Estructura y Función

Sistema Eléctrico

E. Velásquez

Slide 1 KT403306
WA380-6 Electronics System

Slide 2 KT403306
 WA380-6
Electronics
Overview

Slide 3 KT403306
Slow Blow Fuses

Fuse for permanent

Fuse for ribbon power supply
intake air heater

Fuse for main power

supply

Battery relay

Emergency steering
pump motor relay
Preheating
relay R11

Slide 4 KT403306
Starter Motor and Safety Relay
Starter motor 24 Volt, 5,5 kW

Safety relay

Slide 5 KT403306
 Engine Control Module ECM

The ECM is mounted on the engine on a

cooler plate.

NOTE:
There is NO fuel flow through the plate on
the WA380-6

Slide 6 KT403306
 Hydraulic Oil Temperature Sensor

The hydraulic oil temperature sensor R47 is

mounted inside the right front of the rear
frame

Slide 7 KT403306
Relays, Fuses and Controllers

Slide 8 KT403306
Behind the Operator Seat

Slide 9 KT403306
Under the Operator Seat

Diodes under the operator

seat frame

Slide 10 KT403306
Accelerator Pedal

Electric accelerator pedal with potentiometer

and idle validation switch

Slide 11 KT403306
Centralized Connectors under the Cabin

Slide 12 KT403306
 WA380/480-6

How to read the new electrical diagrams

Slide 13 KT403306
Electrical Diagram Information

Slide 14 KT403306
Schematic Information

Wire color code legend

Slide 15 KT403306
Failure code [b@CENS] (Torque converter oil: Overheating)

Starting with a failure code

1. Check causes
2. Two different connectors are used, on one we need to
measure resistance on the other we will measure voltage

Slide 16 KT403306
Connector Locator

Slide 17 KT403306
Circuit diagram for T/C oil temperature sensor

Pin 2 Between
pin 1 & 2

Slide 18 KT403306
Starting Switch Circuit

New symbol for key switch

• Switch terminals B, BR, R1, ACC are all connected when pre-heat is used
• Switch terminals B, BR, and ACC are all connected when the switch is in the on position
• Switch terminals B, BR, R2, C, and ACC are all connected when the switch is held in the
start position

Slide 19 KT403306
Starting Switch Circuit

New symbol for key switch

• Wire for C terminal is circuit 105, wire size 1.25, fg =
flexible wire with GREEN insulation
• Is connected to pin 3 of male half of connector S40 which
is a DT type connector
• from the female half of S40 wire number 105 goes to pin
12 of connector J07

Slide 20 KT403306
Starting Switch Circuit

New key switch circuit

• Connector J07 is a M type connector
• Pin 12 is also common with pins 11 and 13
• Circuit 105 now becomes circuits 105 A and
105B
• Circuit 105B goes to connector TEL pin 7
• Circuit 105A goes to connector L44 pin 4

Slide 21 KT403306
Starting Switch Circuit

• Wire 105A comes from pin 11 of connector J07 this wire

changed color at connector J04 to white with a blue stripe
• Wire 105A for this application is terminated at connector L44

Slide 22 KT403306
Starting Switch Circuit

• Wire 105B from connector J07 13 to TEL pin 7 this wire color was
unchanged
• Connector TEL pin 7 female side is now circuit 105 AB
• Wire 105 AB goes to connector L80 pin 27 and connector W60 pin 3

Slide 23 KT403306
Starting Switch Circuit

• Circuit number on W60 has

changed 105AB to 105AA
•This wire comes from
connector L80 pin 27
• A second wire on 105AA
comes from TEL pin 7

Slide 24 KT403306
Electrical Circuit of Hydraulic Oil Temperature Sensor

Q U IZ

Find the hydraulic oil temperature sensor R47.

The signal line on pin 1 is connected to pin 41 on the next connector FL1.
The ground line on pin 2 is connected through the remaining pins to ground.

Slide 25 KT403306
Electrical Circuit of Hydraulic Oil Temperature Sensor

On the FL1 connecter you will find pin 41 and the connecter name R47 of the hydraulic oil
temperature sensor.
Now find the opposite part of FL1 connector in the schematics.

Slide 26 KT403306
Electrical Circuit of Hydraulic Oil Temperature Sensor

The opposite part of FL1 connector provides the following information:

Connecter L55 is the next connector you you have to look for in the schematic.
The hydraulic oil temperature will be inputted on pin number 7 of the next connector.

Slide 27 KT403306
Electrical Circuit of Hydraulic Oil Temperature Sensor

Monitor Panel Controller

The line arrives at connecter L55 on the monitor panel.

The line comes from connector FL1 pin 41, which was the last connector in this case.
The hydraulic oil temperature signal is an input on pin 7 of the main monitor.

Slide 28 KT403306
CONNECTOR LOCATOR CHART

Connector Locator Chart

Slide 29 KT403306
Connector Locator

Slide 30 KT403306
Connector Locator

Slide 31 KT403306
Connector Locator

Slide 32 KT403306
Connector Locator

Slide 33 KT403306
Connector Locator

Slide 34 KT403306
Connector Locator

Slide 35 KT403306
Connector Locator

Slide 36 KT403306
Connector Locator

Slide 37 KT403306
WA380/480-6 Monitor System

Machine Monitors

Slide 38 KT403306
WA380/480-6 Monitor System

In the machine monitor system:

• Each controller on the network monitors and controls the machine
condition with the sensors and switches installed in various
systems on the machine
• These controllers then send their acquired information as network
information to the machine monitor
• The machine monitor displays this information to notify the
operator of the machine condition.

The machine monitor can displays this

information in either the operator mode or
service mode.

Slide 39 KT403306
WA380/480-6 Monitor System Operator Mode

The operator mode is used to display the normal information

to the operator.
The major functions used in the operator mode are as follows.

Items always displayed

1. Meters (Speedometer or engine tachometer)
2. Gauges (Engine coolant temperature gauge, torque converter
oil temperature gauge, hydraulic oil temperature gauge, and fuel
level gauge)
3. Pilot indicators
4. Service meter

The following items are displayed according to the set

state of the optional device selecting function.
1. Travel speed or engine speed indication
on the character display

Slide 40 KT403306
WA380/480-6 Monitor System

Items displayed when a abnormality is detected

1. Caution lamps
2. Action code (While an action code is
displayed, press the monitor panel mode
selector switch (>) To display the failure code
(6 digits).))

Slide 41 KT403306
WA380/480-6 Monitor System

At service interval time for filters or oil changes

The character display displays that filter or oil
change information.
(Maintenance monitoring function)

Also: the following display, setting and adjustment functions are provided by
using the character display and the machine monitor mode selector switch
1) Display the odometer
2) Reset maintenance interval time
3) Input a telephone number
4) Select your language
5) Adjust machine monitor brightness
6) Travel speed/engine speed display selecting function
7) Function for setting display/no-display of travel speed or engine speed to the
character display
See shop manual
SEN01229-0 page 6

Slide 42 KT403306
WA380/480-6 Monitor System

Service Mode

The service mode function is provided to aid in successful

troubleshooting of all monitored parameters for each
controller on the network
(including the machine monitor itself).
The major functions used in the service mode are as follows.
1. Electrical system failure history display function
2. Mechanical system failure history display function
3. Real-time monitoring function: The input and output signals recognized by
each controller on the network are displayed in real time.
4. Engine reduced-cylinder function
5. No injection cranking function
6. Adjustment function: functions are provided to correct/adjust installation errors,
manufacturing dispersion of the sensors, solenoid valves, etc.
7. Maintenance monitoring function: to changes filter or oil service intervals, also
can switch the maintenance function on or off

Slide 43 KT403306
WA380/480-6 Monitor System

8. Operating information display function: Displays fuel consumption

per operating hour.
9. Optional device selecting function: Verifies the installation of optional
devices or changes their setting.
10Machine serial number input function: Enters the machine serial
number to identify the machine.
11. Model selection function: Enter the information of applicable model.
12. Initialize function: This function is used to set the machine monitor
to the state set when the machine is delivered.

Slide 44 KT403306
WA380/480-6 Monitor System
Items displayed on monitor
Condition for judging that engine is running: When either one or both of following
items 1 and 2 is or are sensed, the machine monitor judges that the engine is
running.
1. The engine speed is above 500 rpm.
2. There is alternator voltage R and there is terminal C input after the starting
switch is turned “ON”.
O: ON
: Flashing (1.6 sec., 50% duty)
: : Intermittent (Period: 240 msec., “ON”: 80 msec., “OFF”: 160 msec.)
Δ: As per separate setting condition
Priority of sounding of buzzer: Continual (w) > Intermittent (A) > Cancellation of
operation > Check of acceptance
of operation.

Slide 45 KT403306
WA380/480-6 Monitor System - MONITOR INFORMATION
See shop manual
SEN00886-00
page 8

Slide 46 KT403306
WA380/480-6 Monitor System

To move from operator mode to service

mode; press and hold the left arrow key
and the box key for 5 seconds, release
these keys when the monitor information
screen changes.
You will be prompted to enter your
password
With key switch off press to view service meter

Slide 47 KT403306
WA380/480-6 Monitor System
Failure code screen (1st layer)
1. Pressing the “>” switch when the Warning screen is on display
changes display to the Failure code screen.
2. If multiple failure codes are present, each pressing of the “>”
switch displays them from the item of higher priority downward. If
items have the same priority, the item that occurred most recently
will be displayed first.

Note: there are 3

simultaneously
occurring failure
codes.
1. from the
transmission
controller
2. from the engine
controller
3. from the monitor
Slide 48 KT403306
WA380/480-6 Monitor System

Functions available to the operator

(2nd layer or below)
Pressing ◊ switch enables to select
each menu.

See the Operation and maintenance

manual for details of each menu.

Slide 49 KT403306
WA380/480-6 Monitor System
Procedure for switching to Service Mode
1. Check that the character display is set to the 1st layer screen in
the operator mode.
2. Display of ID input initial screen Pressing “□” switch and “<”
switch simultaneously for 5 seconds or more, the ID entry initial
screen appears.
3. ID input and confirmation: Operate the machine monitor mode
selector switches < and > and enter ID. (ID: 6491)

C Pressing the < > keys changes the value of this digit in the
range of 0 to 9 one number at a time. Pressing the ◊ key will
accept the integer that you entered. If you have entered an
incorrect integer pressing the □ will take you back one step.

Slide 50 KT403306
WA380/480-6 Monitor System

Slide 51 KT403306
WA380/480-6 Transmission Control System

See shop manual SEN00887-00 page 3-7 to

review auto shift logic
WA380-6

Slide 52 KT403306
WA380/480-6 Transmission Control System

1. Shift hold function: maintains the gear speed chosen when the auto shift
mode is used.
2. Hold function does not allow shifting up or down as the travel speed is
changed (up/down).
3. Pressing the hold switch again resets the shift hold function and turns off the
pilot lamp.
4. The shift hold function is automatically reset when the directional lever, gear
shift lever or kick-down switch is operated.
5. The torque converter lockup is turned off.

Kick-down function
1. In manual-shift mode
When the directional lever is set to “F” and the gear shift lever to “2nd”, pressing
the kick-down switch changes the gear speed to 1st.
2. The kick-down signal is ignored in either “R” or ”N” or in any gear other than 2nd
3. Kick-down is reset when the directional lever is operated or the gear shift lever
is set to any position other than “2nd”.

Slide 53 KT403306
WA380/480-6 Transmission Control System

Kick- down function

In auto-shift mode
1. The kick-down function is enabled when the directional lever
is set to a position other than “N (Neutral)” and the gear shift
lever is set to a position other than the “1st” position.
2. The kick-down function is reset when the directional lever is
operated after the actual gear speed is changed or the no-
shift time for hunting prevention elapses.
3. After the reset, the auto shift based on “Auto-shift points
table” is turned on.

When forward 1st is selected

1. When “E-mode” is selected for the power mode and the gear speed is set
to forward 1st, pressing the kick-down switch changes the power mode to “P-
mode”.
2. The power mode switching function is enabled, independent of the auto or
manual shift, only when forward1st is selected and it is reset as any actual
gear speed other than 1st is selected.

Slide 54 KT403306
WA380/480-6 Transmission Control System

Function of hunting prevention

1. The transmission controller detects and prevents hunting that can
result from shifting the gear from 2nd to 3rd and 3rd to 2nd in the auto shift
mode.
Transmission initial learning and ECMV current adjustment
1. Adjusting the “Transmission initial learning setting” and Transmission
ECMV current adjustment” items by use of the adjustment function of the
machine monitor allows correcting variations of the transmission
itself as well as ECMV.
2. Ignoring above adjustment can lead to generation of gear shifting
shocks or time lag.
Changing shift points
1. The transmission controller has the function of adjusting the gear shift points
of “L-mode” in auto-shift.
2. When hunting is induced by some conditions unique to a worksite, adjust the
shift up and down travel speeds by adjusting the “Adjustment of transmission L-
mode shift point” item by use of the adjustment function of the machine monitor.

Slide 55 KT403306
WA380/480-6 Transmission Control System

4th gear lockout function

1. Restriction of operation in 4th gear speed becomes available by
selecting “ADD” for “23. FORBID 4TH” item using the optional device
selecting function of the machine monitor.
Transmission controller will protect the transmission when an on authorized
directional shift is selected
1. When the directional lever is operated during high-speed travel (3rd/4th),
engagement of the speed clutch is controlled to protect the transmission.

Slide 56 KT403306
WA380/480-6 Transmission Control System

Shift down protection

1. In order to protect the engine and pumps, the transmission controller

rejects a downshift command when travel speed is to great
2. The alarm buzzer is sounded as long as the shift down protection function
is turned on.
3. The buzzer sounds are continued until the gear speed position of the
gear shift lever coincides with the actual gear speed. Thus, shifting up
operation can stop the alarm buzzer sounds even if the travel speed is
not slowed down.
4. The shift down protection rejects the kick-down signal when the travel
speed is to great.
5. If the kick-down switch is pressed while the machine is traveling to fast
the alarm buzzer will be sounded for 3 seconds.

Slide 57 KT403306
WA380/480-6 Transmission Control System

Engine overrun prevention

1. When the transmission output shaft speed reaches a level that corresponds
to an engine RPM of 2,500 rpm or greater, the lockup clutch is disengaged
automatically in order to prevent the engine overrun.
2. The alarm buzzer is sounded as long as the engine overrun prevention
function is turned on.
3. The unlock state is maintained for 5 seconds after it has been determined
that the engine speed is less than 2,500 RPM.
4. Lockup will than be applied again.

Maximum travel speed de-rate function

1. As transmission output shaft speed reached a level corresponding to a travel
speed of 40 km/h or above, this function resets the lockup for safety.
2. The alarm buzzer is sounded as long as the maximum travel speed de-rate
function is turned on.
3. When the lockup clutch is not installed on the machine, alarm buzzer alone will
be sounded.

Slide 58 KT403306
WA380/480-6 Monitor System
Transmission cut-off function
1. The transmission cut-off oil pressure sensor detects the brake pilot pressure
when either brake pedal is pressed and sets the transmission to neutral.
2. This function will work at any brake pedal position, by saving the brake
pressure at any brake pedal angle into the transmission controller memory.
Transmission Outline ●As the transmission cut-off operating conditions are met, the
cut-off control transmission is set to neutral.
●As the transmission cut-off reset conditions are met, the transmission
is released and the transmission gear speed is controlled by the
See shop manual modulation.
SEN0887-00
page 26 for Operating Operating conditions in 1st and 2nd gear speeds
setting condition • Cut-off switch is turned “ON” and the brake pilot oil pressure became
instructions
larger than the cut-off IN pressure.
Operating conditions at 3rd and 4th gear speeds
• Cut-off switch is turned “ON” and brake pilot oil pressure is larger than
the cut-off IN pressure and the accelerator pedal is less than 30%
Reset When any of the following is met, cut-off is reset.
condition • The transmission cut-off switch is turned “OFF”.
• The brake pilot oil pressure is below the cut-off OUT pressure.

Slide 59 KT403306
WA380/480-6 Engine Control System

Engine Control Function

Power mode selecting function

1. Setting the power mode selector switch to “P-mode” sends the P-mode
torque curve information to the engine controller. At the same time, the
power mode pilot lamp is turned on.

Engine stall prevention control

1. When engine speed is at low idle, switching travel direction during high-speed
travel can cause the engine to stall.
2. To prevent engine stall, a specified throttle (accelerator pedal) lower limit
position signal is sent to the engine controller as the travel direction is switched.
3. When the direction was changed from “reverse” to “forward”, this function sends
as much as approximately 25% of the specified throttle lower limit position
values to the engine controller.
4. In the case of “forward” to “reverse”, as much as approximately 15% of the
values are sent. This communication lasts for 2 seconds after the directional
selection is completed.

Slide 60 KT403306
WA380/480-6 Engine Control System

Cooling Fan Control Function

1. Transmission controller 7. Machine monitor mode selector switch 1

2. Machine monitor 8. Machine monitor mode selector switch 2
3. Engine controller 9. Hydraulic oil temperature sensor
4. Cooling fan pump 10. Torque converter oil temperature sensor
4a. Swash plate angle control EPC valve 11. Coolant temperature sensor
5. Cooling fan motor 12. Engine speed sensor
5a. Cooling fan reverse rotation solenoid valve 13. Engine
6. Cooling fan reverse rotation switch 14. Radiator

Slide 61 KT403306
WA380/480-6 Engine Control System

Engine speed, coolant temperature, torque converter, and hydraulic

oil temperature received by the machine monitor are sent to the
transmission controller via the network.
1. Based on the received information, the transmission controller
sends current to the EPC valve on the cooling fan pump to control the
pump swash plate angle to set fan speed to the desired speed

Pump protection function

1. To prevent cooling fan motor overrun, fan pump swash plate angle is set to
minimal when engine speed reached 2,300 rpm or above.
2. If the transmission controller fails to recognize engine speed and temperature
data because of communication error, this function sends (677mA) to the EPC
valve on the pump
3. Now the pump will work as a fixed displacement pump.

Slide 62 KT403306
WA380/480-6 Hydraulic Control

Hydraulic Pump Control

Work Equipment Pump Swash Plate Control Function

Comparing results of calculations done on respective functions, this function
selects the data that makes the work equipment pump delivery smaller (the
data that sets a larger value for the command current to the swash plate
angle control EPC valve).

Engine stall prevention control at low idle

1. Engine stall can result from a radical increase in load at low idle.
2. To prevent this problem, this function restricts the pump delivery at
high pressure by controlling the pump swash plate angle through
EPC.

Slide 63 KT403306
WA380/480-6 Hydraulic Control

Slide 64 KT403306
WA380/480-6 Hydraulic Control

Pickup auxiliary function when engine speed is low

1. Using compound hydraulic operations and steering at a low
engine speed can cause poor engine acceleration because the
hydraulic HP. Demand becomes larger than engine capability.
2. This function is installed to help improve the engine acceleration
performance.
3. As the accelerator pedal is pressed from a low engine speed,
this function sends the command current corresponding to the
steering oil pressure to the main pump EPC valve in order to
alleviate the load by controlling the pump swash plate.

Slide 65 KT403306
Electrical System

Electrical System

Slide 66 KT403306
WA380/480-6 Engine Start Circuit

Slide 67 KT403306
WA380/480-6 Engine Stop Circuit

Slide 68 KT403306
WA380/480-6 Parking Brake System
1. Parking brake relay
2. Parking brake switch
3. Brake oil pressure caution relay
4. Rear brake oil pressure switch
5. Emergency brake oil pressure switch
6. Parking brake solenoid valve
7. Transmission controller
8. Machine monitor
Slide 69
When starting switch is turned “OFF”
1. Turning the starting switch “OFF” opens brake
relay (1). Stopping current flow to the parking
brake circuit, applies the parking brake.
2. Accordingly, when the starting switch is turned
“OFF”, current is not conducted to parking brake
solenoid valve (6) regardless of the position of
parking brake switch (2). And the parking brake
remains applied.
KT403306
WA380/480-6 Parking Brake System
• When PB switch (2) is “ON (applied)”, battery
current flows through PB switch (2), to parking
brake relay (1) and closes the contact.
• With PB relay (1) closed, battery current holds the
contact closed until current from the battery relay is
cut off.
Slide 70 KT403306
• Current does not flow to parking brake solenoid
valve (6). The parking brake is applied.
• Transmission controller (7) responds to PB
switch (2) signal and sets the transmission to N
as long as the parking brake is applied.
• When PB switch (2) is “OFF (released)” current
from the battery goes from PB relay (1), to parking
brake switch (2), to emergency brake oil pressure
switch (5) to parking brake solenoid valve (6) and
release the parking brake.
WA380/480-6 Parking Brake System

When parking brake switch was turned “OFF (released)”

before turning the starting switch “ON”
• While the parking brake switch (2) is “OFF
(released)”, current does not flow to parking brake relay
(1) and its contacts remain open.
• Turning “ON” the starting switch in this case does not
conduct current to parking brake solenoid valve (6).
• Accordingly, the parking brake is not released

Slide 71 KT403306
WA380/480-6 Parking Brake System

When low brake oil pressure is sensed

• If brake oil pressure gets low, rear brake oil pressure • In this case, (unlike when the parking brake
switch (4) opens, cutting off current to caution relay (3). switch was turned “ON (applied))”, current flow
• Brake oil pressure caution relay (3) opens, cutting off from parking brake switch (2) to the
current to machine monitor (8). transmission controller (7) is maintained.
• As the result, machine monitor generates the alarm. • Thus, transmission is not set to the neutral.
• Brake oil pressure switch (5) opens (the operating
pressure setting of which is lower than that of rear brake
oil pressure switch (4) stopping current flow to brake
solenoid valve (6).
• As the result, the parking brake is applied.

Slide 72 KT403306
Slide 73 KT403306
Slide 74 KT403306
 End of Electrical System

Section 2_6

Slide 75 KT403306