Professional Documents
Culture Documents
1200-1500 EDII - Engine Starting Circuits (Sep.2011)
1200-1500 EDII - Engine Starting Circuits (Sep.2011)
Electrical Systems
Engine starting circuits
Contents
4. Accessory Circuits
4-1ޓLights ........................................................................................................................ޓP.12
4-2ޓHorns ........................................................................................................................ޓP.12
4-3ޓWarning Lamps .......................................................................................................ޓP.13
4-4ޓGauges ....................................................................................................................ޓP.18
1
1. Electrical Equipment for Engine Starting Circuits
1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 77 78
PC F 7 (15A) PC1
ESA GT
ENR
1
PC01 F 1 (30A) P1
F 2 (15A) P2
PC00 PC00 PB- ENR
B BR F 3 (15A) P3 ENR
2 ER1 2
101
F 4 (15A) P4 109
R1 R2 C
F 5 (30A) LS-
P5 ER1
ACC 102
F 6 (15A) P6 110
ENR 165 LS-
PC01 PC01 PD022 ER2
1 AOT
108 PS1 166
DC A9
103
/ ESA
S DC A8 111
104 B 154 186
SR1 106
R G ERZ
PC01
G 112
B PC01 B
ENR ENR GT ESA ESB LT AOT RT KT ST HM
M 104 1 2 1
C
S SOL
E AO
NC
DC DC Converter
Air Heater Relay
Air Inlet Heater
Starting Switch
Starting Motor
Battery Relay
StCrter Relay
Hour Meter
Alternator
Lamp test
Battery
Fuse
Fig.1
PC1 Line Power for electrical system, starting switch and radio. If the F7 fuse is blown, the engine is not
able to start.
P1 Line Power for engine ECM, lights, horns, warning lamps, gauges and tachometer. If the F1 fuse is
blown, lose those control. If it is blown while the engine is running, the engine will shut off.
P2 Line Power for I/O relays, solenoid valves, indicators and buzzers. If the F2 fuse is blown, lose
those control.
P3 Line Power for switches, relays, and solenoid valves of the rod changer. If the F3 fuse is blown,
(P03) lose those control.
P4 Line Power for wiper motors and room light. If the F4 fuse is blown, lose those control.
P5 Line Power for air conditioner. If the F5 fuse is blown, lose those control.
P6 Line Power for additional lights (Optional) and 3-D angle indicators (Optional). If the F6 fuse is
blown, lose those control.
2
1-2 Starting Motor
The starting motor drives the flywheel to crank the engine. It consists of starter solenoid and
motor.
Pre-heat
If the inlet manifold temperature is below 0ࠑC [32ࠑF] at key on, the ECM will turn on the
heater and pre-heat lamp. If operators start the engine during pre-heating, the heater will
turn off to allow maximum current to be used by the starting motor.
The pre-heat time is shown in Fig.2.
Fig.2
35
30
Pre-heat time (sec.)
25
20
15
10
5
0
-40 -30 -20 -10 0 10 20 30 40 F°
-40 -34.4 -28.8 -23.3 -17.7 -12.2 -6.6 -1 4.4 ࠑC
Post heat
After successful engine start, the ECM will turn on the heater for a maximum of 300
seconds and it is cycled on a schedule based on the inlet manifold temperature at key on.
3
1-5 Starting Switch
The starting switch activates the circuits. The table below shows the contact capacity and
conduction state of the terminals.
Fig.3
1-7 Alternator
The alternator produces electrical power and supplies current to the circuits. The buildup of
alternator voltage is used to control the hour meter and starter relay.
4
2. Engine Starting Circuits
1 2 3 4 5 6 7 8 9 10 11 15 16 24 5-91
PC F 7 (15A) PC1
ESA GT
PC01 F 1 (30A) P1
PC00 PB-
B BR
ER1
101
109
R1 R2 C
LS- ST1
ACC 102 ER1
110
105
ENR LS-
PC01 ER2
1
108 166 39
103 E.C.M
from ECM ESA
S
111
104 SR1
R
ERZ
PC01
PC01 112
B B
GT ESA ST
M 104 1
C
S
E
NC
Starting Switch
Starting Motor
Battery Relay
Starter Relay
Signal
Battery
Fig.4
1) When the starting switch is turned to the ON position, current flows from the BR terminal of the
starting switch to the timer GT (address 15) and relay ESA (address 16). When the relay coils
are energized, NO contacts of the timer GT (address 5) and NO contacts of the relay ESA
(address 3 and 24) will close.
2) With the relay contacts closed, the battery relay (address 2) is energized, closing the circuit
from the battery to the starting motor terminal.
3) If the engine stop switches PB-ER1/LS-ER1/LS-ER2 are not pressed and the relay ERZ is not
activated, the relay ST1 (address 24) is energized, causing its NO contacts (address 5-91) to
close. With the contacts closed, the engine ECM is powered and ready to start.
4) When the inlet manifold temperature is below 0ࠑC [32ࠑF], the ECM will activate the heater
relay (address 5).
5
2-2 Starting Engine
1 2 3 4 5 6 7 8 9 10 11 15 16
PC F 7 (15A) PC1
ESA GT
PC01
PC00
B BR
101
R1 R2 C
ACC 102
PC01 ENR
1
108
from ECM 103
S
104 SR1
PC01 R
B PC01 B
104 GT ESA
M C
S
E
NC
Starting Switch
Starting Motor
Battery Relay
Starter Relay
Battery
Fig.5
1) When the starting switch is turned to the start position, current flows from the C terminal of the
starting switch to the coil of the starter relay (address 11), causing the relay contacts to close.
With the contacts closed, battery voltage is delivered to the starter solenoid. ޓ
2) When the starter solenoid is energized, a magnetic force moves the plunger, engages the
drive pinion with the flywheel ring gear and 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 4 5 6 7 8 9 10 11 12 14 22 23 77 78
PC1 F 1 (30A)
PC01 P1
ENR ENR
2 2
B BR
Break contact
C
after 30 sec.
R1 R2
ACC 102
165
AOT
PC01 ENR
1
108
from ECM 103
S B 154 186
106 R
104 SR1 G
PC01 R G
B PC01 B ENR ENR
1 2
AOT RT KT HM
M 104 C
S SOL
E AO
NC NC
Starting Switch
Starting Motor
Starter Relay
Hour Meter
Alternator
Fig.6
1) After the engine has started, the altenator (address 14) genelates electricity. The buildup of
alternator voltage reaches 12V, the relay ENR1 and ENR2 (address 12) are energized.
2) When the relay ENR1 is energized, its NC contacts (address 10) open. Current to the starter
relay is cut off, causing the starter relay contacts to open, breaking the circuit from the battery
to the starter solenoid. This is for protection of the starting motor. The starting motor will not
operate even if the operator turns the starting switch to the start position while the engine is
running.
3) When the relay ENR2 is energized, its NO contacts (address 23 and 77) close. The timer AOT,
RT, KT, the hour meter and the solenoid valve AO are energized.
4) The timer AO will activate relay contacts 30 seconds after it is powered. The NC contact of the
relay AO (address 78) remains closed during countdown, causing the solenoid valve AO to be
activated, releasing pressure in the receiver tank.
5) When the hydraulic oil temperature is below 25ࠑC [77ࠑF], the hydraulic oil heat control will
automatically start after preset time of the timer KT has passed (2 minutes).
7
2-4 Stopping Engine
1 2 3 4 5 6 7 8 9 10 11 15 16 24 5-91
PC F 7 (15A) PC1
Break contact
after 5 sec.
ESA GT
PC01 F 1 (30A) P1
PC00 PB-
B BR
ER1
101
109
R1 R2 C
LS- ST1
ACC 102 ER1
110
105
ENR LS-
PC01 ER2
1
108 166 39
103 E.C.M
from ECM ESA
S
111
104 SR1
R
ERZ
PC01
PC01 B 112
B
GT ESA ST
M 104 C 1
S
E
NC
Starting Switch
Starting Motor
Battery Relay
Starter Relay
Signal
Battery
Fig.7
1) When the starting switch is turned off, since current is cut off at the BR terminal, the relay ESA
(address 16) is de-energized, causing its contacts (address 3 and 24) to open. With the
contacts opened, current to the relay ST1 is cut off , causing its contact (address 5-91) to open.
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 timer GT (address 5) remains
closed for 5 seconds, leave the battery relay energized and continue supplying power to the
circuits.
8
3. Engine Control Circuits
79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97
PC1
P1
PL13 ST1
PL11 PL12
(RL) (OL) (WL)
105
A010 A011 A012 107 A016 A005 A006 A007 A015 A008 A017 A009
SS
1 3 -EN
255
5 SS- SS- C E D
MG1
15 LC1 LT2 A DATA LINK B
Engine Speed Control Switch
Pre-heat Lamp
Warning Lamp
Stop Lamp
Fig.8
Manual control
The engine speed can be adjusted by turning the throttle switch (address 84). The engine
speed at each throttle position is as follows.
ޓVoltage between
Position Engine speed A011 and NC
9
Automatic control
The engine speed will automatically increase when the NO contact (5.15) of the I/O relay
(address 89) is closed.
There are two conditions that would cause the relay to be activated
The maximum engine speed can be selected by engine speed control switch SS-EN (address
89) as follows.
Fig.9
When the hydraulic oil volume decreases below 130 litters [34.3 gal.].
(Hyd. oil tank capacity : 220 litters [58 gal.], NC contacts of the relay ERZ at address 24
will open.)
When the engine oil pressure drops below 70 kPa. (by ECM control)
When the coolant temperature reaches 113ࠑC [235.4ࠑF]. (by ECM control)
10
3-3 Engine Diagnostic Lamps
The machines are equipped with engine diagnostic lamps to indicate the existance of an active
fault of the engine. There are three lamps to warn operators of the state of the engine.
11
4. Accessory Circuits
4-1 Lights
116 117
WL WL WL WL WL WL
Head Light Switch
Tail Lights
Fig.10
4-2 Horns
PB
H01
120
HL HH
Horn Switch
Horns
Fig.11
12
4-3 Warning Lamps
52 53 54 55 56 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76
P1
LT ROF EA TL ENR2
ROF EA AT TL OFT
167
125 132
TL LT AT OFT
To 56
SN SN SN T1 T2 SN PL6 PL7 PL8 PL9 PL10
ROF EA AT OFT (OL) (OL) (OL) (RL) (RL)
NC
Self-holding
Hyd. Oil Return Filter Indicator
Self-holding
Discharged Air Temp. Switch
(Spare)
(Spare)
(Spare)
Charge
Fig.12
The machines are equipped with pressure switches and temperature switches. If abnormal
conditions exist, the operator will be alerted by warning lamps. The conditions that would cause
warning lamps to be turned on are as follows;
13
Lamp Test
9 10 18 63 64 65 66 67 68 69 70 71 72 73 74 75 76
PC1 P1
Break contact
after 5 sec. LT ROF EA TL ENR2
OFT
PC00
B BR
PL1 PL2 PL3 PL4 PL5 160 161 162
(RL) (RL) (RL) (RL) (OL)
139 140 141 142 143 126
Air Cleaner
Lamp Test
(Spare)
(Spare)
(Spare)
Charge
Fig.13
When the stating switch is turned on, the current travels from P1 line through diodes and the
NC contacts of the timer LT (address 63 and 71) and back to ground, warning lamps come on
for 5 seconds, checking the operation of lamps. The coil of the timer LT (address 18) is also
energized, it starts countdown. After 5 seconds, the timer LT will break relay contacts, causing
warning lamps to go out.
14
Hydraulic Oil Return Filter
52 53 54 55 56 71 72
When the differential pressure between
P1
inlet and outlet of the oil filter reaches at
275±27 kPa, the indicator switch will
ROF LT ROF
make its contact (SN-ROF) at address
52, allowing the relay ROF to be
128
energized. When the relay ROF is
160 161
energized, its NO contacts (address 72)
MD231
close, causing the circuit between P1
3
06 07 08 09 10 and 161 line to close and the hydraluic
oil return filter warning lamp to come on.
128
SN PL6
ROF (OL)
NC
Filter Lamp
Filter Indicator
Hydraulic Oil Return
Fig.14
SN PL7
EA (OL)
NC
Air Cleaner Indicator
Fig.15
15
Discharged Air Temperature High
NC
Temperature Switch
Temperature High
Discharged Air
Discharged Air
Fig.16
131 144
131
TL
T1 PL8
(OL)
NC
Self-holding
Fig.17
16
Hydraulic Oil Temperature High
52 53 54 55 56 63 66
When the hydraulic oil temperature
P1 reaches at 87±3ࠑC [188±5.4ࠑF], the
thermo switch (H) will make its contact
(T2) at address 56, causing the circuit
between 132 and NC line to close and
PL3
(RL) the hydraulic oil temperature high lamp
141 (address 66) to come on.
MD231
3
06 07 08 09 10
138
132
132
LT
T2
NC
Hyd. Oil Temp. High
Thermo Switch (H)
Lamp Test
Fig.18
Fig.19
17
Alternator Voltage Low
Fig.20
Alternator
Charge
4-4 Gauges
79 80 81 82 83 84 85 86 The temperature gauges indicate the
P1 hydraulic oil, compressor discharged air
and coolant temperature in an analog.
The gauges read electrical resistance of
the sensor or sending unit with changing
B B B B
T T T T temperature.
E E E E
NC
Temp. Sensor
Temp. Gauge
Hyd. Oil Temp. Sensor
Fig.21
Coolant Temp. Gauge
Fuel Gauge
18
Hydraulic Crawler Drill
HCR1200-EDII
Electrical System
Engine Starting Circuits
Phone: 81-3-3231-6982
Fax: 81-3-3231-6993