DM 45 - ELECTRICAL SYSTEM

Rio Paracatu Brazil

July 209
Hans Traub
 ELECTRICAL SYSTEM INFORMATION

The following information is provided to give an understanding of

the electrical system and the relation to the operators control
console.
ELECTRICAL SYSTEM COMPONENTS

Tier 3

Tier 2
ELECTRICAL SYSTEM COMPONENTS
 ELECTRICAL SYSTEM COMPONENTS

Batteries

Note: Four 8D type batteries rated at 12 volts each are used in order to
handle the two starter motors
ELECTRICAL SYSTEM COMPONENTS
Fusible Links
 ELECTRICAL SYSTEM COMPONENTS

The links should never be removed unless they have burned out doing their job.
Then they should be replaced immediately. They should not be replaced with the
regular #1 or #2 wires since there will be no protection for the electrical system.

Bulk fusible link material is listed under CPN 56987795 and the individual 9 inch
length is CPN 56999360. A spare set should be attached to every drill so it is available in
case of a short circuit. If it is not replaced immediately, there is a tendency to forget it
completely over a short period of time. Every mechanic should carry several pieces
with them at all times.

Fusible Links must be in place to operate the drill. If a short circuit destroys a fusible
link, it MUST be replaced before the drill goes back in service.
 ELECTRICAL SYSTEM COMPONENTS

Starter Motor

The starter motor contains the built in starter relay (Relay S2).
The second starter motor used on the engine contains the built in starter relay (Relay S3).

Alternator

The alternator is a 24v, 100 amp model. It is used to charge the batteries and provide
current to the electrical system and the night lights.
 ELECTRICAL SYSTEM COMPONENTS

Key Switch

Note: Always stop the engine and remove the key when leaving the drill unattended or while
performing certain maintenance procedures.
 ELECTRICAL SYSTEM COMPONENTS

Circuit
Breakers

Identification of the circuit breakers on the console

1. 5 amp= Engine Shutdown
2. 15 amp = Windscreen Wipers Note: If there is a recurrence, call for
3. 20 amp = Power Distribution Control service assistance to correct the cause of
4. 15 amp = Compressed Air System the overload in the circuit.
5. 15 amp = Power Distribution Engine
6. 15 amp = Drill Lights
7. 20 amp = Tram Lights
 ELECTRICAL SYSTEM COMPONENTS

Push Buttons

The push buttons on the operators console enable the operator to:

a. Start the engine

b. Pump fuel from the fuel tank to prime the engine fuel system (QSK).
c. Sound an audible warning (horn)
d. Inject ether into the engine intake (option)
e. Bypass the oil pressure switches and engine speed switch (throttle) until the engine
has started and built up sufficient oil pressure.
These push buttons are spring loaded to disconnect power when they are released.

b a e c
d
ELECTRICAL SYSTEM COMPONENTS

Tachometer / Magnetic Pickup

ELECTRICAL SYSTEM COMPONENTS

Engine Throttle Selector

ELECTRICAL SYSTEM COMPONENTS
Relays

NORMAL OPERATION
ELECTRICAL SYSTEM COMPONENTS

SHUTDOWN OCCURS
 ELECTRICAL SYSTEM COMPONENTS

R1B HOLDSPOWER OFF

If the oil pressure remained higher than 10 psi, but lower than 27 psi, the engine would try
to restart at low idle. For this reason we added R1B. When current is interrupted to the fuel
solenoid, it must remain off until the engine stops. To insure this happens, R1B supplies
current to R1 coil continuously to keep it from cycling.
ELECTRICAL SYSTEM COMPONENTS

LIMIT SWITCHES
 ELECTRICAL SYSTEM COMPONENTS

Diodes

Diodes are used in many areas of the electrical system. Their function is to allow
current to flow in one direction but not in the other.
 ELECTROHYDRAULIC CONTROLS (EHC)

OVERVIEW
The primary function of the ElectroHydraulic Controls (EHCs) used on the Drillmaster
Series is to provide a link between operator command and valve or pump operation.
The EHCs are like the manual controls used on other machines in that they translate
commands from the machine operator into movement of the valve spools or pump
swashplates. They differ from manual controls however, in that the link is not direct.
Before the operator commands reach the valve spool or pump servo, they have been:

. Translated into an electrical signal

. Transmitted through a wire
. Translated into a hydraulic pressure.
It is the hydraulic pressure acting on the valve spool or pump servo control which
actually causes the final spool or swashplate movement.
ELECTROHYDRAULIC CONTROLS (EHC)
ELECTROHYDRAULIC CONTROLS (EHC)

GENERAL CONCEPTS AND TERMINOLOGY

CURRENT CONTROL

PULSE WIDTH MODULATION

THRESHOLD

MAXIMUM OUT

DUAL RANGE CONTROLLERS

SINGLE COIL CONTROLLERS

DUAL COIL CONTROLLERS

 EHC ADJUSTMENTS

FEED AND ROTATION CONTROLLERS

 EHC ADJUSTMENTS

Tram Controllers

NOTE: These controllers are mounted very near to one another. When installing,
care should be taken to ensure that the two controllers cannot make contact with
each other. If they contact each other they will not function, or may be sporadically
inoperative.
ELECTROHYDRAULIC CONTROLS (EHC)
9A Controllers
ROTATION AND FEED CONTROLLERS
 ELECTROHYDRAULIC CONTROLS (EHC)
9A Controllers
ROTATION CONTROLLER FEED CONTROLLER
Hold Back Valve

57826356 57826349
 EHC ADJUSTMENTS
9A Controllers
ROTATION AND FEED CONTROLLERS
 ELECTROHYDRAULIC CONTROLS (EHC)
9A Controllers
Tram Controllers

57826331

NOTE: These controllers are mounted very near to one another. When installing,
care should be taken to ensure that the two controllers cannot make contact with
each other. If they contact each other they will not function, or may be sporadically
inoperative.
EHC ADJUSTMENTS
 5A Stroker
Electric Null Adjustment

Remove Hex cap

and adjust electrical
null with allen
wrench

NOTE: When the engine is started, the tracks (rotation) may creep
even though the pump has been mechanically nulled. The electric part
of the adjustment will correct the creeping.
9A Stroker
 EHC ADJUSTMENTS

AUXILIARY FUNCTION CONTROLLERS

 EHC ADJUSTMENTS
Pulldown and Holdback Controllers

54498357

NOTE:
DHD operations require operating the machine with a limited and specific amount of
weight on the bit. Holdback control allows the drill operator to control the amount of
weight on the bit as more pipe is added to the drill string. When a drill pipe is added,
the operator can offset the weight of the new pipe by increasing the Holdback setting.
The Holdback rotary controllers should be checked for proper operation at installation.
 EHC ADJUSTMENTS

To Verify Holdback Function:

1. Turn the Pulldown rotary controller Off.

2. Turn the Holdback controller On.
3. Start the engine.
4. Pull the Feed lever to the down direction.
5. The rotary head may begin to move downward due to main pump charge pressure.
(Approximately 250 psi.)
6. Turn the Holdback regulator to the right to increase the setting until the head stops
moving downward.
7. Refer to the Holdback gauge to see if Holdback pressure rises as the knob is turned
to the right, and as the head slows to a stop. Pressure seen on the Holdback
gauge will show the weight of the rotary head, drill pipe, subs and bit. Once the
rotary head stops, turning the regulator more will not increase the pressure.
Reducing the Holdback setting allows the operator to apply more weight on the bit
while drilling.
 CONTROL VALVES
FEMA PULLDOWN / HOLDBACK CONTROL VALVES
Proportional Remote Control Valve

Cross Section
EHC ADJUSTMENTS

Water Injection

57338279
CONTROL VALVES

APITECH PULSARS
 CONTROL VALVES
6SPOOL VALVE

Current Design VPL 6 Spool

Original VP 6
 CONTROL VALVES
9SPOOL VALVE

The inlet section of the assembly contains the pilot pressurereducing valve and filter
for the 9 spools. The inlet does not have an unloader. This stack sends a signal to the
6Spool Valve unloader that controls the maximum working pressure for both
assemblies.
CONTROL VALVES
 ENGINES ELECTRICAL SYSTEM
Cummins Engines
Drills equipped with Cummins Engines have an electrical system with computer controls
for all engine functions. The Engine Protection System will be explained in detail to give
the operator an understanding of the system and to emphasize the need to call for
specialist assistance in the event the engine system warning lights signal problems
during operation
CAT Engines
Drills equipped with Caterpillar engines have an electrical system with computer controls
for all engine functions. The Engine Monitoring System will be explained to give the
operator an understanding of the system and to emphasize the need to call for specialist
assistance in the event engine system warning lights signal problems during operation.
NOTE:There are two starter motors used. Each starter motor uses two 12 volt batteries,
connected in series, that provide 24 volt direct current (DC) to the system.
The batteries use a machine ground to complete the circuit. The battery
and starter ground cables are size 2/0. They are protected by four sections
of fusible link. One is attached to each starter and the other to the alternator.
Current flows through the ammeter to the number 2, 6 & 7 wires.
Number 7 wire is the hot or (+) wire for the engine controls. Number 2 wire is the
hot or (+) wire for the drill lighting system. Number 6 wire supplies current to the
engine ECM.
 ENGINE SHUTDOWN DEVICES

The drill is equipped with several shutdown devices to prevent harm to the
engine or compressor in case of loss of fluids or other related problems.

Emergency Engine Shutdown

Engine Speed Switch

Engine Oil Pressure Switch

Engine Water Temperature Switch

Compressor Discharge Temperature Switch

 ENGINE SHUTDOWN DEVICES

The temperature sensing bulb must be immersed in coolant or some other medium
to send temperature changes to the switch. Loss of coolant will leave the bulb dry, which
prevents the switch from responding quickly to increasing temperatures, making it useless.

Many of the engine control systems and display modules that are available for Caterpillar
Engines will work in unison with the Engine Monitoring System. Together, the two controls
will provide the engine monitoring function for the specific engine application.
STARTING ENGINES

Do not operate the starter motor for more

than 30 seconds at a time.
Let the starter motor cool for at least 2
minutes before attempting to start again.
Overheating, caused by excessive cranking,
will seriously damage the starter motor.
 STARTING ENGINES

Fuel Primer Pump

Ether Injection
WIRING SCHEMATIC
WIRING SCHEMATIC
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 ELECTRONIC CONTROL MODULES

ENGINE PROTECTIONS HISTORY

There have been changes in laws and regulations related to air pollution fuel emissions.
Diesel engine manufacturers have been required to make changes to engine fuel
systems in order to meet the new requirements. This is an ongoing effort, and fuel
emission controls are being implemented in stages. The implementation of the second
stage, "Tier 2" engines (300 -600 horse power) began January 1, 2001. New emission
controls regulations for larger horsepower engines (600-750 HP), went into affect
January 1. 2002.Third Stage is currently implemented Tier 3
ELECTRONIC CONTROL MODULES
 ELECTRONIC CONTROL MODULES

Some of the parameters that can be

displayed are:

Engine Hours
Engine RPM
System Voltage LED annunciate active
% Engine Load at the current RPM fault messages received by
Coolant Temperature the MDDM from the
Oil Pressure ECM.
Fuel Economy
Throttle Position
Current Fuel Consumption
 ELECTRONIC CONTROL MODULES
Operating Instructions

NOTE: When first powered up some unused parameters may be displayed by the MDDM.
These parameters will be automatically removed from the display after the
initialization cycle is complete.

The following two rules are used for accessing the various items on the main menus:
1. To scroll through the parameter list, press either the UP or Down push buttons.
2. To select or exit a sub-menu SIMULTANEOUSLY press the UP and DOWN push
buttons.
ELECTRONIC CONTROL MODULES
 ELECTRONIC CONTROL MODULES
The MDDM system consists of several components. They are listed
below:

3 Way Harness- ECM-DDM and Header # 57640096

Header board 57632788
MDDM Readout 57632697
Engine Oil Pressure Gauge 57632754
Engine Coolant Temp 57632747
Engine Tachometer ` 57632655
Harness Header to Gauges-
Tachometer, Coolant Temp, and Oil Pressure.57640096
Voltage Regulator 57662744
Regulator W/cable 57409146

Header Board
Connector Display Module
Connector

ECM Connector
ELECTRONIC CONTROL MODULES
 ELECTRONIC CONTROL MODULES

PowerView
Description
The PowerView has been developed to meet the needs for instrumentation and control
on electronically controlled engines communicating using the SAE J1939 Controller
Area Network (CAN).
ELECTRONIC CONTROL MODULES

Faceplate Features and Keypad Functions

ELECTRONIC CONTROL MODULES

MECHANICAL INSTALLATION
Typical Quick--Connect Diagram

PowerView Unit Back View

 ELECTRONIC CONTROL MODULES

POWERVIEW OPERATION

1. When power is first applied to the PowerView, the Logo is displayed.

2. The Wait to Start message will be displayed for engines with a pre--startup sequence.
Once the Wait to Start message is no longer displayed the operator may start the engine.
Note: Displays only when SAE J1939 message is supported by engine manufacturer.
3. Once the engine has started the single engine parameter is displayed.
ELECTRONIC CONTROL MODULES
Main Menu Navigation (continued)
ELECTRONIC CONTROL MODULES

Stored Fault Codes

 ELECTRONIC CONTROL MODULES

FAULTS AND WARNINGS

Note:The fault can only be cleared by correcting the cause of the fault
condition.
ELECTRONIC CONTROL MODULES

Shutdown Codes
ELECTRONIC CONTROL MODULES
ELECTRONIC CONTROL MODULES
GENERAL TROUBLESHOOTING
GENERAL TROUBLESHOOTING
GENERAL TROUBLESHOOTING
WIRING SCHEMATIC
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WIRING SCHEMATIC
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WIRING SCHEMATIC
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We are committed to your
superior productivity through
interaction and innovation.
78