Hyundai HX235 LCR Service Manual
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Hyundai HX235 LCR Service Manual

Crawler excavator
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HX235 LCR
CRAWLER EXCAVATOR
SERVICE MANUAL

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Summary of Contents for Hyundai HX235 LCR

  • Page 1 HX235 LCR 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 SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device Group 2 Main Control Valve Group 3 Swing Device Group 4 Travel Device (type 1, 2) Group 5 Rcv Lever Group 6 Rcv Pedal...
  • Page 3 Group 11 Intelligent Power Control System Group 12 Anti-restart System Group 13 Self-diagnostic System Group 14 Engine Control System Group 15 Eppr Valve Group 16 Monitoring System Group 17 Fuel Warmer System SECTION 6 TROUBLESHOOTING Group 1 Before Troubleshooting Group 2 Hydraulic And Mechanical System Group 3 Electrical System Group 4 Mechatronics Systegroup System SECTION 7 MAINTENANCE STANDARD...

  • Page 4: Foreword

    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 5: 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 6: 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 1.
  • Page 7 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 8 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 9 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 10 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 11 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 12: Section 1 General

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

  • Page 13: 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 14 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 15 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 16 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 17 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 18 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 19 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 20 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 21 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 22: Group 2 Specifications

    GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENT DEF/AdBlue tank Fuel tank Hydraulic tank Main pump Main control valve After treatment device Engine Oil cooler Radiator Charge air cooler Turning joint Swing motor Battery Tooth Bucket Guardrail Boom cylinder Arm cylinder Boom Counterweight Muffler Swing bearing...
  • Page 23 2. SPECIFICATIONS 2. SPECIFICATIONS 1) 1) HX235LCR HX235LCR ·5.68 m (18' 8") BOOM and 2.92 m (9' 7") ARM I(I') 91N6-07102 91N6-07102 B(L) 235F2SP02 Description Unit Specification Operating weight kg (lb) 24000 (52910) Bucket capacity (SAE heaped), standard 0.8 (1.05) Overall length 8910 (29' 3") Overall width, with 600mm shoe...
  • Page 24 2) 2) HX235LCR HX235LCR ·5.65 m (18' 6") HYD ADJUSTABLE BOOM AND 2.4 m (7' 10") ARM WITH DOZER I(I') 91N6-07102 91N6-07102 B(L) 235F2SP02A Description Unit Specification Operating weight kg (lb) 26700 (58860) Bucket capacity (SAE heaped), standard 0.8 (1.05) Overall length A / A' 8910 (29' 3") / 9760 (32' 0")
  • Page 25 3. WORKING RANGE HX235LCR 5.68 m (18' 8") MONO BOOM 235F2SP03 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") Max digging reach on ground 8860 mm...
  • Page 26 HX235LCR 5.65 m (18' 6") ADJUSTABLE BOOM 235F2SP03A Description 2.0 m (6' 7") Arm 2.40 m (7' 10") Arm 2.92 m (9' 7") Arm Max digging reach 9050 mm (29' 8") 9460 mm (31' 0") 10020 mm (32' 10") Max digging reach on ground 8880 mm (29' 2") 9290 mm...
  • Page 27 4. WEIGHT 4. WEIGHT Item Upperstructure assembly ·Main frame weld assembly 2008 4430 ·Engine assembly 1150 ·Main pump assembly ·Main control valve assembly ·Swing motor assembly ·Hydraulic oil tank assembly ·Fuel tank assembly ·Counterweight 5300 11680 ·Cab assembly Lower chassis assembly ·Track frame weld assembly 2720 6000...
  • Page 28 Lifting capacities will vary with different work tools, ground conditions and attachments. The difference between the weight of a work tool attachment must be subtracted. Consult your Hyundai dealer regarding the lifting capacities for specific work tools and attachments. Failure to comply to the rated load can cause possible personal injury or property damage.
  • Page 29 5.68 m (18' 8") boom, 2.40 m (7' 10") arm equipped with 0.80 m (SAE heaped) bucket, 600 mm (24") triple grouser shoe. : 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) 4.5 m (15 ft) 6.0 m (20 ft)
  • Page 30 Lifting capacities will vary with different work tools, ground conditions and attachments. The difference between the weight of a work tool attachment must be subtracted. Consult your Hyundai dealer regarding the lifting capacities for specific work tools and attachments. Failure to comply to the rated load can cause possible personal injury or property damage.
  • Page 31 5.65 m (18' 6") boom, 2.40 m (7' 10") arm equipped with 0.80 m (SAE heaped) bucket, 600 mm (24") triple grouser shoe. : Rating over-front : Rating over-side or 360 degree At max. reach 3.0 m (10 ft) 4.5 m (15 ft) 6.0 m (20 ft) 7.5 m (25 ft) Capacity...
  • Page 32 Work tools and ground conditions have effects on machine performance. Select an optimum combination according to the working conditions and the type of work that is being done. Consult your Hyundai dealer for information on selecting the correct boom arm bucket combination. 1-20...
  • Page 33 HEAVY DUTY AND ROCK-HEAVY DUTY BUCKET 0.90, 1.05 m SAE heaped bucket 0.87 m SAE heaped bucket Recommendation Capacity Width 5.68 m (18' 8") boom Weight Without With 2.0 m arm 2.4 m arm 2.92 m arm heaped heaped side cutter side cutter (6' 7") (7' 10")
  • Page 34 7. UNDERCARRIAGE 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. TYPES OF SHOES Triple grouser Model...
  • Page 35 SELECTION OF TRACK SHOE Suitable track shoes should be selected according to operating conditions. Method of selecting shoes Confirm the category from the list of applications in table 2, then use table 1 to select the shoe. Wide shoes (categories B and C) have limitations on applications. Before using wide shoes, check the precautions, then investigate and study the operating conditions to confirm if these shoes are suitable.
  • Page 36 8. SPECIFICATIONS FOR MAJOR COMPONENTS 8. SPECIFICATIONS FOR MAJOR COMPONENTS ENGINE ENGINE Item Specification Model Cummins QSB6.7 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 Direct injection type Cylinder bore×stroke 107×124 mm (4.2"×4.9")
  • Page 37 GEAR PUMP Item Specification Type Fixed displacement gear pump single stage Capacity 15 cc/rev Maximum pressure 40 kgf/cm (570 psi) Rated oil flow 28.5 /min (7.5 U.S. gpm/6.3 U.K. gpm) MAIN CONTROL VALVE Item Specification Type 9 spools two-block Operating method Hydraulic pilot system Main relief valve pressure 350 kgf/cm...
  • Page 38 CYLINDER Item Specification Bore dia Rod dia Stroke 85 1290 mm Boom cylinder Cushion Extend only Bore dia Rod dia Stroke 100 1510 mm Arm cylinder Cushion Extend and retract Bore dia Rod dia Stroke 85 1055 mm Bucket cylinder Cushion Extend only Bore dia...
  • Page 39 ※ Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of major components.

  • 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 ------------------------------------------------------------------------------------------- 2-29 Group 3 Swing Device ---------------------------------------------------------------------------------------------------- 2-56 Group 4 Travel Device ----------------------------------------------------------------------------------------------------- 2-67 Group 5 RCV Lever --------------------------------------------------------------------------------------------------------- 2-81 Group 6 RCV Pedal -------------------------------------------------------------------------------------------------------- 2-88...

  • Page 41: Group 1 Pump Device

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