Part of the Hyundai Repair Manuals.
Wrenching on a Hyundai R55-3? This 456-page Robex 55-3 Service Manual PDF walks you through the whole excavator, from hydraulic pump and main control valve function to full disassembly of the swing motor, travel motor, and turning joint. You get complete electrical circuit diagrams, cluster connector pinouts, and a hydraulic circuit diagram that shows exactly where every line runs. Inside: operational performance tests, hydraulic pressure adjusting procedures, and troubleshooting sections for both the electrical system and hydraulic components. Set the main relief valve at 210 kgf/cm2 (2987 psi), then check swing motor braking torque against the 11.5 kgf-m (83 lbf-ft) standard. No more chasing a dead cluster with a test light and a hunch. Bookmarked and keyword-searchable; pull it up on your phone next to the machine and go straight to the spec you need.
What's Inside This Hyundai R55-3, ROBEX 55-3 Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 1-20 | Safety Hints, Specifications |
| Structure and Function | 21-78 | Hydraulic Circuit Diagram, Hydraulic Pump, Main Control Valve, Travel Device, Swing Machinery |
| Testing and Adjusting | 79-105 | Operational Performance Test, Testing and Adjusting Hydraulic Pressure |
| Component Location | 106-108 | Hour Meter, Starting Switch, Fuse Box, Cluster, Battery Relay, Horn, Head Lamp |
| Electrical Circuit Diagrams | 109-114 | Circuit Diagram A-1, Circuit Diagram A-2, Circuit Diagram A-3, Circuit Diagram B-1, Circuit Diagram B-2, Circuit Diagram B-3 |
| Electrical Circuit Operation | 115-128 | Power Circuit, Starting Circuit, Charging Circuit, Head and Work Lamp Circuit, Beacon Lamp Circuit, Wiper and Washer Circuit, Monitoring Circuit |
| Monitoring System | 129-140 | Monitor Panel Outline, Cluster Check Procedure, Warning Lamps, Gauge Operation |
| Yanmar Engine Manual, Safety and General (Embedded) | 141-190 | Safety Warnings for Electrical Parts and Battery, Waste Treatment, Precautions for Service Work, Preparation Before Disassembly, Precautions in Disassembly, Inspection and Measurement, Reassembly, Adjustment and Check |
| Yanmar Engine Manual, Engine Body (Embedded) | 191-235 | Cylinder Block Honing and Cross Hatch, Boring and Honing Intervals, Piston Pin Bushing Replacement, Valve Guide Replacement, Oil Seal Replacement |
| Yanmar Engine Manual, Turbocharger 4TNE105T (Embedded) | 236-250 | Waste Gate Valve Opening Pressure and Lift Check, Test Equipment Setup |
| Yanmar Engine Manual, Starting Motor (Embedded) | 251-285 | No-Load Characteristic Test, Current, Voltage and Revolution Measurement, 30-Second Rating Caution |
| Yanmar Engine Manual, Alternator (Embedded) | 286-305 | Alternator Service Standards, Output and Regulator Checks |
| Yanmar Engine Manual, Service Standards (Embedded) | 306-325 | Cylinder Bore and Roundness for 4TNE94 / 4TNE98 / 4TNE106, Crankshaft Pin and Journal Limits, Idle Gear Shaft and Bushing, Gear Backlash, Thrust Bearing Side Gap |
| Trouble Shooting | 321-349 | Electrical System Troubleshooting, Hydraulic Components Troubleshooting |
| Maintenance Standard | 350-364 | Major Components Maintenance, Track and Work Equipment Maintenance |
| Disassembly and Assembly | 365-456 | Hydraulic Pump Disassembly, Main Control Valve Disassembly, Swing Motor Disassembly, Travel Motor Disassembly, Remote Control Valve Disassembly, Turning Joint Disassembly |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Maximum torque at 1600rpm | 19.4kgf·m (140lbf·ft) | p. 16 |
| Braking torque (Swing motor) | 11.5kgf·m (83lbf·ft) | p. 17 |
| Battery | 1 × 12V × 100Ah | p. 16 |
| Main relief valve pressure | 210kgf/cm² (2987psi) | p. 17 |
| Overload relief valve pressure | 230kgf/cm² (3271psi) | p. 17 |
| Battery voltage | 10~12.5V | p. 115 |
| Voltage | 10~12.5V | p. 125 |
| Radiator cap tester pressure | 0.9±0.15 kgf/cm² | p. 169 |
| Fan belt tension | 10-15 mm | p. 170 |
| Operating weight | 5400 kg | p. 11 |
| Travel speed (Low/high) | 2.2/4.0 km/hr | p. 11 |
| Engine oil quantity | 9.7 L | p. 17 |
Hyundai R55-3, ROBEX 55-3 Common Problems This Manual Covers
Hyundai R55-3 hydraulic pump whining under load, boom and bucket slow and weak
Check hydraulic oil level and inspect suction lines for air leaks before condemning the pump. Connect a gauge and test main relief pressure against the 210 kgf/cm2 (2987 psi) spec on page 18. Adjust at the relief valve screw carefully; one full turn changes pressure about 106 kg/cm2, per page 105.
Manual Section: Hydraulic Pump Troubleshooting p. 18Engine cranks slowly or won't start, battery goes dead after sitting overnight
Test battery voltage at the terminals first; normal operating range is 10 to 12.5 V per page 115. With the engine running, charging voltage should hold 10 to 14 V, shown on page 119. Clean and tighten starter and ground connections, load-test the battery, then check the fuse box and battery relay.
Manual Section: Electrical Circuit Operation p. 115Machine meanders during travel, one track slow, poor travel speed on slopes
Compare travel motor relief pressures side to side; both circuits should relieve at 210 kgf/cm2 (2987 psi), listed on page 18. Verify pilot pressure reaches both travel spools and look for a sticking spool or crushed line. Diagnosis for meandering and poor travel speed starts in the troubleshooting section on page 321.
Manual Section: Travel Motor Troubleshooting p. 18Coolant temperature gauge climbs into red during heavy digging, engine overheating in hot weather
Check fan belt deflection midspan: 10 to 15 mm under 98 N (10 kgf) of thumb pressure, per page 170. Pressure-test the radiator cap to 0.9±0.15 kgf/cm2 (page 169) and replace it if it bleeds down. Blow out packed radiator fins; on the 4TNE94-98 engine the thermostat should open between 71 and 85 degrees C (page 178).
Manual Section: Engine Troubleshooting p. 170Boom settles and bucket curls down overnight with controls locked in neutral
Test each overload relief valve; opening pressure should be 230 kgf/cm2 (3271 psi). If reliefs check good, isolate the cylinder: block the circuit and watch for rod movement to catch internal piston seal leakage. Inspect control valve spool seals for scoring; cylinder-drop diagnosis begins in the troubleshooting section on page 321.
Manual Section: Main Control Valve Troubleshooting p. 321Frequently Asked Questions
What is the procedure for troubleshooting the battery charging lamp when it lights up after the engine is started?
If the battery charging lamp remains lit after starting, check the voltage between the alternator 'P' terminal and chassis. If the voltage is 0V, check the voltage between CN-2(2) and the chassis. If that is also 0V, check the voltage between CN-12(11) and the chassis. If the voltage is 10-15V, the cause may be a disconnection in the wiring harness or poor contact between CN-12(11) and CN-2(2). p. 323
What is the standard valve clearance for the 4TNE94/98 engine?
The standard valve clearance for the 4TNE94/98 engine is 0.15 to 0.25 mm. This adjustment should be performed while the engine is cold. p. 171
What is the tightening torque for the cylinder head bolts on the 4TNE94/98 engine?
The cylinder head bolts for the 4TNE94/98 engine should be tightened in two steps. The first step is 49-58.8 Nm (5-6 kgf-m), and the second step is 102.9-112.7 Nm (10.5-11.5 kgf-m). p. 189
What is the standard fan belt tension for the engine?
The standard fan belt tension is 10-15 mm deflection when pushed with a force of 98N (10 kgf). p. 170
What is the standard fuel injection pressure for the 4TNE94/98/106(T) engines?
The standard fuel injection pressure for these engines is 21.57-22.55 MPa (220-230 kgf/cm²). p. 172
What format is this Hyundai R55-3 manual in?
You get a 456-page searchable PDF that downloads instantly after checkout. Open it on your laptop, tablet, or phone, and bring it right to the shop floor.
Can I print specific sections of this Hyundai R55-3 Service Manual?
Yes, printing is unrestricted: a single page, a chapter, or the lot, on letter or A4.
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