Doosan DX225LC Manual
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Doosan DX225LC Manual

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  • Page 2 SP000935 ELECTRICAL SYSTEMSP000935 Electrical System Edition 1 SP000935 Electrical System Page 1...
  • Page 3 MEMO SP000935 Electrical System Page 2...

  • Page 4: Table Of Contents

    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..........
  • Page 5 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 ....64 Work Mode Control..........
  • Page 6 Sun Sensor..............99 Control Panel..............99 Compressor ..............107 Receiver Dryer ............107 Troubleshooting ..........108 Weight of R134a Gas Used In Machines..110 Refrigerant System Repairs ......111 Refrigerant Safe Handling Procedures......111 Repair and Replacement Procedure ......112 Refrigerant Recovery ..........
  • Page 7 MEMO SP000935 Electrical System Page 6...

  • Page 8: Safety Precautions

    Remember, that ultimately safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX225LC 5001 and Up DX225NLC 5001 and Up SP000935 Electrical System Page 7...
  • Page 9 SP000935 Electrical System Page 8...

  • Page 10: Introduction

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

  • Page 11: Electrical Supply System

    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.
  • Page 12 0.5G 12V 100AH 12V 100AH P(R) B(B+) R(I) STARTER SWITCH CONNECTION 0.5 uF I(L) REG. TRIO DIODE START FIELD FG007233 Figure 1 ELECTRIC POWER CIRCUIT DIAGRAM Reference Reference Description Description Number Number Battery Starter Switch Battery Relay Fuse Box Fusible Link Alternator Circuit Breaker Diode...

  • Page 13: Engine Starting Circuit

    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) fusible link (3) fuse box (6)
  • Page 14 CN1-15 CN2-1 P(R) R(I) B(B+) STARTER SWITCH CONNECTION 0.5 uF I(L) REG. TRIO DIODE START FIELD FG007234 Figure 3 STARTER CIRCUIT (1) - WHILE STARTING Reference Reference Description Description Number Number Battery Starter Relay Battery Relay Starter Fusible Link Alternator Circuit Breaker Diode Starter Switch...

  • Page 15: After Start

    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.
  • Page 16 Operation of the Start Circuit (2) - Immediately After Start CN1-15 CN2-1 R(I) P(R) B(B+) 0.5 uF STARTER SWITCH CONNECTION I(L) REG. TRIO DIODE FIELD START FG007237 Figure 4 OPERATION OF START CIRCUIT (2) - IMMEDIATELY AFTER START Reference Reference Description Description Number...

  • Page 17: Engine Preheating System

    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) fusible link (3) fuse box (6) "B" terminal of starter switch (5) "BR"...
  • Page 18 CN6-1,2 CN7-4,5,6 PREHEAT CN4-4,5,6 CN2-1 STARTER SWITCH CONNECTION 1-34,35 1-40 1-13 1-07 START FG007137 Figure 5 ENGINE PREHEAT CIRCUIT Reference Reference Description Description Number Number Battery Preheat Relay Battery Relay Air Heater Fusible Link Preheat Indicator Light Circuit Breaker Diode Starter Switch e-EPOS Controller Fuse Box...

  • Page 19: Engine Stop

    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.
  • Page 20 STARTER SWITCH CONNECTION START 0.5G 1-29 1-87 1-40 FG007138 Figure 7 ENGINE STOP CIRCUIT Reference Reference Description Description Number Number Battery Fuse Box Battery Relay Diode Fusible Link Engine Controller Circuit Breaker Injector Solenoid Starter Switch Emergency Stop Switch SP000935 Electrical System Page 19...

  • Page 21: Charging System

    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.

  • Page 22: Monitoring System

    MONITORING SYSTEM CHECK 02/05 [MO] 11:30 1700 E/G SPEED POWER AUTO FG000547 Figure 9 Reference Reference Description Description Number Number Instrument Panel Warning Buzzer Battery Pump Discharge Pressure Sensor Light Switch Hydraulic Oil Temperature Return Filter Switch Sensor Pilot Filter Switch Fuel Sensor e-EPOS Controller Air Cleaner Indicator...

  • Page 23: Instrument Panel

    Instrument Panel CHECK 02/05 [MO] 11:30 1700 < CONNECTOR AND TERMINAL NO.> E/G SPEED AMP 040 28P POWER AUTO (CN7) (CN6) FG000548 Figure 10 SP000935 Electrical System Page 22...
  • Page 24 Gauges Warning Lights Mode Selector Switches Fuel Gauge Charge Warning Light 13. Power Mode Selector Switch and Indicator Engine Coolant Temperature Engine Oil Pressure Warning Gauge Light 14. Work Mode Selector Switch and Indicator Hydraulic Oil Temperature Coolant Temperature Gauge Warning Light 15.

  • Page 25: Monitoring System Schematic

    Monitoring System Schematic CN6-1 CN6-3 ILL. CN6-2 CN6-12 CN6-11 CN6-9 CN6-10 WARNING LAMP CN2-1 L1 : CHARGE L2 : ENG OIL PRESS L3 : W/T OVER HEAT L4 : E/G WARNING L5 : PREHEAT L6 : WORK LAMP CN3-1 CN3-2 LCD DISPLAY PANEL WATER TEMPERATURE FUEL LEVEL...
  • Page 26 Reference Reference Description Description Number Number Instrument Panel Pilot Filter Switch Pilot Buzzer Return Filter Switch Light Switch Alternator Starter Switch e-EPOS Controller Front Pump Pressure Sensor Battery Rear Pump Pressure Sensor Battery Relay Hydraulic Oil Temperature Circuit Breaker Sensor Fusible Link Fuel Sensor Fuse Box...

  • Page 27: Operation

    OPERATION Instruments Sensor Specification Function Display Input Terminal Input Specification Blue Coolant ECU-CAN Temperature Communication White FG000550 Blue 1/10 LCD (Red Zone) CN3-7 Blinking over 5K ohms Fuel Level CN3-8 FULL under 525 ohms 1/10 Full FG000552 Blue 40°C (104°F) 1,397 ohms 50°C (122°F) 1,139 ohms...
  • Page 28 Sensor Specification Function Display Input Terminal Input Specification N = 162 f / 60 ECU-CAN N = Engine speed (rpm) 1700 E/G SPEED Tachometer Communication f = Frequency of engine speed sensor (Hz) FG000049 28.0 BATTERY Voltmeter VOLT CN2-14 0 - 32 VDC FG000050 Main pump CN3-1...

  • Page 29: Warning And Indicator Lights

    WARNING AND INDICATOR LIGHTS Indication of Warning Lights Input Description Symbol Operation Remarks Terminal It lights in case of no charge [voltage of "R Normally, it lights (I)" terminal is below when starting engine Charge CN2 - 14 12 ±1V] or and is out after engine overcharge [voltage starts.

  • Page 30: Indication Of Multifunction Gauge And Letter Information Area

    Input Description Symbol Operation Remarks Terminal It lights when work Work Light CN2 - 6 light turns "ON" (24V applied). HB4O2003 Indication of Multifunction Gauge and Letter Information Area Input Description Symbol Operation Remarks Terminal When hydraulic oil CN3-9 Hydraulic Oil temperature is above Temperature CN3-10...
  • Page 31 Input Description Symbol Operation Remarks Terminal When pilot filter pressure is above Pilot Filter CN2-18 about 1 kg•cm2 (14 psi) FG000055 Warning buzzer also It flickers in case of starts when boom 2.71V and above and pressure sensor CN3-5 Overload lights continuously in output voltage is Warning...

  • Page 32: Initial Operation

    INITIAL OPERATION Item Input (Terminal) Output (Operation and initial setting mode) Initial When "CN6-1,2" is applied • LCD, all of LED and warning lights are turned Operation battery voltage (starter switch "ON" and turned "OFF" after about 2 seconds. shifts from "OFF" to "ON" •...

  • Page 33: Graphic Information Area Display

    GRAPHIC INFORMATION AREA DISPLAY Overview Many kinds of condition of machine are displayed on the letter information display department. The information display department is divided into two menus. One is main menu for user and the other is special menu for specialist. These menus can be moved from normal display mode by the combination of selector buttons.

  • Page 34: Main Menus For The Graphic Display Area

    Main Menus for the Graphic Display Area Main menu: Language setting, Time setting, Filter/Oil information, Brightness adjustment, Password Special menu: Information of machine status, failure information, Information of machine operation. Menu Selector Buttons Up Arrow Button ( , 1 on Figure 12): Move the cursor to up, left and previous screen.

  • Page 35: Main Menu

    MAIN MENU When the "ESC" button is pressed for more than 3 seconds, the M A I N M E N U main menu screen is displayed. 1. Language Main menu offers submenus (language setting, time setting, or filter/oil information, brightness adjustment, password) to the 2.

  • Page 36: Set Clock

    Set Clock M A I N M E N U It is used to adjust time of the digital clock. 1. Language Pressing the Enter Button ( , 3 on Figure 12) in the Main 2. Set Clock Menu after putting cursor on Set Clock brings Set Clock display. 3.

  • Page 37: Adjust Display

    Menu Display Order and Icon Explanation 1. Fuel Filter 2. Air Cleaner 3. Engine Oil Filter 4. Hyd. Oil Filter 5. Pilot Filter 6. Engine Oil 7. Hydraulic Oil 8. Coolant Water FG001358 Figure 20 Adjust Display M A I N M E N U Pressing the Enter Button ( , 3 on Figure 12) in the main 1.

  • Page 38: Set Password

    Set Password M A I N M E N U This menu is used to apply (lock), release, or change password. 1. Language Please refer to the Operation Manual for details on Password 2. Set Clock Setting. 3. Filter / Oil Info 4.

  • Page 39: Special Menu

    SPECIAL MENU In this menu, many types of operating conditions and functions can be accessed and displayed, including the e-EPOS controller. This menu is mainly used for machine testing and failure diagnostics. The special menu offers three submenus: Machine status. Failure information.

  • Page 40: Special Menu Selections

    Special Menu Screen S P E C I A L ME N U NOTE: Displayed language on the special menu screen consists of Korean and English. 1. Machine Info If any language except for Korean is selected during 2. Failure Info language selection mode of main menu, only English will be displayed on special menu screen.
  • Page 41 Analog Inputs Description Analog Input Items Display Remark 1. Pump P/V Current in pump proportional valve. 2. Cooling Fan P/V N.A. 3. Flow Control P/V Current in flow control proportional valve. 4. Dial Indicating dial voltage. 5. TPS N.A. 6. E/G Control Motor N.A.
  • Page 42 Digital Inputs Descriptions Digital Inputs Items Mark Remark Lights up when output at alternator 1. Alternator "R (I)" terminal is above 12 ±1V. 2. Travel Select SW N.A. (only for wheel type equipment) Lights up when the travel speed 3. High-speed Sel. SW (M) selector switch is set to the "I"...
  • Page 43 Menu Select DIGITAL INPUT STATE DIGITAL INPUT STATE 1. Alternator 7. E/G Oil Press. SW : N.A 2. Travel Select SW 8. Air Cleaner Clogged 3. High Speed Sel. SW (M) 9. Return Filter Clogged 4. High Speed Sel. SW (A) 10.
  • Page 44 Digital Outputs Descriptions Digital Outputs Items Mark Remark Lights up when the relief press up 1. Relief Press. Up S/V solenoid valve is "ON." Lights up when the high-speed 2. High-speed S/V solenoid valve is "ON." Lights up when the swing priority ON / OFF 3.
  • Page 45 Current failure information RE ALTI ME FA I L Current status of failure is displayed (Failure code, failure contents). CODE : V204-05 CODE : E011-04 When several failures produced, failure information can be checked using "UP" ( , 1 on Relief Pressure Up S/V Figure 24) or "DOWN"...
  • Page 46 Input your password with one of No. 1 - 8 switches. DELETE FAIL LOG When "NO" (ESC, 4 on Figure 24) button is pressed, the screen will recover to previous menu without deletion. ENTER PASSWD : Yes ESC: No FG000568 Figure 37 Delete Completed screen will appear 3 seconds and DELETE FAIL LOG...
  • Page 47 Failure Information Code at Machine Side Correct Value Measuring Code Failure Component Remarks Points Active Passive CN7-4 It is a Gauge Panel Communication V201 R = 60 ± 5 composite Error CN7-5 resistance of CAN line. This value has to be CN4-4 measured by V202...
  • Page 48 Correct Value Measuring Code Failure Component Remarks Points Active Passive CN3-1 It has to be V220 Front Pump Press. Sensor V = 1V measured in CN3-2 engine stop CN3-3 state. V221 Rear Pump Press. Sensor V = 1V CN3-4 2.45 ± 0.25 k CN3-9 Hydraulic Oil Temperature (25°C (77°F))
  • Page 49 Failure Information Code at Engine Side Current Valve Measurin Code Failure Component Remarks g Points Active Passive 2-15 R=186 ±5 E011 Coolant temperature sensor (100°C 2-26 (212°F)) R=186 ±5 2-35 E012 Fuel temperature sensor (100°C 2-26 (212°F)) 2-36 R=186 ±5 E013 Boost air temperature sensor (100°C...
  • Page 50 Current Valve Measurin Code Failure Component Remarks g Points Active Passive 2-09 E043 E/G speed (Camshaft) 2-10 Synchronizing error between crankshaft E044 Engine speed sensor speed sensor and camshaft speed sensor. Data storing E045 EEPROM error when engine stop. E046 Recovery When the pressure...
  • Page 51 Current Valve Measurin Code Failure Component Remarks g Points Active Passive Voltage is only measured 1-13 Preheat relay (E/G: High Side R=40 ±5 when after E068 V = V_volt Power stage 1) (25°C (77°F)) heat function is 1-07 operating status. 1-13 Preheat light (E/G: Low Side E083...
  • Page 52 FMIs (Failure Mode Identifier) Above normal range (DATA VALID but ABOVE NORMAL OPERATIONAL RANGE) Below normal range (DATA VALID but BELOW NORMAL OPERATIONAL RANGE) Incorrect signal (DATA ERRATIC, INTERMITTENT OR INCORRECT) Voltage above normal (VOLTAGE ABOVE NORMAL OR SHORTED TO HIGH SOURCE) Voltage below normal (VOLTAGE BELOW NORMAL OR SHORTED TO LOW SOURCE) Current below normal (CURRENT BELOW NORMAL OR OPEN CIRCUIT) Current above normal (CURRENT ABOVE NORMAL OR GROUNDED CIRCUIT)
  • Page 53 Operating Hours Screen OPERATING HOURS Exiting Submenus: If escape button (ESC, 4 on Figure 24) is pressed for more than 1 second, this 1. Power : 00042 Hr information screen will be returned to previous 2. Trenching : 00003 Hr screen.
  • Page 54 Menu Selection of Operation Hour Information 2. Trenching Mode 3. Auto Idle 1. Power Mode 4. Travel Speed 1st, 2nd 6. Coolant Temperature Distribution 5. Hydraulic Oil Temperature Distribution FG000574 Figure 43 Example of Machine Operation Info Screen OPERATING HOURS OPERATING HOURS 1.
  • Page 55 Reset screen of operation hour OPERATING HOURS Exiting Submenus: If escape button (ESC, 4 on Figure 24) is pressed for more than 1 second, this information screen will be returned to previous All Operating screen. Hours will be When "YES" ( , 3 on Figure 24) button is NOTE: DELETED.
  • Page 56 SP000935 Electrical System Page 55...

  • Page 57: Electronic Hydraulic Control System (E-Epos)

    ELECTRONIC HYDRAULIC CONTROL SYSTEM (e-EPOS) Control System Schematic Work Mode Auto Idle Machine Info CHECK E/G speed order 02/05 [MO] 11:30 1700 E/G SPEED POWER AUTO 21 19 FG000795 Figure 50 SP000935 Electrical System Page 56...
  • Page 58 Reference Reference Description Description Number Number Instrument Panel Solenoid Valve (Boost) e-EPOS Controller Solenoid Valve (Swing Priority) Engine Controller (ECU) Solenoid Valve (High-speed) Main Pump Solenoid Valve (Breaker) Aux Pump Travel Motor Control Valve Main Relief Valve Pressure Switch Engine Control Dial Pump Pressure Sensor Breaker/Boost/Shear Selector Switch...

  • Page 59: Power Mode Control

    POWER MODE CONTROL POWER AUTO FG000796 Figure 51 Reference Reference Description Description Number Number Instrument Panel (Power Mode Electromagnetic Proportional Selector Switch) Pressure Reducing Valve (Mode Control) e-EPOS Controller Engine Control Dial Engine Controller (ECU) Aux Mode Switch Main Pump Aux Mode Resistor Aux Pump Control Valve...
  • Page 60 The power mode switch permits the selection of the appropriate engine power depending on the working condition. One of the two, Power Mode or Standard Mode, setting can be selected. When the engine starter switch is turned "ON," the power mode is automatically defaulted to standard mode.

  • Page 61: Operation

    Operation Power Mode This mode should be selected for high-speed work. In this mode the engine output is most efficiently utilized because of the discharged oil volume being controlled based on the equivalent horsepower curve at various loaded pressures. The e-EPOS controller compares the target engine speed with the actual engine speed and controls the signal to the E.P.P.R.
  • Page 62 FG000580 Figure 53 Reference Reference Description Description Number Number Engine Horsepower (hp) Pump Discharge Pressure (kg•cm Engine Speed (rpm) Pump Discharge Volume (lpm) SP000935 Electrical System Page 61...
  • Page 63 Standard Mode Standard Mode is used for general work. When this mode is selected it will reduce noise and fuel consumption in comparison with Power Mode. The current to the E.P.P.R. valve is shut off and pump discharge volume is controlled by pump regulator.
  • Page 64 SP000935 Electrical System Page 63...

  • Page 65: Power Mode Control - Circuit Diagram

    POWER MODE CONTROL - CIRCUIT DIAGRAM CN6-1 CN6-2 CN6-9 CN6-10 CN1-1 CN7-4 CN4-4 CN1-2 CN7-5 CN4-5 CN7-6 CN4-6 CN1-8 CN1-9 1-35 1-34 CN1-10 P/V-(A) 1-53 1-52 CN1-21 VEHICLE CONN (CONN.1) 1-10 1-11 CN3-15 +(5V) CW LOW 1-05 CN3-16 1-06 CN3-17 HIGH 1-08 1-09...
  • Page 66 Reference Reference Description Description Number Number Instrument Panel Aux Mode Resistor Engine Controller Battery e-EPOS Controller Battery Relay E.P.P.R. Valve (Electromagnetic Fuse Proportional Pressure Reducing) Fusible Link Engine Control Dial Starter Switch Aux Mode Switch SP000935 Electrical System Page 65...

  • Page 67: Work Mode Control

    WORK MODE CONTROL POWER AUTO FG000797 Figure 56 Reference Reference Description Description Number Number Instrument Panel (Trenching Aux Pump Mode Selector Switch) Control Valve e-EPOS Controller Solenoid Valve Engine Controller Engine Control Dial Main Pump Depending on the working condition, one of two work modes, "DIGGING"...

  • Page 68: Operation

    Operation Digging Mode This mode is used for general digging work, loading work and ground leveling work requiring quick stops. The current to the solenoid valve for swing priority is shut off. Trenching Mode This mode is used for heavy duty ditch digging work or for loading work requiring big swing angles.

  • Page 69: Work Mode Control - Circuit Diagram

    WORK MODE CONTROL - CIRCUIT DIAGRAM CN6-1 CN6-2 CN6-9 CN6-10 CN1-1 CN7-4 CN4-4 CN1-2 CN7-5 CN4-5 CN7-6 CN4-6 (C5) CN1-13 CN1-8 CN1-9 AMP 070 18P AMP MIC 21P AMP 070 16P AMP 040 12P AMP 040 20P 18 17 21 20 19 18 17 16 15 14 13 12 11 16 15 (CN2)

  • Page 70: Engine Control System

    ENGINE CONTROL SYSTEM (Drive Signal) (Command Signal) FG000584 Figure 59 Reference Reference Description Description Number Number Engine Controller Engine Control Dial e-EPOS Controller When the engine control dial is moved the output voltage changes according to the dial position. The e-EPOS controller converts this output voltage of dial to digital signal and sends it to the engine controller by CAN line.

  • Page 71: Engine Control Dial

    ENGINE CONTROL DIAL 7th STEP 13th STEP 1st STEP ( 10 ) ( 10 ) MECHANICAL MECHANICAL STOP STOP 4.0V 2.5V 1.0V SETUP 1ST 2nd 12th 13th STOP STOP VIEW ( POTENTIOMETER BOTTOM) FG000866 Figure 60 Reference Reference Description Description Number Number Knob...
  • Page 72 The engine control dial has a built in potentiometer. When the control knob is moved the output voltage (through "2 and 3" terminals) will vary from the 5 V supplied from the e-EPOS controller as shown in the graph. SP000935 Electrical System Page 71...

  • Page 73: Engine Control Circuit Diagram

    ENGINE CONTROL CIRCUIT DIAGRAM CN6-1 CN6-2 CN6-9 CN6-10 CN1-1 CN7-4 CN4-4 CN1-2 CN7-5 CN4-5 CN7-6 CN4-6 CN1-8 CN1-9 1-35 1-34 1-53 1-52 VEHICLE CONN CN2-15 (CONN.1) 1-10 1-11 CN3-15 +(5V) CW LOW 1-05 CN2-16 CN3-16 1-06 CN3-17 HIGH 1-08 1-09 1-02 1-03 1-40...
  • Page 74 Reference Reference Description Description Number Number Instrument Panel Fuse Engine Controller Starter Switch e-EPOS Controller Fusible Link Engine Control Dial Pressure Switch (Py) Battery Pressure Switch (Px) Battery Relay SP000935 Electrical System Page 73...

  • Page 75: Automatic Deceleration Control (Auto Idle Control)

    AUTOMATIC DECELERATION CONTROL (AUTO IDLE CONTROL) POWER AUTO FG000798 Figure 62 Reference Reference Description Description Number Number Instrument Panel (Auto Idle Switch) Engine Control Dial e-EPOS Controller Pressure Switch Engine Controller SP000935 Electrical System Page 74...
  • Page 76 If the machine is idling without the controls being operated or is waiting for a dump truck the engine speed is automatically lowered. Once the controls are operated and work is being started the machine will be restored to the previous settings. As a result, noise and fuel consumption will be reduced.

  • Page 77: Engine Overheat Protection System

    ENGINE OVERHEAT PROTECTION SYSTEM (Pump control signal) (E/G overheating signal) CHECK 02/05 [MO] 11:30 (E/G overheating signal) 1700 E/G SPEED POWER AUTO FG000802 Figure 63 Reference Reference Description Description Number Number Instrument Panel Control Valve e-EPOS Controller E.P.P.R. Valve (Electromagnetic Proportional Pressure Reducing Engine Controller Valve)
  • Page 78 When the engine coolant temperature increases to over 107°C (225°F), the engine controller detects it from the sensor mounted in the coolant line and will send a signal to the e-EPOS controller. The e-EPOS controller sends a overheat signal to the instrument panel turning "ON"...

  • Page 79: Power Boost Mode

    POWER BOOST MODE Operation CHECK 02/05 [MO] 11:30 1700 E/G SPEED POWER AUTO FG000800 Figure 64 Reference Reference Description Description Number Number Instrument Panel Solenoid Valve (Boost) e-EPOS Controller Main Relief Valve Engine Controller Breaker/Boost/Shear Selector Switch Main Pump Power Boost Switch (Top of Right Aux Pump Work Lever) Control Valve...
  • Page 80 The Power Boost function is used to temporarily increase the main relief pressure to enhance excavation ability. When the breaker/boost/shear selector switch is set to "BOOST" and the power boost button on the center of the right-hand work lever (joystick) is pressed during work, the e-EPOS controller will activate the power boost solenoid valve and increase the relief valve pressure from 330 - 350 kg•cm (4,700 - 5,000 psi).

  • Page 81: Power Boost Control - Circuit Diagram

    Power Boost Control - Circuit Diagram CN6-1 CN6-2 CN6-9 CN6-10 CN1-1 CN7-4 CN4-4 CN1-2 CN7-5 CN4-5 PRESS CN7-6 CN4-6 SHEAR BREAKER (C4) CN1-11 (POWER MAX) CN2-2 CN1-8 CN1-9 (Center) (POWER MAX / BREAKER) AMP 070 18P AMP MIC 21P AMP 070 16P AMP 040 12P AMP 040 20P 6 5 4...
  • Page 82 SP000935 Electrical System Page 81...

  • Page 83: Automatic Travel Speed Control

    AUTOMATIC TRAVEL SPEED CONTROL FG000799 Figure 66 Reference Reference Description Description Number Number e-EPOS Controller Pump Pressure Sensor Engine Controller Solenoid Valve (High-speed) Main Pump Travel Motor Aux Pump Engine Control Dial Control Valve Selector Switch For Automatic Travel Pressure Switch (Py Port) SP000935 Electrical System Page 82...
  • Page 84 If the automatic travel speed control switch is set to the "OFF" position, the travel motor will run in the I-speed (low speed) range. If the selector switch is set to the "I" position, the travel motor will run in the II-speed (high-speed) range. If the selector switch is set to the "II"...

  • Page 85: Automatic Travel Speed Control - Circuit Diagram

    Automatic Travel Speed Control - Circuit Diagram CN1-1 CN1-2 CN3-1 CN3-2 (C3) CN1-12 CN3-3 CN3-4 CN2-4 CN2-5 CN3-15 CN1-8 +(5V) CN3-16 CN1-9 CN3-17 HIGH AMP 070 18P AMP MIC 21P AMP 070 16P AMP 040 12P AMP 040 20P 6 5 4 15 14 11 10 9 19 18...

  • Page 86: Self-Diagnostic Function

    SELF-DIAGNOSTIC FUNCTION e-EPOS Controller The system operation status and malfunction codes can be checked through the display on top of the e-EPOS controller box the rear cover behind the operator's seat. FG000588 Figure 68 Reference Reference Description Description Number Number Upper Digit Power Monitor (Stays "ON"...
  • Page 87 Normal Operation Display Readout Display Readout Mode Selection Operation Status Upper Digit Lower Digit Normal Operation Power Mode Power Mode HAOH340L Power Mode Normal Operation Standard Mode Standard Mode HAOH350L Normal Operation Digging Digging Mode HAOH370L Work Mode Normal Operation Trenching Trenching Mode HAOH380L...

  • Page 88: Air Conditioner System

    AIR CONDITIONER SYSTEM Outline FG000784 Figure 69 Solid type heater and air conditioner are installed in the cover behind the operator's seat. Temperature of the operator's room is adjusted automatically to the temperature set by operator. SP000935 Electrical System Page 87...

  • Page 89: Internal And External Filters

    (Please refer to the Operation Manual for detailed full automatic control. Vent mode selects the direction of discharged air. Outlets by vent modes Modes Outlets Internal and External Filters Internal and external air purification filters are installed for the operator's room. Filters should be cleaned every 500 hours.
  • Page 90 Turn marked knobs (1, Figure 72) at the rear side of the cabin to open the cover. FG000441 Figure 72 Remove filter attached to the cover and clean the contaminated filter using compressed air. Close the cover, replace the knobs, and secure the cover to the support with butterfly bolts.

  • Page 91: Air-Conditioning System Layout

    Air-Conditioning System Layout FG007144 Figure 74 Reference Reference Description Description Number Number Air Conditioner/heater Unit Liquid Hose (1) Condenser Liquid Hose (2) Compressor Ambient Temperature Sensor Receiver Dryer Sun Sensor Discharge Hose Control Panel Suction Hose SP000935 Electrical System Page 90...

  • Page 92: Air Conditioner/Heater Circuit Diagram

    Air Conditioner/heater Circuit Diagram 0.5RW FUSIBLE LINK LAMP SWITCH STARTER SWITCH BATTERY RELAY AIRCON UNIT BATT. A/C CONTROL PANEL 1.25LR CN11-2 LED 1~12 130C CN9-6 0.85LR CN10-8 CN9-11 0.5WR CN10-18 CN9-5 1.25LR 0.85BW 0.85LR RECEIVER DRIER BLOWER RELAY RELAY COMPRESSOR 168B CN8-10 CN10-16...

  • Page 93: Air Conditioner/Heater Unit

    Air Conditioner/heater Unit Airflow Diagram External Air Inlet Cold Box Internal Air Inlet Outlet Vent Rear Outlet Vent Front Outlet Foot Outlet Outlet External Air VENT COOL DOOR -INTAKE DOOR -MIX Internal Air WARM Heater Evaporator Core FOOT FG001359 Figure 76 SP000935 Electrical System Page 92...
  • Page 94 Door Open by Vent Modes Mode Door Vent Bi-level Foot Def/foot Vent Foot Main Components Actuator - Temp Relay Control Blower Relay Duct Sensor Air Flow Control Module Actuator Blower -Wind Direction Motor Control Water Temp Sensor Actuator Evaporator - Internal/external Air Exchanger Internal Internal...
  • Page 95 Actuator - Wind Direction Control Change of discharged airflow according to selected wind direction mode Change of wind direction: Direction changes in the order of VENT BI-LEVEL FOOT FOOT/DEF VENT. Actuator - Temperature Control Change of discharged air temperature by controlling the position of temperature control door.
  • Page 96 Actuator - Internal/external Air Exchange CN10-20 CN10-2 FG001055 Figure 79 Mode Output Terminal Output Moving of exchange door Intake P1 (+), P2 (-) by selecting intake. Moving of exchange door Recirculate P1 (-), P2 (+) by selecting recirculate. SP000935 Electrical System Page 95...
  • Page 97 Airflow Control Module Airflow is controlled through the control of voltage between GATE and SOURCE. DRAIN (CN10-1) GATE SOURCE (CN10-6) (CN11-1) FG001056 Figure 80 Airflow Output Terminal Output 10 ± 0.5V 12.5 ± 0.5V 15 ± 0.5V CN11-2 CN10-1 17.5 ± 0.5V 20.0 ±...
  • Page 98 Relay - A/C: Power is supplied to the magnetic clutch of the compressor. Specifications Rated voltage Rated current FG001058 Figure 82 Duct Sensor: It is inserted in the core of the evaporator to prevent freezing of the evaporator. The sensor consist of negative characteristic thermistor that resistant value increases and decreases when the temperature rises and falls, respectively.

  • Page 99: Ambient Air Temperature Sensor

    Internal Air Temperature Sensor: Built in the internal air filter, it senses the internal temperature. Temperature (°C) Resistance (K ) 218.2 ± 7.5 97.83 ± 0.9 47.12 ± 0.7 30.0 ± 0.36 19.60 ± 0.3 Figure 85 Ambient Air Temperature Sensor Built at the bottom of the cockpit, it senses the temperature of external air.

  • Page 100: Sun Sensor

    Sun Sensor Built beside the socket of spare power, it senses the quantity of the sun radiation to regulate discharge temperature and airflow as set by operator. 83.7 76.2 67.7 58.8 46.6 36.0 21.4 1.0 2.0 3.0 4.0 5.0 6.0 7.0 LUX(x10,000) FG001062 Figure 87...
  • Page 101 Terminal Terms Term No. Terms Term No. Terms Temperature control Water temperature (warm) sensor Sensor ground Duct sensor Temperature control Sun sensor Power (5V) Mix feedback Ambient air temperature sensor Power (KEY "ON") Internal air temperature sensor Backup A/C output (LOW) Ground D.P.S CHECK Illumination...
  • Page 102 Categories Inputs System Operation Sensor Set temperature In case of sensor failure, following defaults are applied: compensation Internal air temperature Internal air temperature sensor: 25°C, Ambient air sensor temperature sensor: 25°C, Duct sensor: -2°C Ambient air temperature Temperature control actuator: sensor - Set Temperature 17 - 24.5°C: Max cooling, Set Water temperature sensor...
  • Page 103 Categories Inputs System Operation Start condition (AND condition) (1) When wind direction mode is one of the following modes in the Auto or manual control mode - BI-LEVEL, FOOT or FOOT/DEF (2) The Water temperature sensor is stable and the water temperature <...
  • Page 104 Categories Inputs System Operation Starting Water temperature sensor Entry condition (AND condition) control of Ambient air temperature (1) Auto Mode heating (2) sensor (2) Ambient air temperature < 5°C and difference between Internal air temperature ambient and internal air temperature ??5°C sensor (3) Failure of water temperature sensor Auto mode...
  • Page 105 Categories Inputs System Operation Duct sensor Function: Magnetic clutch of compressor is turned "ON/ OFF" depending on temperature of the duct sensor to prevent the freezing of the evaporator with A/C being "ON." Control pattern. 0.5 C 0.5 C Compressor control External temperature Function: Prevention of compressor in winter.
  • Page 106 Self-diagnostics How to start self-diagnostics Starter Switch ON Set temp to 25 C Set temp to 77 F Press the SEL switch more than 3 times in 5 secs while pressing the A/C switch Auto diagnosis starts after every graphic in LCD displays twice every 0.5 sec.
  • Page 107 Error codes Code Description Normal Internal air temperature sensor short Internal air temperature sensor open Ambient air temperature sensor short Ambient air temperature sensor open Duct sensor short Duct sensor open Sun sensor short Sun sensor open Water temperature sensor short Water temperature sensor open D.P.S open Position error of wind direction actuator...

  • Page 108: Compressor

    Compressor Categories Specifications Relief Valve Output 155.3 cc/rev Oil Level 120 cc (ND-OIL8) Refrigerant R134a Rated Voltage Open: 35 - 42.2 kg•cm Relief Valve Close: 28.1 kg•cm Compressor sucks in refrigerant which evaporates completely in FG001365 the evaporator and discharges it to the condenser. Figure 91 Refrigerant undergoes repeated changes of states, in the order of liquid, gas, and liquid in the freezing cycle, and the...

  • Page 109: Troubleshooting

    TROUBLESHOOTING Refrigerant Pressure Check Open all doors and windows. Install manifold gauge set. Start engine and maintain engine speed at 1,800 - 2,000 rpm. Figure 94 Check high / low-pressure of refrigerant. High-pressure: 8.0 - 10.0 kg•cm (114 - 142 psi) Low-pressure: Approximately 1.0 kg•cm (14 psi) Possible Cause: Low Refrigerant Level...
  • Page 110 High-pressure: Over 6 kg•cm (85 psi) Low-pressure: Approximately 760 mmHg (Negative Pressure) Possible Cause: Refrigerant does not circulate Step Inspection Item Remedy Connect manifold gauge and start engine. Turn on air conditioner. Moisture in system, replace receiver dryer. Set blower switch to HIGH position. Turn air conditioner OFF and wait 10 minutes.

  • Page 111: Weight Of R134A Gas Used In Machines

    850 ±20 grams (30 ±0.7 oz) DX140W 800 ±20 grams (28 ±0.7 oz) DX180LC 800 ±20 grams (28 ±0.7 oz) DX225LC 800 ±20 grams (28 ±0.7 oz) DX225NLC 800 ±20 grams (28 ±0.7 oz) DX300LC 800 ±20 grams (28 ±0.7 oz) DX300LL 800 ±20 grams (28 ±0.7 oz)

  • Page 112: Refrigerant System Repairs

    REFRIGERANT SYSTEM REPAIRS WARNING! Always wear protective glasses and gloves when handling refrigerant. If refrigerant comes in contact with the skin or eyes, immediately flush with clean, running water and consult a physician. Select a clean and well ventilated area to work. The refrigerant container is under high-pressure and should be stored below 40°C (104°F).

  • Page 113: Repair And Replacement Procedure

    Do not over tighten connections when working on refrigerant system. The new refrigerant system standards require new tools, equipment and parts. DO NOT attempt to use equipment use in servicing the old refrigerant system. The new refrigerant oil (PAG type) has a high moisture absorption characteristic.
  • Page 114 INSTALL REPAIR TOOL RECOVER REFRIGERANT REPAIR / REPLACE DEFECTIVE PARTS VACUUM SYSTEM (OVER 5 MINUTES) CHECK SYSTEM FOR AIR LEAKAGE REPAIR VACUUM SYSTEM (OVER 20 MINUTES) CHARGE SYSTEM (APPROXIMATELY 100 g) CHECK SYSTEM FOR REFRIGERANT LEAKAGE CHARGE SYSTEM TO PROPER LEVEL (Standard Capacity less Initial Charge) CHECK SYSTEM FOR REFRIGERANT LEAKAGE CHECK FOR PROPER REFRIGERANT LEVEL...

  • Page 115: Refrigerant Recovery

    Refrigerant Recovery Reference Description Number To Compressor Low-pressure Side High-pressure Side From Receiver Refrigerant Recovery Tank Attach the manifold gauges and the refrigerant recovery unit to the refrigerant lines as shown. HDA6067L Figure 97 Be careful not to switch the connections for the NOTE: low and high-pressure valves.
  • Page 116 Check system for vacuum leak. Allow system to sit for 10 minutes and check whether the system is holding the pressure. If the pressure has dropped, it must be repaired before proceeding to the next step. Vacuuming Procedure If the system is holding the pressure and it has not changed for 10 minutes, vacuum out the system for an additional 20 minutes.

  • Page 117: Leakage Check

    Leakage Check Perform leakage check after completing NOTE: vacuuming process. After attaching the manifold gauge, open the high side valve. Charge system until the low side gauge dial indicates a pressure of 1 kg•cm (14 psi) and close the high side valve.
  • Page 118 If refrigerant does not flow freely into system, try starting engine first before operating air conditioner. • Temperature control switch setting: Maximum Cooling Blower Speed Setting: Hi (3 step) Engine Speed: 1,300 - 1,500 rpm WARNING! When charging refrigerant system with the engine running: •...

  • Page 119: Inspecting System For Leakage

    Inspecting System For Leakage After completing charging procedures, clean all joints and connections with a clean dry cloth. Using a refrigerant leak detecting device or soapy water, inspect system for leaks starting from the high-pressure side. When the refrigerant circulation has been stopped NOTE: the high-pressure will start to decrease and the low-pressure will start to increase until they are...

  • Page 120: Wiper System

    WIPER SYSTEM Wiper Circuit (Continuous mode) (Intermittent 1 mode) (Intermittent 2 mode) (Washer mode) AMP MIC 13P CN12 CN13 KET 8P AMP MIC 13P (CN12) (Wiper Motor) (CN13) FG000589 Figure 104 Reference Reference Description Description Number Number Battery Wiper Controller Battery Relay Wiper Switch Panel Fusible Link...

  • Page 121: Wiper Operation

    Wiper operation Continuous operation Operation of wiper motor Pressing the successive operation switch on the wiper switch panel (7) changes the voltage of the "5" terminal of the wiper controller (6) from HIGH (about 5.5 ± 0.5V) to LOW (0+0.5V) and current flows by way of the "3"...
  • Page 122 Intermittent operation Intermittent 1st (3-second) Pressing once the Intermittent switch in the switch panel (7) changes voltage of the "8" terminal in the wiper controller (6) from HIGH (about 5.5 ±0.5V) to LOW (0+0.5V) and current flows through the "3" terminal in the wiper controller (6) the "2"...

  • Page 123: Lighting System

    LIGHTING SYSTEM Lighting System Circuit Diagram CN6-1 CN6-2 CN6-9 CN6-10 CN2-6 CN7-4 CN4-4 CN7-5 CN4-5 CN7-6 CN4-6 CN1-1 CN1-2 CN1-8 CN1-9 FG000590 Figure 105 SP000935 Electrical System Page 122...

  • Page 124: Kind Of Light

    Reference Reference Description Description Number Number Battery Front Cabin Light / Rear Work Light Relay Battery Relay Instrument Panel Fuse Box e-EPOS Controller Light Switch Headlight (2 ea.) Cabin Light Switch Work Light (2 ea.) Headlight Relay (Work Light Indicate Light) Front Cabin Light (4 ea.) Work Light Relay Rear Cabin Light (2 ea.)

  • Page 125: Overload Warning Device

    OVERLOAD WARNING DEVICE Overload Warning Device Circuit Diagram Figure 106 ARS1260L Reference Reference Description Description Number Number Battery e-EPOS Controller Battery Relay OWD Selector Switch Fuse Box Pressure Sensor SP000935 Electrical System Page 124...

  • Page 126: Audio Controller

    AUDIO CONTROLLER Audio Controller Circuit Diagram ANTENNA MODULE Vcc(+5V) (LH) (RH) MICOM Vcc(+5V) DC/DC CONVERTER 1 9 10 13 14 15 1 2 3 4 (Audio Control Panel) (STEREO) FG000591 Figure 107 Reference Reference Description Description Number Number Battery Audio Control Panel Battery Relay Stereo Fuse Box...
  • Page 127 Operations Via Audio Control Panel Connected Terminal of Switch Measured values Operations switch 4.36 ± 0.2V Stereo ON, OFF 1.24 ± 0.2V Volume up "3-4" 0 + 0.2V Volume down SCAN 2.49 ± 0.2V Frequency selection SP000935 Electrical System Page 126...
  • Page 128 SP000936 ELECTRICAL SCHEMATIC (DX180LC/DX225LC/DX225NLC/ DX255LC) SP000936 Electrical Schematic (DX180LC/DX225LC/ DX225NLC/DX255LC) Edition 1 Electrical Schematic (DX180LC/DX225LC/DX225NLC/ SP000936 DX255LC) Page 1...
  • Page 129 MEMO Electrical Schematic (DX180LC/DX225LC/DX225NLC/ SP000936 DX255LC)
  • Page 130 Table of Contents Electrical Schematic (DX180LC/DX225LC/DX225NLC/DX255LC) Safety Precautions..........5 Applicable Models..........5 DX180LC/DX225LC/DX225NLC/DX255LC..7 Electrical Schematic (DX180LC/DX225LC/DX225NLC/ SP000936 DX255LC) Page 3...

  • Page 131: Electrical Schematic (Dx180Lc/Dx225Lc/Dx225Nlc/Dx255Lc)

    MEMO Electrical Schematic (DX180LC/DX225LC/DX225NLC/ SP000936 DX255LC)

  • Page 132: Safety Precautions

    Remember, that ultimately safety is your own responsibility. APPLICABLE MODELS The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DX180LC 5001 and Up DX225LC 5001 and UP DX225NLC 5001 and Up DX255LC 5001 and Up Electrical Schematic...
  • Page 133 Electrical Schematic (DX180LC/DX225LC/DX225NLC/DX255LC) SP000936 Page 6...
  • Page 134 2-PUMP SWITCH 153A 0.85W 0.85W 0.85W 1-16 0.85W (AIR HEATER RELAY) (549-00101/K1002406DXX) 180H 0.85BrW 180E 154B 1-04 0.85BG (AIR HEATER RELAY) 0.85BG 0.85BG 0.85BG DA3-3 0.85GB 0.85GB 0.85GB 0.85GB (CONN.2) (CONN.1) Figure 1 Electrical Schematic (DX180LC/DX225LC/DX225NLC/ SP000936 DX255LC) Page 7...

  • Page 135: Dx180Lc/Dx225Lc/Dx225Nlc/Dx255Lc

    0.85RW 0.5Br 0.5Br 0.5Br 1-40 0.5Br (KEY SW) 153A 0.85W 0.85W 0.85W 1-13 0.85W (AIR HEATER RELAY) 154B 0.85BG 0.85BG 0.85BG 1-07 0.85BG (AIR HEATER RELAY) 0.85GB 0.85GB (CONN.2 ) (CONN.1 ) Figure 2 Electrical Schematic (DX180LC/DX225LC/DX225NLC/DX255LC) SP000936 Page 8...
  • Page 136 (SHEAR-RH HIGH) AMP 12P + 18P 149D 180F 0.85BrW 180C A/C CONT ROL PANE L 0.85B JOYSTICK L EVER SWI TCH DA3-1 DX180LC / DX225LC 0.5WR (ON JOYSTICK R.H) Model 0.85GB 0.85RY 179B 2-PUMP S/V DX225NLC / DX255LC 180A 0.85BrW 180G 0.85BrW...

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