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CONTROL SYSTEM
Outline .......................................................................................................................................3-3-3-1-1
Engine Control ..........................................................................................................................3-3-3-1-2
ELECTRICAL SYSTEM
Outline .......................................................................................................................................3-3-3-2-1
Power Source Circuit ................................................................................................................3-3-3-2-2
Bulb Check Circuit (From Machine Serial No. 1001 to 1045) ...................................................3-3-3-2-3
Bulb Check Circuit (From Machine Serial No. 1046 and After).................................................3-3-3-2-4
Engine Start Circuit (From Machine Serial No. 1001 to 1045)..................................................3-3-3-2-6
Engine Start Circuit (From Machine Serial No. 1046 and After) ...............................................3-3-3-2-8
Charging Circuit (Key Switch: ON) (From Machine Serial No. 1001 to 1045) ........................3-3-3-2-12
Charging Circuit (Key Switch: ON) (From Machine Serial No. 1046 and After)......................3-3-3-2-14
Accessory Circuit ....................................................................................................................3-3-3-2-16
Surge Voltage Prevention Circuit ............................................................................................3-3-3-2-18
3-3-3-1-1
Key Switch
Engine Speed Sensor 2
Governor Angle Sensor
Governor
Engine Control
Dial
T183-02-01-002
3-3-3-1-2
Governor
3-3-3-1-3
T146-02-01-014
Quick-Idle
Switch
Monitor Controller
Relay Drive Circuit
Governor
T183-02-01-006
3-3-3-1-4
Auto-Idle
Switch
Pressure Sensor
P
Main
Controller A
SA
SB
Pilot Pump
Engine Speed
Sensor
PG
PG
ECM
Main Pump 3
Main Pump 2
Main Pump 1
3-3-3-1-5
T183-02-01-001
3-3-3-1-6
Air Heater 2
Key Switch
Preheat
Relay 3
Fusible
Link 8
From Battery
Fuse Box
(ECM) Fuse #4
Fusible
Link 1
ECM
Relay
Fuse Box
(ECM) Fuse #1
Fuse Box
(ECM) Fuse #2
Battery
Air Heater 1
Fuse Box
(ECM)
Fuse #3
Fusible
Link 7
Preheat
Relay 2
Preheat Switch
Engine Stop
Relay
Preheat
Relay 1
Power
Transistor
J2-9
J1-23
Preheat
Indicator
J2-5 J2-11
J2-12
Main
Controller A
Preheat
Indicator
Relay
Monitor Controller
Engine Speed
Sensor 2
Governor
T183-02-01-007
3-3-3-1-7
3-3-3-1-8
Air Heater 2
Key Switch
Preheat
Relay 3
Fusible
Link 7
From Battery
Fuse Box
(ECM) Fuse #4
Fusible
Link 1
ECM
Relay
Fuse Box
(ECM) Fuse #1
Fuse Box
(ECM) Fuse #2
Battery
Air Heater 1
Fuse Box
(ECM)
Fuse #3
Fusible
Link 8
Preheat
Relay 2
Preheat Switch
Engine Stop
Relay
Preheat
Relay 1
Power
Transistor
J2-9
J1-23
Preheat
Indicator
J2-5 J2-11
J2-12
Main
Controller A
Preheat
Indicator
Relay
Monitor Controller
Engine Speed
Sensor 2
Governor
T183-02-01-007
3-3-3-1-9
Monitor
Engine Warning
Indicator Relay
Engine Stop
Indicator
Engine Warning
Indicator
Engine Stop Indicator Relay
Governor Angle
Sensor
Diagnostic Switch
Engine Speed
Sensor 2
Boost
Pressure
Sensor
Governor
T183-02-01-008
3-3-3-1-10
Trouble
Abnormal Engine Control
Dial Signal
Abnormal Turbo Boost
Pressure Sensor Signal
Abnormal Signal
Range
Failure
Indication (Indicator ON)
Failure Indication
(Numbers of
Flashing)
Engine Warning
Indicator (2-5)*
Engine Warning
Indicator (2-3)*
Corrective Measure
to betaken by ECM
Holding engine speed
-1
at 1000 min
Deactivating fuel restriction control by
turbo boost air pressure
Stopping engine
Engine Stop
Indicator
Engine Warning
Indicator (2-1)*
Engine
Stop Indicator
Engine Warning
Indicator (4-1)*
Stopping engine
Engine
Stop Indicator
Engine Warning
Indicator (4-5)*
Stopping engine
Engine Warning
Indicator (4-3)*
None
M183-01-008
3-3-3-1-11
Overheating
1. When coolant temperature increases over 101 C
(214 F), the overheat switch is turned ON, sending a signal to main controller A.
2. Upon receiving the signal, main controller A instructs power increase solenoid valve ST so that
power increase control is deactivated and only
power decrease control by power decrease solenoid valves (SA and SB) are activated. (Refer to
the Pump Control description pages.)
3. Then, pump drive torque is minimized, reducing
the engine loads.
4. At the same time, main controller turns the overheat indicator ON and closes the ground line of
power transistor 2.
5. Then, power transistor 2 magnetizes the engine
protection relay and sends the torque decrease
signal to the ECM.
6. Thereby, the ECM drives the governor so that engine speed and output torque are reduced.
3-3-3-1-12
From Battery
Power
Transistor 2
Engine Oil Pressure Switch
(High Pressure)
Main
Controller
Overheat
Switch
Coolant Level
Switch
Power
Transistor 1
From Battery
Power Increase
Solenoid Valve ST
Power Decrease
Solenoid Valve
SA
Power Decrease
Solenoid Valve SB
T183-02-01-005
3-3-3-1-13
3-3-3-1-14
From Battery
Power
Transistor 2
Engine Oil Pressure Switch
(High Pressure)
Main
Controller
Overheat
Switch
Coolant Level
Switch
Power
Transistor
1
Engine Stop Relay
From Key
Switch
From Battery
Power Increase
Solenoid Valve ST
Power Decrease
Solenoid Valve
SA
Power Decrease
Solenoid Valve SB
T183-02-01-005
3-3-3-1-15
Main Circuit
Engine and accessory circuit
Control Circuit
Engine and pump control circuits consisting of actuators such as solenoid valves, main controller A
and B, ECM (Engine Control Module), sensors,
pressure switches, etc.
Monitor Circuit
Machine operation status indication circuit consisting of sensors, switches, etc.
Outline of the major functions and construction of the
main circuit are explained hereafter.
Charging Circuit
Recharges the batteries and supplies current to all
the electrical components from the alternator.
Accessory Circuit
Operates when the key switch is in the ACC position.
3-3-3-2-1
Key Switch
Fuse Box
Fusible Link
Preheat
Relay 2
Battery
Relay 2
Fuse Box
(ECM)
Load Damp
Relay
Battery
Relay 1
Battery
ECM
Relay
Monitor Controller
Main
Controller B
ECM
T183-02-03-001
3-3-3-2-2
Fuse Box
Key Switch
Fusible Link
Preheat Relay
Junction
Box
Battery
Relay 2
Engine
Stop
Relay
Starter Relay 1
Battery
Relay 1
Battery
Monitor Controller
T183-02-03-002
3-3-3-2-3
Fuse Box
Key Switch
Fusible Link
Preheat Relay
1 Pole
Junction
Battery
Relay 2
Engine
Stop
Relay
Starter Relay 1
Battery
Relay 1
Battery
Monitor
Controller
T183-02-03-010
3-3-3-2-4
3-3-3-2-5
3-3-3-2-6
Key Switch
Fuse
Box
Fuse
Box
Engine Stop
Solenoid
Junction Box
Engine Stop Solenoid Relay
Battery
Relay 2
Engine Stop
Relay
Fusible Link
(100A)
Starter Relay 1
Battery
Relay 1
Starter Relay 2
Battery
Alternator
R
Starter Motor
Motor
T183-02-03-003
Coil
3-3-3-2-7
Main Contactor
3-3-3-2-8
Key Switch
Fuse
Box
Fuse
Box
Engine Stop
Solenoid
1 Pole
Junction
Engine Stop
Relay
Fusible Link
(100A)
Starter Relay 1
Starter Relay 2
Battery
Relay 1
Battery
Alternator
R
Starter Motor
Motor
T183-02-03-012
Coil
3-3-3-2-9
Main Contactor
7. At the same time, current accumulated in condenser C is also routed to starter motor terminal
M via transistor TR, resistance R4, and diode D2.
8. Then, current routed to starter motor terminal M
flows to the vehicle frame via the holding coil and
the pull-in coil. However, winding direction of both
coils are opposite each other so that both coil
magnetic forces are canceled, causing the main
contactor to be held open.
9. Coil C3 is magnetized so that contact P1 is
opened.
10. Then, coil C1 is demagnetized, opening contact
P2. Therefore current from terminal SS is not
routed to starter relay 2 terminal B.
11. Consequently, starter relay 1 is demagnetized,
interrupting current to starter motor terminal C.
12. After discharging the specified voltage condenser
C in the start repeating relay is recharged.
13. When recharging of condenser C is started, current from diode D1 is used to charge condenser C
so that no current is routed to base B of transistor
TR, disconnecting circuit between emitter E and
collector C.
14. Then, coil C3 is also demagnetized.
15. When coil C3 is demagnetized, contact P1 is
closed so that current from terminal SS magnetizes coil C1.
16. When coil C1 is magnetized, contact P2 is closed,
allowing current from terminal SS to flow to starter
relay 2 terminal B.
17. The start repeating relay repeats steps 1 to 16 until the pinion gears in both starters are completely
extended to mesh with the ring gear.
3-3-3-2-10
P1
C3
P2
SW
R1
SS
TR
C
E B
R4
D1
R2
High Voltage
D2
M
Alternator
Fuse Box
Fuse #19
Starter Relay 2
Starter Relay 1
Key Switch
Starter Motor
Pull-In Coil
Battery Relay
T183-02-03-008
Holding Coil
Main Contact
C1
P1
C3
P2
SW
SS
R1
C TR
E
D1 R2
B
C
R4
Low Voltage
D2
M
Fuse Box
Fuse #19
Starter Relay 2
Starter Relay 1
Key Switch
Starter Motor
Pull-In Coil
Battery Relay
Holding Coil
Main Contact
3-3-3-2-11
T183-02-03-009
#6
Current from alternator terminal B is routed to the batteries via fusible link #6 (100 A) and the battery relay,
recharging the batteries. At the same time, current
from alternator terminal B flows to all electrical circuits
via the junction box, fusible link, fuse boxes, and fuse
box (ECM). Current from alternator terminal L is
routed to the monitor controller via the charge relay
(self-magnetizing type), turning the alternator indicator
OFF.
Connected to:
Remarks
Monitor (Backup)
Main Power
Main Controller B
Main Power
ECM Relay
Power
Work Light Relays 1 and 2
Power
Washer Relay, Wiper Relay (L, H1, H2), Power
Wiper Motor
Air Conditioner
Power
Auto-Lubrication Solenoid Valve Relay, Flow Power
Rate Decrease Solenoid Valve Relay, Power
Transistors 1 and 2, Auto-Idle Relay
DC-DC Converter
Power
Main Controllers A and B
Solenoid
Power
Travel Alarm
Power
#7
#8
#9
Air Conditioner
Power
Power
Starter Relay 1
Power
Power
Air Heater 1
Power
Air Heater 2
Power
Fusible Link
#1
(45 A)
#2
(75 A)
#3
(75 A)
#4
(45 A)
#5
(250 A)
#6
(100 A)
#7
(350 A)
#8
(200 A)
Fuse Box
#4
#5
3-3-3-2-12
Main Power
Fuse Box
Key Switch
Fusible Link #1
Fusible Link #7
Preheat Relay 2
Fusible
Link #2
Fuse Box
Fusible
Link #3
Junction
Box
Battery Relay 2
Engine Stop
Fusible
Solenoid Relay Link #4
Fusible Link #5
Battery Relay 1
Battery
Starter Relay 1
Fusible Link #6
100 A (Alternator)
Charge Relay
Monitor
Controller
Alternator
T183-02-03-005
3-3-3-2-13
#6
Current from alternator terminal B is routed to the batteries via fusible link #6 (100 A) and the battery relay,
recharging the batteries. At the same time, current
from alternator terminal B flows to all electrical circuits
via the 1 pole junction, fusible link, fuse boxes, and
fuse box (ECM). Current from alternator terminal L is
routed to the monitor controller via the charge relay
(self-magnetizing type), turning the alternator indicator
OFF.
Connected to:
Remarks
Monitor (Backup)
Main Power
Main Controller B
Main Power
ECM Relay
Power
Work Light Relays 1 and 2
Power
Washer Relay, Wiper Relay (L, H1, H2), Power
Wiper Motor
Air Conditioner
Power
Auto-Lubrication Solenoid Valve Relay, Flow Power
Rate Decrease Solenoid Valve Relay, Power
Transistors 1 and 2, Auto-Idle Relay
DC-DC Converter
Power
Main Controllers A and B
Solenoid
Power
Travel Alarm
Power
#7
#8
#9
Air Conditioner
Power
Power
Starter Relay 1
Power
Power
Air Heater 2
Power
Air Heater 1
Power
Fusible Link
#1
(45 A)
#2
(75 A)
#3
(75 A)
#4
(45 A)
#5
(250 A)
#6
(100 A)
#7
(250 A)
#8
(300 A)
Fuse Box
#4
#5
3-3-3-2-14
Main Power
Fuse Box
Key Switch
Fusible Link #1
Fusible Link #8
Preheat Relay 2
Fusible
Link #2
Fuse Box
Fusible
Link #3
1 Pole
Junction
Battery Relay 2
Engine Stop
Fusible
Solenoid Relay Link #4
Fusible Link #5
Battery Relay 1
Battery
Starter Relay 1
Fusible Link #6
100 A (Alternator)
Fusible Link #7
Preheat Relay 3
Charge Relay
Monitor
Controller
Alternator
T183-02-03-011
3-3-3-2-15
Fuse
Box
Radio
Cigar
Lighter
Cab
Light
Key Switch
Fusible
Link #1
Preheat Relay 2
Horn
Battery Relay 2
Battery Relay 1
Battery
T183-02-03-006
3-3-3-2-16
3-3-3-2-17
3-3-3-2-18
Fuse
Box
Fusible link
Preheat Relay
Stop Solenoid Relay
Load
Damp
Relay
Junction
Box
Power
Transistor 3
Battery Relay
Engine
Stop
Relay
Battery
Main
Controller B
ECM
Alternator
Charge
Relay
Starter Relay 2
Monitor
Con-trol
ler
T183-02-03-007
3-3-3-2-19