INTRODUCTION
INTRODUCTION HOW TO READ WIRING DIAGRAM CAUTION + PRECAUTIONS FOR FOR HANDLING ELECTRICAL ELECTRICAL UNITS + Before Before servicing or repairing repairing electrical electrical parts, be sure the ground cable and body grounding connection are disconnected. The ignition switch should be turned off.
The electric wiring diagrams contained within this service manual use abbreviations, symbols, and numbers. This chapter explains their meanings and how to read the wiring diagrams.
ABBREVIATION The parts abbreviation indicates the name, location and condition of each part, such as a switch, meter, or light. ON
Switch on
OFF
Switch off
ACC
Accessory
ST
Start
RH
Right hand
LH
Left hand
AOH
Air over hydraulic brake
W/L
Warning light
INTRODUCTION
CIRCUIT CONNECTION A circuit connection is indicated by lines showing the electric wires connecting the electrical devices.
Wire size and color code As shown below, the number indicates the size of the wire (nominal sectional area of the conductor, mm2), and the letter at the end of each number indicates the color of the covering.
CEL7058A
Wire color code and symbol The color of a wire covering is indicated by an alphabetical symbol. There are two types of wire colors; one is of a unicolor, the other of a ground unicolor with an identifying stripe color.
INTRODUCTION
The alphabetical symbols are as follows. Alphabetical symbol
Color
Mainly-used locations (Circuit name)
W
White
Power supply
B
Black
Grounding
R
Red
Lighting
Y
Yellow
Meter
G
Green
Signal
L
Blue
Window wiper
BR
Brown
LG
Light green
GY
Gray
With marking (stripe) Example Alphabetical symbol
Ground color
Stripe color
W/B
White
Black
B/R
Black
Red
L/G
B l ue
Green
G/W
Green
White
BR/Y
Brown
Yellow
LG/R
Light green
Red
INTRODUCTION
Indication of joint between connectors A single lead or wire is indicated by a connector at the joint in wiring diagrams. Multiple leads or wires are indicated by terminals of a connector at the joints joints.. The connec connector tor style style is separa separatel tely y indica indicated ted nea nearr the joints to identify the terminals.
CEL6006A
Indication of joint between unit and connector (When unit is provided with terminals) When leads emerge directly from a unit or when a unit is provided with a terminal connector, the terminal numbers corresponding to the leads are indicated by the 1st connector counting from the unit as shown in the figure.
CEL7061A
Indication of ground and battery The The grou ground nd (GND (GND)) symb symbol ol is indi indica cate ted d only only wh when en a unit unit or component is directly grounded to body metal (GND) without using a lead. A combination of the ground and connector symbols are indicated for a unit or component which is grounded using a lead.
INTRODUCTION
Indication of switch The switches are illustrated as in the normal state. The switch which is off in the normal state is called a ‘‘normal open switch’’, and that which is on in the normal state is called a ‘‘normal close switch’’.
INTRODUCTION
Indication of relay The relays use normal open relays. As shown in the figure, the norm normal al open open rela relay y ma make kes s wh when en it is oper operat ated ed.. The The rela relay y that that brea breaks ks when it is operated is called a normal closed relay. Similar to conventional switches, relays are shown in the ‘‘OFF’’ state in wiring diagrams.
CEL6010A
Circuit operation chart All wiring diagrams show the relays in a ‘‘break’’ state in which current does not flow through the electrical components. With the exception of the above, relays which switch from one position to another, such as multi-position switches, are shown in the circuit operation operation chart to clearly clearly indicate indicate the relationshi relationship p of the connections.
CEL6011D
INTRODUCTION
Example 2 a. The connector connector symbol symbol is divided divided into 8 square square sections sections which indicates an 8-pole connector. b. The The wh whit ite e rect rectan angu gula larr sect sectio ion n at the the top top of the the conn connec ecto torr symbol indicates a ‘‘female’’ connector. c. The four four corners corners of the connec connector tor symbol symbol are 90°so 90°so the symbol symbol indicates an ‘‘M’’ type connector.
CEL6012C
HOW TO TRACE CONNECTIONS When tracing a connection between two connections, match them with connector guide placed on the other guide (as if you were closing a book). The squares facing each other in this condition are the corresponding terminals. It is wrong to trace in parallel. NOTE + The connector guide guide is the positioning convex part of the connector.
How to trace SMJ connections The SMJ connector is designed so that each terminal position is indicated by an alphanumerical ‘‘address’’. Since only the ‘‘address’’ is indicated in wiring diagrams, the SMJ connector chart should also be used as a guide in determining a terminal position on the SMJ connector side.
INTRODUCTION
How to trace respective system power supply In each wiring diagram, power supplies located upstream of the applicable fuses are abbreviated as shown in Figures Figures EL-13-2 EL-13-2 & EL-13-4. EL-13-4. To trace a power supply, the leading wiring diagrams (pages EL-13-1 to EL-13-4) should be referred to first and the required power supply can be traced back from the applicable fuse.
ZEL340A
ILLUSTRATION OF CONNECTORS
ILLUSTRATION OF CONNECTORS CONNECTORS The symbol of a connector in the wiring diagram indicates the number of poles, type, and male or female shape of the terminal from which the connector of an electrical device can be checked.
ILLUSTRATION OF CONNECTORS
RELAY
CEL6-017
BATTERY BATTERY AND AND CIRCUIT PROTECTOR PROTECTOR
BATTERY AND CIRCUIT PROTECTOR BATTERY Item Type
Rated voltage [V]
5-hour 20-hour 20-hour rate ampere rate capacity [AH] [AH]
Charging current [A]
115E41R (NS120)
12
88
110
11
115E41R-MF (NS120)
12
88
110
11
115F51 (N120)
12
96
120
12
115F51-MF (N120)
12
96
120
12
115F51-HB (N120)
12
96
120
12
145F51 (NS150)
12
112
140
14
145F51-MF (NS150)
12
112
140
14
145G51 (N150)
12
120
150
15
145G51-MF (N150)
12
120
150
15
195G51 (NX300-15)
12
140
170
17
BATTERY BATTERY AND AND CIRCUIT PROTECTOR PROTECTOR
Inspection 1. Check the electro electrolyte lyte level. The bat batter tery y electr electroly olyte te should should be mainta maintaine ined d bet betwee ween n the upper and lower levels on the case. If low, add distilled water to the the spec specif ifie ied d leve levell and and char charge ge the the batt batter ery y for for at leas leastt 30 minutes.
CT-019E
2. Using Using a gravim gravimete eter, r, measure measure the specif specific ic gravity gravity of the elecelectrolyte in each cell. Maintenance standard [Electrolyte [Electr olyte temperatur te mperature e at 20°C 20°C (68°F)] (68°F)] 1.200 - 1.290 NOTE + Rea Read d the indicat indicatio ion n at the upper upper end of the the ele electr ctroly olyte te surface. + The measured measured specific gravity gravity of the electrolyt electrolyte e must be corrected to the 20°C (68°F) standard. S20 = St + 0.0007 (t − 20) Where, S20: Specific Specific gravity of electroly electrolyte te at standard temperatemperature 20°C (68°F) St: Specific Specific gravit gravity y measured measured at t°C t: Temperatur emperature e of measured measured electrolyt electrolyte e (°C)
CEL1043A
BATTERY BATTERY AND AND CIRCUIT PROTECTOR PROTECTOR
WARNING + Be careful not to spill battery electrolyte on any part of your body, clothes or finished surfaces of parts. + Do not touch your eyes with dirty hands. After handling battery electrolyte, wash your hands thoroughly under running water. water. + If electrolyte should come into contact with your eyes, rinse the eyes for at least fifteen minutes and immediately see a doctor. 3. Chec Check k that that the the batt batter ery y and and batt batter ery y term termin inal als s are are free free from from corrosion corrosion and dirt.
Charging the battery 1. Charge the the battery with with a charger while measurin measuring g the specific specific gravity of the electrolyte every 30 minutes. Charge until the specific gravity reads between 1.25 and 1.29 for 3 consecutive readings and all cells reach a voltage of 2.5 to 2.7 volts. NOTE
BATTERY BATTERY AND AND CIRCUIT PROTECTOR PROTECTOR
- MEMO -
HARNESS HARNESS LAYO LAYOUT UT
HARNESS LAYOUT SCHEMATIC SCHEMATIC DIAGRAM The schematic diagram illustrates how each harness (main harness, chassis harness, floor harness, floor upper harness, body side harness, etc.) is wired on the actual vehicle. Depending on the vehicle model, however, the arrangemen arrangements ts of the wires and units may sometimes sometimes be different, different, so the respective respective schematic schematic diagrams must be carefully checked to see if they coincide with the arrangements in the actual vehicle.
HARNESS HARNESS LAYO LAYOUT UT
t i n u l o r r t e e n g ) z o ) ) u 1 z t ) u c 3 2 a y h . - 1 - 1 i n o U g - b t a g ( l ) ) ) ) i R R n h l B o e n e i e N n ( u c s h e ) D r r l s r t e w t h ( D ( s u i t s s s c i k c e g y u h t s a c t e n t h e e o i h l w i h a l u i c s t r o u r c r i l t c H H r r a a n n t s t i n w t r o o w c r r n m e r r i r G R R e s i e t t n s r ( B ( W ( B ( B ( r s w h a a r t w e c w e r e c c n n n p o h h h h r r r r r a h s t s s a e o f s p k i h e e c s c w z e a n c t s s n c e e e e e h i c c g t o r o m t h m r w r z t t t t t i n l h e t t y i o i h s o u t e o l n i t n c t r e i e b e i t i s s s s s d p p i s n n a t a t g t t b a n e t e k l w i e t l i w w l m d i u l u l u l u l u e r n r d s a e o o b l a s i k a t t r e e l e n p s s d i h a a e c c e r t r c c c c n r h g e i r n c s i i o g u h h c h s s d e m y e a s u t i r r r r r p r o e s a e h r j o r c c e e c r e s e e r b t r r y u r e r a r l l - n a c h a e p e t e t e t e e e c d a a i t t r m d n s o t t t r m o o a t a d e h g c h w n c g u u a a o o a r i o e e e e e m v i p p o n o x u a l l l o t e o c o r o o o x p 2 r i i i C S S R A H E J T F C C M M M M M O C S S F A L F D D B E S 1 T D T A D 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 4 5 7 1 2 9 4 - 4 - 4 - 4 - 4 - 4 - 4 - 4 - 4 - 5 - 5 - 5 - 5 - 5 - 5 - 5 - 5 - 5 - 5 - 6 - 6 - 6 - 6 - 6 - 6 - 6 - 6 - 6 - 6 - 7 - 7 - 7 - 7 - 8 - 8 - 8 M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M
HARNESS HARNESS LAYO LAYOUT UT
h c ) i h t ) ) ) 2 1 . c w 2 t - 1 - 1 i s U - o ( ) ) ) ) R R N w k h B n n e k ) ( c s s c D t e w t ( D ( s h i h s s s i c e h h c o c e h e O l e o h w a u t c s t r r i c n n l l i t c H H e r r s t T l i t r r i r r i w o o G B W B B w h a e e t t n R R n s r P t i ( ( ( ( ( s w c w e t t c c w a a r s t s s a o s h h h h r r r r r n h i s n n h h e z e e c t w r z t s s h k c t h r t e e t e t e t e o t c c t g i g n n a o e i h s o u h e r i e l i s t c p e i t r e i i s s s s t s f n n e e g t t b a n e l e a w r l p i c w w u u u u u r n r d s l a e e o o l a l l l l l i f s a b t r e b i t p s s a i h a a c c e r t r c c c c i n r h g e i g u h h c s g t m d t s h h y e e e p i r r r r r l a e e r o b e c r r r r l s r t r r y i c t c e t n e e t e t e t e m t a n a a a t r r g e m o n d r a r h o d r c i c w a c o g i g p p o o u l u t a a a o l e e e e e o t e o c o r o o o p e r h i a l T T C C S S R H T F C C M M M M M C S S F A L F D D B S R 8 9 0 1 2 3 4 6 9 0 1 2 3 4 5 6 7 9 0 1 2 3 4 5 6 7 8 1 2 3 - 3 - 4 - 4 - 4 - 4 - 4 - 4 - 4 - 5 - 5 - 5 - 5 - 5 - 5 - 5 - 5 - 5 - 6 - 6 - 6 - 6 - 6 - 6 - 6 - 6 - 6 - 7 - 7 M M M M M M M M M M M M M M M M M M M M M M M M M M M M M
HARNESS HARNESS LAYO LAYOUT UT
) ) M M ) ) / M M T / ) T / r d d T / o ) t e T ) r e r c d d e e o o a t p p t ) e r c s t e e c e s e M a r a / p v r p 2 r l s t o 2 t T 1 s f a - r 1 r 2 r t v d 2 o r o o p e 1 c F r o i F ) r 1 e F F ( e o t ( r ( o c t p ) ( ) e o e ) c ) x F F s n ( H H H e H E a v ) ( g ) ) l ( r ) ) r 2 v R L r r r L t r R e e l ) a ( ( e a ( ( o ) ) o t o o t r t v v v e o t h ) 1 l t t 8 4 v v a m t r l v c o c t g w o c c t a l a l h a h h c h F i 3 6 a c a v o i k v a a g g c g g a a r v h h l F t t r t r t i r i c r i l ( t l t l i l t ( i C C h c i e i c v i c t c n ( ( o ) t n r e c l r r r n t c t t n r r r i n n n h o i o o h e t g n h o t i h l 1 o o o i e t s s o i o F o i o g g c - F i w h h t i e a g s s a T n e F F t l w t t t i l F t i n i ( s c h n s ( ( n c ( ( a t ( r e e ( g g ( a a a a i t g t t w m i g e e n o n n a a r r s s e n n n n a n r h i i t r h i t i h e w w s e r n r s m a h m n s s t a e r s a h r s g u a t g e a s e r b l r b b l s m m k i z b i o o t z h e a a g w e l l e e c h m i h a p r p z z f h h n n m m h h m m s o r f e g w h l s r r e o e u o p s i i n w i w b c c l s e o o e p u i s g o g o r a o i i o e e d t a d a i i s b c u s e c c s u - e r t r e - b s h h e c r H L H L g s h l a t h r n r g g s r r n s n e d k k k k i m a e c a c p c c u a m a a e c c a r l b b a L n n e t r e i r / M / M / M / M p e / M L c a e a i c a a h l l P P a a p c h a h i r e e i a u u r e i T T S S F R L B R B A T T T T S E E T S S R R S A C F R R L B B C 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 4 5 3 - 3 - 3 - 4 - 4 - 4 - 4 - 4 - 4 - 4 - 4 - 4 - 4 - 5 - 5 - 5 - 5 - 5 - 5 - 5 - 5 - 5 - 5 - 6 - 6 - 1 - 2 - 3 - 4 - 5 - 6 - 7 - 8 C C C C C C C C C C C C C C C C C C C C C C C C C T T T T T T T T
HARNESS HARNESS LAYO LAYOUT UT
) r ) r o t o t ) ) r c c r o a a o t r t r t t c c e r r a ) a v r r r o o l t t o F a F t r r v c ( ( o ) o a 2 c F t h r r 1 i F ) ( t ( . . c o t t ) ) ) e i r o o ) c n H ) o N N H H w H a g F s r ) r L R r R h ) a ( t ( t ( L ( t o ( h ) o t c c h ) 8 r t t o t t t m h c h i t i i g w h c h c h h g 3 i a o k F a w w h l l i s g ( g t g i g r t i i r i c s l l l l C w t t t ( o ) p n n r l s r e e r r n n n n h o h o o l k k o o s t l 1 o o o o g g i i i i i F s a T S o o t l ( t t i l F t ( e i r t r h ( h ( e t v t ( ( l a e a t e a a e t e n n r s s r s n n n n r t h t h r s s b t h i t i h l r r n h i i t r n r a t a e a h g d g e s e a r b l b l r r e r b b l i i z o o z i e e l e h r r h e a a f a m p z m u t t h h a m m p z n c o t o t e e f r c l s s c c i i n u o p f s e o o e p u t r e o r a o o i i u b c c o o i e e c e s b c u s e e d a h s e r r w e o o e t s m r r n k k p m r n k r k k r m m d m m s a b t c c a r h l b m a a e c a c a b a a e c c i t r i r l e l e h a l l l c a e a r i c a a r a r h i r e e i i t i t i p a a u u r e i T T T S F F T T S J F R L B R B B A A E E C F R R L B B 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 8 9 0 3 4 3 - 3 - 3 - 3 - 3 - 3 - 3 - 3 - 3 - 4 - 4 - 4 - 4 - 4 - 4 - 4 - 4 - 4 - 5 - 5 - 5 - 1 - 2 - 3 - 4 - 5 - 6 - 7 C C C C C C C C C C C C C C C C C C C C C T T T T T T T
LOCATION OF ELECTRICAL UNIT
RELAY (CAB SIDE) RHD model
LOCATION OF ELECTRICAL UNIT
SUPER MULTIPLE JUNCTION (SMJ) Connector mounting bolt : 3 - 5 N·m N·m {0.3 {0.3 - 0.5 kgf kgfzm, 2.2 - 3.6 ftzlbf}
CEL6028A
CEL6028B
FUSE
EARTH POINT
EARTH POINT CHASSIS SIDE CDzCW series
STARTING SYSTEM
ENGINE COOLANT TEMPERATURE SENSOR Specifications Temperature range
−40 to 120°C (−40 to 248°F)
Rated resistance valve
1.011 - 1.411 kΩ
Inspection Using a tester (in ohm range), measure resistance values across the sensor terminals at different test temperatures (see the following table). Test temperature °C (°F)
Current mA
Resistance kΩ
39 - 41 (102 - 106)
1
1.011 - 1.411
59 - 61 (138 - 142)
1
0.505 - 0.805 CEL5011C
SUB STARTER SWITCH Specifications Rated voltage
V
24
Voltage drop
V
0.3 or less in 4 amperes
O
ti
N {k f lbf}
20
39 {2
4 4
9}
METER CLUSTER
Removing the meter cluster 1. Move the steering steering wheel wheel away from from the meter cluster cluster as far far as possible by operating the tilt/telescopic mechanisms. 2. Remove Remove the screws securing securing the meter cluster assembly assembly.. 3. Disconnect Disconnect the the tube from the the air pressure pressure gauge. 4. Disconnect Disconnect various various connectors connectors and speedometer speedometer cable from the meter cluster assembly; remove the meter cluster assembly. CEL6120K
Replacement of bulbs
CEL6120L
Removing the speedometer or tachograph 1. Remove Remove the meter cluster. cluster. (For removal removal procedures, procedures, refer to ‘‘METER CLUSTER’’.) 2. Rem Remove ove the screws screws.. Pull Pull the speedome speedometer ter (tachogr (tachograph aph)) assembly out from the instrument panel. 3. Discon Disconnec nectt the harnes harness s connec connector tors s and speedo speedomet meter er cable cable
WARNI NG SYS SYSTE TE M
WARNING SYSTEM CAUTION + PRECAUTIONS FOR FOR HANDLING ELECTRICAL ELECTRICAL UNITS + Before servicing the electrical electrical unit, be sure to turn turn the key switch switch to ‘‘OFF’’ ‘OFF’’ and disco disconne nnect ct the the negati negative ve (−) cable cable from the battery to ensure safety. For warning system circuit diagrams, refer to ‘‘METER CLUSTER’’.
ENGINE COOLANT LEVEL AND OVER HEAT WARNING BUZZER Inspection Check the continuity, insulation and operation of the buzzer.
CEL5019E
ENGINE OVERRUN BUZZER Inspection Check the continuity, insulation and operation of the buzzer. Rated voltage 24V
WARNI NG SYS SYSTE TE M
LOW AIR PRESSURE WARNING BUZZER Inspection Check the continuity, insulation and operation of the buzzer. Rated voltage 24V
CEL6120R
AIR PRESSURE SWITCH Inspection Using a circuit tester (ohm range), check the switch to see that it makes (body earth) and breaks the circuit under the specified air pressure. Turn-on pressure
Type I
422 422 - 481 481 kPa {4.3 {4.3 - 4.9 4.9 kgf/ gf/cm2, 61 - 70 psi}
Type II
49 - 69 kPa {0. {0.5 - 0.7 kgf/ gf/cm2, 7 - 10 psi}
Turn-off pressure
Type I
422 - 530 530 kPa kPa {4.3 {4.3 - 5.4 5.4 kgf/ gf/cm2, 61 - 77 psi}
Type II
49 - 98 kPa {0. {0.5 - 1.0 kgf/ gf/cm2, 7 - 14 psi}
CEL5023C
LIGHTING SYSTEM
BACK-UP LIGHT Specifications Type I
24V 25W
Type II
24V 21W
CEL5052C
CEL5052D
BACK-UP BACK-UP LIGHT SWITCH Inspection Check the continuity between the terminals with a circuit tester (ohm range). L should be 23 to 24 mm (0.91 to 0.94 in) when the switch is off.
OPERATION SYSTEM
Inspection Check the continuity between the respective terminals of the power window switch with a circuit tester (ohm range).
POWER WINDOW SWITCH (PASSENGER SIDE)
CEL5073E
Inspection Check the continuity between the respective terminals of the power window switch with a circuit tester (ohm range). OPERATION TERMINAL
OPERATION CONNECTED TO
OPERATION SYSTEM
Specifications MANUAL MODE INPUT Terminal No. 1 IGN SW
⊕
Terminal No. 4
Terminal No. 5
Terminal No. 6
MANUAL UP SW
MANUAL DOWN SW
MOTOR (L)
ON
OFF
⊕
@
OFF
ON
@
⊕
OFF
OFF
@
@
ON/OFF
ON/OFF
@
@
ON
OFF
OUTPUT Terminal No. 7
MOTOR (R, L)
AUTO MODE INPUT Terminal No. 1
Terminal No. 2
Terminal No. 3
IGN SW ⊕
AUTO UP SW
AUTO DOWN SW
ON
OFF
OFF
ON
OFF
OFF
ON
OUTPUT
MOTOR REVOLVING CONDITION
MOTOR (L)
DRIVE
⊕
@
STOP
@
@
DRIVE
@
⊕
STOP
@
@
DRIVE
@
@
Terminal No. 6
Terminal No. 7 MOTOR (R, L)
ACCESSORY SYSTEM
- MEMO -
WIRING DIAGRAM
CHARGING SYSTEM RHD model
WIRING DIAGRAM
LHD model
WIRING DIAGRAM
AIR DRYER
WIRING DIAGRAM
TRAILER AND SPRING BRAKE INDICATOR LIGHT RHD model
WIRING DIAGRAM
AIR PRESSURE WARNING LIGHT RHD model
WIRING DIAGRAM
LHD model
WIRING DIAGRAM
LHD model
WIRING DIAGRAM
AIR FILTER WARNING LIGHT RHD model
WIRING DIAGRAM
CLUTCH DISC WEAR WARNING LIGHT
WIRING DIAGRAM
HEADLIGHT RHD model (Except for Australia)
WIRING DIAGRAM
RHD model (For Australia)
WIRING DIAGRAM
BACK-UP LIGHT Except tractor
WIRING DIAGRAM
Tractor
WIRING DIAGRAM
ROTARY BEACON LIGHT
WIRING DIAGRAM
LHD model
WIRING DIAGRAM
TRANSMISSION HIGH-LOW CHANGE SYSTEM 10-speed transmission
WIRING DIAGRAM
THIRD DIFFERENTIAL LOCK SYSTEM RHD model
WIRING DIAGRAM
LHD model
