ELECTRICAL SYSTEM

Description
Console Box 5 4

1 Engine coolant temperature gauge 1

2 Choke control (Gasoline models)
3
3 Fuel gauge
4 Service hourmeter
5 OK monitor
6 Starter switch
7 Light switch 2 7
8 Fuse box
6
8
207221

OK Monitor

1 2 3 4 5 6 7 8

207222
Function

No. Indicator light OFF On or flickering Remarks

1 Powershift transmission oil temp. indicator light Normal Overheating Option
2 Air cleaner element indicator light Normal Clogged Option
3 Brake fluid level indicator light Normal Low
4 Engine oil pressure indicator light Normal Low
5 Alternator not charging indicator light Normal Abnormal
Heating
6 Glow plug indicator light completed Heating Diesel models
7 Fuel filter indicator light Normal Drain water Diesel models
8 Engine coolant level indicator light Normal Low Option

How to check indicator light bulbs

The bulbs are normal if the indicator lights 1, 2, 3 and 7 come ON when the starter switch key
is turned to ❙ (ON) position. (The indicator lights will go OFF when the engine starts.)

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ELECTRICAL SYSTEM

Electrical Components Mounted on Body

8 1 2 5 10 3 4

Electrical components connected

to console box

C
11

A
9

7
6

1
207212A

1 Main harness 9 Alternator relay

2 Fusible link (R.H.) 10 Engine cover harness
3 Fusible link (L.H.) 11 System harness
4 Fuse A: to Directional lever
5 Fuse B: to Turn signal switch
6 Diode C: to Ignition coil
7 Diode assembly
8 Diode

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 ELECTRICAL SYSTEM

Suggestions for Removal and Installation

Console Box
Removal

6
3

2
5

1
207210

Start by:
Turn off the starter switch, and disconnect the
negative (grounding) cable from the battery.
Removal sequence
1. Disconnect the electrical wires at connec-
tors 1. (In the gasoline models, disconnect
the choke cable on the engine side.)
2. Disconnect the electrical wires at connec-
tors, and remove directional lever 2.
3. Remove screws on cover 3 using a flat-tip
screwdriver, and remove the cover.
4. Remove screws on cover (U-RE) 4, and
remove the cover.
5. Remove screws on cover (U-FR) 5, and
remove the cover.
6. Remove bolts on console box assembly 6, and
remove the console box assembly.
Installation
To install, follow the reverse of removal sequence.

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ELECTRICAL SYSTEM

Disassembly and Reassembly

Console Box

3
207175

Disassembly Reassembly
1. Remove screws 1 (two) securing the cover. To reassemble the console box, follow the
(Use a flat-tip screwdriver (–)) reverse of disassembly sequence.
2. Remove screws 2 (six) and separate the front
and rear panels.
3. Remove screws 3 (four) securing the instru-
ment panel.

NOTE
To replace the instrument panel bulbs, remove
screws 2 and 3.

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 ELECTRICAL SYSTEM

Components in Console Box

3
2

1 7

206423

1 Power relay 5 Glow plug relay (diesel models)

2 Power relay 6 Light switch
3 Turn signal relay 7 Starter switch
4 Glow plug relay (diesel models) 8 Fuses

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ELECTRICAL SYSTEM

Combination Meter
Disassembly

2
3

8
9
206480

Sequence
1 Instrument panel 6 Meter case
2 Dial 7 Printed circuit
3 Engine coolant temperature gauge 8 Bulb
4 Service hour meter 9 Socket
5 Fuel gauge

CAUTION
Be careful not to damage the printed circuit
when disassembling the combination meter.

Reassembly Bulb replacement

To reassemble the combination meter, follow For bulb replacement, remove the socket from
the reverse of disassembly sequence. the printed circuit by turning it counterclock-
wise. For configuration of the indicator lights,
refer to “OK Monitor.”

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 ELECTRICAL SYSTEM

Major Electrical Components

Starter Switch (with Anti-restart Lock)
This switch has a built-in anti-restart lock, so
the key cannot be turned from ❙ (ON) to
(START) position while the engine is run-
ning. The gasoline and diesel models use the
same starter switch. In the diesel models, ❙
(ON) position of the switch is for energizing the
glow plugs.

(OFF)
(ON)

(START) B

203561A
Connection for gasoline models
Terminal B M S
Starter, neutral switch
Key Component Fuse box, battery, Fuse box, fuel-cut (powershift transmis-
position alternator solenoid sion models)
(OFF)
❙ (ON)

Connection for diesel models

Terminal B M S
Fuse box, glow Fuse box, fuel-cut Neutral switch,
Key Component plug relay, battery solenoid, glow plug timer, glow plug timer
position alternator glow plug timer relay
(OFF)
❙ (ON)

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ELECTRICAL SYSTEM

Lighting Switch

OFF 1st 2nd Knob position

8 (0.3)
8 (0.3)
Stroke, mm (in.)

206481

Connection chart
Terminal B T H P
Tail lights, licence
Knob Component Battery plate light (option), Head lights Turn signals,
position (fuse) instrument light clearance lights
(OFF)
1st position
2nd position

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 ELECTRICAL SYSTEM

Fuse Box

Code Amp Circuit

Backup lights (manual transmission
A 10A
models, stop lights)
A
Instrument panel light, turn signals,
B B 15A backup lights (powershift
C transmission models)
D C 15A
Spare terminal, engine thermo
E switch
F Tail lights, clearance lights,
D 15A
working lights (option)
G
E 15A Head lights
H
F 10A Spare fuse
J
G 10A Horn
H 15A Spare fuse
J 10A Spare fuse

101441D

Spare Terminals
The spare terminal cord extends from the fuse box
in the console box.
(Another spare terminal is located on the chassis-
side main harness. The spare power supply termi-
nal cord measuring approximately 50 mm (2 in.)
extends from the junction of the transmission
power supply located on the right side of the main
harness. This terminal is secured to the main har-
ness with red vinyl tape.)

Cord color: Lg (light green)

Removing the console box rear panel will expose

this spare terminal which is fastened to the harness
protector with vinyl tape.
Spare
terminal

207209

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ELECTRICAL SYSTEM

Batteries
1. Electrolyte specific gravity (S.G.) reading and battery condition

Electrolyte S.G. reading

Battery condition Adjustment
at 20°C (68°F)

1.280 to 1.265 Battery is fully or well Check each cell for S.G.
charged.

1.260 to 1.225 Battery is half charged. Recharge the battery. Make sure there is neither faulty
component, short-circuited cord nor corroded connection in
the system.

1.220 or lower Battery is discharged. Recharge the battery. If difference in S.G. among the cell
is large, adjust the S.G. during recharging.

When S.G. difference A cell with a low S.G. Recharge until voltage and S.G. stabilize and have remained
among cells is more is in shorted condition. constant for at least 2 hours.
than 0.040 Some electrolyte has During recharging, adjust the S.G. to anywhere between
been lost. Too much 1.280 and 1.265.
electrolyte, or water in If difference in S.G. among the cells is more than 0.040 and
electrolyte, too. a low S.G. is found in certain cells only, replace the battery.

2. Relationship between electrolyte specific
gravity and charging rate
To check the battery for charging, take hydrometer
readings on its electrolyte: the battery may be
deemed to be fully charged if the readings are
between 1.280 and 1.265 at normal temperature. The
tendency of the charging system can be told from the
way the electrolyte level goes down to expose cell
plates. If refilling (with distilled water) is necessary
every month or so, the system is tending to
over-charge the battery. If refilling is not required for
over 3 months, it is likely that the system is
inadequately charging.
3. Precautions for battery charging
(1) In slow-charging a dead battery, the charging
current should be about 1/10 the capacity of the
battery to be charged.
(2) In quick-charging a battery, the battery capacity
in ampere should not be exceeded.
(3) During charging, adjust the charging current to
prevent the battery electrolyte temperature from
rising beyond 45°C (113°F).
(4) When connecting the cables to the battery, begin
with the cable for the positive (+) terminal.
When disconnecting them from the battery, begin
with the cable for the negative (-) terminal.
CAUTION
Be sure to turn off the starter switch and
lighting switch before disconnecting or
connecting the battery cables to prevent the
IC regulator from suffering damage.

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 ELECTRICAL SYSTEM

Light Bulb Specifications

No. of Color of Watts
Light bulbs Shape Remarks
bulbs lens 12 V

Head lamps 2 Colorless 55

Turn
signal 2 Amber 27 Optional
Combination lamps
lamps (front)
Clearance Optional
2 Colorless 10
lamps
Turn
signal 2 Amber 23
lamps

Combination Tail/stop
lamps 2 Red 8/23
lamps (rear)

Backup
lamps 2 Colorless 10

Working lamps 4 Colorless 55 Optional

(front and rear)

License plate lamps 1 Colorless 10 Optional

Instrument panel lamps 2 Colorless 3.8

OK monitor indicator lamps 11 Colorless 3

204964

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ELECTRICAL SYSTEM

Troubleshooting
Starter system

Complaints Possible causes Remedies

Starter will not a) Dead or weak battery Recharge or replace.
crank engine b) Short or open in circuit Repair or replace.
c) Poor continuity in starter switch Replace.
Starter switch

d) Starter and starter relay defective Replace.

e) Forward-reverse lever not in neutral position Move the lever to
neutral position.
Turning off starter a) Open or short in circuit Repair or replace.
switch will not stop b) Engine stop solenoid defective Replaceor readjust.
engine c) Control timer defective Replace.

Gauges

Complaints Possible causes Remedies

Will not indicate a) Open or short circuit Repair or replace.
at all
Temperature gauges

b) Gauge internally defective Replace.

c) Gauge unit defective Replace
Will not indicate a) Gauge or gauge unit not of the type called for Replace.
accurately b) Loose terminal connection Repair.
Will indicate higher a) Ground between gauge and gauge unit grounded Repair.
temperature than is b) Gauge internally defective Replace.
actual

Will not indicate a) Open or short circuit Repair or replace.

at all b) Gauge internally defective Replace.
c) Gauge unit defective Replace.
Will not indicate a) Gauge or gauge unit not of the type called for Replace.
accurately b) Loose terminal connection Retighten.
Fuel gauge

Will indicate “Full” a) Circuit between gauge and gauge unit open Repair.
regardless of or shot
amount of fuel left b) Gauge internally defective Replace.
in tank
c) Gauge unit defective Replace.

Will indicate a) Circuit between gauge and gauge unit grounded Repair.
“Empty” regardless b) Gauge unit defective Replace.
of the amount of c) Gauge internally defective Replace.
fuel left in tank

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 ELECTRICAL SYSTEM

Lighting system

Complaints Possible causes Remedies

Will not light a) Dead or weak battery Recharge or replace.
b) Fuses blown out Check and replace.
c) Open or short in circuit Repair or replace.
d) Poor ground Clean ground spot and
remake connection.
Lamps-general

e) Bulbs burnt out Replace.

Will light dimly a) Dead or weak battery Check and recharge.
b) Burned contact points in switches Repair or replace.
c) Loose terminals Retighten.
d) Dirty lenses Clean.
e) Waterdrops inside lenses Dry and replace.
packings.
f) Bulbs expired service life Replace.
lamps
Head

Will not light a) Lighting switch defective Replace.

b) Bulbs burnt out Replace.

Will not flash a) Bulbs burnt Replace.

b) Turn signal relay defective Replace.
Turn signal lamps

Will not go out a) Turn signal switch defective Replace

b) Turn signal relay defective Replace.
Will flash too slow a) Wrong wattage of bulbs Replace.
b) Weak battery Recharge or replace.
c) Turn signal relay defective Replace.
Will flash too fast a) Wrong wattage of bulbs Replace.
b) Turn signal relay defective Replace.
Backup lights will a) Backup light switch defective Correct if improperly
not lamps installed; replace if
Other lamps

internally defective.
b) Bulbs burnt out Replace.
License number a) Lighting switch defective Replace.
plate lamp
will not lamps b) Bulb burnt out Replace.
Will not give blast a) Fuse blown out Check and replace.
of sound b) Open or short in circuit Repair or replace.
c) Horn switch defective Replace.
Horn

d) Horn defective Replace.

e) Horn button defective Repair or replace.
Will give ugly blast a) Horn switch defective Replace.
of sound b) Horn defective Replace.

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ELECTRICAL SYSTEM

Battery

Complaints Possible causes Remedies

Tends to run down a) Drive belt slipping Readjust.
rapidly * Alternator
b) Stator coil grounded or open-circuited Repair or replace.
c) Rotor coil open Replace.
d) Brushes poorly seating on slip rings Replace brushes if worn.
Clean holder and polish
slip rings.
e) Diode ruptured Replace.
* Regulator
f) Regulated voltage setting too low Readjust.
* Battery
g) Not enough electrolyte or wrong proportion of Refill and check specific
acid to water gravity. 1.280
h) Battery cell plates deteriorated (forming, possibly Replace.
internal short-circuit)
i) Terminal connections loose Clean and retighten.
* Wiring
j) Open or loose connection between starter switch Repair.
and regulator IG terminal
k) Fuse blown, or loosely set in holder Replace and repair.
l) Open or loose connection between F terminals of Repair.
regulator and alternator
Tends to get overcharged * Wiring
a) Regulator IG and F terminals shorted or miswired Repair.
b) Poor grounding of regulator F terminal Repair.
* Regulator
c) Pressure coil open-circuited Replace.
d) Regulated voltage too high Readjust.

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