1 page

INDEX1
Models FA and FB ELECTRICAL EQUIPMENT 20-1

20-340E-05

CHAPTER 20
ELECTRICAL EQUIPMENT
Models FA and FB

GENERAL INSTRUCTIONS ....................................................... 20- 2

LOCATION OF ELECTRICAL EQUIPMENT.............................. 20- 6

POSITION OF THE POWER SUPPLY TERMINALS

FOR EXTRA EQUIPMENT ......................................................... 20-10

PRECAUTIONS ON HANDLING ABS (ANTI-LOCK

BRAKE SYSTEM) ELECTRICAL EQUIPMENT
WHEN MODIFYING THE WHEEL BASE ................................... 20-11

BATTERY .................................................................................... 20-12

STARTING SYSTEM .................................................................. 20-13

ELECTRICAL ENGINE STOP SYSTEM .................................... 20-16

METERS AND GAUGES ............................................................ 20-21

WARNING SYSTEM ................................................................... 20-28

HEAD LAMPS ............................................................................ 20-35

20
HAZARD AND TURN SIGNAL LAMPS ..................................... 20-39

STOP LAMPS ............................................................................. 20-41

BACK-UP LAMPS ...................................................................... 20-44

DOME LAMPS ............................................................................ 20-46

HORN .......................................................................................... 20-48

PRE-HEAT SYSTEM .................................................................. 20-49

WIPER ........................................................................................ 20-51

WINDSHIELD WASHER ............................................................. 20-56

POWER WINDOW ...................................................................... 20-58

SPEAKER AND ANTENNA ........................................................ 20-62

 1 page 1
20-2 ELECTRICAL EQUIPMENT Models FA and FB

GENERAL INSTRUCTIONS

WARNING
Be sure to disconnect the cable from the negative
(–) terminal of the battery before servicing the elec-
trical circuits except for on-vehicle testing.

NOTE: If you use a high-pressure washer, do not di-

rect the washer hose on the electrical parts.

Fig. 1 SM20-1623A

EXAMPLE:
1. WIRING COLOR CODE.
3WB Symbols
B – Black G – Green Gr – Grey
W – White Y – Yellow P – Pink
BLACK L – Blue Br – Brown V – Violet
WHITE
3 mm 2 R – Red Lg – Light green O – Orange
(0.0047 sq.in) Symbols consisting of two letters
First letter – Ground color
Second letter – Color of stripe
Example
Fig. 2 SM20-340 WB .......Indicates a black stripe on a white ground.
P 2. DISCONNECTING CONNECTORS.
LOCK SECTION The basic procedure for disconnecting a connector
is shown in Fig. 1 through Fig. 12.
Disconnect all connectors following these procedures.
1. Hold the connectors, one in each hand, press sec-
tion P with your thumb, and pull them apart.
NOTE: Do not pull on the harness.

Fig. 3 SM20-341
2. Hold the connectors, one in each hand, raise notch
LOCK SECTION A with your thumb, and pull the connectors apart.
NOTE: Do not pull on the harness.

Fig. 4 SM20-342
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-3

3. Hold connector C1 in one hand and C2 in the other.

LOCK SECTION Raise notches A and B with the thumb and finger of
(ON THE REAR ALSO)
one hand, then pull the connectors apart.
C2
NOTE: Do not pull on the harness.
C1

Fig. 5 SM20-343
4. Hold the connectors, one in each hand, press sec-
P
LOCK SECTION
tion P with your thumb, and pull the connectors apart.
NOTE: Do not pull on the wires.

Fig. 6 SM20-344

LOCK SECTION

Fig. 7 SMEE-829

P
LOCK SECTION

Fig. 8 SMEE-829
5. Hold A and B, one in each hand, and pull them apart.
A
NOTE: Do not pull on the wires.
B

Fig. 9 SM20-345
 1 page 1
20-4 ELECTRICAL EQUIPMENT Models FA and FB

3. WHEN CHECKING CONTINUITY OR VOLTAGE WITH

A CIRCUIT TESTER, INSERTION OF THE PROBES
INTO THE RECEPTACLE CONNECTOR MAY OPEN THE
TERMINALS OF THE CONNECTOR AND RESULT IN
POOR CONTACT.
THEREFORE, ENSURE THAT THE PROBES ARE IN-
SERTED ONLY FROM THE WIRE HARNESS SIDE AS
SHOWN.

Fig. 10 SM20-346
4. REPLACING THE TERMINALS.
1. Remove the terminal.
a. Type A
Insert a miniature screwdriver from the open end, dis-
engage the locking lugs, and then pull the terminal
DETAIL out from the rear.

Fig. 11 SM20-347
b. Type B
Insert a miniature screwdriver from the open end, dis-
engage the locking lugs, and then pull the terminal
out from the rear.
2. Install the terminal.
Push the terminal into the connector.
NOTE: Make sure that the locking lugs engage the
connector body securely.

Fig. 12 SM20-348
HOW TO USE THE PULLER 5. REPLACING THE FUSE.
FUSE
1. When replacing a fuse, always use a fuse of the
PULLER specified capacity.
q
NOTE: Use a fuse puller for fuse removal and remove
GOOD the fuse without twisting.
2. If the fuse blows again, determine the cause, repair
any defects, and then install a new fuse.
q
1. NIP w
BLOWN
2. PULL
Fig. 13 SM20-1656
6. REPLACING THE FUSIBLE LINK.
1. When replacing a fusible link, always use a fusible
link of the specified capacity.
NOTE: Each fusible link has a connector colored ac-
cording to its capacity.
2. If the fusible link blows again, determine the cause,
repair any defects, and then install a new fusible link.
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-5

7. CIRCUIT BREAKER RESETTING.

CIRCUIT 1. Circuit breaker removal
BREAKER
Remove the circuit breaker from the connector on
the relay box.

CONNECTOR

Fig. 14 SMEE-824
2. Circuit breaker resetting
CIRCUIT a. Insert a wire into the reset hole and push lightly.
BREAKER
b. Check the circuit breaker for continuity between the
terminals, and replace the circuit breaker if there is
no continuity.

RESET HOLE

Fig. 15 SMEE-825
3. Circuit breaker installation
CIRCUIT
BREAKER
a. Install the circuit breaker on the connector.
b. If the circuit breaker is tripped again, determine the
cause, repair any defects, and then install the circuit
breaker again.

CONNECTOR

Fig. 16 SMEE-824
 1 page 1
20-6 ELECTRICAL EQUIPMENT Models FA and FB

LOCATION OF ELECTRICAL EQUIPMENT

2-way seat (Standard)

1 8 model
2
9
7 15 16

10
6
5
14 17 18
14
11

4
3

19 20

13
21
12 16
24
23

20 22
23
3-way seat (Option) ASM20-3005
model

CAB
1. Combination meter 13. Relay panel
2. Speedometer 14. Clearance lamp
3. Plug hole 15. Identification lamp
4. Starter switch 16. Windshield washer
5. Cigarette lighter 17. Antenna
6. Buzzer 18. Dome lamp
7. Turn signal flasher 19. Windshield wiper assembly
8. Power window relay 20. Side turn signal lamp
9. Coolant level warning controller 21. Speaker
10. Pre-heat timer (Option) 22. Head lamp
11. Fuse block 23. Marker lamp
12. Over-run relay 24. Engine stop motor

Fig. 1
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-7

3
5
2

5
8

7
ASM20-025

CHASSIS
1. Horn 5. Back-up lamp
2. Pre-heat power relay (option) 6. Combination lamps
3. Starter relay 7. Fusible links
4. License plate lamp 8. Fusible link box

Fig. 2
 1 page 1
20-8 ELECTRICAL EQUIPMENT Models FA and FB

Model: FA

4
3 3

1
3 18

2
3 18

17
19

15 20

5
13
6

7
12
8 14
21
16
10

ASM20-026
9 11

RELAYS
1. Injection pump pre-stroke 8. Power relay No.3 16. Horn relay
controller 9. Windshield wiper relay 17. Turn signal flasher
2. Actuator cut relay 10. Stop lamp relay 18. Power window relay
3. ABS relay 11. Power relay 19. Coolant level warning controller
4. ABS-CPU 12. Engine stop relay 20. Pre-heat timer (Option)
5. Head lamp relay (Main) 13. Circuit breaker 21. Over-run relay
6. Power relay No.1 14. Tail lamp relay
7. Power relay No.2 15. Head lamp relay (Dimmer)

Fig. 3
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-9

Model: FB

4
3
1
18
3

2 18

17
19

15 20

5
13
6

7
12
8 14 21
16
10

ASM20-029
9 11

RELAYS
1. Injection pump pre-stroke 8. Power relay No.3 16. Horn relay
controller 9. Windshield wiper relay 17. Turn signal flasher
2. Actuator cut relay 10. Stop lamp relay 18. Power window relay
3. ABS relay 11. Power relay 19. Coolant level warning controller
4. ABS-CPU 12. Engine stop relay 20. Pre-heat timer (Option)
5. Head lamp relay (Main) 13. Circuit breaker 21. Over-run relay
6. Power relay No.1 14. Tail lamp relay
7. Power relay No.2 15. Head lamp relay (Dimmer)

Fig. 4
 1 page 1
20-10 ELECTRICAL EQUIPMENT Models FA and FB

FL-5 FL-1

FL-10 FL-2
FL-12

FL-7
FL-11 FL-6

FL-9

FL-8 FL-3

FL-13 FL-4

ASM20-027

Cartridge type fusible link

Fusible link No. Color Ampere Quantity
FL-1, FL-2, FL-6, FL-5, FL-8, FL-13 Red 50 A 6
FL-3, FL-10 Pink 30 A 2
FL-4 Green 40 A 1
FL-9 Yellow 60 A 1
FL-7, FL-12 Blue 100 A 2
FL-11 (Model: FA) Green 40 A 1

NOTE: Always use the same brand of fusible link as originally equipped.

Fig. 5
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-11

POSITION OF THE POWER SUPPLY TERMINALS FOR EXTRA

EQUIPMENT
Extra equipment should be connected to the power
supply, according to the load used, in one of the fol-
lowing places.

SM20-1622

SM20-2007

Fig. 1
Additional wiring
Additional wiring from a fuse or a circuit breaker
causes overheating and this is prohibited.
Terminals for additional wiring for a radio, a lamp, etc.
are provided in the cab and on the chassis frame.
Additional load capacities are as follows:
Cab : Max. 15A : 12V
Chassis frame : Max. 8A : 12V x 2
 1 page 1
20-12 ELECTRICAL EQUIPMENT Models FA and FB

PRECAUTIONS ON HANDLING ABS (ANTI-LOCK BRAKE SYSTEM)

ELECTRICAL EQUIPMENT WHEN MODIFYING THE WHEEL BASE
1. When removing the ABS harness, turn the starter switch off and remove the battery terminals.

2. In order to extend the harness to extend the wheel base, use the sub- harness as an extension.
Connect it to the connector between the front harness and the rear harness. This is the only
way to extend it for the following reasons.
(1) Some ABS circuits use sealed wires. Cutting and extending them makes them more sus-
ceptible to noise (electro-magnetic interference) which can result in mis-operation of the
ABS system.
(2) Electrical wire connection procedures such as soldering, coaking, etc. can let water in and
cause rust.

3. In case that the harness becomes too long from shortening the wheel base, do not modify the
harness. Instead bundle the excess harness and make sure to attach it to the chassis using
clips and tie-wraps.
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-13

BATTERY

INSPECTION AND REPAIR

INDICATOR
The indicator is located on the representative cell (2nd
cell from the end) of each battery.
The indicator indicates whether the fluid level is correct or
not. It also indicates whether the specific gravity of the
electrolyte is over 1.15 in order to prevent excessive dis-
charging.
Light blue...........Specific gravity of electrolyte and level
of electrolyte are both satisfactory.
Fig. 1
White..................Charge normally with a charging current
of 4-5A until the indicator becomes light
blue.

WARNING
● Since the batteries produce explosive hydrogen
gas, do not allow any open or electric sparks near
the batteries.
● The batteries produce explosive gas and contain
corrosive sulfuric acid. A battery explosion, con-
tact with electrolyte, or an electrical short can re-
sult in personal injury and/or property damage.
● Always shield your eyes or wear safety goggles
when working on the batteries. Do not let electro-
lyte, which is sulfuric acid, come in contact with
eyes, skin, or clothing. Since electrolyte is corro-
sive acid, it can damage skin and clothing. If acid
should contact your skin, eyes or clothing, im-
mediately flush the contact area thoroughly with
water and get medical treatment immediately.
● When working on the batteries, be sure to remove
any metal accessories from your arms. Do not lean
over the batteries.
● This vehicle has a 12-volt, negative grounds sys-
tem. Make sure that any other vehicle used for
jump starting also has a 12-volt, negative ground
system. Do not attempt to jump start when you
are not sure of the voltage or ground of the other
vehicle.
 1 page 1
20-14 ELECTRICAL EQUIPMENT Models FA and FB

STARTING SYSTEM
TROUBLESHOOTING
Symptom Possible cause Remedy

Engine does not crank Key switch

● Poor contact condition ............................. Polish or replace contacts.
Batteries
● Discharged battery ................................... Charge battery.
● Short circuit between electrodes .............. Replace battery.
● Poor contact at battery terminals ............. Polish or retighten.
Engine oil
● Improper viscosity oil ............................... Change oil.
Starter relay
● Defective or poor starter relay contact ..... Repair or replace.
Starter
● Starter does not operate .......................... Repair or replace.
Refer to CHAPTER 22 “STARTER”.

Starter does not Key switch

stop running.
● Contacts keep closing .............................. Replace.
● Key switch sticks ...................................... Replace.
Starter
● Overrunning clutch sticks to armature ..... Repair or replace overrunning clutch
or armature.
Starter relay
● Contacts keep closing .............................. Repair or replace.
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-15

STARTING SYSTEM CIRCUIT

2 3
W BW
4
B

+ - + -
1 6 B

SM20-2097A

1. Battery 5. Starter
2. Fusible link (FL-3) 6. Fusible link (FL-9)
3. Starter switch
4. Starter relay

Fig. 1
 1 page 1
20-16 ELECTRICAL EQUIPMENT Models FA and FB

STARTING SYSTEM CIRCUIT

W BW Set the starter switch to “START” position. Current
B
flows through the circuit, as indicated by the arrows
W
in the diagram in Fig. 2.

+ - + -

Fig. 2 SM20-2097B
INSPECTION
F 1. CHECK THE OPERATION OF THE STARTER RELAY.
S 1. Disconnect the wires and remove the relay.
2. Using an ohmmeter, check that there is no continuity
between terminals F and S .
3. Apply 12V D.C. source across terminals SW and L .
SW
L
Using an ohmmeter, check that there is continuity
between terminals F and S .
Fig. 3 SM20-1652
If the relay does not operate, replace the relay.
2. CHECK THE OPERATION OF THE STARTER SWITCH.
1. Disconnect the connector.
2. Using an ohmmeter, check the continuity of the ter-
minals at each switch position.
M AC B
If there is no continuity between the switch terminals,
replace the switch.
BR E C S

Fig. 4 SM20-2014
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-17

ELECTRICAL ENGINE STOP SYSTEM

Symptom Possible cause Remedy

Engine stop motor No voltage at terminal M of starter ......... Replace starter switch or fusible
does not operate switch when starter switch is ON. link.
(when starting).
Fuse burnt out .......................................... Replace fuse.
No voltage is at terminal w of .................. Check wiring and repair.
engine stop relay.
Relay does not operate ............................ Replace relay.
No voltage at motor terminal LR ............. Check fusible link, engine stop
motor and wiring and repair.

Engine stop motor No voltage at motor terminal WR ............ Check fusible link and wiring and
does not operate repair.
(when stopping).
Stop relay terminal q not grounded ........ Check relay and relay grounding
and replace.
Injection pump lever or cable sticks ......... Repair or replace.
 1 page 1
20-18 ELECTRICAL EQUIPMENT Models FA and FB

ELECTRICAL ENGINE STOP SYSTEM CIRCUIT

4
BR E C S B AC M
OFF
ACC
ON 3
+ +
PH
ST 2 2

WR 1
W FL-3 FL-4

2 6 3 7

3 BR BR
A 1
M
L
B
5
10
9
8
11

SM20-2098A

1. Battery 7. Engine stop motor

2. Fusible link 8. Engine stop motor arm
3. Fuse 9. Engine stop cable
4. Starter switch 10. Engine stop lever (on injection pump)
5. Engine stop relay 11. Return spring
6. Diode

Fig. 1

1. WHEN THE STARTER SWITCH IS IN THE “OFF”

OFF
BR E C S B AC M POSITION.
ACC
ON
PH
+ +
No current is supplied to the circuits.
ST

WR
W FL-3 FL-4

3 BR BR
A 1
M
L
B

Fig. 2 SM20-2098B
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-19

2. WHEN THE STARTER SWITCH IS TURNED TO THE

BR E C S B AC M “ON” POSITION.
OFF
ACC
ON
PH
+ +
1. The relay is switched, sending current to the motor,
ST

WR
which rotates the motor.
2
W FL-3 FL-4
2. The engine stop cable is released, and the stop le-
A
3

1
BR BR ver moves to the “in use” position.
M
L
B

Fig. 3 SM20-2098C
3. When the motor rotates to a certain angle, the me-
OFF
BR E C S B AC M
chanical switch inside operates, and the motor stops.
ACC
ON
+ +
PH
ST

WR
W FL-3 FL-4

3 BR BR
A 1
M
L
B

Fig. 4 SM20-2098D
3. WHEN THE STARTER SWITCH IS IN THE “ON” POSI-
OFF
BR E C S B AC M TION.
ACC
ON
PH
+ + Current is supplied to the circuit, as shown by the
ST

WR
arrow in Fig. 5. The point on the engine stop relay
FL-3 FL-4

2
W
remains held at the top (side A).
3 BR BR
A 1
M
L
B

Fig. 5 SM20-2098E
4. WHEN THE STARTER SWITCH IS TURNED TO THE
BR E C S B AC M
OFF
ACC
“OFF” POSITION.
ON
PH
ST
+ +
1. The relay is switched, sending current to the motor,
WR
W FL-3 FL-4
which rotates the motor.
2
2. The engine stop cable is pulled, and the stop lever
3 BR BR
A
B
1

L
M moves to the “stop” position.

Fig. 6 SM20-2098F
3. When the motor rotates to a certain angle, the me-
OFF
BR E C S B AC M chanical switch inside operates and the motor stops.
ACC
ON
+ +
PH
ST

WR
W FL-3 FL-4

3 BR BR
A 1
M
L
B

Fig. 7 SM20-2098G
 1 page 1
20-20 ELECTRICAL EQUIPMENT Models FA and FB

INSPECTION
STOP POSITION 1. CHECK THE OPERATION OF THE ENGINE STOP
MOTOR AND MECHANICAL SWITCH.
IN USE POSITION
WARNING
When the engine stop cover is removed, do not touch
the cable or pulley with your hands, even when the
SM20-1324 key switch is in the “ACC” or “OFF” (LOCK) posi-
tions. Check the motor only after removing the con-
2 1 SWITCH ON
4 3
nector to the battery to avoid injury to your hands.
NC 3
2
M
NO 1
1. Devise a circuit as shown in Fig. 8.
2. Turn the switch on to rotate the motor. Then confirm
RELAY MOTOR
that the motor stops at the point where the cable
2 1
4 3
spring moves to the “in use” position.
NC 3
2
M 3. The motor and the mechanical switch are both oper-
NO 1
ating normally if when the switch is turned off, the
SWITCH OFF motor rotates and stops at the point where the cable
spring moves to the “stop” position.
Fig. 8 SM20-1325
2. IF THE ENGINE DOES NOT STOP WHEN THE STARTER
SWITCH IS IN THE “OFF” POSITION, DO THE FOL-
LOWING.
1. Turn the starter switch to the “ON” position.
2. Open the front panel.
3. Disconnect the engine stop motor connector.

Fig. 9 SM20-1625
4. Remove the engine stop motor cover.
5. Pull the engine stop cable in the direction of the ar-
row until the engine stops.

Fig. 10 SM20-1626
6. When the engine stops re-install the engine stop
motor cover.
7. Reconnect the engine stop motor connector.
8. Put the starter switch in the “LOCK” position.

Fig. 11 SM20-1627
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-21

3. CHECK THE OPERATION OF THE ENGINE STOP RE-

4 6 LAY.
1. Remove the relay.
1 2 3 2. Using an ohmmeter, check that there is no continuity
between terminals q and r.
1 3 3. Using an ohmmeter, check that there is continuity
4 between terminals e and q.
- + - + 2
6
4. Apply 12V D.C across terminals w and y.
Using an ohmmeter, check that there is continuity be-
Fig. 12 SM20-1668
tween terminals q and r.
If the relay does not operate, replace it.
 1 page 1
20-22 ELECTRICAL EQUIPMENT Models FA and FB

METERS AND GAUGES

TROUBLESHOOTING
Speedometer
Symptom Possible cause Remedy

Needle of speedometer Speedometer cable bend radius .............. Correct the meter cable bending
oscillates irregularly. is less than 150 mm (5.906 in.). radius to more than 150 mm
Oscillation is wide at (5.906 in.).
low speeds and be-
comes narrow as speed Speedometer cable is not ........................ Connect firmly.
increases. connected to speedometer firmly. NOTE:
Irregular noises and needle oscil-
lation are usually caused by poor
installation of the speedometer
cable. Therefore, inspect the in-
stallation of the speedometer
cable.

Speed indicator indicates Worn or underinflated tires ....................... Replace or inflate to correct air
(+). pressure.
Clicking sound is heard as Rubber bushing is not in .......................... Install rubber bushing.
speed of vehicle increases. speedometer cable at meter.

Tachometer
Symptom Possible cause Remedy

Does not move, needle Fuse or fusible link burnt out .................... Determine cause and replace fuse
vibrates, display is incorrect. (When no movement) or fusible link.
Connector for tachometer is ..................... Polish or retighten.
loose or rusted.
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-23

REMOVAL OF THE METER PANEL

1. REMOVE THE BOLTS.

Fig. 1 SM20-2017
2. DISCONNECT THE CONNECTORS FROM THE RE-
VERSE SIDE OF THE METER PANEL.

Fig. 2 SM20-1637
3. REMOVE THE METER PANEL.

Fig. 3 SM20-1613

DISASSEMBLY AND ASSEMBLY OF THE

METER PANEL
1. REPLACE COMPONENTS AS NECESSARY.

Fig. 4 SM20-1611
 1 page 1
20-24 ELECTRICAL EQUIPMENT Models FA and FB

METER AND GAUGES CIRCUIT

10
6 7 9
4

5 8
3

12
2
14 14

13

1
11
15
Model: FA
SM20-2026A
1. Battery 6. Fuel gauge 11. Transmission
2. Fusible link (FL-3) 7. Coolant temperature gauge 12. Electric injection pump control unit
3. Starter switch 8. Coolant temperature gauge unit 13. Engine speed sensor
4. Fuse (10A) 9. Tachometer 14. Vacuum gauge (If so equipped)
5. Fuel gauge unit 10. Speedometer 15. Vacuum tank

Fig. 1
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-25

10
6 7 9

5 8
3

12
2

14

13

1
11

15
Model: FB
SM20-1650B
1. Battery 6. Fuel gauge 11. Transmission
2. Fusible link (FL-3) 7. Coolant temperature gauge 12. Injection pump pre-stroke control unit
3. Starter switch 8. Coolant temperature gauge unit 13. Engine speed sensor
4. Fuse (10A) 9. Tachometer 14. Air pressure gauge
5. Fuel gauge unit 10. Speedometer 15. Air tank

Fig. 2
INSPECTION
Speedometer
CHECK THE OPERATION OF THE SPEEDOMETER
(ON-VEHICLE INSPECTION).
Using a speedometer tester, inspect the speedom-
eter for allowable indicating error and operation of
odometer.
NOTE: ● Tire wear and tire overinflation or under-
inflation will increase indicating error.
Fig. 3 SM20-1646B
Check the speedometer for pointer vibra-
tion or abnormal noises.
● Pointer vibration can be caused by a loose
speedometer cable.
Allowable Error: +15% to –10% at over 22 mile/h
(35 km/h)
Unit inspection with bench tester
Standard speed
20 (32.19) 40 (64.37) 60 (96.54)
mile/h (km/h)
Specified standard +1.8 (2.90) +2.3 (3.70) +3.0 (4.83)
mile/h (km/h) –0 –0 –0
 1 page 1
20-26 ELECTRICAL EQUIPMENT Models FA and FB

(EXAMPLE) Tachometer
CHECK THE OPERATION OF THE TACHOMETER (ON-
VEHICLE INSPECTION).
1. Connect a calibrated test tachometer, and start the
engine.
2. Compare the tester and tachometer indications. If
error is excessive, replace the tachometer.
NOTE: ● Do not reverse the connection of the ta-
chometer because transistors and diodes
inside will be damaged.
Fig. 4 SM20-1650 ● When installing or removing the tachom-
eter, be careful not to drop it or subject it
to heavy shocks.
Unit inspection
Standard rpm 1,000 rpm 2,000 rpm
12V at 25°C
±50 rpm ±100 rpm
(77°F)
Allowable error 10 – 16V at
20 – 60°C ±100 rpm ±200 rpm
(68 – 140°F)

Coolant Temperature Gauge

1. CHECK THE OPERATION OF THE COOLANT TEM-
PERATURE GAUGE (ON-VEHICLE INSPECTION).
1. Disconnect the connector from the temperature
gauge unit and ground the terminal through a 12V,
6W bulb.
2. Turn the starter switch to “ON”. Check that the bulb
lights after several seconds and the coolant tempera-
ture gauge pointer moves to the midway position. If
Fig. 5 SM20-2015
indications are not correct, remove and test the cool-
ant temperature gauge.

2. CHECK THE OPERATION OF THE COOLANT TEM-

PERATURE GAUGE.
Using an ohmmeter, measure the resistance between
each terminal of the gauge.
If resistance is not within specifications, replace the
U + gauge.
E Standard value ;
Terminals +–E U–E +–U
Resistance (Ω) 241.9±24 137.7±14 104.2±11
Fig. 6 SM20-1642
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-27

3. CHECK THE OPERATION OF THE COOLANT TEM-

PERATURE GAUGE UNIT.
Using an ohmmeter, measure the resistance between
the terminal and ground at the indicated coolant tem-
peratures.
If resistance is not within specifications, replace the
gauge unit.

Temperature Resistance
q COOLANT e STIRRING ROD +11.5
TEMPERATURE r SUPPORTER 80°C (176°F) 73.7 –11.2 Ω
t +6.7
GAUGE ELECTRIC HEATER 100°C (212°F) 37.7 –5.5 Ω
w THERMOMETER

Fig. 7 SM20-42

Fuel Gauge
1. CHECK THE OPERATION OF THE FUEL GAUGE (ON-
VEHICLE INSPECTION).
1. Disconnect the connector from the tank side and
ground it.
2. Turn the starter switch to “ON”. Check that the fuel
gauge pointer slowly moves to the “F” position.
If indications are not correct, remove and test the
gauge.
Fig. 8 SM20-2016
2. CHECK THE OPERATION OF THE FUEL GAUGE.
Using an ohmmeter, measure the resistance between
terminal.
If resistance is not within specification, replace the
gauge.
U +
Standard value ;
E Terminals +–E U–E +–U
Resistance (Ω) 256.3 ± 26 150.3 ± 15 106.0 ± 11

Fig. 9 SM20-1642
 1 page 1
20-28 ELECTRICAL EQUIPMENT Models FA and FB

3. CHECK THE OPERATION OF THE FUEL GAUGE UNIT.

Using an ohmmeter, measure the resistance between
the terminal and gauge unit body for each float posi-
tion.
FULL If resistance is not within specifications, replace the
gauge unit.

53°±1° Float position Empty 1/2 Full

Resistance (Ω) 110 ± 3 32.5 ± 2 3±1

1/2

53°±1°

EMPTY

Fig. 10 SM20-1645

Air Pressure Gauge (Model: FB)

CHECK THE OPERATION OF THE AIR PRESSURE
TEST AIR
PRESSURE GAUGE (ON-VEHICLE INSPECTION).
GAUGE
1. Connect a calibrated air pressure test gauge and start
the engine.
2. Compare the tester and the air pressure gauge indi-
cations. If the error is excessive, replace the gauge.
Unit: kg/cm2 (lb/in.2)
3.52 7.03 10.55 14.06
Fig. 11 SM20-1644A Indicator
(50) (100) (150) (200)
Allowable error ± 0.49 (7) ± 0.49 (7) ± 0.49 (7) ± 0.49 (7)
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-29

WARNING SYSTEM

Model: FA

SM20-2099A

1. Battery 7. Vacuum warning lamp 13. Brake fluid level switch

2. Fusible link 8. Parking brake and brake fluid 14. Vacuum warning switch
3. Starter switch warning lamp 15. Engine oil pressure warn-
4. Fuse 9. Cab lock warning lamp ing switch
5. Coolant level warning lamp 10. Warning buzzer 16. Coolant level warning sensor
6. Engine oil pressure warning 11. Parking switch 17. Coolant level warning
lamp 12. Cab lock switch controller

Fig. 1
 1 page 1
20-30 ELECTRICAL EQUIPMENT Models FA and FB

Model: FB

BRAKE
BRAKE
FLUID

5 6 7 8 9 10 11

12

19
10A

4
18
17 16 15 14 13 3
3

2
+ - + -
FL-3
1

SM20-3000A

1. Battery 8. Parking brake warning lamp 15. Brake fluid level switch
2. Fusible link 9. Brake fluid level and air master 16. Low pressure switch
3. Starter switch stroke warning lamp 17. Engine oil pressure warning
4. Fuse 10. Cab lock warning lamp switch
5. Coolant level warning lamp 11. Warning buzzer 18. Coolant level warning sensor
6. Engine oil pressure warning 12. Parking switch 19. Coolant level warning
lamp 13. Cab lock switch controller
7. Air pressure warning lamp 14. Air master stroke sensor

Fig. 2
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-31

INSPECTION
VAC
Warning Lamp Check
CHECK THE OPERATION OF THE WARNING LAMPS.
All the warning lamps must be lit when the starter
switch is in the "ON" position and the warning lamp
10A

check button is pushed, and or starter switch is in

the "H" or "START" position.
FL-3
+ - + -
MODEL: FA At this point, current is supplied to the circuit, as in-
dicated by the arrow in the diagram at the left.
Fig. 3 SM20-2099B

BRAKE
BRAKE
FLUID
10A

+ - + -
FL-3
MODEL: FB

Fig. 4 SM20-3000B

Engine Oil Pressure Warning

VAC
1. ENGINE OIL PRESSURE WARNING LAMP CIRCUIT.
When the engine oil pressure has fallen below 0.5
kg/cm2 (7.11 lb/sq.in.), the oil pressure warning
switch comes on and current flows through the cir-
10A

cuit, as indicated by the arrows in the diagram at the

left, causing the warning lamp to light up and the
FL-3
+ - + - buzzer to sound.

Fig. 5 SM20-2099C
2. CHECK THE OPERATION OF THE OIL PRESSURE
WARNING SWITCH.
1. Disconnect the connector.
2. Using an ohmmeter, check the continuity between the
terminal and ground with the engine stopped (0 ohm)
and with the engine running (infinity).
If not correct, replace the oil pressure warning switch.

Fig. 6 SM20-036 SM20-037

Cab Lock Warning

VAC
CAB LOCK WARNING LAMP CIRCUIT.
If the cab lock switch is closed, current flows through
the circuit, as indicated by the arrows in the diagram
at the left causing the warning lamp to light up and
10A

the buzzer to ring.

+ - + -
FL-3

Fig. 7 SM20-2099D
 1 page 1
20-32 ELECTRICAL EQUIPMENT Models FA and FB

CHECK THE OPERATION OF THE CAB LOCK SWITCH.

Using an ohmmeter, check the continuity between the
terminals with the cab lock and safety switch in "RE-
LEASE POSITION" (0 ohm) and with the cab lock
switch in "PRESS" (infinity).

Fig. 8 SM20-1676B

Vacuum Warning (Model: FA)

1. VACUUM WARNING LAMP CIRCUIT.
If the vacuum pressure falls below 400 mmHg (15.7
inHg), the vacuum warning switch comes on and cur-
rent flows through the circuit, as indicated by the ar-
rows in the diagram at the left causing the warning
lamp to light up and the buzzer to ring.

Fig. 9 SM20-2099E
2. CHECK THE OPERATION OF THE VACUUM WARNING
SWITCH.
1. Disconnect the connector.
2. Using an ohmmeter, check the continuity between the
terminal and ground with vacuum pressure over
400mmHg (15.7 inHg) (infinity) and with vacuum
pressure under 400mmHg (15.7 inHg) (0 ohm).
If not correct, replace the switch.

Fig. 10 SM20-856B

Air Pressure Gauge (Model: FB)

1. AIR PRESSURE WARNING LAMP CIRCUIT.
If the air pressure falls below 4.5 kg/cm2 (64 lb/sq.in.),
the air pressure warning switch comes on and cur-
rent flows through the circuit, as indicated by the
arrows in the diagram at the left, causing the warn-
ing lamp to light up and the buzzer to sound.

Fig. 11 SM20-3000C
2. CHECK THE OPERATION OF THE AIR PRESSURE
WARNING SWITCH.
1. Disconnect the connector.
2. Using an ohmmeter, check the continuity between
the terminal and ground with air pressure above
4.5kg/cm2 (64 lb/sq.in.) (infinity) and with air pressure
below 4.5kg/cm2 (64 Ib/sq.in.) (0 ohm).
If not correct, replace the switch.

Fig. 12 SM20-452B
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-33

Parking Brake Warning and Warning Buzzer

VAC
1. PARKING BRAKE AND WARNING BUZZER CIRCUIT.
When the parking brake is applied, the parking brake
warning lamp is lit and the buzzer circuit is switched
off.
10A

At this point, current is supplied to the circuit as indi-

cated by the arrows in the diagram at the left.
+ - + -
FL-3
MODEL: FA

Fig. 13 SM20-2099F

BRAKE
BRAKE
FLUID
10A

+ - + -
FL-3
MODEL: FB

Fig. 14 SM20-3000D
2. CHECK THE OPERATION OF THE PARKING BRAKE
SWITCH.
1. Disconnect the connector.
2. Using an ohmmeter, check that there is no continuity
between terminals B and GW .
3. Apply the parking lever and using an ohmmeter,
check that there is continuity between terminals B.
and GW .
If readings are not correct, replace the switch.
Fig. 15 SM20-038 SM20-039

Brake Fluid Level Warning

VAC
1. BRAKE FLUID LEVEL WARNING CIRCUIT. (Model: FA)
When the brake fluid level warning switch is closed,
current flows through the circuit, as indicated by the
arrows in the diagram at the left causing the warning
10A

lamp to light up and buzzer to ring.

+ - + -
FL-3

Fig. 16 SM20-2099G
2. BRAKE FLUID LEVEL AND AIR MASTER STROKE
BRAKE
BRAKE
FLUID WARNING CIRCUIT. (Model: FB)
1. When the brake fluid level warning switch and or air
master stroke warnig switch is closed, current flows
10A

through the circuit, as indicated by the arrows in the

diagram at the left causing the warning lamp to light
up and buzzer to ring.
+ - + -
FL-3

Fig. 17 SM20-3000E
 1 page 1
20-34 ELECTRICAL EQUIPMENT Models FA and FB

3. CHECK THE OPERATION OF THE BRAKE AIR MAS-

TER STROKE WARNING SWITCH. (Model: FB)
1. Disconnect the connector.
2. Remove the warning switch from the brake air mas-
ter.
3. Using an ohmmeter, check the continuity between the
terminals, with the switch off (infinity) and with the
switch on (0 ohm).
If not correct, replace the switch.
Fig. 18 SM20-213
4. CHECK THE OPERATION OF THE BRAKE FLUID
LEVEL WARNING SWITCH.
1. Disconnect the connector.
2. Using an ohmmeter, check the continuity between the
terminals, with the float up (infinity) and with the float
down (0 ohm).
If not correct, replace the switch.

Fig. 19 SM20-034 SM20-035

5. CHECK THE OPERATION OF THE WARNING BUZZER.
Apply 12V D.C. across the terminals and check that
the buzzer sounds.
If it does not, replace the buzzer.

Fig. 20 SM20-473
6. CHECK THE OPERATION OF THE DIODE.
BLACK BLACK
1. Set the resistance range to 1k ohm.
2. Touch the red and black tester probes and adjust the
ANODE CATHODE
reading to 0 ohm.
CATHODE ANODE
3. When the black probe is placed on the anode and
the red probe on the cathode of the diode to be
tested, if the tester pointer stops before reaching 0,
RED RED the diode is satisfactory.
4. On the contrary, when the red probe is placed on the
Fig. 21 SM20-054 anode and the black probe on the cathode, the me-
ter needle should not move.
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-35

Coolant Level Warning

1. COOLANT LEVEL WARNING LAMP CIRCUIT.
If the coolant level falls below the minimum level, the
coolant level warning sensor comes on and current
flows through the circuit, as indicated by the arrows
in the diagram at the left causing the warning lamp
to light up and buzzer to ring.

Fig. 22 SM20-2099H
2. CHECK THE OPERATION OF THE COOLANT LEVEL
WARNING SENSOR.
Using an ohmmeter, measure the resistance between
the terminal and ground at the indicated coolant tem-
peratures.
If resistance is not within specifications, replace the
gauge unit.
Resistance
(Wet condition) Dry condition Over 30kΩ
Wet condition Under 10kΩ
Fig. 23 SM20-2042
3. CHECK THE OPERATION OF THE COOLANT LEVEL
WARNING CONTROLLER.
1. When the resistance of the coolant level sensor indi-
cates less than 30kΩ, the coolant level warning con-
troller does not operate, and when more than 30kΩ,
it is operational and the buzzer rings.
2. When the voltage of the power is 12V and the tem-
perature is 20°C±5°C (68°F±41°F) the voltage and
the resistance of sensor operates as follows; (Rx=The
resistance of coolant level sensor)
. When Rx indicates infinity, voltage (Vout) comes
to less than 1.5V and the buzzer rings.
. When Rx indicates 0Ω, voltage (Vout) is nearly
equal to the voltage of the power, the buzzer does
not ring.
3. When the connector of coolant level sensor is taken
off, the warning lamp lights.
Fig. 24 SM20-2043B
4. When terminal No.5 is taken off and is connected to
the ground, Rx indicates almost 0Ω.
Unless it is as noted above, replace the coolant level
sensor.
 1 page 1
20-36 ELECTRICAL EQUIPMENT Models FA and FB

HEAD LAMPS

2
4

6 7 3
3
9
5
3

10
8

SM20-1660A

1. Head lamps
2. Head lamp beam indicator lamp
3. Fuse
4. Head lamp relay (High beam)
5. Head lamp relay (Low beam)
6. Dimmer switch
7. Lighting switch
8. Tail lamp relay
9. Fusible link
10. Battery

Fig. 1
HEAD LAMP CIRCUIT
Turn the lighting switch to the “H” position.
1. LOW BEAM CIRCUIT.
When the dimmer switch is in the home (“HL”) posi-
tion, the two outer head lamps light up.
At this point, current is supplied to the circuit as indi-
cated by the arrow in the diagram in Fig. 2.

Fig. 2 SM20-1660B
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-37

2. HIGH BEAM CIRCUIT.

When the dimmer switch is pushed down (“HU”), the
four head lamps and the high beam indicator lamp
light up.
At this point, current is supplied to the circuit as indi-
cated by the arrow in the diagram in Fig. 3.

Fig. 3 SM20-1660C
3. PASSING CIRCUIT.
When the dimmer switch is pulled up (“HF”), the four
head lamps and high beam indicator lamp light up
even if the lighting switch is not in the “ON” position.
At this point, current is supplied to the circuit as indi-
cated by the arrow in the diagram in Fig. 4.

Fig. 4 SM20-1660D
INSPECTION
1. CHECK THE OPERATION OF THE LIGHTING SWITCH
AND DIMMER SWITCH.
1. Disconnect the connectors.
2. Using an ohmmeter, check the continuity of the ter-
minals in each switch position.
If there is no continuity between the switch terminals,
replace the switch.

Fig. 5 SM20-1649
a. Lighting switch.

EL LT LH
OFF
T
H
T: 1ST STAGE
H: 2ND STAGE

Fig. 6 SM20-1641E
b. Dimmer switch.

DE DL DU EP
HF
HL
HF: PASSING
HL: LOW BEAM HU
HU: HIGH BEAM

Fig. 7 SM20-1641F
 1 page 1
20-38 ELECTRICAL EQUIPMENT Models FA and FB

2. CHECK THE OPERATION OF THE HEAD LAMP RE-

3 4
LAY (THE TAIL LAMP RELAY AND POWER RELAY CAN
BE CHECKED IN THIS WAY AS WELL).
1 2
1. Remove the relay.
2. Using an ohmmeter, check that there is no continu-
ity between terminals r and w.
4 2
- + - +
3. Apply 12V D.C. across terminals q and e.
1 3
Using an ohmmeter, check that there is continuity be-
tween terminals r and w.
Fig. 8 SM20-1722
If the relay does not operate, replace it.
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-39

ADJUSTMENT
1. RELATIVE POSITION OF HEAD LAMPS.
1. Inner head lamps
2. Outer head lamps

Fig. 9 SM20-2023
2. ADJUST THE INNER HEAD LAMPS.
1. Mask the outer head lamps.
2. Switch the head lamps to high beam.
3. Turn the adjusting screw and adjust the direction of
the beam.

Fig. 10 SM20-1640
1. 10 m (393.7 in.)
1
2. Lamp mounting height: H
2
3
H
3. cm
4
10
H
5
4. Main beam
6
5. Inner head lamp
8

W 7
6. Main beam
6
7. Center line of vehicle
8. Center distance of inner head lamp
Fig. 11 SM20-1638B
3. ADJUST THE OUTER HEAD LAMPS.
1. Switch the head lamp to low beam.
2. Turn the adjusting screw and adjust the direction of
the beam.

Fig. 12 SM20-1640
1. 10 m (393.7 in.)
1
2. Lamp mounting height: H
2
3 3. 20 – 26 cm (7.87 – 10.24 in.)
H 4 4. Main beam
5 5. Outer head lamp
7
8
6 6. Center line of outer head lamp
7 7. Main beam
6
8
8. 30 – 35 cm (11.81 – 13.78 in.)
Fig. 13 SM20-1639B
 1 page 1
20-40 ELECTRICAL EQUIPMENT Models FA and FB

HAZARD AND TURN SIGNAL LAMPS

2
9
1

20A 5

6 7 8
4
FL-3

9
3

1
2

SM20-1661A

1. Front turn signal lamp 6. Hazard warning switch

2. Front side turn signal lamp 7. Turn signal switch
3. Battery 8. Hazard and turn signal indicator lamp
4. Fusible link 9. Rear combination lamp (Turn signal)
5. Turn signal flasher

Fig. 1
HAZARD AND TURN SIGNAL LAMP CIRCUIT
1. HAZARD WARNING LAMP.
20A All the turn signal lamps keep on flashing when the
HF HL HR BT TL TR
switch is pushed down.
OFF L
ON N
R At this point, current is supplied to the circuit as indi-
+ - + -
cated by the arrow in the diagram in Fig. 2.

Fig. 2 SM20-1661B
2. TURN SIGNAL LAMPS.
1. When the starter switch is ON and if the turn signal
20A
switch is turned upward, current flows through the
circuit, as indicated by the arrows in the diagram in
HF HL HR BT TL TR
OFF
ON
L
N
R
Fig. 3, causing the right signal lamp and the indica-
+ - + - tor lamp to blink.

Fig. 3 SM20-1661C
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-41

2. When the starter switch is in the “ON” position and if

the turn signal switch is turned downward, current
20A
flows through the circuit, as indicated by the arrows
in the diagram in Fig. 4, causing the left signal lamps
HF HL HR BT TL TR
OFF
ON
L
N
and the indicator lamp to blink.
R

+ - + -

Fig. 4 SM20-1661D

INSPECTION
1. CHECK THE OPERATION OF THE HAZARD WARNING
SWITCH.
1. Disconnect the connector.
2. Using an ohmmeter, check the continuity of the ter-
minals in each switch position.
If there is no continuity between the switch terminals,
replace the switch.
Fig. 5 SM20-1649

HF HL HR
OFF
ON
OFF

ON

Fig. 6 SM20-1641G
2. CHECK THE OPERATION OF THE TURN SIGNAL
SWITCH.
1. Disconnect the connector.
2. Using an ohmmeter, check the continuity of terminals
in each switch position.
If there is no continuity between the switch terminals,
replace the switch.
3. ADDING TURN SIGNAL LAMPS.
As a general rule, do not add turn signal lamps (this
Fig. 7 SM20-1649 also applies to tractors). If, however, it is unavoidably
necessary to add turn signal lamps, be sure to observe
the following.
RH
NOTE: The flasher relay which is installed on the ve-
N
LH
hicle is a variable capacity type (max 29W x
BT TL TR 8 lamps). Its part number is 81980-1430. When
L adding turn signal lamps, ensure that the
capacity of the flasher unit is not exceeded
N
when using the hazard warning lamps (27W
R x 2 lamps can be added). If lamps having a
greater total wattage are added, the life of the
Fig. 8 SM20-1641H flasher unit will be shortened.
 1 page 1
20-42 ELECTRICAL EQUIPMENT Models FA and FB

STOP LAMPS

2 3
W 10A 8
RW 4 3 6 GW B
W WB 10A GR GW
WL GR

GY
1

FL-2 8
RW BW

GW B
1 7
FL-3 5

SM20-2033A
(Model: FA)
1. Fusible link 5. Battery
2. Starter switch 6. Stop lamp relay
3. Fuse 7. Stop lamp switch
4. Power relay No. 2 8. Rear combination lamp (Stop lamp)

Fig. 1

3
2 10A
WL 8
BW 4 3 6 GW B
WL LW 10A GW
GR
G
GY
1

GR
FL-2 8
BW BW
7
GW B
1
FL-3 5

SM20-1662A
(Model: FB)
1. Fusible link 5. Battery
2. Starter switch 6. Stop lamp relay
3. Fuse 7. Stop lamp switch
4. Power relay No.2 8. Rear combination lamp (Stop lamp)

Fig. 2
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-43

STOP LAMP CIRCUIT

W 10A
1. WHEN THE STARTER SWITCH IS IN THE “ON”
GW B

POSITION. (Model: FA)

RW
W WB 10A GR GW
WL GR

B GY
The power relay (No. 1) operates when the starter
FL-2
switch is in the “ON” position.
RW BW

GW B
At this point, current is supplied to the circuit as indi-
+ - + -

FL-3 cated by the arrows in the diagram in Fig. 3.

MODEL: FA
Fig. 3 SM20-2033B
1. WHEN THE STARTER SWITCH IS IN THE “ON”
POSITION. (Model: FB)
The power relay (No.1) operates when the starter
switch is in the “ON” position.
At this point, current is supplied to the circuit as indi-
cated by the arrows in the diagram in Fig. 4.

MODEL: FB
Fig. 4 SM20-1662B
3. WHEN THE BRAKE PEDAL IS PRESSED. (Model: FA)
W 10A
When the starter switch is in the “ON” position and if
the brake pedal is pressed, the stop lamp switch
RW GW B
W WB 10A GR GW
WL GR

B GY comes on and current flows through the circuit, as

indicated by the arrows in the diagram in Fig. 5, and
FL-2
RW BW
the stop lamps lights.
GW B
+ - + -
FL-3

MODEL: FA
Fig. 5 SM20-2033C
4. WHEN THE BRAKE PEDAL IS PRESSED. (Model: FB)
When the starter switch is in the “ON” position and if
the brake pedal is pressed, the stop lamp switch
comes on and current flows through the circuit, as
indicated by the arrows in the diagram in Fig. 6, and
the stop lamp lights.

MODEL: FB
Fig. 6 SM20-1662C
 1 page 1
20-44 ELECTRICAL EQUIPMENT Models FA and FB

CAB UNDER FLOOR

INSPECTION
1. CHECK THE OPERATION OF THE STOP LAMP SWITCH.
1. Disconnect the connector.
2. Set the air pressure gauge and charge the air brake
system.
3. Using an ohmmeter, check the continuity between the
terminal and ground with air pressure above 0.3 kg/
cm2 (4.27 lb/sq.in.) (0 ohm) and with air pressure
below 0.3 kg/cm2 (4.27 lb/sq.in.) (infinity).
Fig. 7 SM20-470 If not correct, replace the switch.
2. CHECK THE OPERATION OF THE STOP LAMP RELAY.
4 6 1. Remove the relay.
2. Using an ohmmeter, check that there is no continuity
1 2 between terminals q and r.
3. Apply 12V D.C. across terminals w and y.
Using an ohmmeter, check that there is continuity
1 4
between terminals q and r.
- + - +
2 6
If the relay does not operate, replace it.

Fig. 8 SM20-1670
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-45

BACK-UP LAMPS

5 6 7
4
2
FL-5 3 4 20A

10A
2 7
FL-3

+ - + -
1

SM20-3001A

1. Battery 5. Power relay (No. 3)

2. Fusible link 6. Back-up lamp switch
3. Starter switch 7. Back-up lamp
4. Fuse

Fig. 1
 1 page 1
20-46 ELECTRICAL EQUIPMENT Models FA and FB

BACK-UP LAMP CIRCUIT

1. WHEN THE STARTER SWITCH IS IN THE “ON” POSI-
FL-5 20A
TION.
10A

FL-3
The power relay (No.3) operates when the starter
switch is in the “ON” position.
At this point, current is supplied to the circuit as indi-
+ - + -
cated by the arrows in the diagram in Fig. 2.

Fig. 2 SM20-3001B
2. WHEN THE TRANSMISSION CONTROL LEVER IS IN
THE “REVERSE” POSITION.
FL-5 20A When the starter switch is in the “ON” position and if
10A the transmission control lever is placed in the “RE-
FL-3
VERSE” position, the back-up lamp switch comes on
and current flows through the circuit, as indicated by
+ - + - the arrows in the diagram in Fig. 3, causing the back-
up lamps to light.

Fig. 3 SM20-3001C
INSPECTION
1. CHECK THE OPERATION OF THE BACK-UP LAMP
SWITCH (FOR MANUAL TRANSMISSION).
1. Disconnect the connector.
2. Using an ohmmeter, check the continuity between the
terminals with the transmission control lever in “NEU-
TRAL” (infinity) and with the transmission control le-
ver in “REVERSE” (0 ohm).
If not correct, replace the switch.
Fig. 4 SMEE-865
2. CHECK THE OPERATION OF THE BACK-UP LAMP
SWITCH (FOR AUTOMATIC TRANSMISSION).
1. Disconnect the connector.
2. Using an ohmmeter, check the continuity between the
terminals (RB-R) with the transmission control lever
in ‘NEUTRAL” (infinity) and with the transmission
control lever in “REVERSE” (0 ohm).
If not correct, replace the switch.

Fig. 5 SM20-476 SM20-477

 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-47

DOME LAMPS

FL-4
2
4

+ - + -
1 6

SM20-3011A

1. Battery 4. Dome lamp

2. Fusible link 5. Dome lamp switch
3. Fuse 6. Courtesy(Door) switch

Fig. 1
DOME LAMP CIRCUIT
FL-4
1. OPERATION BY DOME LAMP SWITCH.
When the “ON” switch is pushed, the two lamps will
light up whether the doors are opened or closed. The
diagram at the left shows the flow of current with ar-
rows when the switch is “ON “
+ - -+ -

Fig. 2 SM20-3011B
2. OPERATION BY COURTESY(DOOR) SWITCH.
If the door switch is placed in the “DOOR” position
FL-4
when the door is opened the dome lamp comes on
and current flows through the circuit, as indicated by
the arrows in the left diagram causing the three lamps
to light.
+ - + -

Fig. 3 SM20-3011C
 1 page 1
20-48 ELECTRICAL EQUIPMENT Models FA and FB

DISASSEMBLY
1. REMOVE THE COURTESY(DOOR) SWITCH.

Fig. 5 SM20-1616

INSPECTION
CHECK THE OPERATION OF THE COURTESY(DOOR)
SWITCH.
Using an ohmmeter, check the continuity between the
terminal and body ground with the courtesy switch
pushed in (infinity) then with the courtesy switch re-
leased (0 ohm). If reading is not correct, replace the
switch.

Fig. 6 SM20-1615
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-49

HORN

5 6

4
2 8
4

3 7
2 8

SM20-2036A

1. Battery 6. Horn relay

2. Fusible link 7. Horn switch
3. Starter switch 8. Horn
4. Fuse
5. Power relay No. 1

Fig. 1
HORN CIRCUIT
Set the starter switch to “ON” and press the horn
button. Current flows through the circuit, as indicated
by the arrows in the diagram in Fig. 2 sounding the
horn.

Fig. 2 SM20-2036B
INSPECTION
3 4
CHECK THE OPERATION OF THE RELAY.
1. Remove the relay.
1 2 2. Using an ohmmeter, check that there is no continuity
between terminals r and w.
4 2
3. Apply 12V D.C. across terminals q and e.
– + – + 1
Using an ohmmeter, check that there is continuity be-
3
tween terminals r and w.
If the relay does not operate, replace it.
Fig. 3 SM20-1722
 1 page 1
20-50 ELECTRICAL EQUIPMENT Models FA and FB

PRE-HEAT SYSTEM (OPTION)

3
TW G2 M N 5

7 L
4
R E
2

– + – +

2 6
1
8

ASM20-3002A
1. Battery 6. Pre-heat power relay
2. Fusible link 7. Coolant temperature sensor
3. Starter switch 8. Heater plug
4. Pre-heat timer 9. To Electronic injection pump control unit
5. Pre-heat indicator lamp

Fig. 1
PRE-HEAT CIRCUIT
1. PRE-HEAT.
TW G2 M N
When the coolant temperature is 0°C (32°F) or be-
R E
L
low, and the starter switch is turned to the “ON” posi-
tion, the current flows, as indicated by the arrows in
the diagram at the left, causing the pre-heating indi-
– + – +
cator lamp to turn on and pre-heating is carried out.
When the coolant temperature is above 0°C (32°F),
the pre-heating indicator lamp lights up momentarily
Fig. 2 ASM20-3002B
only and pre-heating is not carried out.
2. ENGINE START.
When after pre-heat indicator lamp goes off, imme-
diately the starter switch is set to “START”, current
TW G2 M N

L flows through the circuit, as indicated by the arrows

R E
in the left diagram causing the heater plug to glow.
The pre-heat timer turns the heater relay ON and OFF
– + – +
to maintain a constant temperature in the heater plug.

Fig. 3 ASM20-3002C
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-51

INSPECTION
1. VISUALLY CHECK THE CASING OF THE HEATER
PLUG FOR CRACKS OR MELTING.

Fig. 4 SM20-394
2. CHECK THAT THE HEATER PLUG GLOWS.
Check that the heater plug glows when 12V D.C.
source is applied across the heater plug terminals
and the body.

WARNING
Do not touch the glowing heater plug, as the tem-
perature rises to about 700°C – 1,100°C (1,292°F –
2,012°F).
Fig. 5 SM20-394

1,250
Temperature (°C)

1,000
750
500
250

0 10 20 30 40 50 60
Second

Fig. 6 SM20-394
3. CHECK THE RESISTANCE OF THE HEATER PLUG.
Measure the resistance between the terminal and
heater plug body.
If not correct, replace the heater plug.
Resistance: About 0.7 Ω at 20°C (68.0°F)

Fig. 7 SM20-394
4. CHECK THE OPERATION OF THE PRE-HEAT POWER
F RELAY.
1. Disconnect the wires and remove the relay.
S 2. Using an ohmmeter, check that there is no continuity
between terminals F and S .
SW 3. Apply 12V D.C. source across terminals SW and L .
L Using an ohmmeter, check that there is continuity be-
tween terminals F and S .
If the relay does not operate, replace the relay.
Fig. 8 SM20-1651
 1 page 1
20-52 ELECTRICAL EQUIPMENT Models FA and FB

WIPER

11
14

12
10

1 9
8 13

2 5
3
4
6

SM20-2022

1. Pivot 8. Wiper link rod

2. Wiper pivot packing 9. Crank
3. Lock nut 10. Wiper link rod
4. Shield cap 11. Wiper motor
5. Wiper arm 12. Wiper blade
6. Head cover 13. Wiper link rod
7. Washer nozzle 14. Pivot

Fig. 1
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-53

WIPER CIRCUIT

7
6
M

2 3
FL-2 5
4
8
2
FL-3

10
10 11 5 4 7
8
13 M
12

9
1

SM20-1721

1. Battery 6. Fuse (20A)

2. Fusible link 7. Washer motor
3. Starter switch 8. Wiper switch
4. Power relay No. 1 9. Intermittent relay
5. Fuse (10A) 10. Wiper motor

Fig. 1
1. LOW-SPEED.
When the starter switch is in the “ON” position and
FL-2 the wiper switch is set to “LO”, current flows through
FL-3
the circuit, as indicated by the arrows in the left dia-
gram and the motor rotates at low-speed.

Fig. 2 SM20-1721A
2. HIGH-SPEED.
When the starter switch is in the “ON” position and
the wiper switch is set to “HI”, current flows through
the circuit, as indicated by the arrows in the left dia-
gram and the motor rotates at high-speed.

Fig. 3 SM20-1721B
 1 page 1
20-54 ELECTRICAL EQUIPMENT Models FA and FB

3. INTERMITTENT.
When the starter switch is in the “ON” position and
the wiper switch is set to “INT”, current flows through
the circuit, as indicated by the arrows in the diagram
in Fig. 4, and the motor rotates intermittently.

Fig. 4 SM20-1721C
4. AUTO-STOP.
Even if the wiper switch is in the “OFF” position, un-
less the auto-stop switch inside the wiper motor turns
off, current will flow through the circuit, as indicated
by the arrows in the diagram in Fig. 5, and the motor
will continue to rotate at low-speed.

Fig. 5 SM20-1721D
5. WASHER.
When the starter switch is in the “ON” position and
the wiper switch is set to “OFF”, “LO”, or “HI”, if the
washer switch is turned on, current flows through the
circuit, as indicated by the arrows in diagram in Fig.
6, and the washer motor rotates.

Fig. 6 SM20-1721E
DISASSEMBLY
1. REMOVE THE WIPER ARM.

Fig. 7 SM20-1631
2. REMOVE THE PIVOT.

Fig. 8 SM20-1632
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-55

3. REMOVE THE WIPER MOTOR.

Fig. 9 SM20-1629
4. REMOVE EACH LINK.

Fig. 10 SM20-2027
INSPECTION
1. CHECK THE LINKS FOR BENDS.

Fig. 11 SM20-1630
2. CHECK THE BUSHINGS FOR WEAR.

Fig. 12 SM20-1636
3. CHECK THE OPERATION OF THE WIPER SWITCH.
1. Disconnect the connectors.
2. Using an ohmmeter, check the continuity of the ter-
minals in each switch position.
If there is no continuity between the switch terminals,
replace the switch.

Fig. 13 SM20-1649
 1 page 1
20-56 ELECTRICAL EQUIPMENT Models FA and FB

ASSEMBLY
1. INSTALL THE LINKS.
NOTE: Before installing the links, apply grease to the
bushings.

Fig. 14 SM20-486 SM20-2028

2. INSTALL THE WIPER MOTOR.

Fig. 15 SM20-1629
3. INSTALL THE PIVOT.

Fig. 16 SM20-1632
4. INSTALL THE WIPER ARM.

Fig. 17 SM20-1631
5. ADJUST THE POSITION OF THE WIPER BLADE.
Standard width cab: A. 120 mm (4.72 in.)
B. 50 mm (1.97 in.)

Fig. 18 SM20-2021
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-57

WINDSHIELD WASHER

2-WAY SEAT (STANDARD)

MODEL

1. Washer tank and

pump assembly
2. Hose
3. Bracket
2

1
3

SM20-3012

Fig. 1

3-WAY SEAT (OPTION) 1. Washer tank and

MODEL pump assembly
2. Hose

SM20-1634

Fig. 2
 1 page 1
20-58 ELECTRICAL EQUIPMENT Models FA and FB

TROUBLESHOOTING

Symptom Possible cause Remedy

Windshield washer does No fluid remaining in washer tank ............ Replenish tank with washer fluid.
not function
Fuse or fusible link blown out ................... Determine the cause and replace
fuse or fusible link.
Connectors for wiper switch or tank ......... Repair or replace.
are loose or rusted
Wiper switch is defective .......................... Replace.

ADJUSTMENT
1. WASHER NOZZLE.
Adjust the nozzle direction using a needle, thin piece
180 130 130 210 of wire, etc., inserted in the nozzle.
10
2. REPLENISHING THE WASHER FLUID.
Replenish the washer fluid after removing the tank.
Unit : mm Always use the proper washer fluid when replenish-
ing.
Fig. 3 SM20-1680A
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-59

POWER WINDOW

5 14 CL : CLOSE
OP : OPEN

CL OP
4 6 CL OP

7
FL-5 FL-3 CL OP

11 10 9 8

+ - + -
CLOSE CLOSE

12 M 13 M
1

1. Battery 7. Power window switch 12. Power window motor

2. Fusible link (Installed on assistant's seat side) (Driver's seat side)
3. Starter switch 8. Power window relay No.1 13. Power window motor
4. Fuse 9. Power window relay No.2 (Assistant's seat side)
5. Power relay No.4 10. Power window relay No.3 14. Circuit breaker
6. Power window switch 11. Power window relay No.4
(Installed on driver's seat side) ASM20-028

Fig. 1

WARNING
When the power window is operating, do not stick your
face, limbs, or other parts of your body out of the window,
for they will get caught between the window and window
frame. In some cases your neck may get caught in the
window, which is extremely dangerous.
The power window switch is designed so that the power
window motor will operate continuously when the tip of
the switch is pressed and held down in the CLOSE posi-
tion or OPEN position. Release the switch once the win-
dow has finished closing or opening.
 1 page 1
20-60 ELECTRICAL EQUIPMENT Models FA and FB

5 CL : CLOSE
OP : OPEN

POWER WINDOW CIRCUIT

1. WHEN THE STARTER SWITCH IS IN THE “ON”
CL OP
4 6 CL OP

3
POSITION
2

FL-5 FL-3
7
CL OP
The power relay (No.4) operates when the starter
switch is in the ON position.
11 10 9
At this point, current is supplied to the circuit as
8

indicated by the arrows in the diagram in Fig.2.

+ - + - CLOSE CLOSE

12 M 13 M
1

Fig. 2 SM20-3004B
5 CL : CLOSE
OP : OPEN
2. POWER WINDOW SWITCH (INSTALLED ON DRIVER'S
4 6
CL OP
CL OP
SEAT SIDE)
3 1. WHEN THE POWER WINDOW SWITCH (DRIVER'S
2
SEAT SIDE) IS PRESSED IN THE “OPEN”
7
FL-5 FL-3
POSITION
When the starter switch is in the ON position and the
11 10 9 8
power window switch (driver's seat side) is pressed in
the OPEN position, current is supplied to the circuit
+ - + -
12
CLOSE

M 13
CLOSE

M as indicated by the arrows in Fig. 3, opening the

Fig. 3
1

SM20-3004C
window glass in the door on the driver's seat side.
5 CL : CLOSE
OP : OPEN

CL OP
2. WHEN THE POWER WINDOW SWITCH (DRIVER'S
6
4 CL OP
SEAT SIDE) IS PRESSED IN THE “CLOSE”
3

2
POSITION
FL-5 FL-3
7
CL OP
1. When the starter switch is in the ON position and
the power window switch (driver's seat side) is
pressed in the CLOSE position, current is
11 10 9 8
supplied to the circuit as indicated by the arrows
+ - + - CLOSE CLOSE
in Fig. 4, closing the window glass in the door on
1
12 M 13 M
the driver's seat side.
Fig. 4 SM20-3004D
5 CL : CLOSE
OP : OPEN 3. WHEN THE POWER WINDOW SWITCH (ASSIST-
6
CL OP
ANT'S SEAT SIDE) IS PRESSED IN THE “OPEN”
4 CL OP

3
POSITION
2
When the starter switch is in the ON position and the
FL-5 FL-3
7
CL OP
power window switch (assistant's seat side) is pressed
in the OPEN position, current is supplied to the circuit
as indicated by the arrows in Fig. 5, opening the
11 10 9 8
window glass in the door on the assistant's seat side.
+ - + - CLOSE CLOSE

12 M 13 M
1

Fig. 5 SM20-3004E
5 CL : CLOSE

4. WHEN THE POWER WINDOW SWITCH (ASSIST-

OP : OPEN

4 6
CL OP
CL OP
ANT'S SEAT SIDE) IS PRESSED IN THE “CLOSE”
3 POSITION
2
When the starter switch is in the ON position and the
7
FL-5 FL-3 CL OP
power window switch (assistant's seat side) is
pressed in the CLOSE position, current is supplied
11 10 9 8
to the circuit as indicated by the arrows in Fig. 6,
closing the window glass in the door on the assist-
+ - + -
12
CLOSE

M 13
CLOSE

M ant's seat side.

1

Fig. 6 SM20-3004F
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-61
5. WHEN THE POWER WINDOW SWITCH (DRIVER'S
5 CL : CLOSE
OP : OPEN
SEAT SIDE) LOCK SWITCH IS IN THE “LOCK”
4 6
CL OP
CL
POSITION
OP

3
When the starter switch is in the ON position and the
2
lock switch is in the LOCK position, current is supplied
FL-5 FL-3
7
CL OP
to the circuit as indicated by the arrows in Fig. 7. At
this time, the assistant's seat side window will not
11
move, even if the power window switch installed on
10 9 8
the assistant's seat side is pressed. (But the window
+ - + - CLOSE

13
CLOSE can still be opened or closed normally, by operating
12 M M
1 the power window switch installed on the driver's seat.)
Fig. 7 SM20-3004G
5 CL : CLOSE
OP : OPEN 3. POWER WINDOW SWITCH (INSTALLED ON ASSIST-
CL OP
ANT'S SEAT SIDE)
4 6

1. WHEN THE POWER WINDOW SWITCH IS

CL OP

2
PRESSED IN THE “OPEN” POSITION
FL-5 FL-3
7
CL OP
When the starter switch is in the ON position and the
lock switch on the power window switch installed on
the driver's seat side is not in the LOCK position, cur-
11 10 9 8
rent is supplied to the circuit as indicated by the ar-
+ - + - CLOSE CLOSE rows in Fig. 8 when the power window switch is
12 M 13 M
1 pressed in the OPEN position. At this time, the win-
Fig. 8 SM20-3004H dow glass in the door on the assistant's seat side will
5 CL : CLOSE
OP : OPEN open.
4 6
CL OP
CL OP 2. WHEN THE POWER WINDOW SWITCH IS
3
PRESSED IN THE “CLOSE” POSITION
2
When the starter switch is in the ON position and the
7
FL-5 FL-3 CL OP
lock switch on the power window switch installed on the
driver's seat side is not in the LOCK position, current is
11 10 9 8 supplied to the circuit as indicated by the arrows in Fig.
9 when the power window switch is pressed in the
+ - + -
12
CLOSE

M 13
CLOSE

M CLOSE position. At this time, the window glass in the

Fig. 9
1

SM20-3004I door on the assistant's seat side will close.

DRIVER'S SEAT SIDE WINDOW SWITCH INSPECTION

1. CHECKING THE POWER WINDOW SWITCH
(DRIVER'S SEAT SIDE)
1. Remove the connector.
2. Using an ohmmeter, check the terminal current
flow for each switch position. If there is no
WINDOW LOCK
SWITCH switch terminal current flow, replace the
switch.
ASSISTANT'S SEAT SIDE WINDOW SWITCH

Fig. 10 SM20-3006

DRIVER'S SEAT SIDE WINDOW SWITCH

a. Power window switch (driver's seat side)
CLOSE
2 1
6 5 4 3

1 2 3
CLOSE
OFF °°
OPEN
OPEN
° °
Fig. 11 SM20-3007
 1 page 1
20-62 ELECTRICAL EQUIPMENT Models FA and FB

b. Power window switch (assistant's seat side)

2 1
6 5 4 3
(Check the power window switch when it is not in
CLOSE the LOCK position. Pressing the switch downward
WINDOW LOCK
SWITCH
ASSISTANT'S SEAT SIDE will release it from the LOCK position.)
WINDOW SWITCH

1 4 5 6
CLOSE
° °° ° °°
° °
OFF
OPEN
° ° ° °
OPEN

Fig. 12 SM20-3008
2. CHECKING THE POWER WINDOW SWITCH. (ASSIST-
CLOSE ANT'S SEAT SIDE)
2 1 1. Remove the connector.
6 5 4 3 2. Using an ohmmeter, check the terminal current flow for
each switch position. If there is no switch terminal current
OPEN
flow, replace the switch.
1 2 3 4 5
CLOSE
°°
OFF
°° °° ° °
° °
OPEN

Fig. 13 SM20-3009
3. CHECK THE OPERATION OF THE POWER WINDOW
RELAY.
1. Remove the connector.
2. Using an ohmmeter, check that there is no continuity
between terminals q and r .
3. Using an ohmmeter, check that there is continuity be-
tween terminals q and e .
4. Apply voltage to terminals;
12V to terminal w,
Ground to terminal y.
Fig. 14 SM20-3010 5. Using an ohmmeter, check that there is continuity be-
tween terminals q and r.
If the relay does not operate, replace it.
 1 page 1
Models FA and FB ELECTRICAL EQUIPMENT 20-63

SPEAKER AND ANTENNA

REMOVAL OF SPEAKER AND ANTENNA

1. SPEAKER.
1. Remove the corner over head console.

Fig. 1 SM20-2024
2. Remove the speaker fitting bolts and disconnect the
connector of the speaker.
NOTE: The speaker is 4Ω 6W type.

Fig. 2 SM20-1674
 1 page 1
20-64 ELECTRICAL EQUIPMENT Models FA and FB

2. ANTENNA.
1. Remove the over head console.

Fig. 3 SM20-1723A
2. Remove the cable from clips.

CLIPS
Fig. 4 SM20-1724
3. Remove the fitting bolt and disconnect the cable con-
nector.
4. Remove the antenna.

Fig. 5 SM20-1675
INSTALLATION
Carry out installation in the opposite sequence of re-
moval.
Install the antenna securely on the roof, ensuring that
it does not become loose.