GROUP 2 ELECTRICAL CIRCUIT

CAB PART DASHBOARD PART

FRAME / ENGINE PART

20D7EEL02

7-2
MEMORANDUM

7-3
1. POWER CIRCUIT
The negative terminal of the battery is grounded to the machine chassis.
When the start switch is in the OFF position, the current flows from the positive battery terminal.
1) OPERATING FLOW
Battery(+) Start motor[CN-45(B+)] Fusible link[CN-95A(1→2)] Alternator[CN-74(B+)]
I/conn[CN-1(12,13,14) Start switch[CS-2(3)]
Start relay[CR-23(87)]
Fuse box[CN-36] (No.1) Cab[CN-7(1)]
OPSS buzzer[CN-113(2)]
Horn[CN-25(2)]
Brake switch[CD-4]
(No.2) Flasher unit[CR-11(2)]
(No.3) Opss unit[CN-55(12)]

2) CHECK POINT

Engine Key switch Check point Voltage

① - GND (Battery(+))
② - GND (Fusible link)
OFF OFF 10 ~ 13V
③ - GND (Fuse No.1, 2, 3)
④ - GND (Start key)

7-4
 POWER CIRCUIT

3 4 CS-2 CL-16
CN-36 390 W
1 ST RW
200 RW HORN/BRAKE LAMP 10A 4
120 R
3 2 CL RB

H0 I
210 Gr TURN LAMP 10A
2

2
3 TN R

0,
212 Y OPSS UNIT 5A
1

I
START RELAY 5A 4 BR 4 BK LW
- ACC

4
1 R1
ILL/HEAD LAMP 15A B3 5
4 BR G1

5
TRAVEL 5A - ACC
4 BR 6 B GN

6
IG(STOP SOL/ALT) 5A - ACC
2 R2
R/COMBI RH

7
PREHEATING 5A - ST

8
CLUSTER 5A START KEY

9 10 11 12
WORK/BEACON LAMP
CN-17 10A CL-15
200 RW FOR CABIN 15A 390 W
1 1 ST RW
OPSS SYSTEM 5A
2 2 CL RB
3 CD-4 3 TN R
4 FUSE BOX 200 RW
Pa CN-4 4 BK LW
(FOR CABIN) 390 W
1 5
G1
BRAKE SW 2 6 B GN

3 R/COMBI LH
CN-113 4
1 5
200 RW
2 6
OPSS BUZZER 7
8
CR-11 9
L 1 10
G 210 Gr
B 2 11
E 3
12
FLASHER UNIT
CN-55
IGN 1
CN-1
SEAT S/W 2
1
REV S/W 3
CR-23 2
FWD S/W 4 120 R
86 30 87
TRAVEL CUT 5 3
RELAY2 6
30 4
GND 7 86
5
OPS-LAMP 8 85 87 85
6
BUZZER(-) 9 STARTER RELAY 7
BRAKE S/W 10
8
CN-74
RELAY3 11
212 Y 9 1 IG
BATT(+) 12 U
10 2 L
PARK'G S/W 13
14 11
~
120 120 R 120 R 120 R 3 G
OPSS UNIT SP1
12
SP4
B+
120 R 120 R
13 ALTERNATOR
120 R 120 R
14
15
CN-25 16 110 W
CN-95A 2
380 V 2
1 17 100 R
200 RW 1
2 18
F/LINK
HORN
CN-45
M
M
100 R
380 V

B+
G1 B

START MOTOR
CS-12
CS-11

2
3

5
6
7
8
9
4
5

1
1

3
4
2

38SQ(R)
4-FWD

2-TRH
1-TLH
5-REV

4-HO
8-Hi
6-ILL

7-Lo

OPTION

38SQ(B) 38SQ(B)
>

BATTERY
3-HO

3-C 9-C 12V MASTER SW

5-C 1
GEAR SELECTOR COMBI SWITCH

20D7EEL03

7-5
2. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Start motor[CN-45(B+)] Fusible link[CN-95A]
+
Alternator[CN-74(B )] I/conn[CN-1] Start switch[CS-2(3)]
Start relay[CR-23(87)]
Glow relay[CR-24(30)]
※T
The engine can be started only when the gearshift is in neutral position.
(1) When start key switch is in ON position
Start switch ON [CS-2(4)] Fuse box[No. 5→7] [CN-1(19)] Fuel stop solenoid[CN-87(1)]
Fuse box[No. 5→8] Glow relay[CR-24(85→87)] I/conn[CN-1]
Fusible link[CN-95B] Glow plug[CN-80]

(2) When start key switch is START position

Start switch START[CS-2(2)]
Fuse box[CN-36(4)] Glow controller[CN-62(3)]
Neutral relay[CR-5(4→2)]
Safety relay[CR-23(86→30)] I/conn[CN-1] Starter

2) CHECK POINT

Engine Key switch Check point Voltage

① - GND (Battery B+)

② - GND (Fusible link)
Running ON ③ - GND (Fuse box) 10 ~ 14.5V
④ - GND (Start key)
⑤ - GND (Starter relay)

7-6
 STARTING CIRCUIT

3 CS-2
CN-36 170 W
HORN/BRAKE LAMP 10A 4
120 R
3

H0 I
TURN LAMP 10A 180 WR
2

0,
CLUSTER 5A
CR-5 1

I
4 BR
220 Br 220 Br START RELAY 5A - ACC
3 4 4

4
1 R1
ILL/HEAD LAMP 15A B3
3 4 BR

5
320 YB TRAVEL 5A - ACC
2
4 4 BR

6
250 Or IG(STOP SOL/ALT) 5A - ACC
1 2 1 2 R2

7
PREHEATING - ST
RELAY NEUTRAL 260 V 5A

8
CLUSTER 5A START KEY

9 10 11 12
WORK/BEACON LAMP 10A
FOR CABIN 15A
OPSS SYSTEM 5A

FUSE BOX

5 CN-1
1
CR-23 2 CN-95B
86 30 120 R 160 Br
87 3 2
150 Y 170 W
30 4 1
320 YB
86 F/LINK
G1 B 5
85 87 85
6 CN-80
STARTER RELAY
7 170 W
8
CN-62 GLOW PLUG
9
CONTROLLER
GLOW

SENSOR 6
430 PG 10
COIL 5
G1 B 11 CN-87
EARTH 4
220 Y 120 120 R 120 R 150 Y
START 3 12 2
SP1 120 R 120 R SP4 250 Or
LAMP 2 13 1
260 V 120 R 120 R
ON 1 14
STOP SOL
15
CR-24 16
86 30 160 Br
87
120 R 17
30 CN-74
430 PG 18
86 250 Or 250 Or
85
260 V 19 1 IG
85 87 160 160 160 U
20 2 L
GLOW RELAY SP2 160
21
160 SP5 ~
160 160 120 R 3 G
22 B+
23
ALTERNATOR
24
CN-95A
25 110 W
2
2
26 100 R
150 150 Y 150 Y 150 1
27
SP3 150 Y 150 Y SP6 F/LINK
28
CN-45
150 Y
M
M
100 R
B+
START MOTOR

38SQ(R)
OPTION

38SQ(B) 38SQ(B)

BATTERY
12V MASTER SW
1

20D7EEL04

7-7
3. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator release the start switch to the ON
position. Charging current generated by operating alternator flows into the battery.
The current also flows from alternator to each electrical component through the fusible link(CN-95A)
and the fuse box.
1) OPERATING FLOW
(1) Warning flow
Alternator[CN-74(L)] I/conn[CN-2(18)] Cluster charging warning lamp ON[CN-56(14)]
(2) Charging flow
Alternator[CN-74(B+)] Fusible link[CN-95A] Starter motor[CN-45(B+)]
Battery (+)terminal Charging

2) CHECK POINT

Engine Key switch Check point Voltage

① - GND (Alternator B+)

ON ON ② - GND (Start switch) 10 ~ 14.5V
③ - GND (Cluster)
※ GND : Ground
※ Cautions
1. When using an arc welder, always disconnect the ground lead from the battery to prevent alternator
or battery damage.
2. Attach the welding ground clamp as close to the weld area as possible to prevent welding current
from damaging the bearings of the alternator.
3. Do not disconnect the battery when the engine is running. The voltage surge can damage the
diode and resistors in the electrical system.
4. Do not disconnect an electric wire before the engine is stopped and the switches are OFF.

7-8
CHARGING CIRCUIT

CN-36 CS-2
170 W
HORN/BRAKE LAMP 10A 4
120 R
3

H0 I
TURN LAMP 10A 180 WR
2

0,
CLUSTER 5A
1

I
START RELAY 5A 4 BR
- ACC
2 CN-56

4
1 R1
ILL/HEAD LAMP 15A B3
4 BR 1 GLOW LAMP(-)

5
TRAVEL 5A - ACC
4 BR 2 GLOW LAMP(+)

6
250 Or IG(STOP SOL/ALT) 5A - ACC
2 R2 3 -
7
PREHEATING 5A - ST 4 OPSS LAMP
8
CLUSTER 5A START KEY 5 WATER SEPARATOR
9 10 11 12

WORK/BEACON LAMP 6 BRAKE OIL LEVEL

10A
7 PARKING BRAKE
FOR CABIN 15A
8 ENGINE CHECK
OPSS SYSTEM 5A 9 -
10 TURN SIGNAL RH
11 HEAD LAMP
FUSE BOX
12 TURN SIGNAL LH
448 Lg 13 AIR FILTER
14 CHARGE LAMP
15 -
16 T/M OIL TEMP
CN-1 17 ENG. OIL PS

1
3 18 FUEL EMPTY
19 ILLUMINATION
2 20 EARTH
3 CLUSTER
4
5
6
7
8
9
10
11 CN-87
120 120 R 120 R 150 Y
12 2
SP1 120 R 120 R SP4 250 Or
13 1
120 R 120 R
14
STOP SOL
15
16
17
CN-74
448 Lg 448 Lg 250 Or
18 1 IG
250 Or 250 Or 448 Lg U
19 2 L
20
~
120 R 3 G
21 B+
22
ALTERNATOR
23
24
1
25 CN-95A
110 W
2
26 100 R
1
27
28
F/LINK
CN-45
150 Y
M
M
100 R
B+
START MOTOR

38SQ(R)
OPTION

38SQ(B) 38SQ(B)

BATTERY
12V MASTER SW

20D7EEL05

7-9