4-6193136 Elsystem SL GB [PDF]
4 Electrical system Technical Manual, Publ. no. 6193.136 1305, Version 02 CONTENTS SAFETY PRECAUTIONS .................
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4 Electrical system Technical Manual, Publ. no. 6193.136 1305, Version 02
CONTENTS SAFETY PRECAUTIONS ....................................................................................... 4-5 General ...................................................................................................................... 4-5 Precautions when carrying out electric welding .......................................................... 4-5 Precautions when jump starting ................................................................................. 4-5 COMMON ELECTRICAL SYSTEMS .................................................................... 4-6 The structure of the wiring diagrams ......................................................................... 4-6 Cable numbering ....................................................................................................... 4-6 Fuses .......................................................................................................................... 4-6 Fuses under the instrument panel. ...................................................................... 4-7 Fuses in the battery compartment ...................................................................... 4-9 Relay list .................................................................................................................. 4-10 Location of control units ......................................................................................... 4-11 CAN bus with IQAN-MD3 and MDL2 .......................................................... 4-11 Location of connectors ............................................................................................ 4-12 WIRING DIAGRAMS ........................................................................................... 4-14 Power supply ........................................................................................................... 4-14 MD3 ................................................................................................................ 4-14 MDL2 .............................................................................................................. 4-16 Start and Stop Engine .............................................................................................. 4-18 Scania DC9/DC12 ........................................................................................... 4-18 Volvo TAD 620/722 MD3 .............................................................................. 4-20 Volvo TDA 660/760 ........................................................................................ 4-22 Volvo TWD 1240/1250/TAD 1340 ................................................................ 4-24 Cummins QSB 6.7 ........................................................................................... 4-26 Cummins QSM 11 ........................................................................................... 4-28 Scania DC1377A (step 3b) ............................................................................... 4-30 Volvo TAD 562/762/1360VE (step 3b) ........................................................... 4-32 Road light ................................................................................................................ 4-34 MD3 - DANA .................................................................................................. 4-34 MDL2 - DANA ................................................................................................ 4-36 MD3 - ZF ....................................................................................................... 4-38 MDL2 - ZF ...................................................................................................... 4-40 MD3 - DANA - Turn drive seat ...................................................................... 4-42 MDL2 - DANA - Turn drive seat .................................................................... 4-44 MD3 - ZF - Turn drive seat ............................................................................ 4-46 MDL2 - ZF - Turn drive seat .......................................................................... 4-48 Side maker light ....................................................................................................... 4-50 MD3 - DANA .................................................................................................. 4-50 MDL2 - DANA ............................................................................................... 4-52 MD3 - ZF ....................................................................................................... 4-54 MDL2 - ZF ...................................................................................................... 4-56 MD3 - DANA - Turn drive seat ....................................................................... 4-58 MDL2 - DANA - Turn drive seat ..................................................................... 4-60 MD3 - ZF - Turn drive seat ............................................................................. 4-62 MDL2 - ZF - Turn drive seat ........................................................................... 4-64 Work light ............................................................................................................... 4-66 MDL3/MDL2 .................................................................................................. 4-66 MD3/MDL2 - Turn drive seat ......................................................................... 4-68 Windscreen wipers .................................................................................................. 4-70 MD3/MD2 - DANA ........................................................................................ 4-70
Technical Manual, Publ. no. 6193.136 1305, Version 02
Electrical system
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MD3/MDL2 - ZF ............................................................................................ 4-72 Windscreen washer .................................................................................................. 4-74 MD3/MDL2 - DANA ...................................................................................... 4-74 MD3/MDL2 - ZF ............................................................................................ 4-76 HVAC (Heat Control Harness) ............................................................................... 4-78 Beacon,dome light,horn and lubrication .................................................................. 4-80 DANA .............................................................................................................. 4-80 ZF .................................................................................................................... 4-82 Radio,12v and 24v outlet ........................................................................................ 4-84 Governor Control .................................................................................................... 4-86 MD3 ................................................................................................................ 4-86 MDL2 .............................................................................................................. 4-88 Transmission Control 1 ........................................................................................... 4-90 MD3 - DANA .................................................................................................. 4-90 MDL2 - DANA ................................................................................................ 4-92 MD3 - ZF ........................................................................................................ 4-94 MDL2 - ZF ...................................................................................................... 4-96 Brakes ...................................................................................................................... 4-98 MD3 - DANA .................................................................................................. 4-98 MDL2 - DANA .............................................................................................. 4-100 MD3 - ZF ...................................................................................................... 4-102 MDL2 - ZF .................................................................................................... 4-104 Surveillance and IQAN alarm ................................................................................ 4-106 MD3 .............................................................................................................. 4-106 MDL2 ............................................................................................................ 4-108 CAN-BUS ............................................................................................................. 4-110 MD3 .............................................................................................................. 4-110 MDL2 ............................................................................................................ 4-112 Reserve Wires ........................................................................................................ 4-114 Mini-Wheel/Joystick Steering ................................................................................ 4-116 Mast ...................................................................................................................... 4-118 Proportional ................................................................................................... 4-118 On/Off ........................................................................................................... 4-120 Turn Drive Seat Position ....................................................................................... 4-122 Master Clamp unit ................................................................................................ 4-124 Transmission control 2 .......................................................................................... 4-126 DANA TE17 .................................................................................................. 4-126 DANA TE17 FF ............................................................................................. 4-128 DANA TE27-32 FF ....................................................................................... 4-130 ZF 3WG-191 ................................................................................................. 4-132 ZF 4WG-261/311 .......................................................................................... 4-134 Transmission control 3 .......................................................................................... 4-136 DANA TE17 .................................................................................................. 4-136 DANA TE17 FF ............................................................................................. 4-138 DANA TE 27-32 FF ...................................................................................... 4-140 Attachment ............................................................................................................ 4-142 ECB 584/585/586/587/588 ........................................................................... 4-142 ECB 584/585/586/587/588 elec.hyd. ............................................................. 4-144 Gantry 818 ..................................................................................................... 4-146 ECB 588TB 1/2 ............................................................................................. 4-148 ECB 588TB 2/2 ............................................................................................. 4-150 ECB 584-LD .................................................................................................. 4-152 ECB 584-LD elec.hyd. ................................................................................... 4-154 Attchment david brown ......................................................................................... 4-156 Seat buzzer and Grammer ...................................................................................... 4-158 Heater control panel .............................................................................................. 4-160 STD. .............................................................................................................. 4-160
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Electrical system
Technical Manual, Publ. no. 6193.136 1305, Version 02
AC .................................................................................................................. 4-162 ECCl .............................................................................................................. 4-164 Electrical oil cooler fan .......................................................................................... 4-166 REPLACING CONNECTORS ........................................................................... 4-168 Deutsch connectors ............................................................................................... 4-168 AMP connectors .................................................................................................... 4-170 Calibrating the TE transmission with the APC200 ................................................ 4-171
Technical Manual, Publ. no. 6193.136 1305, Version 02
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4-4
Electrical system
Technical Manual, Publ. no. 6193.136 1305, Version 02
Safety precautions SAFETY PRECAUTIONS GENERAL Maintenance may only be performed by trained personnel or by authorised Konecranes Lifttrucks dealers according to a service contract. If you wish to undertake the maintenance of the machine yourself, we recommend that the first three customer service inspections be carried out in the presence of authorised personnel from Konecranes Lifttrucks who can check that the maintenance instructions are adhered to. PRECAUTIONS WHEN CARRYING OUT ELECTRIC WELDING TAKE CARE It is important that these instructions are adhered to when carrying out electrical welding on the machine, otherwise serious damage can occur. Disconnect the battery cables and all control units. 1. Remove the cables for the batteries and the alternator. 2. Important!Disconnect all control units in and on the machine. 3. Connect the weld clamp to the component that is to be welded and close to the area of the weld, never to the engine or so that the current could run through a bearing. When welding is finished, reconnect the cables to the alternator and the control units before reconnecting the batteries. PRECAUTIONS WHEN JUMP STARTING TAKE CARE Jump-starting the engine using a quick-charger, booster, power pack etc., is prohibited. This can cause a power surge and serious damage to the control units. 1. Connect the first cable from the positive pole on the starter battery to the positive pole on the starter motor. 2. Then connect the other cable from the negative pole on the starter battery to the chassis of the machine, e.g. to the starter motor mounting bolts or a frame member close to the starter motor. 3. When the engine has started: remove the cables in reverse order.
Technical Manual, Publ. no. 6193.136 1305, Version 02
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Common electrical systems COMMON ELECTRICAL SYSTEMS THE STRUCTURE OF THE WIRING DIAGRAMS The structure of the wiring diagrams aims to facilitate fault-tracing and service. The different wiring diagrams are divided into circuits with working lights on its own, and heating and ventilation separate etc. This means that when fault-tracing one need only use the wiring diagram that applies to the relevant circuit. Only in a few exceptional cases need one switch to another wiring diagram. If this is necessary there is a grid around the wiring diagram to indicate the correct position. The grid has letters vertically and figures horizontally. CABLE NUMBERING Table 1: Cable function groups Function group number
Function group
01 02 03 04 05 06 07 08 09 10 11 19
Power supply Engine Service lights Working lights Windscreen wipers Heating/AC system Cab Transmission control Control (electrical) Machine control systems Mast Unit
Numbering the cables aims to facilitate fault-tracing and service. The five digit cable number is based on the function group to which it belongs. The two first digits indicate the function group and the three last are a serial number within the function group. Each time the cable connects to an active component the three last digits in the cable number change.
WARNING The battery disconnector switch cuts the power from the battery to all electrical functions. However, in some customised machines not all functions are isolated by the battery disconnector switch and may be live.
FUSES The fuses are located on the left under the instrument panel and in the battery box on the right-hand side of the machine.
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Technical Manual, Publ. no. 6193.136 1305, Version 02
Common electrical systems Fuses under the instrument panel. The fuses are located under the instrument panel. They are numbered 1 (top left) to 40 (bottom right). Italics = optional extra.
Technical Manual, Publ. no. 6193.136 1305, Version 02
Fuse no.
Ratedc urrent
F1
10 A
Engine, charge indicator lamp, alternator, working lights control
F2
7.5 A
Brake lights, side marker lights, interior lighting, and illumination in switches
F3
15 A
Climate control unit
F4
5A
Fuel cock, lubrication pump and seat buzzer
F5
7.5 A
Condenser fan
F6
7.5 A
Service lights and main beam
F7
7.5 A
Service lights and dipped beam
F8
10 A
IQAN-MD3/MDL2
F9
10 A
IQAN-XS2
F10
10 A
IQAN-XA2-B0
F11
10 A
IQAN-XA2-B1
F12
7.5 A
Hazard warning lights and climate control unit
F13
7.5 A
Relay, key switch
F14
15 A
Service lights, main and dipped beam
F15
7.5 A
Foot light
F16
10 A
Windscreen wipers, windscreen washer and signal horn
F17
7.5 A
Indicators and seat heating
F18
10 A
Chair compressor
F19
7.5 A
Working lights unit
F20
7.5 A
Rotating warning lights, electric rear view mirror, reading light and spotlight
F21
7.5 A
Reversing light and reverse alarm
F22
10 A
Radio
F23
10 A
24 V socket
F24
3A
IQAN-MD3/MDL2 (+RTC), diesel heater timer
F25
3A
Left-hand position lamps
F26
3A
Right-hand position lamps
F27
7.5 A
Working lights, right boom
F28
7.5 A
Working lights, left boom
F29
7.5 A
Work light roof
F30
7.5 A
Work light roof
Electrical system
Function
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Common electrical systems
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Fuse no.
Ratedc urrent
Function
F31
10 A
Unit
F32
10 A
Electrically heated rear view mirror
F33
Back-up
F34
Back-up
F35
Back-up
F36
Back-up
F37
10 A
Computer
F38
10 A
Computer, reversing camera
F39
15 A
Reserved for chair compressor
F40
3A
Reversing camera 12 V
Electrical system
Technical Manual, Publ. no. 6193.136 1305, Version 02
Common electrical systems Fuses in the battery compartment The fuses F51-F78 are located in the battery box on the right-hand side of the machine. Fuse number
Ratedc urrent
Function
F51
10 A
Main fuse for fuses F12, F13 and F24
F52
1. Fuses 51-78
Technical Manual, Publ. no. 6193.136 1305, Version 02
Back-up (Relay K31, starter relay Volvo 620/722)
F53
1A
Radio memory
F54
15 A
Diesel heater
F55
15 A
Diesel heater
F56
7.5 A
APC200
F57
15 A
Engine
F58
15 A
Engine
F61
100 A
Main fuse KL 15
F62
60 A
Main fuse KL30
F71
10 A
Elme Spreader
F72
10 A
Back-up
F73
10 A
Back-up
F74
10 A
Engine
F75
7.5 A
APC200
F76
30 A
Back-up
F77
Back-up
F78
Back-up
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Common electrical systems RELAY LIST K1–K20 are located in the electrical distribution unit. K31, K32, K33 and K35 are located next to the main fuses in the battery box. Table 1:
1 14
V0075
1. 2. 3. 4.
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Relay K33 Relay K31 Relay K32, under the fuse board Relay K35, under the fuse board
Relay no.
Function
K1
-
K2
-
K3
-
K4
Work light mast
K5
Work light roof
K6
Working lights unit, extra
K7
Reversing light, reverse alarm
K8
Direction of travel selector interlock during lever steering
K9
-
K10
Rear wiper
K11
Roof wiper
K12
Front wiper
K13
Indicators
K14
-
K15
Rotating seat, reverses the function of the side marker lights
K16
Rotating seat, reverses the function of the brake lights and reverse alarm
K17
Rotating seat, reverses the function of the service lights and reversing lights
K18
-
K19
Shut off relay for main relay K32 in the event of automatic engine shut off
K20
Horn
K31
Starter relay: Volvo 620/722
K32
Main relay
K33
Hold relay for K31 on start up
K35
Starter relay Cummins 6.7/11
Electrical system
Technical Manual, Publ. no. 6193.136 1305, Version 02
Common electrical systems LOCATION OF CONTROL UNITS CAN bus with IQAN-MD3 and MDL2 1. 2. 3. 4. 5. 6. 7.
IQAN-MD3/MDL2 (Control Vehicle Unit) IQAN-XA2 B0 (Expansion Unit) IQAN-XA2 B1 (Expansion Unit) Printer Control Unit (Squarell Technology) Scania, Volvo, Cummins ECU (Engine Control Unit) Transmission TCU IQAN-XS2 (Expansion Unit)
No. Control unit
Position
1.
IQAN-MD3/MDL2
The control unit is located in the cab and constitutes the driver's user interface.
2.
IQAN-XA2 B0
The expansion unit is located on the chassis.
3.
IQAN-XA2 B1
The expansion unit is located on the chassis.
4.
Printer Control Unit
The unit is located in the cab.
5.
Engine ECU
The control unit is located on the engine and controls engine functions
6.
Transmission TCU
The control unit is located by the transmission and manages transmission functions.
7.
IQAN-XS2
The unit is located in the cab.
Technical Manual, Publ. no. 6193.136 1305, Version 02
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Common electrical systems LOCATION OF CONNECTORS -3
-4
-5 -6
X76-
-X69
-1 -2
-X21 -X21 -X22 -7 -8 -X46 -9
1112-
-10
-X20 -X15 -X14
-X19
-X18
-X47
-X24
X106-
-20
13-X55
-14 -X75 -15 -16 -17
-X16/-X98
-X9 -X91/-X95
-X10 -X100
-X180
-X30
-X7 -X6
X60X45-
-19
-18
X108-
-X56
-X98
-X11 -21 -22
X23-
-X92/-X97 -X35
-X95 X35-X25 -X26
-X96
23X155X54-
-X32
-X33
X52X53-31
24-
33-
-X59
34-
-X87
26-
35-
27-
36-
28-
37-
-X63 -X64
38-
2930-
4-12
-X70
25-
X157-
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
32-
Spotlight (option) Reading lamp (option) Interior lighting 12 V socket (option) 24 V socket Loudspeakers (option) Condenser (option) Webasto timer Rear windscreen fan Converter (option)
-40
39-
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Compressor Heat Buzzer Orbitrol pressure sensor Inching 30 bar Brake light Horn Motor, washer reservoir Condenser Inching
21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Converter Webasto Brake pressure Fuel sensor Lever steering Joystick Tilt angel Hydraulics temperature Lift cylinder pressure Rotating driver's seat
Electrical system
31. 32. 33. 34. 35. 36. 37. 38. 39. 40.
Engine Left clamp pressure Right clamp pressure Pressure reduction left Pressure reduction right L90 clamp left L90 clamp right Mast length sensor Auto brake Lever steering
Technical Manual, Publ. no. 6193.136 1305, Version 02
Common electrical systems See the illustration on the preceding page. X1. X2. X3. X4. X5. X6. X7. X8. X9. X10. X11. X12. X14. X15. X16. X18.
Chassis wiring Chassis wiring Wiring engine transmission Wiring cab power supply Wiring engine transmission Wiring lever steering Instrument panel Instrument panel Instrument panel Wiring lever steering IQAN-MDL APC200 Fork handling, joystick Steering wheel switch
X19. Steering wheel switch X20. Direction of travel selector X21. Right/left reversing, brake, side marker lights X22. Rotating beacon, working lights (option) X23. Wiring under the cab X24. Accelerator pedal X25. X26. X30. X32. IQAN-XA2 X33. IQAN-XA2 X35. Paper handling X45. Front windscreen wipers X46. Rear windscreen wipers X47. Brake pedal X48. Rotating driver's seat
Technical Manual, Publ. no. 6193.136 1305, Version 02
Electrical system
X49. Rotating driver's seat X52. Left main and dipped beams, side marker lights, indicators. X53. Right main and dipped beams, side marker lights, indicators. X54. Mast lights X55. Lever steering X56. X59. Diesel heater X60. Heater unit/water valve X63. Rear side marker lights, right indicator, brake lights, reversing lights X64. Rear side marker lights, left indicator, brake lights, reversing lights X69. Radio, cassette player X70. Washer motor X75. Door switch
X76. Roof wiper X87. Lubrication pump X91. Container handling, joystick X92. X95. X96. X97. X98. X100 X101 X106 X108 X109 Chassis wiring X155 Parking brake X157 Fuel valve X180 -
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Wiring Diagrams WIRING DIAGRAMS POWER SUPPLY MD3 Battery voltage is 24 V. The batteries consist of two 12 V batteries connected in series.
1. 2. 3. 4.
Battery Battery disconnect switch Fuse Consumer
24 V voltage is connected through the battery disconnect switch to the following fuses and consumers. • F62, Main fuse 30 A, which in turn provides fuse protection for the following fuses. – F2, Brake lights, side marker lights, interior lighting, service lights switch – F15, Boarding step lighting – F20, Rotating beacon, map lamp – F37, Computer connection – F22, 24/12 V converter for the radio, 12 V socket, reversing camera – F23, 24 V socket – F35, Extra – F36, Extra • F51, Which in turn provides fuse protection for the following fuses. – F12, Hazard warning lights – F13, Key switch – F24, IQAN-MD3 (+RTC), diesel heater timer • F52, Main fuse for starter relay K31 for Volvo 620/722 • F54, Engine preheating • F55, Engine preheating • F56, Transmission, APC200 (DANA) • F57, Engine, Volvo 660/760/Cummins QSB • F58, Engine, extra/Cummins QSB
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Part of the 24 V power supply can be connected and disconnected by relay K32. Connection and disconnection of relay K32 is controlled by K19 and the key switch. This V voltage is connected to the following fuses and consumers. • F61, Main fuse 100 A, which in turn provides fuse protection for the following fuses. – F1, Engine, charge indicator lamp, alternator, working lights control – F3, HVAC, heating, ventilation and AC – F4, Central lubrication, parking brake switch, seat buzzer – F5, Condenser fans – F8, IQAN-MD3, IQAN MDL2, IQAN alarm – F9, IQAN-XS2, seat direction of travel selector, lever steering switch, Autotilt switch, Seat Rotation Front/Rear switch – F10, IQAN XA2 B0, parking brake – F11, IQAN XA2 B1, clamp unit, parking brake (PV Auto Brake) – F14, Service lights (high and low beam) – F16, Windscreen wiper (windscreen, rear windscreen, sunroof ) – F17, Indicator, seat heater – F18, Seat compressor – F21, Reversing light, reverse alarm – F31, (ELME unit) – F32, Electrically heated rear view mirror – F33, Extra – F34, Electrical main box (extra) – F38, Computer, reversing camera The emergency stop switch cuts the power to the key switch, relay K32 de-energizes, the fuel supply to the engine is shut off. The engine stops. The emergency stop switch can also be connected externally. IQAN MD3 can disconnect the power between the key switch and relay K32 by energizing relay K19. When relay K32 is de-energized the power to the machine is disconnected.
Electrical system
Technical Manual, Publ. no. 6193.136 1305, Version 02
Wiring Diagrams
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Wiring Diagrams MDL2 Battery voltage is 24 V. The batteries consist of two 12 V batteries connected in series.
1. 2. 3. 4.
Battery Battery disconnect switch Fuse Consumer
24 V voltage is connected through the battery disconnect switch to the following fuses and consumers. • F62, Main fuse 30 A, which in turn provides fuse protection for the following fuses. – F2, Brake lights, side marker lights, interior lighting, service lights switch – F15, Boarding step lighting – F20, Rotating beacon, map lamp – F37, Computer connection – F22, 24/12 V converter for the radio, 12 V socket, reversing camera – F23, 24 V socket – F35, Extra – F36, Extra • F51, Which in turn provides fuse protection for the following fuses. – F12, Hazard warning lights – F13, Key switch – F24, IQAN-MDL2 (+RTC), diesel heater timer • F52, Main fuse for starter relay K31 for Volvo 620/722 • F54, Engine preheating • F55, Engine preheating • F56, Transmission, APC200 (DANA) • F57, Engine, Volvo 660/760/Cummins QSB • F58, Engine, extra/Cummins QSB
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Part of the 24 V power supply can be connected and disconnected by relay K32. Connection and disconnection of relay K32 is controlled by K19 and the key switch. This V voltage is connected to the following fuses and consumers. • F61, Main fuse 100 A, which in turn provides fuse protection for the following fuses. – F1, Engine, charge indicator lamp, alternator, working lights control – F3, HVAC, heating, ventilation and AC – F4, Central lubrication, parking brake switch, seat buzzer – F5, Condenser fans – F8, IQAN-MD3, IQAN MDL2, IQAN alarm – F9, IQAN-XS2, seat direction of travel selector, lever steering switch, Autotilt switch, Seat Rotation Front/Rear switch – F10, IQAN XA2 B0, parking brake – F11, IQAN XA2 B1, clamp unit, parking brake (PV Auto Brake) – F14, Service lights (high and low beam) – F16, Windscreen wiper (windscreen, rear windscreen, sunroof ) – F17, Indicator, seat heater – F18, Seat compressor – F21, Reversing light, reverse alarm – F31, (ELME unit) – F32, Electrically heated rear view mirror – F33, Extra – F34, Electrical main box (extra) – F38, Computer, reversing camera The emergency stop switch cuts the power to the key switch, relay K32 de-energizes, the fuel supply to the engine is shut off. The engine stops. The emergency stop switch can also be connected externally. IQAN MDL2 can disconnect the power between the key switch and relay K32 by energizing relay K19. When relay K32 is deenergized the power to the machine is disconnected.
Electrical system
Technical Manual, Publ. no. 6193.136 1305, Version 02
Wiring Diagrams
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Technical Manual, Publ. no. 6193.136 1305, Version 02
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Wiring Diagrams START AND STOP ENGINE Scania DC9/DC12 The starter key is supplied with power from the battery through the main switch, fuses F62, F13 and through the emergency stop device. When the starter key is turned to position 1 relay K32 is energized and the electrical system is activated. The APC200 is energized through F75, the Fuel Shutoff solenoid valve (optional extra) is supplied with power through F72. The Fuel Shutoff solenoid valve is a safety valve that opens the fuel cock from the fuel tank when the electrical system is activated. When the starter key is turned to position 3 IQAN MD3 is energized, a signal is transmitted to the engine control unit via the CAN bus and the starter motor starts the engine. With relay K32 energized the Scania S6 (Engine Run) control unit is supplied with power through fuses F61 and F1. To stop the engine turn the starter key to position 0 (P). Relay K32 is de-energized and the power to the APC200 is disconnected. When the power from relay K32 is disconnected the Fuel Shutoff solenoid valve closes the fuel cock from the tank. The engine can also be stopped using the Emergency Stop switch. When the emergency stop device is pressed, the power to the key switch, the Scania S6 control unit and relay K32 is disconnected and the engine stops. IQAN MD3 can disconnect the power between the key switch and relay K32 by energizing relay K19. When relay K32 is de-energized the power to the machine is disconnected.
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Wiring Diagrams
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Wiring Diagrams Volvo TAD 620/722 MD3 The starter key is supplied with power from the battery through the main switch, fuses F62, F13 and through the emergency stop device. When the starter key is turned to position 1 relay K32 is energized and the electrical system is activated.APC200 is supplied with power, solenoid valve Fuel Shutoff (optional extra) is supplied with power. The Fuel Shutoff solenoid valve is a safety valve that opens the fuel cock from the fuel tank when the electrical system is activated. When the starter key is turned to position 3 relay K31 is energized and the starter motor turns the engine. Relay K33 is energized and that means that K31 continues to be energized until the engine has started and the starter key is released back to position 2. To stop the engine turn the starter key to position 0 (P). Relay K32 is de-energized and the power to the APC200 is disconnected. When the power from relay K32 is disconnected the Fuel Shutoff solenoid valve closes the fuel cock from the tank. The engine can also be stopped using the Emergency Stop switch. When the emergency stop device is pressed, the power to the key switch and relay K32 is disconnected and the engine stops. IQAN MD3 can disconnect the power between the key switch and relay K32 by energizing relay K19. When relay K32 is de-energized the power to the machine is disconnected.
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Technical Manual, Publ. no. 6193.136 1305, Version 02
Wiring Diagrams
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Wiring Diagrams Volvo TDA 660/760 The starter key is supplied with power from the battery through the main switch, fuses F62, F13 and through the emergency stop device. When the starter key is turned to position 1 relay K32 is energized and the electrical system is activated.APC200 is supplied with power, solenoid valve Fuel Shutoff (optional extra) is supplied with power. The Fuel Shutoff solenoid valve is a safety valve that opens the fuel cock from the fuel tank when the electrical system is activated. When the starter key is turned to position 3 IQAN MD3 is energized, a signal is transmitted to the engine control unit via the CAN bus and the starter motor starts the engine. To stop the engine turn the starter key to position 0 (P). Relay K32 is de-energized and the power to the Volvo EMS2 control unit and the APC200 is disconnected. When the power from relay K32 is disconnected the Fuel Shutoff solenoid valve closes the fuel cock from the tank. The engine can also be stopped using the Emergency Stop switch. When the emergency stop device is pressed, the power to the key switch, relay K32 and the Volvo EMS2 control unit is disconnected and the engine stops. When Emergency Engine Stop is pressed the Volvo EMS2 control unit receives a stop signal. IQAN MD3 can disconnect the power between the key switch and relay K32 by energizing relay K19. When relay K32 is de-energized the power to the machine is disconnected.
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Wiring Diagrams Volvo TWD 1240/1250/TAD 1340 The starter key is supplied with power from the battery through the main switch, fuses F62, F13 and through the emergency stop device. When the starter key is turned to position 1 relay K32 is energized and the electrical system is activated. The APC200 is energized, the Fuel Shutoff solenoid valve (optional extra) is supplied with power. The Fuel Shutoff solenoid valve is a safety valve that opens the fuel cock from the fuel tank when the electrical system is activated. When the starter key is turned to position 3 IQAN MD3 is energized, a signal is transmitted to the engine control unit via the CAN bus and the starter motor starts the engine. To stop the engine turn the starter key to position 0 (P). Relay K32 is de-energized and the power to the Volvo EMS2 control unit and the APC200 is disconnected. When the power from relay K32 is disconnected the Fuel Shutoff solenoid valve closes the fuel cock from the tank. The engine can also be stopped using the Emergency Stop switch. When the emergency stop device is pressed, the power to the key switch, relay K32 and the Volvo EMS2 control unit is disconnected and the engine stops. When Emergency Engine Stop is pressed the Volvo EMS2 control unit receives a stop signal. IQAN MD3 can disconnect the power between the key switch and relay K32 by energizing relay K19. When relay K32 is de-energized the power to the machine is disconnected.
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Wiring Diagrams Cummins QSB 6.7 The starter key is supplied with power from the battery through the main switch, fuses F62, F13 and through the emergency stop device. When the starter key is turned to position 1 relay K32 is energized and the electrical system is activated. The APC200 is energized, the Fuel Shutoff solenoid valve (optional extra) is supplied with power. The Fuel Shutoff solenoid valve is a safety valve that opens the fuel cock from the fuel tank when the electrical system is activated. The Cummins APC 200 control unit is energized. When the starter key is turned to position 3 relay K35 is energized and the starter motor turns. Power is also supplied to IQAN MD3. To stop the engine turn the starter key to position 0 (P). Relay K32 is de-energized and the power to the Cummins control unit and the APC200 is disconnected. When the power from relay K32 is disconnected the Fuel Shutoff solenoid valve closes the fuel cock from the tank. The engine can also be stopped using the Emergency Stop switch. When the emergency stop device is pressed, the power to the key switch, relay K32 and the Cummins control unit is disconnected and the engine stops. IQAN MD3 can disconnect the power between the key switch and relay K32 by energizing relay K19. When relay K32 is de-energized the power to the machine is disconnected.
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Wiring Diagrams Cummins QSM 11 The starter key is supplied with power from the battery through the main switch, fuses F62, F13 and through the emergency stop device. When the starter key is turned to position 1 relay K32 is energized and the electrical system is activated. The APC200 is energized, the Fuel Shutoff solenoid valve (optional extra) is supplied with power. The Fuel Shutoff solenoid valve is a safety valve that opens the fuel cock from the fuel tank when the electrical system is activated. The Cummins APC 200 control unit is energized. When the starter key is turned to position 3 relay K35 is energized and the starter motor turns. Power is also supplied to IQAN MD3. To stop the engine turn the starter key to position 0 (P). Relay K32 is de-energized and the power to the Cummins control unit and the APC200 is disconnected. When the power from relay K32 is disconnected the Fuel Shutoff solenoid valve closes the fuel cock from the tank. The engine can also be stopped using the Emergency Stop switch. When the emergency stop device is pressed, the power to the key switch, relay K32 and the Cummins control unit is disconnected and the engine stops. IQAN MD3 can disconnect the power between the key switch and relay K32 by energizing relay K19. When relay K32 is de-energized the power to the machine is disconnected.
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Wiring Diagrams Scania DC1377A (step 3b)
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Wiring Diagrams Volvo TAD 562/762/1360VE (step 3b)
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Wiring Diagrams ROAD LIGHT MD3 - DANA Service lights are controlled by the Roading Lights switch. Voltage to the switch comes across fuses F2 and F14. The switch has three positions 0, 1 and 2. With the switch in position 0, the lighting is extinguished. With the switch in position 1 the panel's switches are illuminated and the indicator lamp in the Roading Lights switch is lit. The machine's position lights are also lit in this position. The position lights are provided with fuse protection by fuses F25 and F26. With the switch in position 2 the high and low beam switch is energized. In the high beam (High) position the High Beam Indicator lights at the same time as the high beams are lit. In the low beam (Low) position the low beams are lit and the headlamp flasher (high beam) is lit in the spring return position Opt. The high and low beam lamps are provided with fuse protection by fuses F6 and F7 respectively.
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Wiring Diagrams MDL2 - DANA Service lights are controlled by the Roading Lights switch. Voltage to the switch comes across fuses F2 and F14. The switch has three positions 0, 1 and 2. With the switch in position 0, the lighting is extinguished. With the switch in position 1 the panel's switches are illuminated and the indicator lamp in the Roading Lights switch is lit. The machine's position lights are also lit in this position. The position lights are provided with fuse protection by fuses F25 and F26. With the switch in position 2 the high and low beam switch is energized. In the high beam (High) position the High Beam Indicator lights at the same time as the high beams are lit. In the low beam (Low) position the low beams are lit and the headlamp flasher (high beam) is lit in the spring return position Opt. The high and low beam lamps are provided with fuse protection by fuses F6 and F7 respectively.
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Wiring Diagrams MD3 - ZF Service lights are controlled by the Roading Lights switch. Voltage to the switch comes across fuses F2 and F14. The switch has three positions 0, 1 and 2. With the switch in position 0, the lighting is extinguished. With the switch in position 1 the panel's switches are illuminated and the indicator lamp in the Roading Lights switch is lit. The machine's position lights are also lit in this position. The position lights are provided with fuse protection by fuses F25 and F26. With the switch in position 2 the high and low beam switch is energized. In the high beam (High) position the High Beam Indicator lights at the same time as the high beams are lit. In the low beam (Low) position the low beams are lit and the headlamp flasher (high beam) is lit in the spring return position Opt. The high and low beam lamps are provided with fuse protection by fuses F6 and F7 respectively.
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Wiring Diagrams MDL2 - ZF Service lights are controlled by the Roading Lights switch. Voltage to the switch comes across fuses F2 and F14. The switch has three positions 0, 1 and 2. With the switch in position 0, the lighting is extinguished. With the switch in position 1 the panel's switches are illuminated and the indicator lamp in the Roading Lights switch is lit. The machine's position lights are also lit in this position. The position lights are provided with fuse protection by fuses F25 and F26. With the switch in position 2 the high and low beam switch is energized. In the high beam (High) position the High Beam Indicator lights at the same time as the high beams are lit. In the low beam (Low) position the low beams are lit and the headlamp flasher (high beam) is lit in the spring return position Opt. The high and low beam lamps are provided with fuse protection by fuses F6 and F7 respectively.
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Wiring Diagrams MD3 - DANA - Turn drive seat (Rotating driver's seat) Service lights are controlled by the Roading Lights switch. Voltage to the switch comes across fuses F2 and F14. The switch has three positions 0, 1 and 2. With the switch in position 0, the lighting is extinguished. With the switch in position 1 the panel's switches are illuminated and the indicator lamp in the Roading Lights switch is lit. The machine's position lights are also lit in this position. The position lights are provided with fuse protection by fuses F25 and F26. With the switch in position 2 the high and low beam switch is energized. In the high beam (High) position the High Beam Indicator lights at the same time as the high beams are lit. In the low beam (Low) position the low beams are lit and the headlamp flasher (high beam) is lit in the spring return position Opt. The high and low beam lamps are provided with fuse protection by fuses F6 and F7 respectively. Relay K17 is energized when the driver's seat changes direction of travel. The service lights change direction of travel when relay K17 is energized.
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Wiring Diagrams MDL2 - DANA - Turn drive seat (Rotating driver's seat) Service lights are controlled by the Roading Lights switch. Voltage to the switch comes across fuses F2 and F14. The switch has three positions 0, 1 and 2. With the switch in position 0, the lighting is extinguished. With the switch in position 1 the panel's switches are illuminated and the indicator lamp in the Roading Lights switch is lit. The machine's position lights are also lit in this position. The position lights are provided with fuse protection by fuses F25 and F26. With the switch in position 2 the high and low beam switch is energized. In the high beam (High) position the High Beam Indicator lights at the same time as the high beams are lit. In the low beam (Low) position the low beams are lit and the headlamp flasher (high beam) is lit in the spring return position Opt. The high and low beam lamps are provided with fuse protection by fuses F6 and F7 respectively. Relay K17 is energized when the driver's seat changes direction of travel. The service lights change direction of travel when relay K17 is energized.
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Wiring Diagrams MD3 - ZF - Turn drive seat (Rotating driver's seat) Service lights are controlled by the Roading Lights switch. Voltage to the switch comes across fuses F2 and F14. The switch has three positions 0, 1 and 2. With the switch in position 0, the lighting is extinguished. With the switch in position 1 the panel's switches are illuminated and the indicator lamp in the Roading Lights switch is lit. The machine's position lights are also lit in this position. The position lights are provided with fuse protection by fuses F25 and F26. With the switch in position 2 the high and low beam switch is energized. In the high beam (High) position the High Beam Indicator lights at the same time as the high beams are lit. In the low beam (Low) position the low beams are lit and the headlamp flasher (high beam) is lit in the spring return position Opt. The high and low beam lamps are provided with fuse protection by fuses F6 and F7 respectively. Relay K17 is energized when the driver's seat changes direction of travel. The service lights change direction of travel when relay K17 is energized.
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Wiring Diagrams MDL2 - ZF - Turn drive seat (Rotating driver's seat) Service lights are controlled by the Roading Lights switch. Voltage to the switch comes across fuses F2 and F14. The switch has three positions 0, 1 and 2. With the switch in position 0, the lighting is extinguished. With the switch in position 1 the panel's switches are illuminated and the indicator lamp in the Roading Lights switch is lit. The machine's position lights are also lit in this position. The position lights are provided with fuse protection by fuses F25 and F26. With the switch in position 2 the high and low beam switch is energized. In the high beam (High) position the High Beam Indicator lights at the same time as the high beams are lit. In the low beam (Low) position the low beams are lit and the headlamp flasher (high beam) is lit in the spring return position Opt. The high and low beam lamps are provided with fuse protection by fuses F6 and F7 respectively. Relay K17 is energized when the driver's seat changes direction of travel. The service lights change direction of travel when relay K17 is energized.
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Wiring Diagrams SIDE MAKER LIGHT MD3 - DANA Voltage to the brake lights comes across fuse F2. The lights are lit when the brake pedal is depressed and the Brake Light switch is closed. Voltage to the left and right direction indicator lamps comes across fuse F17. The Hazard Lights switch is in position 0 and the power supply continues to relay K13, Indicator Relay. When the direction indicator is put in the left (L) or right (R) positions the direction indicator lamps are energized and flash. The lamps flash in time with the energizing of relay K13. The direction indicator indicator lamp is energized by K13, Indicator Relay, and through the direction indicator left or right. Voltage for the hazard warning lights comes across fuse F12. The Hazard Lights switch is in position 1 and the power supply continues to relay K13, Indicator Relay. From there the voltage goes across the Hazard Lights switch to both circuits for the left and right direction indicators.
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Wiring Diagrams MDL2 - DANA Voltage to the brake lights comes across fuse F2. The lights are lit when the brake pedal is depressed and the Brake Light switch is closed. Voltage to the left and right direction indicator lamps comes across fuse F17. The Hazard Lights switch is in position 0 and the power supply continues to relay K13, Indicator Relay. When the direction indicator is put in the left (L) or right (R) positions the direction indicator lamps are energized and flash. The lamps flash in time with the energizing of relay K13. The direction indicator indicator lamp is energized by K13, Indicator Relay, and through the direction indicator left or right. Voltage for the hazard warning lights comes across fuse F12. The Hazard Lights switch is in position 1 and the power supply continues to relay K13, Indicator Relay. From there the voltage goes across the Hazard Lights switch to both circuits for the left and right direction indicators.
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Wiring Diagrams MD3 - ZF Voltage to the brake lights comes across fuse F2. The lights are lit when the brake pedal is depressed and the Brake Light switch is closed. Voltage to the left and right direction indicator lamps comes across fuse F17. The Hazard Lights switch is in position 0 and the power supply continues to relay K13, Indicator Relay. When the direction indicator is put in the left (L) or right (R) positions the direction indicator lamps are energized and flash. The lamps flash in time with the energizing of relay K13. The direction indicator indicator lamp is energized by K13, Indicator Relay, and through the direction indicator left or right. Voltage for the hazard warning lights comes across fuse F12. The Hazard Lights switch is in position 1 and the power supply continues to relay K13, Indicator Relay. From there the voltage goes across the Hazard Lights switch to both circuits for the left and right direction indicators.
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Wiring Diagrams MDL2 - ZF Voltage to the brake lights comes across fuse F2. The lights are lit when the brake pedal is depressed and the Brake Light switch is closed. Voltage to the left and right direction indicator lamps comes across fuse F17. The Hazard Lights switch is in position 0 and the power supply continues to relay K13, Indicator Relay. When the direction indicator is put in the left (L) or right (R) positions the direction indicator lamps are energized and flash. The lamps flash in time with the energizing of relay K13. The direction indicator indicator lamp is energized by K13, Indicator Relay, and through the direction indicator left or right. Voltage for the hazard warning lights comes across fuse F12. The Hazard Lights switch is in position 1 and the power supply continues to relay K13, Indicator Relay. From there the voltage goes across the Hazard Lights switch to both circuits for the left and right direction indicators.
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Wiring Diagrams MD3 - DANA - Turn drive seat (Rotating driver's seat) Voltage to the brake lights comes across fuse F2. The lights are lit when the brake pedal is depressed and the Brake Light switch is closed. If the driver's seat changes direction of travel K16 is energized and the front brake lights light when the brake pedal is depressed. Voltage to the left and right direction indicator lamps comes across fuse F17. The Hazard Lights switch is in position 0 and the power supply continues to relay K13, Indicator Relay. When the direction indicator is put in the left (L) or right (R) positions the direction indicator lamps are energized and flash. The lamps flash in time with the energizing of relay K13. If the direction of travel is changed relay K15 will change side for the direction indicator lamps. The direction indicator indicator lamp is energized by K13, Indicator Relay, and through the direction indicator left or right. Voltage for the hazard warning lights comes across fuse F12. The Hazard Lights switch is in position 1 and the power supply continues to relay K13, Indicator Relay. From there the voltage goes across the Hazard Lights switch to both circuits for the left and right direction indicators.
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Wiring Diagrams MDL2 - DANA - Turn drive seat (Rotating driver's seat) Voltage to the brake lights comes across fuse F2. The lights are lit when the brake pedal is depressed and the Brake Light switch is closed. If the driver's seat changes direction of travel K16 is energized and the front brake lights light when the brake pedal is depressed. Voltage to the left and right direction indicator lamps comes across fuse F17. The Hazard Lights switch is in position 0 and the power supply continues to relay K13, Indicator Relay. When the direction indicator is put in the left (L) or right (R) positions the direction indicator lamps are energized and flash. The lamps flash in time with the energizing of relay K13. If the direction of travel is changed relay K15 will change side for the direction indicator lamps. The direction indicator indicator lamp is energized by K13, Indicator Relay, and through the direction indicator left or right. Voltage for the hazard warning lights comes across fuse F12. The Hazard Lights switch is in position 1 and the power supply continues to relay K13, Indicator Relay. From there the voltage goes across the Hazard Lights switch to both circuits for the left and right direction indicators.
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Wiring Diagrams MD3 - ZF - Turn drive seat (Rotating driver's seat) Voltage to the brake lights comes across fuse F2. The lights are lit when the brake pedal is depressed and the Brake Light switch is closed. If the driver's seat changes direction of travel K16 is energized and the front brake lights light when the brake pedal is depressed. Voltage to the left and right direction indicator lamps comes across fuse F17. The Hazard Lights switch is in position 0 and the power supply continues to relay K13, Indicator Relay. When the direction indicator is put in the left (L) or right (R) positions the direction indicator lamps are energized and flash. The lamps flash in time with the energizing of relay K13. If the direction of travel is changed relay K15 will change side for the direction indicator lamps. The direction indicator indicator lamp is energized by K13, Indicator Relay, and through the direction indicator left or right. Voltage for the hazard warning lights comes across fuse F12. The Hazard Lights switch is in position 1 and the power supply continues to relay K13, Indicator Relay. From there the voltage goes across the Hazard Lights switch to both circuits for the left and right direction indicators
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Wiring Diagrams MDL2 - ZF - Turn drive seat (Rotating driver's seat) Voltage to the brake lights comes across fuse F2. The lights are lit when the brake pedal is depressed and the Brake Light switch is closed. If the driver's seat changes direction of travel K16 is energized and the front brake lights light when the brake pedal is depressed. Voltage to the left and right direction indicator lamps comes across fuse F17. The Hazard Lights switch is in position 0 and the power supply continues to relay K13, Indicator Relay. When the direction indicator is put in the left (L) or right (R) positions the direction indicator lamps are energized and flash. The lamps flash in time with the energizing of relay K13. If the direction of travel is changed relay K15 will change side for the direction indicator lamps. The direction indicator indicator lamp is energized by K13, Indicator Relay, and through the direction indicator left or right. Voltage for the hazard warning lights comes across fuse F12. The Hazard Lights switch is in position 1 and the power supply continues to relay K13, Indicator Relay. From there the voltage goes across the Hazard Lights switch to both circuits for the left and right direction indicators.
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Wiring Diagrams WORK LIGHT MDL3/MDL2 Voltage for the working lights comes across fuse F1. When the Working Lights Extra switch is pressed the voltage continues to relay K6 which is energized and the lights (Working Light Extra) are lit. The Working Lights Roof and Working Lights Mast switches work in a similar way to the Working Lights Extra switch. However, the difference is that the switches control relays K5 and K4 respectively. The lamps for working lights Roof and working lights Mast right/left are provided with fuse protection by fuses F29-F30 and F27-F28 respectively. Voltage for the boarding step lighting (optional extra) comes across fuse F15. When one or both of the doors are open the voltage is switched on by the Door Switch Left/Right switches and the boarding step lighting is lit. When the direction of travel selector is put in the R (reverse) position relay K7 is energized. Voltage for the reversing lights and reverse alarm (optional extra) comes across fuse F21. Connection that controls the reversing camera (see page 88) is supplied with power
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Wiring Diagrams MD3/MDL2 - Turn drive seat Voltage for the working lights comes across fuse F1. When the Working Lights Extra switch is pressed the voltage continues to relay K6 which is energized and the lights (Working Light Extra) are lit. The Working Lights Roof and Working Lights Mast switches work in a similar way to the Working Lights Extra switch. However, the difference is that the switches control relays K5 and K4 respectively. The lamps for working lights Roof and working lights Mast right/left are provided with fuse protection by fuses F29-F30 and F27-F28 respectively. Voltage for the boarding step lighting (optional extra) comes across fuse F15. When one or both of the doors are open the voltage is switched on by the Door Switch Left/Right switches and the boarding step lighting is lit. When the direction of travel selector is put in the R (reverse) position relay K7 is energized. Voltage for the reversing lights and reverse alarm (optional extra) comes across fuse F21. Connection that controls the reversing camera (see page 88) is supplied with power. These functions are disconnected if the seat direction of travel is changed to Rear.
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Wiring Diagrams WINDSCREEN WIPERS MD3/MD2 - DANA Voltage for the windscreen wiper switches and relays for the windscreen, sunroof and rear windscreen comes across fuse F16. The windscreen wiper switches for the sunroof and rear windscreen have three positions. 0, 1 and 2. Position 1 is intermittent wiping and position 2 is continuous wiping. Both wiper motors are controlled in the same way. In position 1 (intermittent wiping) the wiper motor receives voltage from the Windshield Wiper Rear/Roof switch, pin 5. The voltage for the switch comes from intermittent wiper relay K10 Rear/K11 Roof. The control of the intermittent wiper relay is from Windshield Wiper switch, pin 3. In position 2 (continuous wiping) the wiper motor receives voltage from the Windshield Wiper Rear/Roof switch, pin 5. The voltage from fuse F16 comes across terminal block X100 and continues to the Windshield Wiper switch, pin 2 and 6. The front windscreen wiper switch has four positions (0, 1, 2 and 3). In position 1 (function selector upwards) intermittent wiping is engaged. In position 2 the wiper motor speed is normal and in position 3 the motor speed is high. Power supply to the function selector is from terminal block X100 and fuse F16. In position 1 intermittent relay K12 is engaged. The relay is energized and power is supplied to the wiper motor across the function selector. With the function selector in position 2, the wiper motor is supplied with power directly from the function selector. In position 3 the wiper motor is supplied with power similarly, but the high speed connection is connected instead. The wiper motors have an automatic return to start position function.
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Wiring Diagrams MD3/MDL2 - ZF Voltage for the windscreen wiper switches and relays for the windscreen, sunroof and rear windscreen comes across fuse F16. The windscreen wiper switches for the sunroof and rear windscreen have three positions. 0, 1 and 2. Position 1 is intermittent wiping and position 2 is continuous wiping. Both wiper motors are controlled in the same way. In position 1 (intermittent wiping) the wiper motor receives voltage from the Windshield Wiper Rear/Roof switch, pin 5. The voltage for the switch comes from intermittent wiper relay K10 Rear/K11 Roof. The control of the intermittent wiper relay is from Windshield Wiper switch, pin 3. In position 2 (continuous wiping) the wiper motor receives voltage from the Windshield Wiper Rear/Roof switch, pin 5. The voltage from fuse F16 comes across terminal block X100 and continues to the Windshield Wiper switch, pin 2 and 6. The front windscreen wiper switch has four positions (0, 1, 2 and 3). In position 1 (function selector upwards) intermittent wiping is engaged. In position 2 the wiper motor speed is normal and in position 3 the motor speed is high. Power supply to the function selector is from terminal block X100 and fuse F16. In position 1 intermittent relay K12 is engaged. The relay is energized and power is supplied to the wiper motor across the function selector. With the function selector in position 2, the wiper motor is supplied with power directly from the function selector. In position 3 the wiper motor is supplied with power similarly, but the high speed connection is connected instead. The wiper motors have an automatic return to start position function.
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Wiring Diagrams WINDSCREEN WASHER MD3/MDL2 - DANA Power supply to the Front and Rear windscreen washer function is across fuse F16. Controlling whether the washer function is for the windscreen or rear windscreen is carried out by switching the polarity of the voltage to the washer motor, depending on which of the Windshield Washer Front and Windshield Washer Rear switches are connected. The front washer function is activated by pressing the Windshield Washer Front switch, 24 V is supplied through the Windshield Washer Rear switch, pins 3 and 2 to the washer motor and to earth through switch pins 5 and 6. Washing the rear windscreen takes place by pressing the Windshield Washer Rear switch, 24 V is supplied across pins 4 and 5 on the washer motor switch and to earth through switch pins 2 and 1.
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Wiring Diagrams MD3/MDL2 - ZF Power supply to the Front and Rear windscreen washer function is across fuse F16. Controlling whether the washer function is for the windscreen or rear windscreen is carried out by switching the polarity of the voltage to the washer motor, depending on which of the Windshield Washer Front and Windshield Washer Rear switches are connected. The front washer function is activated by pressing the Windshield Washer Front switch, 24 V is supplied through the Windshield Washer Rear switch, pins 3 and 2 to the washer motor and to earth through switch pins 5 and 6. Washing the rear windscreen takes place by pressing the Windshield Washer Rear switch, 24 V is supplied across pins 4 and 5 on the washer motor switch and to earth through switch pins 2 and 1.
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Wiring Diagrams HVAC (HEAT CONTROL HARNESS) For a description of the function, please refer to page 160 For a description of the ATM control panel, please refer to page 162 For a description of the ECC control panel, please refer to page 164
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Wiring Diagrams BEACON,DOME LIGHT,HORN AND LUBRICATION DANA Voltage for the switch for the rotating beacon (Beacon) comes across fuse F20. When the switch is depressed the left and right warning lights are supplied with power. Voltage for the electrically heated rear view mirrors (optional extra) comes across fuse F32. Connection of voltage to the rear view mirrors is controlled by the key switch. Voltage for the map lamp comes across fuse F20 and voltage to the cab lighting comes across fuse F2. The lamps are lit with the switches for each lamp. Voltage for the signal horn function selector comes across fuse F16. When the function selector is pressed relay K20 is energized and the signal horn sounds. Voltage for seat heating comes across fuse F17. A thermostat in the seat controls when the seat heating is switched on. The voltage for chassis central lubrication comes across fuse F4 and is controlled by the parking brake switch. The parking brake must be released and the ignition on for the lubrication cycle to start. Voltage for the unit's central lubrication comes across fuse F4. The ignition must be on for the lubrication cycle to start.
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Wiring Diagrams ZF Voltage for the switch for the rotating beacon (Beacon) comes across fuse F20. When the switch is depressed the left and right warning lights are supplied with power. Voltage for the electrically heated rear view mirrors (optional extra) comes across fuse F32. Connection of voltage to the rear view mirrors is controlled by the key switch. Voltage for the map lamp comes across fuse F20 and voltage to the cab lighting comes across fuse F2. The lamps are lit with the switches for each lamp. Voltage for the signal horn function selector comes across fuse F16. When the function selector is pressed relay K20 is energized and the signal horn sounds. Voltage for seat heating comes across fuse F17. A thermostat in the seat controls when the seat heating is switched on. The voltage for chassis central lubrication comes across fuse F4 and is controlled by the parking brake switch. The parking brake must be released and the ignition on for the lubrication cycle to start. Voltage for the unit's central lubrication comes across fuse F4. The ignition must be on for the lubrication cycle to start.
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Wiring Diagrams RADIO,12V AND 24V OUTLET Voltage for the seat compressor comes across fuse F18. 24 V socket are provided with fuse protection by fuse F23. Voltage for the 24/12 V voltage converter comes across fuse F22. The output from the converters is 0 and –12 V. The converter supplies –12 V to the 12 V socket. In addition it supplies the radio and reversing camera with –12 V. The Voltage to the reversing camera comes across relay K7 (see the section "Working lamp") and energized when the direction of travel selector is set to the R position (reverse). Voltage for the Cummins SMS and Scania (diagnostics) comes across fuse F13. Voltage for connecting a computer comes across fuses F37 and F38
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Wiring Diagrams GOVERNOR CONTROL MD3 When the accelerator pedal is activated the switch in the pedal is closed and the input on IQAN-XS2, pin X39:30, receives information that the accelerator pedal is activated. The potentiometer on the accelerator pedal is supplied with power (5 V) from IQAN MD3, pin X38:8. The control voltage from the potentiometer comes in on IQAN MD3, pin X38:1.
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Wiring Diagrams MDL2 When the accelerator pedal is activated the switch in the pedal is closed and the input on IQAN-XS2, pin X39:30, receives information that the accelerator pedal is activated. The potentiometer on the accelerator pedal is supplied with power (5 V) from IQAN MDL2, pin X39:14. The control voltage from the potentiometer comes in on IQAN MDL2, pin X39:18.
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Wiring Diagrams TRANSMISSION CONTROL 1 MD3 - DANA The Park Brake switch is in position 0. When the machine is started an output signal comes from IQAN-XA2 B0, pin X32:8, to energize the Park Brake solenoid valve so that the parking brake releases. IQAN-MD3 detects the position of the Park Brake switch. 24 V in on pin X38:4 means that the switch is in position 0 (not activated). When the switch is activated (position 1) this is indicated by IQAN-MD3. The power supply to the Park Brake solenoid valve is disconnected and the spring in the parking brake applies the parking brake. Detection of the position of the direction of travel selector comes in on IQAN-XS2 pins X39:32 (R) and X39:18 (F) and then continues to APC200, pins A1:J2 (R) and A1:H2 (F). Detection of the position of the gear selector comes in on pins A1:B2, :C2 and :D2. Gear 1 2 3 4
A1:B2 X X X -
A1:C2 X X -
A1:D2 X -
The direction of travel and gear selected are supplied to the transmission from APC200.
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Wiring Diagrams MDL2 - DANA The Park Brake switch is in position 0. When the machine is started an output signal comes from IQAN-XA2 B0, pin X32:8, to energize the Park Brake solenoid valve so that the parking brake releases. IQAN-MDL2 detects the position of the Park Brake switch. 24 V in on pin X39:23 means that the switch is in position 0 (not activated). When the switch is activated (position 1) this is indicated by IQAN-MDL2. The power supply to the Park Brake solenoid valve is disconnected and the spring in the parking brake applies the parking brake. Detection of the position of the direction of travel selector comes in on IQAN-XS2 pins X39:32 (R) and X39:18 (F) and then continues to APC200, pins A1:J2 (R) and A1:H2 (F). Detection of the position of the gear selector comes in on pins A1:B2, :C2 and :D2. Gear 1 2 3 4
A1:B2 X X X -
A1:C2 X X -
A1:D2 X -
The direction of travel and gear selected are supplied to the transmission from APC200.
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Wiring Diagrams MD3 - ZF The Park Brake switch is in position 0. When the machine is started an output signal comes from IQAN-XA2 B0, pin X32:8, to energize the Park Brake solenoid valve so that the parking brake releases. IQAN-MD3 detects the position of the Park Brake switch. 24 V in on pin X38:4 means that the switch is in position 0 (not activated). When the switch is activated (position 1) this is indicated by IQAN-MD3. The power supply to the Park Brake solenoid valve is disconnected and the spring in the parking brake applies the parking brake. Detection of the position of the direction of travel selector comes in on IQAN-XS2 pins X39:32 (R) and X39:18 (F) and then continues to ECU, pinsA1:64 (R) and A1:43 (F). Detection of the position of the gear selector comes in on pins A1:63 and :65. Gear 1 2 3 4
A1:63 (S4) X X
A1:65 (S5) X X
The direction of travel and gear selected are supplied to the transmission from the ECU.
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Wiring Diagrams MDL2 - ZF The Park Brake switch is in position 0. When the machine is started an output signal comes from IQAN-XA2 B0, pin X32:8, to energize the Park Brake solenoid valve so that the parking brake releases. IQAN-MDL2 detects the position of the Park Brake switch. 24 V in on pin X39:23 means that the switch is in position 0 (not activated). When the switch is activated (position 1) this is indicated by IQAN-MDL2. The power supply to the Park Brake solenoid valve is disconnected and the spring in the parking brake applies the parking brake. Detection of the position of the direction of travel selector comes in on IQAN-XS2 pins X39:32 (R) and X39:18 (F) and the continues to ECU, pins A1:64 (R) and A1:43 (F). Detection of the position of the gear selector comes in on pins A1:63 and :65. Gear 1 2 3 4
A1:63 (S4) X X
A1:65 (S5) X X
The direction of travel and gear selected are supplied to the transmission from the ECU.
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Wiring Diagrams BRAKES MD3 - DANA Detection of the brake pedal comes in on APC200, pin P2:E3. Detection of the release of the brake pedal comes in on APC200, pin A2:D3. In this version the automatic disconnection function when the brake pressure exceeds 30 Bar (optional extra) is jumper strapped. Indication of brake pressure too low is detected by IQAN-MD3, pin X38:11. The temperature of the brake cooling oil is detected on pin X38:2. The criteria for the parking brake PV Auto Brake (solenoid valve) to be applied are that the truck be stationary and there be no pressure on the accelerator pedal. The criteria are detected in IQAN MD3 and forwarded via the CAN bus to IQAN-XA2 B1 and to the solenoid valve.
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Wiring Diagrams MDL2 - DANA Detection of the brake pedal comes in on APC200, pin P2:E3. Detection of the release of the brake pedal comes in on APC200, pin A2:D3. In this version the automatic disconnection function when the brake pressure exceeds 30 Bar (optional extra) is jumper strapped. Indication of brake pressure too low is detected by IQAN-MD3, pin X39:22. The temperature of the brake cooling oil is detected on pin X39:19. The criteria for the parking brake PV Auto Brake (solenoid valve) to be applied are that the truck be stationary and there be no pressure on the accelerator pedal. The criteria are detected in IQAN MDL2 and forwarded via the CAN bus to IQAN-XA2 B1 and to the solenoid valve.
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Wiring Diagrams MD3 - ZF Detection of the brake pedal comes in on ECU, pins A1:38 or A1:61. Detection of the release of the brake pedal comes in on ECU, pin A1:66. In this version the automatic disconnection function when the brake pressure exceeds 30 Bar (optional extra) is jumper strapped. Indication of brake pressure too low is detected by IQAN-MD3, pin X38:11. The temperature of the brake cooling oil is detected on pin X38:2. The criteria for the parking brake PV Auto Brake (solenoid valve) to be applied are that the truck be stationary and there be no pressure on the accelerator pedal. The criteria are detected in IQAN MD3 and forwarded via the CAN bus to IQAN-XA2 B1 and to the solenoid valve.
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Wiring Diagrams MDL2 - ZF Detection of the brake pedal comes in on ECU, pins A1:38 or A1:61. Detection of the release of the brake pedal comes in on ECU, pin A1:66. In this version the automatic disconnection function when the brake pressure exceeds 30 Bar (optional extra) is jumper strapped. Indication of brake pressure too low is detected by IQAN-MDL2, pin X39:22. The temperature of the brake cooling oil is detected on pin X39:19. The criteria for the parking brake PV Auto Brake (solenoid valve) to be applied are that the truck be stationary and there be no pressure on the accelerator pedal. The criteria are detected in IQAN MDL2 and forwarded via the CAN bus to IQAN-XA2 B1 and to the solenoid valve.
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Wiring Diagrams SURVEILLANCE AND IQAN ALARM MD3 The fuel volume monitoring signal is transmitted to IQAN-MD3, pin X38:3.
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Wiring Diagrams MDL2 The fuel volume monitoring signal is transmitted to IQAN-MDL2, pin X38:3. In the event of an alarm the signal is transmitted on pin X39:40 to warning lamp Alarm IQAN and to the buzzer Buzzer Alarm IQAN.
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Wiring Diagrams CAN-BUS MD3 The power supply to the control units is across the following fuses. Control unit
Voltage +24 V in (pin)
Fuse
IQAN-MD3
X30:12
F8
IQAN XS2
X39:28
F9
IQAN-XA2 B0
X32:28
F10
IQAN-XA2 B1
X33:28
F11
External communication, in the form of a printer or PC, is to IQAN-MD3 over the RS232 interface. The connection to IQAN-MD3 is on pins X38:6 and :7. The control units handle electrical information in the machine. These control units obtain information from sensors and switches. This signal information or these control signals are taken in and processed in the control units. The information is forwarded to the units that control the operation of the machine, or are forwarded to the relevant control units for further processing and distribution. Communication between control units takes place via CAN buses. The CAN bus consists of two Twisted Pairs. The data packets transmitted via the CAN bus consist of one information packet and one key packet. On data packet is transmitted at a time. The expansion units (IQAN-XA2) are equipped with code keys that mean that the data packets transmitted via the CAN bus can be read in the addressed control unit. When the key code is correct the control unit receives the information and processes it. The keys (terminations) that decode the key packets have the designation T when the key is located in the last control unit in the CAN bus chain. If there is a subsequent control unit the key is not designated T and the subsequent and last control unit is then given a T key. The illustration shows the connection of the CAN bus between the control units in the machine.
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Wiring Diagrams MDL2 The power supply to the control units is across the following fuses. Control unit
Voltage +24 V in (pin)
Fuse
IQAN-MDL2
X39:28
F8
IQAN XS2
X39:28
F9
IQAN-XA2 B0
X32:28
F10
IQAN-XA2 B1
X33:28
F11
External communication, in the form of a printer or PC, is to IQAN-MDL2 over the RS232 interface. The connection to IQAN-MDL2 is on pins X38:6 and :7. The control units handle electrical information in the machine. These control units obtain information from sensors and switches. This signal information or these control signals are taken in and processed in the control units. The information is forwarded to the units that control the operation of the machine, or are forwarded to the relevant control units for further processing and distribution. Communication between control units takes place via CAN buses. The CAN bus consists of two Twisted Pairs. The data packets transmitted via the CAN bus consist of one information packet and one key packet. On data packet is transmitted at a time. The expansion units (IQAN-XA2) are equipped with code keys that mean that the data packets transmitted via the CAN bus can be read in the addressed control unit. When the key code is correct the control unit receives the information and processes it. The keys (terminations) that decode the key packets have the designation T when the key is located in the last control unit in the CAN bus chain. If there is a subsequent control unit the key is not designated T and the subsequent and last control unit is then given a T key. The illustration shows the connection of the CAN bus between the control units in the machine.
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Wiring Diagrams RESERVE WIRES The diagram shows the connections from the Electrical Main Box which are not in use but can be used for additional functions. The Electrical Main Box is the compartment under the cab dashboard.
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Wiring Diagrams MINI-WHEEL/JOYSTICK STEERING The connection of lever steering takes place using the Steering Control switches (position 1) and detection takes place on IQAN-XS2, pin X39:17. When lever steering is engaged, the indicator light in the switch comes on. Detection of the lever steering for turning the wheel angle is detected on IQAN-XS2, pin X39:25. The Pressure Steering pilot valve detects the movements of the steering wheel (P >10 bar). If the steering wheel is moved lever steering is disengaged and steering wheel control is engaged. The signal is transmitted to IQAN-XA2 B0, pin X32:12. IQAN-XA2 B0 obtains information about the current wheel angle on pin X32:24. IQAN-XA2 B0 controls the Steering Left and Steering Right solenoid valves to steer the wheels by supplying power to pins X32:16 and :30 respectively.
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Wiring Diagrams MAST Proportional Autotilt is controlled using the Autotilt switch which is supplied with power across fuse F9. The voltage signal is transmitted to IQAN-XS2, pin X39:16. The angle of the mast is detected by IQAN-XA2 B0, pin X32:13. The pressure in the lift cylinders is detected by IQAN-XA2 B0, pin X32:11. The mast height is detected on IQAN-XA2 B0, pin X32:10. An indication of whether the twistlock is open or closed comes in on IQAN-XS2, pins X39:20 and X39:34 respectively. The control of the solenoid valves from the joystick or control levers comes in on IQAN-XS2. • The control of lifting/lowering comes in on pin X39:10. • The control of mast tilt comes in on pin X39:11. • The control of side-shift comes in on pin X39:12. • The control of fork spreading comes in on pin X39:13. The control of the solenoid valves from IQAN-XA2 B0 takes place from the following pins. • Lifting and lowering, pins X32:17 and :31 • Mast tilt, pins X32:18 and :32 • Side-shift, pins X32:19 and :33 • Fork spreading, pins X32:20 and :34 Communication between the control unit for joystick or control lever control (IQAN XS2), and the control unit for controlling solenoid valves (IQAV-XA2 B0) takes place across the CAN bus.
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Wiring Diagrams On/Off
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Wiring Diagrams TURN DRIVE SEAT POSITION The Seat Rotation Front/Rear switch is supplied with power from fuse F9. Depending on the position of the switch IQAN-MS2 pin X39:21 or :35 will be supplied with power. The position of the seat is registered by the Position Seat switch on IQAN-MS2 pin X39:19 (Rear) and X39:33 (Front). The switch is supplied with power from fuse F9. The control of the solenoid valves from IQAN-XS2 is as follows. • The Seat Front solenoid valve is controlled from pin X39:36 • The Seat Rear solenoid valve is controlled from pin X39:37 • The Seat End Position Valve solenoid valve is controlled from pin X39:2
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Wiring Diagrams MASTER CLAMP UNIT Voltage to the Auto Opening and Clamp Pressure switches 1, 2, 3 and 4 cones from fuse F11. When each switch is pressed the voltage is supplied to IQAN-XA2 B1 as follows. • Voltage from Auto Opening comes in on pin X33:21 • Voltage from Clamp Pressure 1 comes in on pin X33:25 • Voltage from Clamp Pressure 2 comes in on pin X33:38 • Voltage from Clamp Pressure 3 comes in on pin X33:39 • Clamp Pressure is not connected. The clamp unit pressure is a maximum with the Clamp Pressure switch in position 3. The indicator lamps Clamp Pressure 1-4 are lit when each switch is pressed. Control from the joystick, clamp unit left comes in on IQAN-XA2 B1 pin X33:10 and clamp unit right comes in on pin X33:11. Detection of the pressure on the left clamp unit comes in on IQAN-XA2 B1 pin X33:12 and right clamp unit comes in on pin X33:13. The control of the clamp unit solenoid valves is from IQAN-XA2 B1 as follows. • The control of the left clamp unit comes from pins X33:18 and X33:32 • The control of the right clamp unit comes from pins X33:20 and X33:34 • The reduction of the pressure to the left clamp unit comes from pin X33:17 • The reduction of the pressure to the right clamp unit comes from pin X33:19 • The control of the Auto Brake solenoid valve comes from X39:16. The Lock Over Arms/Spread Clamps switch is supplied with power from fuse F11. The switch controls the solenoid valves to lock the load and to separate the clamp unit.
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Wiring Diagrams TRANSMISSION CONTROL 2 DANA TE17 Detection to APC200 of: • the transmission drum speed signal is transmitted to pin A1:B3 • the output speed from the converter (Turbine speed) signal is transmitted to A1:41. • the output speed signal is transmitted to pin A1:D3 • the engine speed signal is transmitted to pin A1:F3 • the transmission temperature is transmitted to pin A1:H3 The direction of travel and gear selected are transmitted to the transmission from APC200: • Gear 2 is controlled by pin A1:D1. • Gears 1 and 3 are controlled by pin A1:H1. Pin A1:F2 controls whether gear 1 or 3 is to be engaged. • Driving forward is controlled by pin A1:B1 and driving backward is controlled by pin A1:F1. • The criteria for engaging the transmission is controlled by pin A1:K1. Pressure switch P in the transmission detects and cuts in when there is a system pressure in the transmission. When this occurs the pressure sensor resistor is connected in parallel. The connection on APC200 A1:A2 detects the resistance in the transmission connection P3:11. When pressure switch P is switched on the resistance is low, and when the pressure switch is off the resistance is high. At normal transmission temperature A1:J3 is supplied with 2.5 V. If the temperature is too high (above120°C) the temperature switch (Temperature SW) is activated and the voltage on A1:J3 is 0 V. APC200 will generate an alarm indicating that the transmission has overheated.
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Wiring Diagrams Dana TE17 FF
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Wiring Diagrams DANA TE27-32 FF Detection to APC200 of: • The transmission drum speed signal is transmitted to pin A1:B3 • The output speed from the converter (Turbine speed) signal is transmitted to A1:G3. • The output speed signal is transmitted to pin A1:D3 • The engine speed signal is transmitted to pin A1:F3 • The sump temperature signal is transmitted to A1:H3 The transmission pressure switches P8 and P9 detect a system pressure in the transmission and are activated if this is the case. APC200 detects this on pins A2:F1 and A1:A2. The direction of travel and gear selected are transmitted to the transmission from APC200: • Pin A1:K1 controls whether the forward gear is to be activated. • Pin A1:E2 controls whether the reverse gear is to be activated. • Forward or reverse gear is controlled by pin A1:B1 • Gears 1 and 3 are controlled by pin A1:D1. Pin A1:K2 controls whether gear 1 or 3 is to be engaged. • Gears 2 and 4 are controlled by pin A1:F1. Pin A1:F2 controls whether gear 2 or 4 is to be engaged. At normal transmission temperature A1:J3 is supplied with 2.5 V. If the temperature is too high (above120°C) the temperature switch (Cooler in) is activated and the voltage on A1:J3 is 0 V. APC200 will generate an alarm indicating that the transmission has overheated.
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Wiring Diagrams ZF 3WG-191 Detection to the ECU of: • The parking brake signal is transmitted to pin A1:21 • The brake pedal signal is transmitted to pin A1:38 • The clutch signal is transmitted to pin A1:66 • The gear selector S5 signal is transmitted to pin A1:65 • The gear selector S4 signal is transmitted to pin A1:63 • The direction of travel selector (Neutral) signal is transmitted to pin A1:67 • The direction of travel selector (Reverse) signal is transmitted to pin A1:64 • The direction of travel selector (Forwards) signal is transmitted to pin A1:43 • The converter temperature signal is transmitted to pin A1:49 • The transmission temperature signal is transmitted to pin A1:39 • The engine speed signal is transmitted to pin A1:19 • The output speed from the converter (Turbine speed) signal is transmitted to A1:41. • The internal speed signal is transmitted to pin A1:42 • The output speed signal is transmitted to pin A1:62 • Pin A1:17 detects whether the filter is clogged. The direction of travel and gear selected are supplied to the transmission from the ECU: • (Y1) connected to pin A1:56. (Not in use) • Driving backward (Y2) is controlled by pin A1:10. • Gear 1 (Y3) is controlled by pin A1:32. • Gear 3 (Y4) is controlled by pin A1:55. • Driving forward (Y5) is controlled by pin A1:9. • Gear 2 (Y6) is controlled by pin A1:51.
Table 1: Transmission ZF 261, activation of the solenoid valves Y1-Y6 for the selected gear package Solenoid valve selected Direction of travel
Gear Y1
Forward
Y2
1
Y3
Y4
X
X
3
X
4
X
1
X
2
X
3
X
Y6
X
2
Backwards
Y5
X
X
X X X X
Activated engagement package K1
KV
KV
K2
K3
KV
K4
K3
KR
K1
KR
K2
KR
K3
Neutral Selected gear
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KR
K4
K1
K3
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KV
K2
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Wiring Diagrams ZF 4WG-261/311 Detection to the ECU of: • The parking brake signal is transmitted to pin A1:21 • The brake pedal signal is transmitted to pin A1:38 • The clutch signal is transmitted to pin A1:66 • The gear selector S5 signal is transmitted to pin A1:65 • The gear selector S4 signal is transmitted to pin A1:63 • The direction of travel selector (Neutral) signal is transmitted to pin A1:67 • The direction of travel selector (Reverse) signal is transmitted to pin A1:64 • The direction of travel selector (Forwards) signal is transmitted to pin A1:43 • The converter temperature signal is transmitted to pin A1:49 • The transmission temperature signal is transmitted to pin A1:39 • The engine speed signal is transmitted to pin A1:19 • The output speed from the converter (Turbine speed) signal is transmitted to A1:41. • The internal speed signal is transmitted to pin A1:42 • The output speed signal is transmitted to pin A1:62 • Pin A1:17 detects whether the filter is clogged. The direction of travel and gear selected are supplied to the transmission from the ECU: • Driving backward (Y1) is controlled by pin A1:10. • (Y2) connected to pin A1:56. Gear 4 forward controlled by Y2 and Y4. • Gear 1 (Y3) is controlled by pin A1:32. • Gear 3 (Y4) is controlled by pin A1:55. • Driving forward (Y5) is controlled by pin A1:9. (NOTE! Y5 is not activated when driving forward in 4th gear) • Gear 2 (Y6) is controlled by pin A1:51.
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Wiring Diagrams TRANSMISSION CONTROL 3 DANA TE17 APC200 is supplied with power from fuses F56 and F75. The voltage comes in on pins A1:A1 and A2:F2 respectively. The parking brake switch is connected to APC200, pin A2:C3. Detection of the release of the brake pedal comes in on APC200, pin A2:D3. In this version the automatic disconnection function when the brake pressure exceeds 30 Bar (optional extra) is jumper strapped. Detection of the brake pedal comes in on pin A2:E3. The gear selector and direction of travel signals come to APC200 as follows. • Gear selector B3 to pin A1:D2 • Gear selector B2 to pin A1:C2 • Gear selector B1 to pin A1:B2 • Direction of travel neutral to pin A1:G2 • Direction of travel forward to pin A1:H2 • Direction of travel backward to pin A1:J2
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Wiring Diagrams Dana TE17 FF
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Wiring Diagrams DANA TE 27-32 FF APC200 is supplied with power from fuses F56 and F75. The voltage comes in on pins A1:A1 and A2:F2 respectively. The parking brake switch is connected to APC200, pin A2:C3. Detection of the release of the brake pedal comes in on APC200, pin A2:D3. In this version the automatic disconnection function when the brake pressure exceeds 30 Bar (optional extra) is jumper strapped. Detection of the brake pedal comes in on pin A2:E3. The gear selector and direction of travel signals come to APC200 as follows. • Gear selector B3 to pin A1:D2 • Gear selector B2 to pin A1:C2 • Gear selector B1 to pin A1:B2 • Direction of travel forward to pin A1:H2 Direction of travel backward to pin A1:J2
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Wiring Diagrams ATTACHMENT ECB 584/585/586/587/588 The power supply to the switches and joystick for controlling the unit come in across fuse F31. The control signals from Joystick Lift and Tilt come to IQAN-XS2, pins X39:10 and :11 respectively. The control of the indicator lamps (Twistlock Unlocked, Seated and Twistlock Locked) come from Connection Box Chassis. • The Twistlock Unlocked indicator lamp is controlled by pin 4. Also indicated by IQAN-XS2, pin X39:20. • The Seated indicator lamp is controlled by pin 12. • The Twistlock Locked indicator lamp is controlled by pin 2. Also indicated by IQAN-XS2, pin X39:34. When the key-operated safety circuit breaker is closed the voltage comes in on Connection Box Chassis, pin 12. The control of the solenoid valves Pressure, Lift Interr. and Low Interr. come from Connection Box Chassis. • The Pressure solenoid valve is controlled by pin 11. • The Lift Interr. solenoid valve is controlled by pin 19. • The Low Interr. solenoid valve is controlled by pin 20. Control out from the unit joystick and switches comes to Connection Box Chassis. See the Attachment Supplier Drawing.
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Wiring Diagrams ECB 584/585/586/587/588 elec.hyd. Control out from the unit joystick and switches comes to the terminal block in the connection box from diagram “Attachment” on page 142. For the control of the Lift Inter and Low Inter solenoid valves, refer to section “Mast” on page 118.
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Wiring Diagrams Gantry 818 The power supply to the switches and joystick for controlling the unit come in across fuse F31. The control signals from Joystick Lift and Tilt come to IQAN-XS2, pins X39:10 and :11 respectively. The control of the indicator lamps (Twistlock Unlocked, Seated and Twistlock Locked) come from Connection Box Chassis. • The Twistlock Unlocked indicator lamp is controlled by pin 4. Also indicated by IQAN-XS2, pin X39:20. • The Seated indicator lamp is controlled by pin 12. • The Twistlock Locked indicator lamp is controlled by pin 2. Also indicated by IQAN-XS2, pin X39:34. When the key-operated safety circuit breaker is closed the voltage comes in on Connection Box Chassis, pin 17. The control of the solenoid valves Pressure, Lift Interr. and Low Interr. come from Connection Box Chassis. Control out from the unit joystick and switches comes to Connection Box Chassis. See the Attachment Supplier Drawing.
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Wiring Diagrams ECB 588TB 1/2
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Wiring Diagrams ECB 588TB 2/2
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Wiring Diagrams ECB 584-LD
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Wiring Diagrams ECB 584-LD elec.hyd.
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Wiring Diagrams ATTCHMENT DAVID BROWN The diagram shows the function of the ECB and Gantry buttons and the lift and tilt joystick functions.
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Wiring Diagrams SEAT BUZZER AND GRAMMER The buzzer is supplied with power from fuse F4 and the Park Brake switch when the parking brake is not active. When the SEAT SW switch in the driver's seat is activated relay K is energized and the voltage to the buzzer is cut. If the Park Brake switch is not active and the driver leaves the driver's seat the SEAT SW switch opens. Relay K de-energizes and the buzzer sounds.
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Wiring Diagrams HEATER CONTROL PANEL STD. See also the diagram in the section “hvac (heat control harness)” on page 78 Voltage for the blower speed switch comes across fuse F3. The blower fan motor is three speeds. Different series resistors are connected to the heater module. If Diesel Fired Preheater is connected (X106:20) the fan speed is automatically at low no matter what speed is selected on the fan speed switch. Relay R3 is energized and the blower fan motor and series resistor are supplied with power from Diesel Fired Preheater. Temperature setting. Set Point is supplied with power from fuse F3. The control regulates the control motor as the temperature is set on Temp. Set Point. If Diesel Fired Preheater is connected the control motor is supplied with power across Relay R1 in the heater module. Relay R2 ensures that the control motor opens the heater valve fully.
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Wiring Diagrams AC See also the diagram in the section “hvac (heat control harness)” on page 78 For the temperature setting function (Temp Set Point) and fan speed (Blower Speed), refer to the section "Heater control panel". The recirculation switch is supplied with power from fuse F3. When the switch is set to the Recirc position the indicator lamp in the switch lights and HVAC module relay R3 is supplied with power. The relay is energized and regulates the control motor. The A/C switch is supplied with power from fuse F3 when the blower speed switch is on. The HVAC module thermostat is supplied with power which, depending on the temperature, supplies power to the condenser and button which in turn supplies power to the compressor. At the same time relay R6 is energized and the voltage from fuse F5 energizes relay R7. Depending on the position of the button relay R8 is also energized. When R7 and R8 are energized the condenser fans are supplied with power and spin.
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Wiring Diagrams ECCl See also the diagram in the section “hvac (heat control harness)” on page 78 For the performance of the condenser and Recirc switch, refer to section "ATM control panel" For other functions (Temp. Set Point, Blower Speed and A/C Switch) control, regulation and detection are carried out by the ECC control unit in the A/C Unit.
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Wiring Diagrams ELECTRICAL OIL COOLER FAN Voltage for the electric fan for hydraulic oil cooling comes across fuse F58. The El. Oil Cooler thermostat controls relay K which in turn controls the voltage to the cooling fan. When the temperature in the hydraulic oil rises the (El. Oil Cooler) thermostat closes energizing relay K and supplying the cooling fan with voltage
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Replacing connectors REPLACING CONNECTORS DEUTSCH CONNECTORS 1. Separate the connectors.
V0119
2. Remove the lock for the pin connectors
V0121
3. Mark up and make a note of the pin numbers on the cables. 1
4
2
3
12
7
1
6
V0120
4. Press out pin connector catches using a screwdriver and pull out the pin. Remove all pins. 5. If the pins are to be replaced: – Cut the cable. – Strip the cable a few millimetres. – Use the special tool and crimp the cable into the pin. 6. Check the marking. Press the pin with cable through the rubber gasket so that the pin snaps into place.
V0122
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Replacing connectors 7. Push blind pins into the rubber grommet where there are empty terminals so that the connector will be watertight.
V0123
8. Check that the rubber seal on the female connector is in place and intact.
V0124
9. Fit the lock for the pin connectors 10. Connect the connector.
V0125
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Replacing connectors AMP CONNECTORS 1. Separate the connectors.
V0126
2. Mark up and make a note of the pin numbers on the cables. 7
1
9
3
V0127
3. Press in the catches for the pins and pull the pins out of the connector. Use a special tool. 4. If the pins are to be replaced: – Cut the cable. – Strip the cable a few millimetres. 5. Use the special tool and crimp the cable into the pin. 6. Check the marking. Press the pin with cable so that the pin snaps into place. 7. Connect the connector.
V0128
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Replacing connectors CALIBRATING THE TE TRANSMISSION WITH THE APC200 Calibrate the transmission using the APC200. NOTE Two people are needed to carry out calibration. NOTE Check the function of the parking brake! The criteria for calibrating the transmission are: • The parking brake must be activated. • The temperature in the oil sump must be higher than 60°C. The engine speed must be 800 rpm ±200 rpm. 1. Depress the “S” button on the APC200 and start the engine. Continue to hold the S button in until the text “trAn” appears in the V0102 display (this takes about 15 seconds). When this happens release the “S” button. (trAn = transmission ) 2. Press the S button once to select transmission calibration. “Go F” appears in the display. V0107
3. Move the direction of travel selector forward to initiate calibration (on certain 28-32 ton trucks one needs to move the gear selector backwards instead to initiate calibration). Calibration starts and the display shows the various stages of calibration. NOTE To stop calibration: move the direction of travel selector to the backward position. 4. When all gears have been calibrated donE appears in the display; this means that calibration is complete. It normally takes 15 minutes to calibrate the transmission.
V0111
5. Turn off the ignition, wait about 5 seconds and then turn it on again. NOTE Do not turn off the battery disconnector switch immediately after calibration. The calibration values will be lost and calibration will have to be carried out again. 6. When the machine is restarted the APC200 will automatically activate the values from calibration.
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