CHAPTER 11

ELECTRIC SYSTEM
 ELECTRICAL SYSTEM

1. HOW TO READ WIRING DIAGRAM

1.1 WIRE CODE

The codes used in wiring diagram represent the size
of wire and the color of insulating cover.
ex) AVS(SS,X) 0.85GR
A : Low-tension cables for automobiles
V : Vinyl insulated
S : Thin-wall type
SS : Very thin-wall type
X : Cross-linked
0.85: Cross sectional area of wire (0.85mm2)
G: Base color of insulating cover
R: Stripe color on the base color
C45WB01A

• When the wire color is striped, the base

(1) Wire
color is given first, followed by the stripe
color as shown below: (2) Stripe ColorBase Color
CAUTION Example : LW = Blue with White stripe (3) Base Color

1.2 WIRE SIZE Code Color Code Color

B Black Y Yellow
The allowable current for wire is specified by cross
L Blue Lg Light-Green
sectional area of wire, and it is marked on the wire
cover. To avoid wire damage, a proper size (sufficient W White Gr Gray
capacity) of wire for electric load should be used when Br Brown O Orange
installing the optional electric equipment. The thick-
ness of wire is determined by considering ambient G Green P Pink
temperature, wire length, current continuity time, and R Red BY Black/Yellow
vibration.
BW Black/White LgR Light-Green/Red

Specification Allowable current BR Black/Red LgW Light-Green/White

AVSS 0.5 11A YG Yellow/Green BL Black/Blue

AVSS 0.85 14A YBr Yellow/Brown LW Blue/White

AVSS 1.25 19A BrR Brown/Red GW Green/White

AVSS 2.0 26A RW Red/White RB Red/Black

AVSS 3.0 44A YW Yellow/White GY Green/Yellow

AVSS 5.0 60A LB Blue/Black RG Red/Green

BrW Brown/White BrB Brown/Black
• This table is based on the ambient PB Pink/Black WG White/Green
temperature of 40°C and the allowable
current can be slightly changed by the
CAUTION external factors such as ambient
temperature.

DC45-W00 Nov-2004 11-3

CHAPTER 11 DK45S(DK451)

1.3 INSTRUMENT PANEL BULBS

Symbol Description Symbol Description

Fuse Dual Bulb

Diode
Slow Blow Fuse
Zenerdiode

LED
Motor
(Light Emitting Diode)

Switch (Normal Open Type)

Photo Diode
Switch (Normal Close Type)

N.P.N Transistor
Compressor
P.N.P Transistor

Ground (Wire)
Meter
Ground (Chassis)

Condenser Thermistor

Resistor Speaker

Coil Pick Up Sensor

Battery Separate Detector

Disconnected Wire Solenoid

Connected Wire Variable Resistor

Single Bulb
Processor

Lamp (Controller, Unit)

11-4 DC45-W00 Nov-2004

 ELECTRICAL SYSTEM

1.4 RELAY AND SWITCH 1.5 MULTIPLE SWITCH

In circuit diagram, switch is marked by symbol and is The continuity of multiple switch is described as below
in normal open condition. Switch is divided into what table.
cuts off and what pass the circuit in "OFF" position. O-O: Continuity between terminals.
NOTE: Normally, wiring diagram represents the circuit as if
• NO: Normal Open, NC: Normal Close the current doesn’t flow. However, when the circuit is
connected to all sorts of electric equipment, the switch
chart is used for displaying the operating condition as
a form of chart.
Section OFF ON
Terminal
1 2 3 4 5
Position
N O OFF
Ty p e 1ST
R Relay 2nd
E
Cut off Pass 3th
L
A
N C
Y
Ty p e
Relay

Pass Cut off

N O
S Switch
W
I Cut off Pass
T C45WB02A

C
H N C
Switch

Pass Cut off

DC45-W00 Nov-2004 11-5

CHAPTER 11 DK45S(DK451)

1.6 RELAY BOX

C45WB03A

(1) Safety Start Relay (5P) (6) Ignition Relay (4P)

(2) Back Up Relay (4P) (7) Brake Relay (4P)
(3) Head Lamp High Relay (4P) (8) Flasher Unit
(4) Head Lamp Low Relay (4P) (9) Hour meter Relay (4P)
(5) PTO Relay (4P) Compressor Relay (4P) - JP

4P relay doesn’t have 87a terminal in the right figure.

Check if the relay switch can supply power to relay coil Load
Resistance Lamp Inductance
and can be turned to ON or OFF as in the figure in Terminal
section 1.4.
Normal open
In 5P relay, switch end consists of 3 terminals, and 40A 30A 30A
(TML 30/87)
terminal 30 and 87a are coupled at contact point and
terminal 30 and terminal 87 are decoupled in normal Normal close
condition (relay "OFF"). 30A 20A 20A
(TML 30/87a)
When supplying electric power (DC+12V) to coil end,
terminal 30 and 87a will be decoupled, and terminal
30 and 87 will be coupled.

11-6 DC45-W00 Nov-2004

 ELECTRICAL SYSTEM

1.7 FUSE CHECK

A. FUSE TEST

(1) Timer Relay (10A)

(2) PTO (10A)
(3) Tail High Low Beam (20A)
(4) Back Up Lamp (15A)
(5) Preheat Controller (10A)
(6) Cigarette Lighter Socket (15A)
(7) 4WD (10A)
4WD, QT, QT TAB (10A) - JP
(8) PTO Lamp Switch (10A)
(9) Spare
Quick Turn Relay Unit (10A) - JP
C45WB04A
(10) FFT Controller (10A)
(11) Spare (10P)
(12) Spare (15A)
(13) Stereo/ Stop Lamp (10A)
(14) Wiper/ Washer Motor (15A)
(15) Spare (20A)
Controller (15A) - JP
(16) Spare (25A)
Controller (10A) - JP
(17) Heater/ Air Conditioner (25A)
(18) Working Lamp (15A)
(19) Flasher Unit (15A)
(20) Timer Relay (15A)
(21) Stereo/Inside Lamp (10A)
(22) Horn (15A) - JP, AU

The blade type fuse can be checked without pulling it

out from the fuse box.
When connecting the lead wires from the test lamp to
test lead wire and grounding, the test lamp should light
up.

C45WB05A

(1) Multitester
(2) Fuse Box

DC45-W00 Nov-2004 11-7

CHAPTER 11 DK45S(DK451)

B. CAUSES OF BLOWN FUSE

a . Excessive current
Do not replace the fuse hastily when the excessive cur-
rent caused it to blow out.
Check whether the short circuits or abnormal parts ex-
ist in system.
Replace the fuse with specified one after eliminating
the causes of blown fuse.
If you do not use specified fuse, it may cause some
troubles on wiring and related parts.
b. Repeated ON and OFF of current
This is a durability type problem, and less usual than
case 1)
C45WB06A
In this case, replace the blown fuse with specified new
one. (A) Blown fuse due to excessive current
(B) Blown fuse due to thermic fatigue

C. DIAGNOSIS PROCEDURES FOR ELEC-

TRIC SYSTEM

A circuit consists of power supplier, switch, relay, load

and ground.
There are various ways to check a circuit such as gen-
eral inspection, voltage check, short circuit check, and
continuity test.
This section provides brief descriptions for each of
them.

a . Voltage check
With the main switch turned on, measure the voltage
value between two positions to be checked with DC
voltmeter.
Measure the voltage value between two terminals by
connecting the positive lead (red) to electric load side C45WB07A
and the negative lead to body or black wire.
(1) Measurement (3) Test Lamp
b. Test Lamp check
(2) To Earth
a) Ground one lead wire from test lamp. If the voltmeter
is used for test lamp, ground the negative wire.
b) Connect the other lead wire from test lamp to the
electric load side. Test lamp should be turned on
and voltmeter should show the voltage value.
c) If the circuit is normal but electric accessories do not
work, perform the visual inspection and voltage check
until you can find the faulty parts. This should be
performed from near connectors.

11-8 DC45-W00 Nov-2004

 ELECTRICAL SYSTEM

1.8 WIRING DIAGRAM

DK45S(DK451)
5.0R 5.0R 5.0R 5.0R 5.0R
A 003 003 003 003 003 003 003

5.0R

(FLASHER
3.0BL
B 011

15A

UNIT)
3.0R
3.0RW 3.0RW 3.0RW 3.0RW
C 030 3.0RW 030 030 030 030

3.0BL

3.0RW

3.0RW
(HEAD LAMP
/TAIL LAMP)
3.0RW
0.5BrR

3.0R
0.5BR 042 042
029 029

(PREHEAT CONTROLLER)

CONTROLLER)
026

10A
0.5BR
7

0.5BrR
5.0R
STARTER AM ACC M G ST

10A
OFF
STARTER SWITCH ACC 042
0.5BrR
042

1.25LB
007 006

2.0R
4 9 11 3 15 6 17 8

0.85BrR

(FFT
1.25RW
ON
RELAY HAZARD COMBINATION SWITCH 10

10A

1.25G
GL

0.5BrR
ST

2.0L
SWITCH POS.
TER. B1 T 1 2 POS.
TER. B2 R L

60A
SLOW BLOW 1.25LB 1.25GY 1.25BW FLASHER UNIT 129 079
043 009 041 088 023 047 096 008
G F 025 024 OFF 1 B E

0.85RW
FUSE 001

3.0RL

0.5BR
SAFETY START L
1 OFF

0.5BrW

0.85LY

0.5GW
0.5RW

0.5GR

0.5BG
0.5Or
0.85B

0.5R
0.85RY

0.5YW
1.25LB
SWITCH 051 2 2 ASS’Y COMBI-METER
1.25RW 008 009 007
028 030 030

2.0R
0.85RW

1.25G
1.25LB
5.0RW

026 026 043 044 045 007 008 009

0.85RW
0.85GW
FFT CONTROLLER

1.25LB
0.85B

0.85BrW

0.85BrB

0.85RW
0.85GW
0.85WB
001 001

1.25G
3.0RL

STARTER 045
7
5.0RW PREHEAT 8 9 4 7 8 2.0R 9

1.25B
002 002 0.5WG
MOTOR
081
AB

0.85WR

0.85WB
CONTROLLER 003 2.0R 003 003

0.5GR
0.5WG
5.0RW

0.5BR
M LOW BEAM HIGH BEAM 128 126

1.25RW
S 088
RELAY RELAY PICK UP
5.0RW

029
1 2 TEMP.
3 SENSOR

1.25BG
1.25W

1.25B
SWITCH

0.5BR

1.25B
0.5PB

0.5WB

0.5YW
5.0BR

0.5GR

0.5GB
0.5YB

0.5PB
003

0.5Gr
033 033
046
1.25B
5 047 6 1.25B 1.25B
085 001 001 001 001

0.85B
0.85YL
5.0R

DIODE

0.5YB
REAR COMBI REAR COMBI FRONT COMBINATION FRONT COMBINATION

FUEL GAUGE SENSOR

HEAD HEAD

TEMP. SENSOR
080 082 079 084 084 089 087 085
ALTERNATOR GLOW

0.85B
0.85B

0.5YB
LAMP(L) LAMP(R) LAMP(L) LAMP(R) LAMP(L) LAMP(R)
RELAY

0.85B

ENGINE OIL SWITCH

0.85YL

BATTERY 10 12 1

0.5B
60A

SLOW BLOW 130 001 1.25B 001

FUSE

1.25B
030 120
HOUR

5.0BY
022 043 009 022 043 008 009 043 008 043 046 047 046 047
GLOW PLUG
RELAY

0.85B

0.85B
0.85R

1.25BG
0.85B

1.25BG

2.0B
0.85GW

2.0B
0.85BrW

1.25W
5.0BY

0.85B

1.25B
0.85B

1.25W
0.85GW

0.5BrW
0.85B

0.85RW

0.5BrW
0.85BrW

0.85GW
0.85BL

0.85BL

0.85B

0.85B
IC REG

0.85B
032
5.0BY
032 16 4 9 16 4 8 9 4 8 4 5 6 5 6 003
2.0R
003 083
0.85Y
2
E 001 001 001 001 001 001 001 001 001 001 001 001 001 001 001 001 001 001 001 001

5.0R 5.0R 5.0R

A 003 003 003

5.0R
(ROOM LAMP)
ONLY CABIN
3.0BL
B 011 011

10A
5.0R

3.0BL

3.0BL
3.0RW 3.0RW 3.0RW 3.0RW
C 030 030 030 030
3.0RW
030
3.0RW
030 3.0RW 030 14 4
(PTO LAMP SWITCH)

(BACK-UP LAMP)

2.0R
3.0RW

3.0BW
13
3.0RW

3.0RW
034

0.85R
(BRAKE LAMP)

(AIR-CONDITIONAL
WIPER SWITCH ANTENNA 019 043

WASHER MOTOR)
3.0RW

0.85RW
3.0RW

0.85R
010 010

3.0RW
W P COM E
15A
10A

(4WD)
(TIMER RELAY)

(TIMER RELAY)

0.85BrW
0.5G

1.25YW
10A

10A
WASH 072
0.5BR

15A
/ HEATER)
OFF 073

15A
0.5L

(CIGAR SOCKET)
WIPE 074

(WIPER,
0.5BL
(PTO)

1.25RG
10A
0.85RL

075
14
WIPE
10A

15A

KEY WASH
+

0.85RG

0.85BW
12

0.85W

0.85G
0.85B -
001 001 122
RELAY 13

2.0RY
048 048

15A
0.85YW
094 013 013 015 016
1.25RG
0.85RL

SPEAKER(L)
0.85B

0.85R
STEREO
1.25RG

0.5GB

2.0RY 1.25RY
WIPER
1.25W

0.85B
059 059 059
0.85RL

BACK-UP

2.0RY
0.85BW
3.0BW

031 102 089

0.85YW
019
0.85YW
019 019 MOTOR
PTO LAMP SWITCH
1.25RG

1.25RB
036 034
3.0BW 4WD
1.25RG

0.5GB

1.25YL
SWITCH
1.25W

0.85B -
(WORKING LAMP)
1.25P

2.0RY
SWITCH 2WD 4WD WASHER M 001
3.0BW

0.85YW

0.85YW
M OFF
049
MOTOR SPEAKER(R)
0.85YW
1.25B

L
0.85LgR

0.85LgR

062 0.85Y
15A

061

1.25RB
M

ROOM LAMP
0.85LgR 0.85G
RESISTOR

0.85R
123 123 063
BACK-UP BRAKE H
0.85LgR

064 0.85L

1.25YL
1.25RB
012 012 012
RELAY PARKING RELAY HEATER
0.85RL

10A
1.25WR

0.5BW
065
NEUTRAL SWITCH SWITCH S/W

1.25RY
PTO TIMER RELAY 1.25WR

0.85LY
1.25B 055 055 EVA.
001
RECEIVE M
0.85BR

0.85BL

CIGAR MOTOR
0.5R

SWITCH AUTO MANUAL

1.25WR

1.25WR
1.25Y

SOCKET AIR-CONDITIONAL DRIVER

SWITCH 066
0.85B

F WORKING WORKING LAMP 021 022

0.5BY
023
0.5RY
0.5RB

LAMP SWITCH

0.85B
1.25Y
0.85BL

050 050
0.5RY 070 071
0.85WR

125 124 124

SWITCH (FRONT)
0.85Y

0.5R

AIR-CONDITIONER
0.85BR

COMPRESSOR

0.85RB
1.25GY

1.25R
0.85WR 096 0.5LY 096
058 058
(REAR) 057 057
1.25Y

1.25Y

PTO 16 RELAY UNIT

SOLENOID TEMP. SENSOR
1.25L

0.85WR
0.85WR

0.85B
0.85B
090 091
0.85Y

0.85Y

0.85LY

RELAY 15
4WD SOLENOID

0.5Or
0.5RB

025 041
ENGINE STOP HYDRONIC
0.5R

103 HIGH
1.25B
1.25B

LOW
0.5RY
0.5RB

0.5LY
VACCUM

BRAKE
SENSOR

2.0B
0.85B

PTO SAFETY 001

SWITCH 067
0.5Or

THERMISTER
1.25L

RELAY WORKING WORKING 0.85WB

041
0.5Or
041 0.5Or 041
LAMP LAMP HEATER 068

0.85L
WORKING WORKING 17
0.85B

(FRONT,L) (FRONT,R) UNIT

0.5Or

0.85WB
LAMP LAMP 069
PTO SOLENOID

026

COMPRESSOR
1.25B

(REAR,L) (REAR,R)
1.25LB

0.85B

0.85B
0.5Or

0.5B
0.85B

0.85B

0.85B
1.25B

0.85B

G MICRO SWITCH

0.85B
001 001 001

11

0.85B
0.85B

001 001 001 001 001 001 001 001 001 001 001 001 001 001 001 001 001 001 001 001 001

C45WB53A

DC45-W00 Nov-2004 11-9

CHAPTER 11 DK45S(DK451)

DK451-JP

C45WB54A

11-10 DC45-W00 Nov-2004

 ELECTRICAL SYSTEM

2. INSTRUMENT PANEL

2.1 SYMBOL DESCRIPTION

USA/AU

JP
8 9 12 10 1 6 11 7

14 13

15

4 3
C45WB08A

(1) Tachometer (7) Hydraulic System Warning Lamp (13) 4WD Lamp
(2) Hourmeter (8) Engine Oil Lamp (14) Quick Turning Lamp
(3) Temperature Gauge (9) Charge Lamp (15) Auto Brake Lamp
(4) Fuel Gauge (10) Glow Lamp (16) Turn Signal Lamp (LH)
(5) Differential Lock Lamp (11) Parking Brake Lamp (17) Turn Signal Lamp (RH)
(6) PTO Lamp (12) Headlamp Indicator (High-Beam)

DC45-W00 Nov-2004 11-11

CHAPTER 11 DK45S(DK451)

A. TACHOMETER

TACHOMETER Specification (electric) TACHOMETER indicator specification

Standard Ignition
Indication standard

800 1000 2000 3000 TACHOMETER input wave form

revolutions method
Tolerance error ±100 ±100 ±150 ±150
-12VMN
3000RPM=553Hz

ENGINE
SIGNAL
1.0MAX
No. of lines:6 minimum level: 0.1hrs
integrator

Minimum levels have white background and red (Ignition period) THRESHOLD LEVEL
numbers, other parts have black background and (3.5-6.8V)
white numbers C45WB09A

B. HOURMETER D. FUEL GAUGE

When there is movement during engine operation, the This gauge indicates the fuel level in tank. When the
minimum level red numbers count 1 per 6 minutes, needle is perpendicular, the remained fuel is the half
and after 1 hour of operation the white colored mini- of full level.
mum level number becomes 1. • Add fuel when the needle approaches
to the "E" in red zone.
Ex) Total used time:
CAUTION
123 hours and 30 minutes 123.5 HR
LEVEL F 1/2 E
C. TEMPERATURE GAUGE Ω)
Resistance(Ω 6 (32.5) 97
This gauge displays the current engine temperature. Tolerance(°) ±2.5° - ±2.5°
The engine temperature is 105°C when the needle is Indication
perpendicular and 120°C when the needle reaches at angle(°) -40°C 0 +40°C
red zone.

• Immediately stop the engine and

check the engine system when the E. DIFFERENTIAL LOCK LAMP
needle approaches to "H". This lamp lights up yellow when the differential lock
CAUTION pedal is engaged.

LEVEL 50°C 70°C 85°C 105°C 120°C

Ω)
Resistance(Ω 210 79.5 48.8 29.2 19.1 F. PTO LAMP
±5°C ±5°C This lamp lights up red while operating PTO.
Tolerance(°) - - (±5°C)
-3°C -3°C • It is not possible to start the engine if
Indication this lamp lights up.
angle(°) -40°C -10°C -5°C -5°C +28°C
CAUTION

11-12 DC45-W00 Nov-2004

 ELECTRICAL SYSTEM

G. HYDRAULIC SYSTEM WARNING LAMP L. HEADLAMP INDICATOR (HIGH-BEAM)

This lamp lights up yellow when the certain problems This indicator lights up blue when the headlamp switch
occur in hydraulic system. is in high-beam position.

• This lamp lights up when the pressure

in hydraulic system drops down be- M. 4WD LAMP
low a specified value due to high oil
CAUTION temperature (approx. 60 5°C) or This lamp lights up yellow when 4WD switch is in "4WD"
blocked oil filter carefully check the position. At this time, the machine drives with 4 wheel
hydraulic system. drive mode.

H. ENGINE OIL LAMP N. QUICK TURNING LAMP

This lamp lights up red when the certain problems oc- Here, at the same time as 4WD activation, the front
cur in engine oil system such as excessive oil con- wheels revolve double speed.
sumption or pressure drops.
This lamp is turned off when the engine oil pressure O. AUTO BRAKE LAMP
drops down below 0.5 0.1kg/Cm².
Here, at the same time as 4WD activation, the front
wheels revolve double speed, and the brakes are
I. CHARGE LAMP activated.

This lamp lights up red when the certain problems oc-

cur in battery charging system. P. TURN SIGNAL LAMP (LH)
• Engine oil lamp and charge lamp light This lamp flashes green when the combination switch
up when ignition switch is turned to on, is in "L" position.
and goes out after starting the engine.
CAUTION
Q. TURN SIGNAL LAMP (RH)
J. GLOW LAMP
This lamp flashes green when the combination switch
The preheating system starts to operate with lighting is in "R" position.
up the glow lamp when ignition switch is turned to on.
Glow lamps stay on for 8 seconds, but it goes out when • Lamp specification: 12V 3.4W (all)
ignition switch is turned to ST (starting the engine)
within this period. It also goes out when the engine
temperature goes over 60 5°C.
IMPORTANT
• In winter season, make sure to start
the engine after turning off this lamp.

CAUTION

K. PARKING BRAKE LAMP

This lamp lights up red when locking the parking brake
while depressing the brake pedal.
• Make sure to drive the machine with
parking brake unlocked.

CAUTION

DC45-W00 Nov-2004 11-13

CHAPTER 11 DK45S(DK451)

2.2 CIRCUIT DIAGRAM OF INSTRUMENT (USA)

A. CIRCUIT DIAGRAM AND CONNECTOR

C45WB10A

(1) Tachometer Signal (9) Fuel Gauge Signal (16) Oil Pressure
(2) PTO Indicator (10) Quick Turn + Auto Brake (Not Use) (17) Transmission Oil Filter
(3) Temp Gauge (11) Quick Turn (Not Use) (18) Charge
(4) Hourmeter Signal (12) 4 Wheel Drive (19) Differential Lock (Not Use)
(5) Turn Signal Indicator (LH) (13) Head Lamp Indicator (High) (20) Power (+)
(6) Turn Signal Indicator (RH) (14) Parking Brake (21) Earth (Temp Gauge)
(7) Panel Illumination (15) Glow (22) Water (Not Use)
(8) Earth (-)

11-14 DC45-W00 Nov-2004

 ELECTRICAL SYSTEM

3. STARTNG SYSTEM

3.1 IGNITION CIRCUIT (WITHOUT THE INSTALLATION OF A HORIZONTAL CONTROLLER)

8
5

10A
AM ACC M G ST
3 OFF
ACC
ON Pto Lamp
2 GL Switch
ST
60A

Neutral

6
4 Auto Manual

10

11

1
7

12

C45WB12A

(1) Battery (7) PTO Safety Relay

(2) Slow-blow Fuse (8) Fuse
(3) Starter Relay (9) PTO Switch
(4) Starter Motor (10) Reverse Switch
(5) Main Switch (11) Reverse Auto PTO Stop Relay
(6) Safety Switch (12) Micro Switch

CIRCUIT EXPLANATION
First, if the PTO switch is in manual or automatic
position, power is supplied to the PTO safety relay which
then is activated and ignition cannot be started.
If the ignition switch (MAIN SWITCH) is placed in the ST
position, the electric current flows from the battery past
the safety ignition switch via the slow blow fuse (the
safety ignition switch turns on when the clutch pedal is
pressed), it then passes the PTO safety relay and ap-
plies power to the ignition relay, and by connecting to
the magnetic switch in the ignition motor, the ignition
motor is made to revolve.

DC45-W00 Nov-2004 11-15

CHAPTER 11 DK45S(DK451)

3.2 IGNITION CIRCUIT

(HORIZONTAL CONTROL INSTALLATION EXPECTATION-ONLY JP)

15A

10A
AM ACC M G ST
OFF
ACC
ON
GL
ST
2

3 6

1
P.T.O SWITCH(ON ) P.T.O SWITCH(OFF )
4

C45WB11A

(1) Battery (5) Main Switch

(2) Slow-blow Fuse (6) Safety Switch
(3) Starter Relay (7) Auto Balance Controller
(4) Starter Motor (8) Fuse

First, check whether the PTO switch is in the manual or If the electric current passes the PTO safety relay and
automatic ‘ON’ position. Next, place the manual or au- is supplied to the ignition relay, the contact point of the
tomatic switch on ‘OFF’. ignition relay switch connects as a result of the mag-
If the ignition switch (MAIN SWITCH) is placed in the ST netic force created by the ignition relay coil and power
position, the electric current flows from the battery past is supplied to the magnetic switch in the ignition motor.
the safety ignition switch via the slow blow fuse (the
safety ignition switch turns on when the clutch pedal is
pressed) and depending on whether the PTO manual
or automatic switch within the rotary level controller is
in the ON or Off position, it activates the PTO safety
relay and applies voltage to the ignition relay coil unit.
If the PTO manual switch is in the ON position, the
contact point of the interior safety relay is switched off
and ignition cannot be started.

11-16 DC45-W00 Nov-2004

 ELECTRICAL SYSTEM

3.3 MAJOR COMPONENTS

A. STARTER MOTOR
a . SPECIFICATION
Nominal Output 12V, 1.7KW
Collection Method Electronically Forced-Push Type
Rating Time 30 seconds
Rotating Direction Clockwise When Seeing At Pinion Shaft Side

Voltage Current Torque Speed

No-load 11V max. 130A - min. 2900 rpm
Guaranteed
Loaded 8V max. 370A min. 1.3Kgf-m min. 1000 rpm
Specification
Holding 4V max 980A min 2.6Kgf-m -
(20°C)
Operating Voltage Of Operating voltage when holding 2 mm of pinion end:
Electronic Switch below 8V

Remark Weight: 4.4Kg F/R BKT material: ALUMINUM Alloy

b. SECTIONAL VIEW OF STARTER MOTOR

a. Starter
The magnet-switch type starter is composed of two main sections. The first section converts battery current into
mechanical rotation to turn the engine crankshaft. It is composed of the field coil, armature, brush, commutator,
pinion, overrunning clutch, etc. The second section allows the pinion and flywheel to engage together and current
to flow through the motor section. It is composed of the pull-in coil, holding doil plunger, drive lever, contact plate,
etc.
(A) Construction

C45WB13A

(1) lever (6) Planet Gear Ass’y (11) Needle Bearing

(2) Internal Gear Ass’y (7) Armature Ass’y (12) Rear Bracket Ass’y
(3) Front Bracket Ass’y (8) Field Coil (13) Nut
(4) Needle Bearing (9) Aual Brush (14) Holding Coil
(5) 6 Roller ORC Ass’y (10) Thraough Bolt (15) Magnet Switch Ass’y

DC45-W00 Nov-2004 11-17

CHAPTER 11 DK45S(DK451)

c. OPERATING PRINCIPLE OF STARTER MOTOR

OPERATING PRINCIPLE
The starter motor has 1.7 kW class of capacity.
The starter motor consists of magnet switch with com-
bined 4 poles and 4 brushes with engaging control of
2 poles the magnet switch consists of two paralleled
coils. Low resistance inductance coil is grounded
through the engine and high resistance inductance coil
is grounded through the solenoid body.
When the ignition switch is turned to ST position with
clutch pedal depressed, the power is supplied to mag-
net switch of starter motor and the current flows through
pull in coil in magnet switch as shown in figure 2.
Accordingly, the plunger is sharply pulled in and pinion
is pushed out. At this point, the plunger makes contact
disk(4) to B+ terminal in starter motor and the current
flows to armature through field coil to run the electric
motor.
While the ignition switch is in ST position, the current
in holding coil keeps the drawn plunger in position
without returning by return spring.
If the contact coil(4) is closed, the current will not flow
into pull in coil any more, and the pulling force of pull in
coil should be eliminated. Due to this, the holding coil
prevents the plunger from returning back. In addition
to, it also prevents the pinion and contact disk from
disengaging due to vibration when starting the engine.
If the ignition switch is turned to ON position from ST
position, the current in pull in coil flows to reverse di- C45WB14A
rection because the contact disk(4) is closed at this
moment. Due to this, also the magnetic field of pull in (1) Magnet Switch (6) Plunger
coil is changed to reverse direction, and eventually the
magnetic force of holding coil will counterbalance the (2) Pull in Coil (7) Lever
force of pull in coil. At this time, the plunger is returned (3) Holding Coil (8) Pinion Sleeve
to its original position by return spring, so the pinion is
(4) Contact Disk (9) Armature
disengaged from ring gear and the contact disk(4) is
released. (5) Field Coil

(A) Activated
(B) Deactivated
d. REMOVAL AND INSTALLATION

1. REMOVAL
Remove the hood side cover from the body.
Disconnect the battery negative (-) cable from the
battery.
Disconnect the battery positive (+) cable from to B+
terminal on starter motor
Unscrew the bolts and nuts fixing the starter motor
Remove the starter motor from engine.
2. INSTALLATION
Installation should follow the removal procedures in
the reverse order.

11-18 DC45-W00 Nov-2004

 ELECTRICAL SYSTEM

B. STARTER RELAY
a . Terminal Layout

C45WB15A
b. Specification
• Rated voltage: DC 12V
• Capacity of switch contact point: 70A

c. Troubleshooting for relay

It is normal that multitester displays approx. 50~60
of resistance between both ends of the coil.
It is also normal that the switch is switched on when
DC 12V is supplied to both ends.

C. SAFETY SWITCH
a . Terminal Layout
Position AVS 2.0 BW AVS 2.0 BW
Free
Push

C45WB16A
b. Specification
(1) Shaft
• Rated voltage: DC 12V
(A) 1.6mm Off Stroke (C) Free
• Capacity of switch contact point: 18A
(B) 6.4mm On Stroke (D) Push
c. Troubleshooting for switch
It is normal that multitester displays 0 of resistance.
To measure the resistance, press the shaft upto ON-
Stroke after connecting the multitester to both ends.
It is also normal that multitester displays DC+12V on
one terminal when the voltage of DC12V is supplied to
the other terminal while pushing the shaft upto ON-
Stroke.

DC45-W00 Nov-2004 11-19

CHAPTER 11 DK45S(DK451)

D. PTO LAMP SWITCH

a . Terminal Layout

TERMINAL
YB LG LB RW BY
Position
Free
Lock

C45WB20A
b. Specification
(1) Lamp (5) AVS 0.5 YB
• Rated voltage: DC 12V
(2) Switch (6) AVS 0.5 LG
c. Troubleshooting for lamp switch (3) AVS 0.5 RW.BY (A) Free
1. Lamp : The lamp should be turned on when DC12V (4) AVS 0.5 LB (B) Lock
is supplied to RW and BY terminal. It is normal that
multitester displays few s (coil resistance) after
connecting the multitester to both terminals.
2. Switch : The multitester should display 0 of resis-
tance between LG and LB when the switch is in
FREE position. And, it should display 0 of resis-
tance between YB and LB when the switch is in
LOCK position.

E. PTO SWITCH (Normal type)

a . Terminal Layout

TERMINAL
3 0 1 Remark
Position
Left (AUTO) On
Center (NEUTRAL) Off
Right (MANUAL) On

C45WB17A
b. Specification
(1) PTO Switch (B) NEUTRAL
• Rated voltage: DC 12V
(A) AUTO (C) MANUAL
• Rated load: 6A

c. Troubleshooting for switch

It is normal that multitester displays 0 of resistance
when the switch is in AUTO or MANUAL position.

11-20 DC45-W00 Nov-2004

 ELECTRICAL SYSTEM

F. PTO CIRCUIT
(Equipped horizontal relay)
a . Ignition Circuit Composition

KEY ON +12[v]

2
START SIGNAL IN(+)
F 6

4
N.C.
START SIGNAL OUT(+)
G 27
PTO SAFTEY PTO MANUAL S/W
7
RELAY

C45WB18A

(1) Main Switch (3) PTO Lamp Switch

(2) PTO Safety Relay (4) Battery

If the manual PTO switch turns on (lamp switch), the

PTO relay is comprised of Normal-Closed , and power
is induced to the PTO safety relay coil unit and stops
the switch which disconnects F & G and ignition is
disabled.

b. Terminal Composition
Wiring Wire Particu-
Circuit explanation
number standards lars
6 Engine ignition input AVS0.5 R
7 PTO switch power AVS0.5 LgR
27 Engine ignition output AVS0.5 G
6 27 7

C45WB19A

DC45-W00 Nov-2004 11-21

CHAPTER 11 DK45S(DK451)
4. CHARGING SYSTEM

4.1 CIRCUIT DIAGRAM

AM ACC M G ST 4
OFF
ACC
ON
GL
1 ST

2
3
P-TAP
B+

6
1N4148

AVS 0.5 PB
R
L
R 5 7
AVS 1.25 R
IC. REG. AVS 0.85 YL
L 800V 3A
TO HOURMETER
C45WB21A

(1) Battery (5) Diode

(2) Slow Blow Fuse(60A) (6) Diode
(3) Alternator (7) Charge Lamp
(4) Main Switch

CIRCUIT DESCRIPTION
When the main switch is in ON position without engine During the charging process, the increased terminal
starting, the positive (+) voltage from battery is sup- voltage of alternator eliminates a potential difference
plied to positive (+) terminal of charging lamp through between both ends of charging lamp. Due to this, the
slow blow fuse, B+ terminal of alternator and M termi- current to charging lamp is cut off and the lamp is turned off.
nal of main switch, and the supplied voltage to R termi- If the generated voltage in alternator reaches up to
nal of regulator magnetizes the field coil. the regulated voltage, regulator outputs constant DC
At this time, the low electric potential is applied to the 14.5V 0.5V of generated voltage through B+ terminal.
terminal of charging lamp according to the low electric
potential of L terminal of regulator, accordingly the
charging lamp lights up.
If the generated voltage in alternator becomes higher
than terminal voltage in battery after starting the engine,
the charging process to battery will be started through
B+ terminal.

11-22 DC45-W00 Nov-2004

 ELECTRICAL SYSTEM

4.2 AC (ALTERNATING CURRENT) ALTERNATOR

A. SPECIFICATION
Nominal output 12V50A
Manufacturer VALEO ELECTRICAL SYSTEMS KOREA LTD.
Rating Continuous
Battery Voltage 12V50A
Normal Output Negative Ground
Regulating System Hic Reg. Built-In
Weight (3.6 kg)
Rated Speed 5000 rpm
Speed In Use 1000 - 15000 rpm
No. Of Poles 12
Hot Condition at 5000 rpm with maximum output after running 40 minutes
Temp.Rise
Thermal Endurance
Initial Cut-In Speed Max. 1200 rpm
Setting Voltage 14.7 0.3 V
Reg.Perf.
Temperature Compensation -7.3 mV/°C
Ambient temperature when driving: max. 100°C

B. SECTIONAL VIEW OF ALTERNATOR

C45WB22A

(1) Hex Nut (6) Stator Assembly (10) Bearing Front

(2) Spring Washer (7) Rotor Assembly (11) R/R Bracket Assembly
(3) Pulley (8) Bearing Rear (12) Rectifier Assembly
(4) Spacer-P (9) F/T Bracket Assembly (13) Regulator Assembly
(5) Through Bolt

DC45-W00 Nov-2004 11-23

CHAPTER 11 DK45S(DK451)

C. CIRCUIT DIAGRAM OF ALTERNATOR

0.5 F

C45WB23A

D. CHARACTERISTIC CURVE E. GUARANTEE (AT 20°C)

Output Current (A) Speed

Voltage (V)
Hot Cold (RPM)

11 (17) 1500
13.5V 32 (40) 2500
45 (53) 5000

C45WB24A

11-24 DC45-W00 Nov-2004

 ELECTRICAL SYSTEM

5. ENGINE GLOW PLUG SYSTEM

5.1 CIRCUIT DIAGRAM

C45WB25A

(1) Battery (7) Fuse 10A

(2) Slow Blow Fuse (60A) (8) Preheat Controller
(3) Alternator (9) Glow Lamp
(4) Main Switch (10) Slow Blow Fuse (60A)
(5) Fuse 15A (11) Glow Relay
(6) Temperature Switch (12) Glow Plug (4 ea)

CIRCUIT DESCRIPTION
Glow system consists of preheat controller, glow lamp, supplying the current from the battery. This process
glow plug, glow relay, and temperature sensor. takes approx. 15 seconds.
When the ignition switch is turned to ON position, the If the ignition switch is turned to ST position for starting
preheat controller starts to preheat. within 15 seconds, the glow relay keeps preheating
The glow lamp on instrument panel lights up for approx. during the ignition switch is in ST position. When the
8 seconds after turning the ignition switch to ON posi- ignition switch is turned back to ON position, the glow
tion below 60°C of engine coolant temperature. plug is afterheated for 15 seconds.

If the ignition switch is turned to ST position for starting The glow lamp and glow relay do not operate if the
within 8 seconds, the glow lamp is turned off engine coolant temperate is over 60°C.
immediately. Preheating and afterheating must stop if the voltage
The glow relay operates as soon as the ignition switch input to preheat controller is over 16 0.9V.
is turned to ON position. It preheats the glow plug by

DC45-W00 Nov-2004 11-25

CHAPTER 11 DK45S(DK451)

5.2 MAJOR COMPONENTS

A. APPEARANCE OF PREHEAT CONTROLLER

KEY ON TO GLOW LAMP

VOLTAGE INDICATOR LAMP INDICATOR LAMP
REGULATOR TIMER OUT

KEY ST TO GLOW RELAY

PREHEATER
START TIMER
RELAY OUT

TEMP. SENSOR EARTH

THERMO SENSOR
SENSING AMP

C45WB26A

B. TERMINAL ARRANGEMENT AND FUNCTION

NO. Function Wire Color
1 Main Switch “ON” 0.85RW
2 Temperature Sensor 0.5WG
3 Main Switch “ST” 1.25LB
4 Glow Relay Coil (+) 0.5BR
5 Earth 0.85B
6 N.C
7 N.C
8 Glow Lamp 0.5GR C45WB28A

11-26 DC45-W00 Nov-2004

 ELECTRICAL SYSTEM

C. TIME CHART OF PREHEAT CONTROLLER

C45WB29A

DC45-W00 Nov-2004 11-27

CHAPTER 11 DK45S(DK451)

D. TROUBLESHOOTING
• Check whether the glow lamp lights up for 8 sec-
onds and the glow relay operates for approx. 15
seconds after turning the ignition switch to ON
position.
• Check whether the glow lamp is turned off when the
ignition switch is turned to ST position and the glow
relay operates for approx. 15 seconds after turning
back the ignition switch to ON position from ST
position.
• Coolant temperature sensor should be switched
on when the coolant temperature is below 60°C,
and should be switched off when the coolant tem-
perature is over 60°C.
• When the coolant temperature is below 60°C, check
the switch operation. If it has the value of 0V or 0
between terminal 1P in coolant temperature sen-
sor and the ground, it operates properly.
• If the coolant temperature is over 60°C and the
switch is turned off (voltage in terminal 1: few Volts),
the glow lamp and glow relay do not operate.

E. GLOW PLUG
a . Appearance of glow plug
b. Specification
1. Rated voltage : DC 11V
2. Current value : 20A Max after 4 seconds loading at
rated voltage.
3. Temperature rising : 800°C Min after 4 seconds load-
ing at rated voltage.
4. Tightening torque
Plug body (M10 P1.25) : 2 ~ 2.5 kg.m
(19.6 ~ 24.5 N.m,
14.5 ~ 18.1 lbf.ft)
Terminal nut (M4 P0.7) : 0.2 kg.m C45WB30A

(1.9 N.m,1.4 lbf.ft)

b. Troubleshooting
It is normal that multitester displays few s (approx. 0.4 )
when measuring the resistance of plug.

F. GLOW RELAY
• same with the starting relay of starting system

11-28 DC45-W00 Nov-2004

 ELECTRICAL SYSTEM

6. PTO SYSTEM (ONLY USA/AU)

6.1 CIRCUIT DIAGRAM

C45WB31A

(1) Battery (10) PTO Lamp Switch

(2) Slow Blow Fuse (11) PTO Switch
(3) Main Switch (12) Micro Switch
(4) Safety Switch (13) Fuse 10A (PTO)
(5) PTO Safety Relay (14) PTO Relay
(6) Fuse 15A (Back-Up) (15) PTO Solenoid
(7) Back-Up Switch (16) PTO Lamp
(8) PTO Stop Relay (17) Diode (800V 3A)
(9) Fuse 10A (PTO Lamp Switch)

DC45-W00 Nov-2004 11-29

CHAPTER 11 DK45S(DK451)

6.2 CIRCUIT DESCRIPTION 6.3 TROUBLESHOOTING

NOTE: • Make sure that the engine is off be-

• PTO circuit is related to starting circuit. See starting fore performing maintenance job for
system for the circuit related to starting. PTO system.
CAUTION
To operate PTO, push the PTO lamp switch(10) with
engine started (the ignition switch must be turned to a . Check if there was a mistake during operation.
ON: power is supplied through M terminal), then put If PTO does not operate when the main switch is on,
the PTO switch(11) to AUTO or MANUAL mode. check the illumination lamp on PTO lamp switch is
In MANUAL mode, PTO relay(14) supplies the current lighting up. And, check if PTO switch is in PTO operat-
to PTO solenoid(15) for operation regardless of ing condition in AUTO or MANUAL mode.
switches, and PTO lamp(16) lights up. In AUTO mode, PTO does not operate if the position
PTO lamp on instrument panel is connected to PTO lever is moving upward and the main shift lever is in
solenoid in parallel. PTO safety relay(5) cuts off the reverse position.
connection with starting circuit when the PTO operates.
In AUTO mode, PTO switch(11) is connected to micro b. Check the power system, fuses and relays
switch through the normal close (NC) contact point of for operation.
PTO stop relay(8) in series and PTO relay(14) allows
PTO to operate.
If the back-up switch(7) is operated by putting the main c. Check the switches for operation.
shift lever to reverse position, PTO stop relay(8) dis- The back-up switch(7) should be turned on when the
connects (disengaging 125 – 127) the relay switch and main shift lever is in reverse position.
PTO stops operating. In addition to, the micro switch
(12) is turned off and PTO stops operating when the If the power is supplied, the voltages in both terminals
position lever moves over a particular level when the should be approx. +12V when the switch is operated.
shift lever is not in reverse position. If the power is not supplied, buzzer should sound dur-
Diode (800V 3A)(17) acts as a safety device to protect ing continuity test or the resistance between both ter-
PTO solenoid from surging voltage. minals should be 0 .
In addition to, check whether the micro switch(12) is
operating properly when moving the position lever up-
ward and downward.

11-30 DC45-W00 Nov-2004

 ELECTRICAL SYSTEM

7. ROTARY LEVEL CONTROL INSTALLATION (ONLY JP)

7.1 SYSTEM COMPOSITION PARTS

C45WB32A

(1) Manual Level Switch (7) Level Controller Assembly

(2) Stop Position Setting VR (8) Wire
(3) Level Adjustment VR (9) Lift Cylinder
(4) Sensitivity Adjustment VR (10) Level Sensor
(5) Automatic Pto Switch (11) Location Sensor
(6) Automatic Level Switch (12) Lift Cylinder Sensor

DC45-W00 Nov-2004 11-31

CHAPTER 11 DK45S(DK451)

7.2 OUTLINE

The level control installation of the tractor rotary is based to the slope in pavement and also the inclination
on a electronic-hydraulic system and is composed to due to the wheels being put into water are dealt with by
maintain level by equalizing the main body and the this installation which always maintains the level of
implement against the slope and irregularity of the the implement and sustains the selected inclination.
pavement. That is, the inclination of the main body due

A. SENSOR DATA
a. Level sensor

NO. Item Assessment standard method. condition

1 Rated voltage DC12V
2 Usage voltage range DC10~16V
3 Usage temperature range -20~ + 60°C
4 Storage temperature range -40~ + 60°C
5 Power consumption Below 50 mA (no load)
6 Power output Below 1 mA
Level detection ± 20°C
7 Detection angle Refer to the diagram on the right
for directional features +angle -angle
1.0V at -15° (reference)
8 Voltage output 2.5V at 0° 0.5V at -20°
4.0V at +15° 4.5V at +20°

Left inclination: +angle

Right inclination: -angle

b. Lift sensor, implement location sensor

NO. Item Initial capacity Output feature chart

1 total resistance 2k ± 20%

OUTPUT
2 electricity effective angle 110° ± 3° VOLTAGE
3 rated power 0.2W 70°C 100(%)
4 usage temperature range -30 ~ +120°C
5 machine activation angle 120° ± 5° 50
6 part angle

Angle
0
()
5 55
110 3
120 5
C45WB33A

11-32 DC45-W00 Nov-2004

 ELECTRICAL SYSTEM

B. LEVEL CONTROL MOTION PRINCIPLE

Rotary works with level control installation Rotary works without level control installation

C45WB34A

a. Working features on inclined areas The input value of the level sensor installed on the
unlike the water farms, there are many inclined areas tractor is averaged out within the predetermined pe-
on the paved surfaces of farms where vegetables and riod and determines the angle of the tractor position in
such are grown. Depending on the pavement, the the existing state. Here, the adjustment time of the level
angles of the inclination can vary widely, and even on sensor value can adjust the level controller to sensi-
the same pavement there could be differences in the tive or non-sensitive depending on the tractor speed by
inclination angles. adjusting the sensitivity control volume.

However, with farmland, it is important to maintain the The concept diagram of the level control installation in
implement level or at the desired angle with respect to inclined pavement areas are shown below.
the pavement surface. When the position of the work
machine is being controlled, it is necessary to control
c. Effects of the Rotary level control
it so that it follows the changes in inclination angles of
the pavement surface. The introduction of work position control with consider-
ation of the subsidence difference of the left and right
tires on inclined areas has made it possible to main-
b. Control Principle tain the implement in a stable position which was pre-
The level control system must fulfill the position con- viously not possible especially in paved areas with
trol condition in an inclined area, and to be able to carry constant change in inclination angles or on uneven
out works level with the inclination, the positional dif- pavement areas. As a result, a uniform finish can be
ference amount caused by the subsidence of the achieved anywhere within the paved area and stable
tractor’s left or right tires must be compensated crop growth can be expected.

The actual inclination angle of the pavement surface is

Pavement inclination angle = tractor position angle –
tire subsidence compensation amount
Also, the angle of the work machine in relation to the
inclination angle of the pavement surface can be ad-
justed by the operator by adding the standard subsid-
ence compensation amount based on the level control
VR. This enables the control of the subsidence com-
pensation amount when the average subsidence
amount is not right due to the tractor weight or the soil
conditions etc.

DC45-W00 Nov-2004 11-33

CHAPTER 11 DK45S(DK451)

7.3 LEVEL CONTROL INSTALLATION

FUNCTION

A B C
C45WB35A

(A) Manual leveling mode operation (C) When operating on maximum platform height
(B) When reverting parallel (maximize platform height)

If the lift cylinder stroke which is controlled by the level A. PTO CONTROL FUNCTIONS
controller is within 90mm in manual or automatic level
control (with the purpose of sensor protection, wire and - Ignition disabled if level controller is not installed
assembly tolerance have been taken into (refer to ignition circuit in 8.2)
consideration), out of the total 110mm lift cylinder stroke - Ignition disabled if the PTO lamp on the dashboard
10mm on maximum and 10mm on minimum have been is on (on PTO activation)
allowed for.
- During movement from PTO activation, PTO is au-
(Maximum limit:3.92V, Minimum limit:1.17V - there tomatically cut when reversing and turns off the PTO
could be slight differences depending on expected as- lamp on the dashboard.
sembly conditions)
- If the PTO manual, automatic switch is on the PTO
The level controller is largely comprised of 2 types of lamp on the dashboard is turned on, and when the
control, implement level control & PTO control which PTO manual switch is ON, the PTO is activated re-
are divided into manual & automatic. gardless of the position of the work machine, and
The seesaw switch located on the right of the fender because the PTO continues to operate on reverse,
exterior is arranged in a line like the manual level switch there is danger of accidents so caution must be
(within the level controller), so the lift cylinder can even taken.
be adjusted from the outside. - During PTO operation, if the stop position setting
VR is adjusted, the PTO deactivation position (PTO
activation or deactivation depending on the height
of the PTO operation area ie. the platform) can be
adjusted on the discretion of the operator (but, if the
work machine location sensor value is over 3.6V,
PTO will be deactivated).
- If the PTO manual switch is OFF, PTO will turn OFF
regardless of the PTO operation. (At this time, the
engine ignition output will be ON)

11-34 DC45-W00 Nov-2004

 ELECTRICAL SYSTEM

B. LEVEL CONTROL FUNCTIONS

- When the level manual switch is ON, OFF the level
solenoid output is turned ON, OFF. (The length of
the lift cylinder is changed)
- If the level automatic switch is ON, the implement
automatically maintains level by the inclination of
the tractor’s main body at a point where the work
machine location sensor value is below 3.6V.
- On automatic leveling, the level position can be
adjusted on the operator’s discretion based on the
level control VR.
- If the platform is higher than the 3.6V value of the
implement location sensor, the automatic leveling
and PTO do not activate and maintains level with
the main body (stroke sensor location 2.5V).
- After the automatic level switch is ON, and when the
manual level switch is controlled up, down, the out-
put of the level solenoid is increased during the
time where operation is done by the manual level
switch, and when the manual level switch is on
neutral, the lift cylinder goes to its original position.
When the manual level switch is on for more than 5
seconds, the solenoid output is turned off to pre-
vent damage.
- When reversing, the PTO is not activated so auto-
matic leveling turns off.

C. REVERTING PARALLEL FUNCTION

- If the implement location sensor value is more than
3.6V, there is a reverting parallel function so that
the lift sensor value becomes 2.5V (to level with the
main body), and the tractor’s center of gravity does
not lean to one side.
In other words, if it is lifted higher than the platform
setting (3.6V), automatic leveling and the PTO do
not activate, and level is maintained with the main
body.
- On manual leveling, if the implement location sen-
sor is lifted above 3.6V, perform the reverting paral-
lel function on the platform, and when the platform
is lowered to 3.52V, it outputs at the level solenoid
so that it becomes the last value before reverting
parallel (when plowing, this function is convenient
when operating on manual mode).

DC45-W00 Nov-2004 11-35

CHAPTER 11 DK45S(DK451)

7.4 ELECTRIC CIRCUIT

KEY +12[v]

Before about +12[V]

1 Rise
Horizontal manual operationS/W
Before river+12[V] Drop
16
Retrogression S/W
2
PTO Ramp
28
Automatic
PTO Automatic S/W
PTO Relay OFF
29
PTO Solenoid Horizontal automatic
movement S/W
PTORamp switch
7

Horizontality At
Manual operationS/W 3
Under
4
Horizontal burglar set VR

Horizontal sensor PTO Standstill

location set VR
19 Auto
Lift cylinderVR
5
Balance
Ascent and descent Controller Horizontality control VR
cancer locationVR 20

22

18
Horizontal rise valve
12
+12[V]
Horizontal drop valve
13

+5[V]
Engine starting input(+) 6

Engine starting output(+) 27 RxD

Engine number of revolution electronic pickup

8 TxD

Before aboutEARTH
17 GND
Before riverARTH
30

C45WB36A

11-36 DC45-W00 Nov-2004

 ELECTRICAL SYSTEM

7.5 TERMINAL ARRANGEMENT TABLE

8 29
NC 7
2 28
1 27
4 17
16 6
3 30

C45WB37A

Wiring number Circuit explanation Wire standards particulars

1 Weak current +12V AVS 0.85 RY
2 Reverse switch AVS 0.5 L
3 Manual leveling S/W up AVS 0.85 RG
4 Manual leveling S/W down AVS 0.85 YR
5 +5V AVS 0.85 LB
6 Engine ignition input AVS 0.85 R
7 PTO manual S/W AVS 0.85 LW
8 Electronic pick up AVS 0.85 YL
9 N.C
10 N.C
11 N.C
12 Level increasing solenoid AVS 0.85 RL
13 Level decreasing solenoid AVS 0.85 LR
14 N.C
15 N.C
16 Strong current +12V AVS 0.85 RW
17 Weak current earth AVS 0.85 Y
18 Earth output AVS 0.85 BW
19 Level sensor AVS 0.85 BrW
20 Implement position VR AVS 0.85 YB
21 Stroke sensor AVS 0.85 GY
22 N.C
23 N.C
24 N.C
25 N.C
26 N.C
27 Engine ignition output AVS 0.85 G
28 PTO lamp AVS 0.85 LY
29 PTO relay AVS 0.85 LB
30 Strong current earth AVS 0.85 B

DC45-W00 Nov-2004 11-37

CHAPTER 11 DK45S(DK451)

8. QUICK TURN (ONLY JP)

8.1 ELECTRIC CIRCUIT

4 5 6

10A

10A

20A
AM ACC M G ST
OFF
ACC
ON
GL
ST
7 8 9 10
11 12 13
60A

15 16

4WD QT
2WD QT+AB

1 17
14

C45WB38A

(1) Battery (10) Q/T + AB Solenoid (RH)

(2) Slow Blow Fuse (11) 4WD Lamp
(3) Main Switch (12) Q/T Lamp
(4) Quick Turn Relay Unit Fuse (13) Q/T + AB Lamp
(5) Quick Turn Fuse (14) Drive Selection Switch
(6) Panel Fuse (15) Safety Switch (Front Axle LH)
(7) 4WD Solenoid (16) Safety Switch (Front Axle RH)
(8) Q/T Solenoid (17) Safety Switch (Range Shift Lever)
(9) Q/T + AB Solenoid (LH)

11-38 DC45-W00 Nov-2004

 ELECTRICAL SYSTEM

CIRCUIT EXPLANATION
The quick turn installation senses the front axle angle At this time, there is no voltage applied to the QT which
and if the axle turns more than the fixed angle voltage turns the front wheel in any direction, so there is no
is applied to the quick or auto brake solenoid so that quick turn.
the turning radius of the tractor is minimized in narrow
If the drive selection switch is in the QT position, volt-
spaces or paved areas.
age is applied to the range shift lever switch. When
It is comprised of the following parts, drive selection this happens, the range shift lever switch turns off on
switch, relay, diode, solenoid valve type, and various high speed, and if the vehicle turns rapidly on high
switches. speed, there is concern of expected overturning, so
Start the ignition and place the Main Switch to the ON when the range shift is on high speed a safety function
position and select the drive mode using the drive se- has been inserted to prevent quick turn.
lection switch. If the range shift lever is on low or medium speed, the
As seen in the above circuit, there are no circuit con- range shift lever switch turns on and voltage is applied
nections in 2WD so it is advantageous on flat roads to the range shift relay coil unit, which then turns on the
where there is no need for towing capability. range shift relay lamp and power is supplied to the left
and right of the safety switch.
If the drive selection switch is on 4WD, voltage is ap-
plied to the 4WD solenoid via the quick turn relay (5P) In this situation, if the left or right front wheel turns
switch (N.C) and activates the 4WD mode. more than the fixed angle, the left and right safety
switches turn on and voltage is applied to the quick
turn relay coil unit and cuts the switch connecting to the
4WD, and then voltage is applied to the quick turn sole-
noid and quick turn is performed.
Here, the left & right auto brake relay are activated but
no voltage is applied to the QT+AB, so the auto brake
does not activate.
If the drive selection switch is put on QT+AB, voltage is
applied to the 4WD unit via diode 2 and then the QT unit
& diode 1, activating quick turn & 4WD and when quick
turn is activated (front axle turns more than the fixed
angle) voltage is applied to the auto brake left & right
relay switch unit which then applies voltage to the auto
brake solenoid, enabling the simultaneous operation
of quick turn and brakes.
QT+AB activation must be performed after releasing
the lock installation on the brakes. For the movement
of each solenoid, the current movement is indicated
on the dashboard indicator lamp.

DC45-W00 Nov-2004 11-39

CHAPTER 11 DK45S(DK451)

8.2 MAIN PARTS COMPOSITION

8 9
6

5 10

11 12
3

17

16

15

14

13

C45WB39A

(1) Auto Brake Solenoid(L) (10) Range Shift Relay/ Switch only Fuse(10A)
(2) Auto Brake Solenoid(R) (11) Range Shift Relay/ High Speed OFF
(3) 4WD Solenoid (12) Range Shift Lever
(4) Quick Ture solenoid (13) Drive Selection Switch
(5) Range Shift Relay (14) 4WD Lamp
(6) Auto Brake Relay(R) (15) QT+AB Lamp
(7) Auto Brake Relay(L) (16) QT Lamp
(8) Quick Ture Relay (17) Safety Switch(L, R)
(9) Drive Selection Switch/ Power Fuse(15A)

11-40 DC45-W00 Nov-2004

 ELECTRICAL SYSTEM

a . Drive selection switch

[Terminal section wiring specification]

Connection Wiring 1 2 3
Function 5 4
point specification
C(QT) TERMINAL
1 AVSS 0.5 R Power input
B(4WD) D(QT+AB)
2 AVSS 0.5 W
3 AVSS 0.5 LW 4WD 3
2
A(2WD) 4
4 AVSS 0.5 RY QT
5
5 AVSS 0.5 Y QT+AB

b. Solenoid valve FRONT VIEW 1

POINT CONTACT
- Determination method of normal conditions
C45WB40A
a. When the 2 terminals connected to each sole-
noid are measured for resistance using a circuit
tester, a measurement of approximately 9~10
is considered normal.
b. If the spool moves when DC12V is applied to the
2 terminals it is considered to be normal.
c. Even if the spool functions normally, if foreign
substances are stuck on it, the hydraulic system
must be checked.(refer to hydraulic system)

c. Sub shift lever switch

The picture below is for D400, D450P use, and the
D450 cabin type is like the safety switch left, right) in
appearance but the switch type is opposite.(Normally-
Closed Type)
This switch is a Normally-Closed Type and the two ter-
minal are usually stuck together so it is always on, but
mm
when the switch is activated the connection between 1.3 OF
F
the 2 terminals are cut, thus it is turned off.
If the sub shift lever is left on high speed, the switch is
activated and the connection between the 2 terminals ON
is cut. If the switch does not activate (turned off) on
high speed, a diversion adjustment must be made.
If the quick turn is activated on high speed, there are C45WB41A
safety risks so extra caution must be taken.

d. Left, right safety switch (Normally-Open Type)

The 2 terminals of this switch are normally separated
and are switched on by external activation.
m
3m
If the switch does not activate, the quick turn & auto ON
brake functions will not work even if you steer the front
F
wheel and turn it past the fixed angle, so to operate it OF
normally diversion control must be performed.

C45WB42A

DC45-W00 Nov-2004 11-41

CHAPTER 11 DK45S(DK451)

8.3 REPAIRS FOR QUICK TURN MAL-

FUNCTIONS
- If there is nothing wrong with the safety switch,
A. STANDARD INSPECTION METHOD check the 3P diode 3 & 4.(The diodes are located
When repairs are being carried out on the electric near the ignition motor in the bonnet wiring)
system, first check the fuse and then conduct an in- with this diode test, if there are no defects in the
spection by sight. After checking the wiring terminal for front terminal of the circuit, measure the voltage
assembly error, shift in the terminal, missing termi- of the middle terminal when the front axle is
nals etc. check the circuit system. Check that each turning; if approximately +12V is measured then
switch has been adjusted well for diversion, and then it is functioning normally.
check the activation of the sub shift switch & safety
- Check the quick turn relay.
switch in the case where the sub shift lever is shifted
and when the front axle is turning. e. Quick turn does not work while the front axle is
turning when the drive selection switch is in
Next, when the relay types are checked, refer to the
QT+AB.
name plate of the relay box to determine the position,
then check that each relay operate well when the re- - c) after checking diode 1,2 in the port if there are
lated switch is activated. no defects d)check the port.
With the diode test, if the + terminal of the circuit tester f. Auto brake does not work while the front axle is
and the diode + is connected in the forward direction turning when the drive selection switch is in
the reading is about 0 ~ and the opposite tester + QT+AB.
terminal and diode – terminal are connected the read- - c)after checking the port, check the auto brake
ing should be in the normal state. relay in the turning direction. (eg: if the turn direc-
Lastly, the solenoid types are tested by resistance tion is left, check the left brake relay)
measurement of the solenoid unit coil or by checking
activation by directly applying DC voltage.

B. MAIN CAUSES FOR EACH MALFUNCTION

CASE
a. 4WD does not work.
- Check the fuse marked 4WD,QT,QT+AB in the
fuse box.
- If there is nothing wrong with the fuse, check the
quick turn relay.
b. When the drive selection switch is on QT, 4WD
does not work when the front axle does not turn.
- After checking the fuse system, check diode 1,
and then check the quick turn relay.
(diode 1 is located near the drive selection switch
wiring)
c. 4WD does not work when the drive selection
switch is in QT+AB and the front axle is not turning.
- After checking the fuse system, check diode 1, 2,
and then check the quick turn relay.
d. Quick turn does not work when the drive selec-
tion switch is in QT and the front axle is turning.
- Check the fuse marked 4WD,QT,QT+AB , sub
shift relay in the fuse box.
- If there is nothing wrong with the fuse, check that
the sub shift lever switch is working.
- Detach the 2 terminals located in the safety switch
in the turning direction from the bonnet wiring.
Check that the safety switch turns on when the
front axle turns and if it doesn’t, adjust the safety
switch diversion to make it turn on.

11-42 DC45-W00 Nov-2004

 ELECTRICAL SYSTEM

9. AIR CONDITIONING SYSTEM

9.1 CIRCUIT DIAGRAM

C45WB46A

(1) Battery (5) Thermistor (9) Receive Driver Pressure Switch

(2) Slow Blow Fuse (60A) (6) Air Conditioner Controller (10) Air Conditioner Relay
(3) Main Switch (7) Compressor (11) Air Conditioner Unit
(4) Ignition Relay (8) Fuse 25A

A. CIRCUIT DESCRIPTION
This is electric circuit diagram for air conditioning Main Switch(3) ON Select switch of air conditioner
system. controller(6) ON (Low, Medium, High) Blower motor
The magnetic clutch in compressor has the operating of Air conditioner(11) unit ON Adjust the temperature
sequence as below. setting by VR for temperature control. The inner relay
continues to operate for turning on the compressor
when the temperature of thermistor is higher than tem-
perature setting. If the temperature of thermistor is lower
than temperature setting, the inner relay is turned off
and the receiver driver pressure switch(9) cuts off the
air conditioner relay(10) to disengage magnetic clutch
on compressor. Pressure switch(9) ON (If the pres-
sure in receiver driver goes over a certain level, the
switch is turned off to disengage magnetic clutch)
Air conditioner relay(10) ON Compressor(5) ON

DC45-W00 Nov-2004 11-43

CHAPTER 11 DK45S(DK451)

9.2 MAJOR COMPONENTS

A. AIR CONDITIONER CONTROLLER AND
UNIT
a . APPEARANCE
(1) Air Con. Unit
(2) Thermistor
(3) Connecter
(4) Blower Motor
(5) Select Switch
(6) LED(Green)
(7) Temp. Control Variable Resistor
(8) Connecter
(9) Air conditioner controller

C45WB47A

b. OPERATION c. TROUBLESHOOTING
• Air conditioner is turned on regardless of the posi- 1. Check whether the power is supplied to air condi-
tion of select switch (Low, Medium, High). tioner controller (LED ON)
• Select the required temperature by temperature con- If the power cannot be properly supplied to air con-
trolling variable resistor (according to the ambient ditioner controller, check the operation of fuse sys-
temperature, season and user's selection etc.). tem and ignition relay when the key is in ON position.
• The blowing speed varies as the selected position 2. If the power can be properly supplied to air condi-
of blower motor (Low, Medium, High). tioner controller, check that the blower motor can
The blowing speed in High position of select switch be operated in which position (Low, Medium and
is faster than that of Medium and Low position be- High).
cause the blow doesn't need to pass through any If the blower motor cannot be operated, check the
internal obstacles. connector and inner resistor for faulty (for resistor,
• Thermistor is a type of temperature sensor that the check the resistance).
resistance value varies as temperature. 3. If the blower motor can be operated but it cannot
The resistance value becomes higher as the ambi- produce cool air, for electric system, check that the
ent temperature is low, and vice versa. setting temperature of temperature control variable
resistor (VR) is too low compared to ambient
Compare the temperature resistance value of ther- temperature. In addition to, check that the magnet
mistor with the setting value by temperature control switch can be operated when the receiver driver
variable resistor in air conditioner controller, and pressure switch and air conditioner relay is turned
adjust the room temperature to setting temperature on.
by controlling the compressor.
For the problems in non-electric system, check the
coolant circulation for faulty.

11-44 DC45-W00 Nov-2004

 ELECTRICAL SYSTEM

B. COMPRESSOR
a . OPERATION
• Voltage : DC 12V , 135W
• The coil inside compressor triggers the magnetic
clutch by its magnetization force when the power is
supplied through the connector.
b. TROUBLESHOOTING
The magnetic clutch should be operated when +12V is
applied to the connector on the compressor that is at-
tached to the frame (ground the compressor body (-)).
Or, it is normal that multitester displays few s be-
tween two terminals in the connector (normal value:
approx. 3 ).
C45WB48A

(1) Magnetic Clutch

(2) Connecter

C. RECEIVER DRIVER PRESSURE SWITCH

a . OPERATION
The pressure switch (Normal Open type) is turned on
to connect two terminals in the connector when the
receiver driver is pressurized.
The pressure switch is turned off (connection between
two terminals is disconnected) when the receiver driver
is not pressurized, for example, when removing the
pressure pipes for maintenance or when the actual
pressure is not sufficient for proper operation.

C45WB49A

(1) Receive Driver

(2) Pressure Switch
(3) Connecter

D. AIR CONDITIONER RELAY

See section 8.6 Relay box (10) Air con. Relay(4P)

DC45-W00 Nov-2004 11-45

CHAPTER 11 DK45S(DK451)

10. HEATER SYSTEM

C45WB50A

(1) Battery (6) Fuse 25A

(2) Slow Blow Fuse (60A) (7) Select Switch
(3) Main Switch (8) Blower Motor
(4) Ignition Relay (9) Connecter
(5) Heater Unit (10) Resistor

A. CIRCUIT DESCRIPTION
If the engine is running, the blower motor of heater unit
can always operate regardless of the heater switch
position (Low or High) and the air flows out through the
hose.

B. TROUBLESHOOTING
a. Check whether the power is supplied to heater unit.
If the power cannot be properly supplied to heater
unit, check the operation of fuse system and igni-
tion relay when the key is in ON position.
b. If the power can be properly supplied to heater unit,
check that the blower motor can be operated in
which position (Low or High).
If the blower motor cannot be operated, check the
connector and inner resistor for faulty (for resistor,
check the resistance).
c. If the blower motor can be operated but it cannot
produce hot air, for the problems in non-electric
system, check the coolant circulation for faulty in
non-electric.

11-46 DC45-W00 Nov-2004