Hyundai HX17E Manual
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Hyundai HX17E Manual

Hyundai HX17E Manual

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Table of Contents
Safety, Specification and Systems Operation
1
Safety
2
Specifications
3
General Maintenance
4
Engine
5
Hydraulic Systems and Components
6
Electrical Systems
Removal and Installation
1
Removal and Installation
Table of Contents
Page 5
1
Maintenance Safety
1
General - Specifications
2
Engine - Specifications
3
Hydraulic Systems and Structure - Specifications
1
General Maintenance Instructions
2
Standard Torques
1
Engine
1
Systems Operation, Description and Inspection
2
Components Operation, Description and Inspection
1
Systems Operation and Description
1
Engine
2
Hydraulic Systems
3
Electric and Electronic

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Summary of Contents for Hyundai HX17E

  • Page 1 Table of Contents Safety, Specification and Systems Operation Safety Maintenance Safety Specifications General - Specifications Engine - Specifications Hydraulic Systems and Structure - Specifications General Maintenance General Maintenance Instructions Standard Torques Engine Engine Hydraulic Systems and Components Systems Operation, Description and Inspection Components Operation, Description and Inspection Electrical Systems Systems Operation and Description...
  • Page 2 Troubleshooting Guide Troubleshooting Wiring Harness Layout Error Code Schematic Hydraulic Schematic Electrical Schematic Table of Contents Page 6...
  • Page 3 Safety, Specification and Systems Operation...
  • Page 5 Track Excavator Maintenance Safety...
  • Page 7 Safety Instructions WARNING AVOID DEATH OR SERIOUS INJURY Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing.
  • Page 8 Safety, Specification and Systems Operation...
  • Page 9 Table of Contents Safety, Specification and Systems Operation...

  • Page 10: Table Of Contents

    Track Excavator Maintenance Safety Safety Instructions..............5 General ................11 Safe Operation is Operator's Responsibility ..11 Know Your Machine ......11 Proper Work Tools and Attachments .
  • Page 11 High-voltage Cables ......35 Underground Operation......35 Working in Water.
  • Page 12 Safety, Specification and Systems Operation 1-10...

  • Page 13: General

    Because HD HYUNDAI CONSTRUCTION EQUIPMENT cannot anticipate, identify or test all attachments that owners may want to install on their machines, contact HD HYUNDAI CONSTRUC- TION EQUIPMENT for written authorization and approval of attachments, and their compatibility with optional kits.

  • Page 14: Pressurized Fluids

    Contact your HD HYUNDAI CONSTRUCTION EQUIPMENT distributor about auxiliary hydraulic kits for attachments installa- tion. If you are in doubt about compatibility of a particular attach- ment with a machine, consult your HD HYUNDAI CONSTRUCTION EQUIPMENT distributor. Pressurized Fluids Figure 1 Pressurized air or fluids can cause debris and/or fluids to be blown out.

  • Page 15: Flying Or Falling Objects

    Operator Protection Guard (OPG) or window guards. Contact your HD HYUNDAI CONSTRUCTION EQUIPMENT distributor for information on available protective guards. To prevent personnel from being struck by flying objects, keep HAOA110L personnel out of work area.

  • Page 16: Crushing And Cutting

    Crushing and Cutting Figure 5 Keep objects away from moving fan blades. Fan blades can throw and cut objects. Do not use a wire rope that is kinked or frayed, or a wire rope with any loss of diameter. Wear leather gloves when handling a wire rope.

  • Page 17: Electrical System And Electrical Shock

    Check the ROPS cabin, mounting, and hardware for damage. Never modify the ROPS cabin. Replace the cabin and hardware if damaged. See your HD HYUNDAI CONSTRUCTION EQUIP- MENT distributor for parts. ROPS − Roll-over Protective Structure complies with DS1901183 ISO 12117-2:2008, EN13531:2001.
  • Page 18 For breaker operation, install a front guard (1) and apply a lami- nated coating sheet to front glass. Contact your HD HYUNDAI CONSTRUCTION EQUIPMENT distributor for recommenda- tions.
  • Page 19 Always contact your HD HYUNDAI CONSTRUC- TION EQUIPMENT distributor for advice. DS1901185 Emergency Exit from Operator's Station Figure 11 This machine is equipped with a glass breaking tool.
  • Page 20 Safety, Specification and Systems Operation 1-18...

  • Page 21: Long Term Storage

    Long Term Storage Figure 12 When a machine is taken out of service and stored for a time exceeding 30 days, steps must be taken to protect the machine. Leaving equipment outdoors exposed to the elements will shorten its life. An enclosure will protect the machine from rapid temperature changes and lessen the amount of condensation that forms in hydraulic components, battery, etc.

  • Page 22: During Storage

    During Storage • Once a month, start the motor and follow the "Hydraulic Oil Warm-up" procedures listed in this manual. • Operate hydraulic functions for traveling, swing and digging two or three times for lubrication after "Hydraulic Oil Warm-up". Coat all the moving parts and surfaces of the components with a new oil film after operating.

  • Page 23: Maintenance

    Maintenance Improper operation and maintenance can result in death or serious injury. Read manual and safety decals before operating or maintaining the machine. Follow all instructions and safety messages. WARNING AVOID DEATH OR SERIOUS INJURY Follow instructions before operating or servicing machine. Read and understand the Operation &...
  • Page 24 • Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention from a physician familiar with this injury. • The maintenance procedures which are given in this manual can be performed by the owner or operator without any specific technical training.

  • Page 25: Warning Tag

    • Unless instructed otherwise, perform maintenance with equip- ment in servicing position. Refer to this manual for procedure for placing equipment in servicing position. Warning Tag Figure 13 Alert others that service or maintenance is being performed by attaching a “DO NOT OPERATE” warning tag to the operator's cabin controls –...

  • Page 26: Proper Tools And Clothing

    solvents can cause a chemical reaction that will dissolve and damage the window. Proper Tools and Clothing Only use tools that are intended for the type of service to be done. Metal pieces from low quality or damaged tools, such as chisels or hammers, can break off and hit a service person in the eyes or face causing serious injury.

  • Page 27: Rubber And Plastics

    (fire), forms hydrogen fluoride and hydrofluoric acid. This acid is very corrosive and cannot be rinsed or washed off from the skin. It causes very severe burns which take a long time to heal. It usually means that damaged tissue must be surgically removed.

  • Page 28: Welding Repairs

    tion or suspension of calcium hydroxide, i.e. slaked lime in water). As a precaution, seals (O-rings and other oil seals) should always be handled as if they were made of rubber that contains fluorides. Treat skin, which is suspected of having touched burned rubber that contains fluorides, with Hydrofluoric Acid Burn Jelly or some- thing similar.

  • Page 29: Warning For Counterweight And Front Attachment Removal

    • If heat is applied directly to rubber hoses or piping under pres- sure, they may suddenly break, so cover and insulate them with a fireproof covering. • Wear protective clothing. • Make sure there is good ventilation. • Remove all flammable objects and make sure a fire extin- guisher is available.

  • Page 30: Working On Machine

    Working on Machine Figure 19 When performing maintenance operations on machine, prevent tripping and falling by keeping area around your feet clean and free of objects and debris. Always do the following: • Do not spill oil or grease. • Do not leave tools laying around. •...

  • Page 31: Compressed Air

    • Wear safety goggles and leather gloves when working on an accumulator. Hydraulic oil under pressure can penetrate skin and result in death or serious injury. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.

  • Page 32: High-Pressure Lines, Tubes And Hoses

    High-pressure Lines, Tubes and Hoses Figure 23 When inspecting or replacing high-pressure piping or hoses, check to verify that pressure has been released from circuit. Failure to release pressure can result in death or serious injury. Release pressure as described in Operation and Maintenance Manual.

  • Page 33: Battery

    Battery Battery Hazard Prevention Figure 24 Battery electrolyte contains diluted sulfuric acid and generates hydrogen gas. Hydrogen gas is highly explosive, and improper handling can cause death or serious injury, or fire. Always observe the following precautions. • Do not smoke or bring any flame near battery. •...
  • Page 34 Safety, Specification and Systems Operation 1-32...

  • Page 35: Environment And Circumstances

    Environment and Circumstances Work Site Areas Requiring Extra Caution • Do not operate too close to edge of a quay, ramp, etc. • Do not operate too close to edge of a steep slope or drop-off. Take care when working in a place where machine may tip over.

  • Page 36: Poor Visibility

    roll-over, and to prevent ground, stockpiles, or banks from collapsing. Do not travel too close to edge of a drop-off. Poor Visibility For good visibility, always do the following: • When working in dark areas, attach working lights and front lights to the machine.

  • Page 37: High-Voltage Cables

    High-voltage Cables Figure 27 Do not travel or operate machine near electrical cables or over- head power lines. There is a hazard of electric shock, which can cause property damage and result in death or serious injury. The bucket or other attachment does not have to make physical contact with power lines for current to cause an electrocution.

  • Page 38: Working In Contaminated Environment

    After working in water, lubricate all lubrication points on undercar- riage, which have been underwater so water is removed. Check that no water has entered travel gearboxes and undercarriage components. Working in Contaminated Environment When working within area which is contaminated or where there is a health risk, check local regulations and contact your distrib- utor for assistance with identifying what additional safety precau- tions need to be taken.
  • Page 39 wax in fuel, make sure that wax formation point of fuel is lower than atmospheric temperature. WARNING AVOID DEATH OR SERIOUS INJURY Explosion of the battery can cause death or serious injury.Never attempt to directly heat the battery with open fire.
  • Page 40 NOTICE Do not store acid type storage batteries near stacks of tires. Acid fumes can damage rubber. 3. Service fuel system as directed in Operation and Maintenance Manual. Check for water content before filling fuel tank. High temperatures and cooling off cause condensation in storage drums.
  • Page 41 mixed with lubricant becomes very abrasive and accelerates wear on parts. 5. Protect machine from dust and sand as much as possible. Park machine under cover to keep dust and sand from damaging unit. Operation in Rainy or Humid Conditions Operation under rainy or humid conditions is similar to that as in extreme heat procedures previously listed.

  • Page 42: Asbestos Information

    • If you are in cabin, remain seated with machine stationary until storm passes. Do not touch controls or anything metal. Asbestos Information WARNING AVOID DEATH OR SERIOUS INJURY Avoid exposure to dust containing asbestos as it can cause death or serious injury to the lungs and other organs (mesothelioma, lung and other cancers, and asbestoses).

  • Page 43: Disposal Of Hazardous Materials

    Disposal of Hazardous Materials Figure 30 Physical contact with used motor oil or gear oil could create a health risk. Wipe oil from your hands promptly and wash off any remaining residue. Used motor oil or gear oil is an environmental contaminant and should only be disposed of at approved collection facilities.
  • Page 44 reduce whole-body vibrations. The following can help the users of earth-moving machinery reduce whole-body vibration levels. 1. Use the right type and size of machine, equipment, and attach- ments. 2. Maintain machines according to the manufacturer's recom- mendations: (for wheeled machine) •...
  • Page 45 • Minimize repeated handling and lifting of loads; • Minimize any shocks and jolts during sports and leisure activities. Safety, Specification and Systems Operation 1-43...
  • Page 46 Safety, Specification and Systems Operation 1-44...

  • Page 47: General Specifications

    General Specifications...
  • Page 49 Safety Instructions WARNING AVOID DEATH OR SERIOUS INJURY Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing.
  • Page 50 Safety, Specification and Systems Operation 1-48...
  • Page 51 Table of Contents General Specifications Safety Instructions ............... 47 General................51 Standard Specification ............53 ..........53 Performance Tests ..............
  • Page 52 Safety, Specification and Systems Operation 1-50...

  • Page 53: General

    General The excavator has three main component sections: • The Upper Structure • The Lower Undercarriage and Track Frames • The Excavator Front-end Attachment The following illustration identifies main components and their locations. Safety, Specification and Systems Operation 1-51...
  • Page 54 Safety, Specification and Systems Operation 1-52...

  • Page 55: Standard Specification

    Standard Specification ITEMS UNIT KR10 EU10 Note KR10 with Quick Coupler 26kg OPERATING WEIGHT (with operator 75kg) 1962 1941 EU10 w/o Quick Coupler BUCKET CAPACITY (ISO) 0.05 0.05 MOTOR POWER 20.5 20.5 (Gross) MOTOR POWER (Continuous) BATTERY CAPACITY 20.4 20.4 MAX.
  • Page 56 950 (1,360) 950 (1,360) WIDTH x HEIGHT ( ): Track extended x 265 x 265 MAX. LIFTING HEIGHT DOZER BLADE MAX. LOWERING DEPTH DOZER LIFTING From track ANGLE OVERALL LENGTH 3,435 3,460 OVERALL WIDTH 950 (1,360) 950 (1,360) ( ): Track extended OVERALL HEIGHT 2,360 2,345...

  • Page 57: Performance Tests

    Performance Tests Use operational performance test procedure to quantitatively check all system and functions on the machine. Purpose of Performance Tests 1. To comprehensively evaluate each operational function by comparing the performance test data with the standard values. 2. According to the evaluation results, repair, adjust, or replace parts or components as necessary to restore the machine’s performance to the desired standard.
  • Page 58 Safety, Specification and Systems Operation 1-56...

  • Page 59: Preparation For Performance Tests

    Preparation for Performance Tests Observe the following rules to perform performance tests accu- rately and safety. The Machine 1. Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks etc, before starting to test. Test Area 1.
  • Page 60 Safety, Specification and Systems Operation 1-58...

  • Page 61: Operational Performance Standard Table

    Operational Performance Stan- dard Table Performan Toleranc Item Model Unit Measuring Conditions Standard SPC Off 2,300 ±25 Power Mode SPC Off + A/I On Standard Mode SPC Off 1,800 ±25 Economy Mode SPC Off 1,500 ±25 Above Air Working 1,200 ±25 Temp.
  • Page 62 Performan Toleranc Item Model Unit Measuring Conditions Standard ±0.2 Boom Down Down (with Lock Valve) Crowd ±0.2 Crowd (with Lock Valve) Dump ±0.3 *Standard, Sudden Bucket Crowd ±0.2 Command. Front *Crawler Dump ±0.2 Speed Type (With Lock Valve) Arti. Down (With Lock Valve) Left to Right ±0.3 Boom...

  • Page 63: Measuring Conditions

    Performan Toleranc Item Model Unit Measuring Conditions Standard mm/5 Boom Down Max. Reach, Bucket Crowd Below posture, (50 mm cylinder lift mm/5 for Arm & Bucket to avoid Arm Crowd Below cushion) Weight: General Purpose Machine – with 1.5 mm/5 Below Bucket Dump Times of Bucket Capacity,...
  • Page 64 Safety, Specification and Systems Operation 1-62...

  • Page 65: Operational Performance Test

    Operational Performance Test Hydraulic Cylinder Cycle Time Summary 1. Check the overall operational performance of the front attach- ment hydraulic system (between the hydraulic pumps and each cylinder) by measuring the cycle time of the boom, arm, bucket, and bucket dump (open/close) cylinders with the empty bucket.

  • Page 66: Travel Speed

    extended (crowded) to the point at which the arm cylinder is fully folded (dumped). C. Bucket cylinder Figure 34 1) Bucket crowd speed Rapidly operate the bucket while fully dumped (extended), and measure the time it takes for the bucket to fold fully.

  • Page 67: Track Revolution Speed

    Measurement 1. Measure both the slow and fast speeds of the machine. 2. Measurement conditions are as below. Travel Mode Power Mode Auto-idle Work Mode Switch Switch Switch Digging Low Mode Power Mode Mode Digging High Mode Power Mode Mode 3.

  • Page 68: Mis Track Check

    Travel Mode Power Mode Auto-idle Work Mode Switch Switch Switch Digging Low Mode Power Mode Mode Digging High Mode Power Mode Mode 3. Operate the travel control lever of the raised track to full stroke. 4. Measure the time required for 3 revolutions in both directions after a constant track revolution speed is obtained.

  • Page 69: Swing Speed

    Preparation 1. Adjust the track sag of both tracks to be equal. Figure 37 Front Zone 2. Provide a flat, solid test yard 20 m (65.6 ft) in length, with extra length of 3 - 5 m (9.8 - 16 ft) on both ends for machine accel- eration and deceleration.

  • Page 70: Swing Function Drift Check

    Preparation 1. Check the lubrication of the swing gear and swing bearing. Figure 38 2. Place the machine on flat, solid ground with ample space lor swinging. Do not conduct this test on slopes. 3. With the bucket empty, position the front attachment as follows.

  • Page 71: Cylinder Creep

    Preparation 1. Check the lubrication of the swing gear and swing bearing. Figure 39 2. Place the machine on flat, solid ground with ample space for swinging. Do not conduct this test on a slope. 3. With the bucket empty, position the front attachment as follow. With the arm cylinder fully retracted, and the bucket cylinder fully extended, raise the boom so bucket pin height is flush with the boom foot pin height.
  • Page 72 Preparation 1. Record the model type of the front end mounted on the machine under test. The standard front end type is the basic option for testing. 2. Position the machine on a level ground with a gradient of 1% or below.
  • Page 73 7. Drift value of the cylinder can be calculated as follows: • Boom and Bucket Cylinder: A - B • Arm Cylinder: B - A 8. After measuring the drift of the cylinder, measure the tempera- tures of the hydraulic tank and cylinder tube. Figure 43How to Measure a Cylinder’s Displacement Mark Mark...
  • Page 74 Safety, Specification and Systems Operation 1-72...

  • Page 75: Approximate Weight Of Workload Materials

    Approximate Weight of Workload Materials NOTICE Weights are approximations of estimated average volume and mass. Exposure to rain, snow or groundwater; settling or compaction because of overhead weight and chemical or industrial processing or changes because of thermal or chemical transformations could all increase value of weights listed in table.
  • Page 76 Density Density Density Density 1,200 kg/m 1,500 kg/m 1,800 kg/m 2,100 kg/m Material (2,000 lb/yd (2,500 lb/yd (3,000 lb/yd (3,500 lb/yd or less or less or less or less 1,202 kg/m Earth, loamy, DRY, loose (2,025 lb/yd 1,522 kg/m Earth, DRY, packed (2,565 lb/yd 1,762 kg/m Earth, WET, muddy...

  • Page 77: Main System

    Main System...

  • Page 79: Electric Power System

    Electric Power System Powerpack Nominal voltage 51 V Energy 20.4 kWh Max Charging Current 268 A Max Discharging Current 500 A Cell type Cylindrical, NR 21700 M50L Cell configuration 14S-20P Dimension (L x W x H) 644 x 362 x 441 mm Weight app.
  • Page 80 LV CONNECTOR HV CONNECTOR HV CONNECTOR PIN ID Description PIN ID Description PIN ID Description AUX IN (12V-) MATE CONN Safety, Specification and Systems Operation 1-78...
  • Page 81 Motor Rated Power 9 kW Phase Current 200 Arms Insulation Class Class H IP Grade IP 65 Speed 3,000 rpm Weight app. 20 kg Operating Temperature -40 to 50 degrees in Celsius Figure 45 INTERNAL SPLINE SEE TABLE DS2300455 LOW VOLTAGE CONNECTION Figure 46 PIN1 V IN (5V)

  • Page 82: Operating Ambient Temperature

    Inverter Nominal Voltage 60 - 84 V (12V) Peak Current 550 Arms (2 min.) IP grade IP 65 Weight app. 6.8 kg Dimension (L x W x H) 275 x 232 x 85 Operating Ambient Temperature -40 to 50 degrees in Celsius Typical Wiring Figure 47 J1-1...
  • Page 83 Connector Wiring Figure 48 TERM L PHASE B ANA OUT SW1/ANA1 COIL CAN H TERM H DRIVER 6 BRK WIPER POT HI RETURN CAN L PHASE POT HI +12V SW2/ANA2 DRIVER 1 DRIVER 3 PROP DRIVER DRIVER 7 POT LOW THR WIPER SW16 I/O GND...
  • Page 84 Nominal Output Power 3.3 kW Input Voltage 82 - 265 Vac AC Input Current < 16 A DC Output Voltage 58.8 Vmax - 65A Dimension (L x W x H) 300 x 204 x 110 mm Weight app. 7 kg Operating Ambient Temperature -35 to 65 (possilbe derating above 40) degrees in Celsius IP grade...
  • Page 85 Nominal Output Power 300 W Output Current M22 A Output Voltage 13.7 V (13.5 - 13.9 V) Dimension (L x W x H) 190 x 76 x 44 mm Weight app. 1 kg Operating Ambient Temperature -40 to 75 degrees in Celsius IP grade IP 67 Figure 49...
  • Page 86 Oil Cooler (E-Fan) Type E-Fan Blower, 9 Blades, Plastic RPM @ Max. RPM 3,000 rpm Safety, Specification and Systems Operation 1-84...
  • Page 87 Figure 50 CONNNECTOR HOLE CONNECTOR DS2300451 Safety, Specification and Systems Operation 1-85...
  • Page 88 Safety, Specification and Systems Operation 1-86...

  • Page 89: Performance Curve

    Performance Curve Motor Performance Curve Figure 51 DS2300463 Safety, Specification and Systems Operation 1-87...
  • Page 90 OBC Performance Curve Figure 52 DS2300464 Safety, Specification and Systems Operation 1-88...

  • Page 91: General Maintenance Instructions

    General Maintenance Instructions...
  • Page 93 Safety Instructions WARNING AVOID DEATH OR SERIOUS INJURY Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing.
  • Page 94 Safety, Specification and Systems Operation 1-108...
  • Page 95 Table of Contents Hydraulic Systems and Structure Specifications Safety Instructions ............... 91 Hydraulic System ..............95 Main Pump ........95 Performance Curves .
  • Page 96 Safety, Specification and Systems Operation 1-110...
  • Page 97 Welding Precautions and Instruc- tions WARNING AVOID DEATH OR SERIOUS INJURY To avoid accidents, personal injury and the possibility of causing damage to the machine or to components, welding must only be performed by properly trained and qualified personnel, who possess the correct certification (when required) for the specific welding fabrication or specialized repair being performed.
  • Page 98 WARNING AVOID DEATH OR SERIOUS INJURY Observe the following safety instructions: 1. Use adequate safety shielding and keep away from fuel and oil tanks, batteries, hydraulic piping lines or other fire hazards when welding. 2. Never weld when the motor is running. Battery cables must be disconnected before the welding procedure is started.

  • Page 99: Hydraulic System - General Precautions

    Hydraulic System - General Precautions Always maintain oil level in the system at recommended levels. Assemblies that operate under heavy loads, at high-speed, with extremely precise tolerances between moving parts (e.g. pistons and cylinders, or shoes and swash plates), can be severely damaged if oil supply runs dry.
  • Page 100 of leaking hydraulic fluid, can help extend the service life of system components. NOTICE Hydraulic system operating conditions (repetitive cycling, heavy workloads, fluid circulating under high-pressure) make it extremely critical that dust, grit or any other contamination be kept out of the system. Observe fluid and filter change maintenance interval recommendations and always preclean any exterior surface of the system before it is exposed to air.

  • Page 101: Maintenance Service And Repair Procedure

    Maintenance Service and Repair Procedure General Precautions Fluid level and condition should always be checked whenever any other maintenance service or repair is being performed. NOTE: If the unit is being used in an extreme temperature envi- ronment (in subfreezing climates or in high temperature, high humidity tropical conditions), frequent purging of moisture condensation from the hydraulic reservoir drain tap must be a regular and frequent part of the operating...
  • Page 102 Safety, Specification and Systems Operation 1-116...

  • Page 103: Hydraulic System Cleanliness And Oil Leaks

    Hydraulic System Cleanliness and Oil Leaks Maintenance Precautions for Hydraulic System Service Whenever maintenance, repairs or any other troubleshooting or service is being performed, it's important to remember that hydraulic system - including both the interior and exterior surfaces of assemblies, and every drop of operating fluid - must be protected from contamination.
  • Page 104 which to enter the circuit. Corrosive salt air, freezing and thawing condensation cycles and working environments that are full of fine dust are especially hazardous. Clogging of valve spools or external piping (especially pilot circuit piping) can gradually diminish or suddenly put a stop to normal hydraulic function. You can prevent having to make these types of repairs by the following recommended assembly procedures: 1.

  • Page 105: Cleaning And Inspection

    Cleaning and Inspection General Instructions All parts must be clean to permit an effective inspection. During assembly, it is very important that no dirt or foreign material enters unit being assembled. Even minute particles can cause malfunction of close installed parts such as thrust bearing, matched parts, etc.

  • Page 106: Bearing Inspection

    worn through. Small nicks may be removed with suitable hone. Inspect shafts and quills to make certain they have not been sprung, bent, or no twisted splines, and that shafts are normal condition. Inspect thrust washers for distortion, scores, burs, and wear. Replace thrust washer if defective or worn.

  • Page 107: Normal Bearing

    Normal Bearing Figure 56 Smooth even surfaces with no discoloration or marks. Bent Cage Figure 57 Cage damage because of improper handling or tool usage. Replace bearing. Figure 58 Galling Figure 59 Metal smears on roller ends because of overheat, lubricant failure or overload.
  • Page 108 Abrasive Step Wear Figure 60 Pattern on roller ends caused by fine abrasives. Clean all parts and housings, check all parts and housings, check seals and bearings and replace if leaking, rough or noisy. Etching Figure 61 Bearing surfaces appear gray or grayish black in color with related etching away of material usually at roller spacing.

  • Page 109: Fatigue Spalling

    Fatigue Spalling Figure 64 Flaking of surface metal resulting from fatigue. Replace bearing - clean all related parts. Brinelling Figure 65 Surface indentations in raceway caused by rollers either under impact loading or vibration while the bearing is not rotating. Replace bearing if rough or noisy.

  • Page 110: Heat Discoloration

    Cracked Inner Race Figure 68 Race cracked because of improper installation, cocking or poor bearing seat. Replace all parts and housings, check seals and bearings and replace if leaking. Smears Figure 69 Smearing of metal because of slippage caused by poor installa- tion, lubrication, overheating, overloads or handling damage.

  • Page 111: Stain Discoloration

    Stain Discoloration Figure 72 Discoloration can range from light brown to black caused by incorrect lubrication or moisture. If the stain can be removed by light polishing or if no evidence of overheating is visible, the bearing can be reused. Check seals and other related parts for damage.
  • Page 112 Safety, Specification and Systems Operation 1-126...

  • Page 113: Standard Torques

    Standard Torques...
  • Page 115 Safety Instructions WARNING AVOID DEATH OR SERIOUS INJURY Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing.
  • Page 116 Safety, Specification and Systems Operation 1-130...
  • Page 117 Table of Contents General Maintenance Instructions Safety Instructions ............. 107 Welding Precautions and Instructions ....... 111 Hydraulic System - General Precautions ......113 Maintenance Service and Repair Procedure..... 115 General Precautions ......115 Hydraulic System Cleanliness and Oil Leaks ....
  • Page 118 Safety, Specification and Systems Operation 1-132...

  • Page 119: Torque Values For Standard Metric Fasteners

    Torque Values for Standard Metric Fasteners NOTE: The units for the torque values are kg.m (ft lb). Grade Dia. x Pitch 10.9 12.9 3.6 (4A) 4.6 (4D) 4.8 (4S) 5.6 (5D) 5.8 (5S) 6.6 (6D) 6.8 (6S) 6.9 (6G) 8.8 (8G) (mm) (10K) (12K)
  • Page 120 Safety, Specification and Systems Operation 1-134...

  • Page 121: Torque Values For Standard U.s. Fasteners

    Torque Values for Standard U.S. Fasteners Bolt Head Type Description Grade Marking WILL HAVE NO MARKINGS IN THE CENTER OF THE HEAD. 1 or 2 Low or Medium Carbon Steel Not Heat-treated. WILL HAVE THREE RADIAL LINES. Quenched and Tempered Medium Carbon Steel. WILL HAVE 6 RADIAL LINES.
  • Page 122 NOTE: Torque values listed throughout this manual are lubricated (wet) threads; values must be increased 1/3 for non lubricated (dry) threads. Heat-treated Material Grade 5 and Grade 8 Grade 5 (3 Radial Dashes on Head) Grade 8 (6 Radial Dashes on Head) Thread Size Foot pounds (ft Newton Meter...

  • Page 123: Type 8 Phosphate Coated Hardware

    Type 8 Phosphate Coated Hard- ware This chart provides tightening torque for general purpose appli- cations using original equipment standard hardware as listed in the Parts Manual for the machine involved. DO NOT SUBSTI- TUTE. In most cases, original equipment standard hardware is defined as Type 8, coarse thread bolts, nuts and thru hardened flat washers (Rockwell "C"...
  • Page 124 Safety, Specification and Systems Operation 1-138...

  • Page 125: Torque Values For Hose Clamps

    Torque Values for Hose Clamps The following chart provides the tightening torques for hose clamps used in all rubber applications (radiator, air cleaner, oper- ating lever boots, hydraulic system, etc.). Torque Radiator, Air Cleaner, Boots, Etc. Hydraulic System Clamp Type and Size Kilogram.meter Inch Pounds (in Kilogram.meter...
  • Page 126 Safety, Specification and Systems Operation 1-140...
  • Page 127 ORFS Swivel Nut Recommended Torque Torque (kg.m) Dash Size Hose I.D. Thread Size Recommended 1/4" 9/16" 2.4 - 2.6 3/8" 11/16" 3.3 - 3.9 1/2" 13/16" 5.1 - 5.7 3/4" 1 3/16" 11.7 - 12.7 1" 1 7/16" 15.3 - 17.3 1 1/4"...
  • Page 128 Safety, Specification and Systems Operation 1-142...

  • Page 129: Torque Values For Split Flanges

    Torque Values for Split Flanges The following chart provides the tightening torques for split flange connections used in hydraulic systems. Split flanges and shoul- ders should install squarely. Install all bolts, finger tight and then torque evenly. NOTE: Over torquing bolts will damage the flanges and/or bolts, which can cause leakage.
  • Page 130 Safety, Specification and Systems Operation 1-144...

  • Page 131: Torque Wrench Extension Tools

    Torque Wrench Extension Tools Very large diameter, high-grade fasteners (nuts, bolts, cap screws, etc.) require a great deal of turning force to achieve recommended tightening torque values. Common problems that could occur as a result are: • Recommended torque exceeds the measuring capacity of the torque wrench.

  • Page 132: Other Uses For Torque Wrench Extension Tools

    • If an extension has to be fabricated that is not perfectly straight (for example, an extension made to go around an obstruction, to allow access to a difficult to tighten fastener), the materials and methods used must be solid enough to transmit full tight- ening torque.
  • Page 133 Main System...

  • Page 135: Safety Instructions

    Safety Instructions WARNING AVOID DEATH OR SERIOUS INJURY Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing.
  • Page 137 Table of Contents Standard Torques Safety Instructions ............. 129 Torque Values for Standard Metric Fasteners ....133 Torque Values for Standard U.S. Fasteners ..... 135 Type 8 Phosphate Coated Hardware ........ 137 Torque Values for Hose Clamps ........139 ORFS Swivel Nut Recommended Torque......141 Torque Values for Split Flanges ........
  • Page 138 Safety, Specification and Systems Operation 1-152...

  • Page 139: General Information

    Overview General information The main system of machine consists of Electric power system and Hydraulic system. The electric power system consists of 4 major parts which are Energy storage part, Charging part, Power distri- bution part, and Drive part. • Energy storage part: Cell, BMS •...
  • Page 140 Layout Figure 75 Reference Reference Description Description Number Number Power Distribution Unit (PDU) Fast Charging Socket Inverter Fast Charging Switch Vehicle Control Unit (VCU) On Board Charger (OBC) Battery Pack...
  • Page 141 Figure 76 Reference Reference Description Description Number Number Slow Charging Socket Inverter Main Pump Vehicle Control Unit (VCU) Motor Power Distribution Unit (PDU) Low voltage DC/DC Converter Cooler (LDC) Battery 12V...

  • Page 143: Battery Pack

    Battery Pack General Information For general information, refer to the drawings and specifications of the battery pack. • Generally, the battery can be charged at a temperature of 0°C or higher. For the module equipped with a PTC heater, the battery can even be charged at a temperature of -20°C - 0°C. •...

  • Page 144: General Maintenance

    3. Only appropriate tools should be used. If the jaws of a wrench are worn out, the wrench might slip during use, causing safety accidents. 4. Do not allow other people to stand or pass under the e-Powerpack when lifting the e-Powerpack with a crane. Before lifting the e-Powerpack, ensure that there is no one around the e-Powerpack and secure enough safe space.
  • Page 145 Layout Figure 78 Reference Reference Description Description Number Number Power Distribution Unit (PDU) Fast Charging Socket Inverter Fast Charging Switch Vehicle Control Unit (VCU) On Board Charger (OBC) Battery Pack...
  • Page 146 Figure 79 Reference Reference Description Description Number Number Slow Charging Socket Inverter Main Pump Vehicle Control Unit (VCU) Motor Power Distribution Unit (PDU) Low voltage DC/DC Converter Cooler (LDC) Battery 12V...
  • Page 149 Inverter Overview OBC (On Board Charger): A device that charges a DC battery using commercial AC power LDC (Low Voltage DC-DC Converter): A device that steps down a high voltage (DC voltage) into a low voltage Inverter: A device that drives an electric motor by converting AC or DC voltage Figure 80...
  • Page 150 Introduction The Inverter delivers smooth power and flexibility in a true dual-voltage package.A 12 V chassis-grounded system can be used for low-power circuits, while the high power, high voltage system is isolated to ensure a high level of protection against electrical shock.These AC controllers contain two microprocessors, which provide the enhanced diagnostic functions required to meet modern safety standards.
  • Page 151 Diagnostics Types of LED display DISPLAY STATUS Neither LED illuminated Controller is not powered on; or vehicle has dead battery; or severe damage. Yellow LED flashing Controller is operating normally. Yellow and red LEDs both on Controller is in Flash program mode. solid No software loaded, or an internal hardware fault detected by the Supervisor or Red LED on solid...
  • Page 153 OVERVIEW The OBC includes additional built-in features not previously seen in an industrial battery charger: • 12V BMS wake-up output • Adjustable 13.5V/27.0V DC-DC output • Full EVSE support: SAE J1772, IEC61851 Mode 2 and Mode 3 • Stackable-ready Figure 82 AC Voltage vs Power 3500 3000...

  • Page 154: In-Rush Current

    In-Rush Current If no AC is detected and all safety checks pass, the charger will pre-charge the bus to match the voltage of the traction pack, close the relay and start producing LV output. This process will take a few seconds (the 120V vari- ants take a few seconds longer than 65V models).

  • Page 155: Electrical Connections

    ELECTRICAL CONNECTIONS CAUTION Mechanical loads applied to the AC, HVDC, and LVDC connectors must be controlled by appropriate strain relief of the cable. No bend/twist/flex is allowed on the cable prior to securement. Cable must be fixed to a point structurally contiguous with the receptacle connector within 75mm from the mating interface of the plug and receptacle.
  • Page 156 AC Input Figure 84 PIN 1 PIN 3 PIN 2 DS2300605 Function Neutral Earth Ground Line...
  • Page 157 Aux DC Output Figure 85 PIN 1 PIN 2 DS2300606 Function Positive Negative...
  • Page 158 Traction DC Connection Figure 86 PIN 1 PIN 2 DS2300606 Function Negative Positive...
  • Page 159 SIG1: Signals Connector 1 (Battery) Figure 87 DS2300607 PREMIER Model BASE Model Notes CAN LO 2* 12V 5A (AC Powered only) aka LV AC-DC CAN HI 2* LVDC GND CAN HI 1* CAN HI 1 CAN LO 1* CAN LO 1 HVDC GND Reference BMS Wakeup 12V 2W max...
  • Page 160 SIG2: Signals Connector 2 (EVSE) DT13-12PB - Blank if EVSE option not installed Figure 88 DS2300608 LED-OUT-0/Actuator Release Button Vehicle Inlet LEDs/Actuator Release Button LED-OUT-1 LED-OUT-4 LED-OUT-2 LED-OUT-5 LED-OUT-3 LV GND Low Voltage Bus Ground PP PROXIMITY-IN Proximity Pilot CP CONTROL-IN Control Pilot ACTUATOR-FB Lock actuator feedback...

  • Page 161: Led Operation

    INTERFACE Figure 89 Charging Low SOC Charging High SOC Charging Complete Alert/Fault LED light DS2300609 Display / UI Status LED Operation No AC DC-DC active Sold Amber Charging: battery at low state of charge Slow GREEN breathing (1s on; 0.2s off) Charging: battery at high state of charge Fast GREEN breathing (0.4s on;...
  • Page 163 PDU (Power Distribution Unit) Figure 90 INVERTER CONN (+) INVERTER CONN (-) DS2300458...
  • Page 164 Figure 91 Pre Charge Resister Pre Charge Relay DC Charging Relay LDC Fuse LV Signal CONN Inverter CONN(+) Main Relay OBC Fuse Inverter CONN(-) LDC CONN DC Charging CONN(-) BATTERY CONN(+) DC Charging CONN(+) BATTERY CONN(-) OBC CONN(-) OBC CONN(+) DS2300459 SUPPLIER MAX CURRENT...
  • Page 165 Figure 92 INVERTER HV BATTERY CONNECTOR CONNECTOR CONNECTOR PRA FUNCTION PRE CHARGE RELAY LDC FUSE MAIN (40A) RELAY PRE CHARGE RESISTER OBC FUSE (125A) CONNECTOR DC CHARGING RELAY LV SIGNAL DC CHARGING CONNECTOR CONNECTOR DC(-) RELAY HSD RELAY LSD RELAY LSD COMMON (COMMON) MAIN(-)

  • Page 167: Inverter Troubleshooting

    Inverter Troubleshooting PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT Controller Over current 1. External short of phase U,V, or Shutdown Motor; Shut down W motor connections. 2. Motor Set: Phase current exceeded Main Contactor; Shutdown EM parameters are mis-tuned.
  • Page 168 PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT Set: Capacitor bank voltage 1. See Monitor menu » Battery: exceeded the Severe Severe B+ Overvoltage Capacitor Voltage. 2. Battery Overvoltage limit (see pages Shutdown Motor; Shutdown Main parameters are misadjusted. 3. 25 and 61) with FET bridge Contactor;...
  • Page 169 PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT Set: Digital Output 6 (pin 19) current exceeded 15 mA. 1. External load impedance on Digital Out 6 Open/Short Digital Clear: Remedy the overcurrent Digital Output 6 driver (pin 19) is Output 6 driver will not turn on.
  • Page 170 PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT Set: Electromagnetic brake driver (pin 5) is either open or EM Brake Open/Short Shutdown 1. Open or short on driver load. 2. shorted. This fault can be set EM Brake; Shutdown Throttle; Dirty connector pins.
  • Page 171 PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT Set: Throttle pot wiper (pin 16) voltage is lower than the low 1. See Monitor menu » Inputs: fault threshold (can be Throttle Wiper Low Shutdown Throttle Pot. 2. Throttle pot wiper changed with the VCL function Throttle.
  • Page 172 PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT 1. These faults can be defined by Set: See OEM documentation. OEM Faults (See OEM the OEM and are implemented in 51–67 Clear: See OEM documentation.) the application-specific VCL code. documentation.
  • Page 173 PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT 1. See Monitor menu » Battery: Insulation Resistance. 2. Insulation Resistance Fault Insulation Resistance Low Set: Insulation Resistance threshold set too high. 3. Electrical Isolation monitor will open circuit dropped below Insulation fault path between high power its connection between the high...
  • Page 174 PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT Encoder Pulse Count Fault Shutdown Motor; Shutdown Main Set: Motor lost IFO control and Contactor; Shutdown EM Brake; accelerated without throttle Shutdown Throttle; Shutdown 1. Encoder Steps parameter does command.

  • Page 175: Hydraulic System

    Hydraulic System...

  • Page 177: Safety Instructions

    Safety Instructions WARNING AVOID DEATH OR SERIOUS INJURY Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing.
  • Page 179 Table of Contents Main System Safety, Specification and Systems Operation 1-193...
  • Page 180 Safety, Specification and Systems Operation 1-194...

  • Page 181: Main Control Valve

    Main Control Valve Overview • Open Center System with adjustable displacement Figure 105 DS2200270 Safety, Specification and Systems Operation 1-203...
  • Page 182 Figure 106 DS2200271 Safety, Specification and Systems Operation 1-204...

  • Page 183: Hydraulic Circuit

    Hydraulic Circuit Figure 107 DS2200272 The pump flow is delivered into each element of the MCV and it has an individual main relief valve for controlling each side system. P3 inlet block has a con flux spool for supporting boom up and travel straight operation.
  • Page 184 6. Conflux valve (for boom up, travel straight) 7. Orifice for pilot signal (auto idle) 8. Load check valve Safety, Specification and Systems Operation 1-206...

  • Page 185: Working Principle

    Working principle Neutral position (Main) Figure 109 DS2200274 The main relief of P1 is in charge of Travel, Boom, and bucket, P2 is in charger of travel and Arm and Option (Two way). The main relief of P3 is in charge of swing, Boom swing, dozer, and option (Rotating).Each main relief valve controls related machine front attachment operation individually.
  • Page 186 Main spool operation Figure 111 DS2200276 In the neutral position of the spool, discharged oil from pump oil goes to tank path through the spool centerline. But spool is shifted for working, the pump oil goes to the actuator and returns oil from actuator goes to the tank.
  • Page 187 Main spool operation (Conflux spool) Figure 112 DS2200277 The neutral position of con flux spool, P3 oil does not mix with P1 and P2 side of oil path in MCV, P3 oil is in charge of P3 side of oil path when P3 side of spool is switched. When the spool is shifted by both track traveling or boom up operation, P3 oil supports to P1 or P2 side for better front attachment operation.
  • Page 188 Figure 113 DS2200278 If under NO swing operation condition and arm crowd operation, P3 oil provides both of P1 and P2 line. When boom up operation, P3 oil provides P1 and P2 line but more oil goes to Boom and bucket side, and delivery oil amount is depended on boom up pilot pressure.When both traveling, P3 oil provide P1 line only for better boom up (Bucket) operation.
  • Page 189 Systems Operation and Description Safety, Specification and Systems Operation 1-211...
  • Page 190 Safety, Specification and Systems Operation 1-212...

  • Page 191: Safety Instructions

    Safety Instructions WARNING AVOID DEATH OR SERIOUS INJURY Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing.
  • Page 193 Table of Contents Safety Instructions Safety, Specification and Systems Operation 1-215...
  • Page 194 Safety, Specification and Systems Operation 1-216...
  • Page 195 Introduction The electrical system for this equipment is DC 12 volts. The rated voltage for all electric components is 12 volts. The system contains one 12 volts battery and a three phase AC generator with a rectifier. The electrical wiring used in the system is easily identifiable by the insulator color.
  • Page 196 Safety, Specification and Systems Operation 1-218...

  • Page 197: System Interface

    Vehicle Control Unit System Interface Figure 114 Diagnostic Connector Buzzer Switch Sensor Components Solenoid Valves EPPR Safety, Specification and Systems Operation 1-219...

  • Page 198: Input & Output List

    Input & Output list Figure 115 DS2300361 Safety, Specification and Systems Operation 1-220...

  • Page 199: Connector Pin

    VCU Controller Figure 116 DS2300594 Connector Terminal Type Res. Unit Power Power 3-13 Sensor 5V 5V PWR CAN-H CAN-L COMM. CAN Shield COMM. RS232 for 1-24 SCI-BOOT 1-22 RS232 for 1-23 Safety, Specification and Systems Operation 1-221...
  • Page 200 Connector Terminal Type Res. Unit 1-10 Pilot Cutoff ON/OFF 1-11 High Speed Switch ON/OFF 1-17 Charge SW ON/OFF 1-18 Quick Coupler Switch ON/OFF 1-19 Key Switch (Key On Signal) ON/OFF 1-20 RESERVED ON/OFF Digital Input 1-21 Emergency Stop SW ON/OFF RESERVED ON/OFF RESERVED...
  • Page 201 Connector Terminal Type Res. Unit 2-10 HV_Main Relay 2-11 Track Expansion Sol V/V 2-12 Working Lamp Relay 1-25 RESERVED (Remove Diode) 1-26 FAN PWM Signal 1-12 LV Main Relay + 1-13 LV Main Relay - PWM Output 3-10 BMS Wake Up + 3-11 BMS Wake Up - 3-21...
  • Page 202 Safety, Specification and Systems Operation 1-224...
  • Page 203 Service Menu tree Service Menu tree, Depth Monitoring Analog Input Analog Output Digital Input Digital Output BMS Signal PMI Signal TMS Information GPS Information Network Information Terminal Information Graph Graph Data Monitoring Graph Data Configuration Failure Information Real Time Failure Information Failure Log Information Operation Hour Information Operation Mode...
  • Page 204 Safety, Specification and Systems Operation 1-226...
  • Page 205 Safety, Specification and Systems Operation 1-227...

  • Page 206: Removal And Installation

    Removal and Installation...
  • Page 208 Hydraulic Systems and Structure...

  • Page 210: Safety Instructions

    (PARTS BOOK) should be used. 4. HD HYUNDAI CONSTRUCTION EQUIPMENT shall not be held accountable for any critical damage or faults which have been caused by the use of unauthorized or remanufactured part.
  • Page 211 4. Do not allow other people to stand or pass under the e-Power- pack when lifting the e-Powerpack with a crane. Before lifting the e-Powerpack, ensure that there is no one around the e-Powerpack and secure enough safe space. 5. Before inspecting or replacing electrical equipment, discon- nect the battery ground wire first.
  • Page 212 3. Only genuine parts should be used for repair. Using unautho- rized or remanufactured parts may cause critical damage and faults in the e-Powerpack for which HD HYUNDAI CONSTRUCTION EQUIPMENT shall not be held account- able. Removal and Installation...
  • Page 213 Removal and Installation...
  • Page 214 Table of Contents Removal and Installation...
  • Page 215 Hydraulic Systems and Structure Safety Instructions..............5 General Information ......5 Cautions for Inspection and Repair....5 General Repair Work .
  • Page 216 Repair Procedure Quick Guide ....41 Removal ........41 Installation .
  • Page 217 Removal and Installation 2-12...

  • Page 218: Before Removing And Installing

    Before Removing and Installing Preparatory Work 1. Park the machine on level ground. And lower front attachment Figure 1 to the ground. 2. Move safety lever to "LOCK" position and then stop the motor. Lock 3. Turn battery disconnect switch to "OFF" position. 4.
  • Page 219 Removal and Installation 2-14...

  • Page 220: Undercovers

    Undercovers Repair Procedure Quick Guide Step-A. Place the machine in the suitable service position Step-B. Remove undercovers Removal Undercovers Figure 3 1. Position the machine on even, firm and level ground. 2. Put attachment on ground. NOTE: Place the machine in the suitable service position 3.
  • Page 221 Removal and Installation 2-16...

  • Page 222: Joystick Valve(Work Lever)

    Joystick Valve(Work Lever) Repair Procedure Quick Guide Step-A. Remove armrest Step-B. Remove stand covers Step-C. Remove control stand bracket Step-D. Disconnect hydraulic hoses and fittings Step-E. Remove joystick valve Removal 1. Turn OFF the battery disconnect switch. Arm Rest 1. Remove the mounting bolts (1) from arm rest. Figure 4 •...
  • Page 223 Stand Cover - Right Side 1. Remove the mounting screws and covers from upper cover. Figure 6 2. Lift off the stand right side cover. DS2300117 Control Stand Bracket Figure 7 1. Remove mounting bolts (1) and bracket (2) from stand. DS2300129 2.

  • Page 224: Installation

    Hydraulic Hoses and Fittings 1. Disconnect hydraulic hoses (1) and from joystick valve (2). Figure 9 NOTE: Attach identification tags to the removed hoses for reassembling. After disconnecting hoses from joystick valve, plug them to prevent dirt or dust from entering. DS2300131 Joystick Valve Figure 10...
  • Page 225 Removal and Installation 2-20...

  • Page 226: Main Control Valve

    Main Control Valve Repair Procedure Quick Guide Step-A. Remove right side frame cover Step-B. Drain hydraulic oil Step-C. Remove wiring harness Step-D. Disconnect hydraulic hoses Step-E. Remove main control valve Removal 1. Turn OFF the battery disconnect switch. Right Side Frame Cover 1.

  • Page 227: Wiring Harness

    Wiring Harness 1. Open the left side frame cover. Figure 13 DS2300162 2. Disconnect the harness from main control valve. Figure 14 DS2300160 Hydraulic Hoses Figure 15 1. Remove hydraulic hoses from main control valve. NOTE: Attach identification tags to the removed hoses for reassembling.

  • Page 228: Installation

    Main Control Valve 1. Separate joint balls from main control valve. Figure 16 DS2300163 2. Remove mounting bolts from frame. Figure 17 • Tool: 17 mm ( • Torque: 63.7 N.m (6.5 kg.m, 47 ft lb) • Main control valve weight: 28 kg (61.7 lb) NOTE: Apply adhesive (Loctite #262) to the mounting bolt.
  • Page 229 Removal and Installation 2-24...

  • Page 230: Main Pump

    Main Pump Repair Procedure Quick Guide Step-A. Remove right side cover Step-B. Drain hydraulic oil Step-C. Remove oil cooler Step-D. Disconnect wiring harness Step-E. Disconnect hydraulic hoses Step-F. Remove main pump Removal 1. Turn OFF the battery disconnect switch. Right Side Cover 1.

  • Page 231: Hydraulic Oil

    Hydraulic Oil 1. Loosen drain plug at the bottom of the hydraulic tank. Drain Figure 21 hydraulic oil. • Tool: 22 mm ( • Hydraulic oil tank volume: 16 L (4.2 U.S. gal) DS2300149 Oil Cooler Figure 22 1. Disconnect wiring harness (1) and hoses (2) from oil cooler. DS2300166 Figure 23 2.

  • Page 232: Installation

    Wiring Harness 1. Disconnect wiring harness from main pump. Figure 24 DS2300168 Hydraulic Hoses Figure 25 1. When disconnecting the hose, oil left in the hose may flow out. Therefore, place the end of the hose into a suitable container to prevent contamination of the ground and environment.
  • Page 233 Removal and Installation 2-28...

  • Page 234: Hydraulic Oil Tank

    Hydraulic Oil Tank Repair Procedure Quick Guide Step-A. Remove undercovers Step-B. Drain hydraulic oil Step-C. Remove front cover Step-D. Disconnect wiring harness Step-E. Remove hydraulic oil tank Removal 1. Open the battery box cover. Figure 27 2. Turn OFF the battery disconnect switch. DS2200981 Undercovers Figure 28...
  • Page 235 Hydraulic Oil 1. Loosen the oil tank air breather slowly to release the pressure Figure 29 inside the hydraulic oil tank. Pulling the air breather cap upward, the check valve opens, and the air is discharged to the atmosphere from the top of the hydraulic oil tank. 2.

  • Page 236: Front Cover

    Front Cover 1. Remove mounting cap and bolts (1) from front cover. Figure 32 • Tool: 19 mm ( • Torque: 107.9 N.m (11 kg.m, 79.6 ft lb) • (2) Cover weight: about 6.5 kg (14.3 lb) • (3) Cover weight: about 11 kg (24.3 lb) 2.

  • Page 237: Hydraulic Tank Assembly

    Figure 35 3. Remove bolts (1) from bracket. 4. Disconnect wiring harness (2) and ECU bracket bolts (3) from oil tank. 5. Remove clip bolts (4) from hydraulic tank. 6. Remove hydraulic hose (5) from hydraulic tank. DS2201533 Hydraulic Tank Assembly Figure 36 1.

  • Page 238: Swing Device

    Swing Device Repair Procedure Quick Guide Step-A. Remove floor plate Step-B. Disconnect hydraulic hoses and fittings - swing device Step-C. Remove swing device Removal 1. Turn OFF the battery disconnect switch. Floor Plate 1. Remove mat from floor. Figure 38 DS2300140 Figure 39 2.

  • Page 239: Installation

    Hydraulic Hoses and Fittings 1. Remove hoses and adapters from the swing device. Figure 40 NOTE: Attach identification tags to the removed hoses for reassembling. After disconnecting hoses from swing device, plug them to prevent dirt or dust from entering. Disconnect the hoses from the bottom to top of swing device.
  • Page 240 3. When installing the swing device, slightly move the end of bucket to align it with the swing bearing gear if the swing device does not fit the gear. Removal and Installation 2-35...
  • Page 241 Removal and Installation 2-36...

  • Page 242: Center Joint

    Center Joint Repair Procedure Quick Guide Step-A. Remove floor plate Step-B. Remove undercarriage cover Step-C. Disconnect hydraulic hoses and fittings - center joint Step-D. Remove center joint Removal 1. Turn OFF the battery disconnect switch. Floor Plate 1. Remove mat from floor. Figure 42 DS2300140 Figure 43...
  • Page 243 Undercarriage Cover 1. Remove bolts (1) and under cover (2) from frame. Figure 44 • Tool: 17 mm ( • Torque: 63.7 N.m (6.5 kg.m, 47.0 ft lb) • Undercover Weight: about 2 kg (4.4 lb) DS2300142 Hydraulic Hoses and Fittings - Center Joint 1.
  • Page 244 3. Remove mounting bolts (1) from frame. Figure 47 • Tool: 17 mm ( • Torque: 63.7 N.m (6.5 kg.m, 47.0 ft lb) NOTE: Apply adhesive (Loctite #262) to the mounting bolt. 4. Remove center joint (2) from frame. • Center joint weight: about 14 kg (30.9 lb) Installation 1.
  • Page 245 Removal and Installation 2-40...
  • Page 246 Travel Device Repair Procedure Quick Guide Step-A. Release the tension of track. Step-D. Remove rubber shoe and sprocket Step-E. Disconnect hydraulic hoses and fittings Step-F. Remove travel device Removal 1. Turn OFF the battery disconnect switch. Tension of Track 1. Position machine on a smooth level surface with adequate Figure 48 space.
  • Page 247 Figure 50 3. Slide in the idler all the way, and remove the rubber crawler from the idler using a steel bar. DS2200040 Figure 51 4. Remove bolt (1) with sprocket (2) from travel device. • Tool: 8 mm ( •...
  • Page 248 2. When disconnecting the hose, oil left in the hose may flow out. Figure 53 Therefore, place the end of the hose into a suitable container to prevent contamination of the ground and environment. EX1504170 Figure 54 3. Remove hoses and adapters from travel device. NOTE: Attach identification tags to the removed hoses for reassembling.
  • Page 249 Figure 56 2. Remove mounting bolts (1) from track frame (2). • Tool: 8 mm ( • Torque: 63.7 N.m (6.5 kg.m, 47.0 ft lb) NOTE: Apply adhesive (Loctite #262) to the mounting bolt. DS2300137 Figure 57 3. Hoist and remove travel device (1) from track frame very slowly.
  • Page 250 Counterweight Repair Procedure Quick Guide Step-A. Remove the motor cover and bracket Step-B. Remove right side cover and bracket Step-C. Remove counterweight Removal 1. Turn OFF the battery disconnect switch. 2. Position the machine on even, firm and level ground. 3.
  • Page 251 Right Side Cover and Bracket 1. Remove right side cover caps and bolts (1) from chassis Figure 60 frame. 2. Remove right side cover (2) from chassis frame. • Right side cover weight: about 5 kg (11.0 lb) DS2300113 Figure 61 3.
  • Page 252 Electric and Electronic...

  • Page 254: Safety Instructions

    (PARTS BOOK) should be used. 4. HD HYUNDAI CONSTRUCTION EQUIPMENT shall not be held accountable for any critical damage or faults which have been caused by the use of unauthorized or remanufactured part.
  • Page 255 4. Do not allow other people to stand or pass under the e-Power- pack when lifting the e-Powerpack with a crane. Before lifting the e-Powerpack, ensure that there is no one around the e-Powerpack and secure enough safe space. 5. Before inspecting or replacing electrical equipment, discon- nect the battery ground wire first.
  • Page 256 3. Only genuine parts should be used for repair. Using unautho- rized or remanufactured parts may cause critical damage and faults in the e-Powerpack for which HD HYUNDAI CONSTRUCTION EQUIPMENT shall not be held account- able. Removal and Installation...
  • Page 257 Removal and Installation 2-52...
  • Page 258 Table of Contents Electric and Electronic Safety Instructions ............... 49 General Information......49 Cautions for Inspection and Repair .
  • Page 259 Removal and Installation 2-54...

  • Page 260: Before Removing And Installing

    Before Removing and Installing Preparatory Work 1. Park the machine on level ground. And lower front attachment Figure 63 to the ground. 2. Move safety lever to "LOCK" position and then stop the motor. Lock 3. Turn battery disconnect switch to "OFF" position. 4.
  • Page 261 Removal and Installation 2-56...

  • Page 262: Battery Assembly

    Battery Assembly Repair Procedure Quick Guide Step-A. Open the rear cover Step-B. Remove terminal on the battery Step-C. Remove battery assembly Removal 1. Turn OFF the battery disconnect switch. 2. Position the machine on even, firm and level ground. 3. Put attachment on ground. NOTE: Place the machine in the suitable service position.

  • Page 263: Installation

    Battery Assembly 1. Remove the hold down bracket (2) and bolts (1). Figure 67 • Tool: 17 mm ( 2. Remove batteries from frame. Installation 1. Perform installation in the reverse order to removal. DS2300110 Removal and Installation 2-58...

  • Page 264: Installation

    TMS Controller Repair Procedure Quick Guide Step-A. Remove TMS cover Step-B. Disconnect wiring harness Step-C. Remove TMS controller Removal 1. Turn OFF the battery disconnect switch. TMS Cover 1. Remove bolts (1) and TMS cover (2). Figure 68 DS2300124 TMS Controller 1.
  • Page 265 Removal and Installation 2-60...

  • Page 266: Vcu Controller

    VCU Controller Repair Procedure Quick Guide Step-A. Remove canopy Step-B. Remove display monitor cover Step-C. Remove display monitor Step-D. Remove armrest Step-E. Remove LH/RHstand covers Step-F. Remove control stand bracket Step-G. Disconnect hydraulic hoses and fittings Step-H. Remove joystick valve Step-I.
  • Page 267 Display Monitor Cover 1. Remove display monitor cover (1) from display monitor Figure 71 bracket. DS2300119 Display Monitor 1. Disconnect wire harness connector (1) from display monitor. Figure 72 2. Remove mounting bolts (2) from display monitor bracket. 3. Remove display monitor (3) from bracket. DS2300120 Arm Rest Figure 73...
  • Page 268 Upper Stand Cover - Left Side 1. Remove mounting screws (1) and cover (2) from upper cover. Figure 74 2. Remove mounting screws (3). 3. Lift off the stand left side cover (4). DS2300128 Upper Stand Cover - Right Side 1.
  • Page 269 Figure 77 7. Pull up switches (1) by using a flat-head screwdriver. NOTE: Be careful not to break the switch assembly. DS1901319 Control Stand Bracket 1. Remove mounting bolts (1) and bracket (2) from stand. Figure 78 DS2300129 Figure 79 2.
  • Page 270 Hydraulic Hoses and Fittings 1. Disconnect hydraulic hoses (1) and from joystick valve (2). Figure 80 NOTE: Attach identification tags to the removed hoses for reassembling. After disconnecting hoses from joystick valve, plug them to prevent dirt or dust from entering. DS2300131 Joystick Valve Figure 81...
  • Page 271 Figure 83 4. Remove oil tank cover caps and bolts (1). • Tool: 13 mm ( 5. Remove oil tank cover (2). • Oil tank cover weight: about 2 kg (4.4 lb) DS2300150 Right Side Stand 1. Remove mounting bolts and screw (1) and right side cover (2). Figure 84 DS2300172 Seat and Seat Base...
  • Page 272 2. Remove left side cover caps and bolts (1) from chassis frame. Figure 86 3. Remove left side cover (2) from chassis frame. • Left side cover weight: about 4 kg (8.8 lb) DS2300122 4. Remove mounting bolts (1, 2) and seat base (3). Figure 87 •...

  • Page 273: Installation

    VCU Controller 1. Remove mounting bolt (1, 4ea) and VCU controller (2) from Figure 89 support. • VCU controller weight: about 2 kg (4.4 lb) DS2300180 Installation 1. Perform installation in the reverse order to removal. Removal and Installation 2-68...

  • Page 274: Cabin Switches

    Cabin Switches Repair Procedure Quick Guide Step-B. Remove armrest Step-C. Remove stand cover Step-D. Disconnect wiring harness Step-E. Remove switches Removal 1. Open the rear cover. 2. Turn OFF the battery disconnect switch. Arm Rest 1. Remove the mounting bolts (1) from arm rest. Figure 90 •...

  • Page 275: Installation

    Switches 1. Disconnect wire harness and screws from starter switch Figure 92 2. Remove the rock nut and quick coupler switch (1) from cover. 3. Remove the screws and motor speed control dial (2) from cover. 4. Remove the nuts and key pad (3) from cover. 5.

  • Page 276: Display Monitor

    Display Monitor Repair Procedure Quick Guide Step-A. Remove display monitor cover Step-B. Remove display monitor Removal 1. Turn OFF the battery disconnect switch. Display Monitor Cover 1. Remove display monitor cover (1) from display monitor Figure 94 bracket. DS2300119 Display Monitor 1.
  • Page 277 Removal and Installation 2-72...

  • Page 278: Hour Meter

    Hour Meter Repair Procedure Quick Guide Step-A. Remove left side cover Step-B. Remove hour meter Removal 1. Turn OFF the battery disconnect switch. Left Side Cover 1. Open the rear cover (1). Figure 96 DS2300121 2. Remove left side cover caps and bolts (1) from chassis frame. Figure 97 3.

  • Page 279: Installation

    Hour Meter 1. Disconnect wire harnesses. Figure 98 2. Remove the fastener from hour meter. 3. Remove the hour meter from support. Installation 1. Perform installation in the reverse order to removal. DS2300123 Removal and Installation 2-74...

  • Page 280: Troubleshooting Guide

    Troubleshooting Guide...

  • Page 282: Wiring Harness Layout

    Wiring Harness Layout...

  • Page 284: Safety Instructions

    Safety Instructions WARNING AVOID DEATH OR SERIOUS INJURY Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing.
  • Page 285 Troubleshooting Guide...
  • Page 286 Table of Contents Wiring Harness Layout Safety Instructions ..............5 Wiring Device ................ 9 Wiring Harness Layout ......9 Main Harness (1/2) .
  • Page 287 Troubleshooting Guide...

  • Page 288: Wiring Harness Layout

    Wiring Device Wiring Harness Layout Figure 1 E-power Harness Cabin Stand Harness Battery Harness Main Harness DS2300595 Troubleshooting Guide...

  • Page 289: Main Harness (1/2)

    Main Harness (1/2) Figure 2 Working Lamp Working Lamp Working Lamp AC Charger Indicator AC Charger Indicator AC Charger Indicator AC Charger SW AC Charger SW AC Charger SW to OBC Charging Harness to OBC Charging Harness to OBC Charging Harness to Cabin Harness_RH 1 to Cabin Harness_RH 1 to Cabin Harness_RH 1...

  • Page 290: Main Harness (2/2)

    Main Harness (2/2) Figure 3 to Cabin Harness_LH 1 to Cabin Harness_LH 1 to Cabin Harness_LH 1 to Cabin Harness_LH 3 to Cabin Harness_LH 3 to Cabin Harness_LH 3 to Cabin Harness_LH 2 to Cabin Harness_LH 2 to Cabin Harness_LH 2 Resistor 1 Resistor 1 Resistor 1...

  • Page 291: Cabin Harness

    Cabin Harness Figure 4 Key Pad Key Pad Key Pad Engine Control Dial Engine Control Dial Engine Control Dial Quick Coupler SW 1 Quick Coupler SW 1 Quick Coupler SW 1 Joystick_RH Joystick_RH Joystick_RH Key SW Key SW 12V Power Socket 12V Power Socket 12V Power Socket Display Monitor 1...

  • Page 292: E-Power Harness

    E-Power Harness Figure 5 PDU_OBC (-) PDU_OBC (-) PDU_OBC (-) PDU_OBC (+) PDU_OBC (+) PDU_OBC (+) PDU_Charging (+) PDU_Charging (+) PDU_Charging (+) PDU_Battery (-) PDU_Battery (-) PDU_Battery (-) PDU_Charging (-) PDU_Charging (-) PDU_Charging (-) PDU_Battery (+) PDU_Battery (+) PDU_Battery (+) to Main Harness to Main Harness to Main Harness...

  • Page 293: Battery Harness

    Battery Harness Figure 6 Disconnect SW to Battery (+) Disconnect SW to Battery (+) Disconnect SW to Battery (+) Battery (+) Battery (+) Battery (+) Disconnect SW Disconnect SW Disconnect SW LDC 2 LDC 2 LDC 2 LDC 1 LDC 1 LDC 1 Battery (-) Battery (-) to Battery Ground...

  • Page 294: Error Code

    Error Code...
  • Page 296 Safety Instructions WARNING AVOID DEATH OR SERIOUS INJURYInstructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments repairs or service.
  • Page 297 Troubleshooting Guide 3-18...
  • Page 298 Table of Contents Error Code Safety Instructions17 EPOS Error Code21 Troubleshooting Guide 3-19...
  • Page 299 Troubleshooting Guide 3-20...
  • Page 300 EPOS Error Code Information Mentioned in Troubleshooting Table • The following information is summarized in the troubleshooting table and the related circuit diagram. Before performing trou- bleshooting, understand that information fully. Failure Code Description of the Problems VCO001-11 GAUGE PANEL ERROR VSP004-03 Px(FRONT) PRESS.
  • Page 301 I ydraulic Schematic...
  • Page 302 Hydraulic Schematic BOOM TRAVEL DEVICE(R) TRAVEL DEVICE(L) BUCKET CYL. BOOM CYL. SWING CYL. ARM CYL. W/S CYL. BLADE CYL. 01. MAIN PUMP 02. MAIN CONTROL VALVE (Ø55xØ30-335) (Ø60xØ35-438) (Ø65xØ35-295) (Ø55xØ35-422) (Ø55xØ30-337) (Ø60xØ30-120) 03. SWING DEVICE 04. BOOM CYLINDER 05. ARM CYLINDER 06.
  • Page 303 Hydraulic Schematic BOOM TRAVEL DEVICE(L) BUCKET CYL. BOOM CYL. SWING CYL. ARM CYL. W/S CYL. BLADE CYL. TRAVEL DEVICE(R) 01. MAIN PUMP 02. MAIN CONTROL VALVE (Ø55xØ30-335) (Ø60xØ35-438) (Ø65xØ35-295) (Ø55xØ35-422) (Ø55xØ30-337) (Ø60xØ30-120) 03. SWING DEVICE 04. BOOM CYLINDER 05. ARM CYLINDER 06.
  • Page 304 Electric Schematic...
  • Page 305 Electrical Schematic INFORMATION Source INFORMATION Source INFORMATION Source GAUGE PANEL F108B Power FAST Charging Relay Active Low OBC Charging Indicator Active Low Quick Charging Ind. Active Low RESERVED Pulse_S RESERVED Low Input RESERVED Sensor CAN1_H CAN1_H RESERVED Low Input RESERVED sensor CAN1_L CAN1_L...
  • Page 306 Electrical Schematic INFORMATION Source INFORMATION Source INFORMATION Source GAUGE PANEL F108B Power FAST Charging Relay Active Low OBC Charging Indicator Active Low BATTERY Quick Charging Ind. Active Low RESERVED Pulse_S LV MAIN(87) RESERVED Low Input RESERVED Sensor CAN1_H CAN1_H RESERVED Low Input RESERVED sensor...

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