Hyundai Robex 210NLC-9 Manuel utilisateur

Robex 210NLC-9

CRAWLER EXCAVATOR

SERVICE MANUAL

TABLE OF CONTENT

FOREWORD 8

1. Structure 8

2. How To Read The Service Manual 9

3. Conversion Table 10

SECTION 1 GENERAL 16

Group 1 Safety 17

Group 2 Specifications 26

1. Major Component 26

2. Specifications 27

3. Working Range 28

4. Weight 29

5. Lifting Capacities 30

6. Bucket Selection Guide 32

7. Undercarriage 34

8. Specifications For Major Components 36

9. Recommended Oils 40

SECTION 2 STRUCTURE AND FUNCTION 41

Group 1 Pump Device 42

1. Structure 42

2. Function 49

Group 2 Main Control Valve 62

1. Structure 62

2. Hydraulic Circuit 65

3. Function 66

Group 3 Swing Device 89

1. Structure 89

2. Principle Of Driving 92

Group 4 Travel Device 100

1. Structure 100

2. Principle Of Driving 102

Group 5 Rcv Lever 108

1. Structure 108

2. Functions 111

Group 6 Rcv Pedal 115

1. Structure 115

2. Function 117

SECTION 3 HYDRAULIC SYSTEM 121

Group 2 Main Circuit 123

1. Suction And Delivery Circuit 123

2. Return Circuit 124

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3. Drain Circuit 125

Group 3 Pilot Circuit 126

1. Suction, Delivery And Return Circuit 127

2. Safety Valve (safety Lever) 128

3. Boom Priority System 129

4. Travel Speed Control System 130

5. Main Relief Pressure Change System 131

6. Arm Regeneration Cut System 132

7. Swing Parking Brake Release 133

Group 4 Single Operation 134

1. Boom Up Operation 134

2. Boom Down Operation 135

3. Arm In Operation 136

4. Arm Out Operation 137

5. Bucket In Operation 138

6. Bucket Out Operation 139

7. Swing Operation 140

8. Travel Forward And Reverse Operation 142

Group 5 Combined Operation 144

1. Outline 144

2. Combined Swing And Boom Up Operation 145

3. Combined Swing And Arm Operation 146

4. Combined Swing And Bucket Operation 147

5. Combined Swing And Travel Operation 148

6. Combined Boom And Travel Operation 149

7. Combined Arm And Travel Operation 150

8. Combined Bucket And Travel Operation 151

9. Combined Boom Up And Bucket Operation 152

SECTION 4 ELECTRICAL SYSTEM 153

Group 1 Component Location 154

1. Location 1 154

2. Location 2 155

Memorandum 158

1. Power Circuit 159

2. Starting Circuit 161

3. Charging Circuit 163

4. Head And Work Light Circuit 165

5. Beacon Lamp And Cab Light Circuit 167

6. Wiper And Washer Circuit 169

Group 3 Electrical Component Specification 174

Group 4 Connectors 182

1. Connector Destination 182

2. Connection Table For Connectors 186

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SECTION 5 MECHATRONICS SYSTEM 205

Group 1 Outline 206

Group 2 Mode Selection System 208

1. Power Mode Selection System 208

2. Work Mode Selection System 209

3. User Mode Selection System 210

Group 3 Automatic Deceleration System 211

1. When Auto Idle Pilot Lamp On 2. When Auto Idle Pilot Lamp Off 211

Group 4 Power Boost System 212

Group 5 Travel Speed Control System 213

Group 6 Automatic Warming Up System 214

Group 7 Engine Overheat Prevention System 215

Group 8 Variable Power Control System 216

Group 9 Attachment Flow Control System 217

Group 10 Anti-restart System 218

1. Anti-restart Function 218

Group 11 Self-diagnostic System 219

3. Machine Error Codes Table 220

4. Engine Fault Code 223

Group 12 Engine Control System 232

1. Mcu And Engine Ecm (electronic Control Module) 232

2. Mcu Assembly 232

Group 13 Eppr Valve 233

1. Pump Eppr Valve 233

2. Boom Priority Eppr Valve 236

Group 14 Monitoring System 238

1. Outline 238

2. Cluster 238

3. Cluster Connector 240

Group 15 Fuel Warmer System 261

1. Specification 261

2. Operation 261

3. Electric Circuit 261

SECTION 6 TROUBLESHOOTING 262

Group 1 Before Troubleshooting 263

1. Introduction 263

2. Diagnosing Procedure 264

Group 2 Hydraulic And Mechanical System 266

1. Introduction 266

2. Drive System 267

3. Hydraulic System 269

4. Swing System 271

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5. Travel System 275

6. Attachment System 280

Group 3 Electrical System 286

1. When Starting Switch Is Turned On, Monitor Panel Display Does Not Appear

286

3. Battery Charging Warning Lamp Lights Up(starting Switch : On) 288

4. When Coolant Overheat Warning Lamp Lights Up (engine Is Started) 289

5. When Air Cleaner Warning Lamp Lights Up (engine Is Started) 290

6. When Engine Oil Pressure Warning Lamp Lights Up (engine Is Started) 291

7. When Hydraulic Oil Temperature Warning Lamp Lights Up (engine Is Started)

292

8. When Coolant Temperature Gauge Does Not Operate (hcespn 304, Fmi 3 Or 4)

293

9. When Fuel Gauge Does Not Operate(hcespn 301, Fmi 3 Or 4) 294

10. When Safety Solenoid Does Not Operate 295

11. When Travel Speed 1, 2 Does Not Operate (hcespn 167, Fmi 5 Or 6) 296

12. When Engine Does Not Start ( Lights Up Condition) 297

13. When Starting Switch On Does Not Operate 298

14. When Starting Switch Is Turned On, Wiper Motor Does Not Operate 299

15. When Starting Switch Is Turned On, Head Lamp Does Not Lights Up 300

16. When Starting Switch Is Turned On, Work Lamp Does Not Lights Up 301

Group 4 Mechatronics Systegroup System 302

1. All Actuators Speed Are Slow 302

2. Engine Stall 304

3. Malfunction Of Cluster Or Mode Selection System 306

4. Malfunction Of Accel Dial 307

5. Auto Decel System Does Not Work 309

6. Malfunction Of Pump 1 Pressure Sensor 311

7. Malfunction Of Pump 2 Pressure Sensor 313

8. Malfunction Of Pump 3 Pressure Sensor 315

9. Malfunction Of Negative 1 Pressure Sensor 317

10. Malfunction Of Negative 2 Pressure Sensor 319

11. Malfunction Of Swing Pressure Sensor 321

12. Malfunction Of Arm In/out & Bucket In Pressure Sensor 323

13. Malfunction Of Boom Up Pressure Sensor 325

14. Malfunction Of Power Max 327

15. Malfunction Of Boom Priority Eppr Valve 329

16. Malfunction Of Arm Regeneration Solenoid 330

SECTION 7 MAINTENANCE STANDARD 332

Group 1 Operational Performance Test 333

1. Purpose 333

2. Terminology 334

3. Operation For Performance Tests 335

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Group 2 Major Component 353

1. Main Pump 353

2. Main Control Valve 354

3. Swing Device 355

4. Travel Motor 356

5. Rcv Lever 357

6. Rcv Pedal 358

7. Turning Joint 359

8. Cylinder 360

Group 3 Track And Work Equipment 361

1. Track 361

2. Work Equipment 367

SECTION 8 DISASSEMBLY AND ASSEMBLY 368

Group 1 Precautions 369

1. Removal Work 369

2. Install Work 370

3. Completing Work 371

Group 2 Tightening Torque 372

1. Major Components 372

2. Torque Chart 373

Group 3 Pump Device 375

1. Removal And Install 375

2. Main Pump (1/2) 377

Group 4 Main Control Valve 404

1. Removal And Install Of Motor 404

2. Structure (1/4) 405

3. Disassembly And Assembly 409

Group 5 Swing Device (type 1) 428

1. Removal And Install Of Motor 428

2. Disassembly And Assembly Of Swing Motor 429

3. Removal And Install Of Reduction Gear 443

4. Disassembly And Assembly Of Reduction Gear 444

Group 5 Swing Device (type 3, 4) 453

1. Removal And Install Of Motor 453

2. Disassembly And Assembly Of Swing Motor 454

3. Disassembly And Assembly Of Reduction Gear 466

4. Assembly Reduction Unit 471

Group 6 Travel Device 483

1. Removal And Install 483

2. Travel Motor 484

3. Outline Of Disassembling 486

4. Outline For Assembling 492

Group 7 Rcv Lever 515

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1. Removal And Install 515

2. Disassembly And Assembly 516

Group 8 Turning Joint 529

1. Removal And Install 529

2. Disassembly And Assembly 530

Group 9 Boom, Arm And Bucket Cylinder 534

1. Removal And Install 534

2. Disassembly And Assembly 540

Group 10 Undercarriage 551

1. Track Link 551

2. Carrier Roller 552

3. Track Roller 553

4. Idler And Recoil Spring 554

Group 11 Work Equipment 563

1. Structure 563

2. Removal And Install 564

SECTION 9 COMPONENT MOUNTING TORQUE 567

Group 1 Introduction Guide 568

Group 2 Engine System 569

Group 3 Electric System 571

Group 4 Hydraulic System 573

Group 5 Undercarriage 576

Group 6 Structure 577

Group 7 Work Equipment 581

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0-1

FOREWORD

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

This section explains the safety hints and gives the specification of the machine and major

components.

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

This section explains the hydraulic circuit, single and combined operation.

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

This section explains the computer aided power optimization system and each component.

SECTION 6 TROUBLESHOOTING

This section explains the troubleshooting charts correlating

problems

problems to

causes

causes.

SECTION 7 MAINTENANCE STANDARD

This section gives the judgement standards when inspecting disassembled parts.

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

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(ΗΘΙÄ)

When a manual is revised, an edition mark is

recorded on the bottom outside corner of the

pages.

Revisions

Revised pages are shown at the list of revised

pages on the between the contents page and

section 1 page.

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

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

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.

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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0-3

3. CONVERSION TABLE

Method of using the Conversion Table

The Conversion Table in this section is provided to enable simple conversion of figures. For details of

the method of using the Conversion Table, see the example given below.

Example

Method of using the Conversion Table to convert from millimeters to inches

Convert 55

into inches.

Locate the number 50

the vertical column at the left side, take this as

, then draw a

horizontal line from

Locate the number 5

the row across the top, take this as

, then draw a perpendicular line

down from

Take the point where the two lines cross as

. This point

gives the value when converting

from millimeters to inches. Therefore, 55

= 2.165 inches.

Convert 550

into inches.

The number 550 does not appear in the table, so divide by 10(Move the decimal point one place

to the left) to convert it to 55

Carry out the same procedure as above to convert 55mm to 2.165 inches.

The original value(550

) was divided by 10, so multiply 2.165 inches by 10(Move the decimal

point one place to the right) to return to the original value.

This gives 550

= 21.65 inches.

(1)

(2)

(3)

(1)

(2)

(3)

Millimeters to inches

Millimeters to inches 1

= 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748

20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142

30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536

40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323

60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717

70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110

80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504

90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

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