Hyundai Robex R220LC-9S Excavator Service Manual PDF

Description

File Details

• Manual type: Service / shop manual
• Brand / models: Hyundai Robex R220LC-9S, R220LC-9S Long Reach, R220LC-9S High Walker
• Language: English
• Page count: 611
• File format: PDF

What This Hyundai Robex Manual Covers

The Hyundai Robex R220LC-9S Excavator Service Manual PDF is written for workshop technicians who need structure, circuit logic, test values, and disassembly order on the Robex 22-ton class crawler. Three machine configurations sit in the specification section: the standard R220LC-9S with a 5.68 m boom and 2.92 m arm, the R220LC-9S Long Reach with an 8.2 m boom and 6.3 m arm, and the R220LC-9S High Walker with extra ground clearance and a wider track gauge. Operating weights printed in the book run 21900 kg on the standard 600 mm shoe machine, 24360 kg on Long Reach, and 23160 kg on High Walker.

Power comes from a Cummins 6BTAA water-cooled 4-cycle turbocharged diesel: 6 cylinders in-line, 102 × 120 mm bore and stroke, 5880 cc displacement, 17.3:1 compression, 150 Hp (112 kW) at 1950 rpm SAE J1995, and 62.6 kgf·m of torque at 1500 rpm. The hydraulic heart is a pair of variable-displacement tandem axial piston pumps rated 2 × 117 cc/rev, 2 × 222 l/min at 1900 rpm, with 350 kgf/cm² main pressure and 380 kgf/cm² on power boost. Those numbers matter when you set relief valves, chase slow cycle times, or decide whether a pump or an EPPR valve is the real problem.

Chapters Covered

• Section 1 General — Safety hints; Specifications
• Section 2 Structure and Function — Pump device; Main control valve; Swing device; Travel device; RCV lever; RCV pedal
• Section 3 Hydraulic System — Hydraulic circuit; Main circuit; Pilot circuit; Single operation; Combined operation
• Section 4 Electrical System — Component location; Electric circuit; Electrical component specification; Connectors
• Section 5 Mechatronics System — Outline; Mode selection system; Automatic deceleration system; Power boost system; Travel speed control system; Automatic warming up function; Engine overheat prevention function; Variable power control system; Attachment flow control system; Anti-restart system; Self-diagnostic system; Engine control system; EPPR valve; Monitoring system; Fuel warmer system
• Section 6 Troubleshooting — Before troubleshooting; Hydraulic and mechanical system; Electrical system; Mechatronics system
• Section 7 Maintenance Standard — Operational performance test; Major components; Track and work equipment
• Section 8 Disassembly and Assembly — Precaution; Tightening torque; Pump device; Main control valve; Swing device; Travel device; RCV lever; Turning joint; Boom, arm and bucket cylinder; Undercarriage; Work equipment
• Section 9 Component Mounting Torque — Introduction guide; Engine system; Electric system; Hydraulic system; Undercarriage; Structure; Work equipment

Taken together, those nine sections give a shop the full path from “what is this component supposed to do” through circuit flow, cluster diagnostics, measured performance limits, and the actual teardown order. The Hyundai Robex R220LC-9S Excavator Service Manual PDF is not a parts catalog and it is not an operator’s handbook; it is the workshop book used to judge wear, set pressures, and put the machine back together to the printed torque values.

Machine Layout, Dimensions, and Fluids

Group 2 of Section 1 maps the major assemblies: engine, radiator, main pump, main control valve, hydraulic tank, fuel tank, swing motor, turning joint, travel motors, boom / arm / bucket cylinders, and undercarriage hardware. Standard overall length is 9530 mm, undercarriage length 4440 mm, track gauge 2390 mm, travel speed 3.4 / 5.3 km/h, swing speed 11.5 rpm, and gradeability 35 degrees. Ground pressure on a 600 mm shoe is 0.46 kgf/cm². Long Reach stretches overall length to 12030 mm and uses an 800 mm shoe; High Walker raises cab height to 3100 mm and minimum ground clearance to 660 mm.

Working-range tables list four standard arms on the 5.68 m boom (2.0 m, 2.40 m, 2.92 m, 3.90 m) with SAE and ISO bucket and arm digging forces, including the power-boost figures in brackets. Recommended oils are tabulated by ambient temperature: 24 l of engine oil, 5.0 l swing-drive gear oil, 5.8 l × 2 final-drive oil, 160 l hydraulic tank / 275 l system, 400 l fuel, and 35 l of 50:50 ethylene-glycol mix in the radiator. Those capacities are the ones you use after a pump change or a final-drive rebuild, not guesses from another Robex model.

Hydraulics, Valves, and Pilot Controls

Section 2 walks the pump device (front pump, rear pump, regulators, and gear pump) with port maps for delivery, suction, drain, pilot, servo-assist, and gauge ports. The main control valve is a 9-spool two-block unit on hydraulic pilot; main relief is 350 kgf/cm² (380 kgf/cm² power boost) and boom / arm / bucket port reliefs sit at 400 kgf/cm². Swing uses a two-unit fixed-displacement axial piston motor at 151 cc/rev with 265 kgf/cm² relief and a spring-applied, hydraulically released brake. Travel motors are variable-displacement axial piston units at 350 kgf/cm² relief. Remote control valves are pressure-reducing type, 6.5–25 kgf/cm², with 61 mm lever stroke and 123 mm pedal stroke.

Section 3 then ties those parts into circuits. The main circuit covers suction, delivery, return, and drain, including cooler bypass check valves at 1.5 and 3.0 kgf/cm² and drain-filter bypass at 1.5 kgf/cm². Pilot circuit pages follow oil from the 15 cc/rev gear pump through the line filter and safety solenoid to the RCV levers and pedals. Single-operation and combined-operation groups show how boom, arm, bucket, swing, and travel share pump flow, which is the section you open when one function steals oil from another or when a confluence valve is suspected.

Electrical System and CAPO Mechatronics

Section 4 locates harnesses and connectors, then documents start, charging, lighting, and wiper circuits for both cluster type 1 and cluster type 2 machines. Connector tables list AMP, Deutsch, and related housings with pin counts and harness roles such as frame-to-engine interconnects. Electrical component specifications give switch thresholds, including the engine-oil pressure switch at 0.5 kgf/cm² normally closed.

Section 5 is the Computer Aided Power Optimization (CAPO) book inside the Hyundai Robex R220LC-9S Excavator Service Manual PDF. Mode selection pairs power modes (P / S / E on cluster type 1, M / H / S on cluster type 2) with a 10-position accel dial. Automatic deceleration drops engine speed to 1150 rpm after four seconds of lever-neutral, then to 1000 rpm after one minute. Power boost, two-speed travel, automatic warm-up below 30°C coolant, overheat protection above about 103–105°C coolant or hydraulic oil, variable power control from RCV stroke and pump load, attachment flow control, and anti-restart after the starter has already cranked are all described with logic tables. The MCU drives the EPPR valve to match pump absorption torque to engine torque. Self-diagnostics list fault codes for coolant sensors, engine-speed signal, pump pressure sensors, preheater, and related circuits. The cluster monitoring chapter covers gauges, warning lamps, ESL password start limit, replacement-interval reminders (engine oil and filter at 500 hours, final-gear oil and hydraulic return filter at 1000 hours, tank breather at 250 hours), and analog monitoring of rpm, oil temperature, voltage, and pressure.

IMAGES PREVIEW

Troubleshooting, Performance Tests, and Rebuilds

Section 6 opens with a method chapter, then fault trees for hydraulic and mechanical complaints (engine runs but nothing moves, all actuators slow, engine stall), electrical lamp and start failures, and mechatronics issues such as EPPR current and pressure out of spec. Several trees tell the technician to contact Cummins when engine power itself is the limit. Section 7 turns those complaints into numbers: start idle 850 ± 100 rpm, P/M mode 2100 ± 50 rpm, travel-speed and drift limits, lever play and stroke, pilot primary pressure, swing-brake release pressure, main-pump delivery at high idle, and system relief 350 (380) ± 10 kgf/cm² on boom, arm, and bucket with 400 ± 10 kgf/cm² port relief at 20 lpm. Wear tables for major components and track / work equipment sit in the same section so you can decide repair versus replace after teardown.

Section 8 is the hands-on rebuild order: pressure release and tank drain (160 l from the hydraulic tank), pump, main control valve, swing and travel devices, RCV lever, turning joint, boom / arm / bucket cylinders (including the Long Reach rod and stroke differences), undercarriage, and work equipment. Cylinder sizes in the spec chapter are boom ø120 × ø85 × 1290 mm, arm ø140 × ø100 × 1510 mm (Long Reach ø140 × ø95 × 1460 mm), and bucket ø120 × ø85 × 1055 mm (Long Reach ø100 × ø70 × 870 mm). Section 9 then lists mounting torques by system so brackets, pumps, and structure bolts go back to the printed kgf·m values rather than a generic chart.

Use This Manual on the Job

With the Hyundai Robex R220LC-9S Excavator Service Manual PDF open, a technician can set main and port reliefs, test EPPR current and secondary pressure, read cluster fault codes, measure cycle times and drift against Section 7 limits, and overhaul the tandem pump, 9-spool valve, swing and travel reductions, turning joint, and work-equipment cylinders in the printed sequence. Correct pressures, rpm targets, and torque figures keep a Cummins-powered Robex from coming back with the same slow-arm or overheat complaint. The file is delivered instantly as a PDF after payment — no shipping wait — and can be opened on a shop computer, tablet, or phone and printed for the bench.