Hyundai Robex 160lc-9 User manual

Robex 160LC-9

CRAWLER EXCAVATOR

OPERATOR'S MANUAL

TABLE OF CONTENT

CONTENTS 2

FOREWORD 3

BEFORE SERVICING THIS MACHINE 4

EC REGULATION APPROVED 5

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 7

SAFETY LABELS 8

MACHINE DATA PLATE 22

GUIDE 23

SAFETY HINTS 24

1. BEFORE OPERATING THE MACHINE 24

2. DURING OPERATING THE MACHINE 39

3. DURING MAINTENANCE 46

4. PARKING 49

SPECIFICATIONS 50

1. MAJOR COMPONENT 50

2. SPECIFICATIONS 51

3. WORKING RANGE 54

4. WEIGHT 56

5. LIFTING CAPACITIES 57

6. BUCKET SELECTION GUIDE 61

7. UNDERCARRIAGE 62

8. SPECIFICATIONS FOR MAJOR COMPONENTS 64

9. RECOMMENDED OILS 67

CONTROL DEVICES 68

1. CAB DEVICES 68

2. CLUSTER 69

3. SWITCHES 90

4. LEVERS AND PEDALS 94

5. AIR CONDITIONER AND HEATER 97

6. OTHERS 104

OPERATION 118

1. SUGGESTION FOR NEW MACHINE 118

2. CHECK BEFORE STARTING THE ENGINE 119

3. STARTING AND STOP THE ENGINE 120

4. MODE SELECTION SYSTEM 123

5. OPERATION OF THE ORKING DEVICE 128

6. TRAVELING OF THE MACHINE 129

7. EFFICIENT WORKING METHOD 132

8. OPERATION IN THE SPECIAL WORK SITES 136

9. NORMAL OPERATION OF EXCAVATOR 138

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10. ATTACHMENT LOWERING (when engine is stopped) 139

11. STORAGE 140

12. RCV LEVER OPERATING PATTERN 142

13. SWITCHING HYDRAULIC ATTACHMENT CIRCUIT 144

TRANSPORTATION 145

1. PREPARATION FOR TRANSPORTATION 145

2. DIMENSION AND WEIGHT 146

3. LOADING THE MACHINE 149

4. FIXING THE MACHINE 151

5. LOADING AND UNLOADING BY CRANE 152

MAINTENANCE 153

1. INSTRUCTION 153

2. TIGHTENING TORQUE 158

3. FUEL, COOLANT AND LUBRICANTS 161

4. MAINTENANCE CHECK LIST 163

5. MAINTENANCE CHART 168

6. SERVICE INSTRUCTION 170

7. ELECTRICAL SYSTEM 191

8. AIR CONDITIONER AND HEATER 194

TROUBLESHOOTING GUIDE 196

1. ENGINE 196

2. ELECTRICAL SYSTEM 197

3. OTHERS 198

HYDRAULIC BREAKER AND QUICK CLAMP 199

1. SELECTING HYDRAULIC BREAKER 199

2. CIRCUIT CONFIGURATION 200

3. MAINTENANCE 201

4. PRECAUTIONS WHILE OPERATING THE BREAKER 202

5. QUICK CLAMP 204

INDEX 206

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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

--------------------------------------------

0-18

Guide (direction, S/No, symbol)

- - - - - - - - - - - - - - - - - - - - - - - -

0-19

SAFETY HINTS

1. Before operating the machine

- - - - - - - - - - - - - - - - - - - -

1-1

2. During operating the machine

- - - - - - - - - - - - - - - - - - - -

1-16

3. During maintenance

-----------------------------------

1-23

4. Parking

--------------------------------------------------------

1-26

SPECIFICATIONS

1. Major components

-------------------------------------

2-1

2. Specifications

--------------------------------------------

2-2

3. Working range

-------------------------------------------

2-5

4. Weight

-------------------------------------------------------

2-7

5. Lifting capacities

----------------------------------------

2-8

6. Bucket selection guide

-------------------------------

2-12

7. Undercarriage

-------------------------------------------

2-13

8. Specification for major components

- - - - - - - - - - -

2-15

9. Recommended oils

------------------------------------

2-18

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

- - - - - - - - - - - - - - - - - - - - - - - - -

3-30

6. Others

--------------------------------------------------------

3-37

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

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

---------------------------------------

6-6

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

1. Engine

------------------------------------------------------

7-1

2. Electrical system

---------------------------------------

7-2

3. Others

-------------------------------------------------------

7-3

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

------------------------------------------------------------

9-1

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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 oper-

ating 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 infor-

mation for your machine or for questions regarding information in this manual.

FOREWORD

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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 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, provin-

cial 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

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0-3

·

Noise level (EN474-1 : 2006 and 2000/14/EC) are as followings.

LWA : 101

dB

(EU only)

LPA : 70

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

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EC Declaration of Conformity

1. HYUNDAI CONSTRUCTION EQUIPMENT EUROPE N.V VOSSENDAAL 11, 2440 GEEL (Belgium), as

authorized representative in the European Community of HYUNDAI CONSTRUCTION EQUIPMENT Co.

Ltd.(Korea)

certiﬁes that the construction equipment machinery.

Machine Type : ******* Brand : HYUNDAI

Model : *****

Serial No : ***

Year of Manufacturing : 20**

2. Manufacturer Hyundai Construction Equipment Co. Ltd.

12th, Fl., Hyundai Bldg. 75, Yulgok-ro, Jongno-Gu, Seoul,

Republic of Korea

HYUNDAI CONSTRUCTION EQUIPMENT EUROPE N.V.

VOSSENDAAL 11, 2440 GEEL

BELGIUM

Authorized representative :

Owner of the technical ﬁle for

machine production

3. Harmonized European directives : 2006/42/EC (Machinery), 97/68/EC (Exhaust Gas Emission),

2004/108/EC (Electromagnetic Compatibility), 200/14/EC (Noise

Emission)

4. Engine Manufacturer : ********

Engine Type :

Gross Power :

Net Power :

**********

*** kW / **** rpm (SAE J1995)

*** kW / **** rpm (SAE J1349)

5. Noise level (Noise Emission Directive 2000/14/EC)

Certiﬁcate No :

Issue Date :

Conformity Assesment Procedure :

Notiﬁed Body Involved :

Measured Sound Power Level :

Guaranteed Sound Power Level :

**********************

DD/MM/YYYY

**********************

** dB(A)

6. EMC Certiﬁcation (EMC Directive 2004/108/EC)

Certiﬁcate No :

Issued Date :

Notiﬁed Body Involved :

Standard(s) :

*********

DD/MM/YYYY

************

*****************

*******

7. Remarks

J. C. JUNG

MANAGING DIRECTOR

Place and date of issue :

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0-4

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 Construction Equipment co., Ltd.

12th, Fl., Hyundai Bldg. 75, Yulgok-ro, Jongno-Gu,

Seoul, 03058, Korea

Hyundai Construction Equipment U.S.A, Inc

6100 Atlantic Boulevard Norcross

GA 30071

U.S.A

Hyundai Construction Equipment Europe N.V.

Vossendal 11

2240 Geel

Belgium

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0-5

SAFETY LABELS

Bucket

1

2

3

4

7

6

PUMP SCREEN

LH CONSOLE BOX BATTERY COVER

CAB INSIDE-RH CAB INSIDE-LH

26

22

20

41

24

22

538

35

SCREEN PLATE

19 45

46

8

9

10

11 33

1212

13

14

15

16

17

48

1828

32

23

29

37

27

43

39

16

30

42 42

39 316

36

40

47

50

949

5134

21

52

1. LOCATION

Always keep these labels clean. If they are lost or damage, attach them again or replace them with

a new label.

16090SL01

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 Lifting eye

11 Name plate

12 Slinging ideogram

13 Keep clear-side

14 Stay fix

15 Shearing-engine hood

16

No step-engine hood and CWT

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

26 Safety lever

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 Connector

39 Falling

40 FOPS FOG plate

41 Turbocharger

42 Reflecting

43 Accumulator

44 Machine control pattern

45 Control ideogram-dozer

46 RCV lever pattern

47 Swing bearing

48 Battery position

49 Beacon lamp

50 Fuel shut off

51 Water separator

52 MCU/ECM connector

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0-6

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

and change of elements prolong engine

life time and maintain the good perfor-

mance of engine.

There are several specific warning labels on this machine please become familiarized with all warn-

ing labels.

Replace any safety label that is damaged, or missing.

1)

ö

21070FW01

TURBOCHARGER COVER

TURBOCHARGER COVER (item 2)

This warning label is positioned on the tur-

bocharger cover.

Do not touch turbocharger or it may

cause severe burn.

2)

21070FW02

14070FW03

21070FW04

RADIATOR CAP

RADIATOR CAP (item 3)

This warning label is positioned on the radi-

ator.

Never open the filler cap while engine

running or at high coolant temperature.

3)

FUELING

FUELING (item 4)

This warning label is positioned on the fuel

filler neck.

Stop the engine when refueling. All

lights or flames shall be kept at a safe

distance while refueling.

4)

0-7

BATTERY ACCIDENT

BATTERY ACCIDENT (item 5)

This warning label is positioned on the bat-

tery cover.

Electrolyte containing sulfuric acid cause

severe burns. Avoid being in contact with

skin, eyes or clothes. In the event of

accident flush with sufficient water, call a

physician immediately.

Maintain the electrolyte at the recom-

mended level.

With electrolyte at proper level, less

space may cause the gases to be accu-

mulated 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

probable 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 bat-

tery terminal with a wet hand.

5)

ö

36070FW05

14070FW29

HIGH PRESSURE HOSE

HIGH PRESSURE HOSE (item 6)

These warning labels are positioned in the

front of upper frame and on the screen

plate.

Escaping fluid under pressure can pene-

trate the skin causing serious injury.

Study the service manual before service

job.

6)

ö

0-8

LIFTING EYE

LIFTING EYE (item 10)

This warning label is positioned on the

counterweight.

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.

10)

ö

21070FW10

14070FW08

HYDRAULIC OIL LUBRICATION

HYDRAULIC OIL LUBRICATION (item 8)

This warning label is positioned on the top

of the hydraulic tank.

Do not mix with different brand oils.

Never open the filler cap while high tem-

perature.

Loosen the cap slowly and release inter-

nal pressure completely.

8)

ö

REAR KEEP CLEAR

REAR KEEP CLEAR (item 9)

This warning label is positioned on the rear

of counterweight.

To prevent serious personal injury or

death keep clear or machine swing radi-

us.

Do not deface of remove this label from

the machine.

9)

21090FW09

21070FW07

HYDRAULIC OIL LEVEL

HYDRAULIC OIL LEVEL (item 7)

This warning label is positioned on the

screen plate.

Place the bucket on the ground whenever

servicing the hydraulic system.

Check oil level on the level gauge.

Refill the recommended hydraulic oil up

to specified level if necessary.

7)

ö

0-9

SHEARING-ENGINE HOOD

SHEARING-ENGINE HOOD (item 15)

This warning label is positioned on the

engine hood.

Don't open the engine hood during the

engine's running.

Don't touch exhaust pipe or it may cause

severe burn.

21070FW15

21070FW13

SIDE KEEP CLEAR

SIDE KEEP CLEAR (item 13)

This warning label is positioned on the LH

side cover.

To prevent serious personal injury or

death keep clear of machine swing radi-

us.

Do not deface or remove this label from

the machine.

STAY FIX

STAY FIX (item 14)

This warning label is positioned on the both

side cover.

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)

11)

12)

21070FW14

0-10

REF OPERATOR MANUAL

REF OPERATOR MANUAL (item 20)

This warning label is positioned on the right

side window of the cab.

Study the operator's manual before start-

ing and operating machine.

21070FW22

TRANSPORTING

TRANSPORTING (item 17)

This warning label is positioned right side

of upper frame.

Study the operator's manual before

transporting the machine, if provided and

tie down arm and track to the carrier with

lashing wire.

See page 5-7 for details.

14070FW17

CONTROL IDEOGRAM

CONTROL IDEOGRAM (item 19)

This warning label is positioned in right

window of the cab.

Check the machine control pattern for

conformance to pattern on this label. If

not, change label to match pattern

before operating machine.

Failure to do so could result in injury or

death.

See page 4-11 for details.

36070FW19

NO STEP-ENGINE HOOD/CWT

NO STEP-ENGINE HOOD/CWT (item 16)

These warning labels are positioned on the

engine hood and counterweight.

Don't step on the engine hood and coun-

terweight.

21070FW16

17)

14)

15)

16)

0-11

MAX HEIGHT

MAX HEIGHT (item 20)

This warning label is positioned on the right

side window of the cab.

Serious injury or death can result from

contact with electric lines.

An electric shock being received by

merely coming into the vicinity of an

electric lines, the minimum distance

should be kept considering the supply

voltage as page 1-7.

21070FW23

INTERFERENCE

INTERFERENCE (item 20)

This warning label is positioned on the

right side window of the cab.

Be careful to operate machine equipped

with quick clamp or extensions.

Bucket may hit cab or boom, boom cylin-

ders when it reached vicinity of them.

18)

19)

21090FW62

ALTERNATE EXIT

ALTERNATE EXIT (item 23)

This warning label is positioned on the

inside of rear window.

The rear window serves us an alternate

exit.

To remove rear window, pull the ring and

push out the glass.

21070FW25

SAFETY FRONT WINDOW

SAFETY FRONT WINDOW (item 22)

This warning label is positioned on the both

side window of the cab.

Be careful that the front window may be

promptly closed.

21

21)

ö

20)

21070FW24

0-12

AIR CONDITIONER FILTER

AIR CONDITIONER FILTER (item 24)

This warning label is positioned on the air

conditioner cover.

Periodic and proper inspection, cleaning

and change of filter prolong air condition-

er life time and maintain good perfor-

mance.

21070FW26

SAFETY LEVER

SAFETY LEVER (item 26)

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 LOCKED posi-

tion.

30007A1FW07A

22)

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23)

REDUCTION GEAR GREASE

REDUCTION GEAR GREASE (item 31)

This warning label is positioned in the front

of upper frame.

Grease is under high pressure.

Grease coming out of the grease plug

under pressure can penetrate the body

causing injury or death.

21070FW35

CLAMP-LOCKING

CLAMP-LOCKING (item 32)

This warning label is positioned on the right

side window of cab.

Serious injury or death can result from

dropping bucket.

Operating the machine with quick clamp

switch unlocked or without safety pin of

moving hook can cause the bucket to

drop off.

14070FW60

24)

25)

0-13

TIE

TIE (item 36)

This warning label is positioned on the

lower frame.

Make sure no personal are standing

close to the tow rope.

See page 4-14 for detail.

4507A0FW02

KEEP CLEAR-BOOM/ARM

KEEP CLEAR-BOOM/ARM (item 37)

This warning label is positioned on both

side of the arm.

Serious injury or death can result from

falling of the attachment.

To prevent serious injury or death, keep

clear the underneath of attachment.

26)

27)

14070FW31

CONNECTOR

CONNECTOR (item 38)

This warning label is positioned on the bat-

tery cover.

Before carrying out any electric welding

on this machine, follow the below proce-

dure.

Pull the connector out of all electric con-

trol units.

Connector the ground lead of the weld-

ing equipment as close to the welding

point as possible.

See page 6-41 for detail.

7807AFW20

ÂBefore 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.

ÂRead the instructions in operator's manual for

details.

W A R N I N G

28)

-

ö

0-14

TURBOCHARGER

TURBOCHARGER (item 41)

This warning label is positioned on the right

window of the cab.

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.

7807AFW20

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.

REFLECTING

REFLECTING (item 42)

This warning label is positioned on the rear

of counterweight.

To prevent serious personal injury or

death keep clear of machine swing radi-

us.

Do not deface or remove this label from

the machine.

30)

31)

21090FW70

FALLING

FALLING (item 39)

These warning labels are positioned on the

top of the hydraulic tank and counterweight.

Falling is one of the major cause of per-

sonal injury.

Be careful of slippery conditions on the

platforms, steps and handrails when

standing on the machine.

14070FW30

29)

0-15

ACCUMULATOR

ACCUMULATOR (item 43)

This warning label is positioned on the

accumulator of the solenoid valve.

The accumulator is filled with high-pres-

sure nitrogen gas, and it is extremely

dangerous if it is handled in the wrong

way. Always observe the following pre-

cautions.

Never make any hole in the accumulator

expose it to flame or fire.

Do not weld anything to the accumulator.

When carrying out disassembly or main-

tenance of the accumulator, or when dis-

posing of the accumulator, it is neces-

sary to release the gas from the accu-

mulator. A special air bleed valve is nec-

essary for this operation, so please con-

tact your Hyundai distributor.

32)

ö

1107A0FW46

MACHINE

CONTROL

PATTERN

(item 44)

This warning label is positioned inside of

screen plate.

Check the machine control pattern for

conformance to pattern on this label. If

not, change label to match pattern

before operating machine.

Failure to do so could result in injury or

death.

See page 4-26 for details.

14W90FW99

33)

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Hyundai Robex 160LC-9 User manual

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