Electrical System

Solar V Excavator

Feb, 2014
Global Product Support
Text No. ELE0001
Preface

Effective Models

-S175LC-V -(S140W-V)
-S225LC-V -(S180W-V)
-S255LC-V -(S210W-V)
-S300LC-V
-S340LC-V
-S420LC-V
-S470LC-V

2
Wire Color

3
Electrical Symbol

X X
O O (Above 3.3 Volts)
X (Below 3.3 Volts)
Not connected wire Diode Zener Diode

Connected wire Relay Switch

4
Electrical Symbol

Fuse Motor Proportional valve

Solenoid valve Temperature sensor Pressure sensor

5
Electrical Symbol

Light Illuminate (Diode) light Heater

Fusible link Circuit breaker (-) Ground

6
Basic

▶ Relay

☞ Question
1) When the switch is open, which lamps are lit?

2) When closed, then?

7
Overall Electrical System of Excavator

Pressure switch Pressure sensor

Indicator
LCD Monitor

Alternator
Fuel level sensor

Temperature sensor
Key switch

Engine control
dial

Low High Speed switch Solenoid valve

Proportional valve

8
Power Supply

▶ Power supply circuit

1. Battery
2. Battery relay
3. Fusible link
4. Circuit Breaker
5. Starter switch
6. Fuse box
7. Alternator
8. Diode

9
Engine Start

▶ Engine Ignition
1. Battery
2. Battery relay
3. Fusible link
4. Circuit Breaker
5. Key switch
6. Fuse box
7. Start controller
8. Start relay
9. Starter
10. Alternator
11. Diode

10
Engine Start

▶ Right after engine ignition

1. Battery
2. Battery relay
3. Fusible link
4. Circuit Breaker
5. Key switch
6. Fuse box
7. Start controller
500rpm 8. Start relay
9. Starter
10. Alternator
11. Diode

☞ Question
Under what condition, the engine starter can be operated even at engine running ?
1) 2)
11
Preheat

1. Battery
2. Battery relay
3. Fusible link
4. Circuit Breaker
5. Key switch
1. Built in Timer
6. Fuse box
2. 19 seconds, L4 on
7. Preheat relay
8. Air heater
9. Preheat lamp
10. Diode

12
After heat (Tier II Engine)

For 120 sec

Input signal Output signal

R(i) Voltage W/Temperature Sensor After Heating terminal
(CN2-1) (CN4-5,CN4-6) (CN1-15)

12 V ↑ AND 3,730Ω±400 ↑(Coolant Temp 10℃ ↓) Heating for 120±5 sec

12 V ↓ OR 3,730Ω±400 ↓( Coolant Temp 10 ℃ ↑ ) Off

13
Engine Stop

▶ Key on & Engine Running

1. Battery
2. Fusible link
3. Key switch
4. Fuse box
5. Engine stop relay
6. Engine stop motor

☞ Question
- During engine running, voltage between P2 and ground?
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Engine Stop

▶ Engine Stop

1. Battery
2. Fusible link
3. Key switch
4. Fuse box
5. Engine stop relay
6. Engine stop motor

15
Charging

1. Battery
2. Battery relay
3. Fusible link
4. Circuit breaker
5. Start switch
6. Fuse box
7. Alternator
8. Diode

16
Monitoring

▶ Components
1. Monitor panel
2. Battery
3. Engine speed sensor
4. Return filter switch
5. Pilot filter switch
6. EPOS Controller
7. Alternator
8. Warning buzzer
9. Pump pressure sensor
10. Engine coolant temp sensor
11. Fuel sensor
12. Air cleaner indicator
13. Engine oil press switch
14. Lamp switch

17
Pressure Sensor

Supply voltage : 10 ~ 30 DCV

Out put voltage : 1~ 5 V DCV
Ground

Load resistance : 10 KΩ Min ( Supply “+” and ground “-” )

Out put voltage with ground is variable by system pressure

Y = 0.00816 * X + 1 Y = 3.5V, X = 300 bar

Y : Out put voltage (V) Y = 2.5V, X = 180 bar
X : Pressure (bar) Y = 1.5V, X = 60 bar

18
Fuel Level Sensor

Floating position F 3/4 1/2 1/4 E

Resistance (KΩ) 0.50 1.20 2.68 3.94 5.00

Tolerance (KΩ) ± 0.5%

19
Hydraulic Oil Temperature Sensor

Temp’ Resistance Temp’ Resistance

(C) (KΩ) (C) (KΩ)

-30 28.6 50 0.808

-20 16.2 60 0.584

-10 9.56 70 0.430

0 5.88 80 0.322

10 3.73 90 0.245

20 2.45 100 0.189

30 1.65 110 0.148

40 1.14 120 0.117

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Temperature Sensor

2.15
Coolant
Temperature Sensor
2.26
ECU
Fuel
Temperature Sensor 2.35

Sensor resistance
- @ 25℃ : 2.5 ㏀ ± 6 %
- @ 100℃ : 0.186 ㏀ ± 2 %

21
Monitoring

▶ Circuit
1. Monitor panel
12 ~ 33V 2. Warning buzzer
3. Lamp switch
4. Start switch
5. Pump pressure sensor
6. Pump pressure sensor
0.00816P + 1.0 7. Engine coolant sensor
8. Fuel sensor
9. Engine speed sensor
10. Hydraulic oil temp sensor
128Ω
11. Engine oil pressure switch
12. Return filter switch
13. Return filter switch
14. Pilot filter switch
15. Alternator
16. EPOS controller
17. Battery
18. Battery Relay
19. Circuit Breaker
0.7k
20. Fusible link
1.5k 21. Fuse box
1.0k
22. Check connector
22
Monitoring

▶ Bar display

23
Schema – EPOS control

1. Monitor panel
2. Engine control motor
3. Engine
4. Main pump
5. Pilot pump
6. Control valve
7. Pressure switch
8. Pump pressure sensor
9. Engine speed sensor
10. EPPR (power shift) valve
11. Solenoid valve (up pressure)
12. Solenoid valve (SP)
13. Solenoid valve (Travel speed)
14. Travel motor
15. Engine throttle controller
16. Engine control dial
17. EPOS controller
18. Auto travel select switch
19. Up pressure switch (RH joystick)

24
Engine Speed control

▶ Schema

2. Engine control motor

3. Engine
15. Throttle controller
16. Engine control dial

25
Engine Control Dial

Supply voltage : 5.0 DCV

Output voltage : 4.0 ~ 1.0 DCV
Ground

Low RPM High RPM

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Engine Speed control

▶ Engine throttle controller

LED Output V
Input signal Status
Red Green Yellow 4(+) – 5(-)

Dial V < Potentio V

Increase rpm X ◎ ○ + 24 V
1V (High RPM) < 4V (Low RPM)
Dial V > Potentio V
Decrease rpm ◎ X ○ - 24 V
4V (Low RPM) < 1V (High RPM)
Dial V = Potentio V
stop ○ ○ ○ 0V
1V (High RPM) = 1V (High RPM)
- Overloaded X X ○ 0V
- No power supply X X X 0V

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Engine Throttle Controller
VR1 – Adjust Auto Idle RPM, VR2 – Adjust Standard RPM

28
Engine Speed control

▶ Circuit

When signal comes in : 9~12V

Multimeter (+) connection

Multimeter (-) connection

▷ Final speed by Throttle controller = Min(A,B,C..)

29
Power mode control

▶ Schema
1. Monitor panel (select button)
2. Engine control motor
3. Engine
4. Main pump
5. Pilot pump
6. Control valve
9. Engine speed sensor
10. EPPR (power shift ) valve
15. Engine throttle controller
16. Engine control dial
17. EPOS controller
20. Work/Travel select switch
(wheel)

30
Power mode control

▶ Circuit

Condition Input Current Output Press

Real Engine PRM ≥ Set engine RPM 600 mA Below 5 k (TongMyung=29bar)

Power Mode
Real Engine PRM < Set engine RPM ↓, till become same ↓, till become same

18 k
STD Mode Regardless of 0 mA
(TongMyung=0bar)
31
Work mode control

▶ Schema
1. Monitor panel (select button)
3. Engine
4. Main pump
5. Pilot pump
6. Control valve
12. Solenoid valve
17. EPOS controller

32
Work mode control

▶ Circuit
1. Battery
2. Battery relay
3. Fuse
4. EPOS controller
5. Monitor panel
6. Solenoid valve (SP)

33
Auto Idle

▶ Schema 1. Monitor panel

2. Engine control motor
3. Engine
7. Pressure switch
15. Throttle controller
16. Engine control dial
17. EPOS controller

PA = Px = arm, boom, bkt, swing, option

PT = Py = travel

Px
Py

PT

PA
34
Auto Idle

▶ Circuit

35
Overheating protection

▶ Schema
1. Monitor panel
2. Engine control motor
3. Engine
4. Main pump
5. Pilot pump
10. Power shift valve
15. Throttle controller
17. EPOS controller
21. Warning buzzer

36
Overheating protection

▶ Circuit

37
Overheating protection

▶ Reference : Hydraulic oil

38
Automatic Travel Control

▶ Schema
3. Engine
4. Main Pump
5. Pilot Pump
6. Main Pump
7. Pressure Switch (Py)
8. Pressure sensors
13. Solenoid valve
14. Travel motors
16. Engine control dial
17. EPOS controller
18. Auto travel switch
2nd step : Auto speed
1st step : high speed
off : low speed

39
Automatic Travel Control

▶ Circuit
High speed condition
(to energize the solenoid)

1. At High speed mode

1) A/T switch “1st step”

2. At Auto speed mode

1) A/T switch “2nd step”
2) Py switch closed
3) Below 2.5 V of dial
(over 1400 rpm)
4) Below 270 bar of both
pumps

40
Diagnosis

▶ Display on EPOS

1. Upper digit 4. Engine speed monitor

2. Lower digit (blinks in proportion to engine speed)
3. Power monitor 5. Communication monitor
( On @ 18.5 ~ 32.5 V of power supply) 6. Communication monitor
41
Diagnosis

▶ Display at Normal condition

42
Diagnosis

▶ Error Code

▷ The error codes on EPOS display window are same as

the letter information on the monitor panel.
( Special mode – Realtime failure)

43
CASE 1 Charging Lamp is still on even after starting engine

Charging Lamp is on approximately for 3

seconds and goes off after engine starts.
* Signal comes from Alt ‘I’ to EPOS CN2-1. This
shows the real voltage value of alternator.

With the engine running, the indicator shows

current voltage coming from alternator.
* Signal comes from fuse box to EPOS CN1-1.
This shows the real voltage value of battery.

Q. What if charging lamp is still on even after engine starts? How it can be diagnosed?

44
 CASE 1 Charging Lamp is still on even after starting engine

If below 12V or over 33V

ON

This charging symbol is ON when the voltage

between CN2-1 & CN1-8 (ground) is below 12V
or over 33V.

1. Check voltage on terminal #3 of Hour meter if 24 volts generated

2. If step 1 is ok, check connection between hour meter terminal #3 and EPOS CN2-1.(using multimeter)
3. If step 1 is NOT ok, check connection of terminal I of Alternator. (I=full voltage, R= half voltage)
4. If step 2 is ok, cause might come from instrument panel.

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END OF DOCUMENT

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