Usage:
Exploded View
1 FRONT COVER
2 SHADOW PLATE
3 WARNING LENS
4 HOUSING
5 COOLANT TEMPERATURE GAUGE
6 HYDRAULIC OIL TEMPERATURE GAUGE
7 FUEL GAUGE
8 HOUR METER
9 LAMP & BUZZER SWITCH
10 RUBBER CAP
11 GASKET
12 METER BOARD
13 MONITOR BOARD
14 LAMP & SOCKET
15 BACK PLATE
16 SCREW
17 TAPPING SCREW
18 DISTANCE BOLT
19 WASHER
20 HEXAGON NUT
21 BRACKET
22 COVER
Tools
Preparation
1. Work bench
Get a work bench large enough to arrange disassembled part on it. Level the work bench to prevent parts from rolling down.
Use special care to prevent dirt, grease, and foreign matters from adhering to detached boards when they are put on the work bench or other places.
2. Tools
Prepare tools necessary for the work according to the tool table.
3. Work site
Do work in a dust-free and well-lit room.
General Precautions
1. Use care in handling precision parts during work to avoid damage caused by striking other parts or from being dropped.
2. Never strike or prize parts forcibly when they are held fast, to prevent damage, burring, or deteriorated performance. Use care and patience.
3. Protect parts from corrosion and dust when disassembly is interrupted for some time. Parts may rust due to moisture or dust when left disassembled.
Parts Replacement
1. Remove the monitor panel.
2. Replace the lamp bulb (warning).
3. Replace the lamp bulb (illumination).
4. Replace the coolant temperature gauge, hydraulic oil temperature gauge, and fuel gauge.
5. Replace the hour meter.
6. Replace the warning lens.
7. Replace the lamp and buzzer switch.
8. Replace the monitor board and meter board.
1. Removal of Monitor Panel
1. Remove six caps on the corners of the front cover by hand.
2. Remove six screws.
3. Hold up the monitor panel.
4. Disconnect the harness connector on the switch box side.
5. Take out the monitor.
2. Replacement of Lamp Bulb (Warning)
1. Remove four screws on the corners of the back plate at the back of the monitor panel.
2. Remove the lamp bulb on the meter board by manually turning it, and renew.
NOTE: Be sure to fully turn the bulb and make sure that it is in place.
3. Replacement Of Lamp Bulb (Illumination)
1. Detach the monitor board by removing two distance bolts and two screws on the upper side of it.
NOTE: The meter board and monitor board are connected to each other through a bracket cable. Do not pull the monitor board too much.
2. Remove the lamp bulb on the meter board by manually turning it, and renew.
4. Replacement of Coolant Temperature Gauge, Hydraulic Oil Temperature Gauge, and Fuel Gauge
1. Remove two screws that fix the shadow plate on the back of the monitor panel to the housing.
2. Carefully take off the gasket bonded to the front cover using a scraper, etc.
3. Remove four nuts fixing the meter to the board by pulling it towards the front, and renew.
NOTE: When re-installing the meter, be sure to insert washer and spring washer, and securely tighten the nut.
5. Replacement of Hour Meter
1. Remove three nuts that secure the hour meter.
2. Pull the hour meter towards the front and detach the leads (red and black) from the joints. Replace the hour meter with a new one.
NOTE: Joint leads of the same color together and use care to prevent excessive force from being applied on the electronic parts for the meter when the leads are formed. Also, avoid interference with other parts. When re-installing the meter, be sure to insert washer and spring washer, and tighten the nut securely.
6. Replacement of Warning Lens
1. Remove the warning lens by hand, and replace it with a new one.
7. Replacement of Lamp and Buzzer Switch
1. Disconnect the switch leads (green and blue) from the joints.
2. Remove the securing nuts on the back of the shadow plate and detach the switch from the cover front. Replace the switch with a new one.
NOTE: Securely joint the switch leads of the same color together.
8. Replacement of Monitor Board and Meter Board
1. Remove the screws that secure the meter board, and replace with a new one.
Storage Standards
Storage of Products and Parts
1. Storage of Monitor Panel
1 Store the products and parts in a dry and clean place not exposed to winds, rains and direct sunlight.
2 Place a cover on the monitor panel to keep out dust. Pay special attention to the connector and make sure that no dust is deposited on the pins.
2. Operation of Monitor Panel (stored for more than six months)
1 Visually check the monitor panel for abnormal condition that might have occurred during storage.
2 Remove the cover and visually check for abnormal condition on the boards and wirings.
3 If there is dust buildup in the monitor panel proper, carefully blow away with compressed air and wipe clean with a dry cloth.
Terminology Associated with Troubleshooting of Electrical System
Connector
Part of a wire assembly or harness where the wire assembly or harness is connected with another wire assembly or harness.
Diode
The name of a semiconductor which allows current to flow only in one direction. A diode allows current to flow only when the voltage on its anode side turns positive (+) the specified amount with respect to the voltage on its cathode side.
Electronic
A term associated with an electric circuit having semiconductors.
External Grounding
External grounding of a component is done by connecting the component with a wire to another component connected to the ground, that is, the negative pole of the battery or the metallic portion of the vehicle.
Harness
An assembly composed of several or many wires held together by a cover.
Indicator
A lamp or light emitting diode which indicates that the vehicle is in a certain state. The lamp or light emitting diode lights or flashes to indicate the state.
Internal Grounding
Internal grounding of a component is done by connecting the component to the metallic portion of the vehicle.
Male and Female Connectors
The male connector of a harness fits in the female connector of another harness.
Normal State
A term used concerning a switch or relay. It means a state where a switch or relay is not operated by the force of hand or the function of temperature, pressure or electricity. Some switches do not have a normal state.
Normally Closed (N.C.)
A N.C. switch or relay is normally in the closed state.
Normally Opened (N.O.)
A N.O. switch or relay is normally in the opened state.
Pin
The male contact of a connector which fits in the female contact of another connector.
Positive (Forward) Bias
To apply voltage in direction that semiconductor operates normally.
Pulse
A short interval of current flow
Receptacle
The female contact of a connector which fits to the male contact of another connector.
Semi-Conductor
Under some condition, it becomes an insulator electrically. And under some condition, it becomes conductive electrically.
Diodes and transistors (solid state circuit) are used for this purpose.
Sensor
A component used in a temperature or pressure gauge. The sensor measures temperature or pressure. A change in its resistance appears in the temperature or pressure gauge. It is an element which plays the role of sending a change to a gauge.
Transistor
A solid state semiconductor used in an electric circuit. The transistor is used as an amplifier which amplifies voltage or current or as a switch.