service repair workshop manual

1. CONTENTS
SECTION 1 GENERAL
Group 1 Safety Hints ---------------------------------------------------------------------------------------------------- 1-1
Group 2 Specifications ------------------------------------------------------------------------------------------------- 1-9
SECTION 2 STRUCTURE AND FUNCTION
Group 1 Pump Device -------------------------------------------------------------------------------------------------- 2-1
Group 2 Main Control Valve ----------------------------------------------------------------------------------------- 2-9
Group 3 Swing Device ------------------------------------------------------------------------------------------------- 2-25
Group 4 Travel Device -------------------------------------------------------------------------------------------------- 2-35
Group 5 RCV Lever ------------------------------------------------------------------------------------------------------ 2-41
Group 6 RCV pedal ------------------------------------------------------------------------------------------------------ 2-48
Group 7 Brake pedal(Valve) ----------------------------------------------------------------------------------------- 2-49
Group 8 Gear box --------------------------------------------------------------------------------------------------------- 2-51
Group 9 Steering valve ------------------------------------------------------------------------------------------------- 2-54
Group 10 Axle ----------------------------------------------------------------------------------------------------------------- 2-56
SECTION 3 HYDRAULIC SYSTEM
Group 1 Hydraulic Circuit --------------------------------------------------------------------------------------------- 3-1
Group 2 Main Circuit ---------------------------------------------------------------------------------------------------- 3-2
Group 3 Pilot Circuit ----------------------------------------------------------------------------------------------------- 3-5
Group 4 Single Operation --------------------------------------------------------------------------------------------- 3-10
Group 5 Combined Operation -------------------------------------------------------------------------------------- 3-25
SECTION 4 ELECTRICAL SYSTEM
Group 1 Component Location -------------------------------------------------------------------------------------- 4-1
Group 2 Monitoring system ------------------------------------------------------------------------------------------ 4-3
Group 3 Electrical Circuit ---------------------------------------------------------------------------------------------- 4-11
Group 4 Electrical Component Specification --------------------------------------------------------------- 4-28
Group 5 Connectors ----------------------------------------------------------------------------------------------------- 4-38
SECTION 5 TROUBLESHOOTING
Group 1 Before Trobleshooting ------------------------------------------------------------------------------------ 5-1
Group 2 Hydraulic and Mechanical System ---------------------------------------------------------------- 5-4
Group 3 Electrical System ------------------------------------------------------------------------------------------- 5-23

2. SECTION 6 MAINTENANCE STANDARD
Group 1 Operational Performance Test ----------------------------------------------------------------------- 6-1
Group 2 Major Components ---------------------------------------------------------------------------------------- 6-19
SECTION 7 DISASSEMBLY AND ASSEMBLY
Group 1 Precaution ------------------------------------------------------------------------------------------------------ 7-1
Group 2 Tightening Torque ------------------------------------------------------------------------------------------ 7-4
Group 3 Pump Device -------------------------------------------------------------------------------------------------- 7-7
Group 4 Main Control Valve ----------------------------------------------------------------------------------------- 7-38
Group 5 Swing Device ------------------------------------------------------------------------------------------------- 7-53
Group 6 Travel Device -------------------------------------------------------------------------------------------------- 7-74
Group 7 Gear box -------------------------------------------------------------------------------------------------------- 7-98
Group 8 Steering valve ------------------------------------------------------------------------------------------------- 7-126
Group 9 Front axle -------------------------------------------------------------------------------------------------------- 7-147
Group 10 Rear axle -------------------------------------------------------------------------------------------------------- 7-238
Group 11 RCV Lever ------------------------------------------------------------------------------------------------------ 7-310
Group 12 Turning Joint --------------------------------------------------------------------------------------------------- 7-324
Group 13 Boom, Arm and Bucket Cylinder ------------------------------------------------------------------- 7-329
Group 14 Work Equipment -------------------------------------------------------------------------------------------- 7-348
SECTION 8 COMPONENT MOUNTING TORQUE
Group 1 Introduction Guide ------------------------------------------------------------------------------------------ 8-1
Group 2 Engine System ----------------------------------------------------------------------------------------------- 8-2
Group 3 Electric System ---------------------------------------------------------------------------------------------- 8-4
Group 4 Hydraulic System ------------------------------------------------------------------------------------------- 8-5
Group 5 Undercarriage ------------------------------------------------------------------------------------------------ 8-7
Group 6 Structure --------------------------------------------------------------------------------------------------------- 8-8
Group 7 Work Equipment -------------------------------------------------------------------------------------------- 8-10

3. 0-1
FOREWORD
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
SECTION 1 GENERAL
This section explains the safety hints and gives the specification of the machine and major
components.
SECTION 2 STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
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 TROUBLESHOOTING
This section explains the troubleshooting charts correlating problems to causes.
SECTION 6 MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
SECTION 7 DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling
each component, as well as precautions to be taken for these operations.
SECTION 8 COMPONENT MOUNTING TORQUE
This section shows bolt specifications and standard torque values needed when mounting
components to the machine.
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your HYUNDAI distributor for the latest information.

4. 0-2
Revised edition mark(①②③…)
When a manual is revised, an edition mark is
recorded on the bottom outside corner of the
pages.
RRevisions
Revised pages are shown at the list of revised
pages on the between the contents page and
section 1 page.
Symbols
So that the shop manual can be of ample
practical use, important places for safety and
quality are marked with the following symbols.
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating
Any additions, amendments or other changes
will be sent to HYUNDAI distributors.
Get the most up-to-date information before you
start 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 safety precautions are
necessary when performing the
work.
Extra special safety precautions
are necessary when performing
the work because it is under
internal pressure.
Special technical precautions or
other precautions for preserving
standards are necessary when
performing the work.
Safety
Caution
※
10 - 4
10 - 4 - 1
10 - 4 - 2
10 - 5
Added pages

5. 0-3
3. CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.
Example
Method of using the Conversion Table to convert from millimeters to inches
Convert 55mm into inches.
Locate the number 50in the vertical column at the left side, take this as ⓐ, then draw a
horizontal line from ⓐ.
Locate the number 5in the row across the top, take this as ⓑ, then draw a perpendicular line
down from ⓑ.
Take the point where the two lines cross as ⓒ. This point ⓒ gives the value when converting
from millimeters to inches. Therefore, 55mm = 2.165 inches.
Convert 550mm into inches.
The number 550 does not appear in the 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.
2.
(1)
(2)
(3)
(1)
(2)
(3)
Millimeters to inches 1mm = 0.03937 in
ⓑ
ⓐ
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 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
ⓒ

6. 1. REMOVAL AND INSTALL
REMOVAL
Lower the work equipment to the ground
and stop the engine.
Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping
Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious
injury.
Loosen the drain plug under the hydraulic
tank and drain the oil from the hydraulic
tank.
·Hydraulic tank quantity : 70ℓ
(18.5 U.S.gal)
Disconnect hydraulic hoses(22, 64, 65).
Remove socket bolts(83) and disconnect
pump suction pipe(10).
WWhen pump suction pipe is
disconnected, the oil inside the piping
will flow out, so catch it in oil pan.
Sling the pump assembly and remove the
pump mounting bolts.
·Weight : 30kg(70lb)
Pull out the pump assembly from
housing.
When removing the pump assembly,
check that all the hoses have been
disconnected.
7-7
GROUP 3 PUMP DEVICE
83
10
46
49
65
A1
A2
A3
46
52
22
A4
64
1)
(1)
(2)
(3)
(4)
(5)
(6)
※
(7)
※
13031GE18
R5577DA01
R5577DA02

7. 7-8
INSTALL
Carry out installation in the reverse order
to removal.
Remove the suction strainer and clean it.
Replace return filter with new one.
Remove breather and clean it.
After adding oil to the hydraulic tank to the
specified level.
Bleed the air from the hydraulic pump.
Loosen the air vent plug.
Start the engine, run at low idling, and
check oil come out from plug.
Tighten plug.
Start the engine, run at low idling(3~5
minutes) to circulate the oil through the
system.
Confirm the hydraulic oil level and check
the hydraulic oil leak or not.
2)
(1)
(2)
(3)
(4)
(5)
(6)
①
②
③
(7)
(8)

8. 7-10
TOOLS AND TIGHTENING TORQUE
Tools
The tools necessary to disassemble/reassemble the pump are shown in the follow list.
2)
(1)
Bearing assembling jig
This is plate to stand the pump facing downward.
A square block may be used instead if the shaft end does not contact.
Jigs
Disassembling table.
(2)
①①
②
Name
Hexagonal bar spanner
Spanner
Plastic hammer
Snap ring pilers
Snap ring pilers
Standard screw-driver
Torque wrench
Grease
Adhesives
Quantity
One each
1
1
1
1
2
-
Small
Small
Size (Nominal)
5, 6, 8, 10
17, 24
Medium size
For hole (Stop ring for 72)
For shaft (Stop rings for 28 and 30)
Medium size
Wrench which can tighten at the
specified torque
-
LOCTITE #270
R55NM7HP01
R55NM7HP02
40
45ormore
Ø25
Ø19
Ø35 ~ Ø55
Ø110 or more
15

9. 7-11
Tightening torque(3)
Part name
Hexagon socket head bolt
PT Plug
PF Plug
M 6
M 8
M12
M16
M18
PT 1/16
PF 1/8
PF 1/4
1.2
3.0
10.0
24.0
34.0
0.9
1.5
3.0
8.7
21.7
72.3
174
246
6.5
10.8
21.7
0.20
0.24
0.39
0.55
0.55
0.16
0.20
0.24
5
6
10
14
14
4
5
6
Bolt size
Torque Wrench size
kgf·m lbf·ft in mm

10. 7-12
R55NM7HP03
R55NM7HP04
Remove the coupling.
3. DISASSEMBLY PROCEDURE
DISASSEMBLING THE GEARED PUMP
Remove the hexagonal socket headed
bolts (M10 × 25, 2 pieces).
Hexagonal bar spanner
(Hex. side distance : 8)
Be careful because the O-ring and filter
are provided to the match surface of the
geared pump.
1)
①
※
②
Remove the cover in a horizontal
condition.
Connect motor to work table.
Be careful because the control plate is
provided to the backside.
When the cover is difficult to remove,
knock lightly with a plastic hammer.
②
※
DISASSEMBLING THE MAIN PUMP
Remove the cover.
Remove the hexagonal socket headed
bolts. (M12 × 30, 3pieces) and (M12×
55, 1piece).
Hexagonal bar spanner
(Hex. side distance : 10)
22)
①
R55NM7HP05
R55NM7HP06

11. 7-13
Remove the O-ring from the cover.
This photo shows the state with the cover
removed.
③
④
R55NM7HP07
R55NM7HP08
Remove the spring seat.②
The removal of the control spring
Remove 2 springs(Inner and outer).
(1)
①
R55NM7HP09
R55NM7HP10

12. 7-14
The removal of rotary group
Lay the pump on the side and take out
the rotary group from the shaft.
(2)
①
Remove the plate.②
R55NM7HP11
R55NM7HP12
The removal of the shaft
Remove the C-type stop ring.
(Snap ring pliers for hole)
(3)
①
Use two standard screw-drivers to
remove the oil seal case.
②
R55NM7HP13
R55NM7HP14

13. 7-15
Remove it while knocking the shaft rear
and lightly with a plastic hammer.
Remove the O-ring.③
④
R55NM7HP15
R55NM7HP16
The removal of the hanger
Remove the hexagonal socket headed
bolts (M6 × 16, 4pieces) and plate.
Hexagonal bar spanner
(Hex. side distance : 5)
((4)
①
Remove the distance piece.②
R55NM7HP17
R55NM7HP18

14. 7-16
Remove the hanger.
Remove the bearing.③
④
R55NM7HP19
R55NM7HP20
The removal of the cover
Remove the control plate.
(5)
①
Remove the C-type stop ring.②
R55NM7HP21
R55NM7HP22

15. 7-17
Remove the filter.③
R55NM7HP23
The removal of the control piston
Remove the hexagonal socket headed
bolts. (M8 × 25, 2pieces)
Hexagonal bar spanner
(Hex. side distance : 6)
The threaded portion of the bolt is coated
with LOCTITE #270.
This disassembly must therefore be
made only when necessary.
((6)
①
Remove the cylinder and parallel pin.
Be careful because 3 O-rings are
provided to the cylinder.
②
※
Take out the piston.③
R55NM7HP24
R55NM7HP25
R55NM7HP26

16. 7-18
Take out three caned disk springs and
spring seats.
④
R55NM7HP27
The removal of the control spring
Remove the hexagonal socket headed
bolts (M8×30, 2pieces) and remove the
cover.
Hexagonal bar spanner
(Hex. side distance : 6).
((7)
①
Remove othe spring seat.②
R55NM7HP28
R55NM7HP29

17. 7-19
The removal of the relief valve
Remove the hexagonal nuts.
Since the pressure has been set, this
assembly must be made only when
necessary.
Spanner (Hex. side distance : 24).
(8)
①
※
Remove the adjusting screw.
Be careful because the shim is inserted.
②
※
R55NM7HP30
R55NM7HP31
Remove the spring.③
Remove the spool.④
R55NM7HP32
R55NM7HP33

18. 7-20
Disassembly of the shaft
Remove the bearing.
Remove the C-type stop ring.
Snap ring pliers for shaft.
(9)
①
Remove it while knocking the rear end of
shaft lightly with a plastic hammer.
②
R55NM7HP34
R55NM7HP35

19. 7-21
Disassembling the geared pump (P4)
Remove the geared pump(P4) from the
center frame.
(2)
①
Pulling out the drive gear and the idle
gear.
Remove the O-ring from the center
frame.
R55NM7HP208
DISASSEMBLING THE GEARED PUMP
Disassembling the P3 and P4 pump
Removed hexagonal socket head bolt
and nut.
Hexagonal socket wrench(8mm).
Hexagonal bar spanner(17mm).
3)
(1)
①
R55NM7HP209
R55NM7HP206
R55NM7HP207
②
③

20. 7-22
Disassembling the geared pump (P3)
Remove the square ring(10).
(3)
①
Remove the plate(5) and the guide
ring(pieces). With O-ring(6, 8).
Remove the O-ring from guide ring.
10
Remove the drive and driven gear(2, 3)
and the side plate(4) assembly.
5 68
R5577MP02
R5577MP01
②
③
Remove the plate(5).④
424 3
R5577MP04
5
R5577MP03

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22. 7-23
Fix the plate with the hexagonal socket
headed bolts (M6 × 16, 4pieces).
Hexagonal bar spanner
(Hex. side distance : 5)
Tightening torque : 1.2 ~ 1.5kgf·m
(8.7 ~ 10.8lbf·ft)
Install the bearing.
44. ASSEMBLING PROCEDURE
ASSEMBLING THE MAIN PUMP
Assembling the hanger.
1)
(1)
(2)
Install the distance piece.
Confirm that pre-load is 0.1 ± 0.2.
(3)
(4)
R55NM7HP50
R55NM7HP50A
R55NM7HP51
R55NM7HP52

23. 7-24
Assembling the shaft
Fit the shaft into the bearing(With the
bearing in the bottom) by using the press
machine and jig. If the press is not
available, use the jig in the similar manner
and drive the shaft into the bearing by
knocking with a plastic hammer.
(5)
①
Install the C-type stop ring to fix the
bearing.
②
Assembling the shaft.
Assemble the shaft into the housing.
Knock the spline end lightly with a plastic
hammer and fix the bearing outer ring
firmly into the housing hole.
③
Apply grease to the O-ring for assembling.(6)
R55NM7HP53
R55NM7HP55
R55NM7HP54
R55NM7HP56