Dash 9S Excavator
Engine R220LC-9S
Cummins
B5.9-C
5,880
K3V112DT
117×2
SCV28P
280
Main Pump R220LC-9S
KHI(Flutek)
MCV R220LC-9S
Parker-Hanil
Travel Reduction and Motor R220LC-9S
Jeil/Sungbo
RMV147/SBTR220
95/146.5
Swing Reduction and Motor R220LC-9S
Jeil/Sungbo
RMF151/SB220H
151
Swing Bearing R220LC-9S
SINIL
Φ1,327
Lower Roller R220LC-9S
Φ160
Φ160
9S The New Generation Major Functional Parts ENGINE Maker : Cummins / Hyundai Model : B5.9-C / D6BV-C Rated Power : 145/1900 ps/rpm Displacement : 5,880 cc / 7,545cc MAIN PUMP Maker : FLUTEK (KAWASAKI) Model : K3V112DT Type : Variable Displacement Piston Rated Flow : 2 x 220 ℓ/min TRAVEL MOTOR Maker : JEIL/SUNGBO Model : RMV147 /SBTR220 Output Speed : 46.3 / 30.0 rpm Output Torque : 2,673 / 4,121 Kgf·m
M.C.V Maker : PAKER-HANIL Model : SCV28P Rated Flow : 280ℓ/min Relief Pressure : 350(380) Kg/㎠
S/W MOTOR & DECELERATOR Maker : JEIL/SUNGBO Model : RMF151 /SB220 Output Speed : 83.5 rpm Output Torque : 1,123 Kgf·m
Standard Version
9S Series
Advanced Technology Diagnosis & Monitoring System
Hydraulic Sys.
CLUSTER
Machine Control Unit
Diagnosis Lists - The Information of Input/Output state & Pressure - Disconnection of electric wire & Faults - Engine & Machine fault codes (Active and Inactive)
Electric Sys.
Cluster Monitoring
■ Mode selection - Work Mode ① Heavy Duty Work Mode : Boom Priority Function for faster boom operation ② General Work Mode : General operation work - Power Mode : H, S, M, U mode
Fault Code ■ Monitoring system - Engine Rpm, Fuel, Hyd. & Coolant Temp - Warning and Indication Lamps - Fault Diagnostics - Maintenance List Maintenance
■ Specification 1) 4 inch TFT LCD application 2) Industrial Application 3) Advanced CPU application
9S The New Generation Performance & System Comparison HHI
Function 9S Series
7 Series
CAT (320DL)
KOMATSU (PC200-7)
Kobelco (EH215)
Doosan (DX300LC)
Volvo (EC290B)
Power Mode - M (Max Power) - H (High Power) - S (Standard Power)
- M (Max Power) - H (High Power) - S (Standard Power)
- U [User Mode]
- U [User Mode]
Work Mode
Auto Work Mode (SMART WORK) ‘Fuel Rate Reduction’ Mode
MODE - Heavy Duty - General Duty - Breaker (switch)
- Heavy Duty - General Duty - Breaker (switch)
ACCEL DIAL (10 LEVEL)
-P ; Power Mode -E ; Economy mode -L ; Lifting mode -B ; Breaker mode -Att ; Attachment mode
-A(Assist) .Trench Digging .Leveling .Spreading .Tamping .Others -M(Manual) .Heavy load work -B(Breaker) .limit Max. flow
-Power Mode .Heavy Load Work -Standard Mode .Fuel Rate Down
-General Duty; .Dump, Pull up .Breaker, Stop -Trenching; .Swing Priority/ Boom, Arm .Swing Torque 10%UP
-P:Max Load S/W, D9 -H:Heavy Load, D9 -G:Multi-usage, D6-D8 -F:Precise, D3-D5 Power Boost, Conflux Cut, Travel Speed ‘Low; -I :Idle, D1-D2
ACCEL DIAL (10 LEVEL)
-
10 LEVEL
10 LEVEL
9 LEVEL
Auto Decel System
1 Level
1 Level
1Level
2 Level
1 Level
1 Level
1 Level
Power Boost
◎
◎
◎ (350k)
◎ (355k -> 380k)
◎ (350k -> 385k)
◎ (330k -> 350k)
◎ (320k -> 350k)
◎ (Coolant water, Hyd. Oil)
◎ (Coolant Water)
◎ (Hyd. Oil)
◎ (Coolant Water)
◎
◎
◎ (Coolant Water)
◎ (Coolant Water, Hyd. Oil)
◎ (Coolant Water, 2 Level)
◎ (Coolant Water, Hyd. Oil)
◎ (Coolant Water , Muti-Stage Control)
◎
◎ (Coolant Water)
X (Overheat Warning)
Auto Warming UP
E/G Overheat
9S The New Generation HHI 9S Series
7 Series
CAT (320D)
◎ (Switch Control
◎ (Switch control
-
_Full Flow Control)
_Max.Limitation)
◎ (Multi Stage)
◎ (Multi Stage)
◎ (Multi Stage)
◎ (Multi Stage)
AntiRestart
◎
◎
◎
◎
◎
◎
◎
Boom/ Swing Priority System
◎ (Solenoid)
◎ (Solenoid)
-
X
◎ (Swing Priority)
◎ (Swing Priority)
◎ (Swing Priority, Hydraulic)
Expendable Manage
X
X
◎ (Filter, Oil, etc)
◎ (Hyd/EG Oil, etc)
X
AntiTheft
◎
X
◎ (Password, Key Switch)
◎ (Password )
-
◎ (Password Setting)
◎ (Password Setting)
ONE TOUCH DECEL
◎
◎
◎
◎
-
◎
◎
PC Comm.
◎ (RS-232)
◎ (RS-232)
◎ (SERIAL, CAN)
◎
X
X
X
◎ (Fault, Status)
◎ (Fault, Status)
◎ (Fault, Status, Recoding)
◎
◎
◎ (Fault, Status)
◎
◎ (Fault, Status)
◎ (Fault, Status)
◎ (Operating History)
◎ (Operating History)
-
구분 Breaker Mode
Monitor
KOMATSU (PC200-7)
Kobelco (EH215)
Doosan (DX300LC)
Volvo (EC290B)
◎ (Hyd Oil, Filter, etc)
X
Self Diagn osis
PC (HC E DT)
◎
◎
(Operating History)
(Operating History)
Excellent cooling system 1. Side by Side type Cooler : improved cooling efficiency OIL COOLER
RADIATOR
CAC
-9 Series Improvement
2. Aluminum Bar Plate type : improved durability
AL BAR PLATE 1) Vacuum brazed core 2) Upper & lower tank TIG welding 3) Far better stiffness
PLATE
Thermal cycle & Pressure cycle test
Corrosion test
Vibration Test
AIR FIN
9S The New Generation Pressure Sensing Method Division
9 Series
7(A) Series
Type
Electronic
Mechanical
Oil Contact Media
Steel (Load Cell)
Diaphragm (Rubber)
Life Cycle
10 Million
1 Million
Feature
Characteristic
1. Avoid the Oil Leaking Problem due to the Failure of Diaphragm 2. Direct Connection of the Electric Connector : The Connector mounting does not nessessary.
Remarks
9S The New Generation (2) Reinforced Electric Circuit ① Water and dust proof type connectors are used to make longer lifetime of connector and to ensure wire connection. ② Additional fuses in fuse box(2) minimize electrical damage. ③ Circuit breaker(1) To improve harness reliability and to reduce repair time, the circuit breaker is applied instead of fusible link. · Type : Water proof & Manual reset · Capacity : 60 Amp ④ Water proof wiring harness at splice point with Dual-wall tubing.
8. Premium (Option) (1) Diagnosis & Monitoring System
Hydraulic Sys.
CLUSTER Machine Control Unit Diagnosis Lists - The Information of Input/Output state & Pressure - Disconnection of electric wire & Faults - Machine fault codes (Active and Inactive)
Electric Sys.
(2) New Cluster
Application of Fault Diagnostics, Maintenance List & Locking Password etc. 1) 7 inch Wide Color TFT LCD application 2) Jog Shuttle & Tact Switch application 3) Rear Viewer Camera & DMB application (Option) 4) Industrial Application 5) Advanced CPU application 6) The video & firmware update are possible with USB host support
Main Display (1 Skin)
Main Display (2 Skin)
Main Menu
Sub Menu
Cluster Operation
14
1. Menu map of the Cluster 1-1) Attachment selection
1. Operation SCREEN
2. Main menu 1) Mode 2) Monitoring 3) Management 4) Display 5) Utilities
1) Mode 1-1) Work tool 1-2) U mode power 1-3) Boom/Arm speed 1-4) Auto power boost 1-5) Initial mode 1-6) Cluster switch (back up)
1-1-1) Breaker 1-1-2) Crusher 1-1-3) Not installed
1-1-1) Breaker flow setting 1-1-2) Crusher flow setting
1-2) U mode power setting 1-3) Boom/Arm speed setting 1-4) Auto power boost setting 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) Monitoring 2-1) Active fault 2-2) Logged fault 2-3) Delete logged fault 2-4) Monitoring (Analog) 2-5) Monitoring (Digital) 2-6) Operating hour
2-1-2) Current ECM faults
2-2) Logged fault 2-2-1) Memorized MCU fault 2-2-1) MCU 2-2-2) Engine ECM
2-2-2) Memorized ECM fault
2-3) Logged fault deletion 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
15
3-1) Maintenance Info.
3-1-1) Maintenance item management
3-2) E/G starting limitation
3) Management 3-1) Maintenance Info. 3-2) Machine security 3-3) Machine Info. 3-4) A/S Phone number 3-5) Service menu
3-2-1) Limitation setting 3-2-2) Password change
3-2-1) Setting for E/G starting 3-2-2) Password resetting
3-3) Machine information 3-4) A/S contact point setting 3-5) Maintenance menu setting 3-5-1) Power shift setting 3-5-2) Replacement history
3-5-2) Replacement info.
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 4-1) Display item 4-2) Clock 4-3) Brightness 4-4) Unit 4-5) Language 4-6) Screen type
4-2) Clock setting 4-3) Screen brightness setting 4-3-1) Manual 4-3-2) Automatic
4-3-1) Manual setting 4-3-2) Automatic selection
4-4) Unit selection 4-5) Language selection 4-6) Screen type selection
5) Utilities 5-1) Tripmeter 5-2) DMB 5-3) Entertainment 5-4) Camera 5-5) Message box
5-1) Tripmeter selection 5-2) DMB Monitoring 5-3) Video monitoring 5-4) Camera setting 5-5) Message display
16
2. Operation SCREEN 1) Description
② Warning lamps
(1) Clock - Resetting: Display → Clock (2) Warning Lamps (3) Gauges including warning lamp - Hyd.oil temperature - Fuel level - Coolant temperature (4) Engine speed (Trip meter) display -Trip meter selection: Move the selection dial two times → Push the dial → Move the selection dial to select the one of three Trip meters (A,B and C). (5) Indication Lamps
③
①
:
④ E/G speed, Trip meter
Accel dial position ⑤ Indication lamps
2) Option screen Selection Dial (Push/Turn)
Menu escape/ Camera monitoring
(1) Oil flow level of optional attachment ①Breaker: Max.180lpm,(47.55 gpm)7steps(10lpm (2.64 gpm) reduction per each step) ②Crusher: Max.480lpm (126.8 gpm), 4steps(20lpm (5.28 gpm) reduction per each step) Oil flow level of optional attachment (Breaker / Crusher)
(2) Accel dial position
17
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 (5.28g)(Fuel tank: 400ℓ(105.66 g)) (2)
①Emergency
②Check Engine
③Overload (option)
for Wheel type machine only - Brake oil, T/M oil pressure
① Emergency - Coolant overheating (above 105℃)(221°F) - Hydraulic oil overheating (above 105℃)(221°F) - 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.
18
2. Main menu selection Note] 1) Menu selection Selected menu group
Main menu groups Move back to the previous menu.
; Enter into the selected menu. ; Menu selection.
(Main menu screen)
2) Setting item selection Selected Menu
(Submenu selection) (Setting item selection
)
19
1) Mode (1) Work tool
※ The Mode should be selected to match the Work tool !
① Breaker setting
② Crusher setting
Cf. When ‘Not installed’ is selected, WORK button will not work.
20
(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
21
(3) Boom/Arm speed
22
(4) Auto power boost
( P Mode only)
(5) Initial Mode
23
(6) Cluster switches (Back up) Even if any switch on cluster is abnormal ( Not Functioning), the function of the abnormal switch can be selected and changed by using the Cluster switch mode.
Use it to escape from the Cluster switch mode.
- In order to escape from the ‘Cluster switch’ mode, move the selection to ‘ESC/CAM’ by turning the Select switch.
- While the ‘Cluster switch’ mode is operated, the existing switches do not work including the Accel dial.
24
2) Monitoring
· Refer to the MACHINE ERROR CODES list (Sample)
· Refer to the ENGINE FAULT CODES list (Sample)
25
26
27
28
3) Management
Maintenance pilot lamp - Elapsed time Reset to ‘0’.
※ Strong recommendation! ☞ After replacement of Filters and Oils, Reset the accumulated time!!
· Interval time can be changed to 12500Hr by the 50Hr.
- Interval time modification.
29
- 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.
30
· Password change - The password should be 5~10 digits.
①
②
③
31
32
(Program up date)
(Replacement history)
(See next page)
33
R210LC-9
34
4) Display ① Display item
35
Day time.
36
37
5) Utilities (1) Tripmeter
- One of three trip meters can be set at the Operation SCREEN (Using the menu Display → Display item). (2) DMB (Digital Multimedia Broadcasting)
38
(3) Entertainment
(4) Camera setting
39
(5) Message box
40
(3-1) Remote Management System –Overview (Option)
Remote Management System
GPS
Satellite
Orbcomm Satellite
Sales CRM QM Production
Machine Base Information
Data Transmitter Receiver
Location/ Operation Information
Statistic Information
Satellite Communication
Location Information Operation Information
Antenna
RMCU
Orbcomm GES
MCU
Internet Web Interface R&D
Sales A/S
HHI Subsidiary
Dealer
Customer
Excavator
Wheel loader
(3-2) Remote Management System - Function Daily Operating Information
Prompt Alarm Information
Theft Prevention
Management
- Hour-meter, Fuel Level, Machine Location, Warning / Fault Information, Hours of operation, etc. - Coolant water / Hyd. Oil Temperature Distribution by time, The number of times for using ‘Auto Idle’, Hours of using ‘Auto Idle’, etc. - Current Operating Information, Check for the request of Machine Location
- Fault Information of Electric Parts - In case of unable to check the location of Machine - Deserting From Boundary - Communicate Fault
- Setting Operating Boundary / Warning of Deserting From Boundary - Setting Password for Starting Engine and Limiting Machine Operation - Report for Machine Location of day / night time
- Fuel Usage (Daily / Monthly / Total / Average) - Hour meter & Operating Hours (Mode / Operating Pressure / rpm Command / Distribution of Torque) - Maintenance intervals(Filters, fluid changes, etc.) - Routine service schedule - Tracing of Machine Location and Travel route using Map
(3) Rear View Camera (Option)
Camera
(4) Start-up Locking Device
9S The New Generation [5] Performance & System Comparison HHI
Function
9S Premium
7 Series
CAT (320D)
KOMATSU (PC200-7)
Kobelco (EH215)
Power Mode -
P (Max Power) S (Standard Power) E (Economy Power) U [User Mode]
- M (Max Power) - H (High Power) - S (Standard Power) - U [User Mode)
Work Mode
MODE - ATT Mode (Hyd . Flow Control) - Digging Mode
- Heavy Duty - General Duty - Breaker
ACCEL DIAL (10 LEVEL)
-P ; Power 7% UP -E ; Noise, Fuel rate Auto Work Down Mode -L ; Hyd. Pressure (SMART WORK) 7% UP -B ; RPM, ‘Fuel Rate Capacity setting Reduction’ -Att ; RPM, Mode Capacity setting
-A(Assist) .Trench Digging .Leveling .Spreading .Tamping .Others -M(Manual) .Heavy load work -B(Breaker) .limit Max. flow
Doosan (DX300LC) -Power Mode .Heavy Load Work -Standard Mode .Fuel Rate Down -General Duty; .Dump, Pull up .Breaker, Stop -Trenching; .Swing Priority/ Boom, Arm .Swing Torque 10%UP
Volvo (EC290B) -P:Max Load S/W, D9 -H:Heavy Load, D9 -G:Multi-usage, D6-D8 -F:Precise, D3D5 Power Boost, Conflux Cut, Travel Speed ‘Low; -I :Idle, D1-D2
ACCEL DIAL (10 LEVEL)
-
10 LEVEL
10 LEVEL
9 LEVEL
Auto Decel System
2-Stage Auto -> Low
1 Level
1Level
2 Level
1 Level
1 Level
1 Level
Power Boost
◎
◎
◎ (350k)
◎ (355k -> 380k)
◎ (350k -> 385k)
◎ (330k -> 350k)
◎ (320k -> 350k)
◎ (Coolant water, Hyd. Oil)
◎ (Coolant Water)
◎ (Hyd. Oil)
◎ (Coolant Water)
◎
◎
◎ (Coolant Water)
◎ (Coolant Water, Hyd. Oil)
◎ (Coolant Water, 2 Level)
◎
◎ (Coolant Water)
X (Overheat Warning)
Auto Warming UP
E/G Overheat
◎ ◎ (Coolant Water, (Coolant Water Hyd. Oil) , Muti-Stage Control)
9S The New Generation 구분
HHI
CAT (320D)
KOMATSU (PC200-7)
Kobelco (EH215)
Doosan (DX300LC)
Volvo (EC290B)
-
◎ (Multi Stage)
◎ (Multi Stage)
◎ (Multi Stage)
◎ (Multi Stage)
9S Premium
7 Series
Break Mode
◎ (Multi Stage)
(Max.Limitation)
AntiRestart
◎
◎
◎
◎
◎
◎
◎
Boom/ Swing Priority System
◎ (Need Consideration)
◎ (Solenoid)
-
X
◎ (Swing Priority)
◎ (Swing Priority)
◎ (Swing Priority, Hydraulic)
Expendabl e Manage
◎
X
◎ (Filter, Oil, etc)
◎ (Hyd/EG Oil, etc)
X
(Hyd Oil, Filter, etc)
X
AntiTheft
◎ (Password Setting)
X
◎ (Password, Key Switch)
◎ (Password )
-
◎ (Password Setting)
◎ (Password Setting)
ONE TOUCH DECEL
◎
◎
◎
◎
-
◎
◎
PC Comm.
◎ (RS-232)
◎ (RS-232)
◎ (SERIAL, CAN)
◎
X
X
X
◎ (Fault, Status, Recoding)
◎ (Fault, Status)
◎ (Fault, Status, Recoding)
◎
◎
◎ (Fault, Status)
◎
◎ (Operating History, Test of Machine Status)
◎ (Fault, Status)
◎
◎
Monito r
Self Diag nosi s
PC (HC ED T)
◎
◎ ◎ (Operating History) (Operating History)
◎
-
(Operating History) (Operating History)
8. LUXURY 7inch CLUSTER
11. IMPROVED EFFICIENCY
9. Remote Filter 12. EXTENDED LIFE OF PARTS
14. REM SYSTEM 13. ENHANCED AIR-CON. SYSTEM
10. REAR VIEW CAMERA Machine Base Information
Data Transmitter Receiver
Location/ Operation Information
Statistic Information
9S The New Generation (6) Extend the Life of Parts Extended Lubricant Bush Life & Polymer Shim
Extended Filter Life
(Wear Resistant & Noise Reducing)
Extended Hydraulic Oil Life
Exchange Intervals 9S Series
7 Series
HYD. OIL
5,000 Hr
2,000 Hr
HYD. OIL FILTER
1,000 Hr
250 Hr
250 Hr
50 Hr
LUBRICANT BUSH
Remark
Oil Exchange Intervals
A. 9S series machines (Outline) Cartridge Valve : All in one package (Compact) R220LC-9S Parts Function
Picture
R210LC-7
4 Solenoid Valves / 1 Check Valve Accumulator (OPT) / Line Filter
5 Solenoid Valves /1 Check Valve Accumulator, Line Filter
Safety / Power Boost / Travel Speed Swing Logic Valve Control
Safety / Power Boost / Max Flow Cut Travel Speed / Boom Priority
3. Arrangement of Solenoid Valve
R290LC-9
49
Solenoid Valve Block Assembly
7 3
8 9
4
5
9
4
8
9
6 7 5
1
1
3 6
8
2
50
4
Boom Priority System
51
Travel 2 Speed Pilot System
52
Power Boost
53
Arm Regeneration System
54
Swing Brake Release
55
Swing Priority
56
9S The New Generation Energy Saving in Hydraulic System
1. Variable Control of Arm In Re-generation - Smooth Control vs. Speed
2. Boom Down Re-generation - Smooth & Fast Operation : Avoiding Cylinder Cavitations
3. Pressure Drop Reduction by re-designing the Oil Passage in MCV
1. Hydraulic Circuit
R220LC-9S
Negative Control
58
2. MCV 2-1. Arrangement of Spool
R220LC-9S
59
2-2. Port Name
R220LC-9S
60
2-3. Main Port-1
Rs
B5
CK2 P04
A5
B4
B2 B1 V4
Pb21
A2 A1
Dr1 P02
Pu
61
2-4. Check Valve Position-1
Ck2
Pb21 Dr1
V4
62
2-5. Main Port-2
D5
P06 PC41
D4
C5 C4
Dr3
D2 D1
C2 C1
P01
63
2-6. Check Valve Position-2
V3
64
2-7. Pilot Port-1
Bottom of MCV
Pc5 Dr5
Pc40 Pc3
Dr4
Pb5 Pb4 Pb3
Pc2
Pb20
Pc1
Pd1
Ck2 Pc42
Dr2
Dr0
65
2-8. Pilot Port-2
Top of MCV
Pcb Pa5 Pa4
Dr7
Pa41
Pd40 Pa21 Pd2
Pa20 Patt
Pd5
Pa1
Pd1 P00
66
R220LC-9S
2-9. P1,P2 Supply and Return Port
P2
T1
V1 P1
Ptr
67
2-10. Negative Pilot Port
R220LC-9S
CK1
Pn1
Pn2
68
4. Boom Operation
R220LC-9S
4-1. Boom Up Operation Pilot signal is transmitted to 4 points on the MCV during boom up operation. ②, boom 2 spool is applied to make oil summation for boom up, ③ ,”Po4” bucket logic valve is used for priority function of boom up and finally ④, “Po3” functions as boom priority for control of variable oil flow rate when boom and swing operate at the same time.
③ ②
Boom Up Pilot Port ① Pa20 Boom Spool ② Pa21 Boom 2 Spool ③ PO4 Bucket Orifice Pilot Port ④ P03 Boom Priority Eppr v/v
④
①
P3
Boom Priority Eppr V/V 69
4-2. Boom Up Operation-2
R220LC-9S
70
4-3. Speed Control of Boom and Arm
R220LC-9S
1. Speed Control of Boom Manual Selection : Fixed boom priority function Automatic Selection : In case boom and swing are operate simultaneously, higher pressure has the precedence over lower pressure by detecting pilot pressure
2. Speed Control of Arm Flow Regeneration Selection : Using arm regeneration function Flow Regeneration Release : Not using arm regeneration function
71
4-3. Boom Priority Function-1 Boom Priority＆Swing Logic Valve
R220LC-9S
1) Valve does not move in single swing operation
In Automatic Selection 1. Boom Up and Swing Pilot pressure send a signal to CPU. P3
2. The voltage signal which is sent to CPU is converted into current value, and then it is transmitted to EPPR valve for valve control. 3. If the swing pilot pressure is high and boom up pressure is low, then CPU sends lower current to EPPR valve for smallest valve movement 72
4-4. Schematic of Electric Circuit for Boom Priority＆ Swing Logic
R220LC-9S
BOOM MCU Boom Priority Eppr + CN 51-2
CN 52-23 CN 51-5
CN 52-24
Boom Priority Eppr -
CN 53-9 CN 53-19
BATT’ POWER 24V
BOOM UP PRESSURE GND. PRESSURE
SWING PRESSURE
▲
SWING
P3 73
4-4-1. Pressure Sensor Specification
R220LC-9S
(Output Signal vs Pressure) (Signal which is transmitted from pressure switch to CPU)
50 bar Pressure Sensor ( P/NO : 31Q8-40520 )
● ●
V (Voltage)
●
bar ●
100 bar Pressure Sensor ( P/NO : 31Q8-40510 )
●
V (Voltage)
●
voltage bar ●
500 bar Pressure Sensor ( P/NO : 31Q8-40500 )
V
●
(Voltage) ●
bar
74
4-5. Position and Diagram of Boom Priority＆Swing Logic Valve
R220LC-9S
75
4-6. Boom Priority Function-2
R220LC-9S
Bucket Logic is applied to use boom priority function Boom up operation takes priority since the pilot pressure acts on “P04” through bucket logic valve during boom up and bucket in operation at the same time
76
4-7. Boom-2 Spool, Swing Priority Spool Operation
R220LC-9S
1) When operating Swing, pilot pressure at “Pc3” allows oil flow for the swing at first priority. 2) When operating Boom-up, pilot pressure at “Pa2” allows the boom summation.
77
5. Boom Down 5-1. Circuit for Boom Down
R220LC-9S
When operating boom down, pressure in return line becomes higher than that of pressure supply line due to this the check valve in boom spool shifts under return pressure and this allows the make-up function to activate.
78
5-2. Make-up function in Boom 1 Spool
R220LC-9S
BOOM 1 SPOOL
79
6. Bucket Operation 6-1. Circuit for Bucket-in
R220LC-9S
CK2
Pa5 Pcb 80
6-2. Bucket Summation
R220LC-9S
When activating Bucket IN operation, Bucket will be summated by pilot pressure in port “PCB” (2 pump flow). PCB
PCB
81
6-3. Bucket Logic Valve
R220LC-9S
P04
1.When operating Bucket only, there is no pilot pressure at bucket logic valve.
Pilot Port for
orifice Pilot Port for bucket out
2.When operating boom up & bucket in at the same time, boom priority functions through the pilot pressure at “P04” and orifice in bucket line in order to achieve boom priority.
bucket-in summation
Bucket in pilot Port
Auto Idle P1 Parallel line
P1 Center Bypass
When operating Boom UP, pilot pressure increases. 82
7. Arm-out
R220LC-9S
83
8. Arm-in
R220LC-9S
8-1. Arm-in
84
8-2. ARM Regeneration
R220LC-9S
Arm regeneration is available through the cluster.
A4 CN135
85
9. Swing Operation
R220LC-9S
9-1. Circuit for Swing Operation
86
9-2. Release Swing Parking Swing parking is released as the auto idle switch signal allows the oil flow to the port “SH” in swing motor when operating any attachments.
R220LC-9S
87
10. Travelling 10-1. Circuit for travelling
R220LC-9S
88
10-2. Travel straight valve
R220LC-9S
89
10-2-1. Circuit for travel straight valve.
R220LC-9S
90
10-2-2. Circuit for travel straight valve
R220LC-9S
Orifice and check valve ●
● ●
●
Check v/v
●
Orifice
●
●
●
P2
P1 91
10-2-3. P1 SIDE
R220LC-9S
① ②
②
①
92
10-2-4. P2 Side R220LC-9S
①②
①
②
93
10-2-5. Travel straight spool shift
R220LC-9S
(Travel + Attachment)
When operating travel and any attachment at the same time, the straight travel spool moves left and oil from P1 mainly flows into MCV parallel line to operate the attachment and oil from P2 flows to the center bypass line to operate the travel. However, in order to avoid any speed drop for travel, an orifice is applied to allow the oil from P1 to flow into P2 line.
⑤ ⑦
⑥
④
③
②
① P01
①
⑦ ④⑥③
P2 ⑤
P1 ② 94
11-1. Option Spool
R220LC-9S
(P2) 1. 2. 3. 4. 5. 6. 7. 8.
Att Safety Solenoid Att Pressure Solenoid Att solenoid Att Flow Control EPPR v/v Safety Solenoid Pilot Selector v/v (Option) Option On/Off Valve 2 Stage Option Pressure v/v
⑧
(P1)
⑦ ⑥
①
②
③ ARM2 SPOOL
④
⑤ P3 95
11-2. Option (Breaker mode)
R220LC-9S
In breaker mode, The CPU allows the current to ATT’ Flow Control EPPR V/V to reduce the oil flow up to 7 Steps. There is no action on 1,2P summation sol. At breaker mode and no use for 2-Stage relief valve.
96
11-3. ATT’ flow control EPPR valve (Breaker) 1) When the breaker or crusher mode is selected on the Cluster, the CPU recognizes the selection. 2) 2CPU controls the oil flow from the main pump by allowing the current to ATT’ FLOW Eppr through CN-53(1 and 11) depending on which attachment is selected. 3) 3) This circuit can work for Posi and Negative systems. MCU
Cluster
Fuse BOX
Main Pump Regulator
Communication wire for Cpu and Cluster
ATT’ FLOW Eppr P3
97
11-4. Breaker Operating Circuit
R220LC-9S
1) When breaker mode is selected at Cluster, The MCU supplies the ground to the Breaker relay “1” connector. 2) key on 24V power is supplied to Relay “3” and Breaker S/W “1” when key on 3) When Breaker S/W is on, the relay is working with 24V power supply to breaker relay through the switch CS-26 (1and 2). 4) When Breaker relay activates, line “5” allows CN-66 (Breaker Sol.) to supply the pilot oil for the operation.
98
11-4. Option (Crusher) When 1,2P Sol. operate in crusher mode, 1.2 P will be confluence. So, machine can use the higher pressure and take advantage of the 2-stage relief vale operation.
R220LC-9S
When 1,2P Sol. operate in crusher mode, 1.2 P will be confluence. So, machine can use the higher pressure and take advantage of the 2-stage relief vale operation. 220 bar (3190 psi) → 280 bar (4061 psi)
99
11-4-1. OPTION CONFLUENCE ON/OFF VALVE
R220LC-9S
If the crusher is select in the cluster, ATT’ SOL will be operated. Pilot pressure will be directed to “P05” and 1P, 2P will be confluence.
P05
P05
P1 parallel line
P05 100
11-4-2. 2-Stage Option relief valve structure
R220LC-9S
The pressure will be at 220 bar when the breaker mode is selected, and it will raise main pressure up to 280 bar when the crusher is selected (2nd Stage)
101
EPPR Functions
1
EPPR Values
2
Boom Priority EPPR Valve
3
Swing System
105
SWING MOTOR Maker : JEIL/SUNGBO Model : RMF151/SB220
ONE
106
Swing System
107
Swing System
108
Swing System
109
R220LC-9S
SWINGRIGHT NEUTRAL SWING SWING MOTOR
OPTION
SH PG DOZER
From Solenoid Valve
BUCKET
Orifice provides 5 second delay
DR ARM 1
A
MU
ARM REGENERATION
ARM 2
BOOM 2
B D2 D2 Pd2
BOOM 1
SWING
TRAVEL (LH)
TRAVEL (RH) Tank
T1 From Solenoid Valve
MCV P2 Pump
P1 Pump
110
111
112
Swing Relief Valve After the swing RCV is Released Pressure increases on the relief valve to point that it can push Plunger 3 to The right against spring 4
Oil pressure passes through orifice m-n into cavity g the Pressure builds until it pushes Piston 6 against collar 7 and Stops.
When the Piston moves to the right and stops at collar 7 the Oil release rate drops and allows The swing to move at a controlled rate
113
Swing Brake Off
114
Swing Brake On
115
Travel System
116
TRAVEL MOTOR & REDUCTION Maker : JEIL/SUNGBO Model : RMV147/SBTR220
117
Travel Motor With Final Drive
118
R220LC-9S (Jeil)
P1,2
Remark This travel motor shifts automatically in 1e speed, at a pressure of 250 bar and up.
SECOND SPEED SPOOL
OVERLOAD RELIEF VALVE
DRAIN (T1,2) SECOND SPEED SPOOL
P1
P1
P1,2
P2
Pm1 2-SPEED-CONTROL PORT (Ps)
P2
(2e SPEED)
NPTF 1/16 PLUGS
Pm2 OVERLOAD RELIEF VALVE
COUNTER BALANCE SPOOL
119
Travel Two Speed (Low)
120
Travel Two Speed (High)
121
Speed Control (Jeil)
R210LC-9S (Jeil)
1st Speed Control
122
Speed Control (Jeil)
R210LC-9S (Jeil)
2nd Speed Control
123
R210LC-9S (Jeil)
Speed Control System
Low Speed
High Speed
When System pressure increases to 265bar/ 3843.5 psi piston #42 shifts to left and shuts off The Pilot from the Solenoid Valve
High -> Low Speed
System pressure : over 265bar System pressure: over 3843.5 psi
124
Automatic Speed Control
125
P=290K
Automatic Speed Control P=290K
A1
A2
Fa1
Fa2
Fs
Fp
Fa1+Fs> Fa2 IF Pi = 40kgf/㎠ Main pressure = 290kgf/㎠ Pilot Presssure Pi=40K
126
R220LC-9S
Travel Motor ( Negative Brake)
127
Travel Holding Position
128
Travel Working Position
129
130
R220LC-9S
MCV
TRAVELFORWARD FORWARDLOW HIGHSPEED TRAVEL SPEED RED
RED
OPTION
DOZER
BUCKET
ARM 1 ARM REGENERATION VA
VB
PK
VB
VA ARM 2
BOOM 2
From Solenoid Valve
BOOM 1
SWING C1
B1
D1 Pd1
A1 Pa1 TRAVEL (LH)
TRAVEL (RH) Tank
T1
From Solenoid Valve
P2 Pump
P1 Pump
131
Air Conditioning System
R134a Flow and State of Change
• Moisture absorption • Coolant reserve
Liquid (High temp., High pressure)
Gas (Low temp., Low pressure)
Receiver Drier Expansion Valve To Inside
To Outside
Cooling fan
Blower
Compressor Condenser
Gas (High temp., High pressure)
Evaporator
Gas (Low temp., Low pressure) 133
Air Conditioning and Heating
PTC Element
Heater core
PTC heater
Eva. core
134
Parts Identification and Location
Item Location 10. Motor Actuator Intake 14.1 Evaporator Core 14.2 Expansion Valve 15. Thermister ( Duct Sensor) 18. Relay 20. Water Valve 22. Motor Actuator Temperature 27. Heater Core 35. Fet (Gate) Fan Speed Control. 36. Motor Actuator Vent Defrost
135
Fan Speed Control Transistor Power TR (FET GATE)
Gate Fan speed signal
Source
3
0 1 2 3 4
Voltage 2
A/C & Heater Controller
1
Drain
0 2 4 8 16
0 2 4 8 16
Fet (Gate) Fan Speed Control See page 8 for location 1
3
2
3 1
2 1 3
136
2
A/C Major Components 1. Increase Capacity 1) Cooling Capacity : 4800 Kcal/hr -> 5700 Kcal/hr (19%) (19047 BTU → 22619 BTU) 2] Heating Capacity : 5000 Kcal/hr -> 6000 Kcal/hr[20%] (19841 BTU → 23809 BTU)
2. Condenser - Expanded front area (365.7H x 490W x 22D→453H x 615W x 22D) - Sub-Cool Type : Improve cooling efficiency (9000 kcal/hr→12000 kcal/hr) (35714.89 BTU → 47619.85 BTU)
HVAC unit
Condenser Heater core
PTC heater
Eva. core
Compressor
Sub-cool type : Remove Receive dryer
PTC Heater
3. Compressor - Improve durability & stability : Fixed type (DKV-14C) → Variable type (V-5)
4. Apply PTC Heater for intense cold 1) PTC : Air Heater which can raise Temp. rapidly, even though in the condition of cold coolant 2) Capacity : 1 Kw/h (860 kcal/h) (3412 BTU)
Variable displacement Piston type Compressor 137
APTC (Air Positive Temperature Coefficient) Heat Operating Factors 1. Air Intake Manifold Temperature : Below 5°C (41°F ) 2. Conditions The following three conditions should be fulfilled at the same time to run the APTC Heater 1) Engine Coolant Temperature : Below 60°C (140°F) 2) Wait to Start Lamp : Engine must be running. 3) Blower Status : Blower Fan should be running.
138
Condenser with Sub Cooler
139
Compressor Evolution
Item
7(A) Series
9 Series
-
Maker
DHC
Korea Delphi
Sanden
Model
DKV-14C
V-5
SD5H14
Type
Fixed Displacement Vane Rotary
Variable Displacement Wobble-plate
Fixed Displacement Wobble-plate
Displacement
140.5 cc/rev.
151 cc/rev.
138 cc/rev.
Compressor Oil
200cc (6.7 oz)
265cc (9.0 oz)
175 cc (6.0 oz)
Rated Voltage
DC 24V
DC 24V
DC 24V
Off : 150±5 (302± 41)
N/A
-
On : 135±5 (275±41)
N/A
-
Kpa
N/A
3600 ~ 4200
-
kg/cm2
N/A
36.7 ~ 42.8
-
psi
N/A
522 ~ 609
-
Thermal Protect (Body Temp.)
High Pressure Relief Valve
℃ (°F)
Shape
140
A/C Wiring Circuit
Incar Sensor is located on the Backside of the Recirculation Filter Ambient Sensor is located outside Under the cab (under AC unit)
CN 255
141
Troubleshooting
142
Repair
143
1. After repairing the AC system it is necessary to do the following procedure. Pull Full Vacuum for 15 minutes. On the Manifold Gauge assembly, close the valve to the center hose, disconnect the vacuum pump from the manifold gauge set after evacuation, 2. Connect the center hose at the manifold gauge set to the Refrigerant charging cylinder valve, Purge the air off the top of the refrigerant in the refrigerant tank, Check the tank temp and pressure chart. For ratio level. To purge to. (Warning Do not allow Refrigerant to be released into the atmosphere obey all rules for Handling R134a.) 3. If a Charging Station is used follow the manufacturers instructions. 4. With the Engine Off open the manifold Low Side valve to allow refrigerant to enter the system, keep the refrigerant cylinder in an upright position. Remove the Plug from the pressure switch in the High Pressure side of system and insert a jumper wire to complete the circuit to allow the compressor to run with low refrigerant 5. While the refrigerant is being drawn into the system start the engine and set the control to Max A/C and Hi - Blower. 6. Continue to add refrigerant to the system until the specified Refrigerant R134a is in the system, then close the manifold Gauge low pressure valve and the refrigerant supply valve. Note. Adhere to the specifications of the manufacturer for the weight and Quantity of refrigerant to be used. 7. Remove the Jumper wire and connect plug back to the pressure switch, 8. Operate the system until the pressures stabilize and verify operation and system pressures Low /High side. 9. When all system pressures are verified and system is working to Acceptable level remove Gauge set and replace protective caps on the Service Gauge valve ports. 144
R134a System Quantity
(Use PAG. ZXL 200PG)
PAG (polyalkylene glycol) and POE (polyolester). Note, check to see how much oil is left in the system from old compressor, remove this amount from new compressor before installation.
145
Duct Sensor (Thermistor) The thermistor functions similar to a resistor used to measure temperature change To prevent freezing of the evaporator, the evaporator core temperature is sensed by the duct sensor which allows the compressor to be on and off.
Evaporator
Characteristics (Temp.-Resistance-Output voltage) Temp. (℃)
Resi. (㏀)
Volt (V)
Temp. (℃)
Resi. (㏀)
Volt (V)
30.00
1.98
0.99
2.00
7.23
2.37
25.00
2.45
1.17
1.00
7.60
2.44
20.00
3.06
1.38
0.00
8.00
2.50
15.00
3.85
1.62
-1.00
8.42
2.56
10.00
4.88
1.89
-2.00
8.87
2.63
5.00
6.22
2.19
-3.00
9.34
2.69
4.00
6.54
2.25
-4.00
9.48
2.71
3.00
6.87
2.31
-5.00
10.37
2.82
Duct Sensor High Low Off
On
Compressor On : 4.0℃±0.5℃ Compressor Off : 0.5℃±0.25℃
146
TXV Location Expansion Valve
147
