OVERVIEW OF

MECHATRONICS

KAP Training Centre Basic Mechatronics 1

WORD ORIGIN OF MECHATRONICS

KAP Training Centre Basic Mechatronics 2

CONTROL ELEMENTS OF MECHATRONICS

KAP Training Centre Basic Mechatronics 3

FOUR ELEMENTS OF MECHATRONICS

KAP Training Centre Basic Mechatronics 4

ELEMENTS OF MECHATRONICS

[Physical value] Wiring Wiring

- Pressure harness harness Actuator
- Temperature Sensor Controller
- Speed Input Output
- Displacement Indicator
- Others
Mechatronics
of construction machinery
Comparison faculties of the human body

Controller
(Brain)
Sensor detects the physical value. (Input
Sensor
(Eye, ear, nose signal)
and Controller makes a judgment.
tactile sense)
Controller sends a command to the
Electro-
Mechanical actuator and indicator. (Output signal)
System Voltage signal is transmitted through

Actuator wiring harnesses.

(Arms and legs) Wiring harness
(Nerve)

KAP Training Centre Basic Mechatronics 5

LAYOUT OF MECHATRONICS SYSTEM ON MACHINE
Sensors Controllers Actuators
Revolution sensor
Engine controller ON-OFF solenoid valve
Oil pressure sensor
Output Proportional solenoid
Temperature
Pump controller valve
sensor

Position sensor Governor motor

Input Transmission controller

Stroke sensor Injector

HST controller
Angle sensor
Work equipment
Inclination sensor controller Indicators
Communication

Level sensor Retarder controller Monitor panel

Acceleration sensor

 Several controllers of different uses are installed on a machine. They share information through
communication lines.
 Service mode of the monitor panel allows service personnel to obtain machine information

needed for servicing and to use it for troubleshooting.

 The monitor panel is also a type of controller.

KAP Training Centre Basic Mechatronics 6

 OBJECTIVE OF “MECHATRONIZATION”

Objective of
Application examples
“Mechatronization”

(1) Adding new functions Radio control system, unmanned control system

(2) Upgrading operation accuracy Slope finishing function, skimming function

(3) Improving energy savings Auto-deceleration system, automatic transmission,

and work efficiency shoe-slip control, pump control

Machine monitoring system, maintenance monitor,

(4) Upgrading machine availability VHMS and KOMTRAX

Lock function, interference prevention function,

(5) Improving safety emergency brake

 Recent construction machinery are requested to be designed with a focus on (3), (4) and (5).
 Over the last ten years or so, adoption of Mechatronics has progressed drastically.

KAP Training Centre Basic Mechatronics 7

 BASIC CIRCUIT

KAP Training Centre Basic Mechatronics 8

BASIC CIRCUIT WHEN SWITCH IS TURNED OFF

Resistance
Switch-OFF

1. “Loop” breaks at the switch portion.

2. No current flows through the circuit.
Electricity stops flowing here. 3. No voltage drop results across the
resistance.
Fuse

+ -

Battery

KAP Training Centre Basic Mechatronics 9

VOLTAGE WHEN SWITCH IS TURNED OFF

Resistance
Switch-OFF E F 1. There is voltage although no current flows
D
through the circuit.
2. Be aware of the difference between current
and voltage!!
3. Voltage represents the difference of
C electric potentials between positive and
1 2 negative terminals on the battery. (Power
B V
to carry current = “Pressure” in the case of
electricity)
Fuse 4. There is no voltage drop, but voltage
A differs between before and after the switch.
+ - (There is a power to produce a current
flow.)
Battery

KAP Training Centre Basic Mechatronics 10

BASIC CIRCUIT WHEN SWITCH IS TURNED ON

1. Wiring harnesses are properly connected

to form a loop.
Resistance Positive and negative terminals on the
Switch-ON battery are connected to the respective
ends of the resistance with wiring
2. Voltage drop
harnesses to form a loop (= circular
circuit).
2. The resistance has a normal value of
resistance.
If condition <1> holds and the resistance
1.“Loop” of the resistance is normal, normal current
is carried through the circuit from the
positive terminal on the battery.
At this time, the current results in
voltage drop across the resistance,
+ -
consuming electric energy, and returns to
the negative side of the battery. This is
Battery
normal operation of an electric circuit.

KAP Training Centre Basic Mechatronics 11

VOLTAGE WHEN SWITCH IS TURNED ON

Resistance 1. Since voltage drop results only across

the resistance, the voltage between a
Switch-ON E F
measuring point from A to E and the
D negative terminal on the battery is 24
VDC.
2. The voltage measured at measuring point
F is 0 VDC because it is located after the
C voltage drop point.
1 2

B V 1. As described above, we have to consider

two cases shown below to understand
Mechatronics.
A
(1) When switch is turned on (current flows
+ - through the circuit)
(2) When switch is turned off (no current
Battery flows)

KAP Training Centre Basic Mechatronics 12

POWER SUPPLY, GROUNDING AND SIGNAL LINE

Measuring point Switch-ON Switch-OFF

Resistance Points A, B and C 24V 24V

E F Points D and E 24V 0V

D Point F 0V 0V

1. When the switch is turned on or off

• Line ・ that has always the power supply voltage
C -> Power supply line
• Line that has always a voltage of 0 VDC
-> Grounding line
B
• Line that has a voltage changing between the
power supply voltage and 0 VDC
-> Signal line
A
2. Color identification of line
+ - • Power supply line Red
• Grounding line Black
Battery • Signal line Blue <- For output

24V

KAP Training Centre Basic Mechatronics 13

WHAT IS BREAK (DISCONNECTION)?

Resistance
E F 1. Break means disconnection of conductor
D of electricity.
2. Not only wiring harness but internal
wiring of electric device may break.
3. When break occurs in the circuit of
C Ex. Point of break electric device, it does not operate
because of no current flow.
B 4. When break occurs, lines in the circuit
may have abnormal voltage as shown
below.
A • No voltage is applied to a power supply
+ - line.
• Voltage is applied to a grounding line.
Battery • Signal line voltage does not vary.

24V

KAP Training Centre Basic Mechatronics 14

WHAT IS SHORT CIRCUIT ?

Resistance 1. Short circuit (Short) means direct connection of

two points in a electric circuit.
E F
2. As for chassis wiring, broken harness cover
D due to vibration, etc. often causes short circuit
by making the wire to contact other wires or
terminals.
Ex. Point of short circuit 3. Short circuit makes overcurrent to flow through
C
the circuit, causing breakage of device parts
and burnout of wiring.
• Fuses or protection circuits are installed to
B prevent damage.
• Glossary
• Hot short = Short circuit between power supply
A line and signal line
• Power short = Short circuit between power
+ -
supply line and grounding line
• Ground short = Short circuit between power
Battery supply line and chassis (chassis grounding line)
24V

KAP Training Centre Basic Mechatronics 15

CIRCUIT PROTECTION
1. Fuse body blows to shut
off the current when
abnormal current flows
through it.
Blade fuse becomes commonly used.
2. Fuse causes fatigue
failure by repeated on-off
of instantaneous rush
current.
3. Fusible link or slow-blow
Cartridge fuse Blade fuse fuse is installed to
prevent instantaneous
rush current from
blowing a fuse easily.
• They are installed
between positive
terminal on battery and
the fuse.
• Circuit breaker is also
installed depending on
machine model.

Fusible link Mounted fusible link

Fuse box
Slow-blow fuse

Circuit breaker
KAP Training Centre Basic Mechatronics 16
ELECTRIC CIRCUIT (RESISTANCE-TYPE SENSOR)

Main circuit of resistance-type sensor 1. Sensor power supply

• Sensor power supply is produced inside the
controller. The power supply voltage is often 5
Variable VDC or 12 VDC.
resistance
-> Sensor power supply line (Orange)
2. Input signal line
• Some circuits are configured as follows;
Resistance varies according to the operation of
sensor -> Input signal voltage also varies -> The
voltage variation is measured by a circuit like volt
meter inside the controller -> Thus, the operation
status of the sensor is grasped depending on the
V voltage variation.
-> Input signal line (Green)
3. Function of controller
• When the controller recognizes abnormal voltage
value of input signal line, it makes a judgment on
whether “error code” should be issued or not.
+ - • When the controller detects an abnormality, it
determines the action to take from among a
variety of options including setting the sensor
Sensor power supply power supply value to 100 % value, taking the
input signal as zero, etc., depending on the
relevant sensor.
Internal circuit of controller

KAP Training Centre Basic Mechatronics 17

BASIC ELECTRIC CIRCUIT (SWITCH-TYPE SENSOR)

Main circuit of switch-type sensor

Resistance 1. Configuration of sensor

• Switch portion of the basic circuit diagram
may be a sensor in an actual
Mechatronics. In the system, all the
resistances and power supply are inside
the controller (or machine monitor).
2. Input signal voltage
V • Input signal voltage changes to 0 VDC or
the power supply voltage according to the
operation of sensor (switch-ON/OFF).
The controller measures the voltage with
volt meter in it to judge whether the
sensor operates or not.
＋ ー 3. Function of controller
• The controller may not be able to issue
“error code” if the system state produced
Sensor power supply
by break is the same as that by switch-
OFF.
Internal circuit of controller

KAP Training Centre Basic Mechatronics 18

CONTROL SYSTEM AND COLOR IDENTIFICATION OF
CIRCUIT
Types of lines Color identification of circuit line (8 colors)

•Grounding line Black

1. Machine monitor line

(1) Standby power line •Standby power line Pink

•Power -ON line
(2) power-ON line Red
(3) Sensor line for machine monitor
•Start signal line
(4) Starting and charging circuit Brown

(5) Light, wiper and window washer line •Sensor power line
Orange
2. Engine control line •Output signal line
Blue
•Switch and relay output
•Controller output
3. Machine control line
• Input signal line
(1) Pump control line (PC) Green
•Monitor input
(2) Transmission and HST control line •Controller input
(for bulldozer and wheel loader)
•Communication
circuit line
Yellow
(3) Work equipment control line

KAP Training Centre Basic Mechatronics 19

EXAMPLE OF COLOR- CODED CIRCUIT DIAGRAM

KAP Training Centre Basic Mechatronics 20

 POWER SOURCE AND
CIRCUIT DIAGRAM

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STANDBY POWER LINE

“Standby power line” means wiring harnesses that always receive the
battery voltage even when the starting switch has not been turned on. -->
Continuous power supply line (Pink)
Normally, the line running through a fusible link (or slow-blow fuse or
circuit breaker) and a fuse up to B terminal on the starting switch receives
continuous power supply.
Continuous power supply is mainly used as a power source of controllers
including machine monitor and KOMTRAX controller that must be operated
while the starting key is being set to OFF position. (The circuit diverges from
the fuse.)

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STARTING SWITCH

C terminal
BR terminal

ACC terminal 1. Structure

B terminal • Starting switch has 4 key
positions that are Preheating
R1 terminal (R1), OFF (OFF), ON
(ACC,accessary) and Starting
(ST) in the order from left.
R2 terminal
2. Contact connection table
• The switch has 6 terminals on its
reverse side and terminals
marked with a circle in the
drawing are connected each
other depending on the key
position.
3. Contact capacity of the starting
switch does not allow it to turn on
or off the starting motor directly.
Therefore, the starting motor turn
on or off the coil that moves the
safety relay contact.

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 POWER-ON LINE

To controller
<4>

<5>
<3>

<1> <2>

<1>

•<1> Turning the starting switch key to ON (ACC) applies voltage to BR terminal on
the battery relay. <2> Accordingly, the battery relay turns on (B and M terminals
connect each other). Battery voltage is supplied to Power-ON line (red) through M
terminal.
•<4> Power-ON line runs through a fusible link (or slow-blow fuse or circuit
breaker) and the powers supplies to several relays and switches from the fuse. <5>
Power-ON supply is used as a start up power source of controller, starting motor
and safety relay and so on.

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BATTERY RELAY AND LIGHTING OF MONITOR PANEL

From positive
•Setting starting switch key to OFF (OFF)
terminal on battery B terminal
position turns off the battery relay. The
BR terminal relay remains turned on (connected) when
the key is set on the position of
ON,Staring,and Preheating. Whether the
From key switch voltage appearing at BR terminal, which is
supplied from the starting switch, is higher
than 24 VDC or not determines the status
of the relay.
•Purpose of use
M terminal E terminal
(1) Turn off the relay when repairing
For grounding electric wiring in servicing.
(2) The relay must be turned off to cut off
Installed battery relay electricity because earth fault of key-ON
power supply line with chassis will cause
exceptionally dangerous situation.
Junction connector
•Monitor panel is connected to continuous
power supply line but does not light up by
the line alone.
•Monitor panel lights up only when a
Fuse voltage is developed in “starting switch
signal line” {deemed as input signal line
(green)}.

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CONNECTOR ID AND TYPE

Male connector Female connector

Pins

A01 （Ｘ－ 4 ）
Socket

Connector ID Type Number of pins Male connector Female connector

•Note
Connector drawing may not indicate •Note
all the pins. Male and female connectors can be
(The figure following the type distinguished each other based on
indicates accurate number of pins.) the pin shape in Komatsu.

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CONNECTOR TABLE AND STEREOGRAM
Connector table Connector layout stereogram

•Note
Connector table and stereogram
are listed at the start of
"Troubleshooting" or “Circuit
diagram collection” at the back of
Shop Manual.

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COLOR SYMBOLS OF WIRING HARNESSES

•Each wiring harness in a circuit drawing always

B 端子 has a code with “Digit (s)” and “Alphabet (s)”.

3R •Connector ID tag is
usually wound
3RW around the wiring
Wire size 3 (3mm2) harness. The
connector must be
Color Red identified according
to the color of the
wiring harness if the
3RW tag is not attached
in such a case of
3R
Wire size 3 (3mm )
2
A35 （ Connector ID tag ） mini construction
machinery.
Color Red background
with white line Wiring harness installed near fusible link

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WIRING HARNESS AND COLOR IDENTIFICATION TABLE

Nominal code •Allowable current

Equivalent old increases as
nominal code
Conductor nominal code
sectional area(mm2) becomes large.
Conductor diameter
•Nominal code
Outside diameter
of cover (mm) approximately is
Standard diameter consistent with
Allowable current
conductor sectional
Allowable short-time
area.
current Note: Wires of
nominal code 0.5
Symbol Color

Units are ( A ) both Allowable Current must be bundled

& Allowable short-time Current when being put in
use.

•Color symbols are basically taken from the first letter of

the English alphabetical name of colors.
Note: Blue only uses the second letter “L” for its color
symbol because its first letter overlaps that of Black.

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TYPE OF COVER TYPE AND SPECIAL ELECTRIC WIRE

Type of cover
Type Symbol Symbol 　 Operating temperature limit (ºC)
•Select an
Soft copper wire
Vinyl-insulated low-voltage Material appropriate
AVS for electric purpose -30 - +60
wire for automobile (AV) (General wiring) wire
Insulator Soft polyvinyl
depending
Soft copper wire for
Heat resistant cross-linked Conductor electric purpose 　 -50 - +110 on its use
polyethylene wire for automobile AEX （ Extremely cold region, environment
Insulator Cross-linked polyethylene high temperature portion ）
.

Special electric wire

Twisted pair wire Shielded wire

•Use the wire for simple noise control. •Use the wire for reliable noise control.
•Noise entering each of positive and negative wires •Noise is controlled by covering signal line wires
are reversed and get balanced out. with metallic mesh called Shield and by grounding
one of the wires.
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 SENSORS AND
MONITORING

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 SENSORS FOR MONITOR SYSTEM

Operation and check before starting engine •Sensors for Monitor systemu
Put starting key (2) into the starting switch, Most of the data detected by these sensors
set it to ON (ON) position, then check on the following. are input to the machine monitor that uses
them to issue cautions and display gauges.
1.Buzzer sounds for about one second and following
monitors and meters light up for about 3 seconds on the
screen of monitor panel.
•Radiator coolant level monitor (4) <1> Level switch Switch-type sensor （ ON-OFF ）
•Engine oil level monitor (5)
•Charge level monitor (6)
<3> Potentiometer
•Fuel level monitor (7)
•Engine water temperature monitor (8) <4> Temperature sensor Resistance-type sensor (Analog)
•Engine oil pressure monitor (9)
•Engine water temperature gauge (10)
•Fuel level gauge (11) <2> Oil pressure switch
•Air cleaner clogging monitor (12)

2) After about 3 seconds, the display changes to

work mode and travel speed display monitor.
Then, the screen changes to the normal screen.
↑Example display of PC200-7→

•Above 4 types of sensors are used

including switch-type and resistance-type
sensors, although the number of monitors
and meters depends on machine model.

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SENSORS FOR MONITOR SYSTEM

•Sensors for Monitor system

Most of the data detected by these sensors are input to the machine monitor that uses them to
issue cautions and display gauges.
•Two (2) types of switch-type sensors are used; level switch and oil pressure switch.
(1) Level switch -> Engine oil level sensor, coolant level sensor, hydraulic oil level sensor, etc.
(2) Oil pressure switch -> Engine oil pressure sensor, air cleaner clogging sensor, charge filter
clogging filter, etc. 　
(Reference: Oil pressure switches are also used in the system related to machine control. 　
Example: PPC oil pressure switch of hydraulic excavators, fill switch, parking brake pressure
switch, stop lamp pressure switch and emergency brake pressure switch of wheel loaders and
off-highway dump trucks, etc.) 　
•Two (2) types of resistance-type sensors are used; temperature sensor and potentiometer.
(1) Temperature sensor: Engine water temperature sensor, hydraulic oil temperature sensor,
transmission oil temperature sensor, HST oil temperature sensor, torque converter oil
temperature sensor, brake oil temperature sensor, etc.
(2) Potentiometer: Fuel level sensor, etc.
(Reference: Potentiometers are also used in the systems related to engine and machine
control. 　 Example: Fuel dial, governor lever position sensor of hydraulic excavators, PPC lever
of bulldozers, accelerator pedal of bulldozers, wheel dozers and off-highway dump trucks, work
equipment position sensor of hydraulic excavators, etc.)

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LEVEL SWITCH ( I )

Glass Reed
Float Lead wire

Inactive filler gas

Structure of reed switch

•Structure and function

•Reed switch (a switch that operates with
action of magnetic field) is inserted in the
Permanent
Permanent magnetMagnet
shaft portion.
•The float has a built-in permanent magnet.
(1) When the level is high, the contact
Traverse-mounded closes (ON) because magnetic attraction is
oil level sensor
larger than the elastic force of the reed.
(cutaway model)
(2) When the level is low, the contact opens
Reed switch
Reed Switch (OFF) because the magnetic field reduces.

Level switch installed on engine oil pan

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LEVEL SWITCH ( II )

•Level switches are

installed to measure oil
Reed Switch level or water level of
Float following components.
Float Reed
•Engine oil level
switch
•Transmission oil level
•Engine water level
•Hydraulic oil level
•Retarder oil level, etc.
Radiator sub tank
(cutaway model)
Vertical-mounted
oil level sensor
(cutaway model)

Coolant level sensor Installed coolant level sensor (PC200-8 ）

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OIL PRESSURE SWITCH ( I )

Turns OFF when pressure is applied •The switch detects oil pressure in a oil line and
operates (turns ON or OFF) at a specified pressure.
Contact ring •The switch is installed on the engine block to pick
up engine oil pressure with its diaphragm. When the
pressure lowers below the specified pressure, the
switch turns ON. In this condition, the caution lamp
lights up and buzzer sounds for caution.
Note: Engine oil pressure switch -> Turns OFF
when pressure is applied,
PPC oil pressure switch -> Turns ON when pressure
is applied

Diaphragm Engine oil pressure switch

Diaphragm

Engine oil pressure switch (cutaway model)

Installed engine oil pressure switch(PC200-7)

KAP Training Centre Basic Mechatronics 36

 OIL PRESSURE SWITCH ( II )
Turns ON when pressure is applied Turns OFF under a negative pressure OFF

Diaphragm
Diaphragm Diaphragm
Diaphragm

PPC oil pressure switch (cutaway model) Air cleaner clogging sensor (cutaway model)

•Oil pressure switches are used for

machine control. Some oil pressure
switches like PPC oil pressure
switch turns ON when pressure is
applied.
•Some of them like air cleaner
PPC oil pressure switch Air cleaner clogging sensor clogging sensor turns OFF under a
negative pressure (-762 mm H2O).
Installed PPC oil pressure switch (PC200-7 ） Installed air cleaner clogging sensor (PC200-7)

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 TEMPERATURE SENSOR

•Thermistor has the characteristics that its electric resistance

changes drastically according to temperature changes as shown
in the graph below and is used in temperature sensors.
•Temperature sensors are installed to measure the temperature of
the following.
Engine water temperature, torque converter oil temperature, brake
oil temperature, HST oil temperature, hydraulic oil temperature,
etc.
Thermistor
Thermistor
Example of resistance-temperature characteristics

Engine water temperature sensor Hydraulic oil temperature Resistance of Thermistor k Ｏｈｍ )
Resistance of（thermistor

Temperature
Temperature （℃）
Installed engine water temperature sensor (PC200-7) Installed hydraulic oil temperature (PC200-8)

KAP Training Centre Basic Mechatronics 38

FUEL LEVEL SENSOR

•Fuel level sensor is installed on inside wall of

Variable resistance Section
the fuel tank and its float goes up and down
depending on the level of remaining fuel in the
tank.
•Float movement transmitted through the arm
changes the resistance of the variable
Arm resistance, resulting in changes of the input
signal voltage. Thus, the remaining fuel level is
displayed on the monitor screen.
•When the level displayed on the maintenance
Float monitor lowers to the specified position, the
caution lamp flashes.

Change in
input
signal voltage

Change in voltage drop amount Change in value Closeup of variable resistance portion
of resistance

KAP Training Centre Basic Mechatronics 39

 STARTING AND
CHARGING CIRCUIT

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ENGINE STARTING CIRCUIT (C TERMINAL LINE)

<4>

<1>

<3>
<4>

<2> <1>

<2>

KAP Training Centre Basic Mechatronics 41

ENGINE STARTING CIRCUIT (C TERMINAL LINE)

<1> AS described in “Key-ON power supply line”, setting the starting switch key
to ON (ACC) position turns on the battery relay (B and M terminals connect each
other). Battery voltage is supplied to B terminal on the starting motor and B
terminal on the safety relay through Power-On line (red).
(Note, however, that the starting motor does not start to rotate because no current
yet flows through the starting motor coil.)
<2> Then, set the starting switch key to START (ST) position. B, BR and C
terminals on the switch are connected each other and S terminal on the safety
relay receives battery voltage through C terminal (start signal) line.
<3> As the result of this, current flows through the coil in the safety relay and B
and C terminals connect each other, <4> allowing current to flow to C terminal on
the starting motor.
(Note that the prerequisite for allowing current to flow through the coil in the safety
relay is that no current has appeared on the alternator electric power generation
signal line (R terminal) or the engine has not yet started to run. If R terminal
receives current, the safety relay will not allow B and C terminals to connect each
other. This is called dual extrusion prevention function of the safety relay.)

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STARTING MOTOR
Motor portion

Transmission of revolution
Operation
<1> When current flows
to C terminal, the
magnetic switch carries
B terminal current to extrude the
pinion.
<2> Since the motor also
Pinion is extruded. carries current, it
extrudes the pinion to
engage with the flywheel
C terminal gear while rotating
slowly.
Magnetic switch portion M terminal
<3> The magnetic switch
C moves to the contacts of
B B and C terminals and
connects with them
M terminal (ON).
<3> C<1>
<4> B terminal in key-on
B power supply line is
<4>
B terminal receiving battery voltage.
M When B terminal is
<2>
To alternator connected, large current
flows through the motor,
allowing it to rotate the
C terminal
engine with its utmost
energy.
From battery relay C terminal line

KAP Training Centre Basic Mechatronics 43

SAFETY RELAY (AT STARTING ENGINE)
Starting motor relay portion Contactor C terminal Operation
<1> Current drawn from C terminal on
the starting switch through S terminal
flows through R4 resistance and turns on
transistor Q2.
<2> L coil of the relay also carries current
to close the relay contact.
<3> Thus, electricity of the battery (from
M terminal on the battery relay) to flow to
C terminal on the starting motor, allowing
B terminal the motor to rotate.
Safety circuit portion Coil TO B TERMINAL ON
BATTERY RELAY
B terminal
S <1> <2> B C terminal

<3>
TO STARTER SWITCH R4
C
<1>
TO 　 R 　 TERMINAL 　 ON
BATTERY 　 CHARGER
R TO C 　
TERMINAL 　
R ＋ S line
Q2
<1> ON
STARTER 　
SWITCH

To starting motor From

battery relay
FOR GROUNDING
Installed safety relay （ PC200-7 ）

KAP Training Centre Basic Mechatronics 44

BATTERY CHARGING CIRCUIT (R TERMINAL LINE)

<2>
<1>

<4>

<1>
<2>

Backflow prevention diode <2> <3>

<2>

KAP Training Centre Basic Mechatronics 45

BATTERY CHARGING CIRCUIT (R TERMINAL LINE)
<1> When engine starts to run, the alternator rotates to generate electricity. Since generated
voltage is higher than the battery voltage (normally 27.5 – 29.5 volts), charging voltage is
supplied to the battery from B terminal on the alternator through B terminal on the starting
motor and the battery relay.
(The circuit to IG terminal on the alternator is to provide electricity to the magnetic force
generation coil (rotor coil). The electricity is supplied from the battery before the engine starts
to run and from the alternator after it starts to generate electricity. ）
<2> While charging is being carried out as shown in <1>, charge signal voltage is supplied
from R terminal line (charge signal line) to BR terminal on the battery relay through the
backflow prevention diode (D01) in order to charge the battery.
(Backflow prevention is one of the two major functions of diodes. If it short-circuits, the engine
will not start because R terminal on the safety relay remains turned on at the time starting
operation.)
<3> R terminal line (charge signal line) is also connected to R terminal on the safety relay
to supply charge signal voltage. When R terminal carries current, the relay does not torn on,
preventing connection of B and C terminals. Since no current flows to C terminal on the
starting motor even if the starting key is set to START position accidentally while the engine is
running. (This is called dual extrusion prevention function of the safety relay.)
<4> In addition, R terminal line (charge signal line) diverges before the backflow
prevention diode and connects to the monitor panel to act as the input signal line for battery
charge level.
(The signal is used to control lighting of the caution lamp for the charge level monitor, etc.)

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ALTERNATOR (GENERATOR)
2 3 4 5 6 7 8 Principle of electric power generation
(1) Flowing direct current through the
1 rotor coil produces magnetic field around
the coil.
9 (2) Since the magnetic field produced as
described in (1) cuts across the stator coil
due to the rotation of the rotor shaft,
alternate current (3-phase AC) is
produced.
(3) Produced 3-phase AC is rectified by 6
semiconductor commutators (diodes) and
converted to DC.
12

11
R and IG
terminals
10

E12 (X-2)
B terminal
connector
1.Semiconductor 5.Stator coil 　　 9.Pulley 　　
regulator 　　 6.Rotor core 10.Commutator
To safety relay, etc. To starting motor
2.Rear bracket 7.Front bracket assembly
3.Rotor coil 8.Fan 11.Slip ring
4.Stator core 12.Rotor shaft Installed alternator (PC200-7)

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SAFETY RELAY (AFTER STARTING ENGINE)
TO B TERMINAL ON Operation after starting engine
BATTERY RELAY <1> Generated current flows from R
terminal on the alternator to R terminal
<2> on the safety relay. The current flows
through R2 resistance and Z Zener
<2> <3> diode, and turns on Q1 transistor.
<2> Even if the starting key is set to
TO STARTER SWITCH
START position again after the engine
started, the current flowing from C
TO R TERMINAL ON terminal through R4 resistance can
BATTERY CHARGER not carried through Q2 transistor and
<2>
① the transistor does not turn on
TO C TERMINAL 　
ON STARTER 　 because Q1 transistor remains turned
SWITCH on.
<1> <1> <3> As a result, L relay does not
operate. The current does not flow to
C terminal on the starting motor and
the motor can not rotate.
<4> Z Zener diode allows the current
FOR GROUNDING to flow through it only when the
generated voltage of the alternator is
higher than a certain level. The safety
relay is designed so as not to cut the
current flow to C terminal immediately
after the start of electric power
generation.

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 SENSORS AND
ACTUATORS

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REVOLUTION SENSOR (ELECTROMAGNETIC PICK-UP)
Structure and function
- Pulse voltage is generated in the pick-up coil
when rotating blade of magnetic material
Coil Permanent magnet approaches or recedes to/from the coil by
electromagnetic induction (electromotive force is
generated by the change of magnetic flux when a
magnet approaches or recedes to/from a coil.)
- By receiving the voltage with an electronic circuit
in the controller and counting the number of the
pulses per unit time, revolution speed of engine,
Cast iron transmission, etc. can be measured.

Engine speed sensor

Magnetic flux increases as Magnetic flux decreases

the rotating blade as the rotating blade recedes.
approaches.

Installed engine speed sensor (PC200-7)

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 REVOLUTION SENSOR (HALL IC)
Structure and function
- Hall ICs are installed on Tier III engines. (Two types
Hole for mounting
of sensors; Ne speed sensor and crank angle sensor)
- Hall IC is built in the sensor head portion. (Hall IC
operates to convert changes of magnetic force into
pulse voltage signal.)
- By receiving the voltage with an electronic circuit in
the controller and counting the number of the pulses
per unit time, revolution speed can be measured.
Sensor head portion
Connector portion
Ne speed sensor Engine controller
Structure of Hall IC
Magnetic Electric signal
force

Hall
IC

Magnetic force (existence

or nonexistence)

Crank angle sensor

Installed CAM sensor and crank angle sensor (SAA6D107E-1)

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STROKE SENSOR (POTENTIOMETER)
Fuel dial Structure and function
- Turning the knob rotates the shaft of the
potentiometer (variable resistance) under the
knob and the value of resistance between the
signal line (No. 2 pin) and grounding line (No. 3
pin) varies.
Front of machine
- Sensor power voltage (5 VDC in most cases,
but depending on controller) is being applied to
across the variable resistance (between No. 1
and No. 3 pins).
- In the structure of fuel dial, change in the value
of resistance leads to change in voltage drop
amount, and then to change in voltage of the
input signal line sequentially, allowing the
1.Knob 　　 controller to grasp the throttle signals.
2.Dial
3.Spring
4.Ball
5.Potentiometer
6.Connector

Fuel dial
Installed fuel dial (PC200-8)

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FUNCTION OF STROKE SENSOR

Characteristics of fuel dial output

Judgment on the value of sensor output signal
voltage
- In fuel dial, the relationship between degree of
Degree of accelerator opening

accelerator opening and throttle ・ voltage is linear

(proportionality relation) as shown in the graph on
the left. The controller grasp the degree of
accelerator opening based on the voltage value.
- When an abnormal voltage (hatched area in the
graph, that is, 0.25 VDC or less, or 4.75 VDC)
appears in the signal line, the controller deems
Throttle voltage characteristics Voltage
the fuel dial malfunctioning and issues “Error
Code”.
Function of potentiometer
Potentiometer, a typical sensor among those used in input signal line, grasps mechanical
stroke amount based on the idea that the voltage varies proportionally to the change of the
stroke. In the engine control line, fuel dial mentioned above utilizes the function of
potentiometer.
Example of use of potentiometer
As described in “Monitor line sensor”, potentiometers are used in various parts of machine
control and engine control lines. Examples of use are given below.
Monitor lime; Fuel level sensor Engine control line; Fuel dial, governor potentiometer
Machine control line; PCCS lever of bulldozers, accelerator pedal of bulldozers, wheel loaders
and off-highway dump trucks, work equipment position sensor of hydraulic excavators, work
equipment lever position sensor of wheel loaders, etc.

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HANDLING OF STROKE SENSOR (INITIAL SETTING)

Precautions when sensor is replaced

- When potentiometer is replaced, the value of voltage at the stroke end of a mechanism changes from
the proper value due to the error in its mounting location. Accordingly, you are usually requested to
carry out the operation to teach the relation between the stroke end position and proper maximum and
minimum voltage values at the position. The operation is called initial setting. (The operation is also
necessary when the controller is replaced.)
(From a viewpoint of safety or accuracy, the operation is unnecessary for some sensors like a fuel dial.)
- Select the option for the operation from the service mode menu of monitor panel and perform it
referring to Shop Manual. (Note that the method depends on machine model and sensor.)

Example: When potentiometer for PC228US-3E0 boom Replacement procedure of boom angle
electronic cushion function is replaced
potentiometer
Reset function Remove and install the boom angle
Calculated value
Perform boom “RAISE” operation until potentiometer according to the following
Standard value procedure.
the boom reaches its stroke end, and
When the boom angle potentiometer is
Correction value input the input rest signal. The removed and installed, the initial setting value
controller calculates the difference stored in the pump controller changes. Be
between boom angle calculated sure to carry out the initial setting operation
based on the output voltage from the after the installation is completed.
potentiometer and the standard angle Installation
stored in it, and stores the difference 1.Install in the reverse order of removal.
as a correction value. 2.Perform the initial setting of the boom angle
When the controller is replaced, you potentiometer from the service mode of
must have the controller store the machine monitor.
correction value by using this Refer to “Special function of machine
function. monitor” for adjustment procedure.
(Adjustment [07] in service mode)

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SOLENOID VALVE (ON-OFF) ( I )

Demagnetized Excited Actuator

Actuator

Spring
force
Electromagnetic force

Controller Controller
or battery or battery

Control circuit Control circuit

9. Coil 　　 ● Structure and function, and operation

10. Spool - Solenoid valve, a typical component among those used in output signal line, operates
12. Spring spool (10) to change the pass of oil flow in order to operate actuators by using its
P. Control circuit, input property of becoming an electromagnet when current flows through the coil in it.
T. Tank circuit - The state of the solenoid when no current flows through the coil is called
A. Actuator circuit Demagnetized. Under this condition, pressurized oil can not flow into the actuator since
spring (12) is pushing spool (10) and P and A ports are disconnected each other. The oil
is drained from port A to the tank through port T.
- When output signal current from the controller or battery flows through the coil, the
solenoid is excited and magnetic force works on spool (10), allowing it to compress
spring (12). The pressurized oil flows in the actuator from port P through port A.

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SOLENOID VALVE (ON-OFF) ( II )

Solenoid valve

Installed Solenoid valve

(PC200-8)
PC200-7
Application (Solenoid valve is used in every machine control.)
- Hydraulic excavators: PPC lock cancel, operation of merge-divider valve, for pressure rise of 2-
stage relief valve, selection of travel speed and releasing swing brake, etc.
- Bulldozers: For PPC lock cancel and releasing parking brake, etc.
- Wheel loaders: Work equipment neutral lock valve, for releasing parking brake, etc.
- Off-highway dump trucks: For transmission cut off and releasing parking brake, hoist
changeover valve, for auto suspension, etc.
- Others: Fan reverse rotation solenoid, etc.

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CONTROL METHOD OF SOLENOID VALVE

Positive control Negative control

24V 24V
Controller Controller

Solenoid valve A Solenoid valve A

Solenoid valve B Solenoid valve B

Solenoid valve C Solenoid valve C

Transistor Transistor

Positive control and negative control

- In positive control method, voltage of 24 VDC is applied to the solenoid valve to be operated
only during operation.
- In negative control method, voltage of 24 VDC is always applied to all the coils and the
solenoid valve to be operated alone is grounded.
- Recent machines have adopted the positive control method increasingly from the viewpoint of
safety. Negative control method, however, is still employed in the circuits of wiper motor,
window washer motor, etc.
- Switching circuit of transistor turns on or off the solenoid valve.

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PROPORTIONAL SOLENOID VALVE ( I )

Controller Actuator 2. Spool

3. Spring 　
4. Push pin
5. Coil
6. Plunger
Structure and function, and operation
- Proportional solenoid (EPC valve) means the
valve that has proportional relationship between
its valve opening and the command current value
sent from the controller to it, allowing it to be
controlled proportionally.
EPC ＝ Electric Pressure Control
- As the current flowing through coil (5) increases,
the generated electromagnetic force increases
Control and pushes spool (2) to the right through push pin
circuit (4) while compressing spring (3).
- The spool stops at the position where the two
forces are balanced as shown below.
Electromagnetic force = PSIG port pressure +
Spring (3) force
- Port PSIG pressure varies in proportion to the
value of the command current (= electromagnetic
force).

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PROPORTIONAL SOLENOID VALVE ( II )
Relationship between command current and output pressure

LS-EPC solenoid

PC-EPC solenoid (rear)

Installed proportional solenoid valve (PC200-8)

Application (Proportional solenoid valve is used in every machine control.)

- Hydraulic excavators: For CLSS pump control (LS-EPC, PC-EPC), OLSS pump control (TVC valve) and
attachment flow rate control, etc.
- Bulldozers: For HST system pump travel motor control, HSS work equipment control and main spool
control of PCCS lever, etc.
- Wheel loaders: For main spool control of electric work equipment lever and steering/ work equipment
pump control, etc.
- Off-highway dump trucks: For transmission and torque converter control (ECMV valve ECMV ＝ Electronic
Control Modulation Valve), etc.
-Others: For fan speed control of hydraulic driven fan, etc.

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PRESSURE SENSOR ( I )

1. Sensor
2. Connector

Structure and function, and operation

- Pressure sensor converts pressure
into voltage signal.
Example of PC200-8 pump - The diaphragm on the pressure
Insulating layer
pressure sensor detection portion bends when oil
pressure from pressure introducing
portion applies to it.
Gauge
portion
- Value of resistance of the gauge
portion varies according to the bend of
the diaphragm. Output voltage resulting
from the resistance variation is amplified
Diaphragm by the amp (amplifier) and sent to the
(Stainless steel)
controller as input signal voltage.
Troubleshooting method
- Since the sensor can not be checked
upon the value of resistance, check it
upon the voltage value after confirming
that the wiring harnesses are no
problem.

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 PRESSURE SENSOR ( II )

Relationship between sensor output voltage and oil pressure

Rear pump pressure sensor
Sensor output voltage (E)

Oil pressure (P)

Application (Pressure sensor is used in every machine control.)

- Hydraulic excavators: Pump pressure sensor (front and rear),
PPC pressure sensor (PC200-8)
- Bulldozers: Sensors for brake pressure, HST charge pressure,
HST pump pressure, work equipment pump pressure and torque
converter input/output pressure, etc.
- Wheel loaders: Sensors for pump pressure lift arm cylinder
bottom pressure and left brake pressure, etc.
Off-highway dump trucks: Sensors for torque converter oil Front pump pressure sensor
pressure, accumulator oil pressure and suspension pressure, etc.
Installed pressure sensor (PC200-8)
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ELECTROMAGNETIC RELAY ( I )

Common terminal Coil Coil terminal

NO terminal
COM terminal
NC contact
NC terminal
OFF ON

Structure and function, and operation

- Electromagnetic relay is a tectonics device
that turns on or off the switch by using
NO contact electromagnetic force generated when applying
current to the coil.
- The relay is used in the circuit where it is
requested to switch on or off large current by
using small current.
- NC contact; Turns on when applying no
current to the coil (normally closed) 　
- NO contact; Turns on when applying current
to the coil (normally open)
- COM terminal; Shared terminal (common
terminal)

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ELECTROMAGNETIC RELAY ( II )
For ON-OFF operation circuit
Application 　
- Hydraulic excavators: Working lamp, PPC lock 　
Turn on/off of lamp - Bulldozers: Working lamp, neutral lock
- Wheel loaders and off-highway dump trucks: Front
lamp, backup lamp, brake lamp, turn signal, neutral lock,
Starting motor cutoff function etc.
- All Komatsu machines: KOMTRAX engine lock 　
Prevents current from flowing to S terminal of the safety relay by cutting off the C terminal line.

For self-holding circuit

Starting motor cutoff relay
<1> Switch 1 closes.

Switch 1
Lamp lights up.

<2> Then, switch 1

opens.
Switch 2
Lamp remains in
Battery lighting up.

<3> Switch 2 opens.

Relay
Lamp
Lamp goes off.
Relay for light

Application - Wheel loaders: For parking brake safety Installed electromagnetic relay (PC200-8)

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HOW TO USE T-ADAPTER
Resistance measurement

Sensor,
Controller solenoid valve, Resistance measurement
etc
- Select suitable T-adapter.
Disconnect Connect - Turn off the chassis power supply.
- Connect the connector on the
resistance measurement side
alone.
- Measure with the tester in
Resistance range.
Ω Measurement box

Voltage measurement
Voltage measurement - Select suitable adapter of T-
Sensor, adapter.
Controller solenoid valve, - Connect T-adapter to connectors
etc on both sides.
Connect Connect - Measure the voltage with chassis
power supply turned on (start the
engine if needed).

Caution
- Never use T-adapter for current
Measurement box measurement.

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 ~ END~

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