Doosan DX140LC, DX180LC Wiring Diagram

1Electrical System

SP001038

ELECTRICAL SYSTEMSP001038

Electrical

System

Edition 1

Electrical System

SP001038

Page 1

MEMO

Electrical System
Page 2

SP001038

SP001038

Page 3

Electrical System

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

SP001038

Electrical System
Page 4

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............... 62

Work Mode Control............................................. 64

Operation ....................................................................... 65

Work Mode Control - Circuit Diagram................. 66

Engine Control System....................................... 67

Engine Control Dial............................................. 68

Engine Control Circuit Diagram .......................... 69

Automatic Deceleration Control

(Auto Idle Control) .............................................. 70

Engine Overheat Protection System .................. 72

Power Boost Mode ............................................. 74

Operation ....................................................................... 74

Power Boost Control - Circuit Diagram ......................... 76

Automatic Travel Speed Control......................... 78

Automatic Travel Speed Control - Circuit Diagram ....... 80

Self-diagnostic Function .....................................81

e-EPOS Controller......................................................... 81

Air Conditioner System....................................... 83

Outline ........................................................................... 83

Internal and External Filters .......................................... 84

Air-Conditioning System Layout .................................... 86

Air Conditioner/heater Circuit Diagram.......................... 87

Air Conditioner/heater Unit ............................................ 88

Ambient Air Temperature Sensor .................................. 93

SP001038

Page 5

Electrical System

Sun Sensor.................................................................... 94

Control Panel................................................................. 94

Compressor ................................................................. 102

Receiver Dryer ............................................................ 102

Troubleshooting................................................ 103

Weight of R134a Gas Used In Machines ......... 105

Refrigerant System Repairs ............................. 106

Refrigerant Safe Handling Procedures........................ 106

Repair and Replacement Procedure ........................... 107

Refrigerant Recovery .................................................. 109

Vacuuming Refrigerant System................................... 109

Leakage Check ........................................................... 111

Refrigerant Charging ................................................... 111

Inspecting System For Leakage .................................. 113

Wiper System ................................................... 114

Wiper Circuit................................................................ 114

Wiper operation ........................................................... 115

Lighting System ................................................ 118

Lighting System Circuit Diagram ................................. 118

Kind of Light ................................................................ 119

Operation ..................................................................... 119

Audio Controller................................................ 120

Audio Controller Circuit Diagram................................. 120

MEMO

Electrical System
Page 6

SP001038

SP001038

Page 7

Electrical System

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 load.

Remember, that ultimately safety is your own personal
responsibility.

MODEL SERIAL NUMBER RANGE

DX140LC 5001 and Up

DX180LC 5001 and Up

Page 8

SP001038Electrical System

SP001038

Page 9

Electrical System

INTRODUCTION

The electrical system for this equipment is DC 24 volts. The
rated voltage for all electric 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 electric
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.

Electric 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 mm

2

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

SP001038Electrical System

Page 10

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) o fusible link (3) o fuse 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) o fusible 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).

SP001038

Page 11

Electrical System

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

SP001038Electrical System

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) o fusible 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 o ground.

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

E

F

H

02/05 [MO] 11:30

E/G SPEED

0

RPM

FG001445

ENTER
PASSWORD

Figure 2

SP001038

Page 13

Electrical System

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

B

A

+

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

SP001038Electrical System

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.

SP001038

Page 15

Electrical System

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

B

E

N

S

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

igure 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

SP001038Electrical System

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) o fusible link (3) o fuse box (6) o "B"
terminal of starter switch (5) o "BR" terminalof 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) o ground.

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) o battery relay (2) o preheat relay
(7) o air heater (8) o ground.

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.

SP001038

Page 17

Electrical System

(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

SP001038Electrical System

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 soleniod 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 injexted 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 emergancy 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

O

I

Figure 6 ENGINE EMERGENCY STOP
SWITCH

SP001038

Page 19

Electrical System

9

1

+- -+

2

1-19

1-45

1-39

8

0.5G

10

3

R2

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

FG001473

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

SP001038Electrical System

Page 20

CHARGING SYSTEM

When the starter switch (5) is turned to the "ON" position, an
initial excited current flows to the field coil of the alternator (7)
through the battery relay (2) and circuit breaker (4). When the
engine is started from this condition the alternator (7) starts
charging. The current flows from the "B(B+)" terminal of
alternator (7) o circuit breaker (4) o battery relay (2) obattery
(1).

The alternator also supplies electric current to other electrical
components. When the alternator (7) starts to operate, a current
flows from the "R(I)" terminal of alternator o diode (8) o battery
relay (2) coil securing a path for the charging current to the
battery (1). Thus preventing the possibility of a high voltage build
up and possible damage to the electric system.

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

FG007238

Figure 8 CHARGING CIRCUIT

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

SP001038

Page 21

Electrical System

MONITORING SYSTEM

The monitoring system displays the various data and warning
signals onto the instrument panel by processing the information
gathered from the e-EPOS controller. It displays information
selected by the operator.

E

B

+

-

R

C

H

E

F

H

C

POWER

1

5

2

3

6

7

AUTO

4

ESC

8

E/G SPEED

02/05 [MO] 11:30

1700

RPM

CHECK

1

2

8

3

4

5

7

9

10

11

12

13

6

FG000547

Figure 9

Reference

Number

Description

1 Instrument Panel

2 Battery

3 Light Switch

4 Return Filter Switch

5 Pilot Filter Switch

6 e-EPOS Controller

7 Alternator

8 Warning Buzzer

9

Pump Discharge Pressure

Sensor

10

Hydraulic Oil Temperature

Sensor

11 Fuel Sensor

12 Air Cleaner Indicator

13 Engine Controller

Reference

Number

Description

SP001038Electrical System

Page 22

Instrument Panel

C

H

E

F

H

C

POWER

1

5

2

3

6

7

AUTO

4

ESC

8

FG000548

E/G SPEED

02/05 [MO] 11:30

1700

RPM

CHECK

7 8 9 10 11 12

5

1

2

15

13

14

3

6

4

17

19

20

16 18

(CN7)

< CONNECTOR AND TERMINAL NO.>

12

6 5114

10 14

8 7

1516

2 1

8 739 12

5 4 3 2 1

1011 9

6

13

(CN6)

AMP 040 28P

1

Figure 10

SP001038

Page 23

Electrical System

When the engine starter switch is turned to the "I" (ON) position,
all gauge bands, switch/button indicator lights and indicator/
warning lights will turn "ON" and the alarm buzzer will sound
about two seconds.

During this functional check, a LOGO will appear on the multi
function gauge in the graphic information area

Gauges Warning Lights Mode Selector Switches

1. Fuel Gauge

2. Engine Coolant Temperature
Gauge

3. Hydraulic Oil Temperature
Gauge

4. Multifunction Gauge and
Letter Information Area

5. Digital Clock

6. Hour Meter

7. Charge Warning Light

8. Engine Oil Pressure Warning
Light

9. Coolant Temperature
Warning Light

10. Engine Check Warning Light

11. Preheat Indicator Light

12. Work Light Indicator Light

13. Power Mode Selector Switch
and Indicator

14. Work Mode Selector Switch
and Indicator

15. Auto Idle Switch and
Indicator

16. Flow Adjusting Switch

17. Up Button Switch

18. Down Button Switch

19. Display Selector Switch

20. Selector Button Switch

SP001038Electrical System

Page 24

Monitoring System Schematic

B

SIG

SIG

1-35

1-34

1-53

1-52

L5

L6

WARNING LAMP

L1 : CHARGE

L5 : PREHEAT

L2 : ENG OIL PRESS

L4 : E/G WARNING

L3 : W/T OVER HEAT

WATER TEMPERATURE

LCD DISPLAY PANEL

L6 : WORK LAMP

GRAPHIC DISPLAY

FUEL LEVEL

CN7-4

CN7-5

CN7-6

CN6-10

CN6-9

4

2

1

3

6

5

14

R(I)

CN4-1

CN2-14

CN3-8

CN3-7

CN3-10

CN3-9

CAN A

-

+

CN4-4

CN3-3

CN3-4

CN4-6

CN4-5

CN4-2

CN4-3

+

-

CN2-1

CN3-2

CN3-1

CN5-3

CN2-17

CN2-18

CN5-7

E

BR

A

L1

L3

L2

L4

ILL.

CN6-3

CN6-1

CN6-2

CN6-12

CN6-11

+

-

R2 B

13

21

6

5

20

14

18

7

8

11

10

12

9

15

1

4

2

3

19

17

16

CN5-2

1-56

TxD

RxD

GND

FG007141

Figure 11

SP001038

Page 25

Electrical System

Reference

Number

Description

1 Instrument Panel

2 Pilot Buzzer

3 Light Switch

4 Starter Switch

5 Front Pump Pressure Sensor

6 Rear Pump Pressure Sensor

7 Hydraulic Oil Temperature

Sensor

8 Fuel Sensor

9 Pedal Pressure Switch (Optional)

10 Air Cleaner Indicator

11 Pilot Filter Switch

12 Return Filter Switch

13 Alternator

14 e-EPOS Controller

15 Battery

16 Battery Relay

17 Circuit Breaker

18 Fusible Link

19 Fuse Box

20 Check Connector

21 Engine Controller

Reference

Number

Description

SP001038Electrical System

Page 26

OPERATION

Instruments

Function Display

Sensor Specification

Input Terminal Input Specification

Coolant
Temperature

ECU-CAN
Communication

Fuel Level

CN3-7

CN3-8

1/10 LCD (Red Zone)
Blinking o over 5K ohms

FULL o under 525 ohms

Hydraulic Oil
Temperature

CN3-9

CN3-10

40°C (104°F) o 1,397 ohms

50°C (122°F) o 1,139 ohms

60°C (140°F) o 881 ohms

94°C (201°F) o 190 ohms

96°C (205°F) o 177 ohms

(When reading increase)

Flow
Adjusting

(Output
Terminal)

CN1-19

CN1-20

48.5 l/min o610 mA

57 l/min o583 mA

66 l/min o555 mA

78.5 l/min o466 mA

(Default Set)

108 l/min o343 mA

114 l/min o290 mA

C

H

FG000550

Blue

White Red

107°C

102°C

41°C

61°C

E

F

FG000552

Blue

Red Full

1/10

C

H

FG000551

Blue

White Red

96°C

94°C

40°C

50°C

FG009964

78.5

96.5

106.5

108

(None)

48.5

57

66

69

90

114

114

SP001038

Page 27

Electrical System

Tachometer

ECU-CAN
Communication

N = 162 f / 60

N = Engine speed (rpm)

f = Frequency of engine
speed sensor (Hz)

Voltmeter CN2-14 0 - 32 VDC

Main pump
discharge
pressure
(front pump)

CN3-1

CN3-2

V = 0.00816 x P + 1.0

V: Sensor output voltage (V)

P: Displayed pressure (Bar)

Main pump
discharge
pressure
(rear pump)

CN3-3

CN3-4

Function Display

Sensor Specification

Input Terminal Input Specification

E/G SPEED

1700

RPM

FG000049

BATTERY

28.0

VOLT

FG000050

FRONT PUMP

320

BAR

FG000051

REAR PUMP

313

BAR

FG000052

SP001038Electrical System

Page 28

WARNING AND INDICATOR
LIGHTS

Indication of Warning Lights

Description Symbol

Input

Terminal

Operation Remarks

Charge CN2 - 14

It lights in case of no
charge [voltage of
"R(I)" terminal is
below 12 ±1V] or
overcharge [voltage
of "R(I)" terminal is
above 33(V)].

Normally, it lights
when starting engine
and is out after engine
starts.

Engine Oil
Pressure

ECU-CAN

Communic

ation

It lights when engine
oil pressure is below
the reference.

After starting engine,
if engine oil pressure
is insufficient after 8
seconds, a warning
buzzer will sound.

Engine
Check

ECU-CAN

Communic

ation

It lights in case of
failure in engine
system.

Coolant
Temperature

ECU-CAN

Communic

ation

It lights when engine
coolant temperature
sensor resistant is
below about 128
ohms.

Preheating CN5-2

It lights during
preheating ("CN5-2"
terminal voltage is
below 2V) and turns
"OFF" after
completion of
preheating.

Preheating period
depends on coolant
temperature.

No preheating at
above 10°C

10 sec preheating at
5°C

20 sec preheating at
below 0°C

HAOA610L

HAOA620L

CHECK

FG000045

HAOD350L

HAOA639L