PDF Service Manual Hyundai HX210 HX220S - 2 MB
Navigate complex repairs with confidence using this official service manual for the Hyundai HX210 and HX220S excavators.
This comprehensive document provides detailed procedures for maintenance, troubleshooting, disassembly, and assembly of all major components.
It includes hydraulic and electrical schematics, making it an indispensable tool for any service technician.
Keep your Hyundai excavators performing at their best with this essential guide.
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--- Page 1 ---
CONTENTS
SECTION 1 GENERAL
Group 1 Safety Hints --------------------------------------------------------------------------------------------------------- 1-1
Group 2 Specifications ------------------------------------------------------------------------------------------------------ 1-10
SECTION 2 STRUCTURE AND FUNCTION
Group 1 Pump Device ------------------------------------------------------------------------------------------------------- 2-1
Group 2 Main Control Valve ---------------------------------------------------------------------------------------------- 2-20
Group 3 Swing Device ------------------------------------------------------------------------------------------------------ 2-56
Group 4 Travel Device ------------------------------------------------------------------------------------------------------- 2-67
Group 5 RCV Lever ----------------------------------------------------------------------------------------------------------- 2-81
Group 6 RCV Pedal ----------------------------------------------------------------------------------------------------------- 2-85
SECTION 3 HYDRAULIC SYSTEM
Group 1 Hydraulic Circuit -------------------------------------------------------------------------------------------------- 3-1
Group 2 Main Circuit --------------------------------------------------------------------------------------------------------- 3-3
Group 3 Pilot Circuit ---------------------------------------------------------------------------------------------------------- 3-6
Group 4 Single Operation ------------------------------------------------------------------------------------------------- 3-13
Group 5 Combined Operation ------------------------------------------------------------------------------------------ 3-23
SECTION 4 ELECTRICAL SYSTEM
Group 1 Component Location ------------------------------------------------------------------------------------------ 4-1
Group 2 Electrical Circuit -------------------------------------------------------------------------------------------------- 4-3
Group 3 Electrical Component Specification ------------------------------------------------------------------ 4-20
Group 4 Connectors ---------------------------------------------------------------------------------------------------------- 4-29
SECTION 5 MECHATRONICS SYSTEM
Group 1 Outline ----------------------------------------------------------------------------------------------------------------- 5-1
Group 2 Mode selection System -------------------------------------------------------------------------------------- 5-3
Group 3 Automatic Deceleration System ------------------------------------------------------------------------ 5-6
Group 4 Travel Speed Control System ---------------------------------------------------------------------------- 5-7
Group 5 Automatic Warming Up Function ---------------------------------------------------------------------- 5-8
Group 6 Engine Overheat Prevention Function -------------------------------------------------------------- 5-9
--- Page 3 ---
SECTION 1 GENERAL
Group 1 Safety Hints ---------------------------------------------------------------------------------------------------- 1-1
Group 2 Specifications ------------------------------------------------------------------------------------------------- 1-10
--- Page 4 ---
SPECIFICATIONS
GROUP 2 SPECIFICATIONS
1. MAJOR COMPONENT
Tool box Fuel tank Hydraulic tank Main pump
Engine
Charge air cooler
Radiator
Tooth Bucket Turning joint Swing motor Main control valve Oil cooler
Arm Arm cylinder Boom Boom cylinder Cab Precleaner Counterweight
Swing
bearing
Bucket cylinder Connecting link Idler Carrier roller Sprocket
Side cutter Connecting rod Track roller Track Travel motor
210S2SP01A
1-10
--- Page 5 ---
Model Type Boom Arm Counterweight Shoe Wheel Dozer Outrigger
MONO Length [mm] Length [mm] weight [kg] width [mm] width [mm] Front Rear Front Rear
HX210S
BOOM 5680 2920 3600 600 - - - - -
B
· : Rating over-front · : Rating over-side or 360 degree A
Lift-point radius (B) At max. reach
Lift-point 1.5 m (4.9 ft) 3.0 m (9.8 ft) 4.5 m (14.8 ft) 6.0 m (19.7 ft) 7.5 m (24.6 ft) Capacity Reach
height (A)
m (ft)
7.5 m kg *4450 4450 *3370 *3370 6.26
(24.6 ft) lb *9810 9810 *7430 *7430 (20.5)
6.0 m kg *4440 *4440 *3100 3080 7.38
(19.7 ft) lb *9790 *9790 *6830 6790 (24.2)
4.5 m kg *4960 4280 4570 2960 *3020 2590 8.07
(14.8 ft) lb *10930 9440 10080 6530 *6660 5710 (26.5)
3.0 m kg *7400 6190 *5790 4030 4450 2850 *3070 2340 8.43
(9.8 ft) lb *16310 13650 *12760 8880 9810 6280 *6770 5160 (27.7)
1.5 m kg *9130 5670 6050 3790 4320 2730 *3250 2240 8.51
(4.9 ft) lb *20130 12500 13340 8360 9520 6020 *7170 4940 (27.9)
0.0 m kg *5920 *5920 9140 5390 5850 3610 4220 2640 *3590 2280 8.32
(0.0 ft) lb *13050 *13050 20150 11880 12900 7960 9300 5820 *7910 5030 (27.3)
-1.5 m kg *6500 *6500 *10400 10130 9040 5300 5770 3530 4190 2610 3950 2470 7.84
(-4.9 ft) lb *14330 *14330 *22930 22330 19930 11680 12720 7780 9240 5750 8710 5450 (25.7)
-3.0 m kg *11120 *11120 *14170 10310 9110 5360 5800 3560 4680 2920 7.00
(-9.8 ft) lb *24520 *24520 *31240 22730 20080 11820 12790 7850 10320 6440 (23.0)
-4.5 m kg *11620 10680 *8190 5570 *6080 4080 5.65
(-14.8 ft) lb *25620 23550 *18060 12280 *13400 8990 (18.5)
Note 1. Lifting capacity are based on ISO 10567.
2. Lifting capacity of the HX series does not exceed 75% of tipping load with the machine on firm,
level ground or 87% of full hydraulic capacity.
3. The Lift-point is bucket pivot mounting pin on the arm (without bucket mass).
4. *Indicates load limited by hydraulic capacity.
※ Lifting capacities are based upon a standard machine conditions.
Lifting capacities will vary with different work tools, ground conditions and attachments.
The difference between the weight of a work tool attachment must be subtracted.
Consult your HD Hyundai Construction Equipment dealer regarding the lifting capacities for
specific work tools and attachments.
Failure to comply to the rated load can cause possible personal injury or property damage.
Make adjustments to the rated load as necessory for non-standard configurations.
1-17
--- Page 6 ---
7. UNDERCARRIAGE
1) TRACKS
X-leg type center frame is integrally welded with reinforced box-section track frames. The design
includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock absorb-
ing springs, and assembled track-type tractor shoes with triple grousers.
2) TYPES OF SHOES
Triple grouser
Model Shapes
Shoe width mm (in) 600 (24) - - 800 (32)
Operating weight kg (lb) 20830 (45920) - - 21380 (47140)
HX210S
Ground pressure kgf/cm2 (psi) 0.48 (6.81) - - 0.42 (5.99)
Overall width mm (ft-in) 2800 (9' 2") - - 3000 (9' 10")
Shoe width mm (in) 600 (24)★ 600 (24) 700 (28) 800 (32)
Operating weight kg (lb) 21260 (46870) 21450 (47290) 21750 (47950) 22040 (48590)
HX220S
Ground pressure kgf/cm2 (psi) 0.45 (6.45) 0.46 (6.51) 0.40 (5.56) 0.35 (5.02)
Overall width mm (ft-in) 2990 (9' 10") 2800 (9' 2") 3090 (10' 2") 3190 (10' 6")
★ : 8.5 T
3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE
Item Quantity
Carrier rollers 2 EA
HX210S 7 EA
Track rollers
HX220S 9 EA
HX210S 46 EA
Track shoes
HX220S 49 EA
1-20
--- Page 7 ---
2) REGULATOR (1/2)
412 876 874 755 858
A
897 B
612
614
615
613
A
875
A 611
P2
B Pf
Pi
438
C
B
641 730 643 708 644 645 646 728 924 801
SECTION B-B
2209S2MP03
438 656 413 438
Port Port name Port size
A Delivery port 3/4"
B Suction port 2 1/2"
735
Pi Pilot port PF 1/4-15
722
Pf Power shift port -
P2 Companion delivery port -
496 724 725 436
VIEW C
2-4
--- Page 8 ---
刮 Overload preventive function
621 651 652 623 612 601 625 626
P1 CL
B(E)
897
F
P2 P1
875
611
Large diameter Small diameter
Servo piston chamber
chamber
D
14W92RG03
When the self pump delivery pressure P1 or the companion pump delivery pressure P2 rises, it
acts on the stepped part of the compensating piston (621). It presses the compensating rod
(623) to the right till the force of the outer spring (625) and inner spring (626) balances with the
hydraulic force. The movement of the compensating rod is transmitted to lever 1 (612) via pin
(875).
Lever 1 rotates around the pin (875) (E) fixed to the casing (601).
Since the large hole section (F) of lever 1 contains a protruding pin (897) fixed to the feedback
lever (611), the feedback lever rotates around the fulcrum of point D as lever 1 rotates, and then
the spool (652) is shifted to the right. As the spool moves, the delivery pressure P1 is admitted
to the large diameter section of the servo piston via port CL, causes the servo piston move to the
right, reduces the pump delivery, flow rate, and prevents the prime mover from being overloaded.
The movement of the servo piston is transmitted to the feedback lever via point D. Then the
feedback lever rotates around the fulcrum of point F and the spool is shifted to the left. The
spool moves till the opening between the spool (652) and sleeve (651) is closed.
2-14
--- Page 9 ---
STRUCTURE (5/8)
18 30 38 37 5 16 59 65
34
57 55 71 7 55 57
70 22 35
C-C' (SWING AND BOOM1)
16
3 4 5 6 7 8 9 10 11 12 13 14 15 16
2 17
1
HOLDING VALVE 220S2MC06
5 Boom 1 spool kit 16-9 Back up ring 30 Plug
7 Swing spool kit 16-10 O-ring 34 Pilot cover A
16 Holding valve assy 16-11 Plug 35 Pilot cover B
16-1 Main poppet 16-12 Pilot piston 37 Check valve poppet 1
16-2 Restrictor 16-13 Piston guide 38 Check valve spring 1
16-3 Pilot spring 16-14 Spring 55 O-ring
16-4 C-ring 16-15 Main piston 57 Hex socket head bolt
16-5 Pilot poppet 16-16 Plug 58 Hex socket head bolt
16-6 Poppet guide 16-17 Block 65 Spring washer
16-7 O-ring 18 Overload relief valve 70 O-ring
16-8 Poppet seat 22 Swing logic valve 71 Hex socket head bolt
2-24
--- Page 10 ---
(3) Travel straight function
This function keeps straight travel in case of simultaneous operation of other actuators (boom,
arm, bucket, swing etc) during a straight travel.
In normal conditions, travel straight spool keeps neutral conditions, the pressurized oil of the P1
and P2 pumps is supplied to each passage independently.
When the attachment spool is operated under the travel operation of both sides, the pilot
pressure is supplied to the spring side port of the travel straight spool and then the travel straight
spool is shifted to the left direction.
P1 parallel passage Tank port T1
P2 port
P1 bypass passage P1 bypass passage
Some of attachment
oil is supplied to rravel
Signal by the combined operating
Travel straight spool of travel and attachment
P1 port
P2 bypass passage
P2 parallel passage
A-A' (STRAIGHT TRAVEL AND SUPPLY) 220S2MC20
After changeover of the travel straight spool, the pressurized oil discharged from the P1 pump is
connected with P2 port oil and is supplied to the attachment line through both parallel passage of
the P1 and P2.
Also, some of the pressurized oil open the check valve of the spool inside through side of the
travel straight spool and is connected with the bypass passage of the P2 side.
On the other hand, the pressurized oil discharged from the P2 pump is connected with P1 port oil
and is supplied to the travel line through both parallel passage of the P1 and P2.
Accordingly the attachment spool is operated under the travel operation of both sides, the
pressurized oil discharged from P2 pump is mainly supplied to left and right travel line and the
pressurized oil discharged from P1 pump is mainly supplied to attachment line.
As a result, simultaneous operation of both travel spools and attachment is not influenced to the
travel operation of the both sides and the machine keeps straight travel.
2-34
--- Page 11 ---
(2) Boom priority function
This function is used to speed up of the boom by reducing the swing speed when the swing
operation with boom operation simultaneously.
The boom priority signal is supplied the pilot port and the poppet of the swing logic valve is closed
and then the pressurized oil from P2 port is reduced by the oil leaking through the orifice.
As a result, the swing speed is slowed.
Orifice shape
Boom priority signal
SWING LOGIC VALVE
220S2MC30
2-44
--- Page 12 ---
12) OPERATION OF PORT RELIEF VALVE
(1) Function as relief valve
刮 The pressurized oil passes through the internal passage of the piston A, fitted in the main
poppet and the orifice A and is filled up in the chamber A of the inside and seats the main
poppet against socket and socket against the housing securely.
Socket
Chamber A
Pilot poppet
Spring
Parallel passage
Housing Tank passage Piston A Main poppet Orifice A
PORT RELIEF VALVE 220S2MC43
刯 When the pressurized oil from the actuators becomes equal to the set pressure of the spring,
the hydraulic oil apply to the pilot poppet and pushes the pilot poppet to the right direction and
flows to tank passage through the piston A internal passage, orifice A, chamber A, periphery
orifice B and the hole E.
Periphery orifice B
Hole E
Parallel passage
Housing Tank passage
OPERATION 1 OF PORT RELIEF VALVE 220S2MC44
2-54
--- Page 13 ---
4) BRAKE SYSTEM
(1) Control valve swing brake system
This is the brake system to stop the swing motion of the excavator during operation.
In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance
created by this throttling works as a brake force to slow down the swing motion.
Work Deceleration Stop
A B A B A B
MCV MCV MCV
MCV A, B opened MCV A, B throttled MCV A, B closed
2-48(1)
(2) Mechanical swing parking brake system
This is function as a parking brake only when all of the RCV lever (except travel pedal) are not
operated.
刮 Brake assembly
Circumferential rotation of separate plate
(14) is constrained by the groove located
at casing (1). When housing is pressed
16
down by brake spring (16) through
friction plate (13), separate plate (14) 8
and parking piston (15), friction force 15
occurs there. 14
Cylinder block (8) is constrained by this 13
friction force and brake acts, while brake 1
Groove
releases when hydraulic force exceeds
spring force.
2209A2SM35
1 Casing 14 Separate plate
8 Cylinder block 15 Parking piston
13 Friction plate 16 Brake spring
2-64
--- Page 14 ---
(2) Operation
Two pieces of overload valves are located at cross-over position in the counterbalance circuit of
brake valve and have the following functions :
刮 When hydraulic motor starts, keep the driving pressure below predetermined value and while
accelerating, bypasses surplus oil to return line.
刯 When stopping the motor, keep the brake pressure, that develops on the outlet side of motor,
under the predetermined value to stop the inertial force.
到 To accelerate sharply while starting, and to mitigate the braking shock while stopping. For these
purposes, the developed pressure is kept comparatively low for a short period, then keep the line
pressure as normal value. While the pressure is low, meshing of reduction gears, crawler and
sprocket etc. can be smoothly done and the shock are absorbed.
When starting, "A" port pressure of overload valve increases, this pressure is applied to the
effective diameter of poppet (42-10) which seats on the poppet seat (42-11) and, at the same
time, is delivered, via small hole, to the spring seat (42-5) located inside the sleeve (42-6) and the
seat bore pressure increases up to "A" port pressure. The poppet (42-10) opposes to spring
(42-4) by the force of the pressure exerted on the area difference between poppet seat's effective
diameter and spring seat bore and keep the predetermined pressure.
When hydraulically braking, the piston (42-7) is at the left position by the driving pressure, and
when "A" port pressure increases, the pressure is applied also to the piston (42-7) through the
small hole in the poppet (42-10) and piston (42-7) moves rightward until it touches the stopper in
rear cover. In this while, the poppet (42-10) maintains "A" port pressure at comparatively low
against the spring (42-4) force and exhaust oil to "B" port side. After the piston reached to the
plug, the valve acts the same as at starting.
Spring(42-4) Piston(42-7) Spring seat(42-5) Poppet seat(42-11)
Port B
Port A
Sleeve(42-6) Small hole
25092TM27
2-74
--- Page 15 ---
2. FUNCTIONS
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and apply-
ing the output pressure (secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following ele-
ments.
(1) Inlet port (P) where oil is supplied from hydraulic pump.
(2) Output ports (1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port (T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port or tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS
Item numbers are based on the type M2.
The functions of the spool (3) are to receive the supply oil pressure from the hydraulic pump at its
port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
ports 1, 2, 3 & 4 or the output port pressure oil to tank port T.
The spring (5) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod (9) is inserted and can slide in the plug (8).
For the purpose of changing the displacement of the push rod through the swash plate (16) and
adjusting nut (17) are provided the handle assy (20) that can be tilted in any direction around the
fulcrum of the universal joint (15) center.
The spring (7) works on the case (1) and spring seat (6) and tries to return the push rod (9) to the
zero-displacement position irrespective of the output pressure, securing its resetting to the center
position.
This also has the effect of a reaction spring to give appropriate control feeling to the operator.
2-84
--- Page 16 ---
SECTION 3 HYDRAULIC SYSTEM
Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------- 3-1
Group 2 Main Circuit --------------------------------------------------------------------------------------------------------- 3-3
Group 3 Pilot Circuit ---------------------------------------------------------------------------------------------------------- 3-6
Group 4 Single Operation ------------------------------------------------------------------------------------------------ 3-13
Group 5 Combined Operation ----------------------------------------------------------------------------------------- 3-23
--- Page 17 ---
4. TRAVEL SPEED CONTROL SYSTEM
ARM BUCKET BOOM
CYLINDER CYLINDER CYLINDER
Pilot valve Control piston
L/H TRAVEL MOTOR R/H
P P
D D
MA MB MA MU Pi2 Pi1
P5 Rs P4 Pn1 Pn2
PCbc
BC1
NRV2 Cck
PDbc
VA(BW) VB(FW) VB(BW) VA(FW) DR9
BC2
NRV1
Cco
A P B
C Dr D 12 Co
CoR Bk
Ak
AkR
Do
DoR P04
PCo PBk
P
PDo PAk
OPTION BUCKET PCbc