HYUNDAI Crawler Excavator R145CR-9 OPERATING Manual

AUTOTOTAL MANUAL Hyundai R145CR-9 Crawler Excavator Operating Manual

CONTENTS CONTENTS Foreword ----------------------------------------------------------- 0-1 Before servicing this machine --------------------------- 0-2 EC regulation approved ------------------------------------ 0-3 Table to enter S/No and distribution --------------------- 0-4 Safety labels ------------------------------------------------------ 0-5 Machine data plate -------------------------------------------- 0-17 Guide (direction, S/No, symbol) ------------------------ 0-18 SAFETY HINTS SAFETY HINTS 1. Before operating the machine -------------------- 1-1 2. During operating the machine -------------------- 1-6 3. During maintenance ----------------------------------- 1-13 4. Parking -------------------------------------------------------- 1-16 SPECIFICATIONS SPECIFICATIONS 1. Major components ------------------------------------- 2-1 2. Specifications -------------------------------------------- 2-2 3. Working range ------------------------------------------- 2-4 4. Weight ------------------------------------------------------- 2-5 5. Lifting capacities ---------------------------------------- 2-6 6. Bucket selection guide ------------------------------- 2-8 7. Undercarriage ------------------------------------------- 2-10 8. Specification for major components ----------- 2-12 9. Recommended oils ------------------------------------ 2-15 CONTROL DEVICES CONTROL DEVICES 1. Cab devices ----------------------------------------------- 3-1 2. Cluster ------------------------------------------------------- 3-2 3. Switches ---------------------------------------------------- 3-23 4. Levers and pedals ------------------------------------- 3-27 5. Air conditioner and heater ------------------------- 3-29 6. Others -------------------------------------------------------- 3-36 OPERATION OPERATION 1. Suggestion for new machine ---------------------- 4-1 2. Check before starting the engine --------------- 4-2 3. Starting and stop the engine ---------------------- 4-3 4. Mode selection system ------------------------------ 4-6 5. Operation of the working device ----------------- 4-11 6. Traveling of the machine ---------------------------- 4-12 7. Efficient working method --------------------------- 4-15 8. Operation in the special work sites ------------- 4-19 9. Normal operation of excavator ------------------- 4-21 10. Attachment lowering ---------------------------------- 4-22 11. Storage ----------------------------------------------------- 4-23 12. RCV lever operating pattern ----------------------- 4-25 13. Switching hydraulic attachment circuit -------- 4-27 TRANSPORTATION TRANSPORTATION 1. Preparation for transportation -------------------- 5-1 2. Dimension and weight ------------------------------- 5-2 3. Loading the machine --------------------------------- 5-4 4. Fixing the machine ------------------------------------ 5-6 5. Loading and unloading by crane ---------------- 5-7 MAINTENANCE MAINTENANCE 1. Instruction ------------------------------------------------- 6-1 2. Tightening torque --------------------------------------- 6-6 3. Fuel, coolant and lubricants ----------------------- 6-9 4. Maintenance check list ------------------------------ 6-11 5. Maintenance chart ------------------------------------ 6-16 6. Service instruction ------------------------------------- 6-18 7. Electrical system --------------------------------------- 6-39 8. Air conditioner and heater -------------------------- 6-42 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE 1. Engine ------------------------------------------------------ 7-1 2. Electrical system --------------------------------------- 7-2 3. Others ------------------------------------------------------- 7-3 HYDRAULIC BREAKER AND QUICK CLAMP HYDRAULIC BREAKER AND QUICK CLAMP 1. Selecting hydraulic breaker ------------------------ 8-1 2. Circuit configuration ----------------------------------- 8-2 3. Maintenance --------------------------------------------- 8-3 4. Precaution while operating the breaker ------ 8-4 5. Quick clamp ---------------------------------------------- 8-6 INDEX INDEX ------------------------------------------------------------ 9-1 AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

EC Declaration of conformity - update 04/01/’10 1. We hereby declare that the following machine comply with the machine directive 2006/42/EC, EMC-directive 2004/108/EC, Non-road mobile machinery emission directive 97/68/EC (amended by 2002/88/EC, 2004/26/EC, 2006/105/EC) and noise emission 2000/14/EC (amended by 2005/88/EC). Excavator Model : Serial Nr. : ******* *** 2. Manufacturer Hyundai Heavy Industries Co. Ltd. 1 Chonha-Dong, Dong-Ku Ulsan The republic of Korea Hyundai Heavy Industries Europe N.V. Vossendal 11 2440 Geel Belgium Authorized representative : Owner of the technical ﬁle for machine production. (TCF : Technical Construction File) 3. Harmonized European directives : EN474-1:2006 +A1:2009, EN474-5: 2006, EN ISO 12100-1:2003, EN ISO 12100-2:2003, EN ISO 2867:2008, EN ISO 7096:2008, EN ISO 6683:2008, EN ISO 2860:2008, EN ISO 6682:2008, EN ISO 3744:2009, EN 982:1996+A1:2008, EN ISO 3457:2008 EN ISO 2860:2008, EN ISO 7096:2008, ISO 5006: 2006 4. Noise level : Certain n˚ : Date : Conformity assessment procedure : Authorized entity : Engine power : Guaranteed sound power level : e13*2000/14*2005/88*0059*08 2009-06-17 Attachment VIII following the periodical inspection on technical extended with “Information on the scope of delivery” by TÜV Rheinland. Société Nationale de Certification et d’Homologation s.à r.l CE0499 11, route de Luxembourg 5230 Sandweiler Luxemburg *** kW *** dB (A) 5. Remarks ***** Managing Director Geel, Belgium **/**/**** AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

0-1 This manual contains a number of instructions and safety recommendations regarding driving, han- dling, lubrication, maintenance, inspection and adjustment of the excavator. The manual is to promote safety maintenance and enhance machine performance. Keep this manual handy and have all personnel read it periodically. If you sell the machine, be sure to give this manual to the new owners. This machine complies with EC directive "2006/42/EC". 1. Read Read and understand understand this manual before operating the machine. This operator's manual may contain attachments and optional equipment that are not available in your area. Please consult your local Hyundai distributor for those items you require. Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death. Some actions involved in operation and maintenance of the machine can cause a serious accident, if they are not done in a manner described in this manual. The procedures and precautions given in this manual apply only to intended uses of the machine. If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or others engage in prohibited uses of actions as described in this manual. 2. Inspect Inspect the jobsite and follow follow the safety recommendations in the safety hints safety hints section before operating the machine. 3. Use genuine Hyundai spare parts genuine Hyundai spare parts for the replacement of parts. We expressly point out that Hyundai will not accept any responsibility for defects resulting from non- genuine parts or non workmanlike repair. In such cases Hyundai cannot assume liability for any damage. Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Hyundai or your Hyundai distributor for the latest available information for your machine or for questions regarding information in this manual. FOREWORD FOREWORD AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

0-2 It is the responsibility of the owner and all service and maintenance personnel to avoid accidents and serious injury by keeping this machine properly maintained. It also is the responsibility of the owner and all service and maintenance personnel to avoid accidents and serious injury while servicing the machine. No one should service or attempt to repair this machine without proper training and supervision. All service and maintenance personnel should be thoroughly familiar with the procedures and precautions contained in this manual. All personnel also must be aware of any federal, state, provincial or local laws or regulations covering the use and service of construction equipment. The procedures in this manual do not supersede any requirements imposed by federal, state, provincial or local laws. Hyundai can not anticipate every possible circumstance or environment in which this machine may be used and serviced. All personnel must remain alert to potential hazards. Work within your level of training and skill. Ask your supervisor if you are uncertain about a particular task. Do not try to do too much too fast. Use your common sense. BEFORE SERVICING THIS MACHINE BEFORE SERVICING THIS MACHINE AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

0-3 · Noise level (EN474-1 : 2006 and 2000/14/EC) are as followings. LWA : 101 dB (EU only) LPA : 71 dB · The value of vibrations transmitted by the operator's seat are lower than standard value of (EN474-1 : 2006 and 2002/44/EC) EC REGULATION APPROVED EC REGULATION APPROVED AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

0-4 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine Serial No. Engine Serial No. Manufacturing year Manufacturer Address Distributor for U.S.A Address Distributor for Europe Address Dealer Address Hyundai Heavy Industries co., Ltd. 1, Jeonha-Dong, Dong-Ku, Ulsan 682-792, Korea Hyundai Heavy Industries U.S.A, Inc 955 Estes Avenue EIK Grove village IL, 60001 U.S.A Hyundai Heavy Industries Europe N. V. Vossendal 11 2240 Geel Belgium AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

0-5 SAFETY LABELS SAFETY LABELS LH CONSOLE BOX BATTERY COVER CAB INSIDE-RH CAB INSIDE-LH 29 37 18 13 14 27 28 12 12 43 8 39 4 2 14 16 39 3 15 23 30 9 9 42 42 1 33 11 47 31 6 32 20 22 34 41 21 22 36 35 24 10 45 5 38 44 7 40 LOWER FRAME 17 19 39 49 46 48 1. LOCATION 1. LOCATION Always keep these labels clean. If they are lost or damage, attach them again or replace them with a new label. 140Z90SL01 1 Air cleaner filter 2 Turbocharger cover 3 Radiator cap 4 Fueling 5 Battery accident 6 High pressure hose 7 Hydraulic oil level 8 Hydraulic oil lub 9 Keep clear-rear 10 Console box tilting 11 Name plate 12 Slinging ideogram 13 Keep clear-side 14 Stay fix 15 Shearing-engine hood 16 No step 17 Transporting 18 Low emission engine 19 Control ideogram 20 Ref operator manual-cab RH pillar 21 Hammer 22 Safety front window 23 Alternate exit 24 Air conditioner filter 27 Model name 28 Logo (ROBEX) 29 Trade mark (boom) 30 Trade mark (CWT) 31 Reduction gear grease 32 Clamp-locking 33 Noise level (LWA) 34 Service instruction 35 Lifting chart 36 Tie 37 Keep clear-Boom/arm 38 ECM connector 39 Falling 40 FOPS FOG plate 41 Turbocharger 42 Reflector 43 Accumulator 44 Machine control pattern 45 Control ideogram-dozer 46 RCV lever pattern 47 Swing bearing 48 Battery position 49 Beacon lamp AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

0-6 2. DESCRIPTION 2. DESCRIPTION AIR CLEANER FILTER AIR CLEANER FILTER (item 1) This warning label is positioned on the air cleaner cover. Periodic and proper inspection, cleaning Periodic and proper inspection, cleaning and change of elements prolong engine and change of elements prolong engine life time and maintain the good perfor- life time and maintain the good performance of engine. mance of engine. There are several specific warning labels on this machine please become familiarized with all warning labels. Replace any safety label that is damaged, or missing. 1) 1) ※ 21070FW01 TURBOCHARGER COVER TURBOCHARGER COVER (item 2) This warning label is positioned on the turbocharger cover. Do not touch turbocharger or it may Do not touch turbocharger or it may cause severe burn. cause severe burn. 2) 2) 21070FW02 14070FW03 21070FW04 RADIATOR CAP RADIATOR CAP (item 3) This warning label is positioned on the radiator. Never open the filler cap while engine Never open the filler cap while engine running or at high coolant temperature. running or at high coolant temperature. 3) 3) FUELING FUELING (item 4) This warning label is positioned on the left side of fuel filler neck. Stop the engine when refueling. All Stop the engine when refueling. All lights or flames shall be kept at a safe lights or flames shall be kept at a safe distance while refueling. distance while refueling. 4) 4) AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

0-7 BATTERY ACCIDENT BATTERY ACCIDENT (item 5) This warning label is positioned on the battery cover. Electrolyte containing sulfuric acid cause Electrolyte containing sulfuric acid cause severe burns. Avoid being in contact with severe burns. Avoid being in contact with skin, eyes or clothes. In the event of skin, eyes or clothes. In the event of accident flush with sufficient water, call a accident flush with sufficient water, call a physician immediately. physician immediately. Maintain the electrolyte at the recom- Maintain the electrolyte at the recommended level. mended level. With electrolyte at proper level, less With electrolyte at proper level, less space may cause the gases to be accu- space may cause the gases to be accu- mulated in the battery. mulated in the battery. Extinguish all smoking materials and Extinguish all smoking materials and open flames before checking the battery. open flames before checking the battery. Do not use matches, lighters or torches Do not use matches, lighters or torches as a light source near the battery for the as a light source near the battery for the probable presence of explosive gas. probable presence of explosive gas. Do not allow unauthorized personnel to Do not allow unauthorized personnel to change the battery or to use booster change the battery or to use booster cables. cables. For safety from electric shock, do not bat- For safety from electric shock, do not battery terminal with a wet hand. tery terminal with a wet hand. 5) 5) ※ 36070FW05 14070FW29 HIGH PRESSURE HOSE HIGH PRESSURE HOSE (item 6) These warning labels are positioned in the front of upper frame and on the right side of MCV box. Escaping fluid under pressure can pene- Escaping fluid under pressure can pene- trate the skin causing serious injury. trate the skin causing serious injury. Study the service manual before service Study the service manual before service job. job. 6) 6) ※ AUTOTOTAL - SERVICE REPAIR MANUAL (SRM)

HYUNDAI Crawler Excavator R145CR-9 OPERATING Manual

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