Trouble Shooting Guide

9-series Excavator

-1- Hyundai Training Center

 Contents
1. On starting engine, E mode changes to S mode
2. Travel deviation occurs
3. Travel deviation occurs
4. Different track speed in the free load condition
5. Different track speed in the free load condition
6. The machine swings reversely on the slope
7. Noise occurs during swing
8. the machine travel deviation happens
9. Auto idle is not operated (Engine rpm is not increased)
10. Breaker is not activated normally due to the shortage of hyd. Flow
11. Machine travel deviation , low swing speed, low pump 1 pressure
12. Engine rpm doesn’t increase over 1300rpm when the travel pedal is pushed down
13. When the attachment is activated, the engine is shut down
14. During working, the engine has been shut down several times a day
15. Engine overheated
16. Service brake is not working
17. Engine rpm is not increased when the machine starts travelling

-2- Hyundai Training Center

 Contents
18. Machine travel speed is slow (work mode (interlock) or travel mode)
19. Auto cruise is not working
20. Power mode malfunction
21. When the working mode is selected, the machine travel occurs
22. A customer wants to increase the swing power on the slope
23. The machine is travelling even though the travel pedal is not touched
24. Engine rpm is not increased during machine travel on “W” mode
25. During travelling on the road, the machine’s Engine shut down
26. Auto idle is not working
27. Auto idle is not working
28. Travel interlock function
29. Low arm out speed
30. Auto cruise is not working
31. Engine rpm is not increased when the machine starts working
32. Machine speed is slow except swing
33. Arm in and boom down is not working occasionally
34. Engine load increased and fuel inefficient

-3- Hyundai Training Center

 Contents
35. Poor power and speed of arm in
36. Instruction of auto warming-up
37. Slow arm-in at initial movement and arm-out by gravity during RCV neutral
positioned

-4- Hyundai Training Center

1.Problem : On starting engine, E mode changes to S mode

Model : R210LC-9

Symptom
1.On starting engine, S mode rpm is activated even though E mode is indicated on the cluster
2.The secondary pressure of EPPR E mode is indicated the value of S mode
3.Negative pressure(1,2) don’t display on the cluster

Possible Cause
Negative pressure sensor failure

Check Points and Remedy

1.Check of cluster error code
-MCU error code (123,124) : negative sensor open(disconnected) : under 1V (5bar)
-out of 3 connectors(A,B,C), A & C connectors disconnect (under 1V)
2.It can be the cause of high fuel consumption
3.The function of negative sensors

-5- Hyundai Training Center

- During the initial engine starting, MCU sends S mode signal
- MCU receives the signal of negative pressure sensors and changes the mode 100 bar – 2EA
to E mode
-If the signal of negative pressure sensor is not correct(open or high
voltage), the machine is working with S mode rpm and EPPR pressure

(SPEC)
Resistance value Voltage value
A+C=24V
A+C=13.5KΩ
B+C=5V
B+C=985Ω
A+B=13.5KΩ

A (Supply)=24V
B (Signal)=5V
C (Return)=Earth

-6- Hyundai Training Center

Reference

Normal Remove Negative 2 Pressure Sensor Remove Negative 2 Pressure Sensor

-7- Hyundai Training Center

Pressure Switch / Sensor

Measuring Range
Item Part No. Connector Color
or Switching Point

Pressure HHI P/N : 31Q4-40560

1 5 bar / 4bar Red
Switch HYDAC P/N : 920180

HHI P/N : 31Q8-40520

2 50 bar Black
HYDAC P/N : 920152

HHI P/N : 31Q8-40510

3 100 bar Blue
Pressure HYDAC P/N : 920153
Sensor HHI P/N : 31Q4-40570
4 200 bar Turquoise
HYDAC P/N : 920154

HHI P/N : 31Q8-40500

5 500 bar Grey
HYDAC P/N : 920155

-8- Hyundai Training Center

Reference data
(Output Signal vs Pressure)

(Signal from Pressure Switch to CPU) ●

●
V
50 bar Pressure Sensor
(Voltage) ●
( P/NO : 31Q8-40520 )
bar

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

●
V
(Voltage) ●

500 bar Pressure Sensor ●

( P/NO : 31Q8-40500 ) bar

-9- Hyundai Training Center

Pressure switch / Sensor measurement

Measuring Tool
How to Check

- 10 - Hyundai Training Center

 Variable Power control

; Optimized engine and pump power control by the data 1) E/G speed control
collection of attachment, Engine speed and pump load (1) Boom up, Arm in/out, Bucket in
pressure → Fuel save and smooth controllability
- Idle setting speed : 1,600rpm
Power Mode Work Mode Sensors - Operation speed : 1,750rpm
☞ E/G speed is inverse proportion to the negative
Condition E General Normal pressure.

Negative
N1 N2 Pressure
RCV pressure pressure (N1,N2)
MCV
P1 E/G speed
pressure

P2
BU BI AI AO pressure
Travel R Travel F
pressure pressure (2) Boom down, Bucket out, Swing(RH/LH)
ECM
☞ Always 1,600 RPM
Boom up Arm in/out
pressure & bucket in
Pump Power
(3) Travel (Front/Rear)
pressure
Shift EPPR
- Idle setting speed : 1,650rpm
☞ E/G speed is inverse proportion to the negative
pressure.
HYUNDA

(4) Confluence operation

I

☞ Higher rpm is selected among the upper (1),(2)

knob
and (3) items.
Power Work User Dial Travel Auto ESC / MCU
E mode Mode Mode Mode Mode Idle CAM
Accel.
Cluster Dial

- 11 - Hyundai Training Center

 Variable power control logic

(1) Program logic chart

Power Mode
Control
Comparison Working Condition
for maximum Controller (Example)
Power Setting
Accel. Dial
1600 ~ 1750 rpm
Heavy Load Lever Work
RCV 1450 – 1600 rpm
Calculation for
Work Mode
Power Command 2ndPress.
Light Load Lever Work 1600 rpm
RPM_Command

(Common) (Boom Down, Swing,

Pressure
sensor weighing Bucket Out, etc.) 1450 rpm
(Main P)
Travel RCV 2nd
Variable Power Control
Press. Travel Lever Work 1400 ~ 1750 rpm
RPM_Command

Pressure + (Crawler)
sensor + RPM Engine Throttle
weighing
(RCV 2nd P) Command Control Device

Travel Mode 800 ~ 2300 rpm

Travel Pedal 2nd Travel
EPPR_Command

Proportional Valve
Press. Pedal
Proportional v/v
for Pump
Pressure Command
Swash-plate Control (Wheel) Work
sensor
(Negative P)
Work Mode 800 ~ 1800 rpm

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

- 12 - Hyundai Training Center

(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

- 13 - Hyundai Training Center

2.Problem : Travel deviation occurs

Model : R290LC-9

Symptom
1.Slow attachment speed
2.Travel deviation occurs when travelling

Possible Cause
Breaker EPPR valve failure

Check Points and Remedy

1.Check of negative pressure PN1 : 5-29bar
2.Check of Breaker EPPR Valve pressure : 39bar(abnormal)
3.Due to EPPR valve leakage, the 39 bar pressure from P3 pump is applied to the P1 pump regulator and
adjust the pump regulator to minimum flow

- 14 - Hyundai Training Center

When breaker mode is selected on the cluster
and breaker switch is touched, MCU sends
some current to breaker EPPR.Then,the MCV PN1
breaker EPPR sends 12b-6b pressure to pump
regulator.

Pressure check
point

Breaker EPPR V/V

leakage

- 15 - Hyundai Training Center

Breaker EPPR valve’s flow control on the breaker mode(Proto machine data)
1 segment = 10lpm by changing the current value (total 7 segments)

(Segment)

Breaker operation -PN1

- PN2

1 2 3 4 5 6 7

- 16 - Hyundai Training Center

3.Problem : Travel deviation occurs

Model : R290LC-9

Symptom
1.”E” mode changes to “S” mode arbitrarily when any attchment is working
2. Bucket In-Out , Arm In-Out , Boom Up-Down , Swing RH/LH, Travel RH/LH

Possible Cause
MCU failure (water infiltrates in the MCU) Water infiltrate is checked

Check Points and Remedy

1.Check the pressure sensor of RCV lever and electric signal
2.Check the pressure sensors of PN1, PN2 (it is OK)

- 17 - Hyundai Training Center

RCV Pilot Pressure Sensor

- 18 - Hyundai Training Center

4.Problem : Different track speed in the free load condition

Model : R290LC-9

Symptom
In the E mode condition, R/H & L/H track speed is different
but during the machine travel, the deviation doesn’t happen
-R/H travel motor is rotating in the free load condition, the engine rpm is changed 1400 rpm to 1700rpm
-L/H travel motor is rotating in the free load condition, the engine rpm is not changed at 1400rpm

Possible Cause
Failed negative pressure sensor (56bar is always indicated on the cluster)

Check Points and Remedy

- 19 - Hyundai Training Center

Travel motor circuit

- 20 - Hyundai Training Center

5.Problem : Different track speed in the free load condition

Model : R140W-9,290LC-9,R360LC-9

Symptom
Engine rpm increases intermittently and returns to the set rpm again

Possible Cause When ECM fuse is removed, the engine

1.Upgrade ECM program (calibration) is running with the default engine rpm
- ECU default rpm changed 1600rpm => 1300 rpm (R140W)
2.Upgrade MCU program
- Regeneration time of MCU during communication failure is reduced from 1.3 sec to 0.4 sec

Check Points and Remedy

1.MCU & ECM makes communication each other by CAN communication.
When the commincation is not done due to noise or other reasons (error code 285), ECM is
running the engine with default rpm
2.The default rpm for R360-9/R290LC-9/R210LC-9 is 1600rpm and R140W-9 is 1300rpm

- 21 - Hyundai Training Center

6.Problem : the machine swings reversely on the slope

Model : 290LC-9

Symptom
Swing motor rotates reversely on the slope(20 degrees) at the moment during pilot pressure at 10-12bar
-boom & arm is 110 degrees and full bucket load
Possible Cause
when this phenomen happens, the boom up and swing activated at the same time, it doesn’t happen

Check Points and Remedy

At the pilot pressure 10-12 bar, when the swing spool opens,
the front pressure of swing spool is lower than swing motor
-if the engine rpm and flow from pump is low or the weight
of bucket is increased, the phenomenon is severe
-the weight of 9-series steel bucket is 300kg heavier than 7-series
standard bucket

on the 9-series machine, swing motor brake is released when

any attachment is activated but on 7 series machine, swing brake is
released when swing is done

Machine condition of problem

- 22 - Hyundai Training Center

(measured data)

Drift area No drift area

(Swing Only) (Swing + Boom up)

-Swing operation (pilot pressure:10~ 12 bar) -Swing operation (pilot pressure:10~ 12 bar)
-The pressure in the front swing spool(black) -the pressure in the front of swing spool:black
< swing motor pressure (motor A,B:red) 〉 swing motor pressure(motor A,B:red)

- 23 - Hyundai Training Center

7.Problem : Noise occurs during swing

Model : R140W-9,R290LC-9,360LC-9
Lubricate swing bearing
-Grease at 3 fittings
(lubricate every 50 hours)
Check Points and Remedy
change grease on the swing bearing (every 1,000hours)

- 24 - Hyundai Training Center

Drain old grease
1.Remove under cover of lower frame
2.Remove drain cover of lower frame
3.Remove filler cover of upper frame
4.Operate full turn of swing several times

Refill new grease

1.Install drain cover
2.Fill with new grease
3.Install filler cover

5mm

- 25 - Hyundai Training Center

- 26 - Hyundai Training Center
8.Problem : the machine travel deviation occures

Model : 290LC-9

Symptom
When breaker mode’s selected, the machine travel deviation happens

Possbile Cause
The breaker pressure sensor(50 Bar) is replaced

Check Points and Remedy

1. Check the pressure between attachment Eppr v/v and P1 regulator pressure
- When breaker mode is not selected, the pressure is checked 0-1 Bar (normal)
- When breaker mode is selected(no operation); 12 Bar checked (abnormal)
the spec.(when breaker mode is applied) : 0-1bar (Sensor Voltage : 1-4.2volt)
- When the breaker pressure sensor(50 bar) is checked ; it is founded to be disconnected.
2. When 4.2 volt input signal is supplied to MCU due to the disconnected breaker pressure sensor,
MCU supplies current to attachment EPPR valve to apply 12 bar pressure to p1 pump regulator.
And then, the pump flow is decreased. It becomes the cause of machine deviation due to the different
flow of P1 and P2 pump.

- 27 - Hyundai Training Center

 Pressure sensor
MCU

Attach. safety / pressure increase / flow summation

EPPR V/V for attachment flow

- 28 - Hyundai Training Center

 50 bar Sonsor
It is located in the engine room near c/weight

Pn1 pressure Att’Eppr

Sensor is disconected

- 29 - Hyundai Training Center

 14-3

Breaker Sol’Sensor
PN1
Att’Eppr

Att’Eppr

- 30 - Hyundai Training Center

9.Problem : Auto idle is not operated (Engine rpm is not increased)

Model : 290LC-9

Symptom
Auto idle is not activated.
-All values for pressure sensors on the cluster are indicated 0 bar
-Power supply (24 Volt) for all sensors is not available

Possible Cause
The negative pressure sensor(50 Bar) is replaced

Check Points and Remedy

- Checked auto idle sensor (A+C=0V) – abnormal .Spec;A+C(24V), B+C(1~ 5V)
- Replaced MCU (the problem is not solved)
- Checked all pressure sensors : 0 bar is indicated(abnormal)
- checked the power on the pin of MCU : CN51(4)+CN51(5)=OV(abnormal),
CN51(5)+CN51(6)=1-5V(normal)
- after disconnecting the CN51(4) of MCU, 24V is checked (normal)
- Due to CN52(4) short or Sensor short, the power is not supplied to other sensors

- 31 - Hyundai Training Center

 MCU supplies 24 volt to all sensors
When a sensor is shorted, all power is supplied
to the shorted sensor with low resistance
And other sensors don’t get a power anymore

24v GND

mcu

Sensor short
Spec:A+C(13.5K ohm)
Act,l:0..2 ohm(short)

- 32 - Hyundai Training Center

 MCU CN52

MCU CN52(23)BOOM UP
PRESS SENSOR
Earth

- 33 - Hyundai Training Center

10.Problem : Breaker is not activated normally due to the shortage of hyd. Flow

Model : 290LC-9

Symptom
1. Breaker is activated so slowly due to the shortage of
hydraulic flow.
2. The hydraulic flow is measured 140-210 lpm but it is changed
intermittently
Possible Cause
The attachment EPPR valve is replaced with a new one

Check Points and Remedy

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

- 34 - Hyundai Training Center

 (Attach EPPR V/V : Normal Flow condition

P1 (regulator)

P3 (gear pump)

Drain

(Attach EPPR V/V)

- 35 - Hyundai Training Center

11.Problem : machine travel deviation , low swing speed, low pump 1 pressure

Model : 290LC-9
Symptom
-machine travevl deviation happens and swing speed is so
slow
-P1 pump pressure is low (1000 rpm : 9 bar)
- Pi1(PN2) pressure : 8 ~ 9 bar
- Main Pump Ass’y was replaced but the problem didn’t work out
-Breaker Attachment EPPR V/V pressure is checked continually
- 1000 rpm: 36 bar / 1600 rpm : 43 bar

Possible Cause
The attachment EPPR valve is replaced with a new one

Check Points and Remedy

Breaker Attach EPPR V/V  P3 Gear Pump
When the hose is connected, the pump flow is minimun position
- 1000 rpm: 36 bar(Attach EPPR): 9 bar(Pi1): 9 bar(P1 pressure)
- 1600 rpm: 43 bar(Attach EPPR): 31 bar(Pi1): 33 bar(P1 pressure)

- 36 - Hyundai Training Center

12.Problem : Engine rpm doesn’t increase over 1300rpm when the travel pedal is pushed down

Model : 290LC-9
Detailed problem
When the travel lever is operated, the engine rpm is not going up over 1300rpm
(E mode condition)
-Except Travel Pedal, other attachment levers are operated normally

The treatment of the problem

-Travel interlocking system (E mode ) is activated (normal condition)
-when travel lever is activated, travel and engine rpm interlocking system is
activated by sensing main pump regulator pressure (PN1/PN2 sensor 100bar)
-PN1/PN2 pressure : 25 bar  5 bar(1st pressure) / 20 bar =>10 bar(2nd pressure ) : MCV inside drain presssure
(7~8 bar checked)
- Engine rpm interlocking : 1300 RPM 1700 RPM
- Travel interlocking system is available on the “E” mode

Reference
In case one of travel level is only activated or the pressure difference between both travel pilots
occures,
- When pressure difference between PN1 and PN2 is over 5bar, the engine rpm changes
according to the value of higher pressure, but it is below 5 bar, the engine rpm changes
according to the average value of both pressure
-When the higher or lower value of signal from pressure sensor then specification, the engine rpm changes according
to the lower value of pressure sensor

- 37 - Hyundai Training Center

13.Problem : When the attachment is activated, the engine is shut down

Model : 290LC-9
Symptom
when the attachement is activated, the engine is shut down

Possible Cause
The alternator is replaced with a new one

Check Points and Remedy

-If the voltage of the alternator is measured over 37.5volt, the MCU send the signal to ECM to keep low engine
rpm (800rpm)

-the voltage of the alternator is over 36 volt, the MCU don’t send any signal to prevent further problems

- 38 - Hyundai Training Center

14.Problem : During working, the engine has been shut down several times a day

Model : 290LC-9
Symptom
During being worked, the engine rpm has been dropped down to 400-500rpm and shut down serveral times a day

Possible Cause
The default rpm of ECM program is modified(calibrated) to 1600rpm
(it is caused by the wrong input program of default rpm)

Check Points and Remedy

When the communication error between MCU & ECM happens due to ECM Fuse
noise or other things(Error Code 285),
ECM sends signal to meet default engine rpm within 0.4 seconds
-R220LC-9/R290LC-9/R380LC-9 : 1600rpm When the fuse is removed, the
-R140W-9 : 1300rpm Engine rpm changes to
default rpm

- 39 - Hyundai Training Center

15.Problem : Engine overheated

Model : R380LC-9
Detailed problem
Engine overheated
Coolant temperature reaches at 100 degrees at E mode
-the speed of cooling fan EPPR is only 700 rpm and it can’t be adjusted

The treatment of the problem

-Replaced the cooling fan motor
-adjusted the cooling fan EPPR valve : 1040 rpm (85 degree ; normal)

Reference
-Spec : E mode cooling fan rpm (1000-1100rpm=> Coolant
85 degree)
-When the fan motor EPPR V/V connector
is disconnected, the rpm is over 1450 rpm
then, the pressure of fan motor is 210bar Hyd.oil

Intake
Temp.

- 40 - Hyundai Training Center

16.Problem : Service brake is not working

Model : R140W-9
Symptom
Service brake is not working
-Service brake pressure on the cluster is indicated : high rpm : 13bar, low rpm : 4bar

Possible Cause
-Clean the BSV “CT1”Priority Valve
but the problem doesn’t work out
(Some pieces of aluminum were founded) PS
-Replace the brake gear pump+BSV

Check Points and Remedy

- 41 - Hyundai Training Center

17.Problem : Engine rpm is not increased when the machine starts travelling

Model : R140W-9
Symptom
Engine rpm was not increased when the travel pedal pushed down
-Engine rpm is just 1000rpm
-Travel sensor in the MCV is not working (the volt (B + C) is always measured at 1.4volt)
-The pressure is changed from 5 to 40bar normally
-Auto idle lamp is turned on the cluster

Check Points and Remedy

Replaced the auto idle pressure sensor

- 42 - Hyundai Training Center

 ●

●
V
Cd6 (travel) Cd7 (work) (Voltage) ●
bar

(Act’l)
Check sensor’s voltage
A+C=26V
B+C=1.4~3.7V(when the machine is traveling)

Sensor’s resistance
(Spec)
B A A+C=13.5KΩ(24V)
B+C=958Ω(1~5V)
A+B=13.5KΩ
MCV
It’s changed according to temp.

- 43 - Hyundai Training Center

18.Problem : machine travel speed is slow (work mode (interlock) or travel mode)

Model : R140W-9
Symptom
Machine travel speed is slow and engine rpm is lower than specification
-Spec. : E => 1,800rpm, S => 2,000rpm, P => 2,150
-Act .: E => 1,760rpm, S=>1,960rpm, P =>2,120rpm

Check Points and Remedy

Adjust the excel. pedal stroke limit bolt

-Propeller shaft rpm on the unload traveling condition

is(when the machine is jacked up) 3400rpm(specification)
-the sensor located under pedal is sensing the pressure and send it
to MCU and MCU communicate with ECM to change engine rpm

rpm adjustment
-Lock nut (13mm)
-Screw bolt(“L”6mm)

- 44 - Hyundai Training Center

Ram Lock Cruise EPPR V/V
Sol..

▲
P3

- 45 - Hyundai Training Center

19.Problem : Auto cruise is not working

Model : R140W-9
Symptom
Auto cruise is not working
-Auto cruise switch is working normally
-checked pin 35 of CN 53 on the MCU and it is working normally
-checked forward pilot pressure sensor and it is working normally
Possible Cause
Replace the brake pressure sensor
-on the cluster, the brake pressure is indicated 7bar(abnormal)
-Actual brake pressure is 0.5 – 1bar
Check Points and Remedy
If the brake pressure is indicated over 3bar on the cluster, auto cruise is not working

5 bar

Brake lamp switch

100 bar

Brake pressure sensor (It sends brake pressure

signal and auto cruise release signal to MCU)

- 46 - Hyundai Training Center

Auto Cruiser System
During travelling, the auto cruise function is selected, the recent travel
speed(engine rpm) is kept.
- Travel EPPR, engine rpm, main pump EPPR

working condition Cruise operation button

Select travel mode(T)
Forward 1 or 2 selected
Engine speed over 1000rpm
Brake released

Cruise operation button

Release Condition

-Brake pedal operation ( over 5bar]

-Touch the cruise button
-Select the direction lever forward or
reverse

- 47 - Hyundai Training Center

Ele. circuit for auto cruise

Work

ECM
Engine RPM data :
- Min. over 1000 rpm
Travel Mode
When released CAN communication

No work

- 48 - Hyundai Training Center

Ele. circuit for auto cruise

- 49 - Hyundai Training Center

Auto Cruiser System hyd. Circuit

Shuttle v/v

Ram Lock Cruise EPPR V/V

Sol.

▲
P3
When “A3” cruise EPPR V/V is worked, the pilot pressure is supplied to forward solenoid
valve

- 50 - Hyundai Training Center

20.Problem : power mode malfunction

Model : R140W-9

Symptom
After engine starting, mode system(E,S,P,U) is not working properly
-When engine is staring with E mode, the mode alternates with the other models arbitrarily
-Even though the MCU is upgraded, it is not worked out

Check Points and Remedy

Replace the MCU with a new one

- 51 - Hyundai Training Center

21.Problem : when the working mode is selected, the machine travel occures

Model : R140W-9

Symptom
-When The travel lever is positioned on the forward position and attachment is activated, the machine
travel occurs, even though the travel pedal is not operated
-When the travel lever is positioned on the reverse position, it doesn’t occur

Check Points and Remedy

-Replaced 3-Cartridge V/V Ass’y which is contaminated
-When the auto idle is released, the rpm and pump flow is increased and travel motor is activated

- 52 - Hyundai Training Center

Auto cruise circuit

Shuttle
고속
valve

저속

Ramlock sol.

- 53 - Hyundai Training Center

22.Problem : a customer wants to increase the swing power on the slope

Model : R140W-9, R140LC-9

Symptom
-A customer wants to increase the swing power on the slope

Check Points and Remedy

-Swing motor pressure increase from 265bar to 285bar by inserting the shims(t=>0.3-0.5)
-the pressure loss in the pipe between hyd. pump and swing motor is about 10bar to 15bar
*the pressure of swing motor : 285 bar
*the pressure of hyd. Pump : 295 bar ~ 300 bar

- 54 - Hyundai Training Center

23.Problem : The machine is travelling even though the travel pedal is not touched

Model : R140W-9

Symptom
-After travelling the machine, the machine is still travelling even though the travel pedal is not pushed down
- After the above problem occurs, the reverse travel is not available

Check Points and Remedy

-Replaced 3-catrige (P/N:31Q4-2014) ass’y
-Back pressure occurs due to the blocked orifice(0.9mm) which is happed by foreign substance
-The forward side of solenoid valve and travel spool of MCV are blocked by foreign substance

- 55 - Hyundai Training Center

Reference 1

1
1

(No 1, Graphic) (No 1, Graphic)

Forward lever is applied and accel. pedal is not actuated When the accel. pedal is not acutated during
(No 2, Graphic) the forward travel, the pilot pressure of
Reverse lever is applied but the forward pliot line presssure MCV drops down – normal condition
of MCV increases and drop slowly again –abnormal condition

- 56 - Hyundai Training Center

Reference 2
A1: Shuttle V/V
(L wrench: 6 mm)

B2:reverse orifice
(L wrench: 3 mm)
B1:forward orifice
(L wrench: 3 mm)

Check V/V

Auto cruise EPPR V/V

Orifice

- 57 - Hyundai Training Center

 Reference 3
R140W Solenoid Ass’y (Auto Cruise/Travel Circuit)

Auto Cruise Shuttle v v

Travel (REV)
Travel (FWD)
Check v v
Return Orifice

MCV MCV (reverse)

(forward)

- 58 - Hyundai Training Center

 Reference 4
Auto Cruise

Return Orifice

Solenoid Valve Return Orifice

Travel (REV) Travel (FWD)

- 59 - Hyundai Training Center

Reference 5
23-6

Shuttle v v

Check v v

Shuttle valve Check Valve

- 60 - Hyundai Training Center

24.Problem : Engine rpm is not increased during machine travel on “W” mode

Model : R140W-9

Symptom
-Engine rpm is not increased during machine travel on ‘W” (E mode) - over 1000rpm is not available
-When the machine is travelling with “W” mode, the engine rpm dropped to 1,000rpm
(then, auto idle indication lamp is on) Pressure Check

Check Points and Remedy

-Clean the orifice screen filter in the MCV

-Travel auto idle sensor was checked [voltage : 1.2-1.6V (abnormal) - spec:1.2-3.7V)
-Checked the pressure of pressure sensor : 5bar (during engine start)-normal
10bar(during machine travelling)-abnormal -spec:35bar
-Orifice screen filter in the MCV is contaminated

Sensor installed

- 61 - Hyundai Training Center

 Work pressure sensor

Contaminated screen

Travel pressure sensor

Pressure check point

AUTO IDLE “PO”

SENSOR P3=>IN

- 62 - Hyundai Training Center

 ●

●
Cd6 (travel) Cd7 (work) V
(Voltage) ●

bar

sensor voltage
A+C=26V
B+C=1.4V-3.7V(during travel)

Check the Sensor resistance value

A B

MCV A+C=13.6K ohm

B+C=958 ohm
A+B=13.5K ohm
C

- 63 - Hyundai Training Center

25.Problem : During travelling on the road, the machine’s Engine shut down

Model : R140W-9
Symptom
-when the machine is running on the road, the engine shuts down and is not starting again

Circuit-Breaker
Remedy
-After resetting the circuit-breaker(60A), it works normally
60A
-Circuit-braker is the component to block the current flow when (MASTER S/W)
the ele. system is overloaded
-Fusible link is the component to disconnect the harness

30A
Reference (KEY S/W)
-When the circuit breaker works, the current can not supply to
start motor and stopper fuse
-Air-compressor and machine is operating at the same time, the power
can not supply due to overload

- 64 - Hyundai Training Center

Starting circuit

- 65 - Hyundai Training Center

26.Problem : Auto idle is not working

Model : R55-9
Symptom
-Auto idle is not working (pilot pressure is checked at 15 bar)
-Auto idle is not working in the condition of RCV lever operation occasionally
-P4 pressure : 30-33bar (normal)

Check Points and Remedy

pressure: 15bar
-Clean MCV orifice filter

Reference
Oil leaks between orifice filter and body => Oil leakage to travel line

- 66 - Hyundai Training Center

Auto Idle circuit

P4

- 67 - Hyundai Training Center

Auto Idle circuit (Idle operation)
Arm Bucket Boom Travel Dozer Swing

PS

P4

- 68 - Hyundai Training Center

Auto Idle circuit (Attachment is operated)
Arm Bucket Boom Travel Dozer Swing

MCU

PS

P4

- 69 - Hyundai Training Center

Auto Idle Circuit
※Auto Idle is divided hyd. system and ele. system through PS(pressure sensor)

… PS MCU
P4

Pump MCV

Hyd. system Ele. system

- 70 - Hyundai Training Center

Auto Idle Circuit check (Pilot pressure setting)

… PS MCU
P4

Pump MCV

how to adjust the P4 pump pressure Crawler Wheel

(pressure setting condition)

- Engine low Idle (1,000 rpm)
-Hyd. Oil temperature : 50~60℃
③ P4 pressure : 30~34bar

P4 relief
Adjustment point of P4 pressure
-Crawler Excavator : Main Pump , Wheel Excavator : K3 valve in the Cut Off Valve K3 relief

- 71 - Hyundai Training Center

Auto Idle Circuit (Pilot Pressure→Pressure Sensor)

… PS MCU
P4

Pump MCV

While working the

attachment, the pressures
must be over 21bar

- 72 - Hyundai Training Center

Auto Idle Circuit Check (Pressure Sensor)

MCU
… PS
P4 Ele. signal
V
Pump MCV ●

After setting P4 pump pressure, check if pressure sensor works normally

OFF:19bar↓, ON: 21bar↑ (2.7V↑)
(pressure sensor V:Bar) bar

A:12V B:5V

32bar
If pressure is over 12V
C:Earth
21bar
PS (MCU)
※ check if the voltage is over 2.7V

(Ground)

- 73 - Hyundai Training Center

Orifice Filter

※ Type changed

- 74 - Hyundai Training Center

27.Problem : Auto idle is not working

Model : R55W-9
Symptom
-In the condition of auto idle, rpm is not increased when the RCV is operated
-when Boom, Arm, Bucket is operated, auto idle is not working
-when Swing, Dozer, travelling is operated, auto idle is working normally

Check Points and Remedy

-clean the check valve of travel straight spool
(it is working normally)
-it happened due to oil leakage from the contaminated
check valve Boom,Arm,bucket operation

Reference
- P4 pressure check : Low Idle, 33bar (Spec: 30~34bar)

- Sensor pressure check : (Spec: ON 21 bar / OFF 19 bar)

- When Boom, Arm, Bucket is operating : 10bar (pressure occurs)
- When Swing, Dozer is operating : 34bar
- Even though the Orifice Filter is cleaning : the problem is not appeared Swing,Dozer operation

- 75 - Hyundai Training Center

Due to bad condition of travel
straight check valve, back Main relief valve
pressure is not occurred and
drain the line is joined
Travel
straight
Check V/v

- 76 - Hyundai Training Center

28.Problem : travel interlock function

Model : R140LC-9,R210LC-9,R290LC-9,R380LC-9

Symptom
When the attachment is working with E mode and auto idle released, E mode rpm is avalable but
the rpm is changed to 1300rpm when the travel pedal is operated

The treatment of the problem

It is normal condition

Check Points and Remedy

-After the auto idle is cancelled, the engine rpm is recovered to the set rpm
-after the auto idle is cancelled, the engine rpm is changed to 1300 rpm during machine traveling
-when the breaker mode is applied, the engine rpm is changed to E mode rpm
-only E Mode available
=>the engine rpm is changed from 1300 rpm to 1700rpm
-the travel interlock system is available on E.S.P mode for R480LC-9/R520LC-9

- 77 - Hyundai Training Center

29.Problem : Low arm out speed

Model : R55W-9

Symptom
-Arm out speed low
main relief pressure : P1 : 225bar / P2 : 182 (During breather open, it must be over 200bar)
Check Points and Remedy
Adjusted main pump horse power (clockwise)
Arm 2 spool pressure goes up due to increased pump flow (pressure :182 bar =>210 bar)

Input horse power adjustment bolt Before adjustment After adjustment

- 78 - Hyundai Training Center

 Hyd. circuit

Arm Out

Return

- 79 - Hyundai Training Center

30.Problem : Auto Cruise is not working

Model : R55W-9

Symptom
Auto cruise is not working (engine rpm is under 1200rpm)

Check Points and Remedy

It is normal
Auto cruise operation condition : engine rpm : over 2000rpm , T mode, Forward 2 nd speed

- 80 - Hyundai Training Center

 (Auto Cruiser System)

■ when travelling and selecting travel mode, max. travel speed is applied
- MCU checks travel EPPR, Engine RPM signal

OPERATION CONDITION Cruise operation

button
. Travel mode [T] photo
. Forward 2nd speed
. Engine speed over 2000rpm

Release condition

. Brake Pedal operation ( 5bar↑)

. Cruise button touched
. Direction lever neutral &reverse selected

- 81 - Hyundai Training Center

R55WS Solenoid Ass’y (Auto Cruiser , Travel ) Circuit

Auto Cruise
Shuttle v v

Travel (FWD) Travel (REV)

Return Orifice Check v v

P4

MCV (forward) MCV (reverse)

- 82 - Hyundai Training Center

Solenoid Valve / Return Orifice location
Auto Cruise
(SOL V/V) Travel (REV)

Travel (FWD)

Return Orifice
(1- 0.9 mm)

- 83 - Hyundai Training Center

Shuttle valve / Check Valve Location

Shuttle v v

Check v v

- 84 - Hyundai Training Center

31. Engine rpm is not increased when the machine starts working

Model : R300LCH

Symptom
1. When starting machine, engine rpm is fixed at 550.
2. When starting working, the engine has been occasionally shut down at 550 rpm.
3. Pressure of p1 is 100bar on the cluster monitoring at the low idle.
4. Pressure of negative p1 is 60bar on the cluster monitoring at the low idle.

Check Points and Remedy

1. Reassembling the hose between attachment eppr valve and MCV.
2. Connecting Pi1 and shuttle valve which is connecting Pi1, attachment eppr valve and M.C.V

Reference
1. The hose from attachment eppr valve to MCV should be plugged for occasional shutting down, but the hose
from Pi1was plugged .
2. It makes low pressure to P1 regulator and increase of oil flow to P1. Increased flow bring out more load to
engine and low rpm (normal rpm : 800)

- 85 - Hyundai Training Center

 Pluging

Attach EPPR

Plugging Pi1 makes supply pressure increased and

negative pressure decreased. engine rpm is dropped
by load increased.

- 86 - Hyundai Training Center

32. Machine speed is slow except swing

Model : R380LCH
Symptom
1.Machine speed is slow during complex operation.
2.The result of operation for performance test is in the specification except swing.
Check Points and Remedy
1. Replacements of new pressure sensor for eppr valve
Reference
1. The different kind of pressure sensor makes abnormal work.(Spec: 50 bar / Act : 100 bar)
2. The different kind of pressure sensor makes signal twice more than normal .
3. The stroke of cylinder is not enough to feel slow operation but swing movement is enough to feel slow.
4. Formal pressure sensor was not fool proofed for odd assembly so that color of pressure sensor connector is
changed.

New pressure sensor makes a color

distinction on the connector with
sensing range.

(Sensor: 100 K) (Sensor: 50 K)

- 87 - Hyundai Training Center

(EPPR V/V pressure with 100 bar sensor : lower speed) (EPPR V/V pressure with 50 bar sensor : normal speed)

- 88 - Hyundai Training Center

33. Arm in and boom down is occasionally not working

Model : R300LCH /R140W

Symptom
1.Arm in and boom down is not working occasionally.
2.When RCV full stroked, arm in and boom down start suddenly with abnormal impact on machine.
3.The more work hours, the more symptoms happened

Check Points and Remedy

1. Tightening plug in boom/arm holding valve ‘B’ kit piston.(refer to below pictures)
→ poor holding valve release because of increased back pressure of drain line.
2. Oil groove on ‘A’ kit piston in boom/arm holding valve is worn-out so that poor drain and pressure increase
happen.
→ make oil groove on piston by hand.(inspect valve worn out especially on old machine )

- 89 - Hyundai Training Center

Remedy 1 : Tightening plug in boom/arm holding valve ‘B’ kit piston

- 90 - Hyundai Training Center

Remedy 2 : Make oil groove on ‘A’ kit piston in boom/arm holding valve

Oil groove

- 91 - Hyundai Training Center

34. Engine load increased and fuel inefficient

Model : R300LC

Symptom
1.Engine load increased and fuel inefficient.
→ Symptom happened after MCU up-dating.(Ver 1.4 → 2.1)
→ Work speed is faster than before.

Check Points and Remedy

1. Pressure on eppr valve is normal after MCU up-dating.(pump delivers max flow)
→ However, the pressure on cluster is different from measurement.(cluster : 40bar, measurement : 0 bar)
2. Modification of eppr valve feedback system.
→ Remove pressure sensor on pump p3 and install it to eppr valve.

Reference
1. MCU that has feedback system transfers 500mA(40bar) into 100mA(15bar) to make eppr valve pressure 0bar.

- 92 - Hyundai Training Center

 Install pressure sensor Remove pressure sensor from
to a4, pump 3 a4 then install screw coupling

Install pressure sensor

Parts list for check to a3, screw coupling Eppr pressure, a3
1.Remove elbow and screw coupling
No. Part name Part No. EA Note
2.Install elbow and tee(31Q4-20170)
1 TEE-TEST PORT 31Q4-20170 1 a4(P/Sensor+S/Coupling) 3.Install screw coupling on the top
4.Install P/Sensor removed from a4(torque :
2 SCREW COUPLING 31EK-11130 1 a4
2kgf ·m)
3 HARNESS 21Q4-43200 1 For extension 5.Install harness removed from a4 to a3 with
extension harness if required
4 ELBOW-90 X520-110001 1 a3

5 PRESSURE SENSOR (31Q8-40520) 0 a3, a4

- 93 - Hyundai Training Center

35. Poor power and slow speed of arm in

Model : R300LCH

Symptom
1.Poor power and slow speed of arm in.
→ Arm in stopped for a little while at the vertical position of the floor.
→ It seems like arm regeneration is disabled.

Check Points and Remedy

1. Replacements of new arm in overload relief valve
→ Lack of make-up oil because O-ring in overload relief valve damaged by heat
2. Result of arm in performance test is 4 seconds.
→ Specification : 3.4 ±0.4 seconds with arm regeneration enabled,
3.7±0.4 seconds with arm regeneration disabled
→ The suspected cause is arm regeneration disabled then replace arm regeneration spool and block of MCV
: no improvement
3. Electrical test of arm regeneration solenoid : normal → enabled(0 V) , disabled(24 V)
Hydraulic test of arm regeneration solenoid : normal → enabled(0 bar) , disabled(40 bar)
Reference
1. A principle of arm overload relief valve.
2. A principle of arm regeneration.

- 94 - Hyundai Training Center

Reference 1.

- 95 - Hyundai Training Center

Reference 2.

- 96 - Hyundai Training Center

Reference 3.

SPOOL

KEY Orifice(L wrench 3mm)

- 97 - Hyundai Training Center

Reference 4.

O-ring shrunk by heat

- 98 - Hyundai Training Center

36. Instruction of auto warming-up

Model : All

Symptom
1.When starting machine, engine rpm is increasing instantly.
2.Engine rpm is increasing after 3~4 seconds after starting machine.
→ When engine rpm is increasing without warming-up pilot lamp alarmed. machine should have
a trouble.
Check Points and Remedy
1. Instruct a customer to understand function of auto warming-up

Reference
1. The MCU receives the engine coolant temperature from the ECM, and if the coolant temperature is below 30°C,
it increases the engine speed from key start rpm to 1200rpm. At this time the mode does not change. If the
coolant temperature sensor has fault, the hydraulic oil temperature signal is substituted.
2. In case of the coolant temperature increases up to 30°C, the engine speed is decreased to key start speed. And if
an operator changes power mode set during the warming up function, the MCU cancels the automatic warming
up function.
→ Step of auto warming-up : warming-up pilot lamp alarmed after 2 seconds of starting → engine rpm is
increasing after 1 second of lamp alarmed.

- 99 - Hyundai Training Center

37. Slow arm-in at initial operation and arm-out by gravity when RCV neutral positioned

Model : R300LCH

Symptom
1.Slow arm-in operation.(Relief pressure is normal)
2.Arm-out by gravity when RCV neutral positioned after break time of working.(arm+boom at an angle of
90°)

Check Points and Remedy

1. Extend a diameter of poppet oil road in arm-in port relief valve(flow increase/ decreased resistance of line)

- 100 - Hyundai Training Center