Service Training

Crawler Excavator
Dash 7 & 7A

1
I. Specification Comparisions

2
R140-7
Hyundai Komastu CAT Hitachi
Unit
R140-7 PC130-6 312C ZX120

Oper. Weight Kg 13980 13050 12200 12200

Power, SAE net HP/rpm 102/2100 86/2200
DIN net PS 103/2100 87/2200 91/1950 85/2100
Bucket PCSA cu m 0.58 0.5 0.5
CECE cu m 0.5 0.45 0.45

Engine Cummins Komatsu CAT Isuzu

Model B3.9-C S4D102E 3064-E1T CC-4BG1TC
Cyl*Bore*Stroke mm 4*102*120 4*102*120
Displacement cc 3920 3920 4250 4329
Max. torque Kgf.m/rpm 46.2/1500

Hydraulic pump LPM 2*130 1*226

Oper. Pressure
Attachment 330 325 305 350
Power boost Kg/cm2 360 - - -
Travel 330 325 350
Swing 240 275

Swing speed rpm 13.6 12.0 12.9 13.7

Travel speed Km/h 3.3/5.5 2.7/3.6/5.5 3.8/5.5 3.4/5.5

Standard machine
Boom m 4600 4600 4650
Arm m 2500 2500 2500 2000
Track shoe width mm 600 500 500 500
Track gauge mm 2000 1960 1990 1990
Tumbler distance mm 3000 2750 2780

Ground pressure kg/cm2 0.36 0.41 0.4 0.38

Max traction force ton 13.3 10.2 11.0
Bucket digging force,SAE ton 9.27 8.5
Arm crawd force,SAE ton 9.27 8.5

Fuel tank liter 270 230 250 250

3
R160LC-7
Hyundai Komastu CAT Hitachi
Unit
R160LC-7 PC160-6 315C ZX160LC

Oper. Weight Kg 17400 16530 16000 15600

Power, SAE net HP/rpm 116/2100 104.5/2100 - -
DIN net PS 118/2100 106/2100 111/2150 100/1950
Bucket PCSA cu m 0.70 0.58 0.65 0.6
CECE cu m 0.60 0.53 0.55 0.55

Engine Mitsubishi Komatsu CAT Isuzu

Model S6S-DT SA4D102E 3046-E3DT A-4BG1TC
Cyl*Bore*Stroke mm 4*94*1200 4*102*120 - -
Displacement cc 4996 3920 4990 4329
Max. torque Kgf.m/rpm 42.5/1500 - - -

Hydraulic pump LPM 2*168 276

Oper. Pressure
Attachment 330 325 350 350
Power boost Kg/cm2 360 355 - -
Travel 330 355 350
Swing 240 325

Swing speed rpm 12.1 12.0 10.2 13.6

Travel speed Km/h 3.7/5.6 2.7/4.0/5.5 3.4/5.6 3.1/5.3

Standard machine
Boom m 5100 5150 5100 5100
Arm m 2600 2600 2600 2580
Track shoe width mm 600 600 500 500
Track gauge mm 1990 1990 1990 1990
Tumbler distance mm 3190 2880 2880 3100

Ground pressure kg/cm2 0.42 0.44 0.51 0.46

Max traction force ton 15.7 13.8 - -
Bucket digging force,SAE ton 12.08 12.54 - 9.2
Arm crawd force,SAE ton 8.35 8.393 - 8.1

Fuel tank liter 260 250 285 280

4
R210LC-7
Hyundai Komastu CAT Hitachi
Unit
R210LC-7 PC210-6 320B EX200-5

Oper. Weight Kg 21700 21570 20518 18800

Power, SAE net HP/rpm 143/2100 133/2200 128/1800 133/1950
DIN net PS 145/2100 130/1800 135/1950
Bucket PCSA cu m 0.92 0.86 0.80 0.80
CECE cu m 0.8 0.70 0.70

Engine Cummins Komatsu CAT Isuzu

Model B5.9-C S6D102E 3116T A-6BG1T
Cyl*Bore*Stroke mm 6*102*120 6*102*120 6*105*127 6*105*125
Displacement cc 5880 5880 6600 6494
Max. torque Kgf.m/rpm 62.0/1600 47/1600

Hydraulic pump LPM 2*220 2*206 2*180 2*185

Oper. Pressure
Attachment 330 325 350 350
Power boost Kg/cm2 360 355 - 370
Travel 330 355 350 350
Swing 240 280 235

Swing speed rpm 12.5 12.4 10.7 13.9

Travel speed Km/h 3.4/5.3 3.2/4.5/5.5 3.4/5.5 3.8/5.5

Standard machine
Boom m 5880 5700 5680 5680
Arm m 2920 2930 2900 2910
Track shoe width mm 600 600 600 600
Track gauge mm 2390 2380 2200 2200
Tumbler distance mm 3650 3640 3265 3370

Ground pressure kg/cm2 0.46 0.45 0.48 0.43

Max traction force ton 21.1 17.7 18.1 17.3
Bucket digging force,SAE ton 14.84 15.0 13.5 12.2
Arm crawd force,SAE ton 10.8 10.1 10.1

Fuel tank liter 320 340 340 310

5
R290LC-7A
Hyundai CAT Komatsu Hitachi
Unit
R290LC-7A 325CL PC290LC-7 ZX270LC

Oper. Weight Kg 29300 27900 28130 27500

Power, SAE net HP/rpm 197/1900 - 179/2050 168/2050
DIN net PS 200/1900 190/1800 182/2050 168/2050
Bucket PCSA cu m 1.27 1.2 1.16 1.1
CECE cu m 1.10 1.1 1.04 1.0

Engine Cummins CAT Komatsu Isuzu

Model QSB6.7 3126B-JE2-TAA SAA6D102E-2 CC-6BG1T
Cyl*Bore*Stroke mm 6*104*132 6*110*127 6*102*120 6*105*125
Displacement cc 6700 7200 5880 6494
Max. torque Kgf.m/rpm 96.8/1400 65/1800

Hydraulic pump LPM 2*252 2*235 2*225 2*209

Oper. Pressure
Attachment 330 350 - 350
Power boost Kg/cm2 360 - 380 370
Travel 330 350 380 355
Swing 265 280 290 282

Swing speed rpm 10.2 10.2 10.5 10.6

Travel speed Km/h 3.1/5.2 3.3/5.3 3.0/4.1/5.5 2.9/4.9

Standard machine
Boom m 6250 6200 5850 6000
Arm m 3050 3000 3000 3100
Track shoe width mm 600 700 600 600
Track gauge mm 2600 2590 2590 2590
Tumbler distance mm 4030 3800 3700 4050

Ground pressure kg/cm2 0.56 0.49 0.58 0.53

Max traction force ton 27.3 24.07 25.4 25.1
Bucket digging force,SAE ton 18.76 - 20.2 17.0
Arm crawd force,SAE ton 13.75 - 15.1 11.8

Fuel tank liter 480 500 400 380

6
R360LC-7A
Hyundai Komatsu Hitachi Volvo
Unit
R360LC-7A PC350LC-7E0 ZAXIS380HH EC360BLC

Oper. Weight Kg 36100 33400 37800 36500

Power, SAE net HP/rpm 271/1850 247/1950 247/2000 247/1700
DIN net PS 275/1850 250/1950 250/2000 250/1700
Bucket PCSA cu m 1.62 1.4 1.5 1.61
CECE cu m 1.4 1.2 1.3 1.4

Engine Cummins CAT Komatsu Volvo

Model QSL SAA6D114E-3 AA-6HK1X D10BEAE2
Cyl*Bore*Stroke mm 6*114*144.5 6*114*135 6*115*125 6*121*140
Displacement cc 8900 8270 7790 9600
Max. torque Kgf.m/rpm 138.3/1400 - 89/1700 128/1400

Hydraulic pump LPM 2*290 2*268 2*290 2*280

Oper. Pressure
Attachment 330 355 320 320
Power boost Kg/cm2 360 380 350 350
Travel 335 380 350 350
Swing 260 285 320 260

Swing speed rpm 9.1 9.5 11.8 9.7

Travel speed Km/h 3.2/4.5 3.2/4.5/5.5 3.2/5.3 3.3/4.5

Standard machine
Boom m 6500 6500 6400 6450
Arm m 3200 3200 3200 3200
Track shoe width mm 600 600 600 600
Track gauge mm 2740 2590 2590 2740
Tumbler distance mm 4340 4030 3730 4240

Ground pressure kg/cm2 0.64 0.64 0.77 0.67

Max traction force ton 31.0 26.9 29.1 26.3
Bucket digging force,SAE ton 22.36 - 20.8 21.5
Arm crawd force,SAE ton 16.91 - 17.3 17.7

Fuel tank liter 520 605 560 620

7
R500LC-7A
Hyundai CAT Komatsu Hitachi
Unit
R500LC-7A 345BLⅡ PC450LC-7 ZX450LC

Oper. Weight Kg 48800 45250 44600 44800

Power, SAE net HP/rpm 321/1900 - - 307/1700
DIN net PS 325/1900 325/2000 335/1850 313/1700
Bucket PCSA cu m 2.15 2.0 1.9 2.07
CECE cu m 1.92 1.7 1.7 1.8

Engine Cummins CAT Komatsu Isuzu

Model QSM11-C 3176CATAAC SA6D125E AA-6WG1TQA
Cyl*Bore*Stroke mm 6*125*147 6*125*140 - 6*147*154
Displacement cc 10800 10300 11045 15681
Max. torque Kgf.m/rpm 170.6/1400 - - 130/1500

Hydraulic pump LPM 2*380 2*360 - 2*360

Oper. Pressure
Attachment 330 350 355 310
Power boost Kg/cm2 360 - - 325
Travel 345 350 380 350
Swing 285 320 - 285

Swing speed rpm 9.0 8.6 9.0 9.0

Travel speed Km/h 3.2/5.0 3.6/4.4 3.0/4.4/5.5 3.4/5.5

Standard machine
Boom m 7060 6900 7000 7000
Arm m 3380 3350 3400 3400
Track shoe width mm 600 750 600 600
Track gauge(Trans./Working) mm 2940/2380 2890/2390 2890/2390 2890/2390
Tumbler distance mm 4470 4340 4350 4470

Ground pressure kg/cm2 0.84 0.64 0.8 0.81

Max traction force ton 38.5 33.75 - 32.5
Bucket digging force,SAE ton 28.15 - - 23.8
Arm crawd force,SAE ton 21.38 - - 19.8

Fuel tank liter 610 720 650 650

8
Ⅱ.Hydraulic System

9
1.Outline of Hyd. System: the equipment to transmit the power by oil flow

-Characteristic of hydraulic oil : incompressible, automatic lubrication, less friction loss,

higher
cooling efficiency, more safety for overload, silent operation, precise control

Hydraulic Tank

Actuator Hydraulic Pump

Control Valve

-Hydraulic Tank : Oil Storage

-Hyd. Pump : Create oil flow to transmit the power
-Control Valve : Direction control of actuator
-Actuator : Working device such as cylinder, motor and etc
Cylinder - Inline movement
Motor – Rotating movement

10
2.Hydraulic Symbol

Component Symbol Explanation

Pipe or hose Color code

-Main line -Supply line : red
-Return line : blue
-Suction line : green
-Pilot line -Pilot line : brown
-Drain or internal leakage -Drain or internal leakage line : green

Line connected each other : Tee joint or

drilled hole

Line cross over without connection

Line closed or plugged for future usage

or special purpose

Orifice Reduced diameter of oil passage to

reduce oil flow

Adjustable orifice Adjustable or variable)

11
 Component Symbol Explanation

Shut off valve

Check valve Direction controlling device to prevent

-Without spring reverse flow

-With spring

-Pilot check valve One check valve & pilot line in one block

Hyd. tank Hyd. oil storage

Filter Filtering all the dirt in hydraulic system

Cooler Exhaust the heat of hyd. oil

Breather Maintain the pressure inside of hydraulic

tank same as atmospheric pressure

12
 Component Symbol Explanation

Hydraulic pump -One direction

-fixed flow pump -Both direction, depending on rotation of
pump

Discharge amount of pump are flexible

-Variable flow pump depending on the pressure at actuator
such as cylinder and motor

Cylinder -Double acting : retract and extend by

direction of oil supply
-Single acting : retract by weight and
extend by oil supply

Pressure control valve Safety device to protect hyd. component

-Relief valve such as hose,pipe,cylinder and etc
When the hyd. system overloaded, relief
valve is open and circuit oil go to the tank
through opened passage

-Regulating valve
Maintain the required pressure all the time
to activate system for transmission clutch
and etc. by increasing decreasing the size
of overflow passage

13
 Component Symbol Explanation

-Reducing valve It is used for low pressure circuit.

When the supplied pressure reach to
required value, supplied oil is cut off

Direction valve For double acting

-2 way
For single acting

Double acting
-3 way

Controlling method of direction control

valve

Hand control lever

Foot control pedal

14
 Component Symbol Explanation

Button control

Hydraulic control by pilot pressure

Electro-magnet control by electricity

Automatic return control by spring tension

Control valve is fixed with selected

direction
N : neutral position

Motor Rotating device

-Reversible motor
-Irreversible motor : rotate one direction
only

Pressure switch

15
 Component Symbol Explanation

Heater

Accumulator

Brake and clutch Applied by spring force

Released by hydraulic pressure

Shuttle valve Two check valve in one block

Oil flow achieved by pressure difference
between left & light hand side

Logic valve Is combined with piston and orifice

Area difference operates direction control
valve

16
Hydraulic Circuit
Main Circuit

17
Pilot System

18
Pilot Circuit (Crawler Type)

R140LC-7A/R160LC-7A/R180LC-7A

R210LC-7A/R250LC-7A

R290LC-7A

R450LC-7A/R500LC-7A 19
20
 Pilot Pressure Requirements

Type : Double Switch Semi Long

Primary Pressure : 500 psi
Secondary Pressure : 92 to 370 psi
Line Filters located at Both Hand and
foot RCV Supply ports.

21
 Pilot Solenoid Block

Pilot Solenoid Block

R140LC-7A/R160LC-7A/R180LC-7A

R210LC-7A/R250LC-7A

R290LC-7A

R450LC-7A/R500LC-7A 22
 Pilot Safety Valve Activation

R140LC-7A/R160LC-7A/R180LC-7A

R210LC-7A/R250LC-7A

R290LC-7A

R450LC-7A/R500LC-7A 23
 Pilot to Main Pump (EPPR)

R140LC-7A/R160LC-7A/R180LC-7A

R210LC-7A/R250LC-7A

R290LC-7A

R450LC-7A/R500LC-7A 24
 Pilot to MCV ( Auto Decel)

Pilot Solenoid Valve Block

Connection on MCV
R140LC-7A/R160LC-7A/R180LC-7A

R210LC-7A/R250LC-7A

R290LC-7A

R450LC-7A/R500LC-7A 25
 Pilot to Swing Holding Brake
(Time Delay Valve)

R140LC-7A/R160LC-7A/R180LC-7A

R210LC-7A/R250LC-7A

R290LC-7A

R450LC-7A/R500LC-7A
26
 R290LC-7A
Remote Control Valve

 Big spring : S2
 Small spring : S1

S
1

F
2
F
D1
1

D2
D1> D2,
( F1> F2)

S1 = F1- F2

 For keeping the balance between the spring force and the force( F1- F2) : S1 = F1- F2

27
 R290LC-7A
Remote Control Pedal

28
 R290LC-7A
Pilot Circuit

29
Operated Position R290LC-7A

30
 R290LC-7A
Turning Joint

31
Oil Return Circuit

Return Pressure (Bar)

Model

Oil Cooler By-pass

R450LC-7 3 5

R360LC-7 3 5

R320LC-7
3 5
R200W-7

R290LC-7A 1.5 3

R210LC-7 3 5

R180LC-7 1.5 3

R140LC-7 1.5 3

R210LC-7A Hydraulic Oil Return Circuit

32
Main Control Valve (MCV)

33
Hanil-MCV R110/140/160/180LC-7
Trav alarm PS FRONT VIEW BACK VIEW
Arm Holding TRAVEL Straight Travel
Valve (AHV) RIGHT Valve (TS) Work PS CD7
Signal to (NO, auto decel)
open v/v
Pc41 TRAVEL
LEFT
SWING Main Relief
Valve PO (PILOT
RETURN
BOOM 1 OIL
Drain3 BOOM2 ENTRANCE
)
ARM1 ARM2 Signal to
open v/v P1 (OUTER
OPTION A Pb21 PUMP)
DOZER
(1 side) P2 (ENG
Option PS 37 Power
BUCKET SIDE
(NO, auto decel) Boost
OPTION C PUMP)
SEC. Signal
RELIEF
V/V BM

relief valve option A

NEGATIVE Regen. Command Sign location
SEC. Drain1
RELIEF Pc42 (From Arm-In)
RELIEF ARM Regen. Cut Sign Pb4
VALVE 2 Swing
V/V BUCK REGENERATION
chek v/v ‘s prior sig
MR
SEC.
RELIEF SEC.
V/V BUCK RELIEF
V/V BOOM
Neg Control Sig
Pn2
OPTION Boom Holding TRAV
ARM2
PORT Valve (BHV) BUCKET BOOM1 LEFT
DRAIN Drain0
SWING
PORT
DOZER ARM1 SWING
Drain2 OPTION C SWING TRAV Straight
PRIORITY
(Sw Prior & RIGHT Trav V/V
Neg Control Sig Boom2)
Pn1
SEC.
RELIEF
V/V ARM
NEGATIVE
RELIEF
VALVE 1

BOTTOM VIEW
34
 TRAVEL R110/140/160/180LC-7
LEFT

Orifice

BOOM 1
Lb1
Lb2

ARM2

OPTION
(1 side) EXTRA A (OPTION)
BUCKET Power
& ARM
boost
REGENERATION

L01
K1

K1
Zm
Qr
Regeneration
Zm K3

K4
Lb1 L01

OPTION K3
PLUG
DRAIN PORT K4
SWING
PLUG
PORT

Lb2

35
 DOZER OPTION
(EXTRA B) (EXTRA C)

OPTION
ARM1
BOOM2
BOOM2
ARM1 &
SWING SWING SWING
PRIORITY
TRAVEL
DOZER
RIGHT
STRAIGHT
TRAVEL

Qr
(REGENERATION)

Q1
Q2 (SUMM)
V3 PLUG
Q2 summation
line for arm
(arm 2)
PO (PILOT OIL
ENTRANCE)

Ks
PLUGS

Q1
p 2-25
Ks
p 2-23

PLUG

36
 R110/140/160/180LC-7

ARM
1 CYL
10 11
15
9

ARM1 ARM2

13
2 7

BOOM2 BOOM1
(OPT)

14
BOOM
HOLDING
BUCKET VAVLE
TANK

SWING

17

TRAVEL LEFT OPTION

8
6

STRAIGHT
3 4
TRAV V/V

12 TRAVEL RIGHT

Hydraulic Schematic

16

Pilot Press 37
 MCV
BOOM UP
OPTION

DOZER BUCKET

ARM 1
ARM
REGENERATION

BOOM 2 ARM 2
B2
A2
Pb21
DR1
Pb20
Pa20
SWING BOOM 1

TRAVEL (RH) TRAVEL (LH)

Tank
T1

From Solenoid Valve

P2 Pump
38
P1 Pump
 MCV

BOOM DOWN
BOOM DOWN
OPTION

DOZER BUCKET

ARM 1
ARM
REGENERATION

BOOM 2 ARM 2
B2
A2
Pb21
DR1
Pb20
Pa20
SWING BOOM 1

Pb1
Pa1

TRAVEL (RH)
Pump 1 TRAVEL (LH)

Tank PO
T1
Pz
From Solenoid Valve

39
P1 Pump
BOOM DOWN
REGENERATION

Pump 1

40
 MCV

BUCKET ROLL IN
OPTION

B5

Pb5

DOZER BUCKET

A2
ARM 1
ARM
REGENERATION

BOOM 2 ARM 2

SWING BOOM 1

TRAVEL (RH) TRAVEL (LH)

Tank PO
T1

From Solenoid Valve

41
P1 Pump
ARM IN
ARM IN
OPTION

DOZER BUCKET

C4

D4 DR3
Pc41 Pb4
Pc40
Pa4

ARM 1 Pc42
ARM
REGENERATION
Pb3

BOOM 2 ARM 2

SWING BOOM 1

TRAVEL (RH) TRAVEL (LH)

Tank
T1

From Solenoid Valve MCV

P2 Pump P1 Pump
42
ARM OUT
OPTION

DOZER BUCKET

C4

D4 DR3

Pd40

ARM 1
ARM
REGENERATION

Pd41

BOOM 2 ARM 2

SWING BOOM 1

TRAVEL (RH) TRAVEL (LH)

Tank
T1

From Solenoid Valve MCV

P2 Pump P1 Pump
43
 MCV
BOOM UP
OPTION

DOZER BUCKET

ARM 1
ARM
REGENERATION

BOOM 2 ARM 2
B2
A2
Pb21
DR1
Pb20
Pa20
SWING BOOM 1

TRAVEL (RH) TRAVEL (LH)

Tank
T1

From Solenoid Valve

P2 Pump
44
P1 Pump
 R210LC-7

4-2.Main Control Valve(kawasaki)

45
 R210LC-7

Side view Upper view

46
 R210LC-7

Side view Upper view

47
 R210LC-7

Bottom view Side view

48
 R210LC-7

RH

LH
49
Foot Relief Valve R210LC-7,R290LC-7A

50
R210LC-7,R290LC-7A

51
Arm-In Operation ( Regeneration)

-Improve arm-in speed

-Prevent arm cylinder cavitation

R210LC-7A Hydraulic Schematic

52
R290LC-7A

53

Qr Gp
saf v/v
BUCKET
OPTION
Pd4o
ARM1 ARM REGEN.
& EXTRA A
K1
ARM2
BOOM2
saf v/v
BOOM1
SWING
Pa2o
TRAVEL
RIGHT TRAVEL
LEFT
STRAIGHT
TRAV V/V

R290LC
-7A
 54
R290LC-7A, Hanil

LEFT BLOCK
VIEW A (BOTTOM)
ARM REGEN.
& EXTRA A
Boom Holding
Valve (BHV) NEGATIVE
BUCKET RELIEF
VALVE 1
Pb21
SEC REL
V/V ‘s
BOOM1
Dr1 TRAVEL
ARM2 LEFT
Main Relief
SEC REL Valve
V/V ‘s ARM
REGENERATION
travel ps CD6
(auto dec)
work ps CD7
NEGATIVE (auto dec) Qr (regeneration)
RELIEF ARM:
VALVE 2
Power (parallel feed)
Boost Q1
Signal
Pilot 02 Q2 (summ)
chek v/v ‘s
(+ORIFICE (A/D))
MR
Pn2
Pn1
Option RIGHT LEFT
port B4
MCV
BLOCK
Swing
drain
load check v/v buck
line
Parallel passage
Center passage MACHINE
DIRECTION
VIEW A (BOTTOM)
Ck2
(bucket summ line)
 55

RIGHT BLOCK
Arm Holding Pc41
Valve (AHV)
Dr3
STRAIGHT
CENTER BY TRAV V/V
PASS Gp
TRAVEL
RIGHT
SWING
BOOM2
ARM1
SEC REL
OPTION
V/V ‘s SWING
PRIORITY
Pilot 01
(+ORIFICE (A/D))
VIEW B (BOTTOM)
Ck1
VIEW B (BOTTOM)
RIGHT LEFT
SEC REL
V/V ‘s
MCV
BLOCK
MACHINE
(cap on swing
DIRECTION
priorrity)
 56

RIGHT BLOCK, VIEW K

TRAVEL RIGHT PORTS
SWING PORTS
ARM1 PORTS
OPTION PORTS
RIGHT LEFT
VIEW K
MCV
BLOCK
MACHINE
DIRECTION
MCV R140LC-7, TOSHIBA

FRONT TOP VIEW

STRAIGHT Bucket Summation Line
Main Relief Valve (12)
Bucket TRAVEL
Summation VALVE (3) TRAVEL
Check Valve LEFT SWING TOP VIEW
BOOM 2 ARM 1
(Ck2)
PRV
TRAVEL
RIGHT OPTION BUCKET Power
F1 signal (Fl)
Boost
BOOM 1 Signal
ARM 2
FOOT RELIEF
VALVE (10)

PRV PRV
XAk2
FOOT RELIEF
VALVE (11)
Ck1

Drain Px Py
F2 signal (Fr) Arm Holding
Valve (9) auto decel
press switches Pilot Oil
Entrance

RETURN
Pa L LINE
signal

P1 P2
FLOW FLOW
SEMI PARALLEL
SPOOL (5)
Drain
(PRV = PORT RELIEF VALVE) auto decel
orifices (16)

R140LC-7A Toshiba Schematic

57
 LEFT VIEW

Center by pass
spool (1)

XAk2

LEFT BACK VIEW

BOTTOM VIEW
ARM 1

XBa1
PRV
stroke limiter (XAk2= summation bucket in signal)
SWING

signal (XAas)

PRV PRV

Priority
Check Straight Travel
Valve (6) Pilot Valve (4)

(PRV = PORT RELIEF VALVE)

Arm Regeneration
Valve (2) 58
 59

STRAIGHT
TRAV V/V
TRAVEL LEFT
BOOM2
SWING
ARM1
MAIN 12
RELIEF
SEC. RELIEF
VALVE
V/V
15
STRAIGHT RTAV
PILOT V/V 4
6
PRIORITY
CHECK
VALVE
ARM
HOLDING V/V FOOT 10
9 CENTER RELIEF
ARM BYPASS VALVE
HOLDING SPOOL 1
PILOT V/V
2
SEC. RELIEF
V/V 15
STROKE
(LEFT)

LIMITER
ARM1
SPOOL
 60

OPTION TRAVEL RIGHT

BUCKET
BOOM1
ARM2
17
SEC. RELIEF
BUCKET
V/V
13 14 SUMMATION
AUTO CHECK V/V
16
DECEL
ORIFICES
CHECK
8
VALVE
FOOT
RELIEF V/V
11
SEMI PARALEL
SPOOL
(CHECK V/V SPOOL)
5
BOOM
HOLDING V/V
SEC. RELIEF
V/V
13 14
BOOM
SUMMATION
CHECK V/V
7
(RIGHT)
MCV R360LC-7A

5 2
3

11

10

12
12

R360LC-7A Schematic
61
 RIGHT BLOCK R360LC-7A

3 BOOM PRIORITY
ORIFICE BOOM HOLDING 5
VALVE

SINGLE LOAD
SECUN. RELIEF V/V
CHECK V/V

DOUBLE LOAD
CHECK V/V

CENTER BY-
PASS V/V ASS

Orifices 12
Auto Decel FOOT RELIEF V/V
SECUN. RELIEF
V/V

PY
1
PX
BOOM RIGHT MIDDLE LEFT

Press Sw
BUCKET
Auto Decel MCV
BLOCK
TRAVEL
RIGHT

MACHINE
DIRECTION

62
 MIDDLE BLOCK R360LC-7A

2 LOGIC CHECK V/V

BUCKET
SUMMATION
CHECK VALVE
1 MAIN RELIEF V/V

STRAIGHT TRAVEL V/V 11

- ARM SUMMATION CHECK VALVE

9 10
- SEMII PARALLEL ORIFICE & CHECK
VALVE

63
 LEFT BLOCK R360LC-7A

SECUN. RELIEF V/V

ARM HOLDING VALVE 6

LOAD CHECK
V/V SW
SWING PRIORITY
ORIFICE 4

BOOM PRIORITY
V/V (ASS) 7

SWING
OPTION
ARM 12 DOUBLE LOAD
CHECK V/Vs
TRAVEL FOOT RELIEF V/V
LEFT SECUN. RELIEF CENTER BY-PASS
V/V V/V ASS

64
MCV R450/500LC-7A
F2 = F1 =

8 8
7 7

6 10

LEFT BLOCK RIGHT BLOCK

4
SIDE SIDE

( ) ( )
R500LC-7A Schematic P2 P1 (left pump) 65
 RIGHT + LEFT BLOCK R450/500LC-7A

B] STRUCTURE (1/3)
FOOT RELIEF V/V 8

FOOT RELIEF V/V 8

P1
T1
ARM REGEN. V/V
6

F1 (PS2) F2 (PS1)

DR1
RIGHT LEFT
P2
Pa11
MCV
BYPASS CUT SPOOL
T4 BLOCK
7

T3
BUCKET SUMM.
SIGN. MACHINE
BYPASS CUT SPOOL DIRECTION
7 66
 RIGHT BLOCK R450/500LC-7A

ARM 2
BOOM HOLDING VALVE 4
BUCKET
PC2
DR2
BOOM 1

TRAVEL
STRAIGHT
TRAVEL 2

CHECK V/V FOR

MAIN RELIEF VALVE

SUMMATION CHECK V/V

FOR BUCKET 9

SUMMATION CHECK V/V

FOR OPTION 10

67
 LEFT BLOCK R450/500LC-7A
ARM 1
PP (PILOT
PRESS) MAIN RELIEF SERVICE
1
VALVE
BOOM 2
PH (POWER
BOOST) SWING

TRAVEL
PA

Press Sw PT CHECK V/V FOR

Auto Decel MAIN RELIEF VALVE

ARM HOLDING VALVE

5

PC6 = SWING REDUCING SIGNAL

DR1 ORIFICE+ 3
SMALL LOAD CHECK V/V
DR3
PC1 68
Pressure Settings -7 & 7A

UNIT: BAR
110LC-7 140LC-7 160LC-7 180LC-7 210LC-7 250LC-7 290LC-7 320LC-7 360LC-7 450LC-7

*500LC-7

MAIN CONTROL MAIN RELIEF 330 330 330 330 330 330 330 330 330 330
VALVE POWER BOOST 360 360 360 360 360 360 360 360 360 360
PORT RELIEF 380 380 380 380 390 390 390 390 390 390
(arm, boom, bucket) *380
SWING MOTOR RELIEF PRESS 240 240 240 240 240 275 265 265 260 285
(measured on swing motor)
BRAKE RELEASE 33~50 30~50 20 20 33~50 33~50 29~32 26 30 20~50
TRAVEL MOTOR RELIEF PRESS 330 330 330 330 365 365 375 330 335 345
BRAKE RELEASE <9 6 6 6 6 6 16 16 9 17~50
PILOT PUMP RELIEF PRESS 35 35 35 35 35 35 35 35 35 33 - *35

Pressure Conversions
OVERLOAD RELIEF PRESSURES FOR LONG REACH MODELS: 6 Bar = 85 psi
9 Bar = 128 psi 270 Bar = 3840 psi
16 Bar = 227 psi 275 Bar = 3911 psi
MODEL ARM IN & OUT BUCKET IN & OUT 280 Bar = 3982 psi
17 Bar = 242 psi
20 Bar = 284 psi 330 Bar = 4694 psi
R210LC/LR-7 300 bar 280 bar 335 Bar = 4764 psi
26 Bar = 370 psi
29 Bar = 412 psi 345 Bar = 4907 psi
R290LC/LR-7 230 bar 270 bar 360 Bar = 5120 psi
30 Bar = 427 psi
32 Bar = 455 psi 365 Bar = 5191 psi
33 Bar = 469 psi 375 Bar = 5334 psi
35 Bar = 498 psi 380 Bar = 5405 psi
50 Bar = 711 psi 390 Bar = 5547 psi
230 Bar = 3271 psi
240 Bar = 3414 psi
260 Bar = 3698 psi
265 Bar = 3769 psi
69
Subject 1 : Only one attachment speed is slow

1.Problem : attachment speed is slow

2.Check & Measure : Only one attachment speed is slow

1) Condition : S Mode, max rpm

2) Test Items and Specifications

Pressure
Test result
Measuring Point Remedy (If not)
(Kg/㎠)
Pilot Main

40Kg/㎠ 330Kg/㎠
Boom
(569 psi) (4693 psi)
40Kg/㎠ 330Kg/㎠
Arm
(569 psi) (4693 psi)
Travel 40Kg/㎠ 330Kg/㎠
(569 psi) (4693 psi)
Deviation 40Kg/㎠ 330Kg/㎠
(569 psi) (4693 psi)

70
Measuring point for pilot pressure

※ How to measure
(1) disconnect Pilot Hose
(2) connect the disconnect
hose to Gauge “T” fitting
(3) start the engine

※ Test Items and Specifications

Pilot Pressure Test result

Attachment Remarks (If Not)
In Neutral Full (Kg/㎠)

Boom See RCV

40Kg/㎠
Arm 0Kg/㎠ See RCV
(569 psi)
Bucket See RCV

71
 Measuring point for main pressure

※ How to measure
1) disconnect pilot hose
2) connect the disconnect
hose to gauge “T” fitting
3) start the engine
Main
relief
※ Test Items and specifications

Relief Pressure
Remarks
Valve (Kg/㎠)

330/360Kg/㎠ Adjust if need

Main
(4694 / 5120 psi)
330/360Kg/㎠
Boom
(4694 / 5120 psi)
330/360Kg/㎠
Arm
(4694 / 5120 psi)
Bucket Arm
Bucket 330/360Kg/㎠ relief relief
(4694 / 5120 psi)
72
Subject 2 : All attachment speeds are slow
Pressure Conversions
6 Bar = 85 psi
1.Problem : All attachment speeds (Boom,Arm and Bucket) are 9 Bar = 128 psi 270 Bar = 3840 psi
275 Bar = 3911 psi
slow 16 Bar = 227 psi
17 Bar = 242 psi 280 Bar = 3982 psi
20 Bar = 284 psi 330 Bar = 4694 psi
2.Check & Measure : 26 Bar = 370 psi 335 Bar = 4764 psi
29 Bar = 412 psi 345 Bar = 4907 psi
30 Bar = 427 psi 360 Bar = 5120 psi
365 Bar = 5191 psi
1) Condition : H Mode, max rpm 32 Bar = 455 psi
33 Bar = 469 psi 375 Bar = 5334 psi
35 Bar = 498 psi 380 Bar = 5405 psi
390 Bar = 5547 psi
2) Pressure check of attachment 50 Bar = 711 psi
230 Bar = 3271 psi
240 Bar = 3414 psi
260 Bar = 3698 psi
265 Bar = 3769 psi

Kgf/㎠ - Bar

Swing +
R/H L/H Bucket Bucket Arm Boom
Swing L/H
Travel Travel out In In/Out Up
Travel
P1 330 150 250 170 330 320 320 220

fr 30/35 - - 150/35 3/35 70/35 70/35 150

P2 30 280 30 240 360 180 180 200

fl - - - 0/35 0/35 0/35 0/35 2

73
Cause

1)Abnormal result of pressure check : L/H travel, bucket out, arm in, boom up
2)Check the pressure for swing and L/H relief to find if the pump 2 oil flows to pump1.
As a result, it was found that pump 2 oil flows to pump1 side of main control valve
-bucket confluence check valve broken

4.Remedy

Replaced bucket confluence check valve Bucket confluence

check valve

Negative control signal

port

74
Main Pump

75
Pump assembly
View of Pump assembly Pi1=Neg. Control P1 P2 Pi
Pm1=Flow Cut Off
Connect to
Engine Regulator 1

M Regulator 2

Pi2=Neg. Control
Pm2=Flow Cut Off

EPPR Pressure

EPPR Valve
35 bar

P1 front P2 rear Pilot Pump

76
K3V series pump

Characteristic
1. High power density

2. High efficiency and

large self-priming capability

3. Long life

4. Low noise

5. Wide range of control

Type K3V63 K3V112 K3V140 K3V180 K3V280

Displacement 63 cm3 112 cm3 140 cm3 180 cm3 280 cm3

Rated 34.3 MPa (4975 psi)

Pressure
Peak 39.2 MPa (5685 psi)

Max. 2,650 min-1 2,360 min-1 2,150 min-1 1,950 min-1 1,600 min-1
Self-Priming ( 700 gpm) (623.44 gpm) (568 psi) (515 gpm) (422 gpm)
Speed
3,250 min-1 2,700 min-1 2,500 min-1 2,300 min-1 2,000 min-1
Max. (607 gpm) (528 gpm)
(858 gpm) (713 gpm) (660 gpm)

77
Structure of pump

Servo Piston Shoe Piston

Swash Plate

Gear Pump Ass`y

Support
Drive Shaft Cylinder Block Valve Plate

78
View & main components of pump

Support

Drive Shaft

Servo Piston
Shoe

Piston

Swash Plate

Cylinder Block

Valve Plate

79
View of regulator

The Portion of Horse Power Control

The Portion of Flow Control

80
 R210LC-7

Drain

Pf (EPPR)

Drain P1 P2

81
The Type and circuit of regulator

Y
X
① ① ⑤ ②
④

⑦
②
X Y
③ ⑥
⑥ ⑥ Section Y-Y
Section X-X

① ** ①~⑦ Regulator Parts Name **

① : Lever 1
③ ② : Lever 2
⑦ ③ : Compensator Piston
④ : Pilot Piston
⑤ : Adjust Screw(QMC)
⑥ : Feed Back Lever
⑥ ⑦ : Spool

④
②

82
Pump Regulation Schematic R290LC-7

83
Pump Regulating System

A. Opening of a spool in the Main Control Valve results in flow

increase of the pump, which supplies oil to the relevant spool.
This flow increase is accomplished by
pressure decrease in front of the foot relief valve.

= NEGATIVE CONTROL SYSTEM signals: Fl & Fr

B. The pump power changes, according to the selected mode on

the cluster (H, S, M, U) and work condition of the machine.
Therefore the CPU sets relevant currents towards the Electric
Proportional Pressure Reducing Valve (EPPR valve), which
establishes the pump power for P1 and P2.

= POWER SHIFT SYSTEM signal: PEPPR

C. If P1 or P2 pressure rises significantly, both pump flows will

be reduced, according to the Pressure-Flow diagram.

= TOTAL POWER CONTROL signal: P1 & P2

84
Regulating Circuit

FOOT RELIEF VALVE 1 FOOT RELIEF VALVE 1

Fl=NEG CONTROL SIGNAL Fr=NEG CONTROL SIGNAL

(0..30 bar) (0..30 bar)

Remark MODE SELECTION SPEED SENSOR

The Main Relief Valve (MR) limits the H, S, M, U
general working pressure to max. 330
bar & 360 bar for POWER BOOST.
This valve is situated on the MCV and
has 2 adjust screws. When the power
boost button (left joystick, on side) is
pushed, the MR opens at 360 bar CPU
instead of 330 bar (only 8 sec). This is
realised by an additional pilot signal at
the back of the MR. (Find more info in RPM
290-7MCV.pdf) SETTING

MR 210LC-7 EPPR Valve

Power Boost 35 bar
Signal

35
bar Power Boost PUMP POWER
Solenoid
SETTING
0...35 bar
85
Minimum flow Maximum flow

REGULATOR REGULATOR

max

86
Maximum flow

-When a machine is operating, oil is supplied to the actuator(cylinder or

motors) so that no oil pressure reaches piston A.
-Then, the piston B goes back to the neutral position by the spring and the
oil in the large chamber of the piston C is returned to the tank
-Now the oil is supplied to LH side of the cylinder C.
-That pressure moves the piston C to RH side, therefore the swash plate
is positioned at maximum flow angle during operation

87
Over Load Preventing Function (Minimizing)

-When a machine is under load or the cylinder arrives at

the end of stroke, the pressure is increased
Cylinder pressure > spring pressure (B + D)
The pressure is applied at the piston D and compresses
the spring D and B
So, the valve B moves to LH side and the oil enters the
piston C through the passage at piston B
The piston C moves the swash plate to reduce the angle
upon the angle upon the load of cylinder.

88
Flow Control

-When the engine is running, the swash plate moves to minimum angle
Minimum
flow position as per the following steps
1.the pressure is created by restriction of the foot relief valve
2.the pressure apply to the piston A
3.the piston A is moved to LH side
4.the valve B is opened
5.the pressure flows to the piston C
6.the piston C is moved to LH side. Therefore the swash plate is
positioned at minimum flow angle

89
Flow Reset Function (Maximizing)

-When the load at the cylinder is gone, the pressure

in
the cylinder and in the position D is decreased
Cylinder pressure < spring force (B+D)
Then, the oil in the cylinder C returns to the tank as
shown in figure, and the swash plate angle is
increased
to give maximum flow

90
Regulator: “Flow” Control System
When operating the excavator, the negative control pressure Fi inside regulator 1 or
2, drops, which results in displacement of the pilot piston and an increase of the
pump flow.
PILOT PISTON NEG CONTROL
ADJUST SCREW
PRESSURE PRESSURE PILOT SPRING
Pm=FLOW CUT OFF Fi=NEG CONTROL

STOPPER
Pm
PISTON Fi

FLOW

FLOW CUT-OFF MAX

ADJUST SCREW

FLOW CUT- OFF ACTIVATED (BREAKER mode) :

When selecting BREAKER mode on the cluster, the CPU activates the MAX FLOW
solenoid, which supplies pilot pressure to both regulators (= Pm signal). As a result,
the max. flows will be cut off.
NEG CONTROL PRESSURE fi

91
HYDRAULIC SYSTEM

92
 MAIN PUMP

40 to 45 kgf/cm2@HIGH IDLE
TO 40 to 45 kgf/cm2@HIGH IDLE
MCV

Pn1 Pn2

Pm1 Pm2

To solenoid valve
93
 Flow Control Signals

MAX FLOW CUT-OFF MAX FLOW CUT-OFF

SIGNAL for P1 SIGNAL for P2
(35 bar ON / 0 bar OFF) (35 bar ON / 0 bar OFF)

35 bar
NEG CONTROL
SIGNAL FOR
P1(0…40bar)

REAR PUMP FRONT PUMP

(P1) (P2)

NEG CONTROL
On –7 models: Max flow cut off Sig is “ON” after selecting BREAKER OPERATION SIGNAL FOR
MODE
On R210/250LC-3: Max flow cut off Sig automatically “ON” in L mode P2 (0…40bar)

94
Regulator: “Power” Control System
By changing the mode (H,S,M,U) the CPU varies the current towards the EPPR valve (Electric Proportional Pressure
Reducing Valve). This results in varying EPPR pressures, which work (together with P1 & P2 pressure) on the power
piston inside each regulator. The power piston & pilot piston are situated near each other and control the swash plate
angle.
In case of significant drop of engine speed, the CPU will automatically increase the current, in order to lower the pump
power and it will do this until the engine speed reaches the set-value again
REGULATOR 1 REGULATOR 2
PEPPR PEPPR
=
EPPR PRESSURE
P2 P1
0…35 bar P1 P2

SERVO PRESSURE OUPUT

35 bar
Power Piston
(Compensating
Piston)
REGULATOR 1

EPPR Valve = Pf (Power Shift ) Valve

REGULATOR 2

CURRENT
0…700 mA INPUT

24V CPUpin EPPR-

fuse
(or CPU pin EPPR+)
TABLE EPPR CURRENTS & PRESSURES
In case of faulty CPU: put machine in emergency
95
-When one of the power modes is selected during operation,
the EPPR valve pressure is applied at the piston D
The piston D compresses the spring and move the valve B to
LH side
Therefore, the pump oil enters to the piston C and reduces
the angle of the swash plate and oil delivery of the pump is
reduced.

96
97
Main Pump R450LC-7(~#463)
R450LC-7 VIEW PUMP ASSEMBLY VIEW REGULATORS

Pm = FLOW CUT OFF

F2 = NEG CONTROL

REG 2

PEPPR

Eppr valve DRAIN ( Pb = back press port: only on R450LC-7)

P2

Drain
P1
Pilot Pump

Pi

F1 F2

98
Main Pump R500LC-7 (& R450LC-7(#464~)
A. MAIN PUMP

F2 = NEG CONTROL Servo assist port (Pi)

Pi
Pm = FLOW CUT OFF
Eppr valve
PEPPR PEPPR

PEPPR

DRAIN P2
P1 F1 F2

PSUCTION
DIFFERENCES R500LC-7 versus R450LC-7
 adjustable undercarriage: see operating manual p. 5-11
B. PILOT PUMP
 bigger oil cooler & radiator
 Mounted on engine  different spools in MCV & different cyl.sizes:
 Max. press. setting with relief valve on pilot pump : 35 Bar R450LC-7 R500LC-7
 Check port near pilot line filter

(Full roller guard in option available)

99
Specification for EPPR Valve

Eng’ RPM Pump EPPR

Mode
Unload Load Current (mA) Pressure (Kg/㎠)
M 1950 1900 160 0
H 1850 1800 225 4.0 (58 psi)
S 1750 1700 225 4.0 (58 psi)
Auto Idle 1200 - 670 38 (551 psi)

4) Measuring Method of EPPR Pressure

By Cluster By Pressure Gauge

Gauge Port
100
Specification of Accel’ and ECM signal

※ Specification Table ※ How to find out

Accel’ Dial (dL) Signal to ECM (Po) By cluster
Step Signal M /rpm H /rpm S /rpm
1 1.9 0V/950 0V/950 0V/950
2 2.1 0.6/1120 0.6/1120 0.6/1120
3 2.2 0.8/1200 0.8/1200 0.8/1200
4 2.4 1.8/1500 1.6/1450 1.6/1450
5 2.6 2.1/1600 2.0/1560 1.8/1490
6 2.8 2.4/1700 2.1/1600 2.0/1560
7 2.9 2.6/1750 2.3/1650 2.1/1600
8 3.1 2.8/1810 2.4/1700 2.3/1650
9 3.2 3.0/1880 2.6/1750 2.4/1700
10 3.4 3.2/1950 2.9/1850 2.6/1750

•Note
1) If the engine rpm is below the desired engine rpm, the CPU controller will increase the
EPPR pressure to recover the engine rpm until the desired engine rpm is achieved.

101
 Measuring Point for Main Pressure

※ Specification Table Unit : Kg/㎠ (psi)

Attachment Pressure Remarks

330/360±10
Main Relief
(4694/5521±145)

Boom, Arm, 330/360±10

Bucket (4694/5521±145)

360±10
Travel
(5521±145)
265±10
Swing
(3843±145)

102
Fr & Fl pressure

※ How to measure
(1) disconnect Fr or Fl hose
(2) connect the disconnect hose to
gauge “T” Fitting
(3) start the engine

※ Specification Table

RCV Lever Test result Spec’ Remarks

In Neutral Below 38Kg/㎠ (551 psi)
In Full Below 5Kg/㎠ (72.5 psi)

103
Subject 2: Deviation for R290LC-7 travel

1.Problem : deviation for travel

2.Check & measure

1)Preparation
- Hyd’ Temp’ : above 50℃
- H Mode, Max rpm

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

3)Specifications

Test result Spec’

Attachment Remedy (If not)
RH LH (Second)
1 speed 35±2.0
2 speed 20±2.0

※ You can decide which one is slower and faster than spec’
104
 .Remedy

1)How to measure the Pressure

- Pull Travel lever fully
- Measure the travel pressure

2) Remedy according to the test result

105
Subject 3 : Pump cavitation

1.Problem :Cavitation occurs in the main pump

2.Check & Remedy:

1)Check if hydraulic tank is showing proper oil level =>Add oil to specified standard level
2)Check if viscosity of hydraulic oil is too high =>Replace oil with one of proper viscosity
3)Check if suction strainer clogged =>Clean suction strainer
4) Air is passing pump suction line =>Retighten Hose clamps or replace Suction hose
5)Check if reservoir breather is clogged =>Clean or replace reservoir breather
6)Check if the hose on pump inlet line collapsed or restricted=> Change hose clear any restrictions

106
Swing System

107
 R140LC-7
Swing Motor
View of Swing Motor

R140LC-7A Swing Hydraulic Circuit

108
 R210LC-7
All excavators have a similar swing device

SWING MOTOR R210LC-7

(ser. nr below E1938)

Reactionless valves

Relief valves

Time delay valve Remark:

PG HOSE
Greasing of the output shaft of swing
SH HOSE reduction is required each 1000 hrs !
109
Swing Circuit Operation R210LC-7

110
R290LC-7A

111
R290LC-7A

112
Swing Port Relief Valve R290LC-7A

113
 R290LC-7A

110bar

114
Releasing of Swing Brake
When operating the swing (SW), the joystick pressure (±5~20 bar) is applied on the MCV swing spool, and
at the same time on the “SH” port of the swing motor: this allows pilot oil (35 bar) to enter in the brake
section of the swing motor and shift up the swing Brake piston, resulting in releasing of the brake.

(±5~20 bar)

(35 bar)

SH
signal

SW left,
from joystick SW right,
to MCV

SW left,
to MCV

SW right,
from joystick

(R140LC-7)

Shuttle valve

115
Swing Brake (Neutral Position) R290LC-7A

116
Make Up Valve R290LC-7A

117
SWING RIGHT
NEUTRAL

SWING MOTOR OPTION

SH

PG
DOZER BUCKET
From Solenoid Valve

Orifice provides 5 second delay

DR

ARM 1
ARM
REGENERATION

A MU B BOOM 2 ARM 2

D2

D2

Pd2

SWING BOOM 1

TRAVEL (RH) TRAVEL (LH)

Tank
T1

From Solenoid Valve

MCV
118
P2 Pump P1 Pump
 Relief
Model Maker
Press

240
R140LC-7 Jeil/Sungbo
(3414 psi)

DongMyung/ 240
R180LC-7
Sungbo (3414 psi)

240
R210LC-7 Jeil/Sungbo
(3414 psi)

DongMyung/ 265
R290LC-7A
Sungbo (3843 psi)

DongMyung/ 265
R320LC-7
Sungbo (3843 psi)
260
R360LC-7A Jeil/Sungbo
(3771 psi)
285
R500LC-7A Toshiba
(4133 psi)

119
Subject 1: Both LH and RH swing actions are not possible
(1) Check hydraulic oil level
(2) Check gear pump pilot pressure
(3) Check safety solenoid valve pressure and function
(4)Check main relief valve pressure settings
(5) Check if swing control valve spool moves by hand
(6) Check swing brake release
(7) Check swing motor rotation and pilot valve

Subject 2 : Machine swings but does not stop

(1) Check the swing control valve return spring

(2) Check if swing control valve spool moves smoothly by hand
(3) Check if MCV pilot pressure is within standard value
(4) Check if the gear pump pilot pressure is within standard level

120
Travel System

121
 Relief
Model Maker Pressure
(bar)

R55-7 Jeil 220

R140LC-7 DongMyung 330

R180LC-7 DongMyung 330

R210LC-7A Jeil/Sungbo 330

R290LC-7A Jeil/Sungbo 330

R320LC-7A Jeil/Sungbo 330

R360LC-7A DongMyung 360

R500LC-7A Hydromatic 345

122
Tong Myung
R360LC-7A

123
-Relief valve press. 370 bar
-Automatic shift press. -
-Brake release press. -

124
Brake Valve R290LC-7A

125
Brake Valve (Accelerating Position) R290LC-7A

126
R450/500LC-7A

127
 R450/500LC-7A

Two Speed
T Control

>30-50Bar

>10Bar

>15Bar

Check
v/v(1)

Shuttle
Check v/v
v/v(2)
Selection
v/v
Relief Mb
Pressure V/V
Reducing
v/v
128
 R450/500LC-7A

Reducing
v/v

Speed
Control v/v Check
v/v(2)

Check
v/v(1)
129
 MCV
TRAVEL FORWARD
TRAVEL HIGH
FORWARD LOW SPEED
SPEED
RED RED OPTION

DOZER BUCKET

ARM 1
ARM
REGENERATION

VA VB VB VA
PK

BOOM 2 ARM 2
From Solenoid Valve

SWING BOOM 1

C1 B1
D1 A1
Pd1 Pa1

TRAVEL (RH) TRAVEL (LH)

Tank
T1

From Solenoid Valve

130
P2 Pump P1 Pump
 MCV
STRAIGHT
TRAVEL TRAVEL
FORWARD HIGH
SPEED
RED RED OPTION

DOZER
TRAVEL (RH) TRAVEL
BUCKET
(LH)

ARM 1
ARM
REGENERATION

VA VB VB VA
PK

BOOM 2 ARM 2
PO From Solenoid Valve

SWING BOOM 1

C1 B1
D1 A1
Pd1 Pa1

TRAVEL (RH) TRAVEL (LH)

Tank PO
P2 Pump T1

From Solenoid Valve

131
P2 Pump P1 Pump
Subject 1 :Travel does not function at all on one side
(1) Check if the travel control valve spool changed over positively
(2) Check if the symptom change when L/H,R/H travel relief valves are exchanged
(3) Check if the symptom change when front and rear pump discharge hoses are
exchanged => hydraulic pump is broken
(4) Check if metallic particles come out of drain port in travel reduction unit
(5) Check if travel brake valve pressure within standard level
(6) Check if counterbalance spool in travel brake valve move lightly by hand
(7) Check if the symptom changes when relief valves in travel motor are exchanged

132
 CAPO System
(Computer Aided Power Optomization)

133
 CAPO SYSTEM
5.1 SYSTEM DIAGRAM

CAPO =
The accel dial permits in
COMPUTER an easy way to set a
AIDED desired RPM in H, S & M
POWER mode.
OPTIMIZATION
In U mode (or MI, MII)
SYSTEM
however, the RPM is fixed.

H, S

M, U
(MI, MII) (Not R110LC-7)

134
 JOYSTICK BUTTONS

(No auto decel on R110LC-7)

 breaker activation for excavators with single breaker piping

135
 MONITORING SYSTEM
MONITOR
PANEL
Via select switch it is possible to show sequentially:
ALL MODEL -7 (NOT RPM / TIME / EPPR pressure / CPU model &
program version
R110LC-7)

Engine check lamp

(only if QSB, QSC, QSM-engine
installed)

User (& Fixed) Mode

OLD NEW
CLUSTER CONNECTOR WIRE COLOR
• MI •M
• MII •U

Brown
Black
Yellow
Blue

136
 CLUSTER CHECK PROCEDURE

(2) Start of
(1) Start key: ON
engine
If not, change cluster

137
 R110LC-7

2.B CLUSTER CHECK

PROCEDURE

138
EXCHANGE METHOD OF THE ROM

139
GENERAL (NOT R110LC-7) MODE SELECTION SYSTEM
First generation machines have 2 fixed power modes (H,S) and 2 user modes (MI, MII)
Second generation machines have 3 fixed power modes (M,H,S) and 1 user mode (U)
A. POWER & USER MODES Find at page 35 the table with RPM & EPPR values for H, S, (& M) modes

FIXED POWER MODES: H, S FIXED POWER MODES: H, S, M

- SECOND GENERATION MACHINES -

- FIRST GENERATION MACHINES -
H = High Power H = High Power
S = Standard Power S = Standard Power
M = Maximum Power

USER MODES: MI, MII USER MODE: U

These are 2 user modes ( = memory modes), There is 1 user mode ( = memory mode) which can be
which can be pre-set, regarding pump & engine pre-set, regarding pump & engine power (RPM)
power (RPM). Refer to page 42 for setting procedure. Refer to page 42 for setting procedure.

MI = User Mode I M
MII = User Mode II U U = User Mode

Note: For working in H, S or M mode, always make sure that the

User mode lamps are extinguished !!! ( otherwise the machine
B. WORK MODES: Heavy / General / Breaker continues to work in User mode)
HEAVY MODE : generates faster boom speed, but less swing speed in case of simultaneous use.  boom priority
see next page
GENERAL MODE : generates faster swing speed, but less boom speed in case of simultaneous use.  swing priority
Remark: * BM (SW) priority function is realized by switching ON/OFF of BM(SW) priority solenoid (CN133)
* On some machines this solenoid also activates or deactivates arm regeneration system via the
arm regeneration cut signal. See next page for more info.
BREAKER MODE: in this mode the flow of both pumps is limited by energizing the flow cut -off solenoid:
see p. 9 & 10 for precise information. 140
 BOOM PRIORITY SYSTEM (HEAVY MODE versus GENERAL MODE) (NOT R110LC-7)
- When selecting HEAVY work mode, the priority solenoid CN133 is either DE-energised, either Energized. (depends on machine type: see below)
Anyhow, boom (&arm) speed will be higher and the swing speed will be lower, when operating the work equipment simultaneously.
- There might be different signals, coming from this solenoid: In general mode, there’s no arm regeneration (sending oil from rod cyl.
1. Blocked, no signal R140 with Toshiba MCV side into large cyl. side of arm cyl.), due to the presence of the arm
2. BM or SW signal to priority valve in MCV R210<->R320 with Kawasaki MCV’s & R360,R450 regeneration cut signal (Pb4). This signal commands a specific valve on
3. Arm regeneration cut (cancel) signal R160,R180,R290 with Hanil MCV’s the MCV. At this time, the arm operates with normal (lower) arm speed.
4. Combination of (2. & 3.) R140 with Hanil MCV

R140LC-7 & R290LC-7 with Hanil MCV’s R210LC-7<->R320LC-7 In this case a pilotable restriction is placed in
with Kawasaki MCV’s the entrance line of the swing spool.
ARM1
BM, ARM

BM, ARM
BOOM2

SWING
PRIORITY
SWING VALVE
swing prior sig. SWING
R140LC-7 boom prior sig.
arm regen. (arm regen.
cut signal cut signal)
R140LC-7
R290LC-7

PRIORITY
PRIORITY BOOM
SOLENOID
SOLENOID
CN133
CN133
PRIORIT
35 PRIORITY 35 PRIORITY Y VALVE
bar SOLENOID bar SOLENOID
HEAVY OFF HEAVY ON
GENERAL ON GENERAL OFF
141
 RPM & EPPR SETTINGS FOR FIXED POWER MODES (1/9)
A] FOR EXCAVATORS WITH 2 FIXED POWER MODES (H, S) & 2 USER MODES (MI, MII)
Remarks
- When selecting H or S mode, make sure that MI, MII LEDS on the cluster are distinguished
- Make sure that accel dial is in MAX SPEED position, when checking RPM.
- Procedure for changing the program version 1.X <-> 2.X: see page 41.
- Tolerance for next values :

RPM  50
EPPR Current  30 mA
EPPR Pressure  3 bar
R140LC-7, ~#1000 (TIER I engine)
Mode Application Power shift by EPPR valve

Default (1.x) Other case (2.x)

RPM RPM EPPR RPM RPM EPPR
UNLOAD LOAD mA bar UNLOAD LOAD mA bar
H High Power 2350 2100 160 0 290 8
S Standard power 2200 2000 340 11 390 15
Auto decel Engine deceleration 1200 - 700 35 see left 700 35
One touch decel Engine quick deceleration 950 - 700 35 700 35
Key start Key switch start position 950 - 700 35 700 35
410 15 410 15
Emergency
(50 Ohm) (50 Ohm)

R140LC-7, #1001~ (TIER II engine)

Mode Application Power shift by EPPR valve

Default (5.x) Other case (6.x)

RPM RPM EPPR RPM RPM EPPR
UNLOAD LOAD mA bar UNLOAD LOAD mA bar

☜
H High Power 2250 2050 250 5 250 5
S Standard power 2100 1900 290 8 340 11
Auto decel Engine deceleration 1200 - 670 31 see left 670 31
TO EPPR
One touch decel Engine quick deceleration 850 - 670 31 670 31
Key start Key switch start position 850 - 670 31 670 31
valve
410 15 410 15
Emergency
(50 Ohm) (50 Ohm)
142
 (EXCAVATORS WITH 2 FIXED POWER MODES H, S
RPM & EPPR SETTINGS FOR & 2 USER MODES MI, MII
FIXED POWER MODES (2/9)
R210LC-7, ~#1000 (TIER I engine)
Mode Application Pow er shift by EPPR valve

Default (1.x) Other case (2.x)

RPM RPM EPPR RPM RPM EPPR
UNLOAD LOAD mA bar UNLOAD LOAD mA bar
H High Pow er 2300 2100 160 0 430 18
S Standard pow er 2150 2000 370 13 480 22
Auto decel Engine deceleration 1200 - 700 35 see left 700 35
One t ouch decel Engine quick deceleration 950 - 700 35 700 35
Key start Key sw itch start position 950 - 700 35 700 35
410 15 410 15
Emergency
(50 Ohm) (50 Ohm)

R210LC-7, #1001~ (TIER II engine)

Mode Application Pow er shift by EPPR valve

Default (5.x) Other case (6.x)

RPM RPM EPPR RPM RPM EPPR
UNLOAD LOAD mA bar UNLOAD LOAD mA bar
H High Pow er 2150 1950 185 2.5 2050 1850 220 4
S Standard pow er 2050 1850 290 8 1950 1750 260 6
Auto decel Engine deceleration 1200 - 600 31 1200 - 600 31
One t ouch decel Engine quick deceleration 1050 - 680 35 1050 - 680 35
Key start Key sw itch start position 1050 - 680 35 1050 - 680 35
440 19 440 19
Emergency

R250LC-7 (TIER II engine)

Mode Application Pow er shift by EPPR valve

Default (1.x) Other case (2.x)

RPM RPM EPPR RPM RPM EPPR
UNLOAD LOAD mA bar UNLOAD LOAD mA bar
H High Pow er 2250 2000 230 4 2150 1900 245 5 Tolerance
S Standard pow er 2150 1900 280 7 2050 1800 260 6 RPM  50
Auto decel Engine deceleration 1200 - 600 31 1200 - 600 31
One t ouch decel Engine quick deceleration 1050 - 700 35 1050 - 700 35
EPPR Current  30 mA
Key start Key sw itch start position 1050 - 700 35 1050 - 700 35 EPPR Pressure  3 bar
143
Emergency
 RPM & EPPR SETTINGS FOR FIXED POWER
MODES (3/9) (EXCAVATORS WITH 2 FIXED POWER MODES H, S
& 2 USER MODES MI, MII
R290LC-7, ~#0111 (TIER I engine)
Mode Application Pow er shift by EPPR valve

Default (1.x) Other case (2.x)

RPM RPM EPPR RPM RPM EPPR
UNLOAD LOAD mA bar UNLOAD LOAD mA bar
H High Pow er 2090 1900 300 9 270 7
S Standard pow er 1950 1800 340 11 210 3
Auto decel Engine deceleration 1200 - 700 35 see left 700 35
One t ouch decel Engine quick deceleration 800 - 700 35 700 35
Key start Key sw itch start position 800 - 700 35 700 35
440 17 440 17
Emergency
(45 Ohm) (45 Ohm)

R290LC-7, #0112~ (TIER II engine, QSB)

Mode Application Pow er shift by EPPR valve

Default (5.x) Other case (6.x)

RPM RPM EPPR RPM RPM EPPR
UNLOAD LOAD mA bar UNLOAD LOAD mA bar
H High Pow er 1950 1900 150 0 210 3
S Standard pow er 1850 1800 225 4 270 7
Auto decel Engine deceleration 1200 - 670 38 see left 670 38
One t ouch decel Engine quick deceleration 950 - 670 38 670 38
Key start Key sw itch start position 950 - 670 38 670 38
440 17 440 17
Emergency
(45 Ohm) (45 Ohm)

R320LC-7 (TIER II engine)

Mode Application Pow er shift by EPPR valve

Default (1.x) Other case (2.x)

RPM RPM EPPR RPM RPM EPPR
UNLOAD LOAD mA bar UNLOAD LOAD mA bar
H High Pow er 1960 1750 250 5 225 4
S Standard pow er 1850 1650 270 6 250 5
Tolerance
Auto decel Engine deceleration 1100 - 700 35 see left 700 35 RPM  50
One t ouch decel Engine quick deceleration 850 - 700 35 700 35 EPPR Current  30 mA
Key start Key sw itch start position 850 - 700 35 700 35
EPPR Pressure  3 bar
Emergency
410 15 410 15 144
( 50Ohm) ( 50Ohm)
 (EXCAVATORS WITH 2 FIXED POWER MODES H, S
& 2 USER MODES MI, MII
3) RPM & EPPR SETTINGS FOR FIXED POWER MODES (4/9)

R360LC-7 (TIER II engine)

Mode Application Pow er shift by EPPR valve

Default (1.x) Other case (2.x)

RPM RPM EPPR RPM RPM EPPR
UNLOAD LOAD mA bar UNLOAD LOAD mA bar
H High Pow er 1950 1900 230 4 160 0
S Standard pow er 1850 1800 330 10 370 12
Auto decel Engine deceleration 1100 - 700 35 see left 700 35
One t ouch decel Engine quick deceleration 900 - 700 35 700 35
Key start Key sw itch start position 900 - 700 35 700 35
440 17 440 17
Emergency
(45 Ohm) (45 Ohm)

R450LC-7 (TIER II engine)

Mode Application Pow er shift by EPPR valve

Default (1.x) Other case (2.x)

RPM RPM EPPR RPM RPM EPPR
Tolerance
UNLOAD LOAD mA bar UNLOAD LOAD mA bar RPM  50
H High Pow er 1950 1900 260 4 340 7
EPPR Current  30 mA
S Standard pow er 1850 1800 320 6 420 11
Auto decel Engine deceleration 1000 - 670 35 see left 670 35
EPPR Pressure  3 bar
One t ouch decel Engine quick deceleration 800 - 710 35 710 35
Key start Key sw itch start position 800 - 710 35 710 35
410 15 410 15
Emergency
(50 Ohm) ( 50 Ohm)

145
 RPM & EPPR SETTINGS FOR FIXED
M = OLD “H” value
POWER MODES (5/9) H = OLD “S” value
B] FOR EXCAVATORS WITH 3 FIXED POWER MODES (H, S, M) & 1 USER MODES (U) S = “H” - 100 rpm
M-mode H-mode S-mode Auto Key

PROGRAM
(MAXIMUM) (HIGH) (STANDARD) DEC start
mA mA mA
Signification RPM EPPR (bar) RPM EPPR (bar) RPM EPPR (bar) RPM RPM

(RPM) = RPM with charge

(pressure K) = EPPR in bar

standard program
setting M
U
option program
setting

(Tier-II)

FIRST SERIE OF
PROGRAM
CONFIGURATIONS
(Stand & Option) :

“X.3“ (Hyundai eng.)

LATER: SEE NEXT

PAGE (Tier-II)

(Tier-II)

146
 (EXCAVATORS WITH 3 FIXED POWER MODES H, S, M
& 1 USER MODES U
Adaptation - (Low noise, 2nd level  marked with “ S” in below table) (6/9)
(#491~) (#1520~) (#542~) (#659~)

M
U

M-mode H-mode S-mode AutodecKey start

 FOR PROGRAM 1.1 & 2.1

R450LC-7 (LATEST MODEL) & R500LC-7 (TIER II engine)

Mode Default (1.2) Other case (2.2)

RPM RPM EPPR RPM RPM EPPR

UNLOAD LOAD mA bar UNLOAD LOAD mA bar  FOR PROGRAM 1.2 & 2.2
M 1950 1900 260 8 1950 1900 150 0
H 1850 1800 320 10 1850 1800 260 8
S 1750 1700 320 10 1750 1700 320 10
Auto decel 1000 - 670 35 1000 - 670 35
One touch decel 800 - 700 35 800 - 700 35
Key start 800 - 700 35 800 - 700 35

Emergency
147
 RPM & EPPR (EXCAVATORS WITH 3 FIXED POWER MODES H, S, M
SETTINGS FOR FIXED & 1 USER MODES U
POWER MODES (7/9)

R160/180LC-7 (TIER II engine)

Mode Default (1.x) Other case (2.x)
M
RPM RPM EPPR RPM RPM EPPR
U
UNLOAD LOAD mA bar UNLOAD LOAD mA bar
M 2200 2000 219 4 2200 2000 130 0
H 2000 1800 310 10 2100 1900 219 4
S 1900 1700 310 10 2000 1800 350 12
Auto decel 1200 - 600 30 1200 - 600 30
One touch decel 950 - 700 35 950 - 700 35
Key start 950 - 700 35 950 - 700 35

Emergency

R110LC-7 (TIER II engine)

Mode Default (1.x) Other case (2.x) <-- Settings for R110LC-7:
RPM RPM EPPR RPM RPM EPPR
3 fixed power modes H, S, L
UNLOAD LOAD mA bar UNLOAD LOAD mA bar
H 2050 1850 245 4.1 2150 1950 245 4.1
S 1950 1750 290 7.5 2050 1850 318 8.8
L 1850 1650 370 14.5 1950 1750 439 17.4
Auto decel - - - - - - - - Tolerance
One touch decel 950 - 650 40 950 - 650 40 RPM  50
Key start 950 - 650 40 950 - 650 40
471 19.8 471 19.8 EPPR Current  30 mA
Emergency
EPPR Pressure  3 bar
148
ELECTRICAL SYSTEM FOR
EXCAVATOR

7A SERIES

149
1. MECHATRONICS SYSTEM

1) INTRODUCTION OF THE MECHATRONICS SYSTEM

The New CAPO (Computer Aided Power Optimization) System
• Control of Engine and Pump mutual power
• Mode Selection
• Self-Diagnosis (Machine Condition, Fault code)
• Using Micro-Process Controller (16bit)

Function
• Mode selection
 Power mode : Engine speed and pump power control (M, H, S Mode)
 Work mode : Hydraulic Flow control (Heavy duty, General, Breaker Mode)
 User mode : A operator set the Engine and Pump power
• Power Max : Increase the digging power (Change the relief pressure, max 10 sec)
• Auto Deceleration
• Anti-Restarting System : To protect the start motor
• Automatic warming up : The coolant temperature is less than 30℃
• Overheat prevention : The coolant temperature is up to 110℃

150
1. MECHATRONICS SYSTEM

2) SYSTEM DIAGRAM

Electrical Engine Control Mechanical Engine Control

151
1. MECHATRONICS SYSTEM

3) ELECTRICAL SYSTEM LAY-OUT

1 Horn switch
16 Speaker
2 Cluster
17 Cassette & radio
3 Starting switch
18 RS232 serial connector
4 Cigar lighter
19 Prolix resistor
5 Accel dial
20 CPU controller
6 Breaker switch
21 J1939 serial connector
7 Beacon switch
22 Fuse box
8 Service meter
23 Master switch
9 Breaker selection switch
24 Aircon & heater switch
10 Cab light switch
panel
11 Travel alarm stop switch
25 One touch decel switch
12 Preheat switch
26 Power max switch
13 Washer switch
27 Safety lever
14 Wiper switch
28 Overload switch
15 Main light switch

152
1. MECHATRONICS SYSTEM

4) CLUSTER STRUCTURE & SWITCH FUNCTION

153
1. MECHATRONICS SYSTEM

5) CLUSTER SYSTEM MENU

Enter the System Menu

Change the Menu Select the Menu

Monitoring Diagnosis Management

Settings Display User Mode

154
1. MECHATRONICS SYSTEM

5) CLUSTER SYSTEM MENU - Monitoring

Display
Group
0, 1

Display
Group
3

Display
Group
4

155
1. MECHATRONICS SYSTEM

5) CLUSTER SYSTEM MENU - Diagnosis

Display
Group
2

Display
Group
2

156
1. MECHATRONICS SYSTEM

5) CLUSTER SYSTEM MENU – User Mode

USER MODE SYSTEM

An operator can set the engine and pump power and memorize it for his preference.

HOW TO THE MEMORY SET

STEP 1) SELECT THE “U” MODE IN MAIN MENU
STEP 2) MOVE TO THE USER MODE SET IN SYSTEM MENU
STEP 3) SET THE ACCEL ENGINE SPEED
- To Change the Engine speed, Press the up or down switch.
- Press the SELECT switch.
- And then “DECEL” blinks at 0.5 seconds interval.
STEP 4) SET THE DECEL ENGINE SPEED
- To Change the Engine speed, Press the up or down switch.
- Press the SELECT switch.
- And then” EPPR” blinks at 0.5 seconds interval.
STEP 5) SET THE EPPR PUMP PRESSURE
- To Change the Engine speed, Press the up or down switch.
- Press the SELECT switch.
- And then ACCEL, DECEL and EPPR value are memorized.
157
1. MECHATRONICS SYSTEM

5) CLUSTER SYSTEM MENU – The Others

Management Menu
• Maintenance Interval time
(Engine Oil, Fuel Filter, Hydraulic Oil, Hydraulic Oil Filter, Hydraulic Oil breather…)

Setting Menu
• Time Setting
• Dual Mode Setting (MCU Standard / Optional Version)

Display Menu
• Operation Skin Selection
• Brightness Setting
• Language Selection (English / Korean)

158
2. MACHINE CONTROL UNIT (MCU)

3) THE MEAN OF LED LAMP

Communicati
LED Color MCU Fail Power Fail Normal
on Fail

Yellow ON - - -

Red - ON - -

Green ON ON OFF ON

159
2. MACHINE CONTROL UNIT (MCU)

4) THE ITEMS OF SELF_DIAGNOSIS (1/2)

GROUP DISP. CODE ITEMS EXAMPLE (7 SERIES)
Pump Prolix S/W PP:on/off
Working PS dP:on/oFF
Power MAX S/W Pb:on/oFF
Travel Oil PS oP:on/oFF
O/T Decel S/W od:on/oFF
Travel Alarm S/W br:on/oFF
#3 0x31 Preheat S/W pH:on/oFF
Boom Damp S/W bd:on/oFF
Heavy Lift S/W HL:on/oFF
Boom Up PS S/W bP:on/oFF
BKT&ARM IN PS CP:on/oFF
Parking S/W Pr:on/oFF
Overload S/W ol:on/oFF

160
2. MACHINE CONTROL UNIT (MCU)

4) THE ITEMS OF SELF_DIAGNOSIS (2/2)

GROUP DISP. CODE ITEMS EXAMPLE (7 SERIES)

Hour meter Ho:on/oFF
Neutral Relay nr:on/oFF
Travel SOL tS:on/oFF
Power MAX SOL PS:on/oFF
Swing Priority SOL SS:on/oFF
Arm Half SOL HS:on/oFF
Boom Priority SOL(1) bS:on/oFF
#4 0x41 Arm Flow CO SOL LS:on/oFF
Boom Priority SOL(2) BS:on/oFF
Travel Buzzer RU:on/oFF
Max Flow SOL FS:on/oFF
Preheat Relay PR:on/oFF
CO Cancel SOL CS:on/oFF
T/M Oil Lamp oL:on/oFF
Brake Fail Lamp bL:on/oFF

161
2. MACHINE CONTROL UNIT (MCU)

5) DELETE FAULT CODE (RECORDED ERROR)

162
 RPM & EPPR SETTINGS FOR FIXED POWER
MODES (8/9)
(EXCAVATORS WITH 3 FIXED POWER MODES H, S, M
-7A EXCAVATORS  TIER III ENGINES & 1 USER MODES U

163
 RPM & EPPR SETTINGS FOR FIXED POWER MODES (9/9)
(EXCAVATORS WITH 3 FIXED POWER MODES H, S, M
& 1 USER MODES U

-7A EXCAVATORS  TIER III ENGINES

164
 REMARK Throttle % values for QSB/QSC/QSM-Tier II
engines
Percentage of Cummins power, used by Hyundai excavator. This Percentage is stored in the Hyundai Controller and is recognised by
Cummins controller via CAN BUS system. The value can be seen when working with the Cummins software (“Insite”)

Values for TIER II engines :

S-Mode H-Mode M-Mode
Equipment Model Engine Model
RPM Throttle % RPM Throttle % RPM Throttle %

R290LC-7 QSB5.9 (VP44) 1750 52 1850 58 1950 65

R290LC-7 (old cluster type: H,S,MI,MII) QSB5.9 (VP44) 1850 58 1950 65 - -
R360LC-7 QSC8.3 1750 62 1850 70 1950 78
R450LC-7 QSM11 1750 77 1850 86 1950 93

REMARK
AUTO DECEL SYSTEM (NOT ON R110LC-7)
a. Definition

 RPM drops to 1000 ~1200 rpm (see above tables)

b. Working
The system operates by means of 2 or 3 pressure switches (Px Py Pz ) situated on the main control valve.
Operating pressure : ± 10 bar
Find more information regarding this in “290-7MCV.pdf”

165
HOW TO CHANGE THE PROGRAM VERSION (1.X <-> 2.X) ON THE CLUSTER
(5.X <->
(…)6.X)

CHANGING PROGRAM VERSION VIA

BUZZER STOP & TRAVEL SPEED SWITCH

166
 USER MODE SELECTION SYSTEM (NOT ON R110LC-7)
The first type of excavators had 2 memory modes (MI & MII) ; the later machines have only 1 memory mode:(U).
Via this modes, the operator can configure a fixed pump power & engine power

OLD NEW
OLD NEW
U
M
U

(U)

MODULATE MEMORY SET VIA

(1 segment = 100 RPM) USER MODE & SELECT SWITCH

(U)

167
 MONITORING DISPLAY & SELF DIAGNOSTIC
1) MONITORING DISPLAY SYSTEM

(Not all monitoring info is applicable for the R110-7)

AP see Remark bottom

2 digits code In case of 4-digits code (for example

SEE (e.g. 03) or ERR “2973”, it will appear in 3 steps:
NEXT 3 digits code 29 297 973
PAGE (e.g. 277)

ol see Remark bottom

CHANGING “GROUP”
DISPLAY VIA
BUZZER STOP & SELECT
SWITCH
Remark: add. group 1: AP --> Ambient pressure (kpa) (only TIER2,3 engine)
add. group 3: ol --> Overload pressure switch (on or off)

168
 ERROR CODES TABLE After ignition on, push 2 times the buzzer stop & select
A. MACHINE ERROR CODES LIST (HYUNDAI) switch simultaneously, to get into the error code group.

(OPTION) (OPTION)

(Not on QS eng.)
(OPTION)

(OPTION)
(OPTION)
(OPTION)
(OPTION) (Not all error codes are applicable for the R110-7)

(OPTION)
Older codes (-3):

08  Short circuit in Cut-off cancel solenoid system

09  Short circuit in swing priority solenoid system
23  Cut-off cancel solenoid is open or shorted to ground
24  Swing priority solenoid is open or shorted to ground
(OPTION) 50  Boom up EPPR v/v is open or shorted to ground
(OPTION) 52  Arm half solenoid circuit is open or shorted to ground
(OPTION) 53  Boom priority solenoid circuit (2) is open or shorted to ground
(OPTION)
54  Arm flow cut-off solenoid circuit is open or shorted to ground
55  Arm flow cut-off solenoid circuit is shorted to battery +
57  EPPR v/v circuit is shorted to battery +
59  Arm half solenoid is shorted to battery +
60  Boom priority solenoid circuit (2) is shorted to battery +

(The data frame count of continuously wrong received from controller is more than 10)

169
ENGINE ERROR CODES LIST FOR R290/360LC-7 (CUMMINS QSB5.9/QSC8.3)  NO High Pressure Common Rail (1/3)

170
ENGINE ERROR CODES LIST FOR R290/360LC-7 (CUMMINS QSB5.9/QSC8.3)  NO High Pressure Common Rail (2/3)

171
ENGINE ERROR CODES LIST FOR R290/360LC-7 (CUMMINS QSB5.9/QSC8.3)  NO High Pressure Common Rail (3/3)

172
ENGINE ERROR CODES LIST FOR “-7A” R210/250/290/320/360 (CUMMINS QSB6.7/QSC8.3/QSL9)  all with High Pressure Common Rail (1/5)

173
ENGINE ERROR CODES LIST FOR “-7A” R210/250/290/320/360 (CUMMINS QSB6.7/QSC8.3/QSL9)  all with High Pressure Common Rail (4/5)

174
ENGINE ERROR CODES LIST FOR “-7A” R210/250/290/320/360 (CUMMINS QSB6.7/QSC8.3/QSL9)  all with High Pressure
Common Rail (5/5)

175
ENGINE ERROR CODES LIST FOR R450/500LC-7(A) (CUMMINS QSM11) (1/3)

176
ENGINE ERROR CODES LIST FOR R450/500LC-7(A) (CUMMINS QSM11) (2/3)

177
B3. ENGINE ERROR CODES LIST FOR R450/500LC-7(A)
(CUMMINS QSM11) (3/3)

178
Engines

179
 Tier III Engines

Cummins Tier III

Engines for R210LC-7A ~ R500LC-7A

R210LC-7A R320LC-7A
R250LC-7A
R290LC-7A QSC

QSB6.7

R450LC-7A
R360LC-7A R500LC-7A

QSC QSM11

180
 RATED POWER
ORIGINAL
RATING
EQUIPMENT MODEL Engine Model (HP/RPM) GROSS NET
hp ps kW rpm hp ps kW rpm

R35Z-7A 3TNV88-BSHYB - 27.2 27.6 20.3 2200 26.5 26.9 19.8 2200

R55-7A 4TNV98-ESHYB - 52.3 53.0 39.0 2200 50.8 51.5 37.9 2200

R55W-7A 4TNV98-EPHYBW - 56.8 57.6 42.4 2400 55.2 56.0 41.2 2400

R80-7A 4TNV98-ZVHYB - 59.6 60.4 44.4 2100 58.5 59.3 43.6 2100

R110-7A D04FD-TAA - 98 72 2000 2000

R140LC-7A, R140W-7A 124/2150 119 121 89 2000 105 106 78 2000

D04FD-TAA
R160, R170W, R180LC-7A 133/2200 126 128 94 2000 116 118 87 2000

7A SERIES R210LC-7A 155/2000 151 153 113 1900 143 145 107 1900

R200W-7A 170/2000 164 166 122 1900 153 155 114 1900
QSB6.7
R250LC-7A 173/2200 176 178 131 1900 163 165 121 1900

R290LC-7A 220/2000 227 230 169 1900 197 200 147 1900

R320LC-7A QSC 250/2200 258 262 193 1750 237 240 177 1750

R360LC-7A QSL 280/2000 296 300 221 1850 271 275 202 1850

R450LC-7A QSM11 335/2100 357 362 266 1900 320 325 239 1900

R750LC-7 QSX 510/1800 510 517 380 1800 460 466 343 1800

181
 QSB Product Evolution
2002 2005 Common Rail Fuel System
Rear Gear Train
Reduced Engine Noise

4 Valve Head with Centered Injection

Full Authority Electronic Fuel System
No Adjust Overhead

Over 2 Million in Service

Great Reliability & Durability

B Mechanical Tier 2 QSB VP44 Tier 3 QSB HPCR

182
Tier 3 QSB6.7 Engine

Features
• High pressure common rail fuel system
• Significant cold start, white smoke improvement
vs. Tier 2 QSB5.9
• Larger displacement (5.9 → 6.7 Liter)
• Rear gear drive camshaft, fuel system and
accessories for more efficient vehicle installation
and noise reduction
• Capable of worldwide fuel usage
• ECM improvement (CM550 → CM850)

183
 3.POWERFUL AND RELIABLE ENGINE
(1) Specification comparisons
Hyundai
CAT Komatsu Volvo Korea
구 분 UNIT
330CL PC300LC-7 EC330BLC
R320LC-7A R320LC-7

Maker/ Cummins Cummins CAT Komatsu VOLVO

-
Engine QSC C8.3-C C9-JE2-TAA SAA6D114E D10B EAE2

Emission - Tier-3 Tier-2

Power
PS/rpm 262/1750 263/1750 - - -
(Gross)
Power
PS/rpm 240/1750 235/1750 247/ 245/1900 250/1700
(Net)

Peak
kgf·m/rpm 114.8/1500 124.3/1300 - - -
Torque

※ EPA Tier III, EU Stage III-A Certified

184
 ④ Specification comparisons

Hyundai
구 분 UNIT Komatsu CAT Hitachi
PC290LC-7 325CL ZX270LC
R290LC-7A R290LC-7

Engine - Cummins Cummins Komatsu CAT Isuzu

QSB6.7 QSB5.9-C SAA6D102E-2 3126B-JE2-TAA CC-6BG1T

Emission - Tier-3 Tier-2

Power(Gross) HP/rpm 230/1900 216/1900 179/2050 - 165/2050

Power(Net) PS/rpm 200/1900 200/1900 182/2050 190/1800 170/2050

Peak Torque kgf·m/rpm 96.8/1400 94.7/1500 134/2050 140/1800 123/2050

※ EPA Tier III, EU Stage III Certified

185
3.POWERFUL AND RELIABLE ENGINE

1. Specification Comparisons

Hyundai
Komatsu Liebherr Volvo Korea
구 분 UNIT
PC300LC-7 R944 EC360BLC
R360LC-7A R360LC-7

Maker/ Cummins Cummins Komatsu Liebherr VOLVO

-
Engine QSL QSC8.3-C SAA6D114E D926T-E D10B EAE2

Emission - Tier-3 Tier-2

Power
PS/rpm 300/1850 284/1900 - - -
(Gross)
Power
PS/rpm 275/1850 265/1900 245/1900 223/2000 250/1700
(Net)
Peak
kgf·m/rpm 138.3/1400 120.3/1400 - - -
Torque
※ EPA Tier III, EU Stage III-A Certified

186
3. POWERFUL AND RELIABLE ENGINE
(1) Specification comparisons

Hyundai CAT Komatsu Volvo Korea

구 분 UNIT
R450LC-7A R450LC-7 345BL PC450LC-6K EC460BLC

Cummins Cummins CAT Komatsu VOLVO

Engine -
QSM11 QSM11-C 3176ATAAC SAA6D125E-3 D12C EAE2

Emission - Tier-3 Tier-2

Power
PS/rpm 362/1900 358/1900
(Gross)
Power
PS/rpm 325/1900 325/1900 325/2000 335/1850 310/1900
(Net)
Peak
kgf·m/rpm 170.6/1300 182.5/1300 - - 158/1400
Torque
※ EPA Tier 2, EU Stage 2 Certified

187
3. POWERFUL AND RELIABLE ENGINE
(1) Specification comparisons

Hyundai CAT Komatsu Volvo Korea

구 분 UNIT
R500LC-7A R500LC-7 345BLⅡ PC450LC-7 EC460BLC

Cummins Cummins CAT Komatsu VOLVO

Engine -
QSM11 QSM11-C 3176ATAAC SAA6D125E-3 D12C EAE2

Emission - Tier-3 Tier-2

Power
PS/rpm 362/1900 358/1900
(Gross)
Power
PS/rpm 325/1900 325/1900 325/2000 335/1850 310/1900
(Net)
Peak
kgf·m/rpm 170.6/1300 182.5/1300 - - 158/1400
Torque
※ EPA Tier 2, EU Stage 2 Certified

188
 Mitsubishi Engine
R140LC-7A @ 91kW
R160LC-7A @ 98kW
R180LC-7A @ 98kW

189
 Training:
Mitsubishi TIER III, D04FD
D04FD--
TAA
Common--rail diesel engine
Common

190
 Mitsubishi

- Mitsubishi was founded in 1870

- Sagamihara factory opened in 1970
- Since 1992 Joint Venture with Caterpillar
for engines and forklifts
- 2200 employees

191
New features in Commen rail engines:

192
Fuel system:

green & orange lines

+/- 300-400 kPa (3-4 Bar)
red line
+/- 30  160 MPa, (300-1600 Bar)
pink line
+/- 35 kPa (+/- 0.35 Bar)

193
Fuel System Handling:

IMPORTANT!
• Thoroughly clean equipment before disassembling
• Cap all fuel passages Immediately after removal with Protective Cap
and Plug Kit
• Do Not “Blow Out” or “Wash Out” any fuel passages
• Place removed parts in clean area
• Do Not pre-fill filters
• Remove packaging and protective caps immediately before installation
• Fuel Lines cannot be reused

194
EXPLANATION OF MONITORING
DISPLAY (1/2)

195
 EXPLANATION OF
MONITORING DISPLAY
(2/2)

Bm/Sw prior.

196
EXPLANATION OF ERROR CODE SYSTEM (SELF DIAGNOSTIC
SYSTEM)

Memorised errors:
only visible at “IGNITION ON”
(not at running engine!)

197
 MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM

• Check display of cluster first 5 sec after ignition on: CLUSTER

brown
All lamps should light up, with buzzer sound POW (IG)
black
GND
RX yellow
• If nothing appears, check on cluster: - Feed line (Brow ) 24 V TX blue
- Ground line (Black) GND
In case of no feed voltage: check fuse for cluster, power relay, wiring
• If display is blurred or some lamps do not lighten up  replace cluster (or light
board inside)

• Check display of cluster: If “ Co Err ” appears, it indicates:

serial communication problem between cluster and CPU

• Check Rx & Tx Voltage on cluster: - Serial- (Rx) line, input (Yellow) 12V
- Serial+(Tx) line, output (Blue) 4V
In case of no voltages: check wiring (Rx & Tx lines)
In case of voltages:  replace CPU

• Check LED’s on CPU:

• Green: Normal condition

• None: Feed poblem (24V) to CPU

• Yellow & Green: Communication problem = “Co Err”

• Red & Green: CPU problem  replace CPU

CPU
• Check CHECK warning light on cluster

• In case of blinking  replace CPU

• Check also Error Code system (see previous) 198

 Emergency Procedure, in case of faulty CPU (1/2)
- ASSURING PUMP POWER CONTROL VIA EMERGENCY RESISTOR:

Emergency
Resistor

CN19 CN47
CN19
&

CN19B
CN19A

Disconnect CN19<>CN19A Connect CN19<>CN19B

Connect Resistor with CN47
It might be that this connection was already
PRINCIPLE: CN19 CN19A established during normal operation: it has
Switch or connectors no effect as long as CN19 is connected with
CN19B CN19A.
NORMAL CPU

24V
Plugging in the emergency resistor assures setting of fixed Eppr
pressure, which results in machine operation, equal to “S-mode”
EMERGENCY

CN47

EPPR
VALVE
Emergency switch
EMERGENCY
RESISTOR
NORMAL (OFF)

EMERGENCY (ON)
First models had emergency switch instead
of connectors, but principle is the same

199
 Emergency Procedure, in case of faulty CPU (2/2)

- ASSURING ENGINE SPEED CONTROL - ASSURING STARTING OF MACHINE

For B3.9, B5.9, C8.3, M11 engine:
- DISCONNECT accelerator cable from injection pump lever (CN96A for wheel exc)
- CONNECT emergency (Push-pull) cable on injection pump lever CN92
 So, in this case MANUAL control of RPM is possible
(SEE NEXT PAGE)
CN92
For QSB, QSC, QSM engine: (CN96B for wheel exc)

Connect CN92: male <> female

CN16  In case of faulty CPU, starting is
CN16
impossible as the “anti restart function”
CN16A CN16B
is active all the time. With above
connection, the machine can “always” be
started. (see also p.63)

Disconnect CN16<>CN16A Connect CN16<>CN16B

 In emergency, engine control is ONLY possible via ACCEL DIAL: ALL EMERGENCY CONNECTORS: NEAR CPU

ACCEL DIAL,
...
... CAN BUS
Potentiometer CONNECTION
CPU ECM Emergency
STANDARD Resistor

CN16 CN16A
R. THROTTLE RETURN
R. THROTTLE POS SIGNAL Emergency
CN16B EMERGENCY R. THROTTLE +5V Connectors
R. THROTTLE ON/OFF INJECTION
PUMP
ECM EMERGENCY INPUT
PINS (on CN93 for QSB/C eng.
& on CN95 for QSM eng.)
200
ENGINE ACCEL ACTUATOR (not for

excavators with QS-engines)

1) ENGINE THROTTLE LEVER

INJECTION PUMP

EMERGENCY
CABLE

2) EMERGENCY CABLE (Push-pull cable)

201
 3) ACCEL ACTUATOR
TYPE A (GENERAL
TYPE)

202
TYPE B (R110LC-7 / R140LC-7,
SN 1001and up) / R140W-7) R110LC-7

203
 ACCEL ACTUATOR CABLE SETTING PROCEDURE

SETTING SCREW

SPECIFICATION OF RPM: SEE RPM TABLE

204
 ENGINE SPEED SENSOR (not for excavators with QS-engines)

A. CUMMINS ENG (B, C series)

B. MITSUBISHI ENG

A. CUMMINS ENG (B, C series)

B. MITSUBISHI ENG

Start Point 0°

Finish Point 135°

205
ELECTRIC COMPONENT LOCATION For exact location of
components,refer to service
manual

R290LC-7, with QSB-engine

CN126: RS232
(4-PIN)
Diagnosis for
Hyundai CPU

CN148: J1939
(3-PIN)
Diagnosis for
Cummins ECM on
QSB,QSC,QSM eng

(R210LC-7)
Box with:
- fuses
- CPU
- relays
13 (R290LC-7, R140LC-7) - emergency resistor
(and/or emergency switch)
- connectors for Hyundai &
Cummins diagnosis &
software updating

206
 FUSES & RELAYS

LOCATION: OUTSIDE OF CPU COMPARTMENT

R210LC-7

Some machines (R210LC-7,…) have “circuit

breakers” which have to be “reset” in case of short
circuit

Safety Relay has an anti-restart function: see

next page
207
 ANTI - RESTART FUNCTION

To protect the start motor from inadvertent restarting,

CPU controller isolates the start motor control line
after the engine is in operation condition.

By-pass connector (CN 92) can make the engine start
(CN96 for wheel exc.)
when CPU controller is removed.

(CN96 for
wheel
exc.)

= SAFETY RELAY (CR5)

208
 ELECTRIC COMPONENT SPECIFICATION
TABLE 1/4

Color Code Electric Wires

Y Yellow
G Green
L Blue
Gr or GY Gray
W White
Br or BR Brown
Or or OR Orange
V Violet
B Black
R Red
Example:
BrL (Br/L) = Brown wire with blue stripe on it

209
TABLE 2/4

210
TABLE 3/4

211
TABLE 4/4

212
8.1 ALL MODEL (NOT R110LC-7) SOLENOID BANK
The solenoid bank is situated in the main pumps compartment

A1 A2 A3 A4 A5

BREAKER / DOUBLE FUNCTION

A1 SAFETY SOLENOID (CN 68) SOLENOID (CN66)
A2 POWER BOOST SOLENOID (CN 88) (pedal activation)
A3 MAX FLOW SOLENOID (CN 137)
A4 SECOND SPEED SOLENOID (CN 70)
A5 BOOM or SWING PRIORITY SOL. (CN 133) (see p.34) to joysticks & pedal levers
Accu
Last guard Filter

Pilot line Filter Pilot Pump

Solenoids on Electrical Schematic 213

 R110LC-7
The solenoid bank is situated in the main pumps compartment

A2 SECOND SPEED
SOLENOID (CN70)

A1 SAFETY SOLENOID
(CN68)

BREAKER SOLENOID
PRESSURE CHECK
PORT
(neg. control signal for
breaker operation)

POWER BOOST SOLENOID

(CN88)

214
 Swing bearing grease

L : Grease bath length

H : Swing bearing tooth
height

⅓H

½L ½L
L

Model 13 ton 17~21 ton 25 ton 29 ton 32ton 36 ton 45 ton

Grease Amount (liter) 4.4 6.9 9.2 11.6 11.2 12.8 15.6

215
 12. SYMBOLS & ABBREVIATIONS
The required circuits can be found in next books:
Electric Circuit Handbook (-3 & -7): part nr. 91E2-30990
Hydraulic Circuit Handbook (-3 & -7): part nr. 91E2-30980
Hydraulic & Electric Circuit Handbook (-3): part nr. 91E2-30950
Hydraulic & Electric Circuit Handbook (-7): part nr. 91E2-30960

EPPR v/v Electro Proportional Pressure Reducing Valve

Px,Py Auto Decel Pressure Switches

ON ELECTRIC CIRCUITS:
CN Connector BZ Buzzer
NC Not Connected ILL. Illumination
Ry Relay INT Intermittent Signal (Wiper Mot)
CR Relay Connector ACC Acceleration
AC Air Conditioner SOL Solenoid
COMP Compressor ACT Actuator
GND Ground CPU Central Processor Unit
I (IG) Ignition ECM Electronic Control Module (Cummins)
S Start OEM Original Equipment Manufacturer = Hyundai
E Earth PCB Printed Circuit Board
B+ Battery Plus LH Left Hand Side
SW Switch RH Right Hand Side
PS Pressure Switch
216
 MEASURE CONDITION:
-Hyd Temp. ±50°C
PRESSURE SETTINGS -Power mode = “M-mode”
- Auto decel OFF ( high idle)

UNIT: BAR
110LC-7 140LC-7 160LC-7 180LC-7 210LC-7 250LC-7 290LC-7 320LC-7 360LC-7 450LC-7

*500LC-7

MAIN CONTROL MAIN RELIEF 330 330 330 330 330 330 330 330 330 330
VALVE POWER BOOST 360 360 360 360 360 360 360 360 360 360
PORT RELIEF 380 380 380 380 390 390 390 390 390 390
(arm, boom, bucket) *380
SWING MOTOR RELIEF PRESS 240 240 240 240 240 275 265 265 260 285
BRAKE RELEASE PRESS 35 35 35 35 35 35 35 35 35 33 - *35
BRAKE RELEASE SPEC. 33~50 30~50 20 20 33~50 33~50 29~32 26 30 20~50
TRAVEL MOTOR RELIEF PRESS 330 330 330 330 365 365 375 330 335 345
BRAKE RELEASE SPEC. <9 6 6 6 6 6 16 16 9 17~50
PILOT PUMP RELIEF PRESS 35 35 35 35 35 35 35 35 35 33 - *35

Note: The indicated swing motor pressures are measured at a lab-sta nd with ±30 l/min pump flow.
The real pressures (measured at relief, with M mode selected) are ± 20~30 bar “higher” then
the indicated values !

OVERLOAD RELIEF PRESSURES FOR LONG REACH MODELS:

MODEL ARM IN & OUT BUCKET IN & OUT

R210LC/LR-7 300 bar 280 bar

R290LC/LR-7 230 bar 270 bar

217
Electrical System

218
Electrical Schematic

219
220
 Fuse Box Location

MCU Location

Batteries
Master Switch

Items 3 & 4 Fusible Links and

Battery disconnect

221
222
223
224
225
226
 Controller (MCU)

CN 50 CN 51

Pin 1

Pin 36

227
 Resistor

CN 19B

CN19 & CN19A

228
229
230