3 - Electrical System PDF
3 - Electrical System PDF
3 - Electrical System PDF
3 20
3 21
3 22
3 27
ELECTRICAL SYSTEM
Main harness
Harness, rear
combination
Harness, front
combination
Harness, front
combination
209620
3-1
ELECTRICAL SYSTEM
Starter switch
Key
Main harness
Harness,
Rear combination
Select switch
Warning buzzer
Back buzzer
Harness, Front
combination
Controller
Clip
Battery seat
Horn
Connector
bracket
Harness, Front
combination
Fuse box,
Fuse
Vehicle speed sensor
(Pulse generator)
Relay box,
Relay
Transmission
209621
3-2
ELECTRICAL SYSTEM
Structure
Console box
1
2
3
4
5
6
7
7
5
209622
3-3
ELECTRICAL SYSTEM
L1 L
L2
L3
209623
Description of function
Code
A
B
Name of monitor
When illuminated
or flashing
Normal level
Low level
Normal temperature
Overheat
ATM truck
MTM truck
Normal
Clutch worn
Fastened
Not fastened
Normal
Malfunction
Normal charging
Abnormal charging
system
Preheating completed
Engine being
preheated
Free
Locked
Free
Locked (flashing)
F or R
Neutral
Neutral lamp
Fuel gauge
Remarks
Printed symbol
Diesel-engine truck
Normal
Diesel-engine truck
Normal level
Low level
Option
Normal element
Clogged
Option
Each warning lamp and indicator lamp are normal if they illuminate with the starter switch turned ON, and no bulbs
are blown.
3-4
ELECTRICAL SYSTEM
M
B2
(START)
G2
B1
S
208540
Connection Table
Gasoline-engine truck (12 V)
Terminal
Connected to
Key position
B1, B2
G1
G2
Battery,
alternator,
fuse box
Fuse box
FNR lever
Fuse box,
engine stop,
control timer
Neutral switch
(starter),
glow timer
OFF
ON (when driving)
START (when starting engine)
Terminal
Connected to
Key position
B1, B2
G1
Battery,
alternator,
fuse box
relay (glow plug)
OFF
ON (when preheating) (when driving)
START (when starting engine)
3-5
G2
ELECTRICAL SYSTEM
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
Forward-reverse
selector switch
4
T-1
T-2
5
1 3
T-3
L-2
L-1
L-3
L-4
L-5
Horn contact
Horn
3-6
209627
ELECTRICAL SYSTEM
Horn
Check that the horn sounds when applying the specified
voltage to both terminals of the horn, T1 and T2.
Up
Replace the horn with a new one if it does not sound or its
sound is abnormal.
T1
T2
Down
Vent hole
Contact
Coil
209628
Tank Unit
3/4
1/2
Fuel pump
Pressure relief
valve
1/4
Fuel filter
Referential Standards
Float position
1/4
1/2
3/4
80
49.5
32
19
10
Tolerance (ohm)
+12
+12
+1.0
-0.5
210782
3-7
ELECTRICAL SYSTEM
3 2 mm
(0.12 0.08 in.)
206672
Unit : mm (in.)
Push
rod
1 M ohm or more
(at 500 V megger)
4
(0.16)
M10x1.25
OFF
2 (0.08)
ON
(illuminates)
208543
Rated voltage: DC 12 V
3-8
ELECTRICAL SYSTEM
F1 Forward 1
F2 Forward 2
N Neutral
R Reverse
Forward of vehicle
Connection table
Wire color
Lever position
GR/L
G/R
L/W
F (Forward)
N (Neutral)
R (Reverse)
209632
3-9
ELECTRICAL SYSTEM
Body
Terminal
Gasoline-engine truck
Temperature
[C (F)]
208546
50
70
100
110
120
(122) (158) (212) (230) (248)
Standard resistance
value (ohm)
136
66
27.2
20.5
17.2
Diesel-engine truck
Temperature 50
60
80
100
106
120
[C (F)]
(122) (140) (176) (212) (222.8) (248)
Standard
resistance
value (ohm)
80
56.3
29.5
16.5
14.3
10
19.6 to 27.4 Nm
(2.0 to 2.8 kgfm)
[14.5 to 20.2 lbfft]
3-10
ELECTRICAL SYSTEM
Terminal
Body
1 M ohm or more
(with contact OFF)
(at 500 V megger)
31.4 to 47.1 Nm
(3.2 to 4.8 kgfm)
[23.2 to 34.7 lbfft]
Tightening torque
CAUTION
Replace the thermoswitch with a new one if an
impact is given to it or if it is dropped.
Main specifications
OFFON
122 3 C
(251.6 37.4 F)
ONOFF
115 C (239 F)
or higher
Operating temperature
Insulation resistance
(with contact OFF)
1 M ohm or more
3-11
ELECTRICAL SYSTEM
80 ohm 10 %
Diesel-engine truck
320 ohm 10 %
Inspection of contact
CAUTION
This part operates on DC 12 V (gasoline-engine
truck) or DC 24 V (diesel-engine truck) power supply.
Be careful not to make a mistake when inspecting.
CAUTION
As the relay has an integrated diode between
terminals, be careful about the polarity when
inspecting, Replace the relay with a new one if
an impact is given to it or if it is dropped.
Coil rating [at 20C (68F)]
Truck type
Rated operating voltage
Working voltage
Open-circuit voltage
Connection diagram
10 M ohm or more
(at 500 V megger)
Item
Gasolin/Diesel-engine truck
DC 12 V
DC 8 V or less
DC 0.6 to 6 V or more
Coil resistance
80 ohm 10 %
150 mA 10 %
3-12
Diode
208548
ELECTRICAL SYSTEM
4 (1.25 WL)
1 (0.85 B)
2 (1.25 BR)
Starter switch
(START)
Glow relay
Battery
Glow
plug
Rated voltage: DC 12 V
OFF
(ON)
Glow timer
3
4
2 1
Glow
indicator
lamp
208549
3-13
ELECTRICAL SYSTEM
52 ohm
Inspection of contact
1
3
4
1 M ohm or more
(at 500 V megger)
Connection diagram
4
208550
Fuel pump
209640
3-14
ELECTRICAL SYSTEM
IN
208536
CAUTION
The valve for DC 12 V has an identification mark
12 V NO on the body side.
3-15
ELECTRICAL SYSTEM
Fuse Box
209645
WORKING
LAMP
15A
BACK UP/OTHERS
15A
METER PANEL
10A
QGS/OTHERS
10A
VCM
20A
10A
SPARE
WIPER
15A
ETC
15A
SPARE
20A
A/C
20A
30A
HEAD
LAMP
15A
HORN
10A
STOP LANP
10A
EGI
30A
EGI
30A
FUSE
PULLER
15A
SBF 100A
BATTERY
SBF 100A
ALTNR
SBF 50A
GLOW
209646
3-16
ELECTRICAL SYSTEM
Head lamps
No. of
bulbs
Watts
Color of lens
Shape
Remarks
12 volt 24 volt
Colorless
45
60
Turn
signals
Amber
27
25
Clearance
lamps
Amber
10
12
Turn
signals
Amber
27
25
Tail/stop
lamps
Red
8/23
10/25
Backup
lamps
Colorless
10
12
Working lamps
(front and rear)
Colorless
45
60
Optional
Colorless
10
12
Optional
Colorless
Socket color:
12 V (Blue)
24 V (Dark Gray)
Standard:
Installed on
overhead guard
Combination
lamps (front)
Combination
lamps (rear)
200016
3-17
ELECTRICAL SYSTEM
Console Box
Disassembly
6
2
5
4
3
1
209648
Reassembly
ELECTRICAL SYSTEM
Instrument Panel
Disassembly
206480
Sequence
1
2
3
4
5
Meter cover
Dial
Water temperature gauge
Liquid crystal
Fuel gauge
6
7
8
9
Meter case
Rigid board
Bulb
Socket
CAUTION
Be careful not to damage the rigid board when
disassembling the instrument panel.
Reassembly
Bulb replacement
3-19
ELECTRICAL SYSTEM
Battery Maintenance
1. State of charge and electrolyte specific gravity (S.G.) adjustment
State of charge
Adjustment
1.280 to 1.265
Fully charged
1.260 to 1.225
One-half charged
1.220 or below
Discharged
If difference in S.G. is
more than 0.040
CAUTION
3. Charging precautions
IDENTIFICATION
34B19L
(Gasoline-engine truck)
55D23L
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.
Color
BLACK
WHITE
RED
GREEN
YELLOW
Br
BROWN
BLUE
Lg
LIGHT GREEN
ORANGE
PINK
Gr
GRAY
Lb
LIGHT BLUE
Dg
DARK GREEN
Ch
CHOCOLATE
3-21
ELECTRICAL SYSTEM
Troubleshooting
Starter System
Recharge or replace.
Repair or replace.
Replace.
Replace.
Repair or replace.
Replace or readjust.
Replace.
Replace.
Repair or replace.
Replace.
Replace.
Replace to a correct
one.
Repair.
Repair.
Replace.
Replace.
Repair or replace.
Replace.
Replace.
Replace to a correct
one.
Repair.
Repair.
Replace.
Replace.
Repair.
Replace.
Replace.
Gauges
Will not indicate at
all
Water
temperature
gauge
3-22
ELECTRICAL SYSTEM
Lighting System
Weak or dead battery
Recharge or replace.
Repair or replace.
Poor grounding
Switch defective
Replace.
Replace.
Weak battery
Repair or replace.
Loose terminals
Repair.
Dirty lenses
Clean.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Backup lamps
will not light
Repair or replace.
Replace.
License number
plate lamp will
not light
Replace.
Replace.
Repair or replace.
Replace.
Horn defective
Replace.
Repair or replace.
Replace.
Horn defective
Replace.
Lamps - general
Head lamps
Turn signals
Will flicker too
slow
Other lamps
Alarm Unit
Will not give
blast of sound
Horn
Will give ugly
blast of sound
3-23
ELECTRICAL SYSTEM
Battery
Drive belt slipping
Readjust.
Alternator
Stator coil grounded or open-circuited
Repair or replace.
Replace.
Diode ruptured
Replace.
Regulator
Tends to run down
rapidly
Replace.
Battery
Not enough electrolyte or wrong concentration of acid
to water
Replace.
Wiring
Open or loose connection between starter switch and
regulator IC terminal
Repair.
Repair.
Wiring
Tends to get
overcharged
Repair.
Repair.
Regulator
Pressure coil open-circuited
Replace.
Replace.
3-24
SCHEMATIC(S) INSERTION
Schematic(s) name/number
ELECTRICAL SYSTEM
Electrical Schematic
Electrical Schematic (1/5): FG15N to FG35N (MC Truck) ................................... 3 29
Fuse, Starter, Alternator, License Lamp ............................................................. 3 31
Head Lamp, Tail Lamp, Parking Lamp, T/S Lamp ............................................... 3 32
Horn, Stop Lamp, Back Buzzer, Warning Buzzer................................................ 3 33
Strobe Lamp, Warning Lamp, Front Wiper .......................................................... 3 34
Meter Panel ........................................................................................................ 3 35
Seat Switch, Lift Cylinder, Tilt Cylinder ............................................................... 3 36
Steering, Hydraulic Sensor................................................................................. 3 37
Electrical Schematic (2/5): FG15N to FG35N (FC Truck) .................................... 3 39
Fuse, Starter, Alternator, License Lamp ............................................................. 3 41
Head Lamp, Tail Lamp, Parking Lamp, T/S Lamp ............................................... 3 42
Horn, Stop Lamp, Back Buzzer, Warning Buzzer................................................ 3 43
Strobe Lamp, Warning Lamp, Front Wiper .......................................................... 3 44
Meter Panel ........................................................................................................ 3 45
Seat Switch, Lift Cylinder, Tilt Cylinder ............................................................... 3 46
Steering, Hydraulic Sensor................................................................................. 3 47
Armrest .............................................................................................................. 3 48
Electrical Schematic (3/5): FD15N to FD35N (MC Truck) ................................... 3 49
Fuse, Starter, Alternator, License Lamp ............................................................. 3 51
Head Lamp, Tail Lamp, Parking Lamp, T/S Lamp ............................................... 3 52
Horn, Stop Lamp, Back Buzzer, Warning Buzzer................................................ 3 53
Strobe Lamp, Warning Lamp, Front Wiper .......................................................... 3 54
Meter Panel ........................................................................................................ 3 55
Seat Switch, Lift Cylinder, Tilt Cylinder ............................................................... 3 56
Steering, Hydraulic Sensor................................................................................. 3 57
Electrical Schematic (4/5): FD15N to FD35N (FC Truck) .................................... 3 59
Fuse, Starter, Alternator, License Lamp ............................................................. 3 61
Head Lamp, Tail Lamp, Parking Lamp, T/S Lamp ............................................... 3 62
Horn, Stop Lamp, Back Buzzer, Warning Buzzer................................................ 3 63
Strobe Lamp, Warning Lamp, Front Wiper .......................................................... 3 64
Meter Panel ........................................................................................................ 3 65
Seat Switch, Lift Cylinder, Tilt Cylinder ............................................................... 3 66
3-27
ELECTRICAL SYSTEM
3-28
ELECTRICAL SYSTEM
3-29
ELECTRICAL SYSTEM
3-39
ELECTRICAL SYSTEM
3-49
ELECTRICAL SYSTEM
3-59
ELECTRICAL SYSTEM
3-69