Hyundai Robex 260LC-9S User manual

Robex 260LC-9S
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 18
Group 2 Specifications 27
1. Major Component 27
2. Specifications 28
3. Working Range 31
4. Weight 33
5. Lifting Capacities 35
6. Bucket Selection Guide 38
7. Undercarriage 40
8. Specifications For Major Components 42
9. Recommended Oils 45
SECTION 2 STRUCTURE AND FUNCTION 46
Group 1 Pump Device 47
1. Structure 47
2. Function 53
Group 2 Main Control Valve 66
1. Structure 66
2. Hydraulic Circuit 72
3. Function 73
Group 3 Swing Device 101
1. Structure 101
2. Function 104
Group 4 Travel Device 112
1. Construction 112
Group 5 Rcv Lever 122
1. Structure 122
2. Functions 125
Group 6 Rcv Pedal 129
1. Structure 129
2. Function 131
SECTION 3 HYDRAULIC SYSTEM 135
Group 1 Hydraulic Circuit (cluster Type 1) 136
Hydraulic Circuit (cluster Type 2) 137
Group 2 Main Circuit 138
1. Suction And Delivery Circuit 138
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2. Return Circuit 139
3. Drain Circuit 140
Group 3 Pilot Circuit 141
1. Suction, Delivery And Return Circuit 142
2. Safety Solenoid Valve (safety Lever) 143
3. Boom Priority System 144
4. Travel Speed Control System 145
5. Main Relief Pressure Change Circuit 146
6. Arm Regeneration Cut System (cluster Type 1) 147
7. Swing Parking Brake Release 148
8. Swing Priority System 149
Group 4 Single Operation 150
1. Boom Up Operation 150
2. Boom Down Operation 151
3. Arm In Operation 152
4. Arm Out Operation 153
5. Bucket In Operation 154
6. Bucket Out Operation 155
7. Swing Operation 156
8. Travel Forward And Reverse Operation 158
Group 5 Combined Operation 160
1. Outline 160
2. Combined Swing And Boom Up Operation 161
3. Combined Swing And Arm Operation 162
4. Combined Swing And Bucket Operation 163
5. Combined Swing And Travel Operation 164
6. Combined Boom And Travel Operation 165
7. Combined Arm And Travel Operation 166
8. Combined Bucket And Travel Operation 167
SECTION 4 ELECTRICAL SYSTEM 168
Group 1 Component Location 169
1. Location 1 169
2. Location 2 170
Memorandum 175
1. Power Circuit (cluster Type 1) 176
2. Starting Circuit (cluster Type 1) 180
3. Charging Circuit (cluster Type 1) 184
4. Head And Work Light Circuit (cluster Type 1) 188
5. Beacon Lamp And Cab Light Circuit (cluster Type 1) 192
6. Wiper And Washer Circuit (cluster Type 1) 196
Group 3 Electrical Component Specification 206
Group 4 Connectors 214
1. Connector Destination 214
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2. Connection Table For Connectors 218
SECTION 5 MECHATRONICS SYSTEM 237
Group 1 Outline (cluster Type 1) 238
Outline (cluster Type 2) 240
Group 2 Mode Selection System (cluster Type 1) 242
1. Power Mode Selection System 242
2. Work Mode Selection System 243
3. User Mode Selection System 244
Mode Selection System (cluster Type 2) 245
1. Power Mode Selection System 245
2. Work Mode Selection System 246
3. User Mode Selection System 247
Group 3 Automatic Deceleration System (cluster Type 1) 248
1. When Auto Idle Pilot Lamp On 2. When Auto Idle Pilot Lamp Off 248
Automatic Deceleration System (cluster Type 2) 249
1. When Auto Idle Pilot Lamp On 2. When Auto Idle Pilot Lamp Off 249
Group 4 Power Boost System (cluster Type 1) 250
Power Boost System (cluster Type 2) 251
Group 5 Travel Speed Control System (cluster Type 1) 252
Travel Speed Control System (cluster Type 2) 253
Group 6 Automatic Warming Up System (cluster Type 1) 254
Automatic Warming Up System (cluster Type 2) 255
Group 7 Engine Overheat Prevention System (cluster Type 1) 256
Engine Overheat Prevention System (cluster Type 2) 257
Group 8 Variable Power Control System (cluster Type 1) 258
Group 9 Attachment Flow Control System (cluster Type 1) 259
Group 10 Anti-restart System 260
1. Anti-restart Function 260
Group 11 Self-diagnostic System (cluster Type 1) 261
3. Machine Error Codes Table 262
Self-diagnostic System (cluster Type 2) 265
3. Error Codes Table 266
Group 12 Engine Control System 268
1. Mcu (machine Control Unit) 2. Mcu Assembly 268
3. Exchange Method Of The Rom In The Cluster (type 2) 269
Group 13 Eppr Valve (cluster Type 1) 270
1. Pump Eppr Valve 270
Eppr Valve (cluster Type 2) 271
1. Pump Eppr Valve 271
2. Boom Priority Eppr Valve (cluster Type 1,2) 274
Group 14 Monitoring System (cluster Type 1) 276
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1. Outline 276
2. Cluster 276
3. Cluster Connector 278
Monitoring System (cluster Type 2) 299
1. Outline Monitoring System Consists Of The Monitor Part And Switch Part. The Monitor
Part Gives Warnings When Any Abnormality 299
Group 15 Fuel Warmer System 308
1. Specification 308
2. Operation 308
3. Electric Circuit 308
SECTION 6 TROUBLESHOOTING 309
Group 1 Before Troubleshooting 310
1. Introduction 310
2. Diagnosing Procedure 311
Group 2 Hydraulic And Mechanical System 313
1. Introduction 313
2. Drive System 314
3. Hydraulic System 316
4. Swing System 318
5. Travel System 322
6. Attachment System 327
Group 3 Electrical System (cluster Type 1) 333
1. When Starting Switch Is Turned On, Monitor Panel Display Does Not Appear
333
3. Battery Charging Warning Lamp Lights Up(starting Switch : On) 335
4. When Coolant Overheat Warning Lamp Lights Up (engine Is Started) 336
5. When Air Cleaner Warning Lamp Lights Up (engine Is Started) 337
6. When Engine Oil Pressure Warning Lamp Lights Up (engine Is Started) 338
7. When Hydraulic Oil Temperature Warning Lamp Lights Up (engine Is Started)
339
8. When Coolant Temperature Gauge Does Not Operate (hcespn 304, Fmi 3 Or 4)
340
9. When Fuel Gauge Does Not Operate(hcespn 301, Fmi 3 Or 4) 341
10. When Safety Solenoid Does Not Operate 342
11. When Travel Speed 1, 2 Does Not Operate (hcespn 167, Fmi 5 Or 6) 343
12. When Engine Does Not Start ( Lights Up Condition) 344
13. When Starting Switch On Does Not Operate 345
14. When Starting Switch Is Turned On, Wiper Motor Does Not Operate 346
15. When Starting Switch Is Turned On, Head Lamp Does Not Lights Up 347
16. When Starting Switch Is Turned On, Work Lamp Does Not Lights Up 348
Group 3 Electrical System (cluster Type 2) 349
1. When Starting Switch Is Turned On, Monitor Panel Display Does Not Appear
349
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2. Communication Error Flashes On The Cluster 350
3. Battery Charging Warning Lamp Lights Up(starting Switch : On) 351
4. When Coolant Overheat Warning Lamp Lights Up(engine Is Started) 352
5. When Air Cleaner Warning Lamp Lights Up(engine Is Started) 353
6. When Engine Oil Pressure Warning Lamp Lights Up(engine Is Started) 354
7. When Hydraulic Oil Temperature Warning Lamp Lights Up(engine Is Started)
355
8. When Coolant Temperature Gauge Does Not Operate 356
9. When Fuel Gauge Does Not Operate(check Warning Lamp On/off) 357
10. When Safety Solenoid Does Not Operate 358
11. When Travel Speed 1, 2 Does Not Operate 359
12. When Engine Does Not Start ( Lights Up Condition) 360
13. When Starting Switch On Does Not Operate 361
14. When Starting Switch Is Turned On, Wiper Motor Does Not Operate 362
15. When Starting Switch Is Turned On, Head Lamp Does Not Lights Up 363
16. When Starting Switch Is Turned On, Work Lamp Does Not Lights Up 364
Group 4 Mechatronics System (cluster Type 1) 365
1. All Actuators Speed Are Slow 365
2. Engine Stall 367
3. Malfunction Of Cluster Or Mode Selection System 369
4. Malfunction Of Accel Dial 370
5. Auto Decel System Does Not Work 372
6. Malfunction Of Pump 1 Pressure Sensor 374
7. Malfunction Of Pump 2 Pressure Sensor 376
8. Malfunction Of Pump 3 Pressure Sensor 378
9. Malfunction Of Swing Pressure Sensor 380
10. Malfunction Of Boom Up Pressure Sensor 382
11. Malfunction Of Power Max 384
12. Malfunction Of Boom Priority Eppr Valve 386
13. Malfunction Of Arm Regeneration Solenoid 387
Mechatronics System (cluster Type 2) 389
1. All Actuators Speed Are Slow 389
2. Engine Stall 391
3. Malfunction Of Cluster Or Mode Selection System 393
4. Malfunction Of Accel Dial 394
5. Auto Decel System Does Not Work 396
6. Malfunction Of Pump 1 Pressure Sensor 398
7. Malfunction Of Pump 2 Pressure Sensor 400
8. Malfunction Of Pump 3 Pressure Sensor 402
9. Malfunction Of Power Max 404
10. Malfunction Of Boom Priority Eppr Valve 406
SECTION 7 MAINTENANCE STANDARD 407
Group 1 Operational Performance Test 408
1. Purpose 408
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2. Terminology 409
3. Operation For Performance Tests 410
Group 2 Major Component 430
1. Main Pump 430
2. Main Control Valve 431
3. Swing Device 432
4. Travel Motor 433
5. Rcv Lever 434
6. Rcv Pedal 435
7. Turning Joint 436
8. Cylinder 437
Group 3 Track And Work Equipment 438
1. Track 438
2. Work Equipment 443
SECTION 8 DISASSEMBLY AND ASSEMBLY 444
Group 1 Precautions 445
1. Removal Work 445
2. Install Work 446
3. Completing Work 447
Group 2 Tightening Torque 448
1. Major Components 448
2. Torque Chart 449
Group 3 Pump Device 451
1. Removal And Install 451
2. Main Pump (1/2) 453
3. Regulator (1/2) 463
Group 4 Main Control Valve 474
1. Removal And Install Of Motor 474
2. Structure 475
3. Disassembly And Assembly 480
Group 5 Swing Device 495
1. Removal And Install Of Motor 495
2. Disassembly And Assembly Of Swing Motor 496
3. Removal And Install Of Reduction Gear 509
4. Disassembly And Assembly Of Reduction Gear 510
Group 6 Travel Device 524
1. Removal And Install 524
2. Specification 1) 525
3. Disassembly 529
4. Reassembly 540
Group 7 Rcv Lever 555
1. Removal And Install 555
2. Disassembly And Assembly 556
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Group 8 Turning Joint 569
1. Removal And Install 569
2. Disassembly And Assembly 570
Group 9 Boom, Arm And Bucket Cylinder 574
1. Removal And Install 574
2. Disassembly And Assembly 580
Group 10 Undercarriage 591
1. Track Link 591
2. Carrier Roller 592
3. Track Roller 593
4. Idler And Recoil Spring 594
Group 11 Work Equipment 603
1. Structure 603
2. Removal And Install 604
SECTION 9 COMPONENT MOUNTING TORQUE 607
Group 1 Introduction Guide 608
Group 2 Engine System 609
Group 3 Electric System 611
Group 4 Hydraulic System 613
Group 5 Undercarriage 616
Group 6 Structure 618
Group 7 Work Equipment 622
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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(①②③…)
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
※
10 - 4
10 - 4 - 1
10 - 4 - 2
10 - 5
Added pages
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