Hyundai Robex 380LC-9SH User manual

Robex 380LC-9SH
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 29
4. Weight 32
5. Lifting Capacities 33
6. Bucket Selection Guide 37
7. Undercarriage 39
8. Specifications For Major Components 41
9. Recommended Oils 44
SECTION 2 STRUCTURE AND FUNCTION 45
Group 1 Pump Device 46
1. Structure 46
2. Function 51
2. Hydraulic Circuit 67
3. Operation 68
4. Combined Operation 81
5. Anti-drift Valve 84
6. Relief Valve Operation 85
Group 3 Swing Device 89
1. Structure (machine Serial No. : -#0893) 89
1. Structure (machine Serial No. : #0894-) 91
2. Function 94
Group 4 Travel Device 103
1. Construction (type 1) 103
2. Function 107
2. Specification 117
3. Principle Of Driving 118
4. Reduction Gear 129
Group 5 Rcv Lever 130
1. Structure 130
2. Functions 133
Group 6 Rcv Pedal 137
1. Structure 137
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2. Function 139
SECTION 3 HYDRAULIC SYSTEM 143
Group 1 Hydraulic Circuit 144
HYDRAULIC CIRCUIT (CLUSTER TYPE 1) 144
HYDRAULIC CIRCUIT (CLUSTER TYPE 2) 145
Group 2 Main Circuit 146
1. Suction And Delivery Circuit 146
2. Return Circuit 147
3. Drain Circuit 148
Group 3 Pilot Circuit 149
1. Suction, Delivery And Return Circuit 150
2. Safety Solenoid Valve (safety Lever) 151
3. Boom Priority System 152
4. Travel Speed Control System 153
5. Main Relief Pressure Change Circuit 154
6. Swing Parking Brake Release 155
Group 4 Single Operation 156
1. Boom Up Operation 156
2. Boom Down Operation 157
3. Arm In Operation 158
4. Arm Out Operation 159
5. Bucket In Operation 160
6. Bucket Out Operation 161
7. Swing Operation 162
8. Travel Forward And Reverse Operation 164
Group 5 Combined Operation 166
1. Outline 166
2. Combined Swing And Boom Up Operation 167
3. Combined Swing And Arm Operation 168
4. Combined Swing And Bucket Operation 169
5. Combined Swing And Travel Operation 170
6. Combined Boom And Travel Operation 171
7. Combined Arm And Travel Operation 172
8. Combined Bucket And Travel Operation 173
SECTION 4 ELECTRICAL SYSTEM 174
Group 1 Component Location 175
1. Location 1 175
2. Location 2 176
Group 2 Electrical Circuit 177
ELECTRICAL CIRCUIT(1/2, CLUSTER TYPE 1) 177
ELECTRICAL CIRCUIT (2/2, CLUSTER TYPE 1) 178
ELECTRICAL CIRCUIT (1/2, CLUSTER TYPE 2) 179
ELECTRICAL CIRCUIT (2/2, CLUSTER TYPE 2) 180
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Memorandum 181
1. Power Circuit (cluster Type 1) 182
2. Starting Circuit (cluster Type 1) 186
3. Charging Circuit (cluster Type 1) 190
4. Head And Work Light Circuit (cluster Type 1) 194
5. Beacon Lamp And Cab Light Circuit (cluster Type 1) 198
6. Wiper And Washer Circuit (cluster Type 1) 202
Group 3 Electrical Component Specification 212
Group 4 Connectors 220
1. Connector Destination 220
2. Connection Table For Connectors 224
SECTION 5 MECHATRONICS SYSTEM 243
Group 1 Outline (cluster Type 1) 244
Outline (cluster Type 2) 246
Group 2 Mode Selection System (cluster Type 1) 248
1. Power Mode Selection System 248
2. Work Mode Selection System 249
3. User Mode Selection System 250
Mode Selection System (cluster Type 2) 251
1. Power Mode Selection System 251
2. Work Mode Selection System 252
3. User Mode Selection System 253
Group 3 Automatic Deceleration System (cluster Type 1) 254
1. When Auto Idle Pilot Lamp On 2. When Auto Idle Pilot Lamp Off 254
Automatic Deceleration System (cluster Type 2) 255
1. When Auto Idle Pilot Lamp On 2. When Auto Idle Pilot Lamp Off 255
Group 4 Power Boost System (cluster Type 1) 256
Power Boost System (cluster Type 2) 257
Group 5 Travel Speed Control System (cluster Type 1) 258
Travel Speed Control System (cluster Type 2) 259
Group 6 Automatic Warming Up System (cluster Type 1) 260
Automatic Warming Up System (cluster Type 2) 261
Group 7 Engine Overheat Prevention System (cluster Type 1) 262
Engine Overheat Prevention System (cluster Type 2) 263
Group 8 Variable Power Control System (cluster Type 1) 264
Group 9 Attachment Flow Control System (cluster Type 1) 265
Group 10 Anti-restart System 266
1. Anti-restart Function 266
Group 11 Self-diagnostic System (cluster Type 1) 267
3. Machine Error Codes Table 268
Self-diagnostic System (cluster Type 2) 271
3. Error Codes Table 272
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Group 12 Engine Control System 274
1. Mcu (machine Control Unit) 2. Mcu Assembly 274
3. Exchange Method Of The Rom In The Cluster (type 2) 275
4. Engine Speed Sensor 276
Group 13 Eppr Valve (cluster Type 1) 277
1. Pump Eppr Valve 277
Eppr Valve (cluster Type 2) 278
1. Pump Eppr Valve 278
2. Boom Priority Eppr Valve (cluster Type 1,2) 281
Group 14 Monitoring System (cluster Type 1) 283
1. Outline 283
2. Cluster 283
3. Cluster Connector 285
Monitoring System (cluster Type 2) 306
1. Outline Monitoring System Consists Of The Monitor Part And Switch Part. The Monitor
Part Gives Warnings When Any Abnormality 306
Group 15 Fuel Warmer System 315
1. Specification 315
2. Operation 315
3. Electric Circuit 315
SECTION 6 TROUBLESHOOTING 316
Group 1 Before Troubleshooting 317
1. Introduction 317
2. Diagnosing Procedure 318
Group 2 Hydraulic And Mechanical System 320
1. Introduction 320
2. Drive System 321
3. Hydraulic System 323
4. Swing System 325
5. Travel System 329
6. Attachment System 334
Group 3 Electrical System (cluster Type 1) 340
1. When Starting Switch Is Turned On, Monitor Panel Display Does Not Appear
340
3. Battery Charging Warning Lamp Lights Up (starting Switch : On) 342
4. When Coolant Overheat Warning Lamp Lights Up (engine Is Started) 343
5. When Air Cleaner Warning Lamp Lights Up (engine Is Started) 344
6. When Engine Oil Pressure Warning Lamp Lights Up (engine Is Started) 345
7. When Hydraulic Oil Temperature Warning Lamp Lights Up (engine Is Started)
346
8. When Coolant Temperature Gauge Does Not Operate (hcespn 304, Fmi 3 Or 4)
347
9. When Fuel Gauge Does Not Operate (hcespn 301, Fmi 3 Or 4) 348
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10. When Safety Solenoid Does Not Operate 349
11. When Travel Speed 1, 2 Does Not Operate (hcespn 167, Fmi 5 Or 6) 350
Group 3 Electrical System (cluster Type 2) 356
1. When Starting Switch Is Turned On, Monitor Panel Display Does Not Appear
356
2. Communication Error Flashes On The Cluster 357
3. Battery Charging Warning Lamp Lights Up(starting Switch : On) 358
4. When Coolant Overheat Warning Lamp Lights Up(engine Is Started) 359
5. When Air Cleaner Warning Lamp Lights Up(engine Is Started) 360
6. When Engine Oil Pressure Warning Lamp Lights Up(engine Is Started) 361
7. When Hydraulic Oil Temperature Warning Lamp Lights Up (engine Is Started)
362
8. When Coolant Temperature Gauge Does Not Operate 363
9. When Fuel Gauge Does Not Operate (check Warning Lamp On/off) 364
10. When Safety Solenoid Does Not Operate 365
11. When Travel Speed 1, 2 Does Not Operate 366
Group 4 Mechatronics System (cluster Type 1) 372
1. All Actuators Speed Are Slow 372
2. Engine Stall 374
3. Malfunction Of Cluster Or Mode Selection System 376
5. Auto Decel System Does Not Work 379
6. Malfunction Of Pump 1 Pressure Sensor 381
7. Malfunction Of Pump 2 Pressure Sensor 383
8. Malfunction Of Pump 3 Pressure Sensor 385
9. Malfunction Of Swing Pressure Sensor 387
10. Malfunction Of Boom Up Pressure Sensor 389
11. Malfunction Of Power Max 391
12. Malfunction Of Boom Priority Eppr Valve 393
Mechatronics System (cluster Type 2) 394
1. All Actuators Speed Are Slow 394
2. Engine Stall 396
3. Malfunction Of Cluster Or Mode Selection System 398
5. Auto Decel System Does Not Work 401
6. Malfunction Of Pump 1 Pressure Sensor 403
7. Malfunction Of Pump 2 Pressure Sensor 405
8. Malfunction Of Pump 3 Pressure Sensor 407
9. Malfunction Of Power Max 409
10. Malfunction Of Boom Priority Eppr Valve 411
SECTION 7 MAINTENANCE STANDARD 412
Group 1 Operational Performance Test 413
1. Purpose 413
2. Terminology 414
3. Operation For Performance Tests 415
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Group 2 Major Component 435
1. Main Pump 435
2. Main Control Valve 436
3. Swing Device 437
4. Travel Motor 438
5. Rcv Lever 442
6. Rcv Pedal 443
7. Turning Joint 444
8. Cylinder 445
Group 3 Track And Work Equipment 446
1. Track 446
2. Work Equipment 451
SECTION 8 DISASSEMBLY AND ASSEMBLY 452
Group 1 Precautions 453
1. Removal Work 453
2. Install Work 454
3. Completing Work 455
Group 2 Tightening Torque 456
1. Major Components 456
2. Torque Chart 457
Group 3 Pump Device 459
1. Removal And Install 459
2. Main Pump (1/2) 461
3. Regulator 472
Group 4 Main Control Valve 483
1. Removal And Install 483
2. Structure (1/3) 484
3. Tightening Torque (1/2) A 487
4. Disassembly And Assembly 489
Group 5 Swing Device 496
1. Removal And Install Of Motor (machine Serial No. : -#0893) 496
2. Swing Motor (machine Serial No. : -#0893) 497
1. Removal And Install Of Motor (machine Serial No. : #0894-) 508
2. Swing Motor (machine Serial No. : #0894-) 509
3. Reduction Gear 522
Group 6 Travel Device 530
2. Travel Motor (type 1) 531
3. Travel Reduction Gear (type 1) 534
4. Disassembling 536
5. Assembling 546
2. Specification 563
2. Disassembling 565
3. Disassembling Reduction Gear 581
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4. Assembling Reduction Gear 586
Group 7 Rcv Lever 598
1. Removal And Install 598
2. Disassembly And Assembly 599
Group 8 Turning Joint 612
1. Removal And Install 612
2. Disassembly And Assembly 613
Group 9 Boom, Arm And Bucket Cylinder 617
1. Removal And Install 617
2. Disassembly And Assembly 623
Group 10 Undercarriage 634
1. Track Link 634
2. Carrier Roller 635
3. Track Roller 636
4. Idler And Recoil Spring 637
Group 11 Work Equipment 646
1. Structure 646
2. Removal And Install 647
SECTION 9 COMPONENT MOUNTING TORQUE 650
Group 1 Introduction Guide 651
Group 2 Engine System 652
Group 3 Electric System 655
Group 4 Hydraulic System 657
Group 5 Undercarriage 660
Group 6 Structure 661
Group 7 Work Equipment 665
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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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