ELECTRICAL SYSTEM

Chassis Electrical Devices Wiring Outline ....................................... 3 – 1

Structure .................................................................................................... 3 – 3
Console box .............................................................................................. 3 – 3
Major Electrical Components .................................................................... 3 – 5
3
Lamp Bulb Specifications ......................................................................... 3 – 17
Console Box ............................................................................................. 3 – 18
Disassembly .............................................................................................. 3 – 18
Instrument Panel ....................................................................................... 3 – 19
Battery Maintenance .............................................................................. 3 – 20
Wire Color .................................................................................................. 3 – 21
Troubleshooting ........................................................................................ 3 – 22
Electrical Schematic Diagram ............................................................. 3 – 25
 ELECTRICAL SYSTEM

Chassis Electrical Devices Wiring Outline (No. 1)

Main harness

Harness, rear
combination

Harness, front
combination

Harness, front
combination

209620

3-1
ELECTRICAL SYSTEM

Chassis Electrical Devices Wiring Outline (No. 2)

Starter switch

Key
Main harness

Harness,
Select switch Rear combination

Warning buzzer
Back buzzer
Harness, Front
combination

Controller

Clip

Horn Battery seat

Connector
bracket

Harness, Front
combination

Fuse box,
Fuse
Relay box,
Relay
Vehicle speed sensor
(Pulse generator)

Transmission

209621

3-2
 ELECTRICAL SYSTEM

Structure 4 3
1
Console box
2
1 Water temperature gauge
2 Fuel gauge 6
3 Various warning lights
4 Instrument panel
5 Starter switch
6 Lighting switch, turn signal switch
7 Forward-reverse lever 7

209622

3-3
ELECTRICAL SYSTEM

Function of Instrument Panel

G2
A B C D E F G1 H

I
N

J L L1 L2 L3 L4 K 104997

Description of function
When illuminated
Code Name of monitor When not illuminated Remarks
or flashing
Parking brake released Parking brake applied
A Parking/brake fluid warning lamp
/normal level /low level
B ECM warning lamp Normal ECM abnormal Gasoline-engine truck
C Engine oil pressure warning lamp Normal oil pressure Low oil pressure
D Seat belt reminder warning lamp Fastened Not fastened
Multi-purpose warning lamp (illuminates when
E warnings indicated by printed symbols occur or minor Normal Malfunction Printed symbol
failures occur)
Abnormal charging
F Charge warning lamp Normal charging
system
Engine being
G1 Glow pilot lamp Preheating completed Diesel-engine truck
preheated
LPG fuel level low or
G2 LP-Gas warning lamp Normal LP-Gas truck
pressure low
H Load/unload interlock lamp Free Locked
Fr, Re interlock lamp Free Locked (flashing)
I
Neutral lamp F or R Neutral
J Fuel gauge Indicates remaining fuel amount with key in “ON” position.
K Water temperature gauge Indicates “Overheat” condition if pointer enters the red zone.
L Liquid crystal (normally acting as hour meter) Indicates operating hours with key in “ON” position.

L1 Fuel filter warning lamp Normal Water drain required Diesel-engine truck
Position and content
of printed symbols

L2 Torque converter fluid warning lamp Normal temperature Overheat

L3 Coolant level warning lamp Normal level Low level Option

L4 Clogged air cleaner element warning lamp Normal element Clogged Option

When major failures occur, bulbs A, C, D, E, and H simultaneously flash.

Inspection method of blown bulbs for Instrument panel

All warning and indicator lamps are normal if they illuminate when the starter switch is turned ON, and no bulbs are
blown.
3-4
 ELECTRICAL SYSTEM

Major Electrical Components

Starter switch
The diesel-engine truck, which uses a distributor type injection pump, is provided with an engine automatic stop
mechanism of the fuel cut off system located by the starter switch.
The gasoline-engine truck also has an engine automatic stop mechanism of the fuel cutoff system.

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 running. This prevents starter breakage or flywheel damage caused by an operator re-starting the truck
when the engine is running. The gasoline- and diesel-engine models use the same starter switch. In the diesel-engine
models, (ON) position of the switch is for energizing the glow plugs.

(OFF)
(ON)
G1
M
B2
(START)
G2
B1
S

208540

Connection Table
Gasoline-engine truck

Terminal B1, B2 G1 G2 M S
Connected to Battery,
alternator, Fuse box FNR lever
Key position fuse box
OFF
ON (when driving)
START (when starting engine)

Diesel-engine truck

Terminal B1, B2 G1 G2 M S
Connected to Battery, Fuse box, Neutral switch
alternator, engine stop, (starter),
fuse box control timer glow timer
Key position relay (glow plug)
OFF
ON (when preheating) (when driving)
START (when starting engine)

3-5
ELECTRICAL SYSTEM

Lighting switch and turn signal switch

Lighting and
turn signal lever

Boot

Horn contact

Steering angle sensor

Boot

Forward-reverse lever

Forward of truck
Lighting switch, turn signal switch

209625

Forward of truck
Lighting switch,
turn signal switch

Forward-reverse
selector switch

209626

Lighting switch and

Forward-reverse turn signal switch
selector switch
T-3 L-2
4 T-1 L-4
2

T-2 L-5
L-1 L-3
5 Steering angle sensor
1 3
Horn contact
4
1 2
Horn

3 5

209627

3-6
 ELECTRICAL SYSTEM

Horn
Check that the horn sounds when applying the specified Up
voltage to both terminals of the horn, T1 and T2.
Replace the horn if it does not sound or its sound is
abnormal.
T1
Operating voltage: DC 12 V
Note: The installed position in an actual truck is as per the
illustration. T2
Down

Vent hole

Contact

Coil

209628

Tank Unit
181.5 mm (7.15 in.)

Fuel pump
1/2

Pressure relief
181.5 mm (7.15 in.)

valve

Fuel filter
(2.05 in.)
52 mm

Referential Standards

Float position E 1/4 1/2 3/4 F

Standard resistance value (ohm) 80 49.5 32 19 10
+12 +1.0
Tolerance (ohm) – ±3 –
+12 -0.5

209629

3-7
ELECTRICAL SYSTEM

Brake fluid sensor

Refer to the brake system.

Indicator ON activating position

(emergency energization)
(0.12 ± 0.08 in.)
3 ± 2 mm
206672

Stop lamp switch

Connect a tester across the terminals and check that the
lamps turn ON and OFF when the push rod extended Unit : mm (in.)

projection is to the specified value.

Measure the insulation resistance value across the terminals Push
when the push rod is pushed in. rod

Replace the switch if the measured insulation resistance

4
value is not more than the value listed below. (0.16)
2 (0.08)

M10x1.25 OFF ON
(illuminates)

1 M ohm or more 208543

Insulation resistance value
(at 500 V megger)

Rated voltage: DC 12 V

3-8
 ELECTRICAL SYSTEM

Forward-reverse lever assembly

Forward of vehicle

F1 Forward 1
(10°) (10°) (10°)

F2 Forward 2

N Neutral

R Reverse

Connection table

Terminal 1 2 3 4 5
Wire color
Lever position GR/L B G/R B L/W

F (Forward)
N (Neutral)
R (Reverse)

209632

3-9
ELECTRICAL SYSTEM

Sender unit (engine coolant temperature)

1. Apply an ohmmeter between the terminal and body of
the sender unit and check for continuity (resistance Body Terminal
value).
2. Replace the sending unit if there is no continuity or the
measured resistance value is outside the standard
resistance value.
Note: The illustration is for a gasoline-engine truck.
Gasoline-engine truck
208546
Temperature 50 70 100 110 120
[°C (°F)] (122) (158) (212) (230) (248)
Standard resistance
136 66 27.2 20.5 17.2
value (ohm)

Diesel-engine truck

Temperature 50 60 80 100 106 120

[°C (°F)] (122) (140) (176) (212) (222.8) (248)
Standard
resistance (80) 56.3 (29.5) (16.5) 14.3 (10)
value (ohm)

3. When installing the sending unit, tighten it to the

specified torque.

19.6 to 27.4 N·m

Sending unit tightening
(2.0 to 2.8 kgf·m)
torque
[14.5 to 20.2 lbf·ft]

3-10
 ELECTRICAL SYSTEM

Thermoswitch (T/C oil)

Apply an ohmmeter between the terminal and body and
check for continuity (resistance value). Replace the Terminal Body
thermoswitch if the measured insulation resistance value is
not more than the value listed in the table below.

1 M ohm or more
Insulation resistance value (with contact OFF)
(at 500 V megger)

Internal resistance: 0.5 ohm or less (with contact ON)

Allowable load: 0.5 A
Note: When installing the thermoswitch, tighten it to the
specified torque.
208547
31.4 to 47.1 N·m
Tightening torque (3.2 to 4.8 kgf·m)
[23.2 to 34.7 lbf·ft]

! CAUTION
Replace the thermoswitch if it was dropped or
abused.

Main specifications
122 ± 3 °C
OFF→ON
(251.6 ± 37.4 °F)
Operating temperature
115 °C (239 °F)
ON→OFF
or higher
Insulation resistance
1 M ohm or more
(with contact OFF)

3-11
ELECTRICAL SYSTEM

Power relay (Backup lamps)

Inspection of coil
Apply an ohmmeter across terminal 1 and terminal 2 and
measure the resistance value of the relay coil. If there is no
continuity or the resistance value measured is outside the
standard resistance value, replace coil.

Resistance value of coil 80 ohm ± 10 %

Inspection of contact
1. Measure the insulation resistance value between
terminal 3 and terminal 4. Replace the contact if the
measured insulation resistance value is not more than
the value listed in the table below. 2 4

10 M ohm or more
Insulation resistance value
(at 500 V megger)
Connection diagram
2. Apply an ohmmeter across terminal 3 and terminal 4. 1 3
3. When applying a voltage of 12 V ON and OFF across
terminal 1 and terminal 2 under the above condition, 2 4
Diode
check to see if the relay activates to cause continuity
between terminal 3 and terminal 4. Replace the relay if
it was dropped or abused. 1 3

208548
! CAUTION
This part operates on DC 12 V power supply.

! CAUTION
As the relay has an integrated diode between
terminals, be careful about the polarity when
inspecting. Replace the relay if an impact is given
to it or if it is dropped.

Coil rating [at 20°C (68°F)]

Rated operating voltage DC 12 V

Working voltage DC 8 V or less
Open-circuit voltage DC 0.6 to 6 V or more
Coil resistance 80 ohm ± 10 %
Rated exciting current 150 mA ± 10 %

3-12
 ELECTRICAL SYSTEM

Glow timer (diesel-engine truck)

Inspection of output time when starter switch is
turned to ON 3 (1.25 Br: MTM truck)
When an ohmmeter is applied to terminal 2 and terminal 1 (1.25 BY: ATM truck)
4 (1.25 WL)
and a voltage of 12 V is applied between terminal 3 and
1 (0.85 B)
terminal 1, there is continuity between terminal 2 and
2 (1.25 BR)
terminal 1 for 1.5 seconds at room temperature. Replace
the glow timer with a new one if it does not operate
properly.

Inspection of output time when starter switch is

turned to START OFF
Starter switch (ON)
When an ohmmeter is applied to terminal 2 and terminal 1 (START)

and a voltage of 12 V is applied between terminal 4 and Glow timer

Glow relay
terminal 1, there is continuity between terminal 2 and 3
4
terminal 1 for 5 seconds. Replace the glow timer with a Battery
2 1
new one if it does not operate properly. Glow
plug Glow
indicator
lamp
Rated voltage: DC 12 V 208549

3-13
ELECTRICAL SYSTEM

Glow relay (diesel-engine truck)

Inspection of coil
Apply an ohmmeter across terminal 3 and terminal 4 and
measure the resistance value of the relay coil. If there is no
continuity or the measured resistance value is outside the
standard resistance value. Replace the coil.

Resistance value of coil

52 ohm
[at 20 °C (68 °F)]

Inspection of contact
1. Measure the insulation resistance value between 1
terminal 1 and terminal 2. Replace the contact with a
3
new one if the measured insulation resistance value is
not more than the value listed in the table below.
4
2
1 M ohm or more
Insulation resistance valve
(at 500 V megger)
Connection diagram

2. Apply a tester to terminal 1 and terminal 2. 1 3

3. When applying a voltage of 12 V ON and OFF across 2 4
terminal 3 and terminal 4 under the above condition,
check to see if the relay activates to cause continuity or 208550
not between terminal 1 and terminal 2. Replace the
relay with a new one if it does not activate properly.

Coil rating [in case of 20°C (68°F)]

Rated operating voltage: DC 12 V
Coil resistance: 52 ohm
Rated exciting current: 80 mA

Fuel pump (gasoline-engine truck)

Fuel pump

209640

3-14
 ELECTRICAL SYSTEM

Solenoid valve (for speed selector valve)

This is an ON/OFF valve (normal open type).
The valve opens the IN/OUT circuit in a non-energized
condition.
Rated operating voltage: DC 12V (gasoline-engine truck,
resin color: grey)
: DC 12V (diesel-engine truck,
resin color: brown)

Solenoid valve (for SR-SF selector valve)

This is an ON/OFF valve (normal open type).
The valve opens the IN/OUT circuit in a non-energized
condition.
Rated operating voltage: DC 12V OUT
Terminal

Wiring to the solenoid valve terminal on SR side

IN
Wire gauge and color 1.25 Br / R tag is attached.

Wiring to the solenoid valve terminal on SF side

Mark of 12 V NO
Wire gauge and color 1.25 LgR / F tag is attached.
208536

! CAUTION
The valve has an identification mark “12 V NO” on
the body side.
Be careful not to supply DC 24 V to the valve to
avoid damage.

3-15
ELECTRICAL SYSTEM

Fuse Box

Fuse box, Fuse

209645

WORKING
LAMP
BACK UP/OTHERS 15A
15A WIPER
ETC 15A
METER PANEL 15A STOP LANP
10A HEAD 10A
QGS/OTHERS A/C LAMP HORN
10A SPARE 20A 10A EGI
15A EGI
VCM 30A 30A
20A 30A
20A
FUSE
PULLER

10A 15A
SBF 100A SBF 100A SBF 50A
SPARE BATTERY ALTNR GLOW

209646

3-16
 ELECTRICAL SYSTEM

Lamp Bulb Specifications

Item Watts
No. of
Color of lens Shape Remarks
bulbs
Type of lamp 12 volt 24 volt

Head lamps 2 Colorless 45 60

Turn
2 Amber 27 25
signals
Standard:
Combination
Installed on
lamps (front)
overhead guard
Clearance
2 Amber 10 12
lamps

Turn
2 Amber 27 25
signals

Combination Tail/stop
2 Red 8/23 10/25
lamps (rear) lamps

Backup
2 Colorless 10 12
lamps

Working lamps
4 Colorless 45 60 Optional
(front and rear)

License plate lamp 1 Colorless 10 12 Optional

Instrument panel lamps 7 Colorless 3 3

200016

3-17
ELECTRICAL SYSTEM

Console Box

Disassembly

2
5

209648

(1) Disconnect the electrical wiring from connector 1.

(2) Remove the screw using a flatblade screwdriver and
remove cover 2.
(3) Remove the screw and then, remove cover (U-Re) 3.
(4) Remove the screw and then, remove cover (U-Fr) 4.
(5) Remove the forward-reverse lever (FNR lever) and
turn signal lever 5.
(6) Remove the bolt and then, remove console box
assembly 6.

Reassembly
Follow the disassembly sequence in reverse.

3-18
 ELECTRICAL SYSTEM

Instrument Panel
Disassembly

206480

Sequence
1 Meter cover 6 Meter case
2 Dial 7 Rigid board
3 Water temperature gauge 8 Bulb
4 Liquid crystal 9 Socket
5 Fuel gauge

! CAUTION
Be careful not to damage the rigid board when
disassembling the instrument panel.

Reassembly Bulb replacement

To reassemble the instrument panel, follow the reverse For bulb replacement, remove the socket from the rigid
of disassembly procedure. board by turning it counterclockwise. For configuration
of the indicator lights, refer to page 3-4.

3-19
ELECTRICAL SYSTEM

Battery Maintenance

1. State of charge and electrolyte specific gravity (S.G.) adjustment

Specific gravity reading

at 20°C (68°F) State of charge Adjustment

1.280 to 1.265 Fully charged If difference in S.G. between any two cells is 0.020 or more,
discharge the battery to minimize the difference and then
recharge battery. Adjust S.G. during recharging.
1.260 to 1.225 One-half charged Recharge battery and adjust electrolyte S.G. Make sure there
is neither faulty components, loosely connected cord or
corroded connection.
1.220 or below Discharged Recharge battery. If difference in S.G. is large, adjust it
during recharging.
If difference in S.G. is A cell with a low S.G. Recharge until voltage and S.G. stabilize and have remained
more than 0.040 is in shorted condition. constant for more than 2 hours.
Electrolyte leakage, During recharging, adjust S.G. to 1.280 to 1.265.
or excessive/diluted If difference in S.G. is more than 0.040 and a low S.G. is
electrolyte. found in certain cells only, replace battery. After leaving
battery for 12 to 96 hours, conduct a high current discharge
test.

2. Specific gravity reading and state of charge

! CAUTION
To check the battery for state of charge, take
Be sure to turn OFF the starter switch and lighting
hydrometer readings on its electrolyte. The battery may
switch before disconnecting or connecting the
be fully charged if the S.G. reading is 1.280 to 1.265 at
battery cables to prevent the IC regulator from
20°C (68°F). The state of charge can be told from the
suffering damage.
way the electrolyte level goes down to expose the cell
plates. If addition of distilled water is necessary every
month or so, the battery is overcharged. If addition is
not required for more than 3 months, it is likely that the
battery is inadequately charged.
3. Charging precautions
(1) In slow charging, the charging current should be
about 1/10 the capacity of the battery to be charged.
(2) In quick charging, the battery capacity in ampere
should not be exceeded.
(3) During charging, adjust the charging current to
prevent the electrolyte temperature from rising
beyond 45°C (113°F).
(4) When connecting the cables to the battery, begin by IDENTIFICATION
installing the cable to the positive (+) terminal. 34B19L
(Gasoline-engine truck)
When disconnecting them from the battery, begin 55D23L
by removing the cable for the negative (−) terminal. 75D26L
95D31L (Diesel-engine truck)
209650

3-20
 ELECTRICAL SYSTEM

Wire Color

Wire colors listed in the table below show standard colors (base colors). For wiring composed of two colors, the first
color shows a base color and the second color a marking color.
Example: The wire color of BW shows that its base color is B with a marking W.

BW
Marking color
Base color

Note: For wiring identification, the same color, in principle, must be used for the circuit from the power supply to the
load.

! CAUTION
Be careful that allowable current differs between solid wires and stranded wires even if they are of the
same gauge.

List of wire colors

Wire color Color

B BLACK
W WHITE
R RED
G GREEN
Y YELLOW
Br BROWN
L BLUE
Lg LIGHT GREEN
O ORANGE
P PINK
Gr GRAY
Lb LIGHT BLUE
Dg DARK GREEN
ch CHOCOLATE

3-21
ELECTRICAL SYSTEM

Troubleshooting

Starter System
Weak or dead battery Recharge or replace.
Short or open circuit Repair or replace.
Starter will not crank
Poor continuity in starter switch Replace.
engine
Starter or starter relay defective Replace.
Forward-reverse lever not in neutral Move lever to neutral
Starter switch position position.
Turning off starter Open or short circuit Repair or replace.
switch will not stop Engine stop solenoid defective Replace or readjust.
engine
Control timer defective Replace.

Gauges
Rigid board defective Replace.
Will not indicate at Open or short circuit Repair or replace.
all Gauge internally defective Replace.
Gauge unit defective Replace.
Water Gauge or gauge unit not of the type Replace to a correct
Will not indicate called for one.
temperature
accurately
gauge Loose terminal connection Repair.
Will indicate higher Circuit between gauge and gauge unit Repair.
than actual grounded
temperature Gauge internally defective Replace.

Rigid board defective Replace.

Will not indicate at Open or short circuit Repair or replace.
all Gauge internally defective Replace.
Gauge unit defective Replace.
Gauge or gauge unit not of the type Replace to a correct
Will not indicate called for one.
accurately
Loose terminal connection Repair.
Fuel gauge Circuit between gauge and gauge unit Repair.
Will indicate “full” open or short
regardless of amount
of fuel left in tank Gauge internally defective Replace.
Gauge unit defective Replace.
Will indicate Circuit between gauge and gauge unit Repair.
“empty” regardless grounded
of amount of fuel Gauge unit defective Replace.
left in tank Gauge internally defective Replace.

3-22
 ELECTRICAL SYSTEM

Lighting System
Weak or dead battery Recharge or replace.
Fuses blown out Check and replace.
Open or short circuit Repair or replace.
Will not light Poor grounding Clean ground spot and
re-make connection.
Switch defective Replace.
Lamps - general Bulbs burnt out Replace.
Weak battery Check and recharge.
Contact points in switches defective Repair or replace.
Loose terminals Repair.
Will light dimly
Dirty lenses Clean.
Waterdrops inside lenses Dry and replace packings.
Bulbs expired in service life Replace.
Lighting switch defective Replace.
Head lamps Will not light
Bulbs burnt out Replace.
Turn signal switch defective Replace.
Will not flicker
Turn signal relay defective Replace.
Turn signal relay defective Replace.
Will not go out
Bulbs burnt out Replace.
Turn signals Low wattage of bulbs Replace to a correct one.
Will flicker too
slow Bulbs burnt out Replace.
Turn signal relay defective Replace.
Will flicker too High wattage of bulbs Replace to a correct one.
fast Turn signal relay defective Replace.

Backup lamps Backup lamp switch defective Repair or replace.

will not light Bulbs burnt out Replace.
Other lamps
License number Lighting switch defective Replace.
plate lamp will
not light Bulb burnt out Replace.

Alarm Unit
Fuse blown out Check and replace.
Open or short circuit Repair or replace.
Will not sound Horn switch defective Replace.
Horn defective Replace.
Horn Horn button defective Repair or replace.
Will give an Horn switch defective Replace.
offensive blast Horn defective Replace.
of sound

3-23
ELECTRICAL SYSTEM

Battery
Drive belt slipping Readjust.
❋ Alternator
Stator coil grounded or open-circuited Repair or replace.
Rotor coil open Replace.
Brushes poorly seating on slip rings Replace brushes if worn.
Clean holder and polish
slip rings.
Diode ruptured Replace.
❋ Regulator
Regulated voltage setting too low Replace.
Tends to run down
rapidly ❋ Battery
Not enough electrolyte or wrong concentration of acid Refill and check specific
to water gravity.
Battery cell plates deteriorated (forming, possibly Replace.
internal short-circuit)
Terminal connections loose Clean and retighten.
❋ Wiring
Open or loose connection between starter switch and Repair.
regulator IC terminal
Fuse blown, or loosely set in holder Replace and repair.
Open or loose connection between F terminals of Repair.
regulator and alternator

❋ Wiring
Regulator IC and F terminals shorted or miswired Repair.
Poor grounding of regulator F terminal Repair.
Tends to get
overcharged ❋ Regulator
Pressure coil open-circuited Replace.
Regulated voltage too high Replace.

3-24