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ELE0003 DL Electric System
ELE0003 DL Electric System
DL Wheel Loader
Feb, 2009
Overseas Product Support Team
Text No. ELE0003
Electric system
??
1
Electric system
Engine start
¾ Key on position.
2
Electric system
Engine start
¾ Engine ignition.
3
Electric system
Engine start
¾ Starter controller.
① Direction signal
from safety relay (24 Volt)
② ALT signal
(Over than 500 rpm)
4
Electric system
Engine start
¾ Preheat.
5
Electric system
Engine start
¾ Preheating time.
Below 0 20
On Complete heating
5 10
(= preheating) Heating light is “on”
Above10 Not working
DL400
Below -12 30
On Complete heating
0 10
(= preheating) Heating light is “on”
Above19 Not working
6
Electric system
Engine start
¾ After heat.
7
Electric system
Engine start
¾ After heating time.
Below 0 120
5 60
Above10 Not working
DL400
Below -19 30
-19 ~ -8 20
-8 ~ 8 10
Above 8 Not working
8
Electric system
Control unit
Key S/W
Safety relay
Alternator
Condition Operation
All lamp “On” with buzzer
Key S/W “On” (#1)
After 2 sec, All lamp and buzzer “Off”
Alternator charging voltage (Below 14.5 V) #2 Charging lamp “On”
Brake press S/W “Closed” (#6)
Alternator charging
Parking brake S/W “Closed” (#7) Buzzer
voltage (Above 14.5 V)
Safety relay “Closed” (#8)
9
Electric system
(- Terminal)
( O output)
(+ Terminal)
10
Electric system
← From Battery
Not approached
Not working Energize magnet
11
Electric system
← From Battery
12
Electric system
Air- conditioner
¾ Air-conditioner.
13
Electric system
Air- conditioner
¾ Blower unit.
Air- conditioner
¾ A/C controller system.
15
Electric system
Air- conditioner
¾ Blower motor.
3.86Ω
1.28Ω
Low. speed
Θ
Θ Mid. speed
Θ
High speed
16
Electric system
Air- conditioner
¾ Recirculation / ventilation.
Θ
Θ Recirculation / Fresh air actuator
Θ
Θ Ventilation air actuator
17
Electric system
Air- conditioner
¾ Temp. control actuator.
12 Volt
18
Electric system
Air- conditioner
¾ Condenser / air- compressor
19
Electric system
Air- conditioner
¾ Foot / Defroster
24 Volt
20
Electric system
Reverse fan
S/W
Coolant Temp.
sensor
50mA ↔ 580mA
21
Electric system
Reverse fan
22
Electric system
Coolant Temp.
T/M oil Temp.
Reverse
Reverse fan
23
Electric system
Transmission system
¾ Schematic of transmission system.
24
Electric system
Transmission system
¾ Neutral position.
XXXXXX
25
Electric system
Transmission system
¾ Traveling condition - Forward 1st
z Y3, Y5 : 500 mA
#13 and#32,#13 and #9 : 9.5V
z Y1, Y2, Y4, Y6 : 100 mA
#13 and other : 1.9V
26
Electric system
Transmission system
¾ Traveling condition - Reverse 1st
z Y1, Y3 : 500 mA
#13 and#10,#13 and #32 : 9.5V
z Y2, Y4, Y5, Y6 : 100 mA
#13 and other : 1.9V
27
Electric system
Transmission system
¾ Traveling condition (Traveling by F&R switch)
Transmission system
¾ 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)
29
Electric system
Transmission system
¾ Kick down - Auto mode.
Transmission system
¾ Transmission cut – off function.
X
X
T/M Cut off switch “On”
with press brake pedal
31
Electric system
Transmission system
¾ Automatic traveling (1-4)
~
~
Transmission system
¾ Automatic traveling (2-4)
~
~
33
Electric system
Transmission system
¾ Control block.
34
Electric system
Transmission system
¾ Temperature sensor in control block.
Open or Short Circuit - Error code display only Resistance : 1000 ~ 1500 Ω
- Travels normally Sensing Temp. for AEB
No Buzzer
35
Electric system
Transmission system
¾ By pass filter switch.
DL400, DL500
36
Electric system
Transmission system
¾ 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
37
Electric system
Transmission system
¾ Transmitter specification .
Specification
Sensor Remark
Frequency Resistance(Ω) Gap (mm)
38
Electric system
Transmission system
¾ Working for each sensor.
Central
39
Electric system
Transmission system
¾ LIS system.
~
~
~
Machine speed
0 I II
40
Electric system
Transmission system
¾ Emergency steering system.
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
(Brake press. drop) Over 5 km/h
for 60 sec with 1 time.
41
Electric system
Transmission system
¾ AEB starter.
42
Electric system
Transmission system
¾ AEB procedure.
Step Order Display Remarks
“OK”
10 Wait until AEB has been finished
(AEB has been successful)
43
Electric system
Transmission system
¾ 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
44
Electric system
Transmission system
¾ 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)
45