HCR900-DS

Electrical Systems
Engine starting circuits
 Contents

1. Electrical Equipment for Engine Starting Circuits

1-1 Power and Fuses ....................................................................................................... P.2
1-2 Starting Motor ............................................................................................................. P.3
1-3 Battery Relay .............................................................................................................. P.3
1-4 Air Heater Relay and Air Inlet Heater ......................................................................... P.3
1-5 Starting Switch ........................................................................................................... P.3
1-6 Starter Relay .............................................................................................................. P.4
1-7 Compressor Oil Timer ................................................................................................ P.4
1-8 Alternator .................................................................................................................... P.4
1-9 Hour Meter ................................................................................................................. P.4

2. Engine Starting Circuits

2-1 Starting Switch On ...................................................................................................... P.5
2-2 Starting Engine ........................................................................................................... P.6
2-3 After Starting Engine .................................................................................................. P.7
2-4 Stopping Engine ......................................................................................................... P.8

3. Engine Control Circuits

3-1 Throttle Control ........................................................................................................... P.9
3-2 Emergency Shut Down Control ................................................................................ P.10
3-3 Diagnostic Lamps ..................................................................................................... P.10

4. Accessory Circuits
4-1 Warning Lamps ........................................................................................................ P.11
4-2 Gauges ..................................................................................................................... P.11
4-3 Lights ........................................................................................................................ P.12
4-4 Horns ........................................................................................................................ P.12

1
1. Electrical Equipment for Engine Starting Circuits
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
PC PC1
F 1 (15A)

F 6 (15A) P6
F 5 (15A) P5
F 4 (15A) ES GT
P4
ENR
F 3 (30A) P3 1
F 2 (15A) P2
PC1
ENR1

201 P0
B BR

204
R2 C ENR0
ACC R1 ENR1
P1
P1 R
206 P1 P0 208
P1 203
S 201 201
POS
S 207 R
B 205 SR1 G
P1 H
B
LT GT ENR1 ENR0 ES HM
M

NC

Engine Running Signal

Engine Starting Signal
Compressor Oil Timer
Air Heater Relay
Air Inlet Heater

Starting Switch
Starting Motor

Battery Relay

Starter Relay

Hour Meter
Lamp Test

Alternator
Battery

Fuse

Fig.1

1-1 Power and Fuses

PC1 Line Power for electrical system, starting switch and radio. If the F1 fuse is blown, the engine is not
able to start.

P2 Line Power for engine throttle, warning lamps, gauges and tachometer. If the F2 fuse is blown,
lose those control.

P3 Line Power for lights, horns and back buzzer. If the F3 fuse is blown, lose those control.

P4 Line Power for switches, relays and solenoid valves. If the F4 fuse is blown, lose those control.

P5 Line Power for wiper motors, cab light, radio speaker and angle indicator (optional). If the F5 fuse is
blown, lose those control.

P6 Line Power for engine ECM, cooler and heater. If the F6 fuse is blown, lose those control. If it is blown
while the engine is running, the engine will shut down.

2
1-2 Starting Motor
The starting motor drives the flywheel to crank the engine. It consists of starter solenoid and
motor.

1-3 Battery Relay

The battery relay is a main switch to provide power from the battery to the circuits.

1-4 Air Heater Relay and Air Inlet Heater

The air heater relay and air inlet heater aid in start-up of the engine.
It is controlled by signals of the engine ECM under the following conditions.

A）Starting switch is in “On” position

The heater will be activated for 30 seconds when the sum of the coolant temperature and
inlet manifold air temperature is below 25゜C [77゜F].

B）Starting switch is in “Start” position

During engine craking, the heater will be activated for 30 seconds when the sum of the
coolant temperature and inlet manifold air temperature is below 25゜C [77゜F].
If the engine fails to start, the ECM will activate the heater for another 30 seconds.

C）After starting engine

After the engine has started, the combination of coolant temperature and inlet manifold
temperature will determine the state of the heater. The state has two strategies.

Continuous strategy： Activate the heater for a maximum of 7 minites.

Intermittent strategy： The heater is cycled for a maximum 13 minutes. It will be turned
on for 10 seconds and turned off for 10 seconds.

The heater will shut off when the sum of the coolant temperature and inlet air temperature
reaches 35゜C [95゜F].

1-5 Starting Switch

The starting switch activates the circuits. The table below shows the contact capacity and
conduction state of the terminals.

Contact capacity 5A 30A 10A 30A 30A

Terminal
Switch position
B BR R1 ACC R2 C
OFF (O)
HEAT (H)
ON (R)
START (HS)

Fig.2

3
1-6 Starter Relay
The starter relay provides high current to the starer solenoid of the starting motor for starting the
engine. Also it cuts the current flow to the starter solenoid while the engine is running.

1-7 Compressor Oil Timer

The compressor oil timer is used to hold the battery current to the circuits for 5 seconds after the
starting switch is turned off.

1-8 Alternator
The alternator produces electrical power and supplies current to the circuits. The buildup of
alternator voltage at R terminal is used to control the hour meter and stater relay.

1-9 Hour Meter

The hour meter shows the operating time of the machine. It records the time in hours and only
operates when the engine is running.

4
2. Engine Starting Circuits
1 2 3 4 5 6 7 8 9 10 11 12 13 14 18 26
PC PC1

F 1 (15A)
P6

ES GT

ES

PC1

201 P0 26
B BR
E.C.M
204
R2 C
ACC R1 ENR1
P1
P1 R

P1 203
S 201 201
S
B 205 SR1
P1 H
B
LT GT ES
M

NC NC
Engine Running Signal
Compressor Oil Timer
Air Heater Relay
Air Inlet Heater

Starting Switch
Starting Motor

Battery Relay

Starter Relay
Lamp Test
Battery

Fuse

Fig.3

2-1 Starting Switch On

1) When the starting switch is turned to the ON position, current flows from the BR terminal of the
starting switch to the relay ES (address 18) and timer GT (address 14). When the relay coils
are energized, the NO contacts of the relay ES (address 7 and 26) and NO contact of the timer
GT (address 9) will close.

2) With the relay contacts closed, the battery relay is energized, closing the circuit from the
battery to the starting motor terminal. This provides engine starting.

3) When the sum of the coolant temperature and inlet air temperature is below 25゜C [77゜F],
the ECM will activate the heater relay (address 8).

5
2-2 Starting Engine

1 2 3 4 5 6 7 8 9 10 11 12 13 14 18
PC PC1
F 1 (15A)

ES GT

PC1

201 P0
B BR

204
R2 C
ACC R1 ENR1
P1
P1 R

P1 203
S 201 201
S
B 205 SR1
P1 H
B
LT GT ES
M

NC

Engine Running Signal

Compressor Oil Timer
Air Heater Relay
Air Inlet Heater

Starting Switch
Starting Motor

Battery Relay

Starter Relay
Lamp Test
Battery

Fuse

Fig.4

1) When the starting switch is turned to the start position, current flows from the C terminal of the
starting switch to the sterter relay (address 13), causing the relay contact to close. With the
relay contact closed, battery voltage is supplied to the starter solenoid, causing the starting
motor to operate.

2) When the starter solenoid is energized, a magnetic force moves the plunger and engages the
drive pinion with the flywheel ring gear. The plunger closes the main battery connection of the
starter solenoid to the starting motor. This allows a heavy flow of current from the battery into
the starting motor to crank the engine.

6
2-3 After Starting Engine

2 3 6 10 11 12 13 15 16 17 19
PC1
P2
P1
P1
ENR1

B BR

204
R2 C
ENR0
ACC R1 ENR1
P1 R
206 P1 208

S 201 201
POS
S
SR1 207 R
205 G
P1
B
ENR1 ENR0 HM
M

NC NC

Engine Starting Signal

Starting Switch
Starting Motor

Starter Relay

Hour Meter
Alternator
Fig.5

1) After the engine has started, the altenator genelates electricity. The buildup of alternator
voltage reaches 12V at the R terminal, the relay ENR0 (address 16) is energized, causing its
NO contact (address 15) to close.

2) With the relay ENR0 contact closed, the relay ENR1 is energized causing its NO contact
(address 19) to close. With the relay ENR1 contact closed, P2 power is delivered to the hour
meter causing the hour meter to operate.

3) Also the NC contact of the relay ENR1 (address 12) opens, cutting current to the starter relay,
causing its contact to open, breaking the circuit from the battery to the starter solenoid. This is
for protection of the starting motor. The starting motor does not operate even if the operator
turns the stating switch to the start position while the engine is running.

7
2-4 Stopping Engine

1 2 3 4 5 6 7 8 9 10 11 12 13 14 18 26
PC PC1
F 1 (15A)
P6
Break contacts
after 5 sec.
ES GT

ES

PC1

201 P0 26
B BR
E.C.M
204
R2 C
ACC R1 ENR1
P1
P1 R

P1 203
S 201 201
S
B SR1
205
P1 H
B
LT GT ES
M

NC NC
Engine Running Signal
Compressor Oil Timer
Air Heater Relay
Air Inlet Heater

Starting Switch
Starting Motor

Battery Relay

Starter Relay
Lamp Test
Battery

Fuse

Fig.6

1) When the starting switch is turned off, since current is cut off at the BR terminal, the relay ES
goes off, causing its contacts to open (address 7 and 26). The current to the engine ECM is cut
off, and engine stops operating.

2) Even if the starting switch is turned off, the NO contact of the relay GT (address 9) remains
closed for 5 seconds, leave the battery relay energized and continue supplying power to the
circuits.

8
3. Engine Control Circuits
22 23 24 25 26 27 28 29 30 31 33
PC1
P6

P2

ES ERX

PL1 PL2 PL3 PB-

(GL) (OL) (RL)
ER1
LAMP1 LAMP2 LAMP3
212

LS-
ER1

213 214 215

1 31 32 26 13 24 25
LS-
10 27 Electronic Control Module 28 ER1
210 211 227

A
C SN
AT PH1 FS ERX ERY
B OFT
ERY

NC
(G) (Y) (R)
High Comp. Air Temp. Signal
Low Hyd. Oil Level Signal

Engine Stop Sub Signal

Emergency Stop Signal

Engine Stop Switch

Diagnostic Lamps
Throttle Switch

Impact Signal

Blow Signal

Fig.7

3-1 Throttle Control

A) Manual control

The engine speed can be adjusted by turning the throttle switch (address 22). The minimum
speed and rated speed (maximum) are set as follows and can not be adjusted.

Minimum speed 1250 min-1

Rated speed 2200 min-1

9
B) Automatic control

The engine speed will automatically increase to the maximum by either of the following input
signals.

1. Proximity switch for impact (CLS-PH) is on.

(NO contacts of the relay PH1 will close, address 29)
2. Flow switch (SN-BF) is off. (NC contacts of the relay FS will close, address 30)

3-2 Emergency Shut Down Control

The engine will shut down in emergency by any of the following conditions.

1. When the emergency push buttons are pressed.

(NC contacts of the PB-ER1 and LS-ER1 will open, address 31.)

2. When the hydraulic oil volume is less than 85 litters [22.4 gal.].
(Hyd. oil tank capacity : 170 litters [44.9 gal.], NC contacts of the SN-OFT will close,
address 25.)

3. When the compressor discharged air temperature reaches 120±2゜C [248±3.6゜F].

(NC contacts of the AT will close, address 26.)

4. When the engine oil pressure is low.

(Approx. less than 100kPa : according to the engine speed, by ECM control)

5. When the coolant temperature reaches 107゜C [224.6゜F]. (By ECM control)

6. When the engine speed reaches 3100 min-1. (By ECM control)

3-3 Diagnostic Lamps

1. Warning lamp (red）
The warning lamp (address 29) warns the operator of engine problems.

2. Diagnostic lamp (yellow）

The diagnostic lamp (address 28) indicates the existence of an active fault by flashing
codes. The active fault codes can be determined by counting the number of flashes. Refer
the engine operation and maintenance manual for detail.

3. Maintenance lamp (green）

This lamp is not used (address 27).

10
4. Accessory Circuits
4-1 Warning Lamps
Each warning lamp will come on under the
35 36 37 38 39 40
following conditions.
P2
・When voltage of the alternator is low.
・When the engine air cleaner element is clogged.
PL4 PL5 PL6 PL7 ・When the hydraulic return filter is clogged.
(RL) (RL) (OL) (RL)
・When the compressor air cleaner element is
clogged.

When the starting switch is in start position, the

relay LT is energized, causing its contact
(address 40) to close. During this period,
address 36-38 lamps will come on and check
217 218 219 220 221 the operation of lamps.

ENR0 LT
SN- SN- SN-
EA ROF CEA

NC
Compressor Air Cleaner
Engine Air Cleaner

Return Filter

Lamp Test
Charge

Fig.8

4-2 Gauges

42 43 44 45 46 47 48 49 50 The gauges display the hydraulic oil,

P2
compressor air and coolant
temperature in an analog. The
B B B gauges indicate temperature by
T T T
E E E
converting a change in resistance of
the sensor.
The tachometer displays engine
speed by counting the voltage pluse
from the sensor.
222 224
225 226

223

NC
Comp. Air Temp. Sensor

Comp. Air Temp. Gauge

Hyd. Oil Temp. Sensor

Coolant Temp. Sensor

Hyd. Oil Temp. Gauge

Coolant Temp. Gauge

Tachometer & Sensor

Fig.9
11
4-3 Lights

52 53 54
P3
When the switch SS2 (address 53) is turned
on, two head lights will come on.
When the switch SS3 (address 54) is turned
on, one tail light will come on.

SS2 SS3

301 302

HL HL RL

NC
Head Light Switch

Tail Light Switch

Head Lights

Tail Light

Fig.10

4-4 Horns

59 60
P3 When the push botton PB-HR (address 59) is
pressed, two horns will sound.

PB-
HR

305

HL HH

NC
Horn Switch

Horn

Fig.11

12