ELECTRICAL SYSTEM DESCRIPTION Console box .. Chassis electrical devices . . MAJOR ELECTRICAL COMPONENTS Starter switch (with anti-restart lock)... . Lighting switch. : Tum signal switch ...... = Buckup light switch (manual transmission models) 31 33 35 36 36 37 37 38 39 39) ‘Neutral switch (powershift transmission models) Spare terminals .. LIGHT BULB SPECIFICATIONS ... 40 41 DISASSEMBLY AND REASSEMBLY Console box . Components in console box . Combination meter. ELECTRICAL SYSTEM SCHEMATIC (GASOLINE MODELS) ELECTRICAL SYSTEM SCHEMATIC (DIESEL MODELS) .... 47 49Console Box 1 Engine coolant temperature gauge 2 Choke control 3 Fuel gauge 4 Service hour meter 5 OK monitor 6 Starter switch 7 Light switch 9 Speed selector switch DESCRIPTION ELECTRICAL SYSTEM 31ELECTRICAL SYSTEM OK monitor toza0e Function Ne. Tbdicatr light OFF ‘ON orfickerng [Remarks 1_| Brake fai level indicator igh Namal | Low 2__| Powentift ransnision ol temp. indir Hight | Normal | Overbeaing 3 | Glow plug indicator Hight TES | Heating Diesel models 4 | Altemator not charging indicator light Namal | Abnormal ‘5_| Engine oil pressure indicator light [Norma | Low 6 | Aircleaner element indicator light [Normal ‘Clogged ‘Option 7_| Fuel ier indicator ight | Nermal | Drain water Diesel modes 8 _| Engine coolant level indicator light | Normal Low Option ‘The bulbs are normal ifthe indicator lights 1, 2, 6 and 7 ceme ON when the starter switch key is tumed to (ON) position. (The indicator lights will go OFF when tke engine starts.)Chassis Electrical Devices ELECTRICAL SYSTEM level sensor stop ight Ground on body switch 206748 The electrical system is divided into engine (4) Instruments electrical system and chassis electrical system Following are the components involved in the chassis electrical system: (2) Wire and fuses Q) Lighting system: Head lights, working light and backup lights (3). Signaling system: ‘Tum signals, clearance lights, tai/stop lights, license plate light and horn ‘The circuit is a one-wire negative-ground system. 33ELECTRICAL SYSTEM Sensors Seder unit Gowers lemperature sensor) [seeee] ereeos] ( SS al ‘Coolant sensor (option) EC The gasoline and diesel models use the following sensors. Each sensor senses a change in physical Quantity and converts that change into a useful ‘input signal for the OK monitor builtin the console box. (1) Brake fluid level sensor (2) Coolant sensor (option) (3) Dust indicator switch (option) (4) Travel speed sensor (standard for DP50; optional for GP40/GPL40and DP40/DPL40/DP45) (S) Powershift transmission oil temperature sensor 34ELECTRICAL SYSTEM MAJOR ELECTRICAL COMPONENTS Starter Switch (with Anti-Restart Lock) ‘This switch has a built-in anti-restart lock, so the _the diesel models, | (ON) position of the switch is key cannot be tumed from | (ON) to@ (START) —_for energizing the glow plugs. position while the engine is running. The gasoline and diesel models use the same starter switch, In © (OFF) 1(0N) 2085618 u 3 Sa pea ry eer | pete | Seared © (OFF) ° 1 ON ——-) | [@orarn o— | Connection for diesel models “erin 3 o L_s | [Bea Ser RES, | See aae teense | Seismic | [O-oFR ° T | | [1x ot | [Berar — ee | 35ELECTRICAL SYSTEM Lighting Switch PIH q B/T| 26a Connection chart of e z P = ES = ‘Tum: tn (| EE ie | Meta i On t clean Ast position or 2nd position Se SS Turn Signal Switch Conecion chart Temi | F = = evens | naa gaa rent ape ge relay ©) _| (RH) a R (Right) oO Ni (Susight) L et) 5 Cord color Green| Yellow | Black 36ELECTRICAL SYSTEM Backup Light Switch (Manual Transmission Models) Backup light switch [| ‘Transmission case 200013 Fuel Tank Unit, a i : = : To ful gauge 3 I = To ground E eS = A £ Indication accuracy 8 “Terminal F [wm] mse F Sandard wsisance (0) | 150 | 954 | 50 [227] 0 “Tolerance (2 raga) ef easa| eee late 209874 37ELECTRICAL SYSTEM Neutral Switch (Powershift Transmission Models) Connection chart Batery | Batery | Neutral | Reverse | Forward L 1 N R FE (eR) =} R68) a my) LS ai aw) 206750 38Fuse Box ELECTRICAL SYSTEM 102607 ‘Circuit 100 10a “Torque convener neural switch 0A 8 15a ‘Tail lights, head lights, clearance 1ights, working lights (option) 10A Hom TOA ‘Spare fase 10A Stop lights 10. ‘Backup lighs | «]zlala |e 15A Spare fase Spare Terminals ‘The spare terminal cord extends from the fuse box in the console box. (Another spare terminal is located on the chassis-side main hamess.) Cord color: Lg (yellowish green) Removing the console box rear panel will expose, this spare terminal which is fastened to the hamess protector with vinyl tape. 39ELECTRICAL SYSTEM and instrument panel light 10 LIGHT BULB SPECIFICATIONS Light Color of lens es sal «Se Remarks “\e t+ Head lights: 2 ‘Colorless ss) 0) a, | nota | te | 2 fame ja} | CE ‘Combination | ‘Standard: ‘lights (front) Installed on overhead guard Clearance : : ele [ole | ao om : signals 2 Amber E> Combinaion | Taiveop | y lights (rear) | lights 2S |e i tans” | 2 | Cotes —— (front and rear) ;* joe - License plate light 1 Colorless | 8 | OK monitor inicaor lights oe |ELECTRICAL SYSTEM BATTERY MAINTENANCE 1. State of charge and electrolyte specific gravity adjustment Siete gaa —adie | saat arse ‘Aalnsatt 12801 1.265 Fuly aged Tienes 56. bowvon any two cls is 0020 oF are OS tre dsp o mnize he | Siecct eae rodang ates, jus SO. cag | recharging. 1260 1228 Onstalfcearged | Recharge bee and adj eoroye 0. Make ae ‘chaps tare cerca esay comet cond Pe SeeiedComesion 1.220 or below Discharged ‘Recharge battery. If difference in S.G. is large, adjust it Sng cre Wallace asc.e | Aedlwit alow 6. | During retarging adn SO. w 1280 w 1265, facia 000 Ae ee or tan 0.00 and alow S.C. Sea conn se tela cal only replace batery. Afr eving Reslarge unl ohMe® | Cy ford toe hous condul «igh coment acarge we citemsan | tal | SReas ee 2. Specific gravity reading and state of charge (4) When connecting the cables to the battery, begin with the cable for the positive (+) terminal, When disconnecting them from the battery, begin with the cable for the negative To check the battery for state of charge, take hydrometer readings on its electrolyte. The battery may be fully charged if the S.G. reading is 1.280 to 1.265 at 20°C [68°F]. The state of charge can © terminal. be told from the way the electrolyte level goes down to expose the cell plates. If addition of distilled water is necessary every month or so, the _| Be sure to tum OFF the starter switch and light battery is overcharged. If addition is not required _| switch before disconnecting or connecting the for more than 3 months, itis likely thatthe battery | battery cables to prevent the IC regulator from is inadequately charged. suffering damage. 3. Charging precautions (1) Inslow charging, the charging current should be about 1/10 the capacity of the battery 10 be charged, (2) In quick charging, the battery capacity in ampere should not be exceeded. @) During charging, adjust the charging current to prevent the electrolyte temperature from rising beyond 45°C [113°F]. 41ELECTRICAL SYSTEM Precautions for servicing charging system (with alternator) ‘The altemator is equipped with a built-in IC Gntegrated circuit) voltage regulator. When servicing the charging system, pay attention to the following precautions: (Q)_ Donot reverse the polarity of the battery. (2) Do not disconnect the battery terminal while the engine is running. (3) Do not ground the terminal L. @)_ Do not short the terminals Land R. (S) Do not direct a blast of steam cleaner to the alternator, Remember, a blast of steam will damage the IC regulator. 42ELECTRICAL SYSTEM DISASSEMBLY AND REASSEMBLY ‘Console Box Disassembly 1, Disconnect the electrical wires at connectors 1. (in the gasoline models, disconnect the choke cable on the engine side.) 2, Remove screws 2 (four) securing the cover. 3. Remove screws 3 (six) and separate the front and rear panels. 4, Remove screws 4 (four) securing the instrument panel. NOTE) To replace the instrument panel bulbs, remove screws 3 and 4. —__/ 2o6e22' Reassembly To reassemble the console box, follow the reverse of disassembly procedure.ELECTRICAL SYSTEM ‘Components in Console Box 1 Power relay 2 Power relay 3 Tum signal relay 4 Glow plug relay (diesel models) 44 i '5 Glow plug timer (diesel models) 6 Light switch 7 Starter switch 8 FusesELECTRICAL SYSTEM Combination Meter Disassembly | ‘Sequence 1 Instrument panel 5 Meter case 2 Dial 17 Printed circuit, 3 Engine coolant temperature gauge 3 Bulb 4 Service hour meter 9 Socket 5 Fuel gauge Be careful not to damage the printed circuit ‘when disassembling the combination meter. Bulb replacement For bulb replacement, remove the socket from the To reassemble the combination meter, follow the printed circuit by turing it to the left. For reverse of disassembly procedure, ‘configuration of the indicator lights, refer to “OK. Monitor.” Reassembly 45