Estructura y Funcin

Sistema Elctrico

E. Velsquez Slide 1 KT403306

WA380-6 Electronics System

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WA380-6 Electronics Overview

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Slow Blow Fuses

Fuse for ribbon intake air heater

Fuse for permanent power supply

Fuse for main power supply Battery relay

Preheating relay R11

Emergency steering pump motor relay

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Starter Motor and Safety Relay

Starter motor 24 Volt, 5,5 kW

Safety relay

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Engine Control Module ECM

The ECM is mounted on the engine on a cooler plate.

NOTE: There is NO fuel flow through the plate on the WA380-6

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Hydraulic Oil Temperature Sensor

The hydraulic oil temperature sensor R47 is mounted inside the right front of the rear frame

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Relays, Fuses and Controllers

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Behind the Operator Seat

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Under the Operator Seat

Diodes under the operator seat frame

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Accelerator Pedal

Electric accelerator pedal with potentiometer and idle validation switch

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Centralized Connectors under the Cabin

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WA380/480-6
How to read the new electrical diagrams

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Electrical Diagram Information

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Schematic Information
Wire color code legend

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Failure code [b@CENS] (Torque converter oil: Overheating)

Starting with a failure code 1. 2. Check causes Two different connectors are used, on one we need to measure resistance on the other we will measure voltage KT403306

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Connector Locator

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Circuit diagram for T/C oil temperature sensor

Pin 2

Between pin 1 & 2

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Starting Switch Circuit

New symbol for key switch

Switch terminals B, BR, R1, ACC are all connected when pre-heat is used
Switch terminals B, BR, and ACC are all connected when the switch is in the on position Switch terminals B, BR, R2, C, and ACC are all connected when the switch is held in the start position

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Starting Switch Circuit

New symbol for key switch Wire for C terminal is circuit 105, wire size 1.25, fg = flexible wire with GREEN insulation Is connected to pin 3 of male half of connector S40 which is a DT type connector from the female half of S40 wire number 105 goes to pin 12 of connector J07

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Starting Switch Circuit

New key switch circuit Connector J07 is a M type connector Pin 12 is also common with pins 11 and 13 Circuit 105 now becomes circuits 105 A and 105B Circuit 105B goes to connector TEL pin 7

Circuit 105A goes to connector L44 pin 4

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Starting Switch Circuit

Wire 105A comes from pin 11 of connector J07 this wire changed color at connector J04 to white with a blue stripe Wire 105A for this application is terminated at connector L44

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Starting Switch Circuit

Wire 105B from connector J07 13 to TEL pin 7 this wire color was unchanged Connector TEL pin 7 female side is now circuit 105 AB Wire 105 AB goes to connector L80 pin 27 and connector W60 pin 3

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Starting Switch Circuit

Circuit number on W60 has changed 105AB to 105AA This wire comes from connector L80 pin 27 A second wire on 105AA comes from TEL pin 7

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Electrical Circuit of Hydraulic Oil Temperature Sensor

QUIZ

Find the hydraulic oil temperature sensor R47. The signal line on pin 1 is connected to pin 41 on the next connector FL1. The ground line on pin 2 is connected through the remaining pins to ground.

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Electrical Circuit of Hydraulic Oil Temperature Sensor

On the FL1 connecter you will find pin 41 and the connecter name R47 of the hydraulic oil temperature sensor. Now find the opposite part of FL1 connector in the schematics.

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Electrical Circuit of Hydraulic Oil Temperature Sensor

The opposite part of FL1 connector provides the following information: Connecter L55 is the next connector you you have to look for in the schematic. The hydraulic oil temperature will be inputted on pin number 7 of the next connector.

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Electrical Circuit of Hydraulic Oil Temperature Sensor

Monitor Panel Controller

The line arrives at connecter L55 on the monitor panel.

The line comes from connector FL1 pin 41, which was the last connector in this case. The hydraulic oil temperature signal is an input on pin 7 of the main monitor.

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CONNECTOR LOCATOR CHART

Connector Locator Chart

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Connector Locator

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Connector Locator

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Connector Locator

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Connector Locator

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Connector Locator

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Connector Locator

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Connector Locator

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Connector Locator

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WA380/480-6 Monitor System

Machine Monitors

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WA380/480-6 Monitor System

In the machine monitor system: Each controller on the network monitors and controls the machine condition with the sensors and switches installed in various systems on the machine These controllers then send their acquired information as network information to the machine monitor The machine monitor displays this information to notify the operator of the machine condition. The machine monitor can displays this information in either the operator mode or service mode.

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WA380/480-6 Monitor System

Operator Mode

The operator mode is used to display the normal information to the operator. The major functions used in the operator mode are as follows.
Items always displayed 1. Meters (Speedometer or engine tachometer) 2. Gauges (Engine coolant temperature gauge, torque converter oil temperature gauge, hydraulic oil temperature gauge, and fuel level gauge) 3. Pilot indicators 4. Service meter The following items are displayed according to the set state of the optional device selecting function. 1. Travel speed or engine speed indication on the character display
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WA380/480-6 Monitor System

Items displayed when a abnormality is detected 1. Caution lamps 2. Action code (While an action code is displayed, press the monitor panel mode selector switch (>) To display the failure code (6 digits).))

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WA380/480-6 Monitor System

At service interval time for filters or oil changes The character display displays that filter or oil change information. (Maintenance monitoring function)

Also: the following display, setting and adjustment functions are provided by using the character display and the machine monitor mode selector switch 1) Display the odometer 2) Reset maintenance interval time 3) Input a telephone number 4) Select your language 5) Adjust machine monitor brightness 6) Travel speed/engine speed display selecting function 7) Function for setting display/no-display of travel speed or engine speed to the character display
See shop manual SEN01229-0 page 6

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WA380/480-6 Monitor System

Service Mode
The service mode function is provided to aid in successful troubleshooting of all monitored parameters for each controller on the network (including the machine monitor itself). The major functions used in the service mode are as follows. 1. Electrical system failure history display function 2. Mechanical system failure history display function 3. Real-time monitoring function: The input and output signals recognized by each controller on the network are displayed in real time. 4. Engine reduced-cylinder function 5. No injection cranking function 6. Adjustment function: functions are provided to correct/adjust installation errors, manufacturing dispersion of the sensors, solenoid valves, etc. 7. Maintenance monitoring function: to changes filter or oil service intervals, also can switch the maintenance function on or off
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WA380/480-6 Monitor System

8. Operating information display function: Displays fuel consumption per operating hour. 9. Optional device selecting function: Verifies the installation of optional devices or changes their setting. 10Machine serial number input function: Enters the machine serial number to identify the machine. 11. Model selection function: Enter the information of applicable model. 12. Initialize function: This function is used to set the machine monitor to the state set when the machine is delivered.

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WA380/480-6 Monitor System

Items displayed on monitor Condition for judging that engine is running: When either one or both of following items 1 and 2 is or are sensed, the machine monitor judges that the engine is running. 1. The engine speed is above 500 rpm. 2. There is alternator voltage R and there is terminal C input after the starting switch is turned ON. O: ON : Flashing (1.6 sec., 50% duty) : : Intermittent (Period: 240 msec., ON: 80 msec., OFF: 160 msec.) : As per separate setting condition Priority of sounding of buzzer: Continual (w) > Intermittent (A) > Cancellation of operation > Check of acceptance of operation.

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WA380/480-6 Monitor System - MONITOR INFORMATION

See shop manual SEN00886-00 page 8

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WA380/480-6 Monitor System

To move from operator mode to service mode; press and hold the left arrow key and the box key for 5 seconds, release these keys when the monitor information screen changes. You will be prompted to enter your password

With key switch off press

to view service meter

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WA380/480-6 Monitor System

Failure code screen (1st layer) 1. Pressing the > switch when the Warning screen is on display changes display to the Failure code screen. 2. If multiple failure codes are present, each pressing of the > switch displays them from the item of higher priority downward. If items have the same priority, the item that occurred most recently will be displayed first. Note: there are 3 simultaneously occurring failure codes. 1. from the transmission controller 2. from the engine controller 3. from the monitor
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WA380/480-6 Monitor System

Functions available to the operator (2nd layer or below) Pressing switch enables to select each menu. See the Operation and maintenance manual for details of each menu.

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WA380/480-6 Monitor System

Procedure for switching to Service Mode 1. Check that the character display is set to the 1st layer screen in the operator mode. 2. Display of ID input initial screen Pressing switch and < switch simultaneously for 5 seconds or more, the ID entry initial screen appears. 3. ID input and confirmation: Operate the machine monitor mode selector switches < and > and enter ID. (ID: 6491)

Pressing the < > keys changes the value of this digit in the range of 0 to 9 one number at a time. Pressing the key will accept the integer that you entered. If you have entered an incorrect integer pressing the will take you back one step.

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WA380/480-6 Monitor System

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WA380/480-6 Transmission Control System

See shop manual SEN00887-00 page 3-7 to review auto shift logic WA380-6

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WA380/480-6 Transmission Control System

1. Shift hold function: maintains the gear speed chosen when the auto shift mode is used. 2. Hold function does not allow shifting up or down as the travel speed is changed (up/down). 3. Pressing the hold switch again resets the shift hold function and turns off the pilot lamp. 4. The shift hold function is automatically reset when the directional lever, gear shift lever or kick-down switch is operated. 5. The torque converter lockup is turned off. Kick-down function 1. In manual-shift mode When the directional lever is set to F and the gear shift lever to 2nd, pressing the kick-down switch changes the gear speed to 1st. 2. The kick-down signal is ignored in either R or N or in any gear other than 2nd 3. Kick-down is reset when the directional lever is operated or the gear shift lever is set to any position other than 2nd.
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WA380/480-6 Transmission Control System

Kick- down function In auto-shift mode 1. The kick-down function is enabled when the directional lever is set to a position other than N (Neutral) and the gear shift lever is set to a position other than the 1st position. 2. The kick-down function is reset when the directional lever is operated after the actual gear speed is changed or the noshift time for hunting prevention elapses. 3. After the reset, the auto shift based on Auto-shift points table is turned on. When forward 1st is selected 1. When E-mode is selected for the power mode and the gear speed is set to forward 1st, pressing the kick-down switch changes the power mode to Pmode. 2. The power mode switching function is enabled, independent of the auto or manual shift, only when forward1st is selected and it is reset as any actual gear speed other than 1st is selected.
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WA380/480-6 Transmission Control System

Function of hunting prevention 1. The transmission controller detects and prevents hunting that can result from shifting the gear from 2nd to 3rd and 3rd to 2nd in the auto shift mode. Transmission initial learning and ECMV current adjustment 1. Adjusting the Transmission initial learning setting and Transmission ECMV current adjustment items by use of the adjustment function of the machine monitor allows correcting variations of the transmission itself as well as ECMV. 2. Ignoring above adjustment can lead to generation of gear shifting shocks or time lag. Changing shift points 1. The transmission controller has the function of adjusting the gear shift points of L-mode in auto-shift. 2. When hunting is induced by some conditions unique to a worksite, adjust the shift up and down travel speeds by adjusting the Adjustment of transmission Lmode shift point item by use of the adjustment function of the machine monitor.

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WA380/480-6 Transmission Control System

4th gear lockout function 1. Restriction of operation in 4th gear speed becomes available by selecting ADD for 23. FORBID 4TH item using the optional device selecting function of the machine monitor.

Transmission controller will protect the transmission when an on authorized directional shift is selected 1. When the directional lever is operated during high-speed travel (3rd/4th), engagement of the speed clutch is controlled to protect the transmission.

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WA380/480-6 Transmission Control System

Shift down protection 1. In order to protect the engine and pumps, the transmission controller rejects a downshift command when travel speed is to great 2. The alarm buzzer is sounded as long as the shift down protection function is turned on. 3. The buzzer sounds are continued until the gear speed position of the gear shift lever coincides with the actual gear speed. Thus, shifting up operation can stop the alarm buzzer sounds even if the travel speed is not slowed down. 4. The shift down protection rejects the kick-down signal when the travel speed is to great. 5. If the kick-down switch is pressed while the machine is traveling to fast the alarm buzzer will be sounded for 3 seconds.

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WA380/480-6 Transmission Control System

Engine overrun prevention 1. When the transmission output shaft speed reaches a level that corresponds to an engine RPM of 2,500 rpm or greater, the lockup clutch is disengaged automatically in order to prevent the engine overrun. 2. The alarm buzzer is sounded as long as the engine overrun prevention function is turned on. 3. The unlock state is maintained for 5 seconds after it has been determined that the engine speed is less than 2,500 RPM. 4. Lockup will than be applied again.

Maximum travel speed de-rate function 1. As transmission output shaft speed reached a level corresponding to a travel speed of 40 km/h or above, this function resets the lockup for safety. 2. The alarm buzzer is sounded as long as the maximum travel speed de-rate function is turned on. 3. When the lockup clutch is not installed on the machine, alarm buzzer alone will be sounded.

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WA380/480-6 Monitor System

Transmission cut-off function 1. The transmission cut-off oil pressure sensor detects the brake pilot pressure when either brake pedal is pressed and sets the transmission to neutral. 2. This function will work at any brake pedal position, by saving the brake pressure at any brake pedal angle into the transmission controller memory.
Transmission cut-off control Outline As the transmission cut-off operating conditions are met, the transmission is set to neutral. As the transmission cut-off reset conditions are met, the transmission is released and the transmission gear speed is controlled by the modulation. Operating conditions in 1st and 2nd gear speeds Cut-off switch is turned ON and the brake pilot oil pressure became larger than the cut-off IN pressure. Operating conditions at 3rd and 4th gear speeds Cut-off switch is turned ON and brake pilot oil pressure is larger than the cut-off IN pressure and the accelerator pedal is less than 30% When any of the following is met, cut-off is reset. The transmission cut-off switch is turned OFF. The brake pilot oil pressure is below the cut-off OUT pressure.

See shop manual SEN0887-00 page 26 for setting instructions

Operating condition

Reset condition

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WA380/480-6 Engine Control System

Engine Control Function

Power mode selecting function 1. Setting the power mode selector switch to P-mode sends the P-mode torque curve information to the engine controller. At the same time, the power mode pilot lamp is turned on.
Engine stall prevention control 1. When engine speed is at low idle, switching travel direction during high-speed travel can cause the engine to stall. 2. To prevent engine stall, a specified throttle (accelerator pedal) lower limit position signal is sent to the engine controller as the travel direction is switched. 3. When the direction was changed from reverse to forward, this function sends as much as approximately 25% of the specified throttle lower limit position values to the engine controller. 4. In the case of forward to reverse, as much as approximately 15% of the values are sent. This communication lasts for 2 seconds after the directional selection is completed.
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WA380/480-6 Engine Control System

Cooling Fan Control Function

1. Transmission controller 2. Machine monitor 3. Engine controller 4. Cooling fan pump 4a. Swash plate angle control EPC valve 5. Cooling fan motor 5a. Cooling fan reverse rotation solenoid valve 6. Cooling fan reverse rotation switch

7. Machine monitor mode selector switch 1 8. Machine monitor mode selector switch 2 9. Hydraulic oil temperature sensor 10. Torque converter oil temperature sensor 11. Coolant temperature sensor 12. Engine speed sensor 13. Engine 14. Radiator

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WA380/480-6 Engine Control System

Engine speed, coolant temperature, torque converter, and hydraulic oil temperature received by the machine monitor are sent to the transmission controller via the network. 1. Based on the received information, the transmission controller sends current to the EPC valve on the cooling fan pump to control the pump swash plate angle to set fan speed to the desired speed Pump protection function 1. To prevent cooling fan motor overrun, fan pump swash plate angle is set to minimal when engine speed reached 2,300 rpm or above. 2. If the transmission controller fails to recognize engine speed and temperature data because of communication error, this function sends (677mA) to the EPC valve on the pump 3. Now the pump will work as a fixed displacement pump.

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WA380/480-6 Hydraulic Control

Hydraulic Pump Control

Work Equipment Pump Swash Plate Control Function Comparing results of calculations done on respective functions, this function selects the data that makes the work equipment pump delivery smaller (the data that sets a larger value for the command current to the swash plate angle control EPC valve). Engine stall prevention control at low idle 1. Engine stall can result from a radical increase in load at low idle. 2. To prevent this problem, this function restricts the pump delivery at high pressure by controlling the pump swash plate angle through EPC.

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WA380/480-6 Hydraulic Control

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WA380/480-6 Hydraulic Control

Pickup auxiliary function when engine speed is low 1. Using compound hydraulic operations and steering at a low engine speed can cause poor engine acceleration because the hydraulic HP. Demand becomes larger than engine capability. 2. This function is installed to help improve the engine acceleration performance. 3. As the accelerator pedal is pressed from a low engine speed, this function sends the command current corresponding to the steering oil pressure to the main pump EPC valve in order to alleviate the load by controlling the pump swash plate.

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Electrical System

Electrical System

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WA380/480-6 Engine Start Circuit

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WA380/480-6 Engine Stop Circuit

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WA380/480-6 Parking Brake System

1. Parking brake relay 2. Parking brake switch 3. Brake oil pressure caution relay 4. Rear brake oil pressure switch 5. Emergency brake oil pressure switch 6. Parking brake solenoid valve 7. Transmission controller 8. Machine monitor

When starting switch is turned OFF 1. Turning the starting switch OFF opens brake relay (1). Stopping current flow to the parking brake circuit, applies the parking brake. 2. Accordingly, when the starting switch is turned OFF, current is not conducted to parking brake solenoid valve (6) regardless of the position of parking brake switch (2). And the parking brake remains applied.

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WA380/480-6 Parking Brake System

When PB switch (2) is ON (applied), battery current flows through PB switch (2), to parking brake relay (1) and closes the contact. With PB relay (1) closed, battery current holds the contact closed until current from the battery relay is cut off.

Current does not flow to parking brake solenoid valve (6). The parking brake is applied. Transmission controller (7) responds to PB switch (2) signal and sets the transmission to N as long as the parking brake is applied. When PB switch (2) is OFF (released) current from the battery goes from PB relay (1), to parking brake switch (2), to emergency brake oil pressure switch (5) to parking brake solenoid valve (6) and release the parking brake.

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WA380/480-6 Parking Brake System

When parking brake switch was turned OFF (released) before turning the starting switch ON While the parking brake switch (2) is OFF (released), current does not flow to parking brake relay (1) and its contacts remain open. Turning ON the starting switch in this case does not conduct current to parking brake solenoid valve (6). Accordingly, the parking brake is not released

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WA380/480-6 Parking Brake System

When low brake oil pressure is sensed

If brake oil pressure gets low, rear brake oil pressure switch (4) opens, cutting off current to caution relay (3). Brake oil pressure caution relay (3) opens, cutting off current to machine monitor (8). As the result, machine monitor generates the alarm. Brake oil pressure switch (5) opens (the operating pressure setting of which is lower than that of rear brake oil pressure switch (4) stopping current flow to brake solenoid valve (6). As the result, the parking brake is applied. Slide 72 KT403306 In this case, (unlike when the parking brake switch was turned ON (applied)), current flow from parking brake switch (2) to the transmission controller (7) is maintained. Thus, transmission is not set to the neutral.

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End of Electrical System

Section 2_6

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