Hyundai Robex 80CR-9 User manual

Robex 80CR-9
CRAWLER EXCAVATOR
SERVICE MANUAL

Table of Content
FOREWORD 7
SECTION 1 GENERAL 15
Group 1 Safety 16
Group 2 Specifications 24
1. Major Component 24
2. Specifications 25
3. Working Range 26
4. Weight 27
5. Lifting Capacities 28
6. Bucket Selection Guide 29
7. Undercarriage 30
8. Specifications For Major Components 31
9. Recommended Oils 34
SECTION 2 STRUCTURE AND FUNCTION 35
Group 1 Hydraulic Pump 36
1. General 36
2. Principal Components And Functions 37
Group 2 Main Control Valve 41
1. Outline 41
2. Hydraulic Circuit 42
3. Structure (1/4) 43
Group 3 Swing Device 47
1. Structure 47
2. Function 50
1. Structure 57
2. Operation Principle 61
3. Operation 62
Group 4 Travel Device 68
1. Construction 68
2. Principle Of Driving 71
2. Reduction Gear 76
Group 5 Rcv Lever 77
1. Structure 77
2. Functions 80
Group 6 Rcv Pedal 84
1. Structure 84
2. Functions 86
SECTION 3 HYDRAULIC SYSTEM 90
Group 1 Hydraulic Circuit 91
Group 2 Main Circuit 92
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1. Suction And Delivery Circuit 92
2. Return Circuit 93
3. Drain Circuit 94
Group 3 Pilot Circuit 95
1. Suction, Delivery And Return Circuit 96
2. Safety Valve (safety Lever) 97
3. Travel Speed Control System 98
4. Swing Parking Brake Release 99
Group 4 Single Operation 100
1. Boom Up Operation 100
2. Boom Down Operation 101
3. Arm Roll In Operation 102
4. Arm Roll Out Operation 103
5. Bucket Roll In Operation 104
6. Bucket Roll Out Operation 105
7. Swing Operation 106
8. Travel Forward And Reverse Operation 108
9. Dozer Up Operation 110
10. Dozer Down Operation 111
Group 5 Combined Operation 112
1. Outline 112
2. Combined Swing And Boom Operation 113
3. Combined Swing And Arm Operation 114
4. Combined Swing And Bucket Operation 115
5. Combined Swing And Travel Operation 116
6. Combined Boom And Travel Operation 117
7. Combined Arm And Travel Operation 118
8. Combined Bucket And Travel Operation 119
SECTION 4 ELECTRICAL SYSTEM 120
Group 1 Component Location 121
1. Location 1 121
2. Location 2 122
Group 2 Monitoring System 123
1. Outline 123
2. Cluster 123
3. Cluster Connector 125
4. Cluster Function 126
Memorandum 137
1. Power Circuit 138
2. Starting Circuit 140
3. Charging Circuit 142
4. Head And Work Lamp Circuit 144
5. Beacon Lamp And Cab Lamp Circuit 146
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6. Wiper And Washer Circuit 148
Group 4 Electrical Component Specification 152
~ 156
Group 5 Connectors 159
1. Connector Destination 159
2. Connection Table For Connectors 162
SECTION 5 TROUBLESHOOTING 176
Group 1 Before Troubleshooting 177
1. Introduction 177
2. Diagnosing Procedure 178
Group 2 Hydraulic And Mechanical System 180
1. Introduction 180
2. Drive System 181
3. Hydraulic System 183
4. Swing System 185
5. Travel System 189
6. Attachment System 194
Group 3 Electrical System 200
1. When Starting Switch Is Turned On, Monitor Panel Display Does Not Appear
200
2. Battery Charging Warning Lamp Lights Up (starting Switch : On) 201
3. When Coolant Overheat Warning Lamp Lights Up (engine Is Started) 202
4. When Air Cleaner Warning Lamp Lights Up (engine Is Started) 203
5. When Engine Oil Pressure Warning Lamp Lights Up (engine Is Started) 204
6. When Hydraulic Oil Temperature Warning Lamp Lights Up (engine Is Started)
205
7. When Coolant Temperature Gauge Does Not Operate 206
8. When Fuel Gauge Does Not Operate (check Warning Lamp On/off) 207
9. When Safety Solenoid Does Not Operate 208
10. When Travel Speed 1, 2 Does Not Operate 209
11. When Starting Switch Is Turned On, Wiper Motor Does Not Operate 210
12. When Starting Switch Is Turned On, Head Lamp Does Not Lights Up 211
13. When Starting Switch Is Turned On, Work Lamp Does Not Lights Up 212
14. When Engine Does Not Start 213
15. When Starting Switch On Does Not Operate 214
SECTION 6 MAINTENANCE STANDARD 215
Group 1 Operational Performance Test 216
1. Purpose 216
2. Terminology 217
3. Operation For Performance Tests 218
Group 2 Major Component 236
1. Main Pump 236
2. Main Control Valve 238
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3. Swing Device 239
4. Travel Device 240
5. Turning Joint 242
6. Cylinder 243
Group 3 Track And Work Equipment 244
1. Track 244
2. Work Equipment 250
SECTION 7 DISASSEMBLY AND ASSEMBLY 251
Group 1 Precautions 252
1. Removal Work 252
2. Install Work 253
3. Completing Work 254
Group 2 Tightening Torque 255
1. Major Components 255
2. Torque Chart 256
Group 3 Pump Device 258
1. Removal And Install 258
2. Main Pump 260
3. Disassembly And Assembly 263
Group 4 Main Control Valve 293
1. Removal And Install Of Motor 293
2. Structure (1/4) 294
3. Disassembly 298
4. Assembly 306
5. Maintenance Standard 314
6. Problem Causes And Measures 315
Group 5 Swing Device 317
1. Removal And Install Of Motor 317
2. Disassembly And Assembly Of Swing Motor 318
3. Removal And Install Of Reduction Gear 331
4. Disassembly And Assembly Of Reduction Gear 332
1. Removal And Install 338
3. Disassembly 343
4. Assembly 350
Group 6 Travel Device 360
1. Removal And Install 360
2. Disassembly 363
3. Assembly 372
Group 7 Rcv Lever 385
1. Removal And Install 385
2. Disassembly And Assembly 386
Group 8 Turning Joint 399
1. Removal And Install 399
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2. Disassembly And Assembly 400
Group 9 Boom, Arm And Bucket Cylinders 404
1. Removal And Install 404
2. Disassembly And Assembly 410
Group 10 Undercarriage 423
1. Track Link 423
2. Carrier Roller 424
3. Track Roller 425
4. Idler And Recoil Spring 426
Group 11 Work Equipment 435
1. Structure 435
2. Removal And Install 436
SECTION 8 COMPONENT MOUNTING TORQUE 439
Group 1 Introduction Guide 440
Group 2 Engine System 441
1. Engine And Accessories Mounting 441
2. Cooling System And Fuel Tank Mounting 442
Group 3 Electric System 443
1. Electric Components Mounting 1 443
Group 4 Hydraulic System 444
1. Hydraulic Components Mounting 1 444
2. Hydraulic Components Mounting 2 445
Group 5 Undercarriage 446
Group 6 Structure 447
1. Cab And Accessories Mounting 447
2. Cowling Mounting 448
Group 7 Work Equipment 449
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SECTION 1 GENERAL
SECTION 1 GENERAL
Group 1 Safety Hints ---------------------------------------------------------------------------------------------------- 1-1
Group 2 Specifications ------------------------------------------------------------------------------------------------- 1-9

1-1
FOLLOW SAFE PROCEDURE
FOLLOW SAFE PROCEDURE
Unsafe work practices are dangerous.
Understand service procedure before doing
work; Do not attempt shortcuts.
WEAR PROTECTIVE CLOTHING
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment
appropriate to the job.
WARN OTHERS OF SERVICE WORK
WARN OTHERS OF SERVICE WORK
Unexpected machine movement can cause
serious injury.
Before performing any work on the excavator,
attach a 「
Do Not Operate
Do Not Operate」tag on the right
side control lever.
USE HANDHOLDS AND STEPS
USE HANDHOLDS AND STEPS
Falling is one of the major causes of personal
injury.
When you get on and off the machine, always
maintain a three point contact with the steps
and handrails and face the machine. Do not
use any controls as handholds.
Never jump on or off the machine. Never mount
or dismount a moving machine.
Be careful of slippery conditions on platforms,
steps, and handrails when leaving the machine.
SECTION 1 GENERAL
SECTION 1 GENERAL
GROUP 1 SAFETY
GROUP 1 SAFETY
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1-2
PREPARE FOR EMERGENCIES
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors,
ambulance service, hospital, and fire
department near your telephone.
PROTECT AGAINST FLYING DEBRIS
PROTECT AGAINST FLYING DEBRIS
Guard against injury from flying pieces of metal
or debris; Wear goggles or safety glasses.
PROTECT AGAINST NOISE
PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause
impairment or loss of hearing.
Wear a suitable hearing protective device such
as earmuffs or earplugs to protect against
objectionable or uncomfortable loud noises.
AVOID POWER LINES
AVOID POWER LINES
Serious injury or death can result from contact
with electric lines.
Never move any part of the machine or load
closer to electric line than 3 m (10 ft ) plus twice the
line insulator length.
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1-3
KEEP RIDERS OFF EXCAVATOR
KEEP RIDERS OFF EXCAVATOR
Only allow the operator on the excavator. Keep
riders off.
Riders on excavator are subject to injury such
as being struck by foreign objects and being
thrown off the excavator. Riders also obstruct
the operator's view resulting in the excavator
being operated in an unsafe manner.
MOVE AND OPERATE MACHINE SAFELY
MOVE AND OPERATE MACHINE SAFELY
Bystanders can be run over. Know the location
of bystanders before moving, swinging, or
operating the machine.
Always keep the travel alarm in working
condition. It warns people when the excavator
starts to move.
Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the
excavator.
OPERATE ONLY FORM OPERATOR'S SEAT
OPERATE ONLY FORM OPERATOR'S SEAT
Avoid possible injury machine damage. Do not
start engine by shorting across starter
terminals.
NEVER start engine while standing on ground.
Start engine only from operator's seat.
PARK MACHINE SAFELY
PARK MACHINE SAFELY
Before working on the machine:
·Park machine on a level surface.
·Lower bucket to the ground.
·Turn auto idle switch off.
·
Run engine at 1/2 speed without load for 2
minutes.
·Turn key switch to OFF to stop engine.
Remove key from switch.
·Move pilot control shutoff lever to locked position.
·Allow engine to cool.
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1-4
SUPPORT MACHINE PROPERLY
SUPPORT MACHINE PROPERLY
Always lower the attachment or implement to the
ground before you work on the machine. If you
must work on a lifted machine or attachment,
securely support the machine or attachment.
Do not support the machine on cinder blocks,
hollow tiles, or props that may crumble under
continuous load.
Do not work under a machine that is supported
solely by a jack. Follow recommended
procedures in this manual.
SERVICE COOLING SYSTEM SAFELY
SERVICE COOLING SYSTEM SAFELY
Explosive release of fluids from pressurized
cooling system can cause serious burns.
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands.
HANDLE FLUIDS SAFELY-AVOID FIRES
HANDLE FLUIDS SAFELY-AVOID FIRES
Handle fuel with care; It is highly flammable.
Do not refuel the machine while smoking or
when near open flame or sparks. Always stop
engine before refueling machine.
Fill fuel tank outdoors.
Store flammable fluids away from fire hazards.
Do not incinerate or puncture pressurized
containers.
Make sure machine is clean of trash, grease,
and debris.
Do not store oily rags; They can ignite and burn
spontaneously.
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1-5
BEWARE OF EXHAUST FUMES
BEWARE OF EXHAUST FUMES
Prevent asphyxiation. Engine exhaust fumes
can cause sickness or death.
If you must operate in a building, be positive
there is adequate ventilation. Either use an
exhaust pipe extension to remove the exhaust
fumes or open doors and windows to bring
enough outside air into the area.
REMOVE PAINT BEFORE WELDING OR
REMOVE PAINT BEFORE WELDING OR
HEATING
HEATING
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint
is heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area.
Dispose of paint and solvent properly.
Remove paint before welding or heating:
·
If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
·If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area.
Allow fumes to disperse at least 15 minutes
before welding or heating.
ILLUMINATE WORK AREA SAFELY
ILLUMINATE WORK AREA SAFELY
Illuminate your work area adequately but safely.
Use a portable safety light for working inside or
under the machine. Make sure the bulb is
enclosed by a wire cage. The hot filament of an
accidentally broken bulb can ignite spilled fuel
or oil.
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