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CONTENTS
Structure, Characteristics, and Circuit Diagram Analysis of Electric System
Power Supply and Starter System
Instrumentation and monitoring system
Automatic leveling of bucket
Lighting
Backup warning system
Wiper and washer
Electric horn
Spare socket
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including
lighting,
directly
influences
the
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2. Start part: Mainly including starter, starter relay, and electric lock, which
are functioned to start the diesel engine.
3. Lighting and signaling part: Mainly including all kinds of lighting and
signal lamps and horns and buzzers, which are functioned to ensure the
safety of human and machine and the successful implementation of
operations under all kinds of operation conditions.
5. Control part: Engine control unit and transmission control unit (detailed
in the engine system and transmission system).
6. Accessory part: Including the electric wiper, heater, and A/C system.
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Every complete circuit is composed of power supply, fuse, switch, control device,
electric device, and wires. The flow direction of the current must start from the
positive post of power supply, reach the electric device through fuse, switch,
control device, and wires, and then return to negative post of power supply
through wire (or grounding wire) to form the circuit. Therefore, there are three
thoughts for reading the electric circuits:
Thought 1: Along the flow direction of the circuit current, start from the positive
post of the power supply, check the electric device, switch, and control device,
and return to negative post of power supply.
Thought 2: Against the flow direction of circuit diagram, start from negative post
of power supply (earthing) and return to positive post of power supply through
electric device, switch, and control device.
Thought 3: Start from electric device, check the control switch, wires, and control
unit, and finally reach the positive post of power supply and grounding wire (or
negative post of power supply).
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I. Battery (6-QW-120B)
The overall machine adopts 2 batteries in
series connection. The battery is one
invertible DC power supply and is parallel
connected with alternator to power the
electric devices. A single battery can supply
200A~600A start current to the starter motor
within a short period (5~10s). The battery is
also equivalent to a large capacitor, which
can absorb the over-voltage that may occur
any time in the circuit, in order to protect the
electric devices against puncture.
Caution: The battery must be securely and reliably installed, in order to
prevent damage due to bumps during traveling of the machine. Please turn
off the power switch when the machine is to be parked for a long time.
Warning: Please keep open fire away from the battery. Before the welding
operations, please disconnect all connecting wires of the battery, in order to
prevent explosion.
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ID rId2
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Electric quantity
The electric quantity is above 65% and the
battery is normal
The electric quantity is less than 65% and the
charging is required.
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When the machine cant be started, firstly please check the electric quantity of
the battery and check the battery cables for reliable connections.
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Warning: When the loader is parked for a long time, please ensure to
turn off the power switch, in order to prevent electric leakage and
other accidents. Before connecting the battery cables, re-tightening
the battery cables, or disconnecting the connecting wires of battery,
please make sure to turn off this switch for the purpose of safety.
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III. Alternator
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4. The voltage regulator utilizes the on/off of switching tube to change the size of
excitation current so as to change the intensity of magnetic field to stabilize the
voltage of the alternator.
5. The filter capacitor is mainly functioned to filter away the peak pulse and high
frequency interference issued by the alternator.
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Warning: Its strictly prohibited for the alternator to independently power the
electric devices without the battery.
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When the power switch is turned on, the 24V terminal voltage of the battery is applied
onto the starter motor via the contact of starter relay. At the moment when the
electric lock is rotated to position START, two coils of the electromagnetic switch
of the starter motor are powered and actuated. The electromagnetic resultant force
generated by above two coils drives the movement of movable contact disc so that
two contacts of the electromagnetic switch are engaged and the current is inputted to
the DC motor coil from the battery for form the circuit via the housing of starter
motor. In such case, the DC motor starts the rotation. At the same time, the iron core
moves to drive the shifting fork to engage the drive gear with the engine flywheel
gear ring. The DC motor drives the rotation of the flywheel and the engine start is
initiated.
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During the start process (within more than 10s when the electric lock is rotated to
position START), the 1# wire is constantly live (24V) and the contacts 1# and 2# are
constantly engaged. As the contact voltage is 24V, the voltage is equal between two
terminals of the pull-in coil and no current is flowing. In such case, the iron core is
maintained at start status under the action of the electromagnetic force of the holding
coil. When the driver release the electric lock key after the successful start of the
engine, the electric lock automatically returns to position ON and the 1# wire is
powered off immediately. Within a really short period, the flow direction of the current
is contact 1# - contact 2# - pull-in coil terminal S holding coil, and grounding. It can
be seen that the current flow direction is opposite between the holding coil and pull-in
coil. As the magnetic fields generated are in opposite directions, the electromagnetic
forces applied onto the iron core are cancelled out with each other and the iron core
returns to initial position under the action of spring force. In such case, the contacts 1#
and 2# are disengaged, no current flows through the pull-in coil and holding coil, and
the driver gear resets to initial position. The starter motor stops working.
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Treatment: While rotating the electric lock to position START, check the
wire voltage at the electromagnetic switch of pneumatic motor. If no
voltage is detected, check the electric lock, starter relay, and battery (For
instance, check the battery set connecting circuit, negative switch, and
grounding wire for reliable connections), or it can be determined as the
malfunction of starter motor that leads to start failure.
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Starter switch
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Battery relay
Back
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Back
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Electric pump
Back
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Left turn
lamp
Working
hourmeter
Vehicle speed
Braking air
pressure gauge gauge
Torque
converter oil
temperature
gauge
Strainer
Preheating Handbrake Charging
indicator
warning lamp indicator indicator
Engine water
temperature
gauge
Low air
pressure
warning lamp
Transmission oil
pressure gauge
Instrument panel
Power
Power case
cutoff lamp working lamp Right turn lamp
Low pressure
alarm
Emergency turn
alarm
Braking pressure
sensor
Flasher
Engine oil
pressure switch
Engine water
temperature sensor
Strainer
warning switch
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2. Sensors
LG958L is fitted with two temperature sensors to monitor the torque converter oil
temperature and engine water temperature. The temperature sensor is equivalent to
a thermistor, of which the resistance is reduced along with the increasing of
temperature. (226Ohm at 26C ambient temperature and 26.4Ohm at 115C)
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The swing of the instrument pointer is achieved by the change of current arising
from the slide of resistor pointer within the sensor, which is caused by the
deformation of beryllium bronze diaphragm due to change of pressure, as shown in
Figure 10-11.
2.3 Fuel level sensor
The fuel level sensor is actually a discrete slide resistor, of which the resistance is
reduced along with the increasing of fuel level. Its installed on the fuel tank.
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Disassemble the sensing wire from the temperature sensor (the torque converter
oil temperature gauge and the water temperature gauge correspond to wire 15#
and wire 14# respectively). If the instrument indicates full measuring range when
the sensing wire is grounded and indicates minimum reading when the sensing
wire is hung in the air, it indicates that the instrument and circuit are normal and
the sensor is damaged. Replace the sensor. Otherwise, check the circuit. If the
circuit is normal, the instrument is malfunctioned.
3.2 Abnormal fuel level indication
Disassemble the sensing wire (wire 19#) from the fuel level sensor. If the
instrument indicates full measuring range when the sensing wire is grounded and
indicates minimum reading when the sensing wire is hung in the air, it indicates
that the instrument and circuit are normal and the sensor is damaged. Replace the
sensor. Otherwise, check the circuit. If the circuit is normal, the instrument is
malfunctioned.
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1. Schematic diagram
The schematic diagram is shown in Figure 10-15.
Floating
solenoid valve
Bucket solenoid
valve
Boom solenoid
valve
Brown
Load
Blue
Black
Brown
Blue
Black
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This device does not incorporate the proximity switch and only
incorporates a boom floating coil that is located on the pilot valve. After
the electric lock is turned on, the coil is powered on constantly. When the
driver pushes the operating lever to most forward position, the magnetic
circuit is turned on so that the electromagnetic field force generated by the
solenoid coil will hold the boom operating lever (in such case, the driver
may release the operating lever and the boom operating lever will not
return to neutral position) and the pilot valve connects the oil lines of
rodless and rod chambers of boom cylinder with the oil pipes by
controlling the distributor valve. In such case, the pressure is zero for both
rodless and rod chambers and the pressure difference is also zero. If the
driver pushes the boom operating lever to floating position during the
loading operations, the bucket will fluctuate along with the ups and downs
of the ground. If the driver pushes the boom operating lever to floating
position to operate the lowering of boom, the boom will lower at fastest
speed under the action of dead weight, in order to improve the working
efficiency.
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Check proximity switch for damage: Turn on the electric lock. The red
indicator shall light up when the metal body approaches (When
measured with multimeter, the black output wire shall be connected to
ground).
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Terminal
GreenBrownYellow Red Black Grey Blue Orange White
Position
Off
Left
turn
Right
turn
Backlight
(headlamp
low beam)
(headlamp
high beam)
H
ea High
dl beam
am
Low
p beam
Terminal
Position
Overtaking
lamp
Off
Br
ow
n
Ye R
lo e
w d
Bl
ac
k
Gr
ey
Bl
ue
O
ra
ng
e
W
hi
te
R
es
er
ve
d
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OFF
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Terminal
Terminal
Position
Headlamp
OFF
Position
Headlamp
OFF
2.1 Four lamps on the top front and rear of the cab are defined as headlamp and rear illuminator,
two lamps on the rear hood are defined as rear lighting lamp. The switch of interior lamp is
attached. Refer to Accessories Rocker Switches for details of switches of rear lighting lamps
and working lamps.
2.2 Schematic diagram: As shown in Figure 10-19 and Figure 10-20.
2.3 The basic principle and the troubleshooting of system malfunction are basic same with the
headlamp circuit and are omitted herein.
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3.2.1
The actual combination switch and installation position are shown in Figure 54 and Figure 5-5 respectively. The turn lamp switch is realized by partial
function of the combination lamp and the wire colors of three pins used are
grey, yellow, and white, of which the grey wire is connected to turn flasher
power supply (wire 33#), the yellow wire is connected to left turn signal wire
(wire 6#), and the white wire is connected to right turn signal wire (wire 7#).
3.2
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3.2.2 Flasher relay (SG252): Three pins of the flasher are defined as below:
B power terminal, connected to wire 21#; L Flasher signal output
terminal, connected to wire 33#; E Grounding, connected to wire
0#. During normal working, the flasher relay will issue slight
rattle sound at a frequency of approximate 50 cycles/min.
Otherwise, it can be determined that the flasher relay is damaged.
3.2.3 Warning lamp switch: The parking lamp switch controls four turn
lamps and two turn indicators on the instrument panel. When this
switch is turned on, four turn lamps and two turn indicators flash at
the same time to alert the vehicles crossing by.
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OF
F
P
o
si
ti
o
n
T
e
rm
in
al
Rocker switch of
backlight
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4.2 The installation positions of the clearance lamps are shown in Figure
10-24 and Figure 10-25.
4.3 The basic principle and the troubleshooting of system malfunction are
basic same with the headlamp circuit and are omitted herein.
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Intermediate relay
(power cutoff)
To backup lamp
To terminal G2 of starter
switch
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When the brake pedal is depressed, the braking air pressure at the brake lamp switch engages the
contact of brake lamp switch so that the current flows to brake lamp through 10A fuse, wire 57# at
brake lamp fuse, brake lamp switch, and wire 8# to light up the brake lamp.
5.3 Brake lamp switch: The switch adopts normally open contact, which acts and engages at
approximate 1.3bar.
Troubleshooting How to judge the damage of brake lamp switch: Firstly determine whether the
braking pressure is normal (turn on the electric lock. If the low service braking pressure alarm lamp
on the instrument panel is off, it indicates that the braking pressure is normal. Otherwise, start the
engine, till the low service braking pressure alarm lamp is off). If normal, unplug the wire at the brake
lamp switch and measure two pins of the switch with 200Ohm measuring range of multimeter. If the
measurement differs from the table below, it indicates that the pressure switch is damaged and shall
be replaced.
OFF
ON
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Backup buzzer
Backup switch
1. Principle description:
When the electric lock is turned on, the 10A backup warning fuse is turned on (24V).
When shifted to reverse gear, the backup switch is turned on, the wire 9# is turned on,
and the backup warning buzzer sounds. At the same time, the backup lamps on the left
and right rear lamps light up.
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1. Principle description
1.1 Principle of washer: When the electric lock is turned on, the 10A wiper fuse is powered
on (24V) to turn on the washer switch (its an automatic resetting rocker switch. Please
refer to the Accessories Rocker Switch for details) so that the washer motor (installed
on the water reservoir) is powered on via wire 37# to pump the water from water
reservoir to the nozzles (installed beneath the front windscreen of the cab) and spray
onto the windscreen.
Rocker switch of washer reservoir (with resetting
function)
Terminal
Spray motor
Position
Position
OFF
OFF
Front wiper
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3.
2.
4.
3.
2.
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Horn button
1. Principle description:
When the electric lock is turned on, the 10A electric horn fuse is turned on
(24V). When the electric horn switch is pressed, the current flows through
10A electric horn fuse electric horn electric horn switch grounding and
the electric horn sounds continually (as shown in Figure 8-2).
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The electric horn fails to sound when the electric lock is turned on and the
electric horn switch is pressed:
2.1
2.3.
2.2
2.4
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Check electric horn switch (the button switch in the center of steering
gear) for normal functioning. Normally, the wire 12# is grounded
when the electric horn button switch is pressed.
Check the electric horn for damage (For two wiring posts of the
electric horn, connect one post to 24V power supply and connect
another to ground. If the electric horn fails to sound, it can be
determined as the damage of electric horn).
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1. Principle description
When the electric lock is turned on, the 10A spare socket fuse is turned on (24V) to turn on
the spare socket through wire 77# and wire 0#. When the external power supply is required,
after the external wire and plug are correctly connected, insert into the socket to obtain the
power. Please be noted that the consuming power shall not exceed 150W. The spare socket
provides a standard DC 24V power socket for connection of external loads such as electric
kettle and interphone. The installation position is shown in Figure 10-33.
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THE END
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