Hyundai Robex 140LC-9 User manual

Robex 140LC-9
CRAWLER EXCAVATOR
SERVICE MANUAL

Table of Content
FOREWORD 8
SECTION 1 GENERAL 16
Group 1 Safety 17
Group 2 Specifications 26
1. Major Component 26
2. Specifications 27
3. Working Range 31
4. Weight 35
5. Lifting Capacities 37
6. Bucket Selection Guide 41
7. Undercarriage 47
8. Specifications For Major Components 49
9. Recommended Oils 52
SECTION 2 STRUCTURE AND FUNCTION 53
Group 1 Pump Device 54
1. Structure 54
2. Function 59
Group 2 Main Control Valve 72
1. Structure 72
2. Hydraulic Circuit 74
3. Function 75
Group 3 Swing Device 99
1. Structure 99
2. Principle Of Driving 102
Group 4 Travel Device 111
1. Construction 111
Group 5 Rcv Lever 121
1. Structure 121
2. Functions 124
Group 6 Rcv Pedal 128
1. Structure 128
2. Function 130
SECTION 3 HYDRAULIC SYSTEM 134
Group 1 Hydraulic Circuit 135
Group 2 Main Circuit 136
1. Suction And Delivery Circuit 136
2. Return Circuit 137
3. Drain Circuit 138
Group 3 Pilot Circuit 139
1. Suction, Delivery And Return Circuit 140
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2. Safety Solenoid Valve (safety Lever) 141
3. Boom Priority System 142
4. Travel Speed Control System 143
5. Main Relief Pressure Change System 144
6. Arm Regeneration Cut System 145
7. Swing Parking Brake Release 146
Group 4 Single Operation 147
1. Boom Up Operation 147
2. Boom Down Operation 148
3. Arm In Operation 149
4. Arm Out Operation 150
5. Bucket In Operation 151
6. Bucket Out Operation 152
7. Dozer Up Operation 153
8. Dozer Down Operation 154
9. Swing Operation 155
8. Travel Forward And Reverse Operation 157
Group 5 Combined Operation 159
1. Outline 159
2. Combined Swing And Boom Up Operation 160
3. Combined Swing And Arm Operation 161
4. Combined Swing And Bucket Operation 162
5. Combined Swing And Travel Operation 163
6. Combined Boom And Travel Operation 164
7. Combined Arm And Travel Operation 165
8. Combined Bucket And Travel Operation 166
SECTION 4 ELECTRICAL SYSTEM 167
Group 1 Component Location 168
1. Location 1 168
2. Location 2 169
Memorandum 172
1. Power Circuit 173
2. Starting Circuit 175
3. Charging Circuit 177
4. Head And Work Light Circuit 179
5. Beacon Lamp And Cab Light Circuit 181
6. Wiper And Washer Circuit 183
Group 3 Electrical Component Specification 188
Group 4 Connectors 196
1. Connector Destination 196
2. Connection Table For Connectors 200
SECTION 5 MECHATRONICS SYSTEM 219
Group 1 Outline 220
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Group 2 Mode Selection System 222
1. Power Mode Selection System 222
2. Work Mode Selection System 223
3. User Mode Selection System 224
Group 3 Automatic Deceleration System 225
1. When Auto Idle Pilot Lamp On 2. When Auto Idle Pilot Lamp Off 225
Group 4 Power Boost System 226
Group 5 Travel Speed Control System 227
Group 6 Automatic Warming Up System 228
Group 7 Engine Overheat Prevention System 229
Group 8 Variable Power Control System 230
Group 9 Attachment Flow Control System 231
Group 10 Anti-restart System 232
1. Anti-restart Function 232
Group 11 Self-diagnostic System 233
3. Machine Error Codes Table 234
4. Engine Fault Code 237
Group 12 Engine Control System 239
1. Mcu And Engine Ecm (electronic Control Module) 239
2. Mcu Assembly 239
Group 13 Eppr Valve 240
1. Pump Eppr Valve 240
2. Boom Priority Eppr Valve 243
Group 14 Monitoring System 245
1. Outline 245
2. Cluster 245
3. Cluster Connector 247
Group 15 Fuel Warmer System 268
1. Specification 268
2. Operation 268
3. Electric Circuit 268
SECTION 6 TROUBLESHOOTING 269
Group 1 Before Troubleshooting 270
1. Introduction 270
2. Diagnosing Procedure 271
Group 2 Hydraulic And Mechanical System 273
1. Introduction 273
2. Drive System 274
3. Hydraulic System 276
4. Swing System 278
5. Travel System 282
6. Attachment System 287
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Group 3 Electrical System 293
1. When Starting Switch Is Turned On, Monitor Panel Display Does Not Appear
293
3. Battery Charging Warning Lamp Lights Up(starting Switch : On) 295
~ 295
4. When Coolant Overheat Warning Lamp Lights Up (engine Is Started) 296
5. When Air Cleaner Warning Lamp Lights Up (engine Is Started) 297
6. When Engine Oil Pressure Warning Lamp Lights Up (engine Is Started) 298
7. When Hydraulic Oil Temperature Warning Lamp Lights Up (engine Is Started)
299
8. When Coolant Temperature Gauge Does Not Operate (hcespn 304, Fmi 3 Or 4)
300
9. When Fuel Gauge Does Not Operate(hcespn 301, Fmi 3 Or 4) 301
10. When Safety Solenoid Does Not Operate 302
11. When Travel Speed 1, 2 Does Not Operate (hcespn 167, Fmi 5 Or 6) 303
12. When Engine Does Not Start ( Lights Up Condition) 304
13. When Starting Switch On Does Not Operate 305
14. When Starting Switch Is Turned On, Wiper Motor Does Not Operate 306
15. When Starting Switch Is Turned On, Head Lamp Does Not Lights Up 307
16. When Starting Switch Is Turned On, Work Lamp Does Not Lights Up 308
Group 4 Mechatronics Systegroup System 309
1. All Actuators Speed Are Slow 309
2. Engine Stall 311
3. Malfunction Of Cluster Or Mode Selection System 313
4. Malfunction Of Accel Dial 314
5. Auto Decel System Does Not Work 316
6. Malfunction Of Pump 1 Pressure Sensor 318
7. Malfunction Of Pump 2 Pressure Sensor 320
8. Malfunction Of Pump 3 Pressure Sensor 322
9. Malfunction Of Negative 1 Pressure Sensor 324
10. Malfunction Of Negative 2 Pressure Sensor 326
11. Malfunction Of Swing Pressure Sensor 328
12. Malfunction Of Arm In/out & Bucket In Pressure Sensor 330
13. Malfunction Of Boom Up Pressure Sensor 332
14. Malfunction Of Power Max 334
15. Malfunction Of Boom Priority Eppr Valve 336
16. Malfunction Of Arm Regeneration Solenoid 337
SECTION 7 MAINTENANCE STANDARD 339
Group 1 Operational Performance Test 340
1. Purpose 340
2. Terminology 341
3. Operation For Performance Tests 342
Group 2 Major Component 360
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1. Main Pump 360
2. Main Control Valve 361
3. Swing Device 362
4. Travel Motor 363
5. Rcv Lever 364
6. Rcv Pedal 365
7. Turning Joint 366
8. Cylinder 367
Group 3 Track And Work Equipment 368
1. Track 368
2. Work Equipment 373
SECTION 8 DISASSEMBLY AND ASSEMBLY 374
Group 1 Precautions 375
1. Removal Work 375
2. Install Work 376
3. Completing Work 377
Group 2 Tightening Torque 378
1. Major Components 378
2. Torque Chart 379
Group 3 Pump Device 381
1. Removal And Install 381
2. Main Pump (1/2) 383
3. Regulator 392
Group 4 Main Control Valve 403
1. Removal And Install Of Motor 403
2. Structure (1/4) 404
3. Disassembly And Assembly 408
Group 5 Swing Device 417
1. Removal And Install Of Motor 417
2. Disassembly And Assembly Of Swing Motor 418
3. Removal And Install Of Reduction Gear 429
4. Disassembly And Assembly Of Reduction Gear 430
Group 6 Travel Device 438
1. Removal And Install 438
2. Travel Motor 439
3. Disassembly 443
4. Reassembly 455
Group 7 Rcv Lever 466
1. Removal And Install 466
2. Disassembly And Assembly 467
Group 8 Turning Joint 480
1. Removal And Install 480
2. Disassembly And Assembly 481
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Group 9 Boom, Arm And Bucket Cylinders 485
1. Removal And Install 485
2. Disassembly And Assembly 491
Group 10 Undercarriage 503
1. Track Link 503
2. Carrier Roller 504
3. Track Roller 505
4. Idler And Recoil Spring 506
Group 11 Work Equipment 515
1. Structure 515
2. Removal And Install 516
SECTION 9 COMPONENT MOUNTING TORQUE 519
Group 1 Introduction Guide 520
Group 2 Engine System 521
1. Engine And Accessories Mounting 521
2. Cooling System And Fuel Tank Mounting 522
Group 3 Electric System 523
1. Electric Components Mounting 1 523
2. Electric Components Mounting 2 524
Group 4 Hydraulic System 525
1. Hydraulic Components Mounting 1 525
2. Hydraulic Components Mounting 2 526
3. Hydraulic Components Mounting 3 527
Group 5 Undercarriage 528
Group 6 Structure 529
1. Cab And Accessories Mounting 529
2. Cab Interior Mounting 530
3. Cowling Mounting 531
4. Counterweight And Covers Mounting 532
Group 7 Work Equipment 533
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SECTION 1 GENERAL
SECTION 1 GENERAL
Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1
Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10

FOLLOW SAFE PROCEDURE
FOLLOW SAFE PROCEDURE
Unsafe work practices are dangerous.
Understand service procedure before doing
work; Do not attempt shortcuts.
WEAR PROTECTIVE CLOTHING
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment
appropriate to the job.
WARN OTHERS OF SERVICE WORK
WARN OTHERS OF SERVICE WORK
Unexpected machine movement can cause
serious injury.
Before performing any work on the excavator,
attach a
Ö
Do Not Operate
Do Not Operate × tag on the right
side control lever.
USE HANDHOLDS AND STEPS
USE HANDHOLDS AND STEPS
Falling is one of the major causes of personal
injury.
When you get on and off the machine, always
maintain a three point contact with the steps
and handrails and face the machine. Do not
use any controls as handholds.
Never jump on or off the machine. Never mount
or dismount a moving machine.
Be careful of slippery conditions on platforms,
steps, and handrails when leaving the machine.
SECTION 1 GENERAL
SECTION 1 GENERAL
GROUP 1 SAFETY
GROUP 1 SAFETY
1-1
13031GE01
13031GE02
13031GE03

PREPARE FOR EMERGENCIES
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors,
ambulance service, hospital, and fire
department near your telephone.
PROTECT AGAINST FLYING DEBRIS
PROTECT AGAINST FLYING DEBRIS
Guard against injury from flying pieces of metal
or debris; Wear goggles or safety glasses.
PROTECT AGAINST NOISE
PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause
impairment or loss of hearing.
Wear a suitable hearing protective device such
as earmuffs or earplugs to protect against
objectionable or uncomfortable loud noises.
AVOID POWER LINES
AVOID POWER LINES
Serious injury or death can result from contact
with electric lines.
Never move any part of the machine or load
closer to electric line than 3m(10ft) plus twice
the line insulator length.
1-2
13031GE04
13031GE05
13031GE06
13031GE07

KEEP RIDERS OFF EXCAVATOR
KEEP RIDERS OFF EXCAVATOR
Only allow the operator on the excavator. Keep
riders off.
Riders on excavator are subject to injury such
as being struck by foreign objects and being
thrown off the excavator. Riders also obstruct
the operator's view resulting in the excavator
being operated in an unsafe manner.
MOVE AND OPERATE MACHINE SAFELY
MOVE AND OPERATE MACHINE SAFELY
Bystanders can be run over. Know the location
of bystanders before moving, swinging, or
operating the machine.
Always keep the travel alarm in working
condition. It warns people when the excavator
starts to move.
Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the
excavator.
OPERATE ONLY FORM OPERATOR'S SEAT
OPERATE ONLY FORM OPERATOR'S SEAT
Avoid possible injury machine damage. Do not
start engine by shorting across starter
terminals.
NEVER start engine while standing on ground.
Start engine only from operator's seat.
PARK MACHINE SAFELY
PARK MACHINE SAFELY
Before working on the machine:
 Park machine on a level surface.
 Lower bucket to the ground.
 Turn auto idle switch off.
 Run engine at 1/2 speed without load for 2 minutes.
 Turn key switch to OFF to stop engine. Remove key
from switch.
 Move pilot control shutoff lever to locked position.
 Allow engine to cool.
1-3
13031GE08
13031GE09
13031GE26

SUPPORT MACHINE PROPERLY
SUPPORT MACHINE PROPERLY
Always lower the attachment or implement to
the ground before you work on the machine. If
you must work on a lifted machine or
attachment, securely support the machine or
attachment.
Do not support the machine on cinder blocks,
hollow tiles, or props that may crumble under
continuous load.
Do not work under a machine that is supported
solely by a jack. Follow recommended
procedures in this manual.
SERVICE COOLING SYSTEM SAFELY
SERVICE COOLING SYSTEM SAFELY
Explosive release of fluids from pressurized
cooling system can cause serious burns.
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands.
HANDLE FLUIDS SAFELY-AVOID FIRES
HANDLE FLUIDS SAFELY-AVOID FIRES
Handle fuel with care; It is highly flammable.
Do not refuel the machine while smoking or
when near open flame or sparks. Always stop
engine before refueling machine.
Fill fuel tank outdoors.
Store flammable fluids away from fire hazards.
Do not incinerate or puncture pressurized
containers.
Make sure machine is clean of trash,
grease, and debris.
Do not store oily rags; They can ignite and
burn spontaneously.
1-4
13031GE10
13031GE11
13031GE12
13031GE13