Hyundai HX430L Manual
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Hyundai HX430L Manual

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Table of Contents

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Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1
Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10
Group 1 Pump Device ------------------------------------------------------------------------------------------------------ 2-1
Group 2 Main Control Valve --------------------------------------------------------------------------------------------- 2-20
Group 3 Swing Device ----------------------------------------------------------------------------------------------------- 2-46
Group 4 Travel Device ------------------------------------------------------------------------------------------------------ 2-58
Group 5 RCV Lever ---------------------------------------------------------------------------------------------------------- 2-72
Group 6 RCV Pedal ---------------------------------------------------------------------------------------------------------- 2-79
Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------- 3-1
Group 2 Main Circuit -------------------------------------------------------------------------------------------------------- 3-2
Group 3 Pilot Circuit --------------------------------------------------------------------------------------------------------- 3-5
Group 4 Single Operation ------------------------------------------------------------------------------------------------ 3-14
Group 5 Combined Operation ----------------------------------------------------------------------------------------- 3-24
Group 1 Component Location ----------------------------------------------------------------------------------------- 4-1
Group 2 Electric Circuit ---------------------------------------------------------------------------------------------------- 4-3
Group 3 Electrical Component Specification ----------------------------------------------------------------- 4-23
Group 4 Connectors --------------------------------------------------------------------------------------------------------- 4-34
Group 1 Outline --------------------------------------------------------------------------------------------------------- ------- 5-1
Group 2 Mode selection System ------------------------------------------------------------------------------------- 5-3
Group 3 Automatic Deceleration System ----------------------------------------------------------------------- 5-6
Group 4 Power Boost System ----------------------------------------------------------------------------------------- 5-7
Group 5 Travel Speed Control System --------------------------------------------------------------------------- 5-8
Group 6 Automatic Warming Up System ----------------------------------------------------------------------- 5-9
Group 7 Engine Overheat Prevention System -------------------------------------------------------------- 5-10
Group 8 Variable power Control System ------------------------------------------------------------------------ 5-11
Group 9 Attachment Flow Control System -------------------------------------------------------------------- 5-12
Group 10 Boom Floating Control System ------------------------------------------------------------------------ 5-13
CONTENTS

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Summary of Contents for Hyundai HX430L

  • Page 1: Table Of Contents

    CONTENTS SECTION 1 GENERAL Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10 SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device ------------------------------------------------------------------------------------------------------ 2-1 Group 2 Main Control Valve --------------------------------------------------------------------------------------------- 2-20 Group 3 Swing Device ----------------------------------------------------------------------------------------------------- 2-46 Group 4 Travel Device ------------------------------------------------------------------------------------------------------ 2-58 Group 5 RCV Lever ---------------------------------------------------------------------------------------------------------- 2-72 Group 6 RCV Pedal ---------------------------------------------------------------------------------------------------------- 2-79 SECTION 3 HYDRAULIC SYSTEM...
  • Page 2 Group 11 Intelligent Power Control System --------------------------------------------------------------------- 5-14 Group 12 Anti-Restart System ------------------------------------------------------------------------------------------ 5-16 Group 13 Self-Diagnostic System ------------------------------------------------------------------------------------ 5-17 Group 14 Engine Control System ------------------------------------------------------------------------------------- 5-56 Group 15 EPPR Valve ------------------------------------------------------------------------------------------------------- 5-57 Group 16 Monitoring System -------------------------------------------------------------------------------------------- 5-62 Group 17 Fuel Warmer System ---------------------------------------------------------------------------------------- 5-99 SECTION 6 TROUBLESHOOTING Group 1 Before Troubleshooting ------------------------------------------------------------------------------------- 6-1 Group 2 Hydraulic and Mechanical System ------------------------------------------------------------------ 6-4...
  • Page 3 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.
  • Page 4 Revised edition mark( Any additions, amendments or other changes will When a manual is revised, an edition mark is be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.
  • Page 5 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 55mm into inches.
  • Page 6 Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457...
  • Page 7 Liter to U.S. Gallon = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189 8.454 8.718 8.982 9.246 9.510...
  • Page 8 kgf m to lbf ft 1kgf m = 7.233lbf ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9...
  • Page 9 kgf/cm to lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
  • Page 10 TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.

  • Page 11: Section 1 General

    SECTION 1 GENERAL Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10...
  • Page 12 SECTION 1 GENERAL GROUP 1 SAFETY FOLLOW SAFE PROCEDURE Unsafe wor k practices are dangerous. Understand service procedure before doing work; Do not attempt shortcuts. WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job. 13031GE01 WARN OTHERS OF SERVICE WORK Unexpected machine movement can cause serious injury.
  • Page 13 PREPARE FOR EMERGENCIES Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance ser vice, hospital, and fire department near your telephone. 13031GE04 PROTECT AGAINST FLYING DEBRIS Guard against injury from flying pieces of metal or debris;...
  • Page 14 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.
  • Page 15 SUPPORT MACHINE PROPERLY Always lower the attachment or implement to the ground before you work on the machine. If you must wor k 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 13031GE10 continuous load.
  • Page 16 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.
  • Page 17 SERVICE MACHINE SAFELY Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
  • Page 18 AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.
  • Page 19 PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3.
  • Page 20 DISPOSE OF FLUIDS PROPERLY Improperly disposing of fluids can harm the environment and ecology. Before draining any fluids, find out the proper way to dispose of waste from your local environmental agency. Use proper containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

  • Page 21: Group 2 Specifications

    GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENT DEF/AdBlue tank Tool box Fuel tank Hydraulic tank Main pump After treatment device Engine Charge air cooler Radiator Oil cooler Main control valve Tooth Bucket Turning joint Swing motor Arm cylinder Boom Boom cylinder Handrail Counterweight Swing...
  • Page 22 2. SPECIFICATIONS HX430 L 6.5 m (21' 4") BOOM and 3.2 m (10' 6") ARM I(I') B(L) 430F2SP02 Description Unit Specification Operating weight kg (lb) 44120 (97270) Bucket capacity (SAE heaped), standard 1.90 (2.49) Overall length 11400 (37' 5") Overall width, with 600 mm shoe 3340 (10'11") Overall height 3630 (11' 11")
  • Page 23 3. WORKING RANGE HX430 L 6.5 m (21' 4") BOOM] 430F2SP03 Description 2.6 m (8' 6") Arm 3.2 m (10' 6") Arm Max digging reach 10750 mm (35' 3") 11160 mm (36' 7") Max digging reach on ground 10520 mm (34' 6") 10930 mm (35' 10") Max digging depth 6910 mm (22' 8")
  • Page 24 4. WEIGHT HX430 L Item Upperstructure assembly 15610 34410 Main frame weld assembly 3045 6710 Engine assembly 1565 Main pump assembly Main control valve assembly Swing motor assembly Hydraulic oil tank assembly Fuel tank assembly Counterweight 7500 16535 Cab assembly 1080 Lower chassis assembly 19600...
  • Page 25 Lifting capacities will vary with different work tools, ground conditions and attachments. The difference between the weight of a work tool attachment must be subtracted. Consult your Hyundai dealer regarding the lifting capacities for specific work tools and attachments. Failure to comply to the rated load can cause possible personal injury or property damage.
  • Page 26 6.5 m (21' 4") boom, 3.2 m (10' 6") arm equipped with 1.90 m (SAE heaped) bucket and 600 mm (24") triple grouser shoe and 6200 kg (13670 lb) counterweight. Load radius At max. reach Load 1.5 m (5.0 ft) 3.0 m (10.0 ft) 4.5 m (15.0 ft) 6.0 m (20.0 ft) 7.5 m (25.0 ft) 9.0 m (30.0 ft) Capacity Reach point...
  • Page 27 Work tools and ground conditions have effects on machine performance. Select an optimum combination according to the working conditions and the type of work that is being done. Consult your Hyundai dealer for information on selecting the correct boom arm bucket combination. 1-16...
  • Page 28 7. UNDERCARRIAGE TRACKS X-leg type center frame is integrally welded with reinforced box-section track frames. The design includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock absorbing springs and assembled track-type tractor shoes with triple grousers. TYPES OF SHOES Triple grouser Model Shapes...
  • Page 29 SELECTION OF TRACK SHOE Suitable track shoes should be selected according to operating conditions. Method of selecting shoes Confirm the category from the list of applications in table 2, then use table 1 to select the shoe. Wide shoes (categories B and C) have limitations on applications. Before using wide shoes, check the precautions, then investigate and study the operating conditions to confirm if these shoes are suitable.
  • Page 30 8. SPECIFICATIONS FOR MAJOR COMPONENTS ENGINE Item Specification Model Cummins QSL9 Type 4-cycle turbocharged charger air cooled diesel engine Cooling method Water cooling Number of cylinders and arrangement 6 cylinders, in-line Firing order 1-5-3-6-2-4 Combustion chamber type Direct injection type Cylinder bore stroke 114 145 mm (4.49"...
  • Page 31 GEAR PUMP Item Specification Type Fixed displacement gear pump single stage Capacity 15cc/rev Maximum pressure 40 kgf/cm (570 psi) Rated oil flow 27.00 /min (7.1 U.S. gpm/5.9 U.K. gpm) MAIN CONTROL VALVE Item Specification Type 9 spools Operating method Hydraulic pilot system Main relief valve pressure 330 kgf/cm (4690 psi) [360 kgf/cm...
  • Page 32 CYLINDER Item Specification Bore dia Rod dia Stroke 110 1500 mm Boom cylinder Cushion Extend only Bore dia Rod dia Stroke 120 1760 mm Arm cylinder Cushion Extend and retract Bore dia Rod dia Stroke 105 1295 mm Bucket cylinder Cushion Extend only Discoloration of cylinder rod can occur when the friction reduction additive of lubrication oil spreads on...
  • Page 33 Using any lubricating oils other than HYUNDAI genuine products may lead to a deterioration of performance and cause damage to major components. Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of major components.

  • Page 34: Section 2 Structure And Function

    SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device ---------------------------------------------------------------------------------------------------- 2-1 Group 2 Main Control Valve ------------------------------------------------------------------------------------------ 2-20 Group 3 Swing Device --------------------------------------------------------------------------------------------------- 2-46 Group 4 Travel Device --------------------------------------------------------------------------------------------------- 2-58 Group 5 RCV Lever -------------------------------------------------------------------------------------------------------- 2-72 Group 6 RCV Pedal -------------------------------------------------------------------------------------------------------- 2-79...

  • Page 35: Group 1 Pump Device

    SECTION 2 STRUCTURE AND FUNCTION GROUP 1 PUMP DEVICE 1. STRUCTURE The pump device consists of main pump, regulator and gear pump. Psv2 (a1) (a2) Psv1 Qmin adjusting screw Qmax adjusting screw Qmin adjusting screw Regulator Regulator Psv1 (a1) (a2) Front pump Port block Rear pump...
  • Page 36 MAIN PUMP (1/2) The main pump consists of two piston pumps (front & rear) and valve block. 380F2MP02 04 Gear pump 271 Pump casing 710 O-ring 111 Drive shaft (F) 311 Valve cove r(F) 717 O-ring 113 Drive shaft (R) 312 Valve cover (R) 719 O-ring 114 Spline coupling...
  • Page 37 FRONT REGULATOR (1/2) Psv1 FRONT Hydraulic circuit 644 645 SECTION B-B 755 541 545 543 722 497 438 Port Port name Port size Pilot port PF 1/4-15 Psv1 Servo assist port PF 1/4-15 Power shift port VIEW C Companion delivery port 38092RG01...
  • Page 38 REAR REGULATOR (1/2) REAR Psv2 Hydraulic circuit 644 645 SECTION B-B Port Port name Port size Pilot port PF 1/4-15 Psv1 Servo assist port PF 1/4-15 Power shift port Companion delivery port 430F2RG02...
  • Page 39 REGULATOR (2/2) SECTION A-A 38092RG03 407 Hexagon socket bolt 625 Outer spring 725 O-ring 408 Hexagon socket bolt 626 Inner spring 728 O-ring 412 Hexagon socket bolt 627 Adjust stem (C) 730 O-ring 413 Hexagon socket bolt 628 Adjust screw (C) 732 O-ring 436 Hexagon socket bolt 629 Cover (C)
  • Page 40 GEAR PUMP 466, 725 29092MP05 307 Poppet 353 Drive gear 466 Plug 308 Seat 354 Driven gear 700 Ring 309 Ring 355 Filter 710 O-ring 310 Spring 361 Front case 725 O-ring 311 Screw 433 Flange socket 732 O-ring 312 Nut 434 Flange socket 850 Snap ring 351 Gear case...
  • Page 41 2. FUNCTION MAIN PUMP The pumps may classified roughly into the rotary group performing a rotary motion and working as the major part of the whole pump function: the swash plate group that varies the delivery rates: and the valve cover group that changes over oil suction and discharge. Rotary group The rotary group consists of drive shaft (F)(111), cylinder block (012), piston...
  • Page 42 Valve block group The valve block group consists of valve cover (F, 311), valve cover (F, 312), valve plate (313, 314), spline coupling (114), booster (130) and valve plate pin (885). The valve plate having two melon-shaped ports is fixed to the valve block and feeds and collects oil to and from the cylinder block.
  • Page 43 REGULATOR Regulator consists of the negative flow control, total horse power control and power shift control function. Negative flow control By changing the pilot pressure Pi, the pump tilting angle (delivery flow) is regulated arbitrarily, as shown in the figure. This regulator is of the negative flow control in which the delivery flow Q decreases as the pilot pressure Pi rises.
  • Page 44 Flow reducing function B(E) Pi(from MCV) Small diameter Servo piston chamber Large diameter chamber 29092MP09A As the pilot pressure Pi rises, the pilot piston (643) moves to the right to a position where the force of the pilot spring (646) balances with the hydraulic force. The groove (A) in the pilot piston is fitted with the pin (875) that is fixed to lever 2 (613).
  • Page 45 Flow increasing function B(E) Small diameter Servo piston chamber Large diameter chamber 29092MP10 As the pilot pressure Pi decreases, the pilot piston (643) moves to the left by the action of the pilot spring (646) and causes lever 2 (613) to rotate around the fulcrum of point B. Since the pin (897) is pressed against the large hole section (C) of lever 2 by the action of the return spring (654) via the spool (652), pin (874), and feedback lever (611), the feedback lever rotates around the fulcrum of point D as lever 2 rotates, and shifts the spool to the left.
  • Page 46 Adjustment of flow control characteristic The flow control characteristic can be adjusted with the adjusting screw. Adjust it by loosening the hexagon nut (801) and by tightening (or loosening) the hexagonal socket head screw (924). Tightening the screw shifts the control chart to the right as shown in the figure.
  • Page 47 Total horsepower control The regulator decreases the pump tilting angle (delivery flow) automatically to limit the input torque within a certain value with a rise in the delivery pressure P1 of the self pump and the delivery pressure P2 of the companion pump.
  • Page 48 Overload preventive function B(E) Large diameter Servo piston Small diameter chamber chamber R130RE01 When the self pump delivery pressure P1 or the companion pump delivery pressure P2 rises, it acts on the stepped part of the compensating piston (621). It presses the compensating rod (623) to the right till the force of the outer spring (625) and inner spring (626) balances with the hydraulic force.
  • Page 49 Flow reset function B(E) Large diameter Small diameter chamber chamber Servo piston R130RE11 As the self pump delivery pressure P1 or the companion pump delivery pressure P2 decreases, the compensating rod (623) is pushed back by the action of the springs (625 & 626) to rotate lever 1 (612) around point E.
  • Page 50 Low tilting angle (low flow) command preferential function As mentioned above, flow control and horsepower control tilting angle commands are transmitted to the feedback lever and spool via the large-hole sections (C & F) of levers 1 and 2. However, since sections C and F have the pins ( 4) protruding from the large hole ( 8), only the lever lessening the tilting angle contacts the pin (897) ;...
  • Page 51 Adjustment of inner spring Adjust it by loosening the hexagon nut (802) and by tightening (or loosening) the adjusting screw QI (627). Tightening the screw increases the flow and then the input horsepower as shown in the figure. Adjusting valves are shown in table. Adjustment of inner spring Speed Tightening...
  • Page 52 Power shift control B(E) Large diameter Small diameter chamber chamber Servo piston R130RE13 The set horsepower valve is shifted by varying the command current level of the proportional pressure reducing valve attached to the pump. Only one proportional pressure reducing valve is provided.
  • Page 53 Adjustment of maximum and minimum flows Adjustment of maximum flow Adjust it by loosening the hexagon nut (808) and by tightening (or loosening) the set screw (954). The maximum flow only is adjusted w i t h o u t c h a n g i n g o t h e r c o n t r o l characteristics.

  • Page 54: Group 2 Main Control Valve

    GROUP 2 MAIN CONTROL VALVE 1. STRUCTURE (1/4) Mark Port name Port size Tightening torque (R3) Make up port 15~18 kgf m (P3) (108.5~130 lbf ft) (P4) (Ck2) Arm 1 (in) pilot port (PTb) (PTa) Arm 1 (out) pilot port Dr3' (P2g) Boom (down) pilot port...
  • Page 55 STRUCTURE (2/4) Mark Port name Port size Tightening torque Nega-con pressure (boom1 side) port Nega-con pressure (arm1 side) port 3.5~4.0 kgf m Drain port PF1/4 (25.3~29 lbf ft) Dr3' Drain port Drain port Main relief valve pilot port for switching 1.5~1.9 kgf m PF1/8 to high pressure...
  • Page 56 STRUCTURE (3/4) Casing-A Spring Casing-B Travel straight spool assy Plug Bypass cut spool Plug Boom confluence spool Plug Arm confluence spool Plug Swing priority spool O-ring Poppet O-ring Poppet O-ring Poppet O-ring Poppet O-ring Boom priority valve assy Cover Spring Cover Spring Cover...
  • Page 57 STRUCTURE (4/4) BOOM TRAVEL TRAVEL SWING TRAVEL BOOM 1 CONFLUENCE STRAIGHT RIGHT LEFT 165 155 SECTION C - C SECTION D - D BUCKET OPTION SECTION E - E ARM 2 ARM 1 BYPASS CUT SECTION F - F SECTION G - G SECTION H - H 380F2MC04 2-23...
  • Page 58 2. FUNCTION HYDRAULIC CIRCUIT (P4) (P3) (OPEN) P2c2 (CLOSE) PAa2 PAa2 PBa2 PBa2 PAcs Dr3' P2c1 (Ck2) P2c1 PAcs PBb2 SWING PRIORITY PBb2 (Px) SH port (Swing motor) (PTb) (PTa) TRAVEL STRAIGHT CMR1 CMR2 380F2MC05 2-24...
  • Page 59 OPERATION Neutral positions of spools When all spools are in the neutral positions, the pressurized oil discharged from the main pump (A2) passes through Port P1, the main path (1), the bypass circuit (2) passing the spools for boom 1, bucket and arm 2, and boom 1 side negative control orifice, and returns to the hydraulic oil tank through the tank port (T1).
  • Page 60 BOOM CONFLUENCE TRAVEL PBb2 OPTION ARM 1 SWING LEFT (PBo) (R3) (PAo) SWING PRIORITY TRAVEL TRAVEL BUCKET ARM 2 STRAIGHT RIGHT BOOM 1 (PTa) PBa2 PAa2 (PTb) 3809A2MC14 2-26...
  • Page 61 Travel operation When pilot port PBL of the travel right spool is pressurized, the bypass circuit (2) in the arm 2 side is shut off and pressurized oil from port P2 passes through port BL and flows to the travel motor. On the other hand, the return oil from the travel motor passes through port AL and returns to the hydraulic oil tank through the tank port (T1).
  • Page 62 Arm out operation During the arm out operation the pilot pressure enters through ports PBa and PBa2. When the pressure enters through port PBa, the spool transfers in the left direction in figure. The hydraulic oil entering through port P2 Passes through the main path (3) and flows to the bypass circuit (2), but the bypass circuit is shut off due to transfer of the arm 1 spool.
  • Page 63 Arm in operation During the arm in operation, the pilot pressure enters through ports PAa and PAa2. When the pressure enters through port PAa, the spool transfers in the right direction in figure MC17A. The hydraulic oil entering through port P2 passes through the main path (3) and flows to the bypass circuit (2), but the bypass circuit is shut off due to transfer of the arm 1 spool.
  • Page 64 During light load only PAa2 PBa2 U-shaped path Parallel circuit LCa1 Arm self weight 3607A2MC17A The pressure in the arm cylinder head side (H) increases. PAa2 PBa2 LCa1 3607A2MC17B 2-30...
  • Page 65 Boom Boom up operation During the boom up operation, the pilot pressure enters through port PBb and moves the boom 1 spool in the left direction in figure. The pressurized oil entering through port P1 passes through the main path (1) and flows to the bypass circuit (2), but the bypass circuit is shut off due to transfer of the boom 1 spool.
  • Page 66 Boom down operation During the boom down operation, the pilot pressure enters through port PAb and transfers the boom 1 spool in the right direction in figure. The pressurized oil entering through port P1 passes through the main path (1) and flows to the bypass circuit (2), but the bypass circuit is shut off due to transfer of the boom 1 spool.
  • Page 67 Bucket Bucket in operation During the bucket in operation, the pilot pressure enters through port PAc and transfers the bucket spool in the right direction in figure. The pressurized oil entering through port P1 passes through the main path (1) and flows through the bypass circuit (2), but the bypass circuit is shut off due to transfer of the bucket spool.
  • Page 68 Bucket out operation During the bucket out operation, the pilot pressure enters through port PBc and transfers the bucket spool in the left direction in figure. The pressurized oil entering through port P1 passes through the main path (1) and flows through the bypass circuit (2), but the bypass circuit is shut off due to transfer of the bucket spool.
  • Page 69 Swing Independent swing operation During the swing operation, the pilot pressure enters through port PAs (or PBs) and transfers the swing spool. The pressurized oil entering through Port P2 flows to Port As (or Bs) and is supplied to the swing motor. The return oil from the swing motor enters Port Bs (or As) and returns to the hydraulic oil tank through the tank port (T1).
  • Page 70 Travel straight operation Simultaneous operating of both travel spools and other spool. A case where both travel spools and swing spool are changed over will be considered. (The pilot ports PAL, PAr and PAs are pressurized.) [Pilot Circuit] Since the side bypass sections of both travel spools close and the side bypass section of the downstream-side swing closes, the pilot pressure from the port Pa enters through the port PTa to transfer the travel straight spool.
  • Page 71 Function of lock valve The lock valve is fitted between the arm cylinder rod side (R) and the arm1 spool (302). It decreases the leakage by the pressure of the cylinder. Another lock valve is similarly fitted between the boom cylinder head side (H) and the boom 1 spool (303).
  • Page 72 Boom down operation During the boom down operation, pilot pressure enters through port P2c1 and PAb. Pilot pressure transfers the spool (511) in lock valve assy in the right direction in figure. By the transfer of the spool, firstly the hole (a) is blocked and pressurized oil from the boom cylinder head side (H) does not enter to spring chamber (RH).
  • Page 73 Function of boom priority valve During both the swing operation and the boom hoisting operation, the pilot pressure enters through ports PAs(or PBs), PBb and Pns. The pressure Pns transfers the piston (356) and the spool (107) to the down direction, and the path from (a) to (b) is closed. Hereby, the pressurized oil pushes open the poppet (102), passes in the path (c) and (d), enters into the chamber (e), and the poppet (101) is pushed to the casing seat.
  • Page 74 (10) Function of main relief valve The main relief valve is fitted in the casing B and functions as follows : The hydraulic oil is filled up in the inside space chamber (A) from the path (P) through a hole of the body (101) and a restriction of the plunger (511), and seats the plunger (511) against body (101) securely.
  • Page 75 (11) Function of port relief valve The port relief valve is fitted between the cylinder port and low-pressure path. In addition to the relief valve, this serves also as an anti-cavitation check valve, and functions as follows: Function as relief valve The pressurized oil passes through hole A of the piston (301), is filled up in chamber B of the inside space, and seat the plunger (511) against the seat (541) securely.
  • Page 76 When the pressure in the path (P) becomes equal to the set pressure of the spring (621 or 622), the pressurized oil pushes open the poppet (611), flows around it, and flows to the low pressure path (R) through Hole C. 3607A2MC30 3607A2MC31 2-42...
  • Page 77 Opening of the poppet (611) causes the pressure in chamber B to fall and the plunger (511) to open. As the result the pressurized oil in the path (P) runs into the low pressure path (R) directly. 3607A2MC32 3607A2MC33 When the pressurized oil higher than pressure 1.5 MPa enters through the port PL, it pushes the piston (624) to change the relief set pressure of the spring (622) to the high pressure.
  • Page 78 Function as anti-cavitation check valve When any negative pressure exists in the path (p), the oil is supplied through the path (R). When the pressure at (R) becomes higher than that in the path (P), the seat (541) moves in the right direction.
  • Page 79 (12) Function of negative control relief valve The negative control relief valve is fitted between the downstream of the center bypass path and low-pressure path, and functions as follows : When the pressure in the path (P) falls below the set level of the spring (621),the poppet (611) is in the condition shown in the figure.

  • Page 80: Group 3 Swing Device

    GROUP 3 SWING DEVICE 1. STRUCTURE Swing device consists swing motor, swing reduction gear. Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve. Dr(RG) Swing motor Time delay valve Reduction gear Port Port name Port size Main port SAE 1"...
  • Page 81 SWING MOTOR 7 40 5 8 12 11 10 9 20 24 23 1 3 4 14 13 16 15 17 39 19 18 22 25 31,32 36,37 SECTION A-A 38092SM02 Body 15 Friction plate 29 O-ring Oil seal 16 Plate 30 Relief valve assy Roller bearing 17 Brake piston...
  • Page 82 REDUCTION GEAR 38092SM03 Casing 17 Carrier 1 33 Pinion gear Drive shaft 18 Planetary gear 1 34 Lock plate Roller bearing 19 Pin 1 35 Hexagon bolt Spacer ring 20 Needle cage 36 Lock washer Oil seal 21 Side plate 1 37 Plug Roller bearing 22 Side plate 2...
  • Page 83 2. FUNCTION ROTARY PART When high pressurized oil enters a cylinder through port (a), which is the inlet of balance plate (1), hydraulic pressure acting on the piston causes axial force F. The pressure force F works via the piston (2) upon the return plate (3) which acts upon the swash plate (4) via an hydrostatic bearing. Force F1 perpendicular to swash plate (4) and force F2 perpendicular to cylinder center.
  • Page 84 MAKE UP VALVE In the system using this type of motor, there is no counter balance functioning valve and there happens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitation caused by insufficient oil flow there is a make up valve to fill up the oil insufficiency. A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure feed pressure required when the hydraulic motor makes a pumping action.
  • Page 85 RELIEF VALVE Body Seat Plunger Spring Adjusting screw Piston Sleeve O-ring Back up ring O-ring 36072SM06 Construction of relief valve The valve casing contains two cartridge type relief valves that stop the regular and reverse rotations of the hydraulic motor. The relief valves relieve high pressure at start or at stop of swing motion and can control the relief pressure in two steps, high and low, in order to insure smooth operation.
  • Page 86 Ports (P, R) at tank pressure. 36072SM07 When hydraulic oil pressure (P A1) reaches the preset force (F ) of spring (4), the plunger (3) moves to the right as shown. +Pg A Fsp+Pg A2 P1 = P=P1 36072SM08 2-52...
  • Page 87 The oil flow chamber g via orifice m and n. When the pressure chamber g reaches the preset force (Fsp) of spring (4), the piston (6) moves left and stop the piston (6) hits the bottom of sleeve (7). P=P2 36072SM09 When piston (6) hits the end of sleeve (7), it stops moving to the left any further.
  • Page 88 BRAKE SYSTEM Control valve swing brake system This is the brake system to stop the swing motion of the excavator for during operation. In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance created by this throttling works as a brake force to slow down the swing motion. Work Deceleration Stop...
  • Page 89 Operating principle When one of the RCV lever (1) is set to the operation position, the each spool is shifted to left or right and the pilot oil flow is blocked. Then the pilot oil go to SH of the time delay valve (3). This pressure moves spool (5) to the leftward against the force of the spring(8), so pilot pump charged oil (P3) goes to the chamber G through port PG.
  • Page 90 When all of the RCV lever (1) are set the neutral position, the spool (5) returns to right. Then, the piston (6) is moved lower by spring force and the return oil from the chamber G flows back to tank port. At this time, the brake works.
  • Page 91 When the swing control (1) lever is set the neutral position the spool (5) returns right in the time delay valve (3). Then, the piston (6) is moved lower by spring force and the return and the return oil from the chamber G flows back to D-port through orifice (10) of the poppet (7).

  • Page 92: Group 4 Travel Device

    GROUP 4 TRAVEL DEVICE 1. CONSTRUCTION Travel device consists travel motor and gear box. Travel motor includes brake valve, parking brake and high/low speed changeover mechanism. FILL LEVEL DRAIN VB VA HYDRAULIC CIRCUIT VIEW A 43092TM01 Port Port name Port size VA, VB Valve port PF 1...
  • Page 93 2. SPECIFICATION TRAVEL MOTOR 43092TM02 Casing 22 Separated plate 43 O-ring Plug 23 Parking piston 44 O-ring Plug 24 D-ring 45 Relief valve assy Oil seal 25 D-ring 46 Spool Snap ring 26 Valve plate 47 Plug Piston 27 Parallel pin 48 Spring seat Piston seal 28 Spring...
  • Page 94 TRAVEL REDUCTION GEAR 21 23 20 24 15 7 13 12 14 16 17 6 33 10 8 30 35 34 28 32 27 25 19 9 18 11 1 26 5 4 31 2 29 3 43092TM03 Ring gear 13 Needle bearing 2 25 Sun gear 1 Ball bearing...
  • Page 95 3. OPERATION MOTOR High pressure oil delivered from hydraulic pump is led to inlet port that is provided in the brake valve portion and, through the rear cover (32) and valve plate (26), led to cylinder block (16). The oil flow and direction of shaft rotation are indicated in table. Shaft rotation Right Shaft rotation Left (Clockwise)
  • Page 96 PARKING BRAKE Parking brake is released when high pressure oil selected by the brake valve portion that is connected directly to the rear cover (32), is applied to the parking piston (23). Otherwise the braking torque is always applied. This braking torque is generated by the friction between the separated plates (22), inserted into the casing (1), and friction plates (21), coupled to cylinder block (16) by the outer splines.
  • Page 97 CAPACITY CONTROL MECHANISM Figure typically shows the capacity control mechanism. When high speed pilot line is charged with the pressure P that overcome the spring (50), the spring (50) is compressed and spool (46) shifts to the right to connect the port P and port C. Then, the highest pressure is selected by the check valve (54) from inlet and outlet pressure of the motor and high speed pilot line pressure and pushes shifter piston (6).
  • Page 98 OVERLOAD RELIEF VALVE Structure This valve is screwed in the motor rear cover (32) and consists of : plug (45-1) that is screwed and fixed in the rear cover (32), poppet (45-9) and supports the poppet seat (45-10), spring (45-4) that is operating relief valve setting pressure and supports the spring seat (45-5), that is inserted in the sleeve (45-6), screw (45-13) that is adjust the spring force, nut (45-14) that fix screw (45-13), piston (45-7) that reduce the shock.
  • Page 99 Operation Two pieces of overload valves are located at cross-over position in the counterbalance circuit of brake valve and have the following functions: When hydraulic motor starts, keep the driving pressure below predetermined value and while accelerating, bypasses surplus oil to return line. When stopping the motor, keep the brake pressure, that develops on the outlet side of motor, under the predetermined value to stop the inertial force.
  • Page 100 BRAKE VALVE Structure The brake valve portion mainly consists of the following parts : Spool By shifting the spool (33), the discharged oil from hydraulic motor is automatically shut off or restricted according to the condition and give the effect of holding, accelerating, stopping and counterbalance operations.
  • Page 101 Operation Holding operation When the control valve is at neutral position, VA and VB ports are connected to the tank, and the spring (36) located on both spool ends holds the spool (33) at central position. Therefore, the passages from VA to MA and VB to MB are closed, which result in closing MA and MB ports connected to hydraulic motor.
  • Page 102 Accelerating operation When VA and VB ports are connected respectively to pump and tank by operating the control valve, hydraulic oil from pump is forwarded through VA port to push open the check valve provided inside spool (33), and oil flows to motor via MA port to rotate the motor. Therefore, the pressure increases and negative brake is released by the pressure supplied from pump.
  • Page 103 Stopping operation Returning the control valve to neutral position while running the motor, the oil supply is cut off and VA and VB ports are connected to the tank line. Then the pressure of the pilot chamber located on both spool ends become equal, and the spool (33) returns to the neutral position by spring (36) force.
  • Page 104 Counterbalance operation Counterbalance operation is required to decelerate slowly the hydraulic motor while absorbing inertia force. In case the hydraulic oil is gradually decreased from pump to VB port, the drive shaft of hydraulic motor tends to rotate faster than that matched to the volume of oil supply. Consequently, the pilot chamber pressure on MB to VB side decreases and the spring (36) force moves the spool (33) leftwards towards neutral position.
  • Page 105 REDUCTION GEAR Reduction unit slows down the rotating speed of motor and converts motor torque to strong rotating force. This reduction unit utilizes two stages, planetary reduction system. Planetary reduction system consists of sun gear, planetary gears, (planetary) carriers, and ring gear.

  • Page 106: Group 5 Rcv Lever

    GROUP 5 RCV LEVER 1. STRUCTURE The casing has the oil inlet port P (primary pressure) and the oil outlet port T (tank). In addition the secondary pressure is taken out through ports 1, 2, 3 and 4 provided at the bottom face. Refer to the parts manual for the types of the RCV lever.
  • Page 107 TYPE L2, L4, L6 Null Null TYPE L2, L4 TYPE L6 Switches Type One touch decel Horn Single Simultaneous L2, L4 operation Power boost Breaker operation One touch decel Horn Power boost Null CCW rotation Close CW rotation Open Number 7 and 8 : Option attachment Hydraulic circuit Pilot ports Port...
  • Page 108 CROSS SECTION Case Bushing Spool Shim Spring Spring seat Spring Plug Push rod 10 O-ring 11 Rod seal 12 Plate 13 Spacer 14 Boot 15 Joint assembly 16 Swash plate 17 Adjusting nut 18 Bushing 19 Plug 20 Handle assembly 21 Handle bar 22 Nut 23 Boot...
  • Page 109 2. FUNCTIONS FUNDAMENTAL FUNCTIONS The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This function is carried out by providing the spring at one end of the main control valve spool and apply- ing the output pressure (secondary pressure) of the pilot valve to the other end.
  • Page 110 OPERATION The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown below and the attached operation explanation drawing. The diagram shown below is the typical application example of the pilot valve. 2-70 Pilot valve Main pump Hydraulic motor...
  • Page 111 Case where handle is in neutral position Port 1 Port 3 300L2RL03 The force of the spring (5) that determines the output pressure of the pilot valve is not applied to the spool (3). Therefore, the spool is pushed up by the spring (7) to the position of port (1, 3) in the operation explanation drawing.
  • Page 112 Case where handle is tilted Port 3 Port 1 300L2RL04 When the push rod (9) is stroked, the spool (3) moves downwards. Then port P is connected with port (1) and the oil supplied from the pilot pump flows through port (1) to generate the pressure.

  • Page 113: Group 6 Rcv Pedal

    GROUP 6 RCV PEDAL 1. STRUCTURE The casing (spacer) has the oil inlet port P (primary pressure), and the oil outlet port T (tank). In addition the secondary pressure is taken out through ports 1,2, 3 and 4 provided at the bottom face. Port Port Port size...
  • Page 114 CROSS SECTION The construction of the RCV pedal is shown in the below drawing. The casing has vertical holes in which reducing valves are assembled. The pressure reducing section is composed of the spool (8), spring (6) for setting secondary pressure, return spring (10), stopper (9), and spring seat (7).
  • Page 115 2. FUNCTION FUNDAMENTAL FUNCTIONS The pilot valve is a valve controls the spool stroke, direction, etc of a main control valve. This function is carried out by providing the spring at one end of the main control valve spool and applying the output pressure (secondary pressure) of the pilot valve to the other end.
  • Page 116 OPERATION The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown below ant the attached operation explanation drawing. The diagram shown below is the typical application example of the pilot valve. 36072SF01 Pilot valve Main pump Hydraulic motor...
  • Page 117 Case where pedal is in neutral position 21092RP03 The force of the spring (6) that determines the output pressure of the pilot valve is not applied to the spool (8). Therefore, the spool is pushed up by the spring (10) to the position of port 2 in the operation explanation drawing.
  • Page 118 Case where pedal is tilted Port 1 Port 2 300L2RL08 When the push rod (14) is stroked, the spool (8) moves downwards. Then port P is connected with port (2), and the oil supplied from the pilot pump flows through port 1 to generate the pressure.

  • Page 119: Section 3 Hydraulic System

    SECTION 3 HYDRAULIC SYSTEM Group 1 Hydraulic Circuit ----------------------------------------------------------------------------------------------- 3-1 Group 2 Main Circuit ------------------------------------------------------------------------------------------------------- 3-2 Group 3 Pilot Circuit -------------------------------------------------------------------------------------------------------- 3-5 Group 4 Single Operation ----------------------------------------------------------------------------------------------- 3-14 Group 5 Combined Operation ---------------------------------------------------------------------------------------- 3-24...

  • Page 120: Group 1 Hydraulic Circuit

    SECTION 3 HYDRAULIC SYSTEM GROUP 1 HYDRAULIC CIRCUIT <1-WAY OPTION> <2-WAY ROTATING OPTION> ( 2 ,Px) (RG) Option Dr B1 ( 21 ,P4) [BREAKER] [FLOW ( 21 ,A1) Main pump CONFLUX] Main control valve <ROTATOR> B(CW) A(CCW) Swing motor ( 2 ,R4) OPTION FLOW CONPLUX ( 2 ,Bs) ( 2 ,As)

  • Page 121: Group 2 Main Circuit

    GROUP 2 MAIN CIRCUIT The main hydraulic circuit consists of suction circuit, delivery circuit, return circuit and drain circuit. The hydraulic system consists of one main pump, one control valve, one swing motor, four cylinders and two travel motors. The swash plate type variable displacement tandem axial piston pump is used as the main pump and is driven by the engine at ratio 1.0 of engine speed.
  • Page 122 2. RETURN CIRCUIT Check valve (2) Check valve(2) 1.5 kgf/cm 1.5kgf/cm Full flow filter Oil cooler Main control valve Actuators Check valve (1) Check valve(1) 5.0kgf/cm 5.0 kgf/cm Check valve (3) Check valve(3) 1.5kgf/cm 1.5 kgf/cm 45073CI02 All oil from each actuator returns to the hydraulic tank through the control valve. The bypass check valves are provided in the return circuit.
  • Page 123 3. DRAIN CIRCUIT Travel motor Swing motor Main pump From return line Turning joint Dr#, dr# Drain filter Hydraulic oil tank Check valve 1.5 kgf/cm 140L3CI03 Besides internal leaks from the motors and main pump, the oil for lubrication circulates. These oil have to be fed to the hydraulic tank passing through drain filter and full flow filter in the hydraulic tank.

  • Page 124: Group 3 Pilot Circuit

    GROUP 3 PILOT CIRCUIT Remote control valve Remote control valve RCV pedal (RH lever) (LH lever) Swing parking brake Safety lock solenoid valve Travel speed solenoid valve Power boost solenoid valve Boom priority EPPR valve Main pump Line filter Relief valve 40 kgf/cm Suction strainer Pilot pump...
  • Page 125 1. SUCTION, DELIVERY AND RETURN CIRCUIT BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 PAcs OPTION BUCKET SWING MOTOR Dr3' P2c1 (Ck2) PBb2 BOOM 2 BOOM 1 SWING TRAVEL(LH) TRAVEL RCV PEDAL TRAVEL(RH) (PTb) P1 P1g...
  • Page 126 2. SAFETY SOLENOID VALVE (SAFETY LEVER) BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 PAcs OPTION BUCKET SWING MOTOR Dr3' P2c1 (Ck2) PBb2 BOOM 2 BOOM 1 SWING TRAVEL(LH) TRAVEL RCV PEDAL TRAVEL(RH) (PTb) P1 P1g...
  • Page 127 3. BOOM PRIORITY SYSTEM BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 PAcs OPTION BUCKET Dr3' SWING MOTOR P2c1 (Ck2) PBb2 BOOM 2 BOOM 1 Swing reducing spool SWING TRAVEL(LH) TRAVEL RCV PEDAL TRAVEL(RH) (PTb) P1 P1g...
  • Page 128 4. TRAVEL SPEED CONTROL SYSTEM BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 PAcs OPTION BUCKET SWING MOTOR Dr3' P2c1 (Ck2) PBb2 BOOM 2 BOOM 1 SWING TRAVEL(LH) TRAVEL RCV PEDAL TRAVEL(RH) (PTb) P1 P1g SWING...
  • Page 129 5. MAIN RELIEF PRESSURE CHANGE CIRCUIT BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 PAcs Auto power boost OPTION BUCKET SWING MOTOR Dr3' P2c1 (Ck2) PBb2 BOOM 2 BOOM 1 SWING TRAVEL(LH) TRAVEL RCV PEDAL TRAVEL(RH)
  • Page 130 6. SWING PARKING BRAKE RELEASE BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 SWING MOTOR (RG) PAcs OPTION BUCKET Dr3' P2c1 (Ck2) BRAKE VALVE PBb2 BOOM 2 BOOM 1 B(CW) A(CCW) SWING TRAVEL(LH) RCV PEDAL TRAVEL...
  • Page 131 7. SWING PRIORITY SYSTEM BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 PAcs OPTION BUCKET SWING MOTOR Dr3' P2c1 (Ck2) SWING PRIORITY SPOOL PBb2 BOOM 2 BOOM 1 SWING TRAVEL(LH) RCV PEDAL TRAVEL TRAVEL(RH) (PTb)
  • Page 132 8. BOOM FLOATING SYSTEM BOOM CYLINDER BUCKET CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) Boom safety lock valve P2c2 Head to tank solenoid PAa2 ARM 2 ARM 1 PBa2 PAcs OPTION Rod to tank solenoid BUCKET Boom floating SWING MOTOR Dr3' solenoid valve P2c1 (Ck2)

  • Page 133: Group 4 Single Operation

    GROUP 4 SINGLE OPERATION 1. BOOM UP OPERATION BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 PAcs OPTION BUCKET Dr3' SWING MOTOR P2c1 (Ck2) Boom holding valve Relief valve PBb2 BOOM 2 BOOM 1 SWING TRAVEL(LH)
  • Page 134 2. BOOM DOWN OPERATION BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 PAcs OPTION BUCKET SWING MOTOR Dr3' P2c1 (Ck2) Relief valve PBb2 BOOM 2 BOOM 1 SWING TRAVEL(LH) TRAVEL(RH) (PTb) P1 P1g 380L3HC11 When the RH control lever is pushed forward, the boom 1 spool in the main control valve is moved to the down position by the pilot oil pressure from the remote control valve.
  • Page 135 3. ARM IN OPERATION BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) Arm holding valve P2c2 Make up valve Relief valve PAa2 ARM 2 ARM 1 PBa2 PAcs OPTION BUCKET SWING MOTOR Dr3' P2c1 (Ck2) PBb2 BOOM 2 BOOM 1 SWING TRAVEL(LH) TRAVEL(RH)
  • Page 136 4. ARM OUT OPERATION BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) Arm holding valve Make up valve P2c2 Relief valve PAa2 ARM 2 ARM 1 PBa2 PAcs OPTION BUCKET SWING MOTOR Dr3' P2c1 (Ck2) PBb2 BOOM 2 BOOM 1 SWING TRAVEL(LH) TRAVEL(RH)
  • Page 137 5. BUCKET IN OPERATION BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 Make up valve Relief valve PAcs OPTION BUCKET SWING MOTOR Dr3' P2c1 (Ck2) PBb2 BOOM 1 BOOM 2 SWING TRAVEL(LH) TRAVEL(RH) (PTb) P1 P1g...
  • Page 138 6. BUCKET OUT OPERATION BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 Make up valve Relief valve PAcs OPTION BUCKET SWING MOTOR Dr3' P2c1 (Ck2) PBb2 BOOM 2 BOOM 1 SWING TRAVEL(LH) TRAVEL(RH) (PTb) P1 P1g...
  • Page 139 7. SWING OPERATION BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 SWING MOTOR (RG) PAcs OPTION BUCKET Dr3' P2c1 (Ck2) PBb2 BOOM 2 BOOM 1 B(CW) A(CCW) SWING TRAVEL(LH) TRAVEL RCV PEDAL TRAVEL(RH) (PTb) P1 P1g...
  • Page 140 SWING CIRCUIT OPERATION SWING MOTOR DEVICE PARKING BRAKE BRAKE RELEASE VALVE (RG) BRAKE OFF BRAKE ON MOTOR BRAKE VALVE ANTI-INVERSION VALVE MAKE UP VALVE B(CW) A(CCW) MAKE UP PORT TO/FROM MAIN CONTROL VALVE 380L3HC17 MOTOR BRAKE VALVE Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing operation and controls the swing motor operating pressure.
  • Page 141 8. TRAVEL FORWARD AND REVERSE OPERATION BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 Turning joint PAcs OPTION BUCKET Dr3' SWING MOTOR P2c1 (Ck2) PBb2 BOOM 2 BOOM 1 SWING TRAVEL(LH) TRAVEL RCV PEDAL TRAVEL(RH) (PTb)
  • Page 142 TRAVEL CIRCUIT OPERATION 380L3HC19 Valves are provided on travel motors to offer the following functions. COUNTER BALANCE VALVE When stopping the motor of slope descending, this valve to prevent the motor over run. OVERLOAD RELIEF VALVE Relief valve limit the circuit pressure below 370 kgf/cm (5260 psi) for the travel motor type 1 and 360 kgf/cm (5120 psi) for the travel motor type 2 to prevent high pressure generated at a time of stopping...

  • Page 143: Group 5 Combined Operation

    GROUP 5 COMBINED OPERATION 1. OUTLINE BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 PAcs OPTION BUCKET SWING MOTOR Dr3' P2c1 (Ck2) PBb2 BOOM 2 BOOM 1 SWING TRAVEL(LH) TRAVEL(RH) (PTb) P1 P1g 380L3HC20 The oil from the A1 and A2 pump flows through the neutral oil passage, bypass oil passage and confluence oil passage in the main control valve.
  • Page 144 2. COMBINED SWING AND BOOM UP OPERATION BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 PAcs OPTION BUCKET SWING MOTOR Dr3' P2c1 (Ck2) PBb2 BOOM 2 BOOM 1 SWING TRAVEL(LH) TRAVEL(RH) (PTb) P1 P1g 380L3HC21 When the swing and boom up functions are operated simultaneously, the swing spool and boom...
  • Page 145 3. COMBINED SWING AND ARM OPERATION BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 PAcs OPTION BUCKET SWING MOTOR Dr3' P2c1 (Ck2) PBb2 BOOM 2 BOOM 1 SWING TRAVEL(LH) TRAVEL(RH) (PTb) P1 P1g 380L3HC22 When the swing and arm functions are operated simultaneously, the swing spool and arm spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote...
  • Page 146 4. COMBINED SWING AND BUCKET OPERATION BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 PAcs OPTION BUCKET SWING MOTOR Dr3' P2c1 (Ck2) PBb2 BOOM 1 BOOM 2 SWING TRAVEL(LH) TRAVEL(RH) (PTb) P1 P1g 380L3HC23 When the swing and bucket functions are operated simultaneously, the swing spool and bucket spool in the main control valve are moved to the functional position by the pilot oil pressure from the...
  • Page 147 5. COMBINED SWING AND TRAVEL OPERATION BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 PAcs OPTION BUCKET SWING MOTOR Dr3' P2c1 (Ck2) PBb2 BOOM 2 BOOM 1 SWING TRAVEL(LH) TRAVEL(RH) (PTb) P1 P1g 380L3HC24 When the swing and travel functions are operated simultaneously, the swing spool and travel spools in the main control valve are moved to the functional position by the pilot oil pressure from the...
  • Page 148 6. COMBINED BOOM AND TRAVEL OPERATION BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 PAcs OPTION BUCKET SWING MOTOR Dr3' P2c1 (Ck2) PBb2 BOOM 2 BOOM 1 SWING TRAVEL(LH) TRAVEL(RH) (PTb) P1 P1g 380L3HC25 When the boom and travel functions are operated simultaneously, the boom spools and travel spools in the main control valve are moved to the functional position by the pilot oil pressure from the...
  • Page 149 7. COMBINED ARM AND TRAVEL OPERATION BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 PAcs OPTION BUCKET SWING MOTOR Dr3' P2c1 (Ck2) PBb2 BOOM 2 BOOM 1 SWING TRAVEL(LH) TRAVEL(RH) (PTb) P1 P1g 380L3HC26 When the arm and travel functions are operated simultaneously, the arm spools and travel spools in the main control valve are moved to the functional position by the pilot oil pressure from the remote...
  • Page 150 8. COMBINED BUCKET AND TRAVEL OPERATION BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 PAcs OPTION BUCKET SWING MOTOR Dr3' P2c1 (Ck2) PBb2 BOOM 2 BOOM 1 SWING TRAVEL(LH) TRAVEL(RH) (PTb) P1 P1g 380L3HC27 When the bucket and travel functions are operated simultaneously, the bucket spool and travel spools in the main control valve are moved to the functional position by the pilot oil pressure from the...
  • Page 151 9. COMBINED BOOM UP AND BUCKET OPERATION BUCKET BOOM CYLINDER CYLINDER CYLINDER TRAVEL MOTOR (P3) (P4) P2c2 PAa2 ARM 2 ARM 1 PBa2 Bucket in strock limiter spool PAcs OPTION BUCKET SWING MOTOR Dr3' P2c1 (Ck2) PBb2 BOOM 2 BOOM 1 SWING TRAVEL(LH) TRAVEL(RH)

  • Page 152: Section 4 Electrical System

    SECTION 4 ELECTRICAL SYSTEM Group 1 Component Location ----------------------------------------------------------------------------------------- 4-1 Group 2 Electrical Circuit ------------------------------------------------------------------------------------------------- 4-3 Group 3 Electrical Component Specification ----------------------------------------------------------------- 4-23 Group 4 Connectors --------------------------------------------------------------------------------------------------------- 4-34...

  • Page 153: Group 1 Component Location

    SECTION 4 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 1. LOCATION 1 Switch panel 380L4EL15 Cigar lighter 10 Emergency engine stop switch 19 Lower wiper & washer switch Radio & USB player 11 One touch decel switch 20 Boom floating switch Haptic controller 12 RS232 &...
  • Page 154 2. LOCATION 2 BOOM SAFETY VALVE SOLENOID VALVE BOOM MAIN CONTROL VALVE AIR CLEANER SHUTTLE BLOCK 380L4EL16 Lamp 11 Overload pressure sensor 21 Attach pressure sensor Fuel sender 12 Start relay 22 Travel pressure sensor Fuel filler pump 13 Heater relay 23 Air cleaner sensor Beacon lamp 14 Alternator...
  • Page 155 GROUP 2 ELECTRICAL CIRCUIT ELECTRICAL CIRCUIT (1/6, SERIAL NO. : -#0016) AC COMP RY CS-74A R/DRYER 5R 146 WASHER P/P WASHER P/P BEACON LAMP RY 145 5W REAR VIEW CAMERA MASTER SW 139 1.2Gr POWER RY CABIN LAMP RY FUSE BOX CN-95 MASTER SW CS-74...
  • Page 156 ELECTRICAL CIRCUIT (2/6, SERIAL NO. : -#0016) CS-67 AUTO GREASE SW DC/DC CONVERTER 12V SOCKET HOUR METER 0.8B 0.8ROr 0.8ROr CN-21 0.8ROr WIPER CUT SW QUICK CLAMP SW CS-33 CN-113 1.2B 0.8Or 0.8Br CS-1 CN-24 1.2Gr 11 0.8G 0.8G LH CONSOLE HARNESS BUZZER 0.8V CN-10...
  • Page 157 ELECTRICAL CIRCUIT (3/6, SERIAL NO. : -#0016) AIR PRESS POWER SUPPLY AIR TEMP RETURN ECM J1 CC24B 0.85Y CAN_HI 0.85YB CAN_LO RELAY_LAMP ECM J1 CN-3 CN-7 0.8YW CN-28 1.2V 0.8LW LAMP_UREA 1.2ROr AIR PRESS 0.8V 1.2ROr AC COMP 1/3 030 POWER SUPPLY 0.8Or 1.2ROr...
  • Page 158 ELECTRICAL CIRCUIT (4/6, SERIAL NO. : #0017-) <HARNESS TWOWAY> ATT. SWING SWING SWING SWING BOOM BOOM MAIN ATT. SAFETY BREAKER PARK PARK PARK FINE DOWN BOOM CYL. PRESS PRESS PRESS PRESS PRESS PUMP THERMISTOR THERMISTOR DOSING CONFLUX CONT. FLOATING FLOATING ROD PS ATT.
  • Page 159 ELECTRICAL CIRCUIT (5/6, SERIAL NO. : #0017-) CS-67 AUTO GREASE DC/DC CONVERTER 12V SOCKET HOUR METER 0.8B 0.8ROr 0.8ROr CN-21 0.8ROr WIPER CUT QUICK COUPLING SW CN-113 1.2B 0.8Or CS-33 BUZZER CN-56B WIPER MOTOR 0.8B CS-1 CAM 6.5V 0.8L 1.2Gr 11 0.8G CAM GND 0.8Br...
  • Page 160 ELECTRICAL CIRCUIT (6/6, SERIAL NO. : #0017-) AIR PRESS POWER SUPPLY AIR TEMP RETURN ECM J1 CC24B 0.85Y CAN_HI 0.85YB CAN_LO RELAY_LAMP CN-7 ECM J1 CN-28 1.2V AC COMP LAMP_UREA 1.2ROr AIR PRESS 1.2ROr POWER SUPPLY 1.2ROr AIR TEMP CR-23 CN-45 1.2ROr RETURN...
  • Page 161 MEMORANDUM HYUNDAI HEAVY INDUSTRIES CO., LTD CONSTRUCTION EQUIPMENT DIV.
  • Page 162 1. POWER CIRCUIT The negative terminal of battery is grounded to the machine chassis. When the start switch is in the OFF position, the current flows from the positive battery terminal as shown below. OPERATING FLOW Battery Battery relay Circuit breaker [CN-60] Master switch [CS-74A] Fuse box [No.1] Engine ECM [CN-93 (1, 25, 26, 27, 28)]...
  • Page 163 POWER CIRCUIT 1.2Gr FUSE BOX POWER RY CS-74 MASTER SW CN-95 CN-93 0.8A BATTERY(+) 0.8A BATTERY(+) CIRCUIT BREAKER 0.8A BATTERY(+) 0.8A BATTERY(+) 0.8A BATTERY(+) CN-60 0.8A BATTERY(-) 0.8A PTC POWER BATTERY(-) 0.8A BATTERY(-) 0.8A BATTERY(-) 0.8A BATTERY(-) CR-51 CR-1 0.8ROr BATTERY 0.8L (12VX2)
  • Page 164 2. STARTING CIRCUIT OPERATING FLOW Battery(+) terminal Battery relay [CR-1] Circuit breaker [CN-60] Master switch [CS-74A] Fuse box [No.5] Master switch [CS-74B] I/conn [CN-5 (36)] Start switch [CS-2A (1)] Power relay [CR-35 (30)] When start key switch is in ON position Start switch ON [CS-2A (2)] I/conn [CN-5 (39)] Battery relay [CR-1]...
  • Page 165 STARTING CIRCUIT 1.2Gr FUSE BOX POWER RY CS-74 MASTER SW CN-95 CIRCUIT BREAKER CN-60 PTC POWER CS-74 CR-1 MASTER SW 1.2B 1.2G BATTERY (12VX2) BATT RY DO-3 0.8G 0.8B CR-36 0.8BOr 0.8ROr 0.8L 0.8GrW AIR HEAT RY CR-39 0.8Br 1.2BOr 0.8Y 0.8BOr STARTER LOCKOUT RY...
  • Page 166 3. CHARGING CIRCUIT When the starter is activated and the engine is started, the operator releases the key switch to the ON position. Charging current generated by operating alternator flows into the battery through the battery relay [CR-1]. The current also flows from alternator to each electrical component and controller through the fuse box. OPERATING FLOW Warning flow Alternator "L"...
  • Page 167 CHARGING CIRCUIT FUSE BOX HAPTIC CS-74 MASTER SW CN-8 CN-95 CIRCUIT BREAKER CN-60 PTC POWER CN-56A 0.8RW CR-1 BATT.24V 0.8VOr IG 24V 1.2B 0.8B CAN1 HI BATTERY CAN1 LO (12VX2) BATT RY CAN2 HI DO-3 CAN2 LO 0.8B RS-232 RX RS-232 TX AUX LEFT AUX RIGHT...
  • Page 168 4. HEAD AND WORK LIGHT CIRCUIT OPERATING FLOW Fuse box (No.19) Head light relay [CR-13 (30, 86)] Fuse box (No.16) Work light relay [CR-4 (30, 86)] Head light switch ON Head light switch ON [CN-376 (13)] Head light relay [CR-13 (85) (87)] Head light ON [CL-3 (2), CL-4 (1), CL-24 (2)] l/conn [CN-7 (1)]...
  • Page 169 HEAD AND WORK LIGHT CIRCUIT FUSE BOX CR-13 1.2Br CN-376 0.8Br IG 24V 1.2ROr 0.8YOr WIPER/OUT R_RH 0.8RW WORK LIGHT HEAD LAMP RY CABIN LIGHT CL-4 1.2B 1.2ROr HEAD LAMP CAN_HI(2) CL-24 WASHER/OUT F_LH 1.2B INT WIPER/OUT R_LH 1.2ROr 0.8RW HEAD LIGHT HEAD LAMP REAR CL-3...
  • Page 170 5. BEACON LAMP AND CAB LIGHT CIRCUIT OPERATING FLOW Fuse box (No.28) Beacon lamp relay [CR-45 (2, 3)] Fuse box (No.17) Cab light relay [CR-9 (30, 86)] Beacon lamp switch ON Beacon lamp switch ON [CN-376 (15)] Beacon lamp relay [CR-45 (1) (5)] I/conn [CN-5 (50)] I/conn [CN-10 (10)]...
  • Page 171 BEACON LAMP AND CAB LIGHT CIRCUIT FUSE BOX CN-376 IG 24V WIPER/OUT R_RH CR-45 0.8BOr WORK LIGHT 0.8RW 0.8ROr CABIN LIGHT 0.8L 0.8GrW BEACON LAMP RELAY CAN_HI(2) WASHER/OUT F_LH CR-9 INT WIPER/OUT R_LH HEAD LIGHT 0.8R 87 85 0.8RW BEACON LAMP 0.8Gr CAB LAMP RELAY CAN_LO(2)
  • Page 172 6. WIPER AND WASHER CIRCUIT OPERATING FLOW Key switch ON Fuse box (No.12) Relay drive unit [CN-376 (1)] Fuse box (No.7) I/conn [CN-5 (18)] I/conn [CN-17 (5)] Wiper motor controller [CN-141(7)] Wiper motor [CN-21(4)] Fuse box (No.18) I/conn [CN-5 (16)] l/conn [CN-17 (4)] Wiper motor controller [CN-141 (6)] Low wiper motor [CN-407 (3)]...
  • Page 173 WIPER AND WASHER CIRCUIT FUSE BOX CN-407 1.2BOr CN-376 1.2GrW 0.8RW IG 24V 1.2B 1.2Br 0.8RW WIPER/OUT R_RH LOW WIPER MOTOR WORK LIGHT CABIN LIGHT CN-408 0.8GrW LOW WASHER PUMP DO-23 CAN_HI(2) 0.8GrW 0.8RW WASHER/OUT F_LH 0.8RW INT WIPER/OUT R_LH DIODE HEAD LIGHT CN-22...
  • Page 174 CONTROLLER CIRCUIT FUSE BOX SUPPLY MODULE NOx SENSOR PURGING LAMP CD-16 RETURN CN-93 0.8A SUPPLY POWER BATTERY(+) 0.8A CN-5 WATER LEVEL SENSOR BATTERY(+) 0.8A BATTERY(+) CD-10 0.8A BATTERY(+) 0.8A RETURN BATTERY(+) 0.8L 0.8RW AIR TEMP BATTERY(-) 0.8L 0.8RW SUPPLY POWER BATTERY(-) AIR PRESS BATTERY(-)
  • Page 175 MONITORING CIRCUIT FUSE BOX CN-249 0.85Y CN-93 LVDS POS 0.8A 0.85B BATTERY(+) 0.8A 0.85BrW BATTERY(+) LVDS NEG 0.8A 0.85R BATTERY(+) 0.8A POWER 6.5V BATTERY(+) 0.8A BATTERY(+) ADJUST SIGNAL BATTERY(-) BATTERY(-) REAR VIEW CAMERA BATTERY(-) CN-56B BATTERY(-) 0.8B BATTERY(-) CAM 6.5V 0.8A 0.8L CAN Hi...
  • Page 176 ELECTRIC CIRCUIT FOR HYDRAULIC (1/2) FUSE BOX AIR-COMP SW AUTO GREASE SW QUICK COUPLING SW QUICK COUPLER SOL CN-5 CS-111 CN-6 CN-263 AIR COMP RY BOOM FLOATING SW CN-4 CN-81 Power CS-29 Decel TRAVEL BZ CS-19 CN-133 CS-4 BOOM PRIORITY CN-135 SAFETY SW ARM REGEN...
  • Page 177 ELECTRIC CIRCUIT FOR HYDRAULIC (2/2) SWING LOCK & FINE SWING SW FUSE BOX CS-26A CN-7 BREAKER CS-111 CN-3 CN-6 BOOM FLOATING SW BREAK CS-26 HORN CS-5 CN-246 RETURN PROPORTIONAL CN-247 CN-4 RETURN P/P VALVE EPPR VLV-A2 EPPR VLV-A1 CONNECTOR 2(C2 BLACK) CONNECTOR 1(C1 GREY) power (PVG 32)

  • Page 178: Group 3 Electrical Component Specification

    GROUP 3 ELECTRICAL COMPONENT SPECIFICATION Part name Symbol Specifications Check Check specific gravity 1.280 over : Over charged 160Ah Battery (2EA) 1.280 ~ 1.250 : Normal 1.250 below : Recharging Check coil resistance(M4 to M4) Rated load Normal : About 50 Battery relay 100A (continuity) Check contact...
  • Page 179 Part name Symbol Specifications Check Check resistance Glow plug 24V 200A 0.25~0.12 CN-80 Check resistance Temperature 50˚C : 804 sensor 80˚C : 310 (hydraulic) 100˚C : 180 CD-8 CD-1 Check contact Air cleaner High level : N.O TYPE pressure switch Low level : 0 CD-10 Check resistance...
  • Page 180 Part name Symbol Specifications Check Check resistance 87 85 Normal : About 160 Relay 24V 16A (for terminal 85-86) 0 (for terminal 30-87a) CR-4 CR-7 CR-9 CR-4 CR-7 CR-9 CR-13 (for terminal 30-87) CR-13 CR-35 CR-46 CR-35 CR-46 CR-50 CR-52 Check resistance Solenoid valve 24V 1A...
  • Page 181 Part name Symbol Specifications Check Check disconnection Normal : 1.0 ON : 0 (For terminal 1-2) Room lamp 24V 10W (For terminal 1-3) OFF : (For terminal 1-2) CL-1 0 (For terminal 1-3) Head lamp, 24V 65W Check disconnection Work lamp, (H3 Type) Normal : 1.2 Cab lamp...
  • Page 182 Part name Symbol Specifications Check Check contact Normal : 1.0 ON : 0 (for terminal A-B) 24V 15A Safety switch (N.C TYPE) (for terminal A-C) OFF : (for terminal A-B) CS-20 0 (for terminal A-C) Wiper cut Check contact switch (N.O TYPE) Normal : 0 (one pin to ground) CS-53...
  • Page 183 Part name Symbol Specifications Check Check voltage DC/DC 12V 3A 24V (for terminal 1-2) Converter 12V (for terminal 1-3) CN-138 Low wiper motor CN-407 Check coil resistance Normal : About 1M Cigar lighter 24V 5A 1.4W Check contact Normal : Operating time : 5~15sec CL - CL-2...
  • Page 184 Part name Symbol Specifications Check Check contact Air conditioner 24V 79W compressor Normal : 13.4 CN-28 Check contact Start relay 24V 300A Normal : 0.94 (for terminal 1-2) CR-23 Check resistance Blower motor 24V 9.5A Normal : 2.5 (for terminal 1-2) Check resistance 1˚C OFF Normal : 0 (for terminal 1-2),...
  • Page 185 Part name Symbol Specifications Check Check disconnection Normal : 0 CN-60 : 30A Circuit breaker CN-95 : 90A (connect ring terminal and check CS-60 CS-95 CN-60 CN-95 resist between terminal 1 and 2) Check disconnection Master switch 6-36V Normal : 0.1 CS-74A, CS-74B Check resistance Breaker switch...
  • Page 186 Part name Symbol Specifications Check Check contact Normal Switch 24V 8A OFF : (for terminal 1-2, 1-3, 4-5, 5-6) CS-100 Check contact Normal Switch 24V 8A OFF : (for terminal 1-2, 1-3, 4-5, 5-6) CS-73 Fuel heater CN-96 DEF/AdBlue® line heater CN-381 CN-382 CN-383 WIF sensor CD-45...
  • Page 187 Part name Symbol Specifications Check POWER 24V CAN LO CAN HI DEF/AdBlue® RETURN sensor CN-399 CN-J6 CN-J7A CN-J7B CN-J10 CN-J17 RETURN AIR TEMP PRS temp SUPPLY POWER sensor AIR PRESS CD-11 CD-10 SIGNAL Water level RETURN(29) SUPPLY POWER 5V(72) sensor CD-16 Temperature sensor...
  • Page 188 Part name Symbol Specifications Check DEF/AdBlue® fill up warning lamp (LED) CL-41 RETURN Proportional Proportional valve sensor CN-246 CN-247 CAN_H CAN_L Start button CS-2B LVDS POS LVDS NEG POWER 24V Camera ADJUST SIGNAL CN-402 CN-403 CN-249 CN-402 CN-403 CN-404 CN-405 CN-404 CN-405 4-33...

  • Page 189: Group 4 Connectors

    GROUP 4 CONNECTORS 1. CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 I/conn (Frame harness-Pump PS harness) S816-010002 S816-110002 CN-2 I/conn (Frame harness-Engine harness) 121583-0135 368301-1 CN-3 TYCO I/conn (Frame harness-Pro vlv harness) 174661-2 368537-1 CN-4 I/conn (Console harness LH-Frame harness)
  • Page 190 Connector part No. Connector No. of Type Destination number Female Male CN-66 DEUTSCH Breaker solenoid DT06-2S-EP06 CN-68 DEUTSCH Safety solenoid DT06-2S-EP06 CN-70 DEUTSCH Travel high solenoid DT06-2S-EP06 CN-74 RING-TERM Alternator "L" terminal S820-105000 CN-74 RING-TERM Alternator "B" terminal S820-108000 CN-75 Pump EPPR valve S816-002002 CN-80...
  • Page 191 Connector part No. Connector No. of Type Destination number Female Male CN-262B DEUTSCH Straight travel solenoid 2 DT06-2S-EP06 CN-263 DEUTSCH Air compressor relay DT06-2S-EP06 DT04-2P-E005 CN-305 DEUTSCH Proportional-Connector-1 DTM06-12SA CN-306 DEUTSCH Proportional-Connector-2 DTM06-12SB CN-307 DEUTSCH Proportional-Service tool DT06-3S-EP06 DT04-3P-E005 CN-308 Proportional-PVG32 2-967059-1 CN-309...
  • Page 192 Connector part No. Connector No. of Type Destination number Female Male CN-J17 TYCO DOC Thermistor 2-1418390-1 CN-J31 BOSCH DEF/AdBlue® dosing module 1_928_403_874 Relay CR-1 RING-TERM Battery relay ST710289-2 CR-2 Horn relay CR-4 Working lamp relay CR-5 Anti restart relay CR-7 Aircon compressor relay CR-9 Cabin lamp relay...
  • Page 193 Connector part No. Connector No. of Type Destination number Female Male CS-99 CARLING Air compressor switch VC2-01 CS-100 CARLING SCR system cleaning switch VC2-01 CS-107 CARLING Travel straight switch VC2-01 CS-108 CARLING Auto grease switch VC2-01 CS-111 CARLING Boom floating switch VC2-01 Light CL-1...
  • Page 194 Connector part No. Connector No. of Type Destination number Female Male CD-69 DEUTSCH Attach pressure sensor DT06-3S-EP06 CD-70 DEUTSCH N1 pressure sensor DT06-3S-EP06 CD-71 DEUTSCH N2 pressure sensor DT06-3S-EP06 CD-85 DEUTSCH Boom down sensor DT06-3S-EP06 CD-87 DEUTSCH Bucket out sensor DT06-3S-EP06 CD-90 DEUTSCH...
  • Page 195 2. CONNECTION TABLE FOR CONNECTORS PA TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S811-005002 S811-105002 S811-007002 S811-107002 S811-009002 3S811-109002 S811-011002 S811-111002 4 - 40...
  • Page 196 No. of Receptacle connector (female) Plug connector (male) S811-013002 S811-113002 S811-017002 S811-117002 S811-021002 S811-121002 4 - 41...
  • Page 197 J TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S816-002001 S816-102001 S816-003001 S816-103001 S816-004001 S816-104001 S816-008001 S816-108001 4 - 42...
  • Page 198 SWP TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S814-001000 S814-101000 S814-002000 S814-102000 S814-003000 S814-103000 S814-004000 S814-104000 4 - 43...
  • Page 199 No. of Receptacle connector (female) Plug connector (male) S814-006000 S814-106000 S814-008000 S814-108000 S814-012000 S814-112000 S814-014000 S814-114000 4 - 44...
  • Page 200 CN TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S810-001202 S810-101202 S810-002202 S810-102202 S810-003202 S810-103202 S810-004202 S810-104202 4 - 45...
  • Page 201 No. of Receptacle connector (female) Plug connector (male) S810-006202 S810-106202 S810-008202 S810-108202 4 - 46...
  • Page 202 375 FASTEN TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S810-002402 S810-102402 AMP ECONOSEAL CONNECTOR No. of Receptacle connector (female) Plug connector (male) 344111-1 344108-1 AMP TIMER CONNECTOR No. of Receptacle connector (female) Plug connector (male) 85202-1 4 - 47...
  • Page 203 AMP 040 MULTILOCK CONNECTOR No. of Receptacle connector (female) Plug connector (male) 174045-2 AMP 070 MULTILOCK CONNECTOR No. of Receptacle connector (female) Plug connector (male) 173852 AMP FASTIN - FASTON CONNECTOR No. of Receptacle connector (female) Plug connector (male) 480003-9 925276-0 4 - 48...
  • Page 204 KET 090 CONNECTOR No. of Receptacle connector (female) Plug connector (male) MG610070 KET 090 WP CONNECTORS No. of Receptacle connector (female) Plug connector (male) MG640605 MG640795 4 - 49...
  • Page 205 KET SDL CONNECTOR No. of Receptacle connector (female) Plug connector (male) MG610406 4 - 50...
  • Page 206 DEUTSCH DT CONNECTORS DT 06 - 3S - Modifications (see below) Number of contacts (P : Pin, S : Socket) 04 : Receptacle, 06 : Plug Deutsch connectors Modification E003 : Standard end cap - gray E004 : Color of connector to be black E005 : Combination - E004 &...
  • Page 207 No. of Receptacle connector (female) Plug connector (male) DT06-6S DT04-6P DT06-8S DT04-8P DT06-12S DT04-12P 4 - 52...
  • Page 208 MOLEX 2CKTS CONNECTOR No. of Receptacle connector (female) Plug connector (male) 35215-0200 35215-0200 ITT SWF CONNECTOR No. of Receptacle connector (female) Plug connector (male) SWF593757 MWP NMWP CONNECTOR No. of Receptacle connector (female) Plug connector (male) NMWP01F-B 4 - 53...
  • Page 209 ECONOSEAL J TYPE CONNECTORS No. of Receptacle connector (female) Plug connector (male) S816-001002 S816-101002 S816-002002 S816-102002 S816-003002 S816-103002 S816-004002 S816-104002 4 - 54...
  • Page 210 No. of Receptacle connector (female) Plug connector (male) S816-006002 S816-106002 S816-008002 S816-108002 S816-010002 S816-110002 S816-012002 S816-112002 4 - 55...
  • Page 211 No. of Receptacle connector (female) Plug connector (male) 368301-1 2-85262-1 METRI-PACK TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) 12040753 DEUTSCH HD30 CONNECTOR No. of Receptacle connector (female) Plug connector (male) HD36-24-23SN HD34-24-23PN 4 - 56...
  • Page 212 DEUTSCH MCU CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) DRC26-40SA/B DEUTSCH SERVICE TOOL CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) HD10-9-96P AMP FUEL WARMER CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) 2-967325-3 4 - 57...
  • Page 213 DEUTSCH ENGINE ECM CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) DRC26-50S-04 DEUTSCH INTERMEDIATE CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) DRB16-60SAE-L018 4 - 58...

  • Page 214: Section 5 Mechatronics System

    SECTION 5 MECHATRONICS SYSTEM Group 1 Outline ---------------------------------------------------------------------------------------------------------------- 5-1 Group 2 Mode Selection System ------------------------------------------------------------------------------------ 5-3 Group 3 Automatic Deceleration System ----------------------------------------------------------------------- 5-6 Group 4 Power Boost System ----------------------------------------------------------------------------------------- 5-7 Group 5 Travel Speed Control System --------------------------------------------------------------------------- 5-8 Group 6 Automatic Warming Up System ----------------------------------------------------------------------- 5-9 Group 7 Engine Overheat Prevention System -------------------------------------------------------------- 5-10 Group 8 Variable Power Control System ------------------------------------------------------------------------ 5-11 Group 9 Attachment Flow Control System -------------------------------------------------------------------- 5-12...

  • Page 215: Group 1 Outline

    SECTION 5 MECHATRONICS SYSTEM GROUP 1 OUTLINE The ADVANCED CAPO (Computer Aided Power Optimization) system controls engine and pump mutual power at an optimum and less fuel consuming state for the selected work by mode selection, auto-deceleration, power boost function, etc. It monitors machine conditions, for instance, engine speed, coolant temperature, hydraulic oil temperature, and hydraulic oil pressure, etc.
  • Page 216 SYSTEM DIAGRAM Attachment pilot Work Travel Work tool pressure pressure pressure Arm 1 Arm 2 SOLENOID VALVE EPPR VALVE Option Bucket Attachment Travel speed Boom 2 Boom 1 pressure(opt) Attachment Boom priority Travel(LH) Power boost Swing conflux(opt) EPPR Travel(RH) Attachment Attachment Arm regen safety(opt)

  • Page 217: Group 2 Mode Selection System

    GROUP 2 MODE SELECTION SYSTEM 1. POWER MODE SELECTION SYSTEM Main control valve Engine Pilot pump Main pump Pump power shift EPPR Cluster Drive signal Haptic controller Power mode pilot lamp Emergency CN-16B Power mode switch signal CN-16A CN-16 CAN #2 Normal 300L5MS02 Mode selection system (micro computer based electro-hydraulic pump and engine mutual control...
  • Page 218 2. WORK MODE SELECTION SYSTEM Work mode consists of the general operation (bucket) and the optional attachment (breaker, crusher). Attachment pilot pressure sensor Main control valve Work tool Arm 1 Arm 2 SOLENOID VALVE Option Bucket Breaker Boom 1 Boom 2 Attachment Travel(LH) Swing...
  • Page 219 3. USER MODE SELECTION SYSTEM Main control valve Engine Pilot pump Main pump Pump power shift EPPR Cluster Drive signal Haptic controller User mode pilot lamp Emergency CN-16B User mode switch signal CN-16A CN-16 CAN #2 Normal 300L5MS04 High idle rpm, auto idle rpm and EPPR pressure can be adjusted and memorized in the U-mode. LCD segment vs parameter setting Step Engine speed...

  • Page 220: Group 3 Automatic Deceleration System

    GROUP 3 AUTOMATIC DECELERATION SYSTEM Work Travel pressure pressure Main control valve Engine Pilot pump Main pump Cluster Pressure signal Haptic controller Auto idle pilot lamp Emergency CN-16B CN-16A Auto idle switch signal CN-16 CAN #2 Normal 300L5MS05 1. WHEN AUTO IDLE PILOT LAMP ON When all of the work equipment control levers including swing and travel levers are at neutral for 4 seconds, MCU sends throttle command to ECM to reduce the engine speed to 1000 rpm.

  • Page 221: Group 4 Power Boost System

    GROUP 4 POWER BOOST SYSTEM Main control valve Arm 1 Arm 2 Option Bucket Boom 1 Boom 2 Travel(LH) Swing Travel(RH) Main relief valve pressure switch pressure switch Power boost solenoid valve Engine Pilot pump Main pump Pump power Power boost button shift EPPR LH control...

  • Page 222: Group 5 Travel Speed Control System

    GROUP 5 TRAVEL SPEED CONTROL SYSTEM Main control valve Travel motor Arm 1 Arm 2 Option Bucket Regulator Boom 1 Boom 2 Travel(LH) Swing Travel(RH) Travel speed solenoid valve Engine Pilot pump Main pump Cluster Drive signal Travel speed pilot lamp Travel speed switch signal CAN #2 330L5MS07...

  • Page 223: Group 6 Automatic Warming Up System

    GROUP 6 AUTOMATIC WARMING UP SYSTEM Main control valve Engine Main pump Pilot pump Pump power shift EPPR Cluster Hydraulic temp sensor Drive signal Haptic controller Emergency CN-16B Warming up pilot lamp signal CN-16A CN-16 Warming up CAN #2 Normal pilot lamp 300L5MS08 The MCU receives the engine coolant temperature from the ECM, and if the coolant temperature is...

  • Page 224: Group 7 Engine Overheat Prevention System

    GROUP 7 ENGINE OVERHEAT PREVENTION SYSTEM Main control valve Engine Main pump Pilot pump Pump power shift EPPR Emergency warning lamp Cluster Hydraulic temp signal Hydraulic temp sensor Drive signal Haptic controller Emergency CN-16B Overheat warning signal CN-16A CN-16 CAN #2 Normal Hydraulic temperature warning lamp...

  • Page 225: Group 8 Variable Power Control System

    GROUP 8 VARIABLE POWER CONTROL SYSTEM Travel pressure Main control valve Engine Main pump Pilot pump Pump power shift EPPR Signal Switch signal Pressure signal Pressure signal RH control LH control lever lever CN-16A CN-16 CAN #2 Normal CN-16B Emergency Haptic controller Cluster Power mode switch signal...

  • Page 226: Group 9 Attachment Flow Control System

    GROUP 9 ATTACHMENT FLOW CONTROL SYSTEM Attachment pilot pressure sensor Main control valve Work tool Arm 1 Arm 2 SOLENOID VALVE Option Bucket Breaker Boom 1 Boom 2 Attachment Travel(LH) Swing conflux Attachment Travel(RH) safety Engine Pilot pump Main pump Attachment Cluster flow EPPR...

  • Page 227: Group 10 Boom Floating Control System

    GROUP 10 BOOM FLOATING CONTROL SYSTEM Boom cylinder Rod pressure Head pressure Head to tank Rod to tank solenoid solenoid Boom down pilot Boom 1 spool cutoff solenoid Main control valve RH control LH control lever lever Breaker Pilot pump Main pump button Signal...

  • Page 228: Group 11 Intelligent Power Control System

    GROUP 11 INTELLIGENT POWER CONTROL SYSTEM Travel pressure Main control valve Arm 1 Arm 2 Option Bucket Boom 1 Boom 2 Swing Travel(LH) Travel(RH) Attach flow EPPR 1 Engine Pilot pump Main pump Power boost Pump power button shift EPPR One touch Horn button decel button...
  • Page 229 IPC MODE SELECTION IPC mode ON/OFF and the levels of flow rate limit can be selected at "Mode setup > IPC mode" Q(cc/rev) Balance mode IPC mode 1 Effi ciency mode IPC mode 2 Pi(bar) 290F3CD311 IPC mode Description Balance mode (default) IPC mode ON, limit level 1 Efficiency mode IPC mode ON, limit level 2...

  • Page 230: Group 12 Anti-Restart System

    GROUP 12 ANTI-RESTART SYSTEM Engine Starter Start safety relay Drive signal 300L5MS12 1. ANTI-RESTART FUNCTION After a few seconds from the engine starts to run, MCU turns off the start safety relay to protect the starter from inadvertent restarting. 5-16...

  • Page 231: Group 13 Self-Diagnostic System

    GROUP 13 SELF-DIAGNOSTIC SYSTEM OUTLINE When any abnormality occurs in the ADVANCED CAPO system caused by electric parts malfunction and by open or short circuit, the MCU diagnoses the problem and sends the error codes to the cluster and also stores them in the memory. MONITORING Active fault 290F3CD120...
  • Page 232 3. MACHINE ERROR CODES TABLE Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Hydraulic Oil Temp. Measurement Voltage > 3.8V 10 seconds continuous, Hydraulic Oil Temp. Measurement Voltage < 0.3V (Results / Symptoms) 1. Monitor – Hydraulic oil temperature display failure 2.
  • Page 233 Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Main Pump 1 (P1) Press. Sensor Measurement Voltage > 5.2V 10 seconds continuous, 0.3V ≤ Main Pump 1 (P1) Press. Sensor Measurement Voltage < 0.8V 10 seconds continuous, Main Pump 1 (P1) Press. Sensor Measurement Voltage <...
  • Page 234 Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Negative 1 Press. Sensor Measurement Voltage > 5.2V 10 seconds continuous, 0.3V≤ Negative 1 Press. Sensor Measurement Voltage < 0.8V 10 seconds continuous, Negative 1 Press. Sensor Measurement Voltage < 0.3V (Results / Symptoms) 1.
  • Page 235 Application Diagnostic Criteria HCESPN FMI (when you had conditions mounting pressure sensor) 10 seconds continuous, Boom Down Pilot Press. Sensor Measurement Voltage > 5.2V (when you had conditions mounting pressure sensor) 10 seconds continuous, 0.3V≤ Boom Down Pilot Press. Sensor Measurement Voltage <...
  • Page 236 Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Swing Pilot Press. Sensor Measurement Voltage > 5.2V 10 seconds continuous, 0.3V≤ Swing Pilot Press. Sensor Measurement Voltage < 0.8V 10 seconds continuous, Swing Pilot Press. Sensor Measurement Voltage < 0.3V (Results / Symptoms) 1.
  • Page 237 Application Diagnostic Criteria HCESPN FMI (Detection) (When Pump EPPR Current is more than 10 mA) 10 seconds continuous, Pump EPPR drive current < 0 mA (Cancellation) (When Pump EPPR Current is more than 10 mA) 3 seconds continuous, Pump EPPR drive current ≥10 mA (Detection) 10 seconds continuous, Pump EPPR drive current >...
  • Page 238 Application Diagnostic Criteria HCESPN FMI (Detection) (When Travel EPPR Current is more than 10 mA) 10 seconds continuous, Travel EPPR drive current = 0 mA (Cancellation) (When Travel EPPR Current is more than 100 mA) 3 seconds continuous, Travel EPPR drive current ≥ 10 mA (Detection) 10 seconds continuous, Travel EPPR drive current >...
  • Page 239 Application Diagnostic Criteria HCESPN FMI (Detection) (When Working Cutoff Relay is Off) 10 seconds continuous, Working Cutoff Relay drive unit Measurement Voltage ≤ 3.0V (Cancellation) (When Working Cutoff Relay is Off) 3 seconds continuous, Working Cutoff Relay drive unit Measurement Voltage >...
  • Page 240 Application Diagnostic Criteria HCESPN FMI (Detection) (When Travel Speed Solenoid is Off) 10 seconds continuous, Travel Speed Solenoid drive unit Measurement Voltage ≤ 3.0V (Cancellation) (When Travel Speed Solenoid is Off) 3 seconds continuous, Travel Speed Solenoid drive unit Measurement Voltage >...
  • Page 241 Application Diagnostic Criteria HCESPN FMI Monitor – Selecting attachment(breaker / crusher) (Detection) (When Attachment Conflux Solenoid is Off) 10 seconds continuous, Attachment Conflux Solenoid drive unit Measurement Voltage ≤ 3.0V (Cancellation) (When Attachment Conflux Solenoid is Off) 3 seconds continuous, Attachment Conflux Solenoid drive unit Measurement Voltage >...
  • Page 242 Application Diagnostic Criteria HCESPN FMI Monitor – Selecting attachment(crusher) (Detection) (When Attachment Safety Solenoid is Off) 10 seconds continuous, Attachment Safety Solenoid drive unit Measurement Voltage ≤ 3.0V (Cancellation) (When Attachment Safety Solenoid is Off) 3 seconds continuous, Attachment Safety Solenoid drive unit Measurement Voltage >...
  • Page 243 Application Diagnostic Criteria HCESPN FMI (Model Parameter) mounting Reverse Cooling Fan Solenoid (Detection) (When Reverse Cooling Fan Solenoid is Off) 10 seconds continuous, Reverse Cooling Fan Solenoid drive unit Measurement Voltage ≤ 3.0V (Cancellation) (When Reverse Cooling Fan Solenoid is Off) 3 seconds continuous, Reverse Cooling Fan Solenoid drive unit Measurement Voltage >...
  • Page 244 Application Diagnostic Criteria HCESPN FMI (Detection) (When Attachment Flow EPPR 2 current is equal or more than 300 mA) 10 seconds continuous, Attachment Flow EPPR drive current < 100 mA (Cancellation) (When Attachment Flow EPPR 2 current is equal or more than 300 mA) 3 seconds continuous, Attachment Flow EPPR drive current ≥...
  • Page 245 Application Diagnostic Criteria HCESPN FMI (Mounting pressure sensor) 10 seconds continuous, Boom Cylinder Rod Press. Sensor Measurement Voltage > 5.2V (Mounting pressure sensor) 10 seconds continuous, 0.3V≤ Boom Cylinder Rod Press. Sensor Measurement Voltage < 0.8V (Mounting pressure sensor) 10 seconds continuous, Boom Cylinder Rod Press. Sensor Measurement Voltage <...
  • Page 246 Application Diagnostic Criteria HCESPN FMI Mounting pressure sensor (HCESPN 128 or 205) (Detection) (When Boom Down Pilot Pressure Cutoff Solenoid is Off) 10 seconds continuous, Boom Down Pilot Pressure Cutoff Solenoid drive unit Measurement Voltage ≤ 3.0V (Cancellation) (When Boom Down Pilot Pressure Cutoff Solenoid is Off) 3 seconds continuous, Boom Down Pilot Pressure Cutoff Solenoid drive unit Measurement Voltage >...
  • Page 247 Application Diagnostic Criteria HCESPN FMI Monitor – Selecting attachment(crusher) (Detection) (When ATT Relief Setting EPPR 2 Current is equal or more than 10 mA) 10 seconds continuous, ATT Relief Setting EPPR 2 drive current = 0 mA (Cancellation) (When ATT Relief Setting EPPR 2 Current is equal or more than 10 mA) 3 seconds continuous, ATT Relief Setting EPPR 2 drive current ≥...
  • Page 248 Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Transmission Oil Press. Sensor Measurement Voltage > 5.2V 10 seconds continuous, 0.3V≤ Transmission Oil Press. Sensor Measurement Voltage < 0.8V 10 seconds continuous, Transmission Oil Press. Sensor Measurement Voltage < 0.3V (Results / Symptoms) 1.
  • Page 249 Application Diagnostic Criteria HCESPN FMI (Detection) (When Parking Relay is Off) 10 seconds continuous, Parking Relay drive unit Measurement Voltage ≤ 3.0V (Cancellation) (When Parking Relay is Off) 3 seconds continuous, Parking Relay drive unit Measurement Voltage > 3.0V (Detection) (When Parking Relay is On) 10 seconds continuous, Parking Relay drive current >...
  • Page 250 Application Diagnostic Criteria HCESPN FMI (Detection) (When Ram Lock Solenoid is Off) 10 seconds continuous, Ram Lock Solenoid drive unit Measurement Voltage ≤ 3.0V (Cancellation) (When Ram Lock Solenoid is Off) 3 seconds continuous, Ram Lock Solenoid drive unit Measurement Voltage > 3.0V (Detection) (When Ram Lock Solenoid is On) 10 seconds continuous, Ram Lock Solenoid drive current >...
  • Page 251 Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Travel Forward Press. Sensor Measurement Voltage > 5.2V 10 seconds continuous, 0.3V≤ Travel Forward Press. Sensor Measurement Voltage < 0.8V 10 seconds continuous, Travel Forward Press. Sensor Measurement Voltage < 0.3V (Results / Symptoms) 1.
  • Page 252 Application Diagnostic Criteria HCESPN FMI (Model Parameter) Mounting Acc. Dial 10 seconds continuous, Acc. Dial Measurement Voltage > 5.2V (Model Parameter) Mounting Acc. Dial 10 seconds continuous, Acc. Dial Measurement Voltage < 0.3V (Results / Symptoms) 1. Monitor – Acc. Dial Voltage display failure 2.
  • Page 253 Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, ECM Communication Data Error (Results / Symptoms) 1. Control Function – ECM operation failure (Checking list) 1. CN-93 (#22) – CN-51 (#21) Checking Open/Short 2. CN-93 (#46) – CN-51 (#31) Checking Open/Short (When mounting the I/O Controller 1) 60 seconds continuous, I/O Controller 1 Communication Data Error (Results / Symptoms)
  • Page 254 Application Diagnostic Criteria HCESPN FMI (When mounting the AAVM) 60 seconds continuous, AAVM communication Data Error (Results / Symptoms) 1. Control Function – AAVM operation failure (Checking list) 1. CN-401 (#86) – CN-51 (#22) Checking Open/Short 2. CN-401 (#87) – CN-51 (#32) Checking Open/Short 60 seconds continuous, RDU communication Data Error (Results / Symptoms) 1.
  • Page 255 4. ENGINE FAULT CODE Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Engine control module critical internal failure - Engine may not start or may be difficult to start. Bad intelligent device or component. Error internal to the ECM related to memory hardware failures or internal ECM voltage supply circuits.
  • Page 256 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Engine oil rifle pressure - Data valid but below Possible reduced engine performance. normal operational range - Moderately severe level. Engine oil pressure signal indicates engine oil pressure is below the engine protection warning limit.
  • Page 257 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Sensor supply 2 circuit - Voltage below normal, Engine power derate. 3510 or shorted to low source. Low voltage detected at the sensor supply number 2 circuit. Coolant level sensor 1 circuit - Voltage above None on performance.
  • Page 258 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Ambient air temperature sensor 1 circuit - Possible reduced engine performance. Voltage below normal or shorted to low source. L ow vo l t a g e d e t e c t e d a t a m b i e n t a i r temperature circuit.
  • Page 259 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Injector solenoid driver cylinder 4 circuit - The current to the injector is shut OFF. Current below normal, or open circuit. Engine power derate. Current detected at injector 4 when voltage is turned OFF.
  • Page 260 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI J1939 data link - Abnormal update rate. Engine will only idle. Communication between the engine control module (ECM) and another device on the SAE J1939 data link has been lost. Water in fuel indicator sensor circuit - Voltage None on performance.
  • Page 261 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Sensor supply 6 circuit - Voltage below normal Possible reduced engine performance. or shorted to low source. 3514 Low voltage detected on the +5 volt sensor supply circuit to the fuel rail pressure sensor.
  • Page 262 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Turbocharger 1 compressor inlet temperature Possible reduced engine performance. sensor circuit - Voltage above normal, or 1172 shorted to high source. High signal voltage detected at turbocharger compressor inlet air temperature circuit.
  • Page 263 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Injector solenoid driver cylinder 4 - Mechanical Possible reduced engine performance. 1143 system not responding or out of adjustment. The ECM has detected an error with the injection timing or quantity.
  • Page 264 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI 1659 Engine misfire cylinder 6 - Condition exists. Possible reduced engine performance. 1328 Engine misfire has been detected in cylinder number 6. Aftertreatment diesel exhaust fluid tank level Possible reduced engine performance.
  • Page 265 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI After treatment diesel oxidation catalyst Possible frequent need for aftertreatment 1691 conversion efficiency - Data valid but below regeneration. 5298 normal operating range - Moderately severe level.
  • Page 266 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Aftertreatment diesel particulate filter differential possible reduced engine performance. pressure sensor circuit - Voltage above normal 1879 or shorted to high source. 3251 H i g h s i g n a l vo l t a g e d e t e c t e d a t t h e aftertreatment differential pressure sensor circuit.
  • Page 267 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI EGR valve control circuit calculated over Possible reduced engine performance. 1961 temperature - Data valid but above normal 2791 operational range - Least severe level. High EGR valve driver temperature has been detected.
  • Page 268 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI EGR Valve position circuit - Voltage below Possible reduced engine performance. 2272 normal or shorted to low source. Low signal voltage has been detected at the EGR valve position sensor circuit Exhaust gas recirculation valve delta pressure Possible reduced engine performance.
  • Page 269 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Exhaust gas pressure sensor circuit - Voltage Possible reduced engine performance. 2373 above normal or shorted to high source. High 1209 signal voltage detected at the exhaust gas pressure circuit.
  • Page 270 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI VGT Actuator driver circuit - abnormal update Possible reduced engine performance. 2636 rate. No communications on the J1939 data link between the engine ECM and the smart VGT controller.
  • Page 271 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI 2973 Intake manifold 1 pressure - Data erratic, Possible reduced engine performance. intermittent, or incorrect. The intake manifold pressure sensor is reading an erratic value. Aftertreatment diesel exhaust fluid dosing unit Possible reduced engine performance.
  • Page 272 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Tachograph output shaft speed - Abnormal None on performance. 3186 update rate. No communication or an invalid 1623 data transfer rate has been detected on the J1939 data link between the ECM and the tachograph output shaft speed sensor.
  • Page 273 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Aftertreatment diesel oxidation catalyst intake Progressive power and/or speed derate temperature - Data valid but above normal increasing in severity from time of alert. If the 3251 operating range - Moderately severe level.
  • Page 274 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Aftertreatment diesel oxidation catalyst intake Possible reduced engine performance. 3313 temperature sensor circuit - Voltage below 4765 normal or shorted to low source. Low signal voltage detected at the catalyst intake sensor circuit.
  • Page 275 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI SAE J1939 Multiplexed accelerator pedal or Engine will only idle. lever sensor system - Abnormal update rate. 3326 The ECM expected infor mation from a multiplexed accelerator pedal or lever sensor but did not receive it soon enough or did not receive it at all.
  • Page 276 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Engine exhaust gas recirculation (EGR) system Possible reduced engine performance. 3383 - Data valid but above normal operating range - 3058 Moderately severe Level. Measured EGR flow is higher than commanded.
  • Page 277 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Wheel-based vehicle speed - Received Engine speed limited to maximum engine 3525 network data in error. The J1939 multiplexing speed without VSS parameter value. controller has indicated a malfunction of the Cruise control, gear-down protection, and road wheel-based vehicle speed sensor.
  • Page 278 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI 3556 Engine wait to start lamp - Received network None on performance. 1081 data in error. The ECM received an invalid signal on the SAE J1939 datalink. Aftertreatment diesel exhaust fluid dosing unit - Possible reduced engine performance.
  • Page 279 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Aftertreatment diesel exhaust fluid return valve Possible reduced engine performance. 3578 - Voltage below normal, or shorted to low 4376 source. Low signal voltage detected at the diesel exhaust fluid return valve.
  • Page 280 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Aftertreatment outlet NOx sensor - Out of None on performance. 3717 calibration. A calibration mismatch between the 3226 aftertreatment outlet NOx sensor and the ECM has been detected. Aftertreatment intake NOx - Out of calibration.
  • Page 281 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Aftertreatment 1 SCR Intermediate NH3 sensor None on performance. 3899 - Voltage below normal, or shorted to low 5848 source. A circuit error has been detected in the NH3 sensor.
  • Page 282 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Aftertreatment selective catalytic reduction Possible reduced engine performance. 4152 temperature sensor module - Abnormal update 5743 rate. No communications on the J1939 data link between the ECM and the aftertreatment SCR temperature sensor module.
  • Page 283 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Aftertreatment selective catalytic reduction Possible reduced engine performance. temperature sensor module - Voltage above 4164 normal, or shorted to high source. 5743 High battery supply voltage detected at the aftertreatment SCR temperature sensor module.
  • Page 284 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Aftertreatment diesel exhaust fluid dosing None on performance. 4249 temperature - Abnormal rate of change. 4337 The aftertreatment diesel exhaust fluid dosing unit temperature is stuck. Aftertreatment 1 diesel exhaust fluid dosing unit None on performance.
  • Page 285 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI 4517 Vehicle Identification number - Out of None on performance. calibration. The vehicle identification number has not been programmed into the ECM. After treatment SCR Inter mediate gas Possible reduced engine performance.
  • Page 286 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Aftertreatment SCR actual dosing reagent Possible reduced engine performance. 4658 quantity - Data valid but below normal 4331 operating range - Moderately severe level. Low after treatment diesel exhaust fluid flow detected.
  • Page 287 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Engine coolant level 2 sensor circuit - Voltage None on performance. 4866 below normal, or shorted to low source. Low 6303 signal voltage detected at the engine coolant level 2 circuit.
  • Page 288 5. AAVM FAULT CODE 5. AAVM FAULT CODE Fault Code Description AAVM Communication Error -AAVM AAVM Communication Error -Front Camera AAVM Communication Error -Rear Camera AAVM Communication Error -Left Camera AAVM Communication Error -Right Camera Manual Setting Fail No MCU CID MCU CID Format Error AAVM Hardware Error -AAVM AAVM Hardware Error -Front Camera...

  • Page 289: Group 14 Engine Control System

    GROUP 14 ENGINE CONTROL SYSTEM 1. MCU and Engine ECM (Electronic Control Module) ECM(Engine control module) Bolt (M8) 330L5MS13 2. MCU ASSEMBLY To match the pump absorption torque with the engine torque, MCU varies EPPR valve output pressure, which control pump discharge amount whenever feedbacked engine speed drops under the reference rpm of each mode set.

  • Page 290: Group 15 Eppr Valve

    GROUP 15 EPPR VALVE 1. PUMP EPPR VALVE COMPOSITION EPPR (Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve installed at main pump. Electro magnet valve Receive electric current from MCU and move the spool proportionally according to the specific amount of electric current value.
  • Page 291 OPERATING PRINCIPLE (pump EPPR valve) Structure 5-22(1) Sleeve O-ring Solenoid valve Spring O-ring Connector Spool Pilot oil supply line (pilot pressure) Return to tank Secondary pressure to flow regulator at main pump Neutral Pressure line is blocked and A oil returns to tank.
  • Page 292 EPPR VALVE CHECK PROCEDURE Spec : 100~700 mA Check electric current value at EPPR valve Adapter(P/no.:21Q6-50410) Disconnect connector CN-75 from CN-75 EPPR valve. EPPR valve Insert the adapter to CN-75 and install multimeter as figure. Multimeter Start engine. Set S-mode and cancel auto decel mode.
  • Page 293 2. BOOM PRIORITY EPPR VALVE COMPOSITION The boom priority EPPR valve is built in a manifold and mainly consisting of valve body and coil. This EPPR valve installed under the solenoid valve. CONTROL The boom priority EPPR valve has to be controlled by a specific electronic amplifier card, which is supplying the coil with a current 580 mA at 30 and 24 V.
  • Page 294 EPPR VALVE CHECK PROCEDURE Spec : 400~600 mA (combined boom up and swing operation) Check electric current value at EPPR valve Disconnect connector CN-133 from Solenoid valve EPPR valve. Insert the adapter to CN-133 and install Boom priority multimeter as figure. EPPR valve Start engine.

  • Page 295: Group 16 Monitoring System

    GROUP 16 MONITORING SYSTEM 1. OUTLINE Monitoring system consists of the monitor part and switch part. The monitor part gives warnings when any abnormality occurs in the machine and informs the condition of the machine. Various select switches are built into the monitor panel, which act as the control portion of the machine control system.
  • Page 296 Start key : ON Check monitor Buzzer sounding for 4 seconds with HYUNDAI logo on cluster. If the ESL mode is set to the enable, enter the password to start engine. After initialization of cluster, the operating screen is displayed on the LCD.
  • Page 297 3. CLUSTER CONNECTOR CN-56A Name Signal Battery 24V 20~32V Power IG (24V) 20~32V CN-56B CN-56A CAN 1 (H) 0~5V CAN 1 (L) 0~5V CAN 2 (H) 20~32V CAN 2 (L) 20~32V RS-232 (RX) ±15V Cluster RS-232 (TX) ±15V Aux left 0~5V Aux right 0~5V...
  • Page 298 GAUGE Operation screen When you first turn starting switch ON, the operation screen will appear. Default Option 290F3CD51 RPM / Speed gauge DEF/AdBlue® level gauge Engine coolant temperature gauge Tripmeter display Hydraulic oil temperature gauge Eco guage Fuel level gauge Accel dial gauge Operation screen type can be set by the screen type menu of the display.
  • Page 299 Hydraulic oil temperature gauge This gauge indicates the temperature of hydraulic oil. White range : 40-105˚C(104-221˚F) Red range : Above 105˚C(221˚F) If the indicator is in the red range or lamp pops up and the buzzer sounds reduce the load on the system. If the gauge stays in the red range, stop the machine and check the cause of the problem.
  • Page 300 Eco gauge This gauge indicates the fuel consumption rate and machine load status. So that operators can be careful with fuel econo- The fuel consumption rate or machine load is higher, the number of segment is increased. The color of Eco gauge indicates operation status. White : Idle operation 290F3CD58 Green : Economy operation...
  • Page 301 WARNING LAMPS Battery charging warning lamp Air cleaner warning lamp Check engine warning lamp Overload warning lamp Engine oil pressure warning lamp Emergency warning lamp Engine stop warning lamp Water in fuel warning lamp Engine coolant Fuel level warning lamp temperature warning lamp DEF/AdBlue level warning lamp...
  • Page 302 Engine coolant temperature warning lamp Engine coolant temperature warning is indicated two steps. 103˚C over : The lamp pops up and the buzzer sounds. 107˚C over : The lamp pops up and the buzzer sounds. The pop-up lamps move to the original position and blinks when the buzzer stop switch is pushed.
  • Page 303 Engine oil pressure warning lamp This warning lamp pops up and the buzzer sounds when the engine oil pressure is low. If the lamp blinks, shut OFF the engine immediately. Check oil level. 290F3CD65 Check engine warning lamp This warning lamp pops up and the buzzer sounds when the communication between MCU and engine ECM on the engine is abnormal, or if the cluster received specific fault code from engine ECM.
  • Page 304 This lamp pops up and the buzzer sounds when the stationary regeneration system is not performed. Refer to page 5-68. Please contact your Hyundai service center or local dealer. (11) DPF (diesel particulate filter) warning lamp This warning lamp lights ON or blinks when the regeneration is needed as table below.
  • Page 305 Manual regeneration method of DPF Manual regeneration applies if the machine is in a fireproof area and there is no plan to turn off the maching during the regeneration. Stop and park the machine. Select user mode and set the engine speed to minimum speed.
  • Page 306 (14) DEF/AdBlue® level warning lamp This warning lamp indicates when ON or blinking, that the DEF/AdBlue® level is low as table below. It is recommended that the DEF/AdBlue® tank be filled completely full of the DEF/AdBlue® in order to correct any fault conditions.
  • Page 307 PILOT LAMPS Warming up pilot lamp Decel pilot lamp Preheat pilot lamp Power max pilot lamp Fuel warmer pilot lamp Maintenance pilot lamp Power/User mode pilot mode lamp Auto idle pilot lamp Work tool mode pilot lamp Travel speed pilot lamp Smart key pilot lamp Entertainment pilot lamp Entertainment pilot lamp...
  • Page 308 Preheat pilot lamp Turning the start key switch ON position starts preheating in cold weather. Start the engine after this lamp is OFF. 290F3CD79 Warming up pilot lamp This lamp is turned ON when the coolant temperature is below 30˚C (86˚F ). The automatic warming up is cancelled when the engine cool- ant temperature is above 30˚C, or when 10 minutes have passed since starting the engine.
  • Page 309 Entertainment pilot lamp This lamp is on when audio or video files are playing. Refer to the page 5-87. 290F3CD84 Smart key pilot lamp (opt) This lamp is ON when the engine is started by the start button. This lamp is red when the a authentication fails, green when succeeds.
  • Page 310 SWITCHES Aircon quick Entertainment touch switch quick touch switch Main menu quick touch switch Work mode Travel speed pilot lamp pilot lamp Auto idle pilot lamp Power/User mode pilot lamp User mode switch Travel speed switch Auto idle/Buzzer stop switch Power mode switch Escape(previous or parent menu) Work mode switch...
  • Page 311 User mode switch This switch is used to memorize the current machine operating status in the MCU and activate the memorized user mode. Memory : Push more than 2 seconds. Action : Push within 2 seconds. Cancel : Push this switch once more within 2 seconds. Refer to the page 5-79 for another set of user mode.
  • Page 312 Head light switch This switch is used to operate the head light. The pilot lamp is turned ON when operating the switch. 290F3CD94 Intermittent wiper switch This switch is used to wipe operates intermittently. The pilot lamp is turned ON when operating the switch. 290F3CD95 (10) Wiper switch...
  • Page 313 (13) Beacon switch This switch turns ON the rotary light on the cab. The pilot lamp is turned ON when operating the switch. 290F3CD97 (14) Overload switch When this switch turned ON, buzzer makes sound and over- load warning lamp comes ON in case that the machine is overload.
  • Page 314 MAIN MENU You can select or set the menu by the haptic controller or touch screen. On the operation screen, tap MENU to access the main menu screen. On the sub menu screen, you can tap the menu bar to access functions or applications. Operation screen Main menu screen Sub menu screen...
  • Page 315 Mode setup Work tool 210WF3CD108 290F3CD253 290F3CD254 Select on installed optional attachment A : It can set the user's attachment. It is available in setting #1~#10. B : Max fl ow - Set the maximum fl ow for the attachment. Relief pressure - Set the relief pressure.
  • Page 316 Auto power boost 210WF3CD118 290F3CD117 The power boost function can be activated or cancelled. Enable - The digging power is automatically increased as working conditions by the MCU. It is operated max 8 seconds. Disable - Not operated. 290F3CD310 290F3CD311 290F3CD304 290F3CD312 290F3CD305...
  • Page 317 Automatic engine shutdown (option) 210WF3CD11 210WF3CD12 210WF3CD13 The automatic engine shutdown function can be set by this menu. One time Always Disable Wait time setting : Max 40 minutes, min 2 minutes Initial mode 290F3CD122 290F3CD119 Key on initial mode Selected the power mode is activated when the engine is started.
  • Page 318 Monitoring Active fault 290F3CD120 290F3CD121 290F3CD125 The active faults of the MCU, engine ECM, air conditioner or AAVM can be checked by this menu. Logged fault 290F3CD128 290F3CD123 290F3CD124 The logged faults of the MCU, engine ECM, air conditioner or AAVM can be checked by this menu.
  • Page 319 Management Fuel rate information 210WF3CD14 210WF3CD15 General record (A) Average fuel rate (left) (from "Reset" to now) Fuel consumption devided by engine run time (service meter time). A days fuel used (right) Fuel consumption from 24:00 (or "Reset" time) to now (MCU real time).
  • Page 320 Maintenance information 210WF3CD131 290F3CD132 290F3CD133 Alarm lamp ( ) is ON when oil or fi lter needs to be changed or replaced. Replacement : The elapsed time will be reset to zero (0). Change interval : The change or replace interval can be changed in the unit of 50 hours. Change or relpace interval Item Interval...
  • Page 321 Machine security 210WF3CD190 290F3CD135 290F3CD136 ESL mode setting ESL : Engine Starting Limit ESL mode is desingned to be a theft deterrent or will pre- vent the unauthorized operation of the machine. If the ESL mode was selected Enable, the password will be required when the start switch is turned ON.
  • Page 322 Machine Information 290F3CD144 290F3CD145 This can confirm the identification of the model information (ECU), MCU, monitor, haptic controller, switch controller, RMCU, relay driver unit, FATC (air conditioner controller), AAVM (opt). Contact (A/S phone number) 290F3CD146 290F3CD147 290F3CD148 Enter the new A/S phone number Service menu 290F3CD149 290F3CD250...
  • Page 323 Update (cluster & ETC devices) 210WF3CD17 210WF3CD18 210WF3CD19 380F3CD05 380F3CD04 ETC devices and cluster can be updated through CAN 2 network. Insert USB memory stick which includes program fi les, start download. 5-89...
  • Page 324 Display Display item 290F3CD154 290F3CD155 290F3CD156 The center display type of the LCD can be selected by this menu. The engine speed or each of the tripmeter (A,B,C) is displayed on the center display. Clock 290F3CD157 290F3CD158 The fi rst line's three spots " "...
  • Page 325 Unit 290F3CD161 290F3CD193 210WF3CD162 Temperature : ˚C ˚F Pressure : bar kgf/cm Volume Flow : lpm Distance : km mile Date format : yy/mm/dd mm/dd/yy dd-mm-yy Language 290F3CD163 290F3CD164 User can select preferable language and all displays are changed the selected language. Screen type 290F3CD165 290F3CD166...
  • Page 326 Utilities Entertainment 290F3CD195 290F3CD196 210WF3CD219 290F3CD197 210WF3CD220 290F3CD198 210WF3CD199 210WF3CD22 Video (A) : This menu operates the video play function. mp4, mkv, avi fi les and so on. Audio (B) : This menu operates the play music. mp3, mp4 fi les and so on. Smart terminal (C) : The menu features a smartphone and operates the miracast.
  • Page 327 Tripmeter 290F3CD168 290F3CD169 Maximum 3 kinds of tripmeters can be used at the same time. Each tripmeter can be turned on by choosing "Start" while it also can be turned off by choosing "Stop". If the tripmeter icon is activated in the operation screen, it can be controlled directly there. Camera setting If the rear camera is not installed on the machine, set disable.
  • Page 328 AAVM (All Around View Monitoring, option) The AAVM buttons of the cluster consist of ESC/CAM and AUTO IDLE/Buzzer stop. Buzzer stop switch Escape switch 290F3CD244 Escape button It will enter into the AAVM mode from the beginning screen if the AAVM is installed. While in the AAVM mode, select the ESC button to return to the beginning screen.
  • Page 329 AIR CONDITIONER AND HEATER Full auto air conditioner and heater system automatically keeps the optimum condition in accor- dance with operator's temperature confi guration sensing ambient and cabin inside temperature. Location of air flow ducts Cluster : Haptic controller : Setting temperature Power switch Temperature switch...
  • Page 330 Power switch This switch makes the system ON/OFF. Just before the power OFF, set values are stored. Default setting values Function Air conditioner In/outlet LCD Temperature Mode Previous sw Previous sw Value Inlet 290F3CD251 Air conditioner switch This switch turns the compressor ON/OFF. Air conditioner operates to remove vapor and drains water through a drain hose.
  • Page 331 Fan speed switch Fan speed is controlled automatically by setted temperature. This switch controls fan speed manually. · There are 8 up/down steps to control fan speed. · The maximum step or the minimum step beeps 5 times. 290F3CD226 Fan speed Steps 1 through 8 to display the amount of wind.
  • Page 332 SELF DIAGNOSIS FUNCTION Diagnostic methods : Diagnostic information window, select Diagnostic indication (Displays fault) Fault code Description Fail safe function Ambient temperature sensor open 20˚C alternate value control Ambient temperature sensor short Cab inside temperature sensor open 25˚C alternate value control Cab inside temperature sensor short Evaporate temperature sensor open 0˚C alternate value control...

  • Page 333: Group 17 Fuel Warmer System

    GROUP 17 FUEL WARMER SYSTEM 1. SPECIFICATION Operating voltage : 24 4 V Power : 350 50 W Current : 15 A Filter head & 2. OPERATION fuel warmer T h e c u r r e n t o f f u e l w a r m e r s y s t e m i s automatically controlled without thermostat according to fuel temperature.

  • Page 334: Section 6 Troubleshooting

    SECTION 6 TROUBLESHOOTING Group 1 Before Troubleshooting -------------------------------------------------------------------------------------- 6-1 Group 2 Hydraulic and Mechanical System ------------------------------------------------------------------- 6-4 Group 3 Electrical System ----------------------------------------------------------------------------------------------- 6-24 Group 4 Mechatronics System ---------------------------------------------------------------------------------------- 6-40...

  • Page 335: Group 1 Before Troubleshooting

    SECTION 6 TROUBLESHOOTING GROUP 1 BEFORE TROUBLESHOOTING 1. INTRODUCTION When a trouble is occurred in the machine, this section will help a service man to refair to maintain the machine with easy. The trouble of machine is parted Hydraulic & Mechanical system, Electrical system and Mechatronics system.
  • Page 336 2. DIAGNOSING PROCEDURE To carry out troubleshooting efficiently, the following steps must be observed. STEP 1. Study the machine system Study and know how the machine is operating, how the system is composing, what kinds of function are installed in the machine and what are specifications of the system components by the machine service manual.
  • Page 337 STEP 4. Inspect the trouble actually on the machine In case that some trouble cannot be confirmed, obtain the details of the malfunction from the operator. Also, check if there are any in complete connections of the wire harnesses are or not. (210-7) 6-3(1) STEP 5.

  • Page 338: Group 2 Hydraulic And Mechanical System

    GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM 1. INTRODUCTION MACHINE IN GENERAL If even a minor fault is left intact and operation is continued, a fatal failure may be caused, entailing a large sum of expenses and long hours of restoration. Therefore when even a small trouble occurs, do not rely on your intuition and experience, but look for the cause based on the troubleshooting principle and perform maintenance and adjustment to prevent major failure from occurring.
  • Page 339 2. DRIVE SYSTEM UNUSUAL NOISE COMES OUT OF PUMP CONNECTION Cause Remedy Coupling element Disassemble is broken. and repair. Remove dust plug under engine flywheel and Replace hub or check if rubber pieces or particles retighten are not present. setscrew. Coupling hub spline is worn or hub fastening...
  • Page 340 ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL Cause Remedy Replenish specified oil to the standard Is oil level in level. Abnormal noise hydraulic oil comes out of Hydraulic pump is Disassemble tank within hydraulic pump broken. and repair. standard level? Do not hydraulic Abnormal noise...
  • Page 341 3. HYDRAULIC SYSTEM HYDRAULIC OIL IS CLOUDY Cause Remedy Water is mixed. Put hydraulic oil still, separate water and Drop hydraulic oil dispose it or sample on hot plate and check if replace hydraulic foams come up. oil. Air is intruded. Check suction line and return line and eliminate...
  • Page 342 CAVITATION OCCURS WITH PUMP Cause Remedy Replenish specified oil to the standard level. Is hydraulic oil volume proper? Replace oil with one of proper Is not viscosity viscosity. of hydraulic oil too high? Clean suction strainer. Is not suction Is not air intruding strainer clogged? Check for air from pump...
  • Page 343 4. SWING SYSTEM BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE Cause Remedy Replenish Does safety specified oil to the solenoid valve standard level. operation Safety solenoid Repair or replace. Is gear pump pilot normal? pressure within valve faulty or not standard level? Is oil in hydraulic operated.
  • Page 344 SWING SPEED IS LOW Cause Remedy Swing port relief Disassemble and Does swing spool valve is faulty. repair or replace. move? Swing control valve Disassemble Is MCV pilot spool is stuck. and repair. pressure same on LH and RH Clogged or oil Clean pilot piping sides? leak.
  • Page 345 SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION Cause Remedy Does symptom Swing port relief Disassemble change when LH and RH port valve is faulty. and repair. relief valves of swing motor are Shuttle valve is Disassemble exchanged? Does swing control faulty.
  • Page 346 THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE Cause Remedy Is swing shuttle valve normal? Shuttle valve is Disassemble faulty. and replace. Is brake spring normal? Is return spring of swing spool Brake spring is Disassemble normal? faulty.
  • Page 347 5. TRAVEL SYSTEM TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE Cause Remedy Does counterbalance spool move lightly by hand? Counter spool is Disassemble Is travel brake valve pressure stuck. and repair or within standard replace. Does the symptom level? change when relief valves in...
  • Page 348 SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES Cause Remedy Brake valve is Disassemble Do LH and RH defective. and repair or travel speeds replace. change when LH and RH travel Relief valve built Disassemble Does the symptom brake valves are change when in travel motor is and repair.
  • Page 349 MACHINE DOES NOT STOP ON A SLOPE Machine is pulled forward as sprocket rotates during digging operation. Cause Remedy Is parking brake None Friction plate is Disassemble friction plate worn? Check if parking faulty. and repair. brake pilot line is clogged.
  • Page 350 TRAVEL ACTION IS POWERLESS (travel only) Cause Remedy Is travel motor's drain rate within standard level? Is travel brake Travel motor is Disassemble pressure within faulty. and repair. standard level? Is travel relief valve pressure Travel brake valve Disassemble within standard is defective.
  • Page 351 MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME Cause Remedy Normal. Is straight spool normal? Straight spool is Repair or Is pilot pressure faulty. replace. for travel straight spool within standard level? Remove dirt on...
  • Page 352 6. ATTACHMENT SYSTEM BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL Cause Remedy Port relief valve is Disassemble Does the symptom change faulty. and repair or when port relief replace. valve is replaced with other valve? Is MCV pilot pressure within standard level? Inspect if pilot See Note 3, 4...
  • Page 353 BOOM, ARM OR BUCKET SPEED IS LOW Cause Remedy Normal. Are other attachment speeds within Is combination Is speed low only standard levels? of oil streams in composite normal at boom operation? Replace up and at arm Does spool of flow extrusion? spring.
  • Page 354 BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS Cause Remedy Port relief valve is Disassemble Does the symptom faulty. and repair or change when port Normal replace. relief valve is replaced with Is control valve normal value? return spring Is not hydraulic normal?
  • Page 355 BOOM, ARM OR BUCKET POWER IS WEAK Cause Remedy Check according to the procedure Is cylinder in Item "Speed is internal leakage within standard low". level? Is relief pressure in port relief Cylinder is faulty. Disassemble valve within and repair. standard level? Is relief pressure in main relief...
  • Page 356 BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED Cause Remedy Frictional noise occurs between the sliding faces of boom cylinder's oil seal and boom Is boom foot pin greased proper. sufficiently? Frictional noise will disappear if they are kept used.
  • Page 357 HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE Lower the bucket teeth to the ground with bucket cylinder fully retracted and arm cylinder rod retracted almost in full. 300L6TS01 Disconnect hose (A) from rod side of boom cylinder and drain oil from cylinders and hose.

  • Page 358: Group 3 Electrical System

    GROUP 3 ELECTRICAL SYSTEM 1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.
  • Page 359 COMMUNICATION ERROR FLASHES ON THE CLUSTER (HCESPN 840, FMI 2) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective cluster...
  • Page 360 BATTERY CHARGING WARNING LAMP LIGHTS UP (Starting switch : ON) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective MCU...
  • Page 361 WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP (engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Check use HRDT...
  • Page 362 WHEN AIR CLEANER WARNING LAMP LIGHTS UP (engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Clogged air filter or...
  • Page 363 WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP (engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective circuit,...
  • Page 364 WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP (engine is started) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy High temperature...
  • Page 365 8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Check use HRDT...
  • Page 366 9. WHEN FUEL GAUGE DOES NOT OPERATE (HCESPN 301, FMI 3 or 4) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective MCU or...
  • Page 367 10. WHEN SAFETY SOLENOID DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No. 24. After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Hydraulic system...
  • Page 368 11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE (HCESPN 167, FMI 4 or 6) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No. 26. After checking, insert the disconnected connectors again immediately unless otherwise specified.
  • Page 369 12. WHEN ENGINE DOES NOT START ( lights up condition) Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No. 1, 5, 9, 21. After checking, insert the disconnected connectors again immediately unless otherwise specified.
  • Page 370 13. WHEN STARTING SWITCH ON DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted, master switch ON and check open circuit of circuit breaker (CN-60). After checking, insert the disconnected connectors again immediately unless otherwise specified.
  • Page 371 14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE Before disconnecting the connector, always turn the starting switch OFF. CN-21 Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No. 7, 12 and 18 are not blown out. After checking, insert the disconnected connectors again immediately unless otherwise specified.
  • Page 372 15. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No. 19. After checking, insert the disconnected connectors again immediately unless otherwise specified.
  • Page 373 16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP Before disconnecting the connector, always turn the starting switch OFF. Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.16. After checking, insert the disconnected connectors again immediately unless otherwise specified.

  • Page 374: Group 4 Mechatronics System

    GROUP 4 MECHATRONICS SYSTEM 1. ALL ACTUATORS SPEED ARE SLOW Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good. Spec : P-mode 1700 50 rpm S -mode 1600 50 rpm E-mode 1500 50 rpm Before carrying out below procedure, check all the related connectors are properly inserted and fault code on the cluster.
  • Page 375 TEST PROCEDURE SPEC : 15~25 (20˚C) Test 1 : Check resistance at connector CN-75. Starting key OFF. EPPR valve CN-75 Disconnect connector CN-75 from EPPR valve at main hydraulic pump. Multimeter Check resistance between 2 lines as figure. Main pump 480L6MS02 Test 2 : Check electric current at EPPR Spec : 100~700 mA...
  • Page 376 2. ENGINE STALL Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Not enough Check engine engine power fault Check pressure Contact cummins at EPPR valve SPEC : 2~25 kgf/cm Defective EPPR Replace See TEST 5 valve...
  • Page 377 TEST PROCEDURE Spec : 100~700 mA Test 4 : Check electric current at EPPR Adapter(P/no.:21Q6-50410) valve. Disconnect connector CN-75 from EPPR CN-75 valve. EPPR valve Insert the adapter to CN-75 and install multimeter as figure. Multimeter Start engine. Set S-mode and cancel auto decel mode.
  • Page 378 3. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy No power supply to Check fuse No.4 the MCU See if all lamps off in the MCU case MCU failure Replace...
  • Page 379 4. AUTO DECEL SYSTEM DOES NOT WORK Fault code : HCESPN 105, FMI 0~4 (work pressure sensor) HCESPN 108, FMI 0~4 (travel oil pressure sensor) Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective MCU...
  • Page 380 TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 7 : Check voltage at CN-52 (38) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of CN-51 CN-52 connectors : One pin to (38) of CN-52. Starting switch ON.
  • Page 381 5. MALFUNCTION OF PUMP 1 PRESSURE SENSOR Fault code : HCESPN 121, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Short circuit or Replace or repair poor connection Check voltage between CN-52...
  • Page 382 TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 9 : Check voltage at CN-52 (12) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (12) of CN-52. Starting switch ON.
  • Page 383 6. MALFUNCTION OF PUMP 2 PRESSURE SENSOR Fault code : HCESPN 120, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Short circuit or Replace or repair poor connection Check voltage between CN-52-...
  • Page 384 TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 10 : Check voltage at CN-52 (29) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (29) of CN-52. CN-51 CN-52 Starting switch ON.
  • Page 385 7. MALFUNCTION OF PUMP 3 PRESSURE SENSOR Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Short circuit or Replace or repair poor connection Check voltage between CN-52- between (32)-CN-1(7) CN-1(7)-GND Check voltage...
  • Page 386 TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 11 : Check voltage at CN-52 (32) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (32) of CN-52. CN-51 CN-52 Starting switch ON.
  • Page 387 8. MALFUNCTION OF NEGATIVE 1 PRESSURE SENSOR Fault code : HCESPN 123, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Short circuit or Replace or repair poor connection Check voltage between CN-52-...
  • Page 388 TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 12 : Check voltage at CN-52 (33) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (33) of CN-52. CN-51 Starting switch ON.
  • Page 389 9. MALFUNCTION OF NEGATIVE 2 PRESSURE SENSOR Fault code : HCESPN 124, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Short circuit or Replace or repair poor connection Check voltage between CN-52-...
  • Page 390 TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 13 : Check voltage at CN-52 (17) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (17) of CN-52. CN-51 CN-52 Starting switch ON.
  • Page 391 10. MALFUNCTION OF SWING PRESSURE SENSOR Fault code : HCESPN 135, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Check voltage between CN-52 Detective swing Replace or repair (36) - GND pressure sensor Short circuit or...
  • Page 392 TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 14 : Check voltage at CN-52 (36) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (36) of CN-52. CN-51 Starting switch ON.
  • Page 393 11. MALFUNCTION OF ARM IN/OUT & BUCKET IN PRESSURE SENSOR Fault code : HCESPN 133, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Check voltage between CN-52 Detective arm in/ Replace or repair (14) - GND...
  • Page 394 TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 15 : Check voltage at CN-52 (14) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (14) of CN-52. CN-51 CN-52 Starting switch ON.
  • Page 395 12. MALFUNCTION OF BOOM UP PRESSURE SENSOR Fault code : HCESPN 127, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Check voltage between CN-52 Detective boom up Replace or repair (19) - GND pressure sensor...
  • Page 396 TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 16 : Check voltage at CN-52 (19) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (19) of CN-52. CN-51 Starting switch ON.
  • Page 397 13. MALFUNCTION OF BOOM DOWN PRESSURE SENSOR Fault code : HCESPN 128, FMI 0~4 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Check voltage between CN-53 Detective boom up Replace or repair (23) - GND pressure sensor...
  • Page 398 TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 17 : Check voltage at CN-53 (23) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (23) of CN-53. CN-53 Starting switch ON.
  • Page 399 14. MALFUNCTION OF POWER MAX Fault code : HCESPN 166, FMI 4 or 6 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Short circuit or poor Repair or replace connection between Check resistance CN-88(1)-CN-52 (2) between CN-88...
  • Page 400 TEST PROCEDURE Starting switch SPEC : ON : 24 1V Starting switch OFF : 0V Test 18: Check voltage between connector CN-88 (2) - GND. Disconnect connector CN-88 from power max solenoid valve. Power max switch Starting switch ON. Check voltage as figure. LH RCV-lever CN-88 Power max...
  • Page 401 15. MALFUNCTION OF BOOM PRIORITY EPPR VALVE Fault code : HCESPN 141, FMI 5 or 6 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Short circuit or poor Repair or replace connection between CN-52(35)-CN-133 (1) or CN-52(34)-...
  • Page 402 16. MALFUNCTION OF ARM REGENERATION SOLENOID Fault code : HCESPN 170, FMI 4 or 6 Before carrying out below procedure, check all the related connectors are properly inserted. INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Check voltage between CN-52 Short circuit or Replace or repair (1)-GND poor connection...
  • Page 403 TEST PROCEDURE SPEC : Starting switch ON : 24 2 V Test 20 : Check voltage at CN-52 (1) and ground. Prepare 1 piece of thin sharp pin, steel or copper. Insert prepared pin to rear side of connectors : One pin to (1) of CN-52. Starting switch ON.

  • Page 404: Section 7 Maintenance Standard

    SECTION 7 MAINTENANCE STANDARD Group 1 Operational Performance Test ------------------------------------------------------------------------- 7-1 Group 2 Major Components -------------------------------------------------------------------------------------------- 7-20 Group 3 Track and Work Equipment ------------------------------------------------------------------------------ 7-30...

  • Page 405: Group 1 Operational Performance Test

    Working condition parts and reassembled at a customer's site, it must be tested to confirm that the operational performance of the machine meets Hyundai spec. Maintenance OPERATIONAL PERFORMANCE OF A record WORKING MACHINE With the passage of time, the machine's...
  • Page 406 2. TERMINOLOGY STANDARD Specifications applied to the brand-new machine, components and parts. 21077MS02 SERVICE LIMIT The lowest acceptable performance level. When the perfor mance level of the machine falls below this level, the machine must be removed from work and repaired. Necessary parts and components must be replaced.
  • Page 407 3. OPERATION FOR PERFORMANCE TESTS Observe the following rules in order to carry out performance tests accurately and safely. The machine Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test. Test area Select a hard, flat surface.
  • Page 408 ENGINE SPEED Measure the engine speed at each power mode The engine speed at each power mode CLUSTER must meet standard RPM; if not, all other operational performance data will be unreliable. It is essential to perform this test first. Preparation Warm up the machine, until the engine coolant temperature reaches 50˚C or...
  • Page 409 TRAVEL SPEED Measure the time required for the excavator to travel a 20 m test track. Preparation Adjust the tension of both tracks to be equal. Prepare a flat and solid test track 20m in length, with extra length of 3 to 5 m on 0.3~0.5m both ends for machine acceleration and deceleration.
  • Page 410 TRACK REVOLUTION SPEED Measure the track revolution cycle time with the track raised off ground. Preparation Adjust the tension of both side tracks to be equal. On the track to be measured, mark one 90~110 shoe with chalk. Swing the upperstructure 90˚ and lower the bucket to raise the track off ground.
  • Page 411 TRAVEL DEVIATION Measure the deviation by the tracks from a 20 m straight line. Preparation Adjust the tension of both tracks to be equal. Provide a flat, solid test yard 20 m in length, with extra length of 3 to 5 m on 0.3~0.5m both ends for machine acceleration and deceleration.
  • Page 412 SWING SPEED Measure the time required to swing three complete turns. Preparation Check the lubrication of the swing gear and swing bearing. Place the machine on flat, solid ground with ample space for swinging. Do not conduct this test on slopes. With the arm rolled out and bucket rolled in, hold the bucket so that the height of the bucket pin is the same as the boom...
  • Page 413 SWING FUNCTION DRIFT CHECK Measure the swing drift on the bearing outer circumference when stopping after a 360˚ full speed swing. Preparation Check the lubrication of the swing gear and swing bearing. Place the machine on flat, solid ground with ample space for swinging. Do not conduct this test on slopes.
  • Page 414 SWING BEARING PLAY Measure the swing bearing play using a dial gauge to check the wear of bearing races and balls. Preparation Check swing bearing mounting cap screws for loosening. Check the lubrication of the swing bearing. Confirm that bearing rotation is smooth and without noise.
  • Page 415 HYDRAULIC CYLINDER CYCLE TIME Measure the cycle time of the boom, standard arm, and standard bucket cylinders. Preparation Boom cylinder To measure the cycle time of the boom Raise cylinders: With the arm rolled out and the empty bucket rolled out, lower the bucket to the ground, as shown.
  • Page 416 Bucket cylinders Measure the time it takes to roll in the bucket, and the time it takes to roll out the bucket. To do so, position the bucket at one stroke end, then move the control lever to the other stroke end as quickly as possible.
  • Page 417 DIG FUNCTION DRIFT CHECK Measure dig function drift, which can be caused by oil leakage in the control valve and boom, standard arm, and standard bucket cylinders, with the loaded bucket. When testing the dig function drift just after cylinder replacement, slowly operate each cylinder to its stroke end to purge air.
  • Page 418 CONTROL LEVER OPERATING FORCE Use a spring scale to measure the maximum resistance of each control lever at the middle of the grip. Preparation Keep the hydraulic oil temperature at 50 5˚C. Measurement Start the engine. Select the following switch positions. Power mode switch : P mode Operate each boom, arm, bucket and swing lever at full stroke and measure the...
  • Page 419 CONTROL LEVER STROKE Measure each lever stroke at the lever top using a ruler. When the lever has play, take a half of this value and add it to the measured stroke. Preparation Keep the hydraulic oil temperature at 50 5˚C. Measurement Stop the engine.
  • Page 420 FOR TRAVEL SPEED SELECTING PRESSURE: Preparation Stop the engine. Loosen the cap and relieve the pressure in the tank by pushing the top of the air breather. To measure the speed selecting pressure: Install a connector and pressure gauge assembly to turning joint P port as shown. Star t the engine and check for on leakage from the adapter.
  • Page 421 SWING PARKING BRAKE RELEASING PRESSURE Preparation Stop the engine. Loosen the cap and relieve the pressure in the tank by pushing the top of the air breather. The pressure release L wrench to bleed air. Install a connector and pressure gauge assembly to swing motor SH port, as shown.
  • Page 422 MAIN PUMP DELIVERY PRESSURE Preparation Main pump Keep the hydraulic oil temperature at 50 5˚C. Measurement Select the following switch positions. Pressure sensor Power mode switch : P mode Measure the main pump deliver y pressure in the P mode (high idle). Monitoring (analog) Cluster...
  • Page 423 SYSTEM PRESSURE REGULATOR RELIEF SETTING Preparation Keep the hydraulic oil temperature at 50 5˚C. Main pump Measurement Select the following switch positions. Power mode switch : P mode Pressure sensor Slowly operate each control lever of boom, arm and bucket functions at full stroke over relief and measure the pressure.

  • Page 424: Group 2 Major Components

    GROUP 2 MAJOR COMPONENT 1. MAIN PUMP 380L7MS01 Recommended Standard Counter measures Part name & inspection item replacement dimension value Clearance Replace piston between piston(1) & 0.043 0.070 or cylinder. cylinder bore(2) (D-d) Play between piston(1) & shoe caulking 0-0.1 section(3) Replace assembly of...
  • Page 425 2. MAIN CONTROL VALVE Part name Inspection item Criteria & measure Existence of scratches, rust or corrosion. In case of damage in following section, Casing replace casing. - Sliding sections of casing hole and spool, especially land sections applied with held pressure.
  • Page 426 3. SWING DEVICE WEARING PARTS Recommended Standard Inspection item replacement Counter measures dimension value Replace piston or Clearance between piston and cylinder block bore 0.028 0.058 cylinder block Replace assembly Play between piston and shoe caulking section ( ) of piston and shoe Replace assembly Thickness of shoe (t) of piston and shoe...
  • Page 427 4. TRAVEL MOTOR The followings are the general maintenance standards. However, it is the most important to determine which parts should be replaced, depending on the characteristics before disassembling, damages and discoloration of exterior view, the purpose of disassembling, the expected remaining service life.
  • Page 428 Check item Measuring method Criteria Allowable Remedy After completion of assembly, set the torque R e p l a c e a l l o f wrench on the shaft 92.6 kgf m 82.8 kgf m separator, friction Parking brake torque end, and measure the (670 lbf ft) (599 lbf ft)
  • Page 429 Recommended Standard Part name & inspection item value for Remedy dimension replacement Replacement of abnormal Radial clearance of needle bearing 0.01-0.04 mm 0.07 mm parts as a set. Replacement if such damage Crack of spline contact part as crack, crevice of chipping is found.
  • Page 430 5. RCV LEVER Maintenance Criteria Remark check item Leakage The valve is to be replaced when the leakage Conditions : becomes more than 1000 cc/m at neutral handle Primary pressure : 40 kgf/cm position, or more than 2000 cc/m during operation. Oil viscosity : 23 cSt Spool...
  • Page 431 6. RCV PEDAL Maintenance Criteria Remark check item Leakage The valve is to be replaced when the leakage effect Conditions : to the system. For example, the primary pressure Primary pressure : 40 kgf/cm drop. Oil viscosity : 23 cSt Spool This is to be replaced when the sliding surface has The leakage at the left condition is...
  • Page 432 7. TURNING JOINT Part name Maintenance standards Remedy Sliding surface with Plating worn or peeled due to seizure or contamination. Replace sealing sections. Sliding surface Worn abnormality or damaged more than 0.1 mm Replace between body and (0.0039 in) in depth due to seizure contamination. stem other than Body, Damaged more than 0.1 mm (0.0039 in) in depth.
  • Page 433 8. CYLINDER Part name Inspecting section Inspection item Remedy Piston rod Neck of rod pin Presence of crack Replace Weld on rod hub Presence of crack Replace Stepped part to which piston is Presence of crack Replace attached. Threads Presence of crack Recondition or replace Plating is not worn off to base Replace or replate...

  • Page 434: Group 3 Track And Work Equipment

    GROUP 3 TRACK AND WORK EQUIPMENT 1. TRACK TRACK ROLLER 32077MS01 Unit : mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange Rebuild or Outside diameter of tread replace Width of tread 54.6 60.6 Width of flange 34.4 Standard size &...
  • Page 435 CARRIER ROLLER 4507AMS04 Unit : mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange Rebuild or Outside diameter of tread replace Width of tread Width of flange Standard size & tolerance Standard Clearance clearance limit Clearance between shaft Shaft Hole Replace...
  • Page 436 IDLER 4707AMS03 Unit : mm Check item Criteria Remedy Standard size Repair limit Outside diameter of protrusion Rebuild or Outside diameter of tread replace Width of protrusion Total width Width of tread 50.5 57.5 Standard size & tolerance Standard Clearance clearance limit Replace...
  • Page 437 TRACK 32077MS04 Unit : mm Check item Criteria Remedy Standard size Repair limit Turn or Link pitch replace 215.9 226.7 Outside diameter of bushing 60.4 Rebuild or Height of grouser replace Height of link Tightening torque Initial tightening torque : 105 5 kgf m Retighten 7-33...
  • Page 438 TRACK FRAME AND RECOIL SPRING 21073MS05 Unit : mm Check item Criteria Remedy Standard size Tolerance Repair limit Track frame Vertical width of idler guide Rebuild or Idler support replace - 1.5 Track frame Horizontal width of idler guide Idler support Standard size Repair limit Installation...
  • Page 439 2. WORK EQUIPMENT 21077MS20 Unit : mm Bushing Remedy Measuring point Normal Recomm. Recomm. Mark & Limit Limit (Pin and Bushing) value service service Remark of use of use limit limit Boom Rear 118.5 120.5 Boom Cylinder Head 98.5 100.5 Boom Cylinder Rod 108.5 110.5...

  • Page 440: Section 8 Disassembly And Assembly

    SECTION 8 DISASSEMBLY AND ASSEMBLY Group 1 Precaution --------------------------------------------------------------------------------------------------------- 8-1 Group 2 Tightening Torque --------------------------------------------------------------------------------------------- 8-4 Group 3 Pump Device ----------------------------------------------------------------------------------------------------- 8-7 Group 4 Main Control Valve -------------------------------------------------------------------------------------------- 8-31 Group 5 Swing Device ---------------------------------------------------------------------------------------------------- 8-51 Group 6 Travel Device ----------------------------------------------------------------------------------------------------- 8-71 Group 7 RCV Lever --------------------------------------------------------------------------------------------------------- 8-101 Group 8 Turning Joint ------------------------------------------------------------------------------------------------------ 8-115 Group 9 Boom, Arm and Bucket Cylinder --------------------------------------------------------------------- 8-120...

  • Page 441: Group 1 Precaution

    SECTION 8 DISASSEMBLY AND ASSEMBLY GROUP 1 PRECAUTIONS 1. REMOVAL WORK Lower the work equipment completely to the ground. If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
  • Page 442 2. INSTALL WORK Tighten all bolts and nuts (sleeve nuts) to the specified torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pin or lock plate securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2-3 drops of adhesive.
  • Page 443 3. COMPLETING WORK If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level.

  • Page 444: Group 2 Tightening Torque

    GROUP 2 TIGHTENING TORQUE 1. MAJOR COMPONENTS Torque Descriptions Bolt size kgf m lbf ft Engine mounting bolt (engine-bracket) 1.75 72.3 Engine mounting bolt (bracket-frame) Engine Radiator, oil cooler mounting bolt 29.7 32.5 Coupling mounting socket bolt 46.5 18.1 Fuel tank mounting bolt 36.9 Main pump housing mounting bolt 34.7...
  • Page 445 2. TORQUE CHART 2. TORQUE CHART Use following table for unspecified torque. 1) 1) BOLT AND NUT BOLT AND NUT (1) (1) Coarse thread Coarse thread 8.8T 10.9T 12.9T Bolt size kgf·m lbf·ft kgf·m lbf·ft kgf·m lbf·ft M 6 × 1.0 0.8 ~ 1.2 5.8 ~ 8.6 1.2 ~ 1.8...
  • Page 446 PIPE AND HOSE (FLARE TYPE) Thread size (PF) Width across flat (mm) kgf·m lbf·ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 130.2 1" 151.9 1-1/4" 253.2 PIPE AND HOSE (ORFS TYPE) Thread size (UNF) Width across flat (mm) kgf·m lbf·ft 9/16-18 28.9 11/16-16...

  • Page 447: Group 3 Pump Device

    GROUP 3 PUMP DEVICE 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
  • Page 448 INSTALL Carry out installation in the reverse order to removal. Remove the suction strainer and clean it. Replace return filter with new one. Remove breather and clean it. After adding oil to the hydraulic tank to the specified level. Bleed the air from the hydraulic pump. Remove the air vent plug (2EA).
  • Page 449 2. MAIN PUMP (1/2) STRUCTURE 380F2MP02 04 Gear pump 271 Pump casing 710 O-ring 111 Drive shaft (F) 311 Valve cove r(F) 717 O-ring 113 Drive shaft (R) 312 Valve cover (R) 719 O-ring 114 Spline coupling 313 Valve plate (R) 724 Square ring 123 Roller bearing 314 Valve plate (L)
  • Page 450 TOOLS AND TIGHTENING TORQUE Tools The tools necessary to disassemble/reassemble the pump are shown in the follow list. Tool name & size Part name Hexagon socket PT plug PO plug Hexagon socket Allen wrench head bolt (PT thread) (PF thread) head setscrew BP-1/16 BP1/ 8...
  • Page 451 Tightening torque Torque Wrench size Part name Bolt size kgf m lbf ft Hexagon socket head bolt 0.16 (material : SCM435) 0.20 21.7 0.24 42.0 0.31 10.0 72.3 0.39 16.0 0.47 24.0 0.55 34.0 0.55 44.0 0.67 PT1/16 0.16 PT plug (material : S45C) Wind a seal tape 1 1/2 to 2 PT 1/8 1.05...
  • Page 452 DISASSEMBLY Select place suitable to disassembling. Select clean place. Spread rubber sheet, cloth or so on on overhaul workbench top to prevent parts from being damaged. Remove dust, rust, etc, from pump surfaces with cleaning oil or so on. Remove drain port plug (468) and let oil out of pump casing (front and rear pump).
  • Page 453 Place pump horizontally on workbench with its regulator-fitting surface down, and separate pump casing (271) from valve cover (F, 311). Before bringing this surface down, spread rubber sheet on workbench without fail to prevent this surface from being damaged. 36078MP03 Separate valve cover (F, 311) from valve cover (R, 312) and pull out booster (130), spline coupling (114).
  • Page 454 (11) Tapping lightly fitting flange section of swash plate support (251) on its pump casing side, separate swash plate support from pump casing. 36078MP06 (12) Remove shoe plate (211) and swash plate (212) from pump casing (271). 36078MP07 (13) Tapping lightly shaft ends of drive shafts (111, 113) with plastic hammer, take out drive shafts from swash plate supports.
  • Page 455 (14) Remove valve plates (313, 314) from valve cover (311, 312). These may be removed in work 7, 9. 36078MP09 (15) If necessary, remove stopper (L, 534), stopper (S, 535), servo piston (532) and tilting pin (531) from pump casing (271), and needle bearing (124) from valve cover (311, 312).
  • Page 456 ASSEMBLY For reassembling reverse the disassem- bling procedures, paying attention to the following items. Do not fail to repair the parts damaged during disassembling, and prepare replacement parts in advance. Clean each part fully with cleaning oil and dry it with compressed air. Do not fail to apply clean working oil to sliding sections, bearings, etc.
  • Page 457 Place pump casing with its regulator fitting surface down, fit tilting bush of swash plate to tilting pin (531) and fit swash plate (212) to swash plate suppor t (251) correctly. Confirm with fingers of both hands that swash plate can be removed smoothly. Apply grease to sliding sections of swash plate and swash plate support, and drive 36078MP11...
  • Page 458 Fit valve plate (313) to valve cover (F, 311), and fit valve plate (314) to valve cover (R, 312), entering pin into pin hole. Take care not to mistake suction / delivery directions of valve plate. 36078MP15 Fit valve block (R, 312) to pump casing (271) and fit spline coupling (114) and booster(130) to shaft (R, 113).
  • Page 459 (11) Putting feedback pin of tilting pin into feedback lever of regulator, fit regulator and tighten hexagon socket head bolts (412,413). Take care not to mistake regulator of front pump for that of rear pump. 36078MP17 Fit drain port plug (468). (12) This is the end of reassembling procedures.
  • Page 460 3. REGULATOR STRUCTURE(1/2) Psv1 FRONT Hydraulic circuit 644 645 SECTION B-B 755 541 545 543 722 497 438 Port Port name Port size VIEW C Pi1,Pi2 Pilot port PF 1/4-15 Psv1,Psv2 Servo assist port PF 1/4-15 430F2RG01 8-20...
  • Page 461 STRUCTURE (2/2) SECTION A-A 38092RG03 625 Outer spring 725 O-ring 407 Hexagon socket bolt 626 Inner spring 728 O-ring 408 Hexagon socket bolt 627 Adjust stem (C) 730 O-ring 412 Hexagon socket bolt 628 Adjust screw (C) 732 O-ring 413 Hexagon socket bolt 629 Cover (C) 733 O-ring 436 Hexagon socket bolt...
  • Page 462 TOOLS AND TIGHTENING TORQUE Tools The tools necessary to disassemble/reassemble the pump are shown in the follow list. Tool name & size Part name Hexagon socket PT plug PO plug Hexagon socket Allen wrench head bolt (PT thread) (PF thread) head setscrew BP-1/16 BP1/ 8...
  • Page 463 Tightening torque Torque Wrench size Part name Bolt size kgf m lbf ft 0.16 Hexagon socket head bolt (material : SCM435) 0.20 21.7 0.24 42.0 0.31 10.0 72.3 0.39 16.0 0.47 24.0 0.55 34.0 0.55 44.0 0.67 PT1/16 0.16 PT plug (material : S45C) Wind a seal tape 1 1/2 to 2 1.05 7.59...
  • Page 464 DISASSEMBLY Since the regulator consists of small precision finished parts, disassembly and assembly are rather complicated. For this reason, replacement of a regulator assembly is recommended, unless there is a special reason, but in case disassembly is necessary for an unavoidable reason, read through this manual to the end before starting disassembly.
  • Page 465 A f t e r r e m o v i n g c o v e r ( C , 6 2 9 ) subassembly, take out outer spring (625), inner spring (626) and spring seat (C, 624) from compensating section. Then draw out adjusting stem (Q, 645), pilot spring (646) and spring seat (644) from pilot section.
  • Page 466 36078RE07 Remove lever2 (613). Do not draw out pin (875). Work will be promoted by using pincers or so on. 36078RE08 (10) Draw out pin (874) and remove feedback lever (611). Push out pin (874, 4 mm in dia.) from above with slender steel bar so that it may not interfere with lever1 (612).
  • Page 467 (11) Remove lever1 (612). Do not draw out pin (875). (12) Draw out pilot piston (643) and spool (652). (13) D r a w o u t p i s t o n c a s e ( 6 2 2 ) , c o m p e n s a t i n g p i s t o n ( 6 2 1 ) a n d compensating rod (623).
  • Page 468 ASSEMBLY For assembly, reverse disassembly procedures, but pay attention to the following items. Always repair parts that were scored at disassembly. Get replacement parts ready before- hand. Mixing of foreign matter will cause malfunction. Therefore, wash parts well with cleaning oil, let them dry with jet air and handle them in clean place.
  • Page 469 Fit feedback lever (611), matching its pin hole with pin hole in spool. Then insert pin (874). Insert pin in feedback lever a little to ease Lever(1) side Lever(2) side operation. (Fulcrum plug of adjusting plug side) Take care not to mistake direction of feedback lever.
  • Page 470 (11) Fit set spring (655) to spool hole and put compensating piston (621) and piston case (622) into compensating hole. Fit pilot cover (641) and tighten it with hexagonal socket head screws (436, 438). 36078RE16 (12) Put spring seat (644), pilot spring (646) and adjusting stem (Q, 645) into pilot hole.

  • Page 471: Group 4 Main Control Valve

    GROUP 4 MAIN CONTROL VALVE 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
  • Page 472 2. STRUCTURE (1/4) HOUSING-P1 (ITEM 101) 380L8MC01 101 Casing A 327 Spring 561 O-ring 155 Plug 332 Spring seat 603 Port relief assy 158 Plug 335 Shim 611 Negative relief valve assy 165 O-ring 336 Spacer bolt 652 Plug 168 O-ring 337 Rod 663 O-ring 201 Spring cover...
  • Page 473 STRUCTURE (2/4) A2 CASING 380L8MC02 155 Plug 305 Swing spool kit 522 Spring 165 O-ring 308 Option spool kit 554 Stopper plug 201 Spring cover 332 Spring seat 557 Plug 202 Spring cover 335 Shim 603 Port relief assy 262 O-ring 336 Spacer bolt 652 Plug 263 O-ring...
  • Page 474 STRUCTURE (3/4) A1 CASING 380L8MC03 102 Casing-B 212 O-ring 371 Spring 551 Plug 151 Plug 252 Lock valve 372 Spring 552 Plug 155 Plug 263 O-ring 373 Spring 553 Plug 158 Plug 264 O-ring 511 Poppet 557 Plug 159 Plug 267 O-ring 512 Poppet 558 Plug...
  • Page 475 STRUCTURE (4/4) A1 CASING 380L8MC04 155 Plug 273 Hex screw 394 Am/Confluence spool kit 165 O-ring 301 Travel spool kit 551 Plug 202 Spring cover 303 Boom spool kit 561 O-ring 208 Spool cover 304 Bucket spool kit 603 Port relief assy 211 Plug 313 Plug 611 Negative relief valve assy...
  • Page 476 3. DISASSEMBLY AND ASSEMBLY GENERAL PRECAUTIONS All hydraulic components must be worked with precision working. Then, before disassembling and assembling them, it is essential to select an especially-clean place. In handling a control valve, pay full attention to prevent dust, sand, etc. from entering into it. When a control valve is to be removed from the machine, apply caps and masking seals to all ports.
  • Page 477 DISASSEMBLING Place control valve on working bench. Disassemble it in clean place and pay attention not to damage flange face. Disassembling of main spool (travel, bucket, swing, option, arm 2, boom 2, swing priority): Loosen hexagon socket head bolts (273) and remove spring cover (201), (206).
  • Page 478 Disassembling of arm 1 spool : Loosen hexagon socket head bolts (273) and remove spring cover (201). Hexagon key wrench : 8 mm Remove arm 1 spool (302), spring (371), spring seat (332) and spacer bolt (336) in spool assembly condition from casing. When pulling out spool assembly from casing, pay attention not to damage 3607A8MC08...
  • Page 479 Disassembling of boom 1 spool : Loosen hexagon socket head bolts (273), remove spring cover (201) and pull out boom 1 spool (303), plug (313), spring (371), spring seats (332) and spacer bolt(336) in spool assembly condition from casing. Hexagon key wrench : 8 mm When pulling out spool assembly from 3607A8MC10 casing, pay attention not to damage...
  • Page 480 Removal of main relief valve and port relief valves : Remove main relief valve (601) and port relief valve (603), (604), (605) from casing. Main relief valve : Spanner 32 mm Port relief valve : Box wrench 36 mm, Spanner 36mm 3607A8MC13 Removal of lock valve assembly : Loosen hexagon socket head bolts and...
  • Page 481 (10) Disassembly of negative control relief valve : Remove plug (551). Hexagon key wrench : 17 mm 3607A8MC17 Remove poppet (611), spring (621) and damping rod(631). 3607A8MC18 8-41...
  • Page 482 (11) Disassembly of check valve : Remove plug (551) and take out poppet (511) and spring (522). Hexagon key wrench : 17 mm Loosen hexagon socket head bolts (274) and remove load check cover (203) and take out poppet (551) and spring (522). Hexagon key wrench : 8 mm Remove plug (553) and take out poppet 3607A8MC19...
  • Page 483 (12) Disassembly of boom priority valve : Loosen hexagon socket head bolts (276, 277) and remove cover sub (205) and poppet sub (515) of boom priority valve. Hexagon key wrench : 8 mm Hold cover sub (205) in mouthpiece- attached vise, remove poppet sub (515). Cover sub (205) : Hold cover in mouthpiece-attached vise, 3607A8MC22...
  • Page 484 (14) Inspection after disassembling : Clean all disassembled parts with clean mineral oil fully, and dry them with compressed air. Then, place them on clean papers or cloths for inspection. Control valve: Check whole surfaces of all parts for burrs, scratches, notches and other defects. Confirm that seal groove faces of casing and block are smooth and free of dust, dent, rust etc.
  • Page 485 ASSEMBLING In this assembling section, explanation only is shown. Refer to figures and photographs shown in disassembling section. Figure in ( ) shown after part name in explanation sentence shows number in construction figure. Cautions in assembling seals Pay attention to keep seals free from defects in its forming and damages in its handling. Apply grease, hydraulic oil or so on to seals and seal-fitting sections for full lubrication.
  • Page 486 Bucket, option confluence plug sub : If you want bucket confluence or option 380 712 401 confluence effective, loosen rod (401) and tighten lock nut (712). If you want to cancel bucket confluence or option confluence, tighten rod (401) and lock nut (712). Spanner : 10 mm for (401) Tightening torque : 3.0~4.0 kgf m 38098MC12...
  • Page 487 Assembly of bypass cut valve 327 251 Assemble bypass cut spool (392), spring (326 & 327) and rod (337) into casing A (101) & casing B(102). Put O-ring (265) onto plug (251) and tighten the latter with its specified torque. Box wrench : 27 mm Tightening torque : 7.95~10.0 kgf m (57.5~72.3 lbf ft)
  • Page 488 (10) Assembling of travel straight spool : Hold end of travel straight spool (391) in mouthpiece-attached vise, set spring seat (332) and spring (373) and tighten spacer bolt (336) with specified torque. Before tightening spacer bolt (336), apply Loctite #262 to it. Hexagon key wrench : 12 mm Tightening torque : 3.77~4.18 kgf m 38098MC21...
  • Page 489 (12) Assembling of arm 1 spool : Hold end of arm 1 spool (302) in mouthpiece-attached vise, set spring seats (332) and spring (371) and tighten spacer bolt (336) with specified torque. Before tightening spacer bolt (336), apply Loctite #262 to it. Hexagon key wrench : 12 mm Tightening Torque : 3.77~4.18 kgf m 38098MC24...
  • Page 490 (14) Assembling of cover : Fit spool covers (202) and (208) to sides reverse to spring sides spools, and tighten hexagon socket head bolts (273) with specified torque. Confirm that O-rings (262) have been fitted to spool cover (202), O-ring (263) to boom 1 spool cover (208).

  • Page 491: Group 5 Swing Device

    GROUP 5 SWING DEVICE 1. REMOVAL AND INSTALL OF MOTOR REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
  • Page 492 2. SWING MOTOR STRUCTURE 7 40 5 8 12 11 10 9 20 24 23 1 3 4 14 13 16 15 17 39 19 18 22 25 31,32 36,37 SECTION A-A 38092SM02 Body 15 Friction plate 29 O-ring Oil seal 16 Plate 30 Relief valve assy Roller bearing...
  • Page 493 TOOLS AND TIGHTENING TORQUE Tools Tool name Remark Allen wrench Socket for socket wrench, spanner Torque wrench Capable of tightening with the specified torques Snap ring plier(for holes, axis) Snap ring(4) Solder hammer Needle bearing(22), pin(6, 21) Oil seal inserting jig Oil seal(2) Induction heating apparatus for bearing Roller bearing(3)
  • Page 494 DISASSEMBLING Disassemble the sub of a TURNING AXIS Unloosing wrench bolt (32) and dis- assemble time delay valve assy (31) from rear cover (23) 3607A8SM01/01A Hang rear cover (23) on hoist, unloose wrench bolt (24, 25) and disassemble from body (1). 3607A8SM02 Using a jig, disassemble break piston (17) from body (1).
  • Page 495 Disassemble shoe plate (8) from body (1). 3607A8SM05 Using a plier jig, disassemble snap ring (4) and shaft assy (5). 3607A8SM06/06A Disassemble cylinder block assy sub Disassemble pistion assy (14), set plate (13) from cylinder block assy. 3607A8SM07 Disassemble ball guide (12), friction plate (15), plate (16) and ball guide seat (11) from cylinder block (9).
  • Page 496 Disassemble spring (10) from cylinder block (9). 3607A8SM09 Disassemble rear cover assy sub Disassemble pin (6, 21) and valve plate (20) from rear cover (23). 3607A8SM10/10A Using a torque wrench, disassemble relief valve assy (30) 2 set from rear cover (23). 3607A8SM11/11A Disassemble make up check valve assy with a torque wrench from rear cover...
  • Page 497 ASSEMBLING Assemble the sub of a turning axls Put roller bearing (3) on preheater and provide heat to inner wheel (compress ing temp : 290˚C for 2 minutes) Roller bearing 3607A8SM21 After assembling and compressing pre- heated roller bearing (3), stop ring (7) into shaft (5).
  • Page 498 Fix snap ring (4) to shaft with a plier jig. Snap ring 3607A8SM06 Spread grease on shoe plate (8) and assemble on the body. Shoe plate 3607A8SM05 Assemble the sub of cylinder block assy Assemble spring (10) 9 set into cylinder block (9).
  • Page 499 Assemble piston assy (14) 9 set into set plate (13). Piston assy Set plate 3607A8SM27 Assemble above item 3607A8SM28 Assemble cylinder block assy into body (1). 3607A8SM04 Assemble 4 set of lining plate (16), fric- tion plate (15) respectively into body. Lining plate Friction plate 3607A8SM29...
  • Page 500 Assemble O-ring (18) into break piston (17). O-ring 3607A8SM30 Insert break piston assy into body (1) and assemble spring (19) into break pis- ton (17). Spring 19EA 3607A8SM31/31A Assemble the sub of rear cover assy After assembling needle bearing (22) into rear cover (23), with a hammer assemble pin (6, 21).
  • Page 501 Assemble relief valve assy (30) 2set into rear cover (23) with a torque wrench. 3607A8SM34/11A Spreading grease on valve plate (20), assemble into rear cover (23). Valve plate 1EA 3607A8SM10/10A Lift up rear cover assy on body (1) by a crane and assemble it with a wrench bolt (24, 25).
  • Page 502 Air pressing test Be sure of leakage, after press air into assembled motor. 14078SM232 Leakage check After cleaning motor by color check No.1, paint No.3 and be sure of leakage. 14078SM233/233A Mount test bench Mounting motor test bench, test the avail- ability of each part.
  • Page 503 3. REDUCTION GEAR STRUCTURE 36,35 32 31 30 3 1 4 8 15 14 12 13 29 17 25 24 18 20 22 23 38092SM03 Casing 17 Carrier 1 33 Pinion gear Drive shaft 18 Planetary gear 1 34 Lock plate Roller bearing 19 Pin 1 35 Hexagon bolt...
  • Page 504 DISASSEMBLY Removal of cover Loosen the socket bolt (24) with 16mm hexagonal socket and remove the cover (37). Removal of sun gear 1 and thrust ring assembly Remove carrier 1(16), install eye bolt to tap hole (M10) and remove carrier 1 assembly itself.
  • Page 505 Remove pin assy 2 (11) from carrier 2 (7), planetary gear 2 (9) and thrust washer (14) with hands. 3607A8SR06 Removal of ring gear Remove ring gear (28) from casing (1). Fluid packing is applied on contacting face of ring gear and gear casing. Therefore, remove ring gear from casing by minus screw driver.
  • Page 506 Remove roller bearing (6) from gear casing (1). 3607A8SR10 Remove oil seal (5) from gear casing (1). 3607A8SR11 Disassembly of shaft assembly Insert motor side of shaft (2) into steel tube (inner dia : 145 mm) and push the end of output shaft side with hydraulic press and then remove roller bearing (3), and spacer ring (4) as assembly from drive shaft (2).
  • Page 507 ASSEMBLY Assembly of drive shaft assembly After assembly drive shaft (2), heat roller bearing (3) up to 50˚C plus surrounding temperature and assemble it to shaft with hydraulic press and then assemble spacer ring (4) in this order. Pay attention to the assembling direction of cover plate (30).
  • Page 508 Install of roller bearing Put gear casing under output shaft and heat roller bearing (6) up to 50˚C plus surrounding temperature and then assemble it to the shaft. 3607A8SR16 Assembly of ring gear Remove oil from mating faces between gear casing (1) and ring gear (28), and knock pin (29).
  • Page 509 Insert spring pin (15) by hammering. Insert as the clearance between spring pins toward planetary gear 2 (9). 3607A8SR20 Assembly of carrier 2 assembly and sun gear 2 Mount eye bolt into tap hole (M10) of carrier 2 (8) and lift carrier assembly and then insert carrier assembly being engaged with internal teeth of ring gear (28).
  • Page 510 Insert sun gear 1 (27) to planetary gear 1 (18). 3607A8SR24 Check rotation of sun gear by turning plunge part of gear casing with hands. (10) Assembly of cover Remove oil from mating faces between ring gear (28) and cover (40) and apply fluid packing.

  • Page 511: Group 6 Travel Device

    GROUP 6 TRAVEL DEVICE 1. REMOVAL AND INSTALL REMOVAL Swing the work equipment 90 and lower it completely to the ground. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
  • Page 512 2. SPECIFICATION TRAVEL MOTOR 43092TM02 Casing 22 Separated plate 43 O-ring Plug 23 Parking piston 44 O-ring Plug 24 D-ring 45 Relief valve assy Oil seal 25 D-ring 46 Spool Snap ring 26 Valve plate 47 Plug Piston 27 Parallel pin 48 Spring seat Piston seal 28 Spring...
  • Page 513 TOOLS AND TIGHTENING TORQUE Tools Tool name B-size Name of part applied Plug (2) Plug (3), Plug (40) Hexagonal L-wrench Plug (56) Hex (53) Plug (47), Connector (51) Relief valve (45) Socket wrench/Spanner Plug (53) Snap ring plier (for holes, axis) Snap ring (5), Snap ring (11) Solder hammer Needle bearing (10), Pin (27), Spring pin(30)
  • Page 514 3. DISASSEMBLING & ASSEMBLING OF TRAVEL MOTOR GENERAL INSTRUCTIONS Combustibles such as white kerosene are used for washing parts. These combustibles are easily ignited, and could result in fire or injury. Be very careful when using. Internal parts are coated with hydraulic fluid during disassembling and are slippery. If a part slips out of your hand and fails, it could result in bodily injury or could damage the park.
  • Page 515 DISASSEMBLING TRAVEL MOTOR Disassemble relief valve assy (45) from rear cover (32) using spanner or torque wrench. 43098TM02 43098TM03 Disassemble main spool cover (35) from rear cover (32) and then disassemble spring (36), spring seat (34), main spool assy (35) in regular sequence.
  • Page 516 Disassemble parking piston (23) using jig. 43098TM09 43098TM10 Disassemble separated plate (22, 7EA) and friction plate (21, 6EA). 43098TM11 43098TM12 43098TM13 43098TM14 Remove cylinder block kit. It is easier to work by placing the casing (1) horizontal. 43098TM15 8-76...
  • Page 517 Disassemble cylinder block (16), retainer plate (19), piston assy (20), ball guide (18) and spring (17) from cylinder block kit. 43098TM16 43098TM17 43098TM18 43098TM19 43098TM20 Disassemble swash plate (15) from shaft casing (1). 43098TM21 43098TM22 (10) Disassemble steel ball (13) and swash piston (6).
  • Page 518 (11) Disassemble pivot (14, 2EA) from casing (1). 43098TM26 (12) Disassemble snap ring (5) using pliers. 43098TM27 (13) In the casing (1), the arrow part of the shaft (8) using a rubber mallet taps and then disassemble the shaft (8) and bearing-roller (9) to the other side.
  • Page 519 (15) Disassemble plug (47), connector (51) from rear cover (32) and then disassemble spring (50), spring-seat (50), pin – parallel (49), spool (47) in regular sequence. 43098TM31 43098TM32 43098TM33 (16) Disassemble plug (40) from rear cover (32) and then disassemble spring (39), restictor (38) from rear cover (34) in regular sequence.
  • Page 520 ASSEMBLING TRAVEL MOTOR - REAR COVER ASSY Insert check valve (55), spring (56) into rear cover (32) and then assemble plug (40) using torque-wrench. Tightening torque : 3.0 0.3 kgf m (21.7 2.17 lbf ft) 43098TM40 43098TM39 Insert restrictor (38), spring (39) into rear cover (32) and then assemble plug (40) using torque- wrench.
  • Page 521 Insert spool (46), parallel pin (49), spring seat (48) and spring (50) in regular sequence and then assemble plug (47), connector (51) using torque-wrench. Tightening torque : 5.5 0.5 kgf m (39.8 3.62 lbf ft) 43098TM46 43098TM47 43098TM48 Press needle bearing (10) into rear cover (32) using jig.
  • Page 522 Assemble valve plate (26) into rear cover (32). Apply grease to the valve plate contact and then assemble it into rear cover (32). 43098TM54 (10) Apply grease to the O-ring (29), and then assemble it into rear cover (34). 43098TM55 (11) Assemble the heated roller bearing (9) onto the shaft (8) and then assemble snap ring (6) into...
  • Page 523 (12) Install casing (1) into assembling jig. 43098TM60 (13) Assemble plug (2), (3) into casing (1). 43098TM61 43098TM62 (14) Assemble oil seal (3) into casing (1) with assembling jig. 43098TM63 43098TM64 (15) Insert assembled shaft assy in the direction of the arrow into casing(1) using a rubber mallet.
  • Page 524 (16) Apply the grease to pivot (14, 2EA) and then assemble pivot (14) into casing(1). 43098TM68 (17) Warm piston seal (7) and assemble it on swash piston (6) and then bind the piston seal (7) with a bend for a minute. Remove the bend and assemble it into casing (1).
  • Page 525 (20) Assemble spring (17), ball guide (18), retainer plate (19), piston assy (20) into cylinder block (16) in regular sequence. 43098TM75 43098TM76 43098TM77 43098TM78 43098TM79 (21) Assemble cylinder block kit into casing (1). 43098TM80 (22) Assemble separated plate (21), friction plate (22) into cylinder block in regular sequence.
  • Page 526 (23) Assemble parallel pin (31) into casing(1). 43098TM83 (24) Apply the grease to D-ring (24, 25) and then assemble them into parking piston (23). 43098TM84 (25) Assemble parking piston into casing using jig. 43098TM85 (26) Assemble parking spring (28, 14EA). 43098TM86 8-86...
  • Page 527 (27) Put on the rear cover (32) on the casing (1). 43098TM87 43098TM88 (28) Assemble rear cover (32) into casing (1) and then tighten the wrench bolt (53) using torque wrench. Tightening torque : 33 3.3 kgf m (239 23.9 lbf ft) 43098TM89 (27) Assemble main spool assy (33) into rear cover...
  • Page 528 (31) Assemble relief valve assy (45) using torque- wrench. Tightening torque : 26 2.6 kgf m (188 18.8 lbf ft) 43098TM95 8-88...
  • Page 529 4. TRAVEL REDUCTION GEAR STRUCTURE 21 23 20 24 15 7 13 12 14 16 17 6 33 10 8 30 35 34 28 32 27 25 19 9 18 11 1 26 5 4 31 2 29 3 43092TM03 Ring gear 13 Needle bearing 2 25 Sun gear 1...
  • Page 530 TOOL AND TIGHTENING TORQUE Tools Tool name B-size Name of part applied Hex socket head bolt (30) Hex socket head bolt (9) Hexagonal L-wrench Plug (32) Hex socket head bolt (31) Socket wrench/Spanner Hex socket head bolt (6) Hammer Needle bearing (13, 21), Pin (15, 16, 17, 23, 24) Torque wrench Capable of tightening with the specified torques Jig for assembling floating seal...
  • Page 531 5. DISASSEMBLING AND ASSEMBLING OF REDUCTION GEAR GENERAL INSTRUCTIONS Combustibles such as white kerosene are used for washing parts. These combustibles are easily ignited, and could result in fire or injury. Be very careful when using. Internal parts are coated with gear oil during disassembling and are slippery. If a part slips off from your hand and fails, it could result in bodily injury or could damage the park.
  • Page 532 DISASSEMBLING TRAVEL REDUCTION GEAR Ready for disassembling Reduction gear removed from machine usually covered with dirt, so clean it with cleaning liquid and dry it. Put reduction gear on stable place with drain port down side and remove oil plug (PF3/4) to pull-out gear oil through drain port.
  • Page 533 Remove No.1 sun gear from reduction gear slowly. When disassemble No.1 sun gear, be sure to keep vertical against ground with No.1 sun gear. 43098TR05 Removing carrier sub No.2 Remove No.2 sun gear slowly. When disassemble No.2 sun gear, be sure to keep vertical against ground with No.2 sun gear.
  • Page 534 Remove nut ring and lock plate Remove hex head bolt (M12 20) using torque wrench which is connecting ring and lock plate. Remove lock plate from motor casing spline. Remove nut ring using designed tools. 43098TR09 Disassemble ring gear and housing Set eye bolt (M20) in flange of housing, pulling ring gear and housing from motor.
  • Page 535 (10) Separate motor casing and floating seal Pull floating seal in motor casing slowly and remove floating seal from motor casing. Do not re-use floating seal. 43098TR13 (11) Disassemble No. 1 carrier assy Put spring pin into No.1 spring pin hole using specially designed tool.
  • Page 536 ASSEMBLYING TRAVEL REDUTION GEAR General precautions Clean all components with kerosene and dry them in shade. Remove all loctite with solvent. Check the components. Apply loctite #262 on thread of hex socket head bolt. Be aware of dropping of parts on foot and safety accident. Check the quantity of all parts in advance.
  • Page 537 Caulking both side of pressed spring pin 180˚ using caulking jig. 43098TR20 Carrier No. 2 assembly Set No. 2 carrier on stable and even place. Put No.2 needle bearing in No.2 planetary gear and place No.2 thrust washer 2pcs on both side of gear.
  • Page 538 Housing & main bearing Heating and cleaning housing with 60~70˚C temperature. Set the housing on working table safely, press fitting main bearing into both side of housing. 43098TR23 Seal cover Apply three bond #1194 on contact surface of housing and seal cover, tighten hex socket head bolt (M10 25) with designed torque 6.3 0.6 kgf ·...
  • Page 539 Nut ring and lock plate Tighten nut ring with designed torque using torque wrench. Set lock plate along with bolt hole of nut ring and assemble them. Tighten hex head bolt (M12 20) with designed torque 8.8 0.9 kgf · m (63.7 6.5 lbf · ft). 43098TR27 (10) Coupling...
  • Page 540 Assemble No.2 sun gear into No.2 carrier assy. 43098TR31 (12) No.1 carrier sub assembly Set eye bolt (M10) in No.1 carrier tap hole and set down No.1 carrier assy slowly. Assemble No.1 sun gear and No.1 carrier assy. Assemble thrust plate and carrier. 43098TR32 (13) Cover assembly...

  • Page 541: Group 7 Rcv Lever

    GROUP 7 RCV LEVER 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
  • Page 542 2. DISASSEMBLY AND ASSEMBLY STRUCTURE 300L2RL06 Case Plug 15 Joint assembly 22 Nut Bushing Push rod 16 Swash plate 23 Boot Spool 10 O-ring 17 Adjusting nut 24 Last guard filter Shim 11 Rod seal 18 Bushing 25 O-ring Spring 12 Plate 19 Plug 26 O-ring...
  • Page 543 TOOLS AND TIGHTENING TORQUE Tools Tool name Remark Allen wrench Spanne (+) Driver Length 150 (-) Driver Width 4~5 Torque wrench Capable of tightening with the specified torques Tightening torque Torque Part name Item Size kgf m lbf ft Joint 25.3 Swash plate 5.0 0.35...
  • Page 544 DISASSEMBLY Procedures are based on the type L1. Clean pilot valve with kerosene. Put blind plugs into all ports Fix pilot valve in a vise with copper (or lead) sheets. Remove end of boot (23) from case (1) and take it out upwards. 300E8RL01 For valve with switch, remove cord also through hole of casing.
  • Page 545 Loosen adjusting nut (17) and swash plate (16) with spanners on them respectively, and remove them. 36078RL01 36078RL02 Turn joint anticlockwise to loosen it, utilizing jig (Special tool). When return spring (7) is strong in force, plate (12), plug (8) and push rod (9) will come up on loosening joint.
  • Page 546 Remove plate (12). 36078RL05 When return spring (7) is weak in force, plug (8) stays in casing because of sliding resistance of O-ring. Take it out with minus screwdriver. Take it out, utilizing external periphery groove of plug and paying attention not to damage it by partial loading.
  • Page 547 Take push rod (9) out of plug (8). (12) 36078RL11 (13) Remove O-ring (10) and seal (11) from plug (8). Use small minus screwdriver or so on to remove this seal. 36078RL12 36078RL13 8-107...
  • Page 548 (14) Remove lock nut (22) and then boot (23). 36078RL14 2507ARL10 8-108...
  • Page 549 (15) Cleaning of parts Put all parts in rough cleaning vessel filled with kerosene and clean them (rough cleaning). If dirty part is cleaned with kerosene just after putting it in vessel, it may be damaged. Leave it in kerosene for a while to loosen dust and dirty oil.
  • Page 550 ASSEMBLY Put shim (4), springs (5) and spring seat (6) onto spool (3) in this order. 36078RL16 Assemble spring (7) into casing (1). Assemble reducing valve subassembly into casing. Assemble them to their original positions. 36078RL18 Assemble O-ring (10) onto plug (8). 36078RL19 Assemble seal (11) to plug (8).
  • Page 551 Assemble push rod (9) to plug (8). Apply working oil on push-rod surface. 36078RL21 Assemble plug subassembly to casing. When return spring is weak in force, subassembly stops due to resistance of O-ring. 36078RL22 When return spring is strong in force, assemble 4 sets at the same time, utilizing plate (12), and tighten joint (15) temporarily.
  • Page 552 (10) Assemble swash plate (16) to joint (15). Screw it to position that it contacts with 4 push rods evenly. Do not screw it over. 36078RL25 (11) Assemble adjusting nut (17), apply spanner to width across flat of plate (16) to fix it, and tighten adjusting nut to the specified torque.
  • Page 553 (13) Fit boot (23) and lock nut (22), and handle subassembly is assembled completely. 2507ARL10 36078RL27 (14) Pull out cord and tube through adjusting nut hole provided in direction 60 to 120 from casing hole. 1408DA66 (15) Assemble bushing (18) to plate and pass cord and tube through it.
  • Page 554 Determine handle direction, tighten lock (16) nut (22) to specified torque to fix handle. 300E8RL05 (17) Apply grease to rotating section of joint and contacting faces of disk and push rod. 300E8RL06 (18) Assemble lower end of bellows to casing. (19) Inject volatile rust-preventives through all ports and then put blind plugs in ports.

  • Page 555: Group 8 Turning Joint

    GROUP 8 TURNING JOINT 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
  • Page 556 2. DISASSEMBLY AND ASSEMBLY STRUCTURE 21098TJ01 Shim 11 Wear ring Shaft Slipper seal 12 Retainer ring Cover O-ring 13 Plug Spacer O-ring 14 Hexagon bolt Shim 10 O-ring 15 Spring washer 8-116 8-116...
  • Page 557 DISASSEMBLY Before the disassembly, clean the turning joint. Remove bolts (14), washer (15) and cover (3). 21078DA10 Remove shim (6) and O-ring (10). Remove retainer ring (12), spacer (4) and shim (5). 21078DA11 Place hub (1) on a V-block and by using a Secure with hand wood buffer at the shaft end, hit out shaft Wooden block...
  • Page 558 ASSEMBLY Clean all parts. As a general rule, replace oil seals and O-ring. Coat the sliding surfaces of all parts with engine oil or grease before installing. Fix seven slipper seal (7) and O-ring (9), two wear ring (11) to hub (1). Fit O-ring (8) to shaft (2).
  • Page 559 Install cover (3) to body (1) and tighten bolts (14). Torque : 10~12.5 kgf · m (72.3~90.4 lbf · ft) 21078DA10 8-119...

  • Page 560: Group 9 Boom, Arm And Bucket Cylinder

    GROUP 9 BOOM, ARM AND BUCKET CYLINDER 1. REMOVAL AND INSTALL BUCKET CYLINDER Removal Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.
  • Page 561 Sling bucket cylinder assembly, and remove bolt (6), plate (7) then pull out pin (5). Remove bucket cylinder assembly (8). Weight : 320 kg (710 lb) 36078CY02 Install Carry out installation in the reverse order to removal. When aligning the mounting position of the pin, do not insert your fingers in the pin hole.
  • Page 562 ARM CYLINDER Removal Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release 13031GE18 the pressure inside the hydraulic tank.
  • Page 563 Sling arm assembly (9), and remove bolt (7), plate (8) then pull out pin (6). Remove arm cylinder assembly (9). Weight : 490 kg (1080 lb) 36078CY06 Install Carry out installation in the reverse order to removal. When aligning the mounting position of the pin, do not insert your fingers in the pin hole.
  • Page 564 BOOM CYLINDER Removal Expand the arm and bucket fully, lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release 13031GE18 the pressure inside the hydraulic tank.
  • Page 565 Disconnect boom cylinder hoses (7), and put plugs on cylinder pipe. 36078CY10 Remove bolt (9) and pull out pin (8). Remove boom cylinder assembly (6). Weight : 370 kg (820 lb) 36078CY10A Install Carry out installation in the reverse order to removal.
  • Page 566 2. DISASSEMBLY AND ASSEMBLY STRUCTURE Bucket cylinder 38098CY01A Tube assembly 12 Back up ring 23 Hexagon socket head bolt Rod assembly 13 Cushion ring 24 Pin bushing Gland 14 Piston 25 Pin bushing DD2 bushing 15 Piston seal 26 Dust seal Snap ring 16 Wear ring 27 Band assembly...
  • Page 567 Arm cylinder 13 14 18,19 20 21 9,10 6,7 8 4 23 5 36 34 3 12,13 1 2 Internal detail 26,27,28,29 24,25 24,25 38098CY02 Tube assembly 14 Piston 27 Coil spring Rod assembly 15 Piston seal 28 O-ring Gland 16 Wear ring 29 Plug DD2 bushing...
  • Page 568 Boom cylinder 9,10 11,12 1 2 13 17 16 18,19 Internal detail 24,26 25,27 3809A8CY03 Tube assembly 12 Back up ring 23 Hexagon socket head bolt Rod assembly 13 Cushion ring 24 Pin bushing (R) Gland 14 Piston 25 Pin bushing (B) DD2 bushing 15 Piston seal 26 Dust seal...
  • Page 569 TOOLS AND TIGHTENING TORQUE Tools Allen wrench Spanner (-) Driver Small and large sizes Torque wrench Capable of tightening with the specified torques Tightening torque Torque Part name Item Size kgf m lbf ft Bucket cylinder 46 5 333 36.1 Socket head bolt Boom cylinder 63 6...
  • Page 570 DISASSEMBLY Remove cylinder head and piston rod Procedures are based on the bucket cylinder. Hold the clevis section of the tube in a vise. Use mouth pieces so as not to damage the machined surface of the cylinder tube. Do not make use of the outside piping as a locking means.
  • Page 571 Note that the plated surface of rod assembly (2) is to be lifted. For this reason, do not use a wire sling and others that may damage it, but use a strong cloth belt or a rope. Place the removed rod assembly on a wooden V-block that is set level.
  • Page 572 Disassemble the piston assembly Remove wear ring (16). Remove dust ring (17) and piston seal (15). Exercise care in this operation not to damage the grooves. 2907A8CY03 Disassemble cylinder head assembly 9 6 7 8 12 11 Remove back up ring (12) and O-ring (11).
  • Page 573 ASSEMBLY Assemble cylinder head assembly Check for scratches or rough surfaces if found smooth with an oil stone. Coat the inner face of gland (3) with hydraulic oil. 21078DA37 Coat dust wiper (9) with grease and fit Press here dust wiper (9) to the bottom of the hole of (Straight down) dust seal.
  • Page 574 Fit back up ring (12) to gland (3). Put the backup ring in the warm water of 30~50˚C . Fit O-ring (11) to gland (3). 21078DA39 Assemble piston assembly Check for scratches or rough surfaces. If found smooth with an oil stone. Coat the outer face of piston (14) with hydraulic oil.
  • Page 575 Install piston and cylinder head Cylinder head assembly Fix the rod assembly to the work bench. Apply hydraulic oil to the outer surface of Rod assembly rod assembly (2), the inner surface of piston and cylinder head. Insert cylinder head assembly to rod assembly.
  • Page 576 Overall assemble Fix with a bar Place a V-block on a rigid work bench. Mount the tube assembly (1) on it and fix Lift the assembly by passing a bar through the clevis pin hole to lock the assembly. Straight Insert the rod assembly in to the tube assembly, while lifting and moving the rod assembly with a crane.

  • Page 577: Group 10 Undercarriage

    GROUP 10 UNDERCARRIAGE 1. TRACK LINK REMOVAL Move track link until master pin is over front idler in the position put wooden block as shown. Master pin Loosen tension of the track link. If track tension is not relieved when the grease valve is loosened, move the machine backwards and forwards.
  • Page 578 2. CARRIER ROLLER Lower frame REMOVAL Grease valve Loosen tension of the track link. 36078UC11 Jack up the track link height enough to permit carrier roller removal. Jack Carrier roller 36078UC12 Loosen the lock nut (1). Carrier roller Open bracket (2) with a screwdriver, push out from inside, and remove carrier roller assembly.
  • Page 579 3. TRACK ROLLER Lower frame REMOVAL Grease valve Loosen tension of the track link. 36078UC14 Using the work equipment, push up track frame on side which is to be removed. After jack up the machine, set a block under the unit. 90 ~ 110 36078UC15 Remove the mounting bolts (1) and draw...
  • Page 580 4. IDLER AND RECOIL SPRING REMOVAL Remove the track link. For detail, see removal of track link. 36078UC17 Sling the recoil spring (1) and pull out idler and recoil spring assembly from track frame, using a pry. Weight : 550 kg (1210 lb) 36078UC18 Remove the bolts (2), washers (3) and separate ilder from recoil spring.
  • Page 581 DISASSEMBLY AND ASSEMBLY OF IDLER Structure 36078UC01 Shell O-ring Spring pin Bushing Seal assembly Plug Shaft Bracket 8-141 8-141...
  • Page 582 Disassembly Press Remove plug and drain oil. Draw out the spring pin (7), using a press. 36078UC21 Pull out the shaft (3) with a press. Press Remove seal (5) from shell (1) and bracket (6). Remove O-ring (4) from shaft. 36078UC22 Remove the bushing (2) from shell, using a special tool.
  • Page 583 Assembly Before assembly, clean the parts. Press Coat the sliding surfaces of all parts with oil. Cool up bushing (2) fully by some dry ice and press it into shell (1). D o n o t p r e s s i t a t t h e n o r m a l temperature, or not knock in with a hammer even after the cooling.
  • Page 584 Install bracket (6) attached with seal (5). 36078UC28 Knock in the spring pin (7) with a hammer. 36078UC29 Lay bracket (6) on its side. Supply engine oil to the specified level, and tighten plug. 36078UC30 8-144 8-144...
  • Page 585 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING Structure 45078UC02 Body Rod seal Lock plate Bracket Back up ring 10 Hex bolt Rod assembly Dust seal 11 Spring washer Spring Lock nut 12 Grease valve 8-145 8-145...
  • Page 586 Disassembly Apply pressure on spring (4) with a press. The spring is under a large installed load. This is dangerous, so be sure to set properly. Spring set load : 28840 kg (63580 lb) Remove bolt (10), spring washer (11) and lock plate (9).
  • Page 587 Assembly Install dust seal (7), back up ring (6) and rod seal (5) to body (1). When installing dust seal (7) and rod seal (5), take full care so as not to damage the lip. 45078UC05 Pour grease into body (1), then push in rod (3) by hand.
  • Page 588 Lighten the press load and confirm the set length of spring (4). After the setting of spring (4), install lock plate (9), spring washer (11) and bolt (10). 45078UC07 8-148 8-148...

  • Page 589: Group 11 Work Equipment

    GROUP 11 WORK EQUIPMENT 1. STRUCTURE SECTION A SECTION B SECTION C 21078DA 44 8-149...
  • Page 590 2. REMOVA L A ND INSTA LL B UCKET A SSEMB LY Removal Lower the work equipment completely to ground with back of bucket facing down. 36078A T04 Remove nuts (1), bolt (2) and draw out the pin (B ). 36078A T01 Remove nuts (3), bolt (4) and draw out the pin (A ).
  • Page 591 A RM A SSEMB LY Removal Loosen the breather slowly to release the pressure inside the hydraulic tank. Escaping fluid under pressure can penetrated the skin causing serious injury. Remove bucket assembly. 36078A T06 For details, see removal of bucket assembly.
  • Page 592 B OOM A SSEMB LY Removal Remove arm and bucket assembly. For details, see removal of arm and bucket assembly. Remove boom cylinder assembly from boom. For details, see removal of arm cylinder assembly. 36078A T08 Disconnect head lamp wiring. Disconnect bucket cylinder hoses (2) and arm cylinder hoses (1).

  • Page 593: Section 9 Component Mounting Torque

    SECTION 9 COMPONENT MOUNTING TORQUE Group 1 Introduction guide --------------------------------------------------------------------------------------------- 9-1 Group 2 Engine system -------------------------------------------------------------------------------------------------- 9-2 Group 3 Electric system ------------------------------------------------------------------------------------------------- 9-4 Group 4 Hydraulic system ---------------------------------------------------------------------------------------------- 9-6 Group 5 Undercarriage --------------------------------------------------------------------------------------------------- 9-9 Group 6 Structure ------------------------------------------------------------------------------------------------------------ 9-10 Group 7 Work equipment ----------------------------------------------------------------------------------------------- 9-14...

  • Page 594: Group 1 Introduction Guide

    This section shows bolt specifications and standard torque values needed when mounting components to the machine. Use genuine Hyundai spare parts. We expressly point out that Hyundai will not accept any responsibility for defects resulted from non-genuine parts. In such cases Hyundai cannot assume liability for any damage.

  • Page 595: Group 2 Engine System

    GROUP 2 ENGINE SYSTEM ENGINE AND ACCESSORIES MOUNTING SCR assy Corrosion resistor Fuel filter Engine DOC assy Engine oil filter Air cleaner HX430L9CM01 Tightening torque Item Size kgf m lbf ft Item Size kgf m lbf ft M 6 1.0 1.44 0.3 10.4 2.2 M12 1.75...
  • Page 596 COOLING SYSTEM AND FUEL TANK MOUNTING Fuel tank Fuel filter Air compressor Air conditioner idle pulley Fuel cooler Oil cooler Needle valve Condenser Radiator Reservoir tank DEF/AdBlue® supply module DEF/AdBlue® tank HX430L9CM02 Tightening torque Item Size kgf m lbf ft Item Size kgf m...

  • Page 597: Group 3 Electric System

    GROUP 3 ELECTRIC SYSTEM ELECTRIC COMPONENTS MOUNTING 1 Engine Work lamp Camera Camera (RH) (LH) Buzzer Washer tank Fuel filler pump MCU 1 Horn MCU 2 Battery Battery relay AAVM controller Washer tank Pro. controller DETAIL A DETAIL B HX430L9CM03 Tightening torque Item Size...
  • Page 598 ELECTRIC COMPONENTS MOUNTING 2 VIEW A Electric box Work lamp Fuse box Remote control unit DC/DC converter Warning buzzer Smart key Button key reader controller unit DETAIL A HX430L9CM04 Tightening torque Item Size kgf m lbf ft Item Size kgf m lbf ft M 6 1.0 1.05 0.2...

  • Page 599: Group 4 Hydraulic System

    GROUP 4 HYDRAULIC SYSTEM HYDRAULIC COMPONENTS MOUNTING 1 4 cartridge valve Fan pump Boom floating valve Main pump Hydraulic tank Fan drive motor Main control valve RCV-RH Swing motor Terminal assy RCV-LH Boom floating solenoid valve Cross VIEW A 2 EPPR valve HX380L9CM05 Tightening torque Item...
  • Page 600 HYDRAULIC COMPONENTS MOUNTING 2 ATTACH PIPING Pro relief valve Travel motor Stop valve S/acting hose joint Pattern change valve Single acting Turning joint solenoid valve 5 shuttle Quick clamp solenoid valve 4 way Double acting solenoid valve Arm safety lock system solenoid valve Arm safety Boom safety lock system...
  • Page 601 HYDRAULIC COMPONENTS MOUNTING 3 4 cartridge valve Accumulator Check valve Line filter BOOM CYLINDER Boom priority EPPR valve Solenoid valve ARM CYLINDER BUCKET CYLINDER HX380L9CM07 Tightening torque Item Size kgf m lbf ft Item Size kgf m lbf ft M10 1.5 3.2 0.3 23.1 2.2 Accumulator...

  • Page 602: Group 5 Undercarriage

    GROUP 5 UNDERCARRIAGE UNDERCARRIAGE MOUNTING ADJUST COMPONENT Swing bearing Track chain Idler Sprocket Cover Adjust component Track guard Cover HX430L9CM08 Tightening torque Item Size kgf m lbf ft Item Size kgf m lbf ft M10 1.5 6.9 1.4 49.9 10.1 M20 2.5 57.9 6.0 419 43.4...

  • Page 603: Group 6 Structure

    GROUP 6 STRUCTURE CAB AND ACCESSORIES MOUNTING Sun roof assy Back latch Side door Non slip plate Striker HX380L9CM09 Tightening torque kgf m lbf ft kgf m lbf ft Item Size Item Size M 6 1.0 1.05 0.2 7.6 1.45 M10 1.5 6.9 1.4 49.9 10.1...
  • Page 604 CAB INTERIOR MOUNTING Seat Console box(RH) Console box(LH) Safety lever Travel lever Bottom plate Viscous Foot rest mount HX430L9CM10 Tightening torque Item Size kgf m lbf ft Item Size kgf m lbf ft M 6 1.0 1.05 0.2 7.6 1.45 M 8 1.25 4.05 0.8 29.3 5.8...
  • Page 605 COWLING MOUNTING Engine hood Side cover(RH) Tank cover Screen Reservoir tank Side cover(LH) HX430L9CM11 Tightening torque Item Size kgf m lbf ft Item Size kgf m lbf ft M 8 1.25 2.5 0.5 18.1 3.6 M12 1.75 12.8 3.0 92.6 21.7 M10 1.5 6.9 1.4 49.9 10.1...
  • Page 606 COUNTERWEIGHT AND COVERS MOUNTING Counterweight Handle pipe Upper frame DEF/AdBlue® tank cover Cover Pump under cover Hyd tank under cover Engine under cover Tool box Fuel tank under cover Radiator under cover MCV under cover Cab under cover HX380L9CM12 Tightening torque Item Size kgf m...

  • Page 607: Group 7 Work Equipment

    GROUP 7 WORK EQUIPMENT Boom pin Boom cylinder rod pin Boom Arm cylinder rod pin Arm cylinder Boom cylinder Arm cylinder head pin Boom cylinder head pin Arm pin Bucket cylinder Bucket cylinder head pin Bucket Bucket control link HX430L9CM13 Tightening torque Item Size...

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