Download as pdf or txt
Download as pdf or txt
You are on page 1of 52

OTHER ELECTRICAL SYSTEM

CONTENTS
PRECAUTIONS FOR OPERATION ............................................................ OE-1
PRECAUTIONS FOR HANDLING ELECTRICAL UNITS ....................... OE-1
ELECTRICAL CIRCUIT CONTINUITY CHECKING PROCEDURE........ OE-1
SMALL-SIZED GENERAL PURPOSE RELAY............................................ OE-3
TYPE ....................................................................................................... OE-3 OE
DESIGNATION ........................................................................................ OE-3
LIST (ISO TYPE)..................................................................................... OE-4
INSPECTION .......................................................................................... OE-4
AUXILIARY BRAKE SWITCH (EEB: EXTRA ENGINE BRAKE) ................. OE-5
REMOVAL AND INSTALLATION ............................................................ OE-5
INSPECTION .......................................................................................... OE-5
AUXILIARY BRAKE CLUTCH SWITCH ...................................................... OE-7
REMOVAL AND INSTALLATION ............................................................ OE-7
INSPECTION .......................................................................................... OE-7
TRANSMISSION PTO SWITCH.................................................................. OE-8
CIRCUIT DIAGRAM ................................................................................ OE-8
REMOVAL AND INSTALLATION ............................................................ OE-8
INSPECTION .......................................................................................... OE-9
PTO CLUTCH SWITCH............................................................................. OE-10
REMOVAL AND INSTALLATION .......................................................... OE-10
INSPECTION ........................................................................................ OE-10
PTO INDICATOR SWITCH......................................................................... OE-11
REMOVAL AND INSTALLATION ........................................................... OE-11
INSPECTION ......................................................................................... OE-11
PTO MAGNETIC VALVE ........................................................................... OE-12
REMOVAL AND INSTALLATION .......................................................... OE-12
INSPECTION ........................................................................................ OE-12
THIRD DIFFERENTIAL LOCK SWITCH ................................................... OE-13
REMOVAL AND INSTALLATION .......................................................... OE-13
INSPECTION ........................................................................................ OE-13
THIRD DIFFERENTIAL LOCK MAGNETIC VALVE .................................. OE-14
REMOVAL AND INSTALLATION .......................................................... OE-14
INSPECTION ........................................................................................ OE-14
HORN SWITCH ......................................................................................... OE-15
INSPECTION ........................................................................................ OE-15
REPAIR AND REPLACEMENT............................................................. OE-15
HOR CHANGEOVER SWITCH ................................................................. OE-16
REMOVAL AND INSTALLATION .......................................................... OE-16
INSPECTION ........................................................................................ OE-16
AIR HORN MAGNETIC VALVE ................................................................. OE-17
REMOVAL AND INSTALLATION .......................................................... OE-17
INSPECTION ........................................................................................ OE-17
ELECTRIC HORN ..................................................................................... OE-18
REMOVAL AND INSTALLATION .......................................................... OE-18
INSPECTION ........................................................................................ OE-18
WIPER AND WINDOW WASHER SWITCH.............................................. OE-19
REMOVAL AND INSTALLATION .......................................................... OE-19
INSPECTION ........................................................................................ OE-19
WIPER MOTOR......................................................................................... OE-20
REMOVAL AND INSTALLATION .......................................................... OE-20
INSPECTION ........................................................................................ OE-20
WINDOW WASHER MOTOR .................................................................... OE-21
REMOVAL AND INSTALLATION .......................................................... OE-21
INSPECTION ........................................................................................ OE-21
POWER WINDOW .................................................................................... OE-22
CIRCUIT DIAGRAM .............................................................................. OE-22
POWER WINDOW SWITCH (DRIVER’S SIDE)........................................ OE-23
REMOVAL AND INSTALLATION .......................................................... OE-23
INSPECTION ........................................................................................ OE-24
POWER WINDOW SWITCH (PASSENGER’S SIDE) ............................... OE-25
REMOVAL AND INSTALLATION .......................................................... OE-25
INSPECTION ........................................................................................ OE-26
POWER WINDOW MOTOR ...................................................................... OE-27
REMOVAL AND INSTALLATION .......................................................... OE-27
INSPECTION ........................................................................................ OE-27
POWER MIRROR SWITCH ...................................................................... OE-28
CIRCUIT DIAGRAM .............................................................................. OE-28
REMOVAL AND INSTALLATION .......................................................... OE-28
INSPECTION ........................................................................................ OE-28
POWER MIRROR MOTOR ....................................................................... OE-29
REMOVAL AND INSTALLATION .......................................................... OE-29
INSPECTION ........................................................................................ OE-29
MIRROR HEATER SWITCH...................................................................... OE-30
REMOVAL AND INSTALLATION .......................................................... OE-30
INSPECTION ........................................................................................ OE-30
TIMER UNIT .............................................................................................. OE-31
CIRCUIT DIAGRAM .............................................................................. OE-31
INSPECTION ........................................................................................ OE-31
CENTRALIZED DOOR LOCK SWITCH .................................................... OE-33
REMOVAL AND INSTALLATION .......................................................... OE-33
INSPECTION ........................................................................................ OE-33
CENTRALIZED DOOR LOCK ACTUATOR............................................... OE-34
REMOVAL AND INSTALLATION .......................................................... OE-34
INSPECTION ........................................................................................ OE-34
KEYLESS ENTRY SYSTEM ..................................................................... OE-35
CIRCUIT DIAGRAM .............................................................................. OE-35
REMOTE CONTROL FOR KEYLESSENTRY SYSTEM....................... OE-35
KEYLESS ENTRY CONTROL UNIT ..................................................... OE-37
AUTO WATER DISCHARGE SWITCH...................................................... OE-38
REMOVAL AND INSTALLATION .......................................................... OE-38
INSPECTION ........................................................................................ OE-38
MALTIDISPLAY OPERATION SWITCH .................................................... OE-39
REMOVAL AND INSTALLATION .......................................................... OE-39
INSPECTION ........................................................................................ OE-39
AUDIO, RADIO, CD................................................................................... OE-40
REMOVAL AND INSTALLATION .......................................................... OE-40
INSPECTION ........................................................................................ OE-40
ANTENNA.................................................................................................. OE-41
REMOVAL AND INSTALLATION .......................................................... OE-41
INSPECTION ........................................................................................ OE-42
CIGARETTE LIGHTER.............................................................................. OE-43
REMOVAL AND INSTALLATION .......................................................... OE-43
INSPECTION ........................................................................................ OE-43
OTHERS.................................................................................................... OE-44
PTO RELAY........................................................................................... OE-44
PTO PARKING BRAKE RELAY ............................................................ OE-44
MIRROR HEATER RELAY .................................................................... OE-44
SERVICE DATA ......................................................................................... OE-45
SPECIFICATIONS................................................................................. OE-45
TIGHTENING TORQUE ........................................................................ OE-49
PRECAUTIONS FOR OPERATION

PRECAUTIONS FOR OPERATION


PRECAUTIONS FOR HANDLING ELECTRICAL
UNITS
 Before servicing the electrical units, be sure to turn the ignition
switch to “OFF” and disconnect the negative cable from bat-
tery to ensure safety.
 If any of the electrical systems and wiring are changed or mod-
ified arbitrarily, there is the possibility of vehicle trouble as well
as fire due to an overloaded circuit or short circuit.
 When cleaning the electrical units, do not use water including
spray and steam or do not wash with organic chemical agent
(such as thinner). Use a dry and soft cloth for cleaning

ELECTRICAL CIRCUIT CONTINUITY CHECK-


ING PROCEDURE
 Do not under any circumstances use the needle of a test light,
since it may damage the electrical wire coating and cause cor-
rosion of the electrical wiring.
 In the situation where continuity testing is being carried out
using the harness connector parts, use the following method.
<Check with the connector connected>
Non-waterproof type connector
Contact a tester lead to the wiring side of the connector.

Waterproof type connectors


Do not contact a tester lead directly to the wiring side of the water-
proof type connector without using a check harness. The water
proofing property of the connector may be reduced, causing corro-
sion.
Insert and connect a check harness (self-made) between the male
and female contacts of the connector to be checked and contact a
tester lead to the connector wiring side of the check harness.

OE-1
PRECAUTIONS FOR OPERATION

<Check with the connector disconnected>


Non-waterproof or waterproof type connector
Do not contact a tester lead directly to the connecting face of the
connector. The terminal may be deformed, causing a poor contact.
Contact a tester lead to the connecting face of the connector via a
lead wire.

OE-2
SMALL-SIZED GENERAL PURPOSE RELAY

SMALL-SIZED GENERAL PURPOSE RELAY


TYPE
The relay falls roughly into two groups based on the contact struc-
ture: Normal open and transfer relay.

NOTE
 The coil in the relay that is not excited is in the normal
state, while the coil that is excited is in the energized
state.

DESIGNATION

OE-3
SMALL-SIZED GENERAL PURPOSE RELAY

LIST (ISO TYPE)

INSPECTION
1. Check continuity and insulation between the relay terminals.
2. Apply 24V to the coil to check for proper operation.

OE-4
AUXILIARY BRAKE SWITCH (EEB: EXTRA ENGINE BRAKE)

AUXILIARY BRAKE SWITCH


(EEB: EXTRA ENGINE BRAKE)
When this switch is moved to the 1st position operation position
when the foot is removed from the accelerator and clutch pedals,
the EEB (low) will engage, and when moved to the 2nd position
operation position under the same conditions, both the EEB (high)
with engage, and the indicator light will illuminate.

REMOVAL AND INSTALLATION


For removal and installation of the auxiliary brake switch (EEB:
Extra Engine Brake). See the Fgrp35 Lighting system.

INSPECTION
1. Using a circuit tester, check continuity between the switch ter-
minals.
2. Check the switch for proper operation.
Switch operation diagram for R.H.D. model

Switch operation diagram for L.H.D. model

OE-5
AUXILIARY BRAKE SWITCH (EEB: EXTRA ENGINE BRAKE)

OE-6
AUXILIARY BRAKE CLUTCH SWITCH

AUXILIARY BRAKE CLUTCH SWITCH


REMOVAL AND INSTALLATION
1. Disconnect the harness connector.
2. Loosen the lock nut and remove the switch assembly.
3. Installation sequence is in the reverse order of removal.
NOTE
 Install the switch so that the end face of the threaded
portion becomes flush with the lock nut end surface.
Tightening torque [N•m {kgf•m}]: 15.7 - 21.6 {1.6 - 2.2}

INSPECTION
1. Check continuity between the switch terminals and insulation
between the terminal and the body ground.

2. Check the switch for proper operation.


Switch operation diagram

OE-7
TRANSMISSION PTO SWITCH

TRANSMISSION PTO SWITCH


CIRCUIT DIAGRAM

REMOVAL AND INSTALLATION


1. Remove the instrument finisher panel. For removal of the
instrument finisher panel. See the Fgrp81 Cab body.
2. Disconnect the harness connector.
3. Push out the switch from the inside of the instrument finisher
panel.
4. Installation sequence is in the reverse order of removal.

OE-8
TRANSMISSION PTO SWITCH

INSPECTION
1. Check continuity and insulation between the switch terminals.
2. Check the switch for proper operation.
Switch operation diagram

OE-9
PTO CLUTCH SWITCH

PTO CLUTCH SWITCH


REMOVAL AND INSTALLATION
1. Disconnect the harness connector.
2. Loosen the lock nut and remove the switch assembly.
3. Installation sequence is in the reverse order of removal.
Tightening torque [N•m {kgf•m}]: 15.7 - 21.6 {1.6 - 2.2}

INSPECTION
1. Check continuity between the switch terminals and insulation
between the terminal and the body ground.
2. Check the switch for proper operation.
Switch operation diagram

OE-10
PTO INDICATOR SWITCH

PTO INDICATOR SWITCH


REMOVAL AND INSTALLATION
Key points of removal
1. Disconnect the harness connector.
2. Remove the PTO indicator switch and the pin or steel ball.

CAUTION
 It is acceptable not to remove the pin or steel ball, but
be careful not to loose it.

Key points of installation


1. Make sure that the pin has been installed. After coating the
area with liquid gasket (Three bond #1215 or equivalent),
install the PTO indicator switch.
Tightening torque: 34 - 39 N•m {3.5 - 4.0 kgf•m}
2. Connect the harness connector.

INSPECTION
1. Check the continuity and the insulation between switch termi-
nals.
Switch operational diagram

2. Make sure that L size when the switch is OFF is 11.5 to 12.3
mm.

OE-11
PTO MAGNETIC VALVE

PTO MAGNETIC VALVE


REMOVAL AND INSTALLATION
1. Disconnect the harness connector.
2. Disconnect the magnetic valve and air pipe.
3. Remove the magnetic valve assembly.
4. Installation sequence is in the reverse order of removal.

INSPECTION
1. Measure resistance between the terminals in the magnetic
valve connector.
Insulating resistance [M]: More than 10 (at 500V mega)
Resistance []: 35.3 - 38.9 {at 20°C}
2. Apply 24V between the terminals in the magnetic valve con-
nector to check if the valves operate properly.
Valve operation diagram

OE-12
THIRD DIFFERENTIAL LOCK SWITCH

THIRD DIFFERENTIAL LOCK SWITCH


REMOVAL AND INSTALLATION
1. Remove the finisher console front. Carefully pull it forward by
hand so as not to damage the tabs.
2. Remove the cluster lid A.
3. Remove the screw and remove the cluster lid C. Carefully pull
it forward by hand so as not to damage the tabs.
4. Disconnect the harness connector.
5. Push out the switch from the inside of the cluster lid C.
6. Installation sequence is in the reverse order of removal.

INSPECTION
1. Check continuity and insulation between the switch terminals.
2. Check the switch for proper operation.
Switch operation diagram

OE-13
THIRD DIFFERENTIAL LOCK MAGNETIC VALVE

THIRD DIFFERENTIAL LOCK MAGNETIC VALVE


REMOVAL AND INSTALLATION
1. Disconnect the harness connector.
2. Disconnect the magnetic valve and air pipe.
3. Remove the magnetic valve assembly.
4. Installation sequence is in the reverse order of removal.

INSPECTION
<CW, GW series>
1. Check continuity and insulation between the magnetic valve
terminals.
2. Apply 24V to the magnetic valve terminals to check if the valve
operates properly.
Valve operation diagram

<GK series>
1. Measure resistance between the terminals in the magnetic
valve connector.
Insulating resistance [M]: More than 10 (at 500V mega)
Resistance []: 35.3 - 38.9 {at 20°C}
2. Apply 24V between the terminals in the magnetic valve con-
nector to check if the valves operate properly.
Valve operation diagram

OE-14
HORN SWITCH

HORN SWITCH
INSPECTION
1. Check continuity voltage between the horn switch terminal and
body ground.
2. Check the horn switch for proper operation.

REPAIR AND REPLACEMENT


The horn switch is incorporated into the steering wheel. When
replacing the horn switch, replace the steering wheel assembly.
See the Fgrp64 Power steering system.

OE-15
HOR CHANGEOVER SWITCH

HOR CHANGEOVER SWITCH


<L.H.D. MODEL ONLY>

REMOVAL AND INSTALLATION


1. Remove the finisher console front. Carefully pull it forward by
hand so as not to damage the tabs.
2. Disconnect the harness connector.
3. Push out the switch from the inside of the finisher console
front.
4. Installation sequence is in the reverse order of removal.

INSPECTION
1. Check continuity and insulation between the switch terminals.

2. Check the switch for proper operation.


Switch operation diagram

OE-16
AIR HORN MAGNETIC VALVE

AIR HORN MAGNETIC VALVE


REMOVAL AND INSTALLATION
1. Disconnect the harness connector.
2. Disconnect the air tube.
3. Remove the horn assembly.
4. Installation sequence is in the reverse order of removal.

INSPECTION
Check continuity between the magnetic valve terminals.

OE-17
ELECTRIC HORN

ELECTRIC HORN
REMOVAL AND INSTALLATION
1. Disconnect the harness connector.
2. Remove the horn assembly.
3. Installation sequence is in the reverse order of removal.

INSPECTION
Check the horn for proper operation.

OE-18
WIPER AND WINDOW WASHER SWITCH

WIPER AND WINDOW WASHER SWITCH


REMOVAL AND INSTALLATION
For removal and installation of the wiper and window washer
switch. See the Fgrp35 Lighting system.

INSPECTION
1. Using a circuit tester, check continuity between the switch ter-
minals.
2. Check the switch for proper operation.
Switch operation diagram

OE-19
WIPER MOTOR

WIPER MOTOR
REMOVAL AND INSTALLATION
1. Remove the wiper link from the wiper motor arm.
2. Remove the screw from the wiper motor bracket and pull out
the wiper motor.
NOTE
 When pulling out the wiper motor, be sure that the
bracket behind the motor and the installation opening
are aligned.

CAUTION
 Before removing, attach a protective material if neces-
sary so as not to damage the panel.

3. Pull out the motor till the connector becomes visible, and dis-
connect the harness connector.
4. Remove the wiper motor assembly.
5. Installation sequence is in the reverse order of removal.

INSPECTION
1. Check continuity and insulation between the terminals of the
wiper motor. (in the automatic stop condition)
Motor connection diagram

2. Check the operation of the wiper motor.

OE-20
WINDOW WASHER MOTOR

WINDOW WASHER MOTOR


REMOVAL AND INSTALLATION
1. Open the front lid.
2. Disconnect the washer tube and harness connector.
3. Remove the mounting bolts (3 pieces) of the window washer
tank assembly and remove the window washer tank assembly.
NOTE
 If washer liquid is in the tank, remove the tank with the
tube turning upward to prevent the liquid from flowing
out.
 Before inspection, discharge washer liquid.
4. Installation sequence is in the reverse order of removal.

INSPECTION
1. Check continuity between the terminals of the washer motor
and insulation between the terminal and the body ground.
2. After installation, refill washer liquid and check the operation of
the washer motor.

OE-21
POWER WINDOW

POWER WINDOW
CIRCUIT DIAGRAM

OE-22
POWER WINDOW SWITCH (DRIVER’S SIDE)

POWER WINDOW SWITCH (DRIVER’S SIDE)


REMOVAL AND INSTALLATION
1. From the front side of the switch, insert a screwdriver wrapped
with soft cloth between the switch assembly and the door trim
to lift the switch unit upward.
2. Press on the pawl of the switch assembly to disengage the
pawl from the hole in the assembly.
3. Disconnect the harness connector to remove the switch
assembly.
4. Installation sequence is in the reverse order of removal.

OE-23
POWER WINDOW SWITCH (DRIVER’S SIDE)

INSPECTION
1. Check continuity and insulation between the switch terminals.
2. Check the switch for proper operation.
Description of the terminal destinations
Terminal Connecting to
1 Ignition power supply
2 Power window motor on driver’s side (UP)
3 Power window motor on driver’s side (DOWN)
Power window switch on passenger’s side
4
(UP signal)
Power window switch on passenger’s side
5
(DOWN signal)
6 Ground

OE-24
POWER WINDOW SWITCH (PASSENGER’S SIDE)

POWER WINDOW SWITCH (PASSENGER’S SIDE)


REMOVAL AND INSTALLATION
For removal and installation of the switch on the passenger's side,
see the Power window switch on the driver’s side.

OE-25
POWER WINDOW SWITCH (PASSENGER’S SIDE)

INSPECTION
1. Check continuity and insulation between the switch terminals.
2. Check the switch for proper operation.
Description of the terminal destinations
Terminal Connecting to
1 Power window motor on passenger’s side (UP)
2 Power window motor on driver’s side (DOWN)
Power window switch on passenger’s side
3
(UP signal)
Power window switch on passenger’s side
4
(DOWN signal)
5 Ignition power supply

OE-26
POWER WINDOW MOTOR

POWER WINDOW MOTOR


REMOVAL AND INSTALLATION
For removal and installation of the power window motor. See the
Fgrp81 Cab body.

INSPECTION
1. Check continuity between the motor terminals and insulation
between the terminal and the body ground.
2. Check the motor for proper operation.
NOTE
 Operation check should be done after installation.
Operating time [seconds]: 1.8 - 3.8

OE-27
POWER MIRROR SWITCH

POWER MIRROR SWITCH


<R.H.D. MODEL ONLY>

CIRCUIT DIAGRAM

REMOVAL AND INSTALLATION


1. Remove the finisher console front. Carefully pull it forward by
hand so as not to damage the tabs.
2. Disconnect the harness connector.
3. Push out the switch from the inside of the console.
4. Installation sequence is in the reverse order of removal.

INSPECTION
1. Check continuity and insulation between the switch terminals.
2. Check the switch for proper operation.
Switch operation diagram

OE-28
POWER MIRROR MOTOR

POWER MIRROR MOTOR


<R.H.D. MODEL ONLY>

REMOVAL AND INSTALLATION


For removal and installation of the mirror motor. See the Fgrp81
Cab body.

INSPECTION
1. Check continuity between the terminals.
2. Apply 24V and check the operation of the motor.
Motor operation diagram

OE-29
MIRROR HEATER SWITCH

MIRROR HEATER SWITCH


<R.H.D. MODEL ONLY>

REMOVAL AND INSTALLATION


1. Remove the finisher console front. Carefully pull it forward by
hand so as not to damage the tabs.
2. Disconnect the harness connector.
3. Push out the switch from the inside of the finisher console
front.
4. Installation sequence is in the reverse order of removal.

INSPECTION
1. Check continuity and insulation between the switch terminals.
2. Check the switch for proper operation.
Switch operation diagram

OE-30
TIMER UNIT

TIMER UNIT
CIRCUIT DIAGRAM

INSPECTION
It is impossible to inspect the timer unit (intermittent time adjust-
ment function) as a separated single unit. Therefore, the unit should
be checked indirectly through inspection of the operation of the sys-
tem and the other units and components. For the installation posi-
tion, See the Fgrp37 Wiring diagram.

OE-31
TIMER UNIT

Control function list


Control function
Variable intermittent wiper control
Wiper control
Washer-interlocked wiper control

Description of the terminal destinations


Terminal Name
5, 24 U-turn harness
7 Wiper switch (Lo)
13 Washer switch
14 Intermittent wiper resistance (R.H.D. model only)
15 Intermittent wiper switch
22 Wiper switch (Hi)
23 Ground
A Ignition switch power source
B Wiper motor (Hi)
E Wiper motor
F Wiper motor (Lo)
G Ground
H Washer motor
J Ignition switch power source (for DC-DC)
K Headlight levelizer

OE-32
CENTRALIZED DOOR LOCK SWITCH

CENTRALIZED DOOR LOCK SWITCH


REMOVAL AND INSTALLATION
For removal and installation of the door lock switch. See the Fgrp81
Cab body.

INSPECTION
Check continuity when moving the swing arm.
Switch operation diagram of R.H.D. model

Switch operation diagram of L.H.D. model

OE-33
CENTRALIZED DOOR LOCK ACTUATOR

CENTRALIZED DOOR LOCK ACTUATOR


REMOVAL AND INSTALLATION
For removal and installation of the door lock actuator. See the
Fgrp81 Cab body.

INSPECTION
Check the moving direction of the swing arm when 24V is applied to
the terminals (for several seconds).
Actuator operation diagram for R.H.D. model

Actuator operation diagram for L.H.D. model

OE-34
KEYLESS ENTRY SYSTEM

KEYLESS ENTRY SYSTEM


<R.H.D. MODEL>

CIRCUIT DIAGRAM

REMOTE CONTROL FOR KEYLESSENTRY SYSTEM


INSPECTION
1. Remove the battery from the remote control unit, and measure
the battery voltage.
Maintenance standard [V]: 2.6 to 3.2

2. If the battery is defective, replace with a new one.


Battery to be used: CR1620 (3V lithium battery)

DOOR LOCK ACTUATOR FOR KEYLESSENTRY SYSTEM (DRIVER'S SIDE)


Removal and installation
For removal and installation of the door lock actuator. See the
Fgrp81 Cab body.

OE-35
KEYLESS ENTRY SYSTEM

Inspection
Check the moving direction of the swing arm when 24V is applied to
the terminals (for several seconds).
Actuator operation

DOOR LOCK ACTUATOR FOR KEYLESS ENTRY SYSTEM (PASSENGR'S SIDE)


Removal and installation
For removal and installation of the door lock actuator. See the
Fgrp81 cab body.
Inspection
Check continuity when moving the swing arm.
Actuator operation

OE-36
KEYLESS ENTRY SYSTEM

KEYLESS ENTRY CONTROL UNIT


REMOVAL AND INSTALLATION
1. Remove the instrument finisher panel.
2. Disconnect the harness connectors of the keyless entry con-
trol unit.
3. Remove the mounting screw of the keyless entry control unit
and remove the unit.
4. Installation sequence is in the reverse order of removal.

INSPECTION
1. Before inspecting the system, check the voltage of the battery
for the remote control unit and adjust it if necessary.
2. If the door lock on passenger's side is not activated by operat-
ing the lock knob on driver's side by hand, check the compo-
nents on the circuit and the harness and harness connector.
3. If no abnormality is found in the components, replace the key-
less control unit and check the operation again.
Description of the terminal destinations
Terminal Name
1 Door switch (driver’s side)
2 Door switch (passenger’s side)
3 Battery power
4 Door lock output (driver’s side)
5 Ground
6 Status detection switch
8 Accessory power supply
12 Door unlock output (driver's side)

OE-37
AUTO WATER DISCHARGE SWITCH

AUTO WATER DISCHARGE SWITCH


REMOVAL AND INSTALLATION
1. Remove the finisher console front by pulling it out carefully so
that its pawl is not broken.
2. Disconnect the harness connector. Pull out the switch assem-
bly from the inside of the instrument finisher panel.
3. Remove auto water discharge switch from back of instrument
finisher panel.
4. Installation is in the reverse order of removal.

INSPECTION
1. Check the continuity and the insulation between switch termi-
nals.
2. Check the operation of the switch.
Switch operation diagram

OE-38
MALTIDISPLAY OPERATION SWITCH

MALTIDISPLAY OPERATION SWITCH


REMOVAL AND INSTALLATION
1. Remove the finisher console front. Carefully pull it forward by
hand so as not to damage the tabs.
2. Remove the cluster lid A.
3. Remove the screw and remove the cluster lid C. Carefully pull
it forward by hand so as not to damage the tabs.
4. Disconnect the harness connector.
5. Push out the switch from the inside of the cluster lid C.
6. Installation sequence is in the reverse order of removal.

INSPECTION
1. Check continuity and insulation between the switch terminals.
2. Check the switch for proper operation.
Switch operation diagram

OE-39
AUDIO, RADIO, CD

AUDIO, RADIO, CD
REMOVAL AND INSTALLATION
1. Remove the finisher console front. Carefully pull it forward by
hand so as not to damage the tabs.
2. Remove the cluster lid A.
3. Remove the screws and remove the cluster lid C. Carefully
pull it forward by hand so as not to damage the tabs.
4. Loosen the screws and remove the radio (cassette player)
assembly.
5. Disconnect the harness connector and antenna feeder con-
nector and remove the radio assembly.

6. Loosen the screws and separate the radio and radio bracket.
7. Installation sequence is in the reverse order of removal.

INSPECTION
To check for audio system function, check in combination with the
power source, antenna and speakers normally installed. To judge
whether it is good or not, check by comparing with the function of
the related parts.

OE-40
ANTENNA

ANTENNA
REMOVAL AND INSTALLATION
Key point of removal
1. Disconnect the antenna feeder plug of the dash panel lower.
2. Tie a string to the feeder lead and attach it to the plug with
adhesive tape.

3. Remove the screws, remove the antenna base, and pull out
the feeder lead together with the antenna rod storage pipe.

OE-41
ANTENNA

Key point of installation


1. Tie the string that is put through the front pillar and dash panel
side to the feeder lead and attach it to the antenna plug with
adhesive tape.
2. Place the storage pipe in the front pillar.
3. Pull the string from the interior and draw the feeder lead into
the interior through the grommet of the dash panel side.
4. Connect it to the feeder lead from the radio with a connection
plug.

INSPECTION
Check the antenna installed in a vehicle.
1. Extend the antenna.
2. Remove the plug.
3. Check continuity between the points indicated in the table
below.
Between A and B
Continuity
Between C and D

4. If there is no continuity in the antenna, replace it with new one.

OE-42
CIGARETTE LIGHTER

CIGARETTE LIGHTER
REMOVAL AND INSTALLATION
1. Remove the instrument finisher panel. For removal of the
instrument finisher panel. See the Fgrp81 Cab body.
2. Disconnect the harness connector.
3. Push out the cigarette lighter assembly from the inside of the
finisher panel and remove it.
4. Installation sequence is in the reverse order of removal.

INSPECTION
1. Install the ring in the cigarette lighter and check between the
terminals for continuity (when pressed in) and insulation (when
pulled back).
2. After installing the cigarette lighter, operate it and check for red
heat.

OE-43
OTHERS

OTHERS
PTO RELAY
For the internal circuit of the PTO relay, refer to SMALL-SIZED
GENERAL PURPOSE RELAY (OE-3).
For the installation position, See the Fgrp37 Wiring diagram.

PTO PARKING BRAKE RELAY


For the internal circuit of the PTO parking brake relay, refer to
SMALL-SIZED GENERAL PURPOSE RELAY (OE-3).
For the installation position, See the Fgrp37 Wiring diagram.

MIRROR HEATER RELAY


R.H.D. model only
For the internal circuit of the mirror heater relay, refer to SMALL-
SIZED GENERAL PURPOSE RELAY (OE-3).
For the installation position, See the Fgrp37 Wiring diagram.

OE-44
SERVICE DATA

SERVICE DATA
SPECIFICATIONS
AUXILIARY BRAKE SWITCH (EEB: EXTRA ENGINE BRAKE)
Rated voltage [V] 24
Rated load [W] 40
Voltage drop [V] Less than 0.25
Operating force [N {kgf}] More than 3.0 {0.3}

AUXILIARY BRAKE CLUTCH SWITCH


Rated voltage [V] 24
Rated current [A] 2.8
Voltage drop [V] Less than 0.25
Operating force [N {kgf}] 6.9 - 12.7 {0.7 - 1.3} (When depressed by 6 mm)

TRANSMISSION PTO SWITCH


Rated voltage [V] 24
Rated load [A] 1.2

PTO CLUTCH SWITCH


Rated voltage [V] 24
Rated load [A] 2.8
Voltage drop [V] Less than 0.25
Operating force [N {kgf}] 6.9 - 12.7 {0.7 - 1.3} (When depressed by 6 mm)

PTO INDICATOR SWITCH


Rated voltage [V] 24
Rated load [W + A] 27 (light) x 2 + 0.1 (electromagnetic buzzer)
Voltage drop [V] Less than 0.2
Insulation resistance [MΩ] More than 1 (at 500VM)
Operating force [N {kgf}] 5.88 - 13.72 {0.6 - 3.1} (first power of push rod)

PTO MAGNETIC VALVE


Rated voltage [V] 24
Rated air pressure 2 834 {8.5}
[kPa {kgf/cm }]
Operating air pressure range [kPa {kgf/cm2}] 294 - 834 {3.0 - 8.5}
Minimum operating voltage [V] 20
Resistance [] 35.3 - 38.9 (at 20°C)

OE-45
SERVICE DATA

THIRD DIFFERENTIAL LOCK SWITCH


Rated voltage [V] 24
Rated load [A] 1.2

THIRD DIFFERENTIAL LOCK MAGNETIC VALVE


Vehicle CW, GW series GK series
Rated voltage [V] 24
Rated air pressure 2 834 {8.5}
[kPa {kgf/cm }]
Operating air pressure range [kPa {kgf/cm2}] 294 - 834 {3.0 - 8.5}
Minimum operating voltage [V] 20
Resistance [] 42.8 - 47.3 (at 20°C) 35.3 - 38.9 (at 20°C)

HORN SWITCH
Rated voltage [V] 24
HORN CONTACT Rated load [A] 1.0
Insulation resistance [M] More than 1
Operating force [N {kgf}] Less than 39 {4}
HORN PAD
Stroke [mm] Less than 3

HOR CHANGEOVER SWITCH


Rated voltage [V] 24
Rated load [A] 1.5

AIR HORN MAGNETIC VALVE


Rated voltage [V] 24
Rated current-carrying time [second] More than 60 (at 24V)
Rated current [A] Less than 1.6 (at 20°C)
Operating air pressure range [kPa {kgf/cm2}] 392 - 981 {4 - 10}
Less than 20
Minimum operating voltage [V]
(with the air pressure at inlet of 785 kPa {8 kgf/cm2})
Sound pressure [dB] Less than 105 - 118

WIPER AND WINDOW WASHER SWITCH


Rated voltage [V] 24
(12) - (13) ...... 2
Rated load [A] (9) - (12), (10) - (12) ...... 7.8 mA
(11) - (12) ...... 5 mA
Wiper [V] Less than 0.5
Voltage drop
Washer [V] Less than 0.5
Operating force Wiper [N {kgf}] 0.17 - 0.26 {1.7 - 2.7}

OE-46
SERVICE DATA

WIPER MOTOR
(No load: Motor as a single unit)
Rated voltage [V] 24
LOW [A] Less than 1.0
Rated current
HIGH [A] Less than 1.5
Starting voltage [V] Less than 16
LOW [rpm] 37 - 45
Revolutions
HIGH [rpm] 56 - 68

WINDOW WASHER MOTOR


Rated voltage [V] 24
Minimum operating voltage [V] Less than 16
Discharge pressure [kPa {kgf/cm2}] More than 78 {0.8}
Discharge height [m] More than 1, vertically upward (at 16V)
Discharge amount [cc/10 seconds] 200

POWER WINDOW SWITCH (DRIVER’S SIDE)


Rated voltage [V] 24
Operating voltage range [V] 18 - 32
2.3 - 4.7 {0.24 - 0.48} (manual)
6.9 - 12.8 {0.7 - 1.3} (automatic)
Operating force [N{kgf}]
2.9 - 6.9 {0.3 - 0.7} (assist)
6.3 - 9.3 {0.65 - 0.95} (lock)

POWER WINDOW SWITCH (PASSENGER’S SIDE)


Rated voltage [V] 24
Rated load [A] 12 (while in steady-state), 25 (when locked)
Voltage drop [V] Less than 0.25
Operating force [N{kgf}] 4.7 - 5.1 {0.48 - 0.50})

POWER WINDOW MOTOR


Rated voltage [V] 28
Rated current [A] Less than 6
Rated revolutions [rpm] 52 - 72
Rated load [N•m {kgf•cm}] 3.4 {35}
Current [A] 2 or less
At no load
Revolutions [rpm] 95
Current [A] 15 or less
When constrained
Torque [N•m {kgf•cm}] 8.7 {90}
Operating time [seconds] 1.8 - 3.8

POWER MIRROR SWITCH (R.H.D. MODEL ONLY)


Rated voltage [V] 24
Rated load [A] 0.5

OE-47
SERVICE DATA

MIRROR HEATER SWITCH (R.H.D. MODEL ONLY)


Rated voltage [V] 24
Rated load [A] + [W] 3 (coil) + 3 (light)

CENTRALIZED DOOR LOCK SWITCH


Rated voltage [V] 24
Operating voltage range [V] 20 - 32
Operating force [N {kgf}] Less than 2.0 {0.2}
Entire stroke [mm] 20

CENTRALIZED DOOR LOCK ACTUATOR


Rated voltage [V] 24
Operating voltage range [V] 20 - 32
Rated current [A] Less than 3
Operating force [N {kgf}] Less than 2.0 {0.2}
Entire stroke [mm] 22.6

KEYLESS ENTRY SYSTEM (R.H.D. MODEL ONLY)


Remote control for keyless entry system
Operating voltage range [V] 2.6 - 3.2
Battery to be used CR1620 (3V lithium battery)

Door lock actuator (Driver's side)


Rated voltage [V] 24
Operating voltage range [V] 16 - 32
Rated current [A] Less than 3
Operating force [N {kgf}] Less than 14.7 {1.5}
Entire stroke [mm] 22.0 - 26.6

Door lock actuator (Passenger's side)


Rated voltage [V] 24
Operating voltage range [V] 16 - 32
Rated current [A] Less than 3
Operating force [N {kgf}] Less than 14.7 {1.52}
Entire stroke [mm] 22.0 - 26.6

AUTO WATER DISCHARGE SWITCH


Rated voltage [V] 24
Rated load [mA] 10

MALTIDISPLAY OPERATION SWITCH


Rated voltage [V] 24
Rated load [mA] 10 (mode) / 10 (select)

OE-48
SERVICE DATA

AUDIO
AM/FM auto tuner radio with
Item AM/FM auto tuner radio
CD player integral
Rated voltage [V] 26.4
Electric power consumption [A] Less than 5
Maximum output [W] 12 + 12 12 + 12 + 12 + 12
Load impedance [ 8 2 8 4
Operating voltage range 21.6 - 31.2
Built-in clock Yes
Alarm Yes Yes

ANTENNA
Electrostatic capacity [PF] 70 - 90 (at 1 MHz)
Q property More than 200 (at 1 MHz)
Rod operating force [N {kgf}] 3 - 20 {0.3 - 2.0}

TIGHTENING TORQUE
Tightening torque
Item
N•m kgf•m
Auxiliary brake clutch switch 15.7 - 21.6 1.6 - 2.2
PTO clutch switch 15.7 - 21.6 1.6 - 2.2
PTO indicator switch 34 - 49 3.5 - 4.0

OE-49

You might also like