Hyundai Crawler Service Guide
Service Guide
Crawler Excavator
INDEX
Ⅰ. Specification Comparisions --------------------------------------------------------------------------------------------- 3
Ⅱ.Hydraulic System -------------------------------------------------------------------------------------------------------------- 7
1.Outline of Hydraulic system ------------------------------------------------------------------------------------------------- 8
2.Hydraulic Symbol --------------------------------------------------------------------------------------------------------------- 9
3.Hydraulic Circuit ---------------------------------------------------------------------------------------------------------------- 15
3-1.Main Circuit
3-2.Pilot Circuit (Crawler Type)
3-3.Pilot Circuit (Wheel Type)
3-4.Oil Return Circuit
4.Main Components --------------------------------------------------------------------------------------------------------------- 19
4-1.Main Control Valve
4-2.Main Pump
4-3.Pilot Circuit
4-4.Swing Motor
4-5.Travel Motor
4-6.Remote Control Valve
4-7.Remote Control Pedal
4-8.Turning Joint
4-9.Safety Valve
4-10.Others
Page1
5.Breaker /Double Function Piping ----------------------------------------------------------------------------------------- 152
5-1.Breaker /Clamshell Piping
5-2.Single Acting Circuit
5-3.Double Acting
5-4.Comparison Table
5-5.Oil Flow / rpm
Ⅲ.Electric & New CAPO System ---------------------------------------------------------------------------------------- 159
1.CAPO System ------------------------------------------------------------------------------------------------------------------- 160
1-1. Power Mode Selection System
1-2. Switches on Joy Stick Lever
Construction Equipment
1-3. Monitor Panel (Cluster)
1-4. Communication
1-5. Automatic Deceleration System
1-6. Power Boost System
1-7. Travel Speed Control System
1-8. Automatic Warming Up & Engine Overheat prevention
1-9. Anti - R estart Function
1-10. Location of Solenoid Valves
1-11. Work/Power Mode Selection
1-12. Monitoring Display on Cluster
1-13. Malfunction of Cluster or Mode Sele ction System
1-14. Accel. Actulator
1-15. Engine Speed Sensor (not for excavators with QS-engines)
1-16. Engine rpm control System
1-17. Hydraulic Oil Flow Control system
1-18. Input & Output Signal
1-19. Intake Air Warming up System
1-20. Troubleshooting Guide
2.Electric System --------------------------------------------------------------------------------------------------------------------- 216
2-1. Component Location (Cabin)
2-2. Fuses & Relays
2-3. Continual Circuit
2-4. IG Circuit
2-5. Start Circuit
2-6. Charging Circuit
2-7. Lights Circuit
2-8. Monitoring Circuit
2-9. Wiper & Washer Circuit
Page2
Construction Equipment
Ⅰ.Specification Comparisions
Page3
Construction Equipment
R140LC-7
Unit
Hyundai Komastu CAT Hitachi
R140-7
PC130-6 312C ZX120
Oper. Weight
Power, SAE net
DIN net
Bucket PCSA
CECE
Engine
Model
Cyl*Bore*Stroke
Displacement
Max. torque
Hydraulic pump LPM
Oper. Pressure
Attachment
Power boost
Travel
Swing
Swing speed
Travel speed
Standard machine
Boom
Arm
Track shoe width
Track gauge
Tumbler distance
Ground pressure
Max traction force
Bucket digging force,SAE
Arm crawd force,SAE
Fuel tank liter
Kg
HP/rpm
PS
cu m
cu m
mm
cc
Kgf.m/rpm
Kg/cm2
rpm
Km/h
m
m
mm
mm
mm
kg/cm2
ton
ton
ton
13980
102/2100
103/2100
0.58
0.5
Cummins
B3.9-C
4*102*120
3920
46.2/1500
2*130
330
360
330
240
13.6
3.3/5.5
4600
2500
600
2000
3000
0.36
13.3
9.27
9.27
270
13050
86/2200
87/2200
Komatsu
S4D102E
4*102*120
3920
1*226
325
325
275
12.0
2.7/3.6/5.5
4600
2500
500
1960
2750
0.41
10.2
8.5
8.5
230 250 250
12200
91/1950
0.5
0.45
CAT
3064-E1T
4250
305
-
350
12.9
3.8/5.5
4650
2500
500
1990
2780
0.4
11.0
12200
85/2100
0.5
0.45
Isuzu
CC-4BG1TC
4329
350
-
13.7
3.4/5.5
2000
500
1990
0.38
Page4
Construction Equipment
R160LC-7
Unit
Hyundai Komastu CAT Hitachi
R160LC-7
PC160-6 315C ZX160LC
Oper. Weight
Power, SAE net
DIN net
Bucket PCSA
CECE
Engine
Model
Cyl*Bore*Stroke
Displacement
Max. torque
Hydraulic pump LPM
Oper. Pressure
Attachment
Power boost
Travel
Swing
Swing speed
Travel speed
Standard machine
Boom
Arm
Track shoe width
Track gauge
Tumbler distance
Ground pressure
Max traction force
Bucket digging force,SAE
Arm crawd force,SAE
Fuel tank liter
Kg
HP/rpm
PS
cu m
cu m
mm
cc
Kgf.m/rpm
Kg/cm2
rpm
Km/h
m
m
mm
mm
mm
kg/cm2
ton
ton
ton
17400
116/2100
118/2100
0.70
0.60
Mitsubishi
S6S-DT
4*94*1200
4996
42.5/1500
2*168
330
360
330
240
12.1
3.7/5.6
5100
2600
600
1990
3190
0.42
15.7
12.08
8.35
260
16530
104.5/2100
106/2100
0.58
0.53
Komatsu
SA4D102E
4*102*120
3920
-
276
325
355
355
325
12.0
2.7/4.0/5.5
5150
2600
600
1990
2880
0.44
13.8
12.54
8.393
250 285 280
16000
-
111/2150
0.65
0.55
CAT
3046-E3DT
-
4990
-
350
-
350
10.2
3.4/5.6
5100
2600
500
1990
2880
0.51
-
-
-
15600
-
100/1950
0.6
0.55
Isuzu
A-4BG1TC
-
4329
-
350
-
13.6
3.1/5.3
5100
2580
500
1990
3100
0.46
-
9.2
8.1
Page5
Construction Equipment
R210LC-7
Unit
Hyundai Komastu CAT Hitachi
R210LC-7
PC210-6 320B EX200-5
Oper. Weight
Power, SAE net
DIN net
Bucket PCSA
CECE
Engine
Model
Cyl*Bore*Stroke
Displacement
Max. torque
Hydraulic pump LPM
Oper. Pressure
Attachment
Power boost
Travel
Swing
Swing speed
Travel speed
Standard machine
Boom
Arm
Track shoe width
Track gauge
Tumbler distance
Ground pressure
Max traction force
Bucket digging force,SAE
Arm crawd force,SAE
Fuel tank liter
Kg
HP/rpm
PS
cu m
cu m
mm
cc
Kgf.m/rpm
Kg/cm2
rpm
Km/h
m
m
mm
mm
mm
kg/cm2
ton
ton
ton
21700
143/2100
145/2100
0.92
0.8
Cummins
B5.9-C
6*102*120
5880
62.0/1600
2*220
330
360
330
240
12.5
3.4/5.3
5880
2920
600
2390
3650
0.46
21.1
14.84
10.8
320
21570
133/2200
0.86
Komatsu
S6D102E
6*102*120
5880
2*206 2*180 2*185
325
355
355
280
12.4
3.2/4.5/5.5
5700
2930
600
2380
3640
0.45
17.7
15.0
10.1
340 340 310
20518
128/1800
130/1800
0.80
0.70
CAT
3116T
6*105*127
6600
350
350
235
10.7
3.4/5.5
5680
2900
600
2200
3265
0.48
18.1
13.5
10.1
133/1950
135/1950
A-6BG1T
6*105*125
47/1600
18800
0.80
0.70
Isuzu
6494
350
370
350
13.9
3.8/5.5
5680
2910
600
2200
3370
0.43
17.3
12.2
Page6
Construction Equipment
Ⅱ.Hydraulic System
Page7
Construction Equipment
1.Outline of Hyd. System:
-Charecteristic of hydraulic oil : incompressible,automatic lubrication,less friction loss, higher
cooling efficiency,more safety for overload,silent operation,precise control
the equipment to transmit the power by oil flow
Hydraulic Tank
Actuator
Hydraulic Pump
Control Valve
-Hydraulic Tank : Oil Storage
-Hyd. Pump : Create oil flow to transmit the power
-Control Valve : Direction control of actuator
-Actuator : Working device such as cylinder,motor and etc
Cylinder - Inline movement
Motor – Rotating movement
Page8
Construction Equipment
2.Hydraulic Symbol
Component Symbol Explanation
Pipe or hose
-Main line
-Pilot line
-Drain or internal leakage
Orifice Reduced diameter of oil passage to
Color code
-Supply line : red
-Return line : blue
-Suction line : green
-Pilot line : brown
-Drain or internal leakage line : green
Line connected each other : Tee joint or
drilled hole
Line cross over without connection
Line closed or plugged for future usuage
or special purpose
reduce oil flow
Page9
Adjustable orifice Adjustable(or variable)
Construction Equipment
Component Symbol Explanation
Shut off valve
Check valve
-Without spring
Direction controlling device to prevent
reverse flow
-With spring
-Pilot check valve
One check valve & pilot line in one block
Hyd. tank Hyd. oil storage
Filter Filtering all the dirt in hydraulic system
Cooler Exhaust the heat of hyd. oil
Breather Maintain the pressure inside of hydraul i c
tank same as atmospheric pressure
Page10
Construction Equipment
Component Symbol Explanation
Hydraulic pump
-fixed flow pump
-One direction
-Both direction, depending on rotation of
pump
Discharge amount of pump are flexible
-Variable flow pump
dependng on the pressure at actuator
such as cylinder and motor
Cylinder -Double acting : retract and extend by
direction of oil supply
-Single acting : retract by weight and
extend by oil supply
Pressure control valve
-Relief valve
Safety device to protect hyd. component
such as hose,pipe,cylinder and etc
When the hyd. system overloaded, relief
valve is open and circuit oil go to the tank
through opened passage
Page11
-Regulating valve
Maintain the required pressure all the time
to activate system for transmission clutch
and etc. by increasing decreasing the size
of overflow passage
Construction Equipment
Component Symbol Explanation
-Reducing vave It is used for low pressure circuit.
When the supplied pressure reach to
required value, supplied oil is cut off
Direction valve
-2 way
-3 way
For double acting
For single acting
Double acting
Controlling method of direction control
valve
Hand control lever
Foot control pedal
Page12
Construction Equipment
Component Symbol Explanation
Button control
Hydraulic control by pilot pressure
Electro-magnet control by electricity
Automatic return control by spring tension
Control valve is fixed with selected
direction
Page13
N : neutral position
Motor Rotating device
-Reversible motor
-Irreversible motor : rotate one direction
only
Pressure switch
Construction Equipment
Component Symbol Explanation
Heater
Accumulator
Brake and clutch Applied by spring force
Released by hydraulic pressure
Page14
Shuttle valve Two check valve in one block
Oil flow achieved by pressure difference
between left & light hand side
Logic valve Is combined with piston and orifice
Area difference operates direction control
valve
Construction Equipment
3. Hydraulic Circuit
3-1.Main Circuit
Page15
Construction Equipment
3-2.Pilot Circuit (Crawler Type)
Page16
Construction Equipment
3-3.Pilot Circuit (Wheel Type)
Page17
Construction Equipment
3-4.Oil Return Circuit
Return Pressure (Bar)
Model
Oil Cooler By-pass
R450LC-7
R360LC-7
R320LC-7
R200W-7
R290LC-7A
R210LC-7
R180LC-7
R140LC-7
3
5
3 5
3
5
1.5 3
35
1.5
1.5
3
3
Page18
Construction Equipment
4. Main Components
4-1A.Main Control Valve (Kawasaki)
R210LC-7
Page19
Construction Equipment
R210LC-7
Page20
Upper viewSide view
Construction Equipment
R210LC-7
Page21
Bottom view
Side view
Construction Equipment
R210LC-7
Page22
RH
LH
Construction Equipment
1)Foot Relief Valve
R210LC-7,R290LC-7A
Page23
Construction Equipment
2)Direction Control Valve
R210LC-7,R290LC-7A
Page24
Construction Equipment
3)Port Relief Valve
R210LC-7,R290LC-7A
Neutral Position
Port Relief
valve
Load check
valve
Port Relief
valve
Operation Position
Port Relief
valve
Load check
valve
Port Relief
valve
Center Bypass valv e
Page25
Construction Equipment
R210LC-7,R290LC-7A
Page26
Construction Equipment
4)Main Relief Valve & Load Check Valve
R210LC-7,R290LC-7A
Port Relief valve
Load check
V/V
Main Relief
valve
Main Pump
Make Up valvePort Relief valve
Main Relief
valve
Main Pump
Page27
Construction Equipment
R210LC-7,R290LC-7A
Page28
Construction Equipment
5)Arm-In Operation ( Regeneration)
-Improve arm-in speed
-Prevent arm cylinder cavitation
Page29
Construction Equipment
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