Hyundai R140-7 User manual

Service Guide
Crawler Excavator

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INDEX
Ⅰ. Specification Comparisions --------------------------------------------------------------------------------------------- 3
Ⅱ.Hydraulic System -------------------------------------------------------------------------------------------------------------- 7
1.Outline of Hydraulic system ------------------------------------------------------------------------------------------------- 8
2.Hydraulic Symbol --------------------------------------------------------------------------------------------------------------- 9
3.Hydraulic Circuit ---------------------------------------------------------------------------------------------------------------- 15
3-1.Main Circuit
3-2.Pilot Circuit (Crawler Type)
3-3.Pilot Circuit (Wheel Type)
3-4.Oil Return Circuit
4.Main Components --------------------------------------------------------------------------------------------------------------- 19
4-1.Main Control Valve
4-2.Main Pump
4-3.Pilot Circuit
4-4.Swing Motor
4-5.Travel Motor
4-6.Remote Control Valve
4-7.Remote Control Pedal
4-8.Turning Joint
4-9.Safety Valve
4-10.Others
5.Breaker /Double Function Piping ----------------------------------------------------------------------------------------- 152
5-1.Breaker /Clamshell Piping
5-2.Single Acting Circuit
5-3.Double Acting
5-4.Comparison Table
5-5.Oil Flow / rpm
Ⅲ.Electric & New CAPO System ---------------------------------------------------------------------------------------- 159
1.CAPO System ------------------------------------------------------------------------------------------------------------------- 160
1-1. Power Mode Selection System
1-2. Switches on Joy Stick Lever

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1-3. Monitor Panel (Cluster)
1-4. Communication
1-5. Automatic Deceleration System
1-6. Power Boost System
1-7. Travel Speed Control System
1-8. Automatic Warming Up & Engine Overheat prevention
1-9. Anti - Restart Function
1-10. Location of Solenoid Valves
1-11. Work/Power Mode Selection
1-12. Monitoring Display on Cluster
1-13. Malfunction of Cluster or Mode Selection System
1-14. Accel. Actulator
1-15. Engine Speed Sensor (not for excavators with QS-engines)
1-16. Engine rpm control System
1-17. Hydraulic Oil Flow Control system
1-18. Input & Output Signal
1-19. Intake Air Warming up System
1-20. Troubleshooting Guide
2.Electric System --------------------------------------------------------------------------------------------------------------------- 216
2-1. Component Location (Cabin)
2-2. Fuses & Relays
2-3. Continual Circuit
2-4. IG Circuit
2-5. Start Circuit
2-6. Charging Circuit
2-7. Lights Circuit
2-8. Monitoring Circuit
2-9. Wiper & Washer Circuit

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Ⅰ.Specification Comparisions

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Hyundai Komastu CAT Hitachi
R140-7 PC130-6 312C ZX120
Oper. Weight
Power, SAE net
DIN net
Bucket PCSA
CECE
Kg
HP/rpm
PS
cu m
cu m
13980
102/2100
103/2100
0.58
0.5
13050
86/2200
87/2200
12200
91/1950
0.5
0.45
12200
85/2100
0.5
0.45
Engine
Model
Cyl*Bore*Stroke
Displacement
Max. torque
mm
cc
Kgf.m/rpm
Cummins
B3.9-C
4*102*120
3920
46.2/1500
Komatsu
S4D102E
4*102*120
3920
CAT
3064-E1T
4250
Isuzu
CC-4BG1TC
4329
Hydraulic pump LPM 2*130 1*226
Oper. Pressure
Attachment
Power boost
Travel
Swing
Kg/cm2
330
360
330
240
325
-
325
275
305
-
350
350
-
Swing speed
Travel speed rpm Km/h
13.6
3.3/5.5 12.0
2.7/3.6/5.5 12.9 3.8/5.5 13.7 3.4/5.5
Standard machine
Boom
Arm
Track shoe width
Track gauge
Tumbler distance
m
m
mm
mm
mm
4600
2500
600
2000
3000
4600
2500
500
1960
2750
4650
2500
500
1990
2780
2000
500
1990
Ground pressure
Max traction force
Bucket digging force,SAE
Arm crawd force,SAE
kg/cm2
ton
ton
ton
0.36
13.3
9.27
9.27
0.41
10.2
8.5
8.5
0.4
11.0 0.38
Fuel tank liter 270 230 250 250
Unit
R140LC-7

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Hyundai Komastu CAT Hitachi
R160LC-7 PC160-6 315C ZX160LC
Oper. Weight
Power, SAE net
DIN net
Bucket PCSA
CECE
Kg
HP/rpm
PS
cu m
cu m
17400
116/2100
118/2100
0.70
0.60
16530
104.5/2100
106/2100
0.58
0.53
16000
-
111/2150
0.65
0.55
15600
-
100/1950
0.6
0.55
Engine
Model
Cyl*Bore*Stroke
Displacement
Max. torque
mm
cc
Kgf.m/rpm
Mitsubishi
S6S-DT
4*94*1200
4996
42.5/1500
Komatsu
SA4D102E
4*102*120
3920
-
CAT
3046-E3DT
-
4990
-
Isuzu
A-4BG1TC
-
4329
-
Hydraulic pump LPM 2*168 276
Oper. Pressure
Attachment
Power boost
Travel
Swing
Kg/cm2
330
360
330
240
325
355
355
325
350
-
350
350
-
Swing speed
Travel speed rpm Km/h
12.1
3.7/5.6 12.0
2.7/4.0/5.5 10.2 3.4/5.6 13.6 3.1/5.3
Standard machine
Boom
Arm
Track shoe width
Track gauge
Tumbler distance
m
m
mm
mm
mm
5100
2600
600
1990
3190
5150
2600
600
1990
2880
5100
2600
500
1990
2880
5100
2580
500
1990
3100
Ground pressure
Max traction force
Bucket digging force,SAE
Arm crawd force,SAE
kg/cm2
ton
ton
ton
0.42
15.7
12.08
8.35
0.44
13.8
12.54
8.393
0.51
-
-
-
0.46
-
9.2
8.1
Fuel tank liter 260 250 285 280
Unit
R160LC-7

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Hyundai Komastu CAT Hitachi
R210LC-7 PC210-6 320B EX200-5
Oper. Weight
Power, SAE net
DIN net
Bucket PCSA
CECE
Kg
HP/rpm
PS
cu m
cu m
21700
143/2100
145/2100
0.92
0.8
21570
133/2200
0.86
20518
128/1800
130/1800
0.80
0.70
18800
133/1950
135/1950
0.80
0.70
Engine
Model
Cyl*Bore*Stroke
Displacement
Max. torque
mm
cc
Kgf.m/rpm
Cummins
B5.9-C
6*102*120
5880
62.0/1600
Komatsu
S6D102E
6*102*120
5880
CAT
3116T
6*105*127
6600
Isuzu
A-6BG1T
6*105*125
6494
47/1600
Hydraulic pump LPM 2*220 2*206 2*180 2*185
Oper. Pressure
Attachment
Power boost
Travel
Swing
Kg/cm2
330
360
330
240
325
355
355
280
350
-
350
235
350
370
350
Swing speed
Travel speed rpm Km/h
12.5
3.4/5.3 12.4
3.2/4.5/5.5 10.7 3.4/5.5 13.9 3.8/5.5
Standard machine
Boom
Arm
Track shoe width
Track gauge
Tumbler distance
m
m
mm
mm
mm
5880
2920
600
2390
3650
5700
2930
600
2380
3640
5680
2900
600
2200
3265
5680
2910
600
2200
3370
Ground pressure
Max traction force
Bucket digging force,SAE
Arm crawd force,SAE
kg/cm2
ton
ton
ton
0.46
21.1
14.84
10.8
0.45
17.7
15.0
10.1
0.48
18.1
13.5
10.1
0.43
17.3
12.2
Fuel tank liter 320 340 340 310
Unit
R210LC-7

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Ⅱ.Hydraulic System

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Hydraulic Tank
Hydraulic Pump
Control Valve
Actuator
1.Outline of Hyd. System: the equipment to transmit the power by oil flow
-Hydraulic Tank : Oil Storage
-Hyd. Pump : Create oil flow to transmit the power
-Control Valve : Direction control of actuator
-Actuator : Working device such as cylinder,motor and etc
Cylinder - Inline movement
Motor – Rotating movement
-Charecteristic of hydraulic oil : incompressible,automatic lubrication,less friction loss, higher
cooling efficiency,more safety for overload,silent operation,precise control

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2.Hydraulic Symbol
Component Symbol Explanation
Line connected each other : Tee joint or
drilled hole
Orifice Reduced diameter of oil passage to
reduce oil flow
Pipe or hose
-Main line
-Pilot line
-Drain or internal leakage
Color code
-Supply line : red
-Return line : blue
-Suction line : green
-Pilot line : brown
-Drain or internal leakage line : green
Line cross over without connection
Line closed or plugged for future usuage
or special purpose
Adjustable orifice Adjustable(or variable)

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Component Symbol Explanation
Check valve
-Without spring
-With spring
-Pilot check valve
Direction controlling device to prevent
reverse flow
One check valve & pilot line in one block
Cooler Exhaust the heat of hyd. oil
Shut off valve
Hyd. tank Hyd. oil storage
Filter Filtering all the dirt in hydraulic system
Breather Maintain the pressure inside of hydraulic
tank same as atmospheric pressure

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Component Symbol Explanation
Cylinder -Double acting : retract and extend by
direction of oil supply
-Single acting : retract by weight and
extend by oil supply
Hydraulic pump
-fixed flow pump
-Variable flow pump
-One direction
-Both direction, depending on rotation of
pump
Discharge amount of pump are flexible
dependng on the pressure at actuator
such as cylinder and motor
Pressure control valve
-Relief valve
-Regulating valve
Safety device to protect hyd. component
such as hose,pipe,cylinder and etc
When the hyd. system overloaded, relief
valve is open and circuit oil go to the tank
through opened passage
Maintain the required pressure all the time
to activate system for transmission clutch
and etc. by increasing decreasing the size
of overflow passage

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Component Symbol Explanation
Direction valve
-2 way
-3 way
For double acting
For single acting
Double acting
-Reducing vave It is used for low pressure circuit.
When the supplied pressure reach to
required value, supplied oil is cut off
Controlling method of direction control
valve
Hand control lever
Foot control pedal

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Component Symbol Explanation
Automatic return control by spring tension
Control valve is fixed with selected
direction
N : neutral position
Motor Rotating device
-Reversible motor
-Irreversible motor : rotate one direction
only
Pressure switch
Button control
Hydraulic control by pilot pressure
Electro-magnet control by electricity

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Component Symbol Explanation
Accumulator
Brake and clutch Applied by spring force
Released by hydraulic pressure
Shuttle valve Two check valve in one block
Oil flow achieved by pressure difference
between left & light hand side
Heater
Logic valve Is combined with piston and orifice
Area difference operates direction control
valve

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3. Hydraulic Circuit
3-1.Main Circuit

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3-2.Pilot Circuit (Crawler Type)

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3-3.Pilot Circuit (Wheel Type)

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3-4.Oil Return Circuit
Return Pressure (Bar)
Model
Oil Cooler By-pass
5
R360LC-7 3 5
R290LC-7A 1.5 3
R210LC-7 35
5
3
3
R450LC-7 3
R320LC-7
R200W-7 3
R180LC-7 1.5
R140LC-7 1.5

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R210LC-7
4-1A.Main Control Valve (Kawasaki)
4. Main Components