Hyundai HX235 LCR, Service Manual

Page 1: ...HX235 LCR T3 CRAWLER EXCAVATOR SERVICE MANUAL ...

Page 2: ...OMPONENT LOCATION 176 2 ELECTRICAL CIRCUIT 178 3 ELECTRICAL COMPONENT SPECIFICATION 197 4 CONNECTORS 208 MECHATRONICS SYSTEM 232 1 OUTLINE 233 2 MODE SELECTION SYSTEM 235 3 AUTOMATIC DECELERATION SYSTEM 238 4 POWER BOOST SYSTEM 239 5 TRAVEL SPEED CONTROL SYSTEM 240 6 AUTOMATIC WARMING UP SYSTEM 241 7 ENGINE OVERHEAT PREVENTION system 242 8 VARIABLE POWER CONTROL SYSTEM 243 9 ATTACHMENT FLOW CONTRO...

Page 3: ...MAINTENANCE STANDARD 396 1 OPERATIONAL PERFORMANCE TEST 397 2 MAJOR COMPONENT 417 3 TRACK AND WORK EQUIPMENT 426 DISASSEMBLY AND ASSEMBLY 433 1 PRECAUTIONS 434 2 TIGHTENING TORQUE 437 3 PUMP DEVICE 440 4 MAIN CONTROL VALVE 468 5 SWING DEVICE 483 6 TRAVEL DEVICE TYPE1 2 513 7 RCV LEVER 545 8 TURNING JOINT 559 9 BOOM ARM AND BUCKET CYLINDER 564 10 UNDERCARRIAGE 585 11 WORK EQUIPMENT 597 Find manuals...

Page 4: ... 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 ai...

Page 5: ...rt 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 safe...

Page 6: ...he left to convert it to 55 mm Carry out the same procedure as above to convert 55 mm 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 23...

Page 7: ...0 3 543 3 583 3 622 3 661 3 701 3 740 3 780 3 819 3 858 3 898 Kilogram to Pound 1 kg 2 2046 lb 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 97 00 99 21 101 41...

Page 8: ... 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 8 359 8 579 40 8 799...

Page 9: ...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 1070 5 1077 7 150...

Page 10: ... 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 2333 2347 2361 2375 2...

Page 11: ...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 12: ...SECTION 1 GENERAL Group 1 Safety Hints 1 1 Group 2 Specifications 1 10 ...

Page 13: ... 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 14: ...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 15: ...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 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 Befor...

Page 16: ...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 17: ... 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 18: ...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 19: ...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 20: ...or 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 U...

Page 21: ...m 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 LABELS Replace missing or damaged safety labels See the machine operator s manual for correct safety label placement LIVE WITH SAFETY Before returning machine t...

Page 22: ...linder 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 Guardrail 235SA2SP01 ...

Page 23: ... 6 1060 3 6 Overall height of engine hood G 2430 8 0 2430 8 0 2430 8 0 Overall height of handrail G 3380 11 1 3380 11 1 3380 11 1 Minimum ground clearance H 470 1 7 470 1 7 470 1 7 Rear end distance I 1780 5 10 1780 5 10 1780 5 10 Rear end swing radius I 1780 5 10 1780 5 10 1780 5 10 Distance between tumblers J 3650 12 0 3650 12 0 3650 12 0 Undercarriage length K 4404 14 5 4404 14 5 4404 14 5 Unde...

Page 24: ...erall height of handrail G 3380 11 1 3380 11 1 3380 11 1 Minimum ground clearance H 470 1 7 470 1 7 470 1 7 Rear end distance I 1780 5 10 1780 5 10 1780 5 10 Rear end swing radius I 1780 5 10 1780 5 10 1780 5 10 Distance between tumblers J 3650 12 0 3650 12 0 3650 12 0 Undercarriage length K 4404 14 5 4404 14 5 4404 14 5 Undercarriage width L 2990 9 10 2990 9 10 2990 9 10 Track gauge M 2390 7 10 2...

Page 25: ...1060 3 6 Overall height of engine hood G 2430 8 0 2430 8 0 2430 8 0 Overall height of handrail G 3380 11 1 3380 11 1 3380 11 1 Minimum ground clearance H 470 1 7 470 1 7 470 1 7 Rear end distance I 1780 5 10 1780 5 10 1780 5 10 Rear end swing radius I 1780 5 10 1780 5 10 1780 5 10 Distance between tumblers J 3650 12 0 3650 12 0 3650 12 0 Undercarriage length K 4404 14 5 4404 14 5 4404 14 5 Underca...

Page 26: ... 10460 34 4 10130 33 3 Max dumping height E 7900 25 11 7540 24 9 7220 23 8 Min swing radius F 2350 7 9 2550 8 4 2860 9 5 Bucket digging force kN SAE 130 4 142 3 130 4 142 3 130 4 142 3 kgf 13300 14510 13300 14510 13300 14510 lbf 29320 31990 29320 31990 29320 31990 kN ISO 150 0 163 7 150 0 163 7 150 0 163 7 kgf 15300 16690 15300 16690 15300 16690 lbf 33730 36800 33730 36800 33730 36800 Arm digging ...

Page 27: ... 1340 Turning joint 56 120 56 120 56 120 Dozer Blade assembly 931 2050 Sprocket 2EA 112 250 112 250 112 250 Track recoil spring 2EA 283 620 283 620 283 620 Idler 2EA 308 680 308 680 308 680 Carrier roller 2EA 41 90 41 90 41 90 Track roller 18EA 855 1880 855 1880 855 1880 Track chain assembly 600 mm standard triple grouser shoe 2894 6380 2894 6380 2894 6380 Track chain assembly 700 mm standard trip...

Page 28: ...specific work tools and attachments Failure to comply to the rated load can cause possible personal injury or property damage Make adjustments to the rated load as necessory for non standard configurations Lift point height A Lift point radius B At max reach 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft 7 5 m 24 6 ft Capacity Reach m ft 7 5 m kg 5900 5900 5930 5930 4 93 24 6 ft lb 13010 13010 13070 130...

Page 29: ...400 5300 600 A B Rating over front Rating over side or 360 degree Lift point height A Lift point radius B At max reach 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft 7 5 m 24 6 ft Capacity Reach m ft 9 0 m kg 6690 6690 3 26 29 5 ft lb 14750 14750 10 7 7 5 m kg 5310 5310 5080 5080 5 52 24 6 ft lb 11710 11710 11200 11200 18 1 6 0 m kg 5510 5510 5120 4890 4610 3990 6 75 19 7 ft lb 12150 12150 11290 10780 1...

Page 30: ...eight A Lift point radius B At max reach 1 5 m 4 9 ft 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft 7 5 m 24 6 ft Capacity Reach m ft 9 0 m kg 4150 4150 4 32 29 5 ft lb 9150 9150 14 2 7 5 m kg 4610 4610 4230 4230 3370 3370 6 20 24 6 ft lb 10160 10160 9330 9330 7430 7430 20 3 6 0 m kg 4870 4870 4630 4630 3100 3100 7 31 19 7 ft lb 10740 10740 10210 10210 6830 6830 24 0 4 5 m kg 7630 7630 5870 5870 5050 4...

Page 31: ... Wheel Dozer Outtriger HX235LCRT3 W DOZER MONO BOOM Length mm Length mm weight kg width mm width mm Front Rear Front Rear 5680 2000 5300 600 Down A B Rating over front Rating over side or 360 degree Lift point height A Lift point radius B At max reach 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft 7 5 m 24 6 ft Capacity Reach m ft 7 5 m kg 5900 5900 5930 5930 4 93 24 6 ft lb 13010 13010 13070 13070 16 2...

Page 32: ...c work tools and attachments Failure to comply to the rated load can cause possible personal injury or property damage Make adjustments to the rated load as necessory for non standard configurations Lift point height A Lift point radius B At max reach 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft 7 5 m 24 6 ft Capacity Reach m ft 7 5 m kg 5900 5900 5930 5930 4 93 24 6 ft lb 13010 13010 13070 13070 16 2...

Page 33: ...ach m ft 9 0 m kg 6690 6690 3 26 29 5 ft lb 14750 14750 10 7 7 5 m kg 5310 5310 5080 5080 5 52 24 6 ft lb 11710 11710 11200 11200 18 1 6 0 m kg 5510 5510 5120 5120 4610 4580 6 75 19 7 ft lb 12150 12150 11290 11290 10160 10100 22 1 4 5 m kg 9050 9050 6510 6510 5460 5440 4490 3810 7 49 14 8 ft lb 19950 19950 14350 14350 12040 11990 9900 8400 24 6 3 0 m kg 7950 7950 6070 5210 5180 3730 4580 3460 7 87...

Page 34: ...stments to the rated load as necessory for non standard configurations Lift point height A Lift point radius B At max reach 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft 7 5 m 24 6 ft Capacity Reach m ft 9 0 m kg 6690 6690 3 26 29 5 ft lb 14750 14750 10 7 7 5 m kg 5310 5310 5080 5080 5 52 24 6 ft lb 11710 11710 11200 11200 18 1 6 0 m kg 5510 5510 5120 5120 4610 4250 6 75 19 7 ft lb 12150 12150 11290 11...

Page 35: ...nt height A Lift point radius B At max reach 1 5 m 4 9 ft 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft 7 5 m 24 6 ft Capacity Reach m ft 9 0 m kg 4150 4150 4 32 29 5 ft lb 9150 9150 14 2 7 5 m kg 4610 4610 4230 4230 3370 3370 6 20 24 6 ft lb 10160 10160 9330 9330 7430 7430 20 3 6 0 m kg 4870 4870 4630 4630 3100 3100 7 31 19 7 ft lb 10740 10740 10210 10210 6830 6830 24 0 4 5 m kg 7630 7630 5870 5870 50...

Page 36: ...int height A Lift point radius B At max reach 1 5 m 4 9 ft 3 0 m 9 8 ft 4 5 m 14 8 ft 6 0 m 19 7 ft 7 5 m 24 6 ft Capacity Reach m ft 9 0 m kg 4150 4150 4 32 29 5 ft lb 9150 9150 14 2 7 5 m kg 4610 4610 4230 4230 3370 3370 6 20 24 6 ft lb 10160 10160 9330 9330 7430 7430 20 3 6 0 m kg 4870 4870 4630 4630 3100 3100 7 31 19 7 ft lb 10740 10740 10210 10210 6830 6830 24 0 4 5 m kg 7630 7630 5870 5870 5...

Page 37: ...1 140 44 9 900 1 980 5 BUCKET SELECTION 1 These recommendations are for general conditions and average use 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 General bucket Rock h...

Page 38: ... SIDE 3 Model Shapes Triple grouser HX235LCRT3 Shoe width mm in 600 24 700 28 800 32 Operating weight kg lb 24200 53350 24500 54010 24700 54450 Ground pressure kgf cm2 psi 0 52 7 33 0 45 6 36 0 39 5 61 Overall width mm ft in 2990 9 10 3090 10 2 3190 10 6 HX235LCRT3 W DOZER Shoe width mm in 600 24 700 28 800 32 Operating weight kg lb 25500 56220 25780 56830 26060 57450 Ground pressure kgf cm2 psi 0...

Page 39: ...Table 1 Track shoe Specification Category 600 mm triple grouser Standard A 700 mm triple grouser Option B 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 obstacles such as bo...

Page 40: ...tion type Cylinder bore stroke 107 124 mm 4 21 4 88 Displacement 6 7ℓ 408 cu in Compression ratio 17 2 1 Gross power 160 Hp 119 kW at 2200 rpm Net power 157 Hp 117 kW at 2200 rpm Max power 165 Hp 123 kW at 2000 rpm Peak Torque 732 N m 540 lbf ft at 1400 rpm Engine oil quantity 23 7ℓ 6 3 U S gal Wet weight 552 kg 1217 lb Starter motor 24 V 4 8 kW Alternator Valeo 24 V 90 A Item Specification Type V...

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