CHAPTER 11 ELECTRIC SYSTEM

Transcription

1 CHAPTER 11 ELECTRIC SYSTEM

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3 1. HOW TO READ WIRING DIAGRAM ELECTRICAL SYSTEM 1.1 WIRE CODE The codes used in wiring diagram represent the size of wire and the color of insulating cover. ex) AVS(SS,X) 0.85GR A : Low-tension cables for automobiles V : Vinyl insulated S : Thin-wall type SS : Very thin-wall type X : Cross-linked 0.85: Cross sectional area of wire (0.85mm 2 ) G: Base color of insulating cover R: Stripe color on the base color CAUTION When the wire color is striped, the base color is given first, followed by the stripe color as shown below: Example : LW = Blue with White stripe (1) Wire (2) Stripe ColorBase Color (3) Base Color C45WB01A 1.2 WIRE SIZE Code Color Code Color The allowable current for wire is specified by cross sectional area of wire, and it is marked on the wire cover. To avoid wire damage, a proper size (sufficient capacity) of wire for electric load should be used when installing the optional electric equipment. The thickness of wire is determined by considering ambient temperature, wire length, current continuity time, and vibration. B L W Br G R BW Black Blue White Brown Green Red Black/White Y Lg Gr O P BY LgR Yellow Light-Green Gray Orange Pink Black/Yellow Light-Green/Red Specification AVSS 0.5 AVSS 0.85 AVSS 1.25 AVSS 2.0 AVSS 3.0 AVSS 5.0 CAUTION 11A 14A 19A 26A 44A 60A Allowable current This table is based on the ambient temperature of 40 C and the allowable current can be slightly changed by the external factors such as ambient temperature. BR YG YBr BrR RW YW LB BrW PB Black/Red Yellow/Green Yellow/Brown Brown/Red Red/White Yellow/White Blue/Black Brown/White Pink/Black LgW BL LW GW RB GY RG BrB WG Light-Green/White Black/Blue Blue/White Green/White Red/Black Green/Yellow Red/Green Brown/Black White/Green DC45-W00 Nov

4 CHAPTER 11 DK45S(DK451) 1.3 INSTRUMENT PANEL BULBS Symbol Description Symbol Description Fuse Dual Bulb Slow Blow Fuse Diode Zenerdiode Motor LED (Light Emitting Diode) Switch (Normal Open Type) Switch (Normal Close Type) Compressor Ground (Wire) Ground (Chassis) Photo Diode N.P.N Transistor P.N.P Transistor Meter Condenser Thermistor Resistor Speaker Coil Pick Up Sensor Battery Separate Detector Disconnected Wire Solenoid Connected Wire Variable Resistor Single Bulb Lamp Processor (Controller, Unit) 11-4 DC45-W00 Nov-2004

5 ELECTRICAL SYSTEM 1.4 RELAY AND SWITCH In circuit diagram, switch is marked by symbol and is in normal open condition. Switch is divided into what cuts off and what pass the circuit in "OFF" position. NOTE: NO: Normal Open, NC: Normal Close Section R E L A Y N O Type Relay N C Type Relay OFF Cut off ON Pass 1.5 MULTIPLE SWITCH The continuity of multiple switch is described as below table. O-O: Continuity between terminals. Normally, wiring diagram represents the circuit as if the current doesn t flow. However, when the circuit is connected to all sorts of electric equipment, the switch chart is used for displaying the operating condition as a form of chart. Terminal Position OFF 1ST 2nd 3th Pass Cut off S W I N O Switch Cut off Pass T C45WB02A C H N C Switch Pass Cut off DC45-W00 Nov

6 CHAPTER 11 DK45S(DK451) 1.6 RELAY BOX C45WB03A (1) Safety Start Relay (5P) (2) Back Up Relay (4P) (3) Head Lamp High Relay (4P) (4) Head Lamp Low Relay (4P) (5) PTO Relay (4P) (6) Ignition Relay (4P) (7) Brake Relay (4P) (8) Flasher Unit (9) Hour meter Relay (4P) Compressor Relay (4P) - JP 4P relay doesn t have 87a terminal in the right figure. Check if the relay switch can supply power to relay coil and can be turned to ON or OFF as in the figure in section 1.4. In 5P relay, switch end consists of 3 terminals, and terminal 30 and 87a are coupled at contact point and terminal 30 and terminal 87 are decoupled in normal condition (relay "OFF"). When supplying electric power (DC+12V) to coil end, terminal 30 and 87a will be decoupled, and terminal 30 and 87 will be coupled. Load Terminal Normal open (TML 30/87) Normal close (TML 30/87a) Resistance 40A 30A Lamp 30A 20A Inductance 30A 20A 11-6 DC45-W00 Nov-2004

7 ELECTRICAL SYSTEM 1.7 FUSE CHECK A. FUSE TEST (1) Timer Relay (10A) (2) PTO (10A) (3) Tail High Low Beam (20A) (4) Back Up Lamp (15A) (5) Preheat Controller (10A) (6) Cigarette Lighter Socket (15A) (7) 4WD (10A) 4WD, QT, QT TAB (10A) - JP (8) PTO Lamp Switch (10A) (9) Spare Quick Turn Relay Unit (10A) - JP (10) FFT Controller (10A) (11) Spare (10P) (12) Spare (15A) (13) Stereo/ Stop Lamp (10A) (14) Wiper/ Washer Motor (15A) (15) Spare (20A) Controller (15A) - JP (16) Spare (25A) Controller (10A) - JP (17) Heater/ Air Conditioner (25A) (18) Working Lamp (15A) (19) Flasher Unit (15A) (20) Timer Relay (15A) (21) Stereo/Inside Lamp (10A) (22) Horn (15A) - JP, AU C45WB04A The blade type fuse can be checked without pulling it out from the fuse box. When connecting the lead wires from the test lamp to test lead wire and grounding, the test lamp should light up. C45WB05A (1) Multitester (2) Fuse Box DC45-W00 Nov

8 CHAPTER 11 DK45S(DK451) B. CAUSES OF BLOWN FUSE a. Excessive current Do not replace the fuse hastily when the excessive current caused it to blow out. Check whether the short circuits or abnormal parts exist in system. Replace the fuse with specified one after eliminating the causes of blown fuse. If you do not use specified fuse, it may cause some troubles on wiring and related parts. b. Repeated ON and OFF of current This is a durability type problem, and less usual than case 1) In this case, replace the blown fuse with specified new one. (A) Blown fuse due to excessive current (B) Blown fuse due to thermic fatigue C45WB06A C. DIAGNOSIS PROCEDURES FOR ELEC- TRIC SYSTEM A circuit consists of power supplier, switch, relay, load and ground. There are various ways to check a circuit such as general inspection, voltage check, short circuit check, and continuity test. This section provides brief descriptions for each of them. a. Voltage check With the main switch turned on, measure the voltage value between two positions to be checked with DC voltmeter. Measure the voltage value between two terminals by connecting the positive lead (red) to electric load side and the negative lead to body or black wire. b. Test Lamp check a) Ground one lead wire from test lamp. If the voltmeter is used for test lamp, ground the negative wire. b) Connect the other lead wire from test lamp to the electric load side. Test lamp should be turned on and voltmeter should show the voltage value. c) If the circuit is normal but electric accessories do not work, perform the visual inspection and voltage check until you can find the faulty parts. This should be performed from near connectors. (1) Measurement (3) Test Lamp (2) To Earth C45WB07A 11-8 DC45-W00 Nov-2004

9 1.8 WIRING DIAGRAM DC45-W00 Nov B ENGINE STOP SOLENOID B 1.25Y RG 15A 3.0RW Y BACK-UP SWITCH BACK-UP RELAY 049 WORKING LAMP (REAR,L) 1.25L 1.25L 1.25RG 1.25W 0.5GB 1.25P 1.25RG 1.25RG 12 (BACK-UP LAMP) 3.0RW 5.0R 1.25B 0.5Or 3.0RW HYDRONIC TEMP. SENSOR VACCUM SENSOR 0.5R 0.5RB 0.5Or 0.5Or TIMER RELAY LgR 1.25RG 10A 3.0RW (TIMER RELAY) 1.25W 5.0R 15A 0.5GB 0.85RL (PTO) 0.85RL 3.0RW 10A (TIMER RELAY) A B C 3.0RW BATTERY 030 STARTER MOTOR S 3.0RW 030 M 5.0RW SLOW BLOW FUSE 003 IC REG 0.85YL 5.0R 002 ALTERNATOR RW 60A 5.0R R STARTER RELAY STARTER SWITCH 1.25LB G F 025 OFF ACC ON GL ST AM ACC M G ST 1.25BW SAFETY START SWITCH 1.25LB 3.0R 3.0BL 3.0RW 3.0R DK45S(DK451) A B C G NEUTRAL PTO SWITCH AUTO MANUAL 5.0R 5.0R LB F Or RB 0.5RY 0.5RY 0.5Or 0.5Or 1.25GY 0.5RB 0.5RY 0.85LgR LgR PTO LAMP SWITCH 0.85LgR MICRO SWITCH PTO SOLENOID PTO SAFETY RELAY 0.85RL (PTO LAMP SWITCH) 0.85RL 10A 3.0RW 0.5BR BR 1.25LB 0.85RW PTO RELAY 1.25GY 1.25LB TEMP. SWITCH 5.0BR GLOW RELAY GLOW PLUG PREHEAT CONTROLLER 3.0RL LB 3.0RL BR BR 0.85R SLOW BLOW FUSE E 60A RW 5.0BY BY 5.0BY DIODE RW 0.5WG WG (PREHEAT CONTROLLER) 0.85RW 10A 3.0BL 3.0RW PB RW 3.0RW 3.0RW B 3.0BL 0.85YL 3 3.0RW 5.0R B M RW 0.5GR 1.25RW 0.85WR 0.85Y 0.5R WR (REAR) SWITCH LAMP WORKING 057 WORKING LAMP SWITCH (FRONT) 057 (FRONT,L) WORKING LAMP (FRONT,R) WORKING LAMP PARKING SWITCH 023 (WORKING LAMP) 15A 0.85YW 0.85YW 0.85YW (BRAKE LAMP) 10A R ONLY CABIN 1.25B ENGINE OIL SWITCH 0.5YB B 0.85Y FUEL GAUGE SENSOR 0.5YB GR 0.5YB 0.5GB 0.5Gr HIGH BEAM RELAY R 0.5Or 5.0R HOUR RELAY 0.85WB 0.5YW YW PICK UP SENSOR 0.85WR 0.85RY 3.0RW 1.25B 0.5PB GR RW 0.5BR (FFT CONTROLLER) 10A 029 HAZARD SWITCH L rw 0.85GW rw 0.85GW 0.85RW 0.5BrW 0.85GW 0.5BrW 1.25W 2.0B 1.25BG 1.25W 2.0B 1.25BG POS. REAR COMBI LAMP(L) OFF 1 2 TER. COMBINATION SWITCH TER. POS. B1 T 1 2 B2 R L 1 OFF REAR COMBI LAMP(R) LAMP(L) FRONT COMBINATION LAMP(R) FRONT COMBINATION LAMP(L) HEAD LAMP(R) HEAD rw 0.85WB rb 1.25G 0.85GW 0.85RW 0.85GW 0.85RW 0.5BrR rr (HEAD LAMP /TAIL LAMP) 10A 3.0RW 3.0RW BrR 0.5BrR TEMP. SENSOR 0.5WB LOW BEAM RELAY FFT CONTROLLER 4 ASS Y COMBI-METER 0.5BrW R 0.5BrR 5.0R R R B 1.25B B 1.25B 1.25W 1.25B 1.25BG FLASHER UNIT B E L B 1.25G 2.0L 1.25G A 5.0R (FLASHER UNIT) WORKING LAMP (REAR,R) 0.85WR 1.25Y KEY RELAY 1.25Y WR 1.25WR 1.25WR 1.25B 3.0BW 0.85RW 3.0RW 0.85WR WR 3.0BW 3.0BW B 0.85Y 0.85Y R 3.0BL YW 0.85YW R BRAKE SWITCH 4WD SOLENOID 0.85LY COMPRESSOR R R L L BRAKE RELAY 0.85YW 16 4WD SWITCH 2WD 4WD (4WD) 10A 3.0RW 3.0RW LY LY 096 HEATER UNIT 0.85L 0.85LY 0.85RG ANTENNA THERMISTER 2.0B WASHER MOTOR WIPER MOTOR WIPER SWITCH HEATER SWITCH AIR-CONDITIONAL SWITCH 0.5BW RECEIVE DRIVER COMPRESSOR RELAY WB 1.25R 0.85RB 012 STEREO AIR-CONDITIONER UNIT 1.25RB 0.85R 0.85Y 1.25RB (WIPER, WASHER MOTOR) M A HIGH LOW 061 M 071 S/W OFF L H M W 0.85W 0.85G 15A 1.25YW rw RESISTOR EVA. M MOTOR 1.25YL 3.0RW 030 CIGAR SOCKET 1.25RY 1.25YL (CIGAR SOCKET) 15A 3.0RW WASH OFF WIPE WIPE WASH W P COM E 3.0BL RB RY W 2.0RY 13 (AIR-CONDITIONAL / HEATER) 15A 3.0BW RY RY 0.85G 0.85L 0.85WB BY 2.0RY 5.0R L 0.5R BG LY R 0.5G 0.5BR 0.5L 0.5BL ELECTRICAL SYSTEM AB SPEAKER(L) SPEAKER(R) C45WB53A 11-9 ROOM LAMP (ROOM LAMP) 5.0R 10A R 0.85R 0.5B 0.5GW

10 CHAPTER 11 DK45S(DK451) DK451-JP C45WB54A DC45-W00 Nov-2004

11 2. INSTRUMENT PANEL ELECTRICAL SYSTEM 2.1 SYMBOL DESCRIPTION USA/AU JP C45WB08A (1) Tachometer (2) Hourmeter (3) Temperature Gauge (4) Fuel Gauge (5) Differential Lock Lamp (6) PTO Lamp (7) Hydraulic System Warning Lamp (8) Engine Oil Lamp (9) Charge Lamp (10) Glow Lamp (11) Parking Brake Lamp (12) Headlamp Indicator (High-Beam) (13) 4WD Lamp (14) Quick Turning Lamp (15) Auto Brake Lamp (16) Turn Signal Lamp (LH) (17) Turn Signal Lamp (RH) DC45-W00 Nov

12 CHAPTER 11 DK45S(DK451) A. TACHOMETER TACHOMETER Specification (electric) TACHOMETER indicator specification Indication standard integrator Standard revolutions Tolerance error ±100 ±100 ±150 ± RPM=553Hz No. of lines:6 minimum level: 0.1hrs Minimum levels have white background and red numbers, other parts have black background and white numbers Ignition method ENGINE SIGNAL TACHOMETER input wave form (Ignition period) -12VMN 1.0MAX THRESHOLD LEVEL ( V) C45WB09A B. HOURMETER When there is movement during engine operation, the minimum level red numbers count 1 per 6 minutes, and after 1 hour of operation the white colored minimum level number becomes 1. Ex) Total used time: 123 hours and 30 minutes HR C. TEMPERATURE GAUGE This gauge displays the current engine temperature. The engine temperature is 105 C when the needle is perpendicular and 120 C when the needle reaches at red zone. D. FUEL GAUGE This gauge indicates the fuel level in tank. When the needle is perpendicular, the remained fuel is the half of full level. CAUTION Add fuel when the needle approaches to the "E" in red zone. LEVEL F 1/2 Resistance(Ω) Tolerance( ) Indication angle( ) E 6 (32.5) 97 ±2.5 - ± C C CAUTION Immediately stop the engine and check the engine system when the needle approaches to "H". E. DIFFERENTIAL LOCK LAMP This lamp lights up yellow when the differential lock pedal is engaged. LEVEL 50 C 70 C Resistance(Ω) Tolerance( ) Indication angle( ) C 105 C 120 C ±5 C -3 C ±5 C -3 C (±5 C) -40 C -10 C -5 C -5 C +28 C F. PTO LAMP This lamp lights up red while operating PTO. It is not possible to start the engine if this lamp lights up. CAUTION DC45-W00 Nov-2004

13 ELECTRICAL SYSTEM G. HYDRAULIC SYSTEM WARNING LAMP This lamp lights up yellow when the certain problems occur in hydraulic system. L. HEADLAMP INDICATOR (HIGH-BEAM) This indicator lights up blue when the headlamp switch is in high-beam position. CAUTION This lamp lights up when the pressure in hydraulic system drops down below a specified value due to high oil temperature (approx C) or blocked oil filter carefully check the hydraulic system. M. 4WD LAMP This lamp lights up yellow when 4WD switch is in "4WD" position. At this time, the machine drives with 4 wheel drive mode. H. ENGINE OIL LAMP This lamp lights up red when the certain problems occur in engine oil system such as excessive oil consumption or pressure drops. This lamp is turned off when the engine oil pressure drops down below kg/Cm². I. CHARGE LAMP This lamp lights up red when the certain problems occur in battery charging system. CAUTION J. GLOW LAMP Engine oil lamp and charge lamp light up when ignition switch is turned to on, and goes out after starting the engine. The preheating system starts to operate with lighting up the glow lamp when ignition switch is turned to on. Glow lamps stay on for 8 seconds, but it goes out when ignition switch is turned to ST (starting the engine) within this period. It also goes out when the engine temperature goes over 60 5 C. In winter season, make sure to start the engine after turning off this lamp. N. QUICK TURNING LAMP Here, at the same time as 4WD activation, the front wheels revolve double speed. O. AUTO BRAKE LAMP Here, at the same time as 4WD activation, the front wheels revolve double speed, and the brakes are activated. P. TURN SIGNAL LAMP (LH) This lamp flashes green when the combination switch is in "L" position. Q. TURN SIGNAL LAMP (RH) This lamp flashes green when the combination switch is in "R" position. IMPORTANT Lamp specification: 12V 3.4W (all) CAUTION K. PARKING BRAKE LAMP This lamp lights up red when locking the parking brake while depressing the brake pedal. CAUTION Make sure to drive the machine with parking brake unlocked. DC45-W00 Nov

14 CHAPTER 11 DK45S(DK451) 2.2 CIRCUIT DIAGRAM OF INSTRUMENT (USA) A. CIRCUIT DIAGRAM AND CONNECTOR (1) Tachometer Signal (2) PTO Indicator (3) Temp Gauge (4) Hourmeter Signal (5) Turn Signal Indicator (LH) (6) Turn Signal Indicator (RH) (7) Panel Illumination (8) Earth (-) (9) Fuel Gauge Signal (10) Quick Turn + Auto Brake (Not Use) (11) Quick Turn (Not Use) (12) 4 Wheel Drive (13) Head Lamp Indicator (High) (14) Parking Brake (15) Glow C45WB10A (16) Oil Pressure (17) Transmission Oil Filter (18) Charge (19) Differential Lock (Not Use) (20) Power (+) (21) Earth (Temp Gauge) (22) Water (Not Use) DC45-W00 Nov-2004

15 3. STARTNG SYSTEM ELECTRICAL SYSTEM 3.1 IGNITION CIRCUIT (WITHOUT THE INSTALLATION OF A HORIZONTAL CONTROLLER) A 3 OFF ACC ON GL ST AM ACC M G ST 10A Pto Lamp Switch 9 Neutral 4 6 Auto Manual C45WB12A (1) Battery (2) Slow-blow Fuse (3) Starter Relay (4) Starter Motor (5) Main Switch (6) Safety Switch (7) PTO Safety Relay (8) Fuse (9) PTO Switch (10) Reverse Switch (11) Reverse Auto PTO Stop Relay (12) Micro Switch CIRCUIT EXPLANATION First, if the PTO switch is in manual or automatic position, power is supplied to the PTO safety relay which then is activated and ignition cannot be started. If the ignition switch (MAIN SWITCH) is placed in the ST position, the electric current flows from the battery past the safety ignition switch via the slow blow fuse (the safety ignition switch turns on when the clutch pedal is pressed), it then passes the PTO safety relay and applies power to the ignition relay, and by connecting to the magnetic switch in the ignition motor, the ignition motor is made to revolve. DC45-W00 Nov

16 CHAPTER 11 DK45S(DK451) 3.2 IGNITION CIRCUIT (HORIZONTAL CONTROL INSTALLATION EXPECTATION-ONLY JP) OFF ACC ON GL ST AM ACC M G ST 15A 10A P.T.O SWITCH(ON ) P.T.O SWITCH(OFF ) C45WB11A (1) Battery (2) Slow-blow Fuse (3) Starter Relay (4) Starter Motor (5) Main Switch (6) Safety Switch (7) Auto Balance Controller (8) Fuse First, check whether the PTO switch is in the manual or automatic ON position. Next, place the manual or automatic switch on OFF. If the ignition switch (MAIN SWITCH) is placed in the ST position, the electric current flows from the battery past the safety ignition switch via the slow blow fuse (the safety ignition switch turns on when the clutch pedal is pressed) and depending on whether the PTO manual or automatic switch within the rotary level controller is in the ON or Off position, it activates the PTO safety relay and applies voltage to the ignition relay coil unit. If the PTO manual switch is in the ON position, the contact point of the interior safety relay is switched off and ignition cannot be started. If the electric current passes the PTO safety relay and is supplied to the ignition relay, the contact point of the ignition relay switch connects as a result of the magnetic force created by the ignition relay coil and power is supplied to the magnetic switch in the ignition motor DC45-W00 Nov-2004

17 ELECTRICAL SYSTEM 3.3 MAJOR COMPONENTS A. STARTER MOTOR a. SPECIFICATION Nominal Output Collection Method Rating Time Rotating Direction Guaranteed Specification (20 C) 12V, 1.7KW Electronically Forced-Push Type 30 seconds Clockwise When Seeing At Pinion Shaft Side No-load Loaded Holding Operating Voltage Of Electronic Switch Remark Weight: 4.4Kg F/R BKT material: ALUMINUM Alloy b. SECTIONAL VIEW OF STARTER MOTOR Voltage 11V 8V 4V Current max. 130A max. 370A max 980A Torque a. Starter The magnet-switch type starter is composed of two main sections. The first section converts battery current into mechanical rotation to turn the engine crankshaft. It is composed of the field coil, armature, brush, commutator, pinion, overrunning clutch, etc. The second section allows the pinion and flywheel to engage together and current to flow through the motor section. It is composed of the pull-in coil, holding doil plunger, drive lever, contact plate, etc. (A) Construction - min. 1.3Kgf-m min 2.6Kgf-m Speed min rpm min rpm Operating voltage when holding 2 mm of pinion end: below 8V - C45WB13A (1) lever (2) Internal Gear Ass y (3) Front Bracket Ass y (4) Needle Bearing (5) 6 Roller ORC Ass y (6) Planet Gear Ass y (7) Armature Ass y (8) Field Coil (9) Aual Brush (10) Thraough Bolt (11) Needle Bearing (12) Rear Bracket Ass y (13) Nut (14) Holding Coil (15) Magnet Switch Ass y DC45-W00 Nov

18 CHAPTER 11 DK45S(DK451) c. OPERATING PRINCIPLE OF STARTER MOTOR OPERATING PRINCIPLE The starter motor has 1.7 kw class of capacity. The starter motor consists of magnet switch with combined 4 poles and 4 brushes with engaging control of 2 poles the magnet switch consists of two paralleled coils. Low resistance inductance coil is grounded through the engine and high resistance inductance coil is grounded through the solenoid body. When the ignition switch is turned to ST position with clutch pedal depressed, the power is supplied to magnet switch of starter motor and the current flows through pull in coil in magnet switch as shown in figure 2. Accordingly, the plunger is sharply pulled in and pinion is pushed out. At this point, the plunger makes contact disk(4) to B+ terminal in starter motor and the current flows to armature through field coil to run the electric motor. While the ignition switch is in ST position, the current in holding coil keeps the drawn plunger in position without returning by return spring. If the contact coil(4) is closed, the current will not flow into pull in coil any more, and the pulling force of pull in coil should be eliminated. Due to this, the holding coil prevents the plunger from returning back. In addition to, it also prevents the pinion and contact disk from disengaging due to vibration when starting the engine. If the ignition switch is turned to ON position from ST position, the current in pull in coil flows to reverse direction because the contact disk(4) is closed at this moment. Due to this, also the magnetic field of pull in coil is changed to reverse direction, and eventually the magnetic force of holding coil will counterbalance the force of pull in coil. At this time, the plunger is returned to its original position by return spring, so the pinion is disengaged from ring gear and the contact disk(4) is released. d. REMOVAL AND INSTALLATION 1. REMOVAL Remove the hood side cover from the body. Disconnect the battery negative (-) cable from the battery. Disconnect the battery positive (+) cable from to B+ terminal on starter motor Unscrew the bolts and nuts fixing the starter motor Remove the starter motor from engine. 2. INSTALLATION Installation should follow the removal procedures in the reverse order. (1) Magnet Switch (2) Pull in Coil (3) Holding Coil (4) Contact Disk (5) Field Coil (A) Activated (B) Deactivated (6) Plunger (7) Lever (8) Pinion Sleeve (9) Armature C45WB14A DC45-W00 Nov-2004

19 ELECTRICAL SYSTEM B. STARTER RELAY a. Terminal Layout b. Specification Rated voltage: DC 12V Capacity of switch contact point: 70A C45WB15A c. Troubleshooting for relay It is normal that multitester displays approx. 50~60 of resistance between both ends of the coil. It is also normal that the switch is switched on when DC 12V is supplied to both ends. C. SAFETY SWITCH a. Terminal Layout Position Free Push AVS 2.0 BW AVS 2.0 BW b. Specification Rated voltage: DC 12V Capacity of switch contact point: 18A c. Troubleshooting for switch (1) Shaft (A) 1.6mm Off Stroke (B) 6.4mm On Stroke (C) Free (D) Push C45WB16A It is normal that multitester displays 0 of resistance. To measure the resistance, press the shaft upto ON- Stroke after connecting the multitester to both ends. It is also normal that multitester displays DC+12V on one terminal when the voltage of DC12V is supplied to the other terminal while pushing the shaft upto ON- Stroke. DC45-W00 Nov

20 CHAPTER 11 DK45S(DK451) D. PTO LAMP SWITCH a. Terminal Layout TERMINAL Position Free Lock YB LG LB RW BY b. Specification Rated voltage: DC 12V c. Troubleshooting for lamp switch 1. Lamp : The lamp should be turned on when DC12V is supplied to RW and BY terminal. It is normal that multitester displays few s (coil resistance) after connecting the multitester to both terminals. (1) Lamp (2) Switch (3) AVS 0.5 RW.BY (4) AVS 0.5 LB (5) AVS 0.5 YB (6) AVS 0.5 LG (A) Free (B) Lock C45WB20A 2. Switch : The multitester should display 0 of resistance between LG and LB when the switch is in FREE position. And, it should display 0 of resistance between YB and LB when the switch is in LOCK position. E. PTO SWITCH (Normal type) a. Terminal Layout TERMINAL Position Left (AUTO) Center (NEUTRAL) Right (MANUAL) Remark On Off On b. Specification Rated voltage: DC 12V Rated load: 6A (1) PTO Switch (A) AUTO (B) NEUTRAL (C) MANUAL C45WB17A c. Troubleshooting for switch It is normal that multitester displays 0 of resistance when the switch is in AUTO or MANUAL position DC45-W00 Nov-2004

21 ELECTRICAL SYSTEM F. PTO CIRCUIT (Equipped horizontal relay) a. Ignition Circuit Composition 1 KEY ON +12[v] START SIGNAL IN(+) F N.C. START SIGNAL OUT(+) G 27 PTO SAFTEY RELAY 7 PTO MANUAL S/W 3 C45WB18A (1) Main Switch (2) PTO Safety Relay (3) PTO Lamp Switch (4) Battery If the manual PTO switch turns on (lamp switch), the PTO relay is comprised of Normal-Closed, and power is induced to the PTO safety relay coil unit and stops the switch which disconnects F & G and ignition is disabled. b. Terminal Composition Wiring number Circuit explanation Wire standards Particulars 6 Engine ignition input AVS0.5 R 7 PTO switch power AVS0.5 LgR 27 Engine ignition output AVS0.5 G C45WB19A DC45-W00 Nov

22 CHAPTER 11 DK45S(DK451) 4. CHARGING SYSTEM 4.1 CIRCUIT DIAGRAM 1 OFF ACC ON GL ST AM ACC M G ST P-TAP B+ 1N IC. REG. R L R L AVS 1.25 R AVS 0.85 YL AVS 0.5 PB 5 800V 3A TO HOURMETER 7 C45WB21A (1) Battery (2) Slow Blow Fuse(60A) (3) Alternator (4) Main Switch (5) Diode (6) Diode (7) Charge Lamp CIRCUIT DESCRIPTION When the main switch is in ON position without engine starting, the positive (+) voltage from battery is supplied to positive (+) terminal of charging lamp through slow blow fuse, B+ terminal of alternator and M terminal of main switch, and the supplied voltage to R terminal of regulator magnetizes the field coil. At this time, the low electric potential is applied to the terminal of charging lamp according to the low electric potential of L terminal of regulator, accordingly the charging lamp lights up. If the generated voltage in alternator becomes higher than terminal voltage in battery after starting the engine, the charging process to battery will be started through B+ terminal. During the charging process, the increased terminal voltage of alternator eliminates a potential difference between both ends of charging lamp. Due to this, the current to charging lamp is cut off and the lamp is turned off. If the generated voltage in alternator reaches up to the regulated voltage, regulator outputs constant DC 14.5V 0.5V of generated voltage through B+ terminal DC45-W00 Nov-2004

23 ELECTRICAL SYSTEM 4.2 AC (ALTERNATING CURRENT) ALTERNATOR A. SPECIFICATION Temp.Rise Reg.Perf. Nominal output Manufacturer Rating Battery Voltage Normal Output Regulating System Weight Rated Speed Speed In Use No. Of Poles Hot Condition Thermal Endurance Initial Cut-In Speed Setting Voltage Temperature Compensation 12V50A VALEO ELECTRICAL SYSTEMS KOREA LTD. Continuous 12V50A Negative Ground Hic Reg. Built-In (3.6 kg) 5000 rpm rpm 12 at 5000 rpm with maximum output after running 40 minutes Max rpm V -7.3 mv/ C Ambient temperature when driving: max. 100 C B. SECTIONAL VIEW OF ALTERNATOR (1) Hex Nut (2) Spring Washer (3) Pulley (4) Spacer-P (5) Through Bolt DC45-W00 Nov-2004 (6) Stator Assembly (7) Rotor Assembly (8) Bearing Rear (9) F/T Bracket Assembly C45WB22A (10) Bearing Front (11) R/R Bracket Assembly (12) Rectifier Assembly (13) Regulator Assembly 11-23

24 CHAPTER 11 DK45S(DK451) C. CIRCUIT DIAGRAM OF ALTERNATOR 0.5 F L R C45WB23A D. CHARACTERISTIC CURVE E. GUARANTEE (AT 20 C) Voltage (V) Output Current (A) Hot Cold Speed (RPM) 11 (17) V 32 (40) (53) 5000 C45WB24A DC45-W00 Nov-2004

25 5. ENGINE GLOW PLUG SYSTEM ELECTRICAL SYSTEM 5.1 CIRCUIT DIAGRAM C45WB25A (1) Battery (2) Slow Blow Fuse (60A) (3) Alternator (4) Main Switch (5) Fuse 15A (6) Temperature Switch (7) Fuse 10A (8) Preheat Controller (9) Glow Lamp (10) Slow Blow Fuse (60A) (11) Glow Relay (12) Glow Plug (4 ea) CIRCUIT DESCRIPTION Glow system consists of preheat controller, glow lamp, glow plug, glow relay, and temperature sensor. When the ignition switch is turned to ON position, the preheat controller starts to preheat. The glow lamp on instrument panel lights up for approx. 8 seconds after turning the ignition switch to ON position below 60 C of engine coolant temperature. If the ignition switch is turned to ST position for starting within 8 seconds, the glow lamp is turned off immediately. The glow relay operates as soon as the ignition switch is turned to ON position. It preheats the glow plug by DC45-W00 Nov-2004 supplying the current from the battery. This process takes approx. 15 seconds. If the ignition switch is turned to ST position for starting within 15 seconds, the glow relay keeps preheating during the ignition switch is in ST position. When the ignition switch is turned back to ON position, the glow plug is afterheated for 15 seconds. The glow lamp and glow relay do not operate if the engine coolant temperate is over 60 C. Preheating and afterheating must stop if the voltage input to preheat controller is over V

26 CHAPTER 11 DK45S(DK451) 5.2 MAJOR COMPONENTS A. APPEARANCE OF PREHEAT CONTROLLER KEY ON VOLTAGE REGULATOR INDICATOR LAMP TIMER INDICATOR LAMP OUT TO GLOW LAMP KEY ST START TIMER PREHEATER RELAY OUT TO GLOW RELAY TEMP. SENSOR THERMO SENSOR SENSING AMP EARTH C45WB26A B. TERMINAL ARRANGEMENT AND FUNCTION NO. Function Wire Color 1 Main Switch ON 0.85RW 2 Temperature Sensor 0.5WG 3 Main Switch ST 1.25LB 4 Glow Relay Coil (+) 0.5BR 5 Earth 6 N.C 7 N.C 8 Glow Lamp 0.5GR C45WB28A DC45-W00 Nov-2004

27 ELECTRICAL SYSTEM C. TIME CHART OF PREHEAT CONTROLLER C45WB29A DC45-W00 Nov

28 CHAPTER 11 DK45S(DK451) D. TROUBLESHOOTING Check whether the glow lamp lights up for 8 seconds and the glow relay operates for approx. 15 seconds after turning the ignition switch to ON position. Check whether the glow lamp is turned off when the ignition switch is turned to ST position and the glow relay operates for approx. 15 seconds after turning back the ignition switch to ON position from ST position. Coolant temperature sensor should be switched on when the coolant temperature is below 60 C, and should be switched off when the coolant temperature is over 60 C. When the coolant temperature is below 60 C, check the switch operation. If it has the value of 0V or 0 between terminal 1P in coolant temperature sensor and the ground, it operates properly. If the coolant temperature is over 60 C and the switch is turned off (voltage in terminal 1: few Volts), the glow lamp and glow relay do not operate. E. GLOW PLUG a. Appearance of glow plug b. Specification 1. Rated voltage : DC 11V 2. Current value : 20A Max after 4 seconds loading at rated voltage. 3. Temperature rising : 800 C Min after 4 seconds loading at rated voltage. 4. Tightening torque Plug body (M10 P1.25) : 2 ~ 2.5 kg.m (19.6 ~ 24.5 N.m, 14.5 ~ 18.1 lbf.ft) Terminal nut (M4 P0.7) : 0.2 kg.m (1.9 N.m,1.4 lbf.ft) b. Troubleshooting It is normal that multitester displays few s (approx. 0.4 ) when measuring the resistance of plug. C45WB30A F. GLOW RELAY same with the starting relay of starting system DC45-W00 Nov-2004

29 6. PTO SYSTEM (ONLY USA/AU) ELECTRICAL SYSTEM 6.1 CIRCUIT DIAGRAM C45WB31A (1) Battery (2) Slow Blow Fuse (3) Main Switch (4) Safety Switch (5) PTO Safety Relay (6) Fuse 15A (Back-Up) (7) Back-Up Switch (8) PTO Stop Relay (9) Fuse 10A (PTO Lamp Switch) (10) PTO Lamp Switch (11) PTO Switch (12) Micro Switch (13) Fuse 10A (PTO) (14) PTO Relay (15) PTO Solenoid (16) PTO Lamp (17) Diode (800V 3A) DC45-W00 Nov

30 CHAPTER 11 DK45S(DK451) 6.2 CIRCUIT DESCRIPTION NOTE: PTO circuit is related to starting circuit. See starting system for the circuit related to starting. To operate PTO, push the PTO lamp switch(10) with engine started (the ignition switch must be turned to ON: power is supplied through M terminal), then put the PTO switch(11) to AUTO or MANUAL mode. In MANUAL mode, PTO relay(14) supplies the current to PTO solenoid(15) for operation regardless of switches, and PTO lamp(16) lights up. PTO lamp on instrument panel is connected to PTO solenoid in parallel. PTO safety relay(5) cuts off the connection with starting circuit when the PTO operates. In AUTO mode, PTO switch(11) is connected to micro switch through the normal close (NC) contact point of PTO stop relay(8) in series and PTO relay(14) allows PTO to operate. If the back-up switch(7) is operated by putting the main shift lever to reverse position, PTO stop relay(8) disconnects (disengaging ) the relay switch and PTO stops operating. In addition to, the micro switch (12) is turned off and PTO stops operating when the position lever moves over a particular level when the shift lever is not in reverse position. Diode (800V 3A)(17) acts as a safety device to protect PTO solenoid from surging voltage. 6.3 TROUBLESHOOTING CAUTION Make sure that the engine is off before performing maintenance job for PTO system. a. Check if there was a mistake during operation. If PTO does not operate when the main switch is on, check the illumination lamp on PTO lamp switch is lighting up. And, check if PTO switch is in PTO operating condition in AUTO or MANUAL mode. In AUTO mode, PTO does not operate if the position lever is moving upward and the main shift lever is in reverse position. b. Check the power system, fuses and relays for operation. c. Check the switches for operation. The back-up switch(7) should be turned on when the main shift lever is in reverse position. If the power is supplied, the voltages in both terminals should be approx. +12V when the switch is operated. If the power is not supplied, buzzer should sound during continuity test or the resistance between both terminals should be 0. In addition to, check whether the micro switch(12) is operating properly when moving the position lever upward and downward DC45-W00 Nov-2004

31 7. ROTARY LEVEL CONTROL INSTALLATION (ONLY JP) 7.1 SYSTEM COMPOSITION PARTS ELECTRICAL SYSTEM C45WB32A (1) Manual Level Switch (2) Stop Position Setting VR (3) Level Adjustment VR (4) Sensitivity Adjustment VR (5) Automatic Pto Switch (6) Automatic Level Switch (7) Level Controller Assembly (8) Wire (9) Lift Cylinder (10) Level Sensor (11) Location Sensor (12) Lift Cylinder Sensor DC45-W00 Nov

32 CHAPTER 11 DK45S(DK451) 7.2 OUTLINE The level control installation of the tractor rotary is based on a electronic-hydraulic system and is composed to maintain level by equalizing the main body and the implement against the slope and irregularity of the pavement. That is, the inclination of the main body due to the slope in pavement and also the inclination due to the wheels being put into water are dealt with by this installation which always maintains the level of the implement and sustains the selected inclination. A. SENSOR DATA a. Level sensor NO. Item Assessment standard method. condition 1 Rated voltage DC12V 2 Usage voltage range DC10~16V 3 Usage temperature range -20~ + 60 C 4 Storage temperature range -40~ + 60 C 5 Power consumption Below 50 ma (no load) 6 Power output Below 1 ma Level detection ± 20 C 7 Detection angle Refer to the diagram on the right for directional features +angle -angle 1.0V at -15 (reference) 8 Voltage output 2.5V at 0 0.5V at V at V at +20 Left inclination: +angle Right inclination: -angle b. Lift sensor, implement location sensor NO. Item Initial capacity 1 total resistance 2k ± 20% electricity effective angle rated power usage temperature range machine activation angle part angle 110 ± 3 0.2W 70 C -30 ~ +120 C 120 ± 5 Output feature chart OUTPUT VOLTAGE 100(%) Angle ( ) C45WB33A DC45-W00 Nov-2004

33 ELECTRICAL SYSTEM B. LEVEL CONTROL MOTION PRINCIPLE Rotary works with level control installation Rotary works without level control installation C45WB34A a. Working features on inclined areas unlike the water farms, there are many inclined areas on the paved surfaces of farms where vegetables and such are grown. Depending on the pavement, the angles of the inclination can vary widely, and even on the same pavement there could be differences in the inclination angles. However, with farmland, it is important to maintain the implement level or at the desired angle with respect to the pavement surface. When the position of the work machine is being controlled, it is necessary to control it so that it follows the changes in inclination angles of the pavement surface. b. Control Principle The level control system must fulfill the position control condition in an inclined area, and to be able to carry out works level with the inclination, the positional difference amount caused by the subsidence of the tractor s left or right tires must be compensated The actual inclination angle of the pavement surface is Pavement inclination angle = tractor position angle tire subsidence compensation amount Also, the angle of the work machine in relation to the inclination angle of the pavement surface can be adjusted by the operator by adding the standard subsidence compensation amount based on the level control VR. This enables the control of the subsidence compensation amount when the average subsidence amount is not right due to the tractor weight or the soil conditions etc. The input value of the level sensor installed on the tractor is averaged out within the predetermined period and determines the angle of the tractor position in the existing state. Here, the adjustment time of the level sensor value can adjust the level controller to sensitive or non-sensitive depending on the tractor speed by adjusting the sensitivity control volume. The concept diagram of the level control installation in inclined pavement areas are shown below. c. Effects of the Rotary level control The introduction of work position control with consideration of the subsidence difference of the left and right tires on inclined areas has made it possible to maintain the implement in a stable position which was previously not possible especially in paved areas with constant change in inclination angles or on uneven pavement areas. As a result, a uniform finish can be achieved anywhere within the paved area and stable crop growth can be expected. DC45-W00 Nov

34 CHAPTER 11 DK45S(DK451) 7.3 LEVEL CONTROL INSTALLATION FUNCTION A B C C45WB35A (A) Manual leveling mode operation (B) When reverting parallel (maximize platform height) (C) When operating on maximum platform height If the lift cylinder stroke which is controlled by the level controller is within 90mm in manual or automatic level control (with the purpose of sensor protection, wire and assembly tolerance have been taken into consideration), out of the total 110mm lift cylinder stroke 10mm on maximum and 10mm on minimum have been allowed for. (Maximum limit:3.92v, Minimum limit:1.17v - there could be slight differences depending on expected assembly conditions) The level controller is largely comprised of 2 types of control, implement level control & PTO control which are divided into manual & automatic. The seesaw switch located on the right of the fender exterior is arranged in a line like the manual level switch (within the level controller), so the lift cylinder can even be adjusted from the outside. A. PTO CONTROL FUNCTIONS - Ignition disabled if level controller is not installed (refer to ignition circuit in 8.2) - Ignition disabled if the PTO lamp on the dashboard is on (on PTO activation) - During movement from PTO activation, PTO is automatically cut when reversing and turns off the PTO lamp on the dashboard. - If the PTO manual, automatic switch is on the PTO lamp on the dashboard is turned on, and when the PTO manual switch is ON, the PTO is activated regardless of the position of the work machine, and because the PTO continues to operate on reverse, there is danger of accidents so caution must be taken. - During PTO operation, if the stop position setting VR is adjusted, the PTO deactivation position (PTO activation or deactivation depending on the height of the PTO operation area ie. the platform) can be adjusted on the discretion of the operator (but, if the work machine location sensor value is over 3.6V, PTO will be deactivated). - If the PTO manual switch is OFF, PTO will turn OFF regardless of the PTO operation. (At this time, the engine ignition output will be ON) DC45-W00 Nov-2004

35 ELECTRICAL SYSTEM B. LEVEL CONTROL FUNCTIONS - When the level manual switch is ON, OFF the level solenoid output is turned ON, OFF. (The length of the lift cylinder is changed) - If the level automatic switch is ON, the implement automatically maintains level by the inclination of the tractor s main body at a point where the work machine location sensor value is below 3.6V. - On automatic leveling, the level position can be adjusted on the operator s discretion based on the level control VR. - If the platform is higher than the 3.6V value of the implement location sensor, the automatic leveling and PTO do not activate and maintains level with the main body (stroke sensor location 2.5V). - After the automatic level switch is ON, and when the manual level switch is controlled up, down, the output of the level solenoid is increased during the time where operation is done by the manual level switch, and when the manual level switch is on neutral, the lift cylinder goes to its original position. When the manual level switch is on for more than 5 seconds, the solenoid output is turned off to prevent damage. - When reversing, the PTO is not activated so automatic leveling turns off. C. REVERTING PARALLEL FUNCTION - If the implement location sensor value is more than 3.6V, there is a reverting parallel function so that the lift sensor value becomes 2.5V (to level with the main body), and the tractor s center of gravity does not lean to one side. In other words, if it is lifted higher than the platform setting (3.6V), automatic leveling and the PTO do not activate, and level is maintained with the main body. - On manual leveling, if the implement location sensor is lifted above 3.6V, perform the reverting parallel function on the platform, and when the platform is lowered to 3.52V, it outputs at the level solenoid so that it becomes the last value before reverting parallel (when plowing, this function is convenient when operating on manual mode). DC45-W00 Nov

36 CHAPTER 11 DK45S(DK451) 7.4 ELECTRIC CIRCUIT KEY +12[v] Before about +12[V] Before river+12[v] 1 16 Rise Drop Horizontal manual operations/w Retrogression S/W PTO Ramp PTO Relay PTO Solenoid PTORamp switch Automatic OFF PTO Automatic S/W Horizontal automatic movement S/W 7 Horizontality Manual operations/w At Under 3 4 Horizontal burglar set VR Horizontal sensor Lift cylindervr Ascent and descent cancer locationvr Auto Balance Controller PTO Standstill location set VR Horizontality control VR Horizontal rise valve Horizontal drop valve Engine starting input(+) Engine starting output(+) Engine number of revolution electronic pickup [V] +5[V] RxD TxD Before aboutearth Before riverarth GND C45WB36A DC45-W00 Nov-2004

37 ELECTRICAL SYSTEM 7.5 TERMINAL ARRANGEMENT TABLE NC C45WB37A Wiring number Circuit explanation Wire standards particulars 1 Weak current +12V AVS 0.85 RY 2 Reverse switch AVS 0.5 L 3 Manual leveling S/W up AVS 0.85 RG 4 Manual leveling S/W down AVS 0.85 YR 5 +5V AVS 0.85 LB 6 Engine ignition input AVS 0.85 R 7 PTO manual S/W AVS 0.85 LW 8 Electronic pick up AVS 0.85 YL 9 N.C 10 N.C 11 N.C 12 Level increasing solenoid AVS 0.85 RL 13 Level decreasing solenoid AVS 0.85 LR 14 N.C 15 N.C 16 Strong current +12V AVS 0.85 RW 17 Weak current earth AVS 0.85 Y 18 Earth output AVS 0.85 BW 19 Level sensor AVS 0.85 BrW 20 Implement position VR AVS 0.85 YB 21 Stroke sensor AVS 0.85 GY 22 N.C 23 N.C 24 N.C 25 N.C 26 N.C 27 Engine ignition output AVS 0.85 G 28 PTO lamp AVS 0.85 LY 29 PTO relay AVS 0.85 LB 30 Strong current earth AVS 0.85 B DC45-W00 Nov

38 CHAPTER 11 DK45S(DK451) 8. QUICK TURN (ONLY JP) 8.1 ELECTRIC CIRCUIT A OFF ACC ON GL ST AM ACC M G ST 3 10A 10A A WD 2WD QT QT+AB C45WB38A (1) Battery (2) Slow Blow Fuse (3) Main Switch (4) Quick Turn Relay Unit Fuse (5) Quick Turn Fuse (6) Panel Fuse (7) 4WD Solenoid (8) Q/T Solenoid (9) Q/T + AB Solenoid (LH) (10) Q/T + AB Solenoid (RH) (11) 4WD Lamp (12) Q/T Lamp (13) Q/T + AB Lamp (14) Drive Selection Switch (15) Safety Switch (Front Axle LH) (16) Safety Switch (Front Axle RH) (17) Safety Switch (Range Shift Lever) DC45-W00 Nov-2004

39 ELECTRICAL SYSTEM CIRCUIT EXPLANATION The quick turn installation senses the front axle angle and if the axle turns more than the fixed angle voltage is applied to the quick or auto brake solenoid so that the turning radius of the tractor is minimized in narrow spaces or paved areas. It is comprised of the following parts, drive selection switch, relay, diode, solenoid valve type, and various switches. Start the ignition and place the Main Switch to the ON position and select the drive mode using the drive selection switch. As seen in the above circuit, there are no circuit connections in 2WD so it is advantageous on flat roads where there is no need for towing capability. If the drive selection switch is on 4WD, voltage is applied to the 4WD solenoid via the quick turn relay (5P) switch (N.C) and activates the 4WD mode. At this time, there is no voltage applied to the QT which turns the front wheel in any direction, so there is no quick turn. If the drive selection switch is in the QT position, voltage is applied to the range shift lever switch. When this happens, the range shift lever switch turns off on high speed, and if the vehicle turns rapidly on high speed, there is concern of expected overturning, so when the range shift is on high speed a safety function has been inserted to prevent quick turn. If the range shift lever is on low or medium speed, the range shift lever switch turns on and voltage is applied to the range shift relay coil unit, which then turns on the range shift relay lamp and power is supplied to the left and right of the safety switch. In this situation, if the left or right front wheel turns more than the fixed angle, the left and right safety switches turn on and voltage is applied to the quick turn relay coil unit and cuts the switch connecting to the 4WD, and then voltage is applied to the quick turn solenoid and quick turn is performed. Here, the left & right auto brake relay are activated but no voltage is applied to the QT+AB, so the auto brake does not activate. If the drive selection switch is put on QT+AB, voltage is applied to the 4WD unit via diode 2 and then the QT unit & diode 1, activating quick turn & 4WD and when quick turn is activated (front axle turns more than the fixed angle) voltage is applied to the auto brake left & right relay switch unit which then applies voltage to the auto brake solenoid, enabling the simultaneous operation of quick turn and brakes. QT+AB activation must be performed after releasing the lock installation on the brakes. For the movement of each solenoid, the current movement is indicated on the dashboard indicator lamp. DC45-W00 Nov

40 CHAPTER 11 DK45S(DK451) 8.2 MAIN PARTS COMPOSITION C45WB39A (1) Auto Brake Solenoid(L) (2) Auto Brake Solenoid(R) (3) 4WD Solenoid (4) Quick Ture solenoid (5) Range Shift Relay (6) Auto Brake Relay(R) (7) Auto Brake Relay(L) (8) Quick Ture Relay (9) Drive Selection Switch/ Power Fuse(15A) (10) Range Shift Relay/ Switch only Fuse(10A) (11) Range Shift Relay/ High Speed OFF (12) Range Shift Lever (13) Drive Selection Switch (14) 4WD Lamp (15) QT+AB Lamp (16) QT Lamp (17) Safety Switch(L, R) DC45-W00 Nov-2004

41 ELECTRICAL SYSTEM a. Drive selection switch [Terminal section wiring specification] Connection point Wiring specification AVSS 0.5 R AVSS 0.5 W AVSS 0.5 LW AVSS 0.5 RY AVSS 0.5 Y Function Power input 4WD QT QT+AB A(2WD) B(4WD) C(QT) D(QT+AB) TERMINAL 4 5 b. Solenoid valve - Determination method of normal conditions a. When the 2 terminals connected to each solenoid are measured for resistance using a circuit tester, a measurement of approximately 9~10 is considered normal. b. If the spool moves when DC12V is applied to the 2 terminals it is considered to be normal. c. Even if the spool functions normally, if foreign substances are stuck on it, the hydraulic system must be checked.(refer to hydraulic system) FRONT VIEW 1 POINT CONTACT C45WB40A c. Sub shift lever switch The picture below is for D400, D450P use, and the D450 cabin type is like the safety switch left, right) in appearance but the switch type is opposite.(normally- Closed Type) This switch is a Normally-Closed Type and the two terminal are usually stuck together so it is always on, but when the switch is activated the connection between the 2 terminals are cut, thus it is turned off. If the sub shift lever is left on high speed, the switch is activated and the connection between the 2 terminals is cut. If the switch does not activate (turned off) on high speed, a diversion adjustment must be made. 1.3mm ON OFF If the quick turn is activated on high speed, there are safety risks so extra caution must be taken. C45WB41A d. Left, right safety switch (Normally-Open Type) The 2 terminals of this switch are normally separated and are switched on by external activation. If the switch does not activate, the quick turn & auto brake functions will not work even if you steer the front wheel and turn it past the fixed angle, so to operate it normally diversion control must be performed. 3mm OFF ON C45WB42A DC45-W00 Nov

42 CHAPTER 11 DK45S(DK451) 8.3 REPAIRS FOR QUICK TURN MAL- FUNCTIONS A. STANDARD INSPECTION METHOD When repairs are being carried out on the electric system, first check the fuse and then conduct an inspection by sight. After checking the wiring terminal for assembly error, shift in the terminal, missing terminals etc. check the circuit system. Check that each switch has been adjusted well for diversion, and then check the activation of the sub shift switch & safety switch in the case where the sub shift lever is shifted and when the front axle is turning. Next, when the relay types are checked, refer to the name plate of the relay box to determine the position, then check that each relay operate well when the related switch is activated. With the diode test, if the + terminal of the circuit tester and the diode + is connected in the forward direction the reading is about 0 ~ and the opposite tester + terminal and diode terminal are connected the reading should be in the normal state. Lastly, the solenoid types are tested by resistance measurement of the solenoid unit coil or by checking activation by directly applying DC voltage. - If there is nothing wrong with the safety switch, check the 3P diode 3 & 4.(The diodes are located near the ignition motor in the bonnet wiring) with this diode test, if there are no defects in the front terminal of the circuit, measure the voltage of the middle terminal when the front axle is turning; if approximately +12V is measured then it is functioning normally. - Check the quick turn relay. e. Quick turn does not work while the front axle is turning when the drive selection switch is in QT+AB. - c) after checking diode 1,2 in the port if there are no defects d)check the port. f. Auto brake does not work while the front axle is turning when the drive selection switch is in QT+AB. - c)after checking the port, check the auto brake relay in the turning direction. (eg: if the turn direction is left, check the left brake relay) B. MAIN CAUSES FOR EACH MALFUNCTION CASE a. 4WD does not work. - Check the fuse marked 4WD,QT,QT+AB in the fuse box. - If there is nothing wrong with the fuse, check the quick turn relay. b. When the drive selection switch is on QT, 4WD does not work when the front axle does not turn. - After checking the fuse system, check diode 1, and then check the quick turn relay. (diode 1 is located near the drive selection switch wiring) c. 4WD does not work when the drive selection switch is in QT+AB and the front axle is not turning. - After checking the fuse system, check diode 1, 2, and then check the quick turn relay. d. Quick turn does not work when the drive selection switch is in QT and the front axle is turning. - Check the fuse marked 4WD,QT,QT+AB, sub shift relay in the fuse box. - If there is nothing wrong with the fuse, check that the sub shift lever switch is working. - Detach the 2 terminals located in the safety switch in the turning direction from the bonnet wiring. Check that the safety switch turns on when the front axle turns and if it doesn t, adjust the safety switch diversion to make it turn on DC45-W00 Nov-2004