Hyundai Robex 140LC-9S User manual

Robex 140LC-9S
CRAWLER EXCAVATOR
SERVICE MANUAL

TABLE OF CONTENT
FOREWORD 9
SECTION 1 GENERAL 17
Group 1 Safety 18
Group 2 Specifications 27
1. Major Component 27
2. Specifications 28
3. Working Range 32
4. Weight 36
5. Lifting Capacities 38
6. Bucket Selection Guide 42
7. Undercarriage 48
8. Specifications For Major Components 50
9. Recommended Oils 53
SECTION 2 STRUCTURE AND FUNCTION 54
Group 1 Pump Device 55
1. Structure 55
2. Function 60
Group 2 Main Control Valve 73
1. Structure 73
2. Hydraulic Circuit 75
3. Function 76
Group 3 Swing Device 100
1. Structure 100
2. Principle Of Driving 103
Group 4 Travel Device 112
1. Construction 112
Group 5 Rcv Lever 122
1. Structure 122
2. Functions 125
Group 6 Rcv Pedal 129
1. Structure 129
2. Function 131
SECTION 3 HYDRAULIC SYSTEM 135
Group 2 Main Circuit 137
1. Suction And Delivery Circuit 137
2. Return Circuit 138
3. Drain Circuit 139
Group 3 Pilot Circuit 140
1. Suction, Delivery And Return Circuit 141
2. Safety Solenoid Valve (safety Lever) 142
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3. Boom Priority System 143
4. Travel Speed Control System 144
5. Main Relief Pressure Change System 145
6. Arm Regeneration Cut System (cluster Type 1) 146
7. Swing Parking Brake Release 147
Group 4 Single Operation 148
1. Boom Up Operation 148
2. Boom Down Operation 149
3. Arm In Operation 150
4. Arm Out Operation 151
5. Bucket In Operation 152
6. Bucket Out Operation 153
7. Dozer Up Operation 154
8. Dozer Down Operation 155
9. Swing Operation 156
8. Travel Forward And Reverse Operation 158
Group 5 Combined Operation 160
1. Outline 160
2. Combined Swing And Boom Up Operation 161
3. Combined Swing And Arm Operation 162
4. Combined Swing And Bucket Operation 163
5. Combined Swing And Travel Operation 164
6. Combined Boom And Travel Operation 165
7. Combined Arm And Travel Operation 166
8. Combined Bucket And Travel Operation 167
SECTION 4 ELECTRICAL SYSTEM 168
Group 1 Component Location 169
1. Location 1 169
2. Location 2 170
Memorandum 175
1. Power Circuit (cluster Type 1) 176
2. Power Circuit (cluster Type 2) 178
3. Starting Circuit (cluster Type 1) 180
4. Starting Circuit (cluster Type 2) 182
5. Charging Circuit (cluster Type 1) 184
6. Charging Circuit (cluster Type 2) 186
7. Head And Work Light Circuit (cluster Type 1) 188
8. Head And Work Light Circuit (cluster Type 2) 190
9. Beacon Lamp And Cab Light Circuit (cluster Type 1) 192
10. Beacon Lamp And Cab Light Circuit (cluster Type 2) 194
11. Wiper And Washer Circuit (cluster Type 1) 196
12. Wiper And Washer Circuit (cluster Type 2) 198
Group 3 Electrical Component Specification 206
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Group 4 Connectors 214
1. Connector Destination 214
2. Connection Table For Connectors 218
SECTION 5 MECHATRONICS SYSTEM 237
Group 1 Outline 238
Group 2 Mode Selection System (cluster Type 1) 241
1. Power Mode Selection System 241
2. Work Mode Selection System 242
3. User Mode Selection System 243
Mode Selection System (cluster Type 2) 244
1. Power Mode Selection System 244
2. Work Mode Selection System 245
3. User Mode Selection System 246
Group 3 Automatic Deceleration System (cluster Type 1) 247
1. When Auto Idle Pilot Lamp On 2. When Auto Idle Pilot Lamp Off 247
Automatic Deceleration System (cluster Type 2) 248
1. When Auto Idle Pilot Lamp On 2. When Auto Idle Pilot Lamp Off 248
Group 4 Power Boost System (cluster Type 1) 249
Power Boost System (cluster Type 2) 250
Group 5 Travel Speed Control System (cluster Type 1) 251
Travel Speed Control System (cluster Type 2) 252
Group 6 Automatic Warming Up System (cluster Type 1) 253
Automatic Warming Up System (cluster Type 2) 254
Group 7 Engine Overheat Prevention System (cluster Type 1) 255
Engine Overheat Prevention System (cluster Type 2) 256
Group 8 Variable Power Control System (cluster Type 1) 257
Group 9 Attachment Flow Control System (cluster Type 1) 258
Group 10 Anti-restart System 259
1. Anti-restart Function 259
Group 11 Self-diagnostic System (cluster Type 1) 260
1. 2. 260
3. Machine Error Codes Table (cluster Type 1) 261
Self-diagnostic System (cluster Type 2) 264
3. Machine Error Codes Table (cluster Type 2) 265
Group 12 Engine Control System 267
1. Mcu (machine Control Unit) 267
2. Mcu Assembly 267
3. Exchange Method Of The Rom In The Cluster (type 2) 268
Group 13 Eppr Valve (cluster Type 1) 269
1. Pump Eppr Valve 269
1) 269
3) 270
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4) 271
2. Boom Priority Eppr Valve (cluster Type 1, 2) 272
4) 273
Eppr Valve (cluster Type 2) 274
1. Pump Eppr Valve 274
1) 274
Group 14 Monitoring System (cluster Type 1) 275
1. Outline 275
2. Cluster 275
3. Cluster Connector 277
Monitoring System (cluster Type 2) 298
1. 2. 298
3. Cluster Connector 300
Group 15 Fuel Warmer System 311
1. Specification 311
2. Operation 311
3. Electric Circuit 311
SECTION 6 TROUBLESHOOTING 312
Group 1 Before Troubleshooting 313
1. Introduction 313
2. Diagnosing Procedure 314
Group 2 Hydraulic And Mechanical System 316
1. Introduction 316
2. Drive System 317
3. Hydraulic System 319
4. Swing System 321
5. Travel System 325
6. Attachment System 330
Group 3 Electrical System (cluster Type 1) 336
1. When Starting Switch Is Turned On, Monitor Panel Display Does Not Appear
336
3. Battery Charging Warning Lamp Lights Up (starting Switch : On) 338
4. When Coolant Overheat Warning Lamp Lights Up (engine Is Started) 339
5. When Air Cleaner Warning Lamp Lights Up (engine Is Started) 340
6. When Engine Oil Pressure Warning Lamp Lights Up (engine Is Started) 341
7. When Hydraulic Oil Temperature Warning Lamp Lights Up (engine Is Started)
342
8. When Coolant Temperature Gauge Does Not Operate (hcespn 304, Fmi 3 Or 4)
343
9. When Fuel Gauge Does Not Operate (hcespn 301, Fmi 3 Or 4) 344
10. When Safety Solenoid Does Not Operate 345
11. When Travel Speed 1, 2 Does Not Operate (hcespn 167, Fmi 5 Or 6) 346
Electrical System (cluster Type 2) 352
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1. When Starting Switch Is Turned On, Monitor Panel Display Does Not Appear
352
3. Battery Charging Warning Lamp Lights Up (starting Switch : On) 354
4. When Coolant Overheat Warning Lamp Lights Up (engine Is Started) 355
5. When Air Cleaner Warning Lamp Lights Up (engine Is Started) 356
6. When Engine Oil Pressure Warning Lamp Lights Up (engine Is Started) 357
7. When Hydraulic Oil Temperature Warning Lamp Lights Up (engine Is Started)
358
8. When Coolant Temperature Gauge Does Not Operate 359
9. When Fuel Gauge Does Not Operate (check Warning Lamp On/off) 360
10. When Safety Solenoid Does Not Operate 361
11. When Travel Speed 1, 2 Does Not Operate 362
Group 4 Mechatronics System (cluster Type 1) 368
1. All Actuators Speed Are Slow 368
2. Engine Stall 370
3. Malfunction Of Cluster Or Mode Selection System 372
5. Auto Decel System Does Not Work 375
6. Malfunction Of Pump 1 Pressure Sensor 377
7. Malfunction Of Pump 2 Pressure Sensor 379
8. Malfunction Of Pump 3 Pressure Sensor 381
9. Malfunction Of Swing Pressure Sensor 383
10. Malfunction Of Boom Up Pressure Sensor 385
11. Malfunction Of Power Max 387
12. Malfunction Of Boom Priority Eppr Valve 389
13. Malfunction Of Arm Regeneration Solenoid 390
10. Malfunction Of Boom Up Pressure Sensor 391
Mechatronics System (cluster Type 2) 393
1. All Actuators Speed Are Slow 393
2. Engine Stall 395
3. Malfunction Of Cluster Or Mode Selection System 397
5. Auto Decel System Does Not Work 400
6. Malfunction Of Pump 1 Pressure Sensor 402
7. Malfunction Of Pump 2 Pressure Sensor 404
8. Malfunction Of Pump 3 Pressure Sensor 406
9. Malfunction Of Power Max 408
10. Malfunction Of Boom Priority Eppr Valve 410
SECTION 7 MAINTENANCE STANDARD 411
Group 1 Operational Performance Test 412
1. Purpose 412
2. Terminology 413
3. Operation For Performance Tests 414
Group 2 Major Component 434
1. Main Pump 434
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2. Main Control Valve 435
3. Swing Device 436
4. Travel Motor 437
5. Rcv Lever 438
6. Rcv Pedal 439
7. Turning Joint 440
8. Cylinder 441
Group 3 Track And Work Equipment 442
1. Track 442
2. Work Equipment 447
SECTION 8 DISASSEMBLY AND ASSEMBLY 448
Group 1 Precautions 449
1. Removal Work 449
2. Install Work 450
3. Completing Work 451
Group 2 Tightening Torque 452
1. Major Components 452
2. Torque Chart 453
Group 3 Pump Device 455
1. Removal And Install 455
2. Main Pump (1/2) 457
3. Regulator 466
Group 4 Main Control Valve 477
1. Removal And Install Of Motor 477
2. Structure (1/4) 478
3. Disassembly And Assembly 482
Group 5 Swing Device (type 2) 512
1. Removal And Install Of Motor 512
Group 6 Travel Device 545
1. Removal And Install 545
2. Travel Motor 546
3. Disassembly 550
4. Reassembly 562
Group 7 Rcv Lever 573
1. Removal And Install 573
2. Disassembly And Assembly 574
Group 8 Turning Joint 587
1. Removal And Install 587
2. Disassembly And Assembly 588
Group 9 Boom, Arm And Bucket Cylinders 592
1. Removal And Install 592
2. Disassembly And Assembly 598
Group 10 Undercarriage 610
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1. Track Link 610
2. Carrier Roller 611
3. Track Roller 612
4. Idler And Recoil Spring 613
Group 11 Work Equipment 622
1. Structure 622
2. Removal And Install 623
SECTION 9 COMPONENT MOUNTING TORQUE 626
Group 1 Introduction Guide 627
Group 2 Engine System 628
1. Engine And Accessories Mounting 628
2. Cooling System And Fuel Tank Mounting 629
Group 3 Electric System 630
1. Electric Components Mounting 1 630
2. Electric Components Mounting 2 631
Group 4 Hydraulic System 632
1. Hydraulic Components Mounting 1 632
2. Hydraulic Components Mounting 2 633
3. Hydraulic Components Mounting 3 634
Group 5 Undercarriage 635
Group 6 Structure 636
1. Cab And Accessories Mounting 636
2. Cab Interior Mounting 637
3. Cowling Mounting 638
4. Counterweight And Covers Mounting 639
Group 7 Work Equipment 640
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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
「
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