Hyundai HL960A Operator's Manual
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Hyundai HL960A Operator's Manual

Hyundai HL960A Operator's Manual

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EC declaration of conformity -- - - - - - - - - - - - - - - - - - - -- - - - - - - - 0-1
Foreword ------- - - - - - - - - -- - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - -- - - - 0-2
(USA and CANADA only) - - -- - - - - - - - - - - - - - - - - - - -- - - - - - - - - - 0-2-1
Before servicing this machine - - - - - - - - - -- - - - - - - - - - - - - - - - - 0-3
Table to enter S/No and distribution -- - - - - - - - - - - - - - - - - - -- 0-4
EC regulation approved - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - 0-5
Safety labels -- - - - - - - - -- - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - -- - - - 0-6
Machine data plate - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - -- - - - - - - 0-17
Guide (direction, S/No, symbol) - - - - - - - - - - -- - - - - - - - - - - - - 0-18
1. SAFETY HINTS
1. California proposition 65 -- - - - - - - - - - - - - - - - - - - -- - - - - - - 1-1
2. Safety rules - - - - - - - - - - -- - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - 1-2
2. SPECIFICATIONS
1. Major components - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - -- 2-1
2. Specifications - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - 2-2
3. Weight ----- - - - - - - - - -- - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - -- - - 2-6
4. Specification for major components - - - - - - - - - - - 2-7
3. CONTROL DEVICES
1. Cab devices - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - 3-1
2. Cluster ---- - -- - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - -- - - - - - - - - - 3-2
3. Monitors - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - 3-13
4. Switches -- - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - 3-44
5. Control device - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - -- - - - - - - - - - - 3-49
6. Air conditioner and heater - - -- - - - - - - - - - - - - - - - - - - - - - - 3-53
7. Others ----- - - -- - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - -- - - - - - - - - 3-56
1. Suggestion for new machine - - - - - - - - - - - -- - - - - - - - - - 4-1
2. Check before starting the engine - - - - - - - - - - - - - - - 4-2
3. Starting and stop the engine - - - - - - - - - - - - - - - -- - - - - - 4-3
4. Warming-up operation - - - - - - -- - - - - - - - - - - - - - - - - - - -- - - - - 4-8
5. Operation of the working device - - - - - - - - - - - - - - - - - 4-9
6. Traveling of the machine - - - - - - - - - - - - - - -- - - - - - - - - - - - - - 4-10
7. Efficient working method - - - - - - - - - - - - - - -- - - - - - - - - - - - - 4-15
8. Adjustment of the work equipment - - -- - - - - - - - - - 4-22
9. Operation in the special work sites - - - - - - - - - - - - - 4-23
10. Storage - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - 4-25
11. Exhaust system cleaning - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - 4-27
12. Open the engine hood -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-28
13. Attachment manually lowering - - - - - - - - - - - - -- - - - - - - - - 4-31
5.
1. Road traveling - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - 5-1
2. Preparation for transportation - - - - - - - - - - - - - - - - - - - - 5-2
3. Loading the machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3
4. Fixing the machine - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - 5-4
5. Loading and unloading by crane - - - - - - - - - - -- - - - - 5-6
6. Towing the machine - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - 5-7
1. Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - 6-1
2. Tightening torque - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - 6-5
3. Spec of fuel, coolant and lubricants - - - - - - - - - - - 6-8
4. Maintenance check list - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-10
5. Maintenance chart - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - 6-13
6. Service instruction - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - 6-15
7. Electrical system - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - 6-50
8. Air conditioner and heater - - - - - - - - - - - - - - -- - - - - - - - - - - 6-53
1. Engine - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - 7-1
2. Electrical system - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - 7-2
3. Power train system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - 7-3
4. Hydraulic system - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-4
2. Quick coupler - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
- - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-1
CONTENTS
8-1
8-9

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  • Page 1: Table Of Contents

    CONTENTS EC declaration of conformity -- - - - - - - - - - - - - - - - - - - -- - - - - - - - 0-1 9. Operation in the special work sites - - - - - - - - - - - - - 4-23 Foreword ------- - - - - - - - - -- - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - -- - - - 0-2 10.

  • 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

    EMISSION-RELATED COMPONENTS 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. 105 dB (EU only) 68 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(RH) 15(RH) 13 34 VIEW C AIR CLEANER ACCUMULATOR RADIATOR...
  • 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 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 and/or the linkage.
  • Page 11 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 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 (item 49) 9800FW08 This warning label is positioned on the inside of inlet cover.

  • Page 19: Machine Data Plate

    6 Maximum certified weight 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.
  • Page 20 GUIDE 1. 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. SERIAL NUMBER Machine serial No. Inform following when you order parts or the machine is out of order.
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  • Page 168: 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 169: 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 170 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 171 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 172 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 173 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 174 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 175: 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 176: 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 177: 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 178 ※ 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 179 (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 180 (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 181 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 182: 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 183 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 184 (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 185 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 186 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 187 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 188 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 189: 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 190: 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 191 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 192: 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 193 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 194: 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 195: 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 196 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 197 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 198: 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 199: 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 200: 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 201: 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 202: 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 203 Block the tires and fix firmly with wire rope or chain to prevent the machine from moving during transportation. 960A5TA07...

  • Page 204: 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 205: 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 206 ※ 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 207 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 208: 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 209 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 210 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 211 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 212: 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 213 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 214 TIGHTENING TORQUE OF MAJOR COMPONENT TIGHTENING TORQUE OF MAJOR COMPONENT Torque Descriptions Bolt size kgf·m lbf·ft 57.9 ± 8.7 419 ± 63 Engine mounting bolt, nut (rubber, 2EA) M20×2.5 11.7 ± 1.8 84.6 ± 13.0 Engine mounting bolt (bracket, 8EA) M12×1.75 4.6 ±...
  • Page 215 ※ 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 216 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 ★6 HL960A HD...

  • Page 217: 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 218 4) 4) EVERY 250 HOURS SERVICE EVERY 250 HOURS SERVICE Check items Service Page Wheel nuts Check, Tight 6-38, 39 Battery (voltage) / Battery cable and connections 6-50, 51 Check Air conditioner and heater filter (inner and outer) 6-53 Check, Clean 5) 5) EVERY 500 HOURS SERVICE EVERY 500 HOURS SERVICE...
  • Page 219 Check, Retighten, Replace 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. EVERY 4500 HOURS SERVICE EVERY 4500 HOURS SERVICE Check items Service Page ★...

  • Page 220: Maintenance Chart

    5. MAINTENANCE CHART 5. MAINTENANCE CHART 24 21 29,30 25 17 16 9,10 14,15 20 21 960A6MI10 7 8 19 9,10 26,28 Caution Caution - EO : Engine oil - EO : Engine oil - GO : Gear oil - GO : Gear oil 1.
  • Page 221 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 222: 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 223 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 224 (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 225 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 226 ※ 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 227 (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 228 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 229 7) 7) 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 230 9) 9) 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 231 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 232 FUEL TANK FUEL TANK Fill fuel fully when system the operation to mini- Strainer mize water condensation, and check it with fuel gauge before starting the machine. Drain the water and sediment in the fuel tank by opening the drain cock. ※...
  • Page 233 (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 234 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 235 DEF/AdBlue® TANK FILTER DEF/AdBlue® TANK FILTER The filter is located on DEF/AdBlue® tank. Loosen the screws (10EA) and remove the cover. Screw Cover 960A6MI31 Loosen the clip and remove the DEF/AdBlue® tank filter. Replace the filter and install the cover and Clip screws.
  • Page 236 DEF/AdBlue® SUPPLY MODULE FILTER DEF/AdBlue® SUPPLY MODULE FILTER Inspect the area around the DEF/AdBlue® supply module filter case for signs of leakage. ※ Turn OFF the master switch located in tool box on the left side of rear frame. Turn OFF the master switch located in tool box on the left side of rear frame. Remove the filter case with the biotube pump spray and filter.
  • Page 237 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 238 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 239 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. 5299073 Feeler gauge ※ Remove the rocker lever cover and gasket, Remove the rocker lever cover and gasket, refer to engine maintenance manual.
  • Page 240 If both of the number 1 cylinder rocker levers are loose, proceed to the next step; If the number 1 cylinder rocker levers are not loose, rotate the crankshaft 360 degrees and proceed to the next step. 300A6MA109 Make sure to check the engine dataplate for cor- rect valve lash (overhead set) specifications.
  • Page 241 The clearance is correct when some resistance is felt when the feeler gauge is slipped between the crosshead and the rocker lever socket. Measure the valve lash (overhead set) by insert- ing a feeler gauge between the crosshead and the rocker lever socket. If the measurement is out of specification, loosen the locknut and adjust the lash to nominal specifications.
  • Page 242 HYDRAULIC OIL CHECK HYDRAULIC OIL CHECK Level gauge Lower the bucket on the ground at a flat location Red line as in the illustration. Stop the engine and then leave for about 5 min- utes. Check the oil level at the level gauge. The level gauge is located on the left side of the hydraulic oil tank.
  • Page 243 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 244 REPLACEMENT OF ELEMENT IN HYDRAULIC REPLACEMENT OF ELEMENT IN HYDRAULIC TANK BREATHER TANK BREATHER Cover Loosen the cap and relieve the pressure in the Element tank by pushing the top of the air breather. Loosen the lock nut and remove the cover. Pull out the filter element.
  • Page 245 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 246 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 247 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. ②...
  • Page 248 CHECK TRANSMISSION OIL LEVEL CHECK TRANSMISSION OIL LEVEL The oil level check must be carried out as follows; oil level check (weekly). 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 249 Remove the transmission oil filter cartridge. 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. 7607A6MI26 Apply a light coat of oil to the gasket of a new transmission oil filter cartridge.
  • Page 250 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. 7607A6MI27 CHECK AND SUPPLYING AXLE OIL CHECK AND SUPPLYING AXLE OIL FRONT AXLE Move the machine to flat ground.
  • Page 251 - Front axle : 35ℓ (9.2 U.S. gal) - Rear axle : 35ℓ (9.2 U.S. gal) ·Oil amount (HL960A HD, HL960A HD XT) - Front axle : 45ℓ (11.9 U.S. gal) - Rear axle : 40ℓ (10.6 U.S. gal) Drain plug...
  • Page 252 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 253 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 254 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 255 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 256 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 257: 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 258 (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 259 (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 260: 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 261 Equipment contains fluorinated greenhouse gas. Equipment contains fluorinated greenhouse gas. Model Type Total mass GWP :1430 HL960A 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 262: Troubleshooting Guide

    7. TROUBLESHOOTING GUIDE 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. off immediately after the engine is Replace the oil filter.

  • Page 263: 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 264: 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 265: 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 266: 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 267 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 268 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 269 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 270 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 271 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 272 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 273 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 274: 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 275 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 276: Index

    INDEX Air cleaner ------ -- --- - - -- - - -- - - -- - - -- - - -- - - -- - - -- - - -- - - -- - - -- - - - - 6-24 LCD -- -- --- --- -- --- --- -- --- --- -- --- --- -- --- --- -- --- -- --- --- -- --- --- -- - 3-12 Air conditioner &...

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