Hyundai Robex 260LC-9S, Service Manual

Page 1: ...Robex 260LC 9S CRAWLER EXCAVATOR SERVICE MANUAL ...

Page 2: ...2 STRUCTURE AND FUNCTION 46 Group 1 Pump Device 47 1 Structure 47 2 Function 53 Group 2 Main Control Valve 66 1 Structure 66 2 Hydraulic Circuit 72 3 Function 73 Group 3 Swing Device 101 1 Structure 101 2 Function 104 Group 4 Travel Device 112 1 Construction 112 Group 5 Rcv Lever 122 1 Structure 122 2 Functions 125 Group 6 Rcv Pedal 129 1 Structure 129 2 Function 131 SECTION 3 HYDRAULIC SYSTEM 135...

Page 3: ...Operation 160 1 Outline 160 2 Combined Swing And Boom Up Operation 161 3 Combined Swing And Arm Operation 162 4 Combined Swing And Bucket Operation 163 5 Combined Swing And Travel Operation 164 6 Combined Boom And Travel Operation 165 7 Combined Arm And Travel Operation 166 8 Combined Bucket And Travel Operation 167 SECTION 4 ELECTRICAL SYSTEM 168 Group 1 Component Location 169 1 Location 1 169 2 ...

Page 4: ...luster Type 1 252 Travel Speed Control System cluster Type 2 253 Group 6 Automatic Warming Up System cluster Type 1 254 Automatic Warming Up System cluster Type 2 255 Group 7 Engine Overheat Prevention System cluster Type 1 256 Engine Overheat Prevention System cluster Type 2 257 Group 8 Variable Power Control System cluster Type 1 258 Group 9 Attachment Flow Control System cluster Type 1 259 Grou...

Page 5: ... Overheat Warning Lamp Lights Up engine Is Started 336 5 When Air Cleaner Warning Lamp Lights Up engine Is Started 337 6 When Engine Oil Pressure Warning Lamp Lights Up engine Is Started 338 7 When Hydraulic Oil Temperature Warning Lamp Lights Up engine Is Started 339 8 When Coolant Temperature Gauge Does Not Operate hcespn 304 Fmi 3 Or 4 340 9 When Fuel Gauge Does Not Operate hcespn 301 Fmi 3 Or ...

Page 6: ...p 4 Mechatronics System cluster Type 1 365 1 All Actuators Speed Are Slow 365 2 Engine Stall 367 3 Malfunction Of Cluster Or Mode Selection System 369 4 Malfunction Of Accel Dial 370 5 Auto Decel System Does Not Work 372 6 Malfunction Of Pump 1 Pressure Sensor 374 7 Malfunction Of Pump 2 Pressure Sensor 376 8 Malfunction Of Pump 3 Pressure Sensor 378 9 Malfunction Of Swing Pressure Sensor 380 10 M...

Page 7: ...Components 448 2 Torque Chart 449 Group 3 Pump Device 451 1 Removal And Install 451 2 Main Pump 1 2 453 3 Regulator 1 2 463 Group 4 Main Control Valve 474 1 Removal And Install Of Motor 474 2 Structure 475 3 Disassembly And Assembly 480 Group 5 Swing Device 495 1 Removal And Install Of Motor 495 2 Disassembly And Assembly Of Swing Motor 496 3 Removal And Install Of Reduction Gear 509 4 Disassembly...

Page 8: ... Link 591 2 Carrier Roller 592 3 Track Roller 593 4 Idler And Recoil Spring 594 Group 11 Work Equipment 603 1 Structure 603 2 Removal And Install 604 SECTION 9 COMPONENT MOUNTING TORQUE 607 Group 1 Introduction Guide 608 Group 2 Engine System 609 Group 3 Electric System 611 Group 4 Hydraulic System 613 Group 5 Undercarriage 616 Group 6 Structure 618 Group 7 Work Equipment 622 Find manuals at https...

Page 9: ...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 10: ...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 11: ...table so divide by 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 inch...

Page 12: ...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 13: ...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 14: ... 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 15: ...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 16: ...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 17: ...SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety Hints 1 1 Group 2 Specifications 1 10 ...

Page 18: ...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 19: ...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 20: ...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 21: ...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 22: ...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 23: ... 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 24: ...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 25: ...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 26: ...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 27: ...wing motor Bucket Tooth Cab Boom cylinder Boom Arm cylinder Arm Muffler Counterweight Bucket cylinder Side cutter Connecting link Connecting rod Idler Track roller Carrier roller Track Sprocket Travel motor 2609S2SP01 Connecting rod 1 MAJOR COMPONENT 1 MAJOR COMPONENT GROUP 2 SPECIFICATIONS GROUP 2 SPECIFICATIONS ...

Page 28: ... width standard Travel speed low high Swing speed Gradeability Ground pressure 600 mm shoe Max traction force km hr mph rpm Degree kgf cm2 psi kg lb 25200 55560 1 08 1 41 9920 32 7 3180 10 5 3220 10 7 2840 9 4 2990 9 10 1115 3 8 2427 8 0 480 1 7 2870 9 5 2975 9 9 3830 12 7 4640 15 3 3180 10 5 2580 8 6 600 24 3 4 5 5 2 1 3 4 12 5 35 70 0 51 7 25 21600 47600 Specification Unit Description A B C D E ...

Page 29: ...h standard Travel speed low high Swing speed Gradeability Ground pressure 600 mm shoe Max traction force kg lb m3 yd3 km hr mph rpm Degree kgf cm2 psi kg lb 25100 55300 1 08 1 41 9920 32 7 2980 9 9 3220 10 7 2840 9 4 2990 9 10 1115 3 8 2427 8 0 480 1 7 2870 9 5 2975 9 9 3830 12 7 4640 15 3 2980 9 9 2380 7 10 600 24 3 4 5 5 2 1 3 4 12 5 35 70 0 51 7 25 21600 47600 mm ft in Specification Unit Descri...

Page 30: ...ravel speed low high Swing speed Gradeability Ground pressure 600 mm shoe Max traction force kg lb m3 yd3 mm ft in km hr mph rpm Degree kgf cm2 psi kg lb 27450 60520 1 08 1 41 9760 32 0 3390 11 1 3240 10 8 2840 9 4 3345 11 0 1470 4 10 2782 9 2 765 2 6 2975 9 9 2870 9 5 4030 13 3 4940 16 2 3390 11 1 2790 9 2 600 24 3 4 5 5 2 1 3 4 12 5 35 70 0 53 7 54 21600 47600 Specification Unit Description A B ...

Page 31: ...0 Arm 34 0 33 5 23 0 22 5 20 2 31 9 21 9 13 1 156 9 171 2 16000 17450 35270 38480 178 5 194 7 18200 19850 40120 43770 130 4 142 3 13300 14510 29320 31990 134 4 146 6 13700 14950 30200 32950 156 9 171 2 16000 17450 35270 38480 178 5 194 7 18200 19850 40120 43770 114 7 125 2 11700 12760 25790 28130 118 7 129 4 12100 13200 26680 29110 SAE ISO SAE ISO kN kgf lbf kN kgf lbf kN kgf lbf kN kgf lbf kN kgf...

Page 32: ... 11 10 Arm SAE ISO SAE ISO 2609S2SP09 R260LC 9S HIGH WALKER R260LC 9S HIGH WALKER 5 85 m 19 2 BOOM 2 2 156 9 171 2 16000 17450 35270 38480 178 5 194 7 18200 19850 40120 43770 134 4 145 9 13700 14870 30200 32790 139 3 151 2 14200 15420 31310 33990 156 9 171 2 16000 17450 35270 38480 178 5 194 7 18200 19850 40120 43770 130 4 142 3 13300 14510 29320 31990 134 4 146 6 13700 14950 30200 32950 156 9 171...

Page 33: ...ser shoe Front attachment assembly 5 85 m boom 3 05 m arm 1 08 m3 SAE heaped bucket 5 85 m boom assembly 3 05 m arm assembly 1 08 m3 SAE heaped bucket Boom cylinder assembly Arm cylinder assembly Bucket cylinder assembly Bucket control rod assembly Item kg lb kg lb 10500 2360 530 136 220 345 220 200 4600 440 9750 3070 280 276 53 140 160 20 40 1500 4950 1940 1020 910 240 340 220 110 23150 5200 1170...

Page 34: ...r Track roller Track chain assembly 600 mm standard triple grouser shoe Front attachment assembly 5 85 m boom 3 05 m arm 1 08 m3 SAE heaped bucket 5 85 m boom assembly 3 05 m arm assembly 1 08 m3 SAE heaped bucket Boom cylinder assembly Arm cylinder assembly Bucket cylinder assembly Bucket control rod assembly Item 10500 2360 530 136 220 345 220 200 4600 440 12000 5280 360 276 53 200 250 55 55 186...

Page 35: ...1160 8440 8550 5030 32 0 3 0 m kg 13640 13640 8400 8400 6540 5360 5660 3620 3630 2090 9 98 10 ft lb 30070 30070 18520 18520 14420 11820 12480 7980 8000 4610 32 7 1 5 m kg 9450 9450 10870 7800 7820 4950 5750 3400 3580 2040 9 95 5 ft lb 20830 20830 23960 17200 17240 10910 12680 7500 7890 4500 32 6 1 5 m kg 9940 9940 13870 13870 12930 7090 7830 4480 5460 3140 4150 2390 9 05 5 ft lb 21910 21910 30580 ...

Page 36: ... 11790 11530 11160 7580 8510 4450 32 0 3 0 m kg 13640 13640 8400 7780 6540 4830 5660 3240 3610 1840 9 98 10 ft lb 30070 30070 18520 17150 14420 10650 12480 7140 7960 4060 32 7 1 5 m kg 9450 9450 10870 6940 7820 4420 5720 3030 3560 1790 9 95 5 ft lb 20830 20830 23960 15300 17240 9740 12610 6680 7850 3950 32 6 1 5 m kg 9940 9940 13870 12620 12870 6250 7790 3960 5430 2760 4130 2100 9 05 5 ft lb 21910...

Page 37: ...5180 4650 4590 2830 9 82 15 ft lb 12370 12370 11420 10250 10120 6240 32 2 3 0 m kg 15320 15320 9030 9030 6850 6450 5830 4430 4370 2660 9 99 10 ft lb 33770 33770 19910 19910 15100 14220 12850 9770 9630 5860 32 8 1 5 m kg 9310 9310 11350 9510 8090 6050 6510 4220 4380 2650 9 90 5 ft lb 20530 20530 25020 20970 17840 13340 14350 9300 9660 5840 32 5 1 5 m kg 10760 10760 14820 14820 13100 8920 9410 5640 ...

Page 38: ...1 44 yd3 1 30 m3 1 70 yd3 Without side cutter 760 mm 29 9 890 mm 35 0 1090 mm 42 9 1130 mm 44 5 1290 mm 50 8 1490 mm 58 7 With side cutter 880 mm 34 6 1010 mm 39 8 1210 mm 47 6 1250 mm 49 2 1410 mm 55 5 1610 mm 63 4 720 kg 1590 lb 790 kg 1740 lb 890 kg 1960 lb 910 kg 2010 lb 1010 kg 2230 lb 1080 kg 2380 lb 2 1m arm 6 11 2 5m arm 8 2 3 05m arm 10 0 3 6m arm 11 10 Recommendation 5 85m 19 2 boom Capa...

Page 39: ...m 57 5 1340 mm 52 8 With side cutter 1120 kg 2470 lb 1160 kg 2560 lb 1240 kg 2730 lb 1320 kg 2910 lb 1280 kg 2820 lb 2 1 m arm 6 11 2 5 m arm 8 2 3 05 m arm 10 0 3 6 m arm 11 10 Recommendation 5 85 m 19 2 boom Capacity Width Weight Applicable for materials with density of 2000 kgf m3 3370 lbf yd3 or less Applicable for materials with density of 1600 kgf m3 2700 lbf yd3 or less Applicable for mater...

Page 40: ...00 26200 0 44 6 26 3280 10 9 700 28 28020 61770 0 46 6 54 3280 10 9 800 32 25800 56900 0 39 5 55 3380 11 1 800 32 28400 62610 0 41 5 83 3380 11 1 900 36 26100 57500 0 35 4 98 3480 11 5 700 28 28620 63100 0 47 6 68 3280 10 9 600 24 25200 55600 0 51 7 25 3180 10 5 600 24 25100 55300 0 51 7 25 2980 9 9 600 24 27450 60520 0 53 7 54 3180 10 5 Triple grouser Double grouser Shapes Shoe width Operating we...

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