5. 4 -5-1
1. POWER CIRCUIT (from #0180 to #1000)
The negative terminal of battery is grounded to the machine chassis through master switch.
When the start switch is in the OFF position, the current flows from the positive battery terminal as
shown below.
OPERATING FLOW
Battery Battery relay Fusible link¡†CN-60¡‡
Fuse box¡†No.1¡‡ l/conn¡†CN-8(12)¡‡ Start switch¡†CS-2(1)¡‡
Power relay¡†CR-35(30)]
Fuse box¡†No.2¡‡ I/conn¡†CN-10(6)¡‡ Room lamp¡†CL-1(2)¡‡ Door switch¡†CS-1¡‡
Cassette radio¡†CN-27(11)¡‡
Fuse box¡†No.3¡‡ l/conn¡†CN-11(4)¡‡ AC & Heater controller¡†CN -116(3, 4)¡‡
Fuse box¡†No.4¡‡ I/conn¡†CN - 5(4)¡‡ I/conn¡†CN -17(5)¡‡ Wiper motor controller
¡†CN-141(7)¡‡
Wiper motor¡†CN-21(4)¡‡
Fuse box¡†No.5¡‡ CPU controller¡†CN-50(7)¡‡
Fuse box¡†No.6¡‡ I/conn¡†CN-11(5)¡‡ Relay(Hi, M2)
¡ I/conn : Intermediate connector
CHECK POINT
Engine Start switch Check point Voltage
1)
2)
¡ GND : Ground
OFF OFF
¤ - GND (Battery 1EA)
¤Ł- GND (Battery 2EA)
¤Ø- GND (Battery 2EA)
¤Œ - GND (Fusible link)
10~12.5V
20~25V
20~25V
20~25V
9. 3. CHARGING CIRCUIT(up to #1000)
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.
OPERATING FLOW
Warning flow
Alternator¡ I¡–terminal I/conn¡†CN-3(6)¡‡ CPU Controller [CN-51(9)]
Cluster warning lamp (Via serial interface)
Charging flow
Alternator "B+" terminal Battery relay(M8) Battery(+) terminal
Reset button[CS-61] Fuse box
4-8
Engine Start switch Check point Voltage
¤ - GND (Battery voltage)
¤Ł- GND (Battery relay)
ON ON ¤Ø- GND (Alternator B¡qterminal) 20~27V
¤Œ- GND (Alternator I terminal)
¤º- GND (CPU)
1)
2)
(1)
(2)
CHECK POINT
¡ GND : Ground
13. 4 -12
5. WORK LAMP CIRCUIT(up to #1000)
OPERATING FLOW
Fuse box (No.15) I/conn [CN-7(8)] Switch panel [CN-116(10,11)]
¡ When work lamp switch ON
Work lamp switch ON [CN-116(2,3)] I/conn [CN-7(2)] I/conn [CN-12(1)]
Work lamp ON [CL-5(2), CL-6(2)]
Engine Key switch Check point Voltage
¤ - GND (Fuse box)
¤Ł- GND (Switch power input)
¤Ø- GND (Switch power output)
¤Œ- GND (Work lamp)
1)
2) CHECK POINT
¡ GND : Ground
STOP ON 20~25V
23. 4-22
1
1
4-19 ELECTRIC CIRCUIT FOR HYDRAURIC
CN-50
CN-51
36PUMPEPPR(+)
35NC
34RS232(GND)
33RS232(-)
32RS232(+)
31GND
30SERIAL-RX
29SERIAL-TX
28GND(MAIN)
27NC
26NC
25NC
BOOMPRIORITYSOL
BRAKEFAILLAMP
POWERIG
BATTERY24V(+)
NC
PARKINGSW
T/MOILLAMP
ENGPREHEATER
NC
COCANCELSOL
HOUR-METER
ACCELACT(-)
ENGOILFILTERSW
PRE-HEATSW
TRAVELSPEEDSOL
OVERLOADSIG
24
NC
23
22
21
20
19
POWERMAXSOL
18
17
16
15
PUMPEPPR(-)
14
TRAVELBUZZER
13
MAXFLOWSOL
ACCELACT(+)
ANTI-RESTARTRY
NC
12
11
10
9
8
7
6
5
4
3
2
1
36NC
35NC
34HYDTEMPSENDOR
33WATERTEMPSENDOR
32PUMPPROLIXSW
31GND(SENSOR)
30NC
29ACCELSW
28T/MOILPS
27BRAKEFAILPS
26TACHOSENSOR(+)
25TACHOSENSOR(-)
WORKINGPS
WATERLEVELSW
FUELLEVELSENSOR
24V(PRES.SENSOR)
POT-SIG
TRAVELHi/LoSW
O/TDECELSW
NC
ALTLEVEL
BOOMUPPS
ENGOILPS
ACCELDIALSIG
5V(POT&DIAL)
HEAVYLIFTSW
TRAVELOILPS
GND(POT&DIAL)
24
P1PRESSSIG.
23
22
21
20
19
TRAVELALARMSW
18
17
16
15
GND(PRES.SENSOR)
14
AIRCLEANERSW
13
POWERMAXSW
P3PRESSSIG.
P2PRESSSIG.
BKT&ARMINPS
12
11
10
9
8
7
6
5
4
3
2
1
2
1
Pa
2
1
2
1
Pa
2
1
2
1
2
1
2
1
2
1
2
1Pa
2
1Pa
2
1
2
1
2
1
2
1
2
1C
27
10A
26
10A
25
10A
24
5A
23
10A
22
5A
21
EARTH 1
FUSE BOX
CD-37
CD-31
OVERLOAD PS
CN-91
1
2
CN-131 BOOM DOWN EPPR
BOOM DOWN PRESS
GND
SIG
24V3
2
1
CD-32
CD-33
BOOM UP PRESS
GND
SIG
24V3
2
1
6
5
4
3
2
1
CN-14
DO-4
QUICK COUPLING
CN-140
CN-13
1
2
CN-66
BREAKER SOL.
SAFETY SOL
CN-68
CN-81
TRAVEL BZ
2PCSBOOMAUTO-IDLEPS
CN-15CN-15
2
1
SPARE
FUELFILLERP/P
SOLENOID3
SAFETYSOL
SOLENOID1
TRAVEL
TRAVEL
PS
CD-6
CD-7
WORK
PS
CN-133
BOOM
PRIORITY1
CN-137
MAX
FLOW
CN-88
POWER
MAX
CN-70
TRAVEL
CD-1
HYD
TEMP
12
11
10
9
8
CN-7
7
6
5
4
3
2
1
12
11
10
9
8
CN-6
7
6
5
4
3
2
1
8
CN-4
7
6
5
4
3
2
1
CN-2
6
5
4
3
2
1
12
11
10
9
8
7
CN-8
6
5
4
3
2
1
CPU CONTROLLER
21
10A
20
10A
ETHER(PRE-HEAT)
CIGARLIGHTER
7
8
6
2
10
9
8
7
6
5
4
3
2
1
109
5
1
CABIN LIGHT 24V
CABIN LIGHT 24V
INT. SIG
TRAVEL ALARM
GND
WASHER SIG
WORK LIGHT 24V
WORK LIGHT 24V
HEAD LIHGT 24V
CABIN LIGHT OUT
CABIN LIGHT OUT
POWER 24V
PRE-HEAT
WIPER MOTOR DRIVE
WORK LIGHT OUT
WORK LIGHT OUT
HEAD LIGHT OUT
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
2
1
CN-116
SWITCH PANEL
BREAKER SW
CS-27
BREAKER
CS-26
7
8
6
2
10
9
8
7
6
5
4
3
2
1
109
5
1
I
CS-52
BOOM DAMPING SW
CS-67
CS-50
QUICKCOUPLINGSWOVERLOADSW
2
1
2
1
SAFETY SW
CS-20
A
CB
C
B
A
POWER MAX
CS-19
ONE TOUCH DECEL
CS-29
CS-4
SAFETY SW
CD-44
PUMP1 PRESS
GND
SIG
24V 3
2
1
CD-43
CD-42
PUMP2 PRESS
PUMP3 PRESS
GND
SIG
24V 3
2
1
GND
SIG
24V 3
2
1
6
5
4
3
2
1
CN-16
20
10AHORN
10
9
8
7
6
5
4
3
2
10
9
8
7
6
5
4
3
2
7
8
6
2
109
5
1
7
8
6
2
109
5
1
R
OR
R
Y
GY
OR
Y
L
G
B
GY
OR
Y
L/W
G
B
GY
OR
Y
L/W
G
Y
B
B
B
B
LL
L
G
G
GY
OR
OR
Y
B
GY
B
G
OR OR
G
GY
Y
G
GY
Y
W
L
BR
G
R
G
V
B
G
GY
L
V
W
V
BR
W
R
B
Y
R
G
GY
Y
R
BR
R
L
R
G
Y
W
G
Y
G
R
RR
VV
BB
VW
VV
RR
R
G
W R
G
W
R
B
V
V
R
B
Y
B
YY
B
B
L
B
L
GY
B
GY
OR
GY
OR
GY
OR GY
GY
GY
B
G
B
G
B
G
B
W
R
V
BR
B
W
R
V
BR
B
W
R
V
B
W
R
V
B
BR
BR
B
B
R
R
R
G
W
R
G
W
R
G
W
GY
B
Y
B
Y
Y
R
B
B
B
B
B
ELECTRIC CIRCUIT FOR HYDRAULIC(up to #1000)
21074EL12
24. 4 -54
1. POWER CIRCUIT (#1001 and up, TIER II)
The negative terminal of battery is grounded to the machine chassis through master switch.
When the start switch is in the OFF position, the current flows from the positive battery terminal as
shown below.
OPERATING FLOW
Battery Battery relay Fusible link¡†CN-60¡‡
Fuse box¡†No.1¡‡ l/conn¡†CN-8(12)¡‡ Start switch¡†CS-2(1)¡‡
Power relay¡†CR-35(30)]
Fuse box¡†No.2¡‡ I/conn¡†CN-10(6)¡‡ Room lamp¡†CL-1(2)¡‡ Door switch¡†CS-1¡‡
Cassette radio¡†CN-27(11)¡‡
Fuse box¡†No.3¡‡ l/conn¡†CN-11(4)¡‡ AC & Heater controller¡†CN -116(3, 4)¡‡
Fuse box¡†No.4¡‡ I/conn¡†CN - 5(4)¡‡ I/conn¡†CN -17(5)¡‡ Wiper motor controller
¡†CN-141(7)¡‡
Wiper motor¡†CN-21(4)¡‡
Fuse box¡†No.5¡‡ CPU controller¡†CN-50(7)¡‡
Fuse box¡†No.6¡‡ I/conn¡†CN-11(5)¡‡ Relay(Hi, M2)
¡ I/conn : Intermediate connector
CHECK POINT
Engine Start switch Check point Voltage
1)
2)
¡ GND : Ground
OFF OFF
¤ - GND (Battery 1EA)
¤Ł- GND (Battery 2EA)
¤Ø- GND (Battery 2EA)
¤Œ - GND (Fusible link)
10~12.5V
20~25V
20~25V
20~25V
28. 4 -58
CHECK POINT
3. CHARGING CIRCUIT (#1001 and up, TIER II)
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.
OPERATING FLOW
Warning flow
Alternator "I" terminal I/conn¡†CN-3(3)¡‡ CPU alternator level¡†CN-51(9)¡‡
Cluster charging warning lamp(Via serial interface)
Charging flow
Alternator "B+" terminal Battery relay(M8) Battery(+) terminal
Reset button¡†CN-60¡‡ Fuse box
1)
2)
(1)
(2)
¡ GND : Ground
Engine Start switch Check point Voltage
Run ON
¤ - GND(Battery voltage)
¤Ł- GND(Battery relay)
¤Ø- GND(Alternator B+ terminal)
¤Œ- GND(Alternator I terminal)
¤º- GND(CPU)
20~30V
30. 4 -60
4. HEAD AND WORK LIGHT CIRCUIT (#1001 and up, TIER II)
OPERATING FLOW
Fuse box (No.14) I/conn¡†CN-7(7)¡‡ Switch panel¡†CN-116(9)¡‡
Fuse box (No.15) I/conn¡†CN-7(8)¡‡ Switch panel¡†CN-116(10,11)¡‡
Head light switch ON
Head light switch ON¡†CN-116(1)¡‡ l/conn¡†CN-7(1)]
Head light ON¡†CL-4(2)¡‡: Head lamp ON
l/conn¡†CN-10(2)¡‡ Cassette radio illumination ON¡†CN-27(7)¡‡
l/conn¡†CN-11(8)¡‡ AC & Heater controller illumination ON
l/conn¡†CN-6(8)¡‡ Cigar light¡†CL-2¡‡
Work light switch ON
Work light switch ON¡†CN-116(2,3)¡‡ l/conn¡†CN-7(2)¡‡ l/conn¡†CN-12(1)¡‡
Work light ON¡†CL-5(2), CL-6(2)¡‡
CHECK POINT
1)
¡ GND : Ground
(1)
(2)
2)
Engine Start switch Check point Voltage
STOP ON
ONSTOP
¤ - GND(Fuse box)
¤Ł- GND(Switch power input)
¤Ø- GND(Switch power output)
¤Œ- GND(Head light)
¤º- GND(Fuse box)
¤ - GND(Switch power input)
¤ -GND(Switch power output)
¤ - GND(Work light)
20~25V
20~25V