Doosan DX225LC User manual

Electrical System
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SP000935
SP000935
ELECTRICAL SYSTEMSP000935
Electrical
System
Edition 1

Electrical System
SP000935
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MEMO

Electrical System
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SP000935
Table of Contents
Electrical System
Safety Precautions................................................ 7
Applicable Models................................................. 7
Introduction........................................................... 9
Electrical Supply System .................................... 10
Engine Starting Circuit........................................ 12
Start Operation .............................................................. 12
After Start ...................................................................... 14
Engine Preheating System ................................. 16
Engine Stop ........................................................ 18
Charging System ................................................ 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
Main Menu.......................................................... 34
Language ...................................................................... 34
Set Clock ....................................................................... 35
Filter/Oil Info .................................................................. 35
Adjust Display................................................................ 36

Electrical System
SP000935
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Set Password................................................................. 37
Special Menu...................................................... 38
Entering/Accessing and Exiting/Escaping Menus ......... 38
Special Menu Selections ............................................... 39
Electronic Hydraulic Control System (e-EPOS).. 56
Control System Schematic ............................................ 56
Power Mode Control ........................................... 58
Operation....................................................................... 60
Power Mode Control - Circuit Diagram ............... 64
Work Mode Control............................................. 66
Operation....................................................................... 67
Work Mode Control - Circuit Diagram................. 68
Engine Control 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
Internal and External Filters .......................................... 88
Air-Conditioning System Layout .................................... 90
Air Conditioner/heater Circuit Diagram.......................... 91
Air Conditioner/heater Unit ............................................ 92
Ambient Air Temperature Sensor .................................. 98

Electrical System
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SP000935
Sun Sensor.................................................................... 99
Control Panel................................................................. 99
Compressor................................................................. 107
Receiver Dryer ............................................................ 107
Troubleshooting ................................................ 108
Weight of R134a Gas Used In Machines.......... 110
Refrigerant System Repairs ............................. 111
Refrigerant Safe Handling Procedures........................ 111
Repair 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 ................................................ 125
Audio Controller Circuit Diagram ................................. 125

Electrical System
SP000935
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MEMO

Electrical System
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SP000935
SAFETY PRECAUTIONS
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
CAUTION!
Follow all safety 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

Electrical SystemSP000935
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Electrical System
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SP000935
INTRODUCTION
The electrical system for this equipment is DC 24 volts. The
rated voltage for all electrical components is 24 volts with the
exception of the stereo and the air-conditioning control actuator.
The system contains two 12 volt batteries connected in series
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
G Green
Or Orange
B Black
L Blue
Lg Light green
R Red
Gr Gray
P Pink
Y Yellow
Br Brown
V Violet

Electrical SystemSP000935
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ELECTRICAL SUPPLY SYSTEM
The electric power circuit supplies electric current to each
electric component. It consists of a battery, battery relay, starter
switch, circuit breaker, fusible link and fuse box.
The negative terminal of the battery is grounded to the vehicle
body.
Even when the starter switch (5) is in the "OFF" position, electric
current is supplied to the following components through battery
(1) ofusible link (3) ofuse box (6).
1. Terminal "1" of DC-DC converter (for memory backup of
stereo)
2. Terminal "B" of starter switch
3. Hour meter
4. Engine 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) ofusible link (3) o fuse
box (6) o "B" terminal of starter switch (5) o"BR" terminal of
starter switch (5) o"BR" terminal of battery relay (2) which
activates the coil of the battery relay and the electric supply
system is energized.
When the battery relay's contacts are connected, all electric
devices can be operated.
While the engine is not running, the electric power for all electric
devices are supplied by the battery. Once the engine is started
the power is supplied from the alternator (7).

Electrical System
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SP000935
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
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

Electrical SystemSP000935
Page 12
ENGINE STARTING CIRCUIT
Start Operation
When the starter switch is turned to the "START" position, the
"S" and "E" terminals of the starter controller (7) are connected.
At this time the contacts in the starter relay (8) are closed by the
current flow from the battery (1) ofusible link (3) ofuse box (6)
o "B" terminal of starter switch (5) o"C" terminal of starter
switch (5) o"30" terminal of starter relay (12) - "87a" terminal o
"C" terminal of starter relay (8) - "D" terminal o"S" terminal of
starter controller (7) - "E" terminal oground.
When the contact point "B" and "PP" of starter relay (8) are
connected, the pinion gear of the starter (9) is pushed forward
and makes contact with the ring gear of the flywheel and the
internal contacts of the starter are connected. The current flows
from the battery (1) o"A" terminal of 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 start the engine. If the
system is "UNLOCKED," no password will be
required and this display screen will not appear.
In the event the security system is locked, current
flows from battery (1)
o fusible link (3) o fuse box (6)
o "B" terminal of starter switch (5) o "ACC" terminal
of starter switch (5)
o "86" terminal of starter relay
(12)
o "85" terminal of starter relay (12) o "CN1-15"
terminal of e-EPOS (13)
o ground. This current flow
causes the coil in starter relay (12) to be activated,
opening contacts at "87a" terminal. This prevents
starter relay (8) from functioning.
C
H
C
EF
H
02/05 [MO] 11:30
E/G SPEED 0 RPM
FG001445
ENTER
PASSWORD
Figure 2

Electrical System
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SP000935
TRIO DIODE
0.5 uF
CN1-15
TML
STARTER SWITCH CONNECTION
ON
START
OFF
PST
F-
E
GRD
R2BRB R1 ACCC
13
CN2-1
6
P(R)
R(I) B(B+)
REG.
I(L)
F+ FIELD
B+
11
4
12
85 86
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
BA
+
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

Electrical SystemSP000935
Page 14
After Start
Once the engine has been started, the belt driven alternator (10)
generates a current.
The output generated by the alternator (10) is a square wave
pulse voltage through the "P" terminal and the frequency of the
pulse voltage is proportional 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 switch (5) is moved to the start position, preventing
possible damage to the starter.

Electrical System
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SP000935
Operation of the Start Circuit (2) - Immediately After Start
FG007237
TRIO DIODE
0.5 uF
ACC
85 86
STARTER SWITCH CONNECTION
ON
START
TML
OFF
PST BRB
CN1-15
ACCR2R1 C
R2
CN2-1
R1
B
C
BR
87
87a
P
30
BE
NS
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
Reference
Number Description

Electrical SystemSP000935
Page 16
ENGINE PREHEATING SYSTEM
An air heater (8) is installed in the intake manifold of the engine.
When the starter switch (5) is turned "ON," the current flows
from the battery (1) ofusible link (3) ofuse box (6) o"B"
terminal of starter switch (5) o"BR" terminal of starter switch (5)
o"1-39" terminal of engine controller (12), causing current to
flow though "1-16" terminal of engine controller (12) o"C and
D" terminals of preheat relay (7) o"1-04" terminals of engine
controller (12) oground.
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) obattery relay (2) opreheat relay
(7) oair heater (8) oground.
The duration of the heating cycle depends on the temperature of
engine coolant. The preheat indicator light in the instrument
panel (9) will turn "ON" during preheating cycle.
The preheat relay (7) is controlled by the engine controller (12)
and operates only at temperatures of 10°C (50°F) and below.
The longer the preheating period, the lower the temperature of
coolant is.

Electrical System
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SP000935
(1)
12
1-07
1-13 D+
H
ON
OFF
START
11
1-40
1-34,35
7
C
PREHEAT L5
CN4-4,5,6
CN2-1
CN7-4,5,6
CN6-1,2
9
6
2
STARTER SWITCH CONNECTION
-
200A
B
TML
PST B BR R1
-
1
+
R1
R2
ACC
B
C
BR
5
E
10
BR
B
ACCR2 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

Electrical SystemSP000935
Page 18
ENGINE STOP
When starter switch (5) is turned "ON" the engine controller (8)
is activated. The engine controller monitors and controls the
engine including the injector solenoid (9). It controls the fuel
deliver rate and the injection timing for each cylinder.
NOTE:
There is an individual injector solenoid (9) for each of
the six cylinders. Only one solenoid is shown in
Figure 7.
When starter switch (5) is turned "OFF," the engine 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 "O" (OFF) position
during normal operation. The switch must be moved and held in
the "I" (EMERGENCY STOP) position until the engine stops.
When released it will automatically move back to the "O" (OFF)
position.
FG001344
OI
Figure 6 ENGINE EMERGENCY STOP
SWITCH

Electrical System
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SP000935
FG007138
9
1
+- -+
2
1-29
1-87
1-40
8
0.5G
10
3R2
4
R1
BR
7
ACC
5
B
C
BR
E
A
2
B
3
BR
STARTER SWITCH CONNECTION
6
START
ON
TML
OFF
PST B ACCR1 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