Page 1: Table Of Contents
CONTENTS CONTENTS EC declaration of conformity ----------------------------- 0-1 9. Operation in the special work sites ------------- 4-23 Foreword ----------------------------------------------------------- 0-2 10. Storage -------------------------------------------------------- 4-25 Emission-related components warranty 11. Exhaust system cleaning ------------------------------ 4-27 (USA and CANADA only) --------------------------------- 0-2-1 12. Open the engine hood ---------------------------------- 4-28 Before servicing this machine --------------------------- 0-3 13.
Page 2: Ec Declaration Of Conformity
12th Fl., Hyundai Bldg. 75, Yulgok-ro, Jongno-gu, Seoul 03058, Korea Hyundai Construction Equipment Europe N.V located at Hyundailaan 4, 3980 Tessenderlo, Belgium, as authorized repre sentative in the European Community is authorized to compile the technical construction file and declares that the product:...
Page 3: Foreword
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.
Page 4 EMISSION-RELATED COMPONENTS WARRANTY WARRANTY (USA AND CANADA ONLY) Hyundai shall have obligation under the EPA (Environmental Protection Agency) regulation of warranty about Emission-related components. This warranty shall exist for 3,000 hours or five years, whichever occurs first. Naturally, this warranty does not cover to damage arising from accident, misuse or negligence, use of non-Hyundai parts, or from alterations not authorized by Hyundai.
Page 5: Before Servicing This Machine
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.
Page 6 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine Serial No. Engine Serial No. Manufacturing year Manufacturer Hyundai Construction Equipment co., Ltd. 12th, Fl., Hyundai Bldg. 75, Yulgok-ro, Jongno-Gu, Address Seoul, 03058, Korea Hyundai Construction Equipment U.S.A, Inc Distributor for U.S.A 6100 Atlantic Boulevard Norcross...
Page 7: Ec Regulation Approved
EC REGULATION APPROVED EC REGULATION APPROVED · Noise level (EN474-1 : 2006 and 2000/14/EC) are as followings. 107 dB (EU only) 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)
Page 8: Safety Labels
SAFETY LABELS SAFETY LABELS 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. CAB INSIDE-LH CAB INSIDE-RH 26 5,6 15(RH) 13 34 B - B AIR CLEANER ACCUMULATOR 1(RH)
Page 9 2. DESCRIPTION 2. DESCRIPTION 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. If a safety label is attached to a part that is replaced, install a safety label on the replacement part. 1) 1) START MOTOR START MOTOR (item 1)
Page 10 5) 5) BUCKET STOPPER BUCKET STOPPER (item 7) This warning label is positioned on the mid- dle of the boom. When working under or around the buck- When working under or around the buck- et or linkage, with bucket raised, proper et or linkage, with bucket raised, proper support must be provided for the bucket support must be provided for the bucket...
Page 11 9) 9) ENGINE START CAUTION ENGINE START CAUTION (item 13) This warning label is positioned on the rear side window of the cab. Study the operator's manual before start- Study the operator's manual before start- ing and operating machine. ing and operating machine. 77070FW08 CONTROL IDEOGRAM CONTROL IDEOGRAM (item 14)
Page 12 LIFT & TIE LIFT & TIE (item 18) This label is positioned on the both side of Lifting the front and rear frame. - Lifting point - Lifting point In order to lift the machine, attach the lifting devices to the lifting points. - Tying point - Tying point Tying...
Page 13 BATTERY ACCIDENT BATTERY ACCIDENT (item 22) This warning label is positioned on the bat- tery box. 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.
Page 14 HIGH PRESSURE HOSE HIGH PRESSURE HOSE (item 24) This warning label is positioned on the left side of the front frame. Escaping fluid under pressure can pene- Escaping fluid under pressure can pene- trate the skin causing serious injury. trate the skin causing serious injury. Avoid the hazard by relieving pressure Avoid the hazard by relieving pressure before disconnecting hydraulic lines or...
Page 15 7. Tighten fuel supply line to its origin position. 8. Recranking. 9. If the engine still would not start, please contact the nearest HYUNDAI or Cummins dealers. 7609A0FW07 DIESEL EXHAUST FLUID DIESEL EXHAUST FLUID (item 33) This warning label is positioned on the right side of the rear frame.
Page 16 JOYSTICK STEERING JOYSTICK STEERING (item 40) This warning label is positioned on the left CAUTION CAUTION side of the cab. ※ While traveling on public roads, the While traveling on public roads, the steering wheel must be used and joystick steering wheel must be used and joystick steering must be prohibited.
Page 17 FUEL SHUT OFF FUEL SHUT OFF (item 43) This warning label is positioned on the hydraulic tank. ※ Fill only the hydraulic oil. Fill only the hydraulic oil. ※ Do not fill the diesel fuel. Do not fill the diesel fuel. Relieve tank pressure with the engine off Relieve tank pressure with the engine off by removing the cap slowly to prevent...
Page 18 NO STEP NO STEP (item 47) This warning label is positioned on the engine hood. Don't step on the engine hood. Don't step on the engine hood. EMERGENCY FIRE HOLE EMERGENCY FIRE HOLE (item 49) 9800FW08 This warning label is positioned on the inside of inlet cover.
Page 19: Machine Data Plate
※ The product identification number assigned to this particular machine and should be used when requesting information or ordering service parts for this machine from your authorized HYUNDAI dealer. The product identification number is also stamped on the frame. 0-17...
Page 20: Guide (Direction, S/No, Symbol)
GUIDE GUIDE 1. 1. DIRECTION DIRECTION Forward The direction of this manual indicate forward, backward, right and left, when machine is on the traveling direction. Left Right Backward 960A0FW15 2. 2. SERIAL NUMBER SERIAL NUMBER Machine serial No. Inform following when you order parts or the machine is out of order.
Page 21: Safety Hints
1. SAFETY HINTS 1. CALIFORNIA PROPOSTION 65 CALIFORNIA PROPOSITION 65 Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Always start and operate the engine in a well-ventilated area. If in an enclosed area, vent the exhaust to the outside.
Page 22: Safety Rules
Make sure that you comply strictly with the safety regulations at all times. Please contact Hyundai Construction Equipment Co., Ltd. or your dealer for more information. It is strictly prohibited to operate or use the machine in any...
Page 23 Safety guidelines Most safety accidents related to the operation, maintenance/ inspection, and repair of the machine result from a failure to comply with the safety rules or to take adequate preventive measures. Safety accidents can be prevented in advance by eliminating potentially hazardous situations.
Page 24 Never modify the operator’s cabin by welding, grinding, drilling holes or adding attachments unless instructed by Hyundai Construction Equipment in writing. Changes to the cabin can cause loss of operator protection from roll-over and falling objects, and result in death or serious injury.
Page 25 Fire and Explosion Prevention of fire The following actions should be taken to minimize the risk of fire : Do the visual inspection before operating the machine to check for any risk of fire. Do not operate the machine if there is a risk of fire. Be sure to identify the primary exit and alternative exit of the machine, and fully understand how to use the exits in the event of a fire.
Page 26 Prevention of explosion The following actions should be taken to minimize the risk of explosion: Preheating function is provided to certain machines that are used in extremely cold environments. Never use starting aid fluid in a low-temperature environment as it can have an adverse effect on the engine performance and may cause an explosion.
Page 27 Corrective Actions Before and After a Fire In the event of a fire in the machine, the top priority should be the safety of the operator and workers in the work area. In the event of a fire at a level that does not endanger the operator or workers, the following actions should be taken: Move the machine well away from any inflammable...
Page 28 Information on fire extinguisher Fire extinguishers (if equipped) should be kept in a fully operable condition, and be inspected by a qualified person on a regular basis. Workers should complete a training course on the use of fire extinguishers in advance. Use fire extinguishers in accordance with the following procedures, if required: Pull the safety pin of the fire extinguisher first.
Page 29 Health and Safety Personal protective equipment The wearing of personal protective gear is mandatory for protecting the human body from hazardous chemicals and hazardous environments. The wearing of personal protective gear is a means of preventing disaster, and should not interfere with the performance of jobs.
Page 30 Health and safety instructions in hazardous environments Comply with the following instructions during operation and maintenance of the machine. When handling oil Failure to wear personal protection may result in burns caused by contact with a high-temperature liquid. Make sure you wear protective goggles, protective gloves and protective clothing when handling oils such as hydraulic oil and engine oil.
Page 31 When handling coolants After operation of the machine the coolant is of high temperature and high pressure, and is retained inside the engine radiator and the heater line. Direct contact of the skin with the coolant may result in serious burns. Open the cap of the radiator only after the engine has sufficiently cooled and the pressure has dropped to a safe level.
Page 32 Personal protection gear for various situations Situation Symbol Oil handling Battery handling Refrigerant handling Coolant handling Repair by welding Working in areas subject to airborne particles and falling objects Working in places with a high level of noise Handling machines damaged by fire or exposed to excessively high temperature WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment...
Page 33 Noise and Vibration Information on vibration This part describes the vibration data of the machine, and methods of calculating the vibration level. The vibration level of the machine varies according to any of the following conditions: Driving habits of the operator (i.e. aggressive/mild temperament when driving) Quality of seat and suspension Type of machine, attachments, and conditions of...
Page 34 The vibration level can be predicted based on the information in the following table which is used to calculate the daily level of vibration exposure. Predict the vibration level in the three vibration directions of axes X, Y, and Z. The mean vibration level should be used under normal operation conditions.
Page 35 Instructions on mitigating vibration Machines should be correctly adjusted and maintained to ensure smooth operation. The terrain conditions should be observed. The following instructions will help reduce the whole body vibration level: Use machines and attachments of the correct types and sizes.
Page 36 The operator’s convenience may be reduced by various risk factors. Comply with the following conditions to effec- tively ensure the operator’s comfort and convenience. Adjust the driver’s seat adjustment device to allow a con- venient posture. Adjust the angles of the mirrors to minimize awkward, compromised posture Avoid working for an excessively long time, and take regular breaks.
Page 37 Safety Information on the Machines and Operation Before Operating the Machine Checking the worksite Carefully examine the following conditions and take the necessary actions, if required, to prevent risk factors before operating the machine: Check the weather condition at the worksite (e.g., fog, rain, etc.).
Page 38 Operator conditions to be checked before operating the machine The machine shall be operated by authorized and skilled operators only. The operator should wear clothes and personal protec- tion gear that are appropriate for the work environment. The operator should only be permitted to operate the machine under normal conditions after checking the state of the operator.
Page 39 During Operation of the Machine Getting on and off Do not jump on or off the machine. Do not try to get on or off the machine while it is moving. Get on or off the machine using the handrail and step (or stepladder, if any).
Page 40 Operation on a slope Comply with the following conditions when operating the machine on a slope: Do not work on slopes of 10˚ or more. The maximum climbing angle of the machine on a slope is 30˚. Do not operate the machine at an angle exceeding this value.
Page 41 Cautions to Be Taken When Driving the Machine If you operate the machine with the parking brake on, it may cause serious damage to the parking brake disk. Select the appropriate gear for the driving speed. Do not change direction when driving the machine at max.
Page 42 Operations to be avoided or prohibited Pay attention when operating the machine in an enclosed space as this may result in the risk of a buildup of hazardous gases. If the machine is operated in the vicinity of a high-voltage line, there is a risk of death or serious injury.
Page 43 Cautions when operating in specific areas Operating in extermely cold environments Do not attempt to start, stop or turn the machine suddenly as this may cause it to slip. There is potential for the machine to slip. Snow-covered or frozen ground may be slippery and dangerous.
Page 44 Operating in dusty or sandy environments Check the radiator grill for clogging by pollutant, and remove them, if any. Check the fuel system, and protect it from dust or sand when refueling. Inspect the air cleaner regularly, and replace it if necessary. If the gauge lamp on the dashboard lights up and the buzzer sounds at the same time, clean or replace the air cleaner independently of the usual inspection cycle.
Page 45 Cautions during maintenance Tools Use the correct tools for each type of work. Using improper tools may damage the machine and its parts. Using deteriorated or damaged tools may result in bodily injury. Inspection and servicing Prevent access to the machine by all unauthorized workers (other than those authorized during operation of the machine).
Page 46 Collision or cutting Never open or remove the engine hood while the machine is in operation. Two workers should perform the job while the engine is running: One worker should be ready to operate the machine or to turn the engine off from the cabin. Keep areas in the vicinity of rotating or moving parts clean.
Page 47 Repair by welding Perform repairs by welding in an area where adequate facilities for welding are available. Welding work may be subject to risks of gas leak, flame and electric shock. Welding should be performed only by a qualified welder. Take the following precautions when welding: Separate and remove the battery to prevent battery explosion.
Page 48 Cautions when working with the high-pressure line or hose Make sure that the internal pressure is released before · replacing or checking the high-pressure line or hose. If the internal pressure is not released, serious injury may · result. Be careful in the following conditions: ·...
Page 49 Battery The battery contains inflammable materials. · · Never smoke in the vicinity of the battery. The battery electrolyte is strong acid. Pay attention to · prevent the skin and eyes from coming into contact with the electrolyte. If the battery electrolyte accidentally comes into contact ·...
Page 50 Parking and Storage Cautions on parking Park the machine on the flat ground as possible. If parking the machine on a slope is unavoidable, use wheel chocks to prevent the machine from moving. Bring the bucket right down to the ground. Make sure that all of the switches are turned to the 'OFF' position.
Page 51 Regular lubrication (during storage) Breaking the lubrication film on parts may cause abnormal abrasion during the next operation. Start up the engine once a month, perform all of the functions, and apply lubrication oil to every part. Check the level of the engine oil and coolant when starting the engine up, and top them up if necessary.
Page 52 Visibility Before you start the machine, perform a walk-around inspection in order to ensure that there are no hazards around the machine. While the machine is in operation, constantly survey the area around the machine in order to identify potential hazards as hazards become visible around the machine. Your machine may be equipped with visual aids.
Page 53 < Top view of the machine at ground level visibility without use of optional visual aids > The shaded areas indicate the approximate location of areas with significant restricted visibility. (Radius = 12 m / 34 ft) There is restricted visibility to the area directly behind the machine with no optional visual aids. Failure to make sure the area is clear could result in serious injury or death.
Page 54 SAFETY REQUIREMENTS FOR STAGE V ENGINE This engine meets the following emission regulations; - United States and Canada : EPA Tier 4 (Final) - European Union : Stage V To comply with the above emission regulations, please make sure to observe the operation methods and safety requirements listed in this manual.
Page 55 Safety Requirements for fuel The engine has been optimized for use with an exhaust aftertreatment to meet the Tier 4 Final/ Stage V off-highway emissions regulations. It must operate on Ultra-Low Sulfur Diesel (ULSD] with a maximum sulfur content of 15 parts per million (ppm) in the United States and 10 ppm in the European Union.
Page 56 1-36...
Page 57: Specifications
2. SPECIFICATIONS 1. MAJOR COMPONENTS Hydraulic tank Radiator Bucket Tire Head light Boom Boom cylinder Main control valve Battery Counterweight Engine Bell crank Bucket cylinder Main pump Air cleaner Bucket link Front axle Steering cylinder Transmission Rear axle Fuel tank 970A2SE01...
Page 58: Specifications
2. SPECIFICATIONS WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL970A) 970A2SE03 Description Unit Specification Operating weight kg (lb) 24200 (53355) Struck 3.6 (4.7) Bucket capacity Heaped 4.2 (5.5) Overall length 8740 (28' 8") Overall width 3100 (10' 2") Overall height 3590 (11' 9") Ground clearance 480 (1' 7")
Page 59 WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL970A XT) 970A2SE03-1 Description Unit Specification Operating weight kg (lb) 25000 (55120) Struck 3.6 (4.7) Bucket capacity Heaped 4.2 (5.5) Overall length 9280 (30' 5") Overall width 3100 (10' 2") Overall height 3590 (11' 9") Ground clearance 480 (1' 7")
Page 60 WITH TOOTH TYPE BUCKET (HL970A) 970A2SE04 Description Unit Specification Operating weight kg (lb) 24110 (53155) Struck 3.4 (4.4) Bucket capacity Heaped 4.0 (5.2) Overall length 8890 (29' 2") Overall width 3150 (10' 4") Overall height 3590 (11' 9") Ground clearance 480 (1' 7")
Page 61 WITH TOOTH TYPE BUCKET (HL970A XT) 970A2SE04-1 Description Unit Specification Operating weight kg (lb) 24910 (54920) Struck 3.4 (4.4) Bucket capacity Heaped 4.0 (5.2) Overall length 9430 (31'11") Overall width 3150 (10' 4") Overall height 3590 (11' 9") Ground clearance 480 (1' 7")
Page 62: Weight
Item Front frame assembly 2153 4746 Rear frame assembly 2387 5262 Front fender (LH & RH) Counterweight (HL970A) 1100 2430 Counterweight (HL970A XT) 1600 3730 Cab assembly 1061 2339 Engine assembly 1712 Transmission assembly (4-speed/5-speed) 807/857 1779/1889 Drive shaft (front)
Page 63: Specification For Major Components
4. SPECIFICATION FOR MAJOR COMPONENTS ENGINE Item Specification Model Cummins L9 Type 4-cycle turbocharged, charge air cooled diesel engine Control type Electronic control 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 114 145 mm (4.5"...
Page 64 FAN + BRAKE PUMP Item Specification Type Variable piston pump Capacity 28 cc/rev Maximum operating pressure 250 kgf/cm (3560 psi) Rated oil quantity (at 2200rpm) 62 min (16.3 U.S.gpm) Maximum speed 2100 rpm MAIN CONTROL VALVE Item Specification Type 2 spool / 3 spool Operating method Hydraulic pilot assist Main relief valve pressure...
Page 65 Bore dia Rod dia Stroke 95 780 mm Bucket cylinder (HL970A) Bore dia Rod dia Stroke 95 565 mm Bucket cylinder (HL970A XT) Bore dia Rod dia Stroke 95 570 mm Steering cylinder Bore dia Rod dia Stroke 50 468 mm...
Page 67 · · · · ※ ※ ① ※...
Page 68 ① ② ※ ① · · ② ※ ① · · ② ※...
Page 69 ① ② ① ②...
Page 70 ① ② ① ② ③ ※ ① ① ② ※ ※ ① ② ※ ※ ※...
Page 71 ① ② ※ ① ※ ※ ② ※ ※ ① ② ※ ① ② ※ ※...
Page 72 ① ② ※ ① ② ※ ③ ※ ※ ※ ℃ ① ② ① ※...
Page 73 ① ※ ※ ① ※...
Page 74 ※ ※ ※ ① ② ② ※ ※ ③ ④ ① ② ③ ※...
Page 75 ① ※ ① ② ③ ※...
Page 76 ① ② ① ※ ① ※ ① ※...
Page 77 ① ※ ① ※ ※ ※ ※...
Page 78 · ※ ※ ※...
Page 79 ① ② ※ ① ② ③ ③ ④ ④ ※ ① ① ※ ※...
Page 80 ② ② · · ③ ③ · · · · ④ ④ · ·...
Page 82 ① ② ① ② ① ① ② ③ · · · ·...
Page 84 ① · ·...
Page 85 ② · · ※ ③ · ·...
Page 86 ④ · ⑤ · ·...
Page 89 ⑦ · · · ⑧ · · ⑨ · · ⑩ · ·...
Page 90 ⑪ · ※ ※ · · ⑫ · · ※ ⑬ · ※...
Page 91 ⑭ · · · · ※ · ① ② ③ ④ ⑤ ⑥ ※...
Page 92 · ※ · ① ② ③ ④ ⑤ ⑥ ※ ※ ※ · ※...
Page 93 · △ ▽ △ ▽ ⑮ · ·...
Page 94 ① · ② · · · · ③ · ※ ※...
Page 95 ④ · ⑤ ·...
Page 96 ① ·...
Page 97 ※ ※ · ·...
Page 98 ② · · · ★ ★ ★ ★...
Page 99 ③ · · · ④ · ·...
Page 100 ⑤ · · ·...
Page 101 ① · · · ② · ③ · ↔ ℓ · ↔ · ↔ · ↔ · ↔ ↔ ↔ ※...
Page 102 ④ · · ·...
Page 103 ⑤ ※ · · · · · · ※ ⑥ ※ · · · · · ·...
Page 104 · · · · ·...
Page 105 ① ② ① ① ② ※...
Page 106 ① ※ ① ※ ① ※ ① ※ ② ※...
Page 107 ① ※ ① ※ ① ②...
Page 108 ※ ① → ② → ③ → ④ → ⑤ → ⑥ → ⑦ → ⑧ → ⑨ → ⑩ ※ ※ ※ ① ① ②...
Page 109 ① ② ③ ① ① ② ① · · ① · · ① ② ※ ※...
Page 110 ① ② ※ ① ② ③...
Page 112 ① ② → → ③ ④...
Page 113 ⑤ ⑥ ⑦ ⑧...
Page 115 ⑨...
Page 116 ⑩ ⑪...
Page 117 ⑫ ⑬ → ⑭ ⑮...
Page 118 ① → → → · · · ② ① ② ① ② ① ② ※ ① ②...
Page 119 · · · ※ ※...
Page 120 ※ ※ ※ ※ ※ ※...
Page 121 ① ① ② ③ ③ ② ① ② ※ ② ※ ※ ② ① ②...
Page 122 ① ② ※ ※ ※ ① ※ · · · ① ② ③...
Page 123 ※ ※ Ⅰ Ⅱ ① ※ ② Ⅰ Ⅱ ③ ※ ※ Ⅰ Ⅱ ① ② · · · ③ ① ②...
Page 124 ※...
Page 125 ① ② ※ ③...
Page 126 ① ② ③ ※ ① ※ ② ③...
Page 127 · ·...
Page 128 ■ ·...
Page 129 ※ ※ ※ ※ ※...
Page 130 ① ※ ② ※ ※...
Page 131 ※...
Page 132 ① ② ③ ④ ① ※ ※...
Page 133 ① ② ※ ※ ① ※ ※ ① ② ① ②...
Page 134 ① ② ① ② ① ② ③...
Page 135 ① ② ① ① ①...
Page 136 ① ② ① ② ※ ※ ※ ※...
Page 137 ① ② ③ ※...
Page 138 ① ② ※ ※ ※ · · · ·...
Page 139 · · · ※...
Page 140 ■...
Page 141 ■ ① ② ③ ④ ※ ⑤...
Page 142 ① ② ③ ④ ⑤ ⑥ ※...
Page 143 ⑦ ⑧ · · · ① ① ※...
Page 144 ■ ① ① ① ①...
Page 145 ① ※...
Page 146 ■ ① ※ ① ① ① ※...
Page 147 ① ※ ※ ※...
Page 148 ■ ※ ※ ※ ※...
Page 149 ■ ※ ※ ※ ※ ※ ① ② ③...
Page 150 ※ ※ ※ ※ ※ ※ ※...
Page 151 ※ ※ ※ ※ ※...
Page 152 ※ ※ ※...
Page 153 ※ ※ ※...
Page 154 ■ ※ ●...
Page 167: Operation
4. OPERATION 4. OPERATION 1. SUGGESTION FOR NEW MACHINE 1. SUGGESTION FOR NEW MACHINE It takes about 100 operation hours to enhance its designed performance. Operate according to below three steps and avoid excessive operation for the initial 100 hours. Service meter Load Until 10 hours...
Page 168: Check Before Starting The Engine
2. CHECK BEFORE STARTING THE ENGINE 2. CHECK BEFORE STARTING THE ENGINE Make sure that the steering frame lock bar is stored in the unlocked position. The steering frame lock bar must be removed The steering frame lock bar must be removed in order to steer the machine.
Page 169 Monitor Monitor Monitor ① The buzzer sounds for 3 seconds with HYUNDAI logo on monitor. ② If the ESL mode is set to the enable, enter the password to start engine. ③ If the password has failed 5 times, please wait 30 minutes before re-attempting to enter the password.
Page 170 2) 2) STARTING ENGINE IN NORMAL TEMPERATURE STARTING ENGINE IN NORMAL TEMPERATURE ※ Sound the horn to warn the surroundings Sound the horn to warn the surroundings after checking if personnel or obstacles are in after checking if personnel or obstacles are in the area.
Page 171 3) 3) STARTING ENGINE IN A COLD WEATHER STARTING ENGINE IN A COLD WEATHER ※ Sound horn to warn surroundings after check- Sound horn to warn surroundings after check- ing if there are obstacles in the area. ing if there are obstacles in the area. ※...
Page 172 INSPECTION AFTER ENGINE START INSPECTION AFTER ENGINE START Inspect and confirm the following after engine starts. Is the level gauge of hydraulic oil tank in the nor- mal level? Are there leakages of oil or water? Are all the warning lamps (1-19) OFF? Check the following after warming up operation.
Page 173 6) 6) TO STOP THE ENGINE TO STOP THE ENGINE ※ If the engine is abruptly stopped before it has If the engine is abruptly stopped before it has cooled down, engine life may be greatly cooled down, engine life may be greatly shortened.
Page 174: Warming-Up Operation
4. WARMING-UP OPERATION 4. WARMING-UP OPERATION ※ The most suitable temperature for the hydraulic The most suitable temperature for the hydraulic oil is about 50 oil is about 50˚C (11 C (112˚F). It can cause serious ˚F). It can cause serious Gear selector lever trouble in the hydraulic system by sudden oper- trouble in the hydraulic system by sudden oper-...
Page 175: Operation Of The Working Device
5. OPERATION OF THE WORKING DEVICE 5. OPERATION OF THE WORKING DEVICE ※ Confirm the operation of control lever and Confirm the operation of control lever and working device. working device. RCV lever Control lever operates the boom and the bucket. EH type When you release the control lever, control lever returns to neutral position automatically.
Page 176: Traveling Of The Machine
6. TRAVELING OF THE MACHINE 6. TRAVELING OF THE MACHINE 1) 1) BASIC OPERATION BASIC OPERATION ※ Secure the engine hood in the fully closed Secure the engine hood in the fully closed position prior to traveling the machine. position prior to traveling the machine. (1) (1) Traveling posture Traveling posture...
Page 177 ※ When traveling at high speed, do not When traveling at high speed, do not abruptly decelerate by using the transmiss- abruptly decelerate by using the transmiss- ion lever, to slow down instead press the ion lever, to slow down instead press the brake pedal.
Page 178 (6) (6) Stopping the machine Stopping the machine ① Press the brake pedal to stop the machine. Gear selector lever Parking brake switch ② Put the gear selector lever in the neutral posi- tion. ③ Push the parking brake switch to the ON posi- tion.
Page 179 (7) (7) Stopping engine Stopping engine ※ If the engine is abruptly stopped before it has If the engine is abruptly stopped before it has Gear selector lever cooled down, its service life may be short- cooled down, its service life may be short- ened.
Page 180 TRAVELING ON A SLOPE TRAVELING ON A SLOPE Never travel down a slope in neutral. Lower the bucket 20-30 cm (1 ft) to the ground so that it can be used as a brake in an emergency. If the machine starts to slide or loses stability, lower the bucket immediately and brake the machine.
Page 181: Efficient Working Method
7. EFFICIENT WORKING METHOD 7. EFFICIENT WORKING METHOD 1) 1) GENERAL GENERAL Lift the bucket about 40-50 cm (2 ft) above the ground to ensure safety and to gain a good range of view. Clear the jobsite and level the ground. Be careful that excessive force is not applied to the bucket.
Page 182 2) 2) EXCAVATION WORK EXCAVATION WORK (1) (1) Shovel work Shovel work As the machine loads on the bucket with travel- ing, tires may start to slip because of heavy load. Then lift the bucket slightly to reduce load. ① Keep the bucket shovel parallel to the ground (If the bucket is pushed in a non-horizontal position, power may be reduced, and the buck-...
Page 183 (2) (2) Excavation on level ground Excavation on level ground Advance the machine with the bucket lowered slightly and make sure that the bucket is evenly loaded on both sides. ① Lower the bucket edge slightly. 73034OP07 ② Advance the machine and lift the bucket using the bucket control lever to dig out the soil.
Page 184 3) 3) LEVELING LEVELING Load the bucket with soil and dump gradually the soil while driving backward. After dumping the soil, move backward with the bucket lowered to the ground to level the ground. Load the bucket with soil and place the bucket in the horizontal position.
Page 185 6) 6) LOADING LOADING Maximum efficiency can be attained by carrying out work in such a way that the swinging angle and the traveling distance are kept as small and short as possible in accordance with the terrain. I method I method ①...
Page 186 If the machine does not stop even though the brake pedal is applied, use the parking brake. ※ After using the parking brake as an emer- gency brake, ask Hyundai dealer to check complete brake system. 760F4OP19 Precautions when driving on a slope Precautions when driving on a slope ①...
Page 187 ③ As the optimum air pressure of tire and opti- mum driving speed is different according to the kinds of tires and road conditions, consult Hyundai dealer or tire distributor. ④ Check the air pressure of tire before driving. ⑤...
Page 188: Adjustment Of The Work Equipment
8. ADJUSTMENT OF THE WORK EQUIPMENT 8. ADJUSTMENT OF THE WORK EQUIPMENT The bucket can be adjusted to a height desired by using the boom kick-out device. Park the machine on level ground and block the Park the machine on level ground and block the tires to prevent sudden movement of the tires to prevent sudden movement of the machine.
Page 189: Operation In The Special Work Sites
9. OPERATION IN THE SPECIAL WORK SITES 9. OPERATION IN THE SPECIAL WORK SITES 1) 1) OPERATION THE MACHINE A COLD WEATHER OPERATION THE MACHINE A COLD WEATHER Use proper engine oil and fuel for the weather. Fill the required amount of antifreeze in the cool- ant.
Page 190 3) 3) SEA SHORE OPERATION SEA SHORE OPERATION Prevent ingress of salt by securely tightening plugs, cocks and bolts of each part. Wash machine after operation to remove salt residue. Pay special attention to electrical parts and hydraulic cylinders to prevent corrosion. Inspection and lubrication must be carried out more frequently.
Page 191: Storage
10. STORAGE 10. STORAGE Maintain the machine taking care of following to pre- vent the deterioration of machine when storing the machine for a long time, over 1 month. 1) 1) CLEANING THE MACHINE CLEANING THE MACHINE Clean the machine. Grease each lubrication part.
Page 192 6) 6) DURING STORAGE DURING STORAGE Start engine and move the machine and working equipment once a month and apply lubrication to Lubrication operation once each part. a month ※ Check the level of engine oil and coolant and fill Check the level of engine oil and coolant and fill if required when starting engine.
Page 193: Exhaust System Cleaning
11. EXHAUST SYSTEM CLEANING EXHAUST SYSTEM CLEANING ※ Exhaust system cleaning events for the catalyst system will happen automatically under normal Exhaust system cleaning events for the catalyst system will happen automatically under normal engine conditions and are controlled by the ECM as long as the exhaust system cleaning engine conditions and are controlled by the ECM as long as the exhaust system cleaning Inhibit switch is not engaged.
Page 194: Open The Engine Hood
12. OPEN THE ENGINE HOOD 12. OPEN THE ENGINE HOOD The engine hood open toggle switch controls the engine hood. It is located in tool box on the left side of rear frame. OFF master switch after lamp off Open the access door. ※...
Page 195 If further access in needed, either side cover can be opened. The levers are positioned in the both side of the engine room. Hold the side cover in place, while unlatching the side cover. Lower the side cover to rest on the tire. The side cover can remain in the open position resting on the tire.
Page 196 9) 9) MANUAL OPERATION OF ENGINE HOOD MANUAL OPERATION OF ENGINE HOOD The engine hood can be operated manually. The engine hood can be operated manually. Open the RH vent cover. Remove the socket (Keep the socket to reuse) and turn the hand crank (6mm hexgon wrench) to open engine hood.
Page 197: Attachment Manually Lowering
13. ATTACHMENT MANUALLY LOWERING 13. ATTACHMENT MANUALLY LOWERING (ENGINE STOPPED) The manual lowering valve on the front frame can be manually lowering the attachment linkage if the CLOSE OPEN engine can't work. Slowly rotate the lowering valve lever to the OPEN position in order to lower the attachment to Manual lowering valve the ground.
Page 198: Transportation
5. TRANSPORTATION 5. TRANSPORTATION 1. ROAD TRAVELING 1. ROAD TRAVELING If it is necessary to travel on a road, observe the followings. Comply with regulations regarding this machine for the sake of safety. Perform daily inspection before starting the machine. Check the air pressure of tires and traveling speed limitations.
Page 199: Preparation For Transportation
2. PREPARATION FOR TRANSPORTATION 2. PREPARATION FOR TRANSPORTATION When transporting the machine, observe the vari- ous road rules, road transportation vehicle laws and vehicle limit ordinances, etc. Overall Make sure the cooling system has proper anti- width freeze if moving machine to a cold climate. Select proper trailer after confirming the weight and dimension from the page 2-2~2-5.
Page 200: Loading The Machine
3. LOADING THE MACHINE 3. LOADING THE MACHINE Load and unload the machine on a flat ground. Use the gangplank with sufficient length, width, thickness and gradient. Move slowly and carefully when the machine is on the gangplank. Do not change the direction of the machine while it is on the gangplank.
Page 201: Fixing The Machine
4. FIXING THE MACHINE 4. FIXING THE MACHINE Fix front and rear frame by linking safety lock bar. Push the parking brake switch. Safety lock bar 960A5TA04 Push the pilot cut off switch to the OFF position to prevent the hydraulic system from operating. Pilot cut off switch Stop the engine, turn the starting switch off and remove the key.
Page 202 Block the tires and fix firmly with wire rope or chain to prevent the machine from moving during transportation. 960A5TA07...
Page 203: Loading And Unloading By Crane
5. LOADING AND UNLOADING BY CRANE 5. LOADING AND UNLOADING BY CRANE Check the weight, length, width and height of the Wire rope machine referring to chapter 2, Specification when you are going to hoist the machine. Stay Stay Use long wire rope and stay to keep the distance with the machine as it should avoid to touch with the machine.
Page 204: Towing The Machine
6. TOWING THE MACHINE 6. TOWING THE MACHINE Personal injury or death could result when tow- Personal injury or death could result when tow- ing a disabled machine incorrectly. ing a disabled machine incorrectly. Block the machine to prevent movement before Block the machine to prevent movement before releasing the brakes.
Page 205 ※ Consult your HYUNDAI dealer for the equipment Consult your HYUNDAI dealer for the equipment that is necessary for towing a disabled machine. that is necessary for towing a disabled machine.
Page 206 3) 3) WHEN THE ENGINE DOES NOT WORK WHEN THE ENGINE DOES NOT WORK When towing the machine with the engine stopped, do it in the following order. The transmission oil does not lubricate the sys- tem, so remove the front and rear drive shafts. Loosen the steering cylinder as the steering operation is not workable.
Page 207: Maintenance
Inspect the engine compartment for any trash build up. Remove any trash build up from the build up. Remove any trash build up from the engine compartment. engine compartment. Ask to your local dealer or Hyundai for the main- tenance advice if unknown.
Page 208 Confirm if the cluster is in the normal condition after completion of service. For more detail information of maintenance, please contact local Hyundai dealer. ※ Be sure to start the maintenance after fully Be sure to start the maintenance after fully understand the chapter 1, understand the chapter 1, Safety hints.
Page 209 4) 4) RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM ※ Spouting of oil can cause the accident when Spouting of oil can cause the accident when loosening the cap or hose right after the oper- loosening the cap or hose right after the oper- ating of the machine as the machine or oil is on ating of the machine as the machine or oil is on...
Page 210 5) 5) PRECAUTION WHEN INSTALLING HYDRAULIC HOSES OR PIPES PRECAUTION WHEN INSTALLING HYDRAULIC HOSES OR PIPES Be particularly careful that the joint of hose, pipe and functioning item are not damaged. Avoid contamination. Assemble after cleaning the hose, pipe and joint of functioning item.
Page 211: Tightening Torque
2. TIGHTENING TORQUE 2. TIGHTENING TORQUE Use following table for unspecified torque. 1) 1) BOLT AND NUT BOLT AND NUT (1) (1) Coarse thread Coarse thread 8.8T 10.9T 12.9T Bolt size kgf·m lbf·ft kgf·m lbf·ft kgf·m lbf·ft M 6 × 1.0 0.8 ~ 1.2 5.8 ~ 8.6 1.2 ~ 1.8...
Page 212 2) 2) PIPE AND HOSE PIPE AND HOSE (FLARE type) Thread size Width across flat (mm) kgf·m lbf·ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 1" 1-1/4" 3) 3) PIPE AND HOSE PIPE AND HOSE (ORFS type) Thread size Width across flat (mm) kgf·m lbf·ft 9/16-18...
Page 213 TIGHTENING TORQUE OF MAJOR COMPONENT TIGHTENING TORQUE OF MAJOR COMPONENT Torque Descriptions Bolt size kgf·m lbf·ft 76.5 ± 7.7 553 ± 55.7 Engine mounting bolt, nut (rubber, 2EA) M24×3.0 Engine mounting bolt (bracket, 8EA) M12×1.75 11.7 84.6 6.63 ± 1.0 48 ±...
Page 214 ※ Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of major components.
Page 215 Soft water : City water or distilled water DEF compatible with AdBlue® ★4 If the machine is equipped with axle oil cooler, ★1 Ultra low sulfur diesel refer to page 6-44. - sulfur content  15 ppm ★5 Hyundai Bio Hydraulic Oil...
Page 216: Maintenance Check List
4. MAINTENANCE CHECK LIST 4. MAINTENANCE CHECK LIST Scheduled maintenance is the normal maintenance necessary to provide proper and efficient machine operation. To protect your investment and prolong the service life of your machine, follow the scheduled maintenance list below. 1) 1) EVERY 10 HOURS SERVICE EVERY 10 HOURS SERVICE...
Page 217 4) 4) EVERY 250 HOURS SERVICE EVERY 250 HOURS SERVICE Check items Service Page Wheel nuts Check, Tight 6-41, 42 Battery (voltage) / Battery cable and connections 6-53, 54 Check Air conditioner and heater filter (inner and outer) 6-56 Check, Clean 5) 5) EVERY 500 HOURS SERVICE EVERY 500 HOURS SERVICE...
Page 218 Hoses, fittings, clamps (fuel, coolant, hydraulic) ★1 Conventional hydraulic oil ★2 If do not want to change HBHO every 2000 hours, contact HYUNDAI dealer and ask about SAMPLING. 9) 9) EVERY 4500 HOURS SERVICE EVERY 4500 HOURS SERVICE Check items...
Page 219: Maintenance Chart
5. MAINTENANCE CHART 5. MAINTENANCE CHART 9 24 27 30 34 25 17 16 2 4 9,10 14,15 9,10 26,28 970A6MI10 Caution Caution - EO : Engine oil - EO : Engine oil - GO : Gear oil - GO : Gear oil 1.
Page 220 Air conditioner and heater outer filter Replace Air conditioner and heater inner filter Clean, Replace When required Air cleaner element (safety) Replace Air cleaner element (primary) Clean, Replace ★1 ★2 ★3 Conventional hydraulic oil Hyundai Bio Hydraulic Oil Hyundai genuine long life hydraulic oil 6-14...
Page 221: Service Instruction
6. SERVICE INSTRUCTION 6. SERVICE INSTRUCTION 1) 1) CHECK ENGINE OIL LEVEL CHECK ENGINE OIL LEVEL Dipstick Check the oil level with the machine on a flat ground before starting engine. Pull out the dipstick and wipe with a clean cloth. Check the oil level by inserting the dipstick com- pletely into the hole and pulling out again.
Page 222 Apply a light film of lubricating oil to the gasket sealing surface before installing the filter. ※ Fill the filter with clean lubricating oil. Fill the filter with clean lubricating oil. 7807AMI07 Install the filler to the filter head. Tighten the filter until the gasket contacts the fil- ter head surface.
Page 223 (10) Operate the engine at low idle and inspect for leaks at the filter and the drain plug. Shut the engine off and check oil level with dip- stick. Allow 15 minutes for oil to drain down before checking. ※ Do not overfill the engine with oil.
Page 224 3-1) 3-1) COOLANT TEST STRIPS INSTRUCTIONS COOLANT TEST STRIPS INSTRUCTIONS (1) (1) Pre-test instruction Pre-test instruction Recommended testing frequency - at every coolant filter change interval. ① Collect coolant sample from the radiator drain valve. Do not collect from the coolant recovery or overflow system Coolant must be between 10~54℃...
Page 225 Maintenance actions based on results Maintenance actions based on results ① Above normal Above normal Do not replace the coolant filter or add DCA4 liquid until additive concentration falls below 3 units per gallon. Test at every subsequent coolant filter change interval. ②...
Page 226 4) 4) FLUSHING AND REFILLING OF RADIATOR FLUSHING AND REFILLING OF RADIATOR Change coolant Change coolant Avoid prolonged and repeated skin contact Avoid prolonged and repeated skin contact with used antifreeze. Such prolonged repeat- with used antifreeze. Such prolonged repeat- ed contact can cause skin disorders or other ed contact can cause skin disorders or other bodily injury.
Page 227 ※ During filling, air must be vented from the During filling, air must be vented from the engine coolant passages. engine coolant passages. The system must be filled slowly to prevent The system must be filled slowly to prevent air locks. Wait 2 to 3 minutes to allow air to air locks.
Page 228 (3) (3) Cooling system filling Cooling system filling SIGHT GAUGE ① Use a mixture of 50 percent soft water and 50 WATER WATER percent ethylene glycol antifreeze to fill the ANTIFREEZE ANTIFREEZE cooling system. Refer to the page 6-9. ※ Never use water alone for coolant.
Page 229 5) 5) COOLANT FILTER COOLANT FILTER Do not remove the rad radiator cap from a hot Do not remove the rad radiator cap from a hot engine. Wait until the coolant temperature is below 50°C (120°C) before removing the radi- engine.
Page 230 Inspect the charge air cooler for dirt and debris blocking the fins. Check for cracks, holes, or other damage. If damage is found, please con- tact hyundai distributor. Inspect the charge air piping and hoses for leaks, holes, cracks, or loose connections.
Page 231 8) 8) FAN BELT FAN BELT Use the belt tension gage to measure the belt tension. ·Fan belt tension : 11.3 kg (25 lb) 120096MA42 Inspect the fan belt for damage. ① Transverse (across the belt) cracks are accept- able. ②...
Page 232 FAN BELT TENSIONER FAN BELT TENSIONER With the engine stopped, check the tensioner arm, pulley, and stops for cracks. If any cracks are found, the tensioner must be replaced. 2609A6MA23 With the belt installed, verify that neither tension- er arm stop is in contact with the spring case stop.
Page 233 CLEANING OF AIR CLEANER CLEANING OF AIR CLEANER (1) (1) Primary element Primary element ① Open the cover and remove the element. ② Wipe all contaminant and debris from inside the housing body. ③ Do not clean the filter element by striking or hitting the filter against any object to shake the debris from the filter element.
Page 234 FUEL TANK FUEL TANK Fill fuel fully when system the operation to mini- mize water condensation, and check it with fuel Strainer gauge before starting the machine. Drain the water and sediment in the fuel tank by opening the drain cock. ※...
Page 235 (3) (3) Air bleeding Air bleeding ① Do hand-priming the lift pump repeatedly until Air vent plug air bubbles comes out from air vent hole com- pletely. ② Tighten the air vent plug to its origin position. The fuel pump, high-pressure fuel lines, and The fuel pump, high-pressure fuel lines, and Lift pump fuel rail contain very high-pressure fuel.
Page 236 LEAKAGE OF FUEL LEAKAGE OF FUEL Be careful and clean the fuel hose, injection Be careful and clean the fuel hose, injection FIRE !!! pump, fuel filter and other connections as the pump, fuel filter and other connections as the leakage from these part can cause fire.
Page 237 DEF/AdBlue® TANK FILTER DEF/AdBlue® TANK FILTER The filter is located top side of the DEF/AdBlue® tank cover. Insert a hex wrench into the filter cover, rotate it anti-clockwise and remove the filter cover. 300A6MA91 Pull out the filter by using a long nose pliers. Pulling part 300A6MA92 Replace the filter and fit with a new filter.
Page 238 Place the filter cover and rotate the cover clock- wise by using hex wrench. ※ Replace the filter every 2000 hours. Replace the filter every 2000 hours. ※ If the filter is reused, take care not to damage If the filter is reused, take care not to damage the thread part of the filter with a long nose pli- the thread part of the filter with a long nose pli- ers.
Page 239 The diesel particulate filter needs to be cleaned and checked using an approved cleaning machine at a authorized service center. ※ Please contact your Hyundai service center or Please contact your Hyundai service center or 7609A6MI45 local dealer. local dealer.
Page 240 VIBRATION DAMPER VIBRATION DAMPER (1) (1) Rubber Rubber ① Check the index lines (A) in the vibration damp- er hub (B) and the inertia member (C). If the lines are more than 1.59 mm (1/16 in) out of alignment, replace the vibration damper. 300A6MA103 ②...
Page 241 OVERHEAD SET ADJUSTMENT OVERHEAD SET ADJUSTMENT ※ This procedures are perform the repair shop. This procedures are perform the repair shop. ※ Service tools Service tools Cummins barring tool, p/no. 3824591 Feeler gauge Remove the capscrews. Remove the rocker lever cover and gasket, refer to engine maintenance manual.
Page 242 With the engine in this position, lash can be checked on the following rocker arms : 1l, 1E, 2l, 3E, 4l and 5E. Lash check limits Item inch 0.152 0.006 Intake 0.559 0.022 0.381 0.015 330A6MA103 Exhaust 0.813 0.032 ※ Lash checks are performed as part of a trouble- shooting procedure, and resetting is not requires suring checks as long as the lash measure-...
Page 243 Using the barring tool, rotate the crankshaft 360 degrees and measure lash for rocker arms 2E, 3l, 4E, 5l, 6l and 6E. Reset the lash if out of specification. 330A6MA105 Place the gasket on the cylinder head. Be sure the gasket is properly aligned around the cylin- der head capscrews.
Page 244 HYDRAULIC OIL CHECK HYDRAULIC OIL CHECK Red line Lower the bucket on the ground at a flat location as in the illustration. Stop the engine and then leave for about 5 min- Level gauge utes. Check the oil level at the level gauge. The level gauge is located on the left side of the hydraulic oil tank.
Page 245 Do not mix any other Bio oil, use only HBHO as bio oil. bio oil. If changing to Bio oil, contact HYUNDAI dealer. If changing to Bio oil, contact HYUNDAI dealer. CLEANING AND REPLACING RETURN FILTER CLEANING AND REPLACING RETURN FILTER...
Page 246 REPLACEMENT OF ELEMENT IN HYDRAULIC REPLACEMENT OF ELEMENT IN HYDRAULIC Rubber cap TANK BREATHER TANK BREATHER Loosen the cap and relieve the pressure in the Cover Element tank by pushing the top of the air breather. Loosen the lock nut and remove the cover. Pull out the filter element.
Page 247 TIRE PRESSURE TIRE PRESSURE Inappropriate tire pressure is a primary cause for tire damage. Insufficient tire pressure will dam- age internal carcass of tire. Repeated excessive bending will damage or break the carcass. Excessive pressure will also cause premature damage of tire. Recommended tire pressure (When tire is cooled) / Refer to the page 5-1.
Page 248 REPLACEMENT OF TIRE REPLACEMENT OF TIRE Disassembly, reassembly, replacement and Disassembly, reassembly, replacement and repair of tire requires special skills and equip- repair of tire requires special skills and equip- ment. Contact a tire repair shop. ment. Contact a tire repair shop. (1) (1) Tires to be replaced Tires to be replaced...
Page 249 Direction of tire to be installed Direction of tire to be installed ① Be careful that the valve should be facing the outside. Valve 73036MI13 Mounting of tire Mounting of tire ① Lightly tighten nuts as shown in the illustration. 18 20 1 ②...
Page 250 CHECK TRANSMISSION OIL LEVEL CHECK TRANSMISSION OIL LEVEL The oil level check must be carried out as follows; oil level check (weekly). Filler cap Before the oil level check, Transmission must have been running to warm up enough. When the oil level is checked, machine must be on flat ground and engine must be at idling speed, transmission must be in neutral position.
Page 251 Remove the transmission oil filter cartridge. Ladder cover inside (LH) Dispose of the used transmission oil filter car- tridge properly. Clean the filter cartridge mounting base. Remove any part of the filter cartridge gasket that remains on the filter cartridge mounting base.
Page 252 CLEANING TRANSMISSION AIR BREATHER CLEANING TRANSMISSION AIR BREATHER Air breather Remove dust or debris around the air breather. Remove the air breather and wash it with cleaning oil. 77076MI27 CHECK AND SUPPLYING AXLE OIL CHECK AND SUPPLYING AXLE OIL FRONT AXLE FRONT AXLE Move the machine to flat ground.
Page 253 CHANGE THE AXLE OIL CHANGE THE AXLE OIL FRONT AXLE Place a case under drain plug to catch oil. Fill & oil level plug Remove the air breather to relieve internal pres- sure. Air breather The basic condition for a correct oil change of the axle is horizontal plane of installation in Drain plug every direction.
Page 254 CLEANING AXLE BREATHER CLEANING AXLE BREATHER Air breather Remove dust or debris around the breather. Remove the breather and wash it with cleaning oil. 7609A6MI53 LUBRICATION LUBRICATION Supply grease through the grease nipple, using grease gun. After lubricating, clean off spilled grease. Press the parking brake switch and fix front and rear frames using the safety lock bar.
Page 255 REPLACEMENT OF BOLT ON CUTTING EDGE REPLACEMENT OF BOLT ON CUTTING EDGE (1) (1) Replacement time Replacement time Replace the cutting edge before it has worn out to the end of bucket. (2) (2) Replacement method Replacement method Make sure the work equipment does not Make sure the work equipment does not move when replacing the cutting edge.
Page 256 REPLACEMENT OF BUCKET TOOTH REPLACEMENT OF BUCKET TOOTH (1) (1) Replacement time Replacement time Replace the bucket tooth before it has worn out to the end of the bucket. Replacement method Replacement method Make sure the work equipment does not Make sure the work equipment does not move when replacing the bucket tooth.
Page 257 MAINTENANCE OF WORK EQUIPMENT MAINTENANCE OF WORK EQUIPMENT Lubricate to each pin of working device. Lubricate the grease to grease nipple in accor- dance with lubrication intervals. Description LH side Bucket cylinder (front frame side) pin Boom cylinder (front frame side) right pin Boom-front frame right connection pin Boom-front frame left connection pin Boom cylinder (front frame side) left pin...
Page 258 WORK EQUIPMENT SUPPORT WORK EQUIPMENT SUPPORT When carrying out inspection and maintenance with the equipment raised, fit a stand under the lift arm securely to prevent the work equipment from coming down. In addition, set the work equipment control levers to the Hold position and put the pilot cut off switch to the OFF position.
Page 259: Electrical System
7. ELECTRICAL SYSTEM 7. ELECTRICAL SYSTEM 1) 1) WIRING, GAUGES WIRING, GAUGES Check regularly and repair loose or malfunctioning gauges when found. 73036MI27 2) 2) BATTERY BATTERY (1) (1) Clean Clean ① Wash the terminal with hot water if it is contami- nated, and apply grease to the terminals after washing.
Page 260 (2) (2) Recycle Recycle Never discard a battery. Always return used batteries to one of the fol- lowing locations. ·A battery supplier ·An authorized battery collection facility ·Recycling facility (3) (3) Method of removing the battery cable Method of removing the battery cable Remove the cable from the ground connection first ( terminal side) and reconnect it last...
Page 261 (3) (3) Taking off the booster cable Taking off the booster cable Disconnection of booster cable ① Take off the booster cable (black). ② Take off the booster cable (red) connected to the (+) terminal. ③ Run engine with high idle until charging the exhausted battery by alternator, fully.
Page 262: Air Conditioner And Heater
8. AIR CONDITIONER AND HEATER 8. AIR CONDITIONER AND HEATER 1) 1) CLEAN AND REPLACE OF INNER AND CLEAN AND REPLACE OF INNER AND OUTER FILTER OUTER FILTER ※ Always stop the engine before servicing. Always stop the engine before servicing. Open the air conditioner cover, loosen the wing bolt and remove the inner and outer filter.
Page 263 Equipment contains fluorinated greenhouse gas. Equipment contains fluorinated greenhouse gas. Model Type Total mass GWP :1430 HL970A HFC-134a 0.75 kg (1.65 lb) 1.07t CO ※ Global warming potential (GWP) is a measure of how much heat a gas traps in the atmosphere relative to that of carbon dioxide (CO2).
Page 264: Troubleshooting Guide
7. TROUBLESHOOTING GUIDE 7. TROUBLESHOOTING GUIDE 1. ENGINE 1. ENGINE ※ This guide is not intended to cover every conditions, however many of the more common possibil- ities are listed. Trouble Service Remark · Engine oil pressure lamp fails to go Add the oil to the specified level.
Page 265: Electrical System
2. ELECTRICAL SYSTEM 2. ELECTRICAL SYSTEM Trouble Service Remark · Voltmeter fluctuates largely even Check for loose terminals open-circuit wiring. with the engine running at a constant · Adjust belt tension. speed. Lamp does not glow brightly even when engine runs at high speed. Lamp flickers while engine runs.
Page 266: Power Train System
3. POWER TRAIN SYSTEM 3. POWER TRAIN SYSTEM Trouble Service Remark · Engine is running but machine Release parking brake. will not move. · Put gear selector lever in position properly. · Add oil to transmission case to the specified level. ·...
Page 267: Hydraulic System
4. HYDRAULIC SYSTEM 4. HYDRAULIC SYSTEM Trouble Service Remark · Bucket lacks lifting power. Check the hydraulic oil level and add if necessary. Bucket lifting speed is slow. · Replace filter in hydraulic tank. Bubbles in oil. · Replace with specified oil. ·...
Page 268: Others
8. OTHERS 8. OTHERS 1. CENTRAL GREASE LUBRICATION SYSTEM 1. CENTRAL GREASE LUBRICATION SYSTEM 1) 1) MAJOR COMPONENT MAJOR COMPONENT Central lubrication pump with integrated electronical controller Main distributor D0 Sub distributor D2 Sub distributor D1 The progressive system supplies the lubrication points in a fixed order. The progressive distributor works consecutively (progressive).
Page 269 2) 2) LAYOUT LAYOUT Main distributor D0 With optical indicator for operation Sub distributor D1 Grease pump 4kg Sub distributor D2 ※ Refer to the CENTRAL GREASE LUB SYSTEM of parts manual for detail. Refer to the CENTRAL GREASE LUB SYSTEM of parts manual for detail. 3) 3) SWITCH SWITCH...
Page 270 4) 4) GREASE PUMP GREASE PUMP Operating voltage 24 V/DC Maximum operating pressure 280 bar Permissible operating temperature -35˚C to +70˚C (depending on the grease type) Reservoir size 4 kg Pump element is delivering : Pump element is drawing in : Desmodromic actuation of the pumping elements Desmodromic actuation of the pumping elements The pumping elements are not driven by a simple return spring but have a desmodromic push-...
Page 271 Summary of signal Indicators Summary of signal Indicators The pump’s function are indicated via two control LEDs (green/red) in the display on the pump’s motor casing, where the red LED always indicates an error in the program sequence. These control LED functions may be indicated in the cab via monitor. Button for activating interim lubrication (reset) Red LED error indicator...
Page 272 6) 6) DISTRIBUTOR DISTRIBUTOR Operating pressure-Inlet Temperature range maximum 300 bar C to +80 ˚ ˚ Modular designed distributor system for optimum lubricant feed rates Flexible extension possibilities Highest precision Comprehensive program of distributor types Optionally with monitoring and blockade control Optimized distributor combination through field test at HCE durability test site 7) 7)
Page 273 8) 8) IDENTIFICATION OF A POINT OF BLOCKAGE IDENTIFICATION OF A POINT OF BLOCKAGE Disconnect the main grease hose line from D0 (master) distributor. Actuate the pump and check ① if lubricant supply is effected in correct manner. Re-connect the main grease hose line to the D0 distributor. ② Remove the cap screws of the D0 distributor outlet one after another and actuate the pump at each of those steps.
Page 274 ② Stick on the high pressure hose with a gripplier and grease or oil the end of this very good. The threaded ferrule turn on the hose left-turning up to the dimension in the sketch (11 mm). High pressure hose Threaded ferrule ③...
Page 275 TROUBLESHOOTING TROUBLESHOOTING Category Applications Service Pump does not work Defective electronic control unit Replace the control unit Electric cable is broken Renew the electric cable Pump is defective Replace the pump Pump is working, but does Air in the feed piston filling Bleed the pump not supply of lubrication Grease level dropped below minimum...
Page 276: Quick Coupler
2. QUICK COUPLER 2. QUICK COUPLER 1) 1) FIXING BUCKET WITH QUICK COUPLER FIXING BUCKET WITH QUICK COUPLER Release the lock pins by pressing the quick coupler switch on monitor. Buzzer Quick coupler switch sounds and the red pilot lamp is turned 9558QC01 Tilt quick coupler forward and align the upper attaching points of the quick coupler...
Page 277 2) 2) REMOVE BUCKET FROM QUICK COUPLER REMOVE BUCKET FROM QUICK COUPLER The attachment should be in a level position on the ground. Release the lock pins by pressing the switch on monitor. Lower the boom so that it disengage from the attachment.
Page 278: Index
INDEX INDEX Air cleaner ------------------------------------------------------- 6-27 LCD ------------------------------------------------------------------ 3-12 Air conditioner & heater ----------------------------------- 3-56 Loading and unloading -------------------------------------- 5-6 Air conditioner filter ------------------------------------------ 6-56 Lubrication -------------------------------------------------------- 6-51 Axle oil ------------------------------------------------------------- 6-46 Machine control unit (MCU) ------------------------------- 3-60 Battery ------------------------------------------------------------- 6-53 Maintenance chart --------------------------------------------- 6-13 Before starting engine ------------------------------------- 4-2 Maintenance check list -------------------------------------- 6-10...

Hyundai HL970A Operator's Manual

Quick Links

Related Manuals for Hyundai HL970A

Summary of Contents for Hyundai HL970A

Table of Contents