Hyundai Robex 235LCR-9 Service Manual
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Hyundai Robex 235LCR-9 Service Manual

Crawler excavator
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Robex 235LCR-9
CRAWLER EXCAVATOR
SERVICE MANUAL

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Summary of Contents for Hyundai Robex 235LCR-9

  • Page 1 Robex 235LCR-9 CRAWLER EXCAVATOR SERVICE MANUAL...

  • Page 2: Table Of Contents

    TABLE OF CONTENT FOREWORD 1. Structure 2. How To Read The Service Manual 3. Conversion Table SECTION 1 GENERAL Group 1 Safety Group 2 Specifications 1. Major Component 2. Specifications 3. Working Range 4. Weight 5. Lifting Capacities 6. Bucket Selection Guide 7.
  • Page 3 2. Return Circuit 3. Drain Circuit Group 3 Pilot Circuit 1. Suction, Delivery And Return Circuit 2. Safety Valve (safety Lever) 3. Boom Priority System 4. Travel Speed Control System 5. Main Relief Pressure Change System 6. Arm Regeneration Cut System 7.
  • Page 4 Group 3 Electrical Component Specification Group 4 Connectors 1. Connector Destination 2. Connection Table For Connectors SECTION 5 MECHATRONICS SYSTEM Group 1 Outline Group 2 Mode Selection System 1. Power Mode Selection System 2. Work Mode Selection System 3. User Mode Selection System Group 3 Automatic Deceleration System 1.
  • Page 5 1. Introduction 2. Drive System 3. Hydraulic System 4. Swing System 5. Travel System 6. Attachment System Group 3 Electrical System 1. When Starting Switch Is Turned On, Monitor Panel Display Does Not Appear 3. Battery Charging Warning Lamp Lights Up(starting Switch : On) 4.
  • Page 6 Group 1 Operational Performance Test 1. Purpose 2. Terminology 3. Operation For Performance Tests Group 2 Major Component 1. Main Pump 2. Main Control Valve 3. Swing Device 4. Travel Motor 5. Rcv Lever 6. Rcv Pedal 7. Turning Joint 8.
  • Page 7 Group 7 Rcv Lever 1. Removal And Install 2. Disassembly And Assembly Group 8 Turning Joint 1. Removal And Install 2. Disassembly And Assembly Group 9 Boom, Arm And Bucket Cylinder 1. Removal And Install 2. Disassembly And Assembly Group 10 Undercarriage 1.

  • Page 8: Foreword

    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. Find manuals at https://best-manuals.com...

  • Page 9: How To Read The Service Manual

    Revised edition mark(①②③…) Any additions, amendments or other changes will When a manual is revised, an edition mark is be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.

  • Page 10: Conversion Table

    3. CONVERSION TABLE 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 Example Method of using the Conversion Table to convert from millimeters to inches...
  • Page 11 Millimeters to inches Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339...
  • Page 12 Liter to U.S. Gallon Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189...
  • Page 13 kgf·m to to lbf lbf·ft ft 1kgf·m = 7.233lbf·ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2...
  • Page 14 kgf/cm kgf/cm to to lbf/in lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7...
  • Page 15 TEMPERATURE TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.

  • Page 16: Section 1 General

    SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10...

  • Page 17: Group 1 Safety

    SECTION 1 GENERAL SECTION 1 GENERAL GROUP 1 SAFETY GROUP 1 SAFETY FOLLOW SAFE PROCEDURE FOLLOW SAFE PROCEDURE Unsafe wor k 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.
  • Page 18 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 ser vice, hospital, and fire department near your telephone. 13031GE04 PROTECT AGAINST FLYING DEBRIS PROTECT AGAINST FLYING DEBRIS Guard against injury from flying pieces of metal or debris;...
  • Page 19 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.
  • Page 20 SUPPORT MACHINE PROPERLY SUPPORT MACHINE PROPERLY Always lower the attachment or implement to the ground before you work on the machine. If you must wor k 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 13031GE10 continuous load.
  • Page 21 BEWARE OF EXHAUST FUMES BEWARE OF EXHAUST FUMES Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. If you must operate in a building, be positive there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.
  • Page 22 SERVICE MACHINE SAFELY SERVICE MACHINE SAFELY Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.
  • Page 23 AVOID HEATING NEAR PRESSURIZED AVOID HEATING NEAR PRESSURIZED FLUID LINES FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.
  • Page 24 PREVENT ACID BURNS PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2.
  • Page 25 DISPOSE OF FLUIDS PROPERLY DISPOSE OF FLUIDS PROPERLY Improperly disposing of fluids can harm the environment and ecology. Before draining any fluids, find out the proper way to dispose of waste from your local environmental agency. Use proper containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

  • Page 26: Group 2 Specifications

    GROUP 2 SPECIFICATIONS GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENT 1. MAJOR COMPONENT Main control valve Fuel tank Hydraulic tank Main pump Engine Radiator Oil cooler Tooth Turning joint Swing motor Battery Bucket Arm cylinder Boom Boom cylinder Muffler Counterweight Bucket cylinder Sprocket Control link Idler...

  • Page 27: Specifications

    2. SPECIFICATIONS 2. SPECIFICATIONS 1) 1) R235LCR-9 R235LCR-9 ·5.68 m (18' 8") BOOM and 2.92 m (9' 7") ARM I(I') B(L) 235Z92SP02 Description Unit Specification Operating weight kg (lb) 23800 (52470) Bucket capacity (SAE heaped), standard 0.8 (1.05) Overall length 8910 (29' 3") Overall width, with 600mm shoe 2990 (9' 10")

  • Page 28: Working Range

    3. WORKING RANGE WORKING RANGE 1) 1) R235LCR-9 R235LCR-9 ·5.68 m (18' 8") BOOM 235Z92SP03 Description 2.0 m (6' 7") Arm 2.40 m (7' 10") Arm 2.92 m (9' 7") Arm Max digging reach 9040 mm (29' 8") 9430 mm (30' 11") 9910 mm (32' 6")

  • Page 29: Weight

    4. WEIGHT 4. WEIGHT 1) 1) R235LCR-9 R235LCR-9 R235LCR-9 Item Upperstructure assembly 11100 24470 Main frame weld assembly 1930 4250 Engine assembly 1240 Main pump assembly Main control valve assembly Swing motor assembly Hydraulic oil tank assembly Fuel tank assembly Counterweight 5600 12350...

  • Page 30: Lifting Capacities

    5. LIFTING CAPACITIES 5. LIFTING CAPACITIES R235LCR-9 R235LCR-9 5.68 m (18' 8") boom, 2.92 m (9' 7") arm equipped with 0.80 m (SAE heaped) bucket, 600 mm (24") triple grouser shoe without dozer blade. · · : Rating over-front : Rating over-side or 360 degree Load radius At max.
  • Page 31 5.68 m (18' 8") boom, 2.92 m (9' 7") arm equipped with 0.80 m (SAE heaped) bucket, 600 mm (24") triple grouser shoe with dozer blade. · · : Rating over-front : Rating over-side or 360 degree Load radius At max. reach Load point 1.5 m (5 ft) 3.0 m (10 ft)

  • Page 32: Bucket Selection Guide

    6. BUCKET SELECTION GUIDE 6. BUCKET SELECTION GUIDE 1) 1) GENERAL BUCKET GENERAL BUCKET 0.51 m 0.80, 0.87, 0.92, 1.10, 1.20 m 1.34 m SAE heaped bucket heaped bucket SAE heaped bucket Recommendation Capacity Width 5.65 m (18' 6") Mono boom Weight CECE Without...
  • Page 33 2) 2) HEAVY DUTY, ROCK-HEAVY DUTY AND SLOPE FINISHING BUCKET HEAVY DUTY, ROCK-HEAVY DUTY AND SLOPE FINISHING BUCKET Heavy duty bucket Rock-Heavy duty bucket Slope fi nishing bucket ◈ 0.74, 0.90, 1.05 m ⊙ 0.87 m ▣ 0.75 m SAE heaped bucket SAE heaped bucket heaped bucket Recommendation...

  • Page 34: Undercarriage

    7. UNDERCARRIAGE 7. UNDERCARRIAGE 1) 1) TRACKS TRACKS X-leg type center frame is integrally welded with reinforced box-section track frames. The design includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock absorb- ing springs and assembled track-type tractor shoes with triple grousers. 2) 2) TYPES OF SHOES TYPES OF SHOES...
  • Page 35 4) 4) SELECTION OF TRACK SHOE SELECTION OF TRACK SHOE Suitable track shoes should be selected according to operating conditions. Method of selecting shoes Method of selecting shoes Confirm the category from the list of applications in table 2 table 2, then use table 1 table 1 to select the shoe.

  • Page 36: Specifications For Major Components

    8. SPECIFICATIONS FOR MAJOR COMPONENTS ENGINE Item Specification Model Cummins QSB6.7 / HYUNDAI HE 6.7 Type 4-cycle turbocharged diesel engine, low emission Cooling method Water cooling Number of cylinders and arrangement 6 cylinders, in-line Firing order 1-5-3-6-2-4 Combustion chamber type...
  • Page 37 3) 3) GEAR PUMP GEAR PUMP Item Specification Type Fixed displacement gear pump single stage Capacity 15 cc/rev Maximum pressure 40 kgf/cm (570 psi) 28.5 ℓ/min (7.5 U.S. gpm/6.3 U.K. gpm) Rated oil flow 4) 4) MAIN CONTROL VALVE MAIN CONTROL VALVE Item Specification Type...
  • Page 38 7) 7) CYLINDER CYLINDER Item Specification Ø120×Ø85×1290 mm Bore dia×Rod dia×Stroke Boom cylinder Cushion Extend only Ø140×Ø100×1510 mm Bore dia×Rod dia×Stroke Arm cylinder Cushion Extend and retract Ø120×Ø85×1055 mm Bore dia×Rod dia×Stroke Bucket cylinder Cushion Extend only ※ Discoloration of cylinder rod can occur when the friction reduction additive of lubrication oil spreads on the rod surface.

  • Page 39: Recommended Oils

    9. RECOMMENDED OILS Use only oils listed below. Do not mix different brand oil. Please use HYUNDAI genuine oil and grease. Ambient temperature C( F) Service Capacity Kind of fluid (U.S. gal) point (-58) (-22) (-4) (14) (32) (50) (68)

  • Page 40: Section 2 Structure And Function

    SECTION 2 STRUCTURE AND FUNCTION 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 ---------------------------------------------------------------------------------------------------------- 2-66 Group 6 RCV Pedal ---------------------------------------------------------------------------------------------------------- 2-73...

  • Page 41: Group 1 Pump Device

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