=xs50 ELECTRICAL SYSTEMAE CONTENTS Group 01- Component Location Group 05- Inspection and Maintenance Component Location .. 04-01-01 Precautions for Inspection and Rolays ...... s+. T04-01-02 Maintenance .........eccece. T0405-01 Monitor and Switch Panel... 04-01-03 Fuse Continuity Test .. To4-05-02 Inspection and Replacement of Group 02- Main Circuit Fusible Links 04-05-03 Outline T04-02-01 Taking Apart Connector To4-05-04 Power Circuit : 04-02-02 Installation and Adjustment of the Engine Start Circuit To4-02-04 ASONSOF ..ceeeecseseceese TOM05-08 Charging Circuit To04-02-06A Positioning and Voltage. Surge Voltage Prevertion Circuit 04-02-08 ‘Adjustment of the EC Sensor .. 04-05-07 Accessory Circuit ............. TO402-10A Inatallation of the EC Motor 04-05-07 Engine Stop Circuit To4-02-114 Type of Connector. =» T04-05-08 (Revised page: OSA, 05A, 064, O7A,O8A, 10A, 11) EC Related Fault Codes ....... 04-05-14 PVC Related Fault Codes ...... T04-05-15 Group 03- Control System Dr. EX Monitor Function wes T04-05-16 Outline .. cesses 0403-014 Outine of Engine Control ..... 04-03-02 Outline of Pump Control T04-03-048, Outline of Preesure Control... T04-03-06 Outline of Work Mode Control... T04-03-07 SECTION 04 X y Outline of Other Controls .. T04-03-08A Diagnosing Function sesese T04-03-09, Engine Control System . T04-03-10 Function . T04-03-13 (Pica page O14, 028, 048, 084, 124) Group 04- Monitor Outline of the Monitor veeeees 04-04-01 Monitor Panel densaneenees T04-04-02 Monitor Function... wees T04-04-03 Monitor Check Procedure ceeeee T04-04-09 (Revised page: 064) 1167-04-01 96031167-04-02ELECTRICAL SYSTEM / Component Location COMPONENT LOCATION 1 Work Light (Boom) 12 Circuit Breaker 34— P Switch Switen 13~ Battery EC 3— Cigar Lighter 14— Fuel Level Sensor Pvc 4— Dome Light 15— Coolant Level Switch 37— Relays 5— Antenna 16— Low Fuel Level Sensor 38 Radio 6 17— Overheat preventive Switch 38— Work Light 7 18— Overheat Switch 40— Wiper 8— Work Light, 18— Coolant Temperature 41— NSensor ‘Switch 9 Starter Relay-t 20~ Alternator 10~ Starter Relay-2 21— Start 32~ Battery Relay 11 Cold Cranking Ald -22— AlrFilter Restriction Switch 23 Fusible Link Relay T04-01-01ELECTRICAL SYSTEM / Component Location Relays 1 Wiper Relay 3— Load Dump Relay 5— Washer Relay 7— Work Light Relay (Boom) 2— EC Motor Relay 4— Hom Relay 8 Work Lignt Relay 8— Charge Relay (Base Machine) T04-01-02ELECTRICAL SYSTEM / Component Location MONITOR AND SWITCH PANEL 1— Monitor 2— Switch Panel (1) ‘3~ Switch Panel (2) 04-01-03ELECTRICAL SYSTEM / Component Location T04-01-04ELECTRICAL SYSTEM / Main Circuit OUTLINE The electrical system consists of three major cir- ‘uit: the main, control, and monitor circuits. The main circuit includes: engine starting, battery charging, and lighting operations, The main circuit operates at 24 volts, The control circuit's function is to control the ma- chine’s operating conditions. It consists of sensors, switches, controllers, and actuators. The monitor circuit is comprised of sensors, switch- 8, controller, and monitors to provide information about the machine’s conditions. Initial electrical power is provided by two 12 volt bat- teries, connected in a series. Electrical power re- quired to operate the microcornpuler anid its circuit is 5 volts, reduced from 24 volts by a transformer. T04-02-01ELECTRICAL SYSTEM / Main Circuit POWER CIRCUIT The negative terminal of the battery is grounded to (1) Voltage standards (monitored by circuit tester) the machine body. When the key switch is in the Voltage standards at various locations are OFF position, the current flows from the positive bat- shown in the electrical circuit table below. Re- tery terminal as shown here. fer to it when performing necessary trouble- shooting. Battory-sBattery relay—-Fusible link—> - v1. Key sich terminal B Engine [Key swite Testpoint | Voltage 2. Load dump relay OFF | OFF |2EOnebattery | 10-125 +3. Fuel pump (Optional) ofr | OFF |3-20nebattery | 10-125 +4. Fuse box OFF | OFF |3-1 Twobatteries | 20-25 Fuse box OFF | OFF |4-E Two batteries | 20-25 Terminal No.1 > Switch panels corr | OFF |5-EFusiblelink | 20-25 (Backup)-> Clock Terminal No.2 EC (Power, Backup) Terminal No.3 eee ar ela Ec (2) Current standard Terminal No.4 > PVC (Backup circuit) The electrical current shown below is backup current to the EC, PVC, and switch panels. Measure backup current at the negative termi- nal of the battery after disconnecting the Tho operation of the EC motor is controlled by the ‘ground cable. key switch. However, backup power is also supplied from the battery directly to the EC motor via the Engine | Key switch [ Test point | Curent controllers and switch panels, in order to retain op- Orr | OFF | 1-E Backup oma eration memory. cout Note: E: Ground T04-02-02ELECTRICAL SYSTEM / Main Circuit Key Switeh Fusibe Link Load Dump Relay Pvc EC Motor Relay, EC, EC Motor EC Monitor Controller ‘Shitch Panel-t, Switch Panel2 Fuel Pump T04-02-03A 9603ELECTRICAL SYSTEM / Main Circuit ENGINE START CIRCUIT When the key switch is turned to the START position, terminal B in the switch comes into contact with terminals G2, M, and ST. The current from terminal M magnetizes the battery relay, allowing the current from the battery to flow via the battery relay into terminal 1 of starter relay 1. Terminal ST of the key switch is connected to coil of the starter relay 1, allowing current to flow into the coil in the starter relay, closing the circuit and allowing the current to flow into terminal S of the starter. The relay in the starter is thereby activated, ‘causing the starter to rotate. Terminal G2 is connected to terminal No. 2 of the monitor controller and the cold cranking aid eyetom Via the fuse box No. 9. Current to monitor controller No. 2 tum off the level check indicator and silences the alarm buzzer, when the engine is cranking, Voltage standards Fngina | Kay switch | Testpoint | Voltage Cranking | START |1-€ Battery 20-25 Cranking | START |2.£ Keyswitch | 20-25 Cranking | START |3-£ Battery relay | 20-25 Cranking | START |4-€ Battery relay | 20-25 Cranking | START |5- Starter(B) | 20-25 Cranking | START |6-£ Starters) | 20-25 Cranking | START |7-£ Starter relay | 20-25 Note: E: Ground T04-02-04ELECTRICAL SYSTEM / Main Circuit Monitor Contoter 2 Monitor Contalier + Hour Meter From Altemator Cold Cranking Aid System T04-02-05A 9603ELECTRICAL SYSTEM / Main Circuit CHARGING CIRCUIT After the engine starts, the operator releases the key ‘Alternator terminal B switch to the ON position. In this position, terminal B connects with terminal ACC and M inside the key —> 1. Battery relay-»Battery switch, + 2.Work light, wiper, air cor The engine drives the alternator, which in turn + 3.Switch panels, PVC, solenoid valve generates current, and charging current flows from + 4.Monitor panel terminal B of the alternator to the battery. x Current from terminal B of the alternator also flows: jo Monlioe contig through the fuse box, supplying power to the work ‘Alternator terminal R light, wiper, cab heater, switch panels, PVC, solenoid valves, monitor panel, and monitor —1.Starter relay 2 controller. Current from terminal R of the alternator flows to the terminal 1 of starter relay 2 , tuning off the relay. Voltage standards Engine | Keyswitch [ Test point | Voltage Fast ON |1-€ Battery | 26-30 Fast ON | 2-€Altemator | 13-30 Fast ON | 8-€ Alternator | 26-30 Fast ON | 4-€ Monitor 26-30 panel Note: E: Ground T04-02-06A 9603ELECTRICAL SYSTEM / Main Circuit Key Switch Travel eee Ec ‘Alan = Dome Light Pvc. Cigar Lighter olencid Valve aco Lubricator Horn Work Light Wiper Heater Fuel Supply Solenoid ‘Atemator Moritor Controller T04-02-07A 9603ELECTRICAL SYSTEM / Main Circuit SURGE VOLTAGE PREVENTION CIRCUIT Alter the engine starts running, current from terminal Vottage standards B of the alternator flows to terminal 4 of the monitor Engine | Key switch | _ Test point | Vohaga controller via charge relay, activating the transistor. Tho ourrent from the battery can then flow through Siow [ON] 1-EAltemator 8 | 26-30 the load dump relay circuit, supplying current to ‘Slow ON 2E Load dump | 26-30 magnetize the battery relay. relay ‘As long as the engine is running, the alternator om lige eae keeps the transistor activated; allowing the battery relay to remain ON in case the engine is suddenly Note: E: Ground switched OFF, thereby preventing surges which could be potentially damaging to such electrical parts as the controllers, transistors, diodes, etc . T04-02-08ELECTRICAL SYSTEM / Main Circuit Key Switch 8 [sfo2per m [sr] Battery Battery Relay Load Dump Circuit Breaker Relay Charge Relay * ToStarterRelay2 (7 ToStarter Relay 2 | Monitor Controller ‘Alternator Transistor T04-02-09A 9603ELECTRICAL SYSTEM / Main Circuit ACCESSORY CIRCUIT When the key is turned to the ACC position, Voltage standards terminal B comes into contact with terminal ACC in Engine | Key switch | Testpoint | Voltage the key switch. When the key is turned to the ON OFF ON ]1-E Dome light] 20-25 position, terminal B comes into contact with both terminal ACC and terminal M OFF ON — | 2-€Cigarlighter | 20 - 25 OFF ON |3-E Radio 20-25 Current from ACC terminal supplies power to the horn, radio, cigar lighter, and dome light, and ACC OFF ON 4-E Horn 20-25 circuits for added-on options. Note: E: Ground ‘The current from terminal M supplies power to the battery relay and, via the fuse box, to the EC. Moreover, the current generated by the alternator with the battery relay ON activates the load dump relay and flows into the battery charging circuit. T04-02-10A 9603ELECTRICAL SYSTEM / Main Circuit ENGINE STOP CIRCUIT ‘When the engine is running, current from terminal M of the key switch flows to the fuel supply solenoid. ‘The solenoid supplies fue! to the injection pump. When the key switch is turned from ON to OFF, the fuel supply solenoid will shut off fuel flow. Koy Switch bee eta iste Fuel Supply Solenoid Fuse Box T04-02-11A 9603ELECTRICAL SYSTEM / Main Circuit T04-02-12ELECTRICAL SYSTEM / Control System OUTLINE Pump and valve controller (PVC) and en controller (EC), having built-in microcomputers, function to control machine operations. Signals from various kinds of sensors and switches are sent to the controllers. After being processed in logic module, machine operation control signals are sent ut to control the solenoid valves, engine control motor (EC motor), and so on, The EC mainly controls the engine, and the PVC controls the pump. Both controllers are connected by serial communication circuits, and communicate with each other when necessary. Input Signals ‘Output Signals PE, L,1 Switches > Accelerator/Decelerator Switches = Auto-Idle Switch = [> Engine Control Motor (EC Motor) Warm-Up Switch =| ec Engine Speed Sensor (N Sensor) > Engine Control Sensor (EC Sensor) = Hydraulic Temperature Sensor (T Sensor) —» Overheat Preventive Switch > Serial Communication Circuit Pressure Sensors (P Sensor) J+ Solenoid Valve 1 (Three Spools) Pump Displacement Angle Sensors (A Sensor) —> ‘SA: Relief Pressure Raise Control Travel Mode Switch = ‘SB: Travel Speed Control Work Mode Selector Switch = ‘SC: Swing Parking Brake Release Control Power Boost Switch Pressure Switches (P Switch) =| pvc | Solenoid Valve 2 (One Spool) Swing, M2 Trenching Mode Control Bucket rot-in, Speed up, Boom raise, + Pump Control Solenoid Valves Arm rollin, Travel, > DrEX Other Differential Pressure Sensors (DP Sensor) —»| T04-03-01A 9603ELECTRICAL SYSTEM / Control System OUTLINE OF ENGINE CONTROL Engine Speed Control After signals from the I, L, E, P switch and accelera- tor/decelerator switch are processed in the EC, the EC. sends a control signal to the EC motor. The EC motor then controls engine speed. Auto-Idle Control The auto-idle functions to reduce fuel consumption and lowers engine noise level. When the auto-idle switch is ON, and the control fevers are in neutral for more than 4 seconds (all pressure switches are OFF), the EC sends ‘a control signal to the EC motor. The EC motor then re- duces engine speed to the preset auto-idle speed. Hydraulic Warm-Up Control Hydraulic oil temperature is raised efficiently by the hy- draulic oil warm-up circuit without operating the actu- ators, The hydraulic oil warm-up circuit automatically controls engine speed and main pump flow rate for a maximum of 16 minutes. When the warm-up switch is depressed, @ sensing signal is sent to the EC. The T sensor also sends a sensing signal to the EC. If the oil temperature is less than 30 °C (86 °F), the EC sends a control signal to the EC motor to increase engine speed. Stopping The Engine The engine is stopped using the key switch. When the key switch is tured to the OFF position, the fuel supply solenoid is moved to the OFF position shutting off the fuel flow. PE, L,1 Switches ec |__| pve ‘Accelerator | Decelerator Switches EC Motor EC Sensor Auto-Idle >| Switch EC ™| Pvc be pressure ment Switches ‘Switches ‘Sensing Signal EC Motor Pump Control Solenoid Vaive |_| Warm-Up Ec Pye ‘Switch T Sensor —>| EC Motor 9603 T04-03-02AELECTRICAL SYSTEM / Control System Engine Speed Programing Circuit Each time, when the key switch is tumed ON, and the P mode switch is depressed, the EC motor functions to Power Mode ———»{ memorize the maximum engine speed. Switch EC *| Pvc — EC Sensor ——> v EC Motor 04-03-03ELECTRICAL SYSTEM / Control System OUTLINE OF PUMP CONTROL Pump Flow Control ‘The main pump flow rate is regulated in proportion to Power Mode the control lever operating stroke by the pump flow cir- Seiector >| | }<—P Switch cuit. CEL) EC PVC. The DP sensor detects differential pressure between the [*—] |" ~ —0P Sensor front and rear ports of the pump control valve in the control valve. Tho DP sensor sends a sensing signal to the PVC. Then, the PVC. sends a control signal to the pump contro! solenoid valve so that the pump delivers oil flow inversely proportional to the differential pressure. Pump Control Solenoid Valve The A sensor checks the actual pump displacement an- gle and sends @ feedback sensing signal to the PVC. ‘The PVC compares the control signal to the pump con- trol solenoid valve with the feedback sensing signal trom the A sensor and regulates the control signal to the pump control solenoid valve to maintain the pump flow within the target value. }x—A Sensor ‘Speed Sensing ‘The speed sensing circuit is designed to utilize engine Power as much as possible for hydraulic pump driving power Mode —»| torque. The N sensor detects engine speed changes Selector, during operation to check if the engine stil has surplus Switch (P,E) | EC Pvc power for the load applied. Then, depending on the de- |<—P Sensor ‘gree of surplus power, hydraulic pump driving torque is adjusted by the PVC. The N sensor and P sensor check the engine speed change and the engine load received, respectively. The PVC receives sensing signals from the P sensor, and the EC receives signals from the N sensor. Then, the PVC and EC communicate with each other and judge whether the engine has surplus power or not. Based on their judgment, the PVC sends a control signal to the pump control solenoid valve to regulate the pump flow rate.The A sensor checks the actual pump displacement angle and sends the sensing signal back to the PVC. Thus, the PVC regulates the pump displacement control signal to maintain the proper operating conditions. }x—A Sensor N sensor ——>| Pump Control Solenoid Valve Power Summation Control }—| | —P sensor ‘The PVC regulates the pump control solenoid valve so EC Fa PVC | op sensor that the pump driving summation power does not ex- ceed the engine output power after having received [<—A Sensor pump control signals from the DP, A, and P sensors. Pump Control Solenoid Valve T04-03-04A 9603ELECTRICAL SYSTEM / Control System ‘Swing Power Decrease Control When the swing pressure switch is turned ON, the PVC. |—+{ ~~]. Swing Pressure decreases the front pump delivery oil flow to the swing EC Pvc ‘Switch function (on the 5-section control valve side) and ine ‘creases the rear pump delivery oil flow (on the 4-section control valve side) to utilize engine power effectively. Pump Control Solenoid Valve Relief Cut-Off Control fc oll J<—P Switch To reduce temperature raise of hydraulic oll and reduce energy loss, the PVC controls the pump control solenoid valve so that the pump flow rate is reduced when the P sensor senses that the relief valve is relieving. However, [<—A Sensor when the travel pressure switch comes ON, relief cut-off function of the both front and rear pumps is deactivated. Y When the swing pressure switch comes ON, relief cut- Pump Control Solenoid Valve ‘off function of the front pump on the §-section control valve side is deactivated. EC Pvc <—P Sensor Bucket Speed Up Control oe |__Bucket Roll-In Pres- ‘sure Switch ‘When only the bucket roll-in pressure switch comes ON, Ec |__| pve the S-section control valve side pump flow rate is in- creased unti it is equal to that of the 4-section control valve side pump. Then, the 5:section control valve side Pump flow is combined with the 4-section control valve 7 side pump flow, increasing pump fiow to increase buck- et cylinder rollin speed while the bucket light loaded, Coen Maximum Pump Flow Control no When either the swing pressure switch or the ovetheat Qverheat _| EC Pvc wich preventive switch is ON, the PVC regulates the pump Preventive>| control solenoid valve so that the maximum pump dis- Switch placement angle is reduced to decrease ail flow. Pump Control Solenoid Valve T04-03-05ELECTRICAL SYSTEM / Control System OUTLINE OF PRESSURE CONTROL. ; — Travel Pressure Relief Pressure Raise Fravel Ec Pvc This system functions under the following operating Monee conditions: lector 1. When the travel pressure switch is turned ON. 2. Work mode M4 ia selected by the work modo selee tor. ‘When signals from the travel pressure switch and work Solenoid Valve 1(SA) mode selector arrive to the PVC, the PVC activates so- ' lenoid valve 1(SA), increasing back pressure behind the relief valve to raise relief pressure setting. Main Relief Valve Power Boost Cuntrol ‘When the power boost switch is pressed while the ma- Lf [Bower Boost chine is operated in either P or E mode, the PVC act PE yl EC Pa vates solenoid valve 1(SA), increasing back pressure Switches <— behind the relief valve to increase relief pressure set- ting ¥ Solenoid Valve 1(SA) Main Relief Valve 04-03-06ELECTRICAL SYSTEM / Control System OUTLINE OF WORK MODE CONTROL M1: General Purpose Mode M2: Trenching Mode When the swing and boom functions are operated si- t—>| _ |<—Work Mode Selector muttaneously, the PVG deactivates solenoid valve 2. EC pve Then, the boom is operated by the 4-section control — valve side pump only, and the swing function is inde- pendently operated by the 5-section control valve. 1 Solenoid Valve 2 M3: Grading Mode When digging with the arm function, the maximum flow — }— Work Mode Selector rates of both pumps connecting to the 4 and 5-section EC Pvc control valves are reduced to allow the arm to move k— more slowly | Aim Rollin Pressure Pump Control Solenoid Valve M4: Precision Mode The flow rate of both pumps connecting to the 4 and 5- t— >| — }x—work mode Selector section control valves are reduced to allow all functions EC Pvc to move slower. At the same time, relief setting pres- — sure of the relief valve is increased, } Pump Control Solenoid Valve Solenoid Valve 1 (SA) 1 Main Relief Valve 04-03-07ELECTRICAL SYSTEM / Control System OUTLINE OF OTHER CONTROLS Travel Speed Control coma als tom th }<—Travel Mode Switch The PVC, ater having received signals from the travel -—| mode selector, P sensor, travel pressure switch and the Ec Pvc [

| sensors and switches, and stores records of such ab- normalities in its memory. When these functions are normal, the LED in the PVC blinks at regular intervals. If any problem occurs, the LED blinks at irregular in- -- Sensor—>| Ec pve }—Switeh [<—Sensor tervals. Diagnosing a problem is possible by connect- ing the Dr. EX to the monitor terminals of the PVC. Monitoring Function The PVC allows the Dr. EX to monitor the control nals from the PVC and EC, and the sensing signals from switches and sensors. Dr. EX T04-03-09ELECTRICAL SYSTEM / Control System ENGINE CONTROL SYSTEM Construction 1= Governor Lever, 2— Fuel Shut Off Lever ue! Supply Solenoid - 5— Key Switen ‘Switen Pane! 2 10— EC Sensor Engine Controller (EC) 11— Control Cable Engine Control Motor (EC Motor) 12 T-Link 9+ Torque Limiter T04-03-10ELECTRICAL SYSTEM / Control System Engine Control Circuit When the operator presses @ power selector switch (1, L, E or P) and either the accelerator or decelera- tor switch, the EC receives a signal. After the micro- ‘computer buitt in the EC converts the signal into a pulse signal, the signal is output to the EC motor via the amplifier in the EC. The pulse signal frequency increases or decreases depending on the condition of the input signal. The pulse signal frequency con- trols the number of coils magnetized, which in turn rotates the EC motor to the desired position. As the last pulse signal is designed to keep the stator coil magnetized, the EC motor is maintained att to stay at the desired position until a new pulse signal arrives. An electrical signal corresponding the pulse signal frequency is sent to the switch panel from the EC, activating a LED on the switch panel. The actual rotary angle of the EC motor is detected by the EC sensor, and its sensing signal is fed back to the EC. Then, the EC rectifies the pulse signal frequency to correct the EC motor position. ‘When the engine is running at slow idle, the signal voltage from the EC sensor to the EC is 2.5 volts, at fast idle speed, it increases to approximately 4.5 volts. EC Motor Position Signal Fo ght I i Input LED Oooo % & oe 070482009 T04-03-11ELECTRICAL SYSTEM / Control System Setting Engine Mode Speeds And Engine Speed Programing ‘The engine controller (EC) controls the rotation of the EC motor. EC motor rotation controls the fuel ‘pump lever that controls engine speed. When the engine is stopped and the key switch is tumod from OFF to ON, the EC sends a pulse signal to the EC motor. The EC motor rotates to a position slightly higher than slow idle. The EC sensor then sends a voltage signal to the EC. The voltage signal is dependent on the amount of EC motor rotation. When the voltage signal reaches 2.5 volts, the EC software recognizes the pulse signal value, and rotates the EC motor enough to operate the fuel pump at slow idle. The slow idle pulse signal value Is then set. When the key switch is turned to START, the engine speed will be slightly higher than slow idle setting. If the | mode switch is pushed, the engine speed will be reduced to slow idle setting. EC Sensor Output Voltage 25V When the P mode switch is pushed, the EC motor rotates to move the fuel pump lever against its fast idle stop screw. As the EC motor rotates, the voltage signal from the EC sensor increases until the fuel pump lever is against the fast idle stop. The voltage stops increasing and becomes constant. The exact point at which it becomes constant is recognized by the EC software as the pulse signal value required to rotate the EC motor enough to move the fuel pump lever against its fast idle stop. Every time the key switch is turned ON and the P mode switch is pushed, the EC repeats this procedure to reset P position. Ihis 1s called Engine speed programing control. The pulse signal from the EC controls the E, L, and slow idle speed settings, E, Land slow idle settings are determined relative to the P mode, with P mode equalling 100% available engine speed. *P* Mode Stat | “L' Mode *E" Mode Position] Position Position Position Idle Auto Idle Position Position [+ Proportional Range ——>| EC Motor Position. ——> T04-03-12A 9603ELECTRICAL SYSTEM / Control System FUNCTION Engine Controller (EC) There are four mode switches on the switch panel in the ‘operator's cab (|, L, E, and P). The operator chooses from among them: touching one sends out signals to the EC, which uses ite micro computer to control the engine speed. The EC is located just behind the operator's seat in the cab. As long as the EC is operating normally, a red LED ‘on top of the EC housing will lash regularly. Pump And Valve Controller (PVC) ue The PVC located just underneath the EC in the operators cab, receives electrical signals generated by various sensors and switches, processes them in its ‘micro computer, and adjusts the hydraulic oil low and pressure via the pump control solenoid valves. Like the EC, the PVC has a red LED on top which flashes e regularly as long as the PVC is operating normally 2 Pump Control Solenoid Valve The pump control solenoid vaive is located in the pump regulator control circuit. Receiving control signals from the PVC, the pump control solenoid valve opens or close the pump regulator control circuit to shift the pump displacement angle. Thus, pump flow rate is con- trolled Fuel Supply Solenoid The fuel supply solenoid is located in the engine control system. When the key switch is tlimad ON, the solenoid is magnetized and starts supplying fuel. When the key switch is turned OFF, the solenoid is de- ‘magnetized and stops supplying fuel T04-03-13ELECTRICAL SYSTEM / Control System EC Motor The EC motor controls the engine speed: The EC motor is a hybrid type, having teeth provided around the outer surface of the rotors and the inner surface of the stator. A magnet is provided inside the rotors. Rotator Core Stator Core Col Magnet Engine Speed Sensor (N Sensor) The N sensor checks engine speed and sends sensing signals to the EC. Based on this signal, the EC controls the pump flow rate. The N sensor is located on the en- gine flywheel housing. Pressure Sensor (P Sensor) ‘The P sensor is located in the block at the pump deliv. ery port. The P sensor detects the pump delivery pres- sure and sends the sensing signal to the PVC, by which the pump flow rate is controlled. Pressure Switch (P Switch) The P switches are provided at 6 places of the pilot cir- tails for the boom raise, arm rollin, swing, travel, buck: et rollin, and other functions. The sensing signals de- tected by the P switches are used to control the auto- idle operation and the pump flow rate. 04-03-14ELECTRICAL SYSTEM / Control System Solenoid Valves Three solenoid valves (solenoid valve 1, solenoid valve 2, and pump control solencid) are provided on this ma- chine. Solenoid valve 1 is a three-spool section vaive, Each section is connected to the circuit of the relief pressure raise/power boost (SA), travel speed control (SB), and swing parking brake roloase control (SC), re: spectively. Solenoid valve 2 is a one spool valve, locat- ‘ed in the M2 trenching mode control circuit. The pump control solenoid valve are located in the main pump reg- ulator control circuit. Differential Pressure Sensor (DP Sensor) ‘The DP sensor is located on the control valve. The DP sensor detects the differential pressure between the front and rear of the pump control valve and sends the sensing signal to the PVC, by which the pump flow rate is controlled. Hydraulic Temperature Sensor (T Sensor) ‘The T sensor, located on the bottom of the hydraulic oil tank, detects the hydraulic oll temperature and sends signals to the PVC. ‘These signals is used in the warm-up operation. Specifications of the T sensor is as follows; Hydraulic oil temperature (°C)| -20°C | o°¢ | 20°c | 40%c | 6oec | soe CF) -4 °F | 32°F | 68 °F | 104 °F | 140 °F | 176 °F Resistance(2) 16.221.6 | (5.88) |2.4520.24] (1.14) | (0.534) | 0.922 T04-03-15ELECTRICAL SYSTEM / Control System T04-03-16ELECTRICAL SYSTEM / Monitor OUTLINE OF THE MONITOR Various devices are provided on the excavator to Monitor display panel gauges, indicators, and an monitor the operating conditions of the machine, alarm buzzer are provided on the display panel of Electrical signals sent to the monitor controller from the monitor. the sensors and switches are processed and Input and output signals of the controller are show transformed, then sent to the proper gauges and here. indicators. Input Signals. Monitor Display Pane! Battery Power > Hour Meter Alternator Voltage > ‘Alternator Indicator Coolant Temperature Switch Coolant Temperature Gauge Fuel Sending Unit > Fuel Gauge Engine Oil Pressure Switch > Engine Oil Pressure Indicator ‘Ovorheat Switch =| Monitor [. Overheat Indicator Air Filter Restriction Switch >| Controller 1, air Filter Restriction Indicator Low Fuel Level Switch > Fuel Level indicator Engine Oil Level Switch > Engine Oil Level indicator Coolant Level Switch = Coolant Level indicator Hydraulic Oil Level Switch > Hydraulic Oil Level indicator Preheat Signal > Preheat Indicator T04-04-01ELECTRICAL SYSTEM / Monitor MONITOR PANEL @ Atternator indicator © Engine Oil Pressure Indicator © air Fter Reston indicator @W | | @ overheat indicator cs |__(2) © Fuel Level indicator Y & © © Preheat indicator a @ Engine Oit evel indicator a aC) 7 © <2 cela eve inate Dy © Hydraulic Oi Level indicator B 1 i Hour Meter © I | ® a4 @ Fuel Gauge @) Coolant Temperature Gauge = 8 per ce 5 Level Gheck Switch = Buzzer Stop Switch @0 cot @ Washer Switch @ Wiper Switch @) Work tight Switch ve S309] ©O@) Work Light Indicator (Base) ors Lig deter Boar) (ele Intermittent Wiper Indicator @® Wiper indicator § $dhh Mm © @ 04-04-02ELECTRICAL SYSTEM / Monitor MONITOR FUNCTION Hour Meter (__ BY ) When the engine is started, the hour meter comes on, It shows a digital display of the number of hours the ma- (2) oe { Yiou } chine has been operated. Coolant Temperature Gauge 5 In normal operating conditions, the pointer of this gauge is in the green range. Although the actual temperature does not appear on the gauge, please refer to the fol- lowing for approximate temperature. Point 1: Approximately 67 °C (159 °F) Point 2: Approximately 103 °C (217 °F) Point 3: Approximately 135 °C (275 °F) Fuel Level Gauge The fuel Level gauge indicates the fuel level in the fuel tank. so401.000 Alternator indicator Comes on when the voltage from the alternator falls be- low the range from 8.5 volts to 11.5 volts and goes out when the voltage reaches the range from 11.5 volts to 145 volts. roe.004 T04-04-03ELECTRICAL SYSTEM / Monitor Engine Oil Pressure Indicator ‘Comes on when the engine oil pressure falls below ap- proximately 39 kPa (0.4 kaffem?, 5.7 psi). The alarm buzzer sounds simultaneously. Overheat Indicator ‘Comes on when the coolant temperature reaches over 98 °C (208 °F). The alarm buzzer sounds simulta- neously. Filter Restriction Indicator Comes on when the air filter element is restricted. 040.006 Fuel Level Indicator The fuel level indicator comes on when fuel level reaches approximate 112.5 mm from the fuel tank bot- ° [|ELECTRICAL SYSTEM / Monitor Engine Oil Level indicator When the level check switch, this indicator light comes fon as long as the engine oil level is above a point 3.5 mm(1/8in) below the *L* mark on the dipstick. Coolant Level Indicator When the level check switch is pressed, this indicator light comes on as long as the coolant level in the reser- Voir is above the "L" mark. Hydraulic Oil Level Indicator ‘When the level check switch is pressed, this indicator light comes on as long as the hydraulic oil level in tank is above a point 48mm (1 7/8in) below the mark on the sight gauge on the hydraulic oil tank. orf mio4o1.019 er4a3.o14 T04-04-05ELECTRICAL SYSTEM / Monitor Engine Oil Pressure Switch This switch remains off so long as the engine oil pres- sure is above approximately 39 kPa (0.4 Kagfiom?, 5.7 psi). When the pressure falls below this level, the switch ‘comes on, activating the engine oil pressure indicator, while at the same time activating the emergency relay to stap the engine. ‘Overheat Switches (L), (H) oO Each overheat switch comes on as illustrated below: on © of. west ao wera meee Rta a Ba (H) 94 °C (201 °F) 107-04-09-017 ‘Coolant Temperature Sensor Tis theme sar mae ha tenga Uo count and vee te aed on te ce tmnerre pg Coolant temperature / sensor resistance correlation table Coolant temperature(°C)} 50+0.2 6020.2 8040.2 1000.3 105+0.3. 1200.3 (CF)} 122404 | 140204 | 176204 | 212405 | 221405 | 248205 Sensor resistance (9) | 1124#10 | 79.345 41.8125 | 23609 | 207106 | 14.2203 T04-04-06A 9603ELECTRICAL SYSTEM / Monitor Engine Oil Level Switch This switch remains on so long as the engine oil level in the oil pan is above the specified minimum. When the oil level falls below this point, the switch turns off. Air Filter Restriction Switch This switch is located at the air cleaner element outlet. When the air cleaner is restricted, the resulting vacuum Pressure activates the switch, which in turn lights the air filter restriction indicator. Low Fuel Level Switch Magnet ‘This switch ts located on the bottom of the fuel tank. ke OFF Feat When the fuel level falls lower than the float, the switch ue Level is activated, turning on the fuel level indicator. nl on 112585 mm Mege1 (4.49202) Hydraulic Oil Level Switch Located on the side of the hydraulic tank, this switch tums off when the level of the hydraulic oil falls below the specified minimum. : ‘38.imef ON [sein —— oF or-eas.oa2 T04-04-07ELECTRICAL SYSTEM / Monitor Fuel Sending Unit ‘As this unit moves up and down with the level of the fuel, it changes the angle of its arc in relation to the variable resistor. This in tur changes the electrical cur- rent flowing to the fuel gauge, moving the fuel gauge in- dicator needle. Float level__| _Resistance(9) FULL 40 5 34 (19.5) 12 3283 14 (49.5) EMPTY 80 Coolant Level Switch | This switch is located on the bottom of the coolant re- serve tank. When the coolant level falls below the switch float, the switch turns off. Fat T04-04-08ELECTRICAL SYSTEM / Monitor MONITOR CHECK PROCEDURE 1. Check for burned-out light bulbs (Before starting 4, Corrective actions to be taken in case of abnor- the engine) Upon turning the key switch (clockwise) to the ON" position, all indicators should light for ap- proximately 2 seconds. If any light does not- come on, this means that the light bulb is burned out. 2. Level check of adequate oil and coolant levels Betore starting the engine, place the key switch in the “ON" position and touch the level check switch. Upon doing so, the green engine oll lev el, engine coolant level, and hydraulic oil level indicator lights should come on. If a lamp does Not go on, this means that the level of that fluid is low. ‘Also, be sure to check these levels regularly with their conventional level gauge. @ When checking the engine oil level, be sure to position the excavator on a level surface and lower the bucket to the ground, otherwise an in- correct indication may be given, 3. Engine start @, When the engine is cranked, the engine cil pressure indicator and alternator indicator both light. b. Once the engine starts, the engine oil pres- ‘sure indicator and alternator indicator go out. @ When the engine is run at a very low speed, the alternator indicator may turn on. If this happens, increase the engine speed, and check ifthe light goes off @ If the engine oil pressure indicator remains ‘ON’ for 6 to 8 seconds after the alternator indicator has gone out, the alarm buzzer will sound. If so, itis necessary to check the en- gine lubricating system. maiity arising during operation. Should an abnormality occur during the opera- tion of the machine, red indicators will come on, It'80, take the following steps: a, Alternator indicator Switch off electrical devices, stop the en- ine, check the electrical system and make the necessary repairs. If operations are con- tinued without repair, the batteries may die. b. Engine oil pressure indicator (Alarm buzzer sounds 2 to § seconds later). Lower the bucket onto the ground, put the machine in a safe position and stop the er gine. If the machine operation is continued as itis, itmay lead to engine damage . . Air fiter restriction indicator Clean or replace the air cleaner element. If used without cleaning or replacing, the en- gine may loose power and black exhaust smoke may increase. 4d. Overheat indicator (Alarm buzzer sounds at the same time). Remove the load from the engine and allow the engine to slow idle un- til the coolant temperature comes down. If the engine is suddenly stopped the coolant temperature may go up rather high. Be sure not to stop the engine before this Indicator goes out © To stop the alarm buzzer, touch the buzz- er stop switch . e. Fuel level indicator Be sure to refuel before the needle of the fuel gauge points to *E” © When the key switch is in the *ON* posi tion but the engine i not running, the engine oil pressure indicator will remain *ON*, but the other indicators will go out after 2'sec- onds. © Under normal conditions, when the engine is running all red indicators. will go out ‘@ If the alarm buzzer stop switch is pressed for about one second, the alarm buzzer will slop atter the switch Is released. The alarm buzzer function is automatically reset, and the alarm buzzer will sound if an abnormal- ity oceurs again T04-04-09ELECTRICAL SYSTEM / Monitor T04-04-10ELECTRICAL SYSTEM / Inspection and Maintenance PRECAUTIONS FOR INSPECTION AND MAINTENANCE 1. Disconnect the power source. Be sure to remove the negative terminals from the batteries first when taking wire hamesses and connectors off for repair or replacement work Failure to do so can result in damage to the wire hamesses, fuses, and fusible links and, in some cases, cause fire due to short circuiting. 2. Color coding of wire harnesses, The color codes of the wire hamesses in the electrical system are shown below. In Gases where two color codes are indicated for one wire, the left initial stands for the base color, while the right initial stands for the mark- ing color. codes | color | codes : color R Red G Green L Fight blue | Lg Light green Or Orange B Black Y Yellow P Pink Br Brown v Violet Gr Gray Sb Sky blue w white i NOTE: (1) Initials *O" and ‘Or both stand for the color orange. (2) Wires with longitudinal stripes print- ed on them are not color coded. Be sure not to confuse them with color coded wires. (3) Color code BW stands for the har- ness with white fine line marking on black base color. 3. Precautions for connecting and disconnecting terminal connectors. (1) When disconnecting hamesses, grasp them by their connectors. Do not pull on the wire liseif. Be sure to release the lock first betore attempting to separate connectors, if @ lock is provided. (2) When connecting terminal connectors pro- vided with a lock, be sure to insert them to- gether until you hear the lock go “click” 4. Handling waterproof connectors. Because waterproof connectors are designed to keep water out, itis very difficult to remove wa- ter once it gets inside these connectors. Be extra careful not to allow water to enter wa- terproof connectors. If water should enter the connector, use it only after it is completely, dried out. T04-05-01ELECTRICAL SYSTEM | Inspection and M: FUSE CONTINUITY TEST Fuse failure is often caused by a fine crack in the fuse, and such fine cracks are very hard to detect by visual inspection, Checking fuse continuity with a tester is far superior to sight inspection. (1) Turn the key switch ON In doing so, the battery relay is activated by the current from terminal M of the key switch, and electric power is supplied to all circuits ex- cept the cold cranking aid system circuit. (2) Remove the fuse box cover and set the correct, voltage measurement range of the tester. ‘Accessory (9) Connect the negative probe to the machine for grounding, and touch the outside terminal of each fuse with the positive probe of the tester. NOTE: (a) All the inside terminals of the fuses in the tuse box are connected to the power source, while the outside ter- ‘minals are connected to the acces- sories. (b) Test all fuses using the same meth- od. When normal continuity of a fuse is intact, the tester wil indicate 20 to 25 volts, (4) To check the fuse for the cold cranking aid system circuit, turn the key switch to. the START position and perform the test as de- scribed in (3). Poewr Sauce Accessory 04-05-02ELECTRICAL SYSTEM / Inspection and Maintenance INSPECTION AND REPLACEMENT OF FUSIBLE LINKS Inspection Confirm that the key switch is in the OFF position. Then inspect fusible links. Replacement 1. Confirm that the key switch is in the OFF positon. 2, Pull out the fusible link and replace it. rieouon 001 T04-05-03ELECTRICAL SYSTEM / Inspection and Maintenance TAKING APART CONNECTORS: 1. Push down on the lock to release it, then pull the connector apart coy Tiitona6re Devices using this type of connector: Tier2#06-02 re Switch 18-Horn Relay ‘Sending Unit _16—Washer Relay EC Motor 17—Wiper Relay EC Sensor 18—EC Motor Relay Angle Sensor 49-Switel NOTE: Pulling on the connector while pushing down on the lock makes disconnecting ditfi- cult. Instead, gently compress the connec- tor, release the lock, then pull Horn 20—Light Relay (1) Speaker 21—Light Relay (2) Wiper 22—Cab Inside and Engine Component Power 9 Load Dump Relay —_-23—Monitor Controller 10—Engine Oil Level 24—Monitor Pane! 11-Radio 25—Heater 12-Pressure Sensor —-26—Lubricator 13—Cooler Relay 27—Travel Alarm (OPT) 44—Coolant Level 04-05-04ELECTRICAL SYSTEM | Inspection and Maintenance 2. Grasp both sides firmly with the fingers, and pull. Devices using this type of connector: SQ x» 1 date oF Temperate 2 Washer 3. Unscrew the bolt on the top of the connector. Devices using this type of connector: 1 ec 2- PvE '3~ Devices inside the cab. (This isthe connecting Point between devices and those in the engine compartment) Necessary tool : 10 mm box wrench NOTE: Be sure to retighten the screw until the raised torque mark (1) appears. T04-05-05ELECTRICAL SYSTEM / Inspection and M INSTALLATION AND ADJUSTMENT OF THE A SENSOR Removal 1 Put matching mark on the A sensor and pump housing. Remove the A sensor connector from its hamess. Remove two A sensor mounting bolts (1). Remove the A sensor. Take care not to lose inter- nal spacer (8) and fastener spring (4). O-ring (6) is provided on the A sensor side. Installation and Adjustment 1 Apply a fim of grease to the surface of fastener spring (4) and install it into the cavity on the feed- back shaft end, With the key switch turned OFF, connect the con- nestor of the A sensor. Then, connect the Dr. EX to the diagnosing connector located in the opera- tor’s cab. Start the engine and operate it in the | mode. Main- tain hydraulic oil temperature at 5025 °C (122 £9 °F). Operate the Dr. EX. Select information for "A Sen- sor Mounting Angle Adjustment” (Push F3 key). ‘Then, increase displacement angle to the maximum by pushing F1 key on the next display. Wait about one second. The pump displacement angle is set to the maximum. Select information for ‘Monitor Data’. Then, push F8 key to indicate the approx. Pump displacement {D4 or BS) on the next display. Before installing the A sensor to the pump, turn the punch mark on the A sensor shaft towards the op- posite side of the hamess so that the reading of the Dr.EX display indicates 245 mLirev. Insert the A sensor shaft into the feedback shaft and tentatively tighten bolts (1). The bolt holes of the A sensor are made in a ellipse form. Adjust the A sensor position using ellipse holes so that the reading of D4 andlor DS on the Dr. EX display in cates 24924 mlrev. Tighten bolts (1) to 9.8 to 147 Nem (1 to 1.8 kgtm). iv4.0406 001 Feedback Shaft Punch Mark T04-05-06ELECTRICAL SYSTEM / Inspection and Maintenance POSITIONING AND VOLTAGE ADJUST- MENT OF THE EC SENSOR 1. Tighten an M8 bolt in the T-link positioning hole. a This is the | mode position, 2, Temporarily mount the EC sensor with bolts so >) that the upper and lower mounting bolts are po- 1 sitloned on the midline of the sensor. Connect the hares. 3. Connect the Dr. EX to its terminal, or connect test hamess (ST 7129) between the EC sensor and hamess. 4, Turn the key switch to the ON position, then touch the I mode switch. Measure output volt- age of the EC sensor, using the Dr. EX or a digital-ype volt meter. 5. Referring to the voltage indicated by either the reece Dr. EX or the digitaltype volt meter, set the EC aan sensor position so that the EC sensor output voltage is within specifications, oroeonars 1 1 Control Cable Tink Specified voltage: 2.5020.05 V INSTALLATION OF THE EC MOTOR Refer tv the following procedures for installation of the EC motor. Stow lal Position 1, Install the EC motor assembly and connect the \ hamess. Siow Ide Postion 2. Turn the key switch to the ON position, then rast te Posto touch the | mode switch to set the slow idle po- } sition i 3. Set the lever at slow idle position from 0.1 to 0.3 mm (0.004 to 0.012 inch) returned position, ‘Temporarily Connect the control cable. f i After connecting the Dr. EX, start the engine. . Referring to the Dr. EX, set the engine speed ‘ in the specified slow idle speed range. ‘Governor Lever ‘After adjusting, tighten the lock nut of the con- trol cable. b 7. Remove the MB bolt from the T-link positioning Clearance 0.1 093mm hole. (€.004 to 0.012inch) 8, Check the Dr. EX or engine tachometer again to Confirm that the engine speed is in the set slow idle speed range. 8. After mounting the EC motor, attempt RETRIAL Ato clear the erroneous data. pas 04-05-07ELECTRICAL SYSTEM / Inspection and Maintenance TYPE OF CONNECTOR Pump and Valve Controller (PVC) PVC side Harness side re 7 1 108101 ey yi eannaat 6 mB 8 16 108 Engine Controller EC side 101 104 T04-05-08ELECTRICAL SYSTEM / Inspection and Maintenance Monitor Controller Controlier side Monitor Panel Monitor panel side 1 5 49 * Eas 6 @ 18 18 Hamess side ee Hee vorarseein ce 04-05-09ELECTRICAL SYSTEM / Inspection and Maintenance Switch Panel 1 a ee Ee ee é Ye ‘ Panel side a is Key Switch ‘Switch side Harness side 04-05-10ELECTRICAL SYSTEM | Inspection and Maintenance Universal Use Relay Relay side Hamess side a4 2 aR Rig BI 1 Wiper Relay 7— Work Light Relay (Boom) 2— ECMotor Relay 8~ Charge Relay 3~ Load Dump Relay Tii6040-002| 4— Horn Relay 5— Washer Relay 6— Work Light Relay (Base) Dr. EX Terminal Dr. EX side Connector side | | 1 2 4 3 a 4 Hydraulic Oil Temperate Sensor (T Sensor) Sensor side Hamess side 2 T04-05-11ELECTRICAL SYSTEM / Inspection and Maintenance Pump Displacement Angle Sensor (A Sensor) Engine Control Sensor (EC Sensor) Differential Pressure Sensor (DP Sensor) Sensor side Harness side Pressure Sensor (P Sensor) Sensor side Hamess side es 3 24 Engine Control Motor (EC Motor) Motor side Harness side 2 1 04-05-12ELECTRICAL SYSTEM / Inspection and Maintenance Pressure Switch (P Switch) ‘Switch side Hamess side 2 1 1 2 Coolant Level Switch Switch side Harness side Engine Speed Sensor (N Sensor) Fuel Sending Unit Solenoid Valve 1 Pump Control Solenoid Valve Solenoid Valve 2 Hydraulic Oil Level Switch Sensor side Harness side Solenoid valve side i 2 T04-05-13ELECTRICAL SYSTEM | Inspection and Maintenance EC-RELATED FAULT CODES Failure (type-t) of EC Failure (type-2) of EC Failure (type-3) of EC Failure (type-4) of EC Signal from PVC is not transmitted toFC Failure (type-6) of EC ‘Short circuit of auxiliary input (EX2) ‘An open in auxiliary input (EX2) (For optional unit) ‘Short circuit of EC sensor and/or harness ‘An open in EC sensor and/or harness Short circuit of auxiliary sensor 1 An open in auxiliary sensor 1 N sensor is abnormal ‘An open in T sensor or overheat preventive switch Perform “RETRIAL A° (For problems with the controller (PVC and EC)) Replace EC if Power mode selector control and or auto-idle is abnormal Perform “RETRIAL A Replace EC if Power mode selector control and jor auto-idle is abnormal Perform “RETRIAL A” Replace EC if Power mode selector control and or auto-idle is abnormal Perform “RETRIAL A” Replace EC if Power mode selector control and Jor over 8 fault codes are found Perform “RETRIAL 8" (For problems with the sensors) Cheek harness Replace PVC or EC if auto-idle is abnormal Perform “RETRIAL B* Replace EC if Power mode selector control is abnormal Perform “RETRIAL B Check hamecs Replace auxiliary input sensor (optional) Perform “RETRIAL B” Check EC sensor harness Replace EC sensor Perform “RETRIAL B Check EC sensor harness Replace EC sensor Perform “RETRIAL B Check sensor harness Replace auxiliary sensor Perform “RETRIAL B Check N sensor harness Replace N sensor Perform “RETRIAL B” Check sensor hamess Replace T sensor Replace overheat preventive switch 04-05-14ELECTRICAL SYSTEM / Inspection and Maintenance PVC-RELATED FAULT CODES 7 Failure (type-17) of PVC Failure (type-18) of PVC Failure (type-19) of PVC Fak Gate Perform “RETRIAL A” Replace PVC if engine stalls or working speed is abnormal 20 Signal from EC is not transmitted to |1) Perform “RETRIAL B” Pvc 2) Check hamess 3) Replace PVC or EC if abnormal speed sensing operation is found 21 Failure (type-21) of PVC 1) Perform “RETRIAL B° 22 Failure (type-22) of PVC 2) Replace PVC 23 ‘Abnormal pump control (4-Spool__| 1) Perform “RETRIAL B° side) 2) Harness check 3) Check pump displacement solenoid valve 24 Abnormal pump control (5-Spool_ 4) Check pump displacement angle sensor side) 5) Check PVC 25 ‘Short circuit of DP sensor and/or | 1) Perform “RETRIAL 8° harness (4-Spool side) 2) Check DP sensor hamess 3) Replace DP sensor ‘An open in DP sensor and/or harness (4-Spoo! side) Short circuit of P sensor and/or 1) Perform “RETRIAL B° hamess (4-Spool side) 2) Check P sensor harness 3) Replace P sensor ‘An open in P sensor andjor hamess (4-Spoo! side) ‘Short circuit of A sensor and/or 1) Perform “RETRIAL B* harness (4-Spoo! side) 2) Check A sensor harness 3) Replace A sensor 30 ‘An open in A sensor andjor harness (4-Spool side) 33 Short circuit of DP eeneor and/or | 1) Perform “RETRIAL B harness (5-Spool side) 2) Check DP sensor harness 3) Replace DP sensor 34 ‘An open in DP sensor and/or harness (6-Spool side) ‘Short circuit of P sensor and/or hamess (5-Spool side) ‘An open in P sensor andjor harness (5-Spool side) Perform “RETRIAL B* Check P sensor hamess Replace P sensor ‘Short circuit of A sensor andor harness (5-Spool side) ‘An open in A sensor and/or harness (5-Spoo! side) Perform “RETRIAL B” ‘Check A sensor harness Replace A sensor T04-05-15ELECTRICAL SYSTEM / Inspection and Maintenance Dr.EX MONITOR FUNCTION When monitor function is selected, sensing signals from the sensors or switches that are connected to the con- troller, or control signals from the controller to the sole- NOTE: 4P; 4-spoo! side noid valves can be monitored on a real-time basis while 5P; 5-spoo! side the machine is being operated. Patt | key i em | No Display Desoription Unit 1 | Fé | Differential Pressure (d04)_| DP sensor output signal @P) | katfem? F7 | Pump Delivery Pressure (Pd4)_| P sensor output signal. (4P) | atom? F8_| Approx. Pump Displacement (04) | Calculated pump displacement. @P) | cofrev 2 | F6 | Desired Pump Displacement (Bra) | Pump displacement control signal. (@P)| _(ccitevy F7 | Pump Displacement Torque (T4) | Calculated torque. (4P) | kgtm F8_| Potential Pump Displacement Pump driving torque control signal (4P) | (kaFm) Torque ra) 3 | F6 | Differential Pressure (dP5)_| DP sensor output signal (6P) | _katfeme F7 | Pump Delivery Pressure (Pd5) | P sensor output signal. (6P) | katieme F8_| Approx. Pump Displacement (05) | Calculated pump displacement. (6P)| _cc/tev 4 | F6 | Desired Pump Displacement (Drs) | Pump displacement control signal (6P) | (ecirev) F7 | Pump Displacement Torque (T5) | Calculated torque. (6P) | kgtm F8 | Approx. Pump Displacement Pump driving torque control signal. (6P)] _ (kgtm) Torque (5) & | F6 | Pump Diop. Angle Gontrol signal | Control signal to pump displacement control a (4) | solenoid valve. (aP) F7 | Pump Disp. Angle Control signal | Control signal to pump displacement control A (5). | solenoid valve (P) F8_| Relief Pressure Raise Signal (St) | Control signal to solenoid valve (SA) On 6 | F6 | Travel High/Low Shift Signal (Sh) | Control signal to solenoid valve (SB) On FT| Swing Parking Brake Release Control signal to solenvid valve (SC) on Signal (Sbs) F8_ | Swing/Boom Operation Signal Control signal to swing/boom circuit solenoi On (Ss) | valve. 7 | F6 | Power Boost Switch On F7_| Travel Mode Switch LoAUHi F8_| Work Mode Selector GP.T.GRP 8 | F6 | Pressure Switch Bm, Am,Ot, SwTr 9 | Fé | Engine Control Angle (Aec) | EC sensor output signal v F7 | EC Motor Position (Ecmp) | EC Motor position control signal. (Pulse) F8_| Actual Engine Speed (Es) _| Actual engine speed. tom T04-05-16ELECTRICAL SYSTEM / Inspection and Maintenance Patt em | A Display Description Unit 70 | Fé | Selected Engine Speed (Es) | Engine Speed control signal, eo) F7 | Deviation Engine Speed (dE) (pm) F8_| Engine Operating Condition (Eng) _} Engine is running or not. (On) 11 | F6 | Power Selector Switch PELL Up,0n F7_ | Auto-tale Switch On F8_| Warm-Up Switch On 12 | F6 | Power Selector Indicator (Psis) PELL F7_| EC motor Signal (Eoms) | Control signal to EC motor (On, S.Up) Fa_ | Warm-Up Signal (Wus) | Control signal to warm-up indicator. (wu) 13 | F6 | ECMotor Relay Signal (Emr) | Control signal to EC motor relay (On) F7 | Swing Dampener Valve (Sdv) (On) F8_| Hydraulic Oil Temperature (To) °c 14 | F6 | Overheat Switch (L) (vn) On F7_| Gounterweight Switch (ow) On 15 | F6 | Auxiliary Sensor 1 (uxt) | Signal from auxilary sensor 1 Vv F7 | Auxiliary Sensor 2 (Aux2) | Signal from auxiliary sensor 2 v Fe_| Auxiliary Sensor3 (Aux3)_| Signal from auxiliary sensor 3 v NOTE: 1. UNIT ABBREVIATIONS NOTE: 2. EX550 has not swing dampener valve, but its item indi- Lo: Siow Speed cates on the display. Me: Medium Speed 3, Auxiliary sensor 3 indicates voltage from the bucket rollin Hi: Fast Speed pressure owitch, GP: General Purpose Mode T: Trenching Mode GR: Grading Mode P : Precision Mode Bm: Boom Am: Arm Ot Other ‘Sw: Swing Tr: Travel Ps Power Mode E: Economy Mode L: Light Mode |: Siow Idle Mode 2. Vor more: OFF Less than 2.5 V: ON T04-05-17