Chapter 7

ELECTRICAL SYSTEM

LAMPS, REFLECTIVE DEVICES AND •••••••••••••••••••••••••••••••••• 1

ASSOCIATED EQUIPMENT
FUSE BLOCK, RELAY PANEL AND FUSIBLE LINK BLOCK •••••• 4
ELECTRICAL POWER SOURCES ••••••••••••••••••••••••••••••••••••••• 11
BACK-UP BUZZER (OPTION EQUIPMENT) ••••••••••••••••••••••••••• 20
HARNESS WIRING •••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 21

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LAMPS, REFLECTIVE DEVICES AND ASSOCIATED EQUIPMENT

Requirements of FMVSS 108

The following devices are provided, located and/or wired by Hino Motors Sales U.S.A., Inc.

Requirements of FMVSS 108.

Head lamps
Front side reflex reflectors
Front side marker lamps
Front turn signal lamps
Front cab roof clearance & I.D. lamps
Side turn signal lamps
* Rear reflex reflectors (Temporary loc.)
* Tail lamps (Temporary loc.)
* Stop lamps (Temporary loc.)
* License plate lamps (Temporary loc.)
* Back up lamps (Temporary loc.)
* Rear turn signal lamps (Temporary loc.)

The following additional devices must be installed on the body and meet all the requirements
of FMVSS 108.
Rear side marker lamps
Rear side reflex reflectors
Rear clearance lamps
Rear identification lamps

The following additional devices must be installed on the body and meet all the requirements
of FMVSS 108 if the overall vehicle length is 30 feet or greater.
Intermediate side marker lamps
Intermediate side reflex reflector

Installation of Rear Lamps

As rear combination lamps (Tail lamps, Stop lamps, Turn signal lamps and Rear reflex reflec-
tors, Back up lamps, License plate lamps) are temporally located on the end of chassis frame
at factory, they should be relocated by subsequent manufacturer to conform to FMVSS 108.

Notes for relocation of rear combination lamps:

• Tail lamps, stop lamps and direction signal lamps, back up lamps, license plate lamps are
designed in one body as rear combination lamps. Do not install the rear combination lamps
horizontally or up side down not to affect the performance of license plate lamps and water
drain holes.

• Install the rear combination lamps to the outside of frame end at right and left using same
holes, bolts and nuts of frame end as temporary fitted.

• When installing the rear combination lamps to the rear body, be sure to prevent breakage,
deflection and vibration of rear combination lamp body.

• Tightening torque for rear combination lamp mounting nuts is 50±20 kgf·cm (3.6±1.4 lb·ft).

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Installation of Rear Combination Lamps

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• Tightening torque for the stay mounting bolts is 210±80 kgf·cm (15±6 lb·ft).

• Do not apply rust-proofing clear lacquer to lamp lens or body.

• Bracket for rear license plate is fitted together with rear combination lamp, LH, to the frame.

Cautions Regarding Additional Turn Signal Lamps

This is to caution you to avoid a possible failure of flasher unit arising from excessive electrical
loading due to the mounting of additional turn signal lamps to the flasher unit of the vehicle.

The flasher unit on each vehicle is designed to accommodate the total wattage of the turn
signal lamps, if anticipated in the design of the vehicle, when they work as hazard warning
lamps, in which case the total wattage doubles that of their use as turn signals.

The turn signal lamps on each vehicle meet the FMVSS (Federal Motor Vehicle Safety Stan-
dard: a regulation in the U.S.A.), and no additional lamp is needed in this regard so long as the
vehicle is used as it was designed.

In consequence, adding the turn signal lamps is strictry prohibited due to design capacity of
flasher unit.

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FUSE BLOCK, RELAY PANEL AND FUSIBLE LINK BLOCK

Location of the Cab Side

The fuse block and the relay panel are located inside the instrument panel as shown below.

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FUSE BLOCK

[NOTE]
Be sure to use each capacity fuse designated in the above table.
Never use the capacity fuse exceeding the designated one in the above, otherwise over cur-
rent may damage the harness wires, and fusible linkage wires are in the same.

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RELAY PANEL

POLE NUMBER
No. OF DESCRIPTION
CONNECTOR
1 4 HEAD LAMP RELAY (MAIN)
2 4 HEAD LAMP RELAY (DIMMER)
3 4 TAIL LAMP RELAY 1
4 4 TAIL LAMP RELAY 2
5 4 POWER RELAY No.1
6 4 POWER RELAY No.2
7 4 POWER RELAY ACC.
8 4 HORN RELAY
9 4 HEATER RELAY (MIRROR)
10 4 HEATER RELAY
11 4 A/C RELAY
12 4 DAY TIME RUNNING LAMP RELAY
13 4 ATM STARTER RELAY (AUTO T/M model only)
14 4 POWER RELAY No.3
15 4 POWER RELAY No.4
16 4 AIR HORN RELAY
17 4 AIR SUS DUMP RELAY No.1
18 4 AIR SUS DUMP RELAY No.2
19 5 ABS EXH CUT RELAY
20 5 PKB IND OFF RELAY
21 5 PKB BZ OFF RELAY
22 4 U2 EXH RELAY
23 4 AMT STARTER RELAY (AMT T/M model only)
24 5 AMT ECU RELAY (AMT T/M model only)
25 5 AMT ECU DUMMY RELAY (AMT T/M model only)

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Location of the Chassis Side

The fusible link block is located on left side of the cab back part as shown
below.

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DETAIL OF FUSIBLE LINK BLOCK

• How to remove fusible link box cover to be installed under the cab, LH.

1.Push lock lever and remove lock. (3 position)

2.Pull-up 2 position of plate lock and remove cover.

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Installation of Additional Switches

Layout of switches
• Standard layout of switches include option equipment are as following figure.
• If you intend to install additional switches at instrument panel for the convenience of body
mounting, be sure to install it at empty space after confirmation of original condition on the
actual vehicle.

Avoid using additional switches with existing switches

• If you install additional switches, fit a caution plate showing the purpose of each switch, etc.,
to prevent accidental operation or confirmation.

INSTRUMENT PANEL

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FLOOR CONSOLE (ATM VEHICLE ONLY)

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Chapter 7 ELECTRICAL SYSTEM

ELECTRICAL POWER SOURCES

If you must take an electrical power supply for the rear body or equipment from the chassis,
take it from the electrical power supply connector.

Power Supply Connectors and Positions

Electrical power supply is fitted to the harness wires.
There are fifteen types of power supply connectors as shown in the table below.
Circuit Coupling
Max. Wire
Connector Pole (Man
Connector Connector Applicable
Code Capacity Size & Parts No. (Spare Parts) Remarks
Mark Application) Model
(A) Color Parts No.

Linked Directly 1.25

A AGK 3.0 97840-4050 97830-4050 All Model • Requires Switch
to Battery W

Idle-up Sensor 0.5 • E/G Control

B %CH – 97840-4050 97830-4050 All Model For Rear Body
(Input) R-B

Linked Key 0.85

C AGM 7 97840-4050 97830-4050 All Model
S/W On L-

K95 Power Supply 0.5

G-Y

0.5 • E/G Control

D K96 Accel sensor – 82580-8660 82580-8650 All Model For Rear Body
R-L
CAB SIDE

0.5
K97 Ground
G-O

Sub Starter 0.5

J %17 – 97840-4050 97830-4050 All Model
(Neutal Signal) B-R

Sub Starter 0.5

K %B7 – 97840-4050 97830-4050 All Model
(Starter Signal) W-B

0.5 • Switches on with

L %14 Fog light – 97840-4050 97830-4050 All Model Head Lamp S/W
R-G

Engine Stop 0.5

M %15 – 97840-4050 97830-4050 All Model
S/W P

N %16 Power Fog 1.25 • For Fog Lamp

9.4 97840-4050 97830-4050 All Model
G
• For Rear Body
Room Lamp
1.25 • Requires Switch
E AM6 Linked Switch On 7 82580-4240 82580-4230 All Model
W (Opiton)
• Connector
Color: Black

Linked with Fr Turn 0.5 • For Side Turn

AP9 Signal Lamp (LH) B-R Lamp (LH)
CHASSIS SIDE

F 0.5 82580-4100 82580-4090 All Model

APA Linked with Fr Turn 0.5 • For Side Turn
Signal Lamp (RH) B-W Lamp (RH)

Switches on with • For Marker Lamp

1.25
G AGQ 82580-4240 82580-4230 All Model • Connector
Lighting Switch G+H W-L
Color: White
TOTAL
Switches on with 10.5 1.25 • For Marker Lamp
H AGP 82580-4240 82580-4230 All Model • Connector
Lighting Switch W-L
Color: White
Linked Key 1.25
P APN 7 82580-4240 82580-4230 All Model
S/W On L-R

[NOTE]
• The permissible current be taken from spare power connector is determined from the capac-
ity of the fuse and wire size. Make sure that the maximum load (current) of the installed
equipment must be kept lower current than the permissible capacity to be able to take from
spare power connector.
• Be sure to keep the lower current value than the alternator generated capacity when switched
on the original and additional equipment same time to avoid over discharging electricity of
the battery.
• When use power supply connector marked F, it should be on the following condition.
1) Turn and hazard lamp should be LED type.
2) If circuit current flow will exceed 0.5A, use power supply connector for operating circuit of
the relay unit which to be operated turn and hazard lamp circuit.

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PROVIDED POSITION INSIDE CAB

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PROVIDED POSITION CHASSIS SIDE

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DETAIL OF POWER SUPPLY CONNECTORS

• Cab side

CONNECTOR

VEHICLE SIDE COMPANION SIDE

A A : AGK
· B : %CH
B
· C : AGM
C J : %17
·
J K : %B7
· L : %14
K M : %15
·
L N : %16
·
M
· PARTS No. 97840 - 4050 PARTS No. 97830 - 4050
N

K95 K96 K97 3 2 1

D

PARTS No. 82580 - 8660 PARTS No. 82580 - 8650

• Chassis side

CONNECTOR

VEHICLE SIDE COMPANION SIDE

E : AM6
E P : APN 1
·
P

PARTS No. 82580 - 4240 PARTS No. 82580 - 4230

AP9 APA 2 1
F

PARTS No. 82580 - 4100 PARTS No. 82580 - 4090

G : AGQ
G H : AGP
· 1
H

PARTS No. 82580 - 4240 PARTS No. 82580 - 4230

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HOW TO TAKE ELECTRICITY FROM POWER SUPPLY CONNECTOR

[NOTE]
• As far as possible take power using sub-harness type.
• If you must take power using direct connecting type, be sure to observe the precautions
described here in after section “HARNESS WIRING”.

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Taking Power Directly from the Battery

If you intend to take power for the body directly from the battery, secure the battery cable and
the body power supply terminal together with the same nut. (For details, see the following
figure.)

In this case, you must install a fuse at a suitable point in the circuit and take precautions to
prevent short circuits as these may lead vehicle fires.

When securing the cable and power terminal, make sure you tighten the nut properly.

• Battery model : GR27

• Battery model : GR31

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Room Lamp Switch, Van Body

Room lamp switch is provided as an optional equipment.
Be sure to follow the manner described in followng figures when install the switch.

INSTALLATION POSITION OF SWITCH

[NOTE]
• Install the switch after
removed cover plate.

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Detail of Provision of Connector

• Connector which is connected with van body room lamp swtch is provided left dash board
panel of meter cluster described in followng figure.
• Remove bundle tape colored red to be bundled optional equipment of the power supply
connector.
• Make sure to connect the power supply connector with switch.

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Precaution for Installing Wires, etc., to Cab

USING THROUGH HOLES FOR FRONT DASH PANEL WIRING
When using through holes for front dash panel wiring, to secure the rust prevention and water
proof before the said taken-in, carry out fitting and wiring according to the following instruc-
tions.
• Through hole ø30 mm (1.2 in.) is provided on the front dash panel but it is closed with a
grommet. Make a slit on this grommet and, after the wiring, sufficiently seal its periphery with
a sealing agent.
• In order to secure the water proofness, lower the wiring once as shown on “Section A - A” to
drain the water and after that bring the wiring into the cab.
• It is prohibited to fix the wiring with a tapping screw etc., because this can be a cause of
penetration of dust.

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BACK-UP BUZZER (OPTION EQUIPMENT)

Back-up buzzer is optional equipment.

At chassis delivery, back-up buzzer is temporarily installed onto the rear combination lamp
bracket (RH side).
Install the back-up buzzer in suitable position at the time of body mounting.
Observe precautions as followings.

Installation angle
• Must be kept the permissible range of installing angles shown in the figure below.
• If the installing angle is not within range, water will accumulate inside the buzzer and may
lead to failure.

Position
Install the back-up buzzer in a position where it is not exposed to splashing with muddy water,
stone or water.

Precaution for painting

Make sure that the buzzer should be covered during painting to protect the paint coming into
buzzer from sound emitting hole for avoiding failure of no sound.

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HARNESS WIRING

• If a mistake is made in the harness wiring while mounting a rear body or equipment, the
harness may be damaged by vehicle vibration while the vehicle is driving, or water, dust, or
mud entering into the harness. If these occur, a short-circuit or fire may result causing a
severe accident.
• Accordingly, be sure to observe the procedures given below for modifications or alterations
of the harness wiring involved with the rear body mounting or other actions.

Important Points in Installing Electrical Equipment and Wiring

Cautions needed when mounting the rear body or equipment
When installing U-bolts or related parts of rear body to chassis frame, be careful that the
harness wires are not squeezed, pinched or forced into contact with sharp edges.

Harness wires, battery cables, terminals and electrical equipments (switches, joints) must be
easily inspected and serviced after mounting rear body.

If you fit additional switches or lamps for a rear body, observe the following precautions.
• To prevent accidental operation or confirmation, install a caution plate showing the purpose
of each switch, etc.

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• Common use of switches which are already installed on the chassis side for control of lamps
installed on the rear body side or other electrical equipment is prohibited.
An overload will occur resulting in burning of the switch contacts or harness.
The control of the electrical equipment on the body side should be done using a separately
installed switch.

If you intended to fit a buzzer for the rear body, make sure that its sound is clearly different from
that of the existing buzzer around the driver’s seat of chassis.

[SPECIFICATION OF EXISTING BUZZER AROUND DRIVER’S SEAT]

Do not force to pull the harness wiring when handle it.

When removing the connector, be sure to hold the male and female parts of the connector by
housing.
Do not remove the connector by holding harness wire.

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Secure an adequate clearance with the high-temperature parts.

Measure the temperature whenever required to eliminate
the safety problems.

• Don’t lay the wiring in the vicinity of the exhaust pipe or muffler or where the wiring is ex-
posed directly to the exhaust gas.

• Clearance against heat-generating parts; Minimum 200mm (8.0 in.).

• When the clearance is less than 200mm (8.0 in.) with heat-generating parts, provide an
insulator to protect wire from heat.

NOTE: The allowable tempeature of vinyl coating harness wire is 20˚C (48˚F) to 60˚C (140˚F).

Addition or Modification of wiring

If you intend to extend wiring, make sure that you use the same size and color of wire as the
original.

Make all connections secure by soldering or pressure joints. After connecting, remove burrs
and cover fully with insulation material.
When making connections in chassis side wiring, cover connections with waterproof sealant,
then cover fully with insulating material.

[EXAMPLE FOR WATERPROOFING AND INSULATION]

• Cover connections with adhesive heat contraction tube.

• Cover connections with butyl rubber.

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When soldering, do not use chlorine.

If you intend to move the battery or modify the battery cable layout, do not extend or shorten
the battery cable.
In areas where the battery cables are subject to movement
due to relative motion of the starter and the frame, do not modify the clamping method, posi-
tions of clamps, or the amount of slack in the cables.

Clamp electric wiring firmly to prevent it from contacting the moving or vibrating parts of the
chassis or rear body, and any sharp edges or corners.

[CLEARANCES FOR WIRE]

Where wiring passes through the frame or a panel, always use a grommet to prevent damage
to the wire and potential short circuits.

EXAMPLE OF USING GROMMET

Protection of harness which

penetrates frame and panel

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Do not install wiring where it may be damaged by accumulation of mud or snow, by freezing, or
by flying stones.
If you must install wiring in such positions, protect it with metal plates.

When wiring of the harness wire is done inside the chassis frame, place the wiring along
already installed wiring and do not wire independently along empty spaces.
Also, when wiring under the floor of the body or inside the roof construction, be sure to place
the wiring along the structure frame, use a clip following the indicated interval, carry out water
proofing measures and observe the harness wiring rules.

Do not make connections by cutting open the coating of a wire and pulling out the bare wire.
This procedure is very
dangerous and may damage other wires.

To prevent water from running along wires and penetrating electrical equipment, always seal
holes through which wires pass using grommets and make connections so that the terminal is
higher than the wire.

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Install wires where they are not exposed to dust or water.

Do not install the harness wire on the top or outer side of the chassis frame.
In such positions, they may be damaged by being stepped on during body mounting, or by
flying stones during vehicle operation.

If there is a harness for the chassis already installed close to the wiring area when wiring is
done inside the chassis frame, the wiring and taping should be done along this harness.

When installing wiring for parts of the engine, transmission, etc., install the wiring in parallel to
existing wires, and be sure to allow sufficient slack to adsorb any relative movement. Make
sure that the wiring does not touch any other part.

Where electrical wiring runs parallel to pipes (including rubber hoses, vinyl hoses, and steel
pipes) or brake system pipes (including brake hoses and brake pipes),
never clamp the wiring together with these pipes.

[CLEARANCES BETWEEN HARNESS WIRES AND PIPES]

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If you move the battery, you may have to temporarily remove the battery cables from the
terminals of the battery.
When refitting the battery cables, observe the specified torque to avoid damaging the battery
terminal:
Unit: kgf·cm (lb·ft)
SIZE OF BOLT
& NUT TIGHTENING TORQUE

M8 77±19 (5.8±1.4)
M10 108±10 (8.1±0.7)

(If a terminal is damaged, replace it with a new part.)

If you move the battery, make sure it is positioned at least 200 mm (8.0 in.) away from the
exhaust system (muffler, tail pipe, etc.).
If you must install the battery within 200 mm (8.0 in.) of the exhaust system, protect it with
insulating panels.

Always use a connector with lock.

If you use a plug-type connecting terminal, fit the female terminal into the power supply side.
This is due to the connecting terminal detaching which does not allow a short-circuit to occur
even if the chassis or rear body construction make contact.

To prevent sagging, contact with other parts or contact with sharp edges or corners, secure all
wiring with clips.

The clips should be spaced at a standard interval of 300~500 mm (12.0~20.0 in.). This interval
should be shorter where conditions dictate.

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All clips should use resin coating or attached grommets.

[RECOMMENDED CLIP TYPES]

Crocodile clips and adhesive clips should only be used for temporary installation.

Harness wires should be installed above fuel hoses or pipes to avoid fuel dripping onto the
harness wire in the event that a
fuel leak occurs.
Keep a clearance of at least 20 mm (0.8 in.) between the harness wire and fuel hose.

Bundle unused harness wires and their terminals should be bundled with other harness wires
and covered with vinyl tape to prevent water from penetrating the terminal.

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Mount a cover or a protector to prevent water entry along the wiring.

• A water-proof boot should be installed facing down.

A connector, if used at a position exposed to water, should always be of water-proof type.

The circuit must be so designed that the ground cable of the additional power supply is con-
nected to the negative “–” terminal of the battery.

Install the ground for an additional power supply always on the engine or frame.

Mount the ground terminal securely in the from of a circular plate terminal.

Fuses of optimum capacity must be used for vehicles considering the operating load and the
operating frequency.
Don’t add any load from accessories to the existing fuses.

Always be sure to insert a fuse in an added wiring circuit.

Use a vinyl-coated clamp, taking adequate care against short circuit.

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• The fuse capacity should be about 1.4 times the load current.

Ex : For the load current of 3A,

3 x 1.4 = 4.2 A

Therefore, the standard fuse capacity of 5A is the best choice.

FUSE RATED CURRENT AGAINST LOAD (Automobile Standard JASO D610-75)

Ex : 5A fuse can be used for the load current of 3.5A maximum.

When installing additional electronic machine, the circuit must be wired through the fusible link
and to be grounded direct to the frame.
• Be sure not to flow the dormant current in the circuit.

Make sure that the clamp of the harness wire should be added to install as occasion demands
to prevent the resonance oscillation of the harness wiring due to engine vibration and vehicle’s
running.
• Take special attention for the clamping that the case to be used harness wiring with fusible
link.

When installing electric motor consumed bigger load, be sure to use the appropriate size of
harness wire.
• If over capacity of spare power circuit, take the power direct from the battery.

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Electric Wire Size and Permissible Currents

Wire Size and Currents

When wiring the harness wire together with the rear body mounting operations, select an
appropriate type of wire harness taking into consideration the power consumption capacity (A)
of the electrical equipment such will be mounted and the condition of the installation location
referring as following table.

CONNECTING WIRE TYPE WIRE SIZE AND LENGTH

FUSE CAPACITY AMBIENT 0.5mm 2 0.85mm2 1.25mm2 2mm2 3mm 2 5mm2 8mm 2
2 2
(A) TEMPERATURE (0.0008 in. ) (0.0013 in. ) (0.002 in.2 ) (0.0031 in.2 ) (0.005 in.2 ) (0.008 in.2 ) (0.012 in.2 )
AV 80˚C (176˚F)
MAX. 30m
5 AVX 100˚C (212˚F)
(MAX. 98 ft)
— — — — — —
AEX 120˚C (248˚F)
AV 80˚C (176˚F)
MAX. 15m MAX. 20m MAX. 30m
10 AVX 100˚C (212˚F)
(MAX. 49 ft) (MAX. 66 ft) (MAX. 98 ft)
— — — —
AEX 120˚C (248˚F)
AV 80˚C (176˚F)
MAX. 15m MAX. 20m MAX. 35m
15 AVX 100˚C (212˚F) X
(MAX. 49 ft) (MAX. 66 ft) (MAX. 115 ft)
— — —
AEX 120˚C (248˚F)
AV 80˚C (176˚F)
MAX. 15m MAX. 25m MAX. 40m
20 AVX 100˚C (212˚F) X X
(MAX. 49 ft) (MAX. 82 ft) (MAX. 131 ft)
— —
AEX 120˚C (248˚F)
AV 80˚C (176˚F)
MAX. 5m MAX. 10m MAX. 15m MAX. 25m
30 AVX 100˚C (212˚F) X X X
(MAX. 16 ft) (MAX. 33 ft) (MAX. 49 ft) (MAX. 82 ft)
AEX 120˚C (248˚F)
AV 80˚C (176˚F)
MAX. 5m MAX. 9m MAX. 20m MAX. 20m
40 AVX 100˚C (212˚F) X X X
(MAX. 16 ft) (MAX. 30 ft) (MAX. 66 ft) (MAX. 66 ft)
AEX 120˚C (248˚F)
AV 80˚C (176˚F)
MAX. 7m MAX. 10m MAX. 15m
50 AVX 100˚C (212˚F) X X X X
(MAX. 23 ft) (MAX. 33 ft) (MAX. 49 ft)
AEX 120˚C (248˚F)
AV 80˚C (176˚F)
MAX. 5m MAX. 10m
60 AVX 100˚C (212˚F) X X X X X
(MAX. 16 ft) (MAX. 33 ft)
AEX 120˚C (248˚F)
AV 80˚C (176˚F)
MAX. 10m
80 AVX 100˚C (212˚F) X X X X X X
(MAX. 33 ft)
AEX 120˚C (248˚F)
WIRE TYPE WIRE SIZE AND PERMISSIBLE CURRENT
2 2
AMBIENT 0.5mm 0.85mm 1.25mm2 2mm2 3mm 2 5mm2 8mm 2
TEMPERATURE (0.0008 in.2 ) (0.0013 in.2 ) (0.002 in.2 ) (0.0031 in.2 ) (0.005 in.2 ) (0.008 in.2 ) (0.012 in.2 )
AV 80˚C (176˚F) 9A 11A 14A 20A 27A 36A 47A
AVX 100˚C (212˚F) 8A 10A 13A 17A 24A 33A 43A
AEX 120˚C (248˚F) 7A 9A 12A 17A 23A 32A 42A

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NOTE:
• Select wires size to suit the power consumption current.
• If you intend to use AEX wire, make sure that you also use heat resistant protective tubing,
tape, and clips.
• Where the wire is subject to movement caused by relative motion, use wire of 0.85 mm2
(0.0013 in.2) cross section or larger.

• Characteristic of wire.

• Marked “x” can not be used.

Marked “—” shows the wire length maximum 50 m (164 ft).

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Coding for Electrical Wires

Wire codes represent size and color

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