Hydraulic System for 9S

Excavators

2017/10/23 – 10/27
Medellin, Colombia
 9S Series Excavators
R35Z-9S, R60-9S

R140LC-9S, R160LC-9S, R180LC-9S

R220LC-9S, R220LC-9SH, R260LC-9S, R300LC-9S

R300LC-9SH, R330LC-9S, R330LC-9SH, R380LC-9SH

R430LC-9SH, R480LC-9S, R520LC-9S

R800LC-9, R850LC-9, R1200-9

R140W-9S, R170W-9S, R180W-9S, R210W-9S

HYDRAULIC SYSTEM
R220LC-9S
R260LC-9S
R300LC-9S
Hydraulic System
Hydraulic Schematic

(1.5 kgf/cm²)

MCV Actuators

3.0 kgf/cm²
(5.0 kgf/cm²:
R480/520LC-9S) Pilot Circuit

1.5
kgf/cm² P1 P2 P3

TANK

3
Hydraulic System

R220LC-9S Cluster1 4
Return Check Valve
Hyd tank

3 bar

High
Pressure
Check v/v Oil
Low 1.5 bar
Pressure
cooler
Check v/v

RETURN
OIL

MCV

Tank

5
 Air Breather
An air breather is prepared on hydraulic tank to keep internal pressure of tank at certain level

Key

Filter

Atmosphere

Tank

6
Pilot Circuit R220LC-9S

Straight Travel

7
MAIN PUMP R220LC-9S

1) Main Pump

2) Gear Pump

8
 Pump Assembly R210LC-7(A)

Pi1=Negative Control
Pm1=Flow Cut Off

Regulator 1

Regulator 2

Pi2=Negative Control
Pm2=Flow Cut Off

EPPR Pressure

EPPR Valve 35 bar

P1 Front P2 Rear Pilot Pump

9
Pump Sectional View

10
Regulator Sectional View

11
 Main Pump Circuit R290LC-9

Flow Control
Pi1 : from MCV or a1 ~ a7 : Pressure check ports
attachment EPPR valve a6/a7 : N/A for R220LC-9S
Pi2 : from MCV

Horsepower
Control

Flow
Control

12
Regulator Control Circuit R220LC-9S

Pi1 P1 P2 Pi2

P1/P2 : Main Pump

Pi1/Pi2 : Negative
Control
from MCV

PSV ATT’ Flow Control

Psv : EPPR V/V

P3 P1 P2

13
 Structure of Regulator
Feedback
Levers
Main Control
Spool

Flow Control

Primary Lever
Horsepower
Control

14
Horsepower Control
Cylinder force Spring force (B+D)

15
Horsepower Control

HP ∝ P X Q

16
 Negative Flow Control
Pi increase
Flow decreases by Pi pressure increase

17
Negative Relief Valve Circuit

18
Location of Att’ Flow Control EPPR Valve
ATT’ Flow control EPPR V/V

Pn2 (MCV) P3 Pump

Shuttle V/V

(Regulator)

Last guard
filter

19
 Pf (Power shift control by EPPR valve)
EPPR v/v pressure and Current per power mode

R220LC-9S

R300LC-9S

20
Pf (Power shift control by EPPR valve)
• MCU sends preset electric current per power mode
selection to EPPR valve
• Then, the pressure from EPPR valve pushes horsepower
control spool to limit pump flow

EPPR pressure increases → Pump flow decreases

EPPR pressure decreases → Pump flow increases

P1 + P2

21
 P-Q Curve

400 R210LC-7(standard) 400 R210LC-7(standard)

R2200LC-7 ( = version 1.X) R2200LC-7 ( = version 2.X)
350 350

300 300
118K
92K 105K
Flow Rate(l/m in)

Flow Rate(l/m in)

250 92K 206L 161K 250
92K 161K
2100rpm 217L 217L217L
217L Emergency mode
215L 215L
200 200 H mode
2000rpm H mode 93K H mode
150 S mode 150
207L 190K
S mode
Emergency mode 246K S mode
Emergency mode 246K
113L
111L 111L
100 177K 100
202K 175K177K 177K
202K
114L 110L 114L 114L
50 107L 50 107L

0 0
0 50 100 150 200 250 300 350 0 50 100 150 200 250 300 350
Delivery Pressure(kgf/cm2) Delivery Pressure(kgf/cm2)

EPPR (bar) EPPR (bar)

H 0 H 18
S 13 S 22
Economy 15 Economy 15

22
Power Mode Control R200W-7

[ CAPO System features ]

1. Quick response
2. Reliable control

1. Condition : Arm in / out

2. Colors (Unit of Axis : Bar)
(1) RED : P1(Main pump) pressure
(2) BLUE: P3(Pilot pump) pressure
(3) GREEN: EPPR V/V 2nd pressure

‘S’ Mode ‘H(M)’ ‘S’ Mode

■ Power Mode setting Mode

23
EPPR Valve

(2nd pressure)

Magnet

MPa

- Pump & Attachment EPPR Valve on

9S Excavators : 2nd pressure is
Attachment EPPR Valve proportional to input current
- Pump flow is inverse proportional to
2nd pressure

mA

24
Pump EPPR Compensation
* MCU compares target pressure and real pressure, which is taken by pressure sensor
* MCU sends adjusted current for EPPR to make the two pressures equal

R220LC-9 Eng’ RPM EPPR

Standard
Mode Hi Idle
Unload Relief
(mA) (Kg/㎠)
P 2100 1900 330 10
S 2000 1800 360 12
E 1900 1700 360 12

Pressure Sensor

25
E/G RPM Recovery R220LC-9S

E/G PUMP Decreased Flow

EPPR
Unload : 2,100 rpm
↓
Load : 1,800 rpm
Initial :
More
330mA,
current
100 rpm lower than 1900 10kg/cm2

P
S MCU
E
Cluster
26
Main Control Valve (MCV)
Specification
1) Main Control Valve

2) Remote Control Valve

27
Main Control Valve (MCV) R290LC-9S

28
Spool Arrangement R290LC-9S
P1 P2

RH

LH

Option relief

29
Check Valves

OPTION

Ck2

Pb21
Dr1

RH

LH

30
 Boom Up Operation R220LC-9S

Bucket

Boom Up has priority over 버켓감속

swing/bucket operation
- swing logic v/v
- bucket-in stroke limiter

Boom2
붐2

Swing

P1 P2

31
Boom Priority (Swing Logic Valve)
When Boom up & Swing are operated simultaneously, it increases Boom up speed. The swing logic valve does not
work in single swing operation.

Manual : Boom up speed depends on manual setting level

Auto : Boom up speed is automatically adjusted according to the pilot
pressures of boom up & swing.

Boom1
spool

Swing
priority
Boom 2
Boom priority EPPR valve

Swing Logic

P2

32
 Electric for Boom Priority
MCU sends signal to boom priority EPPR valve when both
pressures are higher than 8 bar from boom and swing RCV

MCU
XAb1 XAb2 CN 53-9
Boom Priority EPPR +
CN 53-19
Boom RCV Boom Priority EPPR -
CN 51-2
BATT’ POWER 24V

CN 52-23
BOOM UP PRESSURE P03
CN 51-5 (MCV)
GND. PRESSURE

CN 52-24
SWING PRESSURE
XBs XAs

Psp

Swing RCV

▲
P3

33
Swing Logic Valve
To/From cylinder

To tank
Swing spool

P03

Bypass passage P2

Swing
spool P2 bypass passage
P2 parallel passage

From boom priority EPPR v/v

34
 Boom2 & Swing Priority Spool
* Pilot pressure from swing RCV reaches at swing priority spool through Pc3 line
* When boom up is operated, the pilot pressure is applied to “Pa21” and P2 flow is going to boom cylinder

Option
Arm

Pc3

Pa21

Swing
motor

Swing

Boom priority Boom1

EPPR valve
P2

35
Boom2 & Swing Priority Spool
Boom summation passage

P1

Swing priority spool Arm2 spool

Swing pilot Boom up

pressure Pilot pressure

Boom2 spool
P2

P2 parallel passage P2 parallel

(to arm1, option spool)

From arm2
spool
P2

36
Make-up for Boom Down

P1 P2

37
 Make-up, Boom 1 Spool
Boom moves down fast

P1

Boom down
Pilot pressure

P1

Boom down
Pilot pressure

Check valve
Tank

38
Bucket-in Operation

● CK2

● Pa5
Pcb ●

39
 Bucket-in Summation

NRV1

Pcb
NRV2

Pcb
Negative control v/v(NRV2)
Center bypass v/v

P2

P1
P2 oil goes
to Ck2 port NRV2
Pcb Pa5

Main Relief

40
 Bucket Stroke Limiter

Simultaneous operation of Boom up and Bucket-in BK stroke

limiter

- P1 and P2 flow to boom cylinder BK

②P2
- P1 and P2 flow to bucket cylinder
BM up
- Bucket spool stroke is limited by boom up pilot pilot
P2

BM1

①P1

Boom up pilot
Bucket-in (Pb5)
pilot
Stroke limiter spool

41
Arm in Operation

BK

AM1 ARM Reg

AM2
BM2

P2 P1

42
 Arm Regeneration
Since Arm regeneration spool blocks return line,
return oil opens check valve and flows to supply
line.

(Lower pressure)
(Higher pressure)

Arm-in

Arm Regeneration

Arm-in

43
 Arm Regeneration

Arm regeneration would be finished

when arm passes over vertical line to ground

Arm In flow

Arm-in

ARM Regeneration

Arm-in

44
 Arm Regeneration Disabled

ON
(Low pressure)

ARM In flow

Arm-in

ARM Regeneration

Arm-in

45
Option Attachment

Work Tool

- Breaker mode : One way attachment

- Crusher mode : Double acting attachment

Breaker Mode

- Max Flow : Max. breaker demanding flow

- Flow Level : 7 levels, 10 lpm/level

46
 Breaker Circuit Single Acting

From pressure
solenoid
When breaker switch on RH RCV
is pressed on at ‘Breaker’ mode ,
breaker solenoid is shifted and
pilot pressure pushes MCV spool. P2

At this time MCU sends a constant

signal to control Att EPPR valve From confluence
solenoid

Pedal and solenoid block are

necessary for double acting
Breaker sol
attachment
Att’ flow EPPR v/v
3 Solenoid block
- One for relief pressure
- One for flow summation
- One for safety
Safety sol
P3

47
Crusher Mode

- Max Flow : Max. attachment demanding flow

- Flow Level : 4 levels, 20 lpm/level

- Option Relief Valve : 210 bar 280 bar

48
 Option Circuit Double Acting

⑧ 210 bar → 280 bar

P2

⑦
⑥
P05 P1 Arm 2

① ② ③

④
Solenoid Block(Option)
① Option Att’ Safety sol.
MCV (Option)
② Option Att’ pressure sol.
⑥ Pilot selector v/v
③ Option Att’ conflux sol.
P3 ⑦ Option conflux ON/OFF v/v
⑤ 2 way pedal (Option) ④ Option Att’ flow control v/v ⑧ 2-Stage option relief v/v

49
 Work Mode
Crusher
Breaker
MCV
ATT Pilot
Arm1
Pressure Sensor
Option Arm2

Bucket

Swing Boom1

Travel(RH) Travel(LH)
Select V/V
Main
Relief V/V

RCV
ECM
Accel. Dial ATT Safety
SOL V/V
Pump Regulator ATT Conflux
SOL V/V
ATT Pressure
ATT Flow
Cont. EPPR
SOL V/V Instead of solenoids

: General operation

ATT Flow Cont. : Breaker operation(Optional)

Output

MCU : Crusher operation(Optional)

Power Mode, Work Mode,

Power Work Cluster ATT Type, ATT Flow Infomation
Mode Mode

50
Option Confluence On/Off Valve

At crusher mode option att. conflux solenoid is energized to send

pilot oil to option confluence on/off valve on MCV

P05
From option att.
conflux valve

From P2

From P1

51
Option Relief Valve

52
Straight Travel

53
 Straight Travel Circuit

BM

work

X X

Swing parking
TL Brake release
TR Pilot pressure

travel
(P3)

P1 P2

Check v/v

● ●
● ●
● Orifice

P1 for swing and attachments

P1 P2
P2 for travel only

54
 Holding Valve
- Boom up Attachment is firmly held on by holding valve at neutral joystick
- Arm in and Arm out No slipping down

Relief
Boom Cyl Valve
Drain
P3
Release
Signal
Holding Check V/V

Boom Spool

55
 Boom Holding Released

When RCV lever is pushed, the pilot

pressure is applied to boom down(Pb20)
& holding release port. (Pal)

Pal pilot oil pushes piston and pilot

poppet.
Then, the oil inside the holding valve
drains through drain port and it causes P3
check valve to open.

Pb20 → Boom down

56
 Auto Idle

15 bar ~ : RPM up
~ 8 bar : RPM down
Boom/Arm/Bucket/Swing/Option Spools

BM

work

S/parking
TL release
TR

travel
(P3)

P1 P2

57
 Pressure Sensors for Travel/Work

BM

work

S/parking
TL release
TR Pilot
pressure

travel
(P3)

P1 P2

58
Main Relief Valve, MCV

Pu

59
Main Relief Valve, MCV

Line pressure(P) Main relief valve set pressure (350bar)

Pu

60
Main Relief Valve, MCV

Line pressure(P) Main relief valve set pressure (350bar)

Pu

to Tank to Tank

61
Power Boost On
When power boost switch is ON, the pilot pressure enters through hole (A). Then piston(B) is
pushed to the left and that causes to increase the spring force.

350 bar → 380 bar

Pu

(A)

(B)

62
Main Relief Valve Setting, MCV
1) Power booster pressure setting
① Loosen lock nut “A” and tighten screw “B” clockwise securely.
② Loosen lock nut “C” and adjust screw “D” until 380 bar is achieved while power booster
switch is pressed on.
③ Tighten lock nut “C”.

Ⓐ 19mm Lock Nut

• Ⓑ 4mm Adjust screw
•

•
• Ⓓ 22mm Adjust screw
Ⓒ 27mm Lock Nut
※ Screw(D) changes about 130 bar per rotation

2) Main pressure setting

① After the high pressure is set, loosen screw “B” counterclockwise to get main pressure.
② Tighten lock nut “A” when the pressure is set to 350 bar.

63
Load Check Valve

Without load check valve boom

cylinder would be forced down by
heavy attachment at the very initial
moment of boom up operation.

Then, much oil from pump

Port relief valve
eventually overcomes the heavy
weight and can lift up boom.

Load check valve

Main relief valve
Load check valve prevents such issue.

64
Port Relief Valve

Port relief valve

If foreign force causes high pressure in the 400bar

closed circuit when spool in MCV is neutral,
oil has no other way to escape than port
relief valve.

Main relief valve

350 bar

65
Port Relief Valve

Line pressure < Port relief setting pressure

Oil flows through orifice and passage

around piston to poppet but cannot push
the poppet.
So, oil is contained in the chamber A.

Orifice
Chamber A

Piston Poppet
Passage

Line pressure > Port relief v/v pressure

Poppet is pushed backward and the oil in

the chamber A escapes around poppet.
Then, plunger is opened to make return
passage.

66
Port Relief Valve

Make-up Function

- Oil should be provided cylinder if

cylinder is moved by external force
- Oil from return line is delivered to
cylinder by movement of socket

- Difference in forces on socket and

plunger makes the movement possible

67
Port Relief Valve

D
C
B
A

Forces on plunger and socket

Working Pressure (red color) : PW (AB – AA)

Return Pressure (blue color) : PR (AD - AC )

Normal condition : PW (AB – AA) + FSP + FSS > PR (AD - AC )

Make-up condition : PW (AB – AA) + FSP + FSS < PR (AD - AC )

68
Swing Motor R220LC-9S

Item Specification

69
Swing Circuit
Parking brake

PG

Time delay valve

Relief valve

Make up valve

(Make up port)
70
Anti-rotation Valve
Anti-rotation spool enables upper structure to stop swing smoothly
when swing RCV lever is released

71
Anti-rotation Valve

GA GB

A B

MCV spool in neutral

Orifice Poppet Bypass orifice

Bypass passage

72
Anti-rotation Valve
Swing slip

RCV
Neutral Swing slipping to stopping
Motor stop

At early slipping

At almost stopping

73
Swing Parking Brake R210LC-7A

Spring engaged, Hydraulic released type Time delay valve is to protect brake system by
delaying brake timing.
It takes about 6 seconds until swing stops fully

(Swing lever: operated) (Swing lever: released)

BRAKE OFF BRAKE ON

x
SH signal is coming
from swing lever

74
 Swing Parking Release R220LC-9S

When any attachment or swing is working, AUTO IDEL SIGNAL pressure increases.

X
Then, swing parking brake is released.
ARM, BUCKET, OPTION, SWING SPOOL

BM
PG
work

From P3 pump

75
 Swing Relief Valve

The relief valve relieves high pressure at start or 265 bar

at stop of swing motion.
It can control the relief pressure in 2 steps, high
and low, in order to ensure smooth operation. At 50~60% of setting
pressure, 1st relief is
realized for 0.1~0.3
seconds

1 3

P P=P3

2 4

P=P1 P=Ps

76
 Travel Motor R220LC-9S

DRAIN
SECOND
SPEED
SPOOL P1
Pm1
2-SPEED-
CONTROL
PORT (Ps) P2

Pm2

OVERLOAD COUNTER
RELIEF BALANCE SPOOL
VALVE

Item Specification

Automatic shifting to 1st speed

: 250 bar

77
Travel Motor Circuit

11bar

6.5bar

78
Rear Flange T/M

to Brake Piston Counter Balance Valve

P1 P2
T1 T2

Overload Relief Valve

2nd Speed Spool

Ps

79
 Counter Balance Spool T/M

- Smooth start & stop of travel

- Prevention of travel overspeed
on downslope

Orifice

Check valve opened to deliver oil Spool moved to open return line
80
2nd Speed Spool T/M

Swash Swash
Plate Brake
Piston Plate

Low Speed
High Speed

- Ps from travel speed solenoid

- 2nd speed is reduced to 1st
speed when travel working
pressure reaches over 250 bar

Swash
Plate

Ps
81
2nd Speed Spool T/M

Drain
Drain
2-Speed to 2-Speed to
Swash plate Swash plate

Auto shift down

at 250 bar 2-Speed Pilot

82
2nd Speed & Brakes T/M

Brake Release Pressure

Reduction Gears

High Speed Pilot

83
Relief Valve T/M

Piston

84