Robex 220lc9a
Robex 220lc9a
CRAWLER EXCAVATOR
 SERVICE MANUAL
TABLE OF CONTENT
FOREWORD                                                                     9
    1. Structure                                                             9
    2. How To Read The Service Manual                                        10
    3. Conversion Table                                                      11
SECTION 1 GENERAL                                                           17
    Group 1 Safety                                                           28
    Group 2 Specifications                                                   37
          1. Major Component                                                 37
           2. Specifications                                                 38
           3. Working Range                                                  41
           4. Weight                                                         44
           5. Lifting Capacities ·                                           47
          1)                                                                 47
           6. Bucket Selection Guide                                         54
           7. Undercarriage                                                  56
           8. Specifications For Major Components                            58
           9. Recommended Oils                                               62
1. STRUCTURE
 This service manual has been prepared as an aid to improve the quality of repairs by giving the
 serviceman an accurate understanding of the product and by showing him the correct way to
 perform repairs and make judgements. Make sure you understand the contents of this manual and
 use it to full effect at every opportunity.
 This service manual mainly contains the necessary technical information for operations performed in
 a service workshop.
 For ease of understanding, the manual is divided into the following sections.
 SECTION 1 GENERAL
 This section explains the safety hints and gives the specification of the machine and major
 components.
 SECTION 2 STRUCTURE AND FUNCTION
 This section explains the structure and function of each component. It serves not only to give an
 understanding of the structure, but also serves as reference material for troubleshooting.
 SECTION 3 HYDRAULIC SYSTEM
 This section explains the hydraulic circuit, single and combined operation.
 SECTION 4 ELECTRICAL SYSTEM
 This section explains the electrical circuit, monitoring system and each component. It serves not
 only to give an understanding electrical system, but also serves as reference material for trouble
 shooting.
 SECTION 5 MECHATRONICS SYSTEM
 This section explains the computer aided power optimization system and each component.
 SECTION 6 TROUBLESHOOTING
 This section explains the troubleshooting charts correlating problems to causes.
 SECTION 7 MAINTENANCE STANDARD
 This section gives the judgement standards when inspecting disassembled parts.
 SECTION 8 DISASSEMBLY AND ASSEMBLY
 This section explains the order to be followed when removing, installing, disassembling or
 assembling each component, as well as precautions to be taken for these operations.
 SECTION 9 COMPONENT MOUNTING TORQUE
 This section shows bolt specifications and standard torque values needed when mounting
 components to the machine.
 The specifications contained in this shop manual are subject to change at any time and without any
 advance notice. Contact your HYUNDAI distributor for the latest information.
0-1
0-2
    Example
    1. Method of using the Conversion Table to convert from millimeters to inches
       Convert 55mm into inches.
            (1) Locate the number 50in the vertical column at the left side, take this as ⓐ, then draw a
                horizontal line from ⓐ.
            (2) Locate the number 5in the row across the top, take this as ⓑ, then draw a perpendicular line
                down from ⓑ.
            (3) Take the point where the two lines cross as ⓒ. This point ⓒ gives the value when converting
                from millimeters to inches. Therefore, 55mm = 2.165 inches.
    Millimeters to inches                                                   ⓑ
                                                                                                   1mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
                                                            0-3
Millimeters to inches                                                                     1mm = 0.03937in
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9
	 50	     110.23	 112.44	       114.64	   116.85	   119.05	 121.25	   123.46	 125.66	   127.87	     130.07
	 60	     132.28	 134.48	       136.69	   138.89	   141.10	 143.30	   145.51	 147.71	   149.91	     152.12
	 70	     154.32	 156.53	       158.73	   160.94	   163.14	 165.35	   167.55	 169.76	   171.96	     174.17
	 80	     176.37	 178.57	       180.78	   182.98	   185.19	 187.39	   189.60	 191.80	   194.01	     196.21
	 90	     198.42	 200.62	       202.83	   205.03	   207.24	 209.44	   211.64	 213.85	   216.05	     218.26
                                                     0-4
Liter to U.S. Gallon                                                                    1ℓ = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
	 50	      13.209	 13.473	      13.737	   14.001	   14.265	 14.529	   14.795	 15.058	    15.322	   15.586
	 60	      15.850	 16.115	      16.379	   16.643	   16.907	 17.171	   17.435	 17.700	    17.964	   18.228
	 70	      18.492	 18.756	      19.020	   19.285	   19.549	 19.813	   20.077	 20.341	    20.605	   20.870
	 80	      21.134	 21.398	      21.662	   21.926	   22.190	 22.455	   22.719	 22.983	    23.247	   23.511
	 90	      23.775	 24.040	      24.304	   24.568	   24.832	 25.096	   25.631	 25.625	    25.889	   26.153
0 1 2 3 4 5 6 7 8 9
	 50	      10.998	 11.281	      11.438	   11.658	   11.878	 12.098	   12.318	 12.528	    12.758	   12.978
	 60	      13.198	 13.418	      13.638	   13.858	   14.078	 14.298	   14.518	 14.738	    14.958	   15.178
	 70	      15.398	 15.618	      15.838	   16.058	   16.278	 16.498	   16.718	 16.938	    17.158	   17.378
	 80	      17.598	 17.818	      18.037	   18.257	   18.477	 18.697	   18.917	 19.137	    19.357	   19.577
	 90	      19.797	 20.017	      20.237	   20.457	   20.677	 20.897	   21.117	 21.337	    21.557	   21.777
                                                     0-5
kgf·m to lbf·ft                                                                       1kgf·m = 7.233lbf·ft
0 1 2 3 4 5 6 7 8 9
	 50	       361.7	   368.9	   376.1	    383.4	    390.6	   397.8	   405.1	   412.3	    419.5	     426.8
	 60	       434.0	   441.2	   448.5	    455.7	    462.9	   470.2	   477.4	   484.6	    491.8	     499.1
	 70	       506.3	   513.5	   520.8	    528.0	    535.2	   542.5	   549.7	   556.9	    564.2	     571.4
	 80	       578.6	   585.9	   593.1	    600.3	    607.6	   614.8	   622.0	   629.3	    636.5	     643.7
	 90	       651.0	   658.2	   665.4	    672.7	    679.9	   687.1	   694.4	   701.6	    708.8	     716.1
	 100	      723.3	   730.5	   737.8	    745.0	    752.2	   759.5	   766.7	   773.9	    781.2	     788.4
	 110	      795.6	   802.9	   810.1	    817.3	    824.6	   831.8	   839.0	   846.3	    853.5	     860.7
	 120	      868.0	   875.2	   882.4	    889.7	    896.9	   904.1	   911.4	   918.6	    925.8	     933.1
	 130	      940.3	   947.5	   954.8	    962.0	    969.2	   976.5	   983.7	   990.9	    998.2	   10005.4
	 140	     1012.6	 1019.9	    1027.1	   1034.3	   1041.5	 1048.8	   1056.0	 1063.2	   1070.5	    1077.7
	 150	     1084.9	 1092.2	    1099.4	   1106.6	   1113.9	 1121.1	   1128.3	 1135.6	   1142.8	    1150.0
	 160	     1157.3	 1164.5	    1171.7	   1179.0	   1186.2	 1193.4	   1200.7	 1207.9	   1215.1	    1222.4
	 170	     1129.6	 1236.8	    1244.1	   1251.3	   1258.5	 1265.8	   1273.0	 1280.1	   1287.5	    1294.7
	 180	     1301.9	 1309.2	    1316.4	   1323.6	   1330.9	 1338.1	   1345.3	 1352.6	   1359.8	    1367.0
	 190	     1374.3	 1381.5	    1388.7	   1396.0	   1403.2	 1410.4	   1417.7	 1424.9	   1432.1	    1439.4
                                                   0-6
kgf/cm2 to lbf/in2                                                             1kgf / cm2 = 14.2233lbf / in2
0 1 2 3 4 5 6 7 8 9
	 50	        711.2	   725.4	   739.6	   753.8	   768.1	   782.3	   796.5	   810.7	    825.0	       839.2
	 60	        853.4	   867.6	   881.8	   896.1	   910.3	   924.5	   938.7	   953.0	    967.2	       981.4
	 70	        995.6	   1010	    1024	    1038	    1053	    1067	    1081	    1095	     1109	         1124
	 80	         1138	   1152	    1166	    1181	    1195	    1209	    1223	    1237	     1252	         1266
	 90	         1280	   1294	    1309	    1323	    1337	    1351	    1365	    1380	     1394	         1408
	 100	        1422	   1437	    1451	    1465	    1479	    1493	    1508	    1522	     1536	         1550
	 110	        1565	   1579	    1593	    1607	    1621	    1636	    1650	    1664	     1678	         1693
	 120	        1707	   1721	    1735	    1749	    1764	    1778	    1792	    1806	     1821	         1835
	 130	        1849	   2863	    1877	    1892	    1906	    1920	    1934	    1949	     1963	         1977
	 140	        1991	   2005	    2020	    2034	    2048	    2062	    2077	    2091	     2105	         2119
	 150	        2134	   2148	    2162	    2176	    2190	    2205	    2219	    2233	     2247	         2262
	 160	        2276	   2290	    2304	    2318	    2333	    2347	    2361	    2375	     2389	         2404
	 170	        2418	   2432	    2446	    2460	    2475	    2489	    2503	    2518	     2532	         2546
	 180	        2560	   2574	    2589	    5603	    2617	    2631	    2646	    2660	     2674	         2688
	 200	        2845	   2859	    2873	    2887	    2901	    2916	    2930	    2944	     2958	         2973
	 210	        2987	   3001	    3015	    3030	    3044	    3058	    3072	    3086	     3101	         3115
	 220	        3129	   3143	    3158	    3172	    3186	    3200	    3214	    3229	     3243	         3257
	 230	        3271	   3286	    3300	    3314	    3328	    3343	    3357	    3371	     3385	         3399
	 240	        3414	   3428	    3442	    3456	    3470	    3485	    3499	    3513	     3527	         3542
                                                  0-7
TEMPERATURE
Fahrenheit-Centigrade Conversion.
A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse
is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
	 ˚C		               ˚F	      ˚C		              ˚F	         ˚C		           ˚F	      ˚C		               ˚F
	 -40.4	   -40	     -40.0	   -11.7	    11	     51.8	        7.8	    46	   114.8	   27.2	     81	     117.8
	 -37.2	   -35	     -31.0	   -11.1	    12	     53.6	        8.3	    47	   116.6	   27.8	     82	     179.6
	 -34.4	   -30	     -22.0	   -10.6	    13	     55.4	        8.9	    48	   118.4	   28.3	     83	     181.4
	 -31.7	   -25	     -13.0	   -10.0	    14	     57.2	        9.4	    49	   120.2	   28.9	     84	     183.2
	 -28.9	   -20	      -4.0	    -9.4	    15	     59.0	        10.0	   50	   122.0	   29.4	     85	     185.0
                                                      0-8
                                                                               SECTION 1 GENERAL
13031GE01
13031GE02
                                                   1-1
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors,
ambulance ser vice, hospital, and fire
department near your telephone.
13031GE04
13031GE05
13031GE06
13031GE07
                                                    1-2
KEEP RIDERS OFF EXCAVATOR
Only allow the operator on the excavator. Keep
riders off.
Riders on excavator are subject to injury such
as being struck by foreign objects and being
thrown off the excavator. Riders also obstruct
the operator's view resulting in the excavator
being operated in an unsafe manner.
                                                        13031GE08
13031GE26
                                                 1-3
SUPPORT MACHINE PROPERLY
Always lower the attachment or implement to
the ground before you work on the machine. If
you must wor k on a lifted machine or
attachment, securely support the machine or
attachment.
Do not support the machine on cinder blocks,
hollow tiles, or props that may crumble under
continuous load.                                       13031GE10
13031GE11
13031GE12
13031GE13
                                                 1-4
BEWARE OF EXHAUST FUMES
Prevent asphyxiation. Engine exhaust fumes
can cause sickness or death.
If you must operate in a building, be positive
there is adequate ventilation. Either use an
exhaust pipe extension to remove the exhaust
fumes or open doors and windows to bring
enough outside air into the area.
REMOVE PAINT BEFORE WELDING OR
HEATING
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint
is heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area.
Dispose of paint and solvent properly.
Remove paint before welding or heating:
· If you sand or grind paint, avoid breathing the 	         13031GE14
	 dust.
	 Wear an approved respirator.
·If you use solvent or paint stripper, remove
 stripper with soap and water before welding.
 Remove solvent or paint stripper containers
 and other flammable material from area.
 Allow fumes to disperse at least 15 minutes
 before welding or heating.
13031GE15
                                                      1-5
SERVICE MACHINE SAFELY
Tie long hair behind your head. Do not wear a
necktie, scarf, loose clothing or necklace when
you work near machine tools or moving parts.
If these items were to get caught, severe injury
could result.
Remove rings and other jewelry to prevent
electrical shorts and entanglement in moving
parts.                                                   13031GE16
13031GE17
13031GE19
                                                   1-6
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
Flammable spray can be generated by heating
near pressurized fluid lines, resulting in severe
burns to yourself and bystanders. Do not heat
by welding, soldering, or using a torch near
pressurized fluid lines or other flammable
materials.
Pressurized lines can be accidentally cut when            13031GE20
                                                    1-7
PREVENT ACID BURNS
Sulfuric acid in battery electrolyte is poisonous.
It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into
eyes.
Avoid the hazard by:
 1. Filling batteries in a well-ventilated area.
 2. Wearing eye protection and rubber gloves.
 3. Avoiding breathing fumes when electrolyte
    is added.
 4. Avoiding spilling of dripping electrolyte.
 5. Use proper jump start procedure.
If you spill acid on yourself:
  1. Flush your skin with water.
  2. Apply baking soda or lime to help neutralize
     the acid.
  3. Flush your eyes with water for 10-15
     minutes. Get medical attention immediate-
     ly.                                                   13031GE22
If acid is swallowed:
  1. Drink large amounts of water or milk.
  2. Then drink milk of magnesia, beaten eggs,
     or vegetable oil.
  3. Get medical attention immediately.
                                                     1-8
DISPOSE OF FLUIDS PROPERLY
Improperly disposing of fluids can harm the
environment and ecology. Before draining any
fluids, find out the proper way to dispose of
waste from your local environmental agency.
Use proper containers when draining fluids. Do
not use food or beverage containers that may
mislead someone into drinking from them.
DO NOT pour oil into the ground, down a drain,
or into a stream, pond, or lake. Observe                   13031GE24
relevant environmental protection regulations
when disposing of oil, fuel, coolant, brake fluid,
filters, batteries, and other harmful waste.
13031GE25
                                                     1-9
                                                                               SECTION 1 GENERAL
13031GE01
13031GE02
                                                   1-1
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors,
ambulance ser vice, hospital, and fire
department near your telephone.
13031GE04
13031GE05
13031GE06
13031GE07
                                                    1-2
KEEP RIDERS OFF EXCAVATOR
Only allow the operator on the excavator. Keep
riders off.
Riders on excavator are subject to injury such
as being struck by foreign objects and being
thrown off the excavator. Riders also obstruct
the operator's view resulting in the excavator
being operated in an unsafe manner.
                                                        13031GE08
13031GE26
                                                 1-3
SUPPORT MACHINE PROPERLY
Always lower the attachment or implement to
the ground before you work on the machine. If
you must wor k on a lifted machine or
attachment, securely support the machine or
attachment.
Do not support the machine on cinder blocks,
hollow tiles, or props that may crumble under
continuous load.                                       13031GE10
13031GE11
13031GE12
13031GE13
                                                 1-4
BEWARE OF EXHAUST FUMES
Prevent asphyxiation. Engine exhaust fumes
can cause sickness or death.
If you must operate in a building, be positive
there is adequate ventilation. Either use an
exhaust pipe extension to remove the exhaust
fumes or open doors and windows to bring
enough outside air into the area.
REMOVE PAINT BEFORE WELDING OR
HEATING
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint
is heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area.
Dispose of paint and solvent properly.
Remove paint before welding or heating:
· If you sand or grind paint, avoid breathing the 	         13031GE14
	 dust.
	 Wear an approved respirator.
·If you use solvent or paint stripper, remove
 stripper with soap and water before welding.
 Remove solvent or paint stripper containers
 and other flammable material from area.
 Allow fumes to disperse at least 15 minutes
 before welding or heating.
13031GE15
                                                      1-5
SERVICE MACHINE SAFELY
Tie long hair behind your head. Do not wear a
necktie, scarf, loose clothing or necklace when
you work near machine tools or moving parts.
If these items were to get caught, severe injury
could result.
Remove rings and other jewelry to prevent
electrical shorts and entanglement in moving
parts.                                                   13031GE16
13031GE17
13031GE19
                                                   1-6
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
Flammable spray can be generated by heating
near pressurized fluid lines, resulting in severe
burns to yourself and bystanders. Do not heat
by welding, soldering, or using a torch near
pressurized fluid lines or other flammable
materials.
Pressurized lines can be accidentally cut when            13031GE20
                                                    1-7
PREVENT ACID BURNS
Sulfuric acid in battery electrolyte is poisonous.
It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into
eyes.
Avoid the hazard by:
 1. Filling batteries in a well-ventilated area.
 2. Wearing eye protection and rubber gloves.
 3. Avoiding breathing fumes when electrolyte
    is added.
 4. Avoiding spilling of dripping electrolyte.
 5. Use proper jump start procedure.
If you spill acid on yourself:
  1. Flush your skin with water.
  2. Apply baking soda or lime to help neutralize
     the acid.
  3. Flush your eyes with water for 10-15
     minutes. Get medical attention immediate-
     ly.                                                   13031GE22
If acid is swallowed:
  1. Drink large amounts of water or milk.
  2. Then drink milk of magnesia, beaten eggs,
     or vegetable oil.
  3. Get medical attention immediately.
                                                     1-8
DISPOSE OF FLUIDS PROPERLY
Improperly disposing of fluids can harm the
environment and ecology. Before draining any
fluids, find out the proper way to dispose of
waste from your local environmental agency.
Use proper containers when draining fluids. Do
not use food or beverage containers that may
mislead someone into drinking from them.
DO NOT pour oil into the ground, down a drain,
or into a stream, pond, or lake. Observe                   13031GE24
relevant environmental protection regulations
when disposing of oil, fuel, coolant, brake fluid,
filters, batteries, and other harmful waste.
13031GE25
                                                     1-9
GROUP 2 SPECIFICATIONS
1. MAJOR COMPONENT
                                                                                        After
                                                                                        treatment
                                                                                        device
Engine
Radiator
Tooth Bucket Turning joint Swing motor Main control valve Oil cooler
Swing bearing
2209A2SP01
                                                1-10
2. SPECIFICATIONS
 1) R220LC-9A
     ·5.68 m (18' 8") BOOM and 2.92 m (9' 7") ARM
                                                                I(I')                          D
 C
                                                                             E
                                                                            G
                                                                        F
                                                                                                 H
                                                     J                                         M
                                                     K                               N
                                         A                                                    B(L)
21092SP02
                                              1-11
2) R220LC-9A LONG REACH
    ·8.2 m (26' 11") BOOM and 6.3 m (20' 8") ARM
                                                            I(I')                             D
C
                                                                            E
                                                                        G
                                                                    F
                                                                                               H
                                                 J                                           M
                                                 K                           N
                                    A                                                       B(L)
21092SP06
                                              1-12
3) R220LC-9A HIGH WALKER
   ·5.68 m (18' 8") BOOM and 2.92 m (9' 7") ARM
                                                      I(I')                             D
   C
                                                                          E
                                                                      G
                                                                  F
                                                                                            H
                                              J                                         M
                                              K                           N
                                    A                                                  B(L)
                                                                                                  21092SP07
                                              1-13
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