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Hyundai Excavator R210LC-7. Service and repair manual - page 18

5 - 40

SYSTEM DIAGRAM

GROUP 14 OUTLINE (#1001 and up, TIER II )

21075MS51

5 - 41

GROUP 15 MODE SELECTION SYSTEM (#1001 and up, TIER II )

Mode selection system(Micro computer based electro-hydraulic pump and engine mutual control
system) optimizes the engine and pump performance.
The combination of 2 power modes(H, S) and accel dial position(10 set) makes it possible to use the
engine and pump power more effectively corresponding to the work conditions from a heavy and
great power requesting work to a light and precise work.

1. POWER MODE SELECTION SYSTEM

21075MS52

Mode

Application

Ver 5.X(STD)

E/G RPM

Unload

Load

Current

(mA)

Pressure

(kfg/cm

)

Power shift EPPR

E/G RPM

Power shift EPPR

Ver 6.X(OPT)

AUTO DECEL

One touch decel

KEY START

High power

Standard power

Engine deceleration

Engine quick deceleration

Key switch start position

Unload

Load

Current

(mA)

Pressure

(kfg/cm

)

2150 50

2050 50

1200 100

1050 100

1950

1850

190 30

290 30

600 30

680 30

2.5

2050

1950

600 30

680 30

1850

1750

220 30

260 30

600 30

680 30

5 - 42

HEAVY DUTY WORK MODE

The boom priority solenoid is activated to make the boom operation speed faster.

GENERAL WORK MODE

When key switch is turned ON, this mode is selected and swing operation speed is faster than
heavy duty work mode.

BREAKER OPERATION MODE

It sets the pump flow to the optimal operation of breaker by activating the max flow cut-off solenoid.

Work mode

Boom priority solenoid

Max flow cut-off solenoid

Heavy duty

General

Breaker

OFF

2. WORK MODE SELECTION SYSTEM (TIER II)

3 work modes can be selected for the optional work speed of the machine operation.

21075MS53

SECTION 5 MECHATRONICS SYSTEM

Group 1 Outline(up to #1000)

5-1

Group 2 Mode Selection System(up to #1000)

5-3

Group 3 Automatic Deceleration System

5-6

Group 4 Power Boost System

5-7

Group 5 Travel Speed Control System

5-8

Group 6 Automatic Warming Up Function

5-9

Group 7 Engine Overheat Prevention Function

5-10

Group 8 Anti-Restart System

5-11

Group 9 Self-Diagnostic System

5-12

Group 10 Engine Control System

5-15

Group 11 EPPR(Electro Proportional Pressure Reducing) Valve

5-22

Group 12 Prolix Switch(up to #0179)

5-25

Group 13 Monitoring System

5-26

Group 14 Outline(#1001 and up, TIER II)

5-40

Group 15 Mode selection system(#1001 and up, TIER II)

5-41

5 - 1

The NEW CAPO(Computer Aided Power Optimization) system controls engine and pump mutual
power at an optimum and less fuel consuming state for the selected work by mode selection, auto-
deceleration, power boost function, etc. It monitors machine conditions, for instance, engine speed,
coolant temperature, hydraulic oil temperature, and hydraulic oil pressure, etc.
It consists for a CPU controller, a cluster, an accel actuator, an EPPR valve, and other components.
The CPU controller and the cluster protect themselves from over-current and high voltage input, and
diagnose malfunctions caused by short or open circuit in electric system, and display error codes on the
cluster.

SECTION 5 MECHATRONICS SYSTEM

GROUP 1 OUTLINE

NEW CAPO

SYSTEM

Engine control system
Pump control system
Work mode selection
User mode system(MI, MII)

Travel speed control system

Controller & cluster protection
Open-short diagnosis & error code display

Machine condition monitoring
Electric signal monitoring

Mode selection system

Auto deceleration system

Power boost system

Travel speed control system

Automatic warming up system

Engine overheat prevention system

Max flow control system

Anti-restart system

Self-diagnostic system

Machine monitoring system

One touch deceleration system

Boom priority system

5 - 2

SYSTEM DIAGRAM(up to #1000)

Battery

Resistor

Prolix switch

Normal

Emergency

21075MS01

5 - 3

GROUP 2 MODE SELECTION SYSTEM(up to #1000)

Battery

Resistor

Prolix switch

Normal

Emergency

Battery

Mode

Application

Power shift by EPPR valve

Engine rpm

Ver 1. X(STD)

Ver 2. X(OPT)

Unload

Load

Current

(mA)

Current

(mA)

Pressure

(kgf/cm

)

Pressure

(kgf/cm

)

160

370 30

670 30

710 30

430

480

670 30

710 30

2250 50

2150 50

1200 100

950 100

2100

2000

100

AUTO DECEL

One touch decel

KEY START

High power

Standard power

Engine deceleration

Engine quick deceleration

Key switch start position

Power

set
(%)

1. POWER MODE SELECTION SYSTEM

21075MS02

5 - 4

Main control valve

Main relief
valve

Power boost
solenoid valve

Engine speed
sensor

Main pump

Pilot pump

EPPR valve

Drive signal

Battery

Resistor

Prolix switch

Drive signal

P M

Engine

Coolant
temp sensor

Fuel injection
pump

Accel

actuator

Hyd temp
sensor

CPU controller

Serial Communication(-)

Serial Communication(+)

Normal

Emergency

Coolant temperature signal

Motor drive signal

Potentiometer signal

Engine speed sensor signal

Hyd temperature signal

Cluster

Accel dial

Drive signal

Arm 1

Boom 2

Swing

Travel(LH)

Arm 2

Boom 1

Bucket

Option

Travel(RH)

Max flow CO
solenoid valve

Max flow
CO valve

Drive signal

Boom priority
solenoid valve

Accel dial signal

Boom priority
valve

Battery

Resistor

Prolix switch

Normal

Emergency

up to #0179

HEAVY DUTY WORK MODE

The boom priority solenoid is activated to make the boom operation speed faster.

GENERAL WORK MODE

When key switch is turned ON, this mode is selected and swing operation speed is faster than
heavy duty work mode.

BREAKER OPERATION MODE

It sets the pump flow to the optimal operation of breaker by activating the max flow cut-off solenoid.

Work mode

Boom priority solenoid

Max flow cut-off solenoid

Heavy duty

General

Breaker

OFF

2. WORK MODE SELECTION SYSTEM

3 work modes can be selected for the optional work speed of the machine operation.

21075MS03

5 - 5

3. USER MODE SELECTION SYSTEM

Through 2 memory sets of MI and MII, an operator can change the engine and pump power and
memorize it for his preference.

Mode

Operation

MI (Memory mode 1)

MII (Memory mode 2)

High idle rpm, auto decel rpm
EPPR pressure can be modulated and memorized separately

HOW TO MODULATE THE MEMORY SET

Each memory mode has a initial set which are
mid-range of max engine speed, auto decel rpm,
and EPPR valve input current. When you select
MI or MII, cluster LCD displays.

To change the engine high idle speed, press the
USER mode switch and SELECT switch at the
same time and then ACCEL blinks at 0.5 seconds
interval.

- By pressing or switch, will increase or

decrease.

To change DECEL rpm, press the USER mode
switch and SELECT switch once more and then
DECEL blinks at 0.5 seconds interval.

- By pressing or switch, will increase or

decrease.

To change EPPR current, press the USER mode
switch and SELECT switch one more and then
EPPR blinks at 0.5 seconds interval.

- By pressing or switch, will increase or

decrease.

LCD segment vs parameter setting

To memorize the final setting, press the USER
mode switch and SELECT switch one more time.

21074OP03G

21074OP03H

Segment

( )

ACCEL

(rpm)

DECEL

(rpm)

EPPR

(mA)

Low idle

950

1050

1100

1150

*1100

*1150

*1050

Decel rpm

*1200

*1250

1250

1300

1350

1400

1500

*1300

*1350

*1400

*1450

*1500

High idle-900

High idle-800

High idle-700

High idle-600

High idle-500

High idle-400

High idle-300

High idle-200

High idle-100

High idle

150

200

250

300

350

400

450

500

550

600

* : TIER II only

Decel rpm

1200

5 - 6

GROUP 3 AUTOMATIC DECELERATION SYSTEM

P M

Fuel injection
pump

Accel
actuator

Motor drive signal

Potentiometer signal

CPU controller

Main control valve

Work equipment
pressure switch

Auto decel switch signal

Pressure switch signal

Accel dial

Accel dial signal

Travel oil pressure switch

If all the work equipment control levers including swing and travel levers are at neutral for at least 4
seconds, CPU controller drives the governor motor to reduce the engine speed to 1200rpm. As the
result of reducing the engine speed, fuel consumption and noise are effectively cut down during non-
operation of the control levers.
When the Auto decel lamp is turned off by pressing the switch or any control lever is operated, the
reduced engine speed rises upto the speed set before deceleration in a second.

1. WHEN AUTO DECEL LAMP ON

2. WHEN AUTO DECEL LAMP OFF

The engine speed can be set as desired using the engine speed switch, and even if the control levers
are neutral, the engine speed is not reduced.

Note : Auto decel function can be activated when accel dial position is over 4.

Time

Engine rpm

Accel dial set rpm

1200 rpm

4sec

Max

1.5sec

Max

1.5sec

Lever

operation

Lever

neutral

21075MS04

21075MS05

5 - 7

GROUP 4 POWER BOOST SYSTEM

Main control valve

Arm 1

Boom 2

Swing

LH travel

Arm 2

Bucket

Boom 1

Option

RH travel

Main relief
valve

Boom priority
spool

Power boost
solenoid valve

Engine speed
sensor

Main pump

Pilot pump

EPPR valve

Drive signal

P M

Engine

Fuel injection
pump

Accel
actuator

Power boost
button

LH control
lever

CPU controller

Motor drive signal

Potentiometer signal

Engine speed sensor signal

Max flow
CO valve

Mode switch signal

Power boost button signal

When the power boost switch on the left control lever knob is pushed ON, the maximum digging
power is increased by 10%.

When the power set is at H or S and the power boost function is activated, the power boost solenoid
valve pilot pressure raises the set pressure of the main relief valve to increase the digging power.

Description

OFF

Power boost switch

Power seat

Main relief valve set pressure

Time of operation

H or S

330kgf/cm

OFF

360kgf/cm

Even when pressed continuously,

it is canceled after 8 sec.

Default - Power boost solinoid valve : OFF

21075MS06

5 - 8

GROUP 5 TRAVEL SPEED CONTROL SYSTEM

Travel motor

Regulator

Main control valve

Arm 1

Boom 2

Swing

LH travel

Arm 2

Bucket

Boom 1

Service

RH travel

Travel spped
solenoid valve

Main pump

Pilot pump

EPPR valve

Drive signal

CPU controller

Travel speed switch signal

Max flow
CO valve

Engine

Travel speed can be switched manually by pressing the travel speed switch on the cluster.

Default : Turtle(Lo)

Speed

Operation

OFF

Turtle

Rabbit

Low speed, high driving torque in the travel motor

High speed, low driving torque in the travel motor

Travel speed

solenoid valve

Lamp

on cluster

21075MS07

5 - 9

GROUP 6 AUTOMATIC WARMING UP FUNCTION

Main pump

Pilot pump

EPPR valve

Drive signal

P M

Engine

Coolant
temp sensor

Fuel injection
pump

Accel
actuator

CPU controller

Warming up lamp signal

Coolant temperature signal

Motor drive signal

Potentiometer signal

Max flow
CO valve

CPU controller reads engine coolant temperature through the temperature sensor, and if the coolant
temperature is less than 30 C, it increases the engine speed from key start rpm to 1200rpm. At this
time the mode does not change.

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 mode set during the warming up function, the CPU controller
cancels the automatic warming up function.

3. LOGIC TABLE

Actuated

Canceled

Warming up lamp

- Coolant temperature :

Less than 30 C(After engine run)

- Accel dial position is under

- Coolant temperature : Above 30 C

- Warming up time : Above 10 minutes

- Changed mode set by operator

- Increase engine speed by rotating accel

dial clockwise

If any of the above conditions is
applicable, the automatic warming up
function is canceled

- Coolant temperature : Above 30 C

- Mode : Default(

mode)

- Warming up time : 10 minutes(Max)

- Warming up lamp : ON

- Default mode

- Changed mode

- Warming up lamp : OFF

Description

Condition

Function

21075MS08

5 - 10

1. CPU controller reads engine coolant temperature through the temperature sensor and when the

engine coolant boils up to 110 C, it sends overheat warning signal to the cluster and decrease the
engine speed same as accel dial

position.

2. If the coolant temperature drops less than 100 C, the CPU controller returns the mode to the mode

set before. And if mode set is changed during the function, the CPU controller cancels the function.
Even if the overheat prevention function is canceled by mode change, the overheat warning lamp
turns OFF only when the coolant temperature is less than 100

3. LOGIC TABLE

GROUP 7 ENGINE OVERHEAT PREVENTION FUNCTION

Actuated

Canceled

Overheat warning lamp

- Coolant temperature : Above 110 C

- Accel dial set : Above

- Coolant temperature : Less than 100 C

- Changed mode set by operator

If any of the above conditions is
applicable, engine overheat prevention
function is canceled

- Coolant temperature : Less than 100 C

- Engine rpm drop to accel dial 7 position

- Overheat warning lamp & buzzer : ON

- Return to the mode and accel dial set before

- Hold on the changed set

- Overheat warning lamp : OFF

Description

Condition

Function

Main pump

Pilot pump

EPPR valve

Drive signal

P M

Engine

Coolant
temp sensor

Fuel injection
pump

Accel
actuator

CPU controller

Overheat warming signal

Coolant temperature signal

Motor drive signal

Potentiometer signal

Max flow
CO valve

21075MS09

5 - 11

GROUP 8 ANTI-RESTART SYSTEM

Engine

CPU controller

Starter

Start safety relay

Drive signal

CN-92a

CN-92b

1. ANTI-RESTART FUNCTION

After 10 seconds from the engine starts to run, CPU controller turns off the start safety relay to protect
the starter from inadvertent restarting.

2. When a replacement or taking-off of the CPU controller is needed, connect CN-92a and CN-92b to

ensure the engine start without the CPU controller.

21075MS10

5 - 12

GROUP 9 SELF-DIAGNOSTIC SYSTEM

OUTLINE

When any abnormality occurs in the NEW CAPO system caused by electric parts malfunction and by
open or short circuit, the CPU controller diagnoses the problem and sends the error codes to the
cluster and also stores them in the memory.
The current or recorded error codes are displayed at the error display mode selected by touching

SELECT

switch 2 times while pressing

BUZZER STOP

switch.

CURRENT ERROR DISPLAY

Cluster displays

Co : Er

and makes buzzer sound itself to warn the communication error when

communication problem caused by wire-cut or malfunction of the CPU controller occurs.
Cluster displays real time error codes received from CPU controller through communication. In case
of no problem it displays

CHECK

Er : 00

If there are more than 2 error codes, each one can be displayed by pressing and switch
respectively.

Examples

1) Communication Error

Co : Er & Buzzer sound

2) No problem

CHECK

Er :

3) 4 Error codes(03, 06, 10, 43) display

CHECK

Er :

RECORDED ERROR DISPLAY

The recorded error can be displayed only when the key switch is at ON position.

Examples

: 5 Recorded error codes(03, 06, 10, 20, 32) display

TIME

Er :

DELETE ALL RECORDED ERROR CODES

Select recorded error(

TIME

) display and press engine and select switch at the same time for

2 seconds or more. Cluster display changes to

TIME

Er : 00

, which shows that CPU controller

deleted all the recorded error codes in the memory.

0 0

0 3

0 6

1 0

4 3

Start

No change

Press

0 3

Press

0 3

0 6

1 0

2 0

Start

Press

3 2

Press

No change

Press

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