Hyundai Robex 220LC-9S User manual

Robex 220LC-9S
CRAWLER EXCAVATOR
SERVICE MANUAL

TABLE OF CONTENT
FOREWORD 10
1. Structure 10
2. How To Read The Service Manual 11
3. Conversion Table 12
SECTION 1 GENERAL 18
Group 1 Safety 19
Group 2 Specifications 28
2. Specifications 29
3. Working Range 32
4. Weight 35
5. Lifting Capacities 38
6. Bucket Selection Guide 41
7. Undercarriage 43
8. Specifications For Major Components 45
9. Recommended Oils 49
SECTION 2 STRUCTURE AND FUNCTION 50
Group 1 Pump Device 51
1. Structure 51
2. Function 57
Group 2 Main Control Valve 70
1. Structure 70
2. Hydraulic Circuit 76
3. Function 77
Group 3 Swing Device 104
1. Structure 104
2. Principle Of Driving 107
Group 4 Travel Device 115
1. Structure 115
2. Principle Of Driving 117
Group 5 Rcv Lever 123
1. Structure 123
2. Functions 126
Group 6 Rcv Pedal 130
1. Structure 130
2. Function 132
SECTION 3 HYDRAULIC SYSTEM 136
Group 1 Hydraulic Circuit (cluster Type 1) 137
Hydraulic Circuit (cluster Type 2) 138
Group 2 Main Circuit 139
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1. Suction And Delivery Circuit 139
2. Return Circuit 140
3. Drain Circuit 141
Group 3 Pilot Circuit 142
1. Suction, Delivery And Return Circuit 143
2. Safety Solenoid Valve (safety Lever) 144
3. Boom Priority System 145
4. Travel Speed Control System 146
5. Main Relief Pressure Change Circuit 147
6. Arm Regeneration Cut System (cluster Type 1) 148
7. Swing Parking Brake Release 149
8. Swing Priority System 150
Group 4 Single Operation 151
1. Boom Up Operation 151
2. Boom Down Operation 152
3. Arm In Operation 153
4. Arm Out Operation 154
5. Bucket In Operation 155
6. Bucket Out Operation 156
7. Swing Operation 157
8. Travel Forward And Reverse Operation 159
Group 5 Combined Operation 161
1. Outline 161
2. Combined Swing And Boom Up Operation 162
3. Combined Swing And Arm Operation 163
4. Combined Swing And Bucket Operation 164
5. Combined Swing And Travel Operation 165
6. Combined Boom And Travel Operation 166
7. Combined Arm And Travel Operation 167
8. Combined Bucket And Travel Operation 168
SECTION 4 ELECTRICAL SYSTEM 169
Group 1 Component Location 170
1. Location 1 170
2. Location 2 171
Memorandum 176
1. Power Circuit (cluster Type 1) 177
2. Power Circuit (cluster Type 2) 179
3. Starting Circuit (cluster Type 1) 181
4. Starting Circuit (cluster Type 2) 183
5. Charging Circuit (cluster Type 1) 185
6. Charging Circuit (cluster Type 2) 187
7. Head And Work Light Circuit 189
8. Beacon Lamp And Cab Light Circuit 191
9. Wiper And Washer Circuit 193
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Group 3 Electrical Component Specification 201
Group 4 Connectors 209
1. Connector Destination 209
2. Connection Table For Connectors 213
SECTION 5 MECHATRONICS SYSTEM 232
Group 1 Outline 233
Group 2 Mode Selection System (cluster Type 1) 236
1. Power Mode Selection System 236
2. Work Mode Selection System 237
3. User Mode Selection System 238
Mode Selection System (cluster Type 2) 239
1. Power Mode Selection System 239
2. Work Mode Selection System 240
3. User Mode Selection System 241
Group 3 Automatic Deceleration System (cluster Type 1) 242
1. When Auto Idle Pilot Lamp On 2. When Auto Idle Pilot Lamp Off 242
Automatic Deceleration System (cluster Type 2) 243
1. When Auto Idle Pilot Lamp On 2. When Auto Idle Pilot Lamp Off 243
Group 4 Power Boost System (cluster Type 1) 244
Power Boost System (cluster Type 2) 245
Group 5 Travel Speed Control System (cluster Type 1) 246
Travel Speed Control System (cluster Type 2) 247
Group 6 Automatic Warming Up System (cluster Type 1) 248
Automatic Warming Up System (cluster Type 2) 249
Group 7 Engine Overheat Prevention System (cluster Type 1) 250
Engine Overheat Prevention System (cluster Type 2) 251
Group 8 Variable Power Control System (cluster Type 1) 252
Group 9 Attachment Flow Control System (cluster Type 1) 253
Group 10 Anti-restart System 254
1. Anti-restart Function 254
Group 11 Self-diagnostic System (cluster Type 1) 255
1. 2. 255
3. Machine Error Codes Table 256
Self-diagnostic System (cluster Type 2) 259
3. Machine Error Codes Table (cluster Type 2) 260
Group 12 Engine Control System 262
1. Mcu (machine Control Unit) 262
2. Mcu Assembly 262
3. Exchange Method Of The Rom In The Cluster (type 2) 263
Group 13 Eppr Valve (cluster Type 1) 264
1. Pump Eppr Valve 264
1) 264
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3) 265
4) 266
2. Boom Priority Eppr Valve (cluster Type 1, 2) 267
4) 268
Eppr Valve (cluster Type 2) 269
1. Pump Eppr Valve 269
1) 269
Group 14 Monitoring System (cluster Type 1) 270
1. Outline 270
2. Cluster 270
3. Cluster Connector 272
Monitoring System (cluster Type 2) 293
1. 2. 293
3. Cluster Connector 295
Group 15 Fuel Warmer System 306
1. Specification 306
2. Operation 306
3. Electric Circuit 306
SECTION 6 TROUBLESHOOTING 307
Group 1 Before Troubleshooting 308
1. Introduction 308
2. Diagnosing Procedure 309
Group 2 Hydraulic And Mechanical System 311
1. Introduction 311
2. Drive System 312
3. Hydraulic System 314
4. Swing System 316
5. Travel System 320
6. Attachment System 325
Group 3 Electrical System (cluster Type 1) 331
1. When Starting Switch Is Turned On, Monitor Panel Display Does Not Appear
331
3. Battery Charging Warning Lamp Lights Up (starting Switch : On) 333
4. When Coolant Overheat Warning Lamp Lights Up (engine Is Started) 334
5. When Air Cleaner Warning Lamp Lights Up (engine Is Started) 335
6. When Engine Oil Pressure Warning Lamp Lights Up (engine Is Started) 336
7. When Hydraulic Oil Temperature Warning Lamp Lights Up (engine Is Started)
337
8. When Coolant Temperature Gauge Does Not Operate (hcespn 304, Fmi 3 Or 4)
338
9. When Fuel Gauge Does Not Operate (hcespn 301, Fmi 3 Or 4) 339
10. When Safety Solenoid Does Not Operate 340
11. When Travel Speed 1, 2 Does Not Operate (hcespn 167, Fmi 5 Or 6) 341
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12. When Engine Does Not Start ( Lights Up Condition) 342
13. When Starting Switch On Does Not Operate 343
14. When Starting Switch Is Turned On, Wiper Motor Does Not Operate 344
15. When Starting Switch Is Turned On, Head Lamp Does Not Lights Up 345
16. When Starting Switch Is Turned On, Work Lamp Does Not Lights Up 346
Electrical System (cluster Type 2) 347
1. When Starting Switch Is Turned On, Monitor Panel Display Does Not Appear
347
3. Battery Charging Warning Lamp Lights Up (starting Switch : On) 349
4. When Coolant Overheat Warning Lamp Lights Up (engine Is Started) 350
5. When Air Cleaner Warning Lamp Lights Up (engine Is Started) 351
6. When Engine Oil Pressure Warning Lamp Lights Up (engine Is Started) 352
7. When Hydraulic Oil Temperature Warning Lamp Lights Up (engine Is Started)
353
8. When Coolant Temperature Gauge Does Not Operate 354
9. When Fuel Gauge Does Not Operate (check Warning Lamp On/off) 355
10. When Safety Solenoid Does Not Operate 356
11. When Travel Speed 1, 2 Does Not Operate 357
12. When Engine Does Not Start ( Lights Up Condition) 358
13. When Starting Switch On Does Not Operate 359
14. When Starting Switch Is Turned On, Wiper Motor Does Not Operate 360
15. When Starting Switch Is Turned On, Head Lamp Does Not Lights Up 361
16. When Starting Switch Is Turned On, Work Lamp Does Not Lights Up 362
Group 4 Mechatronics System (cluster Type 1) 363
1. All Actuators Speed Are Slow 363
2. Engine Stall 365
3. Malfunction Of Cluster Or Mode Selection System 367
4. Malfunction Of Accel Dial 368
5. Auto Decel System Does Not Work 370
6. Malfunction Of Pump 1 Pressure Sensor 372
7. Malfunction Of Pump 2 Pressure Sensor 374
8. Malfunction Of Pump 3 Pressure Sensor 376
9. Malfunction Of Swing Pressure Sensor 378
10. Malfunction Of Boom Up Pressure Sensor 380
11. Malfunction Of Power Max 382
12. Malfunction Of Boom Priority Eppr Valve 384
13. Malfunction Of Arm Regeneration Solenoid 385
Mechatronics System (cluster Type 2) 387
1. All Actuators Speed Are Slow 387
2. Engine Stall 389
3. Malfunction Of Cluster Or Mode Selection System 391
4. Malfunction Of Accel Dial 392
5. Auto Decel System Does Not Work 394
6. Malfunction Of Pump 1 Pressure Sensor 396
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7. Malfunction Of Pump 2 Pressure Sensor 398
8. Malfunction Of Pump 3 Pressure Sensor 400
9. Malfunction Of Power Max 402
10. Malfunction Of Boom Priority Eppr Valve 404
SECTION 7 MAINTENANCE STANDARD 405
Group 1 Operational Performance Test 406
1. Purpose 406
2. Terminology 407
3. Operation For Performance Tests 408
Group 2 Major Component 427
1. Main Pump 427
2. Main Control Valve 428
3. Swing Device 429
4. Travel Motor 430
5. Rcv Lever 431
6. Rcv Pedal 432
7. Turning Joint 433
8. Cylinder 434
Group 3 Track And Work Equipment 435
1. Track 435
2. Work Equipment 441
SECTION 8 DISASSEMBLY AND ASSEMBLY 442
Group 1 Precautions 443
1. Removal Work 443
2. Install Work 444
3. Completing Work 445
Group 2 Tightening Torque 446
1. Major Components 446
2. Torque Chart 447
Group 3 Pump Device 449
1. Removal And Install 449
2. Main Pump (1/2) 451
3. Regulator (1/2) 461
Group 4 Main Control Valve 472
1. Removal And Install Of Motor 472
2. Structure 473
3. Disassembly And Assembly 478
Group 5 Swing Device (type 1) 493
1. Removal And Install Of Motor 493
2. Disassembly And Assembly Of Swing Motor 494
3. Removal And Install Of Reduction Gear 508
4. Disassembly And Assembly Of Reduction Gear 509
Group 5 Swing Device (type 2, 3) 518
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1. Removal And Install Of Motor 518
2. Disassembly And Assembly Of Swing Motor 519
3. Disassembly And Assembly Of Reduction Gear 531
4. Assembly Reduction Unit 536
Group 6 Travel Device (type 1) 548
1. Removal And Install 548
2. Travel Motor 549
3. Outline Of Disassembling 551
4. Outline For Assembling 557
Group 7 Rcv Lever 580
1. Removal And Install 580
2. Disassembly And Assembly 581
Group 8 Turning Joint 594
1. Removal And Install 594
2. Disassembly And Assembly 595
Group 9 Boom, Arm And Bucket Cylinder 599
1. Removal And Install 599
2. Disassembly And Assembly 605
Group 10 Undercarriage 616
1. Track Link 616
2. Carrier Roller 617
3. Track Roller 618
4. Idler And Recoil Spring 619
Group 11 Work Equipment 628
1. Structure 628
2. Removal And Install 629
SECTION 9 COMPONENT MOUNTING TORQUE 632
Group 1 Introduction Guide 633
Group 2 Engine System 634
1. Engine And Accessories Mounting 634
2. Cooling System And Fuel Tank Mounting 635
Group 3 Electric System 636
1. Electric Components Mounting 1 636
Group 4 Hydraulic System 638
1. Hydraulic Components Mounting 1 638
Group 5 Undercarriage 641
1. Undercarriage Mounting 641
2. Undercarriage Mounting (high Walker) 642
Group 6 Structure 643
1. Cab And Accessories Mounting 643
2. Cab Interior Mounting 644
3. Cowling Mounting 645
4. Counterweight And Covers Mounting 646
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Group 7 Work Equipment 647
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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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