Hyundai Robex 300LC-9S Manual de usuario

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

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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

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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

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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)

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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

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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

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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

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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(①②③…)

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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