Professional Documents
Culture Documents
Cat 4-1
Cat 4-1
1. LOCATION 1
7
9
B
3
A
C
Switch 10
panel 11
28
12
13
14
15
16
17
TONE 2
5 BAL
VOL
ON
BAND
SEEK
push
FAD
TUNE
1
4 PROG
3
PLL
SYNTHESIZE
R
TUNNING
1
6 19
20A
CAB
SPARE
HOLDER
LAMP
SPARE
FUSE
CABIN
LAMP
LAMP SPARE
BEACON
WORK
F/PUMP
LAMP & HEATER FUEL
AC
HEAD 3
MOTOR SOLENOID
LAMP HONE
WIPER 2
BOOM
SOL. LIGHT
SOLENOID
CIGAR
& HEATER SAFETY 1
AC
PANEL - HEAT SOLENOID
MOTOR PRE
SWITCH
WIPER
RY
CUT-OFF TRAVEL
FUEL
CONVERTOR HONE
PANEL
SWITCH RY -2
CR
COMP
AC RY
-7 ETHER
RY CR
POWER - 36
CR
- 35
CR
RY
SAFETY
-5
CR
2 CN-47
20
4
CN-19&19A
CN-19B
8 18
21
CN-92A
CN-92B
24 22
CN-16&16A
CN-16B
25
26 23
27
3207A4EL01
4-1
2. LOCATION 2
1
ON
OFF
1
1
CAB BOOM
3
7
2
6
9
10
5
11
12
3207A4EL02
4-2
1. POWER CIRCUIT
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.
1) OPERATING FLOW
Battery Battery relay Fusible link〔CN-60〕 Master switch〔CS-74〕
Fuse box〔No.1〕 l/conn〔CN-8(12)〕 Start switch〔CS-2(1)〕
Power relay〔CR-35(30)〕
ECM power relay〔CR-45(2)〕
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〕 I/conn〔CN-11(4)〕 AC & Heater controller〔CN-116(10)〕
I/conn〔CN-11(5)〕 AC & Heater controller〔CN-116(3, 4)〕
Relay〔Hi, M2〕
Fuse box〔No.4〕 I/conn〔CN-2(2)〕 ECM earth 〔CN-94(3, 4)〕
Fuse box〔No.5〕 I/conn〔CN - 5(4)〕 I/conn〔CN -17(5)〕 Wiper motor controller
〔CN-141(7)〕
Wiper motor〔CN-21(4)〕
Fuse box〔No.6〕 CPU controller〔CN-50(7)〕
※ I/conn : Intermediate connector
2) CHECK POINT
※ GND : Ground
4-5
CR-45
G45 B
1 2 1
18E W
ECM
2
93A Or
3
2 V
POWER RY
CN-10 4 4 3
CN-27
1
N.C 1
2 CR-35
S.R- 2 18 W
3 30
S.R- 3 93 R 87a 87 85
4 86
S.L- 4 103 3L
5 87
5 4 Y Y 99 G42 B
S.L- 85
6
POWER RY
30 86
N.C 6 7 87a
ILL+ 7 8
POWER CIRCUIT
S.R+ 8 9
S.R+ 9 10 CN-36
18 W START KEY 30A
ACC 10 11 1
CASSETTE RADIO
Y 4a 12 99 Y ROOM LAMP 10A
B+ 11 2
30A
8
65 2RW AC& HEATER
4
8
S.L+ 12 3
S.L+ 13 54 2L ECM 30A
4
5R
103
GY
CN-8
GY
Y
GND 14 110 R WIPER+ 10A
1 5
10A
3L
56 Gr CPU B+
105
2
1
6
CL-1
3 CLUSTER 10A
7
CS-1
54
4 CASSETTE RADIO 10A
8
DOOR SW
5
2L
6 CONVERTOR 10A
ROOM LAMP
5
ST C
CS-2 6 9
SWITCH PANEL 10A
6
9
8
7
5
4
1
6
3
15
14
13
12
11
10
7 10
BR ACC
1 4 9 5A
ECM V 2
R 22 R 93 2L 7 12
START KEY SW
H
4 3 10
OPTION 30A
13
0, I
2 11
W 24 W 18A START 20A
1 12 14
H 0 I
4-6
WIPER MOTOR 10A
15
20
19
7E
7A
2
1
BATTERY(+) 18
4 2
GB 10 10A
CN-94
BEACON LAMP
REVERSE FAN SIG 10 19
3
2RW 65A AC& HEATER 20A
AC & HEATER CONTROLLER 20
5W
4
ECM EARTH
5
BATT (-)
21
BATT (+)
BATT (+)
1 2 1
104
7 PRE-HEAT 10A
3 23
8 10A
3 4 4 TRAVEL
24
3
1 2 1 SOLENOID 1 10A
R 33 25
2 10A
CR-1
3 4 4 27
RELAY(M2) RELAY(HI)
2
FUEL FILLER P/P 30A
3 28
29 R R 110
FUSE BOX
CN-17 4
2
CN-21 1 5
60R
3 1 2 6 CS-74
2
5R
3 7 2
1
2
1
2
5 3 4 8 5R
1
CN-60
CN-95
CS-74
FUSIBLE LINK
R 4A 4 R
4 5 9
(12VX2)
4
MASTER SW
5 6 10
BATTERY
5R
5R
6 2 6 7 11
M CN-50
74
GY 56
5W 115
5W 104
116
8 12 BATTERY 24V(+) 7
60B
13
1
3207A4EL04
CN-141 R 4 15
CONTINUE 24V 7
2) CHECK POINT
Engine Start switch Check point Voltage
① - GND(Battery)
② - GND(Start key)
③ - GND(Battery relay M4)
OPERATING START ④ - GND(Starter B+) 20~25V
⑤ - GND(Starter M)
⑥ - GND(Start relay)
⑦ - GND(Battery relay M8)
※ GND : Ground
4-7
CR-45
G45 B
1 2 1
18E W
ECM
2
93A Or
3
2 V
POWER RY
CN-8 4 4 3
1
2 CR-35
18 W
3 30
93 R 87a 87 85
4 86
103 3L
5 87
6 G42 B
5 85
ST C
CS-2 6
POWER RY
30 86
6 7 87a
BR 21
3 5 8
2 BR 17
BR ACC
B
1 4 9
R 22 R 93 CN-36
START KEY SW
4
H
3 10
STARTING CIRCUIT
0, I
2 11
W 24 W 18A ROOM LAMP 10A
1 12 2
H 0 I
AC& HEATER 30A
3
ECM 30A
4
5R
103
2
WIPER+ 10A
5
CPU B+ 10A
3L
105
6
CLUSTER 10A
7
CASSETTE RADIO 10A
8
CN-51 CONVERTOR 10A
W 16 W/OR 37 9
ALT LEVEL 9 ANTI-RESTART RY 11
SWITCH PANEL 10A
10
CPU CONTROLLER
CPU 10A
11
ECM 5A
V 2
16
94
G41 B W/OR 37A 12
OPTION 30A
W
13
CN-92 BW START 20A
B/OR
127
14
4-8
WIPER MOTOR 10A
37
94
17
9
8
7
5
4
1
6
3
15
14
13
12
11
10
15
20A
CN-2
HEAD LAMP
BR
125 BW 16
W
B/OR
W/OR
WORK LAMP 20A
B/OR
17
CABIN LAMP 20A
86
87
85
30
18
87a
CR-5
17
12
BEACON LAMP 10A
87a
19
3
20A
30
87
AC& HEATER
20
5W
86
HORN 10A
CR-1
21
104
10A
ANTIRESTART RY
CIGAR LIGHTER
22
7
BATT RY
PRE-HEAT 10A
23
TRAVEL 10A
24
9
92
9E
9A
1
16A
10A
G32
SOLENOID 1
18 B
25
6
B
G
V
G
12 B/OR
10A
60R
SAFETY SOL
26
SOLENOID 3 10A
1
1
2
2
2
1
27
1
2
DO-2
DO-3
DO-1
FUEL FILLER P/P 30A
28
DIODE
DIODE
DIODE
FUSE BOX
(12VX2)
BATTERY
CR-23
CS-74
START RY
5R
60B
2
1
2
1
2
5R
17
1
CN-60
CN-95
CS-74
FUSIBLE LINK
W
5
15R
MASTER SW
5R
4
5R
B+
I
74
5W 115
5W 104
B+
116
CN-45
GND
CN-74
STARTER
~
3
M
3207A4EL06
G
U
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 "I" terminal I/conn〔CN-2(13)〕 CPU alternator level〔CN-51(9)〕
Cluster charging warning lamp(Via serial interface)
2) CHECK POINT
① - GND(Battery voltage)
② - GND(Battery relay)
Run ON ③ - GND(Alternator B+ terminal) 20~30V
④ - GND(Alternator I terminal)
⑤ - GND(CPU)
※ GND : Ground
4-9
SERIAL-TX
ALT LEVEL
SERIAL-RX
CLUSTER
TX
RX
GND
CN-5
POWER IG(24V)
1
CN-36
CPU CONTROLLER
2 30A
9
START KEY
30
29
1
RR
CN-50
CN-51
3 ROOM LAMP 10A
2
L
Y
4 AC& HEATER 30A
3
4
3
2
1
W 16
69
68
5 ECM 30A
CN-56
CHARGING CIRCUIT
4
5R
6 WIPER+ 10A
5
L
Y
7 CPU B+ 10A
105
6
70 SH SH 21
8 CLUSTER 10A
7
19
20
9 CASSETTE RADIO 10A
8
68 Y Y 19
10 CONVERTOR 10A
9
69 L L 20 10A
11 SWITCH PANEL
10
CPU 10A
12 11
ECM 5A
13 12
OPTION 30A
14 13
START 20A
15 14
WIPER MOTOR 10A
16
15
HEAD LAMP 20A
W
16
WORK LAMP 20A
17
9
8
7
5
4
1
6
3
15
14
13
12
11
10
CABIN LAMP 20A
4-10
CN-2
18
BEACON LAMP 10A
19
B/OR
W 17
AC& HEATER 20A
20
5W
12
HORN 10A
CR-1
21
104
BATT RY
2
PRE-HEAT 10A
23
TRAVEL 10A
24
9
1
16A
SOLENOID 1 10A
18 B
25
G
W
12 B/OR
10A
60R
SAFETY SOL
26
SOLENOID 3 10A
1
2
27
1
2
DO-1
FUEL FILLER P/P 30A
28
DIODE
FUSE BOX
(12VX2)
BATTERY
CR-23
CS-74
START RY
5R
60B
2
1
2
1
2
5R
17
1
CN-60
CN-95
CS-74
FUSIBLE LINK
W
3
4
15R
MASTER SW
5R
5R
B+
I
74
5W 115
5W 104
B+
116
CN-45
GND
CN-74
STARTER
~
3
M
G
U
ALTERNATOR
3207A4EL07
4. HEAD AND WORK LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.16) I/conn〔CN-7(7)〕 Switch panel〔CN-116(9)〕
Fuse box (No.17) I/conn〔CN-7(8)〕 Switch panel〔CN-116(10,11)〕
(1) Head light switch ON
Head light switch ON〔CN-116(1)〕 l/conn〔CN-7(1)] Head light relay〔CR-13(3)〕
Head light ON〔CL-4(2)〕
l/conn〔CN-10(2)〕 Cassette radio & Remote controller illumination ON〔CN-27(7), CN-114(9)〕
l/conn〔CN-11(8)〕 AC & Heater controller illumination ON
l/conn〔CN-6(8)〕 Cigarlight〔CL-2〕
(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)〕
2) CHECK POINT
Engine Start switch Check point Voltage
① - GND(Fuse box)
② - GND(Switch power input)
STOP ON 20~25V
③ - GND(Switch power output)
④ - GND(Head light relay)
⑤ - GND(Head light)
⑥ - GND(Fuse box)
STOP ON ⑦ - GND(Switch power input) 20~25V
⑧ - GND(Switch power output)
⑨ - GND(Work light)
※ GND : Ground
4-11
CN-11 CN-36
1 1 START KEY 30A
GND 1
GND 2 2 ROOM LAMP 10A
2
BATTERY(+) 3 3 30A
AC& HEATER
3
4 4
B+
BATTERY(+)
N.C
N.C
S.L-
S.L-
30A
ILL+
S.R-
S.R-
ACC
ECM
GND
S.L+
S.L+
S.R+
S.R+
G 5 4
ILLUMINATION 5 5
WIPER+ 10A
6 6 5
8
9
7
6
5
4
3
2
1
POWER IG
14
13
12
11
10
CPU B+ 10A
CN-27
NC 7 7 6
5 G R 6F
8 CLUSTER 10A
8
R
DUCT SENSOR(+) 7
CASSETTE RADIO 10A
DUCT SENSOR(GND) 9
2
8
AC&HEATER CONTROLLER
NC 10 CONVERTOR 10A
CN-10 9
NC 11 1 SWITCH PANEL 10A
CN-144 2R R 6E 10
1 NC 12 2
NC CPU 10A
11
R1 2 NC 13 3
ECM 5A
NC 3 4 12
14
OPTION 30A
R2 4 5 13
1
NC 5 START 20A
6 14
24V OUTPUT 6 WIPER MOTOR 10A
7 15
IG 24V INPUT 7
8 88 GY HEAD LAMP 20A
NC 8 16
R 2A 9 87 Y WORK LAMP 20A
ILLUMINATION 9 17
NC 10 10 CABIN LAMP 20A
18
HEAD AND WORK LIGHT CIRCUIT
REMOTE CONTROLLER
GND 11 11 10A
BEACON LAMP
NC 12 12 19
6
3
20
HORN 10A
21
CN-116 CN-7 122 CIGAR LIGHTER 10A
R 25 25 R R
HEAD LIGHT OUT 1 1 22
V 4 4 V V 91 PRE-HEAT 10A
WORK LIGHT OUT 2 2 23
V 4A TRAVEL 10A
WORK LIGHT OUT 3 3 24
4-12
WIPER MOTOR DRIVE 4 4 SOLENOID 1 10A
25
8
PRE-HEAT 5 5 SAFETY SOL 10A
26
POWER 24V 6 6 10A
29 GY GY 88 SOLENOID 3
2
27
CABIN LIGHT OUT 7 7
2 Y Y 87 FUEL FILLER P/P 30A
CABIN LIGHT OUT 8 8 28
GY 29
FUSE BOX
SWITCH PANEL
WORK LIGHT 24V 11 11
WASHER SIG 12 12
GND 13 13
7
TRAVEL ALARM 14 14
91
G2
INT. SIG 15 15
9
1
CN-12 B
V
2
1
2
3
4
5
6
CL-2
4
G1
6
122
88A
G43
1
2
5
1A
2A
B
R
7
6A
B
R
R
R 8 8 R R
Gr
V
B
B
CIGARLIGHT
9
3
2
4
1
2
1
1
2
1
2
10
CL-5
CL-4
CL-6
4
CR-13
11
1
12
HEAD LAMP
3207A4EL08
WORK LAMP
HEAD LAMP RY
5. BEACON LAMP AND CAB LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.19) I/conn〔CN-8(3)〕 Beacon lamp switch〔CN-23(6)〕
Fuse box (No.18) I/conn〔CN-7(12)〕 Switch panel〔CN-116(16, 17)〕
(1) Beacon lamp switch ON
Beacon lamp switch ON〔CS-23(2)〕 Switch lndicator lamp ON〔CS-23(9)〕
l/conn〔CN-8(4)〕 l/conn〔CN-10(10)〕
Beacon lamp ON〔CL-7〕
(2) Cab light switch ON
Cab light switch ON〔CN-116(7, 8)〕 I/conn〔CN-7(6)〕 I/conn〔CN-10(11)〕
Cab light ON〔CL-8(2), CL-9(2)〕
2) CHECK POINT
① - GND(Fuse box)
② - GND(Switch power input)
STOP ON 20~25V
③ - GND(Switch power output)
④ - GND(Beacon lamp)
⑤ - GND(Fuse box)
⑥ - GND(Switch power input)
STOP ON 20~25V
⑦ - GND(Switch power output)
⑧ - GND(Cab light)
※ GND : Ground
4-13
CN-116 CN-36
HEAD LIGHT OUT 1 START KEY 30A
CN-7
1
WORK LIGHT OUT 2 1 10A
ROOM LAMP
2
WORK LIGHT OUT 3 2
AC& HEATER 30A
WIPER MOTOR DRIVE 4 3 3
7
ECM 30A
PRE-HEAT 5 4 4
SWITCH PANEL
WORK LIGHT 24V 11 10 9
SWITCH PANEL 10A
WASHER SIG 12 11 10
1 R RW 86
10A
6
GND 13 12 CPU
11
TRAVEL ALARM 14 13 ECM 5A
12
INT. SIG 15 14
R 1 OPTION 30A
CABIN LIGHT 24V 16 13
15
R 1A START 20A
CABIN LIGHT 24V 17 14
WIPER MOTOR 10A
CN-10 15
20A
5
1 HEAD LAMP
16
2 WORK LAMP 20A
17
3
3 2B 2B G51 86 R/W CABIN LAMP 20A
4 18
97 Y BEACON LAMP 10A
5 19
6 AC& HEATER 20A
20
7 HORN 10A
8 21
1
9 22
6 G G 96
10 PRE-HEAT 10A
7 OR OR 89 23
11 TRAVEL 10A
4-14
24
12
SOLENOID 1 10A
25
SAFETY SOL 10A
26
SOLENOID 3 10A
3
7
6
27
3B
8
1
2
30A
7
9
FUEL FILLER P/P
3A B
B
28
7A OR
B
OR
G
FUSE BOX
2
1
1
CL-9
CL-8
CL-7
5
6
10
3
7
9
2
6
1
4
5
8
10
M
CABIN LIGHT
CS-23
BEACON LAMP SW
BEACON LAMP
Y
B
G
G
6
16
6A
G1
3
2
CN-8
1
2
16 Y Y 97
3
6 G G 96
4
5
6
7
8
9
10
11
12
3207A4L09
6. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
(1) Key switch ON
Fuse box (No.10) I/conn〔CN-7(5)〕 Switch panel〔CN-116(6)〕
Fuse box (No.5) I/conn〔CN-5(4)〕 I/conn〔CN-17(5)〕 Wiper motor controller〔CN-141(7)〕
Wiper motor〔CN-21(4)〕
Fuse box (No.15) I/conn〔CN-6(5)〕 l/conn〔CN-17(4)〕 Wiper motor controller〔CN-141(6)〕
Washer pump〔CN-22(2)〕
(2) Wiper switch ON : 1st step(Intermittent)
Wiper switch ON〔CN-116(15)〕 〔CN-9(4)〕 I/conn
I/conn 〔CN-6(10)〕 I/conn 〔CN-17(8)〕
Wiper motor controller〔CN-141(10) → (3)〕 Wiper motor intermittently operating〔CN-21(6)〕
(3) Wiper switch ON : 2nd step(Low speed)
Wiper switch ON〔CN-116(4)〕 I/conn〔CN-7(3)〕 I/conn〔CN-6(9)〕 I/conn 〔CN-17(2)〕
Wiper motor controller〔CN-141(2) → (4)〕 Wiper motor operating〔CN-21(2)〕
(4) Washer switch ON
Washer switch ON〔CN-116(12)〕 I/conn〔CN-7(9)〕 I/conn〔CN-5(1)〕 I/conn〔CN-17(7)〕
Wiper motor controller〔CN-141(9) → (8)〕 I/conn〔CN-17(6)〕 I/conn〔CN-6(11)〕
Washer pump〔CN-22(1)〕 Washer operating
Wiper switch ON〔CN-116(4)〕 I/conn〔CN-7(3)〕 I/conn〔CN-6(9)〕 I/conn〔CN-17(2)〕
Wiper motor controller〔CN-141(2) → (4)〕 Wiper motor operating〔CN-21(2), Low speed〕
(5) Auto parking(When switch OFF)
Switch OFF〔CN-116(4)〕 Wiper motor parking position by wiper motor controller
2) CHECK POINT
Engine Start switch Check point Voltage
① - GND(Fuse box)
24V
② - GND(Switch power input)
4-15
WIPER AND WASHER CIRCUIT
FUSE BOX
DO-5
CN-36
10E V
2
80A GrW
1
DIODE
3207A4EL10
4-16
-
+
S
ACCEL DIAL
A
B
C
CN-142
B
W
G/OR 13
12
11
5
4
3
1
8
7
6
2
CN-9
CN-36
CONTROLLER CIRCUIT
6
5
4
3
2
1
CN-16
B
W
G/OR
CN-51 56 GY
B 29
GND (POT&DIAL) 20
G/OR 30
5V (POT&DIAL) 21
NC 22
W 32
ACCEL DIAL SIG 23
NC 25
8 OR
NC 26
NC 32
NC 33
HYD TEMP SENDOR 34
4-17
CN-50
NC 6
GR 56
BATTERY 24V(+) 7
BR 48
PUMP EPPR(-) 8
CPU CONTROLLER
NC 9
PROGRAM DUMP 10
ANTI-RESTART RY 11
NC 12
NC 23
OR 8A
POWER IG 24
GND (MAIN) 28
SERIAL-TX 29
SERIAL-RX 30
GND 31
RS232 (+) 32
RS232 (-) 33
1
2
RS232 (GND) 34
NC 35
Or 52
1
1
2
2
FUSE BOX
PUMP EPPR(+) 36
CN-19B
44
75
CN-19 CN-19A
B
Or
Br
Or
Br
Or
52
48
59
1
2
G44
CN-75
CN-47 OR 8E
1
EPPR VLV
OR 59
2
RESISTER
3207A4EL11