PC200 Hybrid ELEC - System

Market Evaluation
Hybrid Tech Support

Course
PC200LC-8E0 Hybrid
Electrical DRIVE System Komatsu America Corp.
Cartersville Georgia USA
Copyright © 2009 All rights reserved.
Copyright © 2009 Training Presentation PCT0051009E0

Hybrid Electrical System
Objectives
By Completing This Lesson, You Will:
● Understand the HYBRID

Electric Drive Circuits
● Understand the Gen Motor,
Capacitor and Swing Motor
● Examine the Function of the
Inverter, Controller, Contactor
● Study the Capacitor function
and know it’s condition
● Understand the HYBRID lube
and cooling systems

Arrangement of hybrid system devices
(1) Generator motor (4) Inverter (Controller)

(2) High-voltage wiring (Orange color) (5) Cooling device
(3) Capacitor (Battery) (6) Swing electric motor

Compare Electrical System With Standard PC200LC-8

● 4 Major Differences - Swing Motor / Generator
● Engine mounted Generator / Motor
● Ultra Capacitor / Inverter / Controller
● Added 550 Volt AC cables

Outline Electrical Drive System

● Differences in 24 volt DC system will include –
● Added fuses for HYBRID Controller and control circuits
● 24v HYBRID cooling pump motor at Inverter
● No change to Starting and Charging (Batteries) system
● AC DRIVE DEVICES
 Engine’s Generator / Motor – turns with engine, pump – 1 WAY
 Swing Motor / Generator – BI – DIRECTIONAL
 4.0 mm Gen Motor CABLE Connectors (6 Shielded CABLES)
 6.0 mm Motor Gen CABLE Connectors (3 Shielded CABLES)
● DC DRIVE DEVICES
 Inverter - Controller
 Contactor - Controller Operated
 Capacitor – Sealed and Water Cooled

Devices
● Generator Motor
● HV Wiring
● Inverter (HYB Controller)
● Contactor
● Capacitor
● Swing Motor Generator
● Decelerator (HYB Planetary) (Holding Brake)
● Coolant pump
● Tandem Lube pump

Generator Motor
● Engine Mounted at Flywheel

● Pump Drive w/o Damper
● Uni-Directional – no reverse!
● 550 volts AC
● Engine speed

Generator Motor Full weight: 507lbs (F/W included)
● Exploded View:

Generator Motor Assembly WT: 507 LBS w/ F Wheel
● Exploded View:

HYBRID System Wiring
● OTC – One Touch Connector 550 Volts AC

● Orange Colored Looms and OTC’s (4mm, 6mm)
● Safety by Design
● Electrical Shielding
● Electrical “leakage” detection
● Temperature Monitoring
● Low voltage system review

HYBRID System Wiring

Insulating between high-voltage system and low-voltage system (24V)⇒ No electrification even when touching the high-voltage system
High voltage system Connecting devices with Shield and grounded part
power cable shield line
Generator Inverter Swing

motor motor
Grounding with Grounding through machinery

flexible wires
Capacitor and inverter are
Grounding with Capacitor integrated with bolts
flexible wires
Insulation Vehicle frame
Low voltage system (Conventional electrical equipment)

Electrical equipment (Starter, Cooling water Inverter (including Backup
alternator, lamp), controller and pump driving driver and booster) charging circuit
monitor etc. circuit controlling circuit for generator
Insulation Insulation Vehicle earthing

breakdown breakdown
Vehicle Vehicle
body body
Electrification never occurs except two
cases shown in the illustration on the
Insulation
breakdown left where cabling is intentionally
Electric
leakage broken and fingers are inserted.

HYBRID Power Cables

Direct connection with 7 interlock switches
Generator motor
Swing motor
600V 15sq withstand pressure

600V 20sq withstand pressure shield cable shield cable
 4 plug & socket

Yazaki 2P connector 6 plug & socket
2P 3P 3P 3P
Capacitor
Inverter
・All of the power circuit connections has been capable of one-touch operation/connector connection in
order to improve risk assess and assembly easiness (7 points)
・Interlock switch has been installed to each connector to indicate the cable insertion status (7 positions)
・2P connectors made by Yazaki remain only on the capacitor.

Wiring Disconnects
Engine
G/M
S/M
Contactor Inverter
Machinery
Contactor Capacitor
OTC - One-touch connector
Electromagnetic
Waterproof seal
shield
Introducing exclusive process
structure using electromagnetic
shield and waterproof seal

OTC’s for Inverter
G/M1 G/M2 Swing M Capacitor

OTC Connector Structure

Plug Interlock switch contact
Interlock switch
Viewing from bottom
4 plugs for generator motor
 6 plugs for Swing motor & Capacitor Mated connectors

OTC Connector Structure

Plug Interlock switch contact
Interlock switch

Inverter / Capacitor INSTALLED

Viewing from left-side rear of the vehicle
View from above Std. Cooling
Hybrid radiator unit
HyPower cables
Condenser for
air-conditioning
Hybrid
radiator
CONTACTOR
All-in-one
controlling units
(Inverter and booster) Water-cooled capacitor

Capacitor – Inverter (Controller, Contactor)
Inverter
Water pump
Capacitor
Training Presentation 18/56

Copyright © 2009 PCT0051009E0
Electric Swing Motor Generator

● Replaces Hydraulic Swing Motor

Electric Swing Motor Generator - Inside

1
Exploded View of:
1. Resolver (Speed Sensor) 2
2. Upper Bearing Cover (R Flange)
3. Rotor (Perm. Magnets) 3
4. Stator (Coils – 3 phase)
5. Case
4
6. Lower Bearing Cover (F Flange)
● VSR – Variable, Reversible Speed 5

● 550 Volts AC
● Zero to 150 Amps PWM
6

Electric Swing Motor Generator
● Swing Brake Housing Located Below the Electric Motor

Swing Braking and Lock Control

● Static Swing Brake
● Swing Lock Switch
● Emergency Stop Switch
● Temporary Release Switch
● Manual Swing

Hybrid Components REAR VIEW
Rear view (Before installing counterweight)
Cooling unit Four-cylinder engine
All-in-one controlling units

(Inverter, driver and booster)
Engine built-in
Water-cooled capacitor Power cable generator motor

Swing Motor - DETAILS
Power cable
Power cable
Terminal
端子ﾎﾞｯｸｽ box
Cooling/lubricating oil tubing

(Shaft center oil filling) Rotation sensor
Machinery oil filler port Power cable

Swing Motor - INTERNALS Full Wt: 148LBS
Control signal
connector
R-flange Lubricating oil level gauge
Rotor
POWER terminals
Stator
Case Cooling/lubricating oil

filler port
Outlet from water
F-flange cooling jacket
Cooling/lubricating Cooling/lubricating Filler port to water

oil return port oil drain port cooling jacket

Decelerator (HYB Planetary) Full Weight: 661 LBS
Sun gear (1sun)

Swing motor
Carrier assy
Ring gear
Machinery oil Braking spring

filling level
tube Sun gear (2sun)
Brake piston
Brake disc
PC200-8 Machinery case

standard
machinery Oil drain port

Safety of HYBRID Devices
● Insulation and Shielding

● OTC shield switches
● Contactor (Isolation) Operation @ Key OFF
● Electric LEAKAGE Sensor (GM, CAP, MG)
● Auto - Stop (“E09”)
● Swing EMERGENCY STOP SW (Red Button)
● Capacitor Discharge Tools (MH800, Manual)

Safety Goals for Design

1. High-voltage line shall be insulated from vehicle body and no electrification shall occur even when
touching the high-voltage system.
2. The structure shall allow electric leakage sensor with self-diagnosis built in inverter to detect the
deteriorated insulation of high-voltage devices and the short circuit failure with the vehicle body.
3. Any abnormality (high temperature, voltage and current) of hybrid devices shall automatically
stop the system.
4. Swing emergency stop switch shall be equipped.
5. Hybrid devices shall be replaced per assembly and no overhaul shall be conducted in servicing.
Safety at replacement:
(1) Every device shall be disconnected from high-voltage at Key-OFF.
(2) Electric system is blocked by interlock switch when removing power cable at Key-ON.
(3) Electric charge removal function for capacitor shall be equipped for further safety improvement.
Inverter 550V line
Generator
Driver Booster Inverter Swing motor
motor
Electric leakage sensor (Built in

Vehicle the inverter)
Capacitor body earthing

HYB Electrical Abnormality ‘E09’

(1) When exceeding the HEAT balance of each Powered swing system at halt
component 
(2) Excess current of motor or FUSE meltdown Engine and hydraulic system able to
(3) Excess voltage on 550V line operate
(4) When Emergency stop SW is pressed
Inverter 550V line Excess voltage
Generator
Driver Booster Inverter Swing motor
motor
Excess current
Excess current
Power fuse meltdown at

capacitor cable short circuit
Capacitor

Capacitor Charge Removal – MH800

()"Capacitor electric charge removal function" is performed at parts replacement.
Capacitor charging rate

Do you want to perform electric charge removal?
Keep pressing "4" and enter "1+2+3"

to transit to service mode. Press "F1" to start electric charge removal.
07 Adjustment
08 Capacitor charge removal
Capacitor charging rate
l
10 Cylinder cutout mode operation Electric charge removal is in operation.
11 No-injection cranking If you want to cancel electric charge removal,
12 Fuel consumption please put Key OFF.
Select "08 Capacitor electric charge Wait for about 5 minutes. When "Capacitor charging
removal" and press "F6. rate" reaches 0%, put Key OFF and exit.

Lubrication and Cooling of Hybrid System
● Pressure oil lubricated

● Tandem gear pumps (2) (GM, MG)
● Pressure cooling circuits (ENG & HYBRID Radiator)
● Shared Coolant Surge Tank

HYBRID lube and cooling system diagram
HYB coolant water: 15lit/min

Oil
Swing
motor Water
24V water
pump ENG coolant water
ENG
radiator
Engine
HYB
Capacitor
HYD
radiator
Oil cooler
cooler Main
pump
Inverter
After- fan
cooler
FUEL
Cooling/lubricating pump
cooler
Generator motor
Temperature sensor

Generator Motor – Lube System Full weight: 507lbs (F/W included)
Oil level tube Oil circulating pump
Oil filler port
Strainer
Viewed from Z
Heat exchanger

Hybrid Drive Cooling System
All-in-one controlling units View from left-side rear of the vehicle

(Inverter and booster) Cooling unit
Condenser for
air-conditioning
24 volt
Water pump
Hybrid radiator
Water-cooled capacitor
All-in-one controlling units

(Inverter and booster) Water-cooled capacitor
ECO Operation MH800

Selecting Fuel consumption monitor screen/Energy monitor screen
Normal screen
F2 Key F5 Key
Fuel consumption
monitor screen
Fuel consumption log Last 60 min.
F1 Key Energy monitor screen
Fuel consumption log Last 12 hours
Fuel consumption log Last 1 week Energy monitor Instantaneous fuel consumption
Engine
Fuel consumption log Last 1 month Generator/Motor Hydraulic pump
F5 Key
Weeks before
Capacitor Swing motor
Weeks before
Weeks before 35/56

Eco-operation guide
Monitor has been improved to display fuel

Normal screen consumption graphs to help operators be
conscious of eco-operation.
(1) It always displays instantaneous fuel

consumption
(2) It always displays the fuel consumption of
just 5 min. ago or more..
(3) Operator is prompted to select any of past

fuel consumption results via 4 screens for data
of last 1 hour, 12 hours, 1 week or 1 month.
Fuel consumption result screen Fuel consumption result screen

(Up to 1 hour before, every 10 min.) (Up to 1 month before, every week)
Fuel consumption log Last 60 min. Fuel consumption log Last 1 month
Minutes before Weeks before

HYBRID Icon Symbols

Lighted items on the monitor at hybrid-related abnormality (The items other than
below are same as those for standard vehicle.)
Hybrid oil temperature Icon

This monitor item gives a warning on rising hybrid device temperature.
When the temperature of the hybrid devices abnormally increases, this
monitor item is light red.
When this item is light red, interrupt the work to keep engine at low idling
or to stop the engine until this item puts off.
Hybrid Icon
This item lights red when hybrid system does not get ready for operation in
certain period even after engine is started, or when swing emergency stop
switch is ON.
Wait for more than 5 minutes at low idling of engine until the hybrid system
gets ready for operation (this monitor indication puts OFF).
If the swing emergency stop switch is ON, return it to OFF.

Monitoring Data
Monitoring is possible in Service mode.

(The method to enter the Service mode is same as that
for standard vehicles.)
Items possible to monitoring
For details, see shop manual.
Code numbers of 09000s are meant for hybrid-
related items.
Examples:
09100 Swing motor DC current
09200 DC voltage at high voltage and high pressure

User code, Failure codes
Error Code at failures

E09: Errors in hybrid system
Checking of failure history is done in Service mode.
(The method to enter the Service mode is same as that for
standard vehicles.)
Examples:
User code
E09
Failure code:
GA1TKG Capacitor high power and voltage abnormality
GA17MB Functional degradation of generator motor driver
No Codes Trouble:
Refer to the “Y – Section” HYBRID Symptoms Guide

Electrical Diagram

Electrical Diagram

Market Evaluation
Hybrid Tech Support
END of PC200LC-8E0 Hybrid
Course
Electrical DRIVE System
Komatsu America Corp.

Cartersville Georgia USA
Copyright © 2009 All rights reserved.

PC200 Hybrid ELEC - System

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

PC200 Hybrid ELEC - System

Încărcat de

Drepturi de autor:

Formate disponibile

Market Evaluation

Hybrid Tech Support

Copyright © 2009 Training Presentation PCT0051009E0

By Completing This Lesson, You Will:

● Understand the HYBRID

Copyright © 2009 Training Presentation PCT0051009E0

Arrangement of hybrid system devices

(1) Generator motor (4) Inverter (Controller)

Copyright © 2009 Training Presentation PCT0051009E0

Compare Electrical System With Standard PC200LC-8

Copyright © 2009 Training Presentation PCT0051009E0

Outline Electrical Drive System

Copyright © 2009 Training Presentation PCT0051009E0

Copyright © 2009 Training Presentation PCT0051009E0

● Engine Mounted at Flywheel

Copyright © 2009 Training Presentation PCT0051009E0

Generator Motor Full weight: 507lbs (F/W included)

Copyright © 2009 Training Presentation PCT0051009E0

Generator Motor Assembly WT: 507 LBS w/ F Wheel

Copyright © 2009 Training Presentation PCT0051009E0

HYBRID System Wiring

● OTC – One Touch Connector 550 Volts AC

Copyright © 2009 Training Presentation PCT0051009E0

HYBRID System Wiring

Generator Inverter Swing

Grounding with Grounding through machinery

Insulation Vehicle frame

Low voltage system (Conventional electrical equipment)

Insulation Insulation Vehicle earthing

Copyright © 2009 Training Presentation PCT0051009E0

HYBRID Power Cables

600V 15sq withstand pressure

 4 plug & socket

Copyright © 2009 Training Presentation PCT0051009E0

Copyright © 2009 Training Presentation PCT0051009E0

OTC’s for Inverter

G/M1 G/M2 Swing M Capacitor

Copyright © 2009 Training Presentation PCT0051009E0

OTC Connector Structure

 6 plugs for Swing motor & Capacitor Mated connectors

OTC Connector Structure

Copyright © 2009 Training Presentation PCT0051009E0

Inverter / Capacitor INSTALLED

Copyright © 2009 Training Presentation PCT0051009E0

Capacitor – Inverter (Controller, Contactor)

Training Presentation 18/56

Electric Swing Motor Generator

Copyright © 2009 Training Presentation PCT0051009E0

Electric Swing Motor Generator - Inside

● VSR – Variable, Reversible Speed 5

Copyright © 2009 Training Presentation PCT0051009E0

Electric Swing Motor Generator

● Swing Brake Housing Located Below the Electric Motor

Copyright © 2009 Training Presentation PCT0051009E0

Swing Braking and Lock Control

Copyright © 2009 Training Presentation PCT0051009E0

Hybrid Components REAR VIEW

Rear view (Before installing counterweight)

Cooling unit Four-cylinder engine

All-in-one controlling units

Copyright © 2009 Training Presentation PCT0051009E0

Swing Motor - DETAILS

Cooling/lubricating oil tubing