Page 2 Attention Please Subject : Matters needing attention for maintenance and accessories 1. First welcome you to have used our product and thank you for great coordination in business. 2. In case the equipment is in faults, it should be maintained by our Company or the company appointed by our Company using standard parts.
Page 4 Special Explanation Topic: Special explanation of fuel system operation and maintenance for loader In order to let HYUNDAI loader for you to create greater economic benefits, please read this article seri- ously. Fuel quality is the important factors of make the engine to obtain fine performance and prolong service life and realize low emission.
Page 6 Operation & Maintenance Manual Our Company has the right to continuously improve the products so as to promote the best products to the market as possible as we can. These improvements can be implemented at any time; however, we will not change the materials for the products being sold at that time.
Page 7: Table Of Contents
Contents Safety...........................1-1 Advice for Operation of Loader.......................1-1 Safety Decals.........................1-3 Unauthorized Modification......................1-6 General Hazard Information......................1-6 Before Starting Engine........................1-15 Operation of Loader........................1-20 Maintenance Loader........................1-30 Battery............................1-39 Traction............................1-43 Shipping and Transportation......................1-46 Operation Controls ......................2-1 Component Locations....................2-2 Operation lever and Dashboard..................2-4 Manipulating And Motoring System...................2-23 Operation......................3-1 Advice for Operation of New Loader....................3-1 Operation of Loader....................3-16...
Page 8 Electrical system..........................4-11 Bucket............................4-15 Add Shim To Bucket........................4-17 Tires and Wheels..........................4-18 Inspection of Bolt and Nut......................4-22 Maintenance under Special conditions..................4-23 Storage for a long time........................4-24 Transportation........................5-1 Transportation Dimension....................5-5 Trouble Shooting......................6-1 Transmission System........................6-1 Braking System..........................6-3 Hydraulic System for Working Device....................6-4 Steering Hydraulic System......................6-5 Electical System..........................6-6 Specification....................7-1 Standard Specification........................7-1...
Page 10: Safety
Safety ADVICE FOR OPERATION OF LOADER DANGER The irregular operation of the loader can cause serious injure and death. When conducting equipment operation, maintenance, traveling or shipment, if the following safety rules are not obeyed, there may be serious and even fatal injury to the persons or heavy damages to the equipment and periphery.
Page 11: Safety Alert Symbols
Safety Alert Symbols Preparation - understand the description of all operations and safety. This is a Safety Alert Symbol. When working together with other persons, you must ensure that all persons shall be able to understand the sign language being used and warn the people of injury dangers.
Page 12: Safety Decals
SAFETY DECALS Figure 1 The safety decals are attached to the machine. In this Chapter, the locations and descriptions of these decals will be reviewed in the following section. Please become familiarized with all safety decals and their messages. Make sure that all the decals are in correct locations and legible.
Page 13 1.Never stand under the moving arm. Sudden or accidental movement of boom may cause injury or death. Securely brace boom before working or walking under raised boom. Figure 2 2.Never stand under the bucket. Figure 3 3. Standing here is strictly prohibited while the ma- chine is moving.
Page 14 4. Severe injury and death from crushing could occur in articulation position when machine turns. Make sure people are clear of machine before starting engine or moving steering wheel. Figure 5 5. K e e p y o u r h a n d s a w a y f r o m t h e f a n d u r i n g operation.
Page 15: Unauthorized Modification
UNAUTHORIZED MODIFICA- TIONS In case of the safety accidents arising from any modification without authorization by Hyundai, the Owner shall bear the responsibilities. As a safety precaution, all OEM parts must be replaced with the correct authorized or genuine Parts. If the fasteners, bolts or nuts are not...
Page 16 Matters needing attention in cabin When entering the cabin, remove the mud and oil from the soles of your shoes, otherwise, the accident will occur when you step on the accelerator pedal due to the slippage on the sole. Do not stick suction pads on the window glass, be- cause the suction pads could act as a lens which can cause the fire.
Page 17 Breathing masks & Ear Protection Do not neglect the factors which do not have direct hazardous impact on the health. The waste gas and noise pollutions are invisible, but they can cause disability or permanent injury. Getting on and off the loader Before getting on or off machine, if there is any oil, grease, or mud on handrails or steps, wipe it off immediately.
Page 18 Make sure the premises are well ventilated when the fuel, oil, anti-freeze-fluid and hydraulic oil are filled in. Switch off the lamp, control lever and the starter switch after the machine is shut off. Shut off the engine. The equipment should be far away from the flame and heating element.
Page 19 Coolant During operation, the temperature of the engine ● coolant is higher and there is pressure in the engine. All piping lines connected to radiator or to engine have hot water or steam in them. The contact with them will cause severe burns. When checking the coolant liquid level, the en- ●...
Page 20 Fire extinguisher and first-aid kit In case of personal injury or fire happened, please operate as follows Find the Fire extinguisher and carefully read ● the operation description on it to ensure that you can use it. It is recommended to use the multi-functional “A/B/C”...
Page 21 Prohibit reforming or changing any forms of protection structure by adding reinforcing devices (e.g., drilling hole, welding, re-installing or re- installing fasteners etc.). The re-identification of the whole protective system is needed for the protective system which has suffered severe impact or damage.
Page 22 Battery During operation, the battery can produce com- ● bustible gases which may cause explosion. Do not smoke while checking the level of elec- ● trolyte of the battery. The electrolyte is an acidic substance, and it will ● hurt the persons when it touches with skin or eyes.
Page 23 Tire That the fully inflated Tire may be exploded is due to the heating inside of the Tire. Generally, heating is caused from the welding or heating of rim, the external flames or the too frequency of braking. The explosion of Tire is much more powerful than air bleeding.
Page 24: Before Starting Engine
BEFORE STARTING ENGINE Matters needing attention on site Before starting, completely check the working area for the abnormal conditions which may cause dan- gers. Check the terrain and ground surface on site, and identify the best and the safest operation method. Before operation, please make the ground hard and smooth as possible as you can.
Page 25 When the minimum standard or operation restric- tions for barrier protection on site is less strict, the insurance responsibilities scope and the operation license or certificates can be issued by the insti- tutions authorized by the Government; it may be needed to follow the restrictions on laws and regu- lations, policies, standards or equipment required by local authorities;...
Page 26 Check before starting engine Perform the following checks before the starting of engine and before starting your work every day. Otherwise, it will cause serious injury or damage. Check the surrounding of engine and battery for combustible materials Check fuel and lubrication oil and hydraulic oil for the leakage.
Page 27 Start the engine Walk around and check the loader before enter- ing the cab. Check for oil leakage, loose, improper adjustment of components or the possible damage phenomenon of other equipment. In order to prevent the accidents, all cover plates and protective devices for the equipment shall be complete when operating the machine.
Page 28 Before Operating loader If you do not correctly check after the engine is started up, then you may not timely find the abnor- malities of the machine so that the personal injury or machine damage could occur. • Check the machine at a place without any ob- stacles, and do not let anybody to approach the machine while you are checking.
Page 29: Operation Of Loader
OPERATION OF LOADER Matters needing attention on travelling Do not shut off the engine while the machine is travelling. The shutting off engine while the ma- chine is travelling is dangerous. You cannot ma- nipulate the steering wheel effectively. Do not operate the control handle of the attached device while the machine is travelling.
Page 30 Matters needing attention on travelling on slope Do not jump onto the incontrollable machine to shut it off, otherwise you will have the risk of seri- ous injury. Travelling on the slope will cause the machine to tip-over or slipping. Keep the bucket at a position 20-30cm (8-12in) over the ground while the machine is travelling on the hill, on the dyke or on the slope.
Page 31: Prohibited Operation
Prohibited operation Do not shovel the working face under the highland, otherwise it will cause the highland to collapse, making falling objects tramp onto the top of the ma- chine. Working with heavy load on soft, unsmooth or cracked ground may cause the possibility of dan- gerous side force and tipover.
Page 32 Accidents can be avoided under correct and safe operation, please operate the braking system ac- cording to the following advises. • Don’t put your foot on the brake pedal except when it is necessary .Because the brake valve may be pressed by your foot when the loader is running on the rough road, which may put the loader into brake status, and accidents re- sult from failure of the braking system, which is...
Page 33 Be careful for HV cables Do not let the machine touch with overhead cable. The electric shock could be caused even you are only near the HV cable. A safety distance shown in following table should be kept between the machine and the cable.
Page 34 Pay attention to follows to prevent the working device from colliding other ob- jects: When performing operation in tunnels, under bridg- es, beneath cables or in other places where the height is restricted, especially pay attention not to let bucket touch anything. When loading materials into a tipper, pay attention not to let bucket touch with tipper’s cab.
Page 35 When the loader is travelling down a slope , ● please set the transmission on low speed gear, with which the engine can be used to brake. Never shift the gears or put set the transmission to neutral . When the loader is travelling up a slope ,keep the ●...
Page 36 Matters needing attention in cold area Remove thoroughly the water, snow or sludge c o v e r e d o n t h e p a r t s s u c h a s w i r e s , c a b l e connectors, switches, or sensors.
Page 37 Operation on slope Be especially careful for that traveling on the slope will cause the machine to sideslip or tip-over. The bucket must be 200-300mm over the ground while the machine is traveling on the slope. In an emergency, lower the bucket quickly down to the ground to assist the stop of the machine.
Page 38 Parking the machine After the operation, avoid sudden switching-off or shutting-off. Park the loader on a hard plane, far away from traffic lines and high walls, cliffs, and edges of pools and drainage ditch. If the machine must be parked on the slope, it is necessary to stop up the Tires to prevent from moving, and lower the bucket and other working devices down to ground or on the supporting bases.
Page 39: Maintenance
MAINTENANCE Warning labels Warn of that others persons are performing the maintenance, and hang the warning sign on cab control device and other necessary places. Our company branch organizations provide control warning signs Requirements on personnel Figure 27 Operation and maintenance of this machine may only be carried out by personnel equipped with corresponding resources.
Page 40 Pe r fo r m t h e cl e a n i n g wo r k b e fo r e maintenance Perform the cleaning work before inspection and maintenance to prevent the dust from entering the machine and ensure the maintenance can be securely performed.
Page 41 Proper tools Use tools which are proper for the operation. The use of damaged, low quality, unqualified or temporary tools may cause the personal injury. The scraps from chisel or hammer are very dangerous, and they will cause the persons to be blind. Operation of lighting devices Figure 29 The explosion-proof lighting devices should be...
Page 42 Clean and tighten all cable connectors and check the cables for loose or wear every day. Tighten all loose cables and repair all worn cables before operating the machine. T i m e l y c l e a r t h e c o m b u s t i b l e s u b s t a n c e s accumulated on the machine.
Page 43 Welding maintenance Welding maintenance The welding operation should be performed at the specified place. The welding operation should be performed by qualified persons. The toxic gases and flames etc will be produced during welding, therefore, do not allow the unqualified persons to perform the welding operation.
Page 44 Matters needing attention for attachment moving, installation and storage Select the leader for the operation before starting removal and installation. Do not let any unauthorized persons to approach the machine or attachments. Put the attachments removed from the machine at the safety places to prevent from falling.
Page 45 Avoid being crushed or cut W h e n p e r f o r m i n g m a i n t e n a n c e , i f y o u m u s t operating the engine, ensure at least two persons must work together.
Page 46 R e p a i r i n g a n y l o o s e o r d a m a g e d f u e l a n d lubrication oil way, pipes or hoses will possibly cause fire. Please consult the distributor specified by Hyundai for repair or maintenance. Carefully check the pipeline, pipe and hose. Do not use naked hands to check the leakage. Check the leakage using one plate or paper plate.
Page 47: Compressed Air
Compressed air Compressed air may cause the persons to be injured. Wear protective mask, protective clothes and shoes when using compressed air. Use clean compressed air at pressure less than 0.3MPa, with a maximum pressure of 0.3 MPa. Penetration of solution Check the leakage using one plate or paper plate.
Page 48: Battery
BATTERY Prevention of battery risks The battery electrolytes contain sulphur acid, and battery can produce Hydrogen. Hydrogen is highly explosive. If disposing incorrectly, it will cause serious injury or fire. In order to prevent these problems, please accomplish following items: Prohibit smoking or flame approaching the bat- ●...
Page 49 Auxiliary starting or charging the engine battery The incorrect connection of battery cables may cause explosion or fire. Please obey the following items: Switch off all electrical equipments before con- ● necting to battery, including the electric switch for battery charger and auxiliary starting device. When using other machine to perform the aux- ●...
Page 50: Air Conditioning System
Air-conditioning System Filling the refrigerant matters needing attention Refrigerant tank should be far away from fire, ● otherwise will produce the aura and gas, make the operator suffocation; Refrigerant tank should avoid direct sunlight, oth- ● erwise easy to occur the explosion; Connection or remove quick connector, should ●...
Page 51 When using the matters needing atten- tion The warranty period it is strictly prohibited to re- ● move their air conditioning system; Shut down the engine before air conditioning, ● start the engine after the open air conditioning, When summer refrigeration must be closed ●...
Page 52: Traction
TRACTION Matters needing attention on towing If fault occurs during the selection or inspection of the traction string or during performance of traction, it will cause serious injury. Please obey the follow- ing items: Use the methods introduced in Operation and ●...
Page 53 The total height, total width and total weight should not exceed the related regulations. Please consult HYUNDAI Infracore China Corporation or other agents for the solutions. In order to prevent the safety accidents from being...
Page 54 Lifting of loader 1. It is necessary to let the professionals with lift- ing knowledge be responsible for the command and operation. 2. You should calculate the crane’s maximum lift- ing weight and the sling’s bearing capacity to ensure the lifting safety. Meanwhile, the 4 hooks on the sling shall bear load evenly.
Page 55 TOWING Tow the fault machine This machine cannot be towed unless in the emer- gency. Towing is only used for towing this machine to a place where the overhaul can be performed, instead of transporting over a long distance. The towing distance for this machine should not exceed 10km, and the towing speed should not exceed 10km/h, otherwise the gearbox will be damaged for...
Page 56 Matters needing attention for towing: 1. Be sure to release the parking braking. NOTE: you should use wedges to stop the wheels of the machine to prevent the machine from moving. If the ma- chine wheel is not properly stopped by wedges, the machine will move.
Page 57: Operation Controls
Operation Controls Description of each component position and each control switch, instrument and valve through drawings or photos. Indicator lights work besides the gauges on the instrument panel. The operator should monitor machine pressure on the instrument panel with indicator lights. These lights will only show there is a problem.
Page 58: Component Locations
COMPONENT LOCATIONS Figure 1 2-2 Operation Controls...
Page 59 Reference Number Description Reference Number Description Main frame Cab seat Engine and gearbox Trims in cab Engine controls Pedal Fuel tank Stop Hydraulic oil tank Counterweight Driving shaft Front additional device Axle Bucket module Tire Bucket lip Tire hub Bucket knifing edge Cooling pipeline Main pipeline Seat...
Page 60: Operation Lever And Dashboard
OPERATION LEVER AND DASHBOARD Figure 2 Reference Reference Description Description Number Number Washing pot Steering wheel Brake pedal Adjusting handle for seat Bucket manipulating handle Electrical element box Arm manipulating handle Seat Combo switch handle A\C evaporator assembly Throttle pedal Control switch such as OFF A\C Panel Air outlet...
Page 61 Figure 3 Figure 4 Operation Controls 2-5...
Page 62 Manipulating facility Steering Wheel 1. The steering wheel rotation angle is not equal to the machine’s rotation angle. Continuously rotate the steering wheel to increase the rotation angle until to the required position. 2. The quicker the steering wheel rotates, the quicker the machine rotates.
Page 63: Starting Switch
Starting switch Starting switch (also called as electric lock) is lo- cated on the right side panel of the steering wheel Auxiliary – the first position you meet when you insert the starter key and rotate it counterclock- wise, and this gear position can be auto reset (i.e., the button will return to “OFF”...
Page 64 WARNING If the engine starting operation fails, it is necessary to turn the switch to “OFF” position then you can restart. Otherwise it will damage the starter switch! The time for each start should not exceed 15 s; the interval between two starts shall be at least 30s and the times to continuously start should not ex- ceed 3 times;...
Page 65 Operation of pre-heater system The pre-heater system can be used in some re- gions and states where the cold weather may affect the starting ability of the engine. Please read the following specification carefully before operation 1. Turn the starter switch to the position ‘ON’ Starter Switch (‘ON’) When the resistivity of the engine coolant sen- sor is less than 2700 ±...
Page 66 4. If the generator don’t send D+ signal to the con- troller after the reset of the start switch, which means that the engine fail to be started, the con- troller will stop working after 6s;if the generator send D+ signal to the controller (which means that the engine is started),it begin to heat and the heat time is presented as a function of the resistance of the engine coolant sensor whose range is be-...
Page 67: Schematic Diagram
Schematic Diagram Figure 13 Preheating System Schematic Diagram Operation Controls 2-11...
Page 68: Throttle Pedal
Parking braking Parking braking switch (Hand brake) is located on the console on the left side of the cab. When it is pulled up, the braking applies. (Fig.14) Figure 14 Service braking pedal Service braking pedal (foot brake) is located in front left of the cab Floor.
Page 69 Do not selfishly change the shifting manipulating system when the shifting manipulating system of the vehicle is in fault ! If the fault cannot be removed, please contact with autho rized maintenance station and after sales service company of Hyundai for the maintenance. Operation Controls 2-13...
Page 70 Working Device control Leverar 1.Mechanical Working lever is installed on the right side of the seat. It is used for controlling the working device to perform the operation. The inner side is bucket control lever, used to control the movement of the bucket.
Page 71 2.Pilot manipulating handle (Standard configuration) Pilot manipulating handle is installed on the handle manipulating box on the right side of the driver seat. It is used for controlling the working device to perform the operation. The inner side bucket manipulat- ing handle is used to control the bucket’s movement and the outer side arm manipulating handle is used to control the arm’s movement.
Page 72 with ground surface. When the bucket manipulating handle is again pulled backwards to the extreme rear position, the bucket manipulating handle will not be stuck by Bucket Receive holding magnet (it will return back to the middle position under the force of spring when you release your hand) be- cause the Bucket Receive holding magnet is de-energized all the...
Page 73 Lamp and Switch The lamps of the whole vehicle include front combi- nation lamp (there is one at each side), front work- ing lamp (there is one at each side), rear combina- tion lamp (there is one at each side), room lamp, and rear working lamp (there is one at each side).
Page 74 ear combination lamp include after turn light, brake lamp, rear position lamp, reversing light. Figure 23 Figure 24 2-18 Operation Controls...
Page 75 ROCKER SWITCH Hazard Instrument Work Rear Wiper Wiper Spraing Rotating Alarm Small Lamp Lamp lamp Switch Switch Beacon Figure 25 1. Hazard Warning Light Switch This warning light is used when the equipment is stopped due to a malfunction or when an emergency occurs.
Page 76 2. Headlight Switch The small lamp switch can control the four small lamps in front and rear to be lit up or off simultaneously. In addition, it can also control the indicators for all rocker switches and instru- ment lighting. O.
Page 77 5. Rear Wiper Switch O. In this position, this switch turns “OFF” windshieldwiper mounted on rear windshield of operator’s cabin. I. In this position, this switch turns “ON” windshieldwiper mounted on rear windshield of operator’s cabin. Figure 30 6. Rear Washer Spray Switch O.
Page 78 NOTE: Turn lights are controlled by the handle on console assembly. In the case of before turning off the switch of battery, the Over room lamp can be opened out of control of taking the ignition key. Dipped Beam High- Beam Figure 33 WARNING...
Page 79: Monitoring System
MONITORING SYSTEM Monitoring instrument and horn switch Most of monitoring instrument and meters and indi- cators are integrated in the instrument ass`y below the steering wheel. The Instrument include: totaling to 8 meters for cooling water temperature, gear- box oil level, timer, braking air pressure, engine oil pressure, torque converter oil temperature, power supply voltage;...
Page 80 3. Detailed descriptions for Monitoring instrument and Indicating lamp ℃ ℃ Air pressure T/M Oil Temp. Water Temp. Oil Pressure Volt 9 8 10 13 1415 Figure 34 Reference Number Description Reference Number Description Engine oil pressure Gauge Battery Warning Indicator Engine coolant temperature Parking Brake Indicator Gague...
Page 81 1. Engine oil pressure Gauge The meter displays the engine oil pressure; caution：when the engine running, the pointer comes close to red zone means the engine oil pressure lower,and need to be checked. Oil Pressure Figure 35 2. Engine Coolant Temperature Gauge This gauge displays temperature of engine ℃...
Page 82 5. Battery Voltage Gauge This gauge displays the battery Voltage caution: When the pointer indicates red zone, it means the Battery or generator is abnormal.the engine should be shut down to check the charging system Volt Figure 39 6. Hour meter ALCD Meter that records total time.
Page 83: Battery Warning Light
9. Pilot unlock indicator light when the pilot lock is released,the indicator turn on. Figure 43 10. Battery Warning Light When starter switch is first turned to “ON” po- sition, this red warning light should turn “ON”. When engine is running this red light should turn “OFF”.
Page 84 13. Defrost Indicator Light NOT USED Figure 47 14. Emergency Steering Indicator Light NOT USED Figure 48 15. TM Oil Pressure Warning Indicator W h e n t h e T r a n s m i s s i o n O i l P r e s s u r e i s abnormal,this indicator turn “ON”...
Page 85 A/C System Switch The left knob is the blowing rate switch of evapora- tor, divided into low, medium, high gear; The right knob is the temperature control switch of air condi- tioner. Clockwise rotation of the knob, gradually re- duce; Rotate the knob in a clockwise direction, the temperature of air conditioning systems will reduc- es gradually.
Page 86 Audio system---multimedia Audio system is located in the cab, including multimedia, speaker, and antenna. Host panel(Fig.52) Figure 53 Speaker(Fig.53) Figure 54 The multimedia speaker has many functions such as digital radio, USB/SD/MMC, MP3/WMA, clock, adjustable volume. 1. The system configuration Digital tuning radio;...
Page 87 Button directory Figure 55 POWER Power supply switch control key MODE Mode switch / Clock control key BAND The radio band selection; Automatic search station storage key VOL+/VOL- Volume control key TUNE+/TUNE- Automatic sorting table; Last/ Next song ; Clock Settings key M1/ II Station storage;...
Page 88: Operation Specification
Operation Specification 1. Operation 1) M1,M2,M3,M4,M5,M6 are used to memorize the date of FM1,FM2,FM3,AM1,AM2,AM3 respectively. Push the button for shorter than 2s, you can pick up the corresponding pre-saved channels. Push the button until more than 2s, you can store the current channel in corresponding internal storage.
Page 89 2. Operation for USB/SD/MMC 1) M1/ MP3 Suspension control key 2) M2/STP Stop play songs,At this time click this button will not restore play; p r e s s M1/ I I k e y t o p l a y f r o m t h e v e r y beginning 3) M3/RPT Repeat function switch button...
Page 90 Wiper and Scrubber This machine is equipped with wiper for front win- dow. The control switch is located handle-type combo-switch below the steering wheel. 1. Front wiper switch Front window wiper switch has three positions: STOP, LOW SPEED and HIGH SPEED. The wiper can automatically reset when the wiper in STOP state.
Page 91 Reversing auto alarm system Reversing alarm device is located by side of the lift cylinder of the engine cover (Fig.68). When you op- erate the gearshift handle to back the vehicle, the reversing alarm device will automatically hoot. Lifting device for engine hood The rising and dropping of the integrated engine hood of this machine is controlled by hand-oper- ated cylinder and cylinder mechanism which is in-...
Page 92 Adjustment of driver seat The driver seat equipped for this machine can be adjusted in aspects of soft and hard extent (i.e., height, front and rear direction, backrest angle and headrest height) to adapt requirements from different drivers and different work situations. 1.
Page 93 4. Adjustment of softness of the driver seat There is one handle at the lower front portion of the driver seat which is used to adjust softness of the driver seat, to adapt the drivers with dif- ferent weights. Rotate the handle along the ver- tical plane clockwise or counterclockwise.
Page 94 Usage of seat belt The driver seat of this machine is equipped with seat belt. The driver shall tie the seat belt when operating the machine. Check the wear and security of the seat belt before using it. Replace it if necessary.
Page 95: Operation
Operation ADVICE FOR OPERATION OF NEW LOADER All loaders were checked and adjusted before de- livery from the factory. However, during the initial running-in process, you should still obey the follow- ing procedures, otherwise the equipment could be damaged or its performance degraded. If perform the operation with full load before running-in period, it will produce adverse effect on the operation life and safety running, and cause...
Page 96 Lubrication oil and filter element 1. Change engine oil and renew filter element after working for first 50 hours. 2. Change axle gear oil after working for first 100 hours. 3. Change the filter element in hydraulic oil line and renew filter element after working for first 250 hours.
Page 97 6. Pay attention to the lubrication of the machine, change the lubrication oil and lubrication grease as per the specified interval. 7. You must pay attention to the temperatures of gearbox, torque converter, front/rear axles, hubs, parking brake, immediate supporting shaft, and hydraulic oil, cooling fluid, engine oil.
Page 98 Perform the following operations after expiry of running-in period: 1. Completely check bolt and nut of each compo- nent for the tightening. Especially you should check the following components one time: die- sel engine cylinder head bolt, and front/rear axle fixing bolts, rim nuts, propeller shaft connecting bolt, diesel engine fixing bolt, gearbox fixing bolt, front/rear frame hinged-type bolt.
Page 99 Adjustment of bucket auto level- ing device 1. Place the machine on a flat ground and the shifting manipulating handle at the Neutral posi- tion. Operate the pilot manipulating handle and put the bucket on a fl at ground, then pull up parking braking valve button, shut off the en- gine.
Page 100 Adjustment of lifting arm auto lift- ing divice WARNING Be careful for the personal safety when performing the adjustment of arm lifting height limit. Non-working persons shall not approach the machine, and nobody shall stand in the area near arm. 1.
Page 101: Start Engine
Operationg machine Before starting engine, check follows: 1. Check the engine coolant level. 2. Check the engine oil level. 3. Check hydraulic oil level. 4. Check the leakage tightness for each oil pipe, water pipe and each component. 5. C h e c k b a t t e r y c o n n e c t i n g w i r e s . I f t h e connecting wires between battery and cables are found loosened, tighten them timely.
Page 102 Check whether the air flow switch for A/C sys- tem is at “O” position and the transfer switch at “O” position. If not, please toggle it to corre- sponding position. 10. Insert the key into electric lock and rotate clockwise one increment. Switch on power supply and hoot the horn to warn that this ma- chine is to be started and that other persons are not allowed to approach this machine.
Page 103 Note : Pay special attention to the indicated po- sition for the engine oil pressure, which should not be less than 0.07MPa (at idle speed). If it is less than this value, it is nec- essary to stop the machine to check the engine for the faults.
Page 104 Operation of driving loader 1. Operate the manipulating handle and transfer the bucket backwards to the limit position; then raise the arm to the transportation position, i.e., the distance from the hinged point below the arm to the ground is about 500mm. 2.
Page 105 Meanwhile, operate the manipulating handle to lower down the arm to the lowest posi- tion, and tilt the bucket forward to make the bucket lip or knife edge insert in or go against the ground to force the machine to stop, thus ensure the security.
Page 106 After completion of the steering operation, you should toggle the steering lamp to the middle position, and the steering lamp and the steer- ing indicator will go off immediately. When per- forming the steering at higher speed, you must release the throttle pedal and, if necessary, use service braking to decrease the machine speed and then conduct the steering operation so as to ensure the driving safety.
Page 107 Parking of manchine 1. Drive the machine to a flat field. Confirm that there is no risk of falling stones, landslip or Flood. 2. Apply service braking to stop the machine. 3. Toggle the shifting manipulating handle to Neutral position. 4.
Page 108 If the machine needs to be stored for a long time, operate according to the following requirements: A.Before storage Wash each part of the vehicle, dry and ● store in a dry warehouse. If the machine is only allowed to be stored in the open, it is necessary to park the machine on the concrete road surface where the drain is easy, and use the canvas to cover.
Page 109 B. In the process of storage Start the vehicle once a month to operation ● each system, and fill lubrication grease to each movable axis pin, propeller shaft, thus lubricating each movable part. Meanwhile, charge the battery also. Wipe off the grease on the piston rod of ●...
Page 110: Operation Of Loader
OPERATION OF LOADER Preparation before operation Before operation, first use this machine to level the working site, remove the protrusions, fill and level up the pits, shovel the surface of wet ground, clear large and sharp stones on the site to prevent from scratching Tires.
Page 111 Depress the throttle pedal to make the bucket fully insert into the stock pile. When the machine could not advance further, the driver toggle backwards the bucket manipulating handle to move the bucket backwards and then push the bucket manipulating handle back to the middle position.
Page 112 Lift the boom to a certain height so that when the machine retreats, the bucket can avoid the stock pile. The driver holds the steering wheel with right hand and toggle, with left hand, the manipulating handle back to the Gear Reverse position to operate the machine to retreat.
Page 113 Unloading ● 1) Unloading the materials to truck or hopper When the loader with full materials is 15m away from the truck or hopper, you should release throttle pedal. You can use service braking to conduct “snub” if necessary, to reduce the machine speed to slowly approach the truck or hopper.
Page 114 During unloading, the impacting force of bucket limit stop and the arm shall not be too large, and the impacting times shall not be too many to avoid the damage to the machine. After completion of unloading, the driver shall toggle the bucket manipulating handle backwards to the limit rear position.
Page 115 Handling by pushing ● With bucket flatly close to the ground, put the shifting manipulating handle at Gear Forward I and depress the throttle pedal to push forward. During the pushing process, if some obstacles are found to hinder the advance of the vehicle, it is possible to slightly lift the arm to advance continuously.
Page 116: Operation Method
Operation method V-type operation method ● Loader is dead against stock pile, and the included angle between truck and loader driving direction is 60 º, and it stops at a place 12-15m away from the stock pile. When the loader is fully loaded, it will retreat directly back to the place 12-15m away from the stock pile.
Page 117 Operation in cold weather Matters needing attention in cold weather: If the ambient temperature is too low, the engine will be started difficultly and the radiator may be frozen. Therefore, you should obey the following instructions: 1. When the environmental temperature is below 6 ℃, you should wait for about 8 or 10 minutes after you turn on the starting switch, and then start the engine...
Page 118 In order to prevent the vehicle from being not started next day due to the congelation of sludge, water or snow stuck on the machine, the following w o r k m u s t b e d o n e a f t e r c o m p l e t i o n o f t h e operation each day: 1.
Page 119: Operation Under Special Conditios
OPERATION UNDER SPECIAL CONDITIONS Operation under extreme cold conditions If the machine is working in extremely cold weather, it is necessary to adopt protective measures to guarantee the normal operation. The following detailed inspection can ensure the machine to work normally in cold temperature.
Page 120 Start the engine to make it reach the normal temperature before working with load. A. When the machine is in idle state, if the mud and ice are attached on the running components, please heat to melt the frozen substances. B.
Page 121 2. Regularly flush the cooling system, if necessary, to keep the cleanness of the pipeline. Avoid u s i n g t h e w a t e r c o n t a i n i n g h i g h A l k a l i , otherwise, the dirt will be generated more easily.
Page 122 Operation in the dusty or sandy area Dust will be produced in most places during op- erating machines. However, you must adopt the preventive measures in severely dusty or sandy places. 1. Keep the cooling system and cooling area clean. You can use compressed air to purge them for cleaning, and shall adopt this measure as much as possible.
Page 123 Operation in brine The brine and sea wave are highly corrosive. When the equipment is working in brine, pay attention to follow items: 1. When the equipment is corroded by brine, immediately use clean water to wash and dry it completely.
Page 124 ON THE LAST PAGE OF OPERA- TION UNDER SPECIAL CONDI- TIONS Working in Water After working in water, lubricate all lubrication points on front and rear frames which have been under water so water is removed. The water depth is an important factor to take into consideration when the machine is working in swampy areas.
Page 125: Inspection, Maintenance And Adjustment
Inspection, Maintenance and Adjustment The maintenance and inspection of the equipment are necessary in order to keep the equipment working in normal conditions. The time interval, each system and components position and inspection method are listed as follows: The following items list the content and time Note: Figure 1 interval for the maintenance and inspection.
Page 126 Safety instructions 1. In order to prevent some accidental operation during maintenance, you must first identify the hydraulic system control level be positioned in the middle and hang the Warning mark (warning sign). 2. C o n f i r m t h a t t h e o v e r f l o w e d l i q u i d s a r e thoroughly cleared, especially those liquids around the engine.
Page 127: Preparation And Setting Of The Equipment Before Maintenance
PREPARATION AND SETTING OF THE EQUIPMENT BEFORE MAINTENANCE Park the vehicle as the following requirements before performance of maintenance according to the regulations in this manual. Note: Some special maintenance requires the ma- chinery has different parking mode. However, after completion of maintenance, the machine must be reset to the following positions.
Page 128: Recommended Lubrication Table
RECOMMENDED LUBRICATION TABLE KEY POINT Do not use un-recommended lubrication oil. Do not use unapproved products. Note: Refer to maintenance time interval table to make lubrication for the specified positions. Matters needing attention on lubrication The oil must be cleaned and the diesel oil must ●...
Page 129 See following table for oil varieties and brands Classification Name Application location Various rolling bearing, working device axis pin for Lubrication #3 molybdenum disulfide Lithium- rolling bearing, frame pin for steering cylinder axis grease based grease pin, propeller shaft spline of sub-frame pin, and water pump Engine Oil : SAE15W40 Torque...
Page 130: Fluid Capacity
FLUID CAPACITY Item Size Crankcase(Engine oil) 19Litres Engine Cooler system 42Litres Fuel tank 260Litres Hydraulic oil Tank Capacity 260Litres Gearbox system 49Litres Front Axle housing 17Litres Front Hub wheel 5Litres(each single side) Driving axle Rear Axle housing 17Litres Rear Hub wheel 5Litres(each single side) 4-6 Inspection, Maintenance and Adjustment...
Page 131 LUBRICATION OIL & MAINTENANCE CHART Figure 5 Inspection, Maintenance and Adjustment 4-7...
Page 132: Maintenance Period
Maintenance period Service Interval（h） Items To Check Service 500 1000 2000 Front Joint Pin Grease Articulation Pin Grease Stabilizer pin Grease Steer Cylinder Grease Shaft Bearing Grease Engine Oil Engine Oil ● Engine Oil Filter Cartridge ● Fuel Pre-Filter Cartridge ●...
Page 133: Maintenance Items
Maintenance Items 10 Hours/Routine maintenance 250 Hours/Monthly maintenance ● Visually check around the machine for informali- ● Check tightening torque of fixing bolt of rim. ties or oil leakage. ● Check oil level of front/rear axle. ● Check the engine and transmission oil level. ● Check load-carrying welds and fixing bolts of ● Check hydraulic oil level.
Page 134 1000 Hours/Half-yearly maintenance ● Inspect various temperature gauges and pres- sure gauges. ● Check the tightening of engine exhaust pipe. ● Check engine operation. ● Replace the oil return filter element, breather and pilot the filter element of the hydraulic oil tank.
Page 135: Electrical System
ELECTRICAL SYSTEM Note: Strictly prohibit disassemble electric circuit and components. You should consult the agent to solve such problems. Battery WARNING The electrolyte is the diluted Sulfuric acid which can quickly burn the skin and pierce in the clothes. Rinse immediately with water if the battery electrolyte spills over your body on your clothes for your careless operation.
Page 136 Battery in cold weather The battery will consume a lot when performing starting and pre-heating operation in cold weather. Meanwhile, when the temperature decreases, the performance of the battery will also decrease. In extremely cold weather, it is possible to remove the battery and put it in a warmer place, thus help- ing the improvement of battery performance.
Page 137 Maintenance of Air-conditioning System • Clean radiator of outside air conditioning reg- ularly—Condenser Checking approach: Clean condenser with plenty water after remov- ing the condenser fan and exposing condenser completely, but it can’t be rinsed with large water pressure to prevent lodging of condenser fins and affecting the cooling effect.
Page 138 • Checking of loader’s top and energizing of whole loade. 1. Open the control panel and knob third gear to H gear to check if there is some airflow out and whether the air volume is large or notMainte- nance standards: 2.Knob the temperature control switch button of the right of control panel to max clock-wisely to check if the indicator is light and to check...
Page 139: Bucket
BUCKET Replace O-ring seal for the bucket WARNING Wear safety helmet, gloves and goggles when you replace pins because metal objects may fly off. 1. Check the O-ring seal for the bucket, and re- place it if it is worn or damaged Figure 13 2.
Page 140 3. Remove old O-ring seal and install new O-ring seal (1, Fig. 16) onto bushing (2). Confirm that the O-ring seal on connecting rod cover (4) and bucket bushing has been thoroughly cleared 4. Align the bucket connecting rod cover and the bucket link pin hole, and install bucket pin (3, Fig.
Page 141: Add Shim To Bucket
ADD SHIM TO BUCKET Install a new bucket 1. If you want to install new bucket, you should measure the dimension of between internal lugs of the bucket and the dimension of bucket link width. 2. Subtract one dimension from the other, and you will get the dimension of the shim you want to add on both sides.
Page 142: Recommended Air Pressure
TIRES The proper charging of the tire (2. Fig 18) is the important factor to determine tire life and perfor- mance. If tire is inadequately charged (1. Fig 18), it will not support the equipment, and will be worn quickly; if tire is excessively charged (3. Fig 18), the friction is less and it is easily to be pierced.
Page 143 Check Tires for damage WARNING Improper maintenance or replacement of Tires may cause explosion to cause serious injury or death. The maintenance and replacement of Tires may only be carried out by trained person who is properly equipped. For maintenance of Tires, please contact with the nearest Tires agent or Tires manufacturer. WARNING The overheating of the Tire will cause explosion and serious injury or death.
Page 144: Replacement Of Tire
Replacement of Tire WARNING If a wheel and tire must be removed from machine and replaced, or if a tire must be replaced on wheel, use only expe- rienced and trained service personnel. A tire rim could be propelled off wheel and cause death or serious injury. See Figure 20.
Page 145 1. Park the equipment on the Flat ground. 2. Use a jack which can support the weight of the equipment to jack-up the equipment, making an adequate clearance between the Tires and the ground, and put proper strut under the sup- port to sustain the equipment.
Page 146: Inspection Of Bolt And Nut
INSPECTION OF BOLT AND NUT Check all fasteners after working for 50 hours for the first time and every 250 hours from then on. If loose or loss is found, it is necessary to re-tighten or add new products. You must use torque wrench. KEY POINT Clear the fasteners before tightening.
Page 147: Maintenance Under Special Conditions
MAINTENANCE UNDER SPECIAL CONDITIONS Conditions Maintenance requirements Working in mud, water or rain 1. Walk around and check for the loose connector, obvious damage or leakage. 2. After working, clear the mud, rocks and sand on the ma chine. Check the welded parts for the cracks and compo- nents for the loose.
Page 148: Storage For A Long Time
STORAGE FOR A LONG TIME Store the machine as shown in the following table if it will stop for more than one month Conditions Maintenance requirements 1. Cleaning 1. Flush the chassis and wheel drive assy using HP water gun. Check for the damage or the loose components. 2.Lubrication 1.
Page 149: Transporting Machine
The total height, total width and total weight should not exceed the related regulations. Please consult Hyundai or other agents for the solutions. In order to prevent the safety accidents from being occurred during the shipment of the machine, clear the ice and snow as well as other slippery materials on the dock and wagon.
Page 150 Lifting of loader It is necessary to let the professionals with lifting knowledge be responsible for the command and operation. You should calculate the crane’s maximum lifting weight and the sling’s bearing capacity to ensure the lifting safety. Meanwhile, the 4 hooks on the sling shall bear load evenly.
Page 151 Towing of the fault machine This machine cannot be towed unless in the emergency. Towing is only used for towing this machine to a place where the overhaul can be performed, instead of transporting over a long distance. The towing distance for this machine should not exceed 10km, and the towing speed should not exceed 10km/h, otherwise the gearbox will be damaged for short supply of oil.
Page 152 4. Keep the minimum angle of the supporting rope, and the angle between the tow rope and the right ahead should not exceed 30 º 5. The too quick movement of the machine may cause the breakage of tow rope or tow bar.
Page 153: Transportation Dimension
TRANSPORTATION DIMENSION Figure 4 Basic dimension Sign Description Dimensions Transportation length 7780mm Transportation width 2990mm Cab height 3470mm Ground clearance 480mm Space between front and rear Tires 3900mm Transportation 5-5...
Page 154: Trouble Shooting
Troubles Shooting TRANSMISSION SYSTEM Characteristics of faults Cause Remedy 1. Oil level too low in gearbox oil pool 1. Add oil to the specified oil level 2. Leakage in main oil way 2. Check main oil way 3. Gearbox oil filter blocked 3.
Page 155 Characteristics of faults Cause: Remedy 1. Shifting pressure low 1. See I, II 2. Torque converter oil tempera- 2. See III ture too high 3. Impeller of torque converter 3. Disassemble torque converter Driving force not adequate damaged and replace impeller 4.
Page 156: Braking System
BRAKING SYSTEM Characteristics of faults Cause Remedy Air in braking hydraulic pipe- Bleed the pipeline line Oil leakage in brake pad ass’y Replace seals on the brake pad ass’y Check tightness of air compressor, Brake air pressure low combo valve, accumulator and pipe- Foot braking force not ad- line equate...
Page 157: Hydraulic System For Working Device
HYDRAULIC SYSTEM FOR WORKING DEVICE Characteristics of faults Cause Remedy Wear or damage of cylinder oil Replace oil seal seal Distribution valve excessively Disassemble, check and repair worn. Fit clearance between to make the clearance meet re- valve stem and valve body ex- quirements on specified value , ceeds the specified value or replace distribution valve...
Page 158: Steering Hydraulic System
STEERING HYDRAULIC SYSTEM Characteristics of faults Cause Remedy Increase the oil temperature , Oil temperature too low then start working Load sensing oil way blocked Clean it Adjust overflow valve block pres- Hard to make steering Pressure of steering pump low sure according to the regulations Partial bolts for metering motor of full hydraulic steering gear tight-...
Page 159: Electical System
ELECTICAL SYSTEM Characteristics of faults Cause: Remedy Wipe using clean cloth dipping with gaso- Commutator oil stained or worn line, or grind using #00 emery cloth Generator not working, Check external magnetic field , and check Remanence coil open circuit or output low voltage exciting circuit using light bulb Perform magnetizing or replace with new...
Page 160 Characteristics of faults Cause: Remedy Battery damaged or its capacity Replace with new battery or charge inadequate the old battery Electric lock damaged Replace electric lock Electric circuit contact badly or Check and repair short-circuited Check the coil for perfection , the contact for smooth, the fork for Engine could not start or start Starter motor electromagnetic...
Page 161: Specification
Specification STANDARD SPECIFICATION Item Size Bucket capacity 2.7m Rated load 5000kg Boom lifting time(full load) ≤5.3s Cycle time ≤10.3s Gear Forward I 12.2km/h Highest speed at Gear Forward II 38.4km/h each gear Gear Reverse I 16.8km/h Maximum traction force 164±5kN Maximum digging up force 160±5kN Maximum gradability...
Page 162 ENGINE Item Size Type WD10G220E23 diesel engine Rated rotation speed 2000r/min Maximum torque 900N.m/1500r/min Fuel consumption at rated working conditions(rig-test) ≤215g/kw.h Fuel #40 in summer Fan diameter (exhaust) 760mm TRANSMISSION SYSTEM Item Size Type Single turbine Hydraulic torque converter Torque ratio 3.25 Cooling mode Air cooling...
Page 163: Steering System
BRAKING SYSTEM Item Size Single pipeline, air-poppet oil Service braking (foot braking)： 4-wheel caliper disc brake Brake disc diameter φ460mm Service braking Braking slave cylinder φ70mm Friction lining dimensions ( L×W×H) 182×72×15mm System Pressure 0.71~0.784 MPa Auto, manual, hand-operated Parking and emergency pneumatic braking Brake drum diameter...
Page 164 ELECTRICAL SYSTEM Item Size System voltage Battery Two 12V120AH in series Light bulb voltage Diesel engine starting 24V, electric startup OIL FILLING CAPACITY Item Size Fuel tank 260L Hydraulic oil Tank Capacity 260L Crankcase Gearbox system Front axle Axle (differential and planetary system ) Rear axle Front/Rear booster...
Page 165: Integral Dimension
INTEGRAL DIMENSION Figure 1 Intergral dimension sign Description Dimension Transportation length 7780mm Transportation width 2990mm Cab height 3470mm Ground clearance 3160mm Space between front and rear tyres 2900mm Specification 7-5...
Page 166: Operation Scope
OPERATION SCOPE Figure 1 Intergral dimension Description Dimension Machine length 7780mm Machine width 2990mm Machine height 3470mm Axle base 2900mm Wheel base 2150mm Min. Distance above Ground 480mm Unloading angle( Bucket teeth) ≥3030mm Unloading distance( Main knife plate) ≥1210mm Hinged pin height at maximum lifting position 4100mm Maximum unloading angle 45°...
Page 167: Weight Of Operation Load
WEIGHT OF OPERATION LOAD WARNING KEY POINT The weight refers to the approximate value of the estimated average volume. With exposure to rain, snow or underground water, because of the condensation or compression produced from the indirect weight and chemical industrial treatment, or because of the changes induced from heat or chemical conversion, the parameters listed in the table will increase.
Page 168 A little weight or Moderate weight or A lot weight or den- density 1,100KG/M3 density 1,100KG/ sity 1,100KG/M3 ( Material (1,850LB/YD3),OR M3(1,850LB/YD3),OR 1,850LB/YD3),OR LESS LESS LESS 1.762kg/m3 Wet muddy clay - - - - - - - - - - (2.970lb/yd3) C a l c i n a t e d p l a s t e r 961kg/m3...
Page 169 COMPARION TABLE OF BUCKET CAPACITY AND SELECTION Specification 7-9...
Page 170: Environment Protection
Environment protection ENVIRONMENT PROTECTION When you perform the maintenance of the equipment and the disassembling of any pipeline, connector or other associated parts, you should use the special containers to collect coolants, oil liquids, fuel, electrolytes or other materials which may cause environment pollution.

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