Electrical System

DL-A Wheel Loader

Aug, 2014
Product Support Team
Electric system

Wiring color

1
Electric system

Power supply system

 Key off

1. Battery
2. Battery relay
3. Fusible link
4. Circuit breaker
5. Starter switch
6. Fuse box
7. Alternator
8. Diode

2
Electric system

Power supply system

 Key off

4
3

5
1. Battery
2. Battery relay
7 6
3. Fusible link
4. Fuse box
5. Blinker unit
6. Lamp switch
7. Lamp relay
1

3
Electric system

Power supply system (Key ON)

 Key ON

4
Electric system

Power supply system (Key ON)

 Key ON (Engine/alternator is not running)
Battery relay is energized
by battery power

X
5
Electric system

Engine start
 Engine ignition.

1. Battery
2. Battery relay
3. Fusible link
4. Circuit breaker
5. Starter switch
6. Fuse box
7. Starter controller
8. Starter relay
9. Starter
10. Alternator
11. T/M selector switch
12. Diode
13. T/M controller
14. Safety starter relay

6
Electric system

Engine start
 Starter controller.

① Direction signal (F or R)
from safety relay (24 Volt)

② ALT signal
(Over than 500 rpm)

“S” is not connected with “E” when ① or ②

7
Electric system

Engine start
 After start

1. Battery
2. Battery relay
3. Fusible link
4. Circuit breaker
5. Starter switch
6. Fuse box
7. Starter controller
8. Starter relay
9. Starter
10. Alternator
11. T/M selector switch
12. Diode
13. T/M controller
14. Safety starter relay

8
Electric system

Engine start
 After start (Engine/alternator is running – Charging)
Battery relay is energized by
alternator charging power
while engine running

X
Above 3.3 volt
X

Less 3.3V

Zener Diode
If Key off , what happen with
battery relay

9
Electric system

Engine start
 Preheat.

1. Battery
2. Battery relay
3. Fusible link
4. Circuit breaker
5. Starter switch
6. Fuse box
7. Preheat controller
8. Preheat relay
9. Air heater
10. Thermal switch
11. Alternator
12. Instrument panel
13. Diode

10
Electric system

Engine start
 Preheating time.
Key starting position (R2)

Gauge panel (lamp) Key preheating position (R1)

 Alternator (Engine is running or not)

 Pre heating relay

Power supply Ground

Coolant temp(thermo sensor)
DL300A / DL420A
Coolant Preheat light on
Key position Heating time (sec) Remarks
Temp’(℃) time (sec)

Below 15’ While holding 19 Complete heating

Preheating ON
Preheating position Heating light is “on”
Above 15’ 0

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Electric system

Engine start
 After heating time. Key starting position (R2)
Gauge panel (lamp) Key preheating position (R1)

 Alternator (Engine is running or not)

 Pre heating relay

Power supply Ground

Coolant temp(thermo sensor)
DL300A / DL420A

Coolant Preheat light on

Key position Heating time (sec) Remarks
Temp’(℃) time (sec)
Starting ON Below 15’ While cranking 0 Complete heating
(Cranking) Above 15’ position 0 Heating light is “on”
Alternator signal
Below 15’ 15
Key on after Above 10V
15’ or 0’
engine starting Alternator signal
Above 15’ 0
Below 10V
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 Electric system

Engine stop
 Engine running mode

1. Battery
2. Fusible link
3. Starter switch
4. Fuse box
5. Engine stop relay
6. Engine stop motor

13
Electric system

Engine stop
 Engine running mode

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 Electric system

Engine stop
 Engine stop mode

1. Battery
2. Fusible link
3. Starter switch
4. Fuse box
5. Engine stop relay
6. Engine stop motor

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Electric system

Engine stop
 Engine stop mode

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Electric system

Control unit

Input Output
All lamp “On” with buzzer
Starter S/W(#2) “On” After 2 sec,
All lamp and buzzer “Off”
Alternator charging voltage (Below 12 V) Charging lamp(L5) “On”
Engine oil pressure S/W(#9) “ON” Buzzer sounds after 8+-1 seconds
Coolant temperature S/W(#10) “ON”
Alternator charging
voltage (Above 12 V) Brake oil pressure S/W(#11) “ON” Buzzer sounds immediately
F/R lever S/W(#3,4) & Parking brake S/W(#12) “ON”
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Electric system

Monitor panel (Gauge)

Alternator signal

24V
(Supply power)

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Electric system

Monitor panel (Gauge)

24V
(Supply power)

From
TCU

19
Electric system

Proximity switch (Joystick detent function)

 Proximity switch.

(- Terminal)

( O output)

(+ Terminal)

Normal condition Approached condition

(O) and ( - ) Terminal : Opened (O) and ( - ) Terminal : Closed

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 Electric system

Proximity switch (Joystick detent function)

 Detent / release lever ( I )

← From Battery

Not approached
Not working Energize magnet

(Release lever) (Detent lever)

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Electric system

Proximity switch (Joystick detent function)

 Detent / release lever ( II )

← From Battery

Approach lever Energize magnet Not working

(Detent lever) (Release lever)

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Electric system

Transmission system
 Schematic of transmission system.

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Electric system

Transmission system
 Neutral position.

When measure current,

#13 with # 10,56,32,55,9 and 51 are 100 mA

XXXXXX

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Electric system

Transmission system
 Traveling condition - Forward 1st

Engaged KV, K1 Clutch

 Y3, Y5 : 500 mA
#13 and#32,#13 and #9 : 9.5V
 Y1, Y2, Y4, Y6 : 100 mA
#13 and other : 1.9V

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Electric system

Transmission system
 Traveling condition - Reverse 1st

Engaged KR, K1 Clutch

 Y1, Y3 : 500 mA
#13 and#10,#13 and #32 : 9.5V
 Y2, Y4, Y5, Y6 : 100 mA
#13 and other : 1.9V

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Electric system

Transmission system
 Traveling condition (Traveling by F&R switch)

F&R select signal light on

(from gauge panel)

Condition of traveling by F&R switch

- DW-3 T/M selector SW : Neutral position and selected machine speed (1st,2nd,3rd or 4th)
Then, traveling machine by F&R switch without DW-3 T/M operation( F or R selection).
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Electric system

Transmission system
 Kick down - Manual mode : 2nd → 1st

When selected manual traveling mode and pressed kick down switch, the traveling gear is
shifted down ( 2nd speed gear → 1st speed gear).
And pressed kick down switch again, the traveling gear is shifted up ( 1st speed gear → 2nd
speed gear). It works for 1st and 2nd speed only ( not 3rd, 4th speed)
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Electric system

Transmission system
 Kick down - Auto mode.

Press down shift button , 4th → 3rd → 2nd → 1st or 1st

→ 2nd → 3rd → 4th
In order to change 4th → 3rd, engine speed must be
drop from normal engine RPM (RPM gap 200 ~ 300)
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Electric system

Transmission system
 Transmission cut – off function.

T/M Power cut off function is working

only forward & reverse 1st, 2nd speed
(Not 3rd,4th Speed)

X
X
T/M Cut off switch “On”
with press brake pedal

T/M controller cut forward or reverse

clutch power off.

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Electric system

Transmission system
 Automatic traveling (1-4)

Traveling speed is depended on gear shift position.

If operator selects 2nd gear speed, max. speed of the
machine is 2nd gear speed ~
~

~ Normal shifting range is 2nd ↔ 3rd ↔

4th
~
~ If machine is on hard working condition
or traveling load, gear is shifted to
1st ↔ 2nd ↔ 3rd ↔ 4th automatically
Gear shifting is depended on traveling
load. 31
Electric system

Transmission system
 Automatic traveling (2-4)

Traveling speed is depended on gear shift position.

If operator selects 2nd gear speed, max. speed of the
machine is 2nd gear speed
~
~

Normal shifting range is 2nd ↔ 3rd ↔ 4th.

~
~ If operator presses kick down switch ,
under 2nd , the gear will be shifted down
~ to 1st ↔ 2nd ↔ 3rd ↔ 4th.

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Electric system

Transmission system
 Control block.

Input current (mA) Resistance Voltage (VDC)

Regulator Output Press (bar)
Neutral Engaged () Neutral Engaged
Y1~Y6 100 500 19 1.9 9.5 0.8 ~ 8.3

Condition of Pressure Regulator Operation

1) Parking brake released 2) Transmission Oil Temperature : over – 10 degree C

33
Electric system

Transmission system
 Temperature sensor in control block.

Condition Function Remark

Open or Short Circuit - Error code display only Resistance : 1000 ~ 1500 
- Travels normally Sensing Temp. for AEB
No Buzzer

 -30 degree C (T/M oil) - Parking brake engaged

-30 ~ -10 degree C (T/M oil) - 1st, 2nd speed only

 -10 degree C (T/M oil) - Travels normally

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Electric system

Transmission system
 By pass filter switch.

DL400, DL500

Normal condition Closed filter condition

Closed filter
By pass filter switch Normal Resistance () Resistance ()
(= by pass oil)
Open
Closed 500 0
(Error code : BA)

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Electric system

Transmission system
 Location of transmitter.

Central
Engine Turbine Inductive
gear
transmitter

Engine
inductive
transmitter
Filter switch
Turbine
Out put Central gear Out put
speed sensor speed sensor

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Electric system

Transmission system
 Transmitter specification .

Specification
Sensor Remark
Frequency Resistance() Gap (mm)

Engine
- Output torque Control signal
& 0.5~0.8
- Signal for AEB
Turbine 1050  10%
30Hz~50kHz - Keep the original gap by shim (DL400)
(20℃)
- No need gap adjustment(DL300)
Central 0.3 ~ 0.4 - For high speed sensing

Output Propeller shaft speed

- Travel Speed display signal
- LIS system (over 6 km)
Speed 2Hz~5KHz - 1.0~1.3
- Keep the original gap by shim (DL400)
- No need gap adjustment(DL300)
- For high & low speed sensing

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Electric system

Transmission system
 Working for each speed sensor.

1. Engine & turbine sensor :

Compare engine RPM & turbine RPM to get
working condition or engine load.

2. Turbine & central sensor : Engine

Compare turbine RPM & central gear RPM
to get clutch slipping condition or clutch
slipping time
Turbine
Output

Central

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Electric system

Transmission system
 LIS system.

~
~
~
Machine speed

0 I II

Forward - Over 6 km/h : on, Below 4 km/h : off

LIS Sol valve off on
Reverse - Over 4 km/h : on, Below 2 km/h : off

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Electric system

Transmission system
 Emergency steering system.

From fuse box

From starter line

To warning
lamp

Condition
Emergency steering press Operation
Machine speed
S/W
Closed 0 km/h EMR motor is not working
Below 4 km/h EMR motor is not working
Open
EMR motor is working
(Steering press. drop) Over 5 km/h
for 60 sec with 1 time.
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Electric system

Transmission system
 AEB starter.

The AEB has the task to compensate tolerances

(plate clearance and pressure level)
which are influencing the filling procedure of the
clutches.

For each clutch,

the correct filling parameters are determined in one test
cycle for period of the quick-flling time
level of the filling compensating pressure

Need approx. 80’ C of TM oil temp. for AEB (need warm

up)

41
Electric system

Transmission system
 AEB procedure.
Step Order Display Remarks
1 Warm up transmission about 10 to 20 minutes Temperature 80 degree
2 Turn off ignition key

Plug in AEB starter to AEB connector located

3
at the seat base closest to the cab door

4 Put T/M gear selector lever to Neutral position

5 Engage park brake

TCU must recognize “PL” for at least 3 sec
6 Start Engine “PL“
before you press AEB starter button
7 On idling RPM “PL“

The button must not be released before TCU

8 Press button of the AEB Starter “ST” has started the AEB or quit with an error code
(see Error code list)

“K1” TCU has started the AEB, and goes on

9 Hold button until AEB has been started (Information about the adjusting K1, K2,…, KR.
AEB state) (Button may be released from starting)
“OK”
10 Wait until AEB has been finished (AEB has been
successful)
11 Turn off ignition and unplug AEB Starter

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Electric system

Transmission system
 AEB messages.
Symbol Meaning Remarks
PL AEB - Starter is plugged at the diagnostic plug
ST AEB Starter button is pressed
K1..K4,KV,KR Calibrating each clutch K1..K4,KV,KR
_ and Kx Wait for start, initialization of clutch Kx, x : 1, 2, 3, 4, V, R
fast fill time determination of clutch Kx compensating pressure determination of clutch
≡ and Kx Kx
calibration for all clutches finished Transmissions stays in neutral, have to
OK restart the TCU (ignition off/on) after
removing AEB-Starter
STOP AEB canceled (activation stopped) Transmissions stays in neutral, have to
restart the TCU (ignition off/on)
STOP and Kx AEB stopped, clutch Kx can't be Transmissions stays in neutral, have to
calibrated restart the TCU (ignition off/on)
Spanner and Kx couldn't be calibrated, AEB finished Transmissions stays in neutral, have to
Kx restart the TCU (ignition off/on)
↑E Engine speed too low E/G RPM should be raised
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Electric system

Transmission system
 AEB messages.
Symbol Meaning Remarks
↓E Engine speed too high E/G RPM should be down
↑T Transmission oil temperature too low Warm up Transmission
↓T Transmission oil temperature too high Cool down Transmission
FT T/M temp not in defined range during calibration T/M stays in neutral, have to restart the TCU
(key off/on)
FB Operating mode not NORMAL or T/M temp T/M stays in neutral, have to restart the TCU
sensor defective or storing of Calibrated values (key off/on)
to EEPROM-has failed
FO Output speed not zero Transmissions stays in neutral, have to
restart the TCU (ignition off/on)
FN Shift lever not in Neutral position Transmissions stays in neutral, have to
restart the TCU (ignition off/on)
FP Parking brake not applied Transmissions stays in neutral, have to
restart the TCU (ignition off/on)
STOP AEB - Starter was used incorrect or is defective Transmissions stays in neutral, have to
restart the TCU (ignition off/on)
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Electric system

Air- conditioner
 Air-conditioner.

1.Battery. 2.Battery relay.

3.Fusible link. 4.Circuit breaker.
5.Fuse. 6.Lamp S/W.
7.Compressor relay.
8. Foot / defrost actuator
9. Receiver drier.
10. Diode. 11. Compressor.
12. A/C control panel 13. A/C unit.
13-1. Blower motor. 13-2. Resister.
13-3. High speed relay.
13-4. Mid speed relay.
13-5. Low speed relay.
13-6. Recir / Fresh actuator.
13-7. Vent actuator.
13-8. Temp control actuator.
13-9. Temp sensor.

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Electric system

Air- conditioner
 Blower unit.

15-2 Resister 15-8 Temp. control actuator

Fan speed relays

15-7 Vent actuator
15-9 Temp. sensor

15-6 Recirculation / Fresh actuator

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Electric system

Air- conditioner
 A/C controller system.

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Electric system

Air- conditioner
 Blower motor.

3.86Ω
1.28Ω

Low. speed

Θ Mid. speed
Θ
Θ High speed

Blower resister

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Electric system

Air- conditioner
 Recirculation / ventilation.

Θ
Θ Recirculation / Fresh air actuator
Θ
Θ Ventilation air actuator

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Electric system

Air- conditioner
 Temp. control actuator.

12 Volt

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Electric system

Air- conditioner
 Condenser

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Electric system

Air- conditioner
 Foot / Defroster

24 Volt

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