Hyundai Robex 220LC-9A User manual

Robex 220LC-9A
CRAWLER EXCAVATOR
SERVICE MANUAL

TABLE OF CONTENT
FOREWORD 9
1. Structure 9
2. How To Read The Service Manual 10
3. Conversion Table 11
SECTION 1 GENERAL 17
Group 1 Safety 28
Group 2 Specifications 37
1. Major Component 37
2. Specifications 38
3. Working Range 41
4. Weight 44
5. Lifting Capacities · 47
1) 47
6. Bucket Selection Guide 54
7. Undercarriage 56
8. Specifications For Major Components 58
9. Recommended Oils 62
SECTION 2 STRUCTURE AND FUNCTION 63
Group 1 Pump Device 64
1. Structure 64
2. Function 70
Group 2 Main Control Valve 83
1. Structure 83
2. Hydraulic Circuit 86
3. Function 87
Group 3 Swing Device (type 1) 110
1. Structure 110
2. Principle Of Driving 113
Group 4 Travel Device (type 1) 132
1. Structure 132
2. Principle Of Driving 134
Group 4 Travel Device (type 2, 3) 140
1. Construction 140
2. Specification 1) 141
2) 142
3. Operation 143
Group 5 Rcv Lever 154
1. Structure 154
2. Functions 157
Group 6 Rcv Pedal 161
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1. Structure 161
2. Function 163
SECTION 3 HYDRAULIC SYSTEM 167
Group 1 Hydraulic Circuit 168
Group 2 Main Circuit 169
1. Suction And Delivery Circuit 169
2. Return Circuit 170
3. Drain Circuit 171
Group 3 Pilot Circuit 172
1. Suction, Delivery And Return Circuit 173
2. Safety Valve (safety Lever) 174
3. Boom Priority System 175
4. Travel Speed Control System 176
5. Main Relief Pressure Change System 177
6. Arm Regeneration Cut System 178
7. Swing Parking Brake Release 179
Group 4 Single Operation 180
1. Boom Up Operation 180
2. Boom Down Operation 181
3. Arm In Operation 182
4. Arm Out Operation 183
5. Bucket In Operation 184
6. Bucket Out Operation 185
7. Swing Operation 186
8. Travel Forward And Reverse Operation 188
Group 5 Combined Operation 190
1. Outline 190
2. Combined Swing And Boom Up Operation 191
3. Combined Swing And Arm Operation 192
4. Combined Swing And Bucket Operation 193
5. Combined Swing And Travel Operation 194
6. Combined Boom And Travel Operation 195
7. Combined Arm And Travel Operation 196
8. Combined Bucket And Travel Operation 197
9. Combined Boom Up And Bucket Operation 198
SECTION 4 ELECTRICAL SYSTEM 199
Group 1 Component Location 200
1. Location 1 200
2. Location 2 201
Group 2 Electrical Circuit(1/2) 202
Memorandum 204
1. Power Circuit 205
2. Starting Circuit 207
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3. Charging Circuit 209
4. Head And Work Light Circuit 211
5. Beacon Lamp And Cab Light Circuit 213
6. Wiper And Washer Circuit 215
Group 3 Electrical Component Specification 220
Group 4 Connectors 228
1. Connector Destination 228
2. Connection Table For Connectors 232
SECTION 5 MECHATRONICS SYSTEM 251
Group 1 Outline 252
Group 2 Mode Selection System 254
1. Power Mode Selection System 254
2. Work Mode Selection System 255
3. User Mode Selection System 256
Group 3 Automatic Deceleration System 257
1. When Auto Idle Pilot Lamp On 2. When Auto Idle Pilot Lamp Off 257
Group 4 Power Boost System 258
Group 5 Travel Speed Control System 259
Group 6 Automatic Warming Up System 260
Group 7 Engine Overheat Prevention System 261
Group 8 Variable Power Control System 262
Group 9 Attachment Flow Control System 263
Group 10 Anti-restart System 264
1. Anti-restart Function 264
Group 11 Self-diagnostic System 265
1. 2. 265
3. Machine Error Codes Table 266
4. Engine Fault Code 270
Group 12 Engine Control System 290
1. Mcu And Engine Ecm (electronic Control Module) 290
2. Mcu Assembly 290
Group 13 Eppr Valve 291
1. Pump Eppr Valve 291
2. Boom Priority Eppr Valve 294
Group 14 Monitoring System 296
1. Outline 296
2. Cluster 296
3. Cluster Connector 298
Group 15 Fuel Warmer System 321
1. Specification 321
2. Operation 321
3. Electric Circuit 321
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SECTION 6 TROUBLESHOOTING 322
Group 1 Before Troubleshooting 323
1. Introduction 323
2. Diagnosing Procedure 324
Group 2 Hydraulic And Mechanical System 326
1. Introduction 326
2. Drive System 327
3. Hydraulic System 329
4. Swing System 331
5. Travel System 335
6. Attachment System 340
Group 3 Electrical System 346
1. When Starting Switch Is Turned On, Monitor Panel Display Does Not Appear
346
2. Communication Error Flashes On The Cluster (hcespn 840, Fmi 2) 347
3. Battery Charging Warning Lamp Lights Up (starting Switch : On) 348
4. When Coolant Overheat Warning Lamp Lights Up (engine Is Started) 349
5. When Air Cleaner Warning Lamp Lights Up (engine Is Started) 350
6. When Engine Oil Pressure Warning Lamp Lights Up (engine Is Started) 351
7. When Hydraulic Oil Temperature Warning Lamp Lights Up (engine Is Started)
352
8. When Coolant Temperature Gauge Does Not Operate (hcespn 304, Fmi 3 Or 4)
353
9. When Fuel Gauge Does Not Operate (hcespn 301, Fmi 3 Or 4) 354
10. When Safety Solenoid Does Not Operate 355
11. When Travel Speed 1, 2 Does Not Operate (hcespn 167, Fmi 5 Or 6) 356
12. When Engine Does Not Start ( Lights Up Condition) 357
13. When Starting Switch On Does Not Operate 358
14. When Starting Switch Is Turned On, Wiper Motor Does Not Operate 359
15. When Starting Switch Is Turned On, Head Lamp Does Not Lights Up 360
16. When Starting Switch Is Turned On, Work Lamp Does Not Lights Up 361
Group 4 Mechatronics Systegroup System 362
1. All Actuators Speed Are Slow 362
2. Engine Stall 364
3. Malfunction Of Cluster Or Mode Selection System 366
4. Malfunction Of Accel Dial 367
5. Auto Decel System Does Not Work 369
6. Malfunction Of Pump 1 Pressure Sensor 371
7. Malfunction Of Pump 2 Pressure Sensor 373
8. Malfunction Of Pump 3 Pressure Sensor 375
9. Malfunction Of Negative 1 Pressure Sensor 377
10. Malfunction Of Negative 2 Pressure Sensor 379
11. Malfunction Of Swing Pressure Sensor 381
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12. Malfunction Of Arm In/out & Bucket In Pressure Sensor 383
13. Malfunction Of Boom Up Pressure Sensor 385
14. Malfunction Of Power Max 387
15. Malfunction Of Boom Priority Eppr Valve 389
16. Malfunction Of Arm Regeneration Solenoid 390
SECTION 7 MAINTENANCE STANDARD 392
Group 1 Operational Performance Test 393
1. Purpose 393
2. Terminology 394
3. Operation For Performance Tests 395
Group 2 Major Component 413
1. Main Pump 413
2. Main Control Valve 414
3. Swing Device (type 1) 415
4. Travel Motor (type 1) 417
4. Travel Motor (type 2, 3) 418
5. Rcv Lever 419
6. Rcv Pedal 420
7. Turning Joint 421
8. Cylinder 422
Group 3 Track And Work Equipment 423
1. Track 423
2. Work Equipment 428
SECTION 8 DISASSEMBLY AND ASSEMBLY 429
Group 1 Precautions 430
1. Removal Work 430
2. Install Work 431
3. Completing Work 432
Group 2 Tightening Torque 433
1. Major Components 433
2. Torque Chart 434
Group 3 Pump Device 436
1. Removal And Install 436
2. Main Pump (1/2) 438
3. Regulator 448
Group 4 Main Control Valve 459
1. Removal And Install Of Motor 459
2. Structure (1/4) 460
3. Disassembly And Assembly 464
Group 5 Swing Device (type 1) 483
1. Removal And Install Of Motor 483
2. Disassembly And Assembly Of Swing Motor 484
3. Removal And Install Of Reduction Gear 498
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4. Disassembly And Assembly Of Reduction Gear 499
Group 5 Swing Device (type 2) 508
1. Removal And Install Of Motor 508
2. Disassembly And Assembly Of Swing Motor 509
3. Disassembly And Assembly Of Reduction Gear 521
4. Assembly Reduction Unit 526
Group 6 Travel Device (type 1) 538
1. Removal And Install 538
2. Travel Motor 539
3. Outline Of Disassembling 541
4. Outline For Assembling 547
Group 6 Travel Device (type 2) 570
1. Removal And Install 570
2. Travel Motor 571
3. Disassembling 574
4. Reassembling 581
2) 589
6. Disassembling 590
7. Assembly Redution Unit 596
Group 7 Rcv Lever 602
1. Removal And Install 602
2. Disassembly And Assembly 603
Group 8 Turning Joint 616
1. Removal And Install 616
2. Disassembly And Assembly 617
Group 9 Boom, Arm And Bucket Cylinder 621
1. Removal And Install 621
2. Disassembly And Assembly 627
Group 10 Undercarriage 638
1. Track Link 638
2. Carrier Roller 639
3. Track Roller 640
4. Idler And Recoil Spring 641
Group 11 Work Equipment 650
1. Structure 650
2. Removal And Install 651
SECTION 9 COMPONENT MOUNTING TORQUE 654
Group 1 Introduction Guide 655
Group 2 Engine System 656
Group 3 Electric System 658
Group 4 Hydraulic System 660
Group 5 Undercarriage 663
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Group 6 Structure 665
Group 7 Work Equipment 669
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0-1
FOREWORD
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
This section explains the safety hints and gives the specification of the machine and major
components.
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
This section explains the hydraulic circuit, single and combined operation.
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
This section explains the computer aided power optimization system and each component.
SECTION 6 TROUBLESHOOTING
This section explains the troubleshooting charts correlating problems to causes.
SECTION 7 MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
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
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(①②③…)
When a manual is revised, an edition mark is
recorded on the bottom outside corner of the
pages.
Revisions
Revised pages are shown at the list of revised
pages on the between the contents page and
section 1 page.
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
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
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
※
10 - 4
10 - 4 - 1
10 - 4 - 2
10 - 5
Added pages
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