1996-2001 Fuso - Electrical-Sm78

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Group 54
Electrical
Table of Contents
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Pub No. TWME9503-54

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CONNECTOR CONFIGURATION CHART 54
Model
(Number shows number Connection
of pins)
AA AA 1 A
AA 2 A
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AA 2 B
AA 3 A
AA 3 B
AA 4 A
AA 4 B
AA 6 A
TA 54-0-3
CONNECTOR CONFIGURATION CHART
Model
of pins)
AA AA 6 B
AA 8 A
AA10A
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AA12A
AB AB 2 A
AB 3 A
AB 4 A
AB 6 A
AC AC 1 A
54-0-4 TA
54
Model
of pins)
AC AC 2 A
AC 3 A
AC 4 A
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AD AD 1 A
AD 2 A
AE AE 2 A
AE 3 A
AE 5 A
AE 7 A
TA 54-0-5
Model
of pins)
AE AE 9 A
AE11A
AE13A
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AE15A
AE16A
(White, Gray,
Black)
AE16B
(Green)
AE16C
(Blue)
AE17A
AG AG16A
54-0-6 TA
54
Model
of pins)
AG AG20A
AH AH10A
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AH12A
AH18A
AH18B
TA 54-0-7
Model
of pins)
AH AH24A
AJ AJ 2 A
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AJ 4 A
AJ 8 A
AJ10A
AJ12A
54-0-8 TA
54
Model
of pins)
AJ AJ16A
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TA 54-0-9
Model
of pins)
AJ AJ20A
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AK AK 2 A
AK 3 A
AK 4 A
AK 6 A
54-0-10 TA
54
Model
of pins)
AK AK 8 A
AK10A
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AK14A
AK18A
AK20A
TA 54-0-11
Model
of pins)
AK AK20B
AK22A
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AK22B
AL AL 1 A
or
or
AL 2 A
or
or
54-0-12 TA
54
Model
of pins)
AL AL 2 B
AL 3 A
or
or
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AL 3 B
AL 3 C
AL 3 D
or
AL 3 E
or
TA 54-0-13
Model
of pins)
AL AL 4 A
or or
AL 4 B
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AL 6 A
or or
AL 6 B
AL 8 A
or or
AL 8 B
54-0-14 TA
54
Model
of pins)
AM AM 2 A
AM 2 B
AM 2 C
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AM 4 A
AM 4 B
AM 6 A
AM 6 B
AM 8 A
AM 8 B
TA 54-0-15
Model
of pins)
AM AM10A
AN AN 1 A
AN 2 A
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AN 3 A
AN 4 A
AN 4 B
AN 6 A
AN 6 B
AN 8 A
54-0-16 TA
54
Model
of pins)
AN AN 8 B
AP AP 1 A
AP 1 B
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AP 2 A
AP 2 B
AP 2 C
AQ AQ 3 A
AQ 3 B
AQ13A
TA 54-0-17
Model
of pins)
AQ AQ15A
AQ20A
AR AR 2 A
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AR 2 B
AR 2 C
AR 2 D
AR 2 E
AR 2 F
54-0-18 TA
54
Model
of pins)
AR AR 3 A
AS AS 1 A
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AS 2 A
AS 2 B
AT AT 4 A
AU AU 6 A
AU 8 A
AU10A
TA 54-0-19
Model
of pins)
AU AU12A
AU13A
AU16A
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AV AV 1 A
AV 2 A
AW AW 1 A
AW 1 B
AW 2 A
AX AX 4 A
54-0-20 TA
54
Model
of pins)
AY AY 2 A
AZ AZ 2 A
BA BA 3 A
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BB BB 2 A
BB 3 A
BC BC 3 A
BD BD 8 A
BE BE 6 A
BF BF12A
TA 54-0-21
Model
of pins)
BG BG16A
BH BH 4 A
BJ BJ 9 A
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BL BL 2 A
BM BM 2 A
BM 2 B
BM 2 C
54-0-22 TA
54
1 POWER, CHARGING AND GROUND
SPECIFICATIONS .......................................................................... 54-1-2
STRUCTURE AND OPERATION ................................................... 54-1-3
TROUBLESHOOTING .................................................................... 54-1-7
10 0 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE

• Inspection of Alternator ................................................................ 54-1-8
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• Inspection of Regulator ................................................................ 54-1-9
101 BATTERY ........................................................................... 54-1-10
10 4 FUSE ................................................................................. 54-1-14
10 6 ALTERNATOR ................................................................... 54-1-16
110 POWER CIRCUIT .............................................................. 54-1-22
115 RESERVE POWER CIRCUIT ............................................ 54-1-32
125 BATTERY CHARGING CIRCUIT ....................................... 54-1-34
130 GROUND ........................................................................... 54-1-36
54-1-1
SPECIFICATIONS
Battery
Item Specifications
Model 95E41R
Voltage×No. V 12×2 (Parallel connection)
Capacity (5-hour rating) Ah 80
Alternator
Item Specifications
Manufacturer MITSUBISHI ELECTRIC
Type Alternator with built-in regulator (without brush, external fan)
Model A4TU0286
Output V-A 12–80
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54-1-2
STRUCTURE AND OPERATION 54
Alternator
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E
R L
2 3 4
1 5
11
9
10 8
7
08644
1 Rectifier 7 Front bracket B: Terminal B

2 Rotor assembly 8 Field coil E: Terminal E
3 Stator assembly 9 Rear bracket L: Terminal L
4 Fan 10 Regulator R: Terminal R
5 Pulley 11 Rear bearing
6 Front bearing
54-1-3
STRUCTURE AND OPERATION
Battery Charging Circuit
< Air over hydraulic brake >
1 Battery
2 Alternator
3 Warning buzzer
4 Parking brake switch
5 Meter cluster
6 Brake warning lamp
7 Air pressure warning lamp
8 Charge warning lamp
9 Relay and fuse box
10 Starter switch
11 High-current fuse box
12 Main high-current fuse
A : To parking brake warning lamp

B : Terminal B
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C : To brake fluid switch and airmaster
stroke switch
D : To low air pressure switch
E : Terminal E
F : To each unit
L : Terminal L
R : Terminal R
14925
At engine standstill (before starting)

Position of starter switch 10 : ON
• 1→12→11 (FH1)→10→9 (M15)
→2 (R→E)→Ground
→8→2 (L→E)→Ground
• Charge warning lamp Ö 8 lights up.
To improve the low-speed power generation
build-up performance of alternator 2, cur-
rent is fed to terminal R immediately after
the engine is started.
12857
54-1-4
54
After engine start-up
• Alternator 2 starts to generate power.
• The voltage at terminal B of alternator 2
rises higher than the voltage of battery 1.
• As alternator 2 starts to charge battery 1,
units F are supplied with power.
2 (B)→11 (FH6)→12→1→Ground
→11 (FH1)→10→9
(M15)→F
• Since there is no electric potential difference
between the output voltage of terminal L of
alternator 2 and the voltage of battery 1,
charge warning lamp Ö 8 goes off.
12858
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If V-belt snaps while driving
Position of parking brake switch 4 : DRIVE
• Alternator 2 stops generating power and bat-
tery 1 becomes the power source.
9 (M15)→8→2 (L→E)→Ground
→3→4 (DRIVE)
→2 (L→E)→Ground
• Charge warning lamp Ö, brake warning
BRAKE
lamp FLUID and air pressure warning lamp
BRAKE
AIR
light up.
At the same time, warning buzzer 3 sounds.
14926
54-1-5
< Full air brake >
1 Battery
2 Alternator
3 Warning buzzer
4 Parking brake relay
6 Meter cluster
7 Air pressure warning lamp
8 Charge warning lamp
10 Starter switch
A: To parking brake warning lamp

B: Terminal B
C: To low air pressure switch
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E: Terminal E
F: To each unit
L: Terminal L
R: Terminal R
14927
With the exception of the parking brake system, the battery charging circuit for the full air brake is the same as for the air
over hydraulic brake system. Õ P54-1-2
When V-belt snaps while driving

Position of parking brake switch 5 : OFF
• Alternator 2 stops generating power and
battery 1 becomes the power source.
9 (M15)→8→2 (L→E)→Ground
→3→4 (Contact point)→2 (L→E)
→Ground
• Charge warning lamp Ö and air pressure
warning lamp BRAKE AIR
light up.
At the same time, warning buzzer 3 sounds.
14928
54-1-6
TROUBLESHOOTING 54
Symptoms < Air over < Full air
hydraulic
brake >
brake >
Alternator is normal but battery overdischarged

Charge warning lamp Ö does not light when
turning starter switch ON, with engine stopped
Warning buzzer does not stop sounding

Battery electrolyte decreases too early
although parking brake lever is pulled

Battery is normal but overdischarged
although hand control valve is pulled

Remarks
Battery overheating
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Possible causes
Connector connection faulty, harness broken, grounding faulty ● ● ● ●
Fuse blown ● ● ●
V-belts loose ● ● ^ Gr 14
V-belts damaged ● ● ^ Gr 14
Battery faulty ● ●
Stator coil broken ●
Stator coil short-circuited with core ●
Field coil broken ●
Alternator Rectifier faulty ●
Regulator faulty ● ● ●
Wiring faulty ●
Meter cluster faulty ● ● ●
Warning buzzer faulty ● ●
Parking brake switch faulty ● ●
Parking brake relay faulty ●
Hand control valve faulty ● ^ Gr 35B
54-1-7
10 0 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE
Inspection of Alternator
Performance test
V • Connect the meters to the alternator as illustrated.
A : Ammeter (100 amperes class)
A B : Terminal B on alternator
C : Switch
C D D : Terminal
V : Voltmeter
WARNING–
B • Terminal D is always loaded with voltage from the battery.
10808
• You must handle terminal D carefully, it will short-circuit if it
touches any part other than terminal B on the alternator.
• Turn switch C ON to supply battery voltage to terminal B on the

alternator.
• Start the engine.
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• Turn the switches ON of all the lamps on the vehicle immediately.
• Measure the current when the engine speed reaches approximately
2420 rpm.
• The alternator is assumed to be normal if the measured value is
higher than 70% of the specified output.
Specified output of alternator
Alternator model Voltage Output
A4TU0286 12 V 80 A
NOTE
Since the above inspection is only a simplified check, it is neces-
sary to conduct a stringent test bench for an official check.
Õ P54-1-19
54-1-8
54
Inspection of Regulator
Service standards
Location Maintenance item Standard value Limit Remedy
— Adjustment voltage of regulator 14.7±0.3 V — Replace
• Connect the meters to the alternator as illustrated.

V L A : Ammeter (100 amperes class)
B : Terminal B on alternator
B C : Switch
D : Terminal
A L : Terminal L on alternator
C D V : Voltmeter
WARNING–
• Terminal D is always loaded with voltage from the battery.
10809 • You must handle terminal D carefully, it will short-circuit if it
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touches any part other than terminal B on the alternator.
• Turn switch C ON and make sure that voltmeter V indicates 0 volt.

• If the needle of voltmeter V oscillates, something is wrong with the
alternator or the wiring.
• Turn switch C OFF and start the engine.
CAUTION–
Do not start the engine with switch C turned ON because the
starter current will flow into ammeter A and damage it.
• If the charge current is five amperes or less and the engine speed is
approximately 2420 rpm, measure the adjustment voltage.
• If the charge voltage is five amperes or more, do one of the following :
• Run the engine for a while to charge the battery.
• Replace the old battery with a fully-charged one.
• Connect a 1/4 Ω (25 W) resistor in series with the battery to limit the
charge current.
• If the measured value deviates from the standard value, change the
regulators.
54-1-9
101 BATTERY
● Removal sequence
1 1 Battery cover
2 Battery cable ë
3 3 Harness (Main high-current fuse)
4 Starter cable
5 Battery cable ê
5 6 Rubber
4
2 7 Angle frame
8 Set bolt
9 Battery
10 Battery box
● Installation sequence
8 Follow the removal sequence in reverse.
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7
11353
DANGER–
• Since flammable hydrogen gas is generated by battery 9, be sure to obey the following warnings :
• Do not short-circuit the ê and ë terminals on the battery.
• Keep sparks and lit cigarettes away from the battery.
• Do not wear metal objects on your arms and lean over battery 9.
• Because the battery electrolyte is diluted sulfuric acid and is corrosive, when handling battery 9 wear safety
glasses and rubber gloves to protect the eyes and hands.
WARNING–
To prevent a short-circuit be sure that disconnected battery cables 2 and 5 do not accidentally touch the
battery terminals.
CAUTION–
• Make sure that you disconnect battery cable ë 2 first when you disconnect battery cables 2 and 5.
• Make sure that all electrical switches of the vehicle are OFF before connecting battery cables 2 and 5.
• Make sure that you connect battery cable ê 5 before you connect battery cable ë 2.
Service standards
9 Specific gravity of battery electrolyte (20°C {68°F}) 1.280 1.220 Charge or
replace
54-1-10
54
9
◆ Service procedure
Inspection of battery
(1) Visual inspection

• If terminal A is corroded, scrub off the corrosion from it using a wire
A brush.
• If cracks or defects are found on battery 9, replace it since the
cracks or defects can cause liquid spills.
CAUTION–
Make sure you grease the ê side of terminal A because it is easily
corroded.
A
14111
C • If bleed hole C of vent plug B is clogged, clean the hole.
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B
14112
(2) Inspection of fluid level

B
• Make sure that the battery electrolyte level is between UPPER and
LOWER.
• If the level is below LOWER, remove vent plug B and fill the battery
with distilled water or battery replenisher to UPPER.
14113
(3) Measurement of specific gravity

Measure the specific gravity of the battery electrolyte. If the measured
value is lower than the limit, charge the battery.
NOTE
The specific gravity of the battery electrolyte depends on the
liquid temperature. Use the following formula to convert the
actual value to the value were the temperature 20°C {68°F}.
S20 {68} = St + 0.0007 (t–20 {68})

14114
S20 {68} : Specific gravity were the temperature 20°C
{68°F}
St : Specific gravity actually measured with the
temperature at t°C {t°F}
t : Temperature of battery electrolyte
54-1-11
101 BATTERY
(4) Charging
• Although, as a rule, charging of battery 9 should be done
with the battery removed from the vehicle, if you have to
charge the battery while it is on the vehicle, make sure that
you stop the engine and disconnect battery cable ë 2.
• Remove vent plug B before charging the battery.
• For the recommended charge time and current, see the
following table to avoid overcharging.
Upper limit
of fluid
Charge current (A) Charge time (H)
temperature
Specific gravity of battery electrolyte
(°C {°F})
1.280 Value of 5-hour *Amount of
Good
Normal rating capacity discharge (Ah) 45
1.240
charge  ×1.2(to 1.5)
1.220 10 Charge {113}
1.200 current (A)
Charge
1.160 needed Value of 5-hour
Quick
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rating capacity
1.120 charge  0.5 55
1.5 {131}
1.080
0 10 20 30 40 50 60 70 80 90 100 Amount of
discharge (%)
Amount of discharge (%) * Amount of discharge (Ah)=5-hour rating capacity (Ah)× 
100
07789
• Use the graph shown on the left to calculate the amount of
discharge (%).
• Use diluted sulfuric acid, made up of sulfuric acid and
refined or distilled water, as the battery electrolyte.
• The specific gravity of fully-charged battery electrolyte is
1.280 with the temperature at 20°C {68°F}.
DANGER–
• Do not let the battery electrolyte level rise and overflow
while charging the battery.
• Keep naked lights away from the battery while charging
it or it might explode.
• Be careful not to generate sparks while charging the
battery because its dangerous.
• After charging the battery, tighten vent plug B, wash
away sulfuric acid from the battery using water, and dry
the surface.
F Inspection of battery box

• If battery box 10 is corroded, scrub off the corrosion from it using a
wire brush and apply acid resistant coating.
• If battery box 10 is corroded excessively or if it is broken or cracked,
replace it.
54-1-12
54
MEMO
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54-1-13
10 4 FUSE
Installation Position
FH6 FH1
FH2
FH3
FH4
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FH5
2 FH7
M01 to 17 B17 to 25
Spare
3
S01 B07 B01 to 03
A01 to 09
A02 B10 B04 to 06
to 16 12033

CAUTION–
• If a fuse blows, make sure you identify and remedy the cause, then replace the fuse.
• Make sure that you replace the fuse with one having the same rating.
• Make sure that you remove the ë terminal of the battery cable before removing main high-current fuse 1 and
high-current fuses FH1 to 7. Õ 101
54-1-14
54
Main high-current fuse
Fuse Main load Capacity

No.
— High-current fuse box 120 A
High-current fuse box
Fuse Main load Capacity

No.
FH1 Starter switch (Terminal M) 50 A
FH2 Fuse box (B07 to 16) 40 A
FH5 Glow relay (Terminal B) 50 A
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FH6 Alternator (Terminal B) 120 A
FH7 Fuse box (B6) 40 A
FH8 — —
Fuse box
Fuse Main load Capacity Fuse Main load Capacity

No. No.
A01 Audio 10 A B22 Cab lamp 10 A
A02 Cigarette lighter 15 A B23 Fuel-cut motor 10 A
B01 Reserve power (DC) 10 A B24 Horn 15 A
B02 — — B25 — —
B03 Van body dome light relay 15 A M01 — —
B04 Socket connector 20 A M02 Transmission power take-off
B05 — — M03 — —
B06 — — M04 — —
B07 Stop lamp 10 A M05 — —
B08 Turn/hazard 15 A M06 Automatic transmission 10 A
B09 Tail lamp 15 A M07 — —
B10 Headlamp relay 5A M08 Pre-stroke cut relay 20 A
B11 — — M09 Heater 20 A
B12 Headlamp main LH 10 A M10 — —
B13 Headlamp main RH 10 A M11 Pre-stroke control unit 10 A
B14 — — M12 — —
B15 Headlamp dimmer LH 10 A M13 Turn/hazard 10 A
B16 Headlamp dimmer RH 10 A M14 Air dryer 15 A
B17 — — M15 Warning buzzer 10 A
B18 * Air-conditioner 20 A M16 Backup lamp 10 A
B19 — — M17 Wiper 15 A
B20 — — S01 Safety relay 10 A
B21 — — * Fuses are provided for these pieces of equipment only where they
are installed.
54-1-15
10 6 ALTERNATOR
2
1 Ground cable
2 Chassis harness
6 3 Adjusting bolt
E
4 V-belts
5 Alternator Õ P54-1-18
3
6 Adjusting plate
7 Alternator bracket
B
C
A: To terminals L and R
A B: To terminal B
C: Connected to crankcase
4
E: To terminal E
E
1 7 WARNING–
• Terminal B is always loaded with voltage
09500 from the battery, supplied via chassis
harness 2. Therefore when you remove
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the harness from terminal B, make sure
that tools do not touch any adjacent parts
because this would cause a short-circuit.
• Make sure that you disconnect terminal
ë of the battery before removing the har-
ness and insulate the terminal with tape.
Follow the removal sequence in reverse.
● Adjustment after installation
Adjustment of V-belt 4 tension ^ Gr 14
Service standards
5 Output current (* When engine is hot At 1500 rpm 38 A or more — Inspect
and 13.5 V is loaded ) At 2500 rpm 65 A or more —
At 5000 rpm 76 A or more —
Adjustment voltage of regulator (At 5000 rpm, 14.7±0.3 V — Replace
5 A is loaded)
* The value of the ambient temperature is measured after running the engine at maximum power (5000 rpm) for 30
minutes.
54-1-16
54
A V 12 volts DC
5 Inspection of alternator
(1) Inspection of alternator performance (bench test)

• Connect each unit to the alternators as illustrated.
A : Ammeter
C : Switch
C D : Switch
E : Terminal E on alternator
F : Load resistance (variable resistance)
D
G : Alternator drive motor
5
E L : Terminal L on alternator
R : Terminal R on alternator
V : Voltmeter
F
G • Turn switches C, D OFF.
• Run alternator 5 at 5000 rpm.
B
• Adjust load resistance F to maintain the specified cur-
rent.
L
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Specified output of the alternator : 12 V-80 A
• After adjustment, run alternator 5 for 30 minutes.

R • Maximize load resistance F (current hardly flows).
09502 • Turn switches C, D ON.
• Increase the rotation of alternator 5 gradually and meas-
ure current at specified rpm.
• If the measured value deviates from the standard value,
disassemble and inspect alternator 5. Õ P54-1-20
(2) Inspection of regulator (bench test)

A V 12 volts DC • Connect each unit to the alternators as illustrated.
A : Ammeter
C : Switch
E : Terminal E on alternator
C G : Alternator drive motor
L : Terminal L on alternator
R : Terminal R on alternator
V : Voltmeter
E 5 • Turn switch C ON.
• Run alternator 5.
• Make sure that the value of the current at 5000 rpm is five
G amperes or less.
• Measure voltage (adjustment voltage).
B • If the measured value deviates from the standard value,
L replace the regulator (in alternator 5).
R
09503
54-1-17
10 6 ALTERNATOR
Alternator
- -
7 6
- 8
Ù 9
10
11
5
Ê 3 4
2
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12
17
15
07043
● Disassembly sequence
1 Rotor and front bracket assembly 11 Front bracket
2 Nut 12 Stator and rear bracket assembly
3 Pulley 13 Stator assembly
4 Fan 14 Field coil
5 Spacer 15 Regulator
6 Rear bearing 16 Rectifier
7 Rotor assembly 17 Rear bracket
8 Cover
9 Front bearing Ù : Non-reusable parts
10 Oil seal
NOTE
Do not remove parts 6, 9, 13 unless they are faulty.
● Assembly sequence
17 → 16 11 → 10 → 9 → 8
12 → 1 12 : → 14 → 13 1: →5→4→3→2
15 7→6
54-1-18
54
Service standards
14 Field coil resistance (20°C {68°F}) 2.6 to 3.4 Ω — Replace
Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
2 Nut (Pulley mounting) 132 to 162 {98 to 120, 13.5 to 16.5} —
- Lubricant
Location Points of application Kinds Quantity
6 Rear bearing inner periphery Engine oil As required
7 Front bearing installation part of rotor assembly Engine oil As required
9 Front bearing outer periphery Engine oil As required
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13
A
11
1
Rotor and front bracket assembly
[Removal]
• Insert screwdriver A between front bracket 11 and stator assembly 13.
• Use screwdriver A to pry rotor and front bracket assembly 1 away
from stator and rear bracket assembly 12.
CAUTION–
Be careful not to insert the screwdriver too deep or it will damage
coil B of stator assembly 13 and might cause a short-circuit.
12 1
09525
[Disassembly]
D
CAUTION–
Make sure, when you hold rotor assembly 7 in a vise, to grip root
C of the core claws. Gripping claws D can damage them.
7
C 02319
54-1-19
10 6 ALTERNATOR
I Stator assembly
[Removal and installation]
• Disconnect lead A of stator assembly 13 from rectifier 16. The lead is
soldered to diode B of rectifier 16 at three points.
A CAUTION–
Make sure that you desolder within five seconds because the
B diode is heat sensitive.
16
13 02335
• To install, follow the removal sequence in reverse.
[Inspection]
(1) Continuity of each lead wire
• Make sure that each lead wire has continuity.
• If there is no continuity, the lead wire is broken. Replace stator
assembly 13.
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02336
(2) Continuity between lead wires and the core

• Make sure that there is no continuity between lead wires and the core.
• If there is continuity, replace stator assembly 13, since it might be
short-circuited.
J
02337
Inspection of field coil

14
• Measure the resistance between the terminals of field coil 14.
• If the measured value deviates from the standard value, replace field
coil 14.
02325
54-1-20
54
D L Inspection of rectifier
• Inspect whether the diode inside rectifier 16 functions properly, and if
A any fault is found, replace the rectifier.
B E A, B, C : Lead connecting area of stator coil
D, E : Heat sink area
C
F : Regulator connecting area
• Inspect the rectifier twice, before and after the ê side and ë side of
F
the tester have been changed over.
13084
D
CAUTION–
E When inspecting using a tester, the current becomes weaker
than the usual current flowing through rectifier 16. Therefore, an
incomplete resistance value might be indicated.
Also, this tendency increases as the range of the tester gets
smaller. Therefore, use as big a range as possible.
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A B F C
13083
54-1-21
110 POWER CIRCUIT
Power Supply (Battery to High-current Fuse Box to Relay and Fuse Box)
Battery
To alternator
(Terminal B)
Main
high-current
fuse
High-current fuse box
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To starter
(Terminal B)
To glow relay
Chassis
Cab
To each unit
Starter switch Relay and fuse box
10463
54-1-22
54
Fuses A01, A02, S01
Relay and fuse box
To starter switch
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To radio
To cigarette lighter
To transmission
neutral switch
< Manual
transmission >
To sub-starter switch
Gr 13
To safety relay To pre-stroke
control unit
To multipurpose
timing control unit
1 : Manual transmission
2 : Automatic transmission
10459
54-1-23
110 POWER CIRCUIT
Fuses B01 to B08
To high-current
fuse box
Relay and fuse box
To spare DC
outlet
To van body
dome light relay
Socket connector
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To high-current
fuse box
Stop lamp relay To stop lamp

switch
Cab Chassis
Rear chassis
To flasher unit
To rear
combination
lamp (Stop)
10460
54-1-24
54
Fuse B09
To high-current fuse box

Relay and fuse box
To rheostat
switch
Combination
switch
connector
Tail lamp relay To meter cluster
To speedometer
Cab lamp Cab To automatic transmission

range selector
< Automatic transmission >
cardiagn.com
To side marker To radio
lamp, RH
To identification
lamp, RH
To heater control
To identification assembly
lamp, Center To clearance
lamp, LH
To identification
lamp, LH
To side marker
lamp, LH Cab
Chassis
To clearance
lamp, RH
To additional
plug connector
for tail lamp
Chassis
Rear chassis
To rear combination
lamp, RH (Tail lamp)
To license plate
lamp
To rear combination
lamp, LH (Tail lamp)
: Automatic transmission
10461
54-1-25
110 POWER CIRCUIT
Fuses B10 to B24
To high-current
fuse box
Relay and fuse box
Headlamp relay,
LOW
To combination switch
(Dimmer switch)
To headlamp
Headlamp relay,
HIGH
To meter cluster
(Beam)
cardiagn.com
(Dimmer switch)
To headlamp
Cab Headlamp
To high-current To headlamp
fuse box
Cab Chassis
To air-conditioner relay
connector
To condenser fan relay
connector
To radio connector
To rheostat switch
To cab and spot lamp
To fuel-cut motor
To air horn
10462
54-1-26
54
Fuses M02 to M14
To starter switch
(Terminal M) Relay and fuse box
To transmission power take-

off control switch connector
< Manual transmission >
To automatic transmission
fluid cooler fan motor relay
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Gr 13
To memory clear switch
Gr 13
To pre-stroke cut relay
Gr 13
To pre-stroke cut relay
To blower motor
To fin thermostat plug

connector
Gr 13
To pre-stroke control unit
To air dryer
Turn signal
lamp relay
(Turn signal lamp switch)
Cab ground
10458
54-1-27
110 POWER CIRCUIT
Fuse M15
To starter switch
(Terminal M)
Relay and fuse box
To warning
buzzer
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To meter
cluster
Chassis Cab
To alternator To
speedometer
To van body
dome light
To vehicle switch
speed sensor
To parking
brake
To parking brake switch

< Full air brake >
To safety relay
To
multipurpose
timing control
unit
: Wheel parking brake < Full air brake >
13104
54-1-28
54
Fuse M16
To starter switch
(Terminal M)
Relay and fuse box
To backup lamp switch
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To cold start switch
To clutch switch
To transmission power
take-off relay connector
To transmission power
take-off relay connector
: Manual transmission
13105
54-1-29
110 POWER CIRCUIT
Fuse M17
To starter switch
(Terminal M)
Relay and fuse box
To washer motor
Wiper relay, LOW

To diode unit
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Wiper relay, HIGH
To wiper motor To combination switch To multipurpose

(Washer switch) timing control unit
13106
54-1-30
54
MEMO
cardiagn.com
54-1-31
115 RESERVE POWER CIRCUIT
1
Relay and fuse box
Combination switch
connector
2
Tail lamp relay
To lighting switch
a
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b To clearance
lamp, LH
To spare
DC outlet
connector
e c
Cab ground
Roof Cab
d
Chassis
f
Additional plug Rear combination To clearance lamp, RH
connector for lamp, LH
tail lamp
10477
54-1-32
54
a 2 b
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e
c
d
12859
1 Relay and fuse box Õ 104

2 Tail lamp relay Õ 604
54-1-33
125 BATTERY CHARGING CIRCUIT
10 11
Battery
Parking brake 1: Center parking brake < Air over hydraulic brake >
switch 2: Wheel parking brake < Full air brake >
8 < Full air brake >
Alternator
9
Main high-current
fuse
f Rear chassis
Engine
ground Parking brake
switch 7
< Air over
1 Warning buzzer
Chassis hydraulic brake >
High-current ground
12 fuse box
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Chassis Floor Headlamp
a d e
Cab Cab
Cab
To multipurpose
timing control unit
To meter
Gr 13 cluster
To pre-stroke
control unit 5
To diode unit
Parking brake relay
< Full air brake >
To diode unit
b c
Condenser
4
Cab ground
Starter switch Relay and fuse box Meter cluster
6 3 2
14924
54-1-34
54
2
3
4
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d
c b
6 e
7
9 10
8
12 f 11
12860
1 Parking brake switch 7 Warning buzzer

< Air over hydraulic brake > 8 Alternator Õ 106
2 Meter cluster Õ 401 9 Main high-current fuse Õ 104
3 Relay and fuse box Õ 104 10 Battery Õ 101
4 Condenser 11 Parking brake switch < Full air brake >
5 Parking brake relay < Full air brake > 12 High-current fuse box Õ 104
6 Starter switch Õ 210
54-1-35
130 GROUND
Ground Point
3
5
*
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1 2
6
8
7
12
13
11
10 9
12861
54-1-36
54
Location Name Circuit No. Wire diameter-wire color Remarks
1 Cab ground 20 1.25–B
185 3–B
133 1.25–B
160 1.25–B
5 Cab ground 210 8–B
6 Rear chassis ground 38 0.85–B
39 0.85–B
7 Chassis ground 74 B
8 Chassis ground 19 2–B
210 8–B
9 Chassis ground 14 5–B
10 Alternator ground — 20–B
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11 Chassis ground 6 1.25–YL
1575 0.85–B
12 Battery ground — 60–B
13 Chassis ground 1704 0.85–BR
1705 B
9560 0.85–B
9561 0.85–B
* : Box under bed (Behind driver’s seat)
54-1-37
130 GROUND
Entire Ground
• This diagram indicates grounding points.
• See the following pages for branching of grounding (wiring for ✩). (In circuit No. order)
✩ ✩
To headlamp, LH Chassis ground
✩ Tightened together
Socket connector ✩ ✩ Cab
Gr 13
Chassis
Gr 13
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Chassis ground
Engine
Battery Alternator ground Tightened
Tightened together
Cab ground
together To cab and
spot lamp
✩
To headlamp, RH
To fuel gauge unit

To cigarette
lighter
To cold start 3-way magnetic
valve ✩ Gr 13 To front turn
signal lamp,
RH
< Manual
transmission > To diagnosis
To exhaust brake 3- switch
way magnetic
✩
valve
relay Chassis Chassis ChassisChassis Pre-stroke Rear chassis

To ground ground Cab
starter ground ground Cab control unit
ground ground
Tightened
together
To boost air temperature sensor

13414
54-1-38
54
Circuit 19 Chassis Ground
To headlamp, RH
To clearance lamp, RH
To water level sensor
To condenser fan motor connector
To cab tilt switch
Transmission power take-off 3-way

magnetic valve connector
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To side turn signal lamp, RH
: Manual transmission
13421
Circuit 20 Cab Ground
To side turn signal lamp, LH
To headlamp, LH
To clearance lamp, LH
Headlamp
Cab
(Lighting, dimmer switch)
(Hazard switch)
To rheostat switch
13415
54-1-39
130 GROUND
Circuit 38 Rear Chassis Ground
To rear combination lamp, LH
To license plate lamp
To stop lamp switch

< Full air brake >
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: Full air brake
13548
To front turn signal lamp
To wiper motor
Front panel
Cab
To turn signal lamp relay
13422
54-1-40
54
To cab and spot lamp
To spare DC outlet
To side marker lamp
To identification lamp
Roof
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Cab
13416
To cigarette lighter
To air-conditioner
switch connector
To engine stop relay
13417
54-1-41
130 GROUND
To range selector
Floor
Cab
Socket connector
To combination switch To cold start switch

(Wiper and washer switch)
To transmission power take-off
To meter cluster switch connector
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To automatic transmission To vehicle speed sensor
range selector
To fuel-cut motor To condenser
To heater control assembly

To speedometer
To parking brake relay To van body dome light relay

< Full air brake >
To van body dome light switch
To condenser fan relay connector
To multipurpose timing control unit
To clutch switch To exhaust brake cut relay

< Manual transmission > < Manual transmission >
To transmission neutral relay

To diode unit
(Exhaust brake)
To diode unit
(Transmission power take-off)
3 : Wheel parking brake
13418
54-1-42
54
Circuit 1575 Chassis Ground
To exhaust brake 3-way magnetic valve

To cold start 3-way magnetic value
To stop lamp switch
To stop lamp switch

To airmaster stroke check switch

To brake fluid level switch

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To automatic transmission fluid thermostat switch
1 : Air over hydraulic brake

13547
54-1-43
54
2 STARTING, PREHEATING AND

STOPPING ENGINE
SPECIFICATIONS .......................................................................... 54-2-2
TROUBLESHOOTING .................................................................. 54-2-16
200 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE

Inspection of Engine Preheating System ....................................... 54-2-18
cardiagn.com
201 STARTER .......................................................................... 54-2-19
210 ENGINE STARTING CIRCUIT ........................................... 54-2-30
212 SUB-STARTER CIRCUIT .................................................. 54-2-34
215 ENGINE STOPPING CIRCUIT........................................... 54-2-38
220 ENGINE PREHEATING AND COLD START CIRCUIT

< Manual Transmission > ................................................................. 54-2-42
< Automatic Transmission > ............................................................ 54-2-46
54-2-1
SPECIFICATIONS
Item Specifications
Starter Manufacturer MITSUBISHI ELECTRIC
Reduction gear system One-step inner contact spur gear
Model M5T65071 M5T65073
Power V–kW 12–5.5
Magnetic switch operating 8 or less
voltage V
Starter relay Model U1T06280 U1T06284
Voltage rating V–A 12–4
Magnet closing voltage V 8 or less
Magnet opening voltage V 3.5 or less
Allowable cutoff current A 200
Glow plug Model Sheathed type
Voltage–amperage V–A 11–5.3
Glow relay Model U1T06292
Voltage–amperage V–A 12–4
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Magnet closing voltage V 8 or less
Magnet opening voltage V 3.5 or less
Allowable cutoff current A 200
Fuel-cut motor Minimum operating 10 or less
voltage V
Operating amperage A 10 or less
54-2-2
54
MEMO
cardiagn.com
54-2-3
Starter
B S M 6
1 2 3 4
8
9
10
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12 11
21 17 20 19 18 17 16 15 14 13
10847
1 Rear bracket 10 Sleeve bearing 19 Armature

2 Brush 11 Stopper ring 20 Yoke assembly
3 Brush spring 12 Overrunning clutch 21 Rear bearing
4 Brush holder assembly 13 Plate
5 Magnetic switch 14 Gear shaft B : Terminal B
6 Lever 15 Gear shaft bearing M : Terminal M
7 Rubber packing 16 Internal gear S : Terminal S
8 Center bracket 17 Rubber packing
9 Front bracket 18 Front bearing
54-2-4
54
Engine Starting Circuit < Manual Transmission >
1 Battery
2 Starter
3 Starter relay
4 Transmission neutral relay
5 Safety relay
6 Multipurpose timing control unit
Õ P54-9-2
7 Starter switch
11 Transmission neutral switch
A: Alternator L signal
B: Starter switch S signal
C: Safety relay operating signal
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D: To alternator L terminal
H: Holding coil
P: Pull-in coil
11078
• The engine starting circuit lets starter 2 rotate only when the transmission is in neutral.
• When current flows from starter switch 7 terminal S to starter relay 3 for longer than the specified period when starter 2
is rotating, multipurpose timing control unit 6 cuts off the current, preventing the starter from seizing up.
When starter operation is normal

Position of starter switch 7 : S
• 1→9→8→7→10 (S01)→5 (contact point)
→4 (contact point)→3 (coil)→Ground
Starter relay 3 is activated.
• 1→2 (contact point)→3 (contact point)
→2 (P)→2 ( M )
→
→2 (F)→Ground
Current that has flowed through pull-in coil P
rotates starter 2 at low revolution. When the
contact point of the starter closes, the cur-
rent at the pull-in coil cuts off and holding
coil H holds the contact point.
• 1→2 (contact point)→2 ( M )→Ground
Starter rotates at high revolution.
11119
54-2-5
When starter rotates for a long period
• Starter rotates at high revolution. (See previous sec-
tion.)
• 1→9→8→7→10 (S01)È→6
Starter switch S signal È is transmitted to multipur-
pose timing control unit 6.
• DÂ→6
Alternator L signal Â is transmitted to multipurpose
timing control unit 6 through alternator L terminal D
by the revolution of the engine.
• When signals Â and È are continuously transmit-
ted to multipurpose timing control unit 6 for the speci-
fied period, the multipurpose timing control unit
activates safety relay 5 by transmitting safety relay
activation signal Ê.
1→9→8→7→10 (M15)→5 (coil)Ê→6
• Activation of safety relay 5 cuts off the flow of current
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to starter relay 3, stopping starter 2.
11120
When the starter is activated when the

transmission is in a position other than in neutral
Position of transmission neutral switch 11 : OFF
The flow of the current from terminal S of starter switch
7 is cut off and starter relay 3 is not activated.
11121
54-2-6
54
Engine Starting Circuit < Automatic Transmission >
1 Battery
2 Starter
3 Starter relay
5 Safety relay
7 Starter switch
10 Main high-current fuse box
A: Alternator L signal
B: Starter switch S signal
C: Safety relay operating signal
D: To alternator L terminal
H: Holding coil
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P: Pull-in coil
12591
• The engine starting circuit lets starter 2 rotate only when the transmission is in neutral.
• When current flows from starter switch 7 terminal S to starter relay 3 for longer than the specified period when starter 2
is rotating, multipurpose timing control unit 6 cuts off the current, preventing the starter from seizing up.
When starter operation is normal

• 1→10→8→7→9 (S01)→5 (contact point)→4
→3 (coil)→Ground
Starter relay 3 is activated.
• 1→2 (contact point)→3 (contact pint)→2 (P)→2 ( M )
→
→2 (F)→Ground
Current that has flowed through pull-in coil P rotates starter
2 at low revolution. When the contact point of the starter
closes, the current at the pull-in coil cuts off and holding coil
H holds the contact point.
• 1→2 (contact point)→2 ( M )→Ground
Starter rotates at high revolution.
12592
54-2-7
When starter rotates for a long period
• Starter rotates at high revolution. (See previous sec-
tion.)
• 1→10→8→7→9 (S01)È→6
Starter switch S signal È is transmitted to multipur-
pose timing control unit 6.
• DÂ→6
Alternator L signal Â is transmitted to multipurpose
timing control unit 6 through alternator L terminal D
by the revolution of the engine.
• When signals Â and È are continuously transmit-
ted to multipurpose timing control unit 6 for the speci-
fied period, the multipurpose timing control unit
activates safety relay 5 by transmitting safety relay
activation signal Ê.
1→10→8→7→9 (M15)→5 (coil)Ê→6
• Activation of safety relay 5 cuts off the flow of current
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to starter relay 3, stopping starter 2.
12593
When the starter is activated when the

transmission is in a position other than in neutral
Position of transmission neutral switch 4 : OFF
The flow of current from terminal S of starter switch 7 is
cut off and starter relay 3 is not activated.
12594
54-2-8
54
Sub-starter Circuit < Manual Transmission >
1 Battery
2 Starter
3 Starter relay
4 Transmission neutral relay
5 Safety relay
6 Starter switch
10 Sub-starter switch
Position of starter switch 6 : ACC

Position of sub-starter switch 10 : ON
1→11→7→6→8 (A02)→9→10→5 (contact point)
→4 (contact point)→3 (coil)→Ground
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Starter relay 3 is activated to rotate starter. Õ P54-2-5
12646
Sub-starter Circuit < Automatic Transmission >

1 Battery
2 Starter
3 Starter relay
5 Sub-starter switch
7 Starter switch
Position of starter switch 7 : ACC

Position of sub-starter switch 5 : ON
1→9→8→7→6 (A02)→5→4→3 (coil)→Ground
Starter relay 3 is activated to rotate starter. Õ P54-2-7
12647
54-2-9
Engine Preheating and Cold Start Circuit
< Manual Transmission >

1 Starter switch
2 Fuse box
3 Alternator
Õ P54-9-2
12 5 Cold start switch
12 volts DC volts 6 Meter cluster
DC
7 Cold start indicator lamp
8 Exhaust brake indicator lamp
9 Engine preheating indicator lamp
10 Battery
13 Glow relay
14 Glow plug
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15 Water temperature sensor
16 Exhaust brake 3-way magnetic valve
Â Engine start signal

È Alternator charge signal
Ê Glow relay activation signal
Ë _ lighting-up signal
Ì Engine coolant temperature signal
13481
54-2-10
54
● Engine preheating circuit
This circuit improves the engine starting performance
when the engine coolant temperature is low. The
preheating system is controlled by multipurpose timing
control unit 4. Õ P54-9-2
Basic preheating operation

Operation mode Õ P54-2-10
When engine coolant temperature is low
(Approximately 60°C {140°F} or less)
• Position of starter switch 1 : ON
1→2 (M15)→4→Ground
Ì→5→15→Ground
12 Multipurpose timing control unit 4 detects the engine

12 volts DC volts
DC coolant temperature.
• When the engine coolant temperature is low, multi-
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purpose timing control unit 4 outputs glow relay acti-
vation signal Ê.
4 Ê→13→Ground
• Glow relay 13 operates to feed power to glow plug

14 and lights up engine preheating indicator
lamp _ 9.
10→11→12→13 (contact point)→14→Ground
→9Ë→4→Ground
When engine coolant temperature is high
(Approximately 60°C {140°F} or more)
1→2 (M15)→4→Ground
Ì→5→15→Ground
Multipurpose timing control unit 4 detects the engine

13482
coolant temperature.
• When the engine coolant temperature is high, multi-
purpose timing control unit 4 does not output glow
relay activation signal Ê, so no preheating is per-
formed.
Pre-glow and after-glow

START
Starter switch 1 ON
There are two types of preheating: one is pre-glow,
performed before starting the engine; the other is after-
OFF
glow, performed after starting the engine. They are
ON both controlled by start signal Â and alternator charge
Alternator charge
signal È OFF signal È.
ON
Glow relay 13 OFF
13229
54-2-11
Fail-safe
START Â • If the contacts of the glow relay driving relay in
multipurpose timing control unit 4 are welded, en-
Starter switch 1 ON
OFF gine preheating indicator lamp _ 9 blinks to alert
the driver of the fault.
Alternator ON
charge signal È OFF • When all of the following conditions are satisfied, the
fail-safe function turns off glow relay 13.
ON
Glow relay 13
OFF • Coolant temperature is 60°C {140°F} or less.
15 seconds • Engine start signal Â is ON.
• Alternator charge signal È is ON for 15 seconds.
11276
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Cold start circuit
12 volts DC This circuit helps the engine preheating performance when the
ambient temperature is low.
• Position of cold start switch 5 : ON
2→5→7
→
→8→Ground
→
→16→Ground
This circuit forces exhaust brake 3-way magnetic valve 16

to operate, closing exhaust brake butterfly valve F.
This decreases incoming cool air H from the engine exhaust
system and reduces preheating time.
F: Exhaust brake butterfly valve

G: Exhaust brake unit
H: Cool air from engine exhaust system
13483
54-2-12
54
Operation mode
START • Where the engine coolant temperature is
ON
Starter switch 1 60°C {140°F} or more.
OFF
ON
_ 9 OFF
Alternator ON
charge signal È
OFF
ON
Glow relay 13
OFF
08656
• Where the engine coolant temperature is 0

START to 60°C {32 to 140°F}.
Starter switch 1 ON
OFF
ON
_ 9 OFF
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Alternator ON
charge signal È OFF
ON
Glow relay 13
OFF
Approximately
12 seconds
Pre-glow
08657
• Where the engine coolant temperature is

START 0°C {32°F} or less.
Starter switch 1
ON
OFF
ON Approxi-
_ 9
OFF mately 8
Alternator ON seconds
Glow relay 13
ON Approximately
OFF Approximately 20 seconds
12 seconds After-glow
Pre-glow
08658
54-2-13
Operation mode when cold start switch is
Cold start ON
used
switch 5 OFF
• When starter switch 1 is turned ON after
START cold start switch 5 is turned ON.
Starter switch 1 ON
OFF
ON Approxi-
_ 9 OFF mately 8
seconds
Alternator ON
ON
Glow relay 13
OFF Approximately Approximately
12 seconds 20 seconds
After-glow 13230
Pre-glow
• When cold start switch 5 is turned ON after

Cold start ON starter switch 1 is turned ON.
switch 5 OFF (Where the engine coolant temperature is
cardiagn.com
0°C {32°F} or more.)
START
Starter switch 1 ON
OFF
ON Approxi-
_ 9 OFF mately 8
seconds
Alternator ON
ON
Glow relay 13
OFF Approximately Approximately
12 seconds 20 seconds
Pre-glow After-glow
13231
54-2-14
54
< Automatic Transmission >
1 Starter switch
2 Fuse box
3 Alternator
Õ 54-9-2
12 5 Cold start switch
12 volts DC volts 6 Meter cluster
DC
7 Cold start indicator lamp
8 Exhaust brake indicator lamp
9 Engine preheating indicator lamp
10 Battery
13 Glow relay
14 Glow plug
15 Water temperature sensor
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16 Exhaust brake 3-way magnetic valve
Â Engine start signal

È Alternator charge signal
Ê Glow relay activation signal
Ë _ lamp lighting-up signal
Ì Engine coolant temperature signal
13484
The engine preheating and cold start circuits of automatic transmission vehicles are the same as for manual transmission
vehicles, except that parking brake switch 17 is installed in the cold start circuit part in automatic transmission vehicles.
Õ 54-2-10
● Cold start circuit

12 volts DC
This circuit is formed only when the parking brake is
working. The current flow is as follows.
The operating mode is the same as in manual trans-
mission vehicles. Õ P54-2-11

2 (M15)→17 (park)→5→7
→
→8→Ground
→
→16→Ground
F: Exhaust brake butterfly valve

G: Exhaust brake unit
H: Cold air from engine exhaust system
13485
54-2-15
TROUBLESHOOTING
Symptoms Starter works,

but engine does
not start
Pinion engages with ring gear, but does

Pinion does not engage with ring gear
Flywheel rotates, but engine does
Engine cannot be preheated

Remarks
Starter does not work
Engine does not stop
Engine hard to start

not rotate
not start
Possible causes
Connector connection faulty, harness broken, grounding faulty ● ● ● ● ●
cardiagn.com
Fuse blown ●
Battery charge insufficient ● ●
Magnetic switch contact point stuck or melted ●
Magnetic switch coil broken ●
Starter
Overrunning clutch malfunctioned ●
Pinion worn or damaged ●
Starter relay faulty ●
Starter switch faulty ● ●
Flywheel ring gear worn or damaged ● ^ Gr 11
Fuel-cut relay faulty ● ●
Fuel-cut motor faulty ● ●
Engine stop cable broken or damaged ● ● ^ Gr 13
Engine stop cable adjusted incorrectly ● ^ Gr 13
Glow plug faulty ● ●
Glow relay faulty ● ●
Water temperature sensor faulty ● ●
Multipurpose timing control unit faulty ● ●
Connecting plate connection faulty ● ● ^ Gr 11
Transmission neutral switch faulty < Manual transmission > ●
Transmission neutral relay faulty < Manual transmission > ●
Sub-starter switch faulty
Cold start switch faulty
Exhaust brake 3-way magnetic valve faulty
Safety relay faulty ●
54-2-16
54
Engine does not start although sub-starter switch is turned ON

Symptoms
Cold start function does not work

Remarks
Possible causes
Connector connection faulty, harness broken, grounding faulty ● ●
cardiagn.com
Fuse blown ● ●
Battery charge insufficient ● ●
Magnetic switch contact point stuck or melted ●
Magnetic switch coil broken ●
Starter
Overrunning clutch malfunctioned
Pinion worn or damaged
Starter relay faulty ●
Starter switch faulty ●
Flywheel ring gear worn or damaged ^ Gr 11
Fuel-cut relay faulty
Fuel-cut motor faulty
Engine stop cable broken or damaged ^ Gr 13
Engine stop cable adjusted incorrectly ^ Gr 13
Glow plug faulty
Glow relay faulty
Water temperature sensor faulty ●
Multipurpose timing control unit faulty ●
Connecting plate connection faulty ^ Gr 11
Transmission neutral switch faulty ●
Transmission neutral relay faulty < Manual transmission > ●
Sub-starter switch faulty ●
Cold start switch faulty ●
Exhaust brake 3-way magnetic valve faulty ●
Safety relay faulty ● ●
54-2-17
Inspection of Engine Preheating System
Service standards
— Pre-glow time Water 60°C {140°F} or more Does not pre-glow — Inspect
temper- 0 to 60°C {32 to 140°F} Approximately 12 seconds —
ature
0°C {32°F} or less Approximately 12 seconds —
After-glow time Water 60°C {140°F} or more Does not after-glow —
temper- 0 to 60°C {32 to 140°F} Does not after-glow —
ature
Indicator lamp Water 60°C {140°F} or more Does not light —
lighting time temper- 0 to 60°C {32 to 140°F} Does not light —
ature
• Turn the starter switch OFF.

2
• Turn the cold start switch OFF.
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• Connect inspection lamp 2 to glow plug 1.
08718
• Remove water temperature sensor 3 from the engine and plug sensor
mounting part A with plug B (M16×1.5 mm).
Removal and installation of water temperature sensor 3 ^ Gr 14
• Connect extension harness 5 between water temperature sensor 3
and connector 4.
NOTE
A
Connect extension harness 5 to terminal C of the multipurpose
timing control unit.
3
• Put water temperature sensor 3 into a container filled with water.
B • Carry out the following inspection while changing the water tempera-
14362
C ture in the container. If any fault is found, inspect each unit.
5 (1) Inspection of pre-glow time and indicator lamp lighting time

Turn the starter switch ON but do not start the engine. Make sure that
3
the pre-glow time and the indicator lamp lightning time at each water
4 temperature conform to the standard value.
• For pre-glow time inspection, measure the lighting time of inspec-
tion lamp 2.
• For indicator lamp lightning time inspection, measure the lighting
C time of _ lamp within the meter cluster directly.
08719
(2) Inspection of after-glow time
Start the engine and measure the lighting time of inspection lamp 2
from the point _ lamp within the meter cluster goes off, and make
sure that the after-glow time conforms to the standard value.
54-2-18
201 STARTER 54
S
1 Starter cable (to battery connection)
B 2 Starter relay
3 Starter Õ 54-2-20
B : Terminal B
S : Terminal S
B
WARNING–
Never touch the starter with tools when you re-
B 1
S move the harness from terminal B. This is be-
cause voltage is always supplied to it from starter
cable 1, and you will short-circuit the starter.
Before removing the harness from terminal B,
remove the ë battery terminal and tape it up to
3 2 insulate it.
11201
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Follow the removal sequence in reverse.
54-2-19
201 STARTER
Starter
-
5
6
10 - 7
12 16
15
- 14
8 9
19
17 18
1
-
3
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25
24
4
27
28 26
33
22
23
21
11202
● Inspection before disassembly

Õ P54-2-22
1 Connector 13 Overrunning clutch 24 Packing
2 Magnetic switch 14 Plate 25 Yoke and rear bracket assembly
3 Cover 15 Gear shaft bearing 26 Rear bracket
4 Front bracket assembly 16 Gear shaft 27 Brush holder insulator
5 Center bracket 17 Cover 28 Brush holder plate
6 Packing 18 Sleeve bearing 29 Brush spring
7 Adjusting washer 19 Front bracket 30 Brush ë
8 Stopper ring 20 Armature assembly 31 Brush ê
9 Pinion stopper 21 Front bearing 32 Brush holder assembly
10 Stopper 22 Rear bearing 33 Packing
11 Lever 23 Armature 34 Yoke assembly
12 Collar
54-2-20
54
CAUTION–
• Do not remove bearings 15, 21, 22 unless they are faulty.
• Make sure you do not drop armature assembly 20 when you remove yoke and rear bracket assembly 25 from
front bracket assembly 4.
Follow the disassembly sequence in reverse.
NOTE
After replacing magnetic switch 2 adjust the gap of the pinion
● Inspection after assembly

Õ P54-2-22
Service standards Unit : mm {in.}
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— Thrust gap of gear shaft assembly 0.1 to 0.5 {0.0039 to 0.02} — Adjust
— Pinion gap 0.5 to 2.0 {0.02 to 0.079} — Adjust
— No-load characteristic Current 220 A or less — Inspect
(11 V when current flowing) Number of 3200 rpm or more —
revolutions
2 Magnetic switch operating voltage 16 V or less — Replace
20 Armature Outer diameter of commutator 43.2 {1.7} 42.2 {1.66} Replace
assembly
Deflection of commutator periphery 0 to 0.03 {0 to 0.0012} 0.1 {0.0039} Replace
Mica depth between segments 0.4 to 0.6 {0.016 to 0.024} 0.3 {0.012} Replace
or less
29 Pressure of brush spring 25 to 34 N 18 N Replace
{5.6 to 7.6 lbf, 2.55 to 3.45 kgf} {4 lbf, 1.8 kgf}
30, 31 Length of brush 23 {0.91} 14 {0.55} Replace
- Lubricant
Location Points of application Kinds Quantity
2 Contact surface between lever and magnetic switch Multipurpose grease [NLGI No.2 (Ca soap)] As required
5 Gear shaft mounting surface of center bracket Grease for heavy load at low temperature As required
[NLGI No.2 (Li soap)]
13 Friction surfaces of overrunning clutch and lever Multipurpose grease [NLGI No.2 (Ca soap)] As required
16 Clutch spline of gear shaft Grease for heavy load at low temperature As required
Friction surfaces of gear shaft and sleeve bearing Grease for heavy load at low temperature As required
54-2-21
201 STARTER
● Inspection before disassembly
Thrust gap of gear shaft
[Inspection]
• Measure the thrust gap of gear shaft 16 in the axial direction.
• If the measured value deviates from the standard value, adjust the
thrust gap as follows.
16
11957
[Adjustment]
• Remove center bracket 5 from front bracket assembly 4.
• Change the thickness of adjusting washer 7 for adjustment.
4 Available adjustment washers thicknesses: 0.25, 0.5 mm {0.0098,
0.02 in.}
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7 5
11958
● Inspection after assembly

Inspections after assembling the starter should be carried out with
2
current fed to the starter.
WARNING–
• Do not touch pinion C because it jumps out and turns when
current is fed to the starter.
• Take care not to burn your hand, magnetic switch 2 might be hot
after inspection.
C
14353 CAUTION–
• The current feeding time to the starter should be within 10
seconds at pull-in coil P side and within 30 seconds at holding
coil H side. If the current feeding time exceeds these limits the
coil might burn due to overheating.
• When current is flowing into the starter, a current of over 100
amperes is fed. When inspecting, use thick cable, such as a
booster cable, and make secure connections.
14354
54-2-22
54
(1) Performance test
S • Connect the starter as illustrated.
B
A : Ammeter
B : Terminal B of starter
D : Switch
E : DC power supply (12 volts)
S : Terminal S of starter
C V : Voltmeter
• Set the voltage to 11 volts DC.

14412
CAUTION–
E V A Up to 12 volts can be loaded.
• The following work should be done with current fed to the starter. You
must complete the full procedure of measuring the intensity of the
current and the number of revolutions within 30 seconds.
• Turn switch D ON and feed current into the starter. In this state,
pinion C jumps out and rotates.
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14355 CAUTION–
When switch D is turned ON, current is fed both to pull-in coil P
and holding coil H. When a large amount of current is fed into
terminal M from DC power supply E, via terminal B of the starter,
the current stops flowing into the pull-in coil but continues to
flow into the holding coil.
To avoid burning the holding coil, be sure to carry out the per-
formance test within 30 seconds.
• Measure the intensity of the current and the number of revolutions

of the starter. Train a strobe light on pinion C to measure the
revolutions.
• Turn switch D OFF to stop current to the starter.
• If the measured value deviates from the standard value, disassemble
the starter again and inspect it.
(2) Pinion gap
M [Inspection]
S
• Connect the starter as illustrated.
D : Switch G : Cable
E : 12 volts DC M : Terminal M of starter
F : Switch S : Terminal S of starter
G • The following work should be done with current fed to the starter. You
C must complete the full procedure for measuring the pinion gap within
11959 30 seconds.
E • Turn switches D and F ON and feed current to the starter. In this
state, pinion C jumps out and rotates.
D
F
14356
54-2-23
201 STARTER
• Within five seconds of pinion C rotating, turn switch F OFF to stop
E
rotation of the pinion.
D CAUTION–
F When switches D and F are turned ON, current is fed both to pull-
in coil P and holding coil H. The circuit is wired in such a way that
G the voltage is not applied to terminal B of the starter, so the
current continues to flow into the pull-in coil while pinion C
rotates.
To avoid burning the pull-in coil, be sure to turn switch F OFF
14357 within five seconds after the pinion rotates.
C • Push the tip of gear shaft 16 lightly and measure pinion gap H in the
16 axial direction.
• Turn switch D OFF to stop current to the starter.
• If the measured value deviates from the standard value, this means
the starter was assembled incorrectly, so disassemble and reassem-
ble the starter.
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2
H 12413
Magnetic switch
2 S
[Installation]
11 Install magnetic switch 2 onto lever 11 in the direction as illustrated.
S : Terminal S
12414
[Inspection]
Carry out the inspection as follows. If any fault is found, replace magnetic
M switch 2.
S
(1) Testing for coil discontinuity
• Check that there is continuity between terminals S and M.
11960
• Check that there is continuity between terminal M and the body A of

magnetic switch 2.
11961
54-2-24
54
(2) Inspection of welded connections
• Check that there is no continuity between terminals B and M.
B
M
11962
B (3) Inspection of connections

• Push the tip of magnetic switch 2 to close the internal connection.
• Check that there is continuity between terminals B and M.
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G
11963
Installation of lever
Install lever 11 onto overrunning clutch 13 in the direction as illustrated.
11
13
I
11964
Overrunning clutch
[Removal]
• Apply pipe-shaped tool A to pinion stopper 9.
8 • Hammer pipe-shaped tool A gently to remove stopper ring 8 from
pinion stopper 9.
• Remove pinion stopper ring 8 from gear shaft assembly 16 to with-
9
13 draw pinion stopper 9.
16
11965
[Inspection]
13
• Make sure that pinion A of overrunning clutch 13 turns toward direc-
tion B but does not turn toward direction C.
• If any fault is found, replace overrunning clutch 13.
B
A
C 11966
54-2-25
201 STARTER
[Installation]
9 • Install pinion stopper 9 onto gear shaft 16 in the direction as illus-
9 trated.
16
12416
• Install stopper ring 8 onto ring groove D of gear shaft 16.
8
8
16
D
16
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12417
• Pull pinion gear E firmly and set pinion stopper 9 on stopper ring 8
securely.
16
8
9
P
12418
A Inspection of armature assembly

B
20 (1) Testing for coil short-circuit
• Place iron rod B parallel to armature assembly 20.
A : Armature tester
• Rotate armature assembly 20 slowly.
• If iron rod B is pulled or shakes, it indicates that armature assembly
20 is short-circuited, so replace it.
02471
(2) Testing for coil grounding

• Check that there is no continuity between commutator C and core D
(or shaft E).
• If there is continuity between them, they are short-circuited. Re-
place armature assembly 20.
C E
D 02472
54-2-26
54
(3) Deflection of commutator
If the measured value is higher than the limit, adjust the outer diameter
of commutator C within the limit.
20
(4) Rough commutator surface
• If the surface is rough or has stepped wear, polish the surface with
emery paper (300 to 500 grit).
• After polishing, check deflection of commutator C.
C 02473
(5) Outer diameter of commutator

If the measured value is higher than the limit, replace armature as-
sembly 20.
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02474
(6) Mica depth between segments

F
• If the measured value is lower than the limit, correct or replace
armature assembly 20.
F : Mica depth
02475
• If the mica is worn as illustrated, replace armature assembly 20.

● : Good
× : Faulty
Y
02476
Inspection of brush spring

• Use new brushes 30, 31 and measure the load when brush spring 29
is detached from the brushes.
• If the measured value is higher than the limit, replace brush spring 29.
29
30, 31 14833
54-2-27
201 STARTER
Z[ Inspection of brush
(1) Length of brush
If the measured value is lower than the limit, replace brushes 30, 31.
A A : Length of brush
(2) Contact surface with commutator

If the surface where the brushes contact the commutator is rough or
is worn unevenly, polish the surface with emery paper (300 to 500
grit).
14832 CAUTION–
Make sure that the curvature of the surface is finished just like
\
that of the commutator.
Inspection of brush holder assembly

• Check that there is no continuity between the ê side of the brush
32 holder and the ë side of the holder plate.
• If there is continuity, they are grounded. Replace brush holder assem-
bly 32.
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02467
31
^ Inspection of yoke assembly
(1) Testing for coil disconnection

34 • Check that there is continuity between cable A and brush ê 31.
• If there is no continuity, they are disconnected. Replace brush ê 31
A or yoke assembly 34.
02477
(2) Testing for coil grounding

31 • Check that there is no continuity between yoke assembly 34 and
brush ê 31.
34 • If there is continuity, they are grounded. Locate the disconnection. If
it is hard to repair, replace brush ê 31 or yoke assembly 34.
02478
54-2-28
54
MEMO
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54-2-29
210 ENGINE STARTING CIRCUIT
8
< Automatic
6 transmission >
7
Starter Transmission
Starter relay neutral switch
10
Battery
< Manual
Main high- transmission >
12 current fuse Transmission
neutral switch
11 < Manual
transmission >
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To sub-starter
switch
High-current
9 fuse box
Chassis To sub-starter switch
ground < Automatic
transmission >
Chassis
a
Cab To cigarette Cab To sub-starter
lighter ground switch
Starter switch To exhaust

brake cut relay
< Manual
transmission >
5
To alternator
(Terminal L)
To meter
cluster
d
Transmission
Multipurpose Safety relay neutral relay
Relay and b timing control < Manual
fuse box unit 4 transmission >
To warning
buzzer 2 1
3 : F■617
4 : FM657
10445
54-2-30
54
2
1
3
b c
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d
8
6
9
10
12 11
12862
1 Transmission neutral relay 8 Transmission neutral switch

< Manual transmission > Õ 604 < Automatic transmission > Õ 802
2 Multipurpose timing control unit Õ 604 9 High-current fuse box Õ 104
3 Relay and fuse box Õ 104 10 Battery Õ 101
4 Safety relay Õ 604 11 Transmission neutral switch
5 Starter switch < Manual transmission > Õ 802
6 Starter Õ 201 12 Main high-current fuse box Õ 104
7 Starter relay
54-2-31
210 ENGINE STARTING CIRCUIT
5
Inspection of the starter switch
• Follow the table below to inspect continuity:
AP2A AN3A
2 1 1 3 2
A LOCK
F S
ACC ● ●
AN3A M
B ON ● ● ● ●
AP2A START ● ● ● ● ●
04500 B M A F S
● ● : There is continuity between terminals ● and ●.

• If any fault is found, replace starter switch 5. Õ Gr 37
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Inspection of starter relay
3 4 1 2
No current ● ●
Current ● ● ë ê

ë : Indicates that battery voltage is applied to the line
< F■617 > < FM657 >
ê
between the terminals.
• If any fault is found, replace starter relay 7. Õ Gr 54-2-19
11022
54-2-32
54
MEMO
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54-2-33
212 SUB-STARTER CIRCUIT
7
< Automatic
5
6 transmission >
Starter Transmission
Starter relay neutral switch
9
Battery
< Manual
transmission >
Transmission Sub-starter
neutral switch switch
Main high-
8 current fuse
10 11
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High-current Chassis
12 fuse box ground
Chassis
a
Cab To cigarette
lighter
Starter switch
To exhaust brake cut relay
4
b
Relay and fuse box
Transmission neutral relay

Cab ground Safety relay < Manual transmission >
3 1
3 : F■617
4 : FM657
10483
54-2-34
54
cardiagn.com
4
7
b
5 6 8
9
12 10
12863
1 Transmission neutral relay 7 Transmission neutral switch

< Manual transmission > Õ 604 < Automatic transmission > Õ 802
2 Relay and fuse box Õ 104 8 High-current fuse box Õ 104
3 Safety relay Õ 604 9 Battery Õ 101
4 Starter switch Õ 210 10 Transmission neutral switch
5 Starter Õ 201 < Manual transmission > Õ 802
6 Starter relay Õ 210 11 Sub-starter switch
12 Main high-current fuse box Õ 104
54-2-35
212 SUB-STARTER CIRCUIT
G
Inspection of sub-starter switch
• Follow the table below to inspect continuity :
1 2
ON ● ●
OFF

2 1
12142
• If any fault is found, replace sub-starter switch 11.
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54-2-36
54
MEMO
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54-2-37
215 ENGINE STOPPING CIRCUIT
1 3
Relay and fuse box Starter switch
2 Engine stop relay
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b c a
Chassis
d High-current fuse box
Cab Headlamp
Fuel-cut motor
Cab ground Cab ground
10465
54-2-38
54
1 2 a b
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3
12864
1 Relay and fuse box Õ 104 4 Fuel-cut motor

2 Fuel-cut relay Õ 604 5 Main high-current fuse Õ 104
3 Starter switch Õ 210
54-2-39
215 ENGINE STOPPING CIRCUIT
4
Inspection of fuel-cut motor
Inspect the following. If any fault is found, replace fuel-cut motor 4.
(1) When starter switch is OFF (Fuel-cut state)
• Connect inspection harness A between terminals 3
and . 5
• Apply 12 volts DC between terminals and6 1
to ensure that fuel-
cut motor 4 works correctly.
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11041
(2) When starter switch is ON (Fuel-cut reset state)

• Connect inspection harness A between terminals 3
and . 4
• Apply 12 volts DC between terminals and6 1
to ensure that fuel-
cut motor 4 works correctly.
11042
54-2-40
54
MEMO
cardiagn.com
54-2-41
220 ENGINE PREHEATING AND COLD START CIRCUIT < Manual Transmission >
4 1 2
Relay and fuse box Starter switch Meter cluster
a b
c
To backup lamp Multipurpose
switch timing control unit
To warning buzzer
To safety relay
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3
Cold start switch
To exhaust brake
cut relay
Cab ground
Cab
d
Chassis
Water temperature sensor
12 To alternator
(Terminal L)
To water
temperature Glow relay
gauge
7
Main high- 9
current fuse
High-current
fuse box
10
Chassis ground
Battery Exhaust brake Glow plug

3-way magnetic Chassis ground
8 valve 11
6
10482
54-2-42
54
a b 4
1 c
2 3 5
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d
6 7 8
12
10
12865
1 Starter switch Õ 210 7 Main high-current fuse Õ 104

2 Meter cluster Õ 401 8 Battery Õ 101
3 Cold start switch Õ 601 9 Glow relay
5 Multipurpose timing control unit Õ 604 11 Glow plug
6 Exhaust brake 3-way magnetic valve Õ 701 12 Water temperature sensor Õ 801
54-2-43
220 ENGINE PREHEATING AND COLD START CIRCUIT < Manual Transmission >
Service standards
11 Resistance of glow plug (at ambient temperature) 1.0 Ω (Reference value) — Replace
9
Inspection of glow relay
(1) Inspection of fuse

If any fault is found, replace fuse A (127 amperes).
(2) Inspection of body
A 1 2 3 4 5
● ●
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No current
Current ● ● ● ê ë

ê ë : Indicates that 12 volts DC is applied to the line
A : Fuse (127 amperes)
1.25-BW • If any fault is found, replace glow relay 9.
10834
G Inspection of glow plug

• Measure the resistance of glow plug 11 as illustrated.
• If the measured value deviates from the standard value, replace glow
plug 11. ^ Gr 11
02513
54-2-44
54
MEMO
cardiagn.com
54-2-45
220 ENGINE PREHEATING AND COLD START CIRCUIT < Automatic Transmission >
1 2
4
Starter switch Meter cluster
Relay and fuse box
a c b Multipurpose timing
control unit
To safety relay
To warning buzzer 5
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Cold start switch
Cab Floor 6 Parking

brake switch
3 e
Cab ground Cab

d
Chassis
Water temperature sensor
To alternator
13 (Terminal L)
To water
temperature
Glow relay
gauge
8
Main high-current fuse 10
High-current
fuse box
11
Chassis ground
Battery
9
Cold start 3-way Glow plug Chassis
magnetic valve ground
12
7
13549
54-2-46
54
a b 4
1 c
2 3 5
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d
e
7 8 9
13
11
13498
1 Starter switch Õ 210 8 Main high-current fuse Õ 104

2 Meter cluster Õ 401 9 Battery Õ 101
3 Cold start switch Õ 601 10 Glow relay
5 Multipurpose timing control unit Õ 604 12 Glow plug
6 Parking brake switch Õ 510 13 Water temperature sensor Õ 801
7 Cold start 3-way magnetic valve Õ 701
54-2-47
220 ENGINE PREHEATING AND COLD START CIRCUIT < Automatic Transmission >
Service standards
12 Resistance of glow plug (at ambient temperature) 1.0 Ω (Reference value) — Replace
F
Inspection of glow relay
(1) Inspection of fuse

If any fault is found, replace fuse A (127 amperes).
(2) Inspection of body
A 1 2 3 4 5
● ●
cardiagn.com
No current
Current ● ● ● ê ë

ê ë : Indicates that 12 volts DC is applied to the line
A : Fuse (127 amperes)
1.25-BW • If any fault is found, replace glow relay 10.
10834
H Inspection of glow plug

• Measure the resistance of glow plug 12 as illustrated.
• If the measured value deviates from the standard value, replace glow
plug 12. ^ Gr 11
02513
54-2-48
54
3 LIGHTING
SPECIFICATIONS .......................................................................... 54-3-2

Headlamp Aiming ................................................................................ 54-3-8
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310 HEADLAMP CIRCUIT ....................................................... 54-3-10
320 TAIL LAMP, CLEARANCE LAMP AND LICENSE PLATE

LAMP CIRCUITS ............................................................... 54-3-12
325 STOP LAMP CIRCUIT ....................................................... 54-3-14
330 TURN SIGNAL LAMP AND HAZARD

LAMP CIRCUITS ............................................................... 54-3-18
340 BACKUP LAMP CIRCUIT ................................................. 54-3-20
345 CAB LAMP CIRCUIT ......................................................... 54-3-24
348 ILLUMINATION LAMP CIRCUIT ....................................... 54-3-28
349 MARKER LAMP AND IDENTIFICATION LAMP

CIRCUITS .......................................................................... 54-3-30
352 VAN BODY DOME LIGHT CIRCUIT ................................. 54-3-32
54-3-1
SPECIFICATIONS
Item Specifications
Voltage V 12
Headlamp Model Sealed beam
Type Reflex type
HIGH beam W 50
HIGH/LOW beam W 60/40
Front turn signal lamp (also used as hazard lamp) W 21
Clearance lamp W 7.5
Side turn signal lamp 10
(also used as hazard lamp) W
Rear combination lamp Stop/Tail W 27/8
Turn (also used 27
as hazard lamp) W
Backup W 27
License plate lamp W 7.5
Cab and spot lamp Cab W 12
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Spot W 8
Identification lamp W 7.5
Clearance and side marker lamp W 7.5
Back buzzer Rated voltage V 12
Rated current mA 50 or less
Sound pressure dB 85±10 (at 1 m {3.3 ft})
Frequency Times/minute 85±15
54-3-2
54
MEMO
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54-3-3
4
3
2
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6
9 8
7
11205
1 Clearance and side marker lamp 6 Side turn signal lamp

2 Identification lamp 7 Clearance lamp
3 Cab and spot lamp 8 Front turn signal lamp
4 License plate lamp 9 Headlamp
5 Rear combination lamp
54-3-4
54
Headlamp
1 Screw (HIGH beam, horizontal adjustment)
2 Screw (HIGH beam, vertical adjustment)
1 2 3 4 3 Screw (HIGH/LOW beam, vertical adjustment)
4 Screw (HIGH/LOW beam, horizontal adjustment)
5 Extension spring
6 Extension spring
7 Housing
8 Sealed beam unit (HIGH beam)
9 Sealed beam unit (HIGH/LOW beam)
• The headlamp unit consists of sealed beam units 8, 9

separately installed in housing 7. Sealed beam unit 8 is
for HIGH beam, and sealed beam unit 9 is for HIGH/
LOW beam.
7 6 5 • The headlamp aiming can be adjusted by changing the
installation angle of sealed beam units 8, 9.
8 9
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• To adjust the installation angle of sealed beam unit 8,
turn screws 1, 2. Extension spring 6 sets the angle of
the sealed beam unit.
• To adjust the installation angle of sealed beam unit 9,
turn screws 3, 4. Extension spring 5 sets the angle in
the same way as for sealed beam unit 8.
13348
54-3-5
TROUBLESHOOTING
Symptoms Headlamp Tail lamp,
clearance lamp,
license plate
lamp, clearance
and side
marker lamp,
identification
HIGH beam does not light
LOW beam does not light
Stop lamp does not light

lamp
Does not light
Does not light

Dim
Possible causes
Connector connection faulty, harness broken, grounding faulty ● ● ●
cardiagn.com
Battery charge insufficient ●
Alternator output insufficient ●
Bulb burnt-out ● ● ●
Power (wattage) of bulb is lower than specified value
Power (wattage) of bulb is higher than specified value
Lighting switch faulty ● ●
Dimmer switch faulty ● ●
Combination switch
Turn signal switch faulty
Hazard switch faulty
Headlamp relay (HIGH/LOW) faulty ● ● ●
Tail lamp relay faulty ●
Relay box
Flasher unit faulty
Stop lamp relay faulty ●
Stop lamp switch faulty ●
Meter cluster faulty
Backup lamp switch faulty
Back buzzer faulty
Door switch faulty
Cab and spot lamp faulty
Rheostat switch faulty
Turn signal lamp relay faulty
Tail lamp bulb burnt-out
Van body dome light relay faulty
Van body dome light switch faulty
54-3-6
54
Symptoms Turn signal lamp
Meter and heater control illumination lamps

(also used as
hazard lamp)
Meter and heater control illumination lamps
Van body dome light does not light

Cab and spot lamp does not light
Back buzzer does not sound
Backup lamp does not light
Blink interval uneven
cannot be adjusted
Blinks too quickly
Blinks too slowly
Does not go off
Does not light
do not light
Possible causes
Connector connection faulty, harness broken, grounding faulty ● ● ● ● ● ●
Fuse blown ● ● ● ● ●
cardiagn.com
Battery charge insufficient ●
Alternator output insufficient ●
Bulb burnt-out ● ● ● ● ● ●
Power (wattage) of bulb is lower than specified value ●
Power (wattage) of bulb is higher than specified value ●
Lighting switch faulty
Dimmer switch faulty
Combination switch
Turn signal switch faulty ● ●
Hazard switch faulty ● ●
Headlamp relay (HIGH/LOW) faulty
Tail lamp relay faulty ●
Relay box
Flasher unit faulty ● ● ● ● ●
Stop lamp relay faulty
Stop lamp switch faulty
Meter cluster faulty
Backup lamp switch faulty ● ●
Back buzzer faulty ●
Door switch faulty ●
Cab and spot lamp faulty ●
Rheostat switch faulty ● ●
Turn signal lamp relay faulty ●
Tail lamp bulb burnt-out ●
Van body dome light relay faulty ●
Van body dome light switch faulty ●
54-3-7
Headlamp Aiming
1 Screw (HIGH beam, horizontal adjustment)
1 2 3 4
2 Screw (HIGH beam, vertical adjustment)
3 Screw (HIGH/LOW beam, vertical adjustment)
4 Screw (HIGH/LOW beam, holizontal adjustment)
5 HIGH/LOW beam
6 HIGH beam
To adjust the headlamp move the optical axis of HIGH beam 6 by turning
screws 1, 2; and move the optical axis of HIGH/LOW beam 5 by turning
6 5 04907 screws 3, 4. You need to adjust the aiming of both the HIGH and the
HIGH/LOW beams on both the left and right headlamps.
(1) Preparatory work before adjustment

7 • Park the vehicle on a level place.
B 68 kg
{150 lb.}
WARNING–
cardiagn.com
You must put wheel chocks securely in place.
3 m {9.8 ft.}
• Unload the vehicle and make sure no one is in it.

• Inflate the tires to specified pressure. ^ Gr 31
08628 • Seat one person or an equivalent mass (68 kg {150 lb}) in the
185 mm {7.34 in.} vehicle.
• Start the engine and check that the battery is being charged.
• Place convergent headlamp tester 7 in line with HIGH beam 6 or
HIGH/LOW beam 5 of either the left or right headlamp at a distance
84 mm {3.31 in.}
of 3 m {9.8 ft}.
• Align the center of convergent lens B of convergent headlamp
tester 7 with lamp center A of HIGH beam 6 or HIGH/LOW beam
5. (The illustration shows a left headlamp.)
• When adjusting one headlamp, mask the other to avoid light leak-
A
04914 age.
(2) Adjustment
WARNING–
Do not mask a lit headlamp for more than 10 minutes or the
heat generated might cause a fire.
CAUTION–
When completing the adjustment using screws 1 to 4, the
action must be finished in the tightening direction.
54-3-8
54
1 2 ● Adjustment of HIGH beam unit
• Turn on HIGH beam 6.
• Adjust as follows so that the optical axis (maximum illumination point)
C of HIGH beam 6 is located as illustrated:
• Vertical adjustment: Turn screw 2 to adjust.
• Horizontal adjustment: Turn screw 1 to adjust.
The aiming of both left and right HIGH beams 6 should be adjusted to
the position as illustrated.
6 : Tolerance of adjustment
13346
A : Center of headlamp
D : Height from the ground to headlamp center
C A Adjusting direction for optical axis

0.2°
Upward Downward Leftward Rightward

0.48°
D Screw 1 — —
0.5° 0.5° (Counter- (Clockwise)
0.2°
cardiagn.com
clockwise)
08630
Screw 2 — —
(Clockwise) (Counter-
clockwise)
Turning direction of the screws in the table is as viewed from the front.
● Adjustment of HIGH/LOW beam unit

3 4
• Turn on the LOW beam of HIGH/LOW beam 5.
• Adjust as follows so that the optical axis (maximum illumination point)
C of HIGH/LOW beam is located as illustrated:
• Vertical adjustment: Turn screw 3 to adjust.
• Horizontal adjustment: Turn screw 4 to adjust.
The aiming of both left and right HIGH/LOW beams 5 should be
adjusted to the position as illustrated.
: Tolerance of adjustment
5
13347 A: Center of lamp
D: Height from the ground to headlamp center
A Adjusting direction for optical axis
C Upward Downward Leftward Rightward
0.2°
D Screw 3 — —
1.5°
0.5° 0.5°
(Clockwise) (Counter-
0.2°
2° clockwise)
08629
Screw 4 — —
(Counter- (Clockwise)
clockwise)
Turning direction of the screws in the table is as viewed from the front.
54-3-9
310 HEADLAMP CIRCUIT
To high-current fuse box

Relay and fuse box
3
Headlamp relay, b 5
LOW Meter cluster
d
2
Headlamp
4 relay, HIGH
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Combination switch c
Dimmer switch
1 a
Lighting switch
To tail
lamp relay
Cab Cab
Tightened together e f
Headlamp Chassis
Cab ground
HIGH/ Chassis HIGH/ HIGH

HIGH LOW
LOW
ground
Headlamp, LH Headlamp, RH
6 7
10447
54-3-10
54
2 3 4
1
a
b c d
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e
e
f
12866
1 Combination switch Õ 601 5 Meter cluster Õ 401

2 Relay and fuse box Õ 104 6 Headlamp, LH Õ 300
3 Headlamp relay (LOW) Õ 604 7 Headlamp, RH Õ 300
4 Headlamp relay (HIGH) Õ 604
54-3-11
320 TAIL LAMP, CLEARANCE LAMP AND LICENSE PLATE LAMP CIRCUITS
2
Relay and fuse box 1
a
Combination switch
Tail lamp relay
b Lighting switch
d
Clearance lamp,
LH
7
Cab Headlamp
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Cab ground
Cab
c
Rear chassis Chassis
Turn
Stop/
6 Tail 8
Clearance lamp, RH
Back
Rear combination
lamp, LH
Additional plug
License
connector for tail
5 plate
f lamp
lamp
e
Rear chassis ground
Back
Stop/ Chassis ground

4 Tail
Branch of circuit 30
Turn
Rear combination
lamp, RH
10449
54-3-12
54
2
1
a
b 3
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d
8 7 5
f e
6
12867
1 Combination switch Õ 601 6 Rear combination lamp, LH

2 Relay and fuse box Õ 104 7 Clearance lamp, LH
3 Tail lamp relay Õ 604 8 Clearance lamp, RH
4 Rear combination lamp, RH
5 License plate lamp
54-3-13
325 STOP LAMP CIRCUIT
1
Relay and fuse box
2
a
Stop lamp relay
Cab
b
Rear chassis Chassis
cardiagn.com
Turn
Stop/
5 Tail
Back
Rear combination
lamp, LH
Rear chassis
ground
Back
Stop/
4
Tail
Chassis ground
Turn
Stop lamp switch Stop lamp

Rear combination < Air over hydraulic switch
lamp, RH brake >
3, 7
3
Stop lamp switch

< Full air brake >
6 1 : Air over hydraulic brake

2 : Full air brake
10450
54-3-14
54
a 2
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4
c 5
12868
1 Relay and fuse box Õ 104 5 Rear combination lamp, LH

2 Stop lamp relay Õ 604 6 Stop lamp switch < Full air brake >
3 Stop lamp switch < Air over hydraulic brake > 7 Stop lamp switch < Full air brake >
54-3-15
325 STOP LAMP CIRCUIT
Service standards
3, 6, 7 Operating pressure of stop lamp switch 29±9.8 kPa — Replace
{4.3±1.4 lbf/in2, 0.3±0.1 kgf/cm2}
B
367
Inspection of stop lamp switch
Carry out the following inspection. If any fault is found, replace stop lamp
switches 3, 6, 7.
A
• Make sure that there is no continuity between terminals 1 and2
when air pressure A is not applied to stop lamp switches 3, 6, 7.
• Apply air pressure A to stop lamp switches 3, 6, 7 gradually starting
from 0 kPa {0 lbf/in2, 0 kgf/cm2}.
Measure air pressure A when continuity is present between terminals
2 1
12034
1 and 2 to make sure that the value conforms to the standard value.
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B : Air pressure gauge
54-3-16
54
MEMO
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54-3-17
330 TURN SIGNAL LAMP AND HAZARD LAMP CIRCUITS
4
3 Meter cluster
Relay and fuse box
2 Turn signal
lamp relay
d
b c
Cab Headlamp
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e j Side turn signal
lamp, LH
To headlamp, LH
8
Tightened together
LH 9
Cab ground
RH 10
f
Cab Front panel Front turn signal lamp
Cab ground
Cab
g
Chassis Rear chassis
Back
a
Stop/ 6
h Tail
Turn
Rear combination
lamp, RH
Flasher unit Hazard

Turn
switch Turn signal switch
5 Stop/ 7
Combination switch
k Tail
1
1 : Air over hydraulic brake Back
2 : Full air brake
Side turn signal Rear combination
lamp, RH Chassis Rear chassis lamp, LH
ground ground
11
10451
54-3-18
54
b
1
a
c
2
3 d
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e
f
5
11
10
8 h
e
9
j 7
12869
1 Combination switch Õ 601 7 Rear combination lamp, LH

2 Turn signal lamp relay Õ 604 8 Front turn signal lamp, LH
3 Relay and fuse box Õ 104 9 Side turn signal lamp, LH
4 Meter cluster Õ 401 10 Front turn signal lamp, RH
5 Flasher unit Õ 604 11 Side turn signal lamp, RH
54-3-19
340 BACKUP LAMP CIRCUIT
1
Relay and fuse box
Cab
b
Chassis
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5 6
Backup lamp switch Backup lamp switch
< Manual transmission > < Automatic transmission >
Connection Socket
Chassis
c
Rear chassis
Sound
unit
Intermittent
circuit
Turn Stop/ Back Back Stop/ Turn
Tail Rear chassis Tail
Backup buzzer
ground
Rear combination Rear combination
lamp, LH 3
lamp, RH
4 2
10454
54-3-20
54
a 1
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6 2
5 c 4
12870
1 Relay and fuse box Õ 104 5 Backup lamp switch Õ 802

2 Rear combination lamp, RH < Manual transmission >
3 Back buzzer 6 Backup lamp switch Õ 802
4 Rear combination lamp, LH < Automatic transmission >
54-3-21
340 BACKUP LAMP CIRCUIT
3
Back buzzer
[Inspection]
• Make sure that back buzzer 3 sounds intermittently when you apply 12
volts DC between terminals 1 2
and .
• If any fault is found, replace back buzzer 3.
11220
[Installation]
Install back buzzer 3 to the frame within the angle range as illustrated.
CAUTION–
Be careful to install back buzzer 3 within the illustrated angle
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0° range or the back buzzer will not be drained normally.
30°
10902
54-3-22
54
MEMO
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54-3-23
345 CAB LAMP CIRCUIT
1
Relay and fuse box
To warning buzzer
Meter cluster
b
d
5 4
Door switch,
RH
Floor
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Cab
c
Door switch,
LH
Cab ground Cab

e
Roof
Spot Spot
Cab
Cab and spot lamp
10453
54-3-24
54
a 1 b
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c
e
d
12871
1 Relay and fuse box Õ 104 4 Meter cluster Õ 401

2 Cab and spot lamp 5 Door switch, RH
3 Door switch, LH
54-3-25
345 CAB LAMP CIRCUIT
2
Inspection of cab and spot lamp
SPOT (LH) • Follow the table below to inspect continuity:
DOOR 1 3 5
3 2 1
6 5 4
OFF
SPOT (LH) ● ●
CAB
SPOT (RH) ● ●
SPOT (RH) DOOR ● ●
11305 CAB ● ●
● ● : There is continuity between terminals ● and ● (When
valve is installed).
35
• If any fault is found, replace cab and spot lamp 2.
Inspection of door switches
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ON OFF
1 2
OFF
ON ● ●
2 mm {0.079 in.} or more ● ● : There is continuity between terminals ● and ●.
9±1 mm {0.35±0.039
• If any fault is found, replace door switches 3, 5. ^ Gr 42
in.} 11225
54-3-26
54
MEMO
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54-3-27
348 ILLUMINATION LAMP CIRCUIT
2
Relay and fuse box 1
7
Combination
3 Tail lamp Rheostat switch
relay switch
Lighting switch
b c
Automatic transmission
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range selector d
a
8
Meter cluster
Floor Cab
To cab and 4
spot lamp
Illumination lamp
Illumination
lamp
6 Speedometer
5
Heater control
assembly Illumination
Tightened together
To clearance
lamp, LH Cab ground
Branch of circuit 30
: Automatic transmission
10478
54-3-28
54
2 b
1
a
c 3
4 5 6
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d
7
12872
1 Combination switch Õ 601 5 Speedometer Õ 401

2 Relay and fuse box Õ 104 6 Heater control assembly Õ 618
3 Tail lamp relay Õ 604 7 Rheostat switch Õ 601
4 Meter cluster Õ 401 8 Automatic transmission range selector ^ Gr 23
54-3-29
349 MARKER LAMP AND IDENTIFICATION LAMP CIRCUITS
1
Relay and fuse box
2
Tail lamp relay
To lighting switch
a
Combination switch
connector
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c
Cab ground
Cab
b
Cab lamp
LH Center RH Side marker Side marker

lamp, RH lamp, LH
Identification lamp
3 5
4
10484
54-3-30
54
4
1
3 5
a c
2
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b
12873
1 Relay and fuse box Õ 104 4 Identification lamp

2 Tail lamp relay Õ 604 5 Clearance and side marker lamp, LH
3 Clearance and side marker lamp, RH
54-3-31
352 VAN BODY DOME LIGHT CIRCUIT
3
Van body dome light
Relay and fuse box plug connector
a b
Chassis
c
Cab
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To heater control switch
To warning buzzer
Van body dome Cab ground

light switch
1
Van body dome
light relay
10485
54-3-32
54
a 3
b
1
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c
d
12874
1 Van body dome light switch Õ 601

2 Van body dome light relay Õ 604
54-3-33
54
4 METER
SPECIFICATIONS .......................................................................... 54-4-2
401 METER CLUSTER ............................................................... 54-4-4
410 SPEEDOMETER AND TACHOMETER CIRCUITS ........... 54-4-10
420 FUEL GAUGE CIRCUIT .................................................... 54-4-12
cardiagn.com
425 WATER TEMPERATURE GAUGE CIRCUIT..................... 54-4-16
54-4-1
SPECIFICATIONS
Item Specifications
Meter cluster Manufacturer NIPPONDENSO
Voltage V 12
Lighting bulb W 3
Indicator lamp bulb W 1.4
Warning lamp bulb W 1.4
Meter warning buzzer Rated current 50 or less (Mean value)
(Overrunning buzzer) mA
< 10-speed Sound pressure
transmission > 60 +60 (at 1 m {3.3 ft}
dB
Speedometer Manufacturer NIPPONDENSO
Lighting bulb W 2
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54-4-2
TROUBLESHOOTING 54
Symptoms
Needle movement unstable

Needle does not move
Meter generates noise

Remarks
Indication error large

Possible causes
Connector connection faulty, harness broken, grounding faulty ● ●
Fuse blown ●
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Internal circuit of meter cluster faulty ● ● ●
Printed board of meter cluster faulty ●
Engine speed sensor coil broken ●
Tachometer Engine speed sensor installed incorrectly ● ● ^ Gr 13
Tachometer faulty ● ● ● ●
Vehicle speed sensor faulty ●
Vehicle speed sensor installation faulty ●
Tires incorrect ● ^ Gr 31
Speedometer Tires worn and tire pressure incorrect ● ^ Gr 31
Transmission L-joint incorrect (gear ratio different) ● ^ Gr 22
Transmission speedometer gear incorrect (gear ratio different) ● ^ Gr 22
Installation angle of transmission speedometer gear bush ^ Gr 22
●
incorrect (not set at correct gear ratio point)
Speedometer faulty ● ● ● ●
Water temperature sensor faulty ● ●
Water temperature
Water temperature gauge faulty ● ●
gauge
Thermostat does not close ● ^ Gr 14
Fuel gauge unit faulty ● ●
Fuel gauge
Fuel gauge faulty ● ●
54-4-3
401 METER CLUSTER
10 9
7
6
2
12
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16
15
14
13
12367
1 Front plate 9 Print panel
2 Retainer 10 Case
3 Tachometer 11 Speedometer assembly
4 Air pressure gauge and indicator lens 12 Bulb
5 Fuel gauge and water temperature gauge 13 Plate
6 Indicator lens 14 Window plate
7 Bulb 15 Speedometer
8 Meter warning buzzer (Overrunning buzzer) 16 Case
< 10-speed transmission >
Follow the disassembly sequence in reverse.
Installation and removal of meter cluster and speedometer : ^ Gr 42
54-4-4
54
Service standards
3 Indication range of tachometer At 550 rpm 550±35 rpm — Replace
13±0.1 V At 1000 rpm 1000±50 rpm
20±2°C {68±3.6°F}
At 1500 rpm 1500±60 rpm
At 2000 rpm 2000±65 rpm
At 2500 rpm 2500±70 rpm
At 3000 rpm 3000±75 rpm
4 Indication range of air At 40 lbf/in 2
275.8±50 kPa — Replace
pressure gauge {40±7 lbf/in2, 2.8±0.5 kgf/cm2}
At 75.4 lbf/in2 519.9±50 kPa
{75.4±7 lbf/in2, 5.3±0.5 kgf/cm2}
At 120 lbf/in2 827.4±50 kPa
{120±7 lbf/in2, 8.4±0.5 kgf/cm2}
Tolerance of reading by two At 519.9 kPa ±50 kPa
needles under the same {75.4 lbf/in2, 5.3 kgf/cm2} {±7 lbf/in2, 0.5 kgf/cm2}
pressure ±50 kPa
cardiagn.com
At 827.4 kPa
{120 lbf/in2, 8.4 kgf/cm2} {±7 lbf/in2, 0.5 kgf/cm2}
5 Resistance Needle position Full 4Ω — Replace
of fuel gauge 1/ 50 Ω
2
Empty 135 Ω
Resistance Needle position 65°C {149°F} 81.8 Ω
of water
100°C {212°F} 26.6 Ω
temperature
gauge
11 Indication Inspection using At 10 mph 10±2 mph — Replace

range of mph At 20 mph
+2
20 –1.5 mph
speedometer +2.5
At 40 mph 40 –1 mph
14 V 20±2°C +3
{68±3.6°F} At 50 mph 50 0 mph
+3
At 60 mph 60 0 mph
Inspection using At 20 km/h 20±3 km/h
km/h +3
At 35 km/h 35 –0.5 km/h
+3
At 40 km/h 40 –0.5 km/h
+3.5
At 60 km/h 60 –0.5 km/h
+4.5
At 80 km/h 80 –0 km/h
At 100 km/h 100 +50 km/h
3
Inspection of tachometer
• Measure the indication area of tachometer 3 at various revolution
ranges using an engine revolution counter.
• If the measured value deviates from the standard value, carry out the
following inspection. If the inspection does not indicate a fault, replace
tachometer 3.
(1) Inspection of the engine revolution sensor body Õ 801
(2) Inspection of the installed condition of the engine revolution

sensor ^ Gr 13
54-4-5
401 METER CLUSTER
B
4 Inspection of air pressure gauge
• Apply air pressure A to air pressure gauge 4.
4 B : Air pressure gauge
• Measure the indication range of air pressure gauge 4 at standard
pressure.
A • If the measured value deviates from the standard value, replace air
pressure gauge 4.
5
14382
Inspection of fuel gauge and water temperature gauge

A
12 volts DC (1) Fuel gauge
• Connect a variable resistor to fuel gauge 5 as illustrated.
A : Variable resistor
FULL • Measurement order
1/2
FULL → 1/2 → EMPTY
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NOTE
The movement of the gauge needle is subject to hysteresis (os-
EMPTY
12971 cillation). Be sure to measure following the measurement order.
• Increase the value of variable resistor A gradually from 0 Ω.
• Measure the resistance respectively when the needle of fuel gauge
indicates FULL, 1/2 and EMPTY.
• If the measured value deviates from the standard value, replace fuel
gauge and water temperature gauge 5.
(2) Water temperature gauge

A
• Connect a variable resistor to water temperature gauge as illustrated.
12 volts DC
A : Variable resistor
• Measurement order
Low temperature → High temperature
100°C {212°F} NOTE
The movement of the gauge needle is subject to hysteresis (os-
65°C {149°F} cillation). Be sure to measure following the measurement order.
• Increase the value of variable resistor A gradually from 0 Ω.
12972
• Measure the resistance respectively when the needle of water tem-
perature gauge 5 indicates 65°C {149°F} and 100°C {212°F}.
8 gauge and water temperature gauge 5.
Inspection of meter warning buzzer

• Apply 12 volts DC between terminals 1 and 2 to check if meter
warning buzzer 8 sounds.
CAUTION–
• Be careful not to mix up ê and ë when you apply voltage to
meter warning buzzer 8, because this would damage the meter
warning buzzer.
• Make sure you check ê and ë on the top of meter warning buzzer
8.
14853
• If any fault is found, replace meter warning buzzer 8.
54-4-6
54
G Inspection of speedometer
• Measure the indication area of speedometer 11 at various speed
ranges using a speedometer tester.
• If the measured value deviates from the standard value, carry out the
following inspection. If the inspection does not indicate a fault, replace
speedometer 11.
(1) Inspection of vehicle speed sensor body Õ 802
(2) Inspection of installed condition of vehicle speed sensor

^ Gr 22 < Manual transmission >
^ Gr 23 < Automatic transmission >
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54-4-7
401 METER CLUSTER
Meter Cluster Internal Circuit
cardiagn.com
Tachometer
Fuel gauge
Water temperature
gauge
14846
54-4-8
54
1 Speedometer assembly
2 Meter cluster assembly
AU6A AU13A AU16A
Y i
M↑
Z
↑

S1 → S6
16
→
L 7 ←
1 2 AU6A AU10A
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12974
Terminal Terminal Terminal

AU6A AU13A AU16A
No. No. No.
1 — 17 Ground 30 Illumination ê
2 — 18 Tachometer ë 31 Fuel gauge unit ë
3 — 19 — 32 Water temperature unit ë
4 — 20 — 33 Water level, overheating
5 — 21 — 34 Starter switch terminal M
6 Illumination ë 22 Tachometer ê 35 Alternator ë
23 Glow ê 36 Cab tilt ë
24 Glow ë 37 Pre-stroke control ë
25 Turn RH ê 38 —
Terminal AU10A
No. 26 Cold start ê 39 ATF temperature ë
7 Parking brake ê 27 Exhaust brake ê 40 Brake fluid ë
8 Door ë 28 Turn LH ê 41 Brake air ë
9 — 29 Beam ê 42 —
10 Cold start ê 43 Engine oil bypass alarm ë
11 — 44 Engine oil pressure ë
Speedometer
12 Door ë 45 Engine oil and brake ê
Terminal
AU6A
13 Transmission HIGH ê No.
14 Transmission LOW ê S1 Speed pulse ê
15 — S2 Starter switch terminal M
16 — S3 Ground
S4 Illumination ê
S5 Illumination ë
ATF : Automatic transmission fluid
S6 —
54-4-9
410 SPEEDOMETER AND TACHOMETER CIRCUITS
4
Relay and fuse box
To warning buzzer
Meter cluster
Tachometer
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3
Speedometer
Cab ground
Cab
c b
Chassis
To alternator
(Terminal R)
Pre-stroke control unit

1
Vehicle speed Engine revolution

sensor sensor
5 6
10474
54-4-10
54
*
1
2 3
4
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c
5
6
12875
1 Pre-stroke control unit ^ Gr 13

2 Meter cluster Õ 401
3 Speedometer Õ 401
5 Vehicle speed sensor Õ 802
6 Engine revolution sensor Õ 801
*: Box under bed (Behind driver’s seat)
54-4-11
420 FUEL GAUGE CIRCUIT
1
Meter cluster
To warning buzzer Fuel gauge
Relay and fuse box
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Cab ground
Cab
b
Chassis
Chassis ground
Fuel gauge unit

3
10466
54-4-12
54
2 a
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b
12876

3 Fuel gauge unit
54-4-13
420 FUEL GAUGE CIRCUIT
Service standards
3 Resistance of Float arm position EMPTY 150±10 Ω — Replace
fuel gauge unit FULL 0 + 20 Ω
3
Inspection of fuel gauge unit
1 2
• Measure the resistance between terminals and when float arm A
FULL makes contact with both end stoppers (E and F).
A
2 1
gauge unit 3.
EMPTY
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11301
54-4-14
54
MEMO
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54-4-15
425 WATER TEMPERATURE GAUGE CIRCUIT
Relay and fuse box
a
2
To warning buzzer
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Cab
Meter cluster
Chassis
Water
temperature
gauge b
3
1
Water temperature
sensor
Cab ground To cold start switch
10455
54-4-16
54
2 a
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b
12877

3 Water temperature sensor Õ 801
54-4-17
54
5 INDICATOR AND WARNING

• Inspection of Brake Fluid Level Switch
< Air over hydraulic brake > .......................................................... 54-5-7
PARK
510 PARKING BRAKE INDICATOR CIRCUIT BRAKE
< Center Parking Brake > ................................................................... 54-5-8
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< Wheel Parking Brake > ................................................................... 54-5-10
BRAKE BRAKE
515 BRAKE WARNING CIRCUIT FLUID AIR
............................. 54-5-14
530 WATER LEVEL WARNING CIRCUIT Ñ ....................... 54-5-18
536 ENGINE OIL PRESSURE WARNING CIRCUIT B ....... 54-5-22
537 OVERHEATING WARNING CIRCUIT Ñ ...................... 54-5-24
547 AUTOMATIC TRANSMISSION FLUID

T/M OIL
TEMPERATURE WARNING CIRCUIT TEMP ..................... 54-5-26
548 TRANSMISSION HIGH/LOW INDICATOR

CIRCUIT < 10-speed transmission > ì ó ............... 54-5-30
550 CAB TILT WARNING CIRCUIT T ................................ 54-5-32
For details on the following indicator and warning lamps, see the relevant sections.
Ö Õ 125
OVER
RUN Õ 410 < 10-speed transmission >
_ ß Õ 220
x Õ 310
] [ Õ 330
“ Õ 345
ê Õ 710
¶ ^ Gr 13
54-5-1
TROUBLESHOOTING
Symptoms PARK
BRAKE
Lamps do not light when starter switch is ON (engine not

< Air over
< Full air
hydraulic
brake >
brake >
Lamp lights although hand control valve is

Lamp does not light although hand control
Lamp does not go out although parking
Lamp does not light although parking
Remarks
brake lever is returned

brake lever is pulled
valve is pulled
cardiagn.com
started)
pushed
Possible causes
Connector connection faulty, harness broken,
grounding faulty ● ● ●
Internal circuit faulty ● ● ● ● ●
Meter cluster
Bulb burnt-out ● ● ●
Warning buzzer faulty
Parking brake switch faulty ● ● ● ●
Parking brake relay faulty ● ●
Hand control valve faulty ● ● ^ Gr 35B
Brake fluid level switch faulty
Low air pressure switch faulty
Air master stroke switch faulty
Air master faulty ^ Gr 35A
Switch body faulty
Cab tilt lock switch
Installation faulty ^ Gr 42
Overheating switch faulty
Water level sensor faulty
Multipurpose timing control unit faulty
Engine oil pressure switch faulty
Engine oil bypass alarm switch faulty
Transmission HIGH/LOW detection switch (HIGH)
faulty
Transmission HIGH/LOW detection switch (LOW)
faulty
54-5-2
54
Symptoms BRAKE
AIR
BRAKE
FLUID
< Air over hydraulic
Lamp lights although air pressure level in air tank is

Lamp does not light although air pressure level in air
Warning buzzer does not sound although air pres-

brake >
Warning buzzer does not sound although brake

Lamp lights although brake fluid level is
Lamp does not light although brake fluid level
Remarks
sure level in air tank is low
fluid level is insufficient

is insufficient
tank is low
sufficient
cardiagn.com
sufficient
Possible causes
grounding faulty ● ● ● ●
Fuse blown ● ●
Internal circuit faulty ● ● ● ● ● ●
Meter cluster
Bulb burnt-out ● ●
Brake fluid level switch faulty ● ●
Low air pressure switch faulty ● ●
Air master stroke switch faulty ●
Air master faulty ● ^ Gr 35A
Switch body faulty
faulty
faulty
54-5-3
TROUBLESHOOTING
Symptoms Ñ
< Air over < Full air
Lamp lights although engine coolant level is sufficient

Lamp does not light although engine coolant level is
hydraulic brake >
brake >

Lamp does not light when overheating

Lamp lights when not overheating
Remarks
insufficient
cardiagn.com
Possible causes
grounding faulty ● ● ● ●
Fuse blown ● ●
Internal circuit faulty ● ● ● ● ● ●
Meter cluster
Switch body faulty
Overheating switch faulty ● ●
Water level sensor faulty ● ●
Multipurpose timing control unit faulty ● ●
faulty
faulty
54-5-4
54
Symptoms B ó
< Air over
Lamp lights although engine oil hydraulic pressure is

< Full air < 10-speed
Lamp does not light although engine oil hydraulic

hydraulic
brake > transmission >
brake >

Lamp does not light when transmission is in


Remarks
pressure is low
sufficient
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HIGH
Possible causes
● ● ● ●
grounding faulty
Fuse blown ● ●
Internal circuit faulty ● ● ● ● ●
Meter cluster
Switch body faulty
Engine oil pressure switch faulty ● ●
Engine oil bypass alarm switch faulty ● ●
●
faulty
faulty
54-5-5
TROUBLESHOOTING
Symptoms ì T
< 10-speed
Lamp does not light although cab is not locked to rear

Lamp lights although cab is locked to rear cab
transmission >
Lamp does not light when transmission is in

Remarks
cab mounting
mounting
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LOW
Possible causes
● ●
grounding faulty
Fuse blown ● ●
Internal circuit faulty ● ● ●
Meter cluster
Warning buzzer faulty
Parking brake switch faulty
Parking brake relay faulty
Hand control valve faulty ^ Gr 35B
Switch body faulty ● ●
Installation faulty ● ^ Gr 42
faulty
●
faulty
54-5-6
500 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE 54
Inspection of Brake Fluid Level Switch < Air over hydraulic brake >

+3.5 +0.14
— Warning lamp lighting position for brake fluid level 57 –0.5 {2.24 –0.02
} — Replace
switch
• Start engine.
• Drain the brake fluid gradually from fluid tank assembly 1.
1
CAUTION–
A 2 If brake fluid is spilt on any part of the vehicle, wipe it off
immediately, since the solvent in the fluid can damage the
paintwork.
• Measure height A of brake fluid level switch 2 when BRAKE

FLUID warning
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12878 lamp within the meter cluster lights.
• If the measured value deviates from the standard value, remove and
check fluid tank assembly 1.
Removal and installation : ^ Gr 35A

Inspection : Õ 515
54-5-7
510 PARKING BRAKE INDICATOR CIRCUIT < Center Parking Brake >
2
Relay and fuse box
1
a Warning buzzer
Headlamp
To alternator Cab
(Terminal L) Floor
Parking brake
c switch
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To engine oil bypass
alarm switch and engine
oil pressure switch
To diode unit
Cab ground To diode unit
To multipurpose
timing control unit
Meter cluster
10456
54-5-8
54
b 2
cardiagn.com
a
12879
1 Warning buzzer Õ 606

2 1
4 3
4
◆ Service procedures
Inspection of parking brake switch
1 2 3 4
ON OFF ON (PARK) ● ●
OFF (DRIVE) ● ●
5±1 mm
{0.20±0.039 in.} ●● : There is continuity between terminals ● and ●.
13 mm
{0.51 in.} • If any fault is found, replace parking brake switch 4. ^ Gr 36
00079
54-5-9
510 PARKING BRAKE INDICATOR CIRCUIT < Wheel Parking Brake >
2
Relay and fuse box
d
b
Floor
Cab
Headlamp
Warning buzzer
Parking brake relay
1
3
a
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To multipurpose timing
control unit
To engine oil bypass alarm 4

switch and engine oil
pressure switch
To diode unit
Meter cluster
To alternator
(Terminal L) Cab ground
Cab
c
e Parking brake switch
To alternator
(Terminal R)
10472
54-5-10
54
b 2
cardiagn.com
c
4
a
d
3
12880
1 Warning buzzer
3 Parking brake relay
54-5-11
510 PARKING BRAKE INDICATOR CIRCUIT < Wheel Parking Brake >
Service standards
5 Operating pressure When applying pressure 441 to 539 kPa — Replace
of parking brake {64 to 72 lbf/in2, 4.5 to 5.5 kgf/cm2}
switch
When releasing pressure 461 to 559 kPa — Replace
{67 to 81 lbf/in2, 4.7 to 5.7 kgf/cm2}
B
5
Inspection of parking brake switch
Carry out the following inspections. If any fault is found, replace parking
brake switch 5.
A • Make sure that there is continuity between terminals 1
and 2 when
air pressure A is not applied to parking brake switch 5.
• Apply air pressure A to parking brake switch 5 gradually starting from
0 kPa {0 lbf/in2, 0 kgf/cm2}.
1
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Measure the air pressure when continuity is lost between terminals
2 1
12035
and 2 to make sure that the measured value conforms to the stand-
ard value.
• When air pressure A of 785 kPa {115 lbf/in2, 8 kgf/cm2} has been
applied to parking brake switch 5, gradually release the air pressure.
Measure the air pressure when continuity is present between termi-
nals 1 2
and , and make sure that the measured value conforms to
the standard value.
54-5-12
54
MEMO
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54-5-13
515 BRAKE WARNING CIRCUIT
2 To alternator To meter
(Terminal L) cluster
Relay and fuse box
b Meter cluster
1
Warning buzzer 4
Headlamp
Cab
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Floor
d Parking brake relay
Parking brake < Full air brake >
switch
8 < Air over Cab ground
hydraulic
brake > Diode unit 5
Brake fluid  Diode unit

< Air over
level switch  hydraulic
10 < Air over  brake >
hydraulic 
brake > f  Diode unit 3

 Diode unit
< Air over
Airmaster  hydraulic
stroke switch  brake >
9 < Air over
hydraulic
brake > Low air
e pressure 6
c switch
Cab
Chassis ground Chassis
Rear chassis
Parking brake
switch
*1 : Center parking brake < Full air brake >
*2 : Wheel parking brake g 11
< Full air brake >
To alternator
(Terminal R)
10475
54-5-14
54
b 2
a
1
7 3
c
a d 5 4
e f
cardiagn.com
8
g 11
12881
1 Warning buzzer Õ 606 7 Meter cluster Õ 401

2 Relay and fuse box Õ 104 8 Parking brake switch Õ 510
3 Diode unit < Air over hydraulic brake >
4 Parking brake relay Õ 604 9 Airmaster stroke switch < Air over hydraulic brake >
5 Diode unit 10 Brake fluid level switch < Air over hydraulic brake >
6 Low air pressure switch 11 Parking brake switch Õ 510
< Full air brake >
54-5-15
515 BRAKE WARNING CIRCUIT
6 Operating pressure When applying pressure 470 to 510 kPa — Replace
of low air pressure {68 to 74 lbf/in2, 4.8 to 5.2 kgf/cm2}
switch
When releasing pressure 470 to 560 kPa —
{68 to 81 lbf/in2, 4.8 to 5.7 kgf/cm2}
+3.5
10 Continuity position of brake fluid level switch 57 –0.5 {2.24 +0.14
–0.02 } — Replace
(Equivalent to 345 cm3
{21.1 cu.in., 345 cc})
6
Inspection of low air pressure switch
Carry out the following inspection. If any fault is found, replace low air
B pressure switch 6.
• Make sure that there is continuity between terminals 1 and2 (Body)
cardiagn.com
when air pressure A is not applied to low air pressure switch 6.
• Apply air pressure A to low air pressure switch 6 gradually starting
A from 0 kPa {0 lbf/in2, 0 kgf/cm2}.
Measure the air pressure when continuity is lost between terminals 1
12409
and 2 (Body) to make sure that the measured value conforms to the
standard value.
• When air pressure A of 785 kPa {115 lbf/in2, 8 kgf/cm2} has been
applied to low air pressure switch 6, gradually release the air pres-
sure.
1 2
9
nals and (Body), and make sure that the measured value
conforms to the standard value.
Inspection of air master stroke switch

2 1 • Follow the table below to inspect continuity:
1 2
OFF
ON ON ● ●
OFF
●● : There is continuity between terminals ● and ●.
16.6
0
mm {0.65
0
in.} • If any fault is found, replace air master stroke switch 9. ^ Gr 35A
–0.7 –0.028
02387
F Inspection of brake fluid level switch

• Drain the brake fluid gradually from the brake fluid tank assembly.
CAUTION–
If brake fluid is spilt on any part of the vehicle, wipe it off immedi-
2 1
ately, since the solvent in the fluid can damage the paintwork.
A
• Measure height A of brake fluid level switch 10 when continuity is
present between terminals 1
and . 2
10 10316 • If the measured value deviates from the standard value, replace the
fluid tank assembly. ^ Gr 35A
54-5-16
54
MEMO
cardiagn.com
54-5-17
530 WATER LEVEL WARNING CIRCUIT
5
Meter cluster
2
Relay and fuse box
Parking brake relay

< Full air brake >
4
1
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a Warning buzzer
Headlamp
Cab
Floor
Cab ground Parking brake switch
d < Air over hydraulic brake >
To meter cluster
To overheating switch
3
1 : Center parking brake
< Full air brake >
Multipurpose timing
control unit
Cab
c
Parking brake switch

To alternator < Full air brake >
Chassis ground
Water lever (Terminal R)
8
sensor
10457
54-5-18
54
b 2
3
c
cardiagn.com
5
a d 4
e 8
12882
1 Warning buzzer Õ 606 6 Parking brake switch Õ 510

2 Relay and fuse box Õ 104 < Air over hydraulic brake >
3 Multipurpose timing control unit Õ 604 7 Water level sensor
4 Parking brake relay Õ 604 8 Parking brake switch Õ 510
< Full air brake > < Full air brake >
54-5-19
530 WATER LEVEL WARNING CIRCUIT
7
7
Inspection of water level sensor
A
1 2
When water level sensor
is out of the water
When water level sensor
● ●
is in the water
2 1
●● : There is continuity between terminals ● and ●.
12851
• If any fault is found, replace water level sensor 7. ^ Gr 14
A : Engine coolant
cardiagn.com
54-5-20
54
MEMO
cardiagn.com
54-5-21
536 ENGINE OIL PRESSURE WARNING CIRCUIT
4
Meter cluster
Relay and fuse box
b
2
Parking brake relay

< Full air brake >
a
3
1
cardiagn.com
Warning buzzer
Headlamp
Cab ground
Cab
Floor Parking brake switch
< Air over hydraulic
d brake >
To meter cluster
5

< Full air brake >
Cab
c
e
To alternator
(Terminal R)

Engine oil Engine oil
< Full air brake >
pressure bypass alarm
switch switch 8
7 6
12827
54-5-22
54
b 2
a
4
a
d 3
cardiagn.com
5
6 7
e 8
12883

3 Parking brake relay Õ 604 6 Engine oil bypass alarm switch Õ 801
< Full air brake > 7 Engine oil pressure switch Õ 801
4 Meter cluster Õ 401 8 Parking brake switch Õ 510
< Full air brake >
54-5-23
537 OVERHEATING WARNING CIRCUIT
4
Meter cluster
2
Relay and fuse box
Parking brake relay

< Full air brake >
a
3
cardiagn.com
1
Warning buzzer
Headlamp
Cab
Floor
Cab ground
d < Air over hydraulic brake >
To meter cluster

To multipurpose < Air over hydraulic brake >
timing control unit 2 : Wheel parking brake
< Full air brake >
Cab
c
Overheating To alternator Parking brake switch

switch (Terminal R) < Full air brake >
6 7
10486
54-5-24
54
b 2
cardiagn.com
4
f d
3
e 7
12884

3 Parking brake relay Õ 604 6 Overheating switch Õ 801
< Full air brake > 7 Parking brake switch Õ 510
4 Meter cluster Õ 401 < Full air brake >
54-5-25
547 AUTOMATIC TRANSMISSION FLUID TEMPERATURE WARNING CIRCUIT
2 6 1
Relay and fuse box Meter cluster Starter switch
To warning buzzer
b a
Automatic To high-current
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transmission fluid fuse box
cooler fan motor relay
To engine
stop relay
Resistor
Cab
c
Chassis
Chassis ground Chassis ground Chassis ground
Automatic transmission Automatic Automatic

fluid temperature switch transmission fluid transmission fluid
(Warning) thermostat switch cooler fan motor
(Fan motor)
4 8
7
10487
54-5-26
54
a b 2
1
cardiagn.com
6 5
4 3
15037
1 Starter switch Õ 210 5 Automatic transmission fluid cooler fan motor relay
2 Relay and fuse box Õ 104 Õ 604
3 resistor 6 Meter cluster Õ 401
4 Automatic transmission fluid temperature switch 7 Automatic transmission fluid thermostat switch
(Warning) Õ 802 (Fan motor)
8 Automatic transmission fluid cooler fan motor
54-5-27
547 AUTOMATIC TRANSMISSION FLUID TEMPERATURE WARNING CIRCUIT
Service standards
7 Operating temperature of When increases 97±3°C {207±5.4°F} — Replace

automatic transmission (OFF→ON)
fluid thermostat switch When decreases 90°C {194°F} MIN
(ON→OFF)
97±3°C
{207±5.4°F}
7
Inspection of automatic transmission fluid thermostat switch
Carry out the following inspection. If any fault is found, replace automatic
ON
transmission fluid thermostat switch 7. ^ Gr 23
OFF
90°C {194°F} MIN • Make sure that there is no continuity between terminals 1 and 2 at
room temperature (20±5°C {68±9°F}).
• Place automatic transmission fluid thermostat switch 7 in a container
2 1 filled with engine oil and raise the oil temperature while stirring the oil.
cardiagn.com
Measure the temperature when there is continuity between terminals
07807
1 2
and , and make sure that the measured value conforms to the
standard value.
• Lower the oil temperature and measure the temperature when conti-
nuity is lost between terminals 1 2
and , and make sure that the
measured value conforms to the standard value.
8 Inspection of cooler fan motor assembly

• Make sure that cooler fan motor assembly 8 activates when applying
battery voltage to terminals 1 and . 2
• If any fault is found, replace cooler fan motor assembly 8.
2 1
14430
54-5-28
54
MEMO
cardiagn.com
54-5-29
548 TRANSMISSION HIGH/LOW INDICATOR CIRCUIT < 10-speed transmission >
2 1
Relay and fuse box Meter cluster
Cab ground
cardiagn.com
Cab
b
Chassis
4 3
To backup
lamp switch
HIGH LOW
Transmission HIGH/LOW
detection switch
10488
54-5-30
54
a 2
cardiagn.com
3 4
12885

3 Transmission HIGH/LOW detection switch (LOW) Õ 802
4 Transmission HIGH/LOW detection switch (HIGH) Õ 802
54-5-31
550 CAB TILT WARNING CIRCUIT
1 2
Relay and fuse box Meter cluster
cardiagn.com
To warning buzzer
Cab
b
Chassis
Chassis ground

3
10468
54-5-32
54
cardiagn.com
b
12886

3 Cab tilt lock switch
101.5 mm {40.0 in.}(Reference value)

3
Inspection of cab tilt lock switch
1 2
ON ● ●
2 1
OFF
2.5±1 mm {0.098±0.039 in.}
OFF ON
• If any faut is found, replace cab tilt lock switch 3. ^ Gr 42
11907
54-5-33
54
6 CAB SIDE ELECTRICS
SPECIFICATIONS .......................................................................... 54-6-2
601 SWITCH ............................................................................... 54-6-4
604 RELAY AND CONTROL UNIT ............................................. 54-6-8
606 WARNING BUZZER .......................................................... 54-6-11
cardiagn.com
610 CIGARETTE LIGHTER CIRCUIT ...................................... 54-6-12
612 AUDIO CIRCUIT ................................................................ 54-6-14
614 WIPER AND WASHER CIRCUIT ...................................... 54-6-16
616 HORN CIRCUIT ................................................................. 54-6-20
618 HEATER CIRCUIT ............................................................. 54-6-22
54-6-1
SPECIFICATIONS/TROUBLESHOOTING
SPECIFICATIONS
Item Specifications
Minimum operating voltage of relay V 8 or less
Speaker Rated input W 12
Maximum input W 25
Impedance 4±0.6
Air horn Rated voltage V 12
Rated current A 3.2 or less
0
Sound pressure dB 115 –5 (at 2 m {6.6 ft})
Warning buzzer Rated voltage V 12
Rated current mA 150 or less
Sound pressure dB 75±10 (at 1 m {3.3 ft})
TROUBLESHOOTING
Symptoms Ciga-
cardiagn.com
rette Audio
lighter
Specific frequency band does not work
Left and right volume different

Remarks
Spurious noise generated
Sound from one side only

Sound quality poor
Does not return
Does not glow
Possible causes
Connector connection faulty, harness broken, grounding faulty ● ● ●
Fuse blown ●
Cigarette lighter faulty ● ●
Antenna and antenna cable connection faulty ●
Speaker faulty ● ● ● ● ●
Left and right speaker impedance different ●
54-6-2
54
Accessory noise generation source
Accessory Noise Symptoms
Alternator Whistling High pitch sound when accelerator pedal suddenly depressed (Stops
soon after engine stopped)
Water temperature gauge Scratching Occurs when engine running (Continues for a while after engine stops)
Engine oil pressure switch Rattling Depends on engine speed (Does not occur during idling)
Fuel gauge unit Scratching Occurs when engine suddenly revved, while running on rough roads, or
starter switch turned ON
Flasher unit Banging When turn signal blinks
Horn Hissing Occurs when horn button pressed or released
Wiper motor Whining Depends on windshield wiper speed
Washer motor Whining When windshield washer operates
cardiagn.com
Symptoms Horn
Remarks
Sound quality poor

Continuous sound
Small sound
No Sound
Possible causes
Connector connection faulty, harness broken, grounding faulty ●
Fuse blown ●
Horn switch faulty ● ●
Horn faulty ● ● ●
Horn stay warped ● ●
Battery voltage insufficient ● ●
Air leaking from air system ● ● ●
54-6-3
601 SWITCH
cardiagn.com
12887
1 Combination switch
2 Cold start switch
3 Van body dome light switch
4 Rheostat switch
1
Inspection of combination switch
• Operate combination switch 1.
• Check for continuity between connector terminals, referring to the
connector connection table.
There is continuity between terminals ● and ● in the table.
• If any fault is found, replace combination switch 1.
3 2 1 3 2 1
8 7 6 5 4 9 8 7 6 5 4
13 12 11 10 9 15 14 13 12 11 10
AQ13A AQ15A
12888
54-6-4
54
AQ15A Connector connection table
1 2 3 5 6 7 8 9 I Body
ground
Lighting switch OFF
I ● ●
II ● ● ●
Dimmer switch Main
←→
● ●
● ●
● ●
Dimmer ● ●
←→
● ●
● ●
Passing ● ●
Turn signal switch LH ● ●
N (neutral)
RH ● ●
Horn switch OFF
cardiagn.com
ON ● ●
AQ13A Connector Connection Table
1 4 5 6 7 8 9 F G H I
Wiper switch OFF
INT (intermittent) ● ●
LO (LOW) ● ●
HI (HIGH) ● ● ●
WASH (washer) ● ●
Exhaust OFF
brake switch ON ● ●
< Manual
transmission >
Hazard switch OFF

ON ● ● ● ●
54-6-5
601 SWITCH
2 Inspection of cold start switch
1 5 2 4 7 LED (Operation
indication light) 3
ON ● ● ● ●
OFF ● ●

14220
3
• If any fault is found, replace cold start switch 2.
Inspection of van body dome light switch

1 5 7 LED (Operation
indication light)
3
ON ● ● ● ●
cardiagn.com
OFF

14220 • If any fault is found, replace van body dome light switch 3.
4 Inspection of rheostat switch

• Rheostat switch 4 contains a control circuit, because of this it is
difficult to inspect rheostat switch 4 independently, therefore you
should inspect the rheostat switch indirectly, by inspecting the system
harness and the related parts.
• If no fault is found in the related parts but the system is faulty, replace
rheostat switch 4.
54-6-6
54
MEMO
cardiagn.com
54-6-7
604 RELAY AND CONTROL UNIT
cardiagn.com
*
12889
1 Wiper relay (LOW) 11 Exhaust brake cut relay 17 Pre-stroke control unit
2 Wiper relay (HIGH) < Manual transmission > 18 Pre-stroke cut relay
3 Engine stop relay 12 Parking brake relay
4 Headlamp relay (LOW) < Full air brake > * : Box under bed
5 Headlamp relay (HIGH) 13 Safety relay (Behind driver’s seat)
6 Stop lamp relay 14 Transmission neutral relay
7 Turn signal lamp relay < Manual transmission >
8 Tail lamp relay 15 Fan motor relay
9 Flasher unit < Automatic transmission >
10 Multipurpose timing control unit 16 Van body dome light relay
54-6-8
54
123N
Inspection of relay (Open type 5-pin)
6 2 1 3 4
1 2 3 4 6
ë ê No current ● ●
● ●
Current ● ●
ê ë
02233 ● ● : There is continuity between terminals ● and ●.

ê ë : Indicates that 12 volts DC is applied to the line between the
terminals.
45
• If any fault is found, replace the relay.

cardiagn.com
1 2 3 4
421 3 No current
Current
●
●
●
●
êë
ê ë

07141 ê ë : Indicates that 12 volts DC is applied to the line between the
terminals.
678 Inspection of relay (Open type 3-pin)

1 2 3
No current ● ●
● ●
ê ë
Current
ë ê

02231 ê ë : Indicates that 12 volts DC is applied to the line between the
terminals.
54-6-9
604 RELAY AND CONTROL UNIT
9FM Inspection of control unit
Since it is difficult to check each unit separately, judge the soundness of
each unit indirectly by checking switches, harnesses, and related parts in
G
the system.
Inspection of relay (Close type 4-pin)

1 2 3 4
No current ● ●
● ●
ëê Current -----
ê ë

terminals.
: Indicates that the continuity between the terminals is lost.
cardiagn.com
-----
HI Inspection of relay (Close type 4-pin)

1 2 3 4
No current ● ●
● ●
Current -----
ëê
ê ë

terminals.
----- : Indicates that the continuity between the terminals is lost.
JKL

1 2 3 4
421 3 No current ● ●
ê ë Current ● ●
ê ë

07142
terminals.
54-6-10
606 WARNING BUZZER 54
1 Warning buzzer
2 Meter warning buzzer
(Overrunning buzzer)
< 10-speed transmission >
Õ 401
cardiagn.com
< Rear of meter cluster >
12890
1
Inspection of warning buzzer
• Make sure that warning buzzer 1 sounds when you apply 12 volts DC
between terminals 1 2and .
• If any fault is found, replace warning buzzer 1.
1
2
11712
54-6-11
610 CIGARETTE LIGHTER CIRCUIT
Relay and fuse box
a
Cigarette lighter
2
Cab ground
cardiagn.com
10469
a 2
12891
1 Cigarette lighter
Service standards
1 Cigarette lighter plug return time 15±5 seconds — Replace
54-6-12
54
A B
1
Inspection of cigarette lighter
Carry out the following inspection. If any fault is found, replace cigarette
lighter 1 :
• Make sure that there is continuity between heater element A and body
B.
11737
• Make sure that plug C returns to its original position quickly when it is
pushed in.
C
cardiagn.com
11738
• Turn the starter switch to ACC or ON.

• Push plug C into the socket of the vehicle.
• Measure the time required for pushed-in plug C to return to its original
position.
• Make sure that heater element A is glowing.
54-6-13
612 AUDIO CIRCUIT
1
Relay and fuse box
To tail lamp relay

(Illumination)
b a
Radio connector
cardiagn.com
To clearance lamp,
LH
Cab ground To cab and

e
spot lamp
Cab
Roof
c
2
Speaker, RH
Speaker, LH
3
f d
10470
54-6-14
54
1 a
d
*
b
2
cardiagn.com
f
12892
1 Relay and fuse box Õ 104 *: Antenna cable

2 Speaker, RH
3 Speaker, LH
54-6-15
614 WIPER AND WASHER CIRCUIT
3 4
Relay and fuse box Combination switch
2 1 Wiper and washer switch

Wiper relay Wiper relay
(HIGH) (LOW)
c a b
d
cardiagn.com
To warning
buzzer
Cab
e
Front panel
Cab ground
Multipurpose Diode unit Washer

timing control unit motor
6
8 7
Wiper motor
5
10489
54-6-16
54
a 2 3
b c
d
4
cardiagn.com
e
6
8
12893
1 Wiper relay (LOW) Õ 604 5 Wiper motor

2 Wiper relay (HIGH) Õ 604 6 Diode unit
3 Relay and fuse box Õ 104 7 Washer motor
4 Combination switch Õ 601 8 Multipurpose timing control unit Õ 604
54-6-17
614 WIPER AND WASHER CIRCUIT
5
Inspection of wiper motor
• Connect wiper motor 5 as illustrated.
A : Switch
B • Carry out the following inspection. If any fault is found, replace wiper
+5° motor 5. ^ Gr 42
15° -10°
(1) Inspection of motor operation
3 2 1
6 5 4 • Make sure that wiper motor 5 turns at high speed when you turn
switch A to HIGH.
• Make sure that wiper motor 5 turns at low speed when you turn switch
A to LOW.
(2) Inspection of automatic stopping position
• Turn switch A to LOW to turn wiper motor 5 at low speed.
• When crank arm B is at any position other than the automatic
stopping position (other than the illustrated angle), turn switch A to
OFF.
ê
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12 volts DC • Make sure that crank arm B stops at the automatic stopping posi-
ë
tion (within the illustrated angle).
7
A 12036
Inspection of washer motor

• Apply 12 volts DC between terminals 1and 2and make sure that
washer motor 7 operates.
• If washer motor 7 does not operate, replace it. ^ Gr 42
00544
54-6-18
54
MEMO
cardiagn.com
54-6-19
616 HORN CIRCUIT
Relay and fuse box

a
c
3
1
Air horn
Combination switch
Headlamp Cab Horn switch

b
2
cardiagn.com
10471
1 a
12894

2 Combination switch Õ 601
3 Air horn
54-6-20
54
Service standards
3 Minimum operating voltage of air horn valve 10 V or less — Replace
ë ê
2 1
14318
Operating pressure of horn 195 to 980 kPa — Replace
{28 to 142 lbf/in2, 2 to 10 kgf/cm2}
A
3
Inspection of air horn
Carry out the following inspection. If any fault is found, replace air horn 3.
(1) Minimum operating voltage of air horn valve
cardiagn.com
• Apply air pressure A of 785 kPa {115 lbf/in2, 8 kgf/cm2} to air horn 3.
• Apply voltage between terminals and1 2
starting from 0 volt DC
gradually.
• Measure the voltage when air horn 3 sounds.
2 1
(2) Operating pressure of horn
13143
1 2
ë ê
• Apply 12 volts DC between terminals and .
• Apply air pressure A to air horn 3 starting from 0 kPa {0 lbf/in2, 0 kgf/
cm2} gradually.
• Measure air pressure A when air horn 3 sounds.
54-6-21
618 HEATER CIRCUIT
Relay and fuse box

c
e
Air-conditioner relay
2 connector
b Heater control assembly
Blower motor
Air-conditioner
3 switch connector
a
Heater switch
(Fan switch)
Blower resistor
cardiagn.com
4 1
To tail lamp relay
Illumination lamp
To meter cluster
To rheostat switch
e
Fin thermostat
plug connector
Cab ground
Condenser fan
relay connector
Cab
e d
Chassis
f f g
Condenser Dual Magnetic
LO : LOW fan motor pressure clutch plug
ML : MIDDLE LOW connector switch connector
MH : MIDDLE HIGH Chassis connector
HI : HIGH ground
10480
54-6-22
54
2 b c
1 a
3
e 4
cardiagn.com
f
12895
1 Heater control assembly

3 Blower motor
4 Blower resistor
Service standards
4 Resistance of 3–4 0.88 — Replace
blower resistor 3 2 1 2–3 0.27
6 5 4
14364 1–4 1.78
54-6-23
618 HEATER CIRCUIT
1
Inspection of heater control assembly
Inspection of blower switch A

OFF
HI
AL6A AL2A
MH 1 3 2 5 6 4 1 2
A LO ML OFF
3 2 1 1 LOW ● ● ●
6 5 4 2
MIDDLE LOW ● ● ●
MIDDLE HIGH ● ● ●
HIGH ● ● ●
11919
C L ML MH H E ILL
3
• If any fault is found, replace heater control assembly 1.
cardiagn.com
Inspection of blower motor
3
• Make sure that blower motor 3 operates when 12 volts DC is applied
1
between terminals 1 and .2
2 • If any fault is found, replace blower motor 3.
12038
4 Inspection of blower resister

• Measure resistance between terminals and 3 4
(MIDDLE LOW), 2
and 4 (MIDDLE HIGH) and and 1 (LOW).4
• If the measured value deviates from the standard value, replace
blower resistor 4.
3 2 1
6 5 4
14302
54-6-24
54
7 CHASSIS ELECTRICS
701 MAGNETIC VALVE.............................................................. 54-7-2
710 EXHAUST BRAKE CIRCUIT ............................................... 54-7-4

< Manual Transmission >
718 AIR DRYER CIRCUIT .......................................................... 54-7-8
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54-7-1
701 MAGNETIC VALVE
1 3-way magnetic valve
12896
cardiagn.com
Service standards
1 Minimum operating voltage of 3-way magnetic valve 10 V or less — Replace
2 1
14318
1
Inspection of 3-way magnetic valve
Carry out the following inspection. If any fault is found, replace 3-way
magnetic valve 1 :
A
2 1 Air circuit table (There is air continuity between terminals ● and ●.)
Input Output Unused Exhaust

port B port D A port C
D ON ● ●
OFF ● ●
C B 00148
(1) Operation inspection
• Apply voltage between terminals 1 2
and , increasing gradually
from 0 volt.
• Measure voltage (minimum operating voltage) when magnetic valve
1 starts operating. (You can tell if the magnetic valves are ON or
OFF by listening for an operating sound.)
54-7-2
54
(2) Airtightness inspection
• When magnetic valve is ON :
• Close output port D.
• Apply 12 volts DC between terminals 1 and .2
• Make sure that there is no air leaking from exhaust port C when
air pressure (295 to 980 kPa {43 to 140 lbf/in2, 3 to 10 kgf/cm2}) is
applied to input port B.
• When magnetic valve is OFF :
• Make sure that there is no air leaking from exhaust port C or
output port D when air pressure (295 to 980 kPa {43 to 140 lbf/in2,
3 to 10 kgf/cm2}) is applied to input port B.
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54-7-3
710 EXHAUST BRAKE CIRCUIT < Manual Transmission >
2
Relay and fuse box
Transmission power 3
take-off relay Meter cluster
connector
< with transmission To cold
power take-off > start switch
d To transmission
b e power take-off
switch connector
< with transmission
power take-off >
To meter
cluster
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Cab Chassis
To cold start Transmission
switch neutral switch
To backup To diode unit 9

lamp switch < with transmission
power take-off > f
To cigarette
lighter
Cab ground Chassis

Diode 8 ground
unit
Accelerator Exhaust brake
switch
7 Exhaust brake 3-way
cut relay
5 magnetic valve
6
Exhaust brake
switch
< with transmission < without
power take-off > transmission Combination switch
power take-off > 1
Clutch switch
4
10476
54-7-4
54
1
b 2
a c
e d
3
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f
6 7
9
12897
1 Combination switch Õ 601 6 Exhaust brake cut relay Õ 604

2 Relay and fuse box Õ 104 7 Diode unit
3 Meter cluster Õ 401 8 Exhaust brake 3-way magnetic valve Õ 701
4 Clutch switch 9 Transmission neutral switch Õ 802
5 Accelerator switch
54-7-5
710 EXHAUST BRAKE CIRCUIT < Manual Transmission >
3 +1.5 mm {0.12+0.059 in.}

0 0
4
Inspection of clutch switch
1 2
OFF ON OFF
ON ● ●
• If any fault is found, replace clutch switch 4. ^ Gr 21
02548
11.5
+1.5
0
mm {0.45
+0.059
0
in.}
5 Inspection of accelerator switch
2 1
1 2
OFF
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OFF ON ON ● ●
• If any fault is found, replace accelerator switch 5. ^ Gr 13
11366
54-7-6
54
MEMO
cardiagn.com
54-7-7
718 AIR DRYER CIRCUIT
Relay and fuse box

2
Air dryer
Cab Chassis
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10473
54-7-8
54
a 1
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12898

2 Air dryer
54-7-9
718 AIR DRYER CIRCUIT
Service standards
2 Operating temperature of complete thermostat 7±4.0°C {45±7.2°F} — Replace
2
Air dryer
(1) Inspection of complete thermostat

A Carry out the following inspection. If any fault is found, replace the
complete thermostat. ^ Gr 35
1
• Make sure that there is no continuity between terminals and at 2
1 2
room temperature (20°C {68°F}).
• Cool thermostat A in a refrigerator, etc.
Measure the temperature when there is continuity between
terminals 1and 2
, and make sure that the measured value
cardiagn.com
09136
(2) Inspection of heater
1 • Make sure that there is continuity between terminals 1 and 2.

• If any fault is found, replace the heater. ^ Gr 35
2
09137
54-7-10
54
8 ENGINE AND TRANSMISSION

ELECTRICS
801 ENGINE ELECTRICS ........................................................... 54-8-2
802 TRANSMISSION ELECTRICS

< Manual Transmission (5-speed, 6-speed Transmission) > ........... 54-8-6
< Manual Transmission (10-speed Transmission) > ......................... 54-8-8
< Automatic Transmission > ............................................................ 54-8-10
850 TRANSMISSION POWER TAKE-OFF CIRCUIT
cardiagn.com
< Option > ........................................................................................... .54-8-12
54-8-1
801 ENGINE ELECTRICS
cardiagn.com
4
12 11 10
12899
54-8-2
54
1 Water temperature sensor (Connects to 8 Overheating switch
pre-stroke control unit) ^ Gr 13 9 Water temperature sensor (Connects to
2 Glow plug Õ 220 water temperature gauge and multipurpose
3 Pre-stroke actuator ^ Gr 13 timing control unit)
4 Control rod position sensor ^ Gr 13 10 Alternator Õ 106
5 Engine revolution sensor 11 Starter Õ 201
6 Engine oil pressure switch 12 Starter relay Õ 210
7 Engine oil bypass alarm switch
Service standards
5 Resistance of engine revolution sensor 1–2 2.3±0.2 k — Replace
(At room temperature 25°C {77°F})
3 2 1
14366
6 Operating pressure of engine oil pressure switch 49±9.8 kPa — Replace
{7.1±1.4 lbf/in2, 0.5±0.1 kgf/cm2}
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7 Operating pressure of engine oil bypass alarm 200 +500 kPa — Replace
+7.1
switch {27 0 lbf/in2, 1.9 +0.5 2
0 kgf/cm }
8 Operating When temperature increases 110±2°C {230±3.6°F} — Replace

temperature (ON→OFF)
of overheating When temperature decreases 99.5 to 112.5°C {211 to 235°F} —
switch (OFF→ON)
9 Resistance of 1
– (Body) 50°C {122°F} (153.9 ) — Replace
water tempe- (Water temperature 80°C {176°F} 51.9 +4.9
–4.4
rature sensor gauge side)
2 1 2 – (Body) 100°C {212°F}
20°C {68°F}
27.4 +1.9
–1.2
3.25±0.33 k
(Multipurpose timing 60°C {140°F} (620 )
control unit side)
Body 14321 80°C {176°F} (300 )
The values in ( ) are reference values.
5◆ Service procedure
Inspection of engine revolution sensor
• Measure the resistance between terminals and . 1 2
3 2 1 engine revolution sensor 5. ^ Gr 13
11658
54-8-3
801 ENGINE ELECTRICS
B 6 Inspection of engine oil pressure switch

Carry out the following inspection. If any fault is found, replace engine oil
pressure switch 6. ^ Gr 12
• Make sure that there is continuity between terminals 1 and2 (Body)
A when air pressure A is not applied to engine oil pressure switch 6.
• Apply air pressure A to engine oil pressure switch 6 gradually starting
from 0 kpa {0 lbf/in2, 0 kgf/cm2}.
Measure the air pressure when continuity is lost between terminals 1
1
11311
and 2 (body), and make sure that the measured value conforms to
the standard value.
7
Inspection of engine oil bypass alarm switch

B Carry out the following inspection. If any fault is found, replace engine oil
bypass alarm switch 7. ^ Gr 12
A
• Make sure that there is no continuity between terminals 1 and 2
(Body) when air pressure A is not applied to engine oil bypass alarm
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switch 7.
• Apply air pressure A to engine oil bypass alarm switch 7 gradually
1
starting from 0 kpa {0 lbf/in2, 0 kgf/cm2}.
11659
nals 1 and 2 (Body), and make sure that the measured valve
8
Inspection of overheating switch

Carry out the following inspection. If any fault is found, replace overheat-
ing switch 8. ^ Gr 14
• Make sure that there is no continuity between terminals 1 and 2
(Body) at room temperature (20°C {68°F}).
• Place overheating switch 8 in a container filled with engine oil and
raise the oil temperature while stirring the oil.
12037
1 2
and (Body), and make sure that the measured value conforms to
the standard value.
• Lower the oil temperature and measure the temperature when
1 2
continuity is lost between terminals and (Body), and make sure that
9
the measured value conforms to the standard value.
Inspection of water temperature sensor

• Place water temperature sensor 9 in engine oil in a container.
• Raise the oil temperature to the specified values and stir the oil.
• Measure the resistance between terminal 1 and the body, and
terminal 2 and the body.
Terminal 1 : Water temperature gauge connection
Terminal 2 : Multipurpose timing control unit connection
• If the measured value deviates from the standard value, replace water
temperature sensor 9. ^ Gr 14
07195
54-8-4
54
MEMO
cardiagn.com
54-8-5
802 TRANSMISSION ELECTRICS < Manual Transmission (5-speed, 6-speed Transmission) >
cardiagn.com
13095
1 Backup lamp switch

2 Vehicle speed sensor
Service standards
2 Pulse output voltage of 1–2 Low pulse 1.5 V or less — Replace
vehicle speed sensor
(8 pulses)
ê ë
3 2 1 Tester High pulse 12 V– (0.5 V or less) —
14367
54-8-6
54
1
Inspection of backup lamp switch
2 1
1 2
OFF
OFF ON
ON ● ●
+0.024
28+0.6 mm {1.1 –0.012 in.}
• If any fault is found, replace backup lamp switch 1. ^ Gr 22
2
–0.3
11619
Inspection of vehicle speed sensor

1 3
ê ë
D 3 2 1 B
• Apply 12 volts DC between terminals and , and rotate shaft A of
C vehicle speed sensor 2 slowly.
• At this state, measure the maximum voltage (High pulse voltage B)
and the minimum voltage (Low pulse voltage C) generated between
1 2
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terminals and .
D : Tester
A vehicle speed sensor 2. ^ Gr 22
11534
24
+0.5
0
mm {0.94
+0.02
0
in.}
3 Inspection of transmission neutral switch
1 2
2 1
ON OFF OFF
ON ● ●
11370
• If any fault is found, replace transmission neutral switch 3. ^ Gr 22
54-8-7
802 TRANSMISSION ELECTRICS < Manual Transmission (10-speed Transmission) >
cardiagn.com
12900
1 Transmission neutral switch 4 Transmission HIGH/LOW detection switch (HIGH)

2 Backup lamp switch 5 Transmission HIGH/LOW detection switch (LOW)
Service standards
3 Pulse output voltage of 1–2 Low pulse 1.5 V or less — Replace
vehicle speed sensor
(8 pulses)
ê ë
High pulse 12 V–(0.5 V or less) —
3 2 1 Tester
14367
54-8-8
54
25.5±0.3 mm {1±0.012 in.}

1
Inspection of transmission neutral switch
1 2
OFF
ON OFF
ON ● ●
2 1
• If any fault is found, replace transmission neutral switch 1. ^ Gr 22
2
11732
Inspection of backup lamp switch
2 1
1 2
OFF
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OFF ON
ON ● ●
28+0.6 mm {1.1
+0.024
in.}
• If any fault is found, replace backup lamp switch 2. ^ Gr 22
3
–0.3 –0.012
11619

1 3
ê ë
D 3 2 1 B
terminals 1 2
and .
D : Tester
A vehicle speed sensor 3. ^ Gr 22
45
11534
25.5±0.3 mm {1±0.012 in.} Inspection of transmission HIGH/LOW detection switch

1 2
OFF
ON OFF
ON ● ●
2 1
11733
• If any fault is found, replace transmission HIGH/LOW detection
switches 4, 5. ^ Gr 22
54-8-9
802 TRANSMISSION ELECTRICS < Automatic Transmission >
cardiagn.com
4
12901
1 Automatic transmission fluid temperature switch

2 Backup lamp switch ^ Gr 23
4 Automatic transmission neutral switch ^ Gr 23
Service standards
1 Operating When increases (OFF→ON) 140±3°C {284±5.4°F} — Replace
temperature
of automatic
transmission When decreases (ON→OFF) 133°C {271°F} MIN
fluid tempera-
ture switch
3 Output voltage of vehicle 1–2 Low pulse 1.5 V or less — Replace

speed sensor (8 pulses)
ê ë
3 2 1 Tester
High pulse 12 V–(0.5 V or less) —
14367
54-8-10
54
140±3°C
{284±5.4°F}
1
Inspection of automatic transmission fluid temperature
switch
ON
OFF Carry out the following inspection. If any fault is found, replace automatic
133°C {271°F} MIN transmission fluid temperature switch 1.
• Make sure that there is no continuity between terminals 1 and 2 at
room temperature (20±5°C {68±9°F}).
2 1 • Place automatic transmission fluid temperature switch 1 in a container
filled with engine oil and raise the oil temperature while stirring the oil.
07807
1 2
and , and make sure that the measured value conforms to the
standard value.
• Lower the oil temperature and measure the temperature when conti-
nuity is lost between terminals 1 2
and , and make sure that the
3
measured value conforms to the standard value.
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1 3
ê ë
D 3 2 1 B
terminals 1 and .2
D : Tester
vehicle speed sensor 3. ^ Gr 23
A 11534
54-8-11
850 TRANSMISSION POWER TAKE-OFF CIRCUIT < Option >
2
Relay and fuse box
Transmission Transmission power

take-off switch
1
power take-
off relay connector Meter cluster
connector
d
e
b c a
To warning
buzzer
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Transmission power
take-off control switch
h
connector
To backup
lamp switch
Transmission power
take-off 3-way magnetic
valve connector
To clutch switch
f
j
To cold start switch
Chassis
ground
g Cab Chassis
Cab ground
Clutch switch Diode unit Diode unit

connector
3 3
10481
54-8-12
54
b c
1
a 2 e
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g
3
h j
14343

3 Diode unit
54-8-13
54
9 OTHERS
910 MULTIPURPOSE TIMING CONTROL UNIT CIRCUIT ........ 54-9-6
cardiagn.com
54-9-1
Multipurpose Timing Control Unit
• The multipurpose timing control unit controls the following functions:
Intermittent wiper operating function ^ Gr 42
Wiper activation function (Even if the wiper switch is OFF, this function ^ Gr 42
automatically activates the wiper when the window washer works.
Preheating function Õ P 54-2-10
Starter continuity interruption function Õ P54-2-4
Water level warning function ^ Gr 14
• Sensors and switches are fitted to these systems as information sources for the multipurpose timing control unit.
• Using the information provided, circuits in the multipurpose timing control unit control the functions mentioned above.
● Internal structure of multipurpose timing control unit
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12 volts DC Power circuit Reset circuit
Input interface circuit Output interface circuit

RES
Output signal
Input signal
Analog/ CPU
Digital
conversion
Information
ROM
signal
• The internal structure mainly consists of the input interface circuit, *1CPU, *2ROM, and the output interface circuit.
*1CPU : Central Processing Unit. Compares the input information with information stored in the memory to output
commands.
*2ROM : Read Only Memory. Stores fixed data and programs that are not erased even after the power is turned off.
• Input signals are transmitted from information sources, such as sensors and switches, to the input interface circuit.
• The input interface circuit converts these input signals from analog signals to digital signals. This enables the CPU to
calculate data and transmits them to the CPU as information signals.
• The CPU compares the information signals with the data in the ROM, calculates the signals, and sends them to the
output interface circuit.
• The output interface circuit issues commands to systems, based on the above comparison and calculated results, as
output signals.
• Sequential execution of the above processes allows optimum control over functions.
54-9-2
54
Input signals Multipurpose timing control unit Output signals
Wiper and washer switch (WASH) → Wiper activation function (Even
if the wiper switch is OFF, this
function automatically activates
the wiper when the window
washer works)
Wiper and washer switch (INT) → →

Intermittent wiper operating → Wiper relay (LOW)
function
Wiper motor (Cam signal) →
Water temperature sensor →

→ Engine preheating indicator lamp
Starter switch (START signal) → Engine preheating function
→ Glow relay
Alternator (Charge signal) →
→ Starter continuity interruption

→ Safety relay
→ function
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Water level sensor → Water level warning function → Water level warning lamp
Terminal Connecting Terminal Connecting

No. destinations No. destinations
1 Glow relay 9 Wiper relay (LOW)

2 Starter switch (ON power supply) 10 Engine preheating indicator lamp
3 Water temperature sensor 11 Safety relay
4 — 12 Water level warning lamp
5 Ground 13 Ground
6 Water level sensor 14 Alternator terminal L (Charge signal)
V
8 7 6 5 4 3 2 1 7 Wiper switch (Intermittent) 15 Starter switch (Start signal)
16 15 14 13 12 11 10 9 8 Washer switch 16 —
12582
54-9-3
12 volts DC
12 volts DC
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12143
54-9-4
54
Main functions of sensors Information signals
1 Starter switch Detection of START position Ì : Start signal
2 Safety relay Ë : Safety relay activation signal
3 Starter relay
4 Meter cluster
5 Water level warning lamp Í: Ñ light-up signal
6 Engine preheating indicator lamp G : _ light-up signal
7 Glow relay H : Glow relay activation signal
8 Glow plug
9 Alternator Output of alternator charge signal J : Alternator charge signal
10 Water level sensor Detection of engine coolant level K : Engine coolant level signal
11 Water temperature sensor Detection of engine coolant temperature L : Engine coolant temperature signal
12 Cold start switch
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14 Combination switch
15 Wiper and washer switch Ê : Intermittent wiper switch signal
16 Diode unit
17 Washer motor Â : Washer switch signal
18 Wiper motor
20 Wiper relay (LOW) Intermittent wiper operation È : Wiper relay activation signal
21 Wiper relay (HIGH)
22 Fuse
23 Warning buzzer
54-9-5
910 MULTIPURPOSE TIMING CONTROL UNIT CIRCUIT
Relay and fuse box
HIGH Wiper relay LOW
Starter switch
To high-current
fuse box
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Multi-
purpose
timing
control
unit
< Automatic
transmission >
To parking brake Cab
switch Front panel
To transmission
To warning neutral relay
< Manual
buzzer
transmission >
Cab ground
To transmission
neutral relay switch
< Automatic
transmission >
To backup To relay
lamp and fuse Cold start switch
switch box
Safety relay
Wiper motor
54-9-6
54
Meter cluster
To high-current
fuse box
Alternator Glow relay
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Glow plug
To meter cluster
(Cold start)
To water
temperature
gauge
Chassis ground
Cab Chassis
Cab ground
Washer Diode Water

Water
motor unit temperature
level
Wiper and washer switch sensor
sensor
Combination switch
10490
54-9-7

1996-2001 Fuso - Electrical-Sm78

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1996-2001 Fuso - Electrical-Sm78

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cardiagn.

Pub No. TWME9503-54

1 POWER, CHARGING AND GROUND

SPECIFICATIONS .......................................................................... 54-1-2

STRUCTURE AND OPERATION ................................................... 54-1-3

TROUBLESHOOTING .................................................................... 54-1-7

10 0 INSPECTION AND ADJUSTMENT MOUNTED IN VEHICLE

101 BATTERY ........................................................................... 54-1-10

10 4 FUSE ................................................................................. 54-1-14

10 6 ALTERNATOR ................................................................... 54-1-16

110 POWER CIRCUIT .............................................................. 54-1-22

115 RESERVE POWER CIRCUIT ............................................ 54-1-32

125 BATTERY CHARGING CIRCUIT ....................................... 54-1-34

130 GROUND ........................................................................... 54-1-36

1 Rectifier 7 Front bracket B: Terminal B

A : To parking brake warning lamp

At engine standstill (before starting)

A: To parking brake warning lamp

When V-belt snaps while driving

Alternator is normal but battery overdischarged

Warning buzzer does not stop sounding

Warning buzzer does not stop sounding

although parking brake lever is pulled

although hand control valve is pulled

• Turn switch C ON to supply battery voltage to terminal B on the

• Connect the meters to the alternator as illustrated.

• Turn switch C ON and make sure that voltmeter V indicates 0 volt.

(1) Visual inspection

C • If bleed hole C of vent plug B is clogged, clean the hole.

(2) Inspection of fluid level

(3) Measurement of specific gravity

S20 {68} = St + 0.0007 (t–20 {68})

F Inspection of battery box

1 Main high-current fuse

Fuse Main load Capacity

High-current fuse box

Fuse Main load Capacity

Fuse Main load Capacity Fuse Main load Capacity

(1) Inspection of alternator performance (bench test)

• After adjustment, run alternator 5 for 30 minutes.

(2) Inspection of regulator (bench test)

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

(2) Continuity between lead wires and the core

Inspection of field coil

High-current fuse box

Relay and fuse box

Fuses B01 to B08

Stop lamp relay To stop lamp

To high-current fuse box

Tail lamp relay To meter cluster

Cab lamp Cab To automatic transmission

Fuses B10 to B24

To cab and spot lamp

To transmission power take-

To fin thermostat plug

Relay and fuse box

To parking brake switch

: Wheel parking brake < Full air brake >

Relay and fuse box

To backup lamp switch

Relay and fuse box

Wiper relay, LOW

To wiper motor To combination switch To multipurpose