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
2 11
3 12
4
5 13
6
7
Switch
panel 2

Switch
panel 1

14

8 15
16
9
17
18

19

5594EL02

1 Head light switch 8 Breaker operation switch 15 Fuse box

2 Work light switch 9 Accel dial switch 16 Cigar lighter
3 Travel alarm switch 10 Quick clamp switch 17 Horn switch
4 Cab light switch 11 Wiper switch 18 Radio & CD/MP3 player
5 Beacon switch 12 Washer switch 19 Aircon & heater controller
6 Breaker selection switch 13 Master switch
7 Start switch 14 Speaker

4-1
2. LOCATION 2

Cabin 8
3
9
14 10

11
7
56 12
4

13
1

5594EL03

1 Lamp 6 Fuel filler pump 11 Engine oil pressure switch

2 Horn 7 Washer pump 12 Relays
3 Master switch 8 Fuel sender 13 Travel alarm buzzer
4 Battery 9 Temperature sender 14 MCU
5 Battery relay 10 Air clearer switch

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
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.

(2) Start of engine

Η Check machine condition
a. Tachometer pointed at present rpm
b. Gauge and warning lamp : Indicate at present condition.
ö When normal condition : All warning lamp OFF
c. Travel speed pilot lamp : Low (turtle)
Θ 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 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 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 Over heat signal Input

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.

(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
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

(2) Hydraulic oil temperature warning lamp

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

R5573CD11

(3) Overheat warning lamp

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

R5573CD12

(4) Engine oil pressure warning lamp

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

R5573CD13

(5) Air cleaner warning lamp

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

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

(7) Warming up pilot lamp

Η This lamp is turned ON when the coolant temperature is below
30˚C (86˚F).
Θ 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

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

R5573CD19

(9) Travel speed pilot lamp (high)

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

R5573CD20

(10) Travel speed pilot lamp (low)

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

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.

(12) M mode pilot lamp

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

55W7A3CD83

(13) Boom offset pilot lamp

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

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

(2) Auto idle switch

Η This switch is used to actuate or cancel the auto idle function.
Θ 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

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

555C93CD23

(4) Move (down) & buzzer stop switch

Η When the starting switch is turned ON first, normally the alarm
buzzer sounds for 6 seconds during lamp check operation.
Θ 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.
Ι This switch is used to move down or decrease input value.
ö Refer to page 4-11.

(5) Move (up) switch

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

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.

Ι 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 ( ).
ÂYES : ESL function is activated.
ÂNO : ESL function is cancelled.
Κ 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)
ö 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
 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

Μ 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 ( , ).



ö
Refer
Refer to the following pages for the fault codes.

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

TRAVEL HI-LO SOL

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

CIGAR ,WIPER MOTOR

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

AC & HEATER CONTROLLER

BATTERY(+) 4 2

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

REVERSE FAN SIG 10 3 4

26 LG
1 Lo 1
B

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

USB & SOCKET ASSY

000 1
POWER IG 10
74 0.5BW
SEAT HEATER

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

MP3 & RADIO PLAYER

SPK FRT RH+ 11 7
80 0.5L 7
WASHER SW

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

FUEL LEVEL SENDOR 15

30

69 Y
87a 87

SAFETY SW
30

2
87a 87

HYD OIL TEMP SENDOR 16

R
Or
2B

68 GW
86

85
86

85

WATER TEMP SENDOR 17

BEACON LAMP

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

WATER LEVEL SIG. 1

ENG.OIL PS 2 63 G
2
1

70 Or
M

CS-74

AIR CLEANER SIG.

2SQ

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

BOOM SWING SIG. 4

2
1

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

BRAKE FAIL SIG.

6 G

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

OVER LOAD SIG.

22 Br
12 RW

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

ENG.OIL FILTER SIG. 8

Gr
G

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

HEAD LIGHT OUT

WORK LIGHT OUT
ECU IG POWER
CL-3

CL-4

RACK ACTUATOR

ECU MAIN POWER

ROOM LAMP
BEACON LAMP

PRE HEAT SIG. 16

CN-57
HEAD LAMP

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

AIR CLEANER SW sig B 1

45 Or B 2
RETURN C B
BOOM
SWING

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

D OUT GOV. MOTOR 19

CN-16
1.2ROr 80 1
BATT. 12V 20
6 2
2 RS232 TX2 21
5
1 RS232 RX2 22
4
PROGRAM DUMP 23 69 0.8Gr 2.5k
3
1 D IN SPARE3 24 68 0.8W
Govenor DC MOTOR Controller

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

D OUT SPARE 1(SOL) 28

66
A IN TACHO SIG 29
1.2BW 81
POWER IG 12V 30
6
5
4
3
2
1

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

RACK POSITION SIGNAL 36

W 23
ACCEL POSITION SIG. 35 CN-60
Gr 11
30A
CIRCUIT BREAKER

MAIN POWER RY(-) 34

G 8
RACK AC RY(-) 33
LOAD MONITOR- 32
Vi 70
EGR STPM A 31
G 31
RECAN 30
NC 29
B 22E
SENSOR GND 28
EGR TEMP 27
INTAKE AIR TEMP 26
ECU

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
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)]

ö I/conn : Intermediate connector

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

R/LAMP & A/C HEATER

MCU

MCU

CASSETTE RADIO

AC FAN

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

CR-68
FUSE BOX

GW
1
GW 6 3 1
2
3
4
6 2 4
VW
GW

ECU MAIN POWER RY

G
R
R

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

D OUT GOV. MOTOR

5
4

1
6

2
3

BATT. POWER 12V

SENSOR SPARE2

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

GOVENOR DC MOTOR CONTROLLER START KEY SW CLUSTER MP3 &RADIO

PLAYER
5594EL04

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)

ö Start switch : START

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

2) CHECK POINT
Engine Start switch Check point Voltage
Η
 GND (battery)
Θ
 GND (start key)

Ι

GND (battery relay M4)

Operating Start
Κ

GND (starter B+)
10~12.5V
Λ
 GND (starter M)
Μ
 GND (start relay)
Ν

GND (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

FUEL P/P, HORN

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

CABIN LAM/FUEL FEED P/P

CN-36
BATT.POWER 12V 9 85

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
Ι

GND (alternator B+ terminal)
10~12.5V
Κ

GND (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

FUEL P/P, HORN

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

CABIN LAM/FUEL FEED P/P

CN-36
BATT.POWER 12V 9 85

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

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 (head light)
Λ - GND (fuse box)
Μ - GND (switch power input)
STOP ON 10~12.5V
Ν
GND (switch power output)
Ξ
- GND (work light)
ö GND : Ground

4-24
 HEAD AND WORK LAMP CIRCUIT

FUSE BOX CN-36

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

5 6 7 CABIN LIGHT OUT

6 BEACON
6

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

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.

ANALOG

ILL(+)
GND
GND

CLUSTER REMOTE USB & MP3 &

CONTROLLER SOCKET RADIO
ASSY PLAYER

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

FUSE BOX CN-36

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

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
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

HYD OIL TEMP

FUEL SENDOR

AIR CLEANER SW

5594EL10
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

20A
20A
30A

40A

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

AC FAN

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
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

HEAD LIGHT OUT 14

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

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

Part name Symbol Specification Check

ö Check specific gravity

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

ö Check coil resistance

Rated load 
12V
1 Normal : about 12̫

Battery relay 2 100A (continuity)
ö Check contact
1000A (30 second)
CR-1
CR-1 Normal : â̫

BR ACC ST C
öCheck contact
H
5
6
2
3
4

H0 I

OFF : â̫(for each terminal)

Start key 0, I 12V
1

B ON : 0̫(for terminal 1-3 and 1-2)

CS-2
3
2

6
1

4
5

START : 0̫(for terminal 1-5)

Pressure switch Pa 0.5 kgf/cm2 ö Check resistance

(for engine oil) (N.C TYPE) Normal

0̫(CLOSE)

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

Relay 1 12V 60A ö Rated coil current 1.2Ü0.3A

2 2 C2

CR-23 CR-24 CR-47

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

CL-3 CL-4 CL-5

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

Horn 2 12V 100Ü5dB

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)

2 Pa 10bar ö Check contact

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

CD-7 CD-11 CD-12

M 12V ö Check disconnection

Beacon lamp
(Strobe type) Normal : a few̫

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

öCheck coil resistance

3
Normal : about 1M̫

2
Cigar lighter 12V 10A 1.4W ö Check contact
1
Normal : â̫


CL-2
CL-2 Operating time : 5~15sec

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+

SPK FRT LH+

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

REMOCON+
BACK UP+
TEL MUTE

CD/MP3 player
ANT 12V

(for terminal 1-3, 3-8)

GND

GND
ACC

ILL+
ILL-

NC

NC

CN-27

2 Pa
ö Check contact
Receiver dryer 1 12V



Normal : 0̫

CN-29

M B+
ö
Check contact
Starter 12V
Normal : 0.1̫
M
CN-45

B+
G
2 s ö
Check 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

Travel buzzer 12V -

CN-81

Compressor 12V 38W -

CN-28

Air con 1 M
12V 8.5A -
fan motor 2
CN-83

M 1
Fuel feed pump 2 12V -

CN-145

Master switch 12V 1000A -

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

4-37
 Part name Symbol Specification Check

Preheater 12V 42A 500W -

CN-80

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

Int wiper relay 12V 12A -

3
1
CR-6

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

Connector No. of Connector part No.

Type Destination
number pin Female Male
CN-1 AMP 12 Cabin room harness - Main harness S816-012002 S816-112002
CN-2 AMP 12 Aircon harness - Cabin room harness S816-012002 S816-112002
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 AMP 10 Console harness - Main harness S816-010002 S816-110002
CN-12 AMP 2 Boom harness - Work lamp harness S816-002002 S816-102002
CN-20 DEUTSCH 2 Horn DT06-2S-EP06 -
CN-21 AMP 4 Wiper harness 180900-0 -
CN-22 KET 2 Washer tank MG640605 -
CN-23 MOLEX 2 Speaker LH MG610070 -
CN-24 MOLEX 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 AMP 3 Hour meter S816-003002 S816-103002
CN-55 AMP 2 Travel alarm PS S816-002002 S816-102002
CN-56 AMP 12 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 -
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 -

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

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 - øøøø

Modifications (see below)

Number of contacts (P : Pin, S : Socket)
04 : Receptacle, 06 : Plug
Deutsch connectors
ö 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