or traveling-load
b handling motor rises to an abnormal level, this indicator lights up, a
warning sound is
emitted and the output is limited.
 Power select indicator
c The power mode (S, P or H) and its indication on the display change
each time the power select switch on the status screen is pressed.

Battery overheat warning indicator

If the battery fluid temperature rises above the specified level, this
d
indicator lights up, a warning sound is emitted and the output is
limited.

Battery fluid level warning indicator

e If it is detected that there is not enough battery fluid left in the battery,
this indicator lights up to warn the operator.

18 18 The following sentence explains about the timer of charger. 2 7 24

Write the appropriate words in each blank from " a " to " i ".

The battery charge timer consists of three timers: main timer, safety timer and total timer.
The last two are double safety timers activated to cancel charging in an abnormal situation.
1) Main Timer
This performs charge control dividing a charging period into the beginning and
ending phases at the polarity inversion point ( a ).
The charging time of the ending phase is set by the main timer. This charging time is
calculated from the time required for the beginning phase of ( b ).
2) Safety Timer
If the battery ( c ) voltage does not increase by some reason for a long time from
the start of ( d ), and does not reach the polarity inversion point voltage,
the charge will be stopped after the total time since the start of charging reaches a certain
period of time.
This timer is activated to stop charging when the battery voltage still does not reach
the polarity inversion point voltage after ( e ) hours from the start of charging.
The activation of this timer may indicate abnormality in the main circuit.
An abnormality in the main circuit may be preventing power voltage increase.
The main causes of this problem include a ( f ) setting failure, diode puncture,
power voltage failure (lack of phase), transformer failure, and ( g ) switch contact failure.
3) Total Timer
If the main timer does not stop charging by some reason after a long time has passed
from the start of charging, the charge will be stopped by this timer after the total time
since the start of charging reaches a certain period of time.
This timer is activated to stop charging when a charge is still not ended after ( h ) hours

from the start of charging.

The activation of this timer may indicate abnormality in the control circuit.
As well as preventing ( i ), this timer will prevent a risk of fire.

Answer column

a voltage b charge
c terminal d charging (charge)
e 10 f tap
 g magnetic h 16
i overcharging

28 19 Select the correct answer.

a) Terminal 1 is connected to terminal 5 until energized, then terminal 1 is connected to
terminal 4.
b) Terminal 3 is connected to terminal 5 until energized, then terminal 3 is connected to
terminal 4.
c) Terminal 4 is connected to terminal 5 until energized, then terminal 4 is connected to
terminal 3.
d) Terminal 4 is connected to terminal 3 until energized, then terminal 4 is connected to
terminal 5.

Answer c)

2 20 The figure below show the hydraulic circuit of 8FBN series. RM 8FBN15-30 10-2
Write the parts name in each blank from " a " to " h ".
 Answer column

a Oil control b Priority

c Return filter d Suction filter
e Oil pump f Pump motor
g Power steering valve h Solenoid valve

15 21 The following figure shows the oil control valve circuit of 7FB series. 2 8 99

Fill the appropriate word (parts name) in each blank except No. 2, 6, 9 and 13.

Answer column

1 Relief valve main plunger 2

3 Tilt load check valve 4 Lift load check valve
5 Lift spool 6
7 Lift lock check valve 8 Manual down valve
9 10 Tilt spool
11 Tilt cylinder 12 Tilt lock check valve
13 14 Lift cylinder
 Reference pages of step
technical information book

STEP Chapter Page

19 1 The formula for calculating power is Power = ( ). 2 1 61

a. Amps x Watts
b. Amps x Volts
Answer
c. Ohms x Volts
d. Amps x Ohms

20 2 In a series circuit ( ) is the same in any part of the circuit. 2 1 64

a. Resistance
b. Power
Answer
c. Voltage
d. Current

21 3 According to Ohms Law, you must multiply ( ) in order to determine the circuit 2 1 61
voltage.

a. Voltage x Resistance
b. Voltage x Current
Answer
c. Current x Resistance
d. All other answers are incorrect.

24 4 The sum of voltage drops in a series circuit equals ( ). 2 1 61

a. Voltage drop across the largest load

b. Voltage drop across the smallest load
c. Source voltage
d. Shunt circuit voltage
Answer

27 5 Technician X says that adding more branches to a parallel circuit reduces total circuit
resistance.
Technician Y says that adding more branches to a parallel circuit increases the total
current in the circuit.
Who is right?

a. Technician X
b. Technician Y
Answer
c. Both X and Y
d. Neither X nor Y
7 6 1 2 100
The following sentence explains about the advantage of AC induction motor used in 7FB series.

Fill the appropriate word in each blank from " a " to " e ".

1) More reliable than a ( a ) motor due to its simpler structure.

2) ( b ) size of an AC induction motor allows improved performance while maintaining
the size of a product.
3) Because it is practically ( c )-free with no ( d ) or commutator, it does not require
maintenance cost for replacing ( d ) and is environment-friendly.
4) Without the need for the maintenance above, it can be more flexibly placed and designed.
5) Using a ( e )-phase alternating current expands the control range of the motor and
enables the control that has been impossible (such as power control).

Answer column

a b
c d
e
12 7 The following sentence explains characteristics of AC induction motor. 2 2 249

Write the appropriate word in each blank from " a " to " j ".
Select the appropriate word from the selection column.

The characteristics of the AC induction motor are "rotation speed and output torque" and
"rotation speed and ( a )."
The figure below shows the changes in the the motor torque and motor current observed
as the motor, after power-on, starts, accelerates, and reaches a constant speed.
The ( b ) is the highest at startup and decreases as the ( c ) speed increases.
In contrast, the ( d ) increases as the ( e ) speed increases and decreases when a certain
( f ) speed is exceeded. The motor begins to run at a ( g ) speed when the load torque and
the motor torque balance with each other. The current at this point is the load current.
A change in the load torque changes the motor current and ( h ).
The motor cannot run if the load torque is larger than the ( i ) torque of the motor.
If the motor torque is larger than the load torque, the rotation speed ( j ) according to
the difference between them. The motor torque gradually increases as the rotation speed increases
and then decreases after the maximum torque is reached.

Answer column

a b
c d
e f
g h
i j

Selection column

rotation, decrease, speed, constant, starting, increases,

current, maximum, torque
25 8 The motor in the circuit runs slow. A voltmeter indicates 12.6 volts as shown.
Technician X says that a bad ground at the motor could be the cause.
Technician Y says that high resistance in the circuit from the battery to the motor could be
the cause.
Who is right?

Answer

4 9 The following sentence explains OPS function of 8FBN series. NMF 8FBN15-30 2-21 - 2-25
Write the appropriate word in each blank from "a" to "e". Electric Control Functions

1) Travel OPS
When the controller detects the seat switch being turned off for two seconds,
the drive motor stops after acting as the ( a ) brake.
Travel OPS is released by returning the direction lever and ( b ) pedal to the neutral position
and turning on the seat switch.

2) Hydraulic function OPS

When the controller detects the seat switch being turned off for two seconds,
all the ( c ) operations are stopped by valve control.
For this model, hydraulic function OPS is released by returning all the ( d ) to the neutral positions
and turning on the seat switch.

3) OPS operation information function

When the controller detects that the seat switch is turned off, the onboard buzzer in the display
sounds (pi-) for one second and the ( e ) indicator shows up on the display in advance of
OPS activation.
If the operator notices it and is seated again in 2 seconds, the OPS will not activate.
As long as the seat is not taken (seat switch is off), the ( e ) indicator remains lit to inform
the operator that the OPS is activated.
Answer column

a b
c d
e
5 10 The following sentences explain some of the characteristics of 8FBN series. 8FBN new model features (PE321 p
Write the appropriate word in each blank from " a " to " j ".

1) Regenerative brake system

When the accelerator is released during travelling, the regenerative brake works and recovers
electric braking energy into the ( a ). It increases the ( b ) time, extends the life of the brakes
and brings a smooth and powerful deceleration feeling.
This regenerative brake works even when the direction lever is the neutral position.
The adjustment of this regenerative brake feeling is obtained by using the ( c ) function
of the display.
2) Maximum speed limitation function
If the maximum speed limit is set, this function prevents the vehicle from running at speed higher
than the speed limit. It relieves the operator from the need to finely adjust the ( d ) in order to
observe the speed limit, and the administrator from the need to keep watch on the speed limit.
The speed limit can be adjusted in steps of 1 km/h starting at 2 km/h, using the ( c ) function
of the display.
3) Power steering function
This model has the hydraulic power steering. Hydraulic oil is supplied to the power steering circuit
from the oil pump connected to the pump motor. On this model, the amount of hydraulic oil supply is
controlled depending on the steering wheel ( e ).
Thereby, the starting feeling of steering is improved. Hydraulic oil is also supplied continuously
when the ( f ) is operated, or while the vehicle is traveling.
4) Power keep function
The power keep function is provided to maintain the battery performance even when the battery is
significantly ( g ). This function works only in P, S and E modes, and it can be disabled
using the ( c ) function (option setting function) of the display.
5) Over-discharge warning function
If traveling or ( h ) operation is carried out while the battery capacity is at the over-discharge
warning level, a ( i ) and audible warning will be given to inform the operator that the battery is
overdischarged. In addition to that, a limit will be placed on the vehicle performance.
Through these operations, the battery is protected and the operator is prompted to ( j )
the battery.

Answer column

a b
c d
e f
g h
i j
11 11 The following flow is ”Basic checking operation procedure” for electric forklift. 3 3 7

Write the correct word in each blank from " a " to " h ".
Select the appropriate word from the selection column.

Answer column

a b
c d
e f
g h

Selection column

failure, output, error code, harness, input, actuator, controller, sensor

14 12 The following sentence is the troubleshooting procedure of power supply system for 7FB series. 3 3 10

Write the appropriate word in each blank from " a " to " j ".
Symptom: Vehicle moves but display has no illumination
[Identifying failure range]
The first thing is to check and understand the power supply line on the system circuit.
And compare and check the vehicle's symptom to narrow the failure range.
For this symptom, it is understood that the ( a ) board has power supplied and the ( b )V
and 15 V power supply circuits of the ( c ) board are normal because the vehicle moves.
It is estimated that the defect exists in the range from the DC/MD board to the ( d ).
When the power supply system fails, an ( e ) may not be displayed; therefore, the failure range
is identified from the vehicle's symptom.
[Inspection]
While the test lead (black) of a circuit tester is placed on the ( f ) terminal, measure the voltage
sequentially from the battery side to check the end of the ( g ) side electricity.
For this symptom, check the ( h ) level line.
For example, if the voltage of the DC/MD board outlet (Inspection (1) in the diagram) is 15 V and
the voltage of the CPU board inlet (Inspection (2) in the diagram) is ( i ) V, disconnection between
them is assumed. Finally, check the ( j ) of the corresponding harness to identify
the defective spot.

Answer column

a b
c d
e f
g h
i j

23 13 The hydraulic pump contactor is designated as ( ).

a. DMP
b. MP
Answer
c. TMP
d. CSP
29 14 In the circuit shown, the light glows dimly. The first voltmeter reading (V1) is 0.0 volts.
The second voltmeter (V2) reads 7.5 volts. The third voltmeter (V3) reads 4.5 volts.
The problem might be ( ).

a. The fuse is defective

b. The bulb has too little resistance
c. The switch has too much resistance
d. The battery is weak

Answer

30 15 The symbols shown below are used on Toyota wiring diagrams to indicate ( ).

a. a LED and transistor

b. a Zener diode and lamp
Answer
c. a Zener diode and transistor
d. a diode and thermistor

16 16 The following figure shows the oil pressure system of EHPS (Electrically Controlled fully-hydraulic 2 4 50

Power Steering) adopted on 7FB series.

Write the appropriate name in the answer column except for No. 6, 8, 9 and 14.
Select the appropriate name from the selection column.

Answer column

1 2
 3 4
5 6
7 8
9 10
11 12
13 14

Selection column

PS valve, Hydraulic oil tank, Drag link, Tilt angle sensor, Steering wheel,
Knob offset compensation valve, PS motor, Rear axle cylinder, Swing lock
solenoid, Controller, Steering angle sensor, PS pump
3 17 The following figure shows the display used in 8FBN series. RM 8FBN15-30 4-3 - 4-7
Answer the meaning for each symbol from " a" to " e ".

symbol Indicator Meaning (What happens on a truck if this indicator appears?)

e
18 18 The following sentence explains about the timer of charger. 2 7 24

Write the appropriate word in each blank from " a " to " i ".
Select the appropriate word from the selection column.

The battery charge timer consists of three timers: main timer, safety timer and total timer.
The last two are double safety timers activated to cancel charging in an abnormal situation.
1) Main Timer
This performs charge control dividing a charging period into the beginning and
ending phases at the polarity inversion point ( a ).
The charging time of the ending phase is set by the main timer. This charging time is
calculated from the time required for the beginning phase of ( b ).
2) Safety Timer
If the battery ( c ) voltage does not increase by some reason for a long time from
the start of ( d ), and does not reach the polarity inversion point voltage,
the charge will be stopped after the total time since the start of charging reaches a certain
period of time.
This timer is activated to stop charging when the battery voltage still does not reach
the polarity inversion point voltage after ( e ) hours from the start of charging.
The activation of this timer may indicate abnormality in the main circuit.
An abnormality in the main circuit may be preventing power voltage increase.
The main causes of this problem include a ( f ) setting failure, diode puncture,
power voltage failure (lack of phase), transformer failure, and ( g ) switch contact failure.
3) Total Timer
If the main timer does not stop charging by some reason after a long time has passed
from the start of charging, the charge will be stopped by this timer after the total time
since the start of charging reaches a certain period of time.
This timer is activated to stop charging when a charge is still not ended after ( h ) hours

from the start of charging.

The activation of this timer may indicate abnormality in the control circuit.
As well as preventing ( i ), this timer will prevent a risk of fire.

Answer column

a b
c d
e f
g h
i
Selection column

tap, charge, 16, voltage, magnetic, inversion, 10, overcharging, terminal, 4

28 19 Select the correct answer.
a. Terminal 1 is connected to terminal 5 until energized, then terminal 1 is connected to
terminal 4.
b. Terminal 3 is connected to terminal 5 until energized, then terminal 3 is connected to
terminal 4.
c. Terminal 4 is connected to terminal 5 until energized, then terminal 4 is connected to
terminal 3.
d. Terminal 4 is connected to terminal 3 until energized, then terminal 4 is connected to
terminal 5.

Answer

2 20 The figure below show the hydraulic circuit of 8FBN series. RM 8FBN15-30 10-2
Write the parts name in each blank from " a " to " h ".
Answer column

a b
c d
e f
g h
15 21 The following figure shows the oil control valve circuit of 7FB series. 2 8 99

Fill the appropriate name in each blank except No. 2, 6, 9 and 13.
Select the appropriate name from the selection column.

Answer column

1 2
3 4
5 6
7 8
9 10
11 12
13 14

Selection column

Tilt load check valve, Tilt relief valve, Tilt lock check valve, Tilt cylinder, Lift spool, Relief valve
main plunger, Manual down valve, Lift relief valve, Lift load check valve, Tilt spool, Lift cylinder,
Lift lock check valve
1 The formula for calculating power is Power = ( ).

a. Amps x Watts
b. Amps x Volts
Answer b
c. Ohms x Volts
d. Amps x Ohms

2 In a series circuit ( ) is the same in any part of the circuit.

a. Resistance
b. Power
Answer d
c. Voltage
d. Current

3 According to Ohms Law, you must multiply ( ) in order to determine the circuit
voltage.

a. Voltage x Resistance
b. Voltage x Current
Answer c
c. Current x Resistance
d. All other answers are incorrect.

4 The sum of voltage drops in a series circuit equals ( ).

a. Voltage drop across the largest load

b. Voltage drop across the smallest load
c. Source voltage
d. Shunt circuit voltage
Answer c

5 Technician X says that adding more branches to a parallel circuit reduces total circuit
resistance.
Technician Y says that adding more branches to a parallel circuit increases the total
current in the circuit.
Who is right?

a. Technician X
b. Technician Y
Answer c
c. Both X and Y
d. Neither X nor Y
6
The following sentence explains about the advantage of AC induction motor used in 7FB series.

Fill the appropriate word in each blank from " a " to " e ".

1) More reliable than a ( a ) motor due to its simpler structure.

2) ( b ) size of an AC induction motor allows improved performance while maintaining
the size of a product.
3) Because it is practically ( c )-free with no ( d ) or commutator, it does not require
maintenance cost for replacing ( d ) and is environment-friendly.
4) Without the need for the maintenance above, it can be more flexibly placed and designed.
5) Using a ( e )-phase alternating current expands the control range of the motor and
enables the control that has been impossible (such as power control).

Answer column

a DC b Compact
c maintenance d brushes
e three
7 The following sentence explains characteristics of AC induction motor.
Write the appropriate word in each blank from " a " to " j ".
Select the appropriate word from the selection column.

The characteristics of the AC induction motor are "rotation speed and output torque" and
"rotation speed and ( a )."
The figure below shows the changes in the the motor torque and motor current observed
as the motor, after power-on, starts, accelerates, and reaches a constant speed.
The ( b ) is the highest at startup and decreases as the ( c ) speed increases.
In contrast, the ( d ) increases as the ( e ) speed increases and decreases when a certain
( f ) speed is exceeded. The motor begins to run at a ( g ) speed when the load torque and
the motor torque balance with each other. The current at this point is the load current.
A change in the load torque changes the motor current and ( h ).
The motor cannot run if the load torque is larger than the ( i ) torque of the motor.
If the motor torque is larger than the load torque, the rotation speed ( j ) according to
the difference between them. The motor torque gradually increases as the rotation speed increases
and then decreases after the maximum torque is reached.

Answer column

a current b current
c rotation d torque
e rotation f rotation
g constant h speed
i starting j increases

Selection column

rotation, decrease, speed, constant, starting, increases,

current, maximum, torque
8 The motor in the circuit runs slow. A voltmeter indicates 12.6 volts as shown.
Technician X says that a bad ground at the motor could be the cause.
Technician Y says that high resistance in the circuit from the battery to the motor could be
the cause.
Who is right?

Answer Technician x

9 The following sentence explains OPS function of 8FBN series.

Write the appropriate word in each blank from "a" to "e".

1) Travel OPS
When the controller detects the seat switch being turned off for two seconds,
the drive motor stops after acting as the ( a ) brake.
Travel OPS is released by returning the direction lever and ( b ) pedal to the neutral position
and turning on the seat switch.

2) Hydraulic function OPS

When the controller detects the seat switch being turned off for two seconds,
all the ( c ) operations are stopped by valve control.
For this model, hydraulic function OPS is released by returning all the ( d ) to the neutral positions
and turning on the seat switch.

3) OPS operation information function

When the controller detects that the seat switch is turned off, the onboard buzzer in the display
sounds (pi-) for one second and the ( e ) indicator shows up on the display in advance of
OPS activation.
If the operator notices it and is seated again in 2 seconds, the OPS will not activate.
As long as the seat is not taken (seat switch is off), the ( e ) indicator remains lit to inform
the operator that the OPS is activated.
Answer column

a regenerative b accelerator
c load handling (material handling) d levers
e OPS
10 The following sentences explain some of the characteristics of 8FBN series.

Write the appropriate word in each blank from " a " to " j ".

1) Regenerative brake system

When the accelerator is released during travelling, the regenerative brake works and recovers
electric braking energy into the ( a ). It increases the ( b ) time, extends the life of the brakes
and brings a smooth and powerful deceleration feeling.
This regenerative brake works even when the direction lever is the neutral position.
The adjustment of this regenerative brake feeling is obtained by using the ( c ) function
of the display.
2) Maximum speed limitation function
If the maximum speed limit is set, this function prevents the vehicle from running at speed higher
than the speed limit. It relieves the operator from the need to finely adjust the ( d ) in order to
observe the speed limit, and the administrator from the need to keep watch on the speed limit.
The speed limit can be adjusted in steps of 1 km/h starting at 2 km/h, using the ( c ) function
of the display.
3) Power steering function
This model has the hydraulic power steering. Hydraulic oil is supplied to the power steering circuit
from the oil pump connected to the pump motor. On this model, the amount of hydraulic oil supply is
controlled depending on the steering wheel ( e ).
Thereby, the starting feeling of steering is improved. Hydraulic oil is also supplied continuously
when the ( f ) is operated, or while the vehicle is traveling.
4) Power keep function
The power keep function is provided to maintain the battery performance even when the battery is
significantly ( g ). This function works only in P, S and E modes, and it can be disabled
using the ( c ) function (option setting function) of the display.
5) Over-discharge warning function
If traveling or ( h ) operation is carried out while the battery capacity is at the over-discharge
warning level, a ( i ) and audible warning will be given to inform the operator that the battery is
overdischarged. In addition to that, a limit will be placed on the vehicle performance.
Through these operations, the battery is protected and the operator is prompted to ( j )
the battery.

Answer column

a battery b operating
c service d accelerator
e speed f direction lever
g discharged h load handling
i visual j charge
11 The following flow is ”Basic checking operation procedure” for electric forklift.
Write the correct word in each blank from " a " to " h ".
Select the appropriate word from the selection column.

Answer column

a error code b failure

c input d output
e sensor f Controller
g actuator h harness, Harness

Selection column

failure, output, error code, harness, input, actuator, controller, sensor

12 The following sentence is the troubleshooting procedure of power supply system for 7FB series.
Write the appropriate word in each blank from " a " to " j ".
Symptom: Vehicle moves but display has no illumination
[Identifying failure range]
The first thing is to check and understand the power supply line on the system circuit.
And compare and check the vehicle's symptom to narrow the failure range.
For this symptom, it is understood that the ( a ) board has power supplied and the ( b )V
and 15 V power supply circuits of the ( c ) board are normal because the vehicle moves.
It is estimated that the defect exists in the range from the DC/MD board to the ( d ).
When the power supply system fails, an ( e ) may not be displayed; therefore, the failure range
is identified from the vehicle's symptom.
[Inspection]
While the test lead (black) of a circuit tester is placed on the ( f ) terminal, measure the voltage
sequentially from the battery side to check the end of the ( g ) side electricity.
For this symptom, check the ( h ) level line.
For example, if the voltage of the DC/MD board outlet (Inspection (1) in the diagram) is 15 V and
the voltage of the CPU board inlet (Inspection (2) in the diagram) is ( i ) V, disconnection between
them is assumed. Finally, check the ( j ) of the corresponding harness to identify
the defective spot.

Answer column

a CPU b 20
c DC/MD d display
e error code f N1
g positive (plus) h 16
i 0 j continuity

13 The hydraulic pump contactor is designated as ( ).

a. DMP
b. MP
Answer b
c. TMP
d. CSP
14 In the circuit shown, the light glows dimly. The first voltmeter reading (V1) is 0.0 volts.
The second voltmeter (V2) reads 7.5 volts. The third voltmeter (V3) reads 4.5 volts.
The problem might be ( ).

a. The fuse is defective

b. The bulb has too little resistance
c. The switch has too much resistance
d. The battery is weak

Answer c

15 The symbols shown below are used on Toyota wiring diagrams to indicate ( ).

a. a LED and transistor

b. a Zener diode and lamp
Answer a
c. a Zener diode and transistor
d. a diode and thermistor

16 The following figure shows the oil pressure system of EHPS (Electrically Controlled fully-hydraulic
Power Steering) adopted on 7FB series.
Write the appropriate name in the answer column except for No. 6, 8, 9 and 14.
Select the appropriate name from the selection column.

Answer column
 1 Steering wheel 2 Steering angle sensor
3 PS valve 4 Knob offset compensation valve

5 Controller 6
7 Tilt angle sensor 8
9 10 PS motor
11 PS pump 12 Hydraulic oil tank
13 Rear axle cylinder 14

Selection column

PS valve, Hydraulic oil tank, Drag link, Tilt angle sensor, Steering wheel,
Knob offset compensation valve, PS motor, Rear axle cylinder, Swing lock
solenoid, Controller, Steering angle sensor, PS pump
17 The following figure shows the display used in 8FBN series.
Answer the meaning for each symbol from " a" to " e ".

symbol Indicator Meaning (What happens on a truck if this indicator appears?)

OPS indicator
a When the operator leaves the operation seat, this indicator lights up
and the buzzer sounds for 1 second.

Overheat warning indicator

If the temperature of the controller, motor driver or traveling-load
b handling motor rises to an abnormal level, this indicator lights up, a
warning sound is
emitted and the output is limited.

Power select indicator

c The power mode (S, P or H) and its indication on the display change
each time the power select switch on the status screen is pressed.

Battery overheat warning indicator

If the battery fluid temperature rises above the specified level, this
d
indicator lights up, a warning sound is emitted and the output is
limited.

Battery fluid level warning indicator

e If it is detected that there is not enough battery fluid left in the battery,
this indicator lights up to warn the operator.
18 The following sentence explains about the timer of charger.
Write the appropriate word in each blank from " a " to " i ".
Select the appropriate word from the selection column.

The battery charge timer consists of three timers: main timer, safety timer and total timer.
The last two are double safety timers activated to cancel charging in an abnormal situation.
1) Main Timer
This performs charge control dividing a charging period into the beginning and
ending phases at the polarity inversion point ( a ).
The charging time of the ending phase is set by the main timer. This charging time is
calculated from the time required for the beginning phase of ( b ).
2) Safety Timer
If the battery ( c ) voltage does not increase by some reason for a long time from
the start of ( d ), and does not reach the polarity inversion point voltage,
the charge will be stopped after the total time since the start of charging reaches a certain
period of time.
This timer is activated to stop charging when the battery voltage still does not reach
the polarity inversion point voltage after ( e ) hours from the start of charging.
The activation of this timer may indicate abnormality in the main circuit.
An abnormality in the main circuit may be preventing power voltage increase.
The main causes of this problem include a ( f ) setting failure, diode puncture,
power voltage failure (lack of phase), transformer failure, and ( g ) switch contact failure.
3) Total Timer
If the main timer does not stop charging by some reason after a long time has passed
from the start of charging, the charge will be stopped by this timer after the total time
since the start of charging reaches a certain period of time.
This timer is activated to stop charging when a charge is still not ended after ( h ) hours

from the start of charging.

The activation of this timer may indicate abnormality in the control circuit.
As well as preventing ( i ), this timer will prevent a risk of fire.

Answer column

a voltage b charge
c terminal d charging (charge)
e 10 f tap
g magnetic h 16
i overcharging
Selection column

tap, charge, 16, voltage, magnetic, inversion, 10, overcharging, terminal, 4

19 Select the correct answer.
a. Terminal 1 is connected to terminal 5 until energized, then terminal 1 is connected to
terminal 4.
b. Terminal 3 is connected to terminal 5 until energized, then terminal 3 is connected to
terminal 4.
c. Terminal 4 is connected to terminal 5 until energized, then terminal 4 is connected to
terminal 3.
d. Terminal 4 is connected to terminal 3 until energized, then terminal 4 is connected to
terminal 5.

Answer c

20 The figure below show the hydraulic circuit of 8FBN series.

Write the parts name in each blank from " a " to " h ".
Answer column

a Oil control b Priority

c Return filter d Suction filter
e Oil pump f Pump motor
g Power steering valve h Solenoid valve
21 The following figure shows the oil control valve circuit of 7FB series.
Fill the appropriate name in each blank except No. 2, 6, 9 and 13.
Select the appropriate name from the selection column.

Answer column

1 Relief valve main plunger 2

3 Tilt load check valve 4 Lift load check valve
5 Lift spool 6
7 Lift lock check valve 8 Manual down valve
9 10 Tilt spool
11 Tilt cylinder 12 Tilt lock check valve
13 14 Lift cylinder

Selection column

Tilt load check valve, Tilt relief valve, Tilt lock check valve, Tilt cylinder, Lift
spool, Relief valve main plunger, Manual down valve, Lift relief valve, Lift load
check valve, Tilt spool, Lift cylinder, Lift lock check valve