WORKSHOP MANUAL

N-SERIES

CAB AND CHASSIS ELECTRICAL

(RIGHT HAND DRIVE MODEL)

SECTION 8

    

  

       
 NOTICE

Before using this Workshop Manual to assist you in performing

vehicle service and maintenance operations, it is recommended that
you carefully read and thoroughly understand the information
contained in Section-0A under the headings “GENERAL REPAIR
INSTRUCTIONS” and “HOW TO USE THIS MANUAL”.

All material contained in this Manual is based on latest product

information available at the time of publication.
All rights are reserved to make changes at any time without prior
notice.

Applicable Model:

N-Series

This manual is applicable to 2005 year model.

THIS MANUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTENTS

8 CAB AND CHASSIS ELECTRICAL
 CAB AND CHASSIS ELECTRICAL 8-1

CAB AND CHASSIS ELECTRICAL

SECTION 8
CAB AND CHASSIS ELECTRICAL
Contents
GENERAL INFORMATION..................................... 8-2
General Information............................................. 8-2
Notes for Working on Electrical Items ................. 8-2
Symbols and Abbreviations ................................. 8-8
Parts for Electrical Circuit .................................. 8-11
Reading The Circuit Diagram ............................ 8-19
MAIN DATA AND SPECIFICATIONS ................... 8-22
Bulb Specifications ............................................ 8-22
Fuse and Fusible Link Location......................... 8-25
Reference Table of Fuse and Circuit Breaker ... 8-37
Relay Location................................................... 8-42
Diode Location................................................... 8-48
Reference Table of Grounding Point ................. 8-49
Grounding Point Location .................................. 8-50
Cable Harness Routing ..................................... 8-51
SYSTEM REPAIR ................................................. 8-54
Start and Charging ............................................ 8-54
QOS (Quick On Start) II System
(4HF1 and 4JB1 Engine Model) ........................ 8-66
QOS (Quick On Start) III System
(4JG2 Engine Model)......................................... 8-72
Exhaust Brake System ...................................... 8-77
Exhaust Brake System and Engine Control ...... 8-88
Engine Stop System ........................................ 8-132
Headlight, Fog Light, Rear Fog Light and
Cornering Light ................................................ 8-140
Headlight Leveling ........................................... 8-168
Clearance Light, Taillight, License Plate Light
and Illumination Light....................................... 8-177
Turn Signal Light, Hazard Warning Light, and
Stoplight........................................................... 8-191
Horn, Backup Light and Backup Buzzer.......... 8-206
Dome Light and Backup Buzzer ...................... 8-218
Power Door Lock ............................................. 8-229
Power Window................................................. 8-241
Windshield Wiper and Washer ........................ 8-257
Audio and Cigar Lighter................................... 8-276
Meter and Warning/indicator Light................... 8-284
SRS Control System........................................ 8-356
Heater and Air Conditioning ............................ 8-360
Fuel Heater and Rear Heater .......................... 8-371
4WD Transfer (Vacuum Control) ..................... 8-377
Keyless Entry System...................................... 8-383
ABS (Anti-lock Brake System, Without ASR) .. 8-388
ABS/ASR System ............................................ 8-399
HSA (Hill Start Aid) System ............................. 8-404
Transmission Control System (Smoother)....... 8-411
8-2 CAB AND CHASSIS ELECTRICAL

GENERAL INFORMATION
General Information Connecting The Battery Cable
The chassis electrical system is of 12-volt specifications Follow the disconnecting procedure in the reverse or-
with a negative ground polarity. der.
Wire sizes are appropriate to respective circuits, and Caution:
classified by color. (The classification of harnesses by Clean the battery terminal and apply a light coat of
color is shown on the circuit diagram for ease of harness grease to prevent terminal corrosion.
identification.)
The wire size is determined by load capacity and the
length of wire required.
The vehicle harnesses are: body harness, floor harness,
engine harness, frame front harness, frame rear har-
ness, rear body harness, dome light harness, door har-
ness and battery cable.
The harnesses are protected either by tape or corrugat-
ed tube, depending on harness location.
The circuit for each system consists of the power
source, wire, fuse, relay switch, load parts and ground,
all of which are shown on the circuit diagram.
In this manual, each electrical device is classified by
system. For major parts shown on the circuit based on
the circuit diagram for each system, a summary, diagno-
sis of troubles, inspection and removal and installation
procedures are detailed.

Notes for Working on Electrical Items N8A5002E

Battery Cable Connector Handling

Disconnecting The Battery Cable Disconnecting The Connectors
1. All switches should be in the “OFF” position. Some connectors have a tang lock to hold the connec-
2. Disconnect the battery ground cable. tors together during vehicle operation.
3. Disconnect the battery positive cable. Some tang locks are released by pulling them towards
you 1.
4. Disconnect the battery cable 3.
Other tang locks are released by pressing them forward
Caution: 2.
It is important that the battery ground cable be discon- Determine which type of tang lock is on the connector
nected first. being handled.
Disconnecting the battery positive cable first can result Firmly grasp both sides (male and female) of the con-
in a short circuit. nector.
Release the tang lock and carefully pull the two halves
of the connector apart.

N8A5001E
 CAB AND CHASSIS ELECTRICAL 8-3

N8A0003E N8A0005E

Never pull on the wires to separate the connectors. Connector Inspection

This will result in wire breakage. Use a circuit tester to check the connector for continuity.
Insert the test probes from the connector wire side.

N8A0004E
N8A0006E
Connecting the Connector
Firmly grasp both sides (male and female) of the con-
nector. Be sure that the connector pins and pin holes
match. Be sure that both sides of the connector are
aligned with each other. Firmly but carefully push the
two sides of the connector together until a distinct click
is heard.
8-4 CAB AND CHASSIS ELECTRICAL
Never insert the circuit tester test probes into the con- 2. Push the tang lock up (in the direction of the arrow
nector open end to test the continuity. Broken or open in the illustration). Pull the wire with pin free from
connector terminals will result. the wire side of the connector.

N8A0007E N8A0009E

Waterproof Connector Inspection Pin Tang Lock Type

It is not possible to insert the test probes into the con- 1. Insert a slender shaft into the connector housing
nector wire side of a waterproof connector. open end.
Use one side of a connector 1 with its wires cut to make 2. Push the tang lock flat (toward the wire side of the
the test. Connect the test connector 2 to the connector connector). Pull the wire with pin free from the wire
to be tested. Connect the test probes to the cut wires to side of the connector.
check the connector continuity.

N8A0010E
N8A0008E

Connector Pin Removal

Connector Housing Tang Lock Type
1. Insert a slender shaft into the connector housing
open end.
 CAB AND CHASSIS ELECTRICAL 8-5
Connector Pin Insertion Cable Harness
3. Check that the tang lock is fully up. When installing the parts, be careful not to pinch or
4. Insert the pin from the connector wire side. wedge the wiring harness.
Push the pin in until the tang lock closes firmly. All electrical connections must be kept clean and tight.
5. Gently pull on the wires to make sure that the con-
nector pin is firmly set in place.

N8A0013E

Use a grommet or guard tube to protect the wiring har-

N8A0011E ness from contacting a sharp edge or surface.
Parts Handling
Be careful when handling electrical parts. They should
not be dropped or thrown, because short circuit or other
damage may result.

N8A0014E

N8A0012E
8-6 CAB AND CHASSIS ELECTRICAL
Position the wiring harness with a enough clearance 1-2/2″ (40 mm) away from other splices, harness
from the other parts and guard the wiring harness with a branches, or connectors.
vinyl tube and clips to avoid direct contact. 3. Strip the insulation
When replacing a wire, use a wire of the same size
as the original wire. Check the stripped wire for
nicks or cut stands. If the wire is damaged, repeat
the procedure on a new section of wire. The two
stripped wire ends should be equal in length.
4. Crimp the Wires
Select the proper clip to secure the splice. To de-
termine the proper clip size for the wire being
spliced, follow the directions included with your
clips.
Select the correct anvil on the crimper. (On most
crimpers your choice is limited to either a small or
large anvil.) Overlap the two stripped wire ends
and hold them between your thumb and forefinger.
Then, center the splice clip under the stripped
wires and hold it in place.

N8A0015E

The wiring harness between engine and chassis should

be long enough to prevent chafing or damage due to
various vibrations.

N8A0017E

• Open the crimping tool to its full width and rest

one handle on a firm flat surface.
• Center the back of the splice clip on the proper
anvil and close the crimping tool to the point
N8A0016E where the back of the splice clip touches the
wings of the clip.
Splicing Wire
• Make sure that the clip and wires are still in the
1. Open the Harness correct position. Then, apply steady pressure
If the harness is taped, remove the tape. To avoid until the crimping tool closes.
wire insulation damage, use a sewing “seam rip-
per” (available from sewing supply stores) to cut
open the harness.
If the harness has a block plastic conduit, simply
pull out the desired wire.
2. Cut the wire
Begin by cutting as little wire off the harness as
possible. You may need the extra length of wire lat-
er if you decide to cut more wire off to change the
location of a splice. You may have to adjust splice
locations to make certain that each splice is at least
 CAB AND CHASSIS ELECTRICAL 8-7

N8A0018E N8A0020E

Before crimping the ends of the clip, be sure that: 6. Tape the Splice
• The wires extend beyond the clip in each direc- Center and roll the splicing tape. The tape should
tion. cover the entire splice. Roll on enough tape to du-
plicate the thickness of the insulation on the exist-
• No strands of wire are cut loose, and
ing wires. Do not flag the tape. Flagged tape may
• No insulation is caught under the clip. not provide enough insulation, and the flagged
Crimp the splice again, once on each end. Do not ends will tangle with the other wires in the harness.
let the crimping tool extend beyond the edge of the
clip or you may damage or nick the wires.

N8A0021E

N8A0019E

5. Solder
Apply 60/40 rosin core solder to the opening in the
back of the clip. Follow the manufacturer's instruc-
tions for the solder equipment you are using.
8-8 CAB AND CHASSIS ELECTRICAL
If the wire does not belong in a conduit or other har- Symbol Meaning of Symbol
ness covering, tape the wire again. Use a winding
motion to cover the first piece of tape.

Switch

N8A5505E

Switch
(Normal close type)

N8A5506E

N8A0022E
Contact wiring
Symbols and Abbreviations
Symbols
N8A5507E

Symbol Meaning of Symbol

Battery
Fuse

N8A5508E

N8A5501E

Diode
Fusible link

N8A5509E

N8A5502E

Electronic Parts
Fusible link wire

N8A5510E

N8A5503E

Resistor
Switch

N8A5511E

N8A5504E
 CAB AND CHASSIS ELECTRICAL 8-9

Symbol Meaning of Symbol Symbol Meaning of Symbol

Coil (inductor), solenoid,

Speaker
magnetic valve

N8A5512E N8A5519E

Buzzer Relay

N8A5513E N8A5520E

Circuit breaker Connector

N8A5514E N8A5521E

Bulb Light emitting diode

N8A5515E N8A5522E

Double filament bulb Reed switch

N8A5516E N8A5523E

Motor Condenser

N8A5517E N8A5524E

Variable register Rheo-

Horn
stat

N8A5518E N8A5525E
8-10 CAB AND CHASSIS ELECTRICAL

Symbol Meaning of Symbol

Vacuum switching valve

N8A5526E

Abbreviations

Abbreviation Meaning of Abbreviation Abbreviation Meaning of Abbreviation

A Ampere (S) kW kilowatt
ABS Anti-lock brake system LH Left hand
ASM Assembly LWB Long wheel base
AC Alternating current M/T Manual transmission
A/C Air conditioner OD Over drive
ACC Accessories OPT Option
C/B Circuit breaker QOS Quick on start
CSD Cold start device RH Right hand
DIS Direct ignition system RR Rear
EBCM Electronic brake control module RWAL Rear wheel anti-lock brake system
ECGI Electronic control gasoline injection ST Start
ECM Electronic control module STD Standard
ECU Electronic control unit SW Switch
EFE Early fuel evaporation SWB Short wheel base
4X4 Four-wheel drive V Volt
FL Fusible link VSV Vacuum switching valve
FRT Front W Watt (S)
H/L Headlight WOT Wide open throttle
IC Integrated circuit W/ With
IG Ignition W/O Without
 CAB AND CHASSIS ELECTRICAL 8-11
Parts for Electrical Circuit
Wiring
Wire Color
All wires have color-coded insulation.
Wires belonging to a system's main harness will have a
single color. Wires belonging to a system's subcircuits
will have a colored stripe. Striped wires use the following
code to show wire size and colors.

N8A5023E

Abbreviations are used to indicate wire color within a cir-

cuit diagram.
Refer to the following table.

Wire Color Coding

Color-Coding Meaning Color-Coding Meaning

B Black BR Brown
W White LG Light green
R Red GR Grey
G Green P Pink
Y Yellow LB Light blue
L Blue V Violet
O Orange

Distinction of Circuit by Wire Base Color

Base color Circuits Base color Circuits

B Starter circuit Y Instrument circuit
W Charging circuit
L, O, BR,
R Lighting circuit LG, GR, Other circuit
P, LB, V
G Signal circuits

Wire Size
The size of wire used in a circuit is determined by the
amount of current (amperage), the length of the circuit,
and the voltage drop allowed. The following wire size
and load capacity, shown below, are specified by AWG
(American Wire Gauge) (Nominal size means approxi-
mate cross sectional area).
8-12 CAB AND CHASSIS ELECTRICAL

N8A0025E

Wire Size Table

Cross sectional area Outside diameter Allowable current AWG size

Nominal size
(mm2) (mm) (A) (cross reference)
0.3 0.372 1.8 9 22
0.5 0.563 2.0 12 20
0.85 0.885 2.2 16 18
1.25 1.287 2.5 21 16
2 2.091 2.9 28 14
3 3.296 3.6 37.5 12
5 5.227 4.4 53 10
8 7.952 5.5 67 8
15 13.36 7.0 75 6
20 20.61 8.2 97 4

Fuse, Fusible Link and Circuit Breaker

Fuse
Fuses are the most common form of circuit protection
used in vehicle wiring. A fuse is a thin piece of wire or
strip of metal encases in a glass or plastic housing. It is
wired in series with the circuit it protects. When there is
an overload of current in a circuit, such as a short of a
ground, the wire or metal strip is designed to burn out
and interrupt the flow of current. This prevents a surge
of high current from reaching and damaging other com-
ponents in the circuit.
Determine the cause of the overloaded before replacing
the fuse.
The replacement fuse must have the same amperage
specifications as the original fuse.
Never replace a blown fuse with a fuse of a different am-
perage specification.
Doing so can result in an electrical fire or other serious N8A0026E
circuit damage. A blown fuse is easily identified.
 CAB AND CHASSIS ELECTRICAL 8-13
Fusible Link
The fusible link is primarily used to protect circuits where
high amounts of current flow and where is would not be
practical to use a fuse. For example, the starter circuit.
When a current overload occurs, the fusible link melts
open and interrupts the flow of current so as to prevent
the rest of the wiring harness from burning.
Determine the cause of the overload before replacing
the fusible link. The replacement fusible link must have
the same amperage specification as the original fusible
link.
Never replace a blown fusible link with fusible link of a
different amperage specification. Doing so can result in
an electrical fire or other serious circuit damage.
A blown fusible link is easily identified.

N8A0027E

Fusible Link Specifications

Type Rating Case Color Maximum Circuit Current (A)

Connector 30 A Pink 15
Connector 40 A Green 20
Bolted 50 A Red 25
Bolted 60 A Yellow 30
Bolted 80 A Black 40

Circuit Breaker Relay

The circuit breaker is a protective device designed to Battery and load location may require that a switch be
open the circuit when a current load is in excess of rated placed some distance from either component. This
breaker capacity. If there is a short or other type of over- means a longer wire and a higher voltage drop 1.
load condition in the circuit, the excessive current will The installation of a relay between the battery and the
open the circuit between the circuit breaker terminals. load reduces the voltage drop 2.
The reset knob pops out when the circuit is open. Push Because the switch controls the relay, amperage
the reset knob in place to restore the circuit after repair- through the switch can be reduced.
ing it.

N8A5028E
N8A0028E
8-14 CAB AND CHASSIS ELECTRICAL
Relay Specification, Configuration and Inspection

Name/ Rated voltage/ Name/ Rated voltage/

Internal circuit Internal circuit
Color Coil resistance Color Coil resistance
12 V/
Approx. 90 Ω
MR5C
Minimum
(1T)/
operating
Black
voltage: 7 V 12 V/
at 25°C (77°F) Approx. 23 Ω
MR82C/
Minimum
White
12 V/ operating
label
Approx. 90 Ω voltage: 7 V
MR5C at 20°C (68°F)
Minimum
(1T)/
operating
Brown
voltage: 10.5 V
at 25°C (77°F)
N8A0431E N8A0433E

24 V/
Approx. 266 Ω
MR5C
Minimum 1
(1T)/
operating 2 3 4
24 V/
Green
voltage: 16 V 5
Approx. 100 Ω
at 25°C (77°F) MR82C/
Minimum
Green
N8A0432E
operating N8A0434E
label
24 V/ (connector face) voltage: 16 V (connector face)
Approx. 266 Ω at 20°C (68°F)
MR5C
Minimum
(1T)/
operating
Grey
voltage: 20 V
at 25°C (77°F)
Check to see if Check to see if
The there is any conti- The there is any conti-
way nuity between the way nuity between the
relay terminals. relay terminals.
Result (When no voltage is Result
applied relay terminals 2 (When no voltage is
-4) applied relay terminals 4
Normal 3 -5 → continuity Normal -5)
1 -5 → No continuity 2 -3 → No continuity
Inspection
Inspec- (When minimum operat- Inspec-
tion tion (When minimum operat-
ing voltage is applied
ing voltage is applied
relay terminals between
Abnormal Abnormal relay terminals between
2 -4)
4 -5)
3 -5 → continuity
2 -3 → No continuity
1 -5 → No continuity
(When minimum operat-
(When minimum operat-
ing voltage is applied
ing voltage is applied
relay terminals between
Normal Normal relay terminals between
2 -4)
4 -5)
3 -5 → No continuity
2 -3 → continuity
1 -5 → continuity
 CAB AND CHASSIS ELECTRICAL 8-15

Name/ Rated voltage/

Internal circuit
Color Coil resistance

12 V/
ACM Approx. 120 Ω
13221 Minimum
M04/ operating
Black voltage: 8 V
at 25°C (77°F)
N8A5571E

24 V/
ACM Approx. 320 Ω
13222 Minimum
M01/ operating
Green voltage: 18 V
at 25°C (77°F) N8A5572E

(connector face)
Check to see if
The there is any conti-
way nuity between the
relay terminals.
Result (When no voltage is
applied relay terminals 3
- 5)
Normal 1 - 4 → continuity
1 - 2 → No continuity
Inspection
Inspec- (When minimum operat-
tion ing voltage is applied
relay terminals between
Abnormal
3 - 5)
1 - 4 → continuity
1 - 2 → No continuity
(When minimum operat-
ing voltage is applied
relay terminals between
Normal
3 - 5)
1 - 4 → No continuity
1 - 2 → continuity
8-16 CAB AND CHASSIS ELECTRICAL
Diode
Diode Specifications and Configurations

THERE SHOULD BE CONTINUITY IN

SHAPE MARK/ CONSTRUCTION CHECKING
EITHER A OR B WHEN A CIRCUIT
COLOR TESTER IS CONNECTED WITH
DIODE TERMINAL

TERMINAL NO.
2 1
CONNECTION A
BLACK PATTERN B

TERMINAL NO.
3 2 1

CONNECTION A
PATTERN
B
BLACK

TERMINAL NO.
3 2 1
A
CONNECTION
PATTERN
B
BLACK

TERMINAL NO.
4 4 3 2 1

3 A
2 CONNECTION
PATTERN
1
B

BLACK
N8A0032E

Maximum Rating (Temp. = 25°C)

Items Rating Remarks

Peak reverse voltage 400 V
Transient peak reverse voltage 500 V
Average output current 1.5 A Temp. = 40°C
Working ambient temperature −30°C — 80°C
Storage temperature −40°C — 100°C
 CAB AND CHASSIS ELECTRICAL 8-17
Connector Connector is identified with a number.
The connector pin shape determines whether the con-
nector is male or female.
The connector housing configuration does not deter-
mine whether a connector is male or female.

N8A0035E

The applicable terminal number is shown for each con-

nector.
N8A0033E

The symbol illustrated in the figure is used as connector,

in the circuit of this section.

N8A0036E

N8A0034E
8-18 CAB AND CHASSIS ELECTRICAL
Connector terminal numbers are clearly shown. The connectors used for relays have their own terminal
Male side connector terminal numbers are in sequence number assignment, irrespective of the above rule.
from upper right to lower left.
Female side connector terminal numbers are in se-
quence from upper left to lower right.

N8A5038E

N8A0037E

Notice:
For those connectors on which specific terminal num-
bers or symbols are shown (such as ECM), the terminal
numbers or symbols are used in the circuit diagram, ir-
respective of the above rule.

N8A0038E
 CAB AND CHASSIS ELECTRICAL 8-19
Reading The Circuit Diagram
In this manual, each system has its own parts location illustration, circuit diagram and connector configuration used
in the circuit diagram.
Parts Location
The parts location shows the location of the parts 1 and the connector 2 used in each harness routing 3.

N8A5039E
8-20 CAB AND CHASSIS ELECTRICAL
Circuit Diagram
The circuit diagram shows the power supply 4 the load or loads 5 and the grounding point(s) 6.

N8A5040E
 CAB AND CHASSIS ELECTRICAL 8-21
Connector List
The connector list shows each connectors' configuration 7 and the pin number 8.

No. Connector Face No. Connector Face

7
8
B-341 1 E-5
2

002-009 000-009

B-232 1 E-16 1 2
2

002-009 002-014

1 2 3 5
B-51 1 2 3 4 5 6 7 8 9 1011121314 E-110 4
6 7 8 9

014-001 009-003

B-52 1 2 3 4 5 6 E-76 1 2
7 8 9 10 11 12 3 4

012-003

N8A0430E

Connector Symbol

Connector Connector
Harness name Harness name
Symbol Symbol
B Body harness L Dome Light harness
D Door harness N Floor harness (LH & RH)
E Engine harness P Battery harness
H For joint between harnesses R Rear body harness
J Front frame & Rear frame harness
8-22 CAB AND CHASSIS ELECTRICAL

MAIN DATA AND SPECIFICATIONS

Bulb Specifications

Dome light Backup light

Stoplight/
License plate light Taillight

Turn signal
light

Turn signal light

Headlight
Fog light
Cornering light/Clearance light
N8A5563E

Light Name Rated Power No. of Bulb Lens Color Remarks

60 W / 55 W 12 V
Headlight 2 Clear
75 W / 70 W 24 V
Front combi- Turn signal light 21 W 2 Amber 12 V, 24 V
nation light Cornering light / Clearance light 21 W / 5 W 2 Clear 12 V, 24 V
55 W 12 V
Front 2 Clear
Fog light 70 W 24 V
Rear 21 W 1 Red 12 V, 24 V
Stoplight / Taillight 21 W / 5 W 2 Red 12 V, 24 V
Rear
combination Turn signal light 21 W 2 Amber 12 V, 24 V
light Backup light 21 W 2 Clear 12 V, 24 V
1
License plate light 5W Clear 12 V, 24 V
[OPT] 2
10 W 12 V
Dome light 1 White
12 W 24 V
Roof marker light 5W 2 White
 CAB AND CHASSIS ELECTRICAL 8-23

Rated Power
Light Name Except No. of Bulb Remarks
4HK1-TC
4HK1-TC
1.4 W — 12 V
Glow 1
1.4 W 1.8 W 24 V
4WD 1.8 W 1.8 W 1 24 V
1.4 W — 12 V
Engine oil pressure 1
1.4 W 1.8 W 24 V
1.4 W — 12 V
Fuel sedimenter 1
1.4 W 1.8 W 24 V
1.4 W — 12 V
Brake fluid level / Parking brake 1
1.4 W 1.8 W 24 V
1.4 W — 12 V
Charge 1
1.4 W 1.8 W 24 V
Exhaust brake 2W — 1 12 V
1.4 W — 12 V
High beam 1
1.4 W 1.8 W 24 V
1.4 W — 12 V
Turn signal 1
1.4 W 1.8 W 24 V
Indicator / 2W — 12 V
Fuel level 1
Warning 1.8 W 1.8 W 24 V
Light
(In the meter 1.4 W — 12 V
Rear fog 1
assembly) 1.4 W 1.8 W 24 V
1.4 W — 12 V
Brake booster 1
1.4 W 1.8 W 24 V
1.4 W — 12 V
ABS 1
1.4 W 1.8 W 24 V
1.4 W — 12 V
Check engine 1
1.4 W 1.8 W 24 V
1.4 W — 12 V
P.T.O. 1
1.4 W 1.8 W 24 V
2W — 12 V
Seat belt 1
1.8 W 1.8 W 24 V
SRS airbag 1.4 W 1.8 W 1 24 V
Smoother — LED 1 24 V
1st start — LED 1 24 V
ECONO — LED 1 24 V
H.S.A — 1.8 W 1 24 V
ASR — 1.8 W 1 24 V
8-24 CAB AND CHASSIS ELECTRICAL

Rated Power
Light Name Except No. of Bulb Remarks
4HK1-TC
4HK1-TC
Illumination light for meter 3.4 W 12 V
1
assembly 3W 24 V
2W 12 V
Hazard warning Switch 1
1.8 W 24 V
2W 12 V
Dome light switch 1
1.8 W 24 V
2W 12 V
Front fog light switch 1
Illumination 1.8 W 24 V
Rear fog light For indicator 60 mA 1
12 V
switch For illumination 60 mA 1
1.4 W 12 V
Cigar lighter 1
1.8 W 24 V
Heater bezel 1.4 W 1
Ashtray 1.4 W 1
4WD Switch 40 mA 1 24 V
 CAB AND CHASSIS ELECTRICAL 8-25
Fuse and Fusible Link Location
Fuse and Circuit Breaker

Fuse puller
Spare fuse

Fuse( F-25 - F-28 )

Fuse( F-1 - F-24 )

Relay box
Fuse label (Installed on the left side rear of the cab)
N8A5046E

Fuse Label-for 12 Volt (4JB1 / 4JG2) 10 A

METER
(16)
10 A
AIR CON
(1) (17) —
15 A (18) —
EXH. BRAKE, FUEL HEATER
(2) 15 A
HORN, HAZARD
15 A (19)
REAR HEATER
(3) 10 A
ABS (IG)
15 A (20)
AUDIO (B), DOOR LOCK
(4)
15 A
GENERATOR
10 A (21)
STOP LIGHT
(5) 10 A
STARTER
10 A (22)
FRT FOG LIGHT, CORNERING LAMP
(6) 10 A
HEAD LIGHT RH
10 A (23)
TAIL LIGHT
(7) 10 A
HEAD LIGHT LH
10 A (24)
EGR
(8) 15 A
MARKER LAMP
10 A (25)
FUEL CUT
(9)
15 A
COND. FAN
15 A (26)
FRONT WIPER & WASHER
(10) 10 A
RR FOG
10 A (27)
TURN LIGHT
(11) (28) —
10 A
H/LAMP LEVEL Fuse Label-for 12 Volt (4JH1)
(12)
(13) — 10 A
AIR CON
(14) — (1)
15 A 15 A
AUDIO (IG), CIGAR LIGHTER FUEL HEATER
(15) (2)
8-26 CAB AND CHASSIS ELECTRICAL

15 A Fuse Label-for 24 Volt (4HF1 / 4HG1 / 4HE1 except

REAR HEATER Hong Kong)
(3)
15 A 15 A
AUDIO (B), DOOR LOCK HEATER, AIR CON
(4) (1)
10 A 10 A
STOP LIGHT EXH. BRAKE, FUEL HEATER
(5) (2)
10 A 15 A
FRT FOG LIGHT, CORNERING LAMP REAR HEATER
(6) (3)
10 A 15 A
TAIL LIGHT AUDIO (B), DOOR LOCK
(7) (4)
15 A 10 A
ENG. (B1) STOP LIGHT
(8) (5)
15 A 20 A
ENG. (B2) POWER WINDOW
(9) (6)
15 A 10 A
FRONT WIPER & WASHER TAIL LIGHT
(10) (7)
10 A 10 A
TURN LIGHT FRT FOG LIGHT, CORNERING LAMP
(11) (8)
10 A 10 A ENG. (IG)
H/LAMP LEVEL
(12) (9) FUEL CUT
(13) —
15 A
FRONT WIPER & WASHER
(14) — (10)
15 A 10 A
AUDIO (IG), CIGAR LIGHTER TURN LIGHT
(15) (11)
10 A 10 A
METER H/LAMP LEVEL
(16) (12)
(17) — 10 A
ENG. STOP
(18) — (13)

15 A (14) —
HORN, HAZARD
(19) 15 A
AUDIO (IG), CIGAR LIGHTER
(15)
10 A
ABS(IG)
(20) 10 A
METER
(21) — (16)

10 A (17) —
STARTER
(22) 15 A
GENERATOR
(18)
10 A
HEAD LIGHT RH
(23) 15 A
ENG. (B)
10 A (19)
HEAD LIGHT LH
(24) 15 A
HORN, HAZARD
15 A (20)
MARKER LAMP
(25) 10 A
ABS (IG)
(21)
15 A
COND. FAN
(26) 10 A
STARTER
10 A (22)
RR FOG
(27) 10 A
HEAD LIGHT RH
(28) — (23)
10 A
HEAD LIGHT LH
(24)
 CAB AND CHASSIS ELECTRICAL 8-27

15 A 10 A
MARKER LAMP STARTER
(25) (22)
15 A 10 A
COND. FAN HEAD LIGHT RH
(26) (23)
10 A 10 A
RR FOG HEAD LIGHT LH
(27) (24)
(28) — 15 A
MARKER LAMP
(25)
Fuse Label-for 24 Volt (4HE1 for Hong Kong)
15 A
COND. FAN
15 A (26)
HEATER, AIR CON
(1) 10 A
RR FOG
10 A (27)
EXH. BRAKE, FUEL HEATER
(2) (28) —
15 A
REAR HEATER Fuse Label-for 24 Volt (4HK1)
(3)
15 A 15 A
AUDIO (B), DOOR LOCK HEATER, AIR CON
(4) (1)
10 A 10 A
STOP LIGHT FUEL HEATER
(5) (2)
20 A 15 A
POWER WINDOW REAR HEATER
(6) (3)
10 A 15 A
TAIL LIGHT AUDIO (B), DOOR LOCK
(7) (4)
10 A 10 A
FRT FOG LIGHT, CORNERING LAMP STOP LIGHT
(8) (5)
10 A ENG. (IG) 20 A
POWER WINDOW
(9) FUEL CUT (6)
10 A
15 A TAIL LIGHT
FRONT WIPER & WASHER (7)
(10)
10 A 10 A
TURN LIGHT FRT FOG LIGHT
(11) (8)

10 A 10 A
H/LAMP LEVEL ENG. (IG)
(12) (9)
15 A
10 A FRONT WIPER & WASHER
ENG. STOP (10)
(13)
(14) — 10 A
TURN LIGHT
(11)
15 A
AUDIO (IG), CIGAR LIGHTER 10 A
(15) H/LAMP LEVEL
(12)
10 A
METER 10 A
(16) NEES (B)
(13)
(17) —
(14) —
10 A
SRS 15 A
(18) AUDIO (IG), CIGAR LIGHTER
(15)
15 A
ENG. (B) 10 A
(19) METER
(16)
15 A
HORN, HAZARD 10 A NEES (IG)
(20)
(17) HSA
10 A
ABS (IG)
(21)
8-28 CAB AND CHASSIS ELECTRICAL

10 A
SRS
(18)
10 A
ENG. (BACK UP) HSA
(19)
15 A
HORN, HAZARD
(20)
10 A
ABS (IG)
(21)
10 A
STARTER
(22)
10 A
HEAD LIGHT RH
(23)
10 A
HEAD LIGHT LH
(24)
15 A
MARKER LAMP
(25)
15 A
COND. FAN
(26)
10 A
RR FOG
(27)
10 A
ECM. ENG.
(28)

Notice:
The fuse numbers (1) — (28) indicated on the fuse la-
bels are expressed as F-1 — F-28 in the circuit dia-
grams of this manual.
 CAB AND CHASSIS ELECTRICAL 8-29
Fusible Link

Relay box
(Installed on the left side rear of the cab)

2 3 4 5

6 7 8 9

Fusible link

Fusible link
PULLER

26 25
FUSE

N8A5047E

For 12 Volt (4JB1 / 4JG2) 60 A

ABS
(9)
100 A
MAIN
(1)
50 A 30 A
KEY HEATER
(2) (25)
60 A 30 A
GLOW POWER WINDOW
(3) (26)
30 A
HEAD LAMP For 12 Volt (4JH1)
(4)
(5) — 100 A
MAIN
(1)
(6) —
50 A
(7) — KEY
(2)
60 A
STARTER 60 A
(8) GLOW
(3)
8-30 CAB AND CHASSIS ELECTRICAL

30 A 40 A
HEAD LAMP ABS
(4) (9)
(5) —
For 24 Volt (4HK1)
(6) —
100 A /
(7) —
120 A MAIN
60 A (1)
STARTER
(8)
40 A
KEY
60 A (2)
ABS
(9)
60 A
GLOW
(3)
30 A 30 A
HEATER HEAD LAMP
(25) (4)
30 A 40 A
POWER WINDOW ECM. ENG.
(26) (5)
60 A
For 24 Volt (4HF1 / 4HG1 / 4HE1 except Hong Kong) CERAMIC HEATER
(6)
100 A / 60 A
120 A MAIN NEES
(7)
(1)
60 A
40 A STARTER
KEY (8)
(2)
40 A
60 A ABS
GLOW (9)
(3)
30 A
HEAD LAMP Notice:
(4)
The fusible link numbers (1) — (26) are expressed as
(5) — FL-1 — FL-26 in the circuit diagrams of this manual.
(6) —
(7) —
60 A
STARTER
(8)
40 A
ABS
(9)

For 24 Volt (4HE1 for Hong Kong)

100 A /
120 A MAIN
(1)
40 A
KEY
(2)
60 A
GLOW
(3)
30 A
HEAD LAMP
(4)
(5) —
(6) —
(7) —
60 A
STARTER
(8)
 CAB AND CHASSIS ELECTRICAL 8-31
Fuse Block Circuit
For 12 Volt-4JB1 / 4JG2 Engine

GENERATOR B

FL-25 INDICATION ON LABEL

FL-1 30A
MAIN HEATER
100A

FL-26

30A
POWER WINDOW

HEATER &
A/C RELAY F-1 10A
AIR CON
F-2 15A
EXH.BRAKE
CHARGE
RELAY
EXH. BRAKE, FUEL HEATER
WARNING
F-3 15A
RELAY
REAR HEATER
F-4 15A
AUDIO (B), DOOR LOCK
GENERATOR F-5 10A
MARKER
INDICATION ON LABEL LIGHT STOP LIGHT
RELAY MARKER LIGHT F-6 10A
F-25 15A TAIL FRT FOG LIGHT, CORNERING LAMP
MARKER LAMP RELAY F-7 10A
F-26 15A TAIL LIGHT
COND. FAN F-8 10A
REAR FOG COMBINATION EGR
RELAY SWITCH F-9
F-27 10A 10A
RR FOG REAR FOG FUEL CUT
F-10 15A
F-28 KEY ON FRONT WIPER & WASHER
RELAY F-11 10A
TURN LIGHT
KEY SW OFF F-12 10A
FL-2
KEY H/LAMP LEVEL
ACC
50A F-13
ON

ST F-14

CONDENSER FAN F-15 15A

RELAY
AUDIO (IG), CIGAR LIGHTER
F-16 10A
METER
CONDENSER FAN F-17

FL-3 GLOW PLUG F-18

GLOW RELAY
60A
GLOW PLUG F-19 15A
HORN, HAZARD
FL-4 F-20 10A
HEAD LAMP
30A ABS (IG)
F-21 15A
GENERATOR
F-22 10A
HEAD LIGHT STARTER
RELAY F-23 10A
FL-8 STARTER
RELAY
HEAD LIGHT RH
STARTER
60A F-24 10A
STARTER
HEAD LIGHT LH
COMBINATION SWITCH
FL-9
ABS
60A
ABS UNIT

N8A5584E
8-32 CAB AND CHASSIS ELECTRICAL
For 12 Volt-4JH1 Engine

GENERATOR B

FL-25 INDICATION ON LABEL

FL-1 30A
MAIN HEATER
100A

FL-26

30A
POWER WINDOW

HEATER &
A/C RELAY F-1 10A
AIR CON
F-2 15A
HEATER
CHARGE
RELAY
FUEL HEATER
WARNING
F-3 15A
RELAY
REAR HEATER
F-4 15A
AUDIO (B), DOOR LOCK
GENERATOR F-5 10A
MARKER
INDICATION ON LABEL LIGHT STOP LIGHT
RELAY MARKER LIGHT F-6 10A
F-25 15A TAIL FRT FOG LIGHT, CORNERING LAMP
MARKER LAMP RELAY F-7 10A
F-26 15A TAIL LIGHT
COND. FAN F-8 15A
REAR FOG COMBINATION ENG. (B1)
RELAY SWITCH F-9
F-27 10A 15A
RR FOG REAR FOG ENG. (B2)
F-10 15A
F-28 KEY ON FRONT WIPER & WASHER
RELAY F-11 10A
TURN LIGHT
KEY SW OFF F-12 10A
FL-2
KEY H/LAMP LEVEL
ACC
50A F-13
ON

ST F-14

CONDENSER FAN F-15 15A

RELAY
AUDIO (IG), CIGAR LIGHTER
F-16 10A
METER
CONDENSER FAN F-17

FL-3 GLOW PLUG F-18

GLOW RELAY
60A
GLOW PLUG F-19 15A
HORN, HAZARD
FL-4 F-20 10A
HEAD LAMP
30A ABS (IG)
F-21

F-22 10A
HEAD LIGHT STARTER
RELAY F-23 10A
FL-8 STARTER
RELAY
HEAD LIGHT RH
STARTER
60A F-24 10A
STARTER
HEAD LIGHT LH
COMBINATION SWITCH
FL-9
ABS
60A
ABS UNIT

N8A5585E
 CAB AND CHASSIS ELECTRICAL 8-33
For 24 Volt-4HF1 / 4HG1 / 4HE1 (Except Hong Kong) Engine

GENERATOR B

FL-25 INDICATION ON LABEL

FL-1
MAIN
100A or 120A

FL-26

HEATER &
A/C RELAY F-1 15A
HEATER, AIR CON
F-2 10A
EXH.BRAKE
CHARGE
RELAY
EXH. BRAKE, FUEL HEATER
WARNING
F-3 15A
RELAY
REAR HEATER
F-4 15A
AUDIO (B), DOOR LOCK
GENERATOR F-5 10A
MARKER
INDICATION ON LABEL LIGHT STOP LIGHT
RELAY MARKER LIGHT F-6 20A
F-25 15A TAIL POWER WINDOW
MARKER LAMP RELAY F-7 10A
F-26 15A TAIL LIGHT
COND. FAN F-8 10A
REAR FOG COMBINATION FRT FOG LIGHT, CORNERING LAMP
RELAY SWITCH F-9
F-27 10A 10A ENG. (IG)
REAR FOG
RR FOG FUEL CUT
F-10 15A
F-28 KEY ON FRONT WIPER & WASHER
RELAY F-11 10A
TURN LIGHT
KEY SW OFF F-12 10A
FL-2
KEY H/LAMP LEVEL
ACC
40A F-13 10A
ON
ENG. STOP
ST F-14

CONDENSER FAN F-15 15A

RELAY
AUDIO (IG), CIGAR LIGHTER
F-16 10A
METER
CONDENSER FAN F-17

FL-3 GLOW PLUG F-18 15A

GLOW RELAY GENERATOR
60A
GLOW PLUG F-19 15A
ENG. (B)
FL-4 F-20 15A
HEAD LAMP
30A HORN, HAZARD
F-21 10A
ABS (IG)
F-22 10A
HEAD LIGHT STARTER
RELAY F-23 10A
FL-8 STARTER
RELAY
HEAD LIGHT RH
STARTER
60A F-24 10A
STARTER
HEAD LIGHT LH
COMBINATION SWITCH
FL-9
ABS
40A
ABS UNIT

N8A5051E
N8A5586E
8-34 CAB AND CHASSIS ELECTRICAL
For 24 Volt-4HE1 (For Hong Kong) Engine

GENERATOR B

FL-25 INDICATION ON LABEL

FL-1
MAIN
100A or 120A

FL-26

HEATER &
A/C RELAY F-1 15A
HEATER, AIR CON
F-2 10A
EXH.BRAKE
CHARGE
RELAY
EXH. BRAKE, FUEL HEATER
WARNING
F-3 15A
RELAY
REAR HEATER
F-4 15A
AUDIO (B), DOOR LOCK
GENERATOR F-5 10A
MARKER
INDICATION ON LABEL LIGHT STOP LIGHT
RELAY MARKER LIGHT F-6 20A
F-25 15A TAIL POWER WINDOW
MARKER LAMP RELAY F-7 10A
F-26 15A TAIL LIGHT
COND. FAN F-8 10A
REAR FOG COMBINATION FRT FOG LIGHT, CORNERING LAMP
RELAY SWITCH F-9
F-27 10A 10A ENG. (IG)
REAR FOG
RR FOG FUEL CUT
F-10 15A
F-28 KEY ON FRONT WIPER & WASHER
RELAY F-11 10A
TURN LIGHT
KEY SW OFF F-12 10A
FL-2
KEY H/LAMP LEVEL
ACC
40A F-13 10A
ON
ENG. STOP
ST F-14

CONDENSER FAN F-15 15A

RELAY
AUDIO (IG), CIGAR LIGHTER
F-16 10A
METER
CONDENSER FAN F-17

FL-3 GLOW PLUG F-18 10A

GLOW RELAY SRS
60A
GLOW PLUG F-19 15A
ENG. (B)
FL-4 F-20 15A
HEAD LAMP
30A HORN, HAZARD
F-21 10A
ABS (IG)
F-22 10A
HEAD LIGHT STARTER
RELAY F-23 10A
FL-8 STARTER
RELAY
HEAD LIGHT RH
STARTER
60A F-24 10A
STARTER
HEAD LIGHT LH
COMBINATION SWITCH
FL-9
ABS
40A
ABS UNIT

N8A5587E
 CAB AND CHASSIS ELECTRICAL 8-35
For 24 Volt-4HF1 / 4HG1 (For Indonesia) Engine

GENERATOR B

FL-25 INDICATION ON LABEL

FL-1
MAIN
100A or 120A

FL-26

HEATER &
A/C RELAY F-1 15A
HEATER, AIR CON
F-2 10A
EXH.BRAKE
CHARGE
RELAY
EXH. BRAKE, FUEL HEATER
WARNING
F-3 15A
RELAY
REAR HEATER
F-4 15A
AUDIO (B), DOOR LOCK
GENERATOR F-5 10A
MARKER
INDICATION ON LABEL LIGHT STOP LIGHT
RELAY MARKER LIGHT F-6 20A
F-25 15A TAIL POWER WINDOW
MARKER LAMP RELAY F-7 10A
F-26 15A TAIL LIGHT
COND. FAN F-8 10A
REAR FOG COMBINATION FRT FOG LIGHT, CORNERING LAMP
RELAY SWITCH F-9
F-27 10A 10A ENG. (IG)
REAR FOG
RR FOG FUEL CUT
F-10 15A
F-28 KEY ON FRONT WIPER & WASHER
RELAY F-11 10A
TURN LIGHT
KEY SW OFF F-12 10A
FL-2
KEY H/LAMP LEVEL
ACC
40A F-13 10A
ON
ENG. STOP
ST F-14

CONDENSER FAN F-15 15A

RELAY
AUDIO (IG), CIGAR LIGHTER
F-16 10A
METER
CONDENSER FAN F-17

FL-3 GLOW PLUG F-18 15A

GLOW RELAY GENERATOR
60A
GLOW PLUG F-19 15A
ENG. (B)
FL-4 F-20 15A
HEAD LAMP
30A HORN, HAZARD
F-21 10A
ABS (IG)
F-22 10A
HEAD LIGHT STARTER
RELAY F-23 10A
FL-8 STARTER
RELAY
HEAD LIGHT RH
STARTER
60A F-24 10A
STARTER
HEAD LIGHT LH
COMBINATION SWITCH
FL-9
ABS
40A
ABS UNIT

N8A5588E
8-36 CAB AND CHASSIS ELECTRICAL
For 24 Volt-4HK1 Engine

GENERATOR B
INDICATION ON LABEL
FL-25
FL-1
MAIN
100A or 120A
FL-26

HEATER &
A/C RELAY F-1 15A
HEATER, AIR CON
F-2 10A
HEATER
CHARGE
RELAY
FUEL HEATER
WARNING
F-3 15A
RELAY
REAR HEATER
METER F-4 15A
(BOOST IND)
AUDIO (B), DOOR LOCK
GENERATOR F-5 10A
MARKER
INDICATION ON LABEL LIGHT STOP LIGHT
RELAY MARKER LIGHT F-6 20A
F-25 15A TAIL POWER WINDOW
MARKER LAMP RELAY F-7 10A
F-26 15A TAIL LIGHT
COND. FAN F-8 10A
REAR FOG COMBINATION FRT FOG LIGHT
RELAY SWITCH F-9
F-27 10A 10A
RR FOG REAR FOG ENG. (IG)
F-10 15A
F-28 10A KEY ON FRONT WIPER & WASHER
RELAY
ECM. ENG. F-11 10A
TURN LIGHT
FL-2 KEY SW OFF F-12 10A
KEY ACC H/LAMP LEVEL
40A F-13
ON 10A
NEES (B)
ST
F-14
CONDENSER FAN
RELAY
F-15 15A
AUDIO (IG), CIGAR LIGHTER
F-16 10A
CONDENSER FAN
METER
FL-3 GLOW PLUG F-17 10A
GLOW RELAY NEES (IG)
60A HSA
GLOW PLUG F-18 10A

FL-4
SRS
F-19 10A
HEAD LAMP ECM
30A ENG. (BACK UP) HSA
F-20 15A
FL-5 ECM MAIN HORN, HAZARD
ECM. ENG. RELAY F-21 10A
40A
ECM ABS (IG)
ECM F-22 10A
FL-6
HEAD LIGHT STARTER
CERAMIC HEATER RELAY
60A F-23 10A
CERAMIC HEATER HEAD LIGHT RH
FL-7 F-24 10A
GEAR SHIFTER
NEES RELAY COMBINATION SWITCH HEAD LIGHT LH
60A
TCM
TCM
FL-8 STARTER
STARTER RELAY
60A
STARTER

STARTER CUT
RELAY

FL-9
ABS ECM
40A ECM
ABS UNIT

NEUTRAL SWITCH N8A5589E

 CAB AND CHASSIS ELECTRICAL 8-37
Reference Table of Fuse and Circuit Breaker
Fuse
12 Volt 4JB1 / 4JG2 Engine

Fuse No. Capacity Indication on label Main parts (Load)

A/C switch, A/C thermo relay, Pressure switch, Magnetic
F-1 10 A AIR CON
clutch, VSV: FICD, Electronic thermostat
EXH. BRAKE, FUEL Exhaust brake switch, Exhaust brake control relay, Exhaust
F-2 15 A
HEATER brake magnetic valve, Clutch switch, Accel switch, Fuel heater
F-3 15 A REAR HEATER Rear heater, Rear heater switch
Radio & clock, Dome light switch, Dome light, Door switch
AUDIO (B), DOOR (RH & LH), Door lock switch, Door lock actuator, Door lock
F-4 15 A
LOCK controller, Speedometer, Key cylinder switch, Key remind
buzzer
F-5 10 A STOP LIGHT Stoplight switch, Stoplight
FRT FOG LIGHT, Fog light switch, Fog light, Lighting switch, Cornering light
F-6 10 A
CORNERING LAMP relay, Cornering light, Cornering light switch
F-7 10 A TAIL LIGHT Tail relay, Illumination light(s), Clearance light(s), Tail light(s)
F-8 10 A EGR ECM ignition
F-9 10 A FUEL CUT Fuel cut solenoid
FRONT WIPER & Wiper & Washer switch, Wiper motor, Washer motor, Intermit-
F-10 15 A
WASHER tent relay
Flasher unit, Front turn signal light, Rear turn signal light, Turn
F-11 10 A TURN LIGHT
signal light switch, Hazard warning switch
F-12 10 A H/LAMP LEVEL Headlight leveling switch, Headlight leveling motor (actuator)
F-13 — — —
F-14 — — —
AUDIO (IG), CIGAR
F-15 15 A Radio, Cigar lighter
LIGHTER
Exhaust brake control relay, CSD Relay, Key remind buzzer,
Backup light switch, Backup light, Neutral switch, Starter relay,
QOS-II controller, QOS-III controller, Glow relay, Glow-1 relay,
F-16 10 A METER Glow-2 relay, Glow indicator (Meter), Coolant temperature
gauge, Thermo unit, Vehicle speed sensor (Installed on the
meter assembly & Transmission), Meter assembly, Power
window relay, Cornering light relay
F-17 — — —
F-18 — — —
Horn, Horn relay, Horn switch, Flasher unit, Hazard warning
F-19 15 A HORN, HAZARD
switch
F-20 10 A ABS (IG) ABS
F-21 15 A GENERATOR Generator
F-22 10 A STARTER Starter relay, QOS-II controller, QOS-III controller
F-23 10 A HEAD LIGHT RH Headlight (RH), Dimmer relay, High beam indicator light
F-24 10 A HEAD LIGHT LH Headlight (LH), Dimmer relay
F-25 15 A MARKER LAMP Marker light, Marker light relay
F-26 15 A COND. FAN Condenser fan
F-27 10 A RR FOG Rear fog light switch, Rear fog light relay
8-38 CAB AND CHASSIS ELECTRICAL

Fuse No. Capacity Indication on label Main parts (Load)

F-28 — — —

12 Volt 4JH1 Engine

Fuse No. Capacity Indication on label Main parts (Load)

A/C switch, A/C thermo relay, Pressure switch, Magnetic
F-1 10 A AIR CON
clutch, VSV: FICD, Electronic thermostat
F-2 15 A FUEL HEATER Fuel heater
F-3 15 A REAR HEATER Rear heater, Rear heater switch
Radio & clock, Dome light switch, Dome light, Door switch
AUDIO (B), DOOR (RH & LH), Door lock switch, Door lock actuator, Door lock
F-4 15 A
LOCK controller, Speedometer, Key cylinder switch, Key remind
buzzer
F-5 10 A STOP LIGHT Stoplight switch, Stoplight
FRT FOG LIGHT, Fog light switch, Fog light, Lighting switch, Cornering light
F-6 10 A
CORNERING LAMP relay, Cornering light, Cornering light switch
F-7 10 A TAIL LIGHT Tail relay, Illumination light(s), Clearance light(s), Tail light(s)
F-8 15 A ENG. (B1) ECM battery
F-9 15 A ENG. (B2) ECM battery
FRONT WIPER & Wiper & Washer switch, Wiper motor, Washer motor, Intermit-
F-10 15 A
WASHER tent relay
Flasher unit, Front turn signal light, Rear turn signal light, Turn
F-11 10 A TURN LIGHT
signal light switch, Hazard warning switch
F-12 10 A H/LAMP LEVEL Headlight leveling switch, Headlight leveling motor (actuator)
F-13 — — —
F-14 — — —
AUDIO (IG), CIGAR
F-15 15 A Radio, Cigar lighter
LIGHTER
Key remind buzzer, Backup light switch, Backup light, Starter
relay, Glow indicator (Meter), Coolant temperature gauge,
F-16 10 A METER Thermo unit, Vehicle speed sensor (Installed on the meter
assembly & Transmission), Meter assembly, Power window
relay, Cornering light relay
F-17 — — —
F-18 — — —
Horn, Horn relay, Horn switch, Flasher unit, Hazard warning
F-19 15 A HORN, HAZARD
switch
F-20 10 A ABS (IG) ABS
F-21 — — —
F-22 10 A STARTER Starter relay, QOS-II controller, QOS-III controller
F-23 10 A HEAD LIGHT RH Headlight (RH), Dimmer relay, High beam indicator light
F-24 10 A HEAD LIGHT LH Headlight (LH), Dimmer relay
F-25 15 A MARKER LAMP Marker light, Marker light relay
F-26 15 A COND. FAN Condenser fan
F-27 10 A RR FOG Rear fog light switch, Rear fog light relay
F-28 — — —
 CAB AND CHASSIS ELECTRICAL 8-39
24 Volt 4HF1 / 4HG1 / 4HE1 Engine

Fuse No. Capacity Indication on label Main parts (Load)

Blower motor, Blower resistor, Fan switch, A/C switch, A/C
F-1 15 A HEATER, AIR CON thermo relay, Pressure switch, A/C cut relay, Thermo switch
(A/C cut), VSV: FICD, Electronic thermostat
EXH. BRAKE, FUEL Exhaust brake switch, Exhaust brake control relay, Exhaust
F-2 10 A
HEATER brake magnetic valve, Clutch switch, Accel switch, Fuel heater
F-3 15 A REAR HEATER Rear heater, Rear heater switch
Radio & clock, Dome light switch, Dome light, Door switch
AUDIO (B), DOOR (RH & LH), Door lock switch, Door lock actuator, Door lock
F-4 15 A
LOCK controller, Speedometer, Key cylinder switch, Key remind
buzzer
F-5 10 A STOP LIGHT Stoplight switch, Stoplight
F-6 20 A POWER WINDOW Power window
F-7 10 A TAIL LIGHT Tail relay, Illumination light(s), Clearance light(s), Tail light(s)
FRT FOG LIGHT, Fog light switch, Fog light, Lighting switch, Cornering light
F-8 10 A
CORNERING LAMP relay, Cornering light, Cornering light switch
ENG. (IG) ECM ignition (EXCEPT 4HF1-2)
F-9 10 A
FUEL CUT Fuel cut solenoid (4HF1-2)
FRONT WIPER & Wiper & Washer switch, Wiper motor, Washer motor, Intermit-
F-10 15 A
WASHER tent relay
Flasher unit, Front turn signal light, Rear turn signal light, Turn
F-11 10 A TURN LIGHT
signal light switch, Hazard warning switch
F-12 10 A H/LAMP LEVEL Headlight leveling switch, Headlight leveling motor (actuator)
F-13 10 A ENG. STOP Engine stop motor
F-14 — — —
AUDIO (IG), CIGAR
F-15 15 A Radio, Cigar lighter
LIGHTER
Exhaust brake control relay, CSD Relay, Key remind buzzer,
Backup light switch, Backup light, Inhibitor Switch, Neutral
switch, Starter relay, QOS-II controller, QOS-III controller,
F-16 10 A METER Glow relay, Glow-1 relay, Glow-2 relay, Glow indicator (Meter),
Coolant temperature gauge, Thermo unit, Vehicle speed sen-
sor (Installed on the meter assembly & Transmission), Meter
assembly, Power window relay, Cornering light relay
F-17 — — —
15 A GENERATOR Generator (Except Hong Kong)
F-18
10 A SRS SRS (For Hong Kong)
F-19 15 A ENG. (B) ECM battery (4HG1-T)
Horn, Horn relay, Horn switch, Flasher unit, Hazard warning
F-20 15 A HORN, HAZARD
switch
F-21 10 A ABS (IG) ABS
F-22 10 A STARTER Starter relay, QOS-II controller, QOS-III controller
F-23 10 A HEAD LIGHT RH Headlight (RH), Dimmer relay, High beam indicator light
F-24 10 A HEAD LIGHT LH Headlight (LH), Dimmer relay
F-25 15 A MARKER LAMP Marker light, Marker light relay
F-26 15 A COND. FAN Condenser fan
8-40 CAB AND CHASSIS ELECTRICAL

Fuse No. Capacity Indication on label Main parts (Load)

F-27 10 A RR FOG Rear fog light switch, Rear fog light relay
F-28 — — —

24 Volt 4HK1 Engine

Fuse No. Capacity Indication on label Main parts (Load)

Blower motor, Blower resistor, Fan switch, A/C switch, A/C
thermo relay, Pressure switch, VSV: FICD, Electronic thermo-
F-1 15 A HEATER, AIR CON
stat, A/C compressor, A/C thermo relay, Condenser fan, ECM
(A/C compressor SIG.)
Exhaust brake magnetic valve, Clutch switch, Accel switch,
F-2 10 A FUEL HEATER Fuel heater, VSV: Intake throttle, ABS (Exhaust brake SIG.),
Ceramic heater relay
F-3 15 A REAR HEATER Rear heater, Rear heater switch
Radio & clock, Dome light switch, Dome light, Door switch
AUDIO (B), DOOR (RH & LH), Door lock switch, Door lock actuator, Door lock
F-4 15 A
LOCK controller, Speedometer, Key cylinder switch, Key remind
buzzer, Side turn signal light(s)
Stoplight switch, Stoplight, ABS (Stop on SIG.), ECM (brake
F-5 10 A STOP LIGHT
on SIG.)
F-6 20 A POWER WINDOW Power window
Tail relay, Illumination light(s), Clearance light(s), Tail light(s),
F-7 10 A TAIL LIGHT
Roof marker light, License light(s), Marker light relay
Fog light switch, Fog light, Lighting switch, Cornering light
F-8 10 A FRT FOG LIGHT
relay, Cornering light, Cornering light switch
ECM (IG SIG.), Starter cut relay, ECM (Exhaust brake SIG.),
F-9 10 A ENG. (IG) Exhaust brake indicator, ECM (brake off SIG.), ECM (clutch on
SIG.), ALDL connector
FRONT WIPER & Wiper & Washer switch, Wiper motor, Washer motor, Intermit-
F-10 15 A
WASHER tent relay
Flasher unit, Front turn signal light, Rear turn signal light, Turn
F-11 10 A TURN LIGHT signal light switch, Hazard warning switch, Side turn signal
light relay
F-12 10 A H/LAMP LEVEL Headlight leveling switch, Headlight leveling motor (actuator)
F-13 10 A NEES (B) Smoother
F-14 — — —
AUDIO (IG), CIGAR
F-15 15 A Radio, Cigar lighter, Digital clock
LIGHTER
CSD Relay, Key remind buzzer, Backup light switch, Backup
light, Neutral switch, Starter relay, QOS-II controller, Glow
relay, Glow indicator (Meter), Coolant temperature gauge,
Thermo unit, Vehicle speed sensor (Installed on the meter
F-16 10 A METER
assembly & Transmission), Meter assembly, Power window
relay, Cornering light relay, Backup buzzer, ABS indicator
relay, Charge relay, Heater A/C relay, VSV: 2WD (4WD), VSV:
4WD (4WD), 4WD relay
NEES (IG) Smoother (IGN SIG.)
F-17 10 A
HSA HSA
F-18 10 A SRS SRS
 CAB AND CHASSIS ELECTRICAL 8-41

Fuse No. Capacity Indication on label Main parts (Load)

F-19 10 A ENG. (BACK UP) HSA ECM (Back up), HSA control unit
Horn, Horn relay, Horn switch, Flasher unit, Hazard warning
F-20 15 A HORN, HAZARD
switch, Turn light(s), Side turn signal light relay
F-21 10 A ABS (IG) ABS (IGN SIG.)
F-22 10 A STARTER Starter relay, QOS-II controller
F-23 10 A HEAD LIGHT RH Headlight (RH), Dimmer relay, High beam indicator light
F-24 10 A HEAD LIGHT LH Headlight (LH), Dimmer relay
F-25 15 A MARKER LAMP Marker light, Marker light relay
F-26 15 A COND. FAN Condenser fan
F-27 10 A RR FOG Rear fog light switch, Rear fog light relay
F-28 10 A ECM. ENG. ECM
8-42 CAB AND CHASSIS ELECTRICAL
Relay Location

X-16 X-15 X-14 X-13

Relay box No.2

Relay box No.1

X-17

X-5 X-6 X-7 X-8 X-9 X-10 X-11 X-12

X-1 X-2 X-3 X-4

Relay box
(Installed on the left side rear of the cab)

X-18 X-19 X-20

X-22
X-23 X-24 X-25 X-26 X-27 X-28
X-21

N8A5052E
 CAB AND CHASSIS ELECTRICAL 8-43
Relay List
❍: Standard, ❏: Option

X-1 X-2 X-3 X-4 X-5 X-6

Charge ABS Smoother
Key ON Horn Lamp Tail Dimmer
warning IND. main
NHR55 — ❍ ❍ ❍ ❍ — — ❍
NKR55 — ❍ ❍ ❍ ❍ — — ❍
12V NHR69 — ❍ ❍ ❍ ❍ — — ❍
NKR77 — ❍ ❍ ❍ ❍ ❏ — ❍
NPR77 — ❍ ❍ ❍ ❍ ❏ — ❍
NKR66 ❍ — ❍ ❍ ❍ — — ❍
NPR66 ❍ — ❍ ❍ ❍ — — ❍
NQR66 ❍ — ❍ ❍ ❍ — — ❍
NPR70 ❍ — ❍ ❍ ❍ ❏ — ❍
NQR70 ❍ — ❍ ❍ ❍ ❏ — ❍
NKR71 ❍ — ❍ ❍ ❍ — — ❍
NQR71
❍ — ❍ ❍ ❍ — — ❍
24V with turbocharger
NPS71 ❍ — ❍ ❍ ❍ — — ❍
NPR71 ❍ — ❍ ❍ ❍ — — ❍
NQR71
❍ — ❍ ❍ ❍ — — ❍
w/o turbocharger
NPR75 ❍ — ❍ ❍ ❍ — ❏ ❍
NQR75 ❍ — ❍ ❍ ❍ — ❏ ❍
NPS75 ❍ — ❍ ❍ ❍ — — ❍
8-44 CAB AND CHASSIS ELECTRICAL

X-7 X-8 X-9 X-10 X-11 X-12

Power Exh. Corner- Thermo Charge Heater
Heater Key ON
window brake ing lamp A/C warning & A/C
NHR55 ❏ ❏ — ❍ ❏ ❍ — ❍
NKR55 ❏ ❏ — ❍ ❏ ❍ — ❍
12V NHR69 ❏ ❏ — ❍ ❏ ❍ — ❍
NKR77 ❏ — — ❍ ❏ ❍ — ❍
NPR77 ❏ — — ❍ ❏ ❍ — ❍
NKR66 ❏ ❏ — ❍ ❏ — ❍ ❍
NPR66 ❏ ❍ — ❍ ❏ — ❍ ❍
NQR66 ❏ ❍ — ❍ ❏ — ❍ ❍
NPR70 ❏ ❍ — ❍ ❏ — ❍ ❍
NQR70 ❏ ❍ — ❍ ❏ — ❍ ❍
NKR71 ❏ ❏ — ❍ ❏ — ❍ ❍
NQR71
❏ ❍ — ❍ ❏ — ❍ ❍
24V with turbocharger
NPS71 ❏ ❍ — ❍ ❏ — ❍ ❍
NPR71 ❏ ❍ — ❍ ❏ — ❍ ❍
NQR71
❏ ❍ — ❍ ❏ — ❍ ❍
w/o turbocharger
NPR75 ❍ — ❍ ❍ ❍ — ❍ ❍
NQR75 ❍ — ❍ ❍ ❍ — ❍ ❍
NPS75 ❍ — ❍ ❍ ❍ — ❍ ❍
 CAB AND CHASSIS ELECTRICAL 8-45

X-13 X-14 X-17 X-18

Buzzer Smoother Ceramic ECM
Heater ECM Timing
cancel emergency Heater main
NHR55 — — — — — — —
NKR55 — — — — — — —
12V NHR69 — — — — — — —
NKR77 — ❍ ❍ — — — —
NPR77 — ❍ ❍ — — — —
NKR66 — — — — — — —
NPR66 ❏ — — — — — —
NQR66 ❏ — — — — — —
NPR70 ❏ — — ❍ — — —
NQR70 ❏ — — ❍ — — —
NKR71 — — — — — — —
NQR71
❏ — — — — — —
24V with turbocharger
NPS71 — — — — — — —
NPR71 ❏ — — — — — —
NQR71
❏ — — — — — —
w/o turbocharger
NPR75 ❏ — ❍ — ❏ ❏ ❍
NQR75 ❏ — ❍ — ❏ ❏ ❍
NPS75 — — ❍ — ❏ — ❍
8-46 CAB AND CHASSIS ELECTRICAL

X-19 X-20 X-21 X-22 X-23 X-24

4WD
Glow Gear Glow Marker A/C
Starter Rear fog ind.
No.2 shifter plug lamp COMP
lamp
NHR55 — — ❍ ❍ — — — —
NKR55 — — ❍ ❍ — — — —
12V NHR69 ❍ — ❍ ❍ — — — —
NKR77 — — ❍ ❍ ❏ ❏ ❏ —
NPR77 — — ❍ ❍ ❏ ❏ ❏ —
NKR66 — — ❍ ❍ — — — —
NPR66 — — ❍ ❍ — — — —
NQR66 — — ❍ ❍ — — — —
NPR70 — — ❍ ❍ — — — —
NQR70 — — ❍ ❍ — — — —
NKR71 — — ❍ ❍ — — — —
NQR71
— — ❍ ❍ — — — —
24V with turbocharger
NPS71 — — ❍ ❍ — — — ❍
NPR71 — — ❍ ❍ — — — —
NQR71
— — ❍ ❍ — — — —
w/o turbocharger
NPR75 — ❍ ❍ ❍ ❏* ❏* — —
NQR75 — ❍ ❍ ❍ ❏ * ❏ * — —
NPS75 — ❍ ❍ ❍ — — — ❍

* : For EC
 CAB AND CHASSIS ELECTRICAL 8-47

X-25 X-26 X-27 X-28

Exh. Con- Exh.
A/C ON Starter
brake CSD denser brake
SIGNAL cut
control fan cut
NHR55 ❏ ❍ — — — —
NKR55 ❏ ❍ — — — —
12V NHR69 ❏ — — — — —
NKR77 — — ❏ — — —
NPR77 — — ❏ — — —
NKR66 ❏ — — — — —
NPR66 ❍ — — — — —
NQR66 ❍ — — — — —
NPR70 ❍ — — — ❏ ❏
NQR70 ❍ — — — ❏ ❏
NKR71 ❏ — — — — —
NQR71
❍ — — — — —
24V with turbocharger
NPS71 ❍ — — — — —
NPR71 ❍ — — — — —
NQR71
❍ — — — — —
w/o turbocharger
NPR75 — — — ❍ ❏ —
NQR75 — — — ❍ ❏ —
NPS75 — — — ❍ ❏ —
8-48 CAB AND CHASSIS ELECTRICAL
Diode Location

N8A5053E

Connector No. B-17 B-18 J-23 L-1 L-3

QOS III, Dome light,
Usage VSV: FICD Dome light Dome light
Lighting A/C

Connector No. X-33 X-32

A/C, Smoother,
Usage
ECM Dome light
 CAB AND CHASSIS ELECTRICAL 8-49
Reference Table of Grounding Point
Notice:
Abnormal phenomena of electrical components are considered resulted from defective grounding.
In repair, be sure to inspect grounding points and to tighten all fastening parts surrounding the grounding points.

Cable harness
Connector No. Location Main parts (Load)
name
Vehicle speed sensor, Heater & A/C relay, Fan switch,
Ceramic heater relay, Ceramic heater thermo relay,
B-1 Frame-LH (FRT)
Meter, High beam indicator light, PTO lever, TCM, SRS
C/U
Frame-RH
B-275 SRS C/U
(FRT)
Charge relay, Exhaust brake relay, QOS II control unit,
QOS III control unit, Dome light switch, Key remind and
back up buzzer, Meter, Brake fluid switch, Tail relay,
Cornering light switch, Cornering light, Cornering light
relay, Fog light switch, Fog light, Dimmer relay, Door
lock switch, Door lock relay, Power window switch (RH),
Power window relay, Stoplight switch, Mirror switch,
Body harness Wiper motor, Washer motor intermittent relay, ECM,
Pattern select switch, Kickdown switch, Shift indicator,
Shift lock controller, Radio, Cigar lighter, Heater & A/C
Headlight relay, Fan switch, Ceramic heater relay, Ceramic heater
B-7
bracket-LH thermo relay, ALDL connector (ECM), Vehicle speed
sensor, Horn relay, Rear heater switch, Rear heater,
Radio & clock, Cigar lighter, Fan switch, Blower resistor,
A/C switch, Blower motor, Electronic thermostat, Accel
switch, QOS II control unit, Door lock switch, Door lock
controller, Headlight levering switch, Headlight levering
motor, 4WD switch, Shift lock controller, Power window
relay, Power window switch, QOS III control unit, Pat-
tern select switch, Ceramic heater relay, Emergency
relay, Select switch, Emergency adjust switch, PTO-
Smoother switch
Marker light relay, Marker light, Water sedimenter
switch, Fuel tank unit, Starter relay, Inhibitor switch,
4WD switch, VSV; Transfer control (2WD & 4WD), 4WD
detective switch, 4WD relay, Neutral switch, Fuel
heater, Pressure switch, A/C thermo relay, VSV: FICD,
Frame front har- Exhaust brake control relay, Exhaust brake magnetic
J-9 Frame-LH (CTR)
ness valve, Accel switch, Clutch switch, VSV: intake throttle,
Engine stop motor, ECM, ECM main relay, Starter cut
relay, Shift 1,3,5 solenoid, Shift 2,4,R solenoid, Select
solenoid, License plate light, Taillight, Rear fog light,
Rear turn signal light, Stoplight, Stoplight switch,
License plate light, Backup light
8-50 CAB AND CHASSIS ELECTRICAL
Grounding Point Location

N8A5054E

B-7

N8A5055E

N8A5056E
 CAB AND CHASSIS ELECTRICAL 8-51
Cable Harness Routing

N8A5058E
8-52 CAB AND CHASSIS ELECTRICAL

N8A5059E
CAB AND CHASSIS ELECTRICAL 8-53

N8A5060E
8-54 CAB AND CHASSIS ELECTRICAL

SYSTEM REPAIR
Start and Charging
General Description
The system consists of the starter switch, starter, AC generator, starter relay, charge relay, heater and A/C relay, in-
hibitor switch and neutral switch. When the starter SW is set to the “ST” position, the battery voltage is applied to the
starter solenoid coil through the starter relay to start the starter.
• On the 4HK1 engine, the function that ECM controls STARTER RELAY is added.
Starting Circuit

N8A0064E
 For 12 Volt
X-11 Parts Location

J-27
A <4JH1> STARTER "C"
FRAME
HARNESS
A

H-14

J-26
E-17
STARTER "B"
GENERATOR "B" E-18
GENERATOR
X-21
P-5 P-1
P-2

F-16, F-21, F-22 <4JH1>

(12V)
P-3 P-4

N8A5062E
CAB AND CHASSIS ELECTRICAL 8-55
8-56 CAB AND CHASSIS ELECTRICAL
For 24 Volt (Except 4HK1)

J-1,J-2 GENERATOR

B-67

N8A5063E
 X-1 CHARGE RELAY
RELAY BOX ASM (No.1)
For 24 Volt (4HK1)

STARTER SW J-1,J-2 GENERATOR

J-191 ECM

B-67
P-5
P-1

P-2

P-3
BATTERY

P-4
J-9
F-28 FUSE
FL-1, FL-2 FUSIBLE LINK
H-5 ~ H-8 X-21 STARTER RELAY
X-26 STARTER CUT RELAY
FUSE BOX ASM STARTER
F-16, F-22 J-26, J-27 RELAY BOX ASM

N8A5569E
CAB AND CHASSIS ELECTRICAL 8-57
 FUSE BLOCK STARTER SWITCH

FL-1 100A FL-2 50A

ACC F-21 15A
MAIN KEY SW
3W/B 1 2 B GENERATOR
H-7 B-67 ON 3 3B/Y
P-1
B-67 0.5W/R RELAY; EXHAUST
FL-8 60A ST 4
BRAKE(2)
P-2 B-67 RELAY; CHARGE
Circuit Diagram
STARTER
0.85W 1
X-11 0.5W/R CHARGE WARNING
5

8B
X-11
3

30B
3B/Y 0.3B X-11
LIGHT B-52 (3)(METER)
RELAY; STARTER

3W/B
P-5 2L F-22 0.3B 4
3 2 X-11
For 12 Volt (Except 4JH1)

X-21 X-21

0.85W
FRAME STARTER 0.5W/R QOS III CONTROL
1 2L
4 10A UNIT (6)
E-72 X-21 8
P-6 H-5 0.5W/R RELAY; HEATER

3B/W
X-11 & A/C (2)
STARTER J-26
2
B
X-21 3W
C 1

0.3B/W
J-27 5 2 1
E-18 E-18

0.5W/L
IG S

15 GENERATOR

0.85W
1 3
H-5 E-17 B L E-18

0.3B/W
8-58 CAB AND CHASSIS ELECTRICAL

0.5B
0.5B/W
(For THAILAND, WEST MALAYSIA,

0.3B/W
INDONESIA)

0.85W/L
12
14 0.3B
H-14
H-8 11
H-14 0.85W/L

0.85W

QOS II CONTROL UNIT(4)

3W

QOS III CONTROL UNIT(11)

3 2
E-18 E-18
IG S

GENERATOR
8W 1 1
E-17 B L E-18

2B
HEADLIGHT 3B
B-7
BRACKET (LH) 1.25B
FRAME-LH J-9
2B
(CENTER)

N8A5064E
 FUSE BLOCK STARTER SW
METER 0.5W/R RELAY; FUEL
FL-1 100A FL-2 50A HEATER(2)
ACC F-16 10A RELAY; CHARGE
MAIN KEY SW
3W/B 1 2 B METER
H-7 B-67 ON 3 3B/Y 0.5B/Y 3 0.5
B-67 X-11 W/R
P-3 P-1 5
X-11
P-4 P-2 FL-8 60A ST 4
B-67
STARTER
For 12 Volt (4JH1)
0.5B/Y 4
X-11
0.5W/R

3B/Y
RELAY; HEATER

8B
(12V) & A/C(2)

30B
P-5 2L

3W/B
X-11
FRAME
1 2L 2

F-22 10A
E-72 RELAY; STARTER
P-6 3 2
X-21 X-21
STARTER J-26 14
0.5B/W 0.5B/W

STARTER 0.3B/W
4 H-8
B X-21

3B/W
C 1

0.85W/L
J-27

X-21
5
15
H-5

0.5W/L

3
H-14
3W
2
E-18
S
0.85W/L

GENERATOR
8W 1
E-17 B L E-18

0.5B
FRAME-LH J-9
2B
(CENTER)

N8A5065E
CAB AND CHASSIS ELECTRICAL 8-59
 FUSE BLOCK
STARTER SWITCH
100A
or
FL-1 120A FL-2 40A
ACC
MAIN KEY SW F-16 10A
8W/B 3W/L 1 2 B
H-7 B-67 ON 3 3B/Y METER 0.5W/R RELAY; HEATER
P-1 B-67
0.5B/Y & A/C (2)
P-2 ST 4
FL-8 60A B-67

8W/B STARTER RELAY; CHARGE

2
X-1 0.5W/R
3B/Y 1 RELAY; EXHAUST
0.5B/Y 4 X-1
X-1
BRAKE (2)
P-3 F-22 10A

8B
For 24 Volt (Except 4HK1)

0.5B/Y 3

30B
P-4

3W/B
STARTER X-1

3W(66, 71)
X-1
5
P-5 2L

0.5B/W
FRAME
1
RELAY; STARTER
P-6 0.5W/L CHARGE WARNING
3 2
J-26 X-21 X-21 LIGHT B-52 (3)

0.5W/L
STARTER
B
X-21
5

3B/W
C
J-27
8-60 CAB AND CHASSIS ELECTRICAL

15
1
H-5

0.5B/W
X-21
4

3W/L

0.5B/W
0.85W/L

QOS II
14
H-8

0.5B
CONTROL UNIT (4)
2
J-1
1.25W/L

0.5B/W

GENERATOR
8WB 1 1
J-2 B L J-1

0.5B
J-9
2B
FRAME-LH (CENTER)

N8A5066E
 FUSE BLOCK
STARTER SWITCH
100A
or
FL-1 120A FL-2 40A
ACC
MAIN KEY SW F-16 10A
8W/B 3W/L 1 2 B
H-7 B-67 ON 3 3B/Y METER 0.5W/R RELAY; HEATER
P-1 B-67
0.5B/Y & A/C (2)
P-2 ST 4
FL-8 60A B-67
For 24 Volt (4HK1)

STARTER RELAY; CHARGE

8W/B
2
X-1 0.5W/R
3B/Y 1 RELAY; EXHAUST
0.5B/Y 4 X-1
X-1
BRAKE (2)
P-3 F-22 10A

8B
0.5B/Y 3

30B
P-4

3W/B
STARTER X-1

X-1
5
P-5 2L

0.3B/W
FRAME
1
RELAY; STARTER
P-6 0.5W/L CHARGE WARNING
3 2
J-26 X-21 X-21 LIGHT B-52 (3)

0.5W/L
STARTER
B
X-21
5

3B/W
C
J-27 15
1
H-5

0.3B/W
X-21
4

3 W/L

0.3B/W
0.85W/L

QOS II
14
H-8

0.5B
2

CONTROL UNIT (4)

J-1
1.25W/L

0.5B/W
GENERATOR
8W/B 1 1
J-2 B L J-1

F-28 10A
ECM
0.5LG 1.25R RELAY;
ECM MAIN (2)
4 3
X-26 X-26
RELAY;
STARTER
CUT
X-26 X-26
1 5

0.5W/L
14
J-191

0.5B
J-9
2B ECM
FRAME-LH (CENTER)

N8A5600E
CAB AND CHASSIS ELECTRICAL 8-61
8-62 CAB AND CHASSIS ELECTRICAL
Connector List No. Connector Face

No. Connector Face

E-17
1
1
X-11 2 3 4

5 001-001

005-001

E-17

X-1
000-001

005-006

J-2

B-67
1 2
000-001
3 4

004-001

E-18 1 2

3 4
B-67 2 1
4 3
004-003

004-002

J-1
1 2

E-11
1 2
002-003

002-001

E-18
(4JH1) 1 2

E-11 2 1
002-003

002-002

H-14
1 2 3 4
5 6 7 8
9 10 11 12

J-70
13 14 15 16

1 2
016-001

002-001

4 3 2 1
H-14 8 7 6 5
12 11 10 9
16 15 14 13
J-70 2 1
016-002

002-002
 CAB AND CHASSIS ELECTRICAL 8-63

No. Connector Face No. Connector Face

1 P-1
X-21 2 3
(12 V)
4 5

005-003 000-003

X-26 P-2

005-006 000-004

3 2 1 P-1
J-69 6 5 4 (24 V)
9 8 7

009-001 000-004

J-191 P-4

081-001 000-004

E-17 P-2
(4JH1) (24 V)

000-002 000-006

P-3
J-26 (4JH1
12 V)

000-002 000-006

P-6
P-5
(Excep
(12 V)
t 66)

000-002 000-007

P-6
P-5
(Excep
(24 V)
t 66)

000-002 000-008
8-64 CAB AND CHASSIS ELECTRICAL
H-5 Starter Switch
The starter switch positions are LOCK, ACC, ON and
START. Turning the starter key to these positions a cir-
cuit for starting the engine, the operation of accessories,
or stop the engine.

1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 11 12 12 11 10 9 8 7
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 24 23 22 21 20 19
25 26 27 28 29 30 30 29 28 27 26 25
31 32 33 34 35 36 37 38 39 40 40 39 38 37 36 35 34 33 32 31

N8A5488E

H-7, H-8

N8A0072E

1 2 H-6 2 1

1 2 H-7 2 1

1 2 3 4 4 3 2 1

5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14

N8A5489E
 CAB AND CHASSIS ELECTRICAL 8-65
Inspection
Check the continuity between the starter switch connector terminals.
Repair or replace the switch when the result of inspection is found abnormal.

N8A0073E

Removal
Preparation:
Disconnect the battery ground cable.
1. Steering Cowl
Remove four screws and take off the steering cowl.
2. Starter Switch
1) Disconnect the connector.
2) Remove the screw.

N8A5070E

Installation
To install, follow the removal steps in the reverse order.
8-66 CAB AND CHASSIS ELECTRICAL
Neutral switch
Inspection
Check to see if there is any continuity between the
switch terminals.
Replace the switch when the result of inspection is
found abnormal.

N8A5071E

QOS (Quick On Start) II System (4HF1 and 4JB1 Engine Model)

General Description
The circuit consists of starter switch, QOSII control unit, glow relay, thermo switch, glow plug, fuel cut solenoid, CSD
relay, CSD solenoid and glow indicator light.
The QOS-II controller controls glow plug relay by the ON or OFF signal of QOS thermo switch.
Immediately when the starter switch turns “ON”, the glow plug relay indicator light turns on to start preheating.
The engine should be started after the indicator light is off. However, the glow plug relay keeps preheating for a fixed
period even after the indicator light turns off. When the fixed time is over, QOS-II controller performs to switch the
glow plug relay off to stop preheating.
For details, refer to “PREHEATING SYSTEM”.
System Circuit

N8A5072E
 CAB AND CHASSIS ELECTRICAL 8-67
Parts Location

N8A5073E
 FUSE BLOCK STARTER SW
FL-1 100A
2L MAIN
FL-2 50A
ACC
P-1 KEY SW
3W/B 1 3W/L 2 B
H-7 B-67 ON 3 3B/Y
P-2 B-67

NHR55, NKR55
ST 4 3B/Y
B-67
Circuit Diagram
F-9 10A
FUEL CUT 0.5B/O
P-5
FRAME F-16 10A
METER
12
H-5
FL-3 60A F-22 10A
STARTER

0.5B/Y
GLOW
5B/L 0.5B/Y
22

0.5B/O
H-5
0.5B/Y
14
3 2 H-14

X-26 X-26

5B/L
RELAY; GLOW

0.5B/Y
0.5B/Y
8-68 CAB AND CHASSIS ELECTRICAL

0.5B/Y 2 3
X-20 X-20
0.5B/W

RELAY; CSD
X-26 X-26
4 8 5
X-20 4
B-51
0.5Y

0.5L
1.25B/O

5 15
H-14

0.5B/Y
H-14
X-20
5 B-51
0.3B/W

37
1.25L

1.25Y
6 1 1
H-5
1 E-24 E-15

0.3B/R
E-8
3
RELAY; STARTER (4)

H-8

GLOW INDICATOR LIGHT (METER)

0.5GR

0.3O/L
CSD SOLENOID

0.3B/R
THERMO SW(GLOW)
FUEL CUT SOLENOID

1 5 7 1 3 4
E-3 B-10 B-10 B-10 B-10 B-10
GLOW
PLUG
QOS II CONTROL UNIT

B-10
6
0.3B

3B
HEADLIGHT BRACKET (LH) B-7

N8A5074E
 100A
or FUSE BLOCK STARTER SWITCH
FL-1 120A
2L MAIN
FL-2 40A
ACC
P-1 KEY SW
1 2 B
H-7 B-67 ON 3 3B/Y
P-2 3W/L B-67

ST 4 3B/Y
B-67
NKR66, NPR66, NQR66

FL-3 60A
P-3
GLOW
3B/L
P-4
F-16 10A
METER F-22 10A
STARTER

RELAY; GLOW
P-5

0.5B/Y
2 3 22
FRAME X-20 X-20 H-5
0.5B/Y
4
X-20
0.5B/Y

0.5B/Y
X-20
5

3B/Y
0.5Y
0.5B/W

8
B-51
1
E-8

0.3B/R
8
H-14 H-14

0.3B/Y
16 B-51
0.3B/W

H-8 6
0.5Y

3
37
THERMO SWITCH (GLOW)
RELAY; STARTER (4)

GLOW INDICATOR LIGHT (METER)

H-5

3B/Y
0.3O/L

0.3B/R
0.5Y

1 5 7 1 3 4
E-3 B-10 B-10 B-10 B-10 B-10

GLOW PLUG QOS II CONTROL UNIT

B-10
6
0.3B

3B
HEADLIGHT BRACKET (LH) B-7

N8A5075E
CAB AND CHASSIS ELECTRICAL 8-69
8-70 CAB AND CHASSIS ELECTRICAL
Connector List No. Connector Face

No. Connector Face

E-24 1

B-10 1 2 3

4 5 6 7 001-003

007-001

H-14
1 2 3 4
5 6 7 8
9 10 11 12

B-51
13 14 15 16

1 2 3 4 5 6 7 8 9 1011121314
016-001

014-001

4 3 2 1
H-14 8 7 6 5
12 11 10 9
16 15 14 13
B-67
1 2
016-002
3 4

004-001

H-14 5
1
6
2
7
3
8
4
9
(4HF1) 10 11 12 13 14

B-67 2 1
15 16

4 3
016-003

004-002

H-14 9
4
8
3
7
2
6
1
5

(4HF1) 14 13 12 11 10

E-3 16 15

016-004

000-009

1
X-20 2 3

E-8
4 5

005-003

000-010

X-26

E-8
005-006

000-011

P-1

E-24
1
000-004

001-002
 CAB AND CHASSIS ELECTRICAL 8-71

No. Connector Face H-7, H-8

P-4

000-004 1 2 H-6 2 1

1 2 H-7 2 1

1 2 3 4 4 3 2 1
P-2 5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14
000-006

P-3 N8A5489E

Starter Switch
000-006
Refer to “START AND CHARGING” in this section.

Glow Indicator Light Thermo Switch

P-5 Refer to “METER AND WARNING/INDICATOR LIGHT”
(12 V) in this section.

QOSII Control Unit

000-007

P-5
(24 V)

000-002

H-5

1 2 3 4 5 6 6 5 4 3 2 1
N8A0079E
7 8 9 10 11 12 12 11 10 9 8 7
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 24 23 22 21 20 19
25 26 27 28 29 30 30 29 28 27 26 25
31 32 33 34 35 36 37 38 39 40 40 39 38 37 36 35 34 33 32 31
Terminal No. Connected to
1 Starter switch (ON)
2 —
3 Thermo switch
4 Starter switch (ST)
N8A5488E 5 Glow relay
6 Ground
7 Glow indicator (Meter)
8-72 CAB AND CHASSIS ELECTRICAL
QOS (Quick On Start) III System (4JG2 Engine Model)
General Description
The system consists of starter switch, QOS III control unit, glow relay, charge relay, fuel cut solenoid, dropping resis-
tor, thermo sensor, glow plug, engine speed sensor, accel switch and glow indicator light.
Perceiving the engine coolant temperature when the engine started, the thermo sensor varies the glowing time to al-
ways get the most suitable condition for engine starting.
The indicator timer starts to operate as soon as the starter switch turns to “ON” position, and the indicator light turns
on and keeps lit until the glow plugs have been heated to the level ready for the engine starting, when the indicator
light is off.
For details, refer to “PREHEATING SYSTEM”.
System Circuit

N8A5078E
 CAB AND CHASSIS ELECTRICAL 8-73
Parts Location

N8A5079E
 FUSE BLOCK

NHR69
STARTER SWITCH

FL-1 100A FL-2 50A

ACC
2L KEY SW
MAIN 1 2 B
H-7 B-67 ON 3 3B/Y
P-1 3W/B B-67

P-2 ST 4 3B/W
B-67
Circuit Diagram

3B/Y

FL-3 60A
P-5 GLOW 5B/L
FRAME F-18 15A F-16 10A
GENERATOR METER F-22 10A
RELAY; GLOW 2 STARTER
5B/R 2 3
X-19 X-19
5B/L

0.5B/Y
4 22
X-19 H-5
2 0.5B/Y
J-60

X-19

0.85W
5

5B/L
8-74 CAB AND CHASSIS ELECTRICAL

J-60

0.5B/Y
0.5B/W

RELAY; CHARGE
1 RELAY; GLOW 1 8

DROPPING RESISTOR
0.5B/L
3
5B/Y 2 3 X-11 B-51
X-20 X-20 5
X-11
1

0.5B/Y
4 X-11
X-20
0.3B 4
X-11
B-51
6
0.5B/W

X-20 H-8
5 18 X-11

5B/Y
0.5W/L
2
GLOW INDICATOR LIGHT (METER)

METER B-52 (3)

RELAY; STARTER (4)

H-8
0.3O/L

0.85W/L

0.3B/L
GENERATOR (L)

0.5W/L
1

0.3B/R
E-3 E-18 (1)
5 12 6 1 13 11
B-10 B-10 B-10 B-10 B-10 B-10
GLOW PLUG
QOS III CONTROL UNIT

1.25B
B-10 B-10 B-10 B-10
9 8 4 10

0.5GR

0.3W
0.5GR/B

H-5
H-5
37
40
METER B-52 (2) H-14 H-14
5 15
2 1
E-16 E-16
0.5GR 0.5GR/B
THERMO SENSOR (GLOW)
3B 0.3B
HEADLIGHT BRACKET (LH) B-7

N8A5080E
 CAB AND CHASSIS ELECTRICAL 8-75
Connector List No. Connector Face

No. Connector Face

E-2
2 1

B-10 1 2 3 4 5 6

7 8 9 10 11 12 13 002-006

013-001

E-3

B-17
1 2 3 4
000-009

004-004

E-16 1
1
2
X-11 2 3 4

5
002-009

005-001

E-16 1
2
B-51 1 2 3 4 5 6 7 8 9 1011121314
002-010

014-001

1 2 3 4

H-14 5 6 7 8 9
10 11 12 13 14

B-67 15 16

1 2
3 4 016-003

004-001

4 3 2 1

H-14 9 8
14 13 12 11 10
7 6 5

B-67 2 1
16 15

4 3 016-004

004-002

1
X-19 2 3

B-75
4 5
1 2
3 4 5
005-003

005-002

1
X-20 2 3

E-2
4 5

1 2
005-003

002-005
8-76 CAB AND CHASSIS ELECTRICAL

No. Connector Face H-7, H-8

J-60
1 2

002-007 1 2 H-6 2 1

1 2 H-7 2 1

1 2 3 4 4 3 2 1
J-60 2 1 5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14
002-008

P-1 N8A5489E

Starter Switch
000-003
Refer to “START AND CHARGING” in this section.

Glow Indicator Light

Refer to “METER AND WARNING/INDICATOR LIGHT”
P-2 in this section.

QOSIII Control Unit

000-004

P-5

000-007

H-5

1 2 3 4 5 6 6 5 4 3 2 1 N8A5082E
7 8 9 10 11 12 12 11 10 9 8 7
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 24 23 22 21 20 19
25 26 27 28 29 30 30 29 28 27 26 25
31 32 33 34 35 36 37 38 39 40 40 39 38 37 36 35 34 33 32 31
Terminal No. Connected to
1 Starter switch (ON)
2 —
3 —
4 Thermo sensor (-)
N8A5488E
5 Glow 1 relay
6 Charge relay
7 —
 CAB AND CHASSIS ELECTRICAL 8-77

Terminal No. Connected to

8 Thermo sensor (+)
9 Meter
10 Ground
11 Starter switch (ST)
12 Glow 2 relay
13 Glow indicator (Meter)

Exhaust Brake System

General Description
This circuit consists of starter switch, exhaust brake
switch (combination switch), accelerator switch, clutch
switch, vacuum switching valve, neutral switch and re-
lay.
Exhaust brake is a system to increase exhaust pressure
by means of squeezing exhaust gas from engine and
exert engine brake.
Turn the exhaust brake SW on, and the exhaust brake
valve starts to work by the function of the magnetic valve
to enable the exhaust bake to operate, when the ex-
haust brake indicator light will be on.
When either the accelerator pedal or the clutch pedal is
depressed while driving, the switch of the depressed
pedal will turn off, subsequently the exhaust braking will
stop working.
8-78 CAB AND CHASSIS ELECTRICAL
Parts Location
NHR55, NKR55, NHR69

N8A5083E
 CAB AND CHASSIS ELECTRICAL 8-79
NKR66, NPR66, NQR66, NPR71

N8A5084E
 FL-1 100A
MAIN 2
8W H-6
3W/B
RELAY; EXHAUST F-2 15A
STARTER SWITCH BRAKE FUEL HEATER
FL-2 50A OFF 3W 1 EXH BRAKE
X-8

2L
5
KEY SW ACC X-8
3B/R
2 B
B-67 ON 3 3B/Y 4 2
Circuit Diagram
B-67 X-8 X-8

0.5LG

3W/L
ST
P-1 1 5

3B/Y
P-2 H-7 B-69
NHR55, NKR55, NHR69

METER
0.5W/L

F-21 15A

F-16 10A
GENERATOR
P-5
B-69
FRAME 0.85W 2
1

0.5B/Y
22 X-11

(COMBINATION SWITCH)
EXHAUST BRAKE SWITCH
H-5 X-11
3 5
X-11

0.85W
4 0.85W/L
2 X-11 X-11
2
GENERATOR (L)

0.5LG/L
J-50
RELAY; CHARGE
8-80 CAB AND CHASSIS ELECTRICAL

0.5B
0.3B
J-50
B-51 (1)

GENERATOR (IG)

NEUTRAL SWITCH
1
0.5LG/R (69) 17
H-8
EXHAUST BRAKE

0.5LG/Y
4 5
0.5B/G
X-25 X-25
0.5LG/L INDICATOR LIGHT (METER)

X-25 X-25
BRAKE CONTROL
RELAY; EXHAUST

2 3
CLUTCH SWITCH
12 1 2
H-8 B-89 B-89
0.5LG/B

0.5LG/B
0.5LG/R

2B
1.25B ACCEL. SWITCH
2 1
B-75 B-75

32
0.5LG

1 H-5
2B

0.5LG
J-31

J-31
EXHAUST BRAKE
MAGNETIC VALVE

3B
HEADLIGHT BRACKET (LH) B-7
0.5B

J-9
2B 2B
FRAME-LH (CENTER)

N8A5086E
 100A
or
FL-1 120A
MAIN
5W 2
H-6 RELAY; EXHAUST BRAKE F-2 10A
FUEL HEATER
STARTER SWITCH 3W 1 EXH BRAKE
X-8 5 3B/R 0.5LG
FL-2 40A OFF X-8

2L
KEY SW ACC
4 2
2 B X-8 X-8
B-67 ON 3 3B/Y
B-67

0.5LG
ST
5

3W/L
P-1

0.5W/R
1
B-69
P-2 H-7

METER
F-16 10A
0.5B
NKR66, NPR66, NQR66, NPR71

P-3 B-69

0.5B/Y
2
P-4 22
(COMBINATION SWITCH)

H-5
EXHAUST BRAKE SWITCH

0.85W
0.5W/R
0.5LG/L

0.5B/Y
5 X-1
3 5
H-14 X-1
P-5
2 4 2
FRAME X-1 X-1 GENERATOR (L)
E-11
0.85W/L
RELAY; CHARGE

17
E-11 H-8
0.5LG/L 0.5LG/L

NEUTRAL SWITCH
1
H-14
LIGHT (METER) B-51 (1)

10 0.5B/G
4 5
0.5LG/L EXHAUST BRAKE INDICATOR

X-25 X-25

X-25 X-25
RELAY; EXHAUST
BRAKE CONTROL

2 3
CLUTCH SWITCH
12 1 2 2 1
H-8 B-89 B-89 B-75 B-75

2B
0.5LG/B
0.5LG/B

0.5LG/R
ACCEL. SWITCH
0.5LG 32
H-5
0.5LG
0.5LG

1 1
0.5B

J-31 J-40
THROTTLE
VSV INTAKE

J-31 J-40
EXHAUST BRAKE

2 2
MAGNETIC VALVE
0.5B

HEADLIGHT
3B
0.5B

BRACKET (LH) B-7

FRAME-LH (CENTER) J-9

2B

N8A5087E
CAB AND CHASSIS ELECTRICAL 8-81
8-82 CAB AND CHASSIS ELECTRICAL
Connector List No. Connector Face

No. Connector Face

B-69 1 2 3 4
5 6 7 8
B-17 1 2 3 4
008-001

004-004

B-69 4 3 2 1
1
8 7 6 5
X-11 2 3 4

5 008-002

005-001

B-75 1
2
X-1
002-009

005-006

1
B-75
2
X-8
002-010

005-006

B-89 1
2
X-25
002-009

005-006

E-11 1 2

B-47 1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20 002-001

020-001

E-11 2 1

B-67 1 2
002-002
3 4

004-001

J-50 1 2

B-67 2 1
4 3 002-001

004-002
 CAB AND CHASSIS ELECTRICAL 8-83

No. Connector Face No. Connector Face

J-50 2 1 J-40 1 2

002-002 002-014

P-1
J-70 1 2 (12 V)

002-001 000-003

J-70 2 1 P-2

002-002 000-004

1 2 3 4
P-1
H-14 5 6 7 8 9
10 11 12 13 14
(24 V)
15 16

016-003 000-004

4 3 2 1
9 8 7 6 5
H-14 14 13 12 11 10 P-4
16 15

016-004 000-004

1
P-2
X-21
(24 V)
2 3

4 5

005-003 000-006

J-31 1 2
P-3

002-011 000-006

P-5
J-31 2 1 (24 V)

002-012 000-002
8-84 CAB AND CHASSIS ELECTRICAL

No. Connector Face Starter Switch

Refer to “START AND CHARGING” in this section.

Accel Switch
P-5 Inspection
(12 V)
1. Check the continuity between the switch connector
terminals.
000-007
2. Check to see if switch push rod operates smoothly.
Repair or replace the accel switch when result of
H-5
inspection is found abnormal.

1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 11 12 12 11 10 9 8 7
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 24 23 22 21 20 19
25 26 27 28 29 30 30 29 28 27 26 25
31 32 33 34 35 36 37 38 39 40 40 39 38 37 36 35 34 33 32 31

N8A5488E
N8A5091E

H-6, H-7, H-8

Removal
Preparation:
Disconnect the battery ground cable.
1. Accel Switch
1) Disconnect the connector.
2) Loosen the lock nut of the switch.
1 2 H-6 2 1 3) Remove the switch by turning it.

1 2 H-7 2 1

1 2 3 4 4 3 2 1

5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14

N8A5489E

Neutral Switch
Refer to “START AND CHARGING” in this section.

Starter Relay
Refer to “START AND CHARGING” in this section.
N8A0088E
Charge Relay
Refer to “START AND CHARGING” in this section.
 CAB AND CHASSIS ELECTRICAL 8-85
Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Check to see if the accel pedal has been returned
by the return spring to the specified position.
2. Turn the accel switch clockwise until the tip of the
threaded portion of the switch contacts the pedal
arm.
3. Tighten the lock nut to the specified torque.
Tighten:
Lock nut to 13 N⋅m (130 kg⋅cm / 115lb⋅in)

Clutch Switch
Inspection
1. Check the continuity between the switch connector
terminals.
2. Check to see if switch push rod operates smoothly.
Repair or replace the switch when result of inspec-
tion is found abnormal.

N8A0089E

Removal and Installation

Refer to “Accel Switch” in this section.
8-86 CAB AND CHASSIS ELECTRICAL
Exhaust Brake Switch
Inspection
Check the continuity between the terminals of the exhaust brake switch.
Repair or replace the switch when the result of inspection is found abnormal.

N8A5095E

Removal and Installation

Refer to “HEADLIGHT, FOG LIGHT AND CORNERING
LIGHT” in this section.

Exhaust Brake Magnetic Valve (4JG2 Engine)

Inspection
Connect the magnetic valve connector terminal No.1 to
the battery (+) terminal and terminal No. 2 to the (−) ter-
minal and then check the continuity among each port.
Repair or replace the magnetic valve when the result of
inspection is found abnormal.

N8A5096E
 CAB AND CHASSIS ELECTRICAL 8-87
Exhaust Brake Magnetic Valve (4JG2, 4H Series Vacuum Switching Valve: Intake Throttle (4H
Engine) Series Engine)
Inspection Inspection
Connect the magnetic valve connector terminal No. 1 to Connect the magnetic valve connector terminal No. 1 to
the battery (+) terminal and terminal No. 2 to the (−) ter- the battery (+) terminal and terminal No. 2 to the (−) ter-
minal and then check the continuity among each port. minal and then check the continuity among each port.
Repair or replace the vacuum switching valve when the
result of inspection is found abnormal.

N8A0094E

N8A0096E
 Parts Location
FUSE BOX ASM
F-2, F-9, F-13, F-16, F-22
For 4HE1-TC Engine
X-1 CHARGE RELAY

B-52, B-51EXHAUST BRAKE

INDICATOR LIGHT AND
GLOW LIGHT (METER)

B-79 DATA LINK CONNECTOR

8-88 CAB AND CHASSIS ELECTRICAL
Exhaust Brake System and Engine Control

H-15

H-13
H-14

RELAY BOX ASM (No.2)

X-14 TIMING RELAY

B-1
B-233, 234 ECU

N8A5599E
 CAB AND CHASSIS ELECTRICAL 8-89
For 4JH1 Engine

N8A5103E
8-90 CAB AND CHASSIS ELECTRICAL
For 4HK1-TC Engine

N8A5102E
 CAB AND CHASSIS ELECTRICAL 8-91
Circuit Diagram
4HE1-TC Engine for Hong Kong (With ABS) (1)

3B/L

FL-3 FL-2 OFF

60A 40A 0.5B/Y
ACC
GLOW KEY 1 2
3W/L 3
H-7 B-67 ON 3B/Y
B-67
ST
5W B-67
4 3B/Y
FL-1 STARTER SW
5W

100A F-9

0.5B/Y

0.5B/Y
MAIN F-22 F-16 10A
2 10A 10A ENG.
STARTER METER 0.5B/Y 3 4
(IG)
2L

H-6 X-1 X-1

RELAY:CHARGE
0.3B/W

0.5B/Y
3W/B

3W/B
22
P-1 X-1 X-1
H-5
0.5W/R 5 2
P-2 0.5B

0.5W/L
2 1 1 3 4 0.5B/Y 5 F-13
10A
X-8 X-8 X-28 X-28 X-28
EXH BRAKE CUT
EXHAUST BRAKE

H-14 ENG.
2B

15
STOP
0.5P
H-5
RELAY:
RELAY

0.5LG/W

GLOW INDICATOR LIGHT

J-9 2
8
P-3 E-11
SW:NEUTRAL
B-51
X-8 X-8 X-28 X-28
P-4 ACG(L)
4 5 8 5 2
0.5LG/B

F-2 10A
0.5B

FUEL HEATER H-8 14 13 E-11 B-51

EXH BRAKE 10 H-14 H-14 1 0.5L/R 6
0.5LG/W
A
0.5LG/B

H-8
0.5LG

0.5B

P-5
5 8 7
B-69 10 38
J-177 J-177
H-14 H-5
EXH BRAKE

0.3O/L

0.5B/Y
0.5LG/R

ABS
SW:

0.5B/G

0.3B
C/U
B-7

0.3L/R
4 5
J-177 J-177
BRAKE CONTROL

B-69
RELAY:EXHAUST

6 29 X-25 X-25
H/L BRKT 2
0.5LG/R

8 18 3 9 3
LH
B-234 B-233 B-233 B-234 B-234
0.3W/G

B ST GLOW IGN
3 6 ECM
H-15 H-15 X-25 X-25
EXH
2 3 FICD BRAKE
0.3W/B

B-234 B-233
1 30 19
0.5LG/B

24
B-51
0.5B

0.5L/W

H-5

17 37
B-52 H-8 H-5
A/C
10 COMP
0.5LG/B

B-1
0.5G/O
0.5L/W

1
FRAME LH
(FRONT) B-89 3 1
J-23 J-23
0.3W/B

SW:
CLUTCH
DIODE
2
B-89
B-75 J-23
2
SW:ACCEL

0.5LG/R 2
0.5L/G

2
B-75 H-13
1 0.5LG

32
0.5L/R

H-5
6
0.5LG 0.5LG
H-13
1 1 1
J-31 J-40 J-41
MAGNETIC
VALVE:
EXHAUST
BRAKE

J-31 J-40 VSV:INTAKE J-41 VSV:FICD

THROTTLE
2 2 2
0.5B

12
0.58

H-13

FRAME-LH 2B 0.5B
J-9
(CENTER)

N8A5106E
8-92 CAB AND CHASSIS ELECTRICAL
4HE1-TC Engine for Hong Kong (With ABS) (2)

3B/L

0.5B/Y

0.5B/Y
0.5B/Y
4 3
X-20 X-20

RELAY:GLOW
11
H-13
X-20 X-20
THERMO SENSOR
5 2
0.5B/Y

0.5B/Y

0.3B/R

3B/Y
0.5B/Y
E-76 E-76 3 16

2 1 H-8 H-14
0.5GR/B

2 2 2

0.5GR
J-145 J-146 J-147

5B/Y
2
4 8

SW:T/M POSITION
J-131

(LOW OR REV)
H-14 H-14
1
0.3GR/B

0.3GR

E-3 GLOW PLUG

J-145 VSV:VSS J-146 VSV: J-147 VSV:EGR
ANEROID
1 1 COMPENSATOR 1 26 27 J-131
0.5BR/B

0.5BR/Y

0.3B/R
BR/W

H-5 H-5 1
0.5

0.5LG/B
1 3 5
H-13 H-13 H-13
0.5BR/W
0.5BR/B

0.5BR/Y

0.3GR/B

29
0.3GR

9 18 40 H-5

H-8 H-8 H-5

0.5LG/B
0.3BR/W
0.3BR/B

0.3BR/Y

11 13 1 7 8 27 2
B-233 B-233 B-233 B-233 B-233 B-234 B-233
VSV:VSS VSV: VSV:EGR GND SIG GLOW
ANECON RELAY
ECM
RACK MV
DIAG CHECKER RACK- SIG RACK+ ENG- ENG SIG TIMING EVRV- EVRV+ GND
B-234 B-234 B-234 B-234 B-234 B-233 B-233 B-234 B-234 B-234 B-234
16 1 21 7 6 9 10 11 14 13 22
A
0.3BR/Y
0.3V

0.3LG

1 2
0.5W

X-14 X-14
0.3Y

0.5B

0.5R
0.3L

RELAY:TIMING

4
0.5R/W

0.5O
0.3LG
0.3V

6 7 13 7 1 7 16 15
CONNECTOR

X-14 X-14
DATA LINK

B-79 B-79 H-5 H-5 H-5 H-8 H-8 H-8 H-8

5 4
0.5BR/R

13
0.3LG
0.5W
0.5B

0.5R

0.3V

B-79 B-79 B-79

2 4 5 12 6 5
0.5B

1 2 3 15 12 13 14 H-8 H-8 H-8

H-14 H-14 H-14 H-14 H-14 H-14 H-14
0.3BR/R

0.5R/W

0.5O
0.3W/B

0.3LG
0.5W
0.5B

0.5R

0.3V
0.5B

0.5B

11 10 4
0.3B

1 2 3 1 2 H-14 H-13 H-13

0.85BR/R

0.5R/W

E-43 E-43 E-43 E-2 E-2

0.5O
MAGNETIC VALVE:TIMING

1 2 1
0.5 E-74 J-105 J-105
V

RACK SENSOR ENGINE SPEED SENSOR EVRV:EGR

HEAD LIGHT 3B
B-7
BRACKET-LH

FRAME-LH
J-9
(CENTER)

N8A5107E
 CAB AND CHASSIS ELECTRICAL 8-93
4HE1-TC Engine for Hong Kong (Without ABS) (1)

3B/L

FL-3 FL-2 OFF

60A 40A 0.5B/Y
ACC
GLOW KEY 1 2
3W/L 3
H-7 B-67 ON 3B/Y
5W B-67
ST
FL-1 B-67
100A or 120A
2L

4 3B/Y
MAIN STARTER SW
F-9

0.85W

0.85W
2
+ F-22
10A
F-16
10A
10A
H-6 ENG. 3 4
P-1 STARTER METER 0.5B/Y (IG)
X-1 X-1

RELAY:CHARGE
P-2 0.3B/W

0.5B/Y
-
3W/B

3W/B
22
+ H-5
X-1 X-1
0.5W/R 5 2
P-3

0.5W/L
2 1 5
P-4 F-13
X-8 X-8
EXHAUST BRAKE

H-14 10A 15
- ENG.

0.5P
H-5
RELAY

STOP

GLOW INDICATOR LIGHT

2
8
E-11

SW:NEUTRAL
B-51

P-5 X-8 X-8

ACG(L)
4 5
0.5B F-2 10A SW:EXH BRAKE
FUEL HEATER (COMBINATION SW) E-11 B-51
EXH BRAKE 5 2

0.5L/R
0.5LG/R 1 6
0.5LG/W B-69 B-69 A
0.5B

B-7
1
10 38
INDICATOR LIGHT
EXHAUST BRAKE

B-51
H/L BRKT-LH H-14 H-5

0.3O/L

0.5B/Y
0.5 B/G

0.5LG/R

0.3L/R
4 5
B-52
BRAKE CONTROL
RELAY:EXHAUST

X-25 X-25
10 8 18 3 9 3
B-234 B-233 B-233 B-234 B-234
B ST GLOW IGN
ECM
X-25 X-25
EXH
2 3 FICD BRAKE
B-234 B-233
0.5LG/B

30 19
0.5L/W

17
H-8
37 A/C
H-5 COMP
0.5LG/B

0.5L/W

0.5G/O

0.5LG

1
B-89 3 1
SW: J-23 J-23
CLUTCH DIODE
0.5LG/W
2
0.5B

B-89
B-75 J-23
2
SW:ACCEL

0.5LG/R 2
0.5L/G

2
B-75 H-13
1 0.5LG

32
0.5L/R

H-5
6
0.5LG 0.5LG
H-13
1 1 1
J-31 J-40 J-41
MAGNETIC
VALVE:
EXHAUST
BRAKE

J-31 J-40 VSV:INTAKE J-41 VSV:FICD

THROTTLE
2 2 2
0.5B
0.5B

12
H-13
0.5B
FRAME-LH J-9
(CENTER)

N8A5108E
8-94 CAB AND CHASSIS ELECTRICAL
4HE1-TC Engine for Hong Kong (Without ABS) (2)

3B/L

0.5B/Y

0.5B/Y
4 3
0.5B/Y X-20 X-20

RELAY:GLOW
11
H-13
X-20 X-20
THERMO SENSOR 5 2

0.5B/Y
0.5B/Y

0.3B/R

3B/Y
0.5B/Y
E-76 E-76 3 16
H-8 H-14
2 1
0.3GR/B

2 2 2

0.3GR
J-145 J-146 J-147

5B/Y
2
4 8

SW:T/M POSITION
J-131

(LOW or REV)
H-14 H-14
1
0.3GR/B

0.3GR

E-3 GLOW PLUG

J-145 VSV:VSS J-146 VSV: J-147 VSV:EGR
ANEROID
1 1 COMPENSATOR 1 26 27 J-131
0.5BR/B

0.5BR/Y

0.3B/R
BR/W

H-5 H-5 1
0.5

1 3 5 0.5LG/B
H-13 H-13 H-13
0.5BR/W
0.5BR/B

0.5BR/Y

0.3GR/B

29
0.3GR

9 18 40 H-5

H-8 H-8 H-5

0.5LG/B
0.3BR/W
0.3BR/B

0.3BR/Y

11 13 1 7 8 27 2
B-233 B-233 B-233 B-233 B-233 B-234 B-233
VSV:VSS VSV: VSV:EGR GND SIG GLOW
ANECON RELAY
ECM
RACK MV
RACK- SIG RACK+ ENG- ENG SIG TIMING EVRV- EVRV+ GND
B-234 B-234 B-234 B-234 B-234 B-233 B-233 B-234 B-234 B-234 B-234
16 1 21 7 6 9 10 11 14 13 22
A
0.3BR/Y
0.3LG
0.3V

1 2
0.5W

X-14 X-14
0.3Y

0.5B

0.5R
0.3L

RELAY:TIMING

0.5R/W
0.3LG

0.5O
0.3V

6 7 13 7 1 7 161 15 3
CONNECTOR

X-14 X-14
DATA LINK

B-79 B-79 H-5 H-5 H-5 H-8 H-8 H-8 H-8

5 4
0.5BR/R
0.3LG
0.5W
0.5B

0.5R

0.3V

B-79 B-79
4 5 12 6 5
0.5B

1 2 3 15 12 13 14 H-8 H-8 H-8

H-14 H-14 H-14 H-14 H-14 H-14 H-14
0.5BR/R

0.5R/W

0.5O
0.3LG
0.5W
0.5B

0.5R

0.3V

11 10 4
0.5B

0.5B

1 2 3 1 2 H-14 H-13 H-13

0.85BR/R

0.5R/W

E-43 E-43 E-43 E-2 E-2

0.5O
MAGNETIC VALVE:TIMING

1 2 1
0.5 E-74 J-105 J-105
V

RACK SENSOR ENGINE SPEED SENSOR EVRV:EGR

HEAD LIGHT
B-7
BRACKET-LH

FRAME-LH
J-9
(CENTER)

N8A5109E
 P-3 P-1
2L
30BLK 8BLK
SBF-3
SBF-1 SBF-2 GLOW Fuse & Relay Box
MAIN KEY 60A (Behind the Cab)
Battery
100A 50A
4JH1 Engine (1)
3
30 8 WHT/
P-4 P-2 BLK WHT/ BLU
BLK 1 H-7
2 H-6
P-5 3
0.5 Glow Relay
BLK/ 0.5 WHT/
YEL BLK/ BLU
Starter 8
WHT/ YEL 2 B-67
BLK
3 2 X-11

OFF
3 Charge ST Ignition
WHT/ Relay ON ACC Switch
BLK

5 4 X-11
0.5 3 B-67
3 0.5 WHT/ Relay Box
Starter
WHT/ WHT/ BLU (Instrument
Relay
BLK RED Panel)
ACG
1 2 X-12 0.5 0.5 3
BLK/ BLK/ BLK/
YEL YEL BLU
Heater
A/C Relay

2 5 4 X-12 Fuse &

WHT/ Relay Box
BLK 0.5 (Glove Box)
3
BLK
BLU
2
BLK
F-9 F-8 F-5 SBF-25 Fuse &
F-1 3
ENG.(B2) ENG.(B1) STOP LIGHT HEATER Relay Box
AIR CON BLK
15A 15A 10A 30A (Glove Box)
10A
5
BLK

3 B-7
BLK/ 0.5 Headlight
0.85 2 ECM
YEL GRY/ Bracket
BRN BLU W/S-M
YEL
3 3
BLK/ BLK/
YEL YEL

ECM Main Data Link Brake A/C A/C Meter

Relay Connector Switch Thermo Thermo
Relay Relay

N6A3862E
CAB AND CHASSIS ELECTRICAL 8-95
 8BLK
Battery

SBF-2 SBF-4
SBF-1 SBF-8 SBF-9 SBF-3
KEY HEAD
MAIN STARTER ABS GLOW
50A LAMP
100A 60A 60A 60A
30A
4JH1 Engine (2)
3
WHT/ 2 H-6
BLU
Fuse & Relay Box
1 H-7 (Behind the Cab)

3
WHT/
BLU
F-25
3 F-27 F-26
MARKER
WHT/ RR FOG COND.FAN
LAMP
BLU 10A 15A
15A
2 B-67
Glow Plug
Relay

OFF
ST Ignition
ON ACC switch
8-96 CAB AND CHASSIS ELECTRICAL

3
4 3 1 B-67 WHT/
BLU
Heater Heater
3 Relay Relay
BLK/
YEL W/S-G W/S-H

W/S-A 2BLK/YEL

0.5 3 3 2
BLK/ WHT/ WHT/ WHT/
YEL BLK BLK BLK

5 2 X-1

Key ON
Relay

3 1 X-1 Fuse &

3 Relay Box
BLU (Glove Box)

F-15 F-12 F-11 F-10 SBF-26 F-4 F-5 F-8 F-9 F-19
F-22 F-16 F-20 0.5
AUDIO(IG), H/LAMP TURN FRONT WIPER & POWER AUDIO (B), STOP ENG. ENG. HORN,
STATER METER ABS(IG) BLK
CIGAR LIGHTER LEVEL LIGHT WASHER WINDOW DOOR LOCK LIGHT (B1) (B2) HAZARD
10A 10A 10A
15A 10A 10A 15A 30A 15A 10A 15A 15A 15A

N6A3863E
 P-3 P-1
30BLK 8BLK P-2 Refer to
Power Distribution
2L
Battery SBF-2 SBF-8
KEY STARTER
F-16 Fuse & 50A 60A
METER Relay Box Fuse & Relay Box
10A (Glove Box) 3 (Behind the Cab)
4JH1 Engine (3)
P-4 P-2 WHT/
BLU

P-5 3
W/S-M WHT/
BLU

1 H-7
0.5 0.5 8 Fuse &
BLK/ BLK/ WHT Relay Box
YEL YEL Refer to (Glove Box)
Power Distribution
3 2 X-11

2 B-67
30 Relay Box 3 3
Charge
BLK (Instrument WHT/ WHT/
Relay
Panel) BLK BLK

5 4 X-11
OFF
ST Ignition
ON ACC switch
0.5
WHT/BLU
Heater
A/C Relay
3
13 H-6 BLK/
WHT 2 4 X-8
0.85
WHT/BLU 4 B-67
Relay Box
3 Starter
3 H-3 (Instrument
WHT Relay
Panel)
F-22
E-72 STARTER
P-6 10A
0.85
1 J-26 3 5
WHT/BLU X-8

1 P-8 P-9 2 P-8

B 14 H-8
3
S B L 0.5
BLK/
BLK
WHT

Generator

Starter 2
BLK

M
C J-9
Frame

1 J-27

N6A3864E
CAB AND CHASSIS ELECTRICAL 8-97
 F-8 F-9 F-16 Fuse &
ENG.(B1) ENG.(B2) METER Relay Box
15A 15A 10A (Glove Box)

4JH1 Engine (4)

2BLU/RED 3
BLK/
3 3 YEL
BLU/ BLU/
RED RED
3 1.25
15 H-14 BLK/ BLK/
YEL YEL
1 H-6
2
1 2 X-14
RED/ Exhaust Brake
WHT Solenoid Valve
Intake Throttle
7 E-110 Solenoid Valve ECM Relay Box
Neutral Switch Main (Instrument
CAN CAN BAT (+) A/C Compressor Relay Relay Panel)
high low A/C Signal Relay
MAF & IAT Sensor
8-98 CAB AND CHASSIS ELECTRICAL

PCU 5 4
ESO CKP X-14
solenoid sensor
signal signal

6 2 1 5 8 E-110 Glow Relay 0.5

2 BLK/
BLU/ YEL
2 0.5 0.5 0.5 0.5 RED
BLK BLU YEL ORN PNK
0.5
BLU/
BLK
16 5 6 7 8 H-14

2 0.5 0.5 0.5 0.5

BLK RED YEL ORN PNK
W/S-M
2
BLU/
10 11 12 13 H-8 RED Meter

J-9
Frame
0.5 0.5 0.5 0.5
BLU YEL ORN PNK

100 99 105 91 B-233 3 58 39 B-234

ESO CKP
solenoid sensor ECM
signal signal main
output output relay
ECM
control
CAN CAN Battery Ignition voltage
high low voltage
12V

N6A3866E
 Ground Ground
F-9 F-8
Fuse & Relay Box
ENG.(B2) ENG.(B1) Diagnostic EHCU Diagnostic ECM
(Glove Box)
15A 15A request J1850 request Keyword
switch (Class2) switch 2000 4JH1 Engine (5)
4 29 J-177 2 1 45 35 B-234

2 2 0.3 0.3 2 2
WHT/ WHT/ WHT/ WHT/ BLK BLK
BLK BLK GRN BLK

3 4 H-15

3 0.3 0.3 5 0.5 0.5

BLK/ WHT/ WHT/ BLK BLU YEL
YEL GRN BLK

ECM 27 26 H-5
Main
Relay
B-1
0.5 0.3 0.3 Frame
BLK/ WHT/ WHT/
YEL GRN BLK

16 12 2 6 7 B-79

B+ Diagnostic J1850 Diagnostic Keyword

request (Class2) request 2000 Data
switch switch Link
Connector
(DLC)
Ground Ground

4 5 B-79

0.5 0.5
BLK BLK

W/S-C

0.85
BLK
5
J/C-E
9
0.85
BLK

B-7
Headlight Bracket

N6A3867E
CAB AND CHASSIS ELECTRICAL 8-99
 F-16 Exhaust
Fuse & Relay Box
METER Brake
(Glove Box)
10A Switch

0.5 4JH1 Engine (6)

LT GRN/
0.5
BLU
BLK/YEL
8 1 B-51

Speedometer Tachometer
Instrument
Exhaust Panel Cluster
Glow MIL (IPC)
Brake

3 1 B-55 10 8 9 B-52 2 6 4 B-51

0.3 0.5 0.85 0.3

BLK/ YEL/ BLK BLK
YEL GRN
8-100 CAB AND CHASSIS ELECTRICAL

0.5 0.85
BLK BLK
0.85
BLK
31 25 19 H-5 2
BLK

B-7 0.5 B-1 0.5 0.5 0.5

0.3 0.5 Headlight Frame
BLU/ GRN/ ORN/ GRN/
BLK/ YEL/ Bracket GRN RED BLU YEL
YEL GRN

1 3 J-32
0.5 0.5
BLK YEL/
GRN

VSS
68 27 60 43 42 B-234

VSS Engine
signal speed Exhaust Glow
2 J-32 signal brake indicator MIL
output lamp lamp control ECM
control control

12V

N6A3868E
 5V reference 5V reference
ECM
Main Relay
ECM ECM

CKP Idle APP

sensor switch sensor
signal signal signal 4JH1 Engine (7)
90 B-233 69 57 38 B-234

Resistor
0.5
0.5 0.5 GRN/
BLK RED BLK

24 12 H-5 0.5 0.5

ECM Tail RED/ GRN/
Main Relay Relay GRN ORN
0.5
GRN/
0.5 0.5 0.5 BLK
RED 0.5
BLU/ LT GRN/
BRN
RED RED
2 J-183
3 2 1 B-31 1 B-340 3 2 B-80

J-183 Idle APP

CKP Engine
Switch Sensor
Sensor Warm Up
3 Switch

2 B-340 1 B-80

1 J-183 6 5 4 B-31

0.5
0.5 BLK
0.3
BRN/
BLK
RED
0.5
WHT 0.5
BRN/ W/S-C
RED 0.5
BLK/
24 18 H-5 GRN
0.85
BLK

0.5 0.5 0.5

BLK WHT BRN/ B-1
RED Frame

101 98 B-233 46 59 49 B-234

Engine
warm up Engine
Shield Low Low
switch warm up reference
ground reference
signal switch
indicator ECM
lamp
control

N6A3869E
CAB AND CHASSIS ELECTRICAL 8-101
 5V reference 5V reference

5V reference ECM

MAF IAT ECT

sensor sensor sensor
signal signal signal 4JH1 Engine (8)
83 88 84 89 B-233

0.5 0.5 0.5 0.5

WHT/ GRN/ BLK/ GRY
RED RED BLU

16 H-5
ECM
Main Relay
0.5
1 2 H-8 37 H-5
GRY

0.5 0.5 0.5 16 H-14

WHT/ GRN/ BLK/
RED RED BLU 0.5
0.5 0.5
BLU/ BLU/ GRY
RED RED
8-102 CAB AND CHASSIS ELECTRICAL

1 J-105 5 4 2 1 J-182 1 E-16

EGR
ECT
Solenoid
Sensor
Valve
MAF & IAT
Sensor

2 J-105 2 E-16
0.5
BLK/
0.5 PNK
BLK/ 3 J-182
ORN
0.5 11 H-14
BLK/
RED 0.5
BLK/
7 H-8 PNK

6 H-8
0.5 29 H-5
BLK/ 0.5
ORN BLK/ 0.5
RED BLK/
PNK

97 92 93 B-233

EGR
Low Low
solenoid reference reference
valve ECM
control
(PWM)

N6A3870E
 SBF-25 F-1 Fuse & ECM H-6 0.5BLU/RED
HEATER AIR CON Relay Box Main Relay 1 EGR Solenoid Valve
30A 10A (Glove Box) PCU
Exhaust Brake
USW Solenoid Valve
0.5 JOINT2 Intake Throttle
2
BLU / Solenoid Valve
BLU
RED
4JH1 Engine (9)
1.25 0.5
BLU BLU/
3 H-18 RED
0.5 0.5
BLU/ GRN/
RED ORN
0.85
BRN
Diode SBF-3
Glow
60A

4 H-18 3 4 X-20 1 4 X-26 1 4 X-24

1.25
Fuse & Relay Box
LT GRN/
(Behind the Cab)
BLK A/C
2 1 X-10 Glow A/C
Relay Signal Compressor
Relay Relay

A/C Relay Box

Thermo (Instrument 2 5 X-20 5 2 X-26 5 2 X-24
Relay Panel)
0.5 0.85 0.5
0.5
GRN/ GRN/ WHT/
BLK
YEL YEL GRN
4 5 X-10 3
BLK/ 16 H-8 1 H-14 15 H-8
0.85 0.3
0.5 RED
GRN/ BLK/
PNK/ 0.5 J-9
WHT RED 0.85
GRN GRN/ Frame
GRN/
J-6 J-6 YEL
YEL
Electro
Thermo 1 B-339
1 2 3 H-8
Pressure
Switch
0.5
A/C
Resistor WHT/
Compressor
1 J-122 GRN

0.5
2 B-339
GRN/
0.5 0.5
YEL
BLK/ BLK
RED
W/S-C
Glow
Plug 0.85
BLK

B-1
94 B-233 33 Frame 41 B-234

A/C ON
signal A/C
Glow relay compressor
relay signal relay ECM
control
control

N6A3871E
CAB AND CHASSIS ELECTRICAL 8-103
 ECM
Main
Relay
12V
Fuse & F-5
Relay Box STOP Exhaust Exhaust
J/C-E EHCU
(Glove Box) LIGHT brake brake
1 2 (ABS
10A cut cut
Module)
signal signal
output feedback
4JH1 Engine (10)
3 3 6 7 8 input
BLU/
RED
Idle Engine 8 7 J-177
Switch Warm Up
Resistor Switch
1 H-6 0.5 0.5
MAF Sensor LT GRN/ LT GRN/
EGR Solenoid Valve 0.5 0.5 0.5 0.5 WHT BLK
0.5
BLU/ A/C Compressor Relay BLU/ BLU/ BLU/ GRN/
RED A/C Signal Relay RED RED RED YEL

0.5 0.5 10 11 H-14

USW
JOINT2 0.5 BLU/ BLU/
PCU BLK RED RED

1 J-31 1 J-40 1 J-50 1 B-69 1 B-89 2 1 B-66

8-104 CAB AND CHASSIS ELECTRICAL

Glow
Relay 0.5 0.5
Exhaust Intake LT GRN/ LT GRN/
Exhaust
Brake Throttle Neutral Clutch Brake BLK WHT
Brake
Solenoid Solenoid Switch Switch Switch
Switch
Valve Valve

2 J-31 2 J-40 2 J-50 2 B-69 2 B-89 3 4

0.5
BLK/
0.5 WHT 0.5 0.5
0.5 1 B-342
LT GRN/ LT GRN/ GRN
LT GRN 9 H-8
WHT BLU

0.5 40 36 H-5
32 9 H-5 Resistor BLK/ 0.5 Stop
0.5
IPC WHT/
WHT YEL Light
BLK

0.5 2 B-342 0.5 0.5 0.5 0.5

0.5 0.5
LT GRN/ BLK/ LT GRN/ LT GRN/ LT GRN/
LT GRN 0.3 GRN
WHT WHT BLU WHT BLK
BLK

40 B-234 95 W/S-C 87 B-233 64 31 65 30 32 62 B-234

Neutral Exhaust Clutch Brake Brake Exhaust

Exhaust Intake switch brake switch pedal pedal brake Exhaust
brake throttle signal switch signal switch2 switch1 cut brake
solenoid solenoid signal signal signal signal cut
valve valve input signal ECM
control control feedback
output
12V 12V

N6A3872E
 8 BLK

2L Fuse &
SBF-1 SBF-2 SBF-3 SBF-5 SBF-8
MAIN KEY GLOW ECM STARTER Relay Box
100A or 120A 40A 60A 40A 60A (Behind
the Cab)
30
BLK/
RED 1 H-7
8 3 3
WHT/ WHT/ WHT/
4HK1-TC Engine (1)

P-1 BLK 3 RED BLK

BLK/
2 B-67 BLU

P-2
5 4 3 X-20 5 3 X-18 Starter
WHT Relay
P-3 OFF
B-67 Ignition Fuse &
ST Glow ECM Relay Box
2 H-6 ON ACC Switch Relay Box
Plug Main (Instrument
Relay (Behind Relay
P-4 4 Panel)
the Cab)
Battery
3 3 B-67 5 2 X-20 4 2 X-18
P-5 BLK/ 3
YEL BLK/ 0.5 1.25
0.5 0.5 3 0.5
YEL Fuse & YEL/ BLK/ BLK/ BLK BLU/ RED
5 Relay Box BLK RED YEL USW BLK 2
W/S-H
WHT/ (Glove Box) JOINT 3 RED
BLK
F-9 ECM Glow 2 ECM ECM
F-22 F-16 Plug BLK F-28 Fuse &
STARTER ENG. METER
Charge ECM Relay Box
10A (IG) 10A 10A (Behind the Cab)
Relay 10A

J-9
0.5 Frame
WHT/ 3
RED WHT/ 3 3
BLK WHT/ WHT/
0.5 WHT/RED BLK BLK

2 1 X-12 2 1 X-8 2 1 X-4

Relay Box Fuse &

Heater & Heater Tail
(Instrument Relay Box
A/C Relay Relay Relay
Panel) (Glove Box)

4 5 X-12 4 5 X-8 4 5 X-4

0.5 3 0.3
3 GRN/ 3
BLK BLU BLK/ Combination
0.5 BLK ORN WHT
W/S-E RED Switch

2
6 BLK F-1 F-2 F-7 Fuse &
J/C-D HEATER, FUEL TAIL
Relay Box
AIR CON HEATER LIGHT
1 15A 10A 10A (Glove Box)
3
BLK

B-7
H/L Bracket

N6A6628E
CAB AND CHASSIS ELECTRICAL 8-105
 2L
30 BLK/RED 8 BLK 8 BLK

8 BLK

SBF-8 SBF-2 Fuse &

STARTER KEY Relay Box
60A 40A (Behind the Cab)
3 3
B-67 WHT/BLU H-7 WHT/BLU
3 BLK/YEL B-67
2 1
4
4HK1-TC Engine (2)

ECM
Main Relay OFF
ST Ignition
ON ACC Switch
F-22 Fuse & F-28 Fuse &
STARTER Relay Box ECM Relay Box
10A (Glove Box) 10A (Behind
3 the Cab)
P-1
WHT/ 0.3
BLK BLK/WHT
0.85
LT GRN
P-2 14 H-8
0.5
RED/WHT
P-3
0.5
RED/WHT
2
8-106 CAB AND CHASSIS ELECTRICAL

3 4 X-21 J/C-2
P-4
3
Battery Fuse &
Starter
Relay Box
Relay
(Behind the Cab)
0.5
P-5
LT GRN
2 5 X-21

3 0.5
0.5 RED/
BLK/
RED WHT
WHT
1 J-26

B
4 3 X-26 38 H-5

Fuse &
Starter Cut 0.5 0.5
Relay Box 0.5
Relay WHT/ WHT/
(Behind the Cab) WHT/
Starter BLU BLU
BLU

1 5 X-26
16 B-425 14 46 J-191
0.5
BLK
C Start switch
USW Starter signal
JOINT 3 Start cut
cut
relay
2 relay
1 J-27 TCM control ECM
BLK control

J-9

N6A6629E
Frame
 2L
30BLK/RED 8BLK F-16 Fuse &
Fuse & Relay Box
METER Relay Box
10A (Glove Box)
4HK1-TC Engine (3)

SBF-1
MAIN
100A or 120A Fuse & Fuse & 0.5
B Relay Box SBF-2 Relay Box BLK/
P-1 SBF-8 SBF-3 (Behind the Cab) KEY (Behind the Cab) YEL
J-26 STARTER GLOW 40A
Starter 60A 60A
8
W/S-M
P-2 WHT/
BLK
3
P-3 WHT/
BLU 0.5 0.5
3 BLK/ BLK/
Starter Relay Glow Relay WHT/ YEL YEL
P-4 BLU

Battery 0.5
1 J-2 2 J-1 3 4 X-1 BLK/
1 H-7
YEL
P-5 B S
Fuse &
3 Charge Relay Box
ACG WHT/ Relay (Glove Box)
BLU
L

2 B-67 5 1 X-1
1 J-1
18 B-51
1.25
WHT/ Instrument
BLU 0.5
WHT/ Panel
OFF Charge
ST Ignition RED Cluster
ON ACC Switch (IPC)
0.85
WHT/
BLU 10 B-51

15 H-5 0.5
3 B-67 WHT/
BLU
0.85
3 WHT/
BLK/ RED
YEL 0.5
WHT/
0.5 BLU
WHT/
BLU Heater
& A/C Relay

2
1 3

J/C-I

N6A6630E
CAB AND CHASSIS ELECTRICAL 8-107
 SBF-2 SBF-5 Fuse &
KEY ECM Relay Box
40A 40A (Behind the Cab)

USW JOINT 3 0.5BLK 3

WHT/
4HK1-TC Engine (4)

RED
3
WHT/
BLU

1 B-67 5 3 X-18

3
WHT/ ECM Main Relay Box
BLU Relay (Instrument
Panel)

2 B-67
4 2 X-18

OFF
ST Ignition
ON ACC Switch
8-108 CAB AND CHASSIS ELECTRICAL

3 B-67
0.5
2
3 BLU/
2 RED
BLK/ BLK 1.25
BLK YEL RED

Fuse & F-28 Fuse &

F-9
Relay Box ECM Relay Box
ENG. (IG)
(Glove Box) 10A (Behind the Cab)
10A

0.5
YEL/ Exhaust Brake Solenoid Valve
BLU Starter Cut Relay
0.5 0.5 2 2 Intake Throttle Solenoid Valve
BLU/ BLU/ RED RED
BLK BLK
18 H-5

0.5
YEL/
BLU

24 40 21 2 5 J-191

J-9 ECM main

relay control ECM
Frame

Ignition voltage Battery voltage

N6A6631E
 Power Power Power Signal Signal Case
ground ground ground ground ground ground
ECM
Diagnostic
request Keyword
4HK1-TC Engine (5)

switch 2000

52 38 4 3 1 62 43 81 J-191

1.25 1.25 1.25 0.75 0.75 0.5

BLK BLK BLK BLK BLK BLK

0.5 0.5
YEL LT BLU

EHCU
(ABS Module)

0.3 BLK/WHT USW

HSA C/U 20 9 H-4 JOINT 3

3
0.3 BLK/WHT 22
TCM J/C-G 19 0.3 LT BLU
2 HSA C/U
1
J/C-B
18 0.3 LT BLU
SRS C/U 0.3 0.3 TCM
WHT/ WHT/ 21
GRN BLK
2
0.5 0.3 BLK
W/S-C
GRY BLK/
WHT 0.5 0.5
YEL LT BLU

0.5 0.5 1.25

BLK BLK BLK

13 11 12 2 1 7 4 5 B-79

Diagnostic Diagnostic Diagnostic Class 2 Diagnostic Keyword Ground Ground

request request (EHCU) serial request serial Data
(SRS) (TCM or HSA) communication (ECM) communication Link B-1 J-9
(EHCU) (ECM, TCM or Connector Frame Frame
HSA & SRS) (DLC)

N6A6632E
CAB AND CHASSIS ELECTRICAL 8-109
 18 B-51

Engine coolant
F-16 Fuse & Speedometer Tachometer temperature gauge
Instrument
METER Relay Box Exhaust Parking
MIL Glow Charge Panel
10A (Glove Box) Brake Brake Cluster
(IPC)
0.5
BLK/YEL
4HK1-TC Engine (6)

M/T M/T
17 8 B-52 4 B-55 5 B-51 13 B-51 15 B-52 6 B-51 4 B-51 5 B-51 10 B-51
0.5 0.3
0.5 Smoother Smoother 0.5
BLK/ YEL/ 0.3 0.3WHT/VIO
LT BLU WHT/BLU
YEL GRN WHT/
23 H-5 0.5 0.5 0.5 VIO
14 0.3
12 BLU/ ORN/ BLU/ Charge
W/S-M HSA C/U J/C-B LT GRN 0.3 Relay
RED BLU PNK WHT/
13 RED 3
0.3 0.5 Short
BLK/ LT BLU 4 Connector
YEL 0.3WHT/VIO

ECM 10 WITH W/O

31 H-5 25 H-5 3 H-8 7 H-14 24 40 7 8 H-5 HBB HBB
0.5 0.5
YEL/ WHT/ 0.5BRN Buzzer
0.5 0.5 YEL/GRN GRN 0.5 BLK Relay
0.5 2 1 J-128
GRN/
8-110 CAB AND CHASSIS ELECTRICAL

BLK/ LT BLU
YEL 0.5 YEL
BLK/
YEL HBB
Level
1 3 J-32 3 1 E-90 Switch

4 0.5 3 J-128 0.5

WHT/ BLK
RED
VSS ECT
Sensor 0.5 0.5 0.5 12 H-5
BLU/ ORN/ BLU/ 0.3
RED BLU PNK 0.3 WHT/BLK
0.5 WHT/
0.3
YEL/ 7 RED 8 X-33
LT GRN
2 J-32 GRN 2 E-90

0.5 Diode Box

0.5 BLK
BLK M/T
9 X-33 0.5 0.3
WHT/BLK H-12 WHT/BLK
19 H-5
3
ECM
H-12 1 N-6
1 H-5
0.5 5
0.5
BLK WHT/ Smoother
Parking
BLK
Brake
19 8 J-191 6 11 7 48 J-191 Switch
W/S-C
Parking
1.25 VSS Engine
Glow Exhaust brake
BLK signal speed
indicator brake switch
signal MIL
lamp lamp signal J-9
output control ECM
control control Frame
B-1
Frame
+B

N6A6633E
 5V reference 2 5V reference 1
ECM
PTO
APP APP Idle up throttle
sensor 2 sensor 1 sensor sensor
signal signal signal signal

61 64 42 63 66 70 J-191
0.5 0.5
4HK1-TC Engine (7)

RED WHT

0.5
RED

0.5 0.5
RED WHT
12 13 1 11 H-4 1 2 H-4

BARO 0.5 0.5

Sensor RED BRN
IAT
Sensor 0.5
0.5 BLU/
BLU YEL
0.5
0.5 BLU/
0.5RED 0.5WHT BLU WHT
1 2 4 5 B-280 3 2 B-281 1 2 J-166

Idle PTO
APP APP
Up Throttle
Sensor 2 Sensor 1
Sensor Sensor

3 6 B-280 1 B-281 3 J-166

0.5BLK 0.5
BLU/
RED 0.5
BARO BLU/
Sensor RED
IAT
0.5 0.5
Sensor
BLK PNK/
BLK
4 14 10 3 H-4 3 H-4
0.5 0.5
BLK BLK 0.5 0.5
0.3
PNK/ 0.5 PNK/
BLK BLK
BLK PNK/
BLK

39 60 20 41 J-191

ECM

Shield ground Low reference Shield ground Low reference

N6A6657E
CAB AND CHASSIS ELECTRICAL 8-111
 5V reference

5V reference 2 5V reference 1
ECM

APP APP IAT BARO

sensor 2 sensor 1 sensor sensor
signal signal signal signal

61 64 PTO 42 63 72 71 J-191
0.5 0.5 0.5RED 0.5
4HK1-TC Engine (8)

Throttle
RED WHT 0.5RED WHT
Sensor
Idle UP 0.5
Sensor BRN/
0.5 GRN
RED/
GRN

12 13 1 11 H-4 15 H-4

0.5
0.5 BRN/
RED GRN

0.5
0.5 0.5 0.5 BLU/
8-112 CAB AND CHASSIS ELECTRICAL

RED WHT BLU WHT

1 2 4 5 B-280 1 J-190 3 2 B-422

APP APP BARO

IAT
Sensor 2 Sensor 1 Sensor
Sensor

3 6 B-280 2 J-190 1 B-422

0.5 0.5
BLK BLU/
RED
0.5 0.5
BLK BLK

4 14 10 3 H-4
0.5 0.5 0.5
BLK PTO
BLK PNK/BLK
Throttle
Sensor
Idle UP 0.3 0.5
Sensor BLK PNK/BLK
39 60 20 41 J-191

ECM

Shield ground Low reference Shield ground Low reference

N6A6635E
 5V reference 5V reference

5V reference 4
ECM
Boost
pressure ECT FT
sensor sensor sensor
signal signal signal

95 91 84 83 E-111
4HK1-TC Engine (9)

0.5 0.5
WHT RED

0.5 0.5
ECT Gauge GRN/ LT GRN/
3 4 H-105 YEL WHT

0.5
LT BLU
0.5 0.5
RED WHT
3 2 J-216 3 1 E-90 2 E-93

Boost FT
ECT
Pressure Sensor
Sensor
Sensor

1 J-216 2 E-90 1 E-93

0.5
BLK

12 8 H-105 0.5 0.5

BLK BLK

0.5
BLK
CKP 0.5
Sensor BLK
0.5
BLK
108 109 E-111

ECM

Shield ground Low reference

N6A6637E
CAB AND CHASSIS ELECTRICAL 8-113
 +B 5V reference 5 +B
EGR FRP
valve EGR regulator
valve high side ECM
motor high FRP
side position sensor control
control sensor signal (PWM)
signal

111 86 87 82 90 E-111 113 105 E-111

4HK1-TC Engine (10)

0.5 0.5
WHT WHT 0.5 0.5
WHT/ WHT/
RED RED

0.5 0.5 0.5

BLK/ GRN/ WHT/
ORN BLU ORN

0.5
WHT/
RED
0.5
GRN/
BLU

4 1 3 E-94 3 2 E-113 1 E-116

8-114 CAB AND CHASSIS ELECTRICAL

EGR Valve EGR FRP FRP

Motor Position Sensor Sensor Regulator

6 2 E-94 1 E-113 2 E-116

0.5 0.5
BLK BRN 0.5
GRN/
RED
0.5 0.5
ORN BRN

0.5 0.5
GRN/ GRN/
CMP
RED RED
Sensor

103 100 101 E-111 97 89 E-111

EGR
valve FRP
motor low regulator
ECM
side feedback
control Shield ground Low reference
(PWM)

N6A6636E
 12V reference
ECM
CKP
sensor CMP
high sensor
signal signal

107 99 98 E-111
4HK1-TC Engine (11)

0.5 0.5 0.5

YEL BLU/ BLU/
BLK WHT

3 2 E-112
1 E-98

CKP CMP
Sensor Sensor

0.5
2 E-98 BLK 1 E-112

0.5BLK

0.5 0.5
BLK BLK
Boost
FRP
Pressure
Sensor
Sensor 0.5
0.5 ORN 0.5
BLK BLK

108 106 100 E-111

CKP
sensor
low
signal ECM
Shield ground Shield ground

N6A6634E
CAB AND CHASSIS ELECTRICAL 8-115
 Charge voltage Charge voltage
(Common 1) (Common 2)
ECM

121 116
4HK1-TC Engine (12)

2 2
WHT RED

2 2 2
2
WHT WHT RED
RED
1 4 3 2 H-125

1 4 3 2 H-126

0.75 0.75 0.75 0.75

WHT 0.75 WHT WHT RED 0.75 RED RED

1 2 1 2
2 1 2 1
8-116 CAB AND CHASSIS ELECTRICAL

E-138 E-141 E-140 E-139

Cylinder #1 Cylinder #4 Cylinder #3 Cylinder #2

Fuel Fuel Fuel Fuel
Injector Injector Injector Injector

3 E-138 3 E-141 3 E-140 3 E-139

0.75 0.75 0.75 0.75

GRN BLK YEL BLU

5 8 7 6 H-126

5 8 7 6 H-125

0.75 0.75 0.75 0.75

GRN/ WHT/ BLK/ BLK
WHT YEL BLU

119 117 120 118

Cylinder #1 Cylinder #4 Cylinder #3 Cylinder #2

fuel fuel fuel fuel
injector injector injector injector
ECM
control control control control

N6A6638E
 Ignition Switch

Thermo A/C Relay

SBF-3 Fuse & F-9 Fuse &

GLOW Relay Box ENG. (IG) Relay Box 0.85
60A (Behind the Cab) 10A (Glove Box) GRN/
WHT
0.5
YEL/
4HK1-TC Engine (13)

BLU
2 H-5

3 0.85
18 H-5
BLK/ GRN/
BLU 0.5 WHT
YEL/
BLK 1 J-6
0.5 YEL/BLK

3 4 X-20 A/C
Pressure
ECM Switch
Fuse &
Glow
Relay Box 2 B-84
Relay
(Behind the Cab)
2 J-6

0.85 PTO
2 5 X-20 GRN/ Switch
ORN 0.5
3 BLK
BLK/
YEL 0.85GRN/ORN
1 B-84
1 H-120 Refrigerator
Compressor
1 J-7 9 H-105
3 0.5 W/S-C
BLK/ BLU/
YEL 0.75 ORN

E-3 WHT/
0.5 RED
BLK/ 0.5
Glow RED 1 E-5
GRN/
Plug 1.25
ORN 8 H-4
1 BLK

A/C
Compressor
0.5
0.5 BLU/
PNK ORN

B-1
10 Frame
33 34 44 J-191

Refrigerator A/C PTO

switch signal switch
Glow plug signal signal
relay
control ECM

+B

N6A6639E
CAB AND CHASSIS ELECTRICAL 8-117
 Tail Relay Heater Relay Ignition Switch

F-7 F-2 Fuse & Fuse &

TAIL FUEL F-9 F-28
ENG. (IG) Relay Box ECM Relay Box
LIGHT HEATER (Glove Box) (Behind the Cab)
10A 10A 10A 10A

0.85
4HK1-TC Engine (14)

LT GRN/ 0.85
RED LT GRN
4 2
J/C-D 1 J/C-2

9 5
4
0.5 0.5 0.5
0.85
BRN/ BRN/ YEL/
LT GRN/
BLK BLK BLU
RED
11 0.5 0.5 0.5
J/C-B LT GRN LT GRN LT GRN
5
0.5
LT GRN/
5 B-69
RED
2 3 B-31 1 B-89 2 J-50 1 J-31 1 J-40
8-118 CAB AND CHASSIS ELECTRICAL

Exhaust
Exhaust Intake
Engine Brake Clutch Neutral Brake Throttle
Warm up Switch Switch Switch Solenoid Solenoid
Switch (Combination
Valve Valve
Switch)

2 B-89 1 J-50 2 J-31 2 J-40

5 6 4 1 B-31
2 B-69
0.5 0.5
0.5 0.5 0.5
LT GRN LT GRN
BLK BLK 0.5 LT GRN/
/BLU /BLU
BRN/ WHT
0.5
LT GRN/ YEL
W/S-F W/S-C
RED
0.5
LT GRN/
BLU 0.5 0.5 2 H-105
3 1.25 BLK/ BLK
6 H-5 17 H-4
BLK BLK BLU

7 H-4 0.5
0.5 0.5 TCM LT GRN/
LT GRN/ BRN/
0.5 WHT
RED YEL
LT GRN/
B-7 BLU B-1
H/L 51 Frame 45 47 50 15 J-191 102 E-111
Bracket

Engine Exhaust Clutch Neutral

warm up brake switch switch Exhaust Intake
switch switch signal signal brake throttle
signal signal solenoid solenoid ECM
valve valve
control control

N6A6640E
 CAB AND CHASSIS ELECTRICAL 8-119
4HK1-TC Engine (15)

Resistor 1

2 1 B-387

0.5 0.5
BLU/
BLU WHT

3 0.5
1 BLU/WHT B-427 CAN
J/C-F
2 high
2
TCM
6
4 CAN
J/C-F
0.5 BLU 3 low
5

0.5 0.5
BLU BLU/
WHT

7 8 H-8
Without ABS

0.5 0.5
BLU BLU/
WHT

0.5 0.5
BLU/WHT H-15 BLU/WHT J-177 CAN
5 14 high

CAN
0.5 BLU 10 0.5 BLU 15 low
0.5 0.5
BLU/ BLU EHCU
WHT 0.5 0.5
BLU/WHT BLU/WHT CAN
high
9 26

CAN
0.5 BLU 14 0.5 BLU 27 low

0.5 0.5
BLU BLU/
WHT
0.5
BLU/WHT J-191 CAN
18 high
ECM
CAN
0.5 BLU 37 low

0.5 0.5
BLU/
BLU WHT

5 6 H-8

0.5 0.5
BLU BLU/
WHT

3 0.5
2 BLU/WHT
J/C-R
1
DRM
6
5
J/C-R
0.5 BLU
4

0.5 0.5
BLU BLU/
WHT

2 1 B-431

Resistor 2

N6A6641E
8-120 CAB AND CHASSIS ELECTRICAL
Connector List No. Connector Face
For 4HE1-TC Engine

No. Connector Face

B-69 1 2 3 4
5 6 7 8

008-001
B-1

000-001

B-69 4 3 2 1
8 7 6 5

008-002
B-7

000-012

1 2 3 4 5 6 7 8
B-79
9 10 11 12 13 14 15 16

016-005
X-1

005-006

B-75 1
2

002-009
X-8

005-006

1
B-75
2

002-010
X-25

005-006

B-89 1
2

002-009
X-28

005-006

1
B-89
2

002-010
B-67 1 2
3 4

004-001

B-233 1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20 21 22

022-001
B-67 2 1
4 3

004-002
 CAB AND CHASSIS ELECTRICAL 8-121

No. Connector Face No. Connector Face

4 3 2 1
B-234 1 2 3 4 5 6 7 8 9 10 11 12 13 14
H-13 8 7 6 5
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 12 11 10 9

030-001 012-002

B-51 1 2 3 4 5 6 7 8 9 1011121314 E-2 1 2

014-001 002-013

B-52 1 2 3 4 5 6 7 8 9 10 11 12 E-3

012-005 000-009

1 2 3 4

H-14 5 6
10 11 12 13 14
7 8 9
E-11 1 2
15 16

016-003 002-001

4 3 2 1
9 8 7 6 5
H-14 14 13 12 11 10 E-43
1 2 3
16 15

016-004 003-003

1 2 3 4

H-15 5 6
10 11 12 13 14
7 8 9
E-74
1
15 16

016-003 001-013

4 3 2 1
9 8 7 6 5
H-15 14 13 12 11 10 E-76 1 2

3
16 15

016-004 003-004

1 2 3 4
H-13 5 6 7 8 J-9
9 10 11 12

012-001 000-001
8-122 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

X-20 2 3 J-105 1 2
4 5

005-003 002-016

J-23 1 2 3 4 J-147 1 2

004-009 002-017

J-31 1 2
J-177

002-001 034-001

J-131 1 2
P-1

002-001 000-004

J-145 1 2 P-4

002-014 000-004

J-146 1 2 P-2

002-014 000-006

J-40 1 2 P-3

002-015 000-006

J-41 1 2 P-5

002-015 000-002
 CAB AND CHASSIS ELECTRICAL 8-123
H-5 No. Connector Face

B-18 1 2 3 4

004-004

1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 11 12 12 11 10 9 8 7
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 24 23 22 21 20 19 1
25
31
26
32
27
33 34 35 36 37
28
38
29
39
30
40
30
40
29
39
28
38 37 36 35 34
27
33
26
32
25
31 X-10 2 3 4

005-00

X-11 2 3 4
N8A5488E
5

H-6, H-7, H-8 005-00

X-14 2 3 4

1 2 H-6 2 1 005-00

1 2 H-7 2 1

1 2 3 4 4 3 2 1 1

5 6 7 8 8 7 6 5 X-12 2 3 4

5
9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14
005-00

N8A5489E X-20 2 3

4 5

For 4JH1 Engine

005-003

No. Connector Face

X-24
B-1
005-006

000-001

X-26
B-7
005-006

000-012
8-124 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

B-31 1 2 3
B-80 1 2 3

4 5 6

006-001 003-005

B-66 1 2 B-89
3 4 1 2

004-010 002-019

113 112 111 110 109 108 107 106

121 120 119
105 104 103 102 101 100 99 98
B-339 1 2 B-233 118 117
3 4 97 96 95 94 93 92 91 90
116 115 114
89 88 87 86 85 84 83 82

004-010 121-002

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
5 4
B-67 1 2
B-234 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62
3
2 1
3 4 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81

004-001 121-001

B-67 2 1 B-340
4 3
1 2

004-002 002-022

B-69 1 2 3 4 B-341 1
5 6 7 8 2

008-001 002-009

B-69 4 3 2 1 B-342 1
8 7 6 5 2

008-002 002-009

1 2 3 4 5 6 7 8
B-79 B-51 1 2 3 4 5 6 7 8 9 1011121314
9 10 11 12 13 14 15 16

016-005 014-001
 CAB AND CHASSIS ELECTRICAL 8-125

No. Connector Face No. Connector Face

B-52 E-110 6 5 4 2
1 2 3 4 5 6 7 8 9 10 11 12 3
7 8 9 1

012-005 009-002

B-55 1 2 3 4 5 6 7 8 9 10 11 12 J-6 1 2
3 4

012-004 004-011

1 2 3 4

H-14 5 6
10 11 12 13 14
7 8 9
J-9
15 16

016-003 000-001

4 3 2 1
9 8 7 6 5
H-14 14 13 12 11 10 J-31 1 2
16 15

016-004 002-011

1 2 3
H-15 4 5 6 J-31 2 1
7 8

008-023 002-012

3 2 1
H-15 6 5 4 J-32 1 2 3
8 7

008-024 003-018

E-5 J-40 1 2

000-009 002-017

E-16 1 2 J-50

002-014 002-035
8-126 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

J-122 P-5
1
001-007 000-007

H-5

J-177

034-001

J-182
1 2 3 4 5 1
7
2
8
3
9
4
10
5
11
6
12
6
12
5
11
4
10
3
9
2
8
1
7
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 24 23 22 21 20 19
25 26 27 28 29 30 30 29 28 27 26 25
31 32 33 38 39 40 40 39 38 33 32 31
005-004 34 35 36 37 37 36 35 34

J-183
1 2 3

003-006
N8A5488E

H-6, H-7, H-8

P-1

000-002

1 2 H-6 2 1

P-2 1 2 H-7 2 1

1 2 3 4 4 3 2 1

000-002 5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14

P-4

000-014 N8A5489E

P-3

000-014
 CAB AND CHASSIS ELECTRICAL 8-127
For 4HK1-TC Engine No. Connector Face
No. Connector Face

B-69 4 3 2 1
8 7 6 5
B-1
008-002

000-001

B-84 1 2 3
4 5 6
B-7
006-001

000-012

B-89 1
2
B-31 1 2 3
4 5 6 002-009

006-001

1
B-89
2
B-51
002-010

1 2 3 4 5 6 7 8
B-79
9 10 11 12 13 14 15 16
B-52
016-005

B-280 1 2 3

B-67 1 2
3 4 003-005

004-001

B-281
B-67 2 1
4 3
003-028

004-002

B-387
B-69 1 2 3 4
5 6 7 8 002-038

008-001
8-128 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

B-387 H-12 10 9 8 7 6 5 4 3 2 1

22 21 20 19 18 17 16 15 14 13 12 11

002-039 022-002

1 2 3 4

B-422 H-15 5 6 7 8 9

1 2 10 11 12 13 14

15 16

002-027 016-003

4 3 2 1
9 8 7 6 5
B-427 H-15 14 13 12 11 10

16 15

017-001 016-004

3 2 1
B-431 H-105 6 5 4

002-038 006-026

B-431 H-105 1 2 3
4 5 6

002-039 006-027

H-4 1 2 3 4 5 6 7 8 9 H-120
10 11 12 13 14 15 16 1718 19 20 1

020-002 001-023

9 8 7 6 5 4 3 2 1
H-4 H-120 1
20 19 18 17 16 15 14 13 12 11 10

020-003 001-022

H-12 1 2 3 4 5 6 7 8 9 10
H-125 1 2 3 4
11 12 13 14 15 16 17 18 19 20 21 22 5 6 7 8

022-001 008-019
 CAB AND CHASSIS ELECTRICAL 8-129

No. Connector Face No. Connector Face

H-125 4 3 2 1 E-98
8 7 6 5

008-020 002-036

H-126 5 6 7 8 E-112
1 2 3 4

008-022 003-026

H-126 8 7 6 5 E-113
4 3 2 1

008-021 003-029

E-3 E-116

000-009 002-036

E-5 E-138

001-021 003-031

E-90 1 2
E-139
3

003-004 003-031

E-93 E-140

002-035 003-031

E-94 E-141

005-007 003-031
8-130 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

X-1 J-2

005-006 000-001

X-11 2 3 4 J-6 1 2
5

005-00 002-032

X-18 2 3 J-26
4 5

005-003 000-002

X-20 2 3 J-27
4 5

005-003 000-009

X-21 2 3 J-31 1 2
4 5

005-003 002-011

X26 J-31 2 1

005-006 002-012

X-33 1 2 3 4 5 6 J-32 1 2 3
7 8 9 10 11 12 13 14

014-002 003-018

J-1 1 2
J-40 1 2

002-003 002-017
 CAB AND CHASSIS ELECTRICAL 8-131

No. Connector Face No. Connector Face

J-50 P-2

002-035 000-006

J-166 1 2 3
P-3

003-001 000-006

J-177 P-5

034-001 000-002

H-5

J-191

081-001

N-6 1 2 3 4 5 6 6 5 4 3 2 1
1 2 7
13
8
14
9
15
10
16
11
17
12
18
12
18
11
17
10
16
9
15
8
14
7
13
19 20 21 22 23 24 24 23 22 21 20 19
25 26 27 28 29 30 30 29 28 27 26 25
002-022 31 32 33 34 35 36 37 38 39 40 40 39 38 37 36 35 34 33 32 31

N-6
2 1

002-023 N8A5488E

P-1

000-004

P-4

000-004
8-132 CAB AND CHASSIS ELECTRICAL
H-6, H-7, H-8

1 2 H-6 2 1

1 2 H-7 2 1

1 2 3 4 4 3 2 1

5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14

N8A5489E

Engine Stop System

General Description
The circuit consists of starter switch and engine stop
motor.
The engine stop mechanism aims at shut-off of fuel sup-
ply.
Available are motor type and solenoid type depending
on the types of the engine mounted.
Motor type is forcible pull the injection pump control rack
to the direction of fuel supply reduction by means of en-
gine stop motor, thus shutting it off.
Solenoid type is to have the starter switch turn from
“ON” position to “OFF”, so that the solenoid valve fitted
to the injection pump closes to shut off the fuel circuit.

Engine stop system Engine model

Motor type 4HF1, 4HG1, 4HE1
Solenoid type 4JB1, 4JG2
 CAB AND CHASSIS ELECTRICAL 8-133
Parts Location
4JB1 / 4JG2 / 4HF1 (N-Spec) Engine

N8A5123E
8-134 CAB AND CHASSIS ELECTRICAL
4HF1 (S-Spec) / 4HG1 / 4HE1 Engine

FUSE BOX ASM

F-9, F-13

N8A5124E
 CAB AND CHASSIS ELECTRICAL 8-135
Circuit Diagram

STARTER SW
FL-2 40A (24V)
50A (12V) ACC
KEY SW
1 2 B
H-7 B-67 ON 3
3W/B 3W/L B-67
4 P2 A
FL-1 100A or 120A B-68 ST

2L MAIN

3B/Y
P1
2
H-6
P-1 5W 8W/B B-68 B-68
2 1
P-2

3B/Y
3W/B

0.5L/W
P-3

0.5L/Y

0.5L
P-4
F-13 10A F-9 10A
(24V MODEL) ENG. STOP FUEL CUT
(4JB1 / 4JG2 /
4HF1 (N- SPEC)
ENGINE)
P-5
FRAME

0.5B/O
33 34 35
0.5L/R

H-5 H-5 H-5

36 12
0.5L/W

0.5L/Y

H-5 H-5
0.5L

0.5B/O
0.5L/R

5 4 3 14
J-34 J-34 J-34 H-14

P2 P1 A
1.25B/O

6 B
J-34
(4JB1 / 4JG2 / 4HF1 (N-SPEC) ENGINE)
FUEL CUT SOLENOID

1 E E-15
J-34

ENGINE STOP MOTOR

(4HF1 (S-SPEC) / 4HG1 / 4HE1 ONLY)
2B

2B
FRAME-LH (CENTER) J-9

N8A5125E
8-136 CAB AND CHASSIS ELECTRICAL
Connector List No. Connector Face

No. Connector Face

P-1
(24 V)
B-67 1 2
3 4 000-004

004-001

P-4

B-67 2 1
4 3
000-004

004-002

P-2
(24 V)
B-68 1 2
3 4 5 6 000-006

006-002

P-3
2 1
B-68
6 5 4 3 000-006

006-003

P-5
(12 V)
J-34 1 2 3
4 5 6 000-007

006-004

P-5
(24 V)
J-34 3 2 1
6 5 4 000-002

006-005

E-15 1
P-1
(12 V) 001-002

000-003

E-15 1

P-2
001-003

000-004
 CAB AND CHASSIS ELECTRICAL 8-137

No. Connector Face

1 2 3 4
H-14 5 6 7 8
9 10 11 12
13 14 15 16

016-001

4 3 2 1

H-14 8 7 6 5
12 11 10 9
16 15 14 13

016-002

H-5

1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 11 12 12 11 10 9 8 7
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 24 23 22 21 20 19
25 26 27 28 29 30 30 29 28 27 26 25
31 32 33 34 35 36 37 38 39 40 40 39 38 37 36 35 34 33 32 31

N8A5488E

H-6, H-7

1 2 H-6 2 1

1 2 H-7 2 1

1 2 3 4 4 3 2 1

5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14

N8A5489E
8-138 CAB AND CHASSIS ELECTRICAL
Function of Engine Stop Motor

N8A5127E
 CAB AND CHASSIS ELECTRICAL 8-139
Solenoid Type
Starter Switch and Solenoid Valve
Turn the starter switch from “ON” position to “OFF”, and
then the solenoid valve fitted to the injection pump clos-
es to cut off the fuel circuit.
For the circuit of solenoid type fuel cut, refer to QOSIII
circuit diagrams in this section.

N8A5128E
8-140 CAB AND CHASSIS ELECTRICAL
Headlight, Fog Light, Rear Fog Light and Cornering Light
General Description
The circuit consists of headlight, fog light, cornering light, starter switch, combination switch (Lighting switch, dimmer
/ passing switch, cornering light switch), fog light switch, high beam indicator light and relay.
When the lighting SW is turned on by setting it at headlight position, the lighting relay is actuated to turn on the head-
light. The optical axis of the headlight can be turned up or down by operating the dimmer SW while headlight is on.
The passing SW is independent of the lighting SW, and the optical axis of the passing light can be turned up only
while the switch lever is pulled up and held in this state.
Fog light turns on by switching it to “ON” position to activate relay only while lighting SW is on.
When the headlight is on, turn the turn-signal switch left or right, and then the cornering switch built in the combination
switch turns on, followed by the cornering light turning on.
Lighting Circuit

CORNERING LIGHT HEADLIGHT FOG LIGHT REAR FOG LIGHT

Battery (+)

Starter sw.(ON)

Headlight Tail
Lighting sw. relay relay
OFF RR FOG

Cornering
light relay Rear
fog light
relay
Headlight
Cornering
light sw. Fog light
LO HI sw.
Dimmer sw.
Cornering Rear
Fog light fog light
light Dimmer
L H
relay

N8A5573E

Notice:
Arrow marks indicate the direction of current.
 CAB AND CHASSIS ELECTRICAL 8-141
Parts Location
Except NKR For Indonesia

N8A5130E
8-142 CAB AND CHASSIS ELECTRICAL
NKR For Indonesia

N8A0449E
 For 12 Volt
FL-2 50A
KEY SW
3W/B
2L
8W 5W 2 8W/B
H-6
Circuit Diagram
P-3 P-1
FL-1 100A
1 STARTER SWITCH
P-4 P-2
MAIN
2W/R 2 2W/R H-7 OFF
H-7
ACC
FL-4 30A
4JH1 2 B2

3W/L
3W/B
HEAD LAMP B-67 ON 3
2 1 B-67
X-3 X-3 ST

3W/B
3W/B
X-3 X-3 2 1

METER

RELAY; HEADLIGHT
4 5 X-4 X-4

F-16 10A
P-5
0.3R

2R
FRAME

RELAY; TAIL
LIGHTING SWITCH DIODE X-4 X-4

0.3R
0.5B/Y
3 4 5 4JH1:3.0W
OFF
B-17 4JB1, 4JB1-TC:3.0L
H 1 2
B-70 B-17
0.3L/R
F-6
F-7

T 8 B-17 2R
B-70 1

(LH)
(RH)
10A
15A

F-23 10A
TAIL LIGHT

F-24 10A
HEAD LIGHT
HEAD LIGHT
0.5G/O 0.5R/L
FRT FOG LIGHT,
CORNERING LAMP

2 1
7
B-70
0.85R
0.85V

X-9 X-9

0.85R/L

0.3L
Hu 10
B-70
0.5LG/R

RELAY;
4 3 2
B-70
E2 3 3 B-87 B-87
X-9 X-9

COMBINATION SWITCH
0.5R/W
LO HIGH PASS B-4 B-73
4 5

CORNERING LIGHT
LO
CORNERING LIGHT SWITCH
HI
HI
LO

2
B-70
HEADLIGHT B-4 B-4 B-73 B-73 B-87 B-87
HEADLIGHT

0.5R/B
FOG LIGHT SWITCH

1 2 2 1 6 5

LH
RH
1.25R/Y
0.5B

0.3R/L
1.25R/Y
0.85R/G

B-70 B-70 0.85R/G 0.85R/G

11 9 2 1 3

1.25B
0.5R/G

X-6 X-6 X-6

10

0.5P

0.5P/B
0.85R/G

H L B-55
3 3 1 1
B-5 B-74 X-6 X-6 B-3 B-72

RELAY; DIMMER
3B

4 5
B-52
LIGHT (METER)

(LH)
(RH)
10
HIGH BEAM INDICATOR

B-5 B-74 B-3 B-72

1.25B
FOG LIGHT (LH)
FOG LIGHT (RH)

3B

CORNERING LIGHT
1 1 2 2
0.85B
0.5B

0.85B
0.85B
0.5B

0.85B
FRAME-LH (FRONT) B-1

HEADLIGHT 3B
B-7
BRACKET (LH)

N8A5131E
CAB AND CHASSIS ELECTRICAL 8-143
 FL-2 40A
KEY SW
3W/B
2L
5W 2 5W/B 3W/B
H-6
P-1 (AUSTRALIA only)
FL-1 100A or 120A
1 STARTER SWITCH
P-2 X-3
MAIN
2W/R H-7 OFF
2 2W/R 4
H-7
ACC 0.5R
FL-4 30A
B2

3W/L
2
HEAD LAMP B-67 ON 3
2 1 B-67
0.5R
X-3 X-3 ST
P-3 1
B-70
P-4
8
B-70

3W/B
3W/B
X-3 X-3 2 1

RELAY; HEAD LAMP

METER
4 5 X-4 X-4

F-16 10A
7
B-70
P-5
0.3R

2R
FRAME

RELAY; TAIL
LIGHTING SWITCH DIODE X-4 X-4

0.3R
0.5B/Y
3 4 5
OFF
B-17 3W
H 1 2 TAIL LIGHT
B-70 B-17
0.3L/R F-7 10A
FRT

T 8 B-17 2R/W
F-8

B-70 1
LAMP

F-24 10A F-23 10A TAIL LIGHT

HEAD LIGHT HEAD LIGHT
8-144 CAB AND CHASSIS ELECTRICAL
For 24 Volt (Except Europe / NKR For Indonesia)

10A

FOG LIGHT,

(LH) (RH)
CORNERING

0.5R/L
0.3G/O
2 1
7
B-70 X-9 X-9
0.85R
0.85LG/R

0.85R/L

0.3L
10
0.85LG/R

Hu

RELAY;
B-70

4 3 2
B-70
E2 3 3 B-87 B-87
X-9 X-9

COMBINATION SWITCH
0.5R/W
LO HIGH PASS B-73

CORNERING LIGHT
4 5 B-4

CORNERING LIGHT SWITCH

HI

LO
HI
LO

2
B-70
B-4 B-4 B-73 B-73 B-87 B-87
HEADLIGHT
HEADLIGHT

0.5R/B
FOG LIGHT SWITCH

1 2 2 1 6 5

LH
RH
0.85R/Y
0.5B

0.3R/L
0.85R/Y
0.85R/G

B-70 B-70 0.5R/G 0.5R/G

11 9 2 1 3

1.25B
0.5R/G

X-6 X-6 X-6

9

0.5P

0.5P/B
0.85R/G

H L B-51
3 3 1 1
X-6 X-6

RELAY; DIMMER
B-5 B-74 B-3 B-72
3B

4 5
B-53
LIGHT (METER)

(LH)
(RH)
2
HIGH BEAM INDICATOR

B-5 B-74 B-3 B-72

0.85B
FOG LIGHT (LH)
FOG LIGHT (RH)

CORNERING LIGHT
1 1 2 2
0.85B
0.5B

0.85B
0.85B
0.5B

0.85B
FRAME-LH (FRONT) B-1

HEADLIGHT 3B
B-7
BRACKET (LH)

NOTICE: THIS CIRCUIT DIAGRAM SHOWS EQUIPPED WITH CORNERING LIGHT MODEL.

N8A5132E
 FL-2 40A
KEY SW
3W/B
2L
5W 2 5W/B 3W/B
H-6
P-1
FL-1 100A or 120A
1 STARTER SWITCH
P-2
MAIN
2W/R H-7 OFF
2 2W/R
H-7
ACC
FL-4 30A
B2

3W/L
2
HEAD LAMP B-67 ON 3
2 1 B-67
X-3 X-3 ST
P-3
P-4

3W/B
3W/B
X-3 X-3
For 24 Volt (NKR For Indonesia)

2 1

RELAY; HEAD LAMP

METER
4 5 X-4 X-4

F-16 10A
P-5
0.3R

2R
FRAME

RELAY; TAIL
LIGHTING SWITCH DIODE X-4 X-4

0.3R
0.5B/Y
3 4 5
OFF
B-17 3W
H 1 2 TAIL LIGHT
B-70 B-17
0.3L/R F-7 10A
FRT

T 8 B-17 2R/W
F-8

B-70 1
LAMP

F-24 10A F-23 10A TAIL LIGHT

HEAD LIGHT HEAD LIGHT
10A

FOG LIGHT,

(LH) (RH)
CORNERING

0.5R/L
0.3G/O
2 1
7
B-70 X-9 X-9
0.85R
0.85LG/R

0.85R/L

0.3L
10
0.85LG/R

Hu

RELAY;
B-70
LH
4 3 2
B-70
E2 3 3 3 3 B-87 B-87
X-9 X-9

COMBINATION SWITCH
0.5R/W
LO HIGH PASS B-73

CORNERING LIGHT
4 5 B-4 B-148 B-150

CORNERING LIGHT SWITCH

HI

LO
HI
LO

2 B-148 B-150
B-70
0.5R/B B-4 B-4 B-73 B-73 B-87 B-87
2 2
HEADLIGHT (B)
HEADLIGHT (B)

HEADLIGHT (A)
HEADLIGHT (A)
FOG LIGHT SWITCH

1 2 2 1 6 5

LH
RH
0.85R/Y
0.5B

0.3R/L
0.85R/Y
0.85R/G

B-70 B-70 0.5R/G 0.5R/G

11 9 2 1 3

1.25B
0.5R/G

X-6 X-6 X-6

9

0.5P

0.5P/B
0.85R/G

H L B-51
3 3 1 1
X-6 X-6

RELAY; DIMMER
B-5 B-74 B-3 B-72
3B

4 5
B-53
LIGHT (METER)

(LH)
(RH)
2
HIGH BEAM INDICATOR

B-5 B-74 B-3 B-72

0.85B
FOG LIGHT (LH)
FOG LIGHT (RH)

CORNERING LIGHT
1 1 2 2
0.85B
0.5B

0.85B
0.85B
0.5B

0.85B
FRAME-LH (FRONT) B-1

HEADLIGHT 3B
B-7
BRACKET (LH)

NOTICE: THIS CIRCUIT DIAGRAM SHOWS EQUIPPED WITH CORNERING LIGHT MODEL.

N8A0448E
CAB AND CHASSIS ELECTRICAL 8-145
 2W
2L
8W 5W 2 8W/B F-27 15A
H-6
P-3 P-1 FOG LIGHT (REAR)
FL-1 100A

For Europe
P-4 P-2 MAIN

3W/B
2W/R 2 2W/R
H-7
4JH1

3W/B
FL-4 30A
HEAD LAMP 2 1 2 1
X-3 X-3 X-4 X-4
P-5

FRAME

RELAY; TAIL
X-3 X-3 X-4 X-4

RELAY; HEAD LIGHT

4 5 4 5

LIGHTING SW

2R
OFF 3W
0.85LG/W

H 1 0.3R
B-70 2R
T 8 0.3G/O
B-70 F-24 10A F-23 10A F-6 15A F-7 10A
HEAD LIGHT HEAD LIGHT CORNERING TAIL LIGHT
(LH) (RH) LAMP

0.85V
7 0.3R
B-70

0.85LG/R

0.85R

COMBINATION SW
0.85R/L
Hu 10 0.5LG/R 0.85LG/R
B-70
8-146 CAB AND CHASSIS ELECTRICAL

4 3 2 1
B-70
E2 3 3
B-87 B-87 B-87

0.5R/W
LO HIGH PASS B-4 B-73

HI
HI

LO
LO

HEADLIGHT
HEADLIGHT
B-4 B-4 B-73 B-73 B-87 B-87 B-87
0.85LG/R

FOG LIGHT SWITCH

LIGHT (LH) (4)

1 2 2 1 6 5 4
B-70
FRT. COMBINATION

14 1.25R/Y

0.5R/L
0.85R/G
1.25R/Y

0.85R/G 0.85R/G 0.85R/G 4 1

2 1 3
H-5

1.25B
X-23 X-23

0.5R/G
X-6 X-6 X-6
0.85R/G

0.5GR/B
10 1 1
H L RELAY; DIMMER
RELAY;

B-55 B-3 B-72

X-23 X-23
H-8 X-6 X-6
RR FOG LIGHT

2 5
5 4 5
B-52 B-3 B-72

3B
LIGHT (METER)
FOG LIGHT (LH)
FOG LIGHT (RH)

10 2 2 0.85LG/R
HIGH BEAM INDICATOR 4
H-8
0.85R/G

1.25B
0.5B

0.5GR/B 4
3
B-52
H-16
1.25B 0.85B
0.85R/G

0.5B 3
2B

H-15 B-51
(REAR FOG LIGHT)
METER INDICATOR

LICENSE LIGHT

0.5B 15
1
R-12
RR FOG
5B
FRAME-LH (FRONT) B-1 LIGHT
R-12
3B
HEADLIGHT BRACKET (LH) B-7 2

2B 1.25B 7 1.25B 7 0.85B

FRAME-LH (CENTER) J-9 H-16 H-15

N8A5134E
 CAB AND CHASSIS ELECTRICAL 8-147
Connector List No. Connector Face

No. Connector Face

B-5 1 2
3 4
B-3 1 2
004-012

002-001

2 1
B-5
4 3
B-3 2 1
004-013

002-002

B-74 1 2
3 4
B-72 1 2
004-012

002-001

2 1
B-74
4 3
B-72 2 1
004-013

002-002

B-17 1 2 3 4
1
2 3
B-4
004-004

003-007

X-3
1

2 3
B-73
005-006

003-007

X-4
1
2 3
B-148
005-006

003-007

X-6
1
2 3
B-150
005-006

003-007
8-148 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

6 5 4 3 2 1
X-23 B-70
1413 12 11 10 9 8 7

005-006 014-003

X-9 B-87 1 2 3
4 5 6

005-006 006-006

B-51 1 2 3 4 5 6 7 8 9 1011121314 B-153 1 2 3

4 5 6

014-001 006-007

B-52 1 2 3 4 5 6 7 8 9 10 11 12 B-154

012-005 000-010

1 2 3
B-55 1 2 3 4 5 6 7 8 9 10 11 12 H-15 4 5 6

7 8

012-004 008-023

3 2 1
B-67 1 2
H-15 6 5 4

3 4 8 7

004-001 008-024

B-67 2 1 H-16 1 2 3 4
4 3
5 6 7 8

004-002 008-003

B-70 1 2 3 4 5 6 H-16 4 3 2 1
7 8 9 10 11 12 13 14 8 7 6 5

014-002 008-004
 CAB AND CHASSIS ELECTRICAL 8-149

No. Connector Face H-6, H-7, H-8

P-1
(12 V)

000-003 1 2 H-6 2 1

1 2 H-7 2 1

P-2 1 2 3 4 4 3 2 1

5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
000-004 14 15 16 17 18 18 17 16 15 14

P-1
(24 V) N8A5489E

000-004

P-4

000-004

P-2
(24 V)

000-006

P-3

000-006

P-5
(12 V)

000-007

P-5
(24 V)

000-002
8-150 CAB AND CHASSIS ELECTRICAL
Diagnosis
Quick Chart for Check Point
1. Headlight

Check point
Fus-
Dim- Headlight
Fuse ible
Head- Light- mer / Dim- bulb Cable
link
light ing Pass- mer har-
F-6 relay SW ing relay ness
F-23 F-24 FL-4
F-8 SW LH RH
(10 A) (10 A) (30A)
(10 A)
1-1. Both Head-
❍ ❍ ❍ ❍
lights inopera-
(2) (1) (4) (3)
tive
1-2. Headlight
on the left (or ❍ ❍ ❍
right) side inop- (1) ((1)) (2)
erative
1-3. Headlight in
❍ ❍
low-beam inop-
(1) (2)
erative
1-4. Headlight in
❍ ❍
high-beam inop-
(1) (2)
erative
1-5. Headlight
Trouble on the left (or
mode ❍ ❍ ❍
right) side in low
(1) ((1)) (2)
(or high)-beam
inoperative
1-6. Headlight
❍ ❍ ❍ ❍
beam does not
(1) (2) (3) (4)
change
1-7. Headlights
remain on when ❍ ❍ ❍
the lighting (1) (2) (3)
switch turned off
1-8. Headlights
come on with
❍
the lighting SW
(1)
at the clearance
light position

Notice:
Figure in parenthesis “( )” indicates the order of inspection.
 CAB AND CHASSIS ELECTRICAL 8-151
2. Fog Light

Check point
Fuse Fog light bulb
Taillight Fog light Cable
F-8 (10 A): 24 V
relay SW LH RH harness
F-6 (10 A): 12 V
2-1. Both fog lights inopera-
❍ ❍ ❍ ❍
tive (while lighting switch is
(1) (2) (3) (4)
on)
Trouble 2-2. Fog light on the left (or
❍ ❍ ❍
mode right) side inoperative (while
(1) ((1)) (2)
lighting switch is on)
❍ ❍ ❍
2-3. Fog lights remain on
(1) (2) (3)

Notice:
Figure in parenthesis “( )” indicates the order of inspection.
3. Cornering Light

Check point
Fuse
F-8 (24 V), Cornering Cornering Cornering Cable
F-16 light SW light bulb light relay harness
F-6 (12 V)
(10 A)
(10 A)
3-1. Both cornering lights ❍ ❍ ❍ ❍ ❍
inoperative (2) (1) (5) (3) (4)
3-2. Cornering light on the
❍ ❍ ❍
left (or right) side inopera-
Trouble (2) (1) (3)
tive
mode
3-3. Cornering light
remains on even when ❍
steering wheel is in the (1)
straight ahead position

4. Rear Fog Light

Check point
Fuse Rear fog Rear fog Rear fog Cable
F-27 (15 A) light SW light relay light bulb harness
Trouble 4-1. Rear fog light inoperative ❍ ❍ ❍ ❍ ❍
mode (while headlight is ON) (2) (4) (3) (1) (5)
8-152 CAB AND CHASSIS ELECTRICAL
1. Headlight
1-1. Both Headlights Inoperative

N8A0118E

1-2. Headlight on The Left (or Right) Side Inoperative

N8A5137E
 CAB AND CHASSIS ELECTRICAL 8-153
1-3. Headlight in Low-beam Inoperative

N8A0120E

1-4. Headlight in High-beam Inoperative

N8A5139E
8-154 CAB AND CHASSIS ELECTRICAL
1-5. Headlight on The Left (or Right) Side in Low (or High)-beam Inoperative

N8A5140E

1-6. Headlight Beam Does Not Change

N8A0123E
 CAB AND CHASSIS ELECTRICAL 8-155
1-7. Headlight Remains On When The Lighting SW is Turned Off

• IS THE LIGHTING RELAY NORMAL?

YES NO

• DISCONNECT THE LIGHTING SW CONNECTOR REPLACE THE LIGHTING RELAY

• IS THE CONTINUITY BETWEEN THE SWITCH
CONNECTOR TERMINALS 1 B-70 AND 4 B-70
NORMAL?

YES NO

REPAIR A SHORT CIRCUIT BETWEEN 4 X-3 AND REPAIR OR REPLACE THE LIGHTING SW
1 B-70

N8A0124E

1-8. Headlight Comes On With The Lighting SW at The Clearance Light Position

• DISCONNECT THE LIGHTING SW CONNECTOR

• WITH THE LIGHTING SW AT THE CLEARANCE LIGHT
POSITION, IS THE CONTINUITY BETWEEN 1 B-70
AND 4 B-70 NORMAL?
(NO CONTINUITY NORMAL)

NO

REPAIR OR REPLACE THE LIGHTING SW

N8A0125E
8-156 CAB AND CHASSIS ELECTRICAL
2. Fog Light
2-1. Both Fog Lights Inoperative (while Lighting Switch is On)

N8A5144E
 CAB AND CHASSIS ELECTRICAL 8-157
2-2. Fog Light on The Left (or Right) Side Inoperative (while Lighting Switch is On)

• IS THE BULB NORMAL?

YES NO

REPAIR A POOR CONNECTION AT THE CONNECTORS REPLACE THE BULB

OR AN OPEN CIRCUIT BETWEEN 2 B-3 AND B-7
(2 B-72 AND B-7 )

N8A0127E

Notice:
Figures in parenthesis “( )” indicate place of inspection for the fog light on the right.
2-3. Fog Light Remains On

• DO THE TAILLIGHTS GO OFF?

YES NO

REPAIR OR REPLACE THE FOG LIGHT SWITCH REPLACE THE TAIL RELAY

N8A0128E
8-158 CAB AND CHASSIS ELECTRICAL
3. Cornering Light
3-1. Both Cornering Lights Inoperative

N8A5147E
 CAB AND CHASSIS ELECTRICAL 8-159
3-2. Cornering Light on The Left (or Right) Side Inoperative

N8A5149E

Notice:
Figures in parenthesis “( )” indicate place of inspection for the cornering light on the right.
3-3. Cornering Light Remains On Even When Steering Wheel is in Straight Ahead Position

• DOES THE CORNERING LIGHT SWITCH OPERATE

SMOOTHLY?

NO

REPAIR OR REPLACE THE CORNERING LIGHT

SWITCH (COMBINATION SWITCH)

N8A0131E
8-160 CAB AND CHASSIS ELECTRICAL
4. Rear Fog Light
4-1. Rear Fog Light Inoperative (while Headlight is ON)

N8A5151E
 CAB AND CHASSIS ELECTRICAL 8-161

N8A0133E

Starter Switch
Refer to “START AND CHARGING” in this section.

High Beam Indicator Light

Refer to “METER AND WARNING/INDICATOR LIGHT”
in this section. 1 2 3

Headlight Bulb Replacement

Removal
1. Remove the battery ground cable at the battery.
2. Remove the headlight assembly. (Refer to ‘Head-
light Replacement’ below.)
3. Remove the headlight bulb.
• Remove the dust cover (3).
• Remove the clip (1).
• Remove the headlight bulb (2).
N8A5468E
Caution:
Do not touch the glass portion of the bulb with your fin- Installation
gers. 1. Install the headlight bulb.
• Set the headlight bulb (2).
• Fix the headlight bulb with clip (1).
• Install the dust cover (3).
2. Install the headlight assembly.
(Refer to ‘Headlight replacement’ below.)
3. Connect the battery ground cable at the battery.
4. Check if the light lights.
8-162 CAB AND CHASSIS ELECTRICAL
• Remove the front combination light connector.
4. Remove the front grille (4).
• Remove the bolt at the center of the front grille.
• Remove the four clips securing the front grille.
• The grille is secured by 4 clips (2 clips at the in-
1 2 3
side of each headlight). Pull the grille toward
you to remove it.
5. Remove the front corner panel.
6. Remove the headlight (1).
• Remove the four bolts securing the headlight
(loosen the fixing bolts at the bottom of the front
side panel to create working space).
• Remove the headlight clips.
• Remove the headlight connector.

N8A5468E 1 2

Caution:
Do not touch the glass portion of the new bulb with your
fingers.

Headlight Replacement
Removal
Preparation: Disconnect the battery ground cable.
1. Remove the battery ground cable at the battery. 3
2. Remove the seal rubber (3).
• Remove the seal rubber from beneath the
headlight.
3. Remove the front combination light (2). 4
• Open the cab door. Insert a screwdriver (1) into
the space between the cab and the cab door. N8A5472E

Use the screwdriver to force out the stud pin at

the center of the grommet (the pin securing the Installation
front combination light). 1. Assemble the headlight assembly (1).
• Connect the connector.
• Fix it to body panel with four bolts (5).
2. Assemble the front panel side.
(Refer to “DOOR” in section 2.)
3. Install the front grille (4).
4. Install the front combination assembly (2).
Door side Cab side
1) Position it by aligning two pawls with the groove
of H/L.
2) Fit the iron PIN in the upper portion by aligning
it with the center of corresponding grommet.
Notice:
Push it into securely with a force of approx. 250 N (25
kgf) until click is heard.
3) Pull the front combination light assembly lightly
1 toward the front of vehicle to make sure that the
PIN and grommet are engaged securely.
N8A5471E
4) Tighten one bolt (6) in the lower portion of front
• Remove the fixing screw. combination light assembly.
• Remove the two catches. 5) Hook the seal rubber (3) on two projections un-
der H/L.
 CAB AND CHASSIS ELECTRICAL 8-163
5. Connect the battery ground cable.
6. Check the operation and lighting of each lamp.

1 2

6
3

5 N8A5474E

4 Horizontal Adjustment
N8A0441E
Insert the tip of a screwdriver into the hole beneath the
Aiming of Headlight headlight (the shaft of the screwdriver must be slanted
up) until contact is made with the head of the adjusting
Preparation: Place the unloaded vehicle on a level sur-
screw. Turn the screw to adjust headlight focus to the
face and check to see if the inflation pressure of the tires
left or right.
is correct, the lenses are clean, and the battery is suffi-
ciently charged. Adjust the aim with the headlight tester.
When adjusting, follow the procedure of the tester man-
ufacturer’s.

N8A5475E

N8A5473E

Vertical Adjustment
Insert the tip of a screwdriver into the hole beneath the
headlight (the shaft of the screwdriver must be slanted
up) until contact is made with the head of the adjusting
screw. Turn the screw to adjust headlight focus up or
down.
Two vertical aim screws should be turned in the same
direction at the same time to adjust aiming.
8-164 CAB AND CHASSIS ELECTRICAL
Cornering Light Bulb Replacement Installation
Removal 1. Install the cornering / clearance bulb.
1. Remove the battery ground cable at the battery. • While pressing the bulb (2), turn it clockwise to
2. Remove the front combination light. fit.
• Open the cab door. Insert a screwdriver (1) into Notice:
the space between the cab and the cab door. Do not let the glass portion dirty with sebum etc.
Use the screwdriver to force out the stud pin at
• Turn the bulb socket (3) clockwise to fit.
the center of the grommet (the pin securing the
front combination light).

Door side Cab side

3

2
1 N8A0442E

N8A5471E 2. Installation procedure of front combination light as-

sembly
• Remove the fixing screw.
• Connect the connector of the front combination
• Remove the two catches.
light assembly.
• Remove the front combination light (1) connec-
• Position it by aligning two pawls with the groove
tor.
of H/L.
• Fit the iron PIN (1) in the upper portion of the
side by aligning it with the center of correspond-
ing grommet.
Notice:
Push it into securely with a force of approx. 250 N (25
kgf) until click is heard.
• Pull the front combination light assembly lightly
3 toward the front of vehicle to make sure that the
PIN and grommet are engaged securely.
1
• Tighten one bolt in the lower portion of front
combination light assembly.
3. Hook the seal rubber on two projections under H/L.
4. Connect the battery ground cable.
5. Check lighting of each light.
2
N8A5477E

3. Remove the cornering light bulb.

• Turn the cornering / clearance bulb socket (3)
to the left to remove it.
• Press the bulb (2) in and turn it to the left to re-
move it from the socket.
 CAB AND CHASSIS ELECTRICAL 8-165
Fog Light Bulb
Removal
1. Remove the battery ground cable at the battery.
1
2. Remove the four screws (1) to remove the cover
which holds fog light assembly (2).
3. Remove the connector (3).
4. Remove the fog light assembly (2).

N8A0443E

2. Connect the two locations of connector (4).

3. Install the fog light assembly.
• Hold the fog light (2) with right and left covers
(1) and secure it with four screws (3).
3 2
Notice:
Make sure that “TOP” mark on the lens comes upside.
1 N8A5478E
4. Connect the battery ground cable.
5. Bulb 5. Check lighting.
• Push the clip (1) inward as arrow to remove.
• Remove the bulb (2).

1
2
4
2

3 N8A0444E

N8A5479E

Installation
1. Install the fog light bulb.
• Set the fog light bulb (2).
• Hook the clip (1) to secure fog light bulb.
8-166 CAB AND CHASSIS ELECTRICAL
Fog Light Switch
Inspection
Check the continuity between the connector terminals
while operating the switch.
Replace the switch when the result of inspection is
found abnormal.

N8A0435E

Removal
Preparation: N8A5160E
Disconnect the battery ground cable.
Installation
1. Meter Cluster
Refer to “METER AND WARNING/INDICATOR To install, follow the removal steps in the reverse order.
LIGHT” in this section.
2. Fog Light Switch
Release the lock pushing the switch from the back
side of the meter cluster.
 CAB AND CHASSIS ELECTRICAL 8-167
Combination Switch (Lighting Switch, Dimmer, Passing Switch, Cornering Light Switch and Rear
Fog Light Switch)
Inspection
Check the continuity between the connector terminals while operating the switch.
Replace the switch when the result of inspection is found abnormal.

N8A5162E

Removal 4. Combination Switch

Preparation: 1) Remove the four screws.
Disconnect the battery ground cable. 2) Disconnect the connector.
1. Horn Pad
1) Hold the horn pad and pull it upward.
2. Steering Wheel
1) Remove the steering shaft nut.
2) Remove the steering wheel by using steering
wheel remover.
(Refer to Section 3B4 “STEERING COLUMN”
for steering wheel removal steps.)
3. Steering Cowl
Remove the four screws.
8-168 CAB AND CHASSIS ELECTRICAL
Operation of The Circuit
Notice:
Arrow marks indicate the direction of current.
1. When headlight leveling SW is turned to “1” posi-
tion

STARTER SW "ON"

HEADLIGHT LEVELING HEADLIGHT LEVELING

ACTUATOR - LH ACTUATOR - RH

N8A5163E

Installation
To install, follow the removal steps in the reverse order, 0
1 2 3 HEADLIGHT
noting the following point. LEVELING SW

1. Tighten the steering shaft nut to the specified

torque.
N8A0145E
Tighten:
Shaft nut to 49 N⋅m (5 kg⋅m / 36 lb⋅ft) 2. When headlight leveling SW is turned to “0” posi-
tion
Headlight Leveling
General Description STARTER SW "ON"

The circuit consists of starter SW, headlight leveling SW

and headlight leveling actuator.
When the headlight leveling SW is operated with the
starter SW at ON position, the actuator is operated to
change the angle of the optical axis of the headlight.
HEADLIGHT LEVELING HEADLIGHT LEVELING
ACTUATOR - LH ACTUATOR - RH

1 2 3
0 HEADLIGHT
LEVELING SW

N8A0146E
 X-11
KEY ON RELAY (24V ONLY)
FUSE BOX ASM
F-12
Parts Location
B-420
DC-DC CONVERTER X-1
(24V ONLY) KEY ON RELAY (12V ONLY)

B-421

B-494

B-152
HEADLIGHT LEVELING ACTUATOR (RH) P-5
P-1

P-2
BATTERY
P-3
P-4

B-1

B-155

N8D0014E
CAB AND CHASSIS ELECTRICAL 8-169
 2L
ACG B

FL-1 100A

For 12 Volt
2L MAIN
30B 8B
FUSE BLOCK
P-3 P-1
P-4 P-2 FL-2 50A
Circuit Diagram
KEY SW

4JH1

3W/B
STARTER SWITCH
1
H-7 OFF
ACC
2 B
B-67 ON 3
B-67
P-5 FRAME
ST

3W/L
RELAY KEY ON

1 3L
2 X-1
X-1
5 3
8-170 CAB AND CHASSIS ELECTRICAL

X-1 X-1

F-12 10A

0.5B
H/LAMP
LEVEL

3B/Y
3B/Y 0.5R/W

0.5R/W 0.5R/W

SW; H/L LEVELING R1

10 2 0.5O/G 2 1 0.5R/W
B-156 B-494 B-421 B-421
R2
4 3 0.5O/B 3

0.5R/W
9
3 B-156 B-494 B-421
R3
0.5R/Y 0.5R/Y 1 4 2 8 4 0.5O/W 4
B-494 B-156 B-156 B-494 B-421
R4
RESISTOR;
H/L LEVELING

1 7 5 0.5O/L 5
0.5B 0.5B B-156 B-494 B-421

0.5R/Y
0 R5 R6
3 1 2 3 1 2
6 6 0.5O 6 14 0.5B
B-152 B-152 B-152 B-155 B-155 B-155 B-156 B-494 B-421 B-421

ACTUATOR; HLL (RH) ACTUATOR; HLL (LH)

(AS SIDE HEAD LAMP) (DR SIDE HEAD LAMP)

N8D0015E
 FL-1 2L
3W/B
MAIN ACG B
100A
or

For 24 Volt
2L 120A
30B 8B 5W/B
FUSE BLOCK
P-1
P-2 FL-2 40A
KEY SW

3W/B
STARTER SWITCH
1
P-3
H-7 OFF
P-4 ACC
2 B
B-67 ON 3
B-67
ST

P-5 FRAME

3W/L
RELAY KEY ON

1 3L
2 X-11
X-11
5 3
X-11 X-11
F-12 10A

0.5B
H/LAMP
LEVEL

3B/Y
3B/Y 0.5L/O 1 3 0.5B/W
B-420 B-420
CONVERTER;
6 DC-DC(HLL) 2 0.5R/W
B-420 B-420

0.5B/W
0.5R/W

SW; H/L LEVELING R1

10 2 0.5O/G 2 1 0.5R/W
B-156 B-494 B-421 B-421
R2
4 3 0.5O/B 3

0.5B/W
0.5B/W

0.5R/W
0.5R/W
9
3 B-156 B-494 B-421
R3
0.5R/Y 0.5R/Y 1 4 2 8 4 0.5O/W 4
B-494 B-156 B-156 B-494 B-421
R4
RESISTOR;
H/L LEVELING

1 7 5 0.5O/L 5
B-156 B-494 B-421

0.5R/Y
0 R5 R6
1 3 2 1 3 2
6 6 0.5O 6 14 0.5B/W
B-152 B-152 B-152 B-155 B-155 B-155 B-156 B-494 B-421 B-421

ACTUATOR; HLL (RH) ACTUATOR; HLL (LH)

(AS SIDE HEAD LAMP) (DR SIDE HEAD LAMP)

N8D0016E
CAB AND CHASSIS ELECTRICAL 8-171
8-172 CAB AND CHASSIS ELECTRICAL
Connector List No. Connector Face

No. Connector Face

P-2

B-67 1 2
3 4 000-004

004-001

P-5

B-67 2 1
4 3 000-007

004-002

B-420 1 2 3

(24 V) 4 5 6

B-152 1 2
3 006-019

003-016

B-421 1 2 3 4 5 6
7 8 9 10 11 12 13 14

B-155 1 2
3 014-002

003-016

B-494 1 2
3 4 5 6
B-156 1 2 3 4

5 6 7 8 9 10 006-002

010-002

2 1
B-494
6 5 4 3

X-1
006-003

005-006

X-11 2 3 4

005-00

P-1

000-003
 CAB AND CHASSIS ELECTRICAL 8-173
H-7

1 2 H-6 2 1

1 2 H-7 2 1

1 2 3 4 4 3 2 1

5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14

N8A5489E

Diagnosis
Quick Chart for Check Points

Check point
Headlight Headlight
Fuse Cable
leveling leveling
F-12 (10 A) harness
switch actuator
1. Both actuators inoperative ❍ ❍ ❍
2. Actuator on the left (right) side inop-
Trouble ❍ ❍
erative
mode
3. When leveling SW is turned to a
❍ ❍ ❍
certain position, actuator inoperative
8-174 CAB AND CHASSIS ELECTRICAL
1. Both Actuators Inoperative

• IS FUSE F-12 (10A) NORMAL?

YES NO

• IS B-7 GROUNDED SECURELY? REPLACE THE FUSE

YES NO

• TURN THE STARTER SW TO ON POSITION GROUND IT SECURELY

• IS THE BATTERY VOLTAGE APPLIED BETWEEN THE
FUSE TERMINAL AND THE GROUND?

YES NO

• IS THE CONTINUITY IN THE HEADLIGHT LEVELING REPAIR AN OPEN CIRCUIT BETWEEN STARTER
SW NORMAL? SW AND FUSE F-12 (10A)

YES NO

• IS THERE CONTINUITY BETWEEN 6 B-156 AND THE REPAIR OR REPLACE THE SWITCH
GROUND?

YES NO

REPAIR A POOR CONNECTION AT THE CONNECTORS REPAIR AN OPEN CIRCUIT BETWEEN

OR AN OPEN CIRCUIT BETWEEN FUSE F-20 AND 6 B-156 AND B-7
1 B-155 (1 B-152 )

N8A0149E

2. Actuator on the Right (Left) Side Inoperative

N8A5170E
 CAB AND CHASSIS ELECTRICAL 8-175
3. When Headlight Leveling SW is Turned to A Certain Position, Actuator Inoperative

N8A5171E

Inspect and repair the circuit that is corresponding to the

headlight leveling switch position where the actuator be-
comes inoperative.
Actuator - RH

Headlight leveling
Circuit
SW position
1 Between 3 B-156 and 3 B-155
2 Between 2 B-156 and 4 B-155
3 Between 1 B-156 and 5 B-155
0 Between 4 B-156 and 2 B-155

Actuator - LH

Headlight leveling
Circuit
SW position
1 Between 3 B-156 and 3 B-152 N8A5174E

2 Between 2 B-156 and 4 B-152 Removal

3 Between 1 B-156 and 5 B-152 Preparation:
Disconnect the battery ground cable.
0 Between 4 B-156 and 2 B-152
1. Switch Bezel
Starter Switch 2. Headlight Leveling Switch
Disconnect the connector.
Refer to “START AND CHARGING” in this manual.

Headlight Leveling Switch

Inspection
Check the continuity between the switch connector ter-
minals.
Repair or replace the switch when the result of inspec-
tion is found abnormal.
8-176 CAB AND CHASSIS ELECTRICAL

1 2 3
SIGNAL − +

Input signal
voltage ratio
for SIGNAL
when the volt-
age difference
− +
between posi-
tive and nega-
tive is
specified as
100%
Position 10.0% (1.2 V) 0V 12 V
0
N8A5175E
Position 23.4% (2.8 V) 0V 12 V
Installation 1
HEAD
To install, follow the removal steps in the reverse order. Position 36.7% (4.4 V) 0V 12 V
LAMP
2
Headlight Leveling Actuator POSITION
Position 50.0% (6.0 V) 0V 12 V
Inspection 3
This actuator has a mechanism that the angle of head
Position 63.4% (7.6 V) 0V 12 V
light leveling varies according to input voltage of SIG-
4
NAL.
1. Make sure that the voltage specified in table is out-
put to vehicle harness connector which will be con- Caution:
nected to actuator. 1. For vehicles with 12 V and 24 V, this leveling input
If the power supply is not 12 V, the SIGNAL output voltage is 12 V.
varies in proportion to its voltage. 2. Input to SIGNAL must be less than 65% of the in-
2. Connect the connector of actuator and vehicle har- put voltage to positive terminal.
ness connector.
Make sure that the reflector of headlight moves to
the position indicated by HEAD LAMP LEVELING
SW.

B-152 B-155

1 2 Actuator side
3

N8A0154E
 CAB AND CHASSIS ELECTRICAL 8-177
Clearance Light, Taillight, License Plate Light and Illumination Light
General Description
The circuit consists of the lighting switch, clearance light, taillight, license plate light and the illumination light for each
of switch, meter and ashtray.
All these lights come on when the lighting switch is turned on with the switch to either clearance or headlight position.
Lighting Circuit

N8A0156E
 B-52

Parts Location

R-14, R-15 LICENSE

PLATE LIGHT(RH)
R2, R-3
LICENSE
PLATE
LIGHT(LH)
8-178 CAB AND CHASSIS ELECTRICAL

F-25 FUSE
FL-1 FUSIBLE LINK
X-22 MARKER LIGHT RELAY

N8A5179E
 CAB AND CHASSIS ELECTRICAL 8-179
Circuit Diagram
For 12 Volt

CLEARANCE LIGHT (RH)

B-74
CORNERING LIGHT SWITCH (9)

3
(COMBINATION SWITCH)
0.85B

B-74
1
0.5LG/R

B-74
4
CLEARANCE LIGHT (LH)

3
CORNERING LIGHT SWITCH (11)

B-5
(COMBINATION SWITCH)

B-5
1
0.85B

4
B-5
0.5LG/R

TAILLIGHT-RH (REAR COMBINATION LIGHT)

(0.5LG/R)

6
R-6

R-6
0.5G/R 1.25B
TAILLIGHT-LH
(REAR COMBINATION LIGHT)
0.85LG/R 0.5G/R

H-16
(0.5LG/R)

H-16
4

7
4

R-1

R-1
H-5

0.5G/R 1.25B

LICENSE PLATE LIGHT(RH)

0.5G/R 1.25B

H-16
J-62

J-62

R-3

R-2
1

(0.5LG/R) 0.5LG/R

1
0.5B

1
REAR COMBINATION LIGHT-RH (TAIL)
(NKR DUMP VEHICLE)

R-15

R-14
5

0.5G/R

1
1.25B
J-65

J-65

H-5
1

RELAY; MARKER LIGHT LICENSE PLATE LIGHT(LH)

REAR COMBINATION LIGHT-LH (TAIL)
1

0.85LG/B 0.85B
X-22

J-24

J-25
2
X-22

0.5LG/R 0.5B
J-63

J-64
5
H-5

MARKER LIGHT
1

(0.5G/R)
3

0.5B
X-22

X-22

LICENSE PLATE LIGHT

0.5LG/R 0.5B
J-66

J-67
1

LICENSE PLATE LIGHT-LH (TAIL) ASHTRAY

1.25B
B-46

B-46

0.5LG/R 0.3B
1

2
MARKER LIGHT

HEATER BEZEL
0.5LG/R
B-33

B-33

0.3B
F-25 15A

RADIO
B-28

B-28

0.5LG/R 0.5B
0.85LG/W
10

ILLUMINATION LIGHT (METER)

1.25W

TAILLIGHT

B-52

B-52

0.5LG/R 0.85B
F-7 10A

10
5

RELAY; TAIL
0.85LG/R CIGAR LIGHTER
5
X-4

8W/B 3W/B 3W/B

1
H-6

X-4

3W
B-43

B-43

0.5LG/R 0.3B
2

3W/B
2

4
X-4

X-4

RELAY; DIMMER

FOG LIGHT SWITCH

0.5LG/R 0.5B
B-87

B-87
0.3G/O

DIODE
2

5
2
B-17

B-17

0.5R
3

DOME LIGHT SWITCH

B-86

B-86

0.3R 0.5LG/R 0.5B

1

3
0.3L/R
8W

10 0.3R/L

2B

REAR FOG LIGHT SWITCH

0.85B
RELAY; HEADLIGHT (4)

B-153

B-153

0.5LG/R 0.5B
5

4
1

B-70 8

4
B-70

B-70

B-70

B-70

HAZARD WARNING SWITCH

0.5LG/R 0.5B
B-30

B-30
PASS
T
H

Hu

1.25B
LIGHTING SWITCH
FL-1 100A

PASS

3B
MAIN

ROOF MARKER LIGHT (LH)

HIGH

0.5R/G 0.5B
B-1

B-7

J-9
OFF

LO

ROOF MARKER LIGHT (RH)

2L

FRAME-LH (CENTER)
BRACKET (LH)
FRAME-LH (FRONT)

HEADLIGHT

COMBINATION SWITCH 0.5R/G 0.5B

FRAME
P-1
P-2

NPR / NQR (EC / AUSTRALIA)

P-5
4JH1
P-3
P-4

N8A5180E
8-180 CAB AND CHASSIS ELECTRICAL
For 24 Volt

CLEARANCE LIGHT (RH)

(Except AUSTRALIA)

B-74
3
CORNERING LIGHT SWITCH (9)
(COMBINATION SWITCH) 0.85B

B-74
1
0.5LG/R

B-74
4
CLEARANCE LIGHT (LH)
(Except AUSTRALIA)

3
CORNERING LIGHT

B-5
SWITCH (11)

B-5
1
(COMBINATION SWITCH)
0.85B

4
B-5
0.85LG/R

TAILLIGHT-RH (REAR COMBINATION LIGHT)

6
R-6

R-6
0.5G/R 1.25B
TAILLIGHT-LH
(REAR COMBINATION LIGHT)
0.5G/R

H-16
1.25B

H-16
4

7
4

R-1

R-1
H-5
0.5G/R 1.25B

0.5G/R 1.25B 0.5LG/R LICENSE PLATE LIGHT

J-62

J-62
1

H-16
0.5LG/R

R-3
H-5

R-2

1.25B
1

1
REAR COMBINATION LIGHT-RH (TAIL) 0.5LG/R 0.5B
0.5G/R 1.25B RELAY;
J-65

J-65
(DUMP VEHICLE)

MARKER LIGHT
1

MARKER LIGHT

1
1
X-22

1.25G/B

J-24

J-25
REAR COMBINATION LIGHT-LH (TAIL) 0.85B
2
X-22

0.5LG/R 0.5B
J-63

J-64
5
H-5

5
X-22

X-22

0.5B
3
1

0.5G/R
LICENSE PLATE LIGHT

0.5LG/R 0.5B
J-66

J-67
1

LICENSE PLATE LIGHT-LH (TAIL) B-46 ASHTRAY

B-46
0.5LG/R 0.3B
1

2
HEATER BEZEL
0.85LG/R
MARKER LIGHT

0.5LG/R
B-33

B-33

0.3B
1

2
15A
F-25

RADIO
B-28

B-28

2LG/W 0.5LG/R 0.5B

10

ILLUMINATION LIGHT (METER)

B-52

B-52

0.85B
3W/B

0.5LG/R
10
5

RELAY; TAIL
0.85LG/R CIGAR LIGHTER
5
X-4
1
X-4
H-6

B-43

B-43

0.5LG/R 0.3B
2

2
TAILLIGHT
10A

4
X-4

X-4
F-7

4WD SWITCH
0.3B
B-93

B-93

0.5LG/R
5

6
RELAY; DIMMER

PATTERN SELECT SWITCH

(AUSTRALIA only)
B-88

B-88

DIODE 0.5LG/R 0.5B

0.3G/O

6
5
B-17
B-17

0.5R
2
3

FOG LAMP SWITCH

0.85B

3B

2B
2B

0.3R 0.85LG/R 0.5B

B-87

B-87
2

5
0.3L/R
5W

10 0.3R/L

DOME LIGHT SWITCH

RELAY; HEADLIGHT (4)

B-86

B-86

0.85LG/R 0.5B
1

B-70 8

3
B-70

B-70

B-70

B-70
FL-1 100A or 120A

HAZARD WARNING SWITCH

PASS

0.5LG/R
3B

0.85B
B-30

B-30
T
H

Hu

1.25B
MAIN

LIGHTING SWITCH

HIGH PASS

ROOF MARKER
B-1
0.5LG/R

B-7

J-9

LIGHT (LH)
1
1

2
2
OFF

ROOF MARKER
LO

BRACKET (LH)

FRAME-LH (CENTER)
FRAME-LH (FRONT)
2L

0.5B

LIGHT (RH)
HEADLIGHT

COMBINATION SWITCH
1

0.5R/G 0.5B
FRAME
P-1
P-2

P-3
P-4

NPR / NQR (EC / AUSTRALIA)

P-5

N8A5609E
 CAB AND CHASSIS ELECTRICAL 8-181
Connector List No. Connector Face

No. Connector Face

B-30 1 2 3 4
5 6 7 8
B-5 1 2
008-005
3 4

004-012

B-88 1 2 3 4

2 1 5 6 7 8
B-5
4 3 008-005

004-013

B-93 1 2 3 4
5 6 7 8
B-74 1 2
008-005
3 4

004-012

B-87 1 2 3
4 5 6
2 1
B-74
4 3 006-006

004-013

B-33
1 2
B-17 1 2 3 4
002-022

004-004

B-33
2 1
X-4
002-023

005-006

B-46
1 2
X-22
002-022

005-006

B-46
2 1
1 2 3 4 5 6
B-28
7 8 9 10 11 12 13 002-023

013-001
8-182 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

B-43 1 H-16 4 3 2 1

2 8 7 6 5

002-009 008-004

1
B-43 J-24
2

002-010 000-010

B-52 1 2 3 4 5 6 7 8 9 10 11 12 J-24

012-005 000-011

B-70 1 2 3 4 5 6 J-25
7 8 9 10 11 12 13 14

014-002 000-010

6 5 4 3 2 1
B-70 J-25
1413 12 11 10 9 8 7

014-003 000-011

B-86 1 2
J-63
3 4

004-001 000-010

B-153 1 2 3 J-63
4 5 6

006-007 000-011

H-16 1 2 3 4 J-64
5 6 7 8

008-003 000-010
 CAB AND CHASSIS ELECTRICAL 8-183

No. Connector Face No. Connector Face

J-64 R-3

000-011 000-011

J-66 R-14

000-010 000-010

J-66 R-14

000-011 000-011

J-67 R-15

000-010 000-010

J-67 R-15

000-011 000-011

R-2 J-62 1 2 3
4 5 6

000-010 006-010

R-2 J-62 3 2 1
6 5 4

000-011 006-015

R-3 J-65 1 2 3
4 5 6

000-010 006-010
8-184 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

P-5
J-65 3 2 1
6 5 4 (24 V)

006-015 000-002

P-1
R-1 1 2 3
(12 V) 4 5 6

000-003 006-004

P-2 R-1 3 2 1
6 5 4

000-004 006-005

P-1
R-6 1 2 3
(24 V) 4 5 6

000-004 006-004

P-4 R-6 3 2 1
6 5 4

000-004 006-005

H-5

P-2
(24 V)

000-006

P-3 1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 11 12 12 11 10 9 8 7
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 24 23 22 21 20 19
25 26 27 28 29 30 30 29 28 27 26 25
31 32 33 38 39 40 40 39 38 33 32 31
000-006 34 35 36 37 37 36 35 34

P-5
(12 V)

000-007
N8A5488E
 CAB AND CHASSIS ELECTRICAL 8-185
H-6

1 2 H-6 2 1

1 2 H-7 2 1

1 2 3 4 4 3 2 1

5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14

N8A5489E

Diagnosis
Quick Chart for Check Point

Check point
Fuse Light- Tail- Clear- License Marker Cable Marker
F-7 F-25 ing light ance plate light har- light
(10 A) (15 A) SW bulb light bulb light bulb relay ness bulb
1. Both clearance ❍ ❍ ❍ ❍
lights inoperative (1) (3) (2) (4)
2. Clearance light
❍ ❍
on the left (or right)
(1) (2)
side inoperative
3. Both taillights ❍ ❍ ❍
Trouble inoperative (1) (2) (3)
mode 4. Taillight on the
❍ ❍
left (or right) side
(1) (2)
inoperative
5. License plate ❍ ❍
light inoperative (1) (2)
6. Marker light ❍ ❍ ❍ ❍
inoperative (2) (3) (4) (1)

Notice:
Figure in parenthesis “( )” indicates the order of inspection.
8-186 CAB AND CHASSIS ELECTRICAL
1. Both Clearance Lights Inoperative

• ARE BOTH TAILLIGHTS OPERATIVE?

YES NO

• IS B-7 SECURELY GROUNDED? TURN TAILLIGHTS ON (REFER TO TAILLIGHT

DIAGNOSIS IN THIS SECTION)

YES NO

• TURN THE LIGHTING SWITCH TO OR POSITION GROUND IT SECURELY

• IS THERE BATTERY VOLTAGE APPLIED TO
CLEARANCE LIGHT CONNECTOR 4 B-5 (4 B-74 ) AND
GROUND?

YES NO

REPAIR A POOR CONNECTION AT THE CONNECTORS REPAIR A POOR CONNECTION AT THE

OR AN OPEN CIRCUIT BETWEEN CLEARANCE LIGHT CONNECTORS OR AN OPEN CIRCUIT BETWEEN
CONNECTOR TERMINALS 1 B-5 (1 B-74 ) AND B-7 FUSE F-7 (10A) AND 4 B-5 (4 B-74 )

N8A0160E

Notice:
Figure in parenthesis “( )” indicates place of inspection for clearance light on the right side.
2. Clearance Light on the Left (or Right) Side Inoperative

N8A5186E

Notice:
Figure in parenthesis “( )” indicates place of inspection for clearance light on the right side.
 CAB AND CHASSIS ELECTRICAL 8-187
3. Both Taillights Inoperative

N8A5187E
8-188 CAB AND CHASSIS ELECTRICAL
4. Taillight on the Left (or Right) Side Inoperative

• IS TAILLIGHT BULB ON THE LEFT (OR RIGHT) SIDE

NORMAL?

YES NO

• REPAIR A POOR CONNECTION AT THE CONNECTORS REPLACE THE BULB

OR AN OPEN CIRCUIT BETWEEN CONNECTOR
TERMINAL 4 H-16 AND TAILLIGHT CONNECTOR
1 R-1 ( 1 R-6 )

N8A0163E

Notice:
Figure in parenthesis “( )” indicates place of inspection for taillight on the right side.
5. License Plate Light Inoperative

• ARE BOTH TAILLIGHTS OPERATIVE?

YES NO

• IS THE LICENSE PLATE LIGHT BULB NORMAL? TURN THE TAILLIGHTS ON (REFER TO
TAILLIGHT DIAGNOSIS IN THIS SECTION)

YES NO

• IS THERE BATTERY VOLTAGE APPLIED BETWEEN REPLACE THE BULB

5 H-16 AND THE GROUND WHEN TURNING THE
LIGHTING SWITCH ON?

YES NO

• REPAIR A POOR CONNECTION AT THE CONNECTORS REPAIR A POOR CONNECTION AT THE

OR AN OPEN CIRCUIT BETWEEN 1 R-2 OR 1 R-14 CONNECTORS OR AN OPEN CIRCUIT IN THE
AND 7 H-16 CIRCUIT

N8A0164E
 CAB AND CHASSIS ELECTRICAL 8-189
6. Marker Light Inoperative

N8A5191E

Lighting Switch
Refer to “HEADLIGHT, FOG LIGHT AND CORNERING
LIGHT” in this section.

Clearance Light/Bulb
Removal
1. Remove the battery ground cable at the battery. Door side Cab side

2. Remove the front combination light.

• Open the cab door. Insert a screwdriver (1) into
the space between the cab and the cab door.
Use the screwdriver to force out the stud pin at
the center of the grommet (the pin securing the
front combination light).

N8A5471E

• Remove the fixing screw.

8-190 CAB AND CHASSIS ELECTRICAL
• Remove the two catches. • Position it by aligning two pawls with the groove
• Remove the front combination light (1) connec- of H/L.
tor. • Fit the iron PIN (1) in the upper portion of the
side by aligning it with the center of correspond-
ing grommet.
Notice:
Push it into securely with a force of approx. 250 N (25
kgf) until click is heard.
• Pull the front combination light assembly lightly
toward the front of vehicle to make sure that the
PIN and grommet are engaged securely.
3 • Tighten one bolt in the lower portion of front
1 combination light assembly.
3. Hook the seal rubber on two projections under H/L.
4. Connect the battery ground cable.
5. Check lighting of each light.

Taillight Bulb
2 Removal
N8A5477E 1. Lens
2. Bulb
3. Remove the clearance light bulb.
• Turn the bulb socket (3) to the left to remove it.
• Press the bulb (2) in and turn it to the left to re-
move it from the socket.
Installation
Installation procedure of cornering/clearance light bulb
1. Install the cornering/clearance light bulb.
• While pressing the bulb (2), turn it clockwise to
fit.
Notice:
Do not let the glass portion dirty with sebum etc.
• Turn the bulb socket (3) clockwise to fit.

N8A0167E

Installation
To install, follow the removal steps in the reverse order.

2
N8A0442E

2. Installation procedure of front combination light as-

sembly
• Connect the connector of the combination light
assembly.
 CAB AND CHASSIS ELECTRICAL 8-191
License Plate Light Bulb
Removal
1. Cover
2. Lens
3. Bulb

N8A0168E

Installation
To install, follow the removal steps in the reverse order.

Turn Signal Light, Hazard Warning Light,

and Stoplight
General Description
The circuit consists of the starter switch, turn signal light
(front and rear), turn signal light switch, hazard warning
light, flasher unit, stoplight and stoplight switch.
When turning on the respective switches with the starter
switch on, the turn signal light will operate. When the
turn signal light is flashing, the indicator light in the meter
also starts flashing. When the hazard warning switch is
turned on, the current flows to the flasher unit through
the hazard warning switch to cause the hazard warning
light to flash, independent of the position of the starter
switch. At the same time, the indicator lights in the meter
also start flashing.
The stoplight switch will turn on and the light comes on
once the brake pedal is depressed, independent of the
position of the starter switch.
8-192 CAB AND CHASSIS ELECTRICAL
Parts Location

N8A5195E
 CAB AND CHASSIS ELECTRICAL 8-193
Circuit Diagram
For 12 Volt

(Except DUMP VEHICLE)

F-5 10A STOPLIGHT SWITCH STOPLIGHT (RH)
STOP LIGHT 0.5G/Y 2B

11
0.5G

H-16
B-66

B-66

6
1

R-6

R-6
H-5
0.5G

0.5G 1.25B

6
R-1

R-1
F-4 15A
AUDIO STOPLIGHT (LH)
(NKR DUMP VEHICLE)

STOPLIGHT (RH) P/SOURCE

0.5G 2B (SERVICE)
0.85R
2

6
J-62

J-62

SIDE TURN SIGNAL LIGHT (RH)

(S/CAB EC TURKEY ONLY)

0.5G 1.25B (S/CAB)
J-65

J-65
2

0.5W 0.5B
STOPLIGHT (LH)

0.5G/W
F-11 10A
0.5L 0.5B
TURN LIGHT

0.5G/B
8W/B

3B/Y 0.5Y/R SIDE TURN SIGNAL LIGHT (LH)

(S/CAB)
3
B-67

F-19 15A
(NPR/NQR W/CAB
STARTER SWITCH

HORN, HAZARD SIDE TURN SIGNAL LIGHT (RH)

ACC

ON

ST

0.5G (DOOR)
EC ONLY)

5
H-22

H-22
1
WARNING
OFF

HAZARD
1

SWITCH
B-30
B

B
FU

0.5LG/B
B-30
6

IG
5W

B-30
5
B-67

RH

0.5G/W
B-16

TURN SIGNAL
B-30
2

1.25B

INDICATOR LIGHT (RH) (METER)

TB

LH

0.5BR 0.5G/B
11
3W/L

0.85B
FLASHER

B-55

B-55
B-16

B-30

B-30
2

7
3
UNIT
2
H-6

0.5B
B-30

B-30
8

TURN SIGNAL LIGHT

0.5LG/R

(FRONT COMBINATION LIGHT-RH)

1
H-7

0.85B
2
B-74

B-74
1
0.5BR
B-16

0.5G/W

RELAY; TAIL (5)

3
FL-2 50A

3W/B

TURN SIGNAL LIGHT

KEY SW

(REAR COMBINATION LIGHT-RH)

5W

RH

0.5G/W 1.25B
17
13

H-16
B-70

6
R-6

R-6
H-5
12
B-70

LH

0.5G/B 1.25B
10

H-16
B-70

6
5

R-1

R-1
H-5

(For DUMP VEHICLE)

TURN SIGNAL LIGHT
0.5B

TURN SIGNAL LIGHT SWITCH (REAR COMBINATION LIGHT-LH)

7

(COMBINATION SWITCH)
(NKR DUMP VEHICLE)

H-16

TURN SIGNAL LIGHT

(REAR COMBINATION LIGHT-RH)
J-62

J-62
3

0.5G/W 2B
J-65
J-65
3

0.5G/B 1.25B
8W

TURN SIGNAL LIGHT

(REAR COMBINATION LIGHT-LH)
0.5G/B

0.85B
2

1
B-5

B-5

TURN SIGNAL LIGHT

FL-1 100A

(FRONT COMBINATION LIGHT-LH)

0.85B
3B
B-55
B-55
8

7
MAIN

TURN SIGNAL INDICATOR LIGHT (LH) (METER)

(NPR/NQR W/CAB EC ONLY)

SIDE TURN SIGNAL LIGHT (LH)

J-9

(DOOR)
2L

H-20

H-20
1

FRAME-LH (CENTER)
B-1

B-7
FRAME
P-1
P-2

P-5

FRAME-LH

HEADLIGHT
(FRONT)

BRACKET
4JH1
P-3
P-4

(LH)

N8A5602E
8-194 CAB AND CHASSIS ELECTRICAL
For 24 Volt

(Except DUMP VEHICLE)

F-5 10A STOPLIGHT SWITCH STOPLIGHT (RH)
STOP LIGHT 0.5G/Y

11
0.5G 2B

H-16
B-66

B-66

6
1

R-6

R-6
H-5
0.5G

0.5G 1.25B

6
R-1

R-1
F-4 15A
AUDIO STOPLIGHT (LH)

P/SOURCE
(NKR DUMP VEHICLE)

STOPLIGHT (RH) (SERVICE)

0.85R
0.5G 2B
2

6
J-62

J-62

RELAY SIDE TURN SIDE TURN

(S/CAB EC TURKEY ONLY)

(S/CAB) SIGNAL LIGHT (RH)

0.85R
(S/CAB)
0.5G 1.25B
J-65

J-65
2

0.5W 0.5B

4
STOPLIGHT (LH)

2
0.5B

3
0.5G/W
F-11 10A
TURN LIGHT 0.5L 0.5B
5W/B

6
3B/Y 0.5Y/R SIDE TURN

5
SIGNAL LIGHT (LH)

0.5G/B
3

(S/CAB)
B-67

F-20 15A
STARTER SWITCH

(NPR/NQR W/CAB
ACC

HORN, HAZARD
ON

ST

0.5G
EC ONLY)

SIDE TURN SIGNAL LIGHT (RH)

(DOOR)
WARNING
OFF

HAZARD
1

SWITCH

H-22

H-22
1

5
B-30
B

B
FU

0.5LG/B
B-30
6

IG
5W

B-30
5
B-67

RH

0.85B
B-16

0.5G/W
B-30

TURN SIGNAL
2

INDICATOR LIGHT (RH) (METER)

TB

LH

11

0.5BR 0.5G/B
3W/L

0.85B
FLASHER

B-55

B-55
B-16

B-30

B-30

7
2

3
UNIT

5
2
H-6

0.5B
B-30

B-30
8

TURN SIGNAL LIGHT

0.5LG/R

7
1

(FRONT COMBINATION LIGHT-RH)

H-7

2
B-74

B-74

0.85B
1
0.5BR
B-16

0.5G/W

RELAY; TAIL (5)

3
FL-2 40A

3W/B

TURN SIGNAL LIGHT

KEY SW

(REAR COMBINATION LIGHT-RH)

5W

RH

0.5G/W
17
13

1.25B
H-16
B-70

6
R-6

R-6
H-5
12
B-70

LH

10

0.5G/B 1.25B
H-16
B-70

6
5

R-1

R-1
H-5

(For DUMP VEHICLE)

0.5B

TURN SIGNAL LIGHT

TURN SIGNAL LIGHT SWITCH (REAR COMBINATION LIGHT-LH)
7

(COMBINATION SWITCH)
(NKR DUMP VEHICLE)

H-16

TURN SIGNAL LIGHT

(REAR COMBINATION LIGHT-RH)
J-62

J-62
3

0.5G/W 2B
J-65
J-65
3

6
5W

0.5G/B 1.25B
TURN SIGNAL LIGHT
(REAR COMBINATION LIGHT-LH)
0.5G/B
FL-1 100A or 120A

0.85B
2

1
B-5

B-5

TURN SIGNAL LIGHT

(FRONT COMBINATION LIGHT-LH)
3B

0.85B
B-55
B-55
8

7
MAIN

TURN SIGNAL INDICATOR LIGHT (LH) (METER)

(NPR/NQR W/CAB EC ONLY)

SIDE TURN SIGNAL LIGHT (LH)

J-9

(DOOR)
2L

H-20

H-20
1

FRAME-LH (CENTER)
B-1

B-7
FRAME
P-1
P-2

P-3
P-4

P-5

FRAME-LH

HEADLIGHT
(FRONT)

BRACKET
(LH)

N8A5574E
 CAB AND CHASSIS ELECTRICAL 8-195
Connector List No. Connector Face

No. Connector Face

B-52 1 2 3 4 5 6 7 8 9 10 11 12

B-5 1 2
012-005
3 4

004-012

B-51 1 2 3 4 5 6 7 8 9 1011121314

2 1
B-5
4 3 014-001

004-013

B-53 1 2 3 4 5 6 7 8 9 10 11 12

B-74 1 2
3 4 012-004

004-012

B-66
1 2
2 1
B-74
4 3 002-024

004-013

B-16
(12 V B-67 1 2
s/cab 3 4
and
004-001
with- 1 3
out 2
side
turn 003-008

light c/ B-67 2 1
4 3
cab)
004-002
B-16
(24 V
and
12V
with 1 2 3 B-70 1 2 3 4 5 6
4 5 6 7 8 9 10 11 12 13 14
side
turn
006-010 014-002
light c/
cab)

6 5 4 3 2 1
B-70
1413 12 11 10 9 8 7

B-30 1 2 3 4
5 6 7 8 014-003

008-005
8-196 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

H-16 1 2 3 4 J-65 1 2 3
5 6 7 8 4 5 6

008-003 006-010

H-16 4 3 2 1
J-65 3 2 1

8 7 6 5 6 5 4

008-004 006-015

H-20 1 2 3 4 R-1 1 2 3
5 6 7 8 9 10 4 5 6

010-003 006-004

4 3 2 1
H-20 10 9 8 7 6 5
R-1 3 2 1
6 5 4

010-004 006-005

H-22 1 2 3 4 R-6 1 2 3
5 6 7 8 9 10 4 5 6

010-003 006-004

4 3 2 1
H-22 10 9 8 7 6 5
R-6 3 2 1
6 5 4

010-004 006-005

P-1
J-62 1 2 3
4 5 6 (12 V)

006-010 000-003

J-62 3 2 1
P-2
6 5 4

006-015 000-004
 CAB AND CHASSIS ELECTRICAL 8-197

No. Connector Face No. Connector Face

P-1
(24 V)

000-004 000-010

P-4

000-004 000-011

H-5

P-2
(24 V)

000-006

P-3 1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 11 12 12 11 10 9 8 7
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 24 23 22 21 20 19
25 26 27 28 29 30 30 29 28 27 26 25
31 32 33 38 39 40 40 39 38 33 32 31
000-006 34 35 36 37 37 36 35 34

P-5
(12 V)

000-007
N8A5488E

H-7, H-8

P-5
(24 V)

000-002

1 2 H-6 2 1

1 2 H-7 2 1

1 2 3 4 4 3 2 1
000-010
5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14

000-011
N8A5489E
8-198 CAB AND CHASSIS ELECTRICAL
Diagnosis
Quick Chart for Check Point
1. Turn Signal Light, Hazard Warning Light

Check point
Fuse Turn Hazard Turn
Flasher Cable
F-19, F-20 F-11 signal warning signal
unit harness
(15 A) (10 A) light SW light SW light bulb
1-1. Turn signal lights
❍ ❍ ❍ ❍
inoperative
Trouble 1-2. Turn signal lights
❍ ❍
mode flash too quickly
1-3. Hazard warning
❍ ❍
lights inoperative

Notice:
Figure in parenthesis “( )” indicates the order of inspection.
2. Stoplight

Check point
Fuse
Stoplight SW Stoplight bulb Cable harness
F-5 (10 A)
2-1. Both stoplights inoperative ❍ ❍ ❍
Trouble
mode 2-2. Stoplight on the left (or right)
❍ ❍
side inoperative

Notice:
Figure in parenthesis “( )” indicates the order of inspection.
 CAB AND CHASSIS ELECTRICAL 8-199
1. Turn Signal Light, Hazard Warning Light
1-1. Turn Signal Lights Inoperative

N8A0169E
8-200 CAB AND CHASSIS ELECTRICAL

CONTINUED FROM THE PREVIOUS PAGE CONTINUED FROM THE PREVIOUS PAGE

• IS THERE ANY CONTINUITY BETWEEN THE HARNESS GROUND IT SECURELY

SIDE CONNECTORS 3 B-16 AND B-7 ?

YES NO

• DISCONNECT THE COMBINATION SWITCH REPAIR A POOR CONNECTION AT THE

CONNECTOR CONNECTORS OR AN OPEN CIRCUIT BETWEEN
• IS THERE ANY CONTINUITY BETWEEN THE SWITCH THE CIRCUIT
CONNECTORS 5 B-70 AND 12 B-70 (WHEN
TURNING LEFT), 13 B-70 AND 12 B-70 (WHEN
TURNING RIGHT) RESPECTIVELY?

YES NO

• REPAIR A POOR CONNECTION AT THE CONNECTORS REPAIR OR REPLACE THE SWITCH

OR AN OPEN CIRCUIT BETWEEN THE HARNESS SIDE
CONNECTORS 2 B-16 (12V), 5 B-16 (24V) AND
12 B-70

N8A0170E

1-2. Turn Signal Lights Flash Too Quickly

• DOES ANY TURN SIGNAL LIGHT REMAIN

UNLIGHTED?

YES

DISCONNECT AND REINSTALL THE BULB, OR

REPLACE IT, OR REPAIR AN OPEN CIRCUIT IN
THE CIRCUIT OF THE INOPERATIVE BULB, OR
CHECK THE GROUND

N8A0171E
 CAB AND CHASSIS ELECTRICAL 8-201
1-3. Hazard Warning Lights Inoperative

N8A5203E

2. Stoplight
2-1. Both Stoplights Inoperative

• IS FUSE F-5 (10A) NORMAL?

YES NO

• IS J-9 GROUNDED SECURELY? REPLACE THE FUSE

YES NO

• IS BATTERY VOLTAGE APPLIED TO THE 1 B-66 OF GROUND IT SECURELY

THE STOPLIGHT SW?

YES NO

• IS STOPLIGHT SWITCH NORMAL? REPAIR A POOR CONNECTION AT THE

CONNECTORS OR AN OPEN CIRCUIT BETWEEN
THE FUSE F-5 (10A) AND 1 B-66

YES NO

• DOES THE PUSH ROD OF THE STOPLIGHT SW REPLACE THE STOPLIGHT SW

OPERATE SMOOTHLY?

YES NO

REPAIR A POOR CONNECTION AT THE CONNECTORS REPLACE THE STOPLIGHT SW

OR AN OPEN CIRCUIT BETWEEN 2 B-66 AND J-9

N8A0173E
8-202 CAB AND CHASSIS ELECTRICAL
2-2. Stoplight on The Left (or Right) Side Inoperative

N8A5206E

Notice:
Figure in parenthesis “( )” indicates the place of inspection for the right side stoplight.

Starter Switch • Remove the front combination light (1) connec-

Refer to “START AND CHARGING” in this section. tor.

Front Turn Signal Light/Bulb

Removal
3
1. Remove the battery ground cable at the battery.
2. Remove the front combination light.
• Open the cab door. Insert a screwdriver (1) into
the space between the cab and the cab door.
Use the screwdriver to force out the stud pin at
2
the center of the grommet (the pin securing the
1
front combination light).

Door side Cab side N8A5484E

3. Remove the front turn signal light bulb.

• Turn the bulb socket (2) to the left to remove it.
• Press the bulb (3) in and turn it to the left to re-
move it from the socket.
Installation
1. Install the front turn signal light bulb.
• While pressing the bulb (2), turn it clockwise to
1 fit.
N8A5471E
Notice:
Do not let the glass portion dirty with sebum etc.
• Remove the fixing screw.
• Remove the two catches. • Turn the bulb socket (3) clockwise to fit.
 CAB AND CHASSIS ELECTRICAL 8-203
• Tighten one bolt in the lower portion of front
combination light assembly.
1
2
3. Hook the seal rubber on two projections under H/L.
4. Connect the battery ground cable.
5. Check lighting of each light.

Rear Turn Signal Light/Bulb

Removal
3
Preparation:
Disconnect the battery ground cable.
1. Lens
2. Bulb

N8A0445E

2. Installation procedure of front combination light as-

sembly
• Connect the connector of the front combination
light assembly.
• Position it by aligning two pawls with the groove
of H/L.
• Fit the iron PIN (1) in the upper portion of the
side by aligning it with the center of correspond-
ing grommet.
Notice:
Push it into securely with a force of approx. 250 N (25 N8A0176E
kgf) until click is heard.
• Pull the front combination light assembly lightly Installation
toward the front of vehicle to make sure that the To install, follow the removal steps in the reverse order.
PIN and grommet are engaged securely.

Turn Signal Light Switch (Combination Switch)

Inspection
Check the continuity between the terminals of the turn signal light switch.
Repair or replace the switch when the result of inspection is found abnormal.

N8A5209E
8-204 CAB AND CHASSIS ELECTRICAL
Removal and Installation
Refer to “HEADLIGHT, FOG LIGHT AND CORNERING
LIGHT” in this section.

Flasher Unit
Inspection
When a 55W bulb is connected to the unit side terminals B-66 Switch side
“L” and “E” while connecting the battery (+) terminal to 1 2

terminal “B”, and the battery (−) terminal to terminal “E”,

does the bulb light on and off? Terminal No.
Replace the unit when the result of inspection is found SW position
1 2
abnormal. Depress brake pedal (Push
rod out)
Release brake pedal (Push
rod in)

N8A0179E

Removal
Preparation:
Disconnect the battery ground cable.
1. Stoplight Switch
1) Disconnect the connector.
2) Loosen the lock nut of the switch.
3) Remove the switch by turning it.

N8A0178E

Stoplight Bulb
Removal and Installation
Refer to “CLEARANCE LIGHT, TAILLIGHT, LICENSE
PLATE LIGHT AND ILLUMINATION LIGHT” for TAIL- N8A0180E

LIGHT BULB removal and installation steps in this sec-

Installation
tion.
To install, follow the removal steps in the reverse order,
Stoplight Switch noting the following points.
Inspection 1) Check to see if the brake pedal has been re-
1. Check to see if the stoplight switch is installed cor- turned by the return spring to the specified po-
rectly to the specified position. Adjust the position sition.
when the result of the inspection is found abnor- 2) Turn the stoplight switch clockwise until the tip
mal. of the threaded portion of the switch contacts
2. Check to see if there is any continuity between the the pedal arm.
terminals of the stoplight switch. 3) Turn the switch counterclockwise until the
Replace the switch when the result of inspection is space between the tip of the threaded portion
found abnormal. and the pedal arm is 0.5 to 1.0 mm (0.02 —
0.04 in.).
 CAB AND CHASSIS ELECTRICAL 8-205

N8A0181E

Hazard Warning Switch

Inspection
Check the continuity between the terminals of the haz-
ard warning switch.
Repair or replace the switch when the result of inspec-
tion is found abnormal.

N8A5160E

Installation
To install, follow the removal steps in the reverse order
noting the following point.
1. Push the switch with your fingers until locks se-
B-30
curely.

Terminal
SW No. 6 5 1 2 3 4 7 8
position
ON
OFF

N8A0182E

Removal
Preparation:
Disconnect the battery ground cable.
1. Meter Cluster
Refer to the “METER AND WARNING/INDICA-
TOR LIGHT” in this section.
2. Hazard Warning Switch
Release the lock pushing the switch from the back
side of the meter cluster.
8-206 CAB AND CHASSIS ELECTRICAL
Horn, Backup Light and Backup Buzzer
General Description
The circuit consists of the starter switch, horn, horn switch, backup light (Rear combination light), backup light switch,
back buzzer and the relay.
When the horn switch is turned on independent of the position of the starter switch, the relay is activated to sound the
horn. When the backup light switch turns on with the starter switch on, the backup light will operate.
Backup Light and Backup Buzzer Circuit

N8A5216E
 CAB AND CHASSIS ELECTRICAL 8-207
Parts Location

N8A5217E
 STARTER SWITCH
40A(24V)
FL-2 50A(12V)
ACC F-16 10A
KEY SW
1 2 B
H-7 B-67 ON 3 3B/Y METER
3W/L B-67 METER B-51 (8)
0.5B/Y
100A or 120A(24V) ST
FL-1 100A(12V)
Circuit Diagram

0.5B/Y
2L MAIN
2 22
H-6
P-3 P-1 5W(24V) 5W H-5
8W(12V)
P-4 P-2

F-20 15A; (12V) 1 0.5B/Y

4JH1 J-49
F-19 15A; (24V)
HORN, HAZARD

SWITCH

0.5G
BACKUP LIGHT
P-3 J-49

P-4 2

0.5G
(24V MODEL) 1 2
X-2 X-2
P-5
FRAME

0.5R/L
8-208 CAB AND CHASSIS ELECTRICAL

X-2 X-2

RELAY; HORN
5 4

0.5G/R
3
H-5 6
H-16

0.5G/W
(EXCEPT DUMP VEHICLE)
3 0.5R/L
B-70

HORN CONTACT 5 5
R-6 J-62
5 5
1 1 J-65 R-1
J-4 J-5

HORN (LH)
J-65 R-1

HORN (RH)
BACKUP LIGHT

HORN SWITCH
6 6
BACKUP LIGHT

(DUMP VEHICLE)
BACKUP LIGHT
BACKUP LIGHT

(DUMP VEHICLE)

(REAR COMBINATION LIGHT-LH)

R-6 J-62
(COMBINATION SWITCH)
(REAR COMBINATION LIGHT-LH)

6 6
(REAR COMBINATION LIGHT-RH)
(REAR COMBINATION LIGHT-RH)

1.25B
1.25B
2B

1.25B

2B 1.25B 7
FRAME-LH (CENTER) J-9 H-16
(EXCEPT DUMP VEHICLE)

N8A5218E
 CAB AND CHASSIS ELECTRICAL 8-209
Connector List No. Connector Face

No. Connector Face

J-49 2 1

X-2
002-026

005-006

1 2 3 4

H-14 5 6
10 11 12 13 14
7 8 9

B-67
15 16

1 2
3 4 016-003

004-001

4 3 2 1
9 8 7 6 5
H-14 14 13 12 11 10

16 15
B-67 2 1
4 3 016-004

004-002

H-16 1 2 3 4
5 6 7 8
B-70 1 2 3 4 5 6
7 8 9 10 11 12 13 14 008-003

014-002

H-16 4 3 2 1
8 7 6 5
6 5 4 3 2 1
B-70
1413 12 11 10 9 8 7
008-004

014-003

J-4
1
E-10 1 2
001-008

002-025

J-5
1
E-10 2 1
001-008

002-026

J-62 1 2 3
4 5 6
J-49 1 2
006-010

002-025
8-210 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

J-62 3 2 1
P-3
6 5 4

006-015 000-006

P-5
J-65 1 2 3
4 5 6 (12 V)

006-010 000-007

P-5
J-65 3 2 1
6 5 4 (24 V)

006-015 000-002

P-1
R-1 1 2 3
(12 V) 4 5 6

000-003 006-004

P-2 R-1 3 2 1
6 5 4

000-004 006-005

P-1
R-6 1 2 3
(24 V) 4 5 6

000-004 006-004

P-4 R-6 3 2 1
6 5 4

000-004 006-005

P-2
(24 V)

000-006
 CAB AND CHASSIS ELECTRICAL 8-211
H-5 H-6, H-7

1 2 H-6 2 1

1 2 3 4 5 6 6 5 4 3 2 1 1 2 H-7 2 1
7 8 9 10 11 12 12 11 10 9 8 7
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 24 23 22 21 20 19
25 26 27 28 29 30 30 29 28 27 26 25 1 2 3 4 4 3 2 1
31 32 33 34 35 36 37 38 39 40 40 39 38 37 36 35 34 33 32 31
5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14

N8A5488E N8A5489E

Diagnosis
Quick Chart for Check Point
1. Horn

Check point
Fuse
Horn Horn Cable
F-19, F-20 Horn Horn SW
relay contact harness
(15 A)
❍ ❍ ❍ ❍ ❍ ❍
1-1. Horn does not sound
Trouble (1) (4) (6) (2) (5) (3)
mode ❍ ❍ ❍
1-2. Horn does not shut off
(2) (1) (3)

Notice:
Figure in parenthesis “( )” indicates the order of inspection.
2. Backup Light

Check point
Backup light
Fuse Backup Backup Cable
SW
F-16 (10 A) light bulb buzzer harness
(Inhibitor SW)
❍ ❍ ❍
2-1. Both backup lights inoperative
(1) (3) (2)
Trouble 2-2. Backup light on the left (or right) ❍ ❍
mode side inoperative (1) (2)
❍
2-3. Backup light remains on
(1)

Notice:
Figure in parenthesis “( )” indicates the order of inspection.
8-212 CAB AND CHASSIS ELECTRICAL
1. Horn
1-1. Horn Does Not Sound

N8A5222E
 CAB AND CHASSIS ELECTRICAL 8-213
1-2. Horn Does Not Shut Off

N8A5224E

2. Backup Light
2-1. Backup Lights Inoperative

• IS FUSE F-16 (10A) NORMAL?

YES NO

• IS J-9 SECURELY GROUNDED? REPLACE THE FUSE

YES NO

• TURN THE STARTER SW ON GROUND IT SECURELY

• IS THE BATTERY VOLTAGE APPLIED BETWEEN THE
BACKUP LIGHT SWITCH HARNESS SIDE CONNECTOR
1 E-10 (OR 1 J-49 )AND THE GROUND?

YES NO

• ENTER THE TRANSMISSION SHIFT LEVER TO REPAIR A POOR CONNECTION AT THE

REVERSE POSITION CONNECTORS OR AN OPEN CIRCUIT BETWEEN
• WHEN REMOVE THE CONNECTOR OF THE BACKUP FUSE F-16 (10A) AND 1 E-10 OR 1 J-49
LIGHT SWITCH, IS THERE ANY CONTINUITY
BETWEEN THE SW SIDE CONNECTORS 1 E-10 AND
2 E-10 (OR 1 J-49 AND 2 J-49 )?

YES NO

REPAIR A POOR CONNECTION AT THE CONNECTORS REPAIR OR REPLACE THE BACKUP LIGHT
OR AN OPEN CIRCUIT BETWEEN THE BACKUP LIGHT SWITCH OR INHIBITOR SW
SWITCH HARNESS SIDE CONNECTORS 2 E-10
(OR 2 J-49 )AND 4 H-16

N8A0189E
8-214 CAB AND CHASSIS ELECTRICAL
2-2. Backup Light on the Left (or Right) Side Inoperative

N8A5226E

2-3. Backup Light Remains on

REPAIR OR REPLACE THE BACKUP LIGHT SW OR INHIBITOR SW

N8A0191E

Starter Switch
Refer to “START AND CHARGING” in this section.

Horn
Inspection
Check to see if horn sound when a battery voltage be-
tween horn terminal and the fixing bracket. Repair or re-
place the horn when the result of inspection is found
abnormal.

N8A0192E
 CAB AND CHASSIS ELECTRICAL 8-215
Removal Removal
Preparation: Preparation:
Disconnect the battery ground cable. Disconnect the battery ground cable.
1. Bumper 1. Horn Pad
Refer to “BUMPER” in section 2. 1) Hold the horn pad and pull it upward.
2. Horn 2. Steering Wheel
Disconnect the connector (3). 1) Remove the steering shaft nut.
2) Remove the steering wheel by using steering
wheel remover.
(Refer to Section 3B4 “STEERING COLUMN”
for steering wheel removal steps.)
3. Horn Switch

2
3

N8A5485E

Installation
To install, follow the removal steps in the reverse order.

Horn Switch
Inspection N8A5231E

With the contact point of the horn switch pressed to the Installation
switch bracket, check the continuity between the con-
To install, follow the removal steps in the reverse order,
nector terminal and the bracket of the switch.
noting the following point.
Check the contact condition between horn contact of the
combination switch and contact plate of steering wheel. 1. Tighten the steering shaft nut to the specified
Repair or replace the switch when the result of inspec- torque.
tion is found abnormal. Tighten:
Shaft nut to 49 N⋅m (5 kg⋅m / 36 lb⋅ft)

N8A0194E
8-216 CAB AND CHASSIS ELECTRICAL
Backup Light Bulb
Removal
Preparation:
Disconnect the battery ground cable.
1. Lens
2. Bulb

N8A0196E

Removal
Preparation:
Disconnect the battery ground cable.
1. Backup Light Switch
1) Disconnect the connectors.
N8A0195E 2) Remove the switch by turning it counterclock-
wise.
Installation
Installation
To install, follow the removal steps in the reverse order.
1. Backup Light Switch
Backup Light Switch Apply liquid gasket to the screw portion of the
switch to prevent oil leak.
Inspection
1. With the switch installed to the transmission, check Backup Buzzer
the continuity between the terminals of the switch Inspection
connectors.
Apply battery voltage to the backup buzzer connector to
When the continuity is found between the terminals
check the buzzer sound.
only with the switch shifted to the reverse position,
Repair or replace the buzzer when the result of inspec-
the switch is normal.
tion is found abnormal.
2. When the result of the above inspection is found
abnormal, remove the switch from the transmis-
sion and conduct a test on the switch alone.
If the continuity appears between the connector
terminals when the ball of the switch is pushed, the
switch is normal. (When the ball is released, the
continuity disappears.)
3. If there is no continuity with the switch installed to
the transmission, even though the switch is found
to be normal, then adjust the stroke of the switch by
changing the thickness of the switch gasket.

N8A0197E
 CAB AND CHASSIS ELECTRICAL 8-217
Removal
Preparation:
Disconnect the battery ground cable.
1. Rear Combination Light Cover
2. Backup Buzzer
1) Remove the rear combination light connector
fixing screw.
2) Remove buzzer fixing screw.
3) Disconnect the connector.

N8A0198E

Installation
To install, follow the removal steps in the reverse order.
8-218 CAB AND CHASSIS ELECTRICAL
Dome Light and Backup Buzzer
General Description
The circuit consists of the starter switch, dome light, dome light switch, door switch, backup light switch and the back-
up buzzer.
The dome light lights up when the left or right side door is opened with the switch set at the door mode. It can be lit
by operating ON or OFF of the dome light switch.
The dome light can be lit by respective switch independent of the position of the starter switch.
By operating the dome light switch fitted on the instrument panel, the dome light can be lit independent of the switch
position of dome light.
Lighting Circuit

BATTERY (+)

DOOR DOME LIGHT

OFF
ON

DOME LIGHT
(FOR CREW CAB)

DOME DOOR SW DOOR SW

LIGHT SW (FRT PASSENGER (DRIVER SIDE)
SIDE)
: Lighting circuit by door sw

: Lighting circuit by dome light sw

N8A5236E
 CAB AND CHASSIS ELECTRICAL 8-219
Parts Location

N8A5237E
 FL-1 100A or 120A
2L MAIN

P-3 P-1
P-4 P-2

Except Europe
Circuit Diagram

8W/B(12V)
5W/B(24V)
4JH1

5W
2
H-6
0.85R
P-3
0.5R
P-4 F-4 15A 3
AUDIO(B), H-10
DOOR LOCK
(24V MODEL)

0.5R
1

0.5R
2 L-2
P-5 H-20
FRAME

OFF DOOR

DOME LIGHT
ON
8-220 CAB AND CHASSIS ELECTRICAL

L-2 L-2
3 2

0.5Y
1

0.5R
0.5GR/B
1
L-1
H-10

DIODE
L-1

0.5GR/B
2 0.5GR/B 1
1
B-18
L-4

0.5GR
DIODE

DIODE
0.5GR/B

B-18
2 1 2 1 2
L-4 L-3 L-3 H-20
0.5Y 0.5GR 3
2
H-3
H-10
0.5GR/R

DOME LIGHT (CREW CAB)

0.85LG/R (24V) H-12
RELAY; TAIL(5)

0.5GR
0.5GR/B

0.5 LG/R (12V) 1 4

B-86 B-86
1.25GR/B
(CREW CAB)
0.5GR/R

1
1.25GR/R
(CREW CAB)

N-7 1
B-86 B-86 N-2
3 2
DOME LIGHT SWITCH

0.5B
0.5B

3B
DOOR SWITCH (LH)

HEADLIGHT BRACKET (LH) B-7

DOOR SWITCH (RH)

N8A5239E
 STARTER SWITCH
OFF
FL-1 100A or 120A FL-2 40A
ACC
2L MAIN KEY SW
3W/B 3W/L B
H-7 B-67 ON 3B/Y

For Europe
1 2 B-67
P-1 3
P-2 ST
F-16 10A
METER

5W/B
2
H-6 22 0.5B/Y
H-5
0.85R 4
P-3
J-69
P-4 F-4 15A 3
AUDIO(B), H-10
DOOR LOCK
0.5R

0.5R
1
2 L-2

BACKUP SWITCH
P-5 J-69
H-20
7
FRAME

0.5B/Y
0.5R/L
BACKUP LIGHT

METER B-51 (8)

0.5R/L

OFF DOOR
29

DOME LIGHT
J-69
ON

L-2 L-2
3 2
0.5R/L

0.5Y
1

0.5R
L-1 6

0.5GR/B
1 B-83
H-10

DIODE
BACK BUZZER
L-1 0.5GR/B
B-83 B-83
2
1
1 2 5
B-18
L-4

DIODE
DIODE

0.5GR/B
B-18
2 1 2 1 2
L-4 L-3 L-3 H-20

0.5GR
0.5Y 0.5GR 3
2
H-3
H-10

0.5GR/R
0.5R/L

DOME LIGHT (CREW CAB)

0.85LG/R H-12
RELAY; TAIL(5)

0.5GR
0.5B

1 4
0.5R/L

B-86 B-86

0.5GR/B
N-7 N-2
B-86 B-86
3 2

DOME LIGHT SWITCH

DOOR SWITCH (RH)

0.5B
0.5B
DOOR SWITCH (LH)

3B 3B
HEADLIGHT BRACKET (LH) B-7

N8A5240E
CAB AND CHASSIS ELECTRICAL 8-221
8-222 CAB AND CHASSIS ELECTRICAL
Connector List No. Connector Face

No. Connector Face

B-86 2 1
4 3

B-18 1 2 3 4
004-002

004-004

B-83 1 2 3
4 5 6
B-47 1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20 006-010

020-001

E-10 1 2

B-48 1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 002-025

016-007

E-10 2 1

B-54 1 2 3
4 5 6 7 8 002-026

008-009

J-49 1 2
3 2 1
B-54
8 7 6 5 4
002-025

008-010

J-49 2 1

B-67 1 2
3 4 002-026

004-001

1 2 3
H-3 4 5 6

B-67 2 1
4 3
006-014

004-002

H-3 3 2 1
6 5 4

B-86 1 2
006-015
3 4

004-001
 CAB AND CHASSIS ELECTRICAL 8-223

No. Connector Face No. Connector Face

1 2 3 4

H-4 1 2 3 4 5 6 7 8 9 H-14 5 6
10 11 12 13 14
7 8 9

10 11 12 13 14 15 16 1718 19 20
15 16

020-002 016-003

4 3 2 1
9 8 7 6 5 4 3 2 1 9 8 7 6 5
H-4 H-14 14 13 12 11 10
20 19 18 17 16 15 14 13 12 11 10
16 15

020-003 016-004

H-10 H-20 1
1 2 3 2

003-009 002-009

1
H-10 H-20
3 2 1 2

003-010 002-010

L-2 L-1
1 2
1 2 3

003-009 002-027

L-2 L-3
3 2 1 1 2

003-010 002-027

H-12 1 2 3 4 5 6 L-4
7 8 9 10 11 12 13 14 1 2

014-002 002-022

6 5 4 3 2 1
H-12 L-4
1413 12 11 10 9 8 7 2 1

014-003 002-023
8-224 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

P-1
L-6
1 2 (24 V)

002-022 000-004

L-6 P-4
2 1

002-023 000-004

P-2
J-69 1 2 3 4
5 6 7 8 (24 V)

008-007 000-006

J-69 4 3 2 1
P-3
8 7 6 5

008-008 000-006

P-5
N-2
1 (12 V)

001-009 000-007

P-5
N-7
1 (24 V)

001-009 000-002

P-1 1 2 3 4
J-69 5 6 7 8
(12 V) 9 10 11 12

000-003 012-006

4 3 2 1
P-2 J-69 8 7 6 5
12 11 10 9

000-004 012-007
 CAB AND CHASSIS ELECTRICAL 8-225

No. Connector Face Dome Light Bulb

Removal
Preparation:
Disconnect the battery ground cable.
B-231 1 2
7 8
3 4 5
9 10 11 12
6
1. Lens
Hold the lens and pull it downward.
012-008

H-5

1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 11 12 12 11 10 9 8 7
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 24 23 22 21 20 19
25 26 27 28 29 30 30 29 28 27 26 25
31 32 33 34 35 36 37 38 39 40 40 39 38 37 36 35 34 33 32 31

N8A5243E

2. Bulb
Installation
N8A5488E
To install, follow the removal steps in the reverse order.
H-6, H-7
Dome Light Bulb (for Crew Cab)
Removal
Preparation:
Disconnect the battery ground cable.
1. Lens
Hold the lens and pull it down.
1 2 H-6 2 1 2. Bulb

1 2 H-7 2 1

1 2 3 4 4 3 2 1

5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14

N8A5489E

Starter Switch
Refer to “START AND CHARGING” in this section.

Key Cylinder Switch

Refer to “START AND CHARGING” in this section.
N8A0203E
Backup Light Switch
Refer to “HORN, BACKUP LIGHT AND BACKUP Installation
BUZZER” in this section. To install, follow the removal steps in the reverse order.
8-226 CAB AND CHASSIS ELECTRICAL
Dome Light Switch
Inspection
Check the continuity between the dome light switch con-
nector terminals.
Repair or replace the switch when the result of inspec-
tion is found abnormal.

B-86

Terminal
SW No. 2 4 1 3
position
ON
OFF

N8A0204E

Removal
Preparation: N8A5160E
Disconnect the battery ground cable.
Installation
1. Meter cluster
Refer to the “METER AND WARNING/INDICA- To install, follow the removal steps in the reverse order
TOR LIGHT” in this section. noting the following point.
2. Dome Light Switch 1. Push the switch with your fingers until locks se-
Release the lock pushing the switch from the back curely.
side of the meter cluster. Door Switch
Inspection
Check to see if there is any continuity between the ter-
minals and the body while operating the door switch.
Repair or replace the switch, when the result of inspec-
tion is found abnormal.
 CAB AND CHASSIS ELECTRICAL 8-227
Backup Buzzer

Warning function Operative conditions

When the transmission
Warning to reverse driv-
shift lever is engaged to
ing
the reverse position.

Connector
No.
Te N-2 N-7
rm
ina
SW lN
o.
operation 1 Body

Push

Release
N8A5249E

N8A0206E

Removal
Preparation:
Disconnect the battery ground cable.
1. Door Switch
1) Remove the screw.
2) Disconnect the connector of the switch.

N8A0207E

Installation
To install, follow the removal steps in the reverse order.
8-228 CAB AND CHASSIS ELECTRICAL
Inspection of the Buzzer Circuit
Disconnect the backup buzzer connector, measure the continuity and voltage between the harness side connector
terminals.

N8A5250E
 CAB AND CHASSIS ELECTRICAL 8-229
Power Door Lock
General Description
The circuit consists of the door lock switch, actuator for the front passenger door, rear doors and the door lock con-
troller.
The door lock controller is always provided with battery voltage. The key or the inside lock knob on the driver’s door
can activate the lock mechanism of all the doors.
When the driver’s door lock switch is turned on, current flows for about one second to the door lock actuator of each
door connected in parallel with the controller to activate the actuator to lock and unlock the doors.
Operation of Door Lock Controller

When locking When locking

the door. the door.

Battery(+) Battery(+)

Relay;Door lock Relay;Door lock

To actuator
To actuator
(Actuator
(Actuator
operates to
operate
unlock
to lock side)
position)

Door lock sw. Door lock sw.

(Lock position) (Unlock position)

N8A0211E

Notice:
Arrow marks indicate the direction of current.
8-230 CAB AND CHASSIS ELECTRICAL
Parts Location

N8A5252E
 CAB AND CHASSIS ELECTRICAL 8-231
Circuit Diagram

FL-1 100A or 120A(24V)

F-4 15A
MAIN AUDIO, DOOR LOCK
5W/B(24V) 2 0.85R
H-6 DOME LIGHT (1)
8W/B(12V) 5W 3W/B
2L

P-3 P-1 0.85R

P-4 P-2

4JH1

RELAY; 6
DOOR LOCK B-12

P-3
P-4 B-12
0.85BR/R
5

(24V 0.85BR/Y
MODEL) B-12
4
P-5
0.5BR/R

0.5BR/R
0.5BR/Y

0.5BR/Y
FRAME
B-12 B-12 B-12
0.85BR/R

0.85BR/Y

1 2 3

5 13 1 4
0.3R/G

0.3G/B

H-12 H-12 H-3 H-3

0.5BR/R

0.5BR/Y

0.5BR/R

0.5BR/Y
2 4
H-11 H-11 4 3 2 1 2 1
H-2 H-2 H-18 H-18 H-19 H-19
0.85BR/R

0.85BR/Y
0.3R/G

0.3G/B

0.85BR/R

0.85BR/Y

0.85BR/R

0.85BR/Y

2 3
UNLOCK

2 1 1 2 1 2
0.85B

D-4 D-4
D-8 D-8
LOCK

D-9 D-9 D-10 D-10

UNLOCK
UNLOCK

UNLOCK
LOCK

LOCK
LOCK

DOOR LOCK SWITCH-RH D-4

1
0.3B

3 DOOR LOCK DOOR LOCK DOOR LOCK

ACTUATOR-LH ACTUATOR-RH ACTUATOR-LH
H-11
(CREW CAB) (CREW CAB)
2B

HEADLIGHT B-7
3B
BRACKET (LH)

N8A5253E
8-232 CAB AND CHASSIS ELECTRICAL
Connector List No. Connector Face

No. Connector Face

D-10 2 1

B-12 1 2 3
4 5 6 002-002

006-010

H-18 1 2

D-4
1 2 3 002-001

003-003

H-18 2 1

D-4 3 2 1
002-002

003-011

H-19 1 2

D-8 1 2
002-001

002-001

H-19 2 1

D-8 2 1
002-002

002-002

H-2 1 2 3
4 5 6 7 8

D-9 1 2
008-009

002-001

3 2 1
H-2
8 7 6 5 4

D-9 2 1
008-010

002-002

H-11 1 2 3
4 5 6 7 8

D-10 1 2
008-009

002-001
 CAB AND CHASSIS ELECTRICAL 8-233

No. Connector Face No. Connector Face

3 2 1
H-11 P-4
8 7 6 5 4

008-010 000-004

1 2 3 P-2
H-3 4 5 6
(24 V)

006-014 000-006

H-3 3 2 1
P-3
6 5 4

006-015 000-006

P-5
H-12 1 2 3 4 5 6
7 8 9 10 11 12 13 14 (12 V)

014-002 000-007

6 5 4 3 2 1 P-5
H-12
1413 12 11 10 9 8 7 (24 V)

014-003 000-002

H-6

P-1
(12 V)

000-003

1 2 H-6 2 1

P-2 1 2 H-7 2 1

1 2 3 4 4 3 2 1
000-004
5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14

P-1
(24 V)

000-004 N8A5489E
8-234 CAB AND CHASSIS ELECTRICAL
Diagnosis
Quick Chart for Check Point

Check point
Door Door lock actuator
Fuse
Door lock lock SW Front
F-4 Rear Rear Cable
controller (Driver (Passen-
(15 A) (RH) (LH) harness
side) ger side)
1. All the doors do not lock
❍ ❍ ❍
and unlock
2. All the doors do not get
❍ ❍
locked (or unlocked)
3. Driver side door does not
❍ ❍
get locked (or unlocked)
Trouble
mode 4. Front passenger side
door does not get locked (or ❍ ❍
unlocked)
5. Rear door-RH side does
❍ ❍
not get locked (or unlocked)
6. Rear door-LH side does
❍ ❍
not get locked (or unlocked)

Notice:
Figure in parenthesis “( )” indicates the order of inspection.
 CAB AND CHASSIS ELECTRICAL 8-235
All the Doors Do Not Lock and Unlock

N8A5256E

All the Doors Do Not Get Locked (or Unlocked)

N8A5257E
8-236 CAB AND CHASSIS ELECTRICAL
Driver Side Door Does Not Get Locked (or Unlocked)

REPLACE THE DOOR LOCK SWITCH

N8A0216E

FRT Passenger Side Door Does Not Get Locked (or Unlocked)
RR Door-RH Side Does Not Get Locked (or Unlocked)
RR Door-LH Side Does Not Get Locked (or Unlocked)

REPLACE THE DOOR LOCK ACTUATOR

N8A0217E
 CAB AND CHASSIS ELECTRICAL 8-237
Inspection of the Door Lock Circuit
Check the voltage and the continuity between the controller harness side connector terminals.

B-12 1 2 3
4 5 6

Harness side

Termi- Wire Item Connect-

nal color Connected to to be ing Checking conditions Standard
No. checked terminal
Door lock SW Driver seat side Unlock Continuity
1 R/G (Unlock) 1-Ground door
Lock No continuity
Door lock SW Driver seat side Unlock No continuity
2 G/B (Lock) 2-Ground door
Conti- Lock Continuity
nuity
3 B Ground (Resis- 3-Ground - Continuity
tance) Continuity
4 BR/Y Actuator 4-5 - (There is some
(Unlock) resistance)
Continuity
5 BR/R Actuator 5-4 - (There is some
(Lock) resistance)

6 R Fuse F-7 (15A) Voltage 6-Ground - Battery voltage

N8A0218E
8-238 CAB AND CHASSIS ELECTRICAL
Door Lock Controller
The door lock controller sends out to each door lock ac-
tuator the lock/unlock signals received from door lock
switch of driver seat side.

B-12

3 2 1
6 5 4

Controller side
For 12V

N8A0220E

Door Lock Operation Test

After confirming that there is continuity between the har-
For 24 Volt ness side connector terminals 4 B-12 and 5 B-12 of the
door lock controller, apply battery voltage to each of the
terminals to conduct the operation test.
When the door lock will not operate, check the door lock
actuator for any trouble.

N8A0219E B-12

Inspection Harness
1 2 3
Remove the connector of the door lock controller, and 4 5 6 side
check the continuity and the voltage between the con-
troller side connector terminals. Connecting terminal
(Connect the (+) terminal of the battery to 6 B-12 and Operation
4 (BR/Y) 5 (BR/R)
the (−) terminal to 3 B-12 .)
Unlock
3 B-12 — 5 B-12 .................Continuity
3 B-12 — 4 B-12 .................Continuity Lock
(Then, ground 2 B-12 .)
5 B-12 ..................Voltage for approx. 1 second
(Disconnect the ground of 2 B-12 , and ground 1 B-12 .)
N8A0221E
4 B-12 ..................Voltage for approx. 1 second
Replace the controller when the result of inspection is
found abnormal.
 CAB AND CHASSIS ELECTRICAL 8-239
Door Lock Switch (Driver Seat Side) Door Lock Actuator
The door lock switch on the driver’s door is connected Receiving forward or reverse current from the door lock
with the door lock cylinder and the inside lock knob with controller, the door lock actuator locks or unlocks the
a rod. The switch sends lock/unlock signals to the door door with the rod connected to the door lock mecha-
lock controller. nism.

N8A0223E N8A0225E

Inspection Inspection of the Door Lock Actuator

Check to see if there is any continuity between the con- Apply the battery voltage to the connector terminals of
nector terminals of the door lock switch. the door lock actuator to check the operation.
Replace the switch when the result of inspection is When the door lock actuator is checked on the vehicle
found abnormal. and there is no continuity, and when the door lock actu-
ator itself is checked and no trouble is found, check the
circuit between the door lock actuator and the door lock
controller for any failure.

D-4 Switch side

1 2 3

Terminal
Operation No. 1 2 3

Lock

Unlock

N8A0224E

Removal and Installation

Refer to Section 2 “CAB AND FRAME” for “DOOR
LOCK ASSEMBLY”.
8-240 CAB AND CHASSIS ELECTRICAL

N8A5267E

Removal and Installation

Refer to Section 2 “CAB AND FRAME” for “DOOR
LOCK ASSEMBLY”.
 CAB AND CHASSIS ELECTRICAL 8-241
Power Window
General Description
The circuit consists of the starter switch, power window switch for each of the windows and power window motor.
When the starter switch is turned on, the battery voltage is applied to each of the power window switches through the
circuit breaker and the power window relay on the circuit.
By operating the switches of each window to select “UP” or “DOWN”, the revolving direction of the power window
motor changes to open or close the window.
The driver’s power window switch has a built-in one-touch operating circuit which allows to automatically open the
window by operating the switch to the AUTO position.
When the driver’s power lock switch at the driver side is depressed, the power source to the passenger’s power win-
dow switches will be shut off and passenger’s side power window motor will not operate if the switch is operated.
Operation of Passenger Side Window

N8A5268E

Notice:
Arrow marks indicate the direction of current.
8-242 CAB AND CHASSIS ELECTRICAL
Parts Location

N8A5269E
 For 12 Volt
FL-1 100A F-26 30A RELAY; POWER WINDOW
2L MAIN POWER WINDOW 2L/B
8W 5W 2 8W/B 3W/B 2B/L X-7
H-6 X-7 5
1
Circuit Diagram
P-3 P-1
STARTER SWITCH
P-4 P-2 X-7 X-7
OFF 2 4
FL-2 50A 1.25L/B 1
ACC
F-16 10A H-2
4JH1
KEY SW METER 1
1 2 B

0.5B/Y
H-7 B-67 ON 3 H-11 POWER WINDOW SWITCH (DRIVER)
3W/B 3W/L B-67
3B/Y 0.5B/Y
ST 6
D-3
P-5 2L/B B
WINDOW LOCK SWITCH
FRAME 8
D-3
E

0.5B
SWITCH
WINDOW

FL SW

METER B-51 (8)

(PASSENGER)

2B
UP DOWN
AUTO CIRCUIT D-3 D-3
5 4
WINDOW SWITCH (DRIVER)
1.25R/Y
1.25G/Y

8 5
H-11 H-11
1.25L/B

3
H-11
1.25R/Y
1.25G/Y

8 5
H-2 H-2
1.25R/Y
1.25G/Y

UP DOWN 2 4 1
D-3 D-3 D-7 D-7 D-7
1 2

2B
UP DOWN
2B D-7 D-7
3 5
1.25L

1.25L/W
1.25L/Y
1.25BR/Y

1 2
POWER WINDOW SWITCH (PASSENGER)

1 2
D-2 D-2
D-6 D-6

UP DOWN UP DOWN

POWER WINDOW MOTOR POWER WINDOW MOTOR

3B (DRIVER) (PASSENGER)
HEADLIGHT BRACKET (LH) B-7

N8A5270E
CAB AND CHASSIS ELECTRICAL 8-243
 For 24 Volt
FL-1 100A or 120A F-6 20A RELAY; POWER WINDOW
2L MAIN POWER WINDOW 2L/B
5W 5W 2 5W/B 3W/B 2B/L X-7
H-6 X-7 5
1
P-1
STARTER SWITCH
P-2 X-7 X-7
OFF 2 4
FL-2 40A 1.25L/B 1
ACC
F-16 10A H-2
KEY SW METER 1
1 2 B

0.5B/Y
H-7 B-67 ON 3 H-11 POWER WINDOW SWITCH (DRIVER)
3W/B 3W/L B-67
3B/Y 0.5B/Y
P-3 ST 6
D-3
2L/B B
P-4 WINDOW LOCK SWITCH
8
D-3
E

0.5B
P-5
SWITCH
WINDOW

FRAME
FL SW

METER B-51 (8)

(PASSENGER)

2B
UP DOWN
AUTO CIRCUIT D-3 D-3
5 4
8-244 CAB AND CHASSIS ELECTRICAL

WINDOW SWITCH (DRIVER)

1.25R/Y
1.25G/Y

8 5
H-11 H-11
1.25L/B

3
H-11
1.25R/Y
1.25G/Y

8 5
H-2 H-2
1.25R/Y
1.25G/Y

UP DOWN 2 4 1
D-3 D-3 D-7 D-7 D-7
1 2

2B
UP DOWN
D-7 D-7
2B

3 5
1.25L

1.25L/W
1.25L/Y
1.25BR/Y

1 2
POWER WINDOW SWITCH (PASSENGER)

1 2
D-2 D-2
D-6 D-6

UP DOWN UP DOWN

POWER WINDOW MOTOR POWER WINDOW MOTOR

3B (DRIVER) (PASSENGER)
HEADLIGHT BRACKET (LH) B-7

N8A5486E
 CAB AND CHASSIS ELECTRICAL 8-245
Connector List No. Connector Face

No. Connector Face

D-7
1 2 3 4 5

X-7
005-005

005-006

H-2 1 2 3
4 5 6 7 8

B-67 1 2
008-009
3 4

004-001

3 2 1
H-2
8 7 6 5 4

B-67 2 1
4 3
008-010

004-002

H-11 1 2 3
4 5 6 7 8

D-2 1 2
008-009

002-028

3 2 1
H-11
8 7 6 5 4

D-2 2 1
008-010

002-029

P-1
(12V)
D-6 1 2
000-003

002-028

P-2

D-6 2 1
000-004

002-029

P-1
(24V)
D-3 1 2 3

4 5 6 7 8 000-004

008-011
8-246 CAB AND CHASSIS ELECTRICAL

No. Connector Face

P-4

000-004

P-2
(24V)

000-006

P-3

000-006

P-5
(12V)

000-007

P-5
(24V)

000-002

H-6, H-7

1 2 H-6 2 1

1 2 H-7 2 1

1 2 3 4 4 3 2 1

5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14

N8A5489E
 CAB AND CHASSIS ELECTRICAL 8-247
Diagnosis
Quick Chart for Check Point

Check point
12 V Power window Power window
24 V Fus- Power SW motor
Fuse Cable
Fuse ible win- Pas- Pas-
F-16 har-
F-6 link dow Driver sen- Driver sen-
(10A) ness
(20A) F-26 relay side ger side ger
(30A) side side
All windows do not ❍ ❍ ❍ ❍ ❍ ❍
operate (1)
Lock SW does not ❍
function (1)

Driver side window

Window does not ❍ ❍ ❍

operate (1) (2) (3)
One-touch opera-
❍
tion does not oper-
(1)
ate
Window operates in ❍
only one direction (1)
Front passenger side
window
Trouble Window does not ❍ ❍ ❍ ❍
mode operate (2) (1) (3) (4)
Window does not
operate when oper- ❍ ❍
ating the driver side (1) (2)
SW
Window does not
operate when oper- ❍ ❍
ating the passen- (1) (2)
ger side SW
Window operates in
only one direction ❍ ❍
when operating the (1) (2)
driver side SW
Window operates in
only one direction ❍ ❍ ❍
when operating the (2) (1) (3)
passenger side SW

Notice:
Figure in parenthesis “( )” indicates the order of inspection.
8-248 CAB AND CHASSIS ELECTRICAL
All Windows Do Not Operate

N8A5273E
 CAB AND CHASSIS ELECTRICAL 8-249
Lock Sw Does Not Function

REPAIR OR REPLACE THE POWER WINDOW SW

ON THE DRIVER SEAT SIDE

N8A0231E

Window on the Driver Side Does Not Operate

• IS THE POWER WINDOW SWITCH ON THE DRIVER

SEAT SIDE NORMAL?

YES NO

• DISCONNECT THE CONNECTOR OF THE POWER REPLACE THE POWER WINDOW SWITCH
WINDOW MOTOR ON THE DRIVER SEAT SIDE ON THE DRIVER SEAT SIDE
• WHEN CONNECTING THE MOTOR CONNECTOR
1 D-2 TO THE BATTERY (+) TERMINAL AND 2 D-2
TO THE (-) TERMINAL, DOES THE MOTOR ROTATE IN
THE "UP" DIRECTION OF THE WINDOW (OR WHEN
CONNECTING 2 D-2 TO THE (+) TERMINAL AND
1 D-2 TO THE (-) TERMINAL, DOES THE MOTOR
ROTATE IN THE "DOWN" DIRECTION OF THE
WINDOW)?

YES NO

REPAIR A POOR CONNECTION AT THE CONNECTORS REPAIR OR REPLACE THE POWER WINDOW
OR AN OPEN CIRCUIT BETWEEN HARNESS SIDE MOTOR
CONNECTOR TERMINALS 1 D-3 AND POWER
WINDOW MOTOR 1 D-2 OR 2 D-3 AND 2 D-2

N8A0232E
8-250 CAB AND CHASSIS ELECTRICAL
Window on the Front Passenger Side Does Not Operate

• IS THE FRONT PASSENGER SIDE POWER WINDOW

SW NORMAL?

YES NO

• IS THE DRIVER´S POWER WINDOW SW NORMAL? REPAIR OR REPLACE THE SW

YES NO

• REMOVE THE CONNECTOR OF THE FRONT REPAIR OR REPLACE THE SW

PASSENGER SIDE POWER WINDOW MOTOR
• WHEN CONNECTING THE MOTOR CONNECTOR
1 D-6 TO THE BATTERY (+) TERMINAL AND 2 D-6
TO THE (-) TERMINAL, DOES THE MOTOR ROTATE IN
THE "UP" DIRECTION OF THE WINDOW? (OR WHEN
CONNECTING 2 D-6 TO THE (+) TERMINAL AND
1 D-6 TO THE (-) TERMINAL, DOES THE MOTOR
ROTATE IN THE "DOWN" DIRECTION OF THE
WINDOW?)

YES NO

• WITH THE SWITCH AT THE NEUTRAL POSITION, IS REPAIR OR REPLACE THE POWER WINDOW
THERE ANY CONTINUITY BETWEEN THE HARNESS MOTOR
SIDE CONNECTORS 1 D-6 AND 2 D-6 ?

YES NO

REPAIR A POOR CONNECTION AT THE CONNECTORS REPAIR A POOR CONNECTION AT THE

OR AN OPEN CIRCUIT BETWEEN 5 D-3 AND 2 D-7 CONNECTORS OR AN OPEN CIRCUIT BETWEEN
(OR 4 D-3 AND 4 D-7 ) THE PASSENGER SIDE POWER WINDOW SW
AND THE MOTOR CONNECTOR
N8A0233E
 CAB AND CHASSIS ELECTRICAL 8-251
Starter Switch
Refer to “START AND CHARGING” in this section.
Power Window Switch-driver Side
Circuit Inspection
Disconnect the switch connectors to check the voltage and the continuity between the harness side connector termi-
nals.

D-3

Harness side

Termi- Wire Item Connect-

nal color Connected to to be ing Checking conditions Standard
No. checked terminal
1 L/W
Driver seat side motor 1-2
2 L Continuity
- Continuity
4 G/Y Passenger side power (resistance) 4-5
5 R/Y window SW 5-4
6 L/B Power window relay Voltage 6-Ground Starter SW "ON" Battery voltage
Continuity
8 B Ground (resistance) 8-Ground - Continuity

N8A0234E
8-252 CAB AND CHASSIS ELECTRICAL
Inspection
Check the continuity between the connector terminals of the switch.
Repair or replace the switch when the result of inspection is found abnormal.

N8A5278E
 CAB AND CHASSIS ELECTRICAL 8-253
Removal
Preparation:
Disconnect the battery ground cable.
1. Switch
1) Insert the screw driver to the cut off portion to
remove the switch.
2) Disconnect the connector.

N8A5279E

Installation
To install, follow the removal steps in the reverse order.

Power Window Switch-passenger Side

Circuit Inspection
Disconnect the switch connectors to check the voltage and the continuity between the harness side connector termi-
nals.

N8A5280E

Inspection Repair or replace the switch when the result of inspec-

Check the continuity between the connector terminals of tion is found abnormal.
the switch.
8-254 CAB AND CHASSIS ELECTRICAL

D-7

Switch side

Terminal
SW position No. 1 2 4 3 5

UP

OFF

DOWN

N8A5281E

Removal Driver Seat Side Power Window Motor

Preparation: Inspection
Disconnect the battery ground cable. Before checking to see if the motor functions correctly,
1. Switch be sure to check the circuit through the connector D-3
1) Insert the screw driver to the cut off portion to of the driver’s power window switch.
remove the switch. If the motor does not operate smoothly, either the motor
2) Disconnect the connector. or the circuit between the switch and the motor is defec-
tive.
1. Circuit inspection of the driver side window switch
Disconnect the switch connector and apply battery
voltage to the harness side connector terminals to
check its function.

N8A5282E

Installation
To install, follow the removal steps in the reverse order.
 CAB AND CHASSIS ELECTRICAL 8-255
Removal
Preparation:
Disconnect the battery ground cable.
1. Window Regulator Assembly
Refer to Section 2 for Window Regulator and
Glass.
D-3 2. Power Window Motor
Remove three screws.
Harness side

Connecting terminal
Operation
1 (L/W) 2 (L)
DOWN
UP

N8A0240E

2. Inspection of the driver seat side motor

Remove the motor connector and apply battery
voltage to the motor side connector terminals to
check its function.
Replace the motor when the result of inspection is
found abnormal.

N8A0242E

Installation
M D-2 To install, follow the removal steps in the reverse order.

Terminal No.
Direction 1 2
of operation
DOWN
UP

N8A0241E
8-256 CAB AND CHASSIS ELECTRICAL
Front Passenger Seat Side Power Window Mo- 3. Inspection of the front passenger window motor
tor Disconnect the motor connector and apply battery
voltage to the motor side connector terminals to
Inspection
check its function.
Before checking to see if the motor functions correctly,
Repair or replace the motor when the result of in-
be sure to check the circuit through the front passen-
spection is found abnormal.
ger’s switch connector D-7 and the driver’s power win-
dow switch connector D-3 .
If the motor does not operate smoothly, either the motor
or the circuit between the switch and the motor is defec-
tive. M
1. Circuit inspection of the front passenger seat side
window D-6
Disconnect the switch connector and apply battery
voltage to the harness side connector terminals to
check its function.

Terminal No.
Direction 1 2
of operation
D-7
DOWN
UP
Harness side N8A0245E

Connecting terminal Removal

Direction of
3 (L/Y) 5 (BR/Y) operation Preparation:
Disconnect the battery ground cable.
DOWN
1. Window Regulator Assembly
UP
Refer to Section 2 for Window Regulator and
Glass.
2. Power Window Motor
Remove three screws.
N8A0243E

2. Circuit inspection of the driver seat side switch

Disconnect the switch connector and apply battery
voltage to the harness side connector terminals to
check its function.

D-3

Harness side

Connecting terminal Direction of

4 (G/Y) 5 (R/Y) operation
+ DOWN N8A0246E

+ UP
Installation
To install, follow the removal steps in the reverse order.

N8A0244E
 CAB AND CHASSIS ELECTRICAL 8-257
Windshield Wiper and Washer
General Description
The circuit consists of the starter switch, windshield wiper & washer switch, wiper motor, washer motor and the inter-
mittent relay.
When the wiper & washer switch is turned on with starter switch on, the battery voltage is applied to the wiper motor
to activate the wiper.
The washer motor squirts glass cleaning fluid while the washer switch is being pushed. The intermittent relay is used
to control motion of the wiper.
Operation of Windshield Wiper Motor
(When wiper “LO” or “INT” position)

N8A0250E

Notice:
Arrow marks indicate the direction of current.
8-258 CAB AND CHASSIS ELECTRICAL
Parts Location

N8A5299E
 CAB AND CHASSIS ELECTRICAL 8-259
Circuit Diagram

3W/L
FL-1 100A or 120A

MAIN
FUSE BLOCK

STARTER SWITCH
2L

FL-2 40A(24V)
50A(12V)
ACC
KEY SW
1 2 B
H-7 B-67 ON 3
P-3 P-1 3W/B 3W/L B-67

3B/Y
P-4 P-2 ST
(24V) (12V)
5 2 5 2
4JH1
X-11 X-11 X-1 X-1

RELAY
P-3 KEY ON
P-4
X-11 X-11 X-1 X-1
3 1 3 1
0.5B
(24V MODEL)

3L
P-5
F-10 15A
FRAME
WIPER, WASHER

1.25L(12V)
0.5L(24V)

0.5L(24V) 0.5L(24V)
0.85L(12V) 1.25L(12V)

1
B-69 WIPER, WASHER SWITCH
(COMBINATION SWITCH)
1.25L(12V)
0.5L(24V)

OFF I L H W
P

8 B-69 B-69 B-69 B-69 B-69

B-9 3 8 7 4 6
(WITHOUT RELAY; INTERMITTENT)

0.85BR/W(12V)

1.25BR/R(12V)
0.5BR/W(24V)

0.5BR/R(24V)

B 0.5L/R(24V)
3 3
SHORT CIRCUIT CONNECTOR

B-9 PS B-9
0.85L/R 0.85L/R(12V)
RELAY; INTERMITTENT

6 0.5L/O(24V)
I B-9
0.85L/O(12V)

2 3
B-11 B-11
LO HI
4
B-11
B
0.5L/B

7 7 0.5BR/Y(24V) 5
B-9 PM B-9 B-11
0.85L/R 0.85BR/Y(12V) P
4
W B-9 WIPER MOTOR
E
B-11
B-9
1
2
0.5L/B
WASHER MOTOR

1
B-8
0.5B
1.25B(12V)
0.5B(24V)

B-8
2
0.5B

3B
HEADLIGHT BRACKET (LH) B-7

N8A5300E
8-260 CAB AND CHASSIS ELECTRICAL
Connector List No. Connector Face

No. Connector Face

P-1
(12V)
B-8 1
2 000-003

002-009

P-2

B-9 1 2 3 4
5 6 7 8 000-004

008-012

P-1
(24V)
B-11 1 2 3
4 5 6 000-004

006-001

P-4

B-11 3 2 1
6 5 4
000-004

006-016

P-2
(24V)
B-67 1 2
000-006
3 4

004-001

P-3

B-67 2 1
4 3 000-006

004-002

P-5
(12V)
B-69 1 2 3 4
5 6 7 8 000-007

008-001

P-5
(24V)
B-69 4 3 2 1
8 7 6 5 000-002

008-002
 CAB AND CHASSIS ELECTRICAL 8-261

No. Connector Face H-7

X-11

005-006 1 2 H-6 2 1

1 2 H-7 2 1

X-1 1 2 3 4 4 3 2 1

5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
005-006 14 15 16 17 18 18 17 16 15 14

N8A5489E

Diagnosis
Quick Chart for Check Point
1. Windshield Wiper and Washer

Check point
Fuse Wiper&
Intermit- Wiper Washer Cable
F-10 washer
tent relay motor motor harness
(15A) SW
1. Windshield wiper does not op- ❍ ❍ ❍ ❍
erate at any switch position (1) (3) (4) (2)
2. Windshield wiper does not op- ❍ ❍ ❍
erate at “INT” position (1) (3) (2)
3. Windshield wiper does not op- ❍ ❍ ❍
erate at “LO” position (1) (3) (2)
4. Windshield wiper does not op- ❍ ❍ ❍
Trouble
erate at “HI” position (1) (2) (3)
mode
5. Auto-stop function of the
❍ ❍ ❍ ❍
windshield wiper motor does
(1) (4) (2) (3)
not operate
6. Rotation of the windshield ❍ ❍
wiper motor does not stop (1) (2)
7. Windshield washer motor ❍ ❍ ❍
does not operate (1) (3) (2)

Notice:
Figure in parenthesis “( )” indicates the order of inspection.
8-262 CAB AND CHASSIS ELECTRICAL
1. Windshield Wiper and Washer
1-1. Windshield Wiper Does Not Operate at Any Switch Position

• IS FUSE F-10 (15A) NORMAL?

YES NO

• DISCONNECT THE CONNECTOR OF THE WINDSHIELD REPLACE THE FUSE

WIPER & WASHER SWITCH
• TURN THE STARTER SWITCH ON
• IS THE BATTERY VOLTAGE APPLIED BETWEEN THE
SWITCH HARNESS SIDE CONNECTOR 1 B-69 AND THE
GROUND?

YES NO

• IS CONTINUITY IN THE WINDSHIELD WIPER & WASHER REPAIR A POOR CONNECTION AT THE
SWITCH NORMAL? CONNECTORS OR AN OPEN CIRCUIT BETWEEN
THE FUSE F-10 (15A) AND 1 B-69

YES NO

• IS B-7 GROUNDED SECURELY? REPAIR OR REPLACE THE SWITCH

YES NO

• DISCONNECT THE CONNECTOR OF THE WINDSHIELD GROUND IT SECURELY

WIPER MOTOR WITH THE MOTOR CONNECTOR 2 B-11
CONNECTED TO THE BATTERY (+) TERMINAL, AND THE
CONNECTOR 1 B-11 TO THE (-) TERMINAL, DOES THE
MOTOR ROTATE AT A LOW SPEED?
• AND WITH THE CONNECTOR 3 B-11 CONNECTED TO
THE (+) TERMINAL, DOES THE MOTOR ROTATE AT A
HIGH SPEED?

YES NO

REPAIR A POOR CONNECTION AT THE CONNECTORS OR REPAIR OR REPLACE THE WINDSHIELD WIPER
AN OPEN CIRCUIT BETWEEN 1 B-11 AND B-7 MOTOR

N8A0254E
 CAB AND CHASSIS ELECTRICAL 8-263
1-2. Windshield Wiper Does Not Operate at “INT” Position

• IS CONTINUITY IN THE WINDSHIELD WIPER &

WASHER SWITCH NORMAL?

YES NO

• DISCONNECT THE CONNECTOR OF THE REPAIR OR REPLACE WINDSHIELD WIPER &

INTERMITTENT RELAY WASHER SWITCH
• IS THERE CONTINUITY BETWEEN THE RELAY AND
THE WINDSHIELD WIPER & WASHER SWITCH
HARNESS SIDE CONNECTOR 6 B-9 AND 8 B-69 ,
OR 3 B-9 AND 3 B-69 RESPECTIVELY?

YES NO

REPLACE THE INTERMITTENT RELAY REPAIR A POOR CONNECTION OR AN OPEN

CIRCUIT BETWEEN THE CIRCUITS

N8A0255E

1-3. Windshield Wiper Does Not Operate at “LO” Position

• IS CONTINUITY IN THE WINDSHIELD WIPER & WASHER

SWITCH NORMAL?

YES NO

• DISCONNECT THE WINDSHIELD WIPER MOTOR REPAIR OR REPLACE THE WINDSHIELD WIPER &
CONNECTOR WASHER SWITCH
• CONNECT THE BATTERY (+) TERMINAL TO THE
WINDSHIELD WIPER MOTOR CONNECTOR 2 B-11 AND
THE (-) TERMINAL TO 1 B-11
• DOES THE MOTOR ROTATE AT A LOW SPEED?

YES NO

REPAIR A POOR CONNECTION AT THE CONNECTORS OR REPAIR OR REPLACE THE WINDSHIELD WIPER
AN OPEN CIRCUIT BETWEEN THE CONNECTORS 7 B-69 MOTOR
AND 2 B-11

N8A0256E
8-264 CAB AND CHASSIS ELECTRICAL
1-4. Windshield Wiper Does Not Operate at “HI” Position

• IS CONTINUITY IN THE WINDSHIELD WIPER &

WASHER SWITCH NORMAL?

YES NO

• DISCONNECT THE WINDSHIELD WIPER MOTOR REPAIR OR REPLACE THE WINDSHIELD WIPER &
CONNECTOR WASHER SWITCH
• CONNECT THE BATTERY (+) TERMINAL TO THE
WINDSHIELD WIPER MOTOR CONNECTOR 3 B-11 AND
THE (-) TERMINAL TO 1 B-11
• DOES THE MOTOR ROTATE AT A HIGH SPEED?

YES NO

REPAIR A POOR CONNECTION AT THE CONNECTORS REPAIR OR REPLACE THE WINDSHIELD WIPER
OR AN OPEN CIRCUIT BETWEEN 4 B-69 AND 3 B-11 MOTOR

N8A0257E
 CAB AND CHASSIS ELECTRICAL 8-265
1-5. Auto-stop Function of The Windshield Wiper Motor Does Not Operate

• IS CONTINUITY IN THE WINDSHIELD WIPER &

WASHER SWITCH NORMAL?

YES NO

REPAIR OR REPLACE THE WINDSHIELD WIPER &

• DISCONNECT THE CONNECTOR OF THE WINDSHIELD
WASHER SWITCH
WIPER MOTOR
• CONNECT THE MOTOR CONNECTOR 2 B-11 TO THE
BATTERY (+) TERMINAL, AND 1 B-11 TO THE BATTERY
(-) TERMINAL, AND THEN CHANGE THE CONNECTION
OF THE BATTERY (+) TERMINAL TO THE CONNECTOR 4
B-11 WHILE ROTATING THE MOTOR AT A LOW SPEED
• WHEN CONNECTING THE CONNECTOR TERMINALS 2
B-11 AND 5 B-11 IN THIS CONDITION, DOES THE
MOTOR STOP AT AUTO-STOP POSITION?

YES NO

• TURN THE STARTER SWITCH ON REPAIR OR REPLACE THE WINDSHIELD WIPER

• IS THERE BATTERY VOLTAGE APPLIED BETWEEN THE MOTOR
WINDSHIELD WIPER MOTOR HARNESS SIDE
CONNECTOR TERMINAL 4 B-11 AND GROUND?

YES NO

• DISCONNECT THE CONNECTOR OF THE WINDSHIELD REPAIR A POOR CONNECTION AT THE

INTERMITTENT RELAY CONNECTORS OR AN OPEN CIRCUIT BETWEEN
• IS THERE CONTINUITY BETWEEN THE RELAY HARNESS THE FUSE F-10 (15A) AND 4 B-11
SIDE CONNECTOR 7 B-9 AND THE WINDSHIELD WIPER
MOTOR HARNESS SIDE CONNECTOR 5 B-11 ?

YES NO

REPLACE THE WINDSHIELD INTERMITTENT RELAY REPAIR A POOR CONNECTION AT THE

CONNECTORS OR AN OPEN CIRCUIT BETWEEN
THE CIRCUITS

N8A0258E
8-266 CAB AND CHASSIS ELECTRICAL
1-6. Rotation of The Windshield Wiper Motor Does Not Stop

• IS CONTINUITY IN THE WINDSHIELD WIPER &

WASHER SWITCH NORMAL?

YES NO

• THE MOMENT THE WINDSHIELD WIPER COMES TO REPAIR OR REPLACE THE WINDSHIELD WIPER &
AUTO-STOP POSITION, TURN THE STARTER SWITCH WASHER SWITCH
OFF
(ALTERNATIVELY, CONNECT THE BATTERY (+)
TERMINAL TO THE WINDSHIELD WIPER MOTOR
CONNECTOR 2 B-11 AND THE (-) TERMINAL TO 1
B-11 , AND THEN MOVE THE WINDSHIELD WIPER
MOTOR TO AUTO-STOP POSITION AND STOP IT)

YES

CONFIRM CONTINUITY BETWEEN THE WINDSHIELD

WIPER MOTOR SIDE CONNECTOR TERMINALS 4 B-11
AND 5 B-11 , AND REPAIR OR REPLACE THE MOTOR

N8A0259E
 CAB AND CHASSIS ELECTRICAL 8-267
1-7. Windshield Washer Motor Does Not Operate

• IS CONTINUITY IN THE WINDSHIELD WIPER & WASHER

SWITCH NORMAL?

YES NO

• TURN THE STARTER SWITCH ON REPAIR OR REPLACE THE WINDSHIELD WIPER &
• IS THE BATTERY VOLTAGE APPLIED BETWEEN THE WASHER SWITCH
WINDSHIELD WIPER & WASHER SWITCH HARNESS
SIDE CONNECTOR TERMINAL 1 B-69 AND THE
GROUND?

YES NO

• DISCONNECT THE CONNECTOR OF THE WINDSHIELD REPAIR A POOR CONNECTION AT THE

WASHER MOTOR CONNECTORS OR AN OPEN CIRCUIT BETWEEN
• TURN THE STARTER SWITCH ON FUSE F-10 (15A) AND 1 B-69
• WITH THE WASHER BUTTON OF THE WINDSHIELD
WIPER & WASHER SWITCH DEPRESSED, IS THE
BATTERY VOLTAGE APPLIED BETWEEN THE WASHER
MOTOR HARNESS SIDE CONNECTOR TERMINAL 1 B-8
AND THE GROUND?

YES NO

• IS B-7 GROUNDED SECURELY? REPAIR A POOR CONNECTION AT THE

CONNECTORS OR AN OPEN CIRCUIT BETWEEN 1
B-8 AND 6 B-69

YES NO

• CONNECT THE MOTOR SIDE CONNECTOR 1 B-8 OF GROUND IT SECURELY

THE WINDSHIELD WASHER MOTOR TO THE BATTERY
(+) TERMINAL, AND THE CONNECTOR 2 B-8 TO THE (-)
TERMINAL
• DOES THE MOTOR ROTATE?

YES NO

REPAIR A POOR CONNECTION AT THE CONNECTORS OR REPAIR OR REPLACE THE WINDSHIELD WASHER
AN OPEN CIRCUIT BETWEEN 2 B-8 AND B-7 MOTOR

N8A0260E
8-268 CAB AND CHASSIS ELECTRICAL
Starter Switch
Refer to “START AND CHARGING” in this section.

Windshield Wiper & Washer Switch

With the starter switch on, the windshield wiper and
washer switch controls the start and stop operation as
well as the change of operating speeds.
Both the windshield washer motor and the wiper
motor jointly operate while the washer button is
pushed.

N8A5310E

Inspection
Check the continuity between the connector terminals of the switch.
Repair or replace the switch when the result of inspection is found abnormal.

N8A5311E

Removal and Inspection

Refer to “HEADLIGHT, FOG LIGHT AND CORNERING
LIGHT” in this section.
 CAB AND CHASSIS ELECTRICAL 8-269
Windshield Wiper Motor 2. Windshield Wiper Motor
1) Disconnect the connector.
2) Remove four screws.
3) Remove the ball joint between crank arm and
wiper link.

N8A0263E

Inspection
1. Operation in low speed
With the motor connector terminal 2 B-11 connect-
N8A5313E
ed to the battery (+) terminal and the connector 1
B-11 to the (−) terminal, check to see if the motor Installation
rotates in low speed.
To install, follow the removal steps in the reverse order,
2. Operation in high speed noting the following points.
With the motor connector terminal 3 B-11 connect-
• Windshield Wiper Motor
ed to the battery (+) terminal and the connector 1
When the crank arm is removed from the wind-
B-11 to the (−) terminal, check to see if the motor
shield wiper motor, tighten the motor shaft nut with
rotates in low speed.
the specified torque.
3. Stop operation
After stopping the windshield wiper in the position Tighten:
on the way by confirming the operation at the low Shaft nut to 17 N⋅m (170 kg⋅cm/147 lb⋅in)
speed in item No. 1. • Temporarily fit the motor by using one of the four
When the connectors 2 B-11 and 5 B-11 are con- wiper motor fixing screws.
nected, while connecting the motor connector ter- • Put the crank arm ball joint in the wiper link hole
minal 4 B-11 to the battery (+) terminal, check to and fix them together while pulling the wiper link.
see, if the motor rotates at low speed and stops at
the auto-stop position.
Repair or replace the motor when the results of the
above inspections are found abnormal.
Removal
Preparation:
Disconnect the battery ground cable.
1. Glove Box
Refer to “INSTRUMENT PANEL” of section 2.
8-270 CAB AND CHASSIS ELECTRICAL
Windshield Washer Motor Installation
Inspection To install, follow the removal steps in the reverse order.
With the battery (+) terminal connected to the washer
motor connector terminal 1 B-8 and the (−) terminal to
the connector 2 B-8 , check to see if the cleaning fluid
pushes out.
Replace the tank/motor when the result of inspection is
found abnormal.

1 2

B-8

N8A0265E

Removal
Preparation:
Disconnect the battery ground cable.
1. Instrument Panel Under Cover
Refer to “INSTRUMENT PANEL” of section 2.
2. Washer Tank
1) Disconnect the washer motor connector.
2) Disconnect the washer hose.
3) Remove three fixing screws.
3. Clip Band
4. Windshield Washer Motor
Hold the motor and pull it out from the washer tank.

N8A5315E
 CAB AND CHASSIS ELECTRICAL 8-271
Intermittent Relay
Circuit Diagram

N8A0267E
8-272 CAB AND CHASSIS ELECTRICAL
Removal Windshield Wiper Arm & Blade
Preparation: Removal
Disconnect the battery ground cable. 1. Cover
1. Glove Box 2. Wiper Arm Nut
Open the lid and remove the four screws.
3. Wiper Arm & Blade
2. Intermittent Relay
1) Press A position with your finger and pry up B
position with the tip of a screw-driver.
2) When the relay moves up by about 2/3 of its
size, tilt and take off the relay to avoid interfer-
ence with the instrument panel.
2 1
3) Disconnect the connector. 3

N8A5318E

Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Before installing the wiper arm & blade to the shaft,
confirm that the motor stops at the auto-stop posi-
tion.
2. Set the wiper arm & blade so that the tips of both
blades are positioned as shown in the illustration.
3. Tighten the wiper arm nut to the specified torque.
Tighten:
Wiper arm nut to 17 N⋅m (170 kg⋅cm/147 lb⋅in)

N8A5317E Approx. 45mm(STD Cab)

Approx. 70mm(Wide Cab)
Installation
To install, follow the removal steps in the reverse order.

N8A5319E
 CAB AND CHASSIS ELECTRICAL 8-273
Windshield Wiper Linkage
Location of Rod and Pivot

N8A5320E

Removal 2. Pivot Nut

Preparation: Remove the rubber seal, nut and retaining rubber.
Disconnect the battery ground cable.
1. Wiper Arm & Blade
Remove the cover, nut and wiper arm & blade.

Nut Cover
1

N8A5322E

N8A5608E
8-274 CAB AND CHASSIS ELECTRICAL
3. Instrument Panel Assembly 5. Instrument Panel Reinforcement
Refer to “INSTRUMENT PANEL” of section 2. Refer to “INSTRUMENT PANEL” of section 2.

N8A5323E N8A5325E

4. Wiper Motor 6. Wiper Link Assembly

1) Remove the four screws. Remove two retaining nuts from right hand side of
2) Disconnect the ball joint between the crank arm pivot.
and the wiper link.

N8A5326E

N8A0275E
 CAB AND CHASSIS ELECTRICAL 8-275
Remove two retaining nuts from left hand side of
Notice:
pivot.
When the wiper blade has been removed, wrap the tip
of the wiper arm with cloth, to avoid damaging the glass.

N8A5327E

Installation N8A5328E

To install, follow the removal steps in the reverse order,

2. Wiper Blade Rubber
noting the following points.
1) Pull the end of rubber and remove the projec-
• Temporarily fit the wiper motor by using one of the tion from the click of the blade stay.
four wiper motor fixing screws.
2) Pull the rubber out in the same direction.
• Put the crank arm ball joint in the wiper link hole
and fix them together while pulling the wiper link.
• Fit the motor with four screws.
• Tighten the pivot nut with the specified torque.
Tighten:
Pivot nut to 8 N⋅m (80 kg⋅cm/70 lb⋅in)
• Tighten the wiper arm nut with the specified torque.
Tighten:
Wiper arm nut to 17 N⋅m (170 kg⋅cm/147 lb⋅in)

Wiper Blade Rubber

Removal
1. Wiper Blade
Push the wiper blade lock while pulling the wiper
blade in the arrow direction.

N8A0280E
8-276 CAB AND CHASSIS ELECTRICAL
Installation
1. Wiper Blade Rubber
Install the click of the blade stay in the groove of the
new rubber and slide it in. Complete installation by 1
pushing the click.

2
N8A5564E

Audio and Cigar Lighter

General Description
The circuit consists of the starter switch, radio, cigar
N8A0281E
lighter and the relay.
Finally, check that the click of the stay has caught The audio circuit is designed for the current to flow
in the hole of the rubber. through the receiver circuit when the radio switch is
turned on with the starter switch in “ACC” or “ON”. Cur-
rent runs through the memory circuit of the audio regard-
less of the position of the starter switch.
When the cigar lighter is pushed in with the starter
switch at either “ACC” or “ON” position, a circuit is
formed in the cigar lighter case to heat the lighter coil.
The cigar lighter is spring back to its original position af-
ter the lighter coil is heated.

N8A0282E

2. Wiper Blade
Push the lock of wiper blade (1) into the retentive
portion on the tip of wiper arm (2).
 CAB AND CHASSIS ELECTRICAL 8-277
Parts Location

N8A5332E
8-278 CAB AND CHASSIS ELECTRICAL
Circuit Diagram

STARTER SWITCH
OFF
FL-2 100A or 120A
ACC 1
KEY SW B-67
1 2 B
H-7 B-67 ON
3W/B 3W/L
ST
FL-1 100A or 120A
2L MAIN
(12V)

P-1
8W

P-2
5W
5W

3R/Y
2
H-6
5W/B (24V)
8W/B (12V)

P-3
P-4

F-15 15A
(24V MODEL) F-4 15A
AUDIO (IG)
AUDIO (B), CIGAR LIGHTER
DOOR LOCK
0.85G/B

P-5

FRAME

0.5R/Y
3W/B

3W/B

2 1
X-4 X-4
0.5R

RELAY; TAIL

X-4 X-4
4 5
0.5R/Y

F-7 10A

0.5R/Y
TAIL
LIGHT
3W

0.85LG/R 0.5LG/R

0.5LG/R
0.85LG/R
1.3G/O

10 11 4
1 1
B-28 B-28 B-28
CIGAR LIGHTER

B-43 B-44

RADIO & CLOCK

B-28 B-28 B-28 B-28 B-28

9 12 5 13 6
B-43 B-45
0.5G/R
0.5G
0.5O
0.5B

2 1
0.3B
(COMBINAITION SWITCH)

CLEARANCE LIGHT (LH)

7 6 7 6
H-2 H-2 H-11 H-11
0.5B
LIGHTING SWITCH(8)

0.5G/R
0.5G
0.5O
0.5B
1.25B (12V)
0.5B (24V)

1 2 1 2
D-5 D-5 D-1 D-1
2B

SPEAKER (LH) SPEAKER (RH)

3B 2B
HEADLIGHT BRACKET (LH) B-7

N8A5333E
 CAB AND CHASSIS ELECTRICAL 8-279
Connector List No. Connector Face

No. Connector Face

B-44
1
X-4
001-011

005-006

B-45
1
1 2 3 4 5 6
B-28
7 8 9 10 11 12 13 001-009

013-001

B-67 1 2
3 4
B-43 1
2 004-001

002-009

B-67 2 1
4 3
1
B-43
2 004-002

002-010

H-2 1 2 3
4 5 6 7 8

D-1 1
2 008-009

002-009

3 2 1
H-2
8 7 6 5 4

1
D-1
2 008-010

002-010

H-11 1 2 3
4 5 6 7 8

D-5 1
2 008-009

002-009

3 2 1
H-11
8 7 6 5 4

1
D-5
2 008-010

002-010
8-280 CAB AND CHASSIS ELECTRICAL

No. Connector Face H-6, H-7

P-1
(12V)

000-003 1 2 H-6 2 1

1 2 H-7 2 1

P-2 1 2 3 4 4 3 2 1

5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
000-004 14 15 16 17 18 18 17 16 15 14

P-1
(24V) N8A5489E

000-004

P-4

000-004

P-2
(24V)

000-006

P-3

000-006

P-5
(12V)

000-007

P-5
(24V)

000-002
 CAB AND CHASSIS ELECTRICAL 8-281
Diagnosis
Cigar Lighter Does Not Heat Sufficiently

• IS FUSE F-15 (15A) NORMAL?

YES NO

• IS B-7 GROUNDED SECURELY? REPLACE THE FUSE

YES NO

• REMOVE THE CIGAR LIGHTER GROUND IT SECURELY

• SET THE STARTER SWITCH TO EITHER "ACC" OR "ON"
POSITION
• IS THE BATTERY VOLTAGE APPLIED BETWEEN THE
BIMETAL AT THE CENTER OF THE CASE AND OUTER
OF THE CASE?

YES NO

• SET THE STARTER SWITCH TO EITHER "ACC" OR "ON" REPAIR A POOR CONNECTION AT THE
• IS THE BATTERY VOLTAGE APPLIED BETWEEN B-7 CONNECTORS OR AN OPEN CIRCUIT BETWEEN
AND GROUND? FUSE F-15 (15A) AND 1 B-44

YES NO

REPLACE THE CIGAR LIGHTER ASSEMBLY REPAIR A POOR CONNECTION AT THE

CONNECTORS OR AN OPEN CIRCUIT BETWEEN 1
B-45 AND B-7

N8A0285E

The Cigar Lighter Does Not Spring Out After Being Heated

• IS THE FORM OF CIGAR LIGHTER NORMAL?

YES NO

REPLACE THE CIGAR LIGHTER ASSEMBLY REPLACE THE CIGAR LIGHTER

(INCLUDE OUTER CASE)

N8A0286E
8-282 CAB AND CHASSIS ELECTRICAL
Starter Switch
Refer to “START AND CHARGING” in this section.

Radio
Removal
Preparation:
Disconnect the battery ground cable.
1. Center Cluster
1) Pull it to remove. Pry off three clips by the tip of
screwdriver.
2) Remove the cigar lighter power source and its
illumination connector.
Notice:
To remove the center cluster, do not force to pry off
three clips at upper portion of the center cluster.

N8A5338E

Legend
1. Radio

Installation
To install, follow the removal steps in the reverse order.

Antenna
Inspection
The metal A is connected to the pole D at the top of the
antenna through the core of the feeder.
The metal B is fitted in the feeder shielding the core, and
grounded at the screw C to avoid the core hampered by
noise.
Defective grounding would cause noise.

N8A5337E

Legend
1. Center Cluster

2. Radio
1) Remove the two radio fixing screws.
2) Disconnect the connector and feeder plug. N8A0289E
 CAB AND CHASSIS ELECTRICAL 8-283
In checking, measure the following three points with the
circuit tester in the range of “resistance x 1 (Ω).”
Between A and B
No continuity (No reading at the indicator) →
Normal
Continuity (A bite in the feeder. The core grounded) →
Lower reception
Between B and C
Continuity (Indicator reading: 0Ω) → Normal
No continuity (Shielded core disconnected or defective
grounding at the screw → Hampered by noise)
Between A and D
Continuity or no continuity
There are some antenna feeders and relay feeders with
a condenser built in their connections.
Measuring resistance between the two points does not
result in correct judgment. Connect temporarily another
normal antenna to the radio and check to see if its re-
ception is audible. Most antenna now available are slide
type. Rust at the screw C and the cab panel where
grounded would lead no continuity, followed by lower re-
ception.
Keep this portion clean to avoid rust.
Removal
Preparation:
Disconnect the battery ground cable.
1. Antenna
N8A5340E
1) Disconnect the joint connector.
2) Remove the upper and lower side antenna
bracket. Legend
3) Pull out the antenna feeder. 1. Antenna
Notice: Installation
For easier fitting, tie the lead wire to the end of the an-
To install, follow the removal steps in the reverse order.
tenna feeder in advance.
Speaker
Inspection
1. With the circuit tester set to the range of × 1 (Ω),
connect the circuit tester probes (red and black) to
the (+) and (−) terminals of the speaker.
2. When the speaker is normal, a low buzzing sound
is heard.
3. When the speaker is defective, no sound is heard.
However, the distortion or chattering of the sound
cannot be identified.
When the speaker is installed to the vehicle, dis-
connect the connectors before checking.
When no sound is heard, the following are consid-
ered as the cause.
• The speaker wiring is disconnected at the speaker
terminals.
• The speaker body is defective.
• There is an open circuit somewhere in the speaker
harness on the vehicle side.
• The speaker harness on the vehicle side is ground-
ed or caught up.
8-284 CAB AND CHASSIS ELECTRICAL
Removal Cigar Lighter
Preparation: Removal
Disconnect the battery ground cable. Preparation:
1. Door Pad Disconnect the battery ground cable.
Refer to “FRONT DOOR TRIM PAD” of section 2. 1. Center Cluster
2. Speaker Panel Refer to “RADIO” in this section.
Disconnect the speaker connector. 2. Cigar Lighter Assembly
3. Speaker Remove the nut, then remove cigar lighter assem-
4. Waterproof Sheet bly, bezel and outer case.

N8A5341E N8A5342E

Legend Legend
1. Trim Panel 1. Center Cluster
2. Speaker Panel 2. Cigar Lighter Assembly
3. Speaker
Installation
4. Waterproof Sheet
To install, follow the removal steps in the reverse order.
Installation
To install, follow the removal steps in the reverse order. Meter and Warning/indicator Light
General Description
The circuit consists of the starter switch, meter assem-
bly, vacuum tank switch, seat belt switch, oil pressure
switch, fuel sedimenter switch, brake fluid switch, park-
ing brake switch, vehicle speed sensor, fuel tank unit,
thermo unit and engine speed sensor.
The meter assembly contains the speedometer, ta-
chometer, fuel meter, thermometer and the warning/in-
dicator light.
The meter warning/indicator lights and their bulb sock-
ets are a unit, they are installed from the back of the
speedometer assembly.
 For 12 Volt
Parts Location

N-5 SEAT BELT SW

B-236 AIR
PRESSURE SW

X-13
BUZZER CANCEL RELAY
B-338
H-5~H-7 TACHOGRAPH
(IN INST)

X-5 ABS
INDICATOR RELAY
B-18 DIODE
X-33 DIODE

F-4, F-7, F-16 (Except 4JH1)

J-128 HBB
LEVEL SW

N8A5603E
CAB AND CHASSIS ELECTRICAL 8-285
 X-5 INDICATOR RELAY

For 24 Volt

N-5 SEAT BELT SW

X-33
DIODE
8-286 CAB AND CHASSIS ELECTRICAL

H-5~H-8

F-4, F-7, F-16

N8A5604E
 CAB AND CHASSIS ELECTRICAL 8-287
Circuit Diagram
Except 4JH1 / 4HK1 Engine

TACHOMETER

39
8

10

1
H-14
B-52

H-5

E-2
0.3L/O 0.5L/O 0.5L/O
ENGINE
SPEED

38

2
9
B-52

H-14
SENSOR

H-5

E-2
0.5B/L 0.5B/L 0.5B/L

COOLANT THERMO UNIT

1
6
23
4
TEMPERATURE GAUGE

H-14
B-55

H-5

E-7
0.3Y/B 0.5Y/B 0.5Y/B

FUEL LEVEL FUEL TANK UNIT

10

14

2
B-51

J-28
H-5

3
0.3BR/R 0.5BR/R
AUDIO(B), DOOR LOCK

J-28
0.5B

21
FUEL GAUGE

1
5
B-55

J-28
H-5
0.3Y/R 0.5Y/R

7
F-4 15A

0.85B

B-55
VEHICLE SPEED SENSOR

19
12

2
SPEEDOMETER

2
0.85R 0.5R
B-52

B-52

J-32
H-5
0.5B

25
1

3
B-55

J-32
H-5
SIG
0.3Y/G 0.5Y/G

31

1
3
B-55

J-32
H-5
+
5W/B (24V)
8W/B (12V)

0.3B/Y 0.5B/Y
2
B-55

QOS-III CONTROL UNIT (9) SHORT CONNECTOR (W/O HBB)

0.3W
SPEED WARNING
(SAUDI ARABIA)

10

2
DSW
F-16 10A

SHORT CONNECTOR (WITH HBB)

METER
2

VACUUM TANK
H-6

0.5B/Y
B-51

BR/Y
BUZZER SW

0.3

B-71
0.3BR

1
VACUUM

3
SENSOR
POWER SOURCE B-18
0.3W/B

CIRCUIT 0.3W/B
DIODE

REAR FOG
RELAY;
4

B-18 B-18 AIR PRESSURE

B-52

RELAY: BUZZER CANCEL

0.3 SW
2

RR FOG LIGHT(5) 0.5R/B 4

2

B-236
B-52

X-13

X-13

0.3BR BR 0.3BR

1
B-236
TURN - RH
11
3B/Y

TURN SIGNAL LIGHT SW

B-55

B-70 (13)
3

5
X-13

X-13

0.5G/W
BOOST
11
B-51

0.3BR/Y
0.3W/B
8

TURN - LH
8

TURN SIGNAL LIGHT SW

B-55

X-33
0.3W/B

B-70 (5) PARKING BRAKE

0.5G/B SW
3

DIODE

HIGH BEAM 0.3W/B

X-333
9

1
H-12

0.3W/B
B-67

10

0.3W/L
N-6

0.3BR

0.3B
8W

B-55

HEAD LIGHT (LH)

0.3W/B

0.5R/G
0.5B/Y

0.5W/R

HBB LEVEL
EXHAUST BRAKE
ACC

X-33 SW
ON

ST

EXHAUST BRAKE SW
B-51

12

8
STARTER SW

0.5W/B
J-128

J-128
0.3 7

H-5

H-5

B-69 (2)
0.5LG/L
W/R
OFF

ILLUMINATION (X5)
2

0.5BR
J-128

J-128

H-5
5
B-52

0.5LG/R
FUSE NO. 9
0.5B

(24V)
B

RELAY; TAIL (5) CHARGE

0.5W/L
3
B-52
B-67

BRAKE FLUID SWITCH

BRAKE FLUID LEVEL
RELAY; CHARGE (5)
2

1
14

0.3W/B 3B
B-51

B-85

B-85
3W/L

WATER
1

SEDIMENTER WATER SEDIMENTER SW

H-7

12

30

1
B-51

J-53

J-54
H-5

0.3BR/W 0.5BR/W 0.5B

FL-1 100A or 120A

40A(24V)
50A(12V)

OIL PRESSURE OIL PRESSURE SW (55, 69, 66)

20
1

1
B-52

H-5

J-8
KEY SW

0.3SB 0.5SB
MAIN

FL-2

SEAT BELT (SAUDI ARABIA) SEAT BELT SW

10

9
3
2

H-12

H-12
B-51

N-5

N-5

TIMER
0.3W/G 0.3W/G 0.5B 2B
(24V MODEL)

GLOW
B-51

0.3O/L
QOS-III CONTROL UNIT (13)
FRAME

QOS-II CONTROL UNIT (7)

P-1
P-2

P-3
P-4

7
P-5

ABS 0.5W
B-51

X-5

0.5B 2B
X-5
5
3

0.3W/V
3B
X-5
X-5

EHCU ; ABS

ABS INDICATOR RELAY

B-7

B-1
J-9
(CENTER)
BRACKET (LH)

(FRONT)
HEADLIGHT

FRAME-LH

FRAME-LH

0.5B/Y

N8A0527E
8-288 CAB AND CHASSIS ELECTRICAL
For 4JH1 Engine

FOR EC ONLY
1
B-335
TACHOGRAPH

0.5B
(IN METER)

2
B-335

TACHOMETER

B-52
8
ECM (27)

2
1
3

0.5LG
B-334

B-338
B-338

0.5B

9
B-52
B-335

B-335

B-335

6
B-338
0.3W/B

0.3B
TACHOGRAPH
5

COOLANT
(IN INST)
5
B-338

TEMPERATURE GAUGE

23

H-14
B-55
4

1
H-5

E-7
0.5B/Y
0.3Y/B 0.5Y/B 0.5Y/B
0.5LG/R

4
B-338

THERMO UNIT
0.5LG/R

10

14
3

FUEL LEVEL
0.5R

B-338

B-51

2
J-28
H-5
0.5R 0.3BR/R 0.5BR/R 0.5B

J-28
3
21
5

1
B-55

J-28
FUEL GAUGE

H-5
0.3Y/R 0.5Y/R
FUEL TANK UNIT

7
B-55
0.85B

19
10
12

2
0.5R 0.5R
B-52

B-52

J-32
H-5

VEHICLE SPEED
0.85B 0.5B

25
1

3
B-55

J-32
H-5
SPEEDO

SENSOR
0.3Y/G 0.5Y/G
4

6
B-337

B-337

METER
CONVERTER

31
0.3B

1
B-55

J-32
H-5
AUDIO(B), DOOR LOCK

0.3B/Y 0.5B/Y
5
B-337

B-336
3
PLUS

0.3W/R

ECM (60)
1
B-337

SENSOR
15A

0.5B/Y POWER SOURCE

0.85LG/R

CIRCUIT
F-4

SHORT CONNECTOR (W/O HBB)

EXHAUST
BRAKE
1

2
B-51
B-51

EXHAUST BRAKE SWITCH B-69 (2)

(COMBINATION SWITCH) 0.5LG/L 0.5G/R 1

10

2
10A
TAIL LIGHT

ILLUMINATION
SHORT CONNECTOR (WITH HBB)
5

(X5)
B-52
F-7

0.5LG/R
8W/B

TURN (RH)
11

TURN SIGNAL LIGHT SWITCH (RH) B-70 (13)

B-55

VACUUM TANK

BR/Y
(COMBINATION SWITCH) 0.5G/W SW
0.3BR

0.3

B-71
1
TURN (LH)
B-55
8

TURN SIGNAL LIGHT SWITCH (LH) B-70 (5)

3
(COMBINATION SWITCH) 0.5G/B
0.5B/Y

B-18
0.3W/B

0.3W/B

HIGH BEAM
TAIL RELAY

10
B-55

HEADLIGHT (LO)
DIODE

0.5R/G
2
H-6

REAR FOG
4
B-52

RELAY; RR FOG LIGHT (5) RELAY; B-18 B-18 AIR PRESSURE

0.5R/G
BUZZER CANCEL SW
2

VACUUM

B-236
0.3BR
BR 2

1
B-236
2

1
B-52

X-13

X-13

BUZZER
0.3
0.3
BR

70dB
3

5
X-13

X-13
METER

BOOSTER
F-16

11
B-51

0.3BR/Y
10A

0.3W/B
8

X-33
3B/Y

0.5W/B

PARKING BRAKE
SW
DIODE

0.3W/B
X-333
9

1
H-12

N-6

0.3W/B

0.3W/L
5W

0.3BR
3

HBB LEVEL
0.3W/B
B-67

0.5B/Y

0.5W/R

X-33 SW
0.3 7

12

0.5W/B
J-128

J-128
H-5

H-5
W/R

0.5BR
J-128

J-128

H-5
ACC

0.5B
STARTER SWITCH
ON

ST

0.5B/Y

0.5W/L
3

CHARGE
B-51

B-52

BRAKE FLUID SWITCH

BRAKE FLUID RELAY; CHARGE (5)
1
14

LEVEL 0.3W/B 3B
B-51

B-85

B-85
B
8W

CHECK ENGINE
4
B-51
B-67

ECM (43)
0.5G/Y
OIL PRESSURE SWITCH
2
3W/L

20

E-14
H-14

OIL PRESSURE
B-52
1

1
H-5

0.3LB 0.5LB 1.25LB

H-7

WATER SEDIMENTER SWITCH

WATER
12

30

SEDIMENTER
B-51

1
1

J-54
J-53
H-5

0.3LG/W 0.5LG/W 0.5B

6

GLOW
B-51

ECM (43)
0.3O/L
100A

50A
KEY SW

ABS
B-51

X-5
X-5
MAIN

0.85B
FL-1

0.5W 0.5B 2B
FL-2

0.5B
2B

3B
3

5
X-5
X-5

EHCU ; ABS
0.5B/Y 0.3W/V
ABS INDICATOR
RELAY
B-1
B-7
J-9
2L

FRAME
P-1
P-2

(CENTER)

BRACKET (LH)

FRAME-LH
FRAME-LH

HEADLIGHT

(FRONT)
P-5
P-3
P-4

N8A0528E
 CAB AND CHASSIS ELECTRICAL 8-289
For 4HK1 Engine

RELAY: CHARGE
2L

FL-2 FL-1 4 0.5B/Y

X-1
1 40A 100A or 120A 0.5W/R 1
X-1
STARTER J-26 KEY MAIN
Relay:
B 3W/L 2 1 1.25W/L 0.85W/L 15 0.5W/L 0.5W/L 5 3 0.5B/Y Thermo A/C
J-1 AC GEN. J-1 H-5 X-1 X-1
1

8W/B
H-7 J-2 F-1

0.5W/L
8W/B
1 RELAY: HEATER & A/C 15A
5W/B (STD AC GEN.) HEATER,
8W/B (80A AC GEN.)
5 3L AIR CON
X-12
C 2 3W/B 1
X-12 SW:
3W/L

J-27 H-6 0.5W/R 2 4 0.5B Thermo

1 X-12 X-12

5W/B
F-2
RELAY: RELAY: HEATER 10A

3W/B
STARTER FUEL
3W/B 2
2 X-8 HEATER
1 3B/R

3W/B
STARTER X-8
B-67
0.5W/L

SW F-4
15A 3 5 0.5B
X-8 X-8
B

AUDIO(B),
DOOR LOCK
OFF

0.85R 0.5R
ACC

30B/R
ST

ON

0.5B/Y
10 16 18 1
B-67 B-51 B-52 B-51 B-57
3
+
3B/Y

P-1

SEDIMENTER
EXH BRAKE

P-2
CHARGE

ENGINE
BRAKE

GLOW

TACHO SPEED COOLANT

FUEL
-
MIL

TEMPERATURE
FUEL
GAUGE
+
3B/Y

P-3
POWER LAMP
P-4
0.5B/Y

SUPPLY I/F & METER IC DRIVER

F-16 CIRCUIT
-
10A
METER
B-51 B-51 B-51 B-51 B-52 B-51 B-51 B-52 B-52 B-52 B-52 B-52 B-52
5 4 5 13 15 6 15 6 8 17 20 5 10
P-5

0.5BR/W
M/T

Smoother

M/T
0.3W/V

0.3W/V

0.3Y/G
0.3Y/R
0.5O/L
0.5L/R

0.5L/R

0.5L/P

FRAME
0.5B/Y

0.3LG

0.5SB
0.5B

0.5B

0.3W/R

0.5B/Y

0.3W/L

0.5W/B

13
H-5
0.5LG/W

21
H-5
0.3Y/G

SW: FUEL SEDIMENTER

0.5B

2
0.3W/V
0.5Y/R

0.3B/Y

W/CAB J-206

10 2 24 40 7 31 3 25 19 16 1
LEVEL SW: B & C OIL

H-5 H-5 H-5 H-5 H-8 H-5 H-5 H-4 H-5

H-14 B-85
0.5Y/R

0.5Y/G
0.5B/Y

0.3LG

0.5SB
2B

0.5B

1 1 J-206
1.25B

J-28 J-28 1
UNIT: UNIT: 1
B-85
0.5B

FUEL FUEL H-105

1
0.5W/B

SENSOR SENSOR
0.5B

0.5SB

J-28 J-28
0.5O/L
0.5L/R

0.5L/P

2 2
0.5B

12 3
1.25B
3B

H-14
E-90

1 2 3 METER
0.5B

0.5Y/G
3B

5B J-32 J-32 J-32 ECT

2B

SENSOR
6 11 7 V/SPEED SENSOR 8 19 48
J-191 J-191 J-191 J-191 J-191 J-191 J-9
B-1 J-9 B-7
OS-
DIAGL

OS-
GLOWL

OS-
EXBL

OF-
TACHO

IF-SPD

IS-
PBRK

ECM: ENGINE
FRAME-LH
FRAME-LH FRAME-LH HEADLIGHT (CTR)
(FRT) (CTR) BRACKET-LH N8D0012E
 17
2B 0.5B ILL 0.5LG/R 0.85LG/R 0.85LG/R 3W

0.5B/Y

0.3W/L

0.5W/B
0.3W/R
RELAY: TAIL

J-9
B-51

(CTR)
F-7
ILL

10A

FRAME-LH
9
1
2
0.5BR

H-5
J-128
J-128
ILL

8
3
12

4
0.5W/B 0.5W/R 0.3W/R

TAIL LIGHT

H-5
H-5

J-128
J-128
ILL

7
SW: SW:
PARKING HBB LEVEL ILL

X-33
BRAKE M/T

DIODE
EC/Turkey only

3
9

1
0.3W/B 0.5W/B 0.5W/B

N-6
0.5R/G 0.5R/G 0.85R/G

19
REAR FOG

X-33

H-12
RELAY: RR FOG

H-8

B-51

5
H-12
3
TURN (RH) 0.5G/W 0.5G/W

X-33
TURN SIGNAL LIGHT SWITCH

B-52

8
Smoother (COMBINATION SWITCH) (RH) B-70 (13)
0.3W/B

1
TURN (LH) 0.5G/B 0.5G/B
TURN SIGNAL LIGHT SWITCH

B-51
(COMBINATION SWITCH) (LH) B-70 (5)
3B

5
3
2
0.3W/B HIGH BEAM 0.5R/G 0.5R/G
HEAD LAMP (RH/LH)

X-13
X-13
B-51

0.3BR

3B
SW: PRESSURE

0.3B 1
1
3

2
4
0.3BR 0.3BR 0.3BR
BUZZER

B-7
X-13
X-13
B-57

B-236
B-236

HEADLIGHT
RELAY;

BRACKET-LH
4

0.3BR 2

5B
BUZZER CANCEL
B-18 B-18
8-290 CAB AND CHASSIS ELECTRICAL

14
SRS 0.5W/R 0.5W/R

B-1
SRS CONTROLUNIT B-243 (6)

(FRT)
B-51
B-276

DIODE

FRAME-LH
B-18
SW:

3
9
VACUUM TANK BOOST

B-51

1
B-71

1.25B
2
HSA 0.3BR/W

0.3BR
0.3BR
0.3BR

0.3W/V
0.3W/B
0.3W/R

0.3BR/Y
HSA CONTROLUNIT B-285 (12)
B-52

M/T
SW: OIL PRESSURE
39
5
1

SHORT CONNECTOR (With HBB)

11

OIL PRESS 0.5BR/B 0.5BR/B 0.5BR/B

2
6
10
3
4
5
1
J-8

H-5

B-51
H-105

0.5B
SHORT CONNECTOR (Without HBB)
18
30

20
4

ASR 0.3W/L 0.3W/L 0.3W/L ASR IND

H-8

B-51
H-15
J-177

15
9
3
21
0.5B 0.5B 0.5Y/R
17
6

12
3

ABS INVERTER 0.3W/V 0.3W/V 0.3W/V METER

Smoother
With ABS
C/U: ABS

H-12
N-19
N-19
H-12
H-8

B-51
H-15

CIRCUIT
J-177

IND

LEVER
SELECTOR
0.5Y/R

11
8
0.3G/O B-53 SMOOTHER

B-425
0.3B

12
7

0.3Y/G ECONO
B-53

B-425
2B

1st

1
2
1
6

0.5Y/R 0.5Y/R 0.5Y START

J-9

TCM
(CTR)
Without ABS

X-32
X-32
B-53

B-427
FRAME-LH

14
1

0.3P
METER
B-53

B-425
IC
SHIFT IND

N8D0013E
 CAB AND CHASSIS ELECTRICAL 8-291
Connector List No. Connector Face
Except 4JH1 / 4HK1 Engine

No. Connector Face

B-71
1

001-013
B-1

000-001

B-71 1

001-014
B-7

000-001

J-8
1

001-013
B-18 1 2 3 4

004-004

J-8 1

001-014
B-52 1 2 3 4 5 6 7 8 9 10 11 12

012-005

J-9

000-001
B-51 1 2 3 4 5 6 7 8 9 1011121314

014-001

B-85 1
2

002-009
B-55 1 2 3 4 5 6 7 8 9 10 11 12

012-004

1
B-85
2

002-010
B-67 1 2
3 4

004-001

B-236
1 2

002-022
B-67 2 1
4 3

004-002
8-292 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

N-5 1 E-7 1
2 3

003-020 001-018

N-5 1 H-12 1 2 3 4 5 6
7 8 9 10 11 12 13 14
3 2

003-021 014-002

6 5 4 3 2 1
N-6 1
H-12
1413 12 11 10 9 8 7

001-002 014-003

1 2 3 4

N-6 H-14 5 6
10 11 12 13 14
7 8 9

1
15 16

001-011 016-003

4 3 2 1
E-2 9 8 7 6 5
H-14 14 13 12 11 10
(66) 1 2
16 15

002-001 016-004

E-2
J-53
(66) 2 1

002-002 000-010

E-2
J-53
(55,69) 1 2

002-011 000-011

E-2
J-54
(55,69) 2 1

002-012 000-010
 CAB AND CHASSIS ELECTRICAL 8-293

No. Connector Face No. Connector Face

P-1
J-54
(24V)

000-011 000-004

J-28 1 2 P-4
3

003-016 000-004

P-2
J-28 2 1
3 (24V)

003-017 000-006

J-32 1 2 3 P-3

003-018 000-006

P-5
J-128
(12V)

004-018 000-007

P-5
J-9
(24V)

000-001 000-002

P-1 1 2 3 4
H-14 5 6 7 8
(12V) 9 10 11 12
13 14 15 16

000-003 016-001

4 3 2 1

P-2 H-14 8 7 6 5
12 11 10 9
16 15 14 13

000-004 016-002
8-294 CAB AND CHASSIS ELECTRICAL

No. Connector Face H-5

X-5

005-006

1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 11 12 12 11 10 9 8 7
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 24 23 22 21 20 19

X-13 25
31
26
32
27
33 34 35 36 37
28
38
29
39
30
40
30
40
29
39
28
38 37 36 35 34
27
33
26
32
25
31

005-006

X-33 1 2 3 4 5 6
7 8 9 10 11 12 13 14 N8A5488E

014-002 H-6, H-7

J-8
(For 4J
TYPE
ENGIN
1

E)
001-019 1 2 H-6 2 1

1 2 H-7 2 1

1 2 3 4 4 3 2 1

5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14

N8A5489E

For 4JH1 Engine

No. Connector Face

B-1

000-001

B-7

000-017
 CAB AND CHASSIS ELECTRICAL 8-295

No. Connector Face No. Connector Face

X-5 B-67 2 1
4 3

005-006 004-002

X-13 B-71
1

005-006 001-013

X-33 1 2 3 4 5 6 B-71 1
7 8 9 10 11 12 13 14

014-002 001-014

B-18 1 2 3 4 E-14
1

004-004 001-013

B-52 1 2 3 4 5 6 7 8 9 10 11 12 E-14 1

012-005 001-014

B-51 1 2 3 4 5 6 7 8 9 1011121314 B-85 1

2

014-001 002-009

1
B-55 1 2 3 4 5 6 7 8 9 10 11 12 B-85
2

012-004 002-010

B-67 1 2
N-6
2 1
3 4

004-001 002-023
8-296 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

6 5 4 3 2 1
B-236 H-12
1413 12 11 10 9 8 7
1 2

002-022 014-003

1 2 3 4
1 3
B-334 H-14 5 6
10 11 12 13 14
7 8 9

2 4 15 16

004-014 016-003

4 3 2 1
1 5 9 8 7 6 5
B-335 2 6 H-14 14 13 12 11 10
3 7
4 8 16 15

008-014 016-004

B-336 J-9
1 2 3 4 5 6

006-018 000-001

B-337 8765
J-128
1234
008-013 004-018

2 1
B-338 J-53
6 5 4 3

006-003 000-010

E-7 J-53
1

001-009 000-011

H-12 1 2 3 4 5 6 J-54
7 8 9 10 11 12 13 14

014-002 000-010
 CAB AND CHASSIS ELECTRICAL 8-297

No. Connector Face No. Connector Face

J-54 P-5

000-011 000-007

H-5

J-28 1 2
3

003-016

J-28 2 1
1 2 3 4 5 6 6 5 4 3 2 1
3 7 8 9 10 11 12 12 11 10 9 8 7
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 24 23 22 21 20 19
25 26 27 28 29 30 30 29 28 27 26 25
31 32 33 34 35 36 37 38 39 40 40 39 38 37 36 35 34 33 32 31
003-017

J-32 1 2 3

003-018
N8A5488E

H-6, H-7

P-1

000-002

1 2 H-6 2 1

P-2 1 2 H-7 2 1

1 2 3 4 4 3 2 1
000-002
5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14

P-3

000-014
N8A5489E

For 4HK1 Engine

No. Connector Face
P-4

000-014
B-1

000-001
8-298 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

B-7 X-33 1 2 3 4 5 6
7 8 9 10 11 12 13 14

000-001 014-002

J-9 B-51

000-001
020-004

B-18 1 2 3 4 B-52

004-004 020-005

B-53
(With
X-1
Smoot
her)
005-006 012-009

X-8 B-67 1 2
3 4

005-006 004-001

X-12 2 3 4 B-67 2 1
4 3
5

005-001 004-002

X-13 B-71
1

005-006 001-013

X-32
(For
B-71 1
Smooth 1 2 3 4
er)
004-004 001-014
 CAB AND CHASSIS ELECTRICAL 8-299

No. Connector Face No. Connector Face

B-427
(For
J-8
1 Smoot
her)
001-013 017-001

J-8 1 B-57 3 2 1

001-014 003-035

B-85 1 N-6
2 2 1

002-009 002-023

N-19
1 (For
B-85 1 2 3 4

2 Smoot 5 6 7 8 9 10
her)
002-010 010-003

B-236 E-90 1 2

1 2 3

002-022 003-004

B-276 1 2 3 H-4 1 2 3 4 5 6 7 8 9
4 5 6 7 8 10 11 12 13 14 15 16 1718 19 20

008-009 020-002

3 2 1 9 8 7 6 5 4 3 2 1
B-276 H-4
8 7 6 5 4 20 19 18 17 16 15 14 13 12 11 10

008-010 020-003

B-425
H-12
(For
(For 1 2 3 4 5 6
Smoot
M/T) 7 8 9 10 11 12 13 14
her)
031-001 014-002
8-300 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

H-12 4 3 2 1
6 5 4 3 2 1
(For H-105 8 7 6 5
1413 12 11 10 9 8 7
M/T) 12 11 10 9

014-003 012-002

H-12
(For 1 2 3 4 5 6 7 8 9 10
J-1
Smoot 11 12 13 14 15 16 17 18 19 20 21 22
1 2

her)
022-001 002-003

H-12
(For 10 9 8 7 6 5 4 3 2 1
J-2
Smoot 22 21 20 19 18 17 16 15 14 13 12 11
her)
022-002 000-001

1 2 3 4

H-14 5 6
10 11 12 13 14
7 8 9
J-26
15 16

016-003 000-011
000-002

4 3 2 1
9 8 7 6 5
H-14 14 13 12 11 10 J-27
16 15

016-004 000-009
000-011

1 2 3 4

H-15 5 6
10 11 12 13 14
7 8 9
J-28 1 2
3
15 16

016-003 003-016

4 3 2 1
9 8 7 6 5
H-15 14 13 12 11 10 J-28 2 1
3
16 15

016-004 003-017

1 2 3 4
H-105 5 6 7 8 J-32 1 2 3
9 10 11 12

012-001 003-018
 CAB AND CHASSIS ELECTRICAL 8-301

No. Connector Face No. Connector Face

J-128 P-5

004-018 000-002

H-5

J-177 1 2 3

003-018
034-001

J-191
1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 11 12 12 11 10 9 8 7
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 24 23 22 21 20 19
081-001 25 26 27 28 29 30 30 29 28 27 26 25
31 32 33 34 35 36 37 38 39 40 40 39 38 37 36 35 34 33 32 31

J-206 1 2
3 4

004-011
N8A5488E

H-6, H-7, H-8

P-1

000-004

1 2 H-6 2 1

P-4
1 2 H-7 2 1

000-004 1 2 3 4 4 3 2 1

5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14

P-2

000-006
N8A5489E

P-3

000-006
8-302 CAB AND CHASSIS ELECTRICAL
Diagnosis
Quick Chart for Check Point
1. Speedometer

Check point
Vehicle speed
Speedometer Cable harness
sensor
1-1. Speedometer and odometer do not func- ❍ ❍ ❍
tion (3) (1) (2)
1-2. Speedometer does not function ❍
(odometer is normal) (1)
Trouble 1-3. Odometer does not function ❍
mode (Speedometer is normal) (1)
1-4. Speedometer needle fluctuates ❍ ❍ ❍
(May be wide fluctuation) (3) (1) (2)
❍ ❍ ❍
1-5. Speedometer needle jumps erratically
(3) (1) (2)

Notice:
Figure in parenthesis “( )” indicates the order of inspection.
2. Tachometer

Check point
Engine speed
Tachometer Cable harness
sensor
❍ ❍ ❍
2-1. Tachometer does not function
(3) (1) (2)
Trouble 2-2. Tachometer needle fluctuates ❍ ❍ ❍
mode (May be wide fluctuation) (3) (1) (2)
❍ ❍ ❍
2-3. Tachometer needle jumps erratically
(3) (1) (2)

Notice:
Figure in parenthesis “( )” indicates the order of inspection.
3. Coolant Temperature Gauge

Check point
Meter Thermo Thermo Thermo Cable
ASM meter unit seat harness
3-1. Coolant temperature gauge nee- ❍ ❍ ❍ ❍
dle does not move (3) (4) (2) (1)
Trouble 3-2. Coolant temperature gauge read- ❍ ❍ ❍ ❍ ❍
mode ing is too low (or high) (4) (5) (3) (1) (2)
3-3. Needle overshoots (or goes up to ❍ ❍ ❍ ❍
the “H” range) (3) (4) (1) (2)

Notice:
Figure in parenthesis “( )” indicates the order of inspection.
 CAB AND CHASSIS ELECTRICAL 8-303
4. Fuel Gauge

Check point
Fuel tank Cable
Meter ASM Fuel gauge
unit harness
❍ ❍ ❍ ❍
4-1. Fuel gauge needle does not move
(3) (4) (2) (1)
Trouble 4-2. Even when the tank is filled up with fuel, ❍ ❍ ❍ ❍
mode the needle does not reach “F” (3) (4) (2) (1)
4-3. When the tank is not full of fuel, the nee- ❍ ❍ ❍ ❍
dle overshoots (or goes to “F”) (3) (4) (2) (1)

Notice:
Figure in parenthesis “( )” indicates the order of inspection.
8-304 CAB AND CHASSIS ELECTRICAL
5. Warning/indicator Light

Check point
Parking Brake Oil Fuel Sedi- Seat
Light Vacuum 4WD Cable
brake fluid pressure tank menter belt
bulb SW SW harness
SW SW SW unit SW SW
5-1. When the parking
brake lever is pulled, the ❍ ❍ ❍
indicator light does not (2) (1) (3)
light up
5-2. Even when the park-
ing brake lever is ❍ ❍
released, the indicator (1) (2)
light does not go off
5-3. While the engine
operating, the oil pressure ❍ ❍
warning light does not go (2) (1)
off
5-4. Even when the tank is
❍ ❍
full with fuel, the fuel warn-
(1) (2)
ing light lights up
5-5. Even when the tank is
❍ ❍ ❍
empty, the low fuel warn-
Trouble (1) (2) (3)
ing light does not light up
mode
5-6. Even when the trans-
fer level is shifted to 4WD ❍ ❍ ❍
position, the indicator light (2) (1) (3)
does not light up
5-7. Even when the float in
the water sedimenter goes
❍ ❍ ❍
up above the drain warn-
(1) (2) (3)
ing level, the indicator light
does not light up
5-8. Even when the brake
fluid is lower than speci- ❍ ❍ ❍
fied level, the level warn- (2) (1) (3)
ing light does not light up
5-9. Even when the vac-
uum tank is empty vac- ❍ ❍
uum warning buzzer does (1) (2)
not sound

Notice:
Figure in parenthesis “( )” indicates the order of inspection.
 CAB AND CHASSIS ELECTRICAL 8-305
1. Speedometer
1-1. Speedometer and Odometer Do Not Function

N8A5362E

1-2. Speedometer Does Not Function (Odometer Is Normal)

REPLACE THE SPEEDOMETER ASSEMBLY

N8A0300E
8-306 CAB AND CHASSIS ELECTRICAL
1-3. Odometer Does Not Function (Speedometer Is Normal)

REPLACE THE SPEEDOMETER ASSEMBLY

N8A0300E

1-4. Speedometer Needle Fluctuates (May Be Wide Fluctuation)

N8A5366E

1-5. Speedometer Needle Jumps Erratically

N8A5366E
 CAB AND CHASSIS ELECTRICAL 8-307
Except 4HK1 Engine
Inspection of waveform by oscilloscope
1. Connect a resistance of 1.3 to 5k ohm (1.4W or more) between the harness side connectors 8 B-51 and 1 B-55
of the meter.

B-51 B-55

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12

N8A5562E

2. Install a speedometer tester.

3. Turn on the starter SW.
4. Check the waveform at the time when the vehicle speed is at 60 Km (37 mph).

Normal waveform
Approximate battery voltage

0V

2V or less
23.6 m sec.

N8A5367E
8-308 CAB AND CHASSIS ELECTRICAL
For 4HK1 Engine

Inspection of waveform by oscilloscope

1. Connect a resistance of 1.3 to 5k ohm (1.4W or more) between the harness side connectors 18 B-51
and 17 B-52 of the meter.
B-51 B-52

2. Install a speedometer tester.

3. Turn on the starter SW.
4. Check the waveform at the time when the vehicle speed is at 60 Km (37 mph).

Normal waveform
Approximate battery voltage

0V

2V or less
23.6 m sec.
N8B0061E

2. Tachometer
2-1. Tachometer Does Not Function

N8A5368E
 CAB AND CHASSIS ELECTRICAL 8-309
2-2. Tachometer Needle Fluctuates (May Be Wide Fluctuation)

N8A5368E

2-3. Tachometer Needle Jumps Erratically

• IS THE PULSE INPUT NORMAL?

YES NO

REPAIR A POOR CONNECTION AT THE

CONNECTORS IN THE CIRCUIT OR A FAILURE IN
THE HARNESS, OR REPLACE ENGINE SPEED
SENSOR

REPLACE THE TACHOMETER

N8A0307E
8-310 CAB AND CHASSIS ELECTRICAL
3. Coolant Temperature Gauge
3-1. Coolant Temperature Gauge Needle Does Not Move
Except 4HK1 Engine

• IS THE CONNECTOR OF THE THERMO UNIT

CONNECTED SECURELY?

YES NO

CONNECT THE CONNECTOR SECURELY

• DISCONNECT THE CONNECTOR OF THE THERMO
UNIT
• CONNECT A 3.4W BULB BETWEEN THE HARNESS
SIDE CONNECTOR 1 E-7 AND THE GROUND OF THE
THERMO UNIT
• WHEN THE STARTER SW IS TURNED ON, DOES THE
TEMPERATURE GAUGE NEEDLE MOVE ABOUT 10
SECONDS AFTER THAT?

YES NO

• IS THE THERMO UNIT NORMAL? • IS THE CIRCUIT BETWEEN THE TEMPERATURE

GAUGE AND THE THERMO UNIT NORMAL?

YES NO YES NO

REPAIR A POOR REPLACE THE • IS THERE A BROKEN • REPAIR A POOR

CONNECTION AT THE THERMO UNIT WIRE IN THE PRINTED CONNECTION AT THE
CONNECTOR CIRCUIT OF THE CONNECTORS OR AN
METER ASSEMBLY? OPEN CIRCUIT IN THE
CIRCUIT

YES NO

REPLACE THE PRINTED

CIRCUIT BOARD

CHECK THE COOLANT

TEMPERATURE GAUGE
AND REPLACE IT WITH A
CORRECT ONE IF
NECESSARY

N8A0308E
 CAB AND CHASSIS ELECTRICAL 8-311
For 4HK1 Engine

IS THE CONNECTOR OF THE ECT SENSOR

CONNECTED SECURELY?

YES NO

CONNECT THE CONNECTOR SECURELY

DISCONNECT THE CONNECTOR OF THE ECT
SENSOR
CONNECT A 3.4W BULB BETWEEN THE HARNESS
SIDE CONNECTOR 3 E-90 AND THE GROUND OF
THE ECT SENSOR
WHEN THE STARTER SW IS TURNED ON, DOES
THE TEMPERATURE GAUGE NEEDLE MOVE
ABOUT 10 SECONDS AFTER THAT?

YES NO

IS THE ECT SENSOR NORMAL? IS THE CIRCUIT BETWEEN THE TEMPERATURE

GAUGE AND THE ECT SENSOR NORMAL?

YES NO YES NO

REPAIR A POOR REPLACE THE ECT IS THERE A BROKEN REPAIR A POOR

CONNECTION AT THE SENSOR WIRE IN THE PRINTED CONNECTION AT THE
CONNECTOR CIRCUIT OF THE CONNECTORS OR AN
METER ASSEMBLY? OPEN CIRCUIT IN THE
CIRCUIT

YES NO

REPLACE THE PRINTED

CIRCUIT BOARD

CHECK THE COOLANT

TEMPERATURE GAUGE
AND REPLACE IT WITH A
CORRECT ONE IF
NECESSARY

N8B5066E
8-312 CAB AND CHASSIS ELECTRICAL
3-2. Coolant Temperature Gauge Reading Is Too Low (or High)
Except 4HK1 Engine

• DOES THE THERMOSTAT OPERATE NORMALLY?

YES NO

• TURN THE STARTER SWITCH ON REPLACE THE THERMOSTAT

• WHEN INSERTING AND PULLING OUT THE
THERMOSTAT CONNECTOR 1 E-7 SEVERAL
TIMES, DOES THE INDICATION OF THE COOLANT
TEMPERATURE GAUGE VARY?

YES NO

• IS THE THERMO UNIT NORMAL? REPAIR A POOR CONNECTION AT THE CONNECTOR

OF THE THERMO UNIT

YES NO

• IS THERE AN OPEN CIRCUIT IN THE METER REPLACE THE THERMO UNIT

ASSEMBLY PRINTED CIRCUIT BOARD?

YES NO

REPLACE THE PRINTED CIRCUIT BOARD

CHECK THE COOLANT TEMPERATURE GAUGE AND

REPLACE IT IF FOUND DEFECTIVE

N8A0309E
 CAB AND CHASSIS ELECTRICAL 8-313
For 4HK1 Engine

DOES THE THERMOSTAT OPERATE NORMALLY?

YES NO

TURN THE STARTER SWITCH ON REPLACE THE THERMOSTAT

WHEN INSERTING AND PULLING OUT THE
THERMOSTAT CONNECTOR 3 E-90 SEVERAL
TIMES, DOES THE INDICATION OF THE COOLANT
TEMPERATURE GAUGE VARY?

YES NO

IS THE ECT SENSOR NORMAL? REPAIR A POOR CONNECTION AT THE CONNECTOR

OF THE ECT SENSOR

YES NO

IS THERE AN OPEN CIRCUIT IN THE METER REPLACE THE ECT SENSOR

ASSEMBLY PRINTED CIRCUIT BOARD?

YES NO

REPLACE THE PRINTED CIRCUIT BOARD

CHECK THE COOLANT TEMPERATURE GAUGE AND

REPLACE IT IF FOUND DEFECTIVE

N8B5067E
8-314 CAB AND CHASSIS ELECTRICAL
3-3. Needle Overshoots (or Goes Up to the “H” Range)
Except 4HK1 Engine

• DISCONNECT THE CONNECTOR OF THE THERMO

UNIT
• WHEN THE STARTER SW IS TURNED ON, DOES
THE POINTER REACH TO THE "H" RANGE?

YES NO

• IS THERE A SHORT CIRCUIT BETWEEN THE REPLACE THE THERMO UNIT

THERMO UNIT AND THE COOLANT
TEMPERATURE GAUGE?

YES NO

• IS THE PRINTED CIRCUIT OF THE METER REPAIR A SHORT CIRCUIT

ASSEMBLY GROUNDED SECURELY?

YES NO

REPAIR OR REPLACE THE PRINTED CIRCUIT BOARD

CHECK THE COOLANT TEMPERATURE GAUGE AND

REPLACE IT IF FOUND ABNORMAL

N8A0310E
 CAB AND CHASSIS ELECTRICAL 8-315
For 4HK1 Engine

DISCONNECT THE CONNECTOR OF THE ECT

SENSOR
WHEN THE STARTER SW IS TURNED ON, DOES
THE POINTER REACH TO THE "H" RANGE?

YES NO

IS THERE A SHORT CIRCUIT BETWEEN THE REPLACE THE ECT SENSOR

ECT SENSOR AND THE COOLANT
TEMPERATURE GAUGE?

YES NO

IS THE PRINTED CIRCUIT OF THE METER REPAIR A SHORT CIRCUIT

ASSEMBLY GROUNDED SECURELY?

YES NO

REPAIR OR REPLACE THE PRINTED CIRCUIT BOARD

CHECK THE COOLANT TEMPERATURE GAUGE AND

REPLACE IT IF FOUND ABNORMAL

N8B5156E
8-316 CAB AND CHASSIS ELECTRICAL
4. Fuel Gauge
4-1. Fuel Gauge Needle Does Not Move
Except 4HK1 Engine

• IS THE CONNECTOR OF THE FUEL TANK UNIT J-28

CONNECTED SECURELY?

YES NO

CONNECT THE CONNECTOR SECURELY

• DISCONNECT THE CONNECTOR OF THE FUEL
TANK UNIT
• CONNECT A 3.4W BULB BETWEEN THE HARNESS
SIDE CONNECTOR 1 J-28 AND THE GROUND OF
THE FUEL TANK UNIT
• WHEN THE STARTER SW IS TURNED ON, DOES THE
FUEL GAUGE NEEDLE FLUCTUATE AFTER ABOUT 90
SECONDS?

YES NO

• IS THERE CONTINUITY BETWEEN THE FUEL • IS THE CIRCUIT BETWEEN THE FUEL GAUGE AND
TANK UNIT CONNECTOR TERMINALS 1 J-28 THE FUEL TANK UNIT NORMAL?
AND 3 J-28 ?

YES NO YES NO

REPLACE THE FUEL • IS THERE A BROKEN REPAIR A POOR

TANK UNIT WIRE IN THE PRINTED CONNECTION AT THE
CIRCUIT OF THE CONNECTORS OR AN
METER ASSEMBLY? OPEN CIRCUIT IN THE
CIRCUIT

REPAIR A POOR YES NO

CONNECTION AT THE
CONNECTORS OR AN
OPEN CIRCUIT CHECK THE FUEL
BETWEEN THE FUEL METER, AND REPLACE IT
TANK UNIT AND THE IF NECESSARY
METER

REPLACE THE PRINTED

CIRCUIT BOARD

N8A0311E
 CAB AND CHASSIS ELECTRICAL 8-317
For 4HK1 Engine

• IS THE CONNECTOR OF THE FUEL TANK UNIT J-28

CONNECTED SECURELY?

YES NO

CONNECT THE CONNECTOR SECURELY

• DISCONNECT THE CONNECTOR OF THE FUEL
TANK UNIT
• CONNECT A 3.4W BULB BETWEEN THE HARNESS
SIDE CONNECTOR 1 J-28 AND THE GROUND OF
THE FUEL TANK UNIT
• WHEN THE STARTER SW IS TURNED ON, DOES THE
FUEL GAUGE NEEDLE FLUCTUATE AFTER ABOUT 90
SECONDS?

YES NO

• IS THERE CONTINUITY BETWEEN THE FUEL • IS THE CIRCUIT BETWEEN THE FUEL GAUGE AND
TANK UNIT CONNECTOR TERMINALS 1 J-28 THE FUEL TANK UNIT NORMAL?
AND 2 J-28 ?

YES NO YES NO

REPLACE THE FUEL • IS THERE A BROKEN REPAIR A POOR

TANK UNIT WIRE IN THE PRINTED CONNECTION AT THE
CIRCUIT OF THE CONNECTORS OR AN
METER ASSEMBLY? OPEN CIRCUIT IN THE
CIRCUIT

REPAIR A POOR YES NO

CONNECTION AT THE
CONNECTORS OR AN
OPEN CIRCUIT CHECK THE FUEL
BETWEEN THE FUEL METER, AND REPLACE IT
TANK UNIT AND THE IF NECESSARY
METER

REPLACE THE PRINTED

CIRCUIT BOARD

N8B5068E
8-318 CAB AND CHASSIS ELECTRICAL
4-2. Even when The Tank Is Filled Up with Fuel, The Needle Does Not Reach “F”
Except 4HK1 Engine

• WHEN INSERTING AND PULLING OUT THE

CONNECTOR J-28 OF THE FUEL TANK UNIT
SEVERAL TIMES, DOES THE POINTER OF THE FUEL
GAUGE STAY AT THE SAME POSITION?

YES NO

• DISCONNECT THE CONNECTOR OF THE FUEL TANK REPAIR A POOR CONNECTION AT THE CONNECTOR
UNIT OF THE FUEL TANK UNIT
• CONNECT THE FUEL TANK UNIT HARNESS SIDE
CONNECTOR 1 J-28 AND 3 J-28 WITH A LEAD
WIRE
• WHEN THE STARTER SW IS TURNED ON, DOES THE
NEEDLE OVERSHOOT TO "F" AFTER ABOUT 5
MINUTES?

YES NO

• IS THERE A BROKEN CIRCUIT IN THE PRINTED • REMOVE THE FUEL TANK UNIT
CIRCUIT OF THE METER ASSEMBLY? • DOES THE FLOAT ARM OPERATE SMOOTHLY?

YES NO YES

REPLACE THE PRINTED • IS THE RESISTANCE

CIRCUIT BOARD VALUE OF THE FUEL
TANK UNIT NORMAL?

CHECK THE FUEL NO

GAUGE AND REPLACE
IT IF FOUND
ABNORMAL REPLACE THE FUEL
TANK UNIT
N8A0312E
 CAB AND CHASSIS ELECTRICAL 8-319
For 4HK1 Engine

• WHEN INSERTING AND PULLING OUT THE

CONNECTOR J-28 OF THE FUEL TANK UNIT
SEVERAL TIMES, DOES THE POINTER OF THE FUEL
GAUGE STAY AT THE SAME POSITION?

YES NO

• DISCONNECT THE CONNECTOR OF THE FUEL TANK REPAIR A POOR CONNECTION AT THE CONNECTOR
UNIT OF THE FUEL TANK UNIT
• CONNECT THE FUEL TANK UNIT HARNESS SIDE
CONNECTOR 1 J-28 AND 2 J-28 WITH A LEAD WIRE
• WHEN THE STARTER SW IS TURNED ON, DOES THE
NEEDLE OVERSHOOT TO "F" AFTER ABOUT 5
MINUTES?

YES NO

• IS THERE A BROKEN CIRCUIT IN THE PRINTED • REMOVE THE FUEL TANK UNIT
CIRCUIT OF THE METER ASSEMBLY? • DOES THE FLOAT ARM OPERATE SMOOTHLY?

YES NO YES

REPLACE THE PRINTED • IS THE RESISTANCE

CIRCUIT BOARD VALUE OF THE FUEL
TANK UNIT NORMAL?

CHECK THE FUEL NO

GAUGE AND REPLACE
IT IF FOUND
ABNORMAL REPLACE THE FUEL
TANK UNIT

N8B5069E
8-320 CAB AND CHASSIS ELECTRICAL
4-3. When The Tank Is Not Full of Fuel, The Needle Overshoots (or Goes Up to “F”)

• DISCONNECT THE CONNECTOR OF THE FUEL TANK

UNIT
• WHEN THE STARTER SW IS TURNED ON, DOES THE
NEEDLE STILL POINT TO "F"?

YES NO

• IS THE CIRCUIT BETWEEN THE FUEL TANK UNIT • REMOVE THE FUEL TANK UNIT
AND THE FUEL METER NORMAL? • DOES THE FLOAT ARM OPERATE SMOOTHLY?

YES NO YES

• IS THE PRINTED REPAIR A SHORT • ARE THE RESISTANCE VALUES OF THE

CIRCUIT OF THE CIRCUIT IN THE FUEL TANK UNIT AT "E" AND "F" POINTS
METER ASSEMBLY CIRCUIT NORMAL?
GROUNDED
SECURELY?

YES NO NO

REPAIR OR REPLACE REPLACE THE FUEL TANK UNIT

THE PRINTED CIRCUIT
BOARD

CHECK THE FUEL

GAUGE, AND REPLACE
IT IF NECESSARY

N8A0313E
 CAB AND CHASSIS ELECTRICAL 8-321
5. Warning/indicator Light
5-1. When The Parking Brake Lever Is Pulled, The Indicator Light Does Not Light Up
Except 4HK1 Engine

N8A5377E
8-322 CAB AND CHASSIS ELECTRICAL
For 4HK1 Engine

IS THERE CONTINUITY
IN THE CIRCUIT
BETWEEN THE
PARKING BRAKE
SWITCH CONNECTOR
N-6 AND 5 B-51 (4 B-51
: WITH SMOOTHER)
(METER)?

N8D0003E

5-2. Even When The Parking Brake Lever Is Released, The Indicator Light Does Not Go Off
Except 4HK1 Engine

N8A5378E
 CAB AND CHASSIS ELECTRICAL 8-323
For 4HK1 Engine

REPAIR A SHORT CIRCUIT BETWEEN THE PARKING

BRAKE SWITCH CONNECTOR 1 N-6 AND
5 B-51 (4 B-51 : WITH SMOOTHER)
N8D0004E

5-3. While The Engine Is Operating, The Oil Pressure Warning Light Does Not Go Off
Except 4HK1 Engine

• IS THE ENGINE OIL PRESSURE NORMAL?

YES NO

• WITH THE OIL PRESSURE SWITCH CONNECTOR J-8 REFER TO THE "ENGINE" SECTION
DISCONNECTED, DOES THE WARNING LIGHT GO
OFF?

YES NO

• WHILE THE ENGINE IS OPERATING, IS THERE REPAIR A SHORT CIRCUIT BETWEEN 1 J-8 AND 1
CONTINUITY BETWEEN THE OIL PRESSURE SWITCH B-52 (METER)
CONNECTOR J-8 AND THE BODY GROUND?

NO

REPLACE THE OIL PRESSURE SWITCH

N8A0316E
8-324 CAB AND CHASSIS ELECTRICAL
For 4HK1 Engine

• IS THE ENGINE OIL PRESSURE NORMAL?

YES NO

• WITH THE OIL PRESSURE SWITCH CONNECTOR J-8 REFER TO THE "ENGINE" SECTION
DISCONNECTED, DOES THE WARNING LIGHT GO
OFF?

YES NO

• WHILE THE ENGINE IS OPERATING, IS THERE REPAIR A SHORT CIRCUIT BETWEEN 1 J-8 AND
CONTINUITY BETWEEN THE OIL PRESSURE SWITCH 11 B-51 (METER)
CONNECTOR J-8 AND THE BODY GROUND?

NO

REPLACE THE OIL PRESSURE SWITCH

N8B5072E

5-4. Even When The Fuel Tank Is Full with Fuel, The Fuel Warning Light Lights Up
Except 4HK1 Engine

• WHEN THE FUEL TANK UNIT CONNECTOR J-28 IS

DISCONNECTED, DOES THE WARNING LIGHT GO
OFF?

YES NO

• IS THE FUEL TANK UNIT NORMAL? REPAIR A SHORT CIRCUIT BETWEEN THE FUEL
TANK UNIT HARNESS SIDE CONNECTORS 2 J-28
AND 10 B-51 (METER)

NO

REPLACE THE FUEL TANK UNIT

N8A0317E
 CAB AND CHASSIS ELECTRICAL 8-325
For 4HK1 Engine

• WHEN THE FUEL TANK UNIT CONNECTOR J-28 IS

DISCONNECTED, DOES THE WARNING LIGHT GO
OFF?

YES NO

• IS THE FUEL TANK UNIT NORMAL? REPAIR A SHORT CIRCUIT BETWEEN THE FUEL
TANK UNIT HARNESS SIDE CONNECTORS 1 J-28
AND 6 B-52 (METER)

NO

REPLACE THE FUEL TANK UNIT

N8B5073E

5-5. Even When The Fuel Tank Is Empty, The Low Fuel Warning Light Does Not Light Up
Except 4HK1 Engine

• DOES THE WARNING LIGHT HAVE A BURNED OUT

BULB, OR IS THE SOCKET POORLY CONNECTED?

YES NO

• IS THE FUEL TANK UNIT NORMAL? REPLACE THE BULB, OR REPAIR A POOR
CONNECTION AT THE SOCKET

YES NO

REPLACE THE FUEL TANK UNIT

REPAIR A POOR CONNECTION AT THE CONNECTOR

OR AN OPEN CIRCUIT BETWEEN THE HARNESS
SIDE CONNECTORS 2 J-28 AND 10 B-51 (METER)
OR 3 J-28 AND J-9

N8A0318E
8-326 CAB AND CHASSIS ELECTRICAL
For 4HK1 Engine

• DOES THE WARNING LIGHT HAVE A BURNED OUT

BULB, OR IS THE SOCKET POORLY CONNECTED?

YES NO

• IS THE FUEL TANK UNIT NORMAL? REPLACE THE BULB, OR REPAIR A POOR
CONNECTION AT THE SOCKET

YES NO

REPLACE THE FUEL TANK UNIT

REPAIR A POOR CONNECTION AT THE CONNECTOR

OR AN OPEN CIRCUIT BETWEEN THE HARNESS
SIDE CONNECTORS 1 J-28 AND 6 B-52 (METER)
OR 2 J-28 AND J-9

N8B5074E
 CAB AND CHASSIS ELECTRICAL 8-327
5-6. Even When The Transfer Level Is Shifted to 4wd Position, The Indicator Light Does Not Light Up

N8A5382E
8-328 CAB AND CHASSIS ELECTRICAL
5-7. Even When The Float in The Water Sedimenter Goes Up above The Drain Warning Level, The Indicator
Light Does Not Light Up
Except 4HK1 Engine

• DOES THE INDICATOR LIGHT HAVE A BURNED-OUT

BULB OR IS THE SOCKET POORLY CONNECTED?

YES NO

• IS THE WATER SEDIMENTER SWITCH NORMAL? REPLACE THE BULB, OR REPAIR A POOR
CONNECTION AT THE SOCKET

YES NO

REPLACE THE WATER SEDIMENTER SWITCH

REPAIR A POOR CONNECTION AT THE

CONNECTORS OR AN OPEN CIRCUIT IN THE
CIRCUIT BETWEEN THE WATER SEDIMENTER
SWITCH HARNESS SIDE CONNECTOR 1 J-53
AND 12 B-51 (METER), OR 1 J-54 AND J-9

N8A0319E
 CAB AND CHASSIS ELECTRICAL 8-329
For 4HK1 Engine

• DOES THE INDICATOR LIGHT HAVE A BURNED-OUT

BULB OR IS THE SOCKET POORLY CONNECTED?

YES NO

• IS THE WATER SEDIMENTER SWITCH NORMAL? REPLACE THE BULB, OR REPAIR A POOR
CONNECTION AT THE SOCKET

YES NO

REPLACE THE WATER SEDIMENTER SWITCH

REPAIR A POOR CONNECTION AT THE

CONNECTORS OR AN OPEN CIRCUIT IN THE
CIRCUIT BETWEEN THE WATER SEDIMENTER
SWITCH HARNESS SIDE CONNECTOR 2 J-206
AND 10 B-52 (METER) OR 1 J-206 AND J-9

N8B5075E
8-330 CAB AND CHASSIS ELECTRICAL
5-8. Even When The Brake Fluid Is Lower than Specified Level, The Level Warning Light Does Not Light Up
Except 4HK1 Engine

N8A5384E
 CAB AND CHASSIS ELECTRICAL 8-331
For 4HK1 Engine

REPAIR A POOR CONNECTION AT THE

CONNECTORS OR AN OPEN CIRCUIT BETWEEN
THE BRAKE FLUID SWITCH HARNESS SIDE
CONNECTOR 2 B-85 AND 5 B-51
N8B5076E

5-9. Vacuum Warning Buzzer Does Not Sound

Except 4HK1 Engine

N8A0321E
8-332 CAB AND CHASSIS ELECTRICAL
For 4HK1 Engine

REPAIR A POOR CONNECTION AT THE

CONNECTORS OR AN OPEN CIRCUIT BETWEEN
3 B-57 AND 1 B-71

N8B5077E

Starter Switch
Refer to “START AND CHARGING” in this section.

Turn Signal Light Switch

Refer to “TURN SIGNAL LIGHT, HAZARD WARNING
LIGHT AND STOPLIGHT” in this section.

Exhaust Brake Switch

Refer to “EXHAUST BRAKE” in this section.
 CAB AND CHASSIS ELECTRICAL 8-333
Meter Assembly
Layout for Gauges, Warning, Indicator and Illumination Lights
Except 4HK1-TC

Speedometer Warning lens

E F 2 3
1
4
km/h
TRIP A
ODO B
0 x1000 r/min
C H

Fuel gauge Coolant temperature gauge

Tachometer &
digital clock

PUSH
SET

H M

N8A5565E

Notice:
The calibration and the red zone of tachometer are various depending on the models fitted.
8-334 CAB AND CHASSIS ELECTRICAL
For 4HK1-TC

Speedometer Warning lens Tachometer Warning lens

Without Smoother Smoother

1ST
START

Fuel gauge Coolant temperature gauge

N8A5566E
 CAB AND CHASSIS ELECTRICAL 8-335
Bulb Location for Warning Lens
Except 4HK1-TC

N8A5567E
8-336 CAB AND CHASSIS ELECTRICAL
For 4HK1-TC

1ST
START
*12 :: Smoother
* Without Smoother
N8A5568E
 CAB AND CHASSIS ELECTRICAL 8-337
Table for Meter Connector Terminal Connections
Except 4HK1-TC

B-336

B-51

B-52

B-55
N8A0483E

B-336 B-55

Terminal No. Connected to Terminal No. Connected to

1 IGN (+) 1 Speed pulse input
2 — 2 —
3 Speed pulse input 3 Power output (sensor)
4 — 4 ECT unit (GAUGE)
5 Ground 5 Fuel tank unit (GAUGE)
6 Illumination (+) 6 —
7 Ground
B-51
8 Turn signal (LH)
Terminal No. Connected to
9 —
1 Exh. Brake
10 Beam (+)
2 Exh. Brake
11 Turn signal (RH)
3 Airbag
12 —
4 Check engine
5 PTO ECT - Engine Coolant Temperature

6 Glow
7 ABS
8 IGN (+)
9 4WD
10 Fuel low
11 Vacuum / Booster
12 Sedimenter
13 Low coolant
14 Brake
8-338 CAB AND CHASSIS ELECTRICAL
B-52

Terminal No. Connected to

1 Oil pressure
2 Vacuum SW
3 Charge
4 Parking / Rear fog
5 Illumination (+)
6 —
7 Illumination (−)
8 Signal (tacho)
9 Ground (tacho)
10 Ground
11 —
12 +B

For 4HK1-TC

B-52

20 8

9 1

9 20

1 8

B-57

B-53 B-51
N8B5115E
 CAB AND CHASSIS ELECTRICAL 8-339
B-53 (With Smoother) B-52

Terminal No. Connected to Terminal No. Connected to

1 TCM 1 —
2 — 2 HSA
3 — 3 Turn RH
4 — 4 —
5 — 5 Thermal
6 1st Start 6 Fuel
7 ECONO 7 —
8 Smoother 8 TACHO
9 — 9 —
10 — 10 Sedimenter
11 — 11 —
12 — 12 —
13 —
B-51
14 —
Terminal No. Connected to
15 Glow
1 Turn LH
16 Battery
2 Beam
17 Vehicle Speed Sensor
3 —
18 —
4 Brake (*1) / — (*2)
19 —
5 Check Engine (*1) / Brake (*2)
20 Ground
6 Exhaust Brake
7 — B-57

8 — Terminal No. Connected to

9 Brake Booster 1 Battery
10 Charge 2 —
11 Oil Pressure 3 Ground
12 ABS
13 — (*1) / Check Engine (*2)
14 SRS
15 Ground
16 —
17 Illumination +
18 Ignition
19 Rear Fog
20 ASR

*1: With Smoother

*2: Without Smoother
8-340 CAB AND CHASSIS ELECTRICAL
Removal
Preparation:
Disconnect the battery ground cable.
1. Meter Cluster

N8A0327E

Speedometer
The speedometer is made up of the cross coil type am-
meter (movement) that displays indications, the stepper
N8A0325E
motor that drives and adds up the odometer and trip
2. Meter Assembly meter, and the driving circuit (printed circuit board) that
Remove the five screws. makes exchanges between the pulse signals and the
current.

80 100
60
40 120
140
20
km/h
TRIP A 160
0 ODO B

N8A0326E
N8A0328E
Disconnect the meter connectors.
Installation
To install, follow the removal steps in the reverse order.
 CAB AND CHASSIS ELECTRICAL 8-341
For 4HK1-TC (General Export)

Meter display
Tester display speed
permissible level
40 km/h 37 — 41 km/h
50 60
40 70 60 58 — 62
30 80 77.5 — 82.5
80
20 100 97.5 — 103
90
10 MPH
120 117 — 122.5
100
140 137.5 — 143
TRIP A
0 ODO B

For 4HK1-TC (Europe)

Meter display
Tester display speed
permissible level
N8A0330E 20 km/h 20 — 22.5 km/h

On-vehicle Service 40 40 — 42.5

Check the meter display accuracy and the operation of 60 60 — 63.2
the odometer with the speedometer tester. 80 79.7 — 83.4
Notice:
Inappropriate tire inflation may affect the accuracy of the Individual Inspection
odometer. Remove the speedometer from the meter assembly and
(To conduct this test, refer to the tester manufacturer's measure the resistance and the current consumption
instruction manual.) between each terminals.
Since the meter display permissible levels above are Replace the speedometer when the result of inspection
specifications solely for the meter, they are to be used is found abnormal.
as reference values when conducting on-vehicle ser-
vice. 4 Pulse output B
SENSOR
Except 4HK1-TC

Meter display
Tester display speed GND
permissible level
20 km/h 17.5 — 22.5 km/h
40 37.5 — 42.5
60 57.5 — 62.5
80 77.5 — 82.5
100 97.6 — 103.4
120 117.6 — 123.4
140 137.6 — 143.4
IGN
N8A0332E
Meter display
Tester display speed
permissible level
20 MPH 18.3 — 21.7 MPH Terminal symbol Resistance value

40 38.3 — 41.7 IGN — GND 58±20 kΩ

60 58.3 — 61.7 SEN — GND 70±20 kΩ

80 77.8 — 82.8 4P — GND ∞

Removal
Preparation:
Disconnect the battery ground cable.
8-342 CAB AND CHASSIS ELECTRICAL
• Except 4HK1-TC Installation
1. Meter Assembly To install, follow the removal steps in the reverse order.
Refer to “METER ASSEMBLY” in this section.
2. Meter Glass
Tachometer
Remove it by pushing the catches with your finger. The tachometer is made up of the cross coil type amme-
3. Speedometer ter (movement) that displays indications, and the drive
Remove four screws securing the meter at the circuit (printed board) that makes exchange between
back side. the pulse signals and the current.

N8A0334E
N8A0333E

• For 4HK1-TC On-vehicle Service Inspection

1. Remove the meter assembly/speedometer (1). 1. Set up the tune-up tester to the engine.
2. Start the engine and compare the readings dis-
Notice: played by the tachometer and the tester.
Speedometer cannot be removed as a single unit since When the difference between these two readings
it is integrated into the meter assembly. differs largely from the specified value, replace it
• Refer to “Meter Assembly” in this section. with a correct one.
2. Remove the meter plate (2) and meter glass (3). Notice:
• Remove the two installing screws on the meter Since the meter display permissible levels above are
surface. specifications solely for the meter, they are to be used
• Remove the meter plate by pushing the catch- as reference values when conducting on-vehicle inspec-
es with your finger. tion.
Except 4HK1-TC

Meter display
Tester display speed
permissible level
500 400 — 500
1000 800 — 1050
2000 1800 — 2050
3000 2800 — 3050
4000 3800 — 4050

N8A0485E
 CAB AND CHASSIS ELECTRICAL 8-343
For 4HK1-TC For 24 Volt tachometer

Meter display Tester terminal

Tester display speed Terminal
permissible level
symbol Red Black Black Red
750 700 — 800 (+) (−) (−) (+)
2000 1900 — 2150 IGN GND IGN GND
IGN — GND
3000 2950 — 3200 ∞ 30±5 kΩ
4000 3950 — 4200 PIN GND PIN GND
PIN — GND
33±5 kΩ 500 — 1000 kΩ
Individual Inspection
Remove the tachometer from the meter assembly and 2. Current value
measure the resistance value and the current consump- Use the analog type circuit tester.
tion between each terminals. Since the current consumption fluctuates as the power
Replace the tachometer when the result of inspection is voltage varies, check to be sure that the voltage applied
found abnormal. is 12±1 V or 24±1 V.

Connecting Current
Voltage Remarks
terminal consumption
12±1 V
No signal
12Volt (when 12±1 V
input
applied)
IGN — GND
24±1 V
No signal
24Volt (when 24±1 V
input
applied)

Removal
Preparation:
Disconnect the battery ground cable.
• Except 4HK1-TC
1. Meter Assembly
Refer to “METER ASSEMBLY” in this section.
N8A0336E 2. Meter Glass
Remove it by pushing the catches with your finger.
1. Resistance value 3. Tachometer
Use the analog type circuit tester. (Range: 1K) Remove three screws securing the meter at the
For 12 Volt tachometer back side.
Tester terminal
Terminal
symbol Red Black Black Red
(+) (−) (−) (+)
IGN GND IGN GND
IGN−GND
∞ 30±5 kΩ
PIN GND PIN GND
PIN−GND
33±5 kΩ 500 — 1000 kΩ

N0A0337E
8-344 CAB AND CHASSIS ELECTRICAL
• For 4HK1-TC
1. Remove the meter assembly/tachometer (1).
Notice:
Tachometer cannot be removed as a single unit since it
is integrated into the meter assembly.
• Refer to “Meter Assembly” in this section.
2. Remove the meter plate (2) and meter glass (3).
• Remove the two installing screws on the meter
surface.
• Remove the meter plate by pushing the catch-
es with your finger.

N8A0485E

Installation
To install, follow the removal steps in the reverse order.

Coolant Temperature Gauge

Circuit Diagram

Engine coolant temperature gauge

IGN UNIT

Thermo unit
(ECT sensor)
+

-
GND

N8D0005E

Inspection
Remove the coolant temperature gauge from the meter
assembly, and measure the resistance value between
each terminal.
Replace the coolant temperature gauge when the result
of inspection is found abnormal.
 CAB AND CHASSIS ELECTRICAL 8-345

Notice:
Coolant temperature gauge and fuel gauge cannot be
removed as a single unit since they are integrated into
the meter assembly.
• Refer to “Meter Assembly” in this section.
2. Remove the meter plate (2) and meter glass (3).
• Remove the two installing screws on the meter
surface.
• Remove the meter plate by pushing the catch-
es with your finger.

N8A0339E

Terminal symbol Resistance value

IG — U 169 Ω±10%
U—E 333 Ω±10%
IG — E 242 Ω±10%

Removal
Preparation:
Disconnect the battery ground cable.
• Except 4HK1-TC N8A0485E

1. Meter Assembly Installation

Refer to “METER ASSEMBLY” in this section.
To install, follow the removal steps in the reverse order.
2. Meter Glass
Remove it by pushing the catches with your finger.
3. Coolant Temperature Gauge
Remove six screws securing the meter at the back
side.

N8A0340E

• For 4HK1-TC
1. Remove the meter assembly (1).
8-346 CAB AND CHASSIS ELECTRICAL
Fuel Gauge
Circuit Diagram

N8A0341E

Inspection Warning Lens

Remove the fuel gauge from the meter assembly, and Removal
measure the resistance value between each terminal. Preparation:
Replace the meter when the result of inspection is found Disconnect the battery ground cable.
abnormal.
1. Meter Assembly
Refer to “METER ASSEMBLY” in this section.
2. Meter Glass
Remove it by pushing the catches with your finger.
3. Meter Plate
Remove it by pushing the catches with your finger.
4. Warning Lens

4
3

2
N8A0342E

Terminal symbol Resistance value

IG — U 108.1 Ω±10%
U—E 103 Ω±10%
IG — E 211.1 Ω±10% N8A5404E

Removal and Installation

Refer to the “COOLANT TEMPERATURE GAUGE” in
this section.
 CAB AND CHASSIS ELECTRICAL 8-347

Legend
1. Meter Assembly
2. Meter Glass
3. Meter Plate
4. Warning Lens

Installation
To install, follow the removal steps in the reverse order.

Warning Light Bulb, Indicator Light Bulb and Il-

lumination Light Bulb
Removal
Preparation:
Disconnect the battery ground cable.
1. Meter Assembly
Refer to “METER ASSEMBLY” in this section.
2. Socket and Bulb N8A0345E
Hold the bulb socket by hand and rotate it counter-
clockwise to remove them from the meter body. Inspection
3. Bulb 1. Connect a resistance of 390 Ω±5%, 2W between
Pull out the bulb from the socket. connector terminal 1 J-32 and battery (+) terminal
and connect the connector terminal 2 J-32 to the
battery (−) terminal.
Caution:
Be extremely careful not to connect the battery (+) ter-
minal to the connector 3 J-32 .
This may damage the vehicle speed sensor.
2. Rotate the shaft of the vehicle speed sensor slowly
and measure the voltage between 3 J-32 and 2
J-32 with a digital tester.
The voltage, with one rotation of shaft, fluctuates four
times in the following range: 10 to 14V ↔ 24 or less.
Replace the sensor when the result of inspection is
found abnormal.

N8A0344E

Installation
To install, follow the removal steps in the reverse order.

Vehicle Speed Sensor

The vehicle speed sensor is installed on the rear portion
of the transmission or transfer case.
The number of pulses generated is four pulses per one
rotation of the pinion shaft.
8-348 CAB AND CHASSIS ELECTRICAL

Caution:
Tightening must be made at the hexagonal part of the
sensor.
To tighten the connector itself would cause damage.

Thermo Unit (ECT Sensor)

Inspection
The thermo unit is thermistor type and must be inspect-
ed under the conditions as shown below.
1. Put the deviation of the galvanometer to 0 by using
the variable resistor, switch the thermo unit (ECT
sensor) off and then measure the resistance of the
resistor through the bridge.
Confirm that the resistance is continuously variable
in any other points than those shown below.
2. Dip the thermo unit (ECT sensor) into 80 — 90°C
(176 — 194°F) water and confirm that there is no
bubble continuously coming out of inside of the
unit.
Replace the unit (sensor) when the result of in-
spection is found abnormal.

N8A0346E

Removal
Preparation:
Disconnect the battery ground cable.
1. Vehicle Speed Sensor
Disconnect the connector.

Parking brake drum

Connector

N8A5409E

N8A5408E Oil Pressure Switch

Inspection
Installation
Check the continuity between the switch terminal and
1. Tighten the vehicle speed sensor to the specified the body ground with the starter switch is OFF position.
torque. Replace the switch when the result of inspection is
Tighten: found abnormal.
Vehicle speed sensor to 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
 CAB AND CHASSIS ELECTRICAL 8-349
Fuel Tank Unit
The tank unit varies the internal resistance according to
the float position (fluid level) to operate the fuel meter
needle. Also available is the build-in switch type to warn
the driver of low fuel level (about 5 liters left in the tank)
by illuminating the fuel warning light.

N8A5410E

Circuit Inspection
1. Start the engine.
2. When disconnecting the oil pressure switch con-
nector then connecting the harness side connector
to the ground, check to see if the oil pressure warn- N8A5412E
ing light lights up. When the light will not light up,
check the circuit between the meter and the oil
pressure switch, and repair an open circuit if nec-
essary.

N8A5411E
8-350 CAB AND CHASSIS ELECTRICAL
Inspection (Except 4HK1-TC)
(Level Switch type of warn low fuel level)
1. Check the resistance between the connector terminals 1 J-28 and 3 J-28 while shifting the float from “E” to “F”
point.
2. Check if the low fuel warning switch turns on and off at the specified positions. If found defective, replace the
fuel tank unit.

N8A5413E
 CAB AND CHASSIS ELECTRICAL 8-351
(Float type of warn low fuel level)
1. Check the resistance between the connector terminals 1 J-28 and 3 J-28 while shifting the float from “E” to “F”
point.
2. Check if the low fuel warning light turns on when the float is at “E” position. If found defective replace the fuel
tank unit.

N8A5414E
8-352 CAB AND CHASSIS ELECTRICAL
Inspection (For 4HK1-TC)
(Level Switch type of warn low fuel level)
1. Check the resistance between the connector termi-
nals 1 J-28 and 2 J-28 while shifting the float
from “E” to “F” point.
2. Check if the low fuel warning switch turns on and
off at the specified positions. If found defective, re-
place the fuel tank unit.
91.5 mm (Fuel tank capacity: 100L)
91.5 mm (Fuel tank capacity: 75L)
207.7 mm (Fuel tank capacity: 100L)
207.7 mm (Fuel tank capacity: 75L)
330.2 mm (Fuel tank capacity: 100L)
330.2 mm (Fuel tank capacity: 75L)

N8B0063E

Float position Resistance value (Ω)

F 2.5
1/2 33.0
J-28 E 98.3

2 1

N8B0064E
 CAB AND CHASSIS ELECTRICAL 8-353
Removal 1. Engine Speed Sensor
Preparation: 1) Disconnect the connector.
Disconnect the battery ground cable. 2) Remove the engine speed sensor.
1. Fuel Tank Unit
1) Disconnect the connector.
2) Remove five screws.

N8A5417E

Installation
N8A5415E
To install, follow the removal steps in the reverse order.

Installation
Vacuum Switch
To install, follow the removal steps in the reverse order. Inspection
When the pressure value is below 250±30 mm Hg
Engine Speed Sensor (Except 4HK1-TC) (33.3±4.0 kPa), check to see if there is continuity be-
Inspection tween the terminal and the ground. If no continuity, re-
Measure the resistance value between the engine place the switch with a normal one.
speed sensor connector terminals.
Replace the engine speed sensor when the result of
inspection is found abnormal.
4J Series engine = 1.36 — 1.86 KΩ
4H Series engine = 0.57 — 0.86 KΩ

N8A0357E

Removal
Preparation:
Disconnect the battery ground cable.
N8A0355E 1. Vacuum Switch
1) Disconnect the connector.
Removal 2) Remove the vacuum switch.
Preparation:
Disconnect the battery ground cable.
8-354 CAB AND CHASSIS ELECTRICAL

Legend
1. Meter Assembly
2. Vacuum Warning Buzzer

Installation
To install, follow the removal steps in the reverse order.

Water Sedimenter Switch

Inspection
1. When the float in the water sedimenter is above the
drain warning level, confirm if there is continuity be-
tween the switch connector terminals.
2. Turn the starter switch on, disconnect the water
sedimenter connector and connect the harness
side connector terminals. Then confirm that the
sedimenter warning light turns on.
N8A5419E
If found defective, replace the switch or repair a
poor connection or an open circuit between the
Installation connector terminals.
Apply liquid gasket to the screw portion of the switch to
prevent vacuum leak.

Vacuum Warning Buzzer

Inspection
Apply battery voltage to the buzzer connector terminals
to check the buzzer sound.
Replace the buzzer when the result of inspection is
found abnormal.
Removal
Preparation:
Disconnect the battery ground cable.
1. Meter Assembly
Refer to “METER ASSEMBLY” in this section.
2. Vacuum Warning Buzzer
1) Disconnect the connector.
2) Remove the buzzer fixing screw.
N8A0359E

Brake Fluid Switch

Inspection
1. Confirm there is continuity between the switch con-
nector terminals when the brake fluid in the tank is
1 between 60 — 75 cc level.
2. Turn the switch on, disconnect the brake fluid
2 switch connector and connect the harness side
connector terminals. Then confirm that brake
warning light turns on.
If found defective, replace the tank, or repair a poor
connection or an open circuit between the connec-
tor terminals.

N8A0358E
 CAB AND CHASSIS ELECTRICAL 8-355
3. Check to see if brake warning light comes on when
starter switch is turned on and then warning light
goes off after the engine running.

Parking Brake Indicator Light

The parking brake indicator light is connected in series
with the parking brake switch installed to the parking
brake lever bracket.
The light comes on when the parking brake lever is
pulled, and goes out when the parking brake lever is ful-
ly released.
Notice:
The parking brake indicator light illuminates to warn the
driver that the parking brake is on. This light does not in-
dicate the condition of the operability of the parking
brake.
Circuit Inspection
N8A0360E
1. Disconnect the parking brake switch connector.
Removal 2. Connect the harness side connector terminal to the
Preparation: ground.
Disconnect the battery ground cable. 3. Check to see if the indicator light comes on with the
1. Instrument Panel Assembly starter switch “ON”.
Refer to “INSTRUMENT PANEL” of section 2. Check the bulb or the harness when the result of
inspection is found abnormal.
2. Brake Fluid Tank (Brake Fluid Switch)
1) Disconnect the switch connector.
2) Remove four fixing nuts.
3) Drain brake fluid in the tank.
4) Disconnect the tubes.
Caution:
Be very careful not to allow the brake fluid to come in
contact with painted surfaces or resin parts surfaces.

N8A0362E

Parking Brake Switch

Inspection
1. Disconnect the parking brake switch connector.
2. Check to see if there is any continuity between the
switch terminal and the body ground with the circuit
tester connected between them.
N8A5423E
When parking brake applied Continuity
Installation When parking brake released No continuity
To install, follow the removal steps in the reverse order,
noting the following points. Repair the parking brake switch or replace it when the
1. Bleed the air from brake and clutch fluid pipe line. result of inspection is found abnormal.
2. Check to see if the brake fluid level in the tank with-
in specified level.
8-356 CAB AND CHASSIS ELECTRICAL
A sensor is equipped to this circuit to convert the impact
into an electrical signal in case of front collision over cer-
tain degree of impact. The electrical signal generated at
this time will be processed in the SRS control unit to
compare with the value stored in the memory.
When the generated signal exceeds the setting value,
SRS control unit sends sufficient current to SRS airbag
for deployment.

N8A0363E

Removal
Preparation:
Disconnect the battery ground cable.
1. Parking Brake Switch
1) Disconnect the connector.
2) Remove the fixing screw.

N8A0364E

Installation
To install, follow the removal steps in the reverse order.

SRS Control System

General Description
SRS airbag supplements the driver’s seat belt protec-
tion by deploying airbag at the top center of the steering
column.
SRS airbag deploys in case of front collision over certain
degree of impact.
This system consists of SRS control unit, driver’s SRS
airbag, SRS coil assembly, exclusive wire harness, and
“SRS” warning lamp in the meter and forms a deploy-
ment circuit.
 CAB AND CHASSIS ELECTRICAL 8-357
Parts Location

A-1 AIR BAG

B-244 SRS COIL

B-51 SRS WARNING LIGHT

(METER)

B-79 DATA LINK CONNECTOR

B-67

B-276 SRS COUPLING

CONNECTOR

B-243 SRS CONTROL UNIT BATTERY

FL-2 FUSIBLE LINK

H-7

FUSE BOX ASM

B-275 EARTH; FRAME RH (FRONT) F-16, F-18 B-1 EARTH; FRAME LH (FRONT)

N9A0066E
8-358 CAB AND CHASSIS ELECTRICAL
Circuit Diagram

OFF
ACC

3.0 W/L 2 ON 3 3.0 B/Y

B-67 B-67
ST

H-7
STARTER SWITCH
3.0 1
W/L
F-18 10A
F-16 10A
SRS
METER
FL-2 40A
KEY SW
8.0B
0.5 AIR BAG
B/Y
2L

18
B-51
0.5 0.5
B/R B/R
P-1 A-1 A-1
AIR BAG

P-2 METER

SRS COIL
B-51
14
P-3
B-244 B-244
0.5
P-4 W/R 1 2

4 1 2
SRS COUPLING 0.5 0.5
B-276 B-276 B-276
CONNECTOR Y Y/B
P-5

FRAME 0.5 0.5 0.5

W/R B/R B/R
SHORTING SHORTING
CONNECTOR CONNECTOR
5 6 18 20 7 8
B-243 B-243 B-243 B-243 B-243 B-243

SRS CONTROL UNIT

B-243 B-243 B-243 B-243

19 15 4 16

0.5 0.5 0.5

GY SB B

7 6 8
SRS COUPLING
B-276 B-276 B-276
CONNECTOR

0.85 0.5 0.5 0.5 0.85

B GY SB B B

13 7
B-79 B-79

DATA LINK CONNECTOR

B-79 B-79
4 5

0.5 0.5
B B

1.25 B
FRAME LH (FRONT) B-1

FRAME LH (FRONT) B-1

FRAME RH (FRONT) B-275

N9A0085E
 CAB AND CHASSIS ELECTRICAL 8-359
Connector List

No. Connector Face No. Connector Face

A-1 B-244

002-045 002-043

A-1 B-244

002-046 002-044

B-1 B-275

000-001 000-020

B-51 B-276 1 2 3

020- 4 5 6 7 8

008-009

3 2 1
B-67 2
4
1
3
B-276 8 7 6 5 4

004-002 008-010

B-67 1 2 P-1
3 4

004-001 000-004

1 2 3 4 5 6 7 8
B-79 P-2
9 10 11 12 13 14 15 16

016-005 000-006

B-243 P-3

021-001 000-006
8-360 CAB AND CHASSIS ELECTRICAL
ates heat, raising a heater blow-off temperature to en-
No. Connector Face hance heating performance.

P-4

000-004

P-5

000-002

H-7

1 2 H-6 2 1

1 2 H-7 2 1

1 2 3 4 4 3 2 1

5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14

N8A5489E

Heater and Air Conditioning

General Description
The air conditioning consists of compressor, evaporator,
condenser, A/C switch, fan switch, etc. When the engine
is rotating, the A/C starts to work with both the A/C and
fan switches “ON”, followed by the engagement of the
magnetic clutch. It stops to work when either the fan
switch or the A/C switch turns “OFF”. In addition to the
switches, the A/C has the function of temporary stop of
its operation by the sensing system in the A/C cycle,
such as:
• sensing abnormal rise of the refrigerant pressure
by means of the pressure switch.
• sensing temperature of the blowing-off air by
means of the thermo switch preventing the evapo-
rator from freezing.
• sensing the coolant temperature by the thermo
switch (available for limited models only).
When fan control knob (fan switch) is put on with temp.
Control lever being in the “FULL HOT” position (FULL
HOT switch on) ceramic heater within heater unit gener-
 For 12 Volt
Parts Location

RELAY BOX ASM

B-234 ECM

H-5, H-6, H-8

FL-1 FUSIBLE LINK

X-24 A/C COMPRESSOR RELAY
X-26 A/C SIGNAL RELAY

B-339 A/C ON
SIGNAL RESISTOR

N8A5605E
CAB AND CHASSIS ELECTRICAL 8-361
 B-18 DIODE For 24 Volt
X-33 DIODE

J-191
8-362 CAB AND CHASSIS ELECTRICAL

FL-1 FUSIBLE LINK

F-26 FUSE
X-27 CONDENSER FAN RELAY

N8A5606E
 RELAY; PRESSURE
RELAY; A/C THERMO
HEATER & A/C F-1 10A SWITCH
FL-1 100A
AIR CON 5 0.85G/W 2 0.85G/W 1 2 0.85G/O
MAIN 5 3L 0.85BR 1 X-10 H-5 J-6 J-6
X-12 X-10
Circuit Diagram
30B/R 2L 8B 8.0W/B 5.0W/B 3W/B
H-6 X-12
2 1
P-1 2 4
2 X-10 X-10
RELAY; CHARGE (1) X-12 X-12 FL-25 30A
P-2 4
0.5W/R HEATER 0.85G/O

1.25LG/B
For 12 Volt - Except 4JH1

4 7
B-18 H-14
P-5
DIODE

0.85BR
0.5P/G
FRAME
B-18
3
1.25L

0.5B
0.5G/O (69)
0.85G/O (55)

2L
0.5LG
1
3 1 E-5
2 1 2 B-15 B-15
B-14 B-39 B-39

BLOWER
MOTOR
B-14
MAGNETIC CLUTCH
1 A/C SWITCH B-39 B-15 (COMPRESSOR)
3 2

2L/B
0.5G/Y

ELECTRONIC THERMOSTAT
0.5G/O

0.5G/Y
B-13
0.5G/O

2L/B
4 1 1
B-42

2B
3 J-57
2
B-42
(EXCEPT 4JB1-T/C)

1.25L/O 3
B-13 B-42
4 6
(4JB1-T/C ENGINE ONLY)

VSV FICD
VSV FICD

0.85L/Y
B-13 B-42
2 5 2 J-58
2 1
2.0B
B-13 B-42
3 4 1

BLOWER RESISTOR
2B 2B
B-42
1
0.5B
0.5B

FAN SWITCH
3B 3B
HEADLIGHT BRACKET (LH) B-7
5B
FRAME-LH (FRONT) B-1
2B
FRAME-LH (CENTER) J-9

N8A5594E
CAB AND CHASSIS ELECTRICAL 8-363
 RELAY;
RELAY; A/C THERMO
HEATER & A/C F-1 10A
FL-1 100A
AIR CON 5 0.85G/W 2 0.85G/W
MAIN 5 3L 0.85BR 1 X-10 H-5
30B/R 2L 8B 8.0W/B 5.0W/B 3W/B X-12 X-10
H-6 X-12
P-3 2 1
P-1 2 4 1
2 X-10 X-10
RELAY; CHARGE (1) X-12 X-12 FL-25 30A J-6 RELAY;
P-4 P-2 4
0.5W/R HEATER PRESSURE GLOW (4)
SWITCH

1.25LG/B
For 12 Volt - 4JH1 Engine

4 J-6 0.5L/R
B-18 2

0.5L/R
P-5
DIODE 0.85G/O

0.85BR
0.5P/G
FRAME

0.85G/O
B-18
2 3 2 3
3
X-24 X-24 X-26 X-26
1.25L

0.5B
2L
0.5LG
RELAY;
RELAY;

3 1
A/C SIGNAL

X-24 X-24 X-26 X-26

2 1 2 B-15 B-15
A/C COMPRESSOR

1 5 1 5
B-14 B-39 B-39

BLOWER
MOTOR
8-364 CAB AND CHASSIS ELECTRICAL

B-14
0.5G/Y

0.5W/G

0.85G/Y

1 A/C SWITCH B-39 B-15

3 2

2L/B
1 15 16
0.5G/Y

ELECTRONIC THERMOSTAT
H-14 H-8 H-8
1

0.5G/Y
B-13
0.5G/Y

0.5W/G

2L/B
0.85G/Y

4 41 23
B-42 B-234 B-234

2B
3
2
B-42
3 ECM
1.25L/O
B-13 B-42 1
4 6
E-5
0.85L/Y
B-13 B-42
2 5 2

2.0B
B-13 B-42
3 4 1

BLOWER RESISTOR MAGNETIC

0.5B

2B 2B
B-42 CLUTCH
0.5G/Y

1
(COMPRESSOR)

3B 3B FAN SWITCH
HEADLIGHT BRACKET (LH) B-7
A/C ON
SIGNAL RESISTOR
5B
FRAME-LH (FRONT) B-1 0.85B 0.5B 2 1
B-339 B-339

2B
FRAME-LH (CENTER) J-9

N8A5597E
 PRESSURE
FL-1 100A OR 120A F-1 15A SWITCH
2L AIR CON, HEATER 0.85G/W 2 0.85G/W 1 2 0.85G/O 0.5G/O
30B/R 8B MAIN 0.85BR 0.85BR X-10 5 H-5 J-6 J-6
X-10
1
P-1
2 4
P-2 X-10 X-10
0.5G/O

8W/B
2

ECM
RELAY;
H-6 A/C THERMO

0.5LG/B

0.85L
0.85BR

3L
0.85G/O
3 1

5W/B
For 24 Volt - Except 4HK1 Engine

P-3 J-23 J-23

2
0.5G/O

P-4 RELAY; 2 3
B-14
HEATER & A/C B-18 X-33

0.5P/G
1
5

3W/B
6
1 X-12 J-41
X-12 H-14
B-14 J-23
X-12 X-12
2 4 1 3

BLOWER MOTOR
(4HE1 ENGINE ONLY)

(FOR NPR66,

NQR71 ENG.)
B-18 X-33 X-33
0.5L/G

NQR66, NPR71,
1 10 11 3
P-5
VSV FICD

FRAME J-41
(W/O 4HE1 ENGINE)

(FOR NKR66, NKR71 ENG.)

0.5W/R
2
0.85G/O

RELAY; CHARGE (1)

0.5LG
0.5LG
1 2 3 1
1
B-39 B-39 B-15 B-15
E-5
VSV

ELECTRONIC
THERMOSTAT

B-15
A/C SW B-39
2 MAGNETIC
3 CLUTCH
(COMPRESSOR)

0.5G/Y
0.5G/Y

0.5B
0.85L/B
0.5G/Y
1 3 4
B-13 B-42
0.85L/B 2
B-42
4 6 3
B-13 B-42
0.5L/O
0.5B

2 5
B-13 B-42
0.5L/Y 2

2B
3 4
B-13 B-42
0.5L/W 1 OFF
BLOWER RESISTOR

3B 2B 1
HEADLIGHT BRACKET (LH) B-7 B-42
0.85B
B-1
5B
FRAME-LH (FRONT)
FAN SW
J-9
2B
FRAME-LH (CENTER)

N8A5595E
CAB AND CHASSIS ELECTRICAL 8-365
 PRESSURE
FL-1 100A OR 120A F-1 15A SWITCH
2L AIR CON, HEATER 0.85G/W 2 0.85G/W 1 2 0.85G/O 0.5G/O
30B/R 8B MAIN 8W/B 0.85BR 0.85BR X-10 5 H-5 J-6 J-6 J-191 ECM
X-10 34
1
P-1
2 4 0.85G/W
X-10 X-10
For 24 Volt - 4HK1 Engine

P-2 J-6 J-6

5W/B
4 3
2
RELAY;
H-6 A/C THERMO

0.5LG/B

0.85L
0.85BR
0.5G/Y

3L
0.85G/O
F-26 15A

5W/B
P-3
2 COND FAN
P-4 RELAY; 3 RELAY; 2B/L 0.85L/Y
B-14
HEATER & A/C X-33 GLOW

0.5P/G
5 DIODE 1 3

3W/B
9
1 X-12 BOX
X-12 X-27 X-27 H-105
B-14
X-12 X-12
2 4 1

BLOWER MOTOR
X-33 X-33
10 11 RELAY;
P-5
X-27 X-27 CONDENSER FAN
FRAME 2 5

0.5W/R
8-366 CAB AND CHASSIS ELECTRICAL

0.75G/O

0.5LG
0.5B

RELAY; CHARGE (1) 0.85L

0.5LG
1 2 3 1
1
B-39 B-39 B-15 B-15 1
E-5
ELECTRONIC
THERMOSTAT

B-15
A/C SW B-39
2 MAGNETIC
3 CLUTCH
2
CONDENSER FAN

(COMPRESSOR)

0.5G/Y
0.5G/Y
0.85B

0.5B
0.85L/B
0.5G/Y
1 3 4
B-13 B-42
0.85L/B 2
B-42
4 6 3
B-13 B-42
0.5L/O

2 5
B-13 B-42
0.5L/Y 2

2B
3 4
B-13 B-42
0.5L/W 1 OFF
BLOWER RESISTOR

3B 2B 1
HEADLIGHT BRACKET (LH) B-7 B-42
0.85B
B-1
5B
FRAME-LH (FRONT)
FAN SW
J-9
2B
FRAME-LH (CENTER)

N8A5598E
 CAB AND CHASSIS ELECTRICAL 8-367
Connector List No. Connector Face
For 12 Volt

No. Connector Face

B-339 1 2
3 4

004-010
B-1

000-001
1

X-10 2 3 4

005-00
B-7

000-012
1

X-12 2 3 4

005-00
J-9

000-001

X-24

005-006
B-13 1 2
3 4

004-010

X-26

005-006
B-14 1
2

002-009

B-39 1
2 3

003-019
B-15
1 2 3

003-009

B-42 1 2 3
4 5 6

006-001
B-18 1 2 3 4

004-004

E-5
1

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
5 4
001-013
B-234 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62
3
2 1
63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81

121-001
8-368 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

E-5 1 P-2

001-014 000-004

J-57 P-4
1

001-009 000-004

J-58 P-3
1

001-009 000-006

H-14 1 2 3 4
5 6 7 8 9
P-5
(4JH1) 10 11 12 13 14

15 16

016-003 000-007

4 3 2 1 H-14
H-14 9 8 7 6 5 1 2 3 4
14 13 12 11 10 (4JB1/ 5 6 7 8
(4JH1)
4JG2)
9 10 11 12
16 15 13 14 15 16

016-004 016-001

H-14 4 3 2 1

J-6 1 2 (4JB1/ 8 7 6 5
12 11 10 9
3 4 4JG2) 16 15 14 13

004-011 016-002

J-41 1 2

002-015

P-1

000-003
 CAB AND CHASSIS ELECTRICAL 8-369
H-5 No. Connector Face

J-9

000-001

1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 11 12 12 11 10 9 8 7
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 24 23 22 21 20 19
25
31
26
32
27
33 34 35 36 37
28
38
29
39
30
40
30
40
29
39
28
38 37 36 35 34
27
33
26
32
25
31 B-13 1 2
3 4

004-010

B-14 1
N8A5488E 2

H-6, H-8 002-009

B-15
1 2 3

1 2 H-6 2 1 003-009

1 2 H-7 2 1

1 2 3 4 4 3 2 1
B-18 1 2 3 4
5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14 004-004

J-23 1 2 3 4
N8A5489E

For 24 Volt 004-004

No. Connector Face

X-10 2 3 4

5
B-1
005-00

000-001

X-12 2 3 4

5
B-7
005-00

000-012
8-370 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

X-27 J-6 1 2
3 4

005-006 004-011

X-33 1 2 3 4 5 6 J-41 1 2
7 8 9 10 11 12 13 14

014-002 002-015

B-39 1 P-191
2 3

003-019 081-001

B-42 1 2 3
P-1
4 5 6

006-001 000-004

E-5 P-4
1

001-013 000-004

E-5 1 P-2

001-014 000-006

H-14 1 2 3 4

(Except 5 6
10 11 12 13 14
7 8 9
P-3
4HK1) 15 16

016-003 000-006

H-14 4 3 2 1
9 8 7 6 5
(Except 14 13 12 11 10 P-5
4HK1) 16 15

016-004 000-002
 CAB AND CHASSIS ELECTRICAL 8-371

No. Connector Face H-5

H-13 1 2 3

003-001

1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 11 12 12 11 10 9 8 7
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 24 23 22 21 20 19

H-13 3 2 1
25
31
26
32
27
33 34 35 36 37
28
38
29
39
30
40
30
40
29
39
28
38 37 36 35 34
27
33
26
32
25
31

003-002

H-14 1 2 3 4
5 6 7 8
(4HK1) 9 10 11 12 N8A5488E
13 14 15 16

016-001 H-6

H-14 4
8
3
7
2
6
1
5
(4HK1) 12 11 10 9
16 15 14 13

016-002 1 2 H-6 2 1

1 2 H-7 2 1

1 2 3 4
H-105 5 6 7 8
1 2 3 4 4 3 2 1

9 10 11 12 5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
012-001 14 15 16 17 18 18 17 16 15 14

4 3 2 1
H-105 8 7 6 5
12 11 10 9 N8A5489E

012-002 Fuel Heater and Rear Heater

General Description
The circuit consists of fuel heater, rear heater, rear heat-
er switch and the exhaust brake relay.
The fuel heater circuit is always in “ON” position when
the generator is charging and its temperature is auto-
matically controlled by the circuit breaker built in the fuel
heater.
8-372 CAB AND CHASSIS ELECTRICAL
Parts Location

N8A5434E
 CAB AND CHASSIS ELECTRICAL 8-373
Circuit Diagram
Except 4JH1 Engine

FL-1 100A or 120A RELAY; EXHAUST F-2 15A

BRAKE
MAIN EXH. BRAKE,
8W (12V) 5W 2 8W/B (12V) 3W/B 1 FUEL HEATER
H-6 X-8 5 3B/R 6
5W (24V) 5W/B (24V) X-8 H-5
0.5B/R
8B

0.85W/R 0.5W/R 2 4
X-8 X-8
2L

0.5B/R
RELAY; CHARGE(5)

F-3 15A
REAR HEATER

0.5B/R
30B/R

P-1 6 1
H-3 J-52
P-2

FUEL HEATER

0.5B/R
P-3
P-4 0.5B
J-52
1
2
(24 V MODEL) H-25

0.85B/R
P-5
FRAME

3
N-8
REAR HEATER

0.5B

N-8 N-8
2 1
0.85L/W

0.85L/R

H-25 H-25
2 3
0.85L/W

0.85L/R
2B

H-3 H-3
2 5
0.5L/W

0.5L/R

1 4
B-59 B-59
2B

LO HI

OFF

B-59
REAR HEATER
2
SW
3B 0.5B

3B
HEADLIGHT BRACKET (LH) B-7

B-1
5B
FRAME-LH(FRONT)

FRAME-LH (CENER) J-9

N8A5435E
8-374 CAB AND CHASSIS ELECTRICAL
4JH1 Engine

FL-1 100A RELAY; HEATER F-2 15A

MAIN
8W 5W 8W/B 3W/B 1
2B/R FUEL HEATER
2
H-6 X-13 5 6
X-13 H-5
0.5B/R
8B

0.85W/R 0.5W/R 2 4
X-13 X-13
2L

RELAY; CHARGE(5)

F-3 15A

0.5B/R
REAR HEATER
30B/R

0.5B/R
P-3 P-1 6 1
P-4 P-2 H-3 J-52

0.5B/R
0.3B
FUEL HEATER

P-5
1
FRAME
H-25 J-52
2

0.85B/R
3
N-8
REAR HEATER

0.5B

N-8 N-8
2 1
0.85L/W

0.85L/R

H-25 H-25
2 3
0.85L/W

0.85L/R
2B

H-3 H-3
2 5
0.5L/W

0.5L/R

1 4
B-59 B-59
2B

LO HI

OFF

B-59
REAR HEATER
2
SW
3B 0.5B

B-7
3B
HEADLIGHT BRACKET (LH)
B-1
5B
FRAME-LH(FRONT)

FRAME-LH (CENTER) J-9

N8A0396E
 CAB AND CHASSIS ELECTRICAL 8-375
Connector List No. Connector Face

No. Connector Face

J-52 2 1

X-13
002-034

005-006

N-8 1 2 3

X-8
003-022

005-006

N-8 3 2 1

B-59
1 2
003-023
3 4

004-015

P-1
(12 V)
1 2 3
H-3 4 5 6
000-003

006-014

P-2

H-3 3 2 1
6 5 4 000-004

006-015

P-1
(24 V)
H-25 1
2 3 000-004

003-020

P-4

H-25 1
3 2 000-004

003-021

P-2
(24 V)
J-52 1 2
000-006

002-033
8-376 CAB AND CHASSIS ELECTRICAL

No. Connector Face H-6

P-3

000-006 1 2 H-6 2 1

1 2 H-7 2 1

P-5 1 2 3 4 4 3 2 1
(12 V) 5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
000-007 14 15 16 17 18 18 17 16 15 14

P-5
(24 V) N8A5489E

000-002 Fuel Heater

H-5

1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 11 12 12 11 10 9 8 7
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 24 23 22 21 20 19
25 26 27 28 29 30 30 29 28 27 26 25
31 32 33 34 35 36 37 38 39 40 40 39 38 37 36 35 34 33 32 31

N8A0371E

N8A5488E
 CAB AND CHASSIS ELECTRICAL 8-377
Characteristic of fuel heater

N8A5439E

N8A5440E
4WD Transfer (Vacuum Control)
Rear Heater Switch
General Description
Inspection
The circuit consists of the starter switch, 4WD switch,
Check the continuity between the connector terminals 4WD detect switch, 4L switch, vacuum switching valve,
while operating the switch. 4WD indicator light, neutral switch and the relay.
Replace the switch when the result of inspection is When the 4WD switch is turned on to drive in the 4WD
found abnormal. mode, the vacuum switching valve for the transfer con-
trol is activated through the 4WD relay, and the transfer
shift rod connected to the vacuum actuator is shifted to
the 4WD side to turn on the 4WD detect switch. At the
same time, the indicator light in the meter lights on to tell
that the mode is transferred to 4WD mode.
However, when running in the normal mode (2WD), the
4WD switch is not operated. Accordingly, no current
flows through the 4WD vacuum switching valve for the
transfer control, with the 4WD detect switch left in the
“OFF” condition (2WD mode).

N8A5438E

Rear Heater Motor

Inspection
Disconnect the rear heater connector.
Connect the battery positive terminal to the NO.3 termi-
nal of the rear heater motor side connector and negative
to the NO.2. Check to see if rear heater motor operates
low-speed correctly.
Connect the battery positive terminal to the NO.3 termi-
nal of the rear heater motor side connector and negative
to the NO.1. Check to see if rear heater motor operates
high-speed correctly.
Replace the rear heater motor when the result of inspec-
tion is found abnormal.
8-378 CAB AND CHASSIS ELECTRICAL
Parts Location

N8A5441E
 CAB AND CHASSIS ELECTRICAL 8-379
Circuit Diagram

FL-1 100A
2L MAIN
FUSE BLOCK STARTER SWITCH
OFF
FL-2 40A
ACC
KEY SW
1 2 B
H-7 B-67 ON 3
3W/B 3W/L B-67
ST

3B/Y
P-1
P-2

F-16 10A
METER

P-3
P-4

RELAY; TAIL (5) 0.5B/Y

0.5LG/R

0.5B/Y
0.5B/Y

0.5B/Y
P-5

4WD INDICATOR LIGHT

FRAME
8
B-51
5 8
22
B-93 B-93
H-5

(METER)
4WD SWITCH
2WD

4WD

B-51
9
B-93 B-93 B-93

0.3GR/G
6 7 3
0.5GR/B

0.5GR/R 10

0.5B/Y
H-8
9
H-8

0.5GR/G
15
H-8
0.5GR/B

0.5GR/R

1 2 4 5

RELAY; 4WD
VSV:1 TRANSFER

VSV:2 TRANSFER
CONTROL (2WD)

CONTROL (4WD)

J-42 J-42 X-24 X-24

J-42 J-42 X-24 X-24

3 4 2 3
0.3B

0.85B/R

0.5B/R
4WD DETECTIVE SWITCH

0.85B

1
J-43
0.5B

4WD=OFF )
(2WD=ON

J-44
1
0.85B

3B 3B
HEADLIGHT BRACKET (LH) B-7
2B 2B 2B
FRAME-LH (CENTER) J-9

N8A5442E
8-380 CAB AND CHASSIS ELECTRICAL
Connector List No. Connector Face

No. Connector Face

J-43 1

B-51 1 2 3 4 5 6 7 8 9 1011121314
001-003

014-001

J-44 1

B-67 1 2
3 4 001-002

004-001

J-44 1

B-67 2 1
4 3 001-003

004-002

P-1

B-93 1 2 3 4
5 6 7 8 000-004

008-005

P-4

X-24
000-004

005-006

P-2

J-42 1 2
000-006
3 4

004-012

P-3
2 1
J-42
4 3 000-006

004-013

P-5

J-43 1
000-002

001-002
 CAB AND CHASSIS ELECTRICAL 8-381
H-5

1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 11 12 12 11 10 9 8 7
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 24 23 22 21 20 19
25 26 27 28 29 30 30 29 28 27 26 25
31 32 33 34 35 36 37 38 39 40 40 39 38 37 36 35 34 33 32 31

N8A5444E

N8A5488E
Vacuum Switching Valve: Transfer Control (for
H-7 2WD)
Inspection
Connect the vacuum switching valve connector terminal
No. 1 to the battery (+) terminal and terminal No. 3 to the
(−) terminal and then check the continuity among each
port.

1 2 H-6 2 1

1 2 H-7 2 1

1 2 3 4 4 3 2 1

5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14

N8A5489E

Starter Switch
Refer to “START AND CHARGING” in this section.

Neutral Switch
Refer to “START AND CHARGING” in this section.

4WD Indicator Light

Refer to “METER AND WARNING/INDICATOR LIGHT”
in this section.

4WD Switch
Inspection
Check the continuity between the connector terminals
N8A5445E
while operating the switch.
Replace the switch when the result of inspection is
found abnormal.
8-382 CAB AND CHASSIS ELECTRICAL
Vacuum Switching Valve: Transfer Control (for
4WD)
Inspection
Connect the vacuum switching valve connector terminal
No. 2 to the battery (+) terminal and terminal No. 4 to the
(−) terminal and then check the continuity among each
port.

N8A5447E

Inspection
1. Shift the transfer lever to the 4H (4L) position.
2. Check to see if there is continuity between the
4WD switch connectors.
Replace the switch when the result of the inspec-
tion is found abnormal.

N8A5446E

4WD Detective Switch

Inspection of The 4WD Warning Light Circuit
1. Disconnect the 4WD switch connectors.
2. Connect the harness side connector terminals.
3. Check to see if the indicator light comes on with the
starter switch “ON”.
N8A5448E
Check the bulb or harness when the result of in-
spection is found abnormal.
 CAB AND CHASSIS ELECTRICAL 8-383
Keyless Entry System
Keyless Entry Control Unit

Connector for Antenna

N8A5449E

The unit receives a LOCK or UNLOCK signal from the

remote control unit. This signal is conveyed to the driv-
er’s door lock switch and the door lock actuator(s) on the
other door(s).
1. Remote control code registration
• A single code is registered at a time.
• Up to 3 codes can be registered and stored.
• If a 4th code is registered, the oldest existing
code is automatically erased (overwritten).
The remote control unit is built-in to the ignition key.

N8A5452E

Lock button

Unlock button

N8A5450E
8-384 CAB AND CHASSIS ELECTRICAL
2. Timer lock
The doors will automatically relock 30 seconds af-
ter being unlocked with the remote control unit.
A second or more may elapse between lock and
unlock operation when the LOCK and UNLOCK
buttons are pressed in quick succession.

Door switch

Push (OFF)

Automatic
return (ON)

N8A5451E

Diagnostic Functions
When the unit is in diagnostic mode, the door locks operate as specified below to indicate normal operation or a spe-
cific problem.

N8A5453E
 CAB AND CHASSIS ELECTRICAL 8-385
Diagnostic Mode

N8A5454E

Door Lock Operational Test

1. Check for continuity between the 1-B-219 connec-
tor and the 2-B-219 connector (harness side).
2. Check the remaining connectors to see that they
have battery voltage.
1 2 3 4
3. If the above conditions are normal but the lock B-219 5 6 7 8 9 10
does not operate, check the door lock switch (driv-
Harness side
er’s door).
Refer to the item below.
Connector
Position
1(B/R) 2(G/R)
+ - Unlock
- + Lock

N8A5455E
8-386 CAB AND CHASSIS ELECTRICAL
Door Lock Switch Inspection Control Unit Installation
Check for continuity between the connectors. If there is Follow the removal steps in reverse order to install the
no continuity, the switch must be replaced. control unit.

1 2 3
D-4
4 5 6

Door lock switch side

Connector
Position number 4 5 6

Lock

Unlock Bracket

N8A5456E N8A5458E

Control Unit Removal

1. Remove the meter cluster. Refer to the item “Meter
assembly” in this Manual.
2. Release the pawl to remove the brackets holding
the tail lamp and stop lamp warning light relays.
3. Remove the connectors.
4. Remove the distributor from its bracket.
5. Loosen the fixing screws.
6. Remove the control unit from the bracket.

Connector

Distributor Control unit for

keyless entry system

N8A5457E
 CAB AND CHASSIS ELECTRICAL 8-387
Circuit Diagram

ACTUATOR FOR RH ACTUATOR FOR LH

REAR DOOR LOCK REAR DOOR LOCK
(DUAL CAB TYPE)
0.85BR/Y 0.5BR/Y

0.85BR/R 0.5BR/R

(DUAL CAB TYPE)

0.85BR/Y 0.5BR/Y

0.85BR/R 0.5BR/R

0.85BR/Y 0.5BR/Y

ACTUATOR
0.85BR/R 0.5BR/R

(AS)
0.85B

0.3G/B
0.5B
0.3R/G
CIGAR LIGHTER

ACTUATOR ASSY
0.5G/R

RELAY:
DOOR LOCK 0.5G/Y

(DR)
1

0.5B
5

0.5R/Y 0.5B SW:DOOR (AS SIDE)

3

7
CIGAR LIGHTER

0.5GR/R

0.5GR/R
6
3R/Y
AUDIO(IG),

ANT
F-15

SW:DOOR (DR SIDE)

15A
0.85R

0.5GR/B 0.5GR/R
ON
ACC

ST

ROOM LAMP
DOOR
OFF

ON
KEY SW

0.5R

OFF

SW:
D

ROOM LAMP
RADIO

0.5Y 0.5GR 0.3B

0.85R
DOOR LOCK
AUDIO(B),

0.3B
1

3
0.5LG/R
F-4

15A

0.5R
KEY SW

MAIN
100A
FL-1
FL-2

50A

RELAY:

BATTERY
TAIL

FTX

2L

N8A5459E
 RELAY BOX ASM (NO.1) X-25 EXHAUST BRAKE CONTOROL RELAY
X-5 ABS INDICATOR RELAY X-28 EXHAUST BRAKE CUT RELAY
X-8 EXHAUST BRAKE RELAY (24V) J-23 DIODE
FL-1,FL-2,FL-9 FUSIBLE LINK
J-149 R/LH
Parts Location
FUSE BOX ASM
SENSOR (24V)
B-51 ABS WARNING LIGHT (METER) F-2,F-5,F-16
J-31 EXH. BRAKE J-148 R/RH
MAGNETIC VALVE SENSOR (24V) J-78 R/RH,R/LH R-6
B-52 EXH. BRAKE STARTER SW H-13 SENSOR (12V) STOPLIGHT (RH)
IND. LAMP (METER)
J-177
ABS EHCU
B-66 STOPLIGHT SW R-1
(BRAKE SW) STOPLIGHT (LH)

B-75 ACCEL SW

(24V)
8-388 CAB AND CHASSIS ELECTRICAL

B-69 EXH. BRAKE SW

(12V)
ABS (Anti-lock Brake System, Without ASR)

B-79 DATA LINK H-17

CONNECTOR H-14 H-16
H-15
B-89 CLUTCH SW

B-67 IGNITION SW "A"

P-1~P-4
P-5 BATTERY
H-5~H-8
J-9 EARTH ; FRAME

J-74 F/RH SENSOR

B-1 EARTH ; FRAME (FR)

J-75 F/LH SENSOR
B-7 EARTH ; HEADLIGHT B/T
B-233,B-234 ECM

N8A5607E
 CAB AND CHASSIS ELECTRICAL 8-389
Circuit Diagram
For 12 Volt (4JH1 Engine)

F-5
STOP LIGHT SW ; STOP LIGHT
3W/B 10A 0.5G/Y 1 4 0.5G
FL-9
B-66 B-66 A
ABS
60A 3R
B

FL-1
MAIN
8B 100A 8W/B 2 8W/B 3W/B
H-6

FL-2
P-3 P-1
KEY SW
BATTERY
50A
P-4 P-2
3W/L

P-5
1
KEY SW
H-7
OFF

ACC
3W/L 2 B
B-67 F-16
ON 3 3B/Y
B-67 METER
ST 10A

METER
0.5B/Y

ABS
0.5B/Y 8 7
B-51 B-51
22
C
H-5
0.5B/Y
D

0.3W/V
0.5W
4 5
X-5 X-5

RELAY ;
ABS IND.

X-5 X-5

0.5B/Y 1 3

3B 2B 0.5B
HEADLIGHT BRACKET (LH) B-7

0.85B
FRAME LH (FRONT) B-1 E
3B
FRAME-LH (CENTER) J-9 F
3B
G
2B
H

N8A5590E
8-390 CAB AND CHASSIS ELECTRICAL

ECM
0.5G
(30) B-234
0.5G 11 0.5G 2 0.5G 0.5G 2 0.5G
A H-5 H-14 H-16
2 2
R-1 R-6
3R
B
STOP STOP
LIGHT LIGHT
(LH) (RH)

R-1 R-6
0.5G 6 6

1.25B 7
H-16

1.25B
EHCU ; ABS

16 H-14
J-177 STOP LAMP 22 0.5L 2
RL 12V J-177 J-78 SPEED 7
15 3R 24 SENSOR
H-14 J-177 MOTOR +B 34 0.5Y 1 (RR,LH)
RL SIG J-177 J-78
16 3R 2
H-14 J-177 VALVE +B
32 0.5V 1 0.5V 1
7 3B 23 FL SIG J-177 H-15 J-75 SPEED
H-15 J-177 MOTOR GND SENSOR
33 0.5R/B 2 0.5R/B 2 (FRT,LH)
8 3B 1 FL GRD J-177 H-15 J-75
H-15 J-177 VALVE GND

ECM 0.5LG/W 40 0.5LG/W 10 0.5LG 8 EXH.B/CUT

H-5 H-14 J-177
B-234 (32) OUT
10 0.5P 5 0.5P 1
ECM FR SIG J-177 H-15 J-74
0.5LG/B 36 0.5LG/B 11 0.5LG/B 7 EXH.B/CUT SPEED
H-5 H-14 J-177
B-234 (62) IN SENSOR
11 0.5L 6 0.5L 2 (FRT,RH)
FR GRD J-177 H-15 J-74

0.3W/V 35 0.3W/V 12 0.3W/V 6

C H-5 H-14 J-177 IND.

0.5B/Y 9 0.5B/Y 3 21 0.5R 4

D H-14 J-177 IG RR 12V J-177 J-78
SPEED
SENSOR
15 12 0.5W 3 (RR,RH)
J-177 MODE1 RR SIG J-177 J-78

14 29 0.3W/B 4 0.3W/B 26
J-177 MODE2 J1850 J-177 H-15 H-5

17 4 0.3W/G 3 0.3W/G 27
J-177 MODE3 FRASH J-177 H-15 H-5

0.3W/G
DATA LINK
B-79
CONNECTOR
16 15 14 13 12 11 10 9
0.5B/W
0.5B/G

0.5B/R
0.5B/Y

8 7 6 5 4 3 2 1

0.3W/B
4

35 0.5Y
H-17

H-17

H-17

H-17

B-234
ECM
45 0.5L
B-234
VEHICLE TYPE CONNECTOR
1.25B
H-17

H-17

H-17

H-17

0.5B
0.5B

NKR77-3 (FLAT LOW)

H-17

H-17

H-17

H-17

EXCEPT NKR77-3
(EXCEPT FLAT LOW)
0.85B
E
3B
F
3B
G
2B
H
N8A5591E
 CAB AND CHASSIS ELECTRICAL 8-391
For 24 Volt - 4HE1 Engine (Single Cab Model)

F-5
STOP LIGHT SW ; STOP LIGHT
3W/B 10A 0.5G/Y 1 2 0.5G
FL-9
B-66 B-66 A
ABS
40A 3R
B
RELAY ;
FL-1
EXH.BRAKE F-2
MAIN
EXH.BRAKE
100A
or 1 3B/R 10A 0.5LG/W
X-8 0.5LG
8B 120A 8W/B 2 5W/B 3W/B 2 C
H-6 X-8
H-8
RELAY; 0.5W/R 3 5 8
X-8 X-8

0.5LG/W
CHARGE

FL-2 4 2 5
P-1
KEY SW X-28 X-28 X-28
0.5B
BATTERY
P-2 40A
RELAY ;
EXH. B/CUT
(ABS)
0.5B
3W/L

X-28 X-28
P-3
1 3
BATTERY
P-4 1

0.5B
H-7 KEY SW
0.5LG/B

OFF
P-5
ACC
3W/L 2 B 0.5B/Y
B-67 3B/Y
ON 3 F-16
B-67
METER 0.5LG/B
ST
10A
D
ABS
0.5B/Y

0.5B/Y 8 7
B-51 B-51
22 10 E
H-5 H-8 METER
0.5B/Y
F
0.5B/Y

0.3W/V
0.5LG/B

0.5W
0.5B/Y

H-14 4 5
0.5B
5
0.5P

X-5 X-5
5
2
B-69
E-11 RELAY ;
ABS IND.
SW ; NEUTRAL
SW ; EXH.BRAKE
(Neutral=ON) X-5 X-5
1 3
0.5B

E-11
IND. LAMP ; 0.5B
B-69
1 EXH. BRAKE
0.5B

0.5LG/R
2
0.5LG/R 1 10 G
B-51 B-52
H-14 H-5
0.5LG/R

10 38
0.5B/G

3 1
A/C 0.5G/O
X-25 X-25 COMPRESSOR H

RELAY ;
0.85B

EXH. BRAKE
CONTROL

X-25 X-25
5 4
0.5LG/B

0.5LG/R
0.5B

17
H-8 SW ; CLUTCH
0.5LG/B 1 2 0.5LG/R
B-89 B-89

0.5B 0.5B
2B

3B
HEADLIGHT BRACKET (LH) B-7
0.5B

0.85B
FRAME-LH (FRONT) B-1
1.25B
I
3B
J
3B
K
2B
FRAME-LH (CENTER) J-9 L
2B 2B 2B
M

N8A5592E
8-392 CAB AND CHASSIS ELECTRICAL

0.5G 11 2 0.5G 2 0.5G

A H-5 H-14 H-16
2 2
R-1 R-6
3R
B
STOP STOP
LIGHT LIGHT
(LH) (RH)

0.5G
0.5LG 10
C H-14 R-1 R-6
6 6
EHCU ; ABS
1.25B 7
16 H-16
J-177 STOP LAMP 22 0.5L 1
RL 12V J-177 J-149
SPEED

1.25B
3R 15 24 SENSOR
H-14 J-177 MOTOR +B 34 0.5Y 2 (RR,LH)
RL SIG J-177 J-149
3R 16 2 H-14
H-14 J-177 VALVE +B
7
32 0.5V 1 0.5V 1
7 23 FL SIG J-177 H-15 J-75 SPEED
H-15 J-177 MOTOR GND
SENSOR
33 0.5R/B 2 0.5R/B 2 (FRT,LH)
8 1 FL GRD J-177 H-15 J-75
H-15 J-177 VALVE GND

0.5LG 8 EXH.B/CUT
J-177
OUT
10 0.5P 5 0.5P 1
FR SIG J-177 H-15 J-74
0.5LG/B 11 0.5LG/B 7 SPEED
EXH.B/CUT
D H-14 J-177
IN
SENSOR
11 0.5L 6 0.5L 2 (FRT,RH)
FR GRD J-177 H-15 J-74
3B

0.3W/V 6 12 0.3W/V 6
E H-5 H-14 J-177 IND.

0.5B/Y 9 3 21 0.5R 1
F H-14 J-177 IG RR 12V J-177 J-148 SPEED
SENSOR
0.5B/G(NQR) 15 12 0.5W 2 (RR,RH)
J-177 MODE1 RR SIG J-177 J-148

0.5B/R(NQR) 14 29 0.3W/B 4 0.3W/B 24

J-177 MODE2 J1850 J-177 H-15 H-5

4 3 1 2 0.5B/W(NQR) 17 4 0.3W/G 3 0.3W/G 30

J-177 MODE3 FRASH J-177 H-15 H-5
NQR
H-17

H-17

H-17

H-17

0.3W/G
VEHICLE TYPE CONNECTOR
H-17

H-17

H-17

H-17

FOR TURKEY / GCC

(4-WHEEL DRUM BRAKE MODEL)
H-17

H-17

H-17

H-17

FOR OTHER COUNTRIES ECM DATA LINK

B-79
CONNECTOR
21 16 15 14 13 12 11 10 9
B-233 QWS
SW ; ACCEL 8 7 6 5 4 3 2 1
0.5LG/W 2 1 0.5LG 0.5LG 14 14 0.3Y
G B-75 B-75 B-233 EXH.BRAKE CHECKER B-234

0.5L/W 15 29 0.3L 0.3W/B

DIODE ; FICD B-234 FICD DIAG B-234
1 3 0.5L/W 37
H J-23 J-23 H-5 32
J-23 H-5

2
0.5L/G

0.5LG
2 6
H-13 H-13
0.5LG
0.5L/G

0.5B
0.5B

4 1 1
J-41 J-40 J-31
1.25B

VSV ;
FICD

J-41 J-40 VSV ; INT. J-31 MAG.VALVE ;

2 2 THROTTLE 2 EXH.BRAKE
0.5B

0.5B
12
0.5B

H-13
0.5B

1.25B 1.25B
I
3B
J
3B
K
0.5B
L
2B
M

N8A5593E
 CAB AND CHASSIS ELECTRICAL 8-393
For 24 Volt - 4HE1 Engine (Crew Cab Model)

F-5
STOP LIGHT SW ; STOP LIGHT
3W/B 10A 0.5G/Y 1 2 0.5G
FL-9
B-66 B-66 A
ABS
40A 3R
B
RELAY ;
FL-1
EXH.BRAKE F-2
MAIN
EXH.BRAKE
100A
or 1 3B/R 10A 0.5LG/W
X-8 0.5LG
8B 120A 8W/B 2 5W/B 3W/B 2 C
H-6 X-8
H-8
RELAY; 0.5W/R 3 5 8
X-8 X-8

0.5LG/W
CHARGE

FL-2 4 2 5
P-1
KEY SW X-28 X-28 X-28
0.5B
BATTERY
P-2 40A
RELAY ;
EXH. B/CUT
(ABS)
0.5B
3W/L

X-28 X-28
P-3
1 3
BATTERY
P-4 1

0.5B
H-7 KEY SW
0.5LG/B

OFF
P-5
ACC
3W/L 2 B 0.5B/Y
B-67 3B/Y
ON 3 F-16
B-67
METER 0.5LG/B
ST
10A
D
ABS
0.5B/Y

0.5B/Y 8 7
B-51 B-51
22 10 E
H-5 H-8 METER
0.5B/Y
F
0.5B/Y

0.3W/V
0.5LG/B

0.5W
0.5B/Y

H-14 4 5
0.5B
5
0.5P

X-5 X-5
5
2
B-69
E-11 RELAY ;
ABS IND.
SW ; NEUTRAL
SW ; EXH.BRAKE
(Neutral=ON) X-5 X-5
1 3
0.5B

E-11
IND. LAMP ; 0.5B
B-69
1 EXH. BRAKE
0.5B

0.5LG/R
2
0.5LG/R 1 10 G
B-51 B-52
H-14 H-5
0.5LG/R

10 38
0.5B/G

3 1
A/C 0.5G/O
X-25 X-25 COMPRESSOR H

RELAY ;
0.85B

EXH. BRAKE
CONTROL

X-25 X-25
5 4
0.5LG/B

0.5LG/R
0.5B

17
H-8 SW ; CLUTCH
0.5LG/B 1 2 0.5LG/R
B-89 B-89

0.5B 0.5B
2B

3B
HEADLIGHT BRACKET (LH) B-7
0.5B

0.85B
FRAME-LH (FRONT) B-1
1.25B
I
3B
J
3B
K
2B
FRAME-LH (CENTER) J-9 L
2B 2B 2B
M

N8A5592E
8-394 CAB AND CHASSIS ELECTRICAL

0.5G 11 3 0.5G 2 0.5G

A H-5 H-14 H-16
2 2
R-1 R-6
3R
B
STOP STOP
LIGHT LIGHT
(LH) (RH)

0.5G
0.5LG 4
C H-15 R-1 R-6
6 6
EHCU ; ABS
1.25B 7
16 H-16
J-177 STOP LAMP 22 0.5L 1
RL 12V J-177 J-149
SPEED

1.25B
3R 15 24 SENSOR
H-14 J-177 MOTOR +B 34 0.5Y 2 (RR,LH)
RL SIG J-177 J-149
3R 16 2 H-14
H-14 J-177 VALVE +B
7
32 0.5V 7 0.5V 1
15 23 FL SIG J-177 H-15 J-75 SPEED
H-15 J-177 MOTOR GND
SENSOR
33 0.5R/B 12 0.5R/B 2 (FRT,LH)
16 1 FL GRD J-177 H-15 J-75
H-15 J-177 VALVE GND

0.5LG 8 EXH.B/CUT
J-177
OUT
10 0.5P 8 0.5P 1
FR SIG J-177 H-15 J-74
0.5LG/B 2 0.5LG/B 7 SPEED
EXH.B/CUT
D H-15 J-177
IN
SENSOR
11 0.5L 13 0.5L 2 (FRT,RH)
FR GRD J-177 H-15 J-74
3B

0.3W/V 6 3 0.3W/V 6
E H-5 H-15 J-177 IND.

0.5B/Y 1 3 21 0.5R 1
F H-15 J-177 IG RR 12V J-177 J-148 SPEED
SENSOR
0.5B/G(NQR) 15 12 0.5W 2 (RR,RH)
J-177 MODE1 RR SIG J-177 J-148

0.5B/R(NQR) 14 29 0.3W/B 6 0.3W/B 24

J-177 MODE2 J1850 J-177 H-15 H-5

4 3 1 2 0.5B/W(NQR) 17 4 0.3W/G 11 0.3W/G 30

J-177 MODE3 FRASH J-177 H-15 H-5
NQR
H-17

H-17

H-17

H-17

0.3W/G
VEHICLE TYPE CONNECTOR
H-17

H-17

H-17

H-17

FOR TURKEY / GCC

(4-WHEEL DRUM BRAKE MODEL)
H-17

H-17

H-17

H-17

FOR OTHER COUNTRIES ECM DATA LINK

B-79
CONNECTOR
21 16 15 14 13 12 11 10 9
B-233 QWS
SW ; ACCEL 8 7 6 5 4 3 2 1
0.5LG/W 2 1 0.5LG 0.5LG 14 14 0.3Y
G B-75 B-75 B-233 EXH.BRAKE CHECKER B-234

0.5L/W 15 29 0.3L 0.3W/B

DIODE ; FICD B-234 FICD DIAG B-234
1 3 0.5L/W 37
H J-23 J-23 H-5 32
J-23 H-5

2
0.5L/G

0.5LG
2 6
H-13 H-13
0.5LG
0.5L/G

0.5B
0.5B

4 1 1
J-41 J-40 J-31
1.25B

VSV ;
FICD

J-41 J-40 VSV ; INT. J-31 MAG.VALVE ;

2 2 THROTTLE 2 EXH.BRAKE
0.5B

0.5B
12
0.5B

H-13
0.5B

1.25B 1.25B
I
3B
J
3B
K
0.5B
L
2B
M

N8A5575E
 CAB AND CHASSIS ELECTRICAL 8-395
Connector List No. Connector Face

No. Connector Face

B-67 2 1
4 3

B-1
004-002

000-001

B-69 1 2 3 4
5 6 7 8
B-7
008-001

000-012

B-69 4 3 2 1
8 7 6 5
X-5
008-002

005-006

B-75
1 2
X-8
002-022

005-006

B-75
2 1
B-51 1 2 3 4 5 6 7 8 9 1011121314
002-023

014-001

1 2 3 4 5 6 7 8
B-79
9 10 11 12 13 14 15 16

B-52 1 2 3 4 5 6 7 8 9 10 11 12
016-005

012-005

B-89 1
2
B-66 1 2
3 4 002-009

004-010

1
B-89
2
B-67 1 2
002-010
3 4

004-001
8-396 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

B-233 10 9 8 7 6 5 4 3 2 1 H-14 4
8
3
7
2
6
1
5
(24 V) 22 21 20 19 18 17 16 15 14 13 12 11
(12 V) 12 11 10 9
14 13

022-002 014-005

B-234 14 13 12 11 10 9 8 7 6 5 4 3 2 1 H-14 5
1
6
2
7
3
8
4
9

(24 V) 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15
(24 V) 10 11 12 13 14

15 16

030-002 016-003

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 4 3 2 1
B-234 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
5 4
H-14 9 8 7 6 5
3 14 13 12 11 10
(12 V) 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62
2 1 (24 V)
63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81
16 15

121-001 016-004

H-15 1 2 3
E-11 4 5 6
1 2 (12 V)
7 8

002-001 008-023

H-15 3 2 1
E-11 6 5 4
2 1
(12 V) 8 7

002-002 008-024

1 2 3 4 H-15 1 2 3 4

H-13 5 6 7 8
5 6 7 8 9

9 10 11 12 (24 V) 10 11 12 13 14

15 16

012-001 016-003

4 3 2 1
4 3 2 1
H-15 9 8 7 6 5
H-13 8 7 6 5 14 13 12 11 10

12 11 10 9 (24 V)
16 15

012-002 016-004

H-14 1 2 3 4
5 6 7 8 H-16 1 2 3 4
(12 V) 9 10 11 12
5 6 7 8
13 14

014-004 008-003
 CAB AND CHASSIS ELECTRICAL 8-397

No. Connector Face No. Connector Face

H-16 4 3 2 1
J-40 1 2
8 7 6 5

008-004 002-015

H-17 1 2 J-41 1 2
3 4

004-011 002-015

J-9 J-74 1 2

000-001 002-011

X-25 J-74 2 1

005-006 002-012

X-28 J-75 1 2

005-006 002-011

J-23 1 2 3 4 J-75 2 1

004-009 002-012

J-31 1 2
J-148 1 2

002-011 002-011

J-31 2 1
J-148 2 1

002-012 002-012
8-398 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

J-149
P-4
(24 V) 1 2

002-011 000-004

J-149 P-2
(24 V) 2 1 (24 V)

002-012 000-006

J-78
P-3
(12 V)

004-018 000-006

J-78 1 2
P-5
(12 V) 3 4
(12 V)

004-011 000-007

P-5
J-177
(24 V)

034-001 000-002

P-1
R-1 1 2 3
(12 V) 4 5 6

000-003 006-004

P-2 R-1 3 2 1
6 5 4

000-004 006-005

P-1
R-6 1 2 3
(24 V) 4 5 6

000-004 006-004
 CAB AND CHASSIS ELECTRICAL 8-399

No. Connector Face ABS/ASR System

General Description
ABS (Anti-lock Brake System) and ASR (Anti-Slip Reg-
R-6 3 2 1 ulator) are the system to prevent the wheels from lock-
6 5 4 ing and wheel spin, and to assure stability and steering
ability of the vehicle.
006-005 When a malfunction occurs in the system, fail-safe de-
activate the ABS and ASR, and the warning lamp comes
H-5 on. Also, the self-diagnosis function is equipped to im-
prove serviceability.

1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 11 12 12 11 10 9 8 7
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 24 23 22 21 20 19
25 26 27 28 29 30 30 29 28 27 26 25
31 32 33 34 35 36 37 38 39 40 40 39 38 37 36 35 34 33 32 31

N8A5488E

H-6, H-7, H-8

1 2 H-6 2 1

1 2 H-7 2 1

1 2 3 4 4 3 2 1

5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14

N8A5489E
 FL-1, FL-2, FL-9 FUSIBLE LINK
B-125 ASR OFF SW Parts Location
B-51 ABS WARNNING LIGHT (METER) J-148 R/RH
ASR WARNNING LIGHT (METER) FUSE BOX ASM SENSOR
F-5, F-7, F-16, F-21
J-149 R/LH
STARTER SW SENSOR
P-5

B-79 DATA LINK CONNECTOR

B-431 RESISTOR 1
8-400 CAB AND CHASSIS ELECTRICAL

B-66 STOPLIGHT SW
(BRAKE SW)

B-67 IGNITION SW "A" H-14, H-15

J-177 ABS EHCU

P1~P4
H-4~H-8 J-191 ECM BATTERY
J-9 EARTH ; FRAME
B-387 RESISTOR 2

J-74 F/RH SENSOR

B-1 EARTH ; FRAME (FR) J-75 F/LH SENSOR

B-7 EARTH ; HEADLIGHT B/T

N5A2074E
 CAB AND CHASSIS ELECTRICAL 8-401
Circuit Diagram

8B 3W/L

ACG(B)
100A/120A 8W/B
2 TAIL
3B/Y LIGHT
5W/B ABS (IG)
5W/B

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

3R 3R

4 3
0.3W/G

0.3W/B
3B

3B

16 15 11 6
H-15 H-15 H-15 H-15
0.3W/G

0.3W/B
3B

3B

12 13
H-8 H-8 0.5L
0.3W/G
0.3W/B

0.5L/W

0.5L/W

0.5SB 0.5L/W
0.5L

0.5L

7 12 2
B-79 B-79 B-79 8 7 6 5
DATA LINK CONNECTOR H-8 H-8 H-8 H-8
0.5L/W

0.5L/W

B-79 B-79 B-79

0.5L

0.5L

1 5 4
0.5Y

0.5B

0.5B

1 2 1 2
H-4 H-4
B-431 B-431 B-387 B-387
9 20
0.5SB 0.5Y
1.25B

37 18 38 52
3B

3B

J-191 J-191 J-191 J-191

CAN CAN CC- IS-
L H KW2000 DIAG RESISTOR 1 RESISTOR 2
ECM
J-9 B-1 B-7

FRAME-LH (CENTER) FRAME-LH (FRONT) HEADLIGHT BRACKET (LH)

N5A2073E
8-402 CAB AND CHASSIS ELECTRICAL
Connector List
No. Connector Face
No. Connector Face

B-1 B-387

002-038
000-001

B-7 B-387

002-039
000-012

B-431
B-51
020-

002-038

B-431
B-66
1 2

002-039
002-031

B-67 2 1
H-4 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 1718 19 20
4 3

020-002
004-002

9 8 7 6 5 4 3 2 1

B-67 H-4 20 19 18 17 16 15 14 13 12 11 10
1 2
3 4
020-003
004-001

4 3 2 1
9 8 7 6 5

B-79
1 2 3 4 5 6 7 8 H-14 14 13 12 11 10

9 10 11 12 13 14 15 16 16 15

016-004
016-005

1 2 3 4

B-125 H-14 5 6
10 11 12 13 14
7 8 9

1 2 3 4
5 6 7 8 15 16

016-003
008-001
 CAB AND CHASSIS ELECTRICAL 8-403

No. Connector Face No. Connector Face

1 2 3 4

H-15 5 6
10 11 12 13 14
7 8 9
J-148 1 2
15 16

016-003 002-011

4 3 2 1
9 8 7 6 5
H-15 14 13 12 11 10 J-149 2 1
16 15

016-004 002-012

J-9 J-149 1 2

000-001 002-011

J-74 2 1 J-177

002-012 034-001

J-74 1 2 J-177

002-011 034-002

J-75 2 1 J-191

002-012 081-001

J-75 1 2 P-1

002-011 000-004

J-148 2 1 P-2

002-012 000-006
8-404 CAB AND CHASSIS ELECTRICAL

No. Connector Face H-6, H-7, H-8

P-3

000-006
1 2 H-6 2 1

1 2 H-7 2 1

P-4 1 2 3 4 4 3 2 1

5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
000-004 H-8
14 15 16 17 18 18 17 16 15 14

P-5
N8A5489E

000-002 HSA (Hill Start Aid) System

General Description
The HSA (hill start aid) is the system to retain the brake
X-4 force with brake pedal not depressed when the vehicle
is parked, and to automatically release the brake force
when starting the vehicle.
005-006
The HSA control unit drives the HSA valve located in the
pipe route between the master cylinder and the wheel
H-5 cylinder, to hold/release the brake fluid pressure. Also,
alarm function (activates when the door opened with
HSA operating, when the HSA system has running long
time, when the HSA pressure goes down) and self-diag-
nosis function are equipped with the HSA control unit.

N5A2011E
 CAB AND CHASSIS ELECTRICAL 8-405
Parts Location

B-67 N-2
STARTER SW DOOR SW RH

B-51, B-52, L-2

METER ROOM LIGHT

B-106
HSA ADJUST SW N-6 J-32
PARKING BRAKE SW VEHICLE SPEED SENSOR

X-32 DIODE
B-318 X-33 DIODE N-7
HSA OFF SW DOOR SW LH
J-50
B-105 NEUTRAL SW
HSA RESET SW

H-12

H-10
P-5

B-79
DATA LINK
CONNECTOR
P-1~P-4 BATTERY
F-28 FUSE
FL-1, FL-2 FUSIBLE LINK
B-66
STOP LIGHT SW H-5~H-7
J-128 HBB LEVEL SW
B-1

J-155 B-7
F-4, F-5, F-16, F-17, F-19
HSA VALVE H-3 FUSE BOX ASM
B-103 B-285
CLUTCH SENSOR HSA CONTROL UNIT

B-102
CLUTCH FLUID PRESSURE SW
N5A3070E
8-406 CAB AND CHASSIS ELECTRICAL
Circuit Diagram

STARTER SWITCH
8B

OFF
FL-1 100A/120A FL-2 40A
ACC
MAIN KEY SW 3W/L 1 3W/L 2 F-16 10A
H-7 B-67 METER
ON 3 3B/Y 0.5B/Y
P-1
5W/B 8W/B

B-67
P-2 ST

3B/Y
F-17 10A
2 F-19 10A NEES (IG) / HSA
H-6 ENG. (BACK UP)
3W/B HSA
5W/B

0.5B/O
P-3
F-5 10A
P-4
STOP LIGHT

F-4 15A
AUDIO (B)
P-5 DOOR LOCK

0.5B/O
FRAME
0.5R

0.5G/Y

3
H-10
0.5R

1
L-2
1
STOP LIGHT SWITCH

ROOM LIGHT

0.5B/O

0.5B/O

0.5B/O
B-66

3
L-2
0.5Y

CLUTCH FLUID PRESSURE SWITCH

B-66
2 1

HSA ADJUST SWITCH

4 3
HSA RESET SWITCH

B-102
ROOM LIGHT SWITCH

B-105 B-106
0.5W/R

0.5B/O

L-2 SLOW

FAST
0.5G

2
0.5GR/B

B-105 B-106 B-106

6 2 1 B-102
1
2
H-10
0.5G
0.5GY/B

3
X-32
DIODE

0.3GY/R

0.3GY/B
0.3GY/L
STOP LIGHT
0.5G

0.3SB

X-32
4
0.5GY/R
0.3GY/B
0.5GY/R
0.5GY/R

1 19 29 14 7 15 21 6
B-285 B-285 B-285 B-285 B-285 B-285 B-285 B-285
3
H-12
3 HSA CONTROL UNIT
H-3
B-285 B-285 B-285
30 3 23
1.25GR/R

0.3B/W
1.25GR/B

0.3SB
DATA LINK CONNECTOR

11 7
0.5B

B-79 B-79
1 1
B-79 B-79
DOOR SWITCH RH

DOOR SWITCH LH

N-2 N-7 3B 2B
HEADLIGHT BRACKET (LH) B-7 4 5
0.5B

0.5B

1.25B
FRAME LH (FRONT) B-1

N5A3068E
 CAB AND CHASSIS ELECTRICAL 8-407

0.5B/Y
18
B-51 METER

0.3B/Y

PARKING
BRAKE
SPEED

HSA
OMETER

31
H-5 B-51 B-52 B-52
FUSE F-7 5 2 17
TAIL LIGHT

FUSE F-28
0.5LG/R

ECM 3

0.5B/Y
4 0.3W/V
0.5B/O RELAY ;
10 0.3W/V BUZZER
8 1
W/O WITH H-5 J-32
0.5B/Y

6 8 HBB HBB
HSA OFF SWITCH

0.5BR

0.3Y/G
0.5W/B
B-318 B-318 SHORT SPEED
CONNECTOR SENSOR

0.3BR/W
2 1

HBB LEVEL SWITCH

2 J-128 J-128 J-32 J-32
B-318 B-318 3 2
J-50

0.3W/B
NEUTRAL SWITCH

5 7

0.5Y/G

0.5B
0.5LG
J-128 J-128

0.5W/R 4 3
34

0.5B
25 19
H-5 J-50
12 H-5 H-5
1 J-9
H-5
0.5LG

0.5LG
0.5B/L

0.3W/R

0.3Y/G
2 4 FRAME
J-155 J-155 7 8
0.5LG

HSA VALVE

X-33 X-33
DIODE BOX
FRONT
REAR

37
J-155 J-155 X-33
H-5

0.5Y/G
9

0.5B
1 3
0.5LG/R
0.5LG/B

0.3W/B 3 0.5W/B
H-12 0.5W/B
0.5B

1
36 35
0.3B/L

N-6
H-5 H-5
0.5LG/R

PARKING
0.5LG/B

BRAKE
SWITCH
13 8 28 18 2 12 17
B-285 B-285 B-285 B-285 B-285 B-285 B-285

HSA CONTROL UNIT

B-285 B-285 B-285 B-285

26 25 24 10
0.5W/L
0.5Y/B

0.5Y/L
0.5Y

1 2 3 15
B-103 B-103 B-103 H-5

SIG
AC GENERATOR (L)
HEADLIGHT 3B 3B
B-7
BRACKET (LH) CLUTCH SENSOR

FRAME 1.25B
LH (FRONT) B-1

N5A3069E
8-408 CAB AND CHASSIS ELECTRICAL
Connector List
No. Connector Face
No. Connector Face

B-1 B-102
1 2

002-022
000-001

B-7 B-102
2 1

002-023
000-012

B-103
B-51 1 2 3
020-

003-009

B-103
B-52 3 2 1

003-010

B-66 B-105
1 2

006-021
002-031

1
B-67 2 1
B-106 2
4 3 3

003-014
004-002

B-285
1 2 3 4 5 6 7 8 9 10 11 12 13 14

B-67 1 2 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

3 4
030-001
004-001

B-79
1 2 3 4 5 6 7 8 B-318 1 2 3 4
9 10 11 12 13 14 15 16 5 6 7 8

008-005
016-005
 CAB AND CHASSIS ELECTRICAL 8-409

No. Connector Face No. Connector Face

1 2 3
H-3 4 5 6 J-50

006-014 002-035

H-3 3 2 1
J-128
6 5 4

006-015 004-018

H-10 J-155
3 2 1

003-010 004-018

H-10 J-155 1 2
1 2 3 3 4

003-009 004-011

1 2 3 4 5 6 7 8 9 10
H-12 L-2
11 12 13 14 15 16 17 18 19 20 21 22
3 2 1

022-001 003-010

10 9 8 7 6
H-12 L-2
5 4 3 2 1

22 21 20 19 18 17 16 15 14 13 12 11 1 2 3

022-002 003-009

J-9 N-2

000-001 001-020

J-32 1 2 3 N-6
2 1

003-018 002-023
8-410 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

N-6 X-33 1 2 3 4 5 6

1 2 7 8 9 10 11 12 13 14

002-022 014-002

H-5

N-7

001-020

P-1

000-004

P-2

000-006
N5A2011E

H-6, H-7

P-3

000-006

1 2 H-6 2 1

P-4
1 2 H-7 2 1

1 2 3 4 4 3 2 1
000-004
5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14

P-5

000-002
N8A5489E

X-32 1 2 3 4

004-004
 CAB AND CHASSIS ELECTRICAL 8-411
Transmission Control System (Smoother)
General Description
“Smoother” is the name of a new-generation drive train
that provides benefits in terms of both life cycle costs
(low initial cost and maintenance cost, lower fuel con-
sumption, etc.) and easy driving. Smoother is a system
that adds an automatic transmission to the existing
Smoother, for even better fuel consumption and easier
driving. This is accomplished by installing a solenoid
system shift control box on the Smoother, which com-
bines a manual transmission with fluid coupling, so all
shifting is performed automatically in accordance with
signals from the transmission control module (TCM).
When starting moving the vehicle, depressing the brake
pedal and operating the change lever as on an automat-
ic vehicle causes a change lever position signal to be
detected by the TCM. This actuates the shift control box
solenoid and shifts the gear into the starting position or
the reverse position, and then engages the shift change
clutch (wet multi-disc clutch). (After the shift clutch en-
gages, creep force is generated the same as on an AT
vehicle.) Releasing the foot from the brake pedal and
pressing the accelerator pedal starts the vehicle moving
forward. If there is an up-shift or down-shift while run-
ning, the control unit determines the vehicle status
based on vehicle speed, accelerator opening angle, and
other factors, and shifts to the optimal gear automatical-
ly. If the driver moves the change lever in the “+” or “-”
direction, a gear change is indicated, so sequential man-
ual shifting is also possible. (Even during sequential
manual shifting, the transmission shifts to the starting
position when the vehicle is stopped.)
8-412 CAB AND CHASSIS ELECTRICAL
Parts Location

N-19 SELECT SW
X-5 SMOOTHER MAIN RELAY
X-32 DIODE N-17 EMERGENCY SW
N-18 EMERGENCY SHIFT SW
B-417 PTO SWITCH
N-7 DOOR SW (RH)

N-2
DOOR SW (LH)

H-118
H-119

B-425, B-426,
B-427, B-428 H-15
TCM

H-4, H-5, F-28 FUSE

H-6, H-7 SBF1, SBF2, SBF5, SBF7, SBF8
X-18 ECM MAIN RELAY
B-1 X-19 GEAR SHIFTER RELAY
X-14 SMOOTHER X-21 STARTER RELAY
EMERGENCY RELAY H-17 X-26 STARTER CUT RELAY

J-232
TURBINE SPEED SENSOR
J-234
F-4, F-13, F-16, SELECT SOLENOID
J-237 F-17, F-22
SOLENOID & ATF TEMPERATURE SENSOR

J-50
NEUTRAL SW

J-223
SELECT STROKE SENSOR

H-118

J-142 J-236
SHIFT STROKE SENSOR SHIFT SOLENOID 2, 4, R
J-235
SHIFT SOLENOID 1, 3, 5
J-139
INPUT SPEED SENSOR H-119
N8A5601E
 2L
8WHT/BLK 8BLK

B J-26
Circuit Diagram
SBF-1 SBF-6 SBF-4
MAIN SBF-5 CERAMIC SBF-7 SBF-8 SBF-9 SBF-2 SBF-3 HEAD Fuse & Relay Box
Starter ECM NEES STARTER ABS KEY SW GLOW
100A or HEATER 60A 60A 40A 40A 60A LAMP (Behind the Cab)
40A
120A 60A 40A

8 3
P-1
WHT/ WHT/
BLK BLU

P-2
3 3
WHT/ WHT/
P-3
0.5BLK GRN BLU
USW JOINT3
5 2 B-67
WHT/
P-4 5 3 X-18
BLK

Battery
0.5 OFF
1 H-6 Main Fuse & Relay Box ST Ignition
BLK Relay ON ACC Switch
P-5 (Behind the Cab)

4 2 X-18
5
WHT/ 4 3 B-67
BLK
J-9
Frame 2
RED
0.5BLU/BLK 3BLK/YEL
W/S-I/-J ECM W/S-H ON Relay

ECM
W/S-H
3 3BLK/YEL
WHT/ 1.25
BLK RED 3
BLK/
YEL

F-13 F-4 F-5 F-6 Fuse & F-28 Fuse & F-22 F-16 F-17 F-18 F-21 F-9 Fuse &
NEES (B) AUDIO(B) STOP POWER Relay Box ECM Relay Box STARTER METER NEES (IG) SRS ABS (IG) ENG. (IG) Relay Box
10A DOOR LOCK LIGHT WINDOW (Glove Box) 10A (Cab Side) 10A 10A 10A 10A 10A 10A (Glove Box)
15A 10A 10A

N7A2131E
CAB AND CHASSIS ELECTRICAL 8-413
 2L
30 BLK/RED 8 BLK 8 BLK
8 BLK

SBF-8 SBF-2 Fuse &

STARTER KEY Relay Box
60A 40A (Behind the Cab)

3 BLK/YEL B-67 3
WHT/
ECM BLU
4
Main Relay
1 H-7
OFF
ST Ignition
F-22 F-28 F-16 Fuse &
ON ACC Switch
STARTER ECM METER Relay Box 3
10A 10A 10A (Glove Box) WHT/
BLU
3 0.3
WHT/ BLK/WHT 0.5
2 B-67
P-1 BLK BLK/
0.85 YEL
14 H-8 LT GRN W/S-M
0.5
RED/WHT
P-2
0.5
2 BLK/
P-3 J/C-2 YEL
0.5
RED/WHT 3
14 H-12
8-414 CAB AND CHASSIS ELECTRICAL

3 4 X-21 0.5
0.5
P-4 LT GRN BLK/
0.3BLU/RED YEL
Battery Starter Fuse & 1 N-17
Relay Relay Box
(Behind the Cab) 3 1 X-14

P-5
Emergency
Smoother Switch
2 5 X-21
Emergency Relay Box
Relay (Instrument Panel)
3 0.5
0.5 RED/
BLK/ 5 N-17
RED WHT
WHT
1 J-26
5 2 X-14 4 H-12

B 4 3 X-26 0.3
0.3 0.3
BLU/
BLK BLK
RED

Fuse & W/S-E

Starter Cut
Relay Relay Box 38 H-5
(Behind the Cab) 0.3 14
Starter BLK
0.5 0.3 0.5 0.5
WHT/ BLU/ WHT/ WHT/
1 5 X-26 B-7 BLU RED BLU BLU
Headlight 4 B-428 16 B-425 14 46 J-191
0.5 Bracket
BLK
C Emergency Start
USW
JOINT 3 switch switch
Starter
signal Start cut signal
2 cut
1 J-27 relay
BLK relay
TCM control ECM
control

J-9
Frame

N7A2144E
 F-13 F-17
NEES(B) NEES(IG) Fuse & Relay Box
10A 10A (Glove Box)

1.25
GRN/
WHT

0.5
BLK/
0.5 1.25 ORN
GRN/ GRN/
WHT WHT

3 2 X-5

Smoother Relay Box

Main Relay (Instrument Panel)

5 1 X-5

0.5 1.25 0.5 0.5

WHT/ WHT/ BLK/ BLK/
VIO ORN ORN ORN

B-425 1 2 B-426
15 3

Main
relay
control TCM

Battery voltage Ignition voltage

N7A2132E
CAB AND CHASSIS ELECTRICAL 8-415
 Power ground Power ground Signal ground Signal ground TCM
Diagnostic
request
Keyword 2000 switch

9 B-426 18 B-428 8 17 12 4 B-426

0.3 0.3
1.25 1.25 0.5 0.5
LT BLU BLK/
BLK BLK BLK BLK
WHT
18
0.5LT BLU 21
ECM J/C-B
8-416 CAB AND CHASSIS ELECTRICAL

22
EHCU (ABS Module)
W/S-D

EHCU (ABS Module)

2
ECM BLK
0.5
SRS C/U LT BLU

0.5 0.5 0.3 0.3 W/S-C

GRY YEL WHT/ WHT/
GRN BLK 0.5 0.5
BLK BLK

13 1 12 2 7 11 4 5 B-79 1.25
BLK
Diagnostic Diagnostic Diagnostic Class 2 Serial Keyword serial Diagnostic Ground Ground
request request request Communication communication request
(SRS) (ECM) (EHCU)
DLC

B-1
Frame

N7A2133E
 5V reference
+B +B

Gearshift clutch Lock up clutch TCM

solenoid valve solenoid valve
control control TFT
sensor
signal

30 29 B-425 6 B-427
0.5 0.5 0.5
YEL/ RED/ YEL/
BLK YEL RED

3(LHD) 1(LHD) H-17 5 H-4

5(RHD) 0.5 3(RHD) 0.5 0.5
YEL/ RED/ YEL/
BLK YEL RED

7 3 6 H-118
0.5 0.5 0.5
YEL/ RED/ YEL/
BLK YEL RED

3 1 2 J-237

Gearshift clutch Lock up clutch Transmission

solenoid valve solenoid valve fluid Oil Pump ASM
temperature
sensor

4 J-237
0.5
BLU/
WHT
14 H-119

0.5
BLU/
WHT

6 H-4

0.5
BLU/
WHT
12 B-427

TCM
Low reference

N7A2134E
CAB AND CHASSIS ELECTRICAL 8-417
 5V reference 5V reference

5V reference 5V reference TCM

Input shaft Turbine Gear select Gear select
speed sensor Low reference speed sensor Low reference position sensor position sensor
signal signal signal signal

5 11 4 10 B-427 18 19 10 11 B-426
0.5 0.5
0.5 0.5 WHT/ ORN/
YEL BRN 0.5 0.5 0.5 0.5
BLU BLU RED WHT YEL/ YEL/
BLK WHT

9 10 H-8 32 33 H-5
0.5 0.5 0.5 0.5
RED WHT YEL/ YEL/
BLK WHT

2 3 H-119 7 11 H-119
20 26 H-5 23 29 H-5 0.5 0.5 0.5 0.5
0.5 0.5 RED WHT YEL/ YEL/
0.5 0.5
WHT/ ORN/ BLK WHT
YEL BRN
BLU BLU
8-418 CAB AND CHASSIS ELECTRICAL

1 2 J-142 1 2 J-223

Gear Shift Gear Select

Position Position
Sensor Sensor

3 J-142 3 J-223
2 5 H-118 12 8 H-119
0.5 0.5 0.5
0.5 0.5 0.5
WHT/ ORN/ YEL/
YEL BRN BLK
BLU BLU RED

6 15 H-119

0.5
0.5
YEL/
BLK
RED

11 H-8 27 H-5

0.5
2 1 J-139 2 1 J-232 0.5
YEL/
BLK
RED

20 13 B-426

Input
Turbine
Shaft TCM
Speed
Speed
Sensor Low reference Low reference
Sensor

N7A2135E
 Ignition Ignition
voltage voltage
F-28 F-17 F-18 F-16 F-5 Fuse & Relay Box
ECM NEES (IG) SRS METER STOP LIGHT
10A 10A 10A (Glove Box)
10A 10A
TCM

Door PTO
switch switch
signal signal
0.5 0.5
LT GRN BLK/
ORN 12 19 B-428

2
Exhaust J/C-2 0.5 0.5
Brake 4 GRN/ GRY/
6
Solenoid Valve YEL RED
0.3
1 BLU/
5 WHT
0.5 0.5 2
0.5 Room Lamp Tail
BLK/ BLK/
LT GRN TCM Light
ORN ORN
J/C-H
3
2 J-50 4 B-105 3 B-106 1 B-66 0.5GRY/RED 4 3 B-417
1

Brake
Neutral Reset Half-clutch PTO
Pedal
Switch Switch Adjustment Switch
Switch
Switch 3 H-3

6 H-12
1 J-50 6 B-105 2 1 B-106 2 B-66 2 1 B-417
1.25 0.5
0.5 GRY/ GRY/ 2 0.5
BLK/ BLK RED BLK BLK
BLU 0.5
GRN
W/S-D W/S-B
0.5B/L 1 N-7 1 N-2
ECM

0.3 0.3 0.3 5 2 2

0.5GRN H-5 BLK BLK
GRY/ GRY/ GRY/ Stop Light
J/C-G Door Switch Door Switch 7
BLU RED BLK 4 11
6 (Left) (Right)
W/S-C J/C-D
37 H-5
1
1.25 3
0.5
BLK BLK
0.5 GRN
BLK/
BLU
B-1 B-7
10 17 9 2 3 B-428 Frame Headlight
Bracket

Neutral Reset Slow Fast Brake

switch switch switch switch pedal
signal signal signal signal switch

TCM

N7A2136E
CAB AND CHASSIS ELECTRICAL 8-419
 Ignition Ignition Ignition Ignition Ignition Ignition Ignition Ignition Ignition Ignition Ignition
voltage voltage voltage voltage voltage voltage voltage voltage voltage voltage voltage

TCM
Emergency Emergency Emergency 1st gear Economy
shift R shift N shift 1st Lever R Lever N Lever D Lever + Lever - Lever A start mode
switch switch switch switch switch switch switch switch switch switch switch
signal signal signal signal signal signal signal signal signal signal signal

20 6 14 B-428 13 21 14 15 7 8 B-427 1 B-427 13 B-428

B-427 B-428

0.5
0.5
YEL/
BLU
RED
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
0.5YEL/RED
RED WHT GRN RED/ WHT/ ORN BLU/ PNK/ GRN/ IPC
BLK BLK BLK BLK BLK

3 13 9 H-12 8 20 2 12 1 11 21 10 H-12

0.5 0.5 0.5 0.5 0.5 0.5

0.5 0.5 0.5 0.5 0.5
RED/ WHT/ BLU/ PNK/ GRN/ YEL/
RED WHT GRN ORN BLU
8-420 CAB AND CHASSIS ELECTRICAL

BLK BLK BLK BLK BLK RED

1 2 3 N-18 2 6 7 10 8 4 3 5 N-19

4 6 N-20
N

Emergency 1st
R 1 Gear ECONO
Shift Switch Selector
Start Mode
Lever
Switch Switch

R N D + - A 1 3 N-20

5 N-18 9 N-19

IPC
0.5 0.5
BLK BLK

0.5BLK 15 0.5BLK

1.25
BLK

B-1
Frame

N7A2137E
 1-3-5 shift 2-4-6-R shift Select SBF-7
solenoid valve solenoid valve solenoid valve TCM Fuse & Relay Box
NEES
control control control (Behind the Cab)
60A

4 5 21 31 B-425 5 6 8 9 B-425 1 8 16 22 B-428 3

B-426 RED
1.25 1.25 1.25 1.25 1.25 1.25
1.25 1.25 1.25 1.25 1.25 1.25
BLK/ BLK/ BLK/ BLK/ WHT/ WHT/
PNK PNK PNK PNK PNK PNK 2 3
RED RED BLU BLU BLK BLK
RED RED
1.25 4 3 X-19
1.25 WHT/
1.25 BLK/ BLK
BLK/ BLU
RED Gear Shift
W/S-Q Control Box
Relay

14 H-17 12 H-17 10 H-17 5 2 X-19

1.25
1.25 1.25
BLK/
BLU BLK
RED
8 H-118 4 H-119 16 H-119 0.5
3 3
VIO/
PNK PNK
2 2 2 WHT
GRN BLU BLK
2 J-235 2 J-236 2 J-234
1

1-3-5 2-4-6-R
Select
Shift Shift
Solenoid
Solenoid Solenoid

1 J-235 1 J-236 1 J-234

2 2 2
BLK BLK BLK
1 H-118 1 H-119 13 H-119
1.25BLK 19 H-17
1.25BLK
1.25BLK USW
JOINT2
1.25BLK 2
1.25BLK BLK
1.25BLK USW 0.5
6 H-17 7 H-17 8 H-17 VIO/
JOINT1
2 WHT
1.25 1.25 1.25
BLK BLK BLK BLK
1.25BLK 1.25BLK 1.25BLK

J-9
6 7 1 2 B-425 7 15 B-428 Frame 18 B-425

Gear shift
control box
relay control TCM

Ground Ground Ground

N7A2138E
CAB AND CHASSIS ELECTRICAL 8-421
 1-3-5 shift 2-4-6-R shift Select SBF-7
Fuse & Relay Box
solenoid valve solenoid valve solenoid valve TCM NEES
(Behind the Cab)
control control control 60A

3
4 5 21 31 B-425 5 6 8 9 B-425 1 8 16 22 B-428
B-426 RED
1.25 1.25 1.25 1.25 1.25 1.25
1.25 1.25 1.25 1.25 1.25 1.25
BLK/ BLK/ BLK/ BLK/ WHT/ WHT/ 2 3
PNK PNK PNK PNK PNK PNK
RED RED BLU BLU BLK BLK RED RED
4 3 X-19
1.25 1.25
8 1.25 1 BLK/ 15 WHT/
BLK/ BLU BLK
USW Gear Shift
RED
1.25PNK JOINT4 Control Box
1.25PNK
1.25PNK Relay

14 H-17 12 H-17 10 H-17 5 2 X-19

1.25
1.25 1.25
BLK/
BLU BLK
RED
8 H-118 4 H-119 16 H-119 0.5
3 3
VIO/
PNK PNK
2 2 2 WHT
GRN BLU BLK
8-422 CAB AND CHASSIS ELECTRICAL

2 J-235 2 J-236 2 J-234

1

1-3-5 2-4-6-R
Select
Shift Shift
Solenoid
Solenoid Solenoid

1 J-235 1 J-236 1 J-234

2 2 2
BLK BLK BLK
1 H-118 1 H-119 13 H-119
1.25BLK 19 H-17
1.25BLK
1.25BLK USW
JOINT2
1.25BLK 2
1.25BLK BLK
1.25BLK 0.5
21 H-17 19 H-17 17 H-17 USW VIO/
JOINT1 WHT
1.25 1.25 1.25 2
BLK BLK BLK BLK
1.25BLK 1.25BLK 1.25BLK

J-9
6 7 1 2 B-425 7 15 B-428 Frame 18 B-425

Gear shift
control box
relay control TCM

Ground Ground Ground

N7A2139E
 F-16
Fuse & Relay Box
METER
(Glove Box)
10A

0.5
BLK/
YEL
0.5BLK Smoother
W/S-M Emergency Switch
0.5
BLK/
YEL
18 B-51

Gear Transmission
Position ECONO 1st
warning IPC
Indicator lamp START lamp
lamp

1 8 7 6 B-53

0.5
YEL

1 X-32

Diode
0.3 0.3 0.3 B-1
PNK GRN/ YEL/
ORN GRN

2 X-32
0.5
YEL/
RED

Selector Lever

14 11 12 B-425

Gear position
Transmission ECONO
display control
warning lamp lamp
control control TCM

N7A2141E
CAB AND CHASSIS ELECTRICAL 8-423
8-424 CAB AND CHASSIS ELECTRICAL

Resistor 1

2 1 B-387

0.5 0.5
BLU/
BLU WHT

3 0.5
1 BLU/WHT B-427 CAN
J/C-F
2 high
2
TCM
6
4 CAN
J/C-F
0.5 BLU 3 low
5

0.5 0.5
BLU BLU/
WHT

7 8 H-8
Without ABS

0.5 0.5
BLU/
BLU WHT

0.5 0.5
BLU/WHT H-15 BLU/WHT J-177 CAN
5 14 high

CAN
0.5 BLU 10 0.5 BLU 15 low
0.5 0.5
BLU/ BLU EHCU
WHT 0.5 0.5
BLU/WHT BLU/WHT CAN
high
9 26

CAN
0.5 BLU 14 0.5 BLU 27 low

0.5 0.5
BLU/
BLU WHT
0.5
BLU/WHT J-191 CAN
18 high
ECM
CAN
0.5 BLU 37 low

0.5
0.5 BLU/
BLU
WHT

5 6 H-8

0.5 0.5
BLU BLU/
WHT

3 0.5
2 BLU/WHT
J/C-R
1
DRM
6
5
J/C-R
0.5 BLU
4

0.5 0.5
BLU BLU/
WHT

2 1 B-431

Resistor 2

N6A6641E
 CAB AND CHASSIS ELECTRICAL 8-425
Connector list
No. Connector Face
No. Connector Face
l

B-1 B-86 1 2
3 4

004-001
000-001

B-86 2 1
B-7 4 3

004-002
000-018

B-105
B-51
020-

006-021

1
B-106
B-53 2
3

003-014
012-009

B-387
B-66
1 2

002-038
002-031

B-387
B-67 2
4
1
3

002-039
004-002

B-417
B-67 1 2
1 2
3 4
3 4
004-001
004-001

1 2 3 4 5 6 7 8 B-425
B-79
9 10 11 12 13 14 15 16

031-001
016-005
8-426 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

B-426 H-4 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 1718 19 20

024-001 020-002

B-427 H-10
1 2 3

017-001 003-009

B-428 H-10
3 2 1

022-006 003-010

10 9 8 7 6 5 4 3 2 1
B-431 H-12
22 21 20 19 18 17 16 15 14 13 12 11

002-038 022-002

1 2 3 4 5 6 7 8 9 10
B-431 H-12
11 12 13 14 15 16 17 18 19 20 21 22

002-039 022-001

1 2 3 4
1 2 3
H-3 4 5 6 H-15 5 6
10 11 12 13 14
7 8 9

15 16

006-014 016-003

4 3 2 1
9 8 7 6 5

H-3 3 2 1
H-15 14 13 12 11 10
6 5 4
16 15

006-015 016-004

9 8 7 6 5 4 3 2 1
H-4 20 19 18 17 16 15 14 13 12 11 10
H-17

020-003 022-007
 CAB AND CHASSIS ELECTRICAL 8-427

No. Connector Face No. Connector Face

H-17 J-27

022-008 000-009

H-118 1 2 3 4 J-50
5 6 7 8

008-003 002-035

H-118 J-139

008-018 002-040

1 2 3 4

H-119 5 6 7 8 J-142 1 2 3
9 10 11 12
13 14 15 16

016-001 003-005

4 3 2 1

H-119 8 7
12 11 10
6 5
9
J-177
16 15 14 13

016-002 034-001

H-xx 1 J-191

001-002 081-001

J-9 J-223 1 2 3

000-001 003-005

J-26 J-232

000-002 002-040
8-428 CAB AND CHASSIS ELECTRICAL

No. Connector Face No. Connector Face

J-234 1 2
P-3

002-003 000-006

J-235 1 2
P-4

002-003 000-004

J-236 P-5

002-042 000-002

J-237 P-6

004-020 000-002

X-5,
L-2 14, 18,
1 2 3 26
003-009 005-006

X-19,
1

L-2 2 3
3 2 1 21
4 5

003-010 005-003

P-1 X-32 1 2 3 4

000-004 004-004

P-2 X-33 1 2 3 4 5 6
7 8 9 10 11 12 13 14

000-006 014-002
 CAB AND CHASSIS ELECTRICAL 8-429

No. Connector Face H-6, H-7, H-8

N-2

001-020
1 2 H-6 2 1

1 2 H-7 2 1

N-7 1 2 3 4 4 3 2 1

5 6 7 8 8 7 6 5

9 10 11 12 13 13 12 11 10 9
001-020 H-8
14 15 16 17 18 18 17 16 15 14

N-17 1 2 3 4
5 6 7 8 N8A5489E

008-005

N-18 1 2 3
4 5 6

006-007

N-19 1 2 3 4
5 6 7 8 9 10

010-003

H-5

1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 11 12 12 11 10 9 8 7
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 24 23 22 21 20 19
25 26 27 28 29 30 30 29 28 27 26 25
31 32 33 34 35 36 37 38 39 40 40 39 38 37 36 35 34 33 32 31

N8A5488E
MEMO
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 LGCEL-WE-0553RH

You are requested to order this manual using the

manual number that is shown above.

This manual is applicable for vehicles in all

countries except the USA and Canada.

All rights reserved. This manual may not be

reproduced in whole or in part, without the
permission in writing of ISUZU MOTORS LIMITED.

Issued by

ISUZU MOTORS LIMITED

E-Solutions & Service Marketing Dept.

Tokyo, Japan

Second edition December, 2010

No.LGCEL-WE-0553RH PRINTED IN JAPAN