Excavator Maintenance

Pre-service =
MAINTENANCE ?

※ The R220LC-9(S) is mainly mentioned in this guide book.

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※ Precaution and Proper Maintenance instructions

(1) Start to maintenance after you have the full knowledge of the machine.

(2) Use genuine parts(If not, HHI will not reimburse for the failed parts arising from

the wrong use of maintenance check item).

(3) Use the recommended oil.

(4) Remove the dust or water around the inlet of oil tank before supplying oil.

(5) Drain oil when the temperature of oil is warm.

(6) Do not repair anything while operating the Engine. Stop the engine when you fill

the oil.

(7) Relieve hydraulic system of the pressure before repairing the hydraulic system.

(8) Confirm if the cluster is in the normal condition after completion of service.

(9) For more detail information of maintenance, please contact local Hyundai dealer.

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※ Periodical replacement of safety parts
; The following parts are recommended to replace periodically for using the machine
safely for a long time.

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 1) Fuel hose 2) Heater hose

3) Pump Suction and Delivery hose 4) Boom,Arm and Bucket cylinder line hose

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1. Spec. of Fuel, Coolant and Lubricants

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 Note] 1. Long life Hyd. Oil(5,000hrs) application on HYUNDAI Excavator, Wheel Loader and Forklift.
1) VG 46 type : From Oct. 2008 ~ 2) VG 68 type : From Oct. 2009 ~
☞ One can see the life of Hyd. oil at the Decal in Cabin.
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2. Maintenance Chart

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 Note

* Visual check :
1. Bolt Loosening
2. Leakage
3. Narrowness / Wear
4. Cleaning: Radiator,
Cooler…

Rev]Every 250hr

* Air cleaner(Heavy
dusty Air condition)
1) Check : Everyday
2) Clean : Max. 4 Times
3) Replacement :
Every 250Hrs at least.

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 ☞ See Note 2.

* Recommendation:
1,000Hrs(Normal Air condition)
Note] 1.

2. Hyd. oil change guide for

machine use of breaker.

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Note] 3. 9S-Series, Improvement of Pin&Bushing
① Improve Noise and Durability by Reducing The Gap

Assembling Gap
Group Remark
Before After
④
② ③ A 1 mm 0.5 mm
B 2 mm 1 mm
A: Boom + Upper, Boom + Arm
B: Except Cyl’Installation (However, Boom Cyl’Rod
& Arm Cyl’Rod : 2mm)
② Apply Sintering Bush
- Improve Lubrication and Wear-Resistance
⑤ ⑥ (Injection Period : 50hr  250hr)
③ Apply Polymer Shim : Improve Lubrication

④ Apply Wear-Resistant Cover Plate At Arm End

- Improve Wear-Resistance of The Side of Arm
⑤ Improve Wear-Resistance by Increase of
Hardness of Bucket Boss
- Material Change and Add Heat Treatment
(SM50A  S45C)
- Hardness : HB140  HB240
⑥ Add Reinforce Plate To Control Link
- Improve Strength
- Prevent Link Deformation

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3. MAINTENANCE Instruction

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 R1200LC-9

1-1) E/G Oil consumption review

Model R800LC-9 R1200-9 Note

Engine Model QSX15 QSK23

Power 510HP 760HP

Oil tank capacity 45.4ℓ 70.0ℓ

Oil Q’ty
9.4ℓ(45.4-36) 14ℓ(70-56)
(between Low and High)
Fuel Consumption 52.7ℓ/H 78.32ℓ/H S Mode

0.135ℓ/H 0.55ℓ/H Acceptable

Eng’ Oil Consumption 0.10∼0.25% Normal

2.7ℓ/20H 11ℓ/20H Per 1 day

3.5days(9.4÷2.7) 1.3days(14÷11) Acceptable

Running Time without filling
Eng’ Oil 3.6days(9.4/2.6) 3.5days(14/4) Normal

※ Caution! One can meet Oil pressure low error or worst E/G trouble just in one week.

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 1-2) Causes of excessive E/G Oil consumption

(1) Piston Ring and Cylinder Liner wear

(2) Horsepower output(Load Factor)
- E/G Oil Consumption depends strongly on horsepower output.
(3) High E/G temperature
- Overheating causes increase of Piston and E/G Oil temperature result in faster degradation
of E/G Oil level and accumulation of carbon deposit on piston.
As a rule of Thumb, every 11℃ increasing of temperature the chemical reaction rate goes
double which produce deposits.
(4) Improper Piston ring assembly

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 3)

Wing
Outer Nut
Element

Inner Element
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3-1) T/Shooting Case : Imitated Air filter / out of maintenance period problem

Model R210LC-7 Serial 9484 Working Hours 2,509 Hours

Work
Dealer - Dump Delivery date 2008.12.20
condition

Damaged
(1) Symptom section
- Not possible to Engine start (Dark exhaust gas when cranking).

(2) Check Ruined Pad

ⓐ Air Cleaner inspection
- Imitation Air Cleaner. Primary filter was damaged.
- Filter pad was ruined (torn).
ⓑ Engine Oil was polluted severely.
- Engine Oil Level is low.
ⓒ Engine Head inspection : Piston & Ring are all worn out.

(Imitated Air Cleaner)

(3) Service action
- Engine Overhaul.

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(4) Imitational filters - Poor quality

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 R210LC-9, R380LC-9(S),R450LC-9(s) and up
3-2) Oil washed Air cleaner(Option)
Applied Model] R210LC-9(S)＆Bigger model than R380LC-9(S)

Application]

※ HHI option code: EY12

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 (1) Composition

(Filter
including)

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(2) Service instruction

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 (3) Test result

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 4)

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 5)

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 6)

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 7)

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 Note] 1. Service interval change when work with Breaker

A. Hyd.oil change guide for the average operating rate

B. Service interval

※ Replace the following filters at one time.

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 2. Maintenance trouble case
1/2

Model R210LC-7 Serial No. #8,022 Hour meter 2,195 Hours

Work
Dealer AGCO Breaker Delivery date 2008.07.30
classification

1) Symptoms
- Every attachment doesn’t work(Main pump not work).
- Hyd. oil color is dark.

2) Checks
ⓐ Disassembly of the Main pump
- Piston Shoe (1ea) missing.
- Excessive rear of Piston shoe.
ⓑ Hyd. tank inspection (Damaged Main pump)
- Sticky polluted(dark colored) oil on the Return filter
(and on the bottom of the tank).

3) Remedy
- Main Pump Assy’ replacement and hyd tank cleaning.

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 2/2
4) Remarks (Pictures for the damaged Main pump and polluted Return filter)

(Polluted Return filter)

(Damaged Piston Shoe)

5) The reason why sticky oil is in the hyd. tank

- Muddy cloud inflow to the Tank through the Breaker.
- Muddy cloud and pollutant got into the Hyd. System in hot temperature, and so the sticky oil is piled up
on the bottom of the tank.

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 3. Long life Hyd.oil

A. Effect of the Long life Hyd.oil use

Wrong use of Hyd.oil] Normal hyd. oil use – rare case] Long life hyd. oil use]
: Wear prevention additive is not : Poor environment and hard work : Normal more than 5,000 hrs.
included in the Oil. condition(w. high temperature).

B. P/No(Long life Hyd. oil) C. Normal Hyd. oil characteristic

Long life hyd. Oil Remark Flashing Liquidity
Viscosity Viscosity Temp.
(VG 46) Temp.
Index
91EE-61440 20 Litter
P/No.
91EE-61420 200 Litter

♧
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 8)

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 9)

10)

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 11)

Hyd. oil

Gear oil

11-1)

Grease

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 11-2)

12)

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 13)

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 14)

드레인 플러그

15)

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 16)

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 17)

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 18)

☞ see note (Auto-Grease).

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Note] Auto-Grease

(Model : EP-1, for R800LC-7A/Wheel Loader)

(Model : EBP-2000S, for R800LC-9/R1200LC-9)

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 1) Control unit – Control of Grease filling and pause period

(1) Open the control panel cover with a ‘+’driver.

※ Be careful the Over-torque

(2) Adjust the Grease supply timing with a ‘-’driver.

Pause period
Grease Filling period

•Grease filling cycle increase : Adjust clock-wise.

*Grease filling cycle Decrease : Adjust counter clock-wise

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 ① Used for Additional Grease pumping or control
system check.
② Pushing one time: Greasing once for 16 minutes.

Pause time

A. Lubricating period setting Dial

B. Pause period setting Dial

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 2) Indication of LEDs

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3) Lubrication circuit
(1) Lubrication spots

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 (2) Lubrication circuit

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 Bolt Spring washer

D1 Allotter
D0 Allotter

Spring washer

Protection Cover
Bolt

(D2 Allotter-Bucket link)

(D0,D1 Allotter)

(D3 Allotter) (D4 Allotter)

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 4) Installation and Test
(1) Grease filling(through the Grease nipple with Grease gun)
* To the Grease Pump

Grease nipple

※ Fill the Grease while it be leaked through

the Grease vent.
* Capacity : 8Kg
Grease vent
Grease Tank

Grease nipple

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 (2) Filling through the filling press port

Filling press port

!!! When Grease filling is not sufficient at some grease spots, fill the Grease to
the Allotter directly by hand.

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T/Shooting case] Reamed hall of Arm+Bucket bushing
1/3

Model R800LC-7A Serial No. #0021 Hour meter 2,565 Hours

User SBS Work condition Construction Delivery Date 2009.06.08

1. Symptoms
(1) Severe working noise on the Bucket
(2) Bucket linkage check
- Arm Bushing hole is reamed so much.

2. Check
(1) Auto Grease System
- Grease Nipple trouble on the Boom : Grease leak
- Grease leak at the end of Arm : Grease Nipple is modified by user
- Grease Nipple trouble on the distributor for Swing Bearing. Grease leak

3. Cause (Arm Bushing hole wear)

: Grease Nipple is modified by user → Grease leak → Lack of lubrication

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 D3

D0

(Grease leakage)

D1

(Modified Nipple) (Trouble on Grease nipple)

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 5) Troubleshooting

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4. When required Maintenance item

1) Air Conditioner Filter

Full out

(After filter
separation)

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 2) Pilot Pump Relief Valve Screen Filter

View

(Screen filter for relief v/v)

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 3) Last Guard Filter

P-포트

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