Doosan Esquema Eletrico
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1Electrical
System
SP001038 ELECTRICAL SYSTEMSP001038
Electrical System Edition 1
Electrical System
SP001038 Page 1
MEMO
Electrical System Page 2
SP001038
Table of Contents Electrical System Safety Precautions ............................................... 7 Applicable Models ................................................ 7 Introduction ........................................................... 9 Electrical Supply System .................................... 10 Engine Starting Circuit ........................................ 12 Start Operation .............................................................. 12 After Start ...................................................................... 14
Engine Preheating System ................................. 16 Engine Stop ........................................................ 18 Charging System ................................................ 20 Monitoring System .............................................. 21 Instrument Panel ........................................................... 22 Monitoring System Schematic ....................................... 24
Operation ............................................................ 26 Instruments.................................................................... 26
Warning and Indicator Lights .............................. 28 Indication of Warning Lights .......................................... 28 Indication of Multifunction Gauge and Letter Information Area.................................................. 29
Initial Operation .................................................. 31 Mode Selector Switch ......................................... 31 Graphic Information Area Display....................... 32 Overview ....................................................................... 32 Main Menus for the Graphic Display Area..................... 33 Menu Selector Buttons .................................................. 33
Main Menu .......................................................... 34 Language ...................................................................... 34 Set Clock ....................................................................... 35 Filter/Oil Info .................................................................. 35 Adjust Display................................................................ 36
Electrical System
SP001038 Page 3
Set Password ................................................................ 37
Special Menu ...................................................... 38 Entering/Accessing and Exiting/Escaping Menus ......... 38 Special Menu Selections ............................................... 39
Electronic Hydraulic Control System (e-EPOS).. 56 Control System Schematic ............................................ 56
Power Mode Control ........................................... 58 Operation....................................................................... 60
Power Mode Control - Circuit Diagram ............... 62 Work Mode Control............................................. 64 Operation....................................................................... 65
Work Mode Control - Circuit Diagram................. 66 Engine Control System ....................................... 67 Engine Control Dial............................................. 68 Engine Control Circuit Diagram .......................... 69 Automatic Deceleration Control (Auto Idle Control) .............................................. 70 Engine Overheat Protection System .................. 72 Power Boost Mode ............................................. 74 Operation....................................................................... 74 Power Boost Control - Circuit Diagram ......................... 76
Automatic Travel Speed Control......................... 78 Automatic Travel Speed Control - Circuit Diagram ....... 80
Self-diagnostic Function ..................................... 81 e-EPOS Controller......................................................... 81
Air Conditioner System ....................................... 83 Outline ........................................................................... 83 Internal and External Filters .......................................... 84 Air-Conditioning System Layout .................................... 86 Air Conditioner/heater Circuit Diagram.......................... 87 Air Conditioner/heater Unit ............................................ 88 Ambient Air Temperature Sensor .................................. 93
Electrical System Page 4
SP001038
Sun Sensor.................................................................... 94 Control Panel................................................................. 94 Compressor ................................................................. 102 Receiver Dryer ............................................................ 102
Troubleshooting ................................................ 103 Weight of R134a Gas Used In Machines ......... 105 Refrigerant System Repairs ............................. 106 Refrigerant Safe Handling Procedures........................ 106 Repair and Replacement Procedure ........................... 107 Refrigerant Recovery .................................................. 109 Vacuuming Refrigerant System................................... 109 Leakage Check ........................................................... 111 Refrigerant Charging ................................................... 111 Inspecting System For Leakage .................................. 113
Wiper System ................................................... 114 Wiper Circuit................................................................ 114 Wiper operation ........................................................... 115
Lighting System ................................................ 118 Lighting System Circuit Diagram ................................. 118 Kind of Light ................................................................ 119 Operation..................................................................... 119
Audio Controller ................................................ 120 Audio Controller Circuit Diagram................................. 120
Electrical System
SP001038 Page 5
MEMO
Electrical System Page 6
SP001038
SAFETY PRECAUTIONS CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that are in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL
SERIAL NUMBER RANGE
DX140LC
5001 and Up
DX180LC
5001 and Up
Electrical System
SP001038 Page 7
Electrical System Page 8
SP001038
INTRODUCTION The electrical system for this equipment is DC 24 volts. The rated voltage for all electric components is 24 volts with the exception of the stereo and the air-conditioning control actuator. The system contains two 12 volt batteries connected in series and a three phase AC generator with a rectifier. The electric wiring used in the system is easily identifiable by the insulator color. The color symbols used in the electrical system are listed in the following chart. Electric Wire Color
NOTE:
Symbol
Color
W
White
G
Green
Or
Orange
B
Black
L
Blue
Lg
Light green
R
Red
Gr
Gray
P
Pink
Y
Yellow
Br
Brown
V
Violet
RW: Red wire with White stripe R - Base Color, W - Stripe Color
NOTE:
0.85G: Nominal sectional area of wire core less insulator = 0.85 mm2
Electrical System
SP001038 Page 9
ELECTRICAL SUPPLY SYSTEM The electric power circuit supplies electric current to each electric component. It consists of a battery, battery relay, starter switch, circuit breaker, fusible link and fuse box. The negative terminal of the battery is grounded to the vehicle body. Even when the starter switch (5) is in the "OFF" position, electric current is supplied to the following components through battery (1) o fusible link (3) o fuse box (6). 1.
Terminal "1" of DC-DC converter (for memory backup of stereo)
2.
Terminal "B" of starter switch
3.
Hour meter
4.
Engine controller
5.
Fuel feeder pump switch
6.
Terminal "6" of wiper motor
7.
Terminal "13" of wiper controller
8.
Terminal "CN6-11" of instrument panel
9.
Terminal "CN9-6" of air conditioner panel
10.
Cabin light
When the starter switch (5) is in the "ON or START" positions, the current flows from the battery (1) o fusible link (3) ofuse box (6) o"B" terminal of starter switch (5) o "BR" terminal of starter switch (5) o "BR" terminal of battery relay (2) which activates the coil of the battery relay and the electric supply system is energized. When the battery relay's contacts are connected, all electric devices can be operated. While the engine is not running, the electric power for all electric devices are supplied by the battery. Once the engine is started the power is supplied from the alternator (7).
Electrical System Page 10
SP001038
C
ACC B
5
R2
BR
0.5G
R1
6
3 8
2
4
A
B BR E
8
PST
TML
P(R)
R(I)
STARTER SWITCH CONNECTION
B(B+)
+ 12V 100AH
1
0.5 uF
B
BR
R1
R2
C
ACC
B+
OFF
I(L)
7
ON REG.
START
+ 12V 100AH
TRIO DIODE FIELD
F+ FE
GRD
FG007233
Figure 1 ELECTRIC POWER CIRCUIT DIAGRAM Reference Number
Description
Reference Number
Description
1
Battery
5
Starter Switch
2
Battery Relay
6
Fuse Box
3
Fusible Link
7
Alternator
4
Circuit Breaker
8
Diode
Electrical System
SP001038 Page 11
ENGINE STARTING CIRCUIT Start Operation When the starter switch is turned to the "START" position, the "S" and "E" terminals of the starter controller (7) are connected. At this time the contacts in the starter relay (8) are closed by the current flow from the battery (1) o fusible link (3) ofuse box (6) o "B" terminal of starter switch (5) o "C" terminal of starter switch (5) o "30" terminal of starter relay (12) - "87a" terminal o "C" terminal of starter relay (8) - "D" terminal o "S" terminal of starter controller (7) - "E" terminal o ground. When the contact point "B" and "PP" of starter relay (8) are connected, the pinion gear of the starter (9) is pushed forward and makes contact with the ring gear of the flywheel and the internal contacts of the starter are connected. The current flows from the battery (1) o "A" terminal of the battery relay (2) o "B" terminal of the battery relay (2, Figure 3) o "B" terminal of the starter (9). The starter motor is rotated and the engine is started. If the instrument panel has the password function activated , input number should match the set number, otherwise the start circuit closes and the engine does not start. NOTE:
If the security system is "LOCKED," a four-digit password will be required to start the engine. If the system is "UNLOCKED," no password will be required and this display screen will not appear. In the event the security system is locked, current flows from battery (1) o fusible link (3) o fuse box (6) o "B" terminal of starter switch (5) o "ACC" terminal of starter switch (5) o "86" terminal of starter relay (12) o "85" terminal of starter relay (12) o "CN1-15" terminal of e-EPOS (13) o ground. This current flow causes the coil in starter relay (12) to be activated, opening contacts at "87a" terminal. This prevents starter relay (8) from functioning.
Electrical System Page 12
02/05 [MO] 11:30 ENTER PASSWORD E F C
C
H
E/G SPEED
0
H
RPM FG001445
Figure 2
SP001038
7 N P B
9
8 S E
D
PP
C
C
B
B
11 A
87a 30 87 85
86
ACC C
5
B BR
R2
12
R1
CN1-15
3
6 4 A
B CN2-1 BR
13 R(I)
STARTER SWITCH CONNECTION PST
TML
B
BR
E
11 R1
R2
C
P(R)
2
B(B+)
0.5 uF B+
ACC
I(L)
OFF REG.
ON START
10
TRIO DIODE
+
-
+
1
FIELD
F+
-
FE
GRD
FG007234
Figure 3 STARTER CIRCUIT (1) - WHILE STARTING Description
Reference Number
Description
1
Battery
8
Starter Relay
2
Battery Relay
9
Starter
3
Fusible Link
10
Alternator
4
Circuit Breaker
11
Diode
5
Starter Switch
12
Starter Relay 2
6
Fuse Box
13
e-EPOS Controller
7
Starter Controller
Reference Number
Electrical System
SP001038 Page 13
After Start Once the engine has been started, the belt driven alternator (10) generates a current. The output generated by the alternator (10) is a square wave pulse voltage through the "P" terminal and the frequency of the pulse voltage is proportional to the rotation of the alternator. The starter controller (7) monitors the frequency of the output current. Once the frequency is equivalent to 500 rpm, it is sensed and the connection between "S" and "E" terminals and the connection between "B" and "PP" terminals are opened. As a result the rotation of the starter (9) is stopped. Once the engine is running, the starter (9) will not operate even if the starter switch (5) is moved to the start position, preventing possible damage to the starter.
Electrical System Page 14
SP001038
Operation of the Start Circuit (2) - Immediately After Start 7 N P B
9
8 S E
D
PP
C
C
B
B
11 A
87a 30 87 85
86
ACC
C
5
B BR
R2
12
R1
CN1-15
3
6 4
A
B
CN2-1 BR
13 R(I)
P(R)
E
11 B(B+)
2
0.5 uF B+
STARTER SWITCH CONNECTION PST TML
B
BR
R1
R2
C
I(L)
ACC REG.
OFF ON
TRIO DIODE F+
10
-
-
+
1
F-
START
+
FIELD
E
GRD
FG007237
Figure 4 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START Reference Number
Description
Reference Number
Description
1
Battery
8
Starter Relay
2
Battery Relay
9
Starter
3
Fusible Link
10
Alternator
4
Circuit Breaker
11
Diode
5
Starter Switch
12
Starter Relay 2
6
Fuse Box
13
e-EPOS Controller
7
Starter Controller
Electrical System
SP001038 Page 15
ENGINE PREHEATING SYSTEM An air heater (8) is installed in the intake manifold of the engine. When the starter switch (5) is turned "ON," the current flows from the battery (1) o fusible link (3) o fuse box (6) o "B" terminal of starter switch (5) o "BR" terminalof starter switch (5) o "1-39" terminal of engine controller (12), causing current to flow though "1-16" terminal of engine controller (12) o "C and D" terminals of preheat relay (7) o "1-04" terminals of engine controller (12) o ground. This current flow causes the coil in preheat relay (7) to be activated, closing contacts. When the contacts of the preheat relay (7) are closed, the heating coils of the air heating device (8) are heated by current flowing from the battery (1) o battery relay (2) o preheat relay (7) o air heater (8) o ground. The duration of the heating cycle depends on the temperature of engine coolant. The preheat indicator light in the instrument panel (9) will turn "ON" during preheating cycle. The preheat relay (7) is controlled by the engine controller (12) and operates only at temperatures of 10°C (50°F) and below. The longer the preheating period, the lower the temperature of coolant is.
Electrical System Page 16
SP001038
3 6 4
9
2
CN6-1,2 PREHEAT
L5
C
ACC
CN7-4,5,6
A
B
B
5 BR
R2 R1 BR
E
10
CN4-4,5,6 CN2-1 +
-
-
+
1
11
B -
200A
C
1-34,35
7
STARTER SWITCH CONNECTION
1-40
PST
1-13
D
H
(1) +
TML B
BR
R1
R2
C
ACC
OFF ON
1-07
START
12
FG007137
Figure 5 ENGINE PREHEAT CIRCUIT Reference Number
Description
Reference Number
Description
1
Battery
7
Preheat Relay
2
Battery Relay
8
Air Heater
3
Fusible Link
9
Preheat Indicator Light
4
Circuit Breaker
10
Diode
5
Starter Switch
11
e-EPOS Controller
6
Fuse Box
12
Engine Controller
Electrical System
SP001038 Page 17
ENGINE STOP When starter switch (5) is turned "ON" the engine controller (8) is activated. The engine controller monitors and controls the engine including the injector solenoid (9). It controls the fuel deliver rate and the injection timing for each cylinder. NOTE:
There is an individual injector solenoid (9) for each of the six cylinders. Only one soleniod is shown in Figure 7.
When starter switch (5) is turned "OFF," the engine controller stops suppling power to the injector solenoid (9). This stops fuel from being injexted into the engine cylinder, thus stopping the engine. In the event that the engine can be shut down using the starter switch (5), an emergency stop switch (10) is provided to shut down engine. To activate the emergancy stop switch, move it to the "I" (EMERGENCY STOP) position.
O I
The emergency stop switch (10) is in its "O" (OFF) position during normal operation. The switch must be moved and held in the "I" (EMERGENCY STOP) position until the engine stops. When released it will automatically move back to the "O" (OFF) position. FG001344
Figure 6 ENGINE EMERGENCY STOP SWITCH
Electrical System Page 18
SP001038
STARTER SWITCH CONNECTION TML
PST
B
R1
BR
R2
C
ACC
OFF ON START
8
6 0.5G
3 C
ACC
10 2
1-19
5
B 3
R2
BR
2
4
R1
1-45
A
B
1-39
BR E
7 9 -
+
-
+
1 FG001473
Figure 7 ENGINE STOP CIRCUIT Reference Number
Description
Reference Number
Description
1
Battery
6
Fuse Box
2
Battery Relay
7
Diode
3
Fusible Link
8
Engine Controller
4
Circuit Breaker
9
Injector Solenoid
5
Starter Switch
10
Emergency Stop Switch
Electrical System
SP001038 Page 19
CHARGING SYSTEM When the starter switch (5) is turned to the "ON" position, an initial excited current flows to the field coil of the alternator (7) through the battery relay (2) and circuit breaker (4). When the engine is started from this condition the alternator (7) starts charging. The current flows from the "B(B+)" terminal of alternator (7) o circuit breaker (4) o battery relay (2) obattery (1). The alternator also supplies electric current to other electrical components. When the alternator (7) starts to operate, a current flows from the "R(I)" terminal of alternator o diode (8) o battery relay (2) coil securing a path for the charging current to the battery (1). Thus preventing the possibility of a high voltage build up and possible damage to the electric system.
C
ACC
5
B R2
BR
0.5G
R1
6
3 8
2
4
A
B BR E
8
R(I)
P(R)
B(B+)
+ 12V 100AH
1
0.5 uF
STARTER SWITCH CONNECTION PST
TML
B
BR
R1
R2
C
+ 12V 100AH
B+
I(L)
ACC
OFF
REG.
ON
7
TRIO DIODE FIELD
F+
START
FE
GRD
FG007238
Figure 8 CHARGING CIRCUIT Reference Number
Description
Reference Number
Description
1
Battery
5
Starter Switch
2
Battery Relay
6
Fuse Box
3
Fusible Link
7
Alternator
4
Circuit Breaker
8
Diode
Electrical System Page 20
SP001038
MONITORING SYSTEM 1 2
+ -
5 8
7
4 R
B
E
CHECK
9
3 02/05 [MO] 11:30
F
E
C
C
H
E/G SPEED
10
H
1700
RPM
6
POWER AUTO
1
2
3
4
5
6
7
8
ESC
11
13 12 FG000547
Figure 9 Reference Number
Description
Reference Number
Description
1
Instrument Panel
8
Warning Buzzer
9
Pump Discharge Pressure Sensor
10
Hydraulic Oil Temperature Sensor
11
Fuel Sensor
12
Air Cleaner Indicator
13
Engine Controller
2
Battery
3
Light Switch
4
Return Filter Switch
5
Pilot Filter Switch
6
e-EPOS Controller
7
Alternator
The monitoring system displays the various data and warning signals onto the instrument panel by processing the information gathered from the e-EPOS controller. It displays information selected by the operator.
Electrical System
SP001038 Page 21
Instrument Panel
7
8
9
10
5
1
11
12
CHECK
6
02/05 [MO] 11:30
1
3 F
E
4
2 C
C
H
1700
E/G SPEED
H
RPM
17
< CONNECTOR AND TERMINAL NO.>
15 AMP 040 28P
19 6
13
3
2
1
12 11 10 9
5 4
8
7
2
1
16 15 14 13 12 11 10
8
7
6
5
4
3
9
POWER AUTO
1
2
4
3
(CN7)
ESC
(CN6)
20 14
5
6
8
7
16
18 FG000548
Figure 10
Electrical System Page 22
SP001038
Gauges
Warning Lights
Mode Selector Switches
1.
Fuel Gauge
7.
Charge Warning Light
13.
2.
Engine Coolant Temperature Gauge
8.
Engine Oil Pressure Warning Light
Power Mode Selector Switch and Indicator
14.
Hydraulic Oil Temperature Gauge
9.
Coolant Warning Light
Work Mode Selector Switch and Indicator
15.
Multifunction Gauge Letter Information Area
10.
Engine Check Warning Light
Auto Idle Indicator
11.
Preheat Indicator Light
16.
Flow Adjusting Switch
12.
Work Light Indicator Light
17.
Up Button Switch
18.
Down Button Switch
19.
Display Selector Switch
20.
Selector Button Switch
3. 4. 5.
Digital Clock
6.
Hour Meter
and
Temperature
Switch
and
When the engine starter switch is turned to the "I" (ON) position, all gauge bands, switch/button indicator lights and indicator/ warning lights will turn "ON" and the alarm buzzer will sound about two seconds. During this functional check, a LOGO will appear on the multi function gauge in the graphic information area
Electrical System
SP001038 Page 23
Monitoring System Schematic
1 19 CN6-1
3 ILL.
L1 L2
CN6-3 CN6-2
+
CN6-12
-
2
CN6-11
17
L3
4
L4 L5
R2
B
16
B
CN6-9 CN6-10
BR
L6
14
WARNING LAMP
E
CN2-1
L1 : CHARGE L2 : ENG OIL PRESS L3 : W/T OVER HEAT L4 : E/G WARNING L5 : PREHEAT L6 : WORK LAMP
A
18 +
5
15 CN3-1
SIG
CN3-2
-
LCD DISPLAY PANEL WATER TEMPERATURE FUEL LEVEL
+
6
GRAPHIC DISPLAY
CN3-3
SIG
CN5-7
CN3-4
-
9
CN7-4
CN4-4
CN7-5
CN4-5
CN7-6
CN4-6
CN2-17
10 CAN A CN2-18
11
21
CN4-3
GND
CN4-2
RxD
CN4-1
TxD
1-35
12
CN3-7
1
1-34
CN5-3
CN3-8
2
8
3 1-53
4
1-52
20
CN3-9 CN3-10
5
7
6 14
1-56
CN5-2 R(I)
CN2-14
13 FG007141
Figure 11
Electrical System Page 24
SP001038
Reference Number
Description
Reference Number
Description
1
Instrument Panel
11
Pilot Filter Switch
2
Pilot Buzzer
12
Return Filter Switch
3
Light Switch
13
Alternator
4
Starter Switch
14
e-EPOS Controller
5
Front Pump Pressure Sensor
15
Battery
6
Rear Pump Pressure Sensor
16
Battery Relay
7
Hydraulic Oil Temperature Sensor
17
Circuit Breaker
18
Fusible Link
8
Fuel Sensor
19
Fuse Box
9
Pedal Pressure Switch (Optional)
20
Check Connector
10
Air Cleaner Indicator
21
Engine Controller
Electrical System
SP001038 Page 25
OPERATION Instruments Function
Sensor Specification
Display
Input Terminal
Input Specification
Blue
Coolant Temperature
61°C
102°C
41°C
C
107°C
H
White
ECU-CAN Communication
Red FG000550
Blue
CN3-7
Fuel Level
CN3-8
1/10
E
F
Red
1/10 LCD (Red Zone) Blinking o over 5K ohms FULL o under 525 ohms
Full FG000552
40°C (104°F) o 1,397 ohms
Blue
Hydraulic Oil Temperature
50°C (122°F) o 1,139 ohms
CN3-9
50°C
94°C
40°C
96°C
C
H
White
CN3-10
Red
90 106.5 78.5 96.5
(Output Terminal) CN1-19
57
CN1-20
48.5 (None) FG009964
Electrical System Page 26
57 l/min o583 mA
114
66
96°C (205°F) o 177 ohms 48.5 l/min o610 mA
114
69
Flow Adjusting
94°C (201°F) o 190 ohms
(When reading increase)
FG000551
108
60°C (140°F) o 881 ohms
66 l/min o555 mA
78.5 l/min o466 mA (Default Set)
108 l/min o343 mA 114 l/min o290 mA
SP001038
Function
Sensor Specification
Display
Input Terminal
Input Specification
N = 162 f / 60 Tachometer
E/G SPEED
1700
RPM
ECU-CAN Communication
N = Engine speed (rpm)
CN2-14
0 - 32 VDC
f = Frequency of engine speed sensor (Hz)
FG000049
Voltmeter
BATTERY
28.0
VOLT
FG000050
Main pump discharge pressure (front pump)
FRONT PUMP
320
BAR
CN3-1 CN3-2
V = 0.00816 x P + 1.0 FG000051
V: Sensor output voltage (V) P: Displayed pressure (Bar) Main pump discharge pressure (rear pump)
REAR PUMP
313
BAR
CN3-3 CN3-4
FG000052
Electrical System
SP001038 Page 27
WARNING AND INDICATOR LIGHTS Indication of Warning Lights Description
Symbol
Charge
Input Terminal
Operation
Remarks
CN2 - 14
It lights in case of no charge [voltage of "R(I)" terminal is below 12 ±1V] or overcharge [voltage of "R(I)" terminal is above 33(V)].
Normally, it lights when starting engine and is out after engine starts.
ECU-CAN Communic ation
It lights when engine oil pressure is below the reference.
After starting engine, if engine oil pressure is insufficient after 8 seconds, a warning buzzer will sound.
ECU-CAN Communic ation
It lights in case of failure in engine system.
ECU-CAN Communic ation
It lights when engine coolant temperature sensor resistant is below about 128 ohms.
HAOA610L
Engine Oil Pressure HAOA620L
Engine Check
CHECK FG000045
Coolant Temperature HAOD350L
Preheating
CN5-2
HAOA639L
Electrical System Page 28
It lights during preheating ("CN5-2" terminal voltage is below 2V) and turns "OFF" after completion of preheating.
Preheating period depends on coolant temperature. No preheating at above 10°C 10 sec preheating at 5°C 20 sec preheating at below 0°C
SP001038
Description
Symbol
Work Light
Input Terminal
Operation
CN2 - 6
It lights when work light turns "ON" (24V applied).
Remarks
HB4O2003
Indication of Multifunction Gauge and Letter Information Area
Description
Input Terminal
Symbol
CN3-9
Hydraulic Oil Temperature
CN3-10
Operation
Remarks
When hydraulic oil temperature is above about 96°C.
FG000056
CN3-7
Fuel Exhausted
CN3-8
When fuel is almost exhausted.
FG000057
Air Cleaner
CN2-17
When air cleaner is clogged.
CN5-3
When return filter pressure is above about 1.50 kg/cm² (21 psi)
FG000053
Return Filter
FG000054
Electrical System
SP001038 Page 29
Pilot Filter
CN2-18
When pilot filter pressure is above about 1 kg/cm² (14 psi)
FG000055
CN3-5
Overload Warning
CN3-6 FG000253
Boost
Warning buzzer also starts when boom pressure sensor output voltage is about 2.7V while overload warning switch is "ON."
CN2-2
It lights when boost is selected.
CN2-10
It lights when breaker is selected.
CN2-9
It lights when shear is selected.
It flickers in case of 2.71V and above and lights continuously in case of 2.8V and above (and warning buzzer also starts).
FG000554
Breaker
FG001470
Shear
FG001471
Electrical System Page 30
SP001038
INITIAL OPERATION Item
Input (Terminal)
Initial Operation
Output (Operation and initial setting mode)
When "CN6-1,2" is applied battery voltage (starter switch shifts from "OFF" to "ON"
!
LCD, all of LED and warning lights are turned "ON" and turned "OFF" after about 2 seconds.
!
Warning buzzer is activated and turned "OFF" after about 2 seconds.
!
Power mode: Standard mode.
!
Work Mode: Digging mode.
!
Auto Idle: High Output (Activation).
!
Display: Indicating coolant temperature, Fuel level, Hydraulic oil temperature, Engine speed.
!
Clock: Current time display.
Refer to method for setting clock in operation manual for setting time.
NOTE:
MODE SELECTOR SWITCH Power Mode / Trenching Mode Switch
Operation Mode
Output Check (Operation mode display LED)
e-EPOS Output Electromagnetic Proportional Pressure Reducing Valve (E.P.P.R Valve) Current (mA)
Swing Priority Solenoid Valve
7-Segment Display
-
9x
No-load: 150 ±20mA Power Mode
ON
(Max. current: 600 ±20mA)
Power Mode
Work Mode NOTE:
Load: Variable output No-load: 250 ±20mA
Standard Mode
OFF
Load: Variable output
-
7x
Trenching Mode Digging Mode
OFF ON
(Max. current: 600 ±60mA) -
ON OFF
x2 x0
When the engine speed is below 1,000 rpm, the output current of E.P.P.R valve is fixed to be 600 ±60mA.
Auto Idle Switch
Auto Idle
Electrical System
Operation Mode Activation Cancellation
Output Check (Operation mode display LED) ON OFF
SP001038 Page 31
GRAPHIC INFORMATION AREA DISPLAY Overview Many kinds of condition of machine are displayed on the letter information display department. The information display department is divided into two menus. One is main menu for user and the other is special menu for specialist. These menus can be moved from normal display mode by the combination of selector buttons.
CHECK
02/05 [MO] 11:30
5 F
E
C
C
H
E/G SPEED
H
1700
RPM
1
4
POWER AUTO
1
2
3
4
5
6
7
8
ESC
3
2 FG000557
Figure 12
Selector Buttons 1.
Up Arrow Button
2.
Down Arrow Button
3.
Enter Button
4.
Escape Button
Electrical System Page 32
Graphic Display Area 5.
Letter Information Display Department
SP001038
Main Menus for the Graphic Display Area 1.
Main menu: Language setting, Time setting, Filter/Oil information, Brightness adjustment, Password
2.
Special menu: Information of machine status, failure information, Information of machine operation.
Menu Selector Buttons 1.
Up Arrow Button ( , 1 on Figure 12): Move the cursor to up, left and previous screen.
2.
Down Arrow Button ( , 2 on Figure 12): Move the cursor to down, right and next screen.
3.
Enter Button ( , 3 on Figure 12): Move the menu to selected mode. When setting the menu, this button is used to function as the selector button.
4.
Escape Button (ESC, 4 on Figure 12): Move a screen to previous menu or main menu.
Electrical System
SP001038 Page 33
MAIN MENU When the "ESC" button is pressed for more than 3 seconds, the main menu screen is displayed.
MAIN MENU 1. Language 2. Set Clock 3. Filter / Oil Info 4. Adjust Display 5. Set Password
Main menu offers sub-menus (language setting, time setting, or filter/oil information, brightness adjustment, password) to the operator. Refer to the "Operation and Maintenance Manual" for details.
: UP
: DOWN
: SELECT FG000072
Figure 13
Language
MAIN MENU 1. Language 2. Set Clock 3. Filter / Oil Info 4. Adjust Display 5. Set Password
Put the cursor on Language in the main menu and put the Enter Button ( , 3 on Figure 12) and the language select view appears. The default language is Korean, but it will memorize and use the newly set language. Use the Up Arrow Button ( , 1 on Figure 12) or Down Arrow Button ( , 2 on Figure 12) to move cursor to a language to be selected on the Language Select display and press the Enter Button ( , 3 on Figure 12) and the selected language is indicated in the right bottom of the screen.
: UP
: DOWN
: SELECT FG000072
Figure 14
At this point pressing the Enter Button ( , 3 on Figure 12) or the Escape Button (ESC, 4 on Figure 12) more than 1 second brings the main menu with changed language and then pressing the ESC button again shows the default view.
LANGUAGE 1. Korean 2. English
Without pressing a button more than 20 seconds, the default view appears.
: UP
: DOWN
: SELECT FG000783
Figure 15
Electrical System Page 34
SP001038
Set Clock
MAIN MENU 1. Language 2. Set Clock 3. Filter / Oil Info 4. Adjust Display 5. Set Password
It is used to adjust time of the digital clock. Pressing the Enter Button ( , 3 on Figure 12) in the Main Menu after putting cursor on Set Clock brings Set Clock display. Without pressing a button more than 20 seconds, the default view appears. Please refer to the Operation Manual for detailed information on Time Setting.
: UP
: DOWN
: SELECT FG000075
Figure 16
SET CLOCK
06:05 2004 06/29 :
+
:
: MOVE FG000076
Figure 17
Filter/Oil Info
MAIN MENU 1. Language 2. Set Clock 3. Filter / Oil Info 4. Adjust Display 5. Set Password
This mode displays total operating hours of filters and oils. After changing the filter and oil, reset the operating hour and then the operating hours until the next service interval can be easily checked.
: UP
: DOWN
: SELECT FG000077
Figure 18
FILTER / OIL INFO
1. Fuel Filter Hrs : 0025 : UP
: DOWN
: RESET FG000078
Figure 19
Electrical System
SP001038 Page 35
Menu Display Order and Icon Explanation
1. Fuel Filter
2. Air Cleaner
3. Engine Oil Filter
4. Hyd. Oil Filter
5. Pilot Filter
6. Engine Oil
7. Hydraulic Oil
8. Coolant Water FG001358
Figure 20
Adjust Display
MAIN MENU 1. Language 2. Set Clock 3. Filter / Oil Info 4. Adjust Display 5. Set Password
Pressing the Enter Button ( , 3 on Figure 12) in the main menu after putting cursor on Adjust Display brings Adjust Display. Screen brightness can be adjusted using the Up Arrow Button ( , 1 on Figure 12) or the Down Arrow Button ( , 2 on Figure 12). The default brightness is set to 50%.
: UP
: DOWN
: SELECT FG000080
Figure 21
Adjust Display 50% + LCD TEST LCD TEST LCD TEST :
+
: FG000081
Figure 22
Electrical System Page 36
SP001038
Set Password
MAIN MENU 1. Language 2. Set Clock 3. Filter / Oil Info 4. Adjust Display 5. Set Password
This menu is used to apply (lock), release, or change password. Please refer to the Operation Manual for detailed information on Password Setting.
: UP
: DOWN
: SELECT FG000227
Figure 23
Electrical System
SP001038 Page 37
SPECIAL MENU In this menu, many types of operating conditions and functions can be accessed and displayed, including the e-EPOS controller. This menu is mainly used for machine testing and failure diagnostics. The special menu offers three sub-menus: 1.
Machine status.
2.
Failure information.
3.
Information on machine operation.
Entering/Accessing and Exiting/Escaping Menus Entering/Accessing Menus When normal mode screen is displayed, if the enter button ( , 3) and escape button (ESC, 4) are pressed simultaneously for more than 3 seconds, normal mode screen (Figure 25) will be changed to special menu screen (Figure 26).
1
4
POWER AUTO
1
2
3
4
5
6
7
8
2
FG001402
ESC
3
Figure 24 Normal Mode Screen NOTE:
Normal mode screen can display many kinds of display mode by selecting, for example, engine speed (RPM), battery voltage (VOLT), front pump pressure (BAR), rear pump pressure (BAR) and so on by selecting.
02/05 [MO] 11:30
E
C
H
E/G SPEED
F
C
1700
H
RPM FG000043
Figure 25
Electrical System Page 38
SP001038
Special Menu Screen NOTE:
Displayed language on the special menu screen consists of Korean and English.
SPECIAL MENU
1. Machine Info
If any language except for Korean is selected during language selection mode of main menu, only English will be displayed on special menu screen.
2. Failure Info 3. Operating Hrs : UP
: DOWN
: SELECT FG000558
Figure 26 Exiting/Escaping Menus 1.
If escape button (ESC, 4 on Figure 24) is pressed for more than 1 second, the special menu screen will be returned to the normal mode screen.
2.
If this special menu is "ON" without any activity, for more than 20 seconds, it will turn to the normal mode screen.
3.
After the turning starter switch to the "OFF" position, turn it back to the "ON" position, and the normal mode screen displayed once again.
Special Menu Selections Submenu Selection Method Various sub-menus can be selected by pressing "Up ( Figure 24)" and "Down ( , 2 on Figure 24)" button.
SPECIAL MENU
, 1 on
1. Machine Info
Move the cursor to desired menu and a selected menu will be inverse displayed.
2. Failure Info
When the selected menu is inverse displayed, press the "Enter ( , 3 on Figure 24)" button for menu selection.
3. Operating Hrs : UP
: DOWN
: SELECT FG000558
Figure 27
Information of Machine Status 1.
2.
Entering Sub-menus: When cursor is located on "Machine Info" of special menu screen, press "Enter ( , 3 on Figure 24)" button and the "Machine Info" will be displayed. Exiting Sub-menus: If escape button (ESC, 4 on Figure 24) is pressed for more than 1 second, display will be turned to previous screen.
MACHINE INFO 1. Analogue Input State 2. Digital Input State 3. Digital Output State : UP
: DOWN
: SELECT FG000559
Figure 28
Electrical System
SP001038 Page 39
Analog Inputs Description Analog Input Items
Display
Remark
1. Pump P/V
mA
Current in pump proportional valve.
2. Cooling Fan P/V
mA
N.A.
3. Flow Control P/V
mA
N.A.
4. Dial
mV
Indicating dial voltage.
5. TPS
mV
N.A.
6. E/G Control Motor
mV
N.A.
7. Boom Pressure
BAR
Boom cylinder head pressure.
8. Pilot Gear Pump Press
BAR
N.A.
9. Boost Pressure
BAR
Pump pressure for boost.
10. Intake Manifold Temperature
°C
Temperature of air incoming to intake manifold.
11. E/G Oil Pressure
BAR
Engine oil pressure.
12. Fuel Temperature
°C
Fuel temperature.
13. E/G Oil Temperature
°C
Engine oil temperature.
14. Load At Cur. Spd
%
Current load ratio of equipment.
Submenu Selections
ANALOG INPUT STATE 1. Pump P/V 2. Cooling Fan P/V 3. Flow Control P/V 4. Dial 5. TPS 6. E/G Control Motor : UP
: DOWN
ANALOG INPUT STATE : 000BAR 7. Boom Pressure 8. Pilot Gear Pump Press. : N.A 9. Boost Pressure : 000BAR 10. Intake Manifold Temp. : 000 C 11. E/G Oil Pressure : 000BAR : 000 C 12. Fuel Temp.
: 000mA : N.A : 000mA : 000mV : 000mA : N.A Page:1/3
: UP
: DOWN
Page:2/3
ANALOG INPUT STATE 13. E/G Oil Temp. 14. Load at Cur. Spd
: UP
: DOWN
: 000 C : 000 %
Page:3/3 FG008126
Figure 29
Electrical System Page 40
SP001038
Digital Inputs Descriptions Digital Inputs Items
Mark
Remark Lights up when output at alternator "R(I)" terminal is above 12 ±1V.
1. Alternator 2. Travel Select SW
N.A. (only for wheel type equipment)
3. High Speed Sel. SW (M)
Lights up when the travel speed selector switch is set to the "I" position.
4. High Speed Sel. SW (A)
Lights up when the travel speed selector switch is set to the "II" position.
5. Pressure SW (Py)
Lights up when the pressure switch (Py) is "ON."
6. Pressure SW (Px)
Lights up when the pressure switch (Px) is "ON."
7. E/G Oil Press. SW
N.A. (only for mechanical engine)
8. Air Cleaner Clogged
Lights up when the air cleaner indicator contact is "ON."
9. Return Filter Clogged
Lights up when the return filter pressure switch is "ON."
10. Pilot Filter Clogged
Lights up when the pilot filter pressure switch is "ON."
11. OWD Warning SW
Lights up when the overload warning selector switch is "ON."
ON / OFF
12. Brake Oil Press. SW
N.A. (only for wheel type equipment)
13. Pedal Press. SW
Lights up when the pedal pressure switch is ON.
14. One Way Sel. SW
Lights up when the selector switch is turned to breaker.
15. Two-way Sel. SW
Lights up when the Selector Switch is turned to "SHEAR."
16. Power Max. SW
Lights up when the boost button is "ON" with the Select switch turned to "BOOST."
17. Breaker SW
Lights up when the boost button is "ON" with the selector switch turned to "BREAKER."
18. Preheat Select
N.A.
19. Quick Coupler
Lights up when the Quick Coupler switch is "ON."
20. F and R Lever
N.A. (only for wheel type equipment)
21. Preheat Select
Lights up during preheating (CN5-2) terminal voltage is below 2V.
22. Reverse Fan SW
N.A.
23. Pilot Cutoff SW
N.A.
Electrical System
SP001038 Page 41
Menu Select
DIGITAL INPUT STATE 1. Alternator : 2. Travel Select SW : 3. High Speed Sel. SW (M) : 4. High Speed Sel. SW (A) : 5. Pressure SW (Py) : 6. Pressure SW (Px) : : UP
: DOWN
Page:1/4
DIGITAL INPUT STATE 19. 20. 21. 22. 23.
Quick Coupler F&R Lever Preheat Select Reverse Fan SW Pilot Cutoff SW
: UP
: DOWN
: : : : : N.A
Page:4/4
DIGITAL INPUT STATE 7. E/G Oil Press. SW 8. Air Cleaner Clogged 9. Return Filter Clogged 10. Pilot Filter Clogged 11. OWD Warning SW 12. Brake Oil Press. SW : UP
: DOWN
: N.A : : : : : N.A Page:2/4
DIGITAL INPUT STATE 13. 14. 15. 16. 17. 18.
Pedal Press. SW One Way Sel. SW Two Way Sel. SW Power Max. SW Breaker SW Preheat Select
: UP
: DOWN
: : : : : : N.A Page:3/4 FG008136
Figure 30
Electrical System Page 42
SP001038
Digital Outputs Descriptions Digital Outputs Items
Mark
Remark
1. Relief Press. Up S/V
Lights up when the relief press up solenoid valve is "ON."
2. High Speed S/V
Lights up when the high speed solenoid valve is "ON."
3. Swing Priority S/V
ON / OFF
Lights up when the swing priority solenoid valve is "ON."
4. Reverse Fan S/V
N.A.
5. Starter Relay
When the starter relay is "ON."
6. After Heat Relay
N.A.
Menu Select
DIGITAL OUTPUT STATE 1. Relief Press. Up S/V 2. High Speed S/V 3. Swing Priority S/V 4. Reverse Fan S/V 5. Starter Relay 6. Afterheat Relay : UP
: DOWN
: : : : N.A : : N.A Page:1/1 FG003930
Figure 31
Failure Information 1.
2.
SPECIAL MENU
Entering Sub-menus: When a cursor is located in "Failure Info" of special menu screen press enter button ( , 3 on Figure 24) and "Failure Info" screen is displayed.
1. Machine Info 2. Failure Info
Exiting Sub-menus: If escape button (ESC, 4 on Figure 24) is pressed for more than 1 second, this information screen will be returned to previous screen.
3. Operating Hrs : UP
: DOWN
: SELECT FG000563
Figure 32 * Real-time Failure: Current status of failure is displayed.
FA I L U R E I N F O
* Failure Log: Memorized record of past failure is displayed.
1. Realtime Fail
* Delete Fail Log: This mode is used to delete all of the memorized record of past failure.
2. Failure Log 3. Delete Fail Log : UP
: DOWN
: SELECT FG000564
Figure 33
Electrical System
SP001038 Page 43
A.
Current failure information Current status of failure is displayed (Failure code, failure contents). When a number of failures are produced, failure information can be checked using "UP" ( , 1 on Figure 24) or "DOWN" ( , 2 on Figure 24) button. * 1/2: A serial number of current failure/ total quantity of failure. * Vxxx-xx: Vxxx is a unique code and xx is a FMI (Failure Mode Identifier) number.
R E A LT I M E FA I L 1/2 2/2
CODE : V204-05 CODE : E011-04
Relief Pressure Up S/V Current below normal (CURRENT BELOW NORMAL or open circuit) : UP
: DOWN FG000565
Figure 34
- V: Machine related failure code - E: Engine related failure code Refer to the failure information code for unique codes and FMI numbers. This example shows one of two failures. B.
Past failure information Memorized record of past failure is displayed (Failure code, failure contents). When a number of failures are produced, failure information can be checked using "UP" ( , 1 on Figure 24) or "DOWN" ( , 2 on Figure 24) button. NOTE:
" Number: xxx ": "xxx" means that the totally counted number of the same failure. " Period:xxxxxHrxxm ": It indicates the period for which machine has operated until a failure takes place. (For more than two occurrences of the same failure, until the first occurrence time.)
C.
FA I L U R E L O G 1/2 CODE : V204-05 2/2 CODE : E011-04 Period:00254Hr 29m Number:08 Relief Pressure Up S/V Current below normal (CURRENT BELOW NORMAL or open circuit) : UP
: DOWN FG000566
Figure 35
Failure record deletion This mode is used to delete the memorized record of past failure. If this mode is selected, all records will be deleted.
DELETE FAIL LOG All Fail Log will be DELETED.
When "YES" ( , 3 on Figure 24) button is pressed, the memorized record will be deleted. At this time, deletion signal will be displayed and the screen will move to previous menu after deletion.
: Yes
This screen will be displayed during 3 seconds.
ESC: No FG000567
Figure 36
Electrical System Page 44
SP001038
Input your password with one of No. 1 - 8 switches. When "NO" (ESC, 4 on Figure 24) button is pressed, the screen will recover to previous menu without deletion.
DELETE FAIL LOG ENTER PASSWD
: Yes
ESC: No FG000568
Figure 37 Delete Completed screen will appear 3 seconds and the screen will move to Failure Info screen.
DELETE FAIL LOG
It has been shown 3 seconds upon deleting Fail Log.
DELETED!!!
: Yes
ESC: No FG000569
Figure 38 The screen shown on the left will appear 3 seconds in case of wrong password input and then Enter Password screen appears again.
DELETE FAIL LOG
It has been shown 3 seconds in case of password failure.
PASSWORD ERR !!!
: Yes
ESC: No FG000570
Figure 39
Electrical System
SP001038 Page 45
Failure Information Code at Machine Side Code
Failure Component
V201
Gauge Communication Error
V202
Ecu Communication Error
V210
Pump P/V
V211
Cooling Fan P/V
V212
V213
V214
Panel
Flow Control P/V
Relief Pressure Up S/V
High Speed S/V
V215
Swing Priority S/V
V216
Reverse Fan Speed S/V
V217
Starter Relay
V218
After Heat Relay
Electrical System Page 46
Measuring Points CN7-4 CN7-5
CN4-4 CN4-5
CN1-10 CN1-21
Correct Value Active
Passive
-
R 60 ±5 :
-
R 60 ±5 :
-
CN1-19 CN1-20
CN1-1 CN1-11
CN1-1 CN1-12
CN1-1 CN1-13
-
V = V_volt (Note 4.)
V = V_volt
V = V_volt
CN1-15
R 14 ±2 : (25°C (77°F))
R 26.2 ±2 : (25°C (77°F))
R 26.2 ±2 : (25°C (77°F))
R 26.2 ±2 : (25°C (77°F))
It is a composite resistance of CAN line. This value has to be measured by connected condition of CAN line. Pump proportional pressure reducing valve. N.A. Flow control proportional pressure reducing valve. Breaker/boost/ shear selector switch has to be selected as a boost function and the boost switch on the right-hand joystick is "ON" status. Voltage is only measured when the pressure switch (Py) is turned "ON." Work mode has to be selected as a trenching mode.
-
N.A.
V = V_volt
-
It has to be measured in engine start up state.
-
-
N.A.
CN1-1
R 18 ±2 : (25°C (77°F))
Remarks
SP001038
Code
Failure Component
V220
Front Pump Press. Sensor
V221
Rear Pump Press. Sensor
Measuring Points CN3-1 CN3-2 CN3-3 CN3-4
Correct Value Active
Passive
V = IV
-
V = IV
-
-
R 2.45 r25 k: (25°C (77°F))
R 320 ±32 : (80°C (176°F))
CN3-9
Remarks It has to be measured in engine stop state.
V222
Hyd. Oil Temperature Sensor
V223 V224
Water Temperature Sensor
-
-
N.A.
Engine Speed Sensor
-
-
N.A.
V225
V226
Fuel Level Sensor
Alternator Potential
CN3-7
-
CN3-8
CN2-14 CN1-8
V = 2 ±1V
CN3-16
Empty: 5 r25 k: Full: 320 ±32 : R 1.0 r3 k:
It has to be measured in engine stop state.
-
R 4.0 ±1.5 k:
Tps (Wheel)
-
-
N.A.
Parking Brake Press. Sensor
-
-
N.A.
E/g Control Motor Sensor
-
-
N.A.
V227
Dial
V228 V229 V230 NOTE:
CN3-10
CN3-7
1. Active value: Starter switch has to be turned "ON" Measuring points between component and wire harness have to be connected. 2. Passive value: Starter switch has to be turned "OFF" Measuring points between component and wire harness have to be disconnected. 3. Measuring points are engine controller's points and passive value is each component's value. 4. V#batt: Source power of equipment.
Electrical System
SP001038 Page 47
Failure Information Code at Engine Side Code
Failure Component
E011
Coolant temperature sensor
E012
Fuel temperature sensor
E013
Boost air temperature sensor
Measuring Points
Current Valve Active
2-26 2-15 2-26 2-35
-
-
2-36
E014
Boost air pressure sensor
E017
E/G oil temperature sensor
2-25 2-33 2-34
V 1,071 ±58mV (at 23°C (73°F) and absolute pressure 1bar)
2-28
E018
E/G oil pressure sensor
E021
Battery voltage
2-24 2-32 2-27 1-03 1-06
E022
Fuel pressure sensor
E032
Fuel pressure MPROP
monitoring
3-09 3-10 2-14 2-12
1-53 and 1-52
V 2,318 ±80mV (at 23°C (73°F) and absolute pressure 3bar) V = V#volt (Note 4.)
V 1,833 ±28mV (at 23°C (73°F) and absolute pressure 300bar) -
Passive
R 186 ±5 : (100°C (212°F)) R 186 ±5 : (100°C (212°F)) R 186 ±5 : (100°C (212°F)) R 186 ±5 : (100°C (212°F)) -
-
R 60 ±5 : (20°C (68°F))
E038 E039
Engine overspeed
-
-
Main relay (ECU)
-
-
E041
Redundant shutoff path
-
-
E042
E/G speed (Crankshaft)
E043
E/G speed (Camshaft)
Electrical System Page 48
2-23 2-19 2-09 2-10
-
It has to be measured in engine running state.
It has to be measured in engine running state.
R 2.60 ±3.15 : (20°C (68°F))
CAN module
-
It has to be measured in engine running state.
-
E037
1-35 and 1-34
Remarks
R 860 ±6 : (20°C (68°F))
It is a composite resistance of CAN line. This value has to be measured by connected condition of CAN line.
Abnormal engine stop.
-
SP001038
Code
Failure Component
Measuring Points
Current Valve Active
Passive
Remarks
E044
Engine speed sensor
-
-
Synchronizing error between crank shaft speed sensor and cam shaft speed sensor.
E045
EEPROM
-
-
Data storing error when engine stop.
E046
Recovery
-
-
E047
Monitoring of PRV
E048
Power supply
E049
-
-
V = V#volt
-
Booster voltage C1
-
-
E051
Booster voltage C2 ($6, 2 and 4)
-
-
E058
Solenoid power stage 1
-
R 0.31 ±0.42 : (20°C (68°F))
E059
Solenoid power stage 2
-
-
E061
Solenoid power stage 3
-
-
E062
Solenoid power stage 4
-
-
E063
Solenoid power stage 5
-
-
E064
Solenoid power stage 6
-
-
E066
Preheat light (E/G: Lowside Power stage 2)
-
-
E072
Preheat relay (E/G: Highside Power stage 1)
Electrical System
1-03 1-06
3-13 3-04 3-11 3-06 3-05 3-12 3-03 3-14 3-01 3-16 3-02 3-15 1-56 1-06
1-13 1-07
V = V#volt
R 40 ±5 : (25°C (77°F))
When the pressure sensor of common rail or high-pressure pump has a defect.
Voltage is only measured when afterheat function is operating status.
SP001038 Page 49
Measuring Points
Code
Failure Component
E083
Fuel HI pressure pump (E/G: Current controlled Highside power stage 1)
E091
System start-up shutoff path
test
for
Current Valve Active
-
-
-
-
Passive -
-
Remarks Fuel metering unit error of high-pressure pump. Power supply error Engine controller error. Injector error
E092
Monitoring of misfire cylinder 1
-
-
-
E093
Monitoring of misfire cylinder 2
-
-
-
E094
Monitoring of misfire cylinder 3
-
-
-
E095
Monitoring of misfire cylinder 4
-
-
-
E096
Monitoring of misfire cylinder 5
-
-
-
E097
Monitoring of misfire cylinder 6
-
-
-
E098
Monitoring of misfire multiple cylinder
-
-
-
E099 E101
Monitoring of overrun
-
-
-
Engine speed redundant
-
-
-
NOTE:
Speed signal error of cam shaft speed sensor or crank shaft speed sensor.
1. Active value: Starter switch has to be turned "ON" Measuring points between component and wire harness have to be connected. 2. Passive value: Starter switch has to be turned "OFF" Measuring points between component and wire harness have to be disconnected. 3. Measuring points are engine controller's points and passive value is each component's value. 4. V#batt: Source power of equipment.
Electrical System Page 50
SP001038
FMIs (Failure Mode Identifier) FMI 0
Above normal range (DATA VALID but ABOVE NORMAL OPERATIONAL RANGE)
FMI 1
Below normal range (DATA VALID but BELOW NORMAL OPERATIONAL RANGE)
FMI 2
Incorrect signal (DATA ERRATIC, INTERMITTENT OR INCORRECT)
FMI 3
Voltage above normal (VOLTAGE ABOVE NORMAL OR SHORTED TO HIGH SOURCE)
FMI 4
Voltage below normal (VOLTAGE BELOW NORMAL OR SHORTED TO LOW SOURCE)
FMI 5
Current below normal (CURRENT BELOW NORMAL OR OPEN CIRCUIT)
FMI 6
Current above normal (CURRENT ABOVE NORMAL OR GROUNDED CIRCUIT)
FMI 8
Abnormal signal (ABNORMAL FREQUENCY OR PULSE WIDTH OR PERIOD)
FMI 11
Failure mode not identifiable (ROOT CAUSE NOT KNOWN - Malfunction)
FMI 31
NOT AVAILABLE OR CONDITION EXISTS
Information of Machine Operation Accumulated operation hour of each mode and status is displayed. 1.
Operating Hour Information A.
S P E CIA L ME NU
Entering Sub-menus: When a cursor is located in "Operating Hrs" of special menu screen (Figure 40) press enter button ( , 3 on Figure 24) and "Operating Hrs" screen will be displayed (Figure 41).
1. Machine Info 2. Failure Info 3. Operating Hrs : UP
: DOWN
: SELECT FG000571
Figure 40 B.
Information screen of machine operation (Figure 41).
OPERATING HOURS Operating Hours Reset Hours
: UP
: DOWN
: SELECT FG000572
Figure 41
Electrical System
SP001038 Page 51
C.
Operating Hours Screen
D.
Exiting Sub-menus: If escape button (ESC, 4 on Figure 24) is pressed for more than 1 second, this information screen will be returned to previous screen.
OPERATING HOURS 1. Power 2. Trenching 3. Auto idle 4. Travel speed I speed II speed : UP
: DOWN
: 00042 Hr : 00003 Hr : 00005 Hr : 00007 Hr : 00001 Hr : SELECT FG000573
Figure 42 Information contents of operation hour Information Contents
Detection Method
Power Mode
Item
Operation hours used power mode are displayed.
Power mode switch (Instrument panel) "ON" status and Alternator signal (CN2-14) is "HI"
Trenching Mode
Operation hours used trenching mode are displayed.
Trenching mode switch (Instrument panel) - "ON" status and Alternator signal (CN2-14) is "HI"
Auto Idle
Operation hours used auto idle status are displayed.
Auto idle switch (Instrument panel) "ON" status and Alternator signal (CN2-14) is "HI"
Travel Speed:
Operation hours used low speed and high speed are displayed.
1st: High speed s/v "OFF" status
Temperature of hydraulic oil is classified 6 steps. And operation hours of each step are displayed
The resistance delivered from temperature sensor of hydraulic oil is classified 6 steps. And operation hours of each step are displayed. (Alternator output HI status)
-1st - 2nd Hydraulic Oil Temperature Distribution (°C (°F))
Under 30°C (87°F) 31 - 50°C (88 - 123°F) 51 - 75°C (124 - 168°F) 76 - 85°C (169 - 186°F) 86 - 95°C (187 - 203°F) Over 96°C (204°F) Coolant Temperature Distribution (°C (°F))
Temperature of coolant is classified 6 steps. And operation hours of each step are displayed. Under 40°C (105°F) 41 - 60°C (106 - 141°F) 61 - 85°C (142 - 186°F) 86 - 95°C (187 - 204°F) 96 - 105°C (205 - 222°F) Over 106°C (223°F)
Electrical System Page 52
2nd: High speed s/v and travel pressure switch "Py" (control valve) - "ON" status.
The resistance delivered from coolant sensor is classified 6 steps. And operation hours of each step are displayed. (Alternator output HI status)
SP001038
Menu Selection of Operation Hour Information
3. Auto Idle
2. Trenching Mode
1. Power Mode
6. Coolant Temperature Distribution
4. Travel Speed 1st, 2nd
5. Hydraulic Oil Temperature Distribution FG000574
Figure 43 Example of Machine Operation Info Screen
OPERATING HOURS
OPERATING HOURS
1. Power 2. Trenching 3. Auto idle 4. Travel speed I Speed II Speed
5. Hyd. Oil Temp. [ C] : 00003 Hr 30 31 - 50 : 00005 Hr 51 - 75 : 00008 Hr 76 - 85 : 00000 Hr 86 - 95 : 00007 Hr : 00001 Hr 96
: UP
: DOWN
: 00042 Hr : 00003 Hr : 00005 Hr : 00007 Hr : 00001 Hr Page:1/3
: UP
: DOWN
Page:2/3
OPERATING HOURS 6. Coolant Temp. [ C] 40 : 00003 Hr 41 - 60 : 00005 Hr 61 - 85 : 00000 Hr 86 - 95 : 00000 Hr 96 - 105 : 00007 Hr 106 : 00001 Hr : UP
: DOWN
Page:3/3 FG000575
Figure 44 2.
Operation hour reset A.
Entering Sub-menus: When cursor is located in "Reset Hrs" of information screen of operating hours press enter button ( , 3 on Figure 24) and "Machine Operation Info" screen will be displayed.
OPERATING HOURS Operating Hrs Reset Hrs
: UP
: DOWN
: Yes FG000578
Figure 45
Electrical System
SP001038 Page 53
B.
Reset screen of operation hour
C.
Exiting Sub-menus: If escape button (ESC, 4 on Figure 24) is pressed for more than 1 second, this information screen will be returned to previous screen.
NOTE:
NOTE:
OPERATING HOURS All Operating Hours will be DELETED.
When "YES" ( , 3 on Figure 24) button is pressed, operation hours will reset. At this time, resetting signal will be displayed and the screen will move to previous menu after resetting. When "NO" (ESC, 4) button is pressed, the screen will recover to previous menu without resetting.
: Yes
ESC: No FG000579
Figure 46
Machine Operation Info Screen 1.
If you press the YES" ( , 3 on Figure 24) button, password entrance screen appears.
OPERATING HOURS ENTER PASSWD
: Yes
ESC: No FG000576
Figure 47 2.
When right password is input, machine operation periods will be deleted and Reset Completed screen will appear 3 seconds.
OPERATING HOURS
DELETED!!!
: Yes
ESC: No FG000577
Figure 48 3.
If you press the "NO" (ESC, 4) button, the previous screen appears without resetting operation periods.
OPERATING HOURS
PASSWORD ERR !!!
: Yes
ESC: No FG001086
Figure 49
Electrical System Page 54
SP001038
Electrical System
SP001038 Page 55
ELECTRONIC HYDRAULIC CONTROL SYSTEM (e-EPOS) Control System Schematic
16 6
6 7
7
8
11
12
14
8
13 15
E/G
4
4
5
3 9
10 Work Mode Auto Idle Machine Info
2 CHECK
E/G speed order
02/05 [MO] 11:30
F
E
C
C
H
E/G SPEED
23
H
1700
RPM
POWER AUTO
1
2
3
4
5
6
7
8
ESC
R UP
WE
PO
1 17
21 19
18
22
20 FG000795
Figure 50
Electrical System Page 56
SP001038
Reference Number
Description
Reference Number
Description
1
Instrument Panel
12
Solenoid Valve (Swing Priority)
2
e-EPOS Controller
13
Solenoid Valve (High Speed)
3
Engine Controller (ECU)
14
Solenoid Valve (Breaker)
4
Main Pump
15
Travel Motor
5
Aux Pump
16
Main Relief Valve
6
Control Valve
17
Engine Control Dial
7
Pressure Switch
8
Pump Pressure Sensor
18
Breaker/Boost/Shear Selector Switch
19
Auto Travel Selector Switch
9
Electromagnetic Proportional Pressure Reducing Valve (Attachment)
20
Boost Switch (Right Work Lever)
Electromagnetic Proportional Pressure Reducing Valve (Mode Control)
21
Sensor
10
22
Aux Mode Switch
11
Solenoid Valve (Boost)
23
Aux Mode Resistor
Electrical System
SP001038 Page 57
POWER MODE CONTROL
6
6
E/G
5 4
4 3
10
2 1 POWER AUTO
17 23
1
2
3
4
5
6
7
8
ESC
22 FG000796
Figure 51 Reference Number
Description
1
Instrument Panel (Power Mode Selector Switch)
2
e-EPOS Controller
3
Reference Number
Description
10
Electromagnetic Proportional Pressure Reducing Valve (Mode Control)
Engine Controller (ECU)
17
Engine Control Dial
4
Main Pump
22
Aux Mode Switch
5
Aux Pump
23
Aux Mode Resistor
6
Control Valve
Electrical System Page 58
SP001038
The power mode switch permits the selection of the appropriate engine power depending on the working condition. One of the two, Power Mode or Standard Mode, setting can be selected. When the engine starter switch is turned "ON," the power mode is automatically defaulted to standard mode. The desired mode can be selected by pressing the selector button on the instrument panel. When the power mode is selected, the indicator light will turn "ON" to display the selected mode. The quantity of oil discharged by the pump and the engine speed are determined by the mode selected by the operator. The pump output in each mode is determined by the mode selection and is listed in the following table Mode
Standard Mode
Power Mode
Output (%)
Approximately 85%
100%
Electrical System
SP001038 Page 59
Operation 1.
Power Mode This mode should be selected for high speed work. In this mode the engine output is most efficiently utilized due to the discharged oil volume being controlled based on the equivalent horsepower curve at various loaded pressures. The e-EPOS controller compares the target engine speed with the actual engine speed and controls the signal to the E.P.P.R. (Electromagnetic Proportional Pressure Reducing) valve which in turn varies the pump output quantity. If the load increases, the engine speed will fall below the rated speed. When this occurs, the controller senses this decrease and immediately reduces the pump discharge volume to maintain the engine speed at the rated level.
ARO0260L
Figure 52
On the other hand, if the load is decreased the controller increases the discharge volume of the pump to maintain the engine speed at the rated level. By repeating these control operations, the engine speed is maintained at the rated speed so that maximum power can be generated. In Power Mode, the e-EPOS controller receives engine speed signals from the engine control dial and the engine controller (ECU) and converts it to an operating signal current and is then transferred to the pump's E.P.P.R valve. At this time the E.P.P.R. valve converts the electric signal to the corresponding control pressure and sends it to the two pumps, adjusting the pump discharge volume to the desired level.
A
C
B
D FG000580
Figure 53 Reference Number
Description
Reference Number
A
Engine Horsepower (hp)
D
B
Engine Speed (rpm)
C
Pump Discharge Volume (lpm)
Electrical System Page 60
Description Pump Discharge Pressure (kg/cm2)
SP001038
2.
Standard Mode Standard Mode is used for general work. When this mode is selected it will reduce noise and fuel consumption in comparison with Power Mode. The current to the E.P.P.R. valve is shut off and pump discharge volume is controlled by pump regulator.
A
C
B
D FG000581
Figure 54 Reference Number
Description
Reference Number
A
Engine Horsepower (hp)
D
B
Engine Speed (rpm)
C
Pump Discharge Volume (lpm)
Description Pump Discharge Pressure (kg/cm2)
3) Operation in case of failure in the control system (Aux mode operation Though it is impossible to control current of the E.P.P.R (Electromagnetic Proportional Pressure Reducing) Valve controlling the discharge volume of pump due to fault in control system, the machine can be operated in the aux mode. Upon turning "ON" the aux mode switch, the E.P.P.R Valve controlling the discharge volume of pump comes into contact with the aux mode resistor to let current of a certain value flow. At this time, the discharge volume of pump follow the control by the pump regulator, nearly at quantity roughly similar to that in the standard mode.
Electrical System
SP001038 Page 61
POWER MODE CONTROL CIRCUIT DIAGRAM 1 15A
CN6-1 CN6-2
26 4
CN6-9
26
26
15A
10A
25
CN6-10 CN1-1 CN7-4
CN4-4
CN7-5
CN4-5
CN7-6
CN4-6
CN1-2 CAN
CN1-8
11
CN1-9
3
24
23 1-35
22
1-34 1-33
5
1-52
3
CN1-21
1-51
(CONN.1)
P/V-(A)
2
1-53 VEHICLE CONN
10
1
CN1-10
6
4
1-05
17
1-06
CN3-15
1
SIG
CN3-16
2
GND
CN3-17
3
+(5V)
1-10 1-11
CW LOW
HIGH
1-02 1-03 1-08
15A
26
10A
26
1-09 BR
1-40
B
28 AMP 070 16P
AMP 040 12P
8 8
7
6
5
4
3
16 15 14 13 12
2
11 10
1
6
5 4
3
2
1
10 9
12 11 10 9
8
7
20 19 18 17 16 15 14 13 12 11
6
5 4
3
2
7
6
5
4
2
1
10
11 10
9
21 20
3
9
8
7
6
12
18 17 16
15 14 13 12
5
19 18 17
16
11
1
11
AMP 040 28P 3
2
1
12 11 10 9
8
7
6
35
36
53
54
71 72
2
12
(CN1)
5 4
(CN7) 6
4
(CN3)
(ECU CONNECTOR)
18
17
3
15 14 13
1
(CN2) (CN4)
VEHICLE CONN.
1
7
9
(CN5)
7
8
AMP MIC 21P
AMP 070 18P
AMP 040 20P
8
7
6
2
1
16 15 14 13 12 11 10
5
4
3
9
(CN6)
89
ECU CON.1 (89-PIN)
FG008165
Figure 55
Electrical System Page 62
SP001038
Reference Number
Description
Reference Number
Description
1
Instrument Panel
23
Aux Mode Resistor
3
Engine Controller
24
Battery
4
e-EPOS Controller
25
Battery Relay
10
E.P.P.R. Valve (Electromagnetic Proportional Pressure Reducing)
26
Fuse
27
Fusible Link
17
Engine Control Dial
28
Starter Switch
22
Aux Mode Switch
Electrical System
SP001038 Page 63
WORK MODE CONTROL
6
6
12
E/G
5
3
4
4
2 1 POWER AUTO
1
2
3
4
5
6
7
8
ESC
17
FG000797
Figure 56 Reference Number
Description
Instrument Panel (Trenching Mode Selector Switch)
5
Aux Pump
6
Control Valve
2
e-EPOS Controller
12
Solenoid Valve
3
Engine Controller
17
Engine Control Dial
4
Main Pump
Reference Number
Description
1
Depending on the working condition, one of two work modes, "DIGGING" or "TRENCHING" can be selected from the instrument panel. When the engine starter switch is turned "ON," the work mode is automatically defaulted to digging mode. Depending on the trenching mode selected, the control valve solenoid adjusts the assignment of hydraulic oil flow to each device on the equipment.
Electrical System Page 64
SP001038
Operation 1.
Digging Mode This mode is used for general digging work, loading work and ground leveling work requiring quick stops. The current to the solenoid valve for swing priority is shut off.
2.
Trenching Mode This mode is used for heavy duty ditch digging work or for loading work requiring big swing angles. The voltage is assigned to the swing priority control valve activating the swing control valve restricting the flow of oil to the boom and the arm.
ARO0270L
Figure 57
Electrical System
SP001038 Page 65
WORK MODE CONTROL CIRCUIT DIAGRAM
1 04@
BM5,0 BM5,1
26 4
26
04@
BM5,8
25
BM5,0/ BM0,0 BM6,3
BM3,3
BM6,4
BM3,4
BM6,5
BM3,5
BM0,1 B@M
24 12 'B4( BM0,02
BM0,7 BM0,8
@LO/6/05O
@LO/3/01O
7 7
6
5
4
3
2
1
0
5
4 3
2
01 00 0/ 8 05 04 03 02 01
00 0/
'BM4(
1 7
0 6
0/ 8 7
6 5
4 3
@LOLHB10O
@LO/6/07O
@LO/3/1/O 2
1
6
5
4
3
2
1
0/
0
8
7
6
5
1/ 08 07 06 05 04 03 02 01 00
8
07 06 05
04 03 02 01
10 1/
4
00 0/ 8
08 07 06
05
'BM1( 'BM3(
2
1
0
04 03 02
3
01
00
0
'BM0(
'BM2( @LO/3/17O 2
1
0
01 00 0/ 8
5
4 3
7
6
'BM6(
1
0
05 04 03 02 01 00 0/
7 6
5 4
3
2
8
'BM5(
FG000583
Figure 58 Reference Number
Description
Reference Number
Description
1
Instrument Panel
24
Battery
2
e-EPOS Controller
25
Battery Relay
12
Solenoid Valve (Swing Priority)
26
Fuse
Electrical System Page 66
SP001038
ENGINE CONTROL SYSTEM
(Drive Signal)
(Command Signal)
FG000584
Figure 59 Reference Number
Description
Reference Number
Description
3
Engine Controller
17
Engine Control Dial
4
e-EPOS Controller
When the engine control dial is moved the output voltage changes according to the dial position. The e-EPOS controller converts this output voltage of dial to digital signal and sends it to the engine controller by CAN line. According to the dial command, the quantity of fuel injection is adjusted.
Electrical System
SP001038 Page 67
ENGINE CONTROL DIAL
7th STEP
1st STEP
CCW MECHANICAL STOP
13th STEP
( 10 )
( 10 )
CW MECHANICAL STOP
1
(V) 5 4.0V
4 3
2.5V
2
2
1.0V 1 SETUP
0 CCW STOP
1ST 2nd
7th
12th 13th
CW STOP
1 2 3
VIEW ( POTENTIOMETER BOTTOM) 1
2
3
FG000866
Figure 60 Reference Number
Description
Reference Number
1
Knob
2
Description Potentiometer (Variable Resistor)
The engine control dial has a built in potentiometer. When the control knob is moved the output voltage (through "2 and 3" terminals) will vary from the 5 V supplied from the e-EPOS controller as shown in the graph.
Electrical System Page 68
SP001038
ENGINE CONTROL CIRCUIT DIAGRAM 1 15A
CN6-1 CN6-2
26 4
CN6-9
26
15A
25
CN6-10 CN1-1 CN7-4
CN4-4
CN7-5
CN4-5
CN7-6
CN4-6
CN1-2 CAN
24
CN1-8
28
CN1-9
3 1-35 1-34 1-33 1-53 1-52 VEHICLE CONN
29
1-51
Py CN2-15
(CONN.1)
1-05
17
1-06
Px
CN3-15
1
SIG
CN3-16
2
GND
CN3-17
3
+(5V)
1-10
CN2-16
1-11
30
1-02
26
1-03 1-08
CW LOW
HIGH
15A
1-09 BR
1-40
10A
B
26
27 AMP 070 16P
AMP 040 12P
8 8
7
6
5
4
3
2
1
6
5 4
3
12 11 10 9 16 15 14 13 12
11 10
7
10 9 8
7 6
5 4
3
2
7
6
5
4
3
2
10
1
9
8
7
6
18 17 16
15 14 13 12
21 20
11 10 9
5
19 18 17
16
(CN2)
12
11
1
11
AMP 040 28P 6
35
36
53
54
71 72
2
12
(CN1)
5 4
3
2
1
12 11 10 9
8
7
(CN7) 6
4
(CN3)
(ECU CONNECTOR)
18
17
3
15 14 13
1
20 19 18 17 16 15 14 13 12 11
(CN4)
VEHICLE CONN.
1
8
1
9
(CN5)
7
2
AMP MIC 21P
AMP 070 18P
AMP 040 20P
2
1
16 15 14 13 12 11 10
8 7
6 5
4
3
9
(CN6)
89
FG008166
ECU CON.1 (89-PIN)
Figure 61
Reference Number
Description
Reference Number
Description
1
Instrument Panel
26
Fuse
3
Engine Controller
27
Starter Switch
4
e-EPOS Controller
28
Fusible Link
17
Engine Control Dial
29
Pressure Switch (Py)
24
Battery
30
Pressure Switch (Px)
25
Battery Relay
Electrical System
SP001038 Page 69
AUTOMATIC DECELERATION CONTROL (AUTO IDLE CONTROL)
E/G
4
3
1 POWER AUTO
1
2
3
4
5
6
7
8
ESC
2
5
5 FG000798
Figure 62 Reference Number
Description
Reference Number
Description
1
Instrument Panel (Auto Idle Switch)
3
Engine Controller
4
Engine Control Dial
2
e-EPOS Controller
5
Pressure Switch
Electrical System Page 70
SP001038
If the machine is idling without the controls being operated or is waiting for a dump truck the engine speed is automatically lowered. Once the controls are operated and work is being started the machine will be restored to the previous settings. As a result, noise and fuel consumption will be reduced. This function can be selected or cancelled through the Auto Idle Selector Switch on the instrument panel. The initial setting at start-up is with this switch in the select position. Approximately 4 seconds after this function is selected, if all work levers are in the neutral position, the e-EPOS controller compares the automatic reduction signal with the signal set by engine control dial. The lower of the two signals is selected, the e-EPOS controller sends a signal to the engine controller to control the engine speed. The neutral status of the machine is detected by the two pressure switches in the control valve. When the work levers are in the neutral position, the switch is in the "OFF" position.
Electrical System
SP001038 Page 71
ENGINE OVERHEAT PROTECTION SYSTEM
6
6
E/G
4
4
5
3 31
7 (Pump control signal)
2 1 (E/G overheating signal) CHECK
02/05 [MO] 11:30
F
E
(E/G overheating signal)
C
C
H
E/G SPEED
H
1700
RPM
POWER AUTO
1
2
3
4
5
6
7
8
ESC
FG000802
Figure 63 Reference Number
Description
Reference Number
Description
1
Instrument Panel
6
Control Valve
2
e-EPOS Controller
10
3
Engine Controller
4
Main Pump
E.P.P.R. Valve (Electromagnetic Proportional Pressure Reducing Valve)
5
Aux Pump
31
Warning Buzzer
Electrical System Page 72
SP001038
When the engine coolant temperature increases to over 107°C (225°F), the engine controller detects it from the sensor mounted in the coolant line and will send a signal to the e-EPOS controller. The e-EPOS controller sends a overheat signal to the instrument panel turning "ON" the warning light and buzzer simultaneously. Also, the e-EPOS controller returns an overheat signal to the engine controller and changes power mode to standard mode. The engine speed is then set to a low speed by the engine controller. When coolant temperature falls below 95°C (203°F), normal operation will resume.
Electrical System
SP001038 Page 73
POWER BOOST MODE Operation
16 6
6 11
E/G
4
4
5
3
2
1
CHECK
02/05 [MO] 11:30
F
E
C
C
H
E/G SPEED
PO
WER
H
1700
RPM
UP
20
POWER AUTO
1
2
3
4
5
6
7
8
ESC
18 FG000800
Figure 64 Reference Number
Description
Reference Number
Description
1
Instrument Panel
11
Solenoid Valve (Boost)
2
e-EPOS Controller
16
Main Relief Valve
3
Engine Controller
4
Main Pump
18
Breaker/Boost/Shear Selector Switch
5
Aux Pump
20
6
Control Valve
Power Boost Switch (Top of Right Work Lever)
Electrical System Page 74
SP001038
The Power Boost function is used to temporarily increase the main relief pressure to enhance excavation ability. When the breaker/boost/shear selector switch is set to "BOOST" and the power boost button on the center of the right-hand work lever (joystick) is pressed during work, the e-EPOS controller will activate the power boost solenoid valve and increase the relief valve pressure from 330 - 350 kg/cm2 (4,700 - 5,000 psi). The excavation ability is increased by approximately 6%. When the power boost function is in activated, a power boost symbol appears on the information display department of instrument panel. NOTE:
Do not use this switch for more than 10 seconds.
Electrical System
SP001038 Page 75
Power Boost Control - Circuit Diagram
1 15A
CN6-1 CN6-2
26 2
CN6-9
26
26
15A
CN6-10 CN4-4
CN7-5
CN4-5
CN7-6
CN4-6
25
18
CN1-1 CN7-4
20A
CN1-2 CAN
PST SHEAR PRESS BREAKER UP
1
TML
0
2
24
9
11
10 3 (C4)
14
CN1-11
13 11 6
(POWER MAX)
CN2-2
16 15 12
CN1-8 CN1-9
6
3
(Center)
(POWER MAX / BREAKER)
20 AMP 070 16P
AMP 040 12P
7
6
5
4
16 15 14 13 12
(CN5)
3
2
11 10
1
6
5 4
8
7
6
5 4
AMP MIC 21P
AMP 070 18P
AMP 040 20P 8
8
3
2
1
10 9
12 11 10 9
8
7
20 19 18 17 16 15 14 13 12 11
3
2
7
6
5
4
2
1
10
11 10
9
21 20
3
9
8
7
6
18 17 16
15 14 13 12
9
5
19 18 17
16
(CN2) (CN4)
3
2
1
15 14 13
4
12
11
1
(CN1)
(CN3) AMP 040 28P 3
2
1
12 11 10 9
6
5 4
8
7
(CN7)
2
1
16 15 14 13 12 11 10
8
7
6
5
4
3
9
(CN6)
FG000586
Figure 65 Reference Number
Description
Reference Number
1
Instrument Panel
20
2
e-EPOS Controller
Power Boost Switch (Top of Right Work Lever)
11
Solenoid Valve (Pressure Up)
24
Battery
18
Breaker/Boost/Shear Selector Switch
25
Battery Relay
26
Fuse
Electrical System Page 76
Description
SP001038
Electrical System
SP001038 Page 77
AUTOMATIC TRAVEL SPEED CONTROL
6
6 7 13
E/G
8 15 4
4
5
3
17
2
19 FG000799
Figure 66 Reference Number
Description
Reference Number
Description
2
e-EPOS Controller
8
Pump Pressure Sensor
3
Engine Controller
13
Solenoid Valve (High speed)
4
Main Pump
15
Travel Motor
5
Aux Pump
17
Engine Control Dial
6
Control Valve
7
Pressure Switch (Py Port)
19
Selector Switch For Automatic Travel
Electrical System Page 78
SP001038
If the automatic travel speed control switch is set to the "OFF" position, the travel motor will run in the I-speed (low speed) range. If the selector switch is set to the "I" position, the travel motor will run in the II-speed (high speed) range. If the selector switch is set to the "II" position, the e-EPOS controller will monitor the main pump discharge pressure and automatically select the "ON" - "OFF" status of the II - speed travel solenoid valve based on the travel load. The travel speed is changed between the I-speed and the II-speed mode. The travel load is monitored by the two pressure sensors in the discharge lines of the front (upper) and rear (lower) pumps. When the travel load is high (pressure over 300 kg/cm2 (4,300 psi) the solenoid valve is turned "OFF" and I-speed (low) is selected. In the case when the travel load is low (pressure under 160 kg/cm2 (2,280 psi), the solenoid valve will be turned "ON" and the II-speed will be selected. But, if the engine speed control switch dial is set below approximately 1400 rpm, the travel speed will be set to I-speed mode.
Electrical System
SP001038 Page 79
Automatic Travel Speed Control - Circuit Diagram
15A
26 2
26
8
26
15A
15A
25
CN1-1 CN1-2
+ CN3-1
SIG
CN3-2
-
13 24
(C3)
+
CN1-12 CN3-3
SIG
CN3-4
-
19
9
CN2-4
3
CN2-5
6
0 I II
2
0 I II
5 8
7
17 CN1-9
AMP 070 16P
CN3-15
1
SIG
CN3-16
2
GND
CN3-17
3
+(5V)
CN1-8
AMP 040 12P
7
6
5
4
3
2
1
6
5 4
3
2
12 11 10 9 16 15 14 13 12
11 10
(CN5)
8
1 7
10 9
8
7
6
5 4
HIGH
AMP MIC 21P
AMP 070 18P
AMP 040 20P 8
8
CW LOW
3
2
7
6
5
4
2
1
10
11 10
9
21 20
3
9
8
7
6
20 19 18 17 16 15 14 13 12 11
9
18 17 16
15 14 13 12
5
19 18 17
16
(CN2) (CN4)
3
2
1
15 14 13
4
12
11
1
(CN1)
(CN3) AMP 040 28P 3
2
1
12 11 10 9
6
5 4
8
7
(CN7)
2
1
16 15 14 13 12 11 10
8
7
6
5
4
3
9
(CN6)
FG000587
Figure 67 Reference Number
Description
2
e-EPOS Controller
8
Pressure Sensor (Front Pump)
9 13 17
Electrical System Page 80
Reference Number
Description
19
Selector Switch For Automatic Travel
Pressure Sensor (Rear Pump)
24
Battery
Solenoid Valve (High speed)
25
Battery Relay
Engine Control Dial
26
Fuse
SP001038
SELF-DIAGNOSTIC FUNCTION e-EPOS Controller The system operation status and malfunction codes can be checked through the display on top of the e-EPOS controller box the rear cover behind the operator's seat.
1
2
4
3 FG000588
Figure 68
1.
Reference Number
Description
1
Upper Digit
2
Lower Digit
3
Engine Speed Monitor LED (Flash Interval Increases With Engine Speed.)
Reference Number
Description
4
Power Monitor (Stays "ON" While Power Is In Normal Range,)
Power Monitor This LED is turned "OFF" when the input voltage to the e-EPOS controller is below 18.5 ±1 V or above 32.5 ±1 V. Stays "ON" while in normal range.
2.
Engine Speed Monitor This LED light flashes according to the engine speed. The flashing interval is proportional to the engine speed.
Electrical System
SP001038 Page 81
3.
Normal Operation Display Readout Display Readout
Mode Selection
Upper Digit
Lower Digit
Operation Status
Normal Operation Power Mode
Power Mode HAOH340L
Power Mode Normal Operation Standard Mode
Standard Mode HAOH350L
Normal Operation Digging Mode
Digging HAOH370L
Work Mode Normal Operation Trenching Mode
Trenching HAOH380L
4.
Communication Monitor What are shown in the 7-SEGMENT LED are same as those in the Error Codes. Error Code
Indication Code
V201
01
Communication error in instrument panel.
V202
02
Communication error in engine controller.
Electrical System Page 82
Fault Location
SP001038
AIR CONDITIONER SYSTEM Outline
A
A
C
C B
FG000784
Figure 69 Solid-type heater and air conditioner are installed in the cover behind the operator's seat. Temperature of the operator's room is adjusted automatically to the temperature set by operator.
Electrical System
SP001038 Page 83
(Please refer to the Operation Manual for detailed full automatic control. Vent mode selects the direction of discharged air. Outlets by vent modes Modes Outlets
A
A+B
B
B+C
C
Internal and External Filters Internal and external air purification filters are installed for the operator's room. Filters should be cleaned every 500 hours. If machine operates in an excessively contaminated environment, filters should be cleaned more frequently and if necessary, replaced with new ones. How to Check Internal Air Filter 1.
Press both levers on the left and right side at the top of the filter installed at the rear of the operator's seat.
FG000422
Figure 70
How to Check External Air Filter 1.
Open the door at the left side of machine and loosen four marked bolts to remove the cover (1, Figure 71). 1 TOP Donaldson.
FG000440
Figure 71
Electrical System Page 84
SP001038
2.
Turn marked knobs (1, Figure 72) at the rear side of the cabin to open the cover.
1
FG000441
Figure 72 3.
Remove the filter attached to the cover and clean the contaminated filter using compressed air.
4.
Close the cover, replace the knobs, and secure the cover to the support with butterfly bolts.
FG000342
Figure 73
Electrical System
SP001038 Page 85
Air-Conditioning System Layout
3
10
2
11
1
6 5 7
5 4
6
8 9 FG007144
Figure 74 Reference Number
Description
Reference Number
Description
1
Air Conditioner/heater Unit
7
Liquid Hose (1)
2
Condenser
8
Liquid Hose (2)
3
Compressor
9
Ambient Temperature Sensor
4
Receiver Dryer
10
Sun Sensor
5
Discharge Hose
11
Control Panel
6
Suction Hose
Electrical System Page 86
SP001038
Air Conditioner/heater Circuit Diagram
0.5RW
FUSIBLE LINK LAMP SWITCH STARTER SWITCH
20A BATTERY RELAY AIRCON UNIT
A/C CONTROL PANEL LED 1~12
ILL
130C
CN9-6
54E
CN9-11
0.5WR
42B
CN9-5
1.25LR
0.85LR
1.25LR
CN11-2
42C
0.85LR
CN10-8
42D
CN10-18
46B
BATT. 24V
0.85BW
RECEIVER DRIER
42E
BLOWER RELAY
46A
A/C RELAY COMPRESSOR
CN8-10
0.5LG
CN10-16
168A
105B
CN9-8
0.5LB
CN10-5
105A
CN11-4
47A
106B
CN8-11
0.5LY 1.25B
CN10-6
106A
CN11-1
99
-
+
M
CN8-12
0.5LW
CN10-1
107A
108A
CN9-13
0.5GrG
CN10-2
108B
FRE (P1)
109A
CN9-12
0.5GrY
CN10-20
109B
REC (P2)
110A
CN9-15
0.5OrR
CN10-12
110B
DEF (P1)
111A
CN9-14
0.5OrW
CN10-13
111B
VENT (P2)
43A
CN9-16
0.5YB
CN10-11
43B
Vref MODE
CN10-10
44B
MODE F/BACK
WARM (P1)
0.85B
BLOWER
M
CN9-17
0.5YW
99
CN9-10
1.25B
112A
CN9-1
0.5LgW
CN10-19
112B
113A
CN9-18
0.5LgB
CN10-3
113B
COOL (P2)
114A
CN9-3
0.5YR
CN10-7
114B
Vref MIX
115A
CN9-4
0.5YW
CN10-9
115B
MIX F/BACK
167C
CN9-2
1.25BL
CN10-4
167A
GND
116A
CN8-2
0.5OrB
CN10-15
116B
45A
CN8-1
0.5LgR
CN10-14
45B
MODE ACTUATOR
M
Temp. Control ACTUATOR
DUCT SENSOR WATER SENSOR
2 CN8-5
CN10-17
0.5LY
48B
0.85B
INTAKE ACTUATOR
M
44A
47C
47B
FET
107B
48A
0.85LW
DIODE 4
A/C THERMO (LOW)
168B
1
INCAR SENSOR
SUN LOAD SENSOR 142A
CN8-3
0.5Lg
2 -
49A CN8-4
CN10
+ 1
142B
0.5YR 114C 0.85BL
167B
2
0.85YG
49B
1
0.85YG
CN11
AMP 20P
KET 4P
AMBIENT TEMP SENSOR
CN8 CN9 AMP 18P + 12P
AMP 040-III 20P KET 4P 2
1
4
3
AMP 070 12P
AMP 070 18P 9
8
7
6
5 4
3
2
1
8
7
6
5
4
3
2
1
5
4
11 10
9
12
11
3
2
1
8
7
6
20 19 18 17 16 15 14 13 12 11 10
(CN11)
18 17 16
(CN10)
15 14 13 12
(CN9)
10
9
(CN8)
FG001463
Figure 75
Electrical System
SP001038 Page 87
Air Conditioner/heater Unit Air Flow Diagram
External Air Inlet
Vent Rear Outlet
Cold Box Outlet
Internal Air Inlet
Vent Front Outlet Foot Outlet
DEF Outlet
External Air VENT
COOL
DOOR -INTAKE
DOOR -MIX
DEF
Internal Air
WARM
Heater Core FOOT
Evaporator
Fan FG001359
Figure 76
Electrical System Page 88
SP001038
Door Open by Vent Modes Door
Mode Vent
Bi-level
Foot
Def/foot
Def
Vent
100
60
0
0
0
Foot
0
40
100
80
60
Def
0
0
0
20
40
Main Components
Actuator A/C - Temp Control Relay Blower Relay
Duct Sensor Air Flow Control Module
Actuator -Wind Direction Control
Blower Motor
Water Temp Sensor
Actuator - Internal/external Air Exchanger
Evaporator
Internal Air Filter
Internal Air Sensor FG007754
Figure 77
Electrical System
SP001038 Page 89
Actuator - Wind Direction Control Change of discharged air flow according to selected wind direction mode Change of wind direction: Direction changes in the order of VENTo BI-LEVEL o FOOT o FOOT/DEF o VENT. Actuator - Temperature Control Change of discharged air temperature by controlling the position of temperature control door.
FG001361
Figure 78 Actuator - Wind Direction Control Wind Direction Mode
Output Terminal
Voltage
Vent
0.5 ± 0.2V
Bi-level
1.3 ± 0.2V
Foot Foot/def
c(+): CN10-10 b(-): CN10-4
Def
2.45 ± 0.2V 3.5 ± 0.2V 4.5 ± 0.2V
Actuator - Temperature Control Set Temperature Max cooling Max heating
Electrical System Page 90
Output Terminal
Voltage
c(+): CN10-9
Below 0.4V
b(-): CN10-4
Above 4.5V
SP001038
Actuator - Internal/external Air Exchange
CN10-20
CN10-2
FG001055
Figure 79 Mode
Output Terminal
Output
Intake
P1(+), P2(-)
Moving of exchange door by selecting intake.
Recirculate
P1(-), P2(+)
Moving of exchange door by selecting recirculate.
Air Flow Control Module Air flow is controlled through the control of voltage between GATE and SOURCE.
DRAIN (CN10-1)
SOURCE (CN11-1)
GATE (CN10-6) FG001056
Figure 80 Air flow
Output Terminal
Output
1st
10 ± 0.5V
2nd
12.5 ± 0.5V
3rd 4th
15 ± 0.5V CN11-2
CN10-1
17.5 ± 0.5V
5th
20.0 ± 0.5V
6th
22.0 ± 0.5V
7th
More than 25V
Input voltage is 27.5V. The air flow is based on manual set.
Electrical System
SP001038 Page 91
Relay - Blower: Power is supplied to the blower motor when the system is turned "ON." Specifications Rated voltage
24V
Rated current
20A
Figure 81 Relay - A/C: Power is supplied to the magnetic clutch of the compressor. Specifications Rated voltage
24V
Rated current
10A
L
S1
B
S2
(+)
(-) FG001058
Figure 82 Duct Sensor: It is inserted in the core of the evaporator to prevent freezing of the evaporator. The sensor consist of negative characteristic thermistor that resistant value increases and decreases when the temperature rises and falls, respectively. Temperature (°C)
Resistance (K:)
0
11.36 ± 0.1
2
10.39 ± 0.2
2.5
10.17 ± 0.2
3
9.95 ± 0.2
3.5
9.73 ± 0.2
4
9.52 ± 0.2
5
9.12 ± 0.2
10
7.36 ± 0.15
25
4.02 ± 0.08
30
3.33 ± 0.07
Electrical System Page 92
Figure 83
SP001038
Water Temperature Sensor: It senses the temperature of coolant water in the heater core. Temperature (°C)
Resistance (K:)
-10
55.8 ± 1.7
0
32.9 ± 0.9
15
15.76 ± 0.5
25
10.0 ± 0.3
35
6.5 ± 0.2 Figure 84
Internal Air Temperature Sensor: Built in the internal air filter, it senses the internal temperature. Temperature (°C)
Resistance (K:)
-15
218.2 ± 7.5
0
97.83 ± 0.9
15
47.12 ± 0.7
25
30.0 ± 0.36
35
19.60 ± 0.3 Figure 85
Ambient Air Temperature Sensor Built at the bottom of the cockpit, it senses the temperature of external air. Temperature (°C)
Resistance (K:)
-10
163 ± 4.9
0
96.9 ± 2.9
10
59.4 ± 1.8
20
37.4 ± 1.1
25
30 ± 0.9
30
24.2 ± 0.7
Electrical System
FG001064
Figure 86
SP001038 Page 93
Sun Sensor Built beside the socket of spare power, it senses the quantity of the sun radiation to optimize discharge temperature and air flow as set by operator.
OUTPUT VOLTAGE(mV)
83.7 76.2 67.7 58.8 46.6 36.0 21.4
1.0 2.0 3.0 4.0 5.0 6.0 7.0 LUX(x10,000)
FG001062
Figure 87
Control Panel Appearance and Terminal Arrangement
OUTSIDE
A/C AUTO
AUTO
A/C
MAX
TEMP
OFF SEL
MODE
AMP 070 18P 8
7
6
18 17 16
5
4
15 14 13 12
AMP 070 12P 3
2
1
11 10 9
(CN9)
5
4
12 11
10
9
(CN8)
3
2
1
8
7
6
FG001063
Figure 88 Refer to "Air Conditioner and Heater" of operation manual.
Electrical System Page 94
SP001038
Terminal Terms CN
Term No.
Terms
1
CN
Term No.
Terms
Temperature control (warm)
1
Water temperature sensor
2
Sensor ground
2
Duct sensor
3
Temperature control Power (5V)
3
Sun sensor
4
Mix feedback
4
Ambient air temperature sensor
5
Power (KEY "ON")
5
Internal air temperature sensor
6
Back-up
6
-
7
-
7
-
8
A/C output (LOW)
8
-
9
-
9
-
CN8
CN9
10
Ground
10
D.P.S CHECK
11
Illumination
11
Air flow module (gate)
12
Intake/Recirculate (Recirculate)
12
Blower motor (feedback)
13
Intake/Recirculate (Intake)
14
Wind direction control (VENT)
15
Wind direction control (DEF.)
16
Wind direction control Power (5V)
17
Wind direction control (feedback)
18
Temperature control (cool)
Control Logic Categories AUTO
Inputs Set temperature
System Operation 1.
Internal air temperature sensor Ambient air temperature sensor
Temperature, Wind direction, Recirculate/Intake, Air flow, Compressor 2.
Auto mode is released when manually setting any switch except, Temperature Control switch in Auto mode.
3.
Upon the releasing of Auto mode, all of functions except selected switch are controlled automatically.
Water temperature sensor Sun sensor
Electrical System
Automatically adjust room temperature as set and then next items.
SP001038 Page 95
Categories Sensor compensation
Inputs Set temperature
System Operation 1.
In case of sensor failure, following defaults are applied:
Internal air temperature sensor
Internal air temperature sensor: 25°C, Ambient air temperature sensor: 25°C, Duct sensor: -2°C
Ambient air temperature sensor
Temperature control actuator: - Set Temperature 17 - 24.5°C: Max cooling, Set Temperature 25 - 32°C: Max heating
Water temperature sensor
Wind direction mode actuator - VENT: VENT fix, modes other than VENT: Fixed to DEF * Sun sensor is not compensated. Max cooling/ heating control
Auto Setting
1.
Set Temperature 32°C: Max heating
2.
Set Temperature 17°C: Max cooling Max Cooling (17 C)
Max Heating (32 C)
Temp Control Actuator
FULL COOL
FULL HOT
Air Flow
MAX HI
AUTO HI
Compressor
Forced ON
OFF
Intake/Recircle
Recircle
Intake
Wind Direction Mode
VENT
FOOT
* Max cooling/heating control is possible only in Auto mode. Starting Control of Cooling
Auto mode
1.
Prevention of discharge of hot air before discharge temperature drops enough in hot summer weather
2.
Start conditions (AND condition)
Duct sensor
(1) A/C on (AUTO or manual) (2) Temperature sensed by the duct sensor is above 30°C (3) Air flow: Auto mode 3.
One time control in the cycle of engine OFF o engine run
4.
Initial cooling control is executed when the Auto switch is "ON" in the manual status (A/C "OFF" and manual control of air flow) in 5 seconds after engine run.
5.
Initial cooling control should be before max cooling.
6.
Release condition (OR condition) (1) A/C "OFF" (2) Air flow: Manual control (3) Release is possible with the "OFF" switch but not allowed within 12 seconds (after Start "ON") while the system is off using the "OFF" switch and during the time of initial cooling control.
Electrical System Page 96
SP001038
Categories
Inputs
System Operation 1.
Start condition (AND condition) (1) When wind direction mode is one of the following modes in the Auto or manual control mode - BI-LEVEL, FOOT or FOOT/DEF (2) The Water temperature sensor is stable and the water temperature < 73°C (3) Air flow: Auto mode (4) Set temperature > Internal air temperature + 3°C * Air flow falls gradually up to 12 seconds when operation released.
Starting control of heating (1)
Water temperature sensor
2.
One time control in the cycle of engine OFF o engine run
Internal air temperature sensor
3.
Initial heating control should be before max heating.
4.
Air flow is controlled only when the wind direction is in the manual mode and BI-LEVEL, FOOT, or FOOT/DEF is set.
5.
Control through the water temperature sensor for start.
6.
Starting control of heating (2) starts in case of fault of the water temperature sensor during controlling.
7.
Operation release (OR condition)
Auto mode Set Temperature
(1) Only air flow is released if it is selected manually. (2) When handling the wind direction mode switch, only wind direction is released but the air flow control is performed only for the remaining period of the starting control of heater. (3) When Max Cooling (17°C) is selected. (4) Water temperature sensor > 73°C.
Electrical System
SP001038 Page 97
Categories Starting control of heating (2)
Inputs Water temperature sensor
System Operation 1.
Ambient air temperature sensor
(1) Auto Mode (2) Ambient air temperature < 5°C and difference between ambient and internal air temperature d 5°C
Internal air temperature sensor Auto mode
Entry condition (AND condition)
(3) Failure of water temperature sensor
2.
Only one time of engine OFF o engine run
3.
Starting control of heating is before max heating.
4.
Operation release (OR condition) (1) Air flow: Manual selection (2) When handling the wind direction mode switch, only wind direction is released but the air flow control is performed only for the remaining period of the starting control of heater. (3) Difference between temperature>15°C
internal
and
ambient
air
(4) When Max Cooling (17°C) is selected. 5.
Exceptional case Starting control of heating is performed only once during the remaining period if the entry condition is satisfied within the starting control period that is the accumulation of initial start times. (Inclusive of Auto mode "ON" case within the period of starting control of heater.) * Air flow should be reduced slowly for up to 12 seconds in case of exceptional entry case.
Electrical System Page 98
SP001038
Categories
Inputs Duct sensor
System Operation 1.
Function: Magnetic clutch of compressor is turned "ON/ OFF" depending on temperature of the duct sensor to prevent the freezing of the evaporator with A/C being "ON."
2.
Control pattern.
2.0
Compressor control External temperature sensor
0.5 C
3.5
0.5 C
1.
Function: Prevention of compressor in winter.
2.
Control pattern.
*Only for Auto mode.
Electrical System
SP001038 Page 99
Self Diagnosis How to start self diagnosis
Starter Switch ON
Set temp to 25 C
Set temp to 77 F
Press the SEL switch more than 3 times in 5 secs while pressing the A/C switch
Auto diagnosis starts after every graphic in LCD displays twice every 0.5 sec.
A code concerned blinks in the cycle of 0.5-sec ON and 0.5-sec OFF. In case of two or more errors, codes concerned blink twice at a time.
For normal, E0 lights; for error, the first error code is indicated.
For 2 or more error, error codes are indicated upstreams/downstreams if the temp control switch is set to up/down. (For normal condition, only EO lights.)
Press the SEL switch more than 3 times in 5 secs while pressing the A/C switch.
Return to default status if no switch operated for 30 secs in diagnosis mode.
Return to position before auto diagnosis starts. FG001367
Figure 89
Electrical System Page 100
SP001038
Error codes Code
Description
E0
Normal
E1
Internal air temperature sensor short
E2
Internal air temperature sensor open
E3
Ambient air temperature sensor short
E4
Ambient air temperature sensor open
E5
Duct sensor short
E6
Duct sensor open
E7
Sun sensor short
E8
Sun sensor open
E9
Water temperature sensor short
E10
Water temperature sensor open
E11
D.P.S open
E12
Position error of wind direction actuator
E13
Position error of temperature control actuator
NOTE:
The position error means that it fails to move to designated place in 40 seconds. Sun sensor displays E8 in case of no sunlight.
E1
E1
E2
E2
E3
2 and more fails: Codes concerned blinks twice at a time. 0.5 0.5
FG001067
Figure 90 Ambient Temperature Display Selection of both the SEL and MODE switch for more than 3 seconds indicates the ambient temperature in the set temperature display department. - Range of temperature display: -40 - +60°C NOTE:
Display of ambient temperature may be released in the same way for its entry way. It returns automatically to default mode 5 seconds after entering the ambient air temperature display mode.
Electrical System
SP001038 Page 101
Compressor Categories
Specifications
Output
155.3 cc/rev
Oil Level
120 cc (ND-OIL8)
Refrigerant
R134a
Rated Voltage
24V
Relief Valve
Open: 35 - 42.2 kg/cm2G Close: 28.1 kg/cm2G
Compressor sucks in refrigerant which evaporates completely in the evaporator and discharges it to the condenser.
Relief Valve
FG001365
Figure 91
Refrigerant undergoes repeated status change in the order of liquid, gas, and liquid in the freezing cycle, and the compressor makes evaporated refrigerant a high temperature and high-pressured gas to freeze it in the condenser.
Receiver Dryer The receiver dryer reserves refrigerant enough to ensure smooth freezing cycle responding immediately to the change of level in the freezing cycle.
High/Low Pressure Switch
As liquid refrigerant from the condenser may contain refrigerant gas with bubbles whose presence in the expansion valve decreases the freezing power excessively, it separates liquid and gas and sends liquid only to the expansion valve. Water in refrigerant shall be eliminated with dryer and through filter. FG001366
Figure 92
MAX. 0.25 kg/cm2
Volume of refrigerant by model Model
Volume of Refrigerant
DX140LC
800 ± 20 grams
DX180LC
800 ± 20 grams
DX225LC
800 ± 20 grams
DX225NLC
800 ± 20 grams
DX255LC
800 ± 20 grams
DX300LC
800 ± 20 grams
DX340LC
800 ± 20 grams
DX420LC
800 ± 20 grams
DX480LC
800 ± 20 grams
DX520LC
800 ± 20 grams
Electrical System Page 102
2.0 0.2 kg/cm2
32 2 kg/cm2
6 2 kg/cm2
FG001462
Figure 93
SP001038
TROUBLESHOOTING Refrigerant Pressure Check 1.
Open all doors and windows.
2.
Install manifold gauge set.
3.
Start engine and maintain engine speed at 1,800 - 2,000 rpm. LO
HI
HDA6074L
Figure 94
4.
Check high / low-pressure of refrigerant. High-pressure: 8.0 - 10.0 kg/cm2 (114 - 142 psi)
1
Low-pressure: Approximately 1.0 kg/cm2 (14 psi)
Possible Cause: Low Refrigerant Level Step 1
Inspection Item
Remedy
Check for traces of refrigerant oil. Using a leak detection device or soapy water check for refrigerant leakage at all major components and joints.
2
Yes
Reassemble using correct tightening torque.
No
Go to next step.
Yes
Repair leaking component.
No
Recharge system to correct pressure.
High-pressure: Over 23 kg/cm2 (327 psi)
2
Low-pressure: Approximately 2.5 - 3.0 kg/cm2 (36 - 43 psi)
Possible Cause: Overcharge, Frost on condenser Step 1
Inspection Item
Remedy
Check for condenser pin damage or contamination.
Yes
Clean, repair or replace condenser.
No
Refrigerant overcharge.
High-pressure: Approximately 20 - 25 kg/cm2 (285 - 356 psi)
3
Low-pressure: Approximately 2.5 - 3.5 kg/cm2 (36 - 50 psi)
Possible Cause: Air in system. 1.
Recover any remaining refrigerant.
2.
Vacuum out system.
3.
Recharge system. NOTE:
If the system has been exposed to the air for a long period of time, replace the receiver dryer.
Electrical System
SP001038 Page 103
High-pressure: Over 6 kg/cm2 (85 psi)
4
Low-pressure: Approximately 760 mmHg (Negative Pressure) Possible Cause: Refrigerant does not circulate Step
1
Inspection Item
Remedy
1.
Connect manifold gauge and start engine.
2.
Turn on air conditioner.
3.
Set blower switch to HIGH position.
4.
Turn air conditioner OFF and wait 10 minutes.
5.
Recheck high / low-pressure readings.
Yes
High-pressure: 13.0 - 19.0 kg/cm2 (185 - 270 psi)
No
Moisture in system, replace receiver dryer.
Contaminated system, replace expansion valve. (Replace evaporator core assembly.)
2
Low-pressure: 1.5 - 3.3 kg/cm (21.3 - 46.9 psi) High-pressure: Over 6 - 18 kg/cm 2 (85 - 256 psi)
5
Low-pressure: 500 mmHg (Negative Pressure) - Dial indicator needle unstable. Possible Cause: Moisture in system has iced up the expansion valve. NOTE:
When the absorbed moisture freezes the pressure readings may look normal. Careful readings should be made to determine whether pressure is in normal range.
1.
Recover any remaining refrigerant.
2.
Vacuum out system.
3.
Recharge system. NOTE:
If the system has been exposed to the air for a long period of time, replace the receiver dryer. High-pressure: Over 22.0 - 23 kg/cm2 (313 - 327 psi)
6
Low-pressure: 2.5 kg/cm 2 (36 psi)
Possible Cause: Refrigerant pressure problem due to defective expansion valve or temperature sensor. Step 1
Inspection Item
Remedy
Inspect whether the temperature sensor is installed properly.
7
Yes
Replace expansion valve.
No
Exchange duct sensor.
High-pressure: Over 7.0 - 11.0 kg/cm2 (100 - 156 psi) Low-pressure: 4.0 - 6.0 kg/cm2 (57 - 85 psi)
Possible Cause: Low refrigerant pressure due to poor compressor compression. Inspect and replace compressor if necessary.
Electrical System Page 104
SP001038
WEIGHT OF R134a GAS USED IN MACHINES Model
Weight of Gas
DX140LC
800 ±20 grams (28 ±0.7 oz)
DX180LC
800 ±20 grams (28 ±0.7 oz)
DX225LC
800 ±20 grams (28 ±0.7 oz)
DX225NLC
800 ±20 grams (28 ±0.7 oz)
DX255LC
800 ±20 grams (28 ±0.7 oz)
DX300LC
800 ±20 grams (28 ±0.7 oz)
DX340LC
800 ±20 grams (28 ±0.7 oz)
DX420LC
800 ±20 grams (28 ±0.7 oz)
DX480LC
800 ±20 grams (28 ±0.7 oz)
DX520LC
800 ±20 grams (28 ±0.7 oz)
Electrical System
SP001038 Page 105
REFRIGERANT SYSTEM REPAIRS WARNING! Always wear protective glasses and gloves when handling refrigerant. If refrigerant comes in contact with the skin or eyes, immediately flush with clean, running water and consult a physician. Select a clean and well ventilated area to work. The refrigerant container is under high-pressure and should be stored below 40°C (104°F). Be careful not to drop the container from a high location. The contents are under high-pressure and should not be used with compressed air or near an open flame.
Refrigerant Safe Handling Procedures UNION
NUT
TORQUE WRENCH
CORRECT
WRONG
WRONG WRONG CORRECT
O - RING POSITION
CAP & PLUG
CORRECT
WRONG
WRONG HDA6066L
Figure 95 The following procedures should be observed for safe handling of refrigerant during vacuum and charging process. 1.
Use an approved recovery / charging device which can safely perform vacuum and charge work simultaneously.
2.
The new refrigerant has improved cooling characteristics than the old type and care should be used not to overcharge the system.
Electrical System Page 106
SP001038
3.
Do not over tighten connections when working on refrigerant system.
4.
The new refrigerant system standards require new tools, equipment and parts. DO NOT attempt to use equipment use in servicing the old refrigerant system.
5.
The new refrigerant oil (PAG type) has a high moisture absorption characteristic. When the refrigerant system vacuum seal has been broken, immediately plug up all openings to prevent moisture from entering into the system.
6.
When joining unions which use O-ring seals, lightly coat Orings with refrigerant oil. Be careful not to drip oil on the threads of the nut.
7.
Be certain the O-rings are seated properly on the refrigerant line lip. Always use new O-rings when reassembling parts. Do not reuse old O-rings.
8.
Use a vacuum pump to evacuate refrigerant system of air.
9.
When charging the refrigerant system with the engine running, do not open the high-pressure valve on the manifold gauge as the reverse flow of high-pressure refrigerant will rupture the hose.
10.
When releasing the high-pressure hose after completing the charging process, quickly disconnect the hose to minimize refrigerant released to the air.
Repair and Replacement Procedure 1.
Work Procedure A.
2.
Before repairing or replacing any refrigerant components first, return all refrigerant oil to the compressor and perform recovery procedures.
Operating Condition A.
Run engine at maximum engine speed.
B.
Select 'HI' blower fan speed and select A/C switch to 'ON'.
C.
Set the temperature control switch for maximum cooling and leave running for approximately 20 minutes. NOTE:
Electrical System
The manifold gauge dial pointer can vary depending on the outdoor temperatures.
SP001038 Page 107
INSTALL REPAIR TOOL
RECOVER REFRIGERANT
REPAIR / REPLACE DEFECTIVE PARTS
VACUUM SYSTEM (OVER 5 MINUTES)
CHECK SYSTEM FOR AIR LEAKAGE
REPAIR
VACUUM SYSTEM (OVER 20 MINUTES)
CHARGE SYSTEM (APPROXIMATELY 100 g)
CHECK SYSTEM FOR REFRIGERANT LEAKAGE
CHARGE SYSTEM TO PROPER LEVEL¯ (Standard Capacity less Initial Charge)
CHECK SYSTEM FOR REFRIGERANT LEAKAGE
CHECK FOR PROPER REFRIGERANT LEVEL
RUN SYSTEM
RECOVER REFRIGERANT IN CHARGING HOSE
REMOVE REPAIR TOOLS
HDA6067L Figure 96
Electrical System Page 108
SP001038
Refrigerant Recovery
1.
Reference Number
Description
1
To Compressor
2
Low-pressure Side
3
High-pressure Side
4
From Receiver
5
Refrigerant Recovery Tank
Be careful not to switch the connections for the low and high-pressure valves.
3 4
1
Attach the manifold gauges and the refrigerant recovery unit to the refrigerant lines as shown. NOTE:
2.
2
5 HDA6067L
Figure 97
Open the high-pressure valve slowly to release the refrigerant to the recovery unit. NOTE:
Open the valve slowly, while checking to see that refrigerant is not leaking out.
3.
When the manifold gauge dial falls below 3.5 kg/cm2 (50 psi), slowly open the low-pressure valve.
4.
Open both the high and low-pressure valves slowly until the manifold gauge dials indicates 0 kg/cm2 (0 psi).
Vacuuming Refrigerant System 2
Reference Number
Description
1
To Compressor
2
Low-pressure Side
3
High-pressure Side
4
From Receiver
5
Vacuum Pump
3 4
1
5 HDA6068L
1.
Vacuuming Procedure NOTE:
Figure 98
When the A/C system has been exposed to the air, it must be vacuumed out. Perform vacuum process for 30 minutes for complete moisture and air evacuation.
A.
Attach the manifold gauges and vacuum pump to the refrigerant system as shown.
B.
Turn on the vacuum pump and open both valves.
C.
When the low-pressure gauge shows approximately 710 mmHg, close both valves and turn off vacuum pump.
Electrical System
SP001038 Page 109
2.
Check system for vacuum leak. Allow system to sit for 10 minutes and check whether the system is holding the pressure. If the pressure has dropped, it must be repaired before proceeding to the next step.
3.
Vacuuming Procedure If the system is holding the pressure and it has not changed for 10 minutes, vacuum out the system for an additional 20 minutes.
4.
A.
Turn on the vacuum pump and slowly open both valves.
B.
Allow vacuum pump to run for additional 20 minutes until the low-pressure gauge dial reads approximately 750 mmHg.
C.
Close both valves and stop the vacuum pump.
HDA6069L
Figure 99
Installation of Refrigerant Container Reference Number
Description
1
Handle
2
Hose Connection
3
Mounting Disk
1
2 3
A.
Before mounting valve on the container, make sure the handle is in the counterclockwise most position, with the puncture pin retracted and the mounting disk is in the raised position.
B.
Attach the manifold gauge center hose to the valve assembly.
C.
Turn the disk in the clockwise direction and securely mount valve onto refrigerant container.
D.
Turn the valve handle in the clockwise direction and puncture the container seal with the pin.
E.
Once the can has been punctured, turn the handle in the counterclockwise direction so the refrigerant can flow into the manifold gauge center hose. At this time, do not open the low and high-pressure valves of the manifold gauge.
F.
Press the manifold gauge low side valve to eliminate the trapped air in the hose.
Electrical System Page 110
HDA6070L
Figure 100
SP001038
Leakage Check NOTE:
Perform the leakage vacuuming process.
check
after
completing
1.
After attaching the manifold gauge, open the high side valve.
2.
Charge system until the low side gauge dial indicates a pressure of 1 kg/cm2 (14 psi) and close the high side valve.
3.
Using a refrigerant leak detector or soapy water check each joint for leakage. Reference Number
Description
1
Refrigerant Leak Detection Device
4.
If a leak is detected, check for O-ring damage or correct tightening torque and replace or repair as necessary.
5.
If no leaks are detected, proceed with the charging process.
1
HDA6071L
Figure 101
WARNING! For accurate refrigerant leak detection, perform leak detection procedure in a well ventilated area.
Refrigerant Charging 1.
Perform the vacuuming procedure, vacuum holding and leaking tests as described in the proceeding headings. First charge the refrigerant system with 100g (3.5 ounces) of refrigerant with the engine off. Then using the manifold gauges as a guide fully charge the system with the engine running.
NOTE:
When exchanging refrigerant containers, press the manifold gauge low side valve to eliminate air from the charging hose.
2.
Reference Number
Description
1
To Compressor
2
Low-pressure Side
3
High-pressure Side
4
From Receiver
5
Refrigerant Supply Container
1
Charge the system by opening the manifold gauge low side valve. Initial charge amount: 100 g (3.5 ounces).
Electrical System
3
2
4
5 HDA6072L
Figure 102
SP001038 Page 111
3.
If refrigerant does not flow freely into system, try starting engine first before operating air conditioner. !
Temperature Cooling
control
switch
setting:
Maximum
Blower Speed Setting: Hi (3 step) Engine Speed: 1,300 - 1,500 rpm
WARNING! When charging refrigerant system with the engine running:
4.
•
Always keep refrigerant supply container in the upright position.
•
Never open the high side pressure valve.
Open the manifold gauge low side valve and charge system to standard capacity. Gauge Dial
Standard Reading
High Side Gauge
13 - 20 kg/cm2 (185 - 285 psi)
Low Side Gauge
1.5 - 3.5 kg/cm2 (22 - 50 psi)
NOTE:
These standards are for outside temperatures between 30° - 35°C (86° - 95°F). The gauge readings may vary for extreme temperature conditions.
WARNING! •
When outside temperature is low, warm the refrigerant supply container with warm water not exceeding 40°C (104°F). Do not allow water to come in contact with the charging adapter valve handle.
•
When outside temperature is high, cool off refrigerant supply container and condenser to aid the refrigerant charging process.
5.
Close low-pressure side valve.
6.
Shut off engine and close refrigerant supply container adapter valve. Disconnect manifold gauge hoses from vehicle.
Electrical System Page 112
SP001038
Inspecting System For Leakage After completing charging procedures, clean all joints and connections with a clean dry cloth. Using a refrigerant leak detecting device or soapy water, inspect system for leaks starting from the high-pressure side. When the refrigerant circulation has been stopped the high-pressure will start to decrease and the lowpressure will start to increase until they are equalized. Starting the inspection from the high side will result in a accurate test.
NOTE:
2 1
3 4
Reference Number
Description
1
Pressure
2
High-pressure
3
Low-pressure
4
Compressor Stop
HDA6073L
Figure 103
Inspection Procedure 1.
High-pressure Side
2.
Low-pressure side
3.
Compressor
Compressor outlet o condenser inlet o receiver dryer inlet o air conditioner unit inlet.
Compressor inlet o air conditioner unit outlet.
Compressor shaft area, bolt hole area and magnetic clutch area. 4.
Receiver dryer Pressure switch and plug area.
5.
Connection valve area Inspect all valve areas. Verify all valves are capped to prevent leaking. Check for foreign material inside of valve cap.
6.
Interior of air-conditioning unit. After stopping engine, insert detector probe into drain hose. (Leave inserted for 10 seconds minimum.) NOTE:
When inspecting leakage from the airconditioning unit, perform the inspection in a well ventilated area.
Electrical System
SP001038 Page 113
WIPER SYSTEM Wiper Circuit
5 2
+
-
6
M
7
3
4
4
5
6
1
7
5
(Continuous mode)
3
8
(Intermittent 1 mode)
4
10
(Intermittent 2 mode)
5
11
(Washer mode)
6
12
-
8 +
1
P
1
9
6
13 9
2
2
8
AMP MIC 13P CN12
CN13
15A
4
10A
10A
KET 8P
15A
10 2
3 AMP MIC 13P 1
7
2
8
3
9
4
10
1 5
6
11 12 13
4
9
3
2
8
(CN12)
7
(CN13)
6
1
4
5
1
2
6
5
(Wiper Motor)
FG000589
Figure 104 Reference Number
Description
Reference Number
Description
1
Battery
6
Wiper Controller
2
Battery Relay
7
Wiper Switch Panel
3
Fusible Link
8
Window Washer
4
Fuse Box
9
Wiper Cutoff Switch
5
Wiper Motor
10
Light Switch
Electrical System Page 114
SP001038
Wiper operation Continuous operation - Operation of wiper motor Pressing the successive operation switch on the wiper switch panel (7) changes the voltage of the "5" terminal of the wiper controller (6) from HIGH (about 5.5 ±0.5V) to LOW (0+0.5V) and also current flows via the "3" terminal of the wiper controller (6) o the "2" and "4" terminals of the wiper motor (5) o the "4" terminal of the wiper controller (6) to run the wiper motor (5) continuously. - Stop of wiper motor Pressing again the successive operation switch on the wiper switch panel (7) changes the voltage of the "5" terminal of the wiper controller (6) from LOW (0+0.5V) to HIGH (about 5.5 ±0.5V). As the "5" and "6" terminals of the wiper motor are connected still that power is supplied to the "6" terminal of the wiper controller (6), However, the controller (6) runs the wiper motor continuously and then rotates the motor reversely by " letting current flow via the "4" terminal of the wiper controller (6) o the "2" and "4" terminals of the wiper motor (5) o the "3" terminal of he wiper controller (6) when the "1" and "6" terminals of he wiper motor (5) are connected and thus power voltage is supplied to the "7" terminal of the wiper controller (6). The Wiper motor (5) stops reverse revolution when the contact of a cam switch connected to the "6" terminal of the wiper motor (5) moves to an insulation area of the cam plate to disconnect the "5" and "6" terminals of the wiper motor (5). When the wiper motor (5) stops, arm and blade connected to it move to the stop positions of the right pole in the cabin. Intermittent operation - Intermittent 1st (3-second) Pressing once the Intermittent switch in the switch panel (7) changes voltage of the "8" terminal in the wiper controller (6) from HIGH (about 5.5 ±0.5V) to LOW (0+0.5V) and current flows through the "3" terminal in the wiper controller (6) o the "2" and "4" terminals in the wiper motor (5) o the "4" terminal in the wiper controller (6) to start the cycle that wiper stops 3 seconds after every operation.
Electrical System
SP001038 Page 115
- Intermittent 2nd (6-second) Pressing twice the Intermittent switch in the switch panel (7) changes voltage of the "10" terminalG in the wiper controller (6) from HIGH (about 5.5 ±0.5V) to LOW (0+0.5V) and current flows through the "3" terminal in the wiper controller (6) o the "2" and "4" terminals in the wiper motor (5) oG the "4" terminal in the wiper controller (6) to start the cycle that wiper stops 6 seconds after every operation. - Stopping the intermittent action Pressing three times the Intermittent switch in the switch panel (7) while the wiper is operating stops the action of the wiper motor. NOTE:
The wiper system does not work when the wiper cutoff switch (9) is "ON."
Electrical System Page 116
SP001038
Electrical System
SP001038 Page 117
LIGHTING SYSTEM Lighting System Circuit Diagram
7
13
87a 30 87
*15
*16
85
86
*9
6
87a
87a
30
*14
30
87
87 86
85
85
86
12 *8 87a
*5
30 87 85
86
3
6
0 I II 0 I II
2
5 8
7
2
0 I II
5
0 I II
8
3
4 6 7
20A 15A
10
30A 15A
CN6-1
15A
CN6-2
11
CN6-9 L6
3
CN6-10 CN2-6 CN7-4
CN4-4
CN7-5
CN4-5
CN7-6
CN4-6
2
CAN CN1-1 CN1-2
CN1-8
1
CN1-9
FG000590
Figure 105
Electrical System Page 118
SP001038
Reference Number
Description
Reference Number
1
Battery
9
2
Battery Relay
3
Fuse Box
10
Instrument Panel
4
Light Switch
11
e-EPOS Controller
5
Cabin Light Switch
12
Headlight (2 ea.)
6
Headlight Relay (Work Light Indicate Light)
13
Work Light (2 ea.)
14
Front Cabin Light (4 ea.)
7
Work Light Relay
15
Rear Cabin Light (2 ea.)
8
Front Cabin Light Relay
16
Rear Work Light (1 ea.)
NOTE:
Description Front Cabin Light / Rear Work Light Relay
The "*" mark are optional parts.
Kind of Light The lighting system is consists of headlights, work lights, cabin lights (optional), relays and switches.
Operation
Switch
Position
Connected Terminal of switch
Activated Relay
Lit Light
1
"2-3" Terminal
-
Illumination Light of Switch
"2-3" Terminal
-
Illumination Light of Switch
Headlight Relay
Headlight (2 Ea.)
Light Switch
2
1 Cabin Light Switch
Electrical System
"5-6" Terminal
Work Light (2 Ea.) Work Relay
Indicator Light of Work Light (L6)
"2-3" Terminal
Front Cabin Light Relay
Front Cabin Light (2 Ea.) or Front Cabin Light (4 Ea.)
"2-3" Terminal
Front Cabin Light Relay
Front Cabin Light (2 Ea.) or Front Cabin Light (4 Ea.)
"5-6" Terminal
Rear Cabin Light Relay / Rear Work Light Relay
Rear Cabin Light (2 Ea.) and Rear Work Light (1 Ea.)
2
SP001038 Page 119
AUDIO CONTROLLER Audio Controller Circuit Diagram
7
ANTENNA
8
10 MODULE
3
11
15A
2
15
3
16
4
13
(LH)
MICOM
1
+
5 10A
1
9
Vcc(+5V)
-
(RH)
+
-
Vcc(+5V)
DC/DC CONVERTER 1
3
14
2
5
7 17 2
6
10A
10 87a
3
87
4
11
30 86
4
85
2
9 10 11 1 2 3
1
12 13 14 15
16 17 18
4
1 2
3
4
(Audio Control Panel)
5
6
7
8
(STEREO)
FG000591
Figure 106 Reference Number
Description
Reference Number
Description
1
Battery
7
Audio Control Panel
2
Battery Relay
8
Stereo
3
Fuse Box
9
Speaker
4
Fusible Link
10
Antenna Module
5
Converter
11
Light Switch
6
Stereo Relay
Operations Via Audio Control Panel Switch
Connected Terminal of switch
PWR "3-4" SCAN
Electrical System Page 120
Measured values
Operations
4.36 ±0.2V
Stereo ON, OFF
1.24 ±0.2V
Volume up
0+0.2V 2.49 ±0.2V
Volume down Frequency selection
SP001038
SP001357 ELECTRICAL SCHEMATIC (DX140LC)SP001357
1Electrical
Schematic (DX140LC) Edition 1
Electrical Schematic (DX140LC)
SP001357 Page 1
MEMO
Electrical Schematic (DX140LC) Page 2
SP001357
Table of Contents Electrical Schematic (DX140LC) Safety Precautions ............................................... 5 Applicable Models ................................................ 5 DX140LC .............................................................. 7
Electrical Schematic (DX140LC)
SP001357 Page 3
MEMO
Electrical Schematic (DX140LC) Page 4
SP001357
SAFETY PRECAUTIONS CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that are in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL DX140LC
SERIAL NUMBER RANGE 5001 and Up
Electrical Schematic (DX140LC)
SP001357 Page 5
Electrical Schematic (DX140LC) Page 6
SP001357
0.85B
33B 0.85Or
0.85B
(RH) 87a
128A
127E 0.85RG (FL)
0.85B
(LH)
0.5RL
0.85RW
8
0.85WR 54A
0.5WR
SEAT HEATER (OPT) 0
3
144A
1.25R
55A
8 54Q
158B
5
0.85WB 6
158A
63C
6
5 52C
(INT-2)
0.5LG
5
161B
11
(WASHER )
0.5L
6
162B
1
34E
1
0.85Lg 9
0.85B
LOWER WIPER CUT SW
138B
0.5RW
13
130B 138A 99 AMP MIC 13P CN12
2
CIGAR LIGHTER
64B 1.25WL 64A 3
P
1.25RB
N DC/DC CONVERTER 2
0.5WR
0.5RG
0.5P
0.5RW
0.5RW
0.5WR
0.5WR
+ PRESSURE SENSOR(A) (FRONT PUMP)
LCD DISPLAY PANEL WATER TEMPERATURE FUEL ELVEL
DIODE ARRAY PRESSURE SENSOR(B) (REAR PUMP)
GRAPHIC DISPLAY 5
6
7
8
3
4
1
2
3
4
1
2
0.85R
CN5-4
140A
139B
0.85BrW
CN3-5
139A
145A
0.85W
CN3-6
145B
SIG
74B 0.85GR
CN3-1
74A
-
75A 0.85W
CN3-2
75B
+
28F 0.85R CN3-3
76A
SIG
76B 0.85GY
-
77A 0.85WL
CN3-4
77B
4 80A
0.5Y
0.5Y
CN4-4
80B
CN7-5
5 81A
0.5YB
0.5YB
CN4-5
81B
SHIELD
SHIELD
CN4-6
6 82A
141A
CONTROLLER
28E 0.85R
CN7-4
CN7-6
DA4 ~ DA6
DA1 ~ DA3
28D
51D
CN2-6
141B
CN2-4
22B
CN2-5
0.5BrB
(AUTO)
0.5BrW
22A
6
CN2-1
0.5BG
KEY SW "START"
89B
CN1-15
0.5GB
START RELAY
104A
CAN A
CN2-15
HORN RELAY
CN1-1
0.85RL
21D
CN1-2
0.85RL
9D
CN2-14
0.5RW
99
CN1-8
0.85B
99
CN1-9
0.85B
AMP 040 12P
AMP MIC 21P CN1
CN4
AMP 070 18P
CYL.2
CN2
3-01 CN4-3
137A GND
0.5GW
CN4-2
136A RxD
0.5GL
CN4-1
135A TxD
0.5RG
CYL.6
3-15
SEGMENT SPEED SENSOR (CAMSHAFT)(DG6) (VR)#2 (TONE WHEEL WITH SLOTS) (0 281 002 662)
RAIL PRESSURE SENSOR (RGS3) (0 281 002 534)
t}
V
3-03
VEHICLE CONN
3-14
2-24
2
2-28
V
81C
1-34
CAN BL
0.5YB
2-34
1
2-25
80D
1-53
CAN AH
2
2-36
81D
1-52
CAN AL
0.5GW 136B 0.5RG 137B 0.5Y
80E
0.5YB
0.5YB
81E
SHIELD
SHIELD 82E
0.5Y
1
2-35
174A
1-30
0.5YB (DIAGNOSTIC LAMP)
0.5YB
174B
2
2-26
175A
1-22
0.5BY (DIAGNOSTIC LAMP)
0.5BY
175B
163A
1-29
0.5Gr (DIAGNOSTIC SW)
0.5Gr
176B
177A
1-85
0.5Dr (DIAGNOSTIC SW)
0.5Dr
177B
0.5BW
165B
1
2-15
1
2-23
165A
1-89
0.5BW
0.5GBr 166B
E/G EMERGENCY STOP SW 1 0.5R
2-19
164B
1-87
163B 2
0.5B
99
3 164A
2-09
1
2-10
3
2-13
2
2-14
1
2-12
(QUICK CLAMP)
CN2-2
0.5 BrW
(POWER MAX)
CN2-10
150E
CN2-8
0.5RL
(1-WAY)
151C
CN2-9
0.5 RY
(2-WAY)
102B
1
1-56
0.5LW
99
1-10
0.85B
99
1-11
0.85B
99
1-05
0.85B
99
1-06
0.85B
101B
0.85Or
CN1-21
5
78A
7
CN1-19
FUEL SENSOR
11
OIL TEMP SENSOR
72A
73B
0.85BR
CN3-8
73A
26B
0.85LgR
CN3-9
26A
27B
0.85LgW
CN3-10
27A
1.25WR
0.85RG
0.85RY
1.25W
0.85LR
0.85L
0.85BR
0.85WR
2RG
1.25R
2RY
20A
20A
15A 15A 15A
5
6
7
8
9
10
11
12
13
14
56A
66A
30A
93A
166A
40A
130A
83A
133A 143A
21A
19A
42A
0.5GBr
0.85RY
0.85Y
2RW
0.5WR
0.5RW
0.5RW
1.25RL
0.85BL
12B
STARTER RELAY 2
0.5B
OFF DR
10W
2 0.85LB 66B
84A
6
P/V-(A)
79B
CN1-20
0.85LgB 79A
103A
CN2-16
0.85V
DA2-3
0.5B
152B 6
96A PUMP PROPORTIONAL V/ V
DA2-2 BREAKER SELECT 150D
2
Px 0.85B
AUTO IDLE (2) SW
8
CN2-17
0.85BW 67B
0.85B
68A
CN2-18
0.85BG 68B
0.85B
INDICATOR
2
DA2-4
146B 3
(A)
CW
147C
1 0.85OrB
DA5-1
147B 4
69A
70A
CN5-3
CN5-7
0.85RB 69B 1.0bar
0.85B
0.85GB
0.85B
70B
(B)
PEDAL BRAEKER PRESSURE SW (OPTION)
0.5GR
90B
1
CN3-16
0.5G
91B
2
CN3-17
0.5GB
92A
3
1-09
0.85RW
19D
1-02
0.85RW
19E
1-03
0.85RW
2RW
7C
1-40
0.5Br
(KEY SW)
153A
1-13
0.85W
(AIR HEATER RELAY)
0.85W
154B
1-07
0.85BG
(AIR HEATER RELAY)
0.85BG
54J
133G
0.85BrR
133H
0
0.85W
0.85BG
0.85BG
0.5RW
A/C THERMOL ( OW)
130C
CN9-6
54E
CN9-11
42B
0.5WR
CN9-5
1.25LR
CN11-2
42C
0.5LR
CN10-8
42D
CN10-18
46B
1.25LR
RH HIGH
0.85RL
150A
0.5BrW
60A
0.85BrL
134B
0.85YL
61A
3 0.85B
7
148D
3
DA6-3 149B
8
2RW
1.25B
8B
DIODE 1
60B
60R
+
-
12V 100AH
12V 100AH BATTERY
AVX
8W
AVX
1.25WG
AVX
2RW
0.85W
0.5BW
105B
CN9-8
0.5LB
106B
CN8-11
0.5LY
105A
CN10-6
106A
CN11-1
99
0.5LW
CN10-1
107A
11 6 16 15 12
+
M
CN10-2
108B
FRE (P1)
0.5GrY
CN10-20
109B
REC (P2)
110A
CN9-15
0.5OrR
CN10-12
110B
DEF (P1)
111A
CN9-14
0.5OrW
CN10-13
111B
VENT (P2)
43A
CN9-16
0.5YB
CN10-11
43B
Vref MODE
CN10-10
44B
MODE F/BACK
CN10-19
112B
WARM (P1)
CN9-17
0.5YW 1.25B 0.5LgW
E
AIR HEATER
GRD 8B ALTERNAT
COMPRESSOR
M
INTAKE ACTUATOR
0.85LW
47A
47B
0.85B M
ALTERNATOR 80A(OPTION )
MAGNET 47C CLUTCH
BLOWER
0.5GrG
CN9-1
F-
100B
99 -
CN9-12
CN9-10
FIELD
F+
+
15L
FET
CN9-13
112A
TRIO DIODE
(1)
H
100A PREHEAT RELAY
109A
99
I(L)
154A D 0.85BG
108A
44A
4A B+
R
0.5 uF B+
REG.
168A
CN10-5
18A
I
15B
A/C RELAY
BLOWER RELAY
CN10-16
0.5LG
CN8-12
98B B -
46A
CN8-10
9A
153B C
CN11-4
13
3 58B
6
0.5G
(C)
0.85OrB 146A (ROTATING-CCW)
4
0.85OrR 147A (ROTATING-CW)
5
1 133B
0.85BrR
2 133C
0.85BrR
(L)
(R)
(ON JOYSTICK L.H)
DA5-2
148B
149C
BR
8C
1.25BrW
E 0.5WR
HOUR
2
1A A
3A
0.5RW 15R
RECEIVER DRIER (2204-6039A )
1.25B
14
PEDAL SWITCH 0.85BrL
133J
0.85BrR
3 133D
0.85BrR
134C
1
1 0.85OrY 71C
5
4 0.85GY
0.85B
MODE ACTUATOR
TERMINAL NO
113A
CN9-18
0.5LgB
CN10-3
113B
COOL (P2)
114A
CN9-3
0.5YR
CN10-7
114B
Vref MIX
115A
CN9-4
0.5YW
CN10-9
115B
MIX F/BACK
167C
CN9-2
1.25BL
CN10-4
167A
GND
116A
CN8-2
0.5OrB
CN10-15
116B
45A
CN8-1
0.5LgR
CN10-14
45B
71D 6
DA6-4
DA6-2
2 0.85Or
149D 3 0.85B
AMP MIC 13P M
MIX ACTUATOR
1
2
3
7
8
9
2 CN8-5
142A
CN8-3
48B
CN10-17
0.5LY
1
6
3
2
1
12 11 10 9
5 4
8
7
0.85OrY (SHEAR-LH HIGH)
148A
0.85Or (SHEAR-RH HIGH)
149A
(C)
0.5Lg
2 -
8
142B 1 133E
4
0.85RY
(L)
49A CN8-4 2 133F
5 (R)
JOYSTICK LEVER SWITC H
0.85RY
0.5GBr
0.5GBr
2RW
2RW
2RW
0.5Br
0.5Br
0.5Br
0.85W
0.85W
0.85BG
0.85BG
0.85GB
0.85GB
167B
2
0.85YG
49B
1
KET 4P
4
0.85BrW 5
179B 0.5WR 54R
2
0
1
I
3
8
7
70F 180A
0.85BrW
180G 6
0.5B 70G
2-PUMP SWITCH
0.85GB
1
70C
0.85BrW
180D
0.85GB
70D
0.85BrW
180E
7
DA3-3 0.85GB
70E
3
(1)
(2)
DA3-2
2
180H 70H
180C
DA3-1 0.85GB
1
10
9
21 20
3
1 9
4
3
8
7
6
5
(3)
2-PUMP S/V
7
6
19 18 17
2
6
1
11 10
5 4
2
(CN10)
3
6
5 4
AMP 040 2 8
7
6
7
3
2
1
10 9
12 11 10 9
8
7
20 19 18 17 16 15
6
5
9
(CN3
AMP 070 18P 3
4
15 14 13
(CN4)
AMP 040-III 20P 7
5
16
AMP 040 12P
3
4
(CN5)
(CN6)
8
8
9
(CN1)
8
3
2-PUMP CONTROL (OPTION) 180F 0.5WR
5
5
AMP 070 4
2
1
5
4
11 10
3
9
12
11
1
20 19 18 17 16 15 14 13 12 11 10
(CN11)
CN8 CN9 AMP 12P + 18P
6
1
AMBIENT TEMP SENSOR
A/C CONTROL PANEL
0.85RY 0.5GBr
0.5YR 114C 0.85BL
2
11 10
4
15 14 13 12
16 15 14 13 12
2
0.85YG
5
AMP 070 16P 2
KET D/L 4P CN11
AMP 20P
7
(CN7)
INCAR SENSOR
CN10
+ 1
6
7
(CN2)
16 15 14 13 12 11 10
9
6
8
18 17 16
AMP 040 28P
WATER SENSOR
AMP MIC 21P
AMP 070 18P 5
WIPER CONT.
DUCT SENSOR 6
48A
4
11 12 13
10
(CN12)
SUNLOAD SENSOR 0.85BrL 134A (BREAKER/POWER MAX)
(ON JOYSTICK R.H)
2RW
6C
1
AIRCON UNIT
2
(B)
3B
1.25BrW
9D 3
2R
BATTERY RELAY B
8W
4B
0.85W
107B
3
1B 0.5G
CIRCUIT BREAKER
(OPTION)
148C
2A
8W
2
10
151A
SHEAR S/V (OPT) - E3C
CW LOW ENGCONTROL DIAL HIGH
1
2R
2WR
-
42E
9
0.85BrR
2 0.85OrR
2
RETURN FILTER SW
(A) CN3-15
19C
0.5Br 2WR
8A
0.5Br
PST SHEAR PRESS BREAKER TML
0.5WR 0.85RY
99 0.5B (HORN)
ROTATING S/V (OPT) - ERO
PILOT FILTER SW
FUSIBLE LINK
DIODE 2
0.5RW
JOYSTICK LEVER SWITCH
146C
60B 60R
3
4
CCW
67A
150B
0.85RL 150C
(A)
A
0.5WR
BREAKER SHEAR SELECT SW
1
7A
STARTER SWITCH
3W
0.5Br
0.85BrR
151B
0.85Br
0.85Br 7B
2RW
168B
1
BR
6B
9B
0.85LR
71A
5
15R
START 24V 6K
C
B
98A
C
10A R2
HOUR METER
0.85GY
DA2-1
3
(OPTION) P/V-(C) FLOW CONTROL PROPORTIONAL V/ V
103B 19bar
152A
152C
(B)
0.85LgW 96B
90A
0.85RW
ACC 13A
0.85RY
99
7
0.85LgR 95A 95B
3Y
11A
83B
ILL
SHEAR SELECT 152D 0.85RB 5
SIG 91A GND 92B
+(5V)
2WR
B+ 0.5WR
LED 1~12
0.85RL
89A
ROOM LAMP
(Loose) 3
0.5GB
5B
2WR
0.5B
E
0.85BL
87 12A 85
1.25WR
2WR
0.85RL
0.85Y
0.5RL
93B
30
11B 86
R1
0.5RW
NO
84B
5A
1.25RL
DIODE 9 61D
6A
8
18 2C
30A
4
0.85B
0.85YL
LH HIGH
1-08
(CONN.1)
2WR
3
SOL-VALVE
4
(CONN.2)
P
3W
FUSE BOX 1 4E 17
0.5WR 1.25RL
0.85Br
PP 3Y B 3W 4C
12C
13C
5W
0.5RW
1
178A
5W
2D 16
0.5RW
1WAY-2WAY S/V (OPT)
12
2B 2B
19B
STARTER RELAY D
C
14A 0.85BL
87a
16
2B
2
0.5GY
78B
0.85Lg
10
CN3-7
56C 0.5RB
QUICK CLAMP SW
SWING PRIORITY
15
1
(C5)
1
8 9
CN5-2
4D
5W
0.5BrW
6
0.85YR
72B
1.25WR
18 2E
0.5RW
DIODE 6
DA6-1 2B
7
0.5BG
84C
RELIEF PRESS UP
AUXILIARY MODE SW
4
CN15
6
8W
0.5RY
4
0.85B
14
5
0.5GB
0.5Br
0.5Br
94A
0.85OrB 102A 3
2
0.5GBr 178B
CN1-10
3
13
4
0.5BG
(C4)
25A
0.85GrL
3
0.5GB
COM 40B
0.85B
0.5GB
10A 10A 10A 10A 10A 10A 10A 10A
10A 10A 10A 10A 10A 10A 10A 10A
QUICK CLAMP(OPT)
HIGH SPEED
21G
17
ON
(BREAKER)
0.5GY
94B 2
0.5BL 0.5B
2
B 13B
0.85RL 60B
101A
0.5GL 135B
3
0.5 Br
CHECK CONN
SHIELD
V
V
0.5Y
2-33
V
P
CAN BH
4
2
N
1-35
3
2
N
CYL.4
80C
7
DA1-3 25B
0.85GrL
0.85RL 21K
2
14
12
15A 15A 15A
UP
AMP 070 16P
t}
(CONN.3)
2-27
1
86
PILOT CUT-OFF SWITCH
(C3)
23A
0.85GrW
1
AUXI MODE RESISTOR
CN5
SENSOR (0 281 002 209)
INCREMENT SPEED SENSOR (CRANKSHAFT)(DG6) (VR)#1 TONE WHEEL WITH SLOTS) (0 281 002 662)
V
2-32
4
CN1-13
84D CN2-11
0.85BrB
AMP 040 20P
FUEL TEMPERTURE SENSOR (0 281 002 209) TEMPERTURE COOLANT
P& t}
0.85GrW
RS-232
CN3
BOOST PRESSURE SENSOR (LDF 6T) (0 281 002 576)
V
3
25C
71B
CYL.5
3-02
P& t}
CN1-11
5
DA1-1 23B
CYL.3
3-16
85
(Fixing) 1
24A 21E
1
13
11
1.25BrR
(C2)
21F
0.85RL 21H
15A
20A
BREAKER
0.85Gr
88A
10
PILOT CUT OFF
61C
0.85RL 21J
2
0.85RL
0.85RL
3-11 3-06
E
0.85B
0.85RG
99
0.85B
6
DA1-2 24B
0.85Gr
3-05 3-12
OIL PRESSURE SENSOR (ODFT) (0 281 002 420)
CN1-12
41A
0.85YG
(C1)
99
0.85B
0.85RL
24C
41B
0.85YL 61B
4 2
23C
3-08
AUTO IDLE (1) / TRAVEL SW
0.85YG 41C
3
34A
0.85LB
NC
CYL.1
3-13
3-07
BOOST PRESSURE ACTUATOR(EPW)
87
58A
0.5G
0.5G
SOL- VALVE ASSEMBLY
DA4-1
INJECTOR SOLENOIDS
0.85RY 57A
0.85RG
1.25RL
CN4-4
3-04
0.85RY
0.85B
ALT "I"
DA4-2
3-10
0.5WR
0.85B
0.85YL
3-09
0.5RL
8 54H
L.F
0.5BG
1
FUEL HIGH PRESSURE PUMP
5 21L
57C
HORN 2
30 56B 0.85RB
0.5GB
104B 19bar
0.85P
0.5YB
CYLINDER CONN
0 I II
7
0.5RL
131A
20A
0.85RY
0.85B
HIGH SPEED SWITCH 10B
ECU
ENGINE CONN
2 21B
Py
CN4-5 0.5Y
(MANUAL)
0.5BrW
3
0.5B
21C
CN7 CN6 AMP 040 12P+16P
0.5RG 0.5BrB
62A
4F 15
0.5G
CYLINDER CONN.
-
B
0.85RL
ECU CON.2 ( PIN) ENGINE CONN.
SIG -
179A
5W
H.F
0.85RY
ECU CON.3 (16-PIN)
+ PRESSURE SENSOR (OWD)
124A
9
4G
87a 0 I II
63A
52A
30A
FUSE BOX 2
57B
HORN 1
65B
200A
0.5BrY
54P
4
0.85BW
18B
0.85LR
0.85RY
140B
8
FUEL HEATER SWITCH
2.5B FUEL HEATER
ONLY SWING (OPT)
2
28A
ALARM RELAY
WARNING LAMP L1 : CHARGE L2 : ENG OIL PRESS L3 : W/T OVER HEAT L4 : E/G WARNING L5 : PREHEAT L6 : WORK LAMP
12V POWER SOCKET
2RW
I
7
30C
20A
1.25RL
0
3
0.5B
54K
FUEL HEATER RELAY
125A 50A
1.25RB
1 0.5B
7
0.5B
20B
2LR
ECU CON.1 (89-PIN) VEHICLE CONN
8
1.25BrR
OVER LOAD WARNING SWITCH
2
0.5RG
ALARM SWITCH
0.5B
89
I
0.85WR
71 72
0
0.85Y
6
39B
1
39A 3
0.5RW
54
11
86
32A
8 0.5WR 54M
7
4bar SWING PRESS SW
0.5W 85
32C
0.5RG
2RG
0.5RY
0.85RB
7 1
OVER LOAD WARNING (OPT)
53
5 0.5W
86
0.85W
36
6
85 0.5B
0.5GBr
35
18
17
122A
0.85V
30 20C
59A 87
59B
0.85RG
31A 87
0.5Br
12
122B
2.5R
30B 30
87a
0.5W 32B
0 I II
L6 0.85B
2
0.85R
104C
0.85RL
0 I II
3
0.5P
2RL
- 0.85B
0.85LB
ALARM BUZZER
0.85RG
0.5B
0.85BG
0.5B
10 99
0.5WR
0.5RW
9 99
CN6-10
0.5WR
L5
0.85LW
0.5B
14B +
132B
3
0.5LR
0.85 RY
11 130D
CN6-9
CN6-11
L4
ECU CONNECTOR
0.5B
65C 99
0.85BY
87a
0.85BG
(CN15)
(CN14)
0.5BW
11
3
1.25RB
FUEL HEATER (OPT)
0.85RY
10
S
14C
2 132A 0.85R
1
0.85LR
0.85RY
0.5GrL
120A
0.5LW
2 16A 0.85L
0.85B
TRAVEL/SWING ALARM ASSEMBLY (OPT)
2
STEREO RELAY
0.5RW
+ 31B
0.5BY
119A
85
2RL
2RW
4
0.5R 28G 29A
0.5WB
0.85R
+
0.85W
3
12 29B
CN6-12
0.85R 2RL
PILOT BUZZER
0.85BG
L2 L3
2
0.5R
12
MOLEX 4P
1
0.5R
2 28C
0.85W
13
1 28B
CN6-2
0.5GBr
14
CN6-1
L1
0.5Br
8
0.5Br
4
9
DC/DC CONVERTER1
99
0.85RY
1 5
0.5WR
1.25 BrR
2 6 10
0.5WR
0.85RL
3 7 11
0.5WR
17
16C 5
STARTER CONTROLLER
0.85RG
2R W
5
3 54B
118A
0.85L
87 65A
3 17A 0.85BR
1
62B 1.25W
1.25RB
0.5 GBr
6
(CN13)
CN6-3
0.5GrR
17B 14
87a
16B 30
0.5BR 88C 86
0.85WR 15B
2RY
1.25 BrR
7
ILL.
7
0.5BR
117A
0.5BR
1.25R
2RW
8
1
+ 117B
99
1.25RB
0.5GBr
9
2
(L
MICOM
Vcc(+5V)
2 63B 1.25WR
0.85BrR
3
169B 13
Vcc(+5V)
CN14 MOLEX 4P
0.85L
FUEL PUMP SW
0.5G
4
DIAGNOSTIC CONN. 14P
0.5BL
KET 8P
0.5WR
131B KET 118 9P
4 169A
0.5WR
0.5WR
AIR SUSPENSION 143C
8
0.5W
123A 16
54C
CN13
1.25B
P
2
0.5B
121A 15
54D
0.5WR 1
CAR STEREO
0.5WG
3 123B
0.85BR
1.25B
1.25B
VOL.
2 121B
0.5WR
0.85B
ANTENNA WASHER
MODULE (K1002641 )
WINDOW WASHER + 0.85L 0.85RB P 35A 34C 0.5RB 0.5L 35B 34D DIODE 5 0.85L 0.85L
12
34B
0.5R
54G
10
162A
WIPER MOTOR
0.85BR
FUEL PUMP (OPT)
8
7
161A
35C
1
SEAT AIR SUSPENSION (OPT)
SEAT HEATER SWITCH
0.85RG
157A
0.85WR
190B
0.85R
2RY 1.25RB
2 143B
0.85WL 7
WIPER CUT SW
0 I II
6
1
I
7
0.5B
CN2
0.85BR
LOWER WIPER MOTOR 2 52B
157B
0.85G
E 0.85B
1.25R 1
144B
S 37A
FUEL PUMP
2RL
LCD GAUGE PANEL
3
0.5B
SEAT HEATER
TERMINAL NO
LAMP SWITCH 0 I II
86 0.5RG
HEAD LAMP RELAY
0.85B
1.25B
0.5WR LOWER WIPER SW
2
0.5RG
54F
2B
CABIN LAMP
6 7
0.5B
CABIN LAMP RELAY 1
125C 5
0 I II
86 126B 0.5RG
53C
8 54L
190A
M
54K
55B
0.5RL
2 38A
0.85BY
85
2
0.5B 85
0.85B
125B
0 I II
3
I
0.85LR
0.5B
0.5WR 126A
30 125D 2RL
0
88B 3 0.5B 7
1.25WR
0.85B
87
B 88H
RUN
0.85G 37B 1
86 88E
85
0.5BG
(FML)
2RG 127A
8
7
STOP
LOWER WIPER RELAY 36A 87a 30 38B 87 0.85Br
DIODE 4
127D 0.85RG
1.25RW 53A 87
0.85RW
0.85RG 0.5WR
0.85R
0.5WR
2B (FRONT)
DA4, DA5
I
124B 2
0.5GB
DIODE 2 ~ 9
53B
33A 3
52D 30 1.25R
87a
HEAD LAMP CABIN LAMP SWITCH
0
0.5B
0.85B CABIN LAMP RELAY 2
L 36B
ROTATING BEACON SWITCH 1
DIODE 3
(LH)
CABIN LAMP
127C 0.85RG (FMR)
DA1~DA3, DA6
0.85B ROTATING BEACON
0.85B
1. DIODEPART NO DIODE 1 .
0.5RG
WORKING LAMP RELAY
1.25WG
1.25B
0.5RG
86 55C
0.85RG
0.5RW
(FR)
86 128B
85
85
0.5B
0.85B 51C
1.25RB
NOTE.
(RH)
(RL)
0.85B
0.5RW
0.5B
127B 0.85RG
30 125E 1.25RL
87
(REAR)
0.85RG 129D
87a
0.85L
129A
0.85BR
1.25RG
0.85WR
REAR WORKING LAMP
START
-
ON
+
0.85B
0.85B
OFF
18 17 16
15 14 13 12
(CN9)
10
9
(CN8)
System
SP001038 ELECTRICAL SYSTEMSP001038
Electrical System Edition 1
Electrical System
SP001038 Page 1
MEMO
Electrical System Page 2
SP001038
Table of Contents Electrical System Safety Precautions ............................................... 7 Applicable Models ................................................ 7 Introduction ........................................................... 9 Electrical Supply System .................................... 10 Engine Starting Circuit ........................................ 12 Start Operation .............................................................. 12 After Start ...................................................................... 14
Engine Preheating System ................................. 16 Engine Stop ........................................................ 18 Charging System ................................................ 20 Monitoring System .............................................. 21 Instrument Panel ........................................................... 22 Monitoring System Schematic ....................................... 24
Operation ............................................................ 26 Instruments.................................................................... 26
Warning and Indicator Lights .............................. 28 Indication of Warning Lights .......................................... 28 Indication of Multifunction Gauge and Letter Information Area.................................................. 29
Initial Operation .................................................. 31 Mode Selector Switch ......................................... 31 Graphic Information Area Display....................... 32 Overview ....................................................................... 32 Main Menus for the Graphic Display Area..................... 33 Menu Selector Buttons .................................................. 33
Main Menu .......................................................... 34 Language ...................................................................... 34 Set Clock ....................................................................... 35 Filter/Oil Info .................................................................. 35 Adjust Display................................................................ 36
Electrical System
SP001038 Page 3
Set Password ................................................................ 37
Special Menu ...................................................... 38 Entering/Accessing and Exiting/Escaping Menus ......... 38 Special Menu Selections ............................................... 39
Electronic Hydraulic Control System (e-EPOS).. 56 Control System Schematic ............................................ 56
Power Mode Control ........................................... 58 Operation....................................................................... 60
Power Mode Control - Circuit Diagram ............... 62 Work Mode Control............................................. 64 Operation....................................................................... 65
Work Mode Control - Circuit Diagram................. 66 Engine Control System ....................................... 67 Engine Control Dial............................................. 68 Engine Control Circuit Diagram .......................... 69 Automatic Deceleration Control (Auto Idle Control) .............................................. 70 Engine Overheat Protection System .................. 72 Power Boost Mode ............................................. 74 Operation....................................................................... 74 Power Boost Control - Circuit Diagram ......................... 76
Automatic Travel Speed Control......................... 78 Automatic Travel Speed Control - Circuit Diagram ....... 80
Self-diagnostic Function ..................................... 81 e-EPOS Controller......................................................... 81
Air Conditioner System ....................................... 83 Outline ........................................................................... 83 Internal and External Filters .......................................... 84 Air-Conditioning System Layout .................................... 86 Air Conditioner/heater Circuit Diagram.......................... 87 Air Conditioner/heater Unit ............................................ 88 Ambient Air Temperature Sensor .................................. 93
Electrical System Page 4
SP001038
Sun Sensor.................................................................... 94 Control Panel................................................................. 94 Compressor ................................................................. 102 Receiver Dryer ............................................................ 102
Troubleshooting ................................................ 103 Weight of R134a Gas Used In Machines ......... 105 Refrigerant System Repairs ............................. 106 Refrigerant Safe Handling Procedures........................ 106 Repair and Replacement Procedure ........................... 107 Refrigerant Recovery .................................................. 109 Vacuuming Refrigerant System................................... 109 Leakage Check ........................................................... 111 Refrigerant Charging ................................................... 111 Inspecting System For Leakage .................................. 113
Wiper System ................................................... 114 Wiper Circuit................................................................ 114 Wiper operation ........................................................... 115
Lighting System ................................................ 118 Lighting System Circuit Diagram ................................. 118 Kind of Light ................................................................ 119 Operation..................................................................... 119
Audio Controller ................................................ 120 Audio Controller Circuit Diagram................................. 120
Electrical System
SP001038 Page 5
MEMO
Electrical System Page 6
SP001038
SAFETY PRECAUTIONS CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that are in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL
SERIAL NUMBER RANGE
DX140LC
5001 and Up
DX180LC
5001 and Up
Electrical System
SP001038 Page 7
Electrical System Page 8
SP001038
INTRODUCTION The electrical system for this equipment is DC 24 volts. The rated voltage for all electric components is 24 volts with the exception of the stereo and the air-conditioning control actuator. The system contains two 12 volt batteries connected in series and a three phase AC generator with a rectifier. The electric wiring used in the system is easily identifiable by the insulator color. The color symbols used in the electrical system are listed in the following chart. Electric Wire Color
NOTE:
Symbol
Color
W
White
G
Green
Or
Orange
B
Black
L
Blue
Lg
Light green
R
Red
Gr
Gray
P
Pink
Y
Yellow
Br
Brown
V
Violet
RW: Red wire with White stripe R - Base Color, W - Stripe Color
NOTE:
0.85G: Nominal sectional area of wire core less insulator = 0.85 mm2
Electrical System
SP001038 Page 9
ELECTRICAL SUPPLY SYSTEM The electric power circuit supplies electric current to each electric component. It consists of a battery, battery relay, starter switch, circuit breaker, fusible link and fuse box. The negative terminal of the battery is grounded to the vehicle body. Even when the starter switch (5) is in the "OFF" position, electric current is supplied to the following components through battery (1) o fusible link (3) o fuse box (6). 1.
Terminal "1" of DC-DC converter (for memory backup of stereo)
2.
Terminal "B" of starter switch
3.
Hour meter
4.
Engine controller
5.
Fuel feeder pump switch
6.
Terminal "6" of wiper motor
7.
Terminal "13" of wiper controller
8.
Terminal "CN6-11" of instrument panel
9.
Terminal "CN9-6" of air conditioner panel
10.
Cabin light
When the starter switch (5) is in the "ON or START" positions, the current flows from the battery (1) o fusible link (3) ofuse box (6) o"B" terminal of starter switch (5) o "BR" terminal of starter switch (5) o "BR" terminal of battery relay (2) which activates the coil of the battery relay and the electric supply system is energized. When the battery relay's contacts are connected, all electric devices can be operated. While the engine is not running, the electric power for all electric devices are supplied by the battery. Once the engine is started the power is supplied from the alternator (7).
Electrical System Page 10
SP001038
C
ACC B
5
R2
BR
0.5G
R1
6
3 8
2
4
A
B BR E
8
PST
TML
P(R)
R(I)
STARTER SWITCH CONNECTION
B(B+)
+ 12V 100AH
1
0.5 uF
B
BR
R1
R2
C
ACC
B+
OFF
I(L)
7
ON REG.
START
+ 12V 100AH
TRIO DIODE FIELD
F+ FE
GRD
FG007233
Figure 1 ELECTRIC POWER CIRCUIT DIAGRAM Reference Number
Description
Reference Number
Description
1
Battery
5
Starter Switch
2
Battery Relay
6
Fuse Box
3
Fusible Link
7
Alternator
4
Circuit Breaker
8
Diode
Electrical System
SP001038 Page 11
ENGINE STARTING CIRCUIT Start Operation When the starter switch is turned to the "START" position, the "S" and "E" terminals of the starter controller (7) are connected. At this time the contacts in the starter relay (8) are closed by the current flow from the battery (1) o fusible link (3) ofuse box (6) o "B" terminal of starter switch (5) o "C" terminal of starter switch (5) o "30" terminal of starter relay (12) - "87a" terminal o "C" terminal of starter relay (8) - "D" terminal o "S" terminal of starter controller (7) - "E" terminal o ground. When the contact point "B" and "PP" of starter relay (8) are connected, the pinion gear of the starter (9) is pushed forward and makes contact with the ring gear of the flywheel and the internal contacts of the starter are connected. The current flows from the battery (1) o "A" terminal of the battery relay (2) o "B" terminal of the battery relay (2, Figure 3) o "B" terminal of the starter (9). The starter motor is rotated and the engine is started. If the instrument panel has the password function activated , input number should match the set number, otherwise the start circuit closes and the engine does not start. NOTE:
If the security system is "LOCKED," a four-digit password will be required to start the engine. If the system is "UNLOCKED," no password will be required and this display screen will not appear. In the event the security system is locked, current flows from battery (1) o fusible link (3) o fuse box (6) o "B" terminal of starter switch (5) o "ACC" terminal of starter switch (5) o "86" terminal of starter relay (12) o "85" terminal of starter relay (12) o "CN1-15" terminal of e-EPOS (13) o ground. This current flow causes the coil in starter relay (12) to be activated, opening contacts at "87a" terminal. This prevents starter relay (8) from functioning.
Electrical System Page 12
02/05 [MO] 11:30 ENTER PASSWORD E F C
C
H
E/G SPEED
0
H
RPM FG001445
Figure 2
SP001038
7 N P B
9
8 S E
D
PP
C
C
B
B
11 A
87a 30 87 85
86
ACC C
5
B BR
R2
12
R1
CN1-15
3
6 4 A
B CN2-1 BR
13 R(I)
STARTER SWITCH CONNECTION PST
TML
B
BR
E
11 R1
R2
C
P(R)
2
B(B+)
0.5 uF B+
ACC
I(L)
OFF REG.
ON START
10
TRIO DIODE
+
-
+
1
FIELD
F+
-
FE
GRD
FG007234
Figure 3 STARTER CIRCUIT (1) - WHILE STARTING Description
Reference Number
Description
1
Battery
8
Starter Relay
2
Battery Relay
9
Starter
3
Fusible Link
10
Alternator
4
Circuit Breaker
11
Diode
5
Starter Switch
12
Starter Relay 2
6
Fuse Box
13
e-EPOS Controller
7
Starter Controller
Reference Number
Electrical System
SP001038 Page 13
After Start Once the engine has been started, the belt driven alternator (10) generates a current. The output generated by the alternator (10) is a square wave pulse voltage through the "P" terminal and the frequency of the pulse voltage is proportional to the rotation of the alternator. The starter controller (7) monitors the frequency of the output current. Once the frequency is equivalent to 500 rpm, it is sensed and the connection between "S" and "E" terminals and the connection between "B" and "PP" terminals are opened. As a result the rotation of the starter (9) is stopped. Once the engine is running, the starter (9) will not operate even if the starter switch (5) is moved to the start position, preventing possible damage to the starter.
Electrical System Page 14
SP001038
Operation of the Start Circuit (2) - Immediately After Start 7 N P B
9
8 S E
D
PP
C
C
B
B
11 A
87a 30 87 85
86
ACC
C
5
B BR
R2
12
R1
CN1-15
3
6 4
A
B
CN2-1 BR
13 R(I)
P(R)
E
11 B(B+)
2
0.5 uF B+
STARTER SWITCH CONNECTION PST TML
B
BR
R1
R2
C
I(L)
ACC REG.
OFF ON
TRIO DIODE F+
10
-
-
+
1
F-
START
+
FIELD
E
GRD
FG007237
Figure 4 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START Reference Number
Description
Reference Number
Description
1
Battery
8
Starter Relay
2
Battery Relay
9
Starter
3
Fusible Link
10
Alternator
4
Circuit Breaker
11
Diode
5
Starter Switch
12
Starter Relay 2
6
Fuse Box
13
e-EPOS Controller
7
Starter Controller
Electrical System
SP001038 Page 15
ENGINE PREHEATING SYSTEM An air heater (8) is installed in the intake manifold of the engine. When the starter switch (5) is turned "ON," the current flows from the battery (1) o fusible link (3) o fuse box (6) o "B" terminal of starter switch (5) o "BR" terminalof starter switch (5) o "1-39" terminal of engine controller (12), causing current to flow though "1-16" terminal of engine controller (12) o "C and D" terminals of preheat relay (7) o "1-04" terminals of engine controller (12) o ground. This current flow causes the coil in preheat relay (7) to be activated, closing contacts. When the contacts of the preheat relay (7) are closed, the heating coils of the air heating device (8) are heated by current flowing from the battery (1) o battery relay (2) o preheat relay (7) o air heater (8) o ground. The duration of the heating cycle depends on the temperature of engine coolant. The preheat indicator light in the instrument panel (9) will turn "ON" during preheating cycle. The preheat relay (7) is controlled by the engine controller (12) and operates only at temperatures of 10°C (50°F) and below. The longer the preheating period, the lower the temperature of coolant is.
Electrical System Page 16
SP001038
3 6 4
9
2
CN6-1,2 PREHEAT
L5
C
ACC
CN7-4,5,6
A
B
B
5 BR
R2 R1 BR
E
10
CN4-4,5,6 CN2-1 +
-
-
+
1
11
B -
200A
C
1-34,35
7
STARTER SWITCH CONNECTION
1-40
PST
1-13
D
H
(1) +
TML B
BR
R1
R2
C
ACC
OFF ON
1-07
START
12
FG007137
Figure 5 ENGINE PREHEAT CIRCUIT Reference Number
Description
Reference Number
Description
1
Battery
7
Preheat Relay
2
Battery Relay
8
Air Heater
3
Fusible Link
9
Preheat Indicator Light
4
Circuit Breaker
10
Diode
5
Starter Switch
11
e-EPOS Controller
6
Fuse Box
12
Engine Controller
Electrical System
SP001038 Page 17
ENGINE STOP When starter switch (5) is turned "ON" the engine controller (8) is activated. The engine controller monitors and controls the engine including the injector solenoid (9). It controls the fuel deliver rate and the injection timing for each cylinder. NOTE:
There is an individual injector solenoid (9) for each of the six cylinders. Only one soleniod is shown in Figure 7.
When starter switch (5) is turned "OFF," the engine controller stops suppling power to the injector solenoid (9). This stops fuel from being injexted into the engine cylinder, thus stopping the engine. In the event that the engine can be shut down using the starter switch (5), an emergency stop switch (10) is provided to shut down engine. To activate the emergancy stop switch, move it to the "I" (EMERGENCY STOP) position.
O I
The emergency stop switch (10) is in its "O" (OFF) position during normal operation. The switch must be moved and held in the "I" (EMERGENCY STOP) position until the engine stops. When released it will automatically move back to the "O" (OFF) position. FG001344
Figure 6 ENGINE EMERGENCY STOP SWITCH
Electrical System Page 18
SP001038
STARTER SWITCH CONNECTION TML
PST
B
R1
BR
R2
C
ACC
OFF ON START
8
6 0.5G
3 C
ACC
10 2
1-19
5
B 3
R2
BR
2
4
R1
1-45
A
B
1-39
BR E
7 9 -
+
-
+
1 FG001473
Figure 7 ENGINE STOP CIRCUIT Reference Number
Description
Reference Number
Description
1
Battery
6
Fuse Box
2
Battery Relay
7
Diode
3
Fusible Link
8
Engine Controller
4
Circuit Breaker
9
Injector Solenoid
5
Starter Switch
10
Emergency Stop Switch
Electrical System
SP001038 Page 19
CHARGING SYSTEM When the starter switch (5) is turned to the "ON" position, an initial excited current flows to the field coil of the alternator (7) through the battery relay (2) and circuit breaker (4). When the engine is started from this condition the alternator (7) starts charging. The current flows from the "B(B+)" terminal of alternator (7) o circuit breaker (4) o battery relay (2) obattery (1). The alternator also supplies electric current to other electrical components. When the alternator (7) starts to operate, a current flows from the "R(I)" terminal of alternator o diode (8) o battery relay (2) coil securing a path for the charging current to the battery (1). Thus preventing the possibility of a high voltage build up and possible damage to the electric system.
C
ACC
5
B R2
BR
0.5G
R1
6
3 8
2
4
A
B BR E
8
R(I)
P(R)
B(B+)
+ 12V 100AH
1
0.5 uF
STARTER SWITCH CONNECTION PST
TML
B
BR
R1
R2
C
+ 12V 100AH
B+
I(L)
ACC
OFF
REG.
ON
7
TRIO DIODE FIELD
F+
START
FE
GRD
FG007238
Figure 8 CHARGING CIRCUIT Reference Number
Description
Reference Number
Description
1
Battery
5
Starter Switch
2
Battery Relay
6
Fuse Box
3
Fusible Link
7
Alternator
4
Circuit Breaker
8
Diode
Electrical System Page 20
SP001038
MONITORING SYSTEM 1 2
+ -
5 8
7
4 R
B
E
CHECK
9
3 02/05 [MO] 11:30
F
E
C
C
H
E/G SPEED
10
H
1700
RPM
6
POWER AUTO
1
2
3
4
5
6
7
8
ESC
11
13 12 FG000547
Figure 9 Reference Number
Description
Reference Number
Description
1
Instrument Panel
8
Warning Buzzer
9
Pump Discharge Pressure Sensor
10
Hydraulic Oil Temperature Sensor
11
Fuel Sensor
12
Air Cleaner Indicator
13
Engine Controller
2
Battery
3
Light Switch
4
Return Filter Switch
5
Pilot Filter Switch
6
e-EPOS Controller
7
Alternator
The monitoring system displays the various data and warning signals onto the instrument panel by processing the information gathered from the e-EPOS controller. It displays information selected by the operator.
Electrical System
SP001038 Page 21
Instrument Panel
7
8
9
10
5
1
11
12
CHECK
6
02/05 [MO] 11:30
1
3 F
E
4
2 C
C
H
1700
E/G SPEED
H
RPM
17
< CONNECTOR AND TERMINAL NO.>
15 AMP 040 28P
19 6
13
3
2
1
12 11 10 9
5 4
8
7
2
1
16 15 14 13 12 11 10
8
7
6
5
4
3
9
POWER AUTO
1
2
4
3
(CN7)
ESC
(CN6)
20 14
5
6
8
7
16
18 FG000548
Figure 10
Electrical System Page 22
SP001038
Gauges
Warning Lights
Mode Selector Switches
1.
Fuel Gauge
7.
Charge Warning Light
13.
2.
Engine Coolant Temperature Gauge
8.
Engine Oil Pressure Warning Light
Power Mode Selector Switch and Indicator
14.
Hydraulic Oil Temperature Gauge
9.
Coolant Warning Light
Work Mode Selector Switch and Indicator
15.
Multifunction Gauge Letter Information Area
10.
Engine Check Warning Light
Auto Idle Indicator
11.
Preheat Indicator Light
16.
Flow Adjusting Switch
12.
Work Light Indicator Light
17.
Up Button Switch
18.
Down Button Switch
19.
Display Selector Switch
20.
Selector Button Switch
3. 4. 5.
Digital Clock
6.
Hour Meter
and
Temperature
Switch
and
When the engine starter switch is turned to the "I" (ON) position, all gauge bands, switch/button indicator lights and indicator/ warning lights will turn "ON" and the alarm buzzer will sound about two seconds. During this functional check, a LOGO will appear on the multi function gauge in the graphic information area
Electrical System
SP001038 Page 23
Monitoring System Schematic
1 19 CN6-1
3 ILL.
L1 L2
CN6-3 CN6-2
+
CN6-12
-
2
CN6-11
17
L3
4
L4 L5
R2
B
16
B
CN6-9 CN6-10
BR
L6
14
WARNING LAMP
E
CN2-1
L1 : CHARGE L2 : ENG OIL PRESS L3 : W/T OVER HEAT L4 : E/G WARNING L5 : PREHEAT L6 : WORK LAMP
A
18 +
5
15 CN3-1
SIG
CN3-2
-
LCD DISPLAY PANEL WATER TEMPERATURE FUEL LEVEL
+
6
GRAPHIC DISPLAY
CN3-3
SIG
CN5-7
CN3-4
-
9
CN7-4
CN4-4
CN7-5
CN4-5
CN7-6
CN4-6
CN2-17
10 CAN A CN2-18
11
21
CN4-3
GND
CN4-2
RxD
CN4-1
TxD
1-35
12
CN3-7
1
1-34
CN5-3
CN3-8
2
8
3 1-53
4
1-52
20
CN3-9 CN3-10
5
7
6 14
1-56
CN5-2 R(I)
CN2-14
13 FG007141
Figure 11
Electrical System Page 24
SP001038
Reference Number
Description
Reference Number
Description
1
Instrument Panel
11
Pilot Filter Switch
2
Pilot Buzzer
12
Return Filter Switch
3
Light Switch
13
Alternator
4
Starter Switch
14
e-EPOS Controller
5
Front Pump Pressure Sensor
15
Battery
6
Rear Pump Pressure Sensor
16
Battery Relay
7
Hydraulic Oil Temperature Sensor
17
Circuit Breaker
18
Fusible Link
8
Fuel Sensor
19
Fuse Box
9
Pedal Pressure Switch (Optional)
20
Check Connector
10
Air Cleaner Indicator
21
Engine Controller
Electrical System
SP001038 Page 25
OPERATION Instruments Function
Sensor Specification
Display
Input Terminal
Input Specification
Blue
Coolant Temperature
61°C
102°C
41°C
C
107°C
H
White
ECU-CAN Communication
Red FG000550
Blue
CN3-7
Fuel Level
CN3-8
1/10
E
F
Red
1/10 LCD (Red Zone) Blinking o over 5K ohms FULL o under 525 ohms
Full FG000552
40°C (104°F) o 1,397 ohms
Blue
Hydraulic Oil Temperature
50°C (122°F) o 1,139 ohms
CN3-9
50°C
94°C
40°C
96°C
C
H
White
CN3-10
Red
90 106.5 78.5 96.5
(Output Terminal) CN1-19
57
CN1-20
48.5 (None) FG009964
Electrical System Page 26
57 l/min o583 mA
114
66
96°C (205°F) o 177 ohms 48.5 l/min o610 mA
114
69
Flow Adjusting
94°C (201°F) o 190 ohms
(When reading increase)
FG000551
108
60°C (140°F) o 881 ohms
66 l/min o555 mA
78.5 l/min o466 mA (Default Set)
108 l/min o343 mA 114 l/min o290 mA
SP001038
Function
Sensor Specification
Display
Input Terminal
Input Specification
N = 162 f / 60 Tachometer
E/G SPEED
1700
RPM
ECU-CAN Communication
N = Engine speed (rpm)
CN2-14
0 - 32 VDC
f = Frequency of engine speed sensor (Hz)
FG000049
Voltmeter
BATTERY
28.0
VOLT
FG000050
Main pump discharge pressure (front pump)
FRONT PUMP
320
BAR
CN3-1 CN3-2
V = 0.00816 x P + 1.0 FG000051
V: Sensor output voltage (V) P: Displayed pressure (Bar) Main pump discharge pressure (rear pump)
REAR PUMP
313
BAR
CN3-3 CN3-4
FG000052
Electrical System
SP001038 Page 27
WARNING AND INDICATOR LIGHTS Indication of Warning Lights Description
Symbol
Charge
Input Terminal
Operation
Remarks
CN2 - 14
It lights in case of no charge [voltage of "R(I)" terminal is below 12 ±1V] or overcharge [voltage of "R(I)" terminal is above 33(V)].
Normally, it lights when starting engine and is out after engine starts.
ECU-CAN Communic ation
It lights when engine oil pressure is below the reference.
After starting engine, if engine oil pressure is insufficient after 8 seconds, a warning buzzer will sound.
ECU-CAN Communic ation
It lights in case of failure in engine system.
ECU-CAN Communic ation
It lights when engine coolant temperature sensor resistant is below about 128 ohms.
HAOA610L
Engine Oil Pressure HAOA620L
Engine Check
CHECK FG000045
Coolant Temperature HAOD350L
Preheating
CN5-2
HAOA639L
Electrical System Page 28
It lights during preheating ("CN5-2" terminal voltage is below 2V) and turns "OFF" after completion of preheating.
Preheating period depends on coolant temperature. No preheating at above 10°C 10 sec preheating at 5°C 20 sec preheating at below 0°C
SP001038
Description
Symbol
Work Light
Input Terminal
Operation
CN2 - 6
It lights when work light turns "ON" (24V applied).
Remarks
HB4O2003
Indication of Multifunction Gauge and Letter Information Area
Description
Input Terminal
Symbol
CN3-9
Hydraulic Oil Temperature
CN3-10
Operation
Remarks
When hydraulic oil temperature is above about 96°C.
FG000056
CN3-7
Fuel Exhausted
CN3-8
When fuel is almost exhausted.
FG000057
Air Cleaner
CN2-17
When air cleaner is clogged.
CN5-3
When return filter pressure is above about 1.50 kg/cm² (21 psi)
FG000053
Return Filter
FG000054
Electrical System
SP001038 Page 29
Pilot Filter
CN2-18
When pilot filter pressure is above about 1 kg/cm² (14 psi)
FG000055
CN3-5
Overload Warning
CN3-6 FG000253
Boost
Warning buzzer also starts when boom pressure sensor output voltage is about 2.7V while overload warning switch is "ON."
CN2-2
It lights when boost is selected.
CN2-10
It lights when breaker is selected.
CN2-9
It lights when shear is selected.
It flickers in case of 2.71V and above and lights continuously in case of 2.8V and above (and warning buzzer also starts).
FG000554
Breaker
FG001470
Shear
FG001471
Electrical System Page 30
SP001038
INITIAL OPERATION Item
Input (Terminal)
Initial Operation
Output (Operation and initial setting mode)
When "CN6-1,2" is applied battery voltage (starter switch shifts from "OFF" to "ON"
!
LCD, all of LED and warning lights are turned "ON" and turned "OFF" after about 2 seconds.
!
Warning buzzer is activated and turned "OFF" after about 2 seconds.
!
Power mode: Standard mode.
!
Work Mode: Digging mode.
!
Auto Idle: High Output (Activation).
!
Display: Indicating coolant temperature, Fuel level, Hydraulic oil temperature, Engine speed.
!
Clock: Current time display.
Refer to method for setting clock in operation manual for setting time.
NOTE:
MODE SELECTOR SWITCH Power Mode / Trenching Mode Switch
Operation Mode
Output Check (Operation mode display LED)
e-EPOS Output Electromagnetic Proportional Pressure Reducing Valve (E.P.P.R Valve) Current (mA)
Swing Priority Solenoid Valve
7-Segment Display
-
9x
No-load: 150 ±20mA Power Mode
ON
(Max. current: 600 ±20mA)
Power Mode
Work Mode NOTE:
Load: Variable output No-load: 250 ±20mA
Standard Mode
OFF
Load: Variable output
-
7x
Trenching Mode Digging Mode
OFF ON
(Max. current: 600 ±60mA) -
ON OFF
x2 x0
When the engine speed is below 1,000 rpm, the output current of E.P.P.R valve is fixed to be 600 ±60mA.
Auto Idle Switch
Auto Idle
Electrical System
Operation Mode Activation Cancellation
Output Check (Operation mode display LED) ON OFF
SP001038 Page 31
GRAPHIC INFORMATION AREA DISPLAY Overview Many kinds of condition of machine are displayed on the letter information display department. The information display department is divided into two menus. One is main menu for user and the other is special menu for specialist. These menus can be moved from normal display mode by the combination of selector buttons.
CHECK
02/05 [MO] 11:30
5 F
E
C
C
H
E/G SPEED
H
1700
RPM
1
4
POWER AUTO
1
2
3
4
5
6
7
8
ESC
3
2 FG000557
Figure 12
Selector Buttons 1.
Up Arrow Button
2.
Down Arrow Button
3.
Enter Button
4.
Escape Button
Electrical System Page 32
Graphic Display Area 5.
Letter Information Display Department
SP001038
Main Menus for the Graphic Display Area 1.
Main menu: Language setting, Time setting, Filter/Oil information, Brightness adjustment, Password
2.
Special menu: Information of machine status, failure information, Information of machine operation.
Menu Selector Buttons 1.
Up Arrow Button ( , 1 on Figure 12): Move the cursor to up, left and previous screen.
2.
Down Arrow Button ( , 2 on Figure 12): Move the cursor to down, right and next screen.
3.
Enter Button ( , 3 on Figure 12): Move the menu to selected mode. When setting the menu, this button is used to function as the selector button.
4.
Escape Button (ESC, 4 on Figure 12): Move a screen to previous menu or main menu.
Electrical System
SP001038 Page 33
MAIN MENU When the "ESC" button is pressed for more than 3 seconds, the main menu screen is displayed.
MAIN MENU 1. Language 2. Set Clock 3. Filter / Oil Info 4. Adjust Display 5. Set Password
Main menu offers sub-menus (language setting, time setting, or filter/oil information, brightness adjustment, password) to the operator. Refer to the "Operation and Maintenance Manual" for details.
: UP
: DOWN
: SELECT FG000072
Figure 13
Language
MAIN MENU 1. Language 2. Set Clock 3. Filter / Oil Info 4. Adjust Display 5. Set Password
Put the cursor on Language in the main menu and put the Enter Button ( , 3 on Figure 12) and the language select view appears. The default language is Korean, but it will memorize and use the newly set language. Use the Up Arrow Button ( , 1 on Figure 12) or Down Arrow Button ( , 2 on Figure 12) to move cursor to a language to be selected on the Language Select display and press the Enter Button ( , 3 on Figure 12) and the selected language is indicated in the right bottom of the screen.
: UP
: DOWN
: SELECT FG000072
Figure 14
At this point pressing the Enter Button ( , 3 on Figure 12) or the Escape Button (ESC, 4 on Figure 12) more than 1 second brings the main menu with changed language and then pressing the ESC button again shows the default view.
LANGUAGE 1. Korean 2. English
Without pressing a button more than 20 seconds, the default view appears.
: UP
: DOWN
: SELECT FG000783
Figure 15
Electrical System Page 34
SP001038
Set Clock
MAIN MENU 1. Language 2. Set Clock 3. Filter / Oil Info 4. Adjust Display 5. Set Password
It is used to adjust time of the digital clock. Pressing the Enter Button ( , 3 on Figure 12) in the Main Menu after putting cursor on Set Clock brings Set Clock display. Without pressing a button more than 20 seconds, the default view appears. Please refer to the Operation Manual for detailed information on Time Setting.
: UP
: DOWN
: SELECT FG000075
Figure 16
SET CLOCK
06:05 2004 06/29 :
+
:
: MOVE FG000076
Figure 17
Filter/Oil Info
MAIN MENU 1. Language 2. Set Clock 3. Filter / Oil Info 4. Adjust Display 5. Set Password
This mode displays total operating hours of filters and oils. After changing the filter and oil, reset the operating hour and then the operating hours until the next service interval can be easily checked.
: UP
: DOWN
: SELECT FG000077
Figure 18
FILTER / OIL INFO
1. Fuel Filter Hrs : 0025 : UP
: DOWN
: RESET FG000078
Figure 19
Electrical System
SP001038 Page 35
Menu Display Order and Icon Explanation
1. Fuel Filter
2. Air Cleaner
3. Engine Oil Filter
4. Hyd. Oil Filter
5. Pilot Filter
6. Engine Oil
7. Hydraulic Oil
8. Coolant Water FG001358
Figure 20
Adjust Display
MAIN MENU 1. Language 2. Set Clock 3. Filter / Oil Info 4. Adjust Display 5. Set Password
Pressing the Enter Button ( , 3 on Figure 12) in the main menu after putting cursor on Adjust Display brings Adjust Display. Screen brightness can be adjusted using the Up Arrow Button ( , 1 on Figure 12) or the Down Arrow Button ( , 2 on Figure 12). The default brightness is set to 50%.
: UP
: DOWN
: SELECT FG000080
Figure 21
Adjust Display 50% + LCD TEST LCD TEST LCD TEST :
+
: FG000081
Figure 22
Electrical System Page 36
SP001038
Set Password
MAIN MENU 1. Language 2. Set Clock 3. Filter / Oil Info 4. Adjust Display 5. Set Password
This menu is used to apply (lock), release, or change password. Please refer to the Operation Manual for detailed information on Password Setting.
: UP
: DOWN
: SELECT FG000227
Figure 23
Electrical System
SP001038 Page 37
SPECIAL MENU In this menu, many types of operating conditions and functions can be accessed and displayed, including the e-EPOS controller. This menu is mainly used for machine testing and failure diagnostics. The special menu offers three sub-menus: 1.
Machine status.
2.
Failure information.
3.
Information on machine operation.
Entering/Accessing and Exiting/Escaping Menus Entering/Accessing Menus When normal mode screen is displayed, if the enter button ( , 3) and escape button (ESC, 4) are pressed simultaneously for more than 3 seconds, normal mode screen (Figure 25) will be changed to special menu screen (Figure 26).
1
4
POWER AUTO
1
2
3
4
5
6
7
8
2
FG001402
ESC
3
Figure 24 Normal Mode Screen NOTE:
Normal mode screen can display many kinds of display mode by selecting, for example, engine speed (RPM), battery voltage (VOLT), front pump pressure (BAR), rear pump pressure (BAR) and so on by selecting.
02/05 [MO] 11:30
E
C
H
E/G SPEED
F
C
1700
H
RPM FG000043
Figure 25
Electrical System Page 38
SP001038
Special Menu Screen NOTE:
Displayed language on the special menu screen consists of Korean and English.
SPECIAL MENU
1. Machine Info
If any language except for Korean is selected during language selection mode of main menu, only English will be displayed on special menu screen.
2. Failure Info 3. Operating Hrs : UP
: DOWN
: SELECT FG000558
Figure 26 Exiting/Escaping Menus 1.
If escape button (ESC, 4 on Figure 24) is pressed for more than 1 second, the special menu screen will be returned to the normal mode screen.
2.
If this special menu is "ON" without any activity, for more than 20 seconds, it will turn to the normal mode screen.
3.
After the turning starter switch to the "OFF" position, turn it back to the "ON" position, and the normal mode screen displayed once again.
Special Menu Selections Submenu Selection Method Various sub-menus can be selected by pressing "Up ( Figure 24)" and "Down ( , 2 on Figure 24)" button.
SPECIAL MENU
, 1 on
1. Machine Info
Move the cursor to desired menu and a selected menu will be inverse displayed.
2. Failure Info
When the selected menu is inverse displayed, press the "Enter ( , 3 on Figure 24)" button for menu selection.
3. Operating Hrs : UP
: DOWN
: SELECT FG000558
Figure 27
Information of Machine Status 1.
2.
Entering Sub-menus: When cursor is located on "Machine Info" of special menu screen, press "Enter ( , 3 on Figure 24)" button and the "Machine Info" will be displayed. Exiting Sub-menus: If escape button (ESC, 4 on Figure 24) is pressed for more than 1 second, display will be turned to previous screen.
MACHINE INFO 1. Analogue Input State 2. Digital Input State 3. Digital Output State : UP
: DOWN
: SELECT FG000559
Figure 28
Electrical System
SP001038 Page 39
Analog Inputs Description Analog Input Items
Display
Remark
1. Pump P/V
mA
Current in pump proportional valve.
2. Cooling Fan P/V
mA
N.A.
3. Flow Control P/V
mA
N.A.
4. Dial
mV
Indicating dial voltage.
5. TPS
mV
N.A.
6. E/G Control Motor
mV
N.A.
7. Boom Pressure
BAR
Boom cylinder head pressure.
8. Pilot Gear Pump Press
BAR
N.A.
9. Boost Pressure
BAR
Pump pressure for boost.
10. Intake Manifold Temperature
°C
Temperature of air incoming to intake manifold.
11. E/G Oil Pressure
BAR
Engine oil pressure.
12. Fuel Temperature
°C
Fuel temperature.
13. E/G Oil Temperature
°C
Engine oil temperature.
14. Load At Cur. Spd
%
Current load ratio of equipment.
Submenu Selections
ANALOG INPUT STATE 1. Pump P/V 2. Cooling Fan P/V 3. Flow Control P/V 4. Dial 5. TPS 6. E/G Control Motor : UP
: DOWN
ANALOG INPUT STATE : 000BAR 7. Boom Pressure 8. Pilot Gear Pump Press. : N.A 9. Boost Pressure : 000BAR 10. Intake Manifold Temp. : 000 C 11. E/G Oil Pressure : 000BAR : 000 C 12. Fuel Temp.
: 000mA : N.A : 000mA : 000mV : 000mA : N.A Page:1/3
: UP
: DOWN
Page:2/3
ANALOG INPUT STATE 13. E/G Oil Temp. 14. Load at Cur. Spd
: UP
: DOWN
: 000 C : 000 %
Page:3/3 FG008126
Figure 29
Electrical System Page 40
SP001038
Digital Inputs Descriptions Digital Inputs Items
Mark
Remark Lights up when output at alternator "R(I)" terminal is above 12 ±1V.
1. Alternator 2. Travel Select SW
N.A. (only for wheel type equipment)
3. High Speed Sel. SW (M)
Lights up when the travel speed selector switch is set to the "I" position.
4. High Speed Sel. SW (A)
Lights up when the travel speed selector switch is set to the "II" position.
5. Pressure SW (Py)
Lights up when the pressure switch (Py) is "ON."
6. Pressure SW (Px)
Lights up when the pressure switch (Px) is "ON."
7. E/G Oil Press. SW
N.A. (only for mechanical engine)
8. Air Cleaner Clogged
Lights up when the air cleaner indicator contact is "ON."
9. Return Filter Clogged
Lights up when the return filter pressure switch is "ON."
10. Pilot Filter Clogged
Lights up when the pilot filter pressure switch is "ON."
11. OWD Warning SW
Lights up when the overload warning selector switch is "ON."
ON / OFF
12. Brake Oil Press. SW
N.A. (only for wheel type equipment)
13. Pedal Press. SW
Lights up when the pedal pressure switch is ON.
14. One Way Sel. SW
Lights up when the selector switch is turned to breaker.
15. Two-way Sel. SW
Lights up when the Selector Switch is turned to "SHEAR."
16. Power Max. SW
Lights up when the boost button is "ON" with the Select switch turned to "BOOST."
17. Breaker SW
Lights up when the boost button is "ON" with the selector switch turned to "BREAKER."
18. Preheat Select
N.A.
19. Quick Coupler
Lights up when the Quick Coupler switch is "ON."
20. F and R Lever
N.A. (only for wheel type equipment)
21. Preheat Select
Lights up during preheating (CN5-2) terminal voltage is below 2V.
22. Reverse Fan SW
N.A.
23. Pilot Cutoff SW
N.A.
Electrical System
SP001038 Page 41
Menu Select
DIGITAL INPUT STATE 1. Alternator : 2. Travel Select SW : 3. High Speed Sel. SW (M) : 4. High Speed Sel. SW (A) : 5. Pressure SW (Py) : 6. Pressure SW (Px) : : UP
: DOWN
Page:1/4
DIGITAL INPUT STATE 19. 20. 21. 22. 23.
Quick Coupler F&R Lever Preheat Select Reverse Fan SW Pilot Cutoff SW
: UP
: DOWN
: : : : : N.A
Page:4/4
DIGITAL INPUT STATE 7. E/G Oil Press. SW 8. Air Cleaner Clogged 9. Return Filter Clogged 10. Pilot Filter Clogged 11. OWD Warning SW 12. Brake Oil Press. SW : UP
: DOWN
: N.A : : : : : N.A Page:2/4
DIGITAL INPUT STATE 13. 14. 15. 16. 17. 18.
Pedal Press. SW One Way Sel. SW Two Way Sel. SW Power Max. SW Breaker SW Preheat Select
: UP
: DOWN
: : : : : : N.A Page:3/4 FG008136
Figure 30
Electrical System Page 42
SP001038
Digital Outputs Descriptions Digital Outputs Items
Mark
Remark
1. Relief Press. Up S/V
Lights up when the relief press up solenoid valve is "ON."
2. High Speed S/V
Lights up when the high speed solenoid valve is "ON."
3. Swing Priority S/V
ON / OFF
Lights up when the swing priority solenoid valve is "ON."
4. Reverse Fan S/V
N.A.
5. Starter Relay
When the starter relay is "ON."
6. After Heat Relay
N.A.
Menu Select
DIGITAL OUTPUT STATE 1. Relief Press. Up S/V 2. High Speed S/V 3. Swing Priority S/V 4. Reverse Fan S/V 5. Starter Relay 6. Afterheat Relay : UP
: DOWN
: : : : N.A : : N.A Page:1/1 FG003930
Figure 31
Failure Information 1.
2.
SPECIAL MENU
Entering Sub-menus: When a cursor is located in "Failure Info" of special menu screen press enter button ( , 3 on Figure 24) and "Failure Info" screen is displayed.
1. Machine Info 2. Failure Info
Exiting Sub-menus: If escape button (ESC, 4 on Figure 24) is pressed for more than 1 second, this information screen will be returned to previous screen.
3. Operating Hrs : UP
: DOWN
: SELECT FG000563
Figure 32 * Real-time Failure: Current status of failure is displayed.
FA I L U R E I N F O
* Failure Log: Memorized record of past failure is displayed.
1. Realtime Fail
* Delete Fail Log: This mode is used to delete all of the memorized record of past failure.
2. Failure Log 3. Delete Fail Log : UP
: DOWN
: SELECT FG000564
Figure 33
Electrical System
SP001038 Page 43
A.
Current failure information Current status of failure is displayed (Failure code, failure contents). When a number of failures are produced, failure information can be checked using "UP" ( , 1 on Figure 24) or "DOWN" ( , 2 on Figure 24) button. * 1/2: A serial number of current failure/ total quantity of failure. * Vxxx-xx: Vxxx is a unique code and xx is a FMI (Failure Mode Identifier) number.
R E A LT I M E FA I L 1/2 2/2
CODE : V204-05 CODE : E011-04
Relief Pressure Up S/V Current below normal (CURRENT BELOW NORMAL or open circuit) : UP
: DOWN FG000565
Figure 34
- V: Machine related failure code - E: Engine related failure code Refer to the failure information code for unique codes and FMI numbers. This example shows one of two failures. B.
Past failure information Memorized record of past failure is displayed (Failure code, failure contents). When a number of failures are produced, failure information can be checked using "UP" ( , 1 on Figure 24) or "DOWN" ( , 2 on Figure 24) button. NOTE:
" Number: xxx ": "xxx" means that the totally counted number of the same failure. " Period:xxxxxHrxxm ": It indicates the period for which machine has operated until a failure takes place. (For more than two occurrences of the same failure, until the first occurrence time.)
C.
FA I L U R E L O G 1/2 CODE : V204-05 2/2 CODE : E011-04 Period:00254Hr 29m Number:08 Relief Pressure Up S/V Current below normal (CURRENT BELOW NORMAL or open circuit) : UP
: DOWN FG000566
Figure 35
Failure record deletion This mode is used to delete the memorized record of past failure. If this mode is selected, all records will be deleted.
DELETE FAIL LOG All Fail Log will be DELETED.
When "YES" ( , 3 on Figure 24) button is pressed, the memorized record will be deleted. At this time, deletion signal will be displayed and the screen will move to previous menu after deletion.
: Yes
This screen will be displayed during 3 seconds.
ESC: No FG000567
Figure 36
Electrical System Page 44
SP001038
Input your password with one of No. 1 - 8 switches. When "NO" (ESC, 4 on Figure 24) button is pressed, the screen will recover to previous menu without deletion.
DELETE FAIL LOG ENTER PASSWD
: Yes
ESC: No FG000568
Figure 37 Delete Completed screen will appear 3 seconds and the screen will move to Failure Info screen.
DELETE FAIL LOG
It has been shown 3 seconds upon deleting Fail Log.
DELETED!!!
: Yes
ESC: No FG000569
Figure 38 The screen shown on the left will appear 3 seconds in case of wrong password input and then Enter Password screen appears again.
DELETE FAIL LOG
It has been shown 3 seconds in case of password failure.
PASSWORD ERR !!!
: Yes
ESC: No FG000570
Figure 39
Electrical System
SP001038 Page 45
Failure Information Code at Machine Side Code
Failure Component
V201
Gauge Communication Error
V202
Ecu Communication Error
V210
Pump P/V
V211
Cooling Fan P/V
V212
V213
V214
Panel
Flow Control P/V
Relief Pressure Up S/V
High Speed S/V
V215
Swing Priority S/V
V216
Reverse Fan Speed S/V
V217
Starter Relay
V218
After Heat Relay
Electrical System Page 46
Measuring Points CN7-4 CN7-5
CN4-4 CN4-5
CN1-10 CN1-21
Correct Value Active
Passive
-
R 60 ±5 :
-
R 60 ±5 :
-
CN1-19 CN1-20
CN1-1 CN1-11
CN1-1 CN1-12
CN1-1 CN1-13
-
V = V_volt (Note 4.)
V = V_volt
V = V_volt
CN1-15
R 14 ±2 : (25°C (77°F))
R 26.2 ±2 : (25°C (77°F))
R 26.2 ±2 : (25°C (77°F))
R 26.2 ±2 : (25°C (77°F))
It is a composite resistance of CAN line. This value has to be measured by connected condition of CAN line. Pump proportional pressure reducing valve. N.A. Flow control proportional pressure reducing valve. Breaker/boost/ shear selector switch has to be selected as a boost function and the boost switch on the right-hand joystick is "ON" status. Voltage is only measured when the pressure switch (Py) is turned "ON." Work mode has to be selected as a trenching mode.
-
N.A.
V = V_volt
-
It has to be measured in engine start up state.
-
-
N.A.
CN1-1
R 18 ±2 : (25°C (77°F))
Remarks
SP001038
Code
Failure Component
V220
Front Pump Press. Sensor
V221
Rear Pump Press. Sensor
Measuring Points CN3-1 CN3-2 CN3-3 CN3-4
Correct Value Active
Passive
V = IV
-
V = IV
-
-
R 2.45 r25 k: (25°C (77°F))
R 320 ±32 : (80°C (176°F))
CN3-9
Remarks It has to be measured in engine stop state.
V222
Hyd. Oil Temperature Sensor
V223 V224
Water Temperature Sensor
-
-
N.A.
Engine Speed Sensor
-
-
N.A.
V225
V226
Fuel Level Sensor
Alternator Potential
CN3-7
-
CN3-8
CN2-14 CN1-8
V = 2 ±1V
CN3-16
Empty: 5 r25 k: Full: 320 ±32 : R 1.0 r3 k:
It has to be measured in engine stop state.
-
R 4.0 ±1.5 k:
Tps (Wheel)
-
-
N.A.
Parking Brake Press. Sensor
-
-
N.A.
E/g Control Motor Sensor
-
-
N.A.
V227
Dial
V228 V229 V230 NOTE:
CN3-10
CN3-7
1. Active value: Starter switch has to be turned "ON" Measuring points between component and wire harness have to be connected. 2. Passive value: Starter switch has to be turned "OFF" Measuring points between component and wire harness have to be disconnected. 3. Measuring points are engine controller's points and passive value is each component's value. 4. V#batt: Source power of equipment.
Electrical System
SP001038 Page 47
Failure Information Code at Engine Side Code
Failure Component
E011
Coolant temperature sensor
E012
Fuel temperature sensor
E013
Boost air temperature sensor
Measuring Points
Current Valve Active
2-26 2-15 2-26 2-35
-
-
2-36
E014
Boost air pressure sensor
E017
E/G oil temperature sensor
2-25 2-33 2-34
V 1,071 ±58mV (at 23°C (73°F) and absolute pressure 1bar)
2-28
E018
E/G oil pressure sensor
E021
Battery voltage
2-24 2-32 2-27 1-03 1-06
E022
Fuel pressure sensor
E032
Fuel pressure MPROP
monitoring
3-09 3-10 2-14 2-12
1-53 and 1-52
V 2,318 ±80mV (at 23°C (73°F) and absolute pressure 3bar) V = V#volt (Note 4.)
V 1,833 ±28mV (at 23°C (73°F) and absolute pressure 300bar) -
Passive
R 186 ±5 : (100°C (212°F)) R 186 ±5 : (100°C (212°F)) R 186 ±5 : (100°C (212°F)) R 186 ±5 : (100°C (212°F)) -
-
R 60 ±5 : (20°C (68°F))
E038 E039
Engine overspeed
-
-
Main relay (ECU)
-
-
E041
Redundant shutoff path
-
-
E042
E/G speed (Crankshaft)
E043
E/G speed (Camshaft)
Electrical System Page 48
2-23 2-19 2-09 2-10
-
It has to be measured in engine running state.
It has to be measured in engine running state.
R 2.60 ±3.15 : (20°C (68°F))
CAN module
-
It has to be measured in engine running state.
-
E037
1-35 and 1-34
Remarks
R 860 ±6 : (20°C (68°F))
It is a composite resistance of CAN line. This value has to be measured by connected condition of CAN line.
Abnormal engine stop.
-
SP001038
Code
Failure Component
Measuring Points
Current Valve Active
Passive
Remarks
E044
Engine speed sensor
-
-
Synchronizing error between crank shaft speed sensor and cam shaft speed sensor.
E045
EEPROM
-
-
Data storing error when engine stop.
E046
Recovery
-
-
E047
Monitoring of PRV
E048
Power supply
E049
-
-
V = V#volt
-
Booster voltage C1
-
-
E051
Booster voltage C2 ($6, 2 and 4)
-
-
E058
Solenoid power stage 1
-
R 0.31 ±0.42 : (20°C (68°F))
E059
Solenoid power stage 2
-
-
E061
Solenoid power stage 3
-
-
E062
Solenoid power stage 4
-
-
E063
Solenoid power stage 5
-
-
E064
Solenoid power stage 6
-
-
E066
Preheat light (E/G: Lowside Power stage 2)
-
-
E072
Preheat relay (E/G: Highside Power stage 1)
Electrical System
1-03 1-06
3-13 3-04 3-11 3-06 3-05 3-12 3-03 3-14 3-01 3-16 3-02 3-15 1-56 1-06
1-13 1-07
V = V#volt
R 40 ±5 : (25°C (77°F))
When the pressure sensor of common rail or high-pressure pump has a defect.
Voltage is only measured when afterheat function is operating status.
SP001038 Page 49
Measuring Points
Code
Failure Component
E083
Fuel HI pressure pump (E/G: Current controlled Highside power stage 1)
E091
System start-up shutoff path
test
for
Current Valve Active
-
-
-
-
Passive -
-
Remarks Fuel metering unit error of high-pressure pump. Power supply error Engine controller error. Injector error
E092
Monitoring of misfire cylinder 1
-
-
-
E093
Monitoring of misfire cylinder 2
-
-
-
E094
Monitoring of misfire cylinder 3
-
-
-
E095
Monitoring of misfire cylinder 4
-
-
-
E096
Monitoring of misfire cylinder 5
-
-
-
E097
Monitoring of misfire cylinder 6
-
-
-
E098
Monitoring of misfire multiple cylinder
-
-
-
E099 E101
Monitoring of overrun
-
-
-
Engine speed redundant
-
-
-
NOTE:
Speed signal error of cam shaft speed sensor or crank shaft speed sensor.
1. Active value: Starter switch has to be turned "ON" Measuring points between component and wire harness have to be connected. 2. Passive value: Starter switch has to be turned "OFF" Measuring points between component and wire harness have to be disconnected. 3. Measuring points are engine controller's points and passive value is each component's value. 4. V#batt: Source power of equipment.
Electrical System Page 50
SP001038
FMIs (Failure Mode Identifier) FMI 0
Above normal range (DATA VALID but ABOVE NORMAL OPERATIONAL RANGE)
FMI 1
Below normal range (DATA VALID but BELOW NORMAL OPERATIONAL RANGE)
FMI 2
Incorrect signal (DATA ERRATIC, INTERMITTENT OR INCORRECT)
FMI 3
Voltage above normal (VOLTAGE ABOVE NORMAL OR SHORTED TO HIGH SOURCE)
FMI 4
Voltage below normal (VOLTAGE BELOW NORMAL OR SHORTED TO LOW SOURCE)
FMI 5
Current below normal (CURRENT BELOW NORMAL OR OPEN CIRCUIT)
FMI 6
Current above normal (CURRENT ABOVE NORMAL OR GROUNDED CIRCUIT)
FMI 8
Abnormal signal (ABNORMAL FREQUENCY OR PULSE WIDTH OR PERIOD)
FMI 11
Failure mode not identifiable (ROOT CAUSE NOT KNOWN - Malfunction)
FMI 31
NOT AVAILABLE OR CONDITION EXISTS
Information of Machine Operation Accumulated operation hour of each mode and status is displayed. 1.
Operating Hour Information A.
S P E CIA L ME NU
Entering Sub-menus: When a cursor is located in "Operating Hrs" of special menu screen (Figure 40) press enter button ( , 3 on Figure 24) and "Operating Hrs" screen will be displayed (Figure 41).
1. Machine Info 2. Failure Info 3. Operating Hrs : UP
: DOWN
: SELECT FG000571
Figure 40 B.
Information screen of machine operation (Figure 41).
OPERATING HOURS Operating Hours Reset Hours
: UP
: DOWN
: SELECT FG000572
Figure 41
Electrical System
SP001038 Page 51
C.
Operating Hours Screen
D.
Exiting Sub-menus: If escape button (ESC, 4 on Figure 24) is pressed for more than 1 second, this information screen will be returned to previous screen.
OPERATING HOURS 1. Power 2. Trenching 3. Auto idle 4. Travel speed I speed II speed : UP
: DOWN
: 00042 Hr : 00003 Hr : 00005 Hr : 00007 Hr : 00001 Hr : SELECT FG000573
Figure 42 Information contents of operation hour Information Contents
Detection Method
Power Mode
Item
Operation hours used power mode are displayed.
Power mode switch (Instrument panel) "ON" status and Alternator signal (CN2-14) is "HI"
Trenching Mode
Operation hours used trenching mode are displayed.
Trenching mode switch (Instrument panel) - "ON" status and Alternator signal (CN2-14) is "HI"
Auto Idle
Operation hours used auto idle status are displayed.
Auto idle switch (Instrument panel) "ON" status and Alternator signal (CN2-14) is "HI"
Travel Speed:
Operation hours used low speed and high speed are displayed.
1st: High speed s/v "OFF" status
Temperature of hydraulic oil is classified 6 steps. And operation hours of each step are displayed
The resistance delivered from temperature sensor of hydraulic oil is classified 6 steps. And operation hours of each step are displayed. (Alternator output HI status)
-1st - 2nd Hydraulic Oil Temperature Distribution (°C (°F))
Under 30°C (87°F) 31 - 50°C (88 - 123°F) 51 - 75°C (124 - 168°F) 76 - 85°C (169 - 186°F) 86 - 95°C (187 - 203°F) Over 96°C (204°F) Coolant Temperature Distribution (°C (°F))
Temperature of coolant is classified 6 steps. And operation hours of each step are displayed. Under 40°C (105°F) 41 - 60°C (106 - 141°F) 61 - 85°C (142 - 186°F) 86 - 95°C (187 - 204°F) 96 - 105°C (205 - 222°F) Over 106°C (223°F)
Electrical System Page 52
2nd: High speed s/v and travel pressure switch "Py" (control valve) - "ON" status.
The resistance delivered from coolant sensor is classified 6 steps. And operation hours of each step are displayed. (Alternator output HI status)
SP001038
Menu Selection of Operation Hour Information
3. Auto Idle
2. Trenching Mode
1. Power Mode
6. Coolant Temperature Distribution
4. Travel Speed 1st, 2nd
5. Hydraulic Oil Temperature Distribution FG000574
Figure 43 Example of Machine Operation Info Screen
OPERATING HOURS
OPERATING HOURS
1. Power 2. Trenching 3. Auto idle 4. Travel speed I Speed II Speed
5. Hyd. Oil Temp. [ C] : 00003 Hr 30 31 - 50 : 00005 Hr 51 - 75 : 00008 Hr 76 - 85 : 00000 Hr 86 - 95 : 00007 Hr : 00001 Hr 96
: UP
: DOWN
: 00042 Hr : 00003 Hr : 00005 Hr : 00007 Hr : 00001 Hr Page:1/3
: UP
: DOWN
Page:2/3
OPERATING HOURS 6. Coolant Temp. [ C] 40 : 00003 Hr 41 - 60 : 00005 Hr 61 - 85 : 00000 Hr 86 - 95 : 00000 Hr 96 - 105 : 00007 Hr 106 : 00001 Hr : UP
: DOWN
Page:3/3 FG000575
Figure 44 2.
Operation hour reset A.
Entering Sub-menus: When cursor is located in "Reset Hrs" of information screen of operating hours press enter button ( , 3 on Figure 24) and "Machine Operation Info" screen will be displayed.
OPERATING HOURS Operating Hrs Reset Hrs
: UP
: DOWN
: Yes FG000578
Figure 45
Electrical System
SP001038 Page 53
B.
Reset screen of operation hour
C.
Exiting Sub-menus: If escape button (ESC, 4 on Figure 24) is pressed for more than 1 second, this information screen will be returned to previous screen.
NOTE:
NOTE:
OPERATING HOURS All Operating Hours will be DELETED.
When "YES" ( , 3 on Figure 24) button is pressed, operation hours will reset. At this time, resetting signal will be displayed and the screen will move to previous menu after resetting. When "NO" (ESC, 4) button is pressed, the screen will recover to previous menu without resetting.
: Yes
ESC: No FG000579
Figure 46
Machine Operation Info Screen 1.
If you press the YES" ( , 3 on Figure 24) button, password entrance screen appears.
OPERATING HOURS ENTER PASSWD
: Yes
ESC: No FG000576
Figure 47 2.
When right password is input, machine operation periods will be deleted and Reset Completed screen will appear 3 seconds.
OPERATING HOURS
DELETED!!!
: Yes
ESC: No FG000577
Figure 48 3.
If you press the "NO" (ESC, 4) button, the previous screen appears without resetting operation periods.
OPERATING HOURS
PASSWORD ERR !!!
: Yes
ESC: No FG001086
Figure 49
Electrical System Page 54
SP001038
Electrical System
SP001038 Page 55
ELECTRONIC HYDRAULIC CONTROL SYSTEM (e-EPOS) Control System Schematic
16 6
6 7
7
8
11
12
14
8
13 15
E/G
4
4
5
3 9
10 Work Mode Auto Idle Machine Info
2 CHECK
E/G speed order
02/05 [MO] 11:30
F
E
C
C
H
E/G SPEED
23
H
1700
RPM
POWER AUTO
1
2
3
4
5
6
7
8
ESC
R UP
WE
PO
1 17
21 19
18
22
20 FG000795
Figure 50
Electrical System Page 56
SP001038
Reference Number
Description
Reference Number
Description
1
Instrument Panel
12
Solenoid Valve (Swing Priority)
2
e-EPOS Controller
13
Solenoid Valve (High Speed)
3
Engine Controller (ECU)
14
Solenoid Valve (Breaker)
4
Main Pump
15
Travel Motor
5
Aux Pump
16
Main Relief Valve
6
Control Valve
17
Engine Control Dial
7
Pressure Switch
8
Pump Pressure Sensor
18
Breaker/Boost/Shear Selector Switch
19
Auto Travel Selector Switch
9
Electromagnetic Proportional Pressure Reducing Valve (Attachment)
20
Boost Switch (Right Work Lever)
Electromagnetic Proportional Pressure Reducing Valve (Mode Control)
21
Sensor
10
22
Aux Mode Switch
11
Solenoid Valve (Boost)
23
Aux Mode Resistor
Electrical System
SP001038 Page 57
POWER MODE CONTROL
6
6
E/G
5 4
4 3
10
2 1 POWER AUTO
17 23
1
2
3
4
5
6
7
8
ESC
22 FG000796
Figure 51 Reference Number
Description
1
Instrument Panel (Power Mode Selector Switch)
2
e-EPOS Controller
3
Reference Number
Description
10
Electromagnetic Proportional Pressure Reducing Valve (Mode Control)
Engine Controller (ECU)
17
Engine Control Dial
4
Main Pump
22
Aux Mode Switch
5
Aux Pump
23
Aux Mode Resistor
6
Control Valve
Electrical System Page 58
SP001038
The power mode switch permits the selection of the appropriate engine power depending on the working condition. One of the two, Power Mode or Standard Mode, setting can be selected. When the engine starter switch is turned "ON," the power mode is automatically defaulted to standard mode. The desired mode can be selected by pressing the selector button on the instrument panel. When the power mode is selected, the indicator light will turn "ON" to display the selected mode. The quantity of oil discharged by the pump and the engine speed are determined by the mode selected by the operator. The pump output in each mode is determined by the mode selection and is listed in the following table Mode
Standard Mode
Power Mode
Output (%)
Approximately 85%
100%
Electrical System
SP001038 Page 59
Operation 1.
Power Mode This mode should be selected for high speed work. In this mode the engine output is most efficiently utilized due to the discharged oil volume being controlled based on the equivalent horsepower curve at various loaded pressures. The e-EPOS controller compares the target engine speed with the actual engine speed and controls the signal to the E.P.P.R. (Electromagnetic Proportional Pressure Reducing) valve which in turn varies the pump output quantity. If the load increases, the engine speed will fall below the rated speed. When this occurs, the controller senses this decrease and immediately reduces the pump discharge volume to maintain the engine speed at the rated level.
ARO0260L
Figure 52
On the other hand, if the load is decreased the controller increases the discharge volume of the pump to maintain the engine speed at the rated level. By repeating these control operations, the engine speed is maintained at the rated speed so that maximum power can be generated. In Power Mode, the e-EPOS controller receives engine speed signals from the engine control dial and the engine controller (ECU) and converts it to an operating signal current and is then transferred to the pump's E.P.P.R valve. At this time the E.P.P.R. valve converts the electric signal to the corresponding control pressure and sends it to the two pumps, adjusting the pump discharge volume to the desired level.
A
C
B
D FG000580
Figure 53 Reference Number
Description
Reference Number
A
Engine Horsepower (hp)
D
B
Engine Speed (rpm)
C
Pump Discharge Volume (lpm)
Electrical System Page 60
Description Pump Discharge Pressure (kg/cm2)
SP001038
2.
Standard Mode Standard Mode is used for general work. When this mode is selected it will reduce noise and fuel consumption in comparison with Power Mode. The current to the E.P.P.R. valve is shut off and pump discharge volume is controlled by pump regulator.
A
C
B
D FG000581
Figure 54 Reference Number
Description
Reference Number
A
Engine Horsepower (hp)
D
B
Engine Speed (rpm)
C
Pump Discharge Volume (lpm)
Description Pump Discharge Pressure (kg/cm2)
3) Operation in case of failure in the control system (Aux mode operation Though it is impossible to control current of the E.P.P.R (Electromagnetic Proportional Pressure Reducing) Valve controlling the discharge volume of pump due to fault in control system, the machine can be operated in the aux mode. Upon turning "ON" the aux mode switch, the E.P.P.R Valve controlling the discharge volume of pump comes into contact with the aux mode resistor to let current of a certain value flow. At this time, the discharge volume of pump follow the control by the pump regulator, nearly at quantity roughly similar to that in the standard mode.
Electrical System
SP001038 Page 61
POWER MODE CONTROL CIRCUIT DIAGRAM 1 15A
CN6-1 CN6-2
26 4
CN6-9
26
26
15A
10A
25
CN6-10 CN1-1 CN7-4
CN4-4
CN7-5
CN4-5
CN7-6
CN4-6
CN1-2 CAN
CN1-8
11
CN1-9
3
24
23 1-35
22
1-34 1-33
5
1-52
3
CN1-21
1-51
(CONN.1)
P/V-(A)
2
1-53 VEHICLE CONN
10
1
CN1-10
6
4
1-05
17
1-06
CN3-15
1
SIG
CN3-16
2
GND
CN3-17
3
+(5V)
1-10 1-11
CW LOW
HIGH
1-02 1-03 1-08
15A
26
10A
26
1-09 BR
1-40
B
28 AMP 070 16P
AMP 040 12P
8 8
7
6
5
4
3
16 15 14 13 12
2
11 10
1
6
5 4
3
2
1
10 9
12 11 10 9
8
7
20 19 18 17 16 15 14 13 12 11
6
5 4
3
2
7
6
5
4
2
1
10
11 10
9
21 20
3
9
8
7
6
12
18 17 16
15 14 13 12
5
19 18 17
16
11
1
11
AMP 040 28P 3
2
1
12 11 10 9
8
7
6
35
36
53
54
71 72
2
12
(CN1)
5 4
(CN7) 6
4
(CN3)
(ECU CONNECTOR)
18
17
3
15 14 13
1
(CN2) (CN4)
VEHICLE CONN.
1
7
9
(CN5)
7
8
AMP MIC 21P
AMP 070 18P
AMP 040 20P
8
7
6
2
1
16 15 14 13 12 11 10
5
4
3
9
(CN6)
89
ECU CON.1 (89-PIN)
FG008165
Figure 55
Electrical System Page 62
SP001038
Reference Number
Description
Reference Number
Description
1
Instrument Panel
23
Aux Mode Resistor
3
Engine Controller
24
Battery
4
e-EPOS Controller
25
Battery Relay
10
E.P.P.R. Valve (Electromagnetic Proportional Pressure Reducing)
26
Fuse
27
Fusible Link
17
Engine Control Dial
28
Starter Switch
22
Aux Mode Switch
Electrical System
SP001038 Page 63
WORK MODE CONTROL
6
6
12
E/G
5
3
4
4
2 1 POWER AUTO
1
2
3
4
5
6
7
8
ESC
17
FG000797
Figure 56 Reference Number
Description
Instrument Panel (Trenching Mode Selector Switch)
5
Aux Pump
6
Control Valve
2
e-EPOS Controller
12
Solenoid Valve
3
Engine Controller
17
Engine Control Dial
4
Main Pump
Reference Number
Description
1
Depending on the working condition, one of two work modes, "DIGGING" or "TRENCHING" can be selected from the instrument panel. When the engine starter switch is turned "ON," the work mode is automatically defaulted to digging mode. Depending on the trenching mode selected, the control valve solenoid adjusts the assignment of hydraulic oil flow to each device on the equipment.
Electrical System Page 64
SP001038
Operation 1.
Digging Mode This mode is used for general digging work, loading work and ground leveling work requiring quick stops. The current to the solenoid valve for swing priority is shut off.
2.
Trenching Mode This mode is used for heavy duty ditch digging work or for loading work requiring big swing angles. The voltage is assigned to the swing priority control valve activating the swing control valve restricting the flow of oil to the boom and the arm.
ARO0270L
Figure 57
Electrical System
SP001038 Page 65
WORK MODE CONTROL CIRCUIT DIAGRAM
1 04@
BM5,0 BM5,1
26 4
26
04@
BM5,8
25
BM5,0/ BM0,0 BM6,3
BM3,3
BM6,4
BM3,4
BM6,5
BM3,5
BM0,1 B@M
24 12 'B4( BM0,02
BM0,7 BM0,8
@LO/6/05O
@LO/3/01O
7 7
6
5
4
3
2
1
0
5
4 3
2
01 00 0/ 8 05 04 03 02 01
00 0/
'BM4(
1 7
0 6
0/ 8 7
6 5
4 3
@LOLHB10O
@LO/6/07O
@LO/3/1/O 2
1
6
5
4
3
2
1
0/
0
8
7
6
5
1/ 08 07 06 05 04 03 02 01 00
8
07 06 05
04 03 02 01
10 1/
4
00 0/ 8
08 07 06
05
'BM1( 'BM3(
2
1
0
04 03 02
3
01
00
0
'BM0(
'BM2( @LO/3/17O 2
1
0
01 00 0/ 8
5
4 3
7
6
'BM6(
1
0
05 04 03 02 01 00 0/
7 6
5 4
3
2
8
'BM5(
FG000583
Figure 58 Reference Number
Description
Reference Number
Description
1
Instrument Panel
24
Battery
2
e-EPOS Controller
25
Battery Relay
12
Solenoid Valve (Swing Priority)
26
Fuse
Electrical System Page 66
SP001038
ENGINE CONTROL SYSTEM
(Drive Signal)
(Command Signal)
FG000584
Figure 59 Reference Number
Description
Reference Number
Description
3
Engine Controller
17
Engine Control Dial
4
e-EPOS Controller
When the engine control dial is moved the output voltage changes according to the dial position. The e-EPOS controller converts this output voltage of dial to digital signal and sends it to the engine controller by CAN line. According to the dial command, the quantity of fuel injection is adjusted.
Electrical System
SP001038 Page 67
ENGINE CONTROL DIAL
7th STEP
1st STEP
CCW MECHANICAL STOP
13th STEP
( 10 )
( 10 )
CW MECHANICAL STOP
1
(V) 5 4.0V
4 3
2.5V
2
2
1.0V 1 SETUP
0 CCW STOP
1ST 2nd
7th
12th 13th
CW STOP
1 2 3
VIEW ( POTENTIOMETER BOTTOM) 1
2
3
FG000866
Figure 60 Reference Number
Description
Reference Number
1
Knob
2
Description Potentiometer (Variable Resistor)
The engine control dial has a built in potentiometer. When the control knob is moved the output voltage (through "2 and 3" terminals) will vary from the 5 V supplied from the e-EPOS controller as shown in the graph.
Electrical System Page 68
SP001038
ENGINE CONTROL CIRCUIT DIAGRAM 1 15A
CN6-1 CN6-2
26 4
CN6-9
26
15A
25
CN6-10 CN1-1 CN7-4
CN4-4
CN7-5
CN4-5
CN7-6
CN4-6
CN1-2 CAN
24
CN1-8
28
CN1-9
3 1-35 1-34 1-33 1-53 1-52 VEHICLE CONN
29
1-51
Py CN2-15
(CONN.1)
1-05
17
1-06
Px
CN3-15
1
SIG
CN3-16
2
GND
CN3-17
3
+(5V)
1-10
CN2-16
1-11
30
1-02
26
1-03 1-08
CW LOW
HIGH
15A
1-09 BR
1-40
10A
B
26
27 AMP 070 16P
AMP 040 12P
8 8
7
6
5
4
3
2
1
6
5 4
3
12 11 10 9 16 15 14 13 12
11 10
7
10 9 8
7 6
5 4
3
2
7
6
5
4
3
2
10
1
9
8
7
6
18 17 16
15 14 13 12
21 20
11 10 9
5
19 18 17
16
(CN2)
12
11
1
11
AMP 040 28P 6
35
36
53
54
71 72
2
12
(CN1)
5 4
3
2
1
12 11 10 9
8
7
(CN7) 6
4
(CN3)
(ECU CONNECTOR)
18
17
3
15 14 13
1
20 19 18 17 16 15 14 13 12 11
(CN4)
VEHICLE CONN.
1
8
1
9
(CN5)
7
2
AMP MIC 21P
AMP 070 18P
AMP 040 20P
2
1
16 15 14 13 12 11 10
8 7
6 5
4
3
9
(CN6)
89
FG008166
ECU CON.1 (89-PIN)
Figure 61
Reference Number
Description
Reference Number
Description
1
Instrument Panel
26
Fuse
3
Engine Controller
27
Starter Switch
4
e-EPOS Controller
28
Fusible Link
17
Engine Control Dial
29
Pressure Switch (Py)
24
Battery
30
Pressure Switch (Px)
25
Battery Relay
Electrical System
SP001038 Page 69
AUTOMATIC DECELERATION CONTROL (AUTO IDLE CONTROL)
E/G
4
3
1 POWER AUTO
1
2
3
4
5
6
7
8
ESC
2
5
5 FG000798
Figure 62 Reference Number
Description
Reference Number
Description
1
Instrument Panel (Auto Idle Switch)
3
Engine Controller
4
Engine Control Dial
2
e-EPOS Controller
5
Pressure Switch
Electrical System Page 70
SP001038
If the machine is idling without the controls being operated or is waiting for a dump truck the engine speed is automatically lowered. Once the controls are operated and work is being started the machine will be restored to the previous settings. As a result, noise and fuel consumption will be reduced. This function can be selected or cancelled through the Auto Idle Selector Switch on the instrument panel. The initial setting at start-up is with this switch in the select position. Approximately 4 seconds after this function is selected, if all work levers are in the neutral position, the e-EPOS controller compares the automatic reduction signal with the signal set by engine control dial. The lower of the two signals is selected, the e-EPOS controller sends a signal to the engine controller to control the engine speed. The neutral status of the machine is detected by the two pressure switches in the control valve. When the work levers are in the neutral position, the switch is in the "OFF" position.
Electrical System
SP001038 Page 71
ENGINE OVERHEAT PROTECTION SYSTEM
6
6
E/G
4
4
5
3 31
7 (Pump control signal)
2 1 (E/G overheating signal) CHECK
02/05 [MO] 11:30
F
E
(E/G overheating signal)
C
C
H
E/G SPEED
H
1700
RPM
POWER AUTO
1
2
3
4
5
6
7
8
ESC
FG000802
Figure 63 Reference Number
Description
Reference Number
Description
1
Instrument Panel
6
Control Valve
2
e-EPOS Controller
10
3
Engine Controller
4
Main Pump
E.P.P.R. Valve (Electromagnetic Proportional Pressure Reducing Valve)
5
Aux Pump
31
Warning Buzzer
Electrical System Page 72
SP001038
When the engine coolant temperature increases to over 107°C (225°F), the engine controller detects it from the sensor mounted in the coolant line and will send a signal to the e-EPOS controller. The e-EPOS controller sends a overheat signal to the instrument panel turning "ON" the warning light and buzzer simultaneously. Also, the e-EPOS controller returns an overheat signal to the engine controller and changes power mode to standard mode. The engine speed is then set to a low speed by the engine controller. When coolant temperature falls below 95°C (203°F), normal operation will resume.
Electrical System
SP001038 Page 73
POWER BOOST MODE Operation
16 6
6 11
E/G
4
4
5
3
2
1
CHECK
02/05 [MO] 11:30
F
E
C
C
H
E/G SPEED
PO
WER
H
1700
RPM
UP
20
POWER AUTO
1
2
3
4
5
6
7
8
ESC
18 FG000800
Figure 64 Reference Number
Description
Reference Number
Description
1
Instrument Panel
11
Solenoid Valve (Boost)
2
e-EPOS Controller
16
Main Relief Valve
3
Engine Controller
4
Main Pump
18
Breaker/Boost/Shear Selector Switch
5
Aux Pump
20
6
Control Valve
Power Boost Switch (Top of Right Work Lever)
Electrical System Page 74
SP001038
The Power Boost function is used to temporarily increase the main relief pressure to enhance excavation ability. When the breaker/boost/shear selector switch is set to "BOOST" and the power boost button on the center of the right-hand work lever (joystick) is pressed during work, the e-EPOS controller will activate the power boost solenoid valve and increase the relief valve pressure from 330 - 350 kg/cm2 (4,700 - 5,000 psi). The excavation ability is increased by approximately 6%. When the power boost function is in activated, a power boost symbol appears on the information display department of instrument panel. NOTE:
Do not use this switch for more than 10 seconds.
Electrical System
SP001038 Page 75
Power Boost Control - Circuit Diagram
1 15A
CN6-1 CN6-2
26 2
CN6-9
26
26
15A
CN6-10 CN4-4
CN7-5
CN4-5
CN7-6
CN4-6
25
18
CN1-1 CN7-4
20A
CN1-2 CAN
PST SHEAR PRESS BREAKER UP
1
TML
0
2
24
9
11
10 3 (C4)
14
CN1-11
13 11 6
(POWER MAX)
CN2-2
16 15 12
CN1-8 CN1-9
6
3
(Center)
(POWER MAX / BREAKER)
20 AMP 070 16P
AMP 040 12P
7
6
5
4
16 15 14 13 12
(CN5)
3
2
11 10
1
6
5 4
8
7
6
5 4
AMP MIC 21P
AMP 070 18P
AMP 040 20P 8
8
3
2
1
10 9
12 11 10 9
8
7
20 19 18 17 16 15 14 13 12 11
3
2
7
6
5
4
2
1
10
11 10
9
21 20
3
9
8
7
6
18 17 16
15 14 13 12
9
5
19 18 17
16
(CN2) (CN4)
3
2
1
15 14 13
4
12
11
1
(CN1)
(CN3) AMP 040 28P 3
2
1
12 11 10 9
6
5 4
8
7
(CN7)
2
1
16 15 14 13 12 11 10
8
7
6
5
4
3
9
(CN6)
FG000586
Figure 65 Reference Number
Description
Reference Number
1
Instrument Panel
20
2
e-EPOS Controller
Power Boost Switch (Top of Right Work Lever)
11
Solenoid Valve (Pressure Up)
24
Battery
18
Breaker/Boost/Shear Selector Switch
25
Battery Relay
26
Fuse
Electrical System Page 76
Description
SP001038
Electrical System
SP001038 Page 77
AUTOMATIC TRAVEL SPEED CONTROL
6
6 7 13
E/G
8 15 4
4
5
3
17
2
19 FG000799
Figure 66 Reference Number
Description
Reference Number
Description
2
e-EPOS Controller
8
Pump Pressure Sensor
3
Engine Controller
13
Solenoid Valve (High speed)
4
Main Pump
15
Travel Motor
5
Aux Pump
17
Engine Control Dial
6
Control Valve
7
Pressure Switch (Py Port)
19
Selector Switch For Automatic Travel
Electrical System Page 78
SP001038
If the automatic travel speed control switch is set to the "OFF" position, the travel motor will run in the I-speed (low speed) range. If the selector switch is set to the "I" position, the travel motor will run in the II-speed (high speed) range. If the selector switch is set to the "II" position, the e-EPOS controller will monitor the main pump discharge pressure and automatically select the "ON" - "OFF" status of the II - speed travel solenoid valve based on the travel load. The travel speed is changed between the I-speed and the II-speed mode. The travel load is monitored by the two pressure sensors in the discharge lines of the front (upper) and rear (lower) pumps. When the travel load is high (pressure over 300 kg/cm2 (4,300 psi) the solenoid valve is turned "OFF" and I-speed (low) is selected. In the case when the travel load is low (pressure under 160 kg/cm2 (2,280 psi), the solenoid valve will be turned "ON" and the II-speed will be selected. But, if the engine speed control switch dial is set below approximately 1400 rpm, the travel speed will be set to I-speed mode.
Electrical System
SP001038 Page 79
Automatic Travel Speed Control - Circuit Diagram
15A
26 2
26
8
26
15A
15A
25
CN1-1 CN1-2
+ CN3-1
SIG
CN3-2
-
13 24
(C3)
+
CN1-12 CN3-3
SIG
CN3-4
-
19
9
CN2-4
3
CN2-5
6
0 I II
2
0 I II
5 8
7
17 CN1-9
AMP 070 16P
CN3-15
1
SIG
CN3-16
2
GND
CN3-17
3
+(5V)
CN1-8
AMP 040 12P
7
6
5
4
3
2
1
6
5 4
3
2
12 11 10 9 16 15 14 13 12
11 10
(CN5)
8
1 7
10 9
8
7
6
5 4
HIGH
AMP MIC 21P
AMP 070 18P
AMP 040 20P 8
8
CW LOW
3
2
7
6
5
4
2
1
10
11 10
9
21 20
3
9
8
7
6
20 19 18 17 16 15 14 13 12 11
9
18 17 16
15 14 13 12
5
19 18 17
16
(CN2) (CN4)
3
2
1
15 14 13
4
12
11
1
(CN1)
(CN3) AMP 040 28P 3
2
1
12 11 10 9
6
5 4
8
7
(CN7)
2
1
16 15 14 13 12 11 10
8
7
6
5
4
3
9
(CN6)
FG000587
Figure 67 Reference Number
Description
2
e-EPOS Controller
8
Pressure Sensor (Front Pump)
9 13 17
Electrical System Page 80
Reference Number
Description
19
Selector Switch For Automatic Travel
Pressure Sensor (Rear Pump)
24
Battery
Solenoid Valve (High speed)
25
Battery Relay
Engine Control Dial
26
Fuse
SP001038
SELF-DIAGNOSTIC FUNCTION e-EPOS Controller The system operation status and malfunction codes can be checked through the display on top of the e-EPOS controller box the rear cover behind the operator's seat.
1
2
4
3 FG000588
Figure 68
1.
Reference Number
Description
1
Upper Digit
2
Lower Digit
3
Engine Speed Monitor LED (Flash Interval Increases With Engine Speed.)
Reference Number
Description
4
Power Monitor (Stays "ON" While Power Is In Normal Range,)
Power Monitor This LED is turned "OFF" when the input voltage to the e-EPOS controller is below 18.5 ±1 V or above 32.5 ±1 V. Stays "ON" while in normal range.
2.
Engine Speed Monitor This LED light flashes according to the engine speed. The flashing interval is proportional to the engine speed.
Electrical System
SP001038 Page 81
3.
Normal Operation Display Readout Display Readout
Mode Selection
Upper Digit
Lower Digit
Operation Status
Normal Operation Power Mode
Power Mode HAOH340L
Power Mode Normal Operation Standard Mode
Standard Mode HAOH350L
Normal Operation Digging Mode
Digging HAOH370L
Work Mode Normal Operation Trenching Mode
Trenching HAOH380L
4.
Communication Monitor What are shown in the 7-SEGMENT LED are same as those in the Error Codes. Error Code
Indication Code
V201
01
Communication error in instrument panel.
V202
02
Communication error in engine controller.
Electrical System Page 82
Fault Location
SP001038
AIR CONDITIONER SYSTEM Outline
A
A
C
C B
FG000784
Figure 69 Solid-type heater and air conditioner are installed in the cover behind the operator's seat. Temperature of the operator's room is adjusted automatically to the temperature set by operator.
Electrical System
SP001038 Page 83
(Please refer to the Operation Manual for detailed full automatic control. Vent mode selects the direction of discharged air. Outlets by vent modes Modes Outlets
A
A+B
B
B+C
C
Internal and External Filters Internal and external air purification filters are installed for the operator's room. Filters should be cleaned every 500 hours. If machine operates in an excessively contaminated environment, filters should be cleaned more frequently and if necessary, replaced with new ones. How to Check Internal Air Filter 1.
Press both levers on the left and right side at the top of the filter installed at the rear of the operator's seat.
FG000422
Figure 70
How to Check External Air Filter 1.
Open the door at the left side of machine and loosen four marked bolts to remove the cover (1, Figure 71). 1 TOP Donaldson.
FG000440
Figure 71
Electrical System Page 84
SP001038
2.
Turn marked knobs (1, Figure 72) at the rear side of the cabin to open the cover.
1
FG000441
Figure 72 3.
Remove the filter attached to the cover and clean the contaminated filter using compressed air.
4.
Close the cover, replace the knobs, and secure the cover to the support with butterfly bolts.
FG000342
Figure 73
Electrical System
SP001038 Page 85
Air-Conditioning System Layout
3
10
2
11
1
6 5 7
5 4
6
8 9 FG007144
Figure 74 Reference Number
Description
Reference Number
Description
1
Air Conditioner/heater Unit
7
Liquid Hose (1)
2
Condenser
8
Liquid Hose (2)
3
Compressor
9
Ambient Temperature Sensor
4
Receiver Dryer
10
Sun Sensor
5
Discharge Hose
11
Control Panel
6
Suction Hose
Electrical System Page 86
SP001038
Air Conditioner/heater Circuit Diagram
0.5RW
FUSIBLE LINK LAMP SWITCH STARTER SWITCH
20A BATTERY RELAY AIRCON UNIT
A/C CONTROL PANEL LED 1~12
ILL
130C
CN9-6
54E
CN9-11
0.5WR
42B
CN9-5
1.25LR
0.85LR
1.25LR
CN11-2
42C
0.85LR
CN10-8
42D
CN10-18
46B
BATT. 24V
0.85BW
RECEIVER DRIER
42E
BLOWER RELAY
46A
A/C RELAY COMPRESSOR
CN8-10
0.5LG
CN10-16
168A
105B
CN9-8
0.5LB
CN10-5
105A
CN11-4
47A
106B
CN8-11
0.5LY 1.25B
CN10-6
106A
CN11-1
99
-
+
M
CN8-12
0.5LW
CN10-1
107A
108A
CN9-13
0.5GrG
CN10-2
108B
FRE (P1)
109A
CN9-12
0.5GrY
CN10-20
109B
REC (P2)
110A
CN9-15
0.5OrR
CN10-12
110B
DEF (P1)
111A
CN9-14
0.5OrW
CN10-13
111B
VENT (P2)
43A
CN9-16
0.5YB
CN10-11
43B
Vref MODE
CN10-10
44B
MODE F/BACK
WARM (P1)
0.85B
BLOWER
M
CN9-17
0.5YW
99
CN9-10
1.25B
112A
CN9-1
0.5LgW
CN10-19
112B
113A
CN9-18
0.5LgB
CN10-3
113B
COOL (P2)
114A
CN9-3
0.5YR
CN10-7
114B
Vref MIX
115A
CN9-4
0.5YW
CN10-9
115B
MIX F/BACK
167C
CN9-2
1.25BL
CN10-4
167A
GND
116A
CN8-2
0.5OrB
CN10-15
116B
45A
CN8-1
0.5LgR
CN10-14
45B
MODE ACTUATOR
M
Temp. Control ACTUATOR
DUCT SENSOR WATER SENSOR
2 CN8-5
CN10-17
0.5LY
48B
0.85B
INTAKE ACTUATOR
M
44A
47C
47B
FET
107B
48A
0.85LW
DIODE 4
A/C THERMO (LOW)
168B
1
INCAR SENSOR
SUN LOAD SENSOR 142A
CN8-3
0.5Lg
2 -
49A CN8-4
CN10
+ 1
142B
0.5YR 114C 0.85BL
167B
2
0.85YG
49B
1
0.85YG
CN11
AMP 20P
KET 4P
AMBIENT TEMP SENSOR
CN8 CN9 AMP 18P + 12P
AMP 040-III 20P KET 4P 2
1
4
3
AMP 070 12P
AMP 070 18P 9
8
7
6
5 4
3
2
1
8
7
6
5
4
3
2
1
5
4
11 10
9
12
11
3
2
1
8
7
6
20 19 18 17 16 15 14 13 12 11 10
(CN11)
18 17 16
(CN10)
15 14 13 12
(CN9)
10
9
(CN8)
FG001463
Figure 75
Electrical System
SP001038 Page 87
Air Conditioner/heater Unit Air Flow Diagram
External Air Inlet
Vent Rear Outlet
Cold Box Outlet
Internal Air Inlet
Vent Front Outlet Foot Outlet
DEF Outlet
External Air VENT
COOL
DOOR -INTAKE
DOOR -MIX
DEF
Internal Air
WARM
Heater Core FOOT
Evaporator
Fan FG001359
Figure 76
Electrical System Page 88
SP001038
Door Open by Vent Modes Door
Mode Vent
Bi-level
Foot
Def/foot
Def
Vent
100
60
0
0
0
Foot
0
40
100
80
60
Def
0
0
0
20
40
Main Components
Actuator A/C - Temp Control Relay Blower Relay
Duct Sensor Air Flow Control Module
Actuator -Wind Direction Control
Blower Motor
Water Temp Sensor
Actuator - Internal/external Air Exchanger
Evaporator
Internal Air Filter
Internal Air Sensor FG007754
Figure 77
Electrical System
SP001038 Page 89
Actuator - Wind Direction Control Change of discharged air flow according to selected wind direction mode Change of wind direction: Direction changes in the order of VENTo BI-LEVEL o FOOT o FOOT/DEF o VENT. Actuator - Temperature Control Change of discharged air temperature by controlling the position of temperature control door.
FG001361
Figure 78 Actuator - Wind Direction Control Wind Direction Mode
Output Terminal
Voltage
Vent
0.5 ± 0.2V
Bi-level
1.3 ± 0.2V
Foot Foot/def
c(+): CN10-10 b(-): CN10-4
Def
2.45 ± 0.2V 3.5 ± 0.2V 4.5 ± 0.2V
Actuator - Temperature Control Set Temperature Max cooling Max heating
Electrical System Page 90
Output Terminal
Voltage
c(+): CN10-9
Below 0.4V
b(-): CN10-4
Above 4.5V
SP001038
Actuator - Internal/external Air Exchange
CN10-20
CN10-2
FG001055
Figure 79 Mode
Output Terminal
Output
Intake
P1(+), P2(-)
Moving of exchange door by selecting intake.
Recirculate
P1(-), P2(+)
Moving of exchange door by selecting recirculate.
Air Flow Control Module Air flow is controlled through the control of voltage between GATE and SOURCE.
DRAIN (CN10-1)
SOURCE (CN11-1)
GATE (CN10-6) FG001056
Figure 80 Air flow
Output Terminal
Output
1st
10 ± 0.5V
2nd
12.5 ± 0.5V
3rd 4th
15 ± 0.5V CN11-2
CN10-1
17.5 ± 0.5V
5th
20.0 ± 0.5V
6th
22.0 ± 0.5V
7th
More than 25V
Input voltage is 27.5V. The air flow is based on manual set.
Electrical System
SP001038 Page 91
Relay - Blower: Power is supplied to the blower motor when the system is turned "ON." Specifications Rated voltage
24V
Rated current
20A
Figure 81 Relay - A/C: Power is supplied to the magnetic clutch of the compressor. Specifications Rated voltage
24V
Rated current
10A
L
S1
B
S2
(+)
(-) FG001058
Figure 82 Duct Sensor: It is inserted in the core of the evaporator to prevent freezing of the evaporator. The sensor consist of negative characteristic thermistor that resistant value increases and decreases when the temperature rises and falls, respectively. Temperature (°C)
Resistance (K:)
0
11.36 ± 0.1
2
10.39 ± 0.2
2.5
10.17 ± 0.2
3
9.95 ± 0.2
3.5
9.73 ± 0.2
4
9.52 ± 0.2
5
9.12 ± 0.2
10
7.36 ± 0.15
25
4.02 ± 0.08
30
3.33 ± 0.07
Electrical System Page 92
Figure 83
SP001038
Water Temperature Sensor: It senses the temperature of coolant water in the heater core. Temperature (°C)
Resistance (K:)
-10
55.8 ± 1.7
0
32.9 ± 0.9
15
15.76 ± 0.5
25
10.0 ± 0.3
35
6.5 ± 0.2 Figure 84
Internal Air Temperature Sensor: Built in the internal air filter, it senses the internal temperature. Temperature (°C)
Resistance (K:)
-15
218.2 ± 7.5
0
97.83 ± 0.9
15
47.12 ± 0.7
25
30.0 ± 0.36
35
19.60 ± 0.3 Figure 85
Ambient Air Temperature Sensor Built at the bottom of the cockpit, it senses the temperature of external air. Temperature (°C)
Resistance (K:)
-10
163 ± 4.9
0
96.9 ± 2.9
10
59.4 ± 1.8
20
37.4 ± 1.1
25
30 ± 0.9
30
24.2 ± 0.7
Electrical System
FG001064
Figure 86
SP001038 Page 93
Sun Sensor Built beside the socket of spare power, it senses the quantity of the sun radiation to optimize discharge temperature and air flow as set by operator.
OUTPUT VOLTAGE(mV)
83.7 76.2 67.7 58.8 46.6 36.0 21.4
1.0 2.0 3.0 4.0 5.0 6.0 7.0 LUX(x10,000)
FG001062
Figure 87
Control Panel Appearance and Terminal Arrangement
OUTSIDE
A/C AUTO
AUTO
A/C
MAX
TEMP
OFF SEL
MODE
AMP 070 18P 8
7
6
18 17 16
5
4
15 14 13 12
AMP 070 12P 3
2
1
11 10 9
(CN9)
5
4
12 11
10
9
(CN8)
3
2
1
8
7
6
FG001063
Figure 88 Refer to "Air Conditioner and Heater" of operation manual.
Electrical System Page 94
SP001038
Terminal Terms CN
Term No.
Terms
1
CN
Term No.
Terms
Temperature control (warm)
1
Water temperature sensor
2
Sensor ground
2
Duct sensor
3
Temperature control Power (5V)
3
Sun sensor
4
Mix feedback
4
Ambient air temperature sensor
5
Power (KEY "ON")
5
Internal air temperature sensor
6
Back-up
6
-
7
-
7
-
8
A/C output (LOW)
8
-
9
-
9
-
CN8
CN9
10
Ground
10
D.P.S CHECK
11
Illumination
11
Air flow module (gate)
12
Intake/Recirculate (Recirculate)
12
Blower motor (feedback)
13
Intake/Recirculate (Intake)
14
Wind direction control (VENT)
15
Wind direction control (DEF.)
16
Wind direction control Power (5V)
17
Wind direction control (feedback)
18
Temperature control (cool)
Control Logic Categories AUTO
Inputs Set temperature
System Operation 1.
Internal air temperature sensor Ambient air temperature sensor
Temperature, Wind direction, Recirculate/Intake, Air flow, Compressor 2.
Auto mode is released when manually setting any switch except, Temperature Control switch in Auto mode.
3.
Upon the releasing of Auto mode, all of functions except selected switch are controlled automatically.
Water temperature sensor Sun sensor
Electrical System
Automatically adjust room temperature as set and then next items.
SP001038 Page 95
Categories Sensor compensation
Inputs Set temperature
System Operation 1.
In case of sensor failure, following defaults are applied:
Internal air temperature sensor
Internal air temperature sensor: 25°C, Ambient air temperature sensor: 25°C, Duct sensor: -2°C
Ambient air temperature sensor
Temperature control actuator: - Set Temperature 17 - 24.5°C: Max cooling, Set Temperature 25 - 32°C: Max heating
Water temperature sensor
Wind direction mode actuator - VENT: VENT fix, modes other than VENT: Fixed to DEF * Sun sensor is not compensated. Max cooling/ heating control
Auto Setting
1.
Set Temperature 32°C: Max heating
2.
Set Temperature 17°C: Max cooling Max Cooling (17 C)
Max Heating (32 C)
Temp Control Actuator
FULL COOL
FULL HOT
Air Flow
MAX HI
AUTO HI
Compressor
Forced ON
OFF
Intake/Recircle
Recircle
Intake
Wind Direction Mode
VENT
FOOT
* Max cooling/heating control is possible only in Auto mode. Starting Control of Cooling
Auto mode
1.
Prevention of discharge of hot air before discharge temperature drops enough in hot summer weather
2.
Start conditions (AND condition)
Duct sensor
(1) A/C on (AUTO or manual) (2) Temperature sensed by the duct sensor is above 30°C (3) Air flow: Auto mode 3.
One time control in the cycle of engine OFF o engine run
4.
Initial cooling control is executed when the Auto switch is "ON" in the manual status (A/C "OFF" and manual control of air flow) in 5 seconds after engine run.
5.
Initial cooling control should be before max cooling.
6.
Release condition (OR condition) (1) A/C "OFF" (2) Air flow: Manual control (3) Release is possible with the "OFF" switch but not allowed within 12 seconds (after Start "ON") while the system is off using the "OFF" switch and during the time of initial cooling control.
Electrical System Page 96
SP001038
Categories
Inputs
System Operation 1.
Start condition (AND condition) (1) When wind direction mode is one of the following modes in the Auto or manual control mode - BI-LEVEL, FOOT or FOOT/DEF (2) The Water temperature sensor is stable and the water temperature < 73°C (3) Air flow: Auto mode (4) Set temperature > Internal air temperature + 3°C * Air flow falls gradually up to 12 seconds when operation released.
Starting control of heating (1)
Water temperature sensor
2.
One time control in the cycle of engine OFF o engine run
Internal air temperature sensor
3.
Initial heating control should be before max heating.
4.
Air flow is controlled only when the wind direction is in the manual mode and BI-LEVEL, FOOT, or FOOT/DEF is set.
5.
Control through the water temperature sensor for start.
6.
Starting control of heating (2) starts in case of fault of the water temperature sensor during controlling.
7.
Operation release (OR condition)
Auto mode Set Temperature
(1) Only air flow is released if it is selected manually. (2) When handling the wind direction mode switch, only wind direction is released but the air flow control is performed only for the remaining period of the starting control of heater. (3) When Max Cooling (17°C) is selected. (4) Water temperature sensor > 73°C.
Electrical System
SP001038 Page 97
Categories Starting control of heating (2)
Inputs Water temperature sensor
System Operation 1.
Ambient air temperature sensor
(1) Auto Mode (2) Ambient air temperature < 5°C and difference between ambient and internal air temperature d 5°C
Internal air temperature sensor Auto mode
Entry condition (AND condition)
(3) Failure of water temperature sensor
2.
Only one time of engine OFF o engine run
3.
Starting control of heating is before max heating.
4.
Operation release (OR condition) (1) Air flow: Manual selection (2) When handling the wind direction mode switch, only wind direction is released but the air flow control is performed only for the remaining period of the starting control of heater. (3) Difference between temperature>15°C
internal
and
ambient
air
(4) When Max Cooling (17°C) is selected. 5.
Exceptional case Starting control of heating is performed only once during the remaining period if the entry condition is satisfied within the starting control period that is the accumulation of initial start times. (Inclusive of Auto mode "ON" case within the period of starting control of heater.) * Air flow should be reduced slowly for up to 12 seconds in case of exceptional entry case.
Electrical System Page 98
SP001038
Categories
Inputs Duct sensor
System Operation 1.
Function: Magnetic clutch of compressor is turned "ON/ OFF" depending on temperature of the duct sensor to prevent the freezing of the evaporator with A/C being "ON."
2.
Control pattern.
2.0
Compressor control External temperature sensor
0.5 C
3.5
0.5 C
1.
Function: Prevention of compressor in winter.
2.
Control pattern.
*Only for Auto mode.
Electrical System
SP001038 Page 99
Self Diagnosis How to start self diagnosis
Starter Switch ON
Set temp to 25 C
Set temp to 77 F
Press the SEL switch more than 3 times in 5 secs while pressing the A/C switch
Auto diagnosis starts after every graphic in LCD displays twice every 0.5 sec.
A code concerned blinks in the cycle of 0.5-sec ON and 0.5-sec OFF. In case of two or more errors, codes concerned blink twice at a time.
For normal, E0 lights; for error, the first error code is indicated.
For 2 or more error, error codes are indicated upstreams/downstreams if the temp control switch is set to up/down. (For normal condition, only EO lights.)
Press the SEL switch more than 3 times in 5 secs while pressing the A/C switch.
Return to default status if no switch operated for 30 secs in diagnosis mode.
Return to position before auto diagnosis starts. FG001367
Figure 89
Electrical System Page 100
SP001038
Error codes Code
Description
E0
Normal
E1
Internal air temperature sensor short
E2
Internal air temperature sensor open
E3
Ambient air temperature sensor short
E4
Ambient air temperature sensor open
E5
Duct sensor short
E6
Duct sensor open
E7
Sun sensor short
E8
Sun sensor open
E9
Water temperature sensor short
E10
Water temperature sensor open
E11
D.P.S open
E12
Position error of wind direction actuator
E13
Position error of temperature control actuator
NOTE:
The position error means that it fails to move to designated place in 40 seconds. Sun sensor displays E8 in case of no sunlight.
E1
E1
E2
E2
E3
2 and more fails: Codes concerned blinks twice at a time. 0.5 0.5
FG001067
Figure 90 Ambient Temperature Display Selection of both the SEL and MODE switch for more than 3 seconds indicates the ambient temperature in the set temperature display department. - Range of temperature display: -40 - +60°C NOTE:
Display of ambient temperature may be released in the same way for its entry way. It returns automatically to default mode 5 seconds after entering the ambient air temperature display mode.
Electrical System
SP001038 Page 101
Compressor Categories
Specifications
Output
155.3 cc/rev
Oil Level
120 cc (ND-OIL8)
Refrigerant
R134a
Rated Voltage
24V
Relief Valve
Open: 35 - 42.2 kg/cm2G Close: 28.1 kg/cm2G
Compressor sucks in refrigerant which evaporates completely in the evaporator and discharges it to the condenser.
Relief Valve
FG001365
Figure 91
Refrigerant undergoes repeated status change in the order of liquid, gas, and liquid in the freezing cycle, and the compressor makes evaporated refrigerant a high temperature and high-pressured gas to freeze it in the condenser.
Receiver Dryer The receiver dryer reserves refrigerant enough to ensure smooth freezing cycle responding immediately to the change of level in the freezing cycle.
High/Low Pressure Switch
As liquid refrigerant from the condenser may contain refrigerant gas with bubbles whose presence in the expansion valve decreases the freezing power excessively, it separates liquid and gas and sends liquid only to the expansion valve. Water in refrigerant shall be eliminated with dryer and through filter. FG001366
Figure 92
MAX. 0.25 kg/cm2
Volume of refrigerant by model Model
Volume of Refrigerant
DX140LC
800 ± 20 grams
DX180LC
800 ± 20 grams
DX225LC
800 ± 20 grams
DX225NLC
800 ± 20 grams
DX255LC
800 ± 20 grams
DX300LC
800 ± 20 grams
DX340LC
800 ± 20 grams
DX420LC
800 ± 20 grams
DX480LC
800 ± 20 grams
DX520LC
800 ± 20 grams
Electrical System Page 102
2.0 0.2 kg/cm2
32 2 kg/cm2
6 2 kg/cm2
FG001462
Figure 93
SP001038
TROUBLESHOOTING Refrigerant Pressure Check 1.
Open all doors and windows.
2.
Install manifold gauge set.
3.
Start engine and maintain engine speed at 1,800 - 2,000 rpm. LO
HI
HDA6074L
Figure 94
4.
Check high / low-pressure of refrigerant. High-pressure: 8.0 - 10.0 kg/cm2 (114 - 142 psi)
1
Low-pressure: Approximately 1.0 kg/cm2 (14 psi)
Possible Cause: Low Refrigerant Level Step 1
Inspection Item
Remedy
Check for traces of refrigerant oil. Using a leak detection device or soapy water check for refrigerant leakage at all major components and joints.
2
Yes
Reassemble using correct tightening torque.
No
Go to next step.
Yes
Repair leaking component.
No
Recharge system to correct pressure.
High-pressure: Over 23 kg/cm2 (327 psi)
2
Low-pressure: Approximately 2.5 - 3.0 kg/cm2 (36 - 43 psi)
Possible Cause: Overcharge, Frost on condenser Step 1
Inspection Item
Remedy
Check for condenser pin damage or contamination.
Yes
Clean, repair or replace condenser.
No
Refrigerant overcharge.
High-pressure: Approximately 20 - 25 kg/cm2 (285 - 356 psi)
3
Low-pressure: Approximately 2.5 - 3.5 kg/cm2 (36 - 50 psi)
Possible Cause: Air in system. 1.
Recover any remaining refrigerant.
2.
Vacuum out system.
3.
Recharge system. NOTE:
If the system has been exposed to the air for a long period of time, replace the receiver dryer.
Electrical System
SP001038 Page 103
High-pressure: Over 6 kg/cm2 (85 psi)
4
Low-pressure: Approximately 760 mmHg (Negative Pressure) Possible Cause: Refrigerant does not circulate Step
1
Inspection Item
Remedy
1.
Connect manifold gauge and start engine.
2.
Turn on air conditioner.
3.
Set blower switch to HIGH position.
4.
Turn air conditioner OFF and wait 10 minutes.
5.
Recheck high / low-pressure readings.
Yes
High-pressure: 13.0 - 19.0 kg/cm2 (185 - 270 psi)
No
Moisture in system, replace receiver dryer.
Contaminated system, replace expansion valve. (Replace evaporator core assembly.)
2
Low-pressure: 1.5 - 3.3 kg/cm (21.3 - 46.9 psi) High-pressure: Over 6 - 18 kg/cm 2 (85 - 256 psi)
5
Low-pressure: 500 mmHg (Negative Pressure) - Dial indicator needle unstable. Possible Cause: Moisture in system has iced up the expansion valve. NOTE:
When the absorbed moisture freezes the pressure readings may look normal. Careful readings should be made to determine whether pressure is in normal range.
1.
Recover any remaining refrigerant.
2.
Vacuum out system.
3.
Recharge system. NOTE:
If the system has been exposed to the air for a long period of time, replace the receiver dryer. High-pressure: Over 22.0 - 23 kg/cm2 (313 - 327 psi)
6
Low-pressure: 2.5 kg/cm 2 (36 psi)
Possible Cause: Refrigerant pressure problem due to defective expansion valve or temperature sensor. Step 1
Inspection Item
Remedy
Inspect whether the temperature sensor is installed properly.
7
Yes
Replace expansion valve.
No
Exchange duct sensor.
High-pressure: Over 7.0 - 11.0 kg/cm2 (100 - 156 psi) Low-pressure: 4.0 - 6.0 kg/cm2 (57 - 85 psi)
Possible Cause: Low refrigerant pressure due to poor compressor compression. Inspect and replace compressor if necessary.
Electrical System Page 104
SP001038
WEIGHT OF R134a GAS USED IN MACHINES Model
Weight of Gas
DX140LC
800 ±20 grams (28 ±0.7 oz)
DX180LC
800 ±20 grams (28 ±0.7 oz)
DX225LC
800 ±20 grams (28 ±0.7 oz)
DX225NLC
800 ±20 grams (28 ±0.7 oz)
DX255LC
800 ±20 grams (28 ±0.7 oz)
DX300LC
800 ±20 grams (28 ±0.7 oz)
DX340LC
800 ±20 grams (28 ±0.7 oz)
DX420LC
800 ±20 grams (28 ±0.7 oz)
DX480LC
800 ±20 grams (28 ±0.7 oz)
DX520LC
800 ±20 grams (28 ±0.7 oz)
Electrical System
SP001038 Page 105
REFRIGERANT SYSTEM REPAIRS WARNING! Always wear protective glasses and gloves when handling refrigerant. If refrigerant comes in contact with the skin or eyes, immediately flush with clean, running water and consult a physician. Select a clean and well ventilated area to work. The refrigerant container is under high-pressure and should be stored below 40°C (104°F). Be careful not to drop the container from a high location. The contents are under high-pressure and should not be used with compressed air or near an open flame.
Refrigerant Safe Handling Procedures UNION
NUT
TORQUE WRENCH
CORRECT
WRONG
WRONG WRONG CORRECT
O - RING POSITION
CAP & PLUG
CORRECT
WRONG
WRONG HDA6066L
Figure 95 The following procedures should be observed for safe handling of refrigerant during vacuum and charging process. 1.
Use an approved recovery / charging device which can safely perform vacuum and charge work simultaneously.
2.
The new refrigerant has improved cooling characteristics than the old type and care should be used not to overcharge the system.
Electrical System Page 106
SP001038
3.
Do not over tighten connections when working on refrigerant system.
4.
The new refrigerant system standards require new tools, equipment and parts. DO NOT attempt to use equipment use in servicing the old refrigerant system.
5.
The new refrigerant oil (PAG type) has a high moisture absorption characteristic. When the refrigerant system vacuum seal has been broken, immediately plug up all openings to prevent moisture from entering into the system.
6.
When joining unions which use O-ring seals, lightly coat Orings with refrigerant oil. Be careful not to drip oil on the threads of the nut.
7.
Be certain the O-rings are seated properly on the refrigerant line lip. Always use new O-rings when reassembling parts. Do not reuse old O-rings.
8.
Use a vacuum pump to evacuate refrigerant system of air.
9.
When charging the refrigerant system with the engine running, do not open the high-pressure valve on the manifold gauge as the reverse flow of high-pressure refrigerant will rupture the hose.
10.
When releasing the high-pressure hose after completing the charging process, quickly disconnect the hose to minimize refrigerant released to the air.
Repair and Replacement Procedure 1.
Work Procedure A.
2.
Before repairing or replacing any refrigerant components first, return all refrigerant oil to the compressor and perform recovery procedures.
Operating Condition A.
Run engine at maximum engine speed.
B.
Select 'HI' blower fan speed and select A/C switch to 'ON'.
C.
Set the temperature control switch for maximum cooling and leave running for approximately 20 minutes. NOTE:
Electrical System
The manifold gauge dial pointer can vary depending on the outdoor temperatures.
SP001038 Page 107
INSTALL REPAIR TOOL
RECOVER REFRIGERANT
REPAIR / REPLACE DEFECTIVE PARTS
VACUUM SYSTEM (OVER 5 MINUTES)
CHECK SYSTEM FOR AIR LEAKAGE
REPAIR
VACUUM SYSTEM (OVER 20 MINUTES)
CHARGE SYSTEM (APPROXIMATELY 100 g)
CHECK SYSTEM FOR REFRIGERANT LEAKAGE
CHARGE SYSTEM TO PROPER LEVEL¯ (Standard Capacity less Initial Charge)
CHECK SYSTEM FOR REFRIGERANT LEAKAGE
CHECK FOR PROPER REFRIGERANT LEVEL
RUN SYSTEM
RECOVER REFRIGERANT IN CHARGING HOSE
REMOVE REPAIR TOOLS
HDA6067L Figure 96
Electrical System Page 108
SP001038
Refrigerant Recovery
1.
Reference Number
Description
1
To Compressor
2
Low-pressure Side
3
High-pressure Side
4
From Receiver
5
Refrigerant Recovery Tank
Be careful not to switch the connections for the low and high-pressure valves.
3 4
1
Attach the manifold gauges and the refrigerant recovery unit to the refrigerant lines as shown. NOTE:
2.
2
5 HDA6067L
Figure 97
Open the high-pressure valve slowly to release the refrigerant to the recovery unit. NOTE:
Open the valve slowly, while checking to see that refrigerant is not leaking out.
3.
When the manifold gauge dial falls below 3.5 kg/cm2 (50 psi), slowly open the low-pressure valve.
4.
Open both the high and low-pressure valves slowly until the manifold gauge dials indicates 0 kg/cm2 (0 psi).
Vacuuming Refrigerant System 2
Reference Number
Description
1
To Compressor
2
Low-pressure Side
3
High-pressure Side
4
From Receiver
5
Vacuum Pump
3 4
1
5 HDA6068L
1.
Vacuuming Procedure NOTE:
Figure 98
When the A/C system has been exposed to the air, it must be vacuumed out. Perform vacuum process for 30 minutes for complete moisture and air evacuation.
A.
Attach the manifold gauges and vacuum pump to the refrigerant system as shown.
B.
Turn on the vacuum pump and open both valves.
C.
When the low-pressure gauge shows approximately 710 mmHg, close both valves and turn off vacuum pump.
Electrical System
SP001038 Page 109
2.
Check system for vacuum leak. Allow system to sit for 10 minutes and check whether the system is holding the pressure. If the pressure has dropped, it must be repaired before proceeding to the next step.
3.
Vacuuming Procedure If the system is holding the pressure and it has not changed for 10 minutes, vacuum out the system for an additional 20 minutes.
4.
A.
Turn on the vacuum pump and slowly open both valves.
B.
Allow vacuum pump to run for additional 20 minutes until the low-pressure gauge dial reads approximately 750 mmHg.
C.
Close both valves and stop the vacuum pump.
HDA6069L
Figure 99
Installation of Refrigerant Container Reference Number
Description
1
Handle
2
Hose Connection
3
Mounting Disk
1
2 3
A.
Before mounting valve on the container, make sure the handle is in the counterclockwise most position, with the puncture pin retracted and the mounting disk is in the raised position.
B.
Attach the manifold gauge center hose to the valve assembly.
C.
Turn the disk in the clockwise direction and securely mount valve onto refrigerant container.
D.
Turn the valve handle in the clockwise direction and puncture the container seal with the pin.
E.
Once the can has been punctured, turn the handle in the counterclockwise direction so the refrigerant can flow into the manifold gauge center hose. At this time, do not open the low and high-pressure valves of the manifold gauge.
F.
Press the manifold gauge low side valve to eliminate the trapped air in the hose.
Electrical System Page 110
HDA6070L
Figure 100
SP001038
Leakage Check NOTE:
Perform the leakage vacuuming process.
check
after
completing
1.
After attaching the manifold gauge, open the high side valve.
2.
Charge system until the low side gauge dial indicates a pressure of 1 kg/cm2 (14 psi) and close the high side valve.
3.
Using a refrigerant leak detector or soapy water check each joint for leakage. Reference Number
Description
1
Refrigerant Leak Detection Device
4.
If a leak is detected, check for O-ring damage or correct tightening torque and replace or repair as necessary.
5.
If no leaks are detected, proceed with the charging process.
1
HDA6071L
Figure 101
WARNING! For accurate refrigerant leak detection, perform leak detection procedure in a well ventilated area.
Refrigerant Charging 1.
Perform the vacuuming procedure, vacuum holding and leaking tests as described in the proceeding headings. First charge the refrigerant system with 100g (3.5 ounces) of refrigerant with the engine off. Then using the manifold gauges as a guide fully charge the system with the engine running.
NOTE:
When exchanging refrigerant containers, press the manifold gauge low side valve to eliminate air from the charging hose.
2.
Reference Number
Description
1
To Compressor
2
Low-pressure Side
3
High-pressure Side
4
From Receiver
5
Refrigerant Supply Container
1
Charge the system by opening the manifold gauge low side valve. Initial charge amount: 100 g (3.5 ounces).
Electrical System
3
2
4
5 HDA6072L
Figure 102
SP001038 Page 111
3.
If refrigerant does not flow freely into system, try starting engine first before operating air conditioner. !
Temperature Cooling
control
switch
setting:
Maximum
Blower Speed Setting: Hi (3 step) Engine Speed: 1,300 - 1,500 rpm
WARNING! When charging refrigerant system with the engine running:
4.
•
Always keep refrigerant supply container in the upright position.
•
Never open the high side pressure valve.
Open the manifold gauge low side valve and charge system to standard capacity. Gauge Dial
Standard Reading
High Side Gauge
13 - 20 kg/cm2 (185 - 285 psi)
Low Side Gauge
1.5 - 3.5 kg/cm2 (22 - 50 psi)
NOTE:
These standards are for outside temperatures between 30° - 35°C (86° - 95°F). The gauge readings may vary for extreme temperature conditions.
WARNING! •
When outside temperature is low, warm the refrigerant supply container with warm water not exceeding 40°C (104°F). Do not allow water to come in contact with the charging adapter valve handle.
•
When outside temperature is high, cool off refrigerant supply container and condenser to aid the refrigerant charging process.
5.
Close low-pressure side valve.
6.
Shut off engine and close refrigerant supply container adapter valve. Disconnect manifold gauge hoses from vehicle.
Electrical System Page 112
SP001038
Inspecting System For Leakage After completing charging procedures, clean all joints and connections with a clean dry cloth. Using a refrigerant leak detecting device or soapy water, inspect system for leaks starting from the high-pressure side. When the refrigerant circulation has been stopped the high-pressure will start to decrease and the lowpressure will start to increase until they are equalized. Starting the inspection from the high side will result in a accurate test.
NOTE:
2 1
3 4
Reference Number
Description
1
Pressure
2
High-pressure
3
Low-pressure
4
Compressor Stop
HDA6073L
Figure 103
Inspection Procedure 1.
High-pressure Side
2.
Low-pressure side
3.
Compressor
Compressor outlet o condenser inlet o receiver dryer inlet o air conditioner unit inlet.
Compressor inlet o air conditioner unit outlet.
Compressor shaft area, bolt hole area and magnetic clutch area. 4.
Receiver dryer Pressure switch and plug area.
5.
Connection valve area Inspect all valve areas. Verify all valves are capped to prevent leaking. Check for foreign material inside of valve cap.
6.
Interior of air-conditioning unit. After stopping engine, insert detector probe into drain hose. (Leave inserted for 10 seconds minimum.) NOTE:
When inspecting leakage from the airconditioning unit, perform the inspection in a well ventilated area.
Electrical System
SP001038 Page 113
WIPER SYSTEM Wiper Circuit
5 2
+
-
6
M
7
3
4
4
5
6
1
7
5
(Continuous mode)
3
8
(Intermittent 1 mode)
4
10
(Intermittent 2 mode)
5
11
(Washer mode)
6
12
-
8 +
1
P
1
9
6
13 9
2
2
8
AMP MIC 13P CN12
CN13
15A
4
10A
10A
KET 8P
15A
10 2
3 AMP MIC 13P 1
7
2
8
3
9
4
10
1 5
6
11 12 13
4
9
3
2
8
(CN12)
7
(CN13)
6
1
4
5
1
2
6
5
(Wiper Motor)
FG000589
Figure 104 Reference Number
Description
Reference Number
Description
1
Battery
6
Wiper Controller
2
Battery Relay
7
Wiper Switch Panel
3
Fusible Link
8
Window Washer
4
Fuse Box
9
Wiper Cutoff Switch
5
Wiper Motor
10
Light Switch
Electrical System Page 114
SP001038
Wiper operation Continuous operation - Operation of wiper motor Pressing the successive operation switch on the wiper switch panel (7) changes the voltage of the "5" terminal of the wiper controller (6) from HIGH (about 5.5 ±0.5V) to LOW (0+0.5V) and also current flows via the "3" terminal of the wiper controller (6) o the "2" and "4" terminals of the wiper motor (5) o the "4" terminal of the wiper controller (6) to run the wiper motor (5) continuously. - Stop of wiper motor Pressing again the successive operation switch on the wiper switch panel (7) changes the voltage of the "5" terminal of the wiper controller (6) from LOW (0+0.5V) to HIGH (about 5.5 ±0.5V). As the "5" and "6" terminals of the wiper motor are connected still that power is supplied to the "6" terminal of the wiper controller (6), However, the controller (6) runs the wiper motor continuously and then rotates the motor reversely by " letting current flow via the "4" terminal of the wiper controller (6) o the "2" and "4" terminals of the wiper motor (5) o the "3" terminal of he wiper controller (6) when the "1" and "6" terminals of he wiper motor (5) are connected and thus power voltage is supplied to the "7" terminal of the wiper controller (6). The Wiper motor (5) stops reverse revolution when the contact of a cam switch connected to the "6" terminal of the wiper motor (5) moves to an insulation area of the cam plate to disconnect the "5" and "6" terminals of the wiper motor (5). When the wiper motor (5) stops, arm and blade connected to it move to the stop positions of the right pole in the cabin. Intermittent operation - Intermittent 1st (3-second) Pressing once the Intermittent switch in the switch panel (7) changes voltage of the "8" terminal in the wiper controller (6) from HIGH (about 5.5 ±0.5V) to LOW (0+0.5V) and current flows through the "3" terminal in the wiper controller (6) o the "2" and "4" terminals in the wiper motor (5) o the "4" terminal in the wiper controller (6) to start the cycle that wiper stops 3 seconds after every operation.
Electrical System
SP001038 Page 115
- Intermittent 2nd (6-second) Pressing twice the Intermittent switch in the switch panel (7) changes voltage of the "10" terminalG in the wiper controller (6) from HIGH (about 5.5 ±0.5V) to LOW (0+0.5V) and current flows through the "3" terminal in the wiper controller (6) o the "2" and "4" terminals in the wiper motor (5) oG the "4" terminal in the wiper controller (6) to start the cycle that wiper stops 6 seconds after every operation. - Stopping the intermittent action Pressing three times the Intermittent switch in the switch panel (7) while the wiper is operating stops the action of the wiper motor. NOTE:
The wiper system does not work when the wiper cutoff switch (9) is "ON."
Electrical System Page 116
SP001038
Electrical System
SP001038 Page 117
LIGHTING SYSTEM Lighting System Circuit Diagram
7
13
87a 30 87
*15
*16
85
86
*9
6
87a
87a
30
*14
30
87
87 86
85
85
86
12 *8 87a
*5
30 87 85
86
3
6
0 I II 0 I II
2
5 8
7
2
0 I II
5
0 I II
8
3
4 6 7
20A 15A
10
30A 15A
CN6-1
15A
CN6-2
11
CN6-9 L6
3
CN6-10 CN2-6 CN7-4
CN4-4
CN7-5
CN4-5
CN7-6
CN4-6
2
CAN CN1-1 CN1-2
CN1-8
1
CN1-9
FG000590
Figure 105
Electrical System Page 118
SP001038
Reference Number
Description
Reference Number
1
Battery
9
2
Battery Relay
3
Fuse Box
10
Instrument Panel
4
Light Switch
11
e-EPOS Controller
5
Cabin Light Switch
12
Headlight (2 ea.)
6
Headlight Relay (Work Light Indicate Light)
13
Work Light (2 ea.)
14
Front Cabin Light (4 ea.)
7
Work Light Relay
15
Rear Cabin Light (2 ea.)
8
Front Cabin Light Relay
16
Rear Work Light (1 ea.)
NOTE:
Description Front Cabin Light / Rear Work Light Relay
The "*" mark are optional parts.
Kind of Light The lighting system is consists of headlights, work lights, cabin lights (optional), relays and switches.
Operation
Switch
Position
Connected Terminal of switch
Activated Relay
Lit Light
1
"2-3" Terminal
-
Illumination Light of Switch
"2-3" Terminal
-
Illumination Light of Switch
Headlight Relay
Headlight (2 Ea.)
Light Switch
2
1 Cabin Light Switch
Electrical System
"5-6" Terminal
Work Light (2 Ea.) Work Relay
Indicator Light of Work Light (L6)
"2-3" Terminal
Front Cabin Light Relay
Front Cabin Light (2 Ea.) or Front Cabin Light (4 Ea.)
"2-3" Terminal
Front Cabin Light Relay
Front Cabin Light (2 Ea.) or Front Cabin Light (4 Ea.)
"5-6" Terminal
Rear Cabin Light Relay / Rear Work Light Relay
Rear Cabin Light (2 Ea.) and Rear Work Light (1 Ea.)
2
SP001038 Page 119
AUDIO CONTROLLER Audio Controller Circuit Diagram
7
ANTENNA
8
10 MODULE
3
11
15A
2
15
3
16
4
13
(LH)
MICOM
1
+
5 10A
1
9
Vcc(+5V)
-
(RH)
+
-
Vcc(+5V)
DC/DC CONVERTER 1
3
14
2
5
7 17 2
6
10A
10 87a
3
87
4
11
30 86
4
85
2
9 10 11 1 2 3
1
12 13 14 15
16 17 18
4
1 2
3
4
(Audio Control Panel)
5
6
7
8
(STEREO)
FG000591
Figure 106 Reference Number
Description
Reference Number
Description
1
Battery
7
Audio Control Panel
2
Battery Relay
8
Stereo
3
Fuse Box
9
Speaker
4
Fusible Link
10
Antenna Module
5
Converter
11
Light Switch
6
Stereo Relay
Operations Via Audio Control Panel Switch
Connected Terminal of switch
PWR "3-4" SCAN
Electrical System Page 120
Measured values
Operations
4.36 ±0.2V
Stereo ON, OFF
1.24 ±0.2V
Volume up
0+0.2V 2.49 ±0.2V
Volume down Frequency selection
SP001038
SP001357 ELECTRICAL SCHEMATIC (DX140LC)SP001357
1Electrical
Schematic (DX140LC) Edition 1
Electrical Schematic (DX140LC)
SP001357 Page 1
MEMO
Electrical Schematic (DX140LC) Page 2
SP001357
Table of Contents Electrical Schematic (DX140LC) Safety Precautions ............................................... 5 Applicable Models ................................................ 5 DX140LC .............................................................. 7
Electrical Schematic (DX140LC)
SP001357 Page 3
MEMO
Electrical Schematic (DX140LC) Page 4
SP001357
SAFETY PRECAUTIONS CAUTION! Follow all safety recommendations and safe shop practices outlined in the front of this manual or those contained within this section. Always use tools and equipment that are in good working order. Use lifting and hoisting equipment capable of safely handling load. Remember, that ultimately safety is your own personal responsibility.
APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL DX140LC
SERIAL NUMBER RANGE 5001 and Up
Electrical Schematic (DX140LC)
SP001357 Page 5
Electrical Schematic (DX140LC) Page 6
SP001357
0.85B
33B 0.85Or
0.85B
(RH) 87a
128A
127E 0.85RG (FL)
0.85B
(LH)
0.5RL
0.85RW
8
0.85WR 54A
0.5WR
SEAT HEATER (OPT) 0
3
144A
1.25R
55A
8 54Q
158B
5
0.85WB 6
158A
63C
6
5 52C
(INT-2)
0.5LG
5
161B
11
(WASHER )
0.5L
6
162B
1
34E
1
0.85Lg 9
0.85B
LOWER WIPER CUT SW
138B
0.5RW
13
130B 138A 99 AMP MIC 13P CN12
2
CIGAR LIGHTER
64B 1.25WL 64A 3
P
1.25RB
N DC/DC CONVERTER 2
0.5WR
0.5RG
0.5P
0.5RW
0.5RW
0.5WR
0.5WR
+ PRESSURE SENSOR(A) (FRONT PUMP)
LCD DISPLAY PANEL WATER TEMPERATURE FUEL ELVEL
DIODE ARRAY PRESSURE SENSOR(B) (REAR PUMP)
GRAPHIC DISPLAY 5
6
7
8
3
4
1
2
3
4
1
2
0.85R
CN5-4
140A
139B
0.85BrW
CN3-5
139A
145A
0.85W
CN3-6
145B
SIG
74B 0.85GR
CN3-1
74A
-
75A 0.85W
CN3-2
75B
+
28F 0.85R CN3-3
76A
SIG
76B 0.85GY
-
77A 0.85WL
CN3-4
77B
4 80A
0.5Y
0.5Y
CN4-4
80B
CN7-5
5 81A
0.5YB
0.5YB
CN4-5
81B
SHIELD
SHIELD
CN4-6
6 82A
141A
CONTROLLER
28E 0.85R
CN7-4
CN7-6
DA4 ~ DA6
DA1 ~ DA3
28D
51D
CN2-6
141B
CN2-4
22B
CN2-5
0.5BrB
(AUTO)
0.5BrW
22A
6
CN2-1
0.5BG
KEY SW "START"
89B
CN1-15
0.5GB
START RELAY
104A
CAN A
CN2-15
HORN RELAY
CN1-1
0.85RL
21D
CN1-2
0.85RL
9D
CN2-14
0.5RW
99
CN1-8
0.85B
99
CN1-9
0.85B
AMP 040 12P
AMP MIC 21P CN1
CN4
AMP 070 18P
CYL.2
CN2
3-01 CN4-3
137A GND
0.5GW
CN4-2
136A RxD
0.5GL
CN4-1
135A TxD
0.5RG
CYL.6
3-15
SEGMENT SPEED SENSOR (CAMSHAFT)(DG6) (VR)#2 (TONE WHEEL WITH SLOTS) (0 281 002 662)
RAIL PRESSURE SENSOR (RGS3) (0 281 002 534)
t}
V
3-03
VEHICLE CONN
3-14
2-24
2
2-28
V
81C
1-34
CAN BL
0.5YB
2-34
1
2-25
80D
1-53
CAN AH
2
2-36
81D
1-52
CAN AL
0.5GW 136B 0.5RG 137B 0.5Y
80E
0.5YB
0.5YB
81E
SHIELD
SHIELD 82E
0.5Y
1
2-35
174A
1-30
0.5YB (DIAGNOSTIC LAMP)
0.5YB
174B
2
2-26
175A
1-22
0.5BY (DIAGNOSTIC LAMP)
0.5BY
175B
163A
1-29
0.5Gr (DIAGNOSTIC SW)
0.5Gr
176B
177A
1-85
0.5Dr (DIAGNOSTIC SW)
0.5Dr
177B
0.5BW
165B
1
2-15
1
2-23
165A
1-89
0.5BW
0.5GBr 166B
E/G EMERGENCY STOP SW 1 0.5R
2-19
164B
1-87
163B 2
0.5B
99
3 164A
2-09
1
2-10
3
2-13
2
2-14
1
2-12
(QUICK CLAMP)
CN2-2
0.5 BrW
(POWER MAX)
CN2-10
150E
CN2-8
0.5RL
(1-WAY)
151C
CN2-9
0.5 RY
(2-WAY)
102B
1
1-56
0.5LW
99
1-10
0.85B
99
1-11
0.85B
99
1-05
0.85B
99
1-06
0.85B
101B
0.85Or
CN1-21
5
78A
7
CN1-19
FUEL SENSOR
11
OIL TEMP SENSOR
72A
73B
0.85BR
CN3-8
73A
26B
0.85LgR
CN3-9
26A
27B
0.85LgW
CN3-10
27A
1.25WR
0.85RG
0.85RY
1.25W
0.85LR
0.85L
0.85BR
0.85WR
2RG
1.25R
2RY
20A
20A
15A 15A 15A
5
6
7
8
9
10
11
12
13
14
56A
66A
30A
93A
166A
40A
130A
83A
133A 143A
21A
19A
42A
0.5GBr
0.85RY
0.85Y
2RW
0.5WR
0.5RW
0.5RW
1.25RL
0.85BL
12B
STARTER RELAY 2
0.5B
OFF DR
10W
2 0.85LB 66B
84A
6
P/V-(A)
79B
CN1-20
0.85LgB 79A
103A
CN2-16
0.85V
DA2-3
0.5B
152B 6
96A PUMP PROPORTIONAL V/ V
DA2-2 BREAKER SELECT 150D
2
Px 0.85B
AUTO IDLE (2) SW
8
CN2-17
0.85BW 67B
0.85B
68A
CN2-18
0.85BG 68B
0.85B
INDICATOR
2
DA2-4
146B 3
(A)
CW
147C
1 0.85OrB
DA5-1
147B 4
69A
70A
CN5-3
CN5-7
0.85RB 69B 1.0bar
0.85B
0.85GB
0.85B
70B
(B)
PEDAL BRAEKER PRESSURE SW (OPTION)
0.5GR
90B
1
CN3-16
0.5G
91B
2
CN3-17
0.5GB
92A
3
1-09
0.85RW
19D
1-02
0.85RW
19E
1-03
0.85RW
2RW
7C
1-40
0.5Br
(KEY SW)
153A
1-13
0.85W
(AIR HEATER RELAY)
0.85W
154B
1-07
0.85BG
(AIR HEATER RELAY)
0.85BG
54J
133G
0.85BrR
133H
0
0.85W
0.85BG
0.85BG
0.5RW
A/C THERMOL ( OW)
130C
CN9-6
54E
CN9-11
42B
0.5WR
CN9-5
1.25LR
CN11-2
42C
0.5LR
CN10-8
42D
CN10-18
46B
1.25LR
RH HIGH
0.85RL
150A
0.5BrW
60A
0.85BrL
134B
0.85YL
61A
3 0.85B
7
148D
3
DA6-3 149B
8
2RW
1.25B
8B
DIODE 1
60B
60R
+
-
12V 100AH
12V 100AH BATTERY
AVX
8W
AVX
1.25WG
AVX
2RW
0.85W
0.5BW
105B
CN9-8
0.5LB
106B
CN8-11
0.5LY
105A
CN10-6
106A
CN11-1
99
0.5LW
CN10-1
107A
11 6 16 15 12
+
M
CN10-2
108B
FRE (P1)
0.5GrY
CN10-20
109B
REC (P2)
110A
CN9-15
0.5OrR
CN10-12
110B
DEF (P1)
111A
CN9-14
0.5OrW
CN10-13
111B
VENT (P2)
43A
CN9-16
0.5YB
CN10-11
43B
Vref MODE
CN10-10
44B
MODE F/BACK
CN10-19
112B
WARM (P1)
CN9-17
0.5YW 1.25B 0.5LgW
E
AIR HEATER
GRD 8B ALTERNAT
COMPRESSOR
M
INTAKE ACTUATOR
0.85LW
47A
47B
0.85B M
ALTERNATOR 80A(OPTION )
MAGNET 47C CLUTCH
BLOWER
0.5GrG
CN9-1
F-
100B
99 -
CN9-12
CN9-10
FIELD
F+
+
15L
FET
CN9-13
112A
TRIO DIODE
(1)
H
100A PREHEAT RELAY
109A
99
I(L)
154A D 0.85BG
108A
44A
4A B+
R
0.5 uF B+
REG.
168A
CN10-5
18A
I
15B
A/C RELAY
BLOWER RELAY
CN10-16
0.5LG
CN8-12
98B B -
46A
CN8-10
9A
153B C
CN11-4
13
3 58B
6
0.5G
(C)
0.85OrB 146A (ROTATING-CCW)
4
0.85OrR 147A (ROTATING-CW)
5
1 133B
0.85BrR
2 133C
0.85BrR
(L)
(R)
(ON JOYSTICK L.H)
DA5-2
148B
149C
BR
8C
1.25BrW
E 0.5WR
HOUR
2
1A A
3A
0.5RW 15R
RECEIVER DRIER (2204-6039A )
1.25B
14
PEDAL SWITCH 0.85BrL
133J
0.85BrR
3 133D
0.85BrR
134C
1
1 0.85OrY 71C
5
4 0.85GY
0.85B
MODE ACTUATOR
TERMINAL NO
113A
CN9-18
0.5LgB
CN10-3
113B
COOL (P2)
114A
CN9-3
0.5YR
CN10-7
114B
Vref MIX
115A
CN9-4
0.5YW
CN10-9
115B
MIX F/BACK
167C
CN9-2
1.25BL
CN10-4
167A
GND
116A
CN8-2
0.5OrB
CN10-15
116B
45A
CN8-1
0.5LgR
CN10-14
45B
71D 6
DA6-4
DA6-2
2 0.85Or
149D 3 0.85B
AMP MIC 13P M
MIX ACTUATOR
1
2
3
7
8
9
2 CN8-5
142A
CN8-3
48B
CN10-17
0.5LY
1
6
3
2
1
12 11 10 9
5 4
8
7
0.85OrY (SHEAR-LH HIGH)
148A
0.85Or (SHEAR-RH HIGH)
149A
(C)
0.5Lg
2 -
8
142B 1 133E
4
0.85RY
(L)
49A CN8-4 2 133F
5 (R)
JOYSTICK LEVER SWITC H
0.85RY
0.5GBr
0.5GBr
2RW
2RW
2RW
0.5Br
0.5Br
0.5Br
0.85W
0.85W
0.85BG
0.85BG
0.85GB
0.85GB
167B
2
0.85YG
49B
1
KET 4P
4
0.85BrW 5
179B 0.5WR 54R
2
0
1
I
3
8
7
70F 180A
0.85BrW
180G 6
0.5B 70G
2-PUMP SWITCH
0.85GB
1
70C
0.85BrW
180D
0.85GB
70D
0.85BrW
180E
7
DA3-3 0.85GB
70E
3
(1)
(2)
DA3-2
2
180H 70H
180C
DA3-1 0.85GB
1
10
9
21 20
3
1 9
4
3
8
7
6
5
(3)
2-PUMP S/V
7
6
19 18 17
2
6
1
11 10
5 4
2
(CN10)
3
6
5 4
AMP 040 2 8
7
6
7
3
2
1
10 9
12 11 10 9
8
7
20 19 18 17 16 15
6
5
9
(CN3
AMP 070 18P 3
4
15 14 13
(CN4)
AMP 040-III 20P 7
5
16
AMP 040 12P
3
4
(CN5)
(CN6)
8
8
9
(CN1)
8
3
2-PUMP CONTROL (OPTION) 180F 0.5WR
5
5
AMP 070 4
2
1
5
4
11 10
3
9
12
11
1
20 19 18 17 16 15 14 13 12 11 10
(CN11)
CN8 CN9 AMP 12P + 18P
6
1
AMBIENT TEMP SENSOR
A/C CONTROL PANEL
0.85RY 0.5GBr
0.5YR 114C 0.85BL
2
11 10
4
15 14 13 12
16 15 14 13 12
2
0.85YG
5
AMP 070 16P 2
KET D/L 4P CN11
AMP 20P
7
(CN7)
INCAR SENSOR
CN10
+ 1
6
7
(CN2)
16 15 14 13 12 11 10
9
6
8
18 17 16
AMP 040 28P
WATER SENSOR
AMP MIC 21P
AMP 070 18P 5
WIPER CONT.
DUCT SENSOR 6
48A
4
11 12 13
10
(CN12)
SUNLOAD SENSOR 0.85BrL 134A (BREAKER/POWER MAX)
(ON JOYSTICK R.H)
2RW
6C
1
AIRCON UNIT
2
(B)
3B
1.25BrW
9D 3
2R
BATTERY RELAY B
8W
4B
0.85W
107B
3
1B 0.5G
CIRCUIT BREAKER
(OPTION)
148C
2A
8W
2
10
151A
SHEAR S/V (OPT) - E3C
CW LOW ENGCONTROL DIAL HIGH
1
2R
2WR
-
42E
9
0.85BrR
2 0.85OrR
2
RETURN FILTER SW
(A) CN3-15
19C
0.5Br 2WR
8A
0.5Br
PST SHEAR PRESS BREAKER TML
0.5WR 0.85RY
99 0.5B (HORN)
ROTATING S/V (OPT) - ERO
PILOT FILTER SW
FUSIBLE LINK
DIODE 2
0.5RW
JOYSTICK LEVER SWITCH
146C
60B 60R
3
4
CCW
67A
150B
0.85RL 150C
(A)
A
0.5WR
BREAKER SHEAR SELECT SW
1
7A
STARTER SWITCH
3W
0.5Br
0.85BrR
151B
0.85Br
0.85Br 7B
2RW
168B
1
BR
6B
9B
0.85LR
71A
5
15R
START 24V 6K
C
B
98A
C
10A R2
HOUR METER
0.85GY
DA2-1
3
(OPTION) P/V-(C) FLOW CONTROL PROPORTIONAL V/ V
103B 19bar
152A
152C
(B)
0.85LgW 96B
90A
0.85RW
ACC 13A
0.85RY
99
7
0.85LgR 95A 95B
3Y
11A
83B
ILL
SHEAR SELECT 152D 0.85RB 5
SIG 91A GND 92B
+(5V)
2WR
B+ 0.5WR
LED 1~12
0.85RL
89A
ROOM LAMP
(Loose) 3
0.5GB
5B
2WR
0.5B
E
0.85BL
87 12A 85
1.25WR
2WR
0.85RL
0.85Y
0.5RL
93B
30
11B 86
R1
0.5RW
NO
84B
5A
1.25RL
DIODE 9 61D
6A
8
18 2C
30A
4
0.85B
0.85YL
LH HIGH
1-08
(CONN.1)
2WR
3
SOL-VALVE
4
(CONN.2)
P
3W
FUSE BOX 1 4E 17
0.5WR 1.25RL
0.85Br
PP 3Y B 3W 4C
12C
13C
5W
0.5RW
1
178A
5W
2D 16
0.5RW
1WAY-2WAY S/V (OPT)
12
2B 2B
19B
STARTER RELAY D
C
14A 0.85BL
87a
16
2B
2
0.5GY
78B
0.85Lg
10
CN3-7
56C 0.5RB
QUICK CLAMP SW
SWING PRIORITY
15
1
(C5)
1
8 9
CN5-2
4D
5W
0.5BrW
6
0.85YR
72B
1.25WR
18 2E
0.5RW
DIODE 6
DA6-1 2B
7
0.5BG
84C
RELIEF PRESS UP
AUXILIARY MODE SW
4
CN15
6
8W
0.5RY
4
0.85B
14
5
0.5GB
0.5Br
0.5Br
94A
0.85OrB 102A 3
2
0.5GBr 178B
CN1-10
3
13
4
0.5BG
(C4)
25A
0.85GrL
3
0.5GB
COM 40B
0.85B
0.5GB
10A 10A 10A 10A 10A 10A 10A 10A
10A 10A 10A 10A 10A 10A 10A 10A
QUICK CLAMP(OPT)
HIGH SPEED
21G
17
ON
(BREAKER)
0.5GY
94B 2
0.5BL 0.5B
2
B 13B
0.85RL 60B
101A
0.5GL 135B
3
0.5 Br
CHECK CONN
SHIELD
V
V
0.5Y
2-33
V
P
CAN BH
4
2
N
1-35
3
2
N
CYL.4
80C
7
DA1-3 25B
0.85GrL
0.85RL 21K
2
14
12
15A 15A 15A
UP
AMP 070 16P
t}
(CONN.3)
2-27
1
86
PILOT CUT-OFF SWITCH
(C3)
23A
0.85GrW
1
AUXI MODE RESISTOR
CN5
SENSOR (0 281 002 209)
INCREMENT SPEED SENSOR (CRANKSHAFT)(DG6) (VR)#1 TONE WHEEL WITH SLOTS) (0 281 002 662)
V
2-32
4
CN1-13
84D CN2-11
0.85BrB
AMP 040 20P
FUEL TEMPERTURE SENSOR (0 281 002 209) TEMPERTURE COOLANT
P& t}
0.85GrW
RS-232
CN3
BOOST PRESSURE SENSOR (LDF 6T) (0 281 002 576)
V
3
25C
71B
CYL.5
3-02
P& t}
CN1-11
5
DA1-1 23B
CYL.3
3-16
85
(Fixing) 1
24A 21E
1
13
11
1.25BrR
(C2)
21F
0.85RL 21H
15A
20A
BREAKER
0.85Gr
88A
10
PILOT CUT OFF
61C
0.85RL 21J
2
0.85RL
0.85RL
3-11 3-06
E
0.85B
0.85RG
99
0.85B
6
DA1-2 24B
0.85Gr
3-05 3-12
OIL PRESSURE SENSOR (ODFT) (0 281 002 420)
CN1-12
41A
0.85YG
(C1)
99
0.85B
0.85RL
24C
41B
0.85YL 61B
4 2
23C
3-08
AUTO IDLE (1) / TRAVEL SW
0.85YG 41C
3
34A
0.85LB
NC
CYL.1
3-13
3-07
BOOST PRESSURE ACTUATOR(EPW)
87
58A
0.5G
0.5G
SOL- VALVE ASSEMBLY
DA4-1
INJECTOR SOLENOIDS
0.85RY 57A
0.85RG
1.25RL
CN4-4
3-04
0.85RY
0.85B
ALT "I"
DA4-2
3-10
0.5WR
0.85B
0.85YL
3-09
0.5RL
8 54H
L.F
0.5BG
1
FUEL HIGH PRESSURE PUMP
5 21L
57C
HORN 2
30 56B 0.85RB
0.5GB
104B 19bar
0.85P
0.5YB
CYLINDER CONN
0 I II
7
0.5RL
131A
20A
0.85RY
0.85B
HIGH SPEED SWITCH 10B
ECU
ENGINE CONN
2 21B
Py
CN4-5 0.5Y
(MANUAL)
0.5BrW
3
0.5B
21C
CN7 CN6 AMP 040 12P+16P
0.5RG 0.5BrB
62A
4F 15
0.5G
CYLINDER CONN.
-
B
0.85RL
ECU CON.2 ( PIN) ENGINE CONN.
SIG -
179A
5W
H.F
0.85RY
ECU CON.3 (16-PIN)
+ PRESSURE SENSOR (OWD)
124A
9
4G
87a 0 I II
63A
52A
30A
FUSE BOX 2
57B
HORN 1
65B
200A
0.5BrY
54P
4
0.85BW
18B
0.85LR
0.85RY
140B
8
FUEL HEATER SWITCH
2.5B FUEL HEATER
ONLY SWING (OPT)
2
28A
ALARM RELAY
WARNING LAMP L1 : CHARGE L2 : ENG OIL PRESS L3 : W/T OVER HEAT L4 : E/G WARNING L5 : PREHEAT L6 : WORK LAMP
12V POWER SOCKET
2RW
I
7
30C
20A
1.25RL
0
3
0.5B
54K
FUEL HEATER RELAY
125A 50A
1.25RB
1 0.5B
7
0.5B
20B
2LR
ECU CON.1 (89-PIN) VEHICLE CONN
8
1.25BrR
OVER LOAD WARNING SWITCH
2
0.5RG
ALARM SWITCH
0.5B
89
I
0.85WR
71 72
0
0.85Y
6
39B
1
39A 3
0.5RW
54
11
86
32A
8 0.5WR 54M
7
4bar SWING PRESS SW
0.5W 85
32C
0.5RG
2RG
0.5RY
0.85RB
7 1
OVER LOAD WARNING (OPT)
53
5 0.5W
86
0.85W
36
6
85 0.5B
0.5GBr
35
18
17
122A
0.85V
30 20C
59A 87
59B
0.85RG
31A 87
0.5Br
12
122B
2.5R
30B 30
87a
0.5W 32B
0 I II
L6 0.85B
2
0.85R
104C
0.85RL
0 I II
3
0.5P
2RL
- 0.85B
0.85LB
ALARM BUZZER
0.85RG
0.5B
0.85BG
0.5B
10 99
0.5WR
0.5RW
9 99
CN6-10
0.5WR
L5
0.85LW
0.5B
14B +
132B
3
0.5LR
0.85 RY
11 130D
CN6-9
CN6-11
L4
ECU CONNECTOR
0.5B
65C 99
0.85BY
87a
0.85BG
(CN15)
(CN14)
0.5BW
11
3
1.25RB
FUEL HEATER (OPT)
0.85RY
10
S
14C
2 132A 0.85R
1
0.85LR
0.85RY
0.5GrL
120A
0.5LW
2 16A 0.85L
0.85B
TRAVEL/SWING ALARM ASSEMBLY (OPT)
2
STEREO RELAY
0.5RW
+ 31B
0.5BY
119A
85
2RL
2RW
4
0.5R 28G 29A
0.5WB
0.85R
+
0.85W
3
12 29B
CN6-12
0.85R 2RL
PILOT BUZZER
0.85BG
L2 L3
2
0.5R
12
MOLEX 4P
1
0.5R
2 28C
0.85W
13
1 28B
CN6-2
0.5GBr
14
CN6-1
L1
0.5Br
8
0.5Br
4
9
DC/DC CONVERTER1
99
0.85RY
1 5
0.5WR
1.25 BrR
2 6 10
0.5WR
0.85RL
3 7 11
0.5WR
17
16C 5
STARTER CONTROLLER
0.85RG
2R W
5
3 54B
118A
0.85L
87 65A
3 17A 0.85BR
1
62B 1.25W
1.25RB
0.5 GBr
6
(CN13)
CN6-3
0.5GrR
17B 14
87a
16B 30
0.5BR 88C 86
0.85WR 15B
2RY
1.25 BrR
7
ILL.
7
0.5BR
117A
0.5BR
1.25R
2RW
8
1
+ 117B
99
1.25RB
0.5GBr
9
2
(L
MICOM
Vcc(+5V)
2 63B 1.25WR
0.85BrR
3
169B 13
Vcc(+5V)
CN14 MOLEX 4P
0.85L
FUEL PUMP SW
0.5G
4
DIAGNOSTIC CONN. 14P
0.5BL
KET 8P
0.5WR
131B KET 118 9P
4 169A
0.5WR
0.5WR
AIR SUSPENSION 143C
8
0.5W
123A 16
54C
CN13
1.25B
P
2
0.5B
121A 15
54D
0.5WR 1
CAR STEREO
0.5WG
3 123B
0.85BR
1.25B
1.25B
VOL.
2 121B
0.5WR
0.85B
ANTENNA WASHER
MODULE (K1002641 )
WINDOW WASHER + 0.85L 0.85RB P 35A 34C 0.5RB 0.5L 35B 34D DIODE 5 0.85L 0.85L
12
34B
0.5R
54G
10
162A
WIPER MOTOR
0.85BR
FUEL PUMP (OPT)
8
7
161A
35C
1
SEAT AIR SUSPENSION (OPT)
SEAT HEATER SWITCH
0.85RG
157A
0.85WR
190B
0.85R
2RY 1.25RB
2 143B
0.85WL 7
WIPER CUT SW
0 I II
6
1
I
7
0.5B
CN2
0.85BR
LOWER WIPER MOTOR 2 52B
157B
0.85G
E 0.85B
1.25R 1
144B
S 37A
FUEL PUMP
2RL
LCD GAUGE PANEL
3
0.5B
SEAT HEATER
TERMINAL NO
LAMP SWITCH 0 I II
86 0.5RG
HEAD LAMP RELAY
0.85B
1.25B
0.5WR LOWER WIPER SW
2
0.5RG
54F
2B
CABIN LAMP
6 7
0.5B
CABIN LAMP RELAY 1
125C 5
0 I II
86 126B 0.5RG
53C
8 54L
190A
M
54K
55B
0.5RL
2 38A
0.85BY
85
2
0.5B 85
0.85B
125B
0 I II
3
I
0.85LR
0.5B
0.5WR 126A
30 125D 2RL
0
88B 3 0.5B 7
1.25WR
0.85B
87
B 88H
RUN
0.85G 37B 1
86 88E
85
0.5BG
(FML)
2RG 127A
8
7
STOP
LOWER WIPER RELAY 36A 87a 30 38B 87 0.85Br
DIODE 4
127D 0.85RG
1.25RW 53A 87
0.85RW
0.85RG 0.5WR
0.85R
0.5WR
2B (FRONT)
DA4, DA5
I
124B 2
0.5GB
DIODE 2 ~ 9
53B
33A 3
52D 30 1.25R
87a
HEAD LAMP CABIN LAMP SWITCH
0
0.5B
0.85B CABIN LAMP RELAY 2
L 36B
ROTATING BEACON SWITCH 1
DIODE 3
(LH)
CABIN LAMP
127C 0.85RG (FMR)
DA1~DA3, DA6
0.85B ROTATING BEACON
0.85B
1. DIODEPART NO DIODE 1 .
0.5RG
WORKING LAMP RELAY
1.25WG
1.25B
0.5RG
86 55C
0.85RG
0.5RW
(FR)
86 128B
85
85
0.5B
0.85B 51C
1.25RB
NOTE.
(RH)
(RL)
0.85B
0.5RW
0.5B
127B 0.85RG
30 125E 1.25RL
87
(REAR)
0.85RG 129D
87a
0.85L
129A
0.85BR
1.25RG
0.85WR
REAR WORKING LAMP
START
-
ON
+
0.85B
0.85B
OFF
18 17 16
15 14 13 12
(CN9)
10
9
(CN8)
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