Hyundai Robex 290LC-9MH, Service Manual

Page 1: ...Robex 290LC 9MH CRAWLER EXCAVATOR SERVICE MANUAL ...

Page 2: ...mended Oils 39 SECTION 2 STRUCTURE AND FUNCTION 40 Group 1 Pump Device 41 1 Structure 41 2 Function 47 Group 2 Main Control Valve 60 1 Structure 60 2 Hydraulic Circuit 66 3 Function 67 Group 3 Swing Device 94 1 Structure 94 2 Function 97 Group 4 Travel Device type 2 105 1 Construction 105 2 Specification 1 106 2 107 3 Operation 108 Group 4 Travel Device type 1 119 1 Construction 119 2 Specificatio...

Page 3: ...Operation 156 4 Arm Out Operation 157 5 Grapple Open Operation 158 6 Grapple Closed Operation 159 7 Swing Operation 160 8 Travel Forward And Reverse Operation 162 9 Grapple Rotation Operation 164 Group 5 Combined Operation 165 1 Outline 165 2 Combined Swing And Boom Up Operation 166 3 Combined Swing And Arm Operation 167 4 Combined Swing And Grapple Operation 168 5 Combined Swing And Travel Operat...

Page 4: ...ing Up System 235 Group 6 Engine Overheat Prevention System 236 Group 7 Variable Power Control System 237 Group 8 Anti restart System 238 1 Anti restart Function 238 Group 9 Self diagnostic System 239 3 Machine Error Codes Table 240 4 Engine Fault Code 243 Group 10 Engine Control System 252 1 Mcu And Engine Ecm electronic Control Module 2 Mcu Assembly 252 Group 11 Eppr Valve 253 1 Pump Eppr Valve ...

Page 5: ...Does Not Start Lights Up Condition 317 13 When Starting Switch On Does Not Operate 318 14 When Starting Switch Is Turned On Wiper Motor Does Not Operate 319 15 Is Turned On Head Lamp When Starting Switch Does Not Lights Up 320 16 Turned On Work Lamp When Starting Switch Is Does Not Lights Up 321 Group 4 Mechatronics Systegroup System 322 1 All Actuators Speed Are Slow 322 2 Engine Stall 324 3 Malf...

Page 6: ...all Work 388 3 Completing Work 389 Group 2 Tightening Torque 390 1 Major Components 390 2 Torque Chart 391 Group 3 Pump Device 393 1 Removal And Install 393 2 Main Pump 1 2 395 3 Regulator 405 Group 4 Main Control Valve 416 1 Removal And Install Of Motor 416 2 Structure 417 3 Disassembly And Assembly 422 Group 5 Swing Device 437 1 Removal And Install Of Motor 437 2 Swing Motor 438 3 Removal And In...

Page 7: ...Install 541 2 Disassembly And Assembly 542 Group 9 Boom And Arm Cylinder 546 1 Removal And Install 546 2 Disassembly And Assembly 550 Group 10 Undercarriage 560 1 Track Link 560 2 Carrier Roller 561 3 Track Roller 562 4 Idler And Recoil Spring 563 SECTION 9 COMPONENT MOUNTING TORQUE 572 Group 1 Introduction Guide 573 Group 2 Engine System 574 Group 3 Electric System 576 Group 4 Hydraulic System 57...

Page 8: ...TEM 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 SECTION 5 MECHATRONICS SYSTEM This section explains the computer aided power optimization system and each component SECTION 6 TROUBLESH...

Page 9: ...st up to date information before you start any work Filing method 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...

Page 10: ...10 Move the decimal point one place to the left to convert it to 55mm Carry out the same procedure as above to convert 55mm to 2 165 inches The original value 550mm 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 550mm 21 65 inches 1 1 2 1 2 3 1 2 3 Millimeters to inches Millimeters to inches 1mm 0 03937 in ⓑ...

Page 11: ...6 3 425 3 465 3 504 90 3 543 3 583 3 622 3 661 3 701 3 740 3 780 3 819 3 858 3 898 Kilogram to Pound 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...

Page 12: ...2 455 22 719 22 983 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 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...

Page 13: ... 8 622 0 629 3 636 5 643 7 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...

Page 14: ...1266 90 1280 1294 1309 1323 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...

Page 15: ...31 0 32 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 ...

Page 16: ...SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety Hints 1 1 Group 2 Specifications 1 10 ...

Page 17: ...he excavator attach a Do Not Operate Do Not Operate tag on the right side control lever USE HANDHOLDS AND STEPS 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 d...

Page 18: ...s Wear goggles or safety glasses PROTECT AGAINST NOISE 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 AVOID POWER LINES Serious injury or death can result from contact with electric lines Never move an...

Page 19: ...avator 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 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...

Page 20: ...SYSTEM SAFELY 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 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 ...

Page 21: ...side or in a well 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 mi...

Page 22: ... serious injury To prevent accidents use care when working around rotating parts AVOID HIGH PRESSURE FLUIDS 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 hand...

Page 23: ...le materials 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 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 ...

Page 24: ...r 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 PROPERLY Use tools appropriate to the work Makeshift tools parts and procedures can creat...

Page 25: ...em 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 SAFETY SIGNS Replace missing or damaged safety signs See the machine operator s manual for correct safety sign placement LIVE WITH SAFETY LIVE WITH SA...

Page 26: ...ump Fuel tank Battery box Engine Radiator Turning joint Oil cooler Main control valve Swing motor Cab Boom cylinder Boom Arm cylinder Arm Counterweight Idler Track roller Carrier roller Track Sprocket Travel motor Orange grapple Cab riser Grab 2909MH2SP01 7 8 m 25 7 BOOM 5 4 m 17 9 ARM AND 1 2 m 3 11 TILT CAB ...

Page 27: ... joint Oil cooler Main control valve Swing motor Elevating cab divice Boom cylinder Boom Arm cylinder Arm Counterweight Idler Track roller Carrier roller Track Sprocket Travel motor Orange grapple Grab Cab 2909MH2SP05 7 8 m 25 7 BOOM 5 4 m 17 9 ARM AND 2 0 m 6 7 ELEVATING CAB ...

Page 28: ...ance of counterweight F 1185 3 11 Engine cover height G 3190 10 6 Minimum ground clearance H 500 1 8 Rear end distance I 3120 10 3 Rear end swing radius I 3200 10 6 Distance between tumblers J 4030 13 3 Undercarriage length K 4883 16 0 Undercarriage width L 3400 11 2 Track gauge M 2600 8 6 Track shoe width standard N 800 32 Travel speed low high km hr mph 3 5 5 2 2 3 1 Swing speed rpm 10 5 Gradeab...

Page 29: ...d clearance of counterweight F 1185 3 11 Engine cover height G 3190 10 6 Minimum ground clearance H 500 1 8 Rear end distance I 3120 10 3 Rear end swing radius I 3200 10 6 Distance between tumblers J 4030 13 3 Undercarriage length K 4883 16 0 Undercarriage width L 3400 11 2 Track gauge M 2600 8 6 Track shoe width standard N 800 32 Travel speed low high km hr mph 3 5 5 2 2 3 1 Swing speed rpm 10 5 ...

Page 30: ...1 14 3 WORKING RANGE 3 WORKING RANGE C B A 2909MH2SP03 7 8 m 25 7 BOOM Description 5 40 m 17 9 Arm Max working reach A 13090 mm 42 11 Max working height B 14590 mm 47 10 Max working depth C 6190 mm 20 4 ...

Page 31: ... 16090 Cab and fog guard assembly 550 1210 Cab elevating device assembly 1430 3150 Tilt cab riser assembly 1 2 M 630 1390 Lower chassis assembly 10740 23680 Track frame weld assembly 3790 8360 Swing bearing 430 950 Travel motor assembly 400 880 Turning joint 54 120 Track recoil spring 205 450 Idler 252 560 Carrier roller 35 80 Track roller 54 119 Track chain assembly 800 mm standard triple grouser...

Page 32: ... 10349 6931 42 7 1 5 m kg 4895 4895 11165 9076 8820 6712 7334 5239 6282 4232 5234 3502 4649 3104 13 05 4 9 ft lb 10792 10792 24615 20009 19445 14798 16169 11551 13850 9331 11539 7722 10250 6844 42 8 Ground kg 3841 3841 11528 8685 9062 6462 7448 5080 6216 4134 5179 3451 4625 3134 12 9 Line lb 8468 8468 25416 19147 19978 14247 16420 11199 13703 9114 11418 7608 10197 6910 42 3 1 5 m kg 1928 1928 4522...

Page 33: ... 5395 6282 4362 5394 3614 4791 3206 13 05 4 9 ft lb 10792 10792 24615 20575 19445 15225 16169 11893 13850 9617 11892 7967 10562 7067 42 8 Ground kg 3841 3841 11528 8942 9062 6656 7448 5235 6281 4264 5304 3562 4625 3237 12 9 Line lb 8468 8468 25416 19714 19978 14674 16420 11541 13847 9400 11693 7853 10197 7136 42 3 1 5 m kg 1928 1928 4522 4522 11286 8734 8945 6499 7319 5128 6083 4199 4957 3539 4414...

Page 34: ...IDE 6 GRAPPLE GUIDE Item Lifting capacity Max opening width A Weight Orange grapple 0 90m3 1 18 yd3 2000mm 6 7 1400 kg 3090 lb Wood grapple 1 90m3 2 49 yd3 3500mm 11 6 2100 kg 4630 lb Standard A A 300E2SP10 2909MH2SP06 ...

Page 35: ...ER OF ROLLERS AND SHOES ON EACH SIDE NUMBER OF ROLLERS AND SHOES ON EACH SIDE Carrier rollers Track rollers Track shoes 2 EA 9 EA 48 EA Item Quantity 3 3 Model Shapes Triple grouser R290LC 9MH Tilt cab Shoe width mm in 800 32 900 36 Operating weight kg lb 32710 72110 33090 72950 Ground pressure kgf cm2 psi 0 47 6 68 0 42 5 97 Overall width mm ft in 3400 11 1 3500 11 5 R290LC 9MH Elevating cab Shoe...

Page 36: ...isplacement Compression ratio Rated gross horse power SAE J1995 Maximum torque Engine oil quantity Dry weight High idling speed Low idling speed Rated fuel consumption Starting motor Alternator Battery Specification HYUNDAI HE6 7 4 cycle turbocharged diesel engine Water cooling 6 cylinders in line 1 5 3 6 2 4 Direct injection type 107Ý124 mm 4 21 Ý4 88 6700 cc 409cu in 17 2 1 227 Hp at 1900 rpm 16...

Page 37: ...l flow Item Type Capacity Relief pressure Braking system Braking torque Brake release pressure Reduction gear type Item Specification Type 10 spools Operating method Hydraulic pilot system Main relief valve pressure 350 kgf cm2 4980 psi 380 kgf cm2 5400 psi Port relief valve pressure Boom 400 kgf cm2 5690 psi Arm 400 kgf cm2 5690 psi Bucket 400 kgf cm2 5690 psi Item Specification Type Variable dis...

Page 38: ...ylinder performance Discoloration does not cause any harmful effect on the cylinder performance SHOE SHOE 9 9 Item Specification Boom cylinder Bore dia Rod dia Stroke Ø140 Ø100 1465 mm Cushion Extend only Arm cylinder Bore dia Rod dia Stroke Ø150 Ø110 1765 mm Cushion Extend and retract Item Width Ground pressure Link quantity Overall width R290LC 9MH Tilt cab Standard 800 mm 32 0 47 kgf cm2 6 68 p...

Page 39: ...24 6 3 Swing drive Gear oil 6 0 1 6 Final drive 8 0Ý2 2 1Ý2 Hydraulic tank Hydraulic oil Tank 190 50 System 330 87 Fuel tank Diesel fuel 500 132 Fitting grease nipple Grease As required Radiator reservoir tank Mixture of antifreeze and soft water侏1 50 13 2 SAE 30 SAE 10W SAE 10W 30 SAE 15W 40 SAE 80W 90 ISO VG 46 ISO VG 68 侏ASTM D975 NO 1 ASTM D975 NO 2 侏NLGI NO 1 NLGI NO 2 Ethylene glycol base pe...

Page 40: ... 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 54 Group 4 Travel Device 2 65 Group 5 RCV Lever 2 88 Group 6 RCV Pedal 2 95 ...

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