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Doosan DX225LC Manual Download Page 92

Electrical System

Page 91

SP000935

Air Conditioner/heater Circuit Diagram

44B

44A

45B

45A

49A

114C

142B

142A

48A

167B

49B

48B

116A

167C

115A

112A

114A

113A

99

116B

167A

115B

112B

114B

113B

47B

47A

43A

111A

110A

109A

108A

107B

106B

43B

111B

110B

109B

108B

107A

99

106A

46A

105B

168B

42E

42B

54E

130C

105A

168A

46B

42D

42C

47C

MODE F/BACK

CN9-17

0.5YW

CN10-10

(CN11)

4

3

KET 4P

2

1

(CN10)

14

19

20

18 17 16 15

10

11

13 12

18

AMP 040-III 20P

8

9

7 6

2 1

5 4 3

8

(CN8)

AMP 070 12P

(CN9)

15

17 16

12

14 13

9

11 10

12 11

10

AMP 070 18P

6

5

7

4

1

3

2

5

4

6

7

8

9

1

2

3

CN8-1

0.5LgR

CN10-14

AMP 18P + 12P

CN8

CN9

CN8-4

0.85YG

0.5YR

SUN LOAD SENSOR

0.5Lg

CN8-3

-

2

1

+

CN8-5

0.5LY

SENSOR

AMBIENT TEMP

2

0.85BL

0.85YG

1

SENSOR

CN10

AMP 20P

2

CN10-17

1

INCAR

CN11

KET 4P

WATER

SENSOR

CN10-19

CN8-2

0.5OrB

CN9-2

CN9-4

1.25BL

0.5YW

CN9-1

0.5LgW

CN9-3

CN9-18

0.5LgB

0.5YR

CN9-10

1.25B

ACTUATOR

CN10-15

MIX F/BACK

GND

CN10-4

CN10-9

DUCT

SENSOR

WARM (P1)

Vref MIX

COOL (P2)

CN10-7

CN10-3

M

Temp. Control

0.85LW

CN10-1

CN10-2

CN10-20

CN10-12

CN11-1

CN10-11

CN10-13

CN9-16

CN9-14

0.5YB

0.5OrW

CN9-15

CN9-12

0.5OrR

0.5GrY

CN9-13

CN8-12

0.5GrG

0.5LW

CN8-11

1.25B

0.5LY

INTAKE

Vref MODE

VENT (P2)

REC (P2)

DEF (P1)

MODE

ACTUATOR

M

ACTUATOR

M

FRE (P1)

BLOWER

CN10-6

-

M

+

FET

0.85B

0.85BW

A/C THERMO (LOW)

CN9-8

CN8-10

0.5LB

0.5LG

0.85LR

RECEIVER DRIER

ILL

LED 1~12

A/C CONTROL PANEL

0.5WR

1.25LR

CN9-5

CN9-11

0.85LR

CN9-6

1.25LR

CN10-5

CN10-16

BLOWER

RELAY

CN11-4

A/C

RELAY

AIRCON UNIT

CN10-18

CN10-8

CN11-2

DIODE 4

0.85B

COMPRESSOR

24V

BATT.

FUSIBLE LINK

LAMP SWITCH

0.5RW

BATTERY RELAY

20A

STARTER SWITCH

FG001463

Figure 75 

Summary of Contents for DX225LC

Page 1: ......

Page 2: ...Electrical System Page 1 SP000935 SP000935 ELECTRICAL SYSTEMSP000935 Electrical System Edition 1 ...

Page 3: ...Electrical System SP000935 Page 2 MEMO ...

Page 4: ...tem 20 Monitoring System 21 Instrument Panel 22 Monitoring System Schematic 24 Operation 26 Instruments 26 Warning and Indicator Lights 28 Indication of Warning Lights 28 Indication of Multifunction Gauge and Letter Information Area 29 Initial Operation 31 Mode Selector Switch 31 Graphic Information Area Display 32 Overview 32 Main Menus for the Graphic Display Area 33 Menu Selector Buttons 33 Mai...

Page 5: ...ol System 69 Engine Control Dial 70 Engine Control Circuit Diagram 72 Automatic Deceleration Control Auto Idle Control 74 Engine Overheat Protection System 76 Power Boost Mode 78 Operation 78 Power Boost Control Circuit Diagram 80 Automatic Travel Speed Control 82 Automatic Travel Speed Control Circuit Diagram 84 Self diagnostic Function 85 e EPOS Controller 85 Air Conditioner System 87 Outline 87...

Page 6: ...r and Replacement Procedure 112 Refrigerant Recovery 114 Vacuuming Refrigerant System 114 Leakage Check 116 Refrigerant Charging 116 Inspecting System For Leakage 118 Wiper System 119 Wiper Circuit 119 Wiper operation 120 Lighting System 122 Lighting System Circuit Diagram 122 Kind of Light 123 Operation 123 Overload Warning Device 124 Overload Warning Device Circuit Diagram 124 Audio Controller 1...

Page 7: ...Electrical System SP000935 Page 6 MEMO ...

Page 8: ...ety recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling the load Remember that ultimately safety is your own responsibility MODEL SERIAL NUMBER RANGE DX225LC 5001 and Up DX225NLC 5001 and Up ...

Page 9: ...Electrical System SP000935 Page 8 ...

Page 10: ...eries and a three phase AC generator with a rectifier The electrical wiring used in the system is easily identifiable by the insulator color The color symbols used in the electrical system are listed in the following chart Electrical Wire Color NOTE RW Red wire with White stripe R Base Color W Stripe Color NOTE 0 85G Nominal sectional area of wire core less insulator 0 85 mm2 Symbol Color W White ...

Page 11: ...gine controller 5 Fuel feeder pump switch 6 Terminal 6 of wiper motor 7 Terminal 13 of wiper controller 8 Terminal CN6 11 of instrument panel 9 Terminal CN9 6 of air conditioner panel 10 Cabin light When the starter switch 5 is in the ON or START positions the current flows from the battery 1 o fusible link 3 o fuse box 6 o B terminal of starter switch 5 o BR terminal of starter switch 5 o BR term...

Page 12: ... F F E REG I L FIELD GRD 7 12V 100AH R I P R B 8 B B E BR 4 B 12V 100AH 1 2 A 6 R2 ACC R1 B BR C 5 0 5G 3 FG007233 Figure 1 ELECTRIC POWER CIRCUIT DIAGRAM Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Circuit Breaker 5 Starter Switch 6 Fuse Box 7 Alternator 8 Diode Reference Number Description ...

Page 13: ...f the battery relay 2 o B terminal of the battery relay 2 Figure 3 o B terminal of the starter 9 The starter motor is rotated and the engine is started If the instrument panel has the password function activated input number should match the set number otherwise the start circuit closes and the engine does not start NOTE If the security system is LOCKED a four digit password will be required to st...

Page 14: ... 30 87a 87 P N B C BR R2 R1 ACC B 5 E S 11 D C B PP 7 8 2 10 1 BR E B A 3 A B C 9 FG007234 Figure 3 STARTER CIRCUIT 1 WHILE STARTING Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Circuit Breaker 5 Starter Switch 6 Fuse Box 7 Starter Controller 8 Starter Relay 9 Starter 10 Alternator 11 Diode 12 Starter Relay 2 13 e EPOS Controller Reference Number Description ...

Page 15: ...nal to the rotation of the alternator The starter controller 7 monitors the frequency of the output current Once the frequency is equivalent to 500 rpm it is sensed and the connection between S and E terminals and the connection between B and PP terminals are opened As a result the rotation of the starter 9 is stopped Once the engine is running the starter 9 will not operate even if the starter sw...

Page 16: ...a P 30 B E N S C B D PP E B BR A B A C 12 13 10 6 11 4 5 7 11 8 1 2 3 9 F E GRD P R R I I L REG F B B B FIELD Figure 4 OPERATION OF START CIRCUIT 2 IMMEDIATELY AFTER START Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Circuit Breaker 5 Starter Switch 6 Fuse Box 7 Starter Controller 8 Starter Relay 9 Starter 10 Alternator 11 Diode 12 Starter Relay 2 13 e EPOS Controller Re...

Page 17: ...ontroller 12 o ground This current flow causes the coil in preheat relay 7 to be activated closing contacts When the contacts of the preheat relay 7 are closed the heating coils of the air heating device 8 are heated by current flowing from the battery 1 o battery relay 2 o preheat relay 7 o air heater 8 o ground The duration of the heating cycle depends on the temperature of engine coolant The pr...

Page 18: ...ON 200A B TML PST B BR R1 1 R1 R2 ACC B C BR 5 E 10 BR B ACC R2 C A 4 3 FG007137 Figure 5 ENGINE PREHEAT CIRCUIT Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Circuit Breaker 5 Starter Switch 6 Fuse Box 7 Preheat Relay 8 Air Heater 9 Preheat Indicator Light 10 Diode 11 e EPOS Controller 12 Engine Controller Reference Number Description ...

Page 19: ...ine controller stops suppling power to the injector solenoid 9 This stops fuel from being injected into the engine cylinder thus stopping the engine In the event that the engine can be shut down using the starter switch 5 an emergency stop switch 10 is provided to shut down engine To activate the emergency stop switch move it to the I EMERGENCY STOP position The emergency stop switch 10 is in its ...

Page 20: ... BR STARTER SWITCH CONNECTION 6 START ON TML OFF PST B ACC R1 R2 C Figure 7 ENGINE STOP CIRCUIT Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Circuit Breaker 5 Starter Switch 6 Fuse Box 7 Diode 8 Engine Controller 9 Injector Solenoid 10 Emergency Stop Switch Reference Number Description ...

Page 21: ...ponents When the alternator 7 starts to operate a current flows from the R I terminal of alternator o diode 8 o battery relay 2 coil securing a path for the charging current to the battery 1 Thus preventing the possibility of a high voltage build up and possible damage to the electrical system TRIO DIODE 0 5 uF 8 START ON OFF STARTER SWITCH CONNECTION TML PST B BR R1 R2 C ACC F F E REG I L FIELD G...

Page 22: ...E B R C H E F H C POWER 1 5 2 3 6 7 AUTO 4 ESC 8 E G SPEED 02 05 MO 11 30 1700 RPM CHECK 1 2 8 3 4 5 7 9 10 11 12 13 6 FG000547 Figure 9 Reference Number Description 1 Instrument Panel 2 Battery 3 Light Switch 4 Return Filter Switch 5 Pilot Filter Switch 6 e EPOS Controller 7 Alternator 8 Warning Buzzer 9 Pump Discharge Pressure Sensor 10 Hydraulic Oil Temperature Sensor 11 Fuel Sensor 12 Air Clea...

Page 23: ...F H C POWER 1 5 2 3 6 7 AUTO 4 ESC 8 FG000548 E G SPEED 02 05 MO 11 30 1700 RPM CHECK 7 8 9 10 11 12 5 1 2 15 13 14 3 6 4 17 19 20 16 18 CN7 CONNECTOR AND TERMINAL NO 12 6 5 11 4 10 14 8 7 15 16 2 1 8 7 3 9 12 5 4 3 2 1 10 11 9 6 13 CN6 AMP 040 28P 1 Figure 10 ...

Page 24: ...es 1 Fuel Gauge 2 Engine Coolant Temperature Gauge 3 Hydraulic Oil Temperature Gauge 4 Multifunction Gauge and Letter Information Area 5 Digital Clock 6 Hour Meter 7 Charge Warning Light 8 Engine Oil Pressure Warning Light 9 Coolant Temperature Warning Light 10 Engine Check Warning Light 11 Preheat Indicator Light 12 Work Light Indicator Light 13 Power Mode Selector Switch and Indicator 14 Work Mo...

Page 25: ...URE LCD DISPLAY PANEL L6 WORK LAMP GRAPHIC DISPLAY FUEL LEVEL CN7 4 CN7 5 CN7 6 CN6 10 CN6 9 4 2 1 3 6 5 14 R I CN4 1 CN2 14 CN3 8 CN3 7 CN3 10 CN3 9 CAN A CN4 4 CN3 3 CN3 4 CN4 6 CN4 5 CN4 2 CN4 3 CN2 1 CN3 2 CN3 1 CN5 3 CN2 17 CN2 18 CN5 7 E BR A L1 L3 L2 L4 ILL CN6 3 CN6 1 CN6 2 CN6 12 CN6 11 R2 B 13 21 6 5 20 14 18 7 8 11 10 12 9 15 1 4 2 3 19 17 16 CN5 2 1 56 TxD RxD GND FG007141 Figure 11 ...

Page 26: ...6 Rear Pump Pressure Sensor 7 Hydraulic Oil Temperature Sensor 8 Fuel Sensor 9 Pedal Pressure Switch Optional 10 Air Cleaner Indicator 11 Pilot Filter Switch 12 Return Filter Switch 13 Alternator 14 e EPOS Controller 15 Battery 16 Battery Relay 17 Circuit Breaker 18 Fusible Link 19 Fuse Box 20 Check Connector 21 Engine Controller Reference Number Description ...

Page 27: ...lic Oil Temperature CN3 9 CN3 10 40 C 104 F o 1 397 ohms 50 C 122 F o 1 139 ohms 60 C 140 F o 881 ohms 94 C 201 F o 190 ohms 96 C 205 F o 177 ohms When reading increase Flow Adjusting Output Terminal CN1 19 CN1 20 40 lpm o 615 mA 60 lpm o 583 mA 80 lpm o 555 mA 120 lpm o 495 mA Default Set 200 lpm o 376 mA 239 lpm o 260 mA C H FG000550 Blue White Red E F FG000552 Blue Red Full 1 10 C H FG000551 Bl...

Page 28: ... VDC Main pump discharge pressure front pump CN3 1 CN3 2 V 0 00816 x P 1 0 V Sensor output voltage V P Displayed pressure Bar Main pump discharge pressure rear pump CN3 3 CN3 4 Function Display Sensor Specification Input Terminal Input Specification E G SPEED 1700 RPM FG000049 BATTERY 28 0 VOLT FG000050 FRONT PUMP 320 BAR FG000051 REAR PUMP 313 BAR FG000052 ...

Page 29: ...ow the reference After starting engine if engine oil pressure is insufficient after 8 seconds a warning buzzer will sound Engine Check ECU CAN Communic ation It lights in case of failure in engine system Coolant Temperature ECU CAN Communic ation It lights when engine coolant temperature sensor resistant is below about 128 ohms Preheating CN5 2 It lights during preheating CN5 2 terminal voltage is...

Page 30: ...al Operation Remarks HB4O2003 Description Symbol Input Terminal Operation Remarks Hydraulic Oil Temperature CN3 9 CN3 10 When hydraulic oil temperature is above about 96 C Fuel Exhausted CN3 7 CN3 8 When fuel is almost exhausted Air Cleaner CN2 17 When air cleaner is clogged Return Filter CN5 3 When return filter pressure is above about 1 50 kg cm2 21 psi FG000056 FG000057 FG000053 FG000054 ...

Page 31: ...ge is about 2 7V while overload warning switch is ON It flickers in case of 2 71V and above and lights continuously in case of 2 8V and above and warning buzzer also starts Boost CN2 2 It lights when boost is selected Breaker CN2 10 It lights when breaker is selected Shear CN2 9 It lights when shear is selected Description Symbol Input Terminal Operation Remarks FG000055 FG000253 FG000554 FG001470...

Page 32: ...is activated and turned OFF after about 2 seconds Power mode Standard mode Work Mode Digging mode Auto Idle High Output Activation Display Indicating coolant temperature Fuel level Hydraulic oil temperature Engine speed Clock Current time display Operation Mode OutputCheck Operation mode display LED e EPOS Output Electromagnetic Proportional Pressure Reducing Valve E P P R Valve Current mA Swing P...

Page 33: ...o menus One is main menu for user and the other is special menu for specialist These menus can be moved from normal display mode by the combination of selector buttons C H E F H C POWER 1 5 2 3 6 7 AUTO 4 ESC 8 FG000557 E G SPEED 02 05 MO 11 30 1700 RPM CHECK 5 1 4 3 2 Figure 12 Selector Buttons Graphic Display Area 1 Up Arrow Button 2 Down Arrow Button 3 Enter Button 4 Escape Button 5 Letter Info...

Page 34: ...on Information of machine operation Menu Selector Buttons 1 Up Arrow Button 1 on Figure 12 Move the cursor to up left and previous screen 2 Down Arrow Button 2 on Figure 12 Move the cursor to down right and next screen 3 Enter Button 3 on Figure 12 Move the menu to selected mode When setting the menu this button is used to function as the selector button 4 Escape Button ESC 4 on Figure 12 Move a s...

Page 35: ...n 2 on Figure 12 to move cursor to a language to be selected on the Language Select display and press the Enter Button 3 on Figure 12 and the selected language is indicated in the right bottom of the screen At this point pressing the Enter Button 3 on Figure 12 or the Escape Button ESC 4 on Figure 12 more than 1 second brings the main menu with changed language and then pressing the ESC button aga...

Page 36: ...o This mode displays total operating hours of filters and oils After changing the filter and oil reset the operating hour and then the operating hours until the next service interval can be easily checked MAIN MENU 1 Language 4 Adjust Display 5 Set Password 2 Set Clock 3 Filter Oil Info UP DOWN SELECT FG000075 Figure 16 SET CLOCK MOVE FG000076 06 05 2004 06 29 Figure 17 MAIN MENU 1 Language 4 Adju...

Page 37: ...d using the Up Arrow Button 1 on Figure 12 or the Down Arrow Button 2 on Figure 12 The default brightness is set to 50 1 Fuel Filter 2 Air Cleaner 3 Engine Oil Filter 4 Hyd Oil Filter 5 Pilot Filter 6 Engine Oil 7 Hydraulic Oil 8 Coolant Water FG001358 Figure 20 MAIN MENU 1 Language 4 Adjust Display 5 Set Password 2 Set Clock 3 Filter Oil Info UP DOWN SELECT FG000080 Figure 21 Adjust Display FG000...

Page 38: ...rd This menu is used to apply lock release or change password Please refer to the Operation Manual for details on Password Setting MAIN MENU 1 Language 4 Adjust Display 5 Set Password 2 Set Clock 3 Filter Oil Info UP DOWN SELECT FG000227 Figure 23 ...

Page 39: ...scaping Menus Entering Accessing Menus When normal mode screen is displayed if the enter button 3 and escape button ESC 4 are pressed simultaneously for more than 3 seconds normal mode screen Figure 25 will be changed to special menu screen Figure 26 Normal Mode Screen NOTE Normal mode screen can display many kinds of display mode by selecting for example engine speed rpm battery voltage VOLT fron...

Page 40: ...s Submenu Selection Method Various submenus can be selected by pressing Up 1 on Figure 24 and Down 2 on Figure 24 button Move the cursor to desired menu and a selected menu will be inverse displayed When the selected menu is inverse displayed press the Enter 3 on Figure 24 button for menu selection Information of Machine Status 1 Entering Submenus When cursor is located on Machine Info of special ...

Page 41: ...erature C Temperature of air incoming to intake manifold 11 E G Oil Pressure BAR Engine oil pressure 12 Fuel Temperature C Fuel temperature 13 E G Oil Temperature C Engine oil temperature 14 Load At Cur Speed Current load ratio of equipment FG008126 ANALOG INPUT STATE UP DOWN Page 1 3 UP DOWN Page 2 3 UP DOWN Page 3 3 1 Pump P V 2 Cooling Fan P V 3 Flow Control P V 000mA 4 Dial 5 TPS 000mA 6 E G C...

Page 42: ...n the return filter pressure switch is ON 10 Pilot Filter Clogged Lights up when the pilot filter pressure switch is ON 11 OWD Warning SW Lights up when the overload warning selector switch is ON 12 Brake Oil Press SW N A only for wheel type equipment 13 Pedal Press SW Lights up when the pedal pressure switch is ON 14 One Way Sel SW Lights up when the selector switch is turned to breaker 15 Two wa...

Page 43: ...ure SW Py 6 Pressure SW Px 19 Quick Coupler 20 F R Lever 21 Preheat Select 22 Reverse Fan SW 23 Pilot Cutoff SW N A 7 E G Oil Press SW 8 Air Cleaner Clogged 9 Return Filter Clogged 10 Pilot Filter Clogged 11 OWD Warning SW 12 Brake Oil Press SW N A N A 13 Pedal Press SW 14 One Way Sel SW 15 Two Way Sel SW 16 Power Max SW 17 Breaker SW 18 Preheat Select N A DIGITAL INPUT STATE DIGITAL INPUT STATE D...

Page 44: ... all the memorized record of past failure Digital Outputs Items Mark Remark 1 Relief Press Up S V ON OFF Lights up when the relief press up solenoid valve is ON 2 High speed S V Lights up when the high speed solenoid valve is ON 3 Swing Priority S V Lights up when the swing priority solenoid valve is ON 4 Reverse Fan S V N A 5 Starter Relay When the starter relay is ON 6 After Heat Relay N A UP DO...

Page 45: ...s that the totally counted number of the same failure Period xxxxxHrxxm It indicates the period for which machine has operated until a failure takes place For more than two occurrences of the same failure until the first occurrence time C Failure record deletion This mode is used to delete the memorized record of past failure If this mode is selected all records will be deleted When YES 3 on Figur...

Page 46: ...reen will move to Failure Info screen It has been shown 3 seconds upon deleting Fail Log The screen shown on the left will appear 3 seconds in case of wrong password input and then Enter Password screen appears again It has been shown 3 seconds in case of password failure ESC No FG000568 Yes ENTER PASSWD DELETE FAIL LOG Figure 37 ESC No FG000569 Yes DELETED DELETE FAIL LOG Figure 38 ESC No FG00057...

Page 47: ... P V CN1 19 CN1 20 R 14 2 25 C 77 F Flow control proportional pressure reducing valve V213 Relief Pressure Up S V CN1 1 CN1 11 V V_volt Note 4 R 26 2 2 25 C 77 F Breaker boost shear selector switch has to be selected as a boost function and the boost switch on the right hand joystick is ON status V214 High speed S V CN1 1 CN1 12 V V_volt R 26 2 2 25 C 77 F Voltage is only measured when the pressur...

Page 48: ...ress Sensor CN3 1 CN3 2 V 1V It has to be measured in engine stop state V221 Rear Pump Press Sensor CN3 3 CN3 4 V 1V V222 Hydraulic Oil Temperature Sensor CN3 9 CN3 10 R 2 45 0 25 k 25 C 77 F R 320 32 80 C 176 F V223 Water Temperature Sensor N A V224 Engine Speed Sensor N A V225 Fuel Level Sensor CN3 7 CN3 8 Empty 5 0 25 k Full 320 32 V226 Alternator Potential CN2 14 CN1 8 V 2 1V It has to be meas...

Page 49: ... 186 5 100 C 212 F E018 E G oil pressure sensor 2 27 2 32 V 2 318 80mV at 23 C 73 F and absolute pressure 3bar It has to be measured in engine running state E021 Battery voltage 1 03 1 06 V V_volt Note 4 E022 Fuel pressure sensor 2 14 2 12 V 1 833 28mV at 23 C 73 F and absolute pressure 300bar It has to be measured in engine running state E032 Fuel pressure monitoring MPROP 3 09 3 10 R 2 60 3 15 2...

Page 50: ...ply 1 03 1 06 V V_volt E049 Main Relay SCB ECU Engine ECU fail E051 Main Relay ECU Engine ECU fail E058 Solenoid power stage 1 3 04 3 13 R 0 31 0 42 20 C 68 F E059 Solenoid power stage 2 3 11 3 06 E061 Solenoid power stage 3 3 05 3 12 E062 Solenoid power stage 4 3 03 3 14 E063 Solenoid power stage 5 3 01 3 16 E064 Solenoid power stage 6 3 02 3 15 E065 Fuel HI pressure pump E G Current controlled H...

Page 51: ...fter heat function is operating status E083 Preheat light E G Low Side Power stage 2 1 13 1 56 E091 CAN A Line 1 53 1 52 R 60 5 20 C 68 F It is a composite resistance of CAN line This value has to be measured by connected condition of CAN line E097 Monitoring of misfire cylinder 1 Injector error Speed signal error of camshaft speed sensor or crankshaft speed sensor E098 Monitoring of misfire cylin...

Page 52: ...ALID but BELOW NORMAL OPERATIONAL RANGE FMI 2 Incorrect signal DATA ERRATIC INTERMITTENT OR INCORRECT FMI 3 Voltage above normal VOLTAGE ABOVE NORMAL OR SHORTED TO HIGH SOURCE FMI 4 Voltage below normal VOLTAGE BELOW NORMAL OR SHORTED TO LOW SOURCE FMI 5 Current below normal CURRENT BELOW NORMAL OR OPEN CIRCUIT FMI 6 Current above normal CURRENT ABOVE NORMAL OR GROUNDED CIRCUIT FMI 8 Abnormal sign...

Page 53: ...ent panel ON status and Alternator signal CN2 14 is HI Travel Speed 1st 2nd Operation hours used low speed and high speed are displayed 1st High speed s v OFF status 2nd High speed s v and travel pressure switch Py control valve ON status Hydraulic Oil Temperature Distribution C F Temperature of hydraulic oil is classified 6 steps and operation hours of each step are displayed Under 30 C 87 F 31 5...

Page 54: ... Hydraulic Oil Temperature Distribution 6 Coolant Temperature Distribution FG000574 Figure 43 FG000575 OPERATING HOURS UP DOWN Page 1 3 UP DOWN Page 2 3 UP DOWN Page 3 3 1 Power 2 Trenching 3 Auto idle 4 Travel speed I Speed II Speed 00042 Hr 00003 Hr 00005 Hr 00007 Hr 00001 Hr 5 Hyd Oil Temp C 30 31 50 51 75 86 95 96 00003 Hr 00005 Hr 00008 Hr 76 85 00000 Hr 00007 Hr 00001 Hr 6 Coolant Temp C 40 ...

Page 55: ... screen will recover to previous menu without resetting Machine Operation Info Screen 1 If you press the YES 3 on Figure 24 button password entrance screen appears 2 When right password is input machine operation periods will be deleted and Reset Completed screen will appear 3 seconds 3 If you press the NO ESC 4 button the previous screen appears without resetting operation periods ESC No FG000579...

Page 56: ...Electrical System Page 55 SP000935 ...

Page 57: ...TEM e EPOS Control System Schematic Work Mode Auto Idle Machine Info E G E G speed order FG000795 PO WE R UP C H E F H C POWER 1 5 2 3 6 7 AUTO 4 ESC 8 E G SPEED 02 05 MO 11 30 1700 RPM CHECK 5 4 4 3 8 8 7 7 16 6 6 11 12 14 13 15 10 9 2 17 21 19 18 22 20 23 1 Figure 50 ...

Page 58: ...Reducing Valve Attachment 10 Electromagnetic Proportional Pressure Reducing Valve Mode Control 11 Solenoid Valve Boost 12 Solenoid Valve Swing Priority 13 Solenoid Valve High speed 14 Solenoid Valve Breaker 15 Travel Motor 16 Main Relief Valve 17 Engine Control Dial 18 Breaker Boost Shear Selector Switch 19 Auto Travel Selector Switch 20 Boost Switch Right Work Lever 21 Sensor 22 Aux Mode Switch 2...

Page 59: ...Figure 51 Reference Number Description 1 Instrument Panel Power Mode Selector Switch 2 e EPOS Controller 3 Engine Controller ECU 4 Main Pump 5 Aux Pump 6 Control Valve 10 Electromagnetic Proportional Pressure Reducing Valve Mode Control 17 Engine Control Dial 22 Aux Mode Switch 23 Aux Mode Resistor Reference Number Description ...

Page 60: ...ly defaulted to standard mode The desired mode can be selected by pressing the selector button on the instrument panel When the power mode is selected the indicator light will turn ON to display the selected mode The quantity of oil discharged by the pump and the engine speed are determined by the mode selected by the operator The pump output in each mode is determined by the mode selection and is...

Page 61: ...senses this decrease and immediately reduces the pump discharge volume to maintain the engine speed at the rated level On the other hand if the load is decreased the controller increases the discharge volume of the pump to maintain the engine speed at the rated level By repeating these control operations the engine speed is maintained at the rated speed so maximum power can be generated In Power M...

Page 62: ... System Page 61 SP000935 B D C A FG000580 Figure 53 Reference Number Description A Engine Horsepower hp B Engine Speed rpm C Pump Discharge Volume lpm D Pump Discharge Pressure kg cm2 Reference Number Description ...

Page 63: ...ssure Reducing Valve controlling the discharge volume of pump because of fault in control system the machine can be operated in the aux mode Upon turning ON the aux mode switch the E P P R Valve controlling the discharge volume of pump comes into contact with the aux mode resistor to let current of a certain value flow At this time the discharge volume of pump follow the control by the pump regula...

Page 64: ...Electrical System Page 63 SP000935 ...

Page 65: ... 40 1 03 1 02 1 09 1 08 1 06 1 05 1 10 1 11 CONN 1 CONN 1 52 1 53 1 34 1 35 CN7 6 CN6 10 CN6 9 CN7 4 CN7 5 CN6 1 CN6 2 6 14 AMP 040 28P 18 7 15 6 7 3 9 10 11 12 16 8 6 5 4 7 8 1 2 CN2 AMP 070 18P 11 1 14 16 15 6 5 18 17 7 8 19 8 10 9 10 2 1 21 20 9 13 12 4 11 3 9 13 12 11 10 5 1 2 3 4 CN1 14 11 13 12 3 4 2 1 16 17 15 6 5 AMP MIC 21P GND CN3 17 B BR 15A 10A 5V SIG CN3 16 CN3 15 4 3 HIGH CW LOW 2 1 ...

Page 66: ...ent Panel 3 Engine Controller 4 e EPOS Controller 10 E P P R Valve Electromagnetic Proportional Pressure Reducing 17 Engine Control Dial 22 Aux Mode Switch 23 Aux Mode Resistor 24 Battery 25 Battery Relay 26 Fuse 27 Fusible Link 28 Starter Switch Reference Number Description ...

Page 67: ... digging mode Depending on the trenching mode selected the control valve solenoid adjusts the assignment of hydraulic oil flow to each device on the equipment POWER 1 5 2 3 6 7 AUTO 4 ESC 8 2 17 1 5 4 4 6 6 12 3 FG000797 E G Figure 56 Reference Number Description 1 Instrument Panel Trenching Mode Selector Switch 2 e EPOS Controller 3 Engine Controller 4 Main Pump 5 Aux Pump 6 Control Valve 12 Sole...

Page 68: ...ck stops The current to the solenoid valve for swing priority is shut off 2 Trenching Mode This mode is used for heavy duty ditch digging work or for loading work requiring big swing angles The voltage is assigned to the swing priority control valve activating the swing control valve restricting the flow of oil to the boom and the arm ARO0270L Figure 57 ...

Page 69: ... CN4 5 CN6 1 CN6 2 10 11 12 CN6 15 14 9 13 12 11 10 CN7 9 7 8 16 4 9 10 11 16 13 14 15 12 6 5 CN2 18 17 14 18 19 16 17 15 21 20 CN1 6 7 8 5 1 2 3 4 3 1 2 AMP 040 28P 1 2 3 6 5 4 AMP 070 18P 7 8 4 7 8 6 5 AMP MIC 21P 10 9 13 11 12 3 2 1 C5 CN1 13 CN1 9 CN1 8 CN1 2 CN1 1 15A 15A 1 26 4 26 25 24 12 FG000583 Figure 58 Reference Number Description 1 Instrument Panel 2 e EPOS Controller 12 Solenoid Valv...

Page 70: ...EPOS controller converts this output voltage of dial to digital signal and sends it to the engine controller by CAN line According to the dial command the quantity of fuel injection is adjusted FG000584 Drive Signal Command Signal Figure 59 Reference Number Description 3 Engine Controller 4 e EPOS Controller 17 Engine Control Dial Reference Number Description ...

Page 71: ...R BOTTOM 1st STEP 10 10 7th STEP 13th STEP CCW MECHANICAL STOP CW MECHANICAL STOP 2 3 2 3 1 2 3 4 2 5V 1 0V 4 0V 1ST 2nd 7th 12th 13th CW STOP CCW STOP 5 SETUP V 0 FG000866 Figure 60 Reference Number Description 1 Knob 2 Potentiometer Variable Resistor Reference Number Description ...

Page 72: ...e 71 SP000935 The engine control dial has a built in potentiometer When the control knob is moved the output voltage through 2 and 3 terminals will vary from the 5 V supplied from the e EPOS controller as shown in the graph ...

Page 73: ... 040 28P 14 2 1 8 7 4 5 6 8 16 12 11 10 9 3 7 6 15 CN7 AMP 070 18P 8 7 17 18 5 6 15 16 14 1 11 3 11 4 12 13 9 20 21 1 2 10 9 10 8 19 CN2 4 3 2 1 5 10 11 12 13 9 CN6 AMP MIC 21P 5 6 15 17 16 1 2 4 3 12 13 11 14 CN1 CONN 1 1 09 1 02 1 03 1 40 1 11 1 10 1 05 1 06 1 08 1 34 1 53 1 52 CONN VEHICLE 1 35 CN7 5 CN7 4 CN6 10 CN7 6 CN6 2 CN6 1 CN6 9 B BR 10A 15A 5V CN3 15 CN3 16 SIG CN3 17 GND 3 HIGH CW LOW...

Page 74: ...e Number Description 1 Instrument Panel 3 Engine Controller 4 e EPOS Controller 17 Engine Control Dial 24 Battery 25 Battery Relay 26 Fuse 27 Starter Switch 28 Fusible Link 29 Pressure Switch Py 30 Pressure Switch Px Reference Number Description ...

Page 75: ...TROL AUTO IDLE CONTROL POWER 1 5 2 3 6 7 AUTO 4 ESC 8 E G FG000798 2 4 1 3 5 5 Figure 62 Reference Number Description 1 Instrument Panel Auto Idle Switch 2 e EPOS Controller 3 Engine Controller 4 Engine Control Dial 5 Pressure Switch Reference Number Description ...

Page 76: ...on the instrument panel The initial setting at start up is with this switch in the select position Approximately 4 seconds after this function is selected if all work levers are in the neutral position the e EPOS controller compares the automatic reduction signal with the signal set by engine control dial The lower of the two signals is selected the e EPOS controller sends a signal to the engine c...

Page 77: ...E G E G overheating signal E G overheating signal Pump control signal FG000802 6 6 4 4 5 7 31 2 1 3 Figure 63 Reference Number Description 1 Instrument Panel 2 e EPOS Controller 3 Engine Controller 4 Main Pump 5 Aux Pump 6 Control Valve 10 E P P R Valve Electromagnetic Proportional Pressure Reducing Valve 31 Warning Buzzer Reference Number Description ...

Page 78: ... e EPOS controller The e EPOS controller sends a overheat signal to the instrument panel turning ON the warning light and buzzer simultaneously Also the e EPOS controller returns an overheat signal to the engine controller and changes power mode to standard mode The engine speed is then set to a low speed by the engine controller When coolant temperature falls below 95 C 203 F normal operation wil...

Page 79: ...PO WER UP E G FG000800 6 6 16 4 4 5 2 20 18 1 11 3 Figure 64 Reference Number Description 1 Instrument Panel 2 e EPOS Controller 3 Engine Controller 4 Main Pump 5 Aux Pump 6 Control Valve 11 Solenoid Valve Boost 16 Main Relief Valve 18 Breaker Boost Shear Selector Switch 20 Power Boost Switch Top of Right Work Lever Reference Number Description ...

Page 80: ...ter of the right hand work lever joystick is pressed during work the e EPOS controller will activate the power boost solenoid valve and increase the relief valve pressure from 330 350 kg cm2 4 700 5 000 psi The excavation ability is increased by approximately 6 When the power boost function is in activated a power boost symbol appears on the information display department of instrument panel NOTE ...

Page 81: ... 2 CN6 1 CN1 1 CN1 2 15A 15A AMP 040 28P 7 2 1 4 3 5 6 8 15 16 8 7 10 9 12 11 CN7 4 3 2 1 5 6 10 11 12 13 9 14 CN6 19 8 4 9 10 3 2 1 12 13 20 21 11 10 9 CN2 1 AMP MIC 21P 5 6 7 2 4 3 CN1 15 17 16 18 12 13 14 11 Center 6 12 3 14 11 6 15 16 13 PRESS PST SHEAR TML 3 1 0 10 9 UP BREAKER 2 20A FG000586 1 2 26 26 11 18 26 25 24 20 Figure 65 Reference Number Description 1 Instrument Panel 2 e EPOS Contro...

Page 82: ...Electrical System Page 81 SP000935 ...

Page 83: ...9 3 Figure 66 Reference Number Description 2 e EPOS Controller 3 Engine Controller 4 Main Pump 5 Aux Pump 6 Control Valve 7 Pressure Switch Py Port 8 Pump Pressure Sensor 13 Solenoid Valve High speed 15 Travel Motor 17 Engine Control Dial 19 Selector Switch For Automatic Travel Reference Number Description ...

Page 84: ...I speed travel solenoid valve based on the travel load The travel speed is changed between the I speed and the II speed mode The travel load is monitored by the two pressure sensors in the discharge lines of the front upper and rear lower pumps When the travel load is high pressure over 300 kg cm2 4 300 psi the solenoid valve is turned OFF and I speed low is selected In the case when the travel lo...

Page 85: ... 7 12 13 11 10 9 15 14 16 CN2 4 3 2 1 5 7 6 1 8 10 11 12 13 9 14 15 CN6 16 7 CN1 15 17 16 19 18 13 14 20 21 12 11 3 CN3 17 GND HIGH AMP 070 18P CN3 16 SIG 5V CN3 15 CW 2 1 LOW AMP MIC 21P 8 5 2 CN2 5 CN2 4 7 6 II I II 0 0 I 3 CN1 12 C3 CN1 1 CN1 2 15A 15A 15A 8 9 2 26 26 26 25 24 19 17 13 FG000587 Figure 67 Reference Number Description 2 e EPOS Controller 8 Pressure Sensor Front Pump 9 Pressure Se...

Page 86: ...n the input voltage to the e EPOS controller is below 18 5 1 V or above 32 5 1 V Stays ON while in normal range 2 Engine Speed Monitor This LED light flashes according to the engine speed The flashing interval is proportional to the engine speed 1 2 4 3 FG000588 Figure 68 Reference Number Description 1 Upper Digit 2 Lower Digit 3 Engine Speed Monitor LED Flash Interval Increases With Engine Speed ...

Page 87: ...Operation Status Upper Digit Lower Digit Power Mode Power Mode Normal Operation Power Mode Standard Mode Normal Operation Standard Mode Work Mode Digging Normal Operation Digging Mode Trenching Normal Operation Trenching Mode HAOH340L HAOH350L HAOH370L HAOH380L Error Code Indication Code Fault Location V201 01 Communication error in instrument panel V202 02 Communication error in engine controller...

Page 88: ...ONDITIONER SYSTEM Outline Solid type heater and air conditioner are installed in the cover behind the operator s seat Temperature of the operator s room is adjusted automatically to the temperature set by operator FG000784 A A C B C Figure 69 ...

Page 89: ...d every 500 hours If machine operates in an excessively contaminated environment filters should be cleaned more frequently and if necessary replaced with new ones How to Check Internal Air Filter 1 Press both levers on the left and right side at the top of the filter installed behind the operator s seat How to Check External Air Filter 1 Open the door at the left side of machine and loosen four ma...

Page 90: ... the rear side of the cabin to open the cover 3 Remove filter attached to the cover and clean the contaminated filter using compressed air 4 Close the cover replace the knobs and secure the cover to the support with butterfly bolts FG000441 1 Figure 72 FG000342 Figure 73 ...

Page 91: ... 9 8 6 6 10 FG007144 Figure 74 Reference Number Description 1 Air Conditioner heater Unit 2 Condenser 3 Compressor 4 Receiver Dryer 5 Discharge Hose 6 Suction Hose 7 Liquid Hose 1 8 Liquid Hose 2 9 Ambient Temperature Sensor 10 Sun Sensor 11 Control Panel Reference Number Description ...

Page 92: ...BL 0 85YG 1 SENSOR CN10 AMP 20P 2 CN10 17 1 INCAR CN11 KET 4P WATER SENSOR CN10 19 CN8 2 0 5OrB CN9 2 CN9 4 1 25BL 0 5YW CN9 1 0 5LgW CN9 3 CN9 18 0 5LgB 0 5YR CN9 10 1 25B ACTUATOR CN10 15 MIX F BACK GND CN10 4 CN10 9 DUCT SENSOR WARM P1 Vref MIX COOL P2 CN10 7 CN10 3 M Temp Control 0 85LW CN10 1 CN10 2 CN10 20 CN10 12 CN11 1 CN10 11 CN10 13 CN9 16 CN9 14 0 5YB 0 5OrW CN9 15 CN9 12 0 5OrR 0 5GrY ...

Page 93: ...ater Unit Airflow Diagram VENT DEF FOOT Heater Core Evaporator Fan Internal Air External Air Vent Rear Outlet Cold Box Outlet External Air Inlet Internal Air Inlet Vent Front Outlet DEF Outlet Foot Outlet DOOR INTAKE DOOR MIX COOL WARM FG001359 Figure 76 ...

Page 94: ... Def Vent 100 60 0 0 0 Foot 0 40 100 80 60 Def 0 0 0 20 40 FG007754 Actuator Temp Control A C Relay Duct Sensor Blower Relay Air Flow Control Module Blower Motor Actuator Internal external Air Exchanger Internal Air Sensor Internal Air Filter Evaporator Water Temp Sensor Actuator Wind Direction Control Figure 77 ...

Page 95: ...ator Temperature Control Change of discharged air temperature by controlling the position of temperature control door Actuator Wind Direction Control Actuator Temperature Control FG001361 Figure 78 Wind Direction Mode Output Terminal Voltage Vent c CN10 10 b CN10 4 0 5 0 2V Bi level 1 3 0 2V Foot 2 45 0 2V Foot def 3 5 0 2V Def 4 5 0 2V Set Temperature Output Terminal Voltage Max cooling c CN10 9 ...

Page 96: ...00935 Actuator Internal external Air Exchange CN10 20 CN10 2 FG001055 Figure 79 Mode Output Terminal Output Intake P1 P2 Moving of exchange door by selecting intake Recirculate P1 P2 Moving of exchange door by selecting recirculate ...

Page 97: ...low is based on manual set Relay Blower Power is supplied to the blower motor when the system is turned ON DRAIN CN10 1 SOURCE CN11 1 GATE CN10 6 FG001056 Figure 80 Airflow Output Terminal Output 1st CN11 2 CN10 1 10 0 5V 2nd 12 5 0 5V 3rd 15 0 5V 4th 17 5 0 5V 5th 20 0 0 5V 6th 22 0 0 5V 7th More than 25V Figure 81 Specifications Rated voltage 24V Rated current 20A ...

Page 98: ... and decreases when the temperature rises and falls respectively Water Temperature Sensor It senses the temperature of coolant water in the heater core FG001058 L S1 S2 B Figure 82 Specifications Rated voltage 24V Rated current 10A Figure 83 Temperature C Resistance K 0 11 36 0 1 2 10 39 0 2 2 5 10 17 0 2 3 9 95 0 2 3 5 9 73 0 2 4 9 52 0 2 5 9 12 0 2 10 7 36 0 15 25 4 02 0 08 30 3 33 0 07 Figure 8...

Page 99: ...rature Ambient Air Temperature Sensor Built at the bottom of the cockpit it senses the temperature of external air Figure 85 Temperature C Resistance K 15 218 2 7 5 0 97 83 0 9 15 47 12 0 7 25 30 0 0 36 35 19 60 0 3 FG001064 Figure 86 Temperature C Resistance K 10 163 4 9 0 96 9 2 9 10 59 4 1 8 20 37 4 1 1 25 30 0 9 30 24 2 0 7 ...

Page 100: ...tor Control Panel Appearance and Terminal Arrangement Refer to Air Conditioner and Heater of operation manual 83 7 76 2 67 7 58 8 46 6 36 0 21 4 1 0 2 0 3 0 4 0 5 0 6 0 7 0 LUX x10 000 OUTPUT VOLTAGE mV FG001062 Figure 87 AUTO AUTO OFF TEMP A C A C MAX OUTSIDE SEL MODE FG001063 18 8 CN8 AMP 070 12P CN9 15 17 16 12 14 13 9 11 10 12 11 10 AMP 070 18P 6 5 7 4 1 3 2 5 4 6 7 8 9 1 2 3 Figure 88 ...

Page 101: ...edback 13 Intake Recirculate Intake 14 Wind direction control VENT 15 Wind direction control DEF 16 Wind direction control Power 5V 17 Wind direction control feedback 18 Temperature control cool Categories Inputs System Operation AUTO Set temperature Internal air temperature sensor Ambient air temperature sensor Water temperature sensor Sun sensor 1 Automatically adjust room temperature as set and...

Page 102: ...discharge of hot air before discharge temperature drops enough in hot summer weather 2 Start conditions AND condition 1 A C on AUTO or manual 2 Temperature sensed by the duct sensor is above 30 C 3 Airflow Auto mode 3 One time control in the cycle of engine OFF o engine run 4 Initial cooling control is executed when the Auto switch is ON in the manual status A C OFF and manual control of airflow i...

Page 103: ...ycle of engine OFF o engine run 3 Initial heating control should be before max heating 4 Airflow is controlled only when the wind direction is in the manual mode and BI LEVEL FOOT or FOOT DEF is set 5 Control through the water temperature sensor for start 6 Starting control of heating 2 starts in case of fault of the water temperature sensor during controlling 7 Operation release OR condition 1 On...

Page 104: ...2 When handling the wind direction mode switch only wind direction is released but the airflow control is performed only for the remaining period of the starting control of heater 3 Difference between internal and ambient air temperature 15 C 4 When Max Cooling 17 C is selected 5 Exceptional case Starting control of heating is performed only once during the remaining period if the entry condition ...

Page 105: ...or is turned ON OFF depending on temperature of the duct sensor to prevent the freezing of the evaporator with A C being ON 2 Control pattern External temperature sensor 1 Function Prevention of compressor in winter 2 Control pattern Only for Auto mode Categories Inputs System Operation 2 0 0 5 C 3 5 0 5 C ...

Page 106: ... cycle of 0 5 sec ON and 0 5 sec OFF In case of two or more errors codes concerned blink twice at a time For normal E0 lights for error the first error code is indicated For 2 or more error error codes are indicated upstreams downstreams if the temp control switch is set to up down For normal condition only EO lights Press the SEL switch more than 3 times in 5 secs while pressing the A C switch Re...

Page 107: ...bient temperature may be released in the same way for its entry way It returns automatically to default mode 5 seconds after entering the ambient air temperature display mode Code Description E0 Normal E1 Internal air temperature sensor short E2 Internal air temperature sensor open E3 Ambient air temperature sensor short E4 Ambient air temperature sensor open E5 Duct sensor short E6 Duct sensor op...

Page 108: ... responding immediately to the change of level in the freezing cycle As liquid refrigerant from the condenser may contain refrigerant gas with bubbles whose presence in the expansion valve decreases the freezing power excessively it separates liquid and gas and sends liquid only to the expansion valve Water in refrigerant shall be eliminated with dryer and through filter FG001365 Relief Valve Figu...

Page 109: ...on device or soapy water check for refrigerant leakage at all major components and joints Yes Repair leaking component No Recharge system to correct pressure 2 High pressure Over 23 kg cm2 327 psi Low pressure Approximately 2 5 3 0 kg cm2 36 43 psi Possible Cause Overcharge Frost on condenser Step Inspection Item Remedy 1 Check for condenser pin damage or contamination Yes Clean repair or replace ...

Page 110: ...ssible Cause Moisture in system has iced up the expansion valve NOTE When the absorbed moisture freezes the pressure readings may look normal Careful readings should be made to determine whether pressure is in normal range 1 Recover any remaining refrigerant 2 Vacuum out system 3 Recharge system NOTE If the system has been exposed to the air for a long time replace the receiver dryer 6 High pressu...

Page 111: ...50 20 grams 30 0 7 oz DX140W 800 20 grams 28 0 7 oz DX180LC 800 20 grams 28 0 7 oz DX225LC 800 20 grams 28 0 7 oz DX225NLC 800 20 grams 28 0 7 oz DX300LC 800 20 grams 28 0 7 oz DX300LL 800 20 grams 28 0 7 oz DX340LC 800 20 grams 28 0 7 oz DX35Z 450 20 grams 16 0 7 oz DX420LC 800 20 grams 28 0 7 oz DX480LC 800 20 grams 28 0 7 oz DX520LC 800 20 grams 28 0 7 oz ...

Page 112: ...charge the system WARNING Always wear protective glasses and gloves when handling refrigerant If refrigerant comes in contact with the skin or eyes immediately flush with clean running water and consult a physician Select a clean and well ventilated area to work The refrigerant container is under high pressure and should be stored below 40 C 104 F Be careful not to drop the container from a high l...

Page 113: ... parts Do not reuse old O rings 8 Use a vacuum pump to evacuate refrigerant system of air 9 When charging the refrigerant system with the engine running do not open the high pressure valve on the manifold gauge as the reverse flow of high pressure refrigerant will rupture the hose 10 When releasing the high pressure hose after completing the charging process quickly disconnect the hose to minimize...

Page 114: ...FOR AIR LEAKAGE VACUUM SYSTEM OVER 20 MINUTES CHARGE SYSTEM APPROXIMATELY 100 g CHECK SYSTEM FOR REFRIGERANT LEAKAGE CHARGE SYSTEM TO PROPER LEVEL Standard Capacity less Initial Charge CHECK SYSTEM FOR REFRIGERANT LEAKAGE CHECK FOR PROPER REFRIGERANT LEVEL RUN SYSTEM RECOVER REFRIGERANT IN CHARGING HOSE REMOVE REPAIR TOOLS REPAIR HDA6067L Figure 96 ...

Page 115: ...gauge dials indicates 0 kg cm2 0 psi Vacuuming Refrigerant System 1 Vacuuming Procedure NOTE When the A C system has been exposed to the air it must be vacuumed out Perform vacuum process for 30 minutes for complete moisture and air evacuation A Attach the manifold gauges and vacuum pump to the refrigerant system as shown B Turn on the vacuum pump and open both valves C When the low pressure gauge...

Page 116: ...ounting valve on the container make sure the handle is in the counterclockwise most position with the puncture pin retracted and the mounting disk is in the raised position B Attach the manifold gauge center hose to the valve assembly C Turn the disk in the clockwise direction and securely mount valve onto refrigerant container D Turn the valve handle in the clockwise direction and puncture the co...

Page 117: ... leaking tests as described in the proceeding headings NOTE First charge the refrigerant system with 100g 3 5 ounces of refrigerant with the engine off Then using the manifold gauges as a guide fully charge the system with the engine running When exchanging refrigerant containers press the manifold gauge low side valve to eliminate air from the charging hose 2 Charge the system by opening the mani...

Page 118: ...ut off engine and close refrigerant supply container adapter valve Disconnect manifold gauge hoses from vehicle WARNING When charging refrigerant system with the engine running Always keep refrigerant supply container in the upright position Never open the high side pressure valve Gauge Dial Standard Reading High Side Gauge 13 20 kg cm2 185 285 psi Low Side Gauge 1 5 3 5 kg cm2 22 50 psi WARNING W...

Page 119: ...r outlet o condenser inlet o receiver dryer inlet o air conditioner unit inlet 2 Low pressure side Compressor inlet o air conditioner unit outlet 3 Compressor Compressor shaft area bolt hole area and magnetic clutch area 4 Receiver dryer Pressure switch and plug area 5 Connection valve area Inspect all valve areas Verify all valves are capped to prevent leaking Check for foreign material inside of...

Page 120: ...15A 10A 2 8 CN13 KET 8P Continuous mode Intermittent 2 mode Intermittent 1 mode Washer mode 5 1 6 7 11 12 4 2 M 3 10 8 5 4 P 6 1 3 5 4 5 6 7 8 9 4 10 2 3 1 FG000589 Figure 104 Reference Number Description 1 Battery 2 Battery Relay 3 Fusible Link 4 Fuse Box 5 Wiper Motor 6 Wiper Controller 7 Wiper Switch Panel 8 Window Washer 9 Wiper Cutoff Switch 10 Light Switch Reference Number Description ...

Page 121: ...he 5 and 6 terminals of the wiper motor are connected still that power is supplied to the 6 terminal of the wiper controller 6 However the controller 6 runs the wiper motor continuously and then rotates the motor reversely by letting current flow by way of the 4 terminal of the wiper controller 6 o the 2 and 4 terminals of the wiper motor 5 o the 3 terminal of he wiper controller 6 when the 1 and ...

Page 122: ... operation Intermittent 2nd 6 second Pressing twice the Intermittent switch in the switch panel 7 changes voltage of the 10 terminal in the wiper controller 6 from HIGH about 5 5 0 5V to LOW 0 0 5V and current flows through the 3 terminal in the wiper controller 6 o the 2 and 4 terminals in the wiper motor 5 o the 4 terminal in the wiper controller 6 to start the cycle that wiper stops 6 seconds a...

Page 123: ... 6 CN7 4 CN7 5 CN6 10 CN6 9 CN6 1 CN6 2 L6 CN4 5 CN4 4 CN4 6 CN1 9 CN1 8 CN2 6 CN1 2 CN1 1 CAN 30A 15A 15A 20A 15A 30 3 85 86 II I 0 II I 7 6 30 87 87a 0 2 2 8 5 8 5 II 3 I 7 6 I II 0 0 30 86 87a 85 87 87a 87 85 87 85 86 30 86 87a 16 14 9 8 10 11 3 2 1 4 15 13 7 6 12 5 FG000590 Figure 105 ...

Page 124: ...k Light 2 ea 14 Front Cabin Light 4 ea 15 Rear Cabin Light 2 ea 16 Rear Work Light 1 ea Reference Number Description Switch Position Connected Terminal of switch Activated Relay Lit Light Light Switch 1 2 3 Terminal Illumination Light of Switch 2 2 3 Terminal Illumination Light of Switch 5 6 Terminal Headlight Relay Headlight 2 Ea Work Relay Work Light 2 Ea Indicator Light of Work Light L6 Cabin L...

Page 125: ...AD WARNING DEVICE Overload Warning Device Circuit Diagram 5 6 4 2 1 3 ARS1260L Figure 106 Reference Number Description 1 Battery 2 Battery Relay 3 Fuse Box 4 e EPOS Controller 5 OWD Selector Switch 6 Pressure Sensor Reference Number Description ...

Page 126: ...Vcc 5V 13 MICOM 2 15 RH LH ANTENNA MODULE 7 8 5 6 4 3 1 2 11 9 10 12 16 13 14 15 18 17 STEREO 1 2 3 4 Audio Control Panel 3 4 2 1 5 11 7 8 10 9 6 FG000591 Figure 107 Reference Number Description 1 Battery 2 Battery Relay 3 Fuse Box 4 Fusible Link 5 Converter 6 Stereo Relay 7 Audio Control Panel 8 Stereo 9 Speaker 10 Antenna Module 11 Light Switch Reference Number Description ...

Page 127: ...P000935 Page 126 Operations Via Audio Control Panel Switch Connected Terminal of switch Measured values Operations PWR 3 4 4 36 0 2V Stereo ON OFF 1 24 0 2V Volume up 0 0 2V Volume down SCAN 2 49 0 2V Frequency selection ...

Page 128: ...000936 Page 1 Electrical Schematic DX180LC DX225LC DX225NLC DX255LC SP000936 ELECTRICAL SCHEMATIC DX180LC DX225LC DX225NLC DX255LC SP000936 1Electrical Schematic DX180LC DX225LC DX225NLC DX255LC Edition 1 ...

Page 129: ...SP000936 Electrical Schematic DX180LC DX225LC DX225NLC DX255LC MEMO ...

Page 130: ... Page 3 Electrical Schematic DX180LC DX225LC DX225NLC DX255LC Table of Contents Electrical Schematic DX180LC DX225LC DX225NLC DX255LC Safety Precautions 5 Applicable Models 5 DX180LC DX225LC DX225NLC DX255LC 7 ...

Page 131: ...SP000936 Electrical Schematic DX180LC DX225LC DX225NLC DX255LC MEMO ...

Page 132: ...y recommendations and safe shop practices outlined in the front of this manual or those contained within this section Always use tools and equipment that are in good working order Use lifting and hoisting equipment capable of safely handling the load Remember that ultimately safety is your own responsibility MODEL SERIAL NUMBER RANGE DX180LC 5001 and Up DX225LC 5001 and UP DX225NLC 5001 and Up DX2...

Page 133: ...SP000936 Electrical Schematic DX180LC DX225LC DX225NLC DX255LC Page 6 ...

Page 134: ...S V 2 6 5 1 3 0 5LW 0 85BrR 0 85BrL PEDAL SWITCH OPTION DIODE 9 6 2 DA6 1 5 1 1 0 85OrY DA6 2 0 85GY 0 85YL 426 00263 86 30 85 87a 87 0 85G 2544 9033 LOWER WIPER RELAY 0 85BR 0 85BR 0 85G 0 85Br 1 NC PREHEAT LAMP 0 85RY 0 85RY 0 5RG RxD TxD GND 1A 1B 2A 3A 4B 3B 8C 8A 7B 8B 9B 7A 10A 11A 6B 13A 89A 13C 11B 12A 14A 5A 4C 12C 14B 15B 14C 99 18B 131B 99 16A 17A 132A 99 88C 16B 65A 2C 2B 4D 4E 62B 132...

Page 135: ...WARNINGLAMP L2 ENG OIL PRES S L1 CHA RGE L4 E GWARNIN G L5 PREHE AT LCD DISP LAYPANEL L6 WORKLAMP 54 71 7 11 VEHICLE CONN ECU CON 1 89 PIN 1 72 6 89 ECU CONNECTOR 12 36 18 17 13 12 14 11 10 9 CN15 53 35 8 0 1 0 5B 0 5B FRONT PUMP PRESSURE SENSOR A PRESSURE SENSOR SIG OWD SIG 0 85W 0 85R 0 85W 0 85GR I 3 7 2 0 5BrY 0 85R 0 85BrW 0 5WR 8 0 5WB 0 5RW 0 5WR OVER LOAD WARNING OPT CN6 12 CN6 11 CN6 3 11...

Page 136: ...R LOWER WIPER CUT SW 1 2 WIPER M OTOR 0 85WR 0 85B 5 6 M 4 2 1 200A 2 PUMPCONT ROL OPTION AMP 040 III 20P AMP 040 12P 6 12 10 DUCT 2 2 PUMP SWI TCH 8 I 3 7 0 5B 0 85BrW 1 2 0 0 85YG 0 85BL 1 AMBIENT TEMP SENSOR 1 2 AMP 20P CN10 CN10 14 AIRCON UNI T CN11 SENSOR INCAR KET 4P SENSOR SENSOR WATE R CN9 CN8 3 9 10 11 12 9 16 15 14 13 12 11 10 AMP 070 18P 6 16 5 15 18 17 7 8 CN7 14 4 9 10 11 12 3 2 1 13 ...

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