Hyundai Mini R35Z-7 Service Manual
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
-------------------------------------------------------------------------------------------------
2-38
Group 4 Travel Device
--------------------------------------------------------------------------------------------------
2-49
Group 5 RCV Lever
------------------------------------------------------------------------------------------------------
2-68
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
--------------------------------------------------------------------------------------
3-22
SECTION 4 ELECTRICAL SYSTEM
Group 1 Component Location
--------------------------------------------------------------------------------------
4-1
Group 2 Monitoring system
------------------------------------------------------------------------------------------
4-3
Group 3 Electrical Circuit
----------------------------------------------------------------------------------------------
4-9
Group 4 Electrical Component Specification
---------------------------------------------------------------
4-25
Group 5 Connectors
-----------------------------------------------------------------------------------------------------
4-32
SECTION 5 TROUBLESHOOTING
Group 1 Before Troubleshooting
------------------------------------------------------------------------------------
5-1
Group 2 Hydraulic and Mechanical System
----------------------------------------------------------------
5-4
Group 3 Electrical System
-------------------------------------------------------------------------------------------
5-24
SECTION 6 MAINTENANCE STANDARD
Group 1 Operational Performance Test
-----------------------------------------------------------------------
6-1
Group 2 Major Components
----------------------------------------------------------------------------------------
6-21
Group 3 Track and Work Equipment
----------------------------------------------------------------------------
6-31
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
-----------------------------------------------------------------------------------------
7-33
Group 5 Swing Device
-------------------------------------------------------------------------------------------------
7-47
Group 6 Travel Device
--------------------------------------------------------------------------------------------------
7-63
Group 7 RCV Lever
------------------------------------------------------------------------------------------------------
7-90
Group 8 Turning Joint
---------------------------------------------------------------------------------------------------
7-104
Group 9 Boom, Arm and Bucket Cylinder
--------------------------------------------------------------------
7-109
Group 10 Undercarriage
------------------------------------------------------------------------------------------------
7-128
Group 11 Work Equipment
--------------------------------------------------------------------------------------------
7-141
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
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 ELECT
RICAL 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 D
ISASSEMBLY 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.
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
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 55
mm
into inches.
Locate the number 50
in
the vertical column at the left side, take this as ͽ, then draw a
horizontal line from ͽ.
Locate the number 5
in
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, 55
mm
= 2.165 inches.
Convert 550
mm
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 55
mm
.
Carry out the same procedure as above to convert 55mm to 2.165 inches.
The original value(550
mm
) 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 550
mm
= 21.65 inches.
1.
2.
(1)
(2)
(3)
(1)
(2)
(3)
Millimeters to inches
1mm= 0.03937 in
;
ͽ
01 2 3 45 67 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
Ϳ
0-4
Millimeters to inches
1mm= 0.03937
in
01 2 3 45 67 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
Kilogram to Pound
1kg= 2.2046
lb
01 2 3 45 67 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 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
0-5
Liter to U.S. Gallon
1˶ = 0.2642 U.S.Gal
01 2 3 45 67 8 9
0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 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
1˶ = 0.21997 U.K.Gal
01 2 3 45 67 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 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
0-6
kgfÂm
to
lbfÂft
1
kgfÂm
= 7.233
lbfÂft
01 2 3 45 67 8 9
7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
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 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
0-7
kgf/cm2to
lbf/in
2
1
kgf / cm2= 14.2233
lbf / in
2
01 2 3 45 67 8 9
14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 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 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 5603 2617 2631 2646 2660 2674 2688
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
TEMPERATURE
Fahrenheit-Centigrade Conversion.
A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse
is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
0-8
ÁC ÁF ÁC ÁF ÁC ÁF ÁC ÁF
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -6.7 20 68.0 12.8 55 131.0 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 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 35 95.0 21.1 70 158.0 51.7 125 257.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 172 347.0
SECTION 1 GENERAL
Group 1 Safety Hints
----------------------------------------------------------------------------------------------------
1-1
Group 2 Specifications
-------------------------------------------------------------------------------------------------
1-9
FOLLOW SAFE PROCEDURE
Unsafe work practices are dangerous.
Understand service procedure before doing
work; Do not attempt shortcuts.
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment
appropriate to the job.
WARN OTHERS OF SERVICE WORK
Unexpected machine movement can cause
serious injury.
Before performing any work on the excavator,
attach a Ö
D
Do 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 slippery conditions on platforms,
steps, and handrails when leaving the machine.
SECTION 1 GENERAL
GROUP 1 SAFETY
1-1
13031GE01
13031GE02
13031GE03
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors,
ambulance service, hospital, and fire department
near your telephone.
PROTECT AGAINST FLYING DEBRIS
Guard against injury from flying pieces of metal
or debris; Wear 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 electric line than 3m(10ft) plus twice the
line insulator length.
1-2
13031GE04
13031GE05
13031GE06
13031GE07
KEEP RIDERS OFF EXCAVATOR
Only allow the operator on the excavator. Keep
riders off.
Riders on excavator are subject to injury such
as being struck by foreign objects and being
thrown off the excavator. Riders also obstruct
the operator's view resulting in the excavator
being operated in an unsafe manner.
MOVE AND OPERATE MACHINE SAFELY
Bystanders can be run over. Know the location
of bystanders before moving, swinging, or
operating the machine.
Always keep the travel alarm in working
condition. It warns people when the excavator
starts to move.
Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the
excavator.
OPER A TE ONL Y FO R M OPER A TOR '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 working on the machine:
ÂPark machine on a level surface.
ÂLower bucket to the ground.
ÂTurn auto idle switch off.
Â
Run engine at 1/2 speed without load for 2 minutes.
ÂTurn key switch to OFF to stop engine.
Remove key from switch.
ÂMove pilot control shutoff lever to locked position.
ÂAllow engine to cool.
1-3
13031GE08
13031GE09
13031GE26
SUPPORT MACHINE PROPERLY
Always lower the attachment or implement to the
ground before you work on the machine. If you
must work on a lifted machine or attachment,
securely support the machine or attachment.
Do not support the machine on cinder blocks,
hollow tiles, or props that may crumble under
continuous load.
Do not work under a machine that is supported
solely by a jack. Follow recommended
procedures in this manual.
SERVICE COOLING 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 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 flammable fluids away from fire hazards.
Do not incinerate or puncture pressurized
containers.
Make sure machine is clean of trash, grease,
and debris.
Do not store oily rags; They can ignite and burn
spontaneously.
1-4
13031GE10
13031GE11
13031GE12
13031GE13
BEWARE OF EXHAUST FUMES
Prevent asphyxiation. Engine exhaust fumes
can cause sickness or death.
If you must operate in a building, be positive
there is adequate ventilation. Either use an
exhaust pipe extension to remove the exhaust
fumes or open doors and windows to bring
enough outside air into the area.
REMOVE PAINT BEFORE WELDING OR
HEATING
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint
is heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area.
Dispose of paint and solvent properly.
Remove paint before welding or heating:
Â
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 minutes
before welding or heating.
IILLUMINATE WORK AREA SAFELY
Illuminate your work area adequately but safely.
Use a portable safety light for working inside or
under the machine. Make sure the bulb is
enclosed by a wire cage. The hot filament of an
accidentally broken bulb can ignite spilled fuel or
oil.
1-5
13031GE14
13031GE15
SERVICE MACHINE SAFELY
Tie long hair behind your head. Do not wear a
necktie, scarf, loose clothing or necklace when
you work near machine tools or moving parts.
If these items were to get caught, severe injury
could result.
Remove rings and other jewelry to prevent
electrical shorts and entanglement in moving
parts.
STAY CLEAR OF MOVING PARTS
Entanglements in moving parts can cause
serious injury.
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.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may
result.
1-6
13031GE16
13031GE17
13031GE18
13031GE19
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
Flammable spray can be generated by heating
near pressurized fluid lines, resulting in severe
burns to yourself and bystanders. Do not heat
by welding, soldering, or using a torch near
pressurized fluid lines or other flammable
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
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 frozen battery; It may explode.
Warm battery to 16ÁC(60ÁF).
PPREVENT ACID BURNS
Sulfuric acid in battery electrolyte is poisonous. It
is strong enough to burn skin, eat holes in clothing,
and cause blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling of dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 10-15
minutes. Get medical attention immediately.
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.
1-7
13031GE20
13031GE21
13031GE22
USE TOOLS PROPERLY
Use tools appropriate to the work. Makeshift
tools, parts, and procedures can create safety
hazards.
Use power tools only to loosen threaded tools
and fasteners.
For loosening and tightening hardware, use the
correct size tools. DO NOT use U.S.
measurement tools on metric fasteners. Avoid
bodily injury caused by slipping wrenches.
Use only recommended replacement parts.(See
Parts catalogue.)
DISPOSE OF FLUIDS PROPERLY
Improperly disposing of fluids can harm the
environment and ecology. Before draining any
fluids, find out the proper way to dispose of
waste from your local environmental agency.
Use proper containers when draining fluids. Do
not use food or beverage containers that may
mislead someone into drinking from 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 customer, make
sure machine is functioning properly, especially
the safety systems. Install all guards and
shields.
1-8
13031GE23
13031GE24
13031GE25
GROUP 2 SPECIFICATIONS
1. MAJOR COMPONENT
1-9
Main control valve
Tool box
Fuel tank
Hydraulic tank
Main pump
Tooth
Turning joint
Swing motor
Engine
Oil cooler
Radiator
Bucket
Boom swing cylinder
Arm
Travel motor
Sprocket
Counterweight
Muffler
Cab
Boom cylinderBoomArm cylinder
Track
Bucket cylinder
Side cutter
Control link
Control rod
Track roller
Idler
Carrier roller
Dozer blade
Swing post
Tail pipe
R35Z72SP01
1-10
2. SPECIFICATIONS
2.5m( 8' 2") MONO BOOM, 1.3m( 4' 3") ARM, WITH BOOM SWING POST
1)
R35Z72SP02
Operating weight
Bucket capacity(SAE heaped), standard
Overall length
Overall width, with 300mmshoe
Overall height
Overall height of cab
Ground clearance of counterweight
Minimum ground clearance
Rear-end distance
Rear-end swing radius
Distance between tumblers
Undercarriage length
Undercarriage width
Track gauge
Track shoe width, standard
Height of blade
Ground clearance of blade up
Depth of blade down
Travel speed(Low/high)
Swing speed
Gradeability
Ground pressure(300mmshoe)
kg(lb)
m3(yd3)
mm(ft-in)
km/hr(mph)
rpm
Degree(
%
)
kgf/cm2(psi)
Specification
3650(8050)
0.11(0.14)
4790(15' 9")
1740( 5' 9")
2500( 8' 2")
2500( 8' 2")
540( 1' 9")
290( 0' 11")
870( 2' 10")
870( 2' 10")
1700( 5' 7")
2130( 7' 0")
1740( 5' 9")
1440( 4' 9")
300( 1' 0")
370( 1' 3")
375( 1' 3")
390( 1' 3")
2.7/4.5(1.7/2.8)
9.5
30(58)
0.34(4.83)
UnitDescription
A
B
C
E
F
H
I
I'
J
K
L
M
N
O
P
Q
I(I')
C
A
E
P
O
J
F
Q
K
H
N
M
B(L)
3. WORKING RANGE
1-11
2.5
m
(8' 2") MONO BOOM WITH BOOM SWING POST
1)
A
A'
F
D
E
8ft
B
B'
C
R35Z72SP03
Max digging reach
Max digging reach on ground
Max digging depth
Max digging depth (8ft level)
Max vertical wall digging depth
Max digging height
Max dumping height
Min swing radius
Boom swing radius(left/right)
Bucket digging force
Arm crowd force
Description
A
A'
B
B'
C
D
E
F
1.3
m
(4' 3") Arm
5360
mm
5240
mm
3150
mm
2660
mm
2190
mm
4830
mm
3460
mm
2350
mm
(17' 7")
(17' 2")
(10' 4")
( 8' 9")
( 7' 2")
(15'10")
(11' 4")
( 7' 9")
27.9
2850
6280
31.4
3200
7050
18.9
1930
4250
19.5
1990
4390
SAE
ISO
SAE
ISO
kN
kgf
lbf
kN
kgf
lbf
kN
kgf
lbf
kN
kgf
lbf
75ä/50ä
1-12
4. WEIGHT
Upperstructure assembly
Main frame weld assembly
Engine assembly
Main pump assembly
Main control valve assembly
Swing motor assembly
Hydraulic oil tank assembly
Fuel tank assembly
Boom swing post
Counterweight
Cab assembly
Lower chassis assembly
Track frame weld assembly
Swing bearing
Travel motor assembly
Turning joint
Track recoil spring
Yoke
Idler
Carrier roller
Track roller
Sprocket
Rubber track(300mm)
Dozer blade assembly
Front attachment assembly
(2.5mboom, 1.3marm, 0.11
m3SAE heaped bucket)
2.5mboom assembly
1.3marm assembly
0.11
m3SAE heaped bucket
Boom cylinder assembly
Arm cylinder assembly
Bucket cylinder assembly
Bucket control link assembly
Dozer cylinder assembly
Boom swing cylinder assembly
Item
2100
480
155
25
25
40
50
30
80
420
210
1170
400
50
35
15
12.5
5
20
2.7
7.7
7.5
127.5
140
460
140
80
80
40
40
30
20
30
30
kg lb
4630
1060
340
55
55
90
110
70
180
925
460
2580
880
110
77
35
27.5
11
44
6
17
16.5
281
310
1015
310
180
180
90
90
70
45
70
70
5. LIFTING CAPACITIES
1-13
Â
Â
: Rating over-front : Rating over-side or 360 degree
Â
2.5m( 8' 2") boom, 1.3m( 4' 3") arm equipped with 0.11
m3(SAE heaped) bucket and 300mm(12")
rubber track, the dozer blade up with 420
kg
(925lb) counterweight.
1)
Note 1.
2.
3.
4.
Lifting capacity are based on SAE J1097 and ISO 10567.
Lifting capacity of the ROBEX series does not exceed 75% of tipping load with the machine
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
1.0m(3.3ft) 2.0m(6.6ft) 3.0m(9.9ft) 4.0m(13.2ft) Capacity Reach
m(ft)
4.0
mkg
600 510 3.94
(
13.2ft)
lb
1320 1120 (12.9)
3.0
mkg
560 470 420 360 4.74
(
9.9ft)
lb
1230 1040 930 790 (15.6)
2.0
mkg
890 750 540 460 360 300 5.11
(
6.6ft)
lb
1960 1650 1190 1010 790 660 (16.8)
1.0
mkg
830 690 520 440 340 290 5.18
(
3.3ft)
lb
1830 1520 1150 970 750 640 (17.0)
-
1.0
mkg
*2100 *2100 1590 1270 780 650 500 420 440 370 4.45
(-
3.3ft)
lb
*4630 *4630 3510 2800 1720 1430 1100 930 970 820 (14.6)
-
2.0
mkg
1630 1310 810 670
(-
6.6ft)
lb
3590 2890 1790 1480
Ground
kg
1570 1260 790 650 500 420 360 300 4.98
Line
lb
3460 2780 1740 1430 1100 930 790 660 (16.3)
1-14
ÂÂ
: Rating over-front : Rating over-side or 360 degree
Â
2.5
m
( 8' 2") boom, 1.3m( 4' 3") arm equipped with 0.11
m
3
(SAE heaped) bucket and 300
mm
(12")
rubber track, the dozer blade down with 420
kg
(925lb) counterweight.
2)
Note 1.
2.
3.
4.
Lifting capacity are based on SAE J1097 and ISO 10567.
Lifting capacity of the ROBEX series does not exceed 75% of tipping load with the machine
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
1.0m(3.3ft) 2.0m(6.6ft) 3.0m(9.9ft) 4.0m(13.2ft) Capacity Reach
m(ft)
4.0
mkg
*700 510 3.94
(
13.2ft)
lb
*1540 1120 (12.9)
3.0
mkg
*760 470 *630 360 4.74
(
9.9ft)
lb
*1680 1040 *1390 790 (15.6)
2.0
mkg
*1780 750 1410 460 *620 300 5.11
(
6.6ft)
lb
*3920 1650 3110 1010 *1370 660 (16.8)
1.0
mkg
2400 690 1380 440 *650 290 5.18
(
3.3ft)
lb
5290 1520 3040 970 *1430 640 (17.0)
-
1.0
mkg
*2100 *2100 *2850 1270 2330 650 1350 420 *920 370 4.45
(-
3.3
ft
)
lb
*4630 *4630 *6280 2800 5140 1430 2980 930 *2030 820 (14.6)
-
2.0
mkg
*3540 1310 *2050 670
(-
6.6ft)
lb
*7800 2890 *4520 1480
Ground
kg
*1730 1260 2340 650 1360 420 *740 300 4.98
Line
lb
*3810 2780 5160 1430 3000 930 *1630 660 (16.3)
1-15
6. BUCKET SELECTION GUIDE
SAE
heaped
0.11
m
3
(0.14
yd3)
CECE
heaped
0.09
m
3
(0.12
yd3)
Without
side cutter
550
mm
(21.7")
With
side cutter
610
mm
(24.0")
80
kg
(176lb)
1.3
m
(4' 3") arm
Applicable for materials with density of 1600
kgf/m
3
(2700
Ib/yd3) or less
Recommendation
2.5
m
(8' 2") boom
Capacity Width
Weight
0.11
m
3
SAE heaped bucket
1-16
7. UNDERCARRIAGE
TRACKS
X-leg type center frame is integrally welded with reinforced box-section track frames. The design
includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock
absorbing springs and assembled track-type tractor shoes with triple grousers.
TYPES OF SHOES
1)
2)
NUMBER OF ROLLERS AND SHOES ON EACH SIDE
mm(in)
kg(lb)
kgf/cm2(psi)
mm(ft-in)
300(12")
3750(8267)
0.34(4.83)
1740( 5' 9")
300(12")
3650(8050)
0.34(4.83)
1740( 5' 9")
Steel double grouser Rubber track
Shapes
Shoe width
Operating weight
Ground pressure
Overall width
R35Z-7
Model
Carrier rollers
Track rollers
Track shoes
1EA
4EA
44EA
Item Quantity
3)
1-17
8. SPECIFICATIONS FOR MAJOR COMPONENTS
ENGINE
1)
Item
Type
Capacity
Maximum pressure
Rated oil flow
Rated speed
Specification
Variable displacement tandem axis piston pumps
2
Ý
17.5
cc/rev
230
kgf/cm2(3270
psi
)
2Ý38.5
˶/min
(10.2U.S.
gpm
/ 8.5U.K.
gpm
)
2200
rpm
Item
Model
Type
Cooling method
Number of cylinders and arrangement
Firing order
Combustion chamber type
Cylinder boreÝstroke
Piston displacement
Compression ratio
Rated gross horse power(SAE J1995)
Maximum torque at 1400
rpm
Engine oil quantity
Dry weight
High idling speed
Low idling speed
Rated fuel consumption
Starting motor
Alternator
Battery
Specification
Yanmar 3TNV88
4-cycle diesel engine, low emission
Water cooling
3 cylinders, in-line
1-3-2
Direct injection type
88Ý90mm(3.46"Ý3.54")
1642cc(100.2cu in)
19.1 : 1
27Hpat 2200
rpm
(20.3
kW
at 2200
rpm
)
10.8
kgfÂm
(78.1
lbfÂft
)
6.7˶(1.8U.S.
gal
)
155kg(340lb)
240030
rpm
1100Ü30
rpm
185
g/HpÂhr
at 2200
rpm
12V-1.2
kW
12V-40
A
1Ý12VÝ55Ah(5h
rating)
MMAIN PUMP
2)
1-18
TRAVEL MOTOR
GEAR PUMP
MAIN CONTROL VALVE
SWING MOTOR
6)
Item
Type
Capacity
Maximum pressure
Rated oil flow
Specification
Fixed displacement gear pump single stage
10.7/5.1cc/rev
230/30
kgf/cm2(3270/430
psi
)
23.5/11.2
/min
(6.2/3.0U.S.
gpm/
5.2/2.5U.K.
gpm
)
Item
Type
Operating method
Main relief valve pressure
Overload relief valve pressure
Specification
Sectional, 10 spools(11 Blocks)
Hydraulic pilot system
230
kgf/cm2(3270
psi
)
250
kgf/cm2(3560
psi
)
Item
Type
Capacity
Relief pressure
Braking system
Braking torque
Brake release pressure
Reduction gear type
Specification
Fixed displacement axial piston motor
22
cc/rev
200
kgf/cm2(2845
psi
)
Automatic, spring applied hydraulic released
9.2
kgf m
(66.5
lbf ft
)
15~45
kgf/cm2(215~640
psi
)
2 - stage planetary
Item
Type
Relief pressure
Reduction gear type
Braking system
Brake release pressure
Braking torque
Specification
Variable displacement axial piston motor
230
kgf/cm2(3270
psi
)
2-stage planetary
Automatic, spring applied hydraulic released
8
kgf/cm2(114
psi
)
6.5
kgf m
(47
lbf ft
)
3)
4)
5)
1-19
REMOTE CONTROL VALVE
CYLINDER
SHOE
(Steel track)
Item
Type
Specification
Pressure reducing type
5
kgf/cm
2
(71
psi
)
20
kgf/cm
2
(284
psi
)
6.5/8.5
mm
(0.26/0.33
in
)
Operating pressure
Minimum
Maximum
Lever
Single operation stroke
Item
Specification
85 45 540
mm
Extend only
80 45 585
mm
Extend and retract
70 45 510
mm
-
80 45 400
mm
-
95 50 152
mm
-
Bore dia Rod dia Stroke
Cushion
Bore dia Rod dia Stroke
Cushion
Bore dia Rod dia Stroke
Cushion
Bore dia
Rod dia Stroke
Cushion
Bore dia Rod dia Stroke
Cushion
Boom cylinder
Arm cylinder
Bucket cylinder
Boom swing cylinder
Dozer cylinder
7)
8)
9)
Discoloration of cylinder rod can occur when the friction reduction additive of lubrication oil spreads on
the rod surface.
Discoloration does not cause any harmful effect on the cylinder performance.
Item Width
300
mm
(12")
Ground pressure
0.34
kgf/cm2(4.83
psi
)
Link quantity
44
Overall width
1740mm( 5' 9")
R35Z-7
Capacity
SAE heaped CECE heaped
Without side cutter With side cutter
Width
Item
0.11
m3(0.14
yd3)0.09
m3(0.12
yd3) 4 550mm(21.7") 610mm(24.0")
Tooth
quantity
R35Z-7 STD
BUCKET
10)
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