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Hyundai Excavator R210LC-7. Service and repair manual - page 19

5 - 13

5. ERROR CODES TABLE

Fault code No.

Description

Short circuit in governor motor system

Potentiometer circuit is shorted to Vcc(5V) or battery +

Short circuit in pump EPPR valve system

Short circuit in boom down EPPR valve system

Short circuit in travel speed solenoid system

Short circuit in power boost solenoid system

Short circuit in max flow solenoid system

Short circuit in hour-meter system

Accel dial circuit is shorted to Vcc(5V) or battery +

P1 pressure sensor circuit is shorted to power supply(24V) line

P2 pressure sensor circuit is shorted to power supply(24V) line

P3 pressure sensor circuit is shorted to power supply(24) line

Boom down pressure circuit is shorted to power supply(24V) line

Governor motor circuit is open or shorted to ground

Potentiometer circuit is open or shorted to ground

Pump EPPR valve circuit is open or shorted to ground

Boom down EPPR valve circuit is open or shorted to ground

Travel speed solenoid circuit is open or shorted to ground

Power boost solenoid circuit is open or shorted to ground

Max flow solenoid circuit is open or shorted to ground

Hour-meter circuit is open or shorted to ground

Accel dial circuit is open or shorted to ground

P1 pressure sensor circuit is open or shorted to ground

P2 pressure sensor circuit is open or shorted to ground

P3 pressure sensor circuit is open or shorted to ground

Boom down pressure sensor circuit is open or shorted to ground

Engine preheater circuit is open or shorted to ground

Travel alarm buzzer circuit is open or shorted to ground

Alternator circuit is open or shorted to ground

Controller input voltage is below 18V

Controller input voltage is over 38V

Communication error with cluster

Engine speed sensor circuit is open or shorted to ground

Anti-restart relay circuit is open or shorted to ground

Accel actuator does not stop at a target position

There is more than 500rpm difference between target speed and actual speed

5 - 14

Fault code No.

Description

Hydraulic oil temperature sensor circuit is shorted to ground

Fuel level sensor circuit is shorted to ground

Coolant temperature sensor circuit is shorted to ground

Boom up pressure sensor circuit is shorted to power supply(24V) line

Hydraulic oil temperature sensor circuit is open or shorted to battery +

Fuel level sensor circuit is open or shorted to battery +

Coolant temperature sensor circuit is open or shorted to battery +

Boom up pressure sensor circuit is open or shorted to ground

Engine preheater circuit is shorted to battery +

Boom priority solenoid circuit is open or shorted to ground

Travel alarm buzzer circuit is shorted to battery +

Boom priority solenoid circuit is shorted to battery +

SECTION 6 TROUBLESHOOTING

Group 1 Before Troubleshooting

6-1

Group 2 Hydraulic and Mechanical System

6-4

Group 3 Electrical System

6-24

Group 4 Mechatronics System(up to #1000)

6-41

Group 5 Mechatronics System(#1001 and up, TIER II)

6-58

6 - 1

SECTION 6 TROUBLESHOOTING

GROUP 1 BEFORE TROUBLESHOOTING

1. INTRODUCTION

When a trouble is occurred in the machine, this section will help an operator to maintain the machine
with easy.
The trouble of machine is parted Hydraulic & Mechanical system, Electrical system and Mechatronics
system. At each system part, an operator can check the machine according to the troubleshooting
process diagram.

Troubles occur

Mechatronics
part

2 digit
(Machine)

3 digit
(Engine)

Fault codes
displayed on
monitor display

Hydraulic &
Mechanical part

GROUP 2

GROUP 3

GROUP 4

HRDT

by Hyundal

INSITE

by Cummins

Electrical part

If fault codes (2 or 3 digits) are displayed on the monitor, please contact Hyundai or
Cummins.

6 - 2

STEP 1. Study the machine system

Study and know how the machine is operating,
how the system is composing, what kinds of
function are installed in the machine and what
are specifications of the system components by
the machine service manual.
Especially, deepen the knowledge for the
related parts of the trouble.

STEP 2. Ask the operator

Before inspecting, get the full story of
malfunctions from a witness --- the operator.

How the machine is used and when it is
serviced?

When the trouble was noticed and what
work the machine was doing at that time?

What is the phenomenon of the trouble?
Was the trouble getting worse, or did it
come out suddenly for the first time?

Did the machine have any troubles
previously? If so, which parts were repaired
before.

STEP 3. Inspect the machine

Before starting troubleshooting, check the
machine for the daily maintenance points as
shown in the operator's manual.

And also check the electrical system including
batteries, as the troubles in the electrical system
such as low battery voltage, loose connections
and blown out fuses will result in malfunction of
the controllers causing total operational failures
of the machine.

2. DIAGNOSING PROCEDURE

To carry out troubleshooting efficiently, the following steps must be observed.

ON THE

INSPECTION

13031SH02

13031SH03

(210-7) 6-2(3)

6 - 3

STEP 4. Inspect the trouble actually on the

machine

In case that some trouble cannot be confirmed,
obtain the details of the malfunction from the
operator.
Also, check if there are any in complete
connections of the wire harnesses are or not.

STEP 5. Perform troubleshooting

According to where the trouble parts are
located, hydraulic & mechanical system part or
electrical system part or mechatronics system
part, perform troubleshooting the machine refer
to the each system part's troubleshooting
process diagram.

STEP 6. Trace a cause

Before reaching a conclusion, check the most
suspectible causes again. Try to trace what
the real cause of the trouble is.

Make a plan of the appropriate repairing
procedure to avoid consequential malfunctions.

(210-7) 6-3(1)

13031SH05

(210-7) 6-3(3)

6 - 4

GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM

1. INTRODUCTION

MACHINE IN GENERAL

If even a minor fault is left intact and operation is continued, a fatal failure may be caused,
entailing a large sum of expenses and long hours of restoration.
Therefore when even a small trouble occurs, do not rely on your intuition and experience, but look
for the cause based on the troubleshooting principle and perform maintenance and adjustment to
prevent major failure from occurring. Keep in mind that a fault results from a combination of
different causes.

The following lists up commonly occurring faults and possible causes with this machine. For the
troubleshooting of the engine, refer to the coming troubleshooting and repair.

When carrying out troubleshooting, do not hurry to disassemble the components.
It will become impossible to find the cause of the problem.

Ask user or operator the following.

Was there any strange thing about machine before failure occurred?
Under what conditions did the failure occur?
Have any repairs been carried out before the failure?

Check before troubleshooting.

Check oil and fuel level.
Check for any external leakage of oil from components.
Check for loose or damage of wiring and connections.

(1)

(2)

(3)

(4)

(5)

YES

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2. DRIVE SYSTEM

UNUSUAL NOISE COMES OUT OF PUMP CONNECTION

Remove dust plug
under engine
flywheel and
check if rubber
pieces or particles
are not present.

Coupling hub
spline is worn or
hub fastening
setscrew is slack.

If hydraulic pump or engine is
suspected as a culprit refer to this
manual "Structure and function".

Cause

Remedy

Coupling element
is broken.

Disassemble
and repair.

Replace hub or
retighten
setscrew.

6 - 6

ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL

Hydraulic pump is
broken.

Pilot valve is
faulty.

Pilot relief valve is
faulty.

Gear pump is
broken.

Replenish
specified oil to
the standard
level.
Disassemble
and repair.

See item 1).
at page 6-5

Clean pilot
piping interior or
repair piping.

Disassemble
and repair.

Repair or
replace.

Disassemble
and repair.

YES

Is oil level in
hydraulic oil
tank within
standard level?

Do not hydraulic
pump and pump
connections
make abnormal
noise?

Abnormal noise
comes out of
pump
connection

Is primary pilot
pressure within
standard level?

Is not pilot piping
clogged or is not
oil leakage present
on pilot piping?

Is gear pump
delivering oil?

Abnormal noise
comes out of
hydraulic pump

YES

Cause

Remedy

6 - 7

Replenish
specified oil to
the standard
level.
Clean oil cooler.
Secure air
circulation route.

Adjust belt
tension or
replace belt.

Readjust set
pressure.

Reduce load.

YES

Is hydraulic oil
volume proper?

Is not oil cooler
clogged and is
anything blocking
air circulation?

Is main relief
valve used very
often?

Is not the set
pressure of main
relief, relief and
travel relief valve
lower than the
standard level?

Is fan belt
tension proper?

YES

Drop hydraulic oil
sample on hot
plate and check if
foams come up.

Water is mixed.

Air is intruded.

Put hydraulic oil
still, separate
water and
dispose it or
replace hydraulic
oil.

Check suction
line and return
line and eliminate
the air intruding
source.

3. HYDRAULIC SYSTEM

HYDRAULIC OIL IS CLOUDY

HYDRAULIC OIL TEMPERATURE HAS RISEN ABNORMALLY

Cause

Remedy

Cause

Remedy

6 - 8

YES

Is hydraulic oil
volume proper?

Is not air intruding
from pump
suction line?

Is not viscosity
of hydraulic oil
too high?

Is not suction
strainer clogged?

Replenish
specified oil to
the standard
level.

Replace oil with
one of proper
viscosity.

Clean suction
strainer.

Check for air
intrusion in
suction line and
retighten or
replace parts.

CAVITATION OCCURS WITH PUMP

HYDRAULIC OIL IS CONTAMINATED

Has not hydraulic
oil passed
specified replace-
ment hours?

Replace
hydraulic oil to be
specified.

Flush with
hydraulic oil and
replace return
filter.

Has return filter
been replaced at
proper intervals?

Cause

Remedy

Cause

Remedy

YES

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4. SWING SYSTEM

BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE

Are attachment
and travel
motions
impossible at all?

Is safety solenoid
valve pressure
within standard?

YES

Is gear pump pilot
pressure within
standard level?

Is MCV pilot
pressure within
standard level?

Is swing brake
release valve
faulty?

Are broken pieces
of coupling present
when dust plug
under engine fly
wheel is removed?

Does not symptom
change when front
and rear pump
discharge hoses
are exchanged?

Is oil in hydraulic
tank within
standard level?

Does RH travel
function?

Cause

Remedy

Safety valve faulty
or not operated.

Gear pump faulty.

Pump connection
coupling is broken.

Hydraulic pump is
out of order.

Swing control valve
spool is stuck.

Hydraulic pump is
broken.

Swing brake
release valve is
broken.

Swing reduction
unit is broken.

Swing motor is
broken.

Pilot relief valve is
faulty.

Gear pump is out
of order.

Pilot valve is
broken.

Replenish
specified oil to the
standard level.
Repair or replace.

Repair or replace.

Disassemble and
repair.

Disassemble and
repair or replace.

Disassemble and
repair.

Clean pilot piping
interior or repair
piping.
Disassemble and
repair.

Is not main relief
valve faulty?

Does swing
control valve
spool move
lightly by hand?

Does swing
motor rotate?

Is gear pump
delivering oil?

Is not there oil
leakage from
pilot piping or is
not it clogged?

Is gear pump pilot
pressure within
standard level?

YES

6 - 10

SWING SPEED IS LOW

Is the trouble in
one direction or
in both direction?

Clogged or oil
leak.

YES

Does swing control
valve spool move
smoothly by hand?

Is not pilot piping
clogged or is not
it leaking oil?

Is MCV pilot
pressure within
standard level?

Is gear pump pilot
pressure within
standard level?

Is swing motor's
drain rate within
standard value?

YES

Is MCV pilot
pressure same
on LH and RH
sides?

Is Arm speed

within standard
value?

Cause

Remedy

Swing port relief
valve is faulty.

Swing control valve
spool is stuck.

Pilot valve or shuttle
valve is faulty.

Swing control valve
spool is stuck.

Swing motor is
broken.

Pilot valve or
shuttle valve is
faulty.

Pilot relief valve
is defective.

Gear pump is
broken.

Main relief valve
faulty.

Hydraulic pump
is broken.

Shuttle valve is
faulty.

Pilot relief valve
is faulty.

Gear pump is
faulty.

Disassemble and
repair or replace.

Disassemble
and repair.

Clean pilot piping
interior or repair
piping.

Disassemble
and repair.

Clean pilot piping
interior or repair
piping.

Disassemble and
repair or replace.

Disassemble
and repair.

Main relief valve
pressure resetting
or repair.

Disassemble
and repair.

Repair or replace.

Check that pilot
piping is not
clogged or oil is
not leaking from
it?

Clogged or oil leak.

Is gear pump
delivering oil?

Does the symptom
change when front
and rear pump
discharge hoses
are exchanged?

Is gear pump
output pressure
within standard
level?

Is safety valve
pilot pressure
within standard
level?

Both directions

Single direction

Is main relief valve
setting pressure
normal?

YES

Does swing
control valve
spool move
lightly by hand?

YES

6 - 11

YES

Is MCV pilot
pressure same
for LH and RH?

Clogged or oil
leak.

Check if pilot
piping is not
clogged or does
not have oil
leakage.

Does swing control
valve spool move
smoothly by hand?

Does symptom
change when LH
and RH port relief
valves are
exchanged?

SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION

Is swing control
valve's return
spring normal?

Is gear pump pilot
pressure within
standard level?

Does swing control
valve spool move
smoothly by hand?

Is MCV pilot
pressure within
standard value?

MACHINE SWINGS BUT DOES NOT STOP

Pilot relief valve is
faulty.

Gear pump is
broken.

Pilot valve is faulty.

Swing control
valve spool is
stuck.
Return spring is
faulty.

Disassemble and
repair or replace.

Disassemble and
repair.

Disassemble and
replace.

Swing port relief
valve is faulty.

Shuttle valve is
faulty.

Swing control valve
spool is stuck.

Pilot valve is faulty.

Disassemble and
repair.

Clean pilot piping
interior or repair
piping.

Cause

Remedy

Cause

Remedy

6 - 12

YES

Is return spring
of swing control
valve normal?

Is brake spring
normal?

Is swing shuttle
valve normal?

Is drain rate of
swing motor
within standard
value?

THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE

Is swing relief
pressure within
standard level?

Shuttle valve is
faulty.

Brake spring is
faulty.

Return spring of
swing control
valve is faulty.

Swing relief valve
is faulty.

Swing motor is
broken.

Disassemble
and replace.

Disassemble
and repair or
replace.
Disassemble
and repair.

Adjust swing
relief valve
pressure or
replace swing
relief valve.

Cause

Remedy

6 - 13

YES

Is bucket or arm
operation
possible?

Does counterbalance
spool in travel
brake valve move
lightly by hand?

Does the symptom
change when
relief valves in
travel motor are
exchanged?

Has travel
control valve
spool changed
over positively?

Does the symptom
change when front
and rear pump
discharge hoses
are exchanged?

Is travel brake
valve pressure
within standard
level?

Does spool move
lightly by hand?

Counter spool in
travel brake valve
is stuck.

Relief valve built
in travel motor is
faulty.

Control system is
defective.

Travel control
valve spool is
stuck.

Travel reduction
unit is faulty.

Travel motor is
out of order.

Hydraulic pump is
broken.

Travel relief
valves are faulty.

Disassemble
and repair or
replace.

Disassemble
and repair.

Disassemble
inspect and
repair.

Disassemble
and repair.

Disassemble
and repair or
replace.

5. TRAVEL SYSTEM

TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE

Do not metallic
particles come
out of drain port
in travel
reduction unit?

Cause

Remedy

Does the
symptom change
when LH/RH
travel relief valves
are exchanged?

YES

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