Professional Documents
Culture Documents
Main harness
Harness, rear
combination
Harness, front
combination
Harness, front
combination
209620
3-1
ELECTRICAL SYSTEM
Key
Starter switch
Harness,
rear combination
Clip
Select switch
Warning buzzer Back buzzer
Harness, front
combination
Controller
Battery seat
Fuse box,
QGS controller Fuse
(Diesel truck only)
Harness, front
Horn combination
Transmission
212801
3-2
ELECTRICAL SYSTEM
Structure 4 3
1
Console box
2
1 Water temperature gauge
2 Fuel gauge 6
3 Various warning lights
4 Instrument panel
5 Starter switch
6 Lighting switch, turn signal switch
7 Forward-reverse lever 7
213005
3-3
ELECTRICAL SYSTEM
A B C D E F G H
J L1 L L2 L3 K 212802
Description of function
When illuminated
Code Name of monitor When not illuminated Remarks
or flashing
A Brake fluid level warning lamp Normal level Low level
ATM: Torque converter fluid temperature warning lamp Normal temperature Overheat ATM truck
B
MTM: Clutch wear lamp Normal Clutch worn MTM truck
C Engine oil pressure warning lamp Normal oil pressure Low oil pressure
D Seat belt reminder warning lamp Fastened Not fastened
Multi-purpose warning lamp (illuminates when
E warnings indicated by printed symbols occur or minor Normal Malfunction Printed symbol
failures occur)
Abnormal charging
F Charge warning lamp Normal charging
system
Engine being
G Glow pilot lamp Preheating completed Diesel-engine truck
preheated
H Load/unload interlock lamp Free Locked
Fr, Re interlock lamp Free Locked (flashing)
I
Neutral lamp F or R Neutral
J Fuel gauge Indicates remaining fuel amount with key in “ON” position.
K Water temperature gauge Indicates “Overheat” condition if pointer enters the red zone.
L Liquid crystal (normally acting as hour meter) Indicates operating hours with key in “ON” position.
Position and content
of printed symbols
L1 Fuel filter warning lamp Normal Water drain required Diesel-engine truck
L3 Clogged air cleaner element warning lamp Normal element Clogged Option
3-4
ELECTRICAL SYSTEM
(OFF)
(ON)
G1
M
B2
(START)
G2
B1
S
208540
Connection Table
Gasoline-engine truck (12 V)
Terminal B1, B2 G1 G2 M S
Connected to Battery,
alternator, Fuse box FNR lever
Key position fuse box
OFF
ON (when driving)
START (when starting engine)
Terminal B1, B2 G1 G2 M S
Connected to Battery, Neutral switch
alternator, Fuse box (starter),
Key position fuse box QGS controller
OFF
ON (when preheating) (when driving)
START (when starting engine)
3-5
ELECTRICAL SYSTEM
Lighting and
turn signal lever
Boot
Horn contact
Boot
Forward-reverse lever
Forward of truck
Lighting switch, turn signal switch
209625
Forward of truck
Lighting switch,
turn signal switch
F
Forward-reverse
selector switch
212804
T-2 L-5
L-1 L-3
5 Steering angle sensor
1 3
Horn contact
4
1 2
Horn
3 5
209627
3-6
ELECTRICAL SYSTEM
Horn
Check that the horn sounds when applying the specified Up
voltage to both terminals of the horn, T1 and T2.
Replace the horn if it does not sound or its sound is
abnormal.
T1
Operating voltage: DC 12 V
Notice: The installed position in an actual truck is as per
the illustration. T2
Down
Vent hole
Contact
Coil
209628
3/4
Referential Standards
210782
3-7
ELECTRICAL SYSTEM
M10x1.25 OFF ON
1 M ohm or more (illuminates)
Insulation resistance value
(at 500 V megger) 208543
Rated voltage: DC 12 V
3-8
ELECTRICAL SYSTEM
Forward of vehicle
F Forward
(10 ) (10 )
N Neutral
R Reverse
Connection table
Terminal 1 2 3 4 5
Wire color
Lever position *1 B G/R B L/W
F (Forward)
N (Neutral)
R (Reverse)
*1 G/W: Gasoline-engine truck
GY/L: Diesel-engine truck
212805
19.5 mm ON OFF
(0.77 in.)
2 mm 2 mm
Shift rail Backup lamp switch
(0.08 in.) (0.08 in.)
(for forward-reverse)
Transmission case
M12x1.75
208545 200013
3-9
ELECTRICAL SYSTEM
208546
Gasoline-engine truck
Diesel-engine truck
3-10
ELECTRICAL SYSTEM
1 M ohm or more
Insulation resistance value (with contact OFF)
(at 500 V megger)
NOTE
When installing the thermoswitch, tighten it to the 208547
specified torque.
! CAUTION
Replace the thermoswitch if it was dropped or
abused.
Main specifications
122 ± 3 °C
OFF→ON
(251.6 ± 5.4 °F)
Operating temperature
115 °C (239 °F)
ON→OFF
or higher
Insulation resistance
1 M ohm or more
(with contact OFF)
3-11
ELECTRICAL SYSTEM
Inspection of contact 2
3 1
1. Measure the insulation resistance value between
3
terminal 3 and terminal 4. Replace the contact if the 4
measured insulation resistance value is not more than 1 4
the value listed in the table below. 213066
20 M ohm or more
Insulation resistance value
(at 500 V megger)
! CAUTION
As the relay has an integrated diode between
terminals, be careful about the polarity when
inspecting. Replace the relay if it was dropped or
abused.
3-12
ELECTRICAL SYSTEM
Water temperature
Item (Sensor resistance Time turned on
value) Connector A Connector B
-15 °C [+5 °F]
10.0 ± 2.0 sec.
(12.1 kΩ)
Glow lamp, 0 °C [32 °F]
6.4 ± 1.3 sec.
Glow plugs (5.9 kΩ)
Connection diagram
+10 °C [50 °F]
3.0 ± 0.6 sec. Starter switch
(3.8 kΩ) OFF
ON
ST
Rated operating voltage: DC 12 V Glow lamp
3 1
A
QGS
4
Battery B controller
DC12V
5 6
212806
Fuel pump
209640
3-13
ELECTRICAL SYSTEM
SOL b
! CAUTION
P
The valve for DC 12 V has an identification mark
“12 V NO” on the body side.
B A
Solenoid valve b A B a
PT
213067
3-14
ELECTRICAL SYSTEM
Fuse Box
209645
Wiper
Back up/Others Working lamp 15A
15A 15A ETC Head lamp
Meter panel 15A 15A Stop lamp
10A Spare A/C
QGS/Others Horn 10A EGI
20A 10A EGI 30A
10A 20A 30A 30A
VCM Fuse puller
20A
10A 15A
SBF 100A SBF 100A SBF 50A
Spare Battery Alternator Glow
212807
3-15
ELECTRICAL SYSTEM
Item Watts
No. of
Color of lens Shape Remarks
bulbs
Type of lamp 12 volt
Turn
2 Amber 27
signals
Standard:
Combination
Installed on
lamps (front)
overhead guard
Clearance
2 Amber 10
lamps
Turn
2 Amber 20
signals
Combination Tail/stop
2 Red 8/23
lamps (rear) lamps
Backup
2 Colorless 18.4
lamps
213068
3-16
ELECTRICAL SYSTEM
Console Box
Disassembly
2
5
209648
Reassembly
Follow the disassembly sequence in reverse.
3-17
ELECTRICAL SYSTEM
Instrument Panel
Disassembly
2
5
8
9
206480
Sequence
1 Meter cover 6 Meter case
2 Dial 7 Rigid board
3 Water temperature gauge 8 Bulb
4 Liquid crystal 9 Socket
5 Fuel gauge
! CAUTION
Be careful not to damage the rigid board when
disassembling the instrument panel.
3-18
ELECTRICAL SYSTEM
Battery Maintenance
1.280 to 1.265 Fully charged If difference in S.G. between any two cells is 0.020 or more,
discharge the battery to minimize the difference and then
recharge battery. Adjust S.G. during recharging.
1.260 to 1.225 One-half charged Recharge battery and adjust electrolyte S.G. Make sure there
is neither faulty components, loosely connected cord nor
corroded connection.
1.220 or below Discharged Recharge battery. If difference in S.G. is large, adjust it
during recharging.
If difference in S.G. is A cell with a low S.G. Recharge until voltage and S.G. stabilize and have remained
more than 0.040 is in shorted condition. constant for more than 2 hours.
Electrolyte leakage, During recharging, adjust S.G. to 1.280 to 1.265.
or excessive/diluted If difference in S.G. is more than 0.040 and a low S.G. is
electrolyte. found in certain cells only, replace battery. After leaving
battery for 12 to 96 hours, conduct a high current discharge
test.
3-19
ELECTRICAL SYSTEM
Wire Color
Wire colors listed in the table below show standard colors (base colors). For wiring composed of two colors, the first
color shows a base color and the second color a marking color.
Example: The wire color of BW shows that its base color is B with a marking W.
BW
Marking color
Base color
Notice: For wiring identification, the same color, in principle, must be used for the circuit from the power supply to
the load.
! CAUTION
Be careful that allowable current differs between solid wires and stranded wires even if they are of the
same gauge.
3-20
ELECTRICAL SYSTEM
Troubleshooting
Starter System
Weak or dead battery Recharge or replace.
Short or open circuit Repair or replace.
Starter will not crank
Poor continuity in starter switch Replace.
engine
Starter or starter relay defective Replace.
Forward-reverse lever not in neutral Move lever to neutral
Starter switch position (ATM truck) position.
Turning off starter Open or short circuit Repair or replace.
switch will not stop Engine stop solenoid defective Replace or readjust.
engine
Control timer defective Replace.
Gauges
Rigid board defective Replace.
Will not indicate at Open or short circuit Repair or replace.
all Gauge internally defective Replace.
Gauge unit defective Replace.
Water Gauge or gauge unit not of the type Replace to a correct
Will not indicate called for one.
temperature
accurately
gauge Loose terminal connection Repair.
Will indicate higher Circuit between gauge and gauge unit Repair.
than actual grounded
temperature Gauge internally defective Replace.
3-21
ELECTRICAL SYSTEM
Lighting System
Weak or dead battery Recharge or replace.
Fuses blown out Check and replace.
Open or short circuit Repair or replace.
Will not light Poor grounding Clean ground spot and
re-make connection.
Switch defective Replace.
Lamps - general Bulbs burnt out Replace.
Weak battery Check and recharge.
Contact points in switches defective Repair or replace.
Loose terminals Repair.
Will light dimly
Dirty lenses Clean.
Water drops inside lenses Dry and replace packings.
Bulbs expired in service life Replace.
Lighting switch defective Replace.
Head lamps Will not light
Bulbs burnt out Replace.
Turn signal switch defective Replace.
Will not flicker
Turn signal relay defective Replace.
Turn signal relay defective Replace.
Will not go out
Bulbs burnt out Replace.
Turn signals Low wattage of bulbs Replace to a correct one.
Will flicker too
slow Bulbs burnt out Replace.
Turn signal relay defective Replace.
Will flicker too High wattage of bulbs Replace to a correct one.
fast Turn signal relay defective Replace.
Alarm Unit
Fuse blown out Check and replace.
Open or short circuit Repair or replace.
Will not sound Horn switch defective Replace.
Horn defective Replace.
Horn Horn button defective Repair or replace.
Will give an Horn switch defective Replace.
offensive blast
of sound Horn defective Replace.
3-22
ELECTRICAL SYSTEM
Battery
Drive belt slipping Readjust.
❋ Alternator
Stator coil grounded or open-circuited Repair or replace.
Rotor coil open Replace.
Brushes poorly seating on slip rings Replace brushes if worn.
Clean holder and polish
slip rings.
Diode ruptured Replace.
❋ Regulator
Regulated voltage setting too low Replace.
Tends to run down
rapidly ❋ Battery
Not enough electrolyte or wrong concentration of acid Refill and check specific
to water gravity.
Battery cell plates deteriorated (forming, possibly Replace.
internal short-circuit)
Terminal connections loose Clean and retighten.
❋ Wiring
Open or loose connection between starter switch and Repair.
regulator IC terminal
Fuse blown, or loosely set in holder Replace and repair.
Open or loose connection between F terminals of Repair.
regulator and alternator
❋ Wiring
Regulator IC and F terminals shorted or miswired Repair.
Poor grounding of regulator F terminal Repair.
Tends to get
overcharged ❋ Regulator
Pressure coil open-circuited Replace.
Regulated voltage too high Replace.
3-23
ELECTRICAL SYSTEM
Electrical Schematics
3-26