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1. LOCATION 1
1 10
2 11
3 12
4
5 13
6
7
Switch
panel 2
Switch
panel 1
14
8 15
16
9
17
18
19
5594EL02
4-1
2. LOCATION 2
Cabin 8
3
9
14 10
11
7
56 12
4
13
1
5594EL03
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
5593CD02
4-3
2) CLUSTER CHECK PROCEDURE
(1) Start key : ON
Η Check monitor initial 6 seconds
a. All lamps light up.
b. Buzzer sound.
Θ 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
ö During start key ON the engine oil pressure lamp and battery charging lamp go on, but it is not
abnormal.
ö When engine coolant temperature below 30˚C, the warming up lamp lights up and then
operating the preheat switch.
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 Null -
5 Tacho signal Input
6 Anti-restart signal Output
7 Pre-heat signal Output
8 Travel relay Output
9 Power 12V -
10 Power IG 12V -
11 Travel signal Input
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 Hyd oil temp sendor Input 16 15 14 13 12 11 10 9
4-5
4. 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.
5593CD06
4-6
2) WARNING AND PILOT LAMPS
(1) Fuel low level warning lamp
Η This lamp blinks and the buzzer sounds when the level of fuel
is below 18˶(4.8 U.S. gal).
Θ Fill the fuel immediately when the lamp blinks.
R5573CD10
R5573CD11
R5573CD12
R5573CD13
R5573CD14
4-7
(6) Battery charging warning lamp
Η This lamp blinks and the buzzer sounds when the starting
switch is ON, it is turned OFF after starting the engine.
Θ Check the battery charging circuit when this lamp blinks during
engine operation.
R5573CD16
R5573CD19
R5573CD20
R5573CD21
4-8
(11) Auto idel pilot lamp
Η 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.
Θ 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.
55W7A3CD83
555C93CD13
4-9
3) SWITCHES
(1) Travel speed control switch
Η 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
555C93CD18
555C93CD23
5593CD09
4-10
(6) Menu and enter switch
Menu Enter Η 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
Θ 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.
4-11
Λ Change password
- Select ESL function to YES and press the Menu button ( ),
the display is shifted to the password change menu.
ÂInput a new password (Sn : - - - -) after enter the current
password successfully (SC : - - - -).
ÂPush enter ( ) button for a second to finish the setting
after the new password is entered once again (SA : - - - -).
ÂWhen the setting is done, the display will blink 3 times and
return to the time display screen.
5593CD18
4-12
⑦ Machine fault code
Fault code
Description
HCESPN FMI
Hydraulic oil temperature sensor circuit - voltage above normal or shorted to high source (or
3
101 open circuit)
4 Hydraulic oil temperature sensor circuit - voltage below normal or shorted to low source
0 Working pressure sensor data above normal range (or open circuit)
1 Working pressure sensor data below normal range
105
2 Working pressure sensor data error
4 Working pressure sensor circuit - voltage below normal, or shorted to low source
0 Travel oil pressure sensor data above normal range (or open circuit)
1 Travel oil pressure sensor data below normal range
108
2 Travel oil pressure sensor data error
4 Travel oil pressure sensor circuit - voltage below normal or shorted to low source
0 Overload pressure sensor data above normal range (or open circuit)
1 Overload pressure sensor data below normal range
122
2 Overload pressure sensor data error
3 Overload pressure sensor circuit - voltage below normal or shorted to low source
3 Fuel level sensor circuit - voltage above normal or shorted to high source (or open circuit)
301
4 Fuel level sensor circuit - voltage below normal or shorted to low source
0 Brake pressure sensor data above normal range (or open circuit)
1 Brake pressure sensor data below normal range
503
2 Brake pressure sensor data error
4 Brake pressure sensor data - voltage below normal or shorted to low source
0 Working brake pressure sensor data above normal range (or open circuit)
1 Working brake pressure sensor data below normal range
505
2 Working brake pressure sensor data error
4 Working brake pressure sensor circuit - voltage below normal, or shorted to low source
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
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
840 2 Cluster communication data error
841 2 ECM communication data error
4-13
Ξ 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
5R 21
BW 23
1
5W 22
12
3
3
4
9
12
2
10
WB 15
INLET MOTOR(REC) 1 16 BW
BW 16 3
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
85
M
LR 17 4
TEMP MOTOR ACT(+) 3
30
30
BG 18 5
INLET M/ACT
TEMP MOTOR ACT(-) 4
7
11
86
85
87 87a
86
7
8
87 87a
85
86
85
6
20A
10A
20A
GL
20A
10A
20A
86
20A
20A
30A
30A
20A
20A
85
20A
20A
19
20A
40A
20A
20A
20A
20A
15 WB
HORN RY
TEMP M/ACT(PBR) 5
30
30
30
7
10
11
5
9
12
4
8
1
2
3
6
7
Y
30
20
87a
1
87a
86
2
85
30
86
87
85
30
87
QUICK COUPLER SW
MOTOR ACT(REF) 6
12V SOCKET
87 87a
87 87a
CS-67
BREAKE RELAY 1
87 87a
CR-2
CR-62
GW
ECU
21 17 LR
87 87a
MCU
MCU
CN-139
MODE M/ACT(DEF) 7
1
1
BG
AC FAN
22 20 Y
B
R
87a
86
85
87a
30
87
86
85
87a
30
87
86
85
30
87
MODE M/ACT(FOOT) 8
87a
86
85
30
87
2
PRE-HEAT RY
0.8B
ANTI-RESTART
SOLENOID
PRE-HEAT
AIR-CON FAN RY
1.2Br
WR
CR-5
START KEY
M
CR-33
23
FUSE BOX
CR-12
HEAD LAMP
CR-36
AC& HEATER
WORK LAMP
1.2BrW
0.8BrW
MODE M/ACT(M+) 9
SAFETY SOL
Y 26
3
Gr 25
L 12A
L 12B
G 45
4
LB
2A
24 18 BG
BEACON LAMP
GW 15
BrW 58
FUEL P/P.HORN
MODE M/ACT(M-) 10
GW 15A
4
CASSETTE RADIO
YB
2
25 19 GL
58
Or 9
24J
MODE M/ACT(PBR) 11
27E
5
58A
L 32
5
Br 50
Or 9A
Gr 48
G 16
CLUSTER,CASSETTE
LY 54
CLUSTER,SW PANEL
V 49
B 00
LG
Lg 56
26
BW 53
CABIN LAMP/FEED PUMP
TEMP M/ACT
VW 55
BW 00
CN-36
BLOWER RELAY(LO) 12 6
YW 17B
YW 17C
BW 19B
YBr 27 9A GB
7
BLOWER RELAY(M1) 13 7
BG 28
R 2
ROOM LAMP&AC HEATERR 3
G 1
Or 9
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
BLOWER RELAY(HI) 15
3
LW 30 2
COMPRESSOR(DPS) 16 21 GW
GROUP 3 ELECTRICAL CIRCUIT
LY 31 3
CONDENSER FAN 17
M
4
18
5
7
MODE(D/FOOT)
BR 1 6
GND 1 22 BG
BR 2 7
GND 2
RW 3 23 WR
1
BATTERY(+) 3 1
RW 4 20A Y
M
G 5
ILLUMINATION 5 3
4
RY 6 24 LB
POWER IG 6 4
2
25 YB
NC 7 5
5
CS-2
BrR 8 1 G
86
85
MODE(VENT)
DUCT SENSOR(+) 8 6 1
H0 I
GB 9 9B GB 31 Br
30
7
DUCT SENSOR(GND) 9 7 2
0, I
GB 10 23 BW
87 87a
H
AC COMP
NC 11 1
87a
4
86
85
30
87
CR-7
35 YW 2
2 MH 3 32 L
NC 12 5 3
START SW
27 YBr
BR ACC
NC 13 3 ML 2 6
36A L
RESISTOR
NC 14 4 Hi 4 5
Br 50
ST C
YR 46
LW 8B
LW 8A
29 YB
1.25LgB 9 1 2 1
1 33 R
1.25G 8 2
DUCT
2 6B RY
3 CS-2
SENSOR
36 L
RELAY(HI)
4 4
1
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
35 YW
G
6
LY
2B
2R
RELAY(M2)
RY
LW
4 4 3
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
NO.
2 9 8
CN-2
BLOWER
BOOM SWING SW
10
10
AIR CON
GW
2B
11
MCU
B 11 12
3A R
1.25 B
50 Br
48 Gr
8 LW
12
24F RW
FUSE(IG)
EARTH
FUSE(Battery)
2B
ILLUMINATION
GND(BLOWER)
CR-71
DESTINATION
CONDENSOR FAN
BL
GND(CONTROLLER)
30
DPS(COMPRESSOR)
V 87a 87 85
CN-246 86
W
USB(+5V) 1 87
R
USB(D+) 2 85
30 86
BOOM SWING
USB(D-) 3 87a
USB(GND) 4
71 0.5YL
RX 5
72 0.5GY
TX 6
24D 0.5RW
ILLUMINATION 7
0.5B CN-170
GND 8 00
73 0.5LgW 2
TX/S 9 B
GND(JACK) 11
NC 12 CS-3
1
EARTH
CN-245
5B 0.5V 2
I
POWER IG 1 36 V
75 0.5LY 3
0
SIG+ 2
76 0.5BW 4
SIG- 3 35 Or
5
4 4
NC B
77 0.5Lg 6 8
H/F IND+ 5 37 Br
0.5B 7 10
H/F IND- 6 35A Or 3
78 0.5GY 8
WIPER SW
MIC+ 7 7 6
79 0.5BL 9 9
MIC- 8
REMOTE ASSY
24C 0.5RW 10
ILLUMINATION 9 7B ROr
80 0.5L 11
REMOTE SIG+ 10 35 Or 11 12
81 0.5Y 12
REMOTE SIG- 11
0.5B
GND 12
CR-6
37 Br
6
CN-144
78 0.5GY 7 ROr
MIC+ 1 4
71 0.5YL
RX(JACK) 2
76 0.5BW
GND(SEND) 3 35 Or
82 0.5RW 3
TEL MUTE 4 36 V
INT.WIPER RY
73 0.5LgW 1
TX/S 5
83 0.8BOr
CAR AUDIO(-) 6
84 0.8Or CR-4
CAR AUDIO(+) 7 40 G
30
7C ROr 87a 87 85
NC 8 86
5A 0.8V 7D ROr
POWER IG 9 87
79 0.5BL 38 Or
MIC- 10 85
WIPER RY
72 0.5GY 39 Gr
TX(JACK) 11 30 86
87a
74 0.5BW
HANDFREE
GND(JACK) 12
RX(SEND) 13
75 0.5LY
TX(SEND) 14
77 0.5Lg 4 Lo
IND(+) 15 M
NC 16 CN-21
85 0.8BOr 40 G
SPK(-) 17 4
86 0.8Or 7E ROr 3 B
SPK(+) 18 3
0.8B B 1 Pf
GND(MAIN) 19 2
WIPER MOTOR
2 E
NC 20 39 Gr
1
CN-27
5 0.8V
ACC 1 36A V
0.5B 1
ILL- 2 41A G
DO-1
2
GND 3
88 0.8BW
SPK FRT RH- 4
83 0.8BOr
SPK FRT LH- 5 1
82 0.5RW 1 12
TEL MUTE 6 2
ANT 12V 7 3
2 0.8Y B
BACK UP+ 8 4
24B 0.8RW
ILL+ 9 5
41 G
NC 10 6
87 0.8Gr 4
6
REMOCON+ 12 8
81 0.5Y
REMOCON GND 13 9
84 0.8Or
SPK FRT LH+ 14 10
NC 15 11
0.8B 11 12
GND 16 12
CS-30
LH
86 Or
1
85 Br
2
SPEAKER
CN-23
87 0.8Gr
RH
1
88 Y
2
SPEAKER
CN-24
CN-56
EARTH
HIGH BEAM SIG. 1
NEUTRAL SIG. 2
64 LW
ALT.LEVEL SIG. 3
OVER HEAT SIG. 4
TACHO SIG. 5
ANTI-RESTART RY 6
PRE-HEATER RY. 7
56 Lg
TRAVEL RY. 8
3R
BATT.POWER 12V 9
14 Br
2B
6 RL
47 GW
42 Or
10
42 Or
POWER IG 12V
43 RW
18 WOr
43 RW
2B R
18A WOr
42 Or
18 WOr
18A WOr
43 RW
TRAVEL SIG. 11
24E RW
3
2
1
ILLUMINATION 12
4-16
CS-4
RAMLOCK SIG 13
30
86
85
87
2
1
4
3
30
86
85
87
87a
CR-9
CR-85
3
87a
PARKING SIG 14
CN-6
67 YW
1
69 Y
87a 87
SAFETY SW
30
2
87a 87
68 GW
86
85
86
85
ANALOG GND 18
00 B
CABIN LAMP RELAY
GND 19
G
G
Br
Gr
RL
4 R
26 Y
12 L
45 G
49 V
00 B
51 G
31 Br
13 Gr
41 G
25 Gr
29 R
30 R
46 YR
50 Br
CLUSTER
GND
21 5R
20
55 VW
22 5W
47 GW
53 BW
24 RW
57 ROr
2A RW
58 BrW
70 Or
M
CS-74
3
2
8
M
9
5
4
3
7
6
1
2
12
11
10
6
5
3
5
3
4
1
4
1
9
8
7
6
2
9
8
7
2
15
14
13
12
11
10
15
14
13
12
11
10
00
CN-2
CN-3
CN-5
CN-4
CRAWLERWHEEL SELECT 5
L
G
G
Gr
Br
CN-22
5
6
RL
59 V
CN-61
FUEL PUMP
56
33 Br
2 L
5 Y
5A
44 Or
59
60
45A G
6
61 Gr
3 G
7A
6E
9 Br
5E
6A RL
7 Gr
60 ROr
G2
8 YR
1 RW
11 R
10 GW
34A
15 G
19 V
WASHER PUMP
24 5R
7
23 5W
18 BW
17 VW
10 YW
16 ROr
60 Ror
10A YW
59 V
20 BrW
3G
24A RW
HARNESS CABIN
G
B
Br
B
2 L
Br
57 Ror
11 BrW
4 ROr
GW
GW
11A BrW
BW
GW
OrW
1
4
5
8
2
6
10
11
12
3
7
DOWN ENABLE 9
Or
CN-116
B
R
B
NC 10
1
3
2
6
4
1
3
2
6
4
30
30
86
85
86
85
87
87
NC
NC
NC
NC
CR-3
COM GND 11
87a
87a
30
86
85
87
GND
CR-13
CR-68
87a
MASTER SW
B
B
CR-45
12A RW
12 RW
RS232 RX 12
CR-67
BEACON
1
2
BREAKER
CL-1
CL-7
RS232 TX 13
30
30
2 4
87a 87
87a 87
6 3 1
24
6 3 1
30
87a 87
G4
CAN Hi2 14
86
86
85
85
TRAVEL ALARM
POWER 12V(IG)
86
85
SWITCH PANEL
M
2
1
2
HEAD LAMP RY
1
15
WORK LAMP RY
CAN Lo2
CABIN LIGHT OUT
CL-4
RACK ACTUATOR
CN-243
B 73
69 Y
63 Gr
70 Or
L
1
16B G
66 WB
64 LW
67 YW
68 GW
B
62 RW
CN-126
EARTH
G 72 B 73
2 1
RS232
R 71 G 72
3 2
BW
RS232
60 R 71
4 Gr 1
3
5
3
4
1
9
8
7
6
2
12
11
10
CONNECTOR
BW 60
CN-1
4
2
CONNECTOR
L
CD-7
LH
1 B cs-5
R
37 G
35 G
2
43 Y
SUPPLY A
45 Or
L
38 LW
R
B
Lg
41 YW
40 WB
2
42 GW
44 RW
YOr
HORN
B CN-7 1
AUTO IDLE PS
Pa Gr
1
CD-10 B B
2
CN-51 Gr
3
HYD OIL TEMP 0.8GrW 76 L Gr 1
43 Y CAN Hi2 1 4
C 2 0.8R 73 R
B CAN Lo2 2 5
EARTH
1 R L 2
D IN SPARE 3 3 6
CD-1
RH
D IN TRAVEL PS 4 B B 1
WATER TEMP 7 2
0.8Gr 36 5Y Lg 2 R
B 12V POWER SUPPLY 5
2 8 1
C 0.8GrW 76 B GW 3 3 GW cs-26
42 GW A IN WORKING PS 6 2
1 9
6G G 4 4 G B
CD-30 SENSOR SPARE 1 7 10 1
BREAKER
RCV EPPR+ 8 1 RW RW 5
FUEL SENDOR 11
B D OUT GOV. MOTOR+ 9 Gr 6
1 12 CL-2
1.2RW 79 GOr 7 5 RW
41 YW BATT. 12V 10 13 1
2
RS232 TX 1 W 8 6 Gr
CD-2 11 14 2
B 9 1B B
RS232 RX 1 12 15 3
D IN SPARE 4 6
13 16 CIGAR LIGHTER
30 5W D IN SPARE 1 5
B+ 14
G 0.8B 37 4
36 Gr POT DIA 5V 15 0.8Gr 0.8Gr 42 CN-142
s 2 36 7 GOr
~3 38 LW A IN BOOM SWING PS 3 A +
L 1 16 99 0.8W 0.8W 43 8 W
U SENSOR SPARE 2 2 B S
P 17 37 0.8B 0.8B 44 9 B
1
ALTERNATOR
RCV EPPR 18 C -
CN-74
ACCEL DIAL
3W/100? 2
2 A IN POT SIG 25 67 0.8B 2.5k
1
RS-2 SENSOR SPARE 3
DO-1 RESISTER
26
CN-16B
NC
NC
D OUT TRAVEL BZ
GND
12V+
27
CAN L
CAN H
SERVICE TOOL
CAN Hi 1 31
CN-148
CAN Lo 1 32
0.8W 11
B
G
CAN GND 33
36
Vi/W
0.8B 37
6
SIG. GND 34
31
0.8L
36E
2
32
A IN DIAL SIG 35
0.8B 37
ALT LEVEL 36
CN-93 D OUT SPARE 1 37
Br 1
POWER 12V 48 D OUT SPARE 2 38
2B 36 1.2B 3E
GND P 47 GND MAIN 39
1.2R
2B
3A
NC 46 GND MAIN 40
2B 36A
3
GND 45
W 10
AIR HEATER RY(+) 44
YW 35
SENSOR 12V 43
Or 34
RACK ACTUATOR(-) 42
60A
LW 33 5W
CSD COIL 41 2
Vi/W 32 5W
CAN H 40 1
G 31A
CAN L 39 CN-95
GOr 24
SENSOR 5V 38
5R
RESERVE ANALOG 37 2
RW 69 5R
1
MANUL RESET
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
YL 15
FAILURE LAMP(-) 12
GW
5R
26
BATT RY
5W
EGR STPM C 11
NC 10
B 36F
ENG.SPEED SW1(-) 9
L 7
START SIGNAL 8
G 6A
IG POWER 7
30 5W
ENG.SPEED CONT.SW
2SQ
2SQ
6
FROM BATT.RY
REV.DROOP SW 5
31 5R
29 GL
22 YR
TXD 4
B
60R
16 ROr
RXD 3
15 G
YR 17
OVER HEAT LAMP
B
2
B
B
LR 25
1
2
EGR STPM D
B
10 GW
1
19 V
31 5R
1
2
22 Br
B+
7 Gr
34 5R
32 5W
B
34 5R
CN-29
18 BW
33 5W
B
CN-45
7A Gr
CN-12
29 GL
BATTERY
2
1
B
B
12A RW
12 RW
15 G
Pa
B
B
20 BrW
R/DRYER
1
1
60B
2
2
17 VW
1
CN-121
1
2
M
1
2
C2
4
C1
1
2
C2
C1
2
1
34
CN-20
35
69
CN-25
HORN
70
26
30
25
1F
1H
CR-23
CR-24
22A
START MOTOR
TO:STARTER "B" TERM.
CN-83
CN-68
BOOM SWING
2
1
1
2
1
2
1
1
CL-4
2
1
B
2
CL-3
1
2
CN-80
RL
B
CN-66
R
46A
START RY
46
Or
Br
CN-70
Gr
Vi
46
CN-140
LR
14
SAFETY SOL
YW
RW
Pre-heater
C1
AC CON FAN
C2
33
GW
22
27
OrW
C1
C2
29
28
AC COMP
CN-28
L
B
AIR-HEATER RY
G
HEAD LAMP
L
2
1
L
QUICK COUPLER SOL
B
B
BREAKE SOL
L
TRAVEL SOL
Y
CL-5
LW
GR
6
5
4
3
2
1
6
5
4
3
2
1
2
1
1
2
1
2
CN-194
CN-193
CD-11
CD-12
CN-81
1
2
CD-8
1 ry
WORK LAMP
com
com
2 sol
4 rps
CD-17
5 avb
6 gnd
CSD
Pa
stpm c
stpm b
stpm d
stpm a
CD-62
CD-18
Pa
Pa
/h
TRAVEL BZ
Pa
km
EGR VALVE
ENG OIL PRESS
RACK ACTUATOR
TRAVEL ALARM PS
TACHO SENSOR
WATER TEMP SENDOR
5594EL01
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 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)]
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)]
2) CHECK POINT
Engine Start switch Check point Voltage
Η - GND (battery)
OFF OFF Θ - GND (battery relay) 10~12.5V
Ι - GND (fusible link)
ö 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
20A
20A
30A
40A
20A
10A
20A
20A
20A
20A
20A
SOLENOID
ECU
CLUSTER, CASSETTE
CLUSTER, SW PANEL
START KEY
MCU
MCU
CASSETTE RADIO
AC FAN
HEAD LAMP
WORK LAMP
AC & HEATER
SAFETY SOL
BEACON LAMP
PRE-HEAT
GW
1
GW 6 3 1
2
3
4
6 2 4
VW
GW
CR-45
87a 30 86
85
87
86 87a 87 85
GW
30
ECU IG POWER RY
CR-23
C1 1 C1
C2
5W
1
2 2 C2
START RY
CR-24
C1 1 C1
CN-3 C2
5W 5W 5W
1 1
5R 5R
2 2 2 C2
AIR HEATER RY
R
CN-95 60A
CS-74
5W
2
1
2
5W
1
CIRCUIT BREAKER
CS-74 MANUL RESET
CN-2 CN-60 30A
5R
1 2
MASTER SW 2 5R
1
3
1 2 1 4
R R R
2 5
3 6
3 4 4 7
RELAY (HI) 8 3 2
60R 60B
1 2 1 CR-1
R
2 BATTERY
3
3 4 4
RELAY (M2) BATT RY
1
RW
BATTERY(+) 3
RW CN-6
BATTERY(+) 4
1 CL-1
AC & HEATER CONTROLLER 2 1
R R
3 2
CN-2
4 ROOM LAMP
10
11
12
3
6
7
8
9
1
4
5
2
CN-139
R
2
1
1.2ROr
1.2RW
12V SOCKET
0.8Y
CN-51
R
11
12
13
14
15
16
17
18
19
20
10
BW
8
CS-2
A IN BOOM SWING PS
5
4
1
6
2
3
B
D IN SPARE4
D IN SPARE1
POT DIAL 5V
0, I
1
BACK UP B+
RS232 RX1
RS232 TX1
RCV EPPR
BATT. 12V
BATT. 12V
CN-56
CN-27
I 0 H
4
3
2
6
5
C ST ACC BR H
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)]
ö 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)
2) CHECK POINT
Engine Start switch Check point Voltage
Η GND (battery)
Θ GND (start key)
ΙGND (battery relay M4)
Operating Start ΚGND (starter B+) 10~12.5V
Λ GND (starter M)
Μ GND (start relay)
ΝGND (battery relay M8)
ö GND : Ground
4-20
5R
BW
5W
4
14
16
5
7
9
3
8
13
15
18
10
11
12
17
1
19
2
20
85
85
86
86
CN-56
HIGH BEAM SIG. 1
30A
20A
20A
10A
20A
20A
20A
20A
20A
20A
20A
30A
40A
20A
10A
20A
20A
20A
20A
20A
30
30
NEUTRAL SIG.
87 87a
87 87a
2
LW
ECU
MCU
MCU
ALT.LEVEL SIG. 3
85
85
30
30
86
87
86
87
87a
87a
PRE-HEAT RY
AC FAN
OVER HEAT SIG. 4
CR-5
CR-36
ANTI-RESTART RY
SOLENOID
PRE-HEAT
START KEY
FUSE BOX
HEAD LAMP
TACHO SIG. 5
WORK LAMP
SAFETY SOL
AC & HEATER
L
V
G
BEACON LAMP
B
LY
ANTI-RESTART RY 6
BW
BW
BW
CASSETTE RADIO
PRE-HEATER RY. 7 CR-45
CLUSTER, SW PANEL
CLUSTER, CASSETTE
R/LAMP & A/C HEATER
CIGAR, WIPER MOTOR
ALT, ANT RESTART RY
TRAVEL RY. 8 87a 30 86
G
POWER IG 12V 10 87
BW
GW
ROr
BW
TRAVEL SIG. 11 86 87a 87 85
CLUSTER
ILLUMINATION 12 30
ECU IG POWER RY
RAMLOCK SIG 13
STARTING CIRCUIT
PARKING SIG 14
FUEL LEVEL SENDOR 15
2
HYD OIL TEMP SENDOR 16
WATER TEMP SENDOR 17
ANALOG 18
CS-2
GND 19 G
1
H0 I
GND 20 Br
2
0, I
BW
H
G
3 4
LW
RW
Br
B
4 1 2
L
3
START SW
5
BR ACC
5
3
5
3
4
1
4
1
9
8
7
6
2
9
8
7
6
2
6
12
11
10
12
11
10
CN-93
1
2
CN-2
CN-1
5
POWER 12V
CS-74
48
ST C
G
GND P 47
Br
LW
RW
NC 46
GND 45
W
V
AIR HEATER RY(+) 44
Br
CR-24
5R
5W
BW
SENSOR 12V 43 V C1
C2 1
MASTER SW
RACK ACTUATOR(-) B
42 C1
CSD COIL 5W
41
5
3
5
3
4
1
4
1
9
8
7
6
2
9
8
7
6
2
1
1
2
15
14
13
12
11
10
15
14
13
12
11
10
5R
CN-5
CN-3
CN-4
CAN H 40 2 2 C2
AIR-HEATER RY
ENG.SPEED METER(-)
Br
22
5R
5W
BW
EGR STPM B 21
LW
START RY(-) 20
SPEED SENSOR(+) 19
4-21
CN-80
SPEED SENSOR(-) 18 5R
ENG.SPEED SW2(-) 17
WATER TEMP SENDOR 16
ECU
PRE-HEATER
ENG.STOP SW(+) 15
ENG.OIL PRESS 14
4
Rmax1 SW 13
FAILURE LAMP(-) 12
EGR STPM C 5W
11
CN-45
NC 10 60R
ENG.SPEED SW1(-) 9
B+
L M
START SIGNAL 8
START
IG POWER 7 5R
MOTOR
ENG.SPEED CONT.SW
M
6
REV.DROOP SW 5
TXD 4
5
RXD 3
OVER HEAT LAMP 2
EGR STPM D 1
CR-23
5R
2 1 C1
5W
1
CN-51 B
BW C1
BW
START RY
POWER IG 12V 30 C2 2 C2
CAN Hi1 31
CAN Lo1 32
6
CAN GND 33
CONTROLLER
SIG. GND 34
A IN DIAL SIG 35
B
ALT LEVEL 36
GOVENOR DC MOTOR
1
CR-1 60R
Gr
5W
LW
B
1
Br
5R
5R
5W
5W
2
1
1
2
1
2
RS-2
DO-4
1
1
2
2
BATT RY
S
L
P
CN-60
U+2126
CN-95
B+
3W/100\
RESISTOR
BATTERY
CN-74
5594EL05
60B
~
7
G
MANUL RESET
U
CIRCUIT BREAKER
ALTERNATOR
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
Η GND (battery voltage)
Θ GND (battery relay)
Operating Start ΙGND (alternator B+ terminal) 10~12.5V
ΚGND (alternator L terminal)
Λ GND (cluster)
ö GND : Ground
4-22
5R
BW
5W
4
14
16
5
7
9
3
8
13
15
18
10
11
12
17
1
19
2
20
85
85
86
86
CN-56
HIGH BEAM SIG. 1
30A
20A
20A
10A
20A
20A
20A
20A
20A
20A
20A
30A
40A
20A
10A
20A
20A
20A
20A
20A
30
30
NEUTRAL SIG.
87 87a
87 87a
2
LW
ECU
MCU
MCU
ALT.LEVEL SIG. 3
85
85
30
30
86
87
86
87
87a
87a
PRE-HEAT RY
AC FAN
OVER HEAT SIG. 4
CR-5
CR-36
ANTI-RESTART RY
SOLENOID
PRE-HEAT
FUSE BOX
START KEY
HEAD LAMP
TACHO SIG. 5
WORK LAMP
SAFETY SOL
AC & HEATER
L
V
G
BEACON LAMP
B
LY
ANTI-RESTART RY
5
6
BW
BW
BW
CASSETTE RADIO
PRE-HEATER RY. 7 CR-45
CLUSTER, SW PANEL
CLUSTER, CASSETTE
R/LAMP & A/C HEATER
CIGAR, WIPER MOTOR
ALT, ANT RESTART RY
TRAVEL RY. 8 87a 30 86
G
POWER IG 12V 10 87
BW
GW
ROr
BW
TRAVEL SIG. 11 86 87a 87 85
CLUSTER
ILLUMINATION 12 30
ECU IG POWER RY
RAMLOCK SIG 13
CHARGING CIRCUIT
PARKING SIG 14
FUEL LEVEL SENDOR 15
HYD OIL TEMP SENDOR 16
WATER TEMP SENDOR 17
ANALOG 18
CS-2
GND 19 G
1
H0 I
GND 20 Br
2
0, I
BW
H
3 4
Br
B
4 1
LW
2
RW
L
START SW
5 3
BR ACC
5
3
5
3
4
1
4
1
9
8
7
6
2
9
8
7
6
2
6
12
11
10
12
11
10
1
2
CN-93
CN-2
CN-1
5
POWER 12V
CS-74
48
ST C
LW
GND P 47
Br
RW
NC 46
GND 45
W
V
AIR HEATER RY(+) 44
Br
CR-24
5R
5W
BW
SENSOR 12V V C1
43 C2 1
MASTER SW
RACK ACTUATOR(-) B
42 C1
5W
CSD COIL 41
5
3
5
3
4
1
4
1
9
8
7
6
2
9
8
7
6
2
1
1
2
15
14
13
12
11
10
15
14
13
12
11
10
5R
CN-4
CN-5
CN-3
CAN H 40 2 2 C2
AIR-HEATER RY
ENG.SPEED METER(-)
Br
22
5R
5W
BW
EGR STPM B 21
LW
START RY(-) 20
4-23
SPEED SENSOR(+) 19 CN-80
SPEED SENSOR(-) 18 5R
ENG.SPEED SW2(-) 17
WATER TEMP SENDOR 16
PRE-HEATER
ECU
ENG.STOP SW(+) 15
ENG.OIL PRESS 14
Rmax1 SW 13
FAILURE LAMP(-) 12
5W
EGR STPM C 11
CN-45
NC 10 60R
ENG.SPEED SW1(-) 9
B+
START SIGNAL
L
M
8
START
IG POWER 5R
MOTOR
7
M
ENG.SPEED CONT.SW 6
REV.DROOP SW 5
TXD 4
RXD 3
OVER HEAT LAMP 2
EGR STPM D 1
CR-23
5R
2 1 C1
5W
1
CN-51 B
C1
BW BW
START RY
POWER IG 12V 30 C2 2 C2
CAN Hi1 31
CAN Lo1 32
CAN GND 33
CONTROLLER
SIG. GND 34
A IN DIAL SIG 35
B
ALT LEVEL 36
GOVENOR DC MOTOR
1
4
CR-1 60R
Gr
5W
LW
B
1
3
Br
5R
5R
5W
5W
2
1
1
2
1
2
RS-2
DO-4
1
1
2
2
BATT RY
S
L
P
CN-60
CN-95
2
U+2126
B+
3W/100\
RESISTOR
BATTERY
5594EL06
CN-74
3
60B
~
G
MANUL RESET
U
CIRCUIT BREAKER
ALTERNATOR
4. HEAD AND WORK L
LAMP
AMP CIRCUIT
1) OPERATING FLOW
Fuse box (No.10) Head lamp relay [CR-13 (86) Ą (85)] Switch panel [CN-116 (1)]
Fuse box (No.11) Work lamp relay [CR-3 (86) Ą (85)] Switch panel [CN-116 (21)]
(1) Head lamp switch ON
Head lamp switch ON [CN-116(1)] Head lamp relay [CR-13 (85) Ą (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) Ą (87)] l/conn [CN-4 (8)]
l/conn [CN-12 (2)] Work lamp ON [CL-5 (2)]
2) CHECK POINT
4-24
HEAD AND WORK LAMP CIRCUIT
BrW
YW
RL
1 5 CN-116
12 NC
CN-2
11 GND
1 RL
10 POWER IG 12V
2
9 BREAKER
3
8 TRAVEL ALARM
4
G
7 2 5 NC
NC
RW 4
ILLUMINATION 5 8
3 NC
AC & HEATER V
2 WORK LIGHT OUT
CONTROLLER ROr
1 HEAD LIGHT OUT
SWITCH PANEL
CN-7
1 7 CR-3
2
87a
3 V 30 86
85
4
ROr
87
BrW
5 86
BrW 87a 87 85
6 30
B
7 WORK LAMP RY
CL-2
B
8 3 CR-13
3 9 87a
ROr 30 86
2 10 CN-5 85
RW RW RW RW
1 11 1 87
YW
12 2 86
CIGAR LIGHTER YW
30
87a 87 85
13 3
14 4 HEAD LAMP RY
15 5
CL-3
16 6
B
1 1
7
RW
2 2
8
9
HEAD LAMP
CN-4 B
10 1 1
RW RW RW
11 2 2
12 3 CL-4
13 4 4
14 5
15 6 CL-5
CN-12
B B
7 1 1
ROr ROr ROr RL
8 2 2
9 WORK LAMP
10
11
12
13
14
8
15
RW
RW
RW
RW
RL
CN-56
CN-27
CN-246
CN-245
1
2
3
4
5
6
7
8
9
9
12
13
14
18
19
20
11
15
16
17
10
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.
ANALOG
ILL(+)
GND
GND
5594EL07
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-3, 4]
2) CHECK POINT
Engine Start switch Check point Voltage
Η - GND (fuse box)
Θ - GND (switch power input)
STOP ON 10~12.5V
Ι - GND (switch power output)
Κ - GND (beacon & cab lamp)
ö GND : Ground
4-26
BEACON LAMP CIRCUIT
WOr
LW
1 1
4 CR-85
87a
Or 30 86
CL-7 CN-6 85
Or Or Or RW
1 87
M B B B WOr
2 86
WOr 87a 87 85
30
BEACON LAMP RW
3
RW
4 BEACON LAMP RY
CL-3
RW
2
1
B
3
CR-9
87a
Or 30 86
CABIN LAMP RW
85
87
RW WOr
2 86
B WOr 87a 87 85
1 30
CL-4 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 HEAD LIGHT OUT
SWITCH PANEL
5594EL08
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)] Washer pump [CN-22 (2)]
(2) Wipe switch ON : 1st step (low speed)
Wiper switch ON [CS-3 (8) Ą(7)] Int wiper relay [CR-6 (6) Ą(3)] Wiper relay [CR-4 (85) Ą(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)Ą(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)Ą(8)] Int wiper relay [CR-6 (6)Ą(3)]
Wiper relay [CR-4 (85)Ą(30)] Wiper motor [CN-21 (4)]
Wiper motor parking position by wiper motor controller
2) CHECK POINT
Engine Start switch Check point Voltage
Η - GND (fuse box)
Θ - GND (switch power input)
STOP ON 10~12.5V
Ι - GND (switch power output)
Κ - GND (wiper motor)
ö GND : Ground
4-28
WIPER AND WASHER CIRCUIT
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
HIGH BEAM SIG. 1
NEUTRAL SIG. 2
1
ALT.LEVEL SIG. 3 START KEY 30A
OVER HEAT SIG. 4 R 2
CLUSTER, CASSETTE 20A
TACHO SIG. 5 3
ANTI-RESTART RY 6 R/LAMP & A/C HEATER 30A
FUSE BOX
PRE-HEATER RY. 4
7 MCU 20A
TRAVEL RY. 8 5
R
BATT.POWER 12V
ECU 20A
9
RL RL 6
POWER IG 12V 10 CLUSTER, SW PANEL 20A
TRAVEL SIG. 11 7
MCU 20A
ILLUMINATION 12
8
RAMLOCK SIG 13 CASSETTE RADIO 20A
MONITORING CIRCUIT
PARKING SIG 9
14
YW AC FAN 40A
FUEL LEVEL SENDOR 15 10
Y
HYD OIL TEMP SENDOR 16
HEAD LAMP 20A
GW 11
WATER TEMP SENDOR 17 WORK LAMP 20A
ANALOG 18 12
B FUEL P/P, HORN 20A
GND 19
B 13
CLUSTER
GND 20 CIGAR, WIPER MOTOR 20A
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 ALT, ANT RESTART RY 20A
CRAWLERWHEEL SELECT 5 17
SAFETY SOL
BRAKE FAIL SIG. 6 10A
18
OVERLOAD NC 7 BEACON LAMP 20A
ENG. OIL FILTER NC 8 19
PRE-HEAT 20A
DOWN ENABLE 9 20
NC 10 CABIN LAM/FUEL FEED P/P 20A
CN-36
COM GND 11
4-30
RS232 RX 12
RS232 TX 13
CAN Hi2 14
CAN Lo2 15
PRE HEAT SIG. 16
CN-57
5
3
4
1
9
8
7
6
2
12
11
10
CN-1
B
B
B
B
Or
YW
GW
1
1
1
2
2
2
CD-1
CD-2
CD-30
CD-10
C
C
Pa
WATER TEMP
AIR CLEANER SW
5594EL10
ELECTRIC CIRCUIT FOR HYDRAULIC
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
20A
20A
30A
40A
20A
10A
20A
20A
20A
20A
20A
SOLENOID
ECU
CLUSTER, CASSETTE
CLUSTER, SW PANEL
START KEY
MCU
MCU
CASSETTE RADIO
AC FAN
HEAD LAMP
WORK LAMP
AC & HEATER
SAFETY SOL
BEACON LAMP
PRE-HEAT
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
1
2
3
4
5
6
CS-4 7
3
Br
2 1 8
2 9 CN-68
GW GW
1 3 10 2
11
B
SAFETY SW 1
12
SAFETY SOL
CN-116 13
CN-4
BOOM SWING
CN-56 1
Lg
TRANS RY 8 2 CN-140
G
CLUSTER 3 2
4 B
1
5
6 QUICK COUPLER SOL
CR-12
87a 7
30 86 Lg
85 8 CN-70
VW VW
87 9 2
YW B
86 10 1
87a 87 85 YW
30 11
TRAVEL SOL
TRAVEL 12
13
HI-LO SOL
14 CN-66
BrW
15 2
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 RELAY 3
4
5
6
7
8
9
10
11
BrW
BrW
12
GW
GW
RW
B
L
L
L
Br
BL
B
B
W
V
R
CD-11
CN-81
CD-12
CS-2
CR-71
CS-67
87a
87
86
30
85
3
6
7
6
7
1
2
1
2
4
1
2
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
TRAVEL
BOOM TRAVEL
9
ALARM PS
12
4
12
10
10
12
12
SWING BZ
BOOM SWING SW QUICK COUPLER SW
5594EL11
4-31
GROUP 4 ELECTRICAL COMPONENT SPECIFICATION
BR ACC ST C
öCheck contact
H
5
6
2
3
4
H0 I
6
1
4
5
CD-18
ö Check resistance
1 C
Temperature 0.5 kgf/cm 2 50˚C : 804̫
sensor (N.C TYPE) 80˚C : 310̫
2
100˚C : 180̫
CD-8
4-32
Part name Symbol Specification Check
Pa Pressure:
Air cleaner ö Check contact
635mmH2O
pressure switch Normal : â̫
(N.O TYPE)
CD-10
ö Check resistance
2
Full : 100̫
Fuel sender -
1 Low : 500̫
Empty warning :700̫
CD-2
87a 30 86
85
ö Check resistance
87
86
Normal : about 200̫
Relay 30 87a 87 85 12V 20A (for terminal 85-86)
CR-2 CR-3 CR-4 CR-5 : 0̫(for terminal 30-87a)
CR-7 CR-9 CR-12 CR-13 : â̫(for terminal 30-87)
CR33 CR-36 CR-62 CR-85
C2 1 C1
C1
2
ö Check resistance
Solenoid valve 1 12V 1A Normal : 15~25̫
(for terminal 1-2)
CN-66 CN-68
CN-70 CN-140
öCheck resistance
Speaker 4̫ 20W
Normal : 4̫
CN-23(LH)
CN-24(RH)
4-33
Part name Symbol Specification Check
ö Check contact
Boom swing Normal
12V 16A
switch OFF - â̫(for terminal 1-5,2-6)
- 0̫(for terminal 5-7,6-8)
CS-2
ö Check contact
Quick clamp Normal
12V 16A
switch OFF - â̫(for terminal 1-5,2-6)
- 0̫(for terminal 5-7,6-8)
CS-67
2
12V 55W ö Check disconnection
Lamp
1 (H3 TYPE) Normal : 1.2̫
1
ö Check disconnection
Room lamp 2 12V 10W
Normal : a few ̫
CL-1
1 M
12V öCheck operation
Fuel filler pump
2 35 ˶/min Supply power (for terminal 1) : 12V
CN-145
CN-20 CN-25
4-34
Part name Symbol Specification Check
ö Check contact
2 3 1 Normal : 0̫(for terminal A-B)
Safety switch 2 Micro : â̫(for terminal A-C)
3 Operating : â̫(for terminal A-B)
1
CS-4 : 0̫(for terminal A-C)
CL-7
12
6
I 0
öCheck contact
Wiper switch 12V 16A
11
8
9
4
3
7
10
Normal : â̫
10
A
B
7
2
6
1
4
5
8
9
CS-3
H A
öCheck operation
F B
Fuel cut-off 12V Rated full current : 12V 33A
E C Rated hold current : 12V 0.8A
CN-79
CN-79
M 2
öCheck contact
Washer pump 1 12V 3.8A
Normal : 3̫(for terminal 1-2)
CN-22
4-35
Part name Symbol Specification Check
4 Lo
M
4
öCheck contact
Wiper motor 3 B
12V 3A
3 Normal : 6̫(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
ö Check voltage
Radio &
REMOCON GND
SPK FRT RH+
24V 2A 20 ~ 25V
SPK FRT RH-
SPK FRT LH-
REMOCON+
BACK UP+
TEL MUTE
CD/MP3 player
ANT 12V
GND
ACC
ILL+
ILL-
NC
NC
CN-27
2 Pa
ö Check contact
Receiver dryer 1 12V
Normal : 0̫
CN-29
M B+
öCheck contact
Starter 12V
Normal : 0.1̫
M
CN-45
B+
G
2 s öCheck contact
~3
Alternator 1 L 12V 55A Normal : 0̫(for terminal B+-1)
U
P
Normal : 24 ~ 27.5V
CN-74
4-36
Part name Symbol Specification Check
Air con 1 M
12V 8.5A -
fan motor 2
CN-83
M 1
Fuel feed pump 2 12V -
CN-145
IG 4 OUT
1
1
2
Timer 3
12V -
2
GND 3 OUT 4
4-37
Part name Symbol Specification Check
2
12V socket 12V 120W -
1
CN-139
ö Check resistance
Normal : 0̫
1˚C OFF
Duct sensor (for terminal 1-2)
4˚C ON
the atmosphere temp :
over 4˚C
ö Check resistance
Normal : about 5k̫
A + (for terminal A-C)
B S ö Check voltage
Accel dial -
C - Normal : about 5V
CN-142 (for terminal A-C)
: 2~4.5V
(for terminal C-B)
6
4
2
Circuit breaker 12V, 30A (CN-65)
1 -
manual reset 12V, 60A (CN-95)
CN-60
CN-95
4-38
GROUP 5 CONNECTORS
1. CONNECTOR DESTINATION
4-39
Connector No. of Connector part No.
Type Destination
number pin Female Male
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-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 KET 20 Handfree MG610240 -
CN-145 KET 2 Fuel feed pump 7123-6423-30 -
CN-170 AMP 2 Seat heat switch 12162017 -
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
ÂLAMP
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 180923-0 -
CL-7 - 1 Beacon lamp - S822-114000
CL-9 DEUTSCH 1 Cabin lamp DT06-2S-EP06 -
CL-10 DEUTSCH 1 Cabin lamp DT06-2S-EP06 -
ÂRELAY
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 AMP 6 Int wiper relay S810-006002 -
CR-12 AMP 4 Travel relay S810-004002 -
CR-23 KET 2 Start relay S814-002001 -
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-47 KET 2 Fuel cut-off relay S814-002001 -
CR-50 KET 4 Timer relay MG610047-5 -
ÂSENDER
CD-1 AMP 2 Hydraulic temp sender 85202-1 -
CD-2 AMP 2 Fuel sender - S816-102002
4-40
Connector No. of Connector part No.
Type Destination
number pin Female Male
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 -
ÂSWITCH
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-67 SWF 10 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
1
12
1 13
24
36
36
13 25 12
24
25
36
344111-1 344108-1
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
1 6
14
7 14
173852
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
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 - øøøø
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
2
10
1 10
SWF593757
1
1
NMWP01F-B
4-55