Hyundai Robex 200W-7 Excavator Service Manual

Hyundai R200W 7 PDF Crawler Excavator Workshop Service Manual

The Hyundai R200W-7 is a Engine: The excavator is typically equipped with a diesel engine.

The exact specifications of the engine may vary, but it usually has a displacement of around 4.8 liters.

Hyundai R200W 7 PDF Crawler Excavator Workshop Service Manual

SECTION 1 GENERAL Group 1 Safety Hints Group 2 Specifications

1-1 1-9

SECTION 1 GENERAL GROUP 1 SAFETY FOLLOW SAFE PROCEDURE Unsafe work practices are dangerous. Understand service procedure before doing work; do not attempt shortcuts.

WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job.

13031GE01

WARN OTHERS OF SERVICE WORK Unexpected machine movement can cause serious injury.

Before performing any work on the excavator, attach a 「Do Not Operate」tag on the right side control lever.

WARN DO NOT OPERATE

13031GE02

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 slippery conditions on platforms, steps, and handrails when leaving the machine.

13031GE03

1-1

PREPARE FOR EMERGENCIES Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

13031GE04

PROTECT AGAINST FLYING DEBRIS Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.

13031GE05

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.

13031GE06

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 electric line than 3m(10ft) plus twice the line insulator length.

13031GE07

1-2

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.

13031GE08

MOVE AND OPERATE MACHINE SAFELY Bystanders can be run over. Know the location of bystanders before moving, swinging, or operating the machine.

Always keep the travel alarm in working condition. warns people when the excavator starts to move.

It

Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the excavator.

13031GE09

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. engine only from operator's seat.

Start

13031GE26

PARK MACHINE SAFELY Before working on the machine: ·Park machine on a level surface. ·Lower bucket to the ground. ·Turn auto idle switch off. ·Run engine at 1/2 speed without load for 2 minutes. ·Turn key switch to OFF to stop engine. Remove key from switch. ·Move pilot control shutoff lever to locked position. ·Allow engine to cool.

1-3

SUPPORT MACHINE PROPERLY Always lower the attachment or implement to the ground before you work on the machine. If you must work 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 continuous load.

Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.

13031GE10

SERVICE COOLING SYSTEM SAFELY 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.

13031GE11

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.

13031GE12

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags ; they can ignite and burn spontaneously.

13031GE13

1-4

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.

REMOVE PAINT BEFORE WELDING OR HEATING Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

Do all work outside or in a well 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 welding or heating.

13031GE14

ILLUMINATE WORK AREA SAFELY Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

13031GE15

1-5

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.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

13031GE16

STAY CLEAR OF MOVING PARTS Entanglements in moving parts can cause serious injury.

To prevent accidents, use care when working around rotating parts.

13031GE17

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. hands and body from high pressure fluids.

Protect

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

13031GE18

13031GE19

1-6

AVOID HEATING NEAR PRESSURIZED 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.

Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install fire resisting guards to protect hoses or other materials.

13031GE20

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 frozen battery; it may explode. Warm battery to 16° C(60° F).

13031GE21

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. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling of dripping electrolyte.

5. Use proper jump start procedure.

If you spill acid on yourself: 1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 10-15 minutes. Get medical attention immediately.

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

1-7

USE TOOLS PROPERLY Use tools appropriate to the work. Makeshift tools, parts, and procedures can create safety hazards.

Use power tools only to loosen threaded tools and fasteners.

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.

Use only recommended replacement parts.(See Parts manual.)

13031GE23

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.

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.

13031GE24

REPLACE SAFETY SIGNS Replace missing or damaged safety signs. See the machine operator's manual for correct safety sign placement.

13031GE25

LIVE WITH SAFETY Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

1-8

GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENT

Tooth

Outrigger Tool box Fuel tank Hydraulic tank

Main pump

Engine Radiator Oil cooler

Bucket

Arm

Arm cylinder

Boom

Tire Turning joint Swing motor Main control valve

Boom cylinder

Cab

Muffler

Counterweight

Dozer cylinder Dozer blade

Connecting link

Side cutter

Foot step Tool box Travel motor

Rear axle

Bucket cylinder Connecting rod Front axle Front drive shaft Transmission Rear drive shaft

20W72SP01

1-9

2. SPECIFICATIONS 1) 5.65m(18' 6") ONE PIECE BOOM, 2.90m(9' 6") ARM, FRONT OUTRIGGER AND REAR DOZER BLADE I(I')

H

F

G

E

C

D

J

K B(L)

A

20W72SP02

Unit

Specification

Operating weight

kg(lb)

20500(45290)

Bucket capacity(SAE heaped), standard

m3(ydІ)

0.80(1.05)

Description

Overall length

A

9490(31' 2")

Overall width

B

2490( 8' 2")

Overall height

C

3100(10' 2")

Upperstructure width

D

2530( 8' 4")

Cab height

E

3180(10' 5")

Ground clearance of counterweight

F

1310( 4' 3")

Engine cover height

G

Minimum ground clearance

H

345( 1' 2")

Rear-end distance

I

2765( 9' 1")

Rear-end swing radius

I'

2800( 9' 2")

Wheel base

J

2800( 9' 2")

Tread

K

1874( 6' 2")

Dozer blade width

L

2490( 8' 2")

Travel speed

Low

mm(ft-in)

km/hr(mph)

2570( 8' 5")

8.3(5.2) 33(20.5)

High

Swing speed

rpm

11.0

Gradeability

Degree(%)

31.5(61)

1-10

3. WORKING RANGE 1) 5.65m(18' 6") BOOM A A'

C

B'

B

E

D

F

8ft

Description

20W72SP03

2.0m(6' 7") Arm

2.40m(7' 10") Arm

2.90m(9' 6") Arm

Max digging reach

A

9110mm (29'11")

9480mm (31' 1")

9900mm (32' 6")

Max digging reach on ground

A'

8870mm (29' 1")

9260mm (30' 5")

9690mm (31' 9")

Max digging depth

B

5480mm (18' 0")

5880mm (19' 3")

6380mm (20'11")

Max digging depth (8ft level)

B'

5240mm (17' 2")

5670mm (18' 7")

6210mm (20' 4")

Max vertical wall digging depth

C

4970mm (16' 4")

5440mm (17'10")

5810mm (19' 1")

Max digging height

D

9500mm (31' 2")

9730mm (31'11")

9870mm (32' 5")

Max dumping height

E

6670mm (21'11")

6900mm (22' 8")

7050mm (23' 2")

Min swing radius

F

3700mm (12' 2")

3620mm (11'11")

3540mm (11' 7")

133 [146] kN

133 [146] kN

133 [146] kN

13600 [14840] kgf

13600 [14840] kgf

13600 [14840] kgf

29980 [32710] lbf

29980 [32710] lbf

29980 [32710] lbf

152 [166] kN

152 [166] kN

152 [166] kN

15500 [16910] kgf

15500 [16910] kgf

15500 [16910] kgf

34170 [37280] lbf

34170 [37280] lbf

34170 [37280] lbf

135 [148] kN

113 [123] kN

97 [106] kN

13800 [15050] kgf

11500 [12550] kgf

9900 [10800] kgf

30420 [33190] lbf

25350 [27650] lbf

21830 [23810] lbf

142 [155] kN

118 [128] kN

101 [110] kN

14500 [15820] kgf

12000 [13090] kgf

10300 [11240] kgf

31970 [34880] lbf

26460 [28870] lbf

22710 [24770] lbf

SAE Bucket digging force ISO

SAE Arm digging force ISO [ ] : Power boost

1-11

4. WEIGHT 1) MONO BOOM R200W-7

Item

kg

lb

Upperstructure assembly

8950

19730

Main frame weld assembly

1660

3660

Engine assembly

520

1150

Main pump assembly

170

370

Main control valve assembly

200

440

Swing motor assembly

230

510

Hydraulic oil tank assembly

240

530

Fuel tank assembly

200

440

Counterweight

3400

7500

Cab assembly

310

680

Lower frame weld assembly

2370

5230

Swing bearing

260

570

Travel motor assembly

83

180

Turning joint

100

220

Transmission assembly

130

290

Front axle assembly

640

1410

Rear axle assembly

480

1060

Dozer blade assembly

990

2180

Front attachment assembly(5.65m boom, 2.90m arm, 0.80m3 SAE heaped bucket)

3930

8640

5.65m boom assembly

1480

3260

2.90m arm assembly

770

1690

0.80m3 SAE heaped bucket assembly

690

1520

Boom cylinder assembly

190×2EA

420×2EA

Arm cylinder assembly

290

640

Bucket cylinder assembly

180

400

Bucket control link assembly

150

330

Oscillating cylinder assembly

30

70

Front outrigger assembly

390

860

Rear outrigger assembly

1020

2250

Outrigger cylinder assembly

100

220

Blade cylinder assembly

82

180

1-12

5. LIFTING CAPACITIES 1) ROBEX 200W-7 (1) 5.65m(18' 6") boom, 2.0m(6' 7") arm equipped with 0.80m3(SAE heaped) bucket and 4 outrigger down.

·

·

: Rating over-front

: Rating over-side or 360 degree

Load radius Load point height 7.5m kg (25ft) lb 6.0m kg (20ft) lb 4.5m kg (15ft) lb 3.0m kg (10ft) lb 1.5m kg (5ft) lb Ground kg Line lb -1.5m kg (-5ft) lb -3.0m kg (-10ft) lb

Note

3.0m(10ft)

4.5m(15ft)

At max. reach

6.0m(20ft)

7.5m(25ft)

Capacity

Reach m(ft)

*8260 *18210

*13240 *29190 *11640 *25660

*8260 *18210

*13240 *29190 *11640 *25660

*5650 *12460 *7340 *16180 *8700 *19180 *9260 *20410 *9110 *20080 *8210 *18100

*5650 *12460 *7340 *16180 *8700 *19180 8680 19140 8680 19140 *8210 *18100

*4230 *9330 *4710 *10380 *5450 *12020 *6180 *13620 *6620 *14590 *6630 *14620

*4230 *9330 *4710 *10380 *5450 *12020 5580 12300 5440 11990 5420 11950

*4650 *10250 *4980 *10980

4020 8860 3920 8640

*3810 *8400 *3890 *8580 *4020 *8860 *4190 *9240 *4370 *9630 *4570 *10080 *4710 *10380 *4620 *10190

*3810 *8400 *3890 *8580 3370 7430 3150 6940 3140 6920 3350 7390 3920 8640 *4620 *10190

6.85 (22.5) 7.89 (25.9) 8.48 (27.8) 8.73 (28.6) 8.67 (28.4) 8.30 (27.2) 7.57 (24.8) 6.30 (20.7)

1. Lifting capacity are based on SAE J1097 and ISO 10567.

2. Lifting capacity of the ROBEX series does not exceed 75% of tipping load with the machine on firm, level ground or 87% of full hydraulic capacity.

3. The load point is a hook located on the back of the bucket.

4. *indicates load limited by hydraulic capacity.

1-13

(2) 5.65m(18' 6") boom, 2.0m(6' 7") arm equipped with 0.80m3(SAE heaped) bucket and 4 outrigger up.

Load radius Load point height 7.5m kg (25ft) lb 6.0m kg (20ft) lb 4.5m kg (15ft) lb 3.0m kg (10ft) lb 1.5m kg (5ft) lb Ground kg Line lb -1.5m kg (-5ft) lb -3.0m kg (-10ft) lb

3.0m(10ft)

4.5m(15ft)

At max. reach

6.0m(20ft)

7.5m(25ft)

Capacity

Reach m(ft)

*8260 *18210

*13240 *29190 *11640 *25660

*8260 *18210

7100 15650 7310 16120

*5650 *12460 *7340 *16180 8200 18080 8010 17660 8010 17660 8150 17970

4760 10490 4240 9350 3860 8510 3710 8180 3700 8160 3820 8420

*4230 *9330 *4710 *10380 *5450 *12020 5230 11530 5090 11220 5070 11180

3130 6900 2970 6550 2740 6040 2540 5600 2420 5340 2400 5290

3790 8360 3690 8140

1860 4100 1760 3880

*3810 *8400 3690 8140 3190 7030 2970 6550 2960 6530 3160 6970 3690 8140 *4620 *10190

2550 5620 1870 4120 1550 3420 1400 3090 1380 3040 1490 3280 1780 3920 2520 5560

6.85 (22.5) 7.89 (25.9) 8.48 (27.8) 8.73 (28.6) 8.67 (28.4) 8.30 (27.2) 7.57 (24.8) 6.30 (20.7)

(3) 5.65m(18' 6") boom, 2.0m(6' 7") arm equipped with 0.80m3(SAE heaped) bucket, front outrigger and rear dozer blade down.

Load radius Load point height 7.5m kg (25ft) lb 6.0m kg (20ft) lb 4.5m kg (15ft) lb 3.0m kg (10ft) lb 1.5m kg (5ft) lb Ground kg Line lb -1.5m kg (-5ft) lb -3.0m kg (-10ft) lb

3.0m(10ft)

4.5m(15ft)

At max. reach

6.0m(20ft)

7.5m(25ft)

Capacity

Reach m(ft)

*8320 *18340

*13190 *29080 *11570 *25510

*8320 *18340

*13190 *29080 *11570 *25510

*5680 *12520 *7370 *16250 *8720 *19220 *9260 *20410 *9100 *20060 *8170 *18010

*5680 *12520 *7370 *16250 7060 15560 6880 15170 6880 15170 7020 15480

*4260 *9390 *4730 *10430 *5480 *12080 *6190 *13650 *6630 *14620 *6620 *14590

1-14

*4260 *9390 *4730 *10430 4760 10490 4540 10010 4400 9700 4380 9660

*4670 *10300 *4990 *11000

3300 7280 3200 7050

*3830 *8440 *3910 *8620 *4030 *8880 *4190 *9240 *4380 *9660 *4560 *10050 *4700 *10360 *4580 *10100

*3830 *8440 3230 7120 2770 6110 2570 5670 2550 5620 2730 6020 3200 7050 4390 9680

6.85 (22.5) 7.89 (25.9) 8.48 (27.8) 8.73 (28.6) 8.67 (28.4) 8.30 (27.2) 7.57 (24.8) 6.30 (20.7)

(4) 5.65m(18' 6") boom, 2.0m(6' 7") arm equipped with 0.80m3(SAE heaped) bucket, front outrigger and rear dozer blade up.

Load radius Load point height 7.5m kg (25ft) lb 6.0m kg (20ft) lb 4.5m kg (15ft) lb 3.0m kg (10ft) lb 1.5m kg (5ft) lb Ground kg Line lb -1.5m kg (-5ft) lb -3.0m kg (-10ft) lb

4.5m(15ft)

3.0m(10ft)

At max. reach

6.0m(20ft)

7.5m(25ft)

Capacity

Reach m(ft)

*8320 *18340

*13190 *29080 *11570 *25510

*8320 *18340

7100 15650 7310 16120

*5680 *12520 *7370 *16250 8190 18060 8010 17660 8010 17660 8150 17970

4760 10490 4240 9350 3860 8510 3700 8160 3700 8160 3820 8420

*4260 *9390 *4730 *10430 5460 12040 5230 11530 5090 11220 5070 11180

3130 6900 2970 6550 2740 6040 2540 5600 2420 5340 2400 5290

3790 8360 3690 8140

1860 4100 1760 3880

*3830 *8440 3690 8140 3190 7030 2970 6550 2960 6530 3160 6970 3690 8140 *4580 *10100

2550 5620 1870 4120 1550 3420 1400 3090 1380 3040 1490 3280 1780 3920 2520 5560

6.85 (22.5) 7.89 (25.9) 8.48 (27.8) 8.73 (28.6) 8.67 (28.4) 8.30 (27.2) 7.57 (24.8) 6.30 (20.7)

(5) 5.65m(18' 6") boom, 2.4m(7'10") arm equipped with 0.80m3(SAE heaped) bucket and 4 outrigger down.

Load radius Load point height

1.5m(5ft)

3.0m(10ft)

4.5m(15ft)

At max. reach 6.0m(20ft)

7.5m(25ft)

Capacity

Reach m(ft)

7.5m kg (25ft) lb 6.0m kg (20ft) lb 4.5m kg (15ft) lb 3.0m kg (10ft) lb 1.5m kg (5ft) lb Ground kg Line lb -1.5m kg (-5ft) lb -3.0m kg (-10ft) lb -4.5m kg (-15ft) lb

*10060 *22180 *14300 *31530

*10060 *22180 *14300 *31530

*9300 *20500 *13750 *30310 *12340 *27210 *9540 *21030

*9300 *20500 *13750 *30310 *12340 *27210 *9540 *21030

*5090 *11220 *6790 *14970 *8290 *18280 *9080 *20020 *9140 *20150 *8490 *18720 *6550 *14440

*5090 *11220 *6790 *14970 *8290 *18280 8630 19030 8580 18920 *8490 *18720 *6550 *14440

1-15

*3830 *3830 *8440 *8440 *4350 *4350 *4050 *9590 *9590 *8930 *5130 *5130 *4390 *11310 *11310 *9680 *5920 5580 *4790 *13050 12300 *10560 *6460 5410 *5070 *14240 11930 *11180 *6610 5350 *14570 11790 *6120 5420 *13490 11950

*4050 *8930 4020 8860 3900 8600 3810 8400

*3520 *7760 *3610 *7960 *3740 *8250 *3900 *8600 *4090 *9020 *4290 *9460 *4460 *9830 *4500 *9920

*3520 *7760 3570 7870 3110 6860 2910 6420 2900 6390 3070 6770 3530 7780 *4500 *9920

7.34 (24.1) 8.31 (27.3) 8.87 (29.1) 9.10 (29.9) 9.05 (29.7) 8.70 (28.5) 8.00 (26.2) 6.84 (22.4)

(6) 5.65m(18' 6") boom, 2.4m(7'10") arm equipped with 0.80m3(SAE heaped) bucket and 4 outrigger up.

Load radius Load point height

1.5m(5ft)

3.0m(10ft)

4.5m(15ft)

At max. reach 6.0m(20ft)

7.5m(25ft)

Capacity

Reach m(ft)

7.5m kg (25ft) lb 6.0m kg (20ft) lb 4.5m kg (15ft) lb 3.0m kg (10ft) lb 1.5m kg (5ft) lb Ground kg Line lb -1.5m kg (-5ft) lb -3.0m kg (-10ft) lb -4.5m kg (-15ft) lb

*10060 *22180 *14300 *31530

*10060 *22180 *14300 *31530

*9300 *20500 *13750 *30310 *12340 *27210 *9450 *21030

6840 15080 6910 15230 7100 15650 7490 16510

*5090 *11220 *6790 *14970 8220 18120 7970 17570 7920 17460 8020 17680 *6550 *14440

4860 10710 4310 9500 3870 8530 3660 8070 3620 7980 3700 8160 3960 8730

*3830 *8440 *4350 *9590 *5130 *11310 5220 11510 5060 11160 5000 11020 5070 11180

3170 6990 3000 6610 2760 6080 2530 5580 2380 5250 2330 5140 2400 5290

3910 8620 3790 8360 3670 8090 3580 7890

1950 4300 1850 4080 1740 3840 1660 3660

*3520 *7760 3370 7430 2940 6480 2750 6060 2730 6020 2900 6390 3330 7340 4360 9610

2230 4920 1680 3700 1400 3090 1270 2800 1240 2730 1320 2910 1570 3460 2140 4720

7.34 (24.1) 8.31 (27.3) 8.87 (29.1) 9.10 (29.9) 9.05 (29.7) 8.70 (28.5) 8.00 (26.2) 6.84 (22.4)

(7) 5.65m(18' 6") boom, 2.4m(7'10") arm equipped with 0.80m3(SAE heaped) bucket, front outrigger and rear dozer blade down.

Load radius Load point height

1.5m(5ft)

3.0m(10ft)

4.5m(15ft)

At max. reach 6.0m(20ft)

7.5m(25ft)

Capacity

Reach m(ft)

7.5m kg (25ft) lb 6.0m kg (20ft) lb 4.5m kg (15ft) lb 3.0m kg (10ft) lb 1.5m kg (5ft) lb Ground kg Line lb -1.5m kg (-5ft) lb -3.0m kg (-10ft) lb -4.5m kg (-15ft) lb

*10060 *22180 *14300 *31530

*10060 *22180 *14300 *31530

*9300 *20500 *13750 *30310 *12340 *27210 *9540 *21030

*9300 *20500 *13750 *30310 *12340 *27210 *9450 *21030

*5090 *5090 *11220 *11220 *6790 *6790 *14970 *14970 *8290 7080 *18280 15610 *9080 6830 *20020 15060 *9140 6790 *20150 14970 *8490 6890 *18720 15190 *6550 *6550 *14440 *14440

1-16

*3830 *8440 *4350 *9590 *5130 *11310 *5920 *13050 *6460 *14240 *6610 *14570 *6120 *13490

*3830 *8440 *4350 *4050 *9590 *8930 4780 *4390 10540 *9680 4530 *4790 9990 *10560 4370 *5070 9630 *11180 4310 9500 4380 9660

3410 7520 3290 7250 3170 6990 3090 6810

*3520 *7760 *3610 *7960 *3740 *8250 *3900 *8600 *4090 *9020 *4290 *9460 *4460 *9830 *4500 *9920

*3520 *7760 2940 6480 2550 5620 2370 5220 2350 5180 2490 5490 2880 6350 3790 8360

7.34 (24.1) 8.31 (27.3) 8.87 (29.1) 9.10 (29.9) 9.05 (29.7) 8.70 (28.5) 8.00 (26.2) 6.84 (22.4)

(8) 5.65m(18' 6") boom, 2.4m(7'10") arm equipped with 0.80m3(SAE heaped) bucket, front outrigger and rear dozer blade up.

Load radius Load point height

1.5m(5ft)

3.0m(10ft)

4.5m(15ft)

At max. reach 6.0m(20ft)

7.5m(25ft)

Capacity

Reach m(ft)

7.5m kg (25ft) lb 6.0m kg (20ft) lb 4.5m kg (15ft) lb 3.0m kg (10ft) lb 1.5m kg (5ft) lb Ground kg Line lb -1.5m kg (-5ft) lb -3.0m kg (-10ft) lb -4.5m kg (-15ft) lb

*10060 *22180 *14300 *31530

*10060 *22180 *14300 *31530

*9300 *20500 *13750 *30310 *12340 *27210 *9540 *21030

6840 15080 6910 15230 7100 15650 7490 16510

*5090 *11220 *6790 *14970 8220 18120 7970 17570 7920 17460 8020 17680 *6550 *14440

4860 10710 4310 9500 3870 8530 3660 8070 3620 7980 3700 8160 3960 8730

*3830 *8440 *4350 *9590 *5130 *11310 5220 11510 5060 11160 5000 11020 5070 11180

3170 6990 3000 6610 2760 6080 2530 5580 2380 5250 2330 5140 2400 5290

3910 8620 3790 8360 3670 8090 3580 7890

1950 4300 1850 4080 1740 3840 1660 3660

*3520 *7760 3370 7430 2940 6480 2750 6060 2730 6020 2900 6390 3330 7340 4360 9610

2230 4920 1680 3700 1400 3090 1270 2800 1240 2730 1320 2910 1570 3460 2140 4720

7.34 (24.1) 8.31 (27.3) 8.87 (29.1) 9.10 (29.9) 9.05 (29.7) 8.70 (28.5) 8.00 (26.2) 6.84 (22.4)

(9) 5.65m(18' 6") boom, 2.9m(9' 6") arm equipped with 0.80m3(SAE heaped) bucket and 4 outrigger down.

Load radius Load point height

1.5m(5ft)

3.0m(10ft)

4.5m(15ft)

At max. reach 6.0m(20ft)

7.5m(25ft)

Capacity

Reach m(ft)

9.0m kg (30ft) lb 7.5m kg (25ft) lb 6.0m kg *3370 *3370 *2400 (20ft) lb *7430 *7430 *5290 4.5m kg *3920 *3920 *3690 (15ft) lb *8640 *8640 *8140 3.0m kg *10160 *10160 *6150 *6150 *4750 *4750 *4090 (10ft) lb *22400 *22400 *13560 *13560 *10470 *10470 *9020 1.5m kg *8440 *8440 *7810 *7810 *5610 5610 *4550 (5ft) lb *18610 *18610 *17220 *17220 *12370 12370 *10030 Ground kg *9800 *9800 *8830 8640 *6260 5400 *4920 Line lb *21610 *21610 *19470 19050 *13800 11900 *10850 -1.5m kg *9190 *9190 *12890 *12890 *9140 8520 *6560 5300 *5050 (-5ft) lb *20260 *20260 *28420 *28420 *20150 18780 *14460 11680 *11130 -3.0m kg *12400 *12400 *13070 *13070 *8760 8570 *6340 5320 (-10ft) lb *27340 *27340 *28810 *28810 *19310 18890 *13980 11730 -4.5m kg *10830 *10830 *7410 *7410 (-15ft) lb *23880 *23880 *16340 *16340

1-17

*2400 *5290 *3690 *8140 4050 8930 3900 8600 3790 8360 3740 8250

*3120 *6880 *3180 *7010 *3290 *7250 *3430 *7560 *3600 *7940 *3790 *8360 *3990 *8800 *4200 *9260 *4360 *9610

*3120 *6880 *3180 *7010 3240 7140 2850 6280 2680 5910 2650 5840 2790 6150 3150 6940 3960 8730

6.47 (21.2) 7.92 (26.0) 8.81 (28.9) 9.34 (30.6) 9.56 (31.4) 9.51 (31.2) 9.18 (30.1) 8.53 (28.0) 7.46 (24.5)

(10) 5.65m(18' 6") boom, 2.9m(9' 6") arm equipped with 0.80m3(SAE heaped) bucket and 4 outrigger up.

Load radius Load point height

1.5m(5ft)

3.0m(10ft)

4.5m(15ft)

At max. reach 6.0m(20ft)

7.5m(25ft)

Capacity

Reach m(ft)

9.0m kg (30ft) lb 7.5m kg (25ft) lb 6.0m kg (20ft) lb 4.5m kg (15ft) lb 3.0m kg *10160 (10ft) lb *22400 1.5m kg *8440 (5ft) lb *18610 Ground kg *9800 Line lb *21610 -1.5m kg *9190 *9190 *12890 (-5ft) lb *20260 *20260 *28420 -3.0m kg *12400 *12400 *13070 (-10ft) lb *27340 *27340 *28810 -4.5m kg *10830 (-15ft) lb *23880

8080 *6150 17810 *13560 6980 *7810 15390 *17220 6760 7970 14900 17570 6780 7860 14950 17330 6920 7910 15260 17440 7230 *7410 15940 *16340

4430 9770 3940 8690 3660 8070 3560 7850 3600 7940 3780 8330

*3370 *7430 *3920 *8640 *4750 *10470 5250 11570 5050 11130 4950 10910 4970 10960

3250 7170 3060 6750 2800 6170 2550 5620 2370 5220 2290 5050 2310 5090

*2400 *5290 *3690 *8140 3820 8420 3670 8090 3560 7850 3520 7760

2070 4560 2000 4410 1870 4120 1740 3840 1640 3620 1600 3530

*3120 *6880 *3180 *7010 3060 6750 2700 5950 2530 5580 2500 5510 2630 5800 2970 6550 3730 8220

2960 6530 1950 4300 1500 3310 1260 2780 1140 2510 1110 2450 1170 2580 1350 2980 1780 3920

6.47 (21.2) 7.92 (26.0) 8.81 (28.9) 9.34 (30.6) 9.56 (31.4) 9.51 (31.2) 9.18 (30.1) 8.53 (28.0) 7.46 (24.5)

(11) 5.65m(18' 6") boom, 2.9m(9' 6") arm equipped with 0.80m3(SAE heaped) bucket, front outrgger and rear dozer blade down.

Load radius Load point height

1.5m(5ft)

3.0m(10ft)

4.5m(15ft)

At max. reach 6.0m(20ft)

7.5m(25ft)

Capacity

Reach m(ft)

9.0m kg (30ft) lb 7.5m kg (25ft) lb 6.0m kg *3370 *3370 *2290 (20ft) lb *7430 *7430 *5050 4.5m kg *3920 *3920 *3700 (15ft) lb *8640 *8640 *8160 3.0m kg *10070 *10070 *6130 *6130 *4750 *4750 *4100 (10ft) lb *22200 *22200 *13510 *13510 *10470 *10470 *9040 1.5m kg *8690 *8690 *7800 7180 *5610 4560 *4560 (5ft) lb *19160 *19160 *17200 15830 *12370 10050 *10050 Ground kg *9950 *9950 *8830 6850 *6270 4360 *4930 Line lb *21940 *21940 *19470 15100 *13820 9610 *10870 -1.5m kg *9250 *9250 *13040 *13040 *9150 6740 *6560 4270 *5050 (-5ft) lb *20390 *20390 *28750 *28750 *20170 14860 *14460 9410 *11130 -3.0m kg *12490 *12490 *13090 *13090 *8770 6780 *6340 4290 (-10ft) lb *27540 *27540 *28860 *28860 *19330 14950 *13980 9460 -4.5m kg *10820 *10820 *7400 7000 (-15ft) lb *23850 *23850 *16310 15430

1-18

*2290 *5050 3460 7630 3320 7320 3180 7010 3070 6770 3030 6680

*3130 *6900 *3200 *7050 *3310 *7300 *3450 *7610 *3610 *7960 *3800 *8380 *4010 *8840 *4230 *9330 *4390 *9680

*3130 *6900 *3200 *7050 2680 5910 2340 5160 2180 4810 2160 4760 2270 5000 2580 5690 3260 7190

6.42 (21.1) 7.88 (25.9) 8.78 (28.8) 9.30 (30.5) 9.53 (31.3) 9.48 (31.1) 9.15 (30.0) 8.49 (27.9) 7.42 (24.3)

(12) 5.65m(18' 6") boom, 2.9m(9' 6") arm equipped with 0.80m3(SAE heaped) bucket, front outrgger and rear dozer blade up.

Load radius Load point height

1.5m(5ft)

3.0m(10ft)

4.5m(15ft)

At max. reach 6.0m(20ft)

7.5m(25ft)

Capacity

Reach m(ft)

9.0m kg (30ft) lb 7.5m kg (25ft) lb 6.0m kg (20ft) lb 4.5m kg (15ft) lb 3.0m kg *10070 (10ft) lb *22200 1.5m kg *8690 (5ft) lb *19160 Ground kg *9950 Line lb *21940 -1.5m kg *9250 *9250 *13040 (-5ft) lb *20390 *20390 *28750 -3.0m kg *12490 *12490 *13090 (-10ft) lb *27540 *27540 *28860 -4.5m kg *10820 (-15ft) lb *23850

8120 *6130 17900 *13510 7010 *7800 15450 *17200 6770 7980 14930 17590 6780 7860 14950 17330 6930 7910 15280 17440 7240 *7400 15960 *16310

4450 9810 3950 8710 3670 8090 3570 7870 3610 7960 3790 8360

1-19

*3370 *7430 *3920 *8640 *4750 *10470 5260 11600 5050 11130 4960 10930 4980 10980

3250 7170 3060 6750 2810 6190 2550 5620 2380 5250 2290 5050 2310 5090

*2290 *5050 *3700 *8160 3820 8420 3680 8110 3570 7870 3520 7760

2070 4560 2000 4410 1870 4120 1740 3840 1640 3620 1600 3530

*3130 *6900 *3200 *7050 3080 6790 2710 5970 2540 5600 2520 5560 2650 5840 2990 6590 3770 8310

3000 6610 1970 4340 1510 3330 1270 2800 1150 2540 1120 2470 1180 2600 1370 3020 1800 3970

6.42 (21.1) 7.88 (25.9) 8.78 (28.8) 9.30 (30.5) 9.53 (31.3) 9.48 (31.1) 9.15 (30.0) 8.49 (27.9) 7.42 (24.3)

6. BUCKET SELECTION GUIDE 1) GENERAL BUCKET

0.51m3 SAE heaped bucket

※0.80m3 SAE heaped bucket

Capacity

Width

0.87m3 SAE heaped bucket

0.92m3 SAE heaped bucket

1.20m3 SAE heaped bucket

1.34m3 SAE heaped bucket

Recommendation 5.65m (18' 6") boom

Weight

SAE heaped

CECE heaped

0.51m3 (0.67yd3)

0.45m3 (0.59yd3)

700mm (27.6")

820mm (32.3")

580kg (1280lb)

※0.80m3 (1.05yd3)

0.70m3 (0.92yd3)

1000mm (39.4")

1120mm (44.1")

650kg (1430lb)

0.87m3 (1.14yd3)

0.75m3 (0.98yd3)

1090mm (42.9")

1210mm (47.6")

660kg (1460lb)

0.92m3 (1.20yd3)

0.80m3 (1.05yd3)

1130mm (44.5")

1250mm (49.2")

710kg (1570lb)

1.20m3 (1.57yd3)

1.00m3 (1.31yd3)

1400mm (55.1")

-

770kg (1700lb)

1.34m3 (1.75yd3)

1.15m3 (1.50yd3)

1550mm (61.0")

-

800kg (1760lb)

Without With side cutter side cutter

2.0m arm (6' 7")

2.4m arm (7' 10")

※ : Standard bucket

Applicable for materials with density of 2000kg/m3 (3370lb/yd3) or less Applicable for materials with density of 1600kg/m3 (2700lb/yd3) or less Applicable for materials with density of 1100kg/m3 (1850lb/yd3) or less

1-20

2.90m arm (9' 6")

2) HEAVY DUTY, ROCK AND SLOPE FINISHING BUCKET

◈0.74, 0.90, 1.05m3 SAE heaped bucket

Capacity

0.87m3 SAE heaped bucket

Recommendation

Width

5.65m (18' 6") boom

Weight

SAE heaped

CECE Without With heaped side cutter side cutter

◈0.74m3 (0.97yd3)

0.65m3 (0.85yd3)

915mm (36.0")

-

750kg (1650lb)

◈0.90m3 (1.18yd3)

0.80m3 (1.05yd3)

1070mm (42.1")

-

790kg (1740lb)

◈1.05m3 (1.37yd3)

0.92m3 (1.20yd3)

1220mm (48.0")

-

870kg (1920lb)

0.87m3 (1.14yd3)

0.75m3 (0.98yd3)

1140mm (44.9")

-

860kg (1900lb)

▣0.75m3 (0.98yd3)

0.65m3 (0.85yd3)

1810mm (71.3")

-

880kg (1940lb)

◈ : Heavy duty bucket

▣0.75m3 SAE heaped bucket

: Rock bucket(Heavy)

2.0m arm (6' 7")

2.4m arm (7' 10")

▣ : Slope finishing bucket

Applicable for materials with density of 2000kgf/m3 (3370lbf/yd3) or less Applicable for materials with density of 1600kgf/m3 (2700lbf/yd3) or less Applicable for materials with density of 1100kgf/m3 (1850lbf/yd3) or less

1-21

2.92m arm (9' 7")

7. SPECIFICATIONS FOR MAJOR COMPONENTS 1) ENGINE Specification

Item Model

Cummins B5.9-C

Type

4-cycle, turbocharged, charge air cooled, 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

102×120mm(4.02"×4.72")

Piston displacement

5880cc(359cu in)

Compression ratio

17.3 : 1

Rated gross horse power(SAE J1349)

166Hp at 1950rpm(124kW at 1950rpm)

Maximum torque at 1500rpm

68.4kgf·m(495lbf·ft)

Engine oil quantity

14.2ℓ(3.8U.S. gal)

Dry weight

505kg(1113lb)

High idling speed

2200+50rpm

Low idling speed

1000±100rpm

Rated fuel consumption

173g/Hp·hr at 1950rpm

Starting motor

Nippon denso(24V-4.5kW)

Alternator

Delco Remy (24V-50A)

Battery

2×12V×100Ah

2) MAIN PUMP Item

[

Specification

Type

Variable displacement axial piston pump

Capacity

2×113cc/rev

Maximum pressure

330kgf/cm2 (4694psi) [360kgf/cm2 (5120psi)]

Rated oil flow

2×220ℓ/min (58.1U.S. gpm/ 48.4U.K. gpm)

Rated speed

1950rpm

] : Power boost

1-22

3) GEAR PUMP Item

Specification

Type

Fixed displacement gear pump single stage

Capacity

15cc/rev

Maximum pressure

40kgf/cm2(570psi)

Rated oil flow

29.3ℓ/min(7.7U.S. gpm/6.4U.K. gpm)

4) MAIN CONTROL VALVE Item

Specification

Type

9 spools double-block

Operating method

Hydraulic pilot system

Main relief valve pressure

330kgf/cm2(4695psi)[360kgf/cm2(5120psi)]

Overload relief valve pressure

390kgf/cm2(5550psi)

[ ]: Pooer boost

5) SWING MOTOR Item

Specification

Type

Fixed displacement axial piston motor

Capacity

151cc/rev

Relief pressure

240kgf/cm2(3414psi)

Braking system

Automatic, spring applied hydraulic released

Braking torque

59kgf·m(427lbf·ft)

Brake release pressure

33~50kgf/cm2(470~711psi)

Reduction gear type

2 - stage planetary

Swing speed

12.5rpm

6) TRAVEL MOTOR Item

Specification

Type

Variable displacement bent-axis axial piston motor

Relief pressure

360kgf/cm2(5120psi)

Counter balance valve

Applied

Capacity(Max/min)

160/65cc/rev

1-23

7) POWER TRAIN Item

Description

2 speed power shift transmission

Type Transmission

Parking brake

Axle

Gear ratio

Specification

1st

5.35

2nd

1.39

Type

Multi disc brake integrated in transmission

Maximum braking power

168kgf·m(2390lb·ft)

Type

4 wheel drive with differential

Gear ratio

13.55

Brake

Multi disc brake

8) REMOTE CONTROL VALVE Specification

Item Type

Pressure reducing type

Operating pressure Single operation stroke

Minimum

6.5kg/cm2(92psi)

Maximum

26kg/cm2(370psi)

Lever

82.7mm(3.3in)

9) CYLINDER Specification

Item Boom cylinder

Arm cylinder

Bucket cylinder

Dozer cylinder

Outrigger cylinder 2 Piece boom Adjust cylinder

Bore dia×Rod dia×Stroke

Ø120×Ø85×1290mm

Cushion

Extend only

Bore dia×Rod dia×Stroke

Ø140×Ø100×1510mm

Cushion

Extend and retract

Bore dia×Rod dia×Stroke

Ø125×Ø85×1055mm

Cushion

Extend only

Bore dia×Rod dia×Stroke

Ø120×Ø85×229mm

Cushion

Extend only

Bore dia×Rod dia×Stroke

Ø130×Ø80×365mm

Cushion

-

Bore dia×Rod dia×Stroke

Ø160×Ø100×425mm

Cushion

Extend only

1-24

10) BUCKET Item STD

Capacity SAE heaped 3

0.80m (1.05yd )

0.70m3(0.92yd3)

5

1090mm(42.9")

1210mm(47.6")

0.51m3(0.67yd3)

0.45m3(0.59yd3)

3

700mm(27.6")

820mm(32.3")

3

0.87m (1.14yd )

3

0.75m (0.98yd )

5

1000mm(39.4")

1120mm(44.1")

0.92m3(1.20yd3)

0.80m3(1.05yd3)

5

1130mm(44.5")

1250mm(49.2")

3

1.20m (1.57yd )

3

1.00m (1.31yd )

6

1400mm(55.1")

-

1.34m3(1.75yd3)

1.15m3(1.50yd3)

5

1550mm(61.1")

-

3

◈0.74m (0.97yd )

3

0.65m (0.85yd )

5

915mm(36.0")

-

◈0.90m3(1.18yd3)

0.80m3(1.05yd3)

5

1070mm(42.1")

-

3

◈1.05m (1.37yd )

3

0.92m (1.20yd )

5

1220mm(48.0")

-

0.87m3(1.14yd3)

0.75m3(0.98yd3)

5

1140mm(44.9")

-

▣0.75m (0.98yd )

0.65m (0.85yd )

-

1810mm(71.3")

-

3

3

3

OPT

CECE heaped

Width Tooth quantity Without side cutter With side cutter

3

3

3

3

3

3

3

3

3

3

◈ : Heavy duty bucket : Rock bucket(Heavy) ▣ : Slope finishing bucket

1-25

8. RECOMMENDED OILS Use only oils listed below or equivalent.

Do not mix different brand oil.

Ambient temperature 。 C( 。 F) Service point

Kind of fluid

Capacity ℓ(U.S. gal)

-20 (-4)

-10 (14)

0 (32)

10 (50)

20 (68)

30 40 (86) (104)

SAE 30

Engine oil pan

14.2(3.8) SAE 10W Engine oil SAE 10W-30

Transmission case

3.8(1.0)

Gear oil

SAE 15W-40

5.0(1.3)

SAE 85W-140

Swing drive

NLGI NO.1 Grease

1.2(0.3) NLGI NO.2

Gear oil

Center : 12×2(3.2×2) Hub : 2×4(0.5×4)

Hydraulic oil

Tank: 180(47.6) System: 270(71.3)

Front axle Rear axle

Hydraulic tank

SAE 85W-90 LSD or UTTO

ISO VG 32 ISO VG 46 ISO VG 68

ASTM D975 NO.1 Fuel tank

Diesel fuel

320(84.5) ASTM D975 NO.2

NLGI NO.1

Fitting (Grease nipple)

Grease

Radiator (Reservoir tank)

Mixture of antifreeze and water 50 : 50

As required NLGI NO.2

Ethylene glycol base permanent type

35(9.2)

SAE : Society of Automotive Engineers ASTM : American Society of Testing and API : American Petroleum Institute Material ISO : International Organization for Standardization UTTO : Universal Tractor Transmission Oil NLGI : National Lubricating Grease Institute 1-26

SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device Group 2 Main Control Valve Group 3 Swing Device Group 4 Travel Device Group 5 RCV Lever Group 6 Accelerator pedal Group 7 Brake pedal Group 8 Transmission Group 9 Transmission control valve Group 10 Steering valve Group 11 Axle

2-1 2-21 2-47 2-59 2-65 2-72 2-73 2-76 2-83 2-85 2-87

Hyundai R200W 7 PDF Crawler Excavator Workshop Service Manual

The Hyundai R200W-7 is a Engine: The excavator is typically equipped with a diesel engine.

The exact specifications of the engine may vary, but it usually has a displacement of around 4.8 liters.

Hyundai R200W 7 PDF Crawler Excavator Workshop Service Manual