Electrical System

Solar V Excavator

Feb, 2009
Overseas Product Support Team
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
Basic

▶ Wire Color

3
Basic

▶ Relay

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

2) When closed, then?

4
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

5
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

6
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)
7
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

8
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

9
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?
10
Engine Stop

▶ Engine Stop

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

11
Charging

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

12
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

13
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
14
Monitoring

▶ Bar display

15
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)

16
Engine Speed control

▶ Schema

2. Engine control motor

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

17
Engine Speed control

▶ Engine control dial

position

▷ Dial position is converted to

VDC by built in potentiometer.

18
Engine Speed control

▶ Engine control motor

position

▷ Cable stroke is converted to

VDC by built in potentiometer.

19
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

20
Engine Speed control

▶ Circuit

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

21
Engine Speed control

Question 1.
If the below signals are delivered to the engine throttle controller at the same time, what is the
actual engine speed?
(Overheat : 1100 rpm, Auto idle : 1400 rpm, Engine control dial : 1850 rpm)

Question 2.
Engine speed fluctuates (1800 ~1600 rpm) and the rod of engine control motor moves back and
forth repeatedly.
And the voltage between “2” & “3” terminals is harmonized with the one between “6” & “7”
terminals of engine throttle controller.
Then which part need to be replaced ?

22
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)

23
Power mode control

▶ Circuit

Condition Input Current Output Press

Below 5 k
Real Engine PRM ≥ Set engine RPM 600 mA
(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)
24
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

25
Work mode control

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

26
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

27
Auto Idle

▶ Circuit

28
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

29
Overheating protection

▶ Circuit

30
Overheating protection

▶ Reference : Hydraulic oil

31
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

32
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

33
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
34
Diagnosis

▶ Display at Normal condition

35
Diagnosis

▶ Error Code

▷ The error codes on EPOS display window are same as

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

36
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?

37
 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.

38
APPENDIX

39
Coolant / Fuel temp. sensor

2.15
Coolant
Temperature Sensor
2.26
ECU
Fuel
Temperature Sensor 2.35

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

40
Boost pressure & Temp. sensor

2.33

Boost Pressure & 2.34

Temperature 2.25 ECU
Sensor
2.36

• Supply voltage : 4.75V ~ 5.25V

• Resistance with ground to pressure signal (Power supply open): 2.4 ~8.2KΩ
• Resistance with Power supply to pressure signal (ground open): 3.4 ~8.2KΩ
41
Boost pressure & Temp. sensor

• Temp. sensor resistance @25℃ : 2.5 ㏀ ± 6 %, @100℃ : 0,186 ㏀ ± 2 %

• Pressure sensor normal range 0.5 bar ~4.0 bar (0.5 V ~4.5 V)

42
Crank shaft / Cam sensor

• Crankshaft Sensor :
1. Sensing engine RPM to display
2. Sensing Crankshaft rotational angle
3. Decide fuel injection timing

• Cam Shaft Sensor :

1. Sensing TDC point of No.1 cylinder
2. Sensing engine RPM (auxiliary)

2.23
• One sensor has problem
2.19 - Delayed engine start
3 • Both sensor has problem
ECU - Could not start engine
2.09
2.10
3
1 : Sensor Signal
2 : Ground

43
END OF DOCUMENT

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