Part of the Hyundai Repair Manuals.
Every one of the 405 pages in this Hyundai R55-7A, Robex Shop Manual PDF is aimed at one machine: your R55-7A crawler excavator. Inside: complete hydraulic circuit diagrams tracing the main and pilot circuits through single and combined operation, electrical schematics with connector pinouts and component locations, and a full troubleshooting section for both hydraulic and electrical faults. You also get step-by-step disassembly and assembly procedures for the pump device, main control valve, swing device, travel device, and turning joint, backed by mounting torque tables for the entire machine. Torque the main pump mounting bolts to 12.8 kgf·m, set the pilot relief valve at 30 kgf/cm², and change the hydraulic filter every 500 hours like the factory intended. No more chasing hydraulic faults with a gauge and a hunch. Bookmarked and keyword-searchable; pull it up on your phone at the machine and get wrenching.
What's Inside This Hyundai R55-7A Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 3-23 | Safety Hints, Specifications |
| Structure and Function | 24-73 | Pump Device, Main Control Valve, Swing Device, Travel Device, Rcv Lever |
| Hydraulic System | 74-104 | Hydraulic Circuit, Main Circuit, Pilot Circuit, Single Operation, Combined Operation |
| Electrical System | 105-154 | Component Location, Monitoring System, Electrical Circuit, Electrical Component Specification, Connectors |
| Troubleshooting | 155-193 | Before Troubleshooting, Hydraulic and Mechanical System |
| Maintenance Standard | 194-231 | Operational Performance Test, Major Components, Track and Work Equipment |
| Disassembly and Assembly | 232-386 | Precaution, Tightening Torque, Pump Device, Main Control Valve, Swing Device, Travel Device, Rcv Lever, Turning Joint |
| Component Mounting Torque | 387-405 | Introduction Guide, Engine System, Electric System, Undercarriage, Structure, Work Equipment |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Hydraulic oil filter filtration accuracy | 10 μm or less | p. 29 |
| Hydraulic oil filter replacement interval | 500 hours | p. 30 |
| Main pump mounting bolt | 12.8±3.0 kgf·m | p. 235 |
| Carrier roller mounting bolt, nut | 41±5.0 kgf·m | p. 235 |
| Track roller mounting bolt | 41±5.0 kgf·m | p. 235 |
| Boom cylinder gland tightening torque | 95 ± 9.5 kgf·m | p. 392 |
| Boom cylinder lock nut tightening torque | 292 ± 29 kgf·m | p. 392 |
| Main pump housing tightening torque | 12.0 ± 1.0 kgf·m | p. 391 |
| Operating weight | 5700 kg | p. 12 |
| Travel speed (Low/High) | 2.2/4.1 km/hr | p. 12 |
| Engine oil quantity | 11.6 L | p. 19 |
| Main pump maximum pressure | 220 kgf/cm2 | p. 19 |
Hyundai R55-7A Common Problems This Manual Covers
Hyundai R55-7A hydraulic oil temperature warning lamp on, buzzer sounding, machine runs hot under load
Check hydraulic oil level first and top up before anything else. Clean debris from the oil cooler fins with compressed air. Replace the hydraulic oil filter if it is past the 500 hour interval listed on page 30; a clogged element opens the 1.5 kgf/cm2 bypass valve and recirculates hot unfiltered oil.
Manual Section: Hydraulic and Mechanical System Troubleshooting p. 30Engine oil pressure warning lamp blinks right after startup and stays on during operation
Shut the engine down immediately and check the oil level on the dipstick. Fill to the full mark; the R55-7A crankcase holds 11.6 L, listed on page 19. If the lamp still blinks with the level correct, stop running the machine and work through the engine oil pressure checks in the troubleshooting procedure starting on page 155.
Manual Section: Electrical System Troubleshooting p. 19Bucket and travel feel weak, movements erratic, machine hesitates when tracking uphill
Check pilot primary pressure first; the pilot relief is set at 30 kgf/cm2, listed on page 78, and low pilot pressure makes every function sluggish. Then test main pump delivery against the 220 kgf/cm2 maximum for the R55-7A on page 19, following the operational performance test procedures that begin on page 194.
Manual Section: Operational Performance Test p. 194Track chain loose and sagging between rollers, shoes popping over the sprocket during turns
Grease the track tension cylinder through the adjuster fitting until sag is correct, then inspect the cylinder seals for leaks. Check shoe hardware next; loose shoes wallow out bolt holes fast. Torque track shoe bolts and nuts to 19±1.0 kgf·m per the chart on page 235, and track roller bolts to 41±5.0 kgf·m.
Manual Section: Disassembly and Assembly p. 235Swing drifts under load and upperstructure creeps on slopes with levers centered
Run the swing function drift test from the operational performance test procedures beginning on page 194. Verify swing motor relief pressure reaches 220 kgf/cm2 on the R55-7A, listed on page 20. If relief pressure checks out but drift continues, inspect the swing parking brake release circuit and check the motor make-up valves for contamination.
Manual Section: Operational Performance Test p. 20Frequently Asked Questions
How do I reset the alarm buzzer on the Hyundai R55-7A?
If the machine has a problem, the red lamp lights up and the buzzer sounds. You can cancel the buzzer sound by pressing the BUZZER STOP switch, but the red lamp will remain lit until the problem is cleared. p. 113
What causes the battery charging warning lamp to stay on?
The battery charging warning lamp may stay on due to a defective alternator, a disconnection in the wiring harness, or poor contact between the CN-57(4) and CN-2(4) connectors, or between the CN-2(4) connector and the alternator terminal 'L'. p. 179
How do I clear error codes for the engine?
The engine fault warning lamp lights up when the ECM on the engine is abnormal. You must check the fault code using the Yanmar Engine Diagnostic Service Tool (YEDST) and refer to the web (CERES) for the Electronic Control Manual of the TNV Engine. p. 112
What is the tightening torque for the boom cylinder head gland?
The tightening torque for the gland lock nut on the boom cylinder is 292 ± 29 kgf·m (2110 ± 211 lbf·ft). p. 368
What is the required hydraulic oil capacity for the hydraulic tank?
The hydraulic tank capacity is 70 liters (18.5 U.S. gal). p. 238
Will this Hyundai R55-7A Shop Manual download right away?
A single searchable PDF file of 405 pages, downloadable right after payment. Nothing ships, nothing waits in the mail.
Are there any print restrictions on this Hyundai R55-7A manual?
You can. The PDF is unlocked and carries no copy protection, so print the sections you want and keep the file as your backup.
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