Hyundai Robex 235LCR-9A User manual

Robex 235LCR-9A
CRAWLER EXCAVATOR
SERVICE MANUAL

TABLE OF CONTENT
FOREWORD 8
1. Structure 8
2. How To Read The Service Manual 9
3. Conversion Table 10
SECTION 1 GENERAL 16
Group 1 Safety 17
Group 2 Specifications 26
1. Major Component 26
2. Specifications 27
3. Working Range 28
4. Weight 29
5. Lifting Capacities 30
6. Bucket Selection Guide 31
7. Undercarriage 33
8. Specifications For Major Components 35
9. Recommended Oils 38
SECTION 2 STRUCTURE AND FUNCTION 39
Group 1 Pump Device 40
1. Structure 40
2. Function 46
Group 2 Main Control Valve 59
1. Structure 59
2. Hydraulic Circuit 62
3. Function 63
Group 3 Swing Device 86
1. Structure 86
2. Principle Of Driving 89
Group 4 Travel Device 97
1. Construction 97
2. Specification 1) 98
2) 99
3. Operation 100
Group 5 Rcv Lever 111
1. Structure 111
2. Functions 114
Group 6 Rcv Pedal 118
1. Structure 118
2. Function 120
SECTION 3 HYDRAULIC SYSTEM 124
Group 1 Hydraulic Circuit 125
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Group 2 Main Circuit 126
1. Suction And Delivery Circuit 126
2. Return Circuit 127
3. Drain Circuit 128
Group 3 Pilot Circuit 129
1. Suction, Delivery And Return Circuit 130
2. Safety Valve (safety Lever) 131
3. Boom Priority System 132
4. Travel Speed Control System 133
5. Main Relief Pressure Change System 134
6. Arm Regeneration Cut System 135
7. Swing Parking Brake Release 136
Group 4 Single Operation 137
1. Boom Up Operation 137
2. Boom Down Operation 138
3. Arm In Operation 139
4. Arm Out Operation 140
5. Bucket In Operation 141
6. Bucket Out Operation 142
7. Swing Operation 143
8. Travel Forward And Reverse Operation 145
Group 5 Combined Operation 147
1. Outline 147
2. Combined Swing And Boom Up Operation 148
3. Combined Swing And Arm Operation 149
4. Combined Swing And Bucket Operation 150
5. Combined Swing And Travel Operation 151
6. Combined Boom And Travel Operation 152
7. Combined Arm And Travel Operation 153
8. Combined Bucket And Travel Operation 154
9. Combined Boom Up And Bucket Operation 155
SECTION 4 ELECTRICAL SYSTEM 156
Group 1 Component Location 157
1. Location 1 157
2. Location 2 158
Group 2 Electrical Circuit(1/2) 159
Memorandum 161
1. Power Circuit 162
2. Starting Circuit 164
3. Charging Circuit 166
4. Head And Work Light Circuit 168
5. Beacon Lamp And Cab Light Circuit 170
6. Wiper And Washer Circuit 172
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Group 3 Electrical Component Specification 177
Group 4 Connectors 185
1. Connector Destination 185
2. Connection Table For Connectors 189
SECTION 5 MECHATRONICS SYSTEM 208
Group 1 Outline 209
Group 2 Mode Selection System 211
1. Power Mode Selection System 211
2. Work Mode Selection System 212
3. User Mode Selection System 213
Group 3 Automatic Deceleration System 214
1. When Auto Idle Pilot Lamp On 2. When Auto Idle Pilot Lamp Off 214
Group 4 Power Boost System 215
Group 5 Travel Speed Control System 216
Group 6 Automatic Warming Up System 217
Group 7 Engine Overheat Prevention System 218
Group 8 Variable Power Control System 219
Group 9 Attachment Flow Control System 220
Group 10 Anti-restart System 221
1. Anti-restart Function 221
Group 11 Self-diagnostic System 222
1. 2. 222
3. Machine Error Codes Table 223
4. Engine Fault Code 227
Group 12 Engine Control System 247
1. Mcu And Engine Ecm (electronic Control Module) 247
2. Mcu Assembly 247
Group 13 Eppr Valve 248
1. Pump Eppr Valve 248
2. Boom Priority Eppr Valve 251
Group 14 Monitoring System 253
1. Outline 253
2. Cluster 253
3. Cluster Connector 255
Group 15 Fuel Warmer System 278
1. Specification 278
2. Operation 278
3. Electric Circuit 278
SECTION 6 TROUBLESHOOTING 279
Group 1 Before Troubleshooting 280
1. Introduction 280
2. Diagnosing Procedure 281
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Group 2 Hydraulic And Mechanical System 283
1. Introduction 283
2. Drive System 284
3. Hydraulic System 286
4. Swing System 288
5. Travel System 292
6. Attachment System 297
Group 3 Electrical System 303
1. When Starting Switch Is Turned On, Monitor Panel Display Does Not Appear
303
2. Communication Error Flashes On The Cluster (hcespn 840, Fmi 2) 304
3. Battery Charging Warning Lamp Lights Up (starting Switch : On) 305
4. When Coolant Overheat Warning Lamp Lights Up (engine Is Started) 306
5. When Air Cleaner Warning Lamp Lights Up (engine Is Started) 307
6. When Engine Oil Pressure Warning Lamp Lights Up (engine Is Started) 308
7. When Hydraulic Oil Temperature Warning Lamp Lights Up (engine Is Started)
309
8. When Coolant Temperature Gauge Does Not Operate (hcespn 304, Fmi 3 Or 4)
310
9. When Fuel Gauge Does Not Operate (hcespn 301, Fmi 3 Or 4) 311
10. When Safety Solenoid Does Not Operate 312
11. When Travel Speed 1, 2 Does Not Operate (hcespn 167, Fmi 5 Or 6) 313
12. When Engine Does Not Start ( Lights Up Condition) 314
13. When Starting Switch On Does Not Operate 315
14. When Starting Switch Is Turned On, Wiper Motor Does Not Operate 316
15. When Starting Switch Is Turned On, Head Lamp Does Not Lights Up 317
16. When Starting Switch Is Turned On, Work Lamp Does Not Lights Up 318
Group 4 Mechatronics System 319
1. All Actuators Speed Are Slow 319
2. Engine Stall 321
3. Malfunction Of Cluster Or Mode Selection System 323
4. Malfunction Of Accel Dial 324
5. Auto Decel System Does Not Work 326
6. Malfunction Of Pump 1 Pressure Sensor 328
7. Malfunction Of Pump 2 Pressure Sensor 330
8. Malfunction Of Pump 3 Pressure Sensor 332
9. Malfunction Of Negative 1 Pressure Sensor 334
10. Malfunction Of Negative 2 Pressure Sensor 336
11. Malfunction Of Swing Pressure Sensor 338
12. Malfunction Of Arm In/out & Bucket In Pressure Sensor 340
13. Malfunction Of Boom Up Pressure Sensor 342
14. Malfunction Of Power Max 344
15. Malfunction Of Boom Priority Eppr Valve 346
16. Malfunction Of Arm Regeneration Solenoid 347
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SECTION 7 MAINTENANCE STANDARD 349
Group 1 Operational Performance Test 350
1. Purpose 350
2. Terminology 351
3. Operation For Performance Tests 352
Group 2 Major Component 370
1. Main Pump 370
2. Main Control Valve 371
3. Swing Device 372
4. Travel Motor 373
5. Rcv Lever 374
6. Rcv Pedal 375
7. Turning Joint 376
8. Cylinder 377
Group 3 Track And Work Equipment 378
1. Track 378
2. Work Equipment 383
SECTION 8 DISASSEMBLY AND ASSEMBLY 384
Group 1 Precautions 385
1. Removal Work 385
2. Install Work 386
3. Completing Work 387
Group 2 Tightening Torque 388
1. Major Components 388
2. Torque Chart 389
Group 3 Pump Device 391
1. Removal And Install 391
2. Main Pump (1/2) 393
3. Regulator 403
Group 4 Main Control Valve 414
1. Removal And Install Of Motor 414
2. Structure (1/4) 415
3. Disassembly And Assembly 419
Group 5 Swing Device 438
1. Removal And Install Of Motor 438
2. Disassembly And Assembly Of Swing Motor 439
3. Removal And Install Of Reduction Gear 453
4. Disassembly And Assembly Of Reduction Gear 454
Group 6 Travel Device 463
1. Removal And Install 463
2. Travel Motor 464
3. Disassembling 467
4. Reassembling 474
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2) 482
6. Disassembling 483
7. Assembly Redution Unit 489
Group 7 Rcv Lever 495
1. Removal And Install 495
2. Disassembly And Assembly 496
Group 8 Turning Joint 509
1. Removal And Install 509
2. Disassembly And Assembly 510
Group 9 Boom, Arm And Bucket Cylinder 514
1. Removal And Install 514
2. Disassembly And Assembly 520
Group 10 Undercarriage 531
1. Track Link 531
2. Carrier Roller 532
3. Track Roller 533
4. Idler And Recoil Spring 534
Group 11 Work Equipment 543
1. Structure 543
2. Removal And Install 544
SECTION 9 COMPONENT MOUNTING TORQUE 547
Group 1 Introduction Guide 548
Group 2 Engine System 549
Group 3 Electric System 551
Group 4 Hydraulic System 553
Group 5 Undercarriage 557
Group 6 Structure 558
Group 7 Work Equipment 562
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0-1
FOREWORD
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to
perform repairs and make judgements. Make sure you understand the contents of this manual and
use it to full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
SECTION 1 GENERAL
This section explains the safety hints and gives the specification of the machine and major
components.
SECTION 2 STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
SECTION 3 HYDRAULIC SYSTEM
This section explains the hydraulic circuit, single and combined operation.
SECTION 4 ELECTRICAL SYSTEM
This section explains the electrical circuit, monitoring system and each component. It serves not
only to give an understanding electrical system, but also serves as reference material for trouble
shooting.
SECTION 5 MECHATRONICS SYSTEM
This section explains the computer aided power optimization system and each component.
SECTION 6 TROUBLESHOOTING
This section explains the troubleshooting charts correlating problems to causes.
SECTION 7 MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
SECTION 8 DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
SECTION 9 COMPONENT MOUNTING TORQUE
This section shows bolt specifications and standard torque values needed when mounting
components to the machine.
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your HYUNDAI distributor for the latest information.
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0-2
Revised edition mark(①②③…)
When a manual is revised, an edition mark is
recorded on the bottom outside corner of the
pages.
Revisions
Revised pages are shown at the list of revised
pages on the between the contents page and
section 1 page.
Symbols
So that the shop manual can be of ample
practical use, important places for safety and
quality are marked with the following symbols.
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating
Any additions, amendments or other changes will
be sent to HYUNDAI distributors.
Get the most up-to-date information before you
start any work.
Filing method
See the page number on the bottom of the
page.
File the pages in correct order.
Following examples shows how to read the
page number.
Example 1
2 - 3
Item number(2. Structure and
Function)
Consecutive page number for
each item.
Additional pages : Additional pages are
indicated by a hyphen(-) and number after the
page number. File as in the example.
1.
2.
3.
Symbol Item Remarks
Special safety precautions are
necessary when performing the
work.
Extra special safety precautions
are necessary when performing
the work because it is under
internal pressure.
Special technical precautions or
other precautions for preserving
standards are necessary when
performing the work.
Safety
Caution
※
10 - 4
10 - 4 - 1
10 - 4 - 2
10 - 5
Added pages
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0-3
3. CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.
Example
Method of using the Conversion Table to convert from millimeters to inches
Convert 55 mm into inches.
Locate the number 50 in the vertical column at the left side, take this as ⓐ , then draw a
horizontal line from ⓐ .
Locate the number 5 in the row across the top, take this as ⓑ , then draw a perpendicular line
down from ⓑ .
Take the point where the two lines cross as ⓒ . This point ⓒ gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
Convert 550 mm into inches.
The number 550 does not appear in the table, so divide by 10(Move the decimal point one place
to the left) to convert it to 55 mm .
Carry out the same procedure as above to convert 55mm to 2.165 inches.
The original value(550 mm ) was divided by 10, so multiply 2.165 inches by 10(Move the decimal
point one place to the right) to return to the original value.
This gives 550 mm = 21.65 inches.
1.
2.
(1)
(2)
(3)
(1)
(2)
(3)
Millimeters to inches 1
mm = 0.03937 in
ⓑ
ⓐ
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
ⓒ
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