Hyundai R55-7 Manual
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Hyundai R55-7 Manual

Hyundai R55-7 Manual

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Foreword - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 0-1
Before servicing this machine - - - - - - - - - - - - - - - - - - - - - - - - - - 0-2
EC regulation approved - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 0-3
Table to enter S/No and distribution - - - - - - - - - - - - - - - - - - - - - - 0-4
Safety labels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 0-5
Machine data plate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 0-13
Guide(Direction, S/No, Symbol) - - - - - - - - - - - - - - - - - - - - - - - 0-14
1. Before operating the machine - - - - - - - - - - - - - - - - - - - - 1-1
2. During operating the machine - - - - - - - - - - - - - - - - - - - - 1-6
3. During maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13
4. Parking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16
1. Major components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
2. Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
3. Working range - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3
4. Weight - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4
5. Lifting capacities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5
6. Bucket selection guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7
7. Undercarriage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-8
8. Specification for major components - - - - - - - - - - - 2-9
9. Recommended oils - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-12
1. Cab devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
2. Cluster - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2
3. Switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-7
4. Levers and pedals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-11
5. Air conditioner and heater - - - - - - - - - - - - - - - - - - - - - - - - - - 3-14
6. Others - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-16
1. Suggestion for new machine - - - - - - - - - - - - - - - - - - - - - - 4-1
2. Check before starting the engine - - - - - - - - - - - - - - - 4-2
3. Starting and stop the engine - - - - - - - - - - - - - - - - - - - - - - 4-3
4. Operation of the working device - - - - - - - - - - - - - - - - - 4-6
5. Traveling of the machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-7
6. Efficient working method - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-10
7. Operation in the special work sites - - - - - - - - - - - - - 4-14
8. Normal operation of excavator - - - - - - - - - - - - - - - - - - - 4-16
9. Attachment lowering pattern - - - - - - - - - - - - - - - - - - - - - - 4-17
10. Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-18
11. RCV lever operating pattern - - - - - - - - - - - - - - - - - - - - - - - 4-20
1. Preparation for transportation - - - - - - - - - - - - - - - - - - - - 5-1
2. Dimension and weight - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-2
3. Loading the machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-4
4. Fixing the machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-6
5. Loading and unloading by crane - - - - - - - - - - - - - - - - 5-7
1. Instruction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
2. Tightening torque - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-6
3. Fuel, coolant and lubricants - - - - - - - - - - - - - - - - - - - - - - - 6-9
4. Maintenance check list - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-11
5. Maintenance chart - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-16
6. Service instruction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-18
7. Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-36
8. Air conditioner and heater - - - - - - - - - - - - - - - - - - - - - - - - - - 6-39
TROUBLESHOOTING GUIDE
1. Engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
2. Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2
3. Others - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
1. Selecting hydraulic breaker - - - - - - - - - - - - - - - - - - - - - - - - 8-1
2. Circuit configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-2
3. Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-3
5. Quick clamp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-6
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-1
CONTENTS

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  • Page 1: Table Of Contents

    CONTENTS Foreword - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 0-1 6.

  • Page 2: Foreword

    3. Use genuine Hyundai spare parts for the replacement of parts. We expressly point out that Hyundai will not accept any responsibility for defects resulting from non- genuine parts or non workmanlike repair. In such cases Hyundai cannot assume liability for any damage.

  • Page 3: Before Servicing This Machine

    The procedures in this manual do not supersede any requirements imposed by federal, state, provincial or local laws. Hyundai can not anticipate every possible circumstance or environment in which this machine may be used and serviced. All personnel must remain alert to potential hazards.

  • Page 4: Ec Regulation Approved

    E E C REGULATION APPROVED · Noise level (EN474-1 : 2006 and 2000/14/EC) are as followings. 98dB(EU only) 78dB · The value of vibrations transmitted by the operator's seat are lower than standard value of (EN474-1 : 2006 and 2002/44/EC)
  • Page 5 Address 1000, Bangeojinsunhwan-doro, Dong-Ku, Ulsan 682-792, Korea Distributor for U.S.A Hyundai Heavy Industries U.S.A, Inc Address 6100 Atlantic Boulevard Norcross GA 30071 U.S.A Distributor for Europe Hyundai Heavy Industries Europe N. V. Address Vossendal 11 2240 Geel Belgium Dealer Address...

  • Page 6: Safety Labels

    SAFETY LABELS 1. LOCATION Always keep these labels clean. If they are lost or damage, attach them again or replace them with a new label. 19 21 CONSOLE BOX-LH SEAT BASE-LOWER CONSOLE BOX-RH R557A0SL01 Fueling 11 Safety front window 21 General warning-frame Battery-accident 12 Emergency exit 22 Indicate-grease...
  • Page 7 2. DESCRIPTION There are several specific warning labels on this machine please become familiarized with all warning labels. Replace any safety label that is damaged, or missing. FUELING(Item 1) This warning label is positioned on the right side of fuel filler neck. Stop the engine when refueling.
  • Page 8 KEEP CLEAR-BOOM/ARM(Item 5) This warning label is positioned on both side of the boom. Serious injury or death can result from falling of the attachment. To prevent serious injury or death, keep clear the underneath of attachment. R5570FW31 KEEP CLEAR-REAR(Item 6) This warning label is positioned on the rear of engine hood.
  • Page 9 CAUTION-ENGINE ROOM(Item 8) This warning label is positioned on the side of radiator. Do not open the engine hood during the engine's running. Escaping fluid under pressure can penetrate the skin causing serious injury. Study the service manual before service job.
  • Page 10 GENERAL CAUTIONS-CABIN(Item 10) This warning label is positioned on the right side window of the cab. Serious injury or death can result from contact with electric lines. An electric shock being received by merely coming into the vicinity of an electric lines, the minimum distance should be kept considering the supply voltage as page 1-7.
  • Page 11 DECAL-AIRCON FILTER(Item 13) This warning label is positioned on the lower seat base. Periodic and proper inspection, cleaning and change of filter prolong air conditioner life time and maintain good performance. 21070FW26 DECAL-CONSOLE TILTING(Item 14) This warning label is positioned on the LH console box.
  • Page 12 HYDRAULIC OIL LUBRICATION(Item 17) This warning label is positioned on the right side of air breather. Do not mix with different brand oils. Never open the filler cap while engine running or at high hydraulic oil temperature. Loosen the cap slowly and release internal pressure completely.
  • Page 13 GENERAL WARNING-FRAME(Item 21) This warning label is positioned right side of upper frame. Study the operator's manual before transporting the machine, if provided and tie down arm and track to the carrier with lashing wire. See page 5-6 for details. Make sure wire rope is proper size and keep correct hoisting method.

  • Page 14: Machine Data Plate

    ※ The machine serial 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 machine serial number is also stamped on the frame. 0-13...

  • Page 15: Guide(Direction, S/No, Symbol)

    GUIDE 1. DIRECTION Forward The direction of this manual indicate forward, backward, right and left on the standard of operator when the travel motor is in the rear and machine is on the traveling direction. Left Right Travel motor Backward R5570SG01 2.

  • Page 16: Safety Hints

    SAFETY HINTS 1. BEFORE OPERATING THE MACHINE Think-safety first. In special situation, wear protective clothing including a safety helmet, safety shoes, gloves, safety glasses and ear protection as required by the job condition. Almost every accident is caused by disregarding the simple and fundamental safety hints.
  • Page 17 Check daily according to the operation manual. Repair the damaged parts and tighten the loosened bolts. 13031SH05 Check for leakage of engine oil, hydraulic oil, fuel and coolant. Keep machine clean, clean machine regularly. 13031SH06 Do not operate the machine if it requires repairs. Operate after complete repair.

  • Page 18: Unauthorized Modification

    R557A1SH10 ROTATING BEACON Beacon When you operate a machine on a road or beside a road, a rotating beacon is required to avoid any traffic accident. Please contact your Hyundai distributor to install 21071SH03...

  • Page 19: Safety Rules

    Do not use attachments that are not authorized by Hyundai or your Hyundai distributor. Use of unauthorized attachments could create a safety problem and adversely affect the proper operation and useful life of the machine.

  • Page 20: California Proposition

    CALIFORNIA PROPOSITION 65 Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm. This product contains or emits chemicals known to the State of California to cause cancer or birth defects or other reproductive harm.

  • Page 21: During Operating The Machine

    2. DURING OPERATING THE MACHINE Use the handle and footstep when getting on or off the machine. Do not jump on or off the machine. 13031SH09 Sound the horn to warn nearby personnel before operating the machine. Remove all the obstacles like frost on the window before operating the machine for the good visibility.
  • Page 22 Provide proper ventilation when operating engine in a closed area to avoid the danger of exhaust gases. 13031SH13 Check the locations of underground gas pipes or water line and secure the safety before operation. 13031SH14 The operating near the electrical lines is very dangerous.
  • Page 23 Watch out for obstacles. Be particularly careful to check the machine clearance during the swing. 13031SH17 When using the machine as breaker or working in a place where stones may fall down, cab roof guard and head guard should be provided for proper protection.
  • Page 24 The operation on a slope is dangerous. Avoid operating the machine on a slope of over 10 degree. 13031SH21 Operate the machine after making ground flat when operation is required on a slope. 13031SH22 The swing on the slope can be danger of rolling over.
  • Page 25 Avoid traveling in a cross direction on a slope as it can cause the danger of rolling over and sliding. 13031SH25 Traveling on a slope is dangerous. Be sure to operate slowly when traveling down a slope and maintain the bucket at a height of 20~30cm(1ft) above the ground so that it can be used as brake in an emergency.
  • Page 26 Before traveling the machine, sound the horn to warn nearby personnel. Operate forward and backward correctly with confirming the location of the travel motor. 13031SH29 Slow down when traveling through obstacles or uneven ground. 13031SH30 When working on soft ground, place mats or wood boards on the ground to prevent the machine sinking.

  • Page 27: Mounting And Dismounting

    MOUNTING AND DISMOUNTING Never jump on or off the machine. Never get on or off a moving machine. When mounting or dismounting, always face the machine and use the handrails, machine and track shoes. Do not hold any control levers when getting on or off the machine.

  • Page 28: During Maintenance

    3 3 . DURING MAINTENANCE Stop the engine immediately when the trouble of the machine is found. Inspect immediately the cause of trouble such as vibration, overheating and trouble in the cluster then repair. 13031SH33 Park on a flat place and stop the engine for inspecting and repairing.
  • Page 29 There is the danger of fire in fuel and oil. Store in cool and dry area, away from any open flames. 13031SH37 Do not touch exhaust pipe, or may cause severe burn. 13031SH38 Do not open the engine hood and covers while the engine is running.
  • Page 30 The antislip protection should be replaced if they have become worn or have been printed over. Be sure to free of oil, water and grease etc. 13031SH42 Be careful of not touching slip, fall down etc., when you work at the upper frame to service engine and/or other component.

  • Page 31: Parking

    4. PARKING When leaving the machine after parking, lower the bucket to the ground completely and put the safety lever at parking position then remove the key. Lock the cab door. 13031SH44 Park the machine in the flat and safe place. 13031SH45 Hope you can work easily and safely observing safety rules.

  • Page 32: Specifications

    SPECIFICATIONS 1. MAJOR COMPONENT Hydraulic tank Swing motor Fuel tank Tool box Oil cooler Radiator Engine Main pump Turning joint Main control valve Tooth Bucket Arm cylinder Boom Boom cylinder Swing post Precleaner Muffler Counterweight Sprocket Side cutter Track Idler Track roller Travel motor Control link...

  • Page 33: Specifications

    2. SPECIFICATIONS 3.0m( 9'10") MONO BOOM, 1.6m( 5' 3") ARM, WITH BOOM SWING POST I(I') B(L) R557A2SP02 Description Unit Specification kg(lb) Operating weight 5700(12570) Bucket capacity(SAE heaped), standard 0.18(0.24) Overall length 5900(19' 4") Overall width, with 400mm shoe 1920( 6' 4") Overall height 2550( 8' 4") Superstructure width...

  • Page 34: Working Range

    3. WORKING RANGE 3.0m(9' 10") MONO BOOM WITH BOOM SWING POST R5572SP03 Description 1.6m(5' 3") Arm Max digging reach 6150mm (20' 2") Max digging reach on ground 6010mm (19' 9") Max digging depth 3820mm (12' 6") Max digging depth (8ft level) 3420mm (11' 3") Max vertical wall digging depth...

  • Page 35: Weight

    4. WEIGHT Item Upperstructure assembly 2650 5840 Main frame weld assembly 1500 Engine assembly Main pump assembly Main control valve assembly Swing motor assembly Hydraulic oil tank assembly Fuel tank assembly Boom swing post Counterweight Cab assembly Lower chassis assembly 2160 4750 Track frame weld assembly...

  • Page 36: Lifting Capacities

    5. LIFTING CAPACITIES 3.0m( 9'10") boom, 1.6m( 5' 3") arm equipped with 0.18m (SAE heaped) bucket and 400mm(16") triple grouser shoe, the dozer blade up with 210kg(460lb) counterweight. : Rating over-front : Rating over-side or 360 degree Load radius At max. reach Load point 2.0m(6.6ft) 3.0m(9.8ft)
  • Page 37 3.0m( 9'10") boom, 1.6m( 5' 3") arm equipped with 0.18m (SAE heaped) bucket and 400mm(16") triple grouser shoe, the dozer blade down with 210kg(460lb) counterweight. Load radius At max. reach Load point 2.0m(6.6ft) 3.0m(9.8ft) 4.0m(13.1ft) 5.0m(16.4ft) Capacity Reach height m(ft) 5.0m *950 *950...

  • Page 38: Bucket Selection Guide

    6. BUCKET SELECTION GUIDE 0.07m 0.18m heaped bucket heaped bucket Recommendation Capacity Width 3.0m ( 9'10") boom Weight CECE Without With 1.6m ( 5' 3") arm heaped heaped side cutter side cutter 0.07m 0.06m 315mm 360mm 84kg (0.09yd (0.08yd (12.4") (14.2") (185lb) Applicable for materials with density of 1600kgf/m...

  • Page 39: Undercarriage

    7. UNDERCARRIAGE TRACKS X-leg type center frame is integrally welded with reinforced box-section track frames. The design includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock absorbing springs and assembled track-type tractor shoes with triple grousers. TYPES OF SHOES Steel triple grouser Rubber track Model...

  • Page 40: Specification For Major Components

    8 8 . SPECIFICATIONS FOR MAJOR COMPONENTS ENGINE Specification Item Yanmar 4TNV98-EPHYB Model Type 4-cycle diesel engine, low emission Cooling method Water cooling 4 cylinders, in-line Number of cylinders and arrangement Firing order 1-3-4-2 Combustion chamber type Direct injection type 98 110mm(3.85"...

  • Page 41: Main Control Valve

    3 3 ) GEAR PUMP Item Specification Type Fixed displacement gear pump single stage Capacity 16.2/4.5cc/rev Maximum pressure 220/30kgf/cm (3130/430psi) Rated oil flow 35.6/9.9 /min(9.4/2.6U.S. gpm/7.8/2.2U.K. gpm) MAIN CONTROL VALVE Item Specification Type Sectional, 10 spools+1 option Operating method Hydraulic pilot system+Mechanical control system Main relief valve pressure 220kgf/cm (3130psi)

  • Page 42: Remote Control Valve

    REMOTE CONTROL VALVE Item Specification Type Pressure reducing type 5kgf/cm (71psi) Minimum Operating pressure 20kgf/cm (284psi) Maximum Single operation stroke 6.5/8.5mm(0.26/0.33in) Lever CYLINDER Specification Item Bore dia Rod dia Stroke 65 715mm Boom cylinder Extend only Cushion 55 850mm Bore dia Rod dia Stroke Arm cylinder Cushion Extend and retract...

  • Page 43: Recommended Oils

    9. RECOMMENDED OILS Use only oils listed below or equivalent. Do not mix different brand oil. Ambient temperature C( F) Capacity Service point Kind of fluid (U.S. gal) (-4) (14) (32) (50) (68) (86) (104) SAE 30 SAE 10W Engine Engine oil 11.6(3.1) oil pan...

  • Page 44: Control Devices

    CONTROL DEVICES 1. CAB DEVICES The ergonomically designed console box and suspension type seat provide the operator with comfort. ELECTRONIC MONITOR SYSTEM The centralized electronic monitor system allows the status and conditions of the machine to be monitored at a glance. It is equipped with a safety warning system for early detection of machine malfunction.

  • Page 45: Cluster

    2. CLUSTER The cluster consists of gauges and lamps as shown below, to warn the operator in case of abnormal machine operation or conditions for the appropriate operation and inspection. Gauges : Indicate operating status of the machine. Warning lamp : Indicate abnormality of the machine(Red). Pilot lamp : Indicate operating status of the machine.

  • Page 46: Gauges And Displays

    AUGES AND DISPLAYS Service meter This meter shows the total operation hours of the machine. Always ensure the operating condition of the meter during the machine operation. Inspect and service the machine based on hours as indicated in chapter 6, maintenance. R5573CD08 Fuel gauge This gauge indicates the amount of fuel in the fuel tank.
  • Page 47 WARNING AND PILOT LAMPS Fuel low level warning lamp This lamp blinks and the buzzer sounds when the level of fuel is below 13 (3.4U.S. gal). Fill the fuel immediately when the lamp blinks. R5573CD10 Hydraulic oil temperature warning lamp This warning lamp operates and the buzzer sounds when the temperature of hydraulic oil is over 105 C (221 F ) .
  • Page 48 This lamp is ON and the buzzer sounds when the ECM on the engine is abnormal. Check the ECM of the engine. Please contact Hyundai service center in your area. 55W7A3CD81 Preheat pilot lamp When engine preheating switch is turned ON, pilot lamp cames Refer to the preheating switch for details.

  • Page 49: Switches

    SWITCHES Travel speed control switch This switch is to control the travel speed which is changed to high speed(Rabbit mark) by pressing the switch and low speed(Turtle mark) by pressing it again. R5573CD22 Buzzer stop switch When the starting switch is turned ON first, normally the alarm buzzer sounds for 6 seconds during lamp check operation.

  • Page 50: Starting Switch

    3. SWITCHES Wiper switch Washer switch Seat heat switch Travel alarm switch Quick clamp switch Breaker selection switch Air conditioner switch Main light switch Accel dial switch Start switch Switch panel 2 Switch panel 1 Master switch Breaker operation switch Beacon switch Horn switch R557A3CD30A...

  • Page 51: Wiper Switch

    ACCEL DIAL There are 10 dial setting. Setting 1 is low idle and setting 10 is high idle. By rotating the accel dial to right : Engine speed increased. By rotating the accel dial to left : Engine speed decreased. 21073CD34 MAIN LIGHT SWITCH This switch use to operates the head light and work light by two step.

  • Page 52: Master Switch

    TRAVEL ALARM SWITCH(Option) This switch is the signal to alarm surroundings when the machine travels to forward and backward. On pressing this switch, the alarm operates only when the machine is traveling. R5573CD83 BREAKER SELECTION SWITCH(Option) This switch is used to operates breaker. The breaker operates only when this switch is pressed.

  • Page 53: Horn Switch

    HORN SWITCH This switch is at the top of left side control lever. Horn switch On pressing, the horn sounds. LH RCV lever 55W7A3CD31 BREAKER OPERATION SWITCH On pressing this switch, the breaker operates only when the breaker Breaker selection switch on the switch panel is selected. operation switch RH RCV lever 55W7A3CD32...

  • Page 54: Levers And Pedals

    4. LEVERS AND PEDALS Dozer control lever RH control lever Travel lever Boom swing pedal Travel pedal LH control lever Safety lever R557A3CD33A LH CONTROL LEVER This joystick is used to control the swing and the arm. Refer to operation of working device in chapter 4 for details. R557A3CD34 RH CONTROL LEVER This joystick is used to control the boom and the bucket.

  • Page 55: Travel Lever

    SAFETY LEVER LH, RH control levers and dozer control lever are disabled from operation by locating the lever to lock position as shown. ※ Be sure to raise the lever to LOCK position when leaving from Lock operator's seat. By pushing lever to UNLOCK position, machine is operational. ※...

  • Page 56: Boom Swing Pedal

    BOOM SWING PEDAL This pedal is used to swing the boom to the right and left direction. Boom swing pedal Move the lock lever to unlock position by foot. Unlock The pedal is pressed to front side, boom will move to the left direction. The pedal is pressed to rear side, boom will move to the right direction.

  • Page 57: Air Conditioner And Heater

    5. AIR CONDITIONER AND HEATER Air conditioner and heater are equipped for pleasant operation against outside temperature. Location of air flow ducts Switch panel R557A3CD45 FAN SWITCH It is possible to control the fan to four steps. : Low : Medium-Low : Medium-High : High R5573CD74...

  • Page 58: Temperature Control Switch

    OUTLET CHANGE OVER SWITCH Mode Switch position Outlet R5573CD47 TEMPERATURE CONTROL SWITCH Cooling(Air conditioner switch : ON) Turned ON the air conditioner switch on the switch panel. Turn the control switch into blue range to decrease output air temperature. Blue Heating(Air conditioner switch : OFF) Turned OFF the air conditioner switch on the switch panel.

  • Page 59: Others

    6. OTHERS Radio & Cassette 12V socket Speaker Fuse box Seat R557A3CD50 RADIO AND CASSETTE SOUND MUTE BAND JAZZ VOCAL POP CLASSIC DISC VOLUME ROCK FLAT LOUD PRESET VOLUME 7807A3CD81 3-16...

  • Page 60: Power On/Off

    FRONT PANEL PRESENTATION - - - - - - - - Preset button 1 11 RDS - - - - - - - - - - Long press : RDS on/off - - - - - - - - Preset button 2 BAND - - - - - - - Short press : To select band 3 - - - - - - - - - - - - - - - - - Preset button 3...

  • Page 61: Audio Setting

    Sound button SOUND Whether you listen to Jazz, Vocal, Pop, Classic or Rock music, the SOUND button is the perfect setting for your choice. SOUND Press SOUND then the sound button to select BASS-Treb for your own sound style, or adjust the settings with the volume 7807A3CD10 up/down buttons to select one of the pre define sound styles: - BASE -TRE : Your own settings of bass and treble.

  • Page 62: Automatic Search

    RADIO Wave band / Automatic search button WAVEBAND Press BAND to select the desired band: BAND FM I FM II FM AST MWAST(AMAST) MW I SOURCE 7807A3CD13 AUTOMATIC SEARCH Use search tuning to automatically search for a station. Press to tune a station of a lower frequency or to a higher frequency.
  • Page 63 ADIO DATA SYSTEM(RDS) ON FM More and more stations broadcasts RDS informations in order to offer you many advantages including: Program service name(PS) Allows the radio to display the name of the station instead of its frequency. 7807A3CD15 Automatic returning(AF) The set remains tuned to the current station by continually searching the best alternative frequency for best reception.

  • Page 64: Cassette Player

    CASSETTE PLAYER Winding/Rewinding button Only use good quality cassettes. To avoid possible tape damage always take out the cassette after use. Protect your cassettes. Put them back in their boxes immediately after use. Never expose cassettes to heat or direct sunlight. 7807A3CD12 Play back Slide the cassette, with the open side to the right into the cassette...

  • Page 65: Radio Setting

    RADIO SETTING AMERICA Press , No. 1 and No. 4 buttons at the same time. Set up completes displaying " AMERICA". JAZZ VOCAL POP CLASSIC ROCK FLAT LOUD PRESET SOUTH AMERICA Press , No. 2 and No. 5 buttons at the same time. Set up 7807A3CD16 completes displaying "...

  • Page 66: Cigar Lighter

    SEAT The seat is adjustable to fit the contours of the operator's body. It will reduce operator fatigue due to long work hours and enhance work efficiency. Forward/Backward adjustment(A) Pull lever A to adjust seat forward or backward. The seat can be moved forward and backward over 170mm(6.7") in 9 steps.
  • Page 67 FUSE BOX The fuses protect the electrical parts and wiring from burning out. WORK START LAMP The fuse box cover indicates the capacity of each FUEL CASSETTE FILLER P/P ROOM LAMP fuse and circuit it protects. Replace a fuse with another of the same CIGAR CLUSTER LIGHT...

  • Page 68: Operation

    OPERATION 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. Avoid excessive Service meter Load operation for initial 100 hours Until 10 hours About 60% Until 100 hours...

  • Page 69: Check Before Starting The Engine

    2. CHECK BEFORE STARTING THE ENGINE Look around the machine and under the machine to check for loosen nut or bolts, collection of dirt, or leakage of oil, fuel or coolant and check the Check before condition of the work equipment and hydraulic starting system.

  • Page 70: Starting And Stop The Engine

    3. STARTING AND STOP THE ENGINE CHECK INDICATOR LIGHTS Check if all the operating lever is on the neutral position. Turn the starting switch to the ON position, and START check following. If all the lamps light ON and buzzer sounding for 6 seconds.
  • Page 71 STARTING ENGINE Sound horn to warn surroundings after check- ing if there are obstacles in the area. Replace the engine oil and fuel referring to recommended oils at page 2-12. Fill anti-freeze solution to the coolant as required. Check if all levers are on the neutral position. Turn the starting switch to ON position.

  • Page 72: Warming-Up Operation

    INSPECTION AFTER ENGINE START Inspect and confirm the following after engine starts. Is the level gauge of hydraulic oil tank in the normal level? Are there leakages of oil or water? Are all the warning lamps OFF(2~10)? Is the indicator of engine coolant temperature gauge(1) in the normal zone? Is the engine sound and the color of exhaust gas normal?

  • Page 73: To Stop The Engine

    TO STOP THE ENGINE If the engine is abruptly stopped before it has cooled down, engine life may be greatly Low idling for shortened. Consequently, do not abruptly 5 minutes stop the engine apart from an emergency. In particular if the engine has overheated, do not abruptly stop it but run it at medium speed to allow it to cool gradually, then stop it.
  • Page 74 4. OPERATION OF WORKING DEVICE Confirm the operation of control lever and working device. Left control lever controls arm and swing. Right control lever controls boom and bucket. When you release the control lever, control lever returns to neutral position automatically. When operating swing, consider the swing distance by inertia.

  • Page 75: Traveling Of The Machine

    5. TRAVELING OF THE MACHINE BASIC OPERATION Traveling position Traveling position It is the position which the traveling motor is in the rear and the working device is forward. Be careful as the traveling direction will be reversed when the whole machine is swinged 180 degree Traveling operation It is possible to travel by either travel lever or...
  • Page 76 TRAVELING ON A SLOPE Make sure that the travel lever is properly maneuvered by confirming the travel motor is in the right location. Lower the bucket 20 to 30cm(1ft) to the ground so that it can be used as a brake in an emergency.

  • Page 77: Towing The Machine

    TOWING THE MACHINE Tow the machine as follows when it can not move Correct on it's own. Tow the machine by other machine after hook the wire rope to the frame as shown in picture at right. Hook the wire rope to the frame and put a support under each part of wire rope to prevent damage.

  • Page 78: Efficient Working Method

    6. EFFICIENT WORKING METHOD Do the digging work by arm. Use the pulling force of arm for digging and use together with the digging force of the bucket if necessary. 55574OP15 When lowering and raising the boom operate softly for the beginning and the end. In particularly, sudden stops while lowering the boom may cause damage to the machine.
  • Page 79 Dig slowly with keeping the angle of boom and arm, 90-110 degree when maximum digging force is required. 90~110 55574OP18 Operate leaving a small safety margin of cylinder Margin stroke to prevent damage of cylinder when working with the machine. R5574OP19 Keep the bucket to the dumping position and the arm horizontal when dumping the soil from the...
  • Page 80 Never carry out operations which may damage the machine such as overload or over-impact- load. Never travel while carrying a load. In case you need installing over load warning device for object handling procedure, please Incorrect contact Hyundai distributor. R5574OP24/24A 4-12...
  • Page 81 BUCKET WITH HOOK When carrying out lifting work, the special lifting hook is necessary. The following operations are prohibited. Lifting loads with a wire rope fitted around the bucket teeth. Hook Lifting loads with the wire rope wrapped directly around the boom or arm. When performing lifting operation, securely hook the wire rope onto the special lifting hook.

  • Page 82: Operation In The Special Work Sites

    7. OPERATION IN THE SPECIAL WORK SITES OPERATION THE MACHINE IN A COLD WEATHER Use proper engine oil and fuel for the weather. Fill the required amount of antifreeze in the coolant. 50 C Refer to the starting engine in cold weather. Start the engine and extend the warming up operation.
  • Page 83 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 84: Normal Operation Of Excavator

    8. NORMAL OPERATION OF EXCAVATOR Followings may occur during operation due to the nature of a hydraulic excavator. When rolling in the arm, the roll-in movement stop momentary at point X in the picture shown, then recovers speed again after passing point X. The reason for this phenomenon is that movement by the arm weight is faster than the speed of oil flow into the cylinder.

  • Page 85: Attachment Lowering Pattern

    Accumulator release the gas from the accumulator. A special air bleed valve is necessary for this operation, so please contact your Hyundai R5574OP31 distributor. 4-17...

  • Page 86: Storage

    10. STORAGE Maintain the machine taking care of following to prevent the deterioration of machine when storing the machine for a long time, over 1 month. CLEANING THE MACHINE Clean the machine. Check and adjust tracks. Grease each lubrication part. LUBRICATION POSITION OF EACH PART Change all oil.

  • Page 87: During Storage

    DURING STORAGE Start engine and move the machine and work equipment once a month and apply lubrication to each part. Lubricating operation once a month Check the level of engine oil and coolant and fill if required when starting engine. Clean the anticorrosive on the piston rod of cylinder.

  • Page 88: Rcv Lever Operating Pattern

    From Arm out ISO Type Arm in Left Swing right Swing left Boom lower Boom raise Right Bucket out Hyundai Bucket in Boom lower A Type Boom raise Left Swing right Swing left Arm out Arm in Right Bucket out...
  • Page 89 RCV LEVER OPERATING PATTERN(option, A type) Multimode Terminal selector assembly valve A TYPE (Option) ISO TYPE(STD) 55W7A4OP91 Operation Hose connection(Port) Control function Pattern RCV lever MCV port Left Right A Type Boom lower Boom raise Left Swing right Swing left Arm out Arm in Right...
  • Page 90 12. HANDLING THE RUBBER TRACKS 12. HANDLING THE RUBBER TRACKS USING THE RUBBER TRACKS PROPERLY USING THE RUBBER TRACKS PROPERLY Rubber tracks have some advantages over steel tracks. However, you cannot take full advantage of them if you use them in the same manner as steel ones.
  • Page 91 Do not operate the machine when the tracks will be exposed to heat, (i.e., near an open-air fire, on a steel plate that has been exposed to the blazing sun, or on a hot asphalt road.) Never run on one rubber track while the other is held above the ground with the implement. Doing this may damage the rubber track or cause it to come off.
  • Page 92 BE CAREFUL NOT TO COME OFF THE RUBBER TRACKS BE CAREFUL NOT TO COME OFF THE RUBBER TRACKS Keep the tracks in appropriate tension to prevent them from coming off. If the tension is too low, the rubber tracks may come off under the following conditions. Even if the tension is adequate, take care when operating the tracks under these conditions.
  • Page 93 The three cases illustrated above are those which could cause the rubber tracks to loosen. In addi- tion, do not subject machine to such ground con- ditions as are illustrated in the figure at the right. 1694OP34 HOW THE RUBBER TRACKS COME OFF HOW THE RUBBER TRACKS COME OFF When running over a level gap, a clearance is Rubber track...
  • Page 94 Traveling in reverse under the condition illustrat- ed will cause the rubber tracks to come off. 1694OP38 Changing the travel direction of the machine under the condition illustrated will cause the rubber tracks to come off. 1694OP39 4-26...

  • Page 95: Transportation

    TRANSPORTATION 1. PREPARATION FOR TRANSPORTATION When transporting the machine, observe the various road rules, road transportation vehicle Overall laws and vehicle limit ordinances, etc. width Select proper trailer after confirming the weight and dimension from the chapter 2, specification. Check the whole route such as the road width, the height of bridge and limit of weight and etc., which will be passed.

  • Page 96: Dimension And Weight

    2. DIMENSION AND WEIGHT Base machine Mark Description Unit Specification Length mm(ft-in) 2900( 9' 6") Height mm(ft-in) 2550( 8' 4") Width mm(ft-in) 1920( 6' 4") kg(lb) Weight 4810(10640) With 400mm(16") triple grouser shoes and 210kg (460lb) counterweight. R5575TA02 Boom assembly Mark Description Unit...
  • Page 97 Boom cylinder Mark Description Unit Specification Length mm(ft-in) 1210( 3'12") Height mm(ft-in) 150( 0' 6") mm(ft-in) Width 280( 0'11") kg(lb) Weight 55(120) Included piping. 13035TA06 Cab assembly Mark Description Unit Specification mm(ft-in) Length 1510( 4'12") mm(ft-in) 1560( 5' 2") Height Width mm(ft-in) 1060( 3' 6")

  • Page 98: 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. Place the swing lock lever to the LOCK position before fixing the machine at the bed of trailer and confirm if the machine parallels the bed of trailer.
  • Page 99 Lower the working equipment gently after the location is determined. Place rectangular timber under the bucket cylinder to prevent the damage of it during transportation. Be sure to keep the travel speed switch on the LOW(turtle mark) while loading and unloading the machine.

  • Page 100: Fixing The Machine

    4. FIXING THE MACHINE Lower down the working device on the loading Starting switch plate of trailer. Keep the safety lever on the LOCK position. Turn OFF all the switches and remove the key. Safety lever R557A5TA09 Secure all locks. Cabin Engine hood Tool box...

  • Page 101: Loading And Unloading By Crane

    5. LOADING AND UNLOADING BY CRANE Check the weight, length, width and height of the machine referring to the chapter 2, specification when you are going to hoist the machine. Wire rope Use long wire rope and stay to keep the distance Stay with the machine as it should avoid touching with the machine.

  • Page 102: Maintenance

    Do not allow unauthorized personnel to reset them. Ask to your local dealer or Hyundai for the maintenance advice if unknown. Drain the used oil and coolant in a container and handle according to the method of handling for industrial waste to meet with regulations of each province or country.

  • Page 103: Proper Maintenance

    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 understand the chapter 1, safety hints.
  • Page 104 RELIEVING THE PRESSURE IN THE HYDRAULIC SYSTEM Spouting of oil can cause the accident when loosening the cap or hose right after the operating of machine as the machine or oil is on the high pressure on the condition. Be sure to relieve the pressure in the system before repairing hydraulic system.
  • Page 105 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. Use genuine parts. Do not assemble the hose in the condition of twisted or sharp radius.
  • Page 106 PERIODICAL REPLACEMENT OF SAFETY PARTS It is desirable to do periodic maintenance the machine for using the machine safely for a long time. However, recommend to replace regularly the parts related safety not only safety but maintain satisfied performance. These parts can cause the disaster of life and material as the quality changes by passing time and it is worn, diluted, and gets fatigued by using repeatedly.

  • Page 107: Tightening Torque

    2. TIGHTENING TORQUE Use following table for unspecified torque. B B OLT AND NUT Coarse thread Bolt size kgf m lbf ft kgf m lbf ft 0.9 ~ 1.3 6.5 ~ 9.4 1.1 ~ 1.7 8.0 ~ 12.3 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7...
  • Page 108 PIPE AND HOSE(FLARE TYPE) Thread size(PF) Width across flat(mm) lbf ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 130.2 1" 151.9 1-1/4" 253.2 PIPE AND HOSE(ORFS TYPE) Thread size(UNF) Width across flat(mm) kgf m lbf ft 28.9 9/16-18 11/16-16 36.2 13/16-16 68.7 130.2...
  • Page 109 TIGHTENING TORQUE OF MAJOR COMPONENT Torque Descriptions Bolt size lbf ft Engine mounting bolt(Engine-Bracket) 50.6 7.2 Engine mounting bolt(Bracket-Frame) 8.0 1.0 57.9 7.2 Engine Radiator mounting bolt, nut 6.9 1.4 50 10.0 Coupling mounting bolt 6.0 1.0 43.4 7.2 Main pump mounting bolt 1.75 12.8 3.0 92 22.0...

  • Page 110: Fuel, Coolant And Lubricants

    3. FUEL, COOLANT AND LUBRICANTS 1 1 ) NEW MACHINE New machine used and filled with following lubricants. Description Specification Engine oil SAE 15W-40(API CI-4) Hydraulic oil ISO VG 46(SAE 10W) Swing and travel reduction gear SAE 85W-140(API GL-5) Grease Lithium base grease NLGI No.
  • Page 111 2) RECOMMENDED OILS Use only oils listed below or equivalent. Do not mix different brand oil. Ambient temperature C( F) Capacity Service point Kind of fluid (U.S. gal) (-4) (14) (32) (50) (68) (86) (104) SAE 30 SAE 10W Engine Engine oil 11.6(3.1) oil pan...

  • Page 112: Maintenance Check List

    4. MAINTENANCE CHECK LIST DAILY SERVICE BEFORE STARTING Check items Service Page Visual check Fuel tank Check, Refill 6-25 Hydraulic oil level Check, Add 6-27 Engine oil level Check, Add 6-18 Coolant level Check, Add 6-20 Control panel & pilot lamp Check, Clean 6-36 Prefilter...
  • Page 113 NITIAL 50 HOURS SERVICE Check items Service Page Engine oil Change 6-18, 19 Engine oil filter Replace 6-18, 19 Fuel filter Replace 6-26 Bolts & Nuts Check, Tight Sprocket mounting bolts Travel motor mounting bolts Swing motor mounting bolts Swing bearing mounting bolts Engine mounting bolts Counterweight mounting bolts Turning joint locating bolts...

  • Page 114: Every 250 Hours Service

    VERY 250 HOURS SERVICE Check items Service Page Battery electrolyte Check 6-36 Swing reduction gear oil Change 6-29, 30 Element in hydraulic tank breather Replace 6-29 Bolts & Nuts Check, Tight Sprocket mounting bolts Travel motor mounting bolts Swing motor mounting bolts Swing bearing mounting bolts Engine mounting bolts Counterweight mounting bolts...
  • Page 115 EVERY 1000 HOURS SERVICE Check items Service Page Travel motor reduction gear oil Change 6-31 Swing reduction gear oil Change 6-29, 30 6-28 Hydraulic return filter Replace 6-29 Pilot line filter Replace VERY 2000 HOURS SERVICE Check items Service Page Hydraulic tank 6-27 Change...

  • Page 116: When Required

    WHEN REQUIRED Whenever you have trouble in the machine, you must perform the service of related items, system by system. Check items Service Page Fuel system Fuel tank Drain or Clean 6-25 Prefilter Drain or Replace 6-25 Fuel filter Replace 6-26 Engine lubrication system Engine oil...

  • Page 117: Maintenance Chart

    5. MAINTENANCE CHART 23 9 R5576MA05A Caution 1. Service intervals are based on the hour meter reading. 2. The number of each item shows the lubrication point on the machine. 3. Stop engine while filling oil, and use no open flames. 4.
  • Page 118 Service Service Capacity Service Description ℓ(U.S.gal) interval action symbol points No. Hydraulic oil level Check, Add 70(18.5) Engine oil level Check, Add 9.2(2.4) 10 Hours Radiator coolant Check, Add 10(2.6) or daily Water separator Check, Drain Fan belt tension and damage Check, Adjust Attachment pins Check, Add...

  • Page 119: Service Instruction

    6. SERVICE INSTRUCTION CHECK ENGINE OIL LEVEL Filler port 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 completely into the hole and pulling out again.
  • Page 120 Apply a light film of lubricating oil to the gasket sealing surface before installing the filters. R5576MA50 Install the filter to the filter head. Remove the quick coupler hose. Mechanical over-tightening may distort the Engine oil filter threads or damage the filter element seal. Install the filter as specified by the filter manufacturer.

  • Page 121: Check Coolant

    CHECK COOLANT Check if the level of coolant in reservoir tank is between FULL and LOW. Add the mixture of antifreeze and water after removing the cap of the reservoir tank if coolant is not sufficient. Be sure to add the coolant by opening the cap of radiator when coolant level is below LOW.
  • Page 122 Wait until the temperature is below 50 (122 F ) before removing the coolant system pressure cap. Water drain plug Failure to do so can cause personal injury from heated coolant spray. Drain the cooling system by opening the drain valve on the radiator and removing the plug in the bottom of the water inlet.
  • Page 123 Operate the engine for 5 minutes with the coolant temperature above 80 C(176 F) . Shut the engine off, and drain the cooling system. f the water being drained is still dirty, the system must be flushed again until the water is clean.

  • Page 124: Fan Belt Tension

    CLEAN RADIATOR AND OIL COOLER NOT OK Check, and if necessary, clean and dry outside of radiator and oil cooler. After working in a dusty place, clean radiator more frequently. Visually inspect the radiator for clogged radiator fins. Use 550kPa(80psi) air pressure to blow the dirt 550kPa and debris from the fins.
  • Page 125 INSPECTION OF COOLING FAN Personal injury can result from a fan blade failure. Never pull or pry on the fan. This can damage the fan blade and cause fan failure. Rotate the crankshaft by using the engine barring gear. A visual inspection of the cooling fan is NOT OK required daily.
  • Page 126 FUEL TANK Fill fuel fully when system the operation to minimize water condensation, and check it with fuel gauge before starting the machine. Drain the water and sediment in the fuel tank by Fuel gauge opening the drain cock. Be sure to LOCK the cap of fuel tank. Remove the strainer of the fuel tank and clean it if contaminated.

  • Page 127: Bleeding The Fuel System

    Lubricate new bowl seal with clean fuel or motor oil and place in bowl gland. Filter head Attach bowl to new element firmly by hand. Fuel warmer Lubricate new element seal and place in element top gland. Close Attach the element, fuel warmer and bowl to the Element head.

  • Page 128: Hydraulic Oil Check

    LEAKAGE OF FUEL FIRE Be careful and clean the fuel hose, injection pump, fuel filter and other connections as the leakage from these part can cause fire. R5576MA24 HYDRAULIC OIL CHECK Stop the engine after retract the arm and bucket Red line cylinders, then lower the boom and set the bucket on the ground at a flat location as in the...

  • Page 129: Change Hydraulic Oil

    CHANGE HYDRAULIC OIL Lower the bucket on the ground pulling the arm and bucket cylinder to the maximum. Loosen the cap and relieve the pressure in the tank by pushing the top of the air breather. Remove the cover. Tightening torque : 6.9 1.4kgf m (50 10lbf ft) Prepare a suitable container.
  • Page 130 REPLACEMENT OF RETURN FILTER Replace as follows paying attention to the cause Cover to be kept during the replacement. O-ring Remove the cover. Spring Tightening torque : 6.9 1.4kgf m Bypass valve (50 10lbf ft) Return filter Remove the spring, by-pass valve, and return filter in the tank.
  • Page 131 CHECK THE SWING REDUCTION GEAR OIL Pull out the dipstick and clean it. Insert it again. Pull out one more time to check the oil level and fill the oil if the level is not sufficient. R5576MA60 CHANGE SWING REDUCTION GEAR OIL Filling port plug Raise the temperature of oil by swinging the machine before replace the oil and park the...
  • Page 132 CHECK THE TRAVEL REDUCTION GEAR OIL Operate the machine to the position of drain plug down to the flat ground. Loosen the level plug and check the oil level. F I L If the level is at the hole of the plug, it is normal. Fill the oil if it is not sufficient.
  • Page 133 ADJUSTMENT OF TRACK TENSION It is important to adjust the tension of track properly to extend the lifetime of track and 90 ~ 110 traveling device. The wear of pins and bushings on the undercarriage will vary with the working conditions and soil properties.

  • Page 134: Replacement Of Bucket

    REPLACEMENT OF BUCKET When knocking the pin in with a hammer, metal particles may fly and cause serious injury, particularly if they get into your eyes. When carrying out this operation, always wear goggles, helmet, gloves, and other protective equipment. When the bucket is removed, place it in a stable condition.
  • Page 135 REPLACEMENT OF BUCKET TOOTH Timing of replacement Tooth adapter Check wearing condition as shown in the Tooth tip illustration and replace tooth tip before adapter starts to wear. If excessive use, tooth adapter has worn out, replacement may become impossible. R5576MA37 Instructions for replacement Tooth pin...
  • Page 136 LUBRICATE PIN AND BUSHING Lubricate to each pin of working device Lubricate the grease to the grease nipple according to the lubricating interval. Description Lubrication manifold at upper frame Boom connection pin Boom cylinder(Head and rod side) Arm cylinder pin(Head and rod side) Boom and arm connection pin Bucket cylinder pin(Head and rod) Bucket link(Control rod)

  • Page 137: Electrical System

    7. ELECTRICAL SYSTEM WIRING, GAUGES Check regularly and repair loose or malfunctioning gauges when found. 13036MI29 BATTERY Check and repair Check the electrolyte level and fill with distilled water to the prescribed level as necessary. Plug Wash the terminal with hot water if it is contaminated, and apply grease to the terminals after washing.
  • Page 138 3) STARTING THE ENGINE WITH A BOOSTER CABLE Keep following order when you are going to start engine using booster cable. Connection of booster cable Use the same capacity of battery for starting. Connection of booster cable Make sure that the starting switches of the normal machine and trouble machine are both at the OFF position.
  • Page 139 Welding repair Before start to welding, follow the below Cluster Master switch procedure. Shut off the engine and remove the starting switch. Disconnect ground cable from battery by master switch. Before carrying out any electric welding on the machine, the battery cables should be disconnected and the connectors pulled out of the electronic control units(Cluster etc).

  • Page 140: Air Conditioner And Heater

    8. AIR CONDITIONER AND HEATER CLEAN AND REPLACE OF THE CIRCULATION FILTER Always stop the engine before servicing. Remove the screw(1) and cover(2) on the seat base. Remove the bolt(3) and bracket(4). Remove the circulation filter(5). R557A6MA40 Clean the filter using a pressurized air(Below 2kgf/cm , 28psi).

  • Page 141: Engine

    T T ROUBLESHOOTING GUIDE 1. ENGINE This guide is not intended to cover every conditions, however many of the more common possibilities are listed. Trouble Service Remark The engine oil pressure lamp Add the oil to the specified level. lights ON when engine speed is Replace the oil filter cartridge.

  • Page 142: Electrical System

    2. ELECTRICAL SYSTEM Trouble Service Remark Lamp does not glow brightly even Check for loose terminals and open-circuit wiring. when engine runs at high speed. Adjust belt tension. Lamp flickers while engine runs. Battery charging lamp does not Check the alternator. go out even when engine runs at Check and repair wiring.

  • Page 143: Others

    3. OTHERS Trouble Service Remark Track slip out of place. Adjust tension of track. Excessive wear of the sprocket. Add oil to specified level. Bucket either rises slowly or not at all. Slow speed of travel, swing, Add oil to specified level. boom, arm and bucket.

  • Page 144: Hydraulic Breaker And Quick Clamp

    Become familiar with the manual and select breakers suitable to machine specifications. Make careful selection in consideration of oil quantity, pressure and striking force, to enable satisfied performance. When apply a breaker to the machine, consult your local dealer of Hyundai for further explanation.

  • Page 145: Circuit Configuration

    One of spool of the main control valve should be connected to the tank. Select the size of pipe laying considering the back pressure. Shimless tube should be used for the piping. The hose and seal should be used Hyundai genuine parts.

  • Page 146: Maintenance

    3. MAINTENANCE MAINTENANCE OF HYDRAULIC OIL AND FILTER Service interval unit : hours As machine with an hydraulic breaker provides Operating Hydraulic Filter Attachment hydraulic becomes severely rate element contaminated. Breaker 100% So, unless frequently maintained, the machine Replace following filter same time may easily go out of order.

  • Page 147: Precaution While Operating The Breaker

    4. PRECAUTIONS WHILE OPERATING THE BREAKER DO NOT BREAK ROCK WHILE LOWERING Incorrect As the breaker is heavy in comparison with bucket, it must be operated slowly. If breaker is rapidly pushed down, working device may be damaged. 55578OA01 DO NOT USE BREAKER TO CARRY Incorrect BROKEN STONE OR ROCK BY SWING OPERATING...
  • Page 148 DO NOT CONTINUE TO WORKING OVER Incorrect ONE MINUTE AT SAME POSITION OF For one BOOM AND ARM minute This will increase the temperature of the oil, and cause problem in the accumulator and seals. R5578OA05 DO NOT MOVE MACHINE OR BREAKER Incorrect WHILE STRIKING Do not move hammer while striking.

  • Page 149: Quick Clamp

    5. QUICK CLAMP FIXING BUCKET WITH QUICK CLAMP Quick clamp switch Before fixing bucket, remove safety pin of the moving hook. Safety button Pulling safety button, press the quick clamp switch to unlock position. Then, the moving hook is placed on release position. Safety pin quick-1 Aligning the arm and bucket, insert static...
  • Page 150 Be careful to operate the machine equipped with quick clamp. The bucket may hit cab, boom and boom cylinders when it reaches vicinity of them. HYUNDAI will not be responsible for any injury or damage in case that safety pin is not installed properly. 55578QC01...

  • Page 151: Index

    INDEX After engine start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-4 Hydraulic breaker - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 Air breather element - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-29 Hydraulic oil changing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-28...
  • Page 152 Speciation for major component - - - - - - - - - - - - - - - - - - - - - - 2-13 Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2 Start switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-7 Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-19 Suction strainer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-28...

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