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B110

B115

SECTION 55 - ELECTRICAL SYSTEM

1. GENERALITIES ............................................................................................................................................ 3
1.1 TEMPORARY WIRING HARNESS REPAIR ......................................................................................... 3
1.2 FAULT FINDING.................................................................................................................................... 4
2. ELECTRICAL DIAGRAMS............................................................................................................................ 5
2.1 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB ........................................................................... 5
2.2 ELECTRICAL DIAGRAMS - POWERSHIFT CAB ............................................................................... 22
2.3 ELECTRICAL DIAGRAMS - 4WS........................................................................................................ 39
3. CONTROLS AND INSTRUMENTS ............................................................................................................ 57
3.1 FRONT INSTRUMENT PANEL ........................................................................................................... 57
3.2 CALIBRATION OF SPEEDOMETER .................................................................................................. 59
3.3 SIDE INSTRUMENT PANEL ............................................................................................................... 60
3.4 IMMOBILISER CIRCUIT...................................................................................................................... 64
4. DIAGNOSTICS DISPLAY ........................................................................................................................... 65
4.1 SYMBOL .............................................................................................................................................. 66
4.2 SETUP MENU ..................................................................................................................................... 67
4.3 SETUP MENU ..................................................................................................................................... 68
4.4 PROCEDURE ABOUT SELF TEST .................................................................................................... 69
4.5 ON BOARD ERROR CODE RETRIEVAL ........................................................................................... 70
4.6 BACKLIGHTING AND DIMMING......................................................................................................... 71
4.7 WORK HOURS.................................................................................................................................... 72
4.8 FUNCTIONAL DESCRIPTION ............................................................................................................ 73
4.9 MAINTENANCE................................................................................................................................... 79
4.10 WARNING MESSAGES .................................................................................................................... 80
5. STARTING SYSTEM .................................................................................................................................. 86
5.1 DESCRIPTION AND OPERATION...................................................................................................... 86
5.2 FAULT FINDING.................................................................................................................................. 87
5.3 STARTER MOTOR.............................................................................................................................. 90
2 SECTION 55 - ELECTRICAL SYSTEM

6. ALTERNATOR ............................................................................................................................................ 96
6.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 96
6.2 DESCRIPTION AND OPERATION...................................................................................................... 96
6.3 COMPONENTS ................................................................................................................................... 98
6.4 REMOVAL............................................................................................................................................ 99
6.5 PRELIMINARY CHECK AND TESTS ................................................................................................ 100
6.6 FAULT FINDING ................................................................................................................................ 109
7. BATTERY.................................................................................................................................................. 110
7.1 TECHNICAL SPECIFICATIONS........................................................................................................ 110
7.2 DESCRIPTION AND OPERATION.................................................................................................... 110
7.3 BATTERY REPLACEMENT............................................................................................................... 111
7.4 MAINTENANCE ................................................................................................................................. 113
7.5 TESTS................................................................................................................................................ 115
7.6 CONNECTING A BOOSTER BATTERY ........................................................................................... 117
7.7 BATTERY MASTER SWITCH ........................................................................................................... 117
8. COMPONENT TESTING .......................................................................................................................... 118
8.1 GENERAL INTRODUCTION ............................................................................................................. 118
8.2 COMPONENT TESTING ................................................................................................................... 119
8.3 GROUND POINTS............................................................................................................................. 119
8.4 KEY-START AND STOP SWITCH .................................................................................................... 121
8.5 ALTERNATOR ................................................................................................................................... 122
8.6 TRANSMISSIONS ............................................................................................................................. 122
8.7 PARKING BRAKE SWITCH............................................................................................................... 126
8.8 CAB.................................................................................................................................................... 127
8.9 4WD SWITCH .................................................................................................................................... 132
8.10 BRAKE PEDAL SWITCHES ............................................................................................................ 132
8.11 BRAKE OIL LEVEL SWITCH........................................................................................................... 133
8.12 FRONT WORK LAMP SWITCH (1) - REAR WORK LAMP SWITCH (2) MAIN LIGHT SWITCH.... 133
8.13 HAZARD SWITCH ........................................................................................................................... 134
8.14 FLASHER MODULE ........................................................................................................................ 134
8.15 MULTI FUNCTION SWITCH............................................................................................................ 135
8.16 FRONT WIPER MOTOR (1) - REAR WIPER MOTOR - (2) ............................................................ 135
8.17 4WS -STEERING SELECTOR SWITCH ......................................................................................... 136
8.18 STEERING CONTROL UNIT........................................................................................................... 137
8.19 4WS REAR AXLE STEERING SENSOR......................................................................................... 139
8.20 4WS FRONT AXLE STEERING SENSOR ...................................................................................... 139
8.21 STEERING SOLENOIDS................................................................................................................. 140
8.22 DIFFERENTIAL LOCK SWITCH (1) ................................................................................................ 141
8.23 LOADER .......................................................................................................................................... 142
8.24 BACKHOE........................................................................................................................................ 144
8.25 REVERSING BUZZER..................................................................................................................... 149
8.26 FUEL LEVEL SENDER.................................................................................................................... 149
SECTION 55 - ELECTRICAL SYSTEM 3

1. GENERALITIES
1.1 TEMPORARY WIRING HARNESS REPAIR

The following method to repair wiring is a temporary


expedient only. Wiring should be replaced as soon
as possible. Replacement of temporary repaired ca-
bles with new is particularly important if the loader
backhoe is to be used for spraying as chemicals can
enter the repaired area, travel up the cable and dam-
age electrical components. Do not attempt to repair
the wire on any system sensors as these are sealed
and should only be replaced with a new component.

NOTE: when conducting a cable repair it is impor-


tant that only RESIN CORED SOLDER is used. Use
of other types of solder ma result in further cable
damage.

To carry out a temporary repair, proceed as follows:


Locate damaged portion of cable then cut away
outer protective cover on both sides of the dam-
aged area.
Peel back the cable from both ends of the dam-
aged area and carefully cut away the inner cable
cover at the damaged area and strip about 13 mm
(0.5 inch) of insulation from the wires. Do not cut
away any wire strands.
Using a suitable solvent, clean about 50 mm (2 in)
from each cover end. Clean the grey cable cover
and the individual leads.

Twist two bare leads together for each damaged


lead, being careful to match wire colours, then sol-
der the leads using resin cored solder. Tape each
repaired lead with vinyl insulation tape.
Wind a layer of vinyl insulation tape up to the grey
cable cover at each end of the repair section. Make
a paper trough, then apply silicon rubber com-
pound (non hardening sealant) over the repaired
section up to the cover ends. Sufficient sealant
must be used to fill the ends of the cut away area.

Allow the compound to cure then cover the area


with insulating tape taking the tape well over each
end of the repair. An overlap of at least 50 mm
(2 in) of tape at each end is necessary.
Check to ensure the repair is satisfactory and se-
cure the repaired cable so that repeat damage is
avoided.

NOTE: this is a temporary repair only. Ensure the


damaged cable is replaced as soon as possible to
prevent ingress of water or chemicals.
4 SECTION 55 - ELECTRICAL SYSTEM

1.2 FAULT FINDING

PROBLEM CAUSE ACTION


Check battery open circuit voltage
Loose or corroded battery
for 12.6 volts minimum.
connections
Check electrolyte level and specific
Clean and tighten connections
gravity.
Sulphated batteries
Electrical system is inoperative
Re-instate isolator switch.
Battery Isolator switch turned
“off”
Establish reason of failure and
Main machine fuse link blown
replace fuse link.
Clean and tighten loose
Loose or corroded connections
connections.

Check battery open circuit voltage


Low battery output
Starter speed low and engine for 12.6 volts minimum.
cranks slowly Check electrolyte level and specific
gravity.

Use correct viscosity oil for


Incorrect viscosity engine oil
temperature conditions.
Transmission shift lever in gear Place shift lever in neutral.

Loose or corroded connections Clean and tighten loose


Starter inoperative
connections.

Dead batteries Charge or replace batteries.


Low engine idle speed Increase idle speed.

Loose belt Check belt tension.

Charge indicator lamp stays on Malfunctioning battery Check battery open circuit voltage
with engine running for 12.6 volts minimum.
Check electrolyte level and specific
gravity.

Malfunctioning alternator Check alternator.


Clean and tighten connections.
Loose or corroded terminal
connections
Check battery open circuit voltage
Sulphated batteries
for 12.6 volts minimum.
Batteries will not charge
Check electrolyte level and specific
gravity.

Check automatic belt tensioner.


Loose or worn belt
Replace belt if required.
Charge indicator flashing
indicating excessive charging Malfunctioning alternator Check alternator.
voltage
SECTION 55 - ELECTRICAL SYSTEM 5

2. ELECTRICAL DIAGRAMS
2.1 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB

FUSES AND RELAYS DESCRIPTION

NAME DESCRIPTION
Rear windshield wiper and rear windshield washer
F1A
(15 A)
Fuel shut off, (+15) antitheft, (+15) key switch, supply
F1B
(+15) ECU (7.5 A)
F1C Stop lights switch (10 A)
Instruments power supply, switches lamps, brake oil
F2A
level sensor, seat (15 A)
F2B Conditioner (15 A)
F2C Pilot control (15 A)
Rear right/front left side lights, instruments illumination
F3A
(3 A)
F3B Rear left/front right side lights, number plate light (3 A)
Front work light, Ride control, double delivery, 4x1 grab
F3C
switches (10 A)
Forward speed, reverse speed, reverse buzzer, speed
F4A
switch (5 A)
Rear hammer button, grab level valve and sensor,
F4B
clutch shut off buttons (10 A)
Rear excavator lock, rear translation lock, rear transport
F4C
lock (10 A)
F5A Front inner work lights (15 A)
F5B Traffic lights (10 A)
F5C Main beam (15 A)
F6A Beacon lamp (7.5 A)
F6B (+15) Flasher (7.5 A)
F6C Hand hammer, 4WD (7.5 A)
F7A (+30) Warning horn (10 A)
F7B Current intake, radio, roof lamp (10 A)
F7C Front windshield wiper (6 A)
F8A Outer rear work lights (15 A)
F8B Outer front work lights (15 A)
F8C Inner rear work lights (15 A)
6 SECTION 55 - ELECTRICAL SYSTEM

NAME DESCRIPTION
K1 Forward-reverse speed switch relay
K3 Starting relay
K4 Grab level solenoid valve relay
K5 Traffic and main beam lights relay
K6 Inner front work lights relay
K7 Inner rear work lights relay
K8 Outer front work lights relay
K9 Outer rear work lights relay
K10 Reverse speed relay
K11 Forward speed relay
K1A Flasher
SECTION 55 - ELECTRICAL SYSTEM 7

COMPONENTS AND CONNECTORS

NAME DESCRIPTION NAME DESCRIPTION


A1 Right speaker (optional) F2 Power ECU fuse
A2 Left speaker (optional) F4 Electric fan fuse 3th speed
A53 Radio (optional) +30 antitheft, diagnostic plug, switch up/
F31
A106 Engine control unit down, display enter, panel instrument fuse
A131 Flasher unit FG4 Fuse A/C
B107 Water in fuel signal sensor G1 Battery
B4 Air filter switch G67 Alternator
B5 Fuel level sender H7 Reverse buzzer
B24 Hand accelerator sensor H32 Audible alarm
B25 Foot accelerator sensor HA2 Claxon
B26 Grab sender K102 Input start controller relay
B29 Grab level K103 Start relay
B30 Parking brake K104 Engine start relay
B33 Speed sensor (optional) K105 A/C relay
B66 Transmission oil temperature switch M1 Starter
B69 A/C pressure switch M39 Rear windshield wiper
B74 Trasmission oil pressure switch M41 Blower motor (optional)
B129 Brake oil level sender M49 Front windshield wiper
E15 Rotary beacon M56 Front windshield washer
E16 Rotary beacon M57 Rear windshield washer
E17 Lamp for socket M64 A/C compressor
E18 Cab interior light S15 Starting switch
E26 Block control lamp S23 Transmission disconnect button
E27 Number plate light S27 Rear horn button
E28 Rear left light S28 Decluch button
E29 Rear right light S34 Left door switch
E37 Rear right light S35 Right door switch
E38 Rear right work light S36 Rear hammer button (optional)
E40 Rear right work light (optional) S120 Hazard switch
E42 Front right indicator light S122 4WD switch
E44 Front right work light S123 Hand tool switch
E45 Front right work light (optional) S126 Lights switch
E46 Rear left work light (optional) S127 Rotary beacon switch
E47 Rear left work light S130 Windshield wiper-lights switch
E48 Rear left light S132 Gear shift switch
E50 Front left work light (optional) S136 Up and down switch
E51 Front left work light S137 Rear work lights switch
E52 Front left indicator S138 Rear wiper switch
E121 Front left light/horn S139 Display enter switch
E133 Front right light S140 Transport lock switch (optional)
E114 Valve block lamp switch (optional) S141 Front work lights switch
F1 Main fuse
8 SECTION 55 - ELECTRICAL SYSTEM

NAME DESCRIPTION NAME DESCRIPTION


S142 Ride control switch X125 12 ways MIC 70 connector
S143 Hydraulic speed control switch X130 12 ways DT connector
S150 Safety seat switch optional X131 13 Ways MARK connector
S134.1 Stop light switch X132 6 Ways DT connector
S134.2 Stop light switch X133 5 Ways MARK connector
SB1 Battery stopper X144 2 ways DT connector
ST1 Side panel X15.1 Starting switch MERIT connector
ST2 Front panel X15.2 Starting switch MERIT connector
ST3 Grab 4x1 X150 Safety seat switch 2 ways connector
X14 Antitheft-block control lamp X17 Seat option 4 ways connector
X17 Seat option Presetting relay grid heater option 2 ways
X2
X21 Diagnostic connector
X25 Foot accelerator connector X21 Diagnostic 10 ways connector
X31 Front loader quick coupler X23 EGS 9 ways DT connector
X55 Auxiliary 12 V socket X24 Hand accelerator 6 ways DT connector
X72 From pilot control cable X25 Foot accelerator 6 ways connector
X107 Water in fuel (WIF) X26 Grab sensor 3 ways DT connector
X124 Fast connection X27 Number plate 2 ways DT connector
X128 Optional X28 Rear left lamp 4 ways DT connector
XX From pilot control cable X29 Rear right lamp 4 ways DT connector
Y6 Forward speed solenoid valve Speed control solenoid valve 2 ways
X30
connector
Y7 Reverse speed solenoid valve
Front loader quick coupler 2 ways DT
Y8 4WD solenoid valve X208
connector
Y12 4X1 proportional solenoid valves optional
X32 Audible alarm 2 ways connector
Y25 Rear transport lock solenoid valve (optional)
X33 KM sensor 2 ways connector
Y30 Speed control solenoid valve (optional)
X34 Ride control 2 ways connector
Y32 Rear hammer solenoid valve (optional)
X35 Hand hammer button 2 ways connector
Y34 Ride control solenoid valve (optional)
X36 Rear hammer button 2 ways connector
Y35 Hand hammer solenoid valve
X37 Rear right light 4 ways connector
Engine-general wirings interface 18 ways
X1 X38 Rear right light 4 ways connector
connector
Rear windshield wiper motor 4 ways
Service-general wirings interface 31 ways X39
X10 connector
DT connector
X4 Air filter 2 ways connector
X106 Engine controller 89 ways Bosch connector
X40 Rear right light 4 ways connector
X107 Wif JPT 3 ways connector
X41 Blower motor 2 ways connector
X110 A/C 3 ways connector
X46 Left front light 4 ways connector
X111 A/C 9 ways mark connector
X42 Right front indicartor light 4 ways connector
Cabin-general wirings interface 5 ways
X12
MARK connector
X14 Antitheft 11 ways MARK connector
X121 7 ways MARK connector
SECTION 55 - ELECTRICAL SYSTEM 9

NAME DESCRIPTION NAME DESCRIPTION


X43 Beacon lamp 4 ways connector Fuse relay board-genaral wiring 7 ways
XC2
X44 Front right light 4 ways connector connector
X45 A/C 11 ways connector Fuse relay board-genaral wiring 21 ways
XC3
connector
Front right indicator light 4 ways
X58 Fuse relay board-genaral wiring 21 ways
connector XC4
connector
X47 Left rear light 4 ways connector
Fuse relay board-genaral wiring 17 ways
X48 4 ways connector XC5
connector
X49 6 ways connector
Fuse relay board-genaral wiring 13 ways
X5 Fuel level sender 2 ways DT connector XC6
connector
X50 Right front light 4 ways connector Panel instrument 20 ways MIC 70
XST1
X51 Left front light 4 ways connector connector
X52 Left front indicator light 4 ways connector Panel instrument 20 ways MIC 70
XST2
X53 8 ways connector connector
X54 Radio 8 ways connector Rear traslation solenoid valve 2 ways
X202
connector
X55 Plug 90° 2 ways connector
Backhoe transport lock solenoid valve 2
Windshield washer pump 90° 2 ways X203
X56 ways connector
connector
X204 Claxon switch 2 ways connector
Windshield washer pump 90° 2 ways
X57 X210 Decluch button 2 ways DT connector
connector
Forward speed solenoid valve 2 ways
X6
connector
X64 A/C compressure switch 1 ways connector
X67 W/D + alternator 3 ways connector
X69 A/C pressure switch 2 ways DT connector
Reverse speed buzzer 2 ways DT
X7
connector
X72 3 ways connector
X8 4WD solenoid valve 2 ways DT connector
X80 90° 2 ways connector
X81 90° 2 ways connector
General-left side panel interface wirings 13
X87
ways connector
General-right side panel interface wirings 17
X88
ways connector
X9 Front harness 5 ways connector
Fuse relay board-genaral wiring 11 ways
XC1
connector
10 SECTION 55 - ELECTRICAL SYSTEM

START CIRCUIT ENGINE SCHEMATIC


SECTION 55 - ELECTRICAL SYSTEM 11

SOLENOID VALVES SCHEMATIC


12 SECTION 55 - ELECTRICAL SYSTEM

SOLENOID VALVE SCHEMATIC


SECTION 55 - ELECTRICAL SYSTEM 13

LIGHTS SCHEMATIC
14 SECTION 55 - ELECTRICAL SYSTEM

REAR WORK LIGHTS SCHEMATIC


SECTION 55 - ELECTRICAL SYSTEM 15

WORK LIGHTS SCHEMATIC


16 SECTION 55 - ELECTRICAL SYSTEM

WINDSHIELD WIPER WASHER SCHEMATIC


SECTION 55 - ELECTRICAL SYSTEM 17

HEATER AND RADIO SCHEMATIC


18 SECTION 55 - ELECTRICAL SYSTEM

AIR CONDITIONER SCHEMATIC

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S Evaporator box S45 11 way connector


1 3rd speed relay 9 Potentiometer

2 Fuse 25 A 10 Speed switch

3 Ventilated electrical motor 11 Thermostat

4 1 and 2 speed resistor 12 12 V light

5 Electrical cock A Waterproof 2 way connection

X111 9 way connector B Waterproof 5 way connection

X110 2 way power connector


SECTION 55 - ELECTRICAL SYSTEM 19

FRONT INSTRUMENT

Pos. Pin Function Signal


+12 J1 Positive (+12 V)
GND J2 Negative
S1 J3 Speedometer Sensor
L4 J4 W/L driving beams (blue) Positive
L3 J5 W/L position lights (green) Positive
+ILL J6 Backlighting (+) + Light
L8 J7 NC
L7 J8 NC
L6 J9 NC
L5 J10 NC
L1 J11 W/L direction (green) Positive
L2 J12 W/L brake oil level (red) Positive
20 SECTION 55 - ELECTRICAL SYSTEM

SIDE INSTRUMENT

Calibrations

GAGE TYPE INPUT READING TOLERANCE


320 OHMS Empty - minimum reading +0/-2°
FUEL LEVEL 185 OHMS Right - edge of red band ± 3° (Ref)
6.5 OHMS Full - maximum reading +4/-0°
193 OHMS ON ± 5 OHMS
LOW FUEL LAMP
185 OHMS OFF ± 5 OHMS
TACHOMETER Can message 0-3000 RPM ± 50 RPM
Can message Minimum reading 65 °C (149 °F) ± 3° C (37.4 °F)
COOLANT Can message Left edge of red band 106 °C (222.8 °F) ± 2° C (35.6 °F)
Can message Maximum reading 112 °C (233.6 °F) ± 3° C (37.4 °F)
11 V Right edge of lower red band ± 3° C (37.4 °F)
VOLT
16 V Edge of upper red band ± 3° C (37.4 °F)
385 OHMS Minimum reading 75 °C (167 °F) ± 3° C (37.4 °F)
TRANSMISSION 149 OHMS Left edge of red band 105 °C (221 °F) ± 2° C (35.6 °F)
112 OHMS Maximum reading 115 °C (239 °F) ± 3° C (37.4 °F)
SECTION 55 - ELECTRICAL SYSTEM 21

CONNECTORS

CN1 CN2
PIN FUNCTION NOTE PIN FUNCTION NOTE
1 Not used Need to fuse at 1 A
1 Keep alive power
2 Key on power Wake up without disconnect

3 In gear input Digital input 2 Not used

4 Driving lights Digital input Twisted pair, with


3 Can bus input
120 OHM terminator
5 Front work lights Digital input
Twisted pair, with
6 Rear work lights Digital input 4 Can bus input
120 OHM terminator
7 Not used 5 Not used
8 Not used Audible alarm Floyd bell under
6
9 Not used buzzer 80 mA
Air conditioning 40 OHM relay =
10 Digital input 7 Starter interlock
system pressure 300 mA
11 Display input switch Digital input 8 Not used
12 Enter input switch Digital input 9 Not used
13 Up input switch Digital input 10 Not used
14 Down input switch Digital input 11 Not used
15 Cranking Digital input 12 Not used
16 Air filter restriction Digital input 13 Fuel level gauge Variable resistance
17 Not used Transmission
14 Thermistor
18 Park brake Digital input temperature

19 Not used 15 Not used

Idle validation 16 Foot accelerator 0.5-4.5 V


20 Digital input
switch 17 Hand accelerator 0.5-4.5 V
One touch Output monitored
21 Digital input 18 Foot accelerator
deceleration for diagnostics
22 Not used Output monitored
19 Hand accelerator
23 Not used for diagnostics

24 Not used 20 Foot accelerator

Transmission oil 21 Hand accelerator


25 Digital input
pressure 22 Not used
26 Not used 23 Not used
Low alternator
24 Alternator excitation
output signals fault
25 Not used
26 Ground Digital input
22 SECTION 55 - ELECTRICAL SYSTEM

2.2 ELECTRICAL DIAGRAMS - POWERSHIFT CAB

FUSES AND RELAIS DESCRIPTION

NAME DESCRIPTION
Rear windshield wiper and rear windshield washer
F1A
(15 A)
Fuel shut off, (+15) antitheft, (+15) key switch, supply
F1B
(+15) ECU (7.5 A)
F1C Stop lights switch (10 A)
Instruments power supply, switches lamps, brake oil
F2A
level sensor, seat (15 A)
F2B Conditioner (15 A)
F2C Pilot control (15 A)
Rear right/front left side lights, instruments illumination
F3A
(3 A)
F3B Rear left/front right side lights, number plate light (3 A)
Front work light, Ride control, double delivery, grab 4x1
F3C
switches (10 A)
EGS power supply, clutch shut off button, 4WD switch
F4A
(7.5 A)
F4B Rear hammer button, grab level valve and sensor (10 A)
Rear excavator lock, rear translation lock, rear transport
F4C
lock (10 A)
F5A Front inner work lights (15 A)
F5B Traffic lights (10 A)
F5C Main beam (15 A)
F6A Beacon lamp (7.5 A)
F6B (+ 15) Flasher
F6C Hand hammer, differential lock (7.5 A)
F7A (+30) Warning horn (10 A)
F7B Current intake, radio, roof lamp (10 A)
F7C Front windshield wiper (6 A)
F8A Outer rear work lights (15 A)
F8B Outer front work lights (15 A)
F8C Inner rear work lights (15 A)
K3 Starting relay
K4 Grab level solenoid valve relay
K5 Traffic and main beam lights relay
K6 Inner front work lights relay
K7 Inner rear work lights relay
SECTION 55 - ELECTRICAL SYSTEM 23

NAME DESCRIPTION
K8 Outer front work lights relay
K9 Outer rear work lights relay
K10 Differential lock relay
K1A Flasher
24 SECTION 55 - ELECTRICAL SYSTEM

COMPONENTS AND CONNECTORS

NAME DESCRIPTION NAME DESCRIPTION


A1 Right speaker (optional) F2 Power ECU fuse
A2 Left speaker (optional) F4 Electric fan fuse 3th speed
A53 Radio (optional) F5 Water in fuel fuse 5 A
A106 Engine control unit +30 antitheft, diagnostic plug, switch up/
F31
A131 Flasher unit down, display enter, panel instrument fuse
A23 EGS FG4 Fuse A/C
B4 Air filter switch G1 Battery
B5 Fuel level sender G67 Alternator
B24 Hand accelerator sensor H7 Reverse buzzer
B25 Foot accelerator sensor H32 Audible alarm
B26 Grab sender HA2 Claxon
B30 Parking brake K102 Input start controller relay
B66 Transmission oil temperature switch K103 Start relay
B69 A/C pressure switch K104 Engine start relay
B74 Trasmission oil pressure switch K105 A/C relay
B107 Water in fuel signal sensor K14 Trasmission cut relay
B129 Brake oil level sender M1 Starter
E15 Rotary beacon M39 Rear windshield wiper
E16 Rotary beacon M41 Blower motor (optional)
E17 Lamp for socket M49 Front windshield wiper
E18 Cab interior light M56 Front windshield washer
E26 Block control lamp M57 Rear windshield washer
E27 Number plate light M64 A/C compressor
E28 Rear left light S15 Starting switch
E29 Rear right light S27 Rear horn button
E37 Rear right light S34 Left door switch
E38 Rear right work light S35 Right door switch
E40 Rear right work light (optional) S36 Rear hammer button (optional)
E42 Front right indicator light S120 Hazard switch
E44 Front right work light S122 4WD switch
E45 Front right work light (optional) S123 Hand tool switch
E46 Rear left work light (optional) S124 EGS auto-switch
E47 Rear left work light S126 Lights switch
E48 Rear left light S127 Rotary beacon switch
E50 Front left work light (optional) S128 Differential lock switch
E51 Front left work light S130 Windshield wiper-lights switch
E52 Front left indicator S136 Up and down switch
E121 Front left light/horn S137 Rear work lights switch
E133 Front right light S138 Rear wiper switch
E114 Valve block lamp switch (optional) S139 Display enter switch
F1 Main fuse S140 Transport lock switch (optional)
S141 Front work lights switch
SECTION 55 - ELECTRICAL SYSTEM 25

NAME DESCRIPTION NAME DESCRIPTION


S142 Ride control switch X125 12 ways MIC 70 connector
S143 Hydraulic speed control switch X130 12 ways DT connector
S150 Safety seat switch optional X131 13 Ways MARK connector
S134.1 Stop light switch X133 5 Ways MARK connector
S134.2 Stop light switch X144 2 ways DT connector
SB1 Battery stopper X15.1 Starting switch MERIT connector
ST1 Side panel X15.2 Starting switch MERIT connector
ST2 Front panel X150 Safety seat switch 2 ways connector
ST3 Grab 4x1 X17 Seat option 4 ways connector
X205a Front horn button Presetting relay grid heater option 2 ways
X2
X205b Decluch button connector
X14 Antitheft-block control lamp X205 Decluch switch and claxon
X17 Seat option X206 Bucket level solenoid valve connector
X21 Diagnostic X21 Diagnostic 10 ways connector
X25 Foot accelerator connector X23 EGS 9 ways DT connector
X55 Auxiliary 12 V socket X24 Hand accelerator 6 ways DT connector
X72 From pilot control cable X25 Foot accelerator 6 ways connector
X107 Water in fuel (WIF) X26 Grab sensor 3 ways DT connector
X128 Optional X27 Number plate 2 ways DT connector
XX From pilot control cable X28 Rear left lamp 4 ways DT connector
Y12 4X1 proportional solenoid valves optional X29 Rear right lamp 4 ways DT connector
Y8 Differential lock solenoid valve Speed control solenoid valve 2 ways
X30
connector
Y25 Rear transport lock solenoid valve (optional)
Front loader quick coupler 2 ways DT
Y206 Bucket level solenoid valve X208
connector
Y30 Speed control solenoid valve (optional)
X32 Audible alarm 2 ways connector
Y32 Rear hammer solenoid valve (optional)
X34 Ride control 2 ways connector
Y34 Ride control solenoid valve (optional)
X35 Hand hammer button 2 ways connector
Y35 Hand hammer solenoid valve
X36 Rear hammer button 2 ways connector
Engine-general wirings interface 18 ways
X1 X37 Rear right light 4 ways connector
connector
X38 Rear right light 4 ways connector
Service-general wirings interface 31 ways
X10 Rear windshield wiper motor 4 ways
DT connector X39
connector
X106 Engine controller 89 ways Bosch connector
X4 Air filter 2 ways connector
X107 Wif JPT 3 ways connector
X40 Rear right light 4 ways connector
X110 A/C 3 ways connector
X41 Blower motor 2 ways connector
X111 A/C 9 ways mark connector
X46 Left front light 4 ways connector
Cabin-general wirings interface 5 ways
X12 X42 Right front indicartor light 4 ways connector
MARK connector
X14 Antitheft 11 ways MARK connector
X121 7 ways MARK connector
26 SECTION 55 - ELECTRICAL SYSTEM

NAME DESCRIPTION NAME DESCRIPTION


X43 Beacon lamp 4 ways connector Fuse relay board-genaral wiring 7 ways
XC2
X44 Front right light 4 ways connector connector
X45 A/C 11 ways connector Fuse relay board-genaral wiring 21 ways
XC3
connector
X58 Front right indicator light 4 ways connector
Fuse relay board-genaral wiring 21 ways
X47 Left rear light 4 ways connector XC4
connector
X48 4 ways connector
Fuse relay board-genaral wiring 17 ways
X49 6 ways connector XC5
connector
X5 Fuel level sender 2 ways DT connector Fuse relay board-genaral wiring 13 ways
XC6
X50 Right front light 4 ways connector connector
X51 Left front light 4 ways connector Panel instrument 20 ways MIC 70
XST1
X52 Left front indicator light 4 ways connector connector
X53 8 ways connector Panel instrument 20 ways MIC 70
XST2
connector
X54 Radio 8 ways connector
Rear traslation solenoid valve 2 ways
X55 Plug 90° 2 ways connector X202
connector
Windshield washer pump 90° 2 ways
X56 Backhoe transport lock solenoid valve 2
connector X203
ways connector
Windshield washer pump 90° 2 ways
X57 X204 Claxon switch 2 ways connector
connector
X210 Decluch button 2 ways DT connector
X206 4X1 2 ways connector
X64 A/C compressure switch 1 ways connector
X67 W/D + alternator 3 ways connector
X69 A/C pressure switch 2 ways DT connector
Reverse speed buzzer 2 ways DT
X7
connector
X72 3 ways connector
X8 4WD solenoid valve 2 ways DT connector
X80 90° 2 ways connector
X81 90° 2 ways connector
X83 EGS connector
X84 EGS connector
X85 EGS connector
General-left lateral side panel interface
X87
wirings 13 ways connector
General-right lateral side panel interface
X88
wirings 17 ways connector
X9 Front harness 5 ways connector
Fuse relay board-genaral wiring 11 ways
XC1
connector
SECTION 55 - ELECTRICAL SYSTEM 27

START CIRCUIT ENGINE SCHEMATIC


28 SECTION 55 - ELECTRICAL SYSTEM

SOLENOID VALVES SCHEMATIC


SECTION 55 - ELECTRICAL SYSTEM 29

SOLENOID VALVE SCHEMATIC


30 SECTION 55 - ELECTRICAL SYSTEM

LIGHTS SCHEMATIC
SECTION 55 - ELECTRICAL SYSTEM 31

REAR WORK LIGHTS SCHEMATIC


32 SECTION 55 - ELECTRICAL SYSTEM

WORK LIGHTS SCHEMATIC


SECTION 55 - ELECTRICAL SYSTEM 33

WINDSHIELD WIPER WASHER SCHEMATIC


34 SECTION 55 - ELECTRICAL SYSTEM

HEATER AND RADIO SCHEMATIC


SECTION 55 - ELECTRICAL SYSTEM 35

AIR CONDITIONER SCHEMATIC

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S Evaporator box S45 11 way connector


1 3rd speed relay 9 Potentiometer

2 Fuse 25 A 10 Speed switch

3 Ventilated electrical motor 11 Thermostat

4 1 and 2 speed resistor 12 12 V light

5 Electrical cock A Waterproof 2 way connection

X111 9 way connector B Waterproof 5 way connection

X110 2 way power connector


36 SECTION 55 - ELECTRICAL SYSTEM

FRONT INSTRUMENT

Pos. Pin Function Signal


+12 J1 Positive (+12 V)
GND J2 Negative
S1 J3 Speedometer Sensor
L4 J4 W/L driving beams (blue) Positive
L3 J5 W/L position lights (green) Positive
+ILL J6 Backlighting (+) + Light
L8 J7 NC
L7 J8 NC
L6 J9 NC
L5 J10 NC
L1 J11 W/L direction (green) Positive
L2 J12 W/L brake oil level (red) Positive
SECTION 55 - ELECTRICAL SYSTEM 37

SIDE INSTRUMENT

Calibrations

GAGE TYPE INPUT READING TOLERANCE


320 OHMS Empty - minimum reading +0/-2°
FUEL LEVEL 185 OHMS Right - edge of red band ± 3° (Ref)
6.5 OHMS Full - maximum reading +4/-0°
193 OHMS ON ± 5 OHMS
LOW FUEL LAMP
185 OHMS OFF ± 5 OHMS
TACHOMETER Can message 0-3000 RPM ± 50 RPM
Can message Minimum reading 65 °C (149 °F) ± 3° C (37.4 °F)
COOLANT Can message Left edge of red band 106 °C (222.8 °F) ± 2° C (35.6 °F)
Can message Maximum reading 112 °C (233.6 °F) ± 3° C (37.4 °F)
11 V Right edge of lower red band ± 3° C (37.4 °F)
VOLT
16 V Edge of upper red band ± 3° C (37.4 °F)
385 OHMS Minimum reading 75 °C (167 °F) ± 3° C (37.4 °F)
TRANSMISSION 149 OHMS Left edge of red band 105 °C (221 °F) ± 2° C (35.6 °F)
112 OHMS Maximum reading 115 °C (239 °F) ± 3° C (37.4 °F)
38 SECTION 55 - ELECTRICAL SYSTEM

CONNECTORS

CN1 CN2
PIN FUNCTION NOTE PIN FUNCTION NOTE
1 Not used Need to fuse at 1 A
1 Keep alive power
2 Key on power Wake up without disconnect

3 In gear input Digital input 2 Not used

4 Driving lights Digital input Twisted pair, with


3 Can bus input
120 OHM terminator
5 Front work lights Digital input
Twisted pair, with
6 Rear work lights Digital input 4 Can bus input
120 OHM terminator
7 Not used 5 Not used
8 Not used Audible alarm Floyd bell under
6
9 Not used buzzer 80 mA
Air conditioning 40 OHM relay =
10 Digital input 7 Starter interlock
system pressure 300 mA
11 Display input switch Digital input 8 Not used
12 Enter input switch Digital input 9 Not used
13 Up input switch Digital input 10 Not used
14 Down input switch Digital input 11 Not used
15 Cranking Digital input 12 Not used
16 Air filter restriction Digital input 13 Fuel level gauge Variable resistance
17 Not used Transmission
14 Thermistor
18 Park brake Digital input temperature

19 Not used 15 Not used

Idle validation 16 Foot accelerator 0.5-4.5 V


20 Digital input
switch 17 Hand accelerator 0.5-4.5 V
One touch Output monitored
21 Digital input 18 Foot accelerator
deceleration for diagnostics
22 Not used Output monitored
19 Hand accelerator
23 Not used for diagnostics

24 Not used 20 Foot accelerator

Transmission oil 21 Hand accelerator


25 Digital input
pressure 22 Not used
26 Not used 23 Not used
Low alternator
24 Alternator excitation
output signals fault
25 Not used
26 Ground Digital input
SECTION 55 - ELECTRICAL SYSTEM 39

2.3 ELECTRICAL DIAGRAMS - 4WS

FUSES AND RELAIS DESCRIPTION

NAME DESCRIPTION
Rear windshield wiper and rear windshield washer
F1A
(15 A)
Fuel shut off, (+15) antitheft, (+15) key switch, supply
F1B
(+15) ECU (7.5 A)
Stop lights switch (15 A), steering unit, steering switch
F1C
(10 A)
Instruments power supply, switches lamps, brake oil
F2A
level sensor, seat, buzzer
F2B Conditioner (15 A)
F2C Pilot control, front tools (optional) (15 A)
Rear right/front left side lights, instruments illumination
F3A
(3 A)
F3B Rear left/front right side lights, number plate light (3 A)
Front work light, Ride control, double delivery, 4x1 grab
F3C
switches (10 A)
EGS power supply, clutch shut off button, 4WD switches
F4A
(7.5 A)
F4B Rear hammer button, grab level valve and sensor (10 A)
Rear excavator lock, rear translation lock, rear transport
F4C
lock (10 A)
F5A Front inner work lights (15 A)
F5B Traffic lights (10 A)
F5C Main beam (15 A)
F6A Beacon lamp (7.5 A)
F6B (+15) Flasher (7.5 A)
F6C Hand hammer (7.5 A)
F7A (+30) Warning horn (10 A)
F7B Current intake, radio, roof lamp (10 A)
F7C Front windshield wiper (6 A)
F8A Outer rear work lights (15 A)
F8B Outer front work lights (15 A)
F8C Inner rear work lights (15 A)
40 SECTION 55 - ELECTRICAL SYSTEM

NAME DESCRIPTION
K3 Starting relay
K4 Grab level solenoid valve relay
K5 Traffic and main beam lights relay
K6 Inner front work lights relay
K7 Inner rear work lights relay
K8 Outer front work lights relay
K9 Outer rear work lights relay
K10 Optional relay
K1A Flasher
K1B Buzzer
SECTION 55 - ELECTRICAL SYSTEM 41

COMPONENTS AND CONNECTORS

NAME DESCRIPTION NAME DESCRIPTION


A1 Right speaker (optional) F2 Power ECU fuse
A2 Left speaker (optional) F4 Electric fan fuse 3th speed
A53 Radio (optional) F5 Water in fuel fuse 5 A
A106 Engine control unit +30 antitheft, diagnostic plug, switch up/
F31
A131 Flasher unit down, display enter, panel instrument fuse
A23 EGS FG4 Fuse A/C
B4 Air filter switch G1 Battery
B5 Fuel level sender G67 Alternator
B24 Hand accelerator sensor H7 Reverse buzzer
B25 Foot accelerator sensor H32 Audible alarm
B26 Grab sender HA2 Claxon
B30 Parking brake K102 Input start controller relay
B66 Transmission oil temperature switch K103 Start relay
B69 A/C pressure switch K104 Engine start relay
B74 Trasmission oil pressure switch K105 A/C compressor relay
B97 Rear axle sensor K14 Trasmission cut relay
B98 Front axle sensor KS Steering unit
B107 Water in fuel signal sensor M1 Starter
B129 Brake oil level sender M39 Rear windshield wiper
E15 Rotary beacon M41 Blower motor (optional)
E16 Rotary beacon M49 Front windshield wiper
E17 Lamp for socket M56 Front windshield washer
E18 Cab interior light M57 Rear windshield washer
E26 Block control lamp M64 A/C compressor
E27 Number plate light S15 Starting switch
E28 Rear left light S27 Rear horn button
E29 Rear right light S34 Left door switch
E37 Rear right light S35 Right door switch
E38 Rear right work light S36 Rear hammer button (optional)
E40 Rear right work light (optional) S120 Hazard switch
E42 Front right indicator light S122 4WD switch
E44 Front right work light S123 Hand tool switch
E45 Front right work light (optional) S124 EGS auto-switch
E46 Rear left work light (optional) S126 Lights switch
E47 Rear left work light S127 Rotary beacon switch
E48 Rear left light S130 Windshield wiper-lights switch
E50 Front left work light (optional) S132 Steering switch
E51 Front left work light S136 Up and down switch
E52 Front left indicator S137 Rear work lights switch
E121 Front left light/horn S138 Rear wiper switch
E133 Front right light S139 Display enter switch
E144 Lamp switch valve block (optional) S140 Transport lock switch (optional)
F1 Main fuse S141 Front work lights switch
42 SECTION 55 - ELECTRICAL SYSTEM

NAME DESCRIPTION NAME DESCRIPTION


S142 Glide ride switch X14 Antitheft 11 ways MARK connector
S143 Hydraulic speed control switch X121 7 ways MARK connector
S150 Safety seat switch optional X125 12 ways MIC 70 connector
S134.1 Stop light switch X130 12 ways DT connector
S134.2 Stop light switch X131 13 Ways MARK connector
S205a Front horn button X133 5 Ways MARK connector
S205b Decluch button X144 2 ways DT connector
SB1 Battery stopper X15.1 Starting switch MERIT connector
ST1 Side panel X15.2 Starting switch MERIT connector
ST2 Front panel X150 Safety seat switch 2 ways connector
ST3 Grab 4x1 X17 Seat option 4 ways connector
X14 Antitheft-block control lamp Presetting relay grid heater option 2 ways
X2
X17 Seat option connector
X21 Diagnostic X21 Diagnostic 10 ways connector
X25 Foot accelerator connector X23 EGS 9 ways DT connector
X208 Front loader quick coupler X24 Hand accelerator 6 ways DT connector
X55 Auxiliary 12 V socket X25 Foot accelerator 6 ways connector
X72 From pilot control cable X26 Grab sensor 3 ways DT connector
X107 Water in fuel (WIF) X27 Number plate 2 ways DT connector
X128 Optional X28 Rear left lamp 4 ways DT connector
XX From pilot control cable X29 Rear right lamp 4 ways DT connector
Y25 Rear transport lock solenoid valve (optional) Speed control solenoid valve 2 ways
X30
connector
Y206 Bucket level solenoid valve
X32 Audible alarm 2 ways connector
Y12 4X1 proportional solenoid valves optional
X33 2 ways JUMPER connector
Y30 Speed control solenoid valve (optional)
X34 Ride control 2 ways connector
Y32 Rear hammer solenoid valve (optional)
X35 Hand hammer button 2 ways connector
Y34 Ride control solenoid valve (optional)
X36 Rear hammer button 2 ways connector
Y35 Hand hammer solenoid valve
X37 Rear right light 4 ways connector
Y91 Steering solenoid valve
X38 Rear right light 4 ways connector
Y92 4WS Steering solenoid valve
Rear windshield wiper motor 4 ways
Y93 Round steering solenoid valve X39
connector
Y94 2WS steering solenoid valve
X4 Air filter 2 ways connector
Engine-general wirings interface 18 ways
X1 X40 Rear right light 4 ways connector
connector
X41 Blower motor 2 ways connector
Service-general wirings interface 31 ways
X10 X58 Left front light 4 ways connector
DT connector
X106 Engine controller 89 ways Bosch connector X42 Right front indicartor light 4 ways connector
X107 Wif JPT 3 ways connector X43 Beacon lamp 4 ways connector
X110 A/C 3 ways connector X44 Front right light 4 ways connector
X111 A/C 9 ways mark connector
Cabin-general wirings interface 5 ways
X12
MARK connector
SECTION 55 - ELECTRICAL SYSTEM 43

NAME DESCRIPTION NAME DESCRIPTION


X45 A/C 11 ways connector X97 Rear axle sensor 3 ways connector
X46 Left front light 4 ways connector Panel instrument 20 ways MIC 70
XST1
Optional front right indicartor light 4 ways connector
X59
connector Panel instrument 20 ways MIC 70
XST2
X47 Left rear light 4 ways connector connector
X48 4 ways connector
X49 6 ways connector
X5 Fuel level sender 2 ways DT connector
X50 Right front light 4 ways connector
X51 Left front light 4 ways connector
X52 Left front indicator light 4 ways connector
X53 8 ways connector
X54 Radio 8 ways connector
X55 Plug 90° 2 ways connector
Windshield washer pump 90° 2 ways
X56
connector
Windshield washer pump 90° 2 ways
X57
connector
X64 A/C compressure switch 1 ways connector
X67 W/D + alternator 3 ways connector
X69 A/C pressure switch 2 ways DT connector
Reverse speed buzzer 2 ways DT
X7
connector
X72 3 ways connector
X81 90° 2 ways connector
X82 JPT 10 ways connector
X83 EGS connector
X84 EGS connector
X85 EGS connector
General-left side panel interface wirings 13
X87
ways connector
General-right side panel interface wirings 17
X88
ways connector
X9 Front harness 5 ways connector
X91 Steering solenoid valve 2 ways connector
4WS steering solenoid valve 2 ways
X92
connector
Round steering solenoid valve 2 ways
X93
connector
2WS steering solenoid valve 2 ways
X94
connector
X95 Steering unit 12 ways DT connector
X96 Steering unit 8 ways DT connector
X98 Front axle sensor 3 ways connector
44 SECTION 55 - ELECTRICAL SYSTEM

START CIRCUIT ENGINE SCHEMATIC


SECTION 55 - ELECTRICAL SYSTEM 45

SOLENOID VALVES SCHEMATIC


46 SECTION 55 - ELECTRICAL SYSTEM

SOLENOID VALVE SCHEMATIC


SECTION 55 - ELECTRICAL SYSTEM 47

LIGHTS SCHEMATIC
48 SECTION 55 - ELECTRICAL SYSTEM

REAR WORK LIGHTS SCHEMATIC


SECTION 55 - ELECTRICAL SYSTEM 49

WORK LIGHTS SCHEMATIC


50 SECTION 55 - ELECTRICAL SYSTEM

WINDSHIELD WIPER WASHER SCHEMATIC


SECTION 55 - ELECTRICAL SYSTEM 51

STEERING SCHEMATIC
52 SECTION 55 - ELECTRICAL SYSTEM

HEATER AND RADIO SCHEMATIC


SECTION 55 - ELECTRICAL SYSTEM 53

AIR CONDITIONER SCHEMATIC

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Úîéïèï

S Evaporator box S45 11 way connector


1 3rd speed relay 9 Potentiometer

2 Fuse 25 A 10 Speed switch

3 Ventilated electrical motor 11 Thermostat

4 1 and 2 speed resistor 12 12 V light

5 Electrical cock A Waterproof 2 way connection

X111 9 way connector B Waterproof 5 way connection

X110 2 way power connector