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

t t t t controller、
t ll
power supply protector
Index
• Section 1 Electrical parts familiarization

• Section 2 Contents of engine speed control system

• Section 3 Rev calibration

• Section 4 Precautions to service

 Section 1
El t i l parts
Electrical t familiarization
f ili i ti
• Multi-tester
u es e • relays
l
• fuel cut off relay and start • power supply protector
relayy
• coil
il manager
• main power supply relay
• engine oil pressure sensor
• fuse indicator
• b tt
battery、main i power switch、
it h
• wiper controller earth point
• actuator • frame lights
• controllers and extension • in-cab light
harness • h
horns
• monitor • fuel level sensor

返
回
 Section 1
Electrical parts familiarization
• p
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
ev sensor
se so
• electro-magnetic clutch of air
• actuator control
compressor
• neutral switch
• fuel cut-off solenoid valve
• fuse
f box
b
• washer motor、pressure protection
switches • relationship between temperature
sensors and their resistance
• ignition and combination switches
Multi-tester

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Multi-tester

pointer R i
Resistance range

Dc range
Dc voltage range

Ac range
Ac voltage range

voltage、resistance
amperage（series） measurement
（parallel）

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 Fuel cut-off valve relay and start relay

control ends

Fuel cut-off
valve relay

Fuel cut-off valve main contacts start relay

relay
y and start
relay

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Main power supply relay
control
t l ends
d

Main power supply relay

main
i contacts
t t

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Fuse indicator

Number displayed indicates

the corresponding fuse burnt。

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Schematic drawing of fuse indicator

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Wiper
p controller

The location on machine

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Schematic drawingg of wiper
p controller

The location on
schematic drawing

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 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 tto washer
h motor
t

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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
d extends
d or retracts to the
h
ends.

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The location on schematic
d
drawing
i
 Controllers and extensional harness

JP201

JP200

controller

Please fill the serial number into the service extension

report form when the controller fails.

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X62

X63

controller
X64

JP201、JP200 plug
connectors
Extensional harness
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 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(各类传感器)
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to throttle position switch

from auto-idle
selection switch

24V ffrom start

t t
circuit

from pilot
p
pressure
switches

from travel
speed relay

P200(油门位置及自动怠速)
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Monitor

X35connector

Menu

Left

monitor
return

ok

With display and input

function
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 monitor

spare
24V

earthh
shield for
communication communication cables
cables to controller

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Relays

30 86

87

relays
85

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Power supply protector

actuator control

power supply protector

built-in processing circuit

To protect electrical
T l i l parts from
f
being damaged by high voltage.
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Coil manager

X60 connector

coil
il manager

X59 connector

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Coil manager

Fuel cut-off
valve
Coil
g
manager

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Coil manager

• There are three wires (red,(red white,

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
(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.

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Engine oil pressure sensor

Engine oil
pressure
sensor and
switch for
reading
and alarm

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 WK pole Engine oil pressure
sensor and switch
To controller

To controller

G pole

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Battery, main power switch & earth

main power
switch

common earth

battery

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 common
earth

iinspection
ti b tt
battery
window
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 No.111cable

10A fuse battery

No.105 cable
main power switch
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Frame light

T l box
Tool b

f
frame li ht
light

24V from frame light

g relayy

earth

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Indoor lights

built-in switch

indoor lights earthh 24V in

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Horns

horns

24V power
horns
earthh through
h h
horn button
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Fuel level sensor

Fuel level sensor

Resistance range
g is from
0~76Ω. Full level will be
displayed when resistance is
0Ω.

Fuel level sensor

Send a resistance
signal to controller

Earth or suspend

earth
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 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 ppilot))
334 wire transfers a earth or
suspension signal to controller

earth
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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
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Travel solenoid valve, pilot cut-off solenoid valve

Travel
solenoid valve
& pilot cut-off
solenoid valve

X98、X49
connectors

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 pilot
il t cut-off
t ff
solenoid valve

Travel
solenoid valve

connect the wires

correctly (diode inside)

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Start motor

Start motor

Engine harness

X6、X7 connectors

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Start motor turns when 633 wire
is powered.

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Alternator

B+

B-

alternator

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 60A fuse
alternator
lt t

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.
battery
establishes at “L” end to protect the start
motor.
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Water temperature sensor

cooling water
temperature sensor

the sensor resistance

changes according to the
change of water temperature.

output
p cooling water
resistance temperature
of sensor sensor

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 Electro-magnetic clutch

compressor

Compressor will only

work when electro-
magnetic clutch
engages.

24V in electro-magnetic
l i clutch
l h

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Fuel cut-off solenoid valve

Fuel cut-off valve

White, red and

black wires from
solenoid valve to
coil manager

Fuel cut
cut-off
off
1Ω between white and valve
black wires

40Ω between red and

black wires
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 Working principle of fuel cut-off solenoid valve

• When fuel cut

cut-off
off valve is normal, turn the ignition switch to “on”
on position and
holding coil (between red and black wires) is powered (24V), but fuel cut-off valve
doesn’t act；
• At the
th momentt off turning
t i the th ignition
i iti switch t “start”
it h to “ t t” ，the
th pushh & pull
ll coil
il is
i
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
cut-off
off
solenoid
Coil valve
manager

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Washer motor、pressure protection switch

Washer motor

Pressure
protection
t ti
switch

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 Pressure
protection switch
earth or not?

earth

24V power
Washer motor
earthh

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 Ignition
g & combination switches

Ignition switch Auto idle Wash sprayer Travel alarm Boom light

Travel
ave speed Wiper
W pe switch
sw tc Siren
S e lamp
a p Frame
a e light
g t

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Schematic drawing of combination switch

LED

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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

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Throttle knob & AC control panel

AC control
panel

Throttle knob

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Throttle knob

Ten step throttle knob

to controller

to common earth

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AC system

- -
+ fuse
+ fan + heating
- switch
i h
+ compressor

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Lighter

lighter

To common earth

24V from fuse box

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Speaker

speaker

left speaker
connect to brown connector of
the radio

right
g t speaker
spea e

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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
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Hydraulic oil temperature sensor

hydraulic oil temperature sensor

Resistance of the sensor varies

according to the change of
h dra lic oil temperature
hydraulic temperat re

hydraulic oil
temperature sensor

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

40Ԩ 50 Ԩ 60 Ԩ 70 Ԩ 80 Ԩ 90 Ԩ 100 Ԩ 110 Ԩ 120 Ԩ

temperature

resistance 114Ω 118Ω 122Ω 126Ω 130Ω 134Ω 138Ω 142Ω 146Ω

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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
p sensor

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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 Ch
4. Checkk the
th voltage
lt output
t t ffrom speedd sensor after
ft iinstallation
t ll ti tot see if it is
i
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

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 Actuator controller

Different voltage signals from controller

throttle control
feedback signal
acceleration
deceleration 24V from fuse box
power supply
ignition switch 24V from
f fuse
f box
b (start
( t t circuit)
i it)
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

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 Actuator controller

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

To actuator, 24V will be output when the

actuator reaches the right
g pposition

To actuator,, 24V will be output

p when the
actuator reaches the right position
Neutral switch

Neutral switch
Neutral switch

control handle of
pilot cut-off valve

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Accelerating flexible cable

governor A l i flexible
Accelerating fl ibl cable
bl fl ibl cable
flexible bl holder
h ld

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Fuse box

Fuse box

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 11
1

10
20

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 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

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 Summary of engine speed control system

• controller + actuator controller + actuator +

monitor
i + ten step throttle
h l kknobb + pressure switch
i h
(auto idle)
• controller locates under the driver’s seat, actuator
controller locates inside of the control box
• Functions: electronic throttle, auto idle, vehicle
workingg condition collection

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Measurement of voltage

• Battery：voltage should be less than 25.6V

when
h engine
i stalls,
ll andd higher
hi h than
h 26V afterf
start
• Headlights, controller, actuator controller,
monitor, wiper controller, fuel cut-off solenoid
valve and start motor need 24V to work

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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

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 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

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Checking methods of abnormal engine speed

• Rev electrical control • checking step 8 • checking step 15

schematic drawing • checking step 16
• checking step 9
• checking step 1
• actuator control
• checking
h ki step t 2
connection chart
• checking step 3
• checking step 10
• checking
g stepp4
• checking step 5 • checking step 11
• checking step 6 • checking step 12
• checking step 7 • checking step 13
• checking step 14

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Rev electrical control schematic drawingg

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 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
g the main power
p switch

or controller 10A
main controller 10A

Fuse box
actuato

actuator
controller actuator
actuator controller
controls actuator

Main controller
main controller
controls actuator
controller
power

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 Checkingg step
p1

• 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
it is
i normal,
l otherwise
th i check h k the
th connectors
t forf looseness
l or wire
i
no.750,751 for continuity

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Checkingg step
p2

• Power off, unplug the connector

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

750
60Ω

75
1 返回
Checkingg step
p3

• 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 返回
Checking step 4

• check connectors X69 and X53 for waterproof condition.

condition take proper measure
accordingly

X69

X53

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 Checkingg step
p5

• 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

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 Checkingg step
p6

• 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.
A d speed
And d calibration
lib ti should
h ld beb carried
i d outt after
ft that.
th t

Throttle flexible cable

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Checkingg step
p7

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
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Checking step 8

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

Plug of actuator controller

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Checkingg step
p9

If no defect is found during above processes,

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

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Schematic drawing of actuator controller

Actuator controller

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

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Checkingg step
p 10

Wire 227 is earth

earth, wire 888 is throttle position control cable
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.

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Checkingg step
p 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
d the
h plug
l

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 Checkingg step
p 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

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Checkingg step
p 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
g fail, replace
p it
accordingly.

X70 connector

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Actuator controller

throttle control
feedback signal
acceleration
deceleration
power supply
i i i switch
ignition i h
earth
common/spare
change over

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 Checkingg step
p 14

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

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 Checkingg step
p 15

When actuator push rod is at utmost position,

position measure with diode range and digit 400~700
400 700
should be displayed if it is normal.

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Checkingg step
p 16

Iff the
h resistance
i between
b pin
i 3 andd 5 is
i aroundd 10KΩ, and d the
h sum off
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.

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Section 3 Rev calibration

Methods of rev calibration

Calibrating procedures

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 Methods of 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;
• C
Connect t the
th throttle
th ttl cable
bl with
ith the
th throttle
th ttl governor andd fix
fi the
th cable
bl onto
t the
th fastening
f t i
bracket (the tolerance is within 2mm when pull the cable), and ensure engine initial
position is at idle;
• S
Start the
h enginei according
di to theh instruction
i i on the
h monitor
i andd access to “Rev
“R
calibration”;
• Monitor shows the calibrating progress; follow the instruction on the monitor to switch
off the ignition after calibration.

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 Calibratingg procedures
p

step① input password

step②
t ② adjust
dj t th
throttle
ttl flflexible
ibl cable
bl
step③ start engine
step④ ignition off

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 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

********
图 26
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It will return to main interface automaticallyy if the ppassword is not correct;; or it will
show up the menu below:

ÃÜÂëÕýÈ·
ÃÜÂëÕýÈ
Password correct,
ÇëµÈ´ý£¡
Please wait!

图27
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Controller will reply to monitor after receiving the calibration request from the
monitor; and monitor will enter next interface after receiving the response.
response

Please start the engine

ÇëÆô¶¯·¢¶¯»ú
to carryy out calibration
½ ÐÐ ªËٱ궨
½øÐÐתËÙ±ê¶

图 28
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 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.

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 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 …

Done: XX%
ÒÑÍê³É XX %

图 29
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 Step 4: Off the ignition

Off the ignition, please

Çë¹ØµçËø
Restart the engine
ÖØÐÂÆô¶¯»úÆ÷ ¶g

图 30

Rev calibration is over, restart the engine. The whole procedure will take approx. 3 min.

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 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.

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