CAPO System of 9S-Series Excavators

H.J.Kim (Master Kim) 2018.07

HCE Training Center 1
 ◉ CONTENTS ⊙

Ⅰ. 9S-Series CAPO System feature

1.Main Functions

2.Lay-out of Crawler type machine

Ⅱ. Improvement functions

Ⅲ. New functions

Ⅳ. Emergency connection

※ Appendix

HCE Training Center 2

 Ⅰ. 9S-Series, CAPO System feature

1. Main Functions

Improved functions New Functions

(compare to the 7A-series)
- Power/Work mode selection
- Auto & One Touch Decel
- Power Boost(350k →380k)
- Overheat Protection
- Auto Warming Up
Common Wheel Only
* 2-stage Auto Deceleration * Auto Ram Lock
* Variable Power Control * Speedometer
* Attachment Flow Control * (Cruise)
* Overload compensation control
* Boom/Swing Priority
* Arm In flow regeneration

※ Sensors and EPPR V/V / Solenoids

Pressure Sensor EPPR Valve Solenoid Valve
Common Crawler Wheel Common Crawler Wheel Common Crawler Wheel

STD 8 2 4 2 - - 3 1 2
OPT 2 - 1 1 - - 5 - 4

Total 10 2 5 3 - - 8 1 6

HCE Training Center 3

 2. Lay-out of Crawler type machine

2-1) POWER Mode setting

Breaker Attachment
pilot Pn1 Pn2 work Travel
(R220LC-9S)
Pressure pressure pressure pressure pressure

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

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

P3

Governor ECM
actuator P3
position pressure

Pump1 Pump2 Pump3

MCU
HYUNDAI

Power
max S/W Joystick
Acceleration
dial position

SR SL 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

HCE Training Center 4

 2-2) Location of Pressure sensors

Pressure Sensors Pilot Control

* Swing / Boom Up : 50k,2EA

Auto Idle Signal Px, Py

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

Option Att
: 50k, 1EA

Center by-pass Pn1 & Pn2

EPPR v/v : 100k, 2EA
: 50k, 1EA

Main Pump P1 & P2

: 500k, 2EA

Pilot Pump P3
: 50k, 1EA

HCE Training Center 5

 3. Lay-out of Wheel type machine
3-1) POWER Mode setting
(R140W-9S)
ENGINE SPEED EPPR Valve
Breaker Attachment
pilot Pn1 Pn2 work Travel
pressure pressure pressure pressure
Pressure EPPR Valve
Left rotate
Solenoide
EPPR
Arm1 MCV
Travel Attachment Right Pump shift
speed pressure Option Arm2 rotate EPPR
Power Attachment EPPR
Left tilt
Boom
boost conflux Boom2 Bucket EPPR priority EPPR
Arm Attachment Right Cooling
regen safety Swing Boom1 tilt fan EPPR
EPPR
Ram Cooling Travel Attachment
Travel(RH) Travel(LH)
lock fan reverse EPPR flow EPPR

P1
pressure
Overload
pressure P2
Brake oil pressure
pressure
Transmission EPPR v/v
oil pressure pressure

P3

Governor ECM
actuator
position

Pump1 Pump2 Pump3

MCU
HYUNDAI

Power
max S/W Joystick
Travel F Acceleration
lever dial position
Cruise
S/W
OFF ON AUTO
R
W
P T Parking, Ram lock
SR SL BU BI AI AO Working,
S/W
Travel S/W

Cluster

Swing
pressure Boom up
pressure

Rear View
Camera

Power Work User Travel Auto ESC /

Mode Mode Mode Mode Idle CAM

HCE Training Center 6

 Ⅱ. Improvement functions

1. Mode Selection system

Engine 1) Power Mode

ECM
; P(Heavy duty), S(Standard), E(Economy) Mode
- E Mode is default set.
Power Shift
Accel.Dial EPPR

2) Work Mode

; General, ATT Mode (Breaker, Crusher)

MCU

3) U Mode

; User setting Mode

Power Work User Travel Auto ESC
Mode Mode Mode Mode Idle CAM CAN(RS485)
Cluster

HCE Training Center 7

 ※ Mode comparisons

Classifi- 7A Series 9/9S Series

cation

Power - M, H, S Mode - P, S, E Mode

Mode ·P : Auto Power Boost
·S : Standard power
·E : Variable Power control for
Fuel consumption

Work - Heavy Duty : Boom Priority - General : General Work (Digging)

Mode - General : Swing Priority - ATT : Breaker, Crusher Work
- Breaker : Max. Flow Cut *ATT Flow & Pressure Control
*Boom / Swing Variable Priority

U - Engine and Pump Power - Engine speed

Mode setting - Auto deceleration speed
- EPPR v/v output pressure

HCE Training Center 8

 2. POWER Mode selection

(R220LC-9S)

HCE Training Center 9

 3. Work Mode selection

: General operation

: Breaker operation(Optional)

: Crusher operation(Optional)

※ Solenoids work table

HCE Training Center 10

 4. Automatic deceleration system

①st Step] Operation Delay time: 4 sec

-Work/Travel neutral condition
-E/G speed shift down to 1,000 rpm
※ Accel dial position: Higher than 4th

②nd Step] Operation Delay time: 60 sec

- E/G speed down shift : 850(Start) rpm

HCE Training Center 11

 5. Overheat prevention system
Functioning
condition

Classifi- E/G Coolant Remarks

cation or Hyd. Oil
Temperature
1st 100~105℃ - Pump power(EPPR v/v) ↓
Action

2nd 105℃ ~ - Warning Lamp ON : At the

Action same time when the
temperature reaches 105℃.
- Power shift down : to Accel
dial 7th setting speed.

1st 105~100℃ - Warning Lamp OFF

Overheat from 2st Action
- 2nd Overheat Release
Release ① E/G RPM Recovery
② Pump Input Torque
: 1st Overheat Condition

2nd ~ 95℃ -Pump power (EPPR v/v) Recovery

Overheat from 1st
Release Action

HCE Training Center 12

 Ⅲ. New functions

1. Auto Power Boost system

1) Conditions
- P Mode only
- Set to ‘Enable’ on the cluster
-Location: Main pump room
-Spec: 24V, 15~25Ω

- P1 & P2 Pressure are sustained

at high pressure more than 1Sec.

- Accel dial : over 8th position

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

HCE Training Center 13

 3) Power boost system classification

Classification Condition Remarks

System Relief Pressure, Engine and Pump Power Up for 8 Seconds

Power boost
when the switch on RCV is ON.
(Using the Power Improved
※Condition 1. Accel Dial position : Higher than 8th level
boost button)
2. Not for Travel Mode in Wheeled machines.

At P-Mode, When High Load Condition (Pressure) is Continued

Auto Power boost during Certain Period, Automatically Power Max Newly Applied
Solenoid Valve is Engaged for 8 Seconds.

Automatically Power Max Solenoid Valve is Engaged According

Travel Power boost
when Travel RCV is Applied. to Model

HCE Training Center 14

 2. Variable Power control(E-mode)
; Data collection from sensors → Optimal Engine Speed and Main
Pump flow control. 1) E/G speed control
☞ Fuel Save and Smooth controllability. (1) Single operation
① Boom Up
Power Mode Work Mode Sensors
- Idle setting speed : 1,600RPM
Condition E General Normal - Operation speed(Max) : 1,750RPM
☞ E/G speed is Inverse proporation to the Negative
pressure.
Pn1 Pn2
pressure pressure
RCV Negative
MCV Pressure
P1
(Pn1,Pn2)
pressure
See
P2
BU AI AO pressure note ☜

ECM E/G speed

Boom up
pressure
Swing
pressure
pressure ② Arm In/Out, Boom Down, Bucket Out,
Pump Power
Shift EPPR
Swing(RH/LH) ☞ Always 1,600 RPM
(2) Travel (Front/Rear)
- Idle setting speed : 1,650RPM
HYUNDA

☞ E/G speed is Inverse proportion to the Negative

I

pressure.
knob (3) Confluence operation
E mode Dial Travel Auto ESC / MCU
☞ Higher RPM is selected among the upper (1) and
Power Work User
Mode Mode Mode Mode Idle CAM
Accel.
Cluster Dial
(2) items.

HCE Training Center 15

 Note] Pn1/Pn2 pressure understanding
1) RCV Lever Neutral : High pressure.
2) RCV Lever Active : Low pressure.

P2 P1

HCE Training Center 16

 2-1. Variable power control logic

(1) Program logic chart

Working Condition Control

Power Mode
Comparison for maximum Power Setting
Controller (Example)
Accel. Dial
RCV Heavy Load Lever Work 1600 ~ 1750 rpm
Calculation for Power Command 2nd Press.
d
1450 – 1600 rpm
Work Mode
n
a (Common)
mm
Co weighing
Light Load Lever Work 1600 rpm
_
M (Boom Down, Swing,
RP 1450 rpm
Pressure sensor Bucket Out, etc.)
(Main P) d
n
a
m + Variable Power Control
Travel RCV Travel Lever Work 1400 ~ 1750 rpm
m
Co
_
weighing
+ 2nd Press.
M
Pressure RP (Crawler)
sensor RPM Engine Throttle
(RCV 2nd d
n
Command Control
Device
Travel Pedal Travel Travel Mode 800 ~ 2300 rpm
P) a
m
m 2nd Press. Pedal
Proportional v/v

R_Co Command (Wheel) Work

P
PE

Pressure
Proportional Valve
for Pump Work Mode 800 ~ 1800 rpm
Swash-plate
sensor Control
(Pump control)

*Crawler : R210LC-9, Wheel : R1400W-9

HCE Training Center 17

(2) Control chart sample (E mode+Auto Idle)
① Engine
RPM 150

2000

1300

4초

TIME
② Negative
Pressure
Min(N1,N2)

TIME

③ Travel

TIME

④ W1

⑤ W2

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 3. Variable Boom priority system
; Optimized Flow division between Boom and Swing by calculating RCV 2nd pressure and
Load condition to control the EPPR Valve current.

1) Comparisons
Classifi- 7A Series 9/9S Series
cation
Algorithm Fixed Priority Functioning According to - Only at the condition of simultaneous operation
the Work mode selection. : Boom Up + Swing
-Heavy Duty : Boom Priority - Variable Boom Priority : Manual / Auto
-General, Breaker : Swing Priority

Flow ON/OFF Control (Solenoid Valve) of Variable Control (Proportional valve) of

Control Swing Logic Valve Swing Logic valve.

Shock - Smooth movement of Logic valve open-area.

Reduction

HCE Training Center 19

 R210LC-9

2) Boom speed control work on the HYD. system

(1) Manual control ( )

OFF

HCE Training Center 20

 R210LC-9

(2) Automatic control( )

Auto

ON
(Proportional)

HCE Training Center 21

 4. Attachment Flow(Proportional V/V current) control system
1) Composition

Breaker
※ Comparison table(7A vs. 9 Series)
MCV
Arm1
ATT Pilot Classifi- 7A Series 9/9S Series
Pressure Sensor
Option
Arm2 cation

Bucket
Mode Breaker ATT (Breaker, Crusher)
Swing

Boom1
Travel(RH)
Select V/V
Function ON/OFF Variable Flow Control
Main Relief V/V Travel(LH)

Control of According to Optional

RCV
ECM
Pump Max Attachment
Flow Cut
Accel. Dial ATT Safety
SOL V/V
Pump Regulator ATT Conflux New * - Flow Control Only at
SOL V/V

ATT Flow
ATT Pressure Option Operation
SOL V/V
Cont. EPPR
- Several Steps of ATT.
Speed Control
- Selection between
Breaker and Crusher (1
ATT Flow Cont.
Output
Way / 2 Way)
MCU - Option System Press.
Power Mode, Work Mode, ATT
Setting (2 stage) / Flow
Power Work
Mode Mode Cluster Type, ATT Flow Infomation
Conflux

HCE Training Center 22

 4-1. Option ATT selection

1) ‘Breaker’ selection
; The MCU can regulate the ATT’ Flow Control EPPR V/V current as much as the selected flow level on the
Cluster(7 level selection).

- No confluence of P1 and P2, Not use of the relief valve for option Attachment.

①
②
③
④

HCE Training Center 23

 2) ‘CRUSHER’ selection
; The MCU can regulate the ATT’ Flow Control EPPR V/V current as much as the selected flow level on the
Cluster(4 level selection).

- P1 and P2 pump flow confluence, use of the relief valve for option Attachment.

①
②
③
④

HCE Training Center 24

 ① Safety & Pressure Boost

210K → 280K

Option

ON
ON
Option
pedal

HCE Training Center 25

 ② Confluence

Option
②

ON

P1 P2

HCE Training Center 26

 5. Anti - Restart Function
① To protect the start motor from inadvertent restarting, CPU controller isolates the start
motor control line after the engine is in operation condition.
- Start relay disabled after 10sec of E/G start.
② By-pass connector (CN-16) can make the engine start when CPU controller is removed.

HCE Training Center 27

 6. Overload warning(Option)

1) Operation
(1)Overload s/w ‘ON’ : The Warning enable condition.
(2)Warning lamp and buzzer will be come up when the pressure
of Crane operation with the BOOM is over the setting pressure
more than 3 seconds.

2) Setting pressure for warning : 260 Kg/cm2

BOOM cyl.(LH) BOOM cyl.(RH)

Pressure
sensor

(Safety lock v/v)

HCE Training Center 28

 7. RAM LOCK System
1) System diagram

HCE Training Center 29

 2) Logic table
RAMLOCK PARKING/WORKING/TRAVEL SWITCH FUNCTION LAMP SOL
SWITCH

ON - LOCK ON OFF

OFF - UNLOCK OFF ON

AUTO PARKING LOCK ON OFF

TRAVEL UNLOCK OFF ON

WORKING TRAVEL LEVER “NEUTRAL” LOCK ON OFF

TRAVEL LEVER IS Operate brake pedal LOCK ON OFF

NOT NEUTRAL

Not operate brake pedal UNLOCK OFF ON

Note] 1. Operate brake pedal : Above 50 bar

2. Not operate brake pedal : Below 45 bar

Below 45 bar
Operation of brake pedal

Not operation of brake pedal

Above 50 bar

HCE Training Center 30

 Ⅳ. Specification of Electrical components

1. Coolant temperature sensor

2. Hyd. oil temperature sensor

3. Fuel Level sensor

HCE Training Center 31

 4. Pressure sensor
Pressure Sensor (9 Series) Pressure Switch (7 Series) Remarks

Outlook Molded Conector 1. Leakage by Diaphragm Failure

2. Reliability of S pring, Micro S witch, etc.
S train Gauge W elding
-> Leak Free S tructure W ater Flow into W ire

Type Electronic Mechanic

Steel (Strain Gauge, Surge Diaphragm (Rubber)

Absorptive Orifice)

Lifecycle 10 Million 1 Million

Reference 9 Series Excavators & Wheel loaders 7 Series

R800LC-7A

Note] Output Signal vs Pressure(Sensor: 50 Bar)

(Volt)

(Bar)

HCE Training Center 32

 5. Engine Speed Sensor

A. CUMMINS ENG (B, C series)

B. MITSUBISHI ENG

A. CUMMINS ENG (B, C series)

B. MITSUBISHI ENG

HCE Training Center 33

 6. Accel. Actulator

Reduction gear
&
potentiometer
box

HCE Training Center 34

 T/S Case 1. Accel Actuator(DC Motor) malfunction
Model Serial No. Operating Hour Date

R140LC-7 #3515 515Hr

1. Symptoms
: Engine running at 1750rpm only.

2. Check & Measure

1) Checked Accel Dial voltage : 1.9 to 3.6V
2) Potentiometer Sig. voltage remains same 0.6V
3) ERROR No. 1(Short circuit in Accel Actuator system)
4) Checked DC motor wires contact at connector(CN-76, Motor side) : No contact
(CN-76)
5) Checked Motor harness side wires contact at CN-76 :
#3 contact with point #5 and #6

3. Cause
: One of Accel. Actuator driving wires contact with Shield wire(GND).

HCE Training Center 35

 T/S Case 2. MCU program release to solve the trouble of Accel Actuators(June 2013)
* Concerning Field Campaign : SBF-2013-030, MCU Upgrade

1.

☞ Accel Actuator is being under improvement until the End of 2013.

(1) Reinforce stopper 2) Motor torque adjustment

2.

HCE Training Center 36

 7. Usage of pressure sensors

① Crawler Excavator
No. Pressure Sensor Tag Usage Position

1 1). Variable power control(work) 2). Pattern change

Boom Up Swing CD-32
Auto boom up
2
CD-24
valve
3 Arm In/Out, Bucket In CD-35 Variable power control(work)

4 N1 CD-70 1). Variable power control(work) 2). MCV

Travel variable power control
5 N2 CD-71
6 Main Pump 1 (a1) CD-42 1). Variable power control 2). Main Pump
Overload compensation
7 Main Pump 2 (a2) CD-43
3). Auto power boost
8 Working CD-7 Auto idle signal MCV

9 Travel CD-6 1). Auto idle signal

2). Travel buzzer control
10 EPPR Valve (a4) CD-44 For pump power feedback control Main Pump

11 Attachment CD-69 Attachment working check Option block

12 Overload CD-31 Overload Warning Boom(option)

HCE Training Center 37

 ② Wheel Excavator

No. Pressure Sensor Tag Usage Position

1 Boom Up CD-32 1) Variable power control(work) Pattern change

2 Swing CD-24 2) Auto boom up
valve
3 Arm In/Out, Bucket In CD-35 Variable power control(work)

4 N1 CD-70 1) Variable power control(work) MCV

5 N2 CD-71
6 1) Variable power control Main Pump
Main Pump 1 (a1) Main CD-42
7 2) Overload compensation
Pump 2 (a2) CD-43
3) Auto power boost
8 Working CD-7 Auto idle signal MCV

9 Travel CD-6
10 EPPR Valve (a4) CD-44 For pump power feedback control Main Pump

11 Brake oil CD-3 Brake oil low warning TCV Block

12 Transmission oil CD-5 Transmission oil low warning

13 Working Brake CD-38 Working brake “On/Off” check Brake pedal

14 Forward travel CD-73 Engine speed control Travel pedal

15 Reverse travel CD-74 2 Way pedal

16 Attachment CD-69 Attachment working check Option block

17 Overload CD-31 Overload Warning Boom(option)

HCE Training Center 38

 Electrical component identification

Safety 
solenoid

Power Max 
solenoid

Flow cut off  Travel speed  Heavy duty work 

Max solenoid change solenoid mode solenoid

SOLENOID (5EA) BLOCK
39
 Electrical component identification

EPPR SOLENOID
AUTO IDLE Pr. SWITCH

40
 Electrical component identification

AIR CLEANER  FUEL LEVEL SENSOR ENGINE RPM SENSOR

INDICATOR SWITCH

STARTER MOTOR RELAY BATTERY RELAY
DC MOTOR

41
 Analysis of electric system circuit
&
How to find checkpoints in electrical circuits.

H . J . Kim (Master Kim)

2018. 07.
Hyundai Construction Equipment

42
Analysis of electric system circuit

● Understand the flow of power and ground

in the entire electrical circuit.
[Electricity flows from + to -.]
● Electric current must flow through
the load (motor, bulb, etc.) to ground.

● Separate electrical and electronic systems.

● Be sure to read the symbols in the circuit.

● You must distinguish between male / female connector

identification and connector-specific pin numbers.
43
 How to find checkpoints in electrical circuits.

● In the entire electrical schematic, write the electrical diagram

associated with the fault symptom in a separate notepad.
● Distinguish whether it is an electrical system or an electronic system,
and distinguish the polarity of the + & - power on the circuit.
● The checkpoint should be measured by the controller whenever possible.
However, if there is an area to be checked easily,
it is measured at the location
● Find the control unit
(electrical system: relay & electronic system: controller).
● The input section (various switches, sensors, etc.)
is first measured in the control section and the output section
(various electric load devices: actuators) are measured in order.
● The measurement and verification in accordance with
the method of analyzing a circuit diagram by using the electrical tester.
44
Reference. Basic electrical system circuit

Input section Control Output section

Relay

45
Reference 1. Test Lead Usage

Maintain integrity without contact resistance

Terminal Contact Resistance Generation

(Terminal Damage)

Terminal Contact Resistance Generation

(Terminal Damage)

46
Reference 2. Electrical Test Lead Kit

47
 (사례1) 간헐적 전/후진 주행 불가
1-1

모델/호기 HW145 / 210 출고일 발생일 2017.09.

사용시간 4.250 hrs 관련자료 작성자 김재환 팀장

1.모델 :HW145 #132 (4250HRS) 
‐HW210 2대 ,HW145 4대 Field 다수 발생.
2.문제점
‐ 간헐적 전,후진 주행불가 (클러치 압력 경고등 점등)
‐ P3 압력 점검 :40K at1300RPM
‐ Parking Relay (CR66) #1 전압점검(0V:Parking , 24V:W )
P=>W변경 시 (클러치 압력 상승 불가) 24V로 변경되어야 하나 5V에서 약2~3분 후 24V로 변경 (불량)
‐ Parking Relay(경광등 Relay 상호) 교환 TEST
P=>W변경 시 (클러치 압력 상승 정상)0V=>24V로 정상 변경(약 30분 100회 test)
3.조치사항
‐Parking Relay 교환 조치

요청 및 의문 사항
1. 현재 Fiela에서 출고초기 문제 및 3000시간 사용장비에서 다수 발생되고 있습니다
그리고 Relay 여자코일이 5V로 유지될 수 있는지 문의 합니다

‐첨부1.2  및 동영상 참조 바랍니다

48
 첨부 1. HW145 휠 굴삭기 전/후진 관련 전기 회로도

Test 기 장착

멀티미터 데스터기 측정
정상값.
Parking (P)   : 0V. 
Working (W) : 24V.
비정상 시.
P=>W 변경 시 : 0V=>5V=>24V 
시간을 두고 비정상 변경됨.

PWT Switch P선택 시 Parking 
상태이며
W,T선택 시 Parking RY 여자
불가로 작업 또는 주행 상태임

49
첨부 2. 전기 오실로 스코프를 이용한 Parking Relay 측정 파형 분석

50
Reference. Basic electronic system circuit

Input section Control Output section

M
+ C
- P
U

Relay Controller (I/F Circuit)

51
 2-1. Engine rpm control System (9S)

ACCEL ACT(+)

ACCEL ACT(-)

POT-SIG
DIAL-SIG

52
1) Structure

53
2) Function of Eng’ Control System
Accel’ Dial PO Signal
Step Signal H mode S mode
1 1.0 1.9V
2 1.3 2.1
3 1.5 2.1
4 1.8 2.4
5 2.1 2.5
6 2.4 2.6
7 2.7 2.8
8 3.1 2.9
9 3.2 30
10 3.3 3.0
11 3.7 3.0
12 3.9 3.0

* Auto Idle cancelled

54
3) Detail of troubled Accel’ Dial PO Signal
Step Signal R300LC-9S R220LC-9S

- Low stopper of P/Meter is broken by over-run 1 1.0 1.7 1.1

2 1.3 1.9 1.7
3 1.5 2.0 1.8
4 1.8 2.7 2.5
5 2.1 2.8 2.7
6 2.4 3.0 Stopper2.9
7 2.7 3.2 broken3.1
8 3.1 3.3 3.3
9 3.3 3.4 3.5
10 3.6 3.5 3.7
11 3.9 3.5 3.7

55
4) Improved
(1) Change the location of low idle
(2) Change running method for accel’ Actuator
Motor

5) To apply for new program

Location of Low and High
(1) New Program of MCU has to be
downloaded by HCE-DT

Current supplying by MCU

56
2-2. Accel Actuator
** Mechanically controlled CMS E/G

Reduction gear &

potentiometer box

6 Pin Connector

57
 2-3. How to check
Condition
1. Engine running Bar graph function on digital multi meter
2. Auto Idle must be inactive.
3. 6 pin connector must be connected.
4. Turn Accel dial slowly and repeatedly
from 0 to 9 and from 9 to 0 Ignore this digital 
during pin 2, 5, 6 checking. value
Check procedure (6 Pin Connector)
#1 : 5V
#2 : Sig.(0V~5V) Motor potential meter SIG
If there is signal,
(Motor position sensor feedback signal to MCU)
This bar will
#3 : Ground (0V or below 10 Ω )
move.
#4 : not use Ignore this digital 
#5 : M+ 0~24V digital pulse sig. value
(Check Bar graph moving on digital multi meter)
#6 : M- 0~24V digital pulse sig.
(Check Bar graph moving on digital multi meter)
Reference
9 M+ and M- 0~24V digital pulse sig is very fast. (176ms = 0.176 sec)
It is not possible to check voltage with digital multi meter.
9 Therefore, you must use Bar graph function in digital multi meter with slow Accel dial turning.
If there is signal on #5 and #6, bar will move.

‹ If check result of Pin 1, 3, 5, 6 is OK, there is no problem on Accel dial, MCU and harness.

If engine RPM is not changing and check result of Pin 1, 3, 5, 6 is OK, problem would be on DC Motor.
(Motor or Potential meter or Mechanical problem)

58
 Reference 1. Motor driving circuit

MCU(CPU) internal circuit

Accel Actuator(DC Motor) Motor + , - Voltage (#5, #6)

Motor + , - Sig.

MCU
( Motor Voltage
(CPU) 24V )

59
Reference 2. Motor driving signal

Digital pulse signal is very fast.

(176ms = 0.176 sec)
It is not possible to check voltage with
digital multi meter.

60
3. 캔(CAN) 통신 저항 및 시스템 이해

61
62
63
CASE 1 : Low working performance

Model Serial No. Operating Hour Date

R330LC-9S # 1,717 Hr 2014.01

1. Symptoms
1) E/G speed is hunting and black smoke happen at
low Idle speed.
2) Decreased working performance around 60%.
3) No error code.

2. Possible cause
1) MCV failure.
2) Hose connection problem.
※ Without option attachment.
3. Check & Remedy
1) Pressure check - P1: 170Bar, Negative1: 2Bar, Pilot(Work): 30Bar.
2) Option spool pilot pressure : 30~35Bar.
3) Add a By-pass hose.

64
4. Remark
1) Checking machine status(with HCE-DT)

No error code.

65
2) Spools on MCV

66
3) Option spool pilot(XAo) port – Actual

MCV (Bottom side)

OPTION SPOOL Pilot port
(XAo – Plugged)

67
 XAo pressure(Bar)
4) Pressure check on Pilot XAo port

35 Bar(Max)

☞ XAo should be lesser 1bar, but in this case the pressure is up-rising as time goes by.

68
5) Adding a by-pass hose between Option pilot In and Out port

Upper(MCV) Lower(MCV)

69
6) Repair confirmation

☞ No pressure at the XAo port.

70
 Cluster Types
R220LC‐9S

Type2
Type1

Common with 9 Series

71
 Fuse Arrangement
R220LC‐9S
From Battery
From Battery Relay
From Power Relay

72
B+ Power Circuit R220LC‐9S

73
Engine Starting Circuit
R220LC‐9S

MCU cuts ground line of anti‐restart 
relay a few seconds after engine 
starting to protect starter motor

74
Charging Circuit R220LC‐9S

75

75
Hydraulic Related Electric
R220LC‐9S
Cluster2

* Cluster Type1
‐ Boom up PS
‐ Swing PS
EPPR Valve  ‐ Arm Reg. Sol.
missing ‐ Fuse Box
‐ MCU

76
 2-1. WIPER & WASHER Circuit

FUSE Box
POWER
+ / ‘ON’

WIPER&WASHER
Operation

A. INTERMITENT Operation ②
B. NORMAL Operation
C. WASHER Operation

( WIPER CUT SW )

WASHER ‘ON’
CHECK Point
① - GND : 0 ~ 5V
② - GND : 0 ~ 5V
③ - GND : 0V
④ - GND : 0 ~ 5V
⑤ - GND : 24V
⑥ - GND : 24V
③
※ Parking : After turning off the drive signal or Vcc (Key SW), supply the motor drive power only a little.
77
2-2. Wiper Circuit – R210LC-9/9S
CN-116 : SWITCH PANEL 1) MASTER SW ON
2) KEY SW ON
W W 3) WIPER SW Int.
W
I A 4) WIPER SW
I
P S 5) WASHER PUMP SW
P
E H
E CN-36
R E
R 5 4 3 10 7
R
INT.
SW
SW SW

1 2 3 4 5 6 7 8 9 10 11 12

18
19
23
24
30
31
37
43

WIPER CUT SW
CS - 53

WASHER DIODE
PUMP DO-5
CN-22

Operation
78
 1) Operation concept of Wiper Motor

(GND)
1. INTERMITENT Operation
3
1st) Motor drive+ power from w/controller.
(Feed back)
2nd) Feed back signal to w/controller.
CN-21
3rd) Motor drive+ power Time interval. 6 5

2. CONTINUAL Operation
- Continual Motor drive+ power supply to 2 4
(Motor drive +)
w/motor.

(Continue 24V )

WIPER CUT SW

WIPER MOTOR
CONTROLLER

79
 2) WIPER SYSTEM – Components & Connectors

Input Control Output

1:
CN-141(Front Reg.)
CN-116 G 6:Grw
1:BrW 5:L

1:NC CN-21
3:Gr

4:R(W)
6:WOr 12:NC 7:L WIPER MOTOR 13:Gr 6:L(B)

SW PANEL CONTROLLER WIPER MOTOR

80
3) Wiper Controller

Pin waveform
Function Operation condition
No.
CN-141 1G Feed Back Key ON : 0V 24V

Wiper operation : waveform (0~24V) 0V

2W M/Drive Key On : 5V 5V
SIG. Wiper continuous operation : 0V
6 13 3L Motor Key On : 0V
0V

Drive- 0V
Motor drive operation : 0V
5 12 4R Motor Key ON : 0V 24V
Drive+ Motor drive: 24V 0V
5B
4 11 GND 0V 0V

Key Off : 0V 24V

6GrW VCC
Key On : 24V 0V
7R Master SW ON : 24V(B+) 24V
10 B+
Key On & Off : 24V(B+)
Washer 24V
8V Key On : 24v(B+)
P/P Washer SW On : 0V 0V
5V
9L Washer Key On : 5V
3 9 P/P SIG. Washer SW On : 0V 0V
5V
10Br Key On : 5V
Int. SIG
Int. SW On : 0V
2 8 11Or Wiper cut Key On & Off : 5V
0V
5V

SW Wiper cut sw On : 0V 0V
1 7 12 NC(Blank) N.C
13Gr Feed Back Key On : 0V 24V
Wiper operation : waveform (0~24V) 0V

81
※ Wiper Controller(CHECK yourself!), measuring result
Pin Operation condition waveform
Function
No. (Measuring result)
CN-141 1G Feed Back Key ON : ___V 24V

Wiper operation : ___________ 0V

2W M/Drive Key On : ___V 5V
SIG. Wiper continuous operation : ___V
6 13 3L Motor Key On : ___V
0V

Drive- 0V
Motor drive operation : ___V
5 12 4R Motor Key ON : ___V 24V
Drive+ Motor drive: ____V 0V
5B
4 11 GND ___V 0V

Key Off : ___V 24V

6GrW VCC
Key On : ___V 0V
7R Master SW ON : ___V(B+) 24V
10 B+
Key On & Off : ___V(B+)
Washer 24V
8V Key On : ___V(B+)
P/P Washer SW On : ___V 0V
5V
9L Washer Key On : ___V
3 9 P/P SIG. Washer SW On : ___V 0V
5V
10Br Key On : ___V
Int. SIG
Int. SW On : ___V
2 8 11Or Wiper cut Key On & Off : ___V
0V
5V

SW Wiper cut sw On : ___V 0V

1 7 12 NC(Blank) N.C
Feed Back 24V
13Gr Key On : ___V
Wiper operation : __________ 0V

82
CLUSTER for 9S-Series Excavators

HCE Training Center

83
1. Menu map of the Cluster

1-1) Attachment selection

1-1-1) Breaker 1-1-1) Breaker flow setting

1-1-2) Crusher
2. Main menu 1-1-3) Not installed 1-1-2) Crusher flow setting
1. Operation SCREEN 1) Mode
1) Mode 1-1) Work tool 1-2) U mode power setting
2) Monitoring 1-2) U mode power
3) Management 1-3) Boom/Arm speed
4) Display 1-3) Boom/Arm speed setting
1-4) Auto power boost
5) Utilities 1-5) Initial mode
1-6) Cluster switch 1-4) Auto power boost setting
(back up)
1-5) Initial Mode setting
3. Camera
1-6) Cluster switch backing up

2-1) Current fault

2-1-1) Current MCU faults
2-1-1) MCU
2-1-2) Engine ECM
2-1-2) Current ECM faults

2) Monitoring 2-2) Logged fault

2-2-1) Memorized MCU fault
2-1) Active fault 2-2-1) MCU
2-2) Logged fault 2-2-2) Engine ECM
2-3) Delete logged fault 2-2-2) Memorized ECM fault
2-4) Monitoring(Analog)
2-5) Monitoring(Digital) 2-3) Logged fault deletion
2-6) Operating hour
2-4) Monitoring (Analog)

2-5) Monitoring (Digital)

2-5-1) Switch monitoring
2-5-1) Switch status
2-5-2) Output status 2-5-2) Output monitoring

2-6) Operating hours check

84
 3-1) Maintenance Info. 3-1-1) Maintenance item management

3-2) E/G starting limitation

3-2-1) Setting for E/G starting
3) Management 3-2-1) Limitation setting
3-2-2) Password change
3-1) Maintenance Info. 3-2-2) Password resetting
3-2) Machine security
3-3) Machine Info. 3-3) Machine information
3-4) A/S Phone number
3-5) Service menu 3-4) A/S contact point setting

3-5) Maintenance menu setting

3-5-1) Power shift setting

3-5-2) Replacement info.
3-5-2) Replacement history

4-1) Display item setting

4-1-1) Engine speed

4-1-2) Tripmeter A
4-1-3) Tripmeter B
4-1-4) Tripmeter C
4) Display
4-2) Clock setting
4-1) Display item
4-2) Clock
4-3) Brightness 4-3) Screen brightness setting
4-4) Unit 4-3-1) Manual setting
4-3-1) Manual
4-5) Language
4-3-2) Automatic
4-6) Screen type 4-3-2) Automatic selection

4-4) Unit selection

4-5) Language selection

4-6) Screen type

selection
5-1) Tripmeter selection
5) Utilities
5-2) DMB Monitoring
5-1) Tripmeter
5-2) DMB
5-3) Entertainment 5-3) Video monitoring
5-4) Camera
5-5) Message box 5-4) Camera setting

5-5) Message display

85
2. Operation SCREEN
1) Description ② Warning lamps ① :
(1) Clock
- Resetting: Display → Clock
(2) Warning Lamps
(3) Gauges including warning lamp
- Hyd.oil temperature
- Fuel level
- Coolant temperature ③ ④ E/G speed, Trip meter
(4) Engine speed(Trip meter) display
-Trip meter selection: Move the selection dial
two times → Push the dial → Move the Accel dial position
selection dial to select the one of three Trip
meters(A,B and C). ⑤ Indication lamps
(5) Indication Lamps

2) Option screen

Selection Dial
(Push/Turn) Menu escape/
Camera monitoring

(1) Oil flow level of optional attachment

①Breaker: Max.7-steps(10lpm reduction per each step)
②Crusher: Max.4-steps(20lpm reduction per each step)
(2) Accel dial position
Oil flow level of optional attachment (Breaker / Crusher)

86
3) Warning Lamps
(1)On Gauges
① Coolant & Hyd. oil temperature
- White area: 40-105℃
- Red area: Above 105℃
② Fuel level(Ex.R210LC-9)
- Red area: Below 55ℓ(Fuel tank: 400ℓ)

(2)
for Wheel type machine only
- Brake oil, T/M oil pressure
①Emergency ②Check Engine ③Overload (option)

① Emergency
-Coolant overheating(above 105℃)
-Hydraulic oil overheating(above 105℃)
-Pump EPPR v/v circuit abnormal
-Attachment flow EPPR circuit abnormal
-MCU input voltage abnormal
-Accel dial circuit abnormal
-Communication error(MCU-Cluster, MCU-ECM)
② Check Engine
-Communication error between MCU-ECM
-Cluster received any fault code from ECM
③ Overload(Option)
-Overload is detected from the overload switch on the Boom safety
valve.

87
3. Main menu selection

Note] 1) Menu selection

Selected Main menu
menu group groups

Move back to the

previous menu.

; Enter into
the selected
; Menu selection. menu.
(Main menu screen)

2) Setting item selection

Selected Menu

(Submenu selection)

(Setting item selection )

88
1) Mode
(1) Work tool
※ It should be selected properly to mach with the Work tool !

① Breaker setting

② Crusher setting

cf. When ‘Not installed’ is selected, WORK button will not work.

89
(2) U Mode

(If the U Mode is not selected)

① To proceed, the U Mode should be selected first.

Push !

② Engine speed, Idle speed and

Power shift modification

90
(3) Boom/ Arm speed

톨l
|덤 I 를
800mspeed
- Control type
뼈anual - 800m up speed is fixed as set steps.
Auto - Boom up speed is automatically adiusted as working conditions by the MCU.

Ann speed
- Regeneratíon - Arm regeneration function can be activated or cancelled.
Enable - Arm in speed is up.
Disable • Fine operation.

91
(4) Auto power boost

( P Mode only)

(5) Initial Mode

92
2) Monitoring

· Refer to the MACHINE ERROR CODES list(Sample)

· Refer to the ENGINE FAULT CODES list(Sample)

93
 →

· The logged faults of the MCU or engine ECM can be checked by this menu.

94
 3) Management

Maintenance
pilot lamp
- Elapsed time
Reset to ‘0’.

※ Strong recommendation!
☞ After replacement of Filters
and Oils, Reset the accumulated - Interval time modification.
time!!

· Interval time can be changed to 12500Hr by the 50Hr.

95
 7
days. (min. 5 min.)

-Select number and after number selection, enter the ‘＊’.

-Press ‘ESC/CAM’ button or the select dial a little while to escape
from the password set function.
96
· Password change
- The password should be 5~10 digits.

97
’ Machine Information

-‘

2ICOOC067
F

. This can confirm the identification of the cluster，MCU，engine and machine.

I AfS phone number

2W9JC D67J
- -
21 OG7K 21W 3COO71

21(1딩 21093(;C용1Y
3CD67Z

98
(Program up date) (Replacement history)

(See next page)

99
(3) Entertainment

(4) Camera setting

100
(5) Message box
. The history of the machine operating status can be checked by this menu.

---+

101