Electrical System

DL Wheel Loader

Feb, 2009
Overseas Product Support Team
Text No. ELE0003
Electric system

Power supply system

?

??

1
Electric system

Engine start
Key on position.

2
Electric system

Engine start
Engine ignition.

3
Electric system

Engine start
Starter controller.

Direction signal
from safety relay (24 Volt)

ALT signal
(Over than 500 rpm)

S is not connected with E when or

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Electric system

Engine start
Preheat.

5
Electric system

Engine start
Preheating time.

DL200 / DL250 / DL300

Key position Coolant Temp() Heating time (sec) Remarks

Below 0 20
On Complete heating
5 10
(= preheating) Heating light is on
Above10 Not working

DL400

Key position Coolant Temp() Heating time (sec) Remarks

Below -12 30
On Complete heating
0 10
(= preheating) Heating light is on
Above19 Not working

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Electric system

Engine start
After heat.

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Electric system

Engine start
After heating time.

DL200 / DL250 / DL300

Coolant Temp() Heating time (sec)

Below 0 120
5 60
Above10 Not working

DL400

Coolant Temp() Heating time (sec)

Below -19 30
-19 ~ -8 20
-8 ~ 8 10
Above 8 Not working

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Electric system

Control unit

Key S/W
Safety relay

Brake pressure S/W

Parking brake S/W

Alternator

Condition Operation
All lamp On with buzzer
Key S/W On (#1)
After 2 sec, All lamp and buzzer Off
Alternator charging voltage (Below 14.5 V) #2 Charging lamp On
Brake press S/W Closed (#6)
Alternator charging
Parking brake S/W Closed (#7) Buzzer
voltage (Above 14.5 V)
Safety relay Closed (#8)

9
Electric system

Proximity switch ( Joystick detent function)

Proximity switch.

(- Terminal)

( O output)

(+ Terminal)

Normal condition Approached condition

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

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 Electric system

Proximity switch ( Joystick detent function)

Detent / release lever ( I )

From Battery

Not approached
Not working Energize magnet

(Release lever) (Detent lever)

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Electric system

Proximity switch ( Joystick detent function)

Detent / release lever ( II )

From Battery

Approach lever Energize magnet Not working

(Detent lever) (Release lever)

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Electric system

Air- conditioner
Air-conditioner.

1.Battery. 2.Battery relay.

3.Fusible link. 4.Circuit breaker.
5.Fuse. 6.Lamp S/W.
7.Condenser fan relay.
8.Condenser motor.
9.Compressor relay.
10. Foot / defrost actuator.
11. Receiver drier. 12. Diode.
13. Compressor. 14. A/C controller.
15. A/C unit. 15-1. Blower motor.
15-2. Resister. 15-3. High speed relay.
15-4. Mid speed relay.
15-5. Low speed relay.
15-6. Recir / Fresh actuator.
15-7. Vent actuator.
15-8. Temp control actuator.
15-9. Temp sensor.

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Electric system

Air- conditioner
Blower unit.

15-2 Resister 15-8 Temp. control actuator

Fan speed relays

15-7 Vent actuator
15-9 Temp. sensor

15-6 Recirculation / Fresh actuator

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Electric system

Air- conditioner
A/C controller system.

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Electric system

Air- conditioner
Blower motor.

3.86
1.28

Low. speed

Mid. speed

High speed

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Electric system

Air- conditioner
Recirculation / ventilation.

Recirculation / Fresh air actuator

Ventilation air actuator

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Electric system

Air- conditioner
Temp. control actuator.

12 Volt

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Electric system

Air- conditioner
Condenser / air- compressor

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Electric system

Air- conditioner
Foot / Defroster

24 Volt

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Electric system

Engine cooling system

Fan speed control system.

Reverse fan
S/W

Reverse fan T/M oil Temp.

warning lamp sensor

Coolant Temp.
sensor

50mA 580mA

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Electric system

Engine cooling system

Operation controller.

Sensor Target temp. Fan speed Current of Proportional valve

Coolant Temp. 85 ~ 95 Low PRM : 580 mA (40 bar)

400 ~ 1,200 RPM
Mission oil Temp. 95 ~ 103 Max PRM : 50 mA (140 bar)
(DL300 :120 mA)

Reverse fan

Low PRM : 580 mA ( 40 bar)

Reverse S/W on Reverse Max RPM
Max PRM : 50 mA(140 bar)
(DL300 : 120 mA)

Before reversing fan,

Engine must be stop, key switch on condition and press reverse fan S/W.
Start engine, cooling fan will be reversing to max fan RPM for 5 Min.

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 Electric system

Engine cooling system

Operation curve.

Coolant Temp.
T/M oil Temp.

Max. fan RPM

580mA

Reverse

0 fan RPM
50m
A

Reverse fan

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Electric system

Transmission system
Schematic of transmission system.

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Electric system

Transmission system
Neutral position.

When measure currency,

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

XXXXXX

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Electric system

Transmission system
Traveling condition - Forward 1st

Engaged KV, K1 Clutch

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

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Electric system

Transmission system
Traveling condition - Reverse 1st

Engaged KR, K1 Clutch

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

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Electric system

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

F&R select signal light on

(from gauge panel)

Condition of traveling by F&R switch

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

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

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

Transmission system
Kick down - Auto mode.

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

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

Transmission system
Transmission cut off function.

T/M Power cut off function is working

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

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

T/M controller cut forward or reverse

clutch power off.

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Electric system

Transmission system
Automatic traveling (1-4)

~
~

~ Normal shifting range is 2nd 3rd 4th

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

Transmission system
Automatic traveling (2-4)

~
~

Normal shifting range is 2nd 3rd 4th.

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

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Electric system

Transmission system
Control block.

Input current (mA) Resistance Voltage (VDC)

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

Condition of Pressure Regulator Operation

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

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Electric system

Transmission system
Temperature sensor in control block.

Condition Function Remark

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

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

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

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

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Electric system

Transmission system
By pass filter switch.

DL400, DL500

Normal condition Closed filter condition

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

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Electric system

Transmission system
Location of transmitter.

Central
Engine Turbine Inductive
gear
transmitter

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

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Electric system

Transmission system
Transmitter specification .

Specification
Sensor Remark
Frequency Resistance() Gap (mm)

Engine - Output torque Control signal

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

Output Propeller shaft speed

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

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Electric system

Transmission system
Working for each sensor.

1. Engine & turbine sensor :

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

2. Turbine & central sensor : Engine

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

Central

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Electric system

Transmission system
LIS system.

~
~
~
Machine speed

0 I II

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

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

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Electric system

Transmission system
Emergency steering system.

From fuse box

From starter line

To warning
lamp

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

Transmission system
AEB starter.

The AEB has the task to compensate tolerances

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

For each clutch,

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

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Electric system

Transmission system
AEB procedure.
Step Order Display Remarks

1 Warm up transmission about 10 to 20 minutes Temperature 70 degree

2 Turn off ignition key

Plug in AEB starter to AEB connector located at

3
the seat base closest to the cab door

4 Put T/M gear selector lever to Neutral position

5 Engage park brake

TCU must recognize PL for at least 3 sec before

6 Start Engine PL
you press AEB starter button

7 On idling RPM PL

The button must not be released before TCU has

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

K1 TCU has started the AEB, and goes on adjusting

9 Hold button until AEB has been started (Information about the AEB K1, K2,, KR.
state) (Button may be released from starting)

OK
10 Wait until AEB has been finished
(AEB has been successful)

11 Turn off ignition and unplug AEB Starter

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Electric system

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

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