Hyundai Robex 235LCR-9A Service Manual Download | Manualshive

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Robex 235LCR-9A

CRAWLER EXCAVATOR

SERVICE MANUAL

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Summary of Contents for Robex 235LCR-9A

Page 1: ...Robex 235LCR 9A CRAWLER EXCAVATOR SERVICE MANUAL ...

Page 2: ... 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 Gro...

Page 3: ...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 B...

Page 4: ...evention 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 Pum...

Page 5: ...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 Sp...

Page 6: ... 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 A...

Page 7: ...4 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 Gro...

Page 8: ...ngle 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...

Page 9: ... 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...

Page 10: ...the left to convert it to 55mm Carry out the same procedure as above to convert 55mm to 2 165 inches The original value 550mm 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 550mm 21 65 inches 1 2 1 2 3 1 2 3 Millimeters to inches 1mm 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 ...

Page 11: ...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 Kilogram to Pound 1kg 2 2046lb 0 1 2 3 4 5 6 7 8 9 0 2 20 4 41 6 61 8 82 11 02 13 23 15 43 17 64 19 84 10 22 05 24 25 26 46 28 66 30 86 33 07 35 27 37 48 39 68 41 89 20 44 09 46 30 48 50 50 71 51 91 55 12 57 32 59 5 61 73 63 93 30 66 14 68 34 70 55 72 75 74 96 77 16 79 37 81 57 83 78 85 98 40 88 18 90 39 92 59 94 80 9...

Page 12: ...2 455 22 719 22 983 23 247 23 511 90 23 775 24 040 24 304 24 568 24 832 25 096 25 631 25 625 25 889 26 153 Liter to U K Gallon 1ℓ 0 21997 U K Gal 0 1 2 3 4 5 6 7 8 9 0 0 220 0 440 0 660 0 880 1 100 1 320 1 540 1 760 1 980 10 2 200 2 420 2 640 2 860 3 080 3 300 3 520 3 740 3 950 4 179 20 4 399 4 619 4 839 5 059 5 279 5 499 5 719 5 939 6 159 6 379 30 6 599 6 819 7 039 7 259 7 479 7 969 7 919 8 139 8...

Page 13: ...0 629 3 636 5 643 7 90 651 0 658 2 665 4 672 7 679 9 687 1 694 4 701 6 708 8 716 1 100 723 3 730 5 737 8 745 0 752 2 759 5 766 7 773 9 781 2 788 4 110 795 6 802 9 810 1 817 3 824 6 831 8 839 0 846 3 853 5 860 7 120 868 0 875 2 882 4 889 7 896 9 904 1 911 4 918 6 925 8 933 1 130 940 3 947 5 954 8 962 0 969 2 976 5 983 7 990 9 998 2 10005 4 140 1012 6 1019 9 1027 1 1034 3 1041 5 1048 8 1056 0 1063 2...

Page 14: ...280 1294 1309 1323 1337 1351 1365 1380 1394 1408 100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550 110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693 120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835 130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977 140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119 150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262 160 2276 2290 2304 2318 233...

Page 15: ...2 2 90 194 0 26 1 15 5 0 6 7 20 68 0 12 8 55 131 0 32 2 90 194 0 25 6 14 6 8 6 1 21 69 8 13 3 56 132 8 32 8 91 195 8 25 0 13 8 6 5 6 22 71 6 13 9 57 134 6 33 3 92 197 6 24 4 12 10 4 5 0 23 73 4 14 4 58 136 4 33 9 93 199 4 23 9 11 12 2 4 4 24 75 2 15 0 59 138 2 34 4 94 201 2 23 3 10 14 0 3 9 25 77 0 15 6 60 140 0 35 0 95 203 0 22 8 9 15 8 3 3 26 78 8 16 1 61 141 8 35 6 96 204 8 22 2 8 17 6 2 8 27 8...

Page 16: ...SECTION 1 GENERAL Group 1 Safety Hints 1 1 Group 2 Specifications 1 10 ...

Page 17: ... excavator attach a Do Not Operate tag on the right side control lever 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 sl...

Page 18: ...goggles or safety glasses 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 Serious injury or death can result from contact with electric lines Never move any part of the machine or load closer to electri...

Page 19: ...ator 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 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 Before wor...

Page 20: ...LY 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 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 flamma...

Page 21: ... ventilated area Dispose of paint and solvent properly Remove paint before welding or heating If you sand or grind paint avoid breathing the dust Wear an approved respirator If you use solvent or paint stripper remove stripper with soap and water before welding Remove solvent or paint stripper containers and other flammable material from area Allow fumes to disperse at least 15 minutes before weld...

Page 22: ...jury To prevent accidents use care when working around rotating parts AVOID HIGH PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard Protect hands and body from high pressure fluids I...

Page 23: ...ials Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area Install fire resisting guards to protect hoses or other materials PREVENT BATTERY EXPLOSIONS Keep sparks lighted matches and flame away from the top of battery Battery gas can explode Never check battery charge by placing a metal object across the posts Use a volt meter or hydrometer Do not charge a froze...

Page 24: ...r lime to help neutralize the acid 3 Flush your eyes with water for 10 15 minutes Get medical attention immediate ly If acid is swallowed 1 Drink large amounts of water or milk 2 Then drink milk of magnesia beaten eggs or vegetable oil 3 Get medical attention immediately 13031GE22 USE TOOLS PROPERLY Use tools appropriate to the work Makeshift tools parts and procedures can create safety hazards Us...

Page 25: ...om them DO NOT pour oil into the ground down a drain or into a stream pond or lake Observe relevant environmental protection regulations when disposing of oil fuel coolant brake fluid filters batteries and other harmful waste REPLACE SAFETY SIGNS Replace missing or damaged safety signs See the machine operator s manual for correct safety sign placement LIVE WITH SAFETY Before returning machine to ...

Page 26: ... Boom Arm cylinder Arm Track Bucket cylinder Side cutter Control link Control rod Track roller Idler Carrier roller Fuel tank Hydraulic tank Main pump Tooth Turning joint Swing motor Engine Radiator Charge air cooler Bucket Main control valve Battery Oil cooler Swing bearing After treatment device 2359A2SP01 ...

Page 27: ...980 9 9 Overall height of cab E 2950 9 8 Ground clearance of counterweight F 1060 3 6 Engine cover height G 2385 7 10 Minimum ground clearance H 480 1 7 Rear end distance I 1780 5 10 Rear end swing radius I 1780 5 10 Distance between tumblers J 3650 12 0 Undercarriage length K 4440 14 7 Undercarriage width L 2990 9 10 Track gauge M 2390 7 10 Track shoe width standard N 600 24 Travel speed low high...

Page 28: ...250 26900 29210 125 5 136 3 12800 13900 28220 30640 kN kgf lbf kN kgf lbf kN kgf lbf kN kgf lbf B B C D E A A F 8ft 235Z92SP03 2 92 m 9 7 Arm 9910 mm 9750 mm 6700 mm 6530 mm 6270 mm 10830 mm 7890 mm 2350 mm 32 6 32 0 22 0 21 5 20 7 35 6 25 11 7 9 133 4 144 8 13600 14770 29980 32550 152 0 165 0 15500 16830 34170 37100 102 0 110 7 10400 11290 22930 24900 106 9 116 1 10900 11830 24030 26090 kN kgf lb...

Page 29: ...0 19180 Track frame weld assembly 2720 6000 Swing bearing 290 640 Travel motor assembly 305 670 Turning joint 55 120 Track recoil spring 140 310 Idler 170 370 Carrier roller 20 45 Track roller 40 90 Track chain assembly 600 mm standard triple grouser shoe 1350 2980 Front attachment assembly 5 68 m boom 2 92 m arm 0 8 m3 SAE heaped bucket 3965 8740 5 68 m boom assembly 1520 3350 2 92 m arm assembly...

Page 30: ... 0 m kg 3780 3780 3430 2560 8 66 20 0 ft lb 8330 8330 7560 5640 28 4 4 5 m kg 4810 4810 4190 4190 3860 3240 3460 2200 9 24 15 0 ft lb 10600 10600 9240 9240 8510 7140 7630 4850 30 3 3 0 m kg 9730 9730 6240 6240 4860 4540 4150 3100 3520 2020 9 52 10 0 ft lb 21450 21450 13760 13760 10710 10010 9150 6830 7760 4450 31 2 1 5 m kg 9500 9500 7650 6600 5560 4240 4490 2950 3590 1960 9 52 5 0 ft lb 20940 209...

Page 31: ... 2 92marm 9 7 0 51m3 0 67yd3 0 45 m3 0 59 yd3 700mm 27 6 820mm 312 3 570 kg 1260 lb 0 80m3 1 05yd3 0 70 m3 0 92 yd3 1000mm 39 4 1120mm 44 1 700 kg 1540 lb 0 87m3 1 14yd3 0 75 m3 0 98 yd3 1090mm 42 9 1210mm 47 6 740 kg 1630 lb 0 92m3 1 20yd3 0 80 m3 1 05 yd3 1150mm 45 3 1270mm 50 0 770 kg 1700 lb 1 10m3 1 44yd3 0 96 m3 1 26 yd3 1320mm 52 0 1440mm 56 7 830 kg 1830 lb 1 20m3 1 57yd3 1 00 m3 1 31 yd3 ...

Page 32: ...y bucket Slope finishing bucket 0 74 0 90 1 05 m3 SAE heaped bucket 0 87 m3 SAE heaped bucket 0 75 m3 SAE heaped bucket Capacity Width Weight Recommendation 5 65 m 18 6 boom SAE heaped SAE heaped Without side cutter With side cutter 2 0marm 6 7 2 4marm 7 10 2 92marm 9 7 0 74 m3 0 97 yd3 0 65 m3 0 85 yd3 985mm 38 8 770 kg 1700 lb 0 90 m3 1 18 yd3 0 80 m3 1 05 yd3 1070mm 42 1 810 kg 1790 lb 1 05 m3 ...

Page 33: ...ype tractor shoes with triple grousers TYPES OF SHOES 1 2 NUMBER OF ROLLERS AND SHOES ON EACH SIDE 3 Model Shapes Triple grouser R235LCR 9A Shoe width mm in 600 24 700 28 800 32 900 36 Operating weight kg lb 23800 52470 24150 53240 24415 53830 24680 54410 Ground pressure kgf cm2 psi 0 51 7 25 0 44 6 26 0 39 5 55 0 35 4 98 Overall width mm ft in 2990 9 10 3090 10 2 3190 10 6 3290 10 10 Item Quantit...

Page 34: ...hoe Specification Category 600 mm triple grouser Standard A 700 mm triple grouser Option B 800 mm triple grouser Option C 900 mm triple grouser Option C Category Applications Precautions A Rocky ground river beds normal soil Travel at low speed on rough ground with large obstacles such as boul ders or fallen trees B Normal soil soft ground These shoes cannot be used on rough ground with large obst...

Page 35: ...tio 17 3 1 Rated gross horse power SAE J1995 167 Hp at 1950 rpm 124 kW at 1950 rpm Maximum torque at 1500 rpm 74 7 kgf m 540 lbf ft Engine oil quantity 23 1ℓ 6 1 U S gal Dry weight 519 kg 1144 lb High idling speed 1950 50 rpm Low idling speed 850 100 rpm Rated fuel consumption 165 5 g Hp hr at 1950 rpm Starting motor Nippon denso 24 V 4 3 kW Alternator Delco Remy 24 V 95 A Battery 2 12 V 100 Ah It...

Page 36: ...2 570 psi Rated oil flow 28 5 ℓ min 7 5 U S gpm 6 3 U K gpm Item Specification Type Two fixed displacement axial piston motor Capacity 151 cc rev Relief pressure 285 kgf cm2 4050 psi Braking system Automatic spring applied hydraulic released Braking torque 59 kgf m 427 lbf ft Brake release pressure 33 50 kgf cm2 470 711 psi Reduction gear type 2 stage planetary Item Specification Type Variable dis...

Page 37: ...3 3 700 mm 27 6 820 mm 32 3 0 80 m3 1 05 yd3 0 70 m3 0 92 yd3 5 1000 mm 39 4 1120 mm 44 1 0 87 m3 1 14 yd3 0 75 m3 0 98 yd3 5 1090 mm 42 9 1120 mm 47 6 0 92 m3 1 20 yd3 0 80 m3 1 05 yd3 5 1150 mm 45 3 1270 mm 50 0 1 10 m3 1 44 yd3 0 96 m3 1 26 yd3 5 1320 mm 52 0 1440 mm 56 7 1 20 m3 1 57 yd3 1 00 m3 1 31 yd3 5 1400 mm 55 1 1520 mm 60 0 1 34 m3 1 75 yd3 1 15 m3 1 50 yd3 6 1550 mm 61 0 1670 mm 65 7 ...

Page 38: ...tank Mixture of antifreeze and water 50 50 40 10 6 SAE 30 SAE 10W SAE 10W 30 SAE 15W 40 SAE 80W 90 ISO VG 46 ISO VG 68 侏ASTM D975 NO 1 ASTM D975 NO 2 侏NLGI NO 1 NLGI NO 2 Ethylene glycol base permanent type 侏SAE 5W 40 侏SAE 75W 90 侏ISO VG 15 侏Ethyleneglycolbasepermanenttype 60 40 50 30 20 10 0 10 20 30 40 58 22 4 14 32 50 68 86 104 SAE Society of Automotive Engineers API American Petroleum Institut...

Page 39: ...SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device 2 1 Group 2 Main Control Valve 2 20 Group 3 Swing Device 2 47 Group 4 Travel Device 2 58 Group 5 RCV Lever 2 72 Group 6 RCV Pedal 2 79 ...

Page 40: ...sv a4 Pi2 a6 a7 A1 A2 Pi1 A1 A2 Dr A3 Pi1 Pi2 Psv B1 B3 a7 a6 a3 a2 a1 a4 ENG VIEW A A A2 A1 a1 a2 a6 a7 Hydraulic circuit Qmax adjusting screw Port A1 2 B1 Dr Pi1 i2 Psv a1 2 4 a6 7 a3 A3 B3 Port name Delivery port Suction port Drain port Pilot port Servo assist port Gauge port Gauge port Gauge port Gear pump delivery port Gear pump suction port Port size SAE6000psi 1 SAE2500psi 2 1 2 PF 3 4 20 P...

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