Hyundai Robex 22-7 User manual

OPERATION MANUAL
SER. NO. HY2270001~

https://marengine.com/r22-7-excavator

INTRODUCTION
Read this manual carefully before operating the machine to ensure safe
and optimum running conditions. If you do not understand any of the points
in the manual, or the machine breaks down, contact your dealer. In
particular, attention needs to be paid to the following points.
• Read this operation manual if you have any questions or doubts on any
point to ensure proper and safety excavator operation.
• Keep this operation manual in the excavator at any time to ensure readily
access to it in case a need for it arises.
• Be sure to hand over this operation manual to the new owner if the
ownership of the excavator is to be transferred.
• Make every possible effort to ensure proper and safety operation of the
excavator.
mNote that a portion of the contents of this instruction manual may differ from the excavator
you have purchased, which is mainly due to the improvements adopted for it.
mConsult our marketing staff if you have any questions or comments on this operation
manual.
!WARNING

!
!
!
HOW TO USE THE OPERATION MANUAL
Read this manual carefully before operating the machine.
This chapter describes the marks in the operation manual.
Symbols:
DANGER
This symbol shows an immediate hazard that will cause death or
severe injury if the instruction is not observed.
WARNING
This symbol shows a hazard that can cause death or severe injury if
the instruction is not observed.
CAUTION
This symbol shows a hazard that can cause injury of machine
damage if the instruction is not observed.
IMPORTANT
This symbol shows a hazard that can cause damages to the excavator
or reduce its service life if the instruction is not observed.
N-m
This symbol shows the tightening torque for a given bolt that needs
to be strictly observed during the assembly.
This symbol shows related matters or the referring page.
This symbol shows the amount of grease or oil that needs to be filled.
• If you notice any ambiguous points in this manual, consult your dealer.
• The descriptions and figures in this operation manual may not coincide
with the machine due to changes in the specifications.

CONTENTS
OPERATION
Safety Decals .......................................................................................................... 1
Basic Precautoins on Safety ................................................................................... 3
Safety Precautionary Notes before Start................................................................. 4
Safety Precautions during Operation ...................................................................... 6
Safety Precautions during Inspection and Maintenance ....................................... 15
Safety Post Operational Caution ........................................................................... 18
Part Names ........................................................................................................... 19
Explanation of Each Device .................................................................................. 21
Operation .............................................................................................................. 28
Operational Precautions........................................................................................ 32
Transporting by Truck ........................................................................................... 39
Machine Traction................................................................................................... 41
How to Hoist a Machine ........................................................................................ 42
Cold Weather or During-Winter Operations .......................................................... 44
Long-Period Storage ............................................................................................. 46
INSPECTION AND MAINTENANCE
Ordering Parts and Servicing Guidelines .............................................................. 47
Inspections ............................................................................................................ 48
Maintenance after the First 50 Service Hours (New Machine).............................. 53
Maintenance after the First 100 Service Hours (New Machine)............................ 54
Maintenance Every 50 Service Hours ................................................................... 55
Maintenance Every 100 Service Hours ................................................................. 57
Maintenance Every 250 Service Hours ................................................................. 58
Maintenance Every 500 Service Hours ................................................................. 59
Maintenance Every 1000 Service Hours ............................................................... 61
To Pressurize ........................................................................................................ 62
Inspection and Maintenance Procedures for Engine Parts ................................... 64
Inspection and Maintenance Procedures .............................................................. 65
Periodical Inspections and Maintenance List ........................................................ 69
Lubricants.............................................................................................................. 71
OTHERS
Dimensions and Specifications ............................................................................. 75
Hydraulic Circuit .................................................................................................... 77
Electric Circuit ....................................................................................................... 78

MAINTENANCE AFTER THE FIRST 100 SERVICE
HOURS (FOR NEW MACHINE)
1. Replacing the line filter element
Remove the filter with a filter wrench and replace
it with new one.
Before replacing the filter, be sure to open the
hydraulic oil tank to bleed the filter.
2. Cleaning the pilot filter
Remove the plug from under the floor plate with a
wrench (width across flats:27 mm) and pull out the
element.
Clean the element with cleaning oil and remove all
dirt.
3. Cleaning the suction filter
Remove the suction filter from the hydraulic oil
tank. Clean the filter with diesel fuel or kerosene
to remove the dirt. If the strainer is broken,
replace it with new one.
To reinstall the lid, set the O-ring securely into the
flange groove in order to prevent a leak of hydraulic
oil.
Do not perform this operation while the hydraulic oil
is still hot, to avoid being burned.
IMPORTANT
IMPORTANT
Pilot filter
- 54 -
!CAUTION
Line filter
Suction filter

MAINTENANCE EVERY 50 SERVICE HOURS
(PERFORM THE MAINTENANCE AT THE SAME TIME IF IT IS CONTAINED IN THE
DAILY MAINTENANCE.)
Perform the following maintenance after the first 50 service hours.
1. Cleaning the radiator fins
Clean the radiator fins using pressurised air
and steam.
If the fins remain dirty, the engine will overheat.
2. Checking the amount of battery electrolyte
Loose the bolt which fix the battery cover to take out
the battry.
The color of the indicator on the battery shows
battery's condition. Blue is OK. Red is necessary to
charging. White is necessary to add distilled water.
(1) Visually check whether the level of the battery
electrolyte in each block is between the
upper and lower limits.
(2) If it is under the lower limit, take off the cap to
add battery electrolyte or distilled water to the
upper limit in each block.
• When inspecting the batteries, be sure to stop the engine.
• When dealing with the batteries, you must put on a protect glasses.
• Deluted sulfuric acid as electrolyte is dangerous substance. Be careful
not to strain your eyes, hands, clothes and metals. If it gets in your eyes,
wash with a large amount of water at once. Then go and see a doctor.
• As highly flammable hydrogen gas is rising from the batteries, do not
make a spark or use fire in any other way near the batteries.
• When disconnecting the terminals, start with – terminal. Contrarily,
when connecting them, connect the – terminal last.
Radiator fin
!WARNING
!CAUTION
- 55 -
Battery Cap
Terminal

MAINTENANCE EVERY 50 SERVICE HOURS
3. Inspecting the specific gravity of the fluid
Measure the specific gravity of the electrolyte. If it
is lower than the specified values, recharge the
battery. At this time, clean and connect the
terminals, and then coat with grease.
• Always stop the engine while the work.
• Do not coat with grease before connecting the
terminals.
4. Greasing slew bearing
Use a grease gun to lubricate the grease nipples of
screw bearing.
After working in water, give grease without
fail.
5. Eliminating the sediment in the fuel tank
Open the drain cock to eliminate the sediment
and drain the water.
It is effective to do this before starting the engine.
6. Checking the fuel tank strainer
Remove the tank cap, remove any loose dirt on
the strainer and clean it with diesel fuel.
IMPORTANT
!CAUTION
!WARNING Grease
points
- 56 -
Battery Cap
Terminal
Drain plug
Strainer

MAINTENANCE EVERY 100 SERVICE HOURS
1. Inspecting and cleaning the air cleaner
Clean the dust-cover. Inspect and clean the ele-
ment.
For details refer to page 65.
After stopping the engine, clean them.
2. Cleaning the fuel filter element.
You can take out the element by removing the filter
ring nut. Clean the filter with diesel fuel.
Air cleaner element
!WARNING
Fuel filter
- 57 -

MAINTENANCE EVERY 250 SERVICE HOURS
1. Replacing engine oil filter cartridge
(1) Warm up the engine (for about 10 minutes), as
the engine oil should be warm before replacing
the cartridge.
(2) Remove the drain plug of the oil pan, and drain
the oil.
(3) Remove the cartridge with a filter wrench.
(4) Slightly coat the O-ring of the new cartridge with
oil and firmly tighten the cartridge by hand.
(5) Securely replace the drain plug, and add the
specified amount of engine oil through the oil
supply port.
(6) Start and idle the engine for several minutes to
check for oil leakage. After the engine is
stopped,check the oil level using the level gauge.
If short, add oil.
3.5
Perform this operation on level ground. Make sure that dust does not enter
through the oil supply port.
2. Eliminating the sediment in the hydraulic oil
tank
Open the drain plug to eliminate the sediment
and drain the water.
It is dangerous to open the cap on the hydraulic tank after stopping the
engine immediately, because the hydraulic oil is too hot.
IMPORTANT
!CAUTION
Drain plug
Engine oil filter
- 58 -
Engine oil port
Drain plug

MAINTENANCE EVERY 500 SERVICE HOURS
1. Replacing the fuel filter element
You can take out the element by closing the cock
and removing the retainer ring.
Replace it with new one.
O ring must be replaced with new one in this time.
After replacing the element, bleed air.
For details refer to page 64.
2. Replacing cooling water in radiator
Remove the drain plug on radiator to replace the
cooling water.
5.6
3. Cleaning the suction filter
Remove the suction filter from the hydraulic oil
tank. Clean the filter with diesel fuel or kerosene
to remove the dirt. If the strainer is broken,
replace it with new one.
To reinstall the lid, set the O-ring securely into the
flange groove in order to prevent a leak of hydrau-
lic oil.
Do not perform this operation while the hydraulic
oil is still hot to avoid being burned.
4. Replacing the line filter element
Remove the filter with a filter wrench and replace
it with new one.
Before replacing the filter, be sure to open the
hydraulic oil tank to bleed the filter.
Drain plug
!CAUTION
!CAUTION
IMPORTANT
IMPORTANT
Fuel filter
- 59 -
Line filter
Suction filter

MAINTENANCE EVERY 500 SERVICE HOURS
5. Cleaning the pilot filter
Remove the plug from under the floor plate with a
wrench(width across flats:27mm) and pull out the
element.
Clean the element with cleaning oil and remove all
dirt.
6. Replacing air cleaner element
Clean a dust-cover. Replace elements.
For details refer to page 65.
After stopping the engine, clean them.
!WARNING
Pilot filter
Air cleaner element
- 60 -

MAINTENANCE EVERY 1000 SERVICE HOURS
1. Cleaning the Cooling Water Passage
Clean the inside of the radiator and the engine
water passage.
For details refer to page 66.
2. Replacing the Hydraulic Oil
Remove the drain plug and replace all hydraulic oil.
Amount of hydraulic oil: 33
3. Replacing the Lubricating Oil in the Travel Speed
Reduction Gear.
Remove the blind plug in the speed reduction gear
cover, and replace the lubricating oil.
For details refer to page 71.
- 61 -
Cap
Drain plug

TO PRESSURIZE
1. It is necessary to pressurize the hydraulic oil tank in case of the following :
(1) When the cover or the plug on the hydraulic oil tank is removed, due to some reason.
(2) When the hose is removed from the hydraulic circuit for the repair or check, due to
oil leakage or others.
(3) When the major component is exchanged, or others.
2. Purpose
It is easier for the hydraulic pump to suction the oil.
(Suction pressure of the pump should not have the negative pressure.)
3. Procedure
(1) Remove the cover of the hydraulic oil tank. If the machine has a plug on it, it is
advisable to remove only the plug.
(2) Start the engine and extend all cylinders as the Figure 2.
*Hydraulic oil go to the cylinders to be the lowest oil level in the tank.
(3) At the condition of ii), tighten the cover or plug of the tank.
*Work with your caution, the dozer cylinder is also extended at maximum stroke.
After this work and machine is operated, the oil in the cylinder go back to the tank.
And then, the oil level in the tank is increased, inside the tank is pressurised.
This label on the side cover. PART No. 11240-11960
- 62 -
Figure 1

- 63 -
Figure 2

INSPECTION AND MAINTENANCE PROCEDURES
FOR ENGINE PARTS
Air bleeding of fuel system
After cleaning the fuel filter or the water sedimentor, replacing the element or using
up the fuel, bleed the air in according to the following procedure.
(1) Fully fill the fuel tank.
(2) Open the cock of water sedimentor.
(3) Turning the starter switch ON automatically bleeds the air.
The air can ordinarily be bled in about one minute when the fuel filter is
empty.
IMPORTANT
Fuelfilter
Watersedimentor
Fuelpump
Cock
Water sedimentor
Open Close
- 64 -

INSPECTION AND MAINTENANCE PROCEDURES
1. AIR CLEANER ELEMENT
By loosing the air cleaner band, and check the
contamination of the element visually.
Inspection
The inspection method varies depending on how dirty the element is.
(A) If dry dust is adhering to the air cleaner element, blow pressurized air (7kg/cm2or
less) from inside of the air cleaner element to remove it.
(B) If the element is soiled with black carbon or soot, remove it with cleaning liquid.
(1) For the cleaning liquid, dissolve 300g (10.6oz) of air element cleaner
(ND1500) into 20 of water. Immerse the air cleaner element for about 20
minutes.
(2) With the dust cap removed, flush the air cleaner element using tap water.
(3) After cleaning, let the element dry in a place where air circulates freely.
The standard inspection is every 100 service hours. However, inspect
every 50 if the machine is used in a dusty environment.
Never use fire or pressurized air to dry the air cleaner element.
!WARNING
Air cleaner element
- 65 -

INSPECTION AND MAINTENANCE PROCEDURES
2. THE COOLING WATER
Dirt and rust in the water decreases the effective-
ness of the cooling system.
Replacement
(1) Remove the radiator cap and open the drain plug to drain the cooling water.
(2) Close the drain plug and fill the radiator with cleaning fluid. (※1).
(3) Open the radiator drain plug while feeding fresh water through the radiator cap.
Continue this until the clean water comes out.
(4) After clean water comes out, close the plug, feed the neutralization fluid (※2)
and start the idling for 5 minutes.
(5) Stop the engine and open the drain plug to clean the inside of radiator with
water.
Close the drain plug and supply cooling water to the specified level.
Cleaning fluid (※1): dissolve Sodium bisulfite of 250g in water of 1 .
Neutralization fluid (※2): dissolve Sodium carbonate of 6g in water of 1 .
Anti-freeze should be fully mixed with the water in another vessel prior to
feeding it in the radiator. If you do not follow the above, overheating may
occur.
It is very dangerous to remove the radiator cap just after stopping the
engine. If you want to remove the cap, slowly turn the cap to gradually
release the internal steam pressure.
Cooling water is harmful substance. Deal with it appropriately when it is
dumped.
!CAUTION
!DANGER
!WARNING
Cap
- 66 -

INSPECTION AND MAINTENANCE PROCEDURES
3. INSPECTING CRAWLER TENSION
Unequal tensions of the crawlers may cause the
machine to deviate from the travelling path. Make
sure the crawlers are equally tensioned. Always
adjust the tension of the rubber crawler after the first
10 to 20 service hours.
(1) If crawler is too tight, the rolling friction on the
surface idler sprocket contacting with the bear-
ing increases, scoring occurs on the crawler link
pin and the resistance is increased, resulting in
the reduction of travelling ability.
(2) If the crawler is too slack, it may slip off the
sprocket. Resistance increases when going in
reverse and the travelling ability of the machine
is reduced.
Inspection
(1) Insert a grease gun into the grease nipple and
pour the grease to strain the crawler.
(2) For loosening the crawler, loosening the car-
tridge valve, the grease in the cylinder automati-
cally comes out.
※Confirmation of inspection (checking for air locks)
Before straining the crawler, loosen the cartridge valve and make sure grease
comes out by pushing the front idler to the cylinder. Then tighten the valve and
add grease again.
25mm to 35mm
- 67 -