Hyundai Robex 300LC-9S User manual

Robex 300LC-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 32
4. Weight 35
5. Lifting Capacities 38
1)r300lc-9s 38
2)r300nlc-9s 41
3)r300lc-9s Long Reach 44
6. Bucket Selection Guide 48
7. Undercarriage 50
8. Specifications For Major Components 52
9. Recommended Oils 56
SECTION 2 STRUCTURE AND FUNCTION 57
Group 1 Pump Device 58
1. Structure 58
2. Function 64
2. Hydraulic Circuit 83
3. Function 84
Group 3 Swing Device 112
1. Structure 112
2. Function 115
Group 4 Travel Device 122
1. Construction 122
3. Principle Of Driving 124
Group 4 Travel Device (type 2, 3) 131
1. Construction 131
2. Specification 1) 132
2) 133
3. Operation 134
Group 5 Rcv Lever 145
1. Structure 145
2. Functions 148
Group 6 Rcv Pedal 152
Find manuals at https://best-manuals.com

1. Structure 152
2. Function 154
SECTION 3 HYDRAULIC SYSTEM 158
GROUP 1 HYDRAULIC CIRCUIT 159
Group 2 Main Circuit 161
1. Suction And Delivery Circuit 161
2. Return Circuit 162
3. Drain Circuit 163
Group 3 Pilot Circuit 164
1. Suction, Delivery And Return Circuit 165
2. Safety Solenoid Valve (safety Lever) 166
3. Boom Priority System 167
4. Travel Speed Control System 168
5. Main Relief Pressure Change Circuit 169
6. Arm Regeneration Cut System (cluster Type 1) 170
7. Swing Parking Brake Release 171
8. Swing Priority System 172
Group 4 Single Operation 173
1. Boom Up Operation 173
2. Boom Down Operation 174
3. Arm In Operation 175
4. Arm Out Operation 176
5. Bucket In Operation 177
6. Bucket Out Operation 178
7. Swing Operation 179
8. Travel Forward And Reverse Operation 181
Group 5 Combined Operation 183
1. Outline 183
2. Combined Swing And Boom Up Operation 184
3. Combined Swing And Arm Operation 185
4. Combined Swing And Bucket Operation 186
5. Combined Swing And Travel Operation 187
6. Combined Boom And Travel Operation 188
7. Combined Arm And Travel Operation 189
8. Combined Bucket And Travel Operation 190
SECTION 4 ELECTRICAL SYSTEM 191
Group 1 Component Location 192
1. Location 1 192
2. Location 2 193
Memorandum 198
1. Power Circuit (cluster Type 1) 199
2. Starting Circuit (cluster Type 1) 203
3. Charging Circuit (cluster Type 1) 207
Find manuals at https://best-manuals.com

4. Head And Work Light Circuit (cluster Type 1) 211
5. Beacon Lamp And Cab Light Circuit (cluster Type 1) 215
6. Wiper And Washer Circuit (cluster Type 1) 219
Group 3 Electrical Component Specification 229
Group 4 Connectors 237
1. Connector Destination 237
2. Connection Table For Connectors 241
SECTION 5 MECHATRONICS SYSTEM 260
Group 1 Outline (cluster Type 1) 261
Outline (cluster Type 2) 263
Group 2 Mode Selection System (cluster Type 1) 265
1. Power Mode Selection System 265
Group 2 Mode Selection System (cluster Type 1, Hcec Engine) 266
1. Power Mode Selection System 266
2. Work Mode Selection System 267
3. User Mode Selection System 268
3. User Mode Selection System (hcec Engine) 269
Mode Selection System (cluster Type 2) 270
1. Power Mode Selection System 270
2. Work Mode Selection System 271
3. User Mode Selection System 272
Group 3 Automatic Deceleration System (cluster Type 1) 273
1. When Auto Idle Pilot Lamp On 2. When Auto Idle Pilot Lamp Off 273
Group 3 Automatic Deceleration System (cluster Type 1, Hcec Engine)
274
1. When Auto Idle Pilot Lamp On 2. When Auto Idle Pilot Lamp Off 274
Automatic Deceleration System (cluster Type 2) 275
1. When Auto Idle Pilot Lamp On 2. When Auto Idle Pilot Lamp Off 275
Group 4 Power Boost System (cluster Type 1) 276
Power Boost System (cluster Type 2) 277
Group 5 Travel Speed Control System (cluster Type 1) 278
Travel Speed Control System (cluster Type 2) 279
Group 6 Automatic Warming Up System (cluster Type 1) 280
Automatic Warming Up System (cluster Type 2) 281
Group 7 Engine Overheat Prevention System (cluster Type 1) 282
Engine Overheat Prevention System (cluster Type 2) 283
Group 8 Variable Power Control System (cluster Type 1) 284
Group 9 Attachment Flow Control System (cluster Type 1) 285
Group 10 Anti-restart System 286
1. Anti-restart Function 286
Group 11 Self-diagnostic System (cluster Type 1) 287
Find manuals at https://best-manuals.com

3. Machine Error Codes Table 288
Self-diagnostic System (cluster Type 2) 291
3. Error Codes Table 292
Group 12 Engine Control System 294
1. Mcu (machine Control Unit) 2. Mcu Assembly 294
3. Exchange Method Of The Rom In The Cluster (type 2) 295
Group 13 Eppr Valve (cluster Type 1) 296
1. Pump Eppr Valve 296
Eppr Valve (cluster Type 2) 297
1. Pump Eppr Valve 297
2. Boom Priority Eppr Valve (cluster Type 1,2) 300
Group 14 Monitoring System (cluster Type 1) 302
1. Outline 302
2. Cluster 302
3. Cluster Connector 304
Monitoring System (cluster Type 2) 325
1. Outline Monitoring System Consists Of The Monitor Part And Switch Part. The Monitor
Part Gives Warnings When Any Abnormality 325
Group 15 Fuel Warmer System 334
1. Specification 334
2. Operation 334
3. Electric Circuit 334
SECTION 6 TROUBLESHOOTING 335
Group 1 Before Troubleshooting 336
1. Introduction 336
2. Diagnosing Procedure 337
Group 2 Hydraulic And Mechanical System 339
1. Introduction 339
2. Drive System 340
3. Hydraulic System 342
4. Swing System 344
5. Travel System 348
6. Attachment System 353
Group 3 Electrical System (cluster Type 1) 359
1. When Starting Switch Is Turned On, Monitor Panel Display Does Not Appear
359
3. Battery Charging Warning Lamp Lights Up(starting Switch : On) 361
4. When Coolant Overheat Warning Lamp Lights Up (engine Is Started) 362
5. When Air Cleaner Warning Lamp Lights Up (engine Is Started) 363
6. When Engine Oil Pressure Warning Lamp Lights Up (engine Is Started) 364
7. When Hydraulic Oil Temperature Warning Lamp Lights Up (engine Is Started)
365
8. When Coolant Temperature Gauge Does Not Operate (hcespn 304, Fmi 3 Or 4)
Find manuals at https://best-manuals.com

366
9. When Fuel Gauge Does Not Operate(hcespn 301, Fmi 3 Or 4) 367
10. When Safety Solenoid Does Not Operate 368
11. When Travel Speed 1, 2 Does Not Operate (hcespn 167, Fmi 5 Or 6) 369
Group 3 Electrical System (cluster Type 2) 375
1. When Starting Switch Is Turned On, Monitor Panel Display Does Not Appear
375
2. Communication Error Flashes On The Cluster 376
3. Battery Charging Warning Lamp Lights Up(starting Switch : On) 377
4. When Coolant Overheat Warning Lamp Lights Up(engine Is Started) 378
5. When Air Cleaner Warning Lamp Lights Up(engine Is Started) 379
6. When Engine Oil Pressure Warning Lamp Lights Up(engine Is Started) 380
7. When Hydraulic Oil Temperature Warning Lamp Lights Up(engine Is Started)
381
8. When Coolant Temperature Gauge Does Not Operate 382
9. When Fuel Gauge Does Not Operate(check Warning Lamp On/off) 383
10. When Safety Solenoid Does Not Operate 384
11. When Travel Speed 1, 2 Does Not Operate 385
Group 4 Mechatronics System (cluster Type 1) 386
1. All Actuators Speed Are Slow 386
2. Engine Stall 388
3. Malfunction Of Cluster Or Mode Selection System 390
5. Auto Decel System Does Not Work 393
6. Malfunction Of Pump 1 Pressure Sensor 395
7. Malfunction Of Pump 2 Pressure Sensor 397
8. Malfunction Of Pump 3 Pressure Sensor 399
9. Malfunction Of Swing Pressure Sensor 401
10. Malfunction Of Boom Up Pressure Sensor 403
11. Malfunction Of Power Max 405
12. Malfunction Of Boom Priority Eppr Valve 407
13. Malfunction Of Arm Regeneration Solenoid 408
Mechatronics System (cluster Type 2) 410
1. All Actuators Speed Are Slow 410
2. Engine Stall 412
3. Malfunction Of Cluster Or Mode Selection System 414
5. Auto Decel System Does Not Work 417
6. Malfunction Of Pump 1 Pressure Sensor 419
7. Malfunction Of Pump 2 Pressure Sensor 421
8. Malfunction Of Pump 3 Pressure Sensor 423
9. Malfunction Of Power Max 425
10. Malfunction Of Boom Priority Eppr Valve 427
SECTION 7 MAINTENANCE STANDARD 428
Group 1 Operational Performance Test 429
Find manuals at https://best-manuals.com

1. Purpose 429
2. Terminology 430
3. Operation For Performance Tests 431
Group 2 Major Component 451
1. Main Pump 451
2. Main Control Valve 452
3. Swing Device 453
4. Travel Motor 454
5. Travel Reduction Gear 455
6. Rcv Lever 456
7. Rcv Pedal 457
8. Turning Joint 458
9. Cylinder 459
Group 3 Track And Work Equipment 460
1. Track 460
2. Work Equipment 465
SECTION 8 DISASSEMBLY AND ASSEMBLY 466
Group 1 Precautions 467
1. Removal Work 467
2. Install Work 468
3. Completing Work 469
Group 2 Tightening Torque 470
1. Major Components 470
2. Torque Chart 471
Group 3 Pump Device 473
1. Removal And Install 473
2. Main Pump (1/2) 475
3. Regulator 485
Group 4 Main Control Valve 496
1. Removal And Install Of Motor 496
2. Structure 497
3. Disassembly And Assembly 502
Group 5 Swing Device 517
1. Removal And Install Of Motor 517
2. Swing Motor 518
3. Removal And Install Of Reduction Gear 534
4. Reduction Gear 535
Group 6 Travel Device 545
1. Removal And Install 545
2. Disassembling 548
3. Disassembling Reduction Unit 563
6. Assembling Reduction Gear 569
Group 7 Rcv Lever 578
Find manuals at https://best-manuals.com

1. Removal And Install 578
2. Disassembly And Assembly 579
Group 8 Turning Joint 592
1. Removal And Install 592
2. Disassembly And Assembly 593
Group 9 Boom, Arm And Bucket Cylinder 597
1. Removal And Install 597
2. Disassembly And Assembly 603
Group 10 Undercarriage 614
1. Track Link 614
2. Carrier Roller 615
3. Track Roller 616
4. Idler And Recoil Spring 617
Group 11 Work Equipment 626
1. Structure 626
2. Removal And Install 627
SECTION 9 COMPONENT MOUNTING TORQUE 630
Group 1 Introduction Guide 631
Group 2 Engine System 632
Group 3 Electric System 634
Group 4 Hydraulic System 636
Group 5 Undercarriage 639
Group 6 Structure 641
Group 7 Work Equipment 645
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

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