Hyundai R140LC-9 Manual

HYDRAULIC EXCAVATOR
OPERATION & MAINTENANCE
MANUAL
R140LC-9
R140LCD-9
R140LCM-9
Serial No.

INTRODUCTION
1. EC Declaration of Conformity................ 0-1
2. Disclaimer............................................. 0-2
3. Foreword............................................... 0-3
4. Before servicing this machine................0-4
5. EC regulation approved.........................0-5
6. Table to enter serial no. and distributor. 0-6
7. Safety labels..........................................0-7
8. Machine data plate.............................. 0-19
GUIDE
SAFETY HINTS
1. Before operating the machine............... 1-1
2. During the operation..............................1-6
3. During the maintenance...................... 1-13
4. Parking................................................ 1-16
SPECIFICATIONS
1. Major components.................................2-1
2. Specifications........................................2-2
3. Working range....................................... 2-6
4. Weight................................................. 2-10
5. Lifting capacities..................................2-12
6. Bucket selection guide........................ 2-17
7. Undercarriage..................................... 2-21
8. Specifications for major components...2-23
9. Recommended oils............................. 2-26
CONTROL DEVICES
1. Cab devices.......................................... 3-1
2. Cluster...................................................3-2
3. Switches..............................................3-25
4. Levers and pedals............................... 3-30
5. Full auto air conditioner and heater
(Standard)........................................... 3-33
6. Semi auto air conditioner and heater
(Option)............................................... 3-37
7. Others................................................. 3-40
OPERATION
1. Suggestions for new machines..............4-1
2. Check before starting the engine...........4-2
3. Starting and stopping the engine...........4-3
4. Mode selection system..........................4-8
5. Operation of working device................4-13
6. Traveling of the machine..................... 4-14
7. Efficient working method..................... 4-17
8. Operation in special work sites............4-21
9. Normal operation of excavator............ 4-23
10. Attachment lowering (When engine
is stopped)...........................................4-24
11. Storage................................................4-25
12. RCV lever operating pattern................ 4-27
13. Switching hydraulic attachment circuit.4-30
TRANSPORTATION
1. Preparation for transportation................5-1
2. Dimension and weight........................... 5-2
3. Loading the machine............................. 5-5
4. Fixing the machine................................ 5-7
5. Loading and unloading by crane........... 5-8
MAINTENANCE
1. Instruction..............................................6-1
2. Tightening torque.................................. 6-5
3. Fuel, coolant and lubricants...................6-7
4. Maintenance checklist...........................6-9
5. Maintenance chart...............................6-13
6. Service instruction............................... 6-15
7. Electrical system................................. 6-37
8. Air conditioner and heater................... 6-40
TROUBLESHOOTING GUIDE
1. Engine................................................... 7-1
2. Electrical system................................... 7-2
3. Others................................................... 7-3
HYDRAULIC BREAKER AND QUICK
CLAMP
1. Selecting the hydraulic breaker............. 8-1
2. Circuit configuration...............................8-2
3. Maintenance..........................................8-3
4. Precautions while operating the
breaker.................................................. 8-4
5. Quick clamp.......................................... 8-6
INDEX..............................................9- 1
CONTENTS

1. EC DECLARATION OF CONFORMITY
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).
Serial Nr. :
*******
***
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
**/**/****
Excavator Model :
2. Manufacturer Hyundai Heavy Industries Co. Ltd.
1 Chonha-Dong, Dong-Ku
Ulsan
The republic of Korea
0-1

2. DISCLAIMER
THIS TRANSLATION IS BASED UPON THE ORIGINAL ENGLISH OPERATION AND MAINTE-
NANCE MANUAL.
THE ENGLISH VERSION SHALL PREVAIL OVER THE TRANSLATION IN CASE OF ANY LE-
GAL DISPUTE.
0-2

3. FOREWORD
This manual contains a number of instructions and safety recommendations regarding driving, handling,
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 and 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 seri-
ous injury or death.
Some actions involved in operation and maintenance of the machine can cause a serious acci-
dent, 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 the jobsite and follow the safety recommendations in the safety hints section before
operating the machine.
3) Use 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.
0-3

4. BEFORE SERVICING THIS MACHINE
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 precau-
tions 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.
0-4

5. EC REGULATION APPROVED
• Noise levels (EN474-1: 2006 and 2000/14/EC) are as follows:
Lwa: 100 dB (EU only)
Lpa: 71 dB
• The value of vibrations transmitted by the operator's seat are lower than the standard value of
EN474-1: 2006 and 2002/44/EC.
0-5

6. TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial no.
Engine serial no.
Manufacturing year
Manufacturer Hyundai Heavy Industries co., Ltd
Address 1, Jeonha-Dong, Dong-Ku
Ulsan 682-792
The Republic of Korea
Distributor for USA Hyundai Heavy Industries USA, Inc.
Address 955 Estes Avenue, Elk Grove Village
IL 60007
USA
Distributor for Europe Hyundai Heavy Industries Europe N.V.
Address Vossendaal 11
2440 Geel
Belgium
Dealer
Address
0-6

7. SAFETY LABELS
1) LOCATION
Always keep these labels clean. If they are lost or damaged, attach them again or replace them with a
new label.
PUMP SCREEN
LH CONSOLE BOX BATTERY COVER
CAB INSIDE-RH CAB INSIDE-LH SCREEN PLATE
1 Air cleaner filter 17 Transporting 33 Service instruction
2 Turbocharger cover 18 Low emission engine 34 Lifting chart
3 Radiator cap 19 Control ideogram 35 Tie
4 Fueling 20 Ref operator manual-
Cab.RH pillar
36 Keep clear - Boom/arm
5 Battery accident 21 Hammer 37 ECM connector
6 High pressure hose 22 Safety front window 38 Falling
7 Hydraulic oil level 23 Alternate exit 39 FOPS FOG plate
8 Hydraulic oil lub 24 Air conditioner filter 40 Turbocharger
9 Keep clear - rear 25 Safety lever 41 Reflecting
10 Lifting eye 26 Model name 42 Accumulator
11 Name plate 27 Logo (ROBEX) 43 Machine control pattern
12 Slinging ideogram 28 Trade mark (Boom) 44 Control ideogram - dozer
13 Keep clear - side 29 Trade mark
(Counterweight)
45 RCV lever pattern
14 Stay fix 30 Reduction gear grease 46 Swing bearing
0-7

15 Shearing - engine hood 31 Locking - clamp 47 Battery position
16 No step engine hood/
counterweight
32 Noise level (LWA)
2) DESCRIPTION
There are several specific warning labels on this machine. Please become familiarized with all warning
labels.
Replace any safety labels that are damaged or missing.
(1) AIR CLEANER FILTER (Item 1)
This warning label is positioned on the air cleaner
cover.
Periodic and proper inspection, cleaning
and change of elements extend the engine
life time and maintain the good performance
of the engine.
(2) TURBOCHARGER COVER (Item 2)
This warning label is positioned on the turbocharger
cover.
Do not touch the turbocharger as it may
cause severe burns.
(3) RADIATOR CAP (Item 3)
This warning label is positioned on the radiator.
Never open the filler cap while the engine is
running or at high coolant temperature.
0-8

(4) FUELING (Item 4)
This warning label is positioned on the right side of
the fuel filler neck.
Stop the engine when refueling. All lights or
flames shall be kept at a safe distance while
refueling.
(5) BATTERY ACCIDENT (Item 5)
This warning label is positioned on the battery cover.
Electrolyte containing sulfuric acid causes
severe burns. Avoid being in contact with
skin, eyes or clothes. In the event of acci-
dent flush with sufficient water, and call a
physician immediately.
Maintain the electrolyte at the recommended
level.
With electrolyte at proper level, less space
may cause the gases to be accumulated in
the battery.
Extinguish all smoking materials and open
flames before checking the battery.
Do not use matches, lighters or torches as a
light source near the battery for the proba-
ble presence of explosive gas.
Do not allow unauthorized personnel to
change the battery or to use booster cables.
For safety from electric shock, do not touch the battery terminal with a wet hand.
(6) HIGH PRESSURE HOSE (Item 6)
These warning labels are positioned in the front of
the upper frame and on the screen plate.
Escaping fluid under pressure can penetrate
the skin causing serious injury.
Study the service manual before service job.
0-9

(7) HYDRAULIC OIL LEVEL (Item 7)
This warning label is positioned on the screen plate.
Place the bucket on the ground whenever
you are servicing the hydraulic system.
Check oil level on the level gauge.
Refill the recommended hydraulic oil up to
specified level if necessary.
(8) HYDRAULIC OIL LUBRICATION (Item 8)
This warning label is positioned on the top of the hy-
draulic oil tank.
Do not mix different brands of oil.
Never open the filler cap while the engine is
running or at high hydraulic oil temperature.
Loosen the cap slowly and release the inter-
nal pressure completely.
(9) KEEP CLEAR (Item 9)
This warning label is positioned on the rear of the
counterweight.
To prevent serious personal injury or death
keep clear or machine swing radius.
Do not deface of remove this label from the
machine.
(10) LIFTING EYE (Item 10)
This warning label is positioned on the counter-
weight.
Do not lift the machine by using lifting eyes
on the counterweight or the lifting eyes may
be subject to overload causing its breaking
and possible personal injury.
See page 5-8 for proper lifting method of
the machine.
0-10

(11) KEEP CLEAR - SIDE (Item 13)
This warning label is positioned on the LH side cov-
er.
Keep clear of machine swing radius to pre-
vent serious personal injury or death.
Do not deface or remove this label from the
machine.
(12) STAY FIX (Item 14)
This warning label is positioned on both side covers.
Be sure to support the stay when the door
needs to be opened.
Be careful that the opened door may be
closed by the external or natural force like
strong wind.
(13) SHEARING - ENGINE HOOD (Item 15)
This warning label is positioned on the engine hood.
Don't open the engine hood when the engine
is running.
Don't touch the exhaust pipe as it may cause
severe burns.
0-11

(14) NO STEPPING - ENGINE HOOD/COUNTER-
WEIGHT (Item 16)
This warning label is positioned on the engine hood
and counterweight.
Don't step on the engine hood or counter-
weight.
(15) TRANSPORTING (Item 17)
This warning label is positioned right side of upper
frame.
Study the operator's manual, if provided, be-
fore transporting the machine and tie down
arm and track to the carrier with lashing
wire.
See page 5-7 for details.
(16) CONTROL IDEOGRAM (Item 19)
This warning label is positioned on the right window
of the cab.
Check the machine control pattern for con-
formance to the pattern on this label. If not,
change the label to match the pattern before
operating the machine.
Failure to do so could result in injury or
death.
See page 4-27 for details.
(17) REFERENCE OPERATOR MANUAL (Item 20)
This warning label is positioned on the right side win-
dow of the cab.
Read the operator's manual carefully before
starting and operating machine.
0-12

(18) MAX HEIGHT (Item 20)
This warning label is positioned on the right side win-
dow of the cab.
Serious injury or death can result from con-
tact with electric lines.
Keep the minimum distance considering the
supply voltage (see table page 1-7) to
avoid an electric shock by merely coming in-
to the vicinity of electric lines.
(19) INTERFERENCE (Item 20)
This warning label is positioned on the right side win-
dow of the cab.
Be careful to operate a machine equipped
with quick clamp or extensions.
The bucket may hit the cab, boom or boom
cylinders when it reaches vicinity of them.
(20) SAFETY FRONT WINDOW (Item 22)
This warning label is positioned on both side win-
dows of the cab.
Be careful that the front window may be
promptly closed.
(21) EMERGENCY EXIT (Item 23)
This warning label is positioned on the inside of rear
window.
The rear window serves as an emergency
exit.
To remove rear window, pull the ring and
push out the glass.
21070FW25
0-13

(22) AIR CONDITIONER FILTER (Item 24)
This warning label is positioned on the air conditioner
cover.
Periodic and proper inspection, cleaning
and changing of filters extend the air condi-
tioner's life time and maintain good perform-
ance.
(23) SAFETY LEVER (Item 25)
This warning label is positioned on the cover of the
safety lever.
Before you get off the machine be sure to
place the safety lever in the LOCKED posi-
tion.
(24) REDUCTION GEAR GREASE (Item 30)
This warning label is located in the front of the upper
frame.
Grease is under high pressure.
Grease coming out of the grease plug under
pressure can penetrate the body causing in-
jury or death.
(25) CLAMP - LOCKING (Item 31)
This warning label is positioned on the right side win-
dow of cab.
Serious injury or death can result from drop-
ping bucket.
Operating the machine with the quick clamp
switch unlocked or without safety pin of
moving hook can cause the bucket to drop
off.
30007A1FW07A
0-14

(26) TIE (Item 35)
This warning label is positioned on the lower frame.
Never tow the machine using tie hole as it
may break.
See page 4-16 for details.
(27) KEEP CLEAR - BOOM/ARM (Item 36)
This warning label is positioned on both sides of the
arm.
Serious injury or death can result from fall-
ing of the attachment.
To prevent serious injury or death, keep
clear the underneath of attachment.
(28) ECM CONNECTOR (Item 37)
This warning label is positioned on the battery cover.
Before carrying out any electric welding on
this machine follow the below procedure:
- Pull the connectors out of all electric
control units.
- Connect the ground lead of the weld-
ing equipment as close to the welding
point as possible.
See page 6-39 for details.
4507A0FW02
7807AFW20
Before carrying out any electric welding on this
machine
- Pull the connectors out of all electronic control
units.
- Connect the ground lead of the welding equipment
as close to the welding point as possible.
Read the instructions in operator's manual for
details.
W A R N I N G
0-15

(29) FALLING (Item 38)
This warning label is positioned on the top of the hy-
draulic tank and the counterweight.
Falling is one of the major causes of person-
al injury.
Be careful of slippery conditions on the plat-
forms, steps and handrails when standing
on the machine.
(30) TURBOCHARGER (Item 40)
This warning label is positioned on the right window
of the cab.
In order to prevent a turbocharger failure,
please allow more than 5 minutes cool down
period (no load low idle operation) before
shutting the engine off.
(31) REFLECTING (Item 41)
This warning label is positioned on the rear of the
counterweight.
To prevent serious personal injury or death,
stay clear of machine swing radius.
Do not deface or remove this label from the
machine.
(32) ACCUMULATOR (Item 42)
This warning label is positioned on the accumulator
of the solenoid valve.
The accumulator is filled with high-pressure
nitrogen gas, and it is extremely dangerous
if it is handled in the wrong way. Always ob-
serve the following precautions.
Never make any hole in the accumulator ex-
pose it to flame or fire.
Do not weld anything to the accumulator.
When carrying out disassembly or maintenance of the accumulator, or when disposing of
the accumulator, it is necessary to release the gas from the accumulator. A special air
bleed valve is necessary for this operation, so please contact your Hyundai distributor.
C A U T I O N
In order to prevent turbocharger failure,
please allow more than 5 minutes' cool
down period(no load low idle operation)
before shutting the engine off.
0-16