Hyundai Excavator R210LC-7. Service and repair manual

6 - 60

Wiring diagram

2. ENGINE STALL

Before carrying out below procedure, check all the related connectors are properly inserted.

INSPECTION PROCEDURE

YES

SPEC : 200~450mA
See TEST 3

SPEC:5~20kgf/cm

See TEST 4

SPEC : 17.5 1 (20 C)
See TEST 2

Check electric
current at EPPR
valve

Check pressure
at EPPR Valve

Cause

Remedy

Not enough engine
power

Defective EPPR
valve

Short circuit or
poor connection
between
CN-50 - CN-2 or
CN-50 - CN-75

Defective EPPR
valve

Contact cummins
engine dealer

Replace

Check and repair
wire harness

Replace

YES

Check resistance
at EPPR valve

21076MS51

6 - 61

TEST PROCEDURE

Test 3 :

Check electric current at EPPR
valve at S-mode

Install multimeter as figure.
Start engine.
Set the accel dial at "10"(max)
Set S-mode with 2050 50rpm.
Check electric current.

CN-75

Multimeter

EPPR VALVE

CN-75

Supply line, pilot press

Pressure adjusting
screw locknut

(1)

Test 4 :

Check pressure at EPPR valve at
S-mode

Connect pressure gauge at EPPR valve.
Start engine.
Set the accel dial at "10"(max)
Set S-mode with 2050 50rpm.
Operate bucket lever completely push or
pull.
Hold arm lever at the end of stroke.
Check pressure at relief position.

(2)

SPEC : 200~450mA

SPEC : 5~20kgf/cm

(70~280psi)

6-44(1) 290-7

6-44(2) 290-7

6 - 58

GROUP 5 MECHATRONICS SYSTEM (#1001 and up, TIER II)

Wiring diagram

1. ALL ACTUATORS SPEED ARE SLOW

Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good.
Spec : H-mode

2150

50rpm

S-mode

2050

50rpm

Before carrying out below procedure, check all the related connectors are properly inserted.

INSPECTION PROCEDURE

SPEC : 200~450mA
See TEST 3

SPEC : 5~20kgf/cm

See TEST 4

SPEC : 17.5 1 (20 C)
See TEST 2

Check if

Er : 03

on the cluster

Check electric
current at EPPR
valve

Check resistance
at EPPR valve

Check pressure
at EPPR valve

YES

Cause

Remedy

Defective
hydraulic system

Defective
EPPR valve

Defective CPU
controller

Short circuit or
poor connection
between CN-50 -
CN-75

Defective EPPR
valve

Replace

Check and repair
wire harness or
between CN-50-
CN-75

Replace

21076MS51

6 - 59

CN-75

Multimeter

CN-75

Multimeter

EPPR VALVE

Test 2 :

Check resistance at connector
CN-75.

Starting key OFF.
Disconnect connector CN-75 from EPPR
valve at main hydraulic pump.
Check resistance between 2 lines as
figure.

(1)

Test 3 :

Check electric current at EPPR
valve.

Install multimeter as figure.
Start engine.
Set the accel dial at "10"(MAX)
Set S-mode and cancel auto decel mode.
If tachometer show approx 2050 50rpm
check electric current.

(2)

SPEC : 17.5 1 (20 C)

SPEC : 200~450mA(S mode)

CN-75

Supply line, pilot press

Pressure adjusting
screw locknut

SPEC : 5~20kgf/cm

(70~280psi)

Test 4 :

Check pressure at EPPR valve.

Remove plug and connect pressure
gauge as figure.

Gauge capacity : 0 to 40~50kgf/cm

(0 to 570~710psi)

Start engine.
Set the accel dial at "10"(Max).
Set S-mode and cancel auto decel mode.
If tachometer show approx 2050 50rpm
check pressure.
If pressure is not correct, adjust it.
After adjust, test the machine.

(3)

(290-7) 6-38(2)

(290-7) 6-38(3)

(290-7) 6-39(1)

6 - 60

Wiring diagram

2. ENGINE STALL

Before carrying out below procedure, check all the related connectors are properly inserted.

INSPECTION PROCEDURE

YES

SPEC : 200~450mA
See TEST 3

SPEC:5~20kgf/cm

See TEST 4

SPEC : 17.5 1 (20 C)
See TEST 2

Check electric
current at EPPR
valve

Check pressure
at EPPR Valve

Cause

Remedy

Not enough engine
power

Defective EPPR
valve

Short circuit or
poor connection
between
CN-50 - CN-2 or
CN-50 - CN-75

Defective EPPR
valve

Contact cummins
engine dealer

Replace

Check and repair
wire harness

Replace

YES

Check resistance
at EPPR valve

21076MS51

6 - 61

TEST PROCEDURE

Test 3 :

Check electric current at EPPR
valve at S-mode

Install multimeter as figure.
Start engine.
Set the accel dial at "10"(max)
Set S-mode with 2050 50rpm.
Check electric current.

CN-75

Multimeter

EPPR VALVE

CN-75

Supply line, pilot press

Pressure adjusting
screw locknut

(1)

Test 4 :

Check pressure at EPPR valve at
S-mode

(2)

SPEC : 200~450mA

SPEC : 5~20kgf/cm

(70~280psi)

6-44(1) 290-7

6-44(2) 290-7

7 - 1

SECTION 7 MAINTENANCE STANDARD

GROUP 1 OPERATIONAL PERFORMANCE TEST

1. PURPOSE

Performance tests are used to check:

OPERATIONAL PERFORMANCE OF A NEW
MACHINE

Whenever a new machine is delivered in
parts and reassembled at a customer's site,
it must be tested to confirm that the
operational performance of the machine
meets

Hyundai spec

OPERATIONAL PERFORMANCE OF A
WORKING MACHINE

With the passage of time, the machine's
operational performance deteriorates, so
that the machine needs to be serviced
periodically to restore it to its original
performance level.
Before servicing the machine, conduct
performance tests to check the extent of
deterioration, and to decide what kind of
service needs to be done(by referring to the
"Service Limits" in this manual).

OPERATIONAL PERFORMANCE OF A
REPAIRED MACHINE

After the machine is repaired or serviced, it
must be tested to confirm that its
operational performance was restored by
the repair and/or service work done.

Working
condition

Operating

Maintenance
record

21077MS01

7 - 2

2. TERMINOLOGY

STANDARD

Specifications applied to the brand-new
machine, components and parts.

SERVICE LIMIT

The lowest acceptable performance level.
When the performance level of the machine
falls below this level, the machine must be
removed from work and repaired.
Necessary parts and components must be
replaced.

21077MS02

21077MS03

7 - 3

3. OPERATION FOR PERFORMANCE TESTS

Observe the following rules in order to carry
out performance tests accurately and
safely.

The machine

Repair any defects and damage found,
such as oil or water leaks, loose bolts,
cracks and so on, before starting to test.

Test area

Select a hard, flat surface.
Secure enough space to allow the
machine to run straight more than 20m,
and to make a full swing with the front
attachment extended.
If required, rope off the test area and
provide signboards to keep unauthorized
personnel away.

Precautions

Before starting to test, agree upon the
signals to be employed for communication
among coworkers. Once the test is
started, be sure to communicate with
each other using these signals, and to
follow them without fail.
Operate the machine carefully and
always give first priority to safety.
While testing, always take care to avoid
accidents due to landslides or contact
with high voltage power lines. Always
confirm that there is sufficient space for
full swings.
Avoid polluting the machine and the
ground with leaking oil. Use oil pans to
catch escaping oil. Pay special attention
to this when removing hydraulic pipings.

Make precise measurements

Accurately calibrate test instruments in
advance to obtain correct data.
Carry out tests under the exact test
conditions prescribed for each test item.
Repeat the same test and confirm that
the test data obtained can be procured
repeatedly. Use mean values of
measurements if necessary.

(1)

(2)

(3)

(4)

(210-7) 7-3

7 - 4

ENGINE SPEED

Measure the engine speed at each power
mode
The engine speed at each power mode
must meet standard RPM; if not, all other
operational performance data will be
unreliable. It is essential to perform this
test first.

Preparation

Warm up the machine, until the engine
coolant temperature reaches 50

C or

more, and the hydraulic oil is 50 5 C.
Set the accel dial at 10(Max) position.
Push the H-mode switch and confirm
that the fuel injection pump governor
lever comes into contact with the high-
idle stopper.
Measure the engine RPM.

Measurement

Start the engine. The engine will run at
start idle speed. Measure engine speed
with a tachometer.
Measure and record the engine speed at
each mode(H, S).
Select the H-mode.
Lightly operate the bucket control lever a
few times, then return the control lever to
neutral; The engine will automatically
enter the auto-idle speed after 4
seconds.
Measure and record the auto deceleration
speed.

(1)

(2)

(3)

Evaluation

The measured speeds should meet the following specifications.

(4)

Model

R210LC-7

Engine speed

Start idle

H mode

S mode

Auto decel

Standard

950 100 *1050 100

2250 50 *2150 50

2150 50 *2050 50

1200 100

Remarks

Unit : rpm

Condition : Set the accel dial at 10(Max) position.
* TIER II

7 - 5

TRAVEL SPEED

Measure the time required for the
excavator to travel a 20m test track.

Preparation

Adjust the tension of both tracks to be
equal.
Prepare a flat and solid test track 20m in
length, with extra length of 3 to 5m on
both ends for machine acceleration and
deceleration.
Hold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
Keep the hydraulic oil temperature at
50 5 C.

Measurement

Measure both the low and high speeds
of the machine.
Before starting either the low or high
speed tests, adjust the travel mode
switch to the speed to be tested, then
select the following switch positions.
Mode selector : H mode
Start traveling the machine in the
acceleration zone with the travel levers at
full stroke.
Measure the time required to travel 20m.
After measuring the forward travel
speed, turn the upperstructure 180 and
measure the reverse travel speed.
Repeat steps

and

three times in

each direction and calculate the average
values.

Evaluation

0.3~0.5m

R210LC-7

3 ~ 5m

R210LC-7

20m

3 ~ 5m

R210LC-7

(1)

(2)

(3)

The average measured time should meet the following specifications.

(4)

Unit : Seconds / 20m

Model

R210LC-7

Travel speed

1 Speed

2 Speed

Standard

21.2 2.0

13.6 1.0

Maximum allowable

26.5

17.0

Remarks

21077MS04

21077MS05

7 - 6

TRACK REVOLUTION SPEED

Measure the track revolution cycle time
with the track raised off ground.

Preparation

Adjust the tension of both side tracks to
be equal.
On the track to be measured, mark one
shoe with chalk.
Swing the upperstructure 90 and lower
the bucket to raise the track off ground.
Keep the boom-arm angle between 90 to
110 as shown. Place blocks under
machine frame.
Keep the hydraulic oil temperature at
50 5 C.

Measurement

Select the following switch positions.
Travel mode switch : 1 or 2 speed
Mode selector : H mode
Auto decel switch : OFF
Operate the travel control lever of the
raised track in full forward and reverse.
Rotate 1 turn, then measure time taken
for next 3 revolutions.
Raise the other side of machine and
repeat the procedure.
Repeat steps

and

three times and

calculate the average values.

Evaluation

Mark

90~110

(1)

(2)

(3)

The revolution cycle time of each track should meet the following specifications.

Model

R210LC-7

Travel speed

1 Speed

2 Speed

Standard

28.0 2.0

18.0 2.0

Maximum allowable

35.0

22.5

Unit : Seconds / 3 revolutions

(4)

21077MS06

7 - 7

TRAVEL DEVIATION

Measure the deviation by the tracks from
a 20m straight line.

Preparation

Adjust the tension of both tracks to be
equal.
Provide a flat, solid test yard 20m in
length, with extra length of 3 to 5m on
both ends for machine acceleration and
deceleration.
Hold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
Keep the hydraulic oil temperature at
50 5 C.

Measurement

Measure the amount of mistracking at
high and low travel speeds.
Before beginning each test, select the
following switch positions.
Mode selector : H mode
Start traveling the machine in the
acceleration zone with the travel levers at
full stroke.
Measure the distance between a straight
20m line and the track made by the
machine.(Dimension a)
After measuring the tracking in forward
travel, turn the upperstructure 180 and
measure that in reverse travel.
Repeat steps

and

three times and

calculate the average values.

Evaluation

0.3~0.5m

R210LC-7

(1)

(2)

(3)

Unit : mm / 20m

Mistrack should be within the following specifications.

3~5m extra length

20M

Model

R210LC-7

Standard

200 below

Maximum allowable

240

Remarks

(4)

21077MS04

(210-7) 7-7(2)

7 - 8

SWING SPEED

Measure the time required to swing three
complete turns.

Preparation

Check the lubrication of the swing gear
and swing bearing.
Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
With the arm rolled out and bucket rolled
in, hold the bucket so that the height of
the bucket pin is the same as the boom
foot pin. The bucket must be empty.
Keep the hydraulic oil temperature at
50 5 C.

Measurement

Select the following switch positions.
Mode selector : Each mode
Operate swing control lever fully.
Swing 1 turn and measure time taken to
swing next 3 revolutions.
Repeat steps

and

three time and

calculate the average values.

Evaluation

R210LC-7

(1)

(2)

(3)

Unit : Seconds / 3 revolutions

The time required for 3 swings should meet the following specifications.

Model

R210LC-7

Power selector switch

H mode

S mode

Standard

15.2 1.5

10.4 1.5

Maximum allowable

19.0

(4)

21077MS07

7 - 9

SWING FUNCTION DRIFT CHECK

Measure the swing drift on the bearing
outer circumference when stopping after a
360 full speed swing.

Preparation

Measurement

Conduct this test in the H mode.
Select the following switch positions.
Mode selector : H mode
Operate the swing control lever fully and
return it to the neutral position when the
mark on the upperstructure aligns with
that on track frame after swinging 360
Measure the distance between the two
marks.
Align the marks again, swing 360 , then
test the opposite direction.
Repeat steps

and

three times each

and calculate the average values.

Evaluation

R210LC-7

Drift angle

Swing start & stop

360 swing

(1)

(2)

(3)

Unit : Degree

The measured drift angle should be within the following specifications.

(4)

Model

R210LC-7

Mode select switch

H mode

Standard

90 below

Maximum allowable

157.5

Remarks

21077MS07

21077MS08

Hyundai Excavator R210LC-7. Service and repair manual - page 23