9.

ELECTRIC WIRING

9. ELECTRIC WIRING
The electric components of the truck are wired through several types of wire harnesses and color
coded by circuit.
The wire harnesses are connected with connectors (2 types) or screw.

Table 9.1 Color symbols and examples

B Black R Red

G Green W White

L Blue Y Yellow

O Orange Lg Light green

Example: Yellow coating with a blue marking P Pink Sb Light blue Example: White coating without marking

Table 9.2 Connector symbol

Connection type Plug-in side Receptacle side Remarks

Housing The alphabetic letters means colors.

Plug-in type

(Table 9.1)

Plug

Screw type

The dotted lines in the circuit diagrams are given for optional equipment.

DANGER ! Use due caution when handling the battery unit.

1. Never short the circuit, spark, smoke or use fire near the battery unit. Since flammable gas
is always released from the battery, there is a danger of causing an explosion.
2. The battery electrolyte is dilute sulfuric acid. It will cause burns if it gets on the skin. If
electrolyte comes in contact with the skin, flush with water. It can cause blindness if it
gets into eyes. If electrolyte gets into your eyes, flush your eyes out with water and get to a
doctor.

- 111 -
9. ELECTRIC WIRING

REAR COMBINATION LAMP

HEAD LAMP

FRONT
COMBINATION
LAMP

Fig. 9.1 Lamp Installation Position

- 112 -
 9. ELECTRIC WIRING

■ Replacing light bulbs

12V - 55W (HALOGEN) SCREW
Remove the bulb by pushing in and then turning
to the left. REFLECTOR

Reinstall the bulb by pushing in and then turning BULB

to the right. GASKET

(1) Head light and work light

① Remove the screw securing the rim and housing
and remove the rim, lens and gasket.
② Remove the bulb from the reflector and install a LENS

new bulb. RIM

Fig. 9.2 Head Light (Work light)

1. Use caution not to get burnt because the surface of a bulb is hot soon after it is turned
off.
2. Use caution not to contaminate the bulb surface and reflector surface.

③ With the gasket, install the lens and reflector.

BULB
(BACK-UP)
12V - 10W
(2) Rear and front combination lamps
•
① Remove the screw and separate the lens from
•
the body.
② Remove the burned-out bulb and reinstall a new
one. •
③ Reassemble the lens and body with the screw. BULB
(BRAKE,
PARKING)
BULB 12V - 23W
(FLASHER) 12V - 8W
12V - 27W

Fig. 9.3 Rear Combination Lamp

BULB
(FLASHER)
12V - 27W

SCREW

BODY

BULB
(PARKING)
12V - 10W

Fig. 9.4 Front Combination Lamp

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9. ELECTRIC WIRING

■ Fuse box
The fuse box holds fuses which prevent the wire harnesses from burning due to overcurrent. The
fuses are installed for each circuit. The fuses have different capacities for different circuits. Use
caution when replacing the fuses.
When a spare fuse is used, add a fuse of the same capacity.

SPARE FUSE (15A)

SPARE FUSE (3A)

SPARE FUSE (7.5A)

FUSE PULLER

N
H

J E
K F
L G
M I

D C
B A

15A HEAD LAMP AND

POSITION LAMP
A E
7.5A STOP LAMP
F
7.5A HORN
B G
15A RWL (OPTION)
H
7.5A TURN SIGNAL
C I
3A TRANSMISSION
J
3A METER
K
7.5A BACK-UP LAMP
D L
3A ENGINE
M
7.5A INTERLOCK, OPTION
N

Fig. 9.5 Fuse Box

- 114 -
 to LIGHTING SWITCH
to F/R SWITCH

to KEY SWITCH

for OPTIONAL to HORN SWITCH

ELECTRICAL PARTS
to COMBINATION METER to HORN

to ORBITROL
Fig. 9.6 Wire Harness, Front Guard

to PARKING
BRAKE
SWITCH
- 115 -

to WIRE HARNESS,
OVERHEAD GUARD (LEFT)

to WIRE HARNESS,
to OVERHEAD GUARD
NEUTRAL (RIGHT)
SAFETY
RELAY

to TAIL LAMP RELAY

to HEAD LAMP RELAY

to ALARM BUZZER

to NEUTRAL RELAY
to C/V LIFT to C/V
LOCK INTERLOCK

9. ELECTRIC WIRING
to WIRE HARNESS, ENGINE
9. ELECTRIC WIRING

ELECTRIC to WIRE HARNESS, FRONT GUARD

CONTROL ONLY
to WIRE
HARNESS,
ECM

to BRAKE LAMP
SWITCH
to LEAD WIRE SIL
to OKM AUTOMATIC TRANSMISSION
TRUCKS ONLY
to F/R VALVE

to FUSE BOX

to DIODE

MANUAL TRANSMISSION
GROUND TRUCKS ONLY
to AUTO NON-ELECTRIC
CHOKE to BACK-UP LAMP SWITCH
CONTROL ONLY
RELAY to FUEL LEVEL
SENDER to METER to FUEL
CUT-OFF
VALVE

to NEUTRAL SWITCH

to STARTER NON-ELECTRIC
DIODE CONTROL ONLY
to WATER
TEMP. to
to BATTERY SENDER DISTRIBUTOR

to FLASHER
UNIT to OIL PRESSURE
to POTENTIOMETER
to STARTER SWITCH
RELAY

to ALTERNATOR

to BACK-UP BUZZER

to REAR
COMBINATION LAMP

to SEAT SWITCH
to REAR
WORK LIGHT

FUSE BOX

Fig. 9.7 Wire Harness, Engine (Engine-powered trucks with K21 or K25)

- 116 -
 9. ELECTRIC WIRING

to WIRE HARNESS, FRONT GUARD

to BRAKE
LAMP
to LEAD WIRE SIL SWITCH

to OKM AUTOMATIC TRANSMISSION

TRUCKS ONLY
to F/R VALVE

to FUSE BOX

to DIODE
MANUAL TRANSMISSION
GROUND TRUCKS ONLY
to RESISTOR
to BACK-UP LAMP SWITCH
to FUEL LEVEL to OIL
to RESISTOR PRESSURE
SENDER
to METER SWITCH

to
DIODE
to STARTER
to WATER to NEUTRAL
TEMP. SWITCH
to BATTERY SENDER
to GLOW
to GLOW PLUG
RELAY
to FUEL CUT-
OFF VALVE
to FLASHER
UNIT to STEERING
to TIMER to ALTERNATOR
QOS to STARTER POTENTIOMETER
RELAY
to WATER TEMP.
SENSOR
FUSE BOX to SEDIMENTER

to BACK-UP BUZZER

to REAR
COMBINATION
LAMP
to SEAT SWITCH
to REAR
WORK LIGHT

Fig. 9.8 Wire Harness, Engine (Engine-powered trucks with TD27 or QD32)

- 117 -
9. ELECTRIC WIRING

BACK-UP LAMP RELAY

(OPTION)

STARTER RELAY
FUSIBLE LINK

BACK-UP BUZZER BATTERY

FUSE BOX
FLASHER UNIT

View A

AUTO CHOKE RELAY

NEUTRAL SAFETY RELAY

NEUTRAL RELAY
HORN
TAIL LAMP RELAY
HEAD LAMP RELAY

View B

Fig. 9.9 Locations of Electrical Parts (Engine-powered trucks with K21 or K25)

- 118 -
 9. ELECTRIC WIRING

BACK-UP LAMP RELAY

(OPTION)

TIMER

STARTER RELAY
BATTERY
FUSIBLE LINK
FUSE BOX
DETECTOR
FLASHER UNIT

GLOW PLUG RELAY

BACK-UP BUZZER
NEUTRAL SAFETY
RELAY

View A
NEUTRAL RELAY
HORN
TAIL LAMP RELAY
HEAD LAMP RELAY
View B

Fig. 9.10 Locations of Electrical Parts (Engine-powered trucks with TD27 or QD32)

- 119 -
9. ELECTRIC WIRING

COMBINATION
METER

SEAT

ALARM
2P

SEAT
SWITCH

2P

2P

2P

2P
PARKING
SWITCH

6P

6P

Br

TIMER L

10P

View B

Fig. 9.11 Locations of Electrical Parts (for interlock)

- 120 -
 9. ELECTRIC WIRING

METER PANEL
FUEL LEVEL WATER TEMP.
CPU HOUR METER METER METER

TOR‑CON ONLY
HEAD FRONT COMBINATION for STD & EXB,C C A J
FRONT COMBINATION
HEAD
LAMP(L.H) PARKING BRAKE SW LAMP(R.H)
F KEY SWITCH LITING SWITCH TURN SIGNAL SWITCH for STD & EXE,N,A
ORBIT ROL N OFF OFF R & SIL &OKM

5V
T N

DC/DC
R

COM
H L

/
ON

Ra

BATT. +

NO
HORN

GND
3BY

2LR

Br

BR CH

LB GL

YL RA

RY
RY

GW

GW
B
G

G
B

B
B
G

RB
BrR

BrB

BrW

B
LY

WB

WG

RG

RB
L

B
OPTION OPTION

Sb
P

GY

LW
2B
LW

B
B B B B
B B B B
G RW RW G
GW GR GL GW
RY RY RY RY

ALARM BUZZER
RB
5V LG
電源
回路

Ry1 PIC

2YL
LR

BrB

BrW

BrW
WL

Y
R

GW

GW
B

B
TOR‑CON ONLY

BrW
3BY
3BG

WBr

2YL

BrR

LY

RG
Sb

RY
2B
YR

OL
WL

Sb
2R

GO

LY
2L
LW

GR
GL

BR
YB

WB
WG

WR
YW
YG
GY
LG
GW

Y
P

Y
for EXB,C,K F/R
LIFT LOCK INTERLOCK VALVE
SOLENOID SOLENOID
TIMER UNIT NEUTRAL SAFTY HEAD LAMP TAIL LAMP NEUTRAL RELAY

BrW
3BY
3BG

2YL

BrR
CONTROL VALVE

LY

RG
2B
YR

RL
2R

2L
LW

GR
GL

BR
YB

WR
YW
YG
GY
Lg
GW
F R

Y
W
1 7 8 9 6 3 5 2 RELAY RELAY RELAY
B for STD & EXE,N,A & SIL
BrR
LW

WR

WL

LB

RW
L
B

W
W
B
B
BrR BrR BrR BrR
RW RW RW Lg
WR WR WR GW

RB
LW LW LW LW
L L L L

OL
G
G
V
G G G G
WL WL WL V

OL
G
G
B B B B
CLUTCH ONLY

for STD & EXE,N,A & SIL B WR

Y
FLASHER UNIT
DIODE
YW
NEUTRAL SW. (600V 3A×2)

YG WG
E B L

AIR CLEANER
WG
LG

LG
BR
2YL

3BY
3BL
B

WY
B

F.L.W. DISRIBUTER
0.85R SPARK PLUG STARTER
5BY 5BY
B B
WG 3BL C
3BG
3BG
3BY
3BY

OIL PRESS. SW
FUSE BOX
YB
HEAD & POSITION 2R 2R
STOP BrY BrY REGULATOR
5BY
HORN GY GY
5BY

3B E
RWL OPTION
3BY R(LEVEL) SEAT BELT RELAY
TURN WY
BR L(RELAY)
12V

Y T/M
/ YG YR
METER LY LY
BATTERY

SENSOR BACK RY Y
E/G
/ WG WG YL RADIATOR
INTERLOCK B LEVEL
2L 2L
SENSOR
‑
& OPTION

BrW

LY
B

W
LW LW
20B

3B W

W W W Br
R.W.L B B B
E/G for STD & EXB,C SEAT SW
EARTH
RL POTENTIOMETER for STD & EXE,N,A & SIL
WBr WBr
BACK LAMP RELAY B
GO GO GO
BW BW BW
2B

RL
RB
RL

Sb
Y

B
RW
LICENCE
LAMP
for RRE
2B

TURN (23W) GL G TURN (23W)

RW RW
TAIL (8W) RB RB TAIL (8W)
STOP (23W) B B STOP (23W)
RL RL
BACK (STD:10W) BACK(
(STD:10W)
)

REAR CONBINATION REAR CONBINATION

LAMP (L.H.) LAMP (R.H.)

Fig. 9.12 Wiring Diagram (Trucks with K21 or K25)

- 121 -
9. ELECTRIC WIRING

METER PANEL
FUEL LEVEL WATER TEMP.
CPU METER

TOR‑CON ONLY
HEAD FRONT COMBINATION FRONT COMBINATION
for STD & EXB,C HEAD
LAMP(L.H) PARKING BRAKE SW
F KEY SWITCH TURN SIGNAL SWITCH for STD & EXE,N,A
ORBIT ROL N OFF OFF R & SIL &OKM

5V
T N
R ↑

/
ON H L

COM
2

Y
Y

DC/DC

WB
RW
RW
WB
PTG PTS PT+ OV PV N IG2 VF ST VR Ra B S HO‑ HO+ EL LT LH TB TL TR

NO
HORN

B
G
R

B
G
Y
V
G
B

B
BATT. +
GND

Lg
Br
GB
GR
GL

RY
GW
YR
YR
OL
WL
Sb
GW

LY
3BY
3BG
2LR

WBr
B
RB

L
B
LY
BR
WB
LB
WG
YL
RG
RB

BrR
BrB
BrW
OPTION OPTION
TERMINALS TERMINALS

P
G
B

GY
LW

2B
LW
B B B B
B
G RW
GW GR
RY RY

RB
LG
回路

Ry3
Ry1

B
B
R
B
B

WL
Br
RY
2R
Lg
RW
WL
GW
GW

2YL
2LR
BrB
BrW
BrW

TOR‑CON ONLY

P
Y

W
Y

Sb
LY
YL
RG

RY
2B
YR
OL
WL
Sb
2R
GO
LY
2L
LW
GR
GL
BR
YB
LB
WG
WR
YW
YG
GY
LG
GW
BrW

3BY
3BG
WBr
2YL
BrR
for EXB,C,K F/R
LIFT LOCK INTERLOCK VALVE
BRAKE LAMP SOLENOID SOLENOID

B
Y

W
Y
LY
YL
RG

2B
YR
OL
WL
RL
2R
GO
LY
2L
LW
GR
GL
BR
YB
LB
WR
YW
YG
GY
Lg
GW
BrW

WBr
5 2 RELAY CONTROL VALVE F R
B

L
B
B

LW
LB
BrR BrR BrR BrR
for STD & EXE,N,A & SIL
RW RW RW Lg
WR WR WR GW
V

L L L L
W W W OL
G G G G
WL WL WL V
LB LB LB Br
V

B B B B
CLUTCH ONLY
BACK LAMP SW.
for STD & EXE,N,A & SIL DETECTOR
Y
STARTER RELAY FLASHER UNIT STARTER
YB RL
TIMER QOS B
3BL (600V 3A×2)
1 2 7 S
FUEL CUT VALVE YR

BR
WG WL
E B L

B
B
WB
LY
RY

OG
LY

2YL
5BY
5BW
AIR CLEANER

B
2YL
3BY
3BL
B
WY
GB
F.L.W.
0.85R REGULATOR
5BY 5BY 5BY B
3B E
S (LEVEL)

Y
BR

3BG
3BG
3BY
(RELAY)

HEAD & POSITION 2R 2R WATER TEMP.

STOP BrY
HORN GY GY YG

5BY
To B
RWL OPTION RY
TURN WY WY SEAT BELT RELAY
Y T/M
/ YG YR
WATER TEMP.SENSOR
LY
BATT.CAP OG
BACK RY Y
SENSOR B
E/G
/ WG WG YL RADIATOR
INTERLOCK B LEVEL
& OPTION 2L 2L
SENSOR
‑
B
W
LY

BrW

LW LW

3B W
B
W W W Br
R.W.L B
E/G for STD & EXB,C SEAT SW
EARTH
POTENTIOMETER for STD & EXE,N,A & SIL
WBr WBr WBr
BACK LAMP RELAY B
GO GO GO
BW BW BW

2B
RW
GR
RL
RB

Y
RL
Sb
B

LAMP
for RRE
2B
RL
RB

TURN (23W) GL G TURN (23W)

RW RW
TAIL (8W) TAIL (8W)
STOP (23W) B B B STOP (23W)
RL RL
BACK(STD:10W) BACK(STD:10W)

REAR CONBINATION REAR CONBINATION

LAMP(L.H.) LAMP(R.H.)

Fig. 9.13 Wiring Diagram (Trucks with TD27 or QD32)

- 122 -
No. SEF-2A0CE
Issued: February, 2006
Revised: May, 2008
Revised: March, 2009

MARKETING GROUP: 1-15-5, Nishi-shimbashi, Minato-ku, Tokyo
105-0003, Japan
FAX: Japan +81-3-35918154
All rights reserved JB-0903020(HO) Printed in Japan
TCMc
脚 ORATIO
 FG20C3 – FG30T3, FHG20C3 – FHG30T3, FG35T3S
SERVICE MANUAL FD20C3 – FD30T3, FHD20C3A – FHD30T3A, FD35T3S No. SEF-2A0CE