SECTION 4 ELECTRICAL SYSTEM

Group 1 Component Location -------------------------------------------------------------------------------------- 4-1

Group 2 Monitoring system ------------------------------------------------------------------------------------------ 4-3
Group 3 Electrical Circuit ---------------------------------------------------------------------------------------------- 4-16
Group 4 Electrical Component Specification -------------------------------------------------------------- 4-32
Group 5 Connectors ------------------------------------------------------------------------------------------------------ 4-39
 SECTION 4 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION

1. LOCATION 1

1 10
11
2 12
3 13
4
5
6
7 Switch
panel 2 14
Switch
panel 1

15
8 16
17
9 18

CALL

MUTE

MODE

SEEK
V

VOL

19
20

21

80CR94EL02

1 Head light switch 8 Breaker operation switch 15 Speaker

2 Work light switch 9 Accel dial switch 16 Fuse box
3 Travel alarm switch 10 Quick clamp switch 17 Machine control unit
4 Cab light switch 11 Wiper switch 18 Master switch
5 Beacon switch 12 Washer switch 19 Horn switch
6 Breaker selection switch 13 Boom offset switch 20 Aircon & heater controller
7 Start switch 14 Radio & MP3 player 21 Cigar lighter

4-1
2. LOCATION 2

8
7

80CR94EL03

1 Water temp sender 6 Back buzzer

2 Washer tank assy 7 Fuel filler pump
3 Battery 8 Power relay
4 Battery relay 9 Engine control module
5 Horn

4-2
 GROUP 2 MONITORING SYSTEM

1. OUTLINE
Monitoring system consists of the monitor part and switch part.
The monitor part gives warnings when any abnormality occurs in the machine and informs the
condition of the machine.
Various select switches are built into the monitor panel, which act as the control portion of the
machine control system.

2. CLUSTER
1) MONITOR PANEL

Engine RPM gauge

Service meter, Clock
Fuel gauge
Engine coolant temp gauge Fuel low level warning lamp
Overheat warning lamp M mode switch
Auto idle switch Travel speed switch
Air cleaner warning lamp

Boom offset pilot lamp

Engine oil pressure warning lamp
M mode pilot lamp
Preheat pilot lamp
Hyd oil temp warning lamp

Warming up pilot lamp Travel speed pilot lamp(High)

Travel speed pilot lamp(Low)
Auto idle pilot lamp Enter switch
Menu switch Battery charging warning lamp
Move (down) switch
Move (up) switch Buzzer stop switch

5593CD02

4-3
2) CLUSTER CHECK PROCEDURE
(1) Start key : ON
① Check monitor initial 6 seconds
a. All lamps light up.
b. Buzzer sound.
② Check monitor after 3 seconds : Indicate machine condition
a. Tachometer : 0 rpm
b. Fuel gauge : Pointed at appropriate level
c. Engine coolant temperature gauge : Pointed at appropriate level
d. Warning lamp
※ During start key ON the engine oil pressure lamp and battery charging lamp go on, but it is not
abnormal.
※ When engine coolant temperature below 30˚C, the warming up lamp lights up and then
operating the preheat switch.

(2) Start of engine

① Check machine condition
a. Tachometer pointed at present rpm
b. Gauge and warning lamp : Indicate at present condition.
※ When normal condition : All warning lamp OFF
c. Travel speed pilot lamp : Low (turtle)
② When abnormal condition
a. The lamp lights up and the buzzer sounds.
b. If BUZZER STOP switch is pressed, buzzer sound is canceled but the lamp light up until
normal condition.

4-4
3. CLUSTER CONNECTOR
1) CN-56 CONNECTOR
Input/
No. Signal Output
CN-56
1 Null -
10 9 8 7 6 5 4 3 2 1
2 Null - 20 19 18 17 16 15 14 13 12 11
3 Alternator signal Input
4 Over heat signal Input
5 Tacho signal Input
6 Null -
7 Null -
8 Travel relay Output
9 Power 12V -
10 Power IG 12V -
11 Null -
12 Illumination Input
13 Null -
14 Null -
15 Fuel level sender Input
16 Hyd oil temp sendor Input
17 Water temp sender Input
18 GND - Cluster
19 GND -
20 GND -

2) CN-57 CONNECTOR
Input/
No. Signal Output
1 Null - CN-57
2 Engine oil pressure switch Input 8 7 6 5 4 3 2 1
3 Air cleaner signal - 16 15 14 13 12 11 10 9

4 Boom swing signal -

5594EL15
5 Null -
6 Null -
7 Null -
8 Null -
9 Program dump -
10 Null -
11 COM-GND Input
12 RS232-RX Input
13 RS232-TX Output
14 RS485-RX Input
15 RS485-TX Output
16 Pre heat signal Input

4-5
4. MCU (machine control unit) CONNECTOR
1) CN-51 CONNECTOR
No. Signal

1 CAN High (2)

2 CAN Low (2)
5 Pressure sensor supply power (12V)
6 Working pilot pressure
10 9 8 7 6 5 4 3 2 1

7 Overload pressure
20 15 11
10 Battery (12V) 16

30 26 25 21

11 RS232 Tx (1)
40 39 38 37 36 35 34 33 32 31
12 RS232 Rx (1)
15 Accel Dial (5V)
20 Battery (12V)
23 Program Dump
80CR94EL15
30 Key Ignition Power (12V)
31 CAN High (1)
32 CAN Low (1)
33 CAN (Ground)
34 Signal Return Ground
35 Accel Dial Signal
36 Alternator Level Signal
38 Hour meter
39 Battery Ground
40 Battery Ground

4-5-1
4-6
5. CLUSTER FUNCTION
1) GAUGES AND DISPLAYS
(1) LCD display
Service meter
Η Service meter : This meter shows the total operation hours of
the machine.
ö Always ensure the operating condition of the meter during the
machine operation.
ö The last unit indicates 1/10 of hours.
Clock
5593CD03 (for example : 1
10 indicates 6 minutes)
Θ Clock : This displays the current time.
ö Refer to the "menu switch" for the setting time/ESL switch.

(2) Fuel gauge

Η This gauge indicates the amount of fuel in the fuel tank.
Θ Fill the fuel when the red range or warning lamp blinks.
ö If the gauge indicate the red range or warning lamp ON.
Even though the machine is on the normal condition, check
the electric device as that can be caused by the poor
Red range connection of electricity or sensor.
5593CD04

(3) Engine coolant temperature gauge

Η This indicates the temperature of coolant.
Red range Θ When the red range pointed or warning lamp blinks, engine
do not abruptly stop but run it at medium speed to allow it to
cool gradually, then stop it.
Check the radiator and engine.
ö If the engine is stopped without cooled down running, the
5593CD05
temperature of engine parts will rise suddenly, this could cause
severe engine trouble.

(4) Engine rpm gauge

Η This gauge displays the number of engine revolutions per
minute.

5593CD06

4-6
2) WARNING AND PILOT LAMPS
(1) Fuel low level warning lamp
① This lamp blinks and the buzzer sounds when the level of fuel
is below 17ℓ(4.5 U.S. gal).
② Fill the fuel immediately when the lamp blinks.

R5573CD10

(2) Hydraulic oil temperature warning lamp

① This warning lamp operates and the buzzer sounds when the
temperature of hydraulic oil is over 105˚C (221˚F ) .
② Check the hydraulic oil level when the lamp blinks.
③ Check for debris between oil cooler and radiator.

R5573CD11

(3) Overheat warning lamp

① This lamp blinks and the buzzer sounds when the temperature
of coolant is over the normal temperature 110˚C (230˚F ) .
② Check the cooling system when the lamp blinks.

R5573CD12

(4) Engine oil pressure warning lamp

① This lamp blinks and the buzzer sounds after starting the
engine because of the low oil pressure.
② If the lamp blinks during engine operation, shut OFF engine
immediately. Check oil level.

R5573CD13

(5) Air cleaner warning lamp

① This lamp blinks and the buzzer sounds when the filter of air
cleaner is clogged.
② Check the filter and clean or replace it.

R5573CD14

4-7
(6) Battery charging warning lamp
① This lamp blinks and the buzzer sounds when the starting
switch is ON, it is turned OFF after starting the engine.
② Check the battery charging circuit when this lamp blinks during
engine operation.

R5573CD16

(7) Warming up pilot lamp

① This lamp is turned ON when the coolant temperature is below
30˚C (86˚F).
② The automatic warming up is cancelled when the engine
coolant temperature is above 30˚C, or when 10 minutes have
passed since starting.
R5573CD18

(8) Preheat pilot lamp

① When engine preheating switch is turned ON, pilot lamp
cames ON.
② Refer to the preheating switch for details.

R5573CD19

(9) Travel speed pilot lamp (high)

① When this lamp turned ON, the machine travel high speed.
② Refer to the travel speed select switch for details.

R5573CD20

(10) Travel speed pilot lamp (low)

① When this lamp turned ON, the machine travel low speed.
② Refer to the travel speed select switch for details.

R5573CD21

4-8
(11) Auto idel pilot lamp
① If the control lever and pedal are not moved for several
seconds with auto idle switch pressed, the indicator illuminates
and engine speed is decelerated.
② If the auto idle switch is pressed once more or the control lever
or pedal is moved, the indicator turns off and the number of
21073CD17 engine revolution is turned to the previous condition.

(12) M mode pilot lamp

① This lamp is ON when the M mode switch is pressed.
② Engine is operated with a maximum speed.

55W7A3CD83

(13) Boom offset pilot lamp

① This lamp is ON when the boom offset switch is pressed.

555C93CD13

4-9
3) SWITCHES
(1) Travel speed control switch
① This switch is to control the travel speed which is changed to
high speed (rabbit mark) by pressing the switch and low speed
(turtle mark) by pressing it again.

555C93CD15

(2) Auto idle switch

① This switch is used to actuate or cancel the auto idle function.
② When the switch actuated and all control levers and pedals are
at neutral position, engine speed will be lowered automatically
to save fuel consumption.

555C93CD18

(3) M mode switch

① This switch is used to maximum power.
② When this switch is pressed, the M mode pilot lamp is ON or
OFF.

555C93CD23

(4) Move (down) & buzzer stop switch

① When the starting switch is turned ON first, normally the alarm
buzzer sounds for 6 seconds during lamp check operation.
② The lamp lights ON and the buzzer sounds when the machine
has a problem.
In this case, press this switch and buzzer stops, but the lamp
5593CD08 lights until the problem is cleared.
③ This switch is used to move down or decrease input value.
※ Refer to page 4-11.

(5) Move (up) switch

① This switch is used to move up or increase input value.
※ Refer to page 4-11.

5593CD09

4-10
(6) Menu and enter switch
Menu Enter ① These switches are used to set time or set ESL (Engine Start
Limit) function.
- The Enter button ( ) is used to select a function.
- The Menu button ( ) is used to select a menu or return to
the time display menu.
5593CD07

② Setting time
- Press Enter button ( ) to set time, then the screen will be
changed to a display for time setting as a following picture
and time cipher will blink.
- Set hours : When the cipher for hour blinks, press up ( ) or
5593CD10
down ( ) button and set the hour.
- Set
et minutes : When the cipher for minute blinks, press up ( )
or down ( ) button and set the minute.

③ Set ESL (Engine Start Limit) function

- Press Menu button ( ), the display is changed from the time
display menu to ESL function menu.
- Select YES or NO by Move button ( , ) and set the ESL
function by the Enter button ( ).
·YES : ESL function is activated.
·NO : ESL function is cancelled.
④ Set the interval time
- Select ESL function to YES and press the Enter button ( ),
5593CD16 then the display is changed to the interval time set menu.
- Set the interval time by move button ( , ) and press the
Enter button ( ).
- You can finish setting the interval time by inputting the
password and pressing the Enter button ( ) once more.
- Interval times : 5 kinds (0, 10, 30, 60 minutes, 1day)
※ If the ESL function is set to YES, the password is required
when a operator starting engine first.
But the operator can restart the engine within the interval time
period without inputting the password.

4-11
 ⑤ Change password
- Select ESL function to YES and press the Menu button ( ),
the display is shifted to the password change menu.
·Input a new password (Sn : - - - -) after enter the current
password successfully (SC : - - - -).
·Push enter ( ) button for a second to finish the setting
after the new password is entered once again (SA : - - - -).
·When the setting is done, the display will blink 3 times and
return to the time display screen.

5593CD18

⑥ Check machine and engine diagnostic codes

- If the F : Code is displayed on the LCD display, you can check
faults of the machine and / or engine.
- The machine fault code is displayed by pressing the Menu
button ( ) and the engine fault code is displayed by pressing
the Menu button ( ) once more.
- Other fault codes can be displayed by using the Move up /
5593CD14A
down button ( , ).
※ Refer to the following pages for the fault codes.

4-12
 ⑦ Machine fault code
Fault code
Description
HCESPN FMI
0 Working pressure sensor data above normal range (or open circuit)
1 Working pressure sensor data below normal range
2 Working pressure sensor data error
105 4 Working pressure sensor circuit - voltage below normal, or shorted to low source
14 Working pressure sensor circuit - special instructions
16 Working pressure sensor circuit - voltage valid but above normal operational range
18 Working pressure sensor circuit - voltage valid but below normal operational range
Travel speed solenoid circuit - voltage below normal, or shorted to low source (or open
4
167 circuit)
6 Travel speed solenoid circuit - current above normal
0 Brake pressure sensor data above normal range (or open circuit)
1 Brake pressure sensor data below normal range
2 Brake pressure sensor data error
503
4 Brake pressure sensor data - voltage below normal, or shorted to low source
16 Brake pressure sensor data - voltage valid but above normal operational range
18 Brake pressure sensor data - voltage valid but below normal operational range
0 Working brake pressure sensor data above normal range (or open circuit)
1 Working brake pressure sensor data below normal range
2 Working brake pressure sensor data error
505
4 Working brake pressure sensor circuit - voltage below normal, or shorted to low source
16 Working brake pressure sensor circuit - voltage valid but above normal operational range
18 Working brake pressure sensor circuit - voltage valid but below normal operational range
4 Ram lock solenoid circuit - voltage below normal, or shorted to low source (or open circuit)
525
6 Ram lock solenoid circuit - current above normal
0 Travel fwd pilot pressure sensor data above normal range (or open circuit)
1 Travel fwd pilot pressure sensor data below normal range
2 Travel fwd pilot pressure sensor data error
530 4 Travel fwd pilot pressure sensor circuit - voltage below normal, or shorted to low source
14 Travel fwd pilot pressure sensor circuit - special instructions
16 Travel fwd pilot pressure sensor circuit - voltage valid but above normal operational range
18 Travel fwd pilot pressure sensor circuit - voltage valid but below normal operational range
701 4 Hour meter circuit - voltage below normal, or shorted to low source
0 MCU input voltage high
705
1 MCU input voltage low
707 1 Alternator node I voltage low (or open circuit)
3 Acc. dial circuit - voltage above normal, or shorted to high source (or open circuit)
714
4 Acc. dial circuit - voltage below normal, or shorted to low source
830 12 MCU internal memory error
840 2 Cluster communication data error
841 2 ECM communication data error
850 2 RMCU communication data error

4-13
 ⑧ Engine fault code
Fault code
Description
YANMAR SPN FMI
4 Engine fuel rack position sensor : shorted to low source
1210
3 Engine fuel rack position sensor : shorted to high source
4 Accelerator pedal position sensor “A” : shorted to low source
3 Accelerator pedal position sensor “A” : shorted to high source
2 Accelerator pedal position sensor “A” : intermittent fault
91
1 Accelerator pedal position sensor “A” : below normal operational range (SAE J1843)
0 Accelerator pedal position sensor “A” : above normal operational range (SAE J1843)
15 Accelerator pedal position sensor “A” : not available (SAE J1843)
4 Accelerator pedal position sensor “B” : shorted to low source
3 Accelerator pedal position sensor “B” : shorted to high source
2 Accelerator pedal position sensor “B” : intermittent fault
29 1 Accelerator pedal position sensor “B” : below normal operational range (SAE J1843)
0 Accelerator pedal position sensor “B” : above normal operational range (SAE J1843)
8 Accelerator pedal position sensor “B” : communication fault
15 Accelerator pedal position sensor “B” : not available (SAE J1843)
4 Barometric pressure sensor : shorted to low source
108 3 Barometric pressure sensor : shorted to high source
2 Barometric pressure sensor : intermittent fault
4 E-ECU internal temperature sensor : shorted to low source
3 E-ECU internal temperature sensor : shorted to high source
1136
2 E-ECU internal temperature sensor : intermittent fault
0 E-ECU internal temperature : too high
4 Engine coolant temperature sensor : shorted to low source
3 Engine coolant temperature sensor : shorted to high source
110
2 Engine coolant temperature sensor : intermittent fault
0 Engine coolant temperature : too high
4 Sensor 5V : shorted to low source
1079 3 Sensor 5V : shorted to high source
2 Sensor 5V : intermittent fault
1 E-ECU system voltage : too low
158
0 E-ECU system voltage : too high
1078 4 Engine fuel injection pump speed sensor : shorted to low source
522402 4 Auxiliary speed sensor : shorted to low source
4 Engine fuel rack actuator relay : open circuit
3 Engine fuel rack actuator relay : short circuit
522241
7 Engine fuel rack actuator relay : mechanical malfunction
2 Engine fuel rack actuator relay : intermittent fault
4 Air heater relay : open circuit
522243 3 Air heater relay : short circuit
2 Air heater relay : intermittent fault

4-14
 Fault code
Description
YANMAR SPN FMI
4 Cold start device : open circuit
522242 3 Cold start device : short circuit
2 Cold start device : intermittent fault
4 EGR stepping motor “A” : open circuit
522251
3 EGR stepping motor “A” : short circuit
4 EGR stepping motor “B” : open circuit
522252
3 EGR stepping motor “B” : short circuit
4 EGR stepping motor “C” : open circuit
522253
3 EGR stepping motor “C” : short circuit
4 EGR stepping motor “D” : open circuit
522254
3 EGR stepping motor “D” : short circuit
4 Oil pressure switch : shorted to low source
100
1 Oil pressure : too low
4 Battery charge switch : shorted to low source
167
1 Battery charge : charge warning
522314 0 Engine coolant temperature : abnormal temperature
522323 0 Air cleaner : mechanical malfunction
522329 0 Oily water separator : mechanical malfunction
190 0 Engine speed : over speed condition
4 Engine fuel rack actuator : shorted to low source
638 3 Engine fuel rack actuator : shorted to high source
7 Engine fuel rack actuator : mechanical malfunction
639 12 High speed CAN communication : communication fault
2 E-ECU internal fault : EEPROM check sum error (data set 2)
630
12 E-ECU internal fault : EEPROM error
12 E-ECU internal fault : flashROM check sum error (main software)
628 2 E-ECU internal fault : flashROM check sum error (data set 1)
2 E-ECU internal fault : flashROM check sum error (data set 2)
1485 4 E-ECU main relay : shorted to low source
12 E-ECU internal fault : cyclic redundancy check of sub-CPU error
522727 12 E-ECU internal fault : acknowledgement of sub-CPU error
12 E-ECU internal fault : communication with sub-CPU error
522728 12 E-ECU internal fault : engine map data version error
12 Immobilizer : CAN communication fault
522730
8 Immobilizer : pulse communication fault
1202 2 Immobilizer : system fault

4-15
 CR-85
87a 30 86
5R 21 43 RW
85
BW 23 42 Or
1 87
5W 22 18A WOr

12

3
86

3
4
9

12
2

10
WB 15 18 WOr 87a 87 85
INLET MOTOR(REC) 1 16 BW
3 30
BW 16
18 WOr

1
2

4
5
7
9
14
16

3
8
13
15
18

10

1
11
12
17
19
INLET MOTOR(FRE) 2

2
20
86

85

86
12V SOCKET

85
4 BEACON LAMP

M
LR 17

INLET M/ACT
TEMP MOTOR ACT(+) 3

30

30
5

CN-139
BG 18

B
R
TEMP MOTOR ACT(-) 4

7
11

2
HARNESS CABIN

7
8

86

85
87 87a

87 87a

86

85
6

20A
10A
20A

20A
10A
20A

20A

20A

86
30A
30A
20A
30A

20A

20A

85
20A
GL 19

20A

20A
20A

20A

20A
TEMP M/ACT(PBR) 5 15 WB

30
CN-6

CS-67

30
7

10
11

5
9
12

4
8
CL-7

1
2
3
6
7
Y

30
20

2A

87a

87a
86
85

30

QUICK COUPLER SW
86
85
87

30
87
HORN RY
MOTOR ACT(REF) 6 42 Or Or

CR-62
CR-2
Or

BREAKE RY1

87 87a
87 87a
GW 1

ECU
21

87 87a
17 LR

MCU

MCU
MODE M/ACT(DEF) 7 M

1
2B B
LAMP

SPEAR
BG 22 20 Y 2

87a

86
85
87a

30
87
86
85

30
87

87a
MODE M/ACT(FOOT) 8 2B R

86
85

30
87
2 R

CR-12
BEACON

0.8B

SOLENOID
PRE-HEAT
1.2Br

CR-36
WR 3

START KEY
23

M
ANTI-RESTARTCR-5
HEAD LAMP

TRAVEL HI-LO SOL

PRE-HEAT RY
AC& HEATER

WORK LAMP
1.2BrW
0.8BrW
MODE M/ACT(M+) 9

SAFETY SOL
Y 26
3 43 RW

Gr 25

L 12A
L 12B

G 45

4
LB 24 18 BG 4

BEACON LAMP
GW 15
BrW 58

FUEL P/P.HORN
MODE M/ACT(M-) 10 CL-1

GW 15A

FUSE BOX
CN-36
4

CASSETTE RADIO
YB

2
25 19 GL B

58
24J
MODE M/ACT(PBR) 11

27E
5 1

58A

L 32

5
TEMP M/ACT
G 16
CLUSTER,CASSETTE

LY 54
CLUSTER,SW PANEL

V 49
B 00
LG

Lg 56
26

BW 53
R

CABIN LAMP/FEED PUMP

CIGAR ,WIPER MOTOR

VW 55

BW 00
BLOWER RELAY(LO) 12
LAMP

6 2

YW 17B
YW 17C

BW 19B
ROOM

YBr 27 9A GB

7
BLOWER RELAY(M1) 13 7
BG 28

R 2
ROOM LAMP&AC HEATERR 3

G 1
RL 6
L 12
Br 14
BLOWER RELAY(M2) 14

VW 5

VW 5
Gr 13

GW 4
ROr 7
LW 15
LW 20

YW 10
BW 19

ALT,ANT-RESTART RY. GW 16
YB

RW 17

BrW 11
29 1

WOr 18
42 Or

BLOWER RELAY(HI) 15
43 RW

3
18 WOr

LW 30 2 G4
18A WOr

COMPRESSOR(DPS) 16 21 GW
LY 31 3
CONDENSER FAN 17 CL-9
4

M
18 B
1
87

30
85

86

5
87a
CR-9

12 RW

MODE(D/FOOT)

7
BR 1 6 2
GND 1
LH,RH

22 BG
BR 2 7
87a 87
GROUP 3 ELECTRICAL CIRCUIT

30

GND 2 B
RW 3 23 WR 1
85
86

1
BATTERY(+) 3 1 12A RW

AC&HEATER CONTROLLER
CABIN LAMP

RW 4 20A Y
CABIN LAMP RY.

2
BATTERY(+) 4 2
G

M
5 CL-10
ILLUMINATION 5 3

4
RY 6 24 LB
POWER IG 6 4

2
25 YB
NC 7 5 CS-2

5
MODE(VENT)
BrR 8 1 G

86

85
DUCT SENSOR(+) 8 6 1
H0 I

GB 9 9B GB

30
31 Br

7
DUCT SENSOR(GND) 9 7 2
0, I

GB 10 23 BW

87 87a
H

REVERSE FAN SIG 10 3 4

26 LG
1 Lo 1
B

AC COMP
NC 11 4 1

87a

86
85

30
87
CR-7
35 YW 2
2 MH 3 32 L 3
NC 12 5
BR ACC

27 YBr
START SW

NC 13 3 ML 2 6

RESISTOR
36A L
NC 14 4 Hi 4 5
ST C

Br 50
6

YR 46

LW 8B
LW 8A
29 YB
1 2 1
1.25LgB 9
1 33 R
1.25G 8 2

DUCT
2 6B RY CS-47
3

SENSOR
RELAY(HI)
36 L 1
4 4 3
1 12
2
28 BG LgR
1 2 1 3

5
6
GW

31
30
33
10
33A R

32
1,2
2 4
6A RY 5
3

RELAY(M2)
35 YW

G
6

LY
2B

2R
RY
4 4 3

LW
RW
3

1.25B
B
7 7
32 2B RW 9
1 M 8
36 L

8
7
6
5
4
3
2
1
8
7
6
2

5
4
3
1
4
BOOM SWING SW

NO.
CN-2
9 8

BLOWER
10
10

AIR CON
GW

2B
11

MCU
B 11 12

3A R
1.25 B

50 Br
8 LW
12

24F RW
EARTH

FUSE(IG)
EARTH

FUSE(Battery)
2B
CR-71

ILLUMINATION
GND(BLOWER)
87a 30 86

DESTINATION

CONDENSOR FAN
BL

GND(CONTROLLER)
85

DPS(COMPRESSOR)
V
CN-246 87
W
USB(+5V) 1 86
R 87a 87 85
2
BOOM SWING

USB(D+) 30
USB(D-) 3
USB(GND) 4
71 0.5YL
RX 5
72 0.5GY
TX 6
24D 0.5RW
ILLUMINATION 7
0.5B
GND 8
73 0.5LgW
TX/S 9

USB&SOCKET ASS'Y
000
POWER IG 10 CN-170
74 0.5BW 00
GND(JACK) 11
2
NC 12 B
1

CN-245
5B 0.5V
SEAT HEATER

POWER IG 1
75 0.5LY
SIG+ 2 CN-116
76 0.5BW
SIG- 3 60 ROr
ILL LAMP OUT 1
NC 4 59 V
77 0.5Lg WORK LIGHT OUT 2
H/F IND+ 5 30 R
0.5B NC 3 1
H/F IND- 6 29 R
78 0.5GY NC 4 2
MIC+ 7
79 0.5BL NC 5 CS-74
MASTER SW

MIC- 8 33 Br

REMOTE ASS'Y
24C 0.5RW BEACON 6
ILLUMINATION 9 44 Or
80 0.5L CABIN LIGHT OUT 7
REMOTE SIG+ 10 61 Gr
81 0.5Y TRAVEL ALARM 8

SWITCH PANEL
REMOTE SIG- 11 45A G
0.5B BREAKER 9
GND 12 6A RL CS-3
POWER 12V(IG) 10
1
CN-144 GND 11
78 0.5GY 2
I

MIC+ 1 NC 12 36 V
3
0

71 0.5YL
RX(JACK) 2
76 0.5BW 4
GND(SEND) 3 35 Or
82 0.5RW 5
4 CR-13 4
TEL MUTE B
73 0.5LgW 10 YW 6 8
TX/S 5 30 37 Br
85 87 87a 10A YW 7 10
83 0.8BOr 86
EARTH

CAR AUDIO(-) 6 35A Or 3

24A RW 8
WIPER SW

84 0.8Or 87
CAR AUDIO(+) 7 7 6
60 Ror 9
85 9
NC 8
5A 0.8V 10

ILL LAMP RY.

86 30
14 Br

POWER IG 9 87a 7B ROr

47 GW

79 0.5BL 11
MIC- 10 35 Or 11 12
72 0.5GY 12

H/FREE
TX(JACK) 11
3
2
1

74 0.5BW
GND(JACK) 12 CR-3 CR-6
11 BrW
CS-4

RX(SEND) 13 30 37 Br
85 87 87a 11A BrW 6
3

75 0.5LY
TX(SEND) 14 86
7 ROr
1

77 0.5Lg 57 Ror 4
IND(+) 15 87
59 V
2

NC 16 85
SAFETY SW

85 0.8BOr 86 30 35 Or
SPK(-) 17 87a 3
INT.WIPER RY

86 0.8Or 36 V

WORK LAMP RY.

SPK(+) 18 1
0.8B
GND(MAIN) 19
NC 20 CR-4
40 G
30
CN-27 7C ROr 87a 87 85
5 0.8V 86
ACC 1 7D ROr
0.5B 87
ILL- 2 38 Or
85
3
WIPER RY

GND 39 Gr 30 86
88 0.8BW 87a
SPK FRT RH- 4
83 0.8BOr
SPK FRT LH- 5
82 0.5RW
TEL MUTE 6
ANT 12V 7 4 Lo M
2 0.8Y
BACK UP+ 8 CN-21
24B 0.8RW

2SQ
ILL+ 9 40 G
4

5
6
NC 10

7
7E ROr

56
3 B

5A
59
60
7A
6E
87 0.8Gr

5E
3

G2

MP3 & RADIO PLAYER

SPK FRT RH+ 11

34A
B 1 Pf
80 0.5L 2 2 E
WIPER MOTOR

REMOCON+ 12 39 Gr

Br
B

Gr
G

Br
81 0.5Y 1

GW
GW
BW
REMOCON GND 13

GW
L

OrW
G
G
Br

Gr

84 0.8Or
RL
4 R

49 V
51 G

63Gr

62 R
65 W

0.85YW

SPK FRT LH+

70 Or

14
64LW

0.85GW
21 5R

16B G
55 VW

22 5W
53 BW
47 0.85Y

69 YW
41 0.85V

57 ROr
40 0.85Or

Gr
36 1.25R

26 0.85L
37 0.85G

27 0.3Y

G1 5.0B
42 0.85Br

36A V
G2 5.0B
58 BrW
44 0.85Gr
43 0.85Gr

31 0.3Gr
46 0.85LW

3
2
45 0.85GW

6
1

4
1
NC

3
2
15

6
4
87

30
85

86
0.8B 41A G

87a
DO-1

GND 16 2

CR-68
CR-67
CR-45
2

1
1

2
9
5
4
3

7
6
2

8
1
1

9
5
4
3
2

7
6

12
11
10
6
5
3

5
3
4
1

12
11
10
4
1
9
8
7
6
2

9
8
7
2

15
14
13
12
11
10

2 4
6 3 1
15
14
13
12
11
10

24
6 3 1
87a 87
30
CN-2
CN-1
CN-3

86 Or
CN-4
CN-5

LH
1 1

85
86
85 Br
EARTH 2

2 1 12

ECU IG POWER
2

RACK ACTUATOR

ECU MAIN POWER

SPEAKER
CN-23 3
5.0B G1
5.0B G2
0.85R 9
0.85G 1
0.85Gr 2

0.3Gr 11

B
0.85LW 3

0.85YW 6
5.0R 23

0.85YW 8
0.85GW 7

0.85Or 10
1.25R 36

5.0W 22
0.85Y 47
0.85G 37

0.3Y 27

4
0.85Br 42
0.85V 41

0.85Gr 44
0.85Gr 43

0.85L 26
0.85R 24
0.85Or 40

1.25V 29
1.25Br 30
0.3Gr 31

0.3L 13

0.85V 5-1
0.85Br 19
0.85Gr 12

0.85R 20
0.3Y 14
0.85Or 28

0.3G 15
0.85LW 46

0.3Or 18
1.25R 17

0.85B 21
0.85GW 45

0.85LW 33

87 0.8Gr
0.85RW 32

0.85GW 34

1.25VW 16

1.25R 17-1

RH
1 5
88 Y 41 G
2 6
4
7 6

SPEAKER
CN-24 CN-126 7
WASHER SW

R 57A 8
1
CN-56 G 52 9
2

EARTH
NC 1 R 51 10

RS232
3

CONN.
NC 2 Y 54 11
4 11 12
64 LW 12
ALT.LEVEL SIG. 3
OVER HEAT SIG. 4 CS-30
65 W CN-51
TACHO SIG. 5 0.85R 20
ANTI-RESTART RY 6 CAN_Hi2 1
0.85B 21
NC 7 CAN_Lo2 2
56 Lg D_IN SPARE3 3
TRAVEL RY. 8
3R D_IN TRAVEL PS 4
BATT.POWER 12V 9 0.8YW 49
6 RL 12V POWER SUPPLY 5
POWER IG 12V 10
0.8BrW 50
NC 11 A_IN WORKING PS 6

4-16
24E RW SENSOR SPARE1 7
ILLUMINATION 12
NC RCV EPPR+ 8
13
NC D_OUT GOV.MOTOR+ 9
14 1.25R 17-1
67 YW BATT. 12V 10
FUEL LEVEL SENDOR 15 51
0.85R
69 Y RS232_TX1 11
HYD OIL TEMP SENDOR 16 0.85R 52
68 GW RS232_RX1 12
WATER TEMP SENDOR 17
NC 18 D_IN SPARE4 13
00 B D_IN SPARE1 14
GND 19 0.85L 53 Gr 1
00 B POT_DIAL_5V

CLUSTER
GND 20 15

WATER LEVEL SIG. 1 A_IN BOOM SWING PS 16

L 2
ENG.OIL PS 2 63 G SENSOR SPARE2 17
1 B cs-5
LH

AIR CLEANER SIG. 70 Or RCV EPPR- 18 2

3 R
00 2 Lg
D_OUT GOV.MOTOR- 19 1
HORN

BOOM SWING SIG. 4 1.25R 17

NC 5 BATT. 12V 20 2
MCU

B
BOOM
SWING

RS232_TX2
CN-7
NC 6 21 Gr 1
48 0.85OrW
RS232_RX2 22 1
NC 7 0.85Y B
54
PROGRAM_DUMP 23 2
NC 8 Gr
D_IN O/T DECAL SW 24 3
DOWN ENABLE 9 L Gr 1
A_IN POT_SIG 25 4
NC 10 R
SENSOR SPARE3 26 5
EARTH

COM_GND 11 R L 2
CONSOLE BOX

D_OUT TRAVEL BZ 27 6
RS232_RX 12 B 1
RH

D_OUT SPARE1(SOL) 28 7 2
RS232_TX 13 38 0.85L Lg 2 R
A_IN TACHO_SIG 29 8 1
CAN_Hi2 14 1.25VW 39 0.85Y GW 3 3 GW cs-26
16
POWER IG_12V 30 9 2
CAN_Lo2 15 25 0.85G G 4 4 G B
0.85R 55
CAN_Hi1 31 10 1
PRE HEAT SIG. 16 26 0.85L RW 5
BREAKER

CAN_Lo1 32 11
CN-57 0.85V 5-1 44A 0.85RW Gr 6 CL-2
CAN_GND 33 12
0.85R 57 53-1 0.85L GOr 7 5 RW
SIG. GND 34 13 1
0.85G 58 58-1 0.85R W 8 6 Gr
A_IN DIAL_SIG 35 14 2
0.85 LW 3A 57-1 0.85R B 9 1B B
ALT LEVEL 36 15 3
D_OUT SPARE1 37 16
CIGAR LIGHTER

D_OUT SPARE2 38
1.25B G22 CN-142
GND_MAIN 39 7 GOr
1.25B G23 A +
2B

GND_MAIN 40 8 W
B S
3

9 B
C -

1
ACCEL DIAL

CN-243 2
B 73
1
G 72
2
R 71

RS232
CONN.
3
BW 60
4

30 5W
B+
G 36 Gr
s 2
ALT

~3 L 1
38 LW
U
P

CN-74

2
DO-1

1
3W/100\U+2126

2 SERVICE TOOL
RESISTER

RS-2
13 0.3L
14 0.3Y
53 0.85L

15 0.3G

27 0.3Y
55 0.85R
47 0.85Y

58 0.85G
41 0.85V
36 1.25R
31 0.3Gr
9 0.85R

18 0.3Or
G1 5.0B
G2 5.0B

37 0.85G

11 0.3Gr

29 0.85V
1 0.85G

42 0.85Br

24 0.85R
43 0.85Gr
10 0.85Or

40 0.85Or

30 0.85Br
26A 0.85L
19 0.85Br
12 0.85Gr
2 0.85Gr

46 0.85LW

28 0.85Or
49 0.85YW
45 0.85GW
44 0.85RW
33 0.85LW
3 0.85LW

6 0.85YW

50 0.85BrW
8 0.85YW

34 0.85GW
32 0.85RW
7 0.85GW

23 5.0R
22 5.0W

CAN_L
12V+
M

CAN_H

NC
GND

NC
M

CN-16B
6
5
4
3
2
1
CN-148
2
1

8
1

1
2

9
5
4
3

7
6
CN-61

6
5
3
4
1
10

5
3
9
8
7
6
2

4
1

9
8
7
2

6
15
14
13
12
11
10
CN-22

8
15
14
13
12
11
10

9
5
4
3

7
6

1
2
12
11
10
WASHER P/P

CN-13

CN-14

CN-15
FUEL PUMP

5
CN-17

CN-19
EARTH 3

B
G

36

4
0.3L
0.3Y
0.85L

0.3G

0.3Y
0.85G

0.3Gr
0.85BrW
0.85Y

2.5k
0.3Or

Vi/W
5.0R

0.8Gr
0.85V
0.85V
1.25R

69
0.3Gr

0.85G
3G

55 0.85R

0.85R

5.0W
0.85Br
0.85Br

6
0.85L
0.85Gr
0.85Or

0.85Br
0.85Gr
0.85Or
0.85R

0.85Or
0.85G

0.85LW
2 L

0.85YW

3
0.85GW
0.85RW
0.85Gr

31
0.85LW
0.85GW
0.85RW
4 ROr

0.85LW

0.85YW

0.85YW
0.85GW
5.0B G1
5.0B G2

36E

68 0.8W
B

32

2
67 0.8B 2.5k
1
CN-93
Br 1
POWER 12V 48 CN-16
2B 36
GND_P 47 6
NC 46 5
2B 36A
GND 45 4
W 10 36 0.8Gr 0.8Gr 42
AIR HEATER RY(+) 44 3
YW 35 99 0.8W 0.8W 43
SENSOR 12V 43 2
Or 34 37 0.8B 0.8B 44
RACK ACTUATOR(-) 42 1
LW 33
CSD COIL 41
Vi/W 32
CAN_H 40
G 31A
CAN_L 39
GOr 24
SENSOR 5V 38
RESERVE ANALOG 37
RW 69
RACK POSITION SIGNAL 36
W 23
EARTH

ACCEL POSITION SIG. 35

Gr 11 5W
MAIN POWER RY(-) 34 2
G 8 5W
RACK AC RY(-) 33 1
LOAD MONITOR- 32
Vi 70 CN-95
EGR STPM_A 31
G 31 5R
RECAN 30 2
FUSIBLE LINK

5R
NC 29 1
B 22E
SENSOR GND 28 CN-60
EGR TEMP 27
ECU

INTAKE AIR TEMP 26

FUEL TEMP SENDOR 25
DROOP SW(+) 24
RL 12
PRE-HEAT LAMP(-) 23
ENG.SPEED METER(-) 22
EARTH

Gr 30
EGR STPM_B 21
LW 9
START RY(-) 20
L 29
SPEED SENSOR(+) 19
Y 28
SPEED SENSOR(-) 18
B
Br

ENG.SPEED SW2(-) 17
GR 27
WATER TEMP SENDOR 16
1
2

ENG.STOP SW(+)
CR-1

15
G 14A
ENG.OIL PRESS 14
Rmax1 SW- 13
CR-1

FAILURE LAMP(-) 12
BATT RY

GW
5R

26
5W

EGR STPM_C 11
NC 10
ENG.SPEED SW1(-) 9
L 7
START SIGNAL 8
G 6A
B

IG POWER 7
16 ROr

ENG.SPEED CONT.SW- 6
REV.DROOP SW- 5
1
2

TXD 4
CN-12
60R

RXD 3
30 5W

YR 17
FROM BATT.RY

OVER HEAT LAMP 2

B
B

LR 25
EGR STPM_D
B
10 GW

1
31 5R
7 Gr

31 5R

34 5R
32 5W

18 RW
B

33 5W

34 5R
19 LW
B
7A Gr

29 V

15 G

46
B
BATTERY

R
B
45 Or

29 GL

46A

46
B
22 YR

15 G

46
B

YOr
RL
20 BrW
41 YW
43 Y
B

B
2
2

G71 B
1
1

42 GW

1 B
60B

17 VW
B
B

L
B
B

2 RL

LW
LW
86
30

85

4
87
1

L
2

86
M

30

85

L
CN-25

87
CN-20

34
B

35
69

70
26
30
25
B+

1F
HORN

1H
2
TO:STARTER "B" TERM.

22A
CR-23

70A
CR-24
CN-68

1
2

70A
1

2
2
2

1
1

CD-7
1
1
1
2
1
2

2
2

CN-45
CL-6
CL-5

1
1
CD-2

2
2

2
1

2
1
CN-121

1
2
CN-29
CD-1

87
30

1
B sig

CN-81
CN-80
87
30
START RY
CD-10

CD-30

CD-11
CD-12

R
˚C
˚C

Or
CN-70
CN-140

DO-2

Br
CN-66

Gr

Vi
LR
SAFETY SOL

14

YW
RW
33
Pa

GW
22
27

OrW
CN-28

29
28
CN-145
85
86
M

M
A SUPPLY
85
86

C RETURN
Pa

BOOM SWING

Pre-heater
QUICK COUPLER SOL.

G
AC COMP

BREAKE SOL.

AIR-HEATER RY.

AUTO IDLE PS

TRAVEL BZ
Pa

B
R/DRYER

Pa

L
Y
LW
WATER TEMP

TRAVEL SOL.

GR
TRAVEL ALARM PS
FUEL SENDOR
HYD OIL TEMP
AIR

6
5
4
3
2
1
6
5
4
3
2
1
CD-18
FUEL
WORK
WORK

2
1

CN-193
CN-194
1
2

1 ry
LAMP LH

com
LAMP RH

com
2 sol

4 rps
FEED P/P

5 avb
CD-17

6 gnd
START

CD-8

CD-62

CSD

stpm c
stpm b
Pa

stpm a
stpm d
MOTOR

EGR VALVE
CLEANER SW

˚C

/h
km
ENG OIL PRESS

TACHO SENSOR

RACK ACTUATOR
WATER TEMP SENDOR

R80CR94EL01
MEMORANDUM

4-17
1. POWER CIRCUIT
The negative terminal of battery is grounded to the machine chassis.
When the start switch is in the OFF position, the current flows from the positive battery terminal as shown
below.
1) OPERATING FLOW
Battery Battery relay (CR-1) Fusible link (CN-60) I/conn [CN-3 (2)] Master switch [CS-74]
Fuse box [No.1] Start switch [CS-2 (1)]
Fuse box [No.2] MP3 & Radio player [CN-27 (8)]
Cluster [CN-56 (9)]
Switch panel [CN-115 (10)]
Fuse box [No.3] I/conn [CN-2 (5)] AC & Heater controller
I/conn [CN-6 (3)] Room lamp [CL-1 (2)]
12V socket [CN-139 (2)]
Fuse box [No.4] I/conn [CN-2 (7)] DC motor controller [CN-51 (10)]
I/conn [CN-2 (6)] DC motor controller [CN-51 (20)]

※ I/conn : Intermediate connector

2) CHECK POINT
Engine Start switch Check point Voltage
① - GND (battery)
OFF OFF ② - GND (battery relay) 10~12.5V
③ - GND (fusible link)
※ GND : Ground

4-18
 POWER CIRCUIT
5R

5W
BW

CN-36
14

16
13

15

18
10

11

12

17

19

20
6
4

9
3

8
1

30A

20A

20A

10A
20A

20A

20A
20A

20A

30A
20A
30A

20A

20A

10A
20A

20A
20A

20A

20A

SOLENOID
ECU
CLUSTER, CASSETTE

CLUSTER, SW PANEL
START KEY

R/LAMP & A/C HEATER

MCU

MCU

CASSETTE RADIO

SPARE

HEAD LAMP

WORK LAMP

FUEL P/P, HORN

CIGAR, WIPER MOTOR

AC & HEATER

ALT, ANT RESTART RY

SAFETY SOL

BEACON LAMP

PRE-HEAT

CABIN LAM/FUEL FEED P/P

FUSE BOX

CR-68
GW
1
GW 6 3 1
2
3
4
G

GW

VW

6 2 4
ECU MAIN POWER RY
CR-45
87a 30 86
85
87
86 87a 87 85
GW
30
ECU IG POWER RY

CR-23
87 30 86
5W
30

70A
86
85 87 85

START RY
CR-24
CN-3 CN-19 87 30 86
5W 5W 5W 5W 5W 30

70A
1 1
5R 5R 5R 5R
2 2 86
85 87 85
R

AIR HEATER RY
CS-74
1
2

CN-95 60A
5W
2
5W
1
CS-74 CIRCUIT BREAKER
CN-60 MANUL RESET
30A
CN-2 5R
2
1 5R
MASTER SW 2
1
3
1 2
1 4
R R R
2 5
3 6
3 4 4 7
3 2
RELAY (HI) 8 60R 60B

CR-1
1 2
1
R BATTERY
2
3
3 4 4
BATT RY
RELAY (M2) 1
RW CN-6
BATTERY(+) 3
RW 1 CL-1
BATTERY(+) 4
2 1
AC & HEATER CONTROLLER R R
3 2
4 ROOM LAMP
CN-2

10
11
12
3

6
7
8
9
1

4
5
2

CN-139
2
R
1

12V SOCKET
1.25R

1.25R

0.8Y

RL
CN-51

R
11
12
13
14
15
16
17
18
19
20
10

BW

10
9

8
A_IN BOOM SWING PS

CS-2
D_OUT GOV. MOTOR-

5
4

1
6

2
3

BATT. POWER 12V

POWER IG 12V(IG)
SENSOR SPARE2
POT_DIAL_5V

B
D_IN SPARE4
D_IN SPARE1

0, I
1

BACK UP B+
RS232_RX1
RS232_TX1

RCV EPPR-
BATT. 12V

BATT. 12V

CN-116
CN-56

CN-27

I 0 H
4
3
2
6
5

C ST ACC BR H

MCU START KEY SW SWITCH

CLUSTER MP3 &RADIO
PLAYER PANEL

55Z94EL04

4-19
2. STARTING CIRCUIT
1) OPERATING FLOW
Battery (+) terminal Battery relay [CR-1] Fusible link [CN-60]
I/conn [CN-3 (2)] Master switch [CS-74] Fuse box No.1 Start key [CS-2 (1)]

※ Start switch : ON
Start switch ON [CS-2 (2)] ECU IG power relay [CR-45 (86)]
I/conn [CN-5 (9)]
Battery relay [CR-1]:Battery relay operating (all power is supplied with the electric component)
Start switch ON [CS-2 (3)] Fuse box (all power is supplied with electric component)

※ Start switch : START

Start switch START [CS-2 (5)] Anti-restart relay [CR-5 (86) → (87)] I/conn [CN-4 (11)]
Start relay [CR-23 (C2) → (2)] Starter motor operating
I/conn [CN-4 (6)] ECU [CN-93 (8)]

2) CHECK POINT
Engine Start switch Check point Voltage
① - GND (battery)
② - GND (start key)
③ - GND (battery relay M4)
Operating Start ④ - GND (starter B+) 10~12.5V
⑤ - GND (starter M)
⑥ - GND (start relay)
⑦ - GND (battery relay M8)
※ GND : Ground

4-20
 STARTING CIRCUIT

1 BATTERY

START 60B
ECU IG POWER RY AIR-HEATER RY
MOTOR
START SW
START RY

86

85
H BR ACC ST C

85
86

5
6
2
3
4
H0 I PRE-HEATER
3

86

85
87a 87

30
30

87

CN-80
70A

30

87

60R
CR-24
CR-45
87a

0, I

87

85
30
86
87

1
85

86
30

70A
7

CN-45
B

CR-23
B+

87

85
30
86
CS-2

3
2

6
1

4
5

5R
RW
5W
5R
BW

BATT RY
5
BW
4
Br
G

60R

RW
5W

CR-1
6

5R

5R

B
5W

CR-1
2

2
1
Br
B
CN-5 CN-14
Gr Gr
1 1
RW RW
2 2
LW LW
3 3
4 4
CN-170
5 5
1
6 6
2
7 7
SEAT HEATER 8 8
Br Br Br Br
9 9
10 10
11 11
CR-5 12 12
87a 13 13
86 30 LY
85 14 14
BW
87 15 15
L
86
85 87 87a G
30
CN-4 CN-17
ANTI-RESTART RY 1 1
2 2
3 3
4 4
5 5
Y Y
6 6
7 7
8 8
Y Y
CR-36 9 9
Gr Gr
87a 10 10
86 30 B BW RW
85 11 11
V V L
87 12 12
BW
86 13
85 87 87a BW
30 14
PRE-HEAT RY 15

CN-3 CN-19
5W 5W 5W 5W
1 1 CN-60
5R 5R 5R 5R 5R
2 2 2
5R
1
CN-36
30A CABIN LAM/FUEL FEED P/P
20
CIRCUIT BREAKER
20A PRE-HEAT BW MANUL RESET
19 CN-95
20A BEACON LAMP 5W
18
2
10A
CS-74 5W
SAFETY SOL 1
17 2
20A ALT, ANT RESTART RY GW 1
16
10A SOLENOID
5W

15
20A AC & HEATER
14
MASTER SW
20A CIGAR, WIPER MOTOR
13 CN-74
20A FUEL P/P, HORN 5W
12 B+
20A Gr G
WORK LAMP
11
20A
CN-2
LW
2
1
S
L
3 ~
HEAD LAMP 1
10 U
20A SPARE 2 P
9
20A 3 ALT
CASSETTE RADIO
8 4
20A MCU ROr Br VW
BW

7 5 RS-2
20A CLUSTER, SW PANEL 6 1
6
20A ECU 7 2
5
20A MCU
8 RESISTOR
4
9
30A R/LAMP & A/C HEATER
5R

3 10
20A CLUSTER, CASSETTE 11
2
30A START KEY G 12
1

FUSE BOX DO-1

G
CN-1 CN-13 2
G G G
1 1 1
2 2
LW LW LW LW
3 3
4 4
5 5
6 6
7 7
8 8
R R
9 9
R R
10 10
11
12
LW

VW
LW

LW
W

CN-51
CN-56

CN-93
1
2
3
4
5
6
7
8
9

12
13
14

18
19
20
11

15
16
17
10

30
31
32
33
34
35
36
22
21
20
19
18
17
16
15
14
13
12
11
10
48
47
46
45
44
43
42
41
40

9
8
7
6
5
4
3
2
1
HYD OIL TEMP SENDOR
WATER TEMP SENDOR

WATER TEMP SENDOR

ENG.SPEED CONT.SW-
ENG.SPEED METER(-)
FUEL LEVEL SENDOR

RACK ACTUATOR(-)

ENG.SPEED SW2(-)

ENG.SPEED SW1(-)
SPEED SENSOR(+)
ANTI-RESTART RY

AIR HEATER RY(+)

SPEED SENSOR(-)

OVER HEAT LAMP

BATT.POWER 12V

ENG.STOP SW(+)

FAILURE LAMP(-)

REV.DROOP SW-
OVER HEAT SIG.
ALT.LEVEL SIG.

POWER IG_12V
START SIGNAL
POWER IG 12V

ILLUMINATION

A_IN DIAL_SIG
ENG.OIL PRESS

EGR STPM_C

EGR STPM_D
EGR STPM_B
SENSOR 12V

START RY(-)
TACHO SIG.

TRAVEL RY.

Rmax1 SW-
POWER 12V

ALT LEVEL
IG POWER
CSD COIL

SIG. GND
CAN_GND
CAN_Lo1
CAN_Hi1
GND_P

CAN_H
GND
GND

GND

RXD
TXD
NC
NC

NC
NC
NC

NC

NC

NC
NC

CLUSTER ECU MCU

55Z94EL05

4-21
3. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator releases the key switch to the
ON position.
Charging current generated by operating alternator flows into the battery through the Battery relay
(CR-1).
The current also flows from alternator to each electrical component and controller through the fuse
box.
1) OPERATING FLOW
(1) Warning flow
Alternator "L" terminal I/conn [CN-1 (3)] Cluster [CN-56 (3)] Cluster warning lamp
Governor DC motor controller [CN-51 (36)]
(2) Charging flow
Alternator "B+" terminal Battery relay Battery (+) terminal

2) CHECK POINT
Engine Start switch Check point Voltage
① - GND (battery voltage)
② - GND (battery relay)
Operating Start ③ - GND (alternator B+ terminal) 10~12.5V
④ - GND (alternator L terminal)
⑤ - GND (cluster)
※ GND : Ground

4-22
 CHARGING CIRCUIT

1 BATTERY

START 60B
ECU IG POWER RY AIR-HEATER RY
MOTOR
START SW
START RY

86

85
H BR ACC ST C

85
86

5
6
2
3
4
H0 I PRE-HEATER
3

86

85
87a 87

30
30

87

CN-80
70A

30

87

60R
CR-24
CR-45
87a

0, I

87

85
30
86
87

1
85

86
30 70A
7

CN-45
B

CR-23
B+

87

85
30
86
CS-2

3
2

6
1

4
5

5R
RW
5W
5R
BW

BATT RY
5

BW
4
Br
G

60R
L

RW
5W

CR-1
6

5R

5R

B
5W

CR-1
2

2
1
Br
B
CN-5 CN-14
Gr Gr
1 1
RW RW
2 2
LW LW
3 3
4 4
CN-170
5 5
1
6 6
2
7 7
SEAT HEATER 8 8
Br Br Br Br
9 9
10 10
11 11
CR-5 12 12
87a 13 13
86 30 LY
85 14 14
BW
87 15 15
L
86
85 87 87a G
30
CN-4 CN-17
ANTI-RESTART RY 1 1
2 2
3 3
4 4
5 5
Y Y
6 6
7 7
8 8
Y Y
CR-36 9 9
Gr Gr
87a 10 10
86 30 B BW RW
85 11 11
V V L
87 12 12
BW
86 13
85 87 87a BW
30 14
PRE-HEAT RY 15

CN-3 CN-19
5W 5W 5W 5W
1 1 CN-60
5R 5R 5R 5R 5R
2 2 2
5R
1
CN-36
30A CABIN LAM/FUEL FEED P/P
20
CIRCUIT BREAKER
20A PRE-HEAT BW MANUL RESET
19 CN-95
20A BEACON LAMP 5W
18
2
10A
CS-74 5W
SAFETY SOL 1
17 2
20A ALT, ANT RESTART RY GW 1
16
10A SOLENOID
5W

15
20A AC & HEATER
14
MASTER SW
20A CIGAR, WIPER MOTOR
13 CN-74
20A FUEL P/P, HORN 5W
12 B+
20A Gr G
WORK LAMP
11
20A
CN-2 LW
2
1
S
L
3 ~
HEAD LAMP 1
10 U
20A SPARE 2 P
9
20A 3 ALT
CASSETTE RADIO
8 4
20A MCU ROr Br VW
BW

7 5 RS-2
20A CLUSTER, SW PANEL 6 1
6
20A ECU 7 2
5
20A MCU
8 RESISTOR
4
9
30A R/LAMP & A/C HEATER
5R

3 10
20A CLUSTER, CASSETTE 11
2
30A START KEY G 12
1

FUSE BOX DO-1

G
CN-1 CN-13 2
G G G
1 1 1
2 2
LW LW LW LW
3 3
4 4
5 5
6 6
7 7
8 8
R R
9 9
R R
10 10
11
12
LW

VW
LW

LW
W

CN-51
CN-56

CN-93
1
2
3
4
5
6
7
8
9

12
13
14

18
19
20
11

15
16
17
10

30
31
32
33
34
35
36
22
21
20
19
18
17
16
15
14
13
12
11
10
48
47
46
45
44
43
42
41
40

9
8
7
6
5
4
3
2
1
HYD OIL TEMP SENDOR
WATER TEMP SENDOR

WATER TEMP SENDOR

ENG.SPEED CONT.SW-
ENG.SPEED METER(-)
FUEL LEVEL SENDOR

RACK ACTUATOR(-)

ENG.SPEED SW2(-)

ENG.SPEED SW1(-)
SPEED SENSOR(+)
ANTI-RESTART RY

AIR HEATER RY(+)

SPEED SENSOR(-)

OVER HEAT LAMP

BATT.POWER 12V

ENG.STOP SW(+)

FAILURE LAMP(-)

REV.DROOP SW-
OVER HEAT SIG.
ALT.LEVEL SIG.

POWER IG_12V
START SIGNAL
POWER IG 12V

ILLUMINATION

A_IN DIAL_SIG
ENG.OIL PRESS

EGR STPM_C

EGR STPM_D
EGR STPM_B
SENSOR 12V

START RY(-)
TACHO SIG.

TRAVEL RY.

Rmax1 SW-
POWER 12V

ALT LEVEL
IG POWER
CSD COIL

SIG. GND
CAN_GND
CAN_Lo1
CAN_Hi1
GND_P

CAN_H
GND
GND

GND

RXD
TXD
NC
NC

NC
NC
NC

NC

NC

NC
NC

CLUSTER ECU MCU

55Z94EL06

4-23
4. HEAD AND WORK L
LAMP
AMP CIRCUIT
1) OPERATING FLOW
Fuse box (No.10) Head lamp relay [CR-13 (86) → (85)] Switch panel [CN-116 (1)]
Fuse box (No.11) Work lamp relay [CR-3 (86) → (85)] Switch panel [CN-116 (2)]
(1) Head lamp switch ON
Head lamp switch ON [CN-116(1)] Head lamp relay [CR-13 (85) → (87)]
l/conn [CN-4 (2)] Head lamp ON [CL-3, 4 (2)]
I/conn [CN-5 (1)] I/conn [CN-7 (11)] Cigar lighter [CL-2 (1)]
Remote controller illumination ON [CN-245 (9)]
MP3 & Radio player illumination ON [CN-27 (9)]
USB & Socket illumination ON [CN-246 (7)
Cluster illumination ON [CN-56 (12)]
I/conn [CN-2 (8)] AC/Heater controller illumination ON
(2) Work lamp switch ON
Work light switch ON [CN-116 (2)] Work lamp [CR-3 (85) → (87)] l/conn [CN-4 (8)]
l/conn [CN-12 (2)] Work lamp ON [CL-5 (2)]

2) CHECK POINT

Engine Start switch Check point Voltage

① - GND (fuse box)
② - GND (switch power input)
STOP ON 10~12.5V
③ - GND (switch power output)
④ - GND (head light)
⑤ - GND (fuse box)
⑥ - GND (switch power input)
STOP ON 10~12.5V
⑦- GND (switch power output)
⑧ - GND (work light)
※ GND : Ground

4-24
 HEAD AND WORK LAMP CIRCUIT

CN-36
FUSE BOX

RL

YW

BrW
1 4 CN-116
12 NC
CN-2
11 GND
1 RL
10 POWER IG 12V
2
9 BREAKER
3
8 TRAVEL ALARM
4

5
5 7 CABIN LIGHT OUT
6 BEACON
6

7
2 5 NC
G RW 4 NC
ILLUMINATION 5 8
3 NC
V
AC & HEATER 2 WORK LIGHT OUT
CONTROLLER ROr
1 ILL LAMP OUT
SWITCH PANEL

CN-7 6 CR-3
1
87a
2 V 30 86
85
3 ROr
87
4 BrW
86
BrW 87a 87 85
5 30
6
WORK LAM RY
7
B 3
CR-13
CL-2 8
87a
B ROr 30 86
3 9 CN-15 85
2 1
RW
10 87
RW RW RW RW YW
1 11 2 86
YW 87a 87 85
12 3 30
CIGAR LIGHTER 13 4 ILL LAMP RY
14 5

15 6

16 7
1
8
2
9
CN-4 CN-17
10
1 1
11 RW RW
2 2
12
3 3
13
4 4
14
5 5
15
6 6 CN-12 CL-5
B B
7 7 1 1
ROr ROr ROr RL
8 8 2 2
9 9
WORK LAMP
10 10
CL-6
11 11 B
1
12 12 RL
2
13

14
7
15
RW

RW

RW
RW
RL
R
CN-56

CN-245

CN-246

CN-27
1
2
3
4
5
6
7
8
9

7
12
13
14

18
19
20
11

15
16
17

10
9
10

HYD OIL TEMP SENDOR

WATER TEMP SENDOR
FUEL LEVEL SENDOR
ANTI-RESTART RY

BATT.POWER 12V
PRE-HEATER RY.
OVER HEAT SIG.
HIGH BEAM SIG.

ALT.LEVEL SIG.

POWER IG 12V

RAMLOCK SIG

ILLUMINATION

ILLUMINATION
ILLUMINATION
NEUTRAL SIG.

PARKING SIG
TRAVEL SIG.
TACHO SIG.

TRAVEL RY.

BACK UP+
ANALOG

ILL(+)
GND
GND

CLUSTER REMOTE USB & MP3 &

ASS'Y SOCKET RADIO
ASS'Y PLAYER

55Z94EL07

4-25
5. BEACON LAMP AND CAB LAMP CIRCUIT
1) OPERATING FLOW
Fuse box (No.18) Beacon lamp relay [CR-85(30) ‫( ױ‬85)] Switch panel [CN-116 (6)]
Fuse box (No.20) Cab lamp relay [CR-9 (30) ‫( ױ‬85)] Switch panel [CN-116 (7)]
(1) Beacon lamp switch ON
Beacon lamp switch ON [CN-116 (6)] Beacon lamp relay [CR-85 (87)] I/conn [CN-6 (1)]
Beacon lamp ON [CL-7]
(2) Cab lamp switch ON
Cab lamp switch ON [CN-116 (7)] Cab lamp relay [CR-9 (87)] I/conn [CN-6 (4)]
Cab lamp ON [CL-9, 10]

2) CHECK POINT
Engine Start switch Check point Voltage
① - GND (fuse box)
② - GND (switch power input)
STOP ON 10~12.5V
③ - GND (switch power output)
④ - GND (beacon & cab lamp)
※ GND : Ground

4-26
BEACON LAMP CIRCUIT

CN-36
FUSE BOX

WOr

LW
1 1

4 CR-85
87a
RW 30 86
CL-7 CN-6 85
Or Or Or Or
1 87
M B B B WOr
2 86
WOr 87a 87 85
30
BEACON LAMP 3
RW RW
4 BEACON LAMP RY

CL-9
2
RW
B
3
1 CR-9
87a
Or 30 86
CABIN LAMP RW
85
87
RW WOr
2 86
B WOr 87a 87 85
1 30
CL-10 CABIN LAMP RY

CN-116
12 NC
11 GND
10 POWER IG 12V
9 BREAKER
8 TRAVEL ALARM
Or
7 CABIN LIGHT OUT
Br
6 BEACON
5 NC
4 NC
3 NC
2 2 WORK LIGHT OUT
1 ILL LAMP OUT
SWITCH PANEL

55Z94EL08

4-27
6. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
(1) Key switch ON
Fuse box (No.13) Wiper relay [CR-4 (86)]
Int wiper relay [CR-6 (4)]
Wiper switch [CS-3 (11)]
Wiper motor [CN-21 (3)]
I/conn [CN-5 (11)] I/conn [CN-14 (11)] Washer pump [CN-22 (2)]
(2) Wipe switch ON : 1st step (low speed)
Wiper switch ON [CS-3 (8) → (7)] Int wiper relay [CR-6 (6) → (3)] Wiper relay [CR-4 (85) → (30)]
Washer motor operating [CN-21 (4)]
(3) Wiper switch ON : 2nd step (washer)
Wiper switch ON [CS-3 (7)] Int wiper relay [CR-6 (1)] Washer switch [CS-30 (6)]
Wiper relay [CR-4 (85) → (30)]
Wiper motor operating[CN-21(1)]
Washer switch ON [CS-30 (6)] I/conn [CN-5 (3)] Washer pump operating [CN-22 (1)]
(4) Auto parking (when switch OFF)
Switch OFF Wiper motor [CN-21 (1)] Wiper switch [CS-3 (5) → (8)] Int wiper relay [CR-6 (6) → (3)]
Wiper relay [CR-4 (85) → (30)] Wiper motor [CN-21 (4)]
Wiper motor parking position by wiper motor controller

2) CHECK POINT
Engine Start switch Check point Voltage
① - GND (fuse box)
② - GND (switch power input)
STOP ON 10~12.5V
③ - GND (switch power output)
④ - GND (wiper motor)

※ GND : Ground

4-28
WIPER AND WASHER CIRCUIT

FUSE BOX CN-36

Gr
1

CS-3
1
3
2
V
I 0

3
4
Or
4 5
8 6
B
Br
10 7
3 Or
8
6 7
9 9
10
ROr
11
12 11 Or
12

WIPER SW
2
CR-6 Br
6
ROr
4 CN-5
1
Or 2
3
V 3
1
4
INT. WIPER RELAY 5
6
7
CR-4 Gr
87a 8
30 86 Or
85 9
ROr
87 10 CN-22
ROr Gr ROr
86 11 2 M
87a 87 85 G G
30 12 1
WIPER RELAY 13
WASHER PUMP
14
15

Lo 4
M
CN-21
G
4
B 3 ROr
3
Pf 1 B
E 2 2
Gr
1

WIPER MOTOR
4
DO-1
V
1
G
2

CS-30
1
12 1
2
3
4
B
5
G
6
3
7 7
9
8
4
8 9
10
10
11
12 11
12

WASHER SW

5594EL09

4-29
 CN-56
NC
FUSE BOX
1
NC 2
1
ALT.LEVEL SIG. 3 START KEY 30A
OVER HEAT SIG. 4 2
R CLUSTER, CASSETTE 20A
TACHO SIG. 5 3
ANTI-RESTART RY 6 R/LAMP & A/C HEATER 30A
NC 4
7 MCU 20A
TRAVEL RY. 8 5
R
BATT.POWER 12V
ECU 20A
9
RL 6
POWER IG 12V 10 RL CLUSTER, SW PANEL 20A
NC 11 7
MCU 20A
ILLUMINATION 12
8
NC 13 CASSETTE RADIO 20A
NC 9
14
MONITORING CIRCUIT

YW SPARE 20A
FUEL LEVEL SENDOR 15 10
Y
HYD OIL TEMP SENDOR 16
HEAD LAMP 20A
GW 11
WATER TEMP SENDOR 17 WORK LAMP 20A
NC 18 12
B FUEL P/P, HORN 20A
GND 19
B 13
GND 20 CIGAR, WIPER MOTOR 20A

CLUSTER
WATER LEVEL SIG. 1 14
AC & HEATER 20A
ENG.OIL PS 2 15
Or
AIR CLEANER SIG. 3 SOLENOID 10A
16
BOOM SWING SIG. 4

Or
ALT, ANT RESTART RY 20A

YW
YW
GW
NC 5 17
SAFETY SOL
NC 6 10A
18
NC 7

5
3
4
1

9
8
7
6
2

12
11
10
BEACON LAMP 20A

CN-1
NC 8 19
PRE-HEAT 20A
DOWN ENABLE 9

Or
20

YW
YW
GW
NC 10 CABIN LAM/FUEL FEED P/P 30A
COM_GND 11

4-30
CN-36
RS232_RX 12
RS232_TX 13
CAN_Hi2 14
CAN_Lo2 15
PRE HEAT SIG. 16

Or
YW
YW
GW

CN-57
5
3
4
1

9
8
7
6
2

10
CN-13

Or
YW
YW
GW

CN-116
RL
POWER 12V(IG) 10

PANEL
SWITCH
CN-27
Y
BACK UP+ 8

PLAYER
Y

B
B
B
B

Or

MP3 & RADIO

YW

GW

1
1
1
2

2
2
CD-2

CD-1

CD-10
CD-30

C
C

Pa
WATER TEMP

HYD OIL TEMP

FUEL SENDOR

AIR CLEANER SW

55Z94EL10
 ELECTRIC CIRCUIT FOR HYDRAULIC

FUSE BOX CN-36

14

16
13

15

18
10

11

12

17

19

20
6
4

9
3

8
1

30A

20A

20A

10A
20A

20A

20A
20A

20A

30A
20A
30A

20A

20A

10A
20A

20A
20A

20A

20A

SOLENOID
ECU
CLUSTER, CASSETTE

CLUSTER, SW PANEL
START KEY

R/LAMP & A/C HEATER

MCU

MCU

CASSETTE RADIO

SPARE

HEAD LAMP

WORK LAMP

FUEL P/P, HORN

CIGAR, WIPER MOTOR

AC & HEATER

ALT, ANT RESTART RY

SAFETY SOL

BEACON LAMP

PRE-HEAT

CABIN LAM/FUEL FEED P/P

LH RH
BOOM
BREAKER

2
HORN

2
1

1
SWING

cs-5

cs-26
Gr
Gr

B
R

B
R
L

L
2

2
1

1
LW

RW

GW
Gr

G
B
CN-7

10
11
12
13
14
15
16
2

6
7
8
9
1

4
3

5
CN-5 CN-14
1 1
2 2
3 3
4 4
5 5
6 6
CS-4 7 7
3
Br
2 1 8 8
2 9 9 CN-68
GW GW
1 3 10 10 2
B
SAFETY SW 11 11 1
12 12
SAFETY SOL
CN-116 13 13

HEAD LIGHT OUT 14 14

1
15 15
WORK LIGHT PUT 2
CN-13
NC 3
1
NC 4
2
NC 5 3
BEACON 6 4
CABIN LIGHT OUT 7 5
Gr
TRAVEL ARARM 8 10
G CN-15
BREAKER 9
1
POWER 12V(IG) 10 CN-121
2 G
GND 11 2
7 B
NC 12 1
8
SWITCH PANEL 9 BOOM SWING
15

CN-4 CN-17
CN-56
Lg 1 1
TRAVEL RY. 8 CN-140
2 2 G
CLUSTER 3 3 2
B
4 4 1
5 5
QUICK COUPLER SOL
CR-12 6 6
87a 7 7
30 86 Lg CN-70
85 8 8 VW
VW 2
87 9 9
YW B
86 10 10 1
87a 87 85 YW
30 11 11 TRAVEL SOL
12 12
TRAVEL
13 13
HI-LO SOL 14 14 BrW
CN-66
2
15 15 B
1
CR-62 BREAKER SOL
87a
30 86 G
85
BrW
87 CN-2
GW
86 1
87a 87 85 GW
30 2
BREAKER RY1 3
4
5
6
7
11
12
BrW

BrW
GW

GW
RW

B
L
L

L
Br
BL
B

B
W
R
V
CR-71

CD-11
CS-47

CS-67

CD-12

CN-81
87a

87
86
30
85
3

6
7

6
7

2
1

2
1
4

2
1
1

1
5

9
2

2
10

10
11
12

11
12
7

8
11

11
1

1
85
86

Pa

Pa
87a 87
30

BOOM TRAVEL TRAVEL

9

9
12

4
12
10

10
12

12

BOOM SWING SW SWING QUICK COUPLER SW ALARM PS BZ

80CR94EL11

4-31
GROUP 4 ELECTRICAL COMPONENT SPECIFICATION

Part name Symbol Specification Check

※ Check specific gravity

1.280 over : over charged
Battery 12V × 100Ah
1.280 ~ 1.250 : normal
1.250 below : recharging

※ Check coil resistance

Rated load : 12V
1 Normal : about 12Ω
Battery relay 2 100A (continuity)
※ Check contact
1000A (30 second)
CR-1
CR-1 Normal : ∞Ω

BR ACC ST C
※Check contact
H
5
6
2
3
4

H0 I

OFF : ∞Ω(for each terminal)

Start key 0, I 12V
1

B ON : 0Ω(for terminal 1-3 and 1-2)

CS-2
3
2

6
1

4
5

START : 0Ω(for terminal 1-5)

Pressure switch Pa 0.5 kgf/cm2 ※ Check resistance

(for engine oil) (N.C TYPE) Normal : 0Ω(CLOSE)

CD-18

Hydraulic oil, ※ Check resistance

1 C
coolant 0.5 kgf/cm 2 50˚C : 804Ω
temperature (N.C TYPE) 80˚C : 310Ω
sensor 2
100˚C : 180Ω
CD-1 CD-8

4-32
 Part name Symbol Specification Check

Pa Pressure:
Air cleaner ※ Check contact
635mmH2O
pressure switch Normal : ∞Ω
(N.O TYPE)
CD-10

※ Check resistance
2
Full : 100Ω
Fuel sender -
1 Low : 500Ω
Empty warning :700Ω
CD-2

87a 30 86
85
※ Check resistance
87
86
Normal : about 200Ω
Relay 30 87a 87 85 12V 20A (for terminal 85-86)
CR-2 CR-3 CR-4 CR-5 : 0Ω (for terminal 30-87a)
CR-7 CR-9 CR-12 CR-13 : ∞Ω (for terminal 30-87)
CR-36 CR-45 CR-62 CR-71
CR-85

87 30 86

30
Relay 86 12V 70A ※ Rated coil current 1.2±0.3A
85 87 85

CR-23 CR-24

2
※ Check resistance
Solenoid valve 1 12V 1A Normal : 15~25Ω
(for terminal 1-2)
CN-66 CN-68
CN-70 CN-121
CN-140

※Check resistance
Speaker 4Ω 20W
Normal : 4Ω
CN-23(LH)
CN-24(RH)

4-33
 Part name Symbol Specification Check

※ Check contact
Boom swing Normal
12V 16A
switch OFF - ∞Ω (for terminal 1-5,2-6)
- 0Ω (for terminal 5-7,6-8)
CS-47

※ Check contact
Quick clamp Normal
12V 16A
switch OFF - ∞Ω (for terminal 1-5,2-6)
- 0Ω (for terminal 5-7,6-8)
CS-67

2
Work, cab 12V 65W ※ Check disconnection
lamp 1 (H3 TYPE) Normal : 1.2Ω

CL-5 CL-6 CL-9 CL-10

1
※ Check disconnection
Room lamp 2 12V 10W
Normal : a few Ω
CL-1

1 M
12V 20A ※Check operation
Fuel filler pump
2 35 ℓ/min Supply power (for terminal 1) : 12V
CN-145

Horn 2 12V 100±5dB

CN-20 CN-25

4-34
 Part name Symbol Specification Check

※ Check contact
2 3 1 Normal : 0Ω(for terminal A-B)
Safety switch 2 Micro : ∞Ω(for terminal A-C)
3 Operating : ∞Ω(for terminal A-B)
1
CS-4 : 0Ω(for terminal A-C)

2 Pa 10bar ※ Check contact

Pressure switch
1 (N.C type) Normal : 0.1Ω

CD-11 CD-12

M 12V ※ Check disconnection

Beacon lamp
(Strobe type) Normal : a fewΩ

CL-7
12
6

I 0
※Check contact
Wiper switch 12V 16A
11
8

9
4

3
7
10

Normal : ∞Ω
10
A
B

7
2

6
1

4
5

8
9

CS-3

M 2
※Check contact
Washer pump 1 12V 3.8A
Normal : 3Ω(for terminal 1-2)
CN-22

※Check coil resistance

3
Normal : about 1MΩ
2
Cigar lighter 12V 10A 1.4W ※ Check contact
1
Normal : ∞Ω
CL-2
CL-2 Operating time : 5~15sec

4-35
 Part name Symbol Specification Check

4 Lo
M

4
※Check contact
Wiper motor 3 B
12V 3A
3 Normal : 6Ω(for terminal 2-6)
1 Pf
2 2 E
1

CN-21

10
11
12
13
14
15
16
1
2
3
4
5
6
7

9
8

※ Check voltage
Radio & REMOCON GND
SPK FRT RH+

SPK FRT LH+

24V 2A 20 ~ 25V
SPK FRT RH-
SPK FRT LH-

REMOCON+
BACK UP+
TEL MUTE

MP3 player
ANT 12V

(for terminal 1-3, 3-8)

GND

GND
ACC

ILL+
ILL-

NC

NC

CN-27

2 Pa
※ Check contact
Receiver dryer 1 12V
Normal : 0Ω
CN-29

M B+
※ Check contact
Starter 12V × 3kW
Normal : 0.1Ω
M
CN-45

B+
G
2 s ※ Check contact
~3
Alternator 1 L 12V 80A Normal : 0Ω(for terminal B+-1)
U
P
Normal : 24 ~ 27.5V
CN-74

※ Check contact
Travel buzzer 12V 0.5A
Normal : 5.2Ω
CN-81

4-36
 Part name Symbol Specification Check

Compressor 12V 79W -

CN-28

Blower 1 M ※ Check resistance

12V 9.5A
fan motor 2 2.5Ω(for terminal 1-2)

CN-83

M
Fuel feed pump 12V -

CN-61

Master switch 12V 1000A -

IG 4 OUT
1
1
2
Timer 3
12V -
2
GND 3 OUT 4

Preheater 12V 42A 500W -

CN-80

4-37
 Part name Symbol Specification Check

2
12V socket 12V 120W -
1

CN-139

※ Check resistance
Normal : 0Ω
1˚C OFF
Duct sensor (for terminal 1-2)
4˚C ON
the atmosphere temp :
over 4˚C

※ Check resistance
Normal : about 5kΩ
A + (for terminal A-C)
B S ※ Check voltage
Accel dial -
C - Normal : about 5V
CN-142 (for terminal A-C)
: 2~4.5V
(for terminal C-B)

6
4

Int wiper relay 12V 12A -

3
1
CR-6

2 12V, 30A (CN-65)

Fusible link -
1 12V, 60A (CN-95)
CN-60 CN-95

4-38
GROUP 5 CONNECTORS

1. CONNECTOR DESTINATION

Connector No. of Connector part No.

Type Destination
number pin Female Male
CN-1 AMP 12 Cabin room harness - Main harness S816-012002 174663-2
CN-2 AMP 12 Aircon harness - Cabin room harness S816-012002 174663-2
CN-3 YAZAKI 2 Fusible link - Fuse box S813-030201 S813-130201
CN-4 AMP 15 Cabin room harness - Main harness 2-85262-1 368301-1
CN-5 AMP 15 Cabin room harness - Main harness 2-85262-1 368301-1
CN-6 DEUTSCH 4 Cabin harness - Cabin room lamp harness DT06-4S-EP06 DT04-4P-E005
CN-7 KET 20 Console harness - Main harness MG610240 -
CN-8 AMP 12 Cabin harness S816-012002 -
CN-12 AMP 2 Boom harness - Work lamp harness - S816-102002
CN-13 AMP 10 Bottom harness 174655-2 -
CN-14 AMP 15 Bottom harness 2-85262-1 -
CN-15 AMP 15 Bottom harness - 368301-1
CN-17 AMP 12 Bottom harness - 174663-2
CN-19 YAZAKI 2 Bottom harness - S813-130201
CN-20 DEUTSCH 2 Horn DT06-2S-EP06 -
CN-21 AMP 12 Wiper harness S816-012002 -
CN-22 KET 2 Washer tank MG640605 -
CN-23 KET 2 Speaker LH MG610070 -
CN-24 KET 2 Speaker RH MG610070 -
CN-25 DEUTSCH 2 Horn DT06-2S-EP06 -
CN-27 - 16 Cassette radio PK145-16017 -
CN-28 AMP 1 Air-con comp S810-001202 -
CN-29 KET 2 Receiver dryer MG640795 -
CN-36 - - Fuse box 21L7-00250 -
CN-45 TERM 1 Starter ST710246-2 -
CN-48 AMP 40 MCU DRC26-40SA -
CN-51 DEUTSCH 40 Governor DC motor controller DRC26-40SA S816-103002
CN-55 AMP 2 Travel alarm PS S816-002002 S816-102002
CN-56 AMP 20 Cluster 175967-2 -
CN-57 AMP 16 Cluster 175966-2 -
CN-60 YAZAKI 2 Fusible link - 7122-4125-50
CN-61 TERM 1 Fuel filler pump S822-014000 S822-114000
CN-66 DEUTSCH 2 Breaker solenoid DT06-2S-EP06 -
CN-68 DEUTSCH 2 Safety solenoid DT06-2S-EP06 -
CN-70 DEUTSCH 2 Travel HI-LO solenoid DT06-2S-EP06 -

4-39
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-74 KET 2 Alternator ST710285-2 -
CN-76 KET 6 DC motor MG640515-4 -
CN-79 YAZAKI 3 Fuel cut-off solenoid S813-060300 -
CN-80 AMP 1 Pre heater ST710384-2 -
CN-81 DEUTSCH 2 Travel buzzer DT06-2S-EP06 DT04-2P-E005
CN-83 AMP 2 Air-con fan MG640188-5 -
CN-92 KET 1 Anti-restart relay S814-001100 -
CN-95 YAZAKI 2 Fusible link - S813-130201
CN-116 AMP 12 Switch panel 368542-1 -
CN-126 RS232 connector
CN-139 AMP 2 12V socket S810-002202 -
CN-140 DEUTSCH 2 Quick coupler DT06-2S-EP06 DT04-2P-E005
CN-142 DEUTSCH 3 Accel dial DT06-3S-EP06 -
CN-144 AMP 2 Handsfree S810-002202 -
CN-145 KET 2 Fuel feed pump 7123-6423-30 -
CN-148 Service tool
CN-170 PACKARD 2 Seat heat switch 12162017 -
CN-243 RS232 connector
CN-245 AMP 12 Remote controller assy 368542-1 -
CN-246 AMP 12 USB & Socket assy 174045-2 -
CN-258 KET 1 Aircon comp power MG640944-5 MG650943-5
CN-263 DEUTSCH 2 Aircon comp relay DT06-2S-EP06 DT04-2P-E005
·LAMP
CL-1 KET 2 Room lamp MG610392 -
CL-2 AMP 3 Cigar light S810-003202 -
CL-3 DEUTSCH 2 Head lamp DT06-2S-EP06 DT04-2P-E005
CL-4 DEUTSCH 2 Head lamp DT06-2S-EP06 DT04-2P-E005
CL-5 DEUTSCH 2 Work lamp DT06-2S-EP06 -
CL-6 DEUTSCH 2 Work lamp DT06-2S-EP06
CL-7 - 1 Beacon lamp - S822-114000
CL-9 DEUTSCH 2 Cabin lamp DT06-2S-EP06 -
CL-10 DEUTSCH 1 Cabin lamp DT06-2S-EP06 -
·RELAY
CR-1 AMP 2 Battery relay S816-002002 S816-102002
CR-2 AMP 4 Horn relay S810-004002 -
CR-5 AMP 4 Anti-restart relay S810-004002 -
CR-6 KET 6 Int wiper relay S810-006002 -
CR-12 AMP 4 Travel relay S810-004002 -
CR-23 KET 2 Start relay S814-002001 -

4-40
Connector No. of Connector part No.
Type Destination
number pin Female Male
CR-24 KET 2 Air heater relay S814-002001 -
CR-33 AMP 4 Air-con fan relay S810-004002 -
CR-36 AMP 4 Pre-heater relay S810-004002 -
CR-45 ECU IG connector
CR-47 KET 2 Fuel cut-off relay S814-002001 -
CR-50 KET 4 Timer relay MG610047-5 -
CR-67 Sumitomo Denso 6 ECU main power 6020-6161
CR-68 Sumitomo Denso 6 Rack actuator 6020-6161
·SENDER
CD-1 AMP 2 Hydraulic temp sender 85202-1 -
CD-2 AMP 2 Fuel sender - S816-102002
CD-7 DEUTSCH 3 Auto idle pressure switch DT06-3S-EP06 -
CD-10 KET 1 Air cleaner switch ST730057-2 -
CD-11 - 2 Travel pressure switch MG640795 -
CD-12 - 2 Travel pressure switch MG640795 -
CD-18 AMP 1 Engine oil pressure ST710345-1 -
CD-30 AMP 2 Water temp 85202-1 -
CD-45 - 2 WIF sensor - S816-102003
DO-1 - 2 Diode 21EA-50570 -
DO-2 - 2 Diode 21EA-50570 -
DO-3 - 2 Diode 21EA-50570 -
·SWITCH
CS-2 KET 6 Start key switch S814-006000 -
CS-3 SWF 12 Wiper switch 585790 -
CS-4 AMP 3 Safety switch S816-003002 -
CS-5 - 1 Horn-LH switch - DT04-2P-E005
CS-26 DEUTSCH 2 Breaker switch DT06-2S-EP06 -
CS-30 SWF 12 Wiper washer 585790 -
CS-47 SWF 12 Boom swing switch 585790 -
CS-67 SWF 12 Quick coupler switch 589790 -
CS-74 YAZAKI 2 Master switch S813-030201 S813-130201
CS-99 SWF 12 Auto idle switch 589790 -

4-41
2. CONNECTION TABLE FOR CONNECTORS
1) PA TYPE CONNECTOR
No. of
Receptacle connector (female) Plug connector (male)
pin

2 5 1 3

1 3 2 5

S811-005002 S811-105002

3 7 1 4

1 4 3 7

S811-007002 S811-107002

4 9 1 5

1 5 4 9

S811-009002 S811-109002

5 11 1 6

11

1 6 5 11

S811-011002 S811-111002

4-42
No. of
Receptacle connector (female) Plug connector (male)
pin

6 13 1 7

13

1 7 6 13
S811-013002 S811-113002

8 1 9
17

17

1 9 8 17
S811-017002 S811-117002
1 21
1 11

21

1 11 1 21
S811-021002 S811-121002

4-43
2) J TYPE CONNECTOR
No. of
Receptacle connector (female) Plug connector (male)
pin

1 21

2 12

S816-002001

2 3 1

3 1 2

S816-003001 S816-103001

3 1 4 2

4 2 3 1

S816-004001 S816-104001

8 5 2
6 3 1

8 5 2 6 3 1
S816-008001 S816-108001

4-44
3) SWP TYPE CONNECTOR
No. of
Receptacle connector (female) Plug connector (male)
pin

1 1

S814-001000 S814-101000

2 1

1 2

S814-002000 S814-102000

3 1

2 1 23

S814-003000 S814-103000

2 4
1 3

1 3 2 4

S814-004000 S814-104000

4-45
No. of
Receptacle connector (female) Plug connector (male)
pin
3 6
1 4

1 4 3 6

S814-006000 S814-106000
4 8
1 5

1 5 4 8
S814-008000 S814-108000
4 12 1 9

12

1 9 4 12

S814-012000 S814-112000
1 11
3 14

14

3 14
1 11

S814-014000 S814-114000

4-46
4) CN TYPE CONNECTOR
No. of
Receptacle connector (female) Plug connector (male)
pin

1
1

S810-001202 S810-101202

2 2

1 1

S810-002202 S810-102202

3 2

1 2 1 3

S810-003202 S810-103202

2 4
1 3

1 3
2 4
S810-004202 S810-104202

4-47
No. of
Receptacle connector (female) Plug connector (male)
pin

3 6 1 4

1 4 3 6
S810-006202 S810-106202

4 8 1 5

1 5
4 8
S810-008202 S810-108202

4-48
5) 375 FASTEN TYPE CONNECTOR
No. of
Receptacle connector (female) Plug connector (male)
pin

1 2 1 2

S810-002402 S810-102402

6) AMP ECONOSEAL CONNECTOR

No. of
Receptacle connector (female) Plug connector (male)
pin

1
12

1 13
24
36
36
13 25 12
24
25
36
344111-1 344108-1

7) AMP TIMER CONNECTOR

No. of
Receptacle connector (female) Plug connector (male)
pin

85202-1

4-49
8) AMP 040 MULTILOCK CONNECTOR
No. of
Receptacle connector (female) Plug connector (male)
pin

12 1 6

7 12
174045-2

9) AMP 070 MULTILOCK CONNECTOR

No. of
Receptacle connector (female) Plug connector (male)
pin

1 6
14

7 14

173852

10) AMP FASTIN - FASTON CONNECTOR

No. of
Receptacle connector (female) Plug connector (male)
pin

3 1

6
6 4
1
4 6 3

925276-0 480003-9

4-50
11) KET 090 CONNECTOR
No. of
Receptacle connector (female) Plug connector (male)
pin

6 1

MG610070

12) KET 090 WP CONNECTORS

No. of
Receptacle connector (female) Plug connector (male)
pin

1
2

MG640605

2 1

MG640795

4-51
13) KET SDL CONNECTOR
No. of
Receptacle connector (female) Plug connector (male)
pin

1
14
7

14 6

MG610406

4-52
 14) DEUTSCH DT CONNECTORS
DT 06 - 3S - ★★★★

Modifications (see below)

Number of contacts (P : Pin, S : Socket)
04 : Receptacle, 06 : Plug
Deutsch connectors
※ Modification
E003 : Standard end cap - gray
E004 : Color of connector to be black
E005 : Combination - E004 & E003
EP04 : End cap
EP06 : Combination P012 & EP04
P012 : Front seal enhancement - connectors color to black for 2, 3, 4 & 6pin

No. of
Receptacle connector (female) Plug connector (male)
pin

1 2 2 1
2

DT06-2S DT06-2P

2 1 1 2

3 3

DT06-3S DT06-3P

4 1 1 4

3 2 2 3

DT06-4S DT06-4P

4-53
No. of
Receptacle connector (female) Plug connector (male)
pin

6 1 1 6

4 3 3 4

DT06-6S DT06-6P

4 5 5 4

1 8 8 1

DT06-8S DT06-8P

6 7 7 6

12

1 12 12 1

DT06-12S DT06-12P

4-54
15) MOLEX 2CKTS CONNECTOR
No. of
Receptacle connector (female) Plug connector (male)
pin

1 2

35215-0200

16) ITT SWF CONNECTOR

No. of
Receptacle connector (female) Plug connector (male)
pin

2
10
1 10

SWF593757

17) MWP NMWP CONNECTOR

No. of
Receptacle connector (female) Plug connector (male)
pin

1
1

NMWP01F-B

4-55