07 Electric Sysetem LG958L

LG958L Training Material
Chapter X Electric System

Tuesday, May 19, 2015
RELIABILITY IN ACTION
CONTENTS
Structure, Characteristics, and Circuit Diagram Analysis of Electric System
Power Supply and Starter System
Instrumentation and monitoring system
Automatic leveling of bucket
Lighting
Backup warning system
Wiper and washer
Electric horn
Spare socket
Section I Composition, Structural Characteristics, and Circuit

Diagram Analysis of Electric System of Loader
The electric system is an important
part of the loader and is mainly
functioned for start and control of

diesel engine and fulfillment of the
operations
including
lighting,
signal indicators, and instrument
monitoring. The quality of electric

system
directly
influences
the
working reliability and the traveling

and operation safety of the loader.
I. Main Composition of LG958L Electric System
The electric system of loader is mainly composed of the following 5 parts:

1. Power part: Including the battery and alternator assembly.
2. Start part: Mainly including starter, starter relay, and electric lock, which
are functioned to start the diesel engine.
3. Lighting and signaling part: Mainly including all kinds of lighting and
signal lamps and horns and buzzers, which are functioned to ensure the
safety of human and machine and the successful implementation of
operations under all kinds of operation conditions.
4. Instrument monitoring part: Including pressure gauges, pressure

sensors, temperature gauges, temperature sensors, and low pressure
alarms.
5. Control part: Engine control unit and transmission control unit (detailed
in the engine system and transmission system).
6. Accessory part: Including the electric wiper, heater, and A/C system.
II. Characteristics of Electric System of LG958L Loader

1. Low voltage:
The rated voltage for electric system of the LG958L loader is 24V powered by two
12 batteries in series connection.
2. DC
The diesel engine is started by the starter motor. The starter motor is a DC series
excitation motor that must be powered by battery. Therefore, the DC current must
be used to charge the battery, which determines that the electric system of the
loader is a DC system.
3. Single-wire system
All electric devices are in series connection, namely only one wire is connected
from the positive post of power supply to the switch and the electric devices and
the metal bodies such as the loader frame, diesel engine block, transmission, and
torque converter are functioned as the public grounding wire. When the
single-wire system is adopted, the wire that connected to the metal body is
referred to as grounding wire. The connection between the negative post of
battery and metal body (such as frame) is referred to as negative grounding
and the connection between positive post and metal body is referred to as
positive grounding.
III. Circuit Diagram and Malfunction Analysis Method of

Construction Machinery
Expressing method of loader circuit diagram: The circuit diagram is a integral

body in which the power supply, starter system, lighting, instruments, and
accessories are connected by switches, wires, and fuses as per the
corresponding working characteristics and mutual internal relationship.
1) Expressing method for circuit diagram of loader
The expressing methods include circuit diagram, schematic diagram,
harness diagram, and distribution diagram of electric units.
2) Circuit analysis
Abiding principles of circuits:
1. Single-wire system
2. All electric devices are in parallel connection and are controlled by
corresponding switches.
3. Low voltage. All electric devices adopt 24V design (the output voltage
of alternator is 28V).
4. Negative grounding of battery.
IV. Circuit Principles to be Borne in Mind
Every complete circuit is composed of power supply, fuse, switch, control device,
electric device, and wires. The flow direction of the current must start from the
positive post of power supply, reach the electric device through fuse, switch,
control device, and wires, and then return to negative post of power supply
through wire (or grounding wire) to form the circuit. Therefore, there are three
thoughts for reading the electric circuits:
Thought 1: Along the flow direction of the circuit current, start from the positive
post of the power supply, check the electric device, switch, and control device,
and return to negative post of power supply.
Thought 2: Against the flow direction of circuit diagram, start from negative post
of power supply (earthing) and return to positive post of power supply through
electric device, switch, and control device.
Thought 3: Start from electric device, check the control switch, wires, and control
unit, and finally reach the positive post of power supply and grounding wire (or
negative post of power supply).
During the actual application, choose different thoughts depending on specific

circuit. However, please pay attention to this point that, following the extensive
application of the electric control technology, most of the electric device circuits
incorporate the main circuit and control circuit. Therefore, both circuits shall be
taken into consideration while reading the diagram.
8
Circuit diagram of LG958 electric system
Section II Power Supply and Starter System
10
Power circuits of engine and transmission
11
I. Battery (6-QW-120B)
The overall machine adopts 2 batteries in
series connection. The battery is one
invertible DC power supply and is parallel
connected with alternator to power the
electric devices. A single battery can supply
200A~600A start current to the starter motor
within a short period (5~10s). The battery is
also equivalent to a large capacitor, which
can absorb the over-voltage that may occur
any time in the circuit, in order to protect the
electric devices against puncture.
Caution: The battery must be securely and reliably installed, in order to
prevent damage due to bumps during traveling of the machine. Please turn
off the power switch when the machine is to be parked for a long time.
Warning: Please keep open fire away from the battery. Before the welding
operations, please disconnect all connecting wires of the battery, in order to
prevent explosion.
12
ID rId2
13
1. Installation location of battery
2. Structure and color change of charge indicator
1 Green 2 Black 3 Light yellow 4 Battery cap 5 Observation

window 6 Optic charge indicator 7 Green small ball
Color of charge
indicator
Electric quantity
The electric quantity is above 65% and the
battery is normal
The electric quantity is less than 65% and the
charging is required.
The battery is over-charged and shall be

replaced with new one.
Figure 10-1 Structure and color of charge indicator
14
2. Structure and color change of charge indicator

The electric quantity of the battery can be understood via the color change of
charge indicator (also referred to as charge indication densimeter). Green
Normal, black to be charged, light-up (or white) depleted.
When the machine cant be started, firstly please check the electric quantity of
the battery and check the battery cables for reliable connections.
Caution: While frequently checking the battery cable connections and

connecting points for reliable connections, please firstly disconnect the
negative post of power supply.
At the time of assembly, firstly assemble the positive post of battery and then
assemble the negative post. At the time of disassembly, firstly disassemble the
negative post and then disassemble the positive post. This is intended to
prevent the short-circuit from damaging the battery posts and wrenches.
Check method for terminal voltage of battery: Check with DC 200V measuring
range of multimeter. Connect the red probe to the output cable end of the
positive post of battery and connect the black probe to the negative post of the
battery. The reading of the multimeter is the terminal voltage of the battery
(generally at 24V~26V).
15
II. Power switch
Figure 10-2 Power switch
Power switch (K01K18-A, also referred to as

negative switch):
The power switch controls the connection and

disconnection between battery negative post
and frame (grounding). Turn on the power
switch to connect the negative post of battery
with frame. Turn on the electric lock to power
on the electric loads of overall machine. Turn off
the power switch to cut off the negative post of
battery from frame so that no loop is formed in
the circuits of the overall machine. Even when
the electric lock is turned on, the overall
machine cant be powered on nor started. The
installation location of the power switch is
shown in Figure 10-2.
Operations of power switch: is turn-off
position and is turn-on position.
Warning: When the loader is parked for a long time, please ensure to
turn off the power switch, in order to prevent electric leakage and
other accidents. Before connecting the battery cables, re-tightening
the battery cables, or disconnecting the connecting wires of battery,
please make sure to turn off this switch for the purpose of safety.
16
III. Alternator
3.1 Working principle of alternator
The schematic diagram of alternator is

shown in Figure 10-3. The alternator is
composed of rotor, stator, drive pulley,
fan, front and rear end caps, and electric
brush. The excitation winding is generally
wound on the rotor and the stator adopts
Y-shaped connection mode. The rectifier
is generally a 6-tube bridge full wave
rectifier.
1. When a DC voltage is applied on two

ends of excitation winding, the current
will generate a magnetic field. Driven
by the engine, the magnetic field
rotates along with the rotor and the
three-phase symmetric winding of the
stator will, under the application of
rotating magnetic field, generate
three-phase sine electromotive force
with same frequency and same
amplitude in spacing of 120.
17
2. The unidirectional conduction performance of silicone diode is

utilized for rectification. At any moment, only the positive diode
connected with the winding of the phase with highest potential is on.
In same way, the negative diode connected with the winding of the
phase with lowest potential is on. Through the sequential turn-on of
six diodes repeatedly, one relatively stable pulsed DC voltage is
obtained at two sides of the load.
3. The terminal voltage of alternator is proportional to the speed of the
alternator. Due to high speed variation range of the engine, the
terminal voltage of alternator will also vary within a high range and
the output of terminal voltage can't meet the operation requirements
of the loaders electric devices for constant voltage. Therefore, the
voltage regulator must be set.
18
Figure 10-3 Schematic diagram of alternator
4. The voltage regulator utilizes the on/off of switching tube to change the size of
excitation current so as to change the intensity of magnetic field to stabilize the
voltage of the alternator.
5. The filter capacitor is mainly functioned to filter away the peak pulse and high
frequency interference issued by the alternator.
19
3.2 Wiring method of alternator
Figure 10-4 Alternator
The alternator is generally an assorted part of

diesel engine and has three lead terminals, as
shown in the Figure 10-4, which are
respectively:
B+: Alternator power output terminal
D+: Charging indicator signal
W+: Phase output terminal, which can be
functioned as timer signal as well as
speedometer signal.
The alternator is in parallel connection with
battery set to power the electric devices of
whole loader. The electric devices are
powered by the battery before the start of the
loader and are powered by the alternator
after the start of loader. At the same time, the
alternator also charges the battery set.
Warning: Its strictly prohibited for the alternator to independently power the
electric devices without the battery.
Warning: Its prohibited to check the power generation of alternator by instantly

short-circuiting the positive and negative posts of alternator for generation of
spark, in order to prevent burning the diode and impairing the regulator.
20
3.3 Judgment method for normal power generation

of alternator and treatment
1. Check with DC 200V measuring range of multimeter. Turn on the electric

lock, measure the terminal voltage of alternator (connect red probe to
terminal D+ of alternator and connect black probe to grounding), and
record the reading of multimeter (This reading is actually the terminal
voltage of battery and is generally less than 26V). Start the machine,
measure the terminal voltage of alternator again, and record the
reading of multimeter (If the alternator is generating power normally,
this reading shall be approximate 28V).
2. Treatment
If the alternator fails to generate power or the voltage generated is too

low, firstly check the drive belt of alternator for looseness. Turn off the
electric lock and use wrench to check the wiring terminals of alternator for
correct, tightened, and reliable connections. In addition, check the
alternator for reliable grounding.
21
IV. Starter system
22
IV. Composition of starter system
23
I. Structure of starter motor

The starter motor is an assorted
unit of diesel engine. It is mainly
composed of electromagnetic
switch, DC motor, shifting fork,
and drive gear. The starter motor
converts the electric energy of
the battery to mechanical energy
through DC motor and drives the
engine flywheel through drive
gear to realize the start of
Figure 10-5 Exterior view of starter motor engine.
Warning: After the engine is started, immediately release the starter switch, or it
will lead to damage of drive gears, burnout of DC motor, damage of flameout
electromagnet, and serious impairment of service life of the battery.
Caution: Please frequently check the wirings of contacts and terminals for
reliable connections. Before the checking, make sure to disconnect the negative
post of power supply, or it will probably generate short-circuit spark and damage
the wrench and wiring posts.
24
2. Internal structure of starter motor
25
Figure 10-6 Internal structure and principle description of starter motor
3. Working principle of starter motor
When the power switch is turned on, the 24V terminal voltage of the battery is applied
onto the starter motor via the contact of starter relay. At the moment when the
electric lock is rotated to position START, two coils of the electromagnetic switch
of the starter motor are powered and actuated. The electromagnetic resultant force
generated by above two coils drives the movement of movable contact disc so that
two contacts of the electromagnetic switch are engaged and the current is inputted to
the DC motor coil from the battery for form the circuit via the housing of starter
motor. In such case, the DC motor starts the rotation. At the same time, the iron core
moves to drive the shifting fork to engage the drive gear with the engine flywheel
gear ring. The DC motor drives the rotation of the flywheel and the engine start is
initiated.
26
During the start process (within more than 10s when the electric lock is rotated to
position START), the 1# wire is constantly live (24V) and the contacts 1# and 2# are
constantly engaged. As the contact voltage is 24V, the voltage is equal between two
terminals of the pull-in coil and no current is flowing. In such case, the iron core is
maintained at start status under the action of the electromagnetic force of the holding
coil. When the driver release the electric lock key after the successful start of the
engine, the electric lock automatically returns to position ON and the 1# wire is
powered off immediately. Within a really short period, the flow direction of the current
is contact 1# - contact 2# - pull-in coil terminal S holding coil, and grounding. It can
be seen that the current flow direction is opposite between the holding coil and pull-in
coil. As the magnetic fields generated are in opposite directions, the electromagnetic
forces applied onto the iron core are cancelled out with each other and the iron core
returns to initial position under the action of spring force. In such case, the contacts 1#
and 2# are disengaged, no current flows through the pull-in coil and holding coil, and
the driver gear resets to initial position. The starter motor stops working.
27
28
4. Judgment for common malfunctions of starter motor:

1) Malfunction symptom: The starter motor runs automatically after the
negative switch is turned on.
Cause analysis: This symptom is generally caused by the ablated contacts of

starter relay, electric lock, or electromagnetic switch.
Treatment: Re-grind the contacts and movable contact disc or replace

electromagnetic switch or starter motor.
2) Malfunction symptom: No reaction of starter motor at the time of start.
Treatment: While rotating the electric lock to position START, check the
wire voltage at the electromagnetic switch of pneumatic motor. If no
voltage is detected, check the electric lock, starter relay, and battery (For
instance, check the battery set connecting circuit, negative switch, and
grounding wire for reliable connections), or it can be determined as the
malfunction of starter motor that leads to start failure.
29
Starter switch
30
Battery relay
Back
31
Transmission control unit (ECU)
Engine control unit (ECU)
Back
32
Electric pump
Back
33
Section III Instrumentation and monitoring system
1. Circuit diagram of instrumentation system

The instrumentation system includes the instrument panel assembly, sensor, and alarm
pressure switch, of which the schematic diagram is shown in Figure 3-1.
Fuel gauge
Left turn
lamp
Working
hourmeter
Low engine oil

High beam pressure
Emergency
indicator warning lamp turn lamp
Vehicle speed
Braking air
pressure gauge gauge
Torque
converter oil
temperature
gauge
Strainer
Preheating Handbrake Charging
indicator
warning lamp indicator indicator
Engine water
temperature
gauge
Low air
pressure
warning lamp
Transmission oil
pressure gauge
Instrument panel
Power
Power case
cutoff lamp working lamp Right turn lamp
Low pressure
alarm
Emergency turn
alarm
Braking pressure
sensor
Flasher
Parking brake indicator

switch
Engine oil
pressure switch
Engine water
temperature sensor
Torque converter oil

temperature sensor
Fuel level sensor
Strainer
warning switch
Figure 10-7: Schematic diagram of instrumentation and alarm system
34
35
36
37
38
2. Sensors
2.1 Temperature Sensor
LG958L is fitted with two temperature sensors to monitor the torque converter oil
temperature and engine water temperature. The temperature sensor is equivalent to
a thermistor, of which the resistance is reduced along with the increasing of
temperature. (226Ohm at 26C ambient temperature and 26.4Ohm at 115C)
Figure 10-9 Exterior view of

temperature sensor
39
Figure 10-10 Torque converter oil

temperature sensor
2.2 Braking air pressure sensor
Figure 10-11 Internal structure of braking air pressure sensor
The swing of the instrument pointer is achieved by the change of current arising
from the slide of resistor pointer within the sensor, which is caused by the
deformation of beryllium bronze diaphragm due to change of pressure, as shown in
Figure 10-11.
2.3 Fuel level sensor
The fuel level sensor is actually a discrete slide resistor, of which the resistance is
reduced along with the increasing of fuel level. Its installed on the fuel tank.
40
2.5 Alarm pressure switch

The overall machine is fitted with two pressure switches, namely low braking
pressure alarm switch and low engine oil pressure alarm switch.
The specific installation positions are shown in Figure 10-13 and Figure 10-14
respectively.
The alarm indicator will alarm when the braking air pressure is less than
0.45MPa or the engine oil pressure is less than 0.08MPa.
Figure 10-13 Low braking pressure

alarm switch
41
Figure 10-14 Engine oil pressure alarm

switch
3. Examples for troubleshooting of common malfunctions of

instrumentation and monitoring system
3.1 Abnormal indication of temperature gauge
Disassemble the sensing wire from the temperature sensor (the torque converter
oil temperature gauge and the water temperature gauge correspond to wire 15#
and wire 14# respectively). If the instrument indicates full measuring range when
the sensing wire is grounded and indicates minimum reading when the sensing
wire is hung in the air, it indicates that the instrument and circuit are normal and
the sensor is damaged. Replace the sensor. Otherwise, check the circuit. If the
circuit is normal, the instrument is malfunctioned.
3.2 Abnormal fuel level indication
Disassemble the sensing wire (wire 19#) from the fuel level sensor. If the
instrument indicates full measuring range when the sensing wire is grounded and
indicates minimum reading when the sensing wire is hung in the air, it indicates
that the instrument and circuit are normal and the sensor is damaged. Replace the
sensor. Otherwise, check the circuit. If the circuit is normal, the instrument is
malfunctioned.
42
Section IV Automatic Resetting System of Bucket
1. Schematic diagram
The schematic diagram is shown in Figure 10-15.
Floating
solenoid valve
Bucket solenoid
valve
Boom solenoid
valve
Brown
Load
Blue
Black
Brown
Blue
Black
Normally closed (N.C.)
Proximity switch (boom)
Proximity switch (bucket)

Blue
Brown
Black
Figure 10-15: Schematic diagram for circuit of automatic resetting system

43
1.1 Bucket leveling limiter:
Figure 10-16 Bucket retraction

rod and proximity switch
44
This device is composed of proximity switch

installed on the bucket cylinder bracket (as shown
in Figure 10-16) and solenoid valve on the pilot
valve. There is a red indicator on the proximity
switch, which indicates the status of the proximity
switch. When the retraction rod is misplaced from
the proximity switch, the proximity switch is turned
off, the red indicator goes off, and there is no
output signal in the black output wire. If the driver
pulls the bucket operating lever to the most
rearward position when there is no unloading angle
for the bucket, the magnetic circuit is turned on so
that the electromagnetic field force generated by
the solenoid coil will hold the bucket operating
lever (in such case, the driver may release the
operating lever and the bucket operating lever will
not return to neutral position) and the bucket will
keep retracting, till the proximity switch approaches
the retraction rod. In such case, the proximity
switch is turned on, the red indicator lights up, the
solenoid coil is turned off, and the magnetic force
disappears so that the bucket operating lever
automatically returns to neutral position under the
action of spring force and the bucket stops at
leveling position.
1.2 Boom floating device
This device does not incorporate the proximity switch and only
incorporates a boom floating coil that is located on the pilot valve. After
the electric lock is turned on, the coil is powered on constantly. When the
driver pushes the operating lever to most forward position, the magnetic
circuit is turned on so that the electromagnetic field force generated by the
solenoid coil will hold the boom operating lever (in such case, the driver
may release the operating lever and the boom operating lever will not
return to neutral position) and the pilot valve connects the oil lines of
rodless and rod chambers of boom cylinder with the oil pipes by
controlling the distributor valve. In such case, the pressure is zero for both
rodless and rod chambers and the pressure difference is also zero. If the
driver pushes the boom operating lever to floating position during the
loading operations, the bucket will fluctuate along with the ups and downs
of the ground. If the driver pushes the boom operating lever to floating
position to operate the lowering of boom, the boom will lower at fastest
speed under the action of dead weight, in order to improve the working
efficiency.
45
1.3 Troubleshooting of system malfunctions

Check 10A fuse for burnout.
Check all connectors for good connections.
Check gap between metal body and proximity switch (generally no

more than 8~10mm).
Check proximity switch for damage: Turn on the electric lock. The red
indicator shall light up when the metal body approaches (When
measured with multimeter, the black output wire shall be connected to
ground).
Check the pilot coil: The resistance is approximate 100~200Ohm for

three pilot coils.
46
Section V Lighting System
47
1. Circuit of front combination lamp
1.1 Schematic diagram for circuit of front combination lamp

Combination switch
Terminal
GreenBrownYellow Red Black Grey Blue Orange White
Position
Off
Left
turn
Right
turn
Backlight
(headlamp
low beam)
Left combination lamp

Right combination lamp
(headlamp
high beam)
Warning lamp switch
H
ea High
dl beam
am
Low
p beam
Terminal
Position
Overtaking
lamp
Off
Right rear lamp Left rear lamp

Gr
ee
n
Br
ow
n
Ye R
lo e
w d
Bl
ac
k
Gr
ey
Bl
ue
O
ra
ng
e
W
hi
te
R
es
er
ve
d
Figure 10-18: Schematic diagram for circuit of front combination

lamp, turn lamp, and warning lamp
48
1.2 Principle description

When the electric lock is turned on, the 10A headlamp fuse within
the 20-circuit fuse case is turned on (24V) to turn on the
combination switch via wire 44# and turn on the contact of high
beam/low beam relay of front combination lamp via wire 35#. When
the combination switch is not turned on, the wire 49# and wire 50#
are not turned on and both left and right headlamps are not
working. When the combination switch is at high beam or low beam
position, the wire 49# or 50# is turned on (24V) and the coil of high
beam/low beam relay of front combination lamp is turned on and
actuated so that high beam or low beam of front combination lamp
is turned on (24V) and left and right headlamps work at
corresponding position.
49
1.3 Troubleshooting of common malfunctions of system

Lighting failure of headlamp
1.3.1 Check the bulbs for blackening. If yes, it can be determined
that the bulbs are damaged. Replace the bulbs.
1.3.2 Unplug the connector, shift the dimmer switch to high beam
position and low beam position respectively, and measure the
voltage between wire 49# and wire 50# at the connector with
DC voltage measuring range of multimeter. If the voltage is
24V, check the connector for reliable connection. If the
connection is loose, re-connect. If the connection is secure,
the internal wire of headlamp is loose or the bulb is damaged.
If the voltage is 0V, check as below.
1.3.3 Check the 10A headlamp fuse for burnout.
1.3.4 Check the connectors for reliable connections and check the
harnesses for wear.
1.3.5 Check the functions of dimmer switch positions as per the
Accessories Combination Switches.
50
2. Circuits of working lamp, rear lighting lamp, and

interior lamp
Rocker switch of rear lighting lamp (high beam and low beam)
Terminal
Position
Rear lighting lamp
Rear lighting lamp
OFF
Figure 10-19: Schematic diagram of rear lighting lamp
51
Rocker switch of headlamp
Rocker switch of rear illuminator
Terminal
Terminal
Position
Headlamp
OFF
Position
Headlamp
OFF
Figure 10-20 Schematic diagram for headlamps and rear illuminators
2.1 Four lamps on the top front and rear of the cab are defined as headlamp and rear illuminator,
two lamps on the rear hood are defined as rear lighting lamp. The switch of interior lamp is
attached. Refer to Accessories Rocker Switches for details of switches of rear lighting lamps
and working lamps.
2.2 Schematic diagram: As shown in Figure 10-19 and Figure 10-20.
2.3 The basic principle and the troubleshooting of system malfunction are basic same with the
headlamp circuit and are omitted herein.
52
3. Circuit of turn lamps:

3.1
Schematic diagram: As shown in Figure 10-18.
3.2.1
The actual combination switch and installation position are shown in Figure 54 and Figure 5-5 respectively. The turn lamp switch is realized by partial
function of the combination lamp and the wire colors of three pins used are
grey, yellow, and white, of which the grey wire is connected to turn flasher
power supply (wire 33#), the yellow wire is connected to left turn signal wire
(wire 6#), and the white wire is connected to right turn signal wire (wire 7#).
3.2
Introduction of main units:
Figure 10-21 Combination switch
53
Figure 10-22 Installation position of combination switch
3.2.2 Flasher relay (SG252): Three pins of the flasher are defined as below:
B power terminal, connected to wire 21#; L Flasher signal output
terminal, connected to wire 33#; E Grounding, connected to wire
0#. During normal working, the flasher relay will issue slight
rattle sound at a frequency of approximate 50 cycles/min.
Otherwise, it can be determined that the flasher relay is damaged.
3.2.3 Warning lamp switch: The parking lamp switch controls four turn
lamps and two turn indicators on the instrument panel. When this
switch is turned on, four turn lamps and two turn indicators flash at
the same time to alert the vehicles crossing by.
54
The basic principle and the troubleshooting of system malfunction

are basic same with the headlamp circuit and are omitted herein.
4. Circuit of clearance lamp:

4.1 Schematic diagram: As shown in Figure 10-23.
Right combination lamp
OF
F
P
o
si
ti
o
n
T
e
rm
in
al
Rocker switch of
backlight
Right rear lamp
Left rear lamp
Figure 10-23: Schematic diagram for circuit of clearance lamp

55
Figure 10-24: Combination headlamp Left
Figure 10-25: Left rear tail lamp
4.2 The installation positions of the clearance lamps are shown in Figure
10-24 and Figure 10-25.
4.3 The basic principle and the troubleshooting of system malfunction are
basic same with the headlamp circuit and are omitted herein.
56
57
58
5. Brake lamp circuit:

5.1 Schematic diagram: As shown in Figure 10-26.
To ECU case
Intermediate relay
(power cutoff)
Intermediate relay Intermediate relay

(start interlock)
(backup)
Parking brake indicator switch
To starter relay signal

terminal
To backup lamp
To terminal G2 of starter
switch
Brake switch (left)

To instrument panel ECU case indicator
To brake lamp
Brake switch (right)
Figure 10-26: Schematic diagram for circuit of brake lamp
59
5.2 Principle description:
When the brake pedal is depressed, the braking air pressure at the brake lamp switch engages the
contact of brake lamp switch so that the current flows to brake lamp through 10A fuse, wire 57# at
brake lamp fuse, brake lamp switch, and wire 8# to light up the brake lamp.
5.3 Brake lamp switch: The switch adopts normally open contact, which acts and engages at
approximate 1.3bar.
Troubleshooting How to judge the damage of brake lamp switch: Firstly determine whether the
braking pressure is normal (turn on the electric lock. If the low service braking pressure alarm lamp
on the instrument panel is off, it indicates that the braking pressure is normal. Otherwise, start the
engine, till the low service braking pressure alarm lamp is off). If normal, unplug the wire at the brake
lamp switch and measure two pins of the switch with 200Ohm measuring range of multimeter. If the
measurement differs from the table below, it indicates that the pressure switch is damaged and shall
be replaced.
Brake pedal is not

depressed
Brake pedal is
depressed
OFF
ON
Figure 10-27: Installation position of brake lamp switch
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Section VI Backup Warning System

Right rear lamp
Left rear lamp
Backup buzzer
Backup switch
Figure 10-28 Schematic diagram for backup warning system
1. Principle description:
When the electric lock is turned on, the 10A backup warning fuse is turned on (24V).
When shifted to reverse gear, the backup switch is turned on, the wire 9# is turned on,
and the backup warning buzzer sounds. At the same time, the backup lamps on the left
and right rear lamps light up.
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2. Analysis of Common Malfunctions

The backup warning buzzer fails to sound when the electric lock is turned on and
the reverse gear is engaged.
1. Check the 10A backup warning buzzer fuse for burnout.
2. Check the connectors and wires for secure and reliable connections. Generally,
the loose connector or worn harness will lead to middle open-circuit of wire 9#.
3. Check the backup switch for damage. If normal, two wires of the backup switch
are connected when the reverse gear is engaged.
4. If no problem is detected in above checking items, check the voltage of wire 9#
at the backup warning buzzer. If the voltage is normal (24V), it indicates that the
backup warning buzzer is damaged and shall be replaced. If no voltage is
detected, generally the connector is loose or the harness is worn.
Analysis of common malfunctions: After the electric lock is turned on, the backup
warning buzzer sounds constantly no matter which gear is engaged. This problem
is generally caused by the bonded contact of backup switch. In few cases, its
caused by the short-circuit between wire 9# and certain power wire.
62
Section VII Wiper and Washer System
1. Principle description
1.1 Principle of washer: When the electric lock is turned on, the 10A wiper fuse is powered
on (24V) to turn on the washer switch (its an automatic resetting rocker switch. Please
refer to the Accessories Rocker Switch for details) so that the washer motor (installed
on the water reservoir) is powered on via wire 37# to pump the water from water
reservoir to the nozzles (installed beneath the front windscreen of the cab) and spray
onto the windscreen.
Rocker switch of washer reservoir (with resetting
function)
Terminal
Spray motor
Rocker switch of front wiper

Terminal
Position
Position
OFF
OFF
Front wiper
Figure 10-29 Schematic diagram of wiper and washer system
63
1.2 Principle of wiper:

The wiper motor is a permanent magnet motor that adopts the positive control
mode.
As shown in the figure, the wiper motor has 4 output wires, of which the red is
the power wire (the public wire for high speed armature and low speed
armature), the black wire is the resetting wire, the blue wire is another brush wire
for high speed armature, and the white wire is another brush wire for low speed
armature. When the electric lock is turned on, the wire 37# is powered on (24V).
If the wiper switch (refer to Accessories Rocker Switch for details) is at position
I, the pin 37# and pin 24# are connected and the motor runs under low speed
mode.
If the wiper switch is at position II, the pin 37# and pin 26# are connected and
the motor runs under high speed mode.
If the wiper switch is turned off (namely rotate from position I to position
OFF), the pin 24# and pin 25# are connected. At the wiper is not stopped at
the initial position at the moment when the switch is turned off, the current flows
through wire 25# - wiper switch pin 24# - low speed armature grounding
(Note: There is an internal automatic stop device to ensure that the wiper always
stops at initial position. When the wiper is at initial position, the resetting wire is
connected to the ground).
64
2. Troubleshooting of common malfunctions

2.1 Working failure of wiper motor
1.
Check 10A wiper fuse for burnout.
3.
Check connectors for looseness and harnesses for wear.
2.
4.
Check wiper switch for damage.
Check wiper motor armature for short-circuit or opencircuit.
2.2 No water spray from nozzles

1.
Observe the motor for running and pumping of water.
3.
Check the nozzles for blockage.
2.
65
Check water line for interruption (The water pipe is

disconnected or over-tightly bundled).
Section VIII Electric horn system

Horn assembly
Horn button
Figure 10-30: Schematic diagram for circuit of

electric horn
Figure 10-31: Installation

location of electric horn
1. Principle description:
When the electric lock is turned on, the 10A electric horn fuse is turned on
(24V). When the electric horn switch is pressed, the current flows through
10A electric horn fuse electric horn electric horn switch grounding and
the electric horn sounds continually (as shown in Figure 8-2).
66
The electric horn fails to sound when the electric lock is turned on and the
electric horn switch is pressed:
2.1
Check 10A electric horn fuse for burnout.
2.3.
Check connectors for looseness and harnesses for wear.
2.2
2.4
67
Check electric horn switch (the button switch in the center of steering
gear) for normal functioning. Normally, the wire 12# is grounded
when the electric horn button switch is pressed.
Check the electric horn for damage (For two wiring posts of the
electric horn, connect one post to 24V power supply and connect
another to ground. If the electric horn fails to sound, it can be
determined as the damage of electric horn).
Section IX Spare Socket System

Spare socket
Figure 10-32: Schematic diagram for

circuit of spare socket
1. Principle description
Figure 10-33: Installation

position of spare socket
When the electric lock is turned on, the 10A spare socket fuse is turned on (24V) to turn on
the spare socket through wire 77# and wire 0#. When the external power supply is required,
after the external wire and plug are correctly connected, insert into the socket to obtain the
power. Please be noted that the consuming power shall not exceed 150W. The spare socket
provides a standard DC 24V power socket for connection of external loads such as electric
kettle and interphone. The installation position is shown in Figure 10-33.
68

Working failure of spare socket:
2.1 Check the 10A spare socket fuse for burnout.
2.2. Check connectors for looseness and harnesses for wear.

2.3 Check the spare socket for damage.
69
THE END
70

07 Electric Sysetem LG958L

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LG958L Training Material

Chapter X Electric System

Section I Composition, Structural Characteristics, and Circuit

part of the loader and is mainly

functioned for start and control of

signal indicators, and instrument

monitoring. The quality of electric

working reliability and the traveling

I. Main Composition of LG958L Electric System

The electric system of loader is mainly composed of the following 5 parts:

4. Instrument monitoring part: Including pressure gauges, pressure

II. Characteristics of Electric System of LG958L Loader

III. Circuit Diagram and Malfunction Analysis Method of

Expressing method of loader circuit diagram: The circuit diagram is a integral

IV. Circuit Principles to be Borne in Mind

During the actual application, choose different thoughts depending on specific

Circuit diagram of LG958 electric system

Section II Power Supply and Starter System

Power circuits of engine and transmission

1. Installation location of battery

2. Structure and color change of charge indicator

1 Green 2 Black 3 Light yellow 4 Battery cap 5 Observation

The battery is over-charged and shall be

Figure 10-1 Structure and color of charge indicator

2. Structure and color change of charge indicator

Caution: While frequently checking the battery cable connections and

II. Power switch

Figure 10-2 Power switch

Power switch (K01K18-A, also referred to as

The power switch controls the connection and

3.1 Working principle of alternator

The schematic diagram of alternator is

1. When a DC voltage is applied on two

2. The unidirectional conduction performance of silicone diode is

Figure 10-3 Schematic diagram of alternator

3.2 Wiring method of alternator

Figure 10-4 Alternator

The alternator is generally an assorted part of

Warning: Its prohibited to check the power generation of alternator by instantly

3.3 Judgment method for normal power generation

1. Check with DC 200V measuring range of multimeter. Turn on the electric

If the alternator fails to generate power or the voltage generated is too

IV. Starter system

IV. Composition of starter system

I. Structure of starter motor

2. Internal structure of starter motor

Figure 10-6 Internal structure and principle description of starter motor

3. Working principle of starter motor

4. Judgment for common malfunctions of starter motor:

Cause analysis: This symptom is generally caused by the ablated contacts of

Treatment: Re-grind the contacts and movable contact disc or replace

Transmission control unit (ECU)

Engine control unit (ECU)

Section III Instrumentation and monitoring system

1. Circuit diagram of instrumentation system

Low engine oil

Parking brake indicator

Torque converter oil

Fuel level sensor

Figure 10-7: Schematic diagram of instrumentation and alarm system

2.1 Temperature Sensor

Figure 10-9 Exterior view of

Figure 10-10 Torque converter oil

2.2 Braking air pressure sensor