Hyundai Robex 220LC-9SH User manual

Robex 220LC-9SH
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
Group 3 Swing Device (type 2) 105
1. Structure 105
2. Principle Of Driving 108
Group 4 Travel Device 116
1. Structure 116
2. Principle Of Driving 118
Group 5 Rcv Lever 124
1. Structure 124
2. Functions 127
Group 6 Rcv Pedal 131
1. Structure 131
2. Function 133
SECTION 3 HYDRAULIC SYSTEM 137
Group 1 Hydraulic Circuit (cluster Type 1) 138
Find manuals at https://best-manuals.com

Hydraulic Circuit (cluster Type 2) 139
Group 2 Main Circuit 140
1. Suction And Delivery Circuit 140
2. Return Circuit 141
3. Drain Circuit 142
Group 3 Pilot Circuit 143
1. Suction, Delivery And Return Circuit 144
2. Safety Solenoid Valve (safety Lever) 145
3. Boom Priority System 146
4. Travel Speed Control System 147
5. Main Relief Pressure Change Circuit 148
6. Arm Regeneration Cut System (cluster Type 1) 149
7. Swing Parking Brake Release 150
8. Swing Priority System 151
Group 4 Single Operation 152
1. Boom Up Operation 152
2. Boom Down Operation 153
3. Arm In Operation 154
4. Arm Out Operation 155
5. Bucket In Operation 156
6. Bucket Out Operation 157
7. Swing Operation 158
8. Travel Forward And Reverse Operation 160
Group 5 Combined Operation 162
1. Outline 162
2. Combined Swing And Boom Up Operation 163
3. Combined Swing And Arm Operation 164
4. Combined Swing And Bucket Operation 165
5. Combined Swing And Travel Operation 166
6. Combined Boom And Travel Operation 167
7. Combined Arm And Travel Operation 168
8. Combined Bucket And Travel Operation 169
SECTION 4 ELECTRICAL SYSTEM 170
Group 1 Component Location 171
1. Location 1 171
2. Location 2 172
Memorandum 177
1. Power Circuit (cluster Type 1) 178
2. Power Circuit (cluster Type 2) 180
3. Starting Circuit (cluster Type 1) 182
4. Starting Circuit (cluster Type 2) 184
5. Charging Circuit (cluster Type 1) 186
6. Charging Circuit (cluster Type 2) 188
Find manuals at https://best-manuals.com

7. Head And Work Light Circuit 190
8. Beacon Lamp And Cab Light Circuit 192
9. Wiper And Washer Circuit 194
Group 3 Electrical Component Specification 202
Group 4 Connectors 210
1. Connector Destination 210
2. Connection Table For Connectors 214
SECTION 5 MECHATRONICS SYSTEM 233
Group 1 Outline 234
Group 2 Mode Selection System (cluster Type 1) 237
1. Power Mode Selection System 237
2. Work Mode Selection System 238
3. User Mode Selection System 239
Mode Selection System (cluster Type 2) 240
1. Power Mode Selection System 240
2. Work Mode Selection System 241
3. User Mode Selection System 242
Group 3 Automatic Deceleration System (cluster Type 1) 243
1. When Auto Idle Pilot Lamp On 2. When Auto Idle Pilot Lamp Off 243
Automatic Deceleration System (cluster Type 2) 244
1. When Auto Idle Pilot Lamp On 2. When Auto Idle Pilot Lamp Off 244
Group 4 Power Boost System (cluster Type 1) 245
Power Boost System (cluster Type 2) 246
Group 5 Travel Speed Control System (cluster Type 1) 247
Travel Speed Control System (cluster Type 2) 248
Group 6 Automatic Warming Up System (cluster Type 1) 249
Automatic Warming Up System (cluster Type 2) 250
Group 7 Engine Overheat Prevention System (cluster Type 1) 251
Engine Overheat Prevention System (cluster Type 2) 252
Group 8 Variable Power Control System (cluster Type 1) 253
Group 9 Attachment Flow Control System (cluster Type 1) 254
Group 10 Anti-restart System 255
1. Anti-restart Function 255
Group 11 Self-diagnostic System (cluster Type 1) 256
1. 2. 256
3. Machine Error Codes Table 257
Self-diagnostic System (cluster Type 2) 260
3. Machine Error Codes Table (cluster Type 2) 261
Group 12 Engine Control System 263
1. Mcu (machine Control Unit) 263
2. Mcu Assembly 263
3. Exchange Method Of The Rom In The Cluster (type 2) 264
Find manuals at https://best-manuals.com

Group 13 Eppr Valve (cluster Type 1) 265
1. Pump Eppr Valve 265
1) 265
3) 266
4) 267
2. Boom Priority Eppr Valve (cluster Type 1, 2) 268
4) 269
Eppr Valve (cluster Type 2) 270
1. Pump Eppr Valve 270
1) 270
Group 14 Monitoring System (cluster Type 1) 271
1. Outline 271
2. Cluster 271
3. Cluster Connector 273
Monitoring System (cluster Type 2) 294
1. 2. 294
3. Cluster Connector 296
Group 15 Fuel Warmer System 307
1. Specification 307
2. Operation 307
3. Electric Circuit 307
SECTION 6 TROUBLESHOOTING 308
Group 1 Before Troubleshooting 309
1. Introduction 309
2. Diagnosing Procedure 310
Group 2 Hydraulic And Mechanical System 312
1. Introduction 312
2. Drive System 313
3. Hydraulic System 315
4. Swing System 317
5. Travel System 321
6. Attachment System 326
Group 3 Electrical System (cluster Type 1) 332
1. When Starting Switch Is Turned On, Monitor Panel Display Does Not Appear
332
3. Battery Charging Warning Lamp Lights Up (starting Switch : On) 334
4. When Coolant Overheat Warning Lamp Lights Up (engine Is Started) 335
5. When Air Cleaner Warning Lamp Lights Up (engine Is Started) 336
6. When Engine Oil Pressure Warning Lamp Lights Up (engine Is Started) 337
7. When Hydraulic Oil Temperature Warning Lamp Lights Up (engine Is Started)
338
8. When Coolant Temperature Gauge Does Not Operate (hcespn 304, Fmi 3 Or 4)
339
Find manuals at https://best-manuals.com

9. When Fuel Gauge Does Not Operate (hcespn 301, Fmi 3 Or 4) 340
10. When Safety Solenoid Does Not Operate 341
11. When Travel Speed 1, 2 Does Not Operate (hcespn 167, Fmi 5 Or 6) 342
12. When Engine Does Not Start ( Lights Up Condition) 343
13. When Starting Switch On Does Not Operate 344
14. When Starting Switch Is Turned On, Wiper Motor Does Not Operate 345
15. When Starting Switch Is Turned On, Head Lamp Does Not Lights Up 346
16. When Starting Switch Is Turned On, Work Lamp Does Not Lights Up 347
Electrical System (cluster Type 2) 348
1. When Starting Switch Is Turned On, Monitor Panel Display Does Not Appear
348
3. Battery Charging Warning Lamp Lights Up (starting Switch : On) 350
4. When Coolant Overheat Warning Lamp Lights Up (engine Is Started) 351
5. When Air Cleaner Warning Lamp Lights Up (engine Is Started) 352
6. When Engine Oil Pressure Warning Lamp Lights Up (engine Is Started) 353
7. When Hydraulic Oil Temperature Warning Lamp Lights Up (engine Is Started)
354
8. When Coolant Temperature Gauge Does Not Operate 355
9. When Fuel Gauge Does Not Operate (check Warning Lamp On/off) 356
10. When Safety Solenoid Does Not Operate 357
11. When Travel Speed 1, 2 Does Not Operate 358
12. When Engine Does Not Start ( Lights Up Condition) 359
13. When Starting Switch On Does Not Operate 360
14. When Starting Switch Is Turned On, Wiper Motor Does Not Operate 361
15. When Starting Switch Is Turned On, Head Lamp Does Not Lights Up 362
16. When Starting Switch Is Turned On, Work Lamp Does Not Lights Up 363
Group 4 Mechatronics System (cluster Type 1) 364
1. All Actuators Speed Are Slow 364
2. Engine Stall 366
3. Malfunction Of Cluster Or Mode Selection System 368
4. Malfunction Of Accel Dial 369
5. Auto Decel System Does Not Work 371
6. Malfunction Of Pump 1 Pressure Sensor 373
7. Malfunction Of Pump 2 Pressure Sensor 375
8. Malfunction Of Pump 3 Pressure Sensor 377
9. Malfunction Of Swing Pressure Sensor 379
10. Malfunction Of Boom Up Pressure Sensor 381
11. Malfunction Of Power Max 383
12. Malfunction Of Boom Priority Eppr Valve 385
13. Malfunction Of Arm Regeneration Solenoid 386
Mechatronics System (cluster Type 2) 388
1. All Actuators Speed Are Slow 388
2. Engine Stall 390
3. Malfunction Of Cluster Or Mode Selection System 392
Find manuals at https://best-manuals.com

4. Malfunction Of Accel Dial 393
5. Auto Decel System Does Not Work 395
6. Malfunction Of Pump 1 Pressure Sensor 397
7. Malfunction Of Pump 2 Pressure Sensor 399
8. Malfunction Of Pump 3 Pressure Sensor 401
9. Malfunction Of Power Max 403
10. Malfunction Of Boom Priority Eppr Valve 405
SECTION 7 MAINTENANCE STANDARD 406
Group 1 Operational Performance Test 407
1. Purpose 407
2. Terminology 408
3. Operation For Performance Tests 409
Group 2 Major Component 428
1. Main Pump 428
2. Main Control Valve 429
3. Swing Device 430
4. Travel Motor 431
5. Rcv Lever 432
6. Rcv Pedal 433
7. Turning Joint 434
8. Cylinder 435
Group 3 Track And Work Equipment 436
1. Track 436
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
Find manuals at https://best-manuals.com

3. Removal And Install Of Reduction Gear 508
4. Disassembly And Assembly Of Reduction Gear 509
Group 5 Swing Device (type 2, 3) 518
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 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
2. Electric Components Mounting 2 637
Group 4 Hydraulic System 638
1. Hydraulic Components Mounting 1 638
2. Hydraulic Components Mounting 2 639
3. Hydraulic Components Mounting 3 640
Group 5 Undercarriage 641
1. Undercarriage Mounting 641
Find manuals at https://best-manuals.com

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
Group 7 Work Equipment 647
Find manuals at https://best-manuals.com

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.
Find manuals at https://best-manuals.com