Hyundai Heavy Industries Europe NV

HYUNDAI
HEAVY INDUSTRIES EUROPE N.V.
Problem : Hydraulic contamination

Method : travel motor replacement and cleaning of hydraulic circuit

Date : 11/9/2017

Conditions before starting the job:

 Place machine in a proper environment: dust-free and if possible inside a shelter.

 Make sure you have all necessary connection hoses and flanges available before starting to
disassemble.

Goal : clean hydr. oil : NAS 1638 class 6 or ISO/DIS 4406 class 17/15/12

Working procedure for system cleaning:

1. Empty hydraulic tank and collect the oil in proper recipient.

2. Remove return filters, drain filters, tank breather filter and pilot filter.
3. Remove strainer and clean it.
4. Remove main pump suction lines up to the tank and clean it.

5. Remove main pump drain lines up to the tank and clean them.
6. Remove main pump pressure lines to MCV and clean them.
7. Remove main pump damper lines and clean them.
8. Remove pilot pump suction line and clean it
9. Remove pilot pump pressure line and clean it
10. Remove regulator pilot lines from main pump and clean them.

10

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11. Steam clean the hydraulic tank. Dry if necessary.

12. Clean oil cooler piping and replace the oil cooler. Clean return check valves both of them.( not
mandatory).
13. Remove turning joint and install new seals

14. Install the new travel motor

15. re-install all pipes and filters.

16. Install new return filters, drain filters, tank breather and pilot filter.
17. Install a bypass-filter unit on the tank. Filter efficiency at least Beta 10 > 200. Oil flow min 40
Lpm
18. Re-fill the hydraulic tank with fresh oil through the bypass-filter unit.
19. Remove drain piping at the travel motors and insert the piping in a canister

Connect Pg to
drain hose
travel motor

20. Remove the travel motor drain lines at the tank and connect them to Pg line from the swing
motor.
21. Take off the breaker connection lines on front of the arm and clean them
22. Connect breaker inlet and outlet line together.
23. Connect arm cylinder, bucket cylinder and boom cylinder inlet and outlet lines together.
24. Run the engine and flush the travel motor drain piping for 2 minutes.
25. Re install to original
26. Circulate the oil for each movement in each direction during 20 minutes at max. engine
rpm.Let the filter unit run during this flushing action.
 breaker : left and right 15 min = 30 min
 bucket : left and right 15 min = 30 min
 boom : left and right 15 min = 30 min
 arm : left and right 15 min = 30 min
27. Connect for each travel motor the 2 pressure lines together.
28. Circulate the oil during 20 min. each side left and right.
29. Conncect the swing motor pressure lines together
30. Circulate the oil during 20min. in each direction.
 travel fwd and rev. 15 min = 30 min
 swing LH + RH 15 min = 30 min

31. Repeat procedure 20 to 24 with filter Beta 6 > 200 installed on the bypass filter unit

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Hyundai Heavy Industries Europe NV

32. Open all cylinder heads and pull the piston out of the cylinder body.
33. Clean the cylinder inside as much as possible
34. Re-assemble the cylinders and mount back.
35. Connect all lines to the main components again.
36. Run both travel motors without load forward and reverse each direction during 10 min..
Repeat this 3 times.
37. Move boom up and down during 10 minutes without load
38. Move arm in and out during 10 minutes without load
39. Move bucket in and out during 10 minutes without load
40. move the swing motor 10 times left and 10 times rights.
41. Take oil samples and let them analyse. Below, you can find the procedure to take oil samples
correctly.

Recommendations:

1. In case the machine is working in a dusty environment you might consider installing
an extra Hydraulic bypass filter

 Price indication for this Bypass filter with 3l/min capacity: € 800.
 Filter element: € 40

2. We recommend replacing the tank breather each 250h as described in the operator
and maintenance manual.

3. We recommend sampling the oil each 250h h in order to follow up the contamination.

4. We recommend training the local service engineers and the operators on the
importance of clean working during filter replacement,repairs and attachment
replacement.

breaker piping couplings on arm

full of sand.

Procedure to take oil samples from Hydraulic oil

1. start the engine and let the machine run for at least 5 minutes.
2. Install manometer hose on main pump pressure line

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3. take off 0.5L oil in separate recipient.

4. Fill a clean 100ml sampling bottle at half.

5. Mount the cap on the bottle and shake it. empty the bottle in the separate recipient.
6. Fill the 100mL bottle completely and send it to the laboratory.

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