Hyundai Robex 210NLC-9 User manual

Robex 210NLC-9
CRAWLER EXCAVATOR
SERVICE MANUAL

TABLE OF CONTENT
FOREWORD 8
1. Structure 8
2. How To Read The Service Manual 9
3. Conversion Table 10
SECTION 1 GENERAL 16
Group 1 Safety 17
Group 2 Specifications 26
1. Major Component 26
2. Specifications 27
3. Working Range 28
4. Weight 29
5. Lifting Capacities 30
6. Bucket Selection Guide 32
7. Undercarriage 34
8. Specifications For Major Components 36
9. Recommended Oils 40
SECTION 2 STRUCTURE AND FUNCTION 41
Group 1 Pump Device 42
1. Structure 42
2. Function 49
Group 2 Main Control Valve 62
1. Structure 62
2. Hydraulic Circuit 65
3. Function 66
Group 3 Swing Device 89
1. Structure 89
2. Principle Of Driving 92
Group 4 Travel Device 100
1. Structure 100
2. Principle Of Driving 102
Group 5 Rcv Lever 108
1. Structure 108
2. Functions 111
Group 6 Rcv Pedal 115
1. Structure 115
2. Function 117
SECTION 3 HYDRAULIC SYSTEM 121
Group 2 Main Circuit 123
1. Suction And Delivery Circuit 123
2. Return Circuit 124
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3. Drain Circuit 125
Group 3 Pilot Circuit 126
1. Suction, Delivery And Return Circuit 127
2. Safety Valve (safety Lever) 128
3. Boom Priority System 129
4. Travel Speed Control System 130
5. Main Relief Pressure Change System 131
6. Arm Regeneration Cut System 132
7. Swing Parking Brake Release 133
Group 4 Single Operation 134
1. Boom Up Operation 134
2. Boom Down Operation 135
3. Arm In Operation 136
4. Arm Out Operation 137
5. Bucket In Operation 138
6. Bucket Out Operation 139
7. Swing Operation 140
8. Travel Forward And Reverse Operation 142
Group 5 Combined Operation 144
1. Outline 144
2. Combined Swing And Boom Up Operation 145
3. Combined Swing And Arm Operation 146
4. Combined Swing And Bucket Operation 147
5. Combined Swing And Travel Operation 148
6. Combined Boom And Travel Operation 149
7. Combined Arm And Travel Operation 150
8. Combined Bucket And Travel Operation 151
9. Combined Boom Up And Bucket Operation 152
SECTION 4 ELECTRICAL SYSTEM 153
Group 1 Component Location 154
1. Location 1 154
2. Location 2 155
Memorandum 158
1. Power Circuit 159
2. Starting Circuit 161
3. Charging Circuit 163
4. Head And Work Light Circuit 165
5. Beacon Lamp And Cab Light Circuit 167
6. Wiper And Washer Circuit 169
Group 3 Electrical Component Specification 174
Group 4 Connectors 182
1. Connector Destination 182
2. Connection Table For Connectors 186
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SECTION 5 MECHATRONICS SYSTEM 205
Group 1 Outline 206
Group 2 Mode Selection System 208
1. Power Mode Selection System 208
2. Work Mode Selection System 209
3. User Mode Selection System 210
Group 3 Automatic Deceleration System 211
1. When Auto Idle Pilot Lamp On 2. When Auto Idle Pilot Lamp Off 211
Group 4 Power Boost System 212
Group 5 Travel Speed Control System 213
Group 6 Automatic Warming Up System 214
Group 7 Engine Overheat Prevention System 215
Group 8 Variable Power Control System 216
Group 9 Attachment Flow Control System 217
Group 10 Anti-restart System 218
1. Anti-restart Function 218
Group 11 Self-diagnostic System 219
3. Machine Error Codes Table 220
4. Engine Fault Code 223
Group 12 Engine Control System 232
1. Mcu And Engine Ecm (electronic Control Module) 232
2. Mcu Assembly 232
Group 13 Eppr Valve 233
1. Pump Eppr Valve 233
2. Boom Priority Eppr Valve 236
Group 14 Monitoring System 238
1. Outline 238
2. Cluster 238
3. Cluster Connector 240
Group 15 Fuel Warmer System 261
1. Specification 261
2. Operation 261
3. Electric Circuit 261
SECTION 6 TROUBLESHOOTING 262
Group 1 Before Troubleshooting 263
1. Introduction 263
2. Diagnosing Procedure 264
Group 2 Hydraulic And Mechanical System 266
1. Introduction 266
2. Drive System 267
3. Hydraulic System 269
4. Swing System 271
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5. Travel System 275
6. Attachment System 280
Group 3 Electrical System 286
1. When Starting Switch Is Turned On, Monitor Panel Display Does Not Appear
286
3. Battery Charging Warning Lamp Lights Up(starting Switch : On) 288
4. When Coolant Overheat Warning Lamp Lights Up (engine Is Started) 289
5. When Air Cleaner Warning Lamp Lights Up (engine Is Started) 290
6. When Engine Oil Pressure Warning Lamp Lights Up (engine Is Started) 291
7. When Hydraulic Oil Temperature Warning Lamp Lights Up (engine Is Started)
292
8. When Coolant Temperature Gauge Does Not Operate (hcespn 304, Fmi 3 Or 4)
293
9. When Fuel Gauge Does Not Operate(hcespn 301, Fmi 3 Or 4) 294
10. When Safety Solenoid Does Not Operate 295
11. When Travel Speed 1, 2 Does Not Operate (hcespn 167, Fmi 5 Or 6) 296
12. When Engine Does Not Start ( Lights Up Condition) 297
13. When Starting Switch On Does Not Operate 298
14. When Starting Switch Is Turned On, Wiper Motor Does Not Operate 299
15. When Starting Switch Is Turned On, Head Lamp Does Not Lights Up 300
16. When Starting Switch Is Turned On, Work Lamp Does Not Lights Up 301
Group 4 Mechatronics Systegroup System 302
1. All Actuators Speed Are Slow 302
2. Engine Stall 304
3. Malfunction Of Cluster Or Mode Selection System 306
4. Malfunction Of Accel Dial 307
5. Auto Decel System Does Not Work 309
6. Malfunction Of Pump 1 Pressure Sensor 311
7. Malfunction Of Pump 2 Pressure Sensor 313
8. Malfunction Of Pump 3 Pressure Sensor 315
9. Malfunction Of Negative 1 Pressure Sensor 317
10. Malfunction Of Negative 2 Pressure Sensor 319
11. Malfunction Of Swing Pressure Sensor 321
12. Malfunction Of Arm In/out & Bucket In Pressure Sensor 323
13. Malfunction Of Boom Up Pressure Sensor 325
14. Malfunction Of Power Max 327
15. Malfunction Of Boom Priority Eppr Valve 329
16. Malfunction Of Arm Regeneration Solenoid 330
SECTION 7 MAINTENANCE STANDARD 332
Group 1 Operational Performance Test 333
1. Purpose 333
2. Terminology 334
3. Operation For Performance Tests 335
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Group 2 Major Component 353
1. Main Pump 353
2. Main Control Valve 354
3. Swing Device 355
4. Travel Motor 356
5. Rcv Lever 357
6. Rcv Pedal 358
7. Turning Joint 359
8. Cylinder 360
Group 3 Track And Work Equipment 361
1. Track 361
2. Work Equipment 367
SECTION 8 DISASSEMBLY AND ASSEMBLY 368
Group 1 Precautions 369
1. Removal Work 369
2. Install Work 370
3. Completing Work 371
Group 2 Tightening Torque 372
1. Major Components 372
2. Torque Chart 373
Group 3 Pump Device 375
1. Removal And Install 375
2. Main Pump (1/2) 377
Group 4 Main Control Valve 404
1. Removal And Install Of Motor 404
2. Structure (1/4) 405
3. Disassembly And Assembly 409
Group 5 Swing Device (type 1) 428
1. Removal And Install Of Motor 428
2. Disassembly And Assembly Of Swing Motor 429
3. Removal And Install Of Reduction Gear 443
4. Disassembly And Assembly Of Reduction Gear 444
Group 5 Swing Device (type 3, 4) 453
1. Removal And Install Of Motor 453
2. Disassembly And Assembly Of Swing Motor 454
3. Disassembly And Assembly Of Reduction Gear 466
4. Assembly Reduction Unit 471
Group 6 Travel Device 483
1. Removal And Install 483
2. Travel Motor 484
3. Outline Of Disassembling 486
4. Outline For Assembling 492
Group 7 Rcv Lever 515
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1. Removal And Install 515
2. Disassembly And Assembly 516
Group 8 Turning Joint 529
1. Removal And Install 529
2. Disassembly And Assembly 530
Group 9 Boom, Arm And Bucket Cylinder 534
1. Removal And Install 534
2. Disassembly And Assembly 540
Group 10 Undercarriage 551
1. Track Link 551
2. Carrier Roller 552
3. Track Roller 553
4. Idler And Recoil Spring 554
Group 11 Work Equipment 563
1. Structure 563
2. Removal And Install 564
SECTION 9 COMPONENT MOUNTING TORQUE 567
Group 1 Introduction Guide 568
Group 2 Engine System 569
Group 3 Electric System 571
Group 4 Hydraulic System 573
Group 5 Undercarriage 576
Group 6 Structure 577
Group 7 Work Equipment 581
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0-1
FOREWORD
FOREWORD
1. STRUCTURE
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
SECTION 1 GENERAL
This section explains the safety hints and gives the specification of the machine and major
components.
SECTION 2 STRUCTURE AND FUNCTION
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
SECTION 3 HYDRAULIC SYSTEM
This section explains the hydraulic circuit, single and combined operation.
SECTION 4 ELECTRICAL SYSTEM
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
SECTION 5 MECHATRONICS SYSTEM
This section explains the computer aided power optimization system and each component.
SECTION 6 TROUBLESHOOTING
SECTION 6 TROUBLESHOOTING
This section explains the troubleshooting charts correlating
problems
problems to
causes
causes.
SECTION 7 MAINTENANCE STANDARD
SECTION 7 MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
SECTION 8 DISASSEMBLY AND ASSEMBLY
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
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.
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0-2
Revised edition mark
Revised edition mark(ΗΘΙÄ)
When a manual is revised, an edition mark is
recorded on the bottom outside corner of the
pages.
Revisions
Revisions
Revised pages are shown at the list of revised
pages on the between the contents page and
section 1 page.
Symbols
Symbols
So that the shop manual can be of ample
practical use, important places for safety and
quality are marked with the following symbols.
2. HOW TO READ THE SERVICE MANUAL
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating
Distribution and updating
Any additions, amendments or other changes will
be sent to HYUNDAI distributors.
Get the most up-to-date information before you
start any work.
Filing method
Filing method
See the page number on the bottom of the
page.
File the pages in correct order.
Following examples shows how to read the
page number.
Example 1
2 - 3
Item number(2. Structure and
Function)
Consecutive page number for
each item.
Additional pages : Additional pages are
indicated by a hyphen(-) and number after the
page number. File as in the example.
1.
2.
3.
Symbol Item Remarks
Special safety precautions are
necessary when performing the
work.
Extra special safety precautions
are necessary when performing
the work because it is under
internal pressure.
Special technical precautions or
other precautions for preserving
standards are necessary when
performing the work.
Safety
Caution
ö
10 - 4
10 - 4 - 1
10 - 4 - 2
10 - 5
Added pages
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0-3
3. CONVERSION TABLE
3. CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.
Example
Example
Method of using the Conversion Table to convert from millimeters to inches
Method of using the Conversion Table to convert from millimeters to inches
Convert 55
mm into inches.
Locate the number 50
in the vertical column at the left side, take this as ͽ , then draw a
horizontal line from
ͽ .
Locate the number 5
in the row across the top, take this as ; , then draw a perpendicular line
down from
; .
Take the point where the two lines cross as
Ϳ . This point Ϳ gives the value when converting
from millimeters to inches. Therefore, 55
mm = 2.165 inches.
Convert 550
mm into inches.
The number 550 does not appear in the table, so divide by 10(Move the decimal point one place
to the left) to convert it to 55
mm .
Carry out the same procedure as above to convert 55mm to 2.165 inches.
The original value(550
mm ) was divided by 10, so multiply 2.165 inches by 10(Move the decimal
point one place to the right) to return to the original value.
This gives 550
mm = 21.65 inches.
1.
1.
2.
(1)
(2)
(3)
(1)
(2)
(3)
Millimeters to inches
Millimeters to inches 1
mm = 0.03937 in
;
ͽ
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Ϳ
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