205C 225C

Electrical system
 Ac sys. in cabin ignition & combination switch

swing
platform

common
earth

relays

engine

fuse box and wiper controller controller actuator actuator controller

power supply protector
Index
• Section 1 Electrical parts familiarization

• Section 2 Contents of engine speed control system

• Section 3

• Section 4
 Section 1
Electrical parts familiarization
• Multi-tester • relays
• fuel cut off relay and start
• power supply protector
relay
• coil manager
• main power supply relay
• engine oil pressure sensor
• fuse indicator
• battery main power switch
• wiper controller earth point
• actuator • frame lights
• controllers and extension • in-cab light
harness • horns
• monitor • fuel level sensor
 Section 1
Electrical parts familiarization
• pressure switches • throttle knob AC control panel
• travel and pilot cut-off solenoid • lighter
switches • speaker
• start motor
• heating water solenoid valve
• alternator
• hydraulic oil temperature sensor
• water temperature sensor
• Rev sensor
• electro-magnetic clutch of air
• actuator control
compressor
• neutral switch
• fuel cut-off solenoid valve
• fuse box
• washer motor pressure protection
switches • relationship between temperature
sensors and their resistance
• ignition and combination switches
Multi-tester
Multi-tester

pointer Resistance range

Dc range
Dc voltage range

Ac range
Ac voltage range

voltage resistance
amperage series measurement
parallel
 Fuel cut-off valve relay and start relay

control ends

Fuel cut-off
valve relay

Fuel cut-off valve main contacts start relay

relay and start
relay
Main power supply relay
control ends

Main power supply relay

main contacts
Fuse indicator

Number displayed indicates

the corresponding fuse burnt
Schematic drawing of fuse indicator
Wiper controller

The location on machine

Schematic drawing of wiper controller

The location on
schematic drawing
 24V from sprayer switch

wash control
24V from wiper switch
intermittent 1
reset
reverse
forward To wiper motor

sequence control

reverse control
Wiper controller

24V from power supply

power

24V from wiper switch

low speed

earth

washer motor “+”

24V to washer motor
Throttle actuator

The actuator will act as long

as the voltage difference exists
between pin 1 and 4 and it
will be powered off when the
rod extends or retracts to the
ends.
The location on schematic
drawing
 Controllers and extensional harness

JP201

JP200

controller

Please fill the serial number into the service extension

report form when the controller fails.
X62

X63

controller
X64

JP201 JP200 plug

connectors
Extensional harness
 To fuel level sensor

To water temperature sensor

To engine oil pressure sensor

To hydraulic oil temperature sensor

24V power

to throttle actuator

to monitor

to Rev sensor

earth

P201( )
to throttle position switch

from auto-idle
selection switch

24V from start

circuit

from pilot
pressure
switches

from travel
speed relay

P200( )
Monitor

X35connector

Menu

Left

monitor
return

ok

With display and input

function
 monitor

spare
24V

earth
shield for
communication communication cables
cables to controller
Relays

30 86

87

relays
85
Power supply protector

actuator control

power supply protector

built-in processing circuit

To protect electrical parts from

being damaged by high voltage.
Coil manager

X60 connector

coil manager

X59 connector
Coil manager

Fuel cut-off
valve
Coil
manager
Coil manager

• There are three wires (red, white, black) at both ends of coil manager
respectively.
• Red and black wires control the holding coil of the fuel cut-off valve while
white and black control the push & pull coil.
• Wires at input and output ends are consistently connected but the white wire
at output end is restricted by timing device (approx.1s) that is the white wire
at output end will be powered off approx.1s after the circuit is powered. By
doing so, the push & pull coil can be protected.
Engine oil pressure sensor

Engine oil
pressure
sensor and
switch for
reading
and alarm
 WK pole Engine oil pressure
sensor and switch
To controller

To controller

G pole
Battery, main power switch & earth

main power
switch

common earth

battery
 common
earth

inspection battery
window
 No.111cable

10A fuse battery

No.105 cable
main power switch
Frame light

Tool box

frame light

24V from frame light relay

earth
Indoor lights

built-in switch

indoor lights earth 24V in

Horns

horns

24V power
horns
earth through
horn button
Fuel level sensor

Fuel level sensor

Resistance range is from

0~76 . Full level will be
displayed when resistance is
0 .

Fuel level sensor

Send a resistance
signal to controller

Earth or suspend

earth
 Pressure switch (foot pilot)

Senses hydraulic oil pressure in foot

pilot circuit , and the pressure switch
will open when preset pressure is
established. (auto idle signal)

Pressure switch (foot pilot)

Pressure switch
(foot pilot)
334 wire transfers a earth or
suspension signal to controller

earth
Pressure switch (hand pilot)

Senses the hand pilot circuit hydraulic oil

pressure, and the pressure switch will open
when preset pressure is established.
(auto idle signal)

Pressure switch(hand pilot)

Pressure
(hand pilot)
306 wire transfers a earth or
suspension signal to controller

earth
Travel solenoid valve, pilot cut-off solenoid valve

Travel
solenoid valve
& pilot cut-off
solenoid valve

X98 X49
connectors
 pilot cut-off
solenoid valve

Travel
solenoid valve

connect the wires

correctly (diode inside)
Start motor

Start motor

Engine harness

X6 X7 connectors
Start motor turns when 633 wire
is powered.
Alternator

B+

B-

alternator
 60A fuse
alternator

to black wire on fuel

cut-off valve, i.e..
earth

Output B+ provides
To start protection relay, the relay will
power to vehicle and
cut the power to start motor when voltage
charges the battery.
establishes at “L” end to protect the start
motor.
Water temperature sensor

cooling water
temperature sensor

the sensor resistance

changes according to the
change of water temperature.

output cooling water

resistance temperature
of sensor sensor
 Electro-magnetic clutch

compressor

Compressor will only

work when electro-
magnetic clutch
engages.

24V in electro-magnetic clutch

Fuel cut-off solenoid valve

Fuel cut-off valve

White, red and

black wires from
solenoid valve to
coil manager

Fuel cut-off
1 between white and valve
black wires

40 between red and

black wires
 Working principle of fuel cut-off solenoid valve

• When fuel cut-off valve is normal, turn the ignition switch to “on” position and
holding coil (between red and black wires) is powered (24V), but fuel cut-off valve
doesn’t act
• At the moment of turning the ignition switch to start” the push & pull coil is
powered (between white and black) and works together with the holding coil to
actuate the solenoid valve;
• Release the ignition switch and the push & pull coil is powered off, but the
solenoid is still engaged by holding coil.

Fuel cut-off
solenoid
Coil valve
manager
Washer motor pressure protection switch

Washer motor

Pressure
protection
switch
 Pressure
protection switch
earth or not?

earth

24V power
Washer motor
earth
 Ignition & combination switches

Ignition switch Auto idle Wash sprayer Travel alarm Boom light

Travel speed Wiper switch Siren lamp Frame light

Schematic drawing of combination switch

LED
Ignition switch
On the main power switch and B1,B2 is powered (24V)

Ignition on will connect B1and M to power the vehicle

Turn the ignition switch to “start” will connect B1and S

to actuate the start motor
Throttle knob & AC control panel

AC control
panel

Throttle knob
Throttle knob

Ten step throttle knob

to controller

to common earth
AC system

- -
+ fuse
+ fan + heating
- switch
+ compressor
Lighter

lighter

To common earth

24V from fuse box

Speaker

speaker

left speaker
connect to brown connector of
the radio

right speaker
Warm water solenoid valve

Warm water solenoid valve

Controls the water to warm

the cab through AC system

24V in Warm water

solenoid
earth valve
Hydraulic oil temperature sensor

hydraulic oil temperature sensor

Resistance of the sensor varies

according to the change of
hydraulic oil temperature

hydraulic oil
temperature sensor
Relationship between resistance and temperature
of hydraulic oil/water temperature sensors

40 50 60 70 80 90 100 110 120

temperature

resistance 114 118 122 126 130 134 138 142 146
Speed sensor

Speed sensor

It will be no Rev display if there

isn’t any voltage output, and also,
the speed calibration will fail.

Speed sensor
Speed sensor

1. Speed sensor outputs the rev signal after starting the engine
2. Installation of speed sensor screw the sensor in till touches the tip
of the flywheel and then retract 1.5turns back (make a mark before
retraction)
3. 3-28AV could be detected from speed sensor when engine speed is
between 1000~2270r/min
4. Check the voltage output from speed sensor after installation to see if it is
between 3~28V
5. Controller will fail to receive the signal if it is below 3V, and if it is over
28V, controller might be damaged
Actuator controller

Fill the serial number

into the service report
form if the actuator
controller fails

Actuator controller
connects the power
protector

Actuator controller
 Actuator controller

Different voltage signals from controller

throttle control
feedback signal
acceleration
deceleration 24V from fuse box
power supply
ignition switch 24V from fuse box (start circuit)
earth
To common earth
common/spare
change over Between 3and 5 is 5V

When disconnects with actuator,

the voltage is 0V

Then:12V output

Then:24V output
 Actuator controller

throttle control
feedback signal
acceleration
deceleration
power supply Between 3and 5 is 5V
ignition switch
earth
common/spare When connects with actuator, the
change over voltage varies from 0-5V

To actuator, 24V will be output when the

actuator reaches the right position

To actuator, 24V will be output when the

actuator reaches the right position
Neutral switch

Neutral switch
Neutral switch

control handle of
pilot cut-off valve
Accelerating flexible cable

governor Accelerating flexible cable flexible cable holder

Fuse box

Fuse box
 11
1

10
20
 Section 2
Contents of engine speed control system

• summary of engine speed control system

• measurement of voltage
• cable/wire familiarization
• plug connector familiarization
• checking methods of abnormal engine speed
 Summary of engine speed control system

• controller + actuator controller + actuator +

monitor + ten step throttle knob + pressure switch
(auto idle)
• controller locates under the driver’s seat, actuator
controller locates inside of the control box
• Functions: electronic throttle, auto idle, vehicle
working condition collection
Measurement of voltage

• Battery voltage should be less than 25.6V

when engine stalls, and higher than 26V after
start
• Headlights, controller, actuator controller,
monitor, wiper controller, fuel cut-off solenoid
valve and start motor need 24V to work
Cable/wire familiarization

Recognition of cables

e.g.
No. color specs mm2

color code

black blue violet

grey green white

red yellow orange

brown pink
 socket
plug This side up
Number of pins

1 2 3
3 2 1

4 5 6
6 5 4

Name of
connector is
written on
the casing
well plugged
Checking methods of abnormal engine speed
Rev electrical control schematic drawing
 No.1-15fuses get power when ignition switch is on

No.16-19fuses get power when main switch is on

No.20 fuse is normally powered without
switching the main power switch

actuator controller 10A

main controller 10A

Fuse box
actuator
controller actuator
actuator controller
controls actuator

Main controller
main controller
controls actuator
controller
power
 Checking step 1

• Ignition on and turn the throttle knob

• Observe if the value displayed on monitor changes in accordance with the
turning of the knob; if it does, the communication between controller and
monitor is normal, otherwise check the connectors for looseness or wire
no.750,751 for continuity
Checking step 2

• Power off, unplug the connector

• Measure the resistances between wire No.750, 751 and controller respectively
• If resistance is around 60 ohm that means the circuit is normal, otherwise
circuit is open or short
Checking step 3

• Check the condition of controller and throttle control fuses

• check all fuses
• the actual function of particular fuse might not be
in accordance with what labeled out because of
system modification

power in

signal in signal out

Check fuse
controller, monitor or
actuator controller earth
Checking step 4

• check connectors X69 and X53 for waterproof condition. take proper measure
accordingly

X69

X53
Checking step 5

• At the moment of ignition on , movement from actuator push rod could be

observed (retracts a bit and then moves out), and that shows the actuator
controller is normal, otherwise the actuator controller might fail (it has
nothing to do with main controller), carry out next step

push rod of actuator

Checking step 6

• Check the tightness of the engine throttle flexible cable including the fastening
bracket
• If manual throttle is on use at the moment, change it over to electronic throttle.
And speed calibration should be carried out after that.

Throttle flexible cable

Checking step 7

Check the tightness of the connection between actuator and its controller (they are
connected through frame harness)

Plug on
actuator
controller
side

Frame harness
plug on actuator side
Checking step 8

Check the tightness of the connection between actuator controller and frame
harness

Plug of actuator controller

Checking step 9

If no defect is found during above processes,

disconnect X69 and check the plug on
frame harness side, turn the main power and
Ignition switches on and wires 108 and
131should be 24V, otherwise check the
throttle control fuse from the fuse box.

X69 plug connector

Schematic drawing of actuator controller

Actuator controller

throttle control
feedback signal
acceleration
deceleration
power supply
ignition switch
earth
common/spare
change over
Checking step 10

Wire 227 is earth, wire 888 is throttle position control cable.

The voltage should vary from several V to ten V or so in accordance with the
turning of the throttle knob after starting the engine, otherwise check the
connection of wire 888 and controller.
Checking step 11

If wire 888 is well connected with

controller, then redo X69 after stop
the engine;
Start the engine again, if the speed
changes by turning the throttle knob,
then normal engine speed could be
recovered after re-calibration.

Redo the plug

 Checking step 12

If above signals are normal, redo X69 and disconnect X70 (it was X53 before power
protector was introduced);
Measure the socket from actuator controller end, the voltage between pin3and 5 should be
5V, otherwise actuator controller might fail, replace it.

X70 connector
Checking step 13

Pin 1 should have 12V and pin 4 should have 24V when X70 is unplugged;
Redo X70 and turn the throttle knob, either pin 1 or pin 4 should have voltage of less
than 24V, and another should be 24V, otherwise actuator controller might fail, replace it
accordingly.

X70 connector
Actuator controller

throttle control
feedback signal
acceleration
deceleration
power supply
ignition switch
earth
common/spare
change over
 Checking step 14

If above signals are normal, check X70 at actuator end; measure the resistance between pin
1 and 4 with 200 range when actuator push rod is not at utmost position, and the
resistance should be around 4~10
 Checking step 15

When actuator push rod is at utmost position, measure with diode range and digit 400~700
should be displayed if it is normal.
Checking step 16

If the resistance between pin 3 and 5 is around 10K , and the sum of
resistance between pin 2 and 5 and resistance between pin 2 and 3 equals the
resistance between pin 3 and 5, then actuator is normal, otherwise replace the
actuator.
Section 3 Rev calibration
• Turn the main power and ignition switches on after finishing the wiring;
• Get into the “ex-works setting” menu on the monitor and enter the password;
• Select “Rev calibration” item, actuator push rod will reach out to utmost position;
• Connect the throttle cable with the throttle governor and fix the cable onto the fastening
bracket (the tolerance is within 2mm when pull the cable), and ensure engine initial
position is at idle;
• Start the engine according to the instruction on the monitor and access to “Rev
calibration”;
• Monitor shows the calibrating progress; follow the instruction on the monitor to switch
off the ignition after calibration.
Calibrating procedures
 Step 1: enter password

This function could only be used when debugging the new machine or a certain speed need
to be re-calibrated.
Before start the engine, press “up” or “down” key to select “speed calibration”; and common
setting password would be needed at this stage.
The common setting password is “30000000”.

ÇëÊäÈëÃÜÂë
Enter password please

********
It will return to main interface automatically if the password is not correct; or it will
show up the menu below:

ÃÜÂëÕýÈ·
Password correct,
ÇëµÈ´ý£¡
Please wait!
Controller will reply to monitor after receiving the calibration request from the
monitor; and monitor will enter next interface after receiving the response.

Please
ÇëÆô¶¯start the engine
·¢¶¯ »ú
to carry out calibration
½øÐÐתËٱ궨

28
 Step 2: Adjust throttle flexible cable

At the moment, the throttle push rod

is fully out. Connect the throttle cable
with the governor and fix it onto the
fastening bracket.
Ensure the tolerance is within 2mm
when pull the cable.
 Step 3: Start the engine

Enter next interface after start. Engine will speed up from min. to max. speed and
then drop to idle automatically. XX% indicates the calibration speed.

ÕýÔڱ궨תËÙ
Calibrating …

ÒÑÍê³É XX %
Done: XX%
 Step 4: Off the ignition

Çë¹ØµçËø
Off the ignition, please
ÖØÐÂÆô¶¯ »úÆ÷
Restart the engine

30

Rev calibration is over, restart the engine. The whole procedure will take approx. 3 min.
 Section 4 Notice to maintenance

• It’s not allowed to let alternator supply the power alone;

• Do not unplug the connectors with the power on;
• Use proper testing equipment to check if the electrical part is
electrified;
• The actuator has very low possibility of being faulty under normal
condition.