TRAINING MANUAL

R55W--7(A)
R55W

WHEEL EXCAVATOR

- HHIE - - Instructor: P. Everaerts - A/S Dept. - - JAN 2009 -

 CONTENT
PAGE
1] MAIN COMPONENTS LIST 02
2] MAIN PUMP ASSEMBLY 03
3] MAIN CONTROL VALVE 05
4] MAIN OPERATING FUNCTIONS 08
5] CLUSTER R55W-7 09 REMARK
5] CLUSTER R55W-7A 9-2 - ENGINE INFORMATION -7A Æ SIMILAR TO R55-7A
6]] SOLENOID BANK 12 - location of electric eng
eng.components
components
7] PILOT DISTRIBUTION BLOCK 13 - diagnostic system with error codes list
8] CUT OFF VALVE ASSEMBLY 14
9A] BRAKE PEDAL 16 Refer to the manual
“TRAINING-CRAWLER-55-7(A)”
9B] BRAKE LINES & AXLES 16
for more info
10]] ACCELERATOR PEDAL 24
11] TRAVEL DIRECTION SOLENOIDS 25
12] BOOM SWING SOLENOID 26
13] STEERING VALVE 27
14] LOCKING VAVLE FRONT AXLE (RAM LOCK) 28
15] JOYSTICK LINES + SHUTLLE VALVE SWING 29
16] LOCATION OF SOLENOIDS & BLOCKS 30
17] TRAVEL MOTOR 31
18] TRANSMISSION 33
19] ELECTRIC COMPONENT LOCATION 35
ELECTRIC STOP LIGHT CIRCUIT 35 - 1
20] PRESSURE SETTINGS & PERFORMANCE VALUES 36
add. HYDRAULIC CIRCUITS 38
Hyundai Heavy Industries Europe Arranged by Pieter Everaerts
Vossendaal 11 Instructor HHIE
2440 Geel - Belgium Tel 0032 (0)14 56 22 44
Tel 0032 (0)14 56 22 00 Fax 0032 (0)14 56 22 65
Fax 0032 (0)14 56 22 65

Hyundai Heavy Industries Europe page 1

1. MAIN COMPONENTS LIST

COMPONENTS R55W-7 R55W-7A

Engine Yanmar 4TNV94L Yanmar 4TNV98-EPHYB

3054cc 3319cc
Rated Gross horse power (SAEJ1995) Rated Gross horse power (SAEJ1995)
53HP at 2200rpm 57HP at 2400rpm

Max. Torque at 1400 rpm Max. Torque at 1550 rpm

20 6 kkgff
20.6 20 5 kkgff
20.5

Setting max RPM 2400±50 2260±50

("M" mode selected)

Main Pump Dongmeung

2*25cc /rev Same
rated
t d oilil flow
fl 2*55 l/l/min,
i
rated speed 2200 rpm

Gear Pump Dongmeung

16.2 / 4.5 cc /rev Same
rated oil flow 35.6 l/min - 9.9 l/min
rated speed 2200 rpm

Main control valve Hanil

Sectional, 10 spool + 1 option Same

Swing motor Jaeil + Seungbo Same

Travel Motor Dongmeung Same

Transmission Zf 2 speed hydrostatic

Zf, Same

Axles Dana (with neg parking brake in rear axle) Same

C Hyundai Heavy Industries Europe page 2

2. MAIN PUMP ASSEMBLY
2.1 STRUCTURE
air breather
((bleeder valve))
P3 P1 P2
P4

P1 MAIN PUMPS
P2

(P1) (P2) (P3) (P4)

P3

PLUG SW, BM-SW,DOZ &

STEERING PUMP

P4

PILOT& BRAKE PUMP

NO PILOT RELIEF
VALVE !!!!
PUMP si not

C Hyundai Heavy Industries Europe page 3

2.2 SECTIONAL VIEW
Pump power
adjust screw
P1, P2

P3 P4 (pilot & brake pump)

Pump power control is realised by means of 3 pistons

P1, P2 pistons & P3 shift piston.

P2 (P1)

P3
P1

C Hyundai Heavy Industries Europe page 4

Inside components view

Spring

Orifice

Pump power control is realised by means of 3 pistons

P1, P2 pistons & P3 shift piston.

C Hyundai Heavy Industries Europe page 4 - A

3. MAIN CONTROL VALVE
3.1 CIRCUIT

0 5BAR
0.5BAR BREAKER LINE (single
(
function valve) is standard
0.5BAR

P1 P2 P3

(BM2)
220
BAR

T2

sec. relief valve

(BREAKE

boom up is 220
located on travel BAR
ER)

section !!! ”OPTION SECTION”

(e.g. rotation, is NOT
standard)

C Hyundai Heavy Industries Europe page 5

3.2 VIEW

ARM2-SUM. LINE TANK LINE (T1)

CONNECTOR
CHECK VALVE
ARM2 SUM
ARM2-SUM.

P1 P2

AKER
RM2

TRAVEL1

BOOM2 - BREA
AR

TRAVEL2
BOOM1

P3
BUCKET

ARM1

DOZER
TANK (T2)

SWING

BOOM SWING
MAIN RELIEF
VALVE P3
BOOM HOLDING
220 BAR
PILOT SIGNAL

BOOM HOLDING MAIN RELIEF

VALVE VALVE P1,P2 CHECK VALVE
BOOM2-SUM. LINE
220 BAR BOOM2-SUM.

C Hyundai Heavy Industries Europe page 6

3.3 PARTS VIEW See also p.2-10 in service manual BOOM HOLDING
for parts-description VALVE ASS.

END BOOM1
COVER
ARM2

TRAVEL1

BUCKET

TRAVEL
BLOCK

MAIN REL. VALVE

P1, P2 Æ 220bar

TRAVEL2
DOZER
SWING
ARM1
BOOM
SWING
BOOM2/BREAKER

OPTION
(no standard)
INLET
BLOCK
END
COVER

MAIN REL. VALVE

P3 Æ 220bar
C Hyundai Heavy Industries Europe page 7
4. MAIN OPERATING FUNCTIONS
JOYSTICKS BREAKER
SWITCH PANEL 3 (below steering wheel) HORN
FUNCTION

LEFT RIGHT
hazard SW RAM LOCK SW parking SW

SWITCH PANEL 2 Engine speed

SEE NEXT PAGE control dial
(only -7A !!!)

SWITCH PANEL 1
SEE NEXT PAGE
Airoconditioning &
heater panel

Cluster

Gear selector

SWITCH PANEL 3

Engine speed
control lever
(only -7 !!!)

Multifunction switch (LH)

C Hyundai Heavy Industries Europe page 8

Switch panels

R55W-7 R55W-7A

SWITCH PANEL 1

SWITCH PANEL 2

Swapping between “swing control” &

“boom swing control” with joystick

C Hyundai Heavy Industries Europe page 8 - 1

5.1 CLUSTER R55W-7
R55W-7

C Hyundai Heavy Industries Europe page 9

 R55W-7
CLUSTER CONNECTORS

C Hyundai Heavy Industries Europe page 9 - 1

5.2 CLUSTER R55W-7A
R55W-7A

Æ MAX ENG POWER:2260 rpm

C Hyundai Heavy Industries Europe page 9 - 2

 R55W-7A
CLUSTER CONNECTORS

Input

Input
Input
Input
Input
Input
-
Input
p
Input
Input

C Hyundai Heavy Industries Europe page 10

CLUSTER CHECK PROCEDURE

If not, change cluster

C Hyundai Heavy Industries Europe page 11

6. SOLENOID BANK
The solenoid bank is situated in the main pumps compartment

PARKINGPRESSURE SWITCH
Gear Pump ,CD-26,
,CD 26, NC

Location of the other Solenoids

in the machine Æ See p. 30

A1 A2 A3 A4 A5

A1 SAFETY SOLENOID (CN 68)

A2 BREAKER SOLENOID (CN 66)
A3 PARKING SOLENOID SOLENOID (CN 71) to NEG BRAKE in REAR axle
A4 RAM LOCK SOLENOID (CN 69) to ACCELERATOR pedal
A5 BOOM2 CUT OFF SOLENOID ((CN 125)) to TRANSMISSON
(p-line)
(p line)

2e SPEED
PARKING PS
from joystick CD-26, NC pilot feed for sol
boom lift sign. joysticks/pedals
FF
BM2 CUT OF

RAM LOCK

BREAKER
PARKING

SAFETY
Pilot Pump
Cut off
valve ass’y
Pilot line Filter

A2,A5 are energised as soon as breaker is operated. A that time, boom2 function is cancelled by sol. A5

C Hyundai Heavy Industries Europe page 12

7. PILOT DISTRIBUTION BLOCK
PILOT DISTRIBUTION BLOCK (below platform, in the middle)

T sol. 3150 PG
standbye P - 2e speed
port swing sol Plug
T acc. pedal

5- SOLENOID P2
P1 BLOCK
T7 T5 P4 P3 P2
P1
T9 T1 T
T8 T6 T4 T3 T2

TANK

T – F&R sol
brake
b k pedal
d l
T1 brake pedal T - 2e speed
T2 T joystick sol

C Hyundai Heavy Industries Europe page 13

8. CUT OFF VALVE ASSEMBLY 1e TYPE (R55W-7, ~#0312)

BRAKE FAIL
PRESSURE SW. K1: RELIEF VALVE 170 bAR
CD-3,, NC
K2 : UNLOADING VALVE
CUT IN 125 bar
D CUT OFF 150 bar

K3 : RELIEF VALVE
(pilot press ) 30 bar

K5

BRAKE PEDAL

CUT OFF ASS’Y

ASS Y

Brake fail PS
NC

C Hyundai Heavy Industries Europe page 14

8. CUT OFF VALVE ASSEMBLY 1e TYPE (R55W-7, ~#0312)

TOP VIEW SPECIFICATIONS

(check valve)

BOTTOM VIEW

(check valve)

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8. CUT OFF VALVE ASSEMBLY 2e TYPE (R55W-7, #0313~ & R55W-7A)
BRAKE FAIL
PRESSURE
SW.CD-3, NC

Brake fail
PS, NC

K2 : UNLOADING VALVE
CUT IN 125 bar
CUT OFF 150 bar
K1: LOGIC VALVE

K3 : RELIEF VALVE
(pilot press ) 30 bar

K7: RELIEF VALVE 170 bAR

C Hyundai Heavy Industries Europe page 15 - 1

9A. BRAKE PEDAL

STOP LAMP
PRESSURE SW.
CD-4, NO (5bar)

WORKING BRAKE
PRESSURE SW.
CD-38, NO (40bar)

C Hyundai Heavy Industries Europe page 16

9B. BRAKE LINES & AXLES - OVERVIEW -
1) R55W-3 & R55W-7 (#E0269~) & R55W-7A 2) R55W-7 (#E001~# E0268)

front front

rear
NEG. BRAKE
no diff lock disks (front, rear) (rear axle)Æ
via hyd line

rear

NEG. BRAKE
NEG
(rear axle)Æ
lever, moved via
via hyd. cylinder
!!!diff lock disks (front, rear)!!!

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1. R55W-3 & R55W-7 (#E0269~) & R55W-7A

SERVICE BRAKE PRESS

REAR AXLE: 40 Bar

SERVICE BRAKE PRESS

FRONT AXLE: 40 Bar
PARKING BRAKE
PISTON:
S O SEE
S NEXT
PAGE

PARKING BRAKE PRESS

REAR AXLE: 30 Bar

C Hyundai Heavy Industries Europe page 17 - 1

PARKING BRAKE FUNCTIONING R55W-3 & R55W-7 (#E0269~) & R55W-7A

REAR AXLE
PARKING BRAKE
PISTON

actuator

PARKING
BRAKE
UNLOCK
POSITION

(30 bar apllied)

PARKING
BRAKE
LOCK
POSITION

The parking brake (multi disc brake) is situated in the rear axle
and is of the “negative type” : as soon as the machine is
started, 12V is applied on the parking solenoid, oil enters the
actuator and this one releases the parking brake via a lever
(on condition that the PARKING SWITCH is in OFF position).

REAR AXLE

C Hyundai Heavy Industries Europe page 17 - 2

2. R55W-7 (#E001~#E0268) R55W-7 (#E001~#E0268)

SERVICE BRAKE PRESS

REAR AXLE
AXLE: 40 Bar

PARKING BRAKE PRESS

REAR AXLE: 28 Bar

SERVICE BRAKE PRESS

FRONT AXLE: 40 Bar

EMERGENCY SCREW:
UNLOCKING PARKING
BRAKE

Sequence
valve

P2 P1

DIFF LOCK PRESS

25 Bar (when braking)

C Hyundai Heavy Industries Europe page 17 - 3

AXLE BRAKE FUNCTIONING (1/3) R55W-7 (#E001~#E0268)

Differential Lock & Brake Sytem Concept

Differential Lock 100% 25 Bar
Sequence valve
Service brake line (40 bar)

Service Brake
Piston NEG. BRAKE
NEG
IIntermediate
t di t
with disc-springs
Disc A B C (pre-load):
ONLY on
REAR AXLE

DIFF.LOCKING DISCS SPRING

NTIAL

Hydraulic Block
DIFFEREN

Standard differential
Limited Slip 45% Piston
100% Hydralock HALF-SHAFT
Actuation Press
(min max)15-25 bar.

DIFF. CARRIER
SPRING

BRAKE DISCS AXLE HOUSING Total (Brake

piston) Assembly
Module
C Hyundai Heavy Industries Europe page 18
AXLE BRAKE FUNCTIONING (2/3) R55W-7 (#E001~#E0268)

Differential Lock & Brake Sytem Concept

S
Sequence valve
l

Service Brake 25 Bar Service brake line (40 bar)

Service Brake 40 Bar

Piston
IIntermediate
t di t NEG. BRAKE
NEG

Disc A B C with disc-springs

(pre-load):
ONLY on
REAR AXLE

DIFF.LOCKING DISCS SPRING

Hydraulic Block
Piston
HALF-SHAFT

DIFF. CARRIER
SPRING

-6 DIscs
-1.4 mm Gap
BRAKE DISCS AXLE HOUSING Total (Brake
piston) Assembly
Module
C Hyundai Heavy Industries Europe page 19
AXLE BRAKE FUNCTIONING (3/3) R55W-7 (#E001~#E0268)

Differential Lock & Brake Sytem Concept

S.A.H.R. Brake (internal parking brake)
RELEASE PRESSURE (28 Bar)
Service Brake
Piston NEG. BRAKE
NEG
IIntermediate
t di t
Disc A B C with disc-springs
(pre-load):
ONLY on
REAR AXLE

disc
DIFF.LOCKING DISCS SPRING springs
Hydraulic Block
Piston
ACTUATION PIN (3 pieces)

HALF-SHAFT S.A.H.R.
PISTON(Neg. Brake Piston)

DIFF. CARRIER disc

SPRING springs

BRAKE DISCS AXLE HOUSING Total (Brake

piston) Assembly
Module
C Hyundai Heavy Industries Europe page 20
Components view R55W-7 (#E001~#E0268)

REAR AXLE VIEW

Intermediate
Total (Brake
Disc
piston) Assembly
Service Brake
Module
Piston

Hydraulic Block
Piston

Neg. Brake Piston Disc springs

f(or NEG. BRAKE) f(or NEG. BRAKE)

Actuation pins

C Hyundai Heavy Industries Europe page 21

BRAKE CHECK PORTS & COMPONENTS (1/3) R55W-7 (#E001~#E0268)

SEQUENCE VALVE

P1 T

G1

P2

G2

DIFF LOCK PRESS

25 Bar (when braking)

C Hyundai Heavy Industries Europe page 22

BRAKE CHECK PORTS & COMPONENTS (2/3) R55W-7 (#E001~#E0268)

FRONT AXLE
DIFF LOCK SIGNAL

SERVICE BRAKE PRESS

FRONT AXLE: 40 Bar

DIFF LOCK SIGNAL

PARKING BRAKE PRESS

REAR AXLE REAR AXLE: 28 Bar

Left

SERVICE BRAKE PRESS

REAR AXLE: 40 Bar

EMERGENCY SCREW:
UNLOCKING PARKING
BRAKE (see next page)

Right

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UNLOCKING OF PARKING BRAKE R55W-7 (#E001~#E0268)

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10. ACCELERATOR PEDAL

T
A (Out)
P

T
P

O i
Optional
l engine
i controll cable
bl

C Hyundai Heavy Industries Europe page 24

11. TRAVEL DIRECTIONS SOLENOIDS

FLOW TO TRAVEL MOTOR, FORWARD

MAIN
A CONTROL
B VALVE
P
b8 b7
T

a8 a7

FLOW TO TRAVEL MOTOR, REVERSE

TRAVEL TRAVEL
FORWARD REVERSE
SOLENOID SOLENOID
CN 122 CN 123

A (Out)

P T

C Hyundai Heavy Industries Europe page 25

12. BOOM SWING SOLENOID

BOOM SWING SOLENOID (AT THE BACK)

CN 121 (2 coils))
- no voltage Æ swing opperation
- voltage Æ boom swing operation
BOOM SWING & SWING SOLENOID

A1 A3

A2 A4

P1 P2
(from jostick) (from jostick)

C Hyundai Heavy Industries Europe page 26

13. STEERING VALVE (Orbitrol & Priority Valve)

ORBITROL VALVE
Rel. valve (140bar), check valves PRIORITY VALVE

EF
R

SEC. RELIEF VALVES IN ORBITROL: 180 Bar

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14. LOCKING VALVE FRONT AXLE (RAM LOCK)

RELIEF VALVE
9 Bar

OSCILLATING CYLINDERS

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15. JOYSTICK LINES + SHUTLLE VALVE SWING

Shutlle valve for swing

TERMINAL BLOCK (below platform, left side)

Remark
Find in the operating manual – chapter 4.11 information
on the joystick pattern.
Find in Training book R55-7(A) more info about the SWING MOTOR UNIT.

C Hyundai Heavy Industries Europe page 29

16. LOCATION OF SOLENOIDS & BLOCKS

Location of the “Solenoid Bank”

TRAVEL Æ See pp. 12
(2e SPEED)
SOLENOID
CN 70
BOTTOM PLATES VIEW

1. 2.

SOLENOIDS & BNLOCKS

3.
1. TRAVEL DIRECTION SOLENOIDS CN122 (F) & CN123 (R)
2. TRAVEL SPEED (2e SP) SOLENOID CN70
4.
3. BOOM SWING & SWING SOLENOID CN121
4. TERMINAL BLOCK (with SW shutlle valve) 5.
5. PILOT DISTRIBUTION BLOCK

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17. TRAVEL MOTOR (1/2)

C Hyundai Heavy Industries Europe page 31

17. TRAVEL MOTOR (2/2)
LEFT SIDE VIEW
relief valve (230 Bar)
M1: CHECK PORT FOR CHANGE OVER
PRESSURE Æ 150 Bar
M1

MA(B)

relief valve (230 Bar)

RIGHT SIDE VIEW

ADJUST SCREW
CHANGE OVER
PRESSURE relief valve (230 Bar)

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18. TRANSMISSION (1/2)

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18. TRANSMISSION (2/2)

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19. ELECTRIC COMPONENT LOCATION -7/-7A FUSE BOX AT BACK OF CABIN

(1) (10)

(11)
(20)

R55W-7 R55W-7A
(11) (1) (11) (1)

(CN81, behind pump)

R55W-7 Æ CD30
R55W-7A Æ CD8
(10)
(20)
(10)
FOR PICTURES (RELAYS, MASTER SW,...) Æ SEE R55-7(A) TRAINING BOOK (20)

C Hyundai Heavy Industries Europe page 35

ELECTRIC STOP LIGHT & 2e SPEED CIRCUIT -7/-7A cluster

5 BAR

stop lamps
ST EH

40 BAR

on cluster

GROUND for
2e speed lamp
+ 12V (IG)

+12V at "2e sp
0V at "1e sp."
fuse NR. 13 - 20A:
functions:
1)) when closed Æ timer activated Æ it interupts
p

p."
circuit to stop lamp AFTER "..." seconds
2) grounding of reset-line when 1e sp. selected
grounding of set-line when 2e sp. selected

2e sp. sign (-) 1e sp. sign (-)

+ 12V (IG)
shift lever
(2)
(5)

+12V (4)
shift
(1) controller
GND

(3) (6) COM

C Hyundai Heavy Industries Europe page 35 - 1

20. PRESSURE SETTINGS & PERFORMANCE VALUES (1/2)

PRESSURE TABLE (UNIT: BAR) UNIT: BAR

MAIN CONTROL VALVE MAIN RELIEF-1 (P1, P2) --> arm, bucket, boom, travel L & R 220
MAIN RELIEF-2 (P3) --> dozer, swing, boom swing 200
PORT RELIEF (arm, boom, bucket) 240
MAIN PUMP DELIVERY Pressure without operating equipment, at high idle 20
PRESSURE (P1, P2)
SWING MOTOR PORT RELIEF PRESSURE 210
BRAKE RELEASE 20~40
TRAVEL MOTOR PORT RELIEF PRESSURE 230
BRAKE RELEASE 9
CHANGE OVER PRESSURE 150
PILOT & BRAKE PUMP (P4) RELIEF PRESSURE (for brakes, cut off -- >see below) 150 (±5b)
RELIEF PRESSURE (for pilot system) 30 (±3b)

TRANSMISSION CLUTCH PRESSURE 30

STEERING STEERING PRESSURE 140
OVERLOAD STEERING PRESSURE 180
BRAKE SYSTEM, AXLES BRAKE PRESSURE (FRONT & REAR AXLE) 40
BRAKE RELEASE PARKING BRAKE (REAR AXLE) 15~30
BRAKE SYSTEM, CUT-OFF ASS'Y BRAKE ACCU PRESSURE CUT-IN 125 (±5b)
BRAKE ACCU PRESSURE CUT-OFF 150 (±5b)
BRAKE ACCU PRESSURE MAX. (SAFETY) 170 (±3b)

C Hyundai Heavy Industries Europe page 36

20. PRESSURE SETTINGS & PERFORMANCE VALUES (2/2)

R55W-7 R55W-7A
CYCLE TIMES OF EQUIPMENT (UNIT: SEC.) CYCLE TIMES OF EQUIPMENT (UNIT: SEC.)

FIND IN CHAPTER 6 OF SERVICE MANUAL ALL PROCEDURES

& ADDITIONAL INFORMATION FOR COMPLETING
PERFORMANCE TESTS !!!

C Hyundai Heavy Industries Europe page 37

HYDRAULIC CIRCUIT R55W-7 (Ser. Nr. E0183 ↔ E0268)
neg. brake by hydraulic
force inside rear axle

Sequence valve for diff lock in

front & rear axle

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HYDRAULIC CIRCUIT R55W-7 Ser. Nr. from E0269 & R55W-7A

neg. brake by hydr.

operated lever mounted
on rear axle

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C Hyundai Heavy Industries Europe page 40