Hyundai HX220AL, Service Manual

Page 1: ...HX220AL CRAWLER EXCAVATOR SERVICE MANUAL ...

Page 2: ...4 Single Operation 160 Group 5 Combined Operation 170 SECTION 4 ELECTRICAL SYSTEM 179 Group 1 Component Location 180 Group 2 Electrical Circuit 182 Memorandum 185 Group 3 Electrical Component Specification 202 Group 4 Connectors 215 SECTION 5 MECHATRONICS SYSTEM 241 Group 1 Outline 242 Group 2 Mode Selection System 244 Group 3 Automatic Deceleration System 247 Group 4 Power Boost System 248 Group ...

Page 3: ...cs System 396 Group 5 Air Conditioner Heater System 424 SECTION 7 MAINTENANCE STANDARD 427 Group 1 Operational Performance Test 428 Group 2 Major Component 448 Group 3 Track And Work Equipment 457 SECTION 8 DISASSEMBLY AND ASSEMBLY 463 Group 1 Precautions 464 Group 2 Tightening Torque 467 Group 3 Pump Device 470 Group 4 Main Control Valve 496 Group 5 Swing Device type 1 2 520 Group 6 Travel Device...

Page 4: ... SECTION 3 HYDRAULIC SYSTEM This section explains the hydraulic circuit single and combined operation SECTION 4 ELECTRICAL SYSTEM This section explains the electrical circuit monitoring system and each component It serves not only to give an understanding electrical system but also serves as reference material for trouble shooting SECTION 5 MECHATRONICS SYSTEM This section explains the computer ai...

Page 5: ...rt any work Filing method See the page number on the bottom of the page File the pages in correct order Following examples shows how to read the page number Example 1 2 3 Item number 2 Structure and Function Consecutive page number for each item Additional pages Additional pages are indicated by a hyphen and number after the page number File as in the example 1 2 3 Symbol Item Remarks Special safe...

Page 6: ...he left to convert it to 55 mm Carry out the same procedure as above to convert 55 mm to 2 165 inches The original value 550 mm was divided by 10 so multiply 2 165 inches by 10 Move the decimal point one place to the right to return to the original value This gives 550 mm 21 65 inches 1 2 1 2 3 1 2 3 Millimeters to inches 1 mm 0 03937 in ⓑ ⓐ 0 1 2 3 4 5 6 7 8 9 0 0 039 0 079 0 118 0 157 0 197 0 23...

Page 7: ...0 3 543 3 583 3 622 3 661 3 701 3 740 3 780 3 819 3 858 3 898 Kilogram to Pound 1kg 2 2046lb 0 1 2 3 4 5 6 7 8 9 0 2 20 4 41 6 61 8 82 11 02 13 23 15 43 17 64 19 84 10 22 05 24 25 26 46 28 66 30 86 33 07 35 27 37 48 39 68 41 89 20 44 09 46 30 48 50 50 71 51 91 55 12 57 32 59 5 61 73 63 93 30 66 14 68 34 70 55 72 75 74 96 77 16 79 37 81 57 83 78 85 98 40 88 18 90 39 92 59 94 80 97 00 99 21 101 41 1...

Page 8: ... 23 247 23 511 90 23 775 24 040 24 304 24 568 24 832 25 096 25 631 25 625 25 889 26 153 Liter to U K Gallon 1ℓ 0 21997 U K Gal 0 1 2 3 4 5 6 7 8 9 0 0 220 0 440 0 660 0 880 1 100 1 320 1 540 1 760 1 980 10 2 200 2 420 2 640 2 860 3 080 3 300 3 520 3 740 3 950 4 179 20 4 399 4 619 4 839 5 059 5 279 5 499 5 719 5 939 6 159 6 379 30 6 599 6 819 7 039 7 259 7 479 7 969 7 919 8 139 8 359 8 579 40 8 799...

Page 9: ... 90 651 0 658 2 665 4 672 7 679 9 687 1 694 4 701 6 708 8 716 1 100 723 3 730 5 737 8 745 0 752 2 759 5 766 7 773 9 781 2 788 4 110 795 6 802 9 810 1 817 3 824 6 831 8 839 0 846 3 853 5 860 7 120 868 0 875 2 882 4 889 7 896 9 904 1 911 4 918 6 925 8 933 1 130 940 3 947 5 954 8 962 0 969 2 976 5 983 7 990 9 998 2 10005 4 140 1012 6 1019 9 1027 1 1034 3 1041 5 1048 8 1056 0 1063 2 1070 5 1077 7 150 ...

Page 10: ...1337 1351 1365 1380 1394 1408 100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550 110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693 120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835 130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977 140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119 150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262 160 2276 2290 2304 2318 2333 2347 2361 2375 23...

Page 11: ...2 2 90 194 0 26 1 15 5 0 6 7 20 68 0 12 8 55 131 0 32 2 90 194 0 25 6 14 6 8 6 1 21 69 8 13 3 56 132 8 32 8 91 195 8 25 0 13 8 6 5 6 22 71 6 13 9 57 134 6 33 3 92 197 6 24 4 12 10 4 5 0 23 73 4 14 4 58 136 4 33 9 93 199 4 23 9 11 12 2 4 4 24 75 2 15 0 59 138 2 34 4 94 201 2 23 3 10 14 0 3 9 25 77 0 15 6 60 140 0 35 0 95 203 0 22 8 9 15 8 3 3 26 78 8 16 1 61 141 8 35 6 96 204 8 22 2 8 17 6 2 8 27 8...

Page 12: ...SECTION 1 GENERAL Group 1 Safety Hints 1 1 Group 2 Specifications 1 10 ...

Page 13: ... excavator attach a Do Not Operate tag on the right side control lever USE HANDHOLDS AND STEPS Falling is one of the major causes of personal injury When you get on and off the machine always maintain a three point contact with the steps and handrails and face the machine Do not use any controls as handholds Never jump on or off the machine Never mount or dismount a moving machine Be careful of sl...

Page 14: ...goggles or safety glasses PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises AVOID POWER LINES Serious injury or death can result from contact with electric lines Never move any part of the machine or load closer to electri...

Page 15: ...ator starts to move Use a signal person when moving swinging or operating the machine in congested areas Coordinate hand signals before starting the excavator OPERATE ONLY FORM OPERATOR S SEAT Avoid possible injury machine damage Do not start engine by shorting across starter terminals NEVER start engine while standing on ground Start engine only from operator s seat PARK MACHINE SAFELY Before wor...

Page 16: ...LY Explosive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands HANDLE FLUIDS SAFELY AVOID FIRES Handle fuel with care It is highly flammable Do not refuel the machine while smoking or when near open flame or sparks Always stop engine before refueling machine Fill fuel tank outdoors Store flamma...

Page 17: ... ventilated area Dispose of paint and solvent properly Remove paint before welding or heating If you sand or grind paint avoid breathing the dust Wear an approved respirator If you use solvent or paint stripper remove stripper with soap and water before welding Remove solvent or paint stripper containers and other flammable material from area Allow fumes to disperse at least 15 minutes before weld...

Page 18: ...jury To prevent accidents use care when working around rotating parts AVOID HIGH PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard Protect hands and body from high pressure fluids I...

Page 19: ...ials Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area Install fire resisting guards to protect hoses or other materials PREVENT BATTERY EXPLOSIONS Keep sparks lighted matches and flame away from the top of battery Battery gas can explode Never check battery charge by placing a metal object across the posts Use a volt meter or hydrometer Do not charge a froze...

Page 20: ...or lime to help neutralize the acid 3 Flush your eyes with water for 10 15 minutes Get medical attention immediate ly If acid is swallowed 1 Drink large amounts of water or milk 2 Then drink milk of magnesia beaten eggs or vegetable oil 3 Get medical attention immediately 13031GE22 USE TOOLS PROPERLY Use tools appropriate to the work Makeshift tools parts and procedures can create safety hazards U...

Page 21: ...om them DO NOT pour oil into the ground down a drain or into a stream pond or lake Observe relevant environmental protection regulations when disposing of oil fuel coolant brake fluid filters batteries and other harmful waste REPLACE SAFETY SIGNS Replace missing or damaged safety signs See the machine operator s manual for correct safety sign placement LIVE WITH SAFETY Before returning machine to ...

Page 22: ...1 10 220A2SP01 1 MAJOR COMPONENT GROUP 2 SPECIFICATIONS ...

Page 23: ...of engine hood G 2520 8 3 2520 8 3 2520 8 3 2520 8 3 Overall height of handrail G 3210 10 6 3210 10 6 3210 10 6 3210 10 6 Minimum ground clearance H 470 1 7 470 1 7 470 1 7 470 1 7 Rear end distance I 2770 9 1 2770 9 1 2770 9 1 2770 9 1 Rear end swing radius I 2890 9 6 2890 9 6 2890 9 6 2890 9 6 Distance between tumblers J 3650 12 0 3650 12 0 3650 12 0 3650 12 0 Undercarriage length K 4404 14 5 44...

Page 24: ... 3000 9 10 Ground clearance of counterweight F 1060 3 6 Overall height of engine hood G 2520 8 3 Overall height of handrail G 3210 10 6 Minimum ground clearance H 470 1 7 Rear end distance I 2770 9 1 Rear end swing radius I 2890 9 6 Distance between tumblers J 3650 12 0 Undercarriage length K 4404 14 5 Undercarriage width L 2990 9 10 Track gauge M 2390 7 10 Track shoe width standard N 600 24 Trave...

Page 25: ... 9 10 Ground clearance of counterweight F 1060 3 6 Overall height of engine hood G 2520 8 3 Overall height of handrail G 3210 10 6 Minimum ground clearance H 470 1 7 Rear end distance I 2770 9 1 Rear end swing radius I 2890 9 6 Distance between tumblers J 3650 12 0 Undercarriage length K 4404 14 5 Undercarriage width L 3190 10 6 Track gauge M 2390 7 10 Track shoe width standard N 800 32 Travel spe...

Page 26: ... height of engine hood G 2720 8 11 2720 8 11 2720 8 11 2720 8 11 Overall height of handrail G 3410 11 2 3410 11 2 3410 11 2 3410 11 2 Minimum ground clearance H 660 2 2 660 2 2 660 2 2 660 2 2 Rear end distance I 2770 9 1 2770 9 1 2770 9 1 2770 9 1 Rear end swing radius I 2890 9 6 2890 9 6 2890 9 6 2890 9 6 Distance between tumblers J 3650 12 0 3650 12 0 3650 12 0 3650 12 0 Undercarriage length K ...

Page 27: ...1 Min swing radius F 3670 12 0 3750 12 4 3740 12 3 3700 12 2 Bucket digging force kN SAE 133 4 144 8 133 4 144 8 133 4 144 8 133 4 144 8 kgf 13600 14770 13600 14770 13600 14770 13600 14770 lbf 29980 32560 29980 32560 29980 32560 29980 32560 kN ISO 152 0 165 0 152 0 165 0 152 0 165 0 152 0 165 0 kgf 15500 16830 15500 16830 15500 16830 15500 16830 lbf 34170 37100 34170 37100 34170 37100 34170 37100 ...

Page 28: ... digging depth 8 ft level B 6290 20 8 Max vertical wall digging depth C 5560 18 3 Max digging height D 11090 36 5 Max dumping height E 8160 26 9 Min swing radius F 2530 8 4 Bucket digging force kN SAE 133 4 144 8 kgf 13600 14770 lbf 29980 32560 kN ISO 152 0 165 0 kgf 15500 16830 lbf 34170 37100 Arm digging force kN SAE 102 0 110 7 kgf 10400 11290 lbf 22930 24890 kN ISO 106 9 116 0 kgf 10900 11830 ...

Page 29: ...ax digging depth 8 ft level B 11650 38 3 Max vertical wall digging depth C 9610 31 6 Max digging height D 12550 41 2 Max dumping height E 10280 33 9 Min swing radius F 4870 16 0 Bucket digging force kN SAE 72 7 72 7 kgf 7410 7410 lbf 16340 16340 kN ISO 85 0 85 0 kgf 8670 8670 lbf 19110 19110 Arm digging force kN SAE 48 9 48 9 kgf 4990 4990 lbf 11000 11000 kN ISO 49 9 49 9 kgf 5090 5090 lbf 11220 1...

Page 30: ... 6710 22 0 7480 24 6 Min swing radius F 3670 12 0 3750 12 4 3740 12 3 3700 12 2 Bucket digging force kN SAE 133 4 144 8 133 4 144 8 133 4 144 8 133 4 144 8 kgf 13600 14770 13600 14770 13600 14770 13600 14770 lbf 29980 32560 29980 32560 29980 32560 29980 32560 kN ISO 152 0 165 0 152 0 165 0 152 0 165 0 152 0 165 0 kgf 15500 16830 15500 16830 15500 16830 15500 16830 lbf 34170 37100 34170 37100 34170...

Page 31: ...in assembly 600 mm triple grouser shoe 2EA 2 902 6 398 Track chain assembly 700 mm triple grouser shoe 2EA 3 184 7 020 3 184 7 020 Track chain assembly 800 mm triple grouser shoe 2EA 3 468 7 646 3 468 7 646 3 468 7 646 Track chain assembly 900 mm triple grouser shoe 2EA 3 750 8 267 3 750 8 267 Track chain assembly 700 mm double grouser shoe 2EA 3 458 7 624 3 458 7 624 Front attachment assembly 5 6...

Page 32: ...unterweight Shoe Wheel Dozer Outrigger HX220A L MONO BOOM Length mm Length mm weight kg width mm width mm Front Rear Front Rear 5680 2000 3800 600 A B 余 Rating over front Rating over side or 360 degree 余 Lift point height A Lift point radius B At max reach 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft 7 5 m 24 6 ft Capacity Reach m ft 7 5 m kg 5720 5720 5 00 24 6 ft lb 12610 12610 16 4 6 0 m kg 5460 54...

Page 33: ...th mm width mm Front Rear Front Rear 5680 2400 3800 600 A B 余 Rating over front Rating over side or 360 degree 余 Lift point height A Lift point radius B At max reach 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft 7 5 m 24 6 ft Capacity Reach m ft 7 5 m kg 5080 5080 5 58 24 6 ft lb 11200 11200 18 3 6 0 m kg 5010 5010 4610 4430 6 82 19 7 ft lb 11050 11050 10160 9770 22 4 4 5 m kg 6350 6350 5450 5340 5000 ...

Page 34: ... B 余 Rating over front Rating over side or 360 degree 余 Lift point height A Lift point radius B At max reach 1 5 m 4 9 ft 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft 7 5 m 24 6 ft Capacity Reach m ft 7 5 m kg 4460 4460 3370 3370 6 26 24 6 ft lb 9830 9830 7430 7430 20 5 6 0 m kg 4460 4460 3100 3100 7 38 19 7 ft lb 9830 9830 6830 6830 24 2 4 5 m kg 4970 4970 4710 3780 3020 3020 8 07 14 8 ft lb 10960 10...

Page 35: ... B 余 Rating over front Rating over side or 360 degree 余 Lift point height A Lift point radius B At max reach 1 5 m 4 9 ft 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft 7 5 m 24 6 ft Capacity Reach m ft 7 5 m kg 4460 4460 3370 3370 6 26 24 6 ft lb 9830 9830 7430 7430 20 5 6 0 m kg 4460 4460 3100 3100 7 38 19 7 ft lb 9830 9830 6830 6830 24 2 4 5 m kg 4970 4970 4710 3900 3020 3020 8 07 14 8 ft lb 10960 10...

Page 36: ...550 12920 8510 7910 7390 27 3 1 5 m kg 6500 6500 10400 10400 10350 7730 7590 5160 5910 3830 4200 3620 7 84 4 9 ft lb 14330 14330 22930 22930 22820 17040 16730 11380 13030 8440 9260 7980 25 7 3 0 m kg 11120 11120 14180 14180 9820 7790 7250 5180 5420 4250 7 00 9 8 ft lb 24520 24520 31260 31260 21650 17170 15980 11420 11950 9370 23 0 4 5 m kg 11610 11610 8190 8000 6080 5830 5 65 14 8 ft lb 25600 2560...

Page 37: ...2590 12920 9300 7910 7910 27 3 1 5 m kg 6500 6500 10400 10400 10350 8430 7590 5630 5920 4190 4200 3960 7 84 4 9 ft lb 14330 14330 22930 22930 22820 18580 16730 12410 13050 9240 9260 8730 25 7 3 0 m kg 11120 11120 14180 14180 9820 8490 7250 5660 5420 4640 7 00 9 8 ft lb 24520 24520 31260 31260 21650 18720 15980 12480 11950 10230 23 0 4 5 m kg 11610 11610 8190 8190 6080 6080 5 65 14 8 ft lb 25600 25...

Page 38: ...ht Shoe Wheel Dozer Outrigger HX220A L MONO BOOM Length mm Length mm weight kg width mm width mm Front Rear Front Rear 5680 3900 3800 600 A B Rating over front Rating over side or 360 degree Lift point height A Lift point radius B At max reach 1 5 m 4 9 ft 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft 7 5 m 24 6 ft 9 0 m 29 5 ft Capacity Reach m ft 7 5 m kg 2330 2330 7 49 24 6 ft lb 5140 5140 24 6 6 0 ...

Page 39: ...5430 9370 9370 10030 8250 7260 5490 5720 4040 2780 2780 8 85 4 9 ft lb 11970 11970 20660 20660 22110 18190 16010 12100 12610 8910 6130 6130 29 0 3 0 m kg 8510 8510 13040 13040 10030 8210 7340 5450 5660 4030 3380 3380 8 12 9 8 ft lb 18760 18760 28750 28750 22110 18100 16180 12020 12480 8880 7450 7450 26 6 4 5 m kg 12380 12380 13530 13530 9220 8320 6720 5530 4660 4540 6 99 14 8 ft lb 27290 27290 298...

Page 40: ...justments to the rated load as necessory for non standard configurations Lift point height A Lift point radius B At max reach 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft 7 5 m 24 6 ft Capacity Reach m ft 9 0 m kg 4550 4550 4 46 29 5 ft lb 10030 10030 14 6 7 5 m kg 6200 6200 5300 5300 3630 3630 6 32 24 6 ft lb 13670 13670 11680 11680 8000 8000 20 7 6 0 m kg 6430 6430 5760 5560 3300 3300 7 43 19 7 ft l...

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