service repair 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 ----------------------------------------------------------------------------------------- 2-20
Group 3 Swing Device ------------------------------------------------------------------------------------------------- 2-43
Group 4 Travel Device -------------------------------------------------------------------------------------------------- 2-54
Group 5 RCV Lever ----------------------------------------------------------------------------------------------------- 2-65
Group 6 RCV Pedal ----------------------------------------------------------------------------------------------------- 2-72
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 -------------------------------------------------------------------------------------------- 3-13
Group 5 Combined Operation ------------------------------------------------------------------------------------- 3-23
SECTION 4 ELECTRICAL SYSTEM
Group 1 Component Location ------------------------------------------------------------------------------------- 4-1
Group 2 Electrical Circuit --------------------------------------------------------------------------------------------- 4-3
Group 3 Electrical Component Specification --------------------------------------------------------------- 4-20
Group 4 Connectors 4-29
SECTION 5 MECHATRONICS SYSTEM
Group 1 Outline ----------------------------------------------------------------------------------------------------------- 5-1
Group 2 Mode Selection System --------------------------------------------------------------------------------- 5-3
Group 3 Automatic Deceleration System -------------------------------------------------------------------- 5-6
Group 4 Power Boost System ------------------------------------------------------------------------------------- 5-7
Group 5 Travel Speed Control System ------------------------------------------------------------------------ 5-8
Group 6 Automatic Warming Up Function ------------------------------------------------------------------ 5-9
Group 7 Engine Overheat Prevention Function ---------------------------------------------------------- 5-10
Group 8 Anti-Restart System -------------------------------------------------------------------------------------- 5-11
Group 9 Self-Diagnostic System --------------------------------------------------------------------------------- 5-12

2. Group 10 Engine Control System --------------------------------------------------------------------------------- 5-17
Group 11 EPPR(Electro Proportional Pressure Reducing) Valve -------------------------------- 5-19
Group 12 Monitoring System --------------------------------------------------------------------------------------- 5-22
Group 13 Fuel warmer System ------------------------------------------------------------------------------------- 5-33
SECTION 6 TROUBLESHOOTING
Group 1 Before Trobleshooting ------------------------------------------------------------------------------------ 6-1
Group 2 Hydraulic and Mechanical System ---------------------------------------------------------------- 6-4
Group 3 Electrical System ------------------------------------------------------------------------------------------- 6-24
Group 4 Mechatronics System ------------------------------------------------------------------------------------ 6-41
SECTION 7 MAINTENANCE STANDARD
Group 1 Operational Performance Test ----------------------------------------------------------------------- 7-1
Group 2 Major Components ---------------------------------------------------------------------------------------- 7-21
Group 3 Track and Work Equipment --------------------------------------------------------------------------- 7-29
SECTION 8 DISASSEMBLY AND ASSEMBLY
Group 1 Precaution ------------------------------------------------------------------------------------------------------ 8-1
Group 2 Tightening Torque ------------------------------------------------------------------------------------------ 8-4
Group 3 Pump Device ------------------------------------------------------------------------------------------------- 8-7
Group 4 Main Control Valve ---------------------------------------------------------------------------------------- 8-29
Group 5 Swing Device ------------------------------------------------------------------------------------------------- 8-43
Group 6 Travel Device ------------------------------------------------------------------------------------------------- 8-66
Group 7 RCV Lever ----------------------------------------------------------------------------------------------------- 8-110
Group 8 Turning Joint -------------------------------------------------------------------------------------------------- 8-125
Group 9 Boom, Arm and Bucket Cylinder ------------------------------------------------------------------- 8-130
Group 10 Undercarriage ------------------------------------------------------------------------------------------------ 8-147
Group 11 Work Equipment -------------------------------------------------------------------------------------------- 8-159
SECTION 9 COMPONENT MOUNTING TORQUE
Group 1 Introduction Guide ----------------------------------------------------------------------------------------- 9-1
Group 2 Engine System ---------------------------------------------------------------------------------------------- 9-2
Group 3 Electric System ---------------------------------------------------------------------------------------------- 9-4
Group 4 Hydraulic System ------------------------------------------------------------------------------------------- 9-6
Group 5 Undercarriage ------------------------------------------------------------------------------------------------ 9-8
Group 6 Structure -------------------------------------------------------------------------------------------------------- 9-9
Group 7 Work Equipment -------------------------------------------------------------------------------------------- 9-13

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 MECHATRONICS SYSTEM
This section explains the computer aided power optimization system and each component.
SECTION 6 TROUBLESHOOTING
This section explains the troubleshooting charts correlating problems to causes.
SECTION 7 MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
SECTION 8 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 9 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(ΗΘΙÄ)
When a manual is revised, an edition mark is
recorded on the bottom outside corner of the
pages.
R
Revisions
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
ö
10 - 4
10 - 4 - 1
10 - 4 - 2
10 - 5
Added pages

5. 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
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 ͽ, then draw a
horizontal line from ͽ.
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 Ϳ. This point Ϳ 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
;
ͽ
Ϳ

6. 1. REMOVAL AND INSTALL
BUCKET CYLINDER
Removal
Expand the arm and bucket fully, 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.
Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or dust
from entering.
Set block between bucket cylinder and
arm.
8-130
GROUP 09 BOOM, ARM AND BUCKET CYLINDERS
1)
Η
(
(1)
ö
ö
ö
ö
Disconnect bucket cylinder hoses (4) and
put plugs (5) on cylinder pipe.
Ι
Remove bolt (2), nut (3) and pull out pin
(1).
Tie the rod with wire to prevent it from
coming out.
Θ
ö
13031GE18
1408DA80
1408DA81
1408DA82

7. 8-131
Install
Carry out installation in the reverse order
to removal.
When aligning the mounting position of
the pin, do not insert your fingers in the
pin hole.
Bleed the air from the bucket cylinder.
Confirm the hydraulic oil level and check
the hydraulic oil leak or not.
Η
ö
ö
(
(2)
Sling bucket cylinder assembly(8) and
remove bolt(6) then pull out pin (5).
Remove bucket cylinder assembly(8).
ÂWeight : 140kg(310lb)
Κ
Λ
1408DA83

8. 8-132
ARM CYLINDER
Removal
Expand the arm and bucket fully, 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.
Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or dust
from entering.
Set block between arm cylinder and
boom.
2)
Η
(1)
ö
ö
ö
ö
Disconnect arm cylinder hoses (4) and
put plugs on cylinder pipe.
Disconnect greasing pipings (5).
Ι
Κ
Remove bolt (2) and pull out pin (1).
Tie the rod with wire to prevent it from
coming out.
Θ
ö
13031GE18
1408DA84
1408DA85
1408DA86

9. 8-133
Install
Carry out installation in the reverse order
to removal.
When aligning the mounting position
of the pin, do not insert your fingers in
the pin hole.
Bleed the air from the arm cylinder.
Confirm the hydraulic oil level and check
the hydraulic oil leak or not.
Η
ö
ö
(
(2)
Sling arm cylinder assembly (8) and
remove bolt (7) then pull out pin (6).
Remove arm cylinder assembly (8).
ÂWeight : 180kg (400lb)
Λ
Μ
1408DA87

10. 8-134
BOOM CYLINDER
Removal
Expand the arm and bucket fully, 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.
Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or dust
from entering.
Disconnect greasing hoses(1).
Sling boom cylinder assembly.
2
4
5
4
5
3)
Η
Θ
(
(1)
ö
ö
ö
Lower the boom cylinder assembly(6) on
a stand.
Κ
Remove bolt(4), stopper(5) and pull out
pin(2).
Tie the rod with wire to prevent it from
coming out.
Ι
ö
13031GE18
1408DA88
2107A8DA23
1408DA89

11. 8-135
7
8
9
6
Install
Carry out installation in the reverse order
to removal.
When aligning the mounting position
of the pin, do not insert your fingers in
the pin hole.
Bleed the air from the boom cylinder.
Conformed the hydraulic oil level and
check the hydraulic oil leak or not.
Η
ö
ö
(
(2)
Remove bolt (9) and pull out pin (8).
Remove boom cylinder assembly (6).
ÂWeight : 160kg (350lb)
Μ
Ν
Disconnect boom cylinder hoses (7) and
put plugs on cylinder pipe.
Λ
1408DA90
1408DA91

12. 8-136
2. DISASSEMBLY AND ASSEMBLY
STRUCTURE
Bucket cylinder
1)
(1)
4
9,10 6,7 8 3 11,12 5 27 26 11,13 2
1 16,17
14 15 18 19 20 21
28,29 28,29
24 25
Internal detail
22
23
17W78CY01
1 Tube assembly
2 Rod assembly
3 Gland
4 Bushing
5 Snap ring
6 Rod seal
7 Back-up ring
8 Buffer ring
9 Dust wiper
10 Snap ring
11 O-ring
12 Back-up ring
13 Back-up ring
14 Cushion ring
15 Piston
16 O-ring
17 Back-up ring
18 Piston seal
19 Wear ring
20 Dust ring
21 Lock nut
22 Socket head bolt
23 Band assembly
24 Pipe assembly(R)
25 Pipe assembly(B)
26 O-ring
27 Socket head bolt
28 Pin bushing
29 Dust seal

13. 8-137
Arm cylinder
(2)
Internal detail
24
9,10 6,7 4 30 5 29 3 11,12 2
1 15,16
13 14 17 18 19 23
8
31,32 31,32
27 28
25,26
17W78CY02
1 Tube assembly
2 Rod assembly
3 Gland
4 Bushing
5 Snap ring
6 Rod seal
7 Back-up ring
8 Buffer ring
9 Dust wiper
10 Snap ring
11 O-ring
12 Back-up ring
13 Cushion ring
14 Piston
15 O-ring
16 Back-up ring
17 Piston seal
18 Wear ring
19 Dust ring
23 Lock nut
24 Socket head bolt
25 Band assembly(R)
26 Band assembly(B)
27 Pipe assembly(R)
28 Pipe assembly(B)
29 O-ring
30 Socket head bolt
31 Pin bushing
32 Dust seal

14. 8-138
Boom cylinder
(3)
Internal detail
4
9,10 6,7 8 3 11,12 27 5 26 11,13 2
1 16,17
14 15 18 19 20 21
22
Internal detail
28,30 29,31
24 25
23
17W78CY03
1 Tube assembly
2 Rod assembly
3 Gland
4 Bushing
5 Snap ring
6 Rod seal
7 Buck-up ring
8 Buffer ring
9 Dust wiper
10 Snap ring
11 O-ring
12 Buck-up ring
13 Buck-up ring
14 Cushion ring
15 Piston
16 O-ring
17 Buck-up ring
18 Piston seal
19 Wear ring
20 Dust ring
21 Lock nut
22 Socket head bolt
23 Band assembly
24 Pipe assembly(R, LH/RH)
25 Pipe assembly(B, LH/RH)
26 O-ring
27 Socket head bolt
28 Pin bushing
29 Pin bushing
30 Dust seal
31 Dust seal

15. 8-139
TOOLS AND TIGHTENING TORQUE
Tools
(1)
2)
Allen wrench
Spanner
(-) Driver
Torque wrench
6
8
14
17
7
8
Small and large sizes
Capable of tightening with the specified torques
B
Part name Item Size
Torque
kgfÂm lbfÂft
T
Tightening torque
(2)
Socket head bolt
Lock nut
Piston
Bucket cylinder
Boom cylinder
Arm cylinder
Bucket cylinder
Boom cylinder
Arm cylinder
Bucket cylinder
Boom cylinder
Arm cylinder
Bucket cylinder
Boom cylinder
Arm cylinder
M18
M16
M10
M55
M55
M60
-
32Ü3.0
23Ü3.0
5.4Ü0.5
100Ü10.0
150Ü15.0
232Ü21.7
166Ü14.5
39.1Ü3.6
723Ü72.3
1085Ü109
22
24
27
30
21
21
23
15
14

16. 8-140
DISASSEMBLY
Remove cylinder head and piston rod
Procedures are based on the bucket
cylinder.
Hold the clevis section of the tube in a
vise.
Use mouth pieces so as not to damage
the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.
2
2
0
0
m
m
2
22
Hexagon
socket wrench
Cover here
with rag
Turn counter
clockwise
Full straight
sideways
Lift
Oil pan
(1)
3)
ö
Η
ö
Draw out cylinder head and rod assembly
together from tube assembly(1).
Since the rod assembly is heavy in this
case, lift the tip of the rod assembly(2)
with a crane or some means and draw it
out. However, when rod assembly(2)
has been drawn out to approximately
two thirds of its length, lift it in its center to
draw it completely.
Κ
ö
Loosen and remove socket bolts(22) of
the gland in sequence.
Cover the extracted rod assembly(2) with
rag to prevent it from being accidentally
damaged during operation.
Ι
ö
Pull out rod assembly(2) about 200mm
(7.1in). Because the rod assembly is
rather heavy, finish extending it with air
pressure after the oil draining operation.
Θ
21078DA30
21078DA31
21078DA32

17. 8-141
Piston assy
Wooden block
21
15
16
17
14
Pull straight
Lift with a crane
Plastic
hammer
Remove the cylinder head assembly
from rod assembly (2).
If it is too heavy to move, move it by
striking the flanged part of cylinder head
with a plastic hammer.
Pull it straight with cylinder head
assembly lifted with a crane.
Exercise care so as not to damage the lip
of rod bushing (4) and packing
(5,6,7,8,9,10) by the threads of rod
assembly (2).
Remove piston and cylinder head
Remove lock nut (21).
Since lock nut (21) is tightened to a high
torque, use a hydraulic and power
wrench that utilizers a hydraulic cylinder,
to remove the lock nut (21).
Remove piston assembly (15), back up
ring (17), and O-ring (16).
Ι
ö
ö
Place the removed rod assembly on a
wooden V-block that is set level.
Cover a V-block with soft rag.
Λ
ö
Note that the plated surface of rod
assembly(2) is to be lifted. For this
reason, do not use a wire sling and
others that may damage it, but use a
strong cloth belt or a rope.
(
(2)
Η
ö
Θ
21078DA33
16078DA34
14W7A8DA35

18. 8-142
20 19 18 19 20
9107 6 8 4 1211 5 11
13
Disassemble cylinder head assembly
Remove back up ring (12, 13) and O-
ring (11).
Remove snap ring (10), dust wiper (9).
Remove back up ring (7), rod seal (6),
buffer ring (8) and snap ring (5).
Exercise care in this operation not to
damage the grooves.
Do not remove seal and ring, if does not
damaged.
Do not remove bushing (4).
(4)
Η
Θ
Ι
ö
ö
ö
D
Disassemble the piston assembly
Remove wear ring (19).
Remove dust ring (20) and piston seal
(18).
Exercise care in this operation not to
damage the grooves.
(3)
Η
Θ
ö
16078DA51
14W7A8DA36

19. 8-143
3
Press here (Straight down)
Metal
9
6
Push bar
Right
Wrong
Rod seal (6) has its own fitting direction.
Therefore, confirm it before fitting them.
Fitting rod seal (6) upside down may
damage its lip. Therefore check the
correct direction that is shown in fig.
ö
ö
Fit back up ring (7), rod seal (6) and buffer
ring (8) to corresponding grooves, in that
order.
Coat each packing with hydraulic oil
before fitting it.
Insert the backup ring until one side of it
is inserted into groove.
Κ
ö
ö
Coat dust wiper (9) with grease and fit
dust wiper (9) to the bottom of the hole of
dust seal.
At this time, press a pad metal to the
metal ring of dust seal.
Fit snap ring (10) to the stop face.
Θ
Ι
A
ASSEMBLY
Assemble cylinder head assembly
Check for scratches or rough surfaces if
found smooth with an oil stone.
Coat the inner face of gland (3) with
hydraulic oil.
(1)
4)
ö
Η
14W7A8DA37
14W7A8DA37A
8-157(3) 210-7
14W7A8DA38

20. 8-144
12 11 11
13
3
18
20 19 18 19 20
15
Fit wear ring (19) and dust ring (20) to
piston (15).
Ι
Fit piston seal (18) to piston.
Put the piston seal in the warm water of
60~100Á
C for more than 5 minutes.
After assembling the piston seal, press
its outer diameter to fit in.
Θ
ö
ö
Fit back up ring (12, 13) to gland (3).
Put the backup ring in the warm water of
30~50Á
C.
Fit O-ring (11) to gland (3).
Λ
ö
Μ
A
Assemble piston assembly
Check for scratches or rough surfaces.
If found smooth with an oil stone.
Coat the outer face of piston (14) with
hydraulic oil.
(2)
ö
Η
14W7A8DA39
8-158(2) 210-7
16078DA52
16078DA53

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22. 8-145
Rod assembly
Cylinder head assembly
14
Insert
21
Piston assembly
Item
Bucket
Boom
Arm
21
21
23
100Ü10
100Ü10
100Ü10
723Ü72.3
723Ü72.3
723Ü72.3
kgfÂm lbfÂft
Fit lock nut to piston.
ÂTightening torque :
Μ
Fit piston assembly to rod assembly.
ÂTightening torque : 150Ü15.0kgfÂm
(1085Ü109lbfÂft)
Λ
Insert cushion ring (14) to rod assembly.
Note that cushion ring (14) has a
direction in which it should be fitted.
Κ
ö
I
Install piston and cylinder head
Fix the rod assembly to the work bench.
Apply hydraulic oil to the outer surface of
rod assembly (2), the inner surface of
piston and cylinder head.
Insert cylinder head assembly to rod
assembly.
(3)
Η
Θ
Ι
14W7A8DA40
16078DA54
8-159(3) 210-7
16078DA55

23. 8-146
Straight
Lift
Appply liquid packing
Fix with a bar
Place rag
Turn clockwise
Apply loctite
Overall assemble
Place a V-block on a rigid work bench.
Mount the tube assembly(1) on it and fix
the assembly by passing a bar through
the clevis pin hole to lock the assembly.
Insert the rod assembly in to the tube
assembly, while lifting and moving the
rod assembly with a crane.
Be careful not to damage piston seal by
thread of tube assembly.
Match the bolt holes in the cylinder head
flange to the tapped holes in the tube
assembly and tighten socket bolts to a
specified torque.
Refer to the table of tightening torque.
(3)
Η
Θ
ö
Ι
ö
21078DA41
21078DA42