R200W-7(A) Training

Presented by B.R.Son
After Sales & Service department of HHI
1. Engine

Item Specification

Model Cummins QSB6.7

Control type ECM

Number of cylinder 6 cylinders

Firing order 1-5-3-6-2-4

Cylinder bore x stroke 107 x 124mm

Piston displacement 6,700cc

Rated gross horse 155HP at 1900rpm

power
Engine oil 24ℓ

Rated fuel 164.3g/Hp.h at

consumption 1900rpm
2. Engine for R200W-7A & R200W-7

Items R200W-7A R200W-7 Remarks

Model QSB6.7 B5.9-C

Fuel Injection
HPCR Mechanical
Pump

Displacement 6.700cc 5,880cc 14% up

164Hp at 166Hp at
Rated Power Noise reduced
1900rpm 1950rpm

Rated fuel
164.3g/Hp.h 173.0g/Hp.h 6%up
Consumption
 3. Engine rpm Control System
Accel’ Dial Signal to ECM
Step Signal H mode S mode
ECM 1 1.9 0.0V 0.0V
2 2.1 0.6 0.6
3 2.2 0.8 0.8
4 2.4 2.0 1.6
5 2.6 1.9 1.8
6 2.8 2.1 2.0
CPU
7 2.9 2.3 2.1
controller
8 3.1 2.4 2.3
Cluster 9 3.2 2.6 2.4
10 3.4 2.9 2.6

Accelerator
Dial
 4. Signal of accelerator Dial and ECM

1. Signal of Accel’ Dial & PO

Accel’ Dial (dL)
Signal to ECM (Po)

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
2. New Cluster 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
 5. Hydraulic Flow Control System

Eng’ RPM Pump EPPR

Mode Current Pressure
Unload Load
(mA) (Kg/㎠)
M 1700 1650 260 4.5
H 1600 1550 260 4.5
S 1500 1450 260 4.5
EPPR Valve Auto
Pressure 1000 - 700 35
Idle
measuring
point
CPU
Controller
Cluster
Engine Rpm Signal

Accel’ Signal ECM

Accelerator Dial
6. Function how to control the EPPR valve

Specification Load condition

If the current is below than the
Sustained EPPR
Idle rpm sustained rpm
rpm Pressure

EPPR Pressure will be increased to

1600 recover the engine rpm until
1700 (Difference : 4.5Kg/㎠ reaching the sustained rpm.
100rpm)

※ Notices
- Therefore the engine rpm is lower than the sustained rpm,
all attachment operating speed should be slow.
 7. Compensation System of EPPR

※ Notices
- Therefore the engine rpm is lower than the sustained rpm,
all attachment operating speed should be slow.
Specification Load condition
Idle EPPR If the current is below than the
Sustained rpm
rpm Pressure sustained rpm
1600 EPPR Pressure will be increased to
1700 (Difference : 4.5Kg/㎠ recover the engine rpm until reaching
100rpm) the sustained rpm.
8. Self Diagnosis for CPU controller

LED lamp
LED Lamp Trouble Service

G is Turned on Normal

G and R are Trouble on CPU or Change the

Turned on ROM controller

G and Y are Trouble on serial Check serial lines

Turned on communication line between controller
and cluster.
Three LED Trouble on CPU Check the input
Are turned on controller power power wire(24V) of
controller.
9. Main Pump
Measuring Point
for EPPR
To Boom,
Bucket
Regulator
To Arm,
Swing

EPPR valve

Gear Pump
(40Kg/㎠)

P2 Pump P1 Pump
MAIN PUMP R200W-7

f2 (Neg. Signal 2 ) f1 (Neg. Signal 1 ) Max flow cut off signal

EPPR Pressure

EPPR Valve

Pump 2 Pi
Pump 1

Pi

Pilot Pump

P1 P2
Remark ADJUST SCREW
For more detailed information about the pump assembly, RELIEF V/V PILOT
refer to the service manual. PRESSURE 40 bar
10. Internal Section of Main Pump
Oil delivery Port

Drive
n
Gear

P2 Pump
Connected
Engine
Valve Plate

Piston
11. Regulator

MCV
12. Section drawing for regulator

※ Notices
1) Gap B = Large – Small spring
13. Flow regulator
 R210/290LC-7

14. Fr & Fl pressure

RCV Lever
Items
In Neutral Full
Pressure 38Bar Below 5bar

* It is very good information to judge

whether the MCV is good or not
15. Main Control Valve
16. Auto Idle system.

RCV Lever Measuring Point Neutral Full

Signal CN51-#1/13 0 volt 5 Volt
17. Swing Motor

Swing Motor Reduction Gear

 18. Brake of Swing Motor

* When stopped
1. Hydraulic swing Brake
- Pressured oil pumped by swing
motor would disturb to rotate
- To reduce swing speed

2. Mechanical Swing Brake

- It is the function like parking
brake
- To hold the upper & low Frame
 19. Time delay valve

※ Short explanation
It takes time about for 4 second to flow out
oil inside brake piston so after that Brake
piston come down.
20. Transmission for 7 and 7A

Transmission Model
Model Remarks
7A 7
R140W-7A 2HL270
R170W-7A 2HL100
2HL290 24% up
R200W-7A
21. Inside Section of Transmission (2HL100)
22. Hyd’ Circuit for Lower speed travel
23. Hyd’ circuit for High speed travel
SHIFT INTERLOCK (1/2)
1] FIRST GEAR, 2] SECOND GEAR,
- SPEED BELOW DOWNSHIFT POINT - SPEED BELOW DOWNSHIFT POINT
- SPEED ABOVE DOWNSHIFT POINT

Relief valve
4 bar

P2 = LOW SPEED SIGNAL

(TRANSMISSION OIL)
K = PRESSURE TO MULTI DISC CLUTCH
P1 = HIGH SPEED SIGNAL
B = PRESSURE TO MULTI DISC BRAKE
SHIFT INTERLOCK (2/2)
3] SECOND GEAR, 4] FIRST GEAR PRE-SELECTED FROM SECOND GEAR,
- SPEED ABOVE DOWNSHIFT POINT - SPEED ABOVE DOWNSHIFT POINT

P2 = LOW SPEED SIGNAL

(TRANSMISSION OIL)
K = PRESSURE TO MULTI DISC CLUTCH
P1 = HIGH SPEED SIGNAL
B = PRESSURE TO MULTI DISC BRAKE
24. Transmission (2HL 270/290)

B : Port for Brake

S : Press for Lubrication
K : Port for clutch
EB : Bleed V/V for Brake
J : Measuring Point for Brake
EK : Bleed V/V for Clutch
M : Measuring Point for Clutch
PN : Emergency Parking Brake
N : Speed Sensor
20. Drawing of Transmission
24. Hydro-Circuit for transmission

※ Shift down Protection

- Below 9.7Km/h
- Below 1.5Kg/㎠
- Below 800rpm
24. Emergency Parking Brake release

: To release the parking brake for emergency

by using a grease gun

Normal Released by Grease

24. Front & Rear Axle

Axle Model
Model Remarks
7A 7
Front MS-E3060 8.5% Up
R170W-7A B755
Rear MT-E3060
Front MS-E3070 4.5% Up
R200W-7A B765
Rear MT-E3070
24. Front Axle for 7A and 7
1) Features
2) Detail improvement

Items Description Remarks

Final Drive The length longer 42mm

Bearing The size is increased
Service Brake Brake Disc contact Housing Back rush zero
directly
Reduction Gear Simple reduction System
Hydro Brake
Service Brake Disc The size is increased
24. Rear Axle for 7A
1) Features
 28. Brake Disc Wear Measurement

1. Preparation
1) Turn the final drive at 9 o-clock position
2) Install the measuring gauge
3) Apply the service brake pedal

2. Gap worn out

1) Specification : 1.3 ∼ 4.0mm (Max; 6.5mm)

9 O’clock
24. Final Drive of Front Axle (For 7)
25. Final Drive of Rear Axle for 7
26. Check for Service Brake Disc wear
※ Wear Test procedure.
1) Turn the carrier in 2) Measure the X 3) Measure the Y
upper position

Apply for the service brake release the service brake

4) Gap of Brake Disc (G) = X-Y * Torque : 1Kg.m

5) Specification of Gap of Brake Disc

Items Gap
Spec’ Limited
stroke 2.4∼2.8mm 6.25mm
27. Assembly of Brake Disc

•Cautions
1) Install outer plate and inner plate
alternately like the right photo
for lubrication hole
- Outer plate is not a flat plate
28. Travel Motor and Transmission

1. Front Drive Shaft 5. Relief Valve (Forward)

2. Rear Drive shaft 6. Relief Valve (Reverse)
3. Travel Motor 7. Transmission.
4. Counter Balance Valve.
TRAVEL MOTOR (R140/170W-7 ~200W-7)

COUNTER CHANGE OVER PRESSURE

BALANCE SPOOL ADJUST SCREW

Sec. Relief valve

[360bar]

MA (MB) X
T
check point
main pressure MAX SPEED ADJUST SCREW (PRE-SET)
M18 * 1.5
M1 (CHANGE OVER PRESSURE CHECK PORT), M14 * 1.5
[140W: 280bar / 170W: 265bar / 200W: 250bar]

CHANGE OVER PRESSURE

ADJUST SCREW

MAX SPEED ADJUST SCREW (PRE-SET)

 29. Inside Section of Travel Motor

Measuring Point
(Main Pressure)

Adjuster Bolt for start of

control (170Kg/㎠)
Measuring Point
(G1, Regulated)
30. Hydraulic Circuit of Travel Motor
Measuring point for starting of control

From MCV

※ The pressure of beginning of regulation

Model Pressure Remarks

R140W-7 280Kg/㎠
R170W-7 265Kg/㎠
R200W-7 250Kg/㎠
30. Hydraulic Circuit of Travel Motor

※ The pressure of beginning of regulation

Model Pressure Remarks

R140W-7 280Kg/㎠
R170W-7 265Kg/㎠
R200W-7 250Kg/㎠
31. Hydraulic Pilot Circuit for Travel

When forward
travel is selected,
The arm holding
valve is released by
the selector valve.
32. Transmission Control Valve

Travel Sol’
Ram Lock Valve
Sol’ Valve

Parking
Sol’ Valve

Pressure switch for Transmission

fail (26Kg/㎠)
33. Hyd’ Circuit for Transmission Control Valve
Reducing Valve
(33Kg/㎠)(CT3)
To Transmission

Travel
Pedal POD Valve Travel
(13.7Kg/㎠) safety
(CT7) (CT2)
From Pilot Pump
(40Kg/㎠)
PRESSURE TEST PORTS

CLUTCH BRAKE REAR

1e SPEED 60b (140/170W-7)
33b 80b (200W-7)

170W-7 170W-7

CLUTCH BRAKE FRONT STEERING RIGHT STEERING L EFT

2e SPEED 60b (140/170W-7) 180b 180b
33b 80b (200W-7)
34. Brake Supply Valve
Pressure switch for Brake
Fail (90Kg/㎠)
From Gear Pump

To oil cooler

Orifice & check

Valve

Cutoff Valve
(120 ∼150Kg/㎠)

Relief Valve
(170Kg/㎠)
35. 5 Solenoid Valve Block

Travel sol’ Valve for

Forward

Travel Sol’ Valve for

Reverse

Max Flow cutoff Sol’

for Breaker

Booster Sol’ V/V Emergency

(330 → 360Kg/㎠) release safety
Valve

Safety Sol’ Valve

SOLENOID BANK B3 (feed pressure
BREAKER to option pedal)
Most of the solenoids are situated in the main pumps compartment (CN66)

170W-7
A1 SAFETY SOLENOID (for “joystick” operation)
A2 POWER BOOST SOLENOID
A3 MAX FLOW SOLENOID
A4 TRAVEL REVERSE SOLENOID
A5 TRAVEL FORWARD SOLENOID

B1 “HEAVY MODE” FUNCTION

* BOOM (SWING) PRIORITY for R170/200W-7
* ARM REGENERATION CUT for R170/140W-7
B2 DOZER/OUTRIGGER SEL. SOLENOID
B3 BREAKER

200W-7 B2 B1
B2 B1 B1(CN133)& DOZ/OUT BM/SW PRIOR
DOZ/OUT BM/SW PRIOR B2 (CN73) (CN 73) (CN 133)
(CN 73) (CN 133) for R200W-7
BM/SW DOZ/
PRIOR OUT
Pc3, Pns (boom, swing priority)

(arm regeneration cut) to joysticks &

pedal levers
accu

EPPR valve
feed Line

from
travel pedal Pilot Pump

A5 A4 A3 A2 A1
FORW REV MAX FLOW POW BOOST SAF Pilot line Filter
(CN 123) (CN 122) (CN 137) (CN 88) (CN 68)
36. Travel and Work Selection system

Mode Engine rpm EPPR V/V Press

H 1750 7
S 1650 12
Travel 2150 0
 Swing Reducing
37. Boom Priority System Valve

If you select a heavy duty,

the boom priority solenoid
valve is energized by the cpu Boom
controller to increase speed Priority
Valve
of the boom but Arm and
swing speed is decreased

24Volt

Heavy Duty signal Boom

Priority sol’
valve
38. Hydraulic circuit for Boom Priority System

Boom
Priority valve

Boom Priority sol’

valve
If the Boom priority sol’
valve is energized,
1) Swing reducing spool
goes down.
2) Boom priority spool is
closed in order to close
the Arm2.
39. Hydraulic Circuit for Outrigger
 40. Trouble Shooting Case 1

1) Machine and Problems

Model S/No Hour Description Action
R320LC-7 1927 3500 P1 Pump was broken Replaced the P1 Pump
completely assy’

2) The broken parts

- Piston shoes
- Piston retainer
- Pistons are stuck
 3) The suspected Reason broken

If a piston is stuck inside the Cylinder block, the piston retainer

cannot draw the piston which is stuck and the the piston retainer
should be broken and then it cannot arrange piston shoe’s position

※ Suction Stroke
- A piston should be drew by the
piston retainer for oil suction into
piston
 4) Measures to avoid similar problem

(1) The reason why the piston is stuck

- Lack of lubrication
- Small materials of Contaminated Hyd’ oil

(2) Remedy
Reason Remedy
Lack of lubrication 1. The temperature is so high
- Oil Cooler should be cleaned
2. Confirm the specification of Hyd’ Oil
- for extremely hot Area
Small materials of Oil 1. Replaced hyd’ filer on time regularly
Contamination 2. Replaced hyd’ Oil on time