Electiric Basic

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Static Electricity

- -
- -
- - - -
- -
- - - -

+
+
+
+ + +
+ + +
+ +
+

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Dynamic Electricity

-
-
-
-

ELEC-01-02
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Voltage

Voltage is electric potential difference.

High Voltage

Low Voltage

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Voltage
-
-
-
-

-
-
-
-
- -

-
-

Low -

Voltage

High
Voltage

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Current

Current is flow rate of electric charge.

Small Current Big Current

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Current
-

-
-
-
-

-
-

Small -

Current

Big
Current

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Sum of Voltage in a Circuit

+ 10m + (-3)m + (-7)m = 0

- 3m

+ 10m Pump

- 7m

ELEC-01-07
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Sum of Voltage in a Circuit

Sum of voltage in a circuit is zero.

+ 10V + (-7)V + (-3)V = 0.

-7V -3V

10V

10V

ELEC-01-08
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Sum of Current at a Node

+ 10 lpm + (- 3) lpm + (- 7) lpm = 0

m
lp
-7
+10 lpm

-3
lp
m

ELEC-01-09
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Sum of Current at a Node

Sum of current flow to a node is zero.


-7A
+ 10 A + (-3) A + (-7) A = 0

10A

-3A
Node

ELEC-01-10
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DC and AC

DC : Direct Current(e.g. battery power)

Current

0
Time
AC : Alternating Current(e.g. home electric power)

Current

0
Time

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Resistance

Low
Resistance High
Resistance

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Resistance

Big Small
Resistance Resistance

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Ohm's Law

Voltage = Amperage Resistance

V V
V = I R R =
I
I =
R

Unit of Voltage : V (Volt)


Unit of Amperage : A (Ampere)

Unit of Resistance : (Ohm)

EX) Calculate resistance value in this circuit.

I = 6A V 24V
24V R = = = 4
I 6A

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Electric Power

High Voltage
Power Voltage
Low Voltage

Small Current Big Current

Power Current

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Electric Power

Power = Voltage Amperage

V=I R I=V/R
P= I R I P= V V/R

2
V
P = V I 2
P = I R P =
R

Unit of Power : W (Watt)

EX) Calculate power consumed by resistance.

I = 6A P = V I = 24V 6A = 144W
24V

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Parallel Circuit

In parallel circuit, current is divided.

In parallel circuit, voltage is not divided.

Sum of voltage
R1 = 2 in a circuit is zero.
24V + (Vb - Va) = 0
I1 (Va - Vb) = 24V
I=V/R
I1 = (Va - Vb) / R1
a R2 = 4 b = 24 / 2 = 12A
Va Vb I=V/R
I2 I2 = (Va - Vb) / R2
I0 = 24 / 4 = 6A
Sum of current flow
24V At node a to a node is zero.
I0 + (- I1) + (- I2) = 0
I0 = I1 + I2 = 12A + 6A = 18A

ELEC-01-17
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Serial Circuit

In serial circuit, voltage is divided.

In serial circuit, current is not divided. Sum of voltage


in a circuit is zero.
24 + (Vb - Va) + (Vc - Vb) = 0
Va (Va - Vb) = I0 . 2
I0 (Vb - Vc) = I0 . 4
V=I R
R1 = 2 24 - I0 . 2 - I0 . 4 = 0
I0 . 6 = 24
I0 = 4A
24V Vb
(Va - Vb) = I0 . 2
R2 = 4 = 8V

(Vb - Vc) = I0 . 4
= 16V
Vc
(Va - Vc) = 24V = 8V + 16V
ELEC-01-18
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Resistance Measurement (1)

1. Plug in multi-meter terminals to 3. Contact the terminals and set zero ohm
correct position. point (if adjusting screw is installed).
mA V.Hz.

20A COM
0
2. Set multi-meter to the lowest 4. Disconnect component from circuit.
resistance range.
DC AC
V V
20 200 20020
mA 200m 200m mA
2 2
200 200
20A 20A
20M 200
2M 20
KHz
200K o
C
20K 2000p
2K TEMP
200 20 200n
OHM Farad
ELEC-02-01
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Resistance Measurement (2)

5. Contact the terminals to measuring points.


Do not touch the terminals or measuring points with finger or any conductive material.

6. If resistance is too large to measure, increase measuring range step by step.


DC AC
V V
20 200 20020
mA 200m 200m mA

1
2 2
200 200
20A 20A
20M 200
2M 20
KHz
200K o
C
20K 2000p
2K TEMP
200 20 200n
OHM Farad
ELEC-02-02
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DC Voltage Measurement (1)

1. Plug in multi-meter terminals to 3. Leave component at connected condition.


correct position.
mA V.Hz.

20A COM

2. Set multi-meter to the highest 4. Check and match polarity of multi-meter


DC voltage range. terminal and component terminal.
DC AC
V V
20 200 20020
mA 200m 200m mA
2 2
200 200
20A 20A
20M 200
2M 20
KHz
200K o
C
20K 2000p
2K TEMP
200 20 200n
OHM Farad
ELEC-02-03
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DC Voltage Measurement (2)

5. Contact the terminals to measuring points.


Do not touch the terminals or measuring points with finger or any conductive material.

6. If voltage is too small to measure, decrease measuring range step by step.


DC AC
V V
20 200 20020
mA 200m 200m mA

0.001
2 2
200 200
20A 20A
20M 200
2M 20
KHz
200K o
C
20K 2000p
2K TEMP
200 20 200n
OHM Farad
ELEC-02-04
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DC Current Measurement (1)

1. Plug in multi-meter terminals to 3. Disconnect one wire to the component.


correct position. (Plug in plus
terminal to Max. current position)
mA V.Hz.

20A COM

4. Check and match polarity of multi-meter


2. Set multi-meter to same current terminal and component terminal.
range.
DC AC
V V
20 200 20020
mA 200m 200m mA
2 2
200 200
20A 20A
20M 200
2M 20
KHz
200K o
C
20K 2000p
2K TEMP
200 20 200n
OHM Farad
ELEC-02-05
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DC Current Measurement (2)

5. Contact the terminals to measuring points.


Do not touch the terminals or measuring points with finger or any conductive material.
Current flow

6. If current is too small to measure, decrease measuring range step by step.


DC AC
V V
20 200 20020
mA V.Hz. mA 200m 200m mA

0.01
2 2
200 200
20A 20A
20A COM 20M 200
2M 20
KHz
200K o
C
20K 2000p
2K TEMP
200 20 200n
OHM Farad
ELEC-02-06
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Battery (1)
1. Battery is an electric power source with constant voltage.

12V 12V
Battery

2. Charging and Discharging Process


e
Discharg
Chemical Energy Electric Energy

Charge
3. Battery Capacity
Unit : AH(Ampere Hour) Discharging limit
(min. allowable voltage)
Fully charged
Output
Current
(A) Battery Capacity
Time(H)
ELEC-03-01
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Battery (2)
4. Structure

Electrolyte
Plus plate

Isolate plate
Min. level line Minus plate

5. Serial and Parallel Connection

12V
12V 100AH
100AH 12V 12V
100AH 100AH

24V
100AH 12V
200AH

ELEC-03-02
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Fuse (Blade Type - 1)

Capacity (A) Voltage check point

10
10A

Color code
Inside View

Fuse(blade type) Color Codes

Amperage rating Color Amperage rating Color


1A Black 10 A Red
3A Violet 15 A Light blue
4A Pink 20 A Yellow
5A Tan 25 A Natural(White)
7.5 A Brown 30 A Light green
ELEC-03-03
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Fuse (Blade Type - 2)

Burned by Overload Burned by Aging

10

Resistance < 1 : Normal

Resistance > 1 : Replace

ELEC-03-04
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Fuse (Slow Blow Fuse)
Current
150%
60A

Normal Fuse

0.25 ~ Time
15 sec.
Amperage
Color Current
rating
400%
20A Light blue

30A Pink Slow Blow Fuse


300%
40A Green

50A Red

60A Yellow 200%

70A Brown
80A Black 100%
100A Blue
120A Chestnut
colored
within 0.5 ~ 5~ more than
100 sec. 4 hrs. Time
1 sec. 15 sec.
ELEC-03-05
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Wire (1)

Conductor
Stripe Color Base Color (Copper wires)

Wiring Color
Y = Yellow Y/W = Yellow/White
GN = Green GN/R = Green/Red
BL = Blue BN/W = Brown/White
GR = Gray BL/W = Blue/White Base Color / Stripe Color
W = White GN/W = Green/White
BN = Brown BL/Y = Blue/Yellow
OR = Orange BL/R = Blue/Red
VO = Violet
P = Pink
SB = Black
ELEC-03-06
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Wire (2)

BL/Y

BL/R
BL/R

GN/Y GN/Y

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Wire (3)

Low Resistance

High Resistance

Low Resistance

High Resistance

2
P(power consumed at wire) = I R
Heat(generated at wire) Power(consumed at wire)

Thick and Short wire can transmit More Current without heating

ELEC-03-08
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Connector (1)

IL01G
1
IL01G

Connector Connector
Number Type
IL01G
2

Connector
Pin Number

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TYPE P MALE HOUSING FEMALE HOUSING TYPE P MALE HOUSING FEMALE HOUSING

Connector (2) 1 1
D 1 2 2 1
KET 2
2 SDL
SER
2 2 1 3
1 1
8
3 8
4
1 5
2 3 3 2
1 2 2 1
12
E
A 4 AMP 6 12
250 070 1 8
SER. 3 4 4 3 SER

1 3 3 1
18
9 18
6 1 9

4 6 6 4 20
1 4 4 1 10 20
1 2 2 1
8
2
5 8 8 5
1 3 3 1
F 1 2 2 1
58-X
7 SER.
4
4 7 7 4
1 4 4 1
B 3 4 4 3
KET 1 2
9 2 1
118
SER.
G
AMP 2
5 9 9 5 ES
1 6 6 1 SER.

1 1
13
1
7 13 13 7

1 2 2 1
H 1 2
2 1
4 KET 2
SWP
C 3 4 4 3 SER.
KET
D/L 1 3 3 1
1 3 3 1
SER
6 3
4 6 6 4 ELEC-03-10
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Connector (3)

Remove Clamp Press Lock and Align Arrows and Push In


Pull out

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Switch

Open : Current does not flow. Close : Current flow.

SW202

SW301 Switch SW301


Number
2 2
Pin
Number 6 SW202 SW904 6

3 3

1 1

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Select Switches

1 68 9 1 7 9 5 9

0 0 0

3 2 10 5 10 1 10

1 5 9 1 7 2 8 9

0 0

3 10 3 4 10

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Start Switch

ACC BR

C R1 R2 B+ pin pin

Switch Circuit

START

ON

OFF
PRE

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Other Switches

Hydraulic Oil Pressure Switch Thermo Switch

Engine Oil Low Pressure Switch Air Cleaner Restriction Switch

45 (N0)
Coolant Temperature Switch (warning) Safety Limit Switch

+5
25 -3(NC)

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Resistor

Ceramic Resistor Resistor Box

ELEC-03-16
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Resistor Application Circuit

4)
Calculate power consumed at the motor for
each switch connection.
6
3) 2
I = V / R, P = I R
1) I = 24 / 6 = 4A
6
2) P = 16 X 6 = 96W
2) I = 24 / 12 = 2A
6 P = 4 X 6 = 24W
1)
3) I = 24 / 18 = 4/3A
P = 16 / 9 X 6 = 10.7W
24V 6
M
4) I = 24 / 24 = 1A

P = 1 X 6 = 6W

ELEC-03-17
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Thermistor

Re
sist
anc rent
e Cur

Temperature

Thermistor Application Circuit Coolant Temperature Sensor (dual)

Temperature
Gauge
24V

ELEC-03-18
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Potentiometer

Vout
Angle

Potentiometer Application Circuit

Vcc
Controller

Vout

Gnd
Gnd Vout Vcc

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Solenoid

S N

A1 A2 A3

P1 P2 Coil
A1 A2 A3

P1 P2

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Relay

87a
30 87

86

85
87
87a

30
86 85

Terminal array

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Motor

N S N S
M
S

N
N

N S N S N S N S

S
S

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Diode

ELEC-03-23
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Diode Check Procedure (1)

1. Plug in multi-meter terminals to 3. Contact the terminals and check zero ohm
ohm measuring position. point. (Check if multi-meter is normal)
mA V.Hz.

20A COM
0
2. Set multi-meter to 20K or similar 4. Disconnect diode from circuit.
ohm range.
DC AC
V V
20 200 20020
mA 200m 200m mA
2 2
200 200
20A 20A
20M 200
2M 20
KHz
200K o
C
20K 2000p
2K TEMP
200 20 200n
OHM Farad
ELEC-03-24
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Diode Check Procedure (1)

5. Contact red terminal to triangle side pin and black terminal to bar side pin.
Check if some kilo ohm value is displayed.
(This value can be different according to measuring condition)

5.6
6. Contact red terminal to bar side pin and black terminal to triangle side pin.
Check if above measurable value is displayed.

1
ELEC-03-25
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Diode Application Circuit (1)

AC AC
Power Power

Power
Voltage
0
Time

Output
Voltage
0
Time ELEC-03-26
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Diode Application Circuit (2)

t=0 t = 0+

R = 0 ohm R = 10 Mohm
P=0W P = 10 MW
I = 1A I = 1A

t = 0+

R = 10 Mohm
I = 1A

P=0W

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Zener Diode

ELEC-03-28
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Transistor

Iout Psig Flow

Isig

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Alternator (1)
3
1 S Vout

N S N S 0
Time

N
1
2
Vout

2 3

N
S

N S N S S N S N

S
N

Vout Vout

ELEC-03-30
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Alternator (2)

B R I
Master
Switch D D1 R1 R3
Stator DS
Coil F
R4
Battery

C B
C B ZD
E T1
E T2
Field Coil
R2 R5

Field coil : Make magnetic field N S


Stator coil : Generate AC current
Diodes : Convert AC current to DC current AC DC

Regulator : Regulate output voltage to constant independent to rpm 24V


ELEC-03-31
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Alternator (3)

Voltage output between neutral point Vout


and the end of stator coil is AC current.
0
Time

Voltage output between B+ terminal


Vout
and E terminal is maximum voltage
difference between stator coils.
Output voltage is rectified by diodes.
0
Time

Voltage regulating procedure


1. High rpm makes high output voltage
2. High output voltage turns on zener
diode and reduce field coil current
3. Output voltage decreases due to
low magnetic field.

ELEC-03-32
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Explanation to Wiring Diagrams 3
2
1 SW301
7 SCH08
4
IS02Z 2 LA301
IS02Z IM04Z
6 48 3,010
6 7 1
LA302
3,020
5 8
48

SCH12
LA303
IS02Z 3 IS02Z 3,030
1 1 2

LA304
48 3,040
48

6 SCH17
IL01Z
4

11 S02797A
9 10
1. 50 Box = feed designation(positive feed : 30, 15, etc.)
2. SW301 SW = switch, 3 = function group, 01 = running number
3. SCH08 Diagram number
4. 3,010 3 = Function group, 010 = Running number
5. 102 102 = Running number of wiring
6. 201 201 = Running number of wiring
7. IM04Z IM04 = Connector number, Z = Connector type
8. 1 1 = Connector pin number
9. SCH17 Connected diagram number
10. 114 Arrow shaped box = connection to another diagram,
114 = Connected line number of the connected diagram
11. 48 Chassis connection number
ELEC-04-01
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Function Group
1 feeds / chassis connection
2 Engine
3 Electrical system, lighting, etc.
4 Power transmission
5 Brake
6 Steering
7 miscellaneous
8 Cab
9 Hydraulic

Wiring Color
Y = Yellow Y/W = Yellow/White
GN = Green GN/R = Green/Red
BL = Blue BN/W = Brown/White
GR = Gray BL/W = Blue/White
W = White GN/W = Green/White
BN = Brown BL/Y = Blue/Yellow
OR = Orange BL/R = Blue/Red
VO = Violet
P = Pink
SB = Black
ELEC-04-02
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Engine Stop Motor Operation
ACC C

B
R2 BR
R1

3
5
1

4 2

OFF -> ON

ACC C

B
R2 BR
R1

3
5
1

4 2

ON -> OFF
ELEC-04-03
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Control Circuit

Engine
Speed Flow Flow

21
Check Socket Engine Control Control Control
114
Rotator (Excaliever Connector) Engine Coolant Speed Switch Switch Valve

From Key Switch


"ACC" Terminal
Switch RH Temp. Sensor Sensor
o
C
Display Unit 1 2 3 4

Rotator
Sol. RH

D11

D10
Rotator

B11
B12
B13
A1 A2 A3 A4 A5 A7 B3 B4 B1 B2 B16 B17 C8

D9
Sol. LH

C1
V-ECU
C10

C12
D16
D18
B18

B14
B15
C9

Rotator D17 D14 D12 D13 D15 D2 D1 B5 B6 B7 D4 D3 C6 C2 C7


Switch LH
Aux.
Battery
Travel Pilot Pressure Relay
Switch Throttle
Position
Sensor
Attachment Pilot
Pressure Switch Auto/Manual
M Switch

Hammer Pilot Power Shift


Pressure Switch Valve
Stepping Motor
Resistor
658 Box
To Battery Relay
90
Travel Speed To Cluster
Select Switch Indicator
Hammer/Boost
Power Select Switch
Travel Boost Auto Idle Power Max.
Boom Arm
Speed Select Mode Select Hammer
Conflux Conflux
Cut-off Cut-off Switch Switch

ELEC-04-04
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Quick Fit Circuit

RE22 1
RE21 1 5
IS02-W IS03-W 5 BL/SB
R/Y R/Y 607
601 12 601B 1
4 2 SB GN 4 2 SB
606 98B
98A
SW907
SW906 IS03-W IS02-W SB IM02-W
052 48
1 R/GN GN IS03-W GN 4 8 8
1 R/SB 3
R/Y 3 603 606 3 609
601 602
4
R/Y 4 8 W/BL IS03-W R/GN IS02-W IM02-W MA22-Z MA22-Z
8 BL/Y 603 31
601A 605 2 14 12 2 1
604
MA908

IC01-W
I-ECU

14
LC28
CA01-S
B20
20

ELEC-04-05
V1 - 61
Engine Start / Stop Circuit
R Room Lamp
30 30
30 R Hand Lamp
Fuel Filler
2
Pump R
50 Main Power Supply
50 for Fuse Box
FU53
FU50 FU51 80A
FU52 FU19 FU16
80A 30A 30A
R R INSTRUMENT PANEL

2A
R
R
1
R
9
W SB
10 06
RE01
R
8 Y
RE02 12
SB

MO201 To Controller
(For Safety Stop Function)

R/W
3
RW
R

3
700
700
SW102 R/SB
7 D101
11

W/SB R/W
R

658
660 658

17
SB

R
02

R/SB From Aux. Battery Relay


36 (Safety Stop Function

18
D102

R
5
16
Y
SB

Y
12
Y/BN
21A

RE03
W
35
MA201

w SB
SB

SB
03

079
SB
36A 088A
Y/SB
21
060

21
SB

088
SB
To Preheating Controller

ELEC-04-06
V1 - 62
Various Connections

Which lamp(s) will light?


Lamp resistance is 5 ohm and resistor resistance is 5 ohm.

x x x x x
A B C D E
5A
y y y y y

x
x x
F G H
24V

y y
y

ELEC-05-01
V1 - 63
Various Connections

x x x x x
A B C D E
5A
y y y y y

x
x x
F G H
24V
y y
y

Lamp Condition Remark Vx Vy


A No Both line connected to power. 24 24
B Yes(bright) Normal condition 24 0
C No No ground connection 24 24
D Yes(dim) Bad ground connection 24 12
E No No ground connection 24 24
F Yes(dim) Bad power connection 12 0
G No No power connection 0 0
H No Fuse burn. 0 0
ELEC-05-02
V1 - 64
Bad Connection

ELEC-05-03
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Starting Engine with Boost Cables

Check Before Connection


A
- Same battery capacity
- Both machine key off 2 1
- Cables and clips
3
Connecting Procedure
1. Clip 1 to + terminal of to be boosted
2. Clip 2 to + terminal of fully charged
3. Clip 3 to - terminal of fully charged B 4
4. Clip 4 to upper structure of to be boosted

Start the engine with fully charged battery.


Start the engine of to be boosted. A
3 4
Disconnect cables inverse way of
connecting procedure.
2

B 1

ELEC-05-04
V1 - 66
When Welding

ALWAYS turn the master switch OFF or remove the lead from the battery negative(-)
terminal.

ELEC-05-05
V1 - 67

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