R220LC-9S for Laos

Presented by K.Y. Lee

After sales & service department of HHI

After service department 1

 2. Engine
Item Specification

Model Cummins 6BTAA

1) Overview
Control type Mechanical

Number of cylinder 6 cylinders

Right Method
Firing order 1-5-3-6-2-4

Cylinder bore x stroke 102 x 120mm

Piston displacement 5,880cc

Rated gross horse

150HP at 1950rpm
power

Engine oil 24ℓ

Rated fuel
164.8g/ps.h at 1950rpm
consumption

* Left method
1-4-2-6-3-5
After service department 2
2) Engine for R220LC-9S & 9

Items R220LC-9S R220LC-9 Remarks

Model 6BTAA QSB6.7

Fuel Injection
Mechanical HPCR
Pump

Displacement 5,880cc 6,700cc

Rated Power 150Hp at 2100rpm 150Hp at 1900rpm

After service department 3

 3. Engine rpm control System(9S)

1) Structure

(MCU)

After service department 4

 4. Hydraulic Oil Flow Control system

1) Structure

(MCU)

Eng’ RPM Pump EPPR

Mode Current Pressure
Unload Load
(mA) (Kg/㎠)
P 2150 1950 360 10
S 2050 1850 360 12
E 1950 1750 360 12
Auto
After service department 1000 - 700 355
Idle
2) Operating Mechanism of EPPR Valve

Eng’ RPM EPPR Press

Mode
Unload Load Current Bar

P 2150 1950 330 10

S 2050 1850 360 12

E 1950 1750 360 12

Auto 1150 700 700 38

Specification Remarks
Unload Loaded

1950 EPPR Pressure will be increased to

2150 recover the engine rpm until reaching the
(Difference : 200rpm) Loaded rpm.
After service department 6
3) Operation of EPPR Valve
- Fs1 + Fh1 ↔ Fe1 + Fs2

After service department 7

 ※ Trouble Shooting 1

1) Machine and Problems

Model S/No Hour Description Dealer’s action
R220LC-9S 522 869 * After working 20 minutes,
MAS, Laos When pull digging or pull in Arm
Engine shut down
2) Test result of Dealer

Items Idle Full(368B)

EPPR 36.6 13
Press
Engine 850 1900
rpm

After service department 8

 * Mode Spec’
Eng’ RPM EPPR Press
Mode
3) HHI Comments Unload Load Current Bar

P 2150 1950 330 10

S 2050 1850 360 12

E 1950 1750 360 12

Auto 1150 700 700 38

4) Check Table

After service department 9

 □
5) Regulator Adjusting 17or13mm

36mm
24mm

17or13mm

24mm
36mm

After service department 10

6) When Engine Shut Down at the powered working

After service department 11

 5. EPPR Compensation System

1) Function
: when the pressure is different between Mode Eng’ RPM EPPR
the target and real, the current is re- Unload Relief Hi Idle Relief
adjusted to be equal (mA) (Kg/㎠) (Kg/㎠)
P 2150 1950 330 10 10
S 2050 1850 360 12 12
E 1950 1750 360 12 12
2) System Outline

After service department 12

 * Trouble Shooting 1

1) Machine and Problems

Model S/No Hour Description Action
R520LC-9 0015 850 1) All attachments speed are excessively slow
- Power shift Press: 0 Bar
- When the connector of EPPR is
disconnected, all speed is normal

2) Checking Items
Ⓐ Power shift Press : 0 bar Ⓑ Real Power shift Press : 30 bar

After service department 13

3) Actuation Principle

4) Check Table

After service department 14

 6. Engine rpm & Electrical Current

Engine rpm Power shift by EPPR valve

STD Opt
Mode Application
Unload Load Current Pressure Current Pressure
(mA) (Kg/㎠) (mA) (Kg/㎠)
P Heavy Duty 2150 1950 330 10 366 13
S Standard 2050 1850 360 12 400 15

E Economy 1950 1750 360 12 400 15

Auto
Idle
Engine Decel’ 1150 - 700 38 700±30 35

One Engine quick

touch deceleration
1000 - 700 38 ←

Starting
Starting
Position
1000 - 700 38 ←

After service department 15

7. Anti-restarting System

GND

After service department 16

 * Trouble Shooting 1

1) Machine and Problems

Model S/No Hour Description Dealer’s action
R220LC-9S 951 1483 1) The Eng’ doesn’t start
MAS 2) 2 Speed doesn’t be engaged
Laos

2) Test result of Dealer

After service department 17

3) The Function of MCU

TR

Electric Circuit for Solenoid After service department Electric Circuit for Starting 18
 Normal Power
error
Communication
4) Communication of MCU
error

After service department 19

 * Trouble Shooting 2

1) Machine and Problems

Model S/No Hour Description Dealer’s action
R220LC-9S 3827 1551 1) The Eng’ doesn’t be shut down
MAS
Laos

2) Test result of Dealer

- Shut off solenoid valve defected

3) HHI Comments
- Shut off valve is return by Spring Force
- If it doesn’t return,
it should be caused by physical fixedness of Shut off Valve

After service department 20

 9. Attachment Flow Control System For a more detailed description
on the next lesson

1) Work Mode
: General operation

: Breaker operation (Optional) – 1 way

: Crusher operation (Optional) – 2 way

Work Tool
Solenoid General
Breaker Crusher
Flow Level Max 7 step, Reduced 10ℓper step Max 4 step, reduced 20ℓper step
Safety Sol’ On On Off
Press Sol’ Off On Off
Conflux Sol’ Off On/off Off
After service department 21
 10. For Breaker Mode

1) Selection

EPPR
Valve for
Breaker

2) Function
Ⓐ When the breaker mode selected, the safety sol’ is energized
Ⓑ The press of EPPR valve is controlled by MCU to control Flow for Breaker
Ⓒ MCU can realize breaker is operated or not through the press sensor
After service department 22
 * Trouble Shooting 1

1) Machine and Problems

Model S/No Hour Description Dealer’s action
R220LC-9S 3972 54 1) Deviation of travel
GMI - the RH side is much weaker in
the LH side

2) Dealer’s Decision
(1) after checking Press, the results is both RH and LH pressure is almost the same
(2) the main cause of it is the EPPR Valve in Main Pump (not Working anymore) resulting
to unbalance performance of travel

It is an EPPR valve
for breaker
Not for Main Pump

After service department 23

 3) Hydro Circuit for EPPR valve

4) Comments

After service department 24

 * Trouble Shooting 2

1) Machine List
Model S/No Hour Description Dealer’s action
R220LC-9S B809 302 1) Deviation to the Left side
B810 90 - The Spool was scratched/burned
B909 198
B910 165
B917 177/447
B919 143

After service department 25

2) Comments

38∼3bar

38∼breaker selected bar

After service department 26

 11. For Crusher Mode

1) Selection

2) Function of Sol’
Ⓐ When the Crusher mode selected, the safety
sol’ is energized
Ⓑ The press of EPPR valve is controlled by
MCU to control Flow for Crusher
Ⓒ Conflux Sol’ is energized by MCU to join
P1 and P2
Ⓓ Press Sol’ is energized to increase the
system Press for Crusher

3) Function of Press Sensor

Ⓐ To confirm Special Attachment and normal
Ⓑ O bar of Sensor means normal operating
After service department 27
 10. For Crusher Mode

Pedal Pres. Conflux

Attach EPPR

28
Customer Support Dep’t
 12. Auto Idle System

1) Structure

After service department 29

2) Electric & Hydro Circuit

After service department 30

 * Trouble Shooting 1

1) Machine and Problems

Model S/No Hour Description Action

R220LC-9S 674 719 Auto-decel system doesn’t work

745 2151 - Press sensor damaged
MAS, Laos 3685 292
2) Dealer’s Conclusion
- Auto Idle System doesn’t work due to Press sensor of MCV damaged

After service department 31

3) HHI Comments

Eng’ RPM EPPR Press

Mode
Unload Load Current Bar

P 2150 1950 190 3

S 2050 1850 250 5

E 1950 1750 330 10

Auto 1100 700 700 38

After service department 32

 13. Variable Boom Priority system

; Optimized Flow division between Boom and Swing by calculating RCV 2nd pressure
and Load condition to control the EPPR Valve current.
- Calculate Boom up Pilot Press and Swing one and control Boom Up or Swing Speed by Swing EPPR

1) Auto VBP System

Classifi-cation 7A Series 9 Series

Fixed Priority Functioning According to

1) Only at the condition of simultaneous operation
the Work mode selection.
Algorithm : Boom Up + Swing
- Heavy Duty : Boom Priority
2) Variable Boom Priority : Manual / Auto
- General, Breaker : Swing Priority

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

Flow Control
Swing Logic Valve Swing Logic valve.

Shock
- Smooth movement of Logic valve open-area.
Reduction

After service department 33

 Swing

PO3

1P 2P Gear Pump
주행직진
좌 주행
스윙
붐

34
Customer Support Dep’t
 •Working pressure compared
( Boom, Arm, Swing complex operation)

압력

시간
35
Customer Support Dep’t
 14. Auto Power Boost system

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

- P1 & P2 Pressure are sustained

more than 1Sec.

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

P
mode

After service department 36

 3) Auto Power boost system classification

Classifi-cation Condition Remarks

System Relief Pressure, Engine and Pump Power Up for

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

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

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

Automatically Power Max Solenoid Valve is Engaged According to

Travel Power boost
when Travel RCV is Applied. Model

After service department 37

 15. Main Pump

1) Structure

Small Large
Chamber Chamber

After service department 38

1) Negative Regulator
- To save fuel consumption
- For soft starting
- Fr & Fl press would be good evidence to
confirm MCV is good condition or not

After service department 39

 * Trouble Shooting 1

1) Machine and Problems

Model S/No Hour Description Action
R220LC-9S 1110 319 * Power and Speed is low
for all attachment

2) Test Result
- P1 80.4bar
- P2 : 83.6bar during Traveling

After service department 40

3) The broken parts of P2 Main Pump

After service department 41

4) The suspected Reason broken

After service department 42

 5) Measures to avoid similar problem

(1) The reason why the piston is stuck

(2) Remedy
Reason Remedy
Lack of lubrication

Small materials of Oil

Contamination

After service department 43

 16. MCV

1) Hydro Circuit

After service department 44

 17. Boom Holding Valve

1) Function
-Boom is stopped by a Boom spool when
boom downing
-Boom holding valve will be closed 3∼4
seconds later after RCV lever in neutral

Pilot

Drain

Orifice
￠0.4

After service department 45

 18. Boom Regeneration

1) The Function
When the boom come down very slowly,
Oil from boom cyl’ flow into Boom Cyl
Head to prevent cavitation

Holding
Valve

After service department 46

 19. Arm Regeneration

1) STD Mode selected

When the Key turn on, the Arm
Reg’ sol’ valve is energized so
Arm Regen’ is canceled for
smooth operation

After service department 47

2) Heavy Mode selected
When the Heavy Duty is
selected, the sol’ valve is
disenergized, so Arm regen’
can be operated for Arm high
speed from 50 bar to start
and at 150bar the spool is
opened completely

After service department 48

19. Arm Regeneration-Cut

Pb4

49
Customer Support Dep’t
 20. Swing Priority Valve

1) Swing Priority Function

When both operating of Swing and Boom, Swing
priority spool move to right side so oil coming from P2
can flow to Boom 2 Spool

After service department 50

옵션

암1
P2측 병렬 통로 암1측 병렬 통로

51
Customer Support Dep’t
 21. Bucket Summation

1) Bucket Summation Function

When both operating of Swing and Boom,
Swing priority spool move to right side so oil
coming from P2 can flow to Boom 2 Spool

After service department 52

 22. Main & Port Relief Valve

1) Description
When opened the port relief valve,
a port relief valve needs more time
to close than a main relief valve

2) Moving Parts

Port Relief Valve

After service department Main Relief Valve 53

 23. Main & Port Relief Valve (Old)

1) Description
When opened the port relief valve,
a port relief valve needs more time
to close than a main relief valve

2) Moving Parts

Port Relief Valve

After service department Main Relief Valve 54

 * Trouble Shooting 1

1) Machine and Problems

Model S/No Hour S/No Hour Description Action
R220LC- 69 1432 74 1461 * When digging and pull Replaced Port
9S 136 185 166 1956 Arm in no power Relief Valve
154 1192 200 419
- O-ring of Port Relief
195 2434 321 1906
Valve is defective
201 2471 713 779
229 1583 1402 457
263 2720 1402 651
MAS, 275 1822 2951 2416
316 558 3827 157
Laos
334 2054
503 105
948 1892
1427 1684
2627
1526 2062
2759 1308
2959 1237
4082 901 After service department 55
2) Dealer’s Conclusion
- Press of Arm in : 265bar
- Power is weak due to defective O-ring Foreign materials

After service department 56

3) Comments

Port Relief Valve

After service department 57

 24. Boom Holding Valve

1) Structure

After service department 58

 25. Swing Motor

1) Mechanism

After service department 59

2) Structure

After service department 60

3) Oil Supply from MCV

After service department 61

2) Turning Force
- T = W1 x R1

After service department 62

 26. Anti-rotating Valve

1) The Purpose of the Valve

2) Principle of operation

After service department 63

4) When starting 5) When stopping

(1) Closing time : 0.3sec’ (1) Closing time : 1.11sec’(3.7 x 0.3)

(2) Oil quantity flowed for 0.3sec’ : 0.8cc (2) Oil quantity flowed for 0.3sec’ :
: 2.96cc(0.8 x 3.7)

After service department 64

 27. Travel Motor

1) Structure

After service department 65

 28. Relief and Counter Balance Valve

1) Relief Valve for travel Motor

2) Counter Balance Valve

After service department 66

3) Travel Speed Valve

After service department 67

 ※ Trouble Shooting 1
1) Machine and Problems
Model S/No Hour Description Action
R210LC- 0802 1,387 1) Low Travel Speed of LH in Reverse
7A only in cold condition,
2) Disappear after 10minutes

2) Measured Travel Press at Travel Motor during operating

(1) Measured Press
Test Points Measured Spec’
Main Press 325bar 335
Fr & Fl 38 ∼3bar 38 ∼3bar

(2) Trouble Shooting

- Exchanged the hydro Hose of P1 and P2
but same problem happened

After service department 68

3) When low LH travel Speed happened
Test Points if Possible Causes Solution
Travel Main 340bar Counter balance Spool
Press was stuck

38bar Port Relief valve is open

The part of
polished

After service department 69

 ※ Trouble Shooting 2

1) Machine and Problems

Model S/No Hour Description Action
R380LC-9 143 1357 1) After stopping on slop, the
machine slip down at early
morning in winter season

2) Function of Counter Balance Valve

(1) “A” Area : Oil can be returned through orifice
(2) “B” Area : Oil can be returned through Gap
between spool and Cap

￠3.0

￠0.8

After service department 70

3) Possible Causes

After service department 71

 29. Measuring the Travel Speed

1) How to measure
- Rotate 1 turn and then measure
time taken for next 3 revolution

2) Test result

Travel Test result Spec’

Remedy (If not)
Speed RH LH (Second)

1 speed 28.8±2.0

2 speed 19.0±2.0

3) Test Result
- you can decide which the travel motor is more faster or slower
After service department 72
 18. Idler worn out

1) Machine and Problems

Model S/No Hour Description Action
R210LC-9S 12 1374 Idler Bushing and shaft is
201 1702 worn out completely
MAS 216 430 - oil leaked and worn out
Laos 216 285
217 114
217 331
310 358
310 1197
598 829

※ S/No 216, 217, 310

RH & LH Idlers at same time are worn out only 1 or 2 months later
after delivery
After service department 73
2) S/No 216, 285Hrs
- Delivery Date : 2012. 01.12,
Failed Date : 2012.02.24
- Bushing and Shaft of RH & LH Idler
were worn out completely 1 month 12 days late

After service department 74

After service department 75