Trouble Shooting cases

for 9(S)-Series Excavator

- CONTENTS -
Ⅰ. Hydraulic System
Ⅱ. CAPO & Electric System

March , 2015

HHI Training Center

Ⅰ. Troubleshooting Cases
(Maintenance)

Page1 HHI Training Center

 CASE 1: Engine overheating
Model SerialNo. OperatingHour Location

R220LC-9S # Hr MiddleEast

1. Symptoms
1) The engine start overheating after 2 hours working.
2) No other failure.

2. Possible cause
- Temperature sensor failure.
- No good air flow to radiator.

3. Check & Remedy

1) Replace temperature sensor → Same problem happen.
2) Take out the thermostat → Same problem happen.
3) Contamination on the cooling components → Clean Radiator, CAC, Condenser, Oil Cooler

Page2 HHI Training Center

 4. Remark
- Air Flow direction check

Normal
Sucker
Blocked
Dust

A
N
F
D

O
R

R
T
I
O

O
O
C

R
L

L
E
I
A

O
N
D
C

C
Air can be flown this area only

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 CASE 2 : (HYD)Swing & Auto Idle problem happen
Model SerialNo. OperatingHour Location

R220LC-9S # 3,200Hr SoutheastAsia

1. Symptoms
1) Swing is not operated properly
2) Auto Idle Function is not activated

2. Possible cause
- Swing motor failure.
- Malfunction of Auto idle sensor
- Improper action of Hyd. circuit

3. Check & Remedy

[ Dealer action ]
1) Replace Swing motor → Same problem happen.
2) Replace Auto Idle sensor → Same problem happen.

[ Root cause]
: Signal Orifice was blocked with dust → Orifice&Filter cleaning(Lack of Maintenance - Hyd. Oil change).

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 4. Remark
: Signal Orifice check -Location

Orifice blocked

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 CASE 3 : No E/G start
Model/serial R55W/5211 Failure 2014

Hourmeter 4,387Hrs Delivery 2012.05

1. Symptoms
1) The Engine was running after jumpstarting.
2) Machine was jumped again for starting on the next day,
and abnormal smell happen during charging.
3) Engine re-starting was impossible after engine shut off.
4) No warning lamp for battery charging on the cluster.
2. Check
1) Engine did not start after changing new battery, so checked fuse box.
- MCU/cluster10A,cassete 20A, ECM 20A fuses were burn out, and burn out again after changing.
- Checked charging voltage on engine running after disconnection of MCU, cluster, radio jacks.
- 15.7V(at idling condition), charging voltage was increased with rpm up, so stopped engine

3. Possible cause
1) Battery cells were damaged by over-current of alternator over-charging.
- And assumed that MCU and Cluster was damaged(Short to GND).
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 4. Action taken
: Normal operation after replacing of Alternator, MCU and cluster.

5. Remark
1) Photo: Damaged parts in MCU. 2) Inside of the Battery

(+)
PLATE PACKS
END CAP
PLATE (-)
(+) ( + )POLE
(+)POLE
PLATE
PLATE PACKS
(-)
(-)
PLATE POLE
(-)POLE

Damaged IC parts in MCU

Note] Overcharge
1. (+)/(-) plate can be damaged by rapid
aging process.
2. Heat and pressure is increasing.

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 2) Charging circuit
Fuse
damaged

Page8 HHI Training Center

 CASE 4 : Pump failure
Model SerialNo. OperatingHour Location

R220LC-9S # Hr

1. Symptoms
1) Every attachment doesn’t work(Main pump not work).
2) Hyd. oil color is dark.

2. Checks
1) Disassembly of the Main pump
- Piston Shoe (1ea) missing.
- Excessive rear of Piston shoe.
2) Hydraulic oil tank inspection
- Sticky polluted(dark colored) oil on the Return filter
(and on the bottom of the tank).

3. Remedy
1) Main Pump Assy’ replacement and hyd tank cleaning.

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 4. Remarks

(Polluted Return filter)

(Damaged Piston Shoe)

1) The reason why sticky oil is in the Hyd. Oil tank

- Muddy dust inflow to the Tank through the Breaker.
- Muddy dust and other pollutant get together in Hyd. system with hot temperature,
at the time the sticky oil happen.
- It’s gravity is heavy so it is piled up on the bottom of tank.

Page10 HHI Training Center

Ⅱ. Troubleshooting Cases
(CAPO&Electric system)

Page11 HHI Training Center

 CASE 5 : Poor battery charging
Model/serial R300LC/5534 Failure 2014.06

Hourmeter 3,175Hrs Delivery 2011.01

1. Symptoms
- Battery charge warning lamp on when Air-con or light on
during machine operation.

2. Check
1) Battery voltage(on cluster): 26.5V
2) Voltage drop down to 23~24V at Air-con, Light ‘On’

3. Possible cause
1) User changed alternator --- 1st replacement. → Not improved after changingAlternator.
2) Replaced other alternator --- 2nd replacement.
- Same phenomenon after changing of new alternator.
3) Supposed supply voltage of alternator(R-terminal) is low, changed resistor – no improvement
4) Assumed low power from Battery when engine pre-heating system is in operation.
- Not a root reason of problem

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 4. Action taken
- Engine cranking is ok, retightened the battery supply terminal of start motor.
☞ Poor contact at the B+ terminal(Start motor).

5. Remark (Charging circuit)

1) Charging circuit

Poor contact terminal

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 2) Other possibility
(1) Alternator (B) Port mounting

Mounting Nut
loosening – Trace of
Spark

(2) Repair steps

Tightening

Marking

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 CASE 6 : Poor E/G start
Model/serial R140W/8324 Failure 2014.11

Hourmeter 140Hrs Delivery 2014.10

1. Symptoms
- E/G start is impossible.
- No sound on Start motor when start the Engine.

2. Check & Trying

1) Change the Battery relay with new parts.
2) E/G start problem happen again some days after
the change work.

3. Remedy
1) Replace with a upgraded Battery relay
* 21QA-70010 → 21QA-70011(fr. March 2015)
* 12V type : 21M9-54100 → 21M9-54101
Note] Applicable to All Excavator & Wheel Loader
2) If possible, change the Battery relay with old type P/No item.
21QA-70010(Using at present) → 21E5-0003(Previous using item)
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 5. Remark (Charging circuit)
1) Battery RY – Failed part inspection

Intermittently E/G E/G start trouble

start trouble happen. always happen.

Note] Items of Improvement

1. Material
2. Embossing height
Improved part(21QA-70011)

2) Refer to the Service Bulletin : SB-I-2015-007

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 CASE 7 : E/G speed is not match with default E-mode(at Start condition)
Model SerialNo. OperatingHour Date

R300LC-9 #0122 Hr

1. Symptoms
1) After engine starting, S mode rpm is activated even though E mode is indicated on the cluster
2) The Output pressure of EPPR v/v at E mode indicates the value of S mode.
3) Pn1, Pn2 pressure sensors are not shown on the cluster(Monitoring-Analogue)

2. Possible cause
: Negative pressure sensor failure.

3. Check & Remedy

1) Check of cluster error code
- Cluster shows Error code (123,124) : Negative sensor open(disconnected, Below 1V - 5bar)
- Out of 3 connectors(A,B,C), A & C connectors disconnected(Below 1V)
2) It can be the cause of high fuel consumption than ever.

Page17 HHI Training Center

 4. Remark
1) Location of Negative pressure sensor
100 bar – 2EA

PressureSensor(SPEC)

Resistancevalue
Voltagevalue
AandC=13.5KΩ
AandC=24V
BandC=985Ω
BandC=1~5V
AandB=13.5KΩ

Note]Normalvoltagevalue
A(Supply)=24V
B(Signal)=1~5V
C(Return)=Earth

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 2) Negative pressure sensors(Pn1,Pn2)

Page19 HHI Training Center

 2) Display on Cluster

Normal display Take out - Negative1 sensor Take out - Negative1 sensor

Pump2 press Pump2 press

Nega.1 press Nega.2 press Nega.1 press is higher than
Nega.2 press Pilot press normal(Open circuit)
Pilot press Travel pilot press

Disappeared ‘Nega.1 press’ item.

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 4) Output Signal vs Pressure
●

* 50 bar Pressure Sensor ●

( P/NO : 31Q8-40520 )
V
(Voltage) ●

bar

●
V
* 100 bar Pressure Sensor
(Voltage) ●
( P/NO : 31Q8-40510 )
●

bar

●
V
* 500 bar Pressure Sensor (Voltage) ●

( P/NO : 31Q8-40500 )
●

bar

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 5) Operation check at E-Mode - Location of RCV Pilot Pressure Sensors

Note] E-Mode E/G speed should be increased in just 4 cases of

operation : Bucket In, Boom up, Arm in/out

* 9-Series
Model only

Page23 HHI Training Center

 CASE 8 : Travel deviation
Model SerialNo. OperatingHour Date

R220LC-9S # Hr

1. Symptoms
1) All attachment speed is slow.
2) Travel speed is slow as well.

2. Possible cause
- Main relief v/v failure.
- Pump EPPR v/v failure.
- Abnormality of Pilot pump pressure.
- E/G speed is slower than specification.

3. Check & Remedy

1) Replace EPPR v/v with new one. → Not improved.
2) Adjust the Main relief v/v and Pilot relief v/v pressure. → Not improved.
3) Checked E/G Idle speed and adjust push-pull cable (See Remark).

Page24 HHI Training Center

 4. Remark
A. E/G speed Check (High Idle)
Mode E/Gspeed(RPM) Speeddifference
Specification Actual

P 2,050 1,870 180

S 1,900 1,720 180

E 1,800 1,620 180

B. Concept of EPPR Valve current definition

E/G speed
(RPM)

Idle speed

Load speed
(Target RPM)

Pressure

Page25 HHI Training Center

 20Ton Wheel Ex.
C. Power shift control

[ Characteristic of CAPO System ]

1. Fast reactivity
2. Steady power control

Note] 1. Working condition : Arm in / out

2. Color
(1) RED : P1 Pressure
(2) BLUE: P3(Pilot pump) Pressure
(3) GREEN: EPPR V/V - output pressure
‘S’ Mode ‘H’ Mode ‘S’ Mode
■ Power Mode setting

Page26 Page 26
HHI Training Center
 CASE 9 : Travel deviation
Model SerialNo. OperatingHour Date

R300LC-9 #0110 Hr

1. Symptoms
1) Slow speed of attachment speed.
2) Travel deviation occurs when travelling.

2. Possible cause
- Straight travel v/v failure.
- Breaker EPPR valve failure.

3. Check & Remedy

1) Negative pressure Pn1 check : 5 ~ 29bar(Normal)
2) Breaker EPPR Valve pressure check : 39bar(abnormal)
☞ Due to Breaker EPPR valve failure, a 39 bar pressure from P3 pump is always applied to the
P1 pump regulator, therefore it adjusted the pump regulator to minimum flow.

Page27 HHI Training Center

 4. Remark
1. When Breaker mode is selected on the cluster, MCU sends some current to breaker EPPR v/v.
Then the breaker EPPR v/v can supply 12 ~ 6 bar pressure to pump regulator.

From MCV-Pn1

Pressure check
point

Breaker EPPR V/V

leakage(Inside)

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 2. Flow control of Breaker EPPR valve (on condition of Breaker mode, Proto machine data)
* 1 segment = 10 lpm changing by the current value changing (total 7-segments)

(Segment)

Breaker -PN1
operation
- PN2

1 2 3 4 5 6 7

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 CASE 10 : Auto Idle is not operated(Engine rpm is not increased)
Model SerialNo. OperatingHour Date

R300LC-9 # Hr

1. Symptoms
1) All values of pressure sensors on the cluster are indicated 0 bar.
2) Power supply (24 Volt) for all sensors is not checked.

2. Possible cause
1) Electric supply power source is not normal.
2) The negative pressure sensor(50 Bar) is failure.

3. Check & Remedy

1) Checked auto idle sensor (A and C, 0V) ※ Spec: A and C(24V), B and C(1~ 5V)
2) Checked all pressure sensors : 0 bar is indicated(abnormal)
3) Checked the power on the pin of MCU : CN51(4) and CN51(5) is OV(abnormal)
4) After disconnecting the CN51(4) of MCU, 24V is checked (normal) at the MCU port.
- Due to CN52(4) wire is contact to GND or Sensor short, the power is not supplied to all sensors.

Page30 HHI Training Center

 4. Remark

: MCU supplies 24 volt to all pressure sensors.

When pressure sensor power wire is shorted to GND, all pressure sensors don’t get a power anymore.

1) Wires of pressure sensor

GND
24 V

MCU

※ Sensor short check

Checked : 0.2 Ω(short)

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 2) Wire circuit between pressure sensors and MCU

To MCU(CN-52)

Earth(GND)
To MCU
(CN-52)

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 CASE 11 : Breaker operation is not normally activated
Model SerialNo. OperatingHour Date

R300LC-9 # Hr

1. Symptoms
1) Breaker is activated so slowly due to not enough of hydraulic flow.
2) The hydraulic flow is measured 140 ~ 210 lpm, but it is changed intermittently.

2. Possible cause
: The attachment EPPR valve is in failure condition.

3. Check & Remedy

1) Attachment EPPR valve pressure change rate .
☞1 bar : (about)10 lpm
2) If engine rpm changes 100rpm, the lpm changeds
to 100 ×140(cc/rev)=14,000(cc/rev)÷1000=14 Liter

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 4. Remark
1) Regulation circuit on the PUMP

P1 (regulator)

P3 (gear pump)

Drain

(Attach EPPR V/V)

Pilot pressure Drain

(P3 Pump)
P1
(Regulator)

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 2) Attach EPPR V/V : Normal Flow condition

Page35 HHI Training Center

 CASE 12 : Engine speed is 550RPM and Load rate is being increase
Model SerialNo. OperatingHour Date

R300LCH # Hr

1. Symptoms
1) When the attachment is activated with low Idle speed, the Engine is shut down sometimes.
2) No warning.

2. Possible cause
1) The Pump flow control is not good.
2) Engine itself has trouble.

3. Check & Remedy

1) P1 pressure :100bar(Cluster-Monitoring) at low idle condition(Abnormal)
2) Found Pi1 hose is blocked with plug → Attachment EPPR v/v re-connection.
: Connect Pi1 with Shuttle v/v.

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4. Remark
: When option attachment is not used, Attachment EPPR v/v passage blocking is recommended.
Pn1 connecting hose is blocked by mistake on this case, so P1 Regulator input pressure lower → P1 Pump supply

pressure increase(cause of Pump flow increase).

P1 Pump transfers more load to Engine (E/G RPM is on low rpm, Normal : 800 RPM / ACT’L: 550 RPM) 1-2

Faulty Plugged

Attach EPPR
 CASE 13 : Engine is shut down during operation
Model SerialNo. OperatingHour Date

R300LC-9 # Hr

1. Symptoms
1) When the attachment is activated, the engine is shut down.
2) The problem happen occasionally.

2. Possible cause
1) Alternator failure - The charging voltage is not normal sometimes.
2) Communication(between MCU and ECM) is not good sometimes.

3. Check & Remedy

1) Generation voltage of Alternator : 37.5volt(Cluster-monitoring)

2) Engine rpm drop down to about 800rpm sometimes.

4. Remark
: When the voltage of the alternator is over 36 volt, the MCU don’t send any signal to prevent
further problems.

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 CASE 14 : Combination working speed is slow
Model SerialNo. OperatingHour Date

R380LCH # Hr

1. Symptoms
1) Single working speed is normal.
2) Combination working speed is slow.
3) No warning.

2. Possible cause
1) EPPR v/v control is not normal.
2) Pump flow control is not normal.

3. Check & Remedy (Sensor: 100 K) (Sensor: 50 K)

1) EPPR V/V output pressure is 2-times high than expected

2) Founded the EPPR v/v Sensor mounting is wrong(Spec: 50 k / Act’l: 100 k)
- Sensor mounting fault.

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 4. Remark

2 -2

(EPPR V/V Sensor: 100 k ) / Speed low(10 K) (EPPR V/V Sensor: 50 k ) / Speed normal(5 K)

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 CASE 15 : Travel buzzer is not operated
Model SerialNo. OperatingHour Date

R220LC-9S #0225 996Hr

1. Symptoms
1) Travel Buzzer is not activated when travelling.
2) No warning.

2. Possible cause
1) Travel pressure sensor fault.
2) Switch panel failure.
3) MCU & Travel Buzzer fault

3. Action taken
1) Replace Buzzer unit.
2) Replace MCU.
(Buzzer unit)
4. Check
1) Switch panel – Travel alarm control : Normal(Lamp On/Off)
2) The function check: At the Buzzer ‘On’ Condition
- Switch Panel - Lamp ‘On’
- Travel pressure check.
: Travel buzzer sounds when the pressure is more than 15 bar.

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 ※ Check Cluster Information(Monitoring – Analogue)

5. Remedy & Remark

- Replace ‘Travel pressure sensor. (Travel buzzer
- Electric circuit control port)
 CASE 16 : Auto idle is impossible sometimes
Model SerialNo. OperatingHour Date

R55 #0432 5,230Hr

1. Symptoms
1) Auto Idle function not works(Engine rpm is not increasing).
2) Battery charging warning lamp is ‘On’ sometimes.

2. Check
1) Auto Idle indication on the Cluster → normally switched On/Off
2) Checked MCU Fuse & power : 11.2V

3. Possible cause
1) MCU could not send output signal to accel actuator because charging voltage of alternator
is low, so auto idle function not works normally.
☞ There is no power supplying to Accel actuator if charging voltage is lower than 12V
by abnormal alternator or electrical problem.

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 4. Remedy
1) Replaced Alternator ass’y.
- Normal charging voltage of Alternator : 12.7V, detected

5. Remark
RPM signal
Alt. level

Page44 HHI Training Center

Ⅲ. Troubleshooting Cases
(Hydraulic system)

Page45 HHI Training Center

 CASE 17 : Abnormal sound happen when swing operation stop
Model SerialNo. OperatingHour Date

R380LC-9S # 2,800Hr

1. Symptoms
1) Abnormal sound happen when swing operation stop. Listen out for a specific sound in the Video.

2) Swing operation is normal.

3) Attachment & Travel speed is normal.

2. Possible cause
1) Swing motor.
2) Swing bearing.

3. Check & Remedy

1) Swing operation pressure – Normal(See Remark)
2) Insert Orifice(∮0.8 ~∮1.2) fitting between swing spool pilot lines.

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 4. Remedy
1) Necessary parts
to MCV
① Orifice connector + Elbow-Swivel

② Specification of Orifice connector

: PF1/4×UNF9/16, ∮0.9mm(or ∮1.2mm)

2) Hyd. circuit

to RCV

Page47 HHI Training Center

 CASE 18 : Abnormal sound happen when swing operation stop
Model SerialNo. OperatingHour Date

R380LC-9S # 2,800Hr

1. Symptoms
1) Abnormal sound happen when swing
operation stop.
2) Attachment operation is normal.
3) Swing & Attachment speed is normal.

2. Possible cause
1) EPPR v/v control is not normal.
2) Pump flow control is not normal.

3. Check & Remedy

1) EPPR V/V output pressure is 2-times high than expected
2) Founded the EPPR v/v Sensor mounting is wrong(Spec: 50 k / Act’l: 100 k)
- Sensor mounting fault.

Page48 HHI Training Center

 CASE 19 : Arm in operation stops temporary
Model SerialNo. OperatingHour Date

R300LC-9S # 3,640Hr

1. Symptoms
1) Jerking happen when Arm-in operation on condition of Rod movement about 40~50 cm .
2) The other operation is normal.

2. Possible cause
1) Arm in pilot pressure is not steady.
2) Overload relief v/v is in trouble.
3) Poppet in Arm holding v/v is possibly damaged.

3. Check & Remedy

1) Same symptom happen when main relief valve and overload relief was exchanged.
2) Replace Pilot poppet with new one.

Page49 HHI Training Center

 4. Remark
1) Overload relief valve

(27-4)

(27-1)

To
Tank

(27-7)

(From (27-5)
Cylinder)

Damaged

Page50 HHI Training Center

 2) Circuit of Arm in operation
When the LH-RCV is pulled back, the arm
spools are moved to the roll in position.

The oil from the front and rear pump flows

into MCV and then goes to the large chamber.
At the same time, the oil from small chamber
returns to the hydraulic oil tank through Arm
the arm spool. holding v/v
When this happens, the arm rolls in.

The excessive pressure in the arm cylinder

head side is prevented by relief valve.
The cavitation which will happen to the head
side of the arm cylinder is also prevented by
the makeup valve in MCV.

Page51 51 HHI Training Center

 CASE 20 : Slow speed of Bucket-in operation
Model SerialNo. OperatingHour Date

R220LC-9S # 4,633Hr

1. Symptoms
1) Buck-in speed is slow (Actual: 6.0 Sec / Spec: 3.8±0.4 Sec).
2) The other operation is normal.

2. Possible cause
1) Interchanged overload relief valves each other, but same phenomenon.
2) At that time, negative pressure was 28bar, no changing(Pilot pressure :40bar, normal)
3) Root cause is that the Bucket spool didn’t move to full stroke, because bucket stroke limiter
was stuck.

3. Check & Remedy

1) Checked the relief pressure(in:180bar/out:360bar) of bucket in , bucket in was abnormal.
2) Clean the Bucket stroke limiter and replace Hyd. oil.

Page52 HHI Training Center

 4. Remark
: Bucket stroke limiter

Bucket stroke
limiter

Pa5(Bucket in)

← Fr. P2

(Boom up pilot)
↑
↓ Fr. P1
to Tank

Bucket stroke
Pb5 limiter

P04

Page53 HHI Training Center

 CASE 21 : Attachment working speed is slow
Model SerialNo. OperatingHour Date

R520LC-9S # Hr

1. Symptoms
1) When digging operation,Attachments speed
is slow.
2) No warning.

2. Possible cause
1) EPPR v/v control is not normal.
2) Pump flow regulator is not normal.

3. Dealer action & Remedy

1) Replace EPPR valve --- problem happen again.
2) Replace Regulator on the Pump --- problem happen again.
3) Replace EPPR Pressure sensor → problem solved.

Page54 HHI Training Center

 4. Remark

: Check steps to find out root cause.

1) Power shift Pressure check(Cluster-Monitoring menu) : 0 Bar(see Pic.1)

2) When the connector of EPPR is disconnected, all speed is normal.
3) Check actual Power shift Pressure (see Pic.2)

Ⓐ Power shift Press : 0 bar Ⓑ Actual Power shift Press : 30 bar

(Picture 1) (Picture 2)

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 (4) Standard setting
E/GRPM EPPRV/V
Unload Load atUnloadRPM
Mode mA Kg/ ㎠
P 1900 1850 250 5
S 1800 1750 280 7
E 1700 1650 280 7

(5) EPPR current determination system

A. Function
: When the pressure different happen between the target and real, the MCU re-adjusts EPPR
current value to be equal.

B. System Outline

Page56 HHI Training Center

 CASE 22 : Low working performance
Model SerialNo. OperatingHour Date

R330LC-9S # 1,717Hr 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.

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

No error code.

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 2) Spools on MCV

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 3) Option spool pilot(XAo) port – Actual

MCV (Bottom side)

OPTION SPOOL Pilot port
(XAo – Plugged)

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

Upper(MCV)
Lower(MCV)

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 6) Repair confirmation

☞ No pressure at the XAo port.

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