Electric System of 9S-Series Excavators

HHI Training Center 1

 Ⅰ. Component Location
[ Cabin ]

(not applied)

(not applied)

HHI Training Center 2

 [ Frame ]

Work light Cab light

HHI Training Center 3

 Quick Clamp Switch (Option)

1) When Quick clamp s/w is pushed to the

Safety button unlock position releasing safety button,
Unlock quick clamp sol is energized. Then quick
clamp cylinder is operated
2) Quick clamp s/w always must be in lock
position when working.

HHI Training Center 4

 Ref.1 Understanding of Electric System

CONTROL

RELAY

HHI Training Center 5

 Ref.2 BASIC ELECTRONIC SYSTEM

C
+

- P

RELAY
I/F (Interface) Circuit

HHI Training Center 6

 (-9 Series)
Ⅱ. Electric Circuit
1. Power & Master sw ‘ON’
Starting Circuit

CHECK Point
① ~ ④ : 24V

HHI Training Center 7

 (-9 Series)
2. KEY ON Power Circuit

ON! ON!

To.
ECM

ON!

1. Key SW ’ON’
1) Battery RY ‘ON’
2) Power RY ‘ON’
3) ECM Power RY ‘ON’

2. CHECK Point
① ~ ⑦ : 24V

’ON’
HHI Training Center 8
 (-9 Series)
3. Starting & Charging Circuit

ON!

Charging !

CHECK Point
① ~ ⑦ : 24V →(Charging) 27V

ON!
E/G Start !

1) E/G Start circuit

2) Charging circuit
- Indication

’ST’ ’ON’

HHI Training Center 9

 (-9 Series)
4. Head & Work Light Circuit

WORK
Lapm ‘ON’

85
ON!
30 86

Back light ‘ON’ HEAD Lamp

‘ON’
1) HEAD Lamp circuit
85

2) WORK Lamp circuit ON!

30 86

CHECK Point
①,③,④,⑤,⑦,⑧ : 24V Back light
‘ON’
②,⑥ : 0V(Lamp ‘ON’ condition)

Back light ‘ON’ Back light ‘ON’ Back light ‘ON’

HHI Training Center

6. Electric Circuit for Hydraulic (Cluster type 1)

HHI Training Center 11

 CAPO System of 9S-Series Excavators

HHI Training Center 12

 Ⅰ. 9S-Series, CAPO System Feature

1. Main Functions

Improved Functions New Functions

(compared to 7A-series) Common Wheel Only

- Power/Work Mode Selection * Auto Power Boost * Auto Ram Lock

- Automatic Deceleration * Variable Boom/Swing Priority * Speedometer
- Power Boost(350k →380k) * Attachment Flow Control * (Cruise)
- Overheat Protection * Overload Compensation Control
- Auto Warming Up * Arm In Flow Regeneration

※ Sensors and Solenoids

Pressure Sensor EPPR Valve Solenoid Valve

Common Crawler Wheel Common Crawler Wheel Common Crawler Wheel

STD 10 1 5 2 - - 3 - 1

OPT 2 - - - - 1 4 - -

Total 12 1 5 2 - 1 7 - 1

HHI Training Center 13

 2. Lay-out of Crawler type machine

Breaker Attachment
pilot Pn1 Pn2 Work Travel
pressure pressure pressure pressure
2-1) Power Mode setting
pressure

Solenoid MCV EPPR Valve

Arm1 (R220LC-9S)
Attachment Left rotate Pump shift
pressure Option Arm2
Travel
speed
Attachment Right rotate
Boom
priority
ENGINE SPEED EPPR Valve
conflux Boom2 Bucket
Power Attachment Left tilt Attachment
boost safety Swing Boom1 flow
Arm Cooling fan Travel(RH) Travel(LH) Right tilt Cooling fan
regen reverse

P1
pressure
Overload
pressure P2
pressure
Travel alarm
pressure
EPPR v/v
pressure

P3

Governor
Actuator P3
position pressure

Pump1 Pump2 Pump3

MCU
HYUNDAI

Power
max S/W Joystick
Accel dial

BU BI AI AO

Cluster

Swing Boom up
pressure pressure

Rear View
camera

Power Work User Travel Auto ESC/

Mode Mode Mode Mode Idle CAM

HHI Training Center 14

 2-2) Location of Pressure sensors

Pressure Sensors Pilot Control

* Swing / Boom Up : 50b,2EA

Auto Idle Signal Px, Py

(The Lateral Face of MCV)
: 50b, 2EA

Option Att
: 50k, 1EA

EPPR v/v
: 50b, 1EA

Main Pump P1 & P2

: 500b, 2EA

HHI Training Center

 Ⅱ. Improved Functions

1. Mode selection system

Engine
1) Power Mode
Actuator
(DC motor)

; P (Heavy duty), S (Standard), E (Economy) Mode

Power Shift - E Mode is default set.
Accel. Dial EPPR

2) Work Mode

; General work mode (bucket)

MCU Attachment work mode (Breaker, Crusher)

3) U Mode
HYUNDAI
; User setting Mode
Power Work User Travel Auto ESC/
mode mode mode mode idle CAM - Engine speed
Cluster - Auto deceleration speed
- EPPR v/v output pressure

HHI Training Center 16

 2. Power mode selection

(R220LC-9S)

HHI Training Center 17

 3. Work mode selection

: General operation

: Breaker operation(Optional)

: Crusher operation(Optional)

* Solenoids work table

Att work mode

HHI Training Center 18

 4. Automatic deceleration system

1st Step] Operation Delay time: 4 sec

- Work/Travel neutral condition
- E/G speed shift down to 1,150 rpm
※ Accel dial position: Higher than 4th 1150 rpm

1000 rpm

2nd Step] Operation Delay time: 60 sec

- E/G speed shift down to 1000(Start) rpm

HHI Training Center 19

 5. Overheat prevention system

100℃
105℃

E/G Coolant
Step or Hyd. Oil Remarks
Temperature

- Warning lamp & Buzzer : ON

1st Warning Above 100℃
- Pump power (EPPR v/v) ↓

1st Warning
Below 95℃ - Pump power Recovery
Canceled

- Emergency warning lamp ( 7A series )

pops up & Buzzer E/G Coolant Temp > 110℃ → E/G RPM down to Accel dial 7th
2nd Action Above 105℃
- E/G RPM down : to Accel dial 7th
setting speed
setting speed after 10 sec
E/G Coolant Temp < 100℃ → E/G RPM Recovery

2nd Warning
Below 100℃ - E/G RPM Recovery
Canceled

HHI Training Center 20

 -Location: Main pump room
Ⅲ. New Functions -Spec: 24V, 15~25Ω

1. Auto power boost system

1) Conditions
- P Mode only
- Set to ‘Enable’ on the cluster

- Accel dial : over 8th position

- Average pressure of P1 & P2 is
sustained over 330bar for 1sec.

2) Output
- Boost Pressure: 350 → 380bar
- Duration: 8 sec P mode

HHI Training Center 21

 boom
cyl
2. Variable Boom priority system
Only when combined operation of Boom up & Swing.

(1) Manual Mode swing

motor

OFF

Control Level 1 2 3 4 5 6 7 8 9 10

EPPR Current (mA) 100 200 285 320 335 390 425 445 570 600

HHI Training Center 22

 (2) Auto Mode
boom
cyl

swing
motor

Auto

ON
(Proportional)

HHI Training Center 23

 3. Optional Attachment

1) Breaker Mode

HHI Training Center 24

 Breaker circuit (1 way valve)

BREAKER

Fuse Box: SOLENOIDE(25)

“Key ON”

Option spool

HHI Training Center

 ATT’ Flow Control

MCU Cluster Main Pump Regulator

Continuous

Communication wire
Key on
between MCU and Cluster

ATT Flow EPPR

P3
HHI Training Center
 5. Anti - Restart Function

KEY ON POWER
CN-36: FUSE BOX

“KEY START”

CN-51: MCU
HHI Training Center
 Ⅳ. Specification of Electrical components
1. Coolant temperature sensor

2. Hydraulic oil temperature sensor

3. Fuel level sensor

HHI Training Center 28

HHI Training Center 29
 [Ref.] Description of MCU Controller Connectors
1/5

CONNEC INPUT(☜)/ NORMAL CONDITION : A & V

PIN NO. WAVE
TOR OUTPUT(☞) INACTIVE ACTIVE
24V
(1) BATT POWER_24V INPUT(☜) MASTER KEY OFF : 0V MASTER KEY ON : 24V (B+)
0V

24V
(2)-R POWER IG INPUT(☜) KEY OFF : 0V KEY ON : 24V (B+)
0V

24V
(3)-RW POWER_24V OUT OUTPUT(☞) KEY OFF : 0V KEY ON : 24V (B+)
0V

(4) TACHO SENSOR + USED FOR R220LC-9S(CUMMINS EG)

5V
(5)-B GND_5V INPUT(☜) 0 V, 0 Ω 0 V, 0 Ω
0V

5V
(6)-Gr POWER_5V OUT OUTPUT(☞) KEY OFF : 0V KEY ON : 5V
0V

CN-51 24V
(7)(8) G/A MOTOR + / - PWM CONTROL (NOT MEASURED BY MULTIMETER TESTER)
0V

24V
(11)-B GND_MAIN OUTPUT(☞) 0 V, 0 Ω 0 V, 0 Ω
0V

24V
(12)-SH CAN_SHIELD FOR CUTTING EXTERNAL NOISE – ALWAYS 0V
0V

24V
(13)-Y GND_RETURN INPUT(☜) 0 V, 0 Ω 0 V, 0 Ω
0V

(14)-ROr SPEED SENSOR+ (HMC) USED FOR R220LC-9SH(HYUNDAI EG)

(16) PROGRAM DUMP RELATED WITH MCU UPGRADE

KEY OFF : 0V ONE TOUCH DECEL SW 24V

(17) ONE TOUCH DECEL SW OUTPUT(☞)
KEY ON : 24V(B+) (LH RCV 위) ON : 0V 0V

HHI Training Center

 - MCU CONTROLLER CONNECTORS 2/5

CONNEC INPUT(☜)/ NORMAL CONDITION : A & V

PIN NO. WAVE
TOR OUTPUT(☞) INACTIVE ACTIVE

KEY OFF : 0V POWER MAX SW (LH RCV) 24V

(18) POWER BOOST SW OUTPUT(☞)
KEY ON : 24V(B+) ON : 0V 0V

24V
(19)-W HOUR METER OUTPUT(☞) KEY OFF : 0V KEY ON : 24V (B+)
0V

24V
(20)-V ANTI RESTART RY INPUT(☜) E/G NOT RUNNING : 0V E/G RUNNING : 24V
0V

5V
(23)-L RS485+(TX)-CLUSTER OUTPUT(☞) KEY OFF : 0V KEY ON : ABOUT 2.22V
0V

5V
(33)-Y RS485-(RX)-CLUSTER INPUT(☜) KEY OFF : 0V KEY ON : ABOUT 2.22V
0V

(25)-GrW RS232C2_TX-RCM CONNECTED WITH RMCU

CN-51 (35)-BrW RS232C2_RX-RCM CONNECTED WITH RMCU

TRAVEL ALARM TRAVEL ALARM SW (SW 24V

KEY OFF : 0V
(26) OUTPUT(☞)
SELECT SIG KEY ON : 24V(B+) PANEL) ON : 0V 0V

KEY OFF : OV AIR CLEANER FILTER 24V

(29)-GrW AIR CLEANER SW(NO) OUTPUT(☞)
KEY ON : 24V(B+) CLOGGED : 0V 0V

(24)-R RS232C1_TX-HRDT CONNECTED WITH SERVICE TOOL

(34)-G RS232C1_RX-HRDT CONNECTED WITH SERVICE TOOL

PRE-HEATER SW (SW 24V

KEY OFF : 0V
(36) PRE-HEAT SELECT SIG OUTPUT(☞)
KEY ON : 24V(B+) PANEL) ON : 0V 0V

KEY OFF : OV E/G OIL FILTER CLOGGED : 24V

(37) ENGINE OIL FILTER OUTPUT(☞)
KEY ON : 24V(B+) 0V 0V

HHI Training Center

 - MCU CONTROLLER CONNECTORS 4/5

CONNEC INPUT(☜)/ NORMAL CONDITION : A & V

PIN NO. WAVE
TOR OUTPUT(☞) INACTIVE ACTIVE
24V
(1) ARM REGEN SOL INPUT(☜) KEY ON : 24V ARM REGEN DISABLE : 0V
0V

24V
(2) POWER MAX SOL. INPUT(☜) KEY ON : 24V POWER MAX ON : 0V
0V

KEY ON 24V
(3) TRAVEL SPEED SOL. INPUT(☜) SELECT RABBIT : 0V
(TURTLE) : 24V 0V

SELECT ATT. (BREAKER, 24V

(4) ATT_SAFETY SOL. INPUT(☜) KEY ON : 24V
CRUSHER) : 0V 0V

24V
(5) ATT_PRESS SOL. INPUT(☜) KEY ON : 24V SELECT CRUSHER : 0V
0V

SELECT MORE THAN ONE 24V

(6) ATT_CONFLUX SOL. INPUT(☜) KEY ON : 24V
PUMP FLOW : 0V 0V
CN-52
24V
(7) BOOM PRIORITY EPPR+ OUTPUT(☜) BOOM SPEED : 1STEP(100mA) ~ 10STEP(600mA)
0V

24V
(8) POWER IG INPUT(☜) KEY OFF : 0V KEY ON : 24V (B+)
0V

ACCORDING TO MODE(P,E,S) & ACCEL DIAL STEP 24V

(9) PUMP POWER EPPR+ OUTPUT(☜)
& WORK LOAD PRESSURE 0V

GENERAL MODE : AROUND 120mA 24V

(10)-RW ATT FLOW EPPR+ OUTPUT(☜) BREAKER MODE : 100lpm(504mA) ~ 220lpm(360mA)
0V
CRUSHER MODE : 160lpm(407mA) ~ 520lpm(360mA)

KEY ON, COOLANT COOLANT TEMP< 10℃ : 0V 24V

(16)-V FUEL WARMER RY INPUT(☜
TEMP> 60 ℃ : 24V Cluster Heat’g Lamp ON 0V

T/ALARM SW ON + TRAVEL 24V

(13) TRAVEL BUZZER INPUT(☜) KEY ON : 24V
PS > 15bar : 0V 0V

HHI Training Center

 - MCU CONTROLLER CONNECTORS 5/5

CONNEC INPUT(☜)/ NORMAL CONDITION : A & V

PIN NO. WAVE
TOR OUTPUT(☞) INACTIVE ACTIVE
24V
(15) ENG PRE-HEAT RY INPUT(☜) KEY ON : 24V ENG PRE-HEAT ON : 0V
0V

24V
(18) EPPR GND OUTPUT(☜) 0 V, 0 Ω 0 V, 0 Ω
0V

24V
(17)-BOr BOOM PRIORITY EPPR- INPUT(☜) 0 V, 0 Ω 0 V, 0 Ω
0V

24V
(19) PUMP POWER EPPR- INPUT(☜) 0 V, 0 Ω 0 V, 0 Ω
0V

24V
(20) ATT FLOW EPPR- INPUT(☜) 0 V, 0 Ω 0 V, 0 Ω
0V

ACCORDING TO ACCEL DIAL 5V

(23) ACCEL DIAL SIG. INPUT(☜) KEY OFF : 0V
: 1STEP(1V) ~ 10STEP(4V) 0V
CN-52
KEY ON, 5V
(24) HYD. TEMP SENDER INPUT(☜) KEY OFF : 0V
30℃ :3.8V, 110℃ : 1V 0V

5V
KEY ON, ACCORDING TO
(25) WATER TEMP SENSOR INPUT(☜) KEY OFF : 0V
WATER TEMP 0V

KEY ON, HIGH : 0.5V 5V

(26)-OrW FUEL LEVEL SENSOR INPUT(☜) KEY OFF : 0V
LOW : 2.8V (Warning ON) 0V

E/G RUNNING : CHARGE 28.5V

(27) ALT. LEVEL INPUT(☜) KEY ON : 24V(B+)
CHARGING VOLTAGE 28.5V BATTERY 24V

5V
(28) GOV. POTENTIO SIG INPUT(☜) ACCORDING TO ACCEL DIAL POSITION
0V

5V
(29) P1 PRESS SENSOR INPUT(☜) ACCORDING TO P1 PRESS : 0bar(1V) ~ 500bar(5V)
0V

HHI Training Center

 - MCU CONTROLLER CONNECTORS 6/5

CONNEC INPUT(☜)/ NORMAL CONDITION : A & V

PIN NO. WAVE
TOR OUTPUT(☞) INACTIVE ACTIVE
5V
(30) P2 PRESS SENSOR INPUT(☜) ACCORDING TO P2 PRESS : 0bar(1V) ~ 500bar(5V)
0V

5V
(32) PUMP EPPR2 SENSOR INPUT(☜) ACCORDING TO PUMP EPPR PRESS : 0bar(1V)~50bar(5V)
0V

5V
(33) ATT. PRESS SENSOR INPUT(☜) ACCORDING TO OPT PILOT PRESS : 0bar(1V)~50bar(5V)
0V

BOOM UP PRESS ACCORDING TO BM UP PILOT PRESS : 5V

(35) INPUT(☜)
SENSOR 0bar(1V) ~ 50bar(5V) 0V

5V
(36) SWING PRESS SENSOR INPUT(☜) ACCORDING TO SW PILOT PRESS : 0bar(1V) ~ 50bar(5V)
0V

WORK PRESS 5V
(37) INPUT(☜) ACCORDING TO WORKING : 0bar(1V) ~ 50bar(5V)
SENSOR(A) 0V
CN-52
TRAVEL PRESS 5V
(38) INPUT(☜) ACCORDING TO TRAVELLING : 0bar(1V) ~ 50bar(5V)
SENSOR(A) 0V

HHI Training Center

 PWM : Pulse Width Modulation

Low Temp’ High Temp’

DUTY 5% DUTY 30% DUTY 50% DUTY 100%

24V

0V

24V
Slow Fan speed Fast Fan speed

12V

TIME (t)

HHI Training Center