BASIC ELECTRICS

Excavator / Wheel Loader

April, 2012
Product Support AP/E
Doosan Infracore CE
Wire Color

2
Electrical Symbol

X X
O O (Above 3.3 Volts)
X (Below 3.3 Volts)
Not connected wire Diode Zener Diode

Connected wire Relay Switch

3
Electrical Symbol

Fuse Motor Proportional valve

Solenoid valve Temperature sensor Pressure sensor

4
Electrical Symbol

Light Illuminate (Diode) light Heater

Fusible link Circuit breaker (-) Ground

5
Diode

Diodes
odes aree se
semiconductor
co duc o dev
devices
ces which
w c actc ass one
o e way
w y electrical
e ec c check
c ec valves.
v ves.
Diodes will allow current flow in one direction (anode to cathode), but block it in
X the reverse direction (cathode to anode).
O

Diode

Symbols for various diodes are shown. The arrow points in the “forward”
direction of current flow (anode to cathode). Zener diodes have a “Z” shaped
X bar on the cathode side. LEDs and photodiodes are enclosed in a circle with
O (Above 3.3 Volts) incoming or outgoing light indicated.
X (Below 3.3 Volts)
Zener Diode

6
Circuit Breaker

Circuit breakers are used for pprotecting

g circuits temporary
p y overloads mayy
occur and where power must be quickly restored. A bimetal strip is used,
similar to that in a temperature-sensitive switch. When heated, the two
metals expand differently and cause the strip to bend. The “breaker” is
normally closed and it opens when the bimetal element bends. Some circuit
Circuit breaker breakers are self-resetting, others must be manually reset.

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Switch

Temperature-sensitive switch – a bimetal element bends

when heated to make contact completing a circuit or to break
contact opening a circuit. The same principle is also used in
time-delay switches and flashers.
Switch

8
Relay

In operation,
p , when the control circuit switch is open,
p , no current
flows to the relay. The coil is not energized, the contacts are open,
and no power goes to the load. When the control circuit switch is
closed, however, current flows to the relay and energizes the coil.
The resulting magnetic field pulls the armature down, closing the
Relay contacts and allowing power to the load.

* Question
1) When the switch is open, which lamps are lit?
2) When closed, then?
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Fusible Link

Some circuits use fusible links, or fuse links, for overload protection.
Toyotas can have as many as six fusible links protecting circuits for
charging, starting, ignition, and certain accessories. Check the “Power
Source” page in the Electrical Wiring Diagram manual for the specific
vehicle.
Fusible link
A fusible link is a short length of smaller gauge wire installed in a
circuit with larger conductors. High current will melt the link before it
melts the circuit wiring. Such fuse links have special insulation that
blisters or bubbles when the link melts. A melted link must be replaced
with one of the same size after the cause of the overload has been
id tifi d and
identified d the
th problem
bl corrected.
t d

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Fuse

Fuses are the most common circuit protection device. Fuses have a
fusible element, or low-melting-point metal strip, in a glass tube or
plug-in plastic cartridge. These fuses are located in a fuse block
under the dash or behind a kick panel. Most circuits – other than the
h dl
headlamp, starter,
t t and d iignition
iti systems
t – receive
i power th through
h th
the
Fuse fuse block. Battery voltage is supplied to a buss bar in the block.
One end of each fuse is connected to this bar, the other end to the
circuit it protects.

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Pressure Sensor

Supply voltage : 10 ~ 30 DCV

Out put voltage : 1~ 5 V DCV
Ground

Load resistance : 10 KΩ Min ( Supply “+” and ground “-” )

Out put voltage with ground is variable by system pressure

Y = 0.00816 * X + 1 Y = 3.5V, X = 300 bar

Y : Out put voltage (V) Y=2
2.5V,
5V X = 180 bar
X : Pressure (bar) Y = 1.5V, X = 60 bar

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Fuel Level Sensor

Floating position F 3/4 1/2 1/4 E

Resistance (KΩ) 0.50 1.20 2.68 3.94 5.00

Tolerance ((KΩ)) ± 0.5%

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Hydraulic Oil Temperature Sensor

Temp’’
T Resistance
R i t Temp’’
T Resistance
R i t
(C) (KΩ) (C) (KΩ)

-30
30 28 6
28.6 50 0 808
0.808

-20 16.2 60 0.584

-10
10 9 56
9.56 70 0 430
0.430

0 5.88 80 0.322

10 3.73 90 0.245

20 2.45 100 0.189

30 1.65 110 0.148

40 1.14 120 0.117

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Engine Control Dial

Supply voltage : 5.0 DCV

Output voltage : 4.0 ~ 1.0 DCV
Ground

Low RPM High RPM

15
Temperature Sensor

2.15
Coolant
Temperature Sensor
2.26
ECU
Fuel
Temperature Sensor 2.35

Sensor resistance
- @ 25℃ : 2.5 ㏀ ± 6 %
- @ 100℃ : 0.186 ㏀ ± 2 %

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Boost Pressure & Temperature Sensor

2.33

Boost Pressure & 2.34

Temperature Sensor 2.25 ECU
2.36

• Supply voltage : 4.75V ~ 5.25V

• Resistance with ground to pressure signal (Power supply open): 2.4 ~8.2KΩ
• Resistance with Power supply to pressure signal (ground open): 3.4 ~8.2KΩ
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Boost Pressure & Temperature Sensor

• Temp. sensor resistance @25℃ : 2.5 ㏀ ± 6 %, @100℃ : 0,186 ㏀ ± 2 %

• Pressure sensor normal range 0.5 bar ~4.0 bar (0.5 V ~4.5 V)

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Crank Shaft & Cam Shaft Sensor

• Crankshaft Sensor :
1 Sensing engine RPM to display
1.
2. Sensing Crankshaft rotational angle
3. Decide fuel injection timing

• Cam Shaft Sensor :

1. Sensing TDC point of No.1 cylinder
2. Sensing engine RPM (auxiliary)

2.23
• One sensor has problem
2 19
2.19 - Delayed
D l d engine
i start
t t
3 • Both sensor has problem
ECU - Could not start engine
2.09
2.10
3
1 : Sensor Signal
2:G
Ground
d

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VII. Speed Sensor

Gap : 0.75 ~ 1.0 mm

1. Tools : Test meter, test harness.

2. Test Condition : No special mode
3. Procedure
1) Start the engine.
2) Disconnect the speed sensor terminal from main harness and install the test harness to the
end terminal of speed sensor (open circuit)
3) Connect the test leads of test meter to the test harness, measure the output AC voltage and
compare the measured value with below spec.

S
Spec : over 6 AC volts
lt @ llow idl
idle engine
i speed
d

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VII. Speed Sensor

Adjustment

1. Procedure
1) Stop the engine.
2) Loosen the lock nut of speed sensor.
3) T
Turn in
i th
the speedd sensor till it gently
tl makes
k contact
t t with
ith th
the ttooth
th off ring
i gear.
4) Turn out the speed sensor 1/4 ~ 1/2 turn from the contact position.
5) Tighten the lock nut.

Speed Sensor Failure Check

Resistance(Ω) Remark
Resistance between two terminals 1,750 ~ 2,050 Out of range, failure

Resistance between on of terminal and body Infinite

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Overall Electrical System of Excavator

Pressure switch Pressure sensor

Indicator
LCD
C Monitor
o o

Alternator
F l level
Fuel l l sensor

Temperature
p sensor
Key switch

Engine control
dial
Engine ECU

Low High Speed switch Solenoid valve

P
Proportional
ti l valve
l

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END OF DOCUMENT

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