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Hyundai HX220 NL, Service Manual

The Hyundai HX220 NL Service Manual is a comprehensive guide that offers detailed instructions and helpful information for maintaining and repairing your Hyundai HX220 NL. Easily downloadable and completely free, this manual is a valuable resource for all Hyundai HX220 NL owners. Get your free copy from manualshive.com today.

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Summary of Contents for HX220 NL

Page 1: ...HX220 NL CRAWLER EXCAVATOR SERVICE MANUAL ...

Page 2: ...in Control Valve 61 Group 3 Swing Device type 1 2 88 Group 4 Travel Device type 1 2 99 Group 5 Rcv Lever 113 Group 6 Rcv Pedal 120 SECTION 3 HYDRAULIC SYSTEM 126 Group 1 Hydraulic Circuit 127 Group 2 Main Circuit 128 Group 3 Pilot Circuit 131 Group 4 Single Operation 141 Group 5 Combined Operation 151 SECTION 4 ELECTRICAL SYSTEM 160 Group 1 Component Location 161 Memorandum 166 Group 3 Electrical ...

Page 3: ...ing 337 Group 2 Hydraulic And Mechanical System 340 Group 3 Electrical System 360 Group 4 Mechatronics System 376 SECTION 7 MAINTENANCE STANDARD 406 Group 1 Operational Performance Test 407 Group 2 Major Component 427 Group 3 Track And Work Equipment 435 SECTION 8 DISASSEMBLY AND ASSEMBLY 443 Group 1 Precautions 444 Group 2 Tightening Torque 447 Group 3 Pump Device 450 Group 4 Main Control Valve 4...

Page 4: ...Group 4 Hydraulic System 617 Group 5 Undercarriage 620 Group 6 Structure 621 Group 7 Work Equipment 625 Find manuals at https best manuals com ...

Page 5: ...ngle 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...

Page 6: ...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 7: ...he 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 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...

Page 8: ...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 9: ... 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 1 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 10: ... 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 11: ...280 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 2318 233...

Page 12: ...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 13: ...SECTION 1 GENERAL Group 1 Safety Hints 1 1 Group 2 Specifications 1 10 ...

Page 14: ... excavator attach a ÖDo 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 s...

Page 15: ...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 16: ...r 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 workin...

Page 17: ...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 18: ...entilated 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 ÂIf 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 wel...

Page 19: ...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 20: ...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 21: ...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 appropriate to the work Makeshift tools parts and procedures can create safety hazards Us...

Page 22: ...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 23: ...1 10 220F2SP01 GROUP 2 SPECIFICATIONS 1 MAJOR COMPONENT ...

Page 24: ...ne hood G 2468 8 1 Overall height of guardrail G 3211 10 6 Minimum ground clearance H 480 1 7 Rear end distance I 2770 9 1 Rear end swing radius I 2850 9 4 Distance between tumblers J 3650 12 0 Undercarriage length K 4440 14 7 Undercarriage width L 2500 8 2 Track gauge M 2000 6 7 Track shoe width standard N 500 20 Travel speed low high km hr mph 3 4 5 3 2 1 3 3 Swing speed rpm 12 0 Gradeability De...

Page 25: ...0 35190 151 0 164 0 15400 16720 33950 36860 2 4 m 7 10 Arm 9510 mm 9340 mm 6150 mm 5950 mm 5780 mm 9500 mm 6660 mm 3630 mm 31 2 30 8 20 2 19 6 19 0 31 2 21 10 11 11 2 92 m 9 7 Arm 9960 mm 9800 mm 6640 mm 6470 mm 6250 mm 9740 mm 6900 mm 3580 mm 32 8 32 2 21 9 21 3 20 6 31 11 22 8 11 9 133 4 144 8 13600 14770 29980 32550 152 0 165 0 15500 16830 34170 37100 119 6 129 9 12200 13250 26900 29210 125 5 1...

Page 26: ...29980 32550 152 0 165 0 15500 16830 34170 37100 119 6 129 9 12200 13250 26900 29210 125 5 136 3 12800 13900 28220 30640 133 4 144 8 13600 14770 29980 32550 152 0 165 0 15500 16830 34170 37100 102 0 110 7 10400 11290 22930 24900 106 9 116 1 10900 11830 24030 26090 SAE ISO SAE ISO kN kgf lbf kN kgf lbf kN kgf lbf kN kgf lbf kN kgf lbf kN kgf lbf kN kgf lbf kN kgf lbf kN kgf lbf kN kgf lbf kN kgf lbf...

Page 27: ... 56 123 Track chain assembly 500 mm standard triple grouser shoe 1309 2886 Front attachment assembly 5 65 m boom assembly 1370 3020 2 92 m arm assembly 760 1680 0 87 m3 SAE heaped bucket 800 1760 Boom cylinder assembly 180 1EA 400 1EA Arm cylinder assembly 290 640 Bucket cylinder assembly 175 390 Bucket control link assembly 170 370 This information is different with operating and transportation w...

Page 28: ...chine on firm level ground or 87 of full hydraulic capacity The load point is a hook located on the back of the bucket indicates load limited by hydraulic capacity Load point height Load radius At max reach 3 0 m 10 ft 4 5 m 15 ft 6 0 m 20 ft 7 5 m 25 ft Capacity Reach m ft 7 5 m kg 4000 3810 6 61 25 ft lb 8820 8400 21 7 6 0 m kg 4420 4380 4060 2800 7 75 20 ft lb 9740 9660 8950 6170 25 4 4 5 m kg ...

Page 29: ...5030 26 8 3 0 m kg 14320 14320 13400 10600 9170 5470 6630 3550 4750 2940 7 09 10 ft lb 31570 31570 29540 23370 20220 12060 14620 7830 10470 6480 23 3 4 5 m kg 10790 10790 7470 5710 15 ft lb 23790 23790 16470 12590 Load point height Load radius At max reach 1 5 m 5 ft 3 0 m 10 ft 4 5 m 15 ft 6 0 m 20 ft 7 5 m 25 ft Capacity Reach m ft 7 5 m kg 3350 2890 7 76 25 ft lb 7390 6370 25 5 6 0 m kg 2140 21...

Page 30: ...0 3540 5130 2520 4020 2140 8 43 Line lb 20790 11880 15210 7800 11310 5560 8860 4720 27 7 1 5 m kg 10050 10050 8270 5380 6170 3500 3440 2490 7 77 5 ft lb 22160 22160 18230 11860 13600 7720 7580 5490 25 5 3 0 m kg 6160 5520 4350 3610 10 ft lb 13580 12170 9590 7960 Load point height Load radius At max reach 3 0 m 10 0 ft 4 5 m 15 0 ft 6 0 m 20 0 ft 7 5 m 25 0 ft Capacity Reach m ft 9 0 m kg 5730 5470...

Page 31: ... 5 m kg 6720 6720 5540 4310 4390 2860 3740 1850 9 36 15 0 ft lb 14820 14820 12210 9500 9680 6310 8250 4080 30 7 3 0 m kg 12710 12080 8080 6370 6130 4020 5040 2720 3690 1690 9 63 10 0 ft lb 28020 26630 17810 14040 13510 8860 11110 6000 8140 3730 31 6 1 5 m kg 8700 8700 9240 5740 6660 3720 5240 2570 3640 1650 9 63 5 0 ft lb 19180 19180 20370 12650 14680 8200 11550 5670 8020 3640 31 6 Ground kg 9390 ...

Page 32: ...m arm 9 7 0 80m3 1 05yd3 0 70 m3 0 92 yd3 1070 mm 42 1 1160 mm 45 7 770 kg 1700 lb 呾 呾 呾 呾 呾 哂 0 87 m3 1 14 yd3 0 76 m3 0 99 yd3 1140 mm 44 9 1230 mm 48 4 800 kg 1760 lb 呾 呾 呾 呾 呾 哂 0 92 m3 1 20 yd3 0 80 m3 1 05 yd3 1190 mm 46 9 1280 mm 50 4 820 kg 1810 lb 呾 呾 哂 呾 呾 呿 1 10 m3 1 44 yd3 0 96 m3 1 26 yd3 1375 mm 54 1 1465 mm 57 7 890 kg 1960 lb 呾 哂 呿 哂 哂 呿 1 20 m3 1 57 yd3 1 05 m3 1 37 yd3 1390 mm 54...

Page 33: ...e cutter 2 0 m arm 6 7 2 4 m arm 7 10 2 92 m arm 9 7 2 0 m arm 6 7 2 4 m arm 7 10 2 92 m arm 9 7 俕0 90m3 1 18yd3 0 79m3 1 03yd3 1210mm 47 6 880 kg 1940 lb 呾 呾 哂 呾 呾 呿 俕1 05m3 1 37yd3 0 92m3 1 2yd3 1355mm 53 3 940 kg 2070 lb 呾 哂 呿 哂 哂 呿 侔0 87m3 1 14yd3 0 77m3 1 01yd3 1195mm 47 0 940 kg 2070 lb 呾 呾 哂 呾 呾 呿 Applicable for materials with density of 2000 kg m3 3370 lb yd3 or less Applicable for materia...

Page 34: ...lb kgf cm2 psi mm ft in 700 28 22870 50420 0 42 5 97 2700 8 10 600 24 22400 49380 0 48 6 83 2600 8 6 600 24 23100 50930 0 49 6 97 2600 8 6 500 20 22300 49160 0 57 8 11 2500 8 2 500 20 23000 50710 0 59 8 39 2500 8 2 Triple grouser Shapes Shoe width Operating weight Ground pressure Overall width Shoe width Operating weight Ground pressure Overall width HX220 NL MONO BOOM Model HX220 NL ADJUST BOOM C...

Page 35: ...ow speed if it is impossible to avoid going over obsta cles 余 余 余 余 余 余 余 余 侍 Table 2 SELECTION OF TRACK SHOE Suitable track shoes should be selected according to operating conditions Method of selecting shoes Confirm the category from the list of applications in table 2 then use table 1 to select the shoe Wide shoes categories B and C have limitations on applications Before using wide shoes check...

Page 36: ...se power SAE J1349 Rated gross horse power SAE J1995 Maximum torque at 1500 rpm Engine oil quantity Wet weight High idling speed Low idling speed Rated fuel consumption Starting motor Alternator Battery Specification Cummins QSB6 7 4 cycle turbocharged charger air cooled diesel engine Water cooling 6 cylinders in line 1 5 3 6 2 4 Direct injection type 107佴124 mm 4 2 佴4 9 6700 cc 409cu in 17 3 1 17...

Page 37: ...oad relief valve pressure 400 kgf cm2 5690 psi Item Specification Type Variable displacement axial piston motor Relief pressure 350 kgf cm2 4980 psi Reduction gear type 2 stage planetary Braking system Automatic spring applied hydraulic released Brake release pressure 16 1 kgf cm2 229 psi Braking torque 68 8 kgf余m 498 lbf余ft Item Specification Type Two fixed displacement axial piston motor Capacit...

Page 38: ...st Bore dia佴Rod dia佴Stroke 凱120佴凱 85佴1290 mm Cushion Extend only 2nd Bore dia佴Rod dia佴Stroke 凱160佴凱100佴1060 mm Cushion Item Width Ground pressure Link quantity Overall width HX220 NL MONO BOOM Standard 500 mm 20 0 57 kgf cm2 8 11 psi 49 2500 mm 8 2 Option 600 mm 24 0 48 kgf cm2 6 83 psi 49 2600 mm 8 6 700 mm 28 0 42 kgf cm2 5 97 psi 49 2700 mm 8 10 HX220 NL ADJUST BOOM Standard 500 mm 20 0 59 kgf ...

Page 39: ... 0 99 yd3 5 1140 mm 44 9 1230 mm 48 4 0 92 m3 1 20 yd3 0 80 m3 1 05 yd3 5 1190 mm 46 9 1280 mm 50 4 1 10 m3 1 44 yd3 0 96 m3 1 26 yd3 5 1375 mm 54 1 1465 mm 57 7 1 20 m3 1 57 yd3 1 05 m3 1 37 yd3 5 1390 mm 54 7 1480 mm 58 3 1 34 m3 1 75 yd3 1 17 m3 1 53 yd3 6 1525 mm 60 0 1615 mm 63 6 俕0 90 m3 1 18 yd3 0 79 m3 1 03 yd3 5 1210 mm 47 6 0 俕1 05 m3 1 37 yd3 0 92 m3 1 20 yd3 5 1355 mm 53 3 0 俔0 87 m3 1...

Page 40: ...articulate filter DPF Do not use any engine oil other than that specified above as it may clog the diesel particulate filter DPF For HYUNDAI genuine lubricating oils and grease for use in regions with extremely low temperatures please For HYUNDAI genuine lubricating oils and grease for use in regions with extremely low temperatures please contact HYUNDAI dealers contact HYUNDAI dealers HYUNDAI gen...

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