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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

A B C D E F G H

L L2 L4
J
L1 L3 L5 K 209623

Description of function
When illuminated
Code Name of monitor When not illuminated Remarks
or flashing
Parking brake releasd Parking brake applied
A Parking/brake fluid warning lamp
/normal level /low level
B Torque converter fluid temperature warning lamp Normal temperature Overheat
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
G Glow pilot lamp Preheating completed Diesel-engine truck
preheated
H Load/unload interlock lamp Free Locked
Fr, Re interlock lamp Free Locked (flashing)
I
Neutral lamp F or R Neutral
J Fuel gauge Indicate remaining fuel amount with key in “ON.”
K Water temperature gauge Overheat if pointer enters the red zone.
L Liquid crystal (normally acting as hour meter) Indicate operating hours with key in “ON.”
Position and content
of printed symbols

L1 Fuel filter warning lamp Normal Water drain required Diesel-engine truck

L2 Coolant level warning lamp Normal level Low level Option

L3 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


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

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 system by the starter switch.
The gasoline-engine truck is also provided with an engine automatic stop mechanism of the fuel cut 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 the engine from troubles on starting or starter breakage caused by casual re-
starting while 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 with a new one 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 with a new one if the measured


4
insulation resistance value is not more than the value listed (0.16)
2 (0.08)

below. 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 a tester to the sender unit between the terminal
and body and check for continuity (resistance value). Body Terminal

2. Replace the sender unit with a new one 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 sender unit, tighten it to the


specified torque.

19.6 to 27.4 N·m


Sender 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 a tester to the terminal and body and measure the
insulation resistance value. Replace the thermoswitch with Terminal Body
a new one 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 with a new one if an
impact is given to it or if it is dropped.

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 a tester to terminal 1 and terminal 2 and measure the
resistance value of the relay coil. Replace the coil with a
new one if there is no continuity or the resistance value
measured is outside the standard resistance value.

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 with a
new one 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 the tester to 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 or
not between terminal 3 and terminal 4. Replace the
relay with a new one if it does not activate properly. 1 3

CAUTION 208548

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 with a new one 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 a tester is applied to terminal 2 and terminal 1 and a (1.25 BY: ATM truck)
4 (1.25 WL)
voltage of 12 V is applied between terminal 3 and terminal
1 (0.85 B)
1, there is continuity between terminal 2 and terminal 1 for
2 (1.25 BR)
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
When a tester is applied to terminal 2 and terminal 1 and a
Starter switch (ON)
voltage of 12 V is applied between terminal 4 and terminal (START)

1, there is continuity between terminal 2 and terminal 1 for Glow timer


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

3-13
ELECTRICAL SYSTEM

Glow relay (diesel-engine truck)


Inspection of coil
Apply a tester to terminal 3 and terminal 4 and measure the
resistance value of the relay coil. Replace the coil with a
new one if there is no continuity or the measured resistance
value is outside the standard resistance value.

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 nor
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 IDENTIFICATION
with the cable for the positive (+) terminal. When 34B19L
(Gasoline-engine truck)
disconnecting them from the battery, begin with the 55D23L
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 give
blast of sound Horn switch defective Replace.
Horn defective Replace.
Horn Horn button defective Repair or replace.
Will give ugly Horn switch defective Replace.
blast of sound Horn defective Replace.

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
Electrical Schematic (1 / 3) IGN SW FNR LEVER COMB SW
TURN SW LIGHT SW
1 2 3 4 5 1 2 3 4 5 1 2 3 1 2 3 HORN SW
OFF F1 L OFF
ON N N SMALL
610 627 618 START R1 R HEAD
709 670 672 701 702 615 616 628 625 156 600 601
609 626
343 710 711 671 700 127 703 970 617 630 631 155 975 976

431

PATO LAMP
VCM 0.5G/W
W/LAMP SW 431
NEUTRAL REVERSE 221 403 401
CAN MAINTE
SW SW SW LAMP 210 200 402
0.5L
250
SW

120
121
122

125
921
611
922
461

401
402
403
200
221
210
R 120 121
SELECT 122 W 1.25R/W
HAED LAMP(L.H)

1.25R/W
0.3GY/L

0.85R/B
403 211 1.25B

0.3W/B

0.3G/R

0.3L/W

0.5G/R
0.5G/B
0.3B/R
0.3R/B

0.5L/B
921 922

1.25R
0.3B

0.3B
DECISION 611 125 461 224 951

615
616
617
618
970
627
626
343
709
710
711
670
672
671
700
701
609
610

628
630
631
156
155
625
600
601
975
976
127
702
703
1.25R/W
211
1.25B
951 PARK
290 291 0.5R/B 0.5R/B FR COMBI
0.5BR/W

0.3BR/W
224 224

290
291
292
0.5OR/B

958
0.3BR/Y
0.3LG/R

0.3BR/Y

0.5OR/L
0.3W/G

0.5B/W
0.3G/B

0.3G/Y
0.5B/R
0.3B/Y

0.5P/B

0.3P/B
0.5L/R
0.5L/Y
0.5G/R 0.5G/R

1.25G
1.25G
LAMP(L.H)

1.25B
1.25B
292 958 403 403

0.5W

0.3W

0.3G

0.3G
0.5Y
0.5P

0.3B

0.3B
0.3Y
0.5L
0.85B T/S

0.85OR/L
953

0.3OR/L
0.85OR
968 627

123
923

466
924
626
968
627

0.3B
HARNESS F/COMB
626

0.5GY/L
0.85L/R
463 BACK BUZZER

0.5L/W
0.3G
0.3B
0.3Y

0.5B

0.5B
CLUTCH 221 955 405
WEAR SW 442 465 404
0.85R/B 0.85R/B
221 221 TAIL
0.5LG 0.5LG
442 442
0.5G/R 0.5G/R
405 405
0.5L/W
465 0.5L/W
465 STOP
(950 2B) 0.85B 0.85B RE COMBI
955 955
0.5G/B LANP(L.H)
404 T/S
(950 2B)

BACK UP

0.85R/B
0.5L/W
0.5G/B

0.5LG
0.85B
350
943

222 TAIL
0.5BR/W

0.3W
0.5B
0.3B
301 302 611 300 341 610 966 609 441

SEAT BELT
0.5B
349 342 613 612 920 718 717 230 404
464 STOP
METER PANEL RE COMBI

609
966
610
954
LAMP(R.H)

CHARGE LAMP
710 711 709 701 700 T/S

SEAT BELT WARNING LAMP


MULTI-PURPOSE WARNING LAMP
OIL PRESSURE LAMP
POWERSHIFT T / M OIL TEMP LAMP

MAST INTELOCK LAMP


WATER TEMP GAUGE
HARNESS R/COMB

INTEROCK LAMP
BRAKE LAMP
FUEL GAUGE
617 615 618 BACK UP
SEAT SW
616 970 628 629 630 631
0.5BR/W

0.3BR/W

0.5OR/B
0.3BR/Y
0.3LG/R

0.5OR/L

0.5OR/L
0.3BR/Y

0.3W/G 0.85OR/L
291
0.3G/B
0.5B/R

0.5B/R

0.3G/Y
0.3B/Y

0.5P/B

671 670

0.5L/Y
W/LAMP
0.5W

0.3G

0.85B
0.5Y

0.5P

0.3B
0.5L

673 672 702 703 956

ALT L
LAMP
FUEL

TEMP
0.85OR/L

GND
CAN
CAN
12V
PKB
341 102 293

OIL
628
629
W/LAMP
343

709
710
711

670
672
671
673

700
701

702
703

615
616
617
618
970

630
631

R
0.85B

N
F
957
0.85P
341 L
0.85GY/R

717
718
300
230
341
920
402 210

302
349
342
301
613
612
611
102 S
1.25R/W
8R
ALTNTR 223 950
1.25B HAED LAMP(R.H)
101 B
1.25R/W
210

0.3GY/L

0.3B/W
0.3L/W

0.3G/R
0.5Y/R

0.5R/B
0.3Y/B

0.3L/R

0.5P/B
0.3P/L
2B

0.5PU

1.25Y

0.85P
1.25B

1.25B
950
0.5R/B 0.5R/B
223 223
0.5G/B 0.5G/B
402 402 PARK
0.85B FR COMBI
952
R/E

20B
LAMP(R.H)
HARNESS F/COMB T/S
HANDLE
AT OIL TIRE ANGLE T/M SOL T/M SOL SPEED
PS CARIB ANGLE LIFT LOCK SOL UNLOAD

975
920

128
100
TEMP SENSER (L) (R) SENSER 0.5R/B
235
127 SENSER LICENS
155 BATTERY 100 STARTER 0.5B LAMP

0.85R/L
960

0.85GY
156 128
TO ECM

8W
158 0.5G/W
431
545
140 0.5G HORN
430
141
138
TO RELAY BOX 2 137
939 0.3P/B WARNING
371
159 0.3G BUZZR
370
130 370
TO CONSULT- 971
371

BLACK WHITE RED GREEN YELLOW BLUE BROWN Light green ORENGE VIOLET
B W R G Y L Br Lg O V

3) THE CONNECTING SURFACE OF CONNECTOR SHOWS HARNESS SIDE IN THIS


2B SCHEMATICS.
2) HARNESS DRAWINGS, LPGIC DRAWINGS, ELECTRICAL WIRAINGS AND ASSEMBLY
950

DRAWINGS OF EACH MODEL ARE LISTED BELOW.


0.5BR/W

0.5BR/W
1.25B/W
0.3GY/L
0.85R/Y

0.85R/L

0.85L/R

0.85OR
0.85GY

1.25PU
0.3B/W

0.3W/B
0.3W/L

0.3W/L

0.3L/W

0.3B/R
0.3R/B
0.3Y/B

0.3P/B
0.3P/L

0.5L/B
0.5LG

1.25G
1.25R
0.85B

1.25Y
1.25P
NOTES 1) THIS SCHEMATICS SHOWS ELECTRICAL WIREINGS FOR GASOLINE, LPG AND DUAL
0.85L

5W/R

0.85L

0.85L

5W/R
8W/L
5B/Y

0.5G

5B/Y
0.3B

0.3B

0.3B

0.3B

0.3B
0.3L

8W
FUEL TRUCKS. REFER TO ELECTRICAL WIRINGS (3 / 3) FOR ECM.

8R
159 302
373
371
401
400

906
372
904
460
461
125
902
121
122

116
115

129
128

463
462

130
400
300
138
290
440
430
120
500

141
140

600
200

116
115

101
100
159
965
302
969

373
949
349

342

301

BODY EARTH 965 969 373 949 349


0.5Y/R
442

440

0.5PU

FUSE CAT
F1 : HEAD
LAMP Schematic No. Used for Truck Model Serial No.
F2 : HORN
F3 : STOP P3000 AT34 - 00011-up
LAMP
F4 : WAIPER P3500 AT34 - 00011-up
F5 : W / LAMP
F6 : EGI PC4000 AT34 - 50011-up
F7 : EGI
F8 :OPTION
F9 : ETC P4000 AT35 - 00011-up
M F10 : VCM
F11 : METER
ES019-89110 99719-89110 P5000 AT35 - 00011-up
PANEL P5500 AT36 - 00011-up
BRAKAE FUEL FUEL THERMO F12 : BACK UP
PKB SW OIL PRESS LAMP
SW POMP SENSER UNIT

10A
15A
10A
20A

15A
20A
30A
30A
15A
15A
10A
10A
15A
F13 : FUEL P6000 AT13F - 00011-up

FLW 0.85

FLW 0.85
POMP
P6500 AT13F - 50011-up
F13

F12

F11

F10
P7000 AF13F - 50011-up

F9

F8

F7

F6

F5

F4

F3

F2

F1
W/B FRASHER IGN STARTER BACK UP
RELAY RELAY RELAY RELAY RELAY
RELAY BOX 1 FUSE BOX
Pub. No. 99719 - 89110
401 400 906 122 902 461 115 129 463 300 130 400 430 500 140 116 100
371 373 372 904 121 460 125 116 128 462 120 138 290 440 141 200 600 115 101
3 - 27
Electrical Schematic (2 / 3) IGN SW FNR LEVER COMBI SW
TURN SW LIGHT SW HORN
1 2 3 4 5 1 2 3 4 5 1 2 3 1 2 3 SW
OFF F1 L OFF
ON N N SMALL
610 627 676
START R1 R HEAD
374 709 670 672 701 702 615 616 618 628 625 716 600 601
609 343 710 711 671 700 703 626 970 617 630 631 715 975 976

431

PATO
VCM W / LAMP SW 0.5 G / W LAMP
431
NEUTRAL REVERSE 221 403 401
MAINT SW
SW SW LAMP 0.5 L

210
221
461
922

200
403
402
122

921
611

401
120
121

126
SW 120 121
210 200 402 250
SELECT W 1.25 R / W
122 HEAD

1.25 R / W
0.85 R / B
0.3 GR / L
1.25 B

0.3 G / R

0.3 L / W

0.5 G / R
0.5 G / B
403 211

1.25 W / B
LAMP (LH)

1.25 R / B

0.5 L / B
921 922

0.3 B / R

1.25 R
0.3 B
0.3 B
DECISION 224 951
611 125 461

610
374
609

702
703
670
709
710

701

676
615
616
617
618
970

975
976
343

711

672
671
700

600
601
627
626

628
630
631
716
715
625
1.25 R / W
211 PARK
1.25 B
290 291
951

958
291
290

292
0.5 R / B
224
0.5 R / B
224 FR COMBI

0.3 BR / W
0.5 BR / W

1.25 G / W
0.5 OR / B
0.3 LG / B
0.3 LG / R
0.3 BR / Y

0.3 BR / Y

0.5 OR / L
0.5 G / R

0.3 W / G
LAMP (LH)

0.3 W / B

0.3 B / W
0.3 G / B

0.3 G / Y
292 958
0.3 B / Y

0.5 B / R
403

0.5 P / B

0.5 P / B
0.3 L / R
0.5 L / Y

1.25 G

1.25 B
1.25 B

0.3 OR / L
0.85 B

0.3 W
0.5 W

0.3 G
0.3 B
953 T/S

0.3 B
0.5 P
0.5 Y

0.3 Y
0.3 L
968 627

968
627

466
924
626

123
923

0.85 OR
HARNESS F / COMBI

0.3 B
626

0.85 L / R
BACK

0.85 OR / L
463 BUZZER

0.5 L / W
0.5 G / Y
0.3 B
0.3 Y

0.5 B
0.5 B
0.3 L
CLUTCH 221 955 405
WEAR SW
442 465 404
0.85 R / B 0.85 R / B TAIL
221 221
0.5 LG 0.5 LG
442 442
0.5 G / R 0.5 G / R STOP
405 405
0.5 L / W 0.5 L / W
465 465 RE COMBI
(950 2B) 0.85 B 0.85 B
955 955 LAMP (LH)
0.5 G / B
404
T/S

BACK UP

0.85 R / B
0.5 L / W
0.5 G / B

0.5 LG
0.85 B
350
943
0.5 BR / W

222 TAIL

0.3 W

0.3 B
0.5 B
301 302 611 300 102 344 341 610 966 609 441

SEAT BELT
0.5 B
349 342 613 612 920 718 717 230 404 STOP
464

610
966
609
METER PANEL RE COMBI
954
LAMP (RH)

CHARGE LAMP
710 711 709

OIL PRESSURE LAMP


WATER TEMP GAUGE

POWERSHIFT T / M OIL TEMP LAMP

MULTI-PURPOSE WARNING LAMP

SEAT BELT WARNING LAMP


MAST INTELOCK LAMP
INTEROCK LAMP
HARNESS R / COMBI T/S

FUEL GAUGE

BRAKE LAMP

GLOW LAMP
BACK UP
701 700 SEAT SW
0.5 BR / W

0.3 BR / W

0.5 OR / L

0.5 OR / B
0.3 LG / B

0.5 OR / L
0.3 LG / R
0.3 BR / Y

0.3 BR / Y
0.3 W / B

0.3 W / G
0.3 G / B
0.5 B / R
0.5 B / R

0.5 P / B
0.3 B / Y

0.3 G / Y

0.5 L / Y
0.85 OR / L
291
0.5 W

671 670 617 615 618


0.3 B

0.3 G

0.3 B
0.5 Y

0.5 P

0.3 B
0.85 B W / LAMP
673 672 374 947 702 703 977 676 616 970 628 629 630 631 956
102

ALT R
ALT L
GLOW

LAMP
TEMP
FUEL
0.85 OR / L

GND
CAN
CAN
293

PKB

12V
947

676
673

629
672

374

703

977
701
671

628
670

631
702
700

630
970
710
709
343

618
711

616
341
617
615

OIL
0.85 B W / LAMP

N
R
957

F
0.85 P
341 L/R

0.5 P / B
0.85 GR / R

920
341
402 210

612

102
230
301
613
342

717
349

611

300
344

718
302
102

1.25 B
1.25R/W
ALTNTR 223 950 HEAD
8R 1.25B
101 B

0.85 GR / R
LAMP (RH)

0.3 GR / L
1.25 R / W

0.3 B / W
0.3 L / W
210

0.3 R / B
0.3 G / L
0.5 Y / R
0.3 Y / B

0.3 L / R
0.3 P / L
2B

0.5 BR

1.25 B
0.85 P
1.25 Y
950

0.5 V
0.5 R / B 0.5 R / B
223 223
0.5 G / B
402
0.5 G / B
402 PARK
0.85 B FR COMBI

5R/B
952

40 B
R/E LAMP (RH)
HARNESS F / COMBI T/S

0.3 B / W
0.3 L / R

975
SPEED LIFT SW

920
AT OIL TIRE ANGLE T / M SOL T / M SOL PS CARIB W / SEPA HANDLE ANGLE

100
128
SENSOR SENSOR LIFT LOCK UNLOAD
TEMP SENSOR (L) (R) SENSOR 0.5 R / B
235
SOL LICENS

715
716
LAMP

0.85 R / L
STARTER

715
716
BATTERY 100 0.5 B
960
5W

0.85 Gr
128

8W
0.5 G / W
431
0.5 G
HORN
430
RESISTER

0.3 P / B WARNING
371
GLOW GLOW GLOW GLOW 0.3 G
370 BUZZER
PLUG #4 PLUG #3 PLUG #2 PLUG #1 370
371

2B
BLACK WHITE RED GREEN YELLOW BLUE BROWN Light green ORENGE VIOLET

0.5 BR / W

1.25 W / B
1.25 B / W
0.3 GR / L
0.3 GR / L
950

B W R G Y L Br Lg O V
0.3 W / L
0.3 Y / B

0.85 OR
0.3 P / L

0.3 GR / L

5W/R
0.85 R / L

0.85 L / R

5B/Y
1.25 G
0.3 B / W

0.3 L / W

5R/B

1.25 R
0.3 R / B
0.3 W / L

0.3 B / R
0.3 P / B

1.25 Y
0.85 GR
0.5 L / B
0.3 G / W

0.85 L
5W/R

0.5 G
0.3 B
0.3 B

5B/Y

0.85 L

5 BR
0.85 L

0.3 B
0.3 B
0.3 B

0.3 L

8W
8R
0.3 B

0.5 BR / W

157 907
0.5 LG
131

302

600
462

116
124
461

200
463
125
902
121

128

115
372

460
904
949

401
349

129
969

373

400

115

290
906

430
302

500
373

149
371

116

300

440

101
120
150

400
126

100
125

130
301
342

125
BODY EARTH 373 949 349
907

969
157

126 2 ) THE CONNECTING SURFACE OF CONNECTOR SHOWS HARNESS SIDE IN THIS


0.5 Y / R

SCHEMATICS.
442

440

0.5 V

NOTES 1 ) THIS SCHEMATICS SHOWS ELECTRICAL WIRINGS FOR TRUCKS WITH DIESEL ENGINE
1.25 B / W
1.25 R / B
0.3 G / W

FUSE
1.25 B / W

( S4L MODEL ).
0.5 BR
1.25 B
5 BR

F1 : HEAD
5W

LAMP
DIODE F1 : HORN
151

157
150

901
344
122
130

F3 : STOP
LAMP CAT
F4 : WAIPER
Schematic No. Used for Truck Model Serial No.
F5 : W / LAMP
F6 : OPTION
P4000 AT18C - 00011-up
F7 : VCM
F8 : METER P5000 AT18C - 00011-up
FUEL CUT WATER TEMP QGS CONTROLLER PANEL
SOL SENSOR P5500 AT37 - 00011-up
F9 : BACK UP
FUEL PKB SW OIL PRESS THERMO ES019-89110 99719-89110
BRAKE

FLW 0.85

FLW 0.85
FLW 0.85
LAMP

20 A

20 A
15 A
15 A
10 A
10 A
15 A
10 A
15 A
10 A
SW SENSOR UNIT F10 : FUEL
P6000 AT14E - 00011-up
CUT P6500 AT14E - 50011-up

F10
122 130

F7

F6

F5

F4

F3

F2

F1
F8
F9
150 151
IGN STARTER BACK UP
P7000 AT14E - 50011-up
157 901 344 W/B FRASHER
RELAY RELAY RELAY RELAY RELAY
RELAY BOX 1 FUSE BOX
Pub. No. 99719 - 89110
401 400 906 124 902 461 115 129 463 149 300 130 400 430 500 116 100
371 373 372 904 121 460 125 116 128 462 150 120 290 440 200 600 115 101
3 - 29
0.5 B
937
0.5 B / W
174
0.5 OR / L
166
0.5 B

AWU
936
0.5 R / L

537 173 166


173

936 174 937


0.5 OR

1 2 4 3 5 6
537 162

0.5 R
536
0.5 G
172
0.5 W
171
0.5 B
916

ETC
1.25 G

193 916 171


195 172 536
735
163

195
162

972
161

971
736
1.25 W

1 2 4 5 3 6
193
163 161 735 972 971 736

VCM 156
VCM 155

VCM 127
0.3 B

EARTH 975

0.3 B
0.3 B
917
Electrical Schematic (3 / 3)

0.85 B
0.85 B
0.5 LR
0.5 LG

0.5 BW
CONSULT - CONNECTOR

918
0.85 WL

COMBI SW 210
0.85 BW

BRAKE SW 442
919

530
0.5 B / W TO (1 / 6) OR (2 / 6)
0.5 P / B
142
0.5 G / W
180

142 180
529 530
0.5 L / W

02 SEN
2 3 1 4
529

0.5 R / W
182
0.5 B / W
196

GAS INJ #1
182 196 0.5 B
937
0.5 B / W
174
0.5 OR / L
166
0.5 R / B 0.5 B
183 936
0.5 B / W 0.5 LR / L
197 173
0.5 OR
537
912 911

GAS INJ #2
183 197 1.25 W
190
1.25 B
134 190 189

912
1.25 B
911
0.5 R / Y 0.5 L / W
184 143
0.5 B / W 0.5 BR / W
191

198 540
0.5 Y / B
191
143 540 147

GAS INJ #3
184 198 0.5 W / G
147
0.5 L
155

127
0.5 B / W
127 158
139

139
0.5 R / G 0.5 LG
185 158
0.5 B / W 0.5 B / W
199 155
R

0.5 L / R
156
CAN

GAS INJ #4
185 199 0.5 LG
173

156 161 545 937 936


174

166 537

161
0.5 R / W
545
1.25 G / W 1.25 W
108 189
0.85 B 1.25 W / L
925 134
0.5 B / R
148

108 925 148

IGN COIL #1
0.85 G / W
524
1.25 B
926
0.5 PU
149

524 926 149

IGN COIL #2
0.85 G / W
525
0.85 B 0.5 R
927 0.5 G
536
0.5 L / R
ECM

152 0.5 W
172
171
0.5 B
525 927 152 916
1.25 G

IGN COIL #3
195
0.85 G / W 1.25 W
526 193
910

0.85 B 0.5 BR
192

928 148
0.5 GY / R 0.5 PU
195 193

153 149
0.5 L / R
152
0.5 GY / R
526 928 153 156
1.25 B

IGN COIL #4
149 153
148 152

1.25 G / Y
910
192
183 185
142 182 184

0.85 G / W 0.5 Y
527 743
0.85 B 0.5 P / B
529

528 742
0.5 G / W
187

0.5 L / W
180
529
0.5 R / W

CONDENSER
182
0.5 R / B
183
1.25 B

0.5 R / Y

527
528 184
0.5 R / G
0.5 L / R
185
535
0.5 W / G
180 175
181 157

926 177
0.5 BR / Y
177
535
935

0.5 G / L
181
175
169 165

0.5 L / R 0.5 BR / Y
535 170
0.5 B 0.5 B
133 177
132 172

935 933
SENSOR

0.5 W / G 0.5 OR / B
1 2 3
539

177 539
0.5 G
145
FUEL / PRESS

0.5 L
933 181 157
0.5 G
933 916
170 171 131 535 536

154
0.5 BR / Y 0.5 L

(MC)
145
743

181 187
0.3 L 0.5 B 0.5 W / R

RELAY
TEMP

124 933 169


0.3 B 0.5 W / G
WATER

NEUTRAL
939 165
8W/R 0.5 Y
154

741 133
8W 0.3 B 0.5 R
740 167 131
1.25 G / Y 0.5 G / R 0.5 G
192 175 132
1.25 P 0.5 Br / Y
138 170
METER

RELAY 0.5 B
168
0.3 W
AIR FLOW
1 2 3 4 5

533
939 741
533 168 170 175 167

ETC MOTER

539 538
138 740 124 192

0.5 OR / B 0.5 R
539 133
0.5 W
538 131
RELAY
PTC / H

132
GE TYPE

LPG INJ ASIST

133
0.5 G 0.5 Y
145 131
0.5 L
157 132
8W 0.5 W
LE TYPE

522

740 520
RELAY
EGI (2)

8W/L 0.5 B
RELAY BOX 2

140 929
0.5 G
740 140 154
0.5 L
187
1.25 G / W 0.5 B
108 987
LPG INJ / D

1.25 PU 0.5 B
141 988
0.5 LG / R
523 987 520 157 145 988

141 108 522


0.5 Y / R
187 154 929
2 3 4 7 8 9 1 5 6 12

RELAY
EGI (1)

523

0.3 GY / L
137 523 522
0.3 B / W
RELAY

136
0.5 Y 0.5 LG / R
MAIN / C

743 522
0.5 BR / Y 0.5 Y / R
541 523
0.5 BR / W
540
LPG INJ #1

0.5 Y / B
191
0.5 W / G
RELAY

147
0.85 R / Y
159
0.5 L / W
143
FUEL PUMP

1.25 B / W CRANK / ANGLE 0.3 W


130 534
(PHASE) 0.5 W / R
1 2 3

169
137

0.5 B
931
0.3 W
109
0.6 W / G
932 165 109
931 169 534

165
CRANK / ANGLE 0.5 B
932
(POS)
4 5 6

POSITION SENSOR

8 WR
PTC

741
743 130 136 143 159 147 540 541
191

CAT
HEATER

0.5 BR / Y
541
ES019-89110
Schematic No.
LPG SOL

B
G

GAS LAMP
W

0.3 B
L

LPG LAMP 941


R

0.3 R / Y
375
0.3 B
940
G

0.3 Br / Y
374
Used for

GAS 0.5 Y
GLE TYPE

133
LPG AND DUAL FUEL TRUCKS.

99719-89110

0.5 R
131
Y

0.5 G
LPG 132
L

986
1.25 B

3 - 31
1.2
5B

Br

910
2B

SELECT

P7000
P6500
P6000
P5500
P5000
P4000
P3500
P3000
LPG / GAS

PC4000
Truck Model
FUSE BOX 130

Lg

950
131 132 133 375 374

FUEL POMP 159


941 940

RELAY BOX1 138


RELAY BOX1 141
RELAY BOX1 140

Pub. No. 99719 - 89110


TO (1 / 6) OR (2 / 6)
RELAY BOX1 904 (MC)

NEUTRAL SW 123 (MC)

O V
BLACK WHITE RED GREEN YELLOW BLUE BROWN Light green ORENGE VIOLET

Serial No.
(2) REFER TO (1 / 3) FOR CHASSIS ELECTRICAL WIRINGS OF TRUCKS WITH ECM.

AT36 - 00011-up
AT35 - 00011-up
AT35 - 00011-up
AT34 - 50011-up
AT34 - 00011-up
AT34 - 00011-up

AT13F - 50011-up
AT13F - 00011-up

AF13F - 50011-up
NOTES (1) THIS SCHEMATICS SHOWS ELECTRICAL WIREINGS FOR ECM SYSTEM IN GASOLINE,