Dash_9_S_Training.pdf

December 5, 2017 | Author: Paul Galwez | Category: Turbocharger, Valve, Engines, Switch, Electrical Connector
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Description

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





:

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.







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





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





92

10-2-4. P2 Side R220LC-9S

①②





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









① P01



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



(P1)

⑦ ⑥





③ ARM2 SPOOL



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

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